Manual de Servicio - Epson C67

SERVICE MANUAL
Color Inkjet Printer
EPSON Stylus C67/C68/D68
SEIJI05-003
Notice:
All rights reserved. No part of this manual may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SEIKO EPSON CORPORATION. The contents of this manual are subject to change without notice. All effort have been made to ensure the accuracy of the contents of this manual. However, should any errors be detected, SEIKO EPSON would greatly appreciate being informed of them. The above not withstanding SEIKO EPSON CORPORATION can assume no responsibility for any errors in this manual or the consequences thereof. EPSON is a registered trademark of SEIKO EPSON CORPORATION.
General Notice:
Other product names used herein are for identification purpose only and may be trademarks or registered trademarks of their respective owners. EPSON disclaims any and all rights in those marks.
Copyright 2005
SEIKO EPSON CORPORATION. I&I CS/Quality Management & PL Department
PRECAUTIONS
Precautionary notations throughout the text are categorized relative to 1)Personal injury and 2) damage to equipment. DANGER WARNING Signals a precaution which, if ignored, could result in serious or fatal personal injury. Great caution should be exercised in performing procedures preceded by DANGER Headings. Signals a precaution which, if ignored, could result in damage to equipment.
The precautionary measures itemized below should always be observed when performing repair/maintenance procedures.
DANGER
1. 2. 3. ALWAYS DISCONNECT THE PRODUCT FROM THE POWER SOURCE AND PERIPHERAL DEVICES PERFORMING ANY MAINTENANCE OR REPAIR PROCEDURES. NO WORK SHOULD BE PERFORMED ON THE UNIT BY PERSONS UNFAMILIAR WITH BASIC SAFETY MEASURES AS DICTATED FOR ALL ELECTRONICS TECHNICIANS IN THEIR LINE OF WORK. WHEN PERFORMING TESTING AS DICTATED WITHIN THIS MANUAL, DO NOT CONNECT THE UNIT TO A POWER SOURCE UNTIL INSTRUCTED TO DO SO. WHEN THE POWER SUPPLY CABLE MUST BE CONNECTED, USE EXTREME CAUTION IN WORKING ON POWER SUPPLY AND OTHER ELECTRONIC COMPONENTS. WHEN DISASSEMBLING OR ASSEMBLING A PRODUCT, MAKE SURE TO WEAR GLOVES TO AVOID INJURIER FROM METAL PARTS WITH SHARP EDGES.
4.
WARNING
1. 2. 3. 4. 5. 6. REPAIRS ON EPSON PRODUCT SHOULD BE PERFORMED ONLY BY AN EPSON CERTIFIED REPAIR TECHNICIAN. MAKE CERTAIN THAT THE SOURCE VOLTAGES IS THE SAME AS THE RATED VOLTAGE, LISTED ON THE SERIAL NUMBER/RATING PLATE. IF THE EPSON PRODUCT HAS A PRIMARY AC RATING DIFFERENT FROM AVAILABLE POWER SOURCE, DO NOT CONNECT IT TO THE POWER SOURCE. ALWAYS VERIFY THAT THE EPSON PRODUCT HAS BEEN DISCONNECTED FROM THE POWER SOURCE BEFORE REMOVING OR REPLACING PRINTED CIRCUIT BOARDS AND/OR INDIVIDUAL CHIPS. IN ORDER TO PROTECT SENSITIVE MICROPROCESSORS AND CIRCUITRY, USE STATIC DISCHARGE EQUIPMENT, SUCH AS ANTI-STATIC WRIST STRAPS, WHEN ACCESSING INTERNAL COMPONENTS. REPLACE MALFUNCTIONING COMPONENTS ONLY WITH THOSE COMPONENTS BY THE MANUFACTURE; INTRODUCTION OF SECOND-SOURCE ICs OR OTHER NON-APPROVED COMPONENTS MAY DAMAGE THE PRODUCT AND VOID ANY APPLICABLE EPSON WARRANTY. WHEN USING COMPRESSED AIR PRODUCTS; SUCH AS AIR DUSTER, FOR CLEANING DURING REPAIR AND MAINTENANCE, THE USE OF SUCH PRODUCTS CONTAINING FLAMMABLE GAS IS PROHIBITED.
About This Manual

This manual describes basic functions, theory of electrical and mechanical operations, maintenance and repair procedures of the printer. The instructions and procedures included herein are intended for the experienced repair technicians, and attention should be given to the precautions on the preceding page.
Manual Configuration
This manual consists of six chapters and Appendix. CHAPTER 1.PRODUCT DESCRIPTIONS Provides a general overview and specifications of the product. CHAPTER 2.OPERATING PRINCIPLES Describes the theory of electrical and mechanical operations of the product. CHAPTER 3.TROUBLESHOOTING Describes the step-by-step procedures for the troubleshooting. CHAPTER 4.DISASSEMBLY / ASSEMBLY Describes the step-by-step procedures for disassembling and assembling the product. CHAPTER 5.ADJUSTMENT Provides Epson-approved methods for adjustment. CHAPTER 6.MAINTENANCE Provides preventive maintenance procedures and the lists of Epsonapproved lubricants and adhesives required for servicing the product. APPENDIX Provides the following additional information for reference: Exploded Diagram Parts List Circuit Diagrams
Symbols Used in this Manual

Various symbols are used throughout this manual either to provide additional information on a specific topic or to warn of possible danger present during a procedure or an action. Be aware of all symbols when they are used, and always read NOTE, CAUTION, or WARNING messages.
A D J U S T M E N T R E Q U IR E D
Indicates an operating or maintenance procedure, practice or condition that is necessary to keep the products quality.
C A U T IO N
Indicates an operating or maintenance procedure, practice, or condition that, if not strictly observed, could result in damage to, or destruction of, equipment. May indicate an operating or maintenance procedure, practice or condition that is necessary to accomplish a task efficiently. It may also provide additional information that is related to a specific subject, or comment on the results achieved through a previous action. Indicates an operating or maintenance procedure, practice or condition that, if not strictly observed, could result in injury or loss of life.
C H E C K P O IN T
W A R N IN G
Indicates that a particular task must be carried out according to a certain standard after disassembly and before re-assembly, otherwise the quality of the components in question may be adversely affected.
Revision Status
Revision Date of Issue Description
Aug 1, 2005
First Release
Revision A
Contents
Chapter 1 PRODUCT DESCRIPTION
1.1 Features.................................................................................................................. 9 1.2 Specifications ...................................................................................................... 10 1.2.1 Physical Specification................................................................................. 10 1.2.2 Printing Specification ................................................................................. 10 1.2.3 Paper Feeding ............................................................................................. 11 1.2.4 Input Data Buffer ........................................................................................ 11 1.2.5 Electric Specification.................................................................................. 11 1.2.6 Environmental Condition............................................................................ 12 1.2.7 Reliability ................................................................................................... 12 1.2.8 Safety Approvals ........................................................................................ 12 1.2.9 Acoustic Noise............................................................................................ 13 1.2.10 CE Marking .............................................................................................. 13 1.2.11 Black Ink Save Mode................................................................................ 13 1.3 Operator Controls ................................................................................................ 14 1.3.1 Operate Switch............................................................................................ 14 1.3.2 Panel Functions........................................................................................... 14 1.3.3 Printer Condition and LED Status .............................................................. 15 1.3.4 Errors .......................................................................................................... 15 1.4 Paper .................................................................................................................... 16 1.4.1 Paper Support.............................................................................................. 16 1.5 Ink Cartridge........................................................................................................ 21 1.5.1 Ink Cartridge Specification......................................................................... 21
Chapter 2 OPERATING PRINCIPLES

2.1 Overview ............................................................................................................. 2.2 Printer Mechanism .............................................................................................. 2.2.1 Printhead Specifications ............................................................................. 2.2.2 Carriage Mechanism................................................................................... 2.2.3 Paper Feeding Mechanism.......................................................................... 2.2.4 Ink System Mechanism .............................................................................. 2.3 Electrical Circuit Operating Principles................................................................ 2.3.1 C616 PSB/PSE Board................................................................................. 2.3.2 C616 Main Board ....................................................................................... 23 23 24 24 25 26 26 27 27
Chapter 3 TROUBLESHOOTING
3.1 Overview ............................................................................................................. 3.1.1 Specified Tools ........................................................................................... 3.1.2 Preliminary Checks..................................................................................... 3.2 Troubleshooting With LED Error Indications.................................................... 3.2.1 Fatal Error................................................................................................... 3.3 Troubleshooting for Motors and Sensors ............................................................ 29 29 29 30 32 34
Revision A
Chapter 4 DISASSEMBLY/ASSEMBLY
4.1 Overview ............................................................................................................. 4.1.1 Precautions.................................................................................................. 4.1.2 Tools ........................................................................................................... 4.1.3 Screws (T.B.D) ........................................................................................... 4.1.4 Work Completion Check ............................................................................ 4.2 Caution regarding Assembling/Disassembling of the Printer Mechanism, and How to Ensure of Quality on Re-assembled Product ................................... 4.3 Disassembly Procedures...................................................................................... 4.3.1 Removing Housings.................................................................................... 4.3.2 Removing Boards ....................................................................................... 4.3.3 Disassembling Printer Mechanism ............................................................. 36 36 37 37 38 39 41 43 52 56
Chapter 6 MAINTENANCE
6.1 Overview ............................................................................................................. 6.1.1 Cleaning...................................................................................................... 6.1.2 Service Maintenance................................................................................... 6.1.3 Lubrication.................................................................................................. 90 90 90 92
Chapter 7 APPENDIX
7.1 Exploded Diagram............................................................................................... 96 7.2 Parts List............................................................................................................ 102 7.3 Circuit Diagrams ............................................................................................... 103
Chapter 5 ADJUSTMENT
5.1 Adjustment Items and Overview ......................................................................... 5.1.1 Servicing Adjustment Item List.................................................................. 5.1.2 Repaired Adjustmen ................................................................................... 5.1.3 Replacement Part-Based Adjustment Priorities.......................................... 5.2 Adjustment by Using Adjustment Program ........................................................ 5.2.1 Market ID Setting ....................................................................................... 5.2.2 USB ID Input .............................................................................................. 5.2.3 Head ID Input ............................................................................................. 5.2.4 Head Angular Adjustment .......................................................................... 5.2.5 Bi-D Adjustment......................................................................................... 5.2.6 PF Adjustment ............................................................................................ 5.2.7 First Dot Adjustment .................................................................................. 5.2.8 Top Margin Adjustment ............................................................................. 5.2.9 Offset input for CR Motor Calorific Limitation ......................................... 5.2.10 A4 Normal Paper print.............................................................................. 5.2.11 A4 Photo Quality Inkjet Paper Print........................................................ 5.2.12 PF Torque Check Pattern Print ................................................................. 5.3 Adjustment Except Adjustment Program ............................................................ 5.3.1 CR Timing Belt Tension Adjustment ......................................................... 77 77 79 80 82 82 82 82 83 83 84 84 85 85 86 86 87 88 88
YCHAPTER
PRODUCT DESCRIPTION
Revision A
1.1 Features
The major features of EPSON Stylus C67/C68/D68 are: High color print quality 2880 (H) x 1440 (V) dpi printing (Max. resolution) 4 color printing (YMCK) Built-in auto sheet feeder Holds 120 cut-sheets (90 g/m2) Holds 10 envelopes Built-in 1 I/F USB 1.1 Windows/Macintosh exclusive Borderfree Separate ink cartridge for each color Figure 1-1. Product Appearance
PRODUCT DESCRIPTION
Features
Revision A
Table 1-2. Raster Graphics Mode
Horizontal resolution Printable area Available dot Dot size Eco CR speed 723.9 mm/s (285 CPS) 419.1 mm/s (165 CPS) 609.6 mm/s (240 CPS) 609.6 mm/s (240 CPS) 609.6 mm/s (240 CPS) 609.6 mm/s (240 CPS) 609.6 mm/s (240 CPS) 609.6 mm/s (240 CPS) 609.6 mm/s (240 CPS)
1.2 Specifications
This section covers specifications of the printer.
1.2.1 Physical Specification

Weight: Dimension Storage: Printing: 447 mm (W) x 240 mm (D) x 189 mm (H) 447 mm (W) x 436 mm (D) x 309 mm (H) 3.9 kg (without the ink cartridges)
360 dpi
209.8 mm (8.26 inch)
2976
VSD1 VSD2 (Color) VSD2 VSD2' (Black) VSD3 (Color) VSD3
720 dpi
209.8 mm (8.26 inch)
5952
1.2.2 Printing Specification

Print method On demand ink jet Nozzle configuration monochrome: color: Print direction Bi-direction with logic seeking Print speed & Printable columns Table 1-1. Character Mode
Character Pitch 10 CPI (Pitch) Printable Columns 80 digits CR Speed 419.1 mm/s (165 CPS) 1440 dpi 2880 dpi
209.8 mm (8.26 inch) 209.8 mm (8.26 inch)
11904 23808
VSD3 (Black) VSD3
90 nozzles 29 nozzles x 3 (Cyan, Magenta, Yellow) Control Code ESC/P2 expanded raster graphics code EPSON Remote command Character tables none (ASCII 20H to 7FH code support) Internal fonts Bit map LQ font EPSON Courier 10 CPI
PRODUCT DESCRIPTION
Specifications
10
Revision A
220-240 V version Rated voltage: Input voltage range: Rated frequency range: Input frequency range: Rated current: Power consumption: AC220-240 V AC198-264 V 50 - 60 Hz 49.5 - 60.5 Hz 0.2 A (max. 0.4 A) ISO10561 Letter Pattern: 11 W Sleep Mode: 2.5 W Power Off Mode: 0.4 W AC 3000 Vrms for 1 minute (between AC line and chassis)
1.2.3 Paper Feeding

Feeding method Friction feed with ASF Paper path Cut-sheet ASF (Top entry front out) Feed speed T.B.D msec (T.B.D mm/sec) (10.16 mm (0.4 inch) feed) T.B.D msec (T.B.D mm/sec) (Continuous feed)
1.2.4 Input Data Buffer

Input buffer size: 32 KB
Dielectric strength:
1.2.5 Electric Specification

100-120 V version Rated voltage: Input voltage range: Rated frequency range: Input frequency range: Rated current: Power consumption: AC100 - 120 V AC90 - 132 V 50 - 60 Hz 49.5 - 60.5 Hz 0.4 A (max. 0.7 A) ISO10561 Letter Pattern: 11W Sleep Mode: 2.0 W Power Off Mode: 0.3 W AC 3000 Vrms for one minute (between AC line and chassis)
Dielectric strength:
PRODUCT DESCRIPTION
Specifications
11
Revision A
1.2.6 Environmental Condition

Table 1-3. Environmental Condition
Operating Temperature*1 Humidity Resistance to shock Resistance to vibration Note *1: *2: One month at 40C and 120 hours at 60C Under the following conditions
90 80 70 60
1.2.7 Reliability
Total print volume:
Non-operating -20~40 C 5~85 % 2 G, within 2 ms 0.50 G
20,000 pages (A4, Letter) or five years, whichever comes first. Eight billion shots (per nozzle) or five years, whichever comes first.
10~35 C*2 20~80 % 1 G, within 1 ms 0.15 G
Print Head Life:
1.2.8 Safety Approvals

