Lexmark X 204 Service Manual
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Diagnostic information2-35 7011-2xx / 3xx Print quality service checks Note: Ensure cover is closed tightly. A gap in the opening may allow light to expose the photoconductor resulting in a ‘dirty’ print. Using print quality test pages Blank page Black page Note: Incorrect laser exposure or incorrect charging of the photoconductor causes an all-black page. Always verify the same results from a different print cartridge assembly and developer before proceeding.FRU Action“Service error codes” on page 2-9 Toner cartridge (not a FRU) Remove the toner cartridge, and gently shake it to evenly distribute the toner. Check for cartridge damage. Printhead LVPS/HVPS Controller card Toner electrodes (cable assembly)Blank pages can be caused by a defective printhead assembly, LVPS/HVPS, or controller card. • Printhead errors typically result in MFP service errors. • Blank pages typically are caused by the PC roll not being properly discharged. Try a different PC kit. Unplug the MFP and check continuity between the LVPS/HVPS connection pads marked OPC and the corresponding pin inside the MFP. If there is not continuity, call the next level of service. Try a different toner cartridge and PC kit. If those fail, replace the LVPS/HVPS. FRU Action Toner electrodes (not a FRU) Check the electrodes below the print cartridge assembly for contamination or damage. Correct as necessary. Check continuity between the cable connections on the contact tips below the print cartridge assembly. If continuity fails, call the next level of service. LVPS/HVPS board Controller cardWith the MFP off, disconnect the LVPS/HVPS cable from J22 on the controller card. Turn the MFP on and verify +24 V dc on pins 8 and 9 of the cable. Verify ground on pins 7, 12, and 14. • If the voltage is incorrect, replace LVPS/HVPS board. • If voltage is correct and the toner electrodes are good, replace the controller card. CIS If the MFP prints a black page when copying a page but prints a job from the host PC properly, see “Flatbed service check” on page 2-24.
2-36Service Manual 7011-2xx / 3xx Heavy background Poor development or poorly charged toner particles cause excessive background. This is more noticeable as the toner cartridge nears end-of-life. Partial blank image/white spots (no periodic pattern) Variation in image density horizontally across page Poor fusing of image FRU Action Toner cartridge (not a FRU) PC Kit (not a FRU)Make sure the toner cartridge and PC Kit are correctly installed and the high voltage contacts are clean. If the toner cartridge and PC Kit are installed correctly, try a new PC Kit first, and then try a new toner cartridge. LVPS/HVPS Controller cardCheck the contacts for correct installation and contamination where contact is made between the print cartridge assembly and LVPS/ HVPS board. Clean as necessary. If this does not correct the problem, replace the following FRUs one at a time in the order shown: • LVPS/HVPS board • Controller card FRU Action Toner cartridge (not a FRU) Remove the toner cartridge assembly, and gently shake the assembly to evenly distribute the toner. If toner cartridge is low, try a new toner cartridge. Paper (not a FRU) Make sure recommended paper is being used. FRU Action PC Kit (not a FRU) The charge roll may have an unbalanced pressure against the photoconductor (PC) drum. Try a new PC Kit. Transfer roll Check the springs in the left and right transfer roll bearings. The bearing assemblies should support the transfer roll, applying even pressure to the PC drum. Replace the transfer roll assembly if the springs or bearing show signs of damage or fatigue. Inspect the transfer roll for signs of wear, damage, or contamination. Replace as necessary. FRU Action Paper (not a FRU) Make sure recommended paper is being used. Check the media type and texture setting’s on the MFP and in the driver. Fuser The fuser may not be operating at the proper temperature to fuse the toner to the paper. See “Fuser service check” on page 2-27 for more information.
Diagnostic information2-37 7011-2xx / 3xx Light print White or black lines or bands Toner on back of page FRU Action Toner cartridge (not a FRU) Make sure the toner cartridge and PC Kit are installed correctly and that the toner cartridge is not low on toner. If the problem continues, install a new toner cartridge. Recheck condition before replacing PC Kit if necessary. Transfer roll LVPS/HVPS board Check the transfer roll for signs of toner buildup and contamination. Inspect the HVPS contact (transfer roll) for contamination. Verify the high voltage cable is plugged into the LVPS/HVPS. If all components appear free of contamination, replace the following FRUs one at a time in the order shown: • Transfer roll • LVPS/HVPS board FRU Action Print cartridge assembly (not a FRU) Developer drive coupling assemblyBanding appears as light or dark horizontal lines on a uniformly gray page or on a page with a large area of graphics. Banding is primarily due to a variation in the speed of the paper as it feeds through the MFP, especially in the developer and transfer process. Inspect the toner cartridge and paper feed components, especially the drive coupler and drive gears for debris, binds, or damage. FRU Action PC Kit (not a FRU) Inspect the overall paper path for signs of spilled toner. Gently clean the contaminated areas with a soft cloth or compressed air. Fuser The fuser hot roll can cause toner deposits on the back of the paper if toner is building up on the hot roll. This buildup may transfer to the backup roll, later transferring to the back of the paper. Inspect the hot roll and backup roller for signs of contamination. Replace the fuser as necessary. Transfer roll A transfer roll contaminated with toner can cause toner to transfer to the back of printed pages. Inspect the transfer roll for contamination, and replace as necessary.
