Epson 660 Service Manual

SERVICE MANUAL
SERVICE MANUAL
SERVICE MANUALSERVICE MANUAL
Color ink jet printer
EPSONStylusCOLOR660
SEJ99005
Notice:
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The contents of this manual are subject to change without notice.
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All efforthave 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.
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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 © 1999 SEIKO EPSON CORPORATION. Printed in Japan.
PRECAUTIONS
Precautionary notations throughout the text are categorized relative to 1)Personal injury and 2) damage to equipment.
DANGER
WARNING
The precautionary measures itemized below should always be observed when performing repair/maintenance procedures.
Signals a precaution which, if ignored, could result in serious or fatal personal injury. Great caution should be exercised in performing procedures preceded by DANGER Headings.
Signals a precaution which, if ignored, could result in damage to equipment.
DANGER
1. ALWAYS DISCONNECT THE PRODUCT FROM THE POWE R SO URCE A ND PERIPHERAL DE VICES PERFO RMING ANY MAINTENANCE OR REPAIR PROCEDURES.
2. NOWORK SHOULD BE PERFORMED ON THE UNIT B Y P ERSONS 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 CONNE CT THE UNIT TO A POWER SOURCE UNTIL INSTRUCTED TO DO SO. WHEN THE POWER SUPPLY CABLE MUST BE CONNECTED, USE EXTREME CA UTION IN WORK ING ON POWER SUPPLY AND OTHER ELECTRONIC COMPONENTS.
WARNING
1. REPAIRS O N EPSON PRODUCT SHOULD BE PERFORMED ONLY BY AN EPSON CERTIFIED REPAIR TECHNICIAN.
2. MAKE CERTAIN THAT THE SOURCE VOLTAGES IS THE SAME A S THE RA TED V OLTAGE, LISTED ON THE SERIAL NUMBER/RATING PLATE. IF THE EPSON PRODUCT HAS A PRIMARY AC RATING DIFFE RENT FROM AVAILABLE POWER SOURCE, DO N OT CONNECT IT TO THE POWER SOURCE.
3. ALWAYS VERIFY THAT THE EPSON PRODUCT HAS BEEN DISC ONNECTED FRO M THE POWER SOURCE BEFORE REMOVING OR REPLACING PRINTED CIRCUIT BOARDS AND/OR INDIVIDUAL CHIPS.
4. IN O RDE R TO PROTECT SENSITIVE MICROPROCESSORS AND CIRCUITRY, USE STATIC DISCHARGE EQUIPMENT, SUCH AS ANTI­STATIC WRIST S TRA PS, WHEN ACCESSING INTERNAL COMPONENTS.
5. REPLACE MALFUNCTIONING COMPONENTS ONLY WITH THOSE COMP ONENTS B Y THE MA NUFACTUR E; INTRODUCTION OF SECOND-SOURCE ICs OR OTHER NONAPPROVED COMPONENTS MAY DAMAGE THE PRO DUCT AND VOID ANY APPLICABLE EPSON WARRANTY.
PREFACE
This manual describes basic functions, theory of electrical and mechanical operations, maintenance and repair procedures of Stylus COLOR 660. 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. The chapters are organized as follows:
CHAPTER 1. PRODUCT DESCRIPTIONS
Provides a general overview and specifications of the product.
CHAPTER 2. OPERATING PRI NCIPLES
Describes the theory of electrical and mechanical operations of the product.
CHAPTER 3. TROUBLESHOOTING
Provides the step-by-step procedures for troubleshooting.
CHAPTER 4. DISASSEMBLY AND ASSEMBLY
Describes the step-by-step procedures for disassembling and assembling the product.
CHAPTER 5. ADJUSTMENTS
Provides Epson-approved methods for adjustment.
CHAPTER 6. MAINTENANCE
Provides preventive maintenance procedures and the lists of Epson-approved lubricants and adhesives required for servicing the product.
CHAPTER 7. APPENDIX
Provides the following additional information for reference:
• EEPROM Address Map
• Connector P i n Assignments
• Circuit Diagram
Revision Status
Revision Issued Date Description
A August 25, 1999 First Release

