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Lexmark 1020 Printer User Manual

1. 2 6 Envelope Feed Service 2 7 Maintenance Station Service Check 2 8 Paper Feed Service Check 2 9 Paper Path Service 2 11 Parallel Port Service 2 12 Power Service 2 12 Print Quality Service 2 13 Print Quality Noll G8 ree Su nx 2 15 Diagnostic 5 455254222 522520 2 40 Das 3 1 EOF and Home Position Sensors 3 2 Initialize Error LOG ira 3 3 Paralel POR TES suprir qp i 3 4 Print NVRAM Contents casada pes Redan ean EY 3 5 Reset NVRAM to EMEA 3 6 Reset NVRAM to USA Defaults 3 7 RR _ TP CPU ST 3 8 4078 00 MOM N 4 1 Handling ESD Sensitive 4 1 AQUA 4 2 Removal 4 2 Releasing Plastic 4 2 Access Cover 4 3 Base Assembly 4 3 Carrier Belt 4 3 Carrier Frame Assembly R
2. Number Error of Code Power Action Light Flashes Blank 8 Replace the system board 64 7 Replace the system board 65 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 10 Replace the system board and up 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 PON 5 The lights come on The carrier moves The paper feed gears turn After 30 seconds the carrier moves over the maintenance station and caps the printhead All motors stop and the power light stays on If your machine completes POST with no errors go to the Symptom Tables on page 2 4 locate the symptom and take the indicated action If your machine does not complete POST locate the symptom in the following table and take the indicated action 2 2 4078 00 POST Symptom Table Symptom Action No Power On Go to the Power Service Check on page 2 12 light and no motors run Power light but Replace the system board no busy light Paper feed Go to the Paper Feed Service Check on page 2 9 gears do not turn Carrier doesn t Go to the Carrier Transport Service Check on page move 2 6 Carrier slams Go to the Carrier Transport Service Check on page side frame 2 6 Diagnostic Inform
3. break easily release them carefully To remove such parts press the hook end of the latch away from the part to which it is latched Never apply excessive force when releasing the hook Repair Information 4 2 4078 00 Access Cover Removal 1 2 3 Open the access cover Push the mounting tabs towards the center of the machine Remove the access cover Base Assembly Removal OP ONS 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 Remove the ground strap screw from the system board Unlatch the carrier frame from the base assembly and lift it off the base Slide the machine off the base assembly Carrier Belt Removal 4 3 Jop boah Remove the front cover Remove the retainer spring from the left side of the carrier rod Remove the screw from the right side of the carrier rod Slide the carrier rod to the left out of the machine Remove the carrier belt from the rear of the carrier Remove the carrier belt from the carrier transport motor pulley Remove the carrier belt 4078 00 Carrier Frame Assembly Removal The carrier rail mounted by two screws on the carrier frame is included with the carrier frame 11 5436 The carrier which is not ava
4. Description 2 1 1145436 1 Frame Carrier 2 1145438 1 Sensor Carrier Home 3 1145450 1 Motor Carrier Transport Asm See Print Quality Notice on page 2 15 4 1145453 1 Screw PP 5 11 54538 1 Spring Small Feed Asm PP 6 11A5441 1 Feed Roll Assembly Small 7 11A5442 1 Mounting Bracket Small Feed Roll Assembly 8 11A5443 1 Drive Train Assembly 9 11A5444 1 Motor Paper Feed Assembly 10 11A5453 5 Screws Drive Train amp Paper Feed Motor Mounting PP 11 11A5453 1 Arm Tensioner PP 12 11A5449 1 Belt Carrier 13 11A5453 1 Spring Large Feed Roll Dampening PP 14 11A5440 1 Feed Roll Assembly Large 15 11A5439 1 Frame Mid Assembly 16 11A5452 1 Maintenance Assembly 18 11A5453 2 Screw PP 19 11A5453 1 Screw PP 20 11A5453 1 Screw PP 21 1367389 1 Cap and Wiper B M 7 5 4078 00 Assembly 3 Electronics Parts Catalog 7 6 4078 00 am Ge Units Description 3 1 1145455 1 System Board with ROM See Print Quality Notice on page 2 15 2 1145447 1 Power Supply 110V 2 1145446 1 Power Supply 220V 3 11 5453 1 Screws System Board 7 7 4078 00 Assembly 3 Electronics Continued Parts Catalog 7 8 4078 00 Asm Part index Number Units Description 3 4 1339526 1 Power Cord U S 1342536 Power Cord Argentina 1339520 Power Cord Austria 1339520 Power Cord Belgium 1342514 Power Cord Bolivia 1342526 Pow
