Lexmark 1020 User Manual

Color Jetprinter™ 1020

• Table of Contents

• Start Diagnostics

• Safety and Notices

• Trademarks

4078-00X

•Index

• Manuals Menu

Lexmark and Lexmark with diamond
design are trademarks of Lexmark
International, Inc., registered in the
United States and/or other countries.

4078-00X

Second Edition (July, 1996)

The following paragraph does not apply to the United Kingdom or any country where such
provisions are inconsistent with local law: LEXMARK INTERNATIONAL, INC. PROVIDES
THIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS
OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIESOF
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
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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
DFARS252.227-7013 and in applicable FAR provisions: Lexmark International, Inc.,
Lexington KY 40550.

4078-00X

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

iii

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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

iv

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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. ConnectorLocations uses illustrations to identify the connector
locations and test points on the printer.

6. Preventive Maintenance contains the lubrication specifications
and recommendations to prevent problems.

7. Parts Catalog contains illustrations and part numbers for indi­vidual FRUs.

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 injur y 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

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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.

vi

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 børtages 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.

Preface vii

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Chinese Safety Information

Korean Safety Information

viii

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1. General Information

The Color JetprinterTM1020 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 blackprint
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

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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 alternating current
V dc Volts direct current
ZIF Zero Insertion Force

Unique Tools Required For Service

Parallel Wrap Plug P/N 1319128

1-2

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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 par t.

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 “ParallelPort 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

4078-00X

Error Indicator Table

Number

Error
Code

of

Power

Light

Flashes

Action

Blank
64/

65

81

89

127
and
up

8
7

1

4

10

Replace the system board.
Replace the system board.

Go to the “Carrier Transport Service Check” on page

2-6.

Go to the “Carrier Transport Service Check” on page

2-6.

Replace the system board.

Power-On Self Test (POST) Sequence

When you turn the printer on it performs a POST.Turn your machine
on and check for a correct POST operation by observing the
following:

1. 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.

2-2

4078-00X

POST Symptom Table

Symptom Action

No PowerOn
light and no
motors run

Power light, but
no busy light

Paper feed
gears do not
turn

Carrier doesn’t
move

Carrier slams
side frame

Go to the “Power Service Check” on page 2-12.

Replace the system board.

Go to the “Paper Feed Service Check” on page 2-9.

Go to the “Carrier Transport Service Check” on page

2-6.

Go to the “Carrier Transport Service Check” on page

2-6.

Diagnostic Information 2-3

4078-00X

Symptom Tables

Locate the symptom in the following tables and take the appropriate
action.

Carrier Transport Problems

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.

Communications Problems

Symptom Action

Printer not communicating with
host computer.

Go to the “Parallel Port Service

Check” on page 2-12.

Maintenance Station Problems

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.

Operator Panel

Symptom Action

Paper Feed and / or Install print
cartridge buttons do not operate

Busy light does not come on Replace the system board

Replace the system board.

2-4

4078-00X

Paper Feed Problems

Symptom Action

• Fails to pick paper

• Picks more than one sheet of
paper

• Picks paper but fails to feed

• Paper jams

• Paper fails to exit

• Noisy paper feed

Envelopes fail to feed Go to the “Envelope Feed Service

Paper skews Go to the “Paper Path Service

Go to the “Paper Feed Service

Check” on page 2-9.

Check” on page 2-7.

Check” on page 2-11.

Power Problems

Symptom Action

No power in machine, no Power
On light, no motors

Go to the “Power Service Check” on

page 2-12.

Print Quality Problems

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

4078-00X

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

3 Carrier Guide Rod Clean the carrier rod.

4 Carrier Transport

Belt
Idler Pulley Parts
Carrier Frame

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.

Note: Do not lubricate the rod or the carrier rod
bearing surface.

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

4078-00X

FRU Action

6 Home Position

Sensor

7 Maintenance

Station

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.

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.

Envelope Feed Service Check

FRU Action

1 Envelope Guide Be sure the envelopeguide 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.

Diagnostic Information 2-7

4078-00X

Maintenance Station Service Check

The maintenance station has two functions:

1. Cleans the printhead nozzles during the print operation.

2. Seals the printhead when it is not being used to prevent the
nozzles from drying.

FRU Action

1 Maintenance

Station Assembly

2 Wiper A worn wiper causes degraded print quality just

3 Cap A worn cap causes the printhead nozzles to dry

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 a nd
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.

after a maintenance cleaning. Check fora loose or
worn wiper.

and clog. Check for a loose or worn cap.

