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Epson 3800 - Stylus Pro Color Inkjet Printer, Service Manual

The Epson 3800 - Stylus Pro Color Inkjet Printer delivers high-quality prints with precision and clarity. With its user-friendly interface, accessing the printer's manual is hassle-free. Download the manual for free at manualshive.com to maximize your printer's potential and effortlessly navigate its impressive features and settings.

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EPSON Stylus Pro 3800/3800C/3850

Revision A

DISASSEMBLY & ASSEMBLY

Disassembly/Assembly Procedure (Group 2)

183

4.4.1.2  PULLEY, DRIVEN, ASSY.

1.

Remove the HOUSING, UPPER. 

(p106)

2.

Remove the ASF, ASSY. 

(p179)

3.

Remove the EXTENSION SPRING 28.38 from the each hook of the main frame 
and the HOLDER, PULLEY, DRIVEN. 

4.

Slide the HOLDER, PULLEY, DRIVEN to the right to disengage the two tabs, 
and remove the HOLDER, PULLEY, DRIVEN to the front. 

5.

Push down the PULLEY, DRIVEN, ASSY., to release the PULLEY, DRIVEN, 
ASSY. and the BELT, CR from the HOLDER, PULLEY, DRIVEN.

Figure 4-126.  Removing the EXTENSION SPRING 28.38 and HOLDER, PULLEY, DRIVEN

Figure 4-127.   Removing the PULLEY, DRIVEN, ASSY. 

Be sure to install the PULLEY, DRIVEN, ASSY. to the HOLDER, 
PULLEY, DRIVEN so that the protrusion on the shaft of the 
PULLEY, DRIVEN, ASSY. faces downward. 

Rear side

HOLDER, PULLEY, DRIVEN

EXTENSION SPRING 28.38

tabs

protrusion

Left front side

HOLDER, PULLEY, DRIVEN

PULLEY, DRIVEN, ASSY.

BELT, CR

Summary of Contents for 3800 - Stylus Pro Color Inkjet Printer

Page 1: ...EPSONStylusPro3800 3800C 3850 Large Format Color Inkjet Printer S SERVICE MANUAL SEIJ06007 ...

Page 2: ...is manual However should any errors be detected SEIKO EPSON would greatly appreciate being informed of them The above not withstanding SEIKO EPSON CORPORATION can assume no responsibility for any errors in this manual or the consequences thereof EPSON is a registered trademark of SEIKO EPSON CORPORATION General Notice Other product names used herein are for identification purpose only and may be t...

Page 3: ...N WORKING ON POWER SUPPLY AND OTHER ELECTRONIC COMPONENTS 4 WHEN DISASSEMBLING OR ASSEMBLING A PRODUCT MAKE SURE TO WEAR GLOVES TO AVOID INJURY FROM METAL PARTS WITH SHARP EDGES WARNING 1 REPAIRS ON EPSON PRODUCT SHOULD BE PERFORMED ONLY BY AN EPSON CERTIFIED REPAIR TECHNICIAN 2 MAKE CERTAIN THAT THE SOURCE VOLTAGES IS THE SAME AS THE RATED VOLTAGE LISTED ON THE SERIAL NUMBER RATING PLATE IF THE E...

Page 4: ...nal information for reference Connectors Routing ASP List Exploded Diagrams Circuit Diagrams Symbols Used in this Manual Various symbols are used throughout this manual either to provide additional information on a specific topic or to warn of possible danger present during a procedure or an action Be aware of all symbols when they are used and always read NOTE CAUTION or WARNING messages Indicate...

Page 5: ...Revision Status Revision Date of Issue Description A November 30 2006 First release ...

Page 6: ...8 Error Warning Statuses Displayed Indicated on by LCD LED 29 Chapter 2 OPERATING PRINCIPLES 2 1 Overview 36 2 2 Print Mechanism 40 2 3 Ink Supply Mechanism 41 2 3 1 Ink Flow Path 41 2 3 2 Ink Pressurizing Mechanism 41 2 3 3 Ink Change System 43 2 4 Cleaning Mechanism 44 2 5 Carriage Mechanism 46 2 5 1 Carriage Movement Mechanism 46 2 5 2 Platen Gap Adjustment Mechanism 47 2 6 Paper Feed Mechanism...

Page 7: ...5 Description of Adjustments 193 5 1 6 Tools for Adjustments 195 5 1 7 Adjustment Program Basic Operations 196 5 2 Mechanical Adjustment 198 5 2 1 PF Timing Belt Tension Adjustment 198 5 2 2 LD Roller Position Adjustment 200 5 2 3 PG Position Adjustment 201 5 3 Standard Adjustment 203 5 3 1 RTC USB ID 203 5 3 2 Head Rank ID 204 5 3 3 Print Head Slant Adjustment PF 205 5 3 4 Print Head Slant Adjust...

Page 8: ...EPSON Stylus Pro 3800 3800C 3850 Revision A 8 Chapter 7 APPENDIX 7 1 Connectors 263 7 2 Cables Connection Layout 265 7 3 ASP List 267 7 4 Exploded Diagrams 269 7 5 Circuit Diagrams 278 ...

Page 9: ...C H A P T E R 1 PRODUCTDESCRIPTION ...

Page 10: ... complementary colors and 2 complementary blacks 80ml size injection volume new ink cartridge Automatic switching between black ink modes Photo black and Matte black Requires no user intervention and ink used during the conversion is remarkably reduced Two manual paper feeders are provided in addition to the ASF Auto Sheet Feeder Rear manual feeder FA paper Front manual feeder Board paper up to 1 ...

Page 11: ...pi x 1440 dpi Smallest dot size 3 5 picoliters Dot size Refer to Table 1 2 Printing function Borderless printing Silent paper feeding Automatic bottom processing L 4 x 6 Photo high speed printing Automatic adjustment function Auto nozzle check Auto Bi d adjustment Printing speed area Alphanumeric characters Refer to Table 1 3 Graphic mode Refer to Table 1 4 Table 1 1 Cartridge Alignment Sequence R...

Page 12: ...0Hz Input frequency range 49 5 to 60 5Hz Rated current 0 6 A 0 3 A Power consumption Operating Approx 25 W Approx 25 W Low power mode Approx 5 W Approx 5 5 W S W turned OFF Approx 0 3 W Approx 0 4 W Insulation resistance 10 M or more between AC line and chassis at 500 VDC Dielectric strength 1 0 kVrms AC for 1 min or 1 2 kVrms AC for 1 sec between AC line and chassis Leak current 0 25 mA or less C...

Page 13: ...moved If the print head is not capped with the power turned off turn the printer on with the ink cartridges installed then turn it off after confirming the print head is capped Item Target Operating life of the printer Until any one of the following conditions is met 12 000 pages A2 plain paper fine mode 1 600 000 paths carriage movement 5 years MPBF Black 300 pages or more 1 Color 150 pages or mo...

Page 14: ...the methods are shown in the table below For paper type and feeder capacity refer to 1 3 3 Paper Support p15 Item Specification Paper feed method Friction feed Minimum pitch of paper feed 2 94 Pm 1 8640 inch Paper feed speed 25 4 mm 1 inch when line feed 333 msec 3 inch sec Paper Feed Method Paper Size Thickness mm Width mm Length mm Standard paper mm ASF 89 to 431 8 127 to 950 L 4 x6 to A2 USC 0 ...

Page 15: ...to Paper 4 x 6 102 x 152 ASF 20 P Letter 216 x 279 ASF 20 P A4 210 x 297 ASF 20 P A3 297 x 420 ASF 10 P S B A3 329 x 483 ASF 10 P A2 420 x 594 ASF 1 P Premium Luster Photo Paper Letter 216 x 279 ASF 20 P A3 297 x 420 ASF 10 P S B A3 329 x 483 ASF 10 P USC 432 x 559 ASF 1 P Singleweight Matte Paper S B A3 329 x 483 ASF 50 NA M Photo Quality Ink Jet Paper KANZAN for EU A4 only ESF for others A4 210 ...

Page 16: ...e set to zero under special conditions Because the printer detects tilt of loaded paper in a range of 3 mm at both left and right sides an image bleeds off both left and right edges of paper by 3 mm each at borderless printing However if the distance between the paper edges and the platen sponge width is less than 3 mm the bleeding margins are adjusted to less than 3 mm within the range of 0 mm a ...

Page 17: ... x 720 dpi VSD2 280cps Super Photo 2880 dpi 2880 x 1440 dpi VSD3 280cps ISV Square Resolution Mode 1440 x 1440 dpi VSD2 280cps 1 2880 x 2880 dpi VSD3 280cps 2 Table 1 5 Borderless Printing Available Paper Sizes Paper Size Displayed by Driver Borderless Print Letter 8 2 1 x 11 in Available Legal 8 2 1 x 14 in NA Half Letter 5 2 1 x 8 2 1 in NA US B 11 x 17 in Available US C 17 x 22 in Available A6 ...

Page 18: ...home position by 8 m by changing the appropriate setting Table 1 6 Borderless Printing Margins Bleed L 4 x 6 16 9 Wide 5 x 7 8 x 10 A4 Letter 11 x 14 A3 A3 A2 USC Top 1 34mm 19dot 2 96mm 42dot 3 32mm 47dot Left Right 2 54mm 36dot 3 46mm 49dot 4 52mm 64dot Bottom 2 54mm 36dot 4 02mm 57dot 4 52mm 64dot 5 01mm 71dot 3 5m max 5mm max 5mm max Width direction printable area Printable area Paper width Pa...

Page 19: ... D mm Weight 18 5 kg excluding ink cartridges including Maintenance cartridge 19 8 kg including ink cartridges 1 5 2 Part Names Figure 1 6 Parts Names 257 mm 550 mm 684 mm 90 mm 293 mm 376 mm 1040 mm 100 mm Maintenance Cartridge Cover Paper Support AC Connector USB Interface Connector Network Interface Connector Edge Guide Auto Sheet Feeder Paper Support Edge Guide Top Cover Ink Cover Board Paper ...

Page 20: ...oves to the next menu item Descent 4 Back Left Moves to the previous menu item Ascent 5 Ink Cover Open Up Unlocks the Ink Cover Set Value 3 4 6 7 B A 1 2 5 Back Left Ink Cover Open Up Power Cancel Reset Enter Paper Feed Down Menu Right Power LED Paper status LED Ink status LED C 6 Paper Feed Down When paper is set ASF Ejects the paper Manual Rear Backfeeds the paper Manual Front Ejects the paper W...

Page 21: ...ated by the CUSTOM PAPER function in the panel setting menu is displayed 3 Paper type For Cut sheet only This icon is displayed when the number of paper except STANDARD paper created by the CUSTOM PAPER function in the panel setting is selected 4 Platen Gap The platen gap setting made by the PLATEN GAP function in the panel setting menu is indicated 5 Ink Cartridge Status The remaining amount of i...

Page 22: ...n genuine ink cartridge s is used Ink Low Ink Out Indicator The indicators below is displayed when Ink becomes Low or Out Icons Status STANDARD is selected NARROW is selected WIDE is selected WIDER is selected WIDEST is selected 1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 3 0 Table 1 7 Relation between Counters and Remaining Ink No Remaining Ink No Remaining Ink No Remaining Ink No Remaining ...

Page 23: ...enance Cartridge is indicated as shown below Figure 1 12 Maintenance Cartridge Status Table 1 8 Relation between Counters and Remaining Ink No Free Space No Free Space No Free Space 1 96 100 9 58 61 17 20 23 2 91 95 10 53 57 18 15 19 3 86 90 11 48 52 19 10 14 4 81 85 12 43 47 20 5 9 5 77 80 13 39 42 21 1 4 6 72 76 14 34 38 22 0 7 67 71 15 29 33 23 Full 8 62 66 16 24 28 ...

Page 24: ...ing is required or not AUTO Prints a nozzle check pattern firmware version usage count of paper and ink and free space in the maintenance cartridge The ink mark sensor scans the printed check pattern and cleaning is automatically carried out if it is judged necessary STATUS SHEET PRINT Prints information on the printer status NETWORK STATUS SHEET PRINT Prints information on the network status JOB ...

Page 25: ... the printable area The amount increases decreases by the selected percentage of one meter 0 7 to 0 7 PAPER FEED ADJUST B 0 00 Sets paper feed amount for the bottom area out of the printable area The amount increases decreases by the selected percentage of one meter 0 7 to 0 7 DRYING TIME 0 0 SEC Sets a time period to stop the print head movement for drying ink 0 0 SEC to 10 0 SEC MAINTENANCE BLAC...

Page 26: ...formed When the PANEL DEFAULT in the maintenance mode is performed ENABLE IP ADDRESS SETTING AUTO Select the settings for the IP address to use When PANEL is selected the settings in IP SN DG SETTING are enabled PANEL PING IP SN DG SETTING Set the IP address Subnet mask and default gateway APPLE TALK ON Enables ON disables OFF AppleTalk OFF MS NETWORK ON Enables ON disables OFF MS NETWORK OFF BONJ...

Page 27: ...dle 2 1 Large 2 1 WIDEST Minimum 2 1 Small 2 1 Middle 2 1 Large 2 1 0 9mm to 1 5mm 3 5 Table 1 11 Firmware Version Indication Item Explanation o0 A code assigned to each printer Special version is assigned to 0 zero XXXX The version of the firmware installed on the printer xx xx The version of the network firmware I A code assigned by product The code of the printer is 8 B When the business system...

Page 28: ...E MENU LIST Menu Item Settings Bold default Explanation LANGUAGE ENGLISH Select the language to be displayed on the LCD panel JAPANESE FRENCH GERMAN ITALIAN PORTUGUE SPANISH DUTCH UNIT METRIC Select a unit of length to be used for various length information FEET INCH DEFAULT PANEL EXECUTE All settings made in the following menus are returned to their default PRINTER SETUP menu PRINTER STATUS menu ...

Page 29: ...4 FATAL ERROR CR locked Error CARRIAGE LOCKED RELEASE THE CARRIAGE LOCK Light Blink Blink 5 PAPER JAM Fatal Error Error PAPER JAM CLEAR JAMMED PAPER SEE PRINTER GUIDE FOR INSTRUCTIONS Light Blink Blink 6 Timer IC Reset Clearing NVRAM Please wait PLEASE WAIT Light Light Light 7 Updating F W at normal startup UPDATING FIRMWARE Blink Off Off 8 Canceling including Job Cancel RESETTING PLEASE WAIT Ligh...

Page 30: ...NK REPLACE INK CARTRIDGE WITH A NEW ONE Light Off Light 19 Maintenance Cartridge CSIC Read Write Error Error MAINTENANCE CARTRIDGE ERROR REPLACE THE CARTRIDGE Light Off Light 20 Not GENUINE maintenance cartridge error Error MAINTENANCE PLEASE USE GENUINE EPSON CARTRIDGES Light Off Light 21 Not GENUINE maintenance cartridge error Confirmation 1 Error MAINTENANCE NON GENUINE CARTRIDGE MAY NOT PERFOR...

