Lexmark X 204 Service Manual
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Diagnostic information2-25 7011-2xx / 3xx Controller card service check FRU Action Controller card assembly Verify +24 V dc input from the LVPS/HVPS. • Turn the MFP off. • Disconnect the LVPS/HVPS cable from the controller card at J22. See “Controller card” on page 5-4 for more information. • Turn the MFP on. Verify +24 V dc from the cable connector of J22, pins 8 and 9. Verify that pins 7, 12, and 14 on both the cable and the card connectors are ground. • If voltage is correct, check the continuity in the cable. If the cable is good, see the “Controller card” on page 5-4 for more information. • If grounds are not correct on the cable, first check it for continuity and then check the LVPS/HVPS. See “LVPS/ HVPS service check” on page 2-28 • If the grounds are not correct on the controller card, replace the controller card. (Check with one probe on the connector pin and the other on the ground plane of the card found at each screw head.) Note: With all cables connected, the MFP should complete POST within approximately 12–15 seconds in the following sequence: 1. The function and scan quality LEDs illuminate for one second and then flash three times. 2.Loading is displayed on the operator panel. 3. The CIS illuminates, and the scanner performs a calibration. 4. The drive motor runs. 5. The scanner CIS returns to the home position. 6. Error messages are displayed if applicable. 7. The MFP cycles down into standby mode/ready. Ready is displayed on the operator panel. If immediately following power-on, the operator panel lights are active but the MFP does not go through steps 1 and 2 above, replace the controller card assembly.
2-26Service Manual 7011-2xx / 3xx Cover interlock switch service check Note: Make sure a print cartridge assembly is installed and the cover closes all the way, engaging the cover open switch lever. Dead machine service check CAUTIONCheck the AC line voltage. The voltage should be within the following limits: •100 V ac (volts alternating current) – 127 V ac for the 110 V MFP •200 V ac – 240 V ac for the 220 V MFP FRU Action Cover interlock switch Check the cover interlock cable to make sure it is not plugged into J9, and that the cooling fan cable is not plugged ito J11. If they are, switch plug them into their correct connectors. Disconnect the cover interlock cable from the controller card at J11. Verify continuity between cable pin 1 and pin 2 with the door closed but not open. Verify continuity between cable pin 1 and pin 3 with the door open but not closed. • If either fail continuity, replace the cover interlock switch. • If both pass continuity, turn the MFP on and verify +5 V dc on pin 2 at J11 on the controller card. • Verify pins 1 and 3 are ground. • If voltage or ground is not present, see “Controller card service check” on page 2-25 for more information. Verify discontinuity between pins 2 and 3 whether the door is open or closed. Replace the cover interlock switch if faulty. FRU Action LVPS/HVPSUnplug the MFP, and check the fuses on the LVPS/HVPS board for continuity. • If open, replace the LVPS/HVPS board. - If fuse opens again, see “LVPS/HVPS service check” on page 2-28 for more information. • If not open, unplug the cables at CN102 and CN201 (fuser and controller card respectively). Plug LVPS/HVPS board to source, and turn switch on. Verify 24 V dc on pins 8 and 9 at connector CN201. Verify line voltage (110 or 220 V ac) across pins 1 and 2 of CN102. • If either voltage is not correct, replace the LVPS/HVPS board. • If both voltages are correct, check the controller card. See “Controller card service check” on page 2-25 for more information. Verify grounds.
