Lexmark 2591+ Service Manual
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Lexmark 2591+ Service Manual

2500+ series
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Revision: April 3, 2012
™
Lexmark
Forms Printer 2500+ series
2580+, 2581+, 2590+, 2591+
• 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.

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  • Page 1 Forms Printer 2500+ series 2580+, 2581+, 2590+, 2591+ • 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.
  • Page 2 Lexmark, and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. Optra Forms and PrintCryption are trademarks of Lexmark International, Inc.

  • Page 3: Table Of Contents

    2580+, 2581+, 2590+, 2591+ Table of contents Previous Safety information..............vii Preface .
  • Page 4 2580+, 2581+, 2590+, 2591+ 10 beeps and blinking Ready, Paper, Font and Pitch LEDs ......2-18 Previous 3 beeps and Tractor 2 LED blinks 3 times .
  • Page 5 2580+, 2581+, 2590+, 2591+ Paper handling removals ............. 4-19 Previous Forms thickness lever removal .
  • Page 6 2580+, 2581+, 2590+, 2591+ Index ..............I-1 Previous Part number index .

  • Page 7: Safety Information

    2580+, 2581+, 2590+, 2591+ Previous 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 2580+, 2581+, 2590+, 2591+ Previous Sicherheitshinweise • Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprünglichen Modells und bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung für die Sicherheit übernommen. Next • Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen Wartungsfachmann bestimmt.
  • Page 9 2580+, 2581+, 2590+, 2591+ Previous 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 10: Preface

    2580+, 2581+, 2590+, 2591+ Preface Previous This manual contains maintenance procedures for service personnel. It is divided into the following chapters: General information contains a general description of the printer and the maintenance approach used to Next repair it. Special tools and test equipment, as well as general environmental and safety instructions, are discussed.

  • Page 11: Conventions

    2580+, 2581+, 2590+, 2591+ Previous Conventions Note: A note provides additional information. Warning: A warning identifies something that might damage the product hardware or software. Next There are several types of caution statements: CAUTION Go Back A caution identifies something that might cause a servicer harm. CAUTION This type of caution indicates there is a danger from hazardous voltage in the area of the product where you are working.
  • Page 12 2580+, 2581+, 2590+, 2591+ Previous Next Go Back Service Manual...

  • Page 13: Printer Description

    Previous Printer description Next The Lexmark™ Forms Printer 2500+ series printers 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. Go Back Printer specifications •...

  • Page 14: Tools Required For Service

    2580+, 2581+, 2590+, 2591+ Previous Tools required for service The basic tools necessary to service the 2500+ printers are: • Basic CE tool kit Next • #1 Phillips screwdriver • #2 Phillips screwdriver • Feeler gauges 0.33 mm (0.013 in.) and 0.37 mm (0.015 in.) Go Back •...

  • Page 15: Diagnostic Information

    2580+, 2581+, 2590+, 2591+ 2. Diagnostic information Previous Start Next CAUTION Unplug power cord from the electrical outlet before you connect or disconnect any cable or Go Back electronic board or assembly for personal safety and to prevent damage to the printer. Disconnect any connections between the printer and PCs/peripherals.

  • Page 16: Error Indication Table

    2580+, 2581+, 2590+, 2591+ Previous 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 Next this occurs, leave the service check and go to “Symptom check table”...
  • Page 17 2580+, 2581+, 2590+, 2591+ Previous 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 2-16. Next Power None Operator Panel Failure...

  • Page 18: Symptom Check Table

    2580+, 2581+, 2590+, 2591+ Previous Symptom check table Select the symptom that best describes the problem. Perform the appropriate action before you go to the indicated service check. Next Abnormal indications Go Back Symptom Action 7 or more lights turn on but do not turn Disconnect the interface cable from the printer and turn the printer off and off.

  • Page 19: Error Indications

    2580+, 2581+, 2590+, 2591+ Error indications Previous Symptom Action Ready and Paper Out lights blink. Turn the printer off and then back on. Next Go to “Abnormal indications” on page 2-4. Paper Out and Font Turn the printer off and then back on. lights blink.

  • Page 20: Power Problems

    2580+, 2581+, 2590+, 2591+ Previous Symptom Action Lower feed roll shaft rotates, but paper Be sure the Paper Select lever is in the correct position. does not feed. Go to “Paper feed service check” on page 2-13. Pressing FormFeed does not feed paper.