2-38Service Manual 7011-2xx / 3xx Solving print quality problems Problem Action Light or blurred characters. Light print The toner cartridge may be getting low on toner: • Remove the toner cartridge and print cartridge assembly. • Shake it from side to side to redistribute the toner. • Reinstall it and recheck for condition. • Make sure you are using recommended print media (see media types and sizes in the User’s Reference.) • The toner cartridge or PC Kit may be defective. Replace the PC Kit first and recheck. Blurred characters Blurred images, including characters, are usually caused by a defective printhead. See “Light print” on page 2-37. Toner smudges appear on the front or back of the page.• Make sure the paper is straight and unwrinkled. • Make sure you are using recommended print media (see media types and sizes in the User’s Reference.) • Replace the PC Kit and recheck before replacing the toner cartridge. See “Toner on back of page” on page 2-37 for more information. Vertical or horizontal streaks appear on the page.Replace the toner cartridge for vertical black streaks. Wipe the glass lens clean with a soft tissue for vertical “white” streaks. For horizontal streaks, see “White or black lines or bands” on page 2-37 for more information. Toner smears or rubs off the page. • Replace the fuser. The toner is not being fused. See “Fuser service check” on page 2-27 for more information. • Try a different kind of paper. Paper designed for copiers gives the best quality fusing. • For all media types, check the media type and texture setting’s in the driver and on the MFP. • Change the media texture setting. If the setting is not in your driver, you can download the correct Lexmark setup utility from the Lexmark Web site at www.lexmark.com. The print is getting light but the Toner Low message is not displayed. • Remove the toner cartridge, and gently shake it from side to side to redistribute the toner. • Replace the toner cartridge.
Diagnostic information2-39 7011-2xx / 3xx The Toner Low message is displayed. • Remove the toner cartridge, and gently shake it from side to side to redistribute the toner (6K cartridge only). • Replace the toner cartridge. Solid black areas on transparencies or white streaks on paper.• Choose a different fill pattern in your software program. • Try a different type of paper. Paper designed for copiers gives the best quality. • Remove the toner cartridge, and gently shake it from side to side to redistribute the toner. • Replace the toner cartridge. Faint images or repetitive spots appear on the page.• Select a different media type or form type setting from your MFP driver. • Try a different type of paper. Paper designed for copiers gives the best quality. • Replace the toner cartridge. Groups of black spots appear in grayscale images.• Toner cartridge may be damaged. Replace the toner cartridge. Pages are blank. • The print cartridge may be out of toner or defective. Replace the cartridge. • You may have a software error. Try turning the MFP off and back on. • Check the printhead. See “Paper feed service checks” on page 2-33 for more information. The MFP is on, but nothing prints. • Make sure the toner cartridge assembly is installed properly. • Is the MFP processing a scan job? The MFP does not print while scanning. • Make sure the network or USB cable is not damaged and is firmly plugged into the connector on the back of the MFP. • Print a menu setting’s page just to save space. - If you cannot print a menu setting’s page, call the next level of support. - If you can print a menu setting’s page, the problem is one of the following: • Computer • Software program • Cable • (USB only) failed ASIC or controller card. Replace card. Note: Test by unplugging USB and replugging it with the MFP on. If the computer indicates “unknown device,” replace the controller card. Toner Low message is displayed and printing stops. Press Start. Print quality will be diminished. Close Front Door message is displayed.Make sure the printer cover is closed. The media skews or buckles. • Don’t overfill Tray 1(see media capacities in the media types and sizes table in the User’s Reference). • Make sure the paper guides are flush against the edges of the media. Problem Action
2-40Service Manual 7011-2xx / 3xx The paper sticks together/MFP feeds multiple sheets of paper. • Remove the paper from Tray 1, and fan it. • Don’t overfill Tray 1(see media capacities in the media types and sizes chart in the User’s Reference). The paper fails to feed from Tray 1.• Remove the paper from Tray 1, and fan the paper. • Make sure Tray 1 is selected from the MFP driver. • Do not overfill the tray. • Check the condition of the rubber on the paper feed rolls. • Verify clutch for ACM is not slipping. The MFP does not print after a paper jam has been cleared. • Clear all jams. • Press Start or . Open and close the MFP cover to restart the MFP. • Make sure the print cartridge assembly is installed properly. Unexpected characters print or characters are missing.• Ensure correct MFP driver is being used. • Reset MFP to user default setting’s. • Restore factory defaults. • Make sure the USB cable is firmly plugged in at the back of the MFP. Jobs are not printing, and MFP display shows an error message.• Make sure the print cartridge assembly is installed properly. • Make sure the MFP top cover is closed. Problem Action
