Lexmark 4200 Series Service Manual
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Lexmark 4200 Series Service Manual

Lexmark 4200 Series Service Manual

Lexmark international, inc. service manual all-in-one lexmark 4200 series
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See also: Setup Manual
Lexmark 4200 Series
All-In-One
4413-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 4200 Series

  • Page 1 Lexmark 4200 Series All-In-One 4413-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

    4413-XXX Table of Contents Safety information........v Preface .
  • Page 4 4413-00X Repair information ........4-1 Handling ESD-sensitive parts .

  • Page 5: Safety Information

    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 4413-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 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. • La información sobre el mantenimiento de este producto está...
  • Page 8 4413-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 4413-XXX Safety information...

  • Page 10: Preface

    4413-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

    4413-XXX 1. General information The Lexmark™ 4200 Series All-In-One (4413-XXX) is a letter quality print, fax, copy, and scan machine. It is a standalone color/mono copier and fax. The printhead uses small heater plates and nozzles to control ink flow and the formation of characters on the print media.

  • Page 12: Specifications

    4413-XXX Specifications Print engine Technology Speed Resolution Printing Width Feeding Method Emulation Printer Driver Interface Printhead Babbage Mono Standard Printhead 208 nozzles Ink Type Pigment Ink Color Black Ink Yield About 600 sheets Service Manual Thermal Inkjet 2-pin and printhead swapping type Color 10 ppm at Draft Mode...

  • Page 13: Facsimile

    4413-XXX Facsimile General Scan Method Scan Width Feeding Method Guide Stacker Paper Tray Modem Speed Scanning Resolution Contrast Telephone Speed Dial On-Hook Dial Last Number Redial Auto Redial Ringer Volume Tone/Pulse Select Report and Telephone Number List List Self Test Copy Multipage Copy Grayscale...

  • Page 14: Scanner

    4413-XXX Telephone Answering I/F Extension Phone Others Sensors Clock Scanner Compatibility Technology Light Source for Color CIS Power and size Power Source Dimensions Weight (Packed) Service Manual 1-jack, extension phone transfer Paper Jam TWAIN Platen CIS RGB LEDs (Line Order Control) 100V-127V with 2-wire power cord fixed 100V-127V with 2-wire separate power cord (Japan)

  • Page 15: Abbreviations

    4413-XXX Abbreviations All-In-One Auto Sheet Feed Bill of Material Contact Image Sensor End of Form Electrostatic Discharge Flat Printhead Cable Field Replaceable Unit Graphic Display Interface HVPS High Voltage Power Supply Liquid Crystal Display LVPS Low Voltage Power Supply Original Equipment Manufacturer V ac Volts alternating current V dc...
  • Page 16 4413-XXX Service Manual...

  • Page 17: Diagnostic Information

    2. Diagnostic information Start Power-On Self Test (POST) sequence 1. Lexmark 4200 Series is displayed on the LCD. 2. Power, Fax, Copy, Scan and Auto Answer lights turn on. 3. Copy and Scan button lights turn on. 4. Carrier moves to the left and returns to the maintenance station.

  • Page 18: Post Symptom Table

    4413-XXX POST symptom table Symptom Action LCD or Control Go to the Panel buttons do go to the not work and no motors run Paper feed Go to the gears do not turn Carrier does not Go to the move page Carrier slams Go to the...

  • Page 19: Symptom Tables

    4413-XXX Symptom tables Locate the symptom in the following tables and take the appropriate action. Carrier transport problems Symptom • No carrier movement • Slow carrier movement • Carrier stops • Carrier slams side frame Maintenance station problems Symptom Maintenance station: •...
  • Page 20 4413-XXX Symptom Document scan sensor does not detect document Printer communication problem Symptom Not able to print Self Test Page Phone handset/cradle problem Symptom No dial tone Handset does not work Service Manual Action Check control panel cable connector CN5 on the system board. If okay, go to the “Scanner motor with gear assembly service check”...

  • Page 21: Scanner Problems

    4413-XXX Scanner problems Symptom Light does not turn on • Scanned images are faded, or colors are dull, blurry or fuzzy. Images are slanted or crooked and the straight lines in the image appear to be jagged or uneven. • Blank copies •...

  • Page 22: Service Checks

    4413-XXX Power problems Symptom No power in machine, motors do not operate Print quality problems Symptom • Voids in characters • Light print • Prints off the page • Fuzzy print • Carrier moves but no print • Printhead dries prematurely •...
  • Page 23 4413-XXX Carrier Transport Motor Carrier Guide Rod Encoder Strip Carrier Assembly with Belt Carrier Transport Belt Idler Pulley Assembly Action Check the motor for binds, or loose motor pulley. A noisy or chattering motor, or a motor that fails to turn, can be caused by: •...

