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Lexmark 1020 manual

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Table of contents for the manual

  • Page 1

    4078-00X Color Jetprinter™ 1020 Le xmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. • T able of Contents •I n d e x • Safety and Notices • T rademarks • Star t Diagnostics • Manuals Men u[...]

  • Page 2

    Second Edition (Jul y , 1996) The follo wing paragr aph does not apply to the United Kingdom or any country where such provisions are inconsistent with local la w: LEXMARK INTERNA TIONAL, INC . PRO VIDES THIS PUBLICA TION “AS IS” WITHOUT W ARRANTY OF ANY KIND , EITHER EXPRESS OR IMPLIED , INCLUDING, BUT NO T LIMITED T O , THE IMPLIED W ARRANTIE[...]

  • Page 3

    iii 4078-00X Contents 1 P r e f a c e ................................................ v S a f e t yI n f o r m a t i o n ..................................... v G e n e r a lI n f o r m a t i o n .................................... 1 - 1 P o w e rC o n s u m p t i o n.................................. 1 - 1 Maintenance Approach ..................[...]

  • Page 4

    iv 4078-00X R e p a i rI n f o r m a t i o n ...................................... 4 - 1 Handling ESD-Sensitive Parts .......................... 4 - 1 A d j u s t m e n t s ........................................ 4 - 2 R e m o v a lP r o c e d u r e s................................. 4 - 2 R e l e a s i n gP l a s t i cL a t c h e s..............[...]

  • Page 5

    Preface v 4078-002 Preface 2 This manual is divided into the f ollowing chapters: 1. General Information contains a gener al 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 en vironmental and saf ety instructions. 2. Diagnostic Inf ormation c[...]

  • Page 6

    vi 4078-00X Sicherheitshinweise • Die W ar tungsinf or mationen für dieses Produkt wurden zur V erwendung durch einen Wartungsfachmann entwic kelt und sollten nicht von anderen benützt w erden. • Zusätzliches Risiko eines elektrischen Schlags und kör perlicher V er letzung e xistier t während des A useinandernehmens und der Wartung des Ger[...]

  • Page 7

    Preface vii 4078-002 P autas de Seguridad • La inf ormación sobre el mantenimiento de este producto fue escrita para el personal de mantenimiento cualificado y no para cualquier otro usuario . • Existen ma yores riesgos de descargas eléctricas y daños personales durante el desmontaje y la reparación de la máquina. El personal cualificado c[...]

  • Page 8

    viii 4078-00X Chinese Safety Inf ormation K o rean Saf ety Info rmation[...]

  • Page 9

    General Information 1-1 4078-00X 1. General Inf ormation The Color Jetprinter TM 1020 pr inter is a personal, near laser-quality inkjet printer . The print car tridge is a single-unit customer replaceable supply item. A single printhead provides three colors and composite blac k pr inting. The printer also suppor ts a blac k print car tridge and pr[...]

  • Page 10

    1-2 4078-00X Abbreviations Unique T ools Required For Ser vice P arallel Wr ap Plug P/N 1319128 ESD Electrostatic Discharge FR U Field Replaceable Unit HVPS High V oltage P ower Supply L VPS Low V oltage P o wer Supply NVRAM Nonv olatile Random Access Memor y OEM Original Equipment Manufa cturer POST P ower-On Self T est V ac V olts alter nating cu[...]

  • Page 11

    Diagnostic Inf ormation 2-1 4078-00X 2. Diagnostic Inf ormation Use the error indicator table , symptom tables , service checks, and diagnostic aids in chapter 3, to deter mine the f ailing par t. Start Ser vice error indications sho w as a series of flashes of the P ow er On light. There is a pause between each series of flashes. If y our machine [...]

  • Page 12

    2-2 4078-00X Error Indicator T able P ower-On Self T est (POST) Sequence When you turn the printer on it performs a POST . T ur n y our machine on and check f or a correct POST operation by observing the f ollowing: 1. The lights come on. 2. The carrier mov es. 3. The paper f eed gears tur n. 4. After 30 seconds the carrier moves o v er the mainten[...]

  • Page 13

    Diagnostic Inf ormation 2-3 4078-00X POST Symptom T able Symptom Action No P ower On light and no motors run Go to the “P ow er Service Check” on page 2-12 . P ower light, but no busy light Replace the system board. P aper f eed gears do not turn Go to the “P aper F eed Service Check” on page 2-9 . Carrier doesn’t mov e Go to the “Carri[...]

