Epson 4004677 manual

EPSON COLOR INKJET PRINTER Stylus Pro XL SERVICE MANUAL EPSON 4004677[...]

Chapter 1 Product Description Table of Contents 1.1 FEATURES 1-1 1.2 SPECIFICATIONS 1-3 1 . 2 . 1 P r i n t i n gS p e c i f i c a t i o n s ........... ............ ............ ..... 1 - 3 1 . 2 . 2 P a p e rH a n d l i n gS p e c i f i c a t i o n s ........... ............ ........... 1 - 5 1 . 2 . 3 P a p e rS p e c i f i c a t i o n s .......[...]

List of Figures Figure 1-1. Exterior View of the Sty lus Pro XL Figure 1-2. Nozzle Configuration Figure 1-3. Printable Area for Cut Sheet Figure 1-4. Printable Area for Envelope Figure 1-5. Adjustment Lever Setting Figure 1-6. Temperature/Humidity Range Figure 1-7. Data Transmission Timing Figure 1-8. Control Panel Appearance Figure 1-9. C162 MAIN [...]

1.1 FEATURES The Stylus Pro XL is a 64 + 48-nozzle (m onochrome and CMY) color ink jet dot matrix printer. The major features of this printer are: ❏ High-quality color print -Micro Dot 720 dpi printing -Plain paper 720 dp i printing -Special coated paper 720 dpi printing ❏ High print spee d -LQ 200 cps ❏ Built-in auto sheet feeder -Holds 100 [...]

Table 1-1. Interface Cards Interface Card Model Number Serial interface card C823051/C823061 32KB serial interfa ce card C823071/C8230 81 32KB parallel inte rface card C82310 ✽ 32KB IEEE-488 interface card C82313 ✽ LocalTalk ® inte rface card C82312 ✽ Twinax interface card C82315 ✽ Coax interface card C82314 ✽ ✽ The asterisk represents[...]

1.2 SPECIFICATIONS This section provides statistics and other detailed information for the printer. 1.2.1 Printing Specifications Print system: On demand ink jet syste m Nozzle configuration: 64 nozzles (16 × 4 staggered): monochrome 48 nozzles (16 × 3 stagge red): color Printing direction: Bidirectional with logic-seeking Print s peed: See Table[...]

Character sets: Legal and 14 international character sets. Character tables: See Table 1-3. Table 1-3. Character Tables Bit map font Scalable font Character Tables EPSON Rom an EPSON Sans Ser if EPSON Co urie r EPSON Prestige EPSON Script EPSON Roman EPSON Sans Serif EPSON Roman EPSON Sans Serif H Italic ❍❍ m PC437 (U.S ./Standard Eur ope) ❍?[...]

1.2.2 Paper Handling Specifications Feeding method: Friction feed paper is fed from the built-in auto sheet feeder (ASF). Notes: The following ope rations are not allowed. 1. Reverse feeding w ithin 3 mm (0.12 in.) f rom the top edge of the pap er or 16 mm (0.63 in.) from the bottom edge of the pape r. 2. Reverse feeding beyond 7 .9 mm (0.3 in.). L[...]

Printable area: Cut she ets Envelopes Notes: A : T h em i n i m u mt o pm a r g i n=3m m( 0 . 1 2i n . ) B: The minimum left margin = 3 mm (0.12 in.) C: The minimum right margin is: A3+/US B+ size: 3mm (0.12 in.) A3 size: 3 mm (0.12 in.) A4 size: 3 mm (0.12 in.) A4 (Landscape)size:3 mm (0.12 in.) USB size: 9 mm (0.35 in.) Legal size: 9 mm (0.35 in.[...]

Setting the adjust lever: The adjust le ver on the carriage u nit must be set to the p roper position for the paper thickness, as shown in Table 1-6. Table 1-6. Adjust Lever Settings Lever Position Paper Paper Thickness LEFT (Vertical) Cut Sheets 0.08 ∼ 0.11 mm (0.003 ∼ 0.004 in.) RIGHT (Horizontal) Envelopes Less than 0.5 mm (0.020 in.) 1.2.4 [...]

1.2.5 Electrical Specifications Table 1-7. Rated Electrical Ranges Specification 120 V Version 220 - 240 V Version Rated voltage 120 VAC 220 - 240 VAC Input voltage range 103.5 ∼ 132 V 198 ∼ 264 V Rated frequency range 50 ∼ 60 Hz 50 ∼ 60 Hz Input frequency range 49.5 ∼ 60.5 Hz 49.5 ∼ 60.5 Hz Rated current 0.6 A 0.4 A Power consumption A[...]

1.2.7 Reliability Total print volume: 75,000 pages (A4, le tter) Printhead life: 1,000 million dots/nozz le 1.2.8 Safety Approvals Safety standards: 120 V version: UL1950 with D3, CSA22.2 #950 with D3 220-240 V version: EN 60950 (TÜV, SEMKO, DEMKO, NEMKO, SETI) Radio frequency interfer ence (RFI): 120 V ve rsion: FCC Part 15 Subpart B Class B 220-[...]

1.3 INTERFACE SPECIFICATIONS The Stylus Pro XL is standard-equipped with an 8-bit parallel and serial interface. 1.3.1 Parallel Interface Specifications Data format: 8-bit parallel Synchronization: By STROBE pulse synchroniz ation Handshaking: By BUSY and ACKNLG signals Signal level: TTL compatible leve l Adaptable connector: 36-pin 57-30360 (Amphe[...]

Table 1-9 shows the conne ctor pin assignments and signal fu nctions of the 8-bit parallel interface. Table 1-9. Signal and Connector Pin Assignments for Parallel Interface Pin No. Signal Name I/O* Description 1 STROBE I The S T R O B Ep u l s ei su s e dt or e a dd a t af r o mt h eh o s t computer. The pulse width must be 0.5 µ s or more. Normal[...]

