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Chapter 3 Disassembly and Assembly
3.1 OVERVIEW ............................................................................................................3-1
3.1.1 Precautions for Disassembling the Printer.......................................................................... 3-1 3.1.2 Specification for Screws........................................................................................................ 3-2 3.1.3 Tools ........................................................................................................................................ 3-2 3.1.4 Work Completion Check ........................................................................................................ 3-3

3.2 DISASSEMBLY AND ASSEMBLY .........................................................................3-4
3.2.1 Housing Removal ................................................................................................................... 3-5 3.2.2 Circuit Boards Removal......................................................................................................... 3-6 3.2.3 Control Panel Removal .......................................................................................................... 3-8 3.2.4 Waste Ink Pad Assembly Removal ....................................................................................... 3-9 3.2.5 Disassembling the Printer Mechanism............................................................................... 3-10 3.2.5.1 Printhead Removal.................................................................................................. 3-10 3.2.5.2 Pump Assembly and Cap Assembly Removal ........................................................ 3-12 3.2.5.3 CR Motor Assembly Removal ................................................................................. 3-14 3.2.5.4 PF Motor Assembly Removal.................................................................................. 3-16 3.2.5.5 ASF Assembly Removal.......................................................................................... 3-18 3.2.5.5.1 ASF Disassembly......................................................................................... 3-20 3.2.5.5.2 Pick-Up Roller Assembly Removal .............................................................. 3-21 3.2.5.6 Carriage Assembly Removal................................................................................... 3-22 3.2.5.7 PF Roller Assembly Removal.................................................................................. 3-24 3.2.5.8 PE Sensor Assembly Removal ............................................................................... 3-26 3.2.5.9 HP Sensor Assembly Removal ............................................................................... 3-27

Chapter 3 Disassembly and Assembly

3.1 OVERVIEW
This section describes procedures for disassembling the main components of EPSON Stylus Photo. Unless otherwise specified, disassembly units or components can be reassembled by reversing the disassembly procedure. Therefore, no assembly procedures are included in this section. Precautions for any disassembly or assembly procedure are described under the heading "WORK POINT". Any adjustments required after disassembling the units are described under the heading "REQUIRED ADJUSTMENT".

3.1.1 Precautions for Disassembling the Printer
See the precautions below when disassembling or assembling EPSON Stylus Photo.

WARNING



Disconnect the power cable before disassembling or assembling the printer. 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. If ink comes into 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. The leakage may affect other devices close to the battery.) 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 may also be resulted.) 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 manufacture. Dispose the used batteries according to government's law and regulations.


Risque d'explosion si la pile est remplacée incorrectment. Ne remplacer que par une pile du même type ou d'un type équivalent recommandé par le fabricant. Eliminer les piles déchargées selon les lois et les règles de sécurité en vigueur.

CAUTION



Never remove the ink cartridge from the carriage unless manual specify to do so. When transporting the printer after installing the ink cartridge, be sure to pack the printer for transportation 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 the specified adjustments when you disassemble the printer. (See Chapter 4 for details.)

Rev. A

3-1

EPSON Stylus Photo

3.1.2 Specification for Screws
Table 3-1 lists the abbreviation of screws and its use. Refer to the screw number in the following table to identify the type of screw shown in the disassembly procedures. Table 3-1. Screw Identification Table No. 1 Shape Name CBS (Cross/Bind/S-tight screw) Standard M3x6

2 3

CBP (Cross/Bind/P-tight screw)

M3x10 M3x6

4 5 6

CP (Cross/Pan-head screw)

M3x10 M3x8 M3x4

7

CBS with Washer (Cross/Bind/S-tight screw with washer)

M3x6

3.1.3

Tools

Table 3-2 lists the tools required for disassembling and assembling the printer. Use only specified tools to avoid damaging the printer. Table 3-2. Required Tools Name Philips Screw Driver (No.1) Philips Screw Driver (No.2) Tweezers Hexagonal Box Driver (5.5mm) Availability



EPSON Parts Code B743800200 B743800400 B741000100 B741700100

3-2

Rev. A

Chapter 3 Disassembly and Assembly

3.1.4 Work Completion Check
If any service is made to the printer, use the check list shown below, to confirm that all works are completed properly and the printer is ready to return to the user. Category Main Unit Item Self-Print Test Online Print Test Printhead Carriage Mechanism Check Point Is the printing successful? Is the printing successful? Is ink discharged normally from all nozzle? Does it moves smoothly? Is there any abnormal noise in its motion? Is there any dirt or scratch in the CR guide shaft? Is the CR Motor at the correct temperature? (Not too hot) Is paper advanced smoothly? *No paper jamming *No paper skew *No multiple feeding *No abnormal noise Is the PF Motor at the correct temperature? (Not too hot) Is the paper path clear of all obstructions? Are all the adjustments done correctly? Does all the lubrication made at specified points? Is the amount of lubrication correct? Version (Latest): Are brand-new ink cartridges installed correctly? Have all relevant protective materials been attached to the printer? Have all relevant items been included in the package?

Paper Feeding Mechanism

Checked/Not necessary Checked/Not necessary Checked/Not necessary Checked/Not necessary Checked/Not necessary Checked/Not necessary Checked/Not necessary Checked/Not necessary Checked/Not necessary Checked/Not necessary Checked/Not necessary Checked/Not necessary Checked/Not necessary Checked/Not necessary Checked/Not necessary Checked/Not necessary Checked/Not necessary

Status

Adjustment Lubrication

Specified Adjustment Specified Point

System Packing

ROM Version Ink Cartridge Protective Materials

Other

Attachment, Accessories

Rev. A

3-3

EPSON Stylus Photo

3.2 DISASSEMBLY AND ASSEMBLY
This section describes the step-by-step disassembly procedures shown in the diagram below.

Housing Removal Section 3.2.1

Circuit Boards Removal Section 3.2.2

Printer Mechanism Disassembly Seciton 3.2.5

Control Panel Removal Section 3.2.3

Printhead Removal Section 3.2.5.1

Waste Ink Pad Assembly Removal Section 3.2.4

Pump/Cap Assembly Removal Section 3.2.5.2 CR Motor Assembly Removal Section 3.2.5.3 PF Motor Assembly Removal Section 3.2.5.4 ASF Assembly Removal Section 3.2.5.5 Carriage Assembly Removal Section 3.2.5.6 PF Roller Assembly Removal Section 3.2.5.7 PE Sensor Assembly Removal Section 3.2.5.8 HP Sensor Assembly Removal Section 3.2.5.9 ASF Disassembly Section 3.2.5.5.1 Pick-Up Roller Assembly Removal Section 3.2.5.5.2

Figure 3-1. Flow Chart of Disassembly

3-4

Rev. A

Chapter 3 Disassembly and Assembly

3.2.1 Housing Removal
Since the EPSON Stylus Photo has no lower housing as previous EPSON printers, the printer mechanism can be taken out by only removing the upper housing. 1. 2. Open the printer cover and set the PG adjust lever on the right-hand side to (+) position. Remove 4 screws (No.2) and remove the upper housing.

WORK POINT
Pull the front end of the upper housing while lifting up the upper housing to remove it.

CAUTION
Be careful not to pinch the cables with the posts of the upper housing when reinstalling it. (Especially with the cables from the motors and doing so causes fatal damage to the mechanism and the electric circuitry.)

Upper Housing

Figure 3-2. Housing Removal

Rev. A

3-5

EPSON Stylus Photo

3.2.2 Circuit Boards Removal
The electric circuit boards of the printer (Main control circuit board: C209 MAIN / Power supply circuit board: C206 PSB/PSE) are both installed on single metal chassis and attached to the printer mechanism. Therefore, first detach the metal chassis from the printer mechanism to remove the electric circuit boards. 1. 2. 3. 4. 5. Remove the upper housing (Refer to section 3.2.1) Remove 5 screws (No.1 / three at the back of the printer mechanism and one each at both sides of the printer mechanism) Slightly pull out "SHIELD PLATE, M/B" (metal chassis) from the printer mechanism and take out the cable holders inserted to the edge of "SHIELD PLATE, M/B". Fully separate "SHIELD PLATE, M/B" from the printer mechanism and remove all cables connected to the connectors on the main board; C209 MAIN. If you need further to remove each electric circuit board from "SHIELD PLATE, M/B", remove the screws fixing each board and remove the board.

