Color Jetprinter™ 1020 4078-00X • Table of Contents • Start Diagnostics • Safety and Notices • Trademarks • Index • Manuals Menu Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
4078-00X Second Edition (July, 1996) The following paragraph does not apply to the United Kingdom or 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.
4078-00X Contents 1 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Power Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Maintenance Approach. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Abbreviations .
078-00X Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 Handling ESD-Sensitive Parts . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Removal Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Releasing Plastic Latches . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Access Cover Removal . . . . . . . . . . . . . . . .
4078-002 Preface 2 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 error indicator table, symptom table, and service checks used to isolate failing field replaceable units (FRUs). 3.
4078-00X Sicherheitshinweise • Die Wartungsinformationen für dieses Produkt wurden zur Verwendung durch einen Wartungsfachmann entwickelt und sollten nicht von anderen benützt werden. • Zusätzliches Risiko eines elektrischen Schlags und körperlicher Verletzung existiert während des Auseinandernehmens und der Wartung des Geräts. Fachpersonal sollte im vollen Verständnis der Lage entsprechende Vorsichtsmaßnahmen ergreifen.
4078-002 Pautas de Seguridad • La información sobre el mantenimiento de este producto fue escrita para el personal de mantenimiento cualificado y no para cualquier otro usuario. • Existen mayores riesgos de descargas eléctricas y daños personales durante el desmontaje y la reparación de la máquina. El personal cualificado comprende esto y toma las precauciones necesarias. • Los dispositivos de seguridad de algunas partes quizá no siempre puedan ser reconocidas a simple vista.
4078-00X Chinese Safety Information Korean Safety Information viii
4078-00X 1. General Information The Color JetprinterTM 1020 printer is a personal, near laser-quality inkjet printer. The print cartridge is a single-unit customer replaceable supply item. A single printhead provides three colors and composite black printing. The printer also supports a black print cartridge and provides 600 X 300 dpi edge definition for professional quality text image and graphics printing. Power Consumption • • • • Less than 2 Watts - power off and power to the printer 7.
4078-00X Abbreviations ESD FRU HVPS LVPS NVRAM OEM POST V ac V dc ZIF Electrostatic Discharge Field Replaceable Unit High Voltage Power Supply Low Voltage Power Supply Nonvolatile Random Access Memory Original Equipment Manufacturer Power-On Self Test Volts alternating current Volts direct current Zero Insertion Force Unique Tools Required For Service Parallel Wrap Plug P/N 1319128 1-2
4078-00X 2. Diagnostic Information Use the error indicator table, symptom tables, service checks, and diagnostic aids in chapter 3, to determine the failing part. Start Service error indications show as a series of flashes of the Power On light. There is a pause between each series of flashes. If your machine has an error indication, locate the series of flashes in the “Error Indicator Table” on page 2-2 and take the indicated action. Unplug the machine to clear the error indicator.
4078-00X Error Indicator Table Error Code Number of Power Light Flashes Blank 8 Replace the system board. 64/ 65 7 Replace the system board. 81 1 Go to the “Carrier Transport Service Check” on page 2-6. 89 4 Go to the “Carrier Transport Service Check” on page 2-6. 127 and up 10 Action Replace the system board. Power-On Self Test (POST) Sequence When you turn the printer on it performs a POST. Turn your machine on and check for a correct POST operation by observing the following: 1. 2. 3.
4078-00X POST Symptom Table Symptom Action No Power On light and no motors run Go to the “Power Service Check” on page 2-12. Power light, but no busy light Replace the system board. Paper feed gears do not turn Go to the “Paper Feed Service Check” on page 2-9. Carrier doesn’t move Go to the “Carrier Transport Service Check” on page 2-6. Carrier slams side frame Go to the “Carrier Transport Service Check” on page 2-6.