1.3.2 Serial Interface Specifications Data format: RS-422 serial Synchronization: Asynchronous Handshaking: By DTR signal and X-ON/X-OFF protocol Table 1-10. DTR and X-ON/X-OFF Protocol State Buffer Space DTR X-ON/X-OFF Busy Less than 512 bytes Off X-OFF Ready More than 1,024 bytes On X-ON Word length Start bit: Data bit: Parity bit: Stop bit: 1b i[...]

1.4 OPERATIONS This section describes the basic operations of the printer. 1.4.1 Control Panel The control panel for this pr inter has 1 lock-type, 5 non-lock-type push buttons, and 14 LED indicators for easy operation of t he various printer functions. Buttons Operat e Turns the printer on or off. Alt Modifies the function of other buttons. Holdin[...]

Ind icators Operat e On when the printer is on. Blinks during power on and off sequence. Data On when print data is in the input buffer. Data and Pause lights b link if an error occurs. Paper Out On when the printer is out of paper. Blinks whe n a paper jam occurs. No Ink Cartridge On when ink cartridge is out. Economy On when economy printing mode[...]

1.4.3 Default S ettings The printer can save some p rinter setting parameters that define its functio ns at initialization. You can change these parameters by using the printer’s default setting mode. 1.4.3.1 Default Setting Items You can use the default se tting mode to change settings listed in the table below. Activate default-setting mode by [...]

1.4.3.2 Changing th e Default Settings To change the printer’s default settings: 1. Hold down the Economy/Condensed button and turn on the printer. The printer prints a sheet that shows the firmware version and describes how to select t he language used to print messages. 2. Press the Font button until the appropriate font LED is selected. The fo[...]

Table 1-18. Character Table Selection Version Settings Operate LED Data LED Paper Out LED Common Italic U.S. A. Off Off Off ^ Italic Fra nce On Off Off ^ Italic Germany Blinks Off Off ^ Italic U.K. Off On Off ^ Italic Denmark 1 On On Off ^ Italic Sweden Blinks On Off ^ Italic Italy Off B links Off ^ Italic Spain 1 On Blinks Off ^ PC437 Blinks Blink[...]

1.4.4 Error Conditions The printer can detect various errors and indicate them with LEDs. Table 1-19. Error Indications Error Data LED Paper Out LED No Ink Cartridge LED Economy LED Conden sed LED Pause LED Paper out Off On Off Off Off Off No ink cartridge Off Off On Off Off Off Paper jam Off Blinks Off Off Off O ff Maintenance request Blinks Blink[...]

1.5 MAIN COMPONENTS The main components of the Stylus Pro XL are: ❏ Printer mechanism (M-4A60) ❏ Main control board (C162 MAIN Board) ❏ Power supply unit (C137 PSB /PSE Board) ❏ Control panel board (C137 PNL Board) ❏ Housing 1.5.1 Main Control Board (C162 MAIN Board) The Main Control Board (C162 MAIN Board) consists of an H8/3003 16-bit C[...]

1.5.2 Power Supply Board (C137 PSB/PSE Board) The power supply board (C137 PSB/PSE Board) cons ists of an RCC switching regulator circuit. This board is equipped with a power switch connected to the secondary circuit. Thus, if the printer i s turned off, it can continue to operate in order to eject the paper and perfo rm the head capping operation.[...]

1.5.4 Printer Mechanism (M-4A60) The M-4A60 printer mechanism is equipped with a 64-nozzle bl ack printhead and 48-no zzle color (CMY) printhead on the carriage unit. Resolution of 720 dpi is possible with special (non-absorbent) paper. The ink sys tem has both a black pump unit and a color pump unit. Waste ink from each printhead is made to flow i[...]

Chapter 2 Operating Principles Table of Contents 2.1 OVERVIEW 2-1 2.2 OPERATING PRINCIPLES OF THE PRINTER MECHANISM 2-1 2 . 2 . 1 P r i n t e rM e c h a n i s m ..... ............ ............ ............ .. 2 - 2 2 . 2 . 2 C a r r i a g eD r i v eM e c h a n i s m ..... ............ ............ ........ 2 - 5 2 . 2 . 2 . 1 P l a t e nG a p A d j[...]

List of Figures F i g u r e2 - 1 . P r i n t e rM e c h a n i s m B l o c k ............. ............ ........ 2 - 1 F i g u r e2 - 2 . S t r u c t u r eo fP r i n t h e a d ............... ............ ........ 2 - 2 F i g u r e2 - 3 . P r i n c i p l e so ft h eP r i n t i n gO p e r a t i o n .............. ........... 2 - 3 Figure 2-4. Carriag[...]

2.1 OVERVIEW This section de scribes the operating p rinciples of the p rinter mechanism and the ele ctrical circuits of the Stylus P ro XL. 2.2 OPERATING PRINCIPLES OF THE PRINTER MECHANISM The Stylus Pro XL printer mechanism is composed of the printhead unit, paper fe ed mechanism, carriage drive mechanism, pump mechanism, and various sensors. Th[...]

2.2.1 Printer Mechanism The printer me chanism of this printer uses a drop-on-demand ink jet system similar to the system used on all othe r EPSON ink jet printers. However , the printhead in this system is comp letely redesigned to make it more compact and ensure a h igh level of reliability. The figure below shows the structure of the printhead a[...]

Principles of the Printin g Operation The printhead operates in one o f two modes to eject ink from each nozzle: ❏ Normal state No electrical charge is applied to the MLP (Multi-Layer Piezoelectric) elem ent attached to the back of the cavity, and pressure inside the cavity is kept at a constant le vel. ❏ Ejecting state The head data signal is [...]

Micro Dot Printing mode The Stylus Pro XL printer has a special printing mode, called “Micro Dot Printing mode”. This printing mode can be selecte d by a command from the host computer. Using the Micro Dot printing mode can imp rove the quality of output. In Micro Dot Printing mode, the ink dot size became to be sm aller than the normal dot siz[...]

2.2.2 Carriage Drive Mechanism The timing belt attached to the base of the carriage unit is driven by the carriage motor, causing the carriage unit to move along the carriage guide shaft left to right, or vice versa. The carriage drive motor on this printer is a 4-phase, 200-pole, hybrid-type stepping motor mechanism, allowing the printer to stop t[...]

2.2.2.1 Platen Gap Adjust Lever The platen gap adjust leve r, which is attached to the carriage unit, needs to be set to an appropriate position for the paper thickness. To change the platen gap , put the printer in the P AUSE state; then press the Font button, while holding down the Alt button. The carriage unit moves the platen gap position autom[...]

Table 2-5. Drive Terms Mode Frequency (pps) Current Value (mA) Acceleration/ Decelerati on Constant Rush Hold Paper loading 16 00 970/750 750 750 240 ASF feed 16 00 970/750 750 750 240 Paper f eed 391 — / — 970 — 240 Pump drive 1 1800 1380/1380 1380 750 240 Pump drive 2 300 — / — 1380 — 240 PF Tr ansm ission Gear Que nchin g Ro ller PF [...]

2.2.4 Ink System This printer’s ink system is composed of the following mechanisms: ❏ Ink cartridge ❏ Pump mechanism ❏ Cap mechanism ❏ Waste ink drain tank ❏ Wiping mechanism The figure below shows a diagram of the ink system. Air Valve Black Hea d Color Hea d Pu mp 1 Pu mp 2 In k Ab sorb er Wa s t e I n k Dr a i n T a n k Cl eani ng Bl[...]

2.2.5 Pump Mechanism The paper fe ed motor drives the p ump mechanism when the transmission gear is moved to the position where the paper feed motor engages the pump mechanism gear trains, when the carriage unit is at the ink system home position. The figure below shows a block d iagram of the pump mechanism. Pump system operation depends on the ro[...]

Drive: Paper Feed Mechanism Switch Lever: Reset Carriage Figure 2-10. Paper Feed Mechanism Block Diagram Ca rria g e D/E Rese t Le ver D/E Lever Figure 2-11. Switch Lever Reset Operating Principles Stylus Pro XL 2-10 REV.-A[...]

Table 2-6. Pump Mechanism Operation PF Motor Rotational Direction Operation Clockwise (CW) forward rotation ❏ Color absorption ❏ Color micro absorption ❏ Color false absorption ❏ Wiper res et ❏ Carria ge lock r eset Counterclockwise (CCW) backward rotation ❏ Monochrome absorption ❏ Monochrome micro absorption ❏ Monochrome false abso[...]

2.2.6 Cap Mechanism The cap m echanism prevents the p rinthead nozzles from drying and keeps bubble s from forming inside the nozzle while the printer is not in use. The printer performs this operation autom atically when print data is not received or when the printer power is turned off during printing or ink system operations. (The secondary circ[...]

2.3 OPERATING PRINCIPLES OF THE ELECTRICAL CIRCUITS The Stylus Pro XL contains the following circuit board units: ❏ C162 MAIN Board (main control circuit board) ❏ C137 PSB/PSE Board (power s upply circuit board) ❏ C137 PNL (control panel board) In addition to the circuit boards above, part of the printhead drive circuit is built on a sep arat[...]

The figure below shows a block diagram of the power supply circuit (C137 PSB/PSE). The power switch is equipped with a secondary circuit that allows the CPU to rem ain active for a while after the printer is turned off. This allows the printhead to return to the capping position after power is off. The CPU m ounted on the C137 MAIN Board always mon[...]

2.3.2 Operating Principles of the Main Control Circuit The main control circuit of this printer is the C162 MAIN Boa rd. This circuit is controlled by the 16-bit CPU H8/3003 (IC1), running at 14.7456 MHz. This CPU has a unique architecture capable of handling data on the data bus at e ither an 8-bit or 16-bit bus width. Because of this, a 16-bit or[...]

2.3.2.1 Reset Circuits The C162 MAIN Board contains 2 reset circuits: the +5 V monitor reset circuit a nd the +35 V monitor reset circuit. The +5 V monitor reset circuit monitors the voltage level of the +5 V line, using reset IC PST592D (IC12), and outputs a r eset signal to the E05A96 gate array (IC2) when the voltage level drops below +4.2 V. Th[...]

2.3.2.3 Carriage Motor Drive Circuit The carriage motor drive IC SLA7041MS (IC15) outputs a constant current to drive the carriage motor for the printer mechanism. Gate array E05A96EA (IC2) decides the motor phase and speed and then sends a signal to the carr iage motor driver IC (SLA7041MS) using the 4-bit serial transmission line. The first bit i[...]

The following figure shows the cont ents of the four-bit serial data and how this data transacts with the SLA7041MS driver. The step time of the reference voltage is determined by the interval time of the STROBE pulse. STRB CL K SLA7 04 1 MS 1-bi t 2- bi t 3-bi t 4- bit Vref +5 V Vref STRB CL K abc 1-bi t 2- bi t 3-bi t 4- bit abc Vref Voltage Sele[...]

2.3.2.4 Paper Feed Motor Drive Circuit The paper feed motor for this printer drives the following mechanisms: ❏ Paper fee d mechanis m ❏ Paper pickup mechanism ❏ Pump mechanism Driver IC SLA7041MS (IC14) drive s the paper feed motor by a constant current. Its principle of operation is same as for the carriage motor drive circuit. But the driv[...]

2.3.2.5 Printhead Drive Circuit The printhead drive circuit for this printer is compose d of the following two parts: ❏ Common drive circuit (trapezoidal drive pulse generation) ❏ Head drive circuit (nozzle control built on the printhead) SED5620D, the 64-bit thermal head driver in the head drive circuit on the carriage, is used as a nozzle se [...]

Micro Dot Printing Mode The Stylus Pro XL printer has a special printing mode, calle d “Micro Dot Printing Mode.” This printing mode can be selected by command from computer. Using Micro Dot Printing Mode can improve the qua lity of output. In Micro Dot Printing Mode, the ink dot size becomes smaller than the normal dot size. COM GN D BPWC CPW [...]

