Epson L800, L801 SERVICE MANUAL

Инструкция для Epson L800.

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SERVICE MANUAL

Color Inkjet Printer

L800/L801

Confidential

SEMF10-008

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Notice:

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

¸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 contents of this manual are subject to change without notice.

¸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.

Note :Other product names used herein are for identification purpose only and may be trademarks or registered trademarks of their respective owners. EPSON disclaims any and all rights in those marks.

Copyright 2011 SEIKO EPSON CORPORATION

I&I CS Quality Assurance Department

CONFIDENTIAL

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Safety Precautions

All safety procedures described here shall be strictly adhered to by all parties servicing and maintaining this product.

DANGER

WARNING

Strictly observe the following cautions. Failure to comply could result in serious bodily injury or loss of life.

1.Always disconnect the product from the power source and peripheral devices when servicing the product or performing maintenance.

2.When performing works described in this manual, do not connect to a power source until instructed to do so. Connecting to a power source causes high voltage in the power supply unit and some electronic components even if the product power switch is off. If you need to perform the work with the power cable connected to a power source, use extreme caution to avoid electrical shock.

Strictly observe the following cautions. Failure to comply may lead to personal injury or loss of life.

1.Always wear protective goggles for disassembly and reassembly to protect your eyes from ink in working. If any ink gets in your eyes, wash your eyes with clean water and consult a doctor immediately.

2.When using compressed air products; such as air duster, for cleaning during repair and maintenance, the use of such products containing flammable gas is prohibited.

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PRECAUTIONS

Strictly observe the following cautions. Failure to comply may lead to personal injury or damage of the product.

1.Repairs on Epson product should be performed only by an Epson certified repair technician.

2.No work should be performed on this product by persons unfamiliar with basic safety knowledge required for electrician.

3.The power rating of this product is indicated on the serial number/rating plate. Never connect this product to the power source whose voltages is different from the rated voltage.

4.Replace malfunctioning components only with those components provided or approved by Epson; introduction of second-source ICs or other nonapproved components may damage the product and void any applicable Epson warranty.

5.In order to protect sensitive microprocessors and circuitry, use static discharge equipment, such as anti-static wrist straps, when accessing internal components.

6.Do not tilt this product immediately after initial ink charge, especially after performing the ink charge several times. Doing so may cause ink to leak from the product because it may take some time for the waste ink pads to completely absorb ink wasted due to the ink charge.

7.Never touch the ink or wasted ink with bare hands. If ink comes into contact with your skin, wash it off with soap and water immediately. If you have a skin irritation, consult a doctor immediately.

8.When disassembling or assembling this product, make sure to wear gloves to avoid injuries from metal parts with sharp edges.

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

10.Observe the specified torque when tightening screws.

11.Be extremely careful not to scratch or contaminate the following parts.

̈Nozzle plate of the printhead

̈CR Scale

̈PF Scale

̈Coated surface of the PF Roller

̈Gears

̈Rollers

̈Exterior parts

12.Never use oil or grease other than those specified in this manual. Use of different types of oil or grease may damage the component or give bad influence on the printer function.

13.Apply the specified amount of grease described in this manual.

14.Make the specified adjustments when you disassemble the printer.

15.When cleaning this product, follow the procedure described in this manual.

16.When transporting this product after filling the ink in the printhead, pack the printer without removing the ink cartridges in order to prevent the printhead from drying out.

17.Make sure to install antivirus software in the computers used for the service support activities.

18.Keep the virus pattern file of antivirus software up-to-date.

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About This Manual

This manual, consists of the following chapters, is intended for repair service personnel and includes information necessary for properly performing maintenance and servicing the product.

Manual Configuration

CHAPTER 1. DISASSEMBLY / REASSEMBLY

Describes the disassembly/reassembly procedures for main parts/units of the product, and provides the standard operation time for servicing the product.

CHAPTER 2. ADJUSTMENT

Describes the required adjustments for servicing the product.

CHAPTER 3. MAINTENANCE

Describes maintenance items and procedures for servicing the product.

CHAPTER 4. APPENDIX

Provides the following additional information for reference:

•Power-On Sequence

•Standard Operation Time for servicing the product

•Troubleshooting

Symbols Used in this Manual

Various symbols are used throughout this manual either to provide additional information on a specific topic or to warn of possible danger present during a procedure or an action. Pay attention to all symbols when they are used, and always read explanation thoroughly and follow the instructions.

