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Epson STYLUS PRO XL 4004677 Service Manual

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EPSON COLOR INKJET PRINTER
Stylus Pro XL

SERVICE MANUAL

EPSON
4004677

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Summary of Contents for Epson STYLUS PRO XL 4004677

  • Page 1: Service Manual

    EPSON COLOR INKJET PRINTER Stylus Pro XL SERVICE MANUAL EPSON 4004677...

  • Page 2: Table Of Contents

    1.5.3 Control Panel (C137 PNL Board) ....... 1-20 1.5.4 Printer Mechanism (M-4A60) ........1-21 1.5.5 Housing .
  • Page 3 Table 1-9. Signal and Connector Pin Assignments for Parallel Interface Table 1-10. DTR and X-ON/X-OFF Protocol Table 1-11. Signal and Connector Pin Assignments for Serial Interface Table 1-12. Printer Condition Panel Status Table 1-13. Default Setting Items Table 1-14. Characteristics of Print Direction Mode Table 1-15.

  • Page 4: Features

    Stylus Pro XL 1.1 FEATURES The Stylus Pro XL is a 64 + 48-nozzle (monochrome and CMY) color ink jet dot matrix printer. The major features of this printer are: High-quality color print -Micro Dot 720 dpi printing -Plain paper 720 dpi printing...

  • Page 5: Table 1-1. Interface Cards

    Product Description Interface Card Serial interface card 32KB serial interface card 32KB parallel interface card 32KB IEEE-488 interface card ® LocalTalk interface card Twinax interface card Coax interface card The asterisk represents the last digit, which varies by country. Table 1-1. Interface Cards Model Number C823051/C823061 C823071/C823081...

  • Page 6: Specifications

    Stylus Pro XL 1.2 SPECIFICATIONS This section provides statistics and other detailed information for the printer. 1.2.1 Printing Specifications Print system: On demand ink jet system Nozzle configuration: 64 nozzles (16 48 nozzles (16 Yellow Cyan Magenta 1/90" 64/360" Figure 1-2. Nozzle Configuration...

  • Page 7: Table 1-3. Character Table

    - EPSON Prestige - EPSON Script [Scalable fonts] - EPSON Roman - EPSON Sans Serif - EPSON Roman T - EPSON Sans Serif H Control codes: ESC/P 2 and expanded raster graphics code Input data buffer: 64KB Bit map font...

  • Page 8: Paper Handling Specifications

    Stylus Pro XL 1.2.2 Paper Handling Specifications Feeding method: Friction feed paper is fed from the built-in auto sheet feeder (ASF). Notes: The following operations are not allowed. 1. Reverse feeding within 3 mm (0.12 in.) from the top edge of the paper or 16 mm (0.63 in.) from the bottom edge of the paper.

  • Page 9: Figure 1-3. Printable Area For Cut Sheet

    Product Description Printable area: Cut sheets (Left Margin) Figure 1-3. Printable Area for Cut Sheets Envelopes (Left Margin) Figure 1-4. Printable Area for Envelopes Notes: A: The minimum top margin = 3 mm (0.12 in.) B: The minimum left margin = 3 mm (0.12 in.) C: The minimum right margin is: A3+/US B+ size: 3mm (0.12 in.) A3 size:...

  • Page 10: Ink Cartridge Specifications

    Stylus Pro XL Setting the adjust lever: The adjust lever on the carriage unit must be set to the proper position for the paper thickness, as shown in Table 1-6. Table 1-6. Adjust Lever Settings Lever Position LEFT (Vertical) RIGHT (Horizontal) Figure 1-5.

  • Page 11: Electrical Specifications

    Temperature Humidity Shock resistance Vibration resistance : For printer operation, conditions must be in the range shown in the figure below. : These conditions are applicable when the printer is in its shipping container. : Without condensation. Humidity (% RH)

  • Page 12: Reliability

    Stylus Pro XL 1.2.7 Reliability Total print volume: Printhead life: 1.2.8 Safety Approvals Safety standards: Radio frequency interference (RFI): 1.2.9 Physical Specifications Dimensions (W D H): Weight: Rev.A 75,000 pages (A4, letter) 1,000 million dots/nozzle 120 V version: UL1950 with D3, CSA22.2 #950 with D3 220-240 V version: EN 60950 (TÜV, SEMKO, DEMKO,...

  • Page 13: Interface Specifications

    Product Description 1.3 INTERFACE SPECIFICATIONS The Stylus Pro XL is standard-equipped with an 8-bit parallel and serial interface. 1.3.1 Parallel Interface Specifications Data format: 8-bit parallel Synchronization: By STROBE pulse synchronization Handshaking: By BUSY and ACKNLG signals Signal level: TTL compatible level Adaptable connector: 36-pin 57-30360 (Amphenol) or equivalent Data transmission timing:...

