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Epson 3000 PREFACE, APPENDIX, CHAPTER 4. ADJUSTMENT, CHAPTER 6. MAINTENANCE, CHAPTER 5. TROUBLESHOOTING, CHAPTER 1. GENERAL DESCRIPTION, CHAPTER 2. OPERATING PRINCIPLES

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PREFACE

This manual describes functions, theory of electrical and mechanical operations, maintenance, and repair of Stylus COLOR 3000.

The instructions and procedures included herein are intended for the experience repair technician, and attention should be given to the precautions on the preceding page. The Chapters are organized as follows:

CHAPTER 1. GENERAL DESCRIPTION

Provides a general product overview, lists specifications, and illustrates the main components of the printer.

CHAPTER 2. OPERATING PRINCIPLES

Describes the theory of printer operation.

CHAPTER 3. DISASSEMBLY AND ASSEMBLY

Includes a step-by-step guide for product disassembly and assembly.

CHAPTER 4. ADJUSTMENT

Includes a step-by-step guide for adjustment.

CHAPTER 5. TROUBLESHOOTING

Provides EPSON-approved techniques for troubleshooting.

CHAPTER 6. MAINTENANCE

Describes preventive maintenance techniques and lists lubricants and adhesives required to service the equipment.

APPENDIX

Describes connector pin assignments, circuit diagrams, circuit board component layout and exploded diagram.

The contents of this manual are subject to change without notice.

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Contents

SEIKO EPSON CORPORATION NOTICE General Notice: Copyright © 1997 by SEIKO EPSON CORPORATION Nagano, Japan PRECAUTIONS WARNING CAUTION WARNING CAUTION PREFACE CHAPTER 1. GENERAL DESCRIPTION CHAPTER 2. OPERATING PRINCIPLES CHAPTER 3. DISASSEMBLY AND ASSEMBLY CHAPTER 4. ADJUSTMENT Page TABLE OF CONTENTS Chapter Product Descriptions 1.1 Overview 1.2 Options and Consumables Table 1-2.Options and Consumables (continued) 1.3 Specification 1.3.2 Control codes 1.3.3 Character tables Legal and 14 international character sets Typeface Combination of character tables and typefaces 1.3.4 Paper Feeding 1.3.5 Paper Handling Cut Sheet Table 1-6.Cut Sheet Specification Transparency Table 1-7.Transparency Specification Index Card Table 1-9.Index Card Specification Labels (Cut Sheet) Table 1-10.Label Specification Continuous Paper 1.3.6 Printable Area Cut Sheet / Label (cut sheet) Figure 1-3.Printable Area for Cut Sheet Table 1-14.Minimum Margins for Different Cut Sheet Sizes Figure 1-4.Printable Area for Envelopes Table 1-15.Minimum Margin for Envelope Continuous Paper / Label (Continuous Paper) Figure 1-5.Printable Area for Continuous Paper Note) Base sheet of label (continuous) is not printing area 1.3.7 Adjust Lever Table 1-16.Adjust Lever Position PG Adjust Lever Printer Cover Figure 1-6.Adjust Lever Settings 1.3.8 Ink Specification Black ink cartridge Table 1-17.Black Ink Cartridge Specifications Color ink cartridge Table 1-18.Color Ink Cartridge Specifications 1.3.10 Electric Specifications 120 V version 220 - 240V version 1.3.11 Environmental Conditions Temperature 1.3.12 Reliability 1.3.13 Safety Approvals 220 - 240 V version 1.3.14 CE Marking 1.3.15 Acoustic Noise 1.4 Interfaces Figure 1-8.Data Transmission Timing Table 1-20.Data Transmission Timing Table 1-21.Typical Time of Tuck Table 1-22.Connector Pin Assignments and Signals (Forward Channel) Return GND Pin Signal level Reverse Channel Synchronization Handshaking Data transmission timing 1.4.2 Mac Serial Interface Standard Bit rate Word format Recommended I/F cable 1.4.3 Optional Interface Reply message In case of using Co-ax / Twin-axI/F card In case of using an I/F card other than Co-ax / Twin-axI/F card Table 1-26.Replyfor Option Command 1.4.4 Prevention Hosts from Data Transfer Time-out 1.4.5 Interface Selection Manual selection Automatic selection Interface State and Interface Selection 1.5 Operation Panel Functions (Normal Usage) Table 1-28.Panel Functions Note) TOF (Top Of Form) adjustment Tear off adjustment Panel Functions with Power On Indicators Table 1-30.Printer Condition and Printer Status (1) LED Color Indication 1.5.2 Default Setting 1.5.2.1 Setting Method See Figure 1-11for the default setting method Figure 1-11.Default Setting Flowchart The latest values set before power-offare stored in the EEPROM 1.5.2.2 Setting Menu Media Type Table 1-31.Default Setting Menus Menu Setting *1 Table 1-32.Print Direction Mode Characteristics Black and White Printing YMCK Printing (color) Table 1-33.Printing Direction and ESC U Command Character Mode 1.5.3 Printer Adjustment Mode The EPSON Stylus COLOR 3000 allows users to adjust the following items Table 1-35.Printer Adjustment Patterns Pattern No Items 1.5.4 Printer Initialization Power-onInitialization Operator Initialization Software Initialization 1.5.5 Self-testPrinting Mode 1.5.8 Error Condition Table 1-36.Printer Condition and Panel Status (2) 1.6 Main Components 1.6.2 C172 PSB/PSE Board Figure 1-14.C172 PSB/PSE Board Component Layout 1.6.3 Control Panel 1.6.4 Printer Mechanism Unit (M-4J60) 1.6.5 Housing Operating Principles 2.2 Printer Mechanism Operating Principle 2.2.1 Printer Mechanism 2.2.2 Printing Mechanism 2.2.5 Platen Gap (PG) Adjust Mechanism 2.1 Overview 2.2 Printer Mechanism Operating Principle Operating Principles 2.2.2 Printing Mechanism 2.2.2.1 Printhead Structure Figure 2-2.Printhead Structure 2.2.2.2 Printing Process <Step 1> Normal state <Step 2> Ejecting state Normal State Ejecting State 2.2.3 Carriage () Mechanism Table 2-1. Motor Specification Table 2-2.CR Motor Drive Terms Figure 2-4.CR Mechanism 2.2.4 Paper Feed Mechanism Table 2-3.PF Motor Specification Table 2-4.PF Motor Drive Terms Figure 2-5.Paper Feeding Mechanism 2.2.4.1 ASF (Auto Sheet Feeder) Mechanism Figure 2-6.ASF Mechanism 2.2.4.2 Tractor Mechanism Figure 2-7.Tractor Mechanism 2.2.4.3 Manual Feed Mechanism 2.2.5 Platen Gap () Adjust Mechanism Table 2-5.Platen Adjust Lever Positions Figure 2-8.Platen Gap Adjustment Mechanism 2.2.6 Ink System Figure 2-9.Ink System Mechanism 2.2.6.1 Pump Mechanism Figure 2-10.Pump Operation Table 2-6.Pump Motor Specification Item Description 2.2.7 Capping Mechanism Figure 2-11.Capping Mechanism 2.2.7.1 Wiping/CR Lock Mechanism Figure 2-12. Wiping/Carriage Lock Mechanism 2.3 Electrical Circuit Operation Principles Figure 2-14.Power Supply Circuit Diagram +5 VDC line over voltage protection circuit +5 VDC line constant voltage control circuit +42 VDC line over voltage protection circuit +42 VDC line constant voltage control circuit 2.3.2 MAIN Control Board Table 2-8.Location and function of the Major Components Location Head Control Panel Sensors Control Signals Control Signal 2.3.2.1 Reset Circuits Figure 2-16.Reset Circuit Block Diagram 2.3.2.2 Sensor Circuits HP : Output from the HP(Home Position) sensor PE_R : Output from the rear PE (Paper End) sensor Thermistor ASF_PW : Output from the ASF PW (Paper Width) sensor Table 2-9.Paper Width Range ASF_PL : Output from the PL (Paper Length) sensor Table 2-10.Paper Length Detecting Range ASF_PQ :Output from the PQ (Paper Quantity) sensor GAP : Output from the PG (Platen Gap) sensor CR_PW : Output from the CR PW (Paper Width) sensor CPU H8S/2655 2.3.2.3 Motor Driver Circuits Figure 2-18.CR Motor Block Diagram 2.3.2.4 PF Motor Driver Circuit Figure 2-19.PF Motor Driver Circuit Block Diagram 2.3.2.5 Printhead Driver Circuit E05B33 (IC6) IR2C72C IR2C73C C203 MAIN Control Circuit Board Common driver circuit for the black printhead Nozzle selector circuit Common driver circuit BAHDATA BBHDATA #1#64 Color printhead nozzle selector circuit Figure 2-22.Color Data Transmission Timing Special printing Table 2-11.Special Printing Availability Paper Type 180 dpi 360 dpi 2.4 Ink System Management 2.4.2 Counters Protect Counter A Black/Color One-timeFlag Ink Consumption Counter Disassembly and Assembly 3.1.2 Tools 3.2.4 Printhead Removal 3.2.5 HP Sensor Removal 3.2.6 Printer Mechanism Removal 3.1 Overview Disassembly and Assembly 3.1.2 Tools Table 3-1.Tools Tools Distributor Part No 3.2 Disassembly and Assembly 3.2.1 Upper Housing Removal Figure 3-2.Tractor Unit Removal Figure 3-3.Panel Unit Removal WORK POINT Figure 3-4.Upper Housing Removal 3.2.2 ROM Replacement 3.2.3 CR PW (Paper Width) Sensor Board Assembly Removal Figure 3-5.CR PW Sensor Board Assembly Removal 3.2.4 Printhead Removal Be careful handling the damper assembly so that the ink doesn’t leak When removing the black head, be sure not to catch the color head cable REQUIRED ADJUSTMENT After replacing the head, perform necessary adjustments. (See Chapter 4.) Figure 3-6.Black/Color Head Removal 3.2.5 HP Sensor Removal Figure 3-7.HP Sensor Removal 3.2.6 Printer Mechanism Unit Removal 14) WORK POINT REQUIRED ADJUSTMENT Figure 3-8.Printer Mechanism Unit Removal 3.2.7 PSB/PSE Board Assembly Removal WARNING Figure 3-9.PSB/PSE Board Removal 3.2.8 C203 MAIN Board Assembly Removal Be careful in servicing the lithium battery. (See Section 3.1.1.) Pay attention to the sharp edges of the upper shield plate Figure 3-10.C203 MAIN board Removal 3.2.9 Main Waste Ink Drain Pad Removal Figure 3-11.Main Waste Ink Drain Pad Removal 3.2.10 PL (Paper Length) Sensor Removal Figure 3-12.PL Sensor Removal 3.2.11 Printer Mechanism Disassembly 3.2.11.1 CR Motor Removal Figure 3-13.CR Motor Removal Figure 3-14.Adhering the CR Motor Fan to the CR Motor 3.2.11.2 Pump Motor Assembly Removal Figure 3-15.Pump Motor Assembly Removal 3.2.11.3 PF Motor Assembly Removal Figure 3-16.PR Motor Assembly Removal 3.2.11.4 Front/Rear PE Sensor Removal Figure 3-17.Front/Rear PE Sensor Removal 3.2.11.5 Release Sensor Removal Figure 3-18.Release Sensor Removal 3.2.11.6 Paper Eject Frame Unit Removal Figure 3-19.Paper Eject Frame Unit 3.2.11.7 Pump Unit Removal Figure 3-20.Pump Unit Installation 3.2.11.8 Edge Guide Unit Removal Figure 3-21.Edge Guide Unit Removal Page 3.2.11.9 PQ (Paper Quantity) Sensor Board Assembly Removal Figure 3-23.PQ Sensor Removal 3.2.11.10 ASF PW (Paper Width) Sensor Removal PW sensor sliding plate Figure 3-24.PW Sensor Removal 3.2.11.11 Ink Cartridge Holder Unit Removal Note that the coupling screw compresses the tube fixing O-ring 1)Insert the tube to the coupling screw Figure 3-25.Ink Cartridge Holder Removal 3.2.11.12 Ink Sensor Assembly Removal 3.2.11.13 Ink Cartridge Sensor Assembly Removal Figure 3-26.Ink Sensor /Ink Cartridge Sensor Assembly Removal 3.2.11.14 CR Unit Removal Figure 3-27.CR Unit Removal Page 3.2.11.15 LD Shaft Removal Figure 3-29.Ink Tube Unit Removal Figure 3-30.Base Frame Assembly Removal Figure 3-31.Paper Eject Drive Unit Removal Engage the LD gear and the gear (29) in the ASF gear set as shown in Figure LD Gear ASF Transmission Gear Set Bushing LD shaft Edge Guide 3.2.11.16 PF Roller Removal Figure 3-34.PF Roller Removal 3.2.11.17 Rear Paper Guide Removal Figure 3-35.Rear Paper Guide Removal 3.2.11.18 Middle Frame Unit Removal Figure 3-36.Middle Frame Removal Adjustment 4.1 Overview Adjustment 4.1.1 Platen Gap Adjustment The specified value range for the platen gap is 0.02 mm Figure 4-1.Thickness Gauge Placement Table 4-2.Direction for turning the Parallelism Adjust Bushing Start END Figure 4-2.Platen Gap Adjustment Flowchart 4.1.2 Input of Market Setting 2.C203011 (EAI) 2. Adjustment and Check” “E. END” <<<Main 4.1.3 Head Voltage Write Operation “Market Setting” “2. Adjustment & Check “1. VH, EEPROM” <<<Adjustment and Check 4.1.3.1 Finding Out the Head Voltage “2. Adjustment & Check” “7. A4” 6.TITLE BK : 4.1.4 Black Head Angular Adjustment Figure 4-4.Head Angular Adjustment “2. Angle Adjustment” .END” Yes End Figure 4-5.Head Angle Adjustment Flowchart 4.1.5 Head Vertical Adjustment “3. Vertical Adjustment” Figure 4-6.Head vertical Adjustment Flowchart 4.1.6 Head GAP Adjustment “4. Gap” “Gap End Figure 4-7.Head Gap Adjustment Flowchart 4.1.7 Uni-DAdjustment “5 Uni-d” “Uni-d” End Figure 4-8. Uni-DAdjustment Flowchart 4.1.8 Bi-DAdjustment “6 Bi-d” “Bi-D” Figure 4-9. Bi-DAdjustment flowchart 4.1.9 Sensor Check “3. Sensor Check” 4.1.9.1 PQ Sensor Adjustment “Sensor Check” “1.CR-PWS” “2. ASF Quantity” Figure 4-10.Setting the Paper Quantity Detective Adjust Tool Page Page Toubleshooting 5.1 General Description Troubleshooting Table 5-2.Sensor Status Sensor Connector No Signal level Power Pause Out 5.2 Unit Level Troubleshooting 1. The printer does not operate at all END Figure 5-2.Flowchart (1) 2. An error is indicated Figure 5-3.Flowchart (2) 3. Printing operation is abnormal Figure 5-4.Flowchart (3) 4. Paper is fed abnormally Figure 5-5.Flowchart (5) 5. The control panel operates abnormally properly Replace the control panel Figure 5-6.Flowchart (5) 5.3 Repair of the C172 PSB/PSE Board at Component Level 5.4 Component Repair of the C203 MAIN Board Table 5-7.Component Repair of the C211 MAIN Board (continued)) Symptom : CR does not operate normally Symptom : The printer feeds paper abnormally Table 5-8.Component Repair of the C211 MAIN Board (continued)) Symptom : The pump does not operate normally Symptom : The printer does not perform Self-test 5.5 Repair of the M-4J60Printer Mechanism Table 5-10.Repair of M-4I60Printer Mechanism(continued) Symptom : CR motor operates abnormally (continued) Symptom :The printer does not print Symptom : The printer prints abnormally Table 5-11.Repair of M-4I60Printer Mechanism(continued) Symptom : Abnormal printing (continued) Symptom : Paper is fed abnormally Symptom : The printer detects paper size incorrectly Maintenance Cleaning Service Maintenance Lubrication and Adhesive 6.1 Cleaning WARNING 6.2 Service Maintenance 6.3 Lubrication and Adhesive Table 6- 3. Adhesive Points NO Adhesive Points Page Page Figure 6-3.Adhesive Points Appendix A.1 Connector Summary A.1.1 Connector Pin Assignment Table A-1.Connector Summary Circuit Board A-2 PE_R A-4 PWS CCO BCO CR_PW Page A.2 Circuit Diagrams Page A-11 Page A .Rev Diagram Circuit Board PNL C203 .4-AFigure 13-A Page Page A.3 Component Layout A-17 A-18 A-19 A-20 A.4 Exploded Diagrams A-22 Page Page A.5 Dimension and Weight EPSON OVERSEAS MARKETING LOCATIONS EPSON AMERICA, Inc EPSON DEUTCHLAND GmBH EPSON UK LTD EPSON FRANCE S.A