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Chapter 3 Disassembly and Assembly
3.1. Overview ............................................................................................................ 3-1 3.1.1. Precautions for Disassembling the Printer ................................................ 3-1 3.2. Disassembly and Assembly Procedures.................................................................... 3-2 3.2.1. Before Beginning Disassembly ................................................................. 3-4 3.3. C202 MAIN Board Assembly Removal ...................................................................... 3-5 3.4 Upper Case Removal................................................................................................. 3-7 3.4.1. C202 Panel Board Assembly Removal ..................................................... 3-8 3.5. Printhead Removal ................................................................................................... 3-9 3.6. Paper Eject Frame Assembly Removal ..................................................................... 3-12 3.7. Front Paper Guide Assembly Removal ..................................................................... 3-13 3.8. Home Position Sensor (HP) Removal ....................................................................... 3-14 3.9. C202 PSB/PSE Board Assembly Removal................................................................ 3-15 3.10. Carriage Motor (CR Motor) Assembly Removal....................................................... 3-17 3.11. ASF (Auto Sheet Feeder) Removal ......................................................................... 3-18 3.11.1. ASF Assembly Disassembly................................................................... 3-20 3.11.2. ASF HP Sensor Removal ....................................................................... 3-25 3.12. Paper Feed Motor Assembly Removal .................................................................... 3-27 3.13. Printer Mechanism Removal ................................................................................... 3-29 3.13.1. Cap Assembly Removal ......................................................................... 3-30 3.13.2. Pump Assembly Removal ...................................................................... 3-31 3.13.3. Pump Motor Removal ............................................................................ 3-34 3.13.4. Carriage (CR) Assembly Removal .......................................................... 3-35 3.13.5. Top Frame Removal .............................................................................. 3-39 3.13.6. Paper Empty (PE) Sensor Assembly Removal........................................ 3-42 3.13.7. I/S (Ink System) Frame Removal............................................................ 3-44 3.13.8. I/S Frame Disassembly .......................................................................... 3-46 3.13.9. Paper Feed Roller (PF Roller) Assembly Removal .................................. 3-52 3.13.10. Ink Drain Pad Removal ........................................................................ 3-55
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Disassembly and Assembly
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Disassembly and Assembly
3.1 Overview
This section describes procedures for disassembling main components of the EPSON Stylus COLOR 800. Unless otherwise specified, you can assemble units or components by reversing disassembly. Therefore, no assembly procedures are included. Precautions for disassembly or assembly are described under the heading POINTS TO NOTE. Adjustments required after assembling the unit are described under REQUIRED ADJUSTMENTS.
3.1.1 Precautions for Disassembling the Printer
See the precaution below when disassembling and assembling EPSON Stylus COLOR 800.
WARNING
;Disconnect the power cable before disassembling or assembling the printer. ;Wear goggles to protect your eyes from ink. If ink gets in your eye, flush it with fresh water and see a doctor immediately. ;If ink comes in contact with your skin, wash it off with soap and water. If irritation occurs, contact a physician. ;A lithium battery is installed on the main board of this printer. Be sure to observe the following instructions when servicing the battery: Keep the battery away from any metal or other batteries so that electrodes of the opposite polarity do not come in contact with each other. Do not heat the battery or put it near fire. Do not solder on any part of the battery. (Doing so may result in leakage of electrolyte from the battery, burning, or explosion.) Do not charge the battery. (An explosive may be generated inside the battery and cause burning or explosion.) Do not dismantle the battery. (The gas inside the battery may hurt your throat. Leakage, burning, or explosion also may result.) Do not install the battery in the wrong direction. (This may cause burning or
explosion.)
CAUTION
;Danger of explosion if the battery is incorrectly replaced. Replace only with the same or
equivalent type recommended by the manufacturer. Dispose of used batteries according to government laws and regulations.
;Risque d'esplosion si la pile est remplacée incorrectment. Ne remplacer que par une pile fu
mêmetype ou d'un type équivalent recommandé par le fabricant. Eliminer les piles déchargées selon lois et les règles de sécurité en vigueur.
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Disassembly and Assembly
CAUTION
;Never remove the ink cartridge from the carriage unless the manual specifies to do so. ;When transporting the printer after the ink cartridge has been installed, be sure to pack the printer for transport without removing the ink cartridge. ;Use only recommended tools for disassembling, assembling, or adjusting the printer. ;Apply lubricants and adhesives as specified. (See Chapter 6 for details.) ;Make adjustments specified when you disassemble the printer. (See Chapter 4 for details.)
3.2 Disassembly and Assembly Procedures
This section describes disassembly or assembly procedures for printer assemblies and parts.
CAUTION
Read precautions in Section 3.1.1 prior to disassembly and assembly.
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Start
3.2.1. 3-4
Paper Support Removal Stacker Removal
Before Beginning Disassembly
After removing or replacing a part marked by this pattern, perform the required adjustment described in Chapter 4.
3.3.
3-5
C202 MAIN Board Removal
3.4.
3-7
3.4.1.
3-8
Upper Case Removal
Control Panel Removal
3.5.
3-9
3.6.
3-12
3.8.
3-14
Printhead Removal
Paper Eject Frame Assembly Removal
Home Position Sensor Removal
3.9.
3-15
3.7.
C202 PSB/PSE Board Removal
3-13
Front Paper Guide Removal
3.10.
3-17
3.11.
3-18
3.11.1
3-20
Carriage Motor Removal
ASF Assembly Removal
ASF Assembly Disassembly
3.11.2.
3-25
ASF Home Position Sensor Removal
3.12.
3-27
Paper Feed Motor Removal
3.13.
3-29
Printer Mechanism Removal
3.13.1.
3-30
3.13.3.
3-34
3.13.4.
3-35
3.13.10.
3-55
Cap Assembly Removal
Pump Motor Removal
Carriage Assembly Removal
Ink Drain Pad Removal
3.13.2.