  • Page 14: Table 1-9. Signal And Connector Pin Assignments For Parallel Interface

    — 15,18,34 — — The I/O column indicates the direction of the signal as viewed from the printer. Rev.A Description The STROBE pulse is used to read data from the host computer. The pulse width must be 0.5 s or more. Normally, it is HIGH, and data is latched with the rising edge of this signal.

  • Page 15: Serial Interface Specifications

    8-pin mini-circular connector Recommended I/F cable: Apple Table 1-11. Signal and Connector Pin Assignments for Serial Interface Pin No. Signal Name The I/O column indicates the data flow as viewed from the printer. 1-12 Buffer Space ® System Peripheral-8 cable I/O*...

  • Page 16: Operations

    1.4 OPERATIONS This section describes the basic operations of the printer. 1.4.1 Control Panel The control panel for this printer has 1 lock-type, 5 non-lock-type push buttons, and 14 LED indicators for easy operation of the various printer functions. Operate Figure 1-8.

  • Page 17: Panel Operation At Power On

    Data On when print data is in the input buffer. Data and Pause lights blink if an error occurs. On when the printer is out of paper. Blinks when a paper jam occurs. Paper Out No Ink Cartridge On when ink cartridge is out.

  • Page 18: Default Settings

    Stylus Pro XL 1.4.3 Default Settings The printer can save some printer setting parameters that define its functions at initialization. You can change these parameters by using the printer’s default setting mode. 1.4.3.1 Default Setting Items You can use the default setting mode to change settings listed in the table below. Activate default-setting mode by holding down Economy/Condensed while turning on the printer.

  • Page 19: Changing The Default Settings

    Italiana Español Press the Alt button. The printer prints the current settings using the selected language. It also prints a table showing how to change the printer settings. Press the Font button to advance through the setting menu. The current printer settings are indicated by the Courier, Roman T (PS), and San Serif H (PS) LEDs.

  • Page 20: Table 1-18. Character Table Selection

    ISO Latin 1T Bulgaria Repeat steps 4 and 5 to change other printer settings. The setting menu selection will return to the first menu after the last menu selection is over. Turn off the printer. The setting is stored in non-volatile memory.

  • Page 21: Error Conditions

    Hardware initialization is performed by: Turning on the printer. Sending the parallel interface INIT signal. (If the INIT signal is active when the printer is turned on, hardware initialization is started when the INIT signal becomes inactive.) When the hardware initialization is performed: The printer mechanism is initialized.

  • Page 22: Main Components

    Stylus Pro XL 1.5 MAIN COMPONENTS The main components of the Stylus Pro XL are: Printer mechanism (M-4A60) Main control board (C162 MAIN Board) Power supply unit (C137 PSB/PSE Board) Control panel board (C137 PNL Board) Housing 1.5.1 Main Control Board (C162 MAIN Board)

  • Page 23: Power Supply Board (C137 Psb/Pse Board)

    The power supply board (C137 PSB/PSE Board) consists of an RCC switching regulator circuit. This board is equipped with a power switch connected to the secondary circuit. Thus, if the printer is turned off, it can continue to operate in order to eject the paper and perform the head capping operation. The power on off signal is always monitored by the E05A96 gate array on the C162 MAIN Board, and the logic system recognizes the power switch status.

  • Page 24: Printer Mechanism (M-4A60)

    Figure 1-11. Printer Mechanism (M-4A60) 1.5.5 Housing The Stylus Pro XL housing consists of the printer cover, upper case, and the lower case. Attached to the housing are the front paper support and the ejected paper support with paper separator.
  • Page 25 2.2.1 Printer Mechanism ........
  • Page 26 List of Figures Figure 2-1. Printer Mechanism Block ....... . . 2-1 Figure 2-2.

  • Page 27: Overview

    Stylus Pro XL. 2.2 OPERATING PRINCIPLES OF THE PRINTER MECHANISM The Stylus Pro XL printer mechanism is composed of the printhead unit, paper feed mechanism, carriage drive mechanism, pump mechanism, and various sensors. The figure below shows a functional block diagram of the printer mechanism.

  • Page 28: Printer Mechanism

    The printer mechanism of this printer uses a drop-on-demand ink jet system similar to the system used on all other EPSON ink jet printers. However, the printhead in this system is completely redesigned to make it more compact and ensure a high level of reliability. The figure below shows the structure of the printhead and ink supply system.

  • Page 29: Figure 2-3. Principles Of The Printing Operation

    Stylus Pro XL Principles of the Printing Operation The printhead operates in one of two modes to eject ink from each nozzle: Normal state No electrical charge is applied to the MLP (Multi-Layer Piezoelectric) element attached to the back of the cavity, and pressure inside the cavity is kept at a constant level. Ejecting state The head data signal is applied to the specific nozzle control line to select the active nozzle for printing, and the MLP element is gradually charged by the drive voltage.
  • Page 30 Stylus Pro XL Micro Dot Printing mode The Stylus Pro XL printer has a special printing mode, called “Micro Dot Printing mode”. This printing mode can be selected by a command from the host computer. Using the Micro Dot printing mode can improve the quality of output. In Micro Dot Printing mode, the ink dot size became to be smaller than the normal dot size.

