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Epson Stylus COLOR 800 Service Manual
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Epson Stylus COLOR 800 Service Manual

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EPSON
COLOR INK JET PRINTER

EPSON Stylus COLOR 800

SERVICE MANUAL

SEIKO EPSON CORPORATION
4007371
Download Service Manual and Resetter Printer at http://printer1.blogspot.com

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Summary of Contents for Epson Stylus COLOR 800

  • Page 1: Epson Stylus Color

    EPSON COLOR INK JET PRINTER EPSON Stylus COLOR 800 SERVICE MANUAL SEIKO EPSON CORPORATION 4007371 Download Service Manual and Resetter Printer at http://printer1.blogspot.com...
  • Page 2 However, should any errors be detected, SEIKO EPSON would greatly appreciate being informed of them. ƒ The above notwithstanding SEIKO EPSON can assume no responsibility for any errors in this manual or the consequences thereof. EPSON is a registered trademark of SEIKO EPSON CORPORATION.
  • Page 3 POWER SUPPLY CABLE MUST BE CONNECTED, USE EXTREME CAUTION IN WORKING ON POWER SUPPLY AND OTHER ELECTRONIC COMPONENTS. CAUTION 1. REPAIRS ON EPSON PRODUCT SHOULD BE PERFORMED ONLY BY EPSON CERTIFIED REPAIR TECHNICIAN. 2. MAKE CERTAIN THAT THE SOURCE VOLTAGE IS THE SAME AS THE RATED VOLTAGE, LISTED ON THE SERIAL NUMBER/RATING PLATE.
  • Page 4 PREFACE This manual describes functions, theory of electrical and mechanical operations, maintenance, and repair of EPSON Stylus COLOR 800. The instructions and procedures included herein are intended for the experience repair technician, and attention should be given to die precautions on the preceding page. The Chapters are organized as follows: CHAPTER 1.
  • Page 5 REVISION SHEET Revision Issued Data Contents FEBRUARY 17 1997 First issue Rev. A Rev. B MARCH 13 1997 The following chapters have been revised: Chapter 1 (Pages l-l, 1-2, l-6) Chapter 2 (Pages 2-l 4, 2-20, 2-23) Chapter 3 (Page 3-l 0) Chapter 4 (Pages 4-2 through to 4-25) Rev.
  • Page 6 TABLE OF CONTENTS CHAPTER 1. GENERAL DESCRIPTION CHAPTER 2. OPERATING PRINCIPLES CHAPTER 3. DISASSEMBLY AND ASSEMBLY CHAPTER 4. ADJUSTMENT CHAPTER 5. TROUBLESHOOTING CHAPTER 6. MAINTENANCE APPENDIX Download Service Manual and Resetter Printer at http://printer1.blogspot.com...

  • Page 7: Table Of Contents

    Chapter 1 Product Description 1.1 Features......................1-1 1.2 Accessories and Options..................1-2 1.3 Hardware Specifications...................1-3 1.3.1 Printing Specifications................1-3 1.3.2 Print Speed and Printable Columns............1-3 1.3.3 Paper Feeding....................1-4 1.3.4 Paper Specifications ...................1-4 1.3.4.1 Cut Sheets .......................... 1-4 1.3.4.2 Transparencies, Glossy Paper.................... 1-4 1.3.4.3 Envelopes ........................... 1-4 1.3.4.4 Index Cards.........................
  • Page 8 1.7 Main Components ................... 1-27 1.7.1 C202 MAIN Board ..................1-28 1.7.2 C202 PSB/PSE Board................1-29 1.7.3 C202 Panel Board..................1-30 1.7.4 Printer Mechanism ..................1-30 1.7.5 Housing ...................... 1-31 Download Service Manual and Resetter Printer at http://printer1.blogspot.com...

  • Page 9: Features

    Product Description 1.1 Features The EPSON Stylus COLOR 800 is a high-performance color ink jet printer designed for the small office/home office (SOHO) market. The main features of this printer are: High print quality for color graphics ‰High resolution 1440 (H) x 720 (V) dpi printing ‰Colors...

  • Page 10: Accessories And Options

    Serial interface cable from D-SUB 9-pin to D-SUB 25-pin C83605∗ C83606∗ Black ink cartridge S020108 Color ink cartridge S020089 EPSON 360 dpi ink jet paper (A4) S041059 100 sheets S041025 200 sheets EPSON 360 dpi ink jet paper (Letter) S041060...

  • Page 11: Hardware Specifications

    Product Description 1.3 Hardware Specifications 1.3.1 Printing Specifications Print method On-demand ink jet Nozzle configuration Monochrome 128 nozzles (32 x 4 staggered) Color (magenta, cyan, yellow) 64 nozzles (32 X 2 staggered, each color) 320/360 inch 144/360 inch 144/360 inch 144/360 inch 32/360 inch 32/360 inch...

  • Page 12: Paper Feeding

    EPSON Stylus &2/25 800 1.3.3 Paper Feeding ‰Paper Transport Method Friction feed with built-in auto sheet feeder (ASF) ‰Line Spacing 1/6, 1/8, or programmable at 1/360 inch ‰Paper Path Top entry (ASF) with semi straight paper path ‰Feeding Speed 1/3 inch 100 ms Continuous 5.0 inches per second...

  • Page 13: Printable Area

    Product Description 1.3.5 Printable Area Cut Sheets Printable Area Table 1-8. Margins for Different Cut Sheet Sizes Figure 1- 3. Printable Area for Cut Sheets PL (Paper LM (Left RM (Right BM (Bottom Paper Size (Paper Length) Margin) Margin) (Top Margin) Margin) Width) (typical)

  • Page 14: Asf Paper Capacity

    EPSON Stylus &2/25 800 ‰Envelopes Printable area Figure 1- 4. Printable Area for Envelopes Table 1-9. Minimum Margins for Envelopes (Left Margin) (Right Margin) (Top Margin) (Bottom Margin) 3 mm 3 mm 3 mm 14 mm (0.12”) (0.12”) (0.12”) (0.55”) 1.3.6 ASF Paper Capacity...

  • Page 15: Ink Specifications

    Product Description 1.3.7 Ink Specifications ‰Black Ink Cartridge Table 1-11. Black Ink Cartridge Specifications Black Ink Cartridge Type Exclusive cartridge Color Black (Quick Penetration) Print Capacity 900 pages / A4 (ISO/IEC 10561 Letter Pattern at 360 dpi) Ink life 2 years from indicated production date Storage Temperatures Storage –20 to 40°...

  • Page 16: Electric Specifications

    EPSON Stylus &2/25 800 1.3.8 Electric Specifications 120 V Version ‰Rated voltage 120 VAC ‰Input voltage range 103.5 to 132 VAC ‰Rated frequency range 50 to 60 Hz ‰Input frequency range 49.5 to 60.5 Hz ‰Rated current 0.4 A (Maximum 0.5A) ‰Power consumption...

  • Page 17: Environmental Conditions

    Product Description 1.3.13 Environmental Conditions Temperature ‰Operating 10 to 35 * ‰Storage –20 to 40° C (–4 to 104° F) (for less than 1 month at 40°) * ‰Transit –20 to 60° C (–4 to 140° F) (for less than 120 hours at 60°) Humidity ‰Operating 20% to 80% (without condensation) *...

  • Page 18: Firmware Specifications

    EPSON Stylus &2/25 800 1.4 Firmware Specifications 1.4.1 Control Codes and Character Specifications ‰Control Codes ESC P/2 EPSON remote command IBM X 24E emulation ‰Character Tables Legal and 14 international character sets ‰Standard version (11 character tables) Italic table PC 437 (US, Standard Europe)
  • Page 19 EPSON Sans Serif H 10.5 pt.; 8 pt. to 32 pt. (2 pt. increments) Note: Each typeface has 4 variations: Normal, Bold, Italic, and Bold Italic An example of variations for EPSON Roman is as follows: EPSON Roman normal EPSON Roman bold...