5. Maintenance Station 2 8 Paper Feed 2 9 Paper Path 2 11 Parallel Port 2 12 Power 2 12 Print Quality 2 13 Transport 2 6 Start 2 1 Symptom Table POST 2 3 Symptom Tables 2 4 T Tests EOF End of Form 3 2 Home Position 3 2 Initialize Error Log 3 3 X 1 4078 00 Parallel Port 3 4 Print NVRAM Contents 3 5 Reset NVRAM Defaults A 3 6 USA 3 7 TestPage 3 8 Tools 1 2 X 2
6. bidirectional printing alignment when replacing a print cartridge 2 14 4078 00 Print Quality Notice Printers are shipped with three different carrier transport motors displaying a label which reads either 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 replaced check the label on the carrier transport motor All FRU motors will be labeled NMB After completing repairs to the printer connect it to a PC and go to xNToolsM078 where x is the letter of your CD ROM drive on your latest Service Information and Training CD ROM and perform one of the following commands to download the file to your printer Use the file that matches the transport motor label e NMB BIN LPT1 e x COPY APX BIN LPT1 e x COPY B MZM BIN LPT1 Diagnostic Information 2 15 4078 00 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 fr
7. 12 A 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 Remove the large feed roller from the carrier frame Maintenance Station Assembly Removal quot Remove the front cover Remove the rear cover Remove the base assembly Remove the screw from the rear of the carrier frame that secures the maintenance station assembly and slide the assembly out of the machine Maintenance Wiper and Cap Removal 4 7 1 2 3 Remove the front cover Push the carrier to the left away from the maintenance station Gently pull the cap and wiper off their mountings 4078 00 Mid Frame Assembly Removal 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 Remove the front cover 2 Remove the rea
8. Go to the Power Service Check on page 2 12 Symptom Action Voids in characters Light print Prints off the page Fuzzy print Carrier moves but no print Printhead drys prematurely Colors print incorrectly Vertical alignment off Go to the Print Quality Service Check on page 2 13 Ink smearing Vertical streaks on paper Print lines crowded Go to the Paper Feed Service Check on page 2 9 Diagnostic Information 2 5 4078 00 Service Checks Carrier Transport Service Check FRU Action 1 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 If you find a pin shorted to the housing replace the motor If the failure remains replace the system board 2 Carrier Transport 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 carrier transport mechanism With the carrier transport motor cable disconnected from the system board check for zero to ten 0 10 ohms bet
9. 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 With a parallel port wrap plug installed and the printer off press and hold the following button while turning the printer on 2 Paper Feed After five seconds release the button to begin the test The Power On light blinks upon successful completion of the test A failing test causes the Power On light to remain off Turning the power off or unplugging the printer ends the test Diagnostic Aids 3 4 4078 00 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 4 and turn the printer on After five seconds release the button to begin the test 3 5 4078 00 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 print
10. aper 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 FRU Action 1 System Board Turn the printer off and disconnect CN6 from the System board Turn the printer on and check for a pulse of 24 V dc between CN6 1 and ground and CN6 2 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 If you find a shorted pin replace the motor If you still have a failure after replacing the motor replace the system board Diagnostic Information 2 9 4078 00 FRU Action 2 Paper Feed Motor A noisy or chattering motor or a motor that fails to turn can be caused by Anopenor shortin the motor open 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 Although the paper feeds in a forward direction only the paper feed motor turns in two directions If the paper feed motor turns in one direction onl