Indicates an operating or maintenance procedure, practice or

W A R N IN G

condition that, if not strictly observed, could result in serious injury or loss of life.

Indicates an operating or maintenance procedure, practice, or

C A U T IO N

condition that, if not strictly observed, could result in bodily injury, damage or malfunction of equipment.

May indicate an operating or maintenance procedure, practice or

C H E C K

P O INconditionT 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.

For Chapter 1 “Disassembly/Reassembly”, symbols other than indicated above are used to show additional information for disassembly/reassembly. For the details on those symbols, see “ 1.2 Disassembly/Reassembly Procedures (p17)”.

CONFIDENTIAL

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		Revision Status
Revision	Date of Issue	Description
A	April 6, 2011	First Release

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L800/L801	Revision A

CONTENTS

Chapter 1 Disassembly/Reassembly
1.1 Overview ............................................................................................................		10
1.1.1	Tools ........................................................................................................	10
1.1.2	Checks and Precautions before Disassembling .......................................	10
1.1.3	Protection for Transportation ..................................................................	14
1.1.4	Making a Special Tool for Holder Contact .............................................	15
1.1.5	Orientation Definition .............................................................................	16
1.1.6 How to Unlock the Carriage....................................................................		16
1.2 Disassembly/Reassembly Procedures ................................................................		17
1.2.1 Overview .................................................................................................		17
1.2.2	Disassembly Flowchart ...........................................................................	18
1.3 Removing Exterior Parts/Components...............................................................		24
1.3.1	Printer Cover ...........................................................................................	24
1.3.2	Paper Support Assy .................................................................................	24
1.3.3	Stacker Assy / Stacker Cover ..................................................................	25
1.3.4 Housing Upper Assy................................................................................		25
1.4 Removing Control Boards..................................................................................		27
1.4.1 Main Board Unit......................................................................................		27
1.4.2 Panel Assy/ Cover Open Sensor..............................................................		30
1.4.3	P/S Assy...................................................................................................	34
1.5 Disassembling the Printer Mechanism ...............................................................		35
1.5.1 Removing the Printer Mechanism ...........................................................		35
1.5.2	Printhead..................................................................................................	37
1.5.3 CR Scale ..................................................................................................		40
1.5.4 APG Unit.................................................................................................		41
1.5.5	Waste Ink Tray ........................................................................................	42
1.5.6 Waste Ink Pad Lower / Waste Ink Pad Cap Lower .................................		43
1.5.7 Left & Right Guide Stackers / CDR Guide Sensor .................................		44
1.5.8	Ink System ...............................................................................................	45
1.5.9 EJ Frame Assy.........................................................................................		46
1.5.10 PF Encoder / PF Scale ...........................................................................		49
1.5.11 PF Motor................................................................................................		49
1.5.12 CR Motor...............................................................................................		50

1.5.13 CR Unit..................................................................................................		52
1.5.14 ASF Unit................................................................................................		54
1.5.15 Upper Paper Guide ................................................................................		56
1.5.16 APG Sensor Assy ..................................................................................		57
1.5.17 Front Paper Guide Assy ........................................................................		57
1.5.18 CDR Tray Sensor ..................................................................................		60
1.6 Disassembling the CISS section.........................................................................		61
1.6.1	Refilling Ink Label / Valve Position Label .............................................	61
1.6.2 Top Cover................................................................................................		61
1.6.3 Tube Valve Holder Front / Rear..............................................................		62
1.6.4 Valve Lever .............................................................................................		62
1.6.5	Bottom Cover / Left Cover / Right Cover / Cover Joint .........................	63
1.6.6 Ink Supply Tank Assy .............................................................................		64
1.6.7 Ink Supply Tank Tube Assy....................................................................		64
1.6.8	Joint .........................................................................................................	65
1.6.9 Cover Case ..............................................................................................		65
1.6.10 PF Scale Cover / PF Scale Sheet...........................................................		66
1.6.11 Tube Guide Sheet / Tube Guide Sheet Sub...........................................		66
1.6.12 Ink Supply Tube Assy ...........................................................................		67
1.6.13 Adapter Cover .......................................................................................		68
1.6.14	Adapter ..................................................................................................	68
Chapter 2 Adjustment
2.1 Adjustment Items and Overview........................................................................		70
2.1.1	Servicing Adjustment Item List ..............................................................	70
2.1.2	Required Adjustments .............................................................................	74
2.2 Using the Adjustment Program ..........................................................................		77
2.2.1 Top Margin Adjustment ..........................................................................		77
2.2.2 Head Angular Adjustment.......................................................................		77
2.2.3 Bi-D Adjustment .....................................................................................		78
2.2.4	PW Adjustment/First Dot Position Adjustment ......................................	79
2.2.5 PF Adjustment.........................................................................................		80
2.2.6 PG Adjustment ........................................................................................		81

