Lexmark 2580+ Service Manual Download Page 1

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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.

Revision:

April 3, 2012

Summary of Contents for 2580+

Page 1: ...1 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 Revision April 3 2012 ...

Page 2: ...y obligation to you References in this publication to products programs or services do not imply that the manufacturer intends to make these available in all countries in which it operates Any reference to a product program or service is not intended to state or imply that only that product program or service may be used Any functionally equivalent product program or service that does not infringe...

Page 3: ...Operator panel problems 2 5 Paper feed problems 2 5 Power problems 2 6 Print quality problems 2 6 Ribbon feed problems 2 7 Unable to print on network 2 7 Irrecoverable operator errors 2 7 Paper Present sensor 2 7 Paper Select sensor 2 7 Service checks 2 9 Abnormal noise service check 2 9 Auto Sheet Feeder ASF service check 2 9 Auto Sheet Feeder principles of operation 2 9 Carrier service check 2 1...

Page 4: ...7 Setup mode 3 8 Entering Setup mode 3 8 Exiting Setup mode 3 8 Setup menu options 3 8 Interface menu options 3 8 Setting the tear off position 3 10 Setting Top of form continuous pull mode 3 10 Setting Top of form cut forms envelopes 3 10 Printing a network setup page 3 11 Repair information 4 1 Handling ESD sensitive parts 4 1 Removal procedures 4 1 Adjustments 4 2 Printhead to platen gap adjust...

Page 5: ...ller removal 4 38 Connector locations 5 1 Logic board 5 1 Logic board connections 5 2 Carrier fan outputs 9w and 24w 5 2 Carrier motor outputs 9w and 24w 5 2 Dual tractor outputs 92 and 24w 5 2 Operator panel outputs 9w and 24w 5 3 Paper feed motor outputs 9w and 24w 5 3 Parallel interface outputs 9w and 24w at connector J11 5 4 Power supply outputs 5 4 Printhead outputs 24w 5 5 Printhead outputs ...

Page 6: ...vi 2580 2581 2590 2591 Go Back Previous Next Index I 1 Part number index I 3 ...

Page 7: ... agréées Les consignes d entretien et de réparation de ce produit s adressent uniquement à un personnel de maintenance qualifié Le démontage et l entretien de ce produit pouvant présenter certains risques électriques le personnel d entretien qualifié devra prendre toutes les précautions nécessaires ATTENTION Ce symbole indique la présence d une tension dangereuse dans la partie du produit sur laqu...

Page 8: ...a información sobre el mantenimiento de este producto está dirigida exclusivamente al personal cualificado de mantenimiento Existe mayor riesgo de descarga eléctrica y de daños personales durante el desmontaje y la reparación de la máquina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias PRECAUCIÓN este símbolo indica que el voltaje de la parte del eq...

Page 9: ...iment d aquest producte està orientada exclusivament a professionals i no està destinada a ningú que no ho sigui El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de servei d aquest producte El personal professional ha d estar ne assabentat i prendre les mesures convenients PRECAUCIÓ aquest símbol indica que el voltatge de la part de l equip amb la qual e...

Page 10: ...f printer problems 4 Repair information provides instructions for making printer adjustments and removing and installing FRUs 5 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 ...

Page 11: ...on statements CAUTION 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 Unplug the product before you begin or use caution if the product must receive power in order to perform the task CAUTION This type of caution indicates a hot surface CAUTION This type ...

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Page 13: ...dard ribbon life 4 million characters High yield ribbon life 8 million characters Printer life 5 years Power consumption 38 watts maximum 9 watts idle Models The Lexmark 2500 printers are available in the following models Memory Standard DRAM 512 KB Standard Flash 2 MB Options and features The 2500 printers support the following options Automatic Sheet Feeder ASF Internal serial interface RS232 OK...

Page 14: ...sheet feeder CPU Central processing unit EPROM Erasable Programmable Read Only Memory ESD Electrostatic discharge FRU Field replaceable unit HTTP Hypertext transport protocol HV High voltage LED Light emitting diode LV Low voltage MFP Multifunction Printer mm Millimeter NIC Network interface card NVRAM Nonvolatile Random Access Memory POST Power On Self Test RAM Random access memory ROM Read only ...