  • Page 14

    2-4 4078-00X Symptom T ables Locate the symptom in the f ollowing tab les and tak e the appropriate action. Carrier T ranspor t Prob lems Communications Pr oblems Maintenance Station Prob lems Operator P anel Symptom Action • No carrier movement • Slow carrier mov ement • Carrier stops • Carrier slams side frame Go to the “Carrier T ransp[...]

  • Page 15

    Diagnostic Inf ormation 2-5 4078-00X P aper Feed Prob lems Pow e r P ro b l e m s Print Quality Prob lems Symptom Action • F ails to pick paper • Picks more than one sheet of paper • Picks paper b ut f ails to f eed • P aper jams • P aper f ails to e xit • Noisy paper f eed Go to the “P aper F eed Ser vice Check” on page 2-9 . Env e[...]

  • Page 16

    2-6 4078-00X Service Checks Carrier T ranspor t Service Check FRU Action 1 System Board Check the motor f or binds, or loose motor pulley . T urn the pr inter off and disconnect CN4 from the system board. T ur n the printer on and check f or a pulse of (appro ximately) 10 V dc between CN4-1 and ground and CN4-4 and ground, on the system board, as t[...]

  • Page 17

    Diagnostic Inf ormation 2-7 4078-00X En velope Feed Ser vice Chec k 6 Home P osition Sensor Pe r f o r m t h e “ E O Fa n dH o m eP o s i t i o nS e n s o r s Te s t ” o n p a g e 3 - 2 , to check the Home P osition Sensor . If you cannot enter the test, replace the system board. If the test fails , turn the pr inter off and disconnect CN5 from[...]

  • Page 18

    2-8 4078-00X Maintenance Station Service Check The maintenance station has two functions: 1. Cleans the printhead nozzles dur ing the print operation. 2. Seals the printhead when it is not being used to prev ent the nozzles from dr ying. FRU Action 1 Maintenance Station Assembly As the carrier moves to the right o ver the maintenance station, a slo[...]

  • Page 19

    Diagnostic Inf ormation 2-9 4078-00X P aper Feed Service Check If your machine does not ha v e paper jam probl ems, continue with the ser vice chec k. If y our machine does hav e a paper jam prob lem, e xamine it f or the f ollowing before y ou begin the service check: • Check the entire paper path f or obstr uctions . • Be sure there is not to[...]

  • Page 20

    2-10 4078-00X 2 P aper F eed Motor A noisy or chattering motor or a motor that fails to turn, can be caused by: • An open or shor t in the motor • An open or shor t in the motor driver on the system board • A bind in the paper f eed mechanism With the paper f eed motor cable disconnected from the system board, check f or 60 ohms (±15 ohms) b[...]

  • Page 21

    Diagnostic Inf ormation 2-11 4078-00X P aper P ath Ser vice Chec k Examine the machine f or the f ollo wing bef ore y ou begin this ser vice check: • Check the entire paper path f or obstr uctions . • Be sure the correct type of paper is being used. • Be sure the printer is installed on a flat surface. 7 End of Forms Sensor Check the sensor f[...]

  • Page 22

    2-12 4078-00X P arallel P or t Service Check P ower Service Check FRU Action 1 P arallel P or t Run a test page to be sure the printer can print. Run the “P arallel P or t T est” on page 3-4 .I ft h et e s t f ails, replace the system board. FRU Action 1 P ower Supply Disconnect CN7 from the system board and check the f ollowing v oltages on th[...]

  • Page 23

    Diagnostic Inf ormation 2-13 4078-00X Print Quality Service Check FRU / Function Action 1 Print Car tridge Be sure the machine contains a good print car tridge. 2C o l o r P r i n t Car tridge Cross Contamination Cross contamination of color inks results in incorrect colors printed, as when green prints for y e l l o w ,( w h e ny e l l o wa n db l[...]

  • Page 24

    2-14 4078-00X 5 Maintenance Station Intermittent nozzle failures can be caused b y worn par ts in the maintenance station. P erform the “Maintenance Station Ser vice Chec k” on page 2-8 , then retur n to this chec k. 6 P aper F eed Ink smudging and smearing can be caused by paper problems or prob lems in the paper f eed area. Check the f ollowi[...]

  • Page 25

    Diagnostic Inf ormation 2-15 4078-00X Print Quality Notice Printers are shipped with three different carrier transpor t motors displa ying a label which reads either NMB(NMB), Airpax(APX) or Mitsumi(MZM). The label on the motor should match the motor ID in NVRAM. T o verify the motor ID stored in NVRAM, print o ut a T est P age . The three letter d[...]

  • Page 26

    Diagnostic Aids 3-1 4078-00X 3. Diagnostic Aids Use these diagnostic test procedures to verify a repair . The test procedures are entered by pressing and holding a b utton, or b uttons, as you turn on the printer . T o begin the test, hold the buttons until both the operator panel lights come on and then release the buttons after fiv e seconds. Som[...]

  • Page 27

    Diagnostic Aids 3-2 4078-00X EOF and Home P osition Sensors T est This test allows the servicer to test the function of the End-of-Form and Home P osition sensors. To r u n t h e t e s t : 1. With the printer off and the End-of-Form Flag out of the s ensor , press and hold the f ollowing b uttons while turning the pr inter on: 2. P aper F eed 3. In[...]

  • Page 28

    3-3 4078-00X Initialize Error Log This test trac ks inter mittent errors . Use this procedure to reset the error log to zero . The error log is especially helpful in diagnosing inter mittent or difficult prob lems. The test is complete when power is turned off . To r u n t h e t e s t : 1. Place a sheet of paper in the sheet f eeder f ar enough to [...]

  • Page 29

    Diagnostic Aids 3-4 4078-00X Pa r a l l e l P o r t Tes t This test performs a wrap around test between the printer parallel por t and the parallel por t test connector . This test requires a parallel por t wrap plug. Install the wr ap plug in the parallel por t bef ore you star t the test. The power on light flashes if the test is successful. If t[...]

  • Page 30

    3-5 4078-00X Print NVRAM Contents T h i st e s tp r i n t st h ec o n t e n t so fN V R A M ,w h i c hc a nb eu s e df o r diagnostic pur poses . To r u n t h e t e s t : 1. Install a blac k print car tridge. 2. Place a sheet of paper in the sheet f eeder f ar enough to push the End-of-F orm flag out of the sensor . 3. Load paper into the sheet f e[...]

  • Page 31

    Diagnostic Aids 3-6 4078-00X Reset NVRAM to EMEA Defaults This test resets the user def aults area of NVRAM to the EMEA f actory defaults. The page count and the error log do not change . Note: F actor y defaults are initially set to USA. To r u n t h e t e s t : 1. With the printer off, press and hold the f ollo wing buttons while turning the pr i[...]

  • Page 32

    3-7 4078-00X Reset NVRAM to USA Defaults This test resets the user defaults area of NVRAM to the USA f actory def aults. The page count and the error log do not change . Note: F actor y def aults are initially set to USA. To r u n t h e t e s t : 1. With the printer off, press and hold the Install Print Car tridge b utton while turning the pr inter[...]

  • Page 33

    Diagnostic Aids 3-8 4078-00X T est P age This test prints the test page. T o run a complete test page of blac k and color patterns, be sure the print car tr idge is in good condition. Install a b lac k print car tr idge . T o enter the test: • Press and hold the P aper F eed button while turning the printer on. Paper f eeds from the sheet feeder [...]

  • Page 34

    Repair Information 4-1 4078-00X 4. Repair Inf ormation This chapter e xplains how to mak e adjustments to the printer and how to remo v e def ectiv e par ts . Note: Read the f ollowing bef ore handling electronic par ts. Handling ESD-Sensitive P arts Many electronic products use parts that are known to be sensitiv e to electrostatic discharge (ESD)[...]

  • Page 35

    Repair Information 4-2 4078-00X Adjustments The user is directed, in the Printer Control program, to perf orm the bidirectional alignment adjustments after replacing a print car tridge. Remo v al Pr ocedures The f ollowing procedures are arr anged according to the name of the printer par t discussed. Unplug the power cord bef ore removing any par t[...]

  • Page 36

    4-3 4078-00X Access Cover R emov al 1. Open the access cov er . 2. Push the mounting tabs towards the center of the machine . 3. Remov e the access cov er . Base Assembl y Remo val 1. Remov e the front co ver . 2. Remov e the rear co v er . 3. Remov e the sheet f e eder . 4. Disconnect the power supply connector at the system board. 5. Remov e the [...]

  • Page 37

    Repair Information 4-4 4078-00X Carrier Frame Assembl y Remo v al The carrier rail mounted by two screws on the carrier frame is included with the carrier frame (11A5436). The carr ier rail, which is not a v ailable as a FR U , is mounted in the elongated slots at the factory . During adjustment, the rail is pushed to the rear as f ar as it will go[...]

  • Page 38

    4-5 4078-00X Carrier T ranspor t Motor Remo v al 1. Remov e the front co ver . 2. Remov e the rear co v er . 3. Disconnect the carrier transpor t motor connector from the system board. 4. Remov e the belt from the carrier transpor t motor pulley . 5. Remov e the two scre ws securing the carrier transpor t motor to the carrier frame and remov e the [...]

  • Page 39

    Repair Information 4-6 4078-00X Front Co ver Remov al 1. T ur n the printer ov er to e xpose the base. Remo v e the two co ver mounting screws from the front co v er . When reassembling, do not ov er tighten these scre ws as they will break. Replacement screws can be f ound in par ts packet 11A5453. 2. Slide the cov er upwards and off the machine. [...]

  • Page 40

    4-7 4078-00X Large Feed Roll Remo v al 1. Remov e the front co ver . 2. Remov e the rear co v er . 3. Remov e the sheet f e eder . 4. Remov e the base assemb ly . 5. Remov e the system board. 6. Remov e the printhead carrier assembly . 7. Remov e the small f eed roll assemb lies. 8. Remov e the small f eed roll brac ket assembly . 9. Remov e the mi[...]

  • Page 41

    Repair Information 4-8 4078-00X Mid Frame Assembl y Remo v al 1. Remov e the front cov er . 2. Remov e the rear co v er . 3. Remov e the sheet f eeder . 4. Remov e the system board. 5. Remov e the small f eed roll assemb lies. 6. Remov e the small f eed roll brac ket assembly . 7. Remov e the printhead carrier assembly . 8. Lift up the rear of the [...]

  • Page 42

    4-9 4078-00X Printhead Carrier Assembl y Remov al 1. Remov e the front co ver . 2. Remov e the rear co v er . 3. Remov e the sheet f e eder . 4. Unlock the tw o printhead cable connectors and disconnect the printhead cable from the system board. 5. Unlatch the cable retainer from the carrier frame. 6. Remov e the retainer spring from the left end o[...]

  • Page 43

    Repair Information 4-10 4078-00X Rear Cover Remo val 1. Remov e the front cov er . 2. Pr y upw ards on the two rear cov er latches [A]. 3. W ork the tabs of the rear cov er free from the base assembl y . 4. T o reassemble, place the co v er ov er the tabs in the base assembly and press to wards the front of the machine until the cov er latches . Be[...]

  • Page 44

    4-11 4078-00X Sheet Feeder Remov al 1. Remov e the front co ver . 2. Remov e the rear co v er . 3. Remov e the two sheet f eeder 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 f eeder . Note this for reassemb[...]

  • Page 45

    Repair Information 4-12 4078-00X Small Feed Roll Bracket Assemb l y Remov al 1. Remov e the front cov er . 2. Remov e the rear co v er . 3. Remov e the sheet f eeder . 4. Remov e the system board. 5. Remov e the f our small feed roller springs from the carrier frame. 6. Push down on each of the small f eed roll assemblies to remov e them from the s[...]

  • Page 46

    4-13 4078-00X System Board Remo val 1. Remov e the front co ver . 2. Remov e the rear co v er . 3. Remov e the sheet f e eder . 4. Unlock the tw o printhead cable connectors and disconnect the printhead cables from the system board. 5. Disconnect the other cables from the system board. 6. Remov e the three scre ws securing the system board to the c[...]

  • Page 47

    Connector Locations 5-1 4078-00X 5. Connector Locations System Boar d Connectors[...]

  • Page 48

    5-2 4078-00X Connector Connector Names CN1 Printhead Cable 1 CN2 Printhead Cable 2 CN4 Carrier T ranspor t Motor CN5 Home P osition Sensor CN6 P aper F eed Motor CN7 P ower Supply CN8 P arallel P or t SW1 P ower Switch SW2 P aper Feed Switch SW3 Install Print Car tridge Switch LED1 Busy Light LED2 P ower on Light[...]

  • Page 49

    Preventive Maintenance 6-1 4078-00X 6. Preventive Maintenance This chapter contains the lubrication specifications. F ollow these recommendations to pre v ent problems and maintain optimum perf orm ance . Lubrication Specifications Lubricate only when par ts are replaced or as needed, not on a scheduled basis. Use grease P/N 1329301 to lubr icate t[...]

  • Page 50

    P arts Catalog 7-1 4078-00X 7. P ar ts Catalog How T o Use This P arts Catalog • SIMILAR ASSEMBLIES: If two assemb lies contain a majority of identical par ts, the y are brok en down on the same list. Common par ts are shown b y one inde x number . P ar ts peculiar to one or the other of the assemb lies are listed separately and identified by des[...]

  • Page 51

    P arts Catalog 7-2 4078-00X Assembl y 1: Cover s[...]

  • Page 52

    7-3 4078-00X Asm- Index Par t Number Units Description 1 -1 11A5430 1 Base Asm -2 11A5431 1 Felt P ad, Ink Absor ption -3 11A5432 1 Cover , F ront Asm -4 11A5433 1 Cover , Rear Asm -5 11A5434 1 Cov er , Access Asm -6 11A5435 1 Garage Asm NS 11A5453 2 F ront Cov er M ounting Scre ws (PP) N/S 11A5454 1 Replaceable P ackage B/M - Includes: (Car ton, C[...]

  • Page 53

    P arts Catalog 7-4 4078-00X Assembl y 2: P aper Feed / Carrier T ranspor t / Maintenance[...]

  • Page 54

    7-5 4078-00X Asm- Index Par t Number Units Description 2 -1 11A5436 1 F ra me, Carrier -2 11A5438 1 Sensor , Carr ier Home -3 11A5450 1 Motor , Carr ier T ranspor t Asm See “Print Quality Notice” on page 2-15 . -4 11A5453 1 Screw , (PP) -5 11A5453 1 Spring, Small Feed Roll Asm, (PP) -6 11A5441 1 F eed Roll Assembly , Small -7 11A5442 1 Mounting[...]

  • Page 55

    P arts Catalog 7-6 4078-00X Assembl y 3: Electronics[...]

  • Page 56

    7-7 4078-00X Asm- Index Par t Number Units Description 3 -1 11A5455 1 System Board with ROM See “Print Quality Notice” on page 2-15 . -2 11A5447 1 P ow er Supply: 110V -2 11A5446 1 P ow er Supply: 220V -3 11A5453 1 Screws , System Board (PP)[...]

  • Page 57

    P arts Catalog 7-8 4078-00X Assembl y 3: Electronics (Contin ued)[...]

  • Page 58

    7-9 4078-00X Asm- Index Par t Number Units Description 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 13[...]

  • Page 59

    P arts Catalog 7-10 4078-00X Assembl y 4: Carrier[...]

  • Page 60

    7-11 4078-00X Asm- Index Par t Number Units Description 4 -1 11A5448 1 Carrier Assembly -2 11A5437 1 Rod, Carrier Guide -3 11A5436 1 F rame, Carrier -4 11A5453 1 Screw , Carrier Guide Rod (PP) -5 11A5453 1 Spring, Carrier Guide Rod (PP)[...]

  • Page 61

    P arts Catalog 7-12 4078-00X Assembl y 5: Sheet Feeder[...]

  • Page 62

    7-13 4078-00X Asm- Index Par t Number Units Description 5 -1 11A5436 1 F rame , Carrier -2 11A5453 2 Screws , Sheet F eeder Mounting (PP) -3 11A5451 1 Sheet F eeder Asm -4 11A5433 1 Cov er , Rear Asm NS 70G2759 1 Card F eeder Kit, J apan Hagaki[...]

  • Page 63

    4078-00X X-1 A 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 C 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 [...]

  • Page 64

    4078-00X X-2 Parallel Port 3-4 Print NVRAM Contents 3-5 Reset NVRAM Defaults EMEA 3-6 USA 3-7 Test Page 3-8 Tools 1-2[...]