7

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L800/L801					Revision A
2.3	Banding Reduction System (BRS) Adjustment / Paper Feed Amount Profile (PFP)
	Correction............................................................................................................			83
	2.3.1 Overview .................................................................................................			83
	2.3.2	Adjustment Procedure .............................................................................		85
Chapter 3			Maintenance
3.1	Overview		............................................................................................................	89
	3.1.1	Cleaning...................................................................................................		89
	3.1.2	Service Maintenance ...............................................................................		89
	3.1.3	Lubrication ..............................................................................................		90
Chapter 4			Appendix
4.1	Power-On Sequence ...........................................................................................			97
4.2	Standard Operation Time for servicing the product...........................................			99
4.3	Troubleshooting................................................................................................			102
	4.3.1	Troubleshooting Workflow ...................................................................		102
	4.3.2	Fatal Error Code ....................................................................................		104

8

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C H A P T E R

1

DISASSEMBLY/REASSEMBLY

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L800/L801	Revision A
1.1 Overview	1.1.2 Checks and Precautions before Disassembling

C H E CSomeK pictures in this manual are for Epson Stylus Photo R280/ P O INR285/R290;T therefore, the shapes of the parts are different from

those of L800/L801, but the differences does not affect the disassembly/reassembly procedures.

This chapter describes procedures for disassembling the main parts/units of L800/L801. Unless otherwise specified, disassembled parts/units can be reassembled by reversing the disassembly procedure. See the cautions or tips for disassembly/reassembly described in “ 1.2 Disassembly/Reassembly Procedures (p17)”.

Read the following before disassembling and reassembling.

¸“ Safety Precautions (p3)”

¸“ 1.1.2 Checks and Precautions before Disassembling (p10)”

When you have to remove units or parts that are not described in this chapter, see the exploded diagrams of SPI (Service Parts Information).

1.1.1 Tools

Use only specified tools to avoid damaging the printer.

Table 1-1. List of Tools

Tool	Part No.
Phillips Screwdriver (No.1)	1080530
Phillips Screwdriver (No.2)	---
Flathead Screwdriver	---
Precision Screwdriver #1 (flathead)	---
Tweezers	---
Long-nose pliers	---
Acetate tape	1003963
2 pins (thinner than Ø2 mm)	---
Strong tape	1032813

Note : All of the tools listed above are commercially available. EPSON provides the tools listed with EPSON tool code.

1.1.2.1 Factors which Affect the Print Quality

HOW TO PLACE THE INK TANK ASSY WHEN DISASSEMBLING/

REASSEMBLING

The film under sealing film attached on the Ink Supply Tank Assy of this printer is ventilation film. The ink in the ink tanks is vented to atmosphere through this film to keep ink supply to the Printhead stable. If the film gets wet with ink, the ink in the tanks is not properly vented and printing may not be capable.

In order to prevent this from occurring, make sure to place the Ink Supply Tank Assy as shown below after removing it.

OK

Ink Supply Tank Assy

Ink Supply Tank Assy

Ventilation film

			Do not place the Ink Supply Tank Assy with
NG		Ink Supply Tank Assy	its film side down. Otherwise, ink in the Ink
			Supply Tank Assy may reach and cover the
			ventilation film, and the printing failure may
			occur.

Figure 1-1. How to Place the Ink Tank Assy

Disassembly/Reassembly	Overview	10
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L800/L801 Revision A

	1.1.2.2 Factors which Affect the Safety of Service Personnel such as	MEANS DO TO MINIMIZE THE INK SPILL
	Ink Leakage during Operation

Ink may spill when removing the following parts from L800/L801.

