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Lexmark 7200 Color Jetprinter Service Manual

Service manual
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7000 Color Jetprinter™
7200, 7200V Color Jetprinter
4092-00X
• 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 7200 Color Jetprinter

  • Page 1 7200, 7200V Color Jetprinter 4092-00X • 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 Comments may be addressed to Lexmark International, Inc., Department D22A/035-3, 740 New Circle Road, Lexington, Kentucky 40550, U.S.A. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you.If your printer has broken or missing parts, or if you are missing publications, call 1-800- 4LEXBMP.

  • Page 3: Table Of Contents

    4092 Contents Preface ..........vii General Information .
  • Page 4 4092 Code Module Removal......4-6 Edge Guide Asm and Paper Load Shaft Removal ..4-6 Encoder Card Removal .
  • Page 5 4092 Assembly 7: Sheet Feeder......7-16 Assembly 8: Maintenance Station ....7-18 Index .

  • Page 6: Preface

    This product is designed, tested and approved to meet strict global safety standards with the use of specific Lexmark components. The safety features of some parts may not always be obvious. Lexmark is not responsible for the use of other replacement parts. •...
  • Page 7 Lexmark spécifiques. Les caractéristiques de sécurité de certains éléments ne sont pas toujours évidentes. Lexmark ne peut être tenu responsable de l'utilisation d'autres pièces de rechange. • Les consignes d'entretien et de réparation de ce produit s'adressent uniquement à...
  • Page 8 Lexmark. Puede que las características de seguridad de algunas piezas no sean siempre evidentes. Lexmark no se hace responsable del uso de otras piezas de recambio. •...
  • Page 9 Este produto foi concebido, testado e aprovado para satisfazer os padrões globais de segurança na utilização de componentes específicos da Lexmark. As funções de segurança de alguns dos componentes podem não ser sempre óbvias. A Lexmark não é responsável pela utilização de outros componentes de substituição.
  • Page 10 4092 Preface...

  • Page 11: General Information

    4092 1. General Information The Lexmark Color Jetprinter Series 7000, 7200 & 7200V (Machine Type 4092) printers are personal, near laser-quality inkjet printers. The print cartridges contain single-unit customer- replaceable supply items. Dual printheads provide color and true black printing without changing printheads. The black cartridge has a total of 208 nozzles and installs on the left.

  • Page 12: Power Consumption

    4092 Power Consumption • Less than 5 Watts - power off and power to the printer • 10 Watts - Idle Mode (power on - not printing) • 30 Watts - Printing (average) • 40 Watts - Printing (peak) Maintenance Approach The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part.

  • Page 13: Abbreviations

    4092 Abbreviations Customer Engineer Customer Setup End of Forms Electrostatic Discharge Field Replaceable Unit HVPS High Voltage Power Supply Light-Emitting Diode LVPS Low Voltage Power Supply NVRAM Nonvolatile Random Access Memory Original Equipment Manufacturer POST Power-On Self Test V ac Volts alternating current V dc Volts direct current...

  • Page 14: Diagnostic Information

    4092 2. Diagnostic Information Use the error indicator table, symptom tables, service checks, and diagnostic aids to determine the failing part. Start Service error indications show as a series of flashes of the Power light. There is a pause between each series of flashes. If your printer has an error indication, locate the series of flashes in the “Error Indicator Table”...

  • Page 15: Error Indicator Table

    4092 Error Indicator Table Number Error Power Action Code Light Flashes Replace the code module and/or system board and printhead cable. 66 - Replace the code module and/or system board and printhead cable. Replace the Code Module and/or system board. Go to the “Transport Service Check”...

  • Page 16: Post Symptom Table

    4092 If your printer completes POST with no errors, go to the “Symptom Tables” on page 2-4, locate the symptom and take the indicated action. If your printer does not complete POST, locate the symptom in the following table and take the indicated action. POST Symptom Table Symptom Action...

  • Page 17: Symptom Tables

    4092 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 “Transport Service Check” • Slow carrier movement on page 2-15. • Carrier stops •...
  • Page 18 4092 Paper Feed Problems Symptom Action Paper fails to stop at first print line Go to the “First Print Line Service Check” on page 2-6. • Fails to pick paper Go to the “Paper Feed Service • Picks more than one sheet of Check”...

  • Page 19: Service Checks

    4092 Service Checks Envelope Feed Service Check Action Envelope Guide Be sure the envelope guides have been turned to the envelope load positions. Be sure the envelope guides are against the envelopes. Perform the “Paper Feed Service Check” on page 2-8.