PRODUCTDESCRIPTION

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1.1 FEATURES

EPSON Stylus Color 660/660
and low price for hat high performance. Also, Stylus Color 440 printer has the same high color print quality (720 X 720dpi) as Stylus ProXL,
Stylus Color 640,740,660
and quality (1440 X 720) as Stylus Color 600 and Stylus Pro 5000. The major printer features are;
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High color print quality
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720 (H) x 720 (V) dpi printing (for Stylus Color 440)
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1440 (H) X 720 (V) dpi printing (for Stylus Color 640, 660, 740)
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4 color printing (YMCK)
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Traditional and New Microwave
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Black 64 nozzles, CMY 21 nozzles (for Stylus Color 440)
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Black 64 nozzles, CMY 32/color nozzles (for Stylus Color 640,
660)
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Black 144 nozzles, CMY 48/color nozzles (for Stylus Color 740)
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Built-in auto sheet feeder
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Holds 100 cut-sheets (64g/m2)
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Holds 10 envelopes
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Holds 30 transparency films
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Holds 65 special papers
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High-speed print
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200 cps (for Stylus Color 440, 740)
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Normal 200 cps, Draft 400 cps (only for Stylus Color 640, 660)
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By using head drive frequency 14.4KHz, printing speed is twice faster than Stylus Color.
are designed for PC users at home
have the same high color print
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Compact size
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429mm (W) x 231mm (D) x 155mm (H) (for Stylus Color 440)
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429mm (W) x 231mm (D) x 157mm (H) (for Stylus Color 640,
660)
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429mm (W) x 261mm (D) x 157mm (H) (for Stylus Color 740)
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Weight : 5.2Kg (for 3 models)
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Acoustic noise
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Approximately 45 dB (for Stylus Color 440)
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Approximately 47 dB (for Stylus Color 640, 660, 740)
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Interface
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Bi-directional parallel I/F IEEE-1284 level 1 device (for 3 models)
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Mac serial I/F up to approx. 1800 kbps (only for Stylus Color
740)
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USB (only for Stylus Color 740)
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One unit combined black and CMY head
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Windows exclusive (for Stylus Color 440, 640, 660)
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Standard, NLSP, 5 Scaleable fonts (only for Stylus Color 740)
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Stylus Color 660 is the reflesh version based on Stylus Color 640. The difference points are as follows;
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Following EEPROM Datas Address Data *02H: 03H *72H: 36H *73H: 36H *74H: 30H
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See the Table A-20 to A-26 for EEPROM address map of EPSON Stylus Col or 440/640/740 Service Manual.
The rest contents of Product Description is the same as of EPSON Stylus Color 640/660/740.
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Chapter 1 Product Descriptio

OPERATINGPRINCIPLES

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TROUBLESHOOTING

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DISASSEMBLYANDASSEMBLY

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The co ntents of Disassembly and Assembly is the same as of EPSON Stylus Color640/660/740.
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ADJUSTMENT

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5.1 Overview

This chapter describes adjustments r equired for Stylus Color 640/660 when the printer is disassembled and assembled after repair. Refer to Stylus Color 740/640/440 Service Manual for things that are not described here.

5.1.1 Required Adjustments

Stylus Color 640/660 requires the following adjustments. (Refer to Table 5-1) Perform any necessary adjustment referring to the figures and procedures described throughout this chapter.
Table 5 -1 Adjustment Required
No. Adjustment Item Conditions
1 Parallelism Adjustment • When you replace or remove the Carriage
guide shaft.
• When you move the parallelism adjustment bushing.
2 Initial Ink Charge • When you replace or remove the printhead. 3 Head Voltage ID Input • When you replace the printhead.
• When you replace the main board.
Note) The values stored in this address are not
erased by EEPROM reset operation.
4 Printing Head Angle
Adjustment
5 Bi-D Adjustment • When you replace or remove the printhead.
• When you replace or remove the printhead.
• When you move the printhead angle adjusting lever.
• When you replace the main board.
• When you replace the CR Motor.
Table below shows the actions taken and required adjustments i n the order to be performed.
Table 5 -2 Actions Taken and A djustment Required
No. ContentofOperation Adjustment Procedure
1 Removal of the printhead 1. Perform initial ink charge.
2. Perform printhead angle adjustment.
3. Perform Bi-d Adjustment.
2 Replacement of the printhead 1. Perform Vh voltage writing operation.
2. Perform initial ink charge.
3. Perform printhead angle adjustment.
4. Perform Bi-d Adjustment.
3 Replacement of the main board 1. Perform Vh voltage writing operation.
2. Perform Bi-d adjustment.
Note) After performing the above adjustment, replace the following parts.
• Ink cartridge
• Waste Ink Pad The above two kinds of software counter
are erased by replacing the Main board.
4 Replacement or Removal of the
Carriage Unit
5 Replace of the CR Motor 1. Perform Bi-d adjustment. 6 Replacement of the Printer
Mechanism
1. Perform parallel adjustment.
2. Perform printhead angle adjustment.
3. Perform Bi-d adjustment.
1. Perform Head Voltage ID Input.
2. Perform initial ink charge.
3. Perform Bi-d adjustment.
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5.1.2 Adjustment Tools Required