3-32
3.13.5.
3-39
Pump Assembly Removal
Top Frame Removal
3.13.6.
3-42
Paper Empty Sensor Assembly Removal
3.13.7.
3-44
3.13.8
3-46
I/S Frame Removal
I/S Frame Disassembly
3.13.9.
3-50
Paper Feed Roller Assembly Removal
Figure 3-1. Printer Disassembly Procedures
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Disassembly and Assembly
3.2.1 Before Beginning Disassembly
Remove the following parts before beginning disassembly. Paper Support
Output Tray
To remove the output tray, shift it to the right end, then push the handle on the left edge inward. This will help you to remove it more easily.
1. Paper Support
2. Output Tray
Figure 3-2. Before Beginning Disassembly
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3.3 C202 MAIN Board Assembly Removal
1. Remove 2 screws (CBS, 3x8, F/Zn) securing the C202 MAIN board assembly to the back of the printer. (See Figure 3-3.) 2. Move C202 MAIN board about 5 cm (2") out from the back of the printer. (See Figure 3-3.)
CBS Screws (3x8, F/Zn)
Figure 3-3. C202 MAIN Board Assembly Removal 3. Disconnect all cables (CN4, CN6, CN7, CN8, CN11, CN12, and CN13) and FFCs (CN9 and CN10) from C202 MAIN board assembly. Use instructions below to disconnect connectors:
CN11, CN12, CN13: CN4:
Release the connector lock lever by pulling it up, and disconnect the cable. Release the connector lock lever by pressing it down, and disconnect the cable.
4. Remove C202 MAIN board from the printer main board slot. (See Figure 3-3.)
CAUTION
C202 MAIN board assembly shield plate edges are sharp. So, be careful handling them.
REQUIRED ADJUSTMENT
Perform any necessary adjustments after installing the C202 MAIN board (See Chapter 4.)
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Disassembly and Assembly
;Note the direction when connecting cables for CN11, CN12, CN13, and CN4. Be sure to insert the pin 1 side into the position marked with a "1" on the board. ;Ensure that the locks for CN11, CN12, CN13 are locked after connection. ;Hold down the lock lever for CN4 while connecting the cable. ;Make sure no cables or FFCs are cut by the shield plates. ;Tightening torque for the screws (CBS, 3X8, F/Zn) is 8 ~10 kg-cm.
2 2
1 1
1
Disconnecting CN4
Disconnecting CN11, CN12, CN13
Figure 3-4. Connector Removal
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3.4 Upper Housing Removal
1. Remove the parts shown in Figure 3-2. 2. Remove 4 screws (CCP, 4x12, F/Zn): 2 screws securing the upper housing to the front and 2 screws securing the upper housing to the top rear side of the printer. (See Figure 3-5.) 3. Set the platen gap lever to the "+" position. Then, pull the front part of the upper case forward, and lift it backward to remove. 4. Turn the upper case up and disconnect the FFC from the control panel.
;Before installing the upper case, set the platen gap lever to the "+" position to make the job easier. You must set it back to "0" after the upper case is securely positioned. ;Tightening torque for the screws (CCP, 4x12, F/Zn) = 10 kg-cm.
CCP (4x12)
Upper Case CCP (4x12)
Figure 3-5. Upper Case Removal
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Disassembly and Assembly
3.4.1 C202 Panel Board Assembly Removal
1. Remove the upper case. (See Section 3.4.) 2. Turn the upper case up, and release the lock lever for the FFC connector by pushing it out. Then disconnect the FFC. 3. Release 2 hooks attaching the C202 panel board assembly to the upper case. Then remove the C202 panel board assembly from the upper case. (See Figure 3-6.)
Control Panel
Figure 3-6. Control Panel Removal
;During assembly, be careful not to bend the contact plate mounted on the C202 panel
board.
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3.5 Printhead Removal
1. Remove the upper case. (See Section 3.4.) 2. Open the ink cartridge covers and remove the ink cartridges from the CR assembly. 3. Using tweezers, release the ink cartridge covers from the pins fixing them to the CR assembly. Then remove the ink cartridge covers. (See Figure 3-7.)
Figure 3-7. Cartridge Cover Removal 4. Remove 2 head fixing screws and 2 washers (spacers) securing the printheads to the bottom of the CR assembly. 5. Remove 2 compression springs (9.9 g) holding each printhead to the carriage. (Refer to Figure 3-8.)
Head Fixing Screws
Washers (Spacers) Compression Springs (9.9 g)
Figure 3-8. Screw and Spring Removal
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Disassembly and Assembly
6. Remove 2 FFCs from the printheads. (See Figure 3-9.)
Head FFCs
Figure 3-9. Head FFC Removal 7. Shift the printheads forward. Then remove them by lifting upward carefully.
CAUTION
;In handling the printheads, note the following: Ground yourself. The driver IC is attached directly to the printhead unit. Do not touch the printhead surface. ;Before installing a new printhead in the CR assembly, note the voltage ID stamped on the right side of the printhead. ;When tightening and loosening printhead fixing screws, use your hand to support the
bottom of the CR assembly.
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;Before installing the printhead into the CR assembly, move the carriage to the capping position to protect the head surface. ;Procedures for printhead assembly are described below.
1. 2. 3. 4. 5. Remove the 2 FFCs from the clips used to attach them. Insert the color head FFC through the slit in the back of the CR assembly with the exposed terminal facing the rear, and connect it to the color head. Then install the color head in the CR assembly. Insert the black head in the CR assembly. Then insert the black head FFC through the slit with the exposed terminal facing the rear. Fasten the printheads in the CR assembly with the compression springs (9.9 g) and head fixing screws. Place both FFCs back into the clips used to hold them. Be sure they are also placed in the small clip beside the larger one. Be careful not to disconnect the FFCs from the printheads while installing them into the clips. (See Figure 3-10.)
