Lexmark X 204 Service Manual

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3.  Diagnostic aids
This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the 
problem.
Accessing service menus
There are different test menus that can be accessed during POR to identify problems with the printer.
These menus do not require a POR to access them::Configuration Menu 1. Press and hold  and  .
2. Turn on the printer.
3. Release the buttons when 
Performing Self Test 
displays.The Configuration Menu group contains a set of 
menus, setting’s, and operations which are 
infrequently required by a user. Generally, the 
options made available in this menu group are 
used to configure a printer for operation. 
See “Printhead assembly electronic 
adjustment” on page 3-14 for more information. 
Diagnostics Mode 1. Press and hold   and  .
2. Turn on the printer.
3. Release the buttons when 
Performing Self Test 
displays.The Diagnostics Mode group contains the setting’s 
and operations used while manufacturing and 
servicing the printer. 
See “Diagnostics mode” on page 3-2 for more 
information. 
Network SE Menu Press and hold  and   while in 
the network ports menu.
FAX SE Menu Enter **411 while in the Home 
Prime screen
SE Menu From a Web browser on a host 
PC, add /se to the printer IP 
address 
						

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Diagnostics mode
When the Diagnostics mode is entered, each Diagnostics main menu item displays on the operator panel. When 
a diagnostic test is selected from the main menu, a sub menu displays and each individual test displays in the 
order shown. Any options that are referred to in the menus are displayed when the option is installed.
Available tests
The tests display on the operator panel in the order shown:
Diagnostics mode tests
REGISTRATION
Top Margin These tests are performed to adjust the print head registration. See 
“Registration” on page 3-3
Bottom Margin
Left Margin
Right Margin
Quick Test See “Quick test” on page 3-4.
PRINT TESTS
Tray 1 See “Print Tests” on page 3-5.
Manual Feeder (if installed)
Prt Quality Pgs See “Print quality test pages (Prt Quality Pgs)” on page 3-5.
HARDWARE TESTS
Panel Test See “Panel Test” on page 3-5.
Button Test See “Button Test” on page 3-5.
DRAM Test See “DRAM Test” on page 3-6. 
INPUT TRAY TESTS
Feed Tests See “Feed Tests” on page 3-7.
OUTPUT BIN TESTS
Feed Tests See “Feed Tests” on page 3-7.
BASE SENSOR TESTSee “Base Sensor Test” on page 3-7.
Exit
Front Door
Input  
PRINTER SETUP
Defaults See “Defaults” on page 3-7.
Perm Page Count See “Perm Page Count” on page 3-7.
Serial Number See “Serial Number” on page 3-8.
Engine Setting 1 through 4 See “Engine Setting 1-4” on page 3-8.
Model Name See “Model Name” on page 3-8.
Configuration ID See “Configuration ID” on page 3-8.
Edge to Edge See “Edge to Edge” on page 3-9.
Enable Edge to Edge Copy See “Enable Edge to Edge Copy” on page 3-9.
EP SETUP
EP Defaults See “EP Defaults” on page 3-9.
Fuser Temp See “Fuser Temp” on page 3-9. 
						

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Registration
Printer
Print registration makes sure the black printing is properly positioned on the page. 
To set print registration:
1.Select REGISTRATION from the DIAGNOSTICS menu.
2.Use   or   to select Quick Test, and press  . See “Quick test” on page 3-4. 
The message Quick Test Printing… appears on the display, and the page prints.
Retain this page to determine the changes you need to make to the margin setting’s.
3.Use   or   to select the margin setting you need to change, and press  .
4.Use   to decrease or   to increase the offset values, and press   to confirm the value.
The message Submitting changes displays, and the original margin setting screen appears.
The print registration ranges are: Transfer Adjust See “Transfer” on page 3-9.
Print Contrast See “Print contrast” on page 3-9.
Charge Roll See “Charge Roll” on page 3-9.
Gap Adjust See “Gap Adjust” on page 3-10
Auto Dark Adj See “Auto Dark Adjust” on page 3-10.
REPORTS
Main setting’s Page See “Main setting’s Page” on page 3-10.
EVENT LOG
Display Log See “Display Log” on page 3-10.
Print Log See “Print Log” on page 3-10.
Clear Log See “Clear Log” on page 3-11.
Development Menu
Scanner Tests
ASIC Test See “ASIC Test” on page 3-11.
Feed test See “Feed Test” on page 3-11.
Scanner sensor tests See “Sensor Test” on page 3-12.
EXIT DIAGNOSTICSThis selection exits Diagnostics mode, and Resetting the Printer 
displays. The printer performs a POR, and returns to normal mode.
Description Value Direction of change
Top margin -50 to +50 
Each increment corresponds to 8 
scans at a 600 dpi scan rate (0.0133 
inches or 0.339 mm)
. 
The default is 0.A positive change moves the image down the 
page and increases the top margin. A negative 
change moves the image up and decreases 
the top margin. No compression or expansion 
occurs.
Bottom margin -25 to +25 
Each increment causes 
approximately 0.55 mm shift in the 
bottom margin.
The default is 0.A positive offset moves text down the page and 
narrows the bottom margin, while a negative 
offset moves text up the page and narrows the 
bottom margin. The image is compressed or 
expanded.
Diagnostics mode tests (Continued) 
						

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5.Print another copy of the Quick Test to verify your changes.
6.Continue changing the setting’s by repeating steps 3 through 5.
To exit REGISTRATION, press Back (
). 
Quick test
The Quick Test contains the following information:
•Print registration setting’s
•Alignment diamonds at the left, right, top. and bottom
•Horizontal lines to check for skew
•General printer information, including current page count, serial number, and code level.
To print the Quick Test page:
Note:  Print the Quick Test Page on letter or A4 paper.
1.Select REGISTRATION from DIAGNOSTICS.
2.Use   or   to select Quick Test, and press  . 
The message Quick Test Printing… appears on the display.
Once the Quick Test Page completes printing, the Registration screen displays again.Left margin -50 to +50 
Each increment corresponds to 4 
pixels at 600 dpi (0.00666 in. or 
0.1693 mm).
The default is 0.A positive change moves the image to the left, 
and a negative change moves the image to the 
right. No compression or expansion occurs.
Right margin -50 to +50 
Each increment corresponds to an 
approximate shift of 4 pixels at 600 
dpi.
The default is 0.A positive change moves the image to the left, 
and a negative change moves the image to the 
right. Description Value Direction of change
Lexmark x54x 
						

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Print Tests
Input source tests
The purpose of the diagnostic PRINT TESTS is to verify that the printer can print on media from each of the 
installed input options. The contents of the Print Test Page vary depending on the media installed in the selected 
input source.
Check each Test Page from each source to assist in print quality and paper-feed problems.
To run the Print Test Page:
1.Select PRINT TESTS from the Diag Menu, and press Select ().
2.Select the media source (Tray 1,or Manual Feeder), and press Select (),
3.Select Single or Continuous, and press Select ().
•If Single is selected, a single page is printed.
•If Continuous is selected, printing continues until Stop ( ) is pressed to cancel the test.
If a source is selected that contains envelopes, an envelope test pattern is printed. If Continuous is 
selected, the test pattern is printed only on the first envelope.
Note:  The Print Test Page always prints on one side of the paper, regardless of the duplex setting.
4.Press Back ( ) to return to PRINT TESTS. 
Print quality test pages (Prt Quality Pgs)
The print quality test consists of 4 pages. Pages one and two contain a mixture of graphics and text. The 
remainder of the pages contain only graphics. The test prints on the media in tray 1.
This test may be printed from either Configuration Menu or the Diagnostics Menu.
To run the print quality pages from the Diagnostics Menu:
1.Select PRINT TESTS, and press Select ( ). 
2.Select Print Quality Pgs, and press Select ().
The message Printing Quality Test Pages is displayed. 
Note:  Once the test is started, it cannot be canceled. 
When the test pages print, the printer returns to the original screen.
Hardware Tests
Panel Test
This test verifies the operator panel LCD function.
To run the Panel Test:
1.Select Hardware Tests from Diag Menu, and press Select ().
2.Select Panel Test, and press Select ().
The Panel Test continually executes.
Press Stop ( ) to cancel the test.
Button Test
This test verifies the operator panel button function. 
						

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To run the Button Test:
1.Select Hardware Tests from Diag Menu, and press Select ().
2.Select Button Test, and press Select ().
press count: 0 appears.
press each operator panel button, and watch to see if the number of press counts increases by one for 
each press.
Note:  If you press Stop ( ), you end the test.
Press Stop ( ) to cancel the test.
DRAM Test
This test checks the validity of DRAM, both standard and optional. The test writes patterns of data to DRAM to 
verify that each bit in memory can be set and read correctly.
To run the DRAM Test:
1.Select Hardware Tests in Diag Menu, and press Select ().
2.Select DRAM Test, and press Select (). 
a.The printer displays:
b.The printer initiates a POR of the printer, and the following screen is displayed:
c.After the POR, the printer begins testing the memory.
P:###### represents the number of times the memory test has passed and finished successfully. 
Initially, 000000 displays with the maximum pass count being 99,999.
F:##### represents the number of times the memory test has failed and finished with errors. Initially, 
0000 displays with the maximum fail count being 99,999.
3.Once all the memory is tested, the test stops.
To stop the test early, turn off the printer.DRAM Test Testing…
Resetting the 
Printer
DRAM Test 128M
P:###### F:##### 
						

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Input Tray tests
Feed Tests
This test allows you to observe the paper path of media as it passes through the printer. Any installed input tray 
can be tested. The pages fed through the printer are blank.
To run the Feed Test:
1.Select INPUT TRAY TESTS from Diag Menu, and press Select ().
2.Select Feed Tests, and press Select ().
3.Select the tray to be tested. Choices are installed trays, including Tray 1,and MP Feeder.
4.Open the upper rear door to view the paper path.
Note:  Do not open the upper front door. The test will not run if the front door is open.
5.Select Single or Continuous, and press Select ().
•Single—a single sheet of blank paper is fed, and the test stops.
•Continuous—sheets are fed continuously until Stop ( ) is pressed.
To Exit the test, press Back () or Stop ().
Output bin tests
The Output bin tests setting is used to test the printer’s output bins and its sensors.
Feed Tests
This test verifies that the media from the printer’s default input source feeds to the specific output bin. Press   
to select Single, or press   and   to select Continuous. The Single test feeds one sheet of media to the 
default output bin. No buttons are active during this test. The Continuous test feeds media to the default output 
bin until   is pressed. The indicator light blinks green, and the operator panel displays [Select Output Bin] 
Feeding... while either of these tests perform.
Base Sensor Test
These tests allow you to verify the correct functioning of the front door, input, and output sensors.
1.Select Base Sensor Test from Diag Menu, and press Select ().
2.Select the sensor you want to test, and press Select ().
The following test are available: Exit, Front door, and Input.
Printer setup
Defaults
US/Non-US defaults changes whether the printer uses the US factory defaults or the non-US factory defaults. 
The setting’s affected include paper size, envelope size, PCL symbol set, code pages, and units of measure.
Changing this setting resets the printer to factory defaults, and data may be lost. It cannot be undone.
Perm Page Count
You can view, but not change any of the three counts displayed under PAGE COUNTS. 
						

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To view the Prt Color Pg Count, the Prt Mono Pg Count, or the Perm Page Count:
1.Select PRINTER SETUP from DIAGNOSTICS, and press Select ().
2.Select PAGE COUNTS, and press Select ( ). 
3.Select the page count you wish to view:
•Prt Color Pg Count
•Prt Mono Pg Count
•Perm Page Count
4.Press Select ().
The value of the page count appears.
Press Back (
) to return to PRINTER SETUP.
Serial Number
The serial number can only be viewed. It cannot be changed.
To view or change the serial number:
1.Select PRINTER SETUP from DIAGNOSTICS, and press Select ().
2.Select Serial number, and press Select ().
Press Back (
) to return to PRINTER SETUP.
Engine Setting 1-4
Warning:  Do not change these setting’s unless requested to do so by your next level of support. 
Model Name
The model name can only be viewed and cannot be changed.
Configuration ID
The two configuration IDs are used to communicate information about certain areas of the printer that cannot be 
determined using hardware sensors. The configuration IDs are originally set at the factory when the printer is 
manufactured. However, the servicer may need to reset Configuration ID 1 or Configuration ID 2 whenever the 
system board is replaced. The IDs consist of eight digits. The first seven digits in each ID are hexadecimal 
numbers, while the last digit is a checksum of the preceding seven digits. Each ID can contain a combination of 
the digits 0 through 9, and the letters A through F.
Note:  When the printer detects a Configuration ID that is not defined or invalid, the following occurs:
•The default standard model Configuration ID is used instead.
•Configuration ID is the only function available in DIAGNOSTICS.
•Unless the menu is in DIAGNOSTICS, Check Config ID displays. 
To set the configuration ID:
1.Select PRINTER SETUP from DIAGNOSTICS, and press Select ().
2.Select Configuration ID, and press Select ().
The current value for Configuration ID 1 appears with the left character or digit underlined.
3.Enter the Configuration ID 1.
•Change the left character or digit first.
•To change a character or digit, press   to decrease or   to increase the underlined value, and 
press Select (). 
						

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•To move to the next character or digit, press   or  , and press Select ().
•When you press Select ( ) on the last digit, the value will be submitted. 
If Invalid ID appears, the entry is discarded, and the previous Configuration ID 1 is displayed on the 
screen.
If the process is successful, Submitting Selection appears on the display, followed by the current 
value for Configuration ID 2.
4.Repeat the steps for entering the Configuration ID 2, and press Select ().
If the Configuration ID 2 is validated, Submitting Selection appears, and a check ( ) appears next to 
Printer Setup. 
5.Restart the printer. A POR is not automatically performed.
Edge to Edge
Enable Edge to Edge Copy
This setting is set to either on or off. Off is the default setting.
EP Setup
EP Defaults
This setting is used to restore each printer setting listed in EP SETUP to its factory default value. To restore EP 
Defaults:
1.Select EP Setup from Diag Menu, and press Select ().
2.Select EP Defaults, and press Select ().
3.Select Restore to reset the values to the factory setting’s, and select Do Not Restore to exit without 
changing the setting’s.
To cancel and return to the menus, press Back ().
Fuser Temp
This adjustment can be used to help solve some customer problems with paper curl on low-grade papers and 
problems with letterheads on some types of media. 
The fuser temperature can be adjusted to: Low, Normal, High. The default is Normal.
To restore EP Defaults:
1.Select EP Setup from Diag Menu, and press Select ().
2.Select Fuser Temp, and press Select ().
3.Select Normal, High, or Low. The default is Normal.
Transfer
The transfer can be adjusted to Low, Medium, or High. The default setting is Medium.
Print contrast
The print contrast can be adjusted to Low, Medium, or High. The default setting is Medium.
Charge Roll
The charge roll can be adjusted to Low, Medium, or High. The default setting is Medium. 
						

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Gap Adjust
Adjusts the minimum gap between sheets during printing. This setting reduces speed (pages per minute), but 
can be used to reduce curl of printed media and improve stacking in the output bin. 
The range is 0 (default) to 255. Adjusting by one results in 9 mm of increased gap.
Auto Dark Adjust
This setting attempts to optimize the amount of toner used when printing with a specific operating point. Each 
time this setting executes, the printer performs the following:
•Calibrates its toner density sensor
•Measures the reflectivity of its bare drum
•Prints patches on the drum and measures the drum’s reflectivity through the patches
•Cleans the transfer roll
•Calculates reflectivity ratios and operating points in order to attain each operating point’s 
darkness target
•Modifies the EP mechanism as necessary to adjust toner darkness.
No messages are displayed on the operator panel to give any indication that this test is running. When 
deactivated, the printer disables.
Reports
Main setting’s Page
To print the Menu setting’s Page:
1.Select Reports from Diag Menu, and press Select ().
2.Select Menu setting’s Page, and press Select ().
Event Log
Display Log
The event log provides a history of printer errors. It contains the 12 most recent errors that have occurred on the 
printer. The most recent error displays in position 1, and the oldest error displays in position 12 (if 12 errors have 
occurred). If an error occurs after the log is full, the oldest error is discarded. Identical errors in consecutive 
positions in the log are entered, so there may be repetitions. All 2xx and 9xx error messages are stored in the 
event log.
To view the event log:
1.Select EVENT LOG from Diag Menu, and press Select ().
2.Select Display Log, and press Select ().
Up to three error codes display at a time. press  or  to view additional error codes. press   to view 
additional details.
Press Back (
) to return to the EVENT LOG menu.
Print Log
Additional diagnostic information is available when you print the event log from DIAGNOSTICS rather than 
CONFIG MENU. 
The Event Log printed from DIAGNOSTICS includes: