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Lexmark 23XX Series
23XX-XXX
· 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.
Edition: April 2000
THE FOLLOWING PARAGRAPH DOES NOT APPLY TO THE UNITED KINGDOM OR 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. This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the information herein; these changes will be incorporated in later editions of the publication. Improvements or changes in the products or the programs described in this publication may be made at any time. Publications are not stocked at the address given below; requests for publications should be made to your point of purchase. A form for reader's comments is provided at the back of this publication. If the form has been removed, comments may be addressed to Lexmark International, Inc., Department F95/032-2, 740 New Circle Road NW, Lexington, Kentucky 40511, U.S.A. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you. Lexmark is a trademark of Lexmark International, Inc.
Copyright Lexmark International, Inc. 1996, 2000 All rights reserved.
UNITED STATES GOVERNMENT RESTRICTED RIGHTS This software and documentation are provided with RESTRICTED RIGHTS. Use, duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause at DFARS 252.227-7013 and in applicable FAR provisions: Lexmark International, Inc., Greenwich, CT 06836.
Contents
Notices and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . .ix Safety Notices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xiii General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Recommended Machine Usage . . . . . . . . . . . . . . . . . . . . 1-3 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 How To Change The Printer Functions . . . . . . . . . . . . . . 1-6 Serial Interface Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Serial Interface Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Function Switch Setting . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Diagnostic Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Voltage, Ground, And Continuity Readings . . . . . . . . . . . 2-1 Error Indication Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Symptom/Check Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Irrecoverable Operator Errors . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Service Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Abnormal Noise Service Check . . . . . . . . . . . . . . . . . . . 2-14 Auto Sheet Feeder (ASF) Service Check. . . . . . . . . . . . 2-15 Carrier Drive, Home Position Sensor, Ribbon Feed Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Intermittent Problem Service Check . . . . . . . . . . . . . . . 2-20 No Print or Abnormal Print Service Check . . . . . . . . . . . 2-23 Operator Panel Service Check. . . . . . . . . . . . . . . . . . . . 2-24 Paper Empty Sensor Service Check . . . . . . . . . . . . . . . 2-26 Paper Feed Service Check . . . . . . . . . . . . . . . . . . . . . . 2-27 Paper Select Sensor Service Check . . . . . . . . . . . . . . . 2-30 POST Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 Power Service Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32 Print Speed Service Check . . . . . . . . . . . . . . . . . . . . . . 2-34 Printhead Service Check . . . . . . . . . . . . . . . . . . . . . . . . 2-36 Pull Tractor Sensor Service Check . . . . . . . . . . . . . . . . 2-38 Top of Forms Problem Service Check . . . . . . . . . . . . . . 2-39 Tractor 2 Service Check. . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Contents
v
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Power-On Self Test (POST) . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Print Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Hex Dump Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Serial Interface Adapter Print Test . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . 4-5 Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Auto Sheet Feeder Gears Removal . . . . . . . . . . . . . . . . 4-8 Auto Sheet Feeder Pick-up Roller Removal . . . . . . . . . . 4-9 Bottom Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Carrier Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Carrier Motor Assembly Removal . . . . . . . . . . . . . . . . . 4-16 Carrier Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Download or Print Buffer Module Removal . . . . . . . . . . 4-21 Form Thickness Lever Removal . . . . . . . . . . . . . . . . . . 4-22 Head Gap Sensor Removal (238X-001) . . . . . . . . . . . . 4-23 Head Gap Sensor Removal (23XX-002, 003) . . . . . . . . 4-24 Home Position Sensor Removal . . . . . . . . . . . . . . . . . . 4-25 Label Jam Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 Left Side Frame Removal . . . . . . . . . . . . . . . . . . . . . . . 4-28 Lower Feed Roller Removal . . . . . . . . . . . . . . . . . . . . . 4-30 Lower Pinch Roller Removal . . . . . . . . . . . . . . . . . . . . . 4-32 Main Logic Board Removal . . . . . . . . . . . . . . . . . . . . . . 4-33 Operator Panel Assembly Removal . . . . . . . . . . . . . . . 4-34 Paper Empty Sensor And Spring Removal . . . . . . . . . . 4-36 Paper Feed Motor Removal . . . . . . . . . . . . . . . . . . . . . 4-38 Paper Guide Removal (Left And Right) . . . . . . . . . . . . . 4-39 Paper Guide / Platen Assembly Removal . . . . . . . . . . . 4-40 Paper Select Lever Removal. . . . . . . . . . . . . . . . . . . . . 4-42 Paper Select Sensor Removal . . . . . . . . . . . . . . . . . . . 4-43 Paper Separator Removal . . . . . . . . . . . . . . . . . . . . . . . 4-44 Power Supply Removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-46 Print Unit Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47 Printhead Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48 Printhead Cables Removal . . . . . . . . . . . . . . . . . . . . . . 4-49 Pull Tractor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50 Pull Tractor Actuator Removal. . . . . . . . . . . . . . . . . . . . 4-51 Pull Tractor Sensor Removal. . . . . . . . . . . . . . . . . . . . . 4-52
vi
Service Manual
Push Tractor Assembly Removal . . . . . . . . . . . . . . . . . . 4-53 Ribbon Drive Rack Gear Removal . . . . . . . . . . . . . . . . . 4-54 Right Side Frame Removal . . . . . . . . . . . . . . . . . . . . . . 4-56 Right Side Frame Gears Removal . . . . . . . . . . . . . . . . . 4-58 Sub Logic Board Removal . . . . . . . . . . . . . . . . . . . . . . . 4-59 Tension Pulley Plate Assembly . . . . . . . . . . . . . . . . . . . 4-60 Top Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61 Top of Form Sensor, Sensor Flag And Spring Removal 4-64 Upper Feed Roller Removal. . . . . . . . . . . . . . . . . . . . . . 4-66 Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Rear View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Tractor 2 Cable Connectors . . . . . . . . . . . . . . . . . . . . . . . 5-4 Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Block Diagram 238X-001 . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Block Diagram 239X-001 . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Block Diagram 238X-002 . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Block Diagram 239X-002 . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Block Diagram 238X-003 . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Block Diagram 239X-003 . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Signal Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Connector Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 Main Logic Board 23XX-001 . . . . . . . . . . . . . . . . . . . . . 5-20 Main Logic Board 23XX-002 . . . . . . . . . . . . . . . . . . . . . 5-21 Main Logic Board 23XX-003 . . . . . . . . . . . . . . . . . . . . . 5-22 Sub Logic Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Specified Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Lubrication Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Lubrication Points (Oil) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Lubrication Points (Grease) . . . . . . . . . . . . . . . . . . . . . . . 6-4
Contents vii
Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 How To Use This Parts Catalog. . . . . . . . . . . . . . . . . . . . . . . 7-1 Assembly 1: Major Components . . . . . . . . . . . . . . . . . . . . . . 7-2 Assembly 2: Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6 Assembly 3: Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10 Assembly 4: Paper Guide / Platen / Feed Roller . . . . . . . . . 7-16 Assembly 5: Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 Assembly 6: ASF - Roller / Support . . . . . . . . . . . . . . . . . . . 7-26 Assembly 7: ASF - Side Frame / Covers . . . . . . . . . . . . . . . 7-28 Assembly 8:Tractor 2 Option . . . . . . . . . . . . . . . . . . . . . . . . 7-30
viii
Service Manual
Notices and Safety Information Safety Notices · ·
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. There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product. Professional service personnel should understand this and take necessary precautions. The safety features of some parts may not always be obvious. Therefore, replacement parts must have the identical or equivalent characteristics as the original parts.
·
Sicherheitshinweise
· ·
·
Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen Wartungsfachmann bestimmt. Während des Auseinandernehmens und der Wartung des Geräts besteht ein zusätzliches Risiko eines elektrischen Schlags und körperlicher Verletzung. Das zuständige Fachpersonal sollte entsprechende Vorsichtsmaßnahmen treffen. Ersatzteile müssen gleiche oder gleichwertige Merkmale wie die Originalteile aufweisen, da nicht immer offensichtlich ist, welche Teile des Geräts Sicherheitsmerkmale aufweisen.
Consignes de Sécurité
· · ·
Les consignes d'entretien et de réparation de ce produit s'adressent uniquement à un personnel de maintenance qualifié. Le démontage et l'entretien de ce produit pouvant présenter certains risques électriques, le personnel d'entretien qualifié devra prendre toutes les précautions nécessaires. Les normes de sécurité de certaines pièces n'étant pas toujours explicites, les pièces de rechange doivent être identiques ou conformes aux caractéristiques des pièces d'origine.
Notices and Safety Information ix
Norme di sicurezza
· ·
·
Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato. Durante lo smontaggio e la manutenzione di questo prodotto, il rischio di subire scosse elettriche e danni alla persona è più elevato. Il personale di assistenza autorizzato, deve, quindi, adottare le precauzioni necessarie. Poiché non tutti i pezzi di ricambio garantiscono la stessa sicurezza, questi devono avere caratteristiche identiche o equivalenti a quelle dei pezzi originali.
Pautas de Seguridad
· ·
·
La información sobre el mantenimiento de este producto está dirigida exclusivamente al personal cualificado de mantenimiento. Existe mayor riesgo de descarga eléctrica y de daños personales durante el desmontaje y la reparación de la máquina. El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias. Los dispositivos de seguridad de algunas piezas no siempre pueden reconocerse a simple vista. Por lo tanto, los recambios deben poseer características idénticas o equivalentes a las de las piezas originales.
Informações de Segurança
· ·
·
As informações de segurança relativas a este produto destinam-se a profissionais destes serviços e não devem ser utilizadas por outras pessoas. Risco de choques eléctricos e ferimentos graves durante a desmontagem e manutenção deste produto. Os profissionais destes serviços devem estar avisados deste facto e tomar os cuidados necessários. Os dispositivos de segurança de algumas peças poderão não ser sempre suficientemente evidentes. Assim, as peças sobressalentes devem possuir características idênticas ou equivalentes às peças originais.
x
Informació de Seguretat
· ·
·
La informació pel manteniment d'aquest producte està orientada exclusivament a professionals i no està destinada a ningú que no ho sigui. El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de servei d'aquest producte. El personal professional ha d'estar-ne assabentat i prendre les mesures convenients. Les característiques de seguretat d'algunes de les peces poden no ser òbvies. Per tant, les característiques dels recanvis hauran de ser idèntiques o equivalents a les de les peces originals.
Chinese Safety Information
Notices and Safety Information xi
Korean Safety Information
xii
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). "Diagnostic Aids" contains tests and checks used to locate or repeat symptoms of printer problems. "Repair Information" provides instructions for making printer adjustments and removing and installing FRUs. "Connector Locations" uses illustrations to identify the major components and test points on the printer. "Preventive Maintenance" contains lubrication specifications, and maintenance information to prevent problems and maintain optimum performance. "Parts Catalog" contains illustrations and part numbers for individual FRUs.
Preface xiii
xiv
1. General Information Description
The Lexmark 238X and 239X - XXX printers 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 2381 and 2391 are wide-carriage versions of the 2380 and 2390. The 23XX Plus (23XX-002) printers are enhanced versions of the basic 23XX-001 printers. These printers have the following additional features:
· · · · ·
Forms macro and smooth paper scrolling capability, available from the operator panel. Option slot. Resident bar code. Quiet mode. Higher print speed (239X).
The 23XX Forms Printers (23XX-003), in addition to the features of the 23XX-002 printers are 9% (9-wire machines) or 28% (24-wire machines) faster in fast draft mode. They also support the Tractor 2 Options. There is also a PS/1 version of the 2390-001, which has a distinctive PS/1 logo but is otherwise identical to the 2390-001.
General Information 1-1
The following table summarizes the differences between the printers in the 23XX family:
No. of Print Wires
US Logo Name
WTC Logo Name
Mach Type Model #
Paper Width
Paper Knob
PPSII 2380 PPSII 2381 PPSII 2390 PPSII 2391 PS/1 2380 Plus 2381 Plus 2390 Plus 2391 Plus Forms Printer 2380 Plus Forms Printer 2381 Plus Forms Printer 2390 Plus Forms Printer 2391 Plus
2380 2381 2390 2391 N/A 2380 Plus 2381 Plus 2390 Plus 2391 Plus Forms Printer 2380 Plus Forms Printer 2381 Plus Forms Printer 2390 Plus Forms Printer 2391 Plus
2380-001 2381-001 2390-001 2391-001 2390-PS1 2380-002 2381-002 2390-002 2391-002 2380-003
9 9 24 24 24 9 9 24 24 9
Narrow Wide Narrow Wide Narrow Narrow Wide Narrow Wide Narrow
Yes Yes Yes Yes Yes No No No No No
2381-003
9
Wide
No
2390-003
24
Narrow
No
2391-003
24
Wide
No
1-2
Specifications
· · · · · · ·
Printhead life: 140 Million Characters Ribbon Life: 4 Million Characters Printer Life: 5 Years BTU: 409-Maximum/51 Idle (Per Hour) Power Consumption: 120 Watts-Maximum/15 Watts Idle
Recommended Machine Usage
23XX-001 - 10 million characters per year. 23XX-002, 003 - 12 million characters per year.
The character usage per day is calculated by dividing the yearly usage rating by 1300 characters per page, divided by 12 months per year, by 22 working days per month. To reduce the probability of reliability/service problems, field data has shown printer usage should not exceed twice the daily page usage. Notes:
· · ·
All numbers are average or estimates. Performance of individual printers may vary. Lexmark does not represent or warrant that printers will achieve these results. (See the applicable statement of Limited Warranty for all warranty information).
General Information 1-3
Options
The following options may be installed on 238X/239X printers:
· · · · · · · ·
Auto Sheet Feeder (ASF) 32Kb Memory Module, Volatile 32Kb Memory Module, Non-volatile Serial Interface Attachment (RS232/RS422). Extended National Language Support modules (World Trade only) Acoustics Option Extended Cut-sheet Paper Guides Tractor 2 (23XX-003 Only)
Tools
The basic tools needed are:
· · · · ·
Basic CE tool kit #1 Phillips screwdriver #2 Phillips screwdriver Feeler gauges 0.35 mm (0.014 in.) 0.4 mm (0.016 in.) Analog or digital volt-ohmmeter
1-4
Abbreviations
ASIC CSU DRAM EPROM ESD FRU HVPS LAN LCD LED LVPS NVRAM OEM POR POST PQET ROS SRAM UPR V ac V dc Application-Specific Integrated Circuit Customer Setup Dynamic Random Access Memory Erasable Programmable Read-Only Memory Electrostatic Discharge Field Replaceable Unit High Voltage Power Supply Local Area Network Liquid Crystal Display Light-Emitting Diode Low Voltage Power Supply Nonvolatile Random Access Memory Original Equipment Manufacturer Power-On Reset Power-On Self Test Print Quality Enhancement Technology Read-Only Storage Static Random Access Memory Used Parts Replacement Volts alternating current Volts direct current
General Information 1-5
Setup Mode
How To Change The Printer Functions
1. Make sure continuous forms are in the printer. 2. Press Alt and then press Setup to enter Setup Mode.The printer prints out the Main Menu. 3. To select a function, press the buttons listed on the printout. 4. To save the setting and leave Setup Mode, press Start/Stop until out of the menu.
1-6
Serial Interface Adapters
The 23XX printer product line uses three different serial adapters.
·
·
·
23XX-001: · Snaps on back of the printer and plugs into the parallel port. · Power lead plugs into the printer's +5 V port. · Switch settings are for "Snap-On". 23XX-002: · In-line gray box with a short cable to the parallel port. · Some units have a separate power lead to the +5 V port. · Units without the power cord will not work on the 23XX-001. · Switch settings are for "Gray". 23XX-003: · Similar to the 23XX-002, but different switch definitions. · All units have a power lead. · Switch settings are for "Black".
Notes:
· · · · ·
Except as noted, all adapters work with all printers. Some adapters may be installed on printers other than what is listed. Only the "Black" adapter is available as a FRU. Changes to switch settings are valid only after printer power is turned off and then on again. Contact Lexmark Technical Support for questions about serial adapters.
General Information 1-7
Serial Interface Switches
The serial interface has 12 function switches which determine how the printer receives data from the computer or terminal. Set the switches according to your particular equipment requirements.
Function Switch Setting
Switches 1 To 4 - Speed: Define the serial interface speed in bits per second (bps). Snap-On and Gray Serial Adapters
Switch 1 On On On Off Off Off Off On Off Switch 2 On Off Off On On Off Off On Off Switch 3 Off On Off On Off On Off On Off Switch 4 Off Off Off Off Off Off Off Off On Speed (bps) 150 300 600 1,200 2,400 4,800 9,600 19,200 38,400 (RS-422 only)
1-8
Black Serial Adapter
Switch 1 N/A On On Off Off Off Off On On Switch 2 N/A Off Off On On Off Off On On Switch 3 N/A On Off On Off On Off On Off Speed (bps) 150 300 600 1,200 2,400 4,800 9,600 19,200 38,400 (RS-422 Only)
Switch 5 - Data Bits: Selects the number of data bits (7 or 8) in each data frame.
Switch 5 Off On Data Bits 8 7
General Information 1-9
Switches 6 and 7 - Parity: Select the interface parity.
Switch 6 Off Off On On Switch 7 Off On Off On Parity No Ignore Odd Even
Note: When setting the "Ignore" for parity, the printer ignores the received parity and transmits using even parity. For all other parity settings, the transmitted parity matches the received parity.
Switch 8 - Stop Bits (Snap-On):.
Switch 8 Off On Stop Bits 1 Stop Bit 2 Stop Bits
Switch 8 - Buffer Size (Gray and Black): Selects the buffer size.
Switch 8 Off On Buffer Size Normal (2048 bytes) Minimum (2 bytes)
1-10
Switch 9 - Protocol: Selects the type of protocol. Differs depending on which serial interface unit is installed. Snap-On and Gray Units
Protocol Switch 9 Snap-On Off On XON/XOFF DTR pacing (RS232 only) Gray DTR Pacing (RS232 only) XON/XOFF
Black Units
Switch 4 Off Off On Off Switch 9 On Off Off On Protocol XON/XOFF DTR pacing (RS232 only) DTR + XON/XOFF Robust XON/XOFF
Note: DTR protocol is for RS-232C only. Switch 10 - Print Test (All Units): Selects the print test for the serial interface adapter. Refer to "Serial Interface Adapter Print Test" on page 3-6.
Switch 10 Off On Print Test Normal mode Test mode
General Information 1-11
Switch 11- Polarity For RS-422 Serial Interface (All Units): NOR/REV reverses the polarity of the receive and transmit data line for the RS-422 serial interface.
Switch 11 Off On Mode Normal Reverse
Switch 12 - Serial Interface Mode Select: (All Units) Switch 232/422 sets the serial interface in either RS-232C or RS-422 mode.
Switch 12 Off On Mode RS-232C RS-422
1-12
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 done. When a "Line Voltage" measurement is to be done, the voltage on United States and Canada machines should be between 100 V ac and 127 V ac. On World Trade machines, the voltage is according to each country's specification. Ground Checks To check for a correct ground, measure the voltage between the ground and a known good voltage source. The voltage measurement must be the same as the source voltage to consider that the ground is correct. Continuity measurements may be used to check grounds, however, be sure to measure to a known good ground using the lowest ohms scale and check for zero ohms. Note: Always unplug the power cord before doing any continuity measurement. Continuity Readings When measuring continuity, be sure no back circuits affect the measurement. If necessary, unplug connectors to remove any back circuits. Zero the ohm range on the lowest scale (X1). An open circuit will read infinity. A circuit with correct continuity will read zero ohms.
Diagnostic Information 2-1
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 2-6.
Indication LED Power Ready Paper Font Pitch Alt Others Status ON ON ON ON ON ON ON
Alarm None
Action Post Error Go to "POST Service Check" on page 2-31.
LED Power Ready Paper Font Pitch Alt Others
Status ON ON ON ON ON ON OFF
None
RAM, ROM, Timer Interrupt Controller Error Turn the machine off and then on. If you get the same error during power-up, replace the main logic board and readjust the bidirectional print adjustment. If the printer completes POST successfully and eventually gets the same error, go to "Intermittent Problem Service Check" on page 2-20.
2-2
Indication LED Power Ready Paper Font Pitch Alt Others Status ON BLINK BLINK OFF BLINK OFF OFF
Alarm None
Action Switch Scan Test Error Go to "Operator Panel Service Check" on page 2-24.
LED Power Ready Paper Font Pitch Alt Others
Status ON BLINK BLINK BLINK OFF OFF OFF
None
NVRAM Read/Write Error Turn the machine off and then back on. If you get the same error during powerup, replace the main logic board and readjust the bidirectional print adjustment. If the printer completes POST successfully and eventually gets the same error, go to "Intermittent Problem Service Check" on page 2-20.
LED Power Ready Paper Font Pitch Alt Others
Status ON BLINK BLINK BLINK BLINK OFF OFF
Beeps 10 times
Home Position Error Go to "Carrier Drive, Home Position Sensor, Ribbon Feed Service Check" on page 2-17. Tractor 2 Home Position Error If Tractor 2 is installed, remove it to determine whether the problem is with the carrier home sensor or the Tractor 2 home sensor. Refer to the "Tractor 2 Service Check" on page 2-40.
None
Home Position Error Without Alarm Go to "Power Service Check" on page 2-32.
Diagnostic Information 2-3
Indication
Alarm None
Action Logical Error Turn the machine off and then back on. If you get the same error during power-up, replace the main logic board and readjust the bidirectional print adjustment. If the printer completes POST successfully and eventually gets the same error check, go to "Intermittent Problem Service Check" on page 2-20.
LED Power Ready Paper Font Pitch Alt Others
Status ON BLINK BLINK BLINK OFF BLINK OFF
LED Power Ready Paper Font Pitch Alt Others
Status ON BLINK BLINK OFF BLINK BLINK OFF
None
Hardware Drive Error The printhead or the printhead cables can cause this error. Go to "Printhead Service Check" on page 2-36. Turn the machine off and then back on. If you get the same error, replace the main logic board and readjust the "Bidirectional Print Adjustment" on page 4-5. If the printer completes POST successfully and eventually gets the same error, go to "Intermittent Problem Service Check" on page 2-20. If the problem still exists, remove the new main logic board, install the old main logic board, then replace the sub logic board.
LED Power Ready Paper Font Pitch Alt Others
Status OFF OFF OFF OFF OFF OFF 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 2-32.
2-4
Indication LED Power Ready Paper Font Pitch Alt Others Status ON OFF OFF OFF OFF OFF OFF
Alarm None
Action Operator Panel Failure Go to "Operator Panel Service Check" on page 2-24.
If other LED combinations along with the Power LED are on. Any LED on but the Power LED off. If the Power LED blinks or changes intensity. Any
None
Go to "POST Service Check" on page 2-31.
None None
Go to "Operator Panel Service Check" on page 2-24. Go to "Power Service Check" on page 2-32. (Optional Serial Interface Adapter installed) · Turn the printer off and check the connection from the serial interface adapter to the printer. · Turn the printer off and then on. If you get the same error, replace the serial interface adapter. · If turning the printer off and then on is successful, run the "Serial Interface Adapter Print Test" on page 3-6.
Beeps 7 times
Diagnostic Information 2-5
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 7 or more lights turn on but do not turn off. The Power light is on, but POST will not run. Action Disconnect the interface cable from the printer and turn the printer off and then on. If POST now runs correctly, the problem is in the computer or interface cable. Go to the "POST Service Check" on page 2-31.
Abnormal Noise Problems
Symptom During POST, abnormal noise comes from the carrier. During idling, abnormal noise comes from the printer. When feeding paper, abnormal noise is created. During printing or POST, abnormal noise is created. Action Check the ribbon cartridge for binds or damage. Go to the "Carrier Drive, Home Position Sensor, Ribbon Feed Service Check" on page 2-17. Go to "Abnormal Noise Service Check" on page 2-14.
2-6
Abnormal Print Operation Problems
Symptom Printer will not print, or become Ready. Abnormal operation, incorrect characters, or incorrect line width. Printer is ready but will not print from the computer correctly. Undefined or incorrect character(s). Slow printing speed. Go to the "Print Speed Service Check" on page 2-34. Action Be sure the interface cable is connected properly. If the serial interface adapter is installed, be sure it and its power interface cable are installed correctly. (Some adapters do not have a separate power cable.) Go to the "No Print or Abnormal Print Service Check" on page 2-23.
Auto Sheet Feeder Problems
Symptom Auto sheet feeder will not feed paper. Auto sheet feeder double feeds. Auto sheet feeder has intermittent feed problems. Action Be sure Sheet Feed is enabled in the Setup Mode. Be sure the paper select lever is in the cut sheet position. Go to the "Auto Sheet Feeder (ASF) Service Check" on page 2-15.
Diagnostic Information 2-7
Error Indications
Symptom Ready and Paper Out lights blink to indicate a Hardware Error. Paper Out and Alt lights blink to indicate an operator error. Action Turn the printer off and then on. Go to "Abnormal Indications" on page 2-6. Turn the printer off and then on. Go to "Irrecoverable Operator Errors" on page 2-13.
Paper Feed Problems
Symptom Paper Out is blinking with paper in the printer. Paper Out does not blink when no paper is in the printer and ASF is not installed. Print operation starts without paper. Alt + Park/Load does not function when the push tractor is installed. Form feed length is not correct. Alt + Park/Load functions with cut sheets in use. Be sure the paper select lever is in the correct position. Go to the "Paper Select Sensor Service Check" on page 2-30. Action Go to the "Paper Empty Sensor Service Check" on page 2-26. Be sure the paper empty sensor is not blocked. Go to the "Paper Empty Sensor Service Check" on page 2-26.
2-8
Symptom Paper feeds, but Auto Loading does not work.
Action Be sure the paper select lever is in the cut sheet position. Be sure Auto Loading is enabled in the Setup Mode. Go to the "Paper Select Sensor Service Check" on page 2-30.
Alt + Park/Load functions when the pull tractor is installed. With Paper Out blinking, Form Feed does not operate until paper is located at first print line. Lower feed roll shaft rotates, but paper does not feed. Pressing Form Feed 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 does not work. Incorrect Top of Form positioning.
Be sure the paper select lever is in the tractor position. Go to the "Pull Tractor Sensor Service Check" on page 2-38.
Be sure the paper select lever is in the correct position. Go to the "Paper Feed Service Check" on page 2-27.
Go to the "Top of Forms Problem Service Check" on page 2-39.
Diagnostic Information 2-9
Operator Panel Problems
Symptom Start/Stop does not function but no error is indicated. Only the Power light turns on. One or more buttons do not function. One or more lights do not function. Action Turn the printer off and then on. Go to the "Operator Panel Service Check" on page 2-24.
Power Problems
Symptom When the power switch is on, the Power light does not turn on or the printer does not start. The Power light blinks or changes intensity. Action Check continuity of the power cord and the voltage of the user's outlet. Go to the "Power Service Check" on page 2-32.
2-10
Print Quality Problems
Symptom No print, but carrier moves as if printing. Action 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. Be sure the serial interface adapter is installed correctly and the dip switches are set correctly. Check the ribbon cartridge for binds or damage. Go to the "Print Speed Service Check" on page 2-34. Print density is light. Verify that the ribbon density control knob on the ribbon cartridge is not set to 0. If the ribbon has reached its end of life or is worn, the ribbon cartridge needs to be replaced. Go to the "Carrier Drive, Home Position Sensor, Ribbon Feed Service Check" on page 2-17. Uneven print density across the print line. Specific dots missing. Extra dots or lines printing. Be sure the printhead cables are connected correctly to the printhead and the sub logic board. Clean the printhead. Set the form thickness lever to position "1" and run the print test. Go to the "Carrier Drive, Home Position Sensor, Ribbon Feed Service Check" on page 2-17. Scattered ink smearing, blurred characters. Fuzzy print. Clean the printhead nose. Clean the ribbon guide and shield. If the ribbon has reached its end of life or is worn, the ribbon cartridge needs to be replaced. Go to the "Carrier Drive, Home Position Sensor, Ribbon Feed Service Check" on page 2-17.
Diagnostic Information 2-11
Symptom Wavy vertical lines, uneven left margin or character width is reduced.
Action Clean and lubricate the carrier shaft. If the carrier drive belt is worn or broken, replace the carrier unit. Go to the "Carrier Drive, Home Position Sensor, Ribbon Feed Service Check" on page 2-17.
Ribbon Feed Problems
Symptom Ribbon comes off, becomes loose or folded, or jams. Ribbon feeds correctly but is noisy. Action Check the ribbon cartridge for binds or damage. Go to the "Carrier Drive, Home Position Sensor, Ribbon Feed Service Check" on page 2-17.
2-12
Irrecoverable Operator Errors
Alt and Paper Out lights blink to indicate an operator error. If this indication cannot be recovered, the problem may be the paper empty 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 Empty Sensor
Action Remove all paper from the printer. Turn the power on. Go to the "Paper Empty Sensor Service Check" on page 2-26. Check Paper Out blinks when paper does not exist. Paper Out turns off when paper exists.
Paper Select Sensor
Action Turn the power off. Install the Push Tractor. Set the paper select lever to the tractor position and load the continuous forms. Turn the power on. Remove the continuous forms. Set the paper select lever to the cut sheet position and insert a cut sheet. When Auto Loading is enabled, paper feeds automatically. When Auto Loading is disabled, press Form Feed to load a cut sheet. Check that Alt + Park/Load does not function. Go to the "Paper Select Sensor Service Check" on page 2-30. Check Alt + Park/Load function correctly. Go to the "Paper Select Sensor Service Check" on page 2-30.
Diagnostic Information 2-13
Service Checks
Abnormal Noise Service Check
Check the entire printer for loose parts.
FRU 1 2 Ribbon Cartridge Printhead Action Remove and reinstall the ribbon cartridge. Disconnect the printhead cables. Run the print test (do not fold or damage the cables during the test). Replace the printhead if the noise is gone. 3 Carrier Motor Ribbon Drive Mechanism Disconnect the carrier motor connector CN9 from the main logic board, and turn the printer off and then on. If the abnormal noise is gone, look for a problem with the carrier motor or ribbon drive mechanism. 4 Paper Feed Mechanism Disconnect the paper feed motor from CN10 from the main logic board. Perform the Print Test. If the abnormal noise is gone, look for the problem in the paper feed mechanism.
2-14
Auto Sheet Feeder (ASF) Service Check
Note: Be sure the sheet feeder is enabled. Refer to "Setup Mode" on page 1-6. 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. Auto Sheet Feeder must be selected in the Setup menu.
Continuous forms can be used with the ASF installed by moving the paper select lever to continuous forms and pressing Start to feed the continuous forms to the first print line. The ASF contains no electrical parts. It is driven from the gear on the inside of the printer's right side frame. The combination lock mechanism is a clutch that causes the ASF pick rollers to feed only one sheet of paper at a time. When Auto Sheet Feeder is selected on the Setup Menu, the cut sheet paper drive reverses itself for a short distance during paper loading. This reversal engages the clutch and thus engages the paper picker rollers, which feed the top sheet from the cut sheet paper stack. The sheet is fed about 5 inches (125 mm) and the paper path briefly reverses again; this disengages the clutch and the picker rollers. The sheet is then fed to the print line by the ASF's upper and lower feed rollers and the printer's lower feed rollers. Although the ASF picker rollers continue to turn as the paper is fed, their drive is disengaged and they are actually being turned by the paper.
FRU 1 Paper Select Sensor Action With the paper select lever in the cut sheet position, do the following: · Try to load a sheet with Alt+Park/Load. (This button should not work) · If the paper loads go to the "Paper Select Sensor Service Check" on page 2-30.
Diagnostic Information 2-15
FRU 2 Paper Feed
Action If the paper does not feed, do the following: · Remove the ASF. · Be sure the base printer feeds paper correctly. · If it does not feed paper correctly, go to the "Paper Feed Service Check" on page 2-27.
3
Gear Train
Be sure the ASF drive gear on the inside of the printer's right frame rotates. Inspect the right side gear train for damage or debris. Remove the ASF right cover and ensure that all gears are in good condition.
4
Combination Lock Mechanism
Install the ASF and press Form Feed. If the picker drive shaft does not rotate, replace the combination lock mechanism.
5
Left and Right Hoppers
If the ASF picker rollers rotate but a single sheet is not picked, inspect the springs and corner separators on the left and right hoppers. Make sure the paper load lever is in the correct position.
2-16
Carrier Drive, Home Position Sensor, Ribbon Feed Service Check
23XX-001 only: If the carrier stops but the print wires continue to fire (printing one vertical column of dots), or if the carrier does not move after turning the printer off and then on, inspect the area of the main logic board that is below the paperfeed motor. If this area is damaged or cracked, replace the main logic board. Also check the continuity of soldered-on fuse FU1 located on the main logic board near the paper empty sensor. If this fuse is open, replace the main logic board. Turn the printer off and then on. The carrier should move to the left, contact the home position sensor on the left side frame, and immediately move slightly away from the sensor. A Home Position Error occurs when:
· · ·
The sensor is not closed. The sensor is not quickly opened. The sensor is closed any time other than when the printer is turned off and then on.
Diagnostic Information 2-17
.
FRU 1 Carrier Action If there is no Home Position Error, check the carrier belt and the ribbon cartridge for wear or damage. Check the belt and pulley engagement. Manually move the carrier the full length of the carriage to check for binds and to make sure the ribbon advances when the carriage moves in either direction. If the carrier binds check the following: · · · · Correct printhead-to-platen gap. Clean and lubricated carrier shaft. Idler pulley not binding. Ribbon drive rack gear teeth not damaged.
If the carrier still binds: Remove the belt and move the carrier again. If the bind is gone, replace the carrier motor. If the bind still exists, replace the carrier. 2 Home Position Sensor Sub Logic Board Short Flexible Cable If the carrier moves manually without binding but the Home Position Error still occurs, verify that the main logic board is receiving +26 V dc on pin CP11-1. Check that the 5 V dc home position sensor signal is getting to the main logic board. Check CP3-7 on the main logic board. Check CP6-1 on the sub logic board. Replace the sensor, the sub logic board, or the short flexible cable as necessary.
2-18
FRU 3 Carrier Motor
Action If the home position sensor is OK, refer to the table and make sure the resistance of the carrier motor windings are from 1 to 5 ohms for all printers. 238X-001,002,003 239X-002,003 CP9-1 & CP9-5 CP9-2 & CP9-6 CP9-3 & CP9-5 CP9-4 & CP9-6 239X-001 CP9-1 & CP9-6 CP9-2 & CP9-5 CP9-3 & CP9-6 CP9-4 & CP9-5
4
Main Logic Board
If all parts appear OK but the Home Position Error still occurs, replace the main logic board. After replacing the main logic board or any parts affecting the carrier, perform the bidirectional print adjustment. See "Bidirectional Print Adjustment" on page 4-5.
Diagnostic Information 2-19
Intermittent Problem Service Check
FRU/Symptom 1 The machine sometimes fails before POST is complete. Action Check for the following: 1. Loose connectors. Reconnect all connectors to the main and sub logic boards. 2. Electrical noise or static discharge. Check the following items: · Power supply ground. · Machine frame ground. · Printer interface cable is grounded and shielded. · If the upper feed roll shaft does not have a ground spring, install P/N 1368036. 3. Intermittently low voltages. Check for ac and all dc voltages and short circuits on the main and sub logic boards. a. Check the customer's outlet voltage and ensure that it is within tolerance. b. Check the continuity of the power cord. c. Disconnect the power supply cable from the connectors CN11 on the main logic board and CN1 on the sub logic board. Turn the printer power on and check all dc output voltages at CP11 and CP1. Ensure the output voltages are:
CP11-1 (+26 V dc ±10%) & CP11-2 (GND) CP11-3 (+5 V dc ±5%) & CP11-4 (Signal GND) CP 1-1 (+26 V dc ±10%) & CP1-2 (GND) CP 1-3 (+5 V dc ±5%) & CP1-4 (Signal GND)
If the voltages are not correct, replace the Power Supply Unit. If the failure remains, replace the main logic board and sub logic board. Note: When replacing the main logic board, always reset the bidirectional print adjustment. Refer to "Bidirectional Print Adjustment" on page 4-5.
2-20
FRU/Symptom 2 Machine power sometimes turns off.
Action 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 customer'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 the connectors CN11 on the main logic board and CN1 on the sub logic board. Turn the printer power on and check all dc output voltages at CP11 and CP1. Be sure the output voltages are as follows:
CP11-1 (+26 V dc ±10%) & CP11-2 (GND) CP11-3 (+5 V dc ±5%) & CP11-4 (Signal GND) CP 1-1 (+26 V dc ±10% & CP1-2 (GND) CP 1-3 (+5 V dc ±5%) & CP1-4 (Signal GND)
If one of the voltages is 0, go to the "Power Service Check" on page 2-32. If the voltages are not 0 but are incorrect, replace the power supply unit. 3 Intermittently poor print quality. Do the following: · · · · · · Remove paper jams from the paper path. Clean all feed roller surfaces. Clean the ribbon shield and printhead. Clean the platen surface. Install the ribbon cartridge correctly. If the ribbon end of life has been reached, have the customer replace the ribbon cartridge.
Diagnostic Information 2-21
FRU/Symptom 4 If the prior suggestions have not corrected the problem.
Action The service check has not defined the failure, or the machine is having intermittent failures. The following may cause undefined or intermittent failures: 1. Customer's outlet voltage. Be sure that it is within the tolerance. 2. Loose connector pins or keys that fail to contact. Check the following: a.Reconnect the connectors of all FRUs and printer interface cables. b.Check the continuity of the line cord. 3. Electrical noise. Check the following: a. Power supply ground. b. Machine frame ground. c. Printer interface cable is grounded or shielded. 4. Undefined data in customer applications. Check the baud rate at the controller. Check that the printer interface cable matches the printer.
5
Problem occurs only in specific customer applications.
Perform the Trace Print (hexadecimal printing) by the following procedure and check the data streams. 1. Turn the power off. 2. Turn the power on while pressing and holding Alt. 3. Have the customer print the failing job. 4. To stop printing, turn the power switch off. If the failure still occurs, replace the main logic board. Be sure to reset the bidirectional print adjustment, refer to the "Bidirectional Print Adjustment" on page 4-5.
2-22
No Print or Abnormal Print Service Check
FRU/Function 1 Main Logic Board Action If the Print Test does not complete correctly, do the following: · Replace the main logic board. · Reset the bidirectional print adjustment. Refer to "Bidirectional Print Adjustment" on page 4-5. 2 3 Interface Cable Emulation Mode Check the connection and continuity of the interface cable. Enter the Setup Menu and make sure the printer is in the correct emulation mode for the computer, either IBM or Epson. If the serial interface adapter is installed, make sure the dip switches match the computer settings. · Make sure the serial adapter power cable, if present, is securely connected to the printer power connector CN5. · On newer models, make sure the serial interface adapter's power LED is on when printer power is on. Run the "Serial Interface Adapter Print Test" on page 3-6. If the test is not successful replace the serial interface adapter. If no defect is found, the printer and serial interface adapter are working correctly. The problem may be with the interface cable, the computer, the printer driver, or the specific job being sent.
4
Serial Interface Adapter
Diagnostic Information 2-23
Operator Panel Service Check
Note: If the Op-Panel Asm is locked, only the Start/Stop, Form Feed, Alt + Tear Off and Alt + Park/Load buttons are active. Model 2 and 3 printers have a "Lock" LED to indicate that the operator panel is locked. To unlock the operator panel, turn the printer off and then on while pressing Micro and Micro.
FRU 1 Op-Panel Cable Sub Logic Board Action Check the connections from the operator panel to the sub logic board and from the sub logic board to the main logic board. Disconnect the operator panel from its cable and make sure +5 V dc is present on the following pins on the cable: 23XX-001 CP1-1 CP1-7 23XX-002,003 CP1-2 CP1-8
If there is a voltage problem make sure the sub logic board is receiving +5 V dc on CN1-3. Replace the operator panel cable, the sub logic board, or the power cable as necessary.
2-24
FRU 2 Short Flexible Cable
Action Disconnect the short flexible cable from the main logic board. Check the continuity of the operator panel signal lines between the end of the short flexible cable and the operator panel connector on the sub logic board. 238X-001 CP3-4 & CN8-5 CP3-3 & CN8-6 CP3-2 & CN8-4 CP3-1 & CN8-8 239X-001 CP3-4 & CN7-5 CP3-3 & CN7-6 CP3-2 & CN7-4 CP3-1 & CN7-8 238X-002,003 CP3-4 & CN8-2 CP3-3 & CN8-4 CP3-2 & CN8-8 CP3-1 & CN8-6 239X-002,003 CP3-4 & CN7-2 CP3-3 & CN7-4 CP3-2 & CN7-8 CP3-1 & CN7-6
Replace the short flexible cable or the sub logic board as necessary. If there is still a problem, replace the operator panel. If that does not fix the problem, re-install the old operator panel and replace the main logic board. If you replace the main logic board, reset the "Bidirectional Print Adjustment" on page 4-5.
Diagnostic Information 2-25
Paper Empty Sensor Service Check
Note: 23XX-001 machines have a single paper sensor that serves as a paper empty sensor and also determines the top of form setting. 23XX-002 and 23XX-003 machines have two sensors:
· ·
The left sensor is paper empty. The right sensor is Top of Form.
FRU Action With no paper in the printer, the tractor in the push position, and the paper select lever set to continuous forms, press Alt+Park/Load; the gear train should turn forward (to try to load paper). Activate the paper empty sensor with a screwdriver and press Alt+Park/Load again; the gear train should turn backward (to try to park paper). Measure the voltage between CN7-2 (paper empty signal) and CN7-3 (GND) on the main logic board. There should be 0 V dc when there is paper in the printer, and +5 V dc when there is no paper in the printer. Make sure the sensor and its actuator are properly installed and undamaged. Correct the problem or replace the sensor.
1
Paper Empty Sensor
2
Main Logic Board
If the ASF is being used, it is normal for the Paper Out LED not to blink when there is no paper in the printer. Do the following: · Enter the Setup Menu. · Make sure the ASF setting is off unless the ASF is installed. · If the sensor and the ASF setting are OK, replace the main logic board. · Reset the "Bidirectional Print Adjustment" on page 4-5.
2-26
Paper Feed Service Check
Note: If the problem is frequent jams or paper creases, verify that the paper is neither very thick nor very thin. If necessary refer the customer to the User's Guide for specifications of acceptable papers. On 23XX-001 printers check for equal gap between the lower feed rollers and lower pinch rollers. If the gap is smaller on the left, install Shim Kit, P/N 1368067. If the paper does not stop in the correct location, refer to the "Paper Empty Sensor Service Check" on page 2-26 and the "Top of Forms Problem Service Check" on page 2-39.
FRU / Symptom 1 Auto Sheet Feeder Action If the Auto Sheet Feeder is installed, remove it. Enter the Setup Menu and reset "ASF" to off. Verify that the machine works correctly without the ASF installed. If the printer fails only with the Auto Sheet Feeder installed, refer to the "Auto Sheet Feeder (ASF) Service Check" on page 2-15. 2 Gear Train Remove all paper from the machine. Press Form Feed several times and examine all rotating parts to find the problem. For better visibility, remove the covers and reconnect the operator panel to the sub logic board. The upper and lower feed rollers and the upper and lower pinch rollers should all be clean and in good condition, and should all rotate during Form Feed. To turn the gear train manually on a 23XX-002 or 23XX-003, turn the right end of the lower feed roller shaft with a 6 mm wrench.
Diagnostic Information 2-27
FRU / Symptom 3 Paper Selector Lever
Action Make sure the selector lever alternately engages and disengages the tractor gear and the ASF drive gear. Check the operation of the following parts as you move the paper select lever: · The tractor gear engages correctly in the continuous forms position. · The tractor belts are in good condition and rotate correctly. · The pinch roller shafts move downward as the lever moves to the cut sheet position. · The paper separator moves upward as the lever moves to the cut sheet position.
4
Operator Panel
If paper does not move at all, verify that the Form Feed button is working as follows: With the tractor in the push position, power off, power on, then press Alt/Load. The carrier should move to the center of the platen. If it does not, go to the "Operator Panel Service Check" on page 2-24.
5
Paper Feed Motor
Disconnect the paper feed motor cable CN10 from the main logic board. No pin should have continuity to ground. The resistances should be as follows: 23XX-001, 002 = 21 to 24 ohms. CP10-1 to CP10-5 CP10-2 to CP10-5 CP10-3 to CP10-5 CP10-4 to CP10-5 CP10-1 to CP10-6 CP10-2 to CP10-6 CP10-3 to CP10-6 CP10-4 to CP10-6
23XX-003 = 8 to 9 ohms. CP10-1 to CP10-5 CP10-2 to CP10-5 CP10-3 to CP10-5 CP10-4 to CP10-5
2-28
FRU / Symptom 6 Paper Select Sensor
Action Remove all paper from the printer and place the tractor in the push position. Press Form Feed and time how long the gear train rotates. · With the paper select lever in the cut sheet position (sensor open) the gear train should rotate for less than 2 seconds; · With the lever in the continuous forms position (sensor closed), the gear train should rotate for more than 3 seconds. If the printer does not do this, inspect the sensor to make sure it is being opened and closed by the paper separator. Disconnect CN5 from the sub logic board and measure the paper selector sensor resistance from CP5-1 to CP5-2. Replace the sensor if the resistance does not change from zero to infinite as the paper select lever is moved.
7
Pull Tractor Sensor
If the pull tractor sensor has failed to close, Park/Load and Auto Tear Off will not work when using push tractors. If the sensor has failed to open, Park/Load will try to park paper when using pull tractors, but the paper will feed all the way out of the tractors and cannot reload. Refer to the "Pull Tractor Sensor Service Check" on page 2-38.
8
Main Logic Board
If no other problem is found replace the main logic board. Reset the "Bidirectional Print Adjustment" on page 4-5.
Diagnostic Information 2-29
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. See the Setup Mode and Switch Settings section.
FRU 1 Paper Select Sensor Action Remove all paper from the printer and place the tractor in the push position. Make sure the Auto Sheet Feed (ASF) is set to OFF in the Setup Mode. Press Form Feed and time how long the gear train rotates. With the paper select lever in the cut sheet position (sensor open) the gear train should rotate for less than 2 seconds; with the lever in the continuous forms position (sensor closed), the gear train should rotate for more than 3 seconds. If the printer does not do this, inspect the sensor to make sure it is being opened and closed by the paper separator. Disconnect CN5 from the sub logic board and measure the paper selector sensor resistance from CP5-1 to CP5-2. Replace the sensor if the resistance does not change from zero to infinite as the paper select lever is moved from cut sheet to continuous forms. If the sensor is good but the gear train does not run the right length of time, set the head gap to position 1 and disconnect the short flexible cable from CN3 on the main logic board. Check the continuity between CP3-6 (paper select sensor) and GND while actuating the paper select lever. Cut Sheet Continuous Forms 23XX-002 23XX-001 1K ± 0.5K ohms 0K ± 0.5K ohms 12K ± 0.5K ohms 3.5K ± 0.5K ohms If the resistance is correct, replace the main logic board. If the resistance is incorrect, replace the sub logic board.
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FRU 2 Pull Tractor Sensor
Action A failed pull tractor sensor can cause Alt + Park/Load not to function. With the tractor in the push position, press Alt+Park/ Load 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 it does, go to the "Pull Tractor Sensor Service Check" on page 2-38.
POST Service Check
FRU 1 2 Power LED Cables Action If the power LED is not on, go to the "Power Service Check" on page 2-32. A faulty interface cable can cause POST errors. Disconnect the interface cable from the printer and turn the printer off and then on. Check the connections of the short flexible cable and the power cable to the main logic board and sub logic board. Check the condition and continuity of the operator panel cable. 3 Operator Panel If no problem is found, the problem may be in either the operator panel or the main logic board. Replace the operator panel and retest the printer. Replace the main logic board if necessary. Reset the bidirectional print adjustment; refer to "Bidirectional Print Adjustment" on page 4-5.
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Main Logic Board
Diagnostic Information 2-31
Power Service Check
If the symptom is that the Power light varies in intensity, make sure the upper feed roll shaft has the ground spring. If it does not, install ESD Kit P/N 1368036.
FRU 1 Power Supply Action If the carrier does not move to the left after turning the printer off and then on, do the following: · Make sure the line cord voltage to the power supply is correct. · Make sure the power supply outputs are +5 V dc at CN1-2 and +26 V dc at CN1-4. If the voltage is incorrect, check the internal fuses before replacing the power supply. Generally if F3 is blown it is due to a short in the printhead; replace the printhead and the fuse before powering on again. · Check for +5 V dc at main logic board CN11-3 and sub logic board CN1-3, and for +26 V dc at main logic board CN11-1 and sub logic board CN1-1. · Make sure the short flexible cable is undamaged and correctly installed. 2 Sub Logic Board If the carrier moves to the left after turning the printer off and then on, do the following: · Move the carrier to the right and turn power on. The carrier should move to the left. The power LED should be on steady whenever the printer is on. If the carrier moves to the left during after turning the printer off and then on, but the power LED is not on steady: Make sure the sub logic board is receiving voltage by checking for +5 V dc at sub logic board CN1-3. · If no voltage or power cable problem is found, make sure there is +5 V on pins 3 and 9 of the sub logic board connector for the operator panel cable. If the voltage is incorrect replace the sub logic board.
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FRU 3 Op-Panel Op-Panel Cable Carrier Motor
Action If there is still a power LED problem, check the operator panel cable continuity and replace the cable or the operator panel. Disconnect the carrier motor from main logic board CN9 and turn the printer off and then on. If the power LED lights correctly only with the carrier motor disconnected, replace the carrier motor. Disconnect the paper feed motor from main logic board CN10 and turn the printer off and then on. If the power LED lights correctly only with the paper feed motor disconnected, replace the paper feed motor. Disconnect the printhead cable from the sub logic board and turn the printer on. If the power LED lights correctly only with the printhead cables disconnected from the sub logic board, there is a short in the printhead or printhead cables. Disconnect the printhead cable from the sub logic board and make sure none of the leads on the cable are shorted to ground.
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5
Paper Feed Motor
6
Printhead Printhead Cables
7
Main Logic Board
If no problem is found with other components but the printer still has a power problem, replace the main logic board. Reset the bidirectional print adjustment; refer to "Bidirectional Print Adjustment" on page 4-5.
Diagnostic Information 2-33
Print Speed Service Check
Reduced speed while printing the top 2 inch (51 mm) of a job is normal; for Model 003 printers, the slow down can be eliminated by entering Setup Mode and disabling TOF Read. The speed of the 23XX 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 239X printers and protects the printhead from overheating. Depending on the job content, thermal slowdown may occur after 5 to 10 minutes of continuous operation on 239X-001 printers and after 10 to 20 minutes on 239X-002, 003 printers. Print slowdown modes are as follows:
Thermal Slowdown 238X-001 No
Forms Thickness Slowdown 26% speed reduction at Forms Thickness 7. Head Gap Sensor contains one switch. No Forms Thickness speed reduction. No Head Gap Sensor. Reduced print wire force at Forms Thickness 1. 23% speed reduction at Forms Thickness 4 through 7. Head Gap Sensor Assembly contains two switches. Reduced print wire force at Forms Thickness 1. 20% speed reductions at Forms Thickness 4 through 7. Head Gap Sensor Assembly contains two switches.
239X-001
Yes
238X-002 238X-003
No
239X-002 239X-003
Yes
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FRU 1 Head Gap Sensor 23XX-001
Action Check the function of the head gap sensor by moving the forms thickness lever from 6 to 7 and back while printing the Demo Page Alt + Demo. Print speed is reset at the beginning of each line; listen for the printer to slow down in position 7. Disconnect the head gap sensor from connector CN3 on the sub logic board. Check the resistance of the sensor while moving the forms thickness lever. Resistance should be 0 ohms at forms thickness position 7 and infinite at positions 1 through 6.
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Head Gap Sensor 23XX-002 23XX-003
Check the function of the head gap sensor by turning the power on with the Alt + Macro buttons pressed. · With the forms thickness lever at 1, Macro LED 1 will light. · With the forms thickness lever at 2 and 3, Macro LED 2 will light. · With the forms thickness lever at 4 through 7, Macro LED 3 will light. Disconnect the head gap sensor asm from connector CN3 on the sub logic board. Check the resistance of the sensor while moving the forms thickness lever. Resistance should be 0 ohms at position 1 and infinite at positions 2 through 7. Disconnect the head gap sensor asm from connector CN4 on the sub logic board. Check the resistance of the sensor while moving the forms thickness lever. Resistance should be 0 ohms at positions 1 through 3 and infinite at positions 4 through 7.
Diagnostic Information 2-35
Printhead Service Check
FRU 1 Printhead Cables Printhead Action If the problem is missing or extra dots or lines, do the following: · Check the continuity and connection of the printhead cables and the short flexible cable. · Make sure the voltages to the sub logic board are correct. If dots are missing: · Perform the print test to determine which wire is not firing. · Remove the printhead and check the printhead resistance according to the following table. Make sure no pins have continuity to the printhead housing.
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