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Lexmark 2480 - Forms Printer B/W Dot-matrix, Service Manual

The Lexmark 2480 Forms Printer is a reliable B/W Dot-matrix printer suitable for printing various forms. For detailed maintenance and troubleshooting instructions, you can download the free Service Manual from manualshive.com. This manual will guide you through the setup, operation, and maintenance of your printer.

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Repair Information

4-47

24xx

Options Removals

Auto Sheet Feeder Gears Removal 

1. Remove the right cover.

2. Release the joint gear latch [A] and remove the joint gear.

3. Release the idler gear latch and remove the idler gear.

4. Release the pick-up gear latch and remove the gear.

5. Release the combination lock mechanism latch.

6. Remove the tension plate on the locker cam and remove the 

cam.

7. Release the lift gear latch and remove the gear.

Summary of Contents for 2480 - Forms Printer B/W Dot-matrix

Page 1: ...00 Series Lexmark and Lexmark with diamond design are trademarks of Lexmark International Inc registered in the United States and or other countries Table of Contents Index Safety and Notices Trademar...

Page 2: ...ay be addressed to Lexmark International Inc Department D22A 032 2 740 West New Circle Road Lexington Kentucky 40550 U S A or e mail at ServiceInfoAndTraining Lexmark com Lexmark may use or distribute...

Page 3: ...gs 2 1 Error Indication Table 2 2 Symptom Check Table 2 5 Irrecoverable Operator Errors 2 12 Service Checks 2 13 Abnormal Noise Service Check 2 13 Auto Sheet Feeder ASF Service Check 2 14 Carrier Serv...

Page 4: ...ers Front Removal 4 6 Covers Ribbon Access Removal 4 6 Covers Option Removal 4 7 Covers Top Removal 4 8 Covers Operator Panel Assembly Removal 4 11 Covers Bottom Removal 4 12 Electronics Removals 4 13...

Page 5: ...r Locations 5 1 Signal Connections 5 2 Power Supply 9w 24w 5 2 Logic Board Parallel Interface Cable 9w 24w 5 4 Logic Board Serial Board 9w 24w 5 6 Logic Board USB Cable 9w 24w 5 8 Logic Board DC Power...

Page 6: ...se 6 4 Parts Catalog 7 1 How To Use This Parts Catalog 7 1 Assembly 1 Covers 7 2 Assembly 2 Carrier Paper Feed Right Side 7 6 Assembly 3 Carrier Paper Feed Left Side 7 10 Assembly 4 Electronics 7 14 A...

Page 7: ...cing of this product Professional service personnel should understand this and take necessary precautions Consignes de S curit Ce produit a t con u test et approuv pour respecter les normes strictes d...

Page 8: ...le di assistenza autorizzato deve quindi adottare le precauzioni necessarie Sicherheitshinweise Dieses Produkt und die zugeh rigen Komponenten wurden entworfen und getestet um beim Einsatz die weltwei...

Page 9: ...e la m quina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias Informa es de Seguran a Este produto foi concebido testado e aprovado para satisfazer os pa...

Page 10: ...lgunes peces pot ser que no sempre siguin bvies Lexmark no es responsabilitza de l us d altres peces de recanvi La informaci pel manteniment d aquest producte est orientada exclusivament a professiona...

Page 11: ...xi 24xx...

Page 12: ...vice 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 instruction...

Page 13: ...are wide carriage versions of the 2480 and 2490 Printer Specifications Printhead life 300 million characters Standard ribbon life 4 million characters High yield ribbon life 8 million characters Prin...

Page 14: ...nu prints each time you press a button displaying new selections 5 After making your selection the printer prints a page with the changes shown Exiting Setup Mode 1 Press Set TOF until the printer ret...

Page 15: ...face options Defines how information is transferred from computer to the printer Menus Function Interface Automatically select the printer interface Use the parallel cable Use the USB cable Use the se...

Page 16: ...for one second If you have already set Top Of Form and now want to change the tear off bar position follow these steps 1 Press Start Stop to take the printer offline 2 Press and hold Tear Off until th...

Page 17: ...Forms Envelopes Top Of Form can range from minus 1 to plus 22 inches from the top of cut sheet paper To set and save Top Of Form 1 Turn the printer on The Paper Out light blinks if no paper is loaded...