This section describes the parts that may cause ink spill and the means to minimize the ink spill when removing the parts.

THE PARTS THAT MAY CAUSE INK SPILL WHEN REMOVING

Parts	When ink may spill	Location
Joint	Removing the Ink Supply Tank Tube Assy	A
	/ Ink Supply Tube Assy from the Joint
Ink Supply	¸ Removing the tubes of the Ink Supply	A, B
Tank Assy	Tank Tube Assy from the Joint
	¸ Removing the tubes of the Ink Supply
	Tank Tube Assy from the Ink Supply
Ink Supply
Tank Tube Assy	Tank Assy
(w/Valve Assy)
Adapter	Removing the Ink Supply Tube Assy from	C
	the Adapter
Ink Supply	¸ Removing the Ink Supply Tank Tube Assy	A, C
Tube Assy	/ Ink Supply Tube Assy from the Joint
	¸ Removing the Ink Supply Tube Assy
	from the Adapter

Note : These parts are indicated with the			icon in disassembly/reassembly flowchart. (See
“ 1.2 Disassembly/Reassembly Procedures (p17)”.)
						Ink Supply Tank Assy
	Adapter
		C		Joint

		A
			B
Ink Supply Tube Assy		Ink Supply Tank Tube Assy

Figure 1-2. Location

Even observing the points described in this section, ink may

C A U T IO N

spill in the following situations. Therefore, be careful not to contaminate the inside of the printer or its surroundings by preparing the container to receive the leaked ink, or the like.

̈When removing the Ink Supply Tank Tube Assy (w/ Valve Assy), some ink will spill from both ends of the tube even the Valve Lever is closed.

̈When removing the Ink Supply Tube Assy, all the ink in the tube will spill.

Before disassembling, confirm that the printer is in the following condition.

¸ Choke Valve is closed

Do not turn the Valve Lever too much when closing the

C A U T IO N

Choke Valve, otherwise, the Valve Lever and/or Valve Assy may get damaged.

̈Before disassembling:

Turn the Valve Lever and be sure to close the Choke Valve.

̈After reassembling is complete:

Open the Choke Valve to perform the print inspection.

̈Before returning the printer to the user after repairing:

Make sure to turn the Valve Lever up to the choke position to close the Choke Valve before packing the printer.

Open position		Choke position		Choke position
				(When checking with the
				Valve Lever removed.)
				Valve shaft

					Choke Valve shaft is secured more tightly
	Valve Lever		Valve Lever		in Choke position than in Open position.

Figure 1-3. Opening/closing the Choke Valve

Disassembly/Reassembly	Overview	11
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	L800/L801	Revision A
	¸ Adapter is removed
		DISCHRGING INK FROM THE INK SUPPLY TANK

Before disconnecting the joint parts of the ink path, make sure that the Adapter is removed from the Carriage.

Adapter

Carriage

Ink path

Ink valve

Figure 1-4. Adapter

Discharging ink is recommended only when disconnecting the Ink Supply Tank Tube Assy from the Ink Supply Tank. Before performing the above disconnection, discharge ink from the Ink Supply Tank as follows.

̈Necessary tools

•Containers (x 6) for each discharged ink

•Injector (with a tip of φ3.2 mm)

•Tube (capable to be connected to the joint)

C H E C̈ KThe photos in the following procedure are for L200/L201, but P O IN Tthe procedure for L800/L801 is the same; the numbers of the

tube and the location of the Ink Supply Tank Assy in the photos are different from those of L800/L801, though.

̈Prior to the following steps, connect the injector with the tube, and then discharge ink according to the procedure.

C H E CTheKAdapter has an ink valve which cuts off the ink path

P O IN T

when removing the Adapter from the Carriage.

̈Discharging procedure

1.Remove the Housing Upper Assy. (p.25)

2.With the choke value closed (p.11), place the Ink Supply Tank Assy on a place where its bottom is higher than the top of the Printhead.

3.Prepare a container for ink to discharge, then disconnect the Ink Supply Tube from the joint and put its tip into the container for the ink.

4.Open the choke valve to discharge the ink in the Ink Supply Tank Assy to the container.

