Manual - Servicio Epson Stylus Color C67-C68-C68 PDF

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 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.
WARNING 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. ALWAYS DISCONNECT THE PRODUCT FROM THE POWER SOURCE AND PERIPHERAL DEVICES PERFORMING ANY MAINTENANCE OR REPAIR
PROCEDURES.
2. 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.
3. 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.
4. WHEN DISASSEMBLING OR ASSEMBLING A PRODUCT, MAKE SURE TO WEAR GLOVES TO AVOID INJURIER FROM METAL PARTS WITH SHARP EDGES.
WARNING
1. REPAIRS ON EPSON PRODUCT SHOULD BE PERFORMED ONLY BY AN EPSON CERTIFIED REPAIR TECHNICIAN.
2. 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.
3. ALWAYS VERIFY THAT THE EPSON PRODUCT HAS BEEN DISCONNECTED FROM THE POWER SOURCE BEFORE REMOVING OR REPLACING PRINTED
CIRCUIT BOARDS AND/OR INDIVIDUAL CHIPS.
4. IN ORDER TO PROTECT SENSITIVE MICROPROCESSORS AND CIRCUITRY, USE STATIC DISCHARGE EQUIPMENT, SUCH AS ANTI-STATIC WRIST
STRAPS, WHEN ACCESSING INTERNAL COMPONENTS.
5. 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.
6. 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 Symbols Used in this Manual

This manual consists of six chapters and Appendix. Various symbols are used throughout this manual either to provide additional
CHAPTER 1.PRODUCT DESCRIPTIONS information on a specific topic or to warn of possible danger present during a
Provides a general overview and specifications of the product. procedure or an action. Be aware of all symbols when they are used, and always read
CHAPTER 2.OPERATING PRINCIPLES NOTE, CAUTION, or WARNING messages.
Describes the theory of electrical and mechanical operations of the
product. A D J U S T M E N T
Indicates an operating or maintenance procedure, practice or condition
CHAPTER 3.TROUBLESHOOTING R E Q U IR E D that is necessary to keep the product’s quality.
Describes the step-by-step procedures for the troubleshooting.
CHAPTER 4.DISASSEMBLY / ASSEMBLY
Describes the step-by-step procedures for disassembling and assembling
Indicates an operating or maintenance procedure, practice, or condition
the product. C A U T IO N
that, if not strictly observed, could result in damage to, or destruction of,
CHAPTER 5.ADJUSTMENT
equipment.
Provides Epson-approved methods for adjustment.
CHAPTER 6.MAINTENANCE
Provides preventive maintenance procedures and the lists of Epson- May indicate an operating or maintenance procedure, practice or
C H E C K
approved lubricants and adhesives required for servicing the product. condition that is necessary to accomplish a task efficiently. It may also
P O IN T
APPENDIX Provides the following additional information for reference: provide additional information that is related to a specific subject, or
• Exploded Diagram comment on the results achieved through a previous action.
• Parts List
• Circuit Diagrams Indicates an operating or maintenance procedure, practice or condition
W A R N IN G
that, if not strictly observed, could result in injury or loss of life.
Indicates that a particular task must be carried out according to a certain

standard after disassembly and before re-assembly, otherwise the qual-
ity of the components in question may be adversely affected.
Revision Status
Revision Date of Issue Description
A Aug 1, 2005 First Release
B Jan 18, 2006 CHAPTER 4 DISASSEMBLY/ASSEMBLY
“4.3.3.9 CR Cable Head Cover” on page 64. Cautions during assembly are added.
C Mar 14, 2006 CHAPTER 5 ADJUSTMENT
“5.2.12 PF Torque Check Pattern Print” is removed.
EPSON Stylus C67/C68/D68 Revision C
Contents
Chapter 1 PRODUCT DESCRIPTION Chapter 3 TROUBLESHOOTING
1.1 Features.................................................................................................................. 9 3.1 Overview ............................................................................................................. 29
1.2 Specifications ...................................................................................................... 10 3.1.1 Specified Tools ........................................................................................... 29
1.2.1 Physical Specification................................................................................. 10 3.1.2 Preliminary Checks..................................................................................... 29
1.2.2 Printing Specification ................................................................................. 10 3.2 Troubleshooting With LED Error Indications.................................................... 30
1.2.3 Paper Feeding ............................................................................................. 11 3.2.1 Fatal Error................................................................................................... 32
1.2.4 Input Data Buffer ........................................................................................ 11 3.3 Troubleshooting for Motors and Sensors ............................................................ 34
1.2.5 Electric Specification.................................................................................. 11
1.2.6 Environmental Condition............................................................................ 12
Chapter 4 DISASSEMBLY/ASSEMBLY
1.2.7 Reliability ................................................................................................... 12
1.2.8 Safety Approvals ........................................................................................ 12 4.1 Overview ............................................................................................................. 36
1.2.9 Acoustic Noise............................................................................................ 13 4.1.1 Precautions.................................................................................................. 36
1.2.10 CE Marking .............................................................................................. 13 4.1.2 Tools ........................................................................................................... 37
1.2.11 Black Ink Save Mode................................................................................ 13 4.1.3 Screws (T.B.D) ........................................................................................... 37
1.3 Operator Controls ................................................................................................ 14 4.1.4 Work Completion Check ............................................................................ 38
1.3.1 Operate Switch............................................................................................ 14 4.2 Caution regarding Assembling/Disassembling of the Printer Mechanism, and How
1.3.2 Panel Functions........................................................................................... 14 to Ensure of Quality on Re-assembled Product......................................................... 39
1.3.3 Printer Condition and LED Status .............................................................. 15 4.3 Disassembly Procedures...................................................................................... 41
1.3.4 Errors .......................................................................................................... 15 4.3.1 Removing Housings ................................................................................... 43
1.4 Paper .................................................................................................................... 16 4.3.2 Removing Boards ....................................................................................... 52
1.4.1 Paper Support.............................................................................................. 16 4.3.3 Disassembling Printer Mechanism ............................................................. 56
1.5 Ink Cartridge........................................................................................................ 21
1.5.1 Ink Cartridge Specification......................................................................... 21 Chapter 5 ADJUSTMENT
5.1 Adjustment Items and Overview......................................................................... 78
Chapter 2 OPERATING PRINCIPLES 5.1.1 Servicing Adjustment Item List.................................................................. 78
2.1 Overview ............................................................................................................. 23 5.1.2 Repaired Adjustment .................................................................................. 80
2.2 Printer Mechanism............................................................................................... 23 5.1.3 Replacement Part-Based Adjustment Priorities ......................................... 81
2.2.1 Printhead Specifications ............................................................................. 24 5.2 Adjustment by Using Adjustment Program ........................................................ 83
2.2.2 Carriage Mechanism ................................................................................... 24 5.2.1 Market ID Setting ....................................................................................... 83
2.2.3 Paper Feeding Mechanism.......................................................................... 25 5.2.2 USB ID Input.............................................................................................. 83
2.2.4 Ink System Mechanism............................................................................... 26 5.2.3 Head ID Input ............................................................................................. 83
2.3 Electrical Circuit Operating Principles................................................................ 26 5.2.4 Head Angular Adjustment .......................................................................... 84
2.3.1 C616 PSB/PSE Board................................................................................. 27 5.2.5 Bi-D Adjustment......................................................................................... 84
2.3.2 C616 Main Board ....................................................................................... 27 5.2.6 PF Adjustment ............................................................................................ 85
6
5.2.7 First Dot Adjustment .................................................................................. 85

5.2.8 Top Margin Adjustment ............................................................................. 86
5.2.9 Offset input for CR Motor Calorific Limitation ......................................... 86
5.2.10 A4 Normal Paper print.............................................................................. 87
5.2.11 A4 Photo Quality Inkjet Paper Print........................................................ 87
5.3 Adjustment Except Adjustment Program ............................................................ 88
5.3.1 CR Timing Belt Tension Adjustment ......................................................... 88
Chapter 6 MAINTENANCE
6.1 Overview ............................................................................................................. 90
6.1.1 Cleaning ...................................................................................................... 90
6.1.2 Service Maintenance................................................................................... 90
6.1.3 Lubrication.................................................................................................. 92
Chapter 7 APPENDIX
7.1 Exploded Diagram............................................................................................... 96
7.2 Parts List............................................................................................................ 102
7.3 Circuit Diagrams ............................................................................................... 103
7
YCHAPTER
1
PRODUCT DESCRIPTION
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 9

1.2 Specifications Table 1-2. Raster Graphics Mode

Horizontal Available
Printable area Dot size CR speed
This section covers specifications of the printer. resolution dot
Eco 723.9 mm/s (285 CPS)
1.2.1 Physical Specification 360 dpi
209.8 mm
2976
VSD1 419.1 mm/s (165 CPS)
(8.26 inch) VSD2’
Weight: 3.9 kg (without the ink cartridges) 609.6 mm/s (240 CPS)
(Color)
Dimension VSD2 609.6 mm/s (240 CPS)
Storage: 447 mm (W) x 240 mm (D) x 189 mm (H) VSD2'
209.8 mm 609.6 mm/s (240 CPS)
720 dpi 5952 (Black)
Printing: 447 mm (W) x 436 mm (D) x 309 mm (H) (8.26 inch)
VSD3’
609.6 mm/s (240 CPS)
(Color)
1.2.2 Printing Specification VSD3 609.6 mm/s (240 CPS)
209.8 mm
1440 dpi 11904 VSD3’
Print method (8.26 inch) 609.6 mm/s (240 CPS)
(Black)
On demand ink jet 209.8 mm
2880 dpi 23808 VSD3 609.6 mm/s (240 CPS)
Nozzle configuration (8.26 inch)
monochrome: 90 nozzles
Control Code
color: 29 nozzles x 3 (Cyan, Magenta, Yellow)
ESC/P2 expanded raster graphics code
Print direction
EPSON Remote command
Bi-direction with logic seeking
Character tables
Print speed & Printable columns
none (ASCII 20H to 7FH code support)
Table 1-1. Character Mode
Internal fonts
Character Pitch Printable Columns CR Speed
419.1 mm/s Bit map LQ font
10 CPI (Pitch) 80 digits
(165 CPS) EPSON Courier 10 CPI
PRODUCT DESCRIPTION Specifications 10

1.2.3 Paper Feeding 220-240 V version
Feeding method Rated voltage: AC220-240 V
Friction feed with ASF Input voltage range: AC198-264 V
Paper path Rated frequency range: 50 - 60 Hz
Cut-sheet ASF (Top entry front out) Input frequency range: 49.5 - 60.5 Hz
Feed speed Rated current: 0.2 A (max. 0.4 A)
T.B.D msec (T.B.D mm/sec) (10.16 mm (0.4 inch) feed) Power consumption: ISO10561 Letter Pattern: 11 W
Sleep Mode: 2.5 W
T.B.D msec (T.B.D mm/sec) (Continuous feed) Power Off Mode: 0.4 W
Dielectric strength: AC 3000 Vrms for 1 minute
1.2.4 Input Data Buffer (between AC line and chassis)
Input buffer size: 32 KB
1.2.5 Electric Specification

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

1.2.6 Environmental Condition 1.2.7 Reliability

Table 1-3. Environmental Condition Total print volume: 20,000 pages (A4, Letter) or five years,
whichever comes first.
Operating Non-operating
Temperature*1 10~35 °C*2 -20~40 °C Print Head Life: Eight billion shots (per nozzle) or five years,
Humidity 20~80 % 5~85 % whichever comes first.
Resistance to shock 1 G, within 1 ms 2 G, within 2 ms
Resistance to vibration 0.15 G 0.50 G 1.2.8 Safety Approvals
Note *1: One month at 40°C and 120 hours at 60°C 100-120 V version
*2: Under the following conditions Safety standards: UL60950
90 CSA C22.2 No.60950
80 EMI: FCC part15 subpart B class B
70 CSA C108.8 class B
60
220-240V version
Humidity(%) 50
Safety standards: EN 60950
40
30 EMI: EN 55022(CISPR Pub.22) class B
20 AS/NZS CISPR 22 class B
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 -4°C or less. If this is the case, allow the ink to
stand for about three hours at 25°C temperature.

1.2.9 Acoustic Noise

Level: Approx. 45 dB (A) (According to ISO 7779)
1.2.10 CE Marking
Starts printing in black ink
220-240V version save mode.
Starts printing in a normal
Low Voltage Directive 73/23/EEC: EN60950 manner.
EMC Directive 89/336/EEC: EN55022 Class B Starts printing in a normal
manner. This window will
EN61000-3-2 not be displayed until the
EN61000-3-3 black ink cartridges is
replaced.
EN55024
Figure 1-3. Black Ink Save Mode Window

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. User carries out printing from an application.

2. 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”.

1.3 Operator Controls 1.3.2 Panel Functions

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

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

Ink Compulsory power off.
Power LED [Green]
Lights when the power switch is “ON” and AC power is supplied. Note *: Holding down the [Power] switch, press [Ink] for about seven seconds.
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.
PRODUCT DESCRIPTION Operator Controls 14

1.3.3 Printer Condition and LED Status Table 1-7. Error Status
Error Description
Indicators When the total quantity of ink wasted through the cleanings and
Printer status Priority flushing is reaches to the limit, printer indicates this error and
Power LED Paper LED Ink LED Maintenance request
stops. The absorber in the printer enclosure is needed to be
Power on On -- -- 11
replaced with new one by a service person.
Ink level low -- -- Flashes 10
Fatal errors Carriage control error.
Data processing Flashes -- -- 9
No ink cartridge or ink end -- -- On 8
CSIC Error -- -- On 8
Ink sequence Flashes -- -- 7
Ink cartridge change mode Flashes -- -- 6
Paper out -- On -- 5
Paper jam condition -- Flashes -- 4
Maintenance request Flashes Flashes
Off 3
alternately alternately
Fatal error Off Flashes on Flashes on 2
high speed high speed
Power off Flashes on Off Off 1
high speed
Reset request* On On On --
Note *: 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
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
Ink out
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.
Paper out When printer fails to load a sheet, it goes paper out error.
Paper jam When printer fails to eject a sheet, it goes paper jam error.
No ink-cartridge / CSIC When printer detects that ink-cartridge comes off, or failed to read
Error or write CSIC data, it goes this error mode.
PRODUCT DESCRIPTION Operator Controls 15

1.4 Paper Envelopes
Table 1-9. Envelopes*

1.4.1 Paper Support
Dimensions (mm)
Paper type Weight Quality
Cut sheets Width Length
Table 1-8. Cut sheets #10*1 104.8 241.3 bond paper
DL*1 110 220 75-90g/m2 PPC paper
Dimensions Paper Support
Paper Thickness Weight C6*1 114 162 air mail
Width Length Quality Stylus Stylus Stylus
size (mm) (g/m2)
(mm) (mm) C68 D68 C67 Note *: Borderless printing is not supported for envelops.
215.9 355.6 Note *1: There is flap in the long side part, and it is fold down.
Legal OK OK OK
(8.5”) (14”) Loading paper under the oblong condition is done.
215.9 279.4 The flap side is moved to 80-digit side.
Letter OK OK OK *2: Only for Stylus C67/D68.
(8.5”) (11”)
A4 210 297 common OK OK OK Use paper under normal conditions.
B5 182 257 NG OK OK C A U T IO N
paper • Temperature 15 to 25°C (59 to 77°F)
0.08-0.11 64-90
A5 148 210 recycled NG OK OK • Humidity 40 to 60% RH
Half 139.7 215.9 paper
OK NG NG It is necessary that there is no winkle, nap, tear, fold and so on
Letter (5.5") (8.5") in the form.
A6 105 148 OK OK OK The curve and swell of the form must be three mm or below.
User 127- Don't use the adhesive envelope.
50.8-329 OK OK OK
defined 1117.6 Don't use sleeve insert envelope and cellophane window
envelope.
C A U T IO N It is necessary that there is no winkle, nap, tear, fold and so on
As for double-flap envelope, if the envelope is damaged or bent
in the form.
during printing, load the envelope with its flap facing in the
The curve of form must be five mm or below.
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 Table 1-10. Exclusive papers

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

1.4.1.1 Printable Area

PW
Cut sheet (standard printing)
LM RM
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 TM

Paper type LM RM TM BM
A4
A5
A6
Cut Sheet
Paper Feed Direction

B5
Half Letter
Letter
Legal Printable area PL
User defined
Premium Ink Jet Plain Paper
Bright White Ink Jet Paper
12.5mm/
Photo Paper 3mm 3mm 3mm
3mm*1
Premium Glossy Photo Paper
Premium Semigloss Photo Paper
Exclusive papers
Matte Paper-Heavyweight
Double-Sided Matte Paper
Economy Photo Paper BM
Glossy Photo Paper
(RC-X)
Ultra Glossy Photo Paper/ Figure 1-5. Printable Area Cut Sheet (Standard Printing)
Ultra Premium Glossy Photo Paper
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.

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

PL
BM
Figure 1-6. Printable Area for Envelopes

Cut sheet (border-free printing)

LO PW RO
Printable area
For paper width (PW) and paper length (PL), refer to 1.4.1 Paper Support TO
(p16).
Table 1-13. Applicable Paper/Printing Area

Paper type Size LO RO TO BO
Premium Ink Jet Plain Paper A4 2.54 2.54 2.96 4.02
Bright White Ink Jet Paper A4 2.54 2.54 2.96 4.02

A4 2.54 2.54 2.96 4.02
Photo Paper
10x15 2.54 2.54 2.82 3.60
Letter 2.54 2.54 2.96 4.02
A4 2.54 2.54 2.96 4.02 Paper size PL
8" x 10" 2.54 2.54 2.96 4.02
5" x 7" 2.54 2.54 2.96 4.02
10 x 15 2.54 2.54 2.82 3.60
3R 2.54 2.54 2.82 3.60
Letter 2.54 2.54 2.96 4.02
Premium Semigloss Photo
A4 2.54 2.54 2.96 4.02
Exclusive papers
Paper
10 x 15 2.54 2.54 2.82 3.60
Letter 2.54 2.54 2.96 4.02
Matte Paper-Heavyweight
A4 2.54 2.54 2.96 4.02
Letter 2.54 2.54 2.96 4.02
Double-Sided Matte Paper BO
A4 2.54 2.54 2.96 4.02
Economy Photo Paper A4 2.54 2.54 2.96 4.02 Printable area
Letter 2.54 2.54 2.96 4.02
Glossy Photo Paper Figure 1-7. Printable Area for Cut Sheet (Border-free Printing)
10 x 15 2.54 2.54 2.82 3.60
10 x 15 2.54 2.54 2.82 3.60
(RC-X)
Letter 2.54 2.54 2.96 4.02
Ultra Glossy Photo Paper/ A4 2.54 2.54 2.96 4.02

Ultra Premium Glossy Photo 8" x 10" 2.54 2.54 2.96 4.02
Paper 5" x 7" 2.54 2.54 2.96 4.02
10 x 15 2.54 2.54 2.82 3.60

1.5 Ink Cartridge Dimension: 12.7 mm(W) x 73.46 mm(D) x 55.25 mm(H)
1.5.1 Ink Cartridge Specification 12.7 mm
Type: Exclusive cartridge
Table 1-14. Ink Cartridge

Color Size Stylus C67 Stylus C68 Stylus D68
SS Size T0631 - T0611
Black
S Size T0621 T0601 -
SS Size T0632 - T0612
Cyan
S Size - T0602 -
SS Size T0633 - T0613
Magenta
S Size - T0603 -
SS Size T0634 - T0614
Yellow
S Size - T0604 -
Print Capacity: Base View
Black ink cartridge

73.46 mm
Print capacity
S size: 390 pages /A4 (360 dpi, 5% duty each color)
Figure 1-8. Ink Cartridge
SS size: 230 pages /A4 (360 dpi, 5% duty each color)
Color ink cartridge
C A U T IO N Ink cartridge can not re-fill, only ink cartridge is prepared for
Print capacity article of consumption.
S size: 410 pages /A4 (360 dpi, 5% duty each color) Do not use the ink cartridge which has expired.
SS size: 250 pages /A4 (360 dpi, 5% duty each color) Ink will be frozen under -16 °C environment, however it will be
Ink life: Two years from production date usable after placing it more than three hours at room
temperature.
Storage temperature
Table 1-15. Storage Temperature

Storage
Situation Limit
temperature
When transported in individual boxes -30°C ~ 50°C 10 days max. at 50°C
When stored in individual boxes -30°C ~ 40°C 1 month max. at 40°C
When installed in main unit -20°C ~ 40°C
PRODUCT DESCRIPTION Ink Cartridge 21