  • Page 21: Ribbon Feed Problems

    2580+, 2581+, 2590+, 2591+ Previous Symptom Action Scattered ink smearing, blurred Clean the printhead nose. characters Clean the ribbon guide and shield. Fuzzy print If the ribbon has reached its end of life or is worn, replace the ribbon Next cartridge.
  • Page 22 2580+, 2581+, 2590+, 2591+ Previous Action Check Remove the continuous forms. When Auto Ready Cut Sheet is enabled, paper feeds automatically. Set the Paper Select lever to the cut sheet position, and insert a cut sheet. When Auto Ready Cut Sheet is disabled, press FormFeed to load a cut sheet.

  • Page 23: Service Checks

    2580+, 2581+, 2590+, 2591+ Previous Service checks Abnormal noise service check Check the entire printer for loose parts. Next Step Action Go Back 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 24: Carrier Service Check

    2580+, 2581+, 2590+, 2591+ Previous Step Action Paper feed If the paper does not feed, do the following: • Remove the ASF. • Be sure the base printer feeds paper correctly. Next • If the base printer does not feed paper correctly, go to “Paper feed service check”...

  • Page 25: Intermittent Problem Service Check

    2580+, 2581+, 2590+, 2591+ Previous Step Action 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”...

  • Page 26: No Print Or Abnormal Print Service Check

    2580+, 2581+, 2590+, 2591+ Previous Step Action Printer power The cause of this problem may be that the power circuit is failing, or the wiring is intermittently open. Check the following in sequence: sometimes turns off. 1. Check the user’s outlet voltage, and be sure it is within tolerance. 2.

  • Page 27: Operator Panel Service Check

    2580+, 2581+, 2590+, 2591+ Previous Step Action Emulation mode Enter the Setup Menu, and be sure the printer is in the correct emulation mode for the computer, either IBM or Epson. Go to “Setup mode” on page 3-8. Next Operator panel service check If the operator panel is locked, only the Start/Stop, FormFeed, Tear Off, and Load/UnLoad buttons are active.
  • Page 28 2580+, 2581+, 2590+, 2591+ If the paper does not stop in the correct location, see “Paper Present sensor service check” on page 2-13 Previous and the “Top-of-forms service check” on page 2-18. Step Action Auto Sheet Feeder If the Auto Sheet Feeder is installed, remove it. Enter the Setup Menu, and reset Next ASF to off.

  • Page 29: Paper Select Sensor Service Check

    2580+, 2581+, 2590+, 2591+ Paper Select sensor service check Previous 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 3-8.

  • Page 30: Power Service Check

    2580+, 2581+, 2590+, 2591+ Power service check Previous CAUTION Always unplug the power cord before doing any continuity measurement. Next Step Action Go Back 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 J15-1, +40 V dc at J15-2 and +5 V dc at J15-6.

  • Page 31: Print Speed Service Check

    2580+, 2581+, 2590+, 2591+ Print speed service check Previous The speed of the 2500+ 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 2500+ printers and protects the printhead from overheating.

  • Page 32: Pull Tractor Sensor Service Check

    2580+, 2581+, 2590+, 2591+ Pull Tractor sensor service check Previous 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. Next Step Action...

  • Page 33: Beeps And Tractor 2 Led Blinks 3 Times

    2580+, 2581+, 2590+, 2591+ Previous Step Action Tractor 2 Remove the Tractor 2, and turn the printer off and then back on again to Home sensor determine if the fault is in the printer or Tractor 2. Next If the gear teeth chatter just before the beeps, replace the Home sensor. Go Back Logic board Remove Tractor 2 from the printer, but leave the cable connected.

  • Page 34: Tractor 2 Paper Feed Problems

    2580+, 2581+, 2590+, 2591+ Previous Step 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. Next If the slider does not move after turning the printer off and then back on: •...
  • Page 35 2580+, 2581+, 2590+, 2591+ Previous Step Action and questions Open the printer’s Web page in a Go to step 13. Go to step 5. web browser using the printer driver IP address. Next Does the web page open? Print a network configuration Go to step 6.
  • Page 36 2580+, 2581+, 2590+, 2591+ Previous Next Go Back 2-22 Service Manual...