;Tightening torque for the head fixing screw = 2.5 ~ 3.1 kg-cm. ;When mounting a head fixing screw, screw carefully with force while supporting the bottom of the carriage so not to strip the screw head. ;Ensure the head fixing screw washers do not turn after tightening head fixing screws.
Clips Fixing the FFC
Head FFC
Figure 3-10. Head FFC and FFC Clips
REQUIRED ADJUSTMENT
;After replacing or removing the printhead, perform specified adjustments. (See Chapter 4.)
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Disassembly and Assembly
3.6 Paper Eject Frame Assembly Removal
1. Remove the upper case. (See Section 3.4.) 2. Release the CR lock lever using tweezers. Then shift the CR to the left of the FFC holder. 3. Release 2 hooks for the FFC holder, and remove the FFC holder. (See Figure 3-11.)
FFC Holder
Paper Eject Frame
Figure 3-11. FFC Holder Removal 4. Remove the printhead FFCs from the sub holder, and remove the sub holder. Then remove 2 screws (CBS, 3x6, F/Zn) securing the paper eject frame. (See Figure 3-12.)
Paper Eject Frame
CBS Screws (3x7, F/Zn)
Head FFC
Figure 3-12. Screws Securing the Paper Eject Frame 5. Hold down FFC along the paper eject frame, and shift the CR back to the capping position. Then lift the paper eject frame assembly up about 3 mm (0.12") and slide it forward.
;In mounting FFCs, be careful not to damage or catch them while sliding the CR unit. ;Make sure the FFC holder is securely hooked to the paper eject frame assembly. ;Tightening torque for the screws (CBS, 3x6, F/Zn) = 8 ~ 10 kg-cm.
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Disassembly and Assembly
3.7 Front Paper Guide Assembly Removal
1. Remove the paper eject frame assembly. (See Section 3.6.) 2. Lift up the front paper guide assembly slightly, and shift it forward while sliding it to the left to release the pins from the cutouts in the right frame. (See Figure 3-13.)
A
@ B
Front Paper Guide Assembly
Figure 3-13. Front Paper Guide Removal
;There are 4 pins, 2 on each edge. Be sure to fit them into the cutouts in the right frame when installing the front paper guide assembly. ;When engaging the gear (19 mm) on the left edge of the front paper guide assembly and
the gear (17 mm) on the left edge of the paper feed roller, be careful not to damage them.
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Disassembly and Assembly
3.8 Home Position (HP) Sensor Removal
1. Remove the upper housing. (See Section 3.4.) 2. Using tweezers, release 2 hooks fixing the HP sensor to the sub pump frame. Then remove the HP sensor by pulling it downward. (See Figure 3-14.)
Home Position Sensor Sub Pump Frame
Figure 3-14. HP Sensor Removal
3. Disconnect the HP sensor connector cable from the HP sensor.
;Note the direction in which the HP sensor is attached. Place the cable side down. ;Tightening torque for the screws (CBS, 3x8, F/Zn) = 8 ~ 10 kg-cm.
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Disassembly and Assembly
3.9 C202 PSB/PSE Board Assembly Removal
1. Remove the upper case. (See Section 3.4.) 2. Remove 2 screws (CBS, 3x6, F/Zn) securing the C202 PSB/PSE board assembly to the printer mechanism. (See Figure 3-15.)
Carriage Motor CBS Screws (3x6, F/Zn)
ASF Frame
C202 PSB/PSE Board Assembly FG Screw and Wire
Figure 3-15. C202 PSB/PSE Board Removal 3. Hold down the lock lever for CN4 on the C202 MAIN board assembly, and disconnect the connector cable for the C202 PSB/PSE board. 4. Remove all connectors from the clamp attached to the C202 PSB/PSE board assembly. (See Figure 3-16.)
Cable Clamp C202 PSB/PSE Board Assembly
Home Position Sensor
Figure 3-16. Connector Cable Removal
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Disassembly and Assembly
5. Lift up the C202 PSB/PSE board, and remove it from the printer mechanism.
;Place the connectors for the printer mechanism back in the cable clamp after installing the C202 PSB/PSE board assembly ;Tightening torque for the screws (CBS, 3X6, F/Zn) = 8 ~ 10 kg-cm. ;When connecting the cable for the C202 PSB/PSE board to CN4 on the C202 MAIN
board, insert the cable through the slot, as shown in Figure 3-17.
C202 PSB/PSE Board Assembly CN4 Cable
Slit in the Lower Case
Figure 3-17. Removal of Cable for CN4
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Disassembly and Assembly
3.10 Carriage Motor (CR Motor) Assembly Removal
1. Remove the upper case. (See Section 3.4.) 2. Remove the ASF. (See Section 3.11.) 3. Release the CR lock lever using tweezers. Then shift the CR assembly from the capping position manually. 4. Remove 2 screws (CBS, 3x6, F/Zn) securing the CR motor assembly to the top frame. (See Figure 3-18.)
Timing Belt Upper Frame
CBS Screws (3x6, F/Zn)
Figure 3-18. Screws Securing the CR Motor Assembly 5. Disengage the timing belt from the pinion gear. 6. Unlock CN12 on the C202 MAIN board by pulling up the lock lever. Then disconnect the CR motor connector cable from CN12. 7. Remove the CR motor assembly from the printer mechanism.
;When mounting the CR motor assembly to the top frame, insert the CR motor cable facing ;Tightening torque for the screws (CBS, 3x6, F/Zn) = 8 ~ 10 kg-cm.
REQUIRED ADJUSTMENT
the bottom of the printer, and fit the CR motor assembly pins into the cutout in the top frame.
Perform the Bi-d adjustment after reinstalling the CR motor assembly. See Chapter 4.
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Disassembly and Assembly
3.11 ASF (Auto Sheet Feeder) Removal
1. Remove the C202 PSB/PSE board assembly. (See Section 3.4.6.) 2. Remove 2 screws (CPS, 4x10 and ASF fixing screw, F/Zn) securing the ASF to the right frame and to the rear left of the frame, respectively. (See Figure 3-19.)