YCHAPTER
2
OPERATING PRINCIPLES
2.1 Overview
PF timing belt
This section describes the operating principles of the printer mechanism and electrical
circuit boards. PF motor
PF roller
2.2 Printer Mechanism Star wheel

rollers
Printer mechanism of Stylus C67/C68/D68 consists of printhead, carriage mechanism,
paper loading mechanism, paper feeding mechanism, and ink system. CR timing belt
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
CR encoder
using the LD roller and the retard roller. Carriage unit
sensor
Retard roller
Compression
spring
LD roller
PE sensor
Paper eject
Cam, large
roller
Cam, small
CR lock lever
Clutch
Pump unit
Cap unit
CR motor
Figure 2-1. Printer Mechanism Outline
OPERATING PRINCIPLES Overview 23

2.2.1 Printhead Specifications 2.2.2 Carriage Mechanism

The Printhead of this product is a D2-CHIPS head. Main components of the carriage mechanism are carriage unit (including printhead,
CR encoder sensor), CR motor, timing belt, and CR scale.
Nozzle configuration
Monochrome 90 nozzles 2.2.2.1 CR Motor Specifications
Color 29 nozzles x 3 (Cyan, Magenta, Yellow) Table 2-1. CR Motor Specifications
The following shows the arrangement of the nozzles and the color arrangement of each Item Specification
nozzle line when viewed the printhead from behind. Type Motor with DC brush
Drive voltage +42 V ± 5% (applied voltage to the driver)
2.822mm
(40/360 inch) Electric resistance 28.4 Ω ± 10%
Inductance 20.1 mH ± 25%
Drive method PWM, constant-current chopping
K#90
Drive IC A6628
K#89 C#29
Cyan: 29nozzles
C#1
M#29
Black
Color
Paper Loading Direction Magenta: 29nozzles
M#1
Y#29
K#3
Y#3 Yellow: 29nozzles
0.2117mm
(1/120 inch) K#2
Y#2
K#1 Y#1
Carriage Moving Direction

Figure 2-2. Nozzle Rear View
OPERATING PRINCIPLES Printer Mechanism 24

2.2.3 Paper Feeding Mechanism 2.2.3.2 Drive Process

Paper loading/feeding mechanism consist of CR lock lever inside the ink system, 1. Drive of the PF motor is transmitted to the paper eject roller and the PF roller via
holder shaft unit (including clutch mechanism), and ASF unit. 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.
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. The carriage unit moves to the ASF trigger position once the paper loading
command is received.
2.2.3.1 PF Motor Specifications (For both ASF and Pump motor)
3. PF motor is rotated counter clockwise, and the clutch is released by the PF motor
Table 2-2. PF Motor Specification lever.
Item Specification 4. After the clutch is released, the PF motor rotates clockwise. Drive is transmitted to
Type 4-phase, 200-pole HB stepping motor the LD roller and the paper loading operation begins.
Drive voltage +42 V ± 5 % (applied voltage to the driver) 5. During paper loading operation, papers are fed from the ASF unit to inside the
Wire wound
3.0 Ω ± 10% (per one phase at 25 °C) printer by the rotating movement of the two cams of the LD roller.
resistance
Cam, large: releases hopper
Inductance 3.5 mH ± 20% (1KH, 1Vrms)
Bipolar drive Cam, small:releases paper back lever
Drive method
2-2 phase, 1-2 phase, W1-2, 2W1-2, 4W1-2 phase constant-current drive 6. Once a sheet of paper is fed, the hopper and the paper back lever bring back rest of
Drive IC A6628 the papers to the position in readiness by the rotating movement of the two cams
mentioned above.
7. 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.
OPERATING PRINCIPLES Printer Mechanism 25

2.2.4 Ink System Mechanism 2.3 Electrical Circuit Operating Principles

The Ink system mechanism consists of pump mechanism and capping mechanism with
The electric circuit of the Stylus C67/C68/D68 consists of the following boards.
wiper mechanism.
Main board: C616 MAIN Board
2.2.4.1 Pump Unit Mechanism Power supply board: C616 PSB/PSB board
With this printer, when the PF motor turns, power is always transmitted to the ink Panel board: C616 PNL board
system.
This section provides block diagram of both C616 MAIN Board and C616 PSB/PSE
Table 2-3. PF Motor Rotational Direction & Ink System Mechanism Board, C616 PNL board.
Directions* Functions
Counterclockwise • Absorbs the ink by the Pump Unit
C616 PNL Board
Clockwise • Release pump.
Printer Mechanism
Note *: The PF Motor rotational direction = seen from the left side of the printer.
CR Motor
2.2.4.2 Capping Mechanism
The Capping mechanism covers the printhead with the cap to prevent the nozzle from PF Motor
increasing viscosity when the printer is in stand-by state or when the printer is off.
C616 Main Board Head Driver Board
Sensors
CSIC Unit
+42V PowerOFF
C616PSB/C616PSE Board
Figure 2-3. Electrical Circuit Block Diagram
OPERATING PRINCIPLES Electrical Circuit Operating Principles 26

2.3.1 C616 PSB/PSE Board Table 2-4. C616 MAIN Board Major Components and Primary Functions
In the PSB/PSE Board of Stylus C67/C68/D68, the simulated oscillating stimulation IC Location Function
flyback converter circuit method is used, and it supplies +42 VDC to the drive line. FLASHROM IC3 3.3 V drive 4 M bit flash ROM that stores the program.
The application of the output voltage is described below. Reset Regulator IC1 3.3V/1.5V generate regulator, 2 ch reset circuit
C616PSB Board: 100-120V EEPROM IC4 Makes back up of default setting values and parameters
C616PSE Board: 220-240V Drives CR/PF motors, controls PWM by the program timer,
Motor Driver IC6
adjusts 5 V, drives 42 V
AC voltage input from AC inlet first goes through filter circuit that removes high Head Driver IC7 Generates trapezoidal waveform, drives 5 V
frequency components and is then converted to DC voltage via the rectifier circuit and Drives CPU (H8S/2674 base), internal 8 K byte x 4 RAM, 24
the smoothing circuit. DC voltage is then led to the switching circuit and FET Q1 ASIC IC10
Mhz, 3.3 V/1.5V
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
OPERATING PRINCIPLES Electrical Circuit Operating Principles 27

CHAPTER
3
TROUBLESHOOTING
3.1 Overview 3.1.2 Preliminary Checks

This chapter describes how to solve problems. Before starting troubleshooting, be sure to verify that the following conditions
are all met:
W A R N IN G Be careful to avoid electric shocks when checking the electrical The power supply voltage must be within the specification limits. (Measure the
circuit boards (C616 MAIN, PSE and B circuit boards) while voltage at the wall socket.)
the power is turned on.
Touching an FET, transistor or heat sink with one hand while The power code must be free from damage, short circuit or breakage, or miswiring
touching a metal part of the mechanism with the other hand in the power code.
could result in an electric shock, so carefully avoid this.
The printer must be grounded properly.
After initial filling of ink has been repeated several times,
immediate moving or tilting of the printer could result in The printer should not be located in a place where it can be exposed to too high or
leaking of ink that has not been completely absorbed by the low temperature, too high or low humidity, or abrupt temperature change.
Waste Ink Pad. When initial filling of ink has been repeated
The printer should not be located near waterworks, near humidifiers, near heaters
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 or near flames, in a dusty atmosphere or in a place where the printer can be
before moving the printer. exposed to blast from an air conditioner.
The printer should not be located in a place where volatile or inflammable gases
C H E C K Disassembly and reassembly of parts is often required when are produced.
P O IN T identifying the causes of problems. The parts should be
disassembled and re-assembled correctly while referring to The printer should not be located in a place where it can be exposed to direct rays
DISASSEMBLY/ASSEMBLY (p35) so that the operation and of the sun.
status of each check item can be correctly verified.
The printer must be located in a well-ventilated place.
Some individual part and units may require adjustment once
they are removed or replaced. If removing or replacing parts The printer must be placed on a strong and steady level table (without an
which have specific instructions for adjustment included in inclination larger than five degrees).
DISASSEMBLY/ASSEMBLY (p35), be sure to make these
adjustments after repairing the problem location. The paper used must conform to the specification.
There is no error in handling of the printer.
Check the inside of the printer, and remove foreign matters if any, such as paper
3.1.1 Specified Tools clips, staples, bits of paper, paper dust or toner.
This printer does not require any specified tools for troubleshooting. Clean the inside of the printer and the rubber rolls.
TROUBLESHOOTING Overview 29
3.2 Troubleshooting With LED Error Indications

LED error display, cause, and remedy are explained here.
Table 3-1. Troubleshooting With LED Error Indications

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

Table 3-1. Troubleshooting With LED Error Indications

LED status
Error Cause Remedy
Power Paper Ink
Paper jam Even though paper feeding operation is carried out 1. Press the [Paper] switch on the panel.
for predetermined times, leading edge or back-end 2. If paper jam occurred again after pressing the
of the paper could not be detected. switch, open the printer cover and remove all the
--- Flashes --- 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].
Maintenance request As a result of cleaning and flushing, total emission Replace the waste ink pad, and reset the waste ink
(Waste ink overflow) Flashes Flashes of ink has exceeded the specific level. counter (protection counter A) using the adjustment
Off
alternately alternately program. Refer to Chapter5 “ADJUSTMENT”
(p.77) for details.
Fatal error • Home position of the carriage could not be 1. Turn the power off, wait for a few seconds, and
detected. turn the power back on again.
• Abnormal external pressure is applied to the 2. If the fatal error still appears, turn the power off,
printer when the power is on. remove the papers on the hopper, and check the
• Carriage movement is interfered during printing. following:
• Open the printer cover, check the ink cartridges,
Flashes on Flashes on
Off and reinstall them correctly.
high speed high speed
• 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.

3.2.1 Fatal Error

C H E C K As the most recent fatal error (fatal error code) is stored in the
P O IN T 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 Item Description Remedy

DC Error PID aveTi max Error Something is wrong with the CR motor. Check the parts listed below, and replace them as necessary.
PID Overspeed Error Carriage movement speed is abnormal. • CR Motor
PID Lock Error Carriage has been locked for a certain period of time due to • CR Encoder
external factors. • CR Encoder Scale
PID Reverse Rotation Detection Error The number of the carriage reverse rotation has exceeded the • Timing Belt
predetermined times due to external factors. • Main Board
Encoder Abnormality Error (CR Driving One-pass movement cannot be completed though the CR • Connectors and harnesses of each motor or encoder
Time Over Error) motor has been driving longer than the specified time.
Load Positioning Overspeed Error Abnormal carriage movement speed is detected during load
positioning control.
Load Positioning Lock Error 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 The environment temperature of the transistor that generates Check the parts listed below, and replace them as necessary.
Abnormality Error head driving waveform on the Main board is abnormal. • Printhead
Pre-printing X-HOT Detection Error 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.
Post-flushing X-HOT Detection Error During post-printing X-Hot detection, the temperature of the
head driver IC has exceeded the given level for more than two
seconds.