  • Page 37: Diagnostic Aids

    2580+, 2581+, 2590+, 2591+ 3. Diagnostic aids Previous This chapter explains the tests and procedures to identify printer failures and verify if repairs have corrected the problem. The printer does not need to be connected to a computer or terminal to run these tests. Next The tests include the following: •...

  • Page 38: Print Test

    2580+, 2581+, 2590+, 2591+ Previous Print test The Print test helps you test and troubleshoot the printer. To start the Print test: Paper must be at the print position; the test does not print if paper is parked. Next Press and hold Line Feed, and turn the printer on. Release Line Feed when the printing starts.

  • Page 39: Printer Default Settings

    2580+, 2581+, 2590+, 2591+ Previous Printer default settings U.S. defaults To initialize or reset the printer to the U.S. factory defaults: Next (Code page 437, Character Set 1, form length 11 inch) Make sure paper and the ribbon cartridge are installed. Go Back Turn the printer off.

  • Page 40: Clearing Paper Jams

    2580+, 2581+, 2590+, 2591+ Previous Clearing paper jams Cut sheet jams To clear cut form paper jams: Next Turn the printer off. Set the Forms Thickness lever to position 7. Go Back Push the Paper Select lever down to the continuous forms position. Gently pull out the sheet of paper from the front of the printer.

  • Page 41: Web Page At A Glance

    2580+, 2581+, 2590+, 2591+ Previous 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 42: Flashing Firmware

    2580+, 2581+, 2590+, 2591+ • Device information Previous General device information is displayed here. Next Go Back 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: Open the Configuration page of the web server.

  • Page 43: Resetting The Ina To Factory Defaults

    2580+, 2581+, 2590+, 2591+ To import the INA settings, perform the following tasks: Previous Click the import settings link from the Configuration page. The following page will display: Next Go Back Click the Browse button, and search for the file to import. When the file is found, click Submit.

  • Page 44: Setup Mode

    2580+, 2581+, 2590+, 2591+ Previous Setup mode Entering Setup mode Open the operator panel cover to access layer two. Next Press Setup to put the printer in Setup mode and print the Main Menu. Press LineFeed to print a list of all the available options. Select any option from the Main Menu by pressing the corresponding button.
  • Page 45 2580+, 2581+, 2590+, 2591+ Previous Menu Function Data speed • 300 bps • 600 bps • 1200 bps • 2400 bps Next • 4800 bps • 9600 bps • 19200 bps Go Back Data bits 7, 8 Parity No, Ignore, Odd, Even Stop bits 1, 2 Protocol...

  • Page 46: Setting The Tear Off Position

    2580+, 2581+, 2590+, 2591+ Previous 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 Next position, when all of the following are true: •...

  • Page 47: Printing A Network Setup Page

    2580+, 2581+, 2590+, 2591+ Close the operator panel cover. Previous Press Start/Stop to set the printer online. 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 Next printer address.
  • Page 48 2580+, 2581+, 2590+, 2591+ Previous Next Go Back 3-12 Service Manual...

  • Page 49: Repair Information

    2580+, 2581+, 2590+, 2591+ 4. Repair information Previous Warning: Read the following before handling electronic parts. Next Handling ESD-sensitive parts Go Back Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent damage to ESD-sensitive parts, use the following instructions in addition to all the usual precautions, such as turning off power before removing logic boards: •...

  • Page 50: Adjustments

    2580+, 2581+, 2590+, 2591+ Previous Adjustments CAUTION Be sure to unplug the power cord whenever you are working on the printer with one of the covers removed. Next Printhead-to-platen gap adjustment Go Back 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.

  • Page 51: Bidirectional Print Adjustment

    2580+, 2581+, 2590+, 2591+ After adjusting both left and right Gap Adjust bushings, push the printhead to the center of the platen and Previous verify that a gap of 0.33–0.37 mm exists between the printhead and the platen. Note: For maximum print quality, adjust the head gap on both the left and right sides of the printer to within +/- 0.01mm.

  • Page 52: Cover Removals

    2580+, 2581+, 2590+, 2591+ Previous Cover removals Covers, bottom removal Remove the rear cover. See “Covers, rear removal” on page 4-5. Next Remove the top cover. Go to “Covers, top removal” on page 4-5. Remove the logic board. Go to “Logic board removal”...

  • Page 53: Covers, Rear Removal

    2580+, 2581+, 2590+, 2591+ Covers, rear removal Previous From the bottom, pull the rear cover (A) outward and up, removing it from the printer. Next Go Back Covers, ribbon access removal 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 54 2580+, 2581+, 2590+, 2591+ Remove the rear cover. See “Covers, rear removal” on page 4-5. Previous Note: With the option cover removed, you can see the operator panel cable attached to the logic board. Remove the two screws (A) from each side of the front cover area. Next Go Back Turn the printer upside down.
  • Page 55 2580+, 2581+, 2590+, 2591+ Turn the printer right side up, and insert a flat-blade screwdriver into each of the two holes (C) in the back Previous of the top cover. Next Go Back Remove the rear cover. See “Covers, rear removal” on page 4-5.

  • Page 56: Electronics Removals

    2580+, 2581+, 2590+, 2591+ Previous Electronics removals INA support frame removal Remove the rear cover. See “Covers, rear removal” on page 4-5. Next Remove the top cover. Go to “Covers, top removal” on page 4-5. Remove the network card. Go to “Network card removal”...

  • Page 57: Network Card Removal

    2580+, 2581+, 2590+, 2591+ Remove the remaining screw (A) securing the logic board to the bottom cover. Previous Next Go Back Ease the logic board off the printer and remove. Note: Be sure to perform the bidirectional print adjustment after installing the logic board. See “Bidirectional print adjustment”...

  • Page 58: Power Supply Removal

    2580+, 2581+, 2590+, 2591+ Power supply removal Previous CAUTION The power supply may be hot. Next CAUTION Go Back The capacitors may still have a residual charge. Be careful not to touch the terminals of the capacitor. Remove the rear cover. See “Covers, rear removal”...
  • Page 59 2580+, 2581+, 2590+, 2591+ Disconnect the power supply cable (A) from the power supply, and remove. Previous Next Go Back 4-11 Repair information...

  • Page 60: Carrier Removals

    2580+, 2581+, 2590+, 2591+ Previous Carrier removals Carrier removal Remove the ribbon access cover. See “Covers, ribbon access removal” on page 4-5. Next Remove the printhead assembly. See “Printhead removal” on page 4-24. Remove the rear cover. See “Covers, rear removal” on page 4-5.
  • Page 61 2580+, 2581+, 2590+, 2591+ Tighten the tension screw (C). Loosening the screw tightens the belt. Previous Next Go Back Remove the retaining wire (D) from the left side of the carrier shaft. Remove the lower carrier motor mount screw (E). 4-13 Repair information...
  • Page 62 2580+, 2581+, 2590+, 2591+ Remove the two screws (F) from the carrier shaft bushing bracket on the left end of the carrier shaft, and Previous then remove the bracket. Next Go Back Remove the E-clip from the right side of the carrier shaft. Push the carrier shaft (G) from the right side so it goes out of the left side of the printer.

  • Page 63: Carrier Fan Removal

    2580+, 2581+, 2590+, 2591+ Lift the carrier at the angle shown, and carefully remove the carrier from the printer. Previous Next Go Back Note: Following replacement, perform the printhead-to-platen gap adjustment. Go to “Printhead-to-platen gap adjustment” on page 4-2. Carrier fan removal Remove the rear cover.

  • Page 64: Carrier Motor Assembly Removal

    2580+, 2581+, 2590+, 2591+ Remove the screw (B), then ease the carrier fan off the printer. Previous Next Go Back Carrier motor assembly removal Remove the rear cover. See “Covers, rear removal” on page 4-5. Remove the top cover. See “Covers, top removal”...
  • Page 65 2580+, 2581+, 2590+, 2591+ Disconnect the printhead cables (B) from the logic board, and move it back and out of the way. Previous Next Go Back Disconnect the carrier motor cable (J2) from the logic board. Loosen the screw (D) holding the left side of the print unit. 4-17 Repair information...
  • Page 66 2580+, 2581+, 2590+, 2591+ Loosen the two screws (E) from the right side of the print unit. Previous Next Go Back Remove the screw (F) securing the bracket to the grommet. Remove the three screws (G) securing the carrier motor bracket to the print unit. 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.

  • Page 67: Paper Handling Removals

    2580+, 2581+, 2590+, 2591+ Previous Paper handling removals Forms thickness lever removal Remove the rear cover. See “Covers, rear removal” on page 4-5. Next Remove the top cover. Go to “Covers, top removal” on page 4-5. Remove the screw (A) from the lever, and then remove the forms thickness lever. Go Back Paper feed motor removal Remove the rear cover.

  • Page 68: Paper Select Lever Removal

    2580+, 2581+, 2590+, 2591+ Remove the two screws (A) from the paper feed motor bracket. Previous Next Go Back Remove the motor. Disconnect the paper feed motor cable from the logic board. Paper select lever removal Remove the rear cover. See “Covers, rear removal”...

  • Page 69: Print Handling Removals

    2580+, 2581+, 2590+, 2591+ Previous Print handling removals Platen removal Remove the top cover. Go to “Covers, top removal” on page 4-5. Next Remove the two platen screws (A) from each end of the platen. Go Back Remove the platen from the paper tray. Perform the printhead-to-platen gap adjustment.
  • Page 70 2580+, 2581+, 2590+, 2591+ Disconnect all cables from the logic board, except the power supply cable (A). Previous Next Go Back Remove the two grommet-anchored screws (B) from the left side of the print unit. 4-22 Service Manual...
  • Page 71 2580+, 2581+, 2590+, 2591+ Remove the two grommet-anchored screws (C) from the right side of the print unit. Previous Next Go Back Remove the two ground screws (D) from the right side of the print unit. 4-23 Repair information...

  • Page 72: Printhead Removal

    2580+, 2581+, 2590+, 2591+ Remove the ground screw (E) from the left side of the print unit. Previous Next Go Back Remove the print unit from the bottom cover by pulling up forcefully on both sides of the print unit. Printhead removal Remove the ribbon access cover.

  • Page 73: Printhead Cable Removal

    2580+, 2581+, 2590+, 2591+ Disconnect the two cables (B) and remove the printhead. Previous Next Go Back Note: Be sure the printhead cables are correctly aligned and secured. Be sure to perform the printhead-to- platen gap adjustment. See “Printhead-to-platen gap adjustment” on page 4-2.

  • Page 74: Ribbon Drive Rack Gear Removal

    2580+, 2581+, 2590+, 2591+ Unplug the two connectors (C) from the logic board and ease the cable off the printer. Previous Next Go Back Note: Be sure the printhead cables are correctly aligned and secured. They must be flat with no twists. Ribbon drive rack gear removal Remove the rear cover.

  • Page 75: Gears Removals

    2580+, 2581+, 2590+, 2591+ Previous Gears removals Left side gears removal Remove the rear cover. See “Covers, rear removal” on page 4-5. Next Remove the top cover. Go to “Covers, top removal” on page 4-5. Remove the three screws (A) from the serial interface card bracket. Go Back Remove the four screws (B) from the paper feed motor bracket assembly.

  • Page 76: Right Side Gears, Sub Frame Removal

    2580+, 2581+, 2590+, 2591+ Remove the paper feed motor bracket assembly, exposing the gears as shown. Previous Next Go Back Right side gears, sub frame removal Remove the rear cover. See “Covers, rear removal” on page 4-5. Remove the top cover. Go to “Covers, top removal”...
  • Page 77 2580+, 2581+, 2590+, 2591+ Remove the sub frame, exposing the right side gears (D) as shown. Previous Next Go Back 4-29 Repair information...

  • Page 78: Rollers Removals

    2580+, 2581+, 2590+, 2591+ Previous Rollers removals Roller, upper feed removal Remove the rear cover. See “Covers, rear removal” on page 4-5. Next Remove the top cover. Go to “Covers, top removal” on page 4-5. Remove the screw from the print cable shield, and then remove the shield. Remove the gear from the left end of the upper feed roller, as shown.

  • Page 79: Roller, Lower Pinch Removal

    2580+, 2581+, 2590+, 2591+ Roller, lower pinch removal Previous Remove the rear cover. See “Covers, rear removal” on page 4-5. Remove the top cover. Go to “Covers, top removal” on page 4-5. Slide the carrier to the far left of the printer. Remove the four screws (A) from the paper feed motor bracket.
  • Page 80 2580+, 2581+, 2590+, 2591+ Unhook the spring clip (B) from the right end of the lower pinch roller shaft, and then push it off the gray Previous slotted spring block (C) toward the back of the printer, as shown. Next Go Back Slide the carrier to the right side of the printer.

  • Page 81: Roller, Lower Feed Removal

    2580+, 2581+, 2590+, 2591+ While holding the lower pinch roller shaft by the gear (F), move the shaft to the left approximately one-half Previous inch. Lift the shaft up and to the back of the printer, and then carefully remove the lower pinch roller and shaft.

  • Page 82: Sensor Removals

    2580+, 2581+, 2590+, 2591+ Previous Sensor removals Flags, Paper Present/Top-of-form removal Remove the lower feed roller. Go to “Roller, lower feed removal” on page 4-33. Next Remove the Paper Present flag or the Top-of-form flag from the paper guide. Sensor (head gap and home position) Go Back Remove the rear cover.

  • Page 83: Sensor (Pull Tractor And Paper Select) Removal

    2580+, 2581+, 2590+, 2591+ Remove the screw (C) securing the head gap sensor. Previous Next Go Back Ease the sensor (head gap and home position) off the printer, and remove. Note: Pay attention to the original routing of the cable. Sensor (pull tractor and paper select) removal Remove the rear cover.

  • Page 84: Sensor (Top-Of-Form And Paper Present) Removal

    2580+, 2581+, 2590+, 2591+ Sensor (top-of-form and paper present) removal Previous Remove the rear cover. See “Covers, rear removal” on page 4-5. Remove the top cover. See “Covers, top removal” on page 4-5. Remove the INA support frame. See “INA support frame removal” on page 4-8.

  • Page 85: Options Removals

    2580+, 2581+, 2590+, 2591+ Previous Options removals Auto Sheet Feeder gears removal Remove the right cover. Next Release the joint gear latch (A) and remove the joint gear. Go Back Release the idler gear latch, and remove the idler gear. Release the pick-up gear latch, and remove the pick-up gear.

  • Page 86: Auto Sheet Feeder Pick-Up Roller Removal

    2580+, 2581+, 2590+, 2591+ Auto Sheet Feeder pick-up roller removal Previous Remove the covers and the cut sheet support. Release the joint gear latch (A), and remove the joint gear, idler gear, and pick-up gear. Next Go Back Remove the left and right roller bushings. Move the pick-up rollers to the ends of the shaft, and then remove them.

  • Page 87: Connector Locations

    2580+, 2581+, 2590+, 2591+ 5. Connector locations Previous Logic board Next Go Back Note: On the logic board, a white square usually marks the location of pin 1 on a cable. Connector locations...

  • Page 88: Logic Board Connections

    2580+, 2581+, 2590+, 2591+ Logic board connections Previous Connector Connects to number Printhead Next Carrier motor Sensor (pull tractor and paper select) Go Back Sensor (head gap and home position) Sensor (top-of-form and paper present) Parallel interface Operator panel Power supply Carrier fan Printhead Paper feed motor...

  • Page 89: Operator Panel Outputs (9W And 24W)

    2580+, 2581+, 2590+, 2591+ At connector J10 Previous Pin # Output Power Gnd + 5 V dc Next TR2MON D_SET Go Back Signal Gnd TR2MA TR2MB D_HP D_POS Operator panel outputs (9w and 24w) At connector J13 Pin # Output Signal Gnd SCLK Signal Gnd...

  • Page 90: Parallel Interface Outputs (9W And 24W) At Connector J11

    2580+, 2581+, 2590+, 2591+ Parallel interface outputs (9w and 24w) at connector J11 Previous At connector J11 Output Output Next Strobe Signal Gnd Data 0 Signal Gnd Go Back Data 1 Signal Gnd Data 2 Signal Gnd Data 3 Signal Gnd Data 4 Signal Gnd Data 5...

  • Page 91: Printhead Outputs (24W)

    2580+, 2581+, 2590+, 2591+ Printhead outputs (24w) Previous At connector J1 Output Output Next DH2-C DH23-D DH14-D DH19-C Go Back DH6-C DH3-D DH18-D DH15-C DH10-C DH7-D DH10-D DH11-C DH14-C DH11-D DH6-D DH7-C DH18-C DH15-D DH2-D DH3-C DH22-C DH19-D DN22-D + 3.3 V dc DH23-C HDTHERMO At connector J18...

  • Page 92: Sensor (Head Gap And Home Position) Outputs (9W And 24W)

    2580+, 2581+, 2590+, 2591+ At connector J1 Previous Output Output DH2-C DH1-D Next DH8-D DH7-C DH4-C DH3-D Go Back DH4-D DH5-C DH6-C DH5-D DH2-D DH3-C DH8-C DH7-D DH1-C DH9-C DH9-D + 3.3 V dc HDTHERMO Sensor (head gap and home position) outputs (9w and 24w) At connector J4 Pin # Output...

  • Page 93: Serial Board Outputs (9W And 24W)

    2580+, 2581+, 2590+, 2591+ At connector J5 Previous Pin # Output Next Signal Gnd Serial board outputs (9w and 24w) Go Back At connector J200 Pin # Output +5 V dc +5 V dc Signal Gnd SBSET USB outputs (9w and 24w) At connector J12 Pin # Output...
  • Page 94 2580+, 2581+, 2590+, 2591+ Previous Next Go Back Service Manual...

  • Page 95: Preventive Maintenance

    2580+, 2581+, 2590+, 2591+ 6. Preventive maintenance Previous This chapter describes procedures for printer preventive maintenance. Follow these recommendations to help prevent problems and maintain optimum performance. Next Lubrication Go Back Warning: Petroleum-based lubricants can attack polycarbonate parts, causing premature failure. Use only mineral oil-based lubricants.
  • Page 96 2580+, 2581+, 2590+, 2591+ Previous Lubrication points (oil) Description Position Next The oil felt (1) in the carrier block Go Back The tractor shaft (1) Lubrication points (grease) Description Position Gear mounting studs on the right side frame (2) Service Manual...
  • Page 97 2580+, 2581+, 2590+, 2591+ Lubrication points (grease) Previous Description Position The lower pinch roller Next Go Back Gear mounting studs on the left side frame (2) Gear mounting studs on the left ASF side frame Preventive maintenance...
  • Page 98 2580+, 2581+, 2590+, 2591+ Lubrication points (grease) Previous Description Position Gear mounting studs on the right ASF side frame Next Go Back Service Manual...

  • Page 99: Parts Catalog

    PP: (Parts Packet) in the parts description column indicates the part is contained in a parts packet. • Model information used in the parts catalog: Machine Short Long Model name 9-Wire 24-Wire Network type carriage carriage Lexmark 2580+ Forms Printer 2580n+ 2500+ series 2581+ 2581n+ 2590+ 2590n+ 2591+ 2591n+ Parts catalog...

  • Page 100: Assembly 1: Covers

    2580+, 2581+, 2590+, 2591+ Assembly 1: Covers Previous Next Go Back Service Manual...
  • Page 101 2580+, 2581+, 2590+, 2591+ Assembly 1: Covers Previous Asm- Part Description Index number 40X2912 Guide, left paper Next 40X2992 Cover assembly, front unit (2580, 2590) 40X8449 Cover assembly—flint gray, front unit (2580, 2590) 40X2993 Cover assembly, front unit (2581, 2591) Go Back 40X2913 Guide, right paper...
  • Page 102 2580+, 2581+, 2590+, 2591+ Assembly 1 (continued): Covers Previous Next Go Back Service Manual...
  • Page 103 2580+, 2581+, 2590+, 2591+ Assembly 1: Covers Previous Asm- Part Description Index number 40X7984 Cable, operator panel Next 40X2994 Cover, front guide (2580, 2590) 40X2995 Cover, front guide (2581, 2591) 40X2897 Cover, operator panel front with overlay packs Go Back 40X8473 Cover—flint gray, operator panel front with overlay packs...

  • Page 104: Assembly 2: Carrier/Paper Feed (Right Side)

    2580+, 2581+, 2590+, 2591+ Assembly 2: Carrier/paper feed (right side) Previous Next Go Back Service Manual...
  • Page 105 2580+, 2581+, 2590+, 2591+ Assembly 2: Carrier/paper feed (right side) Previous Asm- Part Description Index number 40X2887 Carrier roller set Next 40X7985 Printhead assembly (2580, 2581) 40X7986 Printhead assembly (2590, 2591) 40X7987 Carrier unit (2580/2590) Go Back 40X7988 Carrier unit (2581/2591) 40X7991 Cable, printhead (2580) 40X7992...