  • Page 24: Cis Assembly Service Check

    4413-XXX Maintenance Station Access Door Sensor CIS assembly service check The CIS lamp does not light when scanning is in process. CIS Assembly Service Manual Action A problem with the maintenance station can cause carrier movement problems at the right margin. Go to the “Maintenance station removal”...

  • Page 25: Scanner Motor With Gear Assembly Service Check

    4413-XXX Scanner motor with gear assembly service check Motor will not run. Scanner Motor with Gear Assembly Document Scanner Sensor Action Check scanner motor for shorts. Disconnect connector CN1 from the system board and check for approximately 6 ohms between the following pins on the motor connector.

  • Page 26: Maintenance Station Service Check

    4413-XXX Maintenance station service check The maintenance station has three functions: 1. Wipes the printhead nozzles to clean them of dirt. 2. Provides a place for printheads to fire all nozzles, keeping them clear prior to printing. 3. Seals the printhead when it is not being used to prevent the nozzles from drying.

  • Page 27: Paper Feed Service Check

    4413-XXX Paper feed service check If your machine does not have paper jam problems, continue with the service check. If your machine does have a paper jam, examine it for the following before you begin the service check: • Check the entire paper path for obstructions. •...
  • Page 28 4413-XXX Paper Feed Motor Auto Sheet Feeder Assembly End-of-Forms Flag and Spring 2-12 Service Manual Action A noisy or chattering motor or a motor that fails to turn, can be caused by: • An open or short in the motor •...

  • Page 29: Paper Path Service Check

    4413-XXX Paper path service check Examine the machine for the following before you begin this service check: • Check the entire paper path for obstructions. • Be sure the correct type of paper is being used. • Be sure the printer is installed on a flat surface. Large and Small Feed Rollers Small Feed Roller...

  • Page 30: Power Service Check

    4413-XXX Power service check Power Supply Printhead Cables Paper Feed Motor Carrier Transport Motor Control Panel System Board 2-14 Service Manual Action Plug the machine into an outlet. Check for approximately 30 V dc at CN4 pin 2. If voltage is incorrect, replace the power supply.

  • Page 31: Print Quality Service Check

    4413-XXX Print quality service check FRU / Function Printhead Cartridge Color Printhead Cartridge Cross Contamination Carrier Assembly System Board Carrier Assembly Maintenance Station Action Be sure the machine contains good print cartridges. Cross contamination of color inks results in incorrect colors printed, as when green prints for yellow, (when yellow and blue are mixed in the printhead cartridge).
  • Page 32 4413-XXX FRU / Function Paper Feed Carrier Transport Alignment 2-16 Service Manual Action 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. Also check the paper for curl or wrinkles.

  • Page 33: Scan/Copy Quality Service Check

    4413-XXX Scan/copy quality service check FRU / Function Scanned images are faded, or colors are dull, blurry, or fuzzy. Images are slanted or crooked and the straight lines in the image appear to be jagged or uneven. Blank copies Scanning error Action Check the lighter/darker settings to see if it is correct.

  • Page 34: Fax/Telephone Communication Service Check

    4413-XXX Fax/telephone communication service check FRU / Function System Board Cannot make telephone connection to other fax. Cannot receive faxes 2-18 Service Manual Action No dial tone Verify correct dialing method (tone or pulse). Are TEL and LINE connections reversed? Verify phone number and availability of other fax machine.

  • Page 35: Diagnostic Aids

    4413-XXX 3. Diagnostic aids Theory of mechanism Scanner mechanism The scanner mechanism consists of components which feed, scan, and eject the documents that are to be copied or transmitted to a remote facsimile unit. These components and their functions are explained below.

  • Page 36: Contact Image Sensor (Cis)

    4413-XXX Contact Image Sensor (CIS) The contact image sensor unit consist of LEDs, rod lens array, and a photo sensor. The LEDs illuminate the document to be scanned when the leading edge is detected by the document scan sensor. The LEDs turn off when the document exits the scanner mechanism. The LEDs illuminate the document to obtain an image from the document through the rod lens array, where the image is translated into voltage levels.
  • Page 37 4413-XXX Set up options Setup Print Report Number of Rings Delay Until On Hook Dial Ringer Tone Key Press Tone Speaker Volume Edit Speed Dial Edit Date Time Personalized Fax Blank Paper Size Blank Paper Type Fax Forward Advanced Fax Maintenance Power Save Item...
  • Page 38 4413-XXX Setup Clear Settings Set Defaults Service Manual Item After 2 Minutes Never Use Current Use Factory Default After 2 Minutes...

