Epson 680Pro - LQ B/W Dot-matrix Printer, STYLUS COLOR 680, STYLUS COLOR 777, STYLUS COLOR 777i Service Manual

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EPSON STYLUSCOLOR680/777/777i

Color Inkjet Printer

SEIJ00010

SERVICE MANUAL

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Notice

All rights reserved. No part of this manual may b e reproduced, stored in a retrieval system, or transmitted in any form or by any means electronic, mechanical, photocopying, or otherwise, without the prior written permission of SEIKO EPSON CORPORATION.

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 contentsof 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.

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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 f atal 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 DE VICES PERFORMING ANY MAINTENANCE OR REPAIR PROCEDURES.

2. NO WORK SHOULD BE PERFORMED ON THE UNIT BY PERSONS UNFAMILIAR WITH BASICSAFETY MEASURESAS 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.

WARNING

1. REPAIRS O N EPSON PRODUCT SHOULD BE PERFORMED ONLY BY A N EPSON CERTIFIED REPAIR TECHNICIAN.

2. MAKE CERTAIN THAT THE SOURCE VOLTAGES IS THE SAME A S THE RATED VOLTAGE, LISTED ON THE S ER IAL 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 FRO M THE POWER SOURCE BEFORE REMOVING OR REPLACING PRINTED CIRCUIT BOA RDS AND/OR INDIVIDUAL CHIPS.

4. IN O RDER TO PROTECT SENSITIVE MICROPROCESSORS A ND CIRCUITRY, US E STATIC DISCHARGE EQUIPMENT, SUCH AS

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About This Manual

This manual describes basic functions, theory of electrical and mechanical operations, maintenance and repair procedures of EPSON Stylus Color 680/777/777i. The instructions and procedures included herein are intended for the experienced repair technicians, and a ttention should be given to the precautions on the preceding page.

Contents

This manual consists of six chapters and one Appendix.

CHAPTER 1.PRODUCT DESCRIPTIONS

Provides a general overview and specifications of the product.

CHAPTER 2.OPERATING PRINCIPL ES

Describes the theory of e lectrical and mechanical operations of the product.

CHAPTER 3.TROUBLESHOOTING

Provides the step-by-step procedures for the troubleshooting.

CHAPTER 4.DISASSEMBLY AND ASSEMBLY

Describes the step-by-step procedures for dissaembling and a ssembling 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.

APPENDIXProvides the following additional information for reference:

• Connector pin assignments

• Electric circuit boards components layout

• Exploded diagram

• Electrical circuit boardsschematics

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Symbols Used in This Manual

Various symbols are used throughoutthis manual either to provide additional information on a specific topic or to warn of possible danger present during a procedure or an action. Be aware of all symbols when they are used, and always read WARNING, CAUTION or NOTE m essages.

Indicates an operating or maintenanceprocedure,practice or condition that, if not strictlyobserved,could result in injury or loss of life.

Indicates an operating or maintenanceprocedure,practice,or condition that, if not strictly observed, could result in damage to, or destruction of, equipment.

May indicate an operating or maintenance procedure, practice or condition that is necessary to accomplish a task efficiently. It may also provide additional information that is related to a specific subject, or comment on the results achieved through a previous action.

W A R N IN G

C A U T I O N

C H E C K

P O I N T

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Revision Status

Revision Issued Date Description

A August 10,2000 First Release

B August 31, 2000

Revision:

Added disassembly and reassembly caution to 4.2.1 Housing Removal

Changed the resolution of bit map images when producing PDF files for clearer reading.

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Chapter 1 PRODUCT DESCRIPTION

1.1 FEATURES ........................................................................................ 10

1.2 SPECIFICATIONS.............................................................................. 11

1.2.1 Physical Specification............................................................... 11

1.2.2 Printing Specification................................................................11

1.2.3 Paper Feeding.......................................................................... 12

1.2.4 Input Data Buffer ...................................................................... 12

1.2.5 Electric Specification ................................................................12

1.2.6 Environmental Condition.......................................................... 13

1.2.7 Reliability.................................................................................. 13

1.2.8 Safety Approvals......................................................................13

1.2.9 Acoustic Noise..........................................................................13

1.2.10 CE Marking.............................................................................13

1.3 INTERFACE....................................................................................... 14

1.3.1 Parallel Interface (F orward Channel) ....................................... 14

1.3.2 Parallel Interface (Reserve Channel) ....................................... 17

1.3.3 USB Interface........................................................................... 18

1.3.4 Prevention of Data Transfer Time-out...................................... 19

1.3.5 Interface Selection.................................................................... 19

1.3.6 IEEE1284.4 Protocol................................................................19

1.4 OPERATOR CONTROLS .................................................................. 20

1.4.1 Operating Switch ...................................................................... 20

1.4.2 Control Panel............................................................................ 20

1.4.3 Panel Functions........................................................................21

1.4.4 Printer Condition and Panel Status .......................................... 22

1.4.5 Printer Initialization................................................................... 22

1.4.6 Errors........................................................................................ 23

1.5 PAPER ............................................................................................... 24

1.5.1 Paper Handling......................................................................... 24

1.5.2 Paper Specification.................................................................. 24

1.5.3 Printing Area............................................................................. 26

1.6 INK CARTRIDGE ............................................................................... 28

1.6.1 Black Ink Cartridge...................................................................28

1.6.2 Color Ink Cartridge................................................................... 28

Chapter 2 Operating Principles

2.1 Overview............................................................................................. 30

2.1.1 Printer Mechanism ................................................................... 30

2.1.2 Printhead.................................................................................. 31

2.1.3 Carriage Mechanism................................................................ 33

2.1.4 Paper Feeding Mechanism ...................................................... 34

2.1.5 Paper Loading Mechanism (ASF Unit)..................................... 35

2.1.6 Ink System Mechanism............................................................ 38

2.2 Electrical CircuitOperatingPrinciples................................................ 40

2.2.1 C383 PSB/PSE board .............................................................. 40

2.2.2 C383 MAIN Board.................................................................... 43

Chapter 3 Troubleshooting

3.1 Overview ............................................................................................ 50

3.2 Troubleshootingwith LED Error Indications ....................................... 51

Chapter 4 Disassembly and Assembly

4.1 Overview ............................................................................................ 62

4.1.1 Precautions.............................................................................. 62

4.1.2 Tools ........................................................................................ 63

4.1.3 Work Completion Check .......................................................... 64

4.2 Disassembly....................................................................................... 65

4.2.1 Housing removal...................................................................... 66

4.2.2 OperationPanel removal ......................................................... 67

4.2.3 Printhead removal.................................................................... 68

4.2.4 CR motor removal.................................................................... 71

4.2.5 Waste drain ink pad unit removal............................................. 73

4.2.6 Circuit board removal ............................................................... 75

4.2.7 LD Roller removal .................................................................... 79

4.2.8 HP/PE Sensor removal............................................................ 83

4.2.9 Ink system unit removal (Cap & Pump unit )............................ 85

4.2.10 Paper Eject Roller removal .................................................... 87

4.2.11 PF motor removal................................................................... 89

4.2.12 CR unit removal ..................................................................... 91

4.2.13 Paper feed roller removal....................................................... 94

4.2.14 DisassemblingASF frame unit ............................................... 97

Chapter 5 Adjustment

5.1 Overview .......................................................................................... 101

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5.1.1 Required Adjustment.............................................................. 101

5.1.2 Adjustment Program feature..................................................102

5.1.3 Adjustment Program Installation Procedure........................... 103

5.1.4 Adjustment Program Initial Setting menu ............................... 103

5.1.5 Head ID Input .........................................................................103

5.1.6 Bi-D Adjustment ..................................................................... 105

5.1.7 USB ID input...........................................................................107

5.1.8 Head Cleaning Operation....................................................... 109

5.1.9 Initial Ink Charge Operation....................................................110

5.1.10 Refurbishmentfor DOA........................................................ 111

5.1.11 Protection Counter Check/Reset.......................................... 112

5.1.12 Check pattern printing.......................................................... 114

5.1.13 EEPROM check function...................................................... 115

5.1.14 CSIC Information.................................................................. 116

Chapter 6 Maintenance

6.1 Overview...........................................................................................118

6.1.1 Cleaning................................................................................. 118

6.1.2 Serv ice Maintenance.............................................................. 119

6.1.3 Lubrication.............................................................................. 119

Chapter 7 Appendix

7.1 Connector Summary......................................................................... 124

7.1.1 M ajor Component Unit ...........................................................124

7.1.2 EEPROM Address Map..........................................................127

7.2 Component Layout ........................................................................... 131

7.3 Exploded Diagram............................................................................ 133

7.4 Parts List........................................................................................... 138

7.5 Electrical Circuits.............................................................................. 141

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CHAPTER

PRODUCTDESCRIPTION

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EPSON Stylus COLOR 680/777/777i Revision B

PRODUCT DESCRIPTION

EATURES 10

1.1 FEATURES

The major features of EPSON color inkjetprinters EPSON Stylus COLOR 680/777/ 777i are:

High Color Print Quality

2880 (H) X 720 (V) dpi printing

Four Color Printing (YMCK)

Traditionala nd New Microweave

Built-inAutoSheetFeeder

Holds 100 cut-sheets(64g/m2)

Holds 10 envelopes

Holds 1 transparencyfilms

Two Built-in Interfaces

Bi-directional parallel I/F (IEEE-1284level 1 device)

USB

Windows/Macintoshexclusive

Figure 1-1. External View

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EPSON Stylus COLOR 680/777/777i Revision B

PRODUCT DESCRIPTION

PECIFICATIONS 11

1.2 SPECIFICATIONS

This section covers specificationsof the printers.

1.2.1 Physical Specification

Weight: 4.1kg (without ink cartridges)

Dimension:

Storage: 450 mm (W) x 246 mm (D) x 182 mm (H) Printing: 450 mm (W) x 547 mm (D) x 279 mm (H)

1.2.2 Printing Specification

Print Method

On demand ink jet

Nozzle Configuration

Monochrome 144 nozzles (48 x 3 staggered)

Color 48 nozzles x 3 (Cyan, Magenta,Yellow)

Print Direction

Bi-directionwith logic seeking

Print Speed & PrintableColumns

*This value is the speed of normal-dotprinting.

Control Code

ESC/P Raster command

EPSON Remote command

CharacterTables

Two international charactersets:

- PC 437 (US, Standard Europe)

Typeface

Bit map LQ font: EPSON Courier 10 C PI

Table 1-1. Character Mode

CharacterPitch PrintableColumn LQ Speed

10 CPI (Pica) 80 238 CPS*

Table1-2. RasterGraphicsMode

Horizontal Resolution

Printable Area AvailableDot CR Speed

360 dpi 8.26 inches 2976 23.8 IPS 720 dpi 8.26 inches 5952 20 IPS

1440 dpi 8.26 inches 11904 20 IPS

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EPSON Stylus COLOR 680/777/777i Revision B

PRODUCT DESCRIPTION

PECIFICATIONS 12

1.2.3 Paper Feeding

Feed Method

Friction feed with ASF

Paper Path

Cut-sheet ASF (Top entry,F ront out)

Feed Speed

2.36 inch/sec (Normal,Continuous feed)

4.5 inch/sec (Fast,Continues feed)

1.2.4 Input Data Buffer

32KB

1.2.5 Electric Specification

[120V Version]

Rated Voltage: AC120V Input Voltage Range: AC99∼132V Rated Frequency Range: 50∼ 60Hz Input Frequency Range: 49.5∼ 60.5Hz Rated Current: 0.4A Power Consumption: Approx. 17W (ISO10561 Letter Pattern)

Approx. 2.5W in standby mode EnergyStar compliant

Insulation Resistance: 100M ohms min.

(between AC line and chassis, DC 500V)

Dielectric Strength: AC 1000V rms. 1 minutes or

AC 1200V rms. 1 second (betweenAC line and chassis)

[220 ∼ 240V Version]

Rated Voltage: AC220V∼240V Input Voltage Range: AC198∼264V Rated Frequency Range: 50∼60Hz Input Frequency Range: 49.5∼60.5Hz Rated Current: 0.2 A (for Stylus Color 860)

0.2 A (for Stylus Color 1160)

Power Consumption: Approx. 17W (ISO10561 Letter Pattern)

Approx. 2.5W in standby mode Energy Star compliant

Insulation Resistance: 100M ohms min.

(between AC line and chassis, DC 500V)

Dielectric Strength: AC 1500V rms. 1 minute

(between AC line and chassis)

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EPSON Stylus COLOR 680/777/777i Revision B

PRODUCT DESCRIPTION

PECIFICATIONS 13

1.2.6 Environmental Condition

Temperature

Operating: 10 to 35°C (see the figure below for condition)

Non-operating: -20 to 60°C (with shipment container)

1monthat40°C and 120 hours at 60°C

Humidity

Operating: 20 to 80% RH

(without condensation/ s ee the figure below for condition)

Non-operating: 5 to 85% RH

(without condensation / with shipment container)

Resistance to Shock

Operating: 1G, within 1 ms

Non-operating: 2G, within 2 ms (with shipment container)

Resistance to Vibration

Operating: 0.15G

Non-operating: 0.50G (with shipment container)

Figure 1-2. Temperature/Humidity Range

1.2.7 Reliability

Total Print Volume: 50,000 pages (A4, Letter)

or 5 years although less than 50.000pagesprinting

Print Head Life: 3 billion dots/nozzle

1.2.8 Safety Approvals

[120V Version]

Safety Standards: UL1950

CSA22.2 No.950

EMI: FCC part 15 subpart B Class B

CSA C108.8 Class B

[220∼240V Version]

Safety Standards: EN60950 (VDE) EMI: EN55022 (CISPR Pub.22) Class B

AS/NZS 3548 Class B

1.2.9 Acoustic Noise

Level: Approx.47dB(A) (According to ISO 7779)

-Used media : Plain Paper

- Print Quality: Fine

1.2.10 CE Marking

[220∼240V Version]

Low Voltage Directive 73/23/EEC: E N60950 EMC Directive 89/336/EEC: E N55022 Class B

EN61000-3-2 EN61000-3-3 EN50082-1

IEC801-2 IEC801-3 IEC801-4

273035 40

Temperature (°C)

90 80 70

Humidity (%)

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EPSON Stylus COLOR 680/777/777i Revision B

PRODUCT DESCRIPTION INTERFACE 14

1.3 INTERFACE

The EPSON Stylus COLOR 680/777/777i provide USB andparallelinterface as standard.

1.3.1 Parallel Interface (Forward Channel)

Transmission Mode: 8 bit parallel, IEEE-1284 compatibility mode Synchronization: By STROBE pulse Handshaking: BY BUSY and ACKNLG signal Signal Level: TTL compatible level Adaptable Connector: 57-30360 (amphenol)or equivalent

BUSY signal is set high before setting either -ERROR low or PE high, and held high until all these signals return to theiri nactive state.

BUSY signal is at high level in the following cases:

During data entry (see data transmissiontiming).

When input data buffer is full.

During -INIT signal is at low level or during hardwareinitialization.

During printer error (see -ERROR signal).

When the parallel interface is not selected.

ERROR signal is at low level when the printeris in one of the following states:

Printer hardware error (fatal error)

Paper-out error

Paper-jam error

Ink-out error

PE signal is at high level during paper-out error.

Figure 1-3. Data Transmission Timing

* Rise and fall time of every output signal. ** Riseand fall time of every input signal. *** Typical timing for tack is shown on the following page.

Table 1-3.