ASF Fixing Screw
CBP Screw (4x10, F/Zn)
Figure 3-19. Removal of Screws Fixing the ASF
3. Remove 1 gear (27.2 mm) at the right edge of the ASF from the hopper release lever by squeezing with tweezers or prying a Phillips screwdriver into the joint. (See Figure 3-20.)
Tweezers
Gear (27.2 mm)
Figure 3-20. Gear (27.2 mm) Removal
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Disassembly and Assembly
4. Release the locking tab on the left front side. 5. Slide the ASF assembly to the left, then to the rear; and remove the ASF assembly from the printer mechanism. Be sure to disconnect the ASF HP sensor cable from the sensor.
;Connect the ASF HP cable to the connector at the left edge of the ASF before installing the ASF assembly. ;Several connectors are laid behind the ASF assembly. Make sure they are not cut under the ASF assembly when installing the ASF. ;Tightening torque for the screws (CBP, 4x10, F/Zn) = 10 ~ 12 kg-cm. ;When engaging the gear (27.2 mm) and loading (LD) roller shaft, note the side they face.
Make sure they are correctly adjusted and securely locked. (See Figure 3-21.)
Loading Roller Shaft
Gear (27.2 mm) Hopper Release Lever
Figure 3-21. Engagement of Loading Roller Shaft and Gear (27.2 mm)
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Disassembly and Assembly
3.11.1 ASF Assembly Disassembly
1. Remove the ASF. (See Section 3.11.) 2. Remove the left shaft bushing, located at the left end of the loading (LD) roller shaft. (See Figure 3-22.)
Bushing Fixing the Shaft on the Left Loading Roller Shaft
Figure 3-22. Left Bushing Removal
CAUTION
Remove this bushing with care so you do not damage it.
3. Shift the LD roller shaft about 1 cm (half an inch) left, and using tweezers, and release the tab attaching the detection wheel to the left edge of the LD roller shaft. Then remove the detection wheel. (See Figure 3-23.)
Detection Wheel
Loading Roller Shaft
Figure 3-23. Detection Wheel Removal
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Disassembly and Assembly
4. Release the pin at the top left edge of the hopper assembly from the ASF frame. Then align the right arm of the hopper assembly with the cutout in the ASF right frame, and remove the hopper assembly carefully by lifting up the left edge. Be careful not to bend the compression springs in the paper loading assemblies. (See Figure 3-24.)
Hopper Assembly ASF Frame Arm Cutout in the ASF Frame (Bottom Right)
@ A
Top Left Part of ASF Assembly
Bottom Right Part of ASF Assembly
Figure 3-24. ASF Hopper Assembly Removal 5. Shift the LD roller shaft further left, and remove the ASF assembly along with the paper loading assemblies. 6. Remove the paper loading assemblies from the LD roller shaft. 7. Release 2 hooks securing the LD roller cover to the paper loading assembly using the tweezers. Then remove the LD roller cover. (See Figure 3-25.)
Paper Takup Roller Assembly
Paper Takeup Roller Cover
Locking Tabs
Figure 3-25. LD Roller Cover Removal 8. Release 2 locking tabs securing the LD roller assembly to the paper loading assembly using the tweezers. Then remove the LD roller assembly. (See Figure 3-26.)
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Disassembly and Assembly
Paper Takeup Assembly
Paper Takeup Roller Assembly Locking Tabs
Figure 3-26. Locking Tabs on the LD Roller
CAUTION
Never touch the rubber part of the LD roller assemblies with your bare hands.
;Ensure the following are correctly mounted onto the paper loading assembly before assembling. (See Figure 3-27.) 1 torsion spring 1 extension spring 1 compression spring rod spring ;When installing paper loading assemblies, insert the LD roller's narrow edge to the left.
Extension Spring
Paper Loading Assembly Rod Spring Compression Spring (1.66 g) Torsion Spring
Figure 3-27. Spring Installation
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Disassembly and Assembly
;When installing the LD roller shaft into the ASF frame after mounting both paper loading ;Follow the instructions below when installing the hopper assembly into the ASF frame with
the paper loading assemblies mounted on it: (See Figure 3-28.) 1. Note the direction to place the compression spring. One end is bent straight inward. Be sure to insert the straight end facing up. 2. Hook the straight end to the frame as shown in Figure 3-29. 3. Insert tweezers through the cutout in the back of the ASF frame to release the tabs after mounting the hopper assembly. (See Figure 3-29.)
ASF Frame
assemblies, shift the right paper loading assembly to the right edge of the ASF frame, then fix it by aligning the groove in the back of the paper loading assembly with the rail ribs on the inner side of the ASF frame. The left paper loading assembly, however, moves freely from left to right or vice versa. (See Figure 3-28.)
Paper Takeup Assembly
ASF Frame Rail Ribs
Figure 3-28. Paper Loading Roller Installation
Compression Spring (1.66 g)
Round Cutout in the Back of the ASF Frame
Hooks Straight End of the Compression Spring (1.66 g)
Figure 3-29. Releasing the Compression Spring
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Disassembly and Assembly
;Be sure to fix both right and left pins on the ASF frame securely into the holes in the hopper assembly. ;When installing the detection wheel onto the left end of the LD roller shaft, be sure to engage it in the right direction. Pay attention to which way the end faces. ;Ensure that the left frame of the left paper loading assembly fits correctly into the groove in
the bottom of the left edge guide for the hopper assembly. (See Figure 3-30.)
Left Edge Guide of Hopper Assembly
Bushing Left Frame of Left Paper Takeup Assembly
Figure 3-30. Engaging Hopper Assembly and Bushing
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Disassembly and Assembly
3.11.2 ASF HP Sensor Removal
1. Remove the ASF assembly. (Refer to Section 3.11.) 2. Remove the right hopper release lever in the ASF assembly. 3. Remove the bushing from the left edge of the loading (LD) roller shaft in the ASF assembly. (See Figure 3-31.)