  • Page 39: Repair Information

    4413-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 40: Adjustments

    4413-XXX Adjustments The user is directed, in the Printer Control program, to perform the bidirectional 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. Releasing plastic latches Many of the parts are held in place with plastic latches.

  • Page 41: Removals

    4413-XXX Removals General precautions on removals When you disassemble and reassemble components, use extreme caution. The close proximity of cables to moving parts makes proper routing a must. If components are removed or replaced, any cables disturbed must be replaced as close as possible to their original positions.

  • Page 42: Cis White Roller Assembly Removal

    4413-XXX CIS white roller assembly removal 1. Open the control panel. 2. Press the release arm (A) on the right end of the roller slightly inward, and then rotate it until it reaches the slot. Lift the roller out. Note: If the roller is dirty, wipe it with a soft cloth dampened with water.

  • Page 43: Top Cover Assembly Removal

    4413-XXX Top cover assembly removal 1. Open the control panel and open the print cartridge compartment cover. Remove the white roller assembly. 2. Remove paper support. 3. Remove the eight screws (A). 4. Remove the top cover. Repair information...

  • Page 44: Rollers (Drive Feed Roller Assembly, Exit Shaft) Removal

    4413-XXX Rollers (drive feed roller assembly, exit shaft) removal 1. Remove the top cover assembly. See removal” on page 2. Remove paper support. 3. Disconnect the CIS cable (A) from the system board. Service Manual “Top cover assembly 4-5.
  • Page 45 4413-XXX 4. Remove the screw (B) from the cable support and remove cable support. Repair information...
  • Page 46 4413-XXX 5. Remove three screws (C) from the scanner motor with gear assembly. Service Manual...
  • Page 47 4413-XXX 6. Slide and remove drive feed roller assembly (D). Note: Clean the surface of the rollers with ethyl alcohol. After wiping them, you must dry them completely. Note: Routing of all cables. Repair information...

  • Page 48: Cis (Contact Image Sensor) Removal

    4413-XXX CIS (Contact Image Sensor) removal 1. Remove the top cover assembly. See removal” on page 2. Disconnect the CIS cable from the system board. 3. Depress hinge (A) and lift to remove. 4. Remove CIS assembly. Note: Check the glassy surface of the CIS for any stain or scratch. If stained, wipe off with ethyl alcohol.

  • Page 49: Scanner Motor With Gear Assembly Removal

    4413-XXX Scanner motor with gear assembly removal 1. Remove the top cover assembly. See removal” on page 2. Disconnect scanner motor cable (A) from the system board. “Top cover assembly 4-5. Repair information 4-11...
  • Page 50 4413-XXX 3. Remove three screws (B) as shown and remove the scan motor assembly. 4-12 Service Manual...

  • Page 51: Control Panel Assembly Removal

    4413-XXX Control panel assembly removal 1. Remove the top cover assembly. See removal” on page 2. Disconnect the control panel cable (A) from the system board. 3. Release harness from harness hook. “Top cover assembly 4-5. Repair information 4-13...
  • Page 52 4413-XXX 4. Remove the two ground strap screws (B) from the left side of the printer. 4-14 Service Manual...
  • Page 53 4413-XXX 5. Depress hinge (C) and remove control panel assembly. 4-15 Repair information...

  • Page 54: Print Engine Removal

    4413-XXX Print engine removal 1. Remove the top cover assembly. See removal” on page 2. Remove the paper support. 3. Disconnect the CIS cable from system board. 4. Remove CIS cable support. 5. Disconnect all cables from the system board except for carrier ribbon cables.

  • Page 55: Maintenance Station Removal

    4413-XXX Maintenance station removal 1. Remove the printer unit. 2. Move the maintenance station to the left and up. 3. Disconnect spring and remove maintenance station (A). 4-17 Repair information...

  • Page 56: Carrier Assembly With Belt Removal

    4413-XXX Carrier assembly with belt removal 1. Remove the top cover assembly. See removal” on page 2. Remove print engine. See page 4-16. 3. Depress the belt tensioner (A) until tension is released. 4. Remove the belt (B) from the carrier motor. 5.

  • Page 57: System Board Removal

    4413-XXX System board removal 1. Remove the top cover assembly. See removal” on page 2. Unplug all connectors. 3. Remove four screws (A) securing the system board. 4. Remove the fire shield and disconnect connector CN12. Note: Routing of cables. 5.

