Lexmark 6200 Series Service Manual
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Lexmark 6200 Series Service Manual

Lexmark 6200 Series Service Manual

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Revised: April 2005
Lexmark™ 6200 Series AIO
4411-XXX
• Table of contents
• Start diagnostics
• Safety and notices
• Trademarks
• Index
Lexmark and Lexmark with diamond
design are trademarks of Lexmark
International, Inc., registered in the
United States and/or other countries.

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Summary of Contents for Lexmark 6200 Series

  • Page 1 Revised: April 2005 Lexmark™ 6200 Series AIO 4411-XXX • Table of contents • Start diagnostics • Safety and notices • Trademarks • Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
  • Page 2 You can purchase additional copies of publications related to this product by calling 1-800-553-9727. In other countries, contact your point of purchase. Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.

  • Page 3: Table Of Contents

    4411-XXX Table of contents Safety information........v Preface .
  • Page 4 4411-XXX System board removal ....... .4-12 Maintenance station removal ......4-13 PictBridge door removal .

  • Page 5: Safety Information

    4411-XXX Safety information • The safety of this product is based on testing 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 this product has been prepared for use by a professional service person and is not intended to be used by others.
  • Page 6 4411-XXX Norme di sicurezza • La sicurezza del prodotto si basa sui test e sull'approvazione del progetto originale 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 soltanto al personale di assistenza autorizzato.
  • Page 7 4411-XXX Pautas de Seguridad • La seguridad de este producto se basa en pruebas y aprobaciones del diseño original y componentes específicos. El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas. •...
  • Page 8 4411-XXX 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 responsable de les qüestions de seguretat si s'utilitzen peces de recanvi no autoritzades. •...
  • Page 9 4411-XXX Safety information...

  • Page 10: Preface

    4411-XXX Preface This manual contains maintenance procedures for service personnel. It is divided into the following chapters: 1. General information contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment are listed in this chapter, as well as general environmental and safety instructions.

  • Page 11: General Information

    4411-XXX 1. General information The Lexmark™ 6200 Series (4411-XXX) All-In-One features an electro-mechanical color scanner, printer, and copier that creates characters and graphics by composing programmed patterns of ink dots using a printhead and liquid ink. The printhead uses small heater plates and nozzles to control ink flow and the formation of characters on the print media.

  • Page 12: Power Consumption

    4411-XXX Power consumption • Printing — 14.1 Watts • Idle — 9.7 Watts • Sleep — 8.0 Watts Scanner specifications Scanner Type Flatbed, CIS Scan Modes True Color: 48 Bit Internal 24 Bit External Gray Mode: 16 Bit Internal 8 Bit External Text/Line Art: 1 Bit Per Pixel Scan Method...

  • Page 13: Control Panel

    4411-XXX Control panel Buttons Functions Power Powers AIO on and off. The card reader LED should be on during power up, changing to off when the card reader is accessible for memory card insertion. General information...
  • Page 14 4411-XXX Buttons Functions Mode Cycles the machine between the three selections: copy, scan and photo. The LCD must be updated to display the default screen for the mode selected. For copy mode, the screen contains a transparent overlay across the graphic that displays the following scrolling text: “Place document on scanner and press Start to copy.”...
  • Page 15 4411-XXX Buttons Functions Black Start The Black Start button mirrors the Color Start. Its function is also influenced by the mode selection. The difference between the Black Start and Color Start is that the output, whether from the scanner or printer, is in grayscale instead of color.
  • Page 16 4411-XXX Buttons Functions Resize In Photo selection mode, this button is used to set the image size of photos. In Photo Crop mode, the button is used to change the zoom of the ROI. In Copy mode, the button serves as an enlarge/reduce function. The region of interest is a portion of a photo or an image that is identified by a green outline.
  • Page 17 4411-XXX Buttons Functions Select The Select button allows you to choose an option from a menu. When moving through the menu items, you can scroll through settings for a menu item with the Left and Right Arrow buttons. Press the Select button to save the settings.
  • Page 18 4411-XXX Buttons Functions Stop/Clear The Stop/Clear button will discontinue the current activity and return the display back one level in the menus. It terminates any active scan or print jobs, including returning the scan carriage to its home position and ejecting the unfinished printout. Photo Card Mode: Press the Stop/Clear button to deselect the preview image.