4078-00X Symptom Tables Locate the symptom in the following tables and take the appropriate action. Carrier Transport Problems Symptom Action • • • • Go to the “Carrier Transport Service Check” on page 2-6. No carrier movement Slow carrier movement Carrier stops Carrier slams side frame Communications Problems Symptom Action Printer not communicating with host computer. Go to the “Parallel Port Service Check” on page 2-12.
4078-00X Paper Feed Problems Symptom Action • 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 2-9. Envelopes fail to feed Go to the “Envelope Feed Service Check” on page 2-7. Paper skews Go to the “Paper Path Service Check” on page 2-11.
4078-00X Service Checks Carrier Transport Service Check 1 FRU Action System Board Check the motor for binds, or loose motor pulley. Turn the printer off and disconnect CN4 from the system board. Turn the printer on and check for a pulse of (approximately) 10 V dc between CN4-1 and ground and CN4-4 and ground, on the system board, as the machine goes through P-O-S-T. If the voltage is not present, check for motor pins shorted to the motor housing.
4078-00X FRU Action 6 Home Position Sensor Perform the “EOF and Home Position Sensors Test” on page 3-2, to check the Home Position Sensor. If you cannot enter the test, replace the system board. If the test fails, turn the printer off and disconnect CN5 from the system board. Turn the printer on and check for 5 V dc between CN5-1 and ground, at the system board. If the voltage is present, replace the home position sensor. If the voltage is not present, replace the system board.
4078-00X 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 FRU Action 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.
4078-00X 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: • • • • 1 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.
4078-00X 2 FRU 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 • A bind in the paper feed mechanism With the paper feed motor cable disconnected from the system board, check for 60 ohms (±15 ohms) between the following pins on the motor: Pin 2 to Pin 5 Pin 2 to Pin 6 130 ohms (±20 ohms) between pins 5 and 6. If the readings are incorrect, replace the motor.
4078-00X 7 FRU Action End of Forms Sensor Check the sensor for dirt. Perform the “EOF and Home Position Sensors Test” on page 3-2, to check the end of forms sensor on the system board. If the test fails, replace the system board. 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.
4078-00X Parallel Port Service Check 1 FRU Action Parallel Port Run a test page to be sure the printer can print. Run the “Parallel Port Test” on page 3-4. If the test fails, replace the system board. Power Service Check 1 FRU Action Power Supply Disconnect CN7 from the system board and check the following voltages on the power supply cable: • CN7-1 to GND = +5 V dc • CN7-4 to GND = +24 V dc If you do not have correct voltage, replace the power supply.
4078-00X Print Quality Service Check FRU / Function Action 1 Print Cartridge Be sure the machine contains a good print cartridge. 2 Color Print Cartridge Cross Contamination Cross contamination of color inks results in incorrect colors printed, as when green prints for yellow, (when yellow and blue are mixed in the print cartridge). This problem resolves quickly as the print cartridge is used. If cross contamination occurs, check the following: • The maintenance station wiper for damage.
4078-00X FRU / Function Action 5 Maintenance Station Intermittent nozzle failures can be caused by worn parts in the maintenance station. Perform the “Maintenance Station Service Check” on page 2-8, then return to this check. 6 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. Also check the paper for curl or wrinkles. • Feed rollers for wear, dirt, or looseness.
4078-00X Print Quality Notice Printers are shipped with three different carrier transport motors displaying a label which reads either NMB(NMB), Airpax(APX) or Mitsumi(MZM). The label on the motor should match the motor ID in NVRAM. To verify the motor ID stored in NVRAM, print out a Test Page. The three letter designation will be printed on the service line. If the carrier transport motor or the system board must be replaced, check the label on the carrier transport motor.
4078-00X 3. Diagnostic Aids Use these diagnostic test procedures to verify a repair. The test procedures are entered by pressing and holding a button, or buttons, as you turn on the printer. To begin the test, hold the buttons until both the operator panel lights come on and then release the buttons after five seconds. Some tests require the End-of-Form Flag to be out of the sensor. To remove the End-of-Form Flag from the sensor: 1. Open the sheet feeder. 2.
