Page 3 - iii; Contents
iii 4078-00X Contents 1 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 4 - iv
iv 4078-00X Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 Handling ESD-Sensitive Parts . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Removal Pro...
Page 5 - Preface v; Preface
Preface v 4078-002 Preface 2 This manual is divided into the following chapters: 1. General Information contains a general description of the printer and the maintenance approach used to repair it. Specialtools and test equipment are listed in this chapter, as well asgeneral environmental and safety...
Page 7 - Preface vii; Pautas de Seguridad
Preface vii 4078-002 Pautas de Seguridad • La información sobre el mantenimiento de este producto fue escrita para el personal de mantenimiento cualificado y nopara cualquier otro usuario. • Existen mayores riesgos de descargas eléctricas y daños personales durante el desmontaje y la reparación de l...
Page 8 - viii; Chinese Safety Information
viii 4078-00X Chinese Safety Information Korean Safety Information
Page 9 - General Information 1-1; General Information; The Color Jetprinter; 020 printer is a personal, near laser-quality; Power Consumption; Less than 2 Watts - power off and power to the printer; Maintenance Approach
General Information 1-1 4078-00X 1. General Information The Color Jetprinter TM 1020 printer is a personal, near laser-quality inkjet printer. The print cartridge is a single-unit customerreplaceable supply item. A single printhead provides three colorsand composite black printing. The printer also ...
Page 11 - Diagnostic Information 2-1; Diagnostic Information; “Error Indicator Table” on page 2-2
Diagnostic Information 2-1 4078-00X 2. Diagnostic Information Use the error indicator table, symptom tables, service checks, anddiagnostic aids in chapter 3, to determine the failing part. Start Service error indications show as a series of flashes of the PowerOn light. There is a pause between each...
Page 12 - Error Indicator Table; After 30 seconds the carrier moves over the maintenance
2-2 4078-00X Error Indicator Table Power-On Self Test (POST) Sequence When you turn the printer on it performs a POST. Turn your machineon and check for a correct POST operation by observing thefollowing: 1. The lights come on. 2. The carrier moves. 3. The paper feed gears turn. 4. After 30 seconds ...
Page 13 - Diagnostic Information 2-3; POST Symptom Table
Diagnostic Information 2-3 4078-00X POST Symptom Table Symptom Action No Power Onlight and nomotors run Go to the “Power Service Check” on page 2-12 . Power light, butno busy light Replace the system board. Paper feedgears do notturn Go to the “Paper Feed Service Check” on page 2-9 . Carrier doesn’t...
Page 14 - Symptom Tables; Carrier Transport Problems
2-4 4078-00X Symptom Tables Locate the symptom in the following tables and take the appropriateaction. Carrier Transport Problems Communications Problems Maintenance Station Problems Operator Panel Symptom Action • No carrier movement• Slow carrier movement• Carrier stops• Carrier slams side frame G...
Page 16 - Service Checks; Carrier Transport Service Check
2-6 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 thesystem board. Turn the printer on and check for apulse of (approximately) 10 V dc between CN4-1and ground and CN4-4 ...
Page 17 - Diagnostic Information 2-7; Envelope Feed Service Check
Diagnostic Information 2-7 4078-00X Envelope Feed Service Check 6 Home PositionSensor Perform the “EOF and Home Position Sensors Test” on page 3-2 , to check the Home Position Sensor. If you cannot enter the test, replace thesystem board. If the test fails, turn the printer offand disconnect CN5 fro...
Page 18 - Maintenance Station Service Check; The maintenance station has two functions:
2-8 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 MaintenanceStation Assembly As the carrier moves to ...
Page 19 - Diagnostic Information 2-9; Paper Feed Service Check; Check the entire paper path for obstructions.
Diagnostic Information 2-9 4078-00X Paper Feed Service Check If your machine does not have paper jam problems, continue withthe 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...
Page 21 - Diagnostic Information 2-11; Paper Path Service Check
Diagnostic Information 2-11 4078-00X Paper Path Service Check Examine the machine for the following before you begin this servicecheck: • 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. 7 End of Fo...
Page 23 - Diagnostic Information 2-13; Print Quality Service Check
Diagnostic Information 2-13 4078-00X Print Quality Service Check FRU / Function Action 1 Print Cartridge Be sure the machine contains a good printcartridge. 2 Color PrintCartridge CrossContamination Cross contamination of color inks results inincorrect colors printed, as when green prints foryellow,...
Page 25 - Diagnostic Information 2-15; Print Quality Notice; After completing repairs to the printer, connect it to a PC and go to
Diagnostic Information 2-15 4078-00X Print Quality Notice Printers are shipped with three different carrier transport motorsdisplaying a label which reads either NMB(NMB), Airpax(APX) orMitsumi(MZM). The label on the motor should match the motor ID inNVRAM. To verify the motor ID stored in NVRAM, pr...
Page 27 - EOF and Home Position Sensors Test; press and hold the following buttons while turning the printer on:
Diagnostic Aids 3-2 4078-00X EOF and Home Position Sensors Test This test allows the servicer to test the function of the End-of-Formand Home Position sensors. To run the test: 1. With the printer off and the End-of-Form Flag out of the sensor, press and hold the following buttons while turning the ...
Page 28 - Initialize Error Log; This test tracks intermittent errors.
3-3 4078-00X Initialize Error Log This test tracks intermittent errors. Use this procedure to reset the error log to zero. The error log isespecially 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 ...
Page 29 - Parallel Port Test; and hold the following button while turning the printer on:
Diagnostic Aids 3-4 4078-00X Parallel Port Test This test performs a wrap around test between the printer parallelport and the parallel port test connector. This test requires a parallel port wrap plug. Install the wrap plug inthe parallel port before you start the test. The power on light flashesif...
Page 30 - Print NVRAM Contents; Place a sheet of paper in the sheet feeder far enough to push
3-5 4078-00X Print NVRAM Contents This test prints the contents of NVRAM, which can be used fordiagnostic purposes. To run the test: 1. Install a black print cartridge. 2. Place a sheet of paper in the sheet feeder far enough to push the End-of-Form flag out of the sensor. 3. Load paper into the she...
Page 31 - Reset NVRAM to EMEA Defaults; Note: Factory defaults are initially set to USA.; With the printer off, press and hold the following buttons while
Diagnostic Aids 3-6 4078-00X Reset NVRAM to EMEA Defaults This test resets the user defaults area of NVRAM to the EMEAfactory 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 follow...
Page 32 - Reset NVRAM to USA Defaults; With the printer off, press and hold the Install Print
3-7 4078-00X Reset NVRAM to USA Defaults This test resets the user defaults area of NVRAM to the USA factorydefaults. 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 ...
Page 33 - Test Page; This test prints the test page.
Diagnostic Aids 3-8 4078-00X Test Page This test prints the test page. To run a complete test page of black and color patterns, be sure theprint 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. Pa...
Page 34 - Repair Information 4-1; Repair Information; Note: Read the following before handling electronic parts.; Handling ESD-Sensitive Parts
Repair Information 4-1 4078-00X 4. Repair Information This chapter explains how to make adjustments to the printer andhow 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 sensiti...
Page 35 - Repair Information 4-2; Adjustments; Releasing Plastic Latches
Repair Information 4-2 4078-00X Adjustments The user is directed, in the Printer Control program, to perform thebidirectional alignment adjustments after replacing a print cartridge. Removal Procedures The following procedures are arranged according to the name of theprinter part discussed. Unplug t...
Page 37 - Repair Information 4-4; Carrier Frame Assembly Removal
Repair Information 4-4 4078-00X Carrier Frame Assembly Removal The carrier rail mounted by two screws on the carrier frame is included withthe carrier frame (11A5436). The carrier rail, which is not available as aFRU, is mounted in the elongated slots at the factory. During adjustment, therail is pu...
Page 38 - Carrier Transport Motor Removal; “Print Quality Notice” on page 2-15; Drive Train Assembly Removal
4-5 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 th...
Page 39 - Repair Information 4-6; Front Cover Removal; Turn the printer over to expose the base. Remove the two cover; Gutter Pad Removal; Remove the gutter pad from the base assembly.
Repair Information 4-6 4078-00X Front Cover Removal 1. Turn the printer over to expose the base. Remove the two cover mounting screws from the front cover. When reassembling, donot overtighten these screws as they will break. Replacementscrews can be found in parts packet 11A5453. 2. Slide the cover...
Page 41 - Repair Information 4-8; Mid Frame Assembly Removal
Repair Information 4-8 4078-00X Mid Frame 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 small feed roll assemblies. 6. Remove the small feed roll bracket assembly. 7. Remove the printhead carrier assembly. ...
Page 42 - Printhead Carrier Assembly Removal
4-9 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 ...
Page 43 - Repair Information 4-10; Rear Cover Removal; Work the tabs of the rear cover free from the base assembly.
Repair Information 4-10 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 mac...
Page 44 - Sheet Feeder Removal; Remove the two sheet feeder mounting screws from the rear of; Small Feed Roll Assembly Removal; Remove the four small feed roller springs from the carrier frame.
4-11 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...
Page 45 - Repair Information 4-12; Small Feed Roll Bracket Assembly Removal
Repair Information 4-12 4078-00X Small Feed Roll Bracket 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 asse...
Page 46 - System Board Removal
4-13 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...
Page 47 - Connector Locations 5-1; Connector Locations
Connector Locations 5-1 4078-00X 5. Connector Locations System Board Connectors
Page 49 - Preventive Maintenance 6-1; Preventive Maintenance; All gear mounting studs.
Preventive Maintenance 6-1 4078-00X 6. Preventive Maintenance This chapter contains the lubrication specifications. Follow theserecommendations to prevent problems and maintain optimumperformance. Lubrication Specifications Lubricate only when parts are replaced or as needed, not on ascheduled basis...
Page 50 - How To Use This Parts Catalog
Parts Catalog 7-1 4078-00X 7. Parts Catalog How To Use This Parts Catalog • SIMILAR ASSEMBLIES: If two assemblies contain a majority ofidentical parts, they are broken down on the same list. Commonparts are shown by one index number. Parts peculiar to one orthe other of the assemblies are listed sep...
Page 55 - Assembly 3: Electronics
Page 61 - Assembly 5: Sheet Feeder
Parts Catalog 7-12 4078-00X Assembly 5: Sheet Feeder
Page 63 - Index
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 Er...
Page 64 - EMEA
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