Table 5-3 below shows adjustment tools for Stylus Co lor 640/660.
Table 5-3 Adjustment Tools Required
No. Nam e Adjustment Item Contents/Spec.
1 Thickness Gauge Parallelism Adjustment 1.04 mm 2 Adjustment
Program
CAUTION
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Never use the bent (curved or t ilted) or rusty thickness gauge.
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Erase any dirt, grease or obstacles on the thickness gauge before you use it.
Each Mechanism Settings
ExclusiveProgram; Stylus COLOR 600 640
660
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5.2 Adjustment

This section explains the specific procedures for making the adjustments using the exclusive adjustment program for Stylus Color 640/660.

5.2.1 Adjustment by Adjustment Program

For this printer, it is necessary to set the correct information for each printer mechanism in order to maintain consistent printing function and quality, eliminating differences among each printer mechanism's characteristics. Therefore, in case that the combination of the printer mechanism and main board changes or the printhead is replaced during repair, you must set and save the correct information to the main board, using the exclusive adjustment program.
Main Menu
Adjustment
Market destination check
Head voltage ID input
Maintenance
Head cleaning
Initial ink charge
Print A4 pattern
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Recovery
5.2.1.1 About Adjustment Program
The adjustment program (Program name: Stylus COLOR 600 640 660) enables you to set various values correctly to prevent malfunction and fluctuation of printing quality and printing function caused by difference in components and assemblywhen the printer components are replaced during repairs. Basic adjustment menu in this program are shown in Figure 5-1. Options in the Program.
NOTE:This Adjustment Program can not be used in Windows NT
and Dos environment.
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Head angular adjustment
Bi-Directional adjustment
Indication of the counter value
Figure 5-1. Options in the Program
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5.2.1.2 Entering Stylus COLOR 660 SERVICE PROGRAM
To perform any adjustment, you need to enter the Stylus COLOR 660
SERVICE PROGRAM
steps will bring you to the service program screen.
1. Connect the printer and PC and turn on the printer.
2. Insert Disk 1 for the adjustment program to the floppy disk d rive.
3. Execute Setup.exe of Disk 1.
4. The Setup Wizard for the adjustment program “EPSON Stylus
COLOR 600/640/660 SERVICE PROGRAM Version 4.0” starts,and you can follow the direction indicated by the wizard.
5. The Setup Wizard says “Setup Ne eds The Next Disk.”
6. Take out Disk 1 and insert Disk 2.
7. Program will be installed in your appointed folder.
8. Go to the appointed folder and open the adjustment program.
first. Read the following instructions and these
9. The following screen appears.
Figure 5-2. Initial Screen (1)
10. Choose Stylus Color 660, and click OK. By doing so, the model
name will be written in the EEPROM.
NOTE: If you select wrong model name in the above menu between
Stylus COLOR 640 and 660, the model name will be written in the EEPROM anyway because SC 640 and 660 have compatibility. Be careful not to choose wrong model name. The wrong model name will not be written in EEPROM between SC 660 and SC 640 or between SC 600 and SC 660.
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11. In the next screen, choose th e mar ket destination according to the
market.
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Standard: All the market except ESP.India and Korea
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ESP.India: for ESP India
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Korea: for EKL
NOTE:When you choose the market destination, the respective dot
size used in the economy mode will be written in the EEPROM (6E<H>). Default setting: Normal x 2 dot (Standard) Normal x 1 dot (ESP. India)
NOTE:When Korea is selected, the setting will be the same as in
the case Standard is selected.
13. Following screen appears.
Figure 5-4. Initial Screen (3)
Figure 5-3. Initial Screen (2)
12. Click OK.
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If you want to check t his model name, choose “Check this model name” and click OK. (See step 14)
If you do not ne ed to check the m odel name or finished checking, s elect “Boot this program”. (See step 17)
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14. When you select “Check this model name”, the following screen
appears.
NOTE:While checking the model name, keep the printer ON.
15. After a few seconds, the model name appears on the screen shown
below.
Figure 5-6. Checking the model name (2)
Figure 5-5. Checking the m odel name (1)
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16. Press “OK (Esc)” to go back to the initial screen (3) (Figure 5-4).
NOTE:If the Model name is wrong, choose the right model name on
Figure 5-2.
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17. In the initial screen (3) (Figure 5-4), select “Boot this program” and
you will enter Stylus COLOR 660 SERVICE PROGRAM.
18. Stylus COLOR 660 SERVICE PROGRAM shown below appears.
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Figure 5-7. Stylus COLOR 660 SERVICE PROGRAM
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5.2.1.3 Initial Ink Charge
There is no ink charged in the ink path of a spare printhead and printer mechanism. Therefore, after you replaced any of the following units, perform initial ink charge and return the printer after making sure that ink is ejected correctly from the printhead.
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After replacing the printer mechanism
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After replacing or removing the printhead
1. On the Stylus COLOR 660 SERVICE PROGRAM, select maintenance menu.
2. Select “Initial ink charge” from the maintenance menu. The following screen appears.
Figure 5-9. Initial Ink Charge
CAUTION
Before you set the initial ink charge, replace the installed cartridges with new ones, because the ink amount used for the initial ink charge operation is so large.
3. Click OK, and the printer enters the initial ink charge sequence.
(It takes 90 seconds for this operation to complete the whole
Figure 5-8. Maintenance Menu
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5.2.1.4 Head Cleaning
Stylus Color 660 have no dummy cleaning sequence called CL3, which was performed to prevent ink from being unnecessarily consumed when cleaning was repeated without any printout. However, Stylus Color 660 is alternatively equipped with the strongest cleaning sequence CL2 contained in this adjustment program. With this sequence, you can forcibly solve the clogged nozzle problem caused by viscous ink.
CAUTION
1. On Stylus COLOR 660 SERVICE PROGRAM, select Maintenance menu.
If you can not recover the clogged nozzles de spite you performed CL2 ope ration, enter the Initial ink charge sequence by referring to Section 5.2.1.3.
2. From Maintenance menu, select “Head cleaning”. The following
screen appears.
Figure 5-11. Head Cleaning
3. Click OK. The printer enters the CL2 sequence. (It takes60seconds
for the process to complete.)
Figure 5-10. Maintenance Menu
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5.2.1.5 Indication of the counter value
The program provided with this manual can let you confirm or clear the current protection counter value.
[Confirming the current protection counter value]
1. On Stylus COLOR 660 SERVICE PROGRAM, select the Maintenance menu.
2. From the maintenance menu, select “Indication of the counter value. The screen below appears”.
Figure 5-13. Protection Counter CHECK/CLEAR
Figure 5-12. Maintenance Menu
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3. Click “Check th e present counter values”. Th e screen below
appears.
[Clearing the current protection counter value]
CAUTION
Be sure to replace the ins talled waste ink pad with a new one after or before you clear the current protection counter value.
1. From the maintenance menu (Figure 5-8), select “Indication of the
counter value”. The Protection counter CHECK / CLEAR Screen shown in Figure 5-13 appears.
2. Click “Clear the protect counter values” on the screen. The screen shown below appears.
Figure 5-14. Che ck the present counter values
4. If the present counter value is over 9800 points, advice your
customer to replace the Waste ink drain pad with new one.
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Figure 5-15. Clear the protection counter values
3. Click OK. At the bottom of the screen, it says “The protect counter
has been reset to zero”.
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5.2.1.6 Market Destination
For Stylus Color 660, the market destination is originally set.
1. To check the market destination, click “Market destination check” on the a djustment menu shown below.
Figure 5-16. Adjustment Menu
2. The Market Destination Check screen shown below appears.
Figure 5-17. Ma rket Destination check
3. Click OK. After a few seconds, market destination appears at the
bottom.
NOTE:If the market destination is wrong, click the correct market
destination in Figure 5-3. The correct information will be written in the EEPROM.
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5.2.1.7 Head Voltage ID Input
Head voltage value adjustment function enables you to write printhead ID. This operation is considered the most important to maintain proper printhead operation. If an ID is not written correctly, it results in white or color lines and also gives bad influence on dot weight. This adjustment is required in the following cases.