100-120 V version Safety standards: EMI: 220-240V version Safety standards: EMI: EN 60950 EN 55022(CISPR Pub.22) class B AS/NZS CISPR 22 class B UL60950 CSA C22.2 No.60950 FCC part15 subpart B class B CSA C108.8 class B
Humidity(%)
50 40 30 20
10
20
27 30
35
40
Temperature(C) Figure 1-2. Temperature/Humidity Range
C A U T IO N
Printhead must be capped during storage. When transporting the printer, make sure that the printhead is capped and the ink cartridges are installed in the printer. If the printhead is not capped when the printer is turned off, turn the printer on with the ink cartridges installed, cap the printhead, and turn the power off. Ink inside the ink cartridges freezes if it is left to stand at temperature of -4C or less. If this is the case, allow the ink to stand for about three hours at 25C temperature.
PRODUCT DESCRIPTION
Specifications
12
Revision A
1.2.9 Acoustic Noise

Level: Approx. 45 dB (A) (According to ISO 7779)
1.2.10 CE Marking
220-240V version Low Voltage Directive 73/23/EEC: EMC Directive 89/336/EEC: EN60950 EN55022 Class B EN61000-3-2 EN61000-3-3 EN55024
Starts printing in black ink save mode. Starts printing in a normal manner. Starts printing in a normal manner. This window will not be displayed until the black ink cartridges is replaced.
1.2.11 Black Ink Save Mode

Black ink save mode allows you to print images with color ink only when the remaining amount of black ink is low. This mode can be selected when the remaining amount of color ink is sufficient since black areas of the images are printed with a mixture of other colors. Supported OS: Windows NT4.0, 95, 98, ME, 2000, XP Printing mode: Plain Paper & Text Mode (360 dpi) Operating procedure 1. 2. User carries out printing from an application. The printer driver checks both the printing mode and the amount of remaining ink, and displays the specific window if the conditions described below are all satisfied. Selected printing mode supports black ink save mode. Remaining amount of black ink is less than 5 %, or the status of the black ink is ink low. Remaining amount of all the color ink is more than 10 %, or the status of all the color ink is NOT ink low.
Figure 1-3. Black Ink Save Mode Window
PRODUCT DESCRIPTION
Specifications
13
Revision A
1.3 Operator Controls

1.3.1 Operate Switch
Operate switch is located on the control panel.
1.3.2 Panel Functions

Table 1-4. Panel Functions
Switch Function
Paper
1.3.1.1 Switches
There are three non-lock type push switches and three LEDs. Ink switch Paper switch Power switch
Ink
Loads or ejects paper. In the condition of printing, cancel the print job. Starts the ink cartridge change sequence. Moves the carriage to cartridge change position. In the condition of Ink Low, Ink Out or No Ink Cartridge, moves the carriage to the ink check position. When the carriage is on the ink check position, moves carriage to next ink check position or cartridge change position. When carriage is on the ink change position, returns carriage from ink cartridge change position. Starts the cleaning of head. In the condition of 'Ink Low', 'Ink Out' or 'No Ink Cartridge', starts the ink cartridge change sequence.
Ink (Holding down for three seconds)
Table 1-5. Panel functions with power on

Switch Paper Pressing with Power On function* Starts status printings.
Ink LED
Paper LED Figure 1-4. Control Panel
Power LED
Note *:
Holding down the [Paper] switch, press [Power].
Table 1-6. Panel functions with power off

Switch Ink Note *: Pressing with Power Off function* Compulsory power off.
1.3.1.2 Indicators
Power LED [Green] Lights when the power switch is ON and AC power is supplied. Paper LED [Red] Lights during the paper-out condition, and flashes during the paper-jam condition. Ink LED [Red] Lights during no ink condition, and flashes during the ink low condition.
Holding down the [Power] switch, press [Ink] for about seven seconds.
PRODUCT DESCRIPTION
Operator Controls
14
Revision A
Table 1-7. Error Status
Error Description
1.3.3 Printer Condition and LED Status

Printer status Power on Ink level low Data processing No ink cartridge or ink end CSIC Error Ink sequence Ink cartridge change mode Paper out Paper jam condition Maintenance request Fatal error Power off Reset request* Note *: Indicators Power LED On -Flashes --Flashes Flashes --Off Off Flashes on high speed On Paper LED -------On Flashes Flashes alternately Flashes on high speed Off On Ink LED -Flashes -On On ----Flashes alternately Flashes on high speed Off On Priority 11 10 9 8 8 7 6 5 4 3 2 1 -Maintenance request Fatal errors
When the total quantity of ink wasted through the cleanings and flushing is reaches to the limit, printer indicates this error and stops. The absorber in the printer enclosure is needed to be replaced with new one by a service person. Carriage control error.
When the reset request (e.g. IEEE 1284.4 rs command, Parallel Init signal) occurred, the LED indicates for 0.2 sec.
1.3.4 Errors
Table 1-7. Error Status
Error Description
Ink out Paper out Paper jam No ink-cartridge / CSIC Error
When the printer runs out the most part of the ink of any one color, it warns ink-low and keeps printing.When the printer runs out the whole ink of any one color, it stops printing and indicates ink-out error. User is requested to install a new ink-cartridge in this state. When printer fails to load a sheet, it goes paper out error. When printer fails to eject a sheet, it goes paper jam error. When printer detects that ink-cartridge comes off, or failed to read or write CSIC data, it goes this error mode.
PRODUCT DESCRIPTION
Operator Controls
15
Revision A
Envelopes Table 1-9. Envelopes*
Paper type Dimensions (mm) Width 104.8 110 114 Length 241.3 220 162 75-90g/m2 Weight Quality bond paper PPC paper air mail
1.4 Paper
1.4.1 Paper Support
Cut sheets Table 1-8. Cut sheets
Paper size Legal Letter A4 B5 A5 Half Letter A6 User defined
C A U T IO N
#10*1 Paper Support DL*1 C6*1 Note *: Note *1:
Dimensions Width (mm) 215.9 (8.5) 215.9 (8.5) 210 182 148 139.7 (5.5") 105 50.8-329
Thickness Weight Length (mm) (g/m2) (mm) 355.6 (14) 279.4 (11) 297 257 210 215.9 (8.5") 148 1271117.6 0.08-0.11 64-90
Quality
Stylus Stylus Stylus C68 D68 C67 OK OK OK OK OK OK OK NG OK OK OK OK OK OK OK NG OK OK
Borderless printing is not supported for envelops. There is flap in the long side part, and it is fold down. Loading paper under the oblong condition is done. The flap side is moved to 80-digit side. Only for Stylus C67/D68.
*2:
C A U T IO N
common paper recycled paper
OK NG NG OK OK OK
It is necessary that there is no winkle, nap, tear, fold and so on in the form. The curve of form must be five mm or below.
Use paper under normal conditions. Temperature 15 to 25C (59 to 77F) Humidity 40 to 60% RH It is necessary that there is no winkle, nap, tear, fold and so on in the form. The curve and swell of the form must be three mm or below. Don't use the adhesive envelope. Don't use sleeve insert envelope and cellophane window envelope. As for double-flap envelope, if the envelope is damaged or bent during printing, load the envelope with its flap facing in the opposite direction. (Feeding direction should be changed as well from the printer driver.) If the printed images are skewed or misaligned from the proper position, fold four sides of the envelope tightly. If multi-feed occurs, press the [Paper] switch to feed the envelope before starting printing again.
PRODUCT DESCRIPTION
Paper
16

Exclusive papers Quality: EPSON Exclusive paper Table 1-10. Exclusive papers
Dimensions Item Premium Ink Jet Plain Paper Bright White Ink Jet Paper Photo Paper Size A4 A4 Width Length (mm) (mm) 210 210 210 101.6 215.9 210 203.2 127 101.6 89 215.9 210 101.6 215.9 210 215.9 210 210 215.9 210 215.9 101.6 101.6 297 297 297 152.4 279.4 297 254 178 152.4 127 279.4 297 152.4 279.4 297 279.4 297 297 279.4 297 279.4 152.4 152.4 Paper Support Thickness Weight Stylus Stylus Stylus 2) (mm) (g/m C68 D68 C67 0.11 0.13 0.23 80 92.5 194 NG NG NG NG OK OK OK OK OK NG OK NG NG OK NG OK NG NG OK OK OK OK OK OK OK OK OK NG OK NG OK OK NG NG OK OK NG OK NG OK NG NG OK NG NG NG OK OK NG NG NG OK NG NG OK OK NG OK OK NG OK NG OK OK NG OK NG NG NG Item Ultra Glossy Photo Paper/ Ultra Premium Glossy Photo Paper Size
Revision A
Table 1-10. Exclusive papers
Dimensions Width Length (mm) (mm) Letter 215.9 279.4 A4 210 297 8" x 10" 203.2 254 5" x 7" 127 178 10 x 15 101.6 152.4 Paper Support Thickness Weight Stylus Stylus Stylus (mm) (g/m2) C68 D68 C67 OK NG NG NG OK NG 0.29 209 OK NG NG OK OK NG OK OK NG
Note *:
C A U T IO N
Borderless printing is not supported for Photo Quality Ink Jet Paper.
A4 10x15 Premium Glossy Letter Photo Paper A4 8" x 10" 5" x 7" 10 x 15 3R Premium Semigloss Letter Photo Paper A4 10 x 15 Matte PaperLetter Heavyweight A4 Double-Sided Matte Letter Paper A4 Economy Photo A4 Paper Photo Quality Ink Jet Letter Paper* A4 Glossy Photo Paper Letter 10 x 15 Premium Glossy 10 x 15 Photo Paper (RC-X)
0.27
255
Use paper under normal conditions. Temperature 15 to 25C (59 to 77F) Humidity 40 to 60% RH It is necessary that there is no winkle, nap, tear, fold and so on in the form. The curve of form must be five mm or below.
0.27 0.23 0.25 0.23 0.12 0.23 0.25
250 167 178 188 102 188 238
PRODUCT DESCRIPTION
Paper
17
Revision A
1.4.1.1 Printable Area

Cut sheet (standard printing) Printable area For paper width (PW) and paper length (PL), refer to 1.4.1 Paper Support (p16). Table 1-11. Applicable Paper/Printing Area
Paper type
A4 A5 Cut Sheet B5 Half Letter Letter Legal User defined Premium Ink Jet Plain Paper Bright White Ink Jet Paper Photo Paper Premium Glossy Photo Paper Exclusive papers Premium Semigloss Photo Paper Matte Paper-Heavyweight Double-Sided Matte Paper Economy Photo Paper Glossy Photo Paper Premium Glossy Photo Paper (RC-X) Ultra Glossy Photo Paper/ Ultra Premium Glossy Photo Paper 3mm 3mm 3mm 12.5mm/ 3mm*1 A6
PW LM RM
TM
BM
LM
RM
TM
Paper Feed Direction
Printable area
PL
BM
Figure 1-5. Printable Area Cut Sheet (Standard Printing)
Note *1:
Bottom margin is expanded to 3 mm when paper dimension is defined by using command (ESC (S and Remote SN), otherwise it is not expanded (12.5 mm). From a form lower end 3 mm as for 12.5 mm area a printing may scramble.
PRODUCT DESCRIPTION
Paper
18

Envelopes Printable area For paper width (PW) and paper length (PL), refer to 1.4.1 Paper Support (p16). Table 1-12. Applicable Paper/Printing Area
Paper type #10 DL C6 3mm 3mm 3mm 20mm LM RM TM BM
Revision A
PW LM RM TM Printable area
PL
BM
Figure 1-6. Printable Area for Envelopes
PRODUCT DESCRIPTION
Paper
19

Cut sheet (border-free printing) Printable area For paper width (PW) and paper length (PL), refer to 1.4.1 Paper Support (p16). Table 1-13. Applicable Paper/Printing Area
Paper type
Premium Ink Jet Plain Paper Bright White Ink Jet Paper Photo Paper
Revision A
LO
PW
RO TO
Size
A4 A4 A4 10x15 Letter A4 8" x 10" 5" x 7" 10 x 15 3R Letter A4 10 x 15 Letter A4 Letter A4 A4 Letter 10 x 15 10 x 15 Letter
LO
2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54
RO
2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54 2.54
TO
2.96 2.96 2.96 2.82 2.96 2.96 2.96 2.96 2.82 2.82 2.96 2.96 2.82 2.96 2.96 2.96 2.96 2.96 2.96 2.82 2.82 2.96 2.96 2.96 2.96 2.82
BO
4.02 4.02 4.02 3.60 4.02 4.02 4.02 4.02 3.60 3.60 4.02 4.02 3.60 4.02 4.02 4.02 4.02 4.02 4.02 3.60 3.60 4.02 4.02 4.02 4.02 3.60
Paper size
PL
Premium Glossy Photo Paper
Exclusive papers
Premium Semigloss Photo Paper Matte Paper-Heavyweight Double-Sided Matte Paper Economy Photo Paper Glossy Photo Paper Premium Glossy Photo Paper (RC-X)
BO Printable area Figure 1-7. Printable Area for Cut Sheet (Border-free Printing)
Ultra Glossy Photo Paper/ Ultra Premium Glossy Photo Paper
A4 8" x 10" 5" x 7" 10 x 15
PRODUCT DESCRIPTION
Paper
20
Revision A
Dimension: 12.7 mm(W) x 73.46 mm(D) x 55.25 mm(H)
1.5 Ink Cartridge

1.5.1 Ink Cartridge Specification
Type: Exclusive cartridge Table 1-14. Ink Cartridge
Color Black Cyan Magenta Yellow Size SS Size S Size SS Size S Size SS Size S Size SS Size S Size Stylus C67 T0631 T0621 T0632 T0633 T0634 Stylus C68 T0601 T0602 T0603 T0604 Stylus D68 T0611 T0612 T0613 T0614 -
12.7 mm
Print Capacity: Black ink cartridge Print capacity S size: SS size: Color ink cartridge Print capacity S size: SS size: Ink life: 410 pages /A4 (360 dpi, 5% duty each color) 250 pages /A4 (360 dpi, 5% duty each color)
Base View
73.46 mm
390 pages /A4 (360 dpi, 5% duty each color) 230 pages /A4 (360 dpi, 5% duty each color)
C A U T IO N
Figure 1-8. Ink Cartridge Ink cartridge can not re-fill, only ink cartridge is prepared for article of consumption. Do not use the ink cartridge which has expired. Ink will be frozen under -16 C environment, however it will be usable after placing it more than three hours at room temperature.
Two years from production date
Storage temperature Table 1-15. Storage Temperature

Situation When transported in individual boxes When stored in individual boxes When installed in main unit Storage temperature -30C ~ 50C -30C ~ 40C -20C ~ 40C Limit 10 days max. at 50C 1 month max. at 40C
PRODUCT DESCRIPTION
Ink Cartridge
21
YCHAPTER
OPERATING PRINCIPLES
Revision A
2.1 Overview
This section describes the operating principles of the printer mechanism and electrical circuit boards.
PF timing belt PF motor PF roller
2.2 Printer Mechanism

