Page 1 Edition: November 2007 Lexmark Forms Printer 2500 Series 25XX-100 25XX-110 • Table of contents • Start diagnostics • Start diagnostics • Safety and notices • Trademarks • Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the...
Page 2 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.
Page 3: Table Of Contents
25XX-100, -110 Table of contents Safety information ........1-vii Preface .
Page 4 25XX-100, -110 Pull Tractor sensor service check......2-34 Top-of-forms service check ......2-35 Tractor 2 service check .
Page 5 25XX-100, -110 Carrier removals ........4-17 Carrier removal .
Page 6 25XX-100, -110 Logic board–Printhead (24w) ......5-15 Logic board–Gap Set sensor (9w & 24w) ....5-17 Logic board–Home Position sensor (9w &...
Page 7: Safety Information
25XX-100, -110 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. •...
Page 8 25XX-100, -110 Norme di sicurezza • La sicurezza del prodotto si basa sui test e sull'approvazione del progetto originale e dei componenti specifici. Il produttore non è responsabile per la sicurezza in caso di sostituzione non autorizzata delle parti. •...
Page 9 25XX-100, -110 Pautas de Seguridad • La seguridad de este producto se basa en pruebas y aprobaciones del diseño original y componentes específicos. El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas.
Page 10 25XX-100, -110 Informació de Seguretat • La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components específics. El fabricant no es fa responsable de les qüestions de seguretat si s'utilitzen peces de recanvi no autoritzades.
Page 11 25XX-100, -110...
Page 12: Preface
25XX-100, -110 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.
Page 13: General Information
25XX-100, -110 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.
Page 14: Printer Speeds
25XX-100, -110 Printer speeds 9-Wire 24-Wire 10 cpi 12 cpi 10 cpi 12 cpi Fast draft 438 cps 510 cps 409 cps 465 cps Draft 309 cps 304 cps 274 cps 328 cps NLQ– 77.5 cps 77.5 cps 91.7 cps...
Page 15: Setup Menu Options
25XX-100, -110 Setup menu options Menu Function Forms Macro options Customize macros to print a variety of forms. Data options Define how information is processed. Control options Define how the printer performs basic tasks. Emulation options Determine how the printer interacts with software applications.
Page 16: Printer Settings
25XX-100, -110 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: •...
Page 17: Setting Top-Of-Form (Continuous-Pull Mode)
25XX-100, -110 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.
Page 18: Printing A Network Setup Page
25XX-100, -110 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.
Page 19: Options
25XX-100, -110 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: •...
Page 20 25XX-100, -110 Abbreviations Analog front end Automatic sheet feeder Central processing unit EPROM Erasable Programmable Read-Only Memory Electrostatic discharge Field replaceable unit HTTP Hypertext transport protocol High voltage Light emitting diode Low voltage Multifunction Printer Millimeter Network interface card NVRAM...
Page 21: Diagnostic Information
25XX-100, -110 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.
Page 22 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.
Page 23: Error Indication Table
25XX-100, -110 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”...
Page 24 25XX-100, -110 Status Alarm Action Power Beeps Home Position Error Ready Blinking Go to “Carrier service check” Paper Out Blinking times on page 2-18. Panel Lock Blinking Font Lock Blinking Tractor 2 Home Position Error If Tractor 2 is installed, remove it...
Page 25 25XX-100, -110 Status Alarm Action All LEDs None Power Failure Check the continuity of the power cord and the voltage of the user’s outlet. If they are correct, go to “Power service check” on page 2-30. Power None Operator Panel Failure...
Page 26: Symptom Check Table
25XX-100, -110 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 Action 7 or more lights turn Disconnect the interface cable from the printer and on but do not turn turn the printer off and then back on.
Page 27 25XX-100, -110 Abnormal print operation problems Symptom Action Be sure the interface cable is connected properly. Printer will not print, or become ready. Abnormal operation, Go to “No print or abnormal print service incorrect characters, check” on page 2-23. or incorrect line...
Page 28 25XX-100, -110 Error indications Symptom Action Ready and Paper Turn the printer off and then back on. Out lights blink. Go to “Abnormal indications” on page 2-6. Paper Out and Font Turn the printer off and then back on. lights blink.
Page 29 25XX-100, -110 Paper feed problems Symptom Action Go to “Paper Present sensor service check” on The Paper Out light is blinking when page 2-24. there is paper in the printer. The Paper Out light Be sure the paper present sensor is not blocked.
Page 30 25XX-100, -110 Symptom Action The Load/Unload Be sure the Paper Select lever is in the tractor button functions position. when the pull tractor Go to “Pull Tractor sensor service check” on is installed. page 2-34. The Paper Out light blinks, and the...
Page 31 25XX-100, -110 Power problems Symptom Action When the power Check the continuity of the power cord and the switch is on, the voltage of the user’s outlet. Power light does not Go to “Power service check” on page 2-30. turn on or the printer does not start.
Page 32 25XX-100, -110 Print quality problems Symptom Action No print, but the Adjust the Forms Thickness lever to a lower carrier moves as if number. printing. Be sure the printhead cables are not loose or damaged. Be sure the interface cable is connected properly.
Page 33: Irrecoverable Operator Errors
25XX-100, -110 Ribbon feed problems Symptom Action Check the ribbon cartridge for binds or damage. Ribbon comes off, becomes loose or Go to “Carrier service check” on page 2-18. folded, or jams. Ribbon feeds correctly but is noisy. Unable to print on network...
Page 34: Paper Select Sensor
25XX-100, -110 Paper Select sensor Action Check The Load/Unload button functions correctly. Turn the power off. Install the Push Go to “Paper Select sensor service check” on Tractor. page 2-28. Set the Paper Select lever to the tractor position, and load continuous forms.
Page 35: Service Checks
25XX-100, -110 Service checks Abnormal noise service check Check the entire printer for loose parts. Action Ribbon cartridge Remove and reinstall the ribbon cartridge. Printhead Disconnect the printhead cable(s). Run the print test (do not fold or damage the cables during the test). Go to “Print test”...
Page 36: Auto Sheet Feeder (Asf) Service Check
25XX-100, -110 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.
Page 37 25XX-100, -110 Action Paper Select With the Paper Select lever in the cut sheet sensor 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...
Page 38: Carrier Service Check
25XX-100, -110 Carrier service check Note: The carrier service check includes the carrier drive, Home Position sensor, and ribbon feed. Action Carrier 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.
Page 39 25XX-100, -110 Action Carrier motor 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...
Page 40: Intermittent Problem Service Check
25XX-100, -110 Intermittent problem service check FRU/Symptom Action The printer Check for the following: sometimes fails 1. Loose connectors. Reconnect all before POST is connectors to the logic board. complete. 2. Electrical noise or static discharge. Check the following: • Power supply ground •...
Page 41 25XX-100, -110 FRU/Symptom Action Printer power The cause of this problem may be that the sometimes turns power circuit is failing, or the wiring is off. intermittently open. Check the following in sequence: 1. Check the user’s outlet voltage, and be sure it is within tolerance.
Page 42 25XX-100, -110 FRU/Symptom Action The previous The following may cause undefined or suggestions have intermittent failures: not corrected the • Loose connector pins that fail to contact. problem. Check the following: — Reconnect the connectors of all FRUs and printer interface cables.
Page 43: No Print Or Abnormal Print Service Check
25XX-100, -110 No print or abnormal print service check FRU/Function Action Logic board 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. Interface cable Check the connection and continuity of the interface cable.
Page 44: Paper Present Sensor Service Check
25XX-100, -110 Paper Present sensor service check Action Paper Present With no paper in the printer, the tractor in the sensor push position, and the Paper Select lever set to continuous forms, press Load/Unload; the gear train should turn forward to load paper.
Page 45: Paper Feed Service Check
25XX-100, -110 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 User’s Guide for specifications of acceptable papers. If the paper does not stop in the correct location, see “Paper...
Page 46 25XX-100, -110 FRU/symptom Action Operator panel 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.
Page 47 25XX-100, -110 FRU/symptom Action Logic board If no other problem is found, replace the logic board and reset the “Bidirectional print adjustment” on page 4-4. 2-27 Diagnostic information...
Page 48: Paper Select Sensor Service Check
25XX-100, -110 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. Action...
Page 49: Post Service Check
25XX-100, -110 Action Pull Tractor A failed Pull Tractor sensor can cause the sensor 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.
Page 50: Power Service Check
25XX-100, -110 Power service check Action Power supply 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.
Page 51: Print Speed Service Check
25XX-100, -110 Action Logic board 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.
Page 52: Printhead Service Check
25XX-100, -110 Printhead service check Action Printhead cables If the printout contains missing or extra dots or Printhead 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.
Page 53 25XX-100, -110 Printhead impedance tables 2580, 2590 - approximately 5 ohms 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...
Page 54: Pull Tractor Sensor Service Check
25XX-100, -110 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.
Page 55: Top-Of-Forms Service Check
25XX-100, -110 Top-of-forms service check Action Top-of-form Check that the Top-of-form sensor and its flag sensor are properly installed and are not damaged. Logic board Remove the paper and set the Paper Select lever to the cut sheet position, and turn the printer on.
Page 56: Tractor 2 Service Check
25XX-100, -110 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.
Page 57 25XX-100, -110 Action Logic board 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: •...
Page 58 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. Action Tractor 2...
Page 59 25XX-100, -110 Tractor 2 paper feed problems Action Tractor 2 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.
Page 60: Network Service Check
25XX-100, -110 Network service check Step Questions/actions Is the printer online Go to step 2 Put the printer (Ready)? online. Check all of the network Go to step 3. Properly connections. connect all of the connections. Are all the network...
Page 61 25XX-100, -110 Step Questions/actions Replace the LAN card. Problem solved. Replace the main board. Did this fix the problem? Check the cable Go to step 10. Properly connected to CN15 on connect the the main board. cables. Is the cable connected...
Page 62 25XX-100, -110 2-42 Service Manual...
Page 63: Diagnostic Aids
25XX-100, -110 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) •...
Page 64: Power-On Self Test (Post)
25XX-100, -110 Power-On Self Test (POST) The following tests are automatically performed when the printer is turned on. • LEDs Test–Checks 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.
Page 65: Print Test
25XX-100, -110 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.
Page 66: Hex Trace Mode
25XX-100, -110 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.
Page 67: Printer Default Settings
25XX-100, -110 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.
Page 68: Clearing Paper Jams
25XX-100, -110 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.
Page 69: Web Page At A Glance
25XX-100, -110 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.
Page 70: Configuration Page
25XX-100, -110 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.
Page 71: Flashing Firmware
25XX-100, -110 Flashing firmware If the device is attached to the network, the firmware can be re- flashed, or upgraded from the web page. To reflash the firmware, perform the following steps: 1. Open the Configuration page of the web server.
Page 72: Importing And Exporting Ina Settings
25XX-100, -110 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.
Page 73: Resetting The Ina To Factory Defaults
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.
Page 74 25XX-100, -110 3-12 Service Manual...
Page 75: Repair Information
25XX-100, -110 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).
Page 76: Adjustments
25XX-100, -110 • 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).
Page 77 25XX-100, -110 8. Using a feeler gauge (1), slowly adjust the left Gap Adjust bushing (2) counterclockwise, until a gap of 0.33—0.37 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 0.33—0.37 mm exists...
Page 78: Bidirectional Print Adjustment
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.
Page 79: Covers, Removals
25XX-100, -110 Covers, removals Note: See “Covers” on page 7-3 for the descripton of each part. Repair information...
Page 80: Covers, Front Removal
25XX-100, -110 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.
Page 81: Covers, Option Removal
25XX-100, -110 Covers, option removal 1. From the bottom, pull the option cover (A) outward and up, removing it from the printer. Repair information...
Page 82: Covers, Top Removal
25XX-100, -110 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.
Page 83 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.
Page 84: Covers, Operator Panel Assembly Removal
25XX-100, -110 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.
Page 85: Covers, Bottom Removal
25XX-100, -110 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”...
Page 86: Logic Board Removal
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.
Page 87: Network Card Removal
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.
Page 88: Ina Support Frame Removal
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.
Page 89 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.
Page 90: Power Supply Removal
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”...
Page 91: Carrier Removals
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).
Page 92 25XX-100, -110 4. Remove the retaining wire (B) from the left side of the carrier shaft. 4-18 Service Manual...
Page 93 25XX-100, -110 5. Remove the screw (C) from the forms thickness lever, and then remove the lever. 4-19 Repair information...
Page 94 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. 8. Remove the E-clip from the right side of the carrier shaft.
Page 95 25XX-100, -110 9. Push the carrier shaft (F) from the right side so it goes out of the left side of the printer. 10. Remove the carrier from the printer. Note: Following replacement, perform the printhead-to-platen gap adjustment. Go to “Printhead-to-platen gap adjustment”...
Page 96: Carrier, Motor Assembly Removal
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.
Page 97 25XX-100, -110 4. Remove the screw (B) from the forms thickness lever, and then remove the lever. 4-23 Repair information...
Page 98 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.
Page 99: Paper Handling Removals
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.
Page 100: Forms Thickness Lever Removal
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...
Page 101: Print Handling Removals
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.
Page 102: Printhead Removal
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...
Page 103: Print Unit Removal
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.
Page 104 25XX-100, -110 5. Remove the two grommet-anchored screws (B) from the right side of the print unit. 6. Remove the print unit from the bottom cover by pulling up forcefully on both sides of the print unit. 4-30 Service Manual...
Page 105: Ribbon Drive Rack Gear Removal
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.
Page 106: Gears Removals
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...
Page 107 25XX-100, -110 3. Remove the four screws (B) from the paper feed motor bracket assembly. 4-33 Repair information...
Page 108 25XX-100, -110 4. Remove the paper feed motor bracket assembly, exposing the gears as shown. 4-34 Service Manual...
Page 109: Right Side Gears, Sub Frame Removal
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.
Page 110 25XX-100, -110 5. Remove the sub frame, exposing the right side gears (D) as shown. 4-36 Service Manual...
Page 111: Rollers Removals
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.
Page 112 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.
Page 113: Roller, Lower Pinch Removal
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.
Page 114 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.
Page 115 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. 10. Slide the carrier to the center of the printer.
Page 116: Roller, Lower Feed Removal
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.
Page 117 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.
Page 118: Sensor Removals
25XX-100, -110 Sensor removals 4-44 Service Manual...
Page 119: Sensor, Pull Tractor Removal
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.
Page 120: Sensor, Paper Select Removal
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.
Page 121: Sensor, Home Position Sensor Removal
25XX-100, -110 Sensor, Home Position sensor removal 1. Remove the top cover. Go to “Covers, top removal” on page 4-8. 2. Disconnect the Home Position sensor cable from the logic board. 3. Unsnap the Home Position sensor (A) from the frame.
Page 122: Options Removals
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.
Page 123: Auto Sheet Feeder Pick-Up Roller Removal
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.
Page 124 25XX-100, -110 4-50 Service Manual...
Page 125: Locations And Connectors
25XX-100, -110 5. Locations and connectors This chapter identifies the locations of specific parts of the printer. Tension Ribbon Forms Carrier Paper Ribbon pulley cartridge thickness motor select drive plate lever lever rack assembly Printhead Carrier Printhead On/Off cable(s) switch...
Page 126: Signal Connections
25XX-100, -110 Signal connections Power supply (9w & 24w) Connector Pin # Signal +40 V dc +40 V dc Power Gnd Power Gnd Signal Gnd +5 V dc Power Save Mode Connector Signal Fuse Service Manual...
Page 127 25XX-100, -110 Logic board (9w & 24w) Locations and connectors...
Page 128 25XX-100, -110 Connector Signal Fuse Connector Pin # Signal +40 V dc +40 V dc Power Gnd Power Gnd Signal Gnd +5 V dc Power Save Mode Connector Signal Fuse Service Manual...
Page 129: Logic Board-Parallel Interface Cable (9W & 24W)
25XX-100, -110 Logic board–Parallel interface cable (9w & 24w) Connector Pin # Signal Pin # Signal -Strobe Signal Gnd Data 0 Signal Gnd Data 1 Signal Gnd Data 2 Signal Gnd Data 3 Signal Gnd Data 4 Signal Gnd Data 5...
Page 130 25XX-100, -110 Logic board (9w & 24w) Service Manual...
Page 131: Logic Board-Serial Board (9W & 24W)
25XX-100, -110 Logic board–Serial board (9w & 24w) Connector Pin # Signal +5 V dc +5 V dc -CTS CN200 Signal Gnd SBSET Connector Pin # Signal +5 V dc +5 V dc -CTS Signal Gnd SBSET Locations and connectors...
Page 132 25XX-100, -110 Logic board (9w & 24w) Service Manual...
Page 133: Logic Board-Usb Cable (9W & 24W)
25XX-100, -110 Logic board–USB cable (9w & 24w) Connector Pin # Signal +5 V dc DMNS CN201 DPLS Signal Gnd Logic board–DC power (9w & 24w) Connector Pin # Signal +40 V dc +40 V dc Power Gnd CN12 Power Gnd...
Page 134 25XX-100, -110 Logic board (9w & 24w) 5-10 Service Manual...
Page 135: Logic Board-Printhead (9W)
25XX-100, -110 Logic board–Printhead (9w) Connector Pin # Signal CN400 HDTHERMO +5 V dc 5-11 Locations and connectors...
Page 136 25XX-100, -110 Logic board (9w & 24w) 5-12 Service Manual...
Page 137: Logic Board-Printhead (24W)
25XX-100, -110 Logic board–Printhead (24w) Connector Pin # Signal +40 V dc +40 V dc +40 V dc +40 V dc CN300 +40 V dc +40 V dc +40 V dc 5-13 Locations and connectors...
Page 138 25XX-100, -110 Logic board (9w & 24w) 5-14 Service Manual...
Page 139: Logic Board-Printhead (24W)
25XX-100, -110 Logic board–Printhead (24w) Connector Pin # Signal HDTHERMO CN301 +5 V dc +40 V dc +40 V dc 5-15 Locations and connectors...
Page 140 25XX-100, -110 Logic board (9w & 24w) 5-16 Service Manual...
Page 141: Logic Board-Gap Set Sensor (9W & 24W)
25XX-100, -110 Logic board–Gap Set sensor (9w & 24w) Connector Pin # Signal GAP1 Signal Gnd GAP2 Logic board–Home Position sensor (9w & 24w) Connector Pin # Signal HPSW Signal Gnd Logic board–(9w & 24w) Connector Pin # Signal CN15 Signal Gnd Logic board–Paper Present sensor (9w &...
Page 142 25XX-100, -110 Logic board (9w & 24w) 5-18 Service Manual...
Page 143: Logic Board-Paper Select Sensor (9W & 24W)
25XX-100, -110 Logic board–Paper Select sensor (9w & 24w) Connector Pin # Signal TR/FR Signal Gnd Logic board–Pull Tractor sensor (9w & 24w) Connector Pin # Signal PLTR Signal Gnd Logic board–Top-of-form sensor (9w & 24w) Connector Pin # Signal...
Page 144 25XX-100, -110 Logic board (9w & 24w) 5-20 Service Manual...
Page 145: Logic Board-Carrier Motor (9W & 24W)
25XX-100, -110 Logic board–Carrier motor (9w & 24w) Connector Pin # Signal Logic board–Paper feed motor (9w & 24w) Connector Pin # Signal 5-21 Locations and connectors...
Page 146 25XX-100, -110 Logic board (9w & 24w) 5-22 Service Manual...
Page 147: Logic Board-Operator Panel (9W & 24W)
25XX-100, -110 Logic board–Operator panel (9w & 24w) Connector Pin # Signal +5 V dc SLATCH +5 V dc CN13 Logic board Signal Gnd Signal Gnd SCLK Connector Pin # Signal +5 V dc SLATCH +5 V dc Operator panel...
Page 148 25XX-100, -110 Logic board (9w & 24w) 5-24 Service Manual...
Page 149: Logic Board-Dual Tractor Cable (9W & 24W)
25XX-100, -110 Logic board–Dual tractor cable (9w & 24w) Connector Pin # Signal +40 V dc +40 V dc Power Gnd Power Gnd +5 V dc COCOM CN10 D-SET Signal Gnd D-H.P D-POS 5-25 Locations and connectors...
Page 150: Serial Board-Serial Cable (9W & 24W)
25XX-100, -110 Serial board–Serial cable (9w & 24w) Connector Pin # Signal Pin # Signal Chassis Gnd -CTS Signal Gnd 5-26 Service Manual...
Page 151: Tractor 2 Cable Connectors
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 Mode CN1-1 +26 V dc CN1-2 +26 V dc CN1-3 Frame GND CN1-4 Not used. CN1-5...
Page 152 25XX-100, -110 5-28 Service Manual...
Page 153: Preventive Maintenance
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.
Page 154: Lubrication Points
25XX-100, -110 Lubrication points 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 •...
Page 155: Lubrication Points (Oil)
25XX-100, -110 Lubrication points (oil) The oil felt (1) in the carrier block. The tractor shaft (1). Preventive maintenance...
Page 156: Lubrication Points (Grease)
25XX-100, -110 Lubrication points (grease) Gear mounting studs on the right side frame (2). The lower pinch roller (2). Service Manual...
Page 157 25XX-100, -110 Lubrication points (grease) cont. Gear mounting studs on the left side frame (2) Preventive maintenance...
Page 158 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) Service Manual...
Page 159: Parts Catalog
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.
Page 160: Assembly 1: Covers
25XX-100, -110 Assembly 1: Covers Service Manual...
Page 161 25XX-100, -110 Assembly 1: Covers Asm- Part Description Index number 40X2912 Guide, left paper 40X2992 Cover assembly, front unit (2580, 2590) 40X2993 Cover assembly, front unit (2581, 2591) 40X2913 Guide, right paper 40X3013 Ribbon access cover unit (2580) 40X3014 Ribbon access cover unit (2581)
Page 162 25XX-100, -110 Assembly 1 (cont.): Covers Service Manual...
Page 163 25XX-100, -110 Assembly 1 (cont.): Covers Asm- Part Description Index number 40X4972 Cover, bottom (2580, 2590) 40X4973 Cover, bottom (2581, 2591) 40X3002 Tractor unit (2580, 2590) 40X3003 Tractor unit (2581, 2591) 40X2917 Frame, right side tractor 40X2918 Tractors, left and right...
Page 164: Assembly 2: Carrier/Paper Feed (Right Side)
25XX-100, -110 Assembly 2: Carrier/paper feed (right side) Service Manual...
Page 165 25XX-100, -110 Assembly 2: Carrier/paper feed (right side) Asm- Part Description Index number 40X2887 Carrier roller set 40X2998 Printhead assembly (2580, 2581) 40X2999 Printhead assembly (2590, 2591) 40X2948 Carrier unit (2580) 40X2949 Carrier unit (2581) 40X2950 Carrier unit (2590) 40X2951...
Page 166 25XX-100, -110 Assembly 2 (cont.): Carrier/paper feed (right side) Service Manual...
Page 167 25XX-100, -110 Assembly 2 (cont.): Carrier/paper feed (right side) Asm- Part Description Index number 2-19 40X2988 Shaft, carrier (2580, 2590) 40X2989 Shaft, carrier (2581, 2591) 40X2978 Roller, upper feed (2580, 2590) 40X2979 Roller, upper feed (2581, 2591) Parts catalog...
Page 168: Assembly 3: Carrier/Paper Feed (Left Side)
25XX-100, -110 Assembly 3: Carrier/paper feed (left side) 7-10 Service Manual...
Page 169 25XX-100, -110 Assembly 3: Carrier/paper feed (left side) Asm- Part Description Index number 40X2910 Gears and bushings, parts packet (258X) 40X2926 Screws, washers and clips, parts packet 40X2931 Kit, pull tractor actuator 40X2966 Frame, left side (2580, 2581) 40X2967 Frame, left side (2590, 2591)
Page 170 25XX-100, -110 Assembly 3 (cont.): Carrier/paper feed (left side) 7-12 Service Manual...
Page 171 25XX-100, -110 Assembly 3 (cont.): Carrier/paper feed (left side) Asm- Part Description Index number 3-23 40X2922 Kit, Head Gap adjustment 40X2894 Lever, Forms Thickness 40X2902 Motor, paper feed (with BKT) 40X2956 Gear, idler (258X) 40X2957 Gear, idler (259X) 7-13 Parts catalog...
Page 172: Assembly 4: Electronics
25XX-100, -110 Assembly 4: Electronics 7-14 Service Manual...
Page 173 25XX-100, -110 Assembly 4: Electronics Asm- Part Description Index number 40X2926 Screws, washers and clips, parts packet 40X2983 Kit, ESD ground (2590, 2591) 40X2982 Kit, ESD ground (2580, 2581) 40X2886 Power supply unit, LV 40X2885 Power supply unit, HV 40X3030...
Page 174: Assembly 5: Asf-Roller/Support
25XX-100, -110 Assembly 5: ASF–Roller/support 7-16 Service Manual...
Page 175 25XX-100, -110 Assembly 5: ASF–Roller/support Asm- Part Description Index number 40X2965 Support, ASF cut sheet with guides (2580, 2590) 40X3017 Support, ASF cut sheet with guides (2581, 2591) 40X2888 Roller, ASF upper feed (2580, 2590) 40X3023 Roller, ASF upper feed (2581, 2591)
Page 176: Assembly 6: Asf-Side Frame/Covers
25XX-100, -110 Assembly 6: ASF–Side frame/covers 7-18 Service Manual...
Page 177 25XX-100, -110 Assembly 6: ASF–Side frame/covers Asm- Part Description Index number 40X2891 ASF Springs, parts packet 40X2890 ASF gears and bushings, parts packet 40X2936 Cover, ASF right 40X2892 ASF screws, parts packet 40X3011 Frame, ASF side right 40X2937 Stand, paper...
Page 178: Assembly 7: Tractor 2 Option
25XX-100, -110 Assembly 7: Tractor 2 option 7-20 Service Manual...
Page 179 25XX-100, -110 Assembly 7: Tractor 2 option Asm- Part Description Index number 40X3018 Table, Tractor 2 paper with guides (2580, 2590) 40X2881 Guide, Tractor 2 paper 40X3009 Tractor and frame assembly, Tractor 2 (2580, 2590) 40X2918 Kit, tractors left and right...
Page 180 25XX-100, -110 7-22 Service Manual...
Page 181: Index
25XX-100, -110 Index Abbreviations General information Adjustments Bidirectional print Printhead-to-platen gap Hex Trace mode Principles of operation 2-16 Interface Menu options Irrecoverable operator errors Connections Paper Empty sensor 2-14 Logic Board Paper Present sensor 2-13 Printhead (9w) 5-11 Paper Select sensor...
Page 182 25XX-100, -110 Parts catalog Ribbon drive rack gear 4-31 How to use Right side sub frame 4-35 POST Rollers Preventive maintenance Lower feed 4-42 Lubrication Upper feed 4-37 Lubrication points Upper pinch 4-39 Specified lubricants Sensors Print test Head Gap...
Page 183 25XX-100, -110 Specific printer parts Specifications Start Symptom checks Abnormal indications Abnormal noise problems ASF problems Error indications Operator panel problems Paper feed problems power problems 2-11 Print quality problems 2-12 Tools Voltage, ground, and continuity...
Page 184 25XX-100, -110 Service Manual...
Page 185: Part Number Index
25XX-100, -110 Part number index Description Page 40X0271 Power cord–Malaysia, Singapore, United Kingdom 40X0274 Power cord–Switzerland 40X0275 Power cord–Israel 40X0276 Power cord–South Africa 40X0287 Power cord–Chile, Italy 40X0294 Power cord–Denmark 40X0296 Power cord–Australia, New Zealand 40X0297 Power cord–U.S., AFE (LV), Canada, Central and South America,...
Page 186 25XX-100, -110 40X2914 Cable, operator panel 40X2915 Plate, serial interface card 7-15 40X2916 Frame, left side tractor 40X2917 Frame, right side tractor 40X2918 Kit, tractors left and right 7-21 40X2918 Tractors, left and right 40X2919 Sensor, Top-of-form 7-11 40X2920 Sensor, home position...
Page 187 25XX-100, -110 40X2967 Frame, left side (2590, 2591) 7-11 40X2968 Frame, right side 40X2969 Guide, paper assembly (2580, 2590) 7-11 40X2970 Guide, paper assembly (2581, 2591) 7-11 40X2971 Roller, lower feed (2481, 2491) 40X2972 Sensor, Paper Present 7-11 40X2973 Platen (2580, 2590)
Page 188 25XX-100, -110 40X3019 Roller, lower pinch (2580, 2590) 40X3020 Roller, lower pinch (2581, 2591) 40X3021 Plate, carrier assembly (2580, 2590) 7-11 40X3022 Plate, carrier assembly (2581, 2591) 7-11 40X3023 Roller, ASF upper feed (2581, 2591) 7-17 40X3024 Roller, ASF lower feed (2581, 2591)

This manual is also suitable for:

25xx-110 25**-100 25**-110

Lexmark 25XX-100 Service Manual

Preface

General Information

Diagnostic Information

25 Xx-100, -110

Diagnostic Aids

Repair Information

25 Xx-100, -110

Locations and Connectors

25 Xx-100, -110

Preventive Maintenance

Parts Catalog

Index

Part Number Index

Quick Links

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Summary of Contents for Lexmark 25XX-100

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Table of Contents