C209 MAIN BOARD: C206 PSB/PSE BOARD:

10 screws (No.1 = 7 screws, No.6 = 3 screws) 4 screws (No.1)

Also disconnect the cable from the connector; CN10 (locking type) on the C209 MAIN, when you remove the C206 PSB/PSE BOARD.

WORK POINT
Unlock the connector CN6/7 on the C209 MAIN by pulling its lock before disconnect the cables, and be sure to lock it when reconnecting the cables.

[Cable Holders]

SHIELD PLATE, M/B

Figure 3-3. SHIELD PLATE M/B Removal

3-6

Rev. A

Chapter 3 Disassembly and Assembly

MAIN Board (C209 MAIN)

Power Supply Board (C206 PSB/PSE)

SHIELD PLATE, M/B

Figure 3-4. Circuit Boards Removal

REQUIRED ADJUSTMENT
Be sure to perform the following adjustments when the C209 MAIN board is replaced: 1) VH Setting (Refer to Chapter 4 / Section 4.2.2.4.) 2) Head Angular Adjustment (Refer to Chapter 4 / Section 4.2.2.5.) 3) Bi-D Alignment Adjustment (Refer to Chapter 4 / Section 4.2.2.6.)

Rev. A

3-7

EPSON Stylus Photo

3.2.3 Control Panel Removal
1. Remove the upper housing (Refer to Section 3.2.1) 2. Remove 2 screws (No.1) and remove the "PANEL, ASSEMBLY" and "HOUSING, PANEL, LEFT" from the printer mechanism and disconnect the flat cable from the connector of the panel assembly.

WORK POINT
By removing the control panel assembly, the stacker assembly is also detached from the printer mechanism since it is held by the control panel assembly.

SHIELD PLATE, PANEL

C209 PNL Board

PANEL, ASSEMBLY

STACKER, ASSEMBLY

HOUSING, PANEL, LEFT

Figure 3-5. Control Panel Removal

3-8

Rev. A

Chapter 3 Disassembly and Assembly

3.2.4 Waste Ink Pad Assembly Removal
1. Removing the upper housing (Refer to section 3.2.1) 2. Removing the control panel assembly (Refer to section 3.2.3) 3. Remove 1 screw (No.4) at the right-hand side of the printer mechanism, that fixing "Waste Ink Pad Assembly". 4. Remove "SPACER, TRAY" fixing "Waste Ink Pad Assembly" at the left-hand side of the printer mechanism and remove "Waste Ink Pad Assembly" by pulling it downward.

CAUTION
When you replace "Waste Ink Pad Assembly" to new one, be sure to perform the ink counter reset operation. (Refer to Chapter 1 / Section 1.4.2 for details)

WORK POINT
When re-installing "Waste Ink Pad Assembly", be sure that "Stopper, Stacker" that attached to the exit roller shaft is correctly pushed in to back of the projections of "Waste Ink Pad Assembly".

Section (A)

Waste Ink Pad Assembly SPACER, TRAY

[Projections]

Paper Exit Roller Shaft Front side

STOPPER, STACKER

Push it to the back of projection

Figure 3-6. Waste Ink Pad Assembly Removal

Rev. A

3-9

EPSON Stylus Photo

3.2.5 Disassembling the Printer Mechanism
This section describes the procedures for removing the main components consisting the printer mechanism.

3.2.5.1 Printhead Removal
1. Removing the upper housing. (Refer to section 3.2.1) 2. Rotate "Gear, 67.2" (largest gear at the left-hand side of the printer mechanism) toward the front to disengage the carriage lock mechanism, and move the carriage assembly to the middle of the printer. 3. Remove both black and color ink cartridges. 4. Remove both carriage cover assemblies from the carriage. 5. Remove "Twist Spring, 49" at left-hand side of the carriage and remove 1 screw (No.3) fixing "FASTNER, HEAD". Then, remove "FASTNER, HEAD" from the carriage. 6. Unhook the flat cables from the carriage assembly and tae out the printhead unit from the carriage. 7. Disconnect the cables from the connector of the printhead unit.

WORK POINT



Notice that the grounding plate is installed in correct position. (there are two fixing pins in the carriage) Be sure that fixing pin of the carriage is correctly located into the cut out of the printhead unit.

CAUTION
Once the ink cartridge is removed, it is not re-usable and always install brand-new ink cartridge before returning the printer to the user. When returning the printer to the user, be sure that the ink cartridge is installed and the carriage is at the capping position. (Turn the printer off while the carriage is at the capping position and pack it in that state)
This part should be touching the CR axis receiver. Make sure that this protrusion is in the U ditch of the priht head side.

Make sure that protrusion of carriage is in the hole of the earth board.

Carriage Assembly Print Head

Figure 3-7.Printhead Installation

3-10

Rev. A

Chapter 3 Disassembly and Assembly
Flat Cable

Printhead Unit FASTNER, HEAD

TWIST SPRING, 49

Figure 3-8. Printhead Unit Removal

CAUTION



If you remove the Flat cable from the printer mechanism, make sure that the Flat cable is fixed to the frame firmly when assembling.

REQUIRED ADJUSTMENT
When you remove or replace the printhead unit, be sure to perform the following adjustments: 1) Ink Charge Operation (Refer to Chapter 4 / Section 4.2.2.3.) 2) VH Setting (Refer to Chapter 4 / Section 4.2.2.4.) 3) Head Angular Adjustment (Refer to Chapter 4 / Section 4.2.2.5.)

Rev. A

3-11

EPSON Stylus Photo

3.2.5.2 Pump Assembly and Cap Assembly Removal
1. 2. 3. 4. Removing the upper housing. (Refer to Section 3.2.1) Removing the control panel assembly. (Refer to section 3.2.3) Removing "Waste Ink Pad Assembly". (Refer to section 3.2.4) Loosen 2 screws (No.1) fixing the exit frame assembly and disengage the frame from the side frames. Then, put the printer mechanism on its back as you can see the bottom of the mechanism. 5. At the right-hand of the mechanism, unhook the cap assembly by releasing one hook and take out the cap assembly by lifting up the right end of it. (Note that the cap assembly is still connected to the pump assembly by the ink tube.) 6. Remove 2 screws (No.5) fixing the pump assembly to the frame. 7. Unhook the pump assembly by releasing one hook and slide the pump assembly to the right direction to remove it.

CAUTION



Be careful not to damage rubber part of the cap assembly. (Damaging the rubber part causes incomplete capping and the nozzle condition become unstable.) Be careful with the followings when you handle "CLEANER, HEAD": ·Do not handle it with bare hands and avoid attaching any oil or dust. ·Make sure that the rubber side of "CLEANER, HEAD" is facing to the right.

WORK POINT



Be careful not to popping the components from the pump assembly when you remove it from the mechanism, since there is a spring inside the pump assembly. Be sure that the ink tube from the cap assembly is routed to the correct position and not pinched by the cap assembly and the frame. Verify that "CLEANER, HEAD" moves smoothly by rotating "GEAR, 67.2" after you re-assemble the pump assembly. (Hold the cap assembly to the right direction while you rotating the gear for check)

Ink Tube Routing

OK

(Ink tube goes behind of the cap assembly)

Viewed from front

(The ink tube is on the part of the cap assembly)

NG

Figure 3-9. Ink Tube Routing

3-12

Rev. A

Chapter 3 Disassembly and Assembly

Loosen screw and lift up the exit frame

Unhock the cap assembly PUMP ASSEMBLY

CAP ASSEMBLY

Remove 2 screws and unhook the hooks to remove the pump assembly

Figure 3-10.Cap Assembly Removal

CLEANER, HEAD

Pump Components Assembly Order
Figure 3-11.Pump Assembly Removal

Rev. A

3-13

EPSON Stylus Photo

3.2.5.3 CR Motor Assembly Removal
1. Removing the upper housing. (Refer to section 3.2.1) 2. Rotate "Gear, 67.2" (largest gear at the left-hand side of the printer mechanism) toward the front to disengage the carriage lock mechanism, and move the carriage assembly to the middle of the printer. 3. Push "HOLDER, PULLEY, DRIVEN" inward to loosen the timing belt and detach the timing belt from the drive pulley of CR Motor assembly. 4. Remove 2 screws (No.1) and remove "MOTOR, ASSEMBLY, CR" from the mechanism.