Parameter Minimum Maximum

tsetup 500ns -

thold 500ns -

tstb 500ns -

tready 0 -

tbusy - 500ns tt-out* - 120ns tt-in** - 200ns

treply 0 -

tack 500ns 10us

tnbusy 0 -

tnext 0 -

DATA

databyte n

databyte n+1

-STROBE

BUSY

-ACKNLG

thold

tsetup

tstb

tready

tbusy

treply

tack

tnbusy

tnext

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EPSON Stylus COLOR 680/777/777i Revision B

PRODUCT DESCRIPTION INTERFACE 15

* A low logic level on the Logic H signal is2. 0V or less when theprinter

is powered off, and this signal is equal to or exceeding 3.0V when the printer is powered on.The receiver shall providean impedance equivalent to 7.5K ohm to ground.

Table 1-4. Typical Time of tack

Parallel I/F Mode Typical Timeof tack

High Speed 0.5us

Normal Speed 2us

Table 1-5. Signal Level: TTL Compatible (IEEE-1284 level 1 device)

Parameter Minimum Maximum Condition

VOH* - 5.5V VOL* -0.5V -

IOH* - 0.32mA VOH = 2.4V IOL* - 12mA VOL = 0.4V

CO - 50pF

VIH - 2.0V

VIL 0.8V -

IIH - 0.32mA VIH = 2.0V IIL - 12mA VIL = 0.8V

CI - 50pF

Table 1-6. Connector Pin Assignment and Signals

Pin No. Signal Name

Return

GND Pin

In/Out Functional Description

1 -STROBE 19 In

The strobe pulse. Read-in of data is performed at the fallingedge of this pulse.

2 DATA0 20 In

The DATA0 through DATA7 s ignals represent data bits 0 to 7, respectively.

Each signalis at high levelwhen data is logical 1 and low level when data is logical0.

3 DATA1 21 In 4 DATA2 22 In 5 DATA3 23 In 6 DATA4 24 In 7 DATA5 25 In 8 DATA6 26 In 9 DATA7 27 In

10 -ACKNLG 28 Out

This signalis a negative pulse indicating that theprinter can accept dataagain.

11 BUSY 29 Out

A high signal indicates thatthe printer cannot receive data.

12 PE 28 Out A high signal indicates paper-out error.

13 SLCT 28 Out

Always athigh level when theprinter is powered on.

14 -AFXT 30 In Not used.

31 -INIT 30 In

The fallingedge of a negativepulse or a low signal on this line causesthe printer to initialize. Minimum 50us pulse is necessary.

32 -ERROR 29 Out

A low signal indicatesprinter error

condition. 36 -SLIN 30 In Not used. 18 Logic H - Out Pulled up to +5V via 3.9K ohm resistor.

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EPSON Stylus COLOR 680/777/777i Revision B

PRODUCT DESCRIPTION INTERFACE 16

NOTE: In/Out refers to the direction of signal flow seen from theprinter side.

35 +5V - Out Pulledupto+5Vvia3.3Kohmresistor. 17 ChassisGND - - Chassis GND

16,33,

19-30

GND - - Signal GND

15,34 NC - - Not connected

Table 1-6. Connector Pin Assignment and Signals (continued)

Pin No. Signal Name

Return

GND Pin

In/Out Functional Description

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EPSON Stylus COLOR 680/777/777i Revision B

PRODUCT DESCRIPTION INTERFACE 17

1.3.2 Parallel Interface (Reserve Channel)

Transmission Mode: IEEE-1284 nibble mode Adaptable Connector See forward channel. Synchronization: Refer to the IEEE-1284 specification Handshaking: Refer to the IEEE-1284 specification Data Trans. Timing: Refer to the IEEE-1284 specification Signal Level: IEEE-1284 level 1 device

See forward channel.

NOTE: In/Out refers to the direction of signal flowfrom the printer’s point of

view.

Extensibility Request:

The printer responds affirmatively when the extensibilityre quest values are 00H or 04H, which means,

00H: Request NibbleMode Reverse Channel Transfer. 04H: Request DeviceID;

Return Data Using Nibble Mode Rev Channel Transfer.

Table 1-7. Connector Pin Assignment and Signals

Pin No. Signal Name

Return

GND Pin

In/Out Functional Description

1 HostClk 19 In Host clock signal. 2 DATA0 20 In

The DATA0 through DATA7 signals represent data bits 0 to 7, respectively.

Each signal is athigh level when data is logical1 and low level when data is logical0.

These signals are used totransfer the 1284 extensibility request values to the printer.

3 DATA1 21 In 4 DATA2 22 In 5 DATA3 23 In 6 DATA4 24 In 7 DATA5 25 In 8 DATA6 26 In 9 DATA7 27 In

10 PtrClk 28 Out P rinter clock signal.

PtrBusy /

DataBit-3,7

29 Out

Printer busy signal and reverse channel transferdata bit 3 or 7.

AckDataReq / DataBit-2,6

28 Out

Acknowledgedata request signal and reversechannel transferdata bit 2or 6.

Xflag /

DataBit-1,5

28 Out

X-flag signal and reversechannel

transferdata bit 1 or 5. 14 HostBusy 30 In Host busysignal. 31 -INIT 30 In Not used.

-DataAvail/ DataBit-0,4

29 Out

Dataavailable signal andreversechannel

transferdata bit 0 or4. 36 1284-Active 30 In 1284 active signal. 18 Logic-H - Out Pulledup to +5V via 3.9Kohm resistor. 35 +5V - Out Pulled up to +5V via 3.3K ohm resistor. 17 Chassis GND - - Chassis GND

16,33, 19-30

GND - - Signal GND

15,34 NC - - Not connected

Table 1-7. Connector Pin Assignment and Signals (continued)

Pin No. Signal Name

Return

GND Pin

In/Out FunctionalDescription

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EPSON Stylus COLOR 680/777/777i Revision B

PRODUCT DESCRIPTION INTERFACE 18

Device ID:

The printer sends the followingdevice ID string when requested.

When IEEE1284.4 is enabled,

[00H] [5AH] MFG: EPSON; CMD: ESCPL2, BDC, D4; MDL: Stylus[SP]COLOR[SP]XXX*; CLS: PRINTER; DES: EPSON[SP]Stylus[SP]COLOR[SP]XXX*;

When IEEE1284.4 is disabled,

[00H] [57H] MFG: EPSON; CMD: ESCPL2, BDC; MDL: Stylus[SP]COLOR[SP]XXX*; CLS: PRINTER; DES: EPSON[SP]Stylus[SP]COLOR[SP]860/1160; *XXX is 777 (for EAI spec) or 680 (for EURO/ASIA spec)

Note 1: [00H] denotes a hexadecimal valueofzero. Note2: MDL value depends on the EEPROM setting. Note3: CMD value depends on the IEEE1284.4 setting.

1.3.3 USB Interface

Standard: Based on:

“Universal Serial Bus Specifications Rev. 1.0” “UniversalSerial Bus Device Class Definition

for Printing Devices Version 1.0” Bit Rate: 12Mbps (Full Speed Device) Data Encoding: NRZI Adaptable Connector: USB Series B Recommended Cable Length: 2 meters

Figure 1-4. USB Pin Assignment

Table 1-8. Connector Pin Assignment and Signals

Pin No. Signal Name I/O Function Description

1 VCC - Cable power. Max.power consumption is2mA. 2 -Data Bi-D Data 3 +Data Bi-D Data, pullup to +3.3 V via1.5K ohm resistor. 4 Ground - Cable ground

Pin #1

Pin #3

Pin #2

Pin #4

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EPSON Stylus COLOR 680/777/777i Revision B

PRODUCT DESCRIPTION INTERFACE 19

1.3.4 Prevention of Data Transfer Ti me-out

Generally,hosts abandon data transferto peripherals when theperipheral is in the busy state for dozens of secondscontinuously. To prevent thiskind of time-out,the printer receives data very slowly,several bytes per minute, even if the printer is in the busy state. The slowdown startsw hen the remaining input buffer becomes several hundreds of bytes, and the printer finallygets into the busy state continuously when the input buffer is full. USB and IEEE1284.4 on the parallel interface do not require suchfunction.

1.3.5 Interface Selection

The printer has two built-ininterfaces: the USB and parallel interface. These interfaces are selected automatically.

AutomaticSelection In thisautomatic interface selection mode,the printer is initialized to the idlestate while scanning which interfacereceives data when it is powered on. Then the interface which received data first is selected. When the host stops data transfer and theprinter is in thestand-by state forseconds, the printeris returned to theidle state.As longasthe host sends data or the printerinterface is in the busy state,the selected interface is let as it is.

Interface State and Interface Selection When the parallel interfaceis not selected, the interface gets intothe busy state. When the printeris initialized or returnedto the idle state, the parallelinterface gets into the ready state. Notethat the interrupt signal such as the -INIT signal on the parallel interfaceis not effective while that interface is not selected.

1.3.6 IEEE1284.4 Protocol

The packet protocol describedby IE EE1284.4 standard allows a device to carry on multiple exchangesor conversations which contain data and/or control information with anotherdevice at the sametime across a singlepoint-to-point link.T he protocol is not, however, a device controllanguage. It does provide basic transport-level flow controlandmultiplexing services.The multiplexedlogical channels areindependent of each other and blocking of one has no effect on the others.The protocol operates over IEEE1284.

AutomaticSelection An initial stateis compatible interface and starts IEEE1284.4communication when magic strings (1284.4 synchronous commands) are received.

On An initial state is IEEE1284.4communication and datathat received it by thetime it is ableto take synchronizationby magic string (1284.4synchronous commands) is discarded.

Off An initial stateis compatible interfaceand never starts IEEE1284.4 communication even if magic strings(1284.4 synchronous commands) are received.

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EPSON Stylus COLOR 680/777/777i Revision B

PRODUCT DESCRIPTION

PERATOR CONTROLS 20

1.4 OPERATOR CONTROLS

1.4.1 Operating Switch

Operating switch is located on the control panel.

1.4.2 Control Panel

1.4.2.1 Switches

There are two non-lock type push switches,one lock-type push switch, and two LED lights.

Figure 1-5. Control Panel

1.4.2.2 Indicators

(1) Power

Lights when the operating switchis “ON” and AC power is supplied.

(2) Error

Lights or blinks when some error has occur to the printer.

Power

Maintenance

Ink Cartridge replacement

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EPSON Stylus COLOR 680/777/777i Revision B

PRODUCT DESCRIPTION

PERATOR CONTROLS 21

1.4.3 Panel Functions

* This function is not available in printing status.

*1 Not described in the user's manual. *2 See the table

Table 1-9. Panel Functions

Switch Function

Maintenance

• Loads or Ejects the Paper (Pushingwithin 3seconds).

• Starts the Cleaning of head(Pushing for 3seconds).

• When carriage is on the Ink Cartridge changeposition, return carriage from Ink Cartridgechange position.

Ink Cartridge replacement

• Starts the InkCartridge changesequence. *

Table 1-10. Panel Functions with Power On

Switch Function

Maintenance

• Start status printings.

Ink Cartridge

replacement

• Select IEEE 1284.4mode for parallelI/F. *1

Maintenance

Ink Cartridge

replacement

• Enters the special settingmode (Factory useonly). *3

Table 1-11. Special Setting Mod e

Switch Function

Maintenance

• Initialize EEPROM.

Ink Cartridge replacement

(10 seconds)

• Reset the ink overflow counterin the EEPROM.

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EPSON Stylus COLOR 680/777/777i Revision B

PRODUCT DESCRIPTION

PERATOR CONTROLS 22

1.4.4 Printer Condition and Panel Status

" - " : Indicator status don't change. " A -> B " : A is a indicatorcondition when carriage is on Home Position.

B is a indicator conditionin Ink exchange sequence.

1.4.5 Printer Initialization

There are three kinds of initialization methods,a nd the following explains each initialization.

1. Power-on Initialization This printer is initialized when turning the printerpower on, or printerrecognized the cold-reset command (remote RS command).

When printer is initialized, the following actions are performed: (a) Initializes printer mechanism. (b) Clears input data buffer. (c) Clears print buffer. (d) Sets default values.

2. Operator Initialization This printer is initialized when turning the printerpower on again within10 seconds from last power off, or printer recognized the -INIT signal (negative pulse) of parallel interface.

When printer is initialized, the following actions are performed: (a) Cap the printer head. (b) Ejecta paper. (c) Clears input data buffer. (d) Clears print buffer. (e) Sets default values.

3. Software Initialization The ESC@ command also initialize the printer.

When printer is initialized, the following actions are performed: (a) Clears print buffer. (b) Sets default values.

Table 1-12. Printer Condition and LED Status

Printer Status

Indicators

Priority

Power Error

Power ON condition On - 10 Ink sequence Blink - 6 Ink Cartridgechange mode Blink - 5 Data processing Blink - 9 Paper Out - On 4 Paper jam condition - On 3 Ink end (Black) - On ->Blink 8 Ink levellow (Black) - Bl ink 8 Ink end (Color) - On -> Blink2 8 Ink level low (Color) - Blink 8 Ink end

(Black andColor)

- Blink -> Blink 8

No Ink Cartridge (Black andColor)

- On 7

Reset, Timer IC reset, EEPROM clear

On (1s) On (1s) -

Ink Overflow Counter reset On (2s) On (2s) Maintenancerequest

(Ink Overflow Counter error)

Alt Blink Alt Blink 2

Fatal error Off On 1 Specialsetting Blink Blink -

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EPSON Stylus COLOR 680/777/777i Revision B

PRODUCT DESCRIPTION

PERATOR CONTROLS 23

1.4.6 Errors

Ink Out

When the printer runs out most of the ink of any color, it indicates ink-low and keeps printing. When the printerruns out the whole ink of any color, it stops printing and indicates ink-out error. User is then requested to install a new inkcartridge in this state.An ink-cartridge that has been taken out once should never be used again. Re-installationof the cartridge not filled fully upsetsthe ink level detection andmay eventually cause a serious problem in the print head.

Paper Out

When the printer fails to load a sheet, it goes into a paper out error.

Paper Jam

When the printer fails to eject a sheet, it goes into a paper jam error.

No Ink-Cartridge

When the printer detects that ink-cartridge comes off, or failed to read or write CSIC data, it goes into this errorm ode.

Maintenance Request

When thetotal amount of inkwasted through cleaningsand flushing reachesto the limit, printer indicates this error and stops. In such a case, the absorberin the printer enclosureneeds to be replaced with new one by service personnel.

Fatal Errors

Carriage control error.

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EPSON Stylus COLOR 680/777/777i Revision B

PRODUCT DESCRIPTION PAPER 24

1.5 PAPER

1.5.1 Paper Handling

Do not perform reverse feed more than 1.8mm (0.07”).

1.5.2 Paper Specification

1.5.2.1 Cut Sheet

[Size]

A4: Width 210mm (8.3”) x Length 297mm (11.7”) A5: Width 148mm (5.8”) x Length 210mm (8.3”) A6: Width 105mm (4.1”) x Length 148mm (5.8”) Letter: Width 216mm (8.5”) x Length 279mm (11.0”) Half Letter: Width 139.7mm (5.5”) x Length 216mm(8.5”) B5: Width 182mm (7.2”) x Length 257mm (10.1”) Legal: Width 216mm (8.5”) x Length 356mm (14.0”) Executive: Width 184.2mm (7.25”) x Length 266.7mm (10.5”)

[Thickness]

0.08mm (0.003”) - 0.11mm (0.004”)

[Weight]

64g/m

(17Ib.) - 90g/m2(24Ib.)

[Quality]

Exclusivepaper, Bond paper,PPC

[ASF hopper available capacity]

100 sheets

Note1: No wrinkled,scuffing, torn or folded paper be used. Note2: No curled paper more than 5 mm be used.