Bushing Fixing the Shaft on the Left Loading Roller Shaft
Figure 3-31. Bushing Removal
4. Shift the LD roller shaft left about an inch (2 cm). Then, using tweezers, release the tab fixing the detection wheel at the left edge of the LD roller shaft. (See Figure 3-32.)
Detection Wheel
Loading Roller Shaft
Figure 3-32. Detection Wheel Removal
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Disassembly and Assembly
5. Insert tweezers into the slit in the back of the ASF HP sensor, and release the clips. Then remove the ASF HP sensor. (See Figure 3-33.)
ASF Frame (Left Side)
ASF Home Position Sensor
Tweezers
Figure 3-33. ASF HP Sensor Removal
;When mounting the detection wheel onto the LD roller shaft, push the wheel into the shaft until it clicks. ;The bushing at left end of the LD roller shaft must be located on the right of the left hopper
release lever. (See Figure 3-31.)
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3.12 Paper Feed Motor Assembly Removal
1. Remove the ASF. (Refer to Section 3.11.) 2. Remove 1 C-ring and 1 plain washer securing the combination gear (14 mm, 31.5 mm) to the left frame. 3. Remove 2 screws (CBS, 3x6, F/Zn) securing the paper feed motor assembly to the left frame. (Refer to Figure 3-34.)
CBS Screws (3x6, F/Zn)
Combination Gear (14 mm, 31.5 mm)
C-ring Plain Washer
Figure 3-34. Paper Feed Motor Assembly Removal (1) 4. Push the paper feed motor assembly inward, holding the combination gears, and remove the paper feed motor assembly and the combination gears. (Refer to Figure 3-35.)
Paper Feed Motor Assembly
Left Frame
Combination Gear (14 mm, 31.5 mm)
Figure 3-35. Paper Feed Motor Assembly Removal (2)
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Disassembly and Assembly
5. Disconnect the paper feed motor cable from the CN13 on the C202 MAIN board assembly. 6. Remove the PF motor from the printer mechanism
;Be careful not to damage the teeth on the combination gear (14 mm, 31.5 mm), paper feed pinion gear, or gear (70 mm) when engaging them. ;When installing the paper feed motor assembly in the left frame, be sure to fit the shaft for the combination gear into the cutout in the frame. ;Tightening torque for the screws (CBS, 3X8, F/Zn) = 8 ~ 10 kg-cm.
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Disassembly and Assembly
3.13 Printer Mechanism Removal
1. Remove the units and assemblies by following the procedures described in Section 3.9. 2. Disconnect all the connectors and FFCs from the C202 MAIN board assembly. 3. Remove 4 screws (CB, 4x12, F/Zn) securing the printer mechanism to the lower case. (Refer to Figure 3-36.)
CB Screws (4x12, F/Zn)
CB Screws (4x12, F/Zn)
Figure 3-36. Printer Mechanism Screw Removal
4. Lift up the printer mechanism to remove it from the lower case.
;Make sure the connectors are not cut when you install the printer mechanism. ;Always hold the upper or rear part of the mechanism, and never touch the gears. ;Do not forget to insert the sub ink drain pad into the printer mechanism before installing the mechanism into the lower case. The mounting location is shown in Figure 3-37. ;Tightening torque for the screws (CB, 4x12, F/Zn) = 4 ~ 5 kg-cm.
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Disassembly and Assembly
Sub Ink Drain Pad Printer Mechanism Viewed from the Rear
Figure 3-37. Sub Ink Drain Pad
3.13.1 Cap Assembly Removal
1. Remove the printer mechanism. (Refer to Section 3.13.) 2. Release the CR lock lever using tweezers, and slide the CR assembly left. 3. Remove 1 screw (CBS, 3x6, F/Zn) securing the cap assembly to the top frame. 4. Remove both tubes from the black and color caps carefully. (See Figure 3-38.)
Black Ink Tube
Color Ink Tube
CBS Screw (3x6)
Figure 3-38. Tube Removal
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Disassembly and Assembly
5. Remove the cap assembly from the printer mechanism.
;Tubes linking the pump assembly are made of silicone, and a minor flaw can become a ;Handle the cap assembly carefully, and never touch the rubber portion and pad portion of the caps. ;Align the pin at the left edge with the hole in the right frame when positioning the cap assembly, as show in Figure 3-39. ;Make sure that the right edge of the assembly is located on the right of the left edge of the top frame. ;Tightening torque for the screws (CBS, 3x6, F/Zn) = 8 ~ 10 kg-cm.
Right Frame Cap Assembly
crack. Therefore, use the exclusive tweezers designed for the tubes carefully when positioning the tubes back onto the pins.
Cap Assembly Location Holes
Figure 3-39. Cap Assembly Removal
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Disassembly and Assembly
3.13.2 Pump Assembly Removal
1. Remove the cap assembly. (Refer to Section 3.13.1.) 2. Remove 2 screws (CBS, 3x6, F/Zn) securing the outer sub frame assembly to the middle sub frame assembly and to the slider shaft respectively. Then remove the whole outer sub frame assembly. (Refer to Figure 3-40.)
CBS Screws (3x6, F/Zn)
Middle Sub Frame Assembly
Outer Sub Frame
Figure 3-40. Outer Sub Frame Assembly Removal
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3. Remove 1 screw (CBS, 3X6, F/Zn) securing the pump assembly to the middle sub frame assembly. (Refer to Figure 3-41.)
Pump Assembly
CBS Screw (3x6, F/Zn)
Middle Sub Frame Assembly
Figure 3-41. Pump Assembly Removal 4. Remove the pump assembly from the middle sub frame assembly.
CAUTION
;Be careful not to damage the tubes while removing the pump assembly.
;Tightening torque for the screws (CBS, 3x6, F/Zn) = 8 ~ 10 kg-cm. ;Never install the pump assembly into the printer mechanism before mounting the head ;When mounting the head cleaner on the pump assembly, face the rubber part of the
cleaner on the pump assembly. The head cleaner must not be mounted on the pump assembly alone. cleaner to the right. Be sure to hook the hole in the head cleaner to the pump assembly, as shown in Figure 3-42.
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Disassembly and Assembly
Pump Assembly Hook Fixing the Head Cleaner Pump Assembly Viewed from the Right
Figure 3-42. Head Cleaner Location
3.13.3 Pump Motor Removal
1. Remove the ASF. (See Section 3.11.) 2. Remove the printer mechanism. (See Section 3.13.) 3. Remove 2 screws (CBS, 3x6, F/Zn) securing the pump motor to the pump sub frame. Then remove the pump motor. (Refer to Figure 3-43.)
Pump Motor
CBS Screws (3x6, F/Zn)
ÌßØÝÀE`¤ Printer Mechanism Viewed from the Right
Figure 3-43. Screws Fixing the Pump Motor
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;Be careful not to damage the combination gear (12 mm, 26 mm) when mounting the pump motor pinion gear into the motor pinion gear mounting hole in the pump sub frame. ;When installing the pump motor onto the pump sub frame, insert the motor harness facing the top. ;Tightening torque for the screws (CBS, 3x6, F/Zn) = 8 ~ 10 kg-cm.
3.13.4 Carriage (CR) Assembly Removal
1. Remove the printer mechanism. (Refer to Section 3.13.) 2. Release the CR lock lever using tweezers. Then manually slide the CR assembly from the capping position. 3. Remove 2 screws (CBS, 3x6, F/Zn) securing the CR motor assembly to the printer mechanism top frame. 4. Disengage the timing belt from the pinion gear in the CR motor assembly. (See Figure 3-44.) 5. Remove the printhead. (Refer to Section 3.5.)
Carriage Motor Pinion Gear Timing Belt
Figure 3-44. Timing Belt Removal
CAUTION
To prevent printhead damage, never disassemble or assemble the CR assembly with the printhead installed in it.
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Disassembly and Assembly
6. Remove 1 E-ring and 1 screw (CBS, 3x6, F/Zn) securing the right parallelism adjustment bushing to the top frame. Then turn the bushing forward until it fits into the cutout in the top frame and slide it to the right. (Refer to Figure 3-45.)
A A A A A
Upper Frame
Right Parallelism Adjustment Bushing
Figure 3-45. Parallelism Adjustment Bushing Removal 7. Remove the compression spring (19.9 g) using tweezers. Then shift the pulley holder to the right and remove it from the top frame. (Refer to Figure 3-46.)
Compression Spring (19.9 g) Sub Pulley Holder
Figure 3-46. Driven Pulley Holder Removal
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8. Shift the CR shaft to the right to remove the CR assembly from the platen gap lever and left parallelism adjustment bushing. (See Figure 3-47.)
Platen Gap Lever
Carriage Assembly
Figure 3-47. CR Assembly Removal
9. Take the CR shaft out from the CR assembly. 10. Remove the oil pad from the CR assembly.
;Place the oil pad with the oiled side down onto the CR guide when mounting the oil pad into the CR assembly. ;Install the CR shaft with the edge whose side is cut in a "D" shape to the left. ;When installing the platen gap sub lever onto the CR shaft, insert the side marked with an "{ " out, set the platen gap lever to 0, and engage the platen gap sub lever notch with the platen gap lever by slipping it upward. (See Figure 3-48.) ;When installing the CR assembly, make sure the timing belt has no torsion and is correctly placed between the CR assembly and top frame. ;Fit the groove on the upper edge of the CR assembly to the top edge of the top frame. (See Figure 3-49.) ;Fit the CR shaft into the U-cut of the slider. (See Figure 3-50.) ;Turn the right parallelism adjustment bushing to the rear while pushing the top edge outward. ;When mounting the compression spring (19.9 g) onto the pulley holder, fit the spring to the
pin on the left end of the holder first.
REQUIRED ADJUSTMENT
;When the CR assembly is replaced, perform the necessary adjustments. (See Table 4-1 in
Chapter 4.)
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Disassembly and Assembly
Platen Gap Lever Platen Gap Sub Lever
Figure 3-48. Engaging the PG Sub Lever
Carriage Frame
Carriage Slider
Upper Frame Edge Viewed from the Top
Figure 3-49. Fitting the Cartridge Slider to the Upper Edge
Slider Shaft
Carriage Shaft
Figure 3-50. Engaging the Carriage Shaft and Slider Shaft
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3.13.5 Top Frame Removal
1. Remove the ASF assembly. (See Section 3.11.) 2. Remove the printer mechanism. (See Section 3.13.) 3. Remove the CR assembly. (See Section 3.13.4.)
CAUTION
;It is possible to remove the top frame without removing the CR assembly and ASF
assembly, but it is highly recommended that you remove these assemblies before removing the top frame. Otherwise, the printheads or frames might be damaged or bent.
4. Using tweezers, remove torsion springs (117.6 g) attaching 5 upper paper guide assemblies and 1 right paper guide assembly. Then, take the 5 upper paper guide assemblies out backwards and the right paper guide assembly forward to remove them. (See Figure 3-51.)
Torsion Spring (117.6 g)
Upper Frame
Upper Paper Guide Printer Mechanism Viewed from the Rear
Rear Paper Guide
Figure 3-51. Releasing the Torsion Springs
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Disassembly and Assembly
5. Remove 3 screws (CBS, 3x6, F/Zn) securing the top frame to the printer mechanism, and 1 screw CBS, 3x6, F/Zn) securing the top frame and cap assembly. (See Figure 3-52.)
CBS Screws (3x6, F/Zn)
Figure 3-52. Removing the Screws Securing the Top Frame
6. Disconnect the paper end sensor connector cable from the paper end sensor assembly. Then remove the top frame.
;In installing the top frame to the printer mechanism, be sure not to damage the gear (70 mm) at the left edge. ;Be sure to place the driven roller shafts in the upper paper guide assemblies parallel to the PF roller. Figure 3-53 shows how to engage upper paper guide assembly parts. ;When mounting the right paper guide assembly, insert it into the gap from the front, as shown in Figure 3-54. ;Tightening torque for the screws (CBS, 3x6, F/Zn) = 8 ~ 10 kg-cm.
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Torsion Spring Shaft Upper Paper Guide Frame
Torsion Spring (117.6 g)
Sub Rollers
Sub Roller Shaft
Figure 3-53. Upper Paper Guide Assembly
Top Frame
Right Paper Guide Assembly
Paper Feed Roller
Printer Mechanism Viewed from the Front
Figure 3-54. Right Paper Guide Installation
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Disassembly and Assembly
3.13.6 Paper Empty (PE) Sensor Assembly Removal
1. Remove the top frame. (Refer to 3.13.5.) 2. Release the hook for the PE sensor assembly using tweezers. Then remove the paper end sensor assembly by lifting upward. (See Figure 3-55.)
Hooks Attaching the Paper End Sensor
Upper Frame
Location Holes
Figure 3-55. Paper End Sensor Assembly Removal
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Disassembly and Assembly
;When mounting the paper end sensor assembly on the top frame, be sure to mount the torsion spring correctly at the point shown in Figure 3-56. ;After installing the paper empty sensor lever, ensure it bounces smoothly. ;Install the paper empty sensor and right paper guide assembly in the following order: c Mount the paper empty sensor onto the top frame. d Align the paper empty sensor lever with the cutout in the upper paper guide assembly. e Attach the right paper guide assembly to the top frame, or refer to POINTS TO NOTE in Section 3.13.5. ;Ensure that the hooks for the PE sensor assembly fit securely into the cutouts in the top
frame.
Printer Mechanism Viewed from the Bottom
Paper End Sensor Cable Connector
Torsion Spring (0.22 g)
Figure 3-56. Torsion Spring
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Disassembly and Assembly
3.13.7 I/S (Ink System) Frame Removal
CAUTION
When releasing joints linking the I/S frame and right frame, be careful not to bend the frames.
1. Remove the pump assembly. (Refer to Section 3.13.2.) 2. Remove the top frame. (Refer to Section 3.13.5.) 3. Remove the head FFCs from the sub cable holder. (See Figure 3-57.)
Head FFCs
Sub Cable Holder
Figure 3-57. Head FFC Removal 4. Remove 2 screws (CBS, 3x6, F/Zn) securing the I/S frame and right frame. (See Figure 3-58.)
CBS Screws (3x6, F/Zn)
I/S Frame
Figure 3-58. I/S Frame Removal (1)
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Disassembly and Assembly
5. Slide the I/S frame forward by releasing 3 joints (2 at the back and 1 on the front of the printer mechanism) for the I/S frame and right frame. Then remove the I/S frame by lowering downward. (See Figure 3-59.)
Right Frame
Joints
I/S Frame
Figure 3-59. I/S Frame Removal (2) 6. Remove connector cables for the CR HP sensor and pump motor from the printer mechanism.
;When joining the I/S frame with the right frame, be sure to align it with the slots in the right frame appropriately. Then push until it meets resistance. ;Pay attention to the 20.8 mm gear in the combination gear (12 mm, 20.8 mm) when ;When attaching the I/S frame to the right frame, be sure to mount the screw on the front first. Otherwise, the frame will bend. (See Figure 3-60.) ;After installing the I/S frame onto the printer mechanism, only carry the printer mechanism by holding the bottom frame. ;Tightening torque for the screws (CBS, 3x5, F/Zn) = 8 ~ 10 kg-cm.
connecting the I/S frame to the right frame. It must engage the 16.8 mm gear correctly. Leave some backlash for the combination gear (12 mm, 20.8 mm).
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Disassembly and Assembly
Figure 3-60. Order for Mounting Screws
3.13.8 I/S Frame Disassembly (Removing the Pump Motor)
1. Remove the I/S frame. (See Section 3.13.7.) 2. Remove 2 screws (CBS, 3x6, F/Zn) securing the pump motor. (See Figure 3-61.)
Pump Motor
CBS Screws (3x6, F/Zn)
ÌßØÝÀE`¤ Printer Mechanism Viewed from the Right
Figure 3-61. Removing the Screws Securing the Pump Motor
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3. Remove 1 hexagon nut (6N, class-2, M4) and 1 draft spring (0.4 g) securing the slider shaft to the middle sub frame. Then remove the slider shaft. (See Figure 3-62.)
Extension Spring Shaft Slider
Gear (16.8 mm) Middle Frame
Hexagon Nut (6N, Class-2, M4)
Figure 3-62. Slider Shaft Removal
CAUTION
Be careful not to damage the gear (16.8 mm) when removing the hexagon nut (6N, class-2, M4) securing the slider shaft.
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Disassembly and Assembly
4. Remove 2 screws (CBS, 3x6, F/Zn) securing the inner sub frame. Then remove the inner sub frame and the following 6 parts from the middle sub frame: Combination gear (12 mm, 20.8 mm) Gear (16.8 mm) Plain washer (7.2x0.3x12, S/Na) Compression spring (0.26 g) Compression spring (0.31 g) Plain washer (5.2x0.2x11, S/Na) (See Figure 3-63.)
c e g
d f h
Combination Gear (12 mm, 20.8 mm) Gear (16.8 mm) Plain Washer (7.2x0, 3x12, S/Na) Compression Spring (0.26 g)
CBS Screws (3x6, F/Zn) Sub Inner Frame
Compression Spring (0.31 g)
Plain Washer (5.2x0, 2x10, S/Na)
Figure 3-63. Inner Sub Frame Removal
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5. Remove 2 screws (CBS, 3X6, F/Zn) securing the middle sub frame, then remove the middle sub frame and the following 11 parts from the sub pump frame: Combination gear (12, 15) Plain washer (5.2x0.3x12, S/Na) Spring washer (5.3x0.07x10, S/Na) Combination gear (14.4, 21.6) Cam Torsion spring (7.3) Combination gears (12, 26) Gear (11.5) 3 E-rings (4, F/UC) (See Figure 3-64.)
c e g i k
d f h j
Torsion Spring (7.3 g) Cam Combination Gear (14.4 mm, 21.6 mm) Combination Gear (12 mm, 26 mm)
Sub Middle Frame Gear (11.5 mm) E-ring (4, F/UC) Combination Gear (12 mm,15 mm) CB Screws (3x6, F/Zn) Plain Washer (5.2x0.3x12, S/Na) U-type Spring Washer (5.3x0.07x10, S/Na)
Figure 3-64. Middle Sub Frame Removal
;Do not mount the E-ring before engaging all frames. Otherwise frames and shafts may bend. Be sure to use the exclusive E-ring holder to avoid damaging gears and shafts. ;Notice how gears engage. See figures 3-63 and 3-64. ;Tightening torque for the screws (CBS, 3x6, F/Zn) = 8 ~ 10 kg-cm. ;After tightening screws, make sure the U-shaped spring washer is mounted correctly.
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Disassembly and Assembly
Checklist after Engaging I/S Frame
;Gear engagement
;Engagement of slider and combination gear c Move slider to the right, and check that it engages the combination gear smoothly. ;Cam changeover (pump side) c Insert the cam in the direction shown in Figure 3-65 (top left illustration) and shift the slider to the right. d Turn the combination gear (12 mm, 26 mm) clockwise, and check that the gear
(16 mm) engages the combination gear (12 mm, 15 mm) and cam smoothly. Check that the combination gear (14.4 mm, 21.6 mm) turns along with the cam. Make sure gears rotate smoothly and immediately. If not, turn combination gear (12 mm, 26 mm) in both directions, and check that they engage the slider properly, as shown in Figure 3-65 (bottom left illustration).
Insert the cam in the direction shown in Figure 3-65 (top left illustration), and turn the combination gear right and left. Then check that gears turn smoothly.
;Cam changeover (ASF side) c Insert the cam in the direction shown in Figure 3-65 (top right illustration) and shift the slider to the left. d Turn the combination gears (12 mm, 26 mm) counterclockwise, and check that the
gear (16 mm) engages the combination gear (12 mm, 15 mm) and cam smoothly. Check that the combination gear (14.4 mm, 21.6 mm) turns smoothly along with the cam. Make sure the gears rotate smoothly and immediately.
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Cam Torsion Spring (7.3 g)
Cam
Combination Gear (12 mm, 26 mm)
Combination Gear (14.4 mm, 21.6 mm)
I/S Frame Viewed from the Left
I/S Frame Viewed from the Left
Gear (16 mm) Slider Slider Shaft Combination Gear (12 mm, 15 mm) Shifts the Slider to the Right. Engaging Point with the Combination Gear (12, 15 mm) I/S Frame Viewed from the Top Shifts the Slider to the Left. Engaging Point with the Combination Gear (12, 15 mm) I/S Frame Viewed from the Top
Figure 3-65. Checkpoints for Assembling the I/S Frame
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Disassembly and Assembly
3.13.9 Paper Feed Roller (PF Roller) Assembly Removal
CAUTION
;When releasing or turning lock levers for the paper feed roller bushings, be careful not to damage them. ;When removing the paper feed roller from the right and left frames, be careful not to damage the teeth for the gear (70 mm). ;Never touch the surface of the black-coated roller in the paper feed roller assembly with
1. Remove the top frame. (See Section 3.13.5.) 2. Remove the front paper guide. (See Figure 3-13.) 3. Release 3 hooks securing the rear paper guide to the bottom frame. (See Figure 3-66.)
Paper Feed Roller Assembly Tabs Fixing the Rear Paper Guide
your bare hands. The roller surface coating is so sensitive that it must be handled cautiously to prevent the coating from peeling.
Rear Paper Guide
Rear Frame
Figure 3-66. Rear Paper Guide Removal
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4. Push levers out to release the lock levers for the right and left bushings (12 mm) securing the paper feed roller assembly to the right and left frames. Then turn them forward until they fit through the cutouts in the frames. Shift the paper feed roller assembly left, and remove the paper feed roller assembly and rear paper guide along with the gear (70 mm) by lifting upward. (See Figure 3-67.)
Gear (70 mm)
Paper Feed Roller Assembly
Figure 3-67. Paper Feed Roller Assembly Removal
;When installing the paper feed roller assembly into the right and left frames, insert the right ;Make sure that the bumps on each bushing lever fit into the location holes in the frames. (See Figure 3-68.) ;If you dismount the gear (70 mm) after removing the paper feed roller assembly, be sure to
and left bushing on the left of each frame. Then align the bushings with the cutouts in the frame, and slide the shaft to the right.
;Make sure that 3 hooks fixing the rear paper guide to the bottom frame securely fit into the cutouts in the bottom frame. ;Make sure the contact spring on the left is correctly mounted onto the bottom frame, as
shown in Figure 3-69.
press the gear back into the paper feed roller assembly before reinstalling the paper feed roller assembly to the right and left frames. Do not hold the gear by its teeth during this operation.
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Disassembly and Assembly
Figure 3-68. Bushing Locations
Paper Feed Roller Assembly
Contact Spring Rear Paper Guide Figure 3-69. Contact Spring Location
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3.13.10 Ink Drain Pad Removal
1. Remove the printer mechanism. (See Section 3.13.) 2. Remove the ink drain pad from the lower case.
Ink Drain Pads
Lower Case
Figure 3-70. Ink Drain Pad Removal
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