WORK POINT
Be sure that the projections of the motor bracket is inserted to the holes of the frame properly.

REQUIRED ADJUSTMENT
When you replace "MOTOR, ASSEMBLY, CR", be sure to perform the following adjustment: 1) Bi-D Alignment Adjustment (Refer to Chapter 4 / Section 4.2.2.6.)

COMPRESSION SPRING, 19.6

PULLEY, ASSEMLBLY, DRIVEN TIMING BELT

Outside side frame

Inside side frame

HOLDER, PULLEY, DRIVEN

Figure 3-12. Driven Pulley Removal

3-14

Rev. A

Chapter 3 Disassembly and Assembly

The projections of motor assembly must locate inside the holes Figure 3-13. CR Motor Removal

Rev. A

3-15

EPSON Stylus Photo

3.2.5.4 PF Motor Assembly Removal
1. Removing the upper housing. (Refer to section 3.2.1) 2. Removing "Waste Ink Pad Assembly". (Refer to section 3.2.4) 3. By referring the figure below, remove the specified gears from the mechanism: "GEAR, 67.2" "COMBINATION GEAR, 8, 14.4" "COMBINATION GEAR, 8.8, 21.6" "GEAR, 36" 4. Remove 2 hexagonal lock nuts and remove "MOTOR, ASSEMBLY, PF".



WORK POINT



When removing the PF Motor, first, slightly pulling out the PF Motor from the frame and slide the motor shaft to a larger cut out of the frame and remove it. Be careful with the routing direction of the cable from the PF motor.

COMPRESSION SPRING, 0.9

MOTOR, ASSEMBLY, PF Hexagonal Nut

GEAR, 67.2

COMBINATION GEAR, 8, 14.4

COMBINATION GEAR, 8.8, 21.6 GEAR, 36 Lock Ring

Figure 3-14. PF Motor Removal

3-16

Rev. A

Chapter 3 Disassembly and Assembly

MOTOR, ASSEMBLY, PF (behind the frame)

Cable Direction

Put the motor shaft once in a larger hold then slide it to a smaller hole
Figure 3-15. PF Motor and Frame

Rev. A

3-17

EPSON Stylus Photo

3.2.5.5 ASF Assembly Removal
1. 2. 3. 4. Removing the upper housing. (Refer to section 3.2.1) Remove the locking pin from center of "GEAR, 34" and remove "GEAR, 34" from the shaft. Unhook the cables from the cable hook of the ASF and the printer mechanism. Remove 2 screws (Refer to the figures) fixing the ASF and remove the ASF from the mechanism by detaching the projection of ASF (at left) from the hole of the mechanism.

WORK POINT



Make sure that the ASF is firmly attached to the mechanism. Use proper type of screw at specified position (viewed from the back of the mechanism): Right: "SHAFT, FIXING, CR" Left: Screw - No.7 (CBS with washer)

CAUTION
When re-installing the ASF, be sure that no cables (except the flat cable to the printhead) are pinched between the ASF and the frame. Especially, if the cables from CR/PF Motor is pinched, there is a danger of short-circuit with the frame and possibly causes hazardous problem like over-heating, burning of components.

3-18

Rev. A

Chapter 3 Disassembly and Assembly

SHAFT, FIXING, CR

[CBS with washer] GEAR, 34

The projections of ASF must be in these holes

Figure 3-16. ASF Assembly Removal

Rev. A

3-19

EPSON Stylus Photo

3.2.5.5.1 ASF Disassembly
1. Removing the ASF. (Refer to section 3.2.5.5) 2. Remove "TWIST SPRING, 41.2" by unhooking one end from the ASF frame and remove "LEVER, BRAKE". 3. Remove "BUSH, FIXING, SHAFT" from the right end of "SHAFT, ROLLER, LD" and remove "LEVER, HOPPER, RELEASE". 4. Move the left paper pick-up assembly to the middle of the ASF and remove "BUSH" from the shaft. 5. Push out "SHAFT, ROLLER, LD" to the left and remove "BUSH, FIXING, SHAFT, LEFT" from the leftend of the shaft by unhook it. 6. Unhook the top of "HOPPER, ASSEMBLY" from the both sides of "FRAME, ASF". 7. Push out "SHAFT, ROLLER, LD" to the right while pulling up "PICKUP, ROLLER ASSEMBLY, RIGHT" slightly. Then, detach the left end of "SHAFT, ROLLER, LD" from "FRAME, ASF". 8. Holds "HOPPER, ASSEMBLY" and remove the right cam part of "HOPPER, ASSEMBLY" through the hole at the right side of "FRAME, ASF". To this point, the ASF assembly is disassembled and both left and right "PICKUP, ROLLER ASSEMBLY" and "HOPPER, ASSEMBLY" are separated.

WORK POINT



When removing "HOPPER, ASSEMBLY", be careful that the grease that applied to the cam part of it, not to attach to the other part of the ASF. If so, wipe it off completely. Be careful of the direction when you install the "LEVER, HOPPER, RELEASE". Make sure that bushes at the both ends of the shaft are firmly attached.

HOPPER, ASSEMBLY LEVER, BRAKE TWIST SPRING, 41.2

CAM part

FRAME, ASF
BUSH, FIXING, SHAFT, LEFT

LEVER, HOPPER, RELEASE

BUSH

SHAFT, ROLLER, LD

BUSH, FIXING, SHAFT

Figure 3-17. ASF Disassembly

3-20

Rev. A

Chapter 3 Disassembly and Assembly

3.2.5.5.2 Pick-Up Roller Assembly Removal
1. Disassemble the ASF and separate "PICKUP, ROLLER ASSEMBLY" and "HOPPER, ASSEMBLY". (Refer to section 3.2.5.5.1) 2. Remove "COMPRESSION SPRING, 1.66" from the back of "HOPPER, ASSEMBLY". 3. Pull out the right cam part of "HOPPER, ASSEMBLY" though the hole of right frame of "PICKUP, ROLLER ASSEMBLY, RIGHT". 4. Unhook "ROLLER ASSEMBLY, LD" from the assembly frame and remove "COVER, ROLLER, LD" by unhooking it from the assembly frame. Then, remove "ROLLER ASSEMBLY, LD".

WORK POINT



When you re-assemble, be sure that "ROLLER ASSEMBLY, LD" is hooked to assembly frame firmly. Before re-assemble the unit, make sure that "COMPRESSION SPRING, 1.66" is set on the assembly frame and hooked to the hooks as shown in the figure. This helps you easier assembly. After assemble the unit, do not forget to unhook the springs by rotating the spring from the holes located at the back of the ASF assembly.
COVER, ROLLER, LD (L/R) + HOLDER, SHEET, PF

COMPRESSION SPRING, 1.66

ROLLER, ASSEMBLY, LD (L/R)

ASSEMBLY FRAME

Set the spring and hook it to the assembly frame as illustrated, before re-assembly

Figure 3-18. Pick-Up Roller Removal

Rev. A

3-21

EPSON Stylus Photo

3.2.5.6 Carriage Assembly Removal
1. Removing the upper housing. (Refer to section 3.2.1) 2. Push "HOLDER, PULLEY, DRIVEN" inward to loosen the timing belt and detach the timing belt from the drive pulley of CR Motor assembly. 3. Take out "COMPRESSION SPRING, 19.6" from "HOLDER, PULLEY, DRIVEN". 4. Remove "PULLEY, ASSEMBLY, DRIVEN" and the timing belt together from "HOLDER, PULLEY, DRIVEN" and remove "HOLDER, PULLEY, DRIVEN" from the mechanism. 5. Unhook "LEVER, PG" and remove it. 6. Unhook "LEVER, PG, SUB" and remove "LEVER, PG, SUB" and a spring washer from the end of "SHAFT, CR, GUIDE". 7. Remove 1 screw (No.7) and rotating "BUSH, PARALLEL ADJUST, RIGHT" to match it with the cut out of the frame. Then, take out "BUSH, PARALLEL, ADJUST, RIGHT". 8. Remove "CARRIAGE, ASSEMBLY" together with "SHAFT, CR, GUIDE".

WORK POINT



It is good idea to mark the current position of "BUSH, PARALLEL ADJUST, RIGHT" before removal. This enables you to omit the paper gap adjustment after the assembly. Be careful with the direction of spring washer at the assembly. (A convex side must face the bush)

REQUIRED ADJUSTMENT
When you remove or replace the carriage assembly, be sure to perform the following adjustments: 1) Paper Gap Adjustment (Refer to Chapter 4 / Section 4.2.1.) 2) Head Angular Adjustment (Refer to Chapter 4 / Section 4.2.2.5.) 3) Bi-D Alignment Adjustment (Refer to Chapter 4 / Section 4.2.2.6.)

BUSH, PARALLEL ADJUST, RIGHT

BUSH, PARALLEL ADJUST, RIGHT

Side frame of printer mechanism

Cut out of side frame

Figure 3-19. BUSH PARALLEL ADJUST Removal

3-22

Rev. A

Chapter 3 Disassembly and Assembly
Carriage Assembly
BUSH, PARALLEL ADJUST, LEFT

SHAFT, CR, GUIDE

BUSH, PARALLEL ADJUST, RIGHT LEVER, PG, SUB

Spring Washer (Convex side must be facing the bush)

Figure 3-20. Carriage Assembly Removal

Rev. A

3-23

EPSON Stylus Photo

3.2.5.7 PF Roller Assembly Removal
1. 2. 3. 4. 5. 6. 7. 8. Removing the upper housing. (Refer to section 3.2.1) Removing the carriage assembly (Refer to section 3.2.5.6) Remove 2 screws (No.1) at the top of mechanism and remove "GUIDE PLATE, CABLE". From the back of the mechanism, unhook the springs from the frame and remove "PAPER GUIDE, ASSEMBLY, UPPER" (total 6 pieces). Unhook "PAPER GUIDE, FRONT;B" and remove it. Unhook the both shaft holders of "ROLLER, ASSEMBLY, PAPER EXIT" and remove it. Unhook the left shaft holder of "ROLLER, ASSEMBLY, PF" and rotate it as to match with the cut out of the frame. Slide "ROLLER, ASSEMBLY, PF" to the left and pulling it out.

WORK POINT



When reinstalling "PAPER GUIDE, ASSEMBLY, UPPER" at right-most position (viewed from the front), be careful with the detection lever of the PE sensor. Be careful not to damage the hook of "PAPER GUIDE, FRONT;B" during disassembly and assembly. Be careful not to damage the black coated part of "ROLLER, ASSEMBLY, PF" during disassembly and assembly. Be careful not to damage the gears.
PAPER GUIDE, LEFT

PAPER GUIDE, ASSEMBLY, UPPER
SHAFT, PAPER GUIDE, UPPER TWIST SPRING, 117.6

GUIDE PLATE, CABLE (6 pieces)

Figure 3-21. PAPER GUIDE ASSEMBLY Removal

3-24

Rev. A

Chapter 3 Disassembly and Assembly
PAPER GUIDE, LEFT

PAPER GUIDE, ASSEMBLY, UPPER
SHAFT, PAPER GUIDE, UPPER TWIST SPRING, 117.6

GUIDE PLATE, CABLE (6 pieces)

Figure 3-22. ROLLER, ASSEMBLY, PAPER EXIT Removal

PAPER GUIDE, FRONT;B

ROLLER, ASSEMBLY, PAPER EXIT

Figure 3-23. ROLLER, ASSEMBLY, PF Removal

Rev. A

3-25

EPSON Stylus Photo

3.2.5.8 PE Sensor Assembly Removal
1. Removing the upper housing. (Refer to section 3.2.1) 2. From the front side of the mechanism, unhook two hooks fixing "SENSOR, ASSEMBLY, PE" to the mechanism. Then, slide it to upward to remove it. After removal, disassemble the assembly if necessary.

WORK POINT
When re-install the assembly, be sure that the sensor lever is correctly inserted into a hole of "PAPER GUIDE, ASSEMBLY", UPPER".

Release these hooks to remove the PE Sensor Assembly

From the back side of the mechanism

HOLDER, PE

To frame

BOARD ASSY., PE

LEVER, PE

Figure 3-24.PE Sensor Assembly Removal

CAUTION


3-26

Be careful not to damage the cable when inserting or pulling out it from the PE sensor board. Make sure the sensor lever moves smoothly when installing it.

Rev. A

Chapter 3 Disassembly and Assembly

3.2.5.9 HP Sensor Assembly Removal
1. Removing the upper housing. (Refer to section 3.2.1) 2. Detach the cable from the sensor and remove it by unhook it from the frame.

SENSOR, HP

CR MOTOR

Figure 3-25. HP Sensor Removal

CAUTION



Make sure that the sensor itself is attached firmly to the frame when installing the HP sensor again. Be careful not to damage the sensor board when installing or pulling out the cable from the HP sensor.

Rev. A

3-27

Chapter 4 Adjustment
4.1 OVERVIEW ............................................................................................................4-1
4.1.1 Required Adjustments ........................................................................................................... 4-1 4.1.2 Tools Required for Adjustment ............................................................................................. 4-1

4.2 Adjustments ..........................................................................................................4-2
4.2.1 Paper Gap Adjustment ........................................................................................................... 4-2 4.2.2 Adjustment using Adjustment Program............................................................................... 4-4 4.2.2.1 Overview of Adjustment Program ............................................................................. 4-4 4.2.2.2 Preparation for Adjustment........................................................................................ 4-5 4.2.2.3 Ink Charge Operation ................................................................................................ 4-6 4.2.2.4 VH Setting ................................................................................................................. 4-6 4.2.2.5 Head Angular Adjustment ......................................................................................... 4-8 4.2.2.6 Bi-D Alignment Adjustment ..................................................................................... 4-10

Chapter 4 Adjustment

4.1 OVERVIEW
This section describes the procedure for adjustments required when the printer is disassembled and assembled for repair.

4.1.1 Required Adjustments
Table 4-1 lists all the adjustments required with this printer. If any service listed in this table is carried out, all adjustments corresponding to that service should be performed to ensure proper operation of the printer. Table 4-1. Required Adjustments

Performance Order Service Performed

1 Paper-Gap Adjustment
NA NA NA NA

2 Ink Charge

3 VH Setting

Replacing the printer mechanism Replacing the C209 MAIN board Replacing the printhead unit Replacing the CR Motor Replacing or disassembling the carriage assembly Replacing or disassembling the PF Roller assembly


NA NA NA


NA NA NA

4 Head Angular Adjustment NA

5 Bi-D Adjustment


NA


NA




NA


NA

Note) " ": "NA":



Required adjustment Not applicable

4.1.2 Tools Required for Adjustment
Table 4-2 lists all the tools required to make the specified adjustments. Table 4-2. Required Tools No. 1 2 Name Thickness Gauge Adjustment Program Adjustment Paper-Gap Adjustment



Ink Charge VH Setting Head Angular Bi-D Alignment



Notes Thickness: 1.04mm EPSON Code: B776702201 Program Name: K00A10VE.BAS

CAUTION



Do not use rusty or deformed thickness gauge for adjustment. Wipe off any dirt or dust from the thickness gauge before using.

Rev. A

4-1

EPSON Stylus Photo

4.2 Adjustments
This section describes the detail procedure of each adjustment.

4.2.1 Paper Gap Adjustment
The paper gap is a distance between nozzle surface of the printhead unit and a paper surface and is adjusted to specified gap at the assembly. Therefore, if the carriage assembly is removed from the printer mechanism for any reason, this adjustment should be made to fix the gap.

CAUTION



Do not scratch the surface of "PAPER GUIDE, FRONT;B" and "ROLLER, ASSEMBLY, PF". Be careful not to damage or make dirty the nozzle surface of the printhead unit.

[Paper gap - Right-hand side Adjustment] 1. Attach both "BUSH, PARALLEL ADJUST" (L/R) to the side frame and align the position mark on top edge of it to a notch on the edge of the side frame. 2. Set "LEVER, PG" to front side (Position "0"). 3. Move the carriage assembly to the middle, and put the thickness gauge at the position specified in the figure. 4. Move the carriage assembly over the thickness gauge.

WORK POINT



The thickness gauge must be placed on a flat surface of the ribs of "PAPER GUIDE, FRONT;B". During adjustment, always pull the timing belt to move the carriage assembly.

5. Shift the position of "BUSH, PARALLEL ADJUST, RIGHT" to backward (Gap: Narrower) until when the thickness gauge starts sliding together with the carriage assembly when you move it to right and left for about 20mm. 6. At the point of above step, shift the position of "BUSH, PARALLEL ADJUST, RIGHT" for one notch to forward (Gap: Wider). 7. Then, confirm that the thickness gauge do not slide when you move the carriage assembly, with either "LEVER, PG" is at position "0" or "+".

[Paper gap - Left-hand side Adjustment] 8. Repeat the above step 2 to 7 with "BUSH, PARALLEL ADJUST, LEFT". [Gap Confirmation] 9. Repeat the step 3 to 4 again. 10. Confirm that the thickness gauge do not slide when you move the carriage assembly to right and left for above 20mm. 11. Shift the position of "BUSH, PARALLEL ADJUST, RIGHT" for one notch to backward (Gap: Narrower) and confirm that the thickness gauge is sliding by moving the carriage assembly. If not, return to step 1 and repeat adjustment again. 12. If the gap is correct, shift "BUSH, PARALLEL ADJUST, RIGHT" for one notch to forward (Gap: Wider). [Fixing "BUSH, PARALLEL ADJUST"] 13. Fix both bushes with 2 screws (1 each : No.1).
When the paper gap adjustment complete, confirm that the overlap of printhead nose and "CLEANER, HEAD". 1. Move the carriage assembly next to "CLEANER, HEAD". 2. Confirm that the overlap of printhead nose and top edge of "CLEANER, HEAD" is more than 0.5mm.

4-2

Rev. A

Chapter 4 Adjustment
Left "PAPER GUIDE, FRONT;B" Right (HP side)

Rib: Avoid 2ribs from left

Carriage Assembly

[Thickness Gauge]

Rib: Avoid 1 rib at right end

*Put the gauge on a flat face *Align the center of gauge and the ribs

"ROLLER, ASSEMBLY, PF"

"PAPER GUIDE, FRONT;B"

Figure 4-1. Paper Gap Adjustment - Thickness Gauge Setting

Position Mark

Forward (Gap: Wider)

Backward (Gap: Narrower)

Side Frame

"BUSH, PARALLEL ADJUST, RIGHT"

"LEVER, PG"

Figure 4-2. Paper Gap Adjustment - Adjustment Procedure

Overlap = 0.5mm or more

Printhead (Nose face) "CLEANER, HEAD"

Figure 4-3. "CLEANER, HEAD" Overlap

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4-3

EPSON Stylus Photo

4.2.2 Adjustment using Adjustment Program
Since the characteristic of printer mechanism and its components are varying, every printer mechanism are checked and it's own characteristic information is stored in EEPROM of the main control board as a compensation parameter for the mechanism control. Therefore, if the combination of printer mechanism and the main control board is changed, the printer should be adjusted using the adjustment program in order to maintain optimum performance of the printer.

4.2.2.1 Overview of Adjustment Program
This adjustment program(K00A10VE.BAS) is developed specifically for this printer and the basic operation with this adjustment program is illustrated in figure below.

Main Menu (Item Selection)

Initial Ink Charge

Head VH voltage ID writing.

Head Angle Adjustment

Bi-D Adjustment

Performance of Initial ink charge process

Input of appointed VH voltge ID

*Pattern printing *Confirmation/ Mechanism Adjustment

*Pattern printing *Confirmation/ Input of correct values

Figure 4-4. Adjustment Program Flow

4-4

Rev. A

Chapter 4 Adjustment

4.2.2.2 Preparation for Adjustment
Before you start adjustment, have the following items ready for adjustment.



PC (MS-DOS Machine) I/F cable (Parallel) Brand new ink cartridges (Black and Color) Photo quality ink jet paper (#S041061/2) Printer that is necessary to adjust (At least, the printer mechanism, electrical circuits, boards and panel should be connected.)

CAUTION



Make sure to use the new ink cartridge, which is not used and also not opened before. Use the special ink-jet paper in order to check the adjustment result accurately.

1. Connect the PC to the printer and turn the PC and the printer on. Then, unpack a brand-new ink cartridges and install them on to the printer. 2. Load "GWBASIC.EXE" and execute the adjustment program "K00A10VE". 3. At the menu [SCREEN-1], input "2" to select "Cartridge" and press ENTER key. 4. Then, at the menu [SCREEN-2], input the number corresponding to your market and press ENTER key. [SCREEN-1] ***** TOOL ***** PM-700C/STYLUS COLOR PHOTO K00A10Ve 1. Jig 2. Cartridge Input ITEM No. : ?_

[SCREEN-2]

***** CUSTOMER ***** PM-700C/ STYLUS COLOR PHOTO K00A10Ve 1. 2. 3. 4. 000: (WORLD) 100: (JAPAN) 000: (KOREA) 000: (RUSSIA)

Input ITEM No. :?__

[SCREEN-3]

STYLUS COLOR PHOTO K00A10Ve 1: 2: 3: K: 4: VH Setting Ink Charge Angular Adjust Printing Angular Adjust Setting Bi-d Adjust

XX-XX-XXXX XX:XX:XX CUSTOMER:WORLD Jig No. :CT M/C No. :

P: Print Inspection (GOS) L: Print Inspection (S/F) M: Print Inspection (Post-card)

HEAD VH : CL. Cleaning: 9. INK Discharge E. END / Go to SETTING MENU Input ITEM No. :?_

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4-5

EPSON Stylus Photo

4.2.2.3 Ink Charge Operation
If either of the following service is made, internal ink paths of the printhead unit is completely empty. Therefore, a brand-new ink cartridge must be installed and all ink paths must be charged with fresh ink by performing the following operation to ensure proper printing operation.



Replacing the printer mechanism Replacing the printhead unit

CAUTION
Since this operation consumes large amount of ink, do not perform it unnecessarily: *Black: Approx. 8.8% of the ink charged in the cartridge *Color: Approx. 16.2% of the ink charged in the cartridge (CMYcm total) The ink charge operation takes long time to complete. Do not turn off the printer until it stops completely.(The POWER indicator blinks during the operation.)

1. Start "Preparation for Adjustment" and complete 1 to 4 procedures. (Refer to section 4.2.2.2) 2. At the main menu [SCREEN-3], input "2" to select "Ink Charge" and press ENTER key. Then, the printer starts the ink charge operation.

4.2.2.4 VH Setting
The piezo-electric element used in each printhead unit has unique electrical characteristic and the electrical characteristic of each printhead is measured at the production and each printhead unit is given with the ID code. Therefore, this ID code is need to be stored in EEPROM on the main board when the following service is made and the printer read this information to compensate the difference of characteristic for printing control and an amount of injected ink is maintained at the specified level.



Replacing the printhead unit Replacing the printer mechanism (the after-service unit comes with the printhead unit installed)

*Refer to the next page for [SCREEN -1] to [SCREEN-3]. 1. When replacing the part mentioned above, take a note of the ID code indicated on the unit as below.


2. 3. 4. 5. 6.

Printhead Unit: Printer mechanism:

Stamped at the side of the unit Indicated on a label attached to the packing box for the after-service unit.

Re-assemble the printer. Start "Preparation for Adjustment" and complete 1 to 4 procedures.(Refer to section 4.2.2.2) At the main menu [SCREEN-1], Input "1" to select "VH Setting" and press ENTER key. At the next menu screen[SCREEN-2], input "0" as "M/C No." and press ENTER key. Then next menu [SCREEN-3] appears on the screen, and input the ID code which you noted at the beginning of this procedure.



VH ID Code format:

*1 /2 digits (from left) rd *3 digit th th *4 /5 digits

st

nd

=Normal dot VH ID =Drive frequency ID =Micro dot VH ID

7. After inputting the ID code, the program returns to the main menu and you can continue to another adjustments.

WORK POINT



Timing to write the specified value to EEPROM: Upon pressing ENTER key after ID code input.

4-6

Rev. A

Chapter 4 Adjustment
*[SCREEN-1] to [SCREEN-3] for VH Setting. < MAIN MENU for Production > STYLUS COLOR PHOTO K00A10Ve 1. 2. 3. K. 4. VH Setting Ink Charge Angular Adjust-Printing Angular Adjust-Setting Bi-d Adjust

[SCREEN-1]

XX-XX-XXXX

XX:XX:XX

CUSTOMER:WORLD JIG No. M/C No. HEAD VH :CT : :

P. Printing Inspection (GOS) L. Printing Inspection (S/F) M. Printing Inspection (Post-card) CL. Cleaning 9. INK Discharge E. Go to SETTING MENU Input ITEM No.: ?_

[SCREEN-2]

M/C No.

?_

[SCREEN-3] <<<< HEAD VH WRITE >>>> Head VH ( 5 digit ID (ex.18109 or 18A0 ):

-------------------VD VALUE------------------M/C No. :0 HEAD VH : M/C No. ? 0

Head VH ID

Viewed from front
Figure 4-5.Head VH ID Indication

Rev. A

4-7

EPSON Stylus Photo

4.2.2.5 Head Angular Adjustment
The head angular means the angle at which the printhead unit installed on the carriage assembly against the carriage movement direction and the printhead must be parallel with the carriage movement direction so that the lines printed with each nozzle are evenly positioned. Therefore, this adjustment should be made when the following service is made:



Replacing or removing the printhead unit

The head angular actually set by the adjust lever installed on the carriage assembly and the program print the check pattern to see the level of head angular. *Refer to next page for [SCREEN-1] to [SCREEN-2]. 1. Before performing this adjustment, be sure to perform "VH Setting" (Refer to section 4.2.2.4) 2. At the main menu [SCREEN-1], input "3" to select "Angular Adjust Printing" and press ENTER key. 3. Check to see if the lines printed in MAGENTA color is positioned in the middle of two BLACK lines with the check pattern printed by the program. If the position of MAGENTA lines are incorrect, input "K" to select "Angular Adjust Setting" at the main menu and the carriage assembly moves to the middle of the printer. Then, loosen a screw (No.3) fixing "FASTNER, HEAD" a little bit and shift the position of angular adjust level located at the right bottom of the carriage assembly to either forward (move MAGENTA line to down) or backward (move MAGENTA line to up). 4. After adjusting the position of angular adjust lever, input "Y" and press ENTER key and the carriage assembly returns to the home position. 5. Input "3" to print the check pattern again. If the level is still not correct, repeat the step 3 and 4. 6. If the level is correct, input "K" again and tighten a screw to fix "FASTNER, HEAD". Then, at the menu [SCREEN-2], input "Y" and press ENTER key to complete the adjustment.
Printed pattern BLACK line MAGENTA line

Shift the lever to: Backward

Printed pattern Shift the lever to: Forward

Angular Adjust Lever (Right bottom of the Carriage Assembly)

Figure 4-6. Head Angular Adjustment

4-8

Rev. A

Chapter 4 Adjustment
*[SCREEN-1] to [SCREEN-2] for Head Angular Adjustment. [SCREEN-1] < MAIN MENU for Production > STYLUS COLOR PHOTO K00A10Ve 1. 2. 3. K. 4. VH Setting Ink Charge Angular Adjust Printing Angular Adjust Setting Bi-d Adjust

XX-XX-XXXX

XX:XX:XX

CUSTOMER:WORLD JIG No. M/C No. HEAD VH :CT : :

P. Printing Inspection (GOS) L. Printing Inspection (S/F) M. Printing Inspection (Post-card) CL.Cleaning 9. INK Discharge E. Go to SETTING MENU Input ITEM No. : ?__

[SCREEN-2]

Input ITEM No. : ? k Angular Adjustment Finish (Yes):?_

Rev. A

4-9

EPSON Stylus Photo

4.2.2.6 Bi-D Alignment Adjustment
This adjustment defines the carriage drive control parameters to compensate the variation in mechanism components characteristic so that the print position become even in bi-directional printing. This adjustment is required when one of the following service is made:



Replacing the printer mechanism Replacing the main board (C209 MAIN) Replacing the CR Motor assembly Replacing the carriage assembly

The values defined with this adjustment are stored in EEPROM on the main board. *Refer to next page for [SCREEN-1] to [SCREEN-3]. 1. If the printer mechanism is replaced, the ink charge operation and the VH Setting operation should be performed prior to this adjustment. (Refer to section 4.2.2.3 and 4.2.2.4) 2. Go to the main menu [SCREEN-1]. 3. Input "4" to select "Bi-d Adjust" and press ENTER key. 4. The program prints the check pattern (one with the compensation value="0" and another two patterns each printed with the value "-2" and "+2"). Select the number of the pattern with which the printed lines are most properly aligned, and input the number and press ENTER key at the menu [SCREEN-2]. Then, the program print the sample pattern with the compensation value you have selected. 5. If all patterns printed by the program are completely mis-aligned, confirm the inclination of misalignment with the pattern printed with the value "0" by checking the relative position of the EVEN line to the ODD line:

If EVEN line is shifted to RIGHT = If EVEN line is shifted to LEFT =

Requires (-) value Requires (+) value

Then, once input "Y" and press ENTER key to return to the main menu, and input "E" to select "Go to SETTING MENU" and press ENTER key. At the setting menu screen [SCREEN-3], input "6" to select "BI-D Center" and input the approximation number that corresponding to the inclination of misalignment you have confirmed previously. After changing the reference value for the Bi-D alignment check printing, input "1" to select "(Production)" and back to the main menu and continue for the Bi-D alignment adjustment from step 4.

WORK POINT



Timing to write the specified value to EEPROM: Upon pressing ENTER key after input "Y".

[Printed pattern]

Input (-) value

Input (+) value

Figure 4-7.Bi-D Alignment

4-10

Rev. A

Chapter 4 Adjustment
*[SCREEN-1] to [SCREEN-3] for Bi-D Alignment Adjustment. [SCREEN-1] < MAIN MENU for Production > STYLUS COLOR PHOTO K00A10Ve

1. 2. 3. K. 4.

VH Setting Ink Charge Angular Adjust Printing Angular Adjust Setting Bi-d Adjust

XX-XX-XXXX

XX:XX:XX

CUSTOMER:WORLD

P. Printing Inspection (GOS) L. Printing Inspection (S/F) M. Printing Inspection (Envelope) CL. Cleaning 9. INK Discharge E. Go to SETTING MENU Input ITEM No. : ?_

JIG No. M/C No. HEAD VH

:CT : :

[SCREEN-2] << Definable Range (-30=< x <=30). >> Input Adjust Value (If OK, input Y) :? _

[SCREEN-3]

***** SETTING MENU *****

K00A10Ve

1: (Production)/Adjustment 2: 3: 4: 5: 6: 7: DATE/TIME TOOL CUSTOMER BI-D Center Print Position [XX-XX-XXXX] [XX:XX:XX] [CT] JI=JIG CT=Cartridge WAIT=80s [WORLD] [0] [60]

Q: QUIT Input ITEM No.: ?

Rev. A

4-11

Chapter 5 Troubleshooting
5.1 Troubleshooting....................................................................................................5-1 5.2 Unit Level Troubleshooting .................................................................................5-3
5.2.1 Printer does not operate at power on................................................................................... 5-4 5.2.2 Error is detected ..................................................................................................................... 5-5 5.2.3 Failure occurs during printing .............................................................................................. 5-6 5.2.4 Printer does not feed the paper correctly ............................................................................ 5-7 5.2.5 Control panel operation is abnormal.................................................................................... 5-8

5.3 Unit Repair C206 PSB/PSE Board .......................................................................5-9
5.3.1 Unit Repair - C209 MAIN Board ........................................................................................... 5-11

5.4 Repair of the Printer Mechanism.......................................................................5-13

EPSON Stylus Photo

5.1 Troubleshooting
The printer may exhibit different symptoms for the same problem, which makes troubleshooting more difficult. This section, however, provides simple and effective ways to facilitate troubleshooting. The following flowchart illustrates the main steps of the troubleshooting process.
START

Unit Level Troubleshooting

Unit Repair (C206 PSB/PSE)

Unit Repair (C209 Main)

Unit Repair Printer Mechanism

Disassembly and Adjustment

END

Figure 5-1. Troubleshooting Process Flowchart

Table 5-1. Motor Resistance and Measurement Procedure Motor Name Location Check Point No.* Meter Reading

CR Motor CN6(C209 MAIN) 1 & 3pin or, 7.8 Ohms ±10% Assembly 2 & 4pin (25 °C) PF(Pump) Motor CN7(C209 MAIN) 1 & 3pin or, 7.8 Ohms ±10% Assembly 2 & 4pin (25 °C) Note*) Set the Multi-meter for measuring resistance range. Make sure the power is off and remove the motor connectors from the main board. Table 5-2. Sensor Check Sensor Name Paper end sensor Carriage home position sensor (HP sensor) ASF phase Sensor Black cartridge sensor Color cartridge sensor Thermistor Check Point CN4 / 1-pin, CN5 / 1-pin, Signal Level H (5V) L (GND) H (5V) L (GND) H (5V) L (GND) H (5V) L (GND) H (5V) L (GND) Resistance value Sensor Status No paper Paper in Home position Out of home position Friction(paper feeding) position Release(waiting) position Black ink cartridge out Black ink cartridge exists Color ink cartridge out Color ink cartridge exists It changes according to the peripheral temperature. (10KOhms ±1% at 25°C)

CN11 / 1-pin, CN8 / 1-pin,

CN8 / 2-pin, CN8 / 3-pin,

Rev. A

5-1

Chapter 5 Troubleshooting
Table 5-3. Printer Condition and Panel Status Indicators Error status Power Paper Out Paper jam condition No Ink cartridge or Ink end(black) No Ink cartridge or Ink end(color) Ink low (Black) Ink low (Color) Maintenance error Fatal error ------Ink Out (Black) --Off On Ink Out (Color) --Off --Paper Out On Blink --Load paper then press load/eject button. Eliminate a paper then press load/eject button. Install a new black ink cartridge according to ink cartridge exchange operation. Install a new color ink cartridge according to ink cartridge exchange operation. ----Change the waste ink absorber and reset the protect counter. Turn off the printer and turn it on again. If the printer can not recover, repair the suitable part. Recovery

---

---

On

---

----Blink Blink

Blink --Blink On

--Blink Blink On

----Blink Blink

5-2

Rev.A

EPSON Stylus Photo

5.2 Unit Level Troubleshooting
When a problem occurs, you can identify the defective unit according to the symptoms exhibited. The table below lists the symptoms of certain problems. Once the problem is identified, refer to the flowchart that corresponds to the problem. Table 5-4. Symptom and Problem Symptom Printer does not operate at power on Error is detected Failure occurs during printing Problem

Printer does not feed the paper correctly

Control panel operation is abnormal

· · · · · · · · · ·

LEDs do not light up. Printer mechanism does not operate. Error is indicated by LED indication. Printing is not performed. Abnormal printing(missing dot, etc.) Print quality is poor No paper is fed. Paper feed is irregular. Paper jam occurs. No response to button access.

Flowchart No. 1 2 3

4

5

Rev. A

5-3

Chapter 5 Troubleshooting

5.2.1 Printer does not operate at power on
START

Is AC power voltage normal?
YES Is the fuse(F1) of power supply board opened? NO

NO

Input normal power supply.

YES

Exchange the fuse. Disconnect CN10 in the main board and turn the power on again. NO

Check output voltage of CN2 in the power supply board.

Is the fuse opend again? YES

Is the output voltage NO of power supply normal? YES Exchange the main board. Check the motor and head. Refer to the repair item of the printer mechanism. Exchange the power supply board

END

Figure 5-2. Flow Chart 1

5-4

Rev.A

EPSON Stylus Photo

5.2.2 Error is detected
START

Check the error message.(Refer to Table5-3)

Is it carriage error? NO No ink cartridge error? NO Maintenance Error

Yes

Turn off the printer, and move the carriage by hand.

Yes

Exchange the inkcartridge with new one.

Does the carriage move smoothly? NO Yes Check CR motor. Exchange the main board if there is no problem.

Yes

Does error appear again? NO Yes

Exchange the waste ink absorber and reset the counter. (Refer to 1.4.2)

Is the problem solved? NO Refer to 5.4 Repair of the printer mechanism.

Check ink cartridge sensor and exchange the head if it's ubnormal.

END

END

Figure 5-3. Flow Chart 2

Rev. A

5-5

Chapter 5 Troubleshooting

5.2.3 Failure occurs during printing

START

Perform selftest printing

Is printing carried out O.K? YES Is printing quality normal? NO

NO Is all cables connected to the main YES board? NO Connect cables

Perform printing adjustment. YES (Refer to Chapter4)

Perform cleaning Is the problem solved? YES Is the problem solved? YES

Is the problem solved? YES

NO

Exchange the ink cartridge with new one and perform self-test.

NO

Refer to 5.4 Repair of the printer-mechanism.

YES

Is the problem solved? NO

NO

Refer to 5.4 Repair of the printer-mechanism.

Replace the Main board

YES

Is the problem solved?

NO

END

END

END

Figure 5-4.Flow Chart 3

5-6

Rev.A

EPSON Stylus Photo

5.2.4 Printer does not feed the paper correctly
START

Are papers set in the ASF correctly? YES

NO Set the paper correctly

Does the PF roller and platen rotate? YES

NO

Remove any obstruction in the paper path if there is any.

Is the PF motor running? NO YES Check the PF motor. If there is no problem, replace the main board.

Perform cleaning for the roller of paper path.

problem solved?

Is the

NO

YES

Refer to 5.4.Repair of the printer mechanism.

END

END

Figure 5-5. Flow Chart 4

Rev. A

5-7

Chapter 5 Troubleshooting

5.2.5 Control panel operation is abnormal

START

Is the control panel connected correctly? NO YES Connect the control panel correctly.

Is the problem solved? NO

YES

Replace the control panel.

Is the problem solved? YES

NO Replace the main board.

END

END

Figure 5-6. Flow Chart 5

5-8

Rev.A

EPSON Stylus Photo

5.3 Unit Repair C206 PSB/PSE Board
This section describes the problems related to the power supply board(C206 PSB/PSE). The table below provides various symptoms, likely causes, and checkpoints. The checkpoints refer to waveforms, resistance, and other values to be checked to evaluate the operation of each component.

Table 5-5. C206PSB Power Supply Borad Symptom The printer does not operate at all. Condition +42V line is dead. Cause F1 is open. Checkpoint Check F1 by using a tester. Solution Replace F1.

Transformer coils are open. Switching FET (Q1) is dead.

Check the waveform at Replace T1. the drain of Q1. Check drain side. Replace Q1.

Feed back transistor(Q2, Q3) are dead.

Check corrector side.

Replace Q2 or Q3.

+42 V line is abnormal.

Check following parts. · ZD87,ZD83 · ZD51,ZD81·`ZD86 · PC1

Replace suitable parts.

Rev. A

5-9

Chapter 5 Troubleshooting
Table 5-6. C206PSB Power Supply Board (Continued) Symptom Condition +5V line is dead. Cause IC51 (L4962E) is dead. Checkpoint Check the oscillation(5 -pin) and switching (7pin) waveform of IC51. (5-pin) Solution Replace IC51.

(7-pin)

5-10

Rev.A

EPSON Stylus Photo

5.3.1

Unit Repair C209 MAIN Board

This section describes the problems related to the main controller board(C209 MAIN). The table below provides various symptoms, likely causes, and checkpoints. The check points refer to waveforms, resistance, and other values to be checked to evaluate the operation of each component. Table 5-7. Repair of the C209 MAIN Board Condition Cause Checkpoint CPU does The reset Check the waveform of not operate. circuit is the +5V and /Reset signal defective. (IC8=5,1-pin)

Symptom The printer does not operate at all.

Solution Replace IC8

Control ROM is not selected correctly or it's dead. RAM is defective. CPU is defective.

Check if the signal waveform at 11 pin of the IC3 can be reversed High or Low.

Replace IC3.

Replace RAM. Check the clock waveform at 27 or 28-pin of IC1. Replace IC1 if the oscillation waveform is normal, if it is abnormal, replace the oscillator CR1.

The carriage does not operate normally.

Carriage motor does not operate at all.

IC2 is defective.

Check the signal waveform at 1, 2, 23 and 24 pin of IC14.

Replace IC2.

IC14 is defective.

Check the signal waveform at 3, 6,or 18, 21 pin of IC14.

Replace IC14.

Rev. A

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Chapter 5 Troubleshooting
Table 5-8.Repair of the C209 MAIN Board (Continued) Symptom Printing is abnormal Condition Printing is not executed or, black specks or dots appears on the printing. Cause IC2 is defective. Checkpoint Check the output waveform at 7, 9 and 11 pin of CN8. Solution Replace IC2.

Paper feed operation is abnormal.

Paper feed motor does not work.

IC2 is defective.

Check the output waveform of at 1, 2pin and 23, 24 pin of IC15.

Replace IC2

IC15 is defective.

Check the output waveform of at 3, 6 pin or 18, 21 pin of IC15.

Replace IC15

5-12

Rev.A

EPSON Stylus Photo

5.4 Repair of the Printer Mechanism
This section provides instruction for repairing the printer mechanism. It describes various problems, symptom, likely causes, checkpoints, and solutions. Select appropriate symptom from the table and check each parts and its function as described in the checkpoint. Table 5-9. Repair of the Printer Mechanism Symptom Abnormal pump mechanism operation Condition Abnormal PF motor operation when the power is turned on. Cause Checkpoint Foreign substances Manually drive the are loaded in the PF PF drive gear gears. and check if it rotates normally. Solution Remove any foreign objects.

Ink is not absorbed or is poorly absorbed.

The PF motor is Check the inner coil defective. resistance and see (Refer to Table5-1) if there is any disconnection of the coil. Used ink does not The pump tube is Check the tube go through the crashed. visually. waste ink tube. Check the capping rubber visually. Check if the tube is out of the cap visually. Check the bulb operation visually.

Exchange the PF motor.

Fix the crashed part by the airgun.

Capping rubber is damaged or deformed. The tube is out of the cap. Pump bulb is not closed at absorption. Abnormal carriage Abnormal carriage Foreign substance operation. operation at power in the CR drive on. gear. CR motor is defective.

Replace the cap mechanism. Connect the tube properly. Replace the cap mechanism. Remove any foreign substances. Replace the CR motor.

Check visually if there is any substances or not. Check the inner coil resistance and see if there is any disconnection of the coil. Abnormal carriage Carriage movement Check whether the operation during is not smooth. carriage moves printing. smoothly when moved manually. Check tension of the timing belt.

Clean and lubricate the carriage guide axis. Adjust tension mechanism or exchange it. Remove any foreign substances.

Printing is not performed.

The carriage moves, but no printing is performed.

Check if there is any foreign substances in the carriage path. Head FFC is out of Check if the head Connect the FFC connection. FFC on the board or properly. carriage is connected surely. The FFC is Check the FFC by using Replace the FFC. disconnected a tester. inside. I/C is defective. Install a new I/C and Replace I/C. perform the self-test. Head unit is If the condition does Replace the head defective. not improve even unit. after 2or 3 times cleaning operation, replace the head unit and perform the self-test.

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Chapter 5 Troubleshooting
Table 5-10. Repair of the Printer Mechanism (Continued.) Cause Check-point Solution Print head surface is Perform the cleaning Perform the Abnormal printing Only a particular dot not clean. operation several cleaning. causes abnormal (dot missing) times and check printing. printing. The head unit is Perform the cleaning If condition does not defective. operation several improve even after times and check the cleaning, replace printing. the head. Absorber in the cap Check the absorber Replace the is touching the head in the cap visually. absorber in the cap if surface. it is deformed. A dot is not printed Print head surface Perform the cleaning Perform the occasionally. is not clean. operation several cleaning. (dot-missing) times and check printing. The head FFC is Check the FFC by Replace the head disconnected inside. using a tester. FFC. The head FFC is out Check if the head Connect the FFC of connection. FFC on the board or properly. carriage is connected surely. The head unit is Perform the cleaning If condition does not detective. operation several improve even after times and check the cleaning, replace printing. the head. I/C is defective. Install the new I/C Replace I/C. and perform selftest. Black specks or The head FFC is out Check if the head Connect the FFC dots. of connection. FFC on the board or properly. carriage is connected surely. The head unit is Check connection Replace the head if detective. with the head FFC. there is no connection problem with the FFC. A vertical line is not Bi-directional Perform Bi-D Refer to Chapter4. aligned. alignment is not adjustment. adjusted. White line appears Head angle is not Perform head angle Refer to Chapter4. in the image data. correct. adjustment. Paper feed assembly Perform paper feed Refer to Chapter4. adjustment is not assembly correct. adjustment Dot shooting direction is tilted because head surface is not clean I/C is defective. Head unit is defective. Perform the cleaning Perform the operation several cleaning operation. times and check printing. Install a new I/C and Replace I/C. perform the self-test. Perform the cleaning Replace the head operation several unit. times and check printing. Symptom Condition

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Rev.A

EPSON Stylus Photo
Table 5-11. Repair of the Printer Mechanism (Continued) Symptom Abnormal paper feeding. Solution Clean the PF roller by the cleaning sheet. Replace the PF roller if it does not recover. Abnormal operation Check movement of Replace ASF. of the hopper. the ASF hopper visually. Malfunction of ASF Check if the ASF Replace gears of drive change-over. gear rotates visually. the ASF drive change-over. Printing start point is Friction of the PF Check if the PF Clean the PF roller not right. roller. roller slips during by the cleaning paper feeding. sheet. Replace the PF roller if it does not recover. Printer stops during Fatal error appears. ASF sensor is Check the signal Replace ASF initialization. defective. level of the ASF sensor. sensor.(Refer to Table 5-2) PE sensor is Check the signal Replace PE sensor. defective. level of the PE sensor.(Refer to Table 5-2) HP sensor is Check the signal defective. level of the HP sensor .(Refer to Table 5-2.) Head FFC is Check if the head Connect the head disconnected. FFC is connected. FFC. CR motor is defective. Check the CR motor Replace the CR cable is connected. motor if there is no problem in the cable connection. Check if the PF Replace the PF motor cable is motor if there is no connected. problem in the cable connection. Condition Paper is not fed. Causes Friction of the PF roller. Checkpoint Check if the PF roller rotates when paper is not fed.

PF motor is defective.

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