Ink Supply Tank Assy

Ink Supply Tube

Container for discharged ink Joint

Figure 1-5. Discharging Ink (1)

Disassembly/Reassembly	Overview	12
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L800/L801	Revision A

5.When the ink stops flowing from the tube, close the choke valve, and then connect the Ink Supply Tube back to the joint.

6.Disconnect the Ink Supply Tube of the same color connected to the opposite side of the joint.

7.Connect the tube from the injector.

8.Open the choke valve again, and suck up the remaining ink in the Ink Supply Tank into the injector.

9.Disconnect the tube from the injector, and connect the Ink Supply Tube of the same color back to the joint.

Joint

Tube

Injector (tip of φ 3.2 mm)

Figure 1-6. Discharging Ink (2)

10.Repeat Step 3 to Step 10 for all ink tanks to discharge all ink in the Ink Supply Tank.

C H E C̈ KIt is recommended that the ink in the Ink Supply Tank should P O IN Tbe discharged completely before proceeding to disassembling/

reassembling.

̈After all the reassembling work is complete, the discharged ink of each color should be refilled back to the Ink Supply Tank before performing the adjustment. Confirm the colors indicated on the film of the Ink Supply Tank so as not to mistake them, and make sure to refill each ink back to the correct tank from the corresponding ink supply hole.

Ink Supply Tank Assy

Ink supply hole

Disassembly/Reassembly	Overview	13
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L800/L801	Revision A

1.1.3 Protection for Transportation

Before packing the printer for returning it to the user, secure it at the specified points with strong tape to avoid damaging the printer or ink leakage during transport, and make sure to check the points as follows.

¸Attaching the Air Release Hole Caps

̈To prevent the ventilation film from getting wet, attach the Air Release Hole Caps (part number: 1556135) to the air release holes of the Ink Supply Tank Assy.

		Air release hole		Ink Supply Tank Assy
Air Release Hole Cap

Air Release Hole Cap

Figure 1-7. Attaching the Air Release Hole Caps

¸ Securing each parts

Secure the following parts with strong tape (width: 22 mm).

̈Securing the CR Unit

1.Confirm that the CR Unit is locked in the home position.

2.Attach the unfolded end of strong tape (fold the other end back 10 mm) on the bottom left of the Adapter Cover.

3.Pull the tape to the right side of the housing and attach it tightly.

CR Unit

Strong tape

̈Securing the Ink Tank

•Secure both sides of the Top Cover with strong tape (x2).

•Align the unfolded end of strong tape (x5) with the edge of the Housing Upper, and attach the tape along the shape of the Housing Upper/Ink Supply Tank Assy through the openings between the Air Release Hole Caps.

Air Release Hole Cap

Ink Supply

Tank Assy

Top Cover

Strong tape (80 mm x 22 mm)

Strong tape (60 mm x 22 mm)

Strong tape (60 mm x 22 mm)

Fold over the tape edge by 10 mm

Figure 1-9. Securing the Ink Supply Tank Assy

Figure 1-8. Securing the CR Unit

Disassembly/Reassembly	Overview	14
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L800/L801	Revision A

¸ Points to be checked before packing the printer

̈ The Valve Lever is on the position	̈ All the caps of the Ink Supply Tank
shown below (the Choke Valve is	Assy are securely closed.
closed). (See Figure 1-3.)
Valve Lever
	Cap
̈ The hooks (x2) of the Ink Supply	̈ The opened ink bottle is not
Tank Assy are securely engaged	included in the box.
with the Housing Upper Assy.
Ink Supply
Tank Assy

Housing Upper Assy

1.1.4 Making a Special Tool for Holder Contact

The Holder Contact (refer to p.38) can be easily removed by using a special tool. The method for making the tool is described below.

1.Prepare a handle part of a clip, or a similar metal wire piece.

Handle part

Clip

Figure 1-10. Making Special Tool for Holder Contact (1)

2.Bend the metal wire as shown below.

25mm 7mm

50mm

Special Tool

Figure 1-11. Making Special Tool for Holder Contact (2)

Disassembly/Reassembly	Overview	15
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L800/L801	Revision A

1.1.5 Orientation Definition

Orientation descriptions used in the disassembly/reassembly procedures are as follows.

[Rear Side]

[Left Side]		[Right (home) Side]

[Front Side]

Figure 1-12. Orientation Definition

1.1.6 How to Unlock the Carriage

Unlocking the carriage is required for disassembly of some parts or components. Carry out any of the following operations to unlock the carriage and move the carriage to other than its home position.

Be extremely careful not to damage the EJ Roller gear. Extra care

C A U T IO N

must be taken to avoid injury from sharp metal edges.

̈Power the printer and turn it off forcedly by disconnecting the power cable when the CR Unit is unlocked and moved away from the home position.

̈Turn the EJ Roller gear on the left side of the printer in the direction of the arrow until the carriage is unlocked.

[Left side]
PF Roller Gear	EJ Roller Gear
	Turn this gear

Carriage Lock				Carriage Lock

	Locked		Unlocked
Figure 1-13. How to Unlock the Carriage

Disassembly/Reassembly	Overview	16
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L800/L801	Revision A

1.2 Disassembly/Reassembly Procedures

1.2.1 Overview

This section describes procedures for disassembling the parts/units in a flowchart format. For some parts/units, detailed procedures or precautions are provided (accordingly indicated by icons and cell's color). Refer to the explanations in the example chart below and perform an appropriate disassembling and reassembling procedure. (See“ 1.3 Removing Exterior Parts/Components (p24)”.)

The example below shows how to see the charts on the following pages.

Table 1-2. Explanatory Note

	Item		Description	Reference
Parts/unit		White-letter	Parts/units supplied as an ASP	---
name		Black-letter	Parts/units not supplied as an ASP	---
			Indicates a practice or condition that could result	Indicates the reference
			in injury or loss of life if not strictly observed.	page in blue-letter
			Indicates a practice or condition that could result	Indicates the reference
			in damage to, or destruction of equipment if not	page in blue-letter
			strictly observed.
			Indicates the parts that are inevitably broken in
			the disassembling procedure, and should be	---
			replaced with a new one for reassembly.
			Indicates the parts that may cause the ink spill	“ 1.1.2 Checks and
				Precautions before
			when they are removed.
				Disassembling (p10)”
			Indicates necessary check items in the	Indicates the reference
Icon			disassembling/reassembling procedure.	page in blue-letter
			Indicates supplementary explanation for	Indicates the reference
			disassembly is given.	page in blue-letter
			Indicates particular tasks to keep quality of the	Indicates the reference
			units are required.	page in blue-letter
			Indicates particular adjustment(s) is/are required.	Chapter 2 “ Adjustment
				(p69)”
			Indicates lubrication is required.	Chapter 3 “
				Maintenance (p88)”
			Indicates the number of screws securing the	---
			parts/units.
			Indicates the points secured with other than a	---
			screw such as a hook, rib, dowel or the like.

								Reference page (A)
Black letters indicate a							“ 1.5.8 Ink System (p45)”
part/unit not supplied as				Main Board Unit
an ASP.

Shows the screw types		3
and the specified torque	S7 S15	---
in the “Screw type/torque
list”.
White letters indicate a	Ink Supply Tank		Front Paper
part/unit supplied as an	Tube Assy		Guide Assy
ASP.		---
					2
		---	S9	S15	1
Indicates that the
disassembly procedure of	(P 20)
boxed parts is explained
all together and step by
step in the section shown
as reference page (A).
	Adapter
		---
		1
	(p 18)
	Reference page

Figure 1-14. Example Chart

Disassembly/Reassembly	Disassembly/Reassembly Procedures	17
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L800/L801

Revision A

1.2.2 Disassembly Flowchart

START

	Printer Cover	Paper Support	Stacker Assy	Stacker Cover
		Assy
	---	---	---	---
	2	2	2	2
	(p 24)	(p 24)
			“ 1.3.3 Stacker Assy / Stacker Cover (p25)”
	Paper Support
	Assy

Housing Upper
Assy
	4
S4	---
(p 25)
	1	(p 18)

Cover Ink Tube

Foot

A

(p 19)

---	---
1	---

(p 35)