11. ation 2 3 4078 00 Symptom Tables Locate the symptom in the following tables and take the appropriate action Carrier Transport Problems Symptom Action No carrier movement Go to the Carrier Transport Service Slow carrier movement Check on page 2 6 Carrier stops Carrier slams side frame Communications Problems men Printer not communicating with Go to the Parallel Port Service host computer Check on page 2 12 Maintenance Station Problems Symptom Action Maintenance station Go to the Maintenance Station Fails to cap the printhead FONE ONEC SES Fails to clean the printhead Operator Panel Symptom Action Paper Feed and or Install print Replace the system board cartridge buttons do not operate Busy light does not come on Replace the system board 2 4 4078 00 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 ee e o Envelopes fail to feed Go to the Paper Feed Service Check on page 2 9 Go to the Envelope Feed Service Check on page 2 7 Paper skews Power Problems Go to the Paper Path Service Check on page 2 11 Symptom Action No power in machine no Power On light no motors Print Quality Problems
12. d wear Use only a clean dry cloth to clean the contacts Also check the cable for damage You may need to remove the cable from the carrier to inspect it A worn rubber backer results in poor contact between the printhead cable and the print cartridge Check the rubber backer for wear Diagnostic Information 2 13 4078 00 FRU Function Action 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 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 Gears for wear or binds Paper path for obstructions Carrier Transport Blurred print and voids can be caused by problems in the carrier transport area Check the following Carrier transport belt for wear Carrier guide rod for wear or dirt Carrier to carrier frame engagement should be lubricated with grease P N 1329301 Do not lubricate the carrier guide rod ldler pulley parts for wear damage looseness Alignment Uneven vertical lines can be adjusted by performing the bidirectional alignment The user is directed through the Printer Control program to perform the
13. d 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 The safety features of some parts may not always be obvious Therefore replacement parts must have the identical or equivalent characteristics as the original parts Preface v 4078 00 Sicherheitshinweise Die Wartungsinformationen f r dieses Produkt wurden zur Verwendung durch einen Wartungsfachmann entwickelt und sollten nicht von anderen ben tzt werden Zus tzliches Risiko eines elektrischen Schlags und k rperlicher Verletzung existiert w hrend des Auseinandernehmens und der Wartung des Ger ts Fachpersonal sollte im vollen Verstandnis der Lage entsprechende VorsichtsmaBnahmen ergreifen Ersatzteile m ssen gleiche oder gleichwertige Merkmale wie die Originalteile aufweisen da Sicherheitsvorkehrungen nicht immer offensichtlich sind Consignes de S curit Les consignes d entretien et de r paration de ce produit s adressent uniquement un personnel de maintenance qualifi Le d montage et l entretien de ce produit pouvant pr senter certains risques lectriques le personnel d entretien qualifi devra prendre toutes les pr cautions n cessaires Les normes de s curit de certaines pi ces n tant pas toujours explicites les pi ces de rechange doivent tre identiques
14. e Print Quality Notice on page 2 15 Drive Train Assembly Removal 4 5 JO Om BON 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 Remove the large feed roll Remove the three screws securing the drive train to the carrier frame Push the drive train to the right and remove it from the carrier frame 4078 00 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 11 5453 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 Rotate the front cover over the top edge of the rear cover and press in on both sides opposite the cover latches until they latch Gutter Pad Removal Or d e oc Remove the front cover Remove the rear cover Remove the sheet feeder Remove the base assembly Remove the gutter pad from the base assembly Repair Information 4 6 4078 00 Large Feed Removal ch