  • Page 31: Carriage Drive Mechanism

    4-phase, 200-pole, hybrid-type stepping motor mechanism, allowing the printer to stop the carriage or change the carriage movement at any position. The position of the carriage is recognized by the home position sensor, and position information is fed back to the carriage drive control circuit.

  • Page 32: Platen Gap Adjust Lever

    The platen gap adjust lever, which is attached to the carriage unit, needs to be set to an appropriate position for the paper thickness. To change the platen gap, put the printer in the PAUSE state; then press the Font button, while holding down the Alt button. The carriage unit moves the platen gap position automatically.

  • Page 33: Table 2-5. Drive Terms

    Stylus Pro XL Frequency Mode (pps) Paper loading 1600 ASF feed 1600 Paper feed Pump drive 1 1800 Pump drive 2 PF Transmission Gear PF Motor Pinion Gear Platen Drive Gear Paper Pickup Lever Tension Spring Figure 2-6. Paper Feed Mechanism REV.-A Table 2-5.

  • Page 34: Ink System

    Operating Principles 2.2.4 Ink System This printer’s ink system is composed of the following mechanisms: Ink cartridge Pump mechanism Cap mechanism Waste ink drain tank Wiping mechanism The figure below shows a diagram of the ink system. Color Head Air Valve Figure 2-7.

  • Page 35: Pump Mechanism

    Stylus Pro XL 2.2.5 Pump Mechanism The paper feed motor drives the pump mechanism when the transmission gear is moved to the position where the paper feed motor engages the pump mechanism gear trains, when the carriage unit is at the ink system home position. The figure below shows a block diagram of the pump mechanism.
  • Page 36 Operating Principles Stylus Pro XL Drive: Paper Feed Mechanism Carriage Figure 2-10. Paper Feed Mechanism Block Diagram Switch Lever: Reset Carriage D/E Reset Lever D/E Lever Figure 2-11. Switch Lever Reset 2-10 REV.-A...

  • Page 37: Table 2-6. Pump Mechanism Operation

    The pump draws ink from the printhead nozzles and drains it to the waste ink drain tank. The printer performs this operation to eliminate dust or bubbles in the nozzles. Figure 2-12 illustrates pump operation. When the paper feed drive motor rotates CW (forward), the color pulley pumps in the wheel pump unit rotate in the direction of the arrow while squeezing the ink tube to push the ink inside the tube out to the waste ink drain tank.

  • Page 38: Cap Mechanism

    The printer performs this operation automatically when print data is not received or when the printer power is turned off during printing or ink system operations. (The secondary circuit for the power switch allows this operation to be performed.) Also this printer has two caps, one for the black head and one for the color head.

  • Page 39: Operating Principles Of The Electrical Circuits

    2.3.1 Operating Principles of the Power Supply Circuit The power supply circuitry for this printer is provided either by the C137 PSB Board (120 VAC) or the C137 PSE Board (220-240 VAC). Both boards are identical in design and functionality, except for the components in the primary circuit that accommodate the specified input voltage.

  • Page 40: Figure 2-16. Power Supply Circuit Block Diagram

    CPU to remain active for a while after the printer is turned off. This allows the printhead to return to the capping position after power is off. The CPU mounted on the C137 MAIN Board always monitors the PSC (power on/off) signal. If this signal becomes LOW, the CPU resets each device after performing the head capping sequence.

  • Page 41: Operating Principles Of The Main Control Circuit

    2.3.2 Operating Principles of the Main Control Circuit The main control circuit of this printer is the C162 MAIN Board. This circuit is controlled by the 16-bit CPU H8/3003 (IC1), running at 14.7456 MHz. This CPU has a unique architecture capable of handling data on the data bus at either an 8-bit or 16-bit bus width.

  • Page 42: Reset Circuit

    PE sensor The mechanical switch paper end (PE) sensor is built into the printer mechanism to determine whether there is paper in the printer or not. A LOW level from the signal indicates that no paper is loaded. BCO sensor,...

  • Page 43: Carriage Motor Drive Circuit

    The carriage motor drive IC SLA7041MS (IC15) outputs a constant current to drive the carriage motor for the printer mechanism. Gate array E05A96EA (IC2) decides the motor phase and speed and then sends a signal to the carriage motor driver IC (SLA7041MS) using the 4-bit serial transmission line.

  • Page 44: Figure 2-21. Serial Data Transfer Procedure

    Operating Principles The following figure shows the contents of the four-bit serial data and how this data transacts with the SLA7041MS driver. The step time of the reference voltage is determined by the interval time of the STROBE pulse. +5 V Vref To Mot or (Phase Signal)

  • Page 45: Paper Feed Motor Drive Circuit

    Stylus Pro XL 2.3.2.4 Paper Feed Motor Drive Circuit The paper feed motor for this printer drives the following mechanisms: Paper feed mechanism Paper pickup mechanism Pump mechanism Driver IC SLA7041MS (IC14) drives the paper feed motor by a constant current. Its principle of operation is same as for the carriage motor drive circuit.

  • Page 46: Printhead Drive Circuit

    Operating Principles 2.3.2.5 Printhead Drive Circuit The printhead drive circuit for this printer is composed of the following two parts: Common drive circuit (trapezoidal drive pulse generation) Head drive circuit (nozzle control built on the printhead) SED5620D, the 64-bit thermal head driver in the head drive circuit on the carriage, is used as a nozzle selector to drive the printhead nozzles selectively.

  • Page 47: Figure 2-25. Printhead Drive Circuit Block Diagram

    Stylus Pro XL Micro Dot Printing Mode The Stylus Pro XL printer has a special printing mode, called “Micro Dot Printing Mode.” This printing mode can be selected by command from computer. Using Micro Dot Printing Mode can improve the quality of output. In Micro Dot Printing Mode, the ink dot size becomes smaller than the normal dot size.

  • Page 48: Dma Controller

    Operating Principles 2.3.2.6 DMA Controller Data from the host computer is received automatically by the STB signal via the external Centronics interface. The data is input to the input buffer on the DRAM (IC5). At this time, E05A96 detects the rising edge of the external STB signal and outputs the STBDMA (strobe DMA request) signal to the CPU.
  • Page 49 Stylus Pro XL 2.3.2.7 DRAM Refresh Controller The H8 CPU is equipped with a refresh controller in the internal controller. This CPU can contact the 16-bit-long IC5 DRAM, which is a 2 CAS type. The following table lists the junction method between the H8 CPU and the 2 CAS DRAM.

  • Page 50: Ink System Management

    Operating Principles 2.4 INK SYSTEM MANAGEMENT This section explains how the ink system is controlled to protect the printhead and ink supply system and to ensure high-quality output. Ink system control is composed of the following operations: Power On Cleaning Selection Micro Absorbing Cleaning Power Off Print Start...

  • Page 51: Ink Operations

    4 Power Off Operation This operation ensures the carriage is in the home position when the printer turns off, and prevents the disengage gear from turning continuously when the printer turns off. Power off operation is performed when the secondary side switch is turned off.
  • Page 52 16 Carriage Lock Set This operation prevents the carriage from moving out of the home position if the printer is turned off or is pauesd. This operation is performed when the carriage is in the ink system home position and no paper is loaded.

  • Page 53: Timer And Counter

    2.4.2.1 Protect Counter Protect counter A and Ink Amount Counter R values are stored in the EEPROM on the main board, and while the printer is on, this data is saved in the RAM on the main board. Protect Counter A This counter is used to manage the total amount of drained ink.
  • Page 54 3.2.4 Printer Mechanism (M-4A60) Removal ......3-7 3.2.5 Printer Mechanism Disassembly ....... . 3-8 3.2.5.1 Printhead Unit Removal.
  • Page 55 Figure 3-5. Main Controller Removal ....... . . 3-5 Figure 3-6. Printer Mechanism (M-4A60) Removal ..... . 3-7 Figure 3-7.

  • Page 56: Overview

    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 C162 MAIN Board of this printer. Be sure to observe the following instructions when servicing the battery: 1.

  • Page 57: Disassembly And Assembly

    Disassembly and Assembly 3.2 DISASSEMBLY AND ASSEMBLY Follow the precautions in Section 3.1.1 when disassembling the printer. This section consists of the subheads shown in the diagram below. See the exploded view of the printer in the Appendix, if necessary.

  • Page 58: Upper Case Removal

    3.2.1 Upper Case Removal 1. 1. Remove the printer cover (center of top) by releasing the 2 tabs holding it to the upper case. Remove the front cover (front of top) by releasing the 2 tabs holding it to the lower case.

  • Page 59: Power Supply Unit (C137 Psb/Pse Board) Removal

    Remove the power supply unit by pulling it upward toward the back of the printer. The shield plates of C137 PSB/PSE and C162 MAIN boards have sharp edges, so take care in handling them.

  • Page 60: Main Controller (C162 Main Board) Removal

    Stylus Pro XL 3.2.3 Main Controller (C162 MAIN Board) Removal Remove the upper case (see Section 3.2.1). Remove the grounding plate from the shield plate. Remove the 4 CBB (M3 12) screws securing the shield plate to the lower case. Remove the 2 CBB (M3 12) screws securing the Type-B interface cover to the lower case.
  • Page 61 When you replace the main board, initialize EEPROM contents as follows: 1. Reassemble the printer. 2. Turn the printer on while holding down the Alt, Font , Load/Eject , and Pause buttons on the control panel. It is possible to misconnect the cables. When reconnecting the cables from connectors CN6, CN7 and connectors CN11, CN12 of the C162 MAIN board, see the following instructions.