2.3.2.6 DMA Controller Data from the host computer is received automa tically by the STB signal via the external Centronics interface. The data is inp ut to the input buffe r on the DRAM (IC5). At this time, E05A96 detects the rising edg e of the external STB signal and outputs the STBDMA (strobe DMA request) signal to the CPU. When the CPU dete ct[...]

2.3.2.7 DRAM Refresh Controller The H8 CPU is equipped with a refresh controller in the internal controller. This CPU can contact the 16-bit-long IC5 DRAM, which is a 2 CAS type. The following table lists the junction method between the H8 C PU and the 2 CAS DRAM. Table 2-10. Junction Method (CPU — 2 CAS DRAM) CPU 2 CAS DRAM HWR UCAS LWR LCAS CS3[...]

2.4 INK SYSTEM MANAGEMENT This section explains how the ink syste m is controlled to protect the printhead and ink supply system and to ensure high-quality ou tput. Ink system control is compose d of the following operations: ❏ Power On ❏ Wiping Operation 1 ❏ Cleaning Selection ❏ Wiping O peration 2 ❏ Micro Absorbi ng Cleaning ❏ Rubbing[...]

2.4.1 Ink Operations Various ink operations can be performed selectively by the printer. 1 Power On Operation This operation is performed when power is turned on. 2 Cleaning Selecti on Mode This operation cleans each nozzle to ensure that the nozzle fires and that no dots are skipped during printing. Cleaning selection is perfor med by pressing the[...]

14 Disengage Off Op eration This operation resets the switch lever to the position where it transmits the PF motor drive to the pump mechanism. It also moves the carriage to the flushing position, where the lever is reset to the specified position. 15 Micro Absorb ing Operation When the cartridge is removed, it is possible for a small amount of air[...]

2.4.2 Timer and Counter EEPROM LE93C46 (IC12) on the main board stores certain counter and timer value s used for controlling ink system operation. 2.4.2.1 Protect Counter Protect counter A and Ink Amount C ounter R values are stored in the EEPROM on the main board, and while the printer is on, this data is saved in the RAM on the main board. ❏ P[...]

Chapter 3 Disassembly and Assembly Table of Contents 3.1 OVERVIEW 3-1 3 . 1 . 1 P r e c a u t i o n sf o rD i s a s s e m b l i n gt h eP r i n t e r ........... ............ .. 3 - 1 3.2 DISASSEMBLY AND ASSEMBLY 3-2 3 . 2 . 1 U p p e rC a s eR e m o v a l .................. ............ ........... 3 - 3 3.2.2 P ower Supply Unit (C137 PSB/PSE Boar[...]

List of Figures F i g u r e3 - 1 . D i s a s s e m b l yF l o w c h a r t .................... ............ .. 3 - 2 F i g u r e3 - 2 . C 1 3 7P N LC o n t r o lP a n e lR e m o v a l ........... ............ .. 3 - 3 F i g u r e3 - 3 . U p p e rC a s eR e m o v a l ................... ............ ..... 3 - 3 F i g u r e3 - 4 . P o w e rS u p p l [...]

3.1 OVERVIEW This section describes procedure s for disassembling the main componen ts of this printer. Unless otherwise specified, disassembled units or compone nts can be reassembled by reversing the disassembly procedure. Therefore , no assembly procedure s are included. Precautions for any disassembly or assem bly procedure are described under [...]

3.2 DISASSEMBLY AND ASSEMBLY WARNING Follow the precautions in Section 3.1.1 when disassembling the printer. This section consists of the subheads shown in the diagram below. See the exploded view of the printer in the Appendix , if necessary. START 3. 2.1 3.2.2 3.2.4 3. 2.3 3.2.5 .1 3. 2.5.2 3.2.5 .3 3. 2.5.4 3.2.5 .5 3. 2.5.6 3.2.5.7 - 8 3.2.5.9 [...]

3.2.1 Upper Case Removal 1. 1. Remove the printer cover (center of top ) by releasing the 2 tabs holding it to the upper case. 2. Remove the front cover (front of top) by releasing the 2 tabs holding it to the lower case. 3. Remove the pap er guide by releasing the 2 tabs holding it to the printer mechanism. 4. Move the carriage to the middle of th[...]

3.2.2 Power Supply Unit (C137 PSB/PSE Board) Removal 1. Re move the upper case (see Section 3.2.1). 2. Disconnect the cables f rom connectors CN1 on the C137 PSB /PSE Board and CN5 on th e C162 MAIN Board. 3. Remove the 2 screws, 1 CBN (M3 × 8 )a n d1C B B( M 3 ×12) , securing the shield plate to the lower case via the C137 PSB/PSE Boar d. 4. Rem[...]

3.2.3 Main Controller (C162 MAIN Board) Rem oval 1. Re move the upper case (see Section 3.2.1). 2. Remove the grou nding plate from the shield plate. 3. Remove the 4 CBB (M3 × 12) screws securing the s hield plate to the lower case. 4. Remove the 2 CBB (M3 × 12) screws securing the Type-B interface cover to the lower case. 5. Disconnect the cable[...]

ASSEMBLY POINT ❏ When you replace the main board, initialize EEPROM contents as follows: 1. Reassemble the printer. 2. Turn the printer on while holding down the Alt , Font , Load/Eject ,a n d Pa use buttons on the control panel. ❏ It is possible to misconnect the cables. When reconnecting the cables from connectors CN6, CN7 and connectors CN11[...]

3.2.4 Printer Mechanism (M-4A10) Removal 1. Remove the upper case (see Section 3.2.1). 2. Remove the power supply unit (see Section 3.2.2). 3. Remove the main controller (see Section 3.2.3). 4. Remove the 4 CBN (M4 × 13) screws and take out the printer mechanism. DISASSEMBLY/ASSEMBLY POINT Wipe off any ink around the end of the ink drain tube when[...]

3.2.5 Printer Mechanism Disassembly The procedures described in this section explain how to remove the components within the printer mechanism. 3.2.5.1 Printhead Unit Removal 1. Remove the printer mechanism (see Section 3.2.4). 2. Move the carr iage to the middle o f the printer while pressing the hook that fixes the carriage unit to the home posit[...]

6. Remove the CBB (M3 × 11) screw (under the CR cap cover) a nd plain washer securing the monochrome and color printheads to t he carriage base. 7 Pull the black or color head toward you, and disconnect the head FFC cable on the head d river board (nozzle selector). Then remove the black or color head. Color Head Black Head Figure 3-9. Printhead R[...]

CAUTION ❏ Take proper measures to protect t he printhead unit from static e lectricity, because the driver IC is directly attached to the printhead unit. ❏ Never touch the printhead’s metallic nozzl e cover surface. Handle it only by ho lding the edges of the printhead. ❏ When you replace the printhead or the printer mechanism, you must rep[...]

REQUIRED ADJUSTMENT ❏ When removing or changing the black head, the following adjustments are neede d. 1. Black head angle adjustment (see Section 4.1.4). 2. Black - Color head vertical adjustment (see Section 4.1.5). 3. Head gap adjustment (see Section 4.1.3). 4. Bidirectional alignment adjustment (see Section 4.1.2). ❏ When removing or changi[...]

3.2.5.2 Carriage Unit Removal 1. Remove the printe r mechanism (see Section 3.2.4). 2. Move the carriage to the left side of the printer while pressing the hook that fixes the carriage to the home position. 3. Remove the 2 CBN (O) (M3 × 6) screws securing the eject frame to both side frames. 4. Remove the cartridge holde r with ink cartridge f rom[...]

3.2.5.3 Pump Unit Removal 1. Remove the printer mechanism. (See Section 3.2.4.) 2. Remove the carriage unit. (See Section 3.2.5.2.) 3. Remove the CBS (M3 × 6) screw secur ing the pump unit to the bottom frame. 4. Push the pump unit outward while releasing the tab at the bottom side of the pump unit, and then lift up the pump unit. CBS (M3 x6) Bo t[...]

3.2.5.4 Cleaner Head Replacement 1. Remove the printe r mechanism (see Section 3.2.4). 2. Use tweezers to unhook the cleaner head from the hook on the cleaning lever. CAUTION Keeping the cleaner head clean is extremely important to keep the ink injectio n system working properly in the printhead, and it directly affects printin g quality. Therefore[...]

3.2.5.5 CR Motor Removal 1. Remove the printe r mechanism (see Section 3.2.4). 2. Re lease the timing belt (see section 3.2.5.2 ). 3. Remove the 3 scre ws securing the CR motor to the upp er frame, and then remove the CR motor. 3.2.5.6 PF Motor Removal 1. Remove the printe r mechanism (see Section 3.2.4). 2. Remove the 2 CBN (M3 × 6) screws and th[...]

3.2.5.7 Carriage Home Position Sensor Removal 1. Remove the printer mechanism. (See Section 3.2.4.) 2. Disconnect the sensor cable from the carriage home position sensor. 3. Unhook the 3 notches secu ring the carriage home position sensor to the upper frame. Then remove the carriage home position sensor. 3.2.5.8 PE Sensor Removal 1. Remove the prin[...]

3.2.5.9 Paper Feed Roller Assembly Removal 1. Remove the printe r mechanism (see Section 3.2.4). 2. Re move the carriage unit (see Section 3.2.5.2). 3. Re move the pump unit (see Section 3.2.5.3). 4. Remove the tension spring holding the tension roller assembly to the sub frame. 5. Remove the tension wire o n the left side frame holding the tension[...]

3.2.5.10 Upper Frame Removal 1. Remove the printe r mechanism (see Section 3.2.4). 2. Re move the carriage unit (see Section 3.2.5.2). 3. Remove the E-ring securing the knob shaft to the sub frame; t hen remove the knob with the knob shaft from the right side fram e. 4. Remove the 5 CBN (M3 × 5) screws securing the upper frame to both side frames [...]

Chapter 4 Adjustments Table of Contents 4.1 OVERVIEW 4-1 4 . 1 . 1 D e s t i n a t i o nD a t aW r i t i n gO p e r a t i o n ................ ............ .. 4 - 2 4 . 1 . 2 B i - D( B i d i r e c t i o n a l P r i n t i n g )A l i g n m e n tA d j u s t m e n t ....... ........... 4 - 3 4 . 1 . 3 H e a dG a p A d j u s t m e n t( B l a c ka n dC [...]

4.1 OVERVIEW This section describes adjustm ents required when the printer is disassemb led and asse mbled after repair. Since this printe r has both a black and color he ad, it needs new adjustments not required for previous printers. Refer to the follo wing table to perform the appropriate adjustm ents. WARNING ❏ Always perform the adjustments [...]

4.1.1 Destination Data Writing Operation The setup value that specifies the printer destination is stored in the EEPROM on the C162 MAIN board. Therefore, this setup value must be written into the EEPROM when the MAIN board or EEPROM chip is replaced. CAUTION Before writing the destination data writing, set the interface to parallel. 1. Connect the[...]

4.1.2 Bi-D (Bidirectional Printing) Alignment Adjustm ent The bidirectional alignm ent is required when the printer mechanism , main board, or printhead (board) is replaced. Pe rforming this adjustment deter mines a compensation value to rectify any deviation in the print position. This de viation could be caused by the different pr int speeds, whi[...]

4.1.3 Head Gap Adjustment (Black and Color Head) The head gap adjustment is require d when the printer mecha nism, main board, or printhead (board) is replaced or diassembled. This adjustment calibrates the head drive timing between the black and color head. If this a djustment is not made, the vertical alignment will not be completed. 1. Connect t[...]

4.1.4 Black Head Angle Adjustment The black head angle adjustm ent is required when the black head is replaced or disassembled. If this adjustment is not correct, a white banding problem may o cc ur, or the color head timing may not match the black head timing. The followin g figure illustrates the black he ad angle adjustment. The black head a ngl[...]

1. Connect the PC to the target printe r, and turn the printer on. 2. Execute BASIC on the P C and run the program “VE Rxxx.BAS. ” 1. Destination Setting 2. Head Angle Confirmation Pa ttern Printing (Black Head Spacer Selection) 3. Head Vertical Position Confirmation 4. Head Gap Adjustment 5. Bi-D Adjustmen t 6. Internal Timer Reset 7. END 3. W[...]

7. Turn the printer power off now. 8. Manu ally move the carriage to the center while pressing the carriage lock lever, and remove the two ink cartridges. 9. Remove the r ubber cap covering the head screw at the side of color ink cartridge. Then loosen (but do not remove) 3 screws. (Refer to Figu re 4-6.) WARNING After replacing the spacer, always [...]

11. After replacing the angular spacer, reassemble the ink cartridge holder and reinstall the ink cartridges. Use the BASIC program to verify the angle of the black head. Confirm the angle by performing the steps 1 to 6 again, and if the angle is wrong, perform the adjustment again until the head angle is correct. WARNING ❏ The angular spacer com[...]

4.1.5 Black - Color Head Vertical Adjustment This adjustment calibrates the v ertical position between the black head and the color head. Align the top nozzles (both nozzle #1 on the black head and nozzle #1 on the color head). You can make this adjustment by using only the linear spacers for the black h ead. This adjustment is required when the bl[...]

4. In Figure 4-10, the vertical position is correct when both the magenta line and the black line are aligned (as shown in position OK (0) ). If the vertical position is correct, turn off the printer. If the black and magenta lin es are not aligned, pe rform the vertical adjustment as described in step s 5-10. WARNING ❏ The number shown in the sa[...]

8. Change the linea r spacers (2 spac ers for the monochrome head only) with new ones, referring the figure below. (Replace linear spacers using tweezers to push the head base toward the rear.) 9. Rerun the BASIC program, and choose the “He ad Vertical Position Confirmation” by typing 3 and ENTER ; then confirm that the sample print is correc t[...]

4.1.6 Color Head Angle Adjustm ent The color head angle adjustm ent is required when the color head is rep laced or disassembled. If this adjustment is not corre ct, a white banding problem may occur, or the bla ck head timing may not match the color head timin g. The following figure illustrates the color head angle adjustment. The color hea d ang[...]

Angular spacers for the color head come in five thicknesses, each having its own shape. The following figure shows the relationship between the shape and thickness. Since the color head is not equipped with a linear sp acer, the angle adjustment is decided only by the angular spacer (specifically designed for the color head), w hich is placed under[...]

7. Remove the rubber cap covering the head screw at one side of color ink cartridge. Then loosen (but do not rem ove) 3 screws. (Refer to the figure be low.) 8. Replace the angular spacer on the left side with a new one, referring the figure below. (Replace the angular spacer using tweezers to push the head base toward the rear.) R ubber C ap Scr e[...]

9. Rerun the BASIC program and choose “Head Angle Confirmation Pattern” again by typing 2 and ENTER . Then verify that the confirm ation sample is correct. 10. If the sample is incorrect, repeat steps 5-9 until the upper lines in the sample are aligned with one another and the lower lines in the sample are e xactly equidistant to one another (a[...]

4.1.7 Platen Gap Adjustment This adjustment is required when the carriage unit is replaced or removed from the printer mechanism. Adjust the distance betwe en the printhead nose and the paper surface to 1.1 mm . 1. Attach a thickness gauge (commercially available) to the left side adjustment position on the paper guide plate, as shown in the figure[...]

6. Mov e the carriage manually to the right adjustme nt position and repeat step s 3 and 4, referring to Figures 4-18 and 4-19. 4.1.8 Internal Timer Reset Operation This operation is require d when the M-4A60 printer mechanism is replaced. The re are 6 timer s in this printer: 1. Refresh time r 2. Timer (monochrome and CMY) 3. Flushing leve l decis[...]

Chapter 5 Troubleshooting Table of Contents 5.1 OVERVIEW 5-1 5.2 UNIT LEVEL TROUBLESHOOTING 5-3 5.2.1 Printer Does Not Operate at Power on . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 5.2.2 Error is Detected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 5.2.3 Failure Occurs During Printing . .[...]

Rev.-A 5-i[...]

5.1 OVERVIEW The printer m ay exhibit different symptoms for the same pr oblem, which makes troubleshooting more difficult. However, this section provides sim ple and effective ways to facilitate troubleshooting. The following flowchart illustrates the main steps of the troubleshooting process. Table 5-1. Motor Resistances Motor Resistance Range Te[...]

Table 5-3. Error Codes Error Status LED Recovery Data Paper Out No Ink Cartridge Economy Condensed P ause Paper out On On Load paper in the tray, press Load/ Eject , and then the Pause button. No ink cartridge On O n Install the new ink cartridge and press the Pause button. Paper jam Blinks Load paper and press Pause and Load/Eject buttons. Mainten[...]

5.2 UNIT LEVEL TROUBLESHOOTING When a prob lem occurs, yo u can identify the defective unit based o n the symptoms ex hibited. The table below lists the symptoms of certain problems. Once the problem is identified, refer to the flowchart that corresponds to the problem. Table 5-4. Symptom and Problem Symptom Problem Flowchart No. Printer does not o[...]

5.2.1 Printer does not operate at power on. START END YES NO YES NO YES NO YES NO YES NO Is the AC input voltage correct? Use t he c o rr ect inp ut vo lta ge. Has fu se (F 1) on the C13 7 PSB/ PSE blown? Repl ace the f use and di s connect CN 5 on the C 162 MAIN b oard. Ch eck the ou tput voltag e of t he C 137 PSB/PSE at CN 2. Does the fuse bl ow[...]

5.2.2 Error is detected. START END END YES YES YES YES NO NO NO NO YES NO Identify the type of error indicated. (See Table 5 -3.) Carriage err or Turn t he pr i nte r off and try to mo ve th e carriage manu ally. Do es th e carr ia ge move sm oothl y? No ink cartriage Replace the ink cartridge with a new one. Check CR m otor an d dri vers. If t hey[...]

5.2.3 Failure occurs during printing. Replace the C162 MAIN board. START END END YES YES YES NO NO NO YES YES YES NO NO NO Run the self-test . Connect the cables correctly. Pe rform the c olor o r black h ead cleanin g . Adjust the bidirectional print alignment or readjust the head arrangement adjustment . (See Chapter 4.) See the section describin[...]

5.2.4 Printer does not feed the paper correctly. START END END YES YES NO NO YES YES NO NO YES NO Is paper loaded in the sheet feeder correctly? Load the paper correctly. Ve ri fy that the paper path i s cl ea r. Also c o n f ir m t hat th e r e are n o f o reig n ob j ect s t ha t m ay int e rf e r e wit h p ap er mo veme nt . Check the PF motor a[...]

5.2.5 Control panel operation is abnormal. START END YES YES NO NO END YES NO Connect the control panel correctly. Replace the control panel. Replace the C162 MAIN board. Is the control panel connected properly? Is the probl e m cor r ect ed ? Is the probl e m cor r ect ed ? Troubleshooting Stylus Pro XL 5-8 Rev. -A[...]

5.3 UNIT REPAIR - C137 PSB/PSE BOARD This section describes problems related to the power supply board (C137 PSB/PSE). The table below provides various sym ptoms, likely causes, and checkpoints. The checkpoints r efer to waveforms, resistances, and other values to check to evaluate the ope ration of each component. Table 5-5. Repair of the C137 PSB[...]

5.4 UNIT REPAIR - C162 MAIN BOARD This section describes the problems relate d to the main controller board (C162 MAIN). The table below provides various symptoms, like ly causes, and checkpoints. The checkpoints refer to waveforms, resistance, and other values to be checked to evaluate the ope ration of each component Table 5-6. Repair of the C162[...]

Table 5-6. Repair of the C162 MAIN (Cont.) Symptom Condition Cause Checkpoint S olution Carriage does not operate normally. The carriage does not operate at all. IC15 is defective. Check the output signal at pins 1, 8 or at 11, 18 o f IC15. Replace IC15. Self-test printing is abnormal. Self-test is not execute d. IC2 is defective. Check the output [...]

5.5 UNIT REPAIR - PRINTER MECHANISM (M-4A60) Any problems related to the printer mechanism should be repaired according to the troubleshooting procedures in Table 5-7. Table 5-7. Repair of the Printer Mechanism Symptom Condition Cause Checkpoint Solution The pump mechanism does not operate. The PF motor fails to rotate at power on. Foreign substanc[...]

Table 5-8. Repair of the Printer Mechanism (Continued) Symptom Condition Cause Checkpoint Solution Printing is not performed. The carriage moves, but no printing is performed. The head cable is disconnected. Check whether the head cable is disconnected. Reconnect the head cable. The head cable is defective. Replace the head cable to see if operatio[...]

Table 5-7. Repair of the Printer Mechanism (Cont.) Symptom Condition Cause Checkpoint Solution Paper is not fed normally. Pa per is not fed. Foreign substances are lodged in the paper path. Visually check the paper path. Remove any foreign substances. Paper feeding gears are defective. Visu ally check the gears. Replace defective gears. The paper f[...]

Chapter 6 Maintenance Table of Contents 6.1 PREVENTIVE MAINTENANCE 6-1 6.2 SERVICE MAINTENANCE 6-2 6 . 2 . 1 P r i n t h e a dC l e a n i n g ................ ............ ............ .. 6 - 2 6 . 2 . 2 W a s t eI n kD r a i nT a n kR e p l a c e m e n t.................... ........ 6 - 2 6.3 LUBRICATION AND ADHESIVE 6-3 LIST OF FIGURES Figure 6-1[...]

6.1 PREVENTIVE MAINTENANCE Although this printer is designed so that no specific maintenance is require d on a regular basis, it is recommended that you cle an the printer thoroughly whene ver you get a chance to do so. You ca n cle an: ❒ Outer case Use a soft, clean clot h, dampened with mild detergent, if necessary. ❒ Auto sheet feeder If the[...]

6.2 SERVICE MAINTENANCE Certain maintenance is required when the printer detec ts an error or when a decline in print quality is observed. 6.2.1 Printhead Cleaning If print quality deteriorates, cle an the printhead using the built-in printhead clea ning function. The printer also has an automatic printhead cleaning cycle to ensure the proper nozzl[...]

6.3 LUBRICATION AND ADHESIVES The printer must be lubric ated properly when it is disassembled for component repla cement, or if mechanical noise exceeds a certain lev el. EPSON recommends only the lubricants listed in the table below for this printer, both of which have been tested extensively and comply with the requirements of this printer mecha[...]

❒ Do not apply too much lubricant, as it may stain the mechanism as well as a cause a mechanism malfuncti on. Maintenance Stylus Pro Service Manual 6-4 Rev.A[...]

2 1 17 17 22 30 21 27 9 8 7 4 4 6 5 11 12 20 Figure 6-1. Lubrication Points and Adhesive Points (1) Stylus Pro Service Man ual Maintenance Rev.A 6-5[...]

16 (3) 19 18 18 14 14 28 10 3 1 1 2 2 1 1 2 2 Lubrication Point Adhesive Point Figure 6-2. Lubrication Points and Adhesive Points (2) Maintenance Stylus Pro Service Manual 6-6 Rev.A[...]

Appendix Table of Contents A.1 CONNECTOR SUMMARY A-1 A.2 CIRCUIT DIAGRAM A-7 A.3 CIRCUIT BOARD COMPONENT LAYOUT A-14 A.4 EXPLODED DIAGRAM A-18 List of Figures Figure A-1. Interconnection of Major Component . . . . . . . . . . . . . . . . . . . . . . . A-1 F i g u r eA - 2 . C 1 6 2M A I NB o a r dC i r c u i tD i a g r a m( 1 ) ............... ....[...]

A.1 CONNECTOR SUMMARY The figure below shows the interconnection between the major components of the Stylus Pro XL. CN1 CN2 C137 PSB/PSE C137 PNL C162 MA IN CN1 CN5 CN1 1 CN9 CN8 CN7 CN6 CN10 CN2 CN1 CN CN2 CN3 CN12 CN CN13 AC Input Parallel I/F Type B P ar a lle l I/F RS -4 22 Ser i al I/F PF Motor CR Motor AS F P l unge r Pri nthead U nit HP S en[...]

Table A-1. Connector Summary Board Locat ion Pin Description C162 MAIN CN1 36 Centronics parallel I/F CN2 36 Type B parallel I/F CN3 8 RS-422 serial I/F CN4 — There is no connec tor CN4 CN5 6 Power supply from PS board CN6 5 Carriage motor phase output CN7 5 PF/PM motor phase output CN8 2 P aper end sensor CN9 3 Carriage home p osition sensor CN1[...]

Table A-3. Connector Pin As signments — CN2 Pin I/O Name De scription 1-6 I +5 V Power supply for I/F drive 7 O TXD Transmit data 8 O REA DY Ready signal 9 I RXD Receive data 10 — NC Not connec ted 11 O RESET Reset signal 12 O INH Inhabit signal 13 O CMREQ Command request signal 14 O WRRDY Write ready signal 15 O RDREQ Read request signal 16 O [...]

Table A-6. Connector Pin As signments — CN6 Pin I/O Name Description 1 O CRA Phase A drive signal 2 O CR AP h a s e A drive signal 3 O CRB Phase B drive signal 4 O CR BP h a s e B drive signal 5 O CRCOM Carriage drive power (common v oltage) Table A-7. Connector Pin As signments — CN7 Pin I/O Name Description 1 O PFA Phase A drive signal 2 O PF[...]

Table A-11. Connector Pin Assignments — CN11 Pin I/O Name Description 1 — GND Ground 2 O BCLK Clock signal for black head 3 — GND Ground 4 O BLAT Latch signal for black head 5 — GND Ground 6 O BSI Black head serial data output 7 — GND Ground 8 O BCO Black cartridge out sensor 9 I +5 V Power supply for cartridge out sensor 10 — NC Not co[...]

Table A-14. Part No. Reference Table Ref.No. Description PPL Name 100 LOWER HOUSING HOUSING, LOWER 101 FOOT FOOT 102 LOWER SHIELD PL ATE SHIELD PLATE, LOWER 103 UPPER SHIELD PL ATE SHIELD PLATE, U PPER 104 P/S SHIELD PLATE SHIEL D PLATE, P/S 105 GROUNDING PLATE GROUNDING PLATE 106 PAPER SUPPORT COVER B CO VER, PAPER SUPPORT; B 107 UPPER HOUSING HOU[...]

Table A-14. Part No. Reference Table (Continued) Ref.No. Description PPL Name 200 MA IN BOARD (FOR USA, S.E. ASIA) BOARD ASSY., MAIN (FOR USA, S.E. ASIA) 200 MAIN BOARD (FOR EUROPE) BOARD ASSY., MAIN (FOR EUROPE) 300 POWER SUPPLY BOARD (FOR 120 V) BOARD ASSY., PO WER SUPPLY (FOR 120V) 300 POWER SUPPLY BOARD (FOR 220 V / 240 V) BOARD ASSY., PO WER S[...]

Table A-14. Part No. Reference Table (Continued) Ref.No. Descript ion PPL Name 520 REAR PAPER GUI DE PAPER GUIDE ASSY., REA R 521 PF ROLLER SUPPORT ROLLER , PF, SUPPORT 522 PF HOLDER SU PPORT HOLDER, PF, SUPPORT 523 TORSION SPRING, 5800 TORORSION SPRING, 5800 524 PE HARNESS HARNESS, PE 525 PF STEPPING MOTOR STEPPING MOTOR, PF 526 HP DETECTOR DETECT[...]

Table A-14. Part No. Reference Table (Continued) Ref.No. Description PPL Name 561 BK HEAD BASE BASE, HEAD, BK 562 YMC HEAD BASE BASE, HEAD, YMC 563 UPPER HEAD CABLE HOLDER HOLDER, HEAD CABLE, UPPER 564 LOWER HEAD CABLE HOLDER HOLDER, HEAD C ABLE, LOWER 565 BK CARTRIDGE LEVER LEVER ASSY., CARTRIDGE, BK 566 YMC CARTRIDG E LEVER LEVER ASSY., CART RIDG[...]

Table A-14. Part No. Reference Table (Continued) Ref.No. Description PPL Name 603 EXTENTION SPRING, 1.6 g EXTENTION SPRING, 1.6 604 COMPRESSION SPRING, 90 g CO MPRESSION SPRING, 90 605 TORSION SPRING, 15000 g TOR SION SPRING, 15000 606 TORSION SPRING, 6700 g TORSION SPRING, 6700 607 EXTENSION SPRING, 102 g EXTENSION SPRING, 102 608 COMPRESSION SPRI[...]

Table A-14. Part No. Reference Table (Continued) Ref.No. Description PPL Name 650 CBB SCREW (M3 × 12) C.B.B. SCREW (M3 × 12) 652 CBS SCREW (M3 × 8 F/UC) C.B.S. SCREW (M3 × 8F / U C ) 653 CPB SCREW (3 × 15 F/ZN) C.P .B. SCREW, 3 × 15, F/ZN 654 HEAD MOUNTING PRESSURE PLATE PRESSING PLATE, MOUNTING, HE AD 655 PF ROLLER ROLLER, PF 656 SPUR GEAR, [...]

EPSON[...]