15. e machine Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins If you are removing a pluggable module use the cor rect tool Do not place the ESD sensitive part on the machine cover or on a metal table if you need to put down the ESD sensitive part for any rea son first put it into its special bag Machine covers and metal tables are electrical grounds They increase the risk of damage because they make a discharge path from your body through the ESD sensitive part Large metal objects can be dis charge paths without being grounded Prevent ESD sensitive parts from being accidentally touched by other personnel Install machine covers when you are not working on the machine and do not put unprotected ESD sensitive parts on a table If possible keep all ESD sensitive parts in a grounded metal cabinet case Be extra careful in working with ESD sensitive parts when cold weather heating is used because low humidity increases static electricity Repair Information 4 1 4078 00 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
16. emoval 4 4 Carrier Home Sensor 4 4 Carrier Transport Motor Removal 4 5 Drive Train Assembly 4 5 Front Cover Removal xam ara 4 6 Gutter Pad Removal E pps ER 4 6 Large Feed Roll Removal nee e pons 4 7 Maintenance Station Assembly Removal 4 7 Maintenance Wiper and Cap Removal 4 7 Mid Frame Assembly 4 8 Paper Feed Motor Removal 4 8 Power Supply 4 8 Printhead Carrier Assembly Removal 4 9 Rear Cover 4 10 Sheet Feeder 4 11 Small Feed Assembly 4 11 Small Feed Roll Bracket Assembly Removal 4 12 System Board 4 13 Connector 5 1 System Board 5 1 Preventive Maintenance 6 1 Lubrication Specifications 6 1 Parts Gatalog assises ke XA 7 1 How Use This Parts Catalog a sso cesses mn 7 1 Assembly 1 7 2 Assemb
17. er Cord Brazil LV 1342536 Power Cord Brazil HV 1339526 Power Cord Canada 1342534 Power Cord Chile 1342514 Power Cord Columbia 1342514 Power Cord Costa Rica 1339525 Power Cord Denmark 1342514 Power Cord Ecuador 1339519 Power Cord Egypt 1342514 Power Cord El Salvador 1339520 Power Cord Finland 1339520 Power Cord France 1339520 Power Cord Germany 1342514 Power Cord Guatemala 1342514 Power Cord Honduras 1339521 Power Cord Israel 1339524 Power Cord Italy 70G0496 Power Cord Japan 1342514 Power Cord Mexico 1339520 Power Cord Netherlands 1342514 Power Cord Nicaragua 1339520 Power Cord Norway 1342514 Power Cord Panama 1342536 Power Cord Paraguay 1342514 Power Cord Peru 1339520 Power Cord Portugal 1339517 Power Cord Saudi Arabia 1339523 Power Cord South Africa 1339520 Power Cord Spain 1339520 Power Cord Sweden 1339522 Power Cord Switzerland 1339519 Power Cord United Kingdom 1342536 Power Cord Uruguay 1342514 Power Cord Venezuela 7 9 4078 00 Assembly 4 Carrier Parts Catalog 7 10 4078 00 Ger H Units Description 4 1 1145448 1 Carrier Assembly 2 1145437 1 Rod Carrier Guide 3 1145436 1 Frame Carrier 4 1145453 1 Screw Carrier Guide Rod PP 5 11 5453 1 Spring Carrier Guide Rod 7 11 4078 00 Assembly 5 Sheet Feeder Parts Catalog 7 12 4078 00 wie do Units Description 5 1 1145436 1 Frame Car
18. er off press and hold the following buttons while turning the printer on e Paper Feed 4 Install Print Cartridge i 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 Diagnostic Aids 3 6 4078 00 Reset to USA Defaults 3 7 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 00 Test 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 4 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 Line 3 Model name Line 4 US or EMEA defaults Line 5 Page count followed by the last error The ne
19. g current V dc Volts direct current ZIF Zero Insertion Force Unique Tools Required For Service Parallel Wrap Plug P N 1319128 1 2 4078 00 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 If an error indicator appears go to the error indicator table and take the indicated action for that error The printer also logs the last occurring error If you think it may have an intermittent error or the error indicator lights have been cleared you can retrieve the error 1 Run the Test Page on page 3 8 The error is the last number to print on line five Note the number 2 Run Initialize Error Log on page 3 3 to clear the error the error may not be the result of a current error 3 Run the Parallel Port Test on page 3 4 If no error appears go to Power On Self Test POST Sequence on page 2 2 If your machine does not have an error indicated go to Power On Self Test POST Sequence on page 2 2 Diagnostic Information 2 1 4078 00 Error Indicator Table