  • Page 20: Input Data Buffer

    EPSON Stylus &2/25 800 Combinations of Character Tables and Typefaces Table 1-13. Character Tables and Fonts Character Tables Bitmap Fonts Scalable Fonts Scalable Fonts EPSON Roman EPSON Roman EPSON Roman T EPSON Sans Serif EPSON Sans EPSON Sans Serif H...

  • Page 21: Interfaces

    Product Description 1.5 Interfaces The EPSON Stylus COLOR 800 is equipped with two interfaces: parallel and Mac serial interface, and a card slot for an optional Type-B interface. This section provides information on each interface. 1.5.1 Parallel Interface (Forward Channel)
  • Page 22 EPSON Stylus &2/25 800 The ERROR signal is at a LOW level when one of the following errors has occurred: ‰Printer hardware error (fatal error) ‰Paper-out error ‰Paper-jam error ‰Ink-out error The PE signal is HIGH during a paper-out error.
  • Page 23 Product Description Connector Pin Assignments and Signals Table 1-16. Connector Pin Assignments and Signals (Forward Channel) Pin No. Signal Name Return Description GND Pin The STROBE pulse. Reading in of data is /STROBE performed at the falling edge of this pulse. 20-27 The DATA 0 to DATA 7 signals represent DATA 0-7...

  • Page 24: Parallel Interface (Reverse Channel)

    EPSON Stylus &2/25 800 1.5.2 Parallel Interface (Reverse Channel) ‰Transmission Mode IEEE-1284 nibble mode ‰Adaptable Connector Same as the forward channel ‰Synchronization Refer to the IEEE-1284 specification ‰Handshaking Refer to the IEEE-1284 specification ‰Data Transmission Timing Refer to the IEEE-1284 specification ‰Signal Level...

  • Page 25: Mac Serial Interface

    Product Description 1.5.3 Mac Serial Interface ‰Standard RS-423 compliant ‰Synchronization Synchronous ‰Bit Rate Approximately 900Kbps/1.8 Mbps ‰Word Format Start bit 1 bit Data bits 8 bit Parity bit No parity bit Stop bit 1 bit ‰Handshaking X-ON/X-OFF, DTR protocol ‰Adaptable Connector 8-pin mini circular connector ‰Recommended I/F Cable Apple System Peripheral-8 cables...

  • Page 26: Optional Interface

    Finally, the printer is BUSY continuously when the input buffer is full. 1.5.6 Interface Selection The Stylus COLOR 800 can have three types of interfaces: parallel, serial, and optional Type-B. Each interface can be selected manually or automatically. Both modes are selected through default setting mode.

  • Page 27: Operations

    Product Description 1.6 Operations This section describes the functions of each button on the control panel and LED printer status indicators. 1.6.1 Control Panel The control panel for this printer consists of 3 non-lock pushbuttons, 1 lock type pushbutton, and 4 LED indicators.
  • Page 28 EPSON Stylus &2/25 800 ‰Panel Functions at Power On This printer also enters various functions by holding down a specific button and turning on the printer. Each combination and its function are described in Table 1-23. Table 1-22. Panel Function with Power On...

  • Page 29: Default Settings

    Product Description 1.6.2 Default Settings The printer enters default setting mode when you press the Cleaning (Color) button while turning on the printer. The menus available for this printer are shown in Table 1-25. Table 1-24. Default Setting Menus Menu Setting * Print direction* Auto / Bi-d / Uni-D...
  • Page 30 EPSON Stylus &2/25 800 Table 1-26. Printing Direction and ESC U Command Character Mode Raster Graphics Mode (for DOS) (for Windows / Mac)*1 ESC U 0 Auto Bi-D Auto ESC U 1 Auto Uni-D ESC U 2 Auto Auto ...

  • Page 31: Ink Smudge Prevention Mode

    Product Description 1.6.3 Printhead Alignment Mode The Stylus COLOR 800 allows users to perform printhead alignment operation without a special program. The following list shows adjustments performed for this printer. Table 1-27. Printer Adjustment Patterns Pattern No. Menu Bi-d adjustment (533 cps, units: 1-720 inch) Bi-d adjustment at (400 cps, units: 720 inch) Head gap adjustment in main scan direction —...

  • Page 32: Printer Initialization

    EPSON Stylus &2/25 800 1.6.6 Printer Initialization This printer has the following three initialization types: Power-on initialization, Operator initialization, and Software initialization. Power-on Initialization ‰Triggers Turning on the printer Cold reset command (remote RS command). ‰Actions performed: ‰Initializes the printer mechanism.

  • Page 33: Initialization Items And Values

    On the other hand, values set by other methods are cleared at power off, and the printer returns to the initialization values shown in the table when the printer is initialized. Table 1-29. Initialization Values Initialization Item Default Set EPSON Control Codes? Factory Value by Panel Operation? Print direction Auto...

  • Page 34: Self-Test Function

    EPSON Stylus &2/25 800 1.6.8 Self-test Function Pressing the Load/Eject or Cleaning (Black) button while turning on the printer puts the printer in the self-test mode. The self-test is used to check the following: ‰Control circuit function ‰Printer mechanism function ‰Print quality...

  • Page 35: Main Components

    C202 PSB/PSE board ‰Control panel bard C202 panel board ‰Printer mechanism ‰Housing The following figure shows the main component layout of the Stylus COLOR 800. Housing C202 PNL Board Assembly C202 MAIN Board Assembly C202 PSB/PSE Board Assembly Printer Mechanism Figure 1-10.

  • Page 36: C202 Main Board

    EPSON Stylus &2/25 800 1.7.1 C202 MAIN Board The C202 MAIN board controls various printer operations. It consists of an HD6432653 CPU (128-pin, 19.66 MHz), ASIC E05B33CB (208-pin, 19.66 MHz), 8M-bit-type PROM (42-pin, including CG data) or 8M-bit-type PROM + 8M-bit-type CG (NLSP version only), 4M-bit-type DRAM, EEPROM, and several drivers.

  • Page 37: C202 Psb/Pse Board

    Product Description 1.7.2 C202 PSB/PSE Board This board consists of a transformer, switching FET, regulator IC, diode bridge, photo coupler, fuse, various transistors, and so on. It supplies C202 MAIN board with +5 V and +35 V. Transformaer IC51 Switching FET Q1 Diode Bridge F1 Fuse...

  • Page 38: C202 Panel Board

    EPSON Stylus &2/25 800 1.7.3 C202 Panel Board The C202 panel board is the control panel for the Stylus COLOR 800. It has 4 buttons including the power button and 4 LEDs. Figure 1-13. C202 Panel Board 1.7.4 Printer Mechanism This printer mechanism consists of monochrome / color heads;...

  • Page 39: Housing

    Product Description 1.7.5 Housing This printer consists of the printer cover, upper housing, and lower housing. Printer Cover Upper Housing Lower Housing Figure 1-15. Housing 1-31 Rev. A Download Service Manual and Resetter Printer at http://printer1.blogspot.com...

  • Page 40: General Description

    Chapter 2 Operating Principles 2.1 Overview........................2-1 2.2 Printer Mechanism Operating Principles ............2-1 2.2.1 General Description ....................... 2-1 2.2.2 Printing Mechanism ....................... 2-2 2.2.2.1 Printing Process ......................2-3 2.2.2.2 Printing Methods......................2-3 2.2.3 Carriage (CR) Mechanism...................... 2-4 2.2.4 Paper Feed Mechanism......................2-5 2.2.5 Platen Gap (PG) Adjust Mechanism ..................

  • Page 41: Overview

    Operating Principles 2.1 Overview This chapter provides information on the printer mechanism, electrical circuit, and ink system. The operating principles for each mechanism in the printer mechanism is described individually. The description for the electrical circuit is divided into 2 parts; C202 PSB/PSE board and C202 MAIN board. 2.2 Printer Mechanism Operating Principles 2.2.1 General Description This printer is mainly composed of the printing mechanism, paper feed mechanism, carriage mechanism,...