  • Page 20: Maintenance Station Service Check

    4092 Maintenance Station Service Check The maintenance station has two functions: 1. Cleans the printhead nozzles during the print operation. 2. Seals the printhead when it is not being used to prevent the nozzles from drying. Action Maintenance As the carrier moves to the right over the Station Assembly maintenance station, a slot on the bottom of the carrier engages a tab on the sled of the...

  • Page 21: Paper Feed Service Check

    4092 Paper Feed Service Check If your printer does not have paper jam problems, continue with the service check. If your printer does have a paper jam problem, examine it for the following before you begin the service check: • Check the entire paper path for obstructions.
  • Page 22 4092 Action Paper Feed Motor A noisy or chattering motor or a motor that fails to turn, can be caused by: • An open or short in the motor • An open or short in the motor driver on the system board •...

  • Page 23: Paper Path Service Check

    4092 Paper Path Service Check Examine the printer for the following before you begin this service check: • Check the entire paper path for obstructions. • Be sure the paper guides are not worn or broken and are posi- tioned against the paper without binding or buckling the paper. •...

  • Page 24: Parallel Port Service Check

    4092 Parallel Port Service Check Action Parallel Port Run a test page to be sure the printer can print. Run the “Parallel Port Test” on page 3-5. If the test fails, replace the system board. Power Service Check An Error Code 92 is caused by a shorted Print Cartridge, or a short in the circuit to the Print Cartridges.

  • Page 25: Print Quality Service Check

    4092 Print Quality Service Check Action Print Cartridge Be sure the printer contains good print cartridges. Printhead Carrier Reseat the printhead cables in the system board Assembly and check the following parts for wear or damage: • Print Cartridge Latch •...
  • Page 26 4092 Action System Board • Perform the “Test Page” on page 3-7. Look for a break in the diagonal line of the test pattern. A Printhead Cable broken line indicates one or more print nozzles are not working. Run the test again to verify the Rubber Backer failure.
  • Page 27 4092 Action Paper Feed Ink smudging and smearing can be caused by paper problems or problems in the paper feed area. Check the following: • Correct type of paper is being used. • Paper for curl or wrinkles. • Feed rollers for wear, dirt, or looseness. •...

  • Page 28: Transport Service Check

    4092 Transport Service Check Action Transport Motor Check the motor for binds, or loose motor pulley. Disconnect the transport motor (J4) from the system board. Check for 8 to 18 ohms between pins 1 and 2 on the motor cable. If the reading is incorrect, replace the motor.
  • Page 29 4092 Video Service Check Action Video Board Print a job from a different application. (4092-005) Perform a “Test Page” on page 3-7. Check the cable between the video board and system board. Check the video source connections. If the cable and all connections are good, replace the video board.

  • Page 30: Diagnostic Aids

    4092 3. Diagnostic Aids Use these diagnostic test procedures to verify a repair. There are two ways to enter test procedures, each procedure will indicate the method to use: Procedure 1: • Press and hold the Paper Feed button while turning the printer on.

  • Page 31: Encoder Sensor Test

    4092 Encoder Sensor Test This test disables the printer motors to let you manually move the carrier to verify the encoder is working correctly. To run the test: 1. Turn the printer off and place a two pin jumper on connector J6 as shown below.

  • Page 32: Initialize Error Log

    4092 Initialize Error Log This test lets you track new errors. Use this procedure to reset the error log to zero. The error log is especially helpful in diagnosing intermittent or difficult problems. To run the test: 1. Turn the printer off and place a two pin jumper on connector J6 as shown below.

  • Page 33: End Of Forms (Eof) Test

    4092 End of Forms (EOF) Test This test checks the EOF sensor on the system board. During the test, the power light blinks rapidly. The Busy Light shows the EOF sensor status in the following manner: • On - paper is in sensor •...

  • Page 34: Parallel Port Test

    4092 Parallel Port Test This test performs a wrap around test between the printer parallel port and the parallel port test connector. This test requires a parallel port wrap plug. Install the wrap plug in the parallel port and move the jumper to pins (1 & 2) on the test connector, before you start the test.

  • Page 35: Print Nvram Contents

    4092 Print NVRAM Contents This test prints the contents of NVRAM in hexadecimal format. To run the test: 1. Turn the printer off and place a piece of paper in the manual feed far enough to activate the EOF sensor. 2.

  • Page 36: Test Page

    4092 Test Page This test prints the test page. To run a complete test page of black and color patterns, be sure the print cartridges are in good condition. Install a black print cartridge in the left side of the printhead cradle and a color print cartridge in the right side.

  • Page 37: Repair Information

    4092 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. When working on the printer, always unplug the printer from the wall outlet. High voltage is present in the power supply as long as it is plugged into the wall outlet.

  • Page 38: Adjustments

    4092 Adjustments The user is directed, in the Printer Control program, to perform the head to head and bidirectional alignment adjustments after replacing a print cartridge. Removal Procedures The following procedures are arranged according to the name of the printer part discussed. Unplug the power cord before removing any parts.

  • Page 39: Base Assembly Removal

    4092 Base Assembly Removal 1. Remove the front cover. 2. Remove the rear cover. 3. Disconnect the power supply connector at the system board. 4. Remove the two screws from the maintenance station assembly. Pull up the right side of the mid frame assembly and pull forward and remove the maintenance station assembly.

  • Page 40: Carrier Frame Assembly Removal

    4092 Carrier Frame Assembly Removal 1. Remove the front cover. 2. Remove the rear cover. 3. Remove the base assembly. 4. Disconnect the paper feed motor and power supply connectors from the system board. 5. Remove the four screws [A] securing the carrier frame to the left and right side frames and remove the carrier frame assembly.

  • Page 41: Carrier Transport Motor Removal

    4092 Note: During reassembly: 1. Be sure the small feed roll spring extensions [B] are in the grooves of the small feed roll arms. 2. Be sure the short extensions of the two paper flap springs are trapped under the carrier frame [C]. 3.

  • Page 42: Code Module Removal

    4092 Code Module Removal 1. Remove the front cover. 2. Remove the rear cover. 3. Gently pry the Code Module from the system board noting the position of the notch in the module. The notch is down. Edge Guide Asm and Paper Load Shaft Removal 1.

  • Page 43: Exit Drive Belt Removal

    4092 Exit Drive Belt Removal 1. Remove the front cover. 2. Remove the rear cover. 3. Remove the carrier frame assembly. 4. Remove the paper load door and manual insert tray. 5. Remove the small feed roll shaft. 6. Remove the two screws from the star roller assembly and remove the assembly.

  • Page 44: Front Cover Removal

    4092 Front Cover Removal 1. Place a screwdriver in slot [A] and release the cover latches. 2. Slide the cover forward and off the printer. To reassemble: 1. Slide the cover over the matching pieces on the bottom cover. 2. Press in both sides opposite the cover latches until they latch. Gutter Pad Removal 1.

  • Page 45: Inside Idler Gears Removal

    4092 Inside Idler Gears Removal 1. Remove the front cover. 2. Remove the rear cover. 3. Remove the printer from the base assembly. 4. Remove the paper feed motor. 5. Gently pry the two idler gears from the left side frame.

  • Page 46: Large Feed Roll Removal

    4092 Large Feed Roll Removal 1. Remove the front cover. 2. Remove the rear cover. 3. Remove the carrier frame assembly. 4. Using a small screwdriver, pry open the slot in the retainer clip and remove it and the compound idler gear from the compound idler stud.

  • Page 47: Large Outside Gear Removal

    4092 Large Outside Gear Removal 1. Remove the front cover. 2. Remove the rear cover. 3. Remove the paper load door and manual insert tray. 4. Remove the C-clip from the feed arm assembly and remove the feed arm assembly. 5.

  • Page 48: Left Side Frame Assembly Removal

    4092 Left Side Frame Assembly Removal 1. Remove the front cover. 2. Remove the rear cover. 3. Remove the carrier frame assembly. 4. Remove the paper load door and manual insert tray. 5. Using a small screwdriver, pry open the slot in the retainer clip [A] and remove it and the compound idler gear from the compound idler stud.

  • Page 49: Maintenance Station Assembly Removal

    4092 Maintenance Station Assembly Removal 1. Remove the front cover. 2. Remove the rear cover. 3. Remove the two screws from the maintenance station assembly, lift up the right side of the mid frame assembly and slide the maintenance station assembly forward, out of the printer.

  • Page 50: Paper Feed Motor Removal

    4092 Paper Feed Motor Removal 1. Remove the front cover. 2. Remove the rear cover. 3. Remove the base assembly. 4. Remove the two screws securing the paper feed motor and remove the motor. Note the routing of the motor cable. Paper Guide and EOF Flag Assembly Removal 1.
  • Page 51 4092 Note: During reassembly: 1. Be sure the small feed roll spring extensions [B] are in the grooves of the small feed roll arms. 2. Be sure the short extensions of the two paper flap springs are trapped under the carrier frame [C]. 3.