  • Page 19: Maintenance Approach

    4411-XXX Buttons Functions Menu The Menu button will access the advanced functions of the AIO. Pressing the Menu button opens a menu structure containing all settings or functions pertaining to the currently active mode. Each setting or function takes up two lines. The first line is the setting or function name.

  • Page 20: Abbreviations

    4411-XXX Abbreviations Bill of Material Contact Image Sensor End of Form Electrostatic Discharge Flat Printhead Cable Field Replaceable Unit HVPS High Voltage Power Supply Liquid Crystal Display LVPS Low Voltage Power Supply Original Equipment Manufacturer Region of Interest V ac Volts alternating current V dc Volts direct current...

  • Page 21: Diagnostic Information

    Press the Power button to turn the All-In-One on. 1. The Power and Copy lights turn on. 2. Lexmark appears on the LCD. 3. The Copy, Scan, and Photo Card lights go through a flashing sequence, then the Copy light stays on.

  • Page 22: Error Codes

    4411-XXX Error codes Catastrophic error In this state, the All-In-One is in an error mode such that operation cannot continue. These errors affect the entire All-In-One. The LCD is on and operating. An error message is displayed on the LCD. The All-In-One accepts data, but discards it and does not respond.
  • Page 23 4411-XXX Code Name Description Action 0002 Hardware General hardware Unplug the All-In-One; Failure failure (unable to wait a few seconds, localize failure to a then plug the specific system) All-In-One back in and turn the power on. If the error remains, clean the NVRAM by pressing the Up button and Menu...

  • Page 24: Non-Catastrophic Error

    4411-XXX Non-catastrophic error In this state, an error has occurred, but the All-In-One can continue to operate. You may need to intervene using a button press, or the machine may time out and return to the Error! Reference source not found state, depending upon the error.
  • Page 25 4411-XXX Code Name Description Action 1202 Data Error Incorrect data has Unplug the All-In-One; been sent from the wait a few seconds, host computer to the then plug the printer. All-In-One back in and turn the power on. If the error remains, replace USB cable.

  • Page 26: Post Symptom Table

    4411-XXX Code Name Description Action 2200 Scan Carrier The scan carrier has Unplug the All-In-One; Stall stalled. wait a few seconds, then plug the All-In-One back in and turn the power on. If error remains, check all connections to the scanner.

  • Page 27: Symptom Tables

    4411-XXX Symptom tables Locate the symptom in the following tables and take the appropriate action. Carrier transport problems Symptom Action • No carrier movement Go to the “Carrier transport service check” on page 2-10. • Slow carrier movement • Carrier stops •...
  • Page 28 4411-XXX Printer communication problems Symptom Action Not able to print Test Page Check the USB cable and system board cable connections. If okay, replace the system board. Go to the “System board removal” on page 4-12. Scanner problems Symptom Action •...
  • Page 29 4411-XXX Power problems Symptom Action There is no power in the Go to the “Power service check” All-In-One; motors do not operate. on page 2-14. Print quality problems Symptom Action • Voids in characters Go to the “Print quality service check”...

  • Page 30: Service Checks

    4411-XXX Service checks Carrier transport service check Action • System Board Check the carrier transport motor connector J18 on the system board. If connected, check for • Carrier approximately 30 V dc on pins 1 and 2 or at the Transport Motor wire connections located on the rear of the carrier transport motor.

  • Page 31: Cis Module Assembly Service Check

    4411-XXX Action Carrier Assembly Check the following parts for wear or damage: • Printhead cartridge latch • Latch spring • Carrier • Printhead cables Reseat the printhead cables in the system board. If any of these parts are defective, replace the carrier assembly.

  • Page 32: Maintenance Station Service Check

    4411-XXX Maintenance station service check The maintenance station has three functions: 1. Wipes (cleans) the printhead nozzle plates. 2. Provides a place for printheads to fire all nozzles, keeping them clear before printing. 3. Seals the printhead when it is not being used to prevent the nozzles from drying.

  • Page 33: Paper Feed Service Check

    4411-XXX Paper feed service check If your All-In-One does not have paper jam problems, continue with this service check. If your All-In-One has paper jam problems, examine it for the following before you begin the service check: • Check the entire paper path for obstructions. •...

  • Page 34: Power Service Check

    4411-XXX Action Midframe Check the following for wear: Assembly • Small feed rollers • Large feed roller • Exit roller • Star rollers If any of the rollers are worn and cause a paper feed problem, replace the print engine. Go to the “Print engine removal”...

