Lexmark Forms Printer 2400 Series Users Guide
Edition: June 2000 The following paragraph does not apply to any country where such provisions are inconsistent with local law: LEXMARK INTERNATIONAL, INC., PROVIDES THIS PUBLICATION AS IS WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or implied warranties in certain transactions; therefore, this statement may not apply to you. This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the information herein; these changes will be incorporated in later editions. Improvements or changes in the products or the programs described may be made at any time. Comments about this publication may be addressed to Lexmark International, Inc., Department F95/032-2, 740 West New Circle Road, Lexington, Kentucky 40550, U.S.A. In the United Kingdom and Eire, send to Lexmark International Ltd., Marketing and Services Department, Westhorpe House, Westhorpe, Marlow Bucks SL7 3RQ. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you. You can purchase additional copies of publications related to this product by calling 1-800-553-9727. In the United Kingdom and Eire, call 0628-481500. In other countries, contact your point of purchase. References in this publication to products, programs, or services do not imply that the manufacturer intends to make these available in all countries in which it operates. Any reference to a product, program, or service is not intended to state or imply that only that product, program, or service may be used. Any functionally equivalent product, program, or service that does not infringe any existing intellectual property right may be used instead. Evaluation and verification of operation in conjunction with other products, programs, or services, except those expressly designated by the manufacturer, are the users responsibility. Lexmark, Lexmark with diamond design, ExecJet, and Proprinter are trademarks of Lexmark International, Inc., registered in the United States and other countries. Personal Printer Series is a trademark of Lexmark International, Inc. Other trademarks are the property of their respective owners. Copyright 1993, 2000 Lexmark International, Inc. All rights reserved. UNITED STATES GOVERNMENT RESTRICTED RIGHTS This software and documentation are provided with RESTRICTED RIGHTS. Use, duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause at DFARS 252.227-7013 and in applicable FAR provisions: Lexmark International, Inc., Lexington, KY 40550.

Contents

Chapter 1: About your printer.. 1
Features and functions... 2 Printer description... 7 Printing the demonstration sample.. 10 Connecting the printer to your computer.. 14 Setting up your Windows and DOS application software. 17
Chapter 2: Using the operator panel.. 21
Operator panel layers.... 22 Setting the printer online or offline... 28 Advancing the paper... 29 Using Tear Off.... 29 Using the Load/Unload feature.. 30 Locking/unlocking the operator panel.. 30 Selecting Tractor mode... 30 Selecting or locking a font... 31 Selecting or locking a pitch... 32

Right paper guide

Turn the printer Off. While pressing Font on the operator panel turn the printer On. Continue pressing Font until all the operator panel lights blink.
10 Release the Font button. The Power and Ready lights stay On and the demonstration page prints.

Tractor2 LineFeed

Paper out FormFeed

Start/Stop

Tear Off

Load/Unload

Tractor

Courier Prestige Gothic

Orator Script Draft FastDft

Presentor

Connecting the printer to your computer
These cables are not supplied with your printer. For ordering information, see Supplies on pag e107.
If you are using a parallel cable, see
Connecting the parallel cable on pag e14.
If you are using a USB cable, see
Connecting the USB cable on pag e16.
If you are using the optional serial interface,
see Connecting the serial cable on page 17.
Connecting the parallel cable
Turn the printer and computer Off. Connect the parallel cable at the back of the printer. This cable is not supplied with your printer. Use an IEEE-1284 compatible parallel cable such as Lexmark part number 1329605 (10 ft cable) or 1427498 (20 ft cable).
Note: You do not need to attach a grounding wire to the computer.
Fasten the clip wires to the parallel cable, as shown.
Connect the other end of the parallel cable to your computer. Turn the printer and computer On. Continue with Setting up your Windows and DOS application software on pag e17.

Connecting the USB cable

Turn the printer and computer Off. Connect the USB cable at the back of the printer. This cable is not supplied with your printer. Order the Lexmark USB cable using part number 12A2405.
Connect the other end of the USB cable to your computer. Turn the printer and computer On. Continue with Setting up your Windows and DOS application software on pag e17.
Connecting the serial cable
For installation and connection instructions, see the optional serial interface manual.
Setting up your Windows and DOS application software Windows-based applications
If you are using a Windows program, use the Windows Forms Printer 2400 Series driver available from the Lexmark Web site at www.lexmark.com. Note: Instructions for installing drivers are in the readme.1st file included in the download package.

DOS applications

Follow the instructions that came with your DOS application software to see what printer drivers are available with that specific program. Most programs let you specify the type of printer you are using so the program can take full advantage of the printers features.