Page 15: ...World Trade printers the voltage is according to each country s specification Ground checks To check for a correct ground measure the voltage between the ground and a known good voltage source The voltage measurement must be the same as the source voltage to consider that the ground is correct Continuity measurements may be used to check grounds however be sure to measure to a known good ground us...

Page 16: ... Font Lock ON Blinking Blinking Blinking Blinking Beeps 10 times Home Position Error Go to Carrier service check on page 2 10 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 18 None Home Position Error Without Alarm Go to Power ...

Page 17: ...ractor 2 Paper Out Panel Lock Font Lock ON OFF OFF OFF OFF None Operator Panel Failure Go to Operator panel service check on page 2 13 Any LED on and Power LED off None Go to Operator panel service check on page 2 13 The Power LED blinks or changes intensity None Go to Power service check on page 2 16 Power Ready Font Lock ON Blinking Blinking None Ethernet option not installed Go to Network servi...

Page 18: ... for binds or damage Go to Carrier service check on page 2 10 During idling abnormal noise comes from the printer Abnormal noise when feeding paper Abnormal noise during printing or POST Go to Abnormal noise service check on page 2 9 Symptom Action Printer will not print or become ready Abnormal operation incorrect characters or incorrect line width Printer is ready but will not print from the com...

Page 19: ...he printer and the ASF is not installed Print operation starts without paper Be sure the paper present sensor is not blocked Go to Paper Present sensor service check on page 2 13 The Load Unload button does not function when the push tractor is installed Form feed length is not correct The Load Unload button functions when cut sheets are being used Be sure the Paper Select lever is in the correct ...

Page 20: ...tion No print but the carrier moves as if printing 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 17 Print density is light Turn the ribbon advance knob on the print cartridge from 1 to 2 to increase the...

Page 21: ...r 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 10 Symptom Action Ribbon comes off becomes loose or folded or jams Ribbon feeds correctly but is noisy Check the ribbon cartridge for binds or damage Go to Carrier service check on page 2 10 Symptom Action Unable to print on the network...

Page 22: ... 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 15 Action Check ...

Page 23: ...tack 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 pape...

Page 24: ... 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 ca...

Page 25: ...d and shielded 3 Intermittently low voltages Check for ac and all dc voltages and short circuits on the logic board a Check the user s outlet voltage and ensure that it is within tolerance b Check the continuity of the power cord c Disconnect the power supply cable from connector J15 on the logic board Turn the printer power on and check all dc output voltages at J15 1 J15 2 and J15 6 Verify the f...

Page 26: ...4 The previous suggestions have not corrected the problem 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 ...

Page 27: ...at connectors J13 1 and J13 3 Replace the operator panel cable or the power cable as necessary 2 Operator panel If the problem remains replace the operator panel Step FRU Action 1 Paper Present sensor 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 ...

Page 28: ...ng 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 13 5 Paper feed motor Check if the paper feed motor cable J19 is properly seated Check the continuity of the cable Disconnect the paper feed motor cable J19 from the logic b...

Page 29: ...n 1 and disconnect the short flexible cable from J3 on the logic board Check the continuity between J3 3 paper select sensor and J3 4 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 3 2 Pull Tractor sensor A failed Pull Tractor sensor can cause the Load Unl...

Page 30: ...t the carrier motor from logic board J2 and turn the printer off and then back on If the Power LED lights correctly only with the carrier motor disconnected replace the carrier motor 4 Paper feed motor Disconnect the paper feed motor from logic board J19 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 mo...

Page 31: ...llowing pin locations J4 3 and J4 4 J4 4 and J4 5 Place the Forms Thickness lever in positions 2 and 3 and verify continuity at the following pin location J4 3 and J4 4 Verify that there is no continuity at Forms Thickness lever positions 4 through 7 Step FRU Action 1 Printhead cables Printhead If the printout contains missing or extra dots or lines do the following Check the continuity and connec...

Page 32: ...ile 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 J3 from the logic board There should be continuity from J3 1 and J3 2 when the left pull tractor actuator is pressed and infinite resist...

Page 33: ...er 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 J10 1 The upper right pin at J10 is pin 1 40 V dc and the pin just beneath it is pin 5 5 V dc If these voltages are not pre...

Page 34: ... 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 Wh...

