Lexmark 6200 Series User manual

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

Edition:April 2005
The following paragraph does not apply to any country where such provisions are
inconsistent with local law: LEXMARK 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 allow disclaimer of express or implied warranties in certain transactions; therefore, this
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 without incurring any obligation
to you. 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.
Other trademarks are the property of their respective owners.
© 2004 Lexmark International, Inc.
All rights reserved.
UNITED STATES GOVERNMENT RIGHTS
This software and any accompanying documentation provided under this agreement are
commercial computer software and documentation developed exclusively at private
expense.
4411-XXX
U.S.A. P/N: 12G9481 Japanese P/N: 12G9482

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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
Symptom tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

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System board removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
Maintenance station removal . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
PictBridge door removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
Control panels removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
Rear cover removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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

Safety information v
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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.
•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 precautions.
Consignes de Sécurité
•La sécuritéde ce produit repose sur des tests et des
agréations portant sur sa conception d'origine et sur des
composants particuliers. Le fabricant n'assume aucune
responsabilitéconcernant la sécuritéen cas d'utilisation de
pièces de rechange non agréées.
•Les consignes d'entretien et de réparation de ce produit
s'adressent uniquement àun personnel de maintenance
qualifié.
•Le démontage et l'entretien de ce produit pouvant présenter
certains risques électriques, le personnel d'entretien qualifié
devra prendre toutes les précautions nécessaires.

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Norme di sicurezza
•La sicurezza del prodotto si basa sui test e sull'approvazione
del progetto originale e dei componenti specifici. Il produttore
non èresponsabile 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 èpiù
elevato. Il personale di assistenza autorizzato, deve, quindi,
adottare le precauzioni necessarie.
Sicherheitshinweise
•Die Sicherheit dieses Produkts basiert auf Tests 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 Auseinandernehmens 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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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
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 segurança deste produto baseia-se em testes e aprovações
do modelo original e de componentes específicos. O fabricante
não éresponsável 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.

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Informacióde Seguretat
•La seguretat d'aquest producte es basa en l'avaluaciói
aprovaciódel 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 informaciópel manteniment d’aquest producte està
orientada exclusivament a professionals i no estàdestinada
a ningúque 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 convenients.

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

General information 1-1
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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. The printhead assembly and ink
supply are combined into a single-unit print cartridge 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 blackcartridge 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.

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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 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 One Pass Scanning
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.

General information 1-3
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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.

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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.”The message scrolls or cycles until a
button is pressed. This message returns after two
minutes of inactivity.
Color Start The Color Start button’s function is influenced by the
mode selection. Pressing the Color Start button will
result in output from either 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 machine defaults will affect the
output.
•Photo Mode: Initiates acolor print job ifa photo card
media is present and a photo has been selected. If a
Digital Print Order Format (DPOF) file is detected on
the photo card media, a message will be posted,
and pressing the Color Start button causes the
entire list of pictures on the order form to print.
Buttons Functions

General information 1-5
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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. This does not imply that
all other factors, such as scan resolution and shingling
modes will remain constant.
•Copy Mode: Initiates a mono 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 mono scan. Previous
selections and machine defaults will affect the
output.
•Photo Mode: Initiates a mono print job if a photo
card media is present and a photo has been
selected. If a DigitalPrint Order Format (DPOF) flag
is detected on the photo card media,a message will
be posted and pressing the Black Start button
causes the entire list of pictures on the order form to
print.
Up Arrow
Down Arrow The predominant function is to navigate menu items on the LCD.
Left Arrow
Right Arrow The predominant function is to manipulate menu selections on the LCD.
Buttons Functions

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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. For photos, it is the
portion of the photo that will be displayed based on the
current photo size selection. It is also used with the
Resize button when cropping photos and for indicating
the region to be printed.
•Copy Mode: Changes 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 in., 8.5x14 in. A4, A5, A6, B5, L, 2L,
Hagaki, 3x5 in. 3.5x5 in., 4x6 in. 5x7 in. and 8x10 in.
sizes.
•Scan Mode: Error message displayed.
•Photo (Select) Mode: 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 The Number of Copies button will increment the copy count displayed on the lower left of the LCD in Copy
and Photo modes. It is not active in Scan mode.
•Copy Mode: Increments the copy count.
•Scan Mode: Error message displayed.
•Photo Mode: Increments the copy count.
Rotate The Rotate button will rotate the image in the LCD
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 scan.
•Photo Mode: Rotates the image in the LCD display
by 90°CCW for each time the button is pressed.
Buttons Functions

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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.
The Select button 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 button may be used to initiate a paper feed.
This function is accomplished by pressing the Select
button for more than three seconds.
Page Preview The Page Preview button gives a preview of the
eventual 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 function. Pressing either
the Color Start or Black Start will make a copy,
which will match the preview.
•Scan Mode: Performs a preview scan (scan to LCD)
to verify the information that you wish to scan is
within the scan region. Multiple previews can be
made before scanning.
•Photo Mode: When the Preview button is pressed,
the display on the LCD is updated to representwhat
the printed output will 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 multiple
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.
Buttons Functions

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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 viewing a photo presents a dialogue
asking if you would like to cancel all photo selections,
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.
Buttons Functions

General information 1-9
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Maintenance approach
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.
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. The second line is the scrollable
Options List for that setting. For functions, the second
line advises what button launches the function. Note
the highlighted first item, which indicates that it
currently has focus. You can then navigate the menu
using the Up and Down buttons. Options Lists for each
item are scrolled using the Left and Right buttons. Only
the currently highlighted setting displays Left and Right
Arrows. To select the currently displayed Setting
Option, press Select. A vertical navigation position
indicator is on the right side of the screen. This
elevator indicator is a fixed size (does not change
across varying conditions). At the top of the menu, the
top arrow is grayed out, and at the bottom ofthe menu,
the bottom arrow is grayed out.
After the menu is open, press the Menu button again
to exit the menu system and return the display to the
current mode’s default display. Menu structures, when
navigated with the Up and Down buttons, do not loop.
When the last item in the menu is reached, further
presses of the Down button are ignored. When the first
item in the menu is reached, further presses of the Up
button are ignored. Options Lists scrolled with the Left
and Right buttons do loop. Options List arrows are
never grayed out. The Menu listing for Options Lists
should reflect the current selection when the Menu is
opened.
Buttons Functions

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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