Printer mechanism of Stylus C67/C68/D68 consists of printhead, carriage mechanism, paper loading mechanism, paper feeding mechanism, and ink system. As in the case of conventional models, Stylus C67/C68/D68 has two DC motors; one is for paper loading/feeding mechanism, and the other is for carriage mechanism. Papers are fed from the backside and ejected from the front side of the printer. Paper feeding mechanism, which is also similar to conventional models, feeds papers using the LD roller and the retard roller.
Star wheel rollers CR timing belt
Carriage unit
CR encoder sensor Retard roller Compression spring LD roller PE sensor Cam, large Cam, small Clutch Pump unit
Paper eject roller CR lock lever
Cap unit
CR motor
Figure 2-1. Printer Mechanism Outline
Overview
23
Revision A
2.2.1 Printhead Specifications

The Printhead of this product is a D2-CHIPS head. Nozzle configuration Monochrome 90 nozzles Color 29 nozzles x 3 (Cyan, Magenta, Yellow) The following shows the arrangement of the nozzles and the color arrangement of each nozzle line when viewed the printhead from behind.
2.822mm (40/360 inch)
2.2.2 Carriage Mechanism

Main components of the carriage mechanism are carriage unit (including printhead, CR encoder sensor), CR motor, timing belt, and CR scale.
2.2.2.1 CR Motor Specifications

Table 2-1. CR Motor Specifications
Item Type Drive voltage Electric resistance Inductance Drive method
K#90 K#89 C#29
Specification Motor with DC brush +42 V
5% (applied voltage to the driver) 28.4 10% 20.1 mH 25%

A6628
PWM, constant-current chopping
Drive IC
Cyan: 29nozzles
C#1 M#29
Paper Loading Direction
Color
Black
Magenta: 29nozzles
M#1 Y#29 K#3 0.2117mm (1/120 inch) K#2 K#1
Y#3 Y#2 Y#1
Yellow: 29nozzles
Carriage Moving Direction
Figure 2-2. Nozzle Rear View
Printer Mechanism
24
Revision A
2.2.3 Paper Feeding Mechanism

Paper loading/feeding mechanism consist of CR lock lever inside the ink system, holder shaft unit (including clutch mechanism), and ASF unit. CR lock lever and clutch mechanism play an important role in paper loading mechanism. Refer to 2.2.3.2 Drive Process (p25) for details.
2.2.3.2 Drive Process

1. Drive of the PF motor is transmitted to the paper eject roller and the PF roller via the PF timing belt, however, it is not transmitted to the LD roller and the retard roller owing to the clutch of the holder shaft unit. The carriage unit moves to the ASF trigger position once the paper loading command is received. PF motor is rotated counter clockwise, and the clutch is released by the PF motor lever. After the clutch is released, the PF motor rotates clockwise. Drive is transmitted to the LD roller and the paper loading operation begins. During paper loading operation, papers are fed from the ASF unit to inside the printer by the rotating movement of the two cams of the LD roller. Cam, large: releases hopper Cam, small:releases paper back lever 6. Once a sheet of paper is fed, the hopper and the paper back lever bring back rest of the papers to the position in readiness by the rotating movement of the two cams mentioned above. When the LD roller is turned a full circle, the CR lock lever release the clutch and the drive to the LD roller is interfered.
2. 3. 4. 5.
2.2.3.1 PF Motor Specifications (For both ASF and Pump motor)

Table 2-2. PF Motor Specification
Item Type Drive voltage Wire wound resistance Inductance Drive method Drive IC +42 V Specification 4-phase, 200-pole HB stepping motor
5 % (applied voltage to the driver) 10% (per one phase at 25 C)
3.0
3.5 mH 20% (1KH, 1Vrms) Bipolar drive 2-2 phase, 1-2 phase, W1-2, 2W1-2, 4W1-2 phase constant-current drive A6628
7.
Printer Mechanism
25
Revision A
2.2.4 Ink System Mechanism

The Ink system mechanism consists of pump mechanism and capping mechanism with wiper mechanism.
2.3 Electrical Circuit Operating Principles

The electric circuit of the Stylus C67/C68/D68 consists of the following boards. Main board: Power supply board: Panel board: C616 MAIN Board C616 PSB/PSB board C616 PNL board
2.2.4.1 Pump Unit Mechanism

With this printer, when the PF motor turns, power is always transmitted to the ink system. Table 2-3. PF Motor Rotational Direction & Ink System Mechanism
Directions* Counterclockwise Clockwise Note *: Release pump. Functions Absorbs the ink by the Pump Unit
This section provides block diagram of both C616 MAIN Board and C616 PSB/PSE Board, C616 PNL board.
C616 PNL Board

Printer Mechanism
The PF Motor rotational direction = seen from the left side of the printer.
2.2.4.2 Capping Mechanism

The Capping mechanism covers the printhead with the cap to prevent the nozzle from increasing viscosity when the printer is in stand-by state or when the printer is off.
CR Motor PF Motor C616 Main Board Head Driver Board Sensors CSIC Unit
+42V
PowerOFF
C616PSB/C616PSE Board
Figure 2-3. Electrical Circuit Block Diagram
Electrical Circuit Operating Principles
26
Revision A
Table 2-4. C616 MAIN Board Major Components and Primary Functions
IC FLASHROM Reset Regulator EEPROM Motor Driver Head Driver ASIC Location IC3 IC1 IC4 IC6 IC7 IC10 Function 3.3 V drive 4 M bit flash ROM that stores the program. 3.3V/1.5V generate regulator, 2 ch reset circuit Makes back up of default setting values and parameters Drives CR/PF motors, controls PWM by the program timer, adjusts 5 V, drives 42 V Generates trapezoidal waveform, drives 5 V Drives CPU (H8S/2674 base), internal 8 K byte x 4 RAM, 24 Mhz, 3.3 V/1.5V
2.3.1 C616 PSB/PSE Board

In the PSB/PSE Board of Stylus C67/C68/D68, the simulated oscillating stimulation flyback converter circuit method is used, and it supplies +42 VDC to the drive line. The application of the output voltage is described below. C616PSB Board: 100-120V C616PSE Board: 220-240V AC voltage input from AC inlet first goes through filter circuit that removes high frequency components and is then converted to DC voltage via the rectifier circuit and the smoothing circuit. DC voltage is then led to the switching circuit and FET Q1 preforms the switching operation. By the switching operation of the primary circuit,+42VDC is generated and stabilized at the secondary circuit.
2.3.2 C616 Main Board

The logic circuit of the C616 Main Board is composed of the following; Logic line (CPU-ASIC 2 in 1, Flash-ROM and so on) Motor control/drive circuit (CR Motor, PF Motor) Head control/drive circuit Sensor circuit Reset circuit, EEPROM circuit Figure 2-4. C616 Main Board Block Diagram
Electrical Circuit Operating Principles
27
CHAPTER
TROUBLESHOOTING
Revision A
3.1 Overview
This chapter describes how to solve problems.
W A R N IN G
3.1.2 Preliminary Checks

Before starting troubleshooting, be sure to verify that the following conditions are all met: The power supply voltage must be within the specification limits. (Measure the voltage at the wall socket.) The power code must be free from damage, short circuit or breakage, or miswiring in the power code. The printer must be grounded properly. The printer should not be located in a place where it can be exposed to too high or low temperature, too high or low humidity, or abrupt temperature change. The printer should not be located near waterworks, near humidifiers, near heaters or near flames, in a dusty atmosphere or in a place where the printer can be exposed to blast from an air conditioner. The printer should not be located in a place where volatile or inflammable gases are produced. The printer should not be located in a place where it can be exposed to direct rays of the sun. The printer must be located in a well-ventilated place. The printer must be placed on a strong and steady level table (without an inclination larger than five degrees). The paper used must conform to the specification. There is no error in handling of the printer.
Be careful to avoid electric shocks when checking the electrical circuit boards (C616 MAIN, PSE and B circuit boards) while the power is turned on. Touching an FET, transistor or heat sink with one hand while touching a metal part of the mechanism with the other hand could result in an electric shock, so carefully avoid this. After initial filling of ink has been repeated several times, immediate moving or tilting of the printer could result in leaking of ink that has not been completely absorbed by the Waste Ink Pad. When initial filling of ink has been repeated several times, check the ink remaining in the tip of the Waste Ink Tube and the waste ink not absorbed by the Waste Ink Pad before moving the printer. Disassembly and reassembly of parts is often required when identifying the causes of problems. The parts should be disassembled and re-assembled correctly while referring to DISASSEMBLY/ASSEMBLY (p35) so that the operation and status of each check item can be correctly verified. Some individual part and units may require adjustment once they are removed or replaced. If removing or replacing parts which have specific instructions for adjustment included in DISASSEMBLY/ASSEMBLY (p35), be sure to make these adjustments after repairing the problem location.
C H E C K P O IN T
3.1.1 Specified Tools

This printer does not require any specified tools for troubleshooting.
Check the inside of the printer, and remove foreign matters if any, such as paper clips, staples, bits of paper, paper dust or toner. Clean the inside of the printer and the rubber rolls.
TROUBLESHOOTING
Overview
29
Revision A
3.2 Troubleshooting With LED Error Indications

LED error display, cause, and remedy are explained here. Table 3-1. Troubleshooting With LED Error Indications
Error Ink end/ No ink cartridge/ CSIC error --yPaper Out --On LED status Power Paper Ink Cause Ink inside Bk, Y, M, C ink cartridges has run out. Ink cartridge(s) is not installed. Non-genuine ink cartridge(s) is installed. Paper loading operation is executed when there is no paper. Papers stopped before the PE Snesor or could not be fed. Papers are fed without being placed against the right edge guide. Connector of the PE sensor is disconnected. When performing duplex printing, blank paper is ejected. The printer detected that the paper is too long upon ejection. Remedy Check the ink cartridge(s) and reinstall it correctly. Replace the ink cartridge(s) with a genuine one. 1. If there is no paper on the paper tray, load papers. 2. If the paper has stopped halfway, remove the paper, check if the paper is not bent, fan the paper, and load it against the edge guide. 3. Press the [Paper] switch to release the error.
---
On
---
Multi-feed error --On ---
1. Remove the blank paper, or check the paper size. 2. Press the [Paper] switch to eject the paper and release the error.
TROUBLESHOOTING
Troubleshooting With LED Error Indications
30

Table 3-1. Troubleshooting With LED Error Indications
Error Paper jam LED status Power Paper Ink Cause Even though paper feeding operation is carried out for predetermined times, leading edge or back-end of the paper could not be detected. --Flashes --Remedy
Revision A
1. Press the [Paper] switch on the panel. 2. If paper jam occurred again after pressing the switch, open the printer cover and remove all the papers inside the printer and papers set on the hopper. 3. Making sure there is no paper inside the printer, load paper on the hopper and press [Paper]. Replace the waste ink pad, and reset the waste ink counter (protection counter A) using the adjustment program. Refer to Chapter5 ADJUSTMENT (p.76) for details. 1. Turn the power off, wait for a few seconds, and turn the power back on again. 2. If the fatal error still appears, turn the power off, remove the papers on the hopper, and check the following: Open the printer cover, check the ink cartridges, and reinstall them correctly. Check is there is no foreign material or papers inside the printer. If there is any, remove them. 3. Turn the printer power on. 4. If the fatal error appears again, refer to 3.2.1 Fatal Error (p32) and examine/replace the parts.
Maintenance request (Waste ink overflow)
Off
Flashes alternately
Flashes alternately
As a result of cleaning and flushing, total emission of ink has exceeded the specific level.
Fatal error
Home position of the carriage could not be detected. Abnormal external pressure is applied to the printer when the power is on. Carriage movement is interfered during printing. Off Flashes on high speed Flashes on high speed
TROUBLESHOOTING
31
Revision A
3.2.1 Fatal Error

C H E C K P O IN T
As the most recent fatal error (fatal error code) is stored in the EEPROM (Address: 0AH), it is possible to check the error by using the adjustment program.
Check the parts according to the contents of the fatal error, and replace the parts as necessary.
Classification DC Error Item PID aveTi max Error Description Something is wrong with the CR motor. Remedy
Check the parts listed below, and replace them as necessary. CR Motor PID Overspeed Error Carriage movement speed is abnormal. CR Encoder PID Lock Error Carriage has been locked for a certain period of time due to CR Encoder Scale external factors. PID Reverse Rotation Detection Error The number of the carriage reverse rotation has exceeded the Timing Belt Main Board predetermined times due to external factors. Connectors and harnesses of each motor or encoder Encoder Abnormality Error (CR Driving One-pass movement cannot be completed though the CR Time Over Error) motor has been driving longer than the specified time. Load Positioning Overspeed Error Load Positioning Lock Error Abnormal carriage movement speed is detected during load positioning control. It is detected that the carriage has been locked for a certain period of time during load positioning control.
Load Positioning Cumulative Movement The cumulative movement distance during the load Distance Error positioning control has exceeded the given level Head Error Transistor Environment Temperature Abnormality Error Pre-printing X-HOT Detection Error The environment temperature of the transistor that generates head driving waveform on the Main board is abnormal. Check the parts listed below, and replace them as necessary. Printhead During pre-printing X-Hot detection, the temperature of the Head FFC head driver IC has exceeded the given level for more than two Main Board seconds. During post-printing X-Hot detection, the temperature of the head driver IC has exceeded the given level for more than two seconds.
Post-flushing X-HOT Detection Error
TROUBLESHOOTING
32
Revision A
Classification Sequence Error
Item Left Frame Shock Detection Error Between Left Frame and [TF] Shock Detection Error Between [TF] and [HOME] Shock Detection Error
Description Abnormal pressure has being added to the carriage due to external factors.
Remedy Make sure that there is no obstruction on the carriage moving path, check the parts listed below, and replace them as necessary. CR Motor CR Encoder CR Encoder Scale Timing Belt Main Board
Motor Driving Time Error
PF Driving Time Over Error
Paper feed cannot be completed though the PF motor has been Check the parts listed below, and replace them as necessary. driving longer than the specified time. PF motor Main board Connectors and harnesses of each motor or encoder
TROUBLESHOOTING
33
Revision A
3.3 Troubleshooting for Motors and Sensors

Motor Table 3-2. Motor Resistance and Check Points
Motor name CR motor PF motor Type Motor with DC brush 4-phase, 200-pole HB stepping motor Location CN5 CN6 Check point Pin 1&2 Pin 1&3 Pin 2&4 Resistance 28.4 10% 3.0 10%
Sensor Table 3-3. Sensor Check