  • Page 42: Printing Mechanism

    EPSON Stylus &2/25 800 2.2.2 Printing Mechanism The printing method used for this printer is On-demand ink jet system, same as for other EPSON ink jet printers. This printer, however, uses newly designed MACH Head, which ensures a high level of printing quality at a higher speed.

  • Page 43: Printing Process

    Both black and color printings can be performed in the Micro dot printing mode. In the Normal dot printing, one dot is formed with 2 pulses. On the other hand, EPSON micro dot printing mode forms one dot with single pulse using less ink. As mentioned above, the Micro dot printing for this printer is controlled to use less ink to create images at 1440 dpi, the maximum solution on the horizontal line.

  • Page 44: Carriage (Cr) Mechanism

    EPSON Stylus &2/25 800 2.2.3 Carriage (CR) Mechanism The CR mechanism is composed of the CR motor, Timing Belt, CR Guide Shaft, Top Frame, and Home Position (HP) sensor. The torque from the CR motor is transmitted to the CR unit via the Timing Belt to move the CR unit along the CR Guide Shaft both right and left, depending on the direction in which the CR motor rotates.

  • Page 45: Paper Feed Mechanism

    Operating Principles 2.2.4 Paper Feed Mechanism This printer is equipped with the PF motor which is used to feed paper only to improve feeding speed. The drive from the Pump motor is used to load paper at the ASF and the drive from the PF roller is independently used to feed paper only.

  • Page 46: Platen Gap (Pg) Adjust Mechanism

    EPSON Stylus &2/25 800 2.2.5 Platen Gap (PG) Adjust Mechanism The PG adjust mechanism, located at the left of the printer mechanism, consists of the PG lever, PF sub lever, right/left parallelism adjust bushings, and CR guide shaft. PG adjust mechanism is equipped to keep the proper platen gap according to the paper thickness to prevent ink from having friction.

  • Page 47: Asf Mechanism

    Operating Principles 2.2.7 ASF Mechanism ASF mechanism, which consists of the Pump motor, slider mechanism, disengage mechanism, and ASF unit, loads paper into the paper feed mechanism. When the CR unit returns to the home position, it pushes the slider in the slider mechanism to the right and the Gear (16) in the slider mechanism then comes to engage with the Change cam in the disengage mechanism.
  • Page 48 Download Service Manual and Resetter Printer at http://printer1.blogspot.com...

  • Page 49: Ink System

    Operating Principles 2.2.8 Ink System The ink system for this printer is composed of the following and performs absorbing and ejecting ink, cleaning the printhead surface, and capping the printheads. †Ink cartridge †Pump mechanism †Wiping mechanism †Capping mechanism †Waste ink drain pads This section describes the operational principles of the pump mechanism and capping mechanism.

  • Page 50: Pump Mechanism

    EPSON Stylus &2/25 800 2.2.8.1 Pump Mechanism The functions of the Pump mechanism, which is composed of the Pump motor, Slider mechanism, and Disengage mechanism, are Absorbing black/color ink from the capping unit, false absorption, and setting and resetting of the wiper. When the CR returns to the CR home position, it pushes the slider in the Slider mechanism to the right end.
  • Page 51 Operating Principles The pump unit switches its function depending on the direction in which the pump motor rotates, as show in Table 2-8; Table 2-8. Pump Motor Rotation and Function Motor rotation direction Function Clock wise direction Color ink absorption, Color ink false absorption, (Forward) Color ink Micro absorbing, Resetting the wiper Counter...

  • Page 52: Capping Mechanism

    EPSON Stylus &2/25 800 2.2.8.2 Capping Mechanism The capping mechanism caps the printheads with the cap holder to prevent the ink around the nozzles from increasing viscosity while the printer is in stand-by status or the printer power is off. Is has 2 separate holders;...

  • Page 53: Electrical Circuit Operation Principles

    Operating Principles 2.3 Electrical Circuit Operation Principles This printer consists of the following circuit boards: †C202 MAIN board †C202 PSB/PSE board †C202 Panel board In addition to the circuit boards above, the printhead driver circuit is directly attached to each of the black and color heads in the CR unit.
  • Page 54 EPSON Stylus &2/25 800 Figure 2-15. VDC Circuit Block Diagram The operating principles of various protection circuit and controller circuit in the figure above are described below. ‰+5 VDC line over voltage protection circuit The output voltage level of +5 V is monitored by a Zener diode (AD53) on the secondary circuit. If the voltage level exceeds 9 V, the switching FET Q1 goes Off in the following order, and no induced electromotive is generated and production of +5 VDC and +42 VDC stops as the result.

  • Page 55: C202 Main Control Board

    Operating Principles 2.3.2 C202 MAIN Control Board C202 MAIN control board consists of the following: „Logic circuits for PROM, DRAM, CPU, ASIC and EEPROM „Motor control and driver circuits for CR motor, PF motor, and pump motor „Head control/ driver circuit for the black and color heads „Other circuits for the I/F (Parallel I/F, Mac serial.
  • Page 56 Download Service Manual and Resetter Printer at http://printer1.blogspot.com...
  • Page 57 Operating Principles ‰Black head nozzle selector circuit The printing data is input from the data input ports D0 to D15 of the IC2 E05B33CB gate array to the gate array to be converted into serial data and output to the nozzle selector from the BBHDATA and BHADATA ports.

  • Page 58: Reset Circuits

    EPSON Stylus &2/25 800 2.3.2.2 Reset Circuits The C202 MAIN board contains two reset circuits; for logic line (+5 V) and power line (+42 V). The voltages for +5 V and +42 V in each reset circuit are monitored to prevent printer malfunction caused by abnormal voltage levels.

  • Page 59: Motor Driver Circuits

    Operating Principles 2.3.2.3 Motor Driver Circuits This printer is equipped with the 3 motors; CR motor, PF motor, and pump motor. Since they are all driven by the UDN2917EB, they use the same control system. ‰CR motor driver circuit The phase control signal for the CR motor is converted into the UDN2917EB Micro-step bipolar driver system at the IC2 gate array, then output from the port 55 to the port 43 and 26 of the IC13 UDN2917EB.
  • Page 60 Download Service Manual and Resetter Printer at http://printer1.blogspot.com...

  • Page 61: Ink System Management

    Operating Principles 2.4 Ink System Management This section explains how the ink system is controlled to protect the printheads and the ink supply system to ensure high-quality output. This printer has several ink system control sequences which vary depending on the combinations of the basic ink system operations. The printer selects the most suitable sequence by referring to the various printer information such as values for the timers and counters stored in the EEPROM, flag and numbers of sensor signals.

  • Page 62: Timers And Counters

    EPSON Stylus &2/25 800 2.4.2 Timers and Counters This printer is equipped with numbers of timer counters, soft counters and flag. Their values, which are mostly stored in the EEPROM, are the basis for selecting the ink sequence to be performed.

  • Page 63: Ink System Sequence

    Operating Principles 2.4.3 Ink System Sequence The ink system sequences operated in this printer are combinations of the basic ink system operations described in Section 2.4.1. The printer selects the most suitable ink sequence according to the information provided by the various counters, timers, and flags. The major ink system sequences are described in this section.
  • Page 64 EPSON Stylus &2/25 800 ‰Cartridge Replacement Sequence The printer determines which ink cartridge (black or color) needs replacing in Cartridge replacement CL sequence according to the conditions such as cartridge installation, Ink Low and Ink End. Cartridge replacement CL sequence consists of Wiping, Ink Absorbing, Micro Absorbing, and False Absorbing, and consumes less ink than that of the manual cleaning sequence.

  • Page 65: Disassembly And Assembly

    Chapter 3 Disassembly and Assembly 3.1 Overview........................3-1 3.1.1 Precautions for Disassembling the Printer............3-1 3.2 Disassembly and Assembly Procedures ............3-3 3.2.1 Before Beginning Disassembly ................3-4 3.3 C202 MAIN Board Assembly Removal ..............3-5 3.4 Upper Housing Removal ..................3-6 3.4.1 C202 Panel Board Assembly Removal ..............3-9 3.5 Printhead Removal .....................3-10 3.6 Paper Eject Frame Assembly Removal.............3-13 3.7 Front Paper Guide Assembly Removal.............3-14...

  • Page 66: Overview

    POINTS TO NOTE. Adjustments required after assembling the unit are described under REQUIRED ADJUSTMENTS. 3.1.1 Precautions for Disassembling the Printer See the precaution below when disassembling and assembling EPSON Stylus COLOR 800. WARNING Disconnect the power cable before disassembling or assembling the printer.
  • Page 67 EPSON Stylus &2/25 800 CAUTION Never remove the ink cartridge from the carriage unless the manual specifies to do so. When transporting the printer after the ink cartridge has been installed, be sure to pack the printer for transport without removing the ink cartridge.

  • Page 68: Disassembly And Assembly Procedures

    Disassembly and Assembly 3.2 Disassembly and Assembly Procedures This section describes disassembly or assembly procedures for printer assemblies and parts. CAUTION Read precautions in Section 3.1.1 prior to disassembly and assembly. Figure 3-1. Printer Disassembly Procedures Rev. A Download Service Manual and Resetter Printer at http://printer1.blogspot.com...

  • Page 69: Before Beginning Disassembly

    EPSON Stylus &2/25 800 3.2.1 Before Beginning Disassembly Remove the following parts before beginning disassembly. ‰ Paper Support ‰ Output Tray To remove the output tray, shift it to the right end, then push the handle on the left edge inward.

  • Page 70: C202 Main Board Assembly Removal

    Disassembly and Assembly 3.3 C202 MAIN Board Assembly Removal 1. Remove 2 screws (CBS, 3x8, F/Zn) securing the C202 MAIN board assembly to the back of the printer. (See Figure 3-3.) 2. Move C202 MAIN board about 5 cm (2”) out from the back of the printer. (See Figure 3-3.) CAUTION C202 MAIN board assembly shield plate edges are sharp.
  • Page 71 EPSON Stylus &2/25 800 3. Disconnect all cables (CN4, CN6, CN7, CN8, CN11, CN12, and CN13) and FFCs (CN9 and CN10) from C202 MAIN board assembly. (See Figure 3-4) Use instructions below to disconnect connectors: ‰ CN11, CN12, CN13: Release the connector lock lever by pulling it up, and disconnect the cable.

  • Page 72: Upper Housing Removal

    Disassembly and Assembly 3.4 Upper Housing Removal 1. Remove the parts shown in Figure 3-2. 2. remove 2 screws (CBS, 3X8, F/Zn) securing the C202 MAIN board assembly to the printer. Then draw the C202 MAIN board forward about 5 cm. 3.
  • Page 73 EPSON Stylus &2/25 800 4. Remove 4 screws (CCP, 4x12, F/Zn): 2 screws securing the upper housing to the front and 2 screws securing the upper housing to the top rear side of the printer. (Refer to Figure 3-6.) 5. Set the platen gap lever to the “+” position. Then, pull the front part of the upper housing forward, and lift it backward to remove.

  • Page 74: C202 Panel Board Assembly Removal

    Disassembly and Assembly 3.4.1 C202 Panel Board Assembly Removal 1. Remove the upper housing. (See Section 3.4.) 2. Turn the upper housing up, and release the lock lever for the FFC connector by pushing it out. Then disconnect the FFC. 3.

  • Page 75: Printhead Removal

    EPSON Stylus &2/25 800 3.5 Printhead Removal 1. Remove the upper housing. (Refer to Section 3.4.) 2. Open the ink cartridge covers and remove the ink cartridges from the CR assembly. 3. Using tweezers, release the ink cartridge covers from the pins fixing them to the CR assembly.
  • Page 76 Disassembly and Assembly 6. Remove 2 FFCs from the printheads. (See Figure 3-10.) Figure 3-10. Head FFC Removal 7. Shift the printheads forward. Then remove them by lifting upward carefully. CAUTION In handling the printheads, note the following: ‰ Ground yourself. The driver IC is attached directly to the printhead unit. ‰...
  • Page 77 EPSON Stylus &2/25 800 Before installing the printhead into the CR assembly, move the carriage to the capping position to protect the head surface. Procedures for printhead assembly are described below. Remove the 2 FFCs from the clips used to attach them.

  • Page 78: Paper Eject Frame Assembly Removal

    Disassembly and Assembly 3.6 Paper Eject Frame Assembly Removal 1. Remove the upper housing. (See Section 3.4.) 2. Release the CR lock lever using tweezers. Then shift the CR to the left of the FFC holder. 3. Release 2 hooks for the FFC holder, and remove the FFC holder. (See Figure 3-12.) Figure 3-12.

  • Page 79: Front Paper Guide Assembly Removal

    EPSON Stylus &2/25 800 3.7 Front Paper Guide Assembly Removal 1. Remove the paper eject frame assembly. (See Section 3.6.) 2. Lift up the front paper guide assembly slightly, and shift it forward while sliding it to the left to release the pins from the cutouts in the right frame. (See Figure 3-14.) Figure 3-14.

  • Page 80: Home Position (Hp) Sensor Removal

    Disassembly and Assembly 3.8 Home Position (HP) Sensor Removal 1. Remove the upper housing. (See Section 3.4.) 2. Using tweezers, release 2 hooks fixing the HP sensor to the sub pump frame. Then remove the HP sensor by pulling it downward. (See Figure 3-15.) Figure 3-15.

  • Page 81: C202 Psb/Pse Board Assembly Removal

    EPSON Stylus &2/25 800 3.9 C202 PSB/PSE Board Assembly Removal 1. Remove the upper housing. (See Section 3.4.) 2. Remove 2 screws (CBS, 3x6, F/Zn) securing the C202 PSB/PSE board assembly to the printer mechanism. (See Figure 3-16.) Figure 3-16. C202 PSB/PSE Board Removal 3.
  • Page 82 Disassembly and Assembly Place the connectors for the printer mechanism back in the cable clamp after installing the C202 PSB/PSE board assembly. Tightening torque for the screws (CBS, 3X6, F/Zn) = 8 ~ 10 kg-cm. When connecting the cable for the C202 PSB/PSE board to CN4 on the C202 MAIN board, insert the cable through the slot, as shown in Figure 3-18.

  • Page 83: Carriage Motor (Cr Motor) Assembly Removal

    EPSON Stylus &2/25 800 3.10 Carriage Motor (CR Motor) Assembly Removal 1. Remove the upper housing. (See Section 3.4.) 2. Release the CR lock lever using tweezers. Then shift the CR assembly from the capping position manually. 3. Remove 2 screws (CBS, 3x6, F/Zn) securing the CR motor assembly to the top frame. (See Figure 3-19.)

  • Page 84: Asf (Auto Sheet Feeder) Removal

    Disassembly and Assembly 3.11 ASF (Auto Sheet Feeder) Removal 1. Remove the C202 PSB/PSE board assembly. (See Section 3.4.6.) 2. Remove 2 screws (CPS, 4x10 and ASF fixing screw, F/Zn) securing the ASF to the right frame and to the rear left of the frame, respectively. (See Figure 3-20.) Figure 3-20.
  • Page 85 EPSON Stylus &2/25 800 4. Slide the ASF assembly to the left, then to the rear; and remove the ASF assembly from the printer mechanism. Be sure to disconnect the ASF HP sensor cable from the sensor. Connect the ASF HP cable to the connector at the left edge of the ASF before installing the ASF assembly.

  • Page 86: Asf Assembly Disassembly

    Disassembly and Assembly 3.11.1 ASF Assembly Disassembly 1. Remove the ASF. (See Section 3.11.) 2. Remove the left shaft bushing, located at the left end of the loading (LD) roller shaft. (See Figure 3-23.) Figure 3-23. Left Bushing Removal CAUTION Remove this bushing with care so you do not damage it.
  • Page 87 EPSON Stylus &2/25 800 4. Release the pin at the top left edge of the hopper assembly from the ASF frame. Then align the right arm of the hopper assembly with the cutout in the ASF right frame, and remove the hopper assembly carefully by lifting up the left edge.
  • Page 88 Disassembly and Assembly Figure 3-27. Locking Tabs on the LD Roller CAUTION Never touch the rubber part of the LD roller assemblies with your bare hands. Ensure the following are correctly mounted onto the paper loading assembly before assembling. (See Figure 3-28.) „...
  • Page 89 EPSON Stylus &2/25 800 Follow the instructions below when installing the hopper assembly into the ASF frame with the paper loading assemblies mounted on it: (See Figure 3-29.) 1. Note the direction to place the compression spring. One end is bent straight inward.
  • Page 90 Disassembly and Assembly Be sure to fix both right and left pins on the ASF frame securely into the holes in the hopper assembly. When installing the detection wheel onto the left end of the LD roller shaft, be sure to engage it in the right direction.

  • Page 91: Asf Hp Sensor Removal

    EPSON Stylus &2/25 800 3.11.2 ASF HP Sensor Removal 1. Remove the ASF assembly. (Refer to Section 3.11.) 2. Remove the right hopper release lever in the ASF assembly. 3. Remove the bushing from the left edge of the loading (LD) roller shaft in the ASF assembly.
  • Page 92 Disassembly and Assembly 5. Insert tweezers into the slit in the back of the ASF HP sensor, and release the clips. Then remove the ASF HP sensor. (See Figure 3-34.) Figure 3-34. ASF HP Sensor Removal When mounting the detection wheel onto the LD roller shaft, push the wheel into the shaft until it clicks.
  • Page 93 EPSON Stylus &2/25 800 3.12 Paper Feed (PF) Motor Assembly Removal 1. Remove the ASF. (Refer to Section 3.11.) 2. Remove 1 C-ring and 1 plain washer securing the combination gear (14 mm, 31.5 mm) to the left frame. 3. Remove 2 screws (CBS, 3x6, F/Zn) securing the PF motor assembly to the left frame.
  • Page 94 Disassembly and Assembly 5. Disconnect the paper feed motor cable from the CN13 on the C202 MAIN board assembly. 6. Remove the PF motor from the printer mechansm. Be careful not to damage the teeth on the combination gear (14 mm, 31.5 mm), paper feed pinion gear, or gear (70 mm) when engaging them.

  • Page 95: Printer Mechanism Removal

    EPSON Stylus &2/25 800 3.13 Printer Mechanism Removal 1. Remove the units and assemblies by following the procedures described in Section 3.9. 2. Disconnect all the connectors and FFCs from the C202 MAIN board assembly. 3. Remove 4 screws (CB, 4x12, F/Zn) securing the printer mechanism to the lower case.

  • Page 96: Cap Assembly Removal

    Disassembly and Assembly Figure 3-38. Sub Ink Drain Pad REQUIRED ADJUSTMENT Perform necessary adjustment and data input referring to Table 4-1 in Chapter 4 when the printer mechanism is replace with a new one. 3.13.1 Cap Assembly Removal 1. Remove the printer mechanism. (Refer to Section 3.13.) Figure 3-39.
  • Page 97 EPSON Stylus &2/25 800 Tubes linking the pump assembly are made of silicone, and a minor flaw can become a crack. Therefore, use the exclusive tweezers designed for the tubes carefully when positioning the tubes back onto the pins. Handle the cap assembly carefully, and never touch the rubber portion and pad portion of the caps.

  • Page 98: Pump Assembly Removal

    Disassembly and Assembly 3.13.2 Pump Assembly Removal 1. Remove the cap assembly. (Refer to Section 3.13.1.) 2. Remove 2 screws (CBS, 3x6, F/Zn) securing the outer sub frame assembly to the middle sub frame assembly and to the slider shaft respectively. Then remove the whole outer sub frame assembly with the pump drive gear and the pump reduction gear.
  • Page 99 EPSON Stylus &2/25 800 3. Remove 1 screw (CBS, 3X6, F/Zn) securing the pump assembly to the middle sub frame assembly. (Refer to Figure 3-42.) Figure 3-42. Pump Assembly Removal 4. Remove the pump assembly from the middle sub frame assembly.

  • Page 100: Pump Motor Removal

    Disassembly and Assembly Figure 3-43. Head Cleaner Location 3.13.3 Pump Motor Removal 1. Remove the printer mechanism. (Refer to Section 3.13.) 2. Remove 2 screws (CBS, 3x6, F/Zn) securing the pump motor to the pump sub frame. Then remove the pump motor. (Refer to Figure 3-44.) Figure 3-44.

  • Page 101: Carriage (Cr) Assembly Removal

    EPSON Stylus &2/25 800 3.13.4 Carriage (CR) Assembly Removal 1. Remove the printer mechanism. (Refer to Section 3.13.) 2. Release the CR lock lever using tweezers. Then manually slide the CR assembly from the capping position. 3. Remove 2 screws (CBS, 3x6, F/Zn) securing the CR motor assembly to the printer mechanism top frame.
  • Page 102 Disassembly and Assembly 6. Remove 1 E-ring and 1 screw (CBS, 3x6, F/Zn) securing the right parallelism adjustment bushing to the top frame. Then turn the bushing forward until it fits into the cutout in the top frame and slide it to the right. (Refer to Figure 3-46.) Figure 3-46.
  • Page 103 EPSON Stylus &2/25 800 8. Shift the CR shaft to the right to remove the CR assembly from the platen gap lever and left parallelism adjustment bushing. (See Figure 3-48.) Figure 3-48. CR Assembly Removal 9. Take the CR shaft out from the CR assembly.
  • Page 104 Disassembly and Assembly Figure 3-49. Engaging the PG Sub Lever Figure 3-51. Fitting the Cartridge Slider to the Upper Edge Figure 3-50. Engaging the Cartridge Shaft and Slider Shaft REQUIRED ADJUSTMENT In case that the CR assembly is replaced, perform necessary adjustment (Refer to Table 4-1 in Chapter 4) 3-39 Rev.

  • Page 105: Top Frame Removal

    EPSON Stylus &2/25 800 3.13.5 Top Frame Removal 1. Remove the ASF assembly. (See Section 3.11.) 2. Remove the printer mechanism. (See Section 3.13.) 3. Remove the CR assembly. (See Section 3.13.4.) CAUTION It is possible to remove the top frame without removing the CR assembly and ASF assembly, but it is highly recommended that you remove these assemblies before removing the top frame.
  • Page 106 Disassembly and Assembly 5. Remove 3 screws (CBS, 3x6, F/Zn) securing the top frame to the printer mechanism, and 1 screw CBS, 3x6, F/Zn) securing the top frame and cap assembly. (See Figure 3-53.) Figure 3-53. Removing the Screws Securing the Top Frame 6.

  • Page 107: Paper Empty (Pe) Sensor Assembly Removal

    EPSON Stylus &2/25 800 Figure 3-55. Right Paper Guide Installation 3.13.6 Paper Empty (PE) Sensor Assembly Removal 1. Remove the top frame. (Refer to 3.13.5.) 2. Release the hook for the PE sensor assembly using tweezers. Then remove the paper end sensor assembly by lifting upward.
  • Page 108 Disassembly and Assembly When mounting the paper end sensor assembly on the top frame, be sure to mount the torsion spring correctly at the point shown in Figure 3-57. After installing the paper empty sensor lever, ensure it bounces smoothly. Install the paper empty sensor and right paper guide assembly in the following order: Mount the paper empty sensor onto the top frame.

  • Page 109: I/S (Ink System) Frame Removal

    EPSON Stylus &2/25 800 3.13.7 I/S (Ink System) Frame Removal CAUTION When releasing joints linking the I/S frame and right frame, be careful not to bend the frames. 1. Remove the pump assembly. (Refer to Section 3.13.2.) 2. Remove the top frame. (Refer to Section 3.13.5.) 3.
  • Page 110 Disassembly and Assembly 5. Slide the I/S frame forward by releasing 3 joints (2 at the back and 1 on the front of the printer mechanism) for the I/S frame and right frame. Then remove the I/S frame by lowering downward. (See Figure 3-60.) Figure 3-59.
  • Page 111 EPSON Stylus &2/25 800 When joining the I/S frame with the right frame, be sure to align it with the slots in the right frame appropriately. Then push until it meets resistance. Pay attention to the 20.8 mm gear in the combination gear (12 mm, 20.8 mm) when connecting the I/S frame to the right frame.

  • Page 112: I/S Frame Disassembly (Removing The Pump Motor)

    Disassembly and Assembly 3.13.7.1 I/S Frame Disassembly (Removing the Pump Motor) 1. Remove the I/S frame. (See Section 3.13.7.) 2. Remove 2 screws (CBS, 3x6, F/Zn) securing the pump motor. (See Figure 3-62.) Figure 3-61. Removing the Screws Securing the Pump Motor 3.
  • Page 113 EPSON Stylus &2/25 800 4. Remove 1 hexagon nut (6N, class-2, M4) and 1 draft spring (0.4 g) securing the slider shaft Remove 2 screws (CBS, 3x6, F/Zn) securing the inner sub frame. Then remove the inner sub frame and following 6 parts from the middle sub frame: c Combination gear (12 mm, 20.8 mm)
  • Page 114 Disassembly and Assembly Remove 2 screws (CBS, 3X6, F/Zn) securing the middle sub frame, then remove the middle sub frame and the following 11 parts from the sub pump frame: c Combination gear (12, 15) d Plain washer (5.2x0.3x12, S/Na) e Spring washer (5.3x0.07x10, S/Na) f Combination gear (14.4, 21.6) g Cam...
  • Page 115 EPSON Stylus &2/25 800 Checklist after Engaging I/S Frame Gear engagement Insert the cam in the direction shown in Figure 3-66 (top left illustration), and turn the combination gear right and left. Then check that gears turn smoothly. Engagement of slider and combination gear Move slider to the right, and check that it engages the combination gear smoothly.

  • Page 116: Paper Feed Roller (Pf Roller) Assembly Removal

    Disassembly and Assembly 3.13.8 Paper Feed Roller (PF Roller) Assembly Removal CAUTION When releasing or turning lock levers for the paper feed roller bushings, be careful not to damage them. When removing the paper feed roller from the right and left frames, be careful not to damage the teeth for the gear (70 mm).
  • Page 117 EPSON Stylus &2/25 800 4. Push levers out to release the lock levers for the right and left bushings (12 mm) securing the paper feed roller assembly to the right and left frames. Then turn them forward until they fit through the cutouts in the frames. Shift the paper feed roller assembly left, and remove the paper feed roller assembly and rear paper guide along with the gear (70 mm) by lifting upward.
  • Page 118 Disassembly and Assembly Figure 3-68. Bushing Locations Figure 3-70. Contact Spring Location 3-53 Rev. A Download Service Manual and Resetter Printer at http://printer1.blogspot.com...

  • Page 119: Ink Drain Pad Removal

    EPSON Stylus &2/25 800 3.13.9 Ink Drain Pad Removal 1. Remove the printer mechanism. (See Section 3.13.) 2. Remove the ink drain pad from the lower case. Figure 3-71. Ink Drain Pad Removal 3-54 Rev. A Download Service Manual and Resetter Printer at http://printer1.blogspot.com...
  • Page 120 Chapter 4 Adjustment 4.1 Over View .........................1 4.1.1 Adjustment Required ........................ 2 4.1.2 Adjustment Tools........................3 4.2 Adjustment .......................4 4.2.1 Platen Gap (PG) Adjustment ....................4 4.2.2 Input of Customer Data......................7 4.2.3 Ink Charge ..........................8 4.2.4 Write to the Head Voltage Value ..................... 10 4.2.5 Head Angular Adjustment.......................

  • Page 121: Overview

    Adjustment 4.1 Overview This section describes adjustment required when the printer is reassembled after repair. Read the instructions headed under “CAUTION” before starting adjustment. CAUTION ; Always perform adjustment using the program specified for each unit. ; Ink cartridge used for this printer is one-time-cartridge. If the same cartridge is reinstalled, bubbles are formed in the printhead, which might cause dot missing.

  • Page 122: Adjustment Required

    EPSON Stylus &RORU 800 4.1.1 Adjustment Required This section gives information on the adjustment required after disassembling and reassembling. Be sure to perform the specified adjustment whenever you remove or replace the part for repair. Table 4- 1 lists the required adjustments for several units and corresponding adjust items, which must be accomplished in the order instructed in Table 4-1.

  • Page 123: Adjustment Tools

    Adjustment 4.1.2 Adjustment Tools Table 4-2 shows the tools necessary to adjust this printer and the menus to be adjusted. Table 4- 2. Adjustment Tools Tools for adjusting Item to be adjusted ‰ Customer data writing operation Program disk for adjustment y DOS system ‰...

  • Page 124: Adjustment

    EPSON Stylus &RORU 800 4.2 Adjustment This section provides detailed information on how to perform the adjustments listed below and the notice headed under “CAUTION”. ‰ Platen gap adjustment ‰ Customer data writing operation ‰ Initial ink charge ‰ Head voltage data writing operation ‰...
  • Page 125 Adjustment Turn the left parallelism adjust bushing to the rear (narrower) step by step toward the left parallelism adjust bushing set position, where the thickness gauge starts shifting together with the CR unit. Then shift the lever one step back to the front (wider) from the adjusted position. Left Parallelsm Adjust Bushing Rear side (Close) Front side (Open)
  • Page 126 EPSON Stylus &RORU 800 CAUTION ; After performing the PG gap adjustment, make sure that the “Cleaner Head” and head nose are in contact with each other by the proper portion by following the instruction below. 11. Set the “PG Lever” to the “+” (wide) position.

  • Page 127: Input Of Customer Data

    Set this program to FFD on your PC and turn the PC on. The program automatically sets up and the following menu appears on the screen. Stylus COLOR 800 J70C00E Customer : Standard Customer DATA < **** > 12-03-1996 .....

  • Page 128: Ink Charge

    Set this program to FFD on your PC and turn the PC on. The program automatically sets up and the following menu appears on the screen. Stylus COLOR 800 J70C00E Customer : Standard Customer DATA < **** > 12-03-1996 .....
  • Page 129 “ENTER” key. (See the code list on Page 4-6.) Enter “2” for “Select menu : ?” to select “Adjustment/Print inspection” in the menu. Press “ENTER” key, and the sub menu below appears. Stylus COLOR 800 J70C00E Customer : Standard Customer Data < **** > 12-03-1996 ......

  • Page 130: Write To The Head Voltage Value

    Set this program to FFD on your PC and turn the PC on. The program automatically sets up and the following menu appears on the screen. Stylus COLOR 800 J70C00E Customer : Standard Customer DATA < **** > 12-03-1996 .....
  • Page 131 “ENTER” key. (See the code list on Page 4-6.) Enter “2” for “Select menu : ?” to select “Adjustment/Print inspection” in the menu. Press “ENTER” key, and the sub menu below appears. Stylus COLOR 800 J70C00E Customer : Standard Customer Data < **** > 12-03-1996 ......
  • Page 132 EPSON Stylus &RORU 800 <<<<Write the Head Voltage value>>> Black Head voltage Black Head voltage value (5chr. ID data (ex.18A09)):24B16 Color Head voltage voltage Color Head voltage value (5chr. ID data (ex. 18A09)): 14B14 OK? <Space> to retry <Return> to write the value & return to the MENU...

  • Page 133: Head Angular Adjustment

    Set this program to FFD on your PC and turn the PC on. The program automatically sets up and the following menu appears on the screen. Stylus COLOR 800 J70C00E Customer : Standard Customer DATA < **** > 12-03-1996 .....
  • Page 134 EPSON Stylus &RORU 800 Press “ENTER” key, and the menu below appears. Stylus COLOR 800 J70C00E Customer : Standard Customer Data < **** > 12-03-1996 ......Ink charge ..Write to the Head voltage value ........All adjustment .....
  • Page 135 Adjustment CAUTION ; Slant changes with a unit of 0.02 mm by moving the head angular adjustment lever one step. 11. After adjusting the angular adjustment lever by looking the adjustment pattern sheet, press “SPACE” key to print another adjustment pattern sheet. 12.

  • Page 136: Bk.-Linear Adjustment

    Set this program to FFD on your PC and turn the PC on. The program automatically sets up and the following menu appears on the screen. Stylus COLOR 800 J70C00E Customer : Standard Customer DATA < **** > 12-03-1996 .....
  • Page 137 Adjustment Press “ENTER” key, and the sub menu below appears. Stylus COLOR 800 J70C00E Customer : Standard Customer Data < **** > 12-03-1996 ......Ink charge ..Write to the Head voltage value ........All adjustment ..... Head angular adjustment ..

  • Page 138: Head Gap Timing Adjustment

    Set this program to FFD on your PC and turn the PC on. The program automatically sets up and the following menu appears on the screen. Stylus COLOR 800 J70C00E Customer : Standard Customer DATA < **** > 12-03-1996 .....
  • Page 139 Adjustment Press “ENTER” key, and the sub menu below appears. Stylus COLOR 800 J70C00E Customer : Standard Customer Data < **** > 12-03-1996 ......Ink charge ..Write to the Head voltage value ........All adjustment ..... Head angular adjustment ..
  • Page 140 EPSON Stylus &RORU 800 10. Look at the output to check if the lines for black and color are most closely aligned. If not, input the proper value to adjust the misalignment according to the result, as shown in the figure below.
  • Page 141 “ENTER” key, and the menu below appears. 14. If the value input is incorrect, press “SPACE” and enter the correct value. If the input values are Stylus COLOR 800 J70C00E Customer : Sstandard cistpmer DATA < **** > 12-03-0996 .......

  • Page 142: Bi-D Adjustment

    Set this program to FFD on your PC and turn the PC on. The program automatically sets up and the following menu appears on the screen. Stylus COLOR 800 J70C00E Customer : Standard Customer DATA < **** > 12-03-1996 .....
  • Page 143 Adjustment Press “ENTER” key, and the sub menu below appears. Stylus COLOR 800 J70C00E Customer : Standard Customer Data < **** > 12-03-1996 ......Ink charge ..Write to the Head voltage value ........All adjustment ..... Head angular adjustment BK.-M Linear adjustment...
  • Page 144 EPSON Stylus &RORU 800 10. Look at the output to check if the lines are most closely aligned. If not, adjust the misalignment referring to the output result, as shown in the figure below. Direction in which the paper is fed...
  • Page 145 14. If the value input is incorrect, press “SPACE” and enter the correct value. If the input values are correct, press the “ENTER” key to proceed to the menu shown below. Stylus COLOR 800 J70C00E Customer : Sstandard cistpmer DATA <...

  • Page 146: Troubleshooting

    Chapter 5 Troubleshooting 5.1. General Description ....................5-1 5.2. Troubleshooting Information................5-1 5.2.1. Error mode ..........................5-1 5.2.2. Sensor Check Points......................5-2 5.2.3. Motor Check Points....................... 5-2 5.3. Repair and Replacement of the Unit Part ............5-3 5.4. Repair of the C202 PSB/PSE Board Component ..........5-11 5.5.

  • Page 147: General Description

    Troubleshooting 5.1 General Description This section describes how to identify and troubleshoot the problems when repairing the printer by dividing the troubles into two levels; repair and replacement of the assemblies and units, and repair of the components. When replacing or repairing the unit or assembly, be sure to refer to the corresponding flow chart which enables you to isolate the defective assembly or unit easily according to the symptom occurred.

  • Page 148: Sensor Check Points

    EPSON Stylus &2/25 800 5.2.2 Sensor Check Points Table 5-2 shows the check points for each sensor. Table 5-2. Check Points for Each Sensor Sensor Connector Test pin No Test procedure Meter reading (Meter is set to the DC voltage.)

  • Page 149: Repair And Replacement Of The Unit Part

    Troubleshooting 5.3 Repair and Replacement of the Unit Part This section contains the flow charts which are used to isolate the faulty unit by following the flow chart according to the problem caused during replacing or repairing the unit. You are to identify the faulty unit based on the primary symptom listed in Table 5-4.
  • Page 150 EPSON Stylus &2/25 800 ‰ Flow Chart 1 : The printer does not operate at all. Start Is the AC voltage Apply correct correct? AC voltage. Is the fuse F1 on the PSB/PSE Replace the fuse. board in a good...

  • Page 151: Troubleshooting

    Troubleshooting ‰ Flow Chart 2 : CR moves abnormally. Start Is the Does Fatal error CR motor the CR move occurs when the Connector cable when the printer is printer is turned Connected to turned on? the CN12? Is the Connect the CR motor operation connector cable to the...
  • Page 152 EPSON Stylus &2/25 800 ‰ Flow Chart 3-1 : The printer feeds paper abnormally. Start Does Is the the PF roller PF motor move when the connector cable Connect the connector cable printer is turned on? securely connected securly to the CN13.
  • Page 153 Troubleshooting ‰ Flow Chart 3-2 : The printer feeds paper abnormally. Continued from Figure 5-4. If the load button is If the load button pressed or the printing is pressed or the printing Check that the connector is operation is activated, the printer operation is activated, feeds paper to the middle way...
  • Page 154 Download Service Manual and Resetter Printer at http://printer1.blogspot.com...
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  • Page 158 Download Service Manual and Resetter Printer at http://printer1.blogspot.com...

  • Page 159: Repair Of The C202 Main Board Component

    Troubleshooting 5.5 Repair of the C202 MAIN Board Component This section consists of the procedures for replacing and repairing the C202 MAIN board at the component level. Refer to Table 5-7 which shows symptoms, descriptions causes, check points, and solutions. Table 5-7.
  • Page 160 EPSON Stylus &2/25 800 Table 5-8. Repair of the C202 MAIN Board Component (2) Symptom Description Cause Check points Solution • Check that the driving waveform CR does not CR does not IC13 or IC2 Replace the operate properly. operate properly.
  • Page 161 Troubleshooting Table 5-9. Repair of the C202 MAIN Board Component (3) Symptom Description Cause Check points Solution • Check that the PF motor phase Paper is not fed PF motor does IC16 or IC2 Replace the properly. not operate is defective. MAIN board.

