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EPSON Stylus CX3700/CX3800/CX3805/CX3810/DX3800/DX3850

Revision A

TROUBLESHOOTING

Troubleshooting

76

• Operation

•

–

The leading edge of paper does not go
through between the EJ Roller Unit and
the Star Wheel.

EJ Frame Unit**

3. Check if the Star Wheel Holders does not come off.

3. Reassemble the Star Wheel Holders

correctly.

4. Check if the Spur Gear 36 is not damaged.

4. Replace the EJ Frame Unit with a new one.

The leading edge of paper is not loaded
to the PF Roller Unit.

Paper Guide Upper

Unit **

1. Check if the Paper Guide Upper Unit is correctly

assembled.

1. Reassemble the Paper Guide Upper Unit to

the Main Frame correctly.

* The Carriage Unit can move to home position even if the Torsion Spring 0.22 comes off. However, the PE Sensor Lever keeps the high signal condition in the next operation. Therefore, the paper

jam error is detected.

** In case that the paper jam error occurs in each operation, the jammed paper contacts the nozzle surface of the Print Head and the Print Head may be damaged.

Table 3-11. Check point for the paper jam error according to each phenomenon

Occurrence

timing

CR position

Detailed phenomenon

Defective

unit/part name

Check point

Remedy

Star Wheel Holders

Paper Guide Upper Unit

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Summary of Contents for CX3810 - Stylus Color Inkjet

Page 1: ...EPSON StylusCX3700 CX3800 CX3805 CX3810 DX3800 DX3850 Color Inkjet Printer SEIJ05 012 SERVICE MANUAL ...

Page 2: ...f this 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 ...

Page 3: ...ON POWER SUPPLY AND OTHER ELECTRONIC COMPONENTS 4 WHEN DISASSEMBLING OR ASSEMBLING A PRODUCT MAKE SURE TO WEAR GLOVES TO AVOID INJURIER 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 EPSON PRO...

Page 4: ...d Diagram Parts List Electrical Circuits 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 Indicates an operating or maintenance procedure practice or ...

Page 5: ...Revision Status Revision Issued Date Description A Aug 10 2005 First Release ...

Page 6: ... 5 3 Operations 29 1 5 4 Printer Condition and Panel Status 31 1 5 5 Memory Functions 33 1 5 6 Printer Initialization T B D 34 Chapter 2 OPERATING PRINCIPLES 2 1 Overview 36 2 2 Printer Mechanism 36 2 2 1 Printer Mechanism 36 2 2 2 Print Head 37 2 2 3 Carriage Mechanism 39 2 2 4 Paper Loading Feeding Mechanism 41 2 2 5 Ink System Mechanism 46 2 2 6 Ink Sequence 49 2 3 Scanner Mechanism 51 2 3 1 Sc...

Page 7: ... FFC 121 4 4 20 Paper Guide Upper Unit 124 4 4 21 EJ Frame Unit 125 4 4 22 Ink System Unit 126 4 4 23 Paper Guide Front Unit 127 4 4 24 PF Roller Unit 128 4 5 Scanner Section 129 4 5 1 Scanner Housing Upper 129 4 5 2 Scanner Carriage Unit 130 4 5 3 Scanner Motor Unit Scanner HP Sensor Driven Pulley 132 Chapter 5 ADJUSTMENT 5 1 Overview 134 5 1 1 Required Adjustments 134 5 2 Adjustment by Using Adj...

Page 8: ...C H A P T E R 1 PRODUCTDESCRIPTION ...

Page 9: ...ts from using a more recently developed type of ink which enables photo quality copies to be made not only on special media but even on plain paper Only the basic copy functions are provided for easier operation Paper size can be selected from two options Enlarge Reduce factor can be selected from two options actual size 100 or Fit to page Copy margin is automatically selected from three options r...

Page 10: ...iver Print Speed Printable Width Note CPS Characters Second This speed is when using normal dot printing mode Note Draft Printing B 1 B 2 A 1 A 2 A 3 B 29 C 1 A 30 A 32 A 33 A 31 C 2 C 29 D 1 A 60 A 62 A 63 A 61 D 2 D 28 A 89 A 90 D 29 2 822 40 360 inch 0 2117 1 120 inch 0 2117 1 120 inch Paper Fees Direction Carriage Moving Direction Table 1 2 Print Resolution Horizontal Direction Across Columns ...

Page 11: ... Table 1 5 Graphics Mode Border free Printing Horizontal Resolution Printable Area Max Dot Count CR Speed 360 dpi 215 05 mm 8 46 3048 285 cps 720 dpi 215 05 mm 8 46 6096 285 cps 1440 dpi 215 05 mm 8 46 12192 285 cps 2880 dpi 215 05 mm 8 46 24384 285 cps Table 1 6 Cut Sheets Paper Size Dimensions Thickness Weight Paper Type Width Length A4 210 mm 297 mm 0 08 0 11 mm 64 90 g m2 17 24 lb Plain paper ...

Page 12: ...ounter problems switch to a higher grade of paper It is necessary that there is no wrinkle nap tear fold so on in the form Don t use the adhesive envelopes Don t use sleeve insert envelopes and cellophane window envelopes Table 1 8 Exclusive Papers Item Size Width mm Length mm Thickness mm Weight g m2 Premium Ink Jet Plain Paper 1 A4 210 297 0 11 80 Bright White Ink Jet Paper 1 A4 210 297 0 13 92 ...

Page 13: ... reduce print quality and cause paper jams or other problems If you encounter problems switch to a higher grade of paper It is necessary that there is no wrinkle nap tear fold and so on in the form The curve of form must be 5mm or below Table 1 9 Applicable Paper Printing Area Paper Type Left Margin Right Margin Top Margin Bottom Margin Cut sheets A4 3 mm 0 12 3 mm 0 12 3 mm 0 12 3 mm 0 12 A5 B5 L...

Page 14: ...g Paper Type Size Left Overhang Right Overhang Top Overhang Bottom Overhang Exclusive paper Premium Glossy Photo Paper Letter 2 54 2 54 2 96 4 02 A4 2 54 2 54 2 96 4 02 8 x 10 2 54 2 54 2 96 4 02 5 x 7 2 54 2 54 2 96 4 02 4 x 6 2 54 2 54 2 82 3 60 3R 2 54 2 54 2 82 3 60 Premium Semigloss Photo Paper Letter 2 54 2 54 2 96 4 02 A4 2 54 2 54 2 96 4 02 4 x 6 2 54 2 54 2 82 3 60 Matte Paper Heavyweight...

Page 15: ... A N A N A A4 N A N A N A N A 8 x 10 N A N A N A N A 5 x 7 N A N A N A N A 4 x 6 2 54 2 54 2 96 5 08 3R 2 54 2 54 2 96 5 08 Premium Semigloss Photo Paper Letter N A N A N A N A A4 N A N A N A N A 4 x 6 2 54 2 54 2 96 5 08 Matte Paper Heavyweight Letter N A N A N A N A A4 N A N A N A N A 8 x 10 N A N A N A N A Double sided Matte Paper Letter N A N A N A N A A4 N A N A N A N A Economy Photo Paper A4...

Page 16: ...PL refer to 1 2 1 4 Paper Support p 11 Refer to the following table As for each margin area refer to Figure 1 5 p 16 Figure 1 5 Printable Area for Envelopes Table 1 12 Applicable Paper Printing Area Paper Type Left Margin Right Margin Top Margin Bottom Margin No 10 5 mm 0 20 5 mm 0 20 3 mm 0 12 20 mm 0 79 DL C6 Printable area LM TM RM BM Paper Feed Direction PW PL ...

Page 17: ...mm D x 55 25 mm H Figure 1 6 Ink Cartridge Table 1 13 Ink Cartridge Color Size Europe Asia EAI Black S size T0621 T0601 SS size T0611 T0631 Cyan S size T0602 SS size T0612 T0632 Magenta S size T0603 SS size T0613 T0633 Yellow S size T0604 SS size T0614 T0634 Table 1 14 Storage Temperature Situation Storage Temperature Limit When stored in individual boxes 30 oC to 40 oC 1 month max at 40 oC When i...

Page 18: ...ing resolution 50 to 4800 dpi selectable in 1 dpi steps 7200 dpi 9600 dpi Gradations pixel depth Each color pixel has 16 bit input and either 1 bit or 8 bit output Scanning speed 600 dpi Color Approx 15 msec line Monochrome Approx 5 msec line Light source RGB Three Color LED 1 2 2 2 Detailed Specifications Control commands ESC I D7 Gamma correction Two user defined levels 1 2 2 3 Image Scanning Ar...