Sensor name PE sensor Detecting system Transmission photo interrupter Location CN9 pin 1&2 Signal level 2.4 V or more 0.4 V or less Sensor status Paper loaded No paper
TROUBLESHOOTING
Troubleshooting for Motors and Sensors
34
CHAPTER
DISASSEMBLY/ASSEMBLY
Revision A
4.1 Overview
This section describes procedures for disassembling the main components of the product. Unless otherwise specified, disassembled units or components can be reassembled by reversing the disassembly procedure. Procedures which, if not strictly observed, could result in personal injury are described under the heading WARNING. CAUTION signals a precaution which, if ignored, could result in damage to equipment. Important tips for procedures are described under the heading CHECK POINT. If the assembly procedure is different from the reversed disassembly procedure, the correct procedure is described under the heading REASSEMBLY. Any adjustments required after reassembly of components or parts are described under the heading ADJUSTMENT REQUIRED. When you have to remove any components or parts that are not described in this chapter, refer to the exploded diagrams in the appendix.
C A U T IO N
Make sure that there is enough work space for disassembly/ reassembly. Use only recommended tools for disassembling, assembling or adjusting the printer. Observe the specified torque when tightening screws. Apply lubricants as specified. (See "6.1.3 Lubrication" (p92) for details.) The printer disassembled/assembled to make this manual is a test production, and the colors or configurations may differ from the finished product. However, these differences have no effect for disassembling/assembling the product. When using compressed air products; such as air duster, for cleaning during repair and maintenance, the use of such products containing flammable gas is prohibited.
4.1.1 Precautions
See the precautions given under the handling WARNING and CAUTION in the following columns when disassembling or assembling EPSON Stylus C67/C68/D68.
W A R N IN G
Disconnect the power cable before disassembling or assembling the printer. If you need to work on the printer with power applied, strictly follow the instructions in this manual. Always wear gloves for disassembly and reassembly to avoid injury from sharp metal edges. To protect sensitive microprocessors and circuitry, use static discharge equipment, such as anti-static wrist straps, when accessing internal components.
Overview
36
Revision A
Table 4-2. Screws
No. 6 Parts No. 1080530 1080532 1080527 1080561 (T.B.D) 7 C.B.P.(P2) 3 x 8 8 C.P. 3 x 4 9 Type C.B.S-TITE SCREW 10 Hexagon nut, normal, M3 T.B.D 11 C.P.B (P1) 1.7 x 5 T.B.D C.P. SCREW C.B.P-TITE (P2) SCREW C.B.P. 3 x 10 C.B.P-TITE SCREW Image Name C.B.P. 3 x 8 Type C.B.P-TITE SCREW
4.1.2 Tools
Use only specified tools to avoid damaging the printer. Table 4-1. Tools
Name (+) Phillips screwdriver #1 (+) Phillips screwdriver #1 Flathead screwdriver Tweezer Hex wrench (T.B.D) Supplier EPSON EPSON EPSON EPSON (T.B.D)
4.1.3 Screws (T.B.D)

Screws used on the Stylus C67/C68/D68 are shown below. Table 4-2. Screws
No. 1 C.B.S. 3 x 8 2 C.B.S. 3 x 14 3 C.B.S.(P4) 3 x 6 4 C.B.P. 2.5 x 8 5 C.B.S-TITE SCREW C.B.P-TITE (P4) SCREW C.B.S-TITE SCREW C.B.P-TITE SCREW Image Name C.B.S. 3 x 6
Overview
37
Revision A
Table 4-3. Work Completion Check
Classification Function Item ROM Version Ink Cartridge Status Checked Not necessary Checked Not necessary Checked Not necessary Checked Not necessary Checked Not necessary Checked Not necessary Checked Not necessary Packing Protective materials Attachments, Accessories Version: Are the ink cartridges installed correctly? Have all relevant protective materials been attached to the printer? Have all the relevant items been included in the package? Check Point Status Checked Not necessary Checked Not necessary Checked Not necessary Checked Not necessary
4.1.4 Work Completion Check

If any service is made to the printer, use the checklist shown below to confirm all works are completed properly and the printer is ready to be returned to the user. Table 4-3. Work Completion Check
Classification Item Self-test ON-line Test Printhead Check Point Is the operation normal? Is the printing successful Is ink discharged normally from all the nozzles? Does it move smoothly? Is there any abnormal noise during its operation? Is there any dirt or foreign objects on the CR Guide Shaft? Is the CR Motor at the correct temperature? (Not too hot to touch?) Is paper advanced smoothly? No paper jamming? No paper skew? No multiple feeding? No abnormal noise? Is the PF Motor at correct temperature? Is the paper path free of any obstructions? Adjustment Specified Adjustment Specified Lubrication Are all the adjustment done correctly? Are all the lubrication made at the specified points? Is the amount of lubrication correct?
Others
Carriage Mechanism Main Unit
Checked Not necessary
Paper Feeding MEchanism
Checked Not necessary Checked Not necessary Checked Not necessary Checked Not necessary Checked Not necessary
Lubrication
Overview
38
Revision A
[Z-axis direction] - Make sure that there is no gap between main frame and Housing, Lower. - Make sure that the left side of Printer mechanism is correctly fixed by two tabs. (b) Control of vertical level of guide rail (Guide rail means the portion latched by hooks of IC holder & Print head assy.) [Reason] There is a possibility that printing failure/operation failure occurs by guide rail deformation. [Service treatment] - Do not remove [Mounting Plate, M/B] from Printer mechanism. - Hold up the specified position of main frame to avoid the deformation. (c) How to assemble of ASF unit/Circuit board/Paper guide upper [Reason] There is a possibility that main frame deformation is caused extra force in assembling. As the result, printing failure/operation failure occurs. [Service treatment] Hold the opposite side with hand while you are installing the above parts.
4.2 Caution regarding Assembling/Disassembling of the Printer Mechanism, and How to Ensure of Quality on Re-assembled Product
On current low end models, weve basically forbidden to remove Housing, Lower from Printer mechanism in your repair. This is because there is a possibility of main frame deformation when a part (such as Ink system) is removed from Printer mechanism without Housing, Lower. For this reason, if you want to replace Ink system/PF motor, we recommend to replace with new Printer mechanism with Housing, Lower. On these models, you have to remove Housing, Lower from printer mechanism when replacing Waste Ink Pad with a new one. Therefore, we clarify caution regarding assembling/disassembling of the printer mechanism without Housing, Lower, and how to ensure of quality on repaired products in this section. [Caution regarding assembling/disassembling of the printer mechanism] 1) Main frame (a) Control of assembled standard position. [Reason] The assembled accuracy of each part composed of Printer mechanism is based on Housing, Lower. [Service treatment] Confirm that there is no gap between main frame and Housing, Lower. [Reference] To ensure the assembled accuracy, you have to control the assembled standard position of main frame against X/Y/Z-axis direction. [X-axis direction] - Make sure that main frame is correctly placed on the groove of Housing, Lower. - Make sure that there is no gap between main frame and Housing, Lower. [Y-axis direction] Make sure that cut-out portion of main frame is correctly placed on the square protrusion of Housing, Lower.
Caution regarding Assembling/Disassembling of the Printer Mechanism, and How to Ensure of Quality on Re-assembled

2) Front frame (a) Control of vertical level [Reason] There is a possibility that printing failure occurs by front frame deformation. [Service treatment] Handle Front frame in assembling/disassembling carefully. 3) IC holder (a) Handling of IC holder [Reason] If IC holder is damaged in assembling/disassembling of your repair, there is a possibility that vital problem occurs in users further operation. [Service treatment] Released two hooks of IC holder from the inside of IC holder by the tweezer. [How to ensure of quality on re-assembled product] We judge that the quality of re-assembled product is ensured if there is no problem about the print result by adjustment program.
Revision A
Caution regarding Assembling/Disassembling of the Printer Mechanism, and How to Ensure of Quality on Re-assembled
Revision A
4.3 Disassembly Procedures

This section explains the procedures for disassembling the product. Unless otherwise stated, reassembly should be carried out in the reverse order of the disassembly procedure. For detailed engagement relations among main components, refer to the exploded diagrams in the Appendix. When disassembling each unit, refer to the pages described in the chart below.
START
"Housing, Upper" 4.3.1.1 (p. 43)
"Stacker Assy." 4.3.1.2 (p. 44)
"ASF Unit" 4.3.1.3 (p. 44)
"CR Timing Belt" 4.3.3.5 (p. 60)
"Front Frame" 4.3.3.7 (p. 62)
"CR Encoder Scale" 4.3.3.8 (p. 63)
"CR Cable Head Cover" 4.3.3.9 (p. 64)
"Paper Guide, Upper Assy." 4.3.3.14 (p. 70)
"CR Motor" 4.3.3.6 (p. 61)
"Eject Roller" 4.3.3.15 (p. 70)
"Paper Guide, Front Assy." 4.3.3.16 (p. 72)
"Hopper/Retard Roller Unit" 4.3.1.4 (p. 45)
"Main Board" 4.3.2.1 (p. 52)
"Panel Board" 4.3.2.2 (p. 54)
"PS Board" 4.3.2.3 (p. 55)
Figure 4-1. Disassembling Flowchart (1)
Disassembly Procedures
41
Revision A
START
* Procedure in the broken-line is NOT the shortest removing procedure, but the passing point for the next removing procedure.
"PS Board" 4.3.2.3 (p. 55)
"Panel Board" 4.3.2.2 (p. 54)
"Holder Shaft Unit"4.3.3.2 (p. 56) 4.3.3.2 (p. 56)
"Front Frame" 4.3.3.7 (p. 62)
"Stacker Assy." 4.3.1.2 (p. 44)
"Spool Gear 36.8/Extension Spring 0.143/Clutch" 4.3.3.3 (p. 58)
"CR Encoder Scale" 4.3.3.8 (p. 63)
"Paper Guide, Front Assy." 4.3.3.16 (p. 72)
"PE Sensor Board/PE Detection Lever/Idle Roller" 4.3.3.4 (p. 59)
"CR Cable Head Cover" 4.3.3.9 (p. 64)
"Housing, Lower Assy." 4.3.1.5 (p. 47)
"CR Unit" 4.3.3.10 (p. 64)
"Waste Ink Pad" 4.3.1.6 (p. 51)
"PF Motor" 4.3.3.18 (p. 75)
"Holder Shaft Unit" 4.3.3.2 (p. 56)
"Printhead Assy." 4.3.3.11 (p. 67)
"CR Encoder Sensor Board" 4.3.3.12 (p. 68)
"CSIC Board" 4.3.3.12 (p. 68)
"Pump Unit/Cap Unit" 4.3.3.17 (p. 73)
Figure 4-2. Disassembling Procedure (2)
42
Revision A
4.3.1 Removing Housings

C A U T IO N
Do not damage the tabs in removing the Housings. Do not tilt the printer too much when removing the Housings because ink may flow if the Carriage unit is not at the home position.
4.3.1.1 Housing, Upper

1) Remove the two screws on backside of the Housing, Upper. C.B.P. 3 x 8: 2
C.B.P. 3x8
Tabs
C.B.P. 3x8
2) Insert a flathead screwdriver into the two tabs on upper backside of the Housing, and release the tabs. 3) Open the Stacker Assy. (See 4.3.1.2 Removing Stacker Assy. Step 2). 4) Having your hands on the grooves of the Housing, Lower, press the parts toward the direction of the arrows a shown in Figure 4-3, and remove the Housing, Upper.
Tabs
Figure 4-3. Removing Housing, Upper
43
Revision A
4.3.1.2 Stacker Assy.

1) Remove the Housing, Upper. (p43) 2) Open the Stacker assy. 3) Push the shaft located on the left side of the Stacker Assy. with a flathead screwdriver or a similar tool, release the shaft from the slot of the Housing, Lower, and remove the Stacker Assy.
4.3.1.3 ASF Unit

1) Remove the Housing, Upper. (p43) 2) Open the Stacker Assy. (See 4.3.1.2 Removing Stacker Assy. Step 2) 3) Remove the three screws that secure the ASF Unit to the main unit, and remove the ASF unit. C.B.S. 3 x 6: C.B.S. (P4) 3 x 6: C.B.P. 3 x 8: 1 1 1
ASF Unit
C.B.S. 3 x 6
1
Stacker Assy.
C.B.S.(P4) 3 x 6
3
Shaft C.B.P. 3 x 8
Figure 4-4. Removing Stacker Assy. Figure 4-5. Removing ASF Unit
44
Revision A
When installing the ASF Unit to the main unit, follow the steps described below. 1. Make sure to match the guide pin of the ASF Unit with the positioning hole of the main unit. 2. Make sure to match the shaft of the ASF Unit with the bearing of the Pump Unit. 3. Secure the screws in the order shown in Figure 4-5.
Side Surface of the ASF Unit
4.3.1.4 Hopper/Retard Roller Unit

C A U T IO N
Do not touch the cork on the Retard Roller and the Hopper.
1) Remove the ASF Unit. (p44) 2) Lift up the Hopper toward the direction of the arrow, release the two tabs, and remove the spring and the hopper from the ASF Frame.
Hopper Side ASF Frame Side
Guide Pin
Shaft
Tab
Shaft
Shaft and Bearing Guide Pin and Positioning Hole
Figure 4-6. Installing ASF Unit

Cork
When you replace the ASF unit with a new one, lubricate it as specified. See "6.1.3 Lubrication" (p92) for details. When ASF unit is removed or replaced with new one, the following adjustment must be performed in the order below. 1. Top Margin Adjustment 2. First Dot Adjustment
Hopper
Spring ASF Frame
Retard Roller
Figure 4-7. Removing Hopper
45

3) Remove Extension Spring 0.585 from both the ASF Frame and the Paper back Lever. 4) Remove the Paper Back Lever from the bearing of the ASF frame. 5) Remove Compression Spring 1.88 from the ASF Frame, and remove the Retard Roller Unit.
Paper Back Lever Extension Spring 0.585 Compression Spring 1.88
Revision A
When installing the Retard Roller or the Paper Back Lever, attach the two springs as described below. Extension Spring 0.585 Attach the spring to the tab of the ASF Frame and the one of the Paper Back Lever. Compression Spring 1.88 Attach the spring to the boss of the ASF Frame and the one of the Retard Roller Unit.
Extension Spring 0.585
Bosses Tabs Bearing ASF Frame Compression Spring1.88
Figure 4-9. Attaching the Springs When installing the spring between the Hopper and the ASF Frame, match the spring with the positioning hole (circular dent) of the Hopper and the one of the ASF Frame.
Retard Roller Unit ASF Frame Side Positioning Hole Hopper Side Positioning Hole
Figure 4-8. Removing Retard Roller Unit
Figure 4-10. Attaching the Springs
46
Revision A
4.3.1.5 Housing, Lower Assy.