Page 35: ...e problem Problem solved Go to step 8 8 Replace the LAN card Did this fix the problem Problem solved Replace the main board 9 Check the cable connected to CN15 on the main board Is the cable connected properly Go to step 10 Properly connect the cables 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...

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Page 37: ...that the CPU can write read the RAM Font ROM Microcode Sum Test Checks that the ROM data is correct Timer Interrupt Controller Test Checks that this function works NVRAM Test Checks that the NVRAM data is correct Switch Scan Test Checks the buttons on operator panel Carrier Initialization Carrier moves to the left to activate the Home Position sensor and then moves to the first print position Feed...

Page 38: ...tal lines at the top of the sample are a test of each printhead wire numbered in sequence from top to bottom 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 mod...

Page 39: ...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 p...

Page 40: ...he proper setting for the type of paper you are using Refer to the 2500 User s Guide Continuous forms jams 1 Turn the printer off 2 Detach any continuous forms already printed 3 Set the forms thickness lever to position 7 4 Tear the continuous forms off at the perforation line before the forms enter the printer 5 If you are using the tractor in the push position open the front cover Skip this step...

Page 41: ...sers 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 ...

Page 42: ...uration 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 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 Ex...

Page 43: ...ck 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 10 15 seconds while the...

Page 44: ...p 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 Setup menu options Interface 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 printe...

Page 45: ...80 2581 2590 2591 Go Back Previous Next Data speed 300 bps 600 bps 1200 bps 2400 bps 4800 bps 9600 bps 19200 bps Data bits 7 8 Parity No Ignore Odd Even Stop bits 1 2 Protocol XON XOFF MultiXON XOFF DTR Pacing Menu Function ...

Page 46: ...s 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 ...

Page 47: ... 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 ...

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Page 49: ... path from your body through the ESD sensitive part Large metal objects can be discharge paths without being grounded Prevent ESD sensitive parts from being accidentally touched by other personnel Install machine covers when you are not working on the machine and do not put unprotected ESD sensitive parts on a table If possible keep all ESD sensitive parts in a grounded metal cabinet case Be extra...

Page 50: ...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 8 Using a feeler gauge 1 slowly adjust the left Gap Adjust bush...

Page 51: ...se 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 01 11 6 Press Mi...

Page 52: ...hes from the bottom of the printer 2 Push the front cover up and out of the printer Covers operator panel assembly removal 1 Remove the rear cover See Covers rear removal on page 4 5 2 Remove the top cover Go to Covers top removal on page 4 5 3 Disconnect the operator panel cable from the operator panel card on the inside of the top cover 4 Push down on the two latches A at the top of the operator...

Page 53: ...lacing 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 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...

Page 54: ...te With the option cover removed you can see the operator panel cable attached to the logic board 6 Remove the two screws A from each side of the front cover area 7 Turn the printer upside down 8 Insert a flat blade screwdriver into each of the four holes B in the bottom cover releasing the top cover from the bottom cover B ...

Page 55: ...the rear cover See Covers rear removal on page 4 5 11 Disconnect the operator panel cable D from the logic board 12 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...

Page 56: ...hre screws A then remove the INA support frame Note To avoid printer alignment issues make sure that the screw is not too tight when reinstalling the INA support frame Logic board removal 1 Remove the rear cover See Covers rear removal on page 4 5 2 Remove the top cover See Covers top removal on page 4 5 3 Remove the INA support frame See INA support frame removal on page 4 8 4 Disconnect all cabl...

Page 57: ... perform the bidirectional print adjustment after installing the logic board See Bidirectional print adjustment on page 4 3 Network card removal 1 Remove the top cover Go to Covers top removal on page 4 5 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 pr...

Page 58: ...unit removal on page 4 21 5 Remove the power supply cable See Power supply cable removal on page 4 10 6 Remove the three screws then remove the power supply Power supply cable removal 1 Remove the rear cover See Covers rear removal on page 4 5 2 Remove the top cover See Covers top removal on page 4 5 3 Disconnect the power supply cable A from the logic board CAUTION The power supply may be hot CAU...

Page 59: ...Repair information 4 11 2580 2581 2590 2591 Go Back Previous Next 4 Disconnect the power supply cable A from the power supply and remove A ...