  • Page 162: Repair Of The Printer Mechanism

    EPSON Stylus &2/25 800 5.6 Repair of the Printer Mechanism This section consists of the tables which contains symptoms, descriptions, possible causes, checkpoints, and solutions which you need in troubleshooting the problems with the units in the printer mechanism. Table 5-10. Repair of the Printer Mechanism (1)
  • Page 163 Troubleshooting Table 5-11. Repair of the Printer Mechanism (2) Symptom Description Possible cause Checkpoint Solution CR does not When the CR returns The cap in the Check if the cap Reinstall the cap move properly. to the home position, cap assembly assembly is properly assembly or replace abnormal noise is...
  • Page 164 Download Service Manual and Resetter Printer at http://printer1.blogspot.com...
  • Page 165 Troubleshooting Table 5-13. Repair of the Printer Mechanism (4) Symptom Description Possible cause Checkpoint Solution Abnormal Cleaning is performed Pump unit does 1. Check if the ink 1. Connect the ink printing 5 times or a newly not absorb the absorb tubes are absorb tubes to unpacked ink cartridge...
  • Page 166 EPSON Stylus &2/25 800 Table 5-14. Repair of the Printer Mechanism (5) Symptom Description Possible cause Checkpoint Solution Abnormal Ink smudge Ink on the driven Feed plain paper and Clean the spot printing roller of the check if it gets ink stained with the ink.
  • Page 167 Chapter 6 Maintenance 6.1. GENERAL DESCRIPTION..................6-1 6.2. MAINTENANCE ....................6-1 6.2.1. Cleaning..........................6-1 6.2.2. Lubrication ..........................6-2 6.2.2.1. Recommended Lubricants ..................6-2 6.2.2.2. Lubrication Points and Amounts................6-2 6.2.3. Ink Drain Pad Replacement ....................6-4 6.2.4. Head Cleaning........................6-7 Download Service Manual and Resetter Printer at http://printer1.blogspot.com...
  • Page 168 Maintenance 6.1 General Description In order to keep the printer in the optimum condition, it is essential to perform several types of maintenance on a regular basis. The maintenance includes cleaning, lubrication, ink drain pad replacement, and printhead cleaning. The cleaning is to wiping off the dirt and dust on the outer cases using denatured alcohol as well as vacuuming debris and dust accumulated in the printer.
  • Page 169 The lubricants has to be applied to the specified points of the printer. The specified lubrication points and EPSON recommended lubricants are listed in Table 6-1. The recommended lubricants, G-26 and O-8, have been tested and found the most applicable to this printer mechanisms. It is also required to apply an adequate amount of lubricant since excessive application may damage nearby parts.
  • Page 170 Maintenance Lubricate Never lubricate the roller and the paper path. Figure 6-1. Lubrication Point (1) Lubricate Figure 6-2. Lubrication Point (2) Lubricate Figure 6-3. Lubrication Point (3) Rev. A Download Service Manual and Resetter Printer at http://printer1.blogspot.com...
  • Page 171 EPSON Stylus &2/25 800 Lubricate Left Inner Side of the Upper Frame Figure 6-4. Lubrication Point (4) Oil Pad Lubricate (8) Carriage Viewed from the Bottom Figure 6-5. Lubrication Point (5) Hopper Release Lever Hopper Assembly Figure 6-6. Lubrication Point (6) Rev.
  • Page 172 Maintenance 1.15 cm Lubricate Right Edge of the Upper Frame 2 cm 3.5 cm Figure 6-7. Lubrication Point (7) Lubricate 0.6 cm 4 cm 6 cm Right Edge of the Upper Frame Viewed from the Back Figure 6-8. Lubrication Point (8) Sliding Part Figure 6-9.
  • Page 173 EPSON Stylus &2/25 800 Lubricate Bushing 12 PF Roller Figure 6-10. Lubrication Point (10) Rev. A Download Service Manual and Resetter Printer at http://printer1.blogspot.com...

  • Page 174: Head Cleaning

    The replacement procedures are as follows: Remove the ink drain pad, then replace it with a new one listed as a EPSON exclusive servicing part. (Refer to 3.2.13.10 in Chapter 3.) After the replacement, reset “Protection Counter A”...
  • Page 175 Appendix A.1 EEPROM Address Map ..................A-1 A.2 Connector Summary................... A-6 A.3 Circuit Board Component Layout ..............A-9 A.3.1 C202 MAIN Board Assembly Component Layout ...............A-9 A.3.2 C202 PSB Board Assembly Layout ..................A-10 A.3.3 C202 PSE Board Assembly Layout ..................A-10 Download Service Manual and Resetter Printer at http://printer1.blogspot.com...

  • Page 176: Eeprom Address Map

    Appendix A.1 EEPROM Address Map Address Data Name Data Format ASP Board Factory Value Reserved Market *1 0 : STANDARD1 : NLSP 0 (*1) 0 : Stylus &2/25 Model Name #1 (*1) 1 : MJ- -30 − +30 Bi-d adjustment value (*1) (SLQ) *1 Unit : 1/1440 inch...
  • Page 177 EPSON Stylus &2/25 800 Address Data Name Data Format ASP Board Factory Value Reserved Interface 0 : Auto 1 : Parallel 0 (*3) 2 : Serial 3 : Option Auto I/F wait time 10, 30 Unit : second Panel setting 1...
  • Page 178 Appendix Address Data Name Data Format ASP Board Factory Value Default setting 4 bit 0 : Auto tear-off 0 = Off 1 = On bit 1 : Skip perforation 0 = Off 1 = On bit 2 : State reply 0 = Off 1 = On bit 3...
  • Page 179 EPSON Stylus &2/25 800 Address Data Name Data Format ASP Board Factory Value Cartridge counter (Cc) Cartridge counter (Cy) Reserved Black cleaning timer 0 (*3) Cartridge counter (Cb) Ink value counter (Ry) Ink value counter (Rb) Protection counter (Ar) 0 (*3)
  • Page 180 Appendix *1: The value is adjusted in factory. *2: Following functions can be selected. Panel mask function 1 Panel mask function 2 Panel mask function 3 Font Pitch Page length for ASF Top margin for ASF Bottom margin for ASF Page length for manual insertion Top margin for manual insertion Bottom margin for manual inertion...

  • Page 181: Connector Summary

    EPSON Stylus &2/25 800 A.2 Connector Summary The figure below shows the interconnection between major components of the Stylus COLOR 800. Printer Mechanism C202 C202PNL PSB/PSE Color Head Black Head PE Sensor ASF HP Sensor HP Sensor ASF Pump Motor...
  • Page 182 Appendix Table A-3. Connector Pin Assignment CN5 Pin # Signal Name Description +5V DC Line LED0 LED 0 output signal LED2 LED 2 output signal LED3 LED 3 output signal LED4 LED 4 output signal SW 1 input signal SW 0 input signal SW 2 input signal Power switch ON/OFF signal Power ON/OFF signal...
  • Page 183 EPSON Stylus &2/25 800 Table A-10. Connector Pin Assignment CN9 Pin # Signal Name Description Black cartridge cover open signal – – – BTHM Not used – – – – – – BLAT Black head data latch signal – – –...

  • Page 184: Circuit Board Component Layout

    Appendix A.3 Circuit Board Component Layout A.3.1 C202 MAIN Board Assembly Component Layout Rev. A Download Service Manual and Resetter Printer at http://printer1.blogspot.com...

  • Page 185: C202 Psb Board Assembly Layout

    EPSON Stylus &2/25 800 A.3.2 C202 PSB Board Assembly Layout A.3.3 C202 PSE Board Assembly Layout A-10 Rev. A Download Service Manual and Resetter Printer at http://printer1.blogspot.com...
  • Page 186 EPSON OVERSEAS MARKETING LOCATIONS EPSON AMERICA, Inc. EPSON DEUTCHLAND GmBH 20770 Madrona Avenue, Zülpicher Straße 6, 4549 Düsseldorf P.O. Box 2842 Germany Torrance, CA 90509-2842 Phone: (800)922-8911 Phone: (0211)56030 Fax: (310)782-5220 Telex: 8584786 EPSON UK LTD. EPSON FRANCE S.A. Campus 100, Maylands Avenue,...
  • Page 187 EPSON SEIKO EPSON CORPORATION Download Service Manual and Resetter Printer at http://printer1.blogspot.com...

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