C A U T IO N
C A U T IO N
Do not remove the Housing, Lower Assy. more than is necessary.
When removing the Waste Ink Tube from the Waste Ink Pad, pay attention not to spill the ink.
6) Remove the Waste Ink Tube from the Waste Ink Pad. 1) Remove the Stacker Assy.. (p44) 2) Remove the PS Board. (p55) 3) Remove the Paper Guide, Front Assy.. (p72) 4) Move the CR unit to the center of the printer. (See 4.3.3.2 Removing Holder Shaft Unit Step 3) 5) Remove the two rubber feet located on the PF Motor side.
Bottom Face Waste Ink Tube Tab
Figure 4-12. Removing Waste Ink Tube 7) Remove the Cap Unit from the two guide pins of the Housing, Lower Assy.
Rubber Feet
Guide Pin
Figure 4-11. Removing Rubber Feet

Guide Pin Cap Unit
Figure 4-13. Removing Cap Unit
47

8) Remove the four screws that secure the Housing, Lower Assy to the main unit. C.B.P. 3 x 8: 3 C.B.P.(P2) 3 x 8: 1 3
C.B.P. (P2) 3 x 8
Revision A
C A U T IO N
When performing the following work, be sure to hold the places indicated with dotted circles to avoid deformation of the Main Unit Frame.
9) Release the two tabs on the PF Motor side of the Housing, Lower assy, and remove the Housing, Lower Assy. 2
Holding Position
C.B.P. 3 x 8
Figure 4-14. Removing Housing Lower Assy. (1)
Housing, Lower Assy.
PF Motor Assy.
Tab
Figure 4-15. Removing Housing Lower Assy. (2)
48
Revision A
To ensure the assembling accuracy, you have to control the assembled standard position of the Main Frame against X/Y/Zaxis direction as follows. [X-axis direction] Make sure that main frame is correctly placed on the groove of Housing (Lower). Make sure that there is no gap between main frame and Housing (Lower). [Y-axis direction] Make sure that cut-out portion of main frame is correctly placed on the square protrusion of Housing, Lower.
X-axis Assembled Standard Position Y-axis Assembled Standard Position
[Z-axis direction] Make sure that there is no gap between main frame and Housing, Lower. Make sure that the left side of Printer Mechanism is correctly fixed with two tabs.
Z-axis Assembled Standard Position
Z-axis Assembled Standard Position Tabs
Figure 4-16. X and Y-axis Assembled Standard Position
Figure 4-17. Z-axis Assembled Standard Position
49
Revision A
When installing the Cap Unit, pay attention to the following instructions: Route the Ink Tube underneath the Cap Unit. Make sure that the two bosses of the Cap Unit are located under the Main Unit Frame.
Bosses
When Housing (Lower) is removed or replaced with new one, the following adjustment must be performed in the order below. 1. Top Margin Adjustment 2. PF Adjustment 3. Bi-D Adjustment 4. Head Angular Adjustment 5. First Dot Adjustment
Ink Tube
Figure 4-18. Installing Cap Unit When installing the Cap Unit, route the Waste Ink Tube as shown below, and place it under the protective sheet.
Tab
Protective Sheet
Waste Ink Tube
Figure 4-19. Routing Waste Ink Tube When installing the Main Frame to the Housing, Lower Assy, secure the screws as shown in Figure 4-14.
50
Revision A
4.3.1.6 Waste Ink Pad

1) Remove the Housing, Lower Assy.. (p47) 2) Remove the eight Waste Ink Pad and the protective sheet from the Housing, Lower.
Attach the Waste Ink Pads correctly with reference to Figure 4-21.
Installation Order
Installation Order
4 5 1
Waste Ink Pad
3 1 2
Figure 4-20. Removing Waste Ink Pad

Double-sided Tape Attachment Areas
Figure 4-21. Attaching Waste Ink Pads
51
Revision A
3) Disconnect all the connectors from the Main Board. CN2: CN4: CN5: CN6: CN7: CN8: CN9: Power Supply Cable Panel Board Connector CR Motor Connector PF Motor Connector CR Encoder FFC Head FFC PF Sensor Cable
4.3.2 Removing Boards

4.3.2.1 Main Board
1) Remove the ASF Unit. (p44) 2) Remove the Clump Core from the Main Unit.
Clump Core
CN7
CN8
Figure 4-22. Removing Clump Core

CN9 CN5 CN4
CN6 CN2
Figure 4-23. Removing Main Board (1)
52

4) Remove the four screws that secure the Main Board Unit to the Main Unit, and remove the Main Board Unit. C.B.S. 3 x 14: C.B.S. 3 x 6: 2 2
Main Board Unit
Revision A
5) Remove the Main Board Cover from the Main Board Unit.
Main Board
Main Board Cover
C.B.S. 3 x 14
4
C.B.S. 3 x 6
Figure 4-25. Removing Main Board (3) When installing the Main Board Unit to the Main Unit, Secure the screws in the order shown in Figure 4-24. When attaching the Clump Core, pay attention not to confuse left and right. The side with two portions should be facing to the left.
Figure 4-24. Removing Main Board (2)
Portions
Figure 4-26. Attaching Clump Core
53
Revision A
When replacing the Main board with new one, perform the following service items. If the read-out operation succeeds by adjustment program from defective main board, replace with new board and write the read out data to new one. 1. Ink consumption counter 2. Waste drain ink pad counter 3. Head ID Input 4. Bi-D Adjustment 5. Top Margin Adjustment 6. First Dot Adjustment 7. USB ID Input 8. Market ID Setting 9. Head Angular Adjustment 10. PF Adjustment 11. CR motor drive torque dispersion measurement If the read-out operation is not able to succeed by adjustment program from defective main board, perform the following service items after replacing main board with new one. 1. Replace the Waste drain ink pad with a new one. 2. Head ID Input 3. Bi-D Adjustment 4. Top Margin Adjustment 5. First Dot Adjustment 6. USB ID Input 7. Market ID Setting 8. Head Angular Adjustment 9. PF Adjustment 10. Offset input for CR Motor Calorific Limitation
4.3.2.2 Panel Board

1) Remove the ASF Unit. (p44) 2) Disconnect the Panel Board Connector (CN4) from the Main Board. (See 4.3.2.1 Removing Main Board Step 3) 3) Release the Panel Board from the two tabs and the notch of the Holder Shaft Unit.
Holder Shaft Unit Notch Panel Board
Tabs
Figure 4-27. Removing Panel Board When installing the Panel Board, make sure to hitch the Panel Board Connector to the tab of the Holder Shaft Unit.
Holder Shaft Unit
Tab
Figure 4-28. Routing Panel Board Connector
54
Revision A
5) Remove the four screws that secure the PS Board to the PS Board Frame, Lower, and remove the PS Board. C.B.S 3 x 6: 4
C.B.S. 3 x 6 (61 kgf.cm)
4.3.2.3 PS Board
1) Remove the ASF Unit. (p44) 2) Disconnect the Power Supply Cable (CN2) from the Main Board. (See 4.3.2.1 Removing Main Board Step 3) 3) Remove the three screws that secure the PS Board Unit to the Main Unit, and remove the PS Board Unit. C.B.P. 3 x 10: C.B.S. 3 x 6: 2 1
PS Board Unit C.B.S. 3 x 6 (81 kgf.cm)
2
C.B.P. 3 x 10 (61 kgf.cm)
1 3 2
3
C.B.P. 3 x 10 (61 kgf.cm)
Figure 4-31. Removing PS Board When installing the PS Board to the PS Board Frame, Lower, secure the screws in the order shown in Figure 4-31. When installing PS Board Unit to the Main Unit, secure the screws in the order shown in Figure 4-29.
Figure 4-29. Removing PS Board 4) Release the two tabs on both sides of the PS Board Unit, and remove the PS Board Frame, Upper.
PS Board Frame, Upper
When PS board unit is removed or replaced with new one, the following adjustment must be performed in the order below. 1. Top Margin Adjustment 2. PF Adjustment 3. First Dot Adjustment 4. Offset input for CR Motor Calorific Limitation
Tab
Tab
Figure 4-30. Removing PS Board Frame, Upper
55
Revision A
4.3.3 Disassembling Printer Mechanism

4.3.3.1 Printer Mechanism
C A U T IO N
4.3.3.2 Holder Shaft Unit

1) Remove the Panel Board. (p54) 2) Remove the Clump Core from the Main Unit. (See 4.3.2.1 Removing Main Board Step 2) 3) Press down the CR Lock Lever toward the direction of the arrow, and move the CR unit to the other side of the home position.
When handling the Printer Mechanism, do not hold the Front Frame with your hands.
Follow the following steps to bring out the Printer Mechanism. 1) Remove the Stacker Assy.. (p44) 2) Remove the Main Board. (p52) 3) Remove the Panel Board. (p54) 4) Remove the PS Board. (p55) 5) Remove the Housing, Lower Assy.. (p47)
CR Lock Lever
CR Unit
Figure 4-32. Moving CR Unit
56

4) Disconnect the four connectors from the Main Board. (See 4.3.2.1 Removing Main Board Step 3) CN5: CN7: CN8: CN9: CR Motor Connector CR Encoder FFC Head FFC PF Sensor Cable
Revision A
7) Slide the concave portion of the Pump Unit toward the direction of the arrow, and release the convex portion of the Holder Shaft Unit.
Concave and Convex Portions
5) Release both the CR Encoder FFC and the Head FFC from the tab of the Holder Shaft Unit. 6) Disconnect the CR Motor Cable from the Holder Shaft Unit.
CR Encoder FFC/ Head FFC
Tab Pump Unit
Figure 4-34. Removing Holder Shaft Unit (2)

Holder Shaft Unit
8) Releasing two tab As that secure the Holder Shaft Unit to the Main Unit, Remove the Holder Shaft Unit upward.
CR Motor Cable
Tab As
57
Revision A
When installing the CR Motor Cable to the Holder Shaft Unit, be sure to route the cable as shown below.
Tab Notch
4.3.3.3 Spool Gear 36.8/Extension Spring 0.143/Clutch

C A U T IO N
Never touch the LD Roller. When removing the LD Roller Shaft Unit, pay attention not to drop the Spool Gear 36.8, Extension Spring, and Clutch.
1) Remove the Holder Shaft Unit. (p56)

Holder Shaft Unit CR Motor Cable
2) Remove the LD Roller Shaft Unit from the Holder Shaft Frame. 3) Remove the Spool Gear 36.8 from the LD Roller Shaft Unit. 4) Release the Extension Spring 0.143 that joins the LD Roller Shaft Unit and the Clutch, and remove the Clutch.
Holder Shaft Frame
LD Roller Shaft Unit
LD Roller
Figure 4-36. Routing CR Motor Cable

When Holder shaft unit is removing or replacing Holder shaft Unit with new one, the following adjustment must be performed in the order below. 1. Top Margin Adjustment 2. First Dot Adjustment
Clutch Spool Gear 36.8
Figure 4-37. Removing LD Roller Shaft Unit
58
Revision A
The LD Roller Shaft Unit should be reassemble as shown below.
4.3.3.4 PE Sensor Board/PE Detection Lever/Idle Roller

1) Remove the Spool Gear 36.8/Extension Spring 0.143/Clutch. (p58) 2) Release the tab that secures the PE Sensor Board to the Holder Shaft Frame. 3) Release the cable from the Holder Shaft Frame, and remove the PE Sensor Board.
Clutch LD Roller Shaft
4) Release the shaft of the PE Detection Lever from the bearings of the Holder Shaft Frame, and remove Torsion Spring 0.22 from the PE Detection Lever. 5) Release the Idle Roller from the bearings of the Holder Shaft Frame.
Spool Gear 36.8
Figure 4-38. Assembling LD Roller Shaft Unit

PE Detection Lever
PE Sensor Cable
Idle Roller
PE Sensor Board Torsion Spring 0.22 Tab
Bearings
Figure 4-39. Removing PE Sensor Board/PE Detection Lever/Idle Roller
59
Revision A
When installing the PE Detection Lever, attach Torsion Spring 0.22 as shown below.
4.3.3.5 CR Timing Belt

1) Remove the Housing, Upper. (p43) 2) Move the CR Unit toward the center of the printer. (See 4.3.3.2 Removing Holder Shaft Unit Step 3) 3) Loosen the screw that secures the Drive Pulley Holder Stopper to the Main Unit. C.B.S. (P4) 3 x 6: 1
Torsion Spring 0.22
4) Press the Drive Pulley Holder toward the direction of the arrow, pull the CR Timing Belt toward you, and remove the belt from the Drive Pulley Holder.
Figure 4-40. Attaching Torsion Spring 0.22 When installing the PE Sensor Cable to the Holder Shaft Frame, route the cable as shown below.
Holder Shaft Frame Tab Notch
CR Timing Belt C.B.S. (P4) 3 x 6
Drive Pulley Holder
Drive Pulley Holder Stopper
PE Sensor Cable
Figure 4-42. Removing CR Timing Belt 5) Remove the CR Unit. (p64) When installing the CR Timing Belt to the CR Unit, make sure to attach the belt to the positioning jag as shown in Figure 4-55.
Figure 4-41. Routing PE Sensor Cable
60
Revision A
4.3.3.6 CR Motor
1) Remove the CR Timing Belt. (4.3.3.5 Removing CR Timing Belt Step 2 through Step 4) 2) Disconnect the CR Motor Connector (CN5) from the Main Board. (See 4.3.2.1 Removing Main Board Step 3) 3) Remove the CR Motor Cable from the Holder Shaft Unit. (See 4.3.3.2 Removing Holder Shaft Unit Step 6)
C A U T IO N
When installing the CR Motor, follow the steps described below. 1. Positioning hole of the CR Motor should be on the downside.
Threaded Holes
Make sure to support the CR Motor with your hands when removing the screws.
Positioning Hole
4) Remove the two screws that secure the CR Motor to the Main Unit, and remove the CR Motor. C.P. 3 x 4: 2
Positioning Hole
C.P. 3 x 4 (41 kgf.cm)
2. 3. 1
Figure 4-44. Installing CR Motor Secure the screws in the order shown in Figure 4-43. When installing the CR Motor Cable to the Holder Shaft Unit, route the cable as shown in Figure 4-36.
CR Motor
Figure 4-43. Removing CR Motor
When CR timing belt is removed or replaced with new one, tension adjustment of CR timing belt must be performed by the degital tension gauge. When CR motor is removed or replaced with new one, the following adjustment must be performed in the order below. 1. Top Margin Adjustment 2. PF Adjustment 3. Bi-D Adjustment 4. Head ID Input 5. First Dot Adjustment 6. Offset input for CR Motor Calorific Limitation
61
Revision A
4.3.3.7 Front Frame

1) Remove the Housing, Upper. (p43) 2) Move the CR Unit to the center of the printer. (See 4.3.3.2 Removing Holder Shaft Unit Step 3) 3) Remove both the two screws that secure the Front Frame to the Main Unit and the Front Frame Stopper. C.B.S. 3 x 6: 2
Match the positioning hole with the rib as shown in Figure 4-45 when installing the Front Frame. Secure the screws in the order shown in Figure 4-45.
4) Lift up the CR Unit, and remove the Front Frame.
When you replace Front frame with new one, lubricate it as specified. See "6.1.3 Lubrication" (p92) for details. When Front frame is removed or replaced with new one, the following adjustment must be performed in the order below. 1. PF Adjustment 2. Bi-D Adjustment
Front Frame
CR Unit
C.B.S. 3 x 6 (81 kgf.cm)
C.B.S. 3 x 6 (81 kgf.cm)
1
Positioning Hole and Rib
2
Positioning Hole and Rib
Front Frame Stopper
Front Frame Stopper
Figure 4-45. Removing Front Frame
62
Revision A
5) Release Extension Spring 1.494 on the left side of the CR Encoder Scale from the tab of the Main Unit, turn the CR Encoder Sensor 90 degrees as shown in the figure, and remove the CR Encoder sensor.
4.3.3.8 CR Encoder Scale

1) Remove the Housing, Upper. (p43) 2) Move the CR Unit toward the center of the printer. (See 4.3.3.2 Removing Holder Shaft Unit Step 3) 3) Release the slit on the right side of the CR Encoder Scale from the tab of the Main Unit.
Tab
Slit and Tab
CR Encoder Scale CR Encoder Scale
Figure 4-46. Removing CR Encoder Scale (1) 4) Remove the CR Encoder Scale from the CR Unit. Figure 4-48. Removing CR Encoder Scale (3) When installing the CR Encoder Scale, place the scale so that the chipped part is facing upper left as shown in the figure below.
CR Unit CR Encoder Scale Chipped Part
CR Encoder Scale
Figure 4-47. Removing CR Encoder Scale (2)
Figure 4-49. Installing CR Encoder Scale
63
Revision A
4.3.3.9 CR Cable Head Cover

1) Remove the Housing, Upper. (p43) 2) When removing the CR Cable Head Cover, follow the steps mentioned below. 1. 2. Slide the CR Cable Head Cover downward, and release tab As. Release tab B, slide the CR Cable Head Cover upward, and remove the CR Cable Head Cover.
4.3.3.10 CR Unit
1) Remove the Panel Board. (p54) 2) Remove the Front Frame. (p62)
C A U T IO N
As the Head FFC and the CR Encoder FFC is attached to each other with glue, be careful not to remove them separately.
Tab As
3) Disconnect the two connectors from the Main Board. (4.3.2.1 Removing Main Board Step 1 through Step 3) CN7: CN8: CR Encoder FFC Head FFC
4) Disconnect the CR Encoder FFC and the Head FFC from the Holder Shaft Unit. (See 4.3.3.2 Removing Holder Shaft Unit Step 5) 5) Disconnect the CR Timing Belt. (4.3.3.5 Removing CR Timing Belt Step 3 through Step 4) 6) Remove the CR Encoder Scale. (p63)
Tab B CR Cable Head Cover
7) Remove the CR Cable Head Cover. (p64)
Figure 4-50. Removing CR Cable Head Cover
64

8) Remove the Shield Plate FFC from the Main Unit Frame.
Revision A
C A U T IO N
Make sure to support the CR Unit with your hands so as not to drop it, or the nozzle surface of the printhead may be damaged.
Shield Plate FFC
Double-sided tape attaching location
12) Release the two tabs of the IC Holder, slide the holder toward you, and remove both the CR Unit and the CR Timing Belt from the Main Unit.
Figure 4-51. Removing Shield Plate FFC 9) Remove the CSICFFC from the CSIC Board. 10) Disconnect the CR Encoder FFC (CN1) from the CR Encoder Sensor Board. 11) Release the three FFCs from the three notches.
Rear Tab Tab
CN1
Figure 4-53. Removing CR Unit (1) 13) Remove the CR Timing Belt from the CR Unit.
CR Encoder Sensor Board
Notches
CR Timing Belt CR Encoder FFC CSICFFC CSIC Board
CR Unit
Figure 4-54. Removing CR Unit (2)
Figure 4-52. Removing FFC
65
Revision A
When installing the CR Timing Belt to the CR Unit, make sure to attach the belt to the positioning jag as shown below.
Positioning Jag
CR Unit
CR Timing Belt Figure 4-55. Installing CR Timing Belt When installing the CR Unit to the Main Unit Frame, engage them as shown in Figure 4-52.
CR Unit
Main Unit Frame
When you replace Holder pulley driven, Front Frame, Pulley driven shaft, or Pulley driven holder with new a one, lubricate it as specified. See "6.1.3 Lubrication" (p92) for details. When IC holder/PW sensor/CR encoder sensor is removed or replaced with new one, the following adjustment must be performed in the order below. 1. Top Margin Adjustment 2. PF Adjustment 3. Bi-D Adjustment 4. Head Angular Adjustment 5. First Dot Adjustment 6. Offset input for CR Motor Calorific Limitation When Print head assy. is removed or replaced with new one, the following adjustment must be performed in the order below. 1. Head ID Input 2. Top Margin Adjustment 3. PF Adjustment 4. Bi-D Adjustment 5. Head Angular Adjustment 6. First Dot Adjustment 7. Offset input for CR Motor Calorific Limitation When CR timing belt is removed or replaced with new one, tension adjustment of CR timing belt must be performed by the degital tension gauge.
Figure 4-56. Installing CR Unit Route the three FFCs as shown in Figure 4-52. The Shield Plate FFC should be attached to the location shown in Figure 4-51 with double-sided tape.
66
Revision A
4) Remove the Head FFC from the Printhead Assy.
4.3.3.11 Printhead Assy.

1) Remove the CR Unit. (p64)
C H E C K P O IN T
Before starting the following work, make sure that the two tabs shown in Figure 4-53 are already released.
Head FFC
2) Release the tab from the notch of the IC Holder, and remove the printhead cover. 3) Turn the Printhead Assy. toward the direction of the arrow, and remove the Printhead Assy.
Printhead Assy.
IC Holder Printhead Assy.
Figure 4-58. Removing Printhead Assy. (2)
Printhead Cover
Tab and Notch
Figure 4-57. Removing Printhead Assy. (1)
67
Revision A
When installing the Printhead Assy. to the IC Holder, match the tabs with the notches, and tilt the Printhead as shown below.
4.3.3.12 CR Encoder Sensor Board

1) Remove the CR Unit. (p64) 2) Remove the two screws that secure the CR Encoder Sensor Board to the IC Holder, and remove the CR Encoder Sensor Board.
Tab and Notch
C.P.B. (P1) 1.7 x 5 :2
C.P.B. (P1) 1.7 x 5 Tab and Notch
CR Encoder Sensor Board
Figure 4-60. Removing CR Encoder Sensor Board Figure 4-59. Installing Printhead Assy.
68
Revision A
3) Insert a flathead screwdriver or a similar tool into the six A sections located on bottom of the IC Holder, and remove the CSIC Board.
4.3.3.13 CSIC Board

1) Remove the CR Unit. (p64) 2) Remove the two screws that secure the IC Holder Cover to the IC Holder, release the tab, and remove the IC Holder Cover. C.B.P. 2.5 x 8: 2
CSIC Board
Tab
IC Holder Cover
C.B.P. 2.5 x 8
Bottom
A Sections
Figure 4-61. Removing IC Holder Cover
Figure 4-62. Removing CSIC Board
69
Revision A
4.3.3.14 Paper Guide, Upper Assy.

1) Remove the Housing, Upper. (p43) 2) Push the two guide pins on the Paper Guide, Upper Assy. with a flathead screwdriver or a similar tool, and remove the Paper Guide, Upper Assy. toward you.
Guide Pins
4.3.3.15 Eject Roller

1) Remove the Housing, Upper. (p43) 2) Remove the Front Frame. (p62) 3) Move the CR Unit to the home position. (See 4.3.3.2 Removing Holder Shaft Unit Step 3) 4) Remove the PF Timing Belt from the PF Drive Pulley. 5) Remove the Eject Drive Pulley from the Eject Roller.
PF Drive Pulley PF Timing Belt
Paper Guide, Upper Assy.
Eject Roller Eject Drive Pulley
Figure 4-63. Removing Paper Guide, Upper Assy. 3) Repeat the steps above, and remove all the Paper Guide, Upper Assys.
Figure 4-64. Removing Eject Drive Pulley
When Paper guide upper is removed or replaced with new one, the following adjustment must be performed in the order below. 1. Top Margin Adjustment 2. PF Adjustment 3. Bi-D Adjustment 4. Head Angular Adjustment 5. First Dot Adjustment
70
Revision A
C A U T IO N
Be careful not to damage the rubber area when performing the following work.
6) Release the Eject Roller from the four tabs of the Paper Guide, Upper Assy., and remove the Eject Roller.
Tabs
When you replace Paper eject roller with new one, lubricate it aws specified. See "6.1.3 Lubrication" (p92) for details. When Paper eject roller is removed or replaced with new one, the following adjustment must be performed in the order below. 1. Top Margin Adjustment 2. PF Adjustment 3. Bi-D Adjustment 4. Head Angular Adjustment 5. First Dot Adjustment
Figure 4-65. Removing Eject Roller When installing the Eject Roller, make sure to match the notch of the Eject Drive Pulley with the tab of the Eject roller as shown below.
Eject Drive Pulley Eject Roller
Notch
Tab
Figure 4-66. Installing Eject Drive Pulley
71
Revision A
1) Remove the Eject Roller. (p70) 2) Remove the screw that secures the Paper Guide, Front Assy. to the Main Unit. 1. 2. 3.
Rib Left Paper Guide, Front Assy. C.B.S. 3 x 8 Right Convex Portion and Notch
4.3.3.16 Paper Guide, Front Assy.

C A U T IO N
Never touch the rib on the Paper Guide, Front Assy.
C.B.S. 3 x 8:
3) Follow the steps below when removing the Paper Guide, Front Assy. Lift up the left side of the Paper Guide, Front Assy. Slide the Paper Guide, Front Assy. toward left, and release the two convex portions on the right. Lift up the right side of the Paper Guide, Front Assy, slide it toward right, and remove the Paper Guide, Front Assy.
Figure 4-67. Rib on Paper Guide, Front Assy. Be careful not to bent the four Paper Guide, Front Absorbent Protections.
Convex Portion and Notch
Convex Portion and Hole
Convex Portion and Hole
Paper Guide, Front Assy.
Figure 4-69. Removing Paper Guide, Front Assy.

Paper Guide, Front Absorbent Protections
Figure 4-68. Paper Guide, Front Absorbent Protections
When installing the Paper Guide, Front Assy. to the Main Unit, make sure to match each convex portion with the notches and the holes as shown in Figure 4-69.
72
Revision A
When Paper guide front is removed or replaced with new one, the following adjustment must be performed in the order below. 1. Top Margin Adjustment 2. PF Adjustment 3. Bi-D Adjustment 4. Head Angular Adjustment 5. First Dot Adjustment
4.3.3.17 Pump Unit/Cap Unit

C A U T IO N
When removing the Pump Unit and the Cap Unit, pay attention not to drop the CR Lock Lever and the Gear.
1) Remove the Housing, Lower Assy.. (p47) 2) Remove the Holder Shaft Unit. (p56) 3) Release the three tabs that secure the Pump Unit to the Main Unit, and remove both the Pump Unit and the Cap Unit.
Tabs
Figure 4-70. Removing Pump Unit/Cap Unit (1)
73

4) Remove the Ink Tube that connects the Pump Unit and the Cap Unit.
Cap Unit Pump Unit
Revision A
When you replace Pump Unit/Cap Unit with new one, lubricate it as specified. See "6.1.3 Lubrication" (p92) for details. When Pump Unit/Cap Unit is removed or replaced with new one, the following adjustment must be performed in the order below. 1. Top Margin Adjustment 2. PF Adjustment 3. Bi-D Adjustment 4. Head Angular Adjustment 5. First Dot Adjustment
Ink Tube Joint
Figure 4-71. Removing Pump Unit/Cap Unit (2) Be sure to assemble the Pump Unit as shown below.
Compound Gear 27.2, 19.2
Compound Gear 21, 24
CR Lock Lever
Spool Gear 27.2
Figure 4-72. Assembling Pump Unit
74
Revision A
5) Remove Compression Spring 1.53, and remove the PF Motor.
4.3.3.18 PF Motor
1) Remove the Housing, Lower Assy.. (p47) 2) Disconnect the PF Motor Connector from the Main Board. (See 4.3.2.1 Removing Main Board Step 3) 3) Remove the PF Timing Belt, Idle Roller Assy, and Compression Spring from the Main Unit.
PF Motor
PF Timing Belt
Compression Spring 1.53
Figure 4-75. Removing PF Motor (3) When installing the PF Motor, make sure to attach Compression Spring 1.53 to the part shown in Figure 4-75. When installing the PF Motor, secure the hexagon nuts in the order shown in Figure 4-74.
Compression Spring 1.13 Idle Roller Assy.
Figure 4-73. Removing PF Motor (1) 4) Remove the four hexagon nuts that secure the PF Motor to the Main Unit.
HEXAGON NAT NORMAL M3 (6 1 kgf.cm)
1 4
When PF motor is removed or replaced with new one, the following adjustment must be performed in the order below. 1. Top Margin Adjustment 2. PF Adjustment 3. Bi-D Adjustment 4. Head Angular Adjustment 5. First Dot Adjustment
3 2 Figure 4-74. Removing PF Motor (2)
75
CHAPTER
ADJUSTMENT
Revision A
5.1 Adjustment Items and Overview

This chapter describes adjustments to be made after the disassembly/reassembly of this product.
5.1.1 Servicing Adjustment Item List

The adjustment items of this product are as follows. For details of the adjustment items, refer to the detailed procedures and sketches of the adjustment items.
Table 5-1. Servicing Adjustment Items

Function Item Market setting Purpose At the time of Main board replacement, this adjustment is made to write the board common information on a destination basis. Method Outline Select and execute this function in the exclusive servicing program to save the following data into the EEPROM. Market ID, CSIC printer ID, D4 setting (USB, parallel), First Dot adjustment fixed value. Enter the ID of the head QR code label applied to the Printhead into the exclusive servicing program to save it to the EEPROM on the Main board. (Supplement: Read the QR code label from left to right on the top row and from top to bottom in due order.) Select and execute this function in the exclusive servicing program to save the offset into the EEPROM. Tool Exclusive servicing program Used Media Non-target
Head ID input
At the time of head replacement, this adjustment is made to correct head manufacturing variations and eliminate the individual differences of print quality. When the Main board, CR motor, PS board or Print head assy is changed individually, this adjustment is made to write the maximum offset to prevent the occurrence of damage to the motor at the time of CR motor heat generation. This adjustment is made to correct the error in the Head mounting position (angle of the Head to the paper surface) to keep the nozzle intervals uniform in the CR main scanning direction. This adjustment is made to correct the variations of paper feed accuracy in the band printing mode to improve print quality.
Exclusive servicing program
Non-target
Main adjustment items
Offset input for CR motor calorific limitation. Head angular adjustment
Non-target
Select this function in the exclusive servicing program and print the adjustment pattern. Check the displacement amount of the pattern. Print the exclusive pattern again and adjust the displacement amount. Select this function in the exclusive servicing program and print the adjustment patterns (9 patterns). Select and enter the pattern that has the smallest gap and overlap. The correction value is saved to the specific EEPROM address on the Main Board. Select this function in the exclusive servicing program and print the adjustment patterns to check the displacement amounts of the patterns. Select/enter the pattern number that has the smallest displacement amount in the program. Print the exclusive patterns again and adjust the displacement amount. The correction value is saved into the EEPROM.
Photo Quality Ink Jet Paper (A4) Photo Quality Ink Jet Paper (A4) Plain paper (A4)
PF adjustment
Bi-D adjustment
This adjustment is made to correct the print timing in the go and return paths in bi-directional printing.
ADJUSTMENT
Adjustment Items and Overview
77
EPSON Stylus C67/C68/D68 Table 5-1. Servicing Adjustment Items

Function Item USB ID input Main adjustment items First Dot adjustment Purpose Method Outline Tool Exclusive servicing program Exclusive servicing program
Revision A
Used Media Non-target
This adjustment is made to allow the PC to recognize the Select this function in the exclusive servicing program and enter the serial connected printers individually when multiple printers of the numbers of the printers. The correction value is saved to the specific same model are connected and used with the PC via a USB hub. EEPROM address on the Main board. This adjustment is made to correct the first dot position in the CR main scanning direction. Select and execute this function in the exclusive servicing program. Enter the correction value in the program using the rule position of the print pattern as a reference. The correction value is saved to the specific EEPROM address on the Main board. Select and execute this function in the exclusive servicing program. Enter the correction value in the program using the rule position of the print pattern as a reference. The correction value is saved to the specific EEPROM address on the Main board.
Plain paper (A4)
Top Margin adjustment
This adjustment is made to correct the printout position in the
paper feeding direction.
Plain paper (A4)
Table 5-2. Maintenance Functions

