Lexmark 2580, 2581, 2590, 2591 Service Manual

Lexmark confident ial until announce

Lexmark Forms Printer 2500 Series

• Table of contents

• Start diagnostics

• Start diagnostics

25XX-100
25XX-110

• Safety and notices

•Trademarks

•Index

Lexmark and Lexmark with diam ond
design are trademar ks of Lexmark
International, Inc., registered in the
United States and/or ot her countries.

25XX-100, -110

Edition: September 17, 2007
The following paragraph does not apply to any country where such provisions are

inconsistent with local law: LEXMA R K INTER NATIONAL, INC. PR OVID E S THI S

PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR
IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do
not all o w di sc la im er of e xpr ess or im pl ied w arr an tie s in ce rt ai n tr a ns acti on s; the r efor e , t hi s
statement may not apply to you.

This publ icat ion co uld in clude te chni cal in accura cies or typogr aph ical err ors. Change s are
periodically made to th e inform ation her ein; the s e changes will be incorporated in later
editions. Improvements or changes in the products or the programs described may be
made at any time.

Comments may be addressed to Lexmark Internatio nal, Inc., Department D22A/032-2,
740 West New Circle Road, Lexington, Kentucky 40550, U.S.A or e-mail at
ServiceInfoAndTra [e-mail]. Lexmark may use or distribute any of the
information y ou supply in any way it believe s appropriate without incur ring any obligation
to you.

Lexmark and Lexmark with di amond design are trademarks o f Lexmark International,
Inc., registered in the United States and/or other countries.

All other tr ad em ar ks are the prop er t y of t he ir r es pe c tiv e ow n er s .

© 2007 Lexmark International, Inc.
All rights reserved.

UNITED STATES GOVERNMENT RIGHTS

This software and any accompanying documentation provided under this agreement are
commercial computer software and documentation deve loped exclusively at private
expense.

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

25XX-100, -110

Table of co ntents

Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-vii

Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-xii

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Printer sp e c ifi cations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Printer speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Setup mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Entering Setup mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Exiting Setup mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Setup menu options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Interface menu options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Setting the tear off position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Setting Top-of-form (continuous-pull mode). . . . . . . . . . . . . . . . . 1-5

Setting Top-of-form (cut forms, envelopes) . . . . . . . . . . . . . . . . . 1-5

Printing a network setup page . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Diagnostic information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Voltage, ground, and continuity readings . . . . . . . . . . . . . . . . . . . . . 2-1

Error indication table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Symptom check table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Irrecoverable operator errors . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -13

Service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Abnormal noise service check . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Auto Sheet Feeder (ASF) service check . . . . . . . . . . . . . . . . . . 2-16

Carrier service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

Intermittent problem service check . . . . . . . . . . . . . . . . . . . . . . 2-20

No print or abnormal print service check . . . . . . . . . . . . . . . . . . 2-23

Operator panel service check . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Paper Present sensor service check . . . . . . . . . . . . . . . . . . . . . 2 -24

Paper feed service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 5

Paper Select sensor service check . . . . . . . . . . . . . . . . . . . . . . 2-28

POST service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -29

Power service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

Print speed service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -31

Printhead service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32

iii

25XX-100, -110

Pull Tractor sensor service check . . . . . . . . . . . . . . . . . . . . . . . .2-34

Top-of-forms service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35

Tractor 2 service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36

Network service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40

Diagnostic aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Power-On Self Test (POST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2

Print test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Hex Trace mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Printer default settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

U.S. defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

World Trade defaul t s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

Clearing paper jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Cut sheet jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Continuous forms jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Web page at a glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

Device settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

Configuration page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

Reports page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

Flashing firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

Importing and exporting INA settings . . . . . . . . . . . . . . . . . . . . .3-10

Resetting the INA to factory defaults. . . . . . . . . . . . . . . . . . . . . .3-11

Repa ir inform atio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Handling ESD-sensitive parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Printhead-to-platen gap adjustment . . . . . . . . . . . . . . . . . . . . . . . 4 -2

Bidirectional print adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

Removal procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

Covers, removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

Cove r s, fron t r e m oval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Covers, ribbon access removal. . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Covers, option removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

Cove r s , top rem o val . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

Covers, operator panel assembly removal . . . . . . . . . . . . . . . . .4- 1 0

Cove r s, botto m removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

Electronics removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

EPROM remova l. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

Logic board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

Network card removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

INA support frame removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

Power supply removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

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25XX-100, -110

Carrier removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Carrier removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Carrier, motor assembly removal. . . . . . . . . . . . . . . . . . . . . . . . 4-22

Paper handling removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Paper Select lever removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Paper feed motor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

For ms Thi ckness leve r removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Print handling removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -27

Platen removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -27

Printhead removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -28

Printhead cables removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 8

Print unit removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

Ribbon drive rack gear removal. . . . . . . . . . . . . . . . . . . . . . . . . 4-31

Gears removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -32

Left side gears removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

Right side gears, sub frame removal . . . . . . . . . . . . . . . . . . . . . 4-35

Rollers removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37

Roller, upper feed removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -37

Roller, lower pinch removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -39

Roller, lower feed removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

Sensor removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -44

Sensor, Pull Tractor removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -45

Sensor, Head Gap removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -45

Sensor, Top-of-form removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -45

Sensor, Paper Select removal . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46

Sensor, Paper Present removal. . . . . . . . . . . . . . . . . . . . . . . . . 4-46

Flags, Paper Present/Top-of-form removal . . . . . . . . . . . . . . . . 4 -46

Sensor, Home Position sensor removal. . . . . . . . . . . . . . . . . . . 4-4 7

Options removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48

Auto Sheet Feeder gears removal . . . . . . . . . . . . . . . . . . . . . . . 4-48

Auto Sheet Feeder pick-up roller removal . . . . . . . . . . . . . . . . . 4 - 4 9

Locations and connector s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Signal connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Power supply (9w & 24w). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Logic board–Parallel interface cable (9w & 24w) . . . . . . . . . . . . 5-5

Logic board–Serial board (9w & 24w) . . . . . . . . . . . . . . . . . . . . 5-7

Logic board–USB cable (9w & 24w). . . . . . . . . . . . . . . . . . . . . . 5-9

Logic board–DC power (9w & 24w) . . . . . . . . . . . . . . . . . . . . . . 5-9

Logic board–Printhead (9w) . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Logic board–Printhead (24w) . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

v

25XX-100, -110

Logic board–Printhead (24w) . . . . . . . . . . . . . . . . . . . . . . . . . .5-15

Logic board–Gap Set sensor (9w & 24w) . . . . . . . . . . . . . . . . .5 - 1 7

Logic board–Home Position sensor (9w & 24w) . . . . . . . . . . . .5-17

Logic board–(9w & 24w) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17

Logic board–Paper Present sensor (9w & 24w) . . . . . . . . . . . .5-17

Logic board–Paper Select sensor (9w & 24w) . . . . . . . . . . . . . .5-19

Logic board–Pull Tractor sensor (9w & 24w). . . . . . . . . . . . . . .5-19

Logic board–Top-of-form sensor (9w & 24w) . . . . . . . . . . . . . .5-19

Logic board–Carrier motor (9w & 24w) . . . . . . . . . . . . . . . . . . .5-21

Logic board–Paper feed motor (9w & 24w) . . . . . . . . . . . . . . . . 5 - 2 1

Logic board–Operator panel (9w & 24w). . . . . . . . . . . . . . . . . .5-23

Logic board–Dual tractor cable (9w & 24w) . . . . . . . . . . . . . . .5-25

Serial board–Serial cable (9w & 24w) . . . . . . . . . . . . . . . . . . . .5-26

Tractor 2 cable connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-27

Preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Lubrication points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

Lubrication points (oil) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3

Lubrication points (grease) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

Parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

How to use this parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

Assembly 1: Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2

Assembly 2: Carrier/paper feed (right side) . . . . . . . . . . . . . . . . . . . .7-6

Assembly 3: Carrier/paper feed (left side) . . . . . . . . . . . . . . . . . . . .7-10

Assembly 4: Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14

Assembly 5: ASF–Roller/support . . . . . . . . . . . . . . . . . . . . . . . . . .7-16

Assembly 6: ASF–Side frame/covers . . . . . . . . . . . . . . . . . . . . . . .7-18

Assembly 7: Tractor 2 option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

Part number index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-5

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25XX-100, -110

Safety information

• The safety of this product is based on test ing and approvals of the

original design and specific components. The manufacturer is not
responsible for safety in the event of use of unauthorized replacement
parts.

• The maintenance information for thi s product has been prepared for

use by a professional serv ice person and is not intended to be used by
others.

• There may be an increased risk of electric shock and personal injury

during disasse mbly and servicing of this pro duct. Professional service
personnel should understand this and take necessary precauti ons.

• CAUTION: When you see this symbol, there is a danger

from hazardous voltage in the area of the product where
you are working. Unplug the product before you begin, or
use caution if the product must receive power in order to
perform the task.

Consig n es de sécu ri té

• La sécurité de ce produit repose sur des tests et des

agréations por tant sur sa conception d'or igi ne et sur des composants
particuliers. Le fabricant n'assu me aucune responsabilité concernant
la sécurité en cas d'ut ilisation de pièces de re change non agréées.

• Les consignes d'entretien et de réparation de ce produit s'adressent

uniquement à un personnel de ma intenance 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
laquelle vous travaillez. Débranchez le produit avant de
commencer ou faites preuve de vigilance si l'exécution de
la tâche exige que le produit reste sous tension.

vii

25XX-100, -110

Norme di sicurezza

• La sicurezza del prod ott o si basa sui test e sull'app rovazione del

progetto original e e dei componenti specifici. Il produttore non è
responsabile per la sicurezza in caso di sostituzione non autorizzata
delle parti.

• Le informazioni riguardanti la manutenzione di questo prodotto sono

indirizzate sol tanto al personale di assis tenza autorizzato.

• Durante lo smontaggio e la manutenzione di questo prodotto,

il rischio di subire scosse elettriche e danni alla persona è più elevato .
Il personale di assis tenza autorizzato deve, qui ndi, adottare le
precauzioni neces sarie.

• ATTENZIONE: Questo simbolo indica la presenza

di tensione pericolosa nell'area del prodotto. Scollegare il
prodotto prima di ini ziare o usare cautela se il prodotto
deve essere alimentato per eseguire l'intervento.

Sicherheitshinweise

• Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des

ursprünglich en Mod ells und bestimmter Bauteil e. Bei Verw endung
nicht genehmigter Ersatzteile wi rd vom Hersteller keine Verantwortung
oder Haftung für die Sicherheit übernommen.

• Die Wartungsinformationen fü r di eses Produkt sind ausschließlich für

die Verwendung durch einen Wartungsfachmann bestimmt.

• Während des Auseinande rnehmens und der Wartung des G eräts

besteht ein zusätzliches Risiko eines elektrischen Schlags und
körperlicher Verletzung. Das zuständige Fachper sonal sollte
entsprechende Vorsichtsmaßnahmen treffen.

• ACHTUNG: Dieses Symbol weist auf eine gef ährliche

elektrische Spannung hin, die in diesem Bereich des
Produkts auftreten kann. Ziehen Sie vor den Arbeiten am
Gerät den Netzstecker des Geräts, bzw. arbeiten Sie mit
großer Vorsicht, wenn das Produkt für die Ausführung der
Arbeiten an den Strom angeschlossen sein muß.

viii Service Manual

25XX-100, -110

Pautas de Seg u rid ad

• La seguridad de este producto se basa en pruebas y aprobaciones del

diseño original y componentes específicos. El fabricante no es
responsable de l a seguridad en ca so de uso de piezas de repuesto no
autorizadas.

• La información sobre el mantenimi ento de este producto está diri gida

exclusivament e a l per sonal cualificado de mantenimiento.

• Existe mayor riesgo de descarga eléctrica y de daños personales

durante el desmonta je y l a reparación de la máquina. El perso nal
cualificado debe ser consciente de este pel igro y tomar las
precauciones necesarias.

• PRECAUCIÓN: este símbolo indi ca que el voltaje de la

parte del equipo con la que está trabajando es peligr oso.
Antes de empezar, desenchufe el equi po otenga cuidado
si, para trabajar con él, debe conectarlo.

Inform ações de Segura nça

• A segurança deste produto baseia-se em testes e aprovações do

modelo original e de componentes específico s. O fabr icante não é
responsável pel a segunrança, no caso de uso de peças de
substituição não autorizadas.

• As informações de segurança relativas a este produto destinam-se a

profissionais destes serviços e não devem ser utilizadas por out ras
pessoas.

• Risco de choques eléctricos e ferimentos graves durante a

desmontagem e manutenção deste produto. Os profi ssionais destes
serviços devem estar avisados deste facto e tomar os cuidados
necessários.

• CUIDADO: Quando vir este símbolo, existe a possível

presença de uma potencial tensão perigosa na zona do
produto em que está a trabalhar. Antes de começar,
desligue o produto da tomada eléctrica ou seja cuidadoso
caso o produto tenha de est ar l igado à corrente eléctri ca
para realizar a tarefa necessária.

ix

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 respon sable de les qüestions de
seguretat si s'utilitzen peces de recanvi no autoritzades.

• La informació pel manteniment d’aquest producte està orientada

exclusivament a professionals i no està dest inada
a ningú que no ho sigui.

• El risc de xoc elèctric i de danys personals pot augmenta r durant el

procés de desmuntatge i de servei d’aquest producte. El personal
professional ha d’estar-ne assabentat i prendre
les m e s ures convenients.

• PRECAUCIÓ: aquest símbol indi ca que el voltatge de la

part de l'equip amb la qual esteu treballant és perillós.
Abans de començar, desendolleu l' equip o extremeu les
precaucions si, per tr eballar amb l'equip, l'heu de
connectar.

x Service Manual

25XX-100, -110

xi

25XX-100, -110

Preface

This manual contai ns m aintenance procedures for service personnel. I t is

divided into the following chapters:

1. General inf o rm ation contains a general description of the printer and
the maintenance approach used to repair it. Special tools and test
equipment are listed, as well as general environmental and safety
instructions.

2. Diagnostic information contains an error indicator table, symptom
tables, and service che cks us ed to isolate failing f ie ld replaceab le unit s
(FRUs).

3. Diagnostic aids contains tests and checks used to locate or repeat
symptoms of printer problems.

4. Repair information provides instructions for making printer
adjustments and removi ng and installing FRUs.

5. Connector locations uses illustrations to identify the conne ctor
locations and test points on the printer.

6. Preventive maintenance contains the lubrication specifications and
recommendations to prevent problems.

7. Parts catalog contains illustrations and part numbers for individual
FRUs.

Definitions

Note: A note provides additional information.
Warni ng: A warning identifies something that might damage the product

hardware or software.
CAUTION: A caution identifi es som ething that might cause a servi cer

harm.

CAUTION: When you see this symbol , there i s a danger fr om
hazardous volta ge in the area of the product where you are
working. Unplug the product before you begin, or use ca ution
if the product must receive power in order to perform the task.

xii Ser vice Manual

25XX-100, -110

1. Gen e r a l inform a tion

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 mult i- p ar t f or ms .

Printer specific ations

• Printhead life: 300 million characters

• Sta ndar d ribbon life: 4 milli on ch aracters

• High-yield ribbon life: 8 million characters

• Printer life: 5 years

• Power co nsump tion: 38 watts-maximu m/9 watts idle

Model 9-Wire 24-Wire Short carriage Long carriage

2580-XXX X X
2581-XXX X X
2590-XXX X X
2591-XXX X X

General information 1-1

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–

Near

Letter Quality

cpi = characters per inc h
cps = characters per second

77.5 cps 77.5 cps 91.7 cps 109 cps

Setup mode

Entering Setup mode

1. Open the operator panel cover to access layer two.

2. Press Setup to put the printer in Setup mode and print the Main
Menu.

3. Press LineFeed to print a list of all the available options.

4. Select any option from the Main Menu by pressing the
corresponding button. A new menu prints each time you press a
button, displaying new selections.

5. After making a selection, the printer prints a page with the
changes shown.

Exiting Setup mode

1. Press Set TOF until the printer returns to the Main Menu, or
press Pitch from any menu containing a Return to Main Menu
selection.

2. Press Set TOF again to exit Setup mode. New settings are
saved only when the printer exits Setup mode.

Note: If the printer runs out of paper while in Setup mode, load
more paper into the tractor pins, and press Setup to continue.

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Setup menu options

Menu Function

Forms Macro options Customize macros to print a variety of forms.
Data options Define how information is pro cessed.
Control options Define how the printer performs basic tasks.
Emulation options Determine how the printer interacts with

software applicat ions.

Interface option s Define how information is transferred from a

computer to the printer.

Interface menu options

Menu Function

Interf ac e • Automa ti ca ll y s el e ct the prin te r interfac e .

• Use the parallel cable.

• Use the USB cable.

• Use the serial cable (only appears if
optional ser ial adapter is installed).

Honor init • Enable honors the init signal on the

parallel p or t.

• Disable ignore s the i nit signal on the
parallel p or t.

Data speed • 300 bps

• 600 bp s

• 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

General information 1-3

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:

• The printer has finished printing.

• The paper has advanced to the Top-of-form on the next page.

• No data, printer control codes, or escape codes have been sent

to the printer after advancing to the Top-of-form.

• The print buffer has not received data for one second.

If you have already set Top-of-Form and now want to change the
tear off bar position, follow these steps:

1. Press Start/Stop to ta ke the pri nter offline.

2. Press and hold Tear Off until the printer beep s.

3. Open the operator panel cover to access layer two.

4. Press Micro↑ or Micro ↓ t o mo ve the paper to the correct
position on the tear off bar.

5. Close the operator panel cover. The printer beeps twice. The
paper rolls backward, then goes to the new tear off position.
The Ready light is on.

The paper remains at the current tear off position until you send
another job to the printer . The paper moves from the tear off position
to the Top-of-form and begins printing.

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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.

4. Open the operator panel cover to access layer two.

5. Press any paper movement button (LineFeed, Micro↑, or
Micro ↓) to move the paper to the Top-of-form position.

6. Use the second sheet of continuous forms to set Top-of-form.

7. Press Set TOF to set and save Top-of-form.

8. Close the operator panel cover. Top-of-form is not saved if the
printer is turned off, or if it runs out of paper when the printer is
in Pull Tractor mode.

9. Press Start/Stop to set the printer online.

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

Top-of-form can range from minus 1 to plus 22 inches from the top
of cut sheet paper. To set and save Top-of-form:

1. Turn the printer on. The Paper Out light blinks if no paper is
loaded. If the Paper Out light is off, tear off excess forms and
press Load/Unload. If an individual form is loaded, press
FormFeed to clear the paper path.

2. Move the paper select lever up to the cut forms position.

3. Load a cut sheet of paper or envelope through the manual feed
door. The printer moves the paper or envelope to the current
Top-of-form if Auto Cut Sheet is set to on. If not, press
FormFeed when the Paper Out light goes off.

4. Open the operator panel cover to access layer two.

5. Press any paper movement button (LineFeed, Micro↑, or
Micro ↓) to align the horizontal lines (located on the platen) with
the Top-of-form you want.

6. Press Set TOF to set and save Top-of-form.

7. Close the operator panel cover.

8. Press Start/Stop to set the printer online.

General information 1-5

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.

1. Make sure the printer is on and the paper is loaded.

2. With a paper clip or the tip of a pen, press the recessed button
located just above the Network connection.

3. Check the first section on the network setup page, and confirm
that the status is Connected. If the status is Not Connected,
the LAN drop may not be active, or the network cable may be
malfunctioning. See Networking service check.

4. Check the network setup page to find the IP Address and the
Fully Qualified Domain Nam e. Th e F ully Qualifie d D omain
Name is useful in situations where the Address changes. For
instance, the Address changes if the printer is moved; however,
the Fully Qualified Domain Name does not change.

Note: The network setup page also provides important network
configuration information.

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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:

• Basic CE tool kit

• #1 Phillips screwdriver

• #2 Phillips screwdriver

• Feeler gauges 0.33 mm (0.013 in.) and 0.37 mm (0.015 in.)

• Analog or digital volt-ohmmeter

General information 1-7

25XX-100, -110

Abbreviations

AFE Analog front end
ASF Automatic sheet feeder
CPU Central processing unit
EPROM Erasable Programmable Read-Only Mem ory
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 storage
TCP/IP Transport control protocol/Internet protocol
USB Universal Serial Bus
V ac Volts alternating current
V dc Volts direct current

1-8 Service Manual

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. Unless stated otherwise, all connectors
should be connected normally when a voltage measurem ent is
performed.

When a “line voltage” measurement is to be performed, the voltage
on United States and Canada printers should be between 100 V ac
and 127 V ac. On World Trade printers, the voltage is according to
each 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 using the lowest ohms scale and check for zero ohms.

Warning: Always unplug the power cord before doing any
continuity measurement.

Diagnostic information 2-1

25XX-100, -110

Continuit y readin gs

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.

2-2 Service Manual

25XX-100, -110

Error indic ation table

The following table describes the service check entries for the
printer error indication codes.

When an error indication changes after you have entered a service
check, you have an intermittent problem. If this occurs, leave the
service check and go to “Symptom check table” on page 2-6.

LED Status Alarm Action

Power
Ready
Tractor 2
Paper Out
Panel Lock
Font Lock

Power
Ready
Paper Out
Panel Lock

Power
Ready
Paper Out
Font Lock

ON
ON
ON
ON
ON
ON

ON
Blinking
Blinking
Blinking

ON
Blinking
Blinking
Blinking

None POST

RAM, ROM Controller Error
Go to “POST service check” on

page 2-29.

None Switch Scan Test Error

Go to “Operator panel service

check” on page 2-23.

None NVRAM Read/Write Error

Turn the printer of f and then back
on. If you get the same error
during power-up , replace the logic
board and readjust the
bidirectional print adjustment. Go
to “B i d ir ec t io n a l pr in t

adjustment” on page 4-4.

If the printer completes POST
successfull y and eventually gets
the same error, go to

“Intermittent problem service
check” on page 2-20.

Diagnostic information 2-3

25XX-100, -110

LED Status Alarm Action

Power
Ready
Paper Out
Panel Lock
Font Lock

Power
Ready
Tractor 2
Paper Out
Font Lock

Power
Ready
Tractor 2
Paper Out
Font Lock

ON
Blinking
Blinking
Blinking
Blinking

ON
Blinking
Blinking
Blinking
Blinking

ON
Blinking
Blinking
Blinking
Blinking

Beeps
10
times

None Home Position Error Without

None Timer Error

None Hardware Drive Error

Home Position Error
Go to “C arrier service check”

on page 2- 18.

Tractor 2 Home Posi ti on Error
If Tracto r 2 is installed, remove it

to determine whether t he problem
is with the Carrier Home Position
sensor or the Tr actor 2 Home
Position sensor . See the “Tractor

2 service check” on page 2-36.

Alarm
Go to “P ower service check”

on page 2- 30.

Turn the printer off and then back
on. If you get the same error
during power- up, replace the logic
board and readjust the
bidirectional print adjustment.

Go to “B idirectional print

adjustment” on page 4-4.

The printhead or the printhead
cable(s) can cause this error. Go
to “Printhead service check”

on page 2- 32.

Turn the printer off and then back
on. If you get the same error,
replace the logic board and
readjust the bidir ectional print
adjustment. Go to “Bidirectional

print adjustment ” on page 4-4.

If the printer completes POST
successfully and eventually gets
the same error, go to

“Intermittent problem service
check” on page 2-20.

2-4 Service Manual

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LED Status Alarm Action

All LEDs OFF None Power Failure

Check the continuity of the power
cord and the voltage of t he user’s
outlet. If they are correct, go to

“Power service check” on
page 2-30.

Power
Tractor 2
Paper Out
Panel Lock
Font Lock

Any LED
on and
Power LED
off

The Power
LED blinks
or changes
intensity.

Power
Ready
Font Lock

ON
OFF
OFF
OFF
OFF

ON
Blinking
Blinking

None Operator Panel Failure

Go to “Operator panel service

check” on page 2-23.

None Go to “Operator panel service

check” on page 2-23.

None Go to “Power service check”

on page 2-30.

None Ethernet option not installed. Go

to “Network service check” on

page 2-40.

Diagnostic information 2-5

25XX-100, -110

Sympto m check tab le

1. Select the symptom that best describes the problem.

2. Perform the appropriate action before you go to the indicated
service check.

Abno rmal in d ications

Symptom Action

7 or more lights turn
on but do not turn
off.

The Power light is
on, but POST will
not run.

Disconnect the interf ace cable from the print er and
turn the printer off and then back on. If POST now
runs correctly, the problem is in the computer or
interface cable.

Go to “PO S T service check” on page 2-29.

Abnorma l no ise problems

Symptom Action

During POST,
abnormal noise
comes fr om the
carrier.

Durin g idling,
abnormal noise
comes fr om the
printer.

Abnormal noise
when feeding paper

Abnormal noise
during printing or
POST

Check the ribbon cart ri dge for binds or damage.
Go to “C arrier service check” on page 2-18.

Go to “Abnormal noise service check” on

page 2-15.

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Abnormal print operation problems

Symptom Action

Printer will not print,
or become ready.

Abnormal operat ion,
incorrect charact er s,
or incorrect line
width

Printer is ready but
will not print from the
computer correctly .

Undefined or
incorrect
character(s)

Slow printing speed Go to “Print speed service check” on

Be sure the interface cable is connected prope rl y.

Go to “No print or abnormal print service

check” on page 2-23.

page 2-31.

Auto Sheet Feeder problems

Symptom Action

Auto Sheet Feeder
does not feed paper.

Auto Sheet Feeder
double feeds.

Auto Sheet Feeder
has intermit tent feed
problems.

Be sure Sheet Feed i s enabl ed in t he Setup m ode.

Be sure the Paper Select lever is in the cut sheet
position.

Go to “Auto Sheet Feeder (ASF) servic e chec k”

on page 2-16.

Diagnostic information 2-7

25XX-100, -110

Error indications

Symptom Action

Ready and Paper
Out ligh ts blink.

Paper Out and Font
lights blin k .

Turn the printer off and then back on.
Go to “A bnormal indications” on page 2-6.

Turn the printer off and then back on.
Go to “Irrecoverable operator errors” on

page 2-13.

Operator panel problems

Symptom Action

The Start/Stop
button does not
function, bu t no error
is indicat e d.

Only the Power light
turns on.

One or more buttons
do not function.

One or more lights
do not function.

Turn the printer off and then back on.
Go to “Operator panel service check” on

page 2-23.

2-8 Service Manual

25XX-100, -110

Paper feed problems

Symptom Action

The Paper Out light
is blinking when
there is paper in the
printer.

The Paper Out light
does not blink when
there is no paper in
the printer and the
ASF is not installed.

Print operati on starts
without paper.

The Load/Unload
button does not
function when the
push tractor is
installed.

Form feed length is
not correct.

The Load/Unload
button funct ions
when cut sheets are
being used.

Continuous for m s
feed, but cut shee ts
fail to load.

Go to “Paper Present se nsor s ervi ce check” on

page 2-24.

Be sure the paper present sensor is not blocked.
Go to “Paper Present se nsor s ervi ce check” on

page 2-24.

Be sure the Paper Select lever is in the corr ect
position.

Go to “Paper Select sensor service check” on

page 2-28.

Be sure the Paper Select lever is in the cut sheet
position.

Ver if y that continuous form s have been parked
using the Load/Unload button.

Be sure Auto Cut Sheet is enabled in the Set up
mode.

Go to “Paper Select sensor service check” on

page 2-28.

Diagnostic information 2-9

25XX-100, -110

Symptom Action

The Load/Unload
button functions
when the pull tractor
is installe d .

The Paper Out light
blinks, and the
FormFeed button
does not operate
until paper is located
at first print line.

Lower feed roll shaft
rotates, but paper
does not feed.

Pressing FormFeed
does not feed paper.

Abnormal noise
created while printer
is feeding.

Paper jams, skews,
or creases.

Incorrect or no lin e
spacing: wider,
narrower, or
overlapping lines.

Push/Pull Tractor
does not work.

Be sure the Paper Select lever is in the tractor
position.

Go to “Pull Tractor sensor service check” on

page 2-34.

Be sure the Paper Select lever is in the cor rect
position.

Go to “Paper feed service check” on page2-25.

Incorrect Top-of­form position ing.

2-10 Service Manual

Go to “Top-of-forms service check” on

page 2-35.