4078-00X EOF and Home Position Sensors Test This test allows the servicer to test the function of the End-of-Form and Home Position sensors. To run the test: 1. With the printer off and the End-of-Form Flag out of the sensor, press and hold the following buttons while turning the printer on: 2. Paper Feed 3. Install Print Cartridge After five seconds, release the buttons to begin the test. The Busy light goes on and off as the End-of-Form flag is moved into and out of the End-of-Form sensor.
4078-00X Initialize Error Log This test tracks intermittent errors. Use this procedure to reset the error log to zero. The error log is especially helpful in diagnosing intermittent or difficult problems. The test is complete when power is turned off. To run the test: 1. Place a sheet of paper in the sheet feeder far enough to push the End-of-Form flag out of the sensor. 2. With the printer off, hold down the Install Print Cartridge button while turning the printer on.
4078-00X 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 before you start the test. The power on light flashes if the test is successful. If the test is not successful, the power on light remains off. To run the test: 1.
4078-00X Print NVRAM Contents This test prints the contents of NVRAM, which can be used for diagnostic purposes. To run the test: 1. Install a black print cartridge. 2. Place a sheet of paper in the sheet feeder far enough to push the End-of-Form flag out of the sensor. 3. Load paper into the sheet feeder. 4. With the printer off, press and hold the Paper Feed button and turn the printer on. After five seconds, release the button to begin the test.
4078-00X Reset NVRAM to EMEA Defaults This test resets the user defaults area of NVRAM to the EMEA factory defaults. The page count and the error log do not change. Note: Factory defaults are initially set to USA. To run the test: 1. With the printer off, press and hold the following buttons while turning the printer on: • Paper Feed • Install Print Cartridge 2. After five seconds, release the buttons to begin the test. A sheet of paper will feed and verify the defaults have been set by printing “EMEA”.
4078-00X Reset NVRAM to USA Defaults This test resets the user defaults area of NVRAM to the USA factory defaults. The page count and the error log do not change. Note: Factory defaults are initially set to USA. To run the test: 1. With the printer off, press and hold the Install Print Cartridge button while turning the printer on: 2. After five seconds, release the button to begin the test. A sheet of paper will feed and verify the defaults have been set by printing “US”.
4078-00X Test Page This test prints the test page. To run a complete test page of black and color patterns, be sure the print cartridge is in good condition. Install a black print cartridge. To enter the test: • Press and hold the Paper Feed button while turning the printer on. Paper feeds from the sheet feeder and prints the test page. Pages continue to print until you turn off the power or unplug the printer. The test page prints the following lines. Line 1 - Code level. Line 2 - Manufacturer name.
4078-00X 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).
4078-00X 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. Unplug the power cord before removing any parts. Releasing Plastic Latches Many of the parts are held in place with plastic latches. The latches break easily; release them carefully.
4078-00X Access Cover Removal 1. Open the access cover. 2. Push the mounting tabs towards the center of the machine. 3. Remove the access cover. Base Assembly Removal 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove the front cover. Remove the rear cover. Remove the sheet feeder. Disconnect the power supply connector at the system board. Remove the two screws that secure the carrier frame to the base assembly. Remove the screw that secures the power supply frame to the carrier frame.
4078-00X Carrier Frame Assembly Removal The carrier rail mounted by two screws on the carrier frame is included with the carrier frame (11A5436). The carrier rail, which is not available as a FRU, is mounted in the elongated slots at the factory. During adjustment, the rail is pushed to the rear as far as it will go, before the mounting screws are tightened. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Remove the front cover. Remove the rear cover. Remove the sheet feeder.
4078-00X Carrier Transport Motor Removal 1. Remove the front cover. 2. Remove the rear cover. 3. Disconnect the carrier transport motor connector from the system board. 4. Remove the belt from the carrier transport motor pulley. 5. Remove the two screws securing the carrier transport motor to the carrier frame and remove the motor. Note the routing of the motor cable. 6. See “Print Quality Notice” on page 2-15. Drive Train Assembly Removal 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Remove the front cover.