Page 19: ...nsation 3 Under the following conditions Figure 1 8 Temperature Humidity Range 1 2 3 3 Durability Total print life 10 000 pages black only A4 or five years whichever comes first Print Head Life Seven billion shots per nozzle or five years whichever comes first Scanner head MCBF 22 000 cycles Table 1 16 Primary Power Input 100 120 V model 220 240 V model Rated power supply voltage ACV 100 120 220 2...

Page 20: ...y Standards EMC 1 2 3 6 CE Marking 220 240 V version Low Voltage Directive 73 23 EEC EN60950 EMC Directive 89 336 EEC EN55022 Class B EN61000 3 2 EN61000 3 3 EN55024 Table 1 18 Safety Standards EMC 100 120 V version 220 240 V version Safety standards UL60950 EN 60950 CSA C22 2 No 60950 EMI FCC part15 subpart B class B EN 55022 CISPR Pub 22 class B CAN CSA CEI IEC CISPR 22 Class B AS NZS CISPR22 cl...

Page 21: ... Device ID Model Name Device ID CX3700 00H 5AH MFG EPSON CMD ESCPL2 BDC D4 ESCPR1 MDL Stylus SP CX3700 CLS PRINTER DES EPSON SP Stylus SP CX3700 CX3800 CX3805 CX3810 00H 5AH MFG EPSON CMD ESCPL2 BDC D4 ESCPR1 MDL Stylus SP CX3800 CLS PRINTER DES EPSON SP Stylus SP CX3800 DX3800 DX3850 00H 5AH MFG EPSON CMD ESCPL2 BDC D4 ESCPR1 MDL Stylus SP DX3800 CLS PRINTER DES EPSON SP Stylus SP DX3800 Table 1 ...

Page 22: ...opy Layout The following copy layout is provided according to Paper type Paper size and zoom selections Standard copy Provided for ordinary use with 3mm copy margin from every side BorderFree copy Border free printing of copies occurs when the print area is set as larger than the copy paper s size In such cases the outer edges of the original image may be omitted in the printed copy NOTE Only Stan...

Page 23: ...rn A4 Black 5 sec Fastest mode 360 x 120dpi 14 sec Default 360 x 360dpi Color 14 sec Fastest mode 360 x 120dpi 72 sec Default 360 x 360dpi NOTE CPM is not defined as this unit has single copy function only 1 4 3 Configuration for Copying Note 1 Default is the state in which Fit to page is not selected When Fit to page is selected scan resolution will be optimized according to enlarge reduce scale ...

Page 24: ... mm 11 7 3 mm Table 1 28 Copy printer RM LM TM BM 3 mm 0 12 3 mm 0 12 3 mm 0 12 3 mm 0 12 a a Copy Print area Copy paper Print direction Scan direction Right side of copy Right side of original Original face down Scan area Scan bed BM TM PL RM LM Top PW 2 1 OLM Top RW OTM RL Note 1 This indicates the top left corner of the original Normally this corner is aligned with the scan bed s top right corn...

Page 25: ...7 mm 11 7 1 5 mm 1 mm Table 1 30 Copy printer RO LO TO BO 2 5 mm 2 5 mm 3 0 mm 5 0 mm a a Copy Print area Copy paper Print direction Scan direction Right side of original Original face down Scan area Scan bed BO TO PL Top PW 2 1 OLM Top RW OTM RL Note 1 This indicates the top left corner of the original Normally this corner is aligned with the scan bed s top right corner as the reference point 2 T...

Page 26: ...1 5 mm 1 mm Table 1 32 Copy printer RM LM TM BM 1 5 mm 1 5 mm 1 5 mm 1 5 mm a a Copy Print area Copy paper Print direction Scan direction Right side of copy Right side of original Original face down Scan area Scan bed BM TM PL RM LM Top PW 2 1 OLM Top RW OTM RL Note 1 This indicates the top left corner of the original Normally this corner is aligned with the scan bed s top right corner as the refe...

Page 27: ...ton Function Power Button Execute turning on off this unit Ink Button Execute exchanging ink cartridges or head cleaning Paper Size Button Select paper size Fit to Page Button Alternate zoom of Fit to page and default actual 100 B W Start Button 1 Start monochrome copy Color Start Button Start card print or color copy Stop Button Stop job of copying or printing or sometimes work as shift button Ta...

Page 28: ...e and Asia Power Button Ink Button Paper Size Button Fit to Page Button B W Start Button Color Start Button Stop Button Power LED Error LED Ink LED Paper Size LED 1 2 Fit to Page LED Power Button Ink Button Paper Size Button Fit to Page Button B W Start Button Color Start Button Stop Button Power LED Error LED Ink LED Paper Size LED 1 2 Fit to Page LED Foe Europe For Asia ...

Page 29: ...5 Invalid while printing scanning cleaning head stopping printing or copying exchanging I C or in error status Fit to Page Button Alternate Fit to Page status and turn on or off the Fit to Page LED Invalid while printing scanning cleaning head stopping printing or copying exchanging I C or in error status B W Start Button Start monochrome copy Invalid while printing scanning cleaning head stopping...

Page 30: ...de 1 5 3 3 Nozzle Check Pattern Print Nozzle check pattern can be printed only with this unit Left ink quantity of each color is also printed by the unit of 10 To activate this function turn on this unit while depressing Ink Button After printing the pattern this unit moves to ordinary standby status The example of nozzle check pattern is explained below Figure 1 15 Nozzle check pattern Table 1 36...

Page 31: ...counter returns to the preset number of copies Table 1 37 Printer Condition and Panel Status Printer Status Indicators Priority Power LED Error LED Ink LED Paper Size LED Fit to Page LED 1 2 Power on Normal ready mode On 18 Copying mode Selected size is On On if the setting is on 17 Ink low Blink 16 Power on Data Processing Blink 15 Stopping printing and cancelling the print job Blink 14 The scann...

Page 32: ...sec On 1 sec 6 Power on Initializing operation Blink 5 Maintenance request Liquid waste overflow Blink On On Blink Blink Blink 4 Fatal error Mechanism Blink Blink Blink Blink Blink Blink 3 Fatal error System Fast blink Fast blink Fast blink Fast blink Fast blink Fast blink 2 Power off Processing termination Fast blink Off Off Off Off Off 1 Table 1 37 Printer Condition and Panel Status Printer Stat...

Page 33: ...k remaining in the installed Bk Y M or C cartridge s or ink cartridge s is not installed Liquid waste overflow Amount of ink discharged while cleaning or flushing has exceeded the given level Double feed error This error only occurs when performing duplex printing There are two following cases Blank paper is ejected when loading papers The length of the paper is determined to be long when ejecting...

Page 34: ...ter is initialized when turning the printer power on again within 10 seconds from last power off or printer recognized the INIT signal negative pulse of parallel interface When printer is initialized the following actions are performed a Cap the printer head b Eject a paper c Clears input data buffer d Clears print buffer e Sets default values 3 Software initialization The ESC command also initial...

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

Page 36: ...ous printers the Stylus CX3700 CX3800 CX3805 CX3810 DX3800 DX3850 is equipped with two DC motors one for the Paper Loading Feeding Mechanism and the Pump Mechanism with the CR Lock Mechanism and one for the CR Mechanism The ASF Unit for the Paper Loading Mechanism uses rear entry front eject system The Paper Feeding Mechanism uses the LD Roller and Retard Roller to feed paper to the Printer Mechan...

Page 37: ...nt Program when replacing the Print Head the Main Board Unit the Printer Mechanism with new one Note there are no resistor arrays to determine the Head ID on the Main Board And then based on the stored Head ID into the EEPROM the Main Board generates appropriate PZT drive voltage Following explains the basic components for the Print Head PZT PZT is an abbreviation of Piezo Electric Element Based o...

Page 38: ...ata once by 1 byte unit Based on the drive waveform common voltage generated on the Main Board the PZT selected by the nozzle selector IC pushes the top of the ink cavity By this operation the ink stored in the ink cavity is ejected from nozzles refer to Figure 2 4 p 38 Ejecting state Figure 2 4 Print Head printing process 2 2 2 2 Printing Method The dot printing systems of CX3700 CX3800 CX3805 CX...

Page 39: ... the EEPROM According to the variations individual differences measured in this sequence the voltage is corrected to make the drive current value constant without an individual difference CR measurement sequence To set the appropriate drive current value according to the variation of the CR mechanical load the mechanical load is measured in a CR measurement sequence and saved into the EEPROM in a ...

Page 40: ... to the left frame hit position and the carriage motor is stopped 3 The position that is specified steps right from the stopping place is defined as an origin and from that time positional information is monitored by the linear encoder If the positional information could not be gained during detecting carriage home position due to the following causes fatal error occurs ObstructioMns on the carria...

Page 41: ...igure show you the order of transmission path Figure 2 6 Paper loading feeding mechanism Table 2 2 PF Motor specifications Item Description Motor type DC motor with brushes Drive voltage 42V DC 5 voltage applied to driver Armature resistance 27 5 Ω 10 per phase at 25 degrees Inductance 21 4mH 25 1KH 1Vrms Driving method PWM constant current chopping Driver IC A6627 Table 2 3 ASF unit function PF M...

Page 42: ...ect the ASF home position When the Change Lever is set on the Clutch mechanism with the counterclockwise rotation of the PF Motor pinion gear the ASF home position is detected by this lever for the paper loading operation In this time the printer cannot load a paper from ASF Unit because the drive of the PF Motor is not transmitted to the LD Roller Shaft 2 Paper loading function When the Change Le...

Page 43: ...Lever is locked instantaneously by the protrusion on the backside of the Carriage Unit to change over from the ASF home position detection function to the paper loading function surely Step 1 ASF Home position Step 2 Hopper Paper Back Lever condition LD Roller Shaft Paper Back Lever Torsion spring 6 45 LD Roller Gear rotation direction Right side view Clutch lever Clutch lock tooth PF Motor drive ...

Page 44: ... position the Clutch lever is locked with the Change Lever again In this time the drive of the PF Motor is interrupted and the drive is transmitted only to the PF Roller side for the paper feeding sequence ASF Frame LD Roller Shaft Step 3 Step 4 Hopper Paper Back Lever condition Gear rotation direction Right side view Hopper Paper Back Lever condition Gear rotation direction Right side view PF Mot...

Page 45: ...J Roller Following figure shows you the transmission path for the PF Roller the Paper Guide Roller and the EJ Roller the Star Wheel The top of a paper is loaded to the PF Roller from the ASF Unit in the paper loading sequence And then when the PF Motor pinion gear rotates CW direction left side view a paper is fed by the PF Roller the Paper Guide Roller and the EJ Roller the Star Wheel in the prin...

Page 46: ... only the ink inside the Cap is ejected while the Carriage Unit is in the further right side than the CL position the ink is not absorbed from the Ink Cartridge or the ink cavity The following shows you the Carriage Unit position for each condition easily But on the valveless cap system the above 2 operation is done outside the capping position The Carriage Unit moves outside the CR home position ...

Page 47: ...to the left side the hook of the Carriage unit hits to the Slider lock lever In this time the Slider lock lever is released and the Cap slider returns to the bottom position completely The broken line is the position of the Carriage unit the Slider lock lever just before being released When the Carriage Unit moves to the left side from the Wiper setting position the Cap Unit is pulled back by the ...

Page 48: ...nk cavity and is ejected to the Waste Ink Pad from the Cap when the Ink Tube is pressed by a roller in the Pump Unit Following figure shows you the overview of the Pump Unit mechanism operation Note The PF Motor rotational direction seen from the right side of the printer Figure 2 11 Pump mechanism Figure 2 12 PF Motor drive transmission path to the Pump Unit Table 2 5 PF Motor rotational directio...

Page 49: ... CX3810 DX3800 DX3850 If the power is turned off during the Initial Ink Charge the CL3 will be performed at next power on timing Manual Cleaning The Stylus CX3700 CX3800 CX3805 CX3810 DX3800 DX3850 provides three types of manual cleaning to clean air bubbles clogged ink with viscosity or foreign substances The manual CL can be performed by the Control Panel Operation the Printer Driver Utility and...

Page 50: ...ting The timer command is generated based on the PC s timer and it consists of year month date hour minute and second As soon as the printer receives the timer command from the Printer Driver the printer stores its command in address 06 H and 07 H in the EEPROM Then it is compared with the latest CL time which is stored in address 04 H and 05 H in the EEPROM And In case that the timer cleaning per...

Page 51: ...t by the Rod Lens Array and converts it to digital information using the linear CCD Rod Lens Array Many rod shaped lenses are arranged in parallel and the upright multiple images of each lens is overlapped to form a single continuous image Compared to a regular lens this has the special ability to reduce the distances between images It can project at 1 to 1 size for imaging a linear CCD with a wid...

Page 52: ... the specifications for the stepping motor that controls the Scanner Carriage Mechanism Drive of the Scanner Motor is transferred to the Scanner Carriage Unit by the Scanner Timing Belt The Scanner Carriage Unit slides in the secondary scanning direction The Scanner Motor uses a stepping motor and drives using open loop control When the HP detection flag of the Scanner Carriage Unit disrupts the s...

Page 53: ...X3850 the simulated oscillating stimulation flyback converter circuit method is used and it supplies 42VDC to the drive line The application of the output voltage is described below AC voltage input from AC inlet first goes through filter circuit that removes high frequency components and is then converted to DC voltage via the rectifier circuit and the smoothing circuit DC voltage is then lead to...

Page 54: ...nd it is then used as drive voltage for many elements In addition when SPC shifts to low power mode the 3 3V that was stepped down by the Regulator IC10 is stepped down to 1 5V by the Combination Motor Driver IC9 and elements that had been driven by 3 3V are driven by 1 5V for suppression of power consumption 2 4 2 1 Main Elements Table 2 9 p 54 shows the function of the each main elements on C571...

Page 55: ... The C612 Main Board CPU ASIC 2 in 1 IC8 Data Address SDRAM IC6 Flash ROM IC5 RTC IC7 CN11 CIS Unit AD Converter IC12 CN12 C612 Panel Board CN13 Scanner HP Sensor USB CN2 CN1 C610 PS Board Motor Driver IC9 CN8 CN9 CN10 CR Motor PF Motor Scanner Motor P1 PF Encoder Sensor PE Sensor CN3 Head Driver IC11 Q9 Q10 CN5 CN6 Print Head CN7 CR Encoder Sensor CSIC Board ...

Page 56: ...itten in the memory in the common driver IC11 The addresses for the written data are determined by DATA0 DATA9 signals Then the necessary data is selected from the address and appropriate basic drive waveform is generated Generated basic drive waveform is transferred to nozzle selector IC on the Print Head driver board through the transistor Q9 and Q10 and applied to the nozzle PZT specified by no...

Page 57: ... Motor This product uses PM type stepping motor and performs constant current bi polar drive The Motor Driver IC IC9 forms the motor drive waveform based on the signal output from the CPU IC8 controlling the Scanner Motor When no data has been received for 5 minutes the CPU sets the Motor Driver current value to 0 turning off the Motor Driver in order to conserve electricity Figure 2 20 Motor Driv...

Page 58: ... VEX port of IC7 and if an abnormal voltage is detected a reset signal for the CPU is output from the EXO port of IC7 EEPROM Control Circuit When the printer power is turned off the following information is stored in EEPROM IC7 which is nonvolatile memory And when the printer power is on CPU IC8 reads the information from EEPROM Information stored in EEPROM is listed below Various ink counter I C ...

Page 59: ...d in the CR scan direction Minimum resolution of 1 180 inch is provided and output to the CPU is a high signal for the black slits on the linear scale and a low signal for transparent slits Control of the CR Motor is based on the output signal The home position of the Carriage Unit is detected by this sensor PF Encoder Sensor The sensor is composed of a transmissive photosensors mounted to the loo...

Page 60: ...ensor Circuit Diagram CN4 Scanner HP Sensor CN7 CR Encroacher Sensor CSIC DACDAT CO CCLK CDIO CXRST EA_CR EB_CR EA_PF EB_PF D13 A10 B12 B11 A11 B10 A9 A16 B16 CPU IC8 PF Encoder P1 PE SCNHP AN1 D5 F20 A5 5 1 6 2 3 11 9 CVDD COI CSCK CSDA CRST ENCA ENCB PEV GND PE PEV GND SCN_HP XHOT THM 3 2 1 3 2 1 7 CN5 THM CN3 PE Sensor VOA VOB VCC GND A A 3 3V_SN 3 3V 3 3V 3 3V 3 3V 3 3V_SN 3 3V 3 3V_SN 3 3V_SN...

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

Page 62: ...auses This section describes the LED indications STM3 messages and fault occurrence causes at occurrence of the following errors during any sequence operation e g power on sequence paper feeding loading sequence ink sucking sequence NOTE The STM3 windows shown in the table in the following pages are the ones of Stylus CX3800 however other models show almost the same diplays as those except the fol...

Page 63: ...s error is detected when the SPC cannot communicate with the PC correctly This error is detected when the ink consumption amount reaches about 90 Note Even if this error is indicated on the STM3 you can continue the printing until I C becomes Ink Out condition However the Head Cleaning operation cannot be done so that the remaining ink is low condition This error is detected at resending of paper ...

Page 64: ...is detected when The ink consumption amount reaches 100 The ink cartridge is defective Note The slight amount of the ink is remaining in the I C even if the Ink Out error is detected This is to prevent the Print Head nozzle from the printing operation without firing the ink This error is detected when data from CSIC cannot be read normally or when data cannot be written to CSIC This error is detec...

Page 65: ...intenance request Fatal error Mechanism Indications Power Blink Blink Error On Blink Ink On Blink 7 seg E blink E blink Paper Size 1 Blink Blink 2 Blink Blink Fit to Page Blink Blink Status monitor 3 message Fault Occurrence Cause This error is detected when the Waste Ink Counter exceeds the preset counter value This error is detected when it is determined that the printer cannot operate properly ...

Page 66: ...EMBLY AND ASSEMBLY The following tables describe the error check points Table 3 6 Check point for the communication error according to each phenomenon Occurrence timing CR position Detailed phenomenon Defective unit part name Check point Remedy Power on Anywhere When turning on the power the SPC does not operate at all Panel Unit 1 Check if the Panel FFC is connected to the CN1 on the Panel Board ...

Page 67: ...rectly But when any printer job is sent to the SPC a communication error is indicated with STM3 USB Cable 1 Check if the USB Cable is connected between the SPC and the PC 1 Connect the USB Cable to the SPC and the PC Main Board Unit 1 Check if an incorrect model name is not stored into the address of the EEPROM on the Main Board 1 Use the Adjustment Program to write the correct value to the EEPROM...

Page 68: ...e Main Board 1 Check if an incorrect data is not stored into the address of the EEPROM on the Main Board 1 Set the proper destination by using Adjustment Program Power on Anywhere The SPC does not perform the ink replacement CL and an error is indicated with LEDs and STM3 Ink Cartridge 1 Check if the Ink Cartridge can be used by installing it to other SPC 1 Replace the Ink Cartridge with a brand n...

Page 69: ...n After both surfaces were printed the paper was ejected but an error is displayed ASF Unit 1 Check if the Extension Spring Retard operates correctly in the paper loading sequence 1 Set the Extension Spring Retard between the Retard Roller Unit and the ASF Frame 2 Check if the Paper Back Lever operates correctly in the paper loading sequence 2 Set the Torsion Spring 6 45 between the ASF Frame and ...

Page 70: ... load the paper from the Printer driver The micro pearl on the LD Roller surface is removed To remove severe smear staple a cloth moistened with alcohol to a post card and clean the roller in the same manner If the problem is not solved replace the Holder shaft unit with new one Operation The Hopper does not operate during the paper loading sequence although the LD Roller rotates to load paper fro...

Page 71: ...2 Check if the Clutch does not come off from the dowel of the LD Roller Shaft 2 Reassemble the round portion of the Clutch on the dowel of the LD Roller Shaft 3 Check if the Clutch tooth is not damaged 3 Replace the Holder Shaft Unit with a new one 4 Check if the Clutch is not damaged 4 Replace the Holder Shaft Unit with a new one Table 3 9 Check point for the paper out error according to each phe...

Page 72: ...nk System Unit with a new one Operation The LD Roller is not set to the ASF home position and paper is always loaded from the ASF Unit during the paper loading sequence Ink System Unit 1 Check if the tip of the Change Lever is not damaged 1 Replace the Ink System Unit with a new one Table 3 9 Check point for the paper out error according to each phenomenon Occurrence timing CR position Detailed ph...

Page 73: ...yed Ink Cartridge 1 Check if Ink Cartridge is properly installed 1 Install the Ink Cartridge properly 2 Check if the Memory Chip is not disconnected or not chipped 2 Replace the Ink Cartridge with a new one CSIC Board 1 Check if the Head FFC is connected to connector on the CSIC Board 1 Connect the Head FFC to connector on the CSIC Board 2 Check if the CSIC Board is not damaged 2 Replace the Carri...

Page 74: ...without loading paper in the paper loading sequence ASF Unit 1 Check if the ASF Unit is properly installed 1 Install the ASF Unit properly 2 Check if the Paper Back Lever operates correctly in the paper loading sequence 2 Set the Torsion Spring 6 45 between the ASF Frame and the Paper Back Lever Holder Shaft Unit 1 Check if the Torsion Spring 0 22 is properly installed 1 Set the Torsion Spring 0 2...

Page 75: ...per does not go through between the EJ Roller Unit and the Star Wheel EJ Frame Unit 1 Check if the EJ Frame Unit is correctly assembled 1 Reassemble the EJ Frame Unit correctly Paper Guide Front Unit 2 Check if the Paper Guide Front Unit is correctly assembled 2 Reassemble the Paper Guide Front Unit correctly The Carriage Unit can move to home position even if the Torsion Spring 0 22 comes off How...

Page 76: ...f the Paper Guide Upper Unit is correctly assembled 1 Reassemble the Paper Guide Upper Unit to the Main Frame correctly The Carriage Unit can move to home position even if the Torsion Spring 0 22 comes off However the PE Sensor Lever keeps the high signal condition in the next operation Therefore the paper jam error is detected In case that the paper jam error occurs in each operation the jammed p...

Page 77: ...not initialize when the power is turned on Scanner Motor 1 Check if the Scanner Motor Connector Cable is connected to CN10 on the Main Board 1 Connect the Scanner Motor Connector Cable to CN10 on the Main Board 2 Check if the coil resistance of the Scanner Motor is about 37Ω by using the tester refer to Table 3 1 2 Replace the Scanner Motor with a new one 3 Check if the Scanner Motor Connector Cab...

Page 78: ... the Scanner HP Sensor with a new one 3 Check if the Scanner HP Sensor is not damaged 3 Replace the Scanner HP Sensor with a new one Scanner Carriage FFC 1 Check if the Scanner Carriage FFC is connected to CN11 on the Main Board 1 Connect the Scanner Carriage FFC to CN11 on the Main Board 2 Check if the Scanner Carriage FFC is not damaged 2 Replace the Scanner Carriage FFC with a new one Table 3 1...

Page 79: ...or Cable is not damaged 2 Replace the CR Motor with a new one 3 Check if the CR Motor operates 3 Replace the CR Motor with a new one When turning on the power the PF Motor does not operate at all PF Motor 1 Check if the PF Motor Connector Cable is connected to CN9 on the Main Board 1 Connect the PF Motor Connector Cable to CN9 on the Main Board 2 Check if the PF Motor Connector Cable is not damage...

Page 80: ... Check if the PF Motor operates 3 Replace the PF Motor with a new one Ink System Unit 1 Check if the Compression Spring 2 36 does not come off in the Change Lever 1 Replace the Ink System Unit with a new one Power on Anywhere The Carriage Unit collides with the Guide Upper Unit when power is turned on Paper Guide Upper Unit 1 Check if the Paper Guide Upper Unit is correctly assembled 1 Reassemble ...

Page 81: ... CR Scale is not damaged or contaminated 2 Replace the CR Scale with a new one or clean it completely CR Encoder Board 1 Check if the Encoder FFC is connected to the CR Encoder Board 1 Connect the Encoder FFC to the CR Encoder Board 2 Check if the Encoder FFC is not damaged 2 Replace the Encoder FFC with a new one 3 Check if the CR Encoder Board is not damaged 3 Replace the CR Encoder Board with a...

Page 82: ...cloth coat it with grease Refer to Chapter 6 MAINTENANCE 2 Check if the Scanner Carriage Shaft is set correctly 2 Reassemble the Scanner Carriage Shaft to the Scanner Carriage Unit Operation Anywhere The paper feeding sequence is performed without loading a paper in the paper loading sequence Holder Shaft Unit 1 Check if the PE Sensor Connector Cable is connected to CN3 on the Main Board 1 Connect...

Page 83: ... Front Frame 1 Check if the Slider Lock Lever is correctly released by the CR movement 1 Replace the Front Frame with a new one Main Frame 1 Check if the Slider Lock Lever is correctly released by the CR movement 1 Replace the Printer Mechanism with a new one Table 3 12 Check point for the Fatal error according to each phenomenon Occurrence timing CR position Detailed phenomenon Defective unit par...

Page 84: ...ce timing CR position Detailed phenomenon Defective unit part name Check point Remedy Operation The LEDs and STM3 are not indicating error conditions But multiple sheets of paper are always loaded from the ASF Unit ASF Unit 1 Check if the Extension Spring Retard operates correctly in the paper loading sequence 1 Set the Extension Spring Retard between the Retard Roller Unit and the ASF Frame 2 Che...

Page 85: ... is not bent up 1 Replace the EJ Frame Unit with a new one The Carriage Unit collides to the Paper Guide Upper Unit during each operation Paper Guide Upper Unit 1 Check if the Paper Guide Upper Unit is attached securely check if it interferes with the Carriage Unit 1 Reassemble the Paper Guide Upper to the Main Frame Table 3 15 Check point for poor scanned image quality Scanned image Quality State...

Page 86: ...rectly mounted on the Cap Unit 2 Replace the Ink System Unit with a new one Ink is ejected to the Cap from the Print Head but the SPC does not recover from the error after cleaning or ink change Print Head 1 Check if it returns to normal by performing CL operation or replacing the Ink Cartridge 1 Perform CL operation and the Ink Cartridge replacement specified times If it doesn t work change the P...

Page 87: ...rint Head and the Main Board Connectors 2 Check if the Head FFC is not damaged 2 Replace the Head FFC with a new one Print Head 1 Check if it returns to normal by performing CL operation or replacing the Ink Cartridge 1 Perform CL operation and the Ink Cartridge replacement specified times If it doesn t work change the Print Head with a new one Main Board Unit 1 Check if the Main Board is not dama...

Page 88: ... 2 Check if the Carriage Guide Shaft is properly secured to Main Frame by the CR Guide Shaft Torsion Spring and the CR Guide Shaft Pressing Spring 2 Reassemble the Carriage Guide Shaft correctly 3 Check if the grease is enough on the surface of the Carriage Guide Shaft 3 After wiping the grease on the Carriage Guide Shaft and the Carriage with a dry soft cloth coat it with grease Refer to Chapter ...

Page 89: ...surface of the PF Roller Unit 1 Clean the surface of the PF Roller Unit carefully with the soft cloth 2 Check if the PF Roller Unit is not damaged 2 Replace the PF Roller Unit with a new one The Star wheel mark against the CR movement direction EJ Frame Unit 1 Check if the Star Wheel Holder does not come off 1 Reassemble the Star Wheel Holder correctly 2 Check if the surface of the EJ Frame Unit i...

Page 90: ... error If the problem is not solved replace the Holder Shaft Unit with a new one Ink stain of paper Ink stain occurs at the back top end or bottom end of the print paper Paper Guide Front Unit 1 Check if the Paper Guide Front Unit does not have the ink stain 1 Clean the Paper Guide Front Unit with a soft cloth 2 Check if heaps of ink are not formed on Porous Pad Paper Guide Front 2 Replace the Pap...

Page 91: ...ean the Print Head Cover carefully with a soft cloth Paper Guide Upper Unit 1 Check if the Paper Guide Upper Unit does not have the ink stain 1 Clean the Paper Guide Upper Unit with a soft cloth EJ Frame Unit 1 Check if the Star Wheel Rollers does not have the ink stain 1 Clean the Star Wheel Rollers with a soft cloth Table 3 16 Check point for the poor printing quality Print Quality State Detaile...

Page 92: ...C H A P T E R 4 DISASSEMBLY ASSEMBLY ...

Page 93: ...work on the printer with power applied strictly follow the instructions in this manual Wear protective goggles to protect your eyes from ink If ink gets in your eye flush the eye with fresh water and see a doctor immediately Always wear gloves for disassembly and reassembly to avoid injury from sharp metal edges To protect sensitive microprocessors and circuitry use static discharge equipment such...

Page 94: ...o obstacles at paper route OK NG Scanner unit Mechanism Glass surface is not dirty OK NG Alien substance is not mixed in the CR movement area OK NG CR mechanism CR smoothly operates OK NG CR operates together with scanner unit OK NG CR makes abnormal sound during its operation OK NG LED LED normally turns on and white reflection test is done near home position OK NG On line test On line test Opera...

Page 95: ...Housing Lower Reference To ensure the assembled accuracy you have to control the assembled standard position of main frame against X Y Z axis direction X axis direction Make sure that main frame is correctly placed on the groove of Housing Lower Make sure that there is no gap between Main Frame and Housing Lower Y axis direction Make sure that main frame is correctly placed on the groove of Housin...

Page 96: ...4 4 5 Panel Unit p100 4 4 6 Housing Upper p101 4 4 8 Printer Mechanism p104 4 4 11 Main Board Unit p111 4 4 16 CR Guide Frame p118 4 4 17 CR Motor p119 4 4 19 Carriage Unit CR Encoder Board PW Sensor Board Head FFC p121 4 4 21 EJ Frame Unit p125 4 4 23 Paper Guide Front Unit p127 4 4 24 PF Roller Unit p128 4 4 12 ASF Unit p113 4 4 13 Holder Shaft Unit p115 4 4 22 Ink System Unit p126 4 4 2 Paper S...

Page 97: ...ment Cover Mat ASF Cover None Removal procedure Document Cover 1 Open the Document Cover release the guide pins x2 that secure the Document Cover and remove the Document Cover Document Cover Mat 1 Remove the Document Cover Mat that is secured to the Document Cover with the double sided tapes x2 ASF Cover 1 Release the guide pins x2 that secure the ASF Cover and remove it from the Document Cover AS...

Page 98: ...the guide pins x2 that secure the Paper Support Assy and remove the Paper Support Assy from the Housing Upper 4 4 3 Stacker Assy External view Figure 4 4 Removing Stacker Assy Part Unit that should be removed before removing Stacker Assy None Removal procedure 1 Open the Stacker Assy 2 Release the guide pin x1 that secures the Stacker Assy with a precision screwdriver and remove Stacker Assy Paper...

Page 99: ...t 5 Open the Scanner Unit and remove it by pulling out upward 2 USB Cover 1 CN10 CN13 CN11 C B S 3x6 F Zn 7 1kgfcm FFC Shield Plate Main Board Rib FFC Main Board Unit Double sided Tape Step 5 1 Step 5 2 C B P 3x10 F Zn 6 1kgfcm Guide Pin C B P 3x10 F Zn 6 1kgfcm Scanner Unit Housing Upper C A U T I O N Do not damage the Scanner Carriage FFC when removing installing the screw The Scanner Carriage F...

Page 100: ...at secure the Panel Board and remove the Panel Board together with the Panel FFC and the Grounding Panel 4 Disconnect the Panel FFC from the connector CN1 of the Panel Board 5 Remove the Grounding Panel from the Panel Board 6 Remove the Button Panel from the Panel Housing Panel Unit CN12 Panel FFC Panel Housing Button Panel CN1 Grounding Panel Tab Guide Pin Panel Board C A U T I O N When performin...

Page 101: ...ing Housing Upper Document Cover Paper Support Assy Scanner Unit Panel Unit Removal procedure 1 Remove the screws x7 that secure the Housing Upper 2 Release the tabs x2 that secure the Housing Upper with a flathead screwdriver or a similar tool and lift up to remove the Housing Upper 1 2 3 4 5 Tabs C B P 3x10 F Zn 4 1kgfcm C B S 3x6 F Zn 7 1kgfcm 7 6 Housing Upper Tighten the screws in the order a...

Page 102: ... Cable Cover with a precision screwdriver slide the Cover downward and remove the Head Cable Cover 4 Release the tabs x2 that secures the Sub FFC Guide with a precision screwdriver and remove the Sub FFC Guide 5 Remove the screws x3 that secure the Print Head and lift up to remove Printhead with a longnose pliers 6 Disconnect the Head FFC x1 from the connector x1 of the Print Head and remove the P...

Page 103: ...hown in the figure When installing the Sub FFC Guide insert the rib of the Sub FFC Guide to the notch of the Carriage Unit as shown below Figure 4 10 Installing Sub FFC Guide A D J U S T M E N T R E Q U I R E D After removing replacing the Printhead perform the adjustment in the following order Refer to Chapter 5 ADJUSTMENT 1 PG Adjustment 2 Ink Charge only after replacement 3 Head ID Input only a...

Page 104: ... carefully remove the Waste Ink Tube of the Ink System Unit side 3 Release the Carriage Lock with a flathead screwdriver and move the Carriage Unit to the center of the printer C B P 3x10 F Zn 4 1kgfcm Rear Cover Tabs Housing Lower Carriage Unit Carriage Lock Waste Ink Tube Red Line Tube Clump Tab Eject Ink Joint C A U T I O N The Waste Ink Tube may be broken when it is removed If it breaks replac...

Page 105: ... PS Connector Cable from the connector CN1 of the Main Board 6 Lift up the Printer Mechanism and remove the whole Printer Mechanism from the Housing Lower 1 4 6 5 2 3 Printer Mechanism CN1 Main Board PS Connector Cable C B P 3x8 F Zn 4 1kgfcm Guide Pin Holding Positions CR Guide Frame C A U T I O N Hold the designated position and lift Printer Mechanism upward when performing the following step in...

Page 106: ...are on the right side When installing the Rear Cover match the tabs x2 of the Rear Cover with the notches x2 of the Housing Lower The assembled accuracy of each part composed of Printer mechanism is based on Housing Lower To ensure the assembled accuracy you have to control the assembled standard position of main frame against X Y Z axis direction as the following figure X axis direction Confirm t...

Page 107: ... Place the Ferrite Core to the dent of the Housing Lower Route the PS Connector Cable between the ribs of the Housing Lower and secure them with acetate tape When routing the PS Connector Cable between the ribs of the Housing Lower pay attention to the following instructions The gap between the PS Connector Cable and the Edge of the Housing Lower should be 15 mm The PS Connector Cable should be ru...

Page 108: ... removing Waste Ink Pads Stacker Lock Rubber Feet Document Cover Paper Support Assy Stacker Scanner Unit Panel Unit Housing Upper Printer Mechanism Removal procedure Waste Ink Pads Removal 1 Remove the Waste Ink Tube along with the Tube Clamp and the Eject Ink Joint from the groove of the Housing Lower 2 Remove five pieces of the Waste Ink Pads and the Waste Ink Cover from the Housing Lower Tube C...

Page 109: ...Step 2 Step 3 1 2 3 4 5 6 Step 4 When installing the Waste Ink Tube to the Housing Lower insert the Waste Ink Tube to both the groove of the Housing Lower and the Eject Ink Joint and securely fasten the Waste Ink Tube with the Tube Clamp or ink may leak from the Tube A D J U S T M E N T R E Q U I R E D After replacing the Waste Ink Pads perform the following adjustment Refer to Chapter 5 ADJUSTMEN...

Page 110: ...Lock Removal 1 Remove the tabs x2 that secure the Stacker Lock and remove the Stacker Lock and Compression Spring 5 1 from the Housing Lower Rubber Feet Removal 1 Remove the rubber feet x4 from the Housing Lower Right Side Tabs Shaft and Groove Compression Spring 5 1 Right Side Stacker Lock Rubber Feet Pass the shaft of the Stacker Lock through the groove of the Housing Lower ...

Page 111: ...nd FFCs from the connectors of the Main Board CN3 PE Sensor Connector Cable CN5 Head FFC CN6 Head FFC CN7 Head FFC CN8 CR Motor Connector Cable CN9 PF Motor Connector Cable 3 Remove the screws x2 that secure the Main Board Unit and remove the Main Board Unit from the Printer Mechanism Acetate Tapes Main Board Unit PE Sensor Connector Cable CN3 CN8 CN9 CN6 CN5 CN7 PF Scale 2 1 C B S 3x6 F Zn 7 1kgf...

Page 112: ...20 PF Scale Sensor Positioning Adjustment Right Side Left Side 0 1 1 mm Spacer PF Scale Spacer is not applied to the Main Board Unit for service part Place spacer between Shield Board and Main Board If PF Scale is off to the left remove the spacer If PF Scale is off to the right add an additional spacer Total of 2 spacers A D J U S T M E N T R E Q U I R E D After removing replacing the Main Board ...

Page 113: ... CR Motor Connector Cable from the tab x1 of the ASF Unit 3 Remove the Ferrite Core of the PF Motor Connector Cable from the slot of the ASF Unit 4 Remove the screws x5 that secure the ASF Unit and remove the ASF Unit from the Printer Mechanism Tab CR Motor Connector Cable Ferrite Core PF Motor and Slot 1 3 5 2 4 C B S 3x6 F Zn 8 1kgfcm C B S P2 3x6 F Zn 8 1kgfcm C B P 3x8 F Zn 4 1kgfcm Shaft and ...

Page 114: ...ard Roller C A U T I O N Do not touch the Retard Roller and the Hopper Pad When installing Torsion Spring 6 45 hitch the L shape tip of Torsion Spring 6 45 to the shaft of the Paper Back Lever and hitch the short tip to the groove of the ASF Unit Figure 4 23 Installing Torsion Spring 6 45 Compression Spring 5 58 should be hitched to the rib x2 of the ASF Frame and the rib x1 of the Hopper A D J U ...

Page 115: ...e the tabs x2 that secure the Pump Frame to the Main Frame 2 Move the Pump Frame to the home position and release the guide pin x1 of the Holder Shaft Unit 3 Push the tabs x2 of the Holder Shaft Unit and remove the Holder Shaft Unit upward Holder Shaft Unit LD Roller CN3 PE Sensor Connector Cable Main Board Unit Main Frame C B S 3x6 F Zn 7 1kgfcm Front Tabs Ribs 1 1 Guide Pin Pump Frame Tabs Tab C...

Page 116: ... remove the Paper Block 2 Remove the LD Roller Shaft together with the Clutch Mechanism from the Holder Shaft 3 Remove the Spur Gear 36 8 from the LD Roller Shaft 4 Remove the Extension Spring 0 143 and remove the Clutch from the LD Roller Shaft Guide Pins LD Roller Shaft Unit Holder Shaft Cam Torsion Spring 137 7 Paper Block Ribs Clutch Mechanism Guide Pins Assemble the LD Roller Shaft Unit as sh...

Page 117: ...ever from the Holder Shaft and remove the PE Sensor Lever and Torsion Spring 0 22 in the order as shown in the figure 2 Remove Torsion Spring 0 22 from the PE Sensor Lever 3 Release the PE Sensor Connector Cable from the groove of the Holder Shaft 4 Release the tab x1 that secures the PE Sensor and remove the PE Sensor from the Holder SHaft Straight Tip Shaft Shaft 1 2 Torsion Spring 0 22 L shaped...

Page 118: ...s x3 secured with the double sided tape x1 from the CR Guide Frame 2 Remove the screws x2 that secure the CR Guide Frame and remove the CR Guide Frame from the Printer Mechanism C B S 3x6 F Zn 7 1kgfcm Guide Pins 2 1 Head FFC CR Guide Frame Match the guide pins x2 of the Front Frame with the positioning holes x2 of the CR Guide Frame Tighten the screws in the order as shown in the figure Attach th...

Page 119: ...the Timing Belt by pressing the Driven Pulley Holder in the direction of the arrow as shown in the figure and remove the Timing Belt from the pinion gear of the CR Motor 5 Remove the screws x2 that secure the CR Motor and remove CR Motor from the Printer Mechanism Acetate Tape CR Motor Timing Belt Driven Pulley Holder C P 3x4 F Zn 4 0 5kgfcm 1 2 Pinion Gear Lot No C A U T I O N Do not damage the p...

Page 120: ...the slot x1 of ASF Unit 3 Remove the PF Scale that is secured with double sided tape to the Spur Gear 32 4 4 Remove the Spacer 4 1 x 0 5 that secures Spur Gear 30 8 and remove Spur Gear 30 8 from the Main Frame 5 Remove the screws x2 that secure the PF Motor and remove the PF Motor from the Printer Mechanism Double sided Tape Spur Gear 32 4 Spur Gear 30 8 Spacer 5 2x0 8x9 PF Scale CR Motor Acetate...

Page 121: ...Spur Gear 32 4 with double sided tape x1 4 Remove Spacer 4 1 x 0 5 that secures Spur Gear 30 8 and remove Spur Gear 30 8 from the Main Frame 5 Release CR Guide Shaft Torsion Spring from the tabs x2 of the Main Frame and remove CR Guide Shaft Torsion Spring from the Main Frame Driven Pulley Holder CR Scale Tab Timing Belt Extension Spring 3 289 Tab Chipped Part Slit of CR Encoder Sensor Spacer 5 2x...

Page 122: ... from the notch of the Main Frame 2 Remove the Carriage Guide Shaft along with the Carriage Unit from the Main Frame 9 Pull out the Carriage Guide Shaft from the Carriage Unit CR Guide Shaft Pressing Spring Tab Right Side CR Guide Shaft Parallel Adjustment Lever Left 2 Carriage Unit 1 1 C B S P2 3x6 F Zn 7 1kgfcm Guide Pin C A U T I O N Do not damage the Carriage Guide Shaft Do not stain the Timin...

Page 123: ...the Head FFC from the tabs x4 that secure the Head FFC 4 Disconnect the Head FFC from the connector of the CSIC board Tabs Notch CR Encoder Board Connector C P B P1 1 7x5 F ZB 0 5kgfcm Notch Head FFC Guide Pins Connector Match the guide pins of the Carriage x2 with the positioning hole x2 of the CR Encoder Board A D J U S T M E N T R E Q U I R E D After replacing the Carriage Unit with a new one a...

Page 124: ...it Transparency 1 2 Torsion Spring 75 35 Approx 1 1 5 mm Guide Pins Tabs Rib Reassembly of the Paper Guide Upper Unit 1 Set Torsion Spring 75 35 onto the Paper Guide Upper Unit 2 Temporarily place the tabs x2 of the Paper Guide Upper Unit onto the Main Frame in order as shown in the figure 3 Insert the coil section of Torsion Spring 75 35 into the rib 4 Align the positioning holes x2 of the Main F...

Page 125: ...e from the Printer Mechanism EJ Frame Unit 2 1 3 C B S 3x6 F Zn 7 1kgfcm Rib C A U T I O N Do not hold the EJ Frame Unit while handling the Printer Mechanism in your repair Do not touch the rubber portion of the Eject Roller Match the ribs x4 of the Main Frame with the positioning holes of the Front Frame Tighten the screws in the order as shown in the figure A D J U S T M E N T R E Q U I R E D Af...

Page 126: ...nd remove the Pump Unit 6 Remove the whole Ink System from the Printer Mechanism and remove the gears x4 Pump Pulley and Change Lever Guide Pins C B P 3x8 F Zn 4 1kgfcm Right Side Sealing Rubber Head Cleaner Lower Right Side Tabs Groove Cap Unit Tabs Compound Gears 27 2 19 02 Change Lever Pump Unit Guide Pins Notch and Carriage Lock Position C A U T I O N Do not touch or damage the Sealing Rubber ...

Page 127: ...Front Paper Guide Absorber Protection Coated Area of PF Roller Unit Rib Surface C A U T I O N When performing the following work pay attention to the following instructions Do not damage the ribs on the surface of the Paper Guide Front Unit Do not touch or damage the coated area of the PF Roller Unit Do not touch the rubber part of the EJ Roller Be careful not to bend the Front Paper Guide Absorbe...

Page 128: ...wn by the figure 3 Release the guide pin x1 of Bush 10 Right from the Main Frame and rotate Bush 10 Right to the position shown by the figure 4 Slide the PF Roller Unit toward left and release the tabs x1 of Bush 10 Left Right 5 Remove the PF Roller Unit along the notch at the left end of the Main Frame PF Grounding Spring Notch Groove Guide Pin Bush 10 Left Guide Pin Bush 10 Right Rear S shape 1 ...

Page 129: ...e the hinge R from the Scanner Unit 2 Remove the screws x5 that secure the Scanner Housing Upper 3 Release the tabs x4 that secure the Scanner Housing Upper and remove the Scanner Housing Upper Document Glass Tab Scanner Housing Upper C B P 3x10 F Ni 7 1kgfcm Hinge R C B P 3x10 F Zn 5 5 0 5kgfcm C A U T I O N Following work should be performed in a room where there is a little dust A clean room or...

Page 130: ...f the arrow and remove Compound Gears 22 8 7 762 Driven Holder and Scanner Timing Belt 3 Disconnect the Scanner Carriage FFC from the Scanner Carriage Unit and remove the Scanner Carriage Unit together with the Scanner Timing Belt 1 3 Driven Holder Scanner Carriage Unit 2 Compound Gears 22 8 7 762 Scanner Timing Belt Guide Rail of the Housing Lower Double sided Tape Rib Connector Scanner Carriage ...

Page 131: ...it Scanner Timing Belt Belt Clump Tab Tab Shaft CIS Unit CIS Spring Scanner CR Holder CIS Spring Guide Pin Tip Bottom Attach the Scanner Timing Belt to the Scanner Carriage Unit so that the part where the belt is jagged on both sides is pinched by the groove of the Scanner Carriage Unit Figure 4 45 Attaching Scanner Timing Belt The CIS Springs x2 should be installed with their tips hitched to the ...

Page 132: ...he screw x1 that secures the Scanner HP Sensor and remove the Scanner HP Sensor 6 Release the Scanner Motor Connector Cable and the Scanner HP Sensor Connector Cable from the tab of the Scanner Housing Lower 7 Remove the screws x2 that secure the Scanner Motor Unit and remove the Scanner Motor Unit 1 3 Driven Holder Compound Gears 22 8 7 762 2 Scanner Timing Belt Scanner HP Sensor Connector Cable ...

Page 133: ...C H A P T E R 5 ADJUSTMENT ...

Page 134: ...in Board by using the Adjustment program C H E C K P O I N T In case that any parts are removed and assembled on the repair product while running the Adjustment program make sure to turn off the printer Table 5 1 Required Adjustments EEPROM data copy Market setting USB ID input Waste ink pad counter Ink charge Head ID input Top margin adjustment First dot adjustment Head angular adjustment Bi d ad...

Page 135: ... Required Required Required Required PF motor removal Required Required replacement Required Required Waste ink pad removal replacement Required CR unit removal Required Required Required Required replacement Required Required Required Required Required CR guide shaft removal Required replacement Required Required Star wheel assy removal Required replacement Required PF roller assy removal Require...

Page 136: ... parameter back up function is not available on the defective main board After completing the adjustment check the printing result with A4 check pattern by using the Adjustment program If the result is not good perform appropriate adjustment If using new main board in the printer mechanism replacement you need to perform EEPROM initial setting of main board And then please perform the adjustment b...

Page 137: ... button 3 When the restore operation is succeeded click the next button to perform necessary adjustment When the backup operation is failed 1 Click the next button to perform necessary adjustment 5 2 2 Market Setting Adjustment procedure 1 Select Destination setting in the Adjustment Program Click the Destination setting button to set the market destination setting 5 2 3 USB ID Input Adjustment pr...

Page 138: ...to the edit box and click the Input button Figure 5 1 Top Margin Adjustment Printing Pattern 5 2 8 First Dot Adjustment Adjustment procedure 1 Set Photo Paper A4 Letter on the Paper Support 2 Select First dot position adjustment in the Adjustment Program 3 Click the Print button to print the First dot position adjustment pattern 4 Check the printed patterns and select a pattern number that has 5mm...

Page 139: ...djustment value of checked items 6 Print the check pattern again and check the adjustment result Treatment procedure for NG product 1 Replace the Print Head with new one again 2 Print the check pattern and check the adjustment result 3 If the result is NG level confirm the installation condition of removed parts during disassembly 4 Perform Step 2 again Figure 5 3 Head Angular Adjustment Printing ...

Page 140: ... adjustment result Treatment procedure for NG product 1 Replace the Print Head with new one again 2 Print the check pattern and check the adjustment result 3 If the result is NG level confirm the installation condition of removed parts during disassembly 4 Perform Step 2 again Figure 5 4 Bi D Adjustment Printing Pattern 5 2 11 CR Offset Adjustment procedure 1 Select CR offset in the Adjustment Pro...

Page 141: ...position shown by the figure The thickness gauge should be placed between the front of the Paper Guide Front Unit and the center ribs Figure 5 6 Placement position for thickness gauge 7 Confirm that PG Lever is lowered If PG Lever is raised lower it 8 Move the Carriage Unit on the thickness gauge by using the Timing Belt and check whether the thickness gauge moves or not C A U T I O N Do not remov...

Page 142: ...ness gauge should be placed between the front of the Paper Guide Front Unit and the center ribs Figure 5 10 Placement position for thickness gauge START Move the Carriage Unit by using the Timing Belt Thickness Gauge moves One notch up the Parallel Adjustment Lever Left One notch down the Parallel Adjustment Lever Left Move the Carriage Unit by using the Timing Belt Thickness Gauge moves Advance t...

Page 143: ...T I O N If you push the Carriage Unit directly it s possible to damage the Print Head surface by the friction with the thickness gauge Following is the relationship between Parallel Adjustment Lever Right operation and Platen gap reaction Figure 5 11 Relationship between Parallel Adjustment Lever Right Operation Platen Gap PG up narrower PG down wider START Move the Carriage Unit by using the Timi...

Page 144: ... of sensor adjust position of PF Scale using spacer 0 5mm thickness as shown in diagram below Figure 5 14 PF Scale Sensor positioning adjustment START Move the Carriage Unit by using the Timing Belt ThicknessGauge moves One notch up the Parallel Adjustment Lever Left Move the Carriage Unit by using the Timing Belt ThicknessGauge moves Re adjust from the beginning One notch down the Parallel Adjust...

Page 145: ... 2 Install C592B00W exe to the computer and put the FT program into place Figure 5 15 Original Adjustment 1 3 Open the document cover and place the original adjustment jig as shown in the figure below Figure 5 16 Original Adjustment Jig Setting Position 4 Open the FT select C592_PRN on the Select Parameter Set window and click OK Figure 5 17 Original Adjustment 2 C A U T I O N This adjustment requ...

Page 146: ... Figure 5 19 Original Adjustment 4 7 A progress bar will be displayed followed by the window described below Window displayed when the adjustment is completed successfully Figure 5 20 Window displayed when the adjustment is completed successfully 1 Figure 5 21 Window displayed when the adjustment is completed successfully 2 Single Test Icon Enter the last five digits of the scanner production cont...

Page 147: ...djustment Program 147 Window displayed when the adjustment is failed Figure 5 22 Window displayed when the adjustment is failed If the adjustment could not be completed successfully check whether the parts are correctly installed or not If this does not work perform the part replacement once again ...

Page 148: ...C H A P T E R 6 MAINTENANCE ...

Page 149: ...ility and the Adjustment program In case that the cleaning sequence is performed by the control panel operation confirm that the printer is in stand by state the Power LED is lighting and hold down the Ink SW on the control panel for more than 3 seconds Then the printer starts the cleaning sequence the Power LED blinks during this sequence In case that you select and perform the manual cleaning by...

Page 150: ...Head cleaning operation the ink is drained to the Waste ink pads and the amount of the waste ink is stored as the waste ink counter into the EEPROM on the Main Board Due to this when the waste ink counter has reached the limit of the absorbing capability of the Waste ink pads the Maintenance call error is indicated on Status monitor 3 as following figure Figure 6 3 Maintenance error indication in ...

Page 151: ... T I O N Never use oil or grease other than those specified in this manual Use of different types of oil or grease may damage the component or give bad influence on the printer function Never apply larger amount of grease than specified in this manual Type Name EPSON code Supplier Grease G 26 1080614 EPSON Grease G 45 1033657 EPSON Grease G 71 1304682 EPSON Grease G 74 1409257 EPSON C A U T I O N ...

Page 152: ...80 120mg Two points in total Remarks 1 Use a injector to apply 2 Use a injector to apply Do not adhere G 71 to the Timing Belt Do not let G 71 run off to the Carriage outside surface Hopper 2 1 Lubrication Prohibited Area Paper Back Lever 2 2 1 1 N G O K Carriage Unit Outside Surface Carriage Hole Carriage Guide Shaft G 71 Grease Sectioned Diagram Carriage Unit Carriage Guide Shaft Lubrication Poi...

Page 153: ...x φ of Spool Gear 36 Remarks Use a injector to apply EJ Frame Unit Spool Gear 36 Lubrication Type Contact position between the EJ Roller and the Paper Guide Front Unit Lubrication Type G 74 Lubrication Amount φ1 x 0 04gr x 12 points Remarks Use a flux dispenser to apply Lubrication Point 1 Contact point between the PF Grounding Spring and the PF Roller Unit 2 Contact point between the Paper Guide ...

Page 154: ...re 6 14 Lubrication on PF Roller Unit 2 Lubrication Point Contact point between Bush 10 Right and PF Roller Unit Lubrication Type G 26 Lubrication Amount φ1 x φ of the PF Roller Unit Remarks Use a injector to apply Do not adhere G 26 to Spool Gear 13 5 Bush 10 Right PF Roller Unit Spool Gear 13 5 ...

Page 155: ...C H A P T E R 7 APPENDIX ...

Page 156: ... CN7 Print Head CN8 CR Motor CN12 CN9 PF Motor C612 PNL Table 7 1 Connector Summary for C612 Main Board Connector Function Table to refer to CN1 For connection with the Power Supply Board Table 7 2 p 156 CN2 For connection with the USB interface 1 3 1 USB Interface p 21 CN3 For connection with the PE Sensor Table 7 3 p 157 CN5 to CN7 For connection with the Print Head Table 7 4 p 157 Table 7 5 p 1...

Page 157: ...id waveform Table 7 5 CN6 Print Head Pin Signal Name I O Function 1 GND2 Ground 2 COM O Head drive pulse trapezoid waveform 3 VHV O 42V power supply for nozzle selector 4 GND Ground 5 SI2_Col O Print data output for color nozzles 6 GND Ground 7 SI1_Bk O Print data output for black nozzles 8 GND Ground 9 GND Ground 10 GND Ground Table 7 6 CN7 Print Head Pin Signal Name I O Function 1 COI I Cartridg...

Page 158: ...or LED 2 LED B O LED cathode Blue 3 LED G O LED cathode Green 4 LED R O LED cathode Red 5 VDD Power supply for 5V_SW digital 6 GND Ground 7 TR O Shift pulse 8 RS O Reset 9 M O Clock 10 GND Ground 11 VAD Power supply for filtered 5V_SW analog 12 OS O Output signal Table 7 11 CN12 Panel Board Pin Signal Name I O Function 1 SDI I Switch data serial data input 2 SENB O LED lamp enable signal 3 SLAT O ...

Page 159: ...EPSON Stylus CX3700 CX3800 CX3805 CX3810 DX3800 DX3850 Revision A APPENDIX Exploded Diagram 159 7 2 Exploded Diagram Following pages show exploded diagram ...

Page 160: ...A APPENDIX Exploded Diagram 160 Figure 7 2 Stylus CX3700 CX3800 CX3805 CX3810 DX3800 DX3850 Exploded Diagram 1 114 113 109 109 112 102 103 104 400 115 110 100 101 105 107 106 111 109 109 108 Rev 01 C612 CASE 001 EPSON Stylus CX3700 CX3800 CX3805 CX3810 DX3800 DX3850 ...

Page 161: ...X3805 CX3810 DX3800 DX3850 Revision A APPENDIX Exploded Diagram 161 Figure 7 3 Stylus CX3700 CX3800 CX3805 CX3810 DX3800 DX3850 Exploded Diagram 2 300 200 Rev 01 C612 ELEC 001 EPSON Stylus CX3700 CX3800 CX3805 CX3810 DX3800 DX3850 ...

Page 162: ...ion A APPENDIX Exploded Diagram 162 Figure 7 4 Stylus CX3700 CX3800 CX3805 CX3810 DX3800 DX3850 Exploded Diagram 3 803 804 816 802 801 813 811 800 810 811 812 812 815 809 805 814 806 807 Rev 01 C612 MECH 001 EPSON Stylus CX3700 CX3800 CX3805 CX3810 DX3800 DX3850 ...

Page 163: ...PENDIX Exploded Diagram 163 Figure 7 5 Stylus CX3700 CX3800 CX3805 CX3810 DX3800 DX3850 Exploded Diagram 4 523 506 504 505 507 503 520 509 522 515 508 600 518 516 517 512 513 521 501 510 500 511 Rev 01 C612 MECH 002 EPSON Stylus CX3700 CX3800 CX3805 CX3810 DX3800 DX3850 ...

Page 164: ...PENDIX Exploded Diagram 164 Figure 7 6 Stylus CX3700 CX3800 CX3805 CX3810 DX3800 DX3850 Exploded Diagram 5 546 546 543 545 544 548 547 542 541 540 537 549 538 536 536 536 532 531 535 534 533 530 Rev 01 C612 MECH 003 EPSON Stylus CX3700 CX3800 CX3805 CX3810 DX3800 DX3850 ...

Page 165: ...ARD ASSY PANEL 800 SCANNER UNIT CX3800 801 COVER ASF 802 COVER DOCUMENT ASSY ENB7 CX3800 803 HOUSING SC UPPER ASSY 804 HINGE ASSY 805 HOUSING LOWER SC EDG2 806 HINGE L 816 MAT COVER DOCUMENT 200 MAIN BOARD ASSY 300 POWER SUPPLY UNIT 100V 501 ASF UNIT 500 PRINTER MECHANISM ASP MAP10 100 503 HOLDER SHAFT ASSY 504 BOARD ASSY DETECTOR 505 TORSION SPRING 0 22 506 EXTENSION SPRING 0 143 507 INK SYSTEM A...

Page 166: ...HEET INK EJECT ASP 545 TUBE INK EJECT 546 CLAMP TUBE 547 JOINT INK EJECT B 548 COVER INK EJECT 549 GROUNDING SPRING PF 600 PRINT HEAD 807 MOTOR ASSY SC 809 TIMING BELT CR SC 810 CIS CA 463E 811 SPACER CIS A17 811 SPACER CIS B19 811 SPACER CIS C21 812 SPRING CIS Code Parts Name 813 FFC CIS 814 CLAMP BELT 815 CR CIS NON FIG INK CART UNBOXED BK S PIG T G38C WST AS NON FIG INK CART UNBOXED C S PIG T G...

Page 167: ...3800 DX3850 Revision A APPENDIX Electrical Circuits 167 7 4 Electrical Circuits The electric circuit diagrams below are shown at the following pages C612 Main control circuit board C610 PSB PSE power supply circuit board C612 Panel circuit board ...

Page 168: ...Model Stylus CX3700 CX3800 CX3805 CX3810 DX3800 DX3850 Board C612 MAIN Rev B Sheet 1 2 ...

Page 169: ...Model Stylus CX3700 CX3800 CX3805 CX3810 DX3800 DX3850 Board C610 PSB Rev B Sheet 1 1 ...

Page 170: ...Model Stylus CX3700 CX3800 CX3805 CX3810 DX3800 DX3850 Board C610 PSE Rev B Sheet 1 1 ...

Page 171: ...Model Stylus CX3700 CX3800 CX3805 CX3810 DX3800 DX3850 Board C612 PNL Rev A Sheet 1 1 ...

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