  • Page 62: Printer Mechanism (M-4A60) Removal

    Remove the 4 CBN (M4 13) screws and take out the printer mechanism. DISASSEMBLY/ASSEMBLY POINT Wipe off any ink around the end of the ink drain tube when you remove the printer mechanism. When reinstalling the printer mechanism, check that the waste ink drain tube is properly inserted between the lower case and the waste ink absorbing material.

  • Page 63: Printer Mechanism Disassembly

    3.2.5.1 Printhead Unit Removal Remove the printer mechanism (see Section 3.2.4). Move the carriage to the middle of the printer while pressing the hook that fixes the carriage unit to the home position. Pull the ink cartridge clamp toward you and remove the ink cartridge.

  • Page 64: Figure 3-8. Ink Cartridge Holder Removal

    Stylus Pro XL Remove the CBB (M3 11) screw (under the CR cap cover) and plain washer securing the monochrome and color printheads to the carriage base. Rubber Cap Head Fixing Sczew Figure 3-8. Ink Cartridge Holder Removal Pull the black or color head toward you, and disconnect the head FFC cable on the head driver board (nozzle selector).
  • Page 65 Never touch the printhead’s metallic nozzle cover surface. Handle it only by holding the edges of the printhead. When you replace the printhead or the printer mechanism, you must replace the block resistor at location RM4 (for Micro Mode - Color (R-No.)), RM5 (for Normal Mode - Color (M-No.)), RM11 (for Micro Mode - Monochrome (R-No.)), and RM12 (for Normal...

  • Page 66: Figure 3-10. Head Spacer Position

    Stylus Pro XL REQUIRED ADJUSTMENT When removing or changing the black head, the following adjustments are needed. 1. Black head angle adjustment (see Section 4.1.4). 2. Black - Color head vertical adjustment (see Section 4.1.5). 3. Head gap adjustment (see Section 4.1.3). 4.

  • Page 67: Carriage Unit Removal

    3.2.5.2 Carriage Unit Removal Remove the printer mechanism (see Section 3.2.4). Move the carriage to the left side of the printer while pressing the hook that fixes the carriage to the home position. Remove the 2 CBN (O) (M3 6) screws securing the eject frame to both side frames.

  • Page 68: Pump Unit Removal

    Disassembly and Assembly 3.2.5.3 Pump Unit Removal Remove the printer mechanism. (See Section 3.2.4.) Remove the carriage unit. (See Section 3.2.5.2.) Remove the CBS (M3 6) screw securing the pump unit to the bottom frame. Push the pump unit outward while releasing the tab at the bottom side of the pump unit, and then lift up the pump unit.

  • Page 69: Cleaner Head Replacement

    Disassembly and Assembly 3.2.5.4 Cleaner Head Replacement Remove the printer mechanism (see Section 3.2.4). Use tweezers to unhook the cleaner head from the hook on the cleaning lever. Keeping the cleaner head clean is extremely important to keep the ink injection system working properly in the printhead, and it directly affects printing quality.

  • Page 70: Cr Motor Removal

    Stylus Pro XL 3.2.5.5 CR Motor Removal Remove the printer mechanism (see Section 3.2.4). Release the timing belt (see section 3.2.5.2). Remove the 3 screws securing the CR motor to the upper frame, and then remove the CR motor. CR Motor Figure 3-15.

  • Page 71: Carriage Home Position (Hp) Sensor Removal

    Remove the printer mechanism. (See Section 3.2.4.) Disconnect the connector for the PE sensor. Rotate the printer mechanism upside down; use tweezers to release the 2 hooks securing the PE sensor to the paper feed roller assembly. Then remove the PE sensor.

  • Page 72: Figure 3-19. Tension Roller Assembly Removal

    Stylus Pro XL 3.2.5.9 Paper Feed Roller Assembly Removal Remove the printer mechanism (see Section 3.2.4). Remove the carriage unit (see Section 3.2.5.2). Remove the pump unit (see Section 3.2.5.3). Remove the tension spring holding the tension roller assembly to the sub frame.

  • Page 73: Upper Frame Removal

    Disassembly and Assembly 3.2.5.10 Upper Frame Removal Remove the printer mechanism (see Section 3.2.4). Remove the carriage unit (see Section 3.2.5.2). Remove the E-ring securing the knob shaft to the sub frame; then remove the knob with the knob shaft from the right side frame.
  • Page 74 Chapter 4 Adjustments Table of Contents 4.1 OVERVIEW 4.1.1 Destination Data Writing Operation ......4-2 4.1.2 Bi-D (Bidirectional Printing) Alignment Adjustment .

  • Page 75: Table 4-1. Required Adjustments

    This section describes adjustments required when the printer is disassembled and assembled after repair. Since this printer has both a black and color head, it needs new adjustments not required for previous printers. Refer to the following table to perform the appropriate adjustments.

  • Page 76: Destination Data Writing Operation

    Adjustments 4.1.1 Destination Data Writing Operation The setup value that specifies the printer destination is stored in the EEPROM on the C162 MAIN board. Therefore, this setup value must be written into the EEPROM when the MAIN board or EEPROM chip is replaced.

  • Page 77: Bi-D (Bidirectional Printing) Alignment Adjustment

    5. Bi-D Adjustment 6. Internal Timer Reset 7. END When the main menu appears, choose “Bi-D Adjustment” by typing 5 and ENTER. (The printer prints a check pattern with a sample compensation value.) The next menu appears on the display.

  • Page 78: Head Gap Adjustment (Black And Color Head)

    Adjustments 4.1.3 Head Gap Adjustment (Black and Color Head) The head gap adjustment is required when the printer mechanism, main board, or printhead (board) is replaced or diassembled. This adjustment calibrates the head drive timing between the black and color head. If this adjustment is not made, the vertical alignment will not be completed.

  • Page 79: Black Head Angle Adjustment

    Stylus Pro XL 4.1.4 Black Head Angle Adjustment The black head angle adjustment is required when the black head is replaced or disassembled. If this adjustment is not correct, a white banding problem may occur, or the color head timing may not match the black head timing.

  • Page 80: Figure 4-4. Black Head Angle Adjustment Sample

    The printer prints a pattern like one in the following sample. Only the nozzles in rows A and D are fired (making it is easy to see the angle of the black head).

  • Page 81: Figure 4-6. Removing The Rubber Cap

    Adjust Lever Figure 4-6. Removing the Rubber Cap After replacing the spacer, always install new ink cartridges before returning the printer to the user. During this adjustment, use ink cartridges exclusively for service (Monochrome: 1020626, CMY: 1020627). You can reuse old ink cartridges for other purposes.
  • Page 82 Adjustments 11. After replacing the angular spacer, reassemble the ink cartridge holder and reinstall the ink cartridges. Use the BASIC program to verify the angle of the black head. Confirm the angle by performing the steps 1 to 6 again, and if the angle is wrong, perform the adjustment again until the head angle is correct.
  • Page 83 Ma g en ta C y a n Yellow Figure 4-8. Black-Color Head Vertical Adjustment Concept Connect the PC to the target printer, and turn the printer on. Execute BASIC on the PC and run the program “VERxxx.BAS”. 1. Destination Setting 2.

  • Page 84: Figure 4-10. Removing The Rubber Cap

    In Figure 4-10, the vertical position is correct when both the magenta line and the black line are aligned (as shown in position OK (0)). If the vertical position is correct, turn off the printer. If the black and magenta lines are not aligned, perform the vertical adjustment as described in steps 5-10.
  • Page 85 “OK (0).” 10. When you complete this adjustment, exit the BASIC program and turn off the printer. Rev. A...

  • Page 86: Color Head Angle Adjustment

    When the main menu appears, choose “Head Angle Confirmation Pattern Printing” by typing 2 and ENTER. (The printer prints the check pattern with the sample name.) When replacing both the black head and color head, always adjust the color head angle first.
  • Page 87 Replace the right angular spacer with a thicker one. Figure 4-15. Spacer Selection Turn off the printer now. Move the carriage to the center manually, and loosen (but do not remove) the screw securing the color head to the carriage. Rev. A...

  • Page 88: Figure 4-16. Removing The Rubber Cap

    Adjustments Figure 4-16. Removing the Rubber Cap Remove the rubber cap covering the head screw at one side of color ink cartridge. Then loosen (but do not remove) 3 screws. (Refer to the figure below.) Replace the angular spacer on the left side with a new one, referring the figure below. (Replace the angular spacer using tweezers to push the head base toward the rear.) 4-14 Ru bber Cap...
  • Page 89 10. If the sample is incorrect, repeat steps 5-9 until the upper lines in the sample are aligned with one another and the lower lines in the sample are exactly equidistant to one another (as shown at B in Figure 4-15). 11. When you complete this adjustment, turn off the printer. Rev. A Color Head...

  • Page 90: Platen Gap Adjustment

    Adjustments 4.1.7 Platen Gap Adjustment This adjustment is required when the carriage unit is replaced or removed from the printer mechanism. Adjust the distance between the printhead nose and the paper surface to 1.1 mm. Attach a thickness gauge (commercially available) to the left side adjustment position on the paper guide plate, as shown in the figure below, so that one side hooks the paper feed pinch roller unit.

  • Page 91: Figure 4-19. Confirming The Gap

    Thickness Gauge Figure 4-19. Confirming the Gap 4.1.8 Internal Timer Reset Operation This operation is required when the M-4A60 printer mechanism is replaced. There are 6 timers in this printer: Refresh timer Timer (monochrome and CMY) Flushing level decision timer...
  • Page 92 5.2 UNIT LEVEL TROUBLESHOOTING 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 .
  • Page 93 Rev.-A...