  • Page 106: Assembly 3: Carrier/Paper Feed (Left Side)

    2580+, 2581+, 2590+, 2591+ Assembly 3: Carrier/paper feed (left side) Previous Next Go Back Service Manual...
  • Page 107 2580+, 2581+, 2590+, 2591+ Assembly 3: Carrier/paper feed (left side) Previous Asm- Part Description Index number 40X2910 Gears and bushings, parts packet (258X) Next 40X2926 Screws, washers and clips, parts packet 40X2931 Kit, pull tractor actuator 40X2967 Frame, left side (2590, 2591) Go Back 40X3008 Plate, frame support (2581, 2591)

  • Page 108: Assembly 4: Electronics

    2580+, 2581+, 2590+, 2591+ Assembly 4: Electronics Previous Next Go Back 7-10 Service Manual...
  • Page 109 2580+, 2581+, 2590+, 2591+ Assembly 4: Electronics Previous Asm- Part Description Index number 40X2926 Screws, washers and clips, parts packet Next 40X8011 Power supply unit 40X8071 Board, logic (2580) 40X8073 Board, logic (2581) Go Back 40X8075 Board, logic (2590) 40X8077 Board, logic (2591) 40X2903 Bracket, serial interface card...

  • Page 110: Assembly 5: Asf-Roller/Support

    2580+, 2581+, 2590+, 2591+ Assembly 5: ASF—Roller/support Previous Next Go Back 7-12 Service Manual...
  • Page 111 2580+, 2581+, 2590+, 2591+ Assembly 5: ASF—Roller/support Previous Asm- Part Description Index number 40X2888 Roller, ASF upper feed (2580, 2590) Next 40X3023 Roller, ASF upper feed (2581, 2591) 40X2889 Roller, ASF lower feed (2580, 2590) 40X2984 Roller, ASF pick-up left and right (2580, 2590) Go Back 40X2985 Roller, ASF pick-up left and right (2581, 2591)

  • Page 112: Assembly 6: Asf-Gears/Screws

    2580+, 2581+, 2590+, 2591+ Assembly 6: ASF—gears/screws Previous Next Go Back 7-14 Service Manual...
  • Page 113 2580+, 2581+, 2590+, 2591+ Assembly 6: ASF—gears/screws Previous Asm- Part Description Index number 40X2890 ASF gears and bushings, parts packet Next 40X2892 ASF screws, parts packet Go Back 7-15 Parts catalog...

  • Page 114: Assembly 7: Tractor 2 Option

    2580+, 2581+, 2590+, 2591+ Assembly 7: Tractor 2 option Previous Next Go Back 7-16 Service Manual...
  • Page 115 2580+, 2581+, 2590+, 2591+ Assembly 7: Tractor 2 option Previous Asm- Part Description Index number 40X2918 Kit, tractors left and right Next 40X2882 Parts packet, Tractor 2 40X2880 Motor, Tractor 2 40X2961 Board assembly with cable and ferrite, Tractor 2 Go Back (2581, 2591) 7-17...
  • Page 116 2580+, 2581+, 2590+, 2591+ Previous Next Go Back 7-18 Service Manual...
  • Page 117 2580+, 2581+, 2590+, 2591+ Index Previous Next acronyms Operator errors Adjustments Irrecoverable Bidirectional print options Go Back Printhead-to-platen gap Paper jams Principles of operation Clearing continuous forms Clearing cut sheet ii-xi conventions Parts 7-12 Roller/support Defaults 7-14 Side Frame/covers U.S. 7-10 Carrier/paper feed left side World Trade...
  • Page 118 2580+, 2581+, 2590+, 2591+ 4-19 Paper feed motor Previous 4-20 Paper Select lever Voltage, ground, and continuity 4-21 Platen 4-21 Print unit 4-24 Printhead 4-25 Printhead cable Next 4-26 Ribbon drive rack gear 4-28 Right side sub frame Rollers 4-33 Lower feed Go Back 4-31...
  • Page 119 2580+, 2581+, 2590+, 2591+ Part number index Previous Description Page Next 40X0271 Power cord—Malaysia, Singapore, United Kingdom - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40X0274 Power cord—Switzerland - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40X0275...
  • Page 120 2580+, 2581+, 2590+, 2591+ 40X2979 Roller, upper feed (2581, 2591) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Previous 40X2980 Sub frame, right side - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 121 2580+, 2581+, 2590+, 2591+ 40X8070 Cable, power supply (2581, 2591) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11 Previous 40X8071...
  • Page 122 2580+, 2581+, 2590+, 2591+ Previous Next Go Back Service Manual...

This manual is also suitable for:

2590+2581+2580+

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