1.5.2.2 Transparency, Glossy Paper

[Size]

A4: Width 210mm (8.3”) x Length 297mm (11.7”) Letter: Width 216mm (8.5”) x Length 279mm (11.0”)

[Thickness]

0.075mm (0.003”) - 0.085mm (0.0033”)

[ASF hopper availablec apacity]

1sheets

Note: Transparency printing is available only at normal temperature.

1.5.2.3 Envelope

[Size]

No.10: Width 241m m (9 1/2”) x Length 104.8mm (4 1/8”) DL: Width 220mm (8.7”) x Length 110mm (4.3”) C6: Width 162mm (6.4”) x Length 114mm (4.5”)

[Thickness]

0.16mm (0.006”) - 0.52mm (0.02”)

[Weight]

45g/m2(12Ib.) - 75g/m2(20Ib.)

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EPSON Stylus COLOR 680/777/777i Revision B

PRODUCT DESCRIPTION PAPER 25

[Quality]

Bond paper, Plain paper, Air mail

Note1: Envelope printingis available only at normal temperature. Note 2: Keep the longer side of the envelope horizontally at setting. Note 3: Envelope printing isavailable only in the normal temperature. Note 4: Nowrinkled, scuffing, tornorfolded paper be used. Note 5: Nocurled paper more than 5mm be used. Note 6: No paper with glue on flap be used. Note 7: No double envelops nor withwindowenvelops be used. Note 8: Do not print on the back.

1.5.2.4 Index Card

[Size]

A6 Index Card: Width 105mm (4.1”) x Length 148mm (5.8”) A5 Index Card: Width 148mm (5.8”) x Length 210mm (8.3”) 5 x 8” Index Card: Width 127mm (5.0” x Length 203mm (8.0”) 10 x 8” Index Card: Width 127mm (5.0”) x Length 203mm ( 8.0”)

[Thickness]

Less than 0.23mm (0.0091”)

[ASF hopper available capacity]

30 sheets

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EPSON Stylus COLOR 680/777/777i Revision B

PRODUCT DESCRIPTION PAPER 26

1.5.3 Printing Area

1.5.3.1 Cut Sheet

See the figure below and tables on the right for printable areas.

Figure 1-6. Printable Area for Cut Sheet

* Bottom margin can be reduced to 3mm when paper dimensionis

defined by using command, otherwise itis not reduced (14mm). As for an area between 3mm and 14mm margin, printing quality may decline.

** Referto 1.5.2 Paper Specification for PW (paper width) and PL

(paper length).

Printable Area

Table 1-13. Printing Area

Paper Size

Left Margin

(min.)

Right Margin

(min.)

Top Margin

(min.)

Bottom Margin

(min.)

A4 3 mm (0.12”) 3 mm(0.12”) 3 mm (0.12”)

14 mm (0.54”)/ 3mm (0.12”) *

Letter 3 mm (0.12”) 3 mm (0.12”) 3 mm (0.12”)

14 mm (0.54”)/ 3mm (0.12”) *

B5 3mm (0.12”) 3 mm (0.12”) 3 mm (0.12”)

14 mm (0.54”)/ 3mm (0.12”) *

Legal 3 mm (0.12”) 3 mm (0.12”) 3 mm (0.12”)

14 mm (0.54”)/ 3mm (0.12”) *

Statement 3 mm (0.12”) 3 mm (0.12”) 3 mm (0.12”)

14 mm (0.54”)/ 3mm (0.12”) *

Exclusive 3 mm (0.12”) 3 mm (0.12”) 3 mm (0.12”)

14 mm (0.54”)/ 3mm (0.12”) *

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EPSON Stylus COLOR 680/777/777i Revision B

PRODUCT DESCRIPTION PAPER 27

1.5.3.2 Envelopes

Figure 1-7. Printable Area for Envelopes

Table 1-14. Envelope Margin

Size

Left Margin

(min.)

Right Margin

(min.)

Top Margin

(min.)

Bottom Margin

(min.)

#10 3 mm (0.12”) 28 mm (1.10”) 3 mm (0.12”) 14 mm (0.55”) DL 3 mm (0.12”) 7 mm(0.28”) 3 mm (0.12”) 14mm (0.55”)

C6 3 mm (0.12”) 3 mm (0.12”) 3 mm (0.12”) 14 mm (0.55”)

Printable Area

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EPSON Stylus COLOR 680/777/777i Revision B

PRODUCT DESCRIPTION INK CARTRIDGE 28

1.6 INK CARTRIDGE

1.6.1 Black Ink Cartridge

Type: ExclusiveCa rtridge Color: Black Print Capacity: 600 pages/A4

(ISO/IEC 10561 Letter Pattern at 360 dpi) Ink Life: 2 years from date of production Storage Temperature:

Storage: -20

Cto40oC (within a month at 40oC)

Packing: -30

Cto40oC (within a month at 40oC)

Transit: -30

Cto60oC (within 120 hours at 60oC

and within a month at 40

Dimension: 28.1 mm (W) x 66.85 mm (D) x 43.3 mm (H)

Figure 1-8. Black Ink Cartridge

1.6.2 Color Ink Cartridge

Type: Exclusive Cartridge Color: Magenta, Cyan, Yellow Print Capacity: 300 pages / A4 (360 dpi, 5% duty each color) Ink Life: 2 years from date of production Storage Temperature:

Storage: -20

Cto40oC (within a month at 40oC)

Packing: -30

Cto40oC (within a month at 40oC)

Transit: -30

Cto60oC (within 120 hours at 60oC

and within a month at 40

Dimension: 43.2 mm (W) x 66.85 mm (D) x 43.3 mm (H)

Figure 1-9. Color Ink Cartridge

Note 1: Ink cartridge can not be refilled.The ink cartridge is prepared only

for article of consumption. Note 2: Do not use the ink cartridge which contains life-expired ink. Note 3: Ink will be frozen under -4

C environment; however,it will be usable after being leftat room temperature for more than three hours.

Page 29

CHAPTER

OPERATINGPRINCIPLES

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EPSON Stylus COLOR 680/777/77i Revision B

Operating Principles

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2.1 Overview

This section describes the operating principlesof the printer mechanism and electrical circuit boards.T he Stylus COLOR 680/777/777i has the following boards:

Main board: C383 MAIN (C383 MAIN-B)

NOTE: C383 MAIN-B is compatible with C383 MAIN. Onlys ome chips or parts

are differentfrom each other due to different producers.

Power supply board: C383 PSB/PSE

Panel board: C383 PNL

2.1.1 Printer Mechanism

The printer mechanismfor S tylus COLOR 680/777/777i is designed newly.But,the basic component of the printermechanism is same as previous product. This printer consists of Print Head, Carriage Mechanism, Paper Feeding Mechanism, Paper Loading Mechanism,Ink System (Pump Mechanism, Cap Mechanism, and Carriage Lock Mechanism).

Like other EPSON ink jet printers,theStylus COLOR 680/777/777i is equipped with two stepping motors; one for ASF, Paper feeding/Pumpm echanism, and one for CR mechanism.ASF unit uses rear entryfront eject system. ThisAS F unit is also designed newly and single LD roller loadsthe paper to the printer mechanism.

For capassembly, StylusCOLOR 680/777/777iuses valveless mechanism;new design for this model.

Figure 2-1. Printer Mechanism b lock diagram

ASF Hopper Spring

CR Motor

Paper feed back plate

Paperseparationpad

Clutch mechanism

CR unit

PF Roller

HP/PE/IC Sensor sensor

LD Roller

Pump Assembly

Paper EjectRoller

Star Wheel Roller

CR Timing belt

CR lock lever

PF Motor

Cap Assembly

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Operating Principles

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2.1.2 Printhead

The printhead uses a new developed U-CHIPS headand Stylus COLOR 680/777/777i can perform multiple shot printingand variable printing.

The CSIC is mounted on the ink cartridge. By storingink life data, this IC makes it possible to control theink in ink cartridge unit.

The basic operating principles of the printhead, which playsa m ajor role in printing, are the same as previous models; on-demandm ethod which uses PZT (Piezo Electric Element). In order to uniform thea mount of ejecting ink, the printhead has its own head ID (6 digits for this printhead)which adjustP ZT voltagedrivefeatures. The printhead stores the head ID to EEPROM and generates appropriate PZT drive voltage to prevent amountof ink from varying by printheads.

Following explains printhead basic components.

PZT PZT is an abbreviation of PiezoElectric Element. Certain amount of voltage expandsa nd contracts PTZ. Thedrive wave generated onMAIN board drives PZT and PZT pushesthe top cavity which has inkstored to discharge the inkfrom each nozzle on the nozzleplate.

Ink Cavity The ink absorbed from the ink cartridgegoes through the filter and then is stored temporarilyin this tank called“cavity” until PZT is driven.

Nozzle Plate The board with nozzle holes on the printheadsurface is called Nozzle Plate.

CSIC ConnectionCircuit This circuit connectsthe CSIC mounted on the ink cartridge and the main board. One end of the wire harness connectswith theprint head cable to the main board.

Filter When theink cartridge isinstalled, if anydirt or dust aroundthe cartridgeneedle is absorbed into the head, there is a great possibility of causing nozzle clog and disturbance of ink flow, andfinally causing alignment failureand dot missing.To prevent thisproblem, a filteris set below the cartridgeneedle, where inki s filtered.

Figure 2-2. Printhead Sectional Drawing

Nozzle Selector Board

Needle

Ink Cartridge

Filter

Cavity

PZT

Nozzle Plate

CSIC

CSIC ConnectionCircuit

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Operating Principles

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2.1.2.1 Printing Process

This sectionexplains the processin which the printheads of On-Demandinkjet printers eject ink from each nozzle.

1. Normal State:

When no printing signal is sent from PC, or no PZT drivevoltage is applied, PZT does not change shape, thereforePZT does not squeezethec avity. Ink pressure inside the cavity is kept normal. (Referto Figure 2-3.)

2) Ejecting State:

When the print signal is output from the C383 MAIN board, IC (Nozzle Selector) located ont he printhead unit latches dataonce by 1-byte unit. An appropriate PZT latched by the nozzle selectoris pushed into the cavity by the common voltage applied from the main board. By this operation, ink stored in the cavity spurts out from nozzles.(Refer to Figure 2.1.2.2.)

Figure2-3. Printhead printing process

2.1.2.2 Printing Method

For print dot system, StylusCOL OR 680/777/777i has the following two kinds of printing modes.

Multiple shot printing

Variable dot printing

The above two printing modes are automaticallyselected depending on the media and the resolution setting of the printer driver. The following explains each printing mode.

Multiple shot printing This printing mode is developed to improvethe print quality on plain paper or transparenciesinlow resolution. The multiple shot printingmode uses normal dot and the number of dot shots varies from 1 shot to maximum 4 shots dependingon the print data to enable sharpi mage output even in a low resolution.

Variable dot printing This printing mode is developed to improvethe print quality on exclusive paper. This mode is basically the same as variabledot printing mode used on other products /; micro dot, middledot, and large dot compose this mode. Print dot size varies according toprint data and this mode enables even sharperimage output on exclusive paper.

Ink Path

PZT

Ink Cavity

Nozzle

Nozzle plate

PZT drive voltage

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Operating Principles

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2.1.3 Carriage Mechanism

The carriage mechanism consistsof Carriage motor (CR motor), Carriage unit (including printhead), CR timing belt, CR guide shaft, CR guide frame, CR home detector (HP/PE sensor)etc. The carriage mechanism moves the carriage back and forth according to the drive from the carriagemotor. The following stepping motor is mounted to drive CR mechanism.(See the table below.)

Table 2-1. Carriage Motor Specification

The drive from CRmotoris transferred to the CR unit via CR timingbelt. And the CR home position is detected with the HP/PE sensor. This sensor is available as CR HP detector only in the HP (home position)detection sequence & pump operation sequence. (notavailable in the paper feeding sequencefor the CR HP detector because it is used for only PE sensor during the paper feedingsequence.) Moreover, unlike the previous products,this printer dose not have the PG adjustment mechanism (1.7mm).

Figure 2-4. Carriage Mechanism (Top view)

CR home positionis detected withthe HP/PE/IC sensor andthedetection plate molded in the CR unit as following figure.When the CR home position is detected with this sensor, HIGH signal is output to the CPU.

Figure 2-5. CR h ome position

Items Specifications

Type 4-Phase/ 200-Pole HB Stepping motor Drive Voltage +42 V +/ - 5% (DRV IC voltage) Coil Resistance 7.8 Ω +/ - 10% (per phase at 25 degree) Inductance 14 mH +/ - 20%(1KH 1VmA) Drive Method Bi-Polar drive Driver IC LB11847

CR unit

CR Guide shaft

CR Timing belt

HP/PE Sensor

CR Motor

Right side view

CR HP detection p late

HP/IC detection L ever

Low signal

High signal

HP detectionLever

CR HP detection plate

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Operating Principles

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2.1.4 Paper Feeding Mechanism

The paper feeding mechanism consists of Paperfeed motor (PF motor), PF roller, Paper eject roller, Star wheel roller, and so on. The paper feeding mechanism feeds paper loaded from ASF using the PF roller and PaperEjectRoller & Star wheel roller. For this mechanism,theP F m otor mentioned in the right Table 2-2 is used on this product.

The drive of the PF motor is transfer to the PF rollerand the Paper Eject Roller as following Figure2-6. Followingshows you how to transfer the PF motor drive to the PF rollerand the Paper Eject Roller.

PF motor drive transmission path

PF Motor PinionGear(CW)

→ CombinationGear 16, 21.6 (CCW) → Spur Gear 73.6

(CW) → Spur Gear 15 (CCW)→

Combination Gear 37.6,44.4 (W)→ SpurGear 23.2

(CCW) →

Spur gear 35.2(CW)

Table 2-2. PF Motor Specifications

Figure 2-6. Paper Feeding Mechanism

Paper loaded from ASF is advanced by the followingroller.

Paper feed roller & Paper guide roller(assembled on the Top Frame) → Paper

eject roller & Star w heel roller (assembled onthe Paper ejectframe).

Additionally, the top & end of the paper is detected with the HP/PE sensor. In case the PE sensor dose not detect the paperin the paper loading sequence, the printer detects the “Paperout error”. If the paperis detected after complete the paper eject sequence, the printer detects the “Paper jam error”.

Item Description

Motor type 4-Phase/ 200-Pole HB Stepping motor Drive voltage +42 V +/ - 5% (DRV IC voltage) Coil Resistance 7.8 Ω +/ - 10% (perphase) Inductance 13.5 mH +/ - 20%(1kH1Vrms) Driving method Bi-Polar drive Driver IC LB11847

PF roller

Spur Gear 15

Spur Gear 35.2

Spur Gear 23.2

Combinationgear

37.6, 44.4

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Operating Principles

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2.1.5 Paper Loading Mechanism (ASF Unit)

The Paper loading mechanismis positioned at the printer rear. The Paper loading mechanism loads paper at the ASF unit and feeds paper tothe PF roller.

This ASF unit was designed newly for this product and consistsof LD roller, Pad holder (Paper return plate),ASF Frame, Hopper, and so on. For the major feature of this ASF unit, ASF HP sensor isnot used andthe singleLD roller is builtin the ASF unit. Drive sent from the PF motor is always transmittedto the ASF unit side. But, the Change lever and theClutch mechanism switchON/OFF the PF motordrive to the LD roller with the motor rotational direction.