20. ikoen for elektrisk sted eges under demontering og service af dette produkt hvorfor der b r tages de n dvendige forholdsregler Sikkerhedsforanstaltningerne er ikke altid lige for alle reservedele Der derfor kun anvendes originale reservedele eller reservedele med samme egenskaber som de oprindelige Informa es de Seguran a As informa es de seguran a relativas a este produto destinam se a profissionais destes servi os e n o devem ser utilizadas por outras pessoas Risco de choques el ctricos e ferimentos graves durante desmontagem e manuten o deste produto Os profissionais destes servi os devem estar avisados deste facto e tomar os cuidados necess rios Os dispositivos de seguran a de algumas pe as poder o n o ser sempre suficientemente evidentes Assim as pe as sobressalentes devem possuir caracter sticas id nticas ou equivalentes s pe as originais Preface vii 4078 00 Chinese Safety Information viii RA RIA KP HEP ERLE DARA A REA in aE BEAR ASK AP ie aap MME kdo ARENAS BALADA FATO HAB RA 3 amp 0 2 ERE o ZS e also Het TA ASME HE ez Age H SS 4SH AS 215401 SAS WALL AMS WS ABO HAUS HE IERE ESB oly AXE SINAIS eat TEI PEJSE SS BEA PSC ER We sms SAL SYS 2H 4078 00 1 General Informa
21. ilable as 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 Remove the front cover 2 Remove the rear cover 3 Remove the sheet feeder 4 Disconnect the power supply connector at the system board 5 Remove the two screws that secure the carrier frame to the base assembly 6 Remove the screw that secures the power supply frame to the carrier frame 7 Remove the ground strap screw from the system board 8 Unlatch the carrier frame from the base assembly and lift it off the base 9 Slide the carrier frame assembly off the base assembly 10 To replace the carrier frame remove all associated parts from the old carrier and install them on the new carrier frame Carrier Home Sensor Removal Ov doo Ni e Remove the front cover Remove the rear cover Disconnect the sensor cable from the system board Remove the screw that secures the sensor to the carrier frame Remove the sensor Repair Information 4 4 4078 00 Carrier Transport Motor Removal 1 2 3 6 Remove the front cover Remove the rear cover Disconnect the carrier transport motor connector from the system board Remove the belt from the carrier transport motor pulley Remove the two screws securing the carrier transport motor to the carrier frame and remove the motor Note the routing of the motor cable Se
22. ly 2 Paper Feed Carrier Transport Maintenance 7 4 Assembly 3 Electronics 7 6 Assembly 3 Electronics 7 8 Assembly 4 7 10 Assembly 5 Sheet Feeder 7 12 INOX PEL AA A DDR A sax dd Ra X 1 4078 002 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 error indicator table symptom table 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 indi vidual FRUs Safety Information The maintenance information for this product has been prepared for use by a professional service person and is not intended to be use
23. move 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 End of Form flag Set NVRAM to the country default on the replacement system board see Chapter 3 See Print Quality Notice on page 2 15 4078 00 5 Connector Locations System Board Connectors CN8 1 Connector Locations 5 1 4078 00 5 2 Connector 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 00 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 scheduled basis U
24. n page 2 9 Diagnostic Information 2 7 4078 00 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 FRU Action 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 paris 2 8 2 Wiper A worn wiper causes degraded print quality just after a maintenance cleaning Check for a loose or worn wiper 3 Cap A worn cap causes the printhead nozzles to dry and clog Check for a loose or worn cap 4078 00 Paper Feed Service Check If your machine does not have paper jam problems continue with the service check If your machine does have a p
25. om the sensor 1 Open the sheet feeder 2 Place a sheet of paper in the paper path until the End of Form Flag is tripped To terminate the test turn the printer off Diagnostic Aids 3 1 4078 00 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 i 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 The Power light goes on and off as the Carrier flag is moved into and out of the Home Position sensor Diagnostic Aids 3 2 4078 00 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 3 3 4078 00 Parallel Port Test This test performs a wrap around test between the printer parallel port