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When exchanging the main board
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When exchanging the printhead
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When exchanging the printer mechanism
CAUTION
1. When replacing any of the parts above, make a note of VH voltage ID appointed in advance. You can find the VH voltage ID on the following position:
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Before or a fter performing this operation, refer to the Table 5 -2 on page 16 and perform any appropriate adjustments or operations.
Printhead: On the side face of the printhead.
4. The following screen appears.
Figure 5-18. He ad Voltage ID Input (1)
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Printer mechanism: On the label of the packing box of the
printer mechanism.
2. On Stylus COLOR 660 SERVICE PROGRAM, select Adjustment menu (Figure 5-16).
3. Select “Head voltage ID input”.
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5. Select “Change data”, and the following screen appears.
Figure 5-19. He ad voltage ID input (2)
7. Select “Check present data” on the previous screen (Figure 5-18).
The screen below appears.
6. Input the new head voltage ID number, and click OK. The new ID number will be automatically written in the EEPROM.
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Figure 5-20. Check present data
8. Click OK, and check the head voltage ID is renewed.
NOTE:Although the possibility is quite low, if the logic circuit is still
alive when replacing the main board, you can read Head ID of the failed main board by using this function without removing the head.
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5.2.1.8 Head Angular Adjustment
This adjustment is required in the following cases.
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When a printhead is replaced.
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When the carriage unit is replaced.
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When the angle adjustment lever is moved.
By moving the angle adjustment lever, you can adjust the printhead angle without removing the ink cartridge. Print the check pattern in the adjustment program to determine the angle degree needed for the printhead. Then move the adjustment lever in the carriage unit to set the printhead angle referring to the printed check pattern.
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CAUTION
Before or a fter performing this operation, refer to Table 5 -2 on page 16 and perform appropriate adjustments or operations.
1. Remove the upper case from the main unit. (Refer to Chapter 4.)
NOTE:If you perform this adjustment with the upper case installed,
select “Move the carriage to the head angular adjustment” on Head Angular Adjustment (Figure 5-21) before loosening the screw.
2. Select “Head angular adjustment” in the adjustment menu(Figure 5-16). The following screen appears.
Figure 5-21. Head Angular Adjustment
3. Select “Print the head angular adjustment p attern”. The printer
prints the head angular adjustment pattern (Figure 5-22).
Head Angular Adjustment P attern (BK-M)
Figure 5-22. Sam ple of Head Angular Adjustment Pattern
4. Move the carriage to the head angular adjustment.
For Stylus CO lor 660, the head angular adjustment is at the center, not at the ink cartridge replacing position.
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5. Loosen the screw securing the printhead on the carriage. (You don't
need to remove it completely.)
Printhead securing screw
Figure 5-23. Screw Position
6. Look at the black/magenta combination in the pattern and move the
adjusting lever to make the magenta lines stay b etween the black lines with even space. The figure below shows how the pattern changes as the adjusting lever moves right (rear) or left (front).
To move this down
move the lever
Correct condition = evenly spaced
to the right (rear)
To move th is up
move th e lever to the left (front)
NOTE:Make sure to loosen this screw. Otherwise, the printhead
angle will no change even if the adjusting lever moves.
CHECK
POINT
If more than five minutes passed after moving the carriage, the CR motor becomes OFF and cannot accept the comm and to move the carriage. In order to avoid this, the program indicates the message. When the message “The printer has been left alone for 5 minutes” appears at the bottom of the head a ngular adjustment screen, click the OK button.
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Adjusting Lever
Figure 5-24.
Lever Operation and Corresponding Change in Pattern
7. Repeat the procedures from step 3 to step 6 until th e combination
pattern of black/magenta is correct.
8. After completing the adjustment, tighten the loosened screw, and reinstall the upper case only when you remove it.
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9. After tighten the screw, print the check pattern again to confirm.
If there is any gap, make the adjustment again.
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CHECK
POINT
If a certain amount of gap is generated at a certain direction by tightening the screw, make an adjustment considering the expected gap amount and tighten the screw.
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5.2.1.9 Bi-D Adjustment
You perform this adjustment to correct differences in printing positions, which is caused by incorrect printing timing in right and left directions during the Bi-directional printing. Therefore, you are required to perform this adjustment after performing the following operations.
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Replacing the Print mechanism
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Replacing the main board
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Replacing the CR motor
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Replacing the Carriage Assembly
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Replacing g the Printhead
1. Select “Bi-Directional Adjustment” in the adjustment menu (Figure 5-16). The following screen appears.
2. Select “Print the Bi-D adjustment p attern” on the screen, and the screen bellow appears.
Figure 5-26. Print the Bi-D pattern
3. Click OK. The printer starts printing a Bi-D adjustment pattern. (See
the sample pattern in the following page.)
NOTE:As shown in the sample, gaps between passes are
sometimes created in different directions among patterns. This unexpected change in direction is caused by an ink jet printer-specific reason, which is an ink jet printer inevitably performs a periodical cleaning specified by the flashing timer even during Bi-D pattern printing, so that the printing
Figure 5-25. Bi-D Adjustment Menu
direction suddenly changes. However, this directional difference among Bi-D patterns should not be considered, and you can always confirm and adjust the pattern correctly by referring to gap amount only.
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200 CPS Bi-D Pattern: Data = -2
Left Gap
200 CPS Bi-D Pattern: Data = 0
Right Gap
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4. Go back to “Bi-D A djustment” screen (Figure 5-25), select “Adjust”.
The screen below appears.
200 CPS Bi-D Pattern: Data = 2
5. The value “0” (blue) appears in the center of the screen and changes up/down every time you press the Up/Down arrow key. If you put plus number, the 2nd path pattern shifts to the left; if you put minus number, the 2nd path pattern shifts to the right. Using the keys, apply the number for the most properly aligned pattern in the Bi-D adjustment pattern print.
6. After you set the value correctly, click OK, and the program stores
Figure 5-27. Bi-D ADjustment Pattern Sample
the selected value.
7. Click “Previous”. The current screen returns to the Bi-D adjustment menu. (See Figure 5-25.)
8. Repeat the procedure from step 2 to step 7 until the Bi-D adjustment pattern is correct.
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Figure 5-28. Adjust
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5.2.1.10 Print A4 Pattern
For S tylus Color 660, you can check all the adjustment has done correctly by executing “print A4 pattern”.
1. In the following screen, click OK.
2. The printer starts printing the pattern, and the screen below
appears.
Figure 5-30. Print A4 Pattern (2)
3. After printing all patterns indicated in the menu, press “Previous”.
Figure 5-29. P rint A4 Pattern (1)
NOTE: If you find any white streaks or shades shown below, do the
adjustment again.
Figure 5-31. Nozzle Check (BK)
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5.2.1.11 Recovery
By using this program, you can clean the clogged nozzle. Stylus Color 660 alternately executes CL2 and Nozzle Check Pattern.
1. In the following screen, click OK.
2. The following screen appears. Click OK.
Figure 5-33. Recovery routine for clogged nozzle
3. The printer executes Head Cleaning and prints out the nozzle check
pattern below.
Figure 5-32. Recovery
NOTE: You can do this operation repeatedly. The program counts
how many times the operation is executed.
Figure 5-34. All Nozzle Test Pattern
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MAINTENANCE

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The contents of Maintenance is the same as of EPSON Stylus Color 640/660/740.
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APPENDIX

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