Drive from the PF motor is transmitted to the ASF unit as described below:

Switch the PF motor drive to ASF unit side

PF Motorpinion gear rotatesCCWdirection witha specific steps

→ Combination

Gear 16, 21.6 (CW)

→ Spur Gear 73.6(CCW) → Spur Gear 15(CW) →

Combination Gear37.6, 44.4 (CCW) → Change Lever rotates (CCW) → Release

the Clutch mechanism lock position

Following Figure 2-7 shows you the switching path for PF motor drive to ASF unit side.

Figure 2-7. Switch the PF motor drive to ASF unit side

Transfer the PF motor drive to LD roller

PF Motor pinion gear rotates CW direction

→ Combination Gear 16, 21.6 (CCW)

→ Spur Gear 73.6(CW)→ Spur Gear 15 (CCW) → Combination Gear37.6, 44.4

(CW)

→ Change Lever rotates(CW) → Spur Gear 23.2 (CCW) → SpurGear 35.2

(CW) (include the clutch mechanism)→ LD roller (CW).

Following Figure2-9 shows the PF motor drive transmission path to the LD roller unit built in the ASF unit. The LD rolleri s assembled on the same shaft that the Spur gear

35.2 is assembled.

Figure 2-8. PF motor drive transmission path

When the PF motor torque is switched to the ASF unit sideby the clutch mechanism, the function of the ASF mechanism varies depending on the rotationaldirection of the PF motor, as shown in the table below.

Table2-3. ASF unit function & PF Motor rotationaldirection

(*1): The PF Motor rotational direction = seen from the right side of the printer.

Clutch Mechanism

Unlike the previous products,this product dose not have a ASF HP s ensor. Instead of the ASF HP sensor, Change lever and the Clutch mechanism are used to detect the ASF home position.Following figures describe the mechanism.

Spur Gear 35.2

Spur Gear 23.2

Combination Gear

37.6, 44.4

Change Lever

Spur Gear 15

Directions Corresponding Functions

Clockwise (*1)

• Picks up and loadspaper

Counterclockwise (*1)

• Release the DElever & Clutch mechanism

Spur Gear 35.2

Spur Gear 23.2

CombinationGear

37.6, 44.4

ChangeLever

Spur Gear 15

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Operating Principles

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Figure 2-9. Disengage& Clutch mechanism

The Clutch mechanism transmits the PF motor drive to the LD roller shaft only when the Clutch gear rotates CW direction after the Change lever releases the Clutch lever. If the Clutch gearrotates CCW direction,the PF motor drive is not transmitted to the LD roller. Thisis due to the combination of the shape of the Clutch gearand the Clutch lock tooth such as describedon thefigure.

1. When the paper is advanced with the PF roller, theC hange lever is set on the

Clutch lever a nd the Clutch is pushed down as above Step1’s figure. As the result, the Clutch gear(*1) is releasedfromthe Cluck lock tooth and the drive from the PF motor is not transmitted to the LD roller shaft.

2. When the PF pinion gear rotates CCW directionin the above Step2’s figure, the

Change lever moves to theleftdirection with the CCW rotation of Combination gear 37.6, 44.4. The Clutchturnsback to the engagement position by the tension force of the Tension spring 0.143a nd the Clutch gear is engaged with the Clutch lock tooth as above Step2’sc enter figure.

3. When the PF pinion gear rotates CW directioni n the above Step3’s figure, the

Change lever moves to the rightdirection with the CW rotation of the Combinationgear 37.6,44.4. And thedrive from thePF motor is transmittedto the LD roller shaft via Clutchge ar and Clutch lock tooth.

4. The LD rollershaft rotates about 360degree and the Change leverpush the Clutch

lever and the PF motor drive is interrupted. This position is the ASF home position.

Paper Return Plate (Pad holder)

Unlike the previous products,T he Paper return plateis built in the ASF frame instead of the Paper return lever. The Paper separationpad is also stackedon the plate. It works with the spring force of the Torsion spring 25.7 (mounted in the ASF frame) as following figure.

Figure 2-10. Paper Return Plate

The Paper return plate is set to return the paper to the paper stand-by position in the ASF unit when the ASF unit is in the standby mode. When the paper is fed with the LD roller, the Paper return plateisstored in the ASF frame by the LD roller.

Following figures showyou the ASF paperl oading sequence and the operation of the each mechanism.

Change Lever

Clutch gear

Clutch

Step1

Step2

Step3

Clutch lev er

Clutch lock tooth

Tension spring 0.143

LD rollershaft

Spur gear 35.2

NOTE:

TheClutchgearismoldedon thebacksideoftheSpurgear

35.2such as Combinationgear.

LD roller

ASF frame

Torsion spring 25.7

Paper Return

Plate

Hopper

Compression spring 4.80

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Operating Principles

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Figure2-11. ASF Paper Loading Sequence

When the p aper is advancedwith the PF roller, Change lever push down the Clutch lever as right figure an d the Clutch lock tooth is disengaged from the Clutch gear. As theresult, the drive from the PF motor is interrupted andthe LD roller dose not rotate. This position is the ASF home position. The Paperreturn plateis set to avoidthat the paperis slipped down from the paper setposition.

When the paperis loaded(pick up) from the ASF unit, the Change lever moves to the printer front side with the CCW rotation of the PF motor pinion gear and releases the Clutch lever. As the result, the Clutch turns back to the engagement position by the tension force of the Tension spring 0.143. And the Clutch locktooth isengaged with the Clutch gear as right figure.

The PF motorpiniongear rotates CW direction and the drive from the PF motor is transmitted to the ASF LD roller shaft through the Clutch lock tooth and the Clutch gear. The ASF hopperrelease leverrotates with the ASF LD roller and release the ASF Hopper. The ASF hopper is pushed with the Compression spring

4.80 and thepaper is pickedup with theASF LD roller.

The ASFLD rollerrotates CW direction moreover and the Paper r eturn plate is stored under the ASF frame. The paperis advancedup to the PF roller. and the ASF LDroller &the clutch rotate to the “Step1” position. The Clutch lever is locked with the Change lever. The drive fromthe PF motor is interrupted and the drive is transmitted to the PF roller side.

Step 1

Step 2

Step 3

Step 4

Change lever

Clutch lever

Clutch

LD roller

Hopper

Paper return plate

Clutch g ear

LD rollershaft

Printer front side

PF motor pinion

gear CCW rotation

Tension spring 0.143

PF motor pinion

gearCW rotation

Clutch lock tooth

PF motor pinion

gearCW rotation

LD roller shaft

ASF Hopper release lever

Compression

spring 4.80

ASF Frame

Paper return plate

PF motor pinion

gear CW rotation

ASF hopper

releaselever

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Operating Principles

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2.1.6 Ink System Mechanism

Ink system mechanism consistsof pump unit (include theCR lock lever)and capping mechanism. Ink system mechanism drives the pump unit thatpresses cap to the printhead and ejectsink from ink cartridge, head cavity and cap to the waste ink pad.

2.1.6.1 Pump Unit & Wiper mechanism

The pumpunit is driven byPF motor. PF motor driveis always transmittedto the paper feeding mechanism and pump unit throughthe following gears. Refer to the Figure 2-13.

PF Motor Pinion Gear(CW)

→ Combination Gear 16, 21.6 (CCW)→ Spur Gear 73.6 (CW)

→ Spur Gear 15 (CCW) → Combination Gear37.6, 44.4 (CW) → SpurGear 36.8 (CCW) →

Combination Gear9.6, 24 (CW)→ Pump Unit Gear (CCW)

The Pump unit and Wiper mechanism drivesaccording to the PF motor rotational direction, as shown in the right table.

Table 2-4. PF motor rotational direction & Ink System Mechanism

(*1): The PF Motor rotational direction = seen from the right side of the printer. Following figure shows the overviewof the pump mechanismoperation.

Figure 2-12. Pump mechanism

Figure 2-13. PF motor drive transmission path to the Pump unit

Directions Functions

Counterclockwise (*1)

• Sets the wiper.

• Absorbs ink by thepump unit

• Set the CR lock lever

Clockwise (*1)

• Resets the wiper.

Combination Gear

37.6, 44.4

Spur Gear 15

Combination Gear 9.6, 24

SpurGear36.8

Pump Unit Gear

Capunit

Pumpunit

CR lock lever

Wiper

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2.1.6.2 Capping Mechanism

The cappingmechanism coversthe printheadsw ith the capholder to preventthe nozzle from increasing viscosity when the printer is in stand-by mode or when the printer is off. This product has valveless cap system. Air valve function usedfor the previous models pumps ande jects ink only inside the cap by absorbingink with the valve open. By openingthe Air valve,t he negative pressureis decreased and onlythe ink insidethe cap is ejected. (the ink is not absorbed from Ink cartridge or head cavity.) But, valvelesscapsystem, this operation is done out side of the capping area. The CR movesto left side of theCap assembly and the pumpabsorbs the ink insidethe cap.

Figure 2-14. Cap M echanism

CR unit

Cap

Viewed from front side

Printhead

Slider cap

Waste Ink tube

Slide up

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Operating Principles Electrical Circuit Operating Principles 40

2.2 Electrical Circuit Operating Principles

The electric circuitof the Stylus COLOR 680/777/777i consists of the following boards.

Main board: C383 MAIN Board

Power supply board: C383 PSB/PSE Board

Panel board: C383 PNL Board

This section provides operating principlesof C383 Board and C383 PSB/PSE Board. Refer to Figure 2-15 for the major connection of the each boards and their roles.

Figure 2-15. Electric Circuit

2.2.1 C383 PSB/PSE board

The power supply boards of Stylus COLOR 680/777/777iuse a RCC (Ringing Chalk Converter)circuit, which generates +42VDCfor drive linea nd +5VDC for logicline to drive the printer. The application of the output voltage is described below.

Table 2-5. Application of the DC Voltages

AC voltage input from AC inlet first goes throughfilter circuit that removes high frequency components and is then converted to DC voltage via the rectifiercircuit and the smoothing circuit.DC voltage is then lead tothe switchingcircuit and FET Q1 preforms the switching operation. By the switching operation of the primary circuit, +42VDC is generated and stabilizedat the secondarycircuit. This +42VDC generated by the secondary circuit is converted to +5VDC by the chopping regulator IC of the secondary circuit.

Voltage Application

+42VDC

• Motors (CR Motor, PFMotor)

• Printhead commonvoltage

• Printhead nozzle selector 42V drive voltage

+5VDC

• C383MAIN control circuit logic

•Sensor

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Operating Principles Electrical Circuit Operating Principles 41

Figure 2-16. C383PSB/PSE B oard Block Diagram

The C383 PSB/PSE board has the various control circuits to stop voltage outputif a malfunctionoc curs on the power supply boardor the main board whilet he printer mechanism is on duty. Following explains each control and protectioncircuit.

1. Regardless of the state of the power switch (On or OFF), the voltage is always applied to the primary side of the power supply board from themomentor at the state that AC-plug is plugged in.At this time, F1 playsa role of preventing AC100V from coming into the F1. L1 also prevents high harmonic wave noise generated in the RC circuit filter which consists of C1 from going out, and eliminates the noise from outside here.

2. The AC is full-wave rectified by the diode bridge DB1, and converted to x AC in voltage by the smoothing electrolytic capacitor C11.

3. The pressured up direct current turns Q1 on through the starting resistorR31 and starts the primary side of the circuit.

4. When the primary side is On, the energy (current) led by the electromagnetic induction through thetrans (T1) does not flow to the secondary side since the diode (D51) on the secondary side isinstalled in the opposite direction.

5. When the energy which is charged in the trans is reachingthe saturated state, the voltage whichmakes Q1 on becomesweak gradually.At the point thatthis voltage drops at the certain voltage,C13 a bsorbs the current in the opposite direction and Q1 is quickly shut off by the resulting sharp drop.

6. When the primary side is turned off, the energy charged in the T1 is opened according to the diode(D51)direction which is installed on the secondary side. Basically, 42 V DC is output by these circuit operations and the numberof T 1 spiral coil.

7. +5VDC is generated by pressured down this +42VDC as power supply. IC51 pressures down the +42VDC and generates precise +5VDC by chopping off the output, forming the standardsantooth wave form by the outer RC integration circuit.

The C383PSB/PSE board has the variousc ontrol circuits to stop voltage output if a malfunction occurs on thepower supplyboard or the main board or while the printer mechanism is on duty. Following explains each control and protection circuit.

+42V Line Constant Voltage ControlCircuit: The output level of the +42V lineism onitored by a detection circuit composed of the seven Zener diodes. This circuitprevents the voltage from dropping for a constant level of the outputvoltage.

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Operating Principles Electrical Circuit Operating Principles 42

+5V line over voltageprotection circuit: This protectioncircuit is in the same line as the +42V over voltage protection circuit islocated. The output voltagelevel of the +5V line ism onitored by a Zener diode. This circuits huts down the +5V line forcefully when the voltage level exceeds+9V.

+42VDC line drop limitationcircuit: This protection circuitis in the sameline as +42V overvoltage protectioncircuit is located. The outputvoltage level of the +42V line is monitored by a Zener diode. This circuit shuts down the +42V line forcefully when the voltage level drops to +36V.

+42VDC line over voltage circuit: This circuit is in the same linea s +5V line over voltage protection circuit is located. The output levelis monitored by two Zener diodes. If the voltage level exceeds +48VDC, this circuit shuts down the +42V line forcefully.

+5V line constant voltage/constant current controlcircuit: The output current is monitoredby the +5VDC generationswitching control IC (IC51), which also monitorstheoutput voltage. This information is input to the internal comparator and stabilizes +5V line. The operations of the secondary side switch are explained below.

When the power is turned on, Q1 repeats on/off automatically along with the increase and decrease of energy on the trans coil at the primary side. While the power is on, the PSC signal is input to the power supplyboard from the C383MAIN board.

Thissignal turnsQ84 on andit becomespossible todischarge energybetween the terminals8 and 9 of T1. At this time, even if the power is turned off, the electrolyticcapacitor keeps Q84 on for a while, and by this electrolytic capacitor,voltage output is held at least 30 seconds. This time helps the printer to complete a power-off operation.

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Operating Principles Electrical Circuit Operating Principles 43

2.2.2 C383 MAIN Board

The printer mechanism is controlled by C383 MAIN. See Figure for the C383 MAIN board block diagram.

Figure 2-17. Block Diagram for the C383 MAIN Board

Following shows you the major characteristic of this main board.

Use of the 3.3V chips in the logic circuit The 3.3 V regulator (IC11) onthe C383MAIN produces 3.3 Vby pressuring down the 5.5 VDC, also generated on this board, to drive several chips. See the table below that separately showsthe chips driven by the +5V and +3V.

Table 2-6. 3.3V Drive Chips & 5.5V Drive Chips

Timer IC& Lithium battery are not mounted Unlike the previous products,the Timer IC a nd the Lithium battery are not mounted on the Main board. So, this product performthe Power-onc leaning or Timer cleaning basedon the time command which is sent from the printer driver.

D-RAM 4Mbit and 16Mbit D-RAMS are mounted on the Main board.

One CPU controls the all function on the main board.

+5V 3.3V

Sensors I/F Circuit PNL Board

CPU P-ROM D-RAM

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Operating Principles Electrical Circuit Operating Principles 44

2.2.2.1 Main elements

Table 2-7 shows the function of the each main elementson C 383 MAIN.

Table 2-7. Main Elements

IC Location Function

CPU E01A15CA

IC9

16bit CPU mounted on the MAIN board is driven by clock frequency 24MHz and controls theprinter.