Using IBM emulation mode

If your printer is using IBM mode (the factory default), select a printer from your application software, in the following preferred order. For Lexmark Forms Printer 2480/2481 users: 1 Forms Printer 2480/Forms Printer 2380/2381 plus plus/2381 plus 4 2380/2381 IBM Personal Printer Series II 5 4201/4202 IBM Proprinter III 6 4201/4202 IBM Proprinter II 7 IBM ExecJet Printer Model 4072 For Lexmark Forms Printer 2490/2491 users: 1 Forms Printer 2490/Forms Printer 2390 plus/2391 plus plus/2391 plus 4 2390/2391 IBM Personal Printer Series II IBM Proprinter 24P IBM PS/1 Printer 7 4207/4208 Proprinter X24/XLIBM ExecJet Printer Model 2205 IBM PS/1 Printer If your software does not let you select one of the printers in this list, you may need to customize your printer for Epson emulation mode. 18

Layer 2

1 Power Set TOF Macro LineFeed Macro 4
To lock a pitch so your software application cannot select a different one, continue pressing Pitch until the Pitch Lock light comes On and the pitch you want is selected. The pitch is locked until the printer is turned Off.
To disable Pitch Lock, repeatedly press Pitch until the Pitch Lock light turns Off and the pitch you want is selected. Close the operator panel. If the printer is offline, press Start/Stop. The Ready light comes On and you are ready to print.
To set a Pitch or Pitch Lock as a default setting in the Setup menu, see Using Setup mode to change printer settings on pag e89.
Changing tractor positions
This section describes how to change the tractor unit position.This a tractor unit.

Left latching lever Pin

Left tractor door

Left locking lever

Rubber tractor stop
You can install the tractor unit in the push tractor position or the pull tractor position. To view an illustration of the tractor positions and paper paths available, see Paper paths for the push tractor on page 47.

Tractor positions

Push tractor position
The printer is shipped with the tractor unit installed at the front of the printer, which is the push tractor position. This position lets you use the Tear Off feature of the printer.

Front cover

Pull tractor position
When the tractor unit is installed at the top of the printer, it functions as a pull tractor and supports front and bottom paper loading.
Converting the push tractor to pull tractor position Removing the push tractor
Make sure paper is not loaded in the printer. Pull out the front cover to release it and pivot the cover up out of the way.
Hold down the latching levers while you pull and lift the tractor unit out of the printer.

Tractor unit

Installing the pull tractor
3 Remove the ribbon access cover. Turn the tractor unit around so that the latching levers are upright, facing you. Place the tractor against the back slant of your printer along the tractor guides.
To slide the tractor feeder into the printer: a Hold down the latching levers and gently push the tractor feeder into the printer until it stops. b While still holding down the latching levers, tilt the tractor feeder toward the front of the printer until the hooks at the end of the latching levers fit around the posts on the printer frame.

Latching lever hook

Release the latching levers. The tractor unit fits into place at a 45 angle.
Converting the pull tractor to the push tractor position

Loading continuous forms

You can load continuous paper utilizing four different paper paths, depending on whether you have the push tractor installed or the pull tractor installed. Note: If you have installed the optional Auto Sheet Feeder or Tractor 2 Feeder, refer to the documentation shipped with your option for paper loading instructions.
Paper paths for the push tractor
In these examples, the tractor pushes the paper from the front or the rear of the printer.

Push tractor

Tractor Tractor

Front loading paper

Rear loading paper
Paper paths for the pull tractor
In these examples, the tractor pulls the paper from the front or bottom of the printer.

Pull tractor

Front loading paper Bottom loading paper
Loading continuous forms using the push tractor
The factory setting for your printer is the push tractor position. If the tractor unit is not in this position, see Converting the pull tractor to the push tractor position on pag e40. 1 Turn the printer On.
Make sure the paper path is clear. If a cut form or envelope is loaded in the printer, press FormFeed to remove it.
Set the forms thickness lever to a suitable setting. See Setting the forms thickness lever on page 44.
Move the paper select lever down to the continuous forms position.
Pull up the left and right tractor locking levers to unlock the tractors.

Locking lever

Open the left and right tractor doors. Place the paper pinfeed holes over the second or third pins of the tractor unit. If necessary, move the left or right tractor to adjust the tractors to the paper width. Keeping the left tractor positioned to the left of the rubber tractor stop keeps your paper within the paper sensor area.
Close the left and right tractor doors.
10 Set the left margin. Move the tractor to align the left margin on your paper with the [A symbol printed on the rear plate. For help, see Aligning the left margin on pag e77.
Margin guide printing starts at the [A symbol.
The distance from the [A symbol to the left edge of the paper determines the width of the left margin.
11 Push down the left tractor locking lever to lock the tractor in place.
12 Remove slack from the paper and lock the right locking lever.

16 Open the operator panel cover to access layer 2. 17 Press LineFeed, Micro , or Micro to move the paper to the Top-Of-Form. 18 Press Set TOF to set Top-Of-Form. Top-Of-Form is not saved if the printer is turned Off or runs out of paper when using the pull tractor. 19 Make sure the printer is online (Ready light is On solid). If not, press Start/Stop until the Ready light is On solid.
Loading a cut form or envelope
Cut forms can be a single sheet, an envelope, or a multiple-part form. They are placed one at a time into the manual feeder. Note: If you have installed the optional Auto Sheet Feeder or Tractor 2 Feeder, refer to the documentation shipped with your option for paper loading instructions.
Loading a cut form or envelope manually

1 Turn the printer On.

Make sure the paper path is clear. If continuous forms are currently loaded, tear off the leading edge of the continuous form and then press Load/Unload to park the continuous forms. The Paper Out light is blinking. Set the forms thickness lever to a suitable setting for the type of paper you are using. See Setting the forms thickness lever on page 44 for more information.
Move the paper select lever up to the cut forms position.
Open the manual feed door.
Set the left margin. Move the left paper guide so that the print start position you want aligns with the [A symbol printed on the margin guide. For help, see Aligning the left margin on pag e77.
Margin guide printing begins at the [A symbol. Left paper guide
The distance from the left paper guide to the [A symbol determines the width of the left margin.
Place a cut form or envelope against the left paper guide. If you are loading a preprinted form or envelope, put the top edge in first, printed side up.
Move the right paper guide so the guide aligns with the right edge of the paper.
Envelope Right paper guide
10 Insert paper into the printer until the Paper Out light stops blinking. If Auto Cut Sheet Load is set to On, the paper feeds automatically to the Top-OfForm.
FormFeed. 11 Make sure the printer is online (Ready light is On solid). If it is not, press Start/Stop until the Ready light is On solid.

Aligning the left margin

You can manually change the first print position at the left margin. The first print position is indicated by the [A symbol. You can also set the left margin from your software application. Note: Setting the left margin in your software application, adds it to the left margin setting on the printer. For example, if you set the left margin at 1 inch on the printer, and also have the left margin set at 1 inch in your software application, the printer begins printing 2 inches from the left edge of the page.

Right Margin Select from the following: 8 13.6 (wide carriage models) Lines Per Inch Specify the number of text lines in an inch. Select from the following: Bottom Margin Set the bottom margin the number of lines you want. Eject by FF Eject by FormFeed determines how FormFeed is operated. When set to On, FormFeed is an eject operation for cut forms. When set to Off, FormFeed moves the paper to the next Top-Of-Form.
Macro x Character options Defines the character settings for a macro. See Character options on page 96 for more information. Paper Handling options Defines the paper handling settings for a macro. See Paper handling options on pag e97 for more information. Copy Macro Lets you copy macro settings from one macro to another.

Data menu options

Data options Use these menu options

Buffer

When you want to
Select minimum to set the receive buffer size to zero. Select maximum for 2480/2481 printers to set the buffer size to 64KB or 96KB, depending on whether NLQ II (Near Letter Quality) Download is enabled.
Select maximum for 2490/2491 printers to set the buffer size to 47.5KB or 79.5KB depending on whether Download is enabled. Auto LF Requires a line feed to occur. Set to On, a line feed is performed for each Carrier Return (CR) received. Set to Off, a line feed does not occur when a CR code is received. Auto CR Requires a carrier return to occur. Set to On, a carrier return is performed for each line feed received. Set to Off, a carrier return does not occur when a line feed code is received. Zero Slash Turn Zero Slash On, to print a zero with a slash down the middle instead of a numeric zero. The factory setting of Zero Slash is Off. Download for NLQ II Note: Available for 2480/2481 printers only. Use NLQ II. Select Enable to reserve a portion of the receive buffer for downloading fonts. The factory setting is Enable. Select Disable to use the entire buffer as a receive buffer. Download Note: Available for 2490/2491 printers only. Allocate your printer buffer. Select Enable to reserve a portion of the receive buffer for downloading fonts. The factory setting is Enable. Select Disable to use the entire buffer as a receive buffer.
Data options (continued) Use these menu When you want to options

FF Enable Control form feed commands. Note: Available for the Select On to execute any form feed codes (X'0C'). Select Off to ignore any form feed codes when paper is 2480/2481 printers only. positioned at the current Top-Of-Form. Code Page Sub Substitute code page 858 for 850. This lets older software access the euro character. Enable Disable

Control menu options

Control options Use these menu options

Uni-Dir Printing

Customize the direction of print. Set to On and in NLQ mode, the printer prints unidirectionally by line.
Set to Off, the two passes are printed bidirectionally except Proportional Spacing, which is still printed unidirectionally. The factory setting is Off. Auto Ready Cut Sheet Customize how the printer goes to Ready after a cut sheet is loaded. When set to On, the printer automatically goes to the Ready state after a cut sheet is loaded into the printer. When set to Off, the printer remains offline after a cut sheet is loaded. Press Start/Stop to put the printer in the Ready state. Paper Out Alarm Set the printer to alarm or not. When set to Enable, the alarm sounds when the printer runs out of paper. The factory setting is Enable. When set to Disable, the alarm does not sound. Demo Print Enable or Disable the printers ability to print the Demo page. For instructions to print the Demo page, see Printing the demonstration sample on page 10. Menu Language Select the language you want your menus to print in. The menus can appear in one of the following languages: English, French, German, Italian, Spanish and Brazilian Portuguese. To view the list of steps, see Example: Changing the menu language setting on page 92. TOF Read Have the printer verify the Top-Of-Form before it begins printing continuous forms. For help see, Setting Top-Of-Form on page 81. Quiet Change the noise level of your printer by putting it in Quiet mode. The printer prints slower in Quiet mode.

Emulation menu options

Emulation options Use these menu options
Emulation Selection IBM mode
Select between IBM mode and Epson mode. If you installed an OKI option, OKI is also listed. Use Pro-III mode Proprinter III, available only on 2480/2481 printers, enables compatibility with the Proprinter III. When set to On, the printer emulates a Proprinter III. When set to Off, the printer operates with added capabilities. Use AGM Alternate Graphics mode, available only on 2490/2491 printers, lets you use the high-resolution 24-wire graphics commands. These commands are similar to those used with the Epson LQ570/LQ1070.

on page

on page 118 on page 126 on page 116 on page 123 on page 128 on page 114
Auto Sheet Feeder problems

on page 135

Troubleshooting
Checklist for typical problems
To solve most basic problems, begin by following these steps: 1 Is power getting to the printer? Make sure:
The power cord is both plugged into a
properly grounded outlet and into the printer.
The other items plugged into the same
power source are operating.
The power source cannot be turned Off by a

wall switch.

Is print too light? The ribbon density control knob has been preset to 1. (The knob is located on the ribbon cartridge.) When print becomes light, turn the knob from 1 to 2 to increase darkness of print.
Ribbon density control knob

Ribbon advance knob

Is paper jamming the printer? See Clearing paper jams on pag e126 for information on clearing paper jams.
Are forms catching on items such as a forms carton or a printer stand? Adjust the forms container so paper feeds freely from container to printer.
Is a part damaged? Call for service.
Are options causing the problem? a Run the Printer Test. For more information, see Testing the printer on pag e116. b If the Printer Test fails with no options installed, call service. c If the Printer Test fails with an option installed, try removing the option. Is the Font or Pitch selected from the operator panel not printing or is it changing? Set Font Lock or Pitch Lock On to keep your software application from overriding the font and pitch settings. For more information, see Selecting or locking a font on page 31. If you need to use a nonresident font, change the font within your software application. Note: If you are using Windows programs, most fonts are bitmapped (graphics) and override the printer Font or Pitch Lock. Select a resident font to override from the operator panel.
Is the problem outside the printer? a Turn the printer Off. b Disconnect the printer cable from the back of the printer. c Run the Printer Test. For more information, see Testing the printer on pag e116. If the Printer Test runs, then the problem is in the printer cable or your computer. d Run the test procedures for your computer. For more information, refer to your computers operator manual. If a software application does not run correctly on the printer, does a different software application run correctly?
10 Are you experiencing unexpected printing results? Make sure:
You selected the appropriate printer driver
for your software application. For more information, see Setting up your Windows and DOS application software on pag e17.
You selected the appropriate emulation
mode for your printer. For more information, see Using IBM emulation mode on page 18. 11 Do the buttons on the operator panel not work except for Start/Stop, LineFeed, FormFeed, Tear Off and Load/Unload? The operator panel is locked. For more information, see Locking/unlocking the operator panel on pag e30.

Left margin moves to the right during printing.
The printhead is not moving correctly.
Software application problem.
Line length is wrong; lines do not start at the left margin. Application program problem.
Refer to your software application manual. Make sure the correct printer driver is selected.

Paper loads wrong.

Adjust the left margin by adjusting the tractor or paper guide. Refer to your software application manual. Make sure the correct printer driver is selected.

Graphics do not print.

Line spacing is incorrect, or Forms are jamming overprinting occurs. between printing surface and the printhead.
Reset forms thickness lever. See Setting the forms thickness lever on page 44.
Problem with the software Refer to your software applications. application manual. Specified pitch or font selected is not printing or is changing. Your software is overriding your operator panel selection. Your software is using bitmapped (graphic) fonts. If possible, select resident fonts. Use Font Lock and Pitch Lock. See Selecting or locking a font on page 31.
Printer is printing beyond side edge of forms. Paper is adjusted incorrectly.
Adjust tractors or paper guides and the paper. See Aligning the left margin on page 77.
Problem with the software Refer to your software application. application manual.
A printhead jam caused by Make sure the ribbon the ribbon or a paper jam. cartridge is correctly installed. Clear the paper jam. See Adjusting bidirectional alignment on page 123. Turn the printer Off and then back On. Printing continues beyond Computer program set edge of the form. the assigned paper size larger than the actual page size. The printer is trying to print in the last inch of form. Change the software application so that the assigned paper size is the same as the actual paper size.
Printer sounds as if it is printing but doesnt print; printing is light.
Forms thickness lever is set See Setting the forms too high for the type of thickness lever on page 44. paper you are using. Ribbon is jamming, is twisted, or is not between the printhead and the ribbon shield. Ribbon is out of ink. Make sure the ribbon cartridge is correctly installed and securely snapped down on the carrier. Adjust the ribbon density control knob. See Is print too light? on page 113 for more information. Printer ribbon is out of ink. Replace the ribbon cartridge. See Removing the ribbon cartridge on page 142.

Printing is unstable; wrong If you are using a Make sure the printer cable characters print; left grounded or shielded is properly shielded and margin changes; printing printer cable, it may not correctly connected at both stops. be attached correctly. ends. Wrong driver in software. Select the correct driver. See Setting up your Windows and DOS application software on page 17.
Printer does not feed paper.

Paper is jamming.