4078-00X Front Cover Removal 1. Turn the printer over to expose the base. Remove the two cover mounting screws from the front cover. When reassembling, do not overtighten these screws as they will break. Replacement screws can be found in parts packet 11A5453. 2. Slide the cover upwards and off the machine. To reassemble: 1. Align the tabs on the front cover over the front edge of the base assembly. 2.
78-00X Large Feed Roll Removal 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Remove the front cover. Remove the rear cover. Remove the sheet feeder. Remove the base assembly. Remove the system board. Remove the printhead carrier assembly. Remove the small feed roll assemblies. Remove the small feed roll bracket assembly. Remove the mid frame assembly. Remove the maintenance station assembly. Turn and remove the retainer at the right end of the large feed roller. 12.
4078-00X Mid Frame Assembly Removal 1. 2. 3. 4. 5. 6. 7. 8. Remove the front cover. Remove the rear cover. Remove the sheet feeder. Remove the system board. Remove the small feed roll assemblies. Remove the small feed roll bracket assembly. Remove the printhead carrier assembly. Lift up the rear of the mid frame assembly and remove it from the carrier frame. Paper Feed Motor Removal 1. 2. 3. 4. Remove the front cover. Remove the rear cover. Disconnect the paper feed motor from the system board.
4078-00X Printhead Carrier Assembly Removal 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 4-9 Remove the front cover. Remove the rear cover. Remove the sheet feeder. Unlock the two printhead cable connectors and disconnect the printhead cable from the system board. Unlatch the cable retainer from the carrier frame. Remove the retainer spring from the left end of the carrier guide rod. Remove the screw from the right end of the carrier guide rod. Slide the carrier guide rod out the left side of the machine.
4078-00X Rear Cover Removal 1. Remove the front cover. 2. Pry upwards on the two rear cover latches [A]. 3. Work the tabs of the rear cover free from the base assembly. 4. To reassemble, place the cover over the tabs in the base assembly and press towards the front of the machine until the cover latches. Be sure the parallel connector snaps do not get trapped behind the cover.
4078-00X Sheet Feeder Removal 1. Remove the front cover. 2. Remove the rear cover. 3. Remove the two sheet feeder mounting screws from the rear of the carrier frame. 4. Unlatch the right sheet feeder latch from the front of the carrier frame. Note: The cables are routed through tab slots in the sheet feeder. Note this for reassembly. 5. Remove the sheet feeder. Small Feed Roll Assembly Removal 1. 2. 3. 4. 5. 6. 4-11 Remove the front cover. Remove the rear cover. Remove the sheet feeder.
4078-00X Small Feed Roll Bracket Assembly Removal 1. 2. 3. 4. 5. 6. Remove the front cover. Remove the rear cover. Remove the sheet feeder. Remove the system board. Remove the four small feed roller springs from the carrier frame. Push down on each of the small feed roll assemblies to remove them from the small feed roll bracket. 7. Push the two locking tabs [A] to the rear to release the small feed roll assembly from the carrier frame.
4078-00X System Board Removal 1. 2. 3. 4. 5. 6. 7. 8. 9. 4-13 Remove the front cover. Remove the rear cover. Remove the sheet feeder. Unlock the two printhead cable connectors and disconnect the printhead cables from the system board. Disconnect the other cables from the system board. Remove the three screws securing the system board to the carrier frame and remove the system board. Note the routing of all the cables. Remove the system board being careful not to damage the Endof-Form flag.
4078-00X 5.
4078-00X Connector 5-2 Connector Names CN1 Printhead Cable 1 CN2 Printhead Cable 2 CN4 Carrier Transport Motor CN5 Home Position Sensor CN6 Paper Feed Motor CN7 Power Supply CN8 Parallel Port SW1 Power Switch SW2 Paper Feed Switch SW3 Install Print Cartridge Switch LED1 Busy Light LED2 Power on Light
4078-00X 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: • • • All gear mounting studs. The left and right ends of the large feed roller at the side frames. The carrier to carrier frame engagement.
4078-00X 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. NS: (Not Shown) in the Asm-Index column indicates that the part is procurable but is not pictured in the illustration.
4078-00X Assembly 1: Covers Parts Catalog 7-2
4078-00X AsmIndex Part Number Units 1 -1 11A5430 1 Base Asm -2 11A5431 1 Felt Pad, Ink Absorption -3 11A5432 1 Cover, Front Asm -4 11A5433 1 Cover, Rear Asm -5 11A5434 1 Cover, Access Asm -6 11A5435 1 Garage Asm NS 11A5453 2 Front Cover Mounting Screws (PP) N/S 11A5454 1 Replaceable Package B/M - Includes: (Carton, Cushion Set, Sealing Tape) 7-3 Description
4078-00X Assembly 2: Paper Feed / Carrier Transport / Maintenance Parts Catalog 7-4
4078-00X AsmIndex Part Number Units 2 -1 11A5436 1 Frame, Carrier -2 11A5438 1 Sensor, Carrier Home -3 11A5450 1 Motor, Carrier Transport Asm See “Print Quality Notice” on page 2-15.
4078-00X Assembly 3: Electronics Parts Catalog 7-6
4078-00X AsmIndex Part Number Units 3 -1 11A5455 1 System Board with ROM See “Print Quality Notice” on page 2-15.
4078-00X Assembly 3: Electronics (Continued) Parts Catalog 7-8
4078-00X AsmIndex Part Number 3 -4 1339526 1342536 1339520 1339520 1342514 1342526 1342536 1339526 1342534 1342514 1342514 1339525 1342514 1339519 1342514 1339520 1339520 1339520 1342514 1342514 1339521 1339524 70G0496 1342514 1339520 1342514 1339520 1342514 1342536 1342514 1339520 1339517 1339523 1339520 1339520 1339522 1339519 1342536 1342514 7-9 Units 1 Description Power Cord, U.S.
4078-00X Assembly 4: Carrier Parts Catalog 7-10
4078-00X AsmIndex Part Number Units 4 -1 11A5448 1 Carrier Assembly -2 11A5437 1 Rod, Carrier Guide -3 11A5436 1 Frame, Carrier -4 11A5453 1 Screw, Carrier Guide Rod (PP) -5 11A5453 1 Spring, Carrier Guide Rod (PP) 7-11 Description
4078-00X Assembly 5: Sheet Feeder Parts Catalog 7-12
4078-00X AsmIndex Part Number Units 5 -1 11A5436 1 Frame, Carrier -2 11A5453 2 Screws, Sheet Feeder Mounting (PP) -3 11A5451 1 Sheet Feeder Asm -4 11A5433 1 Cover, Rear Asm NS 70G2759 1 Card Feeder Kit, Japan Hagaki 7-13 Description
4078-00X Index 1 A Maintenance Station Paper Feed 2-5 Power 2-5 Print Quality 2-5 Abbreviations 1-2 Adjustments 4-2 Assemblies 1 Covers 7-2 2 Carrier Transport 7-4 2 Maintenance Station 7-4 2 Paper Feed 7-4 3 Electronics 7-6 4 Carrier 7-10 5 Sheet Feeder 7-12 R Removals Access Cover 4-3 Base Assembly 4-3 Carrier Belt 4-3 Carrier Frame 4-4 Carrier Transport Motor 4-5 Drive Train Assembly 4-5 Front Cover 4-6 Gutter Pad 4-6 Large Feed Roll 4-7 Maintenance Station 4-7 Mid Frame Assembly 4-8 Paper Feed Mot
4078-00X Parallel Port 3-4 Print NVRAM Contents Reset NVRAM Defaults EMEA 3-6 USA 3-7 Test Page Tools 1-2 X-2 3-8 3-5