Classification Item Description Remedy

Sequence Error Left Frame Shock Detection Error Abnormal pressure has being added to the carriage due to Make sure that there is no obstruction on the carriage moving
Between Left Frame and [TF] Shock external factors. path, check the parts listed below, and replace them as necessary.
Detection Error • CR Motor
Between [TF] and [HOME] Shock • CR Encoder
Detection Error • CR Encoder Scale
• Timing Belt
• Main Board
Motor Driving 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.
Time Error driving longer than the specified time. • PF motor
• Main board
• Connectors and harnesses of each motor or encoder

3.3 Troubleshooting for Motors and Sensors

Motor
Table 3-2. Motor Resistance and Check Points

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

Sensor name Detecting system Location Signal level Sensor status
Transmission photo 2.4 V or more Paper loaded

PE sensor CN9 pin 1&2
interrupter 0.4 V or less No paper
TROUBLESHOOTING Troubleshooting for Motors and Sensors 34

CHAPTER
4
DISASSEMBLY/ASSEMBLY
4.1 Overview C A U T IO N Make sure that there is enough work space for disassembly/
reassembly.
This section describes procedures for disassembling the main components of the Use only recommended tools for disassembling, assembling or
product. Unless otherwise specified, disassembled units or components can be adjusting the printer.
reassembled by reversing the disassembly procedure. Observe the specified torque when tightening screws.
Procedures which, if not strictly observed, could result in personal injury are described Apply lubricants as specified.
under the heading “WARNING”. (See "6.1.3 Lubrication" (p92) for details.)
The printer disassembled/assembled to make this manual is a
“CAUTION” signals a precaution which, if ignored, could result in damage to test production, and the colors or configurations may differ
equipment. from the finished product. However, these differences have no
effect for disassembling/assembling the product.
Important tips for procedures are described under the heading “CHECK POINT”. When using compressed air products; such as air duster, for
cleaning during repair and maintenance, the use of such
If the assembly procedure is different from the reversed disassembly procedure, the
products containing flammable gas is prohibited.
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.
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.
DISASSEMBLY/ASSEMBLY Overview 36
4.1.2 Tools Table 4-2. Screws
Use only specified tools to avoid damaging the printer. No. Image Name Type
C.B.P. 3 x 8 C.B.P-TITE SCREW
Table 4-1. Tools
6
Name Supplier Parts No.
(+) Phillips screwdriver #1 EPSON 1080530
C.B.P. 3 x 10 C.B.P-TITE SCREW
(+) Phillips screwdriver #1 EPSON 1080532
Flathead screwdriver EPSON 1080527 7
Tweezer EPSON 1080561
Hex wrench (T.B.D) (T.B.D) (T.B.D) C.B.P.(P2) 3 x 8 C.B.P-TITE (P2) SCREW
8
4.1.3 Screws (T.B.D)
Screws used on the Stylus C67/C68/D68 are shown below. C.P. 3 x 4 C.P. SCREW
Table 4-2. Screws 9
No. Image Name Type

C.B.S. 3 x 6 C.B.S-TITE SCREW C.P.B (P1) 1.7 x 5 T.B.D
1 10
C.B.S. 3 x 8 C.B.P-TITE SCREW Hexagon nut, normal, M3 T.B.D
2 11
C.B.S. 3 x 14 C.B.S-TITE SCREW
C.B.S.(P4) 3 x 6 C.B.P-TITE (P4) SCREW
C.B.P. 2.5 x 8 C.B.S-TITE SCREW
4.1.4 Work Completion Check Table 4-3. Work Completion Check

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

4.3.1.1 (p. 43) 4.3.1.2 (p. 44)
"ASF Unit" "CR Timing Belt" "Front Frame" "CR Encoder Scale" "CR Cable Head "Paper Guide, Upper
4.3.1.3 (p. 44) 4.3.3.5 (p. 60) 4.3.3.7 (p. 62) 4.3.3.8 (p. 63) Cover" Assy."
4.3.3.9 (p. 64) 4.3.3.14 (p. 71)
"CR Motor" "Eject Roller"

4.3.3.6 (p. 61) 4.3.3.15 (p. 71)
"Paper Guide, Front

Assy."
4.3.3.16 (p. 73)
"Hopper/Retard Roller "Main Board" "Panel Board" "PS Board"

Unit" 4.3.2.1 (p. 52) 4.3.2.2 (p. 54) 4.3.2.3 (p. 55)
4.3.1.4 (p. 45)
Figure 4-1. Disassembling Flowchart (1)
DISASSEMBLY/ASSEMBLY Disassembly Procedures 41

START
* Procedure in the broken-line is NOT the
shortest removing procedure, but the
passing point for the next removing
procedure.
"Panel Board" "PS Board"
4.3.2.2 (p. 54) 4.3.2.3 (p. 55)
"Holder Shaft Unit"4.3.3.2 "Front Frame" "Stacker Assy."

(p. 56) 4.3.3.7 (p. 62) 4.3.1.2 (p. 44)
4.3.3.2 (p. 56)
"Spool Gear 36.8/Extension "CR Encoder Scale" "Paper Guide, Front

Spring 0.143/Clutch" 4.3.3.8 (p. 63) Assy."
4.3.3.3 (p. 58) 4.3.3.16 (p. 73)
"PE Sensor Board/PE "CR Cable Head

Detection Lever/Idle Cover" "Housing, Lower Assy."
Roller" 4.3.3.9 (p. 64) 4.3.1.5 (p. 47)
4.3.3.4 (p. 59)
"CR Unit" "Waste Ink Pad" "PF Motor" "Holder Shaft Unit"
4.3.3.10 (p. 65) 4.3.1.6 (p. 51) 4.3.3.18 (p. 76) 4.3.3.2 (p. 56)
"Printhead Assy." "CR Encoder Sensor "CSIC Board"

Board" "Pump Unit/Cap Unit"
4.3.3.11 (p. 68) 4.3.3.12 (p. 69) 4.3.3.17 (p. 74)
4.3.3.12 (p. 69)
Figure 4-2. Disassembling Procedure (2)

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 C.B.P. 3x8 Tabs C.B.P. 3x8
1) Remove the two screws on backside of the Housing, Upper.

• C.B.P. 3 x 8: 2
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). Tabs
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.
Figure 4-3. Removing Housing, Upper

4.3.1.2 Stacker Assy. 4.3.1.3 ASF Unit

1) Remove the Housing, Upper. (p43) 1) Remove the Housing, Upper. (p43)
2) Open the Stacker assy. 2) Open the Stacker Assy. (See 4.3.1.2 Removing Stacker Assy. Step 2)
3) Push the shaft located on the left side of the Stacker Assy. with a flathead 3) Remove the three screws that secure the ASF Unit to the main unit, and
screwdriver or a similar tool, release the shaft from the slot of the Housing, remove the ASF unit.
Lower, and remove the Stacker Assy.
• C.B.S. 3 x 6: 1
• C.B.S. (P4) 3 x 6: 1
• C.B.P. 3 x 8: 1
ASF Unit
C.B.S. 3 x 6
2
1
Stacker Assy.
C.B.S.(P4) 3 x 6
Shaft
C.B.P. 3 x 8
Figure 4-4. Removing Stacker Assy.

Figure 4-5. Removing ASF Unit

4.3.1.4 Hopper/Retard Roller Unit

When installing the ASF Unit to the main unit, follow the steps
described below.
C A U T IO N Do not touch the cork on the Retard Roller and the Hopper.
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. 1) Remove the ASF Unit. (p44)
2) Lift up the Hopper toward the direction of the arrow, release the two tabs, and
Side Surface of the remove the spring and the hopper from the ASF Frame.
ASF Unit
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
A D J U S T M E N T When you replace the ASF unit with a new one, lubricate it as Hopper
R E Q U IR E D
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” Spring Retard Roller
ASF Frame
Figure 4-7. Removing Hopper

3) Remove Extension Spring 0.585 from both the ASF Frame and the Paper back
Lever. When installing the Retard Roller or the Paper Back Lever,
attach the two springs as described below.
4) Remove the Paper Back Lever from the bearing of the ASF frame. • Extension Spring 0.585
5) Remove Compression Spring 1.88 from the ASF Frame, and remove the Attach the spring to the tab of the ASF Frame and the one of
Retard Roller Unit. the Paper Back Lever.
• Compression Spring 1.88
Paper Back Lever Extension Spring 0.585 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 Hopper Side
Figure 4-8. Removing Retard Roller Unit
Positioning Hole Positioning Hole
Figure 4-10. Attaching the Springs

4.3.1.5 Housing, Lower Assy.

C A U T IO N When removing the Waste Ink Tube from the Waste Ink Pad, pay
attention not to spill the ink.
C A U T IO N Do not remove the Housing, Lower Assy. more than is necessary.
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.. (p73)
4) Move the CR unit to the center of the printer. Tab
(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
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

8) Remove the four screws that secure the Housing, Lower Assy
to the main unit. 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
• C.B.P. 3 x 8: 3 Frame.
• C.B.P.(P2) 3 x 8: 1
9) Release the two tabs on the PF Motor side of the Housing, Lower assy, and
3
remove the Housing, Lower Assy.
C.B.P. (P2) 3 x 8 Holding Position

2
4 1
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)

To ensure the assembling accuracy, you have to control the [Z-axis direction]
assembled standard position of the Main Frame against X/Y/Z- • Make sure that there is no gap between main frame and
axis direction as follows. Housing, Lower.
[X-axis direction] • Make sure that the left side of Printer Mechanism is
• Make sure that main frame is correctly placed on the correctly fixed with two tabs.
groove of Housing (Lower).
• Make sure that there is no gap between main frame and Z-axis Assembled Standard Position
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 Assembled Standard Position

Tabs
Figure 4-16. X and Y-axis Assembled Standard Position
Figure 4-17. Z-axis Assembled Standard Position

When installing the Cap Unit, pay attention to the following A D J U S T M E N T When Housing (Lower) is removed or replaced with new one, the
R E Q U IR E D
instructions: following adjustment must be performed in the order below.
• Route the Ink Tube underneath the Cap Unit. 1. “Top Margin Adjustment”
• Make sure that the two bosses of the Cap Unit are located 2. “PF Adjustment”
under the Main Unit Frame. 3. “Bi-D Adjustment”
4. “Head Angular Adjustment”
Bosses
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.