Page 31: ...Error FRONT SLOT CLOSED OPEN THE FRONT MANUAL FEED SLOT Light Light Off 29 No Ink Cartridge Error NO INK CARTRIDGE INSTALL INK CARTRIDGE Light Off Light 30 Ink Cartridge CSIC Read Write Error Error INK CARTRIDGE ERROR REPLACE CARTRIDGE Light Off Light 31 Not GENUINE ink cartridge error Error INK CARTRIDGE PLEASE USE GENUINE EPSON INK CARTRIDGE Light Off Light 32 Not GENUINE ink cartridge error Con...

Page 32: ... Inspection Error PAPER ERROR PRESS THE DOWN BUTTON LOAD PAPER CORRECTLY Light Blink Off 42 Borderless Printing Error Error BORDERLESS ERROR PRESS_THE DOWN BUTTON LOAD THE CORRECT SIZE PAPER Light Blink Off 43 Paper Discharge Failed Error Cut Sheet Paper Remove paper by paper discharge key Error PAPER EJECT_ERROR PRESS THE DOWN_BUTTON AND REMOVE PAPER Light Blink Off 44 Blank Sheet Discharge Multi...

Page 33: ...ROR PRESS THE DOWN BUTTON AND REMOVE THICK PAPER Light Light Off 52 During Initialization PLEASE WAIT Blink Off Off 53 During Sequence PLEASE WAIT Blink Off Off 64 Paper Initial Trigger Waiting Status No waiting time READY Light Off Off 55 Paper Initial Trigger Waiting Status Auto loading READY Light Off Off 56 Paper Setting Error Error PAPER SETTING ERROR CHECK PAPER SOURCE_IN THE DRIVER SETTINGS...

Page 34: ...E THE MAINTENANCE COVER Light Off Blink 64 Maintenance Cartridge Low Warning MAINTENANCE CARTRIDGE IS NEARLY FULL Light Off Blink 65 Printing PRINTING Blink Off Off 66 Analyzing READY Blink Off Off 67 Printable Idling READY PHOTO_BLACK Light Light Light No Error Warning Status Error or Warning Illustration on LCD Message on LCD LED Power Paper Status Ink Status ...

Page 35: ...C H A P T E R 2 OPERATINGPRINCIPLES ...

Page 36: ... is supplied from the cartridges to the print mechanism Main Components Ink Cartridge Ink Cartridge Holder Damper Pressure Pump Ink change system 2 4 Cleaning Mechanism Explains how the print head is cleaned Main Component Pump Cap Unit 2 5 Carriage Mechanism Explains how to move the Carriage Unit Main Components CR Motor CR Scale Timing Belt CR Encoder 2 6 Paper Feed Mechanism Explains how paper ...

Page 37: ... counter information Generates power voltages used by the logic circuits from 42 V supplied from the power supply board Power supply board C635 PSB PSE Generates power system power voltage 42 V from the AC power supply Panel board C635 PNL Printer operations various settings Shows printer status and various setting values on the LCD Indicates printer status by the LED Sub board C635 SUB Relays con...

Page 38: ...5 Ink cover unlock solenoid Ink cover unlock mechanism Type DC solenoid Voltage 42 VDC 5 Pressure pump motor Pressure pump Type DC motor Voltage 42 VDC 5 Ink change motor Ink change system Type DC motor Voltage 42 VDC 5 Pump motor Pump cap unit Type 4 phase 48 pole PM stepping motor Voltage 42 VDC 5 CR motor Carriage unit Type DC motor Voltage 42 VDC 5 APG motor Platen gap mechanism Type 4 phase 9...

Page 39: ...t Voltage 3 3 VDC 5 Ink cartridge sensor CSIC that stores ink cartridge information Type CSIC Voltage 3 3 VDC 5 PG origin sensor Detects the origin position of the platen gap Type Transmissive photo interrupter Voltage 3 3 VDC 5 v Ink change sensor Detects the state of the black ink switch lever Type Mechanical contact Voltage 3 3 VDC 5 Ink mark sensor Auto Bi D adjustment Auto Uni D adjustment Au...

Page 40: ...hind the print head is shown below Printing method On demand ink jet Nozzle configuration 180 nozzles x 8 rows 1440 nozzles Figure 2 4 Nozzle Configuration DRIVE WAVEFORMS The following four drive waveforms are used to create four print modes Paper Feed Direction Carriage Moving Direction Table 2 4 Nozzle Rows and Colors Nozzle Row Color A Magenta B Cyan C Photo Black Matt Black D Yellow E Light L...

Page 41: ...ink pack to the print head This ink pressurizing mechanism consists of a pressure pump unit installed in an ink supply mechanism and tightly sealed ink cartridges Air pumped into the tightly sealed ink cartridge from the pressure pump unit squashes the ink pack in the cartridge causing the ink inside the pack to be transferred to the print head Figure 2 6 Ink Pressurizing Mechanism Ink Cartridge P...

Page 42: ... the pressurizing state is detected Regulator Stops applying pressure when the power is off or during stand by Activated by the pressure pump motor through the clutch The regulator opens the valve to reduce pressure Figure 2 8 Pressure Pump Unit Combination Gear 18 39 Clutch Spur Gear 24 5 Spur Gear 22 Regulator Pressure pump motor Accordion Unit Reducing pressure Applying pressure CW rotation CCW...

Page 43: ...nk flow path Ink change system consists of an ink change motor selection cam selection lever and ink change sensor The following describes the mechanism 1 Drive of the ink change motor rotates the selection cam Ink change sensor detects the rotation angle of the cam 2 The selection lever moves as the selection cam rotates 3 The protruded end of the selection lever pushes the selection pin and the ...

Page 44: ...ock operates in synchronization with the cap unit When the carriage unit moves to the home position carriage lock moves up together with the cap unit and lock the carriage unit Figure 2 12 Cap Unit Carriage Lock Mechanism Table 2 6 Pump Motor Functions Mechanism CCW CW Cap Unit Open Uncapping Close Capping Pump Pump release Pump suction Head Cleaner Wiper reset back to the home Wiper set moves to ...

Page 45: ... rotation of the pump motor moves the conveyance roller away from the pressing position Figure 2 13 Pump Unit Mechanism Head Cleaner The head cleaner wipes off ink dirt or the like from the surface of the head nozzles The CW rotation of the pump motor moves the head cleaner to the wiping position Figure 2 14 Head Cleaner Mechanism To Waste Ink Pad Head Nozzle Conveyance Roller Combination Gear 15 ...

Page 46: ...arriage unit CR motor timing belt carriage guide shaft CR scale and CR encoder Rotational drive of the CR motor is transmitted to the carriage unit through the timing belt and the carriage unit moves left and right along the carriage guide shaft The CR encoder installed on the back of the carriage unit reads the jagged surface of the CR scale and sends the read value to the main board Position and...

Page 47: ...osition as the origin and changes the platen gap according to the number of pulses from the origin Figure 2 16 Drive Transmission Path The relation between the printer status and the platen gap amount is described below Figure 2 17 Platen Gap Adjustment Mechanism Table 2 7 PG Positions in Operations Operation PG At power ON 1 2 Cleaning starts 1 5 Capping Capping is done in the current PG Board pa...

Page 48: ... to the ASF to support thicker paper The following figures show the paper feed paths Figure 2 18 Paper Path of ASF Rear Manual Bypass Figure 2 19 Paper Path of Front Manual Bypass Paper Feeding Thickness Type ASF Auto Sheet Feeder 0 08 to 0 27 mm See 1 3 3 Paper Support p 15 Rear Manual Bypass 0 29 to 0 5 mm Fine Art Paper Front Manual Bypass 1 2 to 1 5 mm Heavy paper like cardboard 1 2 3 1 2 3 ...

Page 49: ...1 Start of the paper loading operation The ASF motor moves to rotate the LD roller shaft 2 Feeding paper to the paper loading position 2 1 The LD roller shaft rotates to release the lever that presses the paper anti slip tab and the tabs go down Figure 2 20 Lowering the Paper Anti slip Tab 2 2 The LD roller shaft rotates to release the hopper actuating the cam that presses the hopper and the hoppe...

Page 50: ... When the hopper actuating cam presses the hopper further in synchronization with the rotation of the LD roller left and right paper guides that regulate the paper width are extended releasing the back end of paper Figure 2 23 Releasing the Back End of Paper 8 Standing by The hopper returns to the stand by position and ends the paper loading operation Figure 2 24 ASF Drive Mechanism Figure 2 25 AS...

Page 51: ...F roller starts to transport the paper FRONT MANUAL BYPASS The status of the board paper tray that is used for the front manual feeding is detected by the leaf switch The leaf switch is moved by the Board Paper Guide Cam which moves together with the board paper tray and according to the switch position the board paper tray status is detected Figure 2 26 Board Paper Tray Open Sensor Board Paper Tr...

Page 52: ...ugh the combination gear When the release lever of the paper guide release shaft presses down the back end of the paper guide upper assy the paper guide upper assy separates from the PF roller When the release motor rotates reversely the paper guide upper assy makes contact with the PF roller The release sensor installed in the release unit and the light shielding plate detects the contact conditi...

Page 53: ...chanism Paper Guide Release Shaft Paper Guide Upper Assy Paper Guide Upper Assy Light shielding Plate Release Sensor Release Motor Spur Gear 20 4 Combination Gear 8 22 986 Combination Gear 9 6 22 Spur Gear 22 Combination Gear 8 22 Spur Gear 22 B Combination Gear 22 32 4 PF Roller Holding status Releasing status ...

Page 54: ...ale PF encoder PF roller front and rear paper eject rollers and star wheels The mechanism transports papers fed from the feeders and ejects them from the front of the printer Figure 2 29 Drive Transmission Path PF Motor PF Motor PF Timing Belt Combination Gear PF Drive Spur Gear 14 4 Spur Gear 68 Front Paper Eject Roller Spur Gear 31 5 Rear Paper Eject Roller ...

Page 55: ...LES Paper Feed Mechanism 55 Figure 2 30 Paper Feed Mechanism Frame EJ Assy Star Wheel Rear Paper Eject Roller PF Encoder Spur Gear 68 Spur Gear 31 5 PF Scale Combination Gear PF Drive PF Timing Belt PF Motor PF Roller Paper Front Paper Eject Roller Spur Gear 14 4 ...

Page 56: ...orrective actions The Ink mark sensor is used for the following adjustments Auto Bi D Adjustment The sensor scans predetermined patterns printed for the adjustment and detects the highest density pattern among them According to the detected result the printer calculates Bi D correction values automatically Auto Uni D Adjustment The sensor scans predetermined patterns printed for the adjustment and...

Page 57: ...to open the cover is performed the solenoid is energized and the lock is released The solenoid unit is equipped with a switch sensor that detects opening closing state of the cover Figure 2 31 Ink Holder Cover Open Close Mechanism MAINTENANCE CARTRIDGE COVER OPEN DETECTION To keep the maintenance cartridge from being removed during printing a switch sensor detects opening closing state of the cove...

Page 58: ...s buffers work areas Capacity 256Mbit Number of pieces two RTC9824 IC9 RTC complex circuit Reset timer EEPROM complex IC E09A54RA IC11 Printer driver A6628SEDT IC7 IC13 Motor driver A6627STPT IC6 Motor driver BCM5980A2KFBG IC10 Ethernet 10 100BASE TX circuit Flash ROM 32Mbit SDRAM 64Mbit x 2 installed Custom ASIC E01A68C IC15 Custom ASIC E09A54RA IC11㧕 Ethenet 10 100BASE TX BCM5980A2KFBG IC10 A662...

Page 59: ...it outputs the rated voltage Power OFF 3V or less The PS unit is instantly shut off Energy Save Signal ESAVE Normal Operation 39 9 to 44 1 V The PS unit outputs the rated voltage Power Saving Operation 15V Typ It takes less than 500 msec to recover from the power saving mode to the rated voltage Overvoltage Detection Signal OVP Detection of overvoltage 0 V Power is shutoff The power is shut off wh...

Page 60: ...r is used to perform the color measurement of the printed pattern 2 Writing the correction value Correction values are automatically calculated based on the result of the color measurement and stored in the NVRAM on the main board 3 Reflecting the correction value Every time the printer makes a print the printer driver reads out the correction values from the NVRAM Each ink droplet weight and the ...

Page 61: ...C H A P T E R 3 TROUBLESHOOTING ...

Page 62: ...When smudges appear on printed pages clean the rubber rollers in the printer mechanism if it solves the problem 8 The rubber rollers in the printer mechanism are engaged correctly showing no signs of wear 9 Initialize the NVRAM on the C635 main board reset the user defined panel settings to their factory default if necessary Execute the DEFAULT PANEL in the Maintenance mode 3 1 2 Troubleshooting P...

Page 63: ...A maintenance cartridge CSIC read write error has occurred p68 MAINTENANCE COVER OPEN CLOSE THE MAINTENANCE COVER The maintenance cartridge cover is open p68 PAPER FEED ERROR REMOVE PAPER AND LOAD PAPER CORRECTLY Failed to feed paper into the printer p68 Error PAPER FEED ERROR LOAD PAPER CORRECTLY AND PRESS PAPER FEED BUTTON Failed to feed board paper into the printer p69 PAPER JAM REMOVE PAPER A ...

Page 64: ...artridge is not an EPSON genuine one Confirmation 1 p71 Table 3 1 List of Panel Messages Category Message on LCD Description Ref Page Error INK CARTRIDGE THIS MAY VOID EPSON S WARRANTY DO YOU ACCEPT THIS ACCEPT DECLINE The ink cartridge is not an EPSON genuine one Confirmation 2 p71 INK CARTRIDGE REPLACE INK CARTRIDGE The ink cartridge is empty p71 INK COVER OPEN CLOSE THE INK COVER The ink cartri...

Page 65: ... the result detected by the ink mark sensor could not determine or the determined value fell outside the adjustable range p73 CLEANING ERROR PRESS THE CANCEL RESET BUTTON Clogging nozzles are detected by the nozzle check after running a head cleaning p73 CLEANING ERROR PRESS THE DOWN BUTTON AND REMOVE THICK PAPER A head cleaning was attempted with a board paper loaded or before printing when the P...

Page 66: ...it does not interfere with printing operation REMEDIES The following tables explains the Warning messages and remedies Table 3 2 Remedies for Warning Messages Message on LCD Description Remedy MAINTENANCE REQUEST XXXX See MAINTENANCE Request XXXX on page 67 INK LOW The remaining ink is low Prepare a new ink cartridge MAINTENANCE CARTRIDGE IS NEARLY FULL The free space of the maintenance cartridge ...

Page 67: ...1 NA NA 0 0 0 NA NA 0 0 RSVD 0008 The RTC backup battery becomes exhausted Replace the battery with a new one and execute RTC initialization using the Adjustment Program 0 0 NA 0 NA NA 1 0 0 NA NA 0 0 RSVD 0040 The pump counter has reached the specified value Replace the pump cap unit PUMP CAP ASSY with a new one and clear the counter using the Adjustment Program 0 0 NA 0 NA NA 0 1 0 NA NA 0 0 RSV...

Page 68: ...he paper feed path and remove any scrap of paper or foreign matter NO MAINTENANCE CART INSTALL THE MAINTENANCE CARTRIDGE No maintenance cartridge has been installed Install a maintenance cartridge The maintenance cartridge cannot be recognized by the printer Remove the maintenance cartridge and reinstall it correctly If this does not solve the problem replace the cartridge with a new one The print...

Page 69: ...ion is observed remove it MAINTENANCE CARTRIDGE NEARLY FULL REPLACE THE CARTRIDGE The maintenance cartridge is near capacity The available space may not be enough to continue the job Replace the maintenance cartridge with a new one NOT ENOUGH INK REPLACE INK CARTRIDGE WITH A NEW ONE The ink cartridge is near empty Replace the ink cartridge with a new one MAINTENANCE PLEASE USE GENUINE EPSON CARTRI...

Page 70: ...Board Paper Tray front feed slot is closed when the tray is selected as the paper source Open the Board Paper Tray front feed slot The Board Paper Tray Open sensor is not connected Check the connection between the sensor and the main board and fix any abnormality The Board Paper Tray Open sensor is broken Replace the sensor FRONT SLOT CLOSED OPEN THE FRONT MANUAL FEED SLOT The Board Paper Tray fro...

Page 71: ...mmand Cancel the job and reset the printer by pressing the Cancel Reset button for more than three seconds Check if the correct printer driver has been installed on the PC If not install the correct driver PAPER SKEW PRESS THE DOWN BUTTON LOAD PAPER CORRECTLY Paper skew was detected when paper was fed from the rear or front manual tray Press the Paper Feed Down button to eject the paper PAPER ERRO...

Page 72: ...ASSY on page 185 PAPER FEED ERROR LOAD PAPER CORRECTLY PRESS THE DOWN BUTTON Sheets of paper stacked on the ASF became misaligned while performing duplex printing Reset the ejected blank paper and press the Paper Feed Down button PAPER REMOVE REMOVE PAPER FROM THE REAR The paper cannot be ejected normally for some reasons Remove the paper The PE sensor is broken Replace the PE sensor PAPER DETECTO...

Page 73: ...o clear the error and retry the head cleaning CLEANING ERROR PRESS THE DOWN BUTTON AND REMOVE THICK PAPER Head cleaning was attempted when board paper had been fed Remove the board paper and close the Board Paper Tray PAPER SETTING ERROR CHECK PAPER SOURCE IN THE DRIVER SETTINGS AND LOAD PAPER CORRECTLY The ASF is specified as the paper source of the received job but paper has been loaded on the f...

Page 74: ... 11 2 BOARD ASSY ENCODER on page 172 Replace the CR scale SCALE CR See 4 3 7 1 SCALE CR on page 130 The carriage unit does not operate due to a CR motor failure or some reasons Move the carriage unit manually to check if it moves smoothly and fix any abnormality Replace the CR motor MOTOR ASSY CR See 4 3 5 3 MOTOR ASSY CR on page 121 1121 CR reverse error An abnormal operation reveres movement of ...

Page 75: ...lock set error The printer cannot lock the carriage unit 1130 Overspeed error PID load positioning The carriage speed detected by the CR encorder exceeded the limit Replace the CR motor MOTOR ASSY CR See 4 3 5 3 MOTOR ASSY CR on page 121 Replace the main board BOARD ASSY MAIN See 4 3 4 1 BOARD ASSY MAIN on page 112 1131 Drive timeover error PID load positioning The condition to stop the CR motor i...

Page 76: ...OR RELEASE ASSY on page 167 1222 Drive timeover error The condition to stop the PF motor is not satisfied when the PF motor has driven for a predetermined time period Replace the PF motor MOTOR RELEASE ASSY See 4 3 10 3 MOTOR RELEASE ASSY on page 167 Replace the main board BOARD ASSY MAIN See 4 3 4 1 BOARD ASSY MAIN on page 112 1220 Overspeed error The motor speed detected by the PF encorder excee...

Page 77: ...nk cartridge Replace the pressure pump PURESSURE PUMP ASSY The home position of the Pressure pump cannot be detected because the ridges of the accordion unit are adhered to each other or the Pressure pump home sensor is broken Replace the pressure pump PURESSURE PUMP ASSY See 4 3 12 1 PRESSURE PUMP ASSY on page 176 Replace the main board BOARD ASSY MAIN See 4 3 4 1 BOARD ASSY MAIN on page 112 1401...

Page 78: ...NK SYSTEM ASSY on page 151 1432 Ink selector drive timeover Changing the ink path by the Ink Selector cannot be completed during a predetermined time period due to a malfunction of the Ink Selector its sensor or motor Replace the Ink Selector INK SYSTEM ASSY and reset the counter using the Adjustment Program See 4 3 9 3 INK SYSTEM ASSY on page 151 1434 Ink cover unlock error The cartridge cover ca...

Page 79: ... 4 3 12 1 PRESSURE PUMP ASSY on page 176 Replace the main board BOARD ASSY MAIN See 4 3 4 1 BOARD ASSY MAIN on page 112 1550 Borderless print ink pad error The counter for the waste ink used at the bleed off margins for borderless printing has reached its upper limit Replace the ink pad for borderless print POROUS PAD INK WASTE BOX RIGHT LEFT and reset the counter using the Adjustment Program See ...

Page 80: ... to install the firmware Reinstall the firmware Replace the main board BOARD ASSY MAIN See 4 3 4 1 BOARD ASSY MAIN on page 112 The FlashROM is broken Replace the main board BOARD ASSY MAIN See 4 3 4 1 BOARD ASSY MAIN on page 112 2009 FLASH SUM CHECK error Failed to install the firmware Reinstall the firmware Replace the main board BOARD ASSY MAIN See 4 3 4 1 BOARD ASSY MAIN on page 112 The FlashRO...

Page 81: ... board BOARD ASSY MAIN See 4 3 4 1 BOARD ASSY MAIN on page 112 There is something wrong with the firmware Install a normal firmware FXXX CPU related error The main board is broken Replace the main board BOARD ASSY MAIN See 4 3 4 1 BOARD ASSY MAIN on page 112 There is something wrong with the firmware Install a normal firmware Error Code Error Name Description Remedy ...

Page 82: ...fired normally due to a failure of the parts listed in the Remedy column Inspect the following parts and fix any abnormality Pump Cap Unit PUMP CAP ASSY See 4 3 9 1 PUMP CAP ASSY on page 148 The tube of the CAP ASSY PUMP is disconnected The tube of the CAP ASSY PUMP has become flat The cap rubber is broken The cleaning blade is broken or some foreign substances have adhered to the blade There is s...

Page 83: ...t See Chapter 5 ADJUSTMENT Check the PF scale SCALE PF for any dirt and clean it if any dirt is observed Check the PF encoder BOARD ASSY ENCODER PF for scratch dirt and clean it if any dirt is observed Replace the PF encoder BOARD ASSY ENCODER PF See 4 3 6 2 ENCODER PF ASSY on page 126 The print head has not been adjusted properly Carry out the Print Head Slant Adjustment PF and the Print Head Sla...

Page 84: ... the CR timing belt and replace it if worn Check the CR motor is correctly installed Image is grainy The adjustments have not been carried out properly Carry out the Print Head Slant Adjustment PF See Chapter 5 ADJUSTMENT Carry out the Print Head Slant Adjustment CR See Chapter 5 ADJUSTMENT Carry out the PF Adjustment See Chapter 5 ADJUSTMENT Carry out the Auto Bi D and the Auto Uni D adjustments ...

Page 85: ...C H A P T E R 4 DISASSEMBLY ASSEMBLY ...

Page 86: ...uld be followed x When replacing the battery replace it with a specified type of battery Using a different type of battery may cause excess heat or explosion x Dispose of used batteries according to manufacture s instructions and local regulations Contact your local government agency for information about battery disposal and recycling x When disposing of the battery be sure to securely cover the ...

Page 87: ...e printer make sure to connect the connectors of the electric components or parts correctly and securely Use extreme care when connecting FFCs flexible flat cables Improper connection of the FFCs such as inserting them diagonally into the connectors could cause short circuiting and lead to breakdown of the electric elements on the boards When reassembling the printer make sure to route the FFCs an...

Page 88: ...indicated in the following table Left Right Rear Up Down Front Table 4 1 Tools Name Epson Part Number Note Precision screwdriver No 2 Commercially available Phillips screwdriver No 0 Commercially available Phillips screwdriver No 1 Commercially available Phillips screwdriver No 2 Commercially available 140 mm or longer shaft length is recommended Flat blade screwdriver Commercially available Long ...

Page 89: ...tion Protective Screw Silver Special Screw C B P 3x8 Silver Phillips Bind P tite Screw C B S 3x8 Silver Phillips Bind S tite Screw C B P 3x6 Silver Phillips Bind P tite Screw C B S 3x6 Silver Phillips Bind S tite Screw C F S 3x6 Silver Phillips Flat Head S tite Screw C B O 4x8 Green Phillips Bind Head S tite Screw with Outside Toothed Lock Washers C P S 2 6x3 Silver Phillips Pan Head S tite Screw ...

Page 90: ...NTER p99 PAPER SUPPORT MANUAL ASSY PAPER SUPPORT ASSY p101 STACKER ASSY p132 BOARD PAPER TRAY p138 COVER HOUSING LOWER p107 MOTOR ASSY APG p118 MOTOR ASSY ASF p120 MOTOR ASSY CR p121 LOCK COVER ASSY p123 ENCODER PF ASSY p126 RELEASE SENSOR p127 MAINTENANCE CARTRIDGE SENSOR SCALE CR p130 STACKER ASSY p132 BOARD PAPER TRAY p138 FRAME PAPER EJECT ASSY p142 PUMP CAP ASSY p148 COVER CR p150 BOARD ASSY ...

Page 91: ... both on site and off site servicing 4 3 1 Unlocking the CARRIAGE ASSY manually 1 Remove the HOUSING RIGHT p103 2 While pressing the carriage lock release gear in the direction of the arrow turn it counterclockwise until it stops to unlock the CARRIAGE ASSY Figure 4 2 Unlocking the CARRIAGE ASSY To lock the CARRIAGE ASSY put it back to the home position and turn the release gear clockwise Carriage...

Page 92: ... Open the COVER IH ASSY 4 Press the Ink Lever of the each Ink Cartridge to release the lock 5 Remove the Ink Cartridges Figure 4 3 Opening the COVER IH ASSY Figure 4 4 Removing the Ink Cartridges C A U T I O N Never touch the IC chips on the Ink Cartridges Doing so may cause a detection error of the Ink Cartridges or a malfunction of the printer Never touch the ink supply port of the Ink Cartridge...

Page 93: ...2 Slightly lift the Maintenance Cartridge and pull it out from the main unit Figure 4 5 Opening the COVER WB Figure 4 6 Removing the Maintenance Cartridge C A U T I O N Never touch the IC chip on the Maintenance Cartridge Doing so may cause a detection error of the Maintenance Cartridge or a malfunction of the printer IC Chip COVER WB Maintenance Cartridge ...

Page 94: ...ion of the arrow to release the guide pin from the main unit Then disengage the left guide pin and remove the COVER IH ASSY Figure 4 7 Removing the COVER IH ASSY C A U T I O N As the COVER IH ASSY is locked by the electric system be sure to open the COVER IH ASSY with the power turned on Never force the COVER IH ASSY open or the lock system LOCK COVER ASSY may be broken Refer to 4 3 2 1 Ink Cartri...

Page 95: ... Assembly Procedure Group 1 95 4 3 3 2 HOUSING REAR ASSY 1 Remove the five screws that secure the HOUSING REAR ASSY and remove it Four C B P 3 x 6 screws 6 1 kgf cm One C B S 3 x 8 screw 6 1 kgf cm Figure 4 8 Removing the HOUSING REAR ASSY C B P 3x6 C B S 3x8 HOUSING REAR ASSY ...

Page 96: ...Position of the points Main unit HOUSING REAR ASSY A Right side Two positioning holes Two guide pins B Right side One positioning hook One positioning tab C Left side Two positioning holes Two guide pins D Left side One positioning hook One positioning tab E Right rear side One positioning hook One positioning tab F Left rear side One positioning hook One positioning tab F C D A B E HOUSING REAR A...

Page 97: ...LEFT to the main unit One C B P 3 x 8 screw 6 1 kgf cm 3 Pull the upper part of the HOUSING FRONT LEFT toward you to release the upper rib and the two lower hooks and remove the HOUSING FRONT LEFT Figure 4 9 Removing the HOUSING FRONT LEFT Be sure to engage the two lower hooks with the cutouts and align the positioning socket with the rib on the main unit rib hooks C B P 3x8 HOUSING FRONT LEFT STA...

Page 98: ...T to the main unit One C B P 3 x 8 screw 6 1 kgf cm 3 Pull the upper part of the HOUSING FRONT RIGHT toward you to release the upper rib and the two lower tabs and remove the HOUSING FRONT RIGHT Figure 4 10 Removing the HOUSING FRONT RIGHT Be sure to engage the two lower tabs with the cutouts and align the positioning socket with the rib on the main unit rib hooks tabs HOUSING FRONT RIGHT C B P 3x...

Page 99: ...assembly Assembly Procedure Group 1 99 4 3 3 5 COVER PRINTER 1 Open the COVER PRINTER 2 Widen the parts shown in Figure 4 11 to release the COVER PRINTER from the two bosses left and right and remove the COVER PRINTER Figure 4 11 Removing the COVER PRINTER COVER PRINTER ...

Page 100: ...Group 1 100 4 3 3 6 PAPER SUPPORT MANUAL ASSY 1 Remove the PAPER SUPPORT MANUAL ASSY upward Figure 4 12 Removing the PAPER SUPPORT MANUAL ASSY Be sure to engage all the hooks two on the upper part five on the lower part of the PAPER SUPPORT MANUAL ASSY with the main unit PAPER SUPPORT MANUAL ASSY ...

Page 101: ...ly Assembly Procedure Group 1 101 4 3 3 7 PAPER SUPPORT ASSY 1 Open the PAPER SUPPORT ASSY 2 Push on the circled points of the PAPER SUPPORT ASSY inward to release its both pivots and remove the PAPER SUPPORT ASSY Figure 4 13 Removing the PAPER SUPPORT ASSY PAPER SUPPORT ASSY ...

Page 102: ...tabs A B on the upper part of the Housing and the hook C in the Housing as shown in Figure 4 14 and remove the HOUSING LEFT Figure 4 14 Removing the HOUSING LEFT C A U T I O N Do not remove or install the HOUSING LEFT roughly or the hooks and the tabs on the HOUSING LEFT may be damaged or broken Be sure to engage the lower hook C with the tab on the main unit first then engage the tabs A B pulling...

Page 103: ...bs A B on the upper part of the Housing and the hook C in the Housing as shown in Figure 4 15 and remove the HOUSING RIGHT Figure 4 15 Removing the HOUSING RIGHT C A U T I O N Do not remove or install the HOUSING RIGHT roughly or the hooks and the tabs on the HOUSING RIGHT may be damaged or broken Be sure to engage the lower hook C with the tab on the main unit first then engage the tabs A B pulli...

Page 104: ...ove the HOUSING FRONT RIGHT p98 4 Remove the COVER PRINTER p99 5 Remove the HOUSING LEFT p102 6 Remove the HOUSING RIGHT p103 7 Remove the five screws that secure the HOUSING FRONT UPPER and remove it Two C B P 3 x 8 screws 6 1 kgf cm Two Shaft Mount Plates 9 1 kgf cm One C B S 3 x 8 screw 9 1 kgf cm Figure 4 16 Removing the HOUSING FRONT UPPER C B P 3x8 C B P 3x8 C B S 3x8 Shaft Mount Plates HOUS...

Page 105: ...NEL ASSY See Figure 4 17 5 Remove the screw that secures the OPERATION PANEL ASSY to the main unit See Figure 4 17 One C B S 3 x 6 screw 9 1 kgf cm 6 Release the hook that secures the OPERATION PANEL ASSY and remove it See Figure 4 18 Figure 4 17 Removing the OPERATION PANEL ASSY 1 Figure 4 18 Removing the OPERATION PANEL ASSY 2 Be sure to insert the two ribs on the OPERATION PANEL ASSY into the p...

Page 106: ...NG UPPER upward 11 Remove the LOCK COVER ASSY from the HOUSING UPPER p123 Figure 4 19 Removing the HOUSING UPPER C A U T I O N Note that the LOCK COVER ASSY is attached to the HOUSING UPPER and it is connected to the main unit with cables When removing the HOUSING UPPER be careful not to separate it too much from the main unit to avoid damaging the cables C H E C K P O I N T When removing the HOUS...

Page 107: ...1 107 4 3 3 13 COVER HOUSING LOWER 1 Remove the HOUSING UPPER p106 2 Pull the upper part of the COVER HOUSING LOWER rightward and remove the COVER HOUSING LOWER upward while avoiding the FFCs on the main unit Figure 4 20 Removing the COVER HOUSING LOWER FFC COVER HOUSING LOWER Right side of the printer ...

Page 108: ...e SHIELD PLATE and the BOARD ASSY PANEL from the OPERATION PANEL ASSY Figure 4 21 Removing the SHIELD PLATE Figure 4 22 Removing the BOARD ASSY PANEL When installing the SHIED PLATE be sure to insert its two positioning holes over the guide pins on the OPERATION BUTTON See Figure 4 21 When installing the BOARD ASSY PANEL be sure to insert its four positioning holes over the guide pins two each on ...

Page 109: ...See Figure 4 23 6 Remove the COVER LCD secured to the OPERATION PANEL with the two sided tape See Figure 4 24 Figure 4 23 Disassembling the OPERATION PANEL ASSY Figure 4 24 Removing the COVER LCD When installing the BUTTON PS be sure to insert its positioning hole over the guide pin on the OPERATION BUTTON BUTTON PS positioning point OPERATION BUTTON OPERATION PANEL OPTICAL TUBE LED LEFT OPTICAL T...

Page 110: ...t hooks and pull out the PAPER GUIDE LOWER LEFT from the back of the printer See Figure 4 26 9 Pull the PAPER GUIDE LOWER RIGHT first rearward and then upward to release it from the 10 hooks and pull out the PAPER GUIDE LOWER RIGHT from the back of the printer See Figure 4 26 Figure 4 25 Removing the FRAME PAPER SUPPORT REAR Figure 4 26 Removing the PAPER GUIDE LOWER LEFT RIGHT C A U T I O N In st...

Page 111: ... MAIN p112 Figure 4 27 Removing the screws from the BASE ENCLOSURE Figure 4 28 Removing the BASE ENCLOSURE C A U T I O N Note that the Main Board and the Power Supply Board are stored in the BASE ENCLOSURE and they are connected to the main unit with the cables When removing the BASE ENCLOSURE be careful not to separate it too much from the main unit to avoid damaging the cables C A U T I O N Do n...

Page 112: ... Figure 4 30 Disconnecting the Power Board Cable from CN13 C A U T I O N Do not disconnect insert the FFCs from into the connectors at an angle Doing so may damage short or break the terminals in the connector resulting in a breakdown of the elements on the board Connect the FFCs to their correct positions matching the numbers written on the FFCs with those printed on the board as shown in Figure ...

Page 113: ... ASSY PG CN46 Red 2 MOTOR ASSY PRESSURIZING CN49 FFC 5 ENCODER PF ASSY CN50 Blue 2 BOARD PAPER TRAY OPEN SENSOR CN51 Red 3 INK COVER SENSOR CN52 White 6 PRESSURE SENSOR PRESSURE PUMP HOME SENSOR CN53 Blue 4 ASF PHASE SENSOR CN54 Yellow 4 PE SENSOR CN57 Yellow 2 MOTOR ASSY RELEASE CN58 Red 4 MOTOR ASSY PUMP CN59 White NA Unassigned CN61 Yellow 3 RELEASE ROLLER POSITION SENSOR CN62 Blue 3 COVER WB S...

Page 114: ...N T The BOARD ASSY MAIN and the BASE ENCLOSURE are adhered to each other with the SHEET HEATSHINK C A U T I O N Do not put the board directly on conductive surfaces with its component side is facing down A lithium battery is pre installed on the boards provided as service parts Therefore direct contact between the component side of the board and conductive materials or putting conductive materials...

Page 115: ... remove the BOARD ASSY POWER SUPPLY Four C B S 3 x 6 screws 6 1 kgf cm Figure 4 32 ÅmConnector Layout of the BOARD ASSY POWER SUPPLY Figure 4 33 Disconnecting the Power Board Cable from CN13 Figure 4 34 Removing the BOARD ASSY POWER SUPPLY C A U T I O N When removing the BOARD ASSY POWER SUPPLY do not start the work immediately after disconnecting the AC cable Wait for at least five minutes for th...

Page 116: ...e that secures the HARNESS AC INLET to the BASE ENCLOSURE 4 Remove the screw that secures the grounding wire to the BASE ENCLOSURE One C B O 4 x 8 screw 6 1 kgf cm 5 Remove the two screws that secure the AC INLET to the BASE ENCLOSURE Two C F S 3 x 6 screws 6 1 kgf cm 6 Remove the AC INLET from the notch of the BASE ENCLOSURE Figure 4 35 Removing the AC INLET C F S 3x6 CN1 AC INLET Grounding Wire ...

Page 117: ... break the terminals in the connector resulting in a breakdown of the elements on the board Connect the FFCs to their correct positions matching the numbers written on the FFCs with those printed on the board as shown in Figure 4 29 and Table 4 3 Secure the grounding terminal of the MOTOR INK SELECTOR together with the BOARD ASSY SUB with the C B S 3 x 6 screw on the right See Figure 4 37 Table 4 ...

Page 118: ...elease the cables of the MOTOR ASSY APG from the three cable hooks See Figure 4 38 5 Peel off the acetate tapes on the COVER ENCLOSURE ASSY to release the cables of the MOTOR ASSY APG See Figure 4 39 Figure 4 38 Releasing the MOTOR ASSY APG cables 1 Figure 4 39 Releasing the MOTOR ASSY APG cables 2 Route the cables of the MOTOR ASSY APG with other cables and secure them with the acetate tapes as s...

Page 119: ...re 4 40 to release the part that contacts with the FRAME ASSY SUB RIGHT and remove the MOTOR ASSY APG toward inside of the main unit See Figure 4 40 Figure 4 40 Removing the screws from the MOTOR ASSY APG When installing the MOTOR ASSY APG be careful of the following The board attached side must face upward The screwing portions of the MOTOR ASSY APG must come to the outside of the main frame Over...

Page 120: ...ving the screws from the MOTOR ASSY ASF C H E C K P O I N T Put a screwdriver with a 60 mm or longer shaft is recommended through the holes on the FRAME ASSY SUB RIGHT to remove the C B P 3x8 screws that secure the MOTOR ASSY ASF as shown in Figure 4 42 Be sure to insert the guide pin of the ASF into the positioning hole of the MOTOR ASSY ASF Secure the grounding terminal and the MOTOR ASSY ASF to...

Page 121: ...106 2 Unlock the CARRIAGE ASSY and move it to the center p91 3 Push the HOLDER PULLEY DRIVEN in the direction of the arrow to reduce the tension of the BELT CR and remove the BELT CR from the Pinion Gear of the MOTOR ASSY CR Figure 4 43 Removing the BELT CR BELT CR Direction to reduce the tension HOLDER PULLEY DRIVEN BELT CR Pinion Gear of the MOTOR ASSY CR ...

Page 122: ...3x4 screws that secure the MOTOR ASSY CR use a stubby screw driver or put a screwdriver with a 140mm or longer shaft is recommended through the holes on the main frame as shown in Figure 4 44 Be sure to install the MOTOR ASSY CR to the main frame so that the label on the MOTOR ASSY CR faces upward See Figure 4 44 A D J U S T M E N T R E Q U I R E D Whenever the MOTOR ASSY CR is replaced the corres...

Page 123: ...106 and remove the HOUSING UPPER from the main unit 2 Release the two hooks that secure the LOCK COVER ASSY with a precision screwdriver or similar tools to remove the LOCK COVER ASSY Figure 4 45 Removing the LOCK COVER ASSY Be sure to insert the two positioning holes of the LOCK COVER ASSY over the guide pins of the HOUSING UPPER LOCK COVER ASSY positioning points Left side of the printer LOCK CO...

Page 124: ...mbly Assembly Procedure Group 1 124 3 Release the LOCK COVER ASSY cables from the hooked tabs on the HOUSING UPPER Figure 4 46 Routing the LOCK COVER ASSY Cables Be sure to route the cables through the tabs as shown in Figure 4 46 HOUSING UPPER Cables of the LOCK COVER ASSY ...

Page 125: ...SY MAIN See Figure 4 29 7 Peel off the acetate tapes on the COVER ENCLOSURE ASSY to release the cables of the LOCK COVER ASSY and remove the LOCK COVER ASSY See Figure 4 48 Figure 4 47 Releasing the LOCK COVER ASSY Cables 1 Figure 4 48 Releasing the LOCK COVER ASSY Cables 2 Route the cables of the LOCK COVER ASSY with other cables and secure them with the acetate tapes as shown in Figure 4 48 cabl...

Page 126: ...gure 4 49 Figure 4 49 Removing the ENCODER PF ASSY C A U T I O N When performing the next step be extremely careful not to contaminate deform or damage the SCALE PF 180 C B S 3x6 Connector SCALE PF 180 ENCODER PF ASSY Insert the SCALE PF 180 into the detection part of the sensor and install the ENCODER PF ASSY When installing the ENCODER PF ASSY be sure to engage the tab of the ENCODER PF ASSY to ...

Page 127: ...or into not detecting state 3 Disconnect the connector from the RELEASE SENSOR See Figure 4 50 4 Release the four hooks that secure the RELEASE SENSOR and remove the RELEASE SENSOR See Figure 4 50 Figure 4 50 Removing the RELEASE SENSOR If the cables have come off the cable guides on the main unit while removing the RELEASE SENSOR be sure to route the cables correctly referring to Figure 4 50 Not ...

Page 128: ...cision screwdriver or similar tools accessing from the bottom of the main unit and remove the MOUNTING PLATE DETECTOR LOWER See Figure 4 51 5 Disengage the two hooks that secure the MAINTENANCE CARTRIDGE SENSOR to the MOUNTING PLATE DETECTOR LOWER and remove the MAINTENANCE CARTRIDGE SENSOR See Figure 4 52 Figure 4 51 Removing the MOUNTING PLATE DETECTOR LOWER Figure 4 52 Removing the MAINTENANCE ...

Page 129: ... B P 3 x 8 screw 5 1 kgf cm 4 Disengage the four tabs that secure the APG SENSOR to the MOUNT PLATE DETECTOR PG and remove the APG SENSOR 5 Disconnect the connector from the APG SENSOR Figure 4 53 Removing the APG SENSOR When installing the MOUNT PLATE DETECTOR PG to the CARRIAGE ASSY be sure to insert the positioning holes of the MOUNT PLATE DETECTOR PG over the guide pins of the CARRIAGE ASSY Se...

Page 130: ...n the direction of the arrow to loosen the tension of the SCALE CR Then remove the SCALE CR from the hook on the right side of the main unit 4 Turn the left hooked end of the TORSION SPRING 24 7 again in the direction of the arrow to remove it from the hole of the SCALE CR 5 Pull out the right end of the SCALE CR from the CARRIAGE ASSY Figure 4 54 Removing the SCALE CR 1 C A U T I O N When perform...

Page 131: ...of the MOUNT PLATE SCALE CR Figure 4 55 Removing the SCALE CR 2 hook SCALE CR MOUNT PLATE SCALE CR Install the SCALE CR so that the marked corner comes to the top left corner The SCALE CR must be routed through the slit of the COVER ENCODER that is attached to the rear side of the CARRIAGE ASSY Left Side marked corner Rear Side of the CARRIAGE ASSY COVER ENCODER SCALE CR CARRIAGE ASSY ...

Page 132: ...ANISM 4 3 8 1 STACKER ASSY DISASSEMBLY 1 Remove the HOUSING FRONT LEFT p97 2 Remove the HOUSING FRONT RIGHT p98 3 Open the STACKER C 4 Push outward on the left and right sides of the STACKER C to widen it and remove the STACKER C while disengaging the two guide pins of the STACKER ASSY Figure 4 56 Removing the STACKER C STACKER ASSY STACKER C ...

Page 133: ... the PLATE STOPPER STACKERs and remove them Two C B S 3 x 6 screws 9 1 kgf cm Figure 4 57 Removing the PLATE STOPPER STACKERs When securing the PLATE STOPPER STACKERs be sure to put their top ends into the each groove of the GUIDE STACKER LEFT RIGHT GUIDE STACKER LEFT GUIDE STACKER RIGHT Insert the top ends under the GUIDE STACKER LEFT RIGHT C B S 3x6 PLATE STOPPER STACKERs ...

Page 134: ... to disengage its right dowel from the main unit while slightly pushing the STACKER ASSY leftward Then disengage the left dowel from the main unit to remove the STACKER ASSY Figure 4 58 Removing the STACKER ASSY If the GUIDE STACKER LEFT RIGHT fall off unintentionally while removing the STACKER ASSY reinstall them referring to Reassembly p135 STACKER ASSY GUIDE STACKER LEFT GUIDE STACKER RIGHT ...

Page 135: ...mentioned below are securely engaged See Figure 4 59 2 Slide the GUIDE STACKER LEFT toward the rear of the printer Figure 4 59 Installing the GUIDE STACKER LEFT Fig GUIDE STACKER LEFT Main unit A positioning tab positioning hole B positioning hole hook C H E C K P O I N T Make sure that the cutout of the GUIDE STACKER LEFT is aligned with the screw hole on the main frame GUIDE STACKER LEFT A B ...

Page 136: ...ntioned below are securely engaged See Figure 4 60 2 Slide the GUIDE STACKER RIGHT toward the rear of the printer Figure 4 60 Installing the GUIDE STACKER RIGHT Fig GUIDE STACKER RIGHT Main unit A positioning hole hook B positioning hole hook C H E C K P O I N T Make sure that the cutout of the GUIDE STACKER RIGHT is aligned with the screw hole on the main frame GUIDE STACKER RIGHT A B ...

Page 137: ...CKER LEFT and GUIDE STACKER RIGHT 2 Put the dowels of the left front and right front of the STACKER ASSY into the slits of the front of the GUIDE STACKER LEFT and GUIDE STACKER RIGHT 3 Push in the STACKER ASSY to the end 4 Secure the left and right of the PLATE STOPPER STACKER with the screws 5 Attach the STACKER C 6 Close the STACKER C Figure 4 61 Installing the STACKER ASSY Left rear Right rear ...

Page 138: ...move the STACKER ASSY p132 4 Push out the BOARD PAPER TRAY while pressing in the middle of the BOARD PAPER TRAY 5 Release the TORSION SPRING 0 15 from the SHAFT PAPER GUIDE BOARD PAPER and loosen the tension of TORSION SPRING 0 15 do this procedure at both sides Figure 4 62 Removing the TORSION SPRING 0 15 BOARD PAPER TRAY SHAFT PAPER GUIDE BOARD PAPER TORSION SPRING 0 15 TORSION SPRING 0 15 SHAFT...

Page 139: ...he E ring and the washer from the SHAFT PAPER GUIDE BOARD PAPER 10 Pull the SHAFT PAPER GUIDE BOARD PAPER to the right Figure 4 63 Removing the SHAFT PAPER GUIDE BOARD PAPER Insert the SPUR GEAR 14 4 into the SHAFT PAPER GUIDE BOARD PAPER as shown in the Figure 4 63 and insert the parallel pin into the hole Insert the SHAFT PAPER GUIDE BOARD PAPER into the connection groove of the CAM PAPER GUIDE ...

Page 140: ...on the hinges of the BOARD PAPER TRAY to disengage its pivots from the GUIDE PAPER GUIDE BOARD PAPER LEFT RIGHT then remove the BOARD PAPER TRAY Figure 4 64 Removing the BOARD PAPER TRAY Left side Right side GUIDE PAPER GUIDE BOARD PAPER LEFT BOARD PAPER TRAY GUIDE PAPER GUIDE BOARD PAPER RIGHT Pivot BOARD PAPER TRAY Pivot ...

Page 141: ...R GUIDE BOARD PAPER RIGHT shown in the Figure 4 65 and put the pivot into the guide holes of the LINK EJ RIGHT and GUIDE PAPER GUIDE BOARD PAPER RIGHT shown in the Figure 4 67 4 After the above steps follow step 1 to step 11 of the disassembly procedure in reverse order to reassemble the BOARD PAPER TRAY Figure 4 65 Inserting the Right Pivot Figure 4 66 Guide holes of the LINK EJ LEFT and GUIDE PA...

Page 142: ...B S 3 x 6 screw 9 1 kgf cm Figure 4 68 Removing the SLIDER FRAME EJ RIGHT C H E C K P O I N T When removing the C B S 3x6 screw that secures the SLIDER FRAME EJ RIGHT use a stubby screw driver or put a screwdriver with a 110 mm or longer shaft is recommended through the holes on the FRAME ASSY SUB RIGHT as shown in Figure 4 68 Insert the two guide pins of the SLIDER FRAME EJ RIGHT into the positio...

Page 143: ...APER GUIDE BOARD PAPER RIGHT Two C B P 3 x 6 screws 9 1 kgf cm Figure 4 69 Removing the TORSION SPRING 0 15 and the screw from the GUIDE PAPER GUIDE BOARD PAPER RIGHT C H E C K P O I N T When removing installing the C B P 3x6 screws that secure the GUIDE PAPER GUIDE BOARD PAPER RIGHT use a stubby screw driver or put a screwdriver with a 110 mm or longer shaft is recommended through the holes on th...

Page 144: ... Figure 4 70 9 Tilt the FRAME PAPER EJECT ASSY in the direction shown in the Figure 4 71 Lift up the right side of the FRAME PAPER EJECT ASSY slightly to pass it over the bump of the FRAME ASSY MAIN as shown in the Figure 4 71 Figure 4 70 Pulling out the GUIDE PAPER GUIDE BOARD PAPER RIGHT Figure 4 71 Tilting the FRAME PAPER EJECT ASSY GUIDE PAPER GUIDE BOARD PAPER RIGHT FRAME PAPER EJECT ASSY ...

Page 145: ...ME PAPER EJECT ASSY See Figure 4 72 11 Push in the FRAME PAPER EJECT ASSY to the end and release the TORSION SPRING 0 046 secured to the both ends of FRAME PAPER EJECT ASSY See Figure 4 73 Figure 4 72 Removing the LINK EJ RIGHT and GUIDE PAPER GUIDE BOARD PAPER RIGHT Figure 4 73 Releasing the TORSION SPRING 0 046 pivot of the FRAME PAPER EJECT ASSY GUIDE PAPER GUIDE BOARD PAPER RIGHT LINK EJ RIGHT...

Page 146: ... the FRAME ASSY MAIN as shown in the Figure 4 74 13 Remove the FRAME PAPER EJECT ASSY following the steps shown in the Figure 4 75 Figure 4 74 Tilting the FRAME PAPER EJECT ASSY Figure 4 75 Removing the FRAME PAPER EJECT ASSY FRAME PAPER EJECT ASSY FRAME PAPER EJECT ASSY dowel 2 Remove the FRAME PAPER EJECT ASSY in the direction of the red arrow Push out the FRAME PAPER EJECT ASSY toward the rear ...

Page 147: ...FT RIGHT shown below Left side Right side GUIDE PAPER GUIDE BOARD PAPER LEFT LINK EJ LEFT LINK EJ RIGHT GUIDE PAPER GUIDE BOARD PAPER RIGHT FRAME PAPER EJECT ASSY FRAME PAPER EJECT ASSY guide hole guide hole Push down both the HOLDER LEVER BLOCK_B toward you and put them under the levers of the FRAME TOP ASSY FRAME PAPER EJECT ASSY HOLDER LEVER BLOCK_B Pushing down Put FRAME PAPER EJECT ASSY under...

Page 148: ...lease the MOTOR ASSY PUMP One C B S 3 x 6 screws 9 1 kgf cm Figure 4 76 Removing the Grounding Wire C A U T I O N When removing the PUMP CAP ASSY ink may leak out of the ink exhaust Have a waste cloth beforehand to wipe out the leaked ink Secure the grounding wire of the MOTOR ASSY ASF and the MOTOR ASSY PUMP together to the main frame Top Grounding Wire MOTOR ASSY ASF Bottom Grounding Wire MOTOR ...

Page 149: ...the screws from the PUMP CAP ASSY Figure 4 78 Removing the PUMP CAP ASSY Insert the two positioning holes of the PUMP CAP ASSY over the guide pins on the FRAME ASSY SUB RIGHT to secure the PUMP CAP ASSY See Figure 4 77 A D J U S T M E N T R E Q U I R E D Whenever the PUMP CAP ASSY is replaced the corresponding adjustments must be carried out See Chapter 5 ADJUSTMENT p190 C B S 3x6 positioning poin...

Page 150: ... remove it One C B P 3 x 6 screw 9 1 kgf cm One C B S 3 x 6 screw 9 1 kgf cm Figure 4 79 Removing the COVER CR C A U T I O N The following are important points when installing the COVER CR Before screwing the unit make sure that the cables are not trapped As different types of screws are used make sure to reinstall the correct type of screws at the correct positions Overhead view COVER CR C B P 3x...

Page 151: ... S 3 x 6 screws 9 1 kgf cm 3 Slide the SHIELD PLATE HOLDER ASSY toward the rear to remove the two tabs on the rear side and remove the SHIELD PLATE HOLDER ASSY Figure 4 80 Removing the SHIELD PLATE HOLDER ASSY Insert the two positioning holes of the SHIELD PLATE HOLDER ASSY over the guide pins of the FRAME HOLDER IC ASSY to secure the SHIELD PLATE HOLDER ASSY FRAME HOLDER IC ASSY positioning point...

Page 152: ...FC ASSY HOLDER from the nine connectors on the FRAME HOLDER IC ASSY 6 Bow the center of the FFC ASSY HOLDER and release it from the 20 tabs 7 Release the FFC ASSY HOLDER from the tab on the left side of the FRAME HOLDER IC ASSY Figure 4 81 Releasing the FFC ASSY HOLDER C A U T I O N When performing the next steps be careful not to bend the FFC FFC ASSY HOLDER tab Connectors tab tube of the PRESSUR...

Page 153: ... IC ASSY Three C B S 3 x 6 screws 9 1 kgf cm 9 Use a precision screwdriver or a similar tool to pull out the guide pin of the HOLDER TUBE from the FRAME TOP ASSY and release the HOLDER TUBE Figure 4 82 Removing the screws from the FRAME HOLDER IC ASSY C B S 3x6 HOLDER TUBE guide pin C B S 3x6 C B S 3x6 FRAME HOLDER IC ASSY Left side of the printer FRAME TOP ASSY ...

Page 154: ...ssembly Assembly Procedure Group 1 154 10 Disengage the tab and open the HOLDER FFC to release the TUBE ASSY Figure 4 83 Releasing the TUBE ASSY Install the HOLDER FFC at the position 250 mm away from the HOLDER TUBE 250 mm HOLDER TUBE HOLDER FFC HOLDER FFC tab TUBE ASSY ...

Page 155: ...mounting tab on the left side from contacting with the main frame remove the FRAME HOLDER IC ASSY Figure 4 84 Removing the FRAME HOLDER IC ASSY Install the FRAME HOLDER IC ASSY so that its screw mounting tab is put over the FRAME TOP ASSY Check that the tabs of the FRAME HOLDER IC ASSY are securely engaged to the FRAME TOP ASSY screw mounting tab tabs FRAME TOP ASSY FRAME HOLDER IC ASSY tabs screw...

Page 156: ... 4 86 Two C B P 3 x 6 screws 3 0 5 kgf cm Figure 4 85 Removing the BOARD ASSY SUB Figure 4 86 Removing the STRENGTHEN PLATE CR C A U T I O N Do not disconnect insert FFCs from into the connectors at an angle Doing so may damage short or break the terminals in the connector resulting in a breakdown of the elements on the board Insert the positioning hole of the STRENGTHEN PLATE CR over the guide pi...

Page 157: ...x 8 screw 2 0 5 kgf cm One C B S 2 5 x 4 screw 2 0 5 kgf cm Figure 4 87 Removing the SELECTOR INK ASSY C A U T I O N When installing the SELECTOR INK ASSY make sure not to mix up the C B P 2 5 x 8 screw and the C B P 2 5 x 4 screws as they are similar to each other A D J U S T M E N T R E Q U I R E D Whenever the INK SYSTEM ASSY is replaced the corresponding adjustments must be carried out See Cha...

Page 158: ...PPER p106 2 Remove the INK SYSTEM ASSY p151 3 Remove the POROUS PAD TRAY INK EJECT from the TRAY INK EJECT Figure 4 88 Removing the POROUS PAD TRAY INK EJECT A D J U S T M E N T R E Q U I R E D Whenever the POROUS PAD TRAY INK EJECT is replaced the corresponding adjustments must be carried out See Chapter 5 ADJUSTMENT p190 TRAY INK EJECT POROUS PAD TRAY INK EJECT ...

Page 159: ...G PLATE SELECT INK and remove it See Figure 4 89 One C B P 2 5 x 8 screw 3 1 kgf cm 5 Remove the EXTENSION SPRING 5 63 from each hooked tab on the CARRIAGE ASSY and the LEAF SPRING LOCK HEAD See Figure 4 90 Figure 4 89 Removing the MOUNTING PLATE SElECT INK Figure 4 90 Removing the EXTENSION SPRING 5 63 Insert the rib of the PRINT HEAD into the cutout of the MOUNTING PLATE SELECT INK to secure the...

Page 160: ...ure 4 91 7 Remove the three screws that secure the LEAF SPRING LOCK HEAD and remove it upward See Figure 4 92 Three C B P 2 5 x 8 screws 3 0 5 kgf cm Figure 4 91 Releasing the GUIDE TUBE CR Figure 4 92 Removing the LEAF SPRING LOCK HEAD Put the far left section of the LEAF SPRING LOCK HEAD under the HARNESS HEAD A B and the film to install it HARNESS HEAD A B and film CARRIAGE ASSY guide pins GUID...

Page 161: ...ee Figure 4 93 Figure 4 93 Removing the PRINT HEAD C A U T I O N Do not disconnect insert FFCs from into the connectors at an angle Doing so may damage short or break the terminals in the connector resulting in a breakdown of the elements on the board A D J U S T M E N T R E Q U I R E D Whenever the PRINT HEAD is replaced the corresponding adjustments must be carried out See Chapter 5 ADJUSTMENT p...

Page 162: ...ve the screw that secures the INK WASTE BOX See Figure 4 94 One C B P 3 x 8 screw 6 1 kgf cm Figure 4 94 Removing the screw from the INK WASTE BOX C H E C K P O I N T When removing installing the screw that secures the INK WASTE BOX insert a screwdriver with a 140 mm or longer shaft is recommended through the hole on the FRAME ASSY SUB RIGHT as shown in Figure 4 94 Insert a screwdriver through thi...

Page 163: ...ure 4 96 Removing the POROUS PAD INK WASTE BOX RIGHT LEFT Align the two guide pins and one positioning groove of the INK WASTE BOX with the two positioning holes and one hooked tab of the main frame to secure the INK WASTE BOX A D J U S T M E N T R E Q U I R E D Whenever the POROUS PAD INK WASTE BOX RIGHT LEFT are replaced the corresponding adjustments must be carried out See Chapter 5 ADJUSTMENT ...

Page 164: ...hat secure the SCALE PF 180 and remove it from the COMBINATION GEAR PF DRIVE Figure 4 97 Removing the SCALE PF 180 C A U T I O N Be careful not to deform or damage the SCALE PF 180 when carrying out the following steps Insert the two positioning holes of the SCALE PF 180 over the two ribs of the COMBINATION GEAR PF DRIVE to secure the SCALE PF 180 holes ribs SCALE PF 180 COMBINATION GEAR PF DRIVE ...

Page 165: ...emove the SCALE PF 180 p164 3 Remove the retaining ring that secure the SPUR GEAR 31 5 See Figure 4 98 4 Remove the two screws that secure the HOUSING LOWER See Figure 4 99 Two C B P 3 x 8 screws 6 1 kgf cm Figure 4 98 Removing the SUPUR GEAR 31 5 1 Figure 4 99 Removing the screws from the HOUSING LOWER SPUR GEAR 31 5 retaining ring C B P 3x8 C B P 3x8 HOUSING LOWER ...

Page 166: ...TIMING BELT PF from the pinion gear and the COMBINATION GEAR PF DRIVE of the MOTOR ASSY PF See Figure 4 101 Figure 4 100 Removing the SUPUR GEAR 31 5 2 Figure 4 101 Removing the TIMING BELT PF A D J U S T M E N T R E Q U I R E D Whenever the TIMING BELT PF is replaced the corresponding adjustments must be carried out See Chapter 5 ADJUSTMENT p190 Left side COMPRESSION SPRING 2 25 SPUR GEAR 31 5 pi...

Page 167: ... the MOTOR RELEASE ASSY See Figure 4 102 5 Release the cables of the parts listed below which are components in the MOTOR RELEASE ASSY from the two cable hooks See Figure 4 103 MOTOR ASSY PF MOTOR ASSY RELEASE RELEASE SENSOR Figure 4 102 Releasing the MOTOR RELEASE ASSY Cables 1 Figure 4 103 Releasing the MOTOR RELEASE ASSY Cables 2 Route the cables of the MOTOR RELEASE ASSY with other cables and ...

Page 168: ... 1 kgf cm 8 Remove the TIMING BELT PF from the pinion gear of the MOTOR ASSY PF and remove the MOTOR RELEASE ASSY Figure 4 104 Removing the HARNESS ENCODER PF Figure 4 105 Removing the screws from the MOTOR RELEASE ASSY A D J U S T M E N T R E Q U I R E D Whenever the MOTOR RELEASE ASSY is replaced the corresponding adjustments must be carried out See Chapter 5 ADJUSTMENT p190 Left side of the pri...

Page 169: ...he MOTOR SSY PUMP and release them from the main frame See Figure 4 106 One C B S 3 x 6 screw 9 1 kgf cm 10 Push the PULLEY DRIVEN ASSY in the direction of the arrow and remove the PULLEY DRIVEN ASSY and the BELT CR from the HOLDER PULLEY DRIVEN See Figure 4 107 Figure 4 106 Releasing the HARNESS Figure 4 107 Removing the PULLEY DRIVEN ASSY Be sure to install the PULLEY DRIVEN ASSY to the HOLDER P...

Page 170: ...nstall the two of the five C B S 3x6 screws insert a screwdriver through the holes on the FRAME ASSY SUB RIGHT shown in Figure 4 108 Make sure to carry out the followings when installing the FRAME ASSY SUB RIGHT to the main unit Be sure to align the seven positioning holes of the FRAME ASSY SUB RIGHT with the seven ribs on the main frame After fastening the screws shown in Figure 4 109 be sure to ...

Page 171: ...1 171 14 Slide the CARRIAGE ASSY rightward to remove it from the Carriage Shaft Figure 4 110 Removing the CARRIAGE ASSY A D J U S T M E N T R E Q U I R E D Whenever the CARRIAGE ASSY is replaced the corresponding adjustments must be carried out See Chapter 5 ADJUSTMENT p190 CARRIAGE ASSY Carriage Shaft ...

Page 172: ...kgf cm Figure 4 111 Removing the COVER ENCODER Figure 4 112 Removing the BOARD ASSY ENCODER Insert the positioning hole of the COVER ENCODER over the guide pin of the CARRIAGE ASSY to secure the COVER ENCODER See Figure 4 111 Table 4 5 Connectors on BOARD ASSY ENCODER Connector No Color No of Pins Destination CN1 FFC 8 BOARD ASSY SUB CN2 FFC 3 BOARD ASSY DETECTOR PW B A D J U S T M E N T R E Q U I...

Page 173: ...rew 1 25 0 25 kgf cm 3 Disconnect the HARNESS INK MARK from CN1 connector on the BOARD ASSY INK MARK and remove the BOARD ASSY INK MARK See Figure 4 114 Figure 4 113 Removing the HOLDER DETECTOR PW Figure 4 114 Removing the BOARD ASSY INK MARK Insert the positioning hole of the BOARD ASSY INK MARK over the guide pin of the CARRIAGE ASSY to secure the BOARD ASSY INK MARK See Figure 4 114 Rear side ...

Page 174: ... screw that secures the HOLDER DETECTOR PW See Figure 4 115 One C P B 1 7 x 8 screw 1 25 0 25 kgf cm 3 Disconnect the HARNESS PW from CN1 connector on the BOARD ASSY DETECTOR PW B and remove the BOARD ASSY DETECTOR PW B See Figure 4 116 Figure 4 115 Removing the HOLDER DETECTOR PW Figure 4 116 Removing the BOARD ASSY DETECTOR PW B Rear side HOLDER DETECTOR PW CARRIAGE ASSY C P B 1 7x8 BOARD ASSY D...

Page 175: ...ear side of the CARRIAGE ASSY Figure 4 117 Removing the BELT CR Make sure to check the following points when installing the BELT CR Set the BELT CR so that its lumpy side faces inward Put the both sides lumpy part of the BELT CR into the belt holding part of the CARRIAGE ASSY Both sides lumpy part Belt holding part Inner side lumpy Outer side flat Inner side lumpy Outer side flat Rear side BELT CR...

Page 176: ...RD ASSY MAIN See Figure 4 29 5 Peel off the acetate tape on the COVER ENCLOSURE ASSY and release the cables of the MOTOR ASSY PRESSURIZING and PRESSURE SENSOR PRESSURE PUMP HOME SENSOR See Figure 4 119 6 Remove the screw that secures the PRESSURE PUMP ASSY and the grounding wire to the main unit and remove the PRESSURE PUMP ASSY See Figure 4 118 One C B S 3 x 6 screw 6 1 kgf cm Figure 4 118 Removi...

Page 177: ... HOUSING LOWER 8 Lift up the left side of the main frame and remove the PRESSURE PUMP ASSY from the main frame See Figure 4 120 Figure 4 120 Removing the PRESSURE PUMP ASSY When installing the PRESSURE PUMP ASSY be sure to insert the hook and rib on the PRESSURE PUMP ASSY into the positioning holes on the main frame PRESSURE PUMP ASSY rib hook Positioning points HOUSING LOWER PRESSURE PUMP ASSY ...

Page 178: ...eter data comes with the PRINTER MECHANISM ASP Load the CD ROM into to the PC 3 Start up the Adjustment program NVRAM Backup utility will automatically start up when the Adjustment program is started Using the utility write the mechanism parameter data into the PRINTER MECHANISM ASP See Chapter 5 5 3 6 Parameter Backup Page 212 for the operation instructions C H E C K P O I N T When the PRINTER ME...

Page 179: ...he two screws that secure the left and right GUIDE ROLLER LDs and remove the two GUIDE ROLLER LDs See Figure 4 121 Two one for each C B S 3 x 6 screws 9 1 kgf cm 4 Lift up the two GUIDE ROLLER LDs on the rear side of the main unit to disengage the hook and the tab and remove the GUIDE ROLLER LDs See Figure 4 122 Figure 4 121 Screws hooks and tabs that secure the GUIDE ROLLER LD Figure 4 122 Removi...

Page 180: ...NESS DETECTOR RELEASE 7 Remove the screw that secures the grounding wire of the MOTOR ASSY ASF and remove the wire See Figure 4 124 One C B P 3 x 8 screw 6 1 kgf cm Figure 4 123 Releasing the FFC and cables Figure 4 124 Removing the screws from the MOTOR ASSY ASF Left side of the printer cable guides ASF SENSOR HARNESS ENCODER PF HARNESS DETECTOR ASF HARNESS DETECTOR RELEASE MOTOR ASSY ASF Put the...

Page 181: ...e Figure 4 125 Two SHAFT MOUNT PLATEs 9 1 kgf cm Two C B S P4 3 x 8 screws 9 1 kgf cm 10 Lift up the ASF ASSY to disengage the two tabs from the main frame and remove the ASF ASSY See Figure 4 125 Figure 4 125 Removing the ASF ASSY A D J U S T M E N T R E Q U I R E D Whenever the ASF ASSY is replaced the corresponding adjustments must be carried out See Chapter 5 ADJUSTMENT p190 SHAFT MOUNT PLATE ...

Page 182: ...ETECTOR RELEASE and the red marking part of the SPUR GEAR 22 B as shown in the figure below to install the MOTOR RELEASE ASSY Route the cables correctly as shown in the figure below SPUR GEAR 22 B FLAG DETECTOR RELEASE positioning point cable of MOTOR ASSY PF cable of MOTOR ASSY RELEASE Adjust the length of the cables and secure them with cable hooks ...

Page 183: ...bs and remove the HOLDER PULLEY DRIVEN to the front 5 Push down the PULLEY DRIVEN ASSY to release the PULLEY DRIVEN ASSY and the BELT CR from the HOLDER PULLEY DRIVEN Figure 4 126 Removing the EXTENSION SPRING 28 38 and HOLDER PULLEY DRIVEN Figure 4 127 Removing the PULLEY DRIVEN ASSY Be sure to install the PULLEY DRIVEN ASSY to the HOLDER PULLEY DRIVEN so that the protrusion on the shaft of the P...

Page 184: ...CTOR ASF on the left side of the ASF ASSY from the inside and remove the FLAG DETECTOR ASF 4 Disengage the four tabs of the ASF SENSOR and remove the ASF SENSOR Figure 4 128 Removing the FLAG DETECTOR ASF Figure 4 129 Removing the ASF SENSOR Be sure to align the two grooves of the FLAG DETECTOR ASF with the ribs of the LD ROLLER SHAFT to install the FLAG DETECTOR ASF FLAG DETECTOR ASF grooves ribs...

Page 185: ...RE ASSY to release the cables of the PAPER DETECTOR ASSY PE SENSOR See Figure 4 130 5 Release the cables of the PAPER DETECTOR ASSY from the three cable hooks See Figure 4 131 6 Remove the ASF ASSY p179 Figure 4 130 Releasing the PAPER DETECTOR ASSY PE SENSOR Cables Figure 4 131 Releasing the PAPER DETECTOR ASSY Cables Route the cables of the PAPER DETECTOR ASSY with other cables and secure them w...

Page 186: ...le hooks on the main frame 8 While releasing the center tab of the PAPER DETECTOR ASSY with a precision screwdriver or a similar tool lift the PAPER DETECTOR ASSY to disengage the two tabs and remove it from the main frame Figure 4 132 Removing the PAPER DETECTOR ASSY Route the cables of the PAPER DETECTOR ASSY as shown in the figure below cable hooks PAPER DETECTOR ASSY ...

Page 187: ...rews 9 1 kgf cm 5 Lift up the SHAFT RELEASE ASSY while pushing down the three tabs on the SHAFT RELEASE ASSY See Figure 4 134 6 Slide the SHAFT RELEASE ASSY leftward to release the SHAFT RELEASE PAPER GUIDE UPPER from the main frame and then remove the SHAFT RELEASE ASSY See Figure 4 134 Figure 4 133 Removing the screws from the SHAFT RELEASE ASSY Figure 4 134 Removing the SHAFT RELEASE ASSY SHAFT...

Page 188: ... UPPER ASSY 1 Remove the MOTOR RELEASE ASSY p167 2 Remove the PAPER DETECTOR ASSY p185 3 Remove the SHAFT RELEASE ASSY p187 4 Release the eight TORSION SPRING PAPER GUIDE UPPERs from each hook on the main frame Figure 4 135 Removing the TORSION SPRING PAPER GUIDE UPPERs TORSION SPRING PAPER GUIDE UPPERs Rear of the printer hook ...

Page 189: ... the eight PAPER GUIDE UPPER ASSYs from the main frame 1 Lift the PAPER GUIDE UPPER ASSY to disengage its left and right dowels from the main frame 2 Slightly move the PAPER GUIDE UPPER ASSY toward the rear of the printer and pull the assy downward to remove it Figure 4 136 Removing the PAPER GUIDE UPPER ASSY PAPER GUIDE UPPER ASSY dowels Front side of the printer ...

Page 190: ...C H A P T E R 5 ADJUSTMENT ...

Page 191: ... all adjustments listed in the table in the given order Always read and follow the precautions given in each section that explains each adjustment Ignoring the precautions can result in malfunction of the printer NO Is the part you repaired or replaced included in Table 5 1 Parts and Units that Require Adjustments P 191 YES 5 5 Reset Counters P 249 5 4 Check Results P 245 5 3 Standard Adjustment P...

Page 192: ... P 198 PF Motor 1 PF Adjustment P 239 2 EJ Adjustment P 241 Print head 1 Cleaning P 215 2 Head Rank ID P 204 3 Print Head Slant Adjustment CR P 207 4 PG Position Adjustment P 201 5 Print Head Slant Adjustment PF P 205 6 Auto Bi D Adjustment P 233 7 Auto Uni D Adjustment P 234 8 Colorimetric Calibration Tool P 217 9 Print Image P 246 10 Reset When Print Head Change P 249 Pump Motor 1 Reset When Pum...

Page 193: ...the print head is slanted in the PF direction and corrects if slanted P 205 Print Head Slant Adjustment CR Prints an adjustment pattern to check if the print head is slanted in the CR direction and corrects if slanted P 207 Initial Ink Charge Flag ON OFF Sets or clears a flag for initial ink charge as necessary after replacing the main board P 211 Parameter Backup Backs up the parameters stored in...

Page 194: ...l Overview Tool Page AU 1 AT 2 Check Nozzle Checks the nozzles for clogging P 245 Print Image Prints an image to check the print quality P 246 Print Results Prints all adjustment parameters life counters and error histories stored on the NVRAM P 247 Check Alignment Checks for any mis alignment P 248 Adjustment General Overview Tool Page AU 1 AT 2 Reset When Cleaning Unit Change Resets life counter...

Page 195: ...able Sonic Tension Meter U 505 1231678 Code type microphone U 505 1277074 Roller LD Height Adjustment Gauge Individually available upon request Roller LD Height Adjustment Tool Individually available upon request Roller LD Height Confirmation Standard Individually available upon request Enhanced Matte Paper A4 or Letter Archival Matte Paper A4 or Letter Genuine paper Economy Super Fine Paper A4 Ge...

Page 196: ...ill automatically start up Unless carrying out parameter writing execute parameter reading before carrying out the adjustments For operation of the NVRAM Backup Utility see 5 3 6 Parameter Backup Page 212 1 Double click on adjwiz2 exe to start the NVRAM Backup Utility 2 See 5 3 6 Parameter Backup Page 212 to execute parameter backup and complete the NVRAM Backup Utility 3 The startup screen of the...

Page 197: ...ou to perform all the required adjustments in a predetermined sequence 1 Highlight the part you replaced or repaired in the left box and click Add 2 Click OK Figure 5 2 Sequential Mode Individual mode This mode allows you to select and perform an adjustment individually 1 Highlight the target adjustment item and click OK Figure 5 3 Individual Mode ...

Page 198: ...001 3 g m z W 005 0 mm z S 0052 mm 2 Put the measurement microphone of the tension meter near the timing belt 3 Push the MEASURE button on the tension meter and pluck the timing belt using the tweezers to perform the tension measurement Figure 5 4 Tension Measurement C A U T I O N When carrying out the following procedure be careful not to deform or damage the SCALE PF C H E C K P O I N T Bring th...

Page 199: ... to the next step to carry out the tension adjustment 5 Loosen the two screws that secure the PF motor and then slide the motor in order to adjust the tension of the timing belt 6 When the adjustment is completed tighten the two screws and perform the measurement again 7 When the measured value falls within the specified range confirm it by performing the measurement another three times Figure 5 5...

Page 200: ... unit 3 Install the right LD roller guide to the main frame and lightly secure it with a screw 4 Turn ON the power of the roller LD height adjustment tool 5 Put the roller LD height adjustment gauge into the hole shown in Figure 5 7 Change the gauge type until the adjustment tool judges that the height is appropriate 6 When the appropriate gauge is selected by the adjustment tool tighten the screw...

Page 201: ...ARRIAGE ASSY manually Page 91 2 Put the thickness gauge on the following location of the platen and move the carriage unit slowly over the thickness gauge z Home Position side Third and fifth rib from the right z Center Ninth and 12th rib from the right z Opposite to the HP side 1 17th and 19th rib from the right Figure 5 8 Thickness Gauge Set Position Figure 5 9 PG Height Check C H E C K P O I N ...

Page 202: ...cure the PG adjustment levers on the left and right side of the carriage unit 7 Carry out the adjustment as follow z When T 0 90 contacts with the head Raise both right and left levers by the same amount z When T 1 00 does not contact with the head Lower both right and left levers by the same amount 8 When the adjustment is completed tighten the two screws and perform the measurement and adjustmen...

Page 203: ...number of the printer USB ID is automatically created according to the serial number 5 Click Write to write RTC USB ID in the NVRAM on the new main board 6 Click Next to display a confirmation screen Click Check to display all the information written on the NVRAM on the screen Confirm the information and click OK 7 Click Finish Figure 5 11 RTC USB ID Screen 1 Figure 5 12 RTC USB ID Screen 2 C A U ...

Page 204: ...and select Head Rank ID 5 Enter the 30 digit ID written down at Step 3 into the edit boxes in the same order as indicated on the label 6 Click Write 7 Click Finish When you already have the Head Rank ID data txt of the new print head 1 Turn the printer ON 2 Start up the Adjustment Program and select Head Rank ID 3 Click File Open and select a Head Rank ID data txt 4 Click Write 5 Click Finish Proc...

Page 205: ...ement result follow the instructions below z A B Pattern2 Click Next twice and then click Run in order to move the carriage unit to its home position Then click Finish on the next screen to finish the adjustment z A B or A B Pattern 1 3 Click Next and start adjustment on the next screen o to Step 8 8 Slightly turn the Head Slant Lever left and right to correct the slant of the print head z A B Pat...

Page 206: ...on A ADJUSTMENT Standard Adjustment 206 Figure 5 16 Head Slant Lever Figure 5 17 Print Head Slant Adjustment PF Screen 1 Figure 5 18 Print Head Slant Adjustment PF Screen 2 Figure 5 19 Print Head Slant Adjustment PF Screen 3 Head Slant Lever ...

Page 207: ... and click Run on the screen shown in Figure 5 28 The carriage unit will return to its home position Click Finish to finish the adjustment z NG Pattern Click Next and start adjustment on the next screen o to Step 8 Figure 5 20 Adjustment Pattern C H E C K P O I N T When removing the HOUSING UPPER do not remove the LOCK COVER ASSY Keep the ink cover closed and turn the ink cover open sensor ON CR_S...

Page 208: ...int of A H Rows Figure 5 22 Confirmation Point of B G Rows C F Rows CR_Slant_Pattern_02 1 4 1 4 1 4 1 4 1 4 1 4 1 4 1 4 1 4 1 4 1 4 1 4 NG Pattern 1 OK Pattern NG Pattern 2 Adjustment direction CR_Slant_Pattern_03 1 3 1 3 1 3 1 3 1 3 1 3 1 3 1 3 1 3 NG Pattern 1 OK Pattern NG Pattern 2 Adjustment direction ...

Page 209: ...the slant of the print head z In case of NG Pattern 1 turn the head adjust lever downward z In case of NG Pattern 2 turn the head adjust lever upward 10 Tighten the three screws loosened at Step 8 in the order of A o B o C 11 Click Back to go back to the previous screen and repeat Step 6 to Step 10 until the correct result is obtained Figure 5 23 Screws Securing the LEAF SPRING LOCK HEAD Figure 5 ...

Page 210: ...A ADJUSTMENT Standard Adjustment 210 Figure 5 25 Print Head Slant Adjustment CR Screen 1 Figure 5 26 Print Head Slant Adjustment CR Screen 2 Figure 5 27 Print Head Slant Adjustment CR Screen 3 Figure 5 28 Print Head Slant Adjustment CR Screen 4 ...

Page 211: ...ard Adjustment 211 5 3 5 Initial Ink Charge Flag ON OFF Procedure 1 Turn the printer ON 2 Start up the Adjustment Program and select Initial Ink Charge Flag ON OFF 3 Select ON or OFF and then click Run 4 Click Finish Figure 5 29 Initial Ink Charge ON OFF Screen ...

Page 212: ...lick Save and save the readout parameters under a new file name 6 To end click End Write Procedure 1 Remove the all Ink Cartridges 2 Remove the Maintenance Cartridge 3 Start up the Adjustment Program The NVRAM Backup Utility will automatically start If the Adjustment Program is already running execute Parameter Backup 4 Turn the printer ON while holding down the Menu Right Back Left Ink Cover Open...

Page 213: ...ty starts up instead of the Adjustment Program Select Operation To perform reading To perform writing Click Read When Not saving Save End Select Parameter file and write End Print Mechanism Operation History Close Adjustment Program starts up End Adjustment Program starts up To exit the Back Up Utility Turn ON the Printer in F W update mode Turn the Printer ON in F W update mode ...

Page 214: ... Program and select Check PG 3 Select any one of the PG settings and then click Run 4 Visually check the PG switch operation Be sure to check the following three points z Does the carriage move upward and downward z Is there any abnormality in driving transmission path z Does the light shielding plate rotate 5 Click Finish Figure 5 32 Check Point 1 Figure 5 33 Check Point 2 Figure 5 34 Check PG sc...

Page 215: ... 3 9 Cleaning Purpose There are four types of head cleaning Select and run a one of them to clean the print head Procedure 1 Turn the printer ON 2 Start up the Adjustment Program and select Cleaning 3 Select the cleaning type and press the corresponding key F1 to F4 to run the selected cleaning 4 When the cleaning is completed click Finish Figure 5 36 Cleaning Screen F5 Key Cleaning Amount of Ink ...

Page 216: ...RAM The stored serial number can be read and displayed for verification Procedure 1 Turn the printer ON 2 Start up the Adjustment Program and select Input Serial Number 3 Enter the 10 digit serial number of the printer and click Write The serial number is written onto the NVRAM on the main board 4 Click Read to display the stored serial number Figure 5 37 Input Serial Number Screen ...

Page 217: ... stable color quality Difference in color among individual products or each mode is reduced Refer to 2 10 Colorimetric Calibration Color ID Overview Page 60 PRINCIPLE The calibration is performed by measuring a printed correction pattern with a calibrator ID information that is calculated based on the acquired color values L a b is transmitted to the printer driver and the printer driver corrects ...

Page 218: ...nting surface protection Plain Paper A3 For alignment check EPSON Enhanced Archival Matte Paper A4 For printing charts Computer Following drivers should be installed beforehand Printer driver for this product USB driver for the calibrator GretagMacbeth eye one i1 Calibrator With UV filter Calibration base plate White plate Accessory provided with the calibrator Scanning ruler Scale Accessory provi...

Page 219: ...al click Next 6 Load an A4 sized EPSON Enhanced Archival Matte paper vertically on the ASF and click Next to print a calibration chart 7 Make sure there is no missing dots in the nozzle check pattern at the bottom of the calibration chart If there are missing dots click Print Calibration Chart Again The calibration chart will be printed again after performing cleaning If there are no missing dots ...

Page 220: ... button on the side of the calibrator until it beeps Do not move or lift the calibrator during pressing the button When the calibration is completed normally the following screen appears Figure 5 40 i1 Calibrator Figure 5 41 Calibration Screen C A U T I O N Do not contaminate the white plate on the calibration base plate If any dirt is observed on the white plate wipe it off using alcohol Button B...

Page 221: ...art facing left side and set the scanning ruler onto the bottom most patch line Figure 5 42 Measurable Time and Date Check Figure 5 43 Setting the Chart and the Scanning Ruler 2005 04 11 14 44 GMT 2005 04 11 05 44 2005 04 18 14 39 GMT 2005 04 18 05 39 S N 0000000000 OS Win BlackInk Matte Printer EPSON PX 6500 Nozzle check pattern Calibration patch 2005 04 11 14 44 GMT 2005 04 11 05 44 2005 04 18 1...

Page 222: ...ure 5 44 Color Measuring Screen Figure 5 45 Setting the Calibrator Measuring Position Measured lines Currently measured line Unmeasured lines C A U T I O N When measuring colors pay attention to the instructions below Take more than 10 seconds to measure one line Keep the scan speed constant as possible Measure each of the lines twice Measure the line as instructed on the program screen Place the ...

Page 223: ...n A ADJUSTMENT Standard Adjustment 223 Figure 5 46 Color Measuring Screen Figure 5 47 Color Measuring Order 2005 04 11 14 44 GMT 2005 04 11 05 44 2005 04 18 14 39 GMT 2005 04 18 05 39 S N 0000000000 OS Win BlackInk Matte Printer EPSON PX 6500 ...

Page 224: ... ADJUSTMENT Standard Adjustment 224 16 Make sure that the READY message is displayed on the printer LCD panel and click Next to write the Color ID to the printer main unit 17 When the writing is completed click Next Figure 5 48 Screen Transition ...

Page 225: ...ct click Print Verify Chart Again The verify chart will be printed again after performing cleaning If there are no missing dots let the chart stand for five minutes until it dries out paying attention not to touch the chart 21 When the verify chart dries out after five minutes click Next 22 Connect the calibrator to the computer and click Color Measuring 23 Place the calibrator on the calibration ...

Page 226: ...o Figure 5 50 lay the chart on the black paper or sheet with the upper part of the chart facing left side and set the scanning ruler onto the bottommost patch line Figure 5 50 Setting the Chart and the Scanning Ruler Figure 5 51 Measurable Date and Time Check Sheet number Sheet2 S N 0000000000 2005 04 07 12 38 GMT 2005 04 07 03 38 2005 04 14 12 33 GMT 2005 04 14 03 33 䐟 䐠 䐡 䐢 䐣 Sheet2 S N 00000000...

Page 227: ...gray part 4 Once the measuring is completed release the button 5 Repeat Step 1 through 4 twice for the same patch line 6 Repeat Step 1 through 5 to measure the bottommost line to the top line The line which needs to be measured is displayed on the screen 28 Once all the lines 5 lines are measured click OK 29 Measure Sheet 2 by following Step 25 through Step 27 Figure 5 52 Color Measuring Order Fig...

Page 228: ...EPSON Stylus Pro 3800 3800C 3850 Revision A ADJUSTMENT Standard Adjustment 228 30 Click Save to save the result under a new file name txt file 31 Click End Figure 5 55 Entire Process Screen ...

Page 229: ...tart the printer in the F W update mode 4 Start the Firmware Update Tool 5 Select the port and the firmware file UPG format 6 Click Send to transfer the firmware data 7 When the transferring is completed Complete pop up window will be displayed Click OK 8 When writing the firmware is completed the printer automatically reboots Figure 5 56 Firmware Update Tool Screen 1 Figure 5 57 Firmware Update T...

Page 230: ...to position of the ink mark sensor Checks if the ink mark sensor functions normally using the auto nozzle check Paper Used Size A4 Letter Type Economy SuperFine Paper Procedure 1 Turn the printer ON 2 Start up the Adjustment Program and select Ink Mark Sensor Adjustment for Auto Nozzle Check 3 Click Run to print an adjustment pattern The printer will automatically conducts the adjustment 4 Click F...

Page 231: ...31 Figure 5 59 Adjustment Pattern IMS Check_01 IMS Level A D XXX D A XX I O 0 OK IMS Position Dx XX Dm XX Dm XX IMS Auto Nozzle Check No NG Pattern Pk Mk X Lk X LLk X C X M X Lc X Lm X Y X OK IMS Auto Nozzle Check 5 NG Pattern H Line Pk Mk X Lk X LLk X C X M X Lc X Lm X Y X OK ...

Page 232: ...CCard 2 Check DrvNo and GrpNo 2 1 Start Menu CONTEC API PAC W32 Start up API TOOL Configuration 2 2 Remember the DrvNo and GrpNo in the board list of Configuration Tool 2 3 Exit the Configuration Tool At this time if the message to save in registry is displayed click Yes 3 Set DrvNo GrpNo 3 1 In the screen of Head Washing and Ink Discharging in Adjustment Program key in the DrvNo and GrpNo as reme...

Page 233: ...ON 2 Start up the Adjustment Program and select Auto Bi D Adjustment 3 Click Run to print the adjustment pattern When the pattern is printed the printer automatically starts to scan the pattern and performs the corrections No manual adjustment is required 4 Click Finish Figure 5 61 Auto Bi D Adjustment Screen Figure 5 62 Adjustment Pattern Auto Bid_01 Bi D VSDX PGXXX M XXX C XXX Pk Mk XXX Y XXX LL...

Page 234: ...uto Uni D Adjustment 3 Click Run to print the adjustment pattern When the pattern is printed the printer automatically starts to scan the pattern and performs the corrections No manual adjustment is required 4 Click Finish Figure 5 63 Auto Uni D Adjustment Screen Figure 5 64 Adjustment Pattern Auto Unid_01 Uni D VSDX PGXXX M XXX C XXX Pk Mk XXX Y XXX LLk XXX Lk XXX Lc XXX Lm XXX VSDX M C Bk Y LLk ...

Page 235: ...printer ON 2 Start up the Adjustment Program and select Check the Release Of Grid Roller 3 Draw out the board paper tray and visually check the release separating operation of the grid roller 4 Close the board paper tray and check whether the grid roller return to the original position or not 5 Click Finish Figure 5 65 Grid Roller Figure 5 66 Check the Release Of Grid Roller Screen grid roller ...

Page 236: ...k Network Communication Purpose Checks the printer communication through network connection Procedure 1 Turn the printer ON 2 Start up the Adjustment Program and select Check Network Communication 3 Input IP address and click Run 4 Click Finish Figure 5 67 Check Network Communication Screen ...

Page 237: ...attern 4 Referring to Figure 5 69 select the numerical value for the position where the printed line is exactly 5mm away from the paper edge for each left right top and bottom sides 5 Enter the numerical values found in Step 4 into the corresponding edit boxes 6 Click Write and then click Print to print the adjustment pattern again 7 After confirming that all values are within the specified range ...

Page 238: ...0 11 12 13 14 15 16 13 14 12 11 10 9 8 7 6 5 4 3 2 1 0 E E 1 2 3 4 5 6 7 8 9 10 11 12 13 16 17 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 10 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 5 6 7 E 4 3 2 5mm 5mm C H E C K P O I N T The under bar _ on the top and bottom margins and the E next to the left and right margins show the current settings ...

Page 239: ...o print the adjustment pattern 4 Examine the printout patterns and select the value for the group of most closely aligned patterns no gap but not overlapping each other 5 Enter the numerical value found in Step 4 into the corresponding edit box 6 Click Write and then click Print to print the adjustment pattern again 7 Confirm the adjustment condition and if they are proper results click Finish If ...

Page 240: ... Stylus Pro 3800 3800C 3850 Revision A ADJUSTMENT Standard Adjustment 240 Figure 5 72 Adjustment Pattern PF Adjustment_01 VSD2L M C Bk Y LLk Lk Lc Lm 0 XXX Dot miss alignment Vertical 5 3 1 1 3 5 4 2 0 E 2 4 ...

Page 241: ...ment pattern 4 Examine the printout patterns and select the value for the pattern of most closely aligned with the upper bar no gap but not overlapping each other 5 Enter the numerical value found in Step 4 into the corresponding edit box 6 Click Write and then click Print to print the adjustment pattern again 7 Confirm the adjustment condition and if they are proper results click Finish If they a...

Page 242: ...EPSON Stylus Pro 3800 3800C 3850 Revision A ADJUSTMENT Standard Adjustment 242 Figure 5 75 Adjustment Pattern EJ Adjustment_01 4 3 2 1 0 1 2 3 4 5 6 7 8 9 ...

Page 243: ...e 4 Turn the printer ON 5 Start up the Adjustment Program and select Check Ink Selector Operation 6 Select MK or PK and then click Run Referring to Figure 5 77 visually check if the ink selector works normally or not 7 Click Finish Figure 5 76 Check Ink Selector Operation Screen Figure 5 77 Ink Selector Switching Operation C H E C K P O I N T When removing the HOUSING UPPER do not remove the LOCK ...

Page 244: ...abel of the CR Motor Then replace the CR Motor and assembly the printer z Induced voltage constant xx x mV rad s z Motor Resistance xx x 2 Turn the printer ON 3 Start up the Adjustment Program and select Write Constant When CR change 4 Input the values written down in Step 1 to the corresponding edit boxes of Voltage Of Motor and Motor Resistance 5 Click Write 6 Click Finish Figure 5 78 Motor Char...

Page 245: ... A4 Letter Type Economy Super Fine Paper Procedure 1 Turn the printer ON 2 Start up the Adjustment Program and select Check Nozzle 3 Click Run to print a nozzle check pattern 4 Check the printout pattern for dot missing 5 When no dot missing is observed click Finish to exit out of the menu If the pattern has broken lines or missing segment run a cleaning Then print the pattern again to check Figur...

Page 246: ...ur selected file Procedure 1 Turn the printer ON 2 Start up the Adjustment Program and select Print Image 3 Click Open and select any one of the image files The image files will be displayed in utility 4 Click Print and printer windows appears Select the printer driver 5 Check the print quality and click Finish Figure 5 82 Print Image Screen ...

Page 247: ...arameters stored on the printer Paper Used Size A3 Type All types of paper Procedure 1 Turn the printer ON 2 Start up the Adjustment Program and select Check Results 3 Click Print to print the Adjustment Result Check Sheet 4 After confirming the result click Finish Figure 5 83 Check Results Screen Figure 5 84 Adjustment Result Check Sheet Sample ...

Page 248: ... an alignment check pattern 4 Check the printout pattern for any misalignment symptoms 5 When no misalignment symptom is observed click Finish to exit out of the menu If misalignment is found on the pattern run a cleaning Then print the pattern to check again Figure 5 85 Check Alignment Screen Figure 5 86 Alignment Check Pattern Alignment Check_01 VSD2L M C Bk Y LLk Lk Lc Lm 0 XXX 0 XXX Dot miss a...

Page 249: ...rogram and select the applicable counter reset menu 3 Click Run to reset the counter 4 Click Finish Figure 5 87 Counter Reset Screen Table 5 5 Counter Reset List Replaced Parts Name Reset Menu Name PUMP CAP ASSY Reset When Cleaning Unit Change Reset When Pump Motor Change PRINT HEAD Reset When Print Head Change INK SYSTEM ASSY Reset When INK SYSTEM ASSY Change POROUS PAD TRAY INK EJECT Reset When ...

Page 250: ...C H A P T E R 6 MAINTENANCE ...

Page 251: ...t it come into contact with your skin If it happens wash out your eye or skin with water immediately If any abnormality is found contact a physician C A U T I O N Ensure sufficient work space for servicing Locate the printer on a stable and flat surface When carrying the printer be sure to hold the printer by its holding positions When using compressed air products such as air duster for cleaning ...

Page 252: ...ace the PUMP CAP ASSY Reset the life counter using the Adjustment program Remaining Life 4 Cartridge Holder Waste Ink Pads Ink Cartridge removal 1 200 times Total amount of 9 inks 160 g MAINTENANCE REQUEST 0080 SERVICE CALL ERROR 1430 Replace the POROUS PAD TRAY INK EJECT Reset the life counter using the Adjustment program 1 194 times Ink Selector Selection lever switching operations 7 800 cycles ...

Page 253: ...ter on it 2 Is there any ink adhered to it Remedy 1 Clean it off with a brush or OA cleaner 2 Wipe it off with a damped cloth and then wipe with a clean dry cloth Cleaning Point Item Paper feed path Point to be checked Has any paper dust been accumulated Remedy Clean it off with a brush or OA cleaner Item ASF PF roller Separation pad Point to be checked Has any paper dust been accumulated Remedy C...

Page 254: ...G 71 Part code 1304682 p 255 2 3 4 PAPER GUIDE UPPER ASSY Part name G 26 Part code 1080614 p 255 5 Spur Gear 22 B SHAFT RELEASE ASSY Part name G 26 Part code 1080614 p 257 6 HOLDER ROLLER SUPPORT L SHAFT RELEASE ASSY Part name G 26 Part code 1080614 p 257 7 HOLDER ROLLER SUPPORT R SHAFT RELEASE ASSY Part name G 26 Part code 1080614 p 258 8 FRAME EJECT ASSY Part name G 26 Part code 1080614 p 258 9 ...

Page 255: ...stains or dust off the lubrication point with a cloth moistened with alcohol Apply with a syringe Pin head I2 mm Lubrication Point GUIDE PLATE CR Part Name PAPER GUIDE UPPER ASSY Lubrication Point From the home position side the first PAPER GUIDE UPPER ASSY as seen from the rear of the printer On the assy with where the release shaft contacts Lubricants G 26 Amount 1 I2 mm x 7 mm x 1 point 2 I2 mm...

Page 256: ... Amount Vertical I2 mm x 7 mm x 2 points Remarks Apply with a syringe Pin head I2 mm PAPER GUIDE UPPER ASSY Lubrication Point Part Name PAPER GUIDE UPPER ASSY Lubrication Point From the home position side the 3rd to 8th PAPER GUIDE UPPER ASSYs as seen from the rear of the printer On the assys with where the release shaft contacts Lubricants G 26 Amount 1 I2 mm x 13 mm x 6 points 2 I2 mm x 7 mm x 6...

Page 257: ...x all around x 1 point 2 I2 mm x all around x 1 point 3 I2 mm x 2 mm x 1 point Remarks Apply with a syringe Pin head I2 mm Washer Spur Gear 22 B Lubrication Point 1 Lubrication Point 2 Lubrication Point 3 Part Name HOLDER ROLLER SUPPORT L SHAFT RELEASE ASSY Lubrication Point On the HOLDER ROLLER SUPPORT L with where the SHAFT RELEASE PAPER GUIDE UPPER contacts Lubricants G 26 Amount 1 I2 mm x 2 mm...

Page 258: ... 3 points Remarks Apply with a syringe Pin head I2 mm HOLDER ROLLER SUPPORT R Lubrication Point Part Name FRAME EJECT ASSY Lubrication Point Left and right pivots of the FRAME EJECT ASSY Left and right shafts for the torsion spring 0 046 Lubricants G 26 Amount 1 I2 mm x all around x each point 2 I2 mm x 5 mm x each point Remarks Apply with a syringe Pin head I2 mm Right side Lubrication Point 2 Lu...

Page 259: ...ricants G 26 Amount 1 I2 mm x all around x each point 2 I2 mm x 2 mm x each point Remarks Apply with a syringe Pin head I2 mm Board Paper Tray Lubrication Point 1 Lubrication Point 2 Part Name Guide Stacker Left Board Paper Tray Lubrication Point In the groove of the Guide Stacker Left On the both inner sides at the corner of the groove Lubricants G 45 Amount I2 mm x 4 mm x 2 points each Remarks A...

Page 260: ...s G 45 Amount I2 mm x 4 mm x 2 points each Remarks Apply with a syringe Pin head I2 mm Guide Stacker Right Lubrication Point Lubrication Point Part Name Torsion Spring 0 15 Lubrication Point On the Torsion Spring 0 15 at the left side of the Board Paper Tray with where the SHAFT PAPER GUIDE BOARD PAPER contacts Lubricants G 45 Amount I2 mm x 2 mm x 2 points Remarks Apply with a syringe Pin head I2...

Page 261: ... points Remarks Apply with a syringe Pin head I2 mm SHAFT PAPER GUIDE BOARD PAPER Torsion Spring 0 15 Lubrication Point Part Name STACKER ASSY Lubrication Point On the SHAFT STACKER A with where the STACKER A contacts three points the left center and right Lubricants G 26 Amount 1 I2 mm x 2 mm x 1 point 2 I2 mm x 2 mm x 1 point 3 I2 mm x 2 mm x 2 points Remarks Apply with a syringe Pin Head I2 mm ...

Page 262: ...C H A P T E R 7 APPENDIX ...

Page 263: ...osition Sensor CN62 Blue 3 Maintenance Cartridge Cover Sensor CN63 FFC 17 BOARD ASSY SUB CN1 CN64 FFC 19 BOARD ASSY PANEL CN1 CN67 4 USB I F CN69 FFC 17 Print Head CN70 FFC 17 Print Head CN71 FFC 17 Print Head CN72 FFC 17 Print Head CN76 FFC 23 Ink Cartridge Sensor CSIC Light Cyan Light Magenta Yellow CN77 FFC 23 Ink Cartridge Sensor CSIC Light Light Black Cyan Magenta CN78 FFC 23 Ink Cartridge Se...

Page 264: ...EPSON Stylus Pro 3800 3800C 3850 Revision A APPENDIX Connectors 264 BLOCK DIAGRAM Figure 7 1 Block Diagram LLK MK PK LK ...

Page 265: ...9 CN69 72 Print Head Main Board FFC 17 x 4 CN62 Maintenance Cartridge Cover Sensor Main Board Cable 2 CN30 Maintenance Cartridge Sensor CSIC Main Board FFC 7 CN76 78 Ink Cartridge Sensor CSIC Main Board FFC 23 x 3 No P CN J Pins S CN1 BOARD ASSY SUB Main Board FFC 17 CN2 Ink Selector Motor Main Board Cable 2 CN3 Ink Mark Sensor Sub Board FFC 4 CN4 PG Origin Sensor Sub Board Cable 3 CN5 Ink Select ...

Page 266: ... Cable 4 Relay Cable Main Board APG Motor Cable 5 CN46 MOTOR ASSY PRESSURE Main Board Cable 2 CN57 MOTOR RELEASE ASSY ESL ASP Main Board Cable 2 No P CN J Pins CN58 MOTOR ASSY PUMP Main Board Cable 4 CN49 BOARD ASSY ENCORDER PF Main Board FFC 5 CN50 Board Paper Tray Open Sensor Main Board Cable 2 CN51 Ink Cover Lock Sensor Main Board Cable 3 CN52 Pressure Pump Home Sensor Main Board Cable 6 Pressu...

Page 267: ...UTTON 145 COVER LCD 147 OPTICAL TUBE LED RIGHT 148 OPTICAL TUBE LED LEFT 149 BUTTON PS 152 SHAFT HINGE COVER PRINTER 153 TORSION SPRING RIGHT 0 17 154 TORSION SPRING LEFT 0 17 155 LEVER OPEN 156 SHEET INK MIST 157 LABEL MAXART K3 B 160 LABEL PAPER SUPPORT MANUAL LABEL PAPER SUPPORT MANUAL B 162 LABEL PX INNOVATION LABEL ULTORA CHROME INK K3 B 163 LABEL PAPER SUPPORT LABEL PAPER SUPPORT B 165 LABEL...

Page 268: ...LIDER STW FT70 t 0 25 542 HOLDER PLANET 543 SPUR GEAR 29 6 544 COMBINATION GEAR 13 6 31 2 545 COMBINATION GEAR 20 34 4 546 COMPRESSION SPRING 3 05 547 POROUS PAD INK EJECT TANK RIGHT 548 MOTOR ASSY APG 552 LEAF SENSOR Table 7 5 After Service Part List Ref No Part Name 553 HARNESS MAINTENANCE TANK 556 FOOT 557 BELT CR 558 HOLDER PULLEY DRIVEN 559 SCALE PF 180 560 TORSION SPRING PAPER GUIDE UPPER 56...

Page 269: ...EPSON Stylus Pro 3800 3800C 3850 Revision A APPENDIX Exploded Diagrams 269 7 4 Exploded Diagrams ...

Page 270: ...Only numbered Service Parts are available No 1 Rev 01 C635 CASE 011 PX 5800 STYLUS PRO 3800 3800C 3850 132 517 556 556 553 552 556 556 556 556 556 556 556 118 133 123 124 125 115 131 130 156 120 A1 ...

Page 271: ... Only numbered Service Parts No 2 Rev 01 C635 CASE 021 PX 5800 STYLUS PRO 3800 3800C 3850 160 113 122 163 162 EHC ONLY 157 134 155 152 154 153 119 143 144 145 147 148 149 128 152 117 116 165 122 129 121 114 B2 B1 C1 ...

Page 272: ...Only numbered Service Parts are available No 3 Rev 01 C635 ELEC 011 PX 5800 STYLUS PRO 3800 3800C 3850 320 310 300 584 200 M1 B1 F1 H1 P3 P2 P1 U2 U1 C2 W1 Y1 A1 E1 X1 I1 K1 L1 J1 G1 V1 X2 B2 D1 D1 ...

Page 273: ...ble Only numbered Service Parts No 4 Rev 01 C635 MECH 011 PX 5800 STYLUS PRO 3800 3800C 3850 569 527 570 527 521 566 567 522 541 544 543 546 542 545 548 547 510 582 581 572 571 583 580 505 H1 G1 I1 K1 J1 L1 E1 F1 ...

Page 274: ...are available Only numbered Service Parts No 5 Rev 01 C635 MECH 021 PX 5800 STYLUS PRO 3800 3800C 3850 512 513 516 538 537 560 560 560 560 560 560 560 560 520 520 520 520 520 520 520 520 110 523 515 ...

Page 275: ...are available Only numbered Service Parts No 6 Rev 01 C635 MECH 031 PX 5800 STYLUS PRO 3800 3800C 3850 526 514 500 511 N2 N1 O2 O4 O6 O7 O5 O3 O9 O8 O9 O8 O7 O6 O5 O4 O3 O2 O1 P3 P1 P2 O1 ...

Page 276: ...red Service Parts No 7 Rev 01 C635 MECH 041 PX 5800 STYLUS PRO 3800 3800C 3850 565 565 565 562 563 529 564 518 558 524 532 530 527 528 573 531 533 534 535 536 506 501 127 126 557 N1 N2 Q1 R1 U3 T1 S1 Q1 R1 T1 C2 U3 S1 U2 U1 V1 ...

Page 277: ...Only numbered Service Parts are available No 8 Rev 01 C635 MECH 051 PX 5800 STYLUS PRO 3800 3800C 3850 111 507 568 559 525 561 X2 W1 Y1 X1 ...

Page 278: ... The circuit diagrams of the EPSON Stylus Pro 3800 3800C 3850 circuit boards are shown on the following pages Main Board 1 C635 MAIN 1 Main Board 2 C635 MAIN 2 Main Board 3 C635 MAIN 3 Main Board 4 C635 MAIN 4 Panel Board C635 PNL 1 Sub Board C635 SUB 1 PSB Board C635 PSB 1 PSE Board C635 PSE 1 ...

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