Page 18: ...sic CE tool kit 1 Phillips screwdriver 2 Phillips screwdriver Feeler gauges 0 33 mm 0 013 in 0 37 mm 0 015 in Analog or digital volt ohmmeter Abbreviations CSU Customer Setup EPROM Erasable Programmab...

Page 19: ...tage 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...

Page 20: ...OST RAM ROM Controller Error Go to POST Service Check on page 2 26 Power Ready Paper Out Panel Lock ON Blinking Blinking Blinking None Switch Scan Test Error Go to Operator Panel Service Check on page...

Page 21: ...g Blinking Blinking None Timer Error Turn the printer off and then back on If you get the same error during power up replace the logic board and readjust the bidirectional print adjustment Go to Bidir...

Page 22: ...Service Check on page 2 27 Power Tractor 2 Paper Out Panel Lock Font Lock ON OFF OFF OFF OFF None Operator Panel Failure Go to Operator Panel Service Check on page 2 21 Any LED on and Power LED off No...

Page 23: ...ct 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 POST Service Check on page 2 26 Symptom...

Page 24: ...ect character s Be sure the interface cable is connected properly Go to No Print or Abnormal Print Service Check on page 2 21 Slow printing speed Go to Print Speed Service Check on page 2 28 Symptom A...

Page 25: ...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 Turn the printer off and then on Go to Operator Panel Servic...

Page 26: ...load Be sure the paper select lever is in the cut sheet position Verify that continuous forms have been parked using the Load Unload button Be sure Auto Cut Sheet is enabled in the Setup Mode Go to P...

Page 27: ...Tractor does not work Be sure the paper select lever is in the correct position Go to Paper Feed Service Check on page 2 23 Incorrect Top of Form positioning Go to Top Of Forms Service Check on page 2...

Page 28: ...ross the print line Specific dots missing Extra dots or lines printing Turn the ribbon advance knob on the print cartridge from 1 to 2 to increase the darkness of print Be sure the printhead cables ar...

Page 29: ...n 2 11 24xx Ribbon Feed Problems Symptom Action Ribbon comes off becomes loose or folded or jams Ribbon feeds correctly but is noisy Check the ribbon cartridge for binds or damage Go to Carrier Servic...

Page 30: ...aper Out turns off when paper exists Go to Paper Present Sensor Service Check on page 2 22 Action Check Turn the power off Install the Push Tractor Set the paper select lever to the tractor position a...

Page 31: ...3 Replace the printhead if the noise is gone 3 Carrier Motor Ribbon Drive Mechanism Disconnect the carrier motor connector CN2 from the logic board Turn the printer off and then on If the abnormal noi...

Page 32: ...n the inside right side frame of the printer 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...

Page 33: ...tly go to Paper Feed Service Check on page 2 23 3 Gear Train Be sure the ASF drive gear on the inside right side frame of the printer rotates Inspect the right side gear train for damage or debris Rem...

Page 34: ...rinthead to platen gap Go to Printhead to Platen Gap Adjustment on page 4 2 Clean and lubricated carrier shaft Idler pulley not binding Ribbon drive rack gear teeth not damaged If the carrier still bi...

Page 35: ...all printers Check the resistance at the following pin locations CN2 1 and CN2 3 CN2 2 and CN2 4 4 Logic Board If all parts appear okay but the home position error still occurs replace the logic boar...

Page 36: ...oard a Check the user 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 connector CN12 on the logic board Turn t...

Page 37: ...ll dc output voltages at CN12 1 CN12 2 and CN12 6 Verify the following output voltages CN12 1 40 V dc 10 CN12 2 40 V dc 10 CN12 3 GND CN12 4 GND CN12 5 Signal GND CN12 6 5 V dc 5 If one of the voltage...

Page 38: ...Undefined data in user applications Check the baud rate at the controller Check that the printer interface cable matches the printer 5 Problem occurs only in specific user applications Perform the He...

Page 39: ...eset the bidirectional print adjustment See Bidirectional Print Adjustment on page 4 4 2 Interface Cable Check the connection and continuity of the interface cable 3 Emulation Mode Enter the Setup Men...

Page 40: ...gnal and CN5 3 GND on the 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 Be sure the paper present sensor and its actuator are p...

Page 41: ...Sheet Feeder installed go to Auto Sheet Feeder ASF Service Check on page 2 14 2 Gear Train Remove all paper from the printer Press FormFeed several times and examine all rotating parts to find the pr...

Page 42: ...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...

Page 43: ...in the continuous forms position sensor closed the gear train should rotate for more than 3 seconds If the gear train does not rotate for more than 3 seconds Inspect the sensor to be sure it opens and...

Page 44: ...ator held down go to Pull Tractor Sensor Service Check on page 2 31 FRU Action 1 Cables A faulty interface cable can cause a POST error Disconnect the interface cable from the printer and turn the pri...

Page 45: ...er LED problem check the operator panel cable continuity and replace the cable or the operator panel 3 Carrier Motor Disconnect the carrier motor from logic board CN2 and turn the printer off and then...

Page 46: ...the function of the head gap sensor by turning the printer on with the Macro button pressed Open the operator panel to the second level and do the following With the forms thickness lever at 1 Macro L...

Page 47: ...s not firing Remove the printhead and verify that no pins on the printhead are broken or missing If pin s are missing replace the printhead Check the printhead resistance according to Printhead Impeda...

Page 48: ...CN400 14 Dot Connector Dot Connector 1 CN300 1 CN301 9 13 CN300 1 CN300 9 2 CN300 1 CN301 11 14 CN300 1 CN300 11 3 CN300 1 CN301 7 15 CN300 1 CN300 2 4 CN300 1 CN301 13 16 CN300 1 CN300 16 5 CN300 1...

Page 49: ...g down and releasing the left pull tractor actuator The paper should load and unload when the actuator is not held down and should not load or unload when the pull tractor actuator is held down If the...

Page 50: ...tion and turn the printer on Measure the voltage between logic board connector CN6 2 TOF signal and CN6 1 GND You should receive the following voltage readings When there is paper in the printer the v...

Page 51: ...When the Tractor 2 is deselected the motor retracts the slider disengages the Tractor 2 gear drive and reengages the printer tractors 10 Beeps and Blinking Ready Paper Font and Pitch LEDs Tractor 2 h...

Page 52: ...on CN1 1 and 5 V dc on CN1 5 If not check the cable connection and the voltages at logic board CN10 1 The upper right pin at CN10 is pin 1 40 V dc and the pin just beneath it is pin 5 5 V dc If these...

Page 53: ...er when Tractor 2 is installed Remove the Tractor 2 cover and be 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 an...

Page 54: ...the pin feed belts With the printer off and be 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 tract...

Page 55: ...necessary The following are special machine modes that run when the printer is turned off and then back on Turn Printer On While Pressing Results LineFeed Prints print test with sample fonts Tractor S...

Page 56: ...Microcode 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 butt...

Page 57: ...rinter on 3 Release Line Feed when the printing starts 4 To interrupt the printer test a Press Start Stop The test stops after a complete line of characters prints b Press Start Stop to continue the t...

Page 58: ...exadecimal instead of ASCII To activate hex trace mode 1 Press and hold Tractor and then turn the printer on 2 After a few seconds release Tractor and the lights go out 3 Start your application progra...

Page 59: ...ves The operator panel lights blink several times Once the carrier moves your settings have been reset to factory defaults World Trade Defaults To initialize or reset the printer to the World Trade de...

Page 60: ...ing for the type of paper you are using Refer to the 24xx User s Guide Continuous Forms Jams 1 Turn the printer off 2 Detach any continuous forms already printed 3 Set the forms thickness lever to pos...

Page 61: ...iture 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 printer Hold the ESD sensitive part by its edge...

Page 62: ...ve all covers with the exception of the bottom cover See Covers Removals on page 4 5 2 Remove the ribbon cartridge and paper 3 Remove the Lock Tite red from the gap adjust bushings on both the left an...

Page 63: ...nthead to the right edge of the rubber on the platen and using a feeler gauge 1 slowly adjust the right gap adjust bushing 2 clockwise until a gap of within 0 33 and 0 37 mm exists between the printhe...

Page 64: ...he operator panel cover to access layer two 4 Press and hold the Pitch key while turning the printer on The draft alignment bars print The current value is the number printed below the bars 5 To set D...

Page 65: ...Repair Information 4 5 24xx Removal Procedures CAUTION Be sure to unplug the power cord whenever you are working on the printer with one of the covers removed Covers Removals...

Page 66: ...spring loaded ribbon access cover release latches A on either side of the ribbon access cover up toward the front of the printer 2 Lift the ribbon access cover up and out of the printer Note When repl...

Page 67: ...Repair Information 4 7 24xx Covers Option Removal 1 From the bottom pull the option cover A outward and up removing it from the printer...

Page 68: ...out of the printer 3 Remove the ribbon access cover Go to Covers Ribbon Access Removal on page 4 6 4 Remove the front cover Go to Covers Front Removal on page 4 6 5 Remove the option cover Go to Cover...

Page 69: ...Repair Information 4 9 24xx 8 Turn the printer upside down 9 Insert a flat blade screwdriver into each of the four holes A in the bottom cover releasing the top cover from the bottom cover...

Page 70: ...s A in the back of the top cover 11 Lift the top cover up and over the print unit assembly Note When replacing the top cover be sure the operator panel cable is correctly aligned and inserted securely...

Page 71: ...el card on the inside of the top cover 3 Push down on the two latches A at the top of the operator panel on the inside of the top cover as shown 4 While holding the latches down push the operator pane...

Page 72: ...ove the top cover Go to Covers Top Removal on page 4 8 2 Remove the logic board Go to Logic Board Removal on page 4 14 3 Remove the power supply unit Go to Power Supply Removal on page 4 15 4 Remove t...

Page 73: ...onics Removals EPROM Removal 1 Remove the options cover A by pulling it outward up and out of the printer 2 Remove the EPROM module Note When replacing the EPROM module be sure the notch on the module...

Page 74: ...g the printhead cable s 3 Remove the top screw A from the serial interface card bracket 4 Remove the three screws B securing the logic board to the bottom cover Take care not to lose the ground clips...

Page 75: ...Go to Covers Top Removal on page 4 8 3 Remove the print unit Go to Print Unit Removal on page 4 28 4 Disconnect the power supply cable A 5 Remove the five screws B securing the power supply to the bot...

Page 76: ...Covers Top Removal on page 4 8 2 Remove the printhead from the carrier Go to Printhead Removal on page 4 27 3 Loosen the carrier belt a Loosen the tension screw A b Remove tension from the belt by pu...

Page 77: ...Repair Information 4 17 24xx 4 Remove the retaining wire A from the left side of the carrier shaft...

Page 78: ...4 18 Service Manual 24xx 5 Remove the screw A from the forms thickness lever and remove the lever...

Page 79: ...Remove the lower carrier motor mount screw A 7 Remove the two screws B from the carrier shaft bushing bracket on the left end of the carrier shaft and remove the bracket 8 Remove the E clip from the r...

Page 80: ...arrier shaft A from the right side and out the left side of the printer 10 Remove the carrier from the printer Note Following replacement perform the Printhead to Platen Gap Adjustment Go to Printhead...

Page 81: ...p cover Go to Covers Top Removal on page 4 8 2 Loosen the carrier belt a Loosen the tension screw A b Remove tension from the carrier belt by pulling up on the belt c Tighten the tension screw Looseni...

Page 82: ...4 22 Service Manual 24xx 4 Remove the screw A from the forms thickness lever and remove the lever...

Page 83: ...ecuring the carrier motor bracket to the print unit 8 Remove the home position sensor C from the top of the carrier motor bracket by pinching the clips underneath the bracket 9 Remove the carrier moto...

Page 84: ...val on page 4 8 2 Release the latch and remove the paper select lever from the right side frame Paper Feed Motor Removal 1 Remove the top cover Go to Covers Top Removal on page 4 8 2 Remove the two sc...

Page 85: ...Repair Information 4 25 24xx Form Thickness Lever Removal 1 Remove the top cover Go to Covers Top Removal on page 4 8 2 Remove the screw A from the lever and remove the form thickness lever...

Page 86: ...1 Remove the top cover Go to Covers Top Removal on page 4 8 2 Remove the two platen screws A from each end of the platen 3 Remove the platen from the paper tray 4 Perform the Printhead to Platen Gap...

Page 87: ...thead Reassembly Note Be sure the printhead cables are correctly aligned and secured Be sure to perform the Printhead to Platen Gap Adjustment procedure Go to Printhead to Platen Gap Adjustment on pag...

Page 88: ...er Go to Covers Top Removal on page 4 8 2 Disconnect all cables from the logic board except the power supply cable 3 Remove the screw from the form thickness lever and remove the lever 4 Remove the tw...

Page 89: ...Information 4 29 24xx 5 Remove the two grommet anchored screws A from the right side of the print unit 6 Remove the print unit from the bottom cover by pulling up forcefully on both sides of the prin...

Page 90: ...vers Top Removal on page 4 8 2 Remove the carrier Go to Carrier Removal on page 4 16 3 Unsnap the white plastic end stop A from the top left side of the print unit 4 Unlatch the left side of the rack...

Page 91: ...Repair Information 4 31 24xx Gears Removals Left Side Gears Removal 1 Remove the top cover Go to Covers Top Removal on page 4 8 2 Remove the three screws A from the serial interface card bracket...

Page 92: ...4 32 Service Manual 24xx 3 Remove the four screws A from the paper feed motor bracket assembly...

Page 93: ...Repair Information 4 33 24xx 4 Remove the paper feed motor bracket assembly exposing the gears as shown...

Page 94: ...Side Gears Sub Frame Removal 1 Remove the top cover Go to Covers Top Removal on page 4 8 2 Unhook the wire retainer A from the carrier shaft 3 Remove the two screws and washers B from the sub frame 4...

Page 95: ...Repair Information 4 35 24xx 5 Remove the sub frame exposing the right side gears A as shown...

Page 96: ...Removals Roller Upper Feed Removal 1 Remove the top cover Go to Covers Top Removal on page 4 8 2 Remove the screw from the print cable shield and remove the shield 3 Remove the gear from the left end...

Page 97: ...feed roller bracket One screw also retains the upper feed roller ground clip 5 Pull the upper feed roller from the left bracket and out of the printer 6 Be sure to perform the Printhead to Platen Gap...

Page 98: ...o the far left of the printer 3 Remove the four screws A from the paper feed motor bracket 4 Remove the screw from the top of the serial interface card bracket 5 Disconnect the paper feed motor cable...

Page 99: ...24xx 7 Unhook the spring clip A from the right end of the lower pinch roller shaft and push it off the gray slotted spring block B toward the back of the printer as shown 8 Slide the carrier to the ri...

Page 100: ...ward the center of the roller shaft taking care that the blocks remain with the shaft during removal 12 Slide the carrier to the right side of the printer 13 While holding the lower pinch roller shaft...

Page 101: ...e 4 16 4 Remove the two screws securing the black bracket to the inside of the right side frame 5 Remove the right side sub frame and the right side gears Go to Right Side Gears Sub Frame Removal on p...

Page 102: ...11 Remove the five screws securing the left side frame and remove the frame 12 Remove the four screws from the right side frame and remove the bottom frame assembly 13 Remove the five screws from the...

Page 103: ...Repair Information 4 43 24xx Sensors Removals...

Page 104: ...ver Go to Covers Top Removal on page 4 8 2 Remove the screw from the forms thickness lever and remove the lever 3 Remove the screw from the head gap sensor and remove the sensor 4 Disconnect the head...

Page 105: ...3 Sensor Paper Present Removal 1 Remove the top cover Go to Covers Top Removal on page 4 8 2 Remove the print unit Go to Print Unit Removal on page 4 28 3 Turn the print unit upside down 4 Remove the...

Page 106: ...l 24xx Sensor Home Position Sensor Removal 1 Remove the top cover Go to Covers Top Removal on page 4 8 2 Disconnect the home position sensor cable from the logic board 3 Unsnap the home position senso...

Page 107: ...joint gear latch A and remove the joint gear 3 Release the idler gear latch and remove the idler gear 4 Release the pick up gear latch and remove the gear 5 Release the combination lock mechanism lat...

Page 108: ...er Removal 1 Remove the covers and the cut sheet support 2 Release the joint gear latch A and remove the joint gear idler gear and pick up gear 3 Remove the left and right roller bushings 4 Move the p...

Page 109: ...Connector Locations 5 1 24xx 5 Connector Locations This chapter identifies the locations of specific parts of the printer...

Page 110: ...5 2 Service Manual 24xx Signal Connections Power Supply 9w 24w...

Page 111: ...Connector Locations 5 3 24xx Connector Pin Signal CN1 1 40 V dc 2 40 V dc 3 Power Gnd 4 Power Gnd 5 Signal Gnd 6 5 V dc 7 Power Save Mode Connector Signal F1 Fuse...

Page 112: ...5 4 Service Manual 24xx Logic Board 9w 24w...

Page 113: ...Gnd 3 Data 1 21 Signal Gnd 4 Data 2 22 Signal Gnd 5 Data 3 23 Signal Gnd 6 Data 4 24 Signal Gnd 7 Data 5 25 Signal Gnd 8 Data 6 26 Signal Gnd 9 Data 7 27 Signal Gnd 10 Acknlg 28 Signal Gnd 11 Busy 29...

Page 114: ...5 6 Service Manual 24xx Logic Board 9w 24w...

Page 115: ...ic Board Serial Board 9w 24w Connector Pin Signal CN200 1 5 V dc 2 5 V dc 3 CTS 4 DTS 5 RXD 6 RTS 7 DSR 8 TXD 9 Signal Gnd 10 SBSET Connector Pin Signal CN1 10 5 V dc 9 5 V dc 8 CTS 7 DTS 6 RXD 5 RTS...

Page 116: ...5 8 Service Manual 24xx Logic Board 9w 24w...

Page 117: ...Logic Board USB Cable 9w 24w Logic Board DC Power 9w 24w Connector Pin Signal CN201 1 5 V dc 2 DMNS 3 DPLS 4 Signal Gnd Connector Pin Signal CN12 1 40 V dc 2 40 V dc 3 Power Gnd 4 Power Gnd 5 Signal G...

Page 118: ...5 10 Service Manual 24xx Logic Board 9w 24w...

Page 119: ...tor Locations 5 11 24xx Logic Board Printhead 9w Connector Pin Signal CN400 1 H4 2 H6C 3 H8C 4 H1C 5 H6 6 H2C 7 H4C 8 H8 9 H2 10 H9 11 HDTHERMO 12 5 V dc 13 H1 14 H9C 15 H3 16 H7C 17 H5 18 H3C 19 H7 2...

Page 120: ...5 12 Service Manual 24xx Logic Board 9w 24w...

Page 121: ...Locations 5 13 24xx Logic Board Printhead 24w Connector Pin Signal CN300 1 40 V dc 2 R15 3 40 V dc 4 R21 5 40 V dc 6 R23 7 40 V dc 8 L24 9 R13 10 L22 11 L14 12 L20 13 40 V dc 14 L18 15 40 V dc 16 L16...

Page 122: ...5 14 Service Manual 24xx Logic Board 9w 24w...

Page 123: ...nector Locations 5 15 24xx Logic Board Printhead 24w Connector Pin Signal CN301 1 R9 2 R11 3 R7 4 R17 5 R5 6 R19 7 R3 8 HDTHERMO 9 R1 10 5 V dc 11 L2 12 40 V dc 13 L4 14 40 V dc 15 L6 16 L12 17 L8 18...

Page 124: ...5 16 Service Manual 24xx Logic Board 9w 24w...

Page 125: ...Set Sensor 9w 24w Logic Board Home Position Sensor 9w 24w Logic Board Paper Present Sensor 9w 24w Connector Pin Signal CN4 1 GAP1 2 Signal Gnd 3 GAP2 Connector Pin Signal CN9 1 HPSW 2 Signal Gnd Conne...

Page 126: ...5 18 Service Manual 24xx Logic Board 9w 24w...

Page 127: ...per Select Sensor 9w 24w Logic Board Pull Tractor Sensor 9w 24w Logic Board Top Of Form Sensor 9w 24w Connector Pin Signal CN8 1 TR FR 2 Signal Gnd Connector Pin Signal CN3 1 PLTR 2 Signal Gnd Connect...

Page 128: ...5 20 Service Manual 24xx Logic Board 9w 24w...

Page 129: ...onnector Locations 5 21 24xx Logic Board Carrier Motor 9w 24w Logic Board Paper Feed Motor 9w 24w Connector Pin Signal CN2 1 CAD 2 CAC 3 CAB 4 CAA Connector Pin Signal CN1 1 LFD 2 LFC 3 LFB 4 LFA 5 NC...

Page 130: ...5 22 Service Manual 24xx Logic Board 9w 24w...

Page 131: ...or Panel 9w 24w Connector Pin Signal CN13 Logic Board 1 5 V dc 2 SLATCH 3 5 V dc 4 TXD 5 Signal Gnd 6 RXD 7 Signal Gnd 8 SCLK 9 SG Connector Pin Signal CN1 Operator Panel 1 5 V dc 2 SLATCH 3 5 V dc 4...

Page 132: ...5 24 Service Manual 24xx Logic Board 9w 24w...

Page 133: ...or Locations 5 25 24xx Logic Board Dual Tractor Cable 9w 24w Connector Pin Signal CN10 1 40 V dc 2 40 V dc 3 Power Gnd 4 Power Gnd 5 5 V dc 6 COCOM 7 D SET 8 Signal Gnd 9 COA 10 COB 11 JAM 12 D H P 13...

Page 134: ...al Board Serial Cable 9w 24w Connector Pin Signal Pin Signal CN2 1 Chassis Gnd 13 NC 2 TXD 14 NC 3 RXD 15 NC 4 RTS 16 NC 5 CTS 17 NC 6 DSR 18 NC 7 Signal Gnd 19 NC 8 NC 20 DTR 9 NC 21 NC 10 NC 22 NC 1...

Page 135: ...N1 4 Not used CN1 5 5 V dc CN1 6 Motor common CN1 7 D Set signal for Tractor 2 plugged in CN1 8 Signal GND CN1 9 Motor phase A 0 V dc except when Tractor 2 motor is on CN1 10 Motor phase B 5 V dc when...

Page 136: ...5 28 Service Manual 24xx...

Page 137: ...polycarbonate parts causing premature failure Use only mineral oil based lubricants The following parts should be lubricated when replaced Oil felt carrier block Tractor unit Side frame left Side fram...

Page 138: ...ctor Shaft Grease Side Frame Left and Gears Side Frame Right and ASF Gears Pinch Roller Pinch Roller Springs and Paper Separator ASF Side Frames Gears and Combination Lock Mechanism ASF Side Frame Lef...

Page 139: ...Preventive Maintenance 6 3 24xx Lubrication Points Oil The oil felt 1 in the carrier block The tractor shaft 1...

Page 140: ...6 4 Service Manual 24xx Lubrication Points Grease Gear mounting studs on the right side frame 2 The lower pinch roller 2...

Page 141: ...Preventive Maintenance 6 5 24xx Lubrication Points Grease Continued Gear mounting studs on the left side frame 2...

Page 142: ...6 6 Service Manual 24xx Lubrication Points Grease Continued Gear mounting studs on the left ASF side frame 2 Gear mounting studs on the right ASF side frame 2...

Page 143: ...d separately and identified by description NS Not Shown in the Asm Index column indicates that the part is procurable but is not pictured in the illustration Note Graphic artwork depicting FRU assembl...

Page 144: ...7 2 Service Manual 24xx Assembly 1 Covers...

Page 145: ...3872 Cover Top 2481 2491 6 12G3870 Cover Option 7 79F4757 Line Cord U S AFE LV Canada Central and South America Mexico Saudi Arabia LV 7 1339519 Line Cord Malaysia and Singapore United Kingdom 7 13395...

Page 146: ...7 4 Service Manual 24xx Assembly 1 Covers...

Page 147: ...Tractor Paper 9D 12G3851 Shaft Set Tractor 2480 2490 9D 12G3852 Shaft Set Tractor 2481 2491 9E 12G3849 Frame Left Side Tractor 10 12G3810 Operator Panel Assembly 248X 10 12G3811 Operator Panel Assembl...

Page 148: ...7 6 Service Manual 24xx Assembly 2 Carrier Paper Feed Right Side...

Page 149: ...80 2481 8 12G3907 Screws Washers and Clips Parts Packet 9 12G3931 Kit Head Gap Adjustment 10 12G3884 Damper Frame Assembly 11 12G3905 Gears and Bushings Parts Packet 248X 11 12G3906 Gears and Bushings...

Page 150: ...7 8 Service Manual 24xx Assembly 2 Carrier Paper Feed Right Side...

Page 151: ...Parts Catalog 7 9 24xx Asm Index Part Number Description 2 22 12G3832 Roller Upper Feed 2480 2490 22 12G3833 Roller Upper Feed 2481 2491...

Page 152: ...7 10 Service Manual 24xx Assembly 3 Carrier Paper Feed Left Side 3 11 7 13 18 5 16 9 15 2 10 17 4 12 8 14 19 1 20 23 21 26 24 22 25 1 1 2 2 2 2 2 2 2 2 2 2 2 10 11 6...

Page 153: ...2G3941 Sensor Paper Select 10 12G3902 Holder Platen 11 12G3884 Damper Frame Assembly 12 12G3946 Sensor Head Gap 13 12G3821 Guide Paper Assembly 2480 2490 13 12G3820 Guide Paper Assembly 2481 2491 14 1...

Page 154: ...7 12 Service Manual 24xx Assembly 3 Carrier Paper Feed Left Side 3 11 7 13 18 5 16 9 15 2 10 17 4 12 8 14 19 1 20 23 21 26 24 22 25 1 1 2 2 2 2 2 2 2 2 2 2 2 10 11 6...

Page 155: ...talog 7 13 24xx Asm Index Part Number Description 3 24 12G3931 Kit Head Gap Adjustment 25 12G3947 Lever Form Thickness 26 56P1224 Motor Paper Feed with BKT 29 11A3274 Gear Idle 248X 29 11A3275 Gear Id...

Page 156: ...7 14 Service Manual 24xx Assembly 4 Electronics...

Page 157: ...LV 5 12G3806 Board Logic W O EPROM 2480 HV 5 12G3803 Board Logic W O EPROM 2481 LV 5 12G3807 Board Logic W O EPROM 2481 HV 5 12G3804 Board Logic W O EPROM 2490 LV 5 12G3808 Board Logic W O EPROM 2490...

Page 158: ...7 16 Service Manual 24xx Assembly 5 ASF Roller Support...

Page 159: ...er ASF Pick up Left and Right 2480 2490 4 1333275 Roller ASF Pick up Left and Right 2481 2491 5 12G3911 Hopper ASF Right 2480 2490 5 12G3893 Hopper ASF Right 2481 2491 6 12G3912 Support ASF Paper Righ...

Page 160: ...7 18 Service Manual 24xx Assembly 6 ASF Side Frame Covers...

Page 161: ...93 ASF Springs Parts Packet 2 95F6892 ASF Gears and Bushings Parts Packet 3 12G3920 Cover ASF Right 4 95F6894 ASF Screws Parts Packet 5 12G3921 Cover ASF TR2 Front 2480 2490 5 12G3930 Cover ASF TR2 Fr...

Page 162: ...7 20 Service Manual 24xx Assembly 7 Tractor 2 Option...

Page 163: ...rame Assembly Tractor 2 2481 2491 4 12G3853 Kit Tractors Left and Right 5 11A3335 Board Assembly W Cable and Ferrite Tractor 2 2480 2490 5 11A3336 Board Assembly W Cable and Ferrite Tractor 2 2481 249...

Page 164: ...ion NS 12G3704 Adapter Coax Power Cable and Adapter NS 12G3705 Adapter Twinax Power Cable and Adapter NS 12G3709 Bracket Adapter Bracket Only NS 13A0297 Cable Coax Cable Only NS 13A0296 Cable Twinax C...

Page 165: ...5 18 Serial Board 5 6 Top of Form Sensor 5 18 USB Cable 5 8 Power Supply 5 2 Serial Board Serial Cable 5 25 Tractor 2 5 26 Connector Locations 5 1 D Defaults U S 3 5 World Trade 3 5 Diagnostic Aids 3...

Page 166: ...Removals 4 5 ASF Gears 4 47 Pick up Roller 4 48 Carrier 4 16 Carrier Motor Assembly 4 21 Covers Bottom 4 12 Front 4 6 Operator Panel 4 11 Option 4 7 Ribbon Access 4 6 Top 4 8 Covers Illustration 4 5...

Page 167: ...ions 1 1 Start 2 1 Symptom Checks 2 5 Abnormal Indications 2 5 Abnormal Noise Problems 2 5 Abnormal Print Problems 2 6 ASF Problems 2 6 Error Indications 2 7 Operator Panel Problems 2 7 Paper Feed Pro...

Page 168: ...7 5 12G3882 7 5 12G3883 7 5 12G3884 7 7 7 11 12G3885 7 15 12G3887 7 7 7 15 12G3888 7 7 12G3889 7 7 12G3890 7 7 12G3891 7 7 12G3893 7 17 12G3894 7 7 12G3895 7 7 12G3896 7 7 7 11 12G3897 7 7 12G3898 7 7...

Page 169: ...22 1333275 7 17 1339517 7 3 1339518 7 3 1339519 7 3 1339520 7 3 1339521 7 3 1339522 7 3 1339523 7 3 1339524 7 3 1339525 7 3 56P1219 7 11 56P1224 7 13 56P1476 7 15 79F4757 7 3 79F4802 7 11 79F4830 7 5...

Page 170: ...I 6 Service Manual 24xx...

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