Function Item Head Cleaning Purpose This function is used to execute CL efficiently when ink is not delivered from the Head properly, e.g. dot missing or skewed injection. This function is used together with the nozzle check pattern to confirm the CL effects. This function is used to drain the Shipping Liquid in the ASP head flow path and simultaneously fill ink in the head flow path to make all nozzles printable and stabilize the ink in the Head. This function is used after repair to read the Waste ink counter, and if the value is close to the predetermined near-end value or end value, to recommend Pad replacement to the user in order to prevent the repaired printer from being returned again for repair in a short time. The reset function is used to reset the Waste ink counter from the exclusive program after Waste ink pad replacement. This function is used to read the above necessary information from the EEPROM of the faulty Main board using the D4 function to reduce the auxiliary adjustment items at the time of Board replacement. This function is used to analyze defective products. Adjustment Outline Select this function in the exclusive servicing program, and execute CL 3. Tool Exclusive servicing program Used Media Non-target
Ink Charge Maintenance items
Select this function in the exclusive servicing program, and execute the ink sucking operation equivalent to the initial charge. Select this function in the exclusive servicing program, read/display the current data from the specific EEPROM address on the Main board, and check whether the current counter value is close to the upper limit or not. For the reset function, select this function in the exclusive servicing program after Waste ink pad replacement, and reset the corresponding data at the specific address in the EEPROM on the Main board. Select this function in the exclusive servicing program, and read the data from the faulty board. After that, change the Main board and then write the read data to a new board. Save the data of all EEPROM addresses.
Exclusive servicing program Exclusive servicing program
Non-target
Waste ink pad counter
Non-target
EEPROM data copy
Non-target
Save all EEPROM data
Others
Non-target
ADJUSTMENT
78
Revision A
Table 5-3. Check Pattern Printing

Function Item A4 Photo Quality Ink Jet Paper print Check pattern items A4 Normal Paper print Nozzle check pattern print PF torque check pattern print Purpose This pattern is used to check whether all adjustment results are normal. This pattern is used to check whether all adjustment results are normal. This pattern is used to check simply whether all nozzles deliver ink or not. The purpose is not to check the defect of the PF motor. This pattern is used to check wthether parts driven with PF motor operates normally when the parts is exchanged. In case of NG, printer becomes fatal errer condition. Adjustment Outline Select this function in the exclusive servicing program, print the print patterns, and check the adjustment result in each pattern. Select this function in the exclusive servicing program, print the print patterns, and check the adjustment result in each pattern. This pattern is used to make a simple print check at the EPSON service company. Select this function in the exclusive servicing program, print the print patterns, and check the adjustment result. Tool Exclusive servicing program Exclusive servicing program Exclusive servicing program Exclusive servicing program Used Media Photo Quality Ink Jet Paper (A4) Plain paper (A4) Plain paper (A4) Plain paper (A4,Letter)
5.1.2 Repaired Adjustmen

If you remove or replace the specific part in your service/repair, you have to perform the appropriate adjustment as listed Table 2-4 below. In this printer, it is necessary to perform appropriate adjustment in order to maintain consistent printing function and quality, eliminate differences of each printer mechanisms characteristics.Therefore, in case that the combination between the printer mechanism and the main board changes or the Printhead is replaced during the repair service, you must input the correct adjustment value into the EEPROM on the Main board by using the Adjustment program.
C H E C K P O IN T
In case that any parts are removed and assembled on the repair product while running the Adjustment program, make sure to turn off the printer.
ADJUSTMENT
79
Revision A
5.1.3 Replacement Part-Based Adjustment Priorities

The following table indicates the adjustment items and priorities on a replacement part basis.
Note: applicable in this table indicates the adjustment items required after removing/replacing the parts.
Performance Priority
3 USB ID input
4 Waste ink pad counter
5 Ink charge
6 Head ID input
7 Top margin adjustment
10
11
12
Adjustment item Replaced part Removal/Replacement

ASF unit removal ASF unit replacement CR motor removal CR motor replacement Paper guide upper removal Paper guide upper replacement Frame front (only) removal Frame front (only) replacement I/C holder removal I/C holder replacement Print Head assy. removal Print Head assy. replacement Main board removal Main board replacement (Read OK) Main board replacement (Read NG) Holder shaft unit removal Holder shaft unit replacement
EEPROM Market data copy setting
Head First dot angular adjustment adjustment

applicable applicable applicable applicable ----applicable applicable applicable applicable applicable applicable ----applicable --------applicable applicable ----applicable applicable applicable applicable applicable applicable ----applicable -----
Offset input for Bi-D PF CR motor adjustment adjustment calorific limitation

----applicable applicable ----applicable applicable applicable applicable applicable applicable ----applicable ----applicable applicable ----applicable applicable ----applicable applicable applicable applicable ----applicable ----------applicable --------------applicable ----applicable -----
--------------------------applicable -------
----------------------------applicable -----
----------------------------applicable -----
------------------------------- (Pad replacement) -----
----------------------applicable -----------
----------------------applicable ----applicable -----
applicable applicable ----applicable applicable ----applicable applicable applicable applicable ----applicable applicable applicable
ADJUSTMENT
80
Revision A
Performance Priority
3 USB ID input
4 Waste ink pad counter
5 Ink charge
6 Head ID input
7 Top margin adjustment
10
11
12
Adjustment item Replaced part Removal/Replacement

Paper eject roller removal Paper eject roller replacement PS board removal PS board replacement Paper guide front removal Paper guide front replacement PF motor removal PF motor replacement Waste ink pad removal Waste ink pad replacement PW sensor removal PW sensor replacement Printer mechanism removal Printer mechanism replacement Ink system removal Ink system replacement
EEPROM Market data copy setting
Offset input for Head First dot PF CR motor Bi-D angular adjustment adjustment adjustment calorific adjustment limitation
--------applicable applicable ----------------------------applicable applicable ----------------------------applicable applicable --------------------applicable applicable ----applicable applicable applicable applicable ----------------------applicable -------------------------
---------------------------------
---------------------------------
---------------------------------
------------------applicable -------------
---------------------------------
---------------------------------
--------applicable applicable applicable applicable -----------------
ADJUSTMENT
81
Revision A
5.2 Adjustment by Using Adjustment Program

The procedures of the adjustment items will be explained here. The intended item is as follows. Market setting USB ID input Head ID input Head angular adjustment Bi-d adjustment PF adjustment First dot adjustment Top margin adjustment Offset input for CR motor calorific limitation A4 Normal Paper print A4 Photo Quality Inkjet Paper print PF torque check pattern print
5.2.1 Market ID Setting

[Adjustment Procedure] 1. 2. 3. Select the Market ID of the adjustment program. Click the [OK] button to write the specific data into EEPROM. Click the [Check] button to check market and model name.
5.2.2 USB ID Input

[Adjustment Procedure] 1. 2. Select USB ID input in the adjustment program. Enter the 10-digits serial number from the label applied to the bottom side of the Upper housing.
5.2.3 Head ID Input

[Adjustment Procedure] 1. 2. Select the Head ID of the adjustment program. Enter the 16-digits code of the Head ID label applied to the Printhead. Enter the Head ID from left to right on the top row and from top to bottom in due order.
ADJUSTMENT
Adjustment by Using Adjustment Program
82
Revision A
5.2.4 Head Angular Adjustment

[Adjustment Procedure] 1. 2. 3. 4. Select Head Angular adjustment in the adjustment program. Click the [Print] button to print Head Angular adjustment pattern of checked items. Select the pattern value of straight line in the printed lines. Click the [Input] button to write the adjustment value of checked items. (Note: The range of the adjustment value is -4 to 4.)
5.2.5 Bi-D Adjustment

[Adjustment Procedure] 1. 2. 3. 4. 5. Select Bi-D adjustment in the adjustment program. Click the [Print] button to print Bi-D adjustment pattern of checked items. Select the pattern that has the smallest displacements in each variable dot, and click the [Go to print page] button in the adjustment program. Click the [Input] button to write the adjustment value of checked items. Click [Go to print page].
[Treatment procedure for NG product] Step1) Replace the print head with new one again. Step2) Print the check pattern, and check the adjustment result. Step3) If the result is NG level, confirm the installation condition of removed parts during disassembly. Step4) Perform step2) again.
OK pattern NG pattern
[Treatment procedure for NG product] Step1) Replace the print head with new one again. Step2) Print the check pattern, and check the adjustment result. Step3) If the result is NG level, confirm the installation condition of removed parts during disassembly. Step4) Perform step2) again.
OK pattern NG pattern
[Judging Standard] - The printed line should be straight line. [Reference:Standard value in manufactory] - Standard : 50m
[Judging Standard] - No gap/overlap between short block pattern and long one. [Reference:Standard value in manufactory] - VSD1:60m, VSD2:60m, VSD3: 40m, VSD4:40m, ECO:85m.
Figure 5-1. Head Angular Printing Pattern

C A U T IO N
Figure 5-2. Bi-D Adjustment Pattern
Please perform Bi-d adjustment keeping all Housing attached.
ADJUSTMENT
83
Revision A
5.2.6 PF Adjustment
[Adjustment Procedure] 1. 2. 3. 4. 5. 6. Select PF adjustment in the adjustment program. Click the [Print] button to PF adjustment pattern. Select the pattern that has the smallest displacements in each variable dot, Click the [Input] button to write the adjustment value of checked items. If the smallest displacements is [*] or [**], and click the corresponded button. Check that [*] or [**] is best of the three, input 4 in case of [*] and -4 in case of [**].
5.2.7 First Dot Adjustment

[Adjustment Procedure] 1. 2. 3. Select First Dot adjustment in the adjustment program. Click the [Print] button to print First Dot adjustment pattern. Determine the adjustment value in the shifting direction for the pattern printed on the left margin. Input can be made in 0.0176mm increments for the adjustment value of 1. Click the [Input] button to write the adjustment value of checked items.
4.
[Treatment procedure for NG product] Step1) Replace the repaired (replaced) part with new one. Step2) Print the check pattern, and check the adjustment result. Step3) If the result is NG level, confirm the installation condition of removed parts during disassembly. [Judging Standard] - Standard : 3.6 1.0 mm away from top edge.
[Treatment procedure for NG product] Step1) Replace the repaired (replaced) part with new one. Step2) Print the check pattern, and check the adjustment result. Step3) If the result is NG level, confirm the installation condition of removed parts during disassembly.
OK pattern
[Judging Standard] - No gap/overlap between short block pattern and long one. [Reference:Standard value in manufactory] - Standard : 35m
Figure 5-4. First Dot Pattern
NG pattern
Figure 5-3. PF Adjustment Pattern
ADJUSTMENT
84
Revision A
5.2.8 Top Margin Adjustment

[Adjustment Procedure] 1. 2. 3. 4. Select Top Margin adjustment in the adjustment program. Click the [Print] button to print Top Margin adjustment pattern. Determine the adjustment value in the shifting direction for the pattern printed on the top margin. (Note: [+] input < 2.6mm, 4.6mm < [-] input ) Click the [Input] button to write the adjustment value of checked items.
5.2.9 Offset input for CR Motor Calorific Limitation

[Adjustment Procedure] 1. 2. Select Offset input for CR motor calorific limitation in the adjustment program. Click the [Input] button to write the specific data in EEPROM.
[Treatment procedure for NG product] Step1) Replace the repaired (replaced) part with new one. Step2) Print the check pattern, and check the adjustment result. Step3) If the result is NG level, confirm the installation condition of removed parts during disassembly. [Judging Standard] - Standard : 3 1.5 mm away from left edge.
Figure 5-5. Top Margin Pattern
ADJUSTMENT
85
Revision A
5.2.10 A4 Normal Paper print

[Adjustment Procedure] 1. 2. Select A4 Normal Paper print in the adjustment program. Click the [Print] button to print A4 Normal Paper print pattern. [Judging Standard]
- PW Sensor adjustment Top / Bottom : 5.0+0.5/-1.0mm Right / Left : 5.0+0.3/-1.0mm - Beta pattern
5.2.11 A4 Photo Quality Inkjet Paper Print

[Adjustment Procedure] 1. 2. 3. Select A4 Photo Quality Inkjet Paper print in the adjustment program. Click the [Print] button to print A4 Photo Quality Inkjet Paper print pattern. Check the adjustment result in each pattern. [Judging Standard] - Bi-D adjustment Make sure that X is the best pattern of the three. - Top Margin adjustment 3 1mm from top edge. ( This standard is different from that of individual Top Margin adjustment. The standard of individual Top Margin adjustment is added about 0.6mm by the circumstance.) - First Dot adjustment 3 1.5mm from left edge. - Head Angular adjustment Make sure that X is the best pattern of the three. - PF adjustment Make sure that X is the best pattern of the three. - Accumulated Pitch Line 259.5 1mm from top line.
No uneven printing / white line.

- Vertical alignment
No thin dot or thick dot / vertical alignment.