4.3.1.6 Waste Ink Pad

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

4.3.2 Removing Boards 3) Disconnect all the connectors from the Main Board.
CN2: Power Supply Cable
4.3.2.1 Main Board CN4: Panel Board Connector
1) Remove the ASF Unit. (p44) CN5: CR Motor Connector
2) Remove the Clump Core from the Main Unit. CN6: PF Motor Connector
CN7: CR Encoder FFC
CN8: Head FFC
Clump Core CN9: PF Sensor Cable
CN7
CN8
Figure 4-22. Removing Clump Core
CN9
CN6
CN5
CN2
CN4
Figure 4-23. Removing Main Board (1)

4) Remove the four screws that secure the Main Board Unit to the Main Unit, 5) Remove the Main Board Cover from the Main Board Unit.
and remove the Main Board Unit.
• C.B.S. 3 x 14: 2
Main Board Main Board Cover
• C.B.S. 3 x 6: 2
Main Board Unit
3 C.B.S. 3 x 14
2
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.
Figure 4-24. Removing Main Board (2) When attaching the Clump Core, pay attention not to confuse
left and right. The side with two portions should be facing to the
left.
Portions
Figure 4-26. Attaching Clump Core

4.3.2.2 Panel Board

A D J U S T M E N T When replacing the Main board with new one, perform the
R E Q U IR E D
following service items. 1) Remove the ASF Unit. (p44)
• If the read-out operation succeeds by adjustment program 2) Disconnect the Panel Board Connector (CN4) from the Main Board.
from defective main board, replace with new board and (See 4.3.2.1 Removing Main Board Step 3)
write the read out data to new one.
1. Ink consumption counter 3) Release the Panel Board from the two tabs and the notch of the Holder Shaft
Unit.
2. Waste drain ink pad counter
3. “Head ID Input”
Holder Shaft Unit
4. “Bi-D Adjustment”
5. “Top Margin Adjustment” Notch
7. “USB ID Input” Panel Board
8. “Market ID Setting”
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 Tabs
the following service items after replacing main board with
new one.
1. Replace the Waste drain ink pad with a new one.
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.
6. “USB ID Input”
Holder Shaft Unit
7. “Market ID Setting”
10. “Offset input for CR Motor Calorific Limitation”
Tab
Figure 4-28. Routing Panel Board Connector

4.3.2.3 PS Board 5) Remove the four screws that secure the PS Board to the PS Board Frame,
Lower, and remove the PS Board.
1) Remove the ASF Unit. (p44)
• C.B.S 3 x 6: 4
2) Disconnect the Power Supply Cable (CN2) from the Main Board.
(See 4.3.2.1 Removing Main Board Step 3)
C.B.S. 3 x 6
3) Remove the three screws that secure the PS Board Unit to the Main Unit, and (6±1 kgf.cm)
remove the PS Board Unit.
• C.B.P. 3 x 10: 2
• C.B.S. 3 x 6: 1
1 4
PS Board Unit C.B.S. 3 x 6
2 (8±1 kgf.cm)
C.B.P. 3 x 10
(6±1 kgf.cm) 1
3 2
Figure 4-31. Removing PS Board

C.B.P. 3 x 10
(6±1 kgf.cm)
When installing the PS Board to the PS Board Frame, Lower,
Figure 4-29. Removing PS Board secure the screws in the order shown in Figure 4-31.
4) Release the two tabs on both sides of the PS Board Unit, and remove the PS When installing PS Board Unit to the Main Unit, secure the
Board Frame, Upper. screws in the order shown in Figure 4-29.
PS Board Frame, Upper

A D J U S T M E N T When PS board unit is removed or replaced with new one,
R E Q U IR E D
the following adjustment must be performed in the order
below.
Tab Tab 4. “Offset input for CR Motor Calorific Limitation”
Figure 4-30. Removing PS Board Frame, Upper

4.3.3 Disassembling Printer Mechanism 4.3.3.2 Holder Shaft Unit

1) Remove the Panel Board. (p54)
4.3.3.1 Printer Mechanism
2) Remove the Clump Core from the Main Unit.
When handling the Printer Mechanism, do not hold the Front (See 4.3.2.1 Removing Main Board Step 2)
C A U T IO N
Frame with your hands. 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.
Follow the following steps to bring out the Printer Mechanism.

CR Lock Lever
1) Remove the Stacker Assy.. (p44)
2) Remove the Main Board. (p52)
4) Remove the PS Board. (p55)
CR Unit
Figure 4-32. Moving CR Unit

4) Disconnect the four connectors from the Main Board. 7) Slide the concave portion of the Pump Unit toward the direction of the arrow,
(See 4.3.2.1 Removing Main Board Step 3) and release the convex portion of the Holder Shaft Unit.
CN5: CR Motor Connector
CN7: CR Encoder FFC
CN8: Head FFC Concave and Convex Portions
CN9: PF Sensor Cable

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


4.3.3.3 Spool Gear 36.8/Extension Spring 0.143/Clutch

When installing the CR Motor Cable to the Holder Shaft Unit, be
sure to route the cable as shown below.
C A U T IO N Never touch the LD Roller.
When removing the LD Roller Shaft Unit, pay attention not to
Tab Notch drop the Spool Gear 36.8, Extension Spring, and Clutch.
1) Remove the Holder Shaft Unit. (p56)
Holder Shaft Unit

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.
CR Motor Cable 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
A D J U S T M E N T When Holder shaft unit is removing or replacing Holder shaft Unit

R E Q U IR E D
with new one, the following adjustment must be performed in the
order below.
2. “First Dot Adjustment” Clutch
Spool Gear
36.8
Extension Spring
0.143
Figure 4-37. Removing LD Roller Shaft Unit

4.3.3.4 PE Sensor Board/PE Detection Lever/Idle Roller

The LD Roller Shaft Unit should be reassemble as shown below.
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 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.
LD Roller
Shaft 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 Sensor Cable

PE Detection Lever
Idle Roller
PE Sensor Board
Torsion Spring 0.22 Tab
Bearings
Figure 4-39. Removing PE Sensor Board/PE Detection Lever/Idle Roller

4.3.3.5 CR Timing Belt

When installing the PE Detection Lever, attach Torsion Spring
0.22 as shown below. 1) Remove the Housing, Upper. (p43)
2) Move the CR Unit toward the center of the printer.
3) Loosen the screw that secures the Drive Pulley Holder Stopper to the Main
Unit.
• C.B.S. (P4) 3 x 6: 1
4) Press the Drive Pulley Holder toward the direction of the arrow, pull the CR
Torsion Spring 0.22 Timing Belt toward you, and remove the belt from the Drive Pulley Holder.
Figure 4-40. Attaching Torsion Spring 0.22

CR Timing Belt
When installing the PE Sensor Cable to the Holder Shaft
Frame, route the cable as shown below. C.B.S. (P4) 3 x 6
Holder Shaft Frame Tab Notch
Drive Pulley Holder Drive Pulley

Holder Stopper
PE Sensor Cable Figure 4-42. Removing CR Timing Belt

5) Remove the CR Unit. (p65)
When installing the CR Timing Belt to the CR Unit, make sure to

attach the belt to the positioning jag as shown in Figure 4-58.
Figure 4-41. Routing PE Sensor Cable

4.3.3.6 CR Motor
When installing the CR Motor, follow the steps described below.
1) Remove the CR Timing Belt.
1. Positioning hole of the CR Motor should be on the
(4.3.3.5 Removing CR Timing Belt Step 2 through Step 4)
downside.
2) Disconnect the CR Motor Connector (CN5) from the Main Board.
(See 4.3.2.1 Removing Main Board Step 3)
Threaded Holes
3) Remove the CR Motor Cable from the Holder Shaft Unit.
C A U T IO N 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
Figure 4-44. Installing CR Motor

C.P. 3 x 4
(4±1 kgf.cm) 2. Secure the screws in the order shown in Figure 4-43.
3. When installing the CR Motor Cable to the Holder
Shaft Unit, route the cable as shown in Figure 4-36.
2 1
A D J U S T M E N T When CR timing belt is removed or replaced with new one,

R E Q U IR E D
tension adjustment of CR timing belt must be performed by the
degital tension gauge.
CR Motor
When CR motor is removed or replaced with new one, the
Figure 4-43. Removing CR Motor 2. “PF Adjustment”

4.3.3.7 Front Frame

Match the positioning hole with the rib as shown in Figure 4-45
1) Remove the Housing, Upper. (p43) when installing the Front Frame.
2) Move the CR Unit to the center of the printer. (See 4.3.3.2 Removing Holder Secure the screws in the order shown in Figure 4-45.
Shaft Unit Step 3)
3) Remove both the two screws that secure the Front Frame to the Main Unit and
the Front Frame Stopper. A D J U S T M E N T When you replace Front frame with new one, lubricate it as
R E Q U IR E D
specified. See "6.1.3 Lubrication" (p92) for details.
• C.B.S. 3 x 6: 2
When Front frame is removed or replaced with new one, the
4) Lift up the CR Unit, and remove the Front Frame. following adjustment must be performed in the order below.
Front Frame
CR Unit
C.B.S. 3 x 6 C.B.S. 3 x 6
(8±1 kgf.cm) (8±1 kgf.cm)
1 2
Positioning Positioning
Hole and Rib Hole and Rib
Front Frame Stopper Front Frame Stopper
Figure 4-45. Removing Front Frame

4.3.3.8 CR Encoder Scale 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
1) Remove the Housing, Upper. (p43)
the figure, and remove the CR Encoder sensor.
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
Extension Spring
1.494
Figure 4-47. Removing CR Encoder Scale (2) Figure 4-49. Installing CR Encoder Scale

4.3.3.9 CR Cable Head Cover

Follow the following procedure to install the CR Cable Head Cover.
1) Remove the Housing, Upper. (p43)
1. Insert the rib of the CR Cable Head Cover shown in Figure
2) When removing the CR Cable Head Cover, follow the steps mentioned below. 4-52 into the hole of CR Unit, and fix tab B on the CR Unit.
1. Slide the CR Cable Head Cover downward, and release tab As. 2. While holding the three portions ( ) shown in Figure 4-67
2. Release tab B, slide the CR Cable Head Cover upward, and remove the with your fingers, slide the CR Cable Head Cover until tab
CR Cable Head Cover. As are securely fixed on the hole of CR Unit.
Tab As
Tab As
Tab B
Rib Tab B
CR Cable Head Cover Figure 4-52. Installing CR Cable Head Cover (2)
Figure 4-50. Removing CR Cable Head Cover Confirm the following points after installing the CR Cable Head Cover.
Tab As should be securely fixed.
When installing the CR Cable Head Cover, make sure that the Head FFC is; The Tab of the CR Cable Head Cover shown below ( )
firmly bent. should be securely fixed on the rib of the CR Unit.
secured under the tabs. CR Cable Head Cover should not come off from the CR Unit
not overlapped with the rib of the CR Unit. when you push down C-part shown in Figure 4-53 with
Otherwise the CR Cable Head Cover may come off. tweezers.
Tab and Rib

Tabs Tab As
Rib
C-part
Head FFC
Figure 4-51. Installing CR Cable Head Cover (1) Figure 4-53. Installing CR Cable Head Cover (3)

4.3.3.10 CR Unit 8) Remove the Shield Plate FFC from the Main Unit Frame.
2) Remove the Front Frame. (p62) Shield Plate FFC
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.
Double-sided tape
attaching location
3) Disconnect the two connectors from the Main Board.

(4.3.2.1 Removing Main Board Step 1 through Step 3)
Figure 4-54. Removing Shield Plate FFC
CN7: CR Encoder FFC
CN8: Head FFC 9) Remove the CSICFFC from the CSIC Board.
4) Disconnect the CR Encoder FFC and the Head FFC from the Holder Shaft 10) Disconnect the CR Encoder FFC (CN1) from the CR Encoder Sensor Board.
Unit. (See 4.3.3.2 Removing Holder Shaft Unit Step 5) 11) Release the three FFCs from the three notches.
5) Disconnect the CR Timing Belt.
(4.3.3.5 Removing CR Timing Belt Step 3 through Step 4) Rear
CN1
6) Remove the CR Encoder Scale. (p63)
7) Remove the CR Cable Head Cover. (p64)
CR Encoder Sensor Board
Notches
CR Encoder FFC CSIC Board

CSICFFC
Figure 4-55. Removing FFC

C A U T IO N Make sure to support the CR Unit with your hands so as not to drop When installing the CR Timing Belt to the CR Unit, make sure
it, or the nozzle surface of the printhead may be damaged. to attach the belt to the positioning jag as shown below.
Positioning Jag
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.
CR Unit
CR Timing Belt
Figure 4-58. Installing CR Timing Belt
When installing the CR Unit to the Main Unit Frame, engage
them as shown in Figure 4-55.
Tab Tab CR Unit
Figure 4-56. Removing CR Unit (1)

13) Remove the CR Timing Belt from the CR Unit. Main Unit Frame
Figure 4-59. Installing CR Unit

Route the three FFCs as shown in Figure 4-55.
The Shield Plate FFC should be attached to the location shown
in Figure 4-54 with double-sided tape.
CR Timing Belt
CR Unit
Figure 4-57. Removing CR Unit (2)

A D J U S T M E N T When you replace Holder pulley driven, Front Frame, Pulley

R E Q U IR E D
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.
When Print head assy. is removed or replaced with new one, the
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.

4.3.3.11 Printhead Assy. 4) Remove the Head FFC from the Printhead Assy.
C H E C K Before starting the following work, make sure that the two tabs Head FFC
P O IN T shown in Figure 4-56 are already released.
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 4-61. Removing Printhead Assy. (2)
Printhead Cover
Tab and Notch
Figure 4-60. Removing Printhead Assy. (1)

4.3.3.12 CR Encoder Sensor Board

When installing the Printhead Assy. to the IC Holder, match the
tabs with the notches, and tilt the Printhead as shown below. 1) Remove the CR Unit. (p65)
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 4-63. Removing CR Encoder Sensor Board
Figure 4-62. Installing Printhead Assy.

4.3.3.13 CSIC Board 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.
2) Remove the two screws that secure the IC Holder Cover to the IC Holder,
release the tab, and remove the IC Holder Cover. CSIC Board
• C.B.P. 2.5 x 8: 2
Tab
IC Holder Cover
C.B.P. 2.5 x 8 Bottom A Sections
Figure 4-64. Removing IC Holder Cover
Figure 4-65. Removing CSIC Board

4.3.3.14 Paper Guide, Upper Assy. 4.3.3.15 Eject Roller

1) Remove the Housing, Upper. (p43) 1) Remove the Housing, Upper. (p43)
2) Push the two guide pins on the Paper Guide, Upper Assy. with a flathead 2) Remove the Front Frame. (p62)
screwdriver or a similar tool, and remove the Paper Guide, Upper Assy.
3) Move the CR Unit to the home position.
toward you.
Guide Pins
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 4-66. Removing Paper Guide, Upper Assy.
3) Repeat the steps above, and remove all the Paper Guide, Upper Assys. Figure 4-67. Removing Eject Drive Pulley
A D J U S T M E N T When Paper guide upper is removed or replaced with new one, the
R E Q U IR E D

A D J U S T M E N T When you replace Paper eject roller with new one, lubricate it
C A U T IO N Be careful not to damage the rubber area when performing the R E Q U IR E D
aws specified. See "6.1.3 Lubrication" (p92) for details.
following work.
When Paper eject roller is removed or replaced with new one,
the following adjustment must be performed in the order
below.
6) Release the Eject Roller from the four tabs of the Paper Guide, Upper Assy., 1. “Top Margin Adjustment”
and remove the Eject Roller. 2. “PF Adjustment”
Tabs 4. “Head Angular Adjustment”
Figure 4-68. 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 4-69. Installing Eject Drive Pulley

4.3.3.16 Paper Guide, Front Assy. 1) Remove the Eject Roller. (p71)
2) Remove the screw that secures the Paper Guide, Front Assy. to the Main Unit.
C A U T IO N Never touch the rib on the Paper Guide, Front Assy.
• C.B.S. 3 x 8: 1
3) Follow the steps below when removing the Paper Guide, Front Assy.
1. Lift up the left side of the Paper Guide, Front Assy.
2. Slide the Paper Guide, Front Assy. toward left, and release the two
convex portions on the right.
3. Lift up the right side of the Paper Guide, Front Assy, slide it toward
right, and remove the Paper Guide, Front Assy.
Rib
Left Right
C.B.S. 3 x 8 Convex Portion
and Notch
Paper Guide, Front Assy.
Figure 4-70. Rib on Paper Guide, Front Assy.

Be careful not to bent the four Paper Guide, Front Absorbent
Protections.
Convex Portion Convex Portion Convex Portion
and Notch and Hole and Hole
Paper Guide, Front Assy.
Figure 4-72. Removing Paper Guide, Front Assy.

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
Figure 4-71. Paper Guide, Front Absorbent Protections holes as shown in Figure 4-72.

4.3.3.17 Pump Unit/Cap Unit

A D J U S T M E N T When Paper guide front is removed or replaced with new one, the
R E Q U IR E D
following adjustment must be performed in the order below. When removing the Pump Unit and the Cap Unit, pay attention not
C A U T IO N
1. “Top Margin Adjustment” to drop the CR Lock Lever and the Gear.
5. “First Dot Adjustment” 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 4-73. Removing Pump Unit/Cap Unit (1)

4) Remove the Ink Tube that connects the Pump Unit and the Cap Unit.
A D J U S T M E N T When you replace Pump Unit/Cap Unit with new one, lubricate
R E Q U IR E D
Cap Unit Pump Unit
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.
Ink Tube Joint
Figure 4-74. 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 4-75. Assembling Pump Unit

4.3.3.18 PF Motor 5) Remove Compression Spring 1.53, and remove the PF Motor.
2) Disconnect the PF Motor Connector from the Main Board.
(See 4.3.2.1 Removing Main Board Step 3) PF Motor
3) Remove the PF Timing Belt, Idle Roller Assy, and Compression Spring from
the Main Unit.
PF Timing Belt
Compression Spring 1.53
Figure 4-78. Removing PF Motor (3)
When installing the PF Motor, make sure to attach

Compression Spring Compression Spring 1.53 to the part shown in Figure 4-78.
1.13 When installing the PF Motor, secure the hexagon nuts in the
Idle Roller Assy. order shown in Figure 4-77.
4) Remove the four hexagon nuts that secure the PF Motor to the Main Unit.
A D J U S T M E N T When PF motor is removed or replaced with new one, the
R E Q U IR E D
HEXAGON NAT NORMAL M3
(6 ± 1 kgf.cm) 2. “PF Adjustment”
1 5. “First Dot Adjustment”
4
3
2

CHAPTER
5
ADJUSTMENT
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

Used
Function Item Purpose Method Outline Tool
Media
Market At the time of Main board replacement, this adjustment is made Select and execute this function in the exclusive servicing program to save Exclusive servicing Non-target
setting to write the board common information on a destination basis. the following data into the EEPROM. program
Market ID, CSIC printer ID, D4 setting (USB, parallel), First Dot
adjustment fixed value.
Head ID At the time of head replacement, this adjustment is made to Enter the ID of the head QR code label applied to the Printhead into the Exclusive servicing Non-target
input correct head manufacturing variations and eliminate the exclusive servicing program to save it to the EEPROM on the Main board. program
individual differences of print quality. (Supplement: Read the QR code label from left to right on the top row and
from top to bottom in due order.)
Offset input When the Main board, CR motor, PS board or Print head assy is Select and execute this function in the exclusive servicing program to save Exclusive servicing Non-target
for CR motor changed individually, this adjustment is made to write the the offset into the EEPROM. program
Main adjustment items
calorific maximum offset to prevent the occurrence of damage to the

limitation. motor at the time of CR motor heat generation.
Head angular This adjustment is made to correct the error in the Head Select this function in the exclusive servicing program and print the Exclusive servicing Photo
adjustment mounting position (angle of the Head to the paper surface) to adjustment pattern. Check the displacement amount of the pattern. Print program Quality Ink
keep the nozzle intervals uniform in the CR main scanning the exclusive pattern again and adjust the displacement amount. Jet Paper
direction. (A4)
PF This adjustment is made to correct the variations of paper feed Select this function in the exclusive servicing program and print the Exclusive servicing Photo
adjustment accuracy in the band printing mode to improve print quality. adjustment patterns (9 patterns). Select and enter the pattern that has the program Quality Ink
smallest gap and overlap. The correction value is saved to the specific Jet Paper
EEPROM address on the Main Board. (A4)
Bi-D This adjustment is made to correct the print timing in the go and Select this function in the exclusive servicing program and print the Exclusive servicing Plain paper
adjustment return paths in bi-directional printing. adjustment patterns to check the displacement amounts of the patterns. program (A4)
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.
ADJUSTMENT Adjustment Items and Overview 78

