Lexmark 6200 Series Service Manual

Revised: March 24, 20067

Lexmark™ 6200 Series AIO

• Table of content s

• Start diagnostics

4411-XXX

• Safety and notices

• Trademarks

•Index

Lexmark and Lexmark with diamond
design are trade ma rks of Lexmark
International, Inc., registered in the
United States and/or ot her countries.

4411-XXX

Edition: March 24, 2006
The following paragraph does not apply to any country where such provisions are

inconsistent with local law: LEXMAR K INTERNATIONAL, INC. PROVIDES THIS

PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR
IMPLIED, INCLUDING , BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do
not all o w di sc la im er o f e x pres s o r i mpl i ed wa rr an tie s i n c ertai n t ra ns act ion s; t he refore, t hi s
statement may not apply to you.

This publication could include technical inaccuracies or typographical errors. Changes are
periodically made to the information herein; these changes will be incorporated in later
editions. Improvements or changes in the products or the programs described may be
made at any time.

Comments may be addressed to Lexmark International, Inc., Department D22A/032-2,
740 West New Circle Road, Lexington, Kentucky 40550, U.S.A or e-mail at
[e-mail]. Lexmark may use or distribute any of the
information you supply in any way it believes appropriate w ithout incurring any obligation
to yo u.

Lexmark and Lexmark with diamond design are trademarks of Lexmark International,
Inc. , registered in the United States and/or other countries.

Other trademark s are the property of their respective owners.

© 2004 Lexmark Inte rna t io nal , Inc.
All rights reserved.

UNITED STATES GOVERNMENT RIGHTS

This software and any accompanying documentation provided under this agreement are
commercial computer softwa re and documentation developed exclusively at private
expense.

U.S.A. P/N: 12G9481

Japanese P/N: 12G9482

4411-XXX

Table of contents

Safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v

Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .x

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .x

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Power consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Scanner specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Maintenance approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Diagnostic information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Power-On Self Test (POST) sequence . . . . . . . . . . . . . . . . . . . . 2-1

Error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Catastrophic error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Non-catastrophic error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

POST symptom table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Sym p tom ta b le s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -10

Carrier transport service check . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

CIS module assembly service check . . . . . . . . . . . . . . . . . . . . . 2-11

Maintenance station service check . . . . . . . . . . . . . . . . . . . . . . 2-12

Paper feed service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Power service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Print quality service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Scan/copy quality service check . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Diagnostic aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Self test mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Repair informatio n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Handling ESD-sensitive parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Removal procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Releasing plastic latches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Scanner module assembly removal. . . . . . . . . . . . . . . . . . . . . . . 4-3

Print engine removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Base assembly removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Carrier assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -10

iii

4411-XXX

System board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

Maintenance station removal . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

PictBridge door removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15

Control panels removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

Rear cove r remo val . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

ASF guide with spring removal . . . . . . . . . . . . . . . . . . . . . . . . . .4-17

Connector locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Lubrication specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

Assembly 1: Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Assembly 2: Print engine, carrier, and electronics . . . . . . . . . . . . . . . . 4

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X-1

iv Service Manual

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 par ts.

• 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.

• There may be an increased risk of electric shock and personal

injury during disassembly and servicing of this product.
Professional service personnel should understand this and take
necessary precaut ions.

Consignes de Sécurité

• La sécurité de ce produit repose sur des tests et des

agréations por tant sur sa conception d'origine et sur des
composants particuliers. Le fabricant n'assume aucune
responsabilité concernant la sécur ité en cas d'utilisation de
pièces de rechange non agréées.

• Les consignes d'entretien et de réparation de ce produit

s'adressent uniquement à un personnel de maintenance
qualifié.

• Le démontage et l'entretien de ce produit pouvant présenter

certains risques électr iqu es, le personnel d'entretien qualifié
devra prendre toutes les précautions nécessaires.

Safety information v

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.

• Durante lo smontaggio e la manutenzione di questo prodotto,

il rischio di subire scosse elettriche e danni alla persona è più
elevato. Il personale di assistenza autorizzato, deve, quindi,
adottare le precauzioni necessarie.

Sicherheitshinweise

• Die Sicherheit dieses Produkts basiert auf T ests und

Zulassungen des ursprünglichen Modells und bestimmter
Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird
vom Hersteller keine Verantwortung oder Haftung für die
Sicherheit übernommen.