- Horizontal alignment
No displacement between the vertical rules of each VSD.
Figure 5-6. A4 Normal Paper Print Pattern
Figure 5-7. A4 Photo Quality Inkjet Paper Print Pattern
ADJUSTMENT
86
Revision A
5.2.12 PF Torque Check Pattern Print

[Adjustment Procedure] 1. 2. 3. Select PF torque check pattern print in the adjustment program. Click the [Print] button to print PF torque check pattern. Check the adjustment result in each pattern.
[Replacement parts list]

This pattern is used to check wthether parts driven with PF motor operates normally when the following parts is exchanged.
- Ink System - Frame Front - Peper Eject Roller - PF motor [Treatment procedure for NG product] Step1) Replace the repaired (replaced) part with new one. Step2) Print the check pattern, and check the adjustment result. Step3) If the result is NG level, please exchange the mecha unit. Step4) Perform step2) again. OK pattern NG pattern
[Judging Standard] Make sure that there is not double printing like the above-mentioned red frame.
Figure 5-8. PF torque check pattern
ADJUSTMENT
87
Revision A
[Treatment for NG product] Step1) Replace the CR timing belt with new one again. Step2) Check the adjustment result again. Step3) If the result is NG level, confirm the installation condition of removed parts during disassembly. Step4) Perform step2) again. Sensor cable [Judging Standard] - CR Timing Belt Tension : 9 1.5N
5.3 Adjustment Except Adjustment Program

Following is adjustment except adjustment program.
5.3.1 CR Timing Belt Tension Adjustment

[Purpose] This adjustment is to optimize the timing belt tension for preventing tooth skip between the pinion of CR motor and the CR timing belt. This adjustment must be made when the CR timing belt is removed. [Adjustment Procedure] 1. 2. Install the CR timing belt to the printer mechanism. Check the CR timing belt tension by using Digital Tension Gauge. [Note] Before this adjustment, the following data should be inputted into Digital Tension Gauge. [UNITTA : Setting of Digital Tension Gauge] - Weight : Input 0.4 - Width : Input 8 - Span : Input 377 3. 4. Return to CR unit to have position. Set the sensor cable to the center of the timing belt vertically. (This time, the distance between the surface of the sensor cable on the timing belt is 10 5mm.) Push the upside of the timing belt with the tail plastic of ballpoint pen / plastic tweezers and check the timing belt tension on display of Digital Tension Gauge. Check the result of tension value on the display.
Figure 5-9. CR Timing Belt Tension adjustment
C A U T IO N
Dont damage timing belt while pushing it with the tail plastic of ballpoint pen / plastic tweezers. Perform this adjustment in quiet environment in order to avoid that the measured result affects by other frequency. Sensor should be set vertically on CR timing belt.
5. 6.
ADJUSTMENT
Adjustment Except Adjustment Program
88
CHAPTER
MAINTENANCE
Revision A
6.1 Overview
This section provides information to maintain the printer in its optimum condition.
6.1.2 Service Maintenance

If any abnormal print (dot missing, white line, etc.) has occurred or the printer indicates the "Maintenance request error" (This error is displayed as "Maintenance call error" in the STM3), take the following actions to clear the error. Printhead cleaning When dot missing or banding phenomenon has occurred, you need to perform the printhead cleaning operation*1 by using the printhead cleaning function. This function can be performed by the control panel operation, the printer driver utility and the Adjustment program. In case that the cleaning sequence is performed by the control panel operation, confirm that the printer is in stand-by state (the Power LED is lighting), and hold down the Error reset button on the control panel for more than 3 seconds. Then, the printer starts the cleaning sequence (the Power LED blinks during this sequence). In case that you select and perform the manual cleaning by the printer driver utility, the most appropriate cleaning mode is selected. The following is the process to perform the printhead cleaning from the printer driver utility. As for the operation of the Adjustment program, refer to Chapter5 ADJUSTMENT (p.76). *1: The Stylus C67/C68/D68 has four modes for manual cleaning, and even during printing, the appropriate cleaning mode is automatically selected and performed according to various conditions. Therefore the ink consumption amount for manual cleaning varies depending on each mode.
6.1.1 Cleaning
This printer has no mechanical components which require regular cleaning except the Printhead. Therefore, when returning the printer to the user, check the following parts and perform appropriate cleaning if stain is noticeable.
.
C A U T IO N
Never use chemical solvents, such as thinner, benzine, and acetone to clean the exterior parts of the printer like the Housing. These chemicals may deform or deteriorate the components of the printer. Be careful not to damage any components when you clean inside the printer. Do not scratch the coated surface of the PF roller. Use soft brush to wipe off any dusts. Use a soft cloth moistened with alcohol to remove the ink stain. Do not use cleaning sheet included in the media for normal usage. It may damage the coated surface of PF roller. If the adhesive surface of the cleaning sheet is set to the LD roller shaft side and used to clean the LD roller surface, it is no problem. When using compressed air products; such as air duster, for cleaning during repair and maintenance, the use of such products containing flammable gas is prohibited.
Exterior parts Use a clean soft cloth moistened with water, and wipe off any dirt. If the exterior parts are stained by the ink, use a cloth moistened with neutral detergent to wipe it off. Inside the printer Use a vacuum cleaner to remove any paper dust. LD Roller When paper loading function does not operate because friction of the LD roller is lowered by any paper dust, set the adhesive side up of the cleaning sheet (included in the media) to remove any paper dust. Repeat loading the cleaning sheet several times.
MAINTENANCE
Overview
90

1. Select the EPSON Status Monitor 3 in the printer driver utility, and make sure that the printer is in stand-by state by using the Status monitor 3. If the printer is in stand-by state, the following figure is indicated on the monitor.
Revision A
Maintenance request error (Maintenance call error) Ink is used for the printhead cleaning operation as well as the printing operation. When the ink is used for the printhead cleaning operation, the ink is drained to the Waste drain ink pad and the amount of the waste ink is stored as the waste ink counter into the EEPROM on the Main board. Due to this, when the waste ink max counter has reached the limit of the absorbing capability of the Waste drain ink pad*,) the Maintenance call error is indicated on Status monitor 3 as following figure. But waste ink max counter is chenged by usage, therefore waste ink max counter is not necessarily right. *): The range of the waste ink counter is 8100 ~ 16900. ( means initial maximam value of mon-used printer.)
Figure 6-1. Status monitor 3 indication

2. Select the Head Cleaning in the printer driver utility, and perform the printhead cleaning. After performing the printhead cleaning operation, print a nozzle check pattern by selecting the Nozzle Check. If you repeat the printhead cleaning operation without selecting the Nozzle Check, CL1, the weakest cleaning, will be repeated.
Figure 6-3. Maintenance error indication in STM3

In this case, replace to new Waste drain ink pad and clear the waste ink counter stored into the EEPROM. The waste ink counter can be reset only from the Adjustment program because this printer dose not have the waste ink counter reset function by the control panel SW. As for the procedure, refer to Chapter5 ADJUSTMENT (p.76). In your repair activity, check the waste ink counter along with the firmware version, Main board checker program version and nozzle check pattern on the nozzle check pattern printing. If the waste ink counter is closed to its limit, recommend that the Waste drain ink pad will be replaced with new one. This is because the "Maintenance request error" will may occur after returning the repaired product to the customer.
Figure 6-2. Head cleaning function in the printer driver utility
MAINTENANCE
Overview
91
Revision A
Refer to the following figures for the lubrication points.
<Lubrication Point> Paper Back Lever Surface
ASF Unit
6.1.3 Lubrication
The characteristics of the grease have great affects on the mechanical function and durability, especially does the characteristics about temperature environment. The type and amount of the grease used to lubricate the printer parts are determined based on the results of the internal evaluations. Therefore, be sure to apply the specified type and amount of the grease to the specified part of the printer mechanism during servicing.
<Lubrication Type> G-26 <Lubrication Amount> 1 x 1 mm <Remarks> G-26 must not be adhered to other parts.
Paper Back Lever
C A U T IO N
Never use oil or grease other than those specified in this manual. Use of different types of oil or grease may damage the component or give bad influence on the printer function. Never apply larger amount of grease than specified in this manual. G-58/G-26 / G-71is already on the printer mechanism for service part in the manufactory.
C H E C K P O IN T
Figure 6-4. Lubrication on Paper Back Lever

<Lubrication Point> Front Frame Surface <Lubrication Type> G-58
Front Frame
Type Grease Grease Grease
Name G-26 G-58 G-71
EPSON code 1080614 1082176 1304682
Supplier EPSON EPSON EPSON

35mm 20mm
<Lubrication Amount> 1mm x 365mm <Remarks> G-58 must not be adhered to the printer mechanism and other parts.
Figure 6-5. Lubrication on Front Frame
MAINTENANCE
Overview
92
Revision A
Rear side view
<Lubrication Point> Front and rear faces of the Main Frame Carriage Slide <Lubrication Type> G-58 <Lubrication Amount> 360 mm x 2 face <Remarks> G-58 moust not be adhered to other parts.
<Lubrication Point> Back side slit of I/C Holder <Lubrication Type> G-71
I/C Holder
<Lubrication Point> 3mm x 3mm <Remarks> G-58 moust not be adhered to other parts.
Main Frame
Figure 6-6. Lubrication on Main Frame

<Lubrication Point> Contact point between Roller Guide and Roller Unit <Lubrication Type> G-58
Upper side view PrintHead Bottom side view
Figure 6-8. Lubrication on I/C Holder

<Lubrication Point> EJ drive pulley Shaft Surface <Lubrication Type> G-58 <Lubrication Amount> 1 mm x diameter of EJ drive pulley <Remarks> G-58 moust not be adhered to other parts.
Roller Unit
Roller Guide
<Lubrication Amount> 1 mm x 4 points <Remarks> Use a injector to apply. G-58 moust not be adhered to other parts.
EJ drive pulley
Figure 6-7. Lubrication on Roller Guide
Figure 6-9. Lubrication on EJ drive pulley
MAINTENANCE
Overview
93
Revision A
<Lubrication Point> Contact point between the PF Grounding Spring and the PF Roller Unit
PF Grounding Spring PF Roller Unit
<Lubrication Type> G-58 <Lubrication Point> 1 mm x 0.5 mm <Remarks> Use a brush to apply. G-58 moust not be adhered to other parts.
Figure 6-10. Lubrication on PF Roller Unit

<Lubrication Point> U-shaped part for the Idle roller assy <Lubrication Point> G-58 <Lubrication Amount> U-shaped part : 1 mm x 2 points <Remarks> G-58 must not be adhered to other parts such as pinion face of the PF Motor or the Timing Belt
Idle roller assy
Figure 6-11. Lubrication on Idle Roller Assy
MAINTENANCE
Overview
94
CHAPTER
APPENDIX
Revision A
7.1 Exploded Diagram

The exploded diagram of this product are shown on the following pages.
APPENDIX
Exploded Diagram
96
400 Without ESP(Iinter),EURO 104
No.1
Rev.01
C616-ACCE-001
105
106 102
100
101
103
No.2
Rev.01
C616-CASE-001
200
A B
300
No.3
Rev.01
C616-ELEC-001
508 505 505 501 501
513
500
502 510 512 507 541 504 514 515 503 511 542 509
No.4
Rev.01
C616-MECH-001
702 708
704 716
A
706
701
710
709 711
707 714 700
703
No.5
Rev.01
C616-MECH-002
Revision A
7.2 Parts List

Parts list for the EPSON Stylus C67/C68/D68
Ref No. 100 101 102 103 104 105 106 200 300 400 500 501 502 503 504 505 507 508 509 510 511 512 513 514 515 541 542 700 HOUSING, UPPER; EDG2 COVER, INK TUBE; EDG2 COVER, I/F; EDG2 STACKER ASSY. PAPER SUPPORT ASSY.; EFS3 COVER, PRINTER; EFS3; C67 BUTTON, SW ASSY., A BOARD ASSY., MAIN POWER SUPPLY ASSY. POWER CABLE PRINTER MECHANISM(ASP)MAD13-100 FOOT POROUS PAD, INK EJECT, UPPER, LARGE POROUS PAD, INK EJECT, LOWER, BIG; D POROUS PAD, INK EJECT, FB INSULATOR, FRAME, MAIN ROLLER, EJECT INKSYSTEM ASSY. PAPER GUIDE, FRONT ASSY. POROUS PAD, INK EJECT, LOWER, SMALL PROUS PAD, CAP, LOWER, SMALL POROUS PAD, TUBE, FASTEN HOLDER, SHAFT ASSY.; B FRAME, FRONT ASSY. POROUS PAD, PAPER GUIDE FRONT, LOWER SHEET, POROUS PAD, COVER DIFFUSION SHEET, INK EJECT, LOWER, ASP PRINT HEAD ASSY. Part Name
Ref No. 701 702 703 704 706 707 708 709 710 711 714 716 NON FIG NON FIG NON FIG NON FIG NON FIG NON FIG NON FIG NON FIG NON FIG SCALE, CR ASF UNIT
Part Name
GROUNDING PLATE, HEAD TORSION SPRING, LEVER, CARTRIDGE SHIELD PLATE, CABLE HEAD ASSY., C616 BOARD ASSY., ENCODER BOARD ASSY., PANEL LABEL, POSITION, CARTRIDGE LEVER, CARTRIDGE HOLDER, I/C ASSY. PLATE, SLIDER TIMING BELT; E INK CART.UNBOXED, BK-SS, PIG'T; G38K, A/A, AS INK CART.UNBOXED, C-SS, PIG'T; G38K, A/A, AS INK CART.UNBOXED, M-SS, PIG'T; G38K, A/A, AS INK CART.UNBOXED, Y-SS, PIG'T; G38K, A/A, AS INTERFACE CABLE; USB2.0 SOFTWARE CD, EAI-LATIN USER'S GUIDE USER'S GUIDE SETTING UP MANUAL
APPENDIX
Parts List
102
Revision A
7.3 Circuit Diagrams

The control electrical circuit diagrams of this product are shown on the following pages.
APPENDIX
Circuit Diagrams
103
Model Board Rev. Sheet
: Stylus C67/C68/D68 : C616 MAIN :B : 1/1
: Stylus C67/C68/D68 : C616 PNL :A : 1/1
: Stylus C67/C68/D68 : C616 PSB :B : 1/1
: Stylus C67/C68/D68 : C616 PSE :A : 1/1

Manual de Servicio - Epson C67

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Manual de Servicio - Epson C67

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SERVICE MANUAL

Color Inkjet Printer

EPSON Stylus C67/C68/D68

SEIKO EPSON CORPORATION. I&I CS/Quality Management & PL Department

About This Manual

Symbols Used in this Manual

EPSON Stylus C67/C68/D68

Chapter 2 OPERATING PRINCIPLES

EPSON Stylus C67/C68/D68

EPSON Stylus C67/C68/D68

EPSON Stylus C67/C68/D68

1.2.1 Physical Specification

209.8 mm (8.26 inch)

VSD1 VSD2 (Color) VSD2 VSD2' (Black) VSD3 (Color) VSD3

209.8 mm (8.26 inch)

1.2.2 Printing Specification

209.8 mm (8.26 inch) 209.8 mm (8.26 inch)

VSD3 (Black) VSD3

EPSON Stylus C67/C68/D68

1.2.3 Paper Feeding

1.2.4 Input Data Buffer

1.2.5 Electric Specification

EPSON Stylus C67/C68/D68

1.2.6 Environmental Condition

10~35 C*2 20~80 % 1 G, within 1 ms 0.15 G

Print Head Life:

1.2.8 Safety Approvals

Temperature(C) Figure 1-2. Temperature/Humidity Range

EPSON Stylus C67/C68/D68

1.2.9 Acoustic Noise

1.2.11 Black Ink Save Mode

Figure 1-3. Black Ink Save Mode Window

EPSON Stylus C67/C68/D68

1.3 Operator Controls

1.3.2 Panel Functions

Ink (Holding down for three seconds)

Table 1-5. Panel functions with power on

Paper LED Figure 1-4. Control Panel

Holding down the [Paper] switch, press [Power].

Table 1-6. Panel functions with power off

EPSON Stylus C67/C68/D68

1.3.3 Printer Condition and LED Status

Ink out Paper out Paper jam No ink-cartridge / CSIC Error

EPSON Stylus C67/C68/D68

#10*1 Paper Support DL*1 C6*1 Note *: Note *1:

Stylus Stylus Stylus C68 D68 C67 OK OK OK OK OK OK OK NG OK OK OK OK OK OK OK NG OK OK

common paper recycled paper

EPSON Stylus C67/C68/D68

0.27 0.23 0.25 0.23 0.12 0.23 0.25

250 167 178 188 102 188 238

EPSON Stylus C67/C68/D68

1.4.1.1 Printable Area

Paper Feed Direction

Figure 1-5. Printable Area Cut Sheet (Standard Printing)

EPSON Stylus C67/C68/D68

Paper Feed Direction

Figure 1-6. Printable Area for Envelopes

EPSON Stylus C67/C68/D68

Paper Feed Direction

Premium Glossy Photo Paper

Ultra Glossy Photo Paper/ Ultra Premium Glossy Photo Paper

A4 8" x 10" 5" x 7" 10 x 15

#101 Paper Support DL1 C61 Note : Note *1: