Lexmark Forms Printer 2500 Series 25XX-100-110

Edition: November 2007
Lexmark Forms Printer 2500 Series
25XX-100 25XX-110
Table of contents Start diagnostics Safety and notices Trademarks Index
Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
25XX-100, -110
Edition: November 29, 2007 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. Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. All other trademarks are the property of their respective owners. 2007 Lexmark International, Inc. All rights reserved. UNITED STATES GOVERNMENT RIGHTS This software and any accompanying documentation provided under this agreement are commercial computer software and documentation developed exclusively at private expense.
U.S.A. P/N: 12G9774
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Table of contents
Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-vii Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-xii General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Printer specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printer speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Entering Setup mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exiting Setup mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup menu options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interface menu options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting the tear off position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting Top-of-form (continuous-pull mode). . . . . . . . . . . . . . . . . Setting Top-of-form (cut forms, envelopes) . . . . . . . . . . . . . . . . . Printing a network setup page . . . . . . . . . . . . . . . . . . . . . . . . . . . Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-2 1-2 1-2 1-2 1-3 1-3 1-4 1-5 1-5 1-6 1-7
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 check . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Paper Present sensor service check . . . . . . . . . . . . . . . . . . . . . 2-24 Paper feed service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Paper Select sensor service check . . . . . . . . . . . . . . . . . . . . . . 2-28 POST service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 Power service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 Print speed service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 Printhead service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
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25XX-100, -110 Pull Tractor sensor service check. . . . . . . . . . . . . . . . . . . . . . . . 2-34 Top-of-forms service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35 Tractor 2 service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36 Network service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 Diagnostic aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Power-On Self Test (POST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Print test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Hex Trace mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Printer default settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 U.S. defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 World Trade defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Clearing paper jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Cut sheet jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Continuous forms jams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Web page at a glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Device settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Configuration page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 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 Covers, top removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Covers, operator panel assembly removal . . . . . . . . . . . . . . . . . 4-10 Covers, bottom removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Electronics removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 EPROM removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Logic board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Network card removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 INA support frame removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Power supply removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
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25XX-100, -110 Carrier removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carrier removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carrier, motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . Paper handling removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paper Select lever removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . Paper feed motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forms Thickness lever removal . . . . . . . . . . . . . . . . . . . . . . . . . Print handling removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Platen removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printhead removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printhead cables removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print unit removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ribbon drive rack gear removal . . . . . . . . . . . . . . . . . . . . . . . . . Gears removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Left side gears removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Right side gears, sub frame removal . . . . . . . . . . . . . . . . . . . . . Rollers removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roller, upper feed removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roller, lower pinch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roller, lower feed removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensor removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensor, Pull Tractor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensor, Head Gap removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensor, Top-of-form removal . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensor, Paper Select removal . . . . . . . . . . . . . . . . . . . . . . . . . . Sensor, Paper Present removal . . . . . . . . . . . . . . . . . . . . . . . . . Flags, Paper Present/Top-of-form removal . . . . . . . . . . . . . . . . Sensor, Home Position sensor removal. . . . . . . . . . . . . . . . . . . Options removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auto Sheet Feeder gears removal . . . . . . . . . . . . . . . . . . . . . . . Auto Sheet Feeder pick-up roller removal . . . . . . . . . . . . . . . . . 4-17 4-17 4-22 4-25 4-25 4-25 4-26 4-27 4-27 4-28 4-28 4-29 4-31 4-32 4-32 4-35 4-37 4-37 4-39 4-42 4-44 4-45 4-45 4-45 4-46 4-46 4-46 4-47 4-48 4-48 4-49
Locations and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Signal connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Power supply (9w & 24w). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Logic boardParallel interface cable (9w & 24w) . . . . . . . . . . . . 5-5 Logic boardSerial board (9w & 24w) . . . . . . . . . . . . . . . . . . . . 5-7 Logic boardUSB cable (9w & 24w). . . . . . . . . . . . . . . . . . . . . . 5-9 Logic boardDC power (9w & 24w) . . . . . . . . . . . . . . . . . . . . . . 5-9 Logic boardPrinthead (9w) . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Logic boardPrinthead (24w) . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
25XX-100, -110 Logic boardPrinthead (24w) . . . . . . . . . . . . . . . . . . . . . . . . . .5-15 Logic boardGap Set sensor (9w & 24w) . . . . . . . . . . . . . . . . .5-17 Logic boardHome Position sensor (9w & 24w) . . . . . . . . . . . .5-17 Logic board(9w & 24w) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17 Logic boardPaper Present sensor (9w & 24w) . . . . . . . . . . . .5-17 Logic boardPaper Select sensor (9w & 24w). . . . . . . . . . . . . .5-19 Logic boardPull Tractor sensor (9w & 24w) . . . . . . . . . . . . . . .5-19 Logic boardTop-of-form sensor (9w & 24w) . . . . . . . . . . . . . .5-19 Logic boardCarrier motor (9w & 24w) . . . . . . . . . . . . . . . . . . .5-21 Logic boardPaper feed motor (9w & 24w) . . . . . . . . . . . . . . . .5-21 Logic boardOperator panel (9w & 24w) . . . . . . . . . . . . . . . . . .5-23 Logic boardDual tractor cable (9w & 24w) . . . . . . . . . . . . . . .5-25 Serial boardSerial cable (9w & 24w) . . . . . . . . . . . . . . . . . . . .5-26 Tractor 2 cable connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-27 Preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 Lubrication . . . . . . . . . . . . . . . Lubrication points . . . . . . . Lubrication points (oil) . . . . Lubrication points (grease) ....... ....... ....... ....... ...... ...... ...... ...... ....... ....... ....... ....... ...... ...... ...... ...... . . . .6-1 . . . .6-2 . . . .6-3 . . . .6-4
Parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1 How to use this parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1 Assembly 1: Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2 Assembly 2: Carrier/paper feed (right side) . . . . . . . . . . . . . . . . . . . .7-6 Assembly 3: Carrier/paper feed (left side) . . . . . . . . . . . . . . . . . . . .7-10 Assembly 4: Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14 Assembly 5: ASFRoller/support . . . . . . . . . . . . . . . . . . . . . . . . . .7-16 Assembly 6: ASFSide frame/covers . . . . . . . . . . . . . . . . . . . . . . .7-18 Assembly 7: Tractor 2 option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1 Part number index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-5
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Safety information
The safety of this product is based on testing and approvals of the
original design and specific components. The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts. The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others. There may be an increased risk of electric shock and personal injury during disassembly and servicing of this product. Professional service personnel should understand this and take necessary precautions. CAUTION: When you see this symbol, there is a danger from hazardous voltage in the area of the product where you are working. Unplug the product before you begin, or use caution if the product must receive power in order to perform the task.
Consignes de scurit
La scurit de ce produit repose sur des tests et des
agrations portant sur sa conception d'origine et sur des composants particuliers. Le fabricant n'assume aucune responsabilit concernant la scurit en cas d'utilisation de pices de rechange non agres. Les consignes d'entretien et de rparation de ce produit s'adressent uniquement un personnel de maintenance qualifi. Le dmontage et l'entretien de ce produit pouvant prsenter certains risques lectriques, le personnel d'entretien qualifi devra prendre toutes les prcautions ncessaires. ATTENTION : Ce symbole indique la prsence d'une tension dangereuse dans la partie du produit sur laquelle vous travaillez. Dbranchez le produit avant de commencer ou faites preuve de vigilance si l'excution de la tche exige que le produit reste sous tension.
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Norme di sicurezza
La sicurezza del prodotto si basa sui test e sull'approvazione del
progetto originale e dei componenti specifici. Il produttore non responsabile per la sicurezza in caso di sostituzione non autorizzata delle parti. Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato. Durante lo smontaggio e la manutenzione di questo prodotto, il rischio di subire scosse elettriche e danni alla persona pi elevato. Il personale di assistenza autorizzato deve, quindi, adottare le precauzioni necessarie. ATTENZIONE: Questo simbolo indica la presenza di tensione pericolosa nell'area del prodotto. Scollegare il prodotto prima di iniziare o usare cautela se il prodotto deve essere alimentato per eseguire l'intervento.
Sicherheitshinweise
Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des
ursprnglichen Modells und bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung fr die Sicherheit bernommen. Die Wartungsinformationen fr dieses Produkt sind ausschlielich fr die Verwendung durch einen Wartungsfachmann bestimmt. Whrend des Auseinandernehmens und der Wartung des Gerts besteht ein zustzliches Risiko eines elektrischen Schlags und krperlicher Verletzung. Das zustndige Fachpersonal sollte entsprechende Vorsichtsmanahmen treffen. ACHTUNG: Dieses Symbol weist auf eine gefhrliche elektrische Spannung hin, die in diesem Bereich des Produkts auftreten kann. Ziehen Sie vor den Arbeiten am Gert den Netzstecker des Gerts, bzw. arbeiten Sie mit groer Vorsicht, wenn das Produkt fr die Ausfhrung der Arbeiten an den Strom angeschlossen sein mu.
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Pautas de Seguridad
La seguridad de este producto se basa en pruebas y aprobaciones del
diseo original y componentes especficos. El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas. La informacin sobre el mantenimiento de este producto est dirigida exclusivamente al personal cualificado de mantenimiento. Existe mayor riesgo de descarga elctrica y de daos personales durante el desmontaje y la reparacin de la mquina. El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias. PRECAUCIN: este smbolo indica que el voltaje de la parte del equipo con la que est trabajando es peligroso. Antes de empezar, desenchufe el equipo o tenga cuidado si, para trabajar con l, debe conectarlo.
Informaes de Segurana
A segurana deste produto baseia-se em testes e aprovaes do
modelo original e de componentes especficos. O fabricante no responsvel pela segunrana, no caso de uso de peas de substituio no autorizadas. As informaes de segurana relativas a este produto destinam-se a profissionais destes servios e no devem ser utilizadas por outras pessoas. Risco de choques elctricos e ferimentos graves durante a desmontagem e manuteno deste produto. Os profissionais destes servios devem estar avisados deste facto e tomar os cuidados necessrios. CUIDADO: Quando vir este smbolo, existe a possvel presena de uma potencial tenso perigosa na zona do produto em que est a trabalhar. Antes de comear, desligue o produto da tomada elctrica ou seja cuidadoso caso o produto tenha de estar ligado corrente elctrica para realizar a tarefa necessria.
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Informaci de Seguretat
La seguretat d'aquest producte es basa en l'avaluaci i aprovaci del
disseny original i els components especfics. El fabricant no es fa responsable de les qestions de seguretat si s'utilitzen peces de recanvi no autoritzades. La informaci pel manteniment daquest producte est orientada exclusivament a professionals i no est destinada a ning que no ho sigui. El risc de xoc elctric i de danys personals pot augmentar durant el procs de desmuntatge i de servei daquest producte. El personal professional ha destar-ne assabentat i prendre les mesures convenients. PRECAUCI: aquest smbol indica que el voltatge de la part de l'equip amb la qual esteu treballant s perills. Abans de comenar, desendolleu l'equip o extremeu les precaucions si, per treballar amb l'equip, l'heu de connectar.
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Preface
This manual contains maintenance procedures for service personnel. It is divided into the following chapters: 1. General information contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment are listed, as well as general environmental and safety instructions. 2. Diagnostic information contains an error indicator table, symptom tables, and service checks used to isolate failing field replaceable units (FRUs). 3. Diagnostic aids contains tests and checks used to locate or repeat symptoms of printer problems. 4. Repair information 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 provides additional information. Warning: A warning identifies something that might damage the product hardware or software. CAUTION: A caution identifies something that might cause a servicer harm. CAUTION: When you see this symbol, there is a danger from hazardous voltage in the area of the product where you are working. Unplug the product before you begin, or use caution if the product must receive power in order to perform the task.
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1. General information
Printer description
The Lexmark Forms Printer 25XX-100 and 25XX-110 are small, versatile tabletop printers suitable for use in the home or small business. They are especially well-suited for applications that use continuous or multi-part forms.
Printer specifications
Model 2580-XXX 2581-XXX 2590-XXX 2591-XXX
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
9-Wire X X X X X X 24-Wire Short carriage X X Long carriage
General information 1-1
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Printer speeds
9-Wire 10 cpi Fast draft Draft NLQNear
Letter Quality
24-Wire 12 cpi 510 cps 304 cps 77.5 cps 10 cpi 409 cps 274 cps 91.7 cps 12 cpi 465 cps 328 cps 109 cps
438 cps 309 cps 77.5 cps
cpi = characters per inch cps = characters per second
Setup mode
Entering Setup mode
1. Open the operator panel cover to access layer two. 2. Press Setup to put the printer in Setup mode and print the Main Menu. 3. Press LineFeed to print a list of all the available options. 4. Select any option from the Main Menu by pressing the corresponding button. A new menu prints each time you press a button, displaying new 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, load more paper into the tractor pins, and press Setup to continue.
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Setup menu options

Menu Forms Macro options Data options Control options Emulation options Interface options Function Customize macros to print a variety of forms. Define how information is processed. Define how the printer performs basic tasks. Determine how the printer interacts with software applications. Define how information is transferred from a computer to the printer.
Interface menu options

Menu Interface Function 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. 300 bps 600 bps 1200 bps 2400 bps 4800 bps 9600 bps 19200 bps
Data speed
Data bits Parity Stop bits Protocol
7, 8 No, Ignore, Odd, Even 1, 2 XON/XOFF MultiXON/XOFF DTR Pacing
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Printer settings
Setting the tear off position
When Auto Tear Off is on, or set to One Second, it moves the top perforation of a continuous form to the tear off position, when all of the following are true:
The printer has finished printing. The paper has advanced to the Top-of-form on the next page. No data, printer control codes, or escape codes have been sent
to the printer after advancing to the Top-of-form.
The print buffer has not received 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. 2. 3. 4. Press Start/Stop to take the printer offline. Press and hold Tear Off until the printer beeps. Open the operator panel cover to access layer two. Press Micro or Micro to move the paper to the correct position on the tear off bar. 5. Close the operator panel cover. The printer beeps twice. The paper rolls backward, then goes to the new tear off position. The Ready light is on.
The paper remains at the current tear off position until you send another job to the printer. The paper moves from the tear off position to the Top-of-form and begins printing.
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Setting Top-of-form (continuous-pull mode)

1. Turn the printer on. The Paper Out light blinks if no paper is loaded. 2. Move the Paper Select lever down to the continuous forms position. 3. Load continuous form paper on the pull tractor feed pins. 4. Open the operator panel cover to access layer two. 5. Press any paper movement button (LineFeed, Micro , or Micro ) to move the paper to the Top-of-form position. 6. Use the second sheet of continuous forms to set Top-of-form. 7. Press Set TOF to set and save Top-of-form. 8. Close the operator panel cover. Top-of-form is not saved if the printer is turned off, or if it runs out of paper when the printer is in Pull Tractor mode. 9. Press Start/Stop to set the printer online.
Setting Top-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 forms position. 3. Load a cut sheet of paper or envelope through the manual feed door. The printer moves the paper or envelope to the current Top-of-form if Auto Cut Sheet is set to on. If not, press FormFeed when the Paper Out light goes off. 4. Open the operator panel cover to access layer two. 5. Press any paper movement button (LineFeed, Micro , or Micro ) to align the horizontal lines (located on the platen) with the Top-of-form you want. 6. Press Set TOF to set and save Top-of-form. 7. Close the operator panel cover. 8. Press Start/Stop to set the printer online.
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Printing a network setup page

If the printer is attached to a network, print a network setup page to verify the network connection and find the printer address. Note: This function is disabled if a USB cable is connected. 1. Make sure the printer is on and the paper is loaded. 2. With a paper clip or the tip of a pen, press the recessed button located just above the Network connection. 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 changes. For instance, the Address changes if the printer is moved; however, the Fully Qualified Domain Name does not change. Note: The network setup page also provides important network configuration information.
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Options
The 25XX printers support the following options:
Automatic Sheet 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
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Abbreviations
AFE ASF CPU EPROM ESD FRU HTTP HV LED LV MFP mm NIC NVRAM POST RAM ROM TCP/IP USB V ac V dc Analog front end Automatic sheet feeder Central processing unit Erasable Programmable Read-Only Memory Electrostatic discharge Field replaceable unit Hypertext transport protocol High voltage Light emitting diode Low voltage Multifunction Printer Millimeter Network interface card Nonvolatile Random Access Memory Power-On Self Test Random access memory Read-only storage Transport control protocol/Internet protocol Universal Serial Bus Volts alternating current Volts direct current
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2. Diagnostic information
Start
Make a quick visual check for defects (loose or broken parts, unplugged connectors, paper jams, and so on).
Voltage, ground, and continuity readings

Voltage readings All DC voltages must be within +5% through -10% of the values to be considered correct. Unless stated otherwise, all connectors should be connected normally when a voltage measurement is performed. When a line voltage measurement 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 countrys specification. Ground checks
To check for a correct ground, measure the voltage between the ground and a known good voltage source. The voltage measurement must be the same as the source voltage to consider that the ground is correct. Continuity measurements may be used to check grounds; however, be sure to measure to a known good ground using the lowest ohms scale and check for zero ohms. Warning: Always unplug the power cord before doing any continuity measurement.
Diagnostic information 2-1
25XX-100, -110 Continuity readings When measuring continuity, be sure no back circuits affect the measurement. If necessary, unplug connectors to remove any back circuits. Zero the ohm range on the lowest scale (X1). An open circuit will read infinity. A circuit with correct continuity will read zero ohms.
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Error indication table

The following table describes the service check entries for the printer error indication codes. When an error indication changes after you have entered a service check, you have an intermittent problem. If this occurs, leave the service check and go to Symptom check table on page 2-6.
LED Power Ready Tractor 2 Paper Out Panel Lock Font Lock Power Ready Paper Out Panel Lock Power Ready Paper Out Font Lock Status ON ON ON ON ON ON ON Blinking Blinking Blinking ON Blinking Blinking Blinking Alarm None Action POST RAM, ROM Controller Error Go to POST service check on page 2-29.
None
Switch Scan Test Error Go to Operator panel service check on page 2-23.
None
NVRAM Read/Write 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. If the printer completes POST successfully and eventually gets the same error, go to Intermittent problem service check on page 2-20.
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LED Power Ready Paper Out Panel Lock Font Lock
Status ON Blinking Blinking Blinking Blinking
Alarm Beeps 10 times
Action Home Position Error Go to Carrier service check on page 2-18. Tractor 2 Home Position Error If Tractor 2 is installed, remove it to determine whether the problem is with the Carrier Home Position sensor or the Tractor 2 Home Position sensor. See the Tractor 2 service check on page 2-36.
None
Home Position Error Without Alarm Go to Power service check on page 2-30.
Power Ready Tractor 2 Paper Out Font Lock
ON Blinking Blinking Blinking Blinking
None
Timer Error Turn the printer off and then back on. If you get the same error during power-up, replace the logic board and readjust the bidirectional print adjustment. Go to 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 Printhead service check on page 2-32. Turn the printer off and then back on. If you get the same error, replace the logic board and readjust the bidirectional print adjustment. Go to Bidirectional print adjustment on page 4-4. If the printer completes POST successfully and eventually gets the same error, go to Intermittent problem service check on page 2-20.
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LED
Status
Alarm
Action
All LEDs
OFF
None
Power Failure Check the continuity of the power cord and the voltage of the users outlet. If they are correct, go to Power service check on page 2-30.
Power Tractor 2 Paper Out Panel Lock Font Lock Any LED on and Power LED off The Power LED blinks or changes intensity. Power Ready Font Lock
ON OFF OFF OFF OFF
None
Operator Panel Failure Go to Operator panel service check on page 2-23.
None
Go to Operator panel service check on page 2-23.
None
Go to Power service check on page 2-30.
ON Blinking Blinking
None
Ethernet option not installed. Go to Network service check on page 2-40.
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Symptom check table

1. Select the symptom that best describes the problem. 2. Perform the appropriate action before you go to the indicated service check. Abnormal indications
Symptom 7 or more lights turn on but do not turn off. The Power light is on, but POST will not run. Action Disconnect the interface cable from the printer and turn the printer off and then 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.
Abnormal noise problems

Symptom During POST, abnormal noise comes from the carrier. During idling, abnormal noise comes from the printer. Abnormal noise when feeding paper Abnormal noise during printing or POST Action Check the ribbon cartridge for binds or damage. Go to Carrier service check on page 2-18.
Go to Abnormal noise service check on page 2-15.
2-6 Service Manual
25XX-100, -110 Abnormal print operation problems

Symptom Printer will not print, or become ready. Abnormal operation, incorrect characters, or incorrect line width Printer is ready but will not print from the computer correctly. Undefined or incorrect character(s) Slow printing speed Go to Print speed service check on page 2-31. Action Be sure the interface cable is connected properly. Go to No print or abnormal print service check on page 2-23.
Auto Sheet Feeder problems

Symptom Auto Sheet Feeder does not feed paper. Auto Sheet Feeder double feeds. Auto Sheet Feeder has intermittent feed problems. Action Be sure Sheet Feed is enabled in the Setup mode. Be sure the Paper Select lever is in the cut sheet position. Go to Auto Sheet Feeder (ASF) service check on page 2-16.
25XX-100, -110 Error indications

Symptom Ready and Paper Out lights blink. Paper Out and Font lights blink. Action Turn the printer off and then back on. Go to Abnormal indications on page 2-6. Turn the printer off and then back on. Go to Irrecoverable operator errors on page 2-13.
Operator panel problems

Symptom 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. Action Turn the printer off and then back on. Go to Operator panel service check on page 2-23.
2-8 Service Manual
25XX-100, -110 Paper feed problems

Symptom The Paper Out light is blinking when there is paper in the printer. The Paper Out light does not blink when there is no paper in the printer and the ASF is not installed. Print operation starts without paper. 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. Continuous forms feed, but cut sheets fail to load. Be sure the Paper Select lever is in the cut sheet position. Verify that continuous forms have been parked using the Load/Unload button. Be sure Auto Cut Sheet is enabled in the Setup mode. Go to Paper Select sensor service check on page 2-28. Be sure the Paper Select lever is in the correct position. Go to Paper Select sensor service check on page 2-28. Action Go to Paper Present sensor service check on page 2-24.
Be sure the paper present sensor is not blocked. Go to Paper Present sensor service check on page 2-24.
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Symptom The Load/Unload button functions when the pull tractor is installed. The Paper Out light blinks, and the FormFeed button does not operate until paper is located at first print line. 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. Incorrect Top-ofform positioning.
Action Be sure the Paper Select lever is in the tractor position. Go to Pull Tractor sensor service check on page 2-34.
Be sure the Paper Select lever is in the correct position. Go to Paper feed service check on page 2-25.
Go to Top-of-forms service check on page 2-35.
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25XX-100, -110 Power problems

Symptom Action
When the power switch is on, the Power light does not turn on or the printer does not start. The Power light blinks or changes intensity.
Check the continuity of the power cord and the voltage of the users outlet. Go to Power service check on page 2-30.
25XX-100, -110 Print quality problems

Symptom No print, but the carrier moves as if printing. Action Adjust the Forms Thickness lever to a lower number. Be sure the printhead cables are not loose or damaged. Be sure the interface cable is connected properly. Check the ribbon cartridge for binds or damage. Go to Print speed service check on page 2-31. Print density is light. Turn the ribbon advance knob on the print cartridge from 1 to 2 to increase the darkness of print. If the ribbon has reached its end of life or is worn, replace the ribbon cartridge. Go to Carrier service check on page 2-18. Uneven print density 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, blurred characters Fuzzy print Clean the printhead nose. Clean the ribbon guide and shield. If the ribbon has reached its end of life or is worn, replace the ribbon cartridge. Go to Carrier service check on page 2-18. Wavy vertical lines, uneven left margin, or character width is reduced Clean and lubricate the carrier shaft. If the carrier drive belt is worn or broken, replace the carrier unit. Go to Carrier service check on page 2-18.
2-12 Service Manual
25XX-100, -110 Ribbon feed problems

Symptom Ribbon comes off, becomes loose or folded, or jams. Ribbon feeds correctly but is noisy. Action Check the ribbon cartridge for binds or damage. Go to Carrier service check on page 2-18.
Unable to print on network

Symptom Unable to print on the network. Action Go to Network service check on page 2-40.
Irrecoverable operator errors

Paper Out and Font lights blink. If this indication occurs, the problem may be with the Paper Present sensor or the Paper Select sensor. Check the following in the order listed, and if the printer does not work correctly, go to the indicated service check. Paper Present sensor
Action Remove all paper from the printer. Turn the power on. Check The Paper Out light blinks when paper is not loaded. The Paper Out light turns off when paper is loaded. Go to Paper Present sensor service check on page 2-24.
25XX-100, -110 Paper Select sensor

Action Turn the power off. Install the Push Tractor. Set the Paper Select lever to the tractor position, and load continuous forms. Turn the power on. Remove the continuous forms. Set the Paper Select lever to the cut sheet position, and insert a cut sheet. When Auto 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 service check on page 2-28. Check The Load/Unload button functions correctly. Go to Paper Select sensor service check on page 2-28.
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Service checks
Abnormal noise service check
Check the entire printer for loose parts.
FRU 1 2 Ribbon cartridge Printhead Action Remove and reinstall the ribbon cartridge. Disconnect the printhead cable(s). Run the print test (do not fold or damage the cables during the test). Go to Print test on page 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 board. Perform the Print Test. Go to Print test on page 3-3. If the abnormal noise is gone, look for the problem in the paper feed mechanism.
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Auto Sheet Feeder (ASF) service check

Note: Be sure the sheet feeder is enabled in the Setup mode. Go to Setup mode on page 1-2. Auto Sheet Feeder principles of operation The Auto Sheet Feeder (ASF) feeds into the cut sheet paper entry throat. To use the ASF:
The Paper Select lever must be set to the cut sheet position. The Auto Sheet Feeder must be selected in the Setup Menu.
Continuous forms can be used with the ASF installed by moving the Paper Select lever to the continuous forms position and pressing Start/Stop to feed the continuous forms to the first print line. The ASF contains no electrical parts. It is driven from the gear on the inside 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 feed the top sheet from the cut sheet paper stack. The sheet is fed about 5 inches (125 mm), and the paper path briefly reverses again; this disengages the clutch and the picker rollers. The sheet is then fed to the print line by the upper and lower feed rollers of the ASF and the lower feed rollers of the printer. Although the ASF picker rollers continue to turn as the paper is fed, their drive is disengaged and they are actually turned by the paper.
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FRU 1 Paper Select sensor
Action With the Paper Select lever in the cut sheet position, do the following: Try to load a cut sheet with the Load/Unload button. (This button should not work.) If paper loads, go to Paper Select sensor service check on page 2-28.
Paper feed
If the paper does not feed, do the following: Remove the ASF. Be sure the base printer feeds paper correctly. If the base printer does not feed paper correctly, go to Paper feed service check on page 2-25.
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.
Combination lock mechanism
Install the ASF, and press FormFeed. If the picker drive shaft does not rotate, replace the combination lock mechanism. If the ASF picker rollers rotate but a single sheet is not picked, inspect the springs and corner separators on the left and right hoppers. Be sure the Paper Load lever is in the correct position.
Left and right hoppers
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Carrier service check

Note: The carrier service check includes the carrier drive, Home Position sensor, and ribbon feed.
FRU 1 Carrier Action Verify the carrier motor connector is connected to the logic board at CN2. If the carrier motor connector is connected properly, check the carrier belt and the ribbon cartridge for wear or damage. Check the belt and pulley engagement. Manually move the carrier the full length of the carriage to check for binds and to be sure the ribbon advances when the carriage moves in either direction. If the carrier binds, check the following: Correct 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 carrier, perform the bidirectional print adjustment. See Bidirectional print adjustment on page 4-4. 2 Home Position sensor If the carrier moves manually without binding but the Home Position Error still occurs, verify that the logic board is receiving +40 V dc on pin CN12-1. Check that the 5 V dc Home Position sensor signal is reaching the logic board. Replace the sensor or the short flexible cable as necessary.
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FRU 3 Carrier motor
Action If the Home Position sensor is okay, verify that the resistance of the carrier motor windings are approximately 2 ohms for all printers. Check the resistance at the following pin locations:
CN2 - 1 and CN2 - 3 CN2 - 2 and CN2 -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.
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Intermittent problem service check

FRU/Symptom 1 The printer sometimes fails before POST is complete. Action Check for the following: 1. Loose connectors. Reconnect all connectors to the logic board. 2. Electrical noise or static discharge. Check the following: Power supply ground Printer frame ground Printer interface cable is grounded and shielded. 3. Intermittently low voltages. Check for ac and all dc voltages and short circuits on the logic board. a. Check the users 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) CN12 - 6 (+5 V dc 5%) CN12 - 7 (Power Save Mode)
If the voltages are incorrect, replace the power supply. If the failure remains, replace the logic board. Note: When replacing the logic board, always reset the bidirectional print adjustment. See Bidirectional print adjustment on page 4-4.
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FRU/Symptom 2 Printer power sometimes turns off.
Action The cause of this problem may be that the power circuit is failing, or the wiring is intermittently open. Check the following in sequence: 1. Check the users outlet voltage, and be sure it is within tolerance. 2. Check the continuity of the power cord. 3. 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) 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. Clean all feed roller surfaces. Clean the ribbon shield and printhead. Clean the platen surface. Install the ribbon cartridge correctly. If the ribbon has reached its end of life, have the user replace the ribbon cartridge.
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FRU/Symptom 4 The previous suggestions have not corrected the problem.
Action The following may cause undefined or intermittent failures: Loose connector pins that fail to contact. Check the following: Reconnect the connectors of all FRUs and printer interface cables.
Check the continuity of the line cord.

Electrical noise. Check the following: Power supply ground Printer frame ground
Printer interface cable is grounded or shielded.

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. Have the user print the failing job. To stop printing, turn the power off. If the failure still occurs, replace the logic board. Be sure to reset the bidirectional print adjustment. See Bidirectional print adjustment on page 4-4.
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No print or abnormal print service check

FRU/Function 1 Logic board Action If the print test does not complete correctly, replace the logic board and reset the bidirectional print adjustment. See Bidirectional print adjustment on page 4-4. Check the connection and continuity of the interface cable. 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.
2 3
Interface cable Emulation mode
Operator panel service check

If the operator panel is locked, only the Start/Stop, FormFeed, Tear Off, and Load/UnLoad buttons are active. 25XX printers have a Padlock LED to indicate that the operator panel is locked. To lock or unlock the operator panel, turn the printer off, and while holding the Load/Unload and Tractor buttons, turn the printer on.
FRU 1 Operator panel cable Action Disconnect the operator panel cable from the operator panel and the logic board, and verify the continuity of the operator panel cable. Connect the operator panel to the logic board, and be sure +5 V dc is present at connectors CN13-1 and CN13-3. Replace the operator panel cable, or the power cable, as necessary. 2 Operator panel If the problem remains, replace the operator panel.
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Paper Present sensor service check

FRU 1 Paper Present sensor Action With no paper in the printer, the tractor in the push position, and the Paper Select lever set to continuous forms, press Load/Unload; the gear train should turn forward to load paper. Activate the Paper Present sensor with a screwdriver, and press Load/Unload again; the gear train should turn backward to park paper. Measure the voltage between CN5-2 (paper present signal) and CN5-3 (GND) on the logic board. There should be 0 V dc when there is paper in the printer, and +5 V dc when there is no paper in the printer. Be sure the Paper Present sensor and its actuator are 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 printer. Do the following: Enter the Setup Menu. Be sure the ASF setting is off, unless the ASF is installed. If the Paper Present sensor is good and the ASF setting is on, replace the logic board and reset the bidirectional print adjustment. Go to Bidirectional print adjustment on page 4-4.
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Paper feed service check

Note: If paper creases or jams frequently, verify that the paper is neither too thick nor thin. If necessary, refer the user to the Users Guide for specifications of acceptable papers. If the paper does not stop in the correct location, see Paper Present sensor service check on page 2-24 and the Top-offorms service check on page 2-35.
FRU/symptom 1 Auto Sheet Feeder Action If the Auto Sheet Feeder is installed, remove it. Enter the Setup Menu, and reset ASF to off. Verify that the printer works correctly without the ASF installed. If the printer fails only with 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 engages and disengages the tractor gear and the ASF drive gear. Check the operation of the following parts as you move the Paper Select lever: The tractor gear engages correctly in the continuous forms position. The tractor belts are in good condition and rotate correctly. The pinch roller shafts move downward as the lever moves to the cut sheet position. The paper separator moves upward as the lever moves to the cut sheet position.
25XX-100, -110
FRU/symptom 4 Operator panel
Action If paper does not move at all, verify that the Load/Unload button is working as follows: With the tractor in the push position, turn the power off and then back on, and then press Load/Unload. The carrier should move to the center of the platen. If it does not, go to Operator panel service check on page 2-23.
Paper feed motor
Disconnect the paper feed motor cable CN1 from the logic board. No pin should have continuity to ground. The resistance should be between 8 to 9 ohms, between CN10 - 1 and CN10 - 5, CN10 - 2 and CN10 - 5, CN10 - 3 and CN10 - 5, CN10 - 4 and CN10 - 5. Remove all paper from the printer, and place the tractor in the push position. Press 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 separator. Replace the sensor if the resistance does not change from zero to infinite as the Paper Select lever is moved.
Paper Select sensor
Pull Tractor sensor
If the pull tractor sensor fails to close, Load/Unload and Auto Tear Off do not work when using push tractors. The sensor fails to open. The Load/Unload button tries to park paper when using the pull tractors but, instead, the paper feeds all of the way out of the tractors and cannot be reloaded. See Pull Tractor sensor service check on page 2-34.
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FRU/symptom 8 Logic board
Action If no other problem is found, replace the logic board and reset the Bidirectional print adjustment on page 4-4.
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Paper Select sensor service check

If the form feed length is off by about 1 inch (25 mm), enter Setup mode and verify that the form length setting is correct. Go to Setup mode on page 1-2.
FRU 1 Paper Select sensor Action Remove all paper from the printer, and do the following: Place the tractor in the push position, and be sure the Auto Sheet Feed (ASF) is set to off in Setup mode. Press 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 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 is good, but the gear train does not run the right length of time: Set the head gap to position 1, and disconnect the short flexible cable from CN8 on the logic board. Check the continuity between CN8-2 (paper select sensor) and GND while activating the Paper Select lever. If the resistance is incorrect, replace the logic board and reset the bidirectional print adjustment. Go to Bidirectional print adjustment on page 4-4.
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FRU 2 Pull Tractor sensor
Action A failed Pull Tractor sensor can cause the Load/Unload button to malfunction. With the tractor in the push position: Press Load/Unload several times while alternately holding down and releasing the left pull tractor actuator. The paper should not park or load when the pull tractor actuator is held down. If the paper does park or load with the pull tractor actuator held down, go to Pull Tractor sensor service check on page 2-34.
POST service check

FRU 1 Cables Action 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 the same error during power-up, verify that the code module on the logic board is correctly installed. Replace the logic board if necessary. and reset the bidirectional print adjustment. Go to Bidirectional print adjustment on page 4-4.
Logic board
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Power service check

FRU 1 Power supply Action If the carrier does not move to the left after turning the printer off and then back on, be sure the line cord voltage to the power supply is correct and the power supply outputs are +40 V dc at CN12-1, +40 V dc at CN12-2 and +5 V dc at CN12-6. If the voltages are incorrect: Check the internal fuse before replacing the power supply. Generally if F1 is blown, it is due to a short-circuit in the printhead; replace the printhead and the fuse before turning the power on again. Be sure the power supply cable from the power supply to the logic board is not damaged and is correctly installed. 2 Operator panel Operator panel cable Carrier motor If there is still a Power LED problem, check the operator panel cable continuity and replace the cable or the operator panel. Disconnect the carrier motor from 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. Disconnect the paper feed motor from logic board CN1, and turn the printer off and then back on. If the Power LED lights correctly only with the paper feed motor disconnected, replace the paper feed motor. Disconnect the printhead cable from the logic board, and turn the printer on. If the Power LED lights correctly only with the printhead cables disconnected from the logic board, there is a short-circuit in the printhead or printhead cables. Disconnect the printhead cable from the logic board, and be sure none of the leads on the cable are shorted to ground.
Paper feed motor
Printhead Printhead cables
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FRU 6 Logic board
Action If no problem is found with the other components, but the power problem still remains, replace the logic board and reset the bidirectional print adjustment. Go to Bidirectional print adjustment on page 4-4.
Print speed service check

The speed of the 25XX printers varies with the font, forms thickness setting, and printhead temperature. Graphics output may print slowly due to data throughput limitations. Thermal sensing is built into the printhead on 25XX printers and protects the printhead from overheating.
FRU 1 Head Gap sensor Action 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 connector CN4 on the logic board. Place the Forms Thickness lever in position 1 and verify continuity at the following pin locations:
CN4 - 1 and CN4 - 2 CN4 - 2 and CN4 - 3
Place the Forms Thickness lever in positions 2 and 3 and verify continuity at the following pin location:
CN4 - 1 and CN4 - 2
Verify that there is no continuity at Forms Thickness lever positions 4 through 7.
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Printhead service check

FRU 1 Printhead cables Printhead Action If the printout contains missing or extra dots or lines, do the following: Check the continuity and connection of the printhead cables and the short flexible cable. Be sure the voltages to the logic board are correct. If dots are missing: Perform the print test to determine which wire 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 carrier and perform the Printhead-to-platen gap adjustment on page 4-2. 2 Carrier shaft Carrier unit Platen assembly Printhead nose Ribbon guide Check and replace worn or damaged parts.
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Printhead impedance tables 2580, 2590 - approximately 5 ohms

Dot 1 2 3 4 5 6 7 8 9 Connector CN400-13 & CN400-4 CN400-9 & CN400-6 CN400-15 & CN400-18 CN400-1 & CN400-7 CN400-17 & CN400-20 CN400-5 & CN400-2 CN400-19 & CN400-16 CN400-8 & CN400-3 CN400-10 & CN400- 14
2581, 2591 - approximately 8 to 16 ohms

Dot 1 2 3 4 5 6 7 8 9 10 11 12 Connector CN300-1 & CN301-9 CN300-1 & CN301-11 CN300-1 & CN301-7 CN300-1 & CN301-13 CN300-1 & CN301-5 CN300-1 & CN301-15 CN300-1 & CN301-3 CN300-1 & CN301-17 CN300-1 & CN301-1 CN300-1 & CN301-18 CN300-1 & CN301-2 CN300-1 & CN301-16 Dot 13 14 15 16 17 18 19 20 21 22 23 24 Connector CN300-1 & CN300-9 CN300-1 & CN300-11 CN300-1 & CN300-2 CN300-1 & CN300-16 CN300-1 & CN301-4 CN300-1 & CN300-14 CN300-1 & CN301-6 CN300-1 & CN300-12 CN300-1 & CN300-4 CN300-1 & CN300-10 CN300-1 & CN300-6 CN300-1 & CN300-8
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Pull Tractor sensor service check

The Pull Tractor sensor detects the tractor in the pull position and disables the load/unload and auto tear-off functions. A failed sensor may prevent load/unload from functioning, with the tractor in the push position.
FRU 1 Pull Tractor sensor Action With the tractor in the push position, press Load/Unload several times while alternately holding down and releasing the left pull tractor actuator. The paper should load and unload when the actuator is not held down, and should not load or unload when the pull tractor actuator is held down. If the 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 pressed. Replace the sensor if necessary. If the sensor is good but the paper still does not move correctly, replace the logic board and reset the bidirectional print adjustment. Go to Bidirectional print adjustment on page 4-4.
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Top-of-forms service check

FRU 1 2 Top-of-form sensor Logic board Action Check that the Top-of-form sensor and its flag are properly installed and are not damaged. Remove the paper and set the Paper Select lever to the cut sheet position, and turn the printer on. Measure the voltage between logic board connector CN6-2 (TOF signal) and CN6-1 (GND). You should receive the following voltage readings: When there is paper in the printer, the 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 the bidirectional print adjustment. Go to Bidirectional print adjustment on page 4-4.
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Tractor 2 service check

The Tractor 2 in-place sensor opens during installation when its actuator touches the printer cover. The Tractor 2 Home sensor detects the position of the slider:
When Tractor 2 is selected, the motor-driven Tractor 2 slider

pushes the printer sub slider cam lever to engage the printer gear train, which drives the Tractor 2 tractors. When the Tractor 2 is deselected, the motor retracts the slider, 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 1 Tractor 2 Home sensor Action Remove the Tractor 2, and turn the printer off and then back on again to determine if the fault is in the printer or Tractor 2. If the gear teeth chatter just before the beeps, replace the Home sensor.
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FRU 2 Logic board
Action Remove Tractor 2 from the printer, but leave the cable connected. Be sure the slider (the black plastic piece just above the right cover) moves after turning the printer off and then back on. If the slider does not move after turning the printer off and then back on: Be sure the slider and gear train are properly connected and move freely with the power off. Be sure the Tractor 2 board is receiving: +40 V 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.
Tractor 2 motor board/cable assembly
Check the resistances of the Tractor 2 motor windings at CN5 on the Tractor 2 board. There should be 101 5 ohms between pins:
CN5 -1 and CN5 - 4 CN5 -1 and CN5 - 6 CN5 -2 and CN5 - 3 CN5 -2 and CN5 - 5
If the motor is good, replace the board/cable assembly. For information on the Tractor 2 cable connectors, see Tractor 2 cable connectors on page 5-27.
25XX-100, -110 3 beeps and Tractor 2 LED blinks 3 times

Tractor 2 is selected from the operator panel, but the printer does not detect Tractor 2 or detects that the Tractor 2 mechanism is not installed. FRU 1 Tractor 2 board/cable assembly Action Check the Tractor 2 in-place sensor or the cable connection. The in-place sensor actuator extends through the Tractor 2 cover and rests on the printer 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 Logic board Check the cable connection from Tractor 2 to the printer. If possible, try the Tractor 2 with another printer to determine if the problem is the Tractor 2 board/cable assembly or the printer logic board.
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25XX-100, -110 Tractor 2 paper feed problems

FRU 1 Tractor 2 Action Be sure the gear on the printer that drives Tractor 2 turns freely when the lever is not pressed, but remains still when the lever is pressed. Remove the Tractor 2 unit from the printer, and remove all paper. With the Paper Select lever in the continuous forms position, press FormFeed; the tractors should rotate. Press the sub slider cam lever below the ASF/Tractor 2 drive gear, and press FormFeed again; the tractors should not rotate, but the drive gear should. Check the condition of the 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 just below the slider is held in place by the cover. When the cover is removed, it tends to move off the stud. Also note that when operating the Tractor 2 with the printer cover removed, the Tractor 2 in-place sensor must be held open. Turn the printer on, and look for mechanical problems. For information on the Tractor 2 cable connectors, go to Tractor 2 cable connectors on page 5-27.
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Network service check
Step 1 2
Questions/actions Is the printer online (Ready)? Check all of the network connections. Are all the network connections connected properly?
Yes Go to step 2 Go to step 3.
No Put the printer online. Properly connect all of the connections.
Are the indicator lights on the network card illuminated? Open the printers Web page in a web browser using the printer driver IP address. Does the web page open?
Go to step 4.
Go to step 9.
Go to step 13.
Go to step 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.
Restart the printer. Is the problem still there?
Go to step 7.
Problem solved.
Reset the INA to factory defaults. See Resetting the INA to factory defaults on page 3-11. Did this fix the problem?
Problem solved.
Go to step 8.
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Step 8
Questions/actions Replace the LAN card. Did this fix the problem?
Yes Problem solved.
No Replace the main board. Properly connect the cables.
Check the cable connected to CN15 on the main board. Is the cable connected properly?
Go to step 10.
10
Perform a continuity 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?
Go to step 6.
Go to START. See Print test on page 3-3.
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3. Diagnostic aids
The printer contains self tests to help find and solve problems. The printer does not need to be connected to a computer or terminal to run these tests. Types of self tests are:
Power-on self test (POST) Print test Hex Trace mode (a computer or terminal is necessary)
The following are special machine modes that run when the printer is turned off and then back on:
Turn printer on while pressing LineFeed Tractor Load/Unload and Tractor Tearoff and Tractor with the printhead at the left limit Tearoff and Load/Unload with the printhead at the left limit Result Prints print test with sample fonts. Sets printer in Hex Trace mode. Disables/enables Operator Panel Lockout mode. Resets the printer to the World Trade defaults. Resets the printer to the U. S. defaults.
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Power-On Self Test (POST)

The following tests are automatically performed when the printer is turned on.
LEDs TestChecks operation of LEDs on the operator panel.

The LEDs turn on and off after the printer is turned on, and then all LEDs turn on for a few seconds. RAM TestChecks that the CPU can write/read the RAM. Font ROM/Microcode Sum TestChecks that the ROM data is correct. Timer/Interrupt Controller TestChecks that this function works. NVRAM TestChecks that the NVRAM data is correct. Switch Scan TestChecks the buttons on operator panel. Carrier InitializationCarrier moves to the left to activate the Home Position sensor, and then moves to the first print position. Feed InitializationForm feed motor rotates forward and then backward.
If any errors occur during the POST tests, a combination of blinking LEDs indicates which test failed. See Start on page 2-1.
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Print test
The Print test helps you test and troubleshoot the printer. To start the Print test: 1. Paper must be at the print position; the test does not print if paper is parked. 2. Press and hold Line Feed, and turn 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 wire numbered in sequence, from top to bottom.
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Hex Trace mode

The Hex Trace mode helps the user test and troubleshoot programs. Use the Hex Trace procedure to get a hexadecimal printout of the data stream sent to the printer. All data, including both control and character data, print 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 in hexadecimal until you turn the printer off. Hex trace mode sample
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Printer default settings

U.S. defaults
To initialize or reset the printer to the U.S. factory defaults: (Code page 437, Character Set 1, form length 11 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 the operator panel side of the printer until it stops. 5. Close the ribbon access cover. 6. Press and hold Tear Off and Load/Unload while you turn the printer on. 7. Continue holding these buttons until the carrier 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 the operator panel side of the printer until it stops. 5. Close the ribbon access cover. 6. Press and hold Tear Off and Tractor while you turn the printer on. 7. Continue holding these buttons until the carrier moves. The operator panel lights blink several times. Once the carrier moves, your settings have been reset to factory defaults.
Diagnostic aids 3-5
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Clearing paper jams

Cut sheet jams
To clear cut form paper jams: 1. Turn the printer off. 2. Set the Forms Thickness lever to position 7. 3. Push the Paper Select lever down to the continuous forms position. 4. Gently pull out the sheet of paper from the front of the printer. 5. Remove the ribbon access cover to clear any torn pieces of paper. 6. Set the Paper Select lever to the cut forms position. 7. Set the Forms Thickness lever to the proper setting for the type of paper you are using. Refer to the 25XX Users 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 using the optional Tractor 2 Feeder.) 6. Open the left and right tractor doors. 7. Lift the paper from the tractor pins. 8. Carefully pull out the paper. 9. Remove the ribbon access cover to clear any torn paper. 10. Remove any torn perforation strips or bits of paper from the paper path.
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Web page at a glance

The 2500 series internal web server enables a user or service technician to view and adjust the device settings. The web 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.
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Configuration page
This page displays numerous links that enable users to access and (with proper permissions) to change various device settings. Changing a configuration setting: 1. From the Configuration page, click the appropriate link to access the desired device setting. 2. Make the desired changes to the selected setting. 3. To save the changes as the new device faults, click 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 revision level, protocol settings, and so on.)
Network setup
Network protocol settings are displayed. Adjustments can also be made to settings here.
Device information
General device information is displayed here.
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Flashing firmware
If the device is attached to the network, the firmware can be reflashed, 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.
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Importing and exporting INA settings

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.
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25XX-100, -110 To import the INA settings, perform the following tasks: 1. Click the import settings link from the Configuration page. The following page will display:
2. Click the Browse 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 1015 seconds while the printer restarts.
Diagnostic aids 3-11
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4. Repair information
This chapter contains adjustments and removal procedures. Whenever parts are replaced, make sure that all adjustments are correct by running diagnostics procedures and checking adjustments as needed.
Handling ESD-sensitive parts

Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent damage to ESD-sensitive parts, follow the instructions below, in addition to all the usual precautions, such as turning off power before removing logic boards:
Keep the ESD-sensitive part in its original shipping container (a

special ESD bag) until you are ready to install the part 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 you are removing a pluggable module, use the correct tool. Do not place the ESD-sensitive part on the printer cover or on a metal table; if you need to put down the ESD-sensitive part for any reason, first put it into its special bag. Printer covers and metal tables are electrical grounds. They increase the risk of damage because they make a discharge path from your body through the ESD-sensitive part. (Large metal objects can be discharge paths without being grounded.)
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Prevent ESD-sensitive parts from being accidently touched by

other personnel. Install printer covers when not working on the printer, and do not put unprotected ESD-sensitive parts on a table. Keep all ESD-sensitive parts in a grounded metal cabinet (case). Low humidity increases static electricity during cold weather.
Adjustments
CAUTION: Be sure to unplug the power cord whenever you are working on the printer with one of the covers removed.
Printhead-to-platen gap adjustment

Perform the printhead-to-platen gap adjustment after replacing the carrier, platen, 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 Forms Thickness lever to position 1 by pushing it toward the back of the printer as far as it will go. 5. Move the printhead to the left edge of the rubber on the platen. 6. Shift the left Gap Adjust bushing clockwise as far as it will go. 7. Shift the right Gap Adjust bushing counterclockwise as far as it will go. Note: At this time, the nose of the printhead should be touching the platen.
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25XX-100, -110 8. Using a feeler gauge (1), slowly adjust the left Gap Adjust bushing (2) counterclockwise, until a gap of 0.330.37 mm exists between the printhead (3) and the platen.
9. Move the printhead to the right edge of the rubber on the platen and using a feeler gauge (1), slowly adjust the right gap adjust bushing (2) clockwise, until a gap of 0.330.37 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 0.330.37 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 +/- 0.01mm. If the gap value exceeds the specified range, return to step 4 and readjust both left and right Gap Adjust bushings.
25XX-100, -110 11. After confirming that the head gap is within the specified range for all printhead positions (left, right and center), apply the thread sealer to both bushings.
Bidirectional print adjustment

After replacing any mechanical part which affects the operation of the logic board or the carrier, perform the following procedure to adjust the bidirectional print. This adjustment cannot be completed if the printer runs out of paper, so be sure to use continuous forms. 1. Through the Setup Menu, be sure the default macro is set to disabled. 2. Turn the printer off. 3. Open the operator panel cover to access layer two. 4. Press and hold the Pitch key while turning the printer on. The draft alignment bars print. The current value is the number printed below the bars. 5. To set draft, select the best alignment from the alignment bars in rows 0111. 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 number printed below the bars. 8. To set NLQ, select the best alignment from the alignment bars in rows 0111. The current value is the number printed below the bar. 9. 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. 10. Press Set TOF to save the selection. 11. Close the operator panel cover. The printer returns to Ready.
Removal procedures
CAUTION: Be sure to unplug the power cord whenever you are working on the printer with one of the covers removed.
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Covers, removals
Note: See Covers on page 7-3 for the descripton of each part.
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Covers, front removal

1. Rotate the front cover out and up about three inches from the bottom of the printer. 2. Push the front cover up and out of the printer.
Covers, ribbon access removal

1. Pull the gray spring-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 ribbon access cover latches snap and lock.
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Covers, option removal

1. From the bottom, pull the option cover (A) outward and up, removing it from the printer.
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Covers, top removal
1. Turn the printer off and disconnect the power cord at the printer. 2. Remove the tractor assembly, if it is installed in the pull tractor position, by pressing the locking levers and pulling the tractor assembly 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. Remove the two screws (A) from each side of the front cover area.
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25XX-100, -110 8. Turn the printer upside down. 9. Insert a flat-blade screwdriver into each of the four holes (B) in the bottom cover, releasing the top cover from the bottom cover.
10. Turn the printer right side up, and insert a flat-blade screwdriver into each of the two holes (C) in the back of the top cover.
C 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 printer.
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Covers, operator panel assembly removal

1. Remove the top cover. Go to Covers, top removal on page 4-8. 2. Disconnect the operator panel cable from the operator 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.
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Covers, bottom removal

1. Remove the top cover. Go to Covers, top removal on page 4-8. 2. Remove the logic board. Go to Logic board removal on page 4-12. 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.
25XX-100, -110
Logic board removal

1. Remove the INA support frame. Go to INA support frame removal on page 4-14. 2. Disconnect all cables connected to the logic board. Go to Logic board (9w & 24w) on page 5-3 for connector location details. Note: Do 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 logic board. Go to Bidirectional print adjustment on page 4-4.
4-12 Service Manual
25XX-100, -110
Network card removal

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.
25XX-100, -110
INA support frame removal

1. Remove 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.
4-14 Service Manual
25XX-100, -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.
25XX-100, -110
Power supply removal

CAUTION: The power supply may be hot. 1. Turn off the printer, and disconnect the power cord at both ends. 2. Remove the top cover. 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.
4-16 Service Manual
25XX-100, -110
Carrier removals
Carrier removal
1. Remove the top cover. 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.
25XX-100, -110 4. Remove the retaining wire (B) from the left side of the carrier shaft.
4-18 Service Manual
25XX-100, -110 5. Remove the screw (C) from the forms thickness lever, and then remove the lever.
25XX-100, -110 6. Remove 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.
E D 8. Remove the E-clip from the right side of the carrier shaft.
4-20 Service Manual
25XX-100, -110 9. Push the carrier shaft (F) from the right side so it goes out of the left side of the printer.
F 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.
25XX-100, -110
Carrier, motor assembly removal

1. Remove the 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.
4-22 Service Manual
25XX-100, -110 4. Remove the screw (B) from the forms thickness lever, and then remove the lever.
25XX-100, -110 5. Remove the screw (C) securing the carrier motor bracket to the bottom cover.
6. Disconnect the printhead cable from the logic board, and move it back and out of the way, as shown. 7. Remove the five screws (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 carrier motor from the motor bracket.
4-24 Service Manual
25XX-100, -110
Paper handling removals

Paper Select lever removal
1. Remove the top cover. Go to Covers, top 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.
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.
4-26 Service Manual
25XX-100, -110
Print handling removals

Platen 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.
25XX-100, -110
Printhead removal
1. Turn the printer off. 2. Disconnect the power cord at the printer, and allow the printhead to cool for 15 minutes before you handle it. 3. Set the Forms Thickness lever to position 7. 4. Remove the ribbon access cover. Go to Covers, ribbon access removal on page 4-6. 5. Remove the ribbon cartridge. 6. Squeeze the printhead latches together while pulling the printhead up and out of the printer. 7. Disconnect the printhead cable(s) from 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. Remove the printhead. Go to Printhead removal on page 4-28. 3. Release the printhead cables from the flexible cable holders. 4. Disconnect the printhead cables from the logic board. Note: Be sure the printhead cables are correctly aligned and secured. They must be flat with no twists.
4-28 Service Manual
25XX-100, -110
Print unit removal

1. Remove the top 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.
25XX-100, -110 5. Remove the two grommet-anchored screws (B) from the right side of the print unit.
B
6. Remove the print unit from the bottom cover by pulling up forcefully on both sides of the print unit.
4-30 Service Manual
25XX-100, -110
Ribbon drive rack gear removal

1. Remove the top cover. Go 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.
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.
4-32 Service Manual
25XX-100, -110 3. Remove the four screws (B) from the paper feed motor bracket assembly.
25XX-100, -110 4. Remove the paper feed motor bracket assembly, exposing the gears as shown.
4-34 Service Manual
25XX-100, -110
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).
25XX-100, -110 5. Remove the sub frame, exposing the right side gears (D) as shown.
4-36 Service Manual
25XX-100, -110
Rollers 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.
25XX-100, -110 4. Remove the two screws (A) from the right 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.
4-38 Service Manual
25XX-100, -110
Roller, lower pinch removal

1. Remove the top cover. Go to Covers, top removal on page 4-8. 2. Slide the carrier 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.
25XX-100, -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.
4-40 Service Manual
25XX-100, -110 9. Unhook the spring clip (D) from the left end of the lower pinch roller shaft, and then push it off the gray slotted spring block (B) toward the back of the printer, as shown. F
10. Slide the carrier to the center of the printer. 11. Slide the gray slotted spring blocks (E), 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. Perform the printhead-to-platen gap adjustment. Go to Printhead-to-platen gap adjustment on page 4-2.
25XX-100, -110
Roller, lower feed 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. Remove the carrier. Go to Carrier removal on 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, upper feed removal on page 4-37.
4-42 Service Manual
25XX-100, -110 9. Remove the two screws (A) securing the platen to the side frames.
10. Remove the carrier motor bracket. Go to Carrier, motor assembly removal on page 4-22. 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.
25XX-100, -110
Sensor removals
4-44 Service Manual
25XX-100, -110
Sensor, Pull Tractor removal

1. Remove the top cover. Go to Covers, top removal on page 4-8. 2. Remove the small screw securing the Pull Tractor sensor to the inside of the left frame. Go to Sensor removals on page 4-44. 3. Disconnect the pull tractor sensor from the logic board.
Sensor, Head Gap removal

1. Remove the top 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 to Print unit removal on page 4-29. 3. Turn the print unit upside down. 4. Unsnap the Top-of-form sensor from the platen. Go to Sensor removals on page 4-44.
25XX-100, -110
Sensor, Paper Select 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 four small screws securing the Paper Select sensor to the left side frame. Go to Sensor removals on page 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 removal on page 4-42. 2. Remove the Paper Present flag or the Top-of-form flag from the paper guide. Go to Sensor removals on page 4-44.
4-46 Service Manual
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.
25XX-100, -110
Options removals
Auto Sheet Feeder gears removal
1. Remove the right cover. 2. Release the joint gear latch (A) and remove the joint gear.
3. Release the idler gear latch, and remove the idler gear. 4. Release the pick-up gear latch, and remove the 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.
4-48 Service Manual
25XX-100, -110
Auto Sheet Feeder pick-up 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.
25XX-100, -110
4-50 Service Manual
25XX-100, -110
5. Locations and connectors

This chapter identifies the locations of specific parts of the printer.
Tension pulley plate assembly On/Off switch Paper select lever Ribbon cartridge Ribbon drive rack Carrier Forms thickness lever Printhead cable(s) Carrier motor
Printhead
Code module Power supply
Tractor 2 option connector Logic board
Parallel interface connector USB connector
Paper feed motor Serial interface cover plate
Locations and connectors 5-1
25XX-100, -110
Signal connections
Power supply (9w & 24w)
Connector
Pin # 1 2
Signal +40 V dc +40 V dc Power Gnd Power Gnd Signal Gnd +5 V dc Power Save Mode
CN1
3 4 5 6 7
Connector F1
Signal Fuse
5-2 Service Manual
25XX-100, -110 Logic board (9w & 24w)
25XX-100, -110
Connector
Signal Fuse
F1
Connector
Pin # 1 2
Signal +40 V dc +40 V dc Power Gnd Power Gnd Signal Gnd +5 V dc Power Save Mode
CN1
3 4 5 6 7
Connector
Signal Fuse
F1
5-4 Service Manual
25XX-100, -110
Logic boardParallel interface cable (9w & 24w)

Connector Pin # 1 2 3 4 5 6 7 8 Signal -Strobe Data 0 Data 1 Data 2 Data 3 Data 4 Data 5 Data 6 Data 7 -Acknlg Busy PE Select -AUTFED NC Signal Gnd Chassis Gnd +5 V dc Pin # 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Signal Signal Gnd Signal Gnd Signal Gnd Signal Gnd Signal Gnd Signal Gnd Signal Gnd Signal Gnd Signal Gnd Signal Gnd Signal Gnd Signal Gnd -INIT -ERROR Signal Gnd NC +5 V dc -SELIN
CN11
9 10 11 12 13 14 15 16 17 18
25XX-100, -110 Logic board (9w & 24w)
5-6 Service Manual
25XX-100, -110
Logic boardSerial board (9w & 24w)

Connector Pin # 1 2 3 4 Signal +5 V dc +5 V dc -CTS DTS RXD RTS DSR TXD Signal Gnd SBSET
CN200
5 6 7 8 9 10
Connector
Pin # 10 9 8 7
Signal +5 V dc +5 V dc -CTS DTS RXD RTS DSR TXD Signal Gnd SBSET
CN1
6 5 4 3 2 1
25XX-100, -110 Logic board (9w & 24w)
5-8 Service Manual
25XX-100, -110
Logic boardUSB cable (9w & 24w)

Connector Pin # 1 Signal +5 V dc DMNS DPLS Signal Gnd
CN201
2 3 4
Logic boardDC power (9w & 24w)

Connector Pin # 1 2 3 Signal +40 V dc +40 V dc Power Gnd Power Gnd Signal Gnd +5 V dc Power Save Mode
CN12
4 5 6 7
25XX-100, -110 Logic board (9w & 24w)
5-10 Service Manual
25XX-100, -110
Logic boardPrinthead (9w)

Connector Pin # 1 2 3 4 5 6 7 8 Signal H4 H6C H8C H1C H6 H2C H4C H8 H2 H9 HDTHERMO +5 V dc H1 H9C H3 H7C H5 H3C H7 HSC
CN400
9 10 11 12 13 14 15 16 17 18 19 20
25XX-100, -110 Logic board (9w & 24w)
5-12 Service Manual
25XX-100, -110

Connector Pin # 1 2 3 4 5 6 7 8 Signal +40 V dc R15 +40 V dc R21 +40 V dc R23 +40 V dc L24 R13 L22 L14 L20 +40 V dc L18 +40 V dc L16 +40 V dc
CN300
9 10 11 12 13 14 15 16 17
25XX-100, -110 Logic board (9w & 24w)
5-14 Service Manual
25XX-100, -110

Connector Pin # 1 2 3 4 5 6 7 8 Signal R9 R11 R7 R17 R5 R19 R3 HDTHERMO R1 +5 V dc L2 +40 V dc L4 +40 V dc L6 L12 L8 L10
CN301
9 10 11 12 13 14 15 16 17 18
25XX-100, -110 Logic board (9w & 24w)
5-16 Service Manual
25XX-100, -110
Logic boardGap Set sensor (9w & 24w)

Connector Pin # 1 Signal GAP1 Signal Gnd GAP2
CN4
2 3
Logic boardHome Position sensor (9w & 24w)

Connector Pin # 1 Signal HPSW Signal Gnd
CN9
Logic board(9w & 24w)

Connector Pin # 1 Signal 5V DD+ Signal Gnd
CN15
2 3 4
Logic boardPaper Present sensor (9w & 24w)

Connector Pin # 1 Signal PE1P PE1 Signal Gnd
CN5
2 3
25XX-100, -110 Logic board (9w & 24w)
5-18 Service Manual
25XX-100, -110
Logic boardPaper Select sensor (9w & 24w)

Connector Pin # 1 Signal TR/FR Signal Gnd
CN8
Logic boardPull Tractor sensor (9w & 24w)

Connector Pin # 1 Signal PLTR Signal Gnd
CN3
Logic boardTop-of-form sensor (9w & 24w)

Connector Pin # 1 Signal Signal Gnd PE2P PE2
CN6
2 3
25XX-100, -110 Logic board (9w & 24w)
5-20 Service Manual
25XX-100, -110
Logic boardCarrier motor (9w & 24w)

Connector Pin # 1 Signal CAD CAC CAB CAA
CN2
2 3 4
Logic boardPaper feed motor (9w & 24w)

Connector Pin # 1 2 Signal LFD LFC LFB LFA NC
CN1
3 4 5
25XX-100, -110 Logic board (9w & 24w)
5-22 Service Manual
25XX-100, -110
Logic boardOperator panel (9w & 24w)

Connector Pin # 1 2 Signal +5 V dc SLATCH +5 V dc TXD Signal Gnd RXD Signal Gnd SCLK SG
CN13 Logic board
3 4 5 6 7 8 9
Connector
Pin # 1 2 3
Signal +5 V dc SLATCH +5 V dc TXD Signal Gnd RXD Signal Gnd SCLK SG
CN1 Operator panel
4 5 6 7 8 9
25XX-100, -110 Logic board (9w & 24w)
5-24 Service Manual
25XX-100, -110
Logic boardDual tractor cable (9w & 24w)

Connector Pin # 1 2 3 4 5 Signal +40 V dc +40 V dc Power Gnd Power Gnd +5 V dc COCOM D-SET Signal Gnd COA COB JAM D-H.P D-POS
CN10
6 7 8 9 10 11 12 13
25XX-100, -110
Serial boardSerial cable (9w & 24w)
Connector
Pin # 1 2 3 4 5
Signal Chassis Gnd TXD RXD RTS -CTS DSR Signal Gnd NC NC NC NC NC
Pin # 13 14 15 16 17 18 19 20 21 22 23 24 25
Signal NC NC NC NC NC NC NC DTR NC NC NC NC NC
CN2
6 7 8 9 10 11 12
5-26 Service Manual
25XX-100, -110
Tractor 2 cable connectors

The Tractor 2 cable is soldered to the Tractor 2 board at CN1; there is no connector.
Connector CN1-1 CN1-2 CN1-3 CN1-4 CN1-5 CN1-6 CN1-7 CN1-8 CN1-9 CN1-10 CN1-11 CN1-12 CN1-13 Mode +26 V dc +26 V dc Frame GND Not used. +5 V dc Motor common D-Set (signal for Tractor 2 plugged in) Signal GND Motor phase A; 0 V dc except when Tractor 2 motor is on. Motor phase B; +5 V dc when Tractor 2 not in use; 0 V dc when Tractor 2 is in use. Not used. Slider home sensor; +5 V dc when open, 0 V dc when closed. Tractor 2 in-place sensor; +5 V dc when open, 0 V dc when closed.
25XX-100, -110
5-28 Service Manual
25XX-100, -110
6. Preventive maintenance
This chapter describes procedures for preventive maintenance for the printer. Following these recommendations can help prevent problems and maintain optimum performance.
Lubrication
Warning: Petroleum-based lubricants can 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 OilP/N 1280443 Approved equivalents:

Mobil DTE27 Shell Tellus 100 Fuchs Renolin MR30 GreaseP/N 6934659 Approved equivalent: Mobil 28
Preventive maintenance 6-1
25XX-100, -110
Lubrication points
Oil
Lubricate the following contact positions:
Oil felt (carrier block) 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
6-2 Service Manual
25XX-100, -110
Lubrication points (oil)

The oil felt (1) in the carrier block.
The tractor shaft (1).
25XX-100, -110
Lubrication points (grease)

Gear mounting studs on the right side frame (2).
The lower pinch roller (2).
6-4 Service Manual
25XX-100, -110
Lubrication points (grease) cont.

Gear mounting studs on the left side frame (2)
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)
6-6 Service Manual
25XX-100, -110
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 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 printhead cables, and there is no artwork depicting the extended carriage models 2581 or 2591.
Parts catalog 7-1
25XX-100, -110
Assembly 1: Covers
7-2 Service Manual
25XX-100, -110
Assembly 1: Covers
AsmIndex 1-1 2 2 3 4 4 4 4 5 5 6 7 7 7 Part number 40X2912 40X2992 40X2993 40X2913 40X3013 40X3014 40X3025 40X3026 40X4974 40X4975 40X2911 40X0297 40X0271 40X1767 Description Guide, left paper Cover assembly, front unit (2580, 2590) Cover assembly, front unit (2581, 2591) Guide, right paper Ribbon access cover unit (2580) Ribbon access cover unit (2581) Ribbon access cover unit (2590) Ribbon access cover unit (2591) Cover, top (2580, 2590) Cover, top (2581, 2591) Cover, rear (2581, 2591) Power cord: U.S., AFE (LV), Canada, Central and South America, Mexico, Saudi Arabia (LV) Power cord: Malaysia, Singapore, United Kingdom Power cord: Austria, Belgium, Brazil, Germany, Greece, Finland, France, Indonesia, Luxembourg, Portugal, Norway, Saudi Arabia (HV), Spain, Sweden, Netherlands, Turkey Power cord: Denmark Power cord: Chile, Italy Power cord: Israel Power cord: South Africa Power cord: Switzerland Power cord: Australia, New Zealand Power cord: Peru
7 7 7 7 7 7 7
40X0294 40X0287 40X0275 40X0276 40X0274 40X0296 40X1766
Parts catalog 7-3
25XX-100, -110
Assembly 1 (cont.): Covers
7-4 Service Manual
25XX-100, -110
Assembly 1 (cont.): Covers

AsmIndex 1-8 8 9 9 9A 9B 9C 9D 9D 9E 10 10 11 12 12 NS NS NS NS Part number 40X4972 40X4973 40X3002 40X3003 40X2917 40X2918 40X2905 40X3000 40X3001 40X2916 40X2962 40X2963 40X2914 40X2994 40X2995 40X2897 40X2996 40X2997 40X2937 Description Cover, bottom (2580, 2590) Cover, bottom (2581, 2591) Tractor unit (2580, 2590) Tractor unit (2581, 2591) Frame, right side tractor Tractors, left and right Support, tractor paper Shaft set, tractor (2580, 2590) Shaft set, tractor (2581, 2591) Frame, left side tractor Operator panel assembly (258X) Operator panel assembly (259X) Cable, operator panel Cover, front guide (2580, 2590) Cover, front guide (2581, 2591) Cover, operator panel front with overlay packs Overlay pack, operator panel (258X) Overlay pack, operator panel (259X) Stand, paper
Parts catalog 7-5
25XX-100, -110
Assembly 2: Carrier/paper feed (right side)
7-6 Service Manual
25XX-100, -110
Assembly 2: Carrier/paper feed (right side)

AsmIndex 2-1 2 2 3 3 3 3 4 4 4 4 5 6 7 7 8 9 10 11 12 12 13 14 15 16 17 17 18 18 NS NS NS NS Part number 40X2887 40X2998 40X2999 40X2948 40X2949 40X2950 40X2951 40X2952 40X2953 40X2954 40X2955 40X2931 40X2906 40X2983 40X2982 40X2926 40X2922 40X2910 40X2980 40X2956 40X2957 40X2907 40X2968 40X3010 40X2896 40X2971 40X2981 40X3019 40X3020 40X3028 40X3029 40X3034 40X3035 Description Carrier roller set Printhead assembly (2580, 2581) Printhead assembly (2590, 2591) Carrier unit (2580) Carrier unit (2581) Carrier unit (2590) Carrier unit (2591) Cable, printhead (2580) Cable, printhead (2581) Cable, printhead (2590) Cable, printhead (2591) Kit, pull tractor actuator Springs, parts packet Kit, ESD ground (2590, 2591) Kit, ESD ground (2580, 2581) Screws, washers and clips, parts packet Kit, Head Gap adjustment Gears and bushings, parts packet (258X) Sub frame, right side Gear, idler (2580, 2581) Gear, idler (2590, 2591) Paper Select lever Frame, right side Holder, lower pinch roller shaft, right Guide, ASF/DTR, right Roller, lower feed (2581, 2591) Roller, lower feed (2580, 2590) Roller, lower pinch (2580, 2590) Roller, lower pinch (2581, 2591) Narrow auto feeder assembly (2580, 2590) Narrow dual tractor assembly (2580, 2590) Wide auto feeder assembly (2581, 2591) Wide dual tractor assembly (2581, 2591)
Parts catalog 7-7
25XX-100, -110
Assembly 2 (cont.): Carrier/paper feed (right side)
7-8 Service Manual
25XX-100, -110
Assembly 2 (cont.): Carrier/paper feed (right side)

AsmIndex 2-19 19 20 20 Part number 40X2988 40X2989 40X2978 40X2979 Description Shaft, carrier (2580, 2590) Shaft, carrier (2581, 2591) Roller, upper feed (2580, 2590) Roller, upper feed (2581, 2591)
Parts catalog 7-9
25XX-100, -110
Assembly 3: Carrier/paper feed (left side)
7-10 Service Manual
25XX-100, -110
Assembly 3: Carrier/paper feed (left side)

AsmIndex 3-1 2 3 4 4 5 6 6 7 8 9 10 11 12 12 13 13 14 15 16 17 17 18 19 19 20 20 21 22 Part number 40X2910 40X2926 40X2931 40X2966 40X2967 40X2938 40X3007 40X3008 40X2921 40X2906 40X2939 40X2908 40X2893 40X2969 40X2970 40X2973 40X2974 40X2895 40X2919 40X2972 40X2986 40X2987 40X2977 40X3021 40X3022 40X2975 40X2976 40X2901 40X2920 Description Gears and bushings, parts packet (258X) Screws, washers and clips, parts packet Kit, pull tractor actuator Frame, left side (2580, 2581) Frame, left side (2590, 2591) Sensor, Pull Tractor Plate, frame support (2580, 2590) Plate, frame support (2581, 2591) Holder, lower pinch roller shaft, left Springs, parts packet Sensor, Paper Select Holder, platen Sensor, Head Gap Guide, paper assembly (2580, 2590) Guide, paper assembly (2581, 2591) Platen (2580, 2590) Platen (2581, 2591) Guide, ASF/DTR, left Sensor, Top-of-form Sensor, Paper Present Gear, ribbon drive rack (2580, 2590) Gear, ribbon drive rack (2581, 2591) Plate, tension pulley assembly Plate, carrier assembly (2580, 2590) Plate, carrier assembly (2581, 2591) Separator, paper (2580, 2590) Separator, paper (2581, 2591) Motor, carrier (with BKT) Sensor, Home Position
Parts catalog 7-11
25XX-100, -110
Assembly 3 (cont.): Carrier/paper feed (left side)
7-12 Service Manual
25XX-100, -110
Assembly 3 (cont.): Carrier/paper feed (left side)

AsmIndex 3-23 24 25 26 26 Part number 40X2922 40X2894 40X2902 40X2956 40X2957 Description Kit, Head Gap adjustment Lever, Forms Thickness Motor, paper feed (with BKT) Gear, idler (258X) Gear, idler (259X)
Parts catalog 7-13
25XX-100, -110
Assembly 4: Electronics
7-14 Service Manual
25XX-100, -110
Assembly 4: Electronics
AsmIndex 4-1 2 2 3 3 4 4 5 5 5 5 5 5 5 5 6 7 8 9 10 10 NS NS NS NS NS NS Part number 40X2926 40X2983 40X2982 40X2886 40X2885 40X3030 40X2964 40X4960 40X4961 40X4962 40X4963 40X4964 40X4965 40X4966 40X4967 40X2903 40X2915 40X4968 40X4791 40X3015 40X3016 40X4969 40X4970 40X5006 40X2909 40X2930 40X2934 Description Screws, washers and clips, parts packet Kit, ESD ground (2590, 2591) Kit, ESD ground (2580, 2581) Power supply unit, LV Power supply unit, HV Module, EPROM (258X) Module, EPROM (259X) Board, logic without EPROM (2580 LV) Board, logic without EPROM (2580 HV) Board, logic without EPROM (2581 LV) Board, logic without EPROM (2581 HV) Board, logic without EPROM (2590 LV) Board, logic without EPROM (2590 HV) Board, logic without EPROM (2591 LV) Board, logic without EPROM (2591 HV) Bracket, serial interface card Plate, serial interface card INA support frame LAN card (INA) Cable, power supply (2580, 2590) Cable, power supply (2581, 2591) INA support plate Earth LAN card INA cable Kit, fuse (LV) Card, serial interface card with plate Serial interface cable
Parts catalog 7-15
25XX-100, -110
Assembly 5: ASFRoller/support
7-16 Service Manual
25XX-100, -110
Assembly 5: ASFRoller/support
AsmIndex 5-1 1 2 2 3 3 4 4 5 6 7 8 9 10 11 12 13 14 15 Part number 40X2965 40X3017 40X2888 40X3023 40X2889 40X3024 40X2984 40X2985 40X3004 40X2927 40X2928 40X2929 40X2891 40X2924 40X2892 40X2932 40X2933 40X3136 40X2935 Description Support, ASF cut sheet with guides (2580, 2590) Support, ASF cut sheet with guides (2581, 2591) Roller, ASF upper feed (2580, 2590) Roller, ASF upper feed (2581, 2591) Roller, ASF lower feed (2580, 2590) Roller, ASF lower feed (2581, 2591) Roller, ASF pick-up left and right (2580, 2590) Roller, ASF pick-up left and right (2581, 2591) Hopper, ASF right (2581, 2591) Support, ASF paper right Support, ASF paper left Hopper, ASF left ASF springs, parts packet Frame, ASF side left ASF screws, parts packet Lever, ASF paper load Link, ASF paper load ASF gears and bushings, parts packet Cover, ASF left
Parts catalog 7-17
25XX-100, -110
Assembly 6: ASFSide frame/covers
7-18 Service Manual
25XX-100, -110
Assembly 6: ASFSide frame/covers

AsmIndex 6-1 2 3 4 5 NS Part number 40X2891 40X2890 40X2936 40X2892 40X3011 40X2937 Description ASF Springs, parts packet ASF gears and bushings, parts packet Cover, ASF right ASF screws, parts packet Frame, ASF side right Stand, paper
Parts catalog 7-19
25XX-100, -110
Assembly 7: Tractor 2 option
7-20 Service Manual
25XX-100, -110
Assembly 7: Tractor 2 option

AsmIndex 7-1 2 3 4 5 5 6 7 8 9 9 Part number 40X3018 40X2881 40X3009 40X2918 40X2960 40X2961 40X2880 40X2882 40X2923 40X2958 40X2959 Description Table, Tractor 2 paper with guides (2580, 2590) Guide, Tractor 2 paper Tractor and frame assembly, Tractor 2 (2580, 2590) Kit, tractors left and right Board assembly with cable and ferrite, Tractor 2 (2580, 2590) Board assembly with cable and ferrite, Tractor 2 (2581, 2591) Motor, Tractor 2 Parts packet, Tractor 2 Cover, Tractor 2, right Shaft, Tractor 2 support (2580, 2590) Shaft, Tractor 2 support (2581, 2591)
Parts catalog 7-21
25XX-100, -110
7-22 Service Manual
25XX-100, -110
Index
A
Abbreviations 1-8 Adjustments 4-2 Bidirectional print 4-4 Printhead-to-platen gap 4-2 ASF Principles of operation 2-16
G
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
C
Connections Logic Board Printhead (9w) 5-11 Logic board Carrier motor 5-21 DC power 5-9 Gap Set sensor 5-17 Home Position sensor 5-17 Paper feed motor 5-21 Paper Present sensor 5-17 Parallel interface cable 5-5 Pull Tractor sensor 5-19 Serial board 5-7 Top-of-form sensor 5-19 Power supply 5-2 Serial board Serial cable 5-26 Tractor 2 5-27
L
Lubrication 6-1
M
Menu Interface Menu options 1-3 Setup Menu options 1-3
O
Operator errors Irrecoverable 2-13 Options 1-7
D
Defaults U.S. 3-5 World Trade 3-5 Diagnostic aids 3-1
P
Paper jams Clearing continuous forms 3-6 Clearing cut sheet 3-6 Parts ASF Roller/support 7-16 Side Frame/covers 7-18 Carrier/paper feed left side 7-10, 7-12 Carrier/paper feed right side 7-6, 7-7, 7-8, 7-9 Covers 7-2 Electronics 7-14 Tractor 2 option 7-20
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
I-1
25XX-100, -110
Parts catalog How to use 7-1 POST 3-2 Preventive maintenance Lubrication 6-1 Lubrication points 6-2 Specified lubricants 6-1 Print test 3-3 Printer Description 1-1 Options 1-7 Settings 1-4 Specifications 1-1 Speeds 1-2 Printer default settings 3-5 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
R
Removals 4-4 ASF Gears 4-48 Pick-up roller 4-49 Carrier 4-17 Carrier motor assembly 4-22 Covers Bottom 4-11 Front 4-6 Operator panel 4-10 Option 4-7 Ribbon access 4-6 Top 4-8 Covers illustration 4-5 Electronics EPROM 4-11 Logic board 4-12 Power supply 4-16 Forms Thickness lever 4-26 Gears Left side 4-32 Right side 4-35 Operator panel 4-10 Paper feed motor 4-25 Paper Select lever 4-25 Platen 4-27 Print unit 4-29 Printhead 4-28 Printhead cables 4-28
S
Safety information vii Service checks 2-15 Abnormal noise 2-15 Abnormal print 2-23 Auto Sheet Feeder 2-16 Carrier 2-18 Intermittent problem 2-20 No print 2-23 Operator panel 2-23 Paper feed 2-25 Paper Present sensor 2-24 Paper Select sensor 2-28 POST 2-29 Power 2-30 Printhead 2-32 Printhead continuity tables 2-33 Pull Tractor sensor 2-34 Top-of-forms 2-35 Tractor 2 2-36 Settings Tear off position 1-4 Top-of-form (continuous) 1-5 Top-of-form (cut forms) 1-5 Top-of-form (envelopes) 1-5 Setup Menu options 1-3 Setup mode 1-2 Entering 1-2 Exiting 1-2 Signal connections 5-2
I-2 Service Manual
25XX-100, -110
Specific printer parts 5-1 Specifications 1-1 Start 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
I-3
25XX-100, -110
I-4 Service Manual
25XX-100, -110
Part number index

P/N 40X0271 40X0274 40X0275 40X0276 40X0287 40X0294 40X0296 40X0297 40X1766 40X1767 Description Page
40X2880 40X2881 40X2882 40X2885 40X2886 40X2887 40X2888 40X2889 40X2890 40X2891 40X2892 40X2893 40X2894 40X2895 40X2896 40X2897 40X2901 40X2902 40X2903 40X2905 40X2906 40X2907 40X2908 40X2909 40X2910 40X2911 40X2912 40X2913
Power cordMalaysia, Singapore, United Kingdom 7-3 Power cordSwitzerland 7-3 Power cordIsrael 7-3 Power cordSouth Africa 7-3 Power cordChile, Italy 7-3 Power cordDenmark 7-3 Power cordAustralia, New Zealand 7-3 Power cordU.S., AFE (LV), Canada, Central and South America, Mexico, Saudi Arabia (LV) 7-3 Power cordPeru 7-3 Power cordAustria, Belgium, Brazil, Germany, Greece, Finland, France, Indonesia, Luxembourg, Portugal, Norway, Saudi Arabia (HV), Spain, Sweden, Netherlands, Turkey 7-3 Motor, Tractor 2 7-21 Guide, Tractor 2 paper 7-21 Parts packet, Tractor 2 7-21 Power supply unit, HV 7-15 Power supply unit, LV 7-15 Carrier roller set 7-7 Roller, ASF upper feed (2580, 2590) 7-17 Roller, ASF lower feed (2580, 2590) 7-17 ASF gears and bushings, parts packet 7-19 ASF springs, parts packet 7-17, 7-19 ASF screws, parts packet 7-17, 7-19 Sensor, head gap 7-11 Lever, Forms Thickness 7-13 Guide, ASF/DTR, left 7-11 Guide, ASF/DTR, right 7-7 Cover, operator panel front with overlay packs 7-5 Motor, carrier (with BKT) 7-11 Motor, paper feed (with BKT) 7-13 Bracket, serial interface card 7-15 Support, tractor paper 7-5 Springs, parts packet 7-7, 7-11 Paper Select lever 7-7 Holder, platen 7-11 Kit, fuse (LV) 7-15 Gears and bushings, parts packet (258X) 7-7, 7-11 Cover, rear (2581, 2591) 7-3 Guide, left paper 7-3 Guide, right paper 7-3
I-5
25XX-100, -110
40X2914 40X2915 40X2916 40X2917 40X2918 40X2918 40X2919 40X2920 40X2921 40X2922 40X2923 40X2924 40X2926 40X2927 40X2928 40X2929 40X2930 40X2931 40X2932 40X2933 40X2934 40X2935 40X2936 40X2937 40X2938 40X2939 40X2948 40X2949 40X2950 40X2951 40X2952 40X2953 40X2954 40X2955 40X2956 40X2956 40X2957 40X2957 40X2958 40X2959 40X2960 40X2961 40X2962 40X2963 40X2964 40X2965 40X2966 Cable, operator panel 7-5 Plate, serial interface card 7-15 Frame, left side tractor 7-5 Frame, right side tractor 7-5 Kit, tractors left and right 7-21 Tractors, left and right 7-5 Sensor, Top-of-form 7-11 Sensor, home position 7-11 Holder, lower pinch roller shaft, left 7-11 Kit, Head Gap adjustment 7-7, 7-13 Cover, Tractor 2, right 7-21 Frame, ASF side left 7-17 Screws, washers and clips, parts packet 7-7, 7-11, 7-15 Support, ASF paper right 7-17 Support, ASF paper left 7-17 Hopper, ASF left 7-17 Card, serial interface card with plate 7-15 Kit, pull tractor actuator 7-7, 7-11 Lever, ASF paper load 7-17 Link, ASF paper load 7-17 Serial interface cable 7-15 Cover, ASF left 7-17 Cover, ASF right 7-19 Stand, paper 7-5, 7-19 Sensor, Pull Tractor 7-11 Sensor, Paper Select 7-11 Carrier unit (2580) 7-7 Carrier unit (2581) 7-7 Carrier unit (2590) 7-7 Carrier unit (2591) 7-7 Cable, printhead (2580) 7-7 Cable, printhead (2581) 7-7 Cable, printhead (2590) 7-7 Cable, printhead (2591) 7-7 Gear, idler (2580, 2581) 7-7 Gear, idler (258X) 7-13 Gear, idler (2590, 2591) 7-7 Gear, idler (259X) 7-13 Shaft, Tractor 2 support (2580, 2590) 7-21 Shaft, Tractor 2 support (2581, 2591) 7-21 Board assembly with cable and ferrite, Tractor 2 7-21 Board assembly with cable and ferrite, Tractor 2 7-21 Operator panel assembly (258X) 7-5 Operator panel assembly (259X) 7-5 Module, EPROM (259X) 7-15 Support, ASF cut sheet with guides (2580, 2590) 7-17 Frame, left side (2580, 2581) 7-11
I-6 Service Manual
25XX-100, -110
40X2967 40X2968 40X2969 40X2970 40X2971 40X2972 40X2973 40X2974 40X2975 40X2976 40X2977 40X2978 40X2979 40X2980 40X2981 40X2982 40X2983 40X2984 40X2985 40X2986 40X2987 40X2988 40X2989 40X2992 40X2993 40X2994 40X2995 40X2996 40X2997 40X2998 40X2999 40X3000 40X3001 40X3002 40X3003 40X3004 40X3007 40X3008 40X3009 40X3010 40X3011 40X3013 40X3014 40X3015 40X3016 40X3017 40X3018 Frame, left side (2590, 2591) Frame, right side Guide, paper assembly (2580, 2590) Guide, paper assembly (2581, 2591) Roller, lower feed (2481, 2491) Sensor, Paper Present Platen (2580, 2590) Platen (2581, 2591) Separator, paper (2580, 2590) Separator, paper (2581, 2591) Plate, tension pulley assembly Roller, upper feed (2580, 2590) Roller, upper feed (2581, 2591) Sub frame, right side Roller, lower feed (2580, 2590) Kit, ESD ground (2580, 2581) Kit, ESD ground (2590, 2591) Roller, ASF pick-up left and right (2580, 2590) Roller, ASF pick-up left and right (2581, 2591) Gear, ribbon drive rack (2580, 2590) Gear, ribbon drive rack (2581, 2591) Shaft, carrier (2580, 2590) Shaft, carrier (2581, 2591) Cover assembly, front unit (2580, 2590) Cover assembly, front unit (2581, 2591) Cover, front guide (2580, 2590) Cover, front guide (2581, 2591) Overlay pack, operator panel (258X) Overlay pack, operator panel (259X) Printhead assembly (2580, 2581) Printhead assembly (2590, 2591) Shaft set, tractor (2580, 2590) Shaft set, tractor (2581, 2591) Tractor unit (2580, 2590) Tractor unit (2581, 2591) Hopper, ASF right (2581, 2591) Plate, frame support (2580, 2590) Plate, frame support (2581, 2591) Tractor and frame assembly, Tractor 2 (2580, 2590) Holder, lower pinch roller shaft, right Frame, ASF side right Ribbon access cover unit (2580) Ribbon access cover unit (2581) Cable, power supply (2580, 2590) Cable, power supply (2581, 2591) Support, ASF cut sheet with guides (2581, 2591) Table, Tractor 2 paper with guides (2580, 2590) 7-11 7-7 7-11 7-11 7-7 7-11 7-11 7-11 7-11 7-11 7-11 7-9 7-9 7-7 7-7 7-7, 7-15 7-7, 7-15 7-17 7-17 7-11 7-11 7-9 7-9 7-3 7-3 7-5 7-5 7-5 7-5 7-7 7-7 7-5 7-5 7-5 7-5 7-17 7-11 7-11 7-21 7-7 7-19 7-3 7-3 7-15 7-15 7-17 7-21
I-7
25XX-100, -110
40X3019 40X3020 40X3021 40X3022 40X3023 40X3024 40X3025 40X3026 40X3028 40X3029 40X3030 40X3034 40X3035 40X3136 40X4791 40X4960 40X4961 40X4962 40X4963 40X4964 40X4965 40X4966 40X4967 40X4968 40X4969 40X4970 40X4972 40X4973 40X4974 40X4975 40X5006 Roller, lower pinch (2580, 2590) Roller, lower pinch (2581, 2591) Plate, carrier assembly (2580, 2590) Plate, carrier assembly (2581, 2591) Roller, ASF upper feed (2581, 2591) Roller, ASF lower feed (2581, 2591) Ribbon access cover unit (2590) Ribbon access cover unit (2591) Narrow auto feeder assembly (2580, 2590) Narrow dual tractor assembly (2580, 2590) Module, EPROM (258X) Wide auto feeder assembly (2581, 2591) Wide dual tractor assembly (2581, 2591) ASF gears and bushings, parts packet LAN card (INA) Board, logic without EPROM (2580 LV) Board, logic without EPROM (2580 HV) Board, logic without EPROM (2581 LV) Board, logic without EPROM (2581 HV) Board, logic without EPROM (2590 LV) Board, logic without EPROM (2590 HV) Board, logic without EPROM (2591 LV) Board, logic without EPROM (2591 HV) INA support frame INA support plate Earth LAN card Cover, bottom (2580, 2590) Cover, bottom (2581, 2591) Cover, top (2580, 2590) Cover, top (2581, 2591) INA cable 7-7 7-7 7-11 7-11 7-17 7-17 7-3 7-3 7-7 7-7 7-15 7-7 7-7 7-17 7-15 7-15 7-15 7-15 7-15 7-15 7-15 7-15 7-15 7-15 7-15 7-15 7-5 7-5 7-3 7-3 7-15
I-8 Service Manual

Lexmark Forms Printer 2500 Series 25XX-100-110

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Lexmark Forms Printer 2500 Series 25XX-100-110

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Edition: November 2007

Lexmark Forms Printer 2500 Series

Table of contents Start diagnostics Safety and notices Trademarks Index

U.S.A. P/N: 12G9774

viii Service Manual

xii Service Manual

General information 1-1

438 cps 309 cps 77.5 cps

cpi = characters per inch cps = characters per second

Exiting Setup mode

1-2 Service Manual

Setup menu options

Interface menu options

Data bits Parity Stop bits Protocol

7, 8 No, Ignore, Odd, Even 1, 2 XON/XOFF MultiXON/XOFF DTR Pacing

General information 1-3

1-4 Service Manual

Setting Top-of-form (continuous-pull mode)

Setting Top-of-form (cut forms, envelopes)

General information 1-5

Printing a network setup page

1-6 Service Manual

General information 1-7

1-8 Service Manual

Voltage, ground, and continuity readings

Diagnostic information 2-1

2-2 Service Manual

Error indication table

Diagnostic information 2-3

LED Power Ready Paper Out Panel Lock Font Lock

Status ON Blinking Blinking Blinking Blinking

Alarm Beeps 10 times

Power Ready Tractor 2 Paper Out Font Lock

ON Blinking Blinking Blinking Blinking

Power Ready Tractor 2 Paper Out Font Lock

ON Blinking Blinking Blinking Blinking

2-4 Service Manual

ON OFF OFF OFF OFF

Operator Panel Failure Go to Operator panel service check on page 2-23.

Go to Operator panel service check on page 2-23.

Go to Power service check on page 2-30.

Ethernet option not installed. Go to Network service check on page 2-40.

Diagnostic information 2-5

Symptom check table

Abnormal noise problems

Go to Abnormal noise service check on page 2-15.

2-6 Service Manual

25XX-100, -110 Abnormal print operation problems

Auto Sheet Feeder problems

Diagnostic information 2-7

25XX-100, -110 Error indications

Operator panel problems

2-8 Service Manual

25XX-100, -110 Paper feed problems

Diagnostic information 2-9

Go to Top-of-forms service check on page 2-35.

2-10 Service Manual

25XX-100, -110 Power problems

Diagnostic information 2-11

25XX-100, -110 Print quality problems