  • Page 52: Paper Load Door Removal

    4092 Paper Load Door Removal Spread the left side frame where it joins the paper load door and remove the door. Pick Roll Shaft, Hub and Envelope Bucklers Removal 1. Remove the front cover. 2. Remove the rear cover. 3. Remove the paper load door and manual insert tray. 4.

  • Page 53: Printhead Cable, Cradle & Paper Deflector Removal

    4092 Printhead Cable, Cradle & Paper Deflector Removal 1. Remove the front cover. 2. Remove the printhead carrier assembly. 3. Disconnect the printhead cable from the encoder card. Note the routing of the cable under the retaining clip on the carrier. 4.
  • Page 54 4092 Note: Be sure the cable is secured under the three retaining clips [B] on the back of the carrier. Repair Information 4-18...

  • Page 55: Printhead Carrier Assembly Removal

    4092 Printhead Carrier Assembly Removal 1. Remove the front cover. 2. Unlock the three printhead cable connectors and disconnect the printhead cable from the system board. 3. Remove the screws from the ends of the carrier guide rod and move the carrier to the left. 4.

  • Page 56: Rear Cover Removal

    4092 Rear Cover Removal 1. Remove the front cover. 2. Place a screwdriver in slot [A] and release the cover latches. 3. Slide the cover up and off the printer. 4. To reassemble, place the cover over the tabs in the bottom cover and press down until the cover latches.

  • Page 57: Small Feed Roll Shaft, Rollers & Paper Flap Removal

    4092 Small Feed Roll Shaft, Rollers & Paper Flap Removal 1. Remove the front cover. 2. Remove the rear cover. 3. Remove the carrier frame assembly. 4. Spread the left and right side frames apart far enough to remove the small feed roll shaft assembly. Star Roller Removal 1.

  • Page 58: Video Board Removal

    4092 Video Board Removal 1. Remove the front cover. Note the routing of the video card cable and the ground strap. 2. Disconnect the video cable from the system board and the ground strap from the frame. 3. Remove the rear cover. 4.

  • Page 59: Connector Locations

    4092 5. Connector Locations System Board Connectors Printhead Cable 1 Printhead Cable 2 Printhead Cable 3 Transport Motor Paper Feed Motor Test Jumper Temperature Sensor Parallel Port Power Supply Video Board Paper Feed Switch Power Switch EOF Sensor Code Module Connector Locations 5-1...

  • Page 60: Encoder Card Connector

    4092 Encoder Card Connector Connector Locations 5-2...

  • Page 61: Preventive Maintenance

    4092 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 1329301 to lubricate the following: •...
  • Page 62 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 63: Parts Catalog

    4092 7. Parts Catalog How To Use This Parts Catalog • SIMILAR ASSEMBLIES: If two assemblies contain a majority of identical parts, they are broken down 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

    4092 Assembly 1: Covers...
  • Page 65 4092 Asm- Part Units Description Index Number 1 -1 17B0150 Base Asm includes Feet, Gutter Pad (4092-001, 003, 006) 17B0151 Base Asm includes Feet, Gutter Pad (4092-002, 004, 005) 13A1234 Exit Tray and Extender (4092-001, 003, 006) 13A1452 Exit Tray and Extender (4092-002, 004, 005) 13B0201 Front Cover Asm, Access Cover with...
  • Page 66 4092 Assembly 1: Covers (continued)
  • Page 67 4092 Asm- Part Units Description Index Number 1 - 4 17B0158 Gutter Pad (Large) 69G4119 Gutter Pad (Small) 13B0203 Lens (LED) & Power Button 13B0239 Screw (PP) 13B0239 Screw (PP) 17B0166 Cover, Video Card 17B0164 Cable, Video Ground 17B0163 Cable, Video Flex 17B0161 Board, Video 17B0162...

  • Page 68: Assembly 2: Frames

    4092 Assembly 2: Frames...
  • Page 69 4092 Asm- Part Units Description Index Number 2 -1 13B0411 Left Side Frame (4092-001, 003, 006) 13B0412 Left Side Frame (4092-002, 004, 005) 13B0272 Mid Frame 13A1236 Right Side Frame (4092-001, 003, 006) 13A1446 Right Side Frame (4092-002, 004, 005) 13B0204 Carrier Frame Parts Catalog 7-7...

  • Page 70: Assembly 3: Paper Feed

    4092 Assembly 3: Paper Feed...
  • Page 71 4092 Asm- Part Units Description Index Number 3 -1 13B0205 Paper Guide Asm includes EOF Flag & Spring 13A1280 Small Feed Roll Shaft Roll B/M and Paper Flap 13B0212 Star Roller Asm 13B0275 Large Feed Roll Asm (includes Small Compound Idler Gear) 13B0276 Paper Feed Motor, Motor Gear, Toroid...

  • Page 72: Assembly 4: Electronics

    4092 Assembly 4: Electronics 7-10...
  • Page 73 4092 Asm- Part Units Description Index Number 4 -1 13B0070 System Board, W/O Code Module 17B0160 System Board, W/O Code Module (4092-005) 13B0214 Power Supply (Universal) with Ground Plane, Insulator, Cover 1339526 Power Cord, U.S. 1342514 Power Cord, Argentina 1339520 Power Cord, Austria 1339520 Power Cord, Belgium...
  • Page 74 4092 Assembly 4: Electronics (continued) 7-12...
  • Page 75 Asm- Part Units Description Index Number 13B0309 Code Module (4092-001, 002, 003, 004, 006) 17B0186 Code Module (4092-005) 13B0239 Screw, System Board Mounting, Frame Mounting (PP) 13B0045 Thermal Sensor Board w/ Cable 13B0239 Screw, Thermal Sensor Mounting (PP) 13B0239 Jumper, 2-Pin (PP) Parts Catalog 7-13...

  • Page 76: Assembly 5: Carrier

    4092 Assembly 5: Carrier 7-14...
  • Page 77 4092 Asm- Part Units Description Index Number 5 -1 13B0237 Printhead Carrier B/M 13B0222 Printhead Cable (Folded) 13B0238 Rubber Backer 13B0217 Carrier Guide Rod 69G4156 Encoder Card Asm 13B0239 Screw, Encoder Card Mounting (PP) 13B0221 Printhead Cartridge Interlock Key 13B0239 Screw, Carrier Guide Rod (PP) 17B0168 Washer, Lock (Packet of 50)

  • Page 78: Assembly 6: Carrier Transport

    4092 Assembly 6: Carrier Transport 7-16...
  • Page 79 4092 Asm- Part Units Description Index Number 6 -1 13B0219 Carrier Transport Motor & Pulley 13B0215 Carrier Belt 69G4403 Encoder Strip 17B0157 Idler Pulley Tension Asm 13B0239 Screw, Carrier Transport Motor Mounting (PP) 13B0239 Tensioner, Encoder Strip (PP) Parts Catalog 7-17...

  • Page 80: Assembly 7: Sheet Feeder

    4092 Assembly 7: Sheet Feeder 7-18...
  • Page 81 4092 Asm- Part Units Description Index Number 7 -1 13A1227 Right Edge Guide & Width Adjust Strip (4092-001, 003, 006) 13A1442 Right Edge Guide & Width Adjust Strip (4092-002, 004, 005) 13A1228 Left Edge Guide (4092-001, 003, 006) 13A1443 Left Edge Guide (4092-002, 004, 005) 69G4131 Upper Paper Support...

  • Page 82: Assembly 8: Maintenance Station

    4092 Assembly 8: Maintenance Station 7-20...
  • Page 83 4092 Asm- Part Units Description Index number 8 -1 13B0160 Maintenance Station Asm 70G0590 Wiper and Cap B/M (one of each) 13B0239 Screw, Maintenance Station Mounting (PP) Parts Catalog 7-21...
  • Page 84 4092 Index Communications Maintenance Station Abbreviations Operator Panel Adjustments Paper Feed Assemblies Power Print Quality 1 Covers 2 Frames 3 Paper Feed 7-10 4 Electronics Removal Procedures 7-14 5 Carrier Removals 7-16 6 Carrier Transport Base Assembly 7-18 7 Sheet Feeder Carrier Belt 7-20 8 Maintenance Station...
  • Page 85 4092 4-22 Video Board Repair Information Service Checks Envelope Feed First Print Line Maintenance Station Paper Feed 2-10 Paper Path 2-11 Parallel Port 2-11 Power 2-12 Print Quality 2-15 Transport 2-16 Video Start Symptom Table (POST) Symptom Tables Tests Encoder Sensor Initialize Error Log Parallel Port Print NVRAM Contents...

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