Lexmark Color Jetprinter 1020 User manual

4078-00X
Color Jetprinter™ 1020
Lexmark and Lexmark with diamond
design are trademarks of Lexmark
International, Inc., registered in the
United States and/or other countries.
• Table of Contents
•Index
• Safety and Notices
• Trademarks
• Start Diagnostics
• Manuals Menu

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. 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 trademark of Lexmark International, Inc., registered in the United States and/or
other countries.
Color Jetprinter is a trademark of Lexmark International, Inc.
Other trademarks are the property of their respective owners.
© Copyright Lexmark International, Inc. 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 (c)(1)(ii) of the Rights in Technical Data and Computer Software clause at
DFARS 252.227-7013 and in applicable FAR provisions: Lexmark International, Inc.,
Lexington KY 40550.
4078-00X

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Contents 1
Preface ................................................v
SafetyInformation..................................... v
GeneralInformation....................................1-1
PowerConsumption..................................1-1
Maintenance Approach................................1-1
Abbreviations....................................1-2
UniqueToolsRequiredForService...................1-2
DiagnosticInformation .................................2-1
Start..............................................2-1
ErrorIndicatorTable...............................2-2
Power-On Self Test (POST) Sequence ................2-2
POSTSymptomTable.............................2-3
SymptomTables .................................2-4
ServiceChecks......................................2-6
CarrierTransportServiceCheck.....................2-6
EnvelopeFeedServiceCheck.......................2-7
MaintenanceStationServiceCheck ..................2-8
Paper Feed Service Check .........................2-9
Paper Path Service Check.........................2-11
ParallelPortServiceCheck........................2-12
PowerServiceCheck.............................2-12
PrintQualityServiceCheck........................2-13
PrintQualityNotice...............................2-15
DiagnosticAids .......................................3-1
EOFandHomePositionSensorsTest....................3-2
InitializeErrorLog....................................3-3
ParallelPortTest....................................3-4
PrintNVRAMContents................................3-5
ResetNVRAMtoEMEADefaults........................3-6
ResetNVRAMtoUSADefaults.........................3-7
TestPage..........................................3-8

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RepairInformation......................................4-1
Handling ESD-Sensitive Parts .......................... 4-1
Adjustments........................................ 4-2
RemovalProcedures................................. 4-2
ReleasingPlasticLatches.......................... 4-2
AccessCoverRemoval............................ 4-3
BaseAssemblyRemoval........................... 4-3
CarrierBeltRemoval.............................. 4-3
CarrierFrameAssemblyRemoval ................... 4-4
CarrierHomeSensorRemoval...................... 4-4
CarrierTransportMotorRemoval.................... 4-5
DriveTrainAssemblyRemoval...................... 4-5
FrontCoverRemoval ............................. 4-6
GutterPadRemoval.............................. 4-6
LargeFeedRollRemoval.......................... 4-7
Maintenance Station Assembly Removal .............. 4-7
Maintenance Wiper and Cap Removal ................ 4-7
MidFrameAssemblyRemoval...................... 4-8
Paper Feed Motor Removal ........................ 4-8
Power Supply Removal. . .......................... 4-8
Printhead Carrier Assembly Removal ................. 4-9
RearCoverRemoval............................. 4-10
Sheet Feeder Removal . . ......................... 4-11
SmallFeedRollAssemblyRemoval................. 4-11
SmallFeedRollBracketAssemblyRemoval .......... 4-12
SystemBoardRemoval........................... 4-13
ConnectorLocations....................................5-1
SystemBoardConnectors............................. 5-1
PreventiveMaintenance .................................6-1
LubricationSpecifications ............................. 6-1
PartsCatalog ..........................................7-1
HowToUseThisPartsCatalog......................... 7-1
Assembly1:Covers............................... 7-2
Assembly 2: Paper Feed / Carrier Transport / Maintenance 7-4
Assembly3:Electronics ........................... 7-6
Assembly3:Electronics(Continued).................. 7-8
Assembly4:Carrier.............................. 7-10
Assembly 5: Sheet Feeder ........................ 7-12
Index ................................................ X-1

Preface v
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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. 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 used by others.
•There may be an increased risk of electric shock and
personal injury during disassembly and servicing of this
product. Professional service personnel should understand
this and take necessary precautions.
•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.

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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.
•Ersatzteile müssen gleiche oder gleichwertige Merkmale wie
die Originalteile aufweisen, da Sicherheitsvorkehrungen nicht
immer offensichtlich sind.
ConsignesdeSécurité
•Les consignes d'entretien et de réparation de ce produit
s'adressent uniquement à un personnel de maintenance
qualifié.
•Le démontage et l'entretien de ce produit pouvant présenter
certains risques électriques, le personnel d'entretien qualifié
devra prendre toutes les précautions nécessaires.
•Les normes de sécurité de certaines pièces n'étant pas
toujours explicites, les pièces de rechange doivent être
identiques ou conformes aux caractéristiques des pièces
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, è possibile il rischio accresciuto di scosse elettriche
e danni personali. Il personale di assistenza autorizzato,
consapevole di ciò, deve adottare le precauzioni necessarie.
•È possibile che le funzioni di sicurezza di alcuni elementi non
siano così ovvie, quindi, i pezzi di ricambio devono avere
caratteristiche identiche o equivalenti a quelle dei pezzi
originali.

Preface vii
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. Por lo tanto,
las partes de reemplazo deben poseer características
idénticas o equivalentes a las partes originales.
Sikkerhedsoplysninger
•Oplysningerne om vedligeholdelse af dette produkt er
forberedt med henblik på professionelt servicepersonale, og
bør derfor ikke benyttes af andre.
•Risikoen for elektrisk stød øges under demontering og
service af dette produkt, hvorfor der bør tages de nødvendige
forholdsregler.
•Sikkerhedsforanstaltningerne er ikke altid lige åpenbare for
alle reservedele. Der bør derfor kun anvendes originale
reservedele eller reservedele med samme egenskaber som
de oprindelige.
Informações de Segurança
•As informações de segurança relativas a este produto
destinam-se a profissionais destes serviços e não devem ser
utilizadas por outras pessoas.
•Risco de choques eléctricos e ferimentos graves durante a
desmontagem e manutenção deste produto. Os profissionais
destes serviços devem estar avisados deste facto e tomar os
cuidados necessários.
•Os dispositivos de segurança de algumas peças poderão
não ser sempre suficientemente evidentes. Assim, as peças
sobressalentes devem possuir características idênticas ou
equivalentes às peças originais.

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Chinese Safety Information
Korean Safety Information

General Information 1-1
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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
•7.5 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.

1-2
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Abbreviations
Unique Tools Required For Service
Parallel Wrap Plug P/N 1319128
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 alternating current
V dc Volts direct current
ZIF Zero Insertion Force

Diagnostic Information 2-1
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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.

2-2
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Error Indicator Table
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. The lights come on.
2. The carrier moves.
3. The paper feed gears turn.
4. After 30 seconds the carrier moves over the maintenance
station and caps the printhead.
5. All motors stop and the power light stays on.
If your machine completes POST with no errors, go to the “Symptom
Tables”onpage2-4, 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.
Error
Code
Number
of
Power
Light
Flashes
Action
Blank 8Replace the system board.
64/
65 7Replace the system board.
81 1Go to the “Carrier Transport Service Check” on page
2-6.
89 4Go to the “Carrier Transport Service Check” on page
2-6.
127
and
up
10 Replace the system board.

Diagnostic Information 2-3
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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.

2-4
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Symptom Tables
Locate the symptom in the following tables and take the appropriate
action.
Carrier Transport Problems
Communications Problems
Maintenance Station Problems
Operator Panel
Symptom Action
• No carrier movement
• Slow carrier movement
• Carrier stops
• Carrier slams side frame
Go to the “Carrier Transport Service
Check” on page 2-6.
Symptom Action
Printer not communicating with
host computer. Go to the “Parallel Port Service
Check” on page 2-12.
Symptom Action
Maintenance station:
• Fails to cap the printhead
• Fails to clean the printhead
Go to the “Maintenance Station
Service Check” on page 2-8.
Symptom Action
Paper Feed and / or Install print
cartridge buttons do not operate Replace the system board.
Busy light does not come on Replace the system board

Diagnostic Information 2-5
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Paper Feed Problems
Power Problems
Print Quality 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.
Symptom Action
No power in machine, no Power
On light, no motors 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.

2-6
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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 turncanbecausedby:
• An open or short in the motor.
• An open or short in the motor driver on the
system board.
• A bind in the carrier transport mechanism.
With the carrier transport motor cable
disconnected from the system board, check for
zero to ten (0 - 10) ohms between the following
pins on the motor:
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.

Diagnostic Information 2-7
4078-00X
Envelope Feed Service Check
6 Home Position
Sensor Perform the “EOFandHomePositionSensors 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.
7 Maintenance
Station A problem with the maintenance station can cause carrier movement problems at the right margin. Go
to the “Maintenance Station Service Check” on
page 2-8.
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” on
page 2-9.
FRU Action

2-8
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Maintenance Station Service Check
The maintenance station has two functions:
1. Cleans the printhead nozzles during the print operation.
2. Seals the printhead when it is not being used to prevent the
nozzles from drying.
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
parts.
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.

Diagnostic Information 2-9
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Paper Feed Service Check
If your machine does not have paper jam problems, continue with
the service check. If your machine does have a paper jam problem,
examine it for the following before you begin the service check:
•Check the entire paper path for obstructions.
•Be sure there is not too much paper in the sheet feeder.
•Be sure the correct type of paper is being used.
•Check for static in the paper.
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.

2-10
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2 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.
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 only,
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.
3DriveTrain
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.
5MidFrameAsm
Access Cover
Asm
Check the following for wear:
• Friction wheels
•Exitroller
•Starrollers
6 End-of-Forms
Flag and Spring Check for binds or damage. If binds are found, replace the small feed roll bracket assembly.
FRU Action