Epson 4004677 Chapter 5 Troubleshooting

Chapter 5 Troubleshooting

Table of Contents

5.1 OVERVIEW 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 - C137 PSB/PSE BOARD 5-9

5.4 UNIT REPAIR - C164 MAIN BOARD 5-10

5.5 UNIT REPAIR - PRINTER MECHANISM (M-4A11) 5-12

LIST OF FIGURES

Figure 5-1. Troubleshooting Process Flowchart. . . . . . . . . . . . . . . . . . . . . . . 5-1

LIST OF TABLES

Table 5-1. Motor Coil Resistance Test Points. . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Table 5-2. Sensor Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Table 5-3. Sensor Test Points . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Table 5-4. Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Table 5-5. Symptoms and Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Table 5-6. Repair of the C137 PSB/PSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Table 5-7. Repair of the C164 MAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Table 5-8. Repair of the Printer Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Contents

Main Chapter 1 Product Description Page 1.1 FEATURES Figure 1-1. Exterior View of the Stylus Pro XL Table 1-1. Interface Cards 1.2 SPECIFICATIONS 1.2.1 Printing Specifications Figure 1-2. Nozzle Configuration Table 1-2. Print Speed and Printable Columns Table 1-3. Character Tables Not supported 1.2.2 Paper Handling Specifications 1.2.3 Paper Specifications Table 1-4. Cut Sheet Paper Specifications Note: Table 1-5. Envelope Specifications Note: Figure 1-3. Printable Area for Cut Sheets Figure 1-4. Printable Area for Envelopes Table 1-6. Adjust Lever Settings Figure 1-5. Setting the Adjust Lever 1.2.4 Ink Cartridge Specifications F); however, it can be used after it returns to room temperature. C(37 1.2.5 Electrical Specifications Table 1-7. Rated Electrical Ranges 1.2.6 Environmental Conditions Table 1-8. Acceptable Environmental Conditions : For printer operation, conditionsmust be in the range shown in the figure below. : These conditions are applicablewhen the printer is in its shipping container. : Without condensation. Page 1.3 INTERFACE SPECIFICATIONS 1.3.1 ParallelInterface Specifications Figure 1-7. Data Transmission Timing Note: Transition time (rise time and fall time) of every input signal mustbe less than 0.2 s. Table 1-9. Signal and Connector Pin Assignments for Parallel Interface * The I/O column indicates the direction of the signal as viewed from the printer. 1.3.2 Serial Interface Specifications Table 1-10. DTR and X-ON/X-OFF Protocol RXD TXD Table 1-11. Signal and Connector Pin Assignments for Serial Interface 1.4 OPERATIONS 1.4.1 Control Panel Figure 1-8. Control Panel Appearance Buttons Indicators 1.4.2 Panel Operation at Power On Table 1-12. Printer Condition Panel Status 1.4.3 Default Settings 1.4.3.1 DefaultSetting Items Table 1-13. Default Setting Items Table 1-14. Characteristics of Print Direction Mode Table 1-15. Printing Direction and ESC U Command Table 1-16. Language Selection Setting Value Table 1-17. Feature Selection Table 1-18. Character Table Selection Operate LED Data LED LED 1.4.4 Error Conditions Table 1-19. Error Indications 1.4.5 Printer Initialization 1.4.5.1 HardwareInitialization 1.4.5.2 SoftwareInitialization 1.5 MAIN COMPONENTS 1.5.1 MainControl Board (C162 MAIN Board) Figure 1-9. C162 MAIN Board Component Layout 1.5.2 Power Supply Board (C137 PSB/PSE Board) Figure 1-10. C137 PSB / PSE Board Component Layout 1.5.3 Control Panel (C137 PNL Board) Page Chapter 2 Operating Principles Page 2.1 OVERVIEW 2.2 OPERATING PRINCIPLES OF THE PRINTER MECHANISM Figure 2-1. Printer Mechanism Block Diagram 2.2.1 Printer Mechanism Figure 2-2. Structure of Printhead Principles of the Printing Operation Figure 2-3. Principles of the Printing Operation Page 2.2.2 Carriage Drive Mechanism Table 2-1. Carriage Drive Motor Specifications Figure 2-4. Carriage Drive Mechanism Table 2-2. Drive Terms 2.2.2.1 Platen Gap Adjust Lever Table 2-3. Platen Gap Adjust Lever Position Figure 2-5. Platen Gap Adjust Lever Operation Gap 2.2.3 Paper Feed Mechanism Table 2-4. Paper Feed Drive Motor Specification Table 2-5. Drive Terms Figure 2-6. Paper Feed Mechanism 2.2.4 Ink System Figure 2-7. Ink System Block Diagram 2.2.5 Pump Mechanism Drive: Pump Mechanism Figure 2-9. Switch Lever Set Drive: Switch Lever Set Figure 2-8. Pump Mechanism Block Page Table 2-6. Pump Mechanism Operation Figure 2-12. Pump Operation 2.2.6 Cap Mechanism 2.2.7 WipingMechanism Figure 2-14. Wiping Mechanism Figure 2-13. Cap Mechanism 2.3 OPERATING PRINCIPLES OF THE ELECTRICAL CIRCUITS Figure 2-15. Block Diagram of the Electrical Circuitry 2.3.1 OperatingPrinciples of the Power Supply Circuit Table 2-7. DCVoltage Distribution R-T02 Head Figure 2-16. Power Supply Circuit Block Diagram 2.3.2 Operating Principles of the Main Control Circuit REV.-A 2-15 From B DMAREQ Figure 2-17. Main Control Circuit Block Diagram Figure 2-18. Reset Circuit Block Diagram Figure 2-19. Sensor Circuit Block Diagram 2.3.2.3 Carriage Motor Drive Circuit Table 2-8. Serial Data Contents Figure 2-20. Carriage Motor Circuit Block Diagram CRB (IC2) 17 CRVRF REF A Figure 2-21. Serial Data Transfer Procedure 2-18 REV.-A 2.3.2.4 Paper Feed Motor Drive Circuit REV.-A 2-19 Table 2-9. Paper Feed Motor Drive Modes Figure 2-22. Paper Feed Motor Drive Circuit Diagram 2.3.2.5 Printhead Drive Circuit Figure 2-23. Normal / Micro Dot Mode Switch Block Micro Dot Printing Mode REV.-A 2-21 On Carriage (Head Driver Board) 6 Figure 2-24. Trapezoidal Drive Waveform 23 68 SI DO32-17 Figure 2-26. DMA Controller Operation 2.3.2.7 DRAM Refresh Controller Table 2-10. Junction Method (CPU 2 CAS DRAM) 23 79 Figure 2-28. Junction Method (CPU DRAM) Figure 2-27. DRAM Cycle Timing 2.4 INK SYSTEM MANAGEMENT 2.4.1 Ink Operations Page 2.4.2 Timer and Counter 2.4.2.1 ProtectCounter Note for Service Chapter 3 Disassembly and Assembly Page 3.1 OVERVIEW 3.1.1 Precautions for Disassembling the Printer ATTENTION 3.2 DISASSEMBLY AND ASSEMBLY 3-2 REV.-A Figure 3-1. Disassembly Flowchart 3.2.4 3.2.2 DISASSEMBLY/ASSEMBLY POINT Figure 3-2. C137 PNL Control Panel Removal Figure 3-3. Upper Case Removal 3.2.2 Power Supply Unit (C137 PSB/PSE Board) Removal CBS (M3x8) C162 MAIN Board CBS(O) (M3x6) C137 PSB Board CBB (M3x12) 3.2.3 Main Controller (C162 MAIN Board) Removal Figure 3-5. Main Controller Removal ASSEMBLY POINT REQUIRED ADJUSTMENT 3.2.4 Printer Mechanism (M-4A10) Removal DISASSEMBLY/ASSEMBLY POINT Figure 3-6. Printer Mechanism (M-4A60) Removal Table 3-1. Insertion Location for Block Resistors 3.2.5 Printer Mechanism Disassembly 3.2.5.1 PrintheadUnit Removal Figure 3-7. Ink Cartridge Clamp Removal Page Table 3-2. Insertion Location of the Block Resistors REQUIRED ADJUSTMENT Figure 3-10. Head Spacer Position Spacer Setting Locations Spacer Head Nose (For Black Head) 3.2.5.2 Carriage Unit Removal ADJUSTMENT REQUIRED Figure 3-11. Front Frame Removal Figure 3-12. Carriage Unit Removal Grounding Wire Parallelism Adjust Bushing Pulley Lever Figure 3-14. Pump Unit Removal 3.2.5.4 Cleaner Head Replacement Cleaner Lever Figure 3-14. Cleaner Head Replacement 3.2.5.5 CR Motor Removal 3.2.5.6 PF Motor Removal Figure 3-15. CR Motor Removal Figure 3-16. PF Motor Removal 3.2.5.7 Carriage Home Position Sensor Removal 3.2.5.8 PE Sensor Removal Sensor Cable Carriage Home Position Sensor Figure 3-18. Carriage Home Position Sensor Removal Figure 3-19. PE Sensor Removal Stylus Pro Service Manual Disassembly and Assembly 3.2.5.9 Paper Feed Roller Assembly Removal Figure 3-19. Tension Roller Assembly Removal Figure 3-20. Paper Feed Roller Assembly Removal 3.2.5.10 Upper Frame Removal ASSEMBLY POINT Figure 3-21. Upper Frame Removal Figure 3-22. Attaching the Torsion Spring Chapter 4 Adjustments List of Table 4.1 OVERVIEW Table 4-1. Required Adjustments 4.1.1 Destination Data Writing Operation 4.1.2 Bi-D (Bidirectional Printing) Alignment Adjustment 4.1.3 Head Gap Adjustment (Black and Color Head) Figure 4-1. Head Gap Adjustment Sample 4.1.4 Black Head Angle Adjustment Rev. A 4-5 Black Head (Angle Adjustment Concept) Black Head (Reverse Side) Figure 4-4. Black Head Angle Adjustment Sample Figure 4-5. Spacer Selection Figure 4-6. Removing the Rubber Cap Figure 4-7. Angular Spacer Replacement Method 4.1.5 Black - Color Head Vertical Adjustment Figure 4-8. Black-Color Head Vertical Adjustment Concept Figure 4-9. Linear Spacer Selection Sample Rubber Cap Figure 4-10. Removing the Rubber Cap Screw 3 Figure 4-11. Linear Spacer Replacement Method 4.1.6 Color Head Angle Adjustment Figure 4-14. Relationship between the Shape and Thickness Figure 4-15. Spacer Selection Figure 4-16. Removing the Rubber Cap Figure 4-17. YMC Angular Spacer Replacement 4.1.7 Platen Gap Adjustment Table 4-2. Gap and Adjustment Direction Figure 4-18. Adjusting the Platen Gap 4.1.8 Internal Timer Reset Operation Figure 4-19. Confirming the Gap Chapter 5 Troubleshooting Page 5.1 OVERVIEW Figure 5-1. Troubleshooting Process Flowchart Table 5-1. Motor Resistances Table 5-2. Sensor Status Table 5-3. Error Codes 5.2 UNIT LEVEL TROUBLESHOOTING Table 5-4. Symptom and Problem 5.2.1 Printer does not operate at power on. START 5-4 Rev. -A END 5.2.2 Error is detected. START Rev. -A 5-5 YES END END 5.2.3 Failure occurs during printing. 5-6 Rev. -A 5.2.4 Printer does not feed the paper correctly. START Rev. -A 5-7 END END 5.2.5 Control panel operation is abnormal. START 5-8 Rev. -A END 5.3 UNIT REPAIR - C137 PSB/PSE BOARD Table 5-5. Repair of the C137 PSB/PSE 5.4 UNIT REPAIR - C162 MAIN BOARD Table 5-6. Repair of the C162 MAIN Table 5-6. Repair of the C162 MAIN (Cont.) 5.5 UNIT REPAIR - PRINTER MECHANISM (M-4A60) Table 5-7. Repair of the Printer Mechanism Table 5-8. Repair of the Printer Mechanism (Continued) Stylus Pro ServiceManual Troubleshooting Table 5-7. Repair of the Printer Mechanism (Cont.) Chapter 6 Maintenance 6.1 PREVENTIVE MAINTENANCE Stylus Pro Service Manual Maintenance 6.2 SERVICE MAINTENANCE 6.2.1 PrintheadCleaning 6.2.2 WasteInk Drain Tank Replacement Maintenance Stylus Pro Service Manual 6.3 LUBRICATION AND ADHESIVES Table 6-1. Recommended Lubricants Note: E = EPSON Exclusive product (Not commercially available) Table 6-2. Lubrication and Adhesive Points Stylus Pro Service Manual Maintenance Page Page Page Appendix List of Table A.1 CONNECTOR SUMMARY Thefigure below shows the interconnection between the m ajorcomponents of the Stylus Pro XL. Rev. A A-1 Figure A-1. Interconnection of Major Components C137 PSB/PSE Table A-1. Connector Summary Table A-2. Connector Pin Assignments CN1 Table A-3. Connector Pin Assignments CN2 Table A-4. Connector Pin Assignments CN3 Table A-5. Connector Pin Assignments CN5 Table A-6. Connector Pin Assignments CN6 Table A-7. Connector Pin Assignments CN7 Table A-8. Connector Pin Assignments CN8 Table A-9. Connector Pin Assignments CN9 Table A-10. Connector Pin Assignments CN10 Table A-11. Connector Pin Assignments CN11 Table A-12. Connector Pin Assignments CN12 Table A-13. Connector Pin Assignments CN13 Table A-14. Part No. Reference Table