Epson 4004677 5.1 OVERVIEW

5.1 OVERVIEW

The printer may exhibit different symptoms for the same problem, which makes troubleshooting

more difficult. However, this section provides simple and effective ways to facilitate

troubleshooting.The following flowchart illustrates the main steps of the troubleshooting process.

Table 5-1. Motor Resistances

Motor Resistance Range Temperature

CR Motor 10.0Ω±10% At 25 °C(77°F)

PF Motor 11.5Ω±10% At 25 °C(77°F)

Table 5-2. Sensor Status

Sensor Point Signal Level Status

PE Sensor CN8

Pin1(PE)toPin2

(GND)

H(5V) Paper exists

L (GND) No paper (paper end)

BCO Sensor CN11

Pin 8 (BCO)to

Pin7(GND)

L (GND) Black cartridge exists

H (5 V) No black cartridge

CCO Sensor CN12

Pin8(CCO)to

Pin7(GND)

L (GND) Color cartridge exists

H(5V) No color cartidge

HP Sensor CN9

Pin3(HPV)to

Pin2(GND)

L Athome position (HP)

HOut of HP

TH Sensor CN10

Pin10(SW0-5)to

Pin1(GND) Analog data Change the pulse width of

the charge pulse for the

common driver circuit

START

UNIT LEVEL TROUBLESH OOTI NG

UNIT REPAIR

[C137 PSB/PSE BOARD] UNIT REPAIR

[C162 MAIN BOARD]

UNIT REPAIR

[M-4A60 MECHANISM]

ASSEMBLY

AND

ADJUSTMENT

END

Figure 5-1. Troubleshooting Process Flowchart

Stylus Pro XL Troubleshooting

Rev. -A 5-1

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