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Confidential

Troubleshooting

Troubleshooting

9

L120

Revision A

1.1 Troubleshooting

This section describes the troubleshooting workflow and fatal error information.

1.1.1 Troubleshooting Workflow

The following page describes the troubleshooting workflow. Follow the flow when troubleshooting problems.

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Summary of Contents for L120

Page 1: ...SERVICE MANUAL CONFIDENTIAL Color Inkjet Printer L120 SEIJ13 005 ...

Page 2: ...EIKO EPSON would greatly appreciate being informed of them The contents of this manual are subject to change without notice 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 Note Other product names used herein are for identification purpose only and ma...

Page 3: ... to personal injury or damage of the product 1 Repairs on Epson product should be performed only by an Epson certified repair technician 2 No work should be performed on this product by persons unfamiliar with basic safety knowledge required for electrician 3 The power rating of this product is indicated on the serial number rating plate Never connect this product to the power source whose voltage...

Page 4: ...oller Gears Rollers LCD Scanner Sensor Exterior parts 14 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 15 Apply the specified amount of grease described in this manual 16 Make the specified adjustments when you disassemble the printer 17 When cleaning this product foll...

Page 5: ...this manual either to provide additional information on a specific topic or to warn of possible danger present during a procedure or an action Pay attention to all symbols when they are used and always read explanation thoroughly and follow the instructions Indicates an operating or maintenance procedure practice or condition that if not strictly observed could result in serious injury or loss of ...

Page 6: ...Confidential Revision Status Revision Date of Issue Description A January 24 2014 First Release ...

Page 7: ...sembly Procedures 28 2 2 1 Disassembly Flowchart 29 2 2 2 Disassembly Flowchart Printhead Main Board 33 2 3 Detailed Disassembly Reassembly Procedure for each Part Unit 34 2 4 Routing FFCs cables 40 Chapter 3 Adjustment 3 1 Required Adjustments 43 3 2 Adjustment Program 47 3 2 1 Operating Environment 47 3 2 2 Details of the Adjustment Program 47 3 2 2 1 CR Motor Heat Protection Control PF Motor He...

Page 8: ...Confidential CHAPTER 1 TROUBLESHOOTING ...

Page 9: ...120 Revision A 1 1 Troubleshooting This section describes the troubleshooting workflow and fatal error information 1 1 1 Troubleshooting Workflow The following page describes the troubleshooting workflow Follow the flow when troubleshooting problems ...

Page 10: ...n the printer driver The error occurs when the actual length is longer than the theoretical length specified in the driver Major Occurrence Timing Paper loading timing Paper eject timing Troubleshooting PE Sensor Lever replacement PE Sensor replacement Main Board replacement Main Board replacement NOTE This error may occur in the manual duplex printing if the inverted sheet printed on the first si...

Page 11: ...lizes the Printhead and checks for the fuse on the circuit boards in the printer 3 2 Checking for waste ink overflow 2 1 Checks the waste ink counter if the waste ink overflow is occurring 3 Seeking the home position 3 1 The CR Unit moves to the 80 digit side slowly and confirms it touches the Change Lever CR lock 3 2 The CR Unit moves to the 0 digit side slowly 3 3 After the PE Sensor checks if p...

Page 12: ...sition and displays on the LCD that the paper jam error has occurred When the user removes the paper and releases the paper jam error by panel operation the normal power on sequence from No 1 Table 1 1 is executed again 2 To recover from the maintenance error the dedicated software that can be downloaded from the web site which can be accessed from STM3 is required The printer operation related to...

Page 13: ...H CR PID lock error CR Encoder failure contaminated detached scale Encoder Sensor failure CR Motor failure CR Unit drive mechanism overload paper jam foreign object insufficient grease deformation of the Main Frame Some part may be detached Paper Guide Upper Assy Cap Assy Cable disconnection Main Board failure Motor driver failure 08H CR load position reverse error CR Encoder failure contaminated ...

Page 14: ...error PF Motor failure PF drive mechanism overload paper jam foreign object Tooth skip of the PF Timing Belt Improper tension of the PF Timing Belt Cable disconnection Motor drive time error D1H CR PID driving time error Main Board failure Firmware failure D2H CR load position driving time error Change Lever failure CR Motor failure Main Board failure Motor driver failure D3H PF PID driving time e...

Page 15: ...Confidential CHAPTER 2 DISASSEMBLY REASSEMBLY ...