• Die Wartungsinformationen für dieses Produkt sind

ausschließlich für die Verwendung durch einen
Wartungsfachmann bestimmt.

• Während des Auseinanderne hme ns und der Wartung des

Geräts besteht ein zusätzliches Risiko eines elektrischen
Schlags und körperlicher Verletzung. Das zuständige
Fachpersonal sollte entsprechende Vorsichtsmaßnahmen
treffen.

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4411-XXX

Pautas de Seguridad

• La seguridad de este producto se basa en pruebas y

aprobaciones del diseño original y component es esp ecíficos.
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

dirigida exclusivamente al personal cualificado de
mantenimiento.

• Existe mayor riesgo de descarga eléctrica y de daños

personales durante el desmontaje y la reparación de la
máquina. El personal cualificado debe ser consciente de este
peligro y tomar las precauciones necesarias.

Informações de Segurança

• A segur a n ça deste produto baseia-se em testes e aprovações

do modelo original e de componentes específicos. O fabricante
não é responsável pela segunrança, no caso de uso de peças
de substituição não autorizadas.

• As informações de segurança relativas a este produto

destinam-se a profissionais destes serviços e não devem ser
utilizadas por outras pessoas.

• Risco de choques eléctricos e ferimentos graves durante a

desmontagem e manutenção deste produto. Os profissionais
destes serviços devem estar avisados deste facto e tomar os
cuidados necessários.

Safety i n fo rmati o n vii

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.

• La in formaci ó pel manteniment d’aquest producte està

orientada exclusivament a professionals i no està destinada
a ningú que no ho sigui.

• El risc de xoc elèctric i de danys personals pot augmentar

durant el procés de desmuntatge i de servei d’aquest producte.
El personal professional ha d’estar-ne assabentat i prendre
les mesures convenie n ts.

viii Service Manual

4411-XXX

Safe ty informat ion ix

4411-XXX

Preface

This manual contains maintenance procedures for service
personnel. It is divided into the following chapters:

1. General informati on 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.

2. Diagnostic information contains an error codes, error indicator
table, symptom tables, and service checks used to isolate failing
field replaceable units (FRUs).

3. D iagnostic aids contains tests and checks used to locate or
repeat symptoms of printer problems.

4. Repair information provides instructions for making printer
adjustments and removing and installing FRUs.

5. Connector locations uses illustrations to identify the connector
locations and test points on the printer.

6. Preventive maintenance contains the lubrication specifications
and recommendations to prevent problems.

7. Parts catalog contains illustrations and part numbers for
individual FRUs.

Definitions

CAUTION: A caution identifies som ething that might cause a

servicer harm.

Warning: A warning identifies something that might damage the

printer hardware or software.

Note: A note provides additional information.

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4411-XXX

1. Gen e r a l informa tion

The Lexmark™ 6200 Series (4411-X XX) 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. The printhead assembly and ink
supply are combined into a single-unit print car tr idge available as a
customer replaceable supply item. Dual printheads provide color
and true black printing without changing printheads. The number
and size of inkjets or nozzles in the printhead determines the overall
quality and capability of the printer. The black cartridge has a total of
640 nozzles and installs on the left. The color cartridge has a total of
480 nozzles and installs on the right. The photo cartridge has a total
of 480 nozzles. The printer is capable of printing in two directions
from either cartridge.

General information 1-1

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Power consumption

• Printing — 14.1 Watts

• Idle — 9.7 Watts

• Sleep — 8.0 Watts

Scanner specifications

Scanner Type Flatbed, CIS
Scan Modes T rue Color:

48 Bit Internal
24 Bit External

Gray Mode:

16 Bit Internal
8 Bit External

Te xt/Line Art:

1 Bit Per Pixel

Scan Method One Pass Scanni ng
Scan Area 8.5 X 11.7 inches

215 X 297 mm

Scan Resolution Horizontal: 1200 dpi

Vertical: 2400 dpi
Interpolated: 19,200 x 19,200

Resolution/Quality

(Applicable when operating via
standalone mode)

Select by setting print resolution in
printer driver and scan resolution in
scanner setting in AIO center when
operating by host based mode.

Select resolution/quality from the
operator panel when operating by
stand-alone mode.

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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 1-3

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Buttons Functions

Mode Cycles the machine between the three selections:

copy, scan and photo. The LCD must be updated to
display the default screen f or the mode selected.