  • Page 94: Chapter 5 Troubleshooting

    Stylus Pro XL 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.
  • Page 95 Pause button. Load paper and press Pause and Load/Eject buttons. Service maintenance request. (Change the Blinks waste ink drain tank and reset the counter.) Turn off the printer Blinks and turn it on again. Rev. -A...

  • Page 96: Unit Level Troubleshooting

    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 Printer does not feed the paper...

  • Page 97: Printer Does Not Operate At Power On

    Troubleshooting 5.2.1 Printer does not operate at power on. START Is the AC input voltage correct? YE S Has fuse (F1) on the C137 PSB/PSE blown ? Check the output voltage of the C137 PSB/PSE at CN2. Is the output...

  • Page 98: Troubleshooting

    (See Chapter 6.) Check ink cartridge sensor and, if bad, replace. Rev. -A Turn the printer off and try to move the carriage manu ally. carriage move Replace the ink cartridge with a new o ne.

  • Page 99: Failure Occurs During Printing

    Is the problem corrected? Check all motors, See the section drivers, and printhead describing repair of for shorts. If they are the printer mechanism. OK, replace the C162 MAIN board. Is the problem corrected? Replace the C162 MAIN board. Stylus Pro XL...

  • Page 100: Printer Does Not Feed The Paper Correctly

    Stylus Pro XL 5.2.4 Printer does not feed the paper correctly. START Is paper loaded in the sheet feeder correctly? Does a paper jam occur? Check the PF motor and driver. If OK, replace the C162 MAIN board. Is the problem corrected? Rev.

  • Page 101: Control Panel Operation Is Abnormal

    Troubleshooting 5.2.5 Control panel operation is abnormal. START Is the control panel connected properly? Replace the control panel. Is the problem corrected? Connect the control panel correctly. Is the problem corrected? Replace the C162 MAIN board. Stylus Pro XL Rev. -A...

  • Page 102: Unit Repair - C137 Psb/Pse Board

    IC51. Oscillation waveform (IC51, pin 5) Switching waveform (IC51, pin 8) Turn off the printer and check the voltage at pin 1 of IC81. Normal voltage = 0 VDC Turn off the printer and check the voltage at plus side of C82.

  • Page 103: Unit Repair - C164 Main Board

    (Drive printer system does does not not operate operate at normally all. when you turn the printer on or Selection of off.) control ROM is abnormal. Either CG or RAM is defective. CPU is defective. The carriage carriage IC2 is defective.
  • Page 104 Stylus Pro XL Table 5-6. Repair of the C162 MAIN (Cont.) Symptom Condition Carriage The carriage does not does not IC15 is defective. operate operate at all. normally. IC2 is defective. Self-test Self-test is printing is not executed. abnormal. Printhead unit is defective.

  • Page 105: Unit Repair - Printer Mechanism (M-4A11)

    Troubleshooting 5.5 UNIT REPAIR - PRINTER MECHANISM (M-4A60) Any problems related to the printer mechanism should be repaired according to the troubleshooting procedures in Table 5-7. Table 5-7. Repair of the Printer Mechanism Symptom Condition The pump The PF motor...
  • Page 106 Stylus Pro Service Manual Table 5-8. Repair of the Printer Mechanism (Continued) Symptom Condition The carriage Printing is moves, but no printing is performed. performed. A particular dot is not printed. A dot is not printed Abnormal occasionally. printing. Printhead characters are not aligned.
  • Page 107 Troubleshooting Table 5-7. Repair of the Printer Mechanism (Cont.) Symptom Condition Paper is not Paper is not fed. fed normally. Paper top of form position slips (comes out too narrow). Note: Cleaning sheets are available as service parts. 5-14 Cause...
  • Page 108 Chapter 6 Maintenance Table of Contents 6.1 PREVENTIVE MAINTENANCE 6.2 SERVICE MAINTENANCE 6.2.1 Printhead Cleaning......... . 6-2 6.2.2 Waste Ink Drain Tank Replacement .

  • Page 109: Preventive Maintenance

    If the pickup roller of the sheet feeder is dirty, clean its surface with a soft, clean cloth. Inside the printer If you notice any dust or dirt that has accumulated inside the printer when you open the outer case for repair, remove all dust and dirt using a small vacuum cleaner designed for such purposes.

  • Page 110: Service Maintenance

    6.2.2 Waste Ink Drain Tank Replacement The printer counts the total amount of ink drained to the waste ink drain tank and this information is stored in the EEPROM on the main board (in Protect Counter A). This value is used for ink system operation management.