Diagnostic information2-27 7011-2xx / 3xx Fuser service check When toner is partially fused to the paper, it is usually caused by low fuser temperature. Note: Improper fusing can result from incorrect media setting’s in the driver, or on the MFP. Check those setting’s before servicing the fuser. Note: Make sure the correct voltage fuser is being used on the MFP. Warning: Avoid handling the lamp as much as possible, as it is easily broken. Be careful not to touch the glass housing with bare hands, because skin acids can weaken the glass. The lamp is not a service part. The line voltage to the MFP must be within the following limits: •100 V ac–127 V ac for the 110 V model MFP •200 V ac–240 V ac for the 220 V model MFP Turn the MFP off, and wait a few minutes for the fuser lamp to cool. Turn the MFP on, and observe the lamp turning on during POST. You can see the light from the lamp by opening the left side cover and observing the upper opening through which the fuser power cables pass. Fuser service check (continued) FRU Action Lamp cable LVPS/HVPS FuserUnplug the MFP and disconnect the fuser lamp cable plug from the LVPS/HVPS board connector CN102. Check for continuity across the fuser lamp by checking across the connector pins. • If there is continuity, go to Step 1: Continuity. • If there is no continuity, go to Step 2: No continuity. Step 1: Continuity Turn the MFP on with only the fuser power disconnected. Measure the voltage at connector CN102 on the LVPS/HVPS. It should match the line voltage. If line voltage is not present, see “LVPS/HVPS service check” on page 2-28 for more information. Make sure the fuser thermistor is correctly connected to the controller board. If the problem persists, disconnect the thermistor cable at J15 and check for less than +5 V dc on pin 1. Pin 2 should be ground. If line voltage is incorrect on pin 1, see “Controller card service check” on page 2-25 for more information. Step 2: No continuity Check the lamp cable for continuity. • If correct, replace the fuser. • If incorrect, replace the lamp cable. Disconnect the thermistor cable from J10 on the controller card. Measure the resistance across the ends of the thermistor cable. See “Controller card” on page 5-4 for more information. Replace the fuser assembly if the resistance is lower than 1K ohm or shorted. Note: Resistance measures approximately 240K ohms when cool and 1.4K ohms hot.
2-28Service Manual 7011-2xx / 3xx Hot fuser service check Note: Ensure correct fuser is installed. LVPS/HVPS service check FRU Action Fuser AC cables LVPS/HVPS FuserMeasure the resistance of the thermistor. The resistance measures from approximately 1K ohms immediately after printing or POR to approximately 240K ohms when thermistor reaches room temperature. (It may take 30 minutes to cool.) Replace the fuser assembly as necessary. FRU Action LVPS/HVPSLVPS portion of board Fuses that open typically indicate a faulty LVPS/HVPS. Use the voltage meter to verify the appropriate voltage at the MFP end of the power cable. Remove the LVPS/HVPS assembly from the MFP. Check continuity on the fuses. If either fuse has opened, replace the card. Ensure the switch is off, and plug the power cord into the card. Turn the switch on. CAUTIONThe card has several points where AC voltage is exposed. Carefully verify the AC voltage between pins 1 and 2 matches the power cable (wall) voltage. • If voltage is incorrect, replace the card assembly. • Verify +24 V dc from pins 8 and 9 at CN201. • If voltage is incorrect, replace the card assembly. HVPS portion of board Problems with the HVPS are exhibited in the print quality. See “Print quality service checks” on page 2-35 for more information.
Diagnostic information2-29 7011-2xx / 3xx Main motor service check Modem service check Networking service check Note: Before starting this service check, print out the network setup page. This page is found under Menu - Reports - Network setting’s. Consult the network administrator to verify that the physical network setting’s displayed on the network setting’s page for the device are properly configured. For more network troubleshooting information, consult the Lexmark Network Setup Guide.FRU Action Main motor cable LVPS/HVPS Controller card Verify +24 V dc at J19, pins 8 and 9, and +5 V dc at pin 6 (controller card). Verify ground at pins 4 and 5 for both the card and cable. • If these voltages are correct, check the main motor cable for continuity. - Remove rear cover to access connector on motor. - If continuity exists on each wire, call next level of service. - If continuity does not exist on one or more of the wires, replace the motor cable. • If these voltages are not correct, see the “LVPS/HVPS service check” on page 2-28, or replace the controller card. Note: The main motor is not a service part. FRU Action Modem Controller cardEnsure the phone line is properly connected to the top RJ-11 jack of the modem and phone jack on the wall. Ensure the modem cable is properly connected to the J25 on the modem card and J25 on the controller card. Check the connectors on both cards for damage. Check pin 10 on J25 for +5V. Check pins 12 and 13 for +3.3V. Pins 2, 4, 6, and 8 should be ground. If voltages are present, replace the modem card. If the voltages are not present, replace the controller card. Step Questions / actions Yes No 1If the device is physically connected to the network, verify that the ethernet cable is properly connected on both ends. Is the cable properly connected?Go to step 3. Go to step 2. 2Connect the ethernet cable. Did this fix the problem?Problem resolved Go to step 3. 3Check the printer’s online status under Printers and Faxes on the host computer. Delete all print jobs in the print queue. Is the printer online and in a Ready state.Go to step 5. Go to step 4. 4Change the printer status to online. Did this fix the issue?Problem resolved. Go to step 5.
2-30Service Manual 7011-2xx / 3xx 5Does the IP address displayed on the network setting’s page match the IP address in the port of the drivers using the printer?Go to step 10. Go to step 6. 6Does the LAN use DHCP? Note: A printer should use a static IP address on a network.Go to step 7. Go to step 9. 7Are the first two segments if the IP address 169.254?Go to step 8. Go to step 9 8POR the printer. Is the problem resolvedProblem resolved Go to step 10. 9Reset the address on the printer to match the IP address on the driver. Did this resolve the issue?Problem fixed. Go to step 10. 10Have the network admin verify that the printer and PC’s IP address have identical subnet addresses. Are the subnet addresses the same?Go to step 12. Go to step 11. 11Using the subnet address supplied by the network admin, assign a unique IP address to the printer. Note: The printer IP address should match the IP address on the printer driver. Did this fix the problem?Problem resolved. Go to step 12. 12Try using a different ethernet cable. Did this remedy the situation?Problem resolved Go to step 13 13Have the network administrator check the network drop for activity. Is the drop functioning properly?Replace the controller board. See “Controller card removal” on page 4-13.Problem with network Step Questions / actions Yes No
Diagnostic information2-31 7011-2xx / 3xx Operator panel service check Inspect the operator panel cable for damage. Make sure the cable is plugged in securely. POR the MFP, and check each light for proper operation. Operator panel service check FRU Action Operator panel Controller cardButtons Check connector J4, pin 2 for 3.3 V. If the voltage is present, replace the operator panel. If the voltage is not present, replace the controller card. Perform the panel test and button tests found in diagnostics. See “Panel Test” on page 3-5 and“Button Test” on page 3-5. If the tests fail, replace the operator panel. Lights If the lights don’t illuminate, make sure the cable is properly connected to the controller card and the operator panel. Ensure the controller card has input voltage to it. Verify +24 V dc on cable pins 8 and 9 at J22. • Check for +5 V dc at J4, pin 1. See “Controller card service check” on page 2-25 or page 4 for more information. • If these voltages are not correct, replace the controller card. • If these voltages are correct, replace the operator panel. If more than one light does not turn on or an individual light stays on solid during POST, replace the operator panel. If all lights are dim and operate erratically during POST or all lights come on and stay on solid during POST, replace the FRUs in the following order one at a time: • Controller card • Operator panel
2-32Service Manual 7011-2xx / 3xx Paperpath sensor service check Printhead service check FRU Action All sensors MPF sensor Exit sensor Paper in sensor Controller cardCheck all the sensor flags for breakage or if they are jammed. Check all the sensors for dirt. Check pin 1 on connector J18 for +5V and pin 2 on J18 for +3.3 V. Pins 3, and 4 should be ground. Check pin 1 on connector J8 for +5V and pin2 on J8 for +3.3V. Pin 3 should be ground. Check pin 1 on connector J17 for +5V and pin2 on J17 for +3.3V. Pin 3 should be ground. If any of the readings are incorrect, replace the controller card. If they are correct, replace the malfunctioning sensor. FRU Action PrintheadUnplug the MFP. Disconnect the printhead cables from J13 and J12 on the controller card. Turn the MFP on. On the 7011-2xx controller card, verify +24 V dc on pin 5 at J13 and +5 V dc on pin 7 at J12. On the 7011-3xx controller card, verify +24 V dc on pin 2 at J13 and +5 V dc on pin 10 at J12. Verify grounds on pin 4 at J13 and on pins 2, 6, and 8 at J12. • If voltages or grounds are incorrect, check the controller card. See “Controller card service check” on page 2-25 for more information. • If voltages are correct, replace the printhead (cables are included).
Diagnostic information2-33 7011-2xx / 3xx Paper feed service checks Paper jam error indication during POST Paper picks during POST and/or continuously Paper picks but stops half way through the MFP Paper never picks FRU Action Exit sensor If the exit sensor flag is not resting within the paper exit sensor during POST, the MFP displays a paper jam message. Make sure the flag is operating freely and is correctly installed. Input sensor Input sensor #1 (under print cartridge assembly) and Input sensor #2 (manual)Make sure the input paper feed sensors are working properly. A stuck or incorrectly installed sensor causes this error. FRU Action ACM (auto comp mechanism or paper feed) clutch Manual feed clutchCheck the ACM clutch for wear. The solenoid interacts with the clutch to control the motion of the pick tires. If the ratchet teeth of the ACM clutch assembly are worn or broken, the solenoid may not stop the ACM from rotating. Replace the ACM clutch assembly if necessary. Check the manual feed clutch for the same damage. FRU Action Input sensor #1 (under print cartridge assembly) and Input sensor #2 (manual)Make sure the input sensors are working properly. Check for a broken or stuck flag on the input sensors. Make sure the cables are seated on the controller card at J20 (Tray 1 input) and J18 (manual input). Check for less than +5 V dc on pin 1 at J20 (Tray 1 input) and pin 3 at J18 (manual input sensor). • If correct, replace the input paper feed sensor. • If these voltages are not correct, replace the controller card. FRU Action Paper feed (pick tires) Paper trayOpen the left cover, and verify the solenoid and clutch are functioning when an attempt is made to feed the paper. Make sure the rubber tires are installed and clean. Replace if necessary. Check the rear guide in the paper tray for proper adjustment.
2-34Service Manual 7011-2xx / 3xx Paper occasionally picks or picks multiple sheets at once Paper “trees,” wrinkles, stacks poorly or curls A4, oversized paperfeed service check FRU Action Tray 1 Check tray for paper catch points. If the sheet being fed stops momentarily, the ACM applies additional vertical force causing additional sheets to feed. Do not mix paper types. Paper pick tires Check the tires in the ACM assembly for signs of wear or damage. Replace the tires as necessary. ACM clutch complete bill of material (CBM) Manual feed clutch CBMOpen the left cover, and observe the solenoid and clutch actions at the ACM and manual feed shafts as a print job is attempted. Replace the faulty part. Controller card Disconnect the solenoid cable at J101 on the controller card. Measure the resistance across cable pins 1 and 2 and then pins 3 and 4. • The resistance should be 180–210 ohms. • If it is not, call the next level of service. • If the resistance is 180–210 ohms, check the controller card. See “Controller card service check” on page 2-25 for more information. Replace controller card as necessary. FRU Action Fuser This problem is most likely due to a worn backup roll. It causes the MFP to run hotter than required for the media being printed. Excessive heat can cause paper treeing problems, poor stacking, or curl. Symptom Action 200.20 and 241.18 paper jams when using A4 paper.Verify that the Size/Type item in the Paper Setup menu is set to A4. Verify A4 is chosen as the paper size in the printer driver. Both of these items need to be set to A4 when printing A4 paper. Note: These jams can also occur if the Size/Type setting and drivers are set to letter, and the paper length exceeds the letter paper length by 1/2 inch.