Table 5-1. Servicing Adjustment Items

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

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

Table 5-3. Check Pattern Printing

Used
Function Item Purpose Adjustment Outline Tool
Media
A4 Photo Quality Ink This pattern is used to check whether all adjustment Select this function in the exclusive servicing program, print the Exclusive servicing Photo Quality Ink
Check pattern items
Jet Paper print results are normal. print patterns, and check the adjustment result in each pattern. program Jet Paper (A4)
A4 Normal Paper print This pattern is used to check whether all adjustment Select this function in the exclusive servicing program, print the Exclusive servicing Plain paper (A4)
results are normal. print patterns, and check the adjustment result in each pattern. program
Nozzle check pattern This pattern is used to check simply whether all nozzles This pattern is used to make a simple print check at the EPSON Exclusive servicing Plain paper (A4)
print deliver ink or not. service company. program
5.1.2 Repaired Adjustment

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 mechanism’s
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 In case that any parts are removed and assembled on the repair
P O IN T product while running the Adjustment program, make sure to
turn off the printer.

5.1.3 Replacement Part-Based Adjustment Priorities Note: “applicable” in this table indicates the adjustment
The following table indicates the adjustment items and priorities on a replacement part basis. items required after removing/replacing the parts.
Performance Priority 1 2 3 4 5 6 7 8 9 10 11 12
Adjustment item Offset input for

Head
EEPROM Market USB ID Waste ink Ink Head ID Top margin First dot Bi-D PF CR motor
Replaced part angular
data copy setting input pad counter charge input adjustment adjustment adjustment adjustment calorific
adjustment
Removal/Replacement limitation
ASF unit removal --- --- --- --- --- --- applicable applicable --- --- applicable ---
ASF unit replacement --- --- --- --- --- --- applicable applicable --- --- applicable ---
CR motor removal --- --- --- --- --- --- --- applicable applicable applicable --- ---
CR motor replacement --- --- --- --- --- --- --- applicable applicable applicable --- applicable
Paper guide upper removal --- --- --- --- --- --- applicable --- --- --- applicable ---
Paper guide upper replacement --- --- --- --- --- --- applicable --- --- --- applicable ---
Frame front (only) removal --- --- --- --- --- --- --- applicable applicable applicable --- ---
Frame front (only) replacement --- --- --- --- --- --- --- applicable applicable applicable --- ---
I/C holder removal --- --- --- --- --- --- applicable applicable applicable applicable applicable ---
I/C holder replacement --- --- --- --- --- --- applicable applicable applicable applicable applicable ---
Print Head assy. removal --- --- --- --- --- --- applicable applicable applicable applicable applicable ---
Print Head assy. replacement --- --- --- --- applicable applicable applicable applicable applicable applicable applicable applicable
Main board removal --- --- --- --- --- --- --- --- --- --- --- ---
Main board replacement (Read OK) applicable --- --- --- --- --- --- --- --- --- --- ---
--- (Pad
Main board replacement (Read NG) --- applicable applicable --- applicable applicable applicable applicable applicable applicable applicable
replacement)
Holder shaft unit removal --- --- --- --- --- --- applicable --- --- --- --- ---
Holder shaft unit replacement --- --- --- --- --- --- applicable --- --- --- --- ---

Performance Priority 1 2 3 4 5 6 7 8 9 10 11 12
Adjustment item Offset input for

Head
EEPROM Market USB ID Waste ink Ink Head ID Top margin First dot Bi-D PF CR motor
Replaced part angular
data copy setting input pad counter charge input adjustment adjustment adjustment adjustment calorific
adjustment
Removal/Replacement limitation
Paper eject roller removal --- --- --- --- --- --- --- --- --- --- applicable ---
Paper eject roller replacement --- --- --- --- --- --- --- --- --- --- applicable ---
PS board removal --- --- --- --- --- --- --- --- --- --- --- ---
PS board replacement --- --- --- --- --- --- --- --- --- --- --- applicable
Paper guide front removal --- --- --- --- --- --- applicable applicable applicable applicable applicable ---
Paper guide front replacement --- --- --- --- --- --- applicable applicable applicable applicable applicable ---
PF motor removal --- --- --- --- --- --- applicable --- --- --- applicable ---
PF motor replacement --- --- --- --- --- --- applicable --- --- --- applicable ---
Waste ink pad removal --- --- --- --- --- --- --- --- --- --- --- ---
Waste ink pad replacement --- --- --- applicable --- --- --- --- --- --- --- ---
PW sensor removal --- --- --- --- --- --- --- --- --- --- --- ---
PW sensor replacement --- --- --- --- --- --- --- --- --- --- --- ---
Printer mechanism removal --- --- --- --- --- --- --- --- --- --- --- ---
Printer mechanism replacement --- --- --- --- --- --- --- --- --- --- --- ---
Ink system removal --- --- --- --- --- --- --- --- --- --- --- ---
Ink system replacement --- --- --- --- --- --- --- --- --- --- --- ---

5.2 Adjustment by Using Adjustment Program 5.2.1 Market ID Setting

[Adjustment Procedure]
The procedures of the adjustment items will be explained here. The intended item is
as follows. 1. Select the Market ID of the adjustment program.
Market setting 2. Click the [OK] button to write the specific data into EEPROM.
USB ID input 3. Click the [Check] button to check market and model name.
Head ID input
Head angular adjustment
5.2.2 USB ID Input
Bi-d adjustment [Adjustment Procedure]
PF adjustment 1. Select USB ID input in the adjustment program.

First dot adjustment 2. Enter the 10-digits serial number from the label applied to the bottom side of the
Upper housing.
Top margin adjustment
Offset input for CR motor calorific limitation 5.2.3 Head ID Input
A4 Normal Paper print
A4 Photo Quality Inkjet Paper print
1. Select the Head ID of the adjustment program.
2. 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 83

5.2.4 Head Angular Adjustment 5.2.5 Bi-D Adjustment

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

Figure 5-1. Head Angular Printing Pattern
C A U T IO N Please perform Bi-d adjustment keeping all “Housing” attached.

5.2.6 PF Adjustment 5.2.7 First Dot Adjustment

1. Select PF adjustment in the adjustment program. 1. Select First Dot adjustment in the adjustment program.
2. Click the [Print] button to PF adjustment pattern. 2. Click the [Print] button to print First Dot adjustment pattern.
3. Select the pattern that has the smallest displacements in each variable dot, 3. 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
4. Click the [Input] button to write the adjustment value of checked items.
value of 1.
5. If the smallest displacements is [*] or [**], and click the corresponded button.
6. Check that [*] or [**] is best of the three, input 4 in case of [*] and
-4 in case of [**]. [Treatment procedure for NG product]
[Treatment procedure for NG product] Step1) Replace the repaired (replaced) part with new one.
Step1) Replace the repaired (replaced) part with new one. Step3) If the result is NG level, confirm the installation condition of removed parts
Step2) Print the check pattern, and check the adjustment result. during disassembly.
during disassembly. [Judging Standard]
- Standard : 3.6 ± 1.0 mm away from top edge.
OK pattern [Judging Standard]
- No gap/overlap between short block
pattern and long one.
Figure 5-4. First Dot Pattern
NG pattern [Reference:Standard value in manufactory]
- Standard : ±35µm
Figure 5-3. PF Adjustment Pattern

5.2.8 Top Margin Adjustment 5.2.9 Offset input for CR Motor Calorific Limitation
1. Select Top Margin adjustment in the adjustment program. 1. Select Offset input for CR motor calorific limitation in the adjustment program.
2. Click the [Print] button to print Top Margin adjustment pattern. 2. Click the [Input] button to write the specific data in EEPROM.
3. Determine the adjustment value in the shifting direction for the pattern printed on
the top margin. (Note: [+] input < 2.6mm, 4.6mm < [-] input )
Step1) Replace the repaired (replaced) part with new one.

during disassembly.
[Judging Standard]
- Standard : 3 ± 1.5 mm away from left edge.
Figure 5-5. Top Margin Pattern

5.2.10 A4 Normal Paper print 5.2.11 A4 Photo Quality Inkjet Paper Print
1. Select A4 Normal Paper print in the adjustment program. 1. Select A4 Photo Quality Inkjet Paper print in the adjustment program.
2. Click the [Print] button to print A4 Normal Paper print pattern. 2. Click the [Print] button to print A4 Photo Quality Inkjet Paper print pattern.
3. Check the adjustment result in each pattern.
[Judging Standard]
- PW Sensor adjustment
Top / Bottom : 5.0+0.5/-1.0mm [Judging Standard]
Right / Left : 5.0+0.3/-1.0mm - Bi-D adjustment
- Beta pattern Make sure that “X“ is the best pattern of the
No uneven printing / white line. three.
- Vertical alignment - Top Margin adjustment
No thin dot or thick dot / vertical 3 ± 1mm from top edge.
alignment. ( This standard is different from that of
- Horizontal alignment individual Top Margin adjustment. The
No displacement between the vertical standard of individual Top Margin adjustment
rules of each VSD. 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.
Figure 5-6. A4 Normal Paper Print Pattern
Figure 5-7. A4 Photo Quality Inkjet Paper Print Pattern

5.3 Adjustment Except Adjustment Program [Treatment for NG product]
Step1) Replace the CR timing belt with new one again.

Following is adjustment except adjustment program. Step2) Check the adjustment result again.
5.3.1 CR Timing Belt Tension Adjustment during disassembly.
[Purpose]
This adjustment is to optimize the timing belt tension for preventing tooth skip between Sensor cable [Judging Standard]
the pinion of CR motor and the CR timing belt. This adjustment must be made when - CR Timing Belt Tension : 9 ± 1.5N
the CR timing belt is removed.
1. Install the CR timing belt to the printer mechanism.