Diagnostic information2-41 7011-2xx / 3xx 840.xx service check Step Questions / actions Yes No 1 POR the machine into configuration mode. Go to the disable scanner menu item. See “Disable Scanner” on page 3-21. Touch “Enable ADF/FB -Enabled and press Submit to save the change. POR the MFP to operating mode. Try running a copy from the ADF and flatbed. Did the 840.xx error recur?Go to step 2. Stop. Problem resolved. 2 Re-enter Configuration mode, scroll to and select the Disable Scanner menu item. Does the screen display ADF Disabled or Auto Disabled?Go to step 3. Go to step 8. 3 Check the ADF cable to ensure it is properly connected to the ADF. Is the cable properly connected?Go to step 5. Go to step 4. 4 Properly connect the cable to the ADF unit and controller board. POR the machine into configuration mode. Go to the disable scanner menu item. See “Disable Scanner” on page 3-21. Touch “Enable ADF/FB -Enabled and press Submit to save the change. POR the MFP to operating mode. Try running a copy from the ADF and flatbed. Did the 840.xx error recur?Go to step 5. Stop. Problem solved. 5 Check the continuity on the ADF cable. Is there continuity?Go to step 7 Go to step 6. 6 Replace the ADF cable. POR the machine into configuration mode. Go to the disable scanner menu item. See “Disable Scanner” on page 3-21. Touch “Enable ADF/FB -Enabled and press Submit to save the change. POR the MFP to operating mode. Try running a copy from the ADF and flatbed. Did the 840.xx error recur?Go to step 7. Stop. Problem solved.
2-42Service Manual 7011-2xx / 3xx 7 Replace the ADF unit. See “ADF assembly removal” on page 4-46. POR the machine into configuration mode. Go to the disable scanner menu item. See “Disable Scanner” on page 3-21. Touch “Enable ADF/FB -Enabled and press Submit to save the change. POR the MFP to operating mode. Run a copy from the ADF. Did the 840.xx error recur?Go to step 8. Stop. Problem solved. 8 Inspect J15, J2, 1 and J5 on the controller board. Are the connections properly connected?Go to step 10. Go to step 9. 9 Properly connect all the connections. Did the 840.xx error recur?Go to step 10. Stop Problem solved. 10 Replace the flatbed unit. See “Flatbed removal” on page 4-48. POR the machine into configuration mode. Go to the disable scanner menu item. See “Disable Scanner” on page 3-21. Touch “Enable ADF/FB -Enabled and press Submit to save the change. POR the MFP to operating mode. Run a copy from the flatbed. Did the 840.xx error recur?Go to step 11 Stop. Problem solved. 11 Replace the controller board. See “Controller card removal” on page 4-13. Did this fix the problem?Problem solved. Contact second-level support. Step Questions / actions Yes No
Diagnostic information2-43 7011-2xx / 3xx Scan quality service checks Image unclear Irregular movement No image Problem Action Dirt on flatbed glass or calibration reference plateClean glass with isopropyl alcohol. Black page If the MFP can print normal pages from the host PC see “Flatbed service check” on page 2-24. Lamp too dark Perform CIS service check. See “Flatbed service check” on page 2-24. Scanner not properly registered Perform scanner registration in diagnostics. See Go to “Scanner Manual Registration” on page 3-20. Problem Action Flatbed motor failure Check the flatbed cable to see if it is properly connected to J1 on the controller Loose belt Visually inspect the belt. If the belt is worn or loose, replace the scanner base assembly. Scanner Freezes (No message) Is the user using TWAIN and WIA (Microsoft Windows) scan drivers simultaneously. These drivers cannot be used at the same time. Home position sensor failure See “Flatbed service check” on page 2-24. Skewed images from the ADF If there is skew on the last 3 or 4 inches of an image, ensure the flatbed cover is properly closed. Problem Action Flatbed cover open Close the flatbed cover. Flatbed motor failure See “Flatbed service check” on page 2-24. Scanner produces blank pages Replace the controller card. Paper in ADF does not feed Go to “ADF service check” on page 2-23. Unable to scan to PC Check to see if the PC and MFP are connected on the network. Go to “Networking service check” on page 2-29.
2-44Service Manual 7011-2xx / 3xx Squeeky print service check Transfer roll service check FRU Action Upper paperfeed deflector assembly (Not a FRU)1. Remove the printer cartridge and photo conductor. 2. Use a spring hook to remove the springs (A) holding the deflector assembly in place. 3. Tilt the assembly up and pull it out of the printer. 4. Pull the shaft out and clean the rollers and deflector with a cloth. 5. Reassmble the deflector and install it in the printer. FRU Action Transfer rollCheck transfer roll area for debris, and clean as necessary. Verify continuity between the spring below the left side bearing and the transfer roll shaft. Verify continuity in the spring and the cable connection on the LVPS/HVPS. Inspect the roll for signs of wear or damage, and replace if necessary. A