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Epson CX4200 - Stylus Color Inkjet, Service Manual

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About This Manual

This manual describes basic functions, theory of electrical and mechanical operations, maintenance and repair procedures of the printer. The instructions and procedures included 
herein are intended for the experienced repair technicians, and attention should be given to the precautions on the preceding page.

Manual Configuration

This manual consists of six chapters and Appendix.

CHAPTER 1. PRODUCT DESCRIPTIONS

Provides a general overview and specifications of the product.

CHAPTER 2. OPERATING PRINCIPLES

Describes the theory of electrical and mechanical operations of the 
product.

CHAPTER 3. TROUBLESHOOTING

Describes the step-by-step procedures for the troubleshooting. 

CHAPTER 4. DISASSEMBLY / ASSEMBLY

Describes the step-by-step procedures for disassembling and 
assembling the product.

CHAPTER 5. ADJUSTMENT

Provides Epson-approved methods for adjustment.

CHAPTER 6. MAINTENANCE

Provides preventive maintenance procedures and the lists of Epson-
approved lubricants and adhesives required for servicing the product.

CHAPTER 7. APPENDIX

Provides the following additional information for reference:
• Connector Summary
• Exploded 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 condition 
that, if not strictly observed, could result in injury or loss of life.

Indicates an operating or maintenance procedure, practice, or condition 
that, if not strictly observed, could result in damage to, or destruction of, 
equipment.

May indicate an operating or maintenance procedure, practice or 
condition that is necessary to accomplish a task efficiently. It may also 
provide additional information that is related to a specific subject, or 
comment on the results achieved through a previous action.

I.ndicates an operating or maintenance procedure, practice or condition 
that, if not strictly observed, could result in injury or loss of life.

Indicates that a particular task must be carried out according to a certain 
standard after disassembly and before re-assembly, otherwise the quality 
of the components in question may be adversely affected.

A D J U S T M E N T

R E Q U I R E D

C A U T I O N

C H E C K

P O I N T

W A R N I N G

Summary of Contents for CX4200 - Stylus Color Inkjet

Page 1: ...EPSON StylusCX4100 CX4200 CX4700 CX4800 DX4200 DX4800 DX4850 Color Inkjet Printer SEIJ05 013 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 NOTE Any illustrations or photos of the printer without a card slot are based on the Stylus CX4100 CX4200 DX4200 Revision Issued Date Description A Aug 10 2005 First Release ...

Page 6: ...ming Function 41 1 5 7 Assignment Rules for Photo Frame Numbers and Rotation 41 1 5 8 Layout Drawings 43 1 5 9 Relation between Paper Type and Quality 46 1 6 Control Panel 47 1 6 1 Buttons 47 1 6 2 Indicators 47 1 6 3 Operations 49 1 6 4 Printer Condition and Panel Status 54 1 6 5 Memory Functions 58 1 6 6 Printer Initialization TBD 59 Chapter 2 OPERATING PRINCIPLES 2 1 Overview 61 2 2 Printer Mec...

Page 7: ...oder Board PW Sensor Board Head FFC 152 4 4 20 Paper Guide Upper Unit 155 4 4 21 Front Frame 156 4 4 22 EJ Frame Unit 157 4 4 23 Ink System Unit 159 4 4 24 Paper Guide Front Unit 160 4 4 25 PG Sensor 161 4 4 26 PF Roller Unit 162 4 5 Scanner Section 163 4 5 1 Scanner Housing Upper 163 4 5 2 Scanner Carriage Unit 164 4 5 3 Scanner Motor Unit Scanner HP Sensor Driven Pulley 166 4 6 Removal procedure...

Page 8: ...ision A 8 Chapter 6 MAINTENANCE 6 1 Overview 188 6 1 1 Cleaning 188 6 1 2 Service Maintenance 188 6 1 3 Lubrication 190 Chapter 7 APPENDIX 7 1 Connector Summary 195 7 1 1 Major Component Unit 195 7 2 Exploded Diagram 201 7 3 Parts List 212 7 4 Electrical Circuits 216 ...

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

Page 10: ... 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 Paper type can be selected from two options plain paper or photo paper which also defines copy quality Enlarge Reduce factor can be selected from two options actual size 100 or Fit to page Copy margin is automatically selected from t...

Page 11: ...ent and can therefore be operated simultaneously from a connected computer Easy operation panel The unit has a simple operation panel equipped with ten buttons including power button LEDs that contain seven segment LED and provides basic functions only for easy operation Note Only for CX4700 CX4800 DX4800 DX4850 9 buttons for the model without card slot Exterior design Use of a CIS scanner engine ...

Page 12: ...aracters Second This speed is when using normal dot printing mode Note Draft Printing A3 A2 A1 Black Cyan Magenta Yellow 2 822 40 360inch A row B row C row D row A90 A89 A88 B3 B2 B1 B89 B88 B90 C3 C2 C1 C89 C88 C90 D3 D2 D89 D88 D90 D1 8 467 120 360inch 2 822 40 360inch 0 2117 3 360inch 0 1411 2 360inch 0 07055 1 360inch Carriage Moving Direction Paper Feed Direction Table 1 2 Print Resolution Ho...

Page 13: ...e 64 Kbytes 1 2 1 3 Paper Feed Specifications Paper feed method Friction feed using one ASF Auto Sheet Feeder Paper path Top feed front out Paper feed rates 203 2 mm sec 8 0 inch sec high quality mode 25 4 mm feed 294 64 mm sec 11 6 inch sec high speed mode continuous feed PF interval Programmable in 0 017 mm 1 1440 inch steps Table 1 5 Graphics Mode Border free Printing Horizontal resolution Prin...

Page 14: ...ams or other problems If you encounter problems switch to a higher grade 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 Use paper under normal conditions Temperature 15 to 25 C 59 to 77 F Humidity 40 to 60 RH Table 1 7 Envelopes Paper size Dimensions Thickness Weight Paper type Width Length No 10 1 241 3 mm 9 5 104 8 mm 4 1...

Page 15: ...0 23 167 A4 210 297 8 x 10 203 254 Double sided Matte Paper 3 Letter 215 9 279 4 0 25 178 A4 210 297 Economy Photo Paper 3 A4 210 297 0 23 188 Photo Quality Ink Jet Paper 3 A4 210 297 0 12 102 Glossy Photo Paper 1 3 Letter 215 9 279 4 0 23 188 4 x 6 101 6 152 4 Premium Glossy Photo Paper 4 x 6 101 6 152 4 0 25 238 Ultra Glossy Photo Paper 2 Ultra Premium Glossy Photo Paper 1 A4 210 297 0 30 290 Le...

Page 16: ...le Area Cut Sheet Standard Printing 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 A6 B5 Letter Legal Executive Half Letter User defined Exclusive papers Photo Paper 3 mm 0 12 3 mm 0 12 3 mm 0 12 3 mm 0 12 Premium Glossy Photo Paper Premium Semigloss Photo Paper Matte Paper Heavyweight D...

Page 17: ...0 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 1 34 2 54 3R 2 54 2 54 1 34 2 54 Premium Semigloss Photo Paper Letter 2 54 2 54 2 96 4 02 A4 2 54 2 54 2 96 4 02 Matte Paper Heavyweight 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 Double sided Matte Paper Letter 2 54 2 54 2 96 4 02 A4 2 54 2 54 2 96 4 02 Economy Photo Paper A4 2 54 2 54 2 96 4 02 Phot...

Page 18: ...ut Sheet Border free Printing Table 1 11 Applicable Paper Printing Area For Copying Paper Type Size LO mm RO mm TO mm BO mm Photo Paper A4 2 54 2 54 2 96 5 08 4 x 6 Premium Glossy Photo Paper Letter A4 8 x 10 5 x 7 4 x 6 3R Premium Semigloss Photo Paper Letter A4 5 x 7 4 x 6 3R Paper size LO RO PW TO BO Paper Feed Direction PL Printable area ...

Page 19: ... PL refer to 1 2 1 4 Paper Support p 14 Refer to the following table As for each margin area refer to Figure 1 5 p 19 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 3mm 0 12 3mm 0 12 3mm 0 12 20mm 0 79 DL C6 220 x 132 Printable area LM TM RM BM Paper Feed Direction PW PL ...

Page 20: ...perature Dimension 12 7mm W x 73 46mm D x 55 25mm H Figure 1 6 Ink Cartridge Table 1 13 Ink Cartridge Color Size Stylus CX4100 CX4700 Stylus CX4200 CX4800 Stylus DX4200 DX4800 DX4850 Black S size T0621 T0601 SS size T0631 T0611 Cyan S size T0602 SS size T0632 T0612 Magenta S size T0603 SS size T0633 T0613 Yellow S size T0604 SS size T0634 T0614 Table 1 14 Storage Temperature Situation Storage Temp...

Page 21: ...canning 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 1200 dpi Color Approx 30 msec line Monochrome Approx 10 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 Scann...

Page 22: ...umidity Range 1 2 3 3 Durability Total print life 10 000 pages black only A4 or five years whichever comes first Print Head Life Six billion shots per nozzle or five years whichever comes first Scanner head MCBF 36 000 cycles Table 1 16 Primary Power Input 100 120 V model 220 240 V model Rated power supply voltage ACV 100 120 220 240 Input voltage range ACV 90 132 198 264 Rated current A 0 4 A max...

Page 23: ...o ISO7779 when for copying 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 CSA22 2 No 60950 EMI FCC part15 subpart B class B EN 55022 CISPR Pub 22 class B CSA C108 8 class B AS NZS CISPR22 class B...

Page 24: ... Only for CX4700 CX4800 DX4800 DX4850 Transfer rate 480 Mbps High Speed Device Data format NRZI Compatible connector USB Series B Recommended cable length 2 m or less Device ID Table 1 19 Device ID Product Name Device ID Stylus CX4700 00H 5AH MFG EPSON CMD ESCPL2 BDC D4 ESCPR1 MDL Stylus SP CX4700 CLS PRINTER DES EPSON SP Stylus SP CX4700 Stylus CX4100 Stylus CX4200 Stylus CX4800 Stylus DX4200 00H...

Page 25: ...able power Max power consumption is 2 mA 2 Data Bi D Data 3 Data Bi D Data pull up to 3 3 V via 1 5 K ohm resistor 4 Ground Cable ground Pin 1 Pin 3 Pin 2 Pin 4 Table 1 21 Endpoint Attribute Card Slot Model I F No Endpoint Address Endpoint Type Linked Interface 0x00 0x01 Bulk Out Scanner 0x02 Bulk In 0x01 0x04 Bulk Out Printer 0x05 Bulk In 0x02 0x07 Bulk Out Card 0x08 Bulk In Table 1 22 Endpoint A...

Page 26: ...MB copy protection function is not supported Memory Stick Duo requires Memory Stick Duo adapter Memory Stick PRO MemoryStick Standard Memory Stick PRO Format Specifications version 1 0 compliant MemoryStick Standard Memory Stick PRO Format Specifications version 1 0 compliant Memory Stick Duo requires Memory Stick Duo adapter Memory Stick PRO Duo requires Memory Stick Duo adapter Memory Stick PRO ...

Page 27: ...ion to computer Macintosh Only the card in the active slot can be mounted on the desktop A card that has been inserted into a non selected slot cannot be mounted on the desktop Details Access priority The access priority among slots is assigned as 1 CF Micro Drive 2 Smart Media xD Picture Card 3 Memory Stick Memory Stick PRO SD MMC Slot selection when power is turned on If cards are inserted in se...

Page 28: ...ically sets the zoom factor of the copy according to the copy paper s printable area 1 4 1 3 Number of Copies Setting This function sets the number of copies The setting range is 1 to 9 and 100 1 4 1 4 Maximum Copy Size 216 mm x 297 mm Table 1 24 Supported Paper Sizes Types and Qualities for EAI Paper type Quality 1 Paper size Paper name Panel indication Paper size Panel indication Plain Paper Pla...

Page 29: ...rner as the origin and any margins that occur during the fitting process occur along the bottom and or right edge Note 1 Actual is the state that Fit to page is not selected 2 Fit to page automatically sets the enlarge reduce scale so that the entire image fits into the printable area or the border free area when border free layout is selected When the original image is smaller than general card s...

Page 30: ...ute Plain Paper 1 0 cpm Color e Memo text A4 size pattern zoom 100 The above speed is for the second and subsequent copies the time between ejection of the first page to ejection of the second page 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 2 Pure b...

Page 31: ... 297 mm 11 7 3 mm Table 1 30 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 ...

Page 32: ... 297 mm 11 7 1 5 mm 1 mm Table 1 32 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 ...

Page 33: ... 7 1 5 mm 1 mm Table 1 34 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 r...

Page 34: ...IO s DSC thumbnail images SCENE Directories containing data for CASIO s DSC Best Shot function MSSONY Directories containing SONY s DSC e mail image data voice memos video files or non compressed images DCIM ALBUM IMAGE Directories containing CASIO s DSC album data save directory 1 5 1 4 Valid Image Size The maximum image size handled by this unit is Horizontal 80 X 9200 pixels Vertical 80 Y 9200 ...

Page 35: ...photo was taken or subsequent saving of data In such cases this unit performs the relevant processing based on the most recently modified date time data 1 5 1 10 Number of Sheets which can be Printed in Total Printing sum total number of sheets presupposes that it is possible to 999 sheets Moreover the printing sum total number of sheets per sheet is possible to 99 sheets 1 5 2 Functions 1 5 2 1 L...

Page 36: ...serting the memory card Note 1 Letter size will be used for Stylus CX4200 CX4800 A4 size will be used for other models 2 The panel indicator only The printer chalks 10 x 15 format to 4 x 6 format Table 1 36 Memory Card Printing Mode Setting Memory card printing mode Description Option setting range etc Layout no menu Print from index sheet printing Print all images DPOF printing Sets print layout ...

Page 37: ... layout is fixed according to the paper type and it is not indicated on the sheet Refer to 1 5 4 Layout and Paper Type Paper Size p 40 Images are arranged in the Index sheet in ascending order of image file number Refer to 1 5 1 7 File Sorting p 34 and 1 5 1 8 File Sorting Rules p 35 Index sheet will be printed from the last page in descending order The sheet containing first thumbnail comes top o...

Page 38: ...le scanning This is to prevent any shifting of the position marks while scanning Do not use paper that allows images to bleed through to the rear side This is to prevent empty bubbles from being filled in by bleed through Set scan area and original Place the Index Sheet face down with its top edge aligned to the left edge of the scan bed and with the corner of the paper set to the original s top l...

Page 39: ... patterns shown above are superimposed on the mark and judgment is made according to this matching ratio The judgment criteria is as follows Black matching 80 or more White matching 50 or more Errors during scanning or printing of index sheets Stops scanning and returns to the menu screen if the card is removed while an index sheet is being scanned or printed Index sheet error No index sheet is di...

Page 40: ...1 2 3 1 2 3 1 2 3 OK patterns NG patterns Table 1 39 Layout and Paper Type Paper Size Layout Paper type Paper size Description Border free Photo Paper EAI Letter 4 x 6 5 x 7 Rest A4 10 x 15 1 13 x 18 Prints with no margins along top bottom and both sides 1 up with borders Plain Paper EAI Letter 4 x 6 5 x 7 Rest A4 10 x 15 13 x 18 Prints with 3 mm margins along top bottom and both sides 20 up EAI 4...

Page 41: ...ame numbers used for various types of layout The direction of the number shown in each photo frame matches the direction of the printed photo to which the horizontal photo data was allocated When there are more pixels vertically than horizontally the vertical photo data is allocated instead and the number shown in the figure below is then rotated 90 before being printed In Index printing mode the ...

Page 42: ...me Numbers and Rotation 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Top edge Border free 1 sheet with borders 20 up 80 up 30 up ...

Page 43: ...00 DX4200 DX4800 DX4850 Paper A C F E G H B D Printable area Table 1 40 Border Free unit mm inch Paper type A B C D E F G H Letter 1 215 90 8 50 279 40 11 00 220 98 8 70 287 53 11 32 2 54 0 10 2 54 0 10 2 96 0 12 4 02 0 16 4 x 6 1 101 60 4 00 152 40 6 00 106 68 4 20 160 53 6 32 2 54 0 10 2 54 0 10 2 82 0 11 3 60 0 14 5 x 7 1 127 5 00 178 7 00 132 08 5 20 186 04 7 32 2 54 0 10 2 54 0 10 2 96 0 12 4...

Page 44: ...00 DX4200 DX4800 DX4850 Printable area C A F E G H D B Table 1 41 Border Free unit mm inch Paper type A B C D E F G H Letter 1 215 90 8 50 279 40 11 00 209 90 8 26 273 40 10 76 3 00 0 12 3 00 0 12 3 00 0 12 3 00 0 12 4 x 6 1 101 60 4 00 152 40 6 00 95 60 3 76 146 40 5 76 3 00 0 12 3 00 0 12 3 00 0 12 3 00 0 12 5 x 7 1 127 0 5 00 178 0 7 00 121 0 4 76 172 0 6 76 3 00 0 12 3 00 0 12 3 00 0 12 3 00 0...

Page 45: ...ill be used for Stylus CX4100 CX4700 DX4200 DX4800 DX4850 Table 1 42 20 up unit mm inch Paper type A B C D E F G H I J K L 4 x 6 1 101 60 4 00 152 40 6 00 20 00 0 79 20 00 0 79 6 10 0 24 6 30 0 25 19 80 0 78 20 30 0 80 3 00 0 12 3 00 0 12 89 30 3 52 112 30 4 42 10cm x 15cm 2 101 60 152 40 20 00 20 00 6 10 6 30 19 80 20 30 3 00 3 00 89 30 112 30 A K L J D E F G H B J J J C I I I Table 1 43 30 up un...

Page 46: ...279 40 11 00 20 07 0 79 20 07 0 79 6 10 0 24 6 10 0 24 6 35 0 25 58 67 2 31 111 00 4 37 A4 210 0 297 0 20 0 20 0 2 0 5 0 18 0 62 0 106 0 Paper type J K L M N O P Q Letter 163 32 6 43 6 35 0 25 11 94 0 47 64 26 2 53 116 59 4 59 168 91 6 65 221 23 8 71 11 94 0 47 A4 150 0 18 0 26 0 76 0 126 0 176 0 226 0 26 0 B C D E F G H I J K L M N O P Q Table 1 45 Relation between Paper Type and Quality Paper ty...

Page 47: ...e of card print mode Copy Button Make transition from Memory Card mode to Copy mode and sets number of copies Paper Type Button Select paper type Paper Size Button Select paper size Fit to Page Button Alternate zoom of Fit to page and default actual 100 B W Start Button 2 Start monochrome copy Color Start Button Start card print or color copy Stop Button Stop job of copying or printing or sometime...

Page 48: ...ize Button Fit to Page Button B W Start Button Color Start Button Stop Button Power LED Error LED Ink LED 7 seg LED Paper Type LED 1 2 Paper Size LED 1 2 Fit to Page LED Power Button Ink Button Memory Card Button Copy Button Paper Type Button Paper Size Button Fit to Page Button B W Start Button Color Start Button Stop Button Power LED Error LED Ink LED Memory Card LED 1 3 7 seg LED Paper Type LED...

Page 49: ...ror Memory Card Button Only for CX4700 CX4800 DX4800 DX4850 Make transition from Stand alone copy mode to Memory card print mode and select and light Print Index Sheet or Print All DPOF if DPOF file exists in the card Turn off both 7 seg LED and Fit to Page LED Select Plain Paper and Letter or A4 Change to next Memory card print function Case Print Index Sheet Change to Print From Index Sheet and ...

Page 50: ...t Load paper in paper out error or double feed error and eject paper in paper jam error Color Start Button Start color copy Start memory card print Make transition from Print Index Sheet to Print From Index Sheet when Print Index Sheet finishes successfully without any error or STOP operation Invalid with no card in slots Move to memory card error status when incompatible memory card is inserted o...

Page 51: ...d Access LED if it is right The LED blinks while memory access occurs to the memory card The Power LED blinks during the card recognition Return from the low power panel mode Card Ejection Turn off Card Access LED Stop print job while memory card print is in process and eject paper Clear memory card error if memory card is wrong Table 1 50 Low Power Panel Mode Action Function Transition to low pow...

Page 52: ...when the initial value is the most appropriate Adjust VSD2 color parameter 1 VSD2 color parameter is ready to adjust while Photo Paper LED is ON 2 Select the most appropriate value regarding the printed pattern 2 by pressing Copy button The initial value is 5 indicated on 7 seg LED and by pressing Copy button the value will change from 1 up to 9 incrementally and cyclically 3 Press B W Start butto...

Page 53: ... The procedure is terminated by pressing Stop button 3 The unit is turned off When Paper Out has occurred the procedure can restart from Print Pattern by pressing Color Start button The error should be removed in advance Ink maintenance operation like exchanging I C or cleaning head can not be done in this mode This unit will be turned off automatically when the procedure is terminated by pressing...

Page 54: ...preset number of copies Table 1 52 Printer Condition and Panel Status Printer status Indicators Priority Power LED Error LED Ink LED Memory Card LED 7 seg LED Paper Type LED Paper Size LED Fit to Page LED Card Access LED 1 2 3 1 2 1 2 3 Power on Normal ready mode On 24 Card printing mode Print All DPOF On Off Selected type is On Selected size is On Off 23 Card printing mode Index Sheet scanning pr...

Page 55: ...Blink 2 2 blink 2 18 Memory card error Blink 2 Off Blink 2 Blink 2 Blink 2 1 blink 2 Off Off Off Off Off Off 17 Power on Data Processing Blink 16 Reading a memory card recognizing image data Blink 15 Stopping printing and cancelling the print job Blink 14 The scanner is operating by a computer Blink Off Off Off Off Off Off Off Off Off Off 13 Printing by a computer Blink Off Off Off Off Off Off Off...

Page 56: ... Off Selected type is On Selected size is On Off Card printing Print index sheet Blink On Off On On Off Double feed On Off 11 Paper out On Off Ink Sequence Processing Blink 10 Ink Cartridge Change Mode Blink 2 Off Blink 2 9 Ink out No Ink cartridge Read error Write error Off On 8 Paper jam Blink Off 7 Reset request Stop request Job cancel request 1 second On 1 sec On 1 sec On 1 sec On 1 sec On 1 s...

Page 57: ...ink Blink Blink E blink Blink Blink Blink Blink Blink Blink 3 Fatal error System Fast blink Fast blink Fast blink Fast blink Fast blink Fast blink Fast E blink Fast blink Fast blink Fast blink Fast blink Fast blink Fast blink 2 Power off Processing termination Fast blink Off Off Off Off Off Off Off Off Off Off Off Off 1 Table 1 52 Printer Condition and Panel Status Printer status Indicators Priori...

Page 58: ... cases Blank paper is ejected when loading papers The length of the paper is determined to be long when ejecting the paper 1 6 5 Memory Functions 1 6 5 1 Parameters that are retained while mode transition The following parameters are retained for each mode while the mode transition from Copy mode to Memory Card Print mode or vice versa Paper Type and Paper Size are retained for each mode as defaul...

Page 59: ...inter 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 initi...

Page 60: ...C H A P T E R 2 OPERATINGPRINCIPLES ...

Page 61: ...ding Mechanism Ink System Like the previous printers Stylus CX4100 CX4200 CX4700 CX4800 DX4200 DX4800 DX4850 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...

Page 62: ...ad 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 on the drive waveform generated on the ...

Page 63: ... 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 63 Ejecting state Figure 2 4 Print Head printing process 2 2 2 2 Printing Method The dot printing systems of Stylus CX4100 CX4200 CX470...

Page 64: ... and saved into 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 t...

Page 65: ... width detection Sensor installed on the Carriage Unit bottom is used to control the printer according to various sequences The following briefly describes the PW Sensor operating principle A dark voltage is measured by the PW Sensor in three places on the right end plane area without the absorber of the Front Paper Guide every time power is switched on and the measurement values are saved into th...

Page 66: ...rs in the following figure 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 5Ω 10 Inductance 21 4mH 25 Driving method PWM constant current chopping Driver IC A6627 Table 2 3 ASF unit function PF Motor rotationa...

Page 67: ...to detect 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 Cha...

Page 68: ...ge 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 dri...

Page 69: ...ep1 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 ...

Page 70: ...he EJ 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 ...

Page 71: ...and 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 positi...

Page 72: ...her 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 ...

Page 73: ...he ink 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 dire...

Page 74: ...X4200 DX4200 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 CX4700 CX4800 DX4800 DX4850 CX4100 CX4200 DX4200 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 t...

Page 75: ... 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 period is o...

Page 76: ...document 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 wit...

Page 77: ...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 si...

Page 78: ... Power Supply Board C610 PSB PSE Board NOTE CPU and ASIC is integrated as one chip IC8 on the Main Board This section provides operating principles of C610 Main Board and C610 PSB PSE Board Refer to Figure 2 17 p 78 for the major connection of the each boards and their roles Figure 2 17 Electric circuit C610 Main Board C610 PSB PSE Board Sensors Head Driver Board PF Motor CR Motor Printer Mechanis...

Page 79: ...ltage 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 the switching circuit and FET Q1 preforms the switching operation By the switching operation of the primary circuit 42VDC is generated and stabilized at the...

Page 80: ...r IC6 is stepped down to 1 5V by the Combination Motor Driver IC5 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 80 shows the function of the each main elements on C610 Main Board Note Only for Stylus CX4700 CX4800 DX4800 DX4850 Table 2 8 3 3V 1 5V 5V Drive Components 5VDC 3 3 VDC 3 3 1 5VDC RTC IC4 Flash ROM IC1 ...

Page 81: ...sh ROM IC1 Card ASIC IC9 Card Slot CN14 Card Slot CN15 RTC IC4 CN11 CIS Unit AD Converter IC11 CN12 C571 577 Panel Board CN13 Scanner HP Sensor USB CN2 CN1 C610 PS Board Motor Driver IC5 CN8 CN9 CN10 CR Motor PF Motor Scanner Motor P1 PF Encoder Sensor PE Sensor PG Sensor CN3 CN4 Common Driver IC7 Q3 Q4 CN5 CN6 Print Head CN7 CR Encoder Sensor PW Sensor CSIC Board Note Only for Stylus CX4700 CX480...

Page 82: ... the common driver IC7 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 Q3 and Q4 and applied to the nozzle PZT specified by nozzle selector IC Nozzle ...

Page 83: ...er 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 Dr...

Page 84: ... at the VEX port of IC4 and if an abnormal voltage is detected a reset signal for the CPU is output from the EXO port of IC4 EEPROM Control Circuit When the printer power is turned off the following information is stored in EEPROM IC4 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 count...

Page 85: ...ft and right edges of the paper being fed Paper absent A low signal is output to the CPU Paper present A high signal output to the CPU CR Encoder Sensor The sensor is composed of a transmissive photosensor mounted to the back of the carriage and a linear scale mounted 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...

Page 86: ...LK CDIO CXRST AIN2 EA_CR EB_CR EA_PF EB_PF A6 C6 B4 A4 B5 B9 B6 A5 A17 B17 CPU IC8 PF Encoder P1 PE PG SCNHP AIN1 D17 D6 D18 C9 5 1 6 2 3 13 10 15 11 9 CVDD COI CSCK CSDA CRST PW EVDD LEDON ENCA ENCB PEV GND PE PG GND PEV GND SCN_HP XHOT THM 3 2 1 1 2 3 2 1 1 VOA VOB VCC GND A A 3 3V_SN 3 3V 3 3V 3 3V 3 3V 3 3V_SN 3 3V 3 3V 3 3V_SN 3 3V_SN CN7 CR Encroacher Sensor PW Sensor CSIC CN13 Scanner HP Se...

Page 87: ...C H A P T E R 3 TROUBLESHOOTING ...

Page 88: ...ribes 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 CX4800 however other models show almost the same diplays as those except the following items 1 SPC name...

Page 89: ...ct card Index Sheet error 2 Incorrect marking Indications Power Error Blink 1 Blink 1 Blink 1 Ink Blink Memory Card only for Stylus CX4700 CX4800 DX4800 DX4850 1 2 Blink 1 Blink 1 3 7 seg H blink 1 4 blink 1 3 blink 1 Paper Type 1 2 Paper Size 1 2 Fit to Page Card Access Status monitor 3 message Fault Occurrence Cause Some ink is near end Platen gap is at open position while standalone function Th...

Page 90: ...Indications Power Error Blink 1 Blink 1 Blink Ink Off Memory Card only for Stylus CX4700 CX4800 DX4800 DX4850 1 Blink 1 2 Blink 1 Blink 1 3 Blink 1 7 seg 2 blink 1 1 blink 1 P blink 2 Paper Type 1 2 Paper Size 1 2 Fit to Page Card Access Status monitor 3 message Fault Occurrence Cause No index sheet is recognized correctly This memory card is not available with this unit Or no image can be found o...

Page 91: ...currence Causes Printer Status Double feed Paper out Paper jam Indications Power Error On On Blink Ink Off Off Off Memory Card only for Stylus CX4700 CX4800 DX4800 DX4850 1 2 3 7 seg Paper Type 1 2 Paper Size 1 2 Fit to Page Card Access Status monitor 3 message Fault Occurrence Cause Double feeding occurred during duplex printing Failure to load paper to print Paper stays in the paper path after p...

Page 92: ...ions Power Blink Blink Error Off On Blink Ink On On Blink Memory Card only for Stylus CX4700 CX4800 DX4800 DX4850 1 Blink Blink 2 Blink Blink 3 Blink Blink 7 seg E blink E blink Paper Type 1 Blink Blink 2 Blink Blink Paper Size 1 Blink Blink 2 Blink Blink Fit to Page Blink Blink Card Access Status monitor 3 message Fault Occurrence Cause Some ink cartridge is running out of ink Ink cartridge is no...

Page 93: ...TROUBLESHOOTING p 87 The following tables describe the error check points Table 3 7 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 Boar...

Page 94: ...correctly 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 EEP...

Page 95: ...w one 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 bra...

Page 96: ...maged 1 Replace the PG Sensor with a new one Main Board 1 Check if the Main Board is not damaged 1 Replace the Main Board with a new one Torsion Spring 26 1 PG Sensor Table 3 10 Check point for the Index Sheet error incorrect card according to each phenomenon Occurrence timing CR position Detailed phenomenon Defective unit part name Check point Remedy Operation This error is generated when attempt...

Page 97: ...perly cover over mark Table 3 12 Check point for the Index Sheet error No index Sheet according to each phenomenon Occurrence timing CR position Detailed phenomenon Defective unit part name Check point Remedy Operation This error is generated when attempting to print from Index Sheet Index Sheet 1 Check if the Index Sheet is set in the wrong way 1 Set the Index Sheet correctly 2 Check if the Index...

Page 98: ...the Memory Card slot pins on the Main Board is not bent 1 Change the Main Board Unit with a new one Table 3 14 Check point for the Double feed error according to each phenomenon Occurrence timing CR position Detailed phenomenon Defective unit part name Check point Remedy Operation After both surfaces were printed the paper was ejected but an error is displayed ASF Unit 1 Check if the Extension Spr...

Page 99: ...y to 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...

Page 100: ...sm 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 15 Check point for the paper out error according to each...

Page 101: ...e Ink 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 15 Check point for the paper out error according to each phenomenon Occurrence timing CR position Detaile...

Page 102: ...splayed 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 C...

Page 103: ...med 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...

Page 104: ...tion The leading edge of paper 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 2 Check if the EJ Roller Unit is correctly assembled 2 Reassemble the EJ Roller Unit correctly The Carriage Unit can move to home position even if the Torsion Spring 0 22 comes off However the PE ...

Page 105: ...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 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 17 Check...

Page 106: ...oes 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...

Page 107: ...lace 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...

Page 108: ...nector 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 da...

Page 109: ...ne 3 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 Reassem...

Page 110: ... the 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 wi...

Page 111: ...loth coat it with grease G 26 Grease Refer to Chapter 6 MAINTENANCE 2 Check if the Guide Rail of the Housing Lower is set correctly 2 Reassemble the Guide Rail of the Housing Lower 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 CN...

Page 112: ...ever 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 18 Check point for the Fatal error according to each phenomenon Occurrence timing CR position Detailed phenomenon Defective unit...

Page 113: ...rrence 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...

Page 114: ...Unit 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 21 Check point for poor scanned image quality Scanned image Quality S...

Page 115: ... correctly 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 t...

Page 116: ...he Print 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 ...

Page 117: ...arriage 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 KEN Grease Refer to Chapter 6 MAIN...

Page 118: ...the 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 Un...

Page 119: ... out 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...

Page 120: ...1 Clean 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 22 Check point for the poor printing quality Print Quality State Det...

Page 121: ...C H A P T E R 4 DISASSEMBLY ASSEMBLY ...

Page 122: ...ou need to 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 equ...

Page 123: ...is no 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 O...

Page 124: ...rences C H E C K P O I N T As for common parts among the card slot model and the model with no card slot descriptions and pictures in this section are based on the card slot model Table 4 3 Differences in Disassembling Procedures Concerning Models With or Without the Card Slot Item Description Stylus CX4700 CX4800 DX4800 DX4850 Card slot model Stylus CX4100 CX4200 DX4200 Model with no card slot Re...

Page 125: ...and 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 Ho...

Page 126: ...ont Unit p160 4 4 25 PG Sensor p161 4 4 26 PF Roller Unit p162 4 4 21 Front Frame p156 4 4 16 CR Guide Frame p149 4 4 12 ASF Unit p144 4 4 13 Holder Shaft Unit p146 4 4 9 PS Board Unit p137 4 4 18 PF Motor p151 4 4 20 Paper Guide Upper Unit p155 4 4 7 Printhead p132 4 4 23 Ink System Unit p159 4 4 2 Paper Support Assy p128 To remove the Ink System Unit all parts shown in the red boxes need to be r...

Page 127: ...e removed before removing Document Cover Document Cover Mat ASF Cover None Removal procedure Document Cover 1 Open the Document Cover and remove it by pulling out upward 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 ASF Cove...

Page 128: ...elease 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 Ass...

Page 129: ... Unit 5 Open the Scanner Unit and remove it by pulling out upward USB Cover 2 1 CN10 CN13 CN11 Main Board FFC Shield Plate C B S 3x6 F Zn 6 1kgfcm 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 Carria...

Page 130: ...x5 Copy Button Stop Button Ink Button and Power Button from the Panel Housing Panel FFC CN12 Tabs Rib Notch Panel Cover 1 2 C B S 3x8 F Zn 7 1kgfcm Panel Unit 1 2 3 Panel Board CN1 Tab Guide Pin Tabs Notches S Button Power Button Copy Button Stop Button Ink Button 1 2 C A U T I O N When performing the following work be careful not to bend the tabs x3 of the Panel Unit C H E C K P O I N T When remo...

Page 131: ...removing Housing Upper Document Cover Paper Support Assy Scanner Unit Panel Unit Removal procedure 1 Remove the screws x6 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 5 2 6 3 4 Tabs C B P 3x10 F Zn 4 1kgfcm C B S 3x6 F Zn 7 1kgfcm Housing Upper Tighten the screws in the orde...

Page 132: ...Head Cable Cover with a precision screwdriver slide the Cover downward and remove the Head Cable Cover 4 Release the tab x1 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 FFCs x2 from the connectors x2 of the Print Head and remove ...

Page 133: ...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 after rep...

Page 134: ... and 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 Rear Cover C B P 3x10 F Zn 4 1kgfcm Housing Lower Tabs Carriage Unit Carriage Lock Waste Ink Tube Tube Clump Eject Ink Joint Red Line Tab C A U T I O N The Waste Ink Tube may be broken when it is removed If it breaks re...

Page 135: ...river and remove whole Printer Mechanism from the Housing Lower 1 4 6 5 2 3 Printer Mechanism CN1 Main Board PS Connector Cable PG Lever Guide Pin Front Paper Guide Support Groove C B P 3x8 F Zn 4 1kgfcm Tab Holding Positions C B P 3x10 F Zn 4 1kgfcm CR Guide Frame C H E C K P O I N T Removal procedures of the model with no card slot Stylus CX4100 CX4200 DX4200 differs from the one of the card slo...

Page 136: ...g 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 that Printer Mechanism is properly pl...

Page 137: ...Unit 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 b...

Page 138: ...nk Pads Removal 1 Remove the screw x1 that secures the PG Lever Mounting Plate and remove the PG Lever PG Lever Mounting Plate and Torsion Spring 26 1 all together from the Housing Lower 2 Remove the Waste Ink Tube along with the Tube Clamp and the Eject Ink Joint from the groove of the Housing Lower 3 Remove 11 pieces of the Waste Ink Pads from the Housing Lower PG Lever Mounting Plate Torsion Sp...

Page 139: ...ing 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 When installing the PG Lever Mounting Plate to the Housing Lower match the guide pins x2 of the Housing Lower with the positioning holes x2 of the PG Lever Mounting Plate A D J U S T M E N T R E Q U I R E D Afte...

Page 140: ...nting Plate 2 Remove Torsion Spring 26 1 from the installation holes x2 of the PG Lever and the PG Lever Mounting Plate and remove the PG Lever Rubber Feet Removal 1 Remove the rubber feet x6 from the Housing Lower Tabs Compression Spring 5 1 Shaft and Groove Inner Surface Stacker Lock Right PG Lever Torsion Spring 26 1 Tabs Installation Holes PG Lever Mounting Plate Rubber Feet Pass the shaft of ...

Page 141: ...e following connector cables and FFCs from the connectors of the Main Board CN3 PE Sensor Connector Cable CN4 PG Sensor Connector Cable CN5 Head FFC CN6 Head FFC CN7 Head FFC CN8 CR Motor Connector Cable CN9 PF Motor Connector Cable 6 Remove the screws x3 that secure the Main Board Unit and remove the Main Board Unit from the Printer Mechanism PG Sensor Connector Cable Head FFC Main Board Unit Ace...

Page 142: ...and remove the Card Slot Spring 3 Release the guide pin x1 of the Card Slot Cover from the Card Slot Housing and remove the Card Slot Cover Card Slot Unit C B S 3x6 F Zn 7 1kgfcm 1 2 Card Slot Cover Spring Tab Tip Card Slot Housing Card Slot Cover Shaft Guide Pin Guide Pins Positioning Holes Set the shaft of Card Slot Cover into the Card Slot Housing and align the guide pin Install the Card Slot S...

Page 143: ...ale 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 Unit per...

Page 144: ...d the Main Board Unit 2 Release the 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 Ferrite Core PF Motor and Slot Tab 1 3 5 2 4 ASF Unit C B S 3x6 F Zn 8 1kgfcm C B S P2 3x6 F Zn 8 1kgfcm C B P 3x8 F Zn ...

Page 145: ...er Hopper Pad 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 25 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...

Page 146: ...lease 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 Frame Main Board Unit C B S 3x6 F Zn 7 1kgfcm Front Tabs Ribs 1 1 Guide Pin Pump Frame Tabs T...

Page 147: ...nd 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 LD Roller Shaft Unit Holder Shaft Guide Pins Torsion Spring 137 7 Cam Paper Block Guide Pins Ribs Clutch Mechanism Assemble the LD Roller Shaft Unit as ...

Page 148: ...r Lever 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 PE Sensor Lever Straight Tip L shaped TIp Torsion Spri...

Page 149: ... Holder and remove the FFC Frame Holder together with the Head FFC 4 Release the Head FFC from the tabs x2 of the FFC Frame Holder 5 Release the Head FFCs x3 secured with the double sided tape x1 from the CR Guide Frame 6 Remove the screws x2 that secure the CR Guide Frame and remove the CR Guide Frame from the Printer Mechanism Acetate Tapes FFC Guide Guide Pins CR Guide Frame FFC Frame Holder Ta...

Page 150: ...ng 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 Driven Pulley Holder Timing Belt Pinion Gear C P 3x4 F Zn 4 0 5kgfcm 1 2 Lot No C A U T I O N Do not damage the pinion ge...

Page 151: ...from 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 PF Motor C P 3x4 F Zn 4 0 5kgfcm Ferrite Core and Slot Acetate Tape CR Motor PF Scale...

Page 152: ... to 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 Timing Belt CR Scale Tab Extension Spring 3 289 Tabs Chipped Part Slit of CR Encoder Sensor Spacer...

Page 153: ...aft 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 Right Side CR Guide Shaft Pressing Spring Tab Parallel Adjustment Lever Left CR Guide Shaft C B S P2 3x6 F Zn 7 1kgfcm Guide Pin Carriage Unit 2 1 1 C A U T I O N Do not damage the Carriage Guide Shaft Do not stain the Ti...

Page 154: ...rom the Carriage Unit 2 Pull out the Head FFC from the notch of the Carriage 3 Release the Head FFC from the tabs x4 that secure the Head FFC 4 Disconnect the Head FFC from the connector of the CSIC board PW Sensor Board Connector Notch Head FFC PWSensor Cap C B P P1 1 7x5 F ZB 2 0 5kgfcm Tabs Notch CR Encoder Board Connector C P B P1 1 7x5 F ZB 2 0 5kgfcm Guide Pins Notch Head FFC Connector Match...

Page 155: ...er Guide Upper Unit 1 2 Torsion Spring 75 35 Guide Pins Tabs Rib Approx 1 1 5mm 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 Mai...

Page 156: ... 1 Remove the screws x3 that secure the Front Frame and remove the Front Frame from the Printer Mechanism 2 1 3 Front Frame C B S 3x6 F Zn 7 1kgfcm Ribs Match the ribs x3 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 After replacing the Front Frame with a new one always apply grease KEN to ...

Page 157: ...nsor Connector Cable 2 Remove the Paper Eject Grounding Spring from the left side of the EJ Frame Unit 3 Release the guide pin x1 of Bush 5 on the left side of the EJ Frame Unit and rotate the Bush 5 downward by 90 4 Release the guide pin x1 of Bush 5 on the right side of the EJ Frame Unit and rotate the Bush 5 upward or downward by 90 5 Release the tabs x3 that secure the EJ Frame Unit while lift...

Page 158: ...uide Support EJ Frame Right Side Guide Pin Tab Bush 5 Left Side Tab Guide Pin C B P 3x6 F Zn 4 1kgfcm EJ Frame Grounding Plate Front Paper Guide Support EJ Roller Unit Match the guide pins x2 of the Front Paper Guide Support with the positioning holes x2 of the EJ Frame Confirm that Bush 5s on both sides are securely inserted into the notches of the Main Frame Figure 4 42 Installing Bush 5s Make s...

Page 159: ... Frame and remove the Pump Unit 6 Remove the whole Ink System from the Printer Mechanism and remove the gears x4 and the Pump Pulley Guide Pins Right Side C B P 3x8 F Zn 4 1kgfcm Sealing Rubber Head Cleaner Lower right side Tabs Cap Unit Groove Pump Unit Compound Gears 27 2 19 2 Change Lever Tabs Guide Pins Notch and Carriage Lock Position C A U T I O N Do not touch or damage the Sealing Rubber or...

Page 160: ...uide Front Unit 1 2 3 Washer 2 6x0 5x8 Guide Pin Guide Pin Guide Pin 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 Be careful not to bend the Fr...

Page 161: ...ab x1 that secures the Link Lever Holder Left with a tweezer and then slide it in the direction of the arrow shown in the figure 4 Release the Link Lever Holder Left from the rib x1 of the Main Frame and remove the Fulcrum Lever Left Lever Link along with the Link Lever Holder Left 5 Release the PG Sensor Connector Cable from the tab x1 of the Link Lever Holder Left and remove the PG Sensor Extens...

Page 162: ...sition shown 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 Bush 10 Left PF Grounding Spring Groove Notch Guide Pin Bush 10 Right Guide Pin Rear ...

Page 163: ...using Upper 4 Release the tabs x2 that secure the Scanner Housing Upper and remove the Scanner Housing Upper Scanner Housing Front Joint Document Glass Scanner Housing Upper Tabs Hinge R C B P 3x10 F Ni 7 1kgfcm Tab C B P 3x10 F Zn 5 5 0 5kgfcm 1 2 3 Tabs 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 a clean bench would be preferable Do not...

Page 164: ...ection of 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 Driven Holder 1 3 Scanner Carriage Unit Compound Gears 22 8 7 762 Scanner Timing Belt 2 Scanner Carriage Shaft Rib Double sided Tape Connector Scanner Carriage F...

Page 165: ...anner Carriage Unit Belt Clump Scanner Timing Belt Tab Tab Scanner CR Holder CIS Spring Shafts CIS Unit CIS Spring Tip Guide Pin 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 52 Attaching Scanner Timing Belt The CIS Springs x2 should be installed with their ti...

Page 166: ...move the 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 Hinge L Scanner Motor Connec...

Page 167: ... of Printer Mechanism p134 2 Remove the screws x7 that secure the Printer Mechanism 3 Disconnect the PS Connector Cable from the connector CN1 of the Main Board 4 Releasing the guide pins x2 of the Front Paper Guide Support and the Housing Lower from the groove of the PG Lever with a precision screwdriver lift up the left side of the Printer Mechanism and remove the whole printer mechanism from th...

Page 168: ... 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 that Printer Mechanism is p...

Page 169: ... Unit Housing Upper Printer Mechanism Removal procedure 1 Perform the removal procedure Step 1 of Waste Ink Pads Stacker Lock PG Lever Rubber Feet p138 2 Follow the instructions below to remove the Waste Ink Tube 1 Release the Waste Ink Tube from the groove of the Housing Lower 2 Pull out the Waste Ink Tube from the Waste Ink Cover 3 Remove the Waste Ink Tube together with the Tube Clump and the E...

Page 170: ... Figure 4 58 Installing Waste Ink Pads 2 When installing the Waste Ink Tube to the Housing Lower insert it 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 When installing the PG Lever Mounting Plate to the Housing Lower match the guide pins x2 with the positioning holes of the PG Lever Mounting...

Page 171: ...C H A P T E R 5 ADJUSTMENT ...

Page 172: ...nt Head is replaced during the repair service you must input the correct adjustment value into the EEPROM on the Main Board by using the Adjustment program Table 5 1 Required Adjustments 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 EEPROM data copy Market setting USB ID input Waste ...

Page 173: ...oval replacement O Paper guide front removal O O O O O O O O replacement O O O O O O O O PF motor removal O O O O replacement O O O O Waste ink pad removal replacement O PW sensor removal O O replacement O O EEPROM data copy Market setting USB ID input Waste ink pad counter Ink charge Head ID input Top margin adjustment First dot adjustment PW sensor adjustment Head angular adjustment Bi d adjustm...

Page 174: ...O O O replacement O O O PF roller assy removal O O O O O replacement O O O O O EEPROM data copy Market setting USB ID input Waste ink pad counter Ink charge Head ID input Top margin adjustment First dot adjustment PW sensor adjustment Head angular adjustment Bi d adjustment PF deterioration adjustment 1 CR offset PF adjustment PF band adjustment C A U T I O N When the Main board is replaced with a...

Page 175: ... Board Unit with a new one 2 Turn on the printer and click the restore 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 2 Click the Destination setting butto...

Page 176: ...ameter 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 ...

Page 177: ... removed parts during disassembly 4 Perform Step 2 again Figure 5 3 PW adjustment Printing Pattern 5 2 10 Head Angular Adjustment Adjustment procedure 1 Set Normal Paper A4 Letter on the Paper Support 2 Select Head angular adjustment in the Adjustment Program 3 Click the Print button to print following two head angular check patterns Band pattern Raster offset pattern 4 Check the printed patterns ...

Page 178: ... 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 5 Bi D Adjustment Printing Pattern OK pattern NG pattern OK pattern NG pattern Band pattern Raster offset pat...

Page 179: ...ration offset in the Adjustment Program 2 Click the Input button to input the maximum value 3 000 of the PF deterioration offset value 5 2 14 CR Offset Adjustment procedure 1 Select CR motor heat protection control in the Adjustment Program 2 Check each box of the replaced parts units checklist and then click the Perform button 3 A dialogue box will be displayed and click the OK button in the box ...

Page 180: ...he 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 7 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 re...

Page 181: ...hickness gauge should be placed between the front of the Paper Guide Front Unit and the center ribs Figure 5 11 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 Advan...

Page 182: ... U 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 12 Relationship between Parallel Adjustment Lever Right Operation Platen Gap PG up narrower PG down wider START Move the Carriage Unit by using the T...

Page 183: ...nter of sensor adjust position of PF Scale using spacer 0 5mm thickness as shown in diagram below Figure 5 15 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 Ad...

Page 184: ...ach 2 Install C592B00W exe to the computer and put the FT program into place Figure 5 16 Original Adjustment 1 3 Open the document cover and place the original adjustment jig as shown in the figure below Figure 5 17 Original Adjustment Jig Setting Position 4 Open the FT select C592_PRN on the Select Parameter Set window and click OK Figure 5 18 Original Adjustment 2 C A U T I O N This adjustment r...

Page 185: ...ton Figure 5 20 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 21 Window displayed when the adjustment is completed successfully 1 Figure 5 22 Window displayed when the adjustment is completed successfully 2 Single Test Icon Enter the last five digits of the scanner production c...

Page 186: ...t Adjustment Program 186 Window displayed when the adjustment is failed Figure 5 23 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 187: ...C H A P T E R 6 MAINTENANCE ...

Page 188: ...n the printer driver utility 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...

Page 189: ...int 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...

Page 190: ...er 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 Table 6 1 Specified lubricants Type Name EPSON code Supplier Grease G 26 1080614 EPSON Grease G 45 1033657 EPSON Grease G 71 1304682 EPSON Grease G 74 1409257 E...

Page 191: ...l 2 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 Paper Back Lever 2 1 Lubrication Prohibited Area 2 2 1 1 Carriage Guide Shaft Carriage Unit N G O K Carriage Unit Outside Surface Carriage Hole CarriageGuide Shaft G 71 Grease Sectioned Diagram Lubrication ...

Page 192: ...ound two guide pins of the Link Lever Holder Left Lubrication Type 1 G 26 2 G 26 Lubrication Amount 1 φ1 x 1mm 2 φ1 x 2 points Remarks Use a injector to apply Left Line Mark Right Line Mark 1 2 2 Link Lever Left Link Lever Holder Left Lubrication Point 1 Edge line of the Link Lever Right 2 Around two guide pins of the Main Frame Right Lubrication Type 1 G 26 2 G 26 Lubrication Amount 1 φ1 x 1mm 2 ...

Page 193: ...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 Spool Gear 13 5 Bush 10 Right PF Roller Unit Spool Gear 13 5 ...

Page 194: ...C H A P T E R 7 APPENDIX ...

Page 195: ... USB Host I F Board Table 7 1 Connector Summary for C610 Main Board Connector Function Table to refer to CN1 For connection with the Power Supply Board Table 7 2 p 195 CN2 For connection with the USB2 0 interface 1 3 1 USB Interface p 24 CN3 For connection with the PE Sensor Table 7 3 p 196 CN4 For connection with the PG Sensor Table 7 4 p 196 CN5 to CN7 For connection with the Print Head Table 7 ...

Page 196: ...ut for Yellow nozzles 5 GND Ground 6 NCHG O All nozzle fire selection pulse 7 GND Ground 8 LAT O Head data latch pulse output 9 NC Not connected 10 GND2 Ground 11 COM O Head drive pulse trapezoid waveform 12 GND2 Ground 13 COM O Head drive pulse trapezoid waveform Table 7 6 CN6 Print Head Pin Signal Name I O Function 1 GND2 Ground 2 COM O Head drive pulse trapezoid waveform 3 GND2 Ground 4 COM O H...

Page 197: ... Power supply for PW sensor Table 7 8 CN8 CR Motor Pin Signal Name I O Function 1 CR A O CR Motor drive signal A 2 CR B O CR Motor drive signal B Table 7 9 CN9 PF Motor Pin Signal Name I O Function 1 PF A O PF Motor drive signal A 2 PF B O PF Motor drive signal B Table 7 10 CN10 Scanner Motor Pin Signal Name I O Function 1 B O Phase drive signal A 2 AX O Phase drive signal B 3 A O Phase drive sign...

Page 198: ...F slot 6 6 CD7 Data bus for CF slot 7 7 CE1 Card enable signal 8 CA10 Address bus for CF slot 10 9 OE Output enable signal 10 CA9 Address bus for CF slot 9 11 CA8 Address bus for CF slot 8 12 CA7 Address bus for CF slot 7 13 VCC Power supply for CompactFlash 14 CA6 Address bus for CF slot 6 15 CA5 Address bus for CF slot 5 16 CA4 Address bus for CF slot 4 17 CA3 Address bus for CF slot 3 18 CA2 Ad...

Page 199: ... CN15 Memory Card Pin Signal Name I O Function 1 CD TBD 2 WP TBD 3 GND Ground 4 SW_GND Ground 5 VCC Power supply for SSFDC Table 7 14 CN14 Memory Card Pin Signal Name I O Function 6 DETECT TBD 7 CD1 TBD 8 GND Ground 9 FD4 SSFDC data Bit 4 10 DAT1 Data Line Bit 1 11 GND Ground 12 DAT0 Data Line Bit 0 13 FD5 SSFDC data Bit 5 14 GND Ground 15 FD3 SSFDC data Bit 3 16 CLK Clock 17 FD6 SSFDC data Bit 6 ...

Page 200: ...d 39 FALE Address latch enable signal 40 VDD Power supply for SD Memory Card 41 FCEB Chip enable signal 42 Ground 43 FCLE Command latch enable signal 44 CMD Command Response 45 VCC Power supply for SmartMedia 46 CD DAT3 Card Detect Data Line Bit 3 47 GND Ground 48 DAT2 Data Line Bit 2 49 WP1 Write protect seal condition Table 7 16 CN16 USB Host I F Board Pin Signal Name I O Function 1 VBUS_IN USB ...

Page 201: ...EPSON Stylus CX4100 CX4200 CX4700 CX4800 DX4200 DX4800 DX4850 Revision A APPENDIX Exploded Diagram 201 7 2 Exploded Diagram Following pages show exploded diagram ...

Page 202: ...xploded Diagram 202 Figure 7 2 PX A650 Stylus CX4700 CX4800 DX4800 DX4850 Exploded Diagram 1 Rev 01 C610 CASE 001 450 115 125 119 123 124 122 121 117 118 116 111 104 103 108 112 110 111 120 111 111 111 111 113 451 102 101 106 100 105 EPSON ޓ PX A650 Stylus CX4700 CX4800 DX4800 DX4850 ...

Page 203: ...00 CX4800 DX4200 DX4800 DX4850 Revision A APPENDIX Exploded Diagram 203 Figure 7 3 PX A650 Stylus CX4700 CX4800 DX4800 DX4850 Exploded Diagram 2 813 812 Rev 01 C610 CASE 002 809 811 EPSON ޓ PX A650 Stylus CX4700 CX4800 DX4800 DX4850 ...

Page 204: ...CX4700 CX4800 DX4200 DX4800 DX4850 Revision A APPENDIX Exploded Diagram 204 Figure 7 4 PX A650 Stylus CX4700 CX4800 DX4800 DX4850 Exploded Diagram 3 Rev 01 C610 ELEC 001 300 200 EPSON ޓ PX A650 Stylus CX4700 CX4800 DX4800 DX4850 ...

Page 205: ...ded Diagram 205 Figure 7 5 PX A650 Stylus CX4700 CX4800 DX4800 DX4850 Exploded Diagram 4 557 556 555 517 518 Rev 01 C610 MECH 001 535 519 516 529 554 530 528 521 539 534 532 531 533 515 523 543 501 504 502 513 512 537 503 508 520 510 500 EPSON ޓ PX A650 Stylus CX4700 CX4800 DX4800 DX4850 ...

Page 206: ...ision A APPENDIX Exploded Diagram 206 Figure 7 6 PX A650 Stylus CX4700 CX4800 DX4800 DX4850 Exploded Diagram 5 567 566 565 563 562 564 561 540 Rev 01 C610 MECH 002 506 541 538 538 542 522 536 527 505 514 525 526 524 EPSON ޓ PX A650 Stylus CX4700 CX4800 DX4800 DX4850 ...

Page 207: ...4850 Revision A APPENDIX Exploded Diagram 207 Figure 7 7 Stylus CX4100 CX4200 DX4200 Exploded Diagram 6 Rev 01 C627 CASE 001 EPSON Stylus CX4100 CX4200 DX4200 450 115 125 119 124 122 121 117 118 116 111 108 112 111 111 111 111 111 113 451 102 101 106 100 105 ...

Page 208: ...4100 CX4200 CX4700 CX4800 DX4200 DX4800 DX4850 Revision A APPENDIX Exploded Diagram 208 Figure 7 8 Stylus CX4100 CX4200 DX4200 Exploded Diagram 7 813 812 Rev 01 C627 CASE 002 809 811 EPSON Stylus CX4100 CX4200 DX4200 ...

Page 209: ...s CX4100 CX4200 CX4700 CX4800 DX4200 DX4800 DX4850 Revision A APPENDIX Exploded Diagram 209 Figure 7 9 Stylus CX4100 CX4200 DX4200 Exploded Diagram 8 Rev 01 C627 ELEC 001 300 200 EPSON Stylus CX4100 CX4200 DX4200 ...

Page 210: ...A APPENDIX Exploded Diagram 210 Figure 7 10 Stylus CX4100 CX4200 DX4200 Exploded Diagram 9 557 556 555 517 518 Rev 01 C627 MECH 001 EPSON Stylus CX4100 CX4200 DX4200 535 519 516 529 554 530 528 521 539 534 532 531 533 515 523 543 501 504 502 513 512 537 503 508 520 510 500 ...

Page 211: ...4800 DX4850 Revision A APPENDIX Exploded Diagram 211 Figure 7 11 Stylus CX4100 CX4200 DX4200 Exploded Diagram 10 567 566 565 563 562 564 561 540 Rev 01 C627 MECH 002 506 541 538 538 542 522 536 527 505 514 525 526 524 EPSON Stylus CX4100 CX4200 DX4200 ...

Page 212: ...OPTICAL TUBE PANEL UPPER 124 COVER LED 125 OPTICAL TUBE PANEL LOWER 450 BOARD ASSY PANEL 809 HINGE ASSY 811 HINGE L 812 COVER DOCUMENT ASSY CX4800 813 SCANNER ASSY EDG2 NON FIG LABEL INK POSITION 200 MAIN BOARD ASSY 300 POWER SUPPLY UNIT 100V 500 PRINTER MECHANISM ASP MAO10 101 501 FRAME FRONT B 502 COVER CABLE HEAD 503 COVER CARTRIDGE EPG2 504 FRAME HOLDER FFC 505 SCALE PF B 506 POROUS PAD CAP LO...

Page 213: ... 51 555 EXTENSION SPRING 0 143 556 TORSION SPRING 6 45 557 SHAFT CR GUIDE 561 POROUS PAD INK EJECT 7 B 562 POROUS PAD INK EJECT 8 B 563 POROUS PAD INK EJECT 6 B 564 POROUS PAD INK EJECT 5 B 565 POROUS PAD INK EJECT 3 B 566 DIFFUSION SHEET INK EJECT ASP 567 POROUS PAD INK EJECT 4 B NON FIG PLANE WASHER 2 6X0 5X8 NON FIG COMPRESSION SPRING 5 1 Code Parts Name NON FIG SPACER 4 1X0 5 L NA NON FIG TORS...

Page 214: ...DOCUMENT ASSY CX4100 NON FIG LABEL INK POSITION 200 MAIN BOARD ASSY 300 POWER SUPPLY UNIT 100V 500 PRINTER MECHANISM ASP MAO10 102 501 FRAME FRONT B 502 COVER CABLE HEAD 503 COVER CARTRIDGE EPG2 504 FRAME HOLDER FFC 505 SCALE PF B 506 POROUS PAD CAP LOWER 508 GUIDE FFC 510 ASF UNIT B 512 CONNECTER CSIC 513 BOARD ASSY CSIC 514 GROUNDING SPRING PF 515 FRAME GUIDE CR 516 LEVER PARALLEL ADJUSTMENT RIG...

Page 215: ...561 POROUS PAD INK EJECT 7 B 562 POROUS PAD INK EJECT 8 B 563 POROUS PAD INK EJECT 6 B 564 POROUS PAD INK EJECT 5 B 565 POROUS PAD INK EJECT 3 B 566 DIFFUSION SHEET INK EJECT ASP 567 POROUS PAD INK EJECT 4 B NON FIG PLANE WASHER 2 6X0 5X8 NON FIG COMPRESSION SPRING 5 1 NON FIG SPACER 4 1X0 5 L NA NON FIG TORSION SPRING LEVER CARTRIDGE B NON FIG SPUR GEAR 30 8 NON FIG COVER INK EJECT NON FIG INK CA...

Page 216: ... DX4850 Revision A APPENDIX Electrical Circuits 216 7 4 Electrical Circuits The electric circuit diagrams below are shown at the following pages C610 Main control circuit board C610 PSB PSE power supply circuit board C571 C577 Panel circuit board C610 I F ...

Page 217: ...Model PX A650 Stylus CX4700 CX4800 DX4800 DX4850 CX4100 CX4200 DX4200 Board C610 MAIN Rev C Sheet 1 2 ...

Page 218: ...Model PX A650 Stylus CX4700 CX4800 DX4800 DX4850 CX4100 CX4200 DX4200 Board C610 MAIN Rev A Sheet 2 2 ...

Page 219: ...Model PX A650 Stylus CX4700 CX4800 DX4800 DX4850 CX4100 CX4200 DX4200 Board C610 PSB Rev B Sheet 1 1 ...

Page 220: ...Model PX A650 Stylus CX4700 CX4800 DX4800 DX4850 CX4100 CX4200 DX4200 Board C610 PSE Rev B Sheet 1 1 ...

Page 221: ...Model PX A650 Stylus CX4700 CX4800 DX4800 DX4850 Board C571 PNL Rev D Sheet 1 1 ...

Page 222: ...Model Stylus CX4100 CX4200 DX4200 Board C577 PNL Rev A Sheet 1 1 ...

Page 223: ...Model PX A650 Stylus CX4700 CX4800 DX4800 DX4850 CX4100 CX4200 DX4200 Board C610 I F Rev B Sheet 1 1 ...

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