2. Check the CR timing belt tension by using Digital Tension Gauge.
[Note]
Before this adjustment, the following data should be inputted into Digital Tension Figure 5-8. CR Timing Belt Tension adjustment
Gauge.
[UNITTA : Setting of Digital Tension Gauge]

- Weight : Input “0.4” C A U T IO N Don’t damage timing belt while pushing it with the tail plastic of
- Width : Input “8” ballpoint pen / plastic tweezers.
- Span : Input “377” Perform this adjustment in quiet environment in order to avoid
that the measured result affects by other frequency.
3. Return to CR unit to have position. Sensor should be set vertically on CR timing belt.
4. 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.)
5. 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.
6. Check the result of tension value on the display.
ADJUSTMENT Adjustment Except Adjustment Program 88

CHAPTER
6
MAINTENANCE
6.1 Overview 6.1.2 Service Maintenance

If any abnormal print (dot missing, white line, etc.) has occurred or the printer indicates
This section provides information to maintain the printer in its optimum condition.
the "Maintenance request error" (This error is displayed as "Maintenance call error" in
the STM3), take the following actions to clear the error.
6.1.1 Cleaning Printhead cleaning
This printer has no mechanical components which require regular cleaning except the When dot missing or banding phenomenon has occurred, you need to perform the
Printhead. Therefore, when returning the printer to the user, check the following parts printhead cleaning operation*1 by using the printhead cleaning function. This
and perform appropriate cleaning if stain is noticeable. function can be performed by the control panel operation, the printer driver utility
.
and the Adjustment program.
Never use chemical solvents, such as thinner, benzine, and In case that the cleaning sequence is performed by the control panel operation,
C A U T IO N
acetone to clean the exterior parts of the printer like the confirm that the printer is in stand-by state (the Power LED is lighting), and hold
Housing. These chemicals may deform or deteriorate the down the Error reset button on the control panel for more than 3 seconds. Then,
components of the printer. the printer starts the cleaning sequence (the Power LED blinks during this
Be careful not to damage any components when you clean sequence).
inside the printer. 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
Do not scratch the coated surface of the PF roller. Use soft
process to perform the printhead cleaning from the printer driver utility.
brush to wipe off any dusts. Use a soft cloth moistened with
As for the operation of the Adjustment program, refer to
alcohol to remove the ink stain.
Chapter5 “ADJUSTMENT” (p.77).
Do not use cleaning sheet included in the media for normal
usage. It may damage the coated surface of PF roller.
*1: The Stylus C67/C68/D68 has four modes for manual cleaning, and even during
If the adhesive surface of the cleaning sheet is set to the LD
printing, the appropriate cleaning mode is automatically selected and performed
roller shaft side and used to clean the LD roller surface, it is no
according to various conditions. Therefore the ink consumption amount for
problem.
manual cleaning varies depending on each mode.
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 Maintenance request error (Maintenance call error)
that the printer is in stand-by state by using the Status monitor 3. If the printer is in Ink is used for the printhead cleaning operation as well as the printing operation.
stand-by state, the following figure is indicated on the monitor. 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.77).
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
6.1.3 Lubrication Refer to the following figures for the lubrication points.
The characteristics of the grease have great affects on the mechanical function and <Lubrication Point>
durability, especially does the characteristics about temperature environment. The type Paper Back Lever Surface
and amount of the grease used to lubricate the printer parts are determined based on the ASF Unit
results of the internal evaluations. Therefore, be sure to apply the specified type and <Lubrication Type>
amount of the grease to the specified part of the printer mechanism during servicing. G-26
<Lubrication Amount>
Paper Back Lever
φ1 x 1 mm
C A U T IO N Never use oil or grease other than those specified in this <Remarks>
manual. Use of different types of oil or grease may damage the • G-26 must not be adhered to
component or give bad influence on the printer function. other parts.
Never apply larger amount of grease than specified in this
manual.
G-58 / G-26 / G-71 is already on the printer mechanism for Figure 6-4. Lubrication on Paper Back Lever
C H E C K
P O IN T service part in the manufactory.
<Lubrication Point>
Front Frame Surface
<Lubrication Type>
G-58
Type Name EPSON code Supplier
Front Frame <Lubrication Amount>
Grease G-26 1080614 EPSON
φ1mm x 365mm
Grease G-58 1082176 EPSON
Grease G-71 1304682 EPSON <Remarks>

• G-58 must not be adhered to
35mm 20mm the printer mechanism and
other parts.
Figure 6-5. Lubrication on Front Frame
<Lubrication Point> <Lubrication Point>

Rear side view Front and rear faces of the Main Back side slit of I/C Holder
Frame Carriage Slide
<Lubrication Type>
<Lubrication Type> G-71
G-58 I/C Holder
<Lubrication Point>
<Lubrication Amount> φ 3mm x 3mmφ
360 mm x 2 face
<Remarks>
<Remarks> • G-58 moust not be adhered to
Main Frame • G-58 moust not be adhered to other parts.
other parts.
Figure 6-6. Lubrication on Main Frame Figure 6-8. Lubrication on I/C Holder
<Lubrication Point> <Lubrication Point>

Roller Unit Roller Guide Contact point between Roller EJ drive pulley Shaft Surface
Guide and Roller Unit
<Lubrication Type>
<Lubrication Type> G-58
G-58
Upper side view <Lubrication Amount>
<Lubrication Amount> φ1 mm x diameter of EJ drive
PrintHead Bottom side view φ1 mm x 4 points pulley
<Remarks> <Remarks>
Use a injector to apply. • G-58 moust not be adhered to
EJ drive pulley other parts.
• G-58 moust not be adhered to
other parts.
Figure 6-7. Lubrication on Roller Guide Figure 6-9. Lubrication on EJ drive pulley
<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>
φ 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
Idle roller assy assy
<Lubrication Point>
G-58
<Lubrication Amount>
U-shaped part : φ 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
Figure 6-11. Lubrication on Idle Roller Assy
CHAPTER
7
APPENDIX
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
EPSON Stylus C67/C68/D68 No.1 Rev.01 C616-ACCE-001

105
106
102
101
100
103
EPSON Stylus C67/C68/D68 No.2 Rev.01 C616-CASE-001

200
A 300
EPSON Stylus C67/C68/D68 No.3 Rev.01 C616-ELEC-001

513
508
505 505
501
501
500
502
510 512
507
541 509
504
514
515
503
511
542
EPSON Stylus C67/C68/D68 No.4 Rev.01 C616-MECH-001

702
708
B
704
716
A
701 710
706
709
711
707
714
700
703
EPSON Stylus C67/C68/D68 No.5 Rev.01 C616-MECH-002

7.2 Parts List Ref No. Part Name

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

7.3 Circuit Diagrams

The control electrical circuit diagrams of this product are shown on the following pages.
APPENDIX Circuit Diagrams 103

Model : Stylus C67/C68/D68
Board : C616 MAIN
Rev. :B
Sheet : 1/1
Board : C616 PNL
Rev. :A
Sheet : 1/1
Board : C616 PSB
Rev. :B
Sheet : 1/1
Board : C616 PSE
Rev. :A
Sheet : 1/1

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SERVICE MANUAL

Color Inkjet Printer

EPSON Stylus C67/C68/D68

Copyright © 2005 SEIKO EPSON CORPORATION.

WARNING Signals a precaution which, if ignored, could result in damage to equipment.

Manual Configuration Symbols Used in this Manual

Indicates that a particular task must be carried out according to a certain

5.2.7 First Dot Adjustment .................................................................................. 85

PRODUCT DESCRIPTION Features 9

1.2 Specifications Table 1-2. Raster Graphics Mode

PRODUCT DESCRIPTION Specifications 10

1.2.3 Paper Feeding  220-240 V version

 Feeding method  Rated voltage: AC220-240 V

 Friction feed with ASF  Input voltage range: AC198-264 V

 Paper path  Rated frequency range: 50 - 60 Hz

 Feed speed  Rated current: 0.2 A (max. 0.4 A)

1.2.5 Electric Specification

PRODUCT DESCRIPTION Specifications 11

1.2.6 Environmental Condition 1.2.7 Reliability

C A U T IO N  Printhead must be capped during storage.

PRODUCT DESCRIPTION Specifications 12

1.2.9 Acoustic Noise

Figure 1-3. Black Ink Save Mode Window

1. User carries out printing from an application.

PRODUCT DESCRIPTION Specifications 13

1.3 Operator Controls 1.3.2 Panel Functions

Table 1-5. Panel functions with power on

1.3.1.2 Indicators Switch Pressing with Power Off function*

PRODUCT DESCRIPTION Operator Controls 14

PRODUCT DESCRIPTION Operator Controls 15

1.4 Paper  Envelopes

Table 1-9. Envelopes*

PRODUCT DESCRIPTION Paper 16

 Exclusive papers Table 1-10. Exclusive papers

PRODUCT DESCRIPTION Paper 17

1.4.1.1 Printable Area

Table 1-11. Applicable Paper/Printing Area TM

Paper Feed Direction

PRODUCT DESCRIPTION Paper 18

Paper Feed Direction

Figure 1-6. Printable Area for Envelopes

PRODUCT DESCRIPTION Paper 19

 Cut sheet (border-free printing)

Table 1-13. Applicable Paper/Printing Area

Paper Feed Direction

Ultra Glossy Photo Paper/ A4 2.54 2.54 2.96 4.02

PRODUCT DESCRIPTION Paper 20

1.5.1 Ink Cartridge Specification 12.7 mm

 Type: Exclusive cartridge

Table 1-14. Ink Cartridge

 Black ink cartridge

Table 1-15. Storage Temperature

PRODUCT DESCRIPTION Ink Cartridge 21

2.2 Printer Mechanism Star wheel

Figure 2-1. Printer Mechanism Outline

OPERATING PRINCIPLES Overview 23

2.2.1 Printhead Specifications 2.2.2 Carriage Mechanism

Paper Loading Direction Magenta: 29nozzles

Carriage Moving Direction

1.2.3 Paper Feeding 220-240 V version

Feeding method Rated voltage: AC220-240 V

Friction feed with ASF Input voltage range: AC198-264 V

Paper path Rated frequency range: 50 - 60 Hz

Feed speed Rated current: 0.2 A (max. 0.4 A)

C A U T IO N Printhead must be capped during storage.

1.4 Paper Envelopes

Exclusive papers Table 1-10. Exclusive papers

Cut sheet (border-free printing)

Type: Exclusive cartridge

Black ink cartridge

W A R N IN G Disconnect the power cable before disassembling or assembling

C A U T IO N Do not damage the tabs in removing the Housings.