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Lexmark 2380 - Forms Printer B/W Dot-matrix, Service Manual

The Lexmark 2380 is a reliable and efficient Forms Printer featuring black and white dot-matrix technology. To help you make the most of this innovative device, we offer a free Service Manual for download at manualshive.com. This manual provides detailed instructions and troubleshooting tips, ensuring optimal performance for your Lexmark 2380.

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Service Manual

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

23xx.bk  Page vi  Wednesday, March 13, 2002  10:42 AM

Summary of Contents for 2380 - Forms Printer B/W Dot-matrix

Page 1: ...XX Series Lexmark and Lexmark with diamond design are trademarks of Lexmark International Inc registered in the United States and or other countries Index Safety and Notices Trademarks Start Diagnostics Table of Contents ...

Page 2: ...ade 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...

Page 3: ... 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 Ch...

Page 4: ... 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...

Page 5: ...ew 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 ...

Page 6: ...log 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 ...

Page 7: ...artungsfachmann 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 Sicherhei...

Page 8: ...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 informaç...

Page 9: ...oc 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 Inf...

Page 10: ...xii Korean Safety Information ...

Page 11: ... 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 lub...

Page 12: ...xiv ...

Page 13: ...e 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 ...

Page 14: ...391 2391 2391 001 24 Wide Yes PS 1 N A 2390 PS1 24 Narrow Yes 2380 Plus 2380 Plus 2380 002 9 Narrow No 2381 Plus 2381 Plus 2381 002 9 Wide No 2390 Plus 2390 Plus 2390 002 24 Narrow No 2391 Plus 2391 Plus 2391 002 24 Wide No Forms Printer 2380 Plus Forms Printer 2380 Plus 2380 003 9 Narrow No Forms Printer 2381 Plus Forms Printer 2381 Plus 2381 003 9 Wide No Forms Printer 2390 Plus Forms Printer 23...

Page 15: ...ter 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 rep...

Page 16: ...ile 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 ...

Page 17: ...t HVPS High Voltage Power Supply LAN Local Area Network LCD Liquid Crystal Display LED Light Emitting Diode LVPS Low Voltage Power Supply NVRAM Nonvolatile Random Access Memory OEM Original Equipment Manufacturer POR Power On Reset POST Power On Self Test PQET Print Quality Enhancement Technology ROS Read Only Storage SRAM Static Random Access Memory UPR Used Parts Replacement V ac Volts alternati...

Page 18: ...tinuous 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 ...

Page 19: ...ead 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 ...

Page 20: ... 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 Switch 2 Switch 3 Switch 4 Speed bps On On Off Off 150 On Off On Off 300 On Off Off Off 600 Off On On Off 1 200 Off On Off Off 2 400 Off Off On Off 4 800 Off Off Off Off 9 600 On On On Off 19 200 Off Off Off On 38 400 RS 422 only ...

Page 21: ...the number of data bits 7 or 8 in each data frame Switch 1 Switch 2 Switch 3 Speed bps N A N A N A 150 On Off On 300 On Off Off 600 Off On On 1 200 Off On Off 2 400 Off Off On 4 800 Off Off Off 9 600 On On On 19 200 On On Off 38 400 RS 422 Only Switch 5 Data Bits Off 8 On 7 ...

Page 22: ...en parity For all other parity settings the transmitted parity matches the received parity Switch 8 Stop Bits Snap On Switch 8 Buffer Size Gray and Black Selects the buffer size Switch 6 Switch 7 Parity Off Off No Off On Ignore On Off Odd On On Even Switch 8 Stop Bits Off 1 Stop Bit On 2 Stop Bits Switch 8 Buffer Size Off Normal 2048 bytes On Minimum 2 bytes ...

Page 23: ...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 9 Protocol Snap On Gray Off XON XOFF DTR Pacing RS232 only On DTR pacing RS232 only XON XOFF Switch 4 Switch 9 Protocol Off On XON XOFF Off Off DTR pacing RS232 only On Off DTR XON XOFF Off On Robust XON XOFF Switch 10 Print Test Off Normal mode On ...

Page 24: ... the polarity of the receive and transmit data line for the RS 422 serial interface Switch 12 Serial Interface Mode Select All Units Switch 232 422 sets the serial interface in either RS 232C or RS 422 mode Switch 11 Mode Off Normal On Reverse Switch 12 Mode Off RS 232C On RS 422 ...

Page 25: ...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 che...

Page 26: ...on None Post Error Go to POST Service Check on page 2 31 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 LED Status Po...

Page 27: ...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 Indication Alarm Action LE...

Page 28: ... 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 None Power Failure Check the continuity of the power cord and the voltage of the user...

Page 29: ...nges intensity None Go to Power Service Check on page 2 32 Any Beeps 7 times 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 Pr...

Page 30: ...ter 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 Symptom Action During POST abnormal noise comes from the carrier Check the ribbon cartridge for binds or damage Go to the Carrier Drive Home Position Sensor Ribbon Feed Service Check on page 2 17 During idling abnormal noise comes from the ...

Page 31: ...erface 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 Slow printing speed Go to the Print Speed Service Check on page 2 34 Symptom Action Auto sheet feeder will not feed paper Auto sheet feeder double feeds Auto sheet feeder has intermittent feed p...

Page 32: ...king with paper in the printer Go to the Paper Empty Sensor Service Check on page 2 26 Paper Out does not blink when no paper is in the printer and ASF is not installed Print operation starts without paper Be sure the paper empty sensor is not blocked Go to the Paper Empty Sensor Service Check on page 2 26 Alt Park Load does not function when the push tractor is installed Form feed length is not c...

Page 33: ...line Be sure the paper select lever is in the tractor position Go to the Pull Tractor Sensor Service Check on page 2 38 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 Be sure the paper select ...

Page 34: ...ne or more lights do not function Turn the printer off and then on Go to the Operator Panel Service Check on page 2 24 Symptom Action 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 Check continuity of the power cord and the voltage of the user s outlet Go to the Power Service Check on page 2 32 ...

Page 35: ...nd 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 a...

Page 36: ...n or broken replace the carrier unit Go to the Carrier Drive Home Position Sensor Ribbon Feed Service Check on page 2 17 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 the Carrier Drive Home Position Sensor Ribbon Feed Service Check on page 2 17 Symptom Action ...

Page 37: ...oes not exist Paper Out turns off when paper exists Go to the Paper Empty Sensor Service Check on page 2 26 Action Check 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 Alt Park Load function correctly Go to the Paper Select Sensor Service Check on page 2 30 Remove the continuous forms Set the paper sele...

Page 38: ...eplace 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 I...

Page 39: ...nly 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 th...

Page 40: ...pect 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 separ...

Page 41: ...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 Positi...

Page 42: ...ng 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...

Page 43: ... 003 239X 002 003 239X 001 CP9 1 CP9 5 CP9 1 CP9 6 CP9 2 CP9 6 CP9 2 CP9 5 CP9 3 CP9 5 CP9 3 CP9 6 CP9 4 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 FRU...

Page 44: ...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 CP...

Page 45: ...utput 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 Remo...

Page 46: ... 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 Tu...

Page 47: ...computer either IBM or Epson 4 Serial Interface Adapter 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 Prin...

Page 48: ...Micro and Micro FRU Action 1 Op Panel Cable Sub Logic Board 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 23XX 002 003 CP1 1 CP1 2 CP1 7 CP1 8 If there is a voltage problem make sure the sub logic board ...

Page 49: ...2 CP3 3 CN8 6 CP3 3 CN8 4 CP3 2 CN8 4 CP3 2 CN8 8 CP3 1 CN8 8 CP3 1 CN8 6 239X 001 239X 002 003 CP3 4 CN7 5 CP3 4 CN7 2 CP3 3 CN7 6 CP3 3 CN7 4 CP3 2 CN7 4 CP3 2 CN7 8 CP3 1 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 m...

Page 50: ...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 senso...

Page 51: ...1 Auto Sheet Feeder 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 rotati...

Page 52: ... 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 ...

Page 53: ...tor 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 Loa...

Page 54: ...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...

Page 55: ... to the Power Service Check on page 2 32 2 Cables 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 t...

Page 56: ... 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 po...

Page 57: ...D lights correctly only with the paper feed motor disconnected replace the paper feed motor 6 Printhead Printhead Cables 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 su...

Page 58: ...hermal 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 Forms Thickness Slowdown 238X 001 No 26 speed reduction at Forms Thickness 7 Head Gap Sensor contains one switch 239X 001 Yes No Forms Thickness speed reduction No Head Gap Sensor 238X 002 238X 003 No R...

Page 59: ...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...

Page 60: ...y 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 ...

Page 61: ...ot4 CP8 14 CP8 11 Dot5 CP8 4 CP8 7 Dot6 CP8 16 CP8 11 Dot7 CP8 2 CP8 9 Dot8 CP8 18 CP8 11 Dot9 CP8 1 CP8 9 Dot10 CP8 17 CP9 10 Dot11 CP8 3 CP8 9 Dot12 CP8 15 CP9 10 Dot13 CP8 5 CP9 8 Dot14 CP9 16 CP9 12 Dot15 CP9 4 CP9 8 Dot16 CP9 17 CP9 12 Dot17 CP9 2 CP9 8 Dot18 CP9 15 CP9 12 Dot19 CP9 1 CP9 6 Dot20 CP9 13 CP9 14 Dot21 CP9 3 CP9 6 Dot22 CP9 11 CP9 14 Dot23 CP9 5 CP9 6 Dot24 If the problem is not...

Page 62: ...es while alternately holding down and releasing the left pull tractor actuator The paper should park and load when the actuator is not held down and should not park or load when the pull tractor actuator is held down If the paper does not move correctly Disconnect CN4 from the main logic board There should be 0 ohms from CP4 1 to CP4 2 when the left pull tractor actuator is pressed and infinite re...

Page 63: ...right sensor is top of form FRU Action 1 Top of Form Sensor Check that the top of form sensor and its flag are properly installed and are undamaged 2 Main Logic Board Remove the paper and set the paper select lever to the cut sheet position and turn the power on Measure the voltage between main logic board CN8 2 TOF signal and CN8 3 GND When there is paper in the printer the voltage should be 0 V ...

Page 64: ... printer cover The home sensor detects the position of the slider When Tractor 2 is selected the motor driven Tractor 2 slider pushes the printer sub slider cam lever to engage the printer gear train which drives the Tractor 2 tractors When the Tractor 2 is deselected the motor retracts the slider disengaging the Tractor 2 gear drive and reengaging the printer tractors ...

Page 65: ...ves after turning the printer off and then on If the slider does not move after turning the printer off and then on Make sure the slider and gear train are properly connected and move freely with the power off Make sure the Tractor 2 board is receiving 26 V dc on CN1 1 and 5 V dc on CN1 5 If not check the cable connection and the voltages at main logic board CN6 1 The upper right pin at CN6 is pin...

Page 66: ...2 is installed Remove the Tractor 2 cover and make sure the in place sensor opens when the Tractor 2 is installed The voltage at Tractor 2 CN1 13 should be 5 V dc with the sensor open and 0 with it closed Replace the Tractor 2 board cable asm if the sensor signal is wrong For information on the Tractor 2 cable connectors see Tractor 2 Cable Connectors on page 5 4 2 Main Logic Board Check the cable...

Page 67: ...n of the pin feed belts With the power off make sure the slider does not bind Verify When the slider is to the rear the white gear drives the tractors When the slider is to the front the gear and tractors are not connected Remove the Tractor 2 cover and reinstall Tractor 2 in the printer if necessary remove the printer covers also Note that the small idler gear just below the slider is held in pla...

Page 68: ...2 44 ...

Page 69: ... Print Test The following are special machine modes that run when the printer is turned off and then back on Turn the printer on while Pressing Does This Line Feed Print test with sample fonts Alt Sets printer in Hex Dump mode Micro Micro Disables Enables Operator Panel Lockout Mode Alt Tear Off with printhead at extreme left Resets to World Trade default paper sizes Alt Setup with printhead at ex...

Page 70: ...e Sum Test Checks that the ROM data is correct Timer Interrupt Controller Test Checks that this function works NVRAM Test Checks that the NVRAM data is correct Switch Scan Test Checks the buttons on operator panel Carrier Initialization Carrier moves to the left to activate the home position sensor then moves to the first print position Feed Initialization Form feed motor rotates forward then back...

Page 71: ... stop the printer test turn the printer off The printout should be similar to the print test samples shown on page 3 4 If the printout is not like the sample go to Start on page 2 1 Note that the short horizontal lines at the top of the sample are a test of each printhead wire numbered in sequence from top to bottom Service Notes Before starting the 2380 and 2390 print test be sure letter size pap...

Page 72: ...3 4 Print Test Sample 9 wire Print Test Sample 24 wire ...

Page 73: ...cter data print in hexadecimal instead of ASCII To activate hex dump mode 1 Press and hold Alt and then turn the printer on 2 After a few seconds release Alt 3 Start your application program Be sure the printout is similar to the hex dump sample shown Two hexadecimal digits followed by a space are printed for each byte of data sent to the printer 4 The printer continues to print in hexadecimal unt...

Page 74: ...e adapter code level and switch settings and the printer character set To run the serial interface test print 1 Turn the printer off 2 Turn on serial interface Switch 10 3 Turn the printer on If the printer does not generate a printout there is a problem with the serial interface adapter or its connection to the printer Check the switch settings and be sure the serial interface adapter is correctl...

Page 75: ...ure Put the ESD wrist strap on your wrist Connect the wrist band to the system ground point This discharges any static electricity in your body to the machine Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins If you are removing a pluggable module use the correct tool Do not place the ESD sensitive part on the machine cover or on a metal table if you need to put ...

Page 76: ...his adjust ment is made be sure a gap exists between the printhead and the right end of the platen before you turn the printer on Perform the printhead to platen gap adjustment after replacing or disassembling any of the following parts Carrier Platen Pinch Roller Lower Ribbon Drive Rack Gear Side Frame Left Side Frame Right Paper Separator Feed Roller Lower Paper Guide Note Make sure the top cove...

Page 77: ...ler approximately 50 mm 2 0 in from the left side frame 6 Using feeler gauges 1 of 0 35 mm and 0 40 mm 0 014 in and 0 016 in move the left carrier bushing 2 forward or backward until the gap between the printhead 3 and platen 4 is between 0 35 mm 0 40 mm 0 014 in 0 016 in Note The gap should be wide enough for the 0 35 mm 0 014 in feeler gauge to slide in smoothly without catching but too narrow t...

Page 78: ... 014 in 0 016 in Note The gap should be wide enough for the 0 35 mm 0 014 in feeler gauge to slide in smoothly without catching but too narrow to insert the 0 40 mm 0 016 in feeler gauge 9 Repeat Steps 5 and 6 and readjust the gap if necessary 10 Repeat Steps 7 and 8 and readjust the gap if necessary 11 Set the form thickness lever to suit the paper thickness you are using 12 Install the ribbon ca...

Page 79: ...aper so be sure to use continuous forms 1 Be sure the ribbon cartridge and continuous forms are installed 2 Turn the printer on 3 Press Alt and then press Micro The printer enters Setup Mode 4 Press the Control Options button Button varies with model 5 Press the Bidirectional Alignment button Button varies with model 6 Press Font The printer prints out the pattern shown below The first and third l...

Page 80: ...s shift toward the left Each time Micro is pressed the second and fourth lines shift toward the right 8 Continue adjusting the bidirectional alignment by repeating step 7 until your printout resembles the one shown 9 When the bidirectional alignment is satisfactory press Start Stop to exit the bidirectional alignment mode ...

Page 81: ... The procedures in this section are mainly for the 2380 and 2390 printers When a procedure for the 2381 and 2391 printers differ the procedure for the 2381 and 2391 is described under Wide Carriage CAUTION Be sure to unplug the power cord whenever you are working on the printer with one of the covers removed ...

Page 82: ...he idler gear 2 4 Release the latch A and then remove the idler gear 3 5 Release the latch 8 and then remove the pick up gear 4 6 Release the latch A and then remove the combination lock mechanism 5 7 Remove the tension plate 10 on the locker cam 6 8 Remove the locker cam 6 9 Release the latch 9 and then remove the lift gear 7 ...

Page 83: ... covers and the cut sheet support 2 Remove the idler gear and pick up gear see Auto Sheet Feeder Gears Removal on page 4 8 3 Remove the left roller bushing 1 as shown 4 Remove the right roller bushing 2 5 Move the pick up roller 3 to both ends of the shaft and then remove them ...

Page 84: ... print unit see Print Unit Removal on page 4 47 6 Remove the rubber board support 5 7 2380 2390 Release the two latches 1 and then remove the Main Logic Board ground plate 2 by sliding it toward you 2381 2391 Remove the two screws securing the Main Logic Board ground plate 2 to the bottom cover Release the two latches 1 and then remove the Main Logic Board ground plate from the bottom cover by sli...

Page 85: ...Repair Information 4 11 ...

Page 86: ...e 4 49 4 Remove the sub logic board see Sub Logic Board Removal on page 4 59 5 Remove the paper feed motor and the paper feed motor plate see Paper Guide Platen Assembly Removal on page 4 40 6 Move the carrier to the center of the printer 7 Remove the belt tension spring 1 from the hook closest to the tension pulley 8 Loosen the screw 4 securing the tension pulley plate asm 2 9 Remove the carrier ...

Page 87: ...the carrier shaft and forms thickness lever to the left and remove them together from the printer Do not to lose the gap set collar 15 attached to the right end of the carrier shaft 14 Lift the rear of the carrier 12 to disengage the carrier ribbon drive gears then remove the carrier Do not to lose the oil felt 14 15 Be sure to get the carrier shaft correctly through the oil felt 16 Perform the Pr...

Page 88: ...4 14 ...

Page 89: ...Repair Information 4 15 This Page Intentionally Blank ...

Page 90: ...emoval on page 4 61 2 Remove the sub logic board see Sub Logic Board Removal on page 4 59 3 Move the carrier to the center of the printer 4 Remove the belt tension spring 1 and loosen the screw 2 5 Remove the carrier belt 3 from the tension pulley and the carrier motor pulley ...

Page 91: ...Repair Information 4 17 6 Disconnect the carrier motor cable 4 from connector CN9 on the main logic board 7 Remove the screws 5 and 6 and then remove the carrier motor assembly from the left side frame ...

Page 92: ... Pulley Plate Assembly on page 4 60 10 Remove the carrier see Carrier Removal on page 4 12 11 23XX 002 003 Remove the tractor idler gear 12 23XX 002 003 Remove the support plate 13 Remove the lower pinch roller see Lower Pinch Roller Removal on page 4 32 14 Remove the gears on the right side frame see Right Side Frame Gears Removal on page 4 58 15 Remove the ribbon drive rack gear see Ribbon Drive...

Page 93: ...Repair Information 4 19 ...

Page 94: ...4 20 21 Gently bend both side frames outward to release tabs 7 from the slots 8 Lift and remove the carrier plate ...

Page 95: ...Buffer Module are options 1 Remove the rear cover 2 Remove the paper support 3 Insert a small flat screwdriver 1 under each end of the module and lift up gently On 23XX 002 003 printers only one end of the module is accessible Do not insert the screwdriver too deep or the main logic board may be damaged Note Be careful not to bend the pins when you re install the module ...

Page 96: ... Logic Board Removal on page 4 59 3 Remove the paper feed motor and the paper feed motor plate see Paper Guide Platen Assembly Removal on page 4 40 4 Remove the lever stop bracket from the carrier motor bracket not present on all machines 5 Remove the screw and washer 3 6 Release the latch 4 and remove the form thickness lever 5 ...

Page 97: ...e 4 61 2 Remove the sub logic board see Sub Logic Board Removal on page 4 59 3 Remove the paper feed motor and the paper feed motor plate see Paper Guide Platen Assembly Removal on page 4 40 When the paper feed motor plate is removed the idler gear 3 may come off simultaneously 4 Remove the head gap sensor 2 ...

Page 98: ...page 4 59 3 Remove the paper feed motor and the paper feed motor plate see Paper Guide Platen Assembly Removal on page 4 40 4 Move the forms thickness lever to position 7 5 Remove the screw 1 and remove the head gap sensor assembly 2 6 When you re install the sensor be sure the rear of the head gap sensor assembly is held in place by the paper feed motor plate ...

Page 99: ...op cover see Top Cover Removal on page 4 61 2 Disconnect the home position sensor cable from the sub logic board 3 Remove the screw 1 and then remove the home position sensor from the left side frame The sensor is attached to the left side support plate on newer models ...

Page 100: ... Assembly Removal on page 4 53 3 Remove the print unit see Print Unit Removal on page 4 47 4 Remove the paper separator see Paper Separator Removal on page 4 44 5 Carefully remove the jammed label from the mylar strip on the paper separator If the mylar strip is damaged replace the paper separator If the label is jammed below the carrier plate or on the lower plastic portion of the paper guide pla...

Page 101: ...Repair Information 4 27 This Page Intentionally Blank ...

Page 102: ...e Lower Pinch Roller Removal on page 4 32 11 Remove the print unit see Print Unit Removal on page 4 47 12 Remove the home position sensor see Home Position Sensor Removal on page 4 25 13 Remove the pull tractor sensor see Pull Tractor Sensor Removal on page 4 52 14 238X 001 Remove the head gap sensor see Head Gap Sensor Removal 238X 001 on page 4 23 23XX 002 003 Remove the head gap sensor assembly...

Page 103: ...20 Remove the screw 4 21 Release the two latches 5 22 Remove the left side frame 23 Be sure to perform the Printhead to Platen Gap Adjustment after you re assemble the printer see Printhead to Platen Gap Adjustment on page 4 2 ...

Page 104: ...er see Upper Feed Roller Removal on page 4 66 10 Remove the lower pinch roller see Lower Pinch Roller Removal on page 4 32 11 Remove the gears on the right side frame see Right Side Frame Gears Removal on page 4 58 12 Remove the print unit see Print Unit Removal on page 4 47 13 Remove the right side frame see Right Side Frame Removal on page 4 56 14 Remove the idler gear 1 then remove the left fee...

Page 105: ...Repair Information 4 31 ...

Page 106: ...the center pinch roller ground spring 3 Remove the left and right pinch roller springs 1 4 Move the carrier to the right as far as it will go 5 Slide the left end of the lower pinch roller to the front of the printer and lift it up and to the left to remove it 6 Be sure to perform the Printhead to Platen Gap Adjustment procedure see Printhead to Platen Gap Adjustment on page 4 2 ...

Page 107: ...cted to the main logic board connectors may not be exactly as shown Note Do not twist the flexible cable when disconnecting CN3 3 Remove the two screws 1 and then remove the main logic board by pulling it out towards the back 4 Replace the main logic board 5 Be sure to check the Bidirectional Print Adjustment after you install the board ...

Page 108: ...p cover see Top Cover Removal on page 4 61 2 Release the two latches 1 and then remove the operator panel assembly Note Be sure the flexible cable is correctly aligned and inserted securely The end with the 90 degree fold connects to the sub logic board ...

Page 109: ...Repair Information 4 35 This Page Intentionally Blank ...

Page 110: ... Removal on page 4 42 5 Release the four latches 1 and then remove the paper empty sensor Carefully remove the paper empty sensor cable to avoid cable damage 6 Disconnect the paper empty sensor cable from the latch on the paper guide 7 Carefully grasp the paper empty lever at 2 with a pair of needle nose pliers and remove the paper empty lever by pulling it perpendicular away from the paper guide ...

Page 111: ...Repair Information 4 37 ...

Page 112: ...r CN10 on the main logic board 4 Remove the screw 3 5 Rotate the paper feed motor 2 clockwise then remove it The paper feed motor plate 4 can also be removed at this time as it is held in place only by the motor 2 238X 001 The head gap sensor may come loose It is held in place by the paper feed motor plate 6 238X 001 Be sure the head gap sensor is positioned correctly before installing the paper f...

Page 113: ...air Information 4 39 Paper Guide Removal Left And Right 1 Remove the front cover and place it front down on a flat surface 2 Press down the paper guide 1 release the two latches and remove the paper guide ...

Page 114: ...XX 002 003 Remove the rear support plate mounting screw that was covered by the gear Remove the metal support plate mounting screw and the support plate Remove the platen bar screw that was covered by the support plate 11 Remove the upper feed roller see Upper Feed Roller Removal on page 4 66 12 Remove the lower pinch roller see Lower Pinch Roller Removal on page 4 32 13 Remove the gears on the si...

Page 115: ...Repair Information 4 41 ...

Page 116: ...4 42 Paper Select Lever Removal 1 Remove the top cover see Top Cover Removal on page 4 61 2 Release the latch 2 and then remove the paper select lever 1 from the right side frame ...

Page 117: ...Print Unit Removal on page 4 47 3 Using diagonal pliers cut 4 mm off the ends of the last two ribs on the paper guide to allow better screwdriver access If necessary also remove the molded hook on the paper guide 4 Use a 1 Phillips screwdriver to remove the screw 1 and the sensor 2 Disconnect the sensor connector from the sub logic board ...

Page 118: ...ator spring from the screw 2 8 Remove the separator screw 2 and the two screws 3 that hold the carrier plate to the right side frame Warning The following two steps must be performed with extreme care to avoid damaging the side frames 9 While holding the front portion of the right side frame and the carrier plate gently spread the right side frame away from the carrier plate enough to allow the ri...

Page 119: ...Repair Information 4 45 ...

Page 120: ...ire screw 1 Do not lose the star washer 2 if present located between the ground wire and the shield plate 4 Disconnect the power supply cable 3 5 Remove the four mounting screws 4 6 Remove the power supply Reassembly Note The platen ground leg 5 goes on top of the power supply cover The ground spring on top of the power supply goes behind the frame support shaft and in front of the upper feed roll...

Page 121: ...ower supply cable from connector CN1 on the sub logic board 5 Disconnect the ground wire from the sub logic board plate 6 Remove the screw 1 7 Remove two screws 2 and then remove the inserts 8 Do the following for the left and right side frames Insert a screwdriver between the bottom front of the side frame and the bottom cover Raise the screwdriver gently to release the latch while sliding the pr...

Page 122: ...the printhead set the form thickness lever to position 7 4 Remove the ribbon access cover 5 Remove the ribbon cartridge 6 Release the two latches 1 and then lift the printhead up and remove If necessary gently pry the printhead upward with a screwdriver inserted under it from the right side 7 Disconnect the printhead cables 2 from the printhead connector Reassembly Note Be sure the printhead cable...

Page 123: ...r see Top Cover Removal on page 4 61 2 Remove the printhead see Printhead Removal on page 4 48 3 Release the printhead cables from the flexible cable holders 4 Disconnect the printhead cables 1 from connector CN8 and CN9 239X or CN9 238X on the sub logic board 2 Reassembly Note Be sure the printhead cables are correctly aligned and secured They must be flat with no twists ...

Page 124: ...4 50 Pull Tractor Removal 1 Press the tractor assembly locking levers 1 down tilt the tractor assembly in the direction indicated by the arrow and remove it from the printer ...

Page 125: ...e tractor assembly see Pull Tractor Removal on page 4 50 2 Remove the top cover see Top Cover Removal on page 4 61 3 Remove the left pull tractor actuator 1 4 Remove the right pull tractor actuator 2 Note If the pull tractor actuator is difficult to remove or is accidentally dropped inside the printer remove the top cover ...

Page 126: ...e top cover see Top Cover Removal on page 4 61 2 Disconnect the pull tractor sensor cable from connector CN4 on the main logic board 3 Use a 1 Phillips screwdriver held in the position shown to remove the screw then remove the pull tractor sensor ...

Page 127: ...Repair Information 4 53 Push Tractor Assembly Removal 1 Open the front cover 1 2 Press both tractor assembly locking levers 2 down then pull the tractor assembly 3 straight out of the printer ...

Page 128: ...e the forms thickness lever to position 1 3 Position the carrier midway between the two rack mounting tabs 1 shown 4 Remove the stop 2 if present 5 Release the snap 3 and move the rack 4 to the right 6 Press the tab on the right and move the rack down to disengage the rack from the ribbon drive gear ...

Page 129: ...Repair Information 4 55 This Page Intentionally Blank ...

Page 130: ...e left side frame Release the latch on the forms thickness lever and slide the carrier shaft half way out so it is free of the right side frame Do not lose the small bushing on the right end of the carrier shaft 10 Raise the right pinch roller spring and slide the black retainer toward the center of the shaft Remove the spring from the right side frame 11 Remove the gears on the right side frame s...

Page 131: ...cluded with the new side frame the old slider cam will not work properly although it may seem to fit The hub side of all gears goes toward the side frame While installing the large idler gear the slider should be in the outer position The conical side of the gear goes toward the side frame The lower feed roll gear may be a very tight fit 238X 001 Be sure the head gap sensor is in the correct posit...

Page 132: ...then remove the ASF drive gear 4 23XX 003 Remove the two screws and remove the shaft support plate not shown 5 Remove both E rings 2 3 and then remove the ASF idler gear and the shift gear from the right side together with their washer and spring To prevent the washer and spring from springing off hold them down while removing the E ring 6 Remove the lower feed roller right gear 4 ...

Page 133: ... disconnect CN3 3 Disconnect all of the cables connected to the sub logic board 2 Do not bend or twist the flat cables when you disconnect them from CN7 CN8 and CN9 4 Disconnect the ground wire 1 5 Remove the screws 3 4 and then remove the sub logic board 2 Note 4 is a self tapping screw 6 To replace first connect the short flexible cable to the sub logic board at CN2 The contact side of the cable...

Page 134: ...Remove the top cover see Top Cover Removal on page 4 61 2 Remove the belt tension spring 1 from the hook 3 Remove the screw 2 4 Remove the carrier belt 3 5 Remove the tension pulley plate assembly 4 by sliding it toward the right rear view ...

Page 135: ... the tractor assembly see Pull Tractor Removal on page 4 50 5 Remove the front cover 2 and the ribbon access cover 3 6 Release the two latches 9 and then remove the rear cover 3 7 Set the paper select lever 4 to the cut sheet position 8 Remove the two screws 8 9 Stand the printer on its side Insert a flat blade screwdriver into each of the five holes in the bottom cover and release the five latche...

Page 136: ...rator panel cable 7 from the sub logic board and then remove the top cover Reinstallation Note Be sure that the operator panel cable is correctly aligned and inserted securely WARNING Damage to the operator panel cable may cause failure of other electrical components of the printer Be sure not to crimp or pinch this cable while reinstalling the top cover ...

Page 137: ...Repair Information 4 63 This Page Intentionally Blank ...

Page 138: ...Tractor Assembly Removal on page 4 53 2 Remove the top cover see Top Cover Removal on page 4 61 3 Remove the print unit and position the print unit on its front see Print Unit Removal on page 4 47 4 Remove the screw 1 and the leaf spring 2 5 Push the sensor 3 to the right to unsnap and remove it ...

Page 139: ...efully remove the sensor flag spring 4 from the bottom end of the sensor flag 3 Pivot the upper tip of the sensor flag downward through the open area just to the right of the center feed roll and lift the lower end of the flag until it becomes free 4 The sensor flag spring hooks over the lower arm of the flag Be sure the point of the sensor flag is kept in the paper path by the spring force Be sur...

Page 140: ...the left side frame and twisting Bend the paper feed motor plate slightly to the left to remove the gear 4 Release the latch and move the upper feed roller gear 3 to the left until it touches the paper feed motor plate It will stay on the feed roller shaft 5 Release the latch and remove the upper bushings 2 Move the left bushing to the left it will stay on the feed roller shaft 6 Release tab A and...

Page 141: ...rier Motor D Paper Feed Motor E Parallel Interface Connector F Main Logic Board G Sub Logic Board H Power Supply I Tractor Unit J Pull Tractor Actuator K Ribbon Cartridge L Ribbon Drive Rack Gear M Pinch Roller Lower N Feed Roller Lower O Printhead P Printhead Cables Q Carrier R Tension Pulley Plate S Feed Roller Upper T Platen U Side Frame Right V Side Frame Left W Carrier Plate ...

Page 142: ...5 2 Front View ...

Page 143: ...Connector Locations 5 3 Rear View ...

Page 144: ... 5 5 V dc CN1 6 Motor Common CN1 7 D Set Signal for Tractor 2 Plugged in CN1 8 Signal GND CN1 9 Motor Phase A 0 V dc except when Tractor 2 motor is on CN1 10 Motor Phase B 5 V dc when Tractor 2 not in use 0 V dc when Tractor 2 is in use CN1 11 Not used CN1 12 Slider Home Sensor 5 V dc when open 0 V dc when closed CN1 13 Tractor 2 In Place Sensor 5 V dc when open 0 V dc when closed ...

Page 145: ...Connector Locations 5 5 Wiring Diagrams Block Diagram 238X 001 ...

Page 146: ...5 6 Block Diagram 239X 001 ...

Page 147: ...Connector Locations 5 7 Block Diagram 238X 002 ...

Page 148: ...5 8 Block Diagram 239X 002 ...

Page 149: ...Connector Locations 5 9 Block Diagram 238X 003 ...

Page 150: ...5 10 Block Diagram 239X 003 ...

Page 151: ...ly Main Logic Board Sub Logic Board Power Supply Main Logic Board Sub Logic Board CN1 CN11 CN1 Pin 1 Pin 2 Pin 3 Pin 4 SIGNAL GND 5 V POWER GND 26 V Pin 4 Pin 3 Pin 2 Pin 1 SIGNAL GND 5 V POWER GND 26 V Pin 4 Pin 3 Pin 2 Pin 1 SIGNAL GND 5 V POWER GND 26 V ...

Page 152: ...Pin 23 Pin 24 Pin 25 Pin 26 Pin 27 Pin 28 Pin 29 Pin 30 Pin 31 Pin 32 Pin 33 Pin 34 Pin 35 Pin 36 STROBE DATA 0 DATA 1 DATA 2 DATA 3 DATA 4 DATA 5 DATA 6 DATA 7 ACKNLG BUSY PE SELECT AUTO FEED Not Used SIGNAL GND CHASSIS GND Not Used SIGNAL GND SIGNAL GND SIGNAL GND SIGNAL GND SIGNAL GND SIGNAL GND SIGNAL GND SIGNAL GND SIGNAL GND SIGNAL GND SIGNAL GND SIGNAL GND INIT ERROR SIGNAL GND Not Used Not...

Page 153: ...Pin 29 Pin 28 Pin 27 Pin 26 Pin 25 Pin 24 Pin 23 Pin 22 Pin 21 Pin 20 Pin 19 Pin 18 Pin 17 Pin 16 Pin 15 Pin 14 Pin 13 Pin 12 Pin 11 Pin 10 Pin 9 Pin 8 Pin 7 Pin 6 Pin 5 Pin 4 Pin 3 Pin 2 Pin 1 SCLK LEDD SWO SW LTCH 3SW PUL CSF HP Not Used Not Used Not Used HD8 HD6 HD4 HD2 HD1 HD3 HD5 HD7 HD9 HD11 HD13 HD15 HD17 Not Used HD21 Not Used Not Used Not Used Not Used HD18 HD16 HD14 HD12 HD10 Pin 34 Pin ...

Page 154: ... HD24 HD22 HD20 Pin 28 Pin 27 Pin 26 Pin 25 Pin 24 Pin 23 Pin 22 Pin 21 Pin 20 Pin 19 Pin 18 Pin 17 Pin 16 Pin 15 Pin 14 Pin 13 Pin 12 Pin 11 Pin 10 Pin 9 Pin 8 Pin 7 Pin 6 Pin 5 Pin 4 Pin 3 Pin 2 Pin 1 SCLK LEDD SWD SW LTCH GAP SW PUL CSF HP THRMO HD8 HD6 HD4 HD2 HD1 HD3 HD5 HD7 HD9 HD11 HD13 HD15 HD17 HD18 HD16 HD14 HD12 HD10 HD21 MSW Pin 34 Pin 33 Pin 32 Pin 31 Pin 30 Pin 29 Pin 28 Pin 27 Pin 2...

Page 155: ...ogic Board Serial Interface Card option Main Logic Board Paper Empty Sensor Main Logic Board Top of Form Sensor 23XX 002 CN4 Pin 1 Pin 2 PUL TRA SIGNAL GND CN5 Pin 1 Pin 2 5 V SIGNAL GND CN7 Pin 1 Pin 2 Pin 3 PE1P PE1 SIGNAL GND CN8 Pin 1 Pin 2 Pin 3 TOFP TOF SIGNAL GND ...

Page 156: ... Feed Motor Sub Logic Board 238X 001 Head Gap Sensor CN9 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 CAD CAC CAB CAA CACOMB CACOMA CN10 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 LFD LFC LFB LFA LFCOMB LFCOMA Not used on Model 003 Not Used CN3 Pin 1 Pin 2 Aid Port Gap ...

Page 157: ...ead Gap Pos 1 to 2 Sub Logic Board 238X 002 003 Head Gap Pos 3 to 4 Sub Logic Board Paper Select Sensor Sub Logic Board Home Position Sensor CN3 Pin 1 Pin 2 SIGNAL GND GS2 CN4 Pin 1 Pin 2 5 V GS1 CN5 Pin 1 Pin 2 F T SIGNAL GND CN6 Pin 1 Pin 2 HP SIGNAL GND ...

Page 158: ...GNAL GND SCLK 5 V Pin 9 Pin 8 Pin 7 Pin 6 Pin 5 Pin 4 Pin 3 Pin 2 Pin 1 SIGNAL GND SIGNAL GND 5 V LEDD SW LTCH SWD SIGNAL GND SCLK 5 V Sub Logic Board Operator Panel CN7 239X CN8 238X CN1 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 Pin 10 SIGNAL GND SIGNAL GND 5 V LEDD SW LTCH SWD SIGNAL GND SCLK 5 V MSW Pin 10 Pin 9 Pin 8 Pin 7 Pin 6 Pin 5 Pin 4 Pin 3 Pin 2 Pin 1 SIGNAL GND SIGNAL GND 5...

Page 159: ... HDD5 HDD1 HDD7 HDD3 HDU5 HDU9 HDU3 HDU7 CN8 CN9 Printhead Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 Pin 10 Pin 11 Pin 12 Pin 13 Pin 14 Pin 15 Pin 16 Pin 17 Pin 18 HDP10 HDP8 HDP12 HDP6 HDP14 HDP4 COM HDP2 COM HDP1 COM HDP3 COM HDP5 HDP13 HDP7 HDP11 HDP9 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 Pin 10 Pin 11 Pin 12 Pin 13 Pin 14 Pin 15 Pin 16 Pin 17 HDP20 HDP18 HDP22 HDP16...

Page 160: ...5 20 Connector Locations Main Logic Board 23XX 001 ...

Page 161: ...Connector Locations 5 21 Main Logic Board 23XX 002 ...

Page 162: ...5 22 Main Logic Board 23XX 003 ...

Page 163: ...Connector Locations 5 23 Sub Logic Boards ...

Page 164: ...5 24 ...

Page 165: ...Connector Locations 5 25 Power Supply ...

Page 166: ...5 26 Operator Panel ...

Page 167: ...olycarbonate parts causing premature failure Use only mineral oil based lubricant The following parts should be lubricated when replaced Oil felt carrier block Tractor unit Side frame left Side frame right Pinch roller lower Pinch roller spring left Pinch roller spring center Pinch roller spring right Paper separator Specified Lubricants Oil P N 1280443 Approved equivalents Mobil DTE27 Shell Tellu...

Page 168: ...er Lower and Pinch Roller Spring Left Pinch Roller Lower and Pinch Roller Spring Center Pinch Roller Lower and Pinch Roller Spring Right Pinch Roller Lower and Paper Separator ASF Side Frame Right and Joint Gear ASF Side Frame Right and Idler Gear ASF Side Frame Right and Idler Gear ASF Side Frame Right and Combination Lock Mechanism ASF Side Frame Right and Feed Roll Gear Lower ASF Side Frame Rig...

Page 169: ...Preventive Maintenance 6 3 Lubrication Points Oil The oil felt 1 in the carrier block The tractor shaft 1 ...

Page 170: ...6 4 Lubrication Points Grease Gear mounting studs on the right side frame 2 The lower pinch roller 2 ...

Page 171: ...Preventive Maintenance 6 5 Lubrication Points Grease Continued Gear mounting studs on the left side frame 2 ...

Page 172: ...6 6 Lubrication Points Grease Continued Gear mounting studs on the left ASF side frame 2 Gear mounting studs on the right ASF side frame 2 ...

Page 173: ...P Non Procurable in the Units column indicates that the part is non procurable and that the individual parts or the next higher assembly should be ordered NR Not Recommended in the Units column indicates that the part is procurable but not recommended for field replacement and that the next higher assembly should be ordered R Restricted in the Units column indicates that the part has a restricted ...

Page 174: ...7 2 Assembly 1 Major Components ...

Page 175: ...01 2390 001 3 79F4827 Tractor Unit 2381 001 2391 001 3 1333153 Tractor Unit 2380 002 003 2390 002 003 3 1333157 Tractor Unit 2381 002 003 2391 002 003 4 79F4851 Operator Panel Overlay Pack 238X 001 4 79F4846 Operator Panel Overlay Pack 239X 001 4 1333212 Operator Panel Overlay Pack 238X 002 4 1333213 Operator Panel Overlay Pack 239X 002 4 11A3300 Operator Panel Overlay Pack 238X 003 4 11A3301 Oper...

Page 176: ...7 4 Assembly 1 Major Components Continued ...

Page 177: ... 1333158 Tractor Side Frame L 23XX 002 003 10 79F4810 Gear and Bushing Kit 238X 001 002 10 79F4806 Gear and Bushing Kit 239X 001 002 10 11A3272 Gear and Bushing Kit 238X 003 10 11A3273 Gear and Bushing Kit 239X 003 11 79F4770 Side Frame Locking Plates 12 79F4860 Screw Washer Clip Kit 23XX 001 12 1333219 Screw Washer Clip Kit 23XX 002 12 11A3344 Screw Washer Clip Kit 23XX 003 13 79F4830 Tractor Pap...

Page 178: ...7 6 Assembly 2 Covers ...

Page 179: ...LV 2391 001 4 1180844 Top Cover 2390 PS 1 4 79F4852 Top Cover EMEA and AFE HV 2380 001 4 79F4853 Top Cover EMEA and AFE HV 2381 001 4 79F4854 Top Cover EMEA and AFE HV 2390 001 4 79F4855 Top Cover EMEA and AFE HV 2391 001 4 11A3305 Top Cover with logo kit 2380 002 003 2390 002 003 4 11A3306 Top Cover with logo kit 2381 002 003 2391 002 003 5 79F4778 Front Cover Unit 2380 001 2390 001 5 79F4824 Fro...

Page 180: ...7 8 Assembly 2 Covers Continued ...

Page 181: ... 002 003 10 1180861 Right Extended Paper Guide Option 23XX 001 10 1333165 Right Extended Paper Guide Option 23XX 002 003 11 1180862 Center Extended Paper Guide Option 23XX 001 11 1333166 Center Extended Paper Guide Option 23XX 002 003 12 1332972 Acoustics Kit Option 2380 2390 12 1332973 Acoustics Kit Option 2381 2391 ...

Page 182: ...7 10 Assembly 3 Carrier ...

Page 183: ...381 3 79F4828 Printhead Cable 2390 3 79F4829 Printhead Cable 2391 4 1180877 Carrier Shaft 2380 2390 4 1180878 Carrier Shaft 2381 2391 5 79F4814 Paper Select Lever 23XX 001 5 1333154 Paper Select Lever 23XX 002 003 6 79F4805 Tension Pulley Plate Assembly 23XX 001 002 6 11A3346 Tension Pulley Plate Assembly 23XX 003 7 11A3186 Carrier Motor Assembly 238X 001 7 1333221 Carrier Motor Assembly 238X 002 ...

Page 184: ...7 12 Assembly 3 Carrier Continued ...

Page 185: ...3273 Gear and Bushing Kit 239X 003 14 79F4811 Spring Kit 23XX 001 2381 002 2391 002 14 1333228 Spring Kit 2380 002 2390 002 14 11A3308 Spring Kit 2380 003 2390 003 14 11A3309 Spring Kit 2381 003 2391 003 15 79F4860 Screw Washer and Clip Kit 23XX 001 15 1333219 Screw Washer and Clip Kit 23XX 002 15 11A3344 Screw Washer and Clip Kit 23XX 003 NS 1333229 ESD Kit 238X 002 003 NS 1333230 ESD Kit 239X 00...

Page 186: ...7 14 Assembly 4 Paper Guide Platen Feed Roller ...

Page 187: ...r 2380 2390 4 79F4832 Pinch Roller Lower 2381 2391 5 79F4808 Pull Tractor Actuator Kit 6 1180927 Side Frame Right with Slider Cam 23XX 001 002 6 11A3312 Side Frame Right 23XX 003 7 79F4802 Ribbon Drive Rack Gear 2380 2390 7 79F4834 Ribbon Drive Rack Gear 2381 2391 8 1368031 Carrier Plate 2380 2390 8 1368032 Carrier Plate 2381 2391 9 79F4801 Feed Roller Lower 2380 2390 9 79F4833 Feed Roller Lower 2...

Page 188: ...7 16 Assembly 4 Paper Guide Platen Feed Roller Cont ...

Page 189: ...g Kit 2380 003 2390 003 16 11A3309 Spring Kit 2381 003 2391 003 17 79F4860 Screw Washer and Clip Kit 23XX 001 17 1333219 Screw Washer and Clip Kit 23XX 002 17 11A3344 Screw Washer and Clip Kit 23XX 003 18 95F3675 Idler Gear 238X 001 002 18 95F3676 Idler Gear 239X 001 002 18 11A3274 Idler Gear 238X 003 18 11A3275 Idler Gear 239X 003 19 1333238 Frame Support Shaft 2380 002 003 2390 002 003 19 133323...

Page 190: ...7 18 Assembly 5 Electronics ...

Page 191: ...777 Base 2381 001 LV 3 79F5218 Base 2381 001 HV 3 79F4822 Base 2390 001 LV 3 79F4844 Base 2390 001 HV 3 79F4823 Base 2391 001 LV 3 79F5245 Base 2391 001 HV 3 1333206 Base 2380 002 003 2390 002 003 3 1333207 Base 2381 002 003 2391 002 003 3 1180962 Base 2390 PS 1 4 1180968 Main Logic Board W EPROM 2380 001 LV 4 1180969 Main Logic Board W EPROM 2380 001 HV 4 1333252 Main Logic Board W EPROM 2380 002...

Page 192: ...7 20 Assembly 5 Electronics Continued ...

Page 193: ...d W EPROM Variable Forms Length 2381 001 HV 4 1368007 Main Logic Board W EPROM Variable Forms Length 2390 001 LV 4 1368008 Main Logic Board W EPROM Variable Forms Length 2390 001 HV 4 1368016 Main Logic Board W EPROM Variable Forms Length 2391 001 LV 4 1368017 Main Logic Board W EPROM Variable Forms Length 2391 001 HV 4 11A3322 Main Logic Board W O EPROM 2380 003 LV 4 11A3324 Main Logic Board W O ...

Page 194: ...7 22 Assembly 5 Electronics Continued ...

Page 195: ...nded NLS Module Eastern Countries Option 239X 002 5 1332990 Extended NLS Module Middle East Countries Option 239X 002 5 11A3285 Extended NLS Module Eastern Europe Option 238X 003 5 11A3286 Extended NLS Module Eastern Europe Option 239X 003 5 11A3287 Extended NLS Module Middle East Countries Option 238X 003 5 11A3288 Extended NLS Module Middle East Countries Option 239X 003 6 79F4860 Screw Washer a...

Page 196: ...7 24 Assembly 6 ASF Roller Support ...

Page 197: ... 1333275 Pick up Roller L R 2381 003 2391 003 5 95F6885 Pick up Roller All others 6 95F6889 Hopper R 7 1333278 Paper Support R 2381 003 2391 003 7 95F6879 Paper Support R All others 8 95F6880 Paper Support C 2381 2391 9 95F6878 Paper Support L 10 1333280 Hopper L 2381 003 2391 003 10 95F6888 Hopper L All others 11 1333161 Paper Load Lever 2381 003 2391 003 11 95F6890 Paper Load Lever All others 12...

Page 198: ...7 26 Assembly 7 ASF Side Frame Covers ...

Page 199: ...Number Description 7 1 95F6893 Spring Kit ASF 2 95F6892 Gear and Bushing Kit ASF 3 95F6882 Cover R 4 95F6894 Screw Kit ASF 5 95F6899 Side Frame R 6 95F6901 Stacking Support 7 95F6902 Front Cover 2380 2390 7 95F6903 Front Cover 2381 2391 ...

Page 200: ...7 28 Assembly 8 Tractor 2 Option ...

Page 201: ...339 Tractor and Frame Asm Narrow 3 11A3340 Tractor and Frame Asm Wide 4 1333160 Tractor Kit L R 5 11A3335 Board Asm W Cable and Ferrite Narrow 5 11A3336 Board Asm W Cable and Ferrite Wide 6 11A3337 Motor 7 11A3341 Parts Packet 8 11A3332 Right Cover 9 95F6902 Front Cover Narrow 9 95F6903 Front Cover Wide 10 11A3283 Support Shaft Narrow 10 11A3284 Support Shaft Wide ...

Page 202: ...7 30 ...

Page 203: ...ver 4 10 Carrier 4 12 Carrier Motor Assembly 4 16 Carrier Plate 4 18 Download Buffer 4 21 Form Thickness Lever 4 22 Head Gap Sensor 23XX 002 4 24 238X 001 4 23 Home Position Sensor 4 25 Jammed Label 4 26 Label Jam 4 26 Left Side Frame 4 28 Lower Feed Roller 4 30 Main Logic Board 4 33 Operator Panel 4 34 Paper Empty Sensor 4 36 Paper Empty Spring 4 36 Paper Feed Motor 4 38 Paper Guide Platen 4 40 P...

Page 204: ... Paper Select Sensor 2 30 POST 2 31 Power 2 32 Print Speed 2 34 Printhead 2 36 Pull Tractor Sensor 2 38 Ribbon Feed 2 17 Top of Forms Problem 2 39 Tractor 2 2 40 Setup Mode 1 6 Symptom Checks Abnormal Indications 2 6 Abnormal Noise Problems 2 6 Abnormal Print Problems 2 7 ASF Problems 2 7 Error Indications 2 8 Operator Panel Problems 2 10 Paper Feed Problems 2 8 Power Problems 2 10 Print Quality P...

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