PROM IC1

• Capacity 8/16/32/64MB, Bus= 16 bit

•ProgramforCPU

RAM IC5,IC8 Bus= 16 bit, 4Mbit DRAM and 16Mbit DRAM

EEPROM IC15

1kbit EEPROM

• Default value setting

• Parameter backup

Reset IC IC16

Reset IC

• For +5V; reset when +4.2V is detected

• For +42V, reset when +33.2 is detected

Common Driver IC10

Head drive control HIC

• Generates head common voltage. Motor Driver IC12 CR motor drive IC Motor Driver IC13 PF motor driveIC ParallelI/F IC IC6 IEEE1284 parallelI/F transceiver IC. USB IC IC2, IC3 USB transceiverIC

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Operating Principles Electrical Circuit Operating Principles 45

2.2.2.2 Printhead Driver Circuit

The printhead driverc ircuit consists of the following two components:

Common driver IC (IC10:E09A14RA) directly attached to the C383MAIN board.

Nozzle selector IC on the head board.

The common driver (IC10:E09A14RA) generatesa referencedrive waveform according to the output signalsfrom the C383MAIN board. The reference drive waveform is amplified by the transistorsQ2 and Q3and then transferredto the nozzle selector IC on the head board. Print data is convertedto serialda ta by the CPU (IC9) and then sent to the nozzle selectorIC on the head board.Based on the serial data, the nozzle selector IC determines the nozzles to be actuated. The selected nozzles are driven by the drive waveforms produced by the common driver. See Figure 2-18 for the printhead driver circuit block diagram.

Head commondriver circuit The reference head drivewaveformis producedin the common driver (IC10:E09A14RA)based on the following 12 signal lines output from the ASIC (IC8 E05B70CD); A0-A4, CLK1, CLK2, RST, FLOOR, DATA, DCLK, and E. By the DATA signal output from the CPU (IC9), the original data for the head drivewaveform is writtenin the memoryinthe IC10. Theaddresses for thewritten data are determined by the A0 - A4 signals,and, of among, data used to determine the waveform angles is selected. Then, setting the selected data, producing trapezoid waveform value,and cancelingthe data are performed by the rising edgesoftheCLK1andCLK2signals.

Head nozzle selectorcircuit Printing data isconverted into serial data by the CPU (IC9). Then the converted data is allocatedto the six rows, the numberofthe head nozzlerows, to be transferredto the nozzle selector throughthe six signallines (HS01 to HS06).Data transmissionfrom the CPU(IC9) to the nozzleselector synchronizeswith the LAT signal and SCK clock signal. Referring to the transferred data, nozzles to be activatedareselected, and the PZTs oftheselected nozzles are driven bythe drive waveform output from the head common driver.

Figure 2-18. Printhead Driver Circuit

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Operating Principles Electrical Circuit Operating Principles 46

2.2.2.3 PF Motor (PF/ PUMP/ ASF Motor) Driver Circuit

The motor driver IC (IC13) on the MAIN board drives PF motor. This product uses 4phase 200-pole hybrid type steppingmotor and performs constant currentbi-polar drive.

CPU (IC9) converts PF motor phase control signal to LB11847 micro step drive form and outputs to motor driver IC (IC13)LB11847 from port 101,112. Based on this signal, IC13 determinesthephase mode.

The current value on each phase is determinedby CPU (IC9) and outputs from port 104, 105, 107, 108, 109, 110 to driver IC (IC13). Motor driverIC generates motor driverwa veform based on theseinput signals andcontrols the motor. Ifthe printer dose not receive any datafrom PC for 5 minutes, CPUset the motor drivecurrent to 0 via port 104, 105, 107, 108, 109, 110 and the motor drive is turnedoff to save the power consumption.

Figure 2-19. PF Motor Driver Circuit Block Diagram

2.2.2.4 CR Motor Driver Circuit

The motor driver IC (IC12) on the MAIN board drives PF motor. This product uses 4phase 200-pole hybrid type steppingmotor and performs constant current bi-polar drive.

CPU (IC9) converts PF motor phase controlsignal to LB11847 micro step drive form and outputs tomotordriver IC (IC12) LB11847 from port 81,94. Based on this signal, IC12 determines the phase mode.

The current valueon each phase is determined by CPU (IC9) andoutputs from port 83, 84, 85, 86, 87, 88, 90, 91 to driver IC (IC12). Motor driver IC generates motor driver waveform based on these input signals and controlsthe motor. If the printer dose not receive any data from PC for 5 minutes, CPU set the motor drive current to 0 via port 83, 84, 85, 86, 87, 88, 90, 91 and the motor drive is turned off to save the power consumption.

Figure 2-20. CR Mot or Driver Circuit Block Diagram

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Operating Principles Electrical Circuit Operating Principles 47

2.2.2.5 Reset Circuit

Reset circuits consistof the rest IC (IC16). Reset circuits are mounted on the MAIN board to monitor the two voltages:+5V for the logic line and +42V for the drive line. When each circuit detects abnormality on the corresponding line, it outputsa reset signal to reset CPU (IC9). This function is necessary to prevent the printer from operating abnormally. This IC monitors both +5V and +45 lines but can reset them independently. The resetcircuits outputs reset signal when +5V line becomes 4.2V or loweror+42Vlinebecomes33.2Vorlower.

Unlike the previous products, the timer IC is not built in the reset IC and the Lithium battery alsois not equipped on the main board.

Figure 2-21. Reset Circuit Block Diagram

Main signal linesare explained below;

OUT1: Interrupt signal

OUT2: Resetline

IN: +42V line monitoringline

VCC: +5V line monitoring line

2.2.2.6 EEPROM Control Circuit

Since EEPROM is nonvolatile memory,it keepswritten information if the printer power is turned off. When the printer is turned ON, CPU (IC9) reads data from EEPROM (IC15) and when the power is turned OFF it stores data to EEPROM.

Information stored in EEPROM is listed below.

Various ink counter (I/C consumption counter, waste pad counter,etc.)

Mechanicalsetting value (HeadID, Bi-D adjustment,USB ID,etc.)

See Table 7-9, “EEPROM Address Map,” on page 127 that providesdetailed information on the values stored in EEPROM.

Figure 2-22. EEPROM Circuit Diagram

EEPROM is connected to CPU with 4 lines and each line has the followingfunction.

CS: Chip selection signal

CK: Data synchronism clock pulse

DI: Data writing line (serial data)at poweroff.

DO: Data reading line (serial data)at power on.

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Operating Principles Electrical Circuit Operating Principles 48

2.2.2.7 Sensor Circuit

C383 MAIN is equipped with the followingtwo sensors to detect the status of the printer. Unlikethe previous product, ASF HP sensor is not equipped on the ASF and the ASF HP is determinedw ith the clutch mechanism (2.1.4 PaperFeeding Mechanism).

HP/PE Sensor

This sensor usesphotointerrupter method and detects the following three status. The photo interrupt componentand two detection levers consists of this sensor.

CR home position The CR home position is detectedon theright edge of the CR shaft with the HP/PE sensor during thepower on sequence. In case the CR home position is detected in the power on sequence, this sensor outputs HIGH signalto the CPU. When the LOW signal is output to the CPU in the detection position, the CR unit is out of home position.

Paper Top & End position When the Paper isin the paperpath, this sensor outputs the HIGH signal. When the Paper is not in the paper path, thissensor outputs the LOW signal. This status is always monitoredduring the printer is in the power on status with this sensor.

Thermistor(THM)

The thermistor is attacheddirectly on the printhead driver board. It monitorsthe temperature aroundthe printhead and determines the proper head drive voltage according to the ink viscositythatvaries by the temperature. This information is fed back to the CPU analog port. When the temperature rises, the head drive circuit lowers the drivevoltage: When the temperature lowers, the head drive circuit risesthe drive voltage.

The block diagram for the sensor circuitis shown below

Figure 2-23. Sensor Circuit Diagram

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CHAPTER

TROUBLESHOOTING

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verview 50

3.1 Overview

This chapter describes how to identify troubles in two levels:unit level repair and component level repair.Referto the flowchartin this chapter to identify the defective unit and performcomponent level repair if necessary. This chapteralso explains motor coil resistance, sensor specification and error indication.

Figure 3-1. Troubleshooting Flowchart

START

Unit level Troubleshooting

Unit repair

Assemble& Adjustment

END

Table 3-1. Motor, Coil Resistance

Motor Location Check Point Resistance

CR Motor CN12

Pin1and3 Pin2and4

7.8 Ohms

± 10%

(at 25

°C/ phase)

PF Motor CN7

Pin1and3 Pin2and4

7.8 Ohms ±10% (at 25

°C/ phase)

Table 3-2. Sensor Check Point

Sensor Name Check Point Signal Level Switch Mode

HP/PE Sensor CN4/Pin 1 and 2

Less than0.7V

Off

• Out of HP range

•Nopaper

•DetecttheI/C

More than2.4V

• Within HP range

• Detect the paper

• Not detects the I/C

Thermistor (THM)

TH1 (on theHead driverboard)

Analog signal 10 K (at 24

°C)

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3.2 Troubleshooting with LED Error Indications

This section describes how to troubleshoot the problemwhen the printer indicates an error at power on and can not print. The Stylus COLOR 680/777/777i candetectthe following six errors andsevens tatus, and indicates them with the LEDs, as shows below.

" - " : Indicator status don't change.

" A -> B " : A is a indicator condition when carriage is on Home Position.

B is a indicator conditionin Ink exchange sequence.

See the following tables which show the error conditions and corresponding possible causes:

Table 3-3. Error Indicator of Operation Panel

PrinterStatus

Indicators

Priority

Power Error

Power ON condition On - 10 Ink sequence Blink - 6 Ink Cartridge change mode Blink - 5 Data processing Blink - 9 Paper Out - On 4 Paper jamcondition - On 3 Ink end (Black) - On -> Blink 8 Ink level low (Black) - Blink 8 Ink end (Color) - On -> Blink2 8 Ink level low (Color) - Blink 8 Ink end (Black and Color) - Blink -> Blink 8 No InkCartridge (Black and Color) - On 7 Maintenance request

(Ink Overflow Counter error)

Alt Blink Alt Blink 2

Fatal error Off On 1

Table 3-4. Error Condition and possible cause

Symptom Possible Cause Checktable

Paper out error indication (Paper is not loaded correctly)

• The frictionof the LD rolleris lowered due to the paper dust.

• The clutch mechanism is broken.

• Tension spring0.143 comeoff in the clutch mechanism.

• Compression spring0.98 comes off.

• Tip of Change leverhas any damage.

• PF motor is broken.

Table 3-5 Table 3-6 Table 3-7

Paper jam error indication

• Star wheel assembly is not assembled on the Paper eject frame.

• The Spur gear 15 is not assembled correctly.

• The paper guide front is notassembled correctly or hasany damage.

• The PE detectionlever dose not move smoothly.

Table 3-8 Table 3-9 Table 3-10

No I/C or Ink Out e rror indication

•

Multiplepapers arealways loaded

• The paper return plate dose not work correctly.

Table 3-12

Paper is always loaded without any print job

• The Change lever isbroken in the Clutch mechanism.

Table 3-13

Fatal errorindication

• HP sensor lever orPE sensor lever dose not move smoothly.

• HP/PE sensor is defective.

• CR motor is defective.

• PF motor is defective.

• Main board is defective.

• Printer Housingdose not securedwith screw on -the printer mechanism.

Table 3-14 Table 3-15 Table 3-16

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If the problemfits to the detailphenomenon in thetable, make sure thecheck point and repair the product followingthe corresponding remedy mentioned in the table when you find the defective partsin the check point.

Any errorindication isnot displayed. But, the paper is not ejected completely. Paper j am dose not occur.

• Paper eject rollergear is disengaged from the pump’sgears.

• The Paper eject frame is not assembled in the Papereject frame.

Figure 3-17

Dot missing occur andit is not recovered with CL

• Pump unit dose not absorb the inkfrom the printhead.

• Cap unit dosenot stickon the surface ofthe printhead completely.

• The printhead is broken.

• The head FFC has any damage.

• The main board isdefective.

Figure 3-18 Figure 3-19 Figure 3-20

Print quality is not good

• Vertical banding

• Horizontal banding

• Printing is blurred

• Ink stains the paper

• The accuracy of theCR motor is lowered.

• The lack of thelubricant around the CR unit.

• The both I/C is not held in the CR unit securely.

• The Paper eject frame is deformed.

• Any foreign material is sticking around the printhead.

• Paper feed accuracy is lowered.

• Printer driver setting is not suitable.

• Paper path has inkstain somewhere.

Table 3-21 Table 3-22 Table 3-23

Table 3-4. Error Condition and possible cause (continued)

Symptom Possible Cause Checktable

Table 3-5. Paper out error indication

Step

No.

Detail phenomenon Check point Remedy

ASF LD roller attempt to loadthe paper. But, paperis not loaded at all. The LD roller seems slipping.

• Check the surface of the LD roller if the micropearl or severe smear is adhered.

If it is no problem, proceed the next step.

• Set a cleaning sheet in the ASF upside down. Then holding the top edge, tryto load the paper fromthe Printer driver. The micro pearl on the LD roller surface is removed. To remove severe smear, staple a cloth moistened with alcohol to a post card and clean the roller in the same manner.

• If the problem isnot solved, replace the LD roller with new one.

LD roller

C L S h e e t

N o n - a d h e s i v e A r e a

A d h e s i v e A r e a

T h i s s i d e d o w n

( U s e a p o s t c a r d f o r t h e b a s e s h e e t . )

S t a p l e r s

C l o t h m o i s t e n e d w i t h a l c o h o l

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Table 3-6. Paper out error indication

Step

No.

Detail phenomenon Check point Remedy

ASFLD rollerdose not attempttoloadthe paper. But, the PF motorandthe Spurgear

35.2 is rotating.

• Check if the clutch tooth is broken.

If it is no problem, proceed the next step.

• Replace the clutch mechanism with new one.

ASFLD rollerdose not attempttoloadthe paper. But, the PF motorandthe Spurgear

35.2 is rotating.

1. Check if the tension spring 0.143 comes off in the Clutch mechanism.

1. Se the t ension spring

0.143 in the clutch mechanism.

2. Set the Compression spring 1.47 in the Change lever.

Spur gear 35.2

Clutch tooth

Tension spring

0.143

Table 3-7. Paper out error indication

Step

No.

Detail phenomenon Check point Remedy

When the print data is sentto theprinter,ASF LD rollercontinue to load thepaper even if thefirst paperis loaded to thePF rollerand the paper is ejected while the ASF hopper is flapping.

1. Check if the tipof the Change leverhas any damage.

2. Check if the Compression spring

1.47 comesoff from theChangelever.

If it isno problem, proceed the next step.

1. Replace the Change lever with new one.

2. Set the Compression spring 1.47 in the Change lever.

Whenthe printeris turnedon, ASFhopper dose notoperate at all in the power on sequence.

1. Check if the PF motor connectoris connected to theCN7.

2. Check if the PF motor coil resistance isabout

7.8 ohm byusing tester Refer toTable 3-1.

1. Connect the PFmotor connectorto the CN7 on the Mainboard.

2. Replace the PFmotor with new one.

3. If the problem is not solved,replace the Main board with new one.

Change lever

comp. spring 1.47

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Table 3-8. Paper jam error indication

Step

No.

Detail phenomenon Check point Remedy

Paper i s not ejected completely and jammed around the Paper eject frame.

• Check ifthe starwheel assemblyis assembled in the Paper eject frame.

If it isno problem, proceed the next step.

• Remove the jammed paper andassemble the Star wheelassembly in the Papereject frame completely. If thehook portionof the Star wheelassembly is broken, replace the Star wheel assembly with new one.

2 Ditto

• Check if the Paper eject roller is rotating correctly.

If it isno problem, proceed the next step.