Page 60: ...move the rear cover See Covers rear removal on page 4 5 4 Remove the top cover See Covers top removal on page 4 5 5 Remove the forms thickness lever See Forms thickness lever removal on page 4 19 6 Remove the clip A holding the printhead cable Note Pay attention to how the ends B of the clip are engaged to the carrier slots 7 Loosen the carrier belt 7 1 Loosen the tension screw C 7 2 Remove tensio...

Page 61: ...0 2581 2590 2591 Go Back Previous Next 7 3 Tighten the tension screw C Loosening the screw tightens the belt 8 Remove the retaining wire D from the left side of the carrier shaft 9 Remove the lower carrier motor mount screw E C D ...

Page 62: ...wo screws F from the carrier shaft bushing bracket on the left end of the carrier shaft and then remove the bracket 11 Remove the E clip from the right side of the carrier shaft 12 Push the carrier shaft G from the right side so it goes out of the left side of the printer F E G ...

Page 63: ...rom the printer Note Following replacement perform the printhead to platen gap adjustment Go to Printhead to platen gap adjustment on page 4 2 Carrier fan removal 1 Remove the rear cover See Covers rear removal on page 4 5 2 Remove the top cover See Covers top removal on page 4 5 3 Disconnect the carrier fan cable A from the logic board A ...

Page 64: ...ers top removal on page 4 5 3 Remove the sensor head gap and home position See Sensor head gap and home position on page 4 34 4 Remove the forms thickness lever See Forms thickness lever removal on page 4 19 5 Loosen the carrier belt 5 1 Loosen the tension screw A 5 2 Remove tension from the carrier belt by pulling up on the belt 5 3 Tighten the tension screw A Loosening the screw tightens the bel...

Page 65: ...91 Go Back Previous Next 7 Disconnect the printhead cables B from the logic board and move it back and out of the way 8 Disconnect the carrier motor cable J2 from the logic board 9 Loosen the screw D holding the left side of the print unit B D ...

Page 66: ...screw F securing the bracket to the grommet 12 Remove the three screws G securing the carrier motor bracket to the print unit 13 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 14 Ease the carrier motor assembly off the printer and remove E F G ...

Page 67: ...e rear cover See Covers rear removal on page 4 5 2 Remove the top cover Go to Covers top removal on page 4 5 3 Remove the screw A from the lever and then remove the forms thickness lever Paper feed motor removal 1 Remove the rear cover See Covers rear removal on page 4 5 2 Remove the top cover Go to Covers top removal on page 4 5 A ...

Page 68: ... bracket 4 Remove the motor 5 Disconnect the paper feed motor cable from the logic board Paper select lever removal 1 Remove the rear cover See Covers rear removal on page 4 5 2 Remove the top cover Go to Covers top removal on page 4 5 3 Release the latch and remove the paper select lever from the right side frame ...

Page 69: ...emove 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 Print unit removal 1 Remove the rear cover See Covers rear removal on page 4 5 2 Remove the top cover See Covers top removal on page 4 5 3 Remove the forms thickness lever See Forms thickness lever removal on page 4 19 4 Remove the INA support frame See INA sup...

Page 70: ...ce Manual 2580 2581 2590 2591 Go Back Previous Next 5 Disconnect all cables from the logic board except the power supply cable A 6 Remove the two grommet anchored screws B from the left side of the print unit A B ...

Page 71: ...ormation 4 23 2580 2581 2590 2591 Go Back Previous Next 7 Remove the two grommet anchored screws C from the right side of the print unit 8 Remove the two ground screws D from the right side of the print unit C D ...

Page 72: ... E from the left side of the print unit 10 Remove the print unit from the bottom cover by pulling up forcefully on both sides of the print unit Printhead removal 1 Remove the ribbon access cover See Covers ribbon access removal on page 4 5 2 Remove the two screws A from the printhead E A ...

Page 73: ...thead to platen gap adjustment on page 4 2 Printhead cable removal 1 Remove the ribbon access cover See Covers ribbon access removal on page 4 5 2 Remove the printhead See Printhead removal on page 4 24 3 Remove the rear cover See Covers rear removal on page 4 5 4 Remove the top cover See Covers top removal on page 4 5 5 Remove the clip A holding the printhead cable Note Pay attention to how the e...