  • Page 58: Exit Rollers Removal

    4413-XXX Exit rollers removal 1. Remove the top cover. See page 4-5. 2. Remove print engine. See page 4-16. 3. Remove two screws (A) from exit roller assembly. 4-20 Service Manual “Top cover assembly removal” on “Print engine removal” on...

  • Page 59: Large Feed Roller Assembly With Gear Removal

    4413-XXX 4. Remove exit roller assembly. Large feed roller assembly with gear removal 1. Remove the top cover. See page 4-5. 2. Remove the print engine. See page 4-16. 3. Remove system board. See page 4-19. 4. Disconnect four springs (A) from the pressure feed roller assembly and remove.
  • Page 60 4413-XXX 5. Remove the feed roller bearing (B) from the main frame. Pull the feed roller and remove. Be careful not to damage the bearing. 4-22 Service Manual...

  • Page 61: Paper Feed Motor Assembly With Gears Removal

    4413-XXX Paper feed motor assembly with gears removal 1. Remove the top cover. See page 4-5. 2. Remove the print engine. See page 4-16. 3. Remove carrier shaft. 4. Unplug paper feed motor from system board. 5. Remove large feed roller. 6.

  • Page 62: Carrier Transport Motor Removal

    4413-XXX Carrier transport motor removal 1. Remove the top cover assembly. Go to the assembly removal” on page 2. Remove the print engine. See page 4-16. 3. Manually move the carrier to the center of the machine. 4. Press the idler pulley and remove the belt from the carrier transport pulley.

  • Page 63: Connector Locations

    4413-XXX 5. Connector locations System board Units Description Scanner Motor with Gear Assembly Carrier Transport Motor Power Supply Control Panel Paper Feed Motor Carrier Carrier CN10 Speaker CN11 Handset and Cradle - K03,AK3 CN12 Phone Receptacles - K01,AK1,K03,AK3 Access Door Sensor Connector locations...
  • Page 64 4413-XXX Service Manual...

  • Page 65: Preventive Maintenance

    4413-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 66 4413-XXX Service Manual...

  • Page 67: Parts Catalog

    4413-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 68 4413-XXX Assembly 1: Main assembly Service Manual...

  • Page 69: Index

    4413-XXX Assembly 1: Main assembly Asm- Part Units Index Number 56P2521 56P2522 56P2523 56P2524 56P2525 56P2526 56P2527 56P2529 56P2530 56P2531 56P2532 56P2533 56P2534 56P2449 56P2450 56P2445 56P2520 Description Control cover K01,AK1,K03,AK3 English, EMEA/APG Control cover K01,AK1,K03,AK3 Spanish Control cover K01,AK1,K03,AK3 French Control cover K01,AK1,K03,AK3 Brazil/ Portuguese Control cover K01,AK1,K03,AK3 German...
  • Page 70 4413-XXX Assembly 2: Base unit Service Manual...
  • Page 71 4413-XXX Assembly 2: Base unit Asm- Part Units Index Number 13D0400 13D0401 13D0402 13D0403 56P2452 56P2455 56P2453 56P2451 56P2443 56P2442 11B6074 56P1040 11B6078 11B6073 11B6076 14D0632 14D0630 Description Power supply 120V K01,AK1,K03,AK3 Power supply 220V K01,AK1,K03,AK3 Power supply 100V 50/60 Hz K01,AK1,K03,AK3 Power supply 100V K01,AK1,K03,AK3 Contact, image sensor (CIS)
  • Page 72 4413-XXX Assembly 3: Engine Service Manual...
  • Page 73 4413-XXX Assembly 3: Engine Asm- Part Units Index Number 56P2444 56P2447 56P2448 56P1168 12G6968 56P2454 Description Motor, paper feed assembly with gears K01,AK1,K03,AK3 System board K01,AK1 System board K03,AK3 Motor, carrier transport K01,AK1,K03,AK3 Strip, encoder K01,AK1,K03,AK3 Carrier assembly with belt K01,AK1,K03,AK3 Parts catalog...
  • Page 74 4413-XXX Service Manual...
  • Page 75 4413-XXX Index abbreviations adjustments alignment 2-16 base unit carrier transport 2-16 CIS assembly connector locations contact image sensor control panel diagnostic aids diagnostic information document sensors drive feed roller assembly engine ESD-sensitive parts fax communication 2-18 lubrication specifications main assembly maintenance station paper feed 2-11...
  • Page 76 4413-XXX specifications facsimile power and size print engine printhead scanner symptom tables carrier transport problems control panel problems maintenance station problems paper feed problems phone handset/cradle problem POST power problems print quality problems printer communication problems scanner problems system board telephone communication theory of mechanism contact image sensor...

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