• Set the tip of the Spur gear 25.6to the Combination gear 11.6,

36.8 and assemble it correctly.

Star wheel assy

Spur gear 25.6

Paper eject roller

Table 3-9. Paper jam error indication

Step

No.

Detail phenomenon Check point Remedy

The paper is jammed around the Front paper guide.

1. Check if the Front paper guide is floating from the assemble position.

2. Check if thereis any damage around the rear edgeof the each ribontheFrontpaper guide.

If it isno problem, proceed the next step.

1. Assemble the Front paper guidefront to the suitableportion and confirm t he PF grounding spring is securing the Front paper guide.

2. Replace the Frontpaper guide withnew one.

Paper is loaded correctly from ASF.

But, after complete the print job,paper jam indicated on the screen without any paper jam.

If you sendthe new print jobin this condition,the General error is indicated on the screen.

• Check if the Torsion spring 0.22comes off on the bothPE sensor lever.

• If the Torsion spring

0.22 is not set on the correct position, set it correctly. If any paper dust i s placed around the PE sensorlever, remove it.

• If it is no problem, proceed the next step.

Front paper guide

PF grounding spring

Front Paper guide

Tensionspring

0.22

PE sensor lever

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Table 3-10. Paper jam error indication

Step

No.

Detail phenomenon Check point Remedy

When the paperis loadedfrom the ASF and ejected without any printing. After eject the paper, paper ejectsequence is continued.

If any print job is sent to the printer, General error is displayed.

1. Check if the CN4 connectorcable for HP/PE sensor cable is disconnected on the Main boardor sensor.

2. Check if the HP/PE sensor operates correctlybyusingthe tester. Refer to Table 3-2.

1. Connect the CN4 connectorcable to the CN4ontheMainboard.

2. Replace the HP/PE sensor with new one.

3. If the problem is not solved, replace the Main board withnew one.

Table 3-11. No Ink Cartridge or Ink Out error indication

Step

No.

Detail phenomenon Check point Remedy

A[No InkCartridge] or [Ink Out Error] message isdisplayed when the power to the printer is switchedon.

1. Check toascertainthat an ink cartridge has been setin place.

2. Check theremaining

ink with the printer driver or STM3.

3. Check toascertainthat

the headFFC is been attachedcorrectly to the head.

4. Check toascertainthat

the head FFC hasbeen attachedcorrectly to the mainboard.

1. Set the ink cartridge in place.

2. Remove and thenreset

the ink cartridgein place.

3. Replace theink cartridge

(faulty CSIC.)

4. Replace theink cartridge

(faulty CSIC.)

Table 3-12. Multiple papers are always loaded

Step

No.

Detail phenomenon Check point Remedy

Any errorindication is not displayed on the monitor. But, multiple papers are always loaded from ASF.

Check if thePaper return plate is operating correctlyintheASF when the paper is loaded.

• Assemble the torsion spring 25.7in the ASF frame.

Table 3-13. Paper is always loaded without any print job

Step

No.

Detail phenomenon Check point Remedy

Paperisalwaysloaded from ASF without any print job.

ASF hopper continueto flapping when the printeris turned on.

1. Check if the tipof the Change leverhas any damage.

2. Check if the Compression spring

1.47 comesoff from theChangelever.

1. Replace the Change lever with new one.

2. Set the Compression spring 1.47 in the Change lever.

Torsion spring 25.7

Change lever

comp. spring 1.47

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Table3-14. FatalErrorindication

Step

No.

Detail phenomenon Check point Remedy

When the printer is turned on, the printer continuethe paper eject sequence even if the paperis not in the paper path.

1. Check if the Torsion spring 0.22 comes off on the bothHP sensor lever.

2. Check if the Torsion spring 0.22 comes off on the bothPE sensor lever.

3. Check if the CN4 connectorcable is connectedon the CN4 on the Mainboard or sensor.

4. Check if the HP/PE sensor work correctly by using thetester. Refer to Table 3-2.

1. Set the Torsionspring

0.22 on the HP sensor lever.

2. Set the Torsionspring

0.22 on the PE sensor lever.

3. Connect the CN4 connector cable to the CN4ontheMainboard.

4. Replace the HP/PE sensor with new one.

5. If the problem is not solved,replace the Main board with new one.

Torsion spring

0.22

Tensionspring

0.22

PE sensor lever

Table 3-15. Fastal Error in dication

Step

No.

Detail phenomenon Check point Remedy

When theprinter is turned on, the CR unit dose not moveat all in the poweron sequence.

1. Check if t he CR motor connector is connected CN12 on the Mainboard.

2. Check if the coil resistance of the CR motor is about 7.8ohm by using the tester. Refer to Table 3-1.

1. Connect the CR motor connectorto the CN12 on the Mainboard.

2. Replace the CR motor with new one.

3. If the problem is not solved,replace theMain board withnew one.

When theprinter is turned on, PF roller dose notrotate at allin the poweron sequence.

1. Check if thePF motor connectori s connected to the CN7.

2. Check if thePF motor coilresistanceis about

7.8 ohm by using tester.

1. Connect the PF motor connectorto the CN7 on the Mainboard.

2. Replace the PF motor with new one.

3. If the problem is not solved,replace theMain board withnew one.

HP sensor lever

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Table3-16. FatalErrorindication

Step

No.

Detail phenomenon Check point Remedy

When the printer is turned on, it sounds strangenoise and the CR unit isstopped around the CR lock lever.

1. Check if the Top housing is secured with the fixing screw at the front side.

2. Check if the Change leverisplacedtothe printer front side.

3. Check if the PF motor is operated. Checkthe CN7 connector andthe coil resistance for PF motor.

4. If the CR locklever is not released even ifthe PF motor rotate in the power on sequence, check ifone of the gears hasany damage in the PF motor torque transportation path. Refer to Figure 2-13.

1. Secure the Housing fixing screw at the printerfront side.

2. Turn back theChange lever to the printer back side with the tweezer or small screw driver.

3. Connect the PF motor cable t o CN7 on the Main board. Replace the PF motor with new one.

4. Change the damaged gear withnew one.

5. If the problemis not solved,replace the Main board withnew one.

Top housing

Change lever

Table 3-17. Paper is not ejected completely without any error indication

Step

No.

Detail phenomenon Checkpoint Remedy

Printing is normal. But, the paperis notejected completely and the bottom area stay around the Paper eject frame.

1. Check if thePaper eject roller rotate when the paper is ejected.

2. Check if thePaper eject frame is secured with thethree fixing screws to the Main frame.

1. Assemble the Spur gear

25.6 t o the Combination gear 11.6, 36.8.

2. Secure the Paper eject frame witt the two fixing screws to the Main frame.

Paper eject frame

Spur gear 25.6

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Table 3-18. Dot missing occur and it is n ot recovered with CL

Step

No.

Detail phenomenon Check point Remedy

In theCL sequence, the pump unit seems work correctly. But, inkisnotejectedtothe waste ink pad atall.

Moreover,any ink is not absorbed fromthe head tothe cap.

1. Check if ink is ejected to the waste ink pad via pump unit in the CL sequence.

2. Check if thereis any foreign material around theseal rubber parts on the cap assembly.

3. Check if any damage is observed aroundthe seal rubberparts on the cap assembly.

4. Check if the two compression spring are assembled in the Cap assembly correctly.

1. If ink is not ejected at all to the waste ink pad in the CL sequence, proceed the following check point 2).

2. Remove the foreign material around the seal rubber parts.

3. Replace the Cap assembly with new one.

4. Set the Compression spring into the Cap assembly.

Cap seal rubber

parts

Compression

spring

Table 3-19. Dot missing occur and it is not recovered with CL

Step

No.

Detail phenomenon Check point Remedy

In the CL sequence, the pump unit seems work correctly.But, any ink isnot ejected to wasteink pad.

Moreover,any ink is not absorbed from the head to the cap.

5. Check if the Pump tube isconnected to the bottom of the Cap assembly correctly

6. Check if the pump tube has a little slack between the Cap assemblyand the pump unit when the Capassemblyisslide up completely.

7. Connect the Pump tube to the bottom of the Cap assemblydeeply.

8. Pump unit may coil the pump tube inside the unit. Inthis case,pull out the coiled tube from the pump unitcarefully. After that,connect the pump tube to the Cap assemblyafter placing thetubecorrectly.

9. If the problem is not solved,replace thePump unit withnew one.

Pumptube

connectionpoint

Pumpunit

Tube

Cap assy.

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Table 3-20. Dot missing occur and it is n ot recovered with CL

Step

No.

Detail phenomenon Check point Remedy

In the CLsequence, ink is ejected to the Waste inkpad (this means pumpunit & cap unit are working correctly). But, the dot missing is not solved at the specific nozzles even ifthe several CLs are performed.

1. Check ifthe segmentin the nozzle check patter is reducedevery CL & Nozzle check pattern printing.

2. Check if anydamage is observedon the Head FFC.

1. Replace the I/C with new onein theI/C replacement sequence.

2. Replace the Head FFC with the new one.

3. Replace theprinthead with newone.

In the CLsequence, ink is ejectedto the Waste inkpad.But,dot missingisoccurredon allnozzle inthe printing and is not solved in the severalCLs.

1. Check if theHead FFC is connected to the CN8 and CN9 on the Main boardorHeadFFC.

1. Connect the HeadFFC securelyto the CN8 and CN9 on the Mainboard or Printhead.

2. Replace the Printhead with newone.

3. Replace theMain board with newone.

Table 3-21. Print quality is not good

Step

No.

Detail phenomenon Check point Remedy

Verticalbanding is appeared against theCR movementdirection. Andit looks like uneven printing.

1. Check if eachsegment is printed correctly in the nozzlecheck pattern.

2. Check if the surface of theCR guideshaft dose not haveany sever stain.

3. Check if the surface of the CR sliding portion on the Paperejectframe has enoughoil.

4. Check if the CR guide shaftis assembled in the correctportion securely.

5. Check if the surface of the CR guide shaftis flat.

6. Check if the surface of the Papereject frame is flat.

1. Perform theCL andcheck the nozzlecheck pattern.

2. Clean the surfaceof the CR guide shaft with the dry soft cloth and lubricateG-55 inside the CR guide shaft.

3. Clean the surfaceof the CR sliding portion on the Paper eject frame and lubricatespecific amount of the G-26.

4. Reassemble the CR guide shaft intothe mounting slaton the both side frame and secureit with Rod spring.

5. Replace the CR guide shaft withnew one.

6. Replace the Papereject frame withnew one.

CR movement

direction

G26 lubrication

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Table 3-22. Print quality is not good

Step

No.

Detail phenomenon Check point Remedy

1 Ditto

7. Replace the following parts.

• CR motor

•CRtimingbelt

• Compression spring 19.6

Microbanding appears horizontallyagainst t he paperfeeding direction anditappearswiththe same width.

1. Check ifeach segment is printed correctly in the nozzlecheck pattern.

2. Check if the suitable

paper isused accordingto the printerdriver setting.

3. Check if the Paper

feed roller is dirty.

4. Check ifthe following

parts donot have any damage.

• Combination gear 16,

21.6

• Combination gear

11.6, 36.8

• Spur gear 73.6

• Spur gear 25.6

1. Perform the CL and check the nozzle check pattern.by using the Adjustmentprogram.

2. Use the suitable paper

according to the printer driver setting.

3. Clean the surface of the

PF roller carefullywith the soft brush

4. Replace the damaged

parts withnew one.

5. Replace thePrinthead

with new one.

CR movement

direction

Table 3-23. Print quality is not good

Step

No.

Detail phenomenon Check point Remedy

3 Printing is blurred

1. Check if the suitable paper is used accordingtothe printerdriver setting.

2. Check if the correct headID isstoredin the EEPROM by usingthe Adjustmentprogram.

1. Use the suitablepaper accordingtothedriver setting.

2. Input 6digits code of the head ID into the EEPROM by using the Adjustmentprogram.

4 Ink stains thepaper

1. Check if thefollowing parts are stained with ink.

• Upper paper driven roller

•PFroller

• Paper guide front

• Paper eject roller.

2. Check if thereis some ink drops around the backsideof the printhead.

3. If the bottomarea of the printed paper has ink stain, check if the Paper eject frame is securedwith three screws.

4. If the bottomarea of the printed paper has ink stain, check if the Paper eject frame is bent upward.

1. Clean the ink stained parts with soft cloth.

2. Wipe off the inkdrop with the soft cloth carefully.

3. Securethe screws fixing the Papereject frame.

4. Replace the Paper eject frame withnew one.

Page 61

CHAPTER

DISASSEMBLYANDASSEMBLY

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Disassembly and Assembly

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4.1 Overview

This sectiondescribes procedures for disassembling themain components ofthe Stylus COLOR 680/777/777i.Unless otherwise specified, disassembly unitsor components can be reassembled by reversingthe disassembly procedure. Things, if not strictly observed, that could resultin injuryor loss of life are describedunder the heading “Warning”. Precautions for any disassembly or assembly proceduresa re described under the heading “CAUTION”. Chipsfor disassembling procedures are described under the heading “CHECK POINT”. If the assembling procedure is different from the reversedprocedure of the disassembling,the procedure is described under the heading “REASSEMBLY”. Any adjustments requiredafter disassemblingthe units aredescribed under theheading “ADJUSTMENT REQUIRED”. When you have to remove any units or parts that are not described in this chapter, refer to the exploded diagrams in the appendix.

Read precautionsdescribed in the next section before starting.

4.1.1 Precautions

See the precautions given under the handling“WARNING” and “CAUTION” in the following columnwhen disassembling or assemblingEPSON Stylus COLOR 680/777/ 777i.

W A R N I N G

Disconnect the power cable beforedisassembling or assembling the printer.

Wear protective goggles to protectyour eyesfrom ink.If ink gets in your eye, flush the eye with fresh water and see a doctor immediately.

Always wear gloves for disassembly and reassembly.

If ink comes into contact with your skin, washitoffwithsoap and water. If irritation occurs, contact a physician.

A lithiumbatteryis installedon themain boardof thisprinter. Be sure to observe the following instructions when serving the battery:

1. Keep the batteryaway from any metal or otherbatteries so that electrodesof the oppositepolarity donot come incontact with each other.

2. Do not heat the battery or put it near fire.

3. Do not solderon any part of thebattery. (Doing so may result in leakage of electrolytefrom the battery, burning or explosion. The leakage may affect other devices close to the battery.)

4. Do not charge theba ttery. (An explosion may be generated inside the battery, and cause burningor explosion.)

5. Do not dismantlethe battery. (The gas inside the battery may hurt your throat. Leakage,burning or explosion may also be resulted.)

6. Do not installthe battery in the wrong direction. (This may cause burning or explosion.)

Danger of explosion if the battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacture. Dispose the used batteries according to government’s law and regulations.

Wear gloves when disassembly and reassembly to protect sharp metal edges.

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4.1.2 Tools

Use only specified tools to avoid damaging theprinter.

C A U T I O N

Risque d’explosion si la pile est remplacée incorrect me nt. Ne remplacerqueparunepiledumêmetypeoud’untypeéquivalent recommandépar le fabricant.Eliminer les pilesdéchargéesselon les lois et les règles de sécurité en vigueur.

C A U T I O N

Never removethe ink cartridge fromthe carriage unlessthis manualspecifiestodoso.

When transporting the printer after installing the ink cartridge, be sure to pack the printer for transportation witho ut removing the ink cartridge.

Use only recommended tools for disassembling, assembling or adjusting the printer.

Apply lubricants and adhesives as specified. (See Chapter 6 for details.)