  • Page 35: Print Quality Service Check

    Cleaning the nozzles using the computer: 1. Load plain paper. 2. Open the Lexmark Solution Center. 3. From the Maintenance tab, click Clean to fix horizontal streaks. 4. Click Print. A nozzle page prints, forcing ink through the nozzles to clean the clogged nozzles.
  • Page 36 4411-XXX FRU / Function Action Color print Be sure the print cartridge nozzle plate is clean. cartridge cross Clean with a soft cloth. contamination If cross contamination occurs, check for: • Maintenance station wiper damage. • Used tape on the printhead nozzle plate. If wiper damage is found, replace the maintenance station.

  • Page 37: Scan/Copy Quality Service Check

    To align the print cartridges: 1. Load plain paper. 2. Open the Lexmark Solution Center. 3. From the Maintenance tab, click Align to fix blurry edges. 4. Click Print to print an alignment page and to automatically align the cartridges.
  • Page 38 4411-XXX FRU / Function Action Blank Copies. If blank copies are found, make sure the original document is facing down on the scanner bed. Check the print cartridges to see if they need to be cleaned or replaced. Check the Copy Quality settings. 1.

  • Page 39: Diagnostic Aids

    4411-XXX 3. Diagnostic aids Self test mode To enter the Self Test mode, press the Up Arrow and Menu simultaneously. The LCD displays the Self Test menu screen when the Self Test mode is enabled. USB serial number — To view the USB serial number, press the Up Arrow and Menu buttons simultaneously and hold.
  • Page 40 4411-XXX SRAM test — Verifies all the address buses and data buses that connect to the SRAM area work correctly, and performs the read/ write of data to the SRAM area with all the address buses and data buses. While checking, a “Testing” message is displayed. After that, a “Success”...

  • Page 41: Repair Information

    4411-XXX 4. Repair information This chapter explains how to make adjustments to the printer and how to remove defective parts. Note: Read the following before handling electronic parts. Handling ESD-sensitive parts Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD).

  • Page 42: Adjustments

    4411-XXX Adjustments The user is directed in the Lexmark Solution Center to perform the printhead alignment adjustments after replacing a print cartridge. Removal procedures The following procedures are arranged according to the name of the printer part discussed. CAUTION: Unplug the power cord before removing any parts.

  • Page 43: Scanner Module Assembly Removal

    4411-XXX Scanner module assembly removal 1. Lift and remove scanner lid. 2. Depress tab (A) and remove paper support. 3. Lift scanner assembly. Repair information...
  • Page 44 4411-XXX 4. Depress tabs (B) on scanner support. 5. Depress two latches (C) and lift scanner lid. Service Manual...
  • Page 45 4411-XXX 6. Remove three screws (D) from the midframe cover. Repair information...
  • Page 46 4411-XXX 7. Release tab (E) and lift cover. 8. Unplug all cables from system board. 9. Lift and remove scanner assembly. Service Manual...

  • Page 47: Print Engine Removal

    4411-XXX Print engine removal 1. Remove scanner assembly. 2. Remove eight screws (A). Repair information...
  • Page 48 4411-XXX 3. Lift and remove small exit roller assembly (B). 4. Depress tab (C) on small feed roller. Service Manual...

  • Page 49: Base Assembly Removal

    4411-XXX 5. Depress tabs (D) and loosen back cover. 6. Lift and remove print engine. Base assembly removal 1. Remove scanner assembly. 2. Remove print engine. 3. Remove base assembly. Repair information...

  • Page 50: Carrier Assembly Removal

    4411-XXX Carrier assembly removal 1. Remove scanner assembly. 2. Remove print engine. 3. Disconnect carrier cables from system board. 4. Remove carrier shaft retainer clips (A). 5. Remove carrier shaft from left side. 4-10 Service Manual...
  • Page 51 4411-XXX 6. Disconnect encoder strip (B). 7. Depress carrier belt tensioner (C) and remove belt (D). 8. Lift and remove carrier. 4-11 Repair information...

  • Page 52: System Board Removal

    4411-XXX System board removal 1. Remove scanner assembly. 2. Remove print engine. 3. Disconnect all cables. 4. Remove three screws (A). 5. Remove system board. Warning: When removing the system board, be careful not to damage the end-of-forms flag (B). 4-12 Service Manual...

  • Page 53: Maintenance Station Removal

    4411-XXX Maintenance station removal 1. Remove scanner assembly. 2. Remove print engine. 3. Depress three clips (A). 4-13 Repair information...
  • Page 54 4411-XXX 4. Slide forward and down to remove. 4-14 Service Manual...

  • Page 55: Pictbridge Door Removal

    4411-XXX PictBridge door removal 1. Depress tab (A). 2. Lift and remove. 4-15 Repair information...

  • Page 56: Control Panels Removal

    4411-XXX Control panels removal 1. Lift and remove. Rear cover removal 1. Remove scanner assembly. 2. Depress four clips (A). 3. Remove rear cover. 4-16 Service Manual...

  • Page 57: Asf Guide With Spring Removal

    4411-XXX ASF guide with spring removal 1. Flex ASF guide and remove tab (A) from hole. 2. Remove guide and spring. 4-17 Repair information...
  • Page 58 4411-XXX 3. When reinstalling, ensure the spring goes back into hole (B). 4-18 Service Manual...

  • Page 59: Connector Locations

    4411-XXX 5. Connector locations Units Description Approximate voltage Media Sensor Carrier — Card Reader Pin 2 9 Volts Carrier Carrier Card Reader Control Panel Card Reader Paper Feed Encoder Dial — Scanner Motor Pins 1,2,3,4 1 Volt — Transport Carrier Pins 1 &...
  • Page 60 4411-XXX Service Manual...

  • Page 61: Preventive Maintenance

    4411-XXX 6. Preventive maintenance This chapter contains the lubrication specifications. Follow these recommendations to prevent problems and maintain optimum performance. Lubrication specifications Lubricate only when parts are replaced or as needed, not on a scheduled basis. Use grease P/N 99A0394 to lubricate the following: •...
  • Page 62 4411-XXX Service Manual...

  • Page 63: Parts Catalog

    4411-XXX 7. Parts catalog How to use this parts catalog • SIMILAR ASSEMBLIES: If two assemblies contain a majority of identical parts, they are shown on the same list. Common parts are shown by one index number. Parts peculiar to one or the other of the assemblies are listed separately and identified by description.

  • Page 64: Assembly 1: Covers

    4411-XXX Assembly 1: Covers Service Manual...
  • Page 65 4411-XXX Assembly 1: Covers Asm- Part Units Description Index Number 56P2612 Support, paper (K01, K02) 56P2772 Guide, ASF with spring (K01, K02) 56P2613 Control panel scanner assembly (K01) 56P3809 Control panel scanner assembly (K02) 56P2746 Cover, rear (K01) 56P3810 Cover, rear (K02) 56P2614 Support, scanner (K01, K02) 56P2615...

  • Page 66: Assembly 2: Print Engine, Carrier, And Electronics

    4411-XXX Assembly 2: Print engine, carrier, and electronics Service Manual...
  • Page 67 4411-XXX Print engine, carrier, and electronics Assembly 2: Asm- Part Units Description Index Number 56P2610 Board, system (K01, K02) 21G0175 Printing engine (K01, K02) 13D0400 Power supply (LV) 120 V (K01, K02) 56P2611 Carrier w/cable assembly (K01, K02) 56P2617 Maintenance station assembly (K01, K02) 13D0401 Power supply (HV) 220 V (K01, K02) 13D0402...
  • Page 68 4411-XXX Service Manual...
  • Page 69 4411-XXX Index POST symptom tables power consumption abbreviations 1-10 preventive maintenance adjustments 2-17 print quality carrier transport 2-16 removals cartridge ASF guide with spring 4-17 CIS module assembly 2-11 base assembly connector locations carrier assembly 4-10 control panel control panels 4-16 maintenance station 4-13...
  • Page 70 4411-00X scanner problems table of contents 1-iii Part Numbers 13D0400 13D0401 13D0402 13D0403 21G0175 56P1040 56P2565 56P2604 56P2605 56P2606 56P2607 56P2608 56P2609 56P2610 56P2611 56P2612 56P2613 56P2614 56P2615 56P2616 56P2617 56P2619 56P2620 56P2621 56P2622 56P2623 56P2624 56P2625 56P2626 56P2627 56P2746 56P2747 56P2772 56P2795...

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