Remove all forms and pieces of paper. Look for loose pinfeed hole strips that can sometimes tear from continuous forms and remain in the printer. The right tractor position may be incorrectly adjusted. Before you load new forms, fan the forms to loosen the sheets.
The forms thickness lever is set incorrectly for the type of paper you are using. The Continuous form paper is parked. The Auto Cut Sheet Load option is not set. The right paper guide is not set correctly for your paper width. The paper select lever is in the wrong position.
See Setting the forms thickness lever on page 44 for more information. Press Load/Unload. See Auto Cut Sheet Load on page 97 for more information. Adjust the right paper guide.
If you are trying to print a cut sheet, make sure the paper select lever is in the position. cut sheet If you are trying to print continuous forms, make sure the paper select lever is in the continuous sheet position.
Cannot adjust right tractor past rubber tractor stop in pull tractor position.
Rubber tractor stop has been pushed out of seated position.
Firmly slide tractor and rubber tractor stop.
Printer problems (continued) Problem
Paper does not feed from the Auto Sheet Feeder.
The Auto Sheet Feeder locking lever is in the front position. The paper select lever is in the tractor feed position. The optional Auto Sheet Feeder is not set to On in Setup mode. Too many sheets are in the paper bin.
Set the Auto Sheet Feeder locking lever to the back position. Set the paper select lever to the cut sheet position. Enter Setup mode and set the option to On. See Entering Setup mode on page 90 for more information. Remove the extra sheets. Ensure that the stack of paper is not more than 150 sheets (64 g/m2). For larger or thicker paper, use fewer sheets. Remove all paper from the paper bin and install paper that has a lower weight. See the optional Auto Sheet Feeder manual for recommended paper weights. Remove all paper from the paper bin and fan the top and bottom edges with your thumb. Then place the paper in the paper bin. For help, see Cleaning the Auto Sheet Feeder rollers on page 143.

The weight of the paper is too great.
Paper sheets seem to hold together at the bottom edge.

Dirty feed rollers.

Paper jam in the Auto Sheet Feeder.
The paper is not loaded correctly in the paper bin. The paper is not stacked evenly in the supply bin. The Auto Sheet Feeder is not correctly installed. Foreign objects are in the Auto Sheet Feeder paper path.
Remove the paper and reload the paper bin. Remove the paper, align the edges of the paper, and reload the paper bin. Remove the Auto Sheet Feeder, and reinstall it. Remove the Auto Sheet Feeder. Remove the foreign objects. Reinstall the Auto Sheet Feeder. Remove the Auto Sheet Feeder. Remove pieces of paper from the paper feed path. Reinstall the Auto Sheet Feeder. Remove the Auto Sheet Feeder, and then reinstall it. Move the paper guide to the left. Remove the Auto Sheet Feeder. Move the continuous forms to the park position using the Load/Unload button. Adjust the forms thickness lever. For help, see Setting the forms thickness lever on page 44.
Paper fed from Auto Sheet Feeder jams at entrance to printer.
The printer paper feed path is dirty or the ribbon is jammed.
The Auto Sheet Feeder is not correctly installed. The paper guide is too far to the right. The continuous forms were not moved to the park position before the Auto Sheet Feeder was used. Forms thickness lever is set incorrectly for your paper thickness.
Paper fed from the Auto Sheet Feeder is skewed in the printer.
The left and right paper guides are not correctly adjusted. Paper is not correctly placed in the paper bin.
Adjust the left and right paper guides so they are tight against the edge of the paper. Remove paper from the paper bin. Fan the paper. Reload the paper correctly.
The Auto Sheet Feeder feeds multiple sheets.
Paper is not correctly placed in the paper bin. The weight of the paper is too low.
Remove paper from the paper bin. Reload the paper correctly. Remove all paper from the paper bin, and install a heavier paper. See the optional Auto Sheet Feeder manual for recommended paper weights. Remove all paper from the paper bin and fan the top and bottom edges with your thumb. Place the paper in the paper bin. Add more paper to the paper bin.
Not enough paper in the paper bin.
The Auto Sheet Feeder feeds paper at an incorrect rate.
Remove all paper from the Auto Sheet Feeder and use paper that has a lower weight. See the optional Auto Sheet Feeder manual for recommended paper weights. See Paper fed from Auto Sheet Feeder jams at entrance to printer. on pag e136. Adjust the forms thickness lever. See Setting the forms thickness lever on page 44 for more information. Remove some of the paper.

Printer power switch is On, but Power light is Off.
Printer is not getting power.
Make sure the power cord is correctly connected at both ends. Verify that the power source works.

Printer alarm sounds.

This might indicate an error or normal operation. The option is incorrectly installed.
Check the status of the operator panel lights. See Checking the printer status on page 118. Remove and reinstall the option. For help, refer to the documentation shipped with your option. Check the forms thickness lever. Make sure the setting is appropriate for the thickness of your forms. Printing speed is slower when the setting is 4 or higher. Your software application is using bitmapped (graphic) fonts. If possible, select resident fonts. Note: Automatic thermal slowdown protects the printhead from overheating. This operation is normal and is affected by print type being used (letter quality, for example) and the amount and density of graphics being printed.
The optional Auto Sheet Feeder or Tractor 2 Feeder is noisy. Printing speed becomes slower.
The print operation has slowed down.

Maintenance

This section describes how to remove the ribbon cartridge and clean the printer.
Removing the ribbon cartridge
Turn the printer Off. Remove the ribbon access cover. Set the forms thickness lever to position 7. Squeeze the left and right latches on the ribbon cartridge and lift. The cartridge unlatches from the printer carrier.

Cleaning the printer

Before you clean the printer: Turn the printer Off. Unplug the power cord. Wait until the printhead is cool. Remove the ribbon cartridge.
Cleaning the inside of the printer: Every few months, use a soft brush and a vacuum to remove dust, ribbon lint, and pieces of paper. Vacuum any dust from around the printhead and in the printer cavity. Cleaning the cover: Clean the outside of the printer with a damp cloth and mild soap. Do not use any spray-type or chemical cleaners anywhere on your printer. Do not put any liquids or spray near the air vents. For stubborn ink stains on the cover, use a commercial mechanic's hand cleaner.
Cleaning the Auto Sheet Feeder rollers 1 Remove all paper from the printer. 2 Turn the Auto Sheet Feeder upside down and place it on a flat surface. 3 Clean the two paper-guide wheels located inside the bottom of the Auto Sheet Feeder using isopropyl alcohol and a clean cloth. You can rotate one roller while applying the cleaning cloth to the other roller.

Notices

Electronic emission notices
Federal Communications Commission (FCC) statement
The Lexmark Forms Printer 2480, 2481, 2490, and 2491 have been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. The FCC Class B limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

software, setting up 17 Start/Stop button 24 stopping the printer 29 Supplies ordering 107
tear bar 9 Tear Off, using 29 testing the printer 116 top cover 7 Top-Of-Form aligning 83 for a cut form or envelope 85 for continuous form paper in pull mode 84 for continuous forms in push mode 81
trace mode 116 tractor 33 pull 35 push 34 Tractor 2 feeder paper feeding problems 139 tractor mode 30 tractor parts latching levers 33 locking levers 33 pins 33 Troubleshooting 111 type style sample 10
US defaults 121 USB interface connector 16

Lexmark 2400 Forms Printer 24XX-100
Extracted From Service Manual
Edition: November 2000 The following paragraph does not apply to any country where such provisions are inconsistent with local law: LEXMARK INTERNATIONAL, INC. PROVIDES THIS PUBLICATION AS IS WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or implied warranties in certain transactions; therefore, this statement may not apply to you. This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the information herein; these changes will be incorporated in later editions. Improvements or changes in the products or the programs described may be made at any time. Comments may 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 any of the information you supply in any way it believes appropriate without incurring any obligation to you. You can purchase additional copies of publications related to this product by calling 1-800-553-9727. In other countries, contact your point of purchase. Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. Other trademarks are the property of their respective owners. Copyright Lexmark International, Inc. 2000. All rights reserved. UNITED STATES GOVERNMENT RESTRICTED RIGHTS This software and documentation are provided with RESTRICTED RIGHTS. Use, duplication or disclosure by the Government is subject to restrictions as set forth in subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause at DFARS 252.227-7013 and in applicable FAR provisions: Lexmark International, Inc., Lexington, KY 40550.

U.S.A. P/N: 12G3662

7. Parts Catalog
How To Use This Parts Catalog
SIMILAR ASSEMBLIES: If two assemblies contain a majority of identical parts, they are shown on the same list. Common parts are shown by one index number. Parts peculiar to one or the other of the assemblies are listed 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 assemblies is designed using the 2480-100 (9-wire) model, as reference. Some of the artwork may not be completely representative of all models. For example, the 24wire models are not depicted with two printhead cables and there is no artwork depicting the extended carriage models 2481 or 2491.

Parts Catalog 7-1

Assembly 1: Covers

7-2 Service Manual

AsmIndex 1-Part Number 12G3877 12G3873 12G3874 12G3878 12G3858 12G3859 12G3868 12G3869 12G3871 12G3872 12G3870 79F4757
Description Guide, Left Paper Cover, Front Unit (2480, 2490) Cover, Front Unit (2481, 2491) Guide, Right Paper Cover, Ribbon Access Unit (2480) Cover, Ribbon Access Unit (2481) Cover, Ribbon Access Unit (2490) Cover, Ribbon Access Cover (2491) Cover, Top (2480, 2490) Cover, Top (2481, 2491) Cover, Option Line Cord: U.S., AFE (LV), Canada, Central and South America, Mexico, Saudi Arabia (LV) Line Cord: Malaysia, and Singapore, United Kingdom Line Cord: Austria, Belgium, Brazil, Germany, Greece, Finland, France, Indonesia, Luxembourg, Portugal, Norway, Saudi Arabia (HV), Spain, Sweden, The Netherlands, Turkey Line Cord - Denmark Line Cord - Chile, Italy Line Cord - Israel Line Cord - South Africa Line Cord - Switzerland Line Cord: Argentina, Australia, New Zealand, Paraguay Line Cord - Peru

1339519 1339520

1339517

Parts Catalog 7-3

7-4 Service Manual
AsmIndex 1-9A 9B 9C 9D 9D 9E 12 NS NS NS NS Part Number 12G3856 12G3857 12G3854 12G3855 12G3850 12G3853 79F4830 12G3851 12G3852 12G3849 12G3810 12G3811 12G3883 12G3875 12G3876 12G3999 12G3881 12G3882 12G3939
Description Cover, Bottom (2480, 2490) Cover, Bottom (2481, 2491) Tractor Unit (2480, 2490) Tractor Unit (2481, 2491) Frame, Right Side Tractor Tractors, Left and Right Support, Tractor Paper Shaft Set, Tractor (2480, 2490) Shaft Set, Tractor (2481, 2491) Frame, Left Side Tractor Operator Panel Assembly (248X) Operator Panel Assembly (249X) Cable, Operator Panel Cover, Front Guide (2480, 2490) Cover, Front Guide (2481, 2491) Cover, Operator Panel Front w/ Overlay Packs Overlay Pack, Operator Panel (248X) Overlay Pack, Operator Panel (249X) Stand, Paper

Parts Catalog 7-5

Assembly 2: Carrier / Paper Feed Right Side

7-6 Service Manual

AsmIndex 2-Part Number 12G3841 12G3894 12G3895 12G3838 12G3837 12G3840 12G3839 12G3889 12G3888 12G3891 12G3890 12G3942 12G3896 12G3836 12G3887 12G3907 12G3931 12G3884 12G3905 12G3906 12G3834 12G3898 11A3274 11A3275 12G3897 12G3819 12G3932 12G3949 12G3823 12G3822 12G3835 12G3943 12G3900 12G3901
Description Carrier Roller Set Printhead Assembly (2480, 2481) Printhead Assembly (2490, 2491) Carrier Unit (2480) Carrier Unit (2481) Carrier Unit (2490) Carrier Unit (2491) Cable, Printhead (2480) Cable, Printhead (2481) Cable, Printhead (2490) Cable, Printhead (2491) Kit, Pull Tractor Actuator Springs, Parts Packet Kit, ESD Ground (2490, 2491) Kit, ESD Ground (2480, 2481) Screws, Washers and Clips, Parts Packet Kit, Head Gap Adjustment Damper, Frame Assembly Gears and Bushings, Parts Packet (248X) Gears and Bushings, Parts Packet (249X) Sub Frame, Right Side Cam, Release Slider and Sub Slider Gear, Idler (2480, 2481) Gear, Idler (2490, 2491) Lever, Paper Select Lever Frame, Right Side Holder, Lower Pinch Roller Shaft, Right Guide, ASF/DTR, Right Roller, Lower Feed (2480, 2490) Roller, Lower Feed (2481, 2491) Roller, Lower Pinch (2480, 2490) Roller, Lower Pinch (2481, 2491) Shaft, Carrier (2480, 2490) Shaft, Carrier (2481, 2491)

Parts Catalog 7-7

7-8 Service Manual
AsmIndex 2 - Part Number 12G3832 12G3833
Description Roller, Upper Feed (2480, 2490) Roller, Upper Feed (2481, 2491)

Parts Catalog 7-9

Assembly 3: Carrier / Paper Feed Left Side

7-10 Service Manual

AsmIndex 3-Part Number 12G3905 12G3906 12G3907 12G3942 12G3817 12G3818 12G3940 12G3922 12G3844 12G3935 12G3896 12G3941 12G3902 12G3884 12G3946 12G3821 12G3820 12G3826 12G3825 12G3948 12G3909 12G3824 79F4802 79F4834 12G3831 12G3937 12G3938 12G3828 12G3827 12G3846 12G3892 12G3845
Description Gears and Bushings, Parts Packet (248X) Gears and Bushings, Parts Packet (249X) Screws, Washers and Clips, Parts Packet Kit, Pull Tractor Actuator Frame, Left Side (2480, 2481) Frame, Left Side (2490, 2491) Sensor, Pull Tractor Plate, Frame Support (2480, 2490) Plate, Frame Support (2481, 2491) Holder, Lower Pinch Roller Shaft, Left Springs, Parts Packet Sensor, Paper Select Holder, Platen Damper, Frame Assembly Sensor, Head Gap Guide, Paper Assembly (2480, 2490) Guide, Paper Assembly (2481, 2491) Platen (2480, 2490) Platen (2481, 2491) Guide, ASF/DTR, Left Sensor, Top-Of-Form Sensor, Paper Present Gear, Ribbon Drive Rack (2480, 2490) Gear, Ribbon Drive Rack (2481, 2491) Plate, Tension Pulley Assembly Plate, Carrier Assembly (2480, 2490) Plate, Carrier Assembly (2481, 2491) Separator, Paper (2480, 2490) Separator, Paper (2481, 2491) Motor, Carrier Bracket, Carrier Motor Sensor, Home Position

Parts Catalog 7-11

7-12 Service Manual
AsmIndex 3 - Part Number 12G3931 12G3947 12G3842 12G3843 11A3274 11A3275
Description Kit, Head Gap Adjustment Lever, Form Thickness Motor, Paper Feed Bracket, Paper Feed Motor Assembly Gear, Idle (248X) Gear, Idle (249X)

Parts Catalog 7-13

Assembly 4: Electronics

7-14 Service Manual

AsmIndex 4-NS NS NS NS Part Number 12G3907 12G3836 12G3887 12G3801 12G3800 12G3812 12G3813 12G3848 12G3802 12G3806 12G3803 12G3807 12G3804 12G3808 12G3805 12G3809 12G3886 12G3885 12G3861 12G3860 12G3903 12G3904 12G3929 12G3936
Description Screws, Washers and Clips, Parts Packet Kit, ESD Ground (2490, 2491) Kit, ESD Ground (2480, 2481) Power Supply Unit, LV Power Supply Unit, HV Module, EPROM (248X) Module, EPROM (249X) Module, EPROM (Okidata MICROLINE) Board, Logic W/O EPROM (2480 LV) Board, Logic W/O EPROM (2480 HV) Board, Logic W/O EPROM (2481 LV) Board, Logic W/O EPROM (2481 HV) Board, Logic W/O EPROM (2490 LV) Board, Logic W/O EPROM (2490 HV) Board, Logic W/O EPROM (2491 LV) Board, Logic W/O EPROM (2491 HV) Bracket, Serial Interface Card Plate, Serial Interface Card Cable, Power Supply (2480, 2490) Cable, Power Supply (2481, 2491) Kit, Fuse (LV) Kit, Fuse (HV) Card, Serial Interface Card with Plate Cable, Serial Interface Cable

Parts Catalog 7-15

Assembly 5: ASF - Roller / Support

7-16 Service Manual

AsmIndex 5-16 Part Number 12G3814 12G3908 95F6886 95F6896 95F6887 95F6897 95F12G3911 12G3893 12G3912 12G3914 12G3915 12G3916 12G3933 12G3934 12G3918 95F6892 95F6893 95F6894 12G3944
Description Support, ASF Cut Sheet W/ Guides (2480, 2490) Support, ASF Cut Sheet W/ Guides (2481, 2491) Roller, ASF Upper Feed (2480, 2490) Roller, ASF Upper Feed (2481, 2491) Roller, ASF Lower Feed (2480, 2490) Roller, ASF Lower Feed (2481, 2491) Roller, ASF Pick-up Left and Right (2480, 2490) Roller, ASF Pick-up Left and Right (2481, 2491) Hopper, ASF Right (2480, 2490) Hopper, ASF Right (2481, 2491) Support, ASF Paper Right Support, ASF Paper Center (2481, 2491) Support, ASF Paper Left Hopper, ASF Left Lever, ASF Paper Load Link, ASF Paper Load Cover, ASF Left ASF Gears and Bushings, Parts Packet ASF Springs, Parts Packet ASF Screws, Parts Packet Frame, ASF Side Left

Parts Catalog 7-17

Assembly 6: ASF - Side Frame / Covers

7-18 Service Manual

AsmIndex 6 -6 NS Part Number 95F6893 95F6892 12G3920 95F6894 12G3921 12G3930 12G3945 12G3939
Description ASF Springs, Parts Packet ASF Gears and Bushings, Parts Packet Cover, ASF Right ASF Screws, Parts Packet Cover, ASF/TR2 Front (2480, 2490) Cover, ASF/TR2 Front (2481, 2491) Frame, ASF Side Right Stand, Paper

Parts Catalog 7-19

Assembly 7: Tractor 2 Option

7-20 Service Manual

AsmIndex 7-10 Part Number 12G3923 12G3924 11A3338 12G3926 12G3927 12G3853 11A3335 11A3336 11A3337 11A3341 12G3928 12G3921 12G3930 11A3283 11A3284
Description Table, Tractor 2 Paper W/ Guides (2480, 2490) Table, Tractor 2 Paper W/ Guides (2481, 2491) Guide, Tractor 2 Paper Tractor and Frame Assembly, Tractor 2 (2480, 2490) Tractor and Frame Assembly, Tractor 2 (2481, 2491) Kit, Tractors Left and Right Board Assembly W/Cable and Ferrite, Tractor 2 (2480, 2490) Board Assembly W/Cable and Ferrite, Tractor 2 (2481, 2491) Motor, Tractor 2 Parts Packet, Tractor 2 Cover, Tractor 2, Right Cover, ASF/Tractor 2, Front (2480, 2490) Cover, ASF/Tractor 2, Front (2481, 2491) Shaft, Tractor 2 Support (2480, 2490) Shaft, Tractor 2 Support (2481, 2491)

Parts Catalog 7-21

Coax / Twinax Adapter
AsmIndex NS NS NS NS NS NS Part Number 12G3704 12G3705 12G3709 13A0297 13A0296 11A6109 Description Adapter, Coax (Power Cable and Adapter) Adapter, Twinax (Power Cable and Adapter) Bracket, Adapter (Bracket Only) Cable, Coax (Cable Only) Cable, Twinax (Cable Only) Cable, Socket Power Coax, Twinax (Socket Power Cable Only)

7-22 Service Manual