Make thespecifiedadjustmen t s when you disassemble theprinter. (See Chapter 5 for details.)

When assembling, if an ink cartridge is removed and needs to be installed again, be sure to install a ne w ink cartridge because of the followingreasons;

1. Once the ink cartridgemounted on the printer is removed, air comes in and creates bubbles in the cartridge. These bubbles clog ink path and cause printingmalfunction.

2. If anink cartridge in use is removedand is reinstalled, inkquantity will not be detected correctlysince the counter to check ink consumption is cleared.

Because of the reasons above, make sure to return the printer to the user with a new ink cartridge installed.

Name Supplier Parts No.

Phillips Screw Driver (No.1) EPSON B743800100 Phillips Screw Driver (No.2) EPSON B743800200 Nipper EPSON B740500100 Tweezers EPSON B741000100

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4.1.3 Work Completion Check

If any service is made to the printer, usethe checklistshown below to confirm all works are completed properly and the printer is ready to be returned to the user.

Table 4-1. Work Completion Check

Classifi-

cation

Item Check Point Status

MainUnit

Self-test Is the operation normal?

Checked

Not necessary

On-line Test Is the printingsuccessful?

Checked

Not necessary

Printhead

Isinkdischargednormallyfrom all the nozzles?

Checked

Not necessary

Carriage Mechanism

Does it move smoothly?

Checked

Not necessary

Is thereany abnormal noise during its operation?

Checked

Not necessary

Is thereany dirt or foreign objectson the CR Guide Shaft?

Checked

Not necessary

Is theCR Motor at the correct temperature? (Not too heated?)

Checked

Not necessary

Paper Feeding Mechanism

Is paper advanced smoothly?

• No paper jamming?

• No paper skew?

• No multiple feeding?

• No abnormal noise?

Checked

Not necessary

Is thePF Motor at correct temperature?

Checked

Not necessary

Is thepaper path freeof any obstructions?

Checked

Not necessary

Adjustment

Specified Adjustment

Arealltheadjustmentdone correctly?

Checked

Not necessary

Lubrication

Specified Lubrication

Areallthelubricationmadeat the specified points?

Checked

Not necessary

Is the amount of lubrication correct?

Checked

Not necessary

Function ROM Version Version:

Checked

Not necessary

Packing

Ink Cartridge

Are the ink cartridges installed correctly?

Checked

Not necessary

Protective Materials

Have all relevant protective materialsbeenattachedtothe printer?

Checked

Not necessary

Others

Attachments, Accessories

Have all therelevant itemsbeen includedin the package?

Checked

Not necessary

Table 4-1. Work Completion Ch eck (continued)

Classifi-

cation

Item Check Point Status

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4.2 Disassembly

The flowchartbelow shows step-by-step disassemblyprocedures. Whendisassembling each unit, refer to the page number shown in the figure.

Figure 4-1. Disassembling Flowchart

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4.2.1 Housing removal

1. Open the printer cover and remove 2 screws (C.B.S-TITE R 3x6 F/Uc) at the printer front side.

Figure 4-2. Removing 2screws f or Housing

2. Remove 2 screws (C.B.S. 3x6 F/Zn) at the back of the printerand remove the Housing.

Figure 4-3. Removing 2scews for Housing

3. Remove the Upper Housing from the Left and Right Panel as well as the Mechanism.

C.B.S-TITE R 3x6 F/Uc

C.B.S 3x6F/Zn screws

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4.2.2 Operation Panel removal

The panel board equipped with printeris as follows:

- Stylus COLOR 680: C383PNL

1. Remove the Housing from the printer. (Refer to Section 4.2.1.)

2. Remove 2 screws(C.B.S 3x6 F/Zn)securing theOperation PanelAs sembly. Then, disconnect the OperationPanel Assembly from the Printer Mechanism.

Figure 4-4. Removing 2 screws for Operation Panel

C A U T I O N

When removing the U pper Housing from t he left and right Panel, don’t broke these parts since they were fastened slightly with glue. (Refer to following pictures.)

Tightening Torque for screw

• C.B.S-TITE R3x6 F/ Uc screw for housingfront side: 6+/- 1kgf.cm

• C.B.S 3x6 F/Zn screw for housing back side : 6+/- 1kgf.cm

It is not necessary to glue the Upper Housing to the Left and Right Panel.

C A U T I O N

EnsurethatC.B.S-TITE 3 x 6 F/Uc screwsare used for the two screws on the front side of the printer. The tips of these screws are rounded for user’s safty.

Fasten Portion

C.B.S 3x6 F/Zn

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3. Remove2 screws (C.B.P-TITE3x8 F/Zn) anddetach the SubRight Panel Housing from the Operation Panel Assembly.

Figure 4-5. Removing 2 screws for C383PNL board

4. Remove the Panel Shield Plateandthe C383PNL board from the Operation Panel Assembly.

5. Disconnect the Panel FFC from the connector on the C383PNL board.

4.2.3 Printhead removal

1. Remove the Housing from the printer. (Refer to Section 4.2.1.)

2. Open the Cover Cartridge and remove the both blackand colorink cartridge.

3. Remove the Cover Cartridges for black and color ink cartridgesfrom the CR Assembly.

4. Remove the Head FFC Holder from the CR Assembly by releasing two hooks. Refer to Figure4-x.

Figure 4-6. Removing the Head FFC Holder

5. Disconnect the Printhead'sFFC from the connectoron thePrinthead.

C H E C K

P O I N T

Removing the Operation Panel Assembly also se parates the stacker assembly from the Printer Mechanism, since the Stacker Assembly is heldwithO peration Panel.

C.B.P-TITE 3x8 F/Zn

Hooks

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6. Remove two screws (C.B.P-TITE3x6 F /Zn and +Bind B-TITE SEMS W2 2.5x5 F/Zn) tighieningthe Printhead.

Figure 4-7. Removing the two screws tightening the Printhead

7. Remove the Printheadfrom the CR unit.

Figure 4-8. Placing the Printhead’s FFC

C H E C K

P O I N T

Place the Printhead’s FFC in the cable holder by the four portions indicated in the fo llowing Figure4-8.

Make sure that the Head Grounding Plate is insta lled to the carriage correctly. Refer to Figure 4-9.

Make sure that two holes of the Printhead correctly fit in the installing position pins. Figur e 4-9 .

C.B.P-TITE 3x6 F/Zn

+BindB-TITESEMSW22.5x5F/Zn

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Disassembly and Assembly Disassembly 70

Figure 4-9.

Printhead installing the position pin & the grounding plate.

Tightening Torque for screw

• C.B.P-TITE 3x6 screw f or printhead: 6+/1kgf.cm

A D J U S T M E N T

R E Q U I R E D

When the Printhead is replaced with a new one, following adjustments must be performed in the order below:

1. Initial inkcharge

2. Printhead ID input

3. Bi-d adjustment When the Printheadisremoved and reinstalled, onlythefollowing adjustment is required.

1. Head cleaning

2. Bi-d adjustment

Head grounding plate

Headinstallingposition pins

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Disassembly and Assembly Disassembly 71

4.2.4 CR motor removal

1. Remove the Housing from the printer.(Refer to Section 4.2.1.)

2. Using tweezers or a small screwdriver, slide the CR Lock Lever to front and release theCR Lock Lever fromthe CR unit. Then move the CR unit to the center area of the CR shaft.

3. Loosen the CR Timing Belt by pushing the Driven Pulley Holder to right using a screwdriver,and remove the Timing Beltc arefully from the piniongear on the CR motor. Refer to Figure 4-xx.

Figure 4-10. Removing the Timing Belt

Step 2

CR Timing belt

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4. Remove four Hexagon Nuts while holding the CR motor and remove the CR motor assembly.Re fer to Figure 4-11.

Figure 4-11. Removing the CR motor

5. Take the CR motor's cable out from the cable hookin t he Waste drain inkpad unit.

6. Disconnect the CR motor connectorc able from the CN12 on the Main board with tweezers.

A D J U S T M E N T

R E Q U I R E D

The Gap adjustment (Bi-d adjustment) is r eq uired when the CR motor is removed or replaced.

Connect the CR motor connector cable to the CN12 on the Main board. Use of tweezers or pincers is recommended to facilitate the job, since the CN12 is not located near the r ear edge of the Main board.

Hexagonnuts

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4.2.5 Waste drain ink pad unit removal

1. Remove the Housing from the printer. (Refer to Section 4.2.1.)

2. Remove one screw (C.B.P-TITE 3x8 F/Zn)on thefront rightside of the printer. (viewed from front side)

Figure 4-12. Removing one screw securing the Waste ink pad unit

3. Remove two screws (C.B.P- TITE 3x8 F/Zn) and takesomecables off from the cable hook in the Waste drain ink pad unit as shown in the followingfigure.

Figure 4-13. Removing one screws & cables at the back side of the printer

4. Remove the Waste drain ink pad unit from the printer

C.B.P-TITE 3x8 F/Zn screw

C.B.P-TITE 3x8 F/Zn

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Disassembly and Assembly Disassembly 74

Figure 4-14. Drain ink tube setting position

C H E C K

P O I N T

After assembling the Waste drain ink pad unit, be sure to set the some cables in the cable hook in the Waste drain ink pad unit. Refer to the Figure 4-13.

When assembling the Waste drain ink pad unit, be sure to set the tip of the waste ink tube in the suitable position of the Waste drain ink pad. Refer to the Figure 4-14.

A D J U S T M E N T

R E Q U I R E D

WhentheWastedraininkpadisreplacedwithanewone, followingservice item is required.

Wastedrain ink counterreset operation.

Tightening torque for screw

• C.B.P-TITE 3x8 screwfor Waste drain i nk pad unit :9+/1 kgf.cm

Waste drain ink pad

Ink tube

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4.2.6 Circuit board removal

1. Remove the Housing from the printer. (Refer to Section 4.2.1.)

2. Remove threescrews (C.B.S 3x6 F/Zn)securing the Circuitboard unit at the front side of the Printer mechanism.

Figure 4-15. Removing four screws at the printer front side

3. Remove four screws (C.B.S 3x6 F/Zn) securing the Circuit board unita t the back side of the Printer mechanism and remove two screws (C.B.S 3x6 F/Zn) securing the Circuit board unit at the right side (viewedfrom back side).

Figure 4-16. Removing six screws at the printer back side & right side

C.B.S 3x6 F/Zn

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4. Holding the Left housing lightly,pull down the Circuit board unit. Then disconnect the followingfour cables from the corresponding connectors on the Main board.

CR motor connectorcable : CN12

PFmotorconnectorcable :CN7

Printhead FFC : CN8, CN9

HP/PE sensor cable : CN4

5. Remove the following screwss ecuring each circuit board to the Shield plate. Figure Figure 4-17.

C383 MAIN : Remove five screws.

C.B.S 3x6 F/Zn (Red circled screws) : 3pcs (for Main board) C.P. 3x6 F/Zn (Yellow circled screws) : 2pcs (for Parallel I/F)

connector)

C383PSB/E : Remove five screws.

C.B.S 3x6 F/Zn (Yellow circled screws) : 3pcs (for PS board) C.B.S-TITE R 3x6 F/UC (Red circled screw) :1pcs (for PS board)

C.B.(O) 4x5 F/ZG for 120V(Gre en circled screw) :1pcs (for Earth terminal) Hexagon nut, Normal M4(Green circled) : 1pcs (for Earth terminal) (C.B.S 3x6 F/Zn for 220V (Green circled screw) : 1pcs (for Earth terminal))

NOTE: 110V type of the PS board dose not have earth wire.

Figure 4-17. Remove the screw securing each circuit board

A D J U S T M E N T

R E Q U I R E D

When replacing the Main board with a new one, perform the following service items.

Before removing the Main board, connecttheparallel I/F or USB Cable and try to read out the following data by using the Adjustment program. If this operation succeeds, replace the Main boardand write the readout data to thenew Main board through the Adjustment program.

1) I/C Ink consumption counter.

2) Waste ink dr ain pad counter.

3) Printhead ID input.

4) Gap adjustment (Bi-d adjustment) In case the abov e mentioned data are not able to be read out from the defective Main board, performthe following service items.

Replace the both ink cartridgeswitha brand new one.

Replace the Waste ink drain pad with a new one.

Input the Printhead ID.

Adjust the Bi-d alignment.

C383 MAIN Board

C383 PSE/PSE board

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Since the cable between C383 MAIN board and C383 PSB/E board are directly soldered,take the following steps when replacing only onecircuit boardinthe service activity.

1. Take off the cable on the Main board by removing the solderby heating it withthesoldering iron.

2. Replace the defective circuitboard with new one.

3. Insert the tip of thecableinto the soldering hole of the ASP Main board and solder it securely.

Tightening Torque for screw

• C.B.S 3x6 F/Zn screwfor PS board : 6+/- 1kgf.cm

• C.B.S-TITE R 3x6 F/Ucscrew for PS board : 6+/- 1kgf.cm

• C.B.S 3x6 F/Zn screw for Mainboard : 6+/- 1kgf.cm

• C.P. 3x6 F/Zn screwfor Parallel I/Fconnector : 6+/-1kgf.cm

• C.B.S 3x6 F/Zn screwfor Circuit unit : 6+/-1kgf.cm

• C.B.(O) 4x5 F/ZG screw for Earthcable :11+/-1kgf.cm

C H E C K

P O I N T

When replacing or removing the PS board, be sure to use the following suitable screw to secure the PS board.

Figure 4-18. PS board fixing screws

Install a new cartridge before sending back the printer to the user, since the ink cartridge once taken out c an not be used again.

Installation of I/C must be carried out by I/C replacement sequence. Otherwise, ink may not eject properly.

C.B.S-TITE R 3x6, F/UC

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C H E C K

P O I N T

Check the Earth terminal and wire position. Refer to the following figure. The earth wire for 120V must be placed back side of the Heat sinkerHT1.Be sure to leave atleast2.5 mm of space between heat sink HT1 and thewire. If this is not possible, secure the wire with tape or other methodto be sure that a minimum of 2.5 mm spacing is preserved.And the earth wire for 220V must be placed in front of the Heat sinker HT1 as following figure.

Figure 4-19. Earth terminal and wire position

Earth terminal

120V Type

Heat sinker

2.5mm

Heat sinker

220V Type

Earth terminal

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4.2.7 LD Roller removal

1. Remove the Housing from the printer.(Refer to Section 4.2.1.)

2. Take the Head FFC off from the Head FFC holder located along the LD roller shaft holder.

Figure 4-20. Taking Head FFC out from t he FFC holder

3. Remove two screws (C.B.S 3x6 F/Zn) securing theLD rollerholder to the Main frame.

Figure 4-21. Removing two sc rews se curing the LD roller holder

Head FFCholder

LD roller shaft holder

C.B.S 3x6 F/Zn screws

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4. Push the two hooks of the LD roller shaft holder as shown in the followingfigure.

5. Pull the LD roller shaft holder unit upward fromthe Main frame.

Figure 4-22. Pushing two hooks of the LD roller shaft holder

6. Remove the LD roller along with the Clutch mechanismfromthe LD roller shaft holder unit.

Figure 4-23. Removing the LD roller with Clutch mechanism

Two hooks forLD rollerholder

LD Roller

Clutch mechanism

LD Rollershaft holder unit

Washer

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Disassembly and Assembly Disassembly 81

C A U T I O N

Do not damage the tooth of the Spur g ear 35.2 a nd the Spur gear

23.2 when assembling the L D roller shaft holder unit.

Figure 4-24.

Spur Gear 23.2 and Spur Gear 35.2

Spur gear 23.2

Spur gear 35.2

Spur gear 23.2

Before assembling the LD roller shaft, make sure that the round hole of the Clutch is set on the protrusion on the LD roller shaft as shown in the following figure.

