Lexmark 25**-100 Service Manual Download

Page: 5 / 188

25XX-100, -110

Carrier removals

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Carrier removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Carrier, motor assembly removal

. . . . . . . . . . . . . . . . . . . . . . . . 4-22

Paper handling removals

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

Paper Select lever removal

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

Paper feed motor removal

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

Forms Thickness lever removal

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

Print handling removals

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

Platen removal

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

Printhead removal

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

Printhead cables removal

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

Print unit removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

Ribbon drive rack gear removal

. . . . . . . . . . . . . . . . . . . . . . . . . 4-31

Gears removals

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

Left side gears removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

Right side gears, sub frame removal

. . . . . . . . . . . . . . . . . . . . . 4-35

Rollers removals

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37

Roller, upper feed removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37

Roller, lower pinch removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39

Roller, lower feed removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

Sensor removals

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

Sensor, Pull Tractor removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45

Sensor, Head Gap removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45

Sensor, Top-of-form removal

. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45

Sensor, Paper Select removal

. . . . . . . . . . . . . . . . . . . . . . . . . . 4-46

Sensor, Paper Present removal

. . . . . . . . . . . . . . . . . . . . . . . . . 4-46

Flags, Paper Present/Top-of-form removal

. . . . . . . . . . . . . . . . 4-46

Sensor, Home Position sensor removal

. . . . . . . . . . . . . . . . . . . 4-47

Options removals

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48

Auto Sheet Feeder gears removal

. . . . . . . . . . . . . . . . . . . . . . . 4-48

Auto Sheet Feeder pick-up roller removal

. . . . . . . . . . . . . . . . . 4-49

Locations and connectors

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Signal connections

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Power supply (9w & 24w)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Logic board–Parallel interface cable (9w & 24w)

. . . . . . . . . . . . 5-5

Logic board–Serial board (9w & 24w)

. . . . . . . . . . . . . . . . . . . . 5-7

Logic board–USB cable (9w & 24w)

. . . . . . . . . . . . . . . . . . . . . . 5-9

Logic board–DC power (9w & 24w)

. . . . . . . . . . . . . . . . . . . . . . 5-9

Logic board–Printhead (9w)

. . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Logic board–Printhead (24w)

. . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Summary of Contents for 25**-100

Page 1: ...s 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 Trademarks Start diagnostics Edition November 2007 Start diagnostics ...

Page 2: ...nts 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...

Page 3: ... Diagnostic information 2 1 Start 2 1 Voltage ground and continuity readings 2 1 Error indication table 2 3 Symptom check table 2 6 Irrecoverable operator errors 2 13 Service checks 2 15 Abnormal noise service check 2 15 Auto Sheet Feeder ASF service check 2 16 Carrier service check 2 18 Intermittent problem service check 2 20 No print or abnormal print service check 2 23 Operator panel service ch...

Page 4: ... 8 Reports page 3 8 Flashing firmware 3 9 Importing and exporting INA settings 3 10 Resetting the INA to factory defaults 3 11 Repair information 4 1 Handling ESD sensitive parts 4 1 Adjustments 4 2 Printhead to platen gap adjustment 4 2 Bidirectional print adjustment 4 4 Removal procedures 4 4 Covers removals 4 5 Covers front removal 4 6 Covers ribbon access removal 4 6 Covers option removal 4 7 ...

Page 5: ...7 Roller lower pinch removal 4 39 Roller lower feed removal 4 42 Sensor removals 4 44 Sensor Pull Tractor removal 4 45 Sensor Head Gap removal 4 45 Sensor Top of form removal 4 45 Sensor Paper Select removal 4 46 Sensor Paper Present removal 4 46 Flags Paper Present Top of form removal 4 46 Sensor Home Position sensor removal 4 47 Options removals 4 48 Auto Sheet Feeder gears removal 4 48 Auto She...

Page 6: ...w 24w 5 21 Logic board Operator panel 9w 24w 5 23 Logic board Dual tractor cable 9w 24w 5 25 Serial board Serial cable 9w 24w 5 26 Tractor 2 cable connectors 5 27 Preventive maintenance 6 1 Lubrication 6 1 Lubrication points 6 2 Lubrication points oil 6 3 Lubrication points grease 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...

Page 7: ...oduct before you begin or use caution if the product must receive power in order to perform the task Consignes de sécurité La sécurité de ce produit repose sur des tests et des agréations portant sur sa conception d origine et sur des composants particuliers Le fabricant n assume aucune responsabilité concernant la sécurité en cas d utilisation de pièces de rechange non agréées Les consignes d ent...

Page 8: ...odotto deve essere alimentato per eseguire l intervento Sicherheitshinweise Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprünglichen Modells und bestimmter Bauteile Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung für die Sicherheit übernommen Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwend...

Page 9: ... o tenga cuidado si para trabajar con él debe conectarlo Informações de Segurança A segurança deste produto baseia se em testes e aprovações do modelo original e de componentes específicos O fabricante não é responsável pela segunrança no caso de uso de peças de substituição não autorizadas As informações de segurança relativas a este produto destinam se a profissionais destes serviços e não devem...

Page 10: ...oducte està orientada exclusivament a professionals i no està destinada a ningú que no ho sigui El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de servei d aquest producte El personal professional ha d estar ne assabentat i prendre les mesures convenients PRECAUCIÓ aquest símbol indica que el voltatge de la part de l equip amb la qual esteu treballant é...

Page 11: ...xi 25XX 100 110 ...

Page 12: ... provides instructions for making printer adjustments and removing and installing FRUs 5 Connector locations uses illustrations to identify the connector locations and test points on the printer 6 Preventive maintenance contains the lubrication specifications and recommendations to prevent problems 7 Parts catalog contains illustrations and part numbers for individual FRUs Definitions Note A note ...

Page 13: ...ess They are especially well suited for applications that use continuous or multi part forms Printer specifications Printhead life 300 million characters Standard ribbon life 4 million characters High yield ribbon life 8 million characters Printer life 5 years Power consumption 38 watts maximum 9 watts idle Model 9 Wire 24 Wire Short carriage Long carriage 2580 XXX X X 2581 XXX X X 2590 XXX X X 25...

Page 14: ...ew selections 5 After making a selection the printer prints a page with the changes shown Exiting Setup mode 1 Press Set TOF until the printer returns to the Main Menu or press Pitch from any menu containing a Return to Main Menu selection 2 Press Set TOF again to exit Setup mode New settings are saved only when the printer exits Setup mode Note If the printer runs out of paper while in Setup mode...

Page 15: ...terface options Define how information is transferred from a computer to the printer Menu Function Interface Automatically select the printer interface Use the parallel cable Use the USB cable Use the serial cable only appears if optional serial adapter is installed Honor init Enable honors the init signal on the parallel port Disable ignores the init signal on the parallel port Data speed 300 bps...

Page 16: ...data 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 the printer beeps 3 Open the operator panel cover to access layer two 4 Press Micro or Micro to move the paper to the correct position on the tear off bar 5 Close the operator panel cover The print...

Page 17: ...of form cut 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 If the Paper Out light is off tear off excess forms and press Load Unload If an individual form is loaded press FormFeed to clear the paper path 2 Move the paper select lever up to the cut...

Page 18: ...nection 3 Check the first section on the network setup page and confirm that the status is Connected If the status is Not Connected the LAN drop may not be active or the network cable may be malfunctioning See Networking service check 4 Check the network setup page to find the IP Address and the Fully Qualified Domain Name The Fully Qualified Domain Name is useful in situations where the Address c...

Page 19: ...et Feeder ASF Internal serial interface RS232 OKI emulation 9 wire only Tractor 2 sheet feeder Tools The basic tools necessary to service the 25XX printers are Basic CE tool kit 1 Phillips screwdriver 2 Phillips screwdriver Feeler gauges 0 33 mm 0 013 in and 0 37 mm 0 015 in Analog or digital volt ohmmeter ...

Page 20: ...ceable unit HTTP Hypertext transport protocol HV High voltage LED Light emitting diode LV Low voltage MFP Multifunction Printer mm Millimeter NIC Network interface card NVRAM Nonvolatile Random Access Memory POST Power On Self Test RAM Random access memory ROM Read only storage TCP IP Transport control protocol Internet protocol USB Universal Serial Bus V ac Volts alternating current V dc Volts di...

Page 21: ...urement is to be performed the voltage on United States and Canada printers should be between 100 V ac and 127 V ac On World Trade printers the voltage is according to each country s specification Ground checks To check for a correct ground measure the voltage between the ground and a known good voltage source The voltage measurement must be the same as the source voltage to consider that the grou...

Page 22: ...measuring continuity be sure no back circuits affect the measurement If necessary unplug connectors to remove any back circuits Zero the ohm range on the lowest scale X1 An open circuit will read infinity A circuit with correct continuity will read zero ohms ...

Page 23: ...ON None POST RAM ROM Controller Error Go to POST service check on page 2 29 Power Ready Paper Out Panel Lock ON Blinking Blinking Blinking None Switch Scan Test Error Go to Operator panel service check on page 2 23 Power Ready Paper Out Font Lock ON Blinking Blinking Blinking None NVRAM Read Write Error Turn the printer off and then back on If you get the same error during power up replace the log...

Page 24: ...ng 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 Bidirectional print adjustment on page 4 4 Power Ready Tractor 2 Paper Out Font Lock ON Blinking Blinking Blinking Blinking None Hardware Drive Error The printhead or the printhead cable s can cause this error Go to Printh...

Page 25: ...Out Panel Lock Font Lock ON OFF OFF OFF OFF None Operator Panel Failure Go to Operator panel service check on page 2 23 Any LED on and Power LED off None Go to Operator panel service check on page 2 23 The Power LED blinks or changes intensity None Go to Power service check on page 2 30 Power Ready Font Lock ON Blinking Blinking None Ethernet option not installed Go to Network service check on pag...

Page 26: ...n Disconnect the interface cable from the printer and turn the printer off and then back on If POST now runs correctly the problem is in the computer or interface cable Go to POST service check on page 2 29 Symptom Action During POST abnormal noise comes from the carrier Check the ribbon cartridge for binds or damage Go to Carrier service check on page 2 18 During idling abnormal noise comes from ...

Page 27: ...or incorrect character s Be sure the interface cable is connected properly Go to No print or abnormal print service check on page 2 23 Slow printing speed Go to Print speed service check on page 2 31 Symptom Action Auto Sheet Feeder does not feed paper Auto Sheet Feeder double feeds Auto Sheet Feeder has intermittent feed problems Be sure Sheet Feed is enabled in the Setup mode Be sure the Paper S...

Page 28: ...ge 2 6 Paper Out and Font lights blink Turn the printer off and then back on Go to Irrecoverable operator errors on page 2 13 Symptom Action The Start Stop button does not function but no error is indicated Only the Power light turns on One or more buttons do not function One or more lights do not function Turn the printer off and then back on Go to Operator panel service check on page 2 23 ...

Page 29: ...ensor service check on page 2 24 The Load Unload button does not function when the push tractor is installed Form feed length is not correct The Load Unload button functions when cut sheets are being used Be sure the Paper Select lever is in the correct position Go to Paper Select sensor service check on page 2 28 Continuous forms feed but cut sheets fail to load Be sure the Paper Select lever is ...

Page 30: ...nsor service check on page 2 34 Lower feed roll shaft rotates but paper does not feed Pressing FormFeed does not feed paper Abnormal noise created while printer is 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 lever is in the correct position Go to Paper feed service check on page 2 25 I...

Page 31: ...ptom 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 the continuity of the power cord and the voltage of the user s outlet Go to Power service check on page 2 30 ...

Page 32: ...sity across 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 are connected correctly to the printhead Clean the printhead Set the Forms Thickness lever to position 1 and run the print test Go to Carrier service check on page 2 18 Scattered ink smearing blu...

Page 33: ...he indicated service check Paper Present sensor 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 service check on page 2 18 Symptom Action Unable to print on the network Go to Network service check on page 2 40 Action Check Remove all paper from the printer Turn the power on The Paper Ou...

Page 34: ...utton functions correctly Go to Paper Select sensor service check on page 2 28 Remove the continuous forms Set the Paper Select lever to the cut sheet position and insert a cut sheet When Auto Ready Cut Sheet is enabled paper feeds automatically When Auto Ready Cut Sheet is disabled press FormFeed to load a cut sheet Verify that the Load Unload button does not function Go to Paper Select sensor se...

Page 35: ...3 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 back on If the abnormal noise is gone look for a problem with the carrier motor or ribbon drive mechanism Go to Carrier service check on page 2 18 4 Paper feed mechanism Disconnect the paper feed motor CN1 from the logic...

Page 36: ...en from the gear on 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 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 f...

Page 37: ...per correctly go to Paper feed service check on page 2 25 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 Remove the ASF right cover and ensure that all the gears are in good condition 4 Combination lock mechanism Install the ASF and press FormFeed If the picker drive shaft does not rotate replace ...

Page 38: ...ect printhead 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 binds Remove the belt and move the carrier again If the bind is gone replace the carrier motor If the bind remains replace the carrier After replacing the logic board or any parts affecting the car...

Page 39: ...s for 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 board After replacing the logic board or any parts affecting the carrier perform the bidirectional print adjustment See Bidirectional print adjustment on page 4 4 FRU Action ...

Page 40: ...gic board 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 the printer power on and check all 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 C...

Page 41: ...ck all 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 voltages is 0 go to Power service check on page 2 30 If the voltages are not 0 but are incorrect replace the power supply unit 3 Intermittent poor print quality Remove paper jams from the paper path Clea...

Page 42: ... 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 Hex Trace Print hexadecimal printing by performing the following procedure and check the data streams Go to Hex Trace mode on page 3 4 Turn the printer off Press and hold Tractor and turn the printer on...

Page 43: ...d reset 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 Menu and be sure the printer is in the correct emulation mode for the computer either IBM or Epson Go to Setup mode on page 1 2 FRU Action 1 Operator panel cable Disconnect the operator panel cable fr...

Page 44: ...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 properly installed and not damaged If the problem remains replace the Paper Present sensor 2 Logic board If the ASF is being used it is normal for the Paper Out LED not to blink when there is no paper in the printe...

Page 45: ...the Auto Sheet Feeder installed go to Auto Sheet Feeder ASF service check on page 2 16 2 Gear train Remove all paper from the printer Press FormFeed several times and examine all rotating parts to find the problem The feed rollers and pinch roller should all be clean and in good condition and should all rotate when pressing FormFeed 3 Paper Select lever Be sure the selector lever alternately engag...

Page 46: ...ress FormFeed and time how long the gear train rotates With the Paper Select lever in the cut sheet position sensor open the gear train should rotate for less than 2 seconds With the lever in the continuous forms position sensor closed the gear train should rotate for more than 3 seconds If the printer does not do either of the above Inspect the sensor to be sure it opens and closes by the paper s...

Page 47: ...Diagnostic information 2 27 25XX 100 110 8 Logic board If no other problem is found replace the logic board and reset the Bidirectional print adjustment on page 4 4 FRU symptom Action ...

Page 48: ...s 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 closes by the paper separator Replace the paper select 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 Paper Select sensor ...

Page 49: ...n go to Pull Tractor sensor service check on page 2 34 FRU Action 1 Cables A faulty interface cable can cause a POST error Disconnect the interface cable from the printer and turn the printer off and then back on Check the connections of the power cable to the logic board Check the condition and continuity of the operator panel cable 2 Code module Turn the printer off and then back on If you get t...

Page 50: ...a Power 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 back on If the Power LED lights correctly only with the carrier motor disconnected replace the carrier motor 4 Paper feed motor Disconnect the paper feed motor from logic board CN1 and turn the ...

Page 51: ...ead Gap sensor Check the function of the Head Gap sensor by turning the printer on while pressing the Macro button Open the operator panel to the second level and do the following With the Forms Thickness lever at 1 Macro LED 1 lights With the Forms Thickness lever at 2 and 3 Macro LED 2 lights With the Forms Thickness lever at 4 through 7 Macro LED 3 lights Disconnect the Head Gap sensor from con...

Page 52: ...is 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 impedance tables on page 2 33 Be sure no pins have continuity to the printhead housing If the printout does not contain missing or extra dots or lines be sure the printhead is securely installed in the car...

Page 53: ... CN400 10 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 CN301 5 17 CN300 1 CN301 4 6 CN300 1 CN301 15 18 CN300 1 CN300 14 7 CN300 1 CN301 3 19 CN300 1 CN301 6 8 CN300 1 CN301 17 20 CN300 1 CN300 12 9 CN300 1 CN301 1 21 CN300 1 CN300 4 10 CN300 1 C...

Page 54: ...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 paper does not move correctly disconnect CN3 from the logic board There should be continuity from CN3 1 and CN3 2 when the left pull tractor actuator is pressed and infinite resistance when the actuator is not ...

Page 55: ...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 voltage should be 0 V dc When there is no paper in the printer the voltage should be 5 V dc Replace the Top of form sensor if the voltage is incorrect Replace the logic board if the voltage is correct and reset...

Page 56: ...tors 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 Home sensor never made after turning the printer off and then on or made at the wrong time The same error indication is used for carrier home failure FRU Action 1 Tractor 2 Home sensor Remove the T...

Page 57: ... dc on CN1 1 and 5 V dc on CN1 5 If the slider does move 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 voltages are not present replace the logic board 3 Tractor 2 motor board cable assembly Check the resistances of the Tractor 2 motor windings at CN5 on the Tractor 2 board There s...

Page 58: ...ter cover 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 and 0 when it is closed Replace the Tractor 2 board cable assembly if the sensor signal is wrong For information on the Tractor 2 cable connectors see Tractor 2 cable connectors on page 5 27 2 Lo...

Page 59: ...he pin feed belts With the printer off make sure that the slider does not bind Verify that 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 2 Tractor 2 cover Remove the Tractor 2 cover and reinstall the Tractor 2 unit in the printer if necessary remove the printer covers also Note that the small idler gear jus...

Page 60: ...ed Go to step 4 Go to step 9 4 Open the printer s Web page in a web browser using the printer driver IP address Does the web page open Go to step 13 Go to step 5 5 Print a network configuration page See Printing a network setup page on page 1 6 Are the first two segments of the IP address 169 254 XXX XXX Go to step 6 Go to step 7 6 Restart the printer Is the problem still there Go to step 7 Proble...

Page 61: ... check on the USB cable connecting the LAN card and the main board Is there continuity Go to step 12 Go to step 11 11 Replace the LAN USB cable Did the problem go away Problem solved Go to step 12 12 Check pin 1 on CN15 of the main board for 5V DC and pin 4 for ground Are the readings correct Replace LAN card Replace main board 13 Perform a print test See Print test on page 3 3 Did the job print G...

Page 62: ...2 42 Service Manual 25XX 100 110 ...

Page 63: ... necessary The following are special machine modes that run when the printer is turned off and then back on Turn printer on while pressing Result LineFeed Prints print test with sample fonts Tractor Sets printer in Hex Trace mode Load Unload and Tractor Disables enables Operator Panel Lockout mode Tearoff and Tractor with the printhead at the left limit Resets the printer to the World Trade defaul...

Page 64: ... ROM 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 buttons on operator panel Carrier Initialization Carrier moves to the left to activate the Home Position sensor and then moves to the first print position Feed Initialization Form feed motor rotates ...

Page 65: ...n the printer 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 test sample 5 To stop the printer test turn the printer off If the Print test fails go to Start on page 2 1 Note The short horizontal lines at the top of the sample are a test of each printhead ...

Page 66: ... in hexadecimal 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 program Be sure the printout is similar to the hex trace 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 i...

Page 67: ...er moves 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 defaults Code page 858 Character Set 2 form length 12 inch 1 Make sure paper and the ribbon cartridge are installed 2 Turn the printer off 3 Open the ribbon access cover 4 Move the printhead toward...

Page 68: ...ng for the type of paper you are using Refer to the 25XX 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 position 7 4 Tear the continuous forms off at the perforation line before the forms enter the printer 5 If you are using the tractor in the push position open the front cover Skip this step if you are usi...

Page 69: ...b page can be accessed by opening a web browser and pointing it to the IP address of the networked printer The Device Status Configuration and Reports pages are the commonly used pages to view printer settings and make adjustments to the settings Device settings The Device Status Page presents an at a glance summary of essential information about the status of the device ...

Page 70: ...lick Submit Or to cancel any changes and restore all fields on the form to their original values click Reset Note Changes to network settings of the device should only be performed by the network administrator Reports page The Reports page contains the following links Print server setup The Print Server Setup page lists important print server information for example hardware addresses firmware rev...

Page 71: ...lashed or upgraded from the web page To reflash the firmware perform the following steps 1 Open the Configuration page of the web server 2 Click the Update firmware link 3 Click the Browse button 4 A standard Windows file browse dialog will open Search for the desired flash file 5 When the file is found click Submit ...

Page 72: ...gs If the INA needs to be replaced the internal settings can be downloaded to a file To export the INA settings perform the following tasks 1 Click the Export settings link from the Configuration page The following page will display 2 In the file save dialog click Save ...

Page 73: ...button and search for the file to import 3 When the file is found click Submit Resetting the INA to factory defaults 1 Turn off the printer 2 Insert a pen or pencil into the hole above the network port Make sure the button in the hole is depressed when the pen or pencil is inserted 3 Restart the printer while depressing the button Keep the button depressed for 10 15 seconds while the printer resta...

Page 74: ...3 12 Service Manual 25XX 100 110 ...

Page 75: ...art into the printer Make as few movements as possible with your body to prevent an increase of static electricity from clothing fibers carpets and furniture 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 connector shroud cover do not touch its pins If...

Page 76: ...aten lower pinch roller ribbon drive rack gear left side frame right side frame paper separator lower feed roller or paper guide 1 Turn the printer off and remove all covers with the exception of the bottom cover Go to Covers removals on page 4 5 2 Remove the ribbon cartridge and paper 3 Remove the thread sealer from the Gap Adjust bushings on both the left and right side of the printer 4 Set the ...

Page 77: ...adjust bushing 2 clockwise until a gap of 0 33 0 37 mm exists between the printhead 3 and the platen 10 After adjusting both left and right Gap Adjust bushings push the printhead to the center of the platen and verify that a gap of 0 33 0 37 mm exists between the printhead and the platen Note For maximum print quality adjust the head gap on both the left and right sides of the printer to within 0 ...

Page 78: ...nted below the bars 5 To set draft select the best alignment from the alignment bars in rows 01 11 6 Press Micro or Micro to select the best alignment by number or keep the current value After selecting the printer prints a single row showing the current alignment setting 7 Press Set TOF to save the selection The printer automatically prints the alignment bars for NLQ The current value is the numb...

Page 79: ...Repair information 4 5 25XX 100 110 Covers removals Note See Covers on page 7 3 for the descripton of each part ...

Page 80: ...ring loaded ribbon access cover release latches A located 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 replacing the ribbon access cover be sure to hook the front hinge points on either side of the ribbon access cover first and then lower the cover into place Be sure that both gray spring loaded ribb...

Page 81: ...Repair information 4 7 25XX 100 110 Covers option removal 1 From the bottom pull the option cover A outward and up removing it from the printer ...

Page 82: ...mbly 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 Covers option removal on page 4 7 Note With the option cover removed you can see the operator panel cable attached to the logic board 6 Disconnect the operator panel cable from the logic board 7 Remov...

Page 83: ...e printer right side up and insert a flat blade screwdriver into each of the two holes C 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 into the logic board Damage to the operator panel cable may cause failure of other electrical components in the pr...

Page 84: ...panel 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 panel out of the top cover toward the bottom of the cover Note During replacement be sure the operator panel cable is correctly inserted into both the operator panel card and the logic board ...

Page 85: ... 3 Remove the power supply unit Go to Power supply removal on page 4 16 4 Remove the print unit Go to Print unit removal on page 4 29 Electronics removals EPROM removal 1 Remove the options cover A by pulling it outward and then up and out of the printer 2 Remove the EPROM module Note When replacing the EPROM module be sure the notch on the module is toward the front of the printer ...

Page 86: ...o not twist the flexible cable when disconnecting the printhead cable s 3 Remove the screw A securing the logic board to the bottom cover Take care not to lose the ground clip which must be replaced between the ground plate and the board 4 Remove the ground clip screw B from the bottom cover 5 Remove the logic board Note Be sure to perform the bidirectional print adjustment after installing the lo...

Page 87: ...1 Remove the top cover Go to Covers top removal on page 4 8 2 Disconnect the USB cable A from the network card 3 Remove the three screws B that secure the network card to the INA support frame 4 Slide the network card to the left and remove it from the printer ...

Page 88: ...ove the network card Go to Network card removal on page 4 13 2 Remove the screw A that secures the INA support frame to the paper feed mechanism Note To avoid printer alignment issues make sure that the screw is not too tight when reinstalling the INA support frame ...

Page 89: ...0 110 3 Remove the two screws B and the ground clips that secure the INA support frame to the bottom cover Note The ground clips need to be used when reinstalling the INA support frame 4 Remove the INA support frame from the printer ...

Page 90: ...er Go to Covers top removal on page 4 8 3 Remove the print unit Go to Print unit removal on page 4 29 4 Disconnect the power supply cable A 5 Remove the five screws B securing the power supply to the bottom cover Take care not to lose the ground clips which must be replaced between the ground plate and the board 6 Remove the two ground wire screws C 7 Remove the power supply ...

Page 91: ...r Go to Covers top removal on page 4 8 2 Remove the printhead from the carrier Go to Printhead removal on page 4 28 3 Loosen the carrier belt 1 Loosen the tension screw A 2 Remove tension from the belt by pulling up on the belt 3 Tighten the tension screw Loosening the screw tightens the belt ...

Page 92: ...4 18 Service Manual 25XX 100 110 4 Remove the retaining wire B from the left side of the carrier shaft B ...

Page 93: ...Repair information 4 19 25XX 100 110 5 Remove the screw C from the forms thickness lever and then remove the lever C ...

Page 94: ...emove the lower carrier motor mount screw D 7 Remove the two screws E from the carrier shaft bushing bracket on the left end of the carrier shaft and then remove the bracket 8 Remove the E clip from the right side of the carrier shaft E D ...

Page 95: ...carrier shaft F from the right side so it goes out of 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 to platen gap adjustment on page 4 2 F ...

Page 96: ... top cover Go to Covers top removal on page 4 8 2 Loosen the carrier belt 1 Loosen the tension screw A 2 Remove tension from the carrier belt by pulling up on the belt 3 Tighten the tension screw Loosening the screw tightens the belt 3 Slip the belt off the carrier motor pulley ...

Page 97: ...Repair information 4 23 25XX 100 110 4 Remove the screw B from the forms thickness lever and then remove the lever B ...

Page 98: ...D securing the carrier motor bracket to the print unit 8 Remove the Home Position sensor E from the top of the carrier motor bracket by pinching the clips underneath the bracket 9 Remove the carrier motor bracket from the print unit by pulling up and out on the rubber grommet F between the motor bracket and the bottom cover 10 Disconnect the carrier motor cable from the logic board 11 Remove the c...

Page 99: ...op removal 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 screws A from the paper feed motor bracket 3 Remove the motor 4 Disconnect the paper feed motor cable from the logic board ...

Page 100: ...4 26 Service Manual 25XX 100 110 Forms 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 then remove the Forms Thickness lever C ...

Page 101: ...removal 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 adjustment Go to Printhead to platen gap adjustment on page 4 2 ...

Page 102: ...m the printhead Reassembly Note Be sure the printhead cables are correctly aligned and secured Be sure to perform the printhead to platen gap adjustment Go to Printhead to platen gap adjustment on page 4 2 Printhead cables removal Warning Be careful not to damage the printhead cable s as they are secured with double sided adhesive tape 1 Remove the top cover Go to Covers top removal on page 4 8 2 ...

Page 103: ... cover 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 Forms Thickness lever and then remove the lever 4 Remove the two grommet anchored screws A from the left side of the print unit ...

Page 104: ...vice Manual 25XX 100 110 5 Remove the two grommet anchored screws B 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 print unit B ...

Page 105: ...o to Covers top removal on page 4 8 2 Remove the carrier Go to Carrier removal on page 4 17 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 from the top of the print unit 5 Slide the rack to the right and out of the print unit ...

Page 106: ...4 32 Service Manual 25XX 100 110 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 107: ...Repair information 4 33 25XX 100 110 3 Remove the four screws B from the paper feed motor bracket assembly B B ...

Page 108: ...4 34 Service Manual 25XX 100 110 4 Remove the paper feed motor bracket assembly exposing the gears as shown ...

Page 109: ... Right 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 Remove the Paper Select lever C ...

Page 110: ...4 36 Service Manual 25XX 100 110 5 Remove the sub frame exposing the right side gears D as shown D ...

Page 111: ...ers 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 then remove the shield 3 Remove the gear from the left end of the upper feed roller as shown ...

Page 112: ... upper feed roller bracket One screw also retains the upper feed roller ground clip 5 Pull the upper feed roller from the left bracket and then out of the printer 6 Be sure to perform the Printhead to platen gap adjustment Go to Printhead to platen gap adjustment on page 4 2 ...

Page 113: ... to 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 from the logic board and then remove the paper feed motor and bracket from the printer 6 Slide the carrier to the left side of the printer B B ...

Page 114: ...110 7 Unhook the spring clip B from the right end of the lower pinch roller shaft and then push it off the gray slotted spring block C toward the back of the printer as shown 8 Slide the carrier to the right side of the printer C B ...

Page 115: ...on each end toward 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 by the gear F move the shaft to the left approximately one half inch Lift the shaft up and to the back of the printer and then carefully remove the lower pinch roller and shaft 14 Perfo...

Page 116: ...page 4 17 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 page 4 35 6 Remove the left side gears Go to Left side gears removal on page 4 32 7 Remove the gears and C clip from both ends of the lower feed roller 8 Remove the upper feed roller Go to Roller up...

Page 117: ... 22 11 Remove the five screws securing the left side frame and then remove the frame 12 Remove the four screws from the right side frame and then remove the bottom frame assembly 13 Remove the five screws from the frame support plate and then remove the lower feed roller 14 Be sure to perform the printhead to platen gap adjustment Go to Printhead to platen gap adjustment on page 4 2 ...

Page 118: ...4 44 Service Manual 25XX 100 110 Sensor removals ...

Page 119: ...cover Go to Covers top removal on page 4 8 2 Remove the screw from the Forms Thickness lever and then remove the lever 3 Remove the screw from the Head Gap sensor and then remove the sensor 4 Disconnect the Head Gap sensor cable from the logic board Go to Sensor removals on page 4 44 Sensor Top of form removal 1 Remove the top cover Go to Covers top removal on page 4 8 2 Remove the print unit Go t...

Page 120: ...e 4 44 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 29 3 Turn the print unit upside down 4 Remove the small screw securing the Paper Present sensor to the bottom frame Go to Sensor removals on page 4 44 Flags Paper Present Top of form removal 1 Remove the lower feed roller Go to Roller lower feed...

Page 121: ... 25XX 100 110 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 sensor A from the frame ...

Page 122: ...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 pick up 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 ...

Page 123: ...roller 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 pick up rollers to the ends of the shaft and then remove them ...

Page 124: ...4 50 Service Manual 25XX 100 110 ...

Page 125: ...e printer Tension pulley plate assembly Paper select lever Ribbon cartridge Ribbon drive rack Forms thickness lever On Off switch Printhead Carrier Printhead cable s Carrier motor Code module Tractor 2 option connector Parallel interface connector Paper feed motor Power supply Logic board USB connector Serial interface cover plate ...

Page 126: ... 2 Service Manual 25XX 100 110 Signal connections Power supply 9w 24w 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 127: ...Locations and connectors 5 3 25XX 100 110 Logic board 9w 24w ...

Page 128: ...5 4 Service Manual 25XX 100 110 Connector Signal F1 Fuse 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 129: ... Signal 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 Signal Gnd 12 PE 30 Signal Gnd 13 Select 31 INIT 14 AUTFED 32 ERROR 15 NC 33 Signal Gnd 16 Signal Gnd 34 NC 17 Chassis Gnd 35 5 V dc 18 5 V dc 36 SELIN ...

Page 130: ...5 6 Service Manual 25XX 100 110 Logic board 9w 24w ...

Page 131: ...110 Logic 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 4 DSR 3 TXD 2 Signal Gnd 1 SBSET ...

Page 132: ...5 8 Service Manual 25XX 100 110 Logic board 9w 24w ...

Page 133: ...00 110 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 Gnd 6 5 V dc 7 Power Save Mode ...

Page 134: ...5 10 Service Manual 25XX 100 110 Logic board 9w 24w ...

Page 135: ...nd connectors 5 11 25XX 100 110 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 20 HSC ...

Page 136: ...5 12 Service Manual 25XX 100 110 Logic board 9w 24w ...

Page 137: ...nnectors 5 13 25XX 100 110 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 17 40 V dc ...

Page 138: ...5 14 Service Manual 25XX 100 110 Logic board 9w 24w ...

Page 139: ... and connectors 5 15 25XX 100 110 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 L10 ...

Page 140: ...5 16 Service Manual 25XX 100 110 Logic board 9w 24w ...

Page 141: ...d Home Position sensor 9w 24w Logic board 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 Connector Pin Signal CN15 1 5V 2 D 3 D 4 Signal Gnd Connector Pin Signal CN5 1 PE1P 2 PE1 3 Signal Gnd ...

Page 142: ...5 18 Service Manual 25XX 100 110 Logic board 9w 24w ...

Page 143: ...board Paper 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 Connector Pin Signal CN6 1 Signal Gnd 2 PE2P 3 PE2 ...

Page 144: ...5 20 Service Manual 25XX 100 110 Logic board 9w 24w ...

Page 145: ...ons and connectors 5 21 25XX 100 110 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 146: ...5 22 Service Manual 25XX 100 110 Logic board 9w 24w ...

Page 147: ...d Operator 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 TXD 5 Signal Gnd 6 RXD 7 Signal Gnd 8 SCLK 9 SG ...

Page 148: ...5 24 Service Manual 25XX 100 110 Logic board 9w 24w ...

Page 149: ...d connectors 5 25 25XX 100 110 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 D POS ...

Page 150: ... Serial 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 11 NC 23 NC 12 NC 24 NC 25 NC ...

Page 151: ...me GND CN1 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 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 whe...

Page 152: ...5 28 Service Manual 25XX 100 110 ...

Page 153: ...n attack 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 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 ...

Page 154: ...k Tractor shaft Grease Lubricate the following contact positions 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 left and upper feed roll shaft ASF pick up roller shaft and roller bushings ...

Page 155: ...Preventive maintenance 6 3 25XX 100 110 Lubrication points oil The oil felt 1 in the carrier block The tractor shaft 1 ...

Page 156: ...6 4 Service Manual 25XX 100 110 Lubrication points grease Gear mounting studs on the right side frame 2 The lower pinch roller 2 ...

Page 157: ...Preventive maintenance 6 5 25XX 100 110 Lubrication points grease cont Gear mounting studs on the left side frame 2 ...

Page 158: ...6 6 Service Manual 25XX 100 110 Lubrication points grease cont Gear mounting studs on the left ASF side frame 2 Gear mounting studs on the right ASF side frame 2 ...

Page 159: ...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 2580 XXX 9 wire model as reference Some of the artwork may not be completely representative of all models For example the 24 wire models are not depicted with two printh...

Page 160: ...7 2 Service Manual 25XX 100 110 Assembly 1 Covers ...

Page 161: ...ver top 2580 2590 5 40X4975 Cover top 2581 2591 6 40X2911 Cover rear 2581 2591 7 40X0297 Power cord U S AFE LV Canada Central and South America Mexico Saudi Arabia LV 7 40X0271 Power cord Malaysia Singapore United Kingdom 7 40X1767 Power cord Austria Belgium Brazil Germany Greece Finland France Indonesia Luxembourg Portugal Norway Saudi Arabia HV Spain Sweden Netherlands Turkey 7 40X0294 Power cor...

Page 162: ...7 4 Service Manual 25XX 100 110 Assembly 1 cont Covers ...

Page 163: ...0X2905 Support tractor paper 9D 40X3000 Shaft set tractor 2580 2590 9D 40X3001 Shaft set tractor 2581 2591 9E 40X2916 Frame left side tractor 10 40X2962 Operator panel assembly 258X 10 40X2963 Operator panel assembly 259X 11 40X2914 Cable operator panel 12 40X2994 Cover front guide 2580 2590 12 40X2995 Cover front guide 2581 2591 NS 40X2897 Cover operator panel front with overlay packs NS 40X2996 ...

Page 164: ...7 6 Service Manual 25XX 100 110 Assembly 2 Carrier paper feed right side ...

Page 165: ...1 7 40X2982 Kit ESD ground 2580 2581 8 40X2926 Screws washers and clips parts packet 9 40X2922 Kit Head Gap adjustment 10 40X2910 Gears and bushings parts packet 258X 11 40X2980 Sub frame right side 12 40X2956 Gear idler 2580 2581 12 40X2957 Gear idler 2590 2591 13 40X2907 Paper Select lever 14 40X2968 Frame right side 15 40X3010 Holder lower pinch roller shaft right 16 40X2896 Guide ASF DTR right...

Page 166: ...7 8 Service Manual 25XX 100 110 Assembly 2 cont Carrier paper feed right side ...

Page 167: ...0 Assembly 2 cont Carrier paper feed right side Asm Index Part number Description 2 19 40X2988 Shaft carrier 2580 2590 19 40X2989 Shaft carrier 2581 2591 20 40X2978 Roller upper feed 2580 2590 20 40X2979 Roller upper feed 2581 2591 ...

Page 168: ...7 10 Service Manual 25XX 100 110 Assembly 3 Carrier paper feed left side ...

Page 169: ...s parts packet 9 40X2939 Sensor Paper Select 10 40X2908 Holder platen 11 40X2893 Sensor Head Gap 12 40X2969 Guide paper assembly 2580 2590 12 40X2970 Guide paper assembly 2581 2591 13 40X2973 Platen 2580 2590 13 40X2974 Platen 2581 2591 14 40X2895 Guide ASF DTR left 15 40X2919 Sensor Top of form 16 40X2972 Sensor Paper Present 17 40X2986 Gear ribbon drive rack 2580 2590 17 40X2987 Gear ribbon driv...

Page 170: ...7 12 Service Manual 25XX 100 110 Assembly 3 cont Carrier paper feed left side ...

Page 171: ...embly 3 cont Carrier paper feed left side Asm Index Part number Description 3 23 40X2922 Kit Head Gap adjustment 24 40X2894 Lever Forms Thickness 25 40X2902 Motor paper feed with BKT 26 40X2956 Gear idler 258X 26 40X2957 Gear idler 259X ...

Page 172: ...7 14 Service Manual 25XX 100 110 Assembly 4 Electronics ...

Page 173: ...ic without EPROM 2581 LV 5 40X4963 Board logic without EPROM 2581 HV 5 40X4964 Board logic without EPROM 2590 LV 5 40X4965 Board logic without EPROM 2590 HV 5 40X4966 Board logic without EPROM 2591 LV 5 40X4967 Board logic without EPROM 2591 HV 6 40X2903 Bracket serial interface card 7 40X2915 Plate serial interface card 8 40X4968 INA support frame 9 40X4791 LAN card INA 10 40X3015 Cable power sup...

Page 174: ...7 16 Service Manual 25XX 100 110 Assembly 5 ASF Roller support ...

Page 175: ...580 2590 3 40X3024 Roller ASF lower feed 2581 2591 4 40X2984 Roller ASF pick up left and right 2580 2590 4 40X2985 Roller ASF pick up left and right 2581 2591 5 40X3004 Hopper ASF right 2581 2591 6 40X2927 Support ASF paper right 7 40X2928 Support ASF paper left 8 40X2929 Hopper ASF left 9 40X2891 ASF springs parts packet 10 40X2924 Frame ASF side left 11 40X2892 ASF screws parts packet 12 40X2932...

Page 176: ...7 18 Service Manual 25XX 100 110 Assembly 6 ASF Side frame covers ...

Page 177: ...Side frame covers Asm Index Part number Description 6 1 40X2891 ASF Springs parts packet 2 40X2890 ASF gears and bushings parts packet 3 40X2936 Cover ASF right 4 40X2892 ASF screws parts packet 5 40X3011 Frame ASF side right NS 40X2937 Stand paper ...

Page 178: ...7 20 Service Manual 25XX 100 110 Assembly 7 Tractor 2 option ...

Page 179: ...ctor and frame assembly Tractor 2 2580 2590 4 40X2918 Kit tractors left and right 5 40X2960 Board assembly with cable and ferrite Tractor 2 2580 2590 5 40X2961 Board assembly with cable and ferrite Tractor 2 2581 2591 6 40X2880 Motor Tractor 2 7 40X2882 Parts packet Tractor 2 8 40X2923 Cover Tractor 2 right 9 40X2958 Shaft Tractor 2 support 2580 2590 9 40X2959 Shaft Tractor 2 support 2581 2591 ...

Page 180: ...7 22 Service Manual 25XX 100 110 ...

Page 181: ...ld Trade 3 5 Diagnostic aids 3 1 E Entering Setup mode 1 2 Error codes 2 3 Error indication table 2 3 ESD sensitive parts 4 1 Exiting Setup mode 1 2 G General information 1 1 H Hex Trace mode 3 4 I Interface Menu options 1 3 Irrecoverable operator errors Paper Empty sensor 2 14 Paper Present sensor 2 13 Paper Select sensor 2 14 L Lubrication 6 1 M Menu Interface Menu options 1 3 Setup Menu options...

Page 182: ...unit 4 29 Printhead 4 28 Printhead cables 4 28 Ribbon drive rack gear 4 31 Right side sub frame 4 35 Rollers Lower feed 4 42 Upper feed 4 37 Upper pinch 4 39 Sensors Head Gap 4 45 Home Position 4 47 Paper Present 4 46 Paper Present flag 4 46 Paper Select 4 46 Pull Tractor 4 45 Top of form 4 45 Repair information 4 1 S Safety information vii Service checks 2 15 Abnormal noise 2 15 Abnormal print 2 ...

Page 183: ...art 2 1 Symptom checks 2 6 Abnormal indications 2 6 Abnormal noise problems 2 6 ASF problems 2 7 Error indications 2 8 Operator panel problems 2 8 Paper feed problems 2 9 power problems 2 11 Print quality problems 2 12 T Tools 1 7 V Voltage ground and continuity 2 1 ...

Page 184: ...I 4 Service Manual 25XX 100 110 ...

Page 185: ...er supply unit HV 7 15 40X2886 Power supply unit LV 7 15 40X2887 Carrier roller set 7 7 40X2888 Roller ASF upper feed 2580 2590 7 17 40X2889 Roller ASF lower feed 2580 2590 7 17 40X2890 ASF gears and bushings parts packet 7 19 40X2891 ASF springs parts packet 7 17 7 19 40X2892 ASF screws parts packet 7 17 7 19 40X2893 Sensor head gap 7 11 40X2894 Lever Forms Thickness 7 13 40X2895 Guide ASF DTR le...

Page 186: ...oad 7 17 40X2934 Serial interface cable 7 15 40X2935 Cover ASF left 7 17 40X2936 Cover ASF right 7 19 40X2937 Stand paper 7 5 7 19 40X2938 Sensor Pull Tractor 7 11 40X2939 Sensor Paper Select 7 11 40X2948 Carrier unit 2580 7 7 40X2949 Carrier unit 2581 7 7 40X2950 Carrier unit 2590 7 7 40X2951 Carrier unit 2591 7 7 40X2952 Cable printhead 2580 7 7 40X2953 Cable printhead 2581 7 7 40X2954 Cable pri...

Page 187: ...80 2590 7 9 40X2989 Shaft carrier 2581 2591 7 9 40X2992 Cover assembly front unit 2580 2590 7 3 40X2993 Cover assembly front unit 2581 2591 7 3 40X2994 Cover front guide 2580 2590 7 5 40X2995 Cover front guide 2581 2591 7 5 40X2996 Overlay pack operator panel 258X 7 5 40X2997 Overlay pack operator panel 259X 7 5 40X2998 Printhead assembly 2580 2581 7 7 40X2999 Printhead assembly 2590 2591 7 7 40X3...

Page 188: ...591 7 7 40X3035 Wide dual tractor assembly 2581 2591 7 7 40X3136 ASF gears and bushings parts packet 7 17 40X4791 LAN card INA 7 15 40X4960 Board logic without EPROM 2580 LV 7 15 40X4961 Board logic without EPROM 2580 HV 7 15 40X4962 Board logic without EPROM 2581 LV 7 15 40X4963 Board logic without EPROM 2581 HV 7 15 40X4964 Board logic without EPROM 2590 LV 7 15 40X4965 Board logic without EPROM...

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