Page 16: ...lable 2 EPSON provides the tools listed with EPSON part code 2 1 2 Jigs Note If performing the disassembling reassembling procedure is difficult using tweezers such as when reassembling Cap Lever Cap Assy p35 the spring hook jig helps you to remove attach the spring easier 2 1 2 1 Making the Spring Hook Jig Fold a clip commercial item as shown in Fig 2 1 Figure 2 1 Making the Spring Hook Jig Name ...

Page 17: ...uct Exterior parts Figure 2 2 Exterior Parts The parts units which can not be seen in the following pictures are indicated in dotted lines No Name No Name 1 Housing Upper p31 5 Buttons p31 2 Printer Cover p29 6 Paper Support Assy p29 3 Cap Tank p29 7 Paper Support Joint p29 4 Ink Supply Tank Upper Housing p29 8 Frame Base Assy p30 1 2 Front Right 3 4 7 Rear 8 6 Left 5 ...

Page 18: ...Scale p30 7 CR Unit p32 3 CR Timing Belt p32 8 PF Roller Unit p32 4 Printhead p31 9 Star Wheel Holder Assy p31 5 CR Encoder Sensor p32 10 Paper Guide Upper Assy p32 11 Joint p31 No Name No Name 1 LD Roller Assy p30 6 Pump Unit p32 2 LD Roller Cover p30 7 Cap Assy p29 3 Hopper p30 8 Porous Pad for Cap Assy p29 4 Retard Roller Assy p29 9 Cap Lever p29 5 Paper Back Lever p29 1 2 3 5 8 11 7 10 4 9 6 9...

Page 19: ... Printer Mechanism Rear No Name No Name 1 PF Encoder Sensor p29 4 PF Scale p29 2 EJ Roller p31 5 PF Timing Belt p29 3 EJ Roller Gear p29 6 PF Motor Assy p32 No Name No Name 1 CR Motor p30 4 PE Sensor Lever p30 2 Head FFC p32 5 PS Unit p29 3 Main Board Assy p30 6 Waste Ink Pad Assy p29 6 1 2 3 5 4 1 2 4 3 5 6 ...

Page 20: ...k Supply Tank Assy Figure 2 7 Ink Supply Tank Assy No Name No Name 1 Ink Supply Tank Tube Assy p31 4 Ink Supply Tank Ink Supply Tank p31 Ink Supply Tank p31 Ink Supply Tank p31 Ink Supply Tank p31 2 Ink Supply Tube Assy p31 3 Ink Supply Tank Lower Housing p31 4 2 3 1 ...

Page 21: ...upply Tank 0 51 0 51 Ink Supply Tank Tube Assy 1 31 1 31 Ink Supply Tank Lower Housing 2 35 2 35 Housing Upper Assy 1 56 1 56 Housing Upper 2 05 2 05 Buttons 2 22 2 22 PS Unit 2 16 2 16 Cap Assy 3 12 3 12 Porous Pad for Cap Assy 3 18 3 18 PF Encoder Sensor 2 35 2 35 PF Scale 2 48 2 48 PF Grounding Spring 2 54 2 54 PF Driven Pulley Assy 3 40 1 10 4 50 PF Timing Belt 3 58 1 10 5 08 FFC Holder 2 10 2...

Page 22: ...20 59 PF Motor Assy 15 55 1 08 17 03 Frame Base 15 55 15 55 Tube Guide Sheet Sub 2 26 2 26 Joint 4 16 4 16 Tube Pressing Plate 2 12 2 12 Star Wheel Holder Assy 2 46 3 18 6 04 EJ Roller 3 21 3 18 6 39 Ink Supply Tube Assy 3 30 3 30 Tube Guide Sheet 2 58 2 58 Adapter 2 43 2 43 Holder Board 2 58 2 58 Printhead 4 46 17 39 22 25 Cap Tank 0 57 0 57 Table 2 1 Standard Operation Time Parts Unit Time mm ss...

Page 23: ... ink in the tanks may leak from the air release hole If the air release hole is sealed up with the leaked ink ventilation to the atmosphere cannot be done properly and the print quality may be affected adversely In order to prevent this from happening make sure to place the Ink Supply Tank Assy as shown below after removing it Figure 2 8 How to Place the Ink Tank Assy Ink Supply Tank Assy Ink Supp...

Page 24: ... See 2 2 Disassembly Reassembly Procedures p28 Figure 2 9 Location Parts When ink may spill Location Joint Removing the Ink Supply Tank Tube Assy Ink Supply Tube Assy from the Joint A Ink Supply Tank Removing the tubes of the Ink Supply Tank Tube Assy from the Joint Removing the tubes of the Ink Supply Tank Tube Assy from the Ink Supply Tank A B Ink Supply Tank Tube Assy Adapter Removing the Ink S...

Page 25: ...the film on the Adapter Figure 2 10 Adapter Even observing the points described in this section ink may spill in the following situations Therefore be careful not to contaminate the inside of the printer or its surroundings by preparing the container to receive the leaked ink or the like When removing the Ink Supply Tube Assy all the ink in the tube will spill Carriage Film Adapter ...

Page 26: ...p the assy higher than the container and insert the tip of the Ink Supply Tank Tube of the color you want to discharge the ink from into the container 5 Put the Ink Supply Tank of the ink to discharge on the other Ink Supply Tanks and remove the Cap Tank 6 Move the clips x 2 so that only the ink to discharge can flow in the Ink Supply Tank Tube 7 The ink in the Ink Supply Tank is discharged into t...

Page 27: ...ssembling After all the reassembling work is complete the discharged ink of each color should be refilled back to the Ink Supply Tank before performing the adjustment Confirm the colors indicated on the film of the Ink Supply Tank so as not to mistake them and make sure to refill each ink back to the correct tank from the corresponding ink supply hole Ink supply hole Ink Supply Tank Assy ...

Page 28: ...tter Indicates the parts that are inevitably broken in the disassembling procedure and should be replaced with a new one for reassembly Indicates the reference page in blue letter Indicates the parts that may cause the ink spill when they are removed 2 1 5 Checks and Precautions before Disassembling p23 Indicates necessary check items in the disassembling assembling procedure Indicates the referen...

Page 29: ... P SCREW 2 6x3 F ZN 3C 4 0 5 kgf cm C P S TITE S P1 SCREW 3x6 F ZN 3C 7 5 0 5 kgf cm S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 S11 S12 S13 A Paper Support Assy 1 Waste Ink Pad Assy 1 2 p 34 p 42 S5 Paper Back Lever 2 p 52 Retard Roller Assy 2 p 42 PS Unit 2 p 34 p 40 p 42 EJ Roller Gear p 34 p 52 Extension Spring x2 FFC Holder 1 p 40 C p 31 Printer Cover 2 B p 29 Cable CN501 START Cap Tank 2 Housing Upper As...

Page 30: ...t cable CN501 4 Remove disconnect all FFCs cables CR Scale 2 p 34 LD Roller Cover 1 S5 Frame Base Assy p 42 Extension Spring LD Roller Cover p30 p 29 Extension spring Hopper 2 p 42 Shield Plate 2 1 S9 Main Board Assy 3 p 34 p 40 p 42 S10 S11 PF Encoder Sen sor p29 FFC Cable 4 p 32 3 p 32 4 CR Timing Belt Transistor Cover 4 p 39 Screw type torque list Symbol Screw Type Torque C B P TITE SCREW 2 6x5...

Page 31: ...ube Assy Ink Supply Tank Tube Assy Ink Supply Tank Tube Assy Ink Supply Tank Tube Assy Ink Supply Tank 4 p 37 Ink Supply Tank p31 Ink Supply Tank p31 Ink Supply Tank p31 Ink Supply Tank Lower Housing Ink Supply Tank Tube Assy 8 p 37 Screw type torque list Symbol Screw Type Torque C B P TITE SCREW 2 6x5 F ZN 3C 2 55 0 05 kgf cm C B P TITE SCREW 2x8 F ZN 3C 2 55 0 05 kgf cm C B P TITE SCREW 2x8 F ZN...

Page 32: ...ller Gear p29 PF Driven Pul ley Assy p29 PF Timing Belt p29 Antistatic Cloth 1 S8 FFC Holder p29 PF Grounding Spring p29 p 30 p 30 Screw type torque list Symbol Screw Type Torque C B P TITE SCREW 2 6x5 F ZN 3C 2 55 0 05 kgf cm C B P TITE SCREW 2x8 F ZN 3C 2 55 0 05 kgf cm C B P TITE SCREW 2x8 F ZN 3C 2 0 5 kgf cm C B P TITE SCREW 3x10 F ZB 3C 6 1 kgf cm C B P TITE SCREW 3x10 F ZN 3C 6 1 kgf cm C B...

Page 33: ...1 Main Board Assy 3 p 34 p 40 p 42 S10 S11 Note Proceed to the next step with the part detached temporarily because the part cannot be removed fully there PF Encoder Sensor 1 p 36 p 40 S2 FFC Cable 7 Holder Board 2 Head FFC Screw type torque list Symbol Screw Type Torque C B P TITE SCREW 2 6x5 F ZN 3C 2 55 0 05 kgf cm C B P TITE SCREW 2x8 F ZN 3C 2 55 0 05 kgf cm C B P TITE SCREW 2x8 F ZN 3C 2 0 5...

Page 34: ...ad Assy in the direction of the arrow to align the hole of the Waste Ink Pad Assy with the hook of the Frame Base 3 Confirm the following first and then tighten the screw to secure the Waste Ink Pad Assy The rib of the Waste Ink Pad Assy is correctly inserted into the hole of the Frame Base The Waste Ink Pad Assy is secured firmly with the hook of the Frame Base C B P TITE SCREW 3x10 F ZN 3C 6 1 k...

Page 35: ...Assy and the dowel of the PF Motor Frame 3 Attach the PF Timing Belt in the order of the pinion gear of the PF Motor PF Driven Pulley and Combination Gear 29 2 42 4 Rotate the Combination Gear 29 2 42 clockwise three times to confirm the PF Timing Belt is correctly attached and then secure the PF Driven Pulley Assy with the screw and washer to the PF Motor Frame Pinion gear of PF Motor Hook PF Mot...

Page 36: ... Belt to be extended by the tension of the Compression Spring 13 98 6 Secure the CR Driven Pulley Assy wit the screw Main Frame Rib CR Driven Pulley Assy Dowel Compression Spring 13 98 CR Timing Belt Pinion gear of CR Motor Main Frame C P S TITE S P1 SCREW 3x6 F ZN 3C 7 0 5 kg fcm PF Encoder Sensor PF Scale Do not reuse the removed PF Scale and make sure to replace it with a new one when removing ...

Page 37: ... how to place the Ink Supply Tank in order to prevent printing failure from occurring See 2 1 5Checks and Precautions before Disassembling p23 Before removing the Ink Supply Tank release the hook on the Ink Supply Tank Lower Housing and disengage Section A of the Ink Supply Tank from the rib on the Ink Supply Tank Lower Housing When installing the Ink Supply Tank align the dowels x 2 on the bottom...

Page 38: ...kings with edge of grooves CR Unit Grooves Step 6 NG Ink Supply Tube Section A Hole Tube Guide Sheet Sub Tube Pressing Plate Ink Supply Tube Step 2 4 Step 3 C B P TITE SCREW 2 6x5 F ZN 3C 2 55 0 05 kg fcm Joint When attaching the Joint align the cutout of the Joint with the rib of the Ink Supply Tube Guide 2nd Make sure the gaps between the end of Ink Supply Tank Tubes or Ink Supply Tubes and the ...

Page 39: ...age or peel off the film of the Adapter Use a precision screwdriver when releasing the hooks of the Adapter Adapter Film Hook Connection of Ink Supply Tubes Hook Ink Supply Tube Transistor Cover When removing the Transistor Cover release the dowels x 2 on the Transistor Cover and slide it upward Transistor Cover back side Dowel Transistor Cover ...

Page 40: ...ct it to the connector on the CR Encoder Make sure that the CR Encoder FFC is not in contact with the protrusion on the CR Unit When routing the Head FFC CR Encoder FFC engage the fold to the hook on the CR Unit while aligning their shapes then connect them to the connector on the Printhead Inside of CR Unit CR Unit Connector of Printhead Head FFC Outside of CR Unit CR Encoder FFC Rib Connector of...

Page 41: ...ugh the rib B of the Frame Base and then route it through the rib A taking care not to let the CR Motor cable red come over the CR Motor cable black 3 Twist the CR Motor cable black and CR Motor cable red twice and then route them through the hook C of the Main Frame 4 Route the CR Motor cable black and CR Motor cable red in the order of hook D of the Main Frame groove of the FFC Holder dowel of t...

Page 42: ...Confidential CHAPTER 3 ADJUSTMENT ...

Page 43: ...check If you find a problem with the printout patterns carry out the adjustment again When replacing the Main Board the adjustment should be made after performing the initial setting The table items and marks used in the Required Adjustment List provided on the following pages have the following meanings O indicates that the adjustment must be carried out indicates that the adjustment is not requi...

Page 44: ...g to the replaced parts To measure and correct the electrical variation of the motor and the power supply board To measure and correct the electrical variation of the motor and the power supply board Part Name Waste Ink Pad Assy Remove Replace O Retard Roller Assy Remove Replace O PS Unit Remove Replace O O Paper Guide Upper Assy Remove Replace O O O PF Roller Unit Remove O Replace O O O O O PF Mo...

Page 45: ...lt of the Printhead caused at the installation through software control To correct the print start position in the CR Unit moving direction through software control This corrects top margin of printout To reset the counter or set it to its maximum according to the replaced parts To measure and correct the electrical variation of the motor and the power supply board To measure and correct the elect...

Page 46: ...ed at the installation through software control To correct the print start position in the CR Unit moving direction through software control This corrects top margin of printout To reset the counter or set it to its maximum according to the replaced parts To measure and correct the electrical variation of the motor and the power supply board To measure and correct the electrical variation of the m...

Page 47: ... Power Supply Board to determine the correction value used for estimating the current values of the motors Risks if the adjustment is not correctly made The printer cannot measure the current value of motor correctly then the heat generation caused by motor drive cannot be estimated accurately either and which may results in trouble such as incorrect control of motors when allotting a cool down pe...

Page 48: ...d jigs according to this manual If the PG cannot fall within the standard range after performing the platen gap check described in this section first check if the unit is correctly reassembled following the instructions in this manual Even if the unit is correctly reassembled but the PG still cannot fall within the standard range replace the unit with a new refurbished one The standard range of th...

Page 49: ...the CR Unit to both ends and confirm the CR Unit touches the thickness gauges 2 8 Move the CR Unit to the center and place the thickness gauges 2 0 mm on the position B shown in Figure 3 1 9 Pull the CR Timing Belt to move the CR Unit to both ends and confirm the CR Unit touches the thickness gauges 2 Note 1 If the CR Unit comes in contact with the thickness gauges the PG is smaller than the stand...

Page 50: ...f the standard range replace the unit with a new refurbished one Figure 3 2 Checking the CR Timing Belt Tension This printer is designed so that the each tension of the CR Timing Belt and PF Timing Belt fall within the expected range if you correctly reassemble the unit according to this manual However deformation of any related part s can cause improper tension of the belt In such case replace th...

Page 51: ...f the belt three times 4 Check the average of the measured values falls within the standard range Within the standard range the PF Timing Belt tension check is complete Out of the standard range reinstall the PF Driven Pulley Assy PF Timing Belt p35 and then perform the PF Timing Belt Tension Check again Figure 3 3 Checking the PF Timing Belt Tension Perform the PF Belt tension check before instal...

Page 52: ...Confidential CHAPTER 4 MAINTENANCE ...

Page 53: ...ined based on the results of the internal evaluations Therefore refer to 4 2 Lubrication Points and Instructions p54 for the repairing procedures below and apply the specified type and amount of the grease to the specified part of the printer mechanism 4 2 Lubrication Points and Instructions p54 also provides information about whether or not the parts which require lubrication are supplied as ASP ...

Page 54: ...e Apply grease on sides Application Point Figure 4 3 Lubrication of the Frame Base 3 Part supply as ASP None Lubrication status when supplied as ASP Lubrication Point Contact points x15 on the ribs on the Frame Base with the Hopper Type G 74 Application Amount Appropriate amount Remarks Apply with flux dispenser Stir G 74 before use Application Point Frame Base Figure 4 4 Lubrication of the Frame ...

Page 55: ...Not lubricated Lubrication Point Contact points x2 on the Paper Back Lever with the Frame Base Type G 71 Application Amount 0 06 g x 2 points Remarks Apply with injector Lubricate before attaching the part Paper Back Lever Application Point Figure 4 9 Lubrication of the CR Driven Pulley Assy Figure 4 10 Lubrication of the CR Driven Pulley CR Driven Pulley Shaft Part supply as ASP None Lubrication ...

Page 56: ...Confidential CHAPTER 5 APPENDIX ...

Page 57: ... Figure 5 1 Connector Diagram 5 2 Points to be checked before packing the printer All the caps of the Ink Supply Tank Assy are securely closed The opened ink bottle is not included in the box CN501 CN7 CN13 CN12 CN6 CN102 Printhead PE Sensor CR Motor PF Motor USB CN3 PF Encoder CR Encoder AC in PS Board Main Board CN1 CR Unit Cap ...

Page 58: ... CR Timing Belt and move the CR Unit to the 80 digit side slightly so that the CR Unit can touch the side of the tip on the Change Lever 3 Attach the unfolded portion of the strong tape on the CR Unit as shown below 4 Apply the folded portion of the strong tape on the Housing Upper Assy to finish securing the CR Unit Figure 5 2 Securing the CR Unit In order to prevent damaging the Change Lever the...

Page 59: ...erformed The Printer Cover will be scratched and the abrasion powder will be produced due to the shock during transportation Preparation Prepare two pieces of strong tape length 115 mm width 14 mm fold one end 5 mm Method Apply strong tape on the Printer Cover and Housing Upper Assy to secure the Printer Cover Figure 5 3 Securing the Printer Cover Folded ends Housing Upper Assy Printer Cover Stron...

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