Figure 4-25. Assembling the Clutch

Assemble the LD roller shaft holder unit to the printer mechanism in the following procedure.

1) Set the tip of the Change lever to the printer front side.

Figure 4-26. LD Roller shaft holder assembling

procedure (1)

round hole on the Clutch

Protrusionon theLD rollershaft

Changelever

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2) Assemble the LD roller shaft holder unit while storing the Paper return plate into the ASF frame.

Figure 4-27. LD R oller shaft holder assembling

procedure (2)

Fasten the LD roller shaft holder with two C.B.S 3x6 F/Zn screws in theorderindicated in the followingfigure.

Figure 4-28. Fastening the L D roller shaft holder

Tightening torque for screw

C.B.S 3x6F/Zn screw for LD rollershaft holder unit : 9+/1 kgf.cm

Paper return plate

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4.2.8 HP/PE Sensor removal

1. Remove the Housing from the printer.(Refer to Section 4.2.1.)

2. Remove the LD roller from the LD roller shaftholder. (Refer to Section 4.2.7.)

3. Remove HP detection leverfrom the LD roller shaftholder and disconnect the cable from the sensor connector.

Figure 4-29. Removing the HP detection lever

4. Release the two fixing hooks for the sensor from the LD roller shaft holder and remove the sensor.

Figure 4-30. Releasing two fixing hooks for the sensor

HP/IC detection lever

HP/PE sensor

Two fixing hooks

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C H E C K

P O I N T

Tor

Make sure that the Torsion spring 0.22 is hu ng to the following suitable position.

Figure 4-31. Torsion spring 0.22 for PE detection lever

Figure 4-32. Torsion spring 0.22 for HP detection lever

Torsion spring 0.22

PE sensor lever

Torsion spring 0.22

HP/IC sensorlever

C H E C K

P O I N T

Make sure that theHP/PE sensor cable is placedtothe suitable groove on the LD roller shaft holder.

Figure 4-33. Sensor cable placing position (1)

Figure 4-34. Sensor cable placing position (2)

Make sure that the each sensor lever turn back smoothly by moving it after the s ensor was assembled to the LD r oller shaft holder.

HP/PE sensor

HP/PE sensor cable

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4.2.9 Ink system unit removal (Cap & Pump unit )

1. Remove the Housing from the printer.(Refer to Section 4.2.1.)

2. Remove the Waste drain ink pad from the printer.(Refer to Section 4.2.6.)

3. Remove the LD roller holder fromt he Printer. (Refer to Section 4.2.8.)

4. Remove threescrews (C.B.S 3x6 F/Zn)securing the Ink system frame andthe Cap assembly to theframe.

Figure 4-35. Removing three screws securing the Ink system

5. Remove the Ink system unit (Cap andP ump unit) carefully along with the Ink system frame.

6. Release one hook for Cap assembly on the Ink system frame and take the Cap assembly out from the Ink system frame.

7. Disconnect the waste drain ink tube carefullyfrom the bottom of the Cap assembly.

C A U T I O N

When the Inksystem unit is removed, be careful thatthegears do not come off from each shaft on the Ink system frame.

C.B.S3x6 F/Zn screws

C A U T I O N

Since the compression spring is included in the Pu mp assembly, watch out for the spring and the gear that pop out from the unit when the Pump assembly is removed fro m the Ink system unit.

When replacing the cleaner head built in the Pump assembly, be careful of the following points.

1) Do not touch the cleaner head with your bare hands. Ware glovesor use tweezers.

2) Do not smear the head cleaner with oil or grease.

When installing the Cleaner head, setthe rubber side (black side) facing toward the right side of the fr ame .

When installing the Cleaner head, set the two square cut offs on the Cleaner head into the two hooks on the Ink system.

When replacing the Cap Assembly, do no t touch the sealing rubber portion of the Cap Assembly.

The component parts in the Pump Assembly are not individually supplied as ASP. So please replace the whole Pump Assembly when replacing the Pump Assembly.

Be careful not to crush or leave any stress on the ink tube connecting the pump assembly and the cap assembly.

Cleaner head

hook & cut off

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C H E C K

P O I N T

Make sure that all gears are set in each gear shaft on the Ink system frame .

Figure 4-36. Gear engagement on the Ink system frame

Make sure that the ink tube is placed along the following position.

Figure 4-37. Ink tube placing position

After installing the Pump Assembly, ensure t ha t the cleaner parts move back and forth by rotating the Gear.

Combination gear

37.6, 44.4

Combination gear

9.6, 24

Cap assembly

Ink tube

Pumpunit

Tightening torque for screw

• C.B.S 3x6 F/Zn screwfor Ink systemframe & Cap assy.: 9+/1 kgf.cm

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4.2.10 Paper Eject Roller removal

1. Remove the Housing from the printer.(Section 4.2.1 Housing removal)

2. Remove three screws (C.B.S3x6 F/Zn) securing the Front frame to the Main frame.

Figure 4-38. Removing the Fr ont frame

3. Lift up the right side of the Front frame and slide it to the lefts ide a little bit and then remove it.

4. .Remove the Plain washer and then remove the Combinationgear 11.6, 36.8 carefully. Refer to Figure 4-xx.

Figure 4-39.

C A U T I O N

When removing the Front frame, if the CR unit is out of the CR home position, the nozzle surface of the Printhead may come in contact with Paper guide front as soon as the Front frame is removed. This is b ec ause the CR unit is held with this frame. Therefore, be sure to set the CR unit in the CR home position before removing the Front frame. Otherwise, the dot missing problem may occur.

C.B.S3x6 F/Zn screw

Plainwasher

Combinationgear 11.6,36.8

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5. Open the spurgear 25.6 hook with a pairof tweezers and then slidethe paper eject roller to the right whilepulling it toward to remove it.

Spur gear 25.6

Paper eject roller

A D J U S T M E N T

R E Q U I R E D

When you replace the Frame front, make sure to lubricatethe specific amount of G26 to the Fr ame front. Referto the Chapter 6Figure6-5.

When you replace the Paper eject roller with new one,makesure to lubricate the s pecific amount of G26 to the Spur gear 25.6. Refer to the Chapter 6 Figure.

Assemble the Paper eject roller in the following procedure.

1. Set the Spu r Gear 25.6 to the cut out hole in the Main fr a me .

2. Align the shape with the spur gear 25.6 hole, insert the paper eject roller shaft, and the n press the spur gear 25.6 hook until it is closed.

3. Slide the pa per eject roller and then insert it in the sha ft guide holder.

When you assem bl e the Front frame to the Printer mechanism, set the CR unit to the left side and as semble the Front frame from the right side. Be careful not damage the CR lock lever.

Fasten the Front frame with C.B.S Screw 3x6 F/Zn in the order of 1,2.

Tightening torque for screw

• C.B.S 3x6 F/Zn screwfor Front frame : 9+/-1 kgf.cm

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4.2.11 PF motor removal

1. Remove the Housing from the printer.(Refer to Section 4.2.1.)

2. Remove the Waste drain ink pad unit from the printer. (Refer to Section 4.2.6.)

3. Remove the Front frame and Paper eject roller. (Refer to Section 4.2.10.)

4. Remove the Plain washer and thenre move the Combination gear 11.6, 36.8 carefully. Referto Figure 4-38.

Figure 4-40. Removing the Plain washer and Combination gear 11.6, 36.8

5. Remove three nuts (Hexagon Nut M3) securing the PF motor to the left frame.

Figure 4-41. Removing two sc rews securing the PF motor

6. Disconnect the connector cable for PF motor from CN7 on the Main board.

7. Remove the PF motor from the left frame.

Plainwasher

Combinationgear 11.6,36.8

Hexagon Nut M3

PF motor

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C H E C K

P O I N T

Be sure that the PF motor cable is placed to the backward. Refer to theFigure4-42.

Figure 4-42. PF motor cable

Since the CN 7 is not located near the rear edge o f the Main board, it is easier to use the tweezers or pincers to connect the cable to the CN7.

Tightening torque for screw

• Hexagon Nut M3 forPF motor : 9+/1 kgf.cm

PF motor cable

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4.2.12 CR unit removal

1. Remove the Housing from the printer.(Refer to Section 4.2.1.)

2. Remove the CR timing belt from the CR pinion gear.(Refer to Section 4.2.4.)

3. Release the Printhead FFC from the cable holders on the LD roller shaft holder. And disconnectthe PrintheadFFC from theconnectors CN8and CN9 onthe Main board.

Figure 4-43. Taking Printhead FFC off

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4. Release two CR guide shaft rod springs from the both hooks on the left andright sides of the Main frame.

Figure 4-44. Release Left Rod spring for CR shaft

Figure 4-45. Release Right Rod spring for CR shaft

5. Pull the left edge of the CR guide shaft upward to align it with the round cutout portion. Then, holdingthe CR unit by hand, remove the CR guide shaft by sliding it to left or right.

Figure 4-46. Removing the CR guide shaft

Left CR guide shaft rodspring

RightCRguideshaftrodspring

C A U T I O N

Remove the CR gui de shaft while holding the CR unit by hand. If you remove the CR guide shaft without holding the CR unit, the nozzle surface of the Printhead may come in contact with the Paper guide front, wh ich causes the dot missing problem.

CR guide shaft

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C H E C K

P O I N T

Unlike the previous products, the oil pad is not built in the C R unit.

Make sure that the tips of the CR guide shaft rod springs are set in the holes in the Main frame.

Make sure that the CR guide shaft rod springs are correctly set in the suitable position. Refer to Figure 4-44,Figure4-45.

If you disassemble the CR unit after removing the CR unit from the printer, make sure that the CR Grounding plate is assembled in the suitable position in the CR unit. Refer to Figure 4-47.

.Make sure that the CR slider is assembled on the CR unit.

Figure 4-47. Grounding plate assembling position

If you remove the Printhead from the CR unit, make sure that the Head grounding plate is set in the CR unit. Refer to Figure4-9.

Make sure that the groove on the CR guide shaft must be set to the left side.

CR slider

CR Grounding plate

C H E C K

P O I N T

If the CR unit is disassembled or replaced with a new one, make sure that the CR timing belt is set in the assembling groove correctly as following figure.

Figure 4-48. CR timing belt setting position

A D J U S T M E N T

R E Q U I R E D

When you replace the CR unit with a new one , lubricate it with the suitable amount of the G-55 grease by the specified position. Refer to Chapter 6 Figure 6-4.

When you replace the CR Pulley shaft with new one, lubricate it with the suitable amount of G-26 grease by the spe cific position. Refer to Chapter 6 Figure6 -3.

When removing or replacin g the CR unit with a new one, adjust

the Gap (Bi-d).

Assemblinggroove

CR timing belt

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4.2.13 Paper feed roller removal

1. Remove the Housing from the printer.(Refer to Section 4.2.1.)

2. Remove the Paper Eject roller.(Refer to Section 4.2.10.)

3. Remove the CR unit. (Refer to Section4.2.12.)

4. Release the PF grounding springfromt he Main frame.

Figure4-49. Releasing the PF grounding spring

5. Release one hook located on the right edge of the Front paper guide.

Figure 4-50. Release one hook of the Front paper guide

PF groundingspring

Frontpaper guide

hook

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6. Lift up the left edge of the Front paper guide while slanting the Front paper guide by pulling up its front edge, andthen slide the Frontpaper guide to the left side after releasingthe right hookon the Front paperguide.

Figure 4-51. Remove the Front paper guide

7. Fit the protrusions of the Left PF roller bushing to the notches in the frames as shown in the following figure andremove the PF roller fastenspacer with tweezer.

Figure 4-52.

Fit the protrusions of the Left PF roller bushing to each notches

8. Slide the Left PF roller bushing to right side as abovefigureStep 2.

Step1

Step2

Paper guide front

Left PF roller bushing

PF rollerfasten spacer

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9. Fit the protrusions of the Right PF rollerbushing to the notches in the frames as shown in the following figure.

Figure 4-53. Fit the protrusions of the Left PF roller bushing to each

notches

10. Slide the PF roller to the left side along withthe both PF rollerbushings and remove the PF rollerfrom the printer mechanism.

Right PF rollerbushing

C H E C K

P O I N T

AfterassemblethePFroller,makesurethatthedowelofthe both left and right PF roller bushing holder fit in the cut hole of both frames.

After assemble the Front paper guide to the printer m echanism, make sure that the hooks and the dowel pins on the Front paper guide is set to the fitting positions secure. Slide the Front paper guide to the right side by pushing it and make sure that the right hook on the Front paper guide is locked to the frame securely. If the Front pape r g ui de is not fixed securely to the suitable position,it may causethe paperjam problem.

Figure 4-54. Front paper gu ide assembling notice

A D J U S T M E N T

R E Q U I R E D

When youreplace thePF roller withn ew one, be sure to lubricate a specificamount of G-26 between the Left PF roller bushing holder and the left edge of the PF roller. Refer to Chapter 6 Figure.

When you assem bl e the Front frame to the Printer mechanism, set the CR unit to the left side and as semble the Front frame from the right side. Be careful not damage the CR lock lever.

Right hook

Two dowel pins

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4.2.14 Disassembling ASF frame unit

1. Remove the Housing from the printer.(Refer to Section 4.2.1.)

2. Remove the LD roller shaft holderunit(Refer to Section 4.2.7.)

3. Remove two screws (C.B.S.-TITE (P4) 3x8,F/Zn screw, C.B.S-TITE (P4) 3x6 F/ Zn) securing the ASF frame unit and remove the ASF frame unit from the printer mechanism.

Figure 4-55. Removing the screws securing the ASF frame

4. Remove the Spur gear 23.2 from the ASF frame.

Figure 4-56. Removing the Gears from ASF frame unit

C.B.S-TITE(P4) 3x8 F/Zn screw

ASF Frame unit

C.B.S-TITE 3x6 F/Zn

Spur gear 23.2

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5. Remove the CompressionSpring2.67 located between the ASF Frame and the Hopper, and remove the Hopper from the ASF frame.

Figure 4-57. Removing the Comp ression spring 2.67

6. Remove the Torsion spring 25.7 from the bottom of the ASF frame and the Pad holder (Paper return plate).

Figure 4-58. Removing the Torsion spring 25.7

ASFHopper

Compression spring 2.67

ASFFrame

Torsion spring 25.7

ASF Frame

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7. Remove the Pad holder (Paper return plate) from the ASF frame.

Figure 4-59. Removing the Pad holder (Paper return plate)

C H E C K

P O I N T

Make surethatthe each tip oftheTorsion spring 25.7isset in the slot of the Pad holder and ASF frame. Refer to Figure 4-57.

Make sure that the Pad holder moves smoothly after assembling it to the ASF frame.

Pad holder

ASF Frame

When you rep lace the ASF frame or Ho pper with the new one, make sure to lubricate the specificamount ofG26intothe groove on ASF frame. Refer to Figure 6-2 Figure 6-3 & Figure6-4 in the Chapter 6.

Fasten the ASF unit C.B. S-TITE (P4) 3x8 F/Zn screw (left screw in the following figure),C. B.S-TITE3x6 F/Zn screw (right screw in the following figure) in the order of following figure.

Figure4-60. ASF fixingscrews fasteningorder

Tightening torque for screw

• C.B.S-TITE (P4) 3x6 F/Zn screw for ASF : 9+/-1 kgf.cm (rightscrew in above figure)

• C.B.S-TITE(P4) 3x8 F/Zn screw for ASF : 9+/-1kgf.cm (left screwin above figure)

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CHAPTER

ADJUSTMENT