Page 74: ...flat with no twists Ribbon drive rack gear removal 1 Remove the rear cover See Covers rear removal on page 4 5 2 Remove the top cover Go to Covers top removal on page 4 5 3 Remove the carrier Go to Carrier removal on page 4 12 4 Unsnap the white plastic end stop A from the top left side of the print unit 5 Unlatch the left side of the rack from the top of the print unit 6 Slide the rack to the rig...

Page 75: ...eft side gears removal 1 Remove the rear cover See Covers rear removal on page 4 5 2 Remove the top cover Go to Covers top removal on page 4 5 3 Remove the three screws A from the serial interface card bracket 4 Remove the four screws B from the paper feed motor bracket assembly B B ...

Page 76: ...g the gears as shown Right side gears sub frame removal 1 Remove the rear cover See Covers rear removal on page 4 5 2 Remove the top cover Go to Covers top removal on page 4 5 3 Unhook the wire retainer A from the carrier shaft 4 Remove the two screws and washers B from the sub frame 5 Remove the Paper Select lever C ...

Page 77: ...Repair information 4 29 2580 2581 2590 2591 Go Back Previous Next 6 Remove the sub frame exposing the right side gears D as shown D ...

Page 78: ...ew from the print cable shield and then remove the shield 4 Remove the gear from the left end of the upper feed roller as shown 5 Remove the two screws A from the right upper feed roller bracket One screw also retains the upper feed roller ground clip 6 Pull the upper feed roller from the left bracket and then out of the printer 7 Be sure to perform the Printhead to platen gap adjustment Go to Pri...

Page 79: ...s top removal on page 4 5 3 Slide the carrier to the far left of the printer 4 Remove the four screws A from the paper feed motor bracket 5 Remove the screw from the top of the serial interface card bracket 6 Disconnect the paper feed motor cable from the logic board and then remove the paper feed motor and bracket from the printer 7 Slide the carrier to the left side of the printer B B ...

Page 80: ...ht side of the printer 10 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 11 Slide the carrier to the center of the printer 12 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...

Page 81: ...et to the inside of the right side frame 6 Remove the right side sub frame and the right side gears Go to Right side gears sub frame removal on page 4 28 7 Remove the left side gears Go to Left side gears removal on page 4 27 8 Remove the gears and C clip from both ends of the lower feed roller 9 Remove the upper feed roller Go to Roller upper feed removal on page 4 30 10 Remove the two screws A s...

Page 82: ...al on page 4 33 2 Remove the Paper Present flag or the Top of form flag from the paper guide Sensor head gap and home position 1 Remove the rear cover See Covers rear removal on page 4 5 2 Remove the top cover See Covers top removal on page 4 5 3 Disconnect the sensor cable A from the logic board 4 Release the latches B and pull the the home position sensor off the bracket A B ...

Page 83: ...outing of the cable Sensor pull tractor and paper select removal 1 Remove the rear cover See Covers rear removal on page 4 5 2 Remove the top cover See Covers top removal on page 4 5 3 Remove the INA support frame See INA support frame removal on page 4 8 4 Remove the print unit See Print unit removal on page 4 21 5 Remove the two small screws A securing the two sensors 6 Remove the sensor pull tr...

Page 84: ...removal on page 4 5 3 Remove the INA support frame See INA support frame removal on page 4 8 4 Remove the print unit See Print unit removal on page 4 21 5 From the bottom of the print unit remove the screw A from the top of form sensor 6 Release the latches B holding the paper present sensor 7 Release the sensor from its cable holder and remove Note Pay attention to the original routing of the cab...

Page 85: ...r 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 ...

Page 86: ...eder 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 ...

Page 87: ...s 5 1 2580 2581 2590 2591 Go Back Previous Next 5 Connector locations Logic board Note On the logic board a white square usually marks the location of pin 1 on a cable J11 J4 J17 J3 J20 J200 J18 J1 J2 J19 J12 J13 J5 J15 ...

Page 88: ...r motor J3 Sensor pull tractor and paper select J4 Sensor head gap and home position J5 Sensor top of form and paper present J11 Parallel interface J12 USB J13 Operator panel J15 Power supply J17 Carrier fan J18 Printhead J19 Paper feed motor J20 LAN card J200 Serial board At connector J17 Pin Output 1 V_FAN 2 Signal Gnd At connector J2 Pin Output 1 PHD 2 PHC 3 PHB 4 PHA At connector J10 Pin Outpu...

