Lexmark 3200 Color Jetprinter User manual

4097-00X
Lexmark 3200 Color Jetprinter™
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
• Manuals Menu

First Edition (June, 1998)
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 ortypographical 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 D22/035-3,
740 New Circle Road N.W., 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. 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 Optra are trademarks of Lexmark International, Inc., registered in the United
States and/or other countries.
Color Jetprinter is a trademark of Lexmark International, Inc.
Other trademarks are the property of their respective owners.
© Copyright Lexmark International, Inc. 1998.
All rights reserved.
UNITED STATES GOVERNMENT RESTRICTED RIGHTS
This software and documentation are provided with RESTRICTED RIGHTS. Use,
duplication or disclosure by the Government is subject to restrictions as set forth in
subparagraph (c)(1)(ii) of the Rights in Technical Data and Computer Software clause at
DFARS 252.227-7013 and in applicable FAR provisions: Lexmark International, Inc.,
Lexington, KY 40550.
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Table of Contents
Preface.................................................v
SafetyInformation.......................................vi
GeneralInformation....................................1-1
Power Consumption .....................................1-1
Operator Panel .........................................1-1
Maintenance Approach ..................................1-2
Abbreviations ........................................1-2
DiagnosticInformation .................................2-1
Start .................................................2-1
Indicator Light Table...................................2-1
Power-On Self Test (POST) Sequence ....................2-2
POST Symptom Table.................................2-2
Symptom Tables .....................................2-3
Service Checks ........................................2-5
Carrier Transport Service Check .........................2-5
Maintenance Station Service Check ......................2-7
Paper Feed Service Check .............................2-8
Paper Path Service Check.............................2-10
Power Service Check.................................2-11
Print Quality Service Check ............................2-12
DiagnosticAids .......................................3-1
Test Page .............................................3-1
RepairInformation .....................................4-1
Handling ESD-Sensitive Parts .............................4-1
Adjustments ...........................................4-2
Removal Procedures ....................................4-2
Releasing Plastic Latches ..............................4-2
ConnectorLocations ...................................5-1
Preventive Maintenance ................................6-1
Lubrication Specifications .................................6-1
PartsCatalog .........................................7-1
Index..................................................I-1

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Preface v
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Preface
This manual 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 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.

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Safety Information
•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.
•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
•Ce produit a été conçu, testé et approuvé pour respecter les
normes strictes de sécurité globale lors de l'utilisation de
composants 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 un 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.

Safety Information vii
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Norme di sicurezza
•Il prodotto è stato progettato, testato e approvato in conformità a
severi standard di sicurezza e per l’utilizzo con componenti
Lexmark specifici. Le caratteristiche di sicurezza di alcune
parti non sempre sono di immediata comprensione. Lexmark
non è responsabile per l’utilizzo di parti di ricambio di altri
produttori.
•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
•Dieses Produkt und die zugehörigen Komponenten wurden
entworfen und getestet, um beim Einsatz die weltweit gültigen
Sicherheitsanforderungen zu erfüllen. Die sicherheitsrelevanten
Funktionen der Bauteile und Optionen sind nicht immer
offensichtlich. Sofern Teile eingesetzt werden, die nicht von
Lexmark sind, wird von Lexmark keinerlei Verantwortung oder
Haftung für dieses Produkt 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
•Este producto se ha diseñado, verificado y aprobado para
cumplir los más estrictos estándares de seguridad global
usando los componentes específicos de 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.
•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
•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.
•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 Information ix
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Informació de Seguretat
•Aquest producte està dissenyat, comprovat i aprovat per tal
d'acomplir les estrictes normes de seguretat globals amb la
utililització de components específics de Lexmark. Les
característiques de seguretat d'algunes peces pot ser que no
sempre siguin òbvies. Lexmark no es responsabilitza de l'us
d'altres peces de recanvi.
•La informació 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 convenients.

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General Information 1-1
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1. General Information
The Lexmark 3200 Color JetprinterTM is a personal, near laser-
quality inkjet printer. The printer contains 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 right. The color cartridge
has a total of 192 nozzles and installs on the left. The printer is
capable of printing in two directions from either cartridge.
Power Consumption
•<8 Watts - power off and power to the printer
•8 Watts - Idle Mode (power on - not printing)
•15 Watts - Printing (average)
•25 Watts - Printing (peak)
Operator Panel
Buttons Lights
Left Button
• Power On/Off Left Light • Steady - Power On
• Flashing - Printer Error
Right Button
• Paper Feed - clears a paper jam
or loads paper when there is a
paper out condition.
Right Light
• Steady - Busy
• Flashing - Paper Out/Jam

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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. Begin with “Indicator Light Table” on page 2-1.
After you complete the repair, perform tests as needed to verify the
repair.
Abbreviations
ESD Electrostatic Discharge
FRU Field Replaceable Unit
HVPS High Voltage Power Supply
LVPS Low Voltage Power Supply
OEM Original Equipment Manufacturer
V ac Volts alternating current
V dc Volts direct current
ZIF Zero Insertion Force

Diagnostic Information 2-1
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2. Diagnostic Information
Start
Use the indicator light table, the symptom tables, service checks,
and diagnostic aids in chapter 3, to determine the printer failure.
Indicator Light Table
Power light on Machine is on.
Power light on and busy light
flashes two times Paper out.
Power light on and busy light
flashes on and off Paper jam.
Power light and busy light flash Go to the “Carrier Transport Service
Check” on page 2-5.
Both lights on at the same time Printer is busy or printing.

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Power-On Self Test (POST) Sequence
Turn the printer on and check for a correct POST operation by
observing the following:
1. The power light comes on.
2. The carrier moves over the maintenance station two times and
seals the printheads.
3. The paper feed gears turn.
4. All motors stop and the power light stays on.
If your printer completes POST with no errors, go to the “Symptom
Tables” on page 2-3, 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
No power light
andnomotors
run
Go to the “Power Service Check” on page 2-11.
Paper feed
gears do not
turn
Go to the “Paper Feed Service Check” on page 2-8.
Carrier does not
move Go to the “Carrier Transport Service Check” on page 2-5.
Carrier slams
side frame Go to the “Carrier Transport Service Check” on page 2-5.
No busy light Replace the operator panel, or the system board.

Diagnostic Information 2-3
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Symptom Tables
Locate the symptom in the following tables and take the appropriate
action.
Carrier Transport Problems
Maintenance Station Problems
Operator Panel Problems
• No carrier movement
• Slow carrier movement
• Carrier stops
• Carrier slams side frame
Go to the “Carrier Transport
Service Check” on page 2-5.
Symptom Action
Maintenance station:
• Fails to cap the printheads
• Fails to clean the printheads
Go to the “Maintenance Station
Service Check” on page 2-7.
Symptom Action
• Paper feed or power buttons do
not operate
• Busy or paper feed lights do not
come on
Replace the operator panel,or the
system board.

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Paper Feed Problems
Power Problems
Print Quality Problems
• Fails to pick paper
• Picks more than one sheet of
paper
• Picks paper but fails to feed
• Paper jams
• Paper fails to exit
• Noisy paper feed
Go to the “Paper Feed Service
Check” on page 2-8.
Envelopes fail to feed Go to the “Paper Feed Service
Check” on page 2-8.
Paper skews Go to the “Paper Path Service
Check” on page 2-10.
No power in machine, motors do
not operate Go to the “Power Service Check” on page 2-11.
• Voids in characters
• Light print
• Prints off the page
•Fuzzyprint
• Carrier moves but no print
• Printhead drys prematurely
• Colors print incorrectly
• Vertical alignment off
Go to the “Print Quality Service
Check” on page 2-12.
• Ink smearing
• Vertical streaks on paper
• Print lines crowded
Go to the “Paper Feed Service
Check” on page 2-8.

Diagnostic Information 2-5
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Service Checks
Carrier Transport Service Check
1 System Board Unplug the printer and disconnect the carrier
transport motor connector (J4) from the system
board. Plug in the printer and check for
approximately 12 V dc between (J4-1) and ground.
If the voltage is incorrect, replace the system
board. If the voltage is correct, check for carrier
transport motor pins shorted to the housing. If a
short is detected, replace the carrier transport
motor.
2 Carrier Transport
Motor Check the motor for binds, or loose motor pulley.
A noisy or chattering motor or a motor that fails to
turncanbecausedby:
An open or short in the motor.
An open or short in the motor driver on the system
board.
A bind in the carrier transport mechanism.
With the carrier transport motor cable
disconnected from the system board, check for
zero to ten (0 - 10) ohms between the following
pins on the motor:
J4-1 and J4-2
J4-3 and J4-4
If the readings are incorrect, replace the motor.
3 Carrier Guide Rod Clean the carrier rod.
Note: Lubricate the rod and the carrier rod bearing
surfaces with grease P/N 99A0394.
4 Carrier Transport
Belt
Idler Pulley Parts
Carrier Frame
Check for worn, loose or broken parts. Check for
obstructions blocking carrier movement.
Carrier to carrier frame engagement should be
lubricated with grease P/N 99A0394.

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5 Printhead Cable /
Home Sensor Disconnect the printer and check the carrier printhead connector (J1). If the connection is
good, remove the printhead carrier and rod,
without disconnecting the printhead cables. Insert
a piece of paper into the sensor. Plug in the printer
andcheckfor5Vdcatconnection(C)locatedon
the rear of the sensor. The voltage drops when
paper is removed. If voltage does not change
when paper is removed, replace the home position
sensor. If the problem remains, replace the system
board.
6 Maintenance
Station A problem with the maintenance station can cause carrier movement problems at the right margin. Go
to the “Maintenance Station Service Check” on
page 2-7.
7 Access Cover
Sensor If the carrier does not move toward the cartridge load position when the access cover is opened,
verify that power is on. If the carrier still does not
move, check the actuator arm for binds. If the arm
is working correctly, replace the system board.

Diagnostic Information 2-7
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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.
1 Maintenance
Station Assembly As the carrier moves to the right over the maintenance station, a slot on the bottom of the
carrier engages a tab on the sled of the
maintenance station causing the cap to rise and
seal the printhead. Carrier movement to the left
uncaps the printhead. The wiper cleans the
printhead nozzles as the carrier leaves the
maintenance station. The wiper cleans the
printhead only when the carrier is moving to the
left. There should be no wiping action of the
printhead nozzles when the carrier is moving to
the right. After the cleaning operation is complete,
a tab on the maintenance station engages a tab on
the carrier, causing the wiper to lower.
Check the maintenance station for worn or broken
parts.
2 Wiper Worn wipers cause degraded print quality just after
a maintenance cleaning. Check for loose or worn
wipers.
3 Cap Worn caps cause the printhead nozzles to dry and
clog. Check for loose or worn caps.

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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 problem,
examine it for the following before you begin the service check:
•Check the entire paper path for obstructions.
•Be sure there is not too much paper in the sheet feeder.
•Be sure the correct type of paper is being used.
•Check for static in the paper.
1 System Board Unplug the printer and disconnect the paperfeed
motor (J3) from the system board. Plug the printer
in and check for approximately 9 - 12 V dc
between (J3-1) and ground and (J3-2) and ground
on the system board. If the voltage is not present,
check for motor pins shorted to the motor housing.
If you find a shorted pin, replace the motor. If you
still have a failure after replacing the motor,
replace the system board.