26. ou conformes aux caract ristiques des pi ces d origine Norme di sicurezza Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale dell assistenza autorizzato Durante lo smontaggio e il manutenzionamento di questo prodotto possibile il rischio accresciuto di scosse elettriche e danni personali Il personale di assistenza autorizzato consapevole di ci deve adottare le precauzioni necessarie possibile che le funzioni di sicurezza di alcuni elementi non siano cosi ovvie quindi i pezzi di ricambio devono avere caratteristiche identiche o equivalenti a quelle dei pezzi originali vi 4078 002 Pautas de Seguridad La informaci n 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 el ctricas y dafios personales durante el desmontaje y la reparaci n de la m quina El personal cualificado comprende esto y toma las precauciones necesarias Los dispositivos de seguridad de algunas partes quiz no siempre puedan ser reconocidas a simple vista Por lo tanto las partes de reemplazo deben poseer caracter sticas id nticas o equivalentes a las partes originales Sikkerhedsoplysninger Oplysningerne om vedligeholdelse af dette produkt er forberedt med henblik p professionelt servicepersonale og derfor ikke benyttes af andre Ris
27. r cover 3 4 Remove the two screws mounting the paper feed motor to the Disconnect the paper feed motor from the system board drive train assembly and remove the motor Power Supply Removal OO P Go Remove the front cover Remove the rear cover Remove the sheet feeder Disconnect the power supply connector from the system board Remove the screw that secures the power supply to the carrier frame Push down on the latch at the left rear of the power supply and slide it off the base Repair Information 4 8 4078 00 Printhead Carrier Assembly Removal 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 Remove the belt from the back of the carrier Lift the carrier out of the machine Pes Tor oO ON 4 9 4078 00 Rear Cover Removal Remove the front cover 1 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
28. re the printer is installed on a flat surface FRU 1 Large and Small Feed Rollers Action Check for wear and binds 2 Small Feed Roller Springs Check for damage 3 Auto Sheet Feeder Check the pick rollers for wear 4 Mid Frame Asm Access Cover Asm Check the following for wear Friction wheels Exit roller Star rollers 5 End of Forms Flag Check for binds or damage Diagnostic Information 2 11 4078 00 Parallel Port Service Check FRU Action 1 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 FRU Action 1 Power Supply Disconnect CN7 from the system board and check the following voltages on the power supply cable e 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 Be sure to unplug the machine before you reconnect the power supply to the System board 2 Printhead Cable Carrier Home Sensor Parallel Cable Turn off the printer Disconnect one of the printhead cables and turn on the printer Look for a symptom change Check the failing part for shorts and replace as necessary Repeat this procedure for the carrier home sensor and parallel cable 3 System Board 2 12 If the symptom has no
29. rier 2 11 5453 2 Screws Sheet Feeder Mounting PP 3 1145451 1 Sheet Feeder Asm 4 1145433 1 Cover Rear Asm NS 70G2759 1 Card Feeder Kit Japan Hagaki 7 13 4078 00 Index A Abbreviations 1 2 Adjustments 4 2 Assemblies 1 Covers 7 2 2 Carrier Transport 7 4 2 Maintenance Station 7 4 2 PaperFeed 7 4 3 Electronics 7 6 4 Carrier 7 10 5 Sheet Feeder 7 12 Connector Locations 5 1 Connectors System Board 5 1 D Diagnostic Aids 3 1 Diagnostic Information 2 1 E Error Indicator Table 2 2 ESD Sensitive Parts 4 1 G General Information 1 1 L Lubrication Specifications 6 1 Maintenance Approach 1 1 Parts Catalog 7 1 Plastic Latches 4 2 POST Sequence 2 2 Symptom Table 2 3 Power Consumption 1 1 Preventive Maintenance 6 1 Problems Carrier Transport 2 4 Communications 2 4 Maintenance Station 2 4 Paper Feed 2 5 Power 2 5 Print Quality 2 5 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 Motor 4 8 Power Supply 4 8 Printhead Carrier 4 9 Rear Cover 4 10 Sheet Feeder 4 11 Small Feed Roll Assembly 4 11 Small Feed Roll Bracket 4 12 System Board 4 13 Wiper amp 4 7 Repair Information 4 1 5 Safety Information v Service Checks Envelope Feed 2 7 First Print Line 2 8
30. rk 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 O Copyright Lexmark International Inc 1995 1996 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 1 1 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 4078 00 Contents Preface Safety Informati 254524524 Da EE General Information 1 1 Power 1 1 Eer lee 1 1 ee 1 2 Unique Tools Required For 1 2 Diagnostic Information 2 1 Dara da dc dpi a dedu ag 2 1 Error Indicator Table RES 2 2 Power On Self Test POST Sequence 2 2 POST Symptom Table ded 2 3 Symptom Tabl ssa rasas asda hue des 2 4 SMC asad de qot 2 6 Carrier Transport Service Check
31. se Color Jetprinter 1020 4078 00X Service Manual e Table of Contents e Start Diagnostics e Safety and Notices e Trademarks e Index e Manuals Menu LEXMARK 4078 00 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 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 of the publication Improvements or changes in the products or the programs described in this publication may be made at any time Publications are not stocked at the address given below requests for publications should be made to your point of purchase Comments may be addressed to Lexmark International Inc Department D22A 035 3 740 New Circle Road 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 Lexmark is a tradema
32. se grease P N 1329301 to lubricate the following All gear mounting studs e The left and right ends of the large feed roller at the side frames The carrier to carrier frame engagement Do not lubricate the carrier guide rod or carrier guide rod bearings Preventive Maintenance 6 1 4078 00 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 PP inthe parts descriptions column indicates the part is available in the listed parts packet Parts Catalog 7 1 4078 00 Assembly 1 Covers Parts Catalog 7 2 4078 00 wie Ge Units Description 1 1 11 5430 1 Base Asm 2 1145431 1 Felt Pad Ink Absorption 3 1145432 1 Cover Front Asm 4 11 5433 1 Cover Rear 5 1145434 1 Cover Access Asm 6 11 5435 1 Garage Asm NS 11 5453 2 Front Cover Mounting Screws N S 1145454 1 Replaceable Package B M Includes Carton Cushion Set Sealing Tape 7 3 4078 00 Assembly 2 Paper Feed Carrier Transport Maintenance Parts Catalog 7 4 4078 00 Asm Part index Number Units
33. t changed replace the System board 4078 00 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 lf cross contamination occurs check the following The maintenance station wiper for damage The printhead nozzle plate was resealed with tape 3 Printhead Carrier Assembly Reseat the printhead cables in the system board and check the following parts for wear or damage Print Cartridge Latch Latch Spring Carrier 4 System Board Printhead Cable Rubber Backer Run the Test Page on page 3 8 Look for a break in the diagonal line of the test pattern A broken line indicates one or more print nozzles are not working Run the test again to verify the failure If there are even breaks in the diagonal line similar to the pattern shown below ensure the printhead cables are connected properly If the symptom remains replace the system board ZER e e If there is a single break or random breaks in the diagonal line check the following Check the gold plated contacts on the end of the cable that connect to the carrier for dirt an
34. the machine until the cover latches Be sure the parallel connector snaps do not get trapped behind the cover Repair Information 4 10 4078 00 Sheet Feeder Removal 1 2 3 4 5 Remove the front cover Remove the rear cover Remove the two sheet feeder mounting screws from the rear of the carrier frame 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 Remove the sheet feeder Small Feed Roll Assembly Removal 4 11 O E ON 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 4078 00 Small Feed Bracket Assembly Removal 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 E ON Repair Information 4 12 4078 00 System Board Removal 4 13 Remove the front cover Re
35. tion The Color Jetprinter 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 5 Watts Idle Mode power on not printing 12 Watts Printing average 25 Watts Printing peak Maintenance Approach The diagnostic information in this manual leads you to the correct field replaceable unit FRU or part Use the error code charts symptom index service checks and diagnostic aids to determine the symptom and repair the failure Begin with Start on page 2 1 This printer can be serviced without being connected to a host computer The user is directed in the Printer Control program to perform the bidirectional alignment adjustments after replacing a print cartridge After you complete the repair perform tests as needed to verify the repair General Information 1 1 4078 00 Abbreviations ESD Electrostatic Discharge FRU Field Replaceable Unit HVPS High Voltage Power Supply LVPS Low Voltage Power Supply NVRAM Nonvolatile Random Access Memory OEM Original Equipment Manufacturer POST Power On Self Test V ac Volts alternatin
36. ween the following pins on the motor CN4 1 and CN4 2 CN4 3 and CN4 4 If the readings are incorrect replace the motor 3 Carrier Guide Rod Clean the carrier rod Note Do not lubricate the rod or the carrier rod bearing surface 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 1329301 2 6 4078 00 Action 6 Home Position Perform the EOF and Home Position Sensors Sensor 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 5 from the system board Turn the printer on and check for 5 V de 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 7 Maintenance A problem with the maintenance station can cause Station carrier movement problems at the right margin Go to the Maintenance Station Service Check on page 2 8 Envelope Feed Service Check FRU Action 1 Envelope Guide Be sure the envelope guide has been turned to the envelope load position Be sure the envelope guide is against the envelopes Perform the Paper Feed Service Check o
37. xt line is the black print cartridge nozzle pattern The next three lines are the purge pattern where all nozzles are printing This action cleans purges the nozzles Another nozzle test pattern follows These test patterns are used to verify all print cartridge nozzles are working There should be no breaks in the diagonal line A break in the diagonal line indicates one or more nozzles are not working The rest of the page contains the user defaults followed by a printout of the printer resident fonts Diagnostic Aids 3 8 4078 00 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 paris Handling ESD Sensitive Parts Many electronic products use parts that are known to be sensitive to electrostatic discharge ESD To prevent damage to ESD sensitive paris follow the instructions below in addition to all the usual precautions such as turning off power before removing logic boards Keep the ESD sensitive part in its original shipping container a special ESD bag until you are ready to install the part into the machine Make the least possible movements with your body to prevent an increase of static electricity from clothing fibers carpets and furniture Put the ESD wrist strap on your wrist Connect the wrist band to the system ground point This discharges any static electricity in your body to th
38. y replace the system board Binds in the paper feed motor or gear train can cause intermittent false paper jam errors Remove the paper feed motor and check the shaft for binds Also check for loose or worn motor gear 3 Drive Train Assembly Check for binds in the gear train and paper feed mechanism by removing the paper feed motor and rotating the large gear by hand If you notice a bind replace the drive train assembly Check the feed clutch inside the large feed gear Remove the sheet feeder Turn the clutch gear and check that it rotates freely in one direction and locks when turned in the opposite direction 4 Auto Sheet Feeder Check the pick rollers for wear 5 Mid Frame Asm Access Cover Asm Check the following for wear Friction wheels Exitroller Star rollers 6 End of Forms Flag and Spring Check for binds or damage If binds are found replace the small feed roll bracket assembly 2 10 4078 00 Action 7 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 e Check the entire paper path for obstructions sure the correct type of paper is being used su

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