Page 89: ...w 4 Power Gnd 5 5 V dc 6 TR2MON 7 D_SET 8 Signal Gnd 9 TR2MA 10 TR2MB 11 NC 12 D_HP 13 D_POS At connector J13 Pin Output 1 Signal Gnd 2 SCLK 3 Signal Gnd 4 SC0 5 Signal Gnd 6 S10 7 5 V dc 8 SLATCH 9 5 V dc 10 5 V dc 11 START 12 GREEN_LED 13 AMBER_LED At connector J19 Pin Output 1 PHD 2 PHC 3 PHB 4 PHA 5 NC At connector J10 Pin Output ...

Page 90: ...ta 2 22 Signal Gnd 5 Data 3 23 Signal Gnd 6 Data 4 24 Signal Gnd 7 Data 5 25 Signal Gnd 8 Data 6 26 Signal Gnd 9 Data 7 27 Signal Gnd 10 Ack 28 Signal Gnd 11 Busy 29 Signal Gnd 12 PE 30 Signal Gnd 13 Select 31 INPRM 14 Autofeed 32 ERROR 15 NC 33 Signal Gnd 16 Signal Gnd 34 NC 17 Chassis Gnd 35 5 V dc 18 5 V dc 36 SEL_IN At connector J15 Pin Output 1 40 V dc 2 40 V dc 3 Power Gnd 4 Power Gnd 5 Sign...

Page 91: ...7 DH14 C 20 DH11 D 8 DH6 D 21 DH7 C 9 DH18 C 22 DH15 D 10 DH2 D 23 DH3 C 11 DH22 C 24 DH19 D 12 DN22 D 25 3 3 V dc 13 DH23 C 26 HDTHERMO At connector J18 Pin Output Pin Output 1 DH1 D 13 DH24 D 2 DH4 C 14 DH21 C 3 DH4 D 15 DH13 D 4 DH8 C 16 DH17 C 5 DH16 D 17 DH17 D 6 DH12 C 18 DH13 C 7 DH20 D 19 DH21 D 8 DH16 C 20 DH9 C 9 DH12 D 21 DH9 D 10 DH20 C 22 DH5 C 11 DH8 D 23 DH5 D 12 DH24 C 24 DH1 C At ...

Page 92: ...24w 3 DH2 C 16 DH1 D 4 DH8 D 17 DH7 C 5 DH4 C 18 DH3 D 6 DH4 D 19 DH5 C 7 DH6 C 20 DH5 D 8 DH2 D 21 DH3 C 9 DH8 C 22 DH7 D 10 NC 23 DH1 C 11 DH9 C 24 NC 12 DH9 D 25 3 3 V dc 13 NC 26 HDTHERMO At connector J4 Pin Output 1 HPSW 2 Signal Gnd 3 GAP1 4 GAP2 5 Signal Gnd At connector J3 Pin Output 1 PLTR 2 Signal Gnd 3 TR_FR 4 Signal Gnd At connector J5 Pin Output 1 LED 2 PE1 3 Signal Gnd At connector J...

Page 93: ...l board outputs 9w and 24w USB outputs 9w and 24w 4 LED 5 PE2 6 Signal Gnd At connector J200 Pin Output 1 5 V dc 2 5 V dc 3 CTS 4 DTS 5 RXD 6 RTS 7 DSR 8 TXD 9 Signal Gnd 10 SBSET At connector J12 Pin Output 1 3 2 V dc 2 DMNS 3 DPLS 4 Signal Gnd At connector J5 Pin Output ...

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Page 95: ... left Side frame right Pinch roller lower Pinch roller spring left Pinch roller spring center Pinch roller spring right Paper separator Specified lubricants Oil P N 1280443 Approved equivalents Mobil DTE27 Shell Tellus 100 Fuchs Renolin MR30 Grease P N 6934659 Approved equivalent Mobil 28 Lubrication points Oil Lubricate the following contact positions Oil felt carrier block Tractor shaft Grease L...

Page 96: ...81 2590 2591 Go Back Previous Next Lubrication points oil Description Position The oil felt 1 in the carrier block The tractor shaft 1 Lubrication points grease Description Position Gear mounting studs on the right side frame 2 ...

Page 97: ...enance 6 3 2580 2581 2590 2591 Go Back Previous Next The lower pinch roller 2 Gear mounting studs on the left side frame 2 Gear mounting studs on the left ASF side frame 2 Lubrication points grease Description Position ...

Page 98: ...6 4 Service Manual 2580 2581 2590 2591 Go Back Previous Next Gear mounting studs on the right ASF side frame 2 Lubrication points grease Description Position ...

Page 99: ... a particular option It does not include the rest of the base machine Units FRU Refers to the number of units packaged together and identified by the part number NS Not shown in the Asm Index column indicates that the part is procurable but is not pictured in the illustration PP Parts Packet in the parts description column indicates the part is contained in a parts packet Model information used in...

Page 100: ...7 2 Service Manual 2580 2581 2590 2591 Go Back Previous Next Assembly 1 Covers ...

Page 101: ...d South America Mexico Saudi Arabia LV 7 40X0271 Power cord Malaysia Singapore United Kingdom 7 40X3141 Power cord Austria Belgium Brazil Germany Greece Finland France Indonesia Luxembourg Portugal Norway Saudi Arabia HV Spain Sweden Netherlands Turkey 7 40X0294 Power cord Denmark 7 40X0287 Power cord Chile Italy 7 40X0275 Power cord Israel 7 40X0276 Power cord South Africa 7 40X0274 Power cord Sw...

Page 102: ...7 4 Service Manual 2580 2581 2590 2591 Go Back Previous Next Assembly 1 continued Covers ...

Page 103: ...perator panel 12 40X2994 Cover front guide 2580 2590 12 40X2995 Cover front guide 2581 2591 NS 40X2897 Cover operator panel front with overlay packs NS 40X8473 Cover flint gray operator panel front with overlay packs NS 40X2996 Overlay pack operator panel 258X NS 40X8480 Overlay pack flint gray all languages NS 40X2937 Stand paper ...

Page 104: ...7 6 Service Manual 2580 2581 2590 2591 Go Back Previous Next Assembly 2 Carrier paper feed right side ...

Page 105: ...6 Springs parts packet 7 40X2926 Screws washers and clips parts packet 8 40X2922 Kit Head Gap adjustment 9 40X2910 Gears and bushings parts packet 258X 10 40X2980 Sub frame right side 11 40X2956 Gear idler 2580 2581 11 40X2957 Gear idler 2590 2591 12 40X2907 Paper Select lever 13 40X2971 Roller lower feed 2581 2591 13 40X2981 Roller lower feed 2580 2590 14 40X3019 Roller lower pinch 2580 2590 14 4...

Page 106: ...7 8 Service Manual 2580 2581 2590 2591 Go Back Previous Next Assembly 3 Carrier paper feed left side ...

Page 107: ...580 2590 9 40X2970 Guide paper assembly 2581 2591 10 40X2973 Platen 2580 2590 10 40X2974 Platen 2581 2591 11 40X7998 Sensor top of form and paper present 12 40X2986 Gear ribbon drive rack 2580 2590 12 40X2987 Gear ribbon drive rack 2581 2591 13 40X2977 Plate tension pulley assembly 14 40X3021 Plate carrier assembly 2580 2590 14 40X3022 Plate carrier assembly 2581 2591 15 40X2975 Separator paper 25...

Page 108: ...7 10 Service Manual 2580 2581 2590 2591 Go Back Previous Next Assembly 4 Electronics 3 7 6 1 1 1 1 5 4 8 1 2 ...

Page 109: ...3 Board logic 2581 3 40X8075 Board logic 2590 3 40X8077 Board logic 2591 4 40X2903 Bracket serial interface card 5 40X2915 Plate serial interface card 6 40X4968 INA support frame 7 40X4791 LAN card INA 8 40X8069 Cable power supply 2580 2590 8 40X8070 Cable power supply 2581 2591 NS 40X4970 Earth LAN card NS 40X5006 INA cable NS 40X2909 Kit fuse LV NS 40X2930 Card serial interface card with plate N...

Page 110: ...7 12 Service Manual 2580 2581 2590 2591 Go Back Previous Next Assembly 5 ASF Roller support ...