For cop y 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.” The message scrolls or cycles until a
button is pressed. This message returns after two
minut es of i nac tivity.

Color Start The Color Start button’s function is influenced by the

mode selection. Pressing the Color Start button will
result in output from eit her printer or scanner.

• Copy Mode: Initiates a color copy. Previous
selections of Resize and Number of Copies and
machine defaults such as Blank Paper Size will
affect the output.

• Scan Mode: Initiates a color scan. Previous
selections and mac hine defaults will affect the
output.

• Photo Mode: Ini tiat es a col or print job i f a pho to ca rd
media is present and a photo has been selec ted. If a
Digital Print Order F ormat (DPOF) file is detect ed on
the photo card media, a mes sage will be posted,
and pressing the Color Start button causes the
entire list of pictures on the order form to print.

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Buttons Functions

Black Start The Black Start button mirrors the Color Start. Its

function is also i nfluenced by the mode selection. The
difference between the Black Start and Color Start is
that the output, whet her from the scanner or printer, is
in grayscale instead of color. This does not imply th at
all other factors, such as scan resol ution and shingli ng
modes will remain constant.

• Copy Mode: Init iat es a m ono copy. Previous
selections of Resize and Number of Copies, and
machine defaults such as Blank Paper Si ze will
affect th e output.

• Scan Mode: Initiates a mono scan. Previous
selections and machi ne defaults will a ffect th e
output.

• Photo Mode: Initiates a mono print job if a photo
card media is present and a photo has been
selected. If a Digital Print Order F ormat (DPOF) flag
is detected on the ph oto card media, a message will
be posted and pressing t he Black Start button
causes the entir e list of pictur es on the or der form to
print.

Up Arrow
Down Arrow

Left Arrow
Right Arrow

The predominant func tion is to navigate menu i tems
on the LCD .

The predominant func tion is to manipulate menu
selections on the LCD.

General information 1-5

4411-XXX

Buttons Functions

Resize In Photo selection mode, this button is used to set t he

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 b y a green out l ine. For photos , it is t he
portion of the photo that wil l be dis pla y ed based on th e
current photo size selection. It is also used with the
Resize button when cropping photos and for indica ti ng
the region to be printed.

• Copy Mode: Chan ges the zoom. Options are 50%,
100%, 200%, Custom (From 25% up to 400%. The
increment is by 1%.) 2x2, 3x3, and 4x4 Posters, Fit
to Page, 8.5x11 i n., 8. 5x14 in. A4, A5, A6, B5, L, 2L,
Hagaki, 3x5 in . 3.5x5 in. , 4 x6 in. 5x 7 in. an d 8x10 in.
sizes.

• Scan Mode: Error message displayed.

• Photo (Select) Mo de: Changes the output image

size. Options are 8.5x11 in., A4, A5, A6, L, 2L,
Hagaki 2.5x3.5 in., 3.5x5 in., 4x6 in., 5x7 in., and
8x10 in. sizes.

• Photo (Copy) Mode: Changes the zoom of the ROI.
Options are 1x, 1.5x, 2x, 2.5x, and 3x.

Number of
Copies

Rotate The Rotate button will rotate the image in the LCD

The Number of Copies button will increment the copy
count displa yed on the lower left of the LCD in Copy
and Photo modes. It is not act ive in Scan mode.

• Copy Mode: Increments the copy count .

• Scan Mode: Error message displayed.

• Photo Mode: Increments the copy count.

display by 90° CCW for each time the button is
pressed. It is also used to rotate the ROI when in the
Crop function of the Photo mode .

• Copy Mode: Rotate is not available in copy.

• Scan Mode: Rotate is not available in sc an.

• Photo Mode: Rotates the image in the LCD display
by 90° CCW for each time the button is pressed.

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4411-XXX

Buttons Functions

Select The Select button allows you to choose an op ti on from

a menu. When moving through the menu items, you
can scroll through settings for a menu it em with the
Left and Right Arrow buttons. Press the Select button
to save the settings.

The Select butt on also acknowledges errors noted by
the Error LED and LCD. In the Photo mode the Select
button selects images to be printed. Pressing Select
when a photo is already selected deselects the photo.

The Select but ton m ay b e used t o ini tiate a pap er f eed .
This function is accomplished by pressing the Select
button for more than three seconds.

Page Pr eview The Page Preview button giv es a preview of the

ev entual output as it would appear on the selected
page size before it is printed or scanned. Its function is
dependent upon the active AIO mode.

• Copy Mode: Scan to LCD funct ion. Pressing either
the Colo r S ta rt or Black Sta rt will make a copy,
which will match the preview.

• Scan Mode: Performs a preview scan (scan t o LCD)
to verify the information that you wish to scan is
within the scan region. Mu lt iple previews can be
made before scanning.

• Photo Mode: When the Previ ew button is pressed,
the displa y on the LCD is updated to r epresent what
the printed output wi ll look like based on the current
selections. Press either the Color Start or Black
Start to perform the print, which will match the
preview. If enough photos are selected for mu lt iple
pages of output, arrow hints and page numbers are
added to allow viewing of all pages by pressing the
Left or Right arrows. If this button is pressed without
a card being inserted, an error message will display.

General information 1-7

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. Pressing the Stop/Clear
button twice while vi ewing a photo presents a dialogue
asking if you would like to cancel all photo sel ections,
thereby deselecting all images. Pressing the Stop/
Clear button twice when one of the default mode
screens is present returns all the settings to the
machine default settings. A confirmation dialog will
verify that you want to clear all settings.

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4411-XXX

Buttons Functions

Menu The Menu b utton will a cces s the adv anc ed func tions of

the AIO. Pres sing the Menu button opens a men u
structure containing all sett ings or functions pertaining
to the currently active mode. Each setting or function
takes up two li nes. The first line is the sett ing or
function name. The second line is the scrolla ble
Options List for that setting. F or functions, the second
line advises what button launches the function. Note
the highlighted first item, which indicate s that it
currently has focus. You can then navigate the menu
using the Up and Down bu ttons . Opt ions Li sts f or each
item are sc roll ed usi ng the Lef t and Ri ght b ut tons . O nly
the current ly hi ghli ghted setti ng di spla ys Lef t and Right
Arrows. To select the currently displayed Setting
Option, press Select. A vertical navigati on position
indicator is on the right side of the screen. This
elevator indicator is a fixed size (does not change
across varyin g conditions). At the top of the menu, the
top arrow i s grayed out, and at the bot tom of t he menu ,
the bottom arrow is gr ayed out.

After the menu is open, press the Menu button again
to exit th e men u system and return the display to the
current mode’s default displ ay. Menu structures, when
navigated wi th t he Up and Down buttons, do not loop.
When the last item in the menu is reached, further
presses of th e Do wn b utton a re igno red. When t he fi rst
item in the menu i s reached, further presses of the Up
button are ignored. Options Lists scrolled with the Left
and Right buttons do loop. Options List arrows are
nev er grayed out . The Menu listing for Options Lists
should reflect the current selection when the Menu is
opened.

Maint en an ce ap proa ch

The diagnostic information in this manual leads you to the correct
field replaceable unit (FRU) or part. Use the symptom index, service
checks, and diagnostic aids to determine the symptom and repair
the failure.

After you complete the repair, perform tests as needed to verify the
repair.

General information 1-9

4411-XXX

Abbreviations

B/M Bill of Material
CIS Contact Image Sensor
EOF End of Form
ESD Electrostatic Discharge
FPC Flat Printhead Cable
FRU Field Replaceable Unit
HVPS High Voltage Power Supply
LCD Liquid Crystal Display
LVPS Low Voltage Power Supply
OEM Original Equipment Manufacturer
ROI Region of Interest
V ac Volts alternating current
V dc Volts direct current
ZIF Zero Insertion Force

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4411-XXX

2. Diagnostic information

Start

Use the error code tab l es , post sy mptom tab l e, sympt om tab les , and service
checks in this chapter to determine the All-In-One failure.

Power-On Self Test (POST) sequence

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 flashi ng
sequence, then the Copy light sta ys on.

4. The carrier moves off the maintenance stati on and returns.

5. The scanner (CIS) moves from the home position and returns.

Note: After the sequence above, the Power light, Copy light, and LCD
remain on.

If your All-In-One completes POST with no errors, go to the “Symptom

tables” on page 2-7, locate the symptom and take the appropriate action.

If your All-In-One does not complete POST, go to the “POST symptom

table” on page 2-6, locate the symptom and take the appropriate acti on.

Diagnostic information

2-1