2-8

4078-00X

Paper Feed Service Check

If your machine does not have paper jam problems, continue with
the service check. If your machine does have a paper jam problem,
examine it for the following before you begin the service check:

• 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

4078-00X

FRU Action

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 feedmotor and check the shaft forbinds.
Also check for loose or worn motor gear.

3DriveTrain

Assembly

4 Auto Sheet

Feeder

5MidFrameAsm

Access Cover
Asm

6 End-of-Forms

Flag and Spring

2-10

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. Turnthe clutch gear and check that it
rotates freely in one direction and locks when
turned in the opposite direction.

Check the pick rollers for wear.

Check the following for wear:

• Friction wheels

•Exitroller

•Starrollers

Check for binds or damage. If binds are found,
replace the small feed roll bracket assembly.

4078-00X

FRU 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:

• Check the entire paper path for obstructions.

• Be sure the correct type of paper is being used.

• Be sure the printer is installed on a flat surface.

FRU Action

1 Large and Small

Feed Rollers

2 Small Feed Roller

Springs

3 Auto Sheet

Feeder

4MidFrameAsm

Access Cover
Asm

Check for wear and binds.

Check for damage.

Check the pick rollers for wear.

Check the following for wear:

• Friction wheels

• Exit roller

•Starrollers

5End-of-Forms

Flag

Check for binds or damage.

Diagnostic Information 2-11

4078-00X

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.Ifthetest
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:

• 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

3 System Board If the symptom has not changed, replace the

Turn off the printer. Disconnect one of the
printhead cablesand 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.

system board.

2-12

4078-00X

Print Quality Service Check

FRU / Function Action

1 Print Cartridge Be sure the machine contains a good print

cartridge.

2ColorPrint

Cartridge Cross
Contamination

3 Printhead Carrier

Assembly

4 System Board

Printhead Cable
Rubber Backer

Cross contamination of color inks results in
incorrect colors printed, as when green prints for
yellow,(whenyellowandbluearemixedinthe
print cartridge). This problem resolves quickly as
the print cartridge is used.

If cross contamination occurs, check the following:

• Themaintenance station wiper for damage.

• Theprinthead nozzle plate was resealed with
tape.

Reseat the printhead cables in the system board
and check the following parts for wear or damage:

• Print Cartridge Latch

• Latch Spring

•Carrier

•Runthe“Test Page” on page 3-8.Lookfora
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.

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 and
wear. Use only a clean dry cloth to clean the
contacts. Also check the cable for damage. You
mayneedtoremovethecablefromthecarrier
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

4078-00X

FRU / Function Action

5 Maintenance

Station

6 Paper Feed Ink smudging and smearing can be caused by

7 Carrier Transport Blurred print and voidscan be caused byproblems

8 Alignment Uneven vertical lines can be adjusted by

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 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.

• Gearsforwearorbinds.

• Paper path for obstructions.

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.

• Idler pulley parts for wear, damage, or
looseness.

performing the bidirectional alignment. The user is
directed, through the Printer Control program, to
perform the bidirectional printing alignment, when
replacing a print cartridge.

2-14

4078-00X

Print Quality Notice

Printers are shipped with three different carrier transport motors
displaying a label which reads either NMB(NMB), Airpax(APX) or
Mitsumi(MZM). The label on the motor should match the motor ID in
NVRAM. To verify the motor ID stored in NVRAM, print out a Test
Page. The three letter designation will be printed on the service line.

If the carrier transport motor or the system board must be
replaced, check the label on the carrier transport motor. All FRU

motors will be labeled NMB.
After completing repairs to the printer, connect it to a PC and go to

x

:\Tools\4078 (wherexis 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.

•

x

:COPY /B NMB.BIN LPT1

•

x

:COPY /B APX.BIN LPT1

•

x

:COPY /B MZM.BIN LPT1

Diagnostic Information 2-15

4078-00X

3. Diagnostic Aids

Use these diagnostic test procedures to verify a repair. The test
procedures are entered by pressing and holding a button,or buttons,
as you turn on the printer. To begin the test, hold the buttons until
both the operator panel lights come on and then release the buttons
after five seconds. Some tests require the End-of-Form Flag to be
out of the sensor.

To remove the End-of-Form Flag from the sensor

1. Open the sheet feeder.

2. 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

4078-00X

EOF and Home Position Sensors Test

This test allows the ser vicer 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 followingbuttons while turning the printer on:

2. Paper Feed

3. Install Print Cartridge

After five seconds, release the buttons to begin the test.
The Busy light goes on and off as the End-of-Form flag is movedinto

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

4078-00X

Initialize Error Log

This test tracks intermittent errors.

Use this procedure to reset the error log to zero. The error log is
especially helpful in diagnosing intermittent or difficult problems.
The test is complete when power is turned off.

To run the test

1. Place a sheet of paper in the sheet feeder far enough to push
the End-of-Form flag out of the sensor.

2. With the printer off, hold down the Install Print Cartridge
button while turning the printer on.

:

3-3

4078-00X

Parallel Port Test

This test performs a wrap around test between the printer parallel
port and the parallel port test connector.

This test requires a parallel port wrap plug. Install the wrap plug in
the parallel port before you start the test. The power on light flashes
if the test is successful. If the test is not successful, the power on
light remains off.

To run the test

1. 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

4078-00X

Print NVRAM Contents

ThistestprintsthecontentsofNVRAM,whichcanbeusedfor
diagnostic pur poses.

To run the test:

1. Install a black print cartridge.

2. Place a sheet of paper in the sheet feeder far enough to push
the End-of-Form flag out of the sensor.

3. Load paper into the sheet feeder.

4. With the printer off, press and hold the Paper Feed button
and turn the printer on. After fiveseconds, release the button to
begin the test.

3-5

4078-00X

Reset NVRAM to EMEA Defaults

This test resets the user defaults area of NVRAM to the EMEA
factory defaults. The page count and the error log do not change.

Note: Factory defaults are initially set to USA.
To run the test

1. With the printer off, press and hold the following buttons while
turning the printer on:

:

• Paper Feed

• Install Print Cartridge

2. After five seconds, release the buttons to begin the test.

A sheet of paper will feed and verify the defaults have been set by
printing “EMEA”.

Diagnostic Aids 3-6

4078-00X

Reset NVRAM to USA Defaults

This test resets the user defaultsarea 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”.

3-7

4078-00X

Test Page

This test prints the test page.
To run a complete test page of blackand color patterns, be sure the

print cartridge is in good condition. Install a black print cartridge.
To enter the test:

• Press and hold the Paper Feed button while turning the

printer on. Paper feeds from the sheet feeder and prints the test
page. Pages continue to print until you turn off the power or

unplug the printer.
The test page prints the following lines.
Line 1 - Code level.

Line 2 - Manufacturer name.
Line 3 - Model name.
Line 4 - US or EMEA defaults.
Line 5 - Page count followed by the last error.
The next line is the black pri nt 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 work ing.

The rest of the page contains the user defaults followed by a printout
of the printer resident fonts.

Diagnostic Aids 3-8

4078-00X

4. Repair Information

This chapter explains how to make adjustments to the pr inter and
how to remove defective parts.

Note: Read the following before handling electronic parts.

Handling ESD-Sensitive Parts

Many electronic products use parts that are known to be sensitive to
electrostatic discharge (ESD). To prevent damage to ESD-sensitive
parts, follow the instructions below in addition to all the usual
precautions, such as turning off power before removing logic boards:

• Keep the ESD-sensitivepart 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 the 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 forany 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

4078-00X

Adjustments

The user is directed, in the Printer Control program, to perform the
bidirectional alignment adjustments after replacing a print cartridge.

Removal Procedures

The following procedures are arranged according to the name of the
printer part discussed. Unplug the power cord before removing any
parts.

Releasing Plastic Latches

Many of the parts are held in place with plastic latches. The latches
break easily; release them carefully.To remove such parts, press the
hook end of the latch away from the part to which it is latched.

Hook

Never apply excessive force
when releasing the hook.

Repair Information 4-2

4078-00X

Access Cover Removal

1. Open the access cover.

2. Push the mounting tabs towards the center of the machine.

3. Remove the access cover.

Base Assembly Removal

1. 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 machine off the base assembly.

Carrier Belt Removal

1. Remove the front cover.

2. Remove the retainer spring from the left side of the carrier rod.

3. Remove the screw from the right side of the carrier rod.

4. Slide the carrier rod to the left, out of the machine.

5. Remove the c arrier belt from the rear of the carrier.

6. Remove the carrier belt from the carrier transport motor pulley.

7. Remove the carrier belt.

4-3

4078-00X

Carrier Frame Assembly Removal

The carrier rail mounted by two screws on the carrier frame is included with
the carrier frame (11A5436). The carrier rail, which is not available as a
FRU, is mounted in the elongated slots at the factory.During adjustment, the
rail is pushed to the rear as far as it will go, before the mounting screws are
tightened.

1. Remove the front cover.

2. Remove the r ear 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 frame and install them on the new carrier frame.

Carrier Home Sensor Removal

1. Remove the front cover.

2. Remove the r ear cover.

3. Disconnect the sensor cable from the system board.

4. Remove the screw that secures the sensor to the carrier frame.

5. Remove the sensor.

Repair Information 4-4

4078-00X

Carrier Transport Motor Removal

1. Remove the front cover.

2. Remove the rear cover.

3. Disconnect the carrier transport motor connector from the
system board.

4. Remove the belt from the carrier transport motor pulley.

5. Remove the two screws securing the carrier transport motor to
the carrier frame and remove the motor. Note the routing of the
motor cable.

6. See “Print Quality Notice” on page 2-15.

Drive Train Assembly Removal

1. Remove the front cover.

2. Remove the rear cover.

3. Remove the sheet feeder.

4. Remove the base assembly.

5. Remove the system board.

6. Remove the printhead carrier assembly.

7. Remove the small feed roll assemblies.

8. Remove the small feed roll bracket assembly.

9. Remove the m id frame assembly.

10. Remove the maintenance station assembly.

11. Remove the large feed roll.

12. Remove the three screws securing the drive train to the carrier
frame.

13. Push the drive train to the right and remove it from the carrier
frame.

4-5

4078-00X

Front Cover Removal

1. Turn the printer overto expose the base. Removethe two cover
mounting screws from the front cover. When reassembling, do
not overtighten these screws as they will break. Replacement
screws can be found in parts packet 11A5453.

2. Slide the cover upwards and off the machine.

To reassemble:

1. Align the tabs on the front cover over the front edge of the base
assembly.

2. 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

1. Remove the front cover.

2. Remove the r ear cover.

3. Remove the sheet feeder.

4. Removethebaseassembly.

5. Remove the gutter pad from the base assembly.

Repair Information 4-6

4078-00X

Large Feed Roll Removal

1. Remove the front cover.

2. Remove the rear cover.

3. Remove the sheet feeder.

4. Remove the base assembly.

5. Remove the system board.

6. Remove the printhead carrier assembly.

7. Remove the small feed roll assemblies.

8. Remove the small feed roll bracket assembly.

9. Remove the m id frame assembly.

10. Remove the maintenance station assembly.

11. Turn and remove the retainer at the right end of the large feed
roller.

12. Remove the large feed roller from the carrier frame.

Maintenance Station Assembly Removal

1. Remove the front cover.

2. Remove the rear cover.

3. Remove the base assembly.

4. 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

1. Remove the front cover.

2. Push the carrier to the left away from the maintenance station.

3. Gently pull the cap and wiper off their mountings.

4-7

4078-00X

Mid Frame Assembly Removal

1. Remove the front cover.

2. Remove the r ear cover.

3. Remove the sheet feeder.

4. Remove the system board.

5. Remove the small feed roll assemblies.

6. Remove the small feed roll bracket assembly.

7. Remove the printhead carrier assembly.

8. 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 r ear cover.

3. Disconnect the paper feed motor from the system board.

4. Remove the two screws mounting the paper feed motor to the
drive train assembly and remove the motor.

Power Supply Removal

1. Remove the front cover.

2. Remove the r ear cover.

3. Remove the sheet feeder.

4. Disconnect the power supply connector from the system board.

5. Remove the screw that secures the power supply to the carrier
frame.

6. Push down on the latch at the left rear of the power supply and
slide it off the base.

Repair Information 4-8

4078-00X

Printhead Carrier Assembly Removal

1. Remove the front cover.

2. Remove the rear cover.

3. Remove the sheet feeder.

4. Unlock the two printhead cable connectors and disconnect the
printhead cable from the system board.

5. Unlatch the cable retainer from the carrier frame.

6. Remove the retainer spring from the left end of the carrier guide
rod.

7. Remove the screw from the right end of the carr ier guide rod.

8. Slide the carrier guide rod out the left side of the machine.

9. Remove the belt from the back of the carrier.

10. Lift the carrier out of the machine.

4-9

4078-00X

Rear Cover Removal

1. Remove the front cover.

2. Pry upwards on the two rear cover latches [A].

3. Work the tabs of the rear cover free from the base assembly.

4. To reassemble, place the cover over the tabs in the base
assembly and press towards the front of the machine until the
cover latches. Be sure the parallel connector snaps do not get
trapped behind the cover.

Repair Information 4-10

4078-00X

Sheet Feeder Removal

1. Remove the front cover.

2. Remove the rear cover.

3. Remove the two sheet feeder mounting screws from the rear of
the carrier frame.

4. Unlatch the right sheet feeder latch from the front of the carrier
frame.

Note: The cables are routed through tab slots in the sheet
feeder. Note this for reassembly.

5. Remove the sheet feeder.

Small Feed Roll Assembly Removal

1. Remove the front cover.

2. Remove the rear cover.

3. Remove the sheet feeder.

4. Remove the system board.

5. Remove the four small feed roller springs from the carrier frame.

6. Push down on each of the small feed roll assemblies to remove
them from the small feed roll bracket.

4-11

4078-00X

Small Feed Roll Bracket Assembly Removal

1. Remove the front cover.

2. Remove the r ear cover.

3. Remove the sheet feeder.

4. Remove the system board.

5. Remove the four small feed roller springs from the carrier frame.

6. 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.

Repair Information 4-12

4078-00X

System Board Removal

1. Remove the front cover.

2. Remove the rear cover.

3. Remove the sheet feeder.

4. Unlock the two printhead cable connectors and disconnect the
printhead cables from the system board.

5. Disconnect the other cables from the system board.

6. Remove the three screws securing the system board to the
carrier frame and remove the system board. Note the routing of
all the cables.

7. Remove the system board being careful not to damage the End­of-Form flag.

8. Set NVRAM to the country default on the replacement system
board; see Chapter 3.

9. See “Print Quality Notice” on page 2-15.

4-13

4078-00X

5. Connector Locations

System Board Connectors

Connector Locations 5-1

4078-00X

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

5-2

4078-00X

6. Preventive Maintenance

This chapter contains the lubrication specifications. Follow these
recommendations to prevent problems and maintain optimum
performance.

Lubrication Specifications

Lubricate only when parts are replaced or as needed, not on a
scheduled basis. Use grease P/N 1329301 to lubricate the following:

• All gear mounting studs.

• The left and right ends of the large feedroller 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

4078-00X

7. Parts Catalog

How To Use This Parts Catalog

• SIMILAR ASSEMBLIES: If two assemblies contain a majority of

identical parts, they are broken down on the same list. Common
parts are shown by one index number. Parts peculiar to one or
the other of the assemblies are listed separately and identified
by description.

• NS: (Not Shown) in the Asm-Index column indicates that the

part is procurable but is not pictured in the illustration.

• PP: in the parts descriptions column indicates the part is

available in the listed parts packet.

Parts Catalog 7-1

4078-00X

Assembly 1: Covers

Parts Catalog 7-2

4078-00X

Asm­Index

1 -1 11A5430 1 Base Asm

-2 11A5431 1 Felt Pad, Ink Absorption

-3 11A5432 1 Cover, Front Asm

-4 11A5433 1 Cover, Rear Asm

-5 11A5434 1 Cover,Access Asm

-6 11A5435 1 Garage Asm

NS 11A5453 2 Front Cover Mounting Screws (PP)
N/S 11A5454 1 Replaceable PackageB/M - Includes:

Part
Number

Units Description

(Carton, Cushion Set, Sealing Tape)

7-3

4078-00X

Assembly 2: Paper Feed / Carrier Transport / Maintenance

Parts Catalog 7-4

4078-00X

Asm­Index

2 -1 11A5436 1 Frame, Carrier

-2 11A5438 1 Sensor, Carrier Home

-3 11A5450 1 Motor, Carrier Transport Asm

-4 11A5453 1 Screw, (PP)

-5 11A5453 1 Spring, Small Feed Roll Asm, (PP)

-6 11A5441 1 Feed Roll Assembly, Small

-7 11A5442 1 Mounting Bracket,

-8 11A5443 1 Drive Train Assembly

-9 11A5444 1 Motor, Paper Feed Assembly

-10 11A5453 5 Screws, Drive Train & Paper Feed

-11 11A5453 1 Arm, Tensioner (PP)

-12 11A5449 1 Belt, Carrier

Part
Number

Units Description

See “Print Quality Notice” on page

2-15.

Small Feed Roll Assembly

Motor Mounting (PP)

-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

4078-00X

Assembly 3: Electronics

Parts Catalog 7-6

4078-00X

Asm­Index

3 -1 11A5455 1 System Board with ROM

-2 11A5447 1 PowerSupply: 110V

-2 11A5446 1 PowerSupply: 220V

-3 11A5453 1 Screws, System Board (PP)

Part
Number

Units Description

See “Print Quality Notice” on page 2-15.

7-7

4078-00X

Assembly 3: Electronics (Continued)

Parts Catalog 7-8

4078-00X

Asm­Index

3 -4 1339526

Part
Number

1342536
1339520
1339520
1342514
1342526
1342536
1339526
1342534
1342514
1342514
1339525
1342514
1339519
1342514
1339520
1339520
1339520
1342514
1342514
1339521
1339524
70G0496
1342514
1339520
1342514
1339520
1342514
1342536
1342514
1339520
1339517
1339523
1339520
1339520
1339522
1339519
1342536
1342514

Units Description

1PowerCord,U.S.

Power Cord, Argentina
Power Cord, Austria
Power Cord, Belgium
Power Cord, Bolivia
Power Cord, Brazil (LV)
Power Cord, Brazil (HV)
Power Cord, Canada
Power Cord, Chile
Power Cord, Columbia
Power Cord, Costa Rica
Power Cord, Denmark
Power Cord, Ecuador
Power Cord, Egypt
Power Cord, El Salvador
Power Cord, Finland
Power Cord, France
Power Cord, Germany
Power Cord, Guatemala
Power Cord, Honduras
Power Cord, Israel
Power Cord, Italy
Power Cord, Japan
Power Cord, Mexico
Power Cord, Netherlands
Power Cord, Nicaragua
Power Cord, Norway
Power Cord, Panama
Power Cord, Paraguay
Power Cord, Peru
Power Cord, Portugal
Power Cord, Saudi Arabia
Power Cord, South Africa
Power Cord, Spain
Power Cord, Sweden
Power Cord, Switzerland
Power Cord, United Kingdom
Power Cord, Uruguay
Power Cord, Venezuela

7-9

4078-00X

Assembly 4: Carrier

Parts Catalog 7-10

4078-00X

Asm­Index

4 -1 11A5448 1 Carrier Assembly

-2 11A5437 1 Rod, Carrier Guide

-3 11A5436 1 Frame, Carrier

-4 11A5453 1 Screw, Carrier Guide Rod (PP)

-5 11A5453 1 Spring, Carrier Guide Rod (PP)

Part
Number

Units Description

7-11

4078-00X

Assembly 5: Sheet Feeder

Parts Catalog 7-12

4078-00X

Asm­Index

5 -1 11A5436 1 Frame, Carrier

-2 11A5453 2 Screws,

-3 11A5451 1 Sheet Feeder Asm

-4 11A5433 1 Cover,Rear Asm
NS 70G2759 1 Card Feeder Kit, Japan Hagaki

Part
Number

Units Description

Sheet Feeder Mounting (PP)

7-13

4078-00X

Index 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

General Information 1-1

L

Lubrication Specifications 6-1

M

Maintenance Approach 1-1

P

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 & Cap 4-7

Repair Information 4-1

S

Safety Information v
Service Checks

Envelope Feed 2-7
First Print Line 2-8
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

4078-00X

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

X-2