  • Page 111: Lubrication And Adhesives

    The printer must be lubricated properly when it is disassembled for component replacement, or if mechanical noise exceeds a certain level. EPSON recommends only the lubricants listed in the table below for this printer, both of which have been tested extensively and comply with the requirements of this printer mechanism.
  • Page 112 Maintenance Stylus Pro Service Manual Do not apply too much lubricant, as it may stain the mechanism as well as a cause a mechanism malfunction. Rev.A...
  • Page 113 Stylus Pro Service Manual Figure 6-1. Lubrication Points and Adhesive Points (1) Rev.A Maintenance...
  • Page 114 Maintenance Stylus Pro Service Manual Lubrication Point Adhesive Point Figure 6-2. Lubrication Points and Adhesive Points (2) Rev.A...
  • Page 115 Appendix Table of Contents A.1 CONNECTOR SUMMARY A.2 CIRCUIT DIAGRAM A.3 CIRCUIT BOARD COMPONENT LAYOUT A.4 EXPLODED DIAGRAM Figure A-1. Interconnection of Major Component ..... . . A-1 Figure A-2.
  • Page 116 Rev. A C N 2 C N 5 Black Color C162 MAI N C N 6 C N 7 Appendix ASF Plunger Printhead Unit HP S en sor CR Senso r PF Mot or CR Mot or Printer Mechanism (M-4A60)
  • Page 117 DC output (+5 V / +35 V) (to C162 MAIN) Description Strobe signal Data strobe signal ACK signal Busy signal Paper end signal Printer select signal Auto line feed signal Not connected Ground Frame ground +5 VDC Ground INIT signal...
  • Page 118 Stylus Pro XL Table A-3. Connector Pin Assignments — CN2 Name +5 V READY — RESET CMREQ WRRDY RDREQ 19-24 — 25-28 A3-A0 29-36 D15-D8 Table A-4. Connector Pin Assignments — CN3 Name — — TXD - — RXD - TXD+ —...
  • Page 119 Appendix Table A-6. Connector Pin Assignments — CN6 Name CRCOM Table A-7. Connector Pin Assignments — CN7 Name PFCOM Table A-8. Connector Pin Assignments — CN8 Name — Table A-9. Connector Pin Assignments — CN9 Name — Table A-10. Connector Pin Assignments — CN10 Name 1, 3, 5, 7 —...
  • Page 120 Stylus Pro XL Table A-11. Connector Pin Assignments — CN11 Name — BCLK — BLAT — — +5 V — 11-16 17-22 Table A-12. Connector Pin Assignments — CN12 Name — CCLK — CLAT — — +5 V 11-16 18-22 Table A-13.
  • Page 121 FOOT LOWER SHIELD PLATE UPPER SHIELD PLATE P/S SHIELD PLATE GROUNDING PLATE PAPER SUPPORT COVER B UPPER HOUSING REAR PRINTER COVER PAPER SUPPORT EDGE GUIDE GROUNDING PLATE D PAPER SUPPORT SUPPORT PLATE LOGO PLATE B PS EARTH PLATE I/F GROUNDING PLATE...
  • Page 122 (220 V) POWER CABLE (220 V) POWER CABLE POWER CABLE (100 V) HARNESS (220 V / 240 VAC INLET) PANEL BOARD PRINTER MECHANISM (M-4A60) DRIVEN PULLEY BASE FRAME PE DETECTOR (0 V, 0 A, 0 W) LEFT FRAME MIDDLE FRAME...
  • Page 123 Stylus Pro XL Table A-14. Part No. Reference Table (Continued) Ref.No. Description REAR PAPER GUIDE PF ROLLER SUPPORT PF HOLDER SUPPORT TORSION SPRING, 5800 PE HARNESS PF STEPPING MOTOR HP DETECTOR HP HARNESS PUMP B UPPER YMC CAP POROUS PAD LOWER YMC CAP POROUS PAD UPPER BK CAP POROUS PAD LOWER BK CAP POROUS PAD...
  • Page 124 Appendix Table A-14. Part No. Reference Table (Continued) Ref.No. Description BK HEAD BASE YMC HEAD BASE UPPER HEAD CABLE HOLDER LOWER HEAD CABLE HOLDER BK CARTRIDGE LEVER YMC CARTRIDGE LEVER CR COVER CAP PUMP SPEED UP SHAFT OIL PAD PRESSURE PLATE KNOB KNOB SHAFT DRIVEN ROLLER E...
  • Page 125 Stylus Pro XL Table A-14. Part No. Reference Table (Continued) Ref.No. Description EXTENTION SPRING, 1.6 g COMPRESSION SPRING, 90 g TORSION SPRING, 15000 g TORSION SPRING, 6700 g EXTENSION SPRING, 102 g COMPRESSION SPRING, 1500 g EXTENSION SPRING, 10 g COMPRESSION SPRING, 100 g COMPRESSION SPRING, 485 g SPUR GEAR, 25 mm...
  • Page 126 Appendix Table A-14. Part No. Reference Table (Continued) Ref.No. Description CBB SCREW (M3 12) CBS SCREW (M3 8 F/UC) CPB SCREW (3 15 F/ZN) HEAD MOUNTING PRESSURE PLATE PF ROLLER SPUR GEAR, 9 mm SPUR GEAR, 27 mm SPUR GEAR, 12 mm PLUNGER EXTENSION SPRING, 3.35 g EXTENSION SPRING, 0.196 g...
  • Page 127 EPSON...

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