Page 111: ... feed 2580 2590 1 40X3023 Roller ASF upper feed 2581 2591 2 40X2889 Roller ASF lower feed 2580 2590 3 40X2984 Roller ASF pick up left and right 2580 2590 4 40X2985 Roller ASF pick up left and right 2581 2591 4 40X2927 Support ASF paper right 5 40X2928 Support ASF paper left 6 40X2891 ASF springs parts packet 7 40X3136 ASF gears and bushings parts packet ...

Page 112: ...7 14 Service Manual 2580 2581 2590 2591 Go Back Previous Next Assembly 6 ASF gears screws 1 2 2 2 1 ...

Page 113: ...arts catalog 7 15 2580 2581 2590 2591 Go Back Previous Next Assembly 6 ASF gears screws Asm Index Part number Description 6 1 40X2890 ASF gears and bushings parts packet 2 40X2892 ASF screws parts packet ...

Page 114: ...7 16 Service Manual 2580 2581 2590 2591 Go Back Previous Next Assembly 7 Tractor 2 option ...

Page 115: ...ck Previous Next Assembly 7 Tractor 2 option Asm Index Part number Description 7 1 40X2918 Kit tractors left and right 2 40X2882 Parts packet Tractor 2 3 40X2880 Motor Tractor 2 4 40X2961 Board assembly with cable and ferrite Tractor 2 2581 2591 ...

Page 116: ...7 18 Service Manual 2580 2581 2590 2591 Go Back Previous Next ...

Page 117: ... Menu options 3 8 models 1 1 N navigation buttons ii x O Operator errors Irrecoverable 2 7 options 1 1 P Paper jams Clearing continuous forms 3 4 Clearing cut sheet 3 4 Parts ASF Roller support 7 12 Side Frame covers 7 14 Carrier paper feed left side 7 8 7 10 Carrier paper feed right side 7 6 7 7 7 8 Covers 7 2 Electronics 7 10 Tractor 2 option 7 16 POST 3 1 Preventive maintenance Lubrication 6 1 ...

Page 118: ...o Sheet Feeder 2 9 Carrier 2 10 Intermittent problem 2 11 No print 2 12 Operator panel 2 13 Paper feed 2 13 Paper Present sensor 2 13 Paper Select sensor 2 15 POST 2 15 Power 2 16 Printhead 2 17 Pull Tractor sensor 2 18 Top of forms 2 18 Tractor 2 2 18 Settings Tear off position 3 10 Top of form continuous 3 10 Top of form cut forms 3 10 Top of form envelopes 3 10 Setup Menu options 3 8 Setup mode...

Page 119: ...2907 Paper Select lever 7 7 40X2908 Holder platen 7 9 40X2909 Kit fuse LV 7 11 40X2910 Gears and bushings parts packet 258X 7 7 7 9 40X2911 Cover rear 2581 2591 7 3 40X2912 Guide left paper 7 3 40X2913 Guide right paper 7 3 40X2915 Plate serial interface card 7 11 40X2918 Kit tractors left and right 7 17 40X2918 Tractors left and right 7 3 40X2922 Kit Head Gap adjustment 7 7 7 9 40X2926 Screws was...

Page 120: ...bon access cover unit 2590 7 3 40X3026 Ribbon access cover unit 2591 7 3 40X3028 Narrow auto feeder assembly 2580 2590 7 7 40X3035 Wide dual tractor assembly 2581 2591 7 7 40X3136 ASF gears and bushings parts packet 7 13 40X3141 Power cord Austria Belgium Brazil Germany Greece Finland France Indonesia Luxembourg Portugal Norway Saudi Arabia HV Spain Sweden Netherlands Turkey 7 3 40X4791 LAN card I...

Page 121: ... 2581 7 11 40X8075 Board logic without EPROM 2590 LV 7 11 40X8077 Board logic without EPROM 2591 7 11 40X8449 Cover assembly flint gray front unit 2580 2590 7 3 40X8455 Cover flint gray rear 7 3 40X8474 Cover flint gray top 2580 2590 7 3 40X8475 Cover flint gray bottom 2580 2590 7 3 40X8476 Operator panel assembly flint gray 258X 7 3 40X8480 Overlay pack flint gray all languages 7 5 ...

Page 122: ...I 6 Service Manual 2580 2581 2590 2591 Go Back Previous Next ...

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