---

B	(p 20)	Cover Open	CR Scale	Adapter Cover	Joint	APG Unit	Panel Assy
		Sensor

		---	---		1		---		2			2
		2	2	S6	3		2	S15	---	S4	S14	1
	(p 30)		(p 40)	(p 68)		(p 65)	(p 69)	(p 41)	(p 88)			(p 30)
				Adapter
		“ 1.3.4 Housing Upper Assy (p25)”			---				2	(p 19)
1	(p 18)				1
				(p 68)
				(p 69)
Housing Right			Decoration Belt
			Right
	---		---	Holder Contact		Cover FFC Inner		Cover FFC
	2		2		---		---		---
					2		1		1
				---		---		---
Housing Upper
				Printhead
	---
					3
	---
				S2	---

“ 1.5.2 Printhead (p37)”

			Screw type/torque list
				Symbol	Screw type	Torque
3		(p 19)		S1	C.B.P. 2.6X8	3.5-4.5kgf.cm
				S2	C.B.P. 2.6X8	3-5kgf.cm
				S3	C.B.P. 3X10	3-5kgf.cm
				S4	C.B.P. 3X10	5-7kgf.cm
				S5	C.B.P. 3X6	3-5kgf.cm
				S6	C.B.P. 3X8	5-7kgf.cm
				S7	C.B.P.(P2) 3X8	5-7kgf.cm
				S8	C.B.S 3X6	5-7kgf.cm
				S9	C.B.S. (P2) 3X8	6-8kgf.cm
				S10	C.B.S. (P4) 3X6	7-9kgf.cm
				S11	C.B.S. (P4) 3X6	9-11kgf.cm
				S12	C.B.S. 3X10	4-6kgf.cm
				S13	C.B.S. 3X6	4-6kgf.cm
				S14	C.B.S. 3X6	5-7kgf.cm
				S15	C.B.S. 3X6	7-9kgf.cm
				S16	C.P. 3X4	3-5kgf.cm
				S17	C.P. 3X6	3-5kgf.cm
				S18	C.P. 3X6	4-6kgf.cm

Disassembly/Reassembly

Disassembling/Reassembling Flowchart

18

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L800/L801

Revision A

A (p 18)

Top Cover

---

2

(p 61)

Valve Position

Label

---

---

(p 61)

Refilling Ink

Label

---

---

(p 61)

Tube Valve

Holder Rear

	3
S5	6

(p 62)

Bottom Cover

	8
S5	---

(p 63)

Valve Lever

---

2

(p 62)

Cap

---

---

---

Top Cover Label

---

---

(p 61)

Bottom Cover

Valve Lever	Left Cover	Left Cover
	---	Valve Lever
Right Cover	7	Right Cover

---	(p 63)
7	Cover Joint
(p 63)	---
	2
	(p 63)

Tube Valve

Holder Front

---

---

(p 62)

“ 1.5.4 APG Unit (p41)”

2 (p 18)

	Spur Gear 12.8	Spur Gear 28.8	Spur Gear 33.6	Combination
				Gear 14.22
	---	---	---	---
	---	---	---	---
	---		---	---

Compression	Compression	Combination
Spring 2.25	Spring 0.97	Gear 12.8.27

---	---	---
---	---	---
---	---	---

APG Holder

---

---

---

3 (p 18)	“ 1.4.2 Panel Assy/ Cover Open Sensor (p30)”

Panel Cover

Assy

	2
S3	---

---

Panel Unit

---

---

---

Panel Cover

---

---

---

Open Sensor

Holder

	1
S3	4

---

Panel Shield
Plate
	2
S3	---

	Panel Board	Housing Panel
		Assy
	---	---
	1	---
	---	---

Decoration Belt

Left

---

---

---

Screw type/torque list

Symbol	Screw type	Torque
S1	C.B.P. 2.6X8	3.5-4.5kgf.cm
S2	C.B.P. 2.6X8	3-5kgf.cm
S3	C.B.P. 3X10	3-5kgf.cm
S4	C.B.P. 3X10	5-7kgf.cm
S5	C.B.P. 3X6	3-5kgf.cm
S6	C.B.P. 3X8	5-7kgf.cm
S7	C.B.P.(P2) 3X8	5-7kgf.cm
S8	C.B.S 3X6	5-7kgf.cm
S9	C.B.S. (P2) 3X8	6-8kgf.cm
S10	C.B.S. (P4) 3X6	7-9kgf.cm
S11	C.B.S. (P4) 3X6	9-11kgf.cm
S12	C.B.S. 3X10	4-6kgf.cm
S13	C.B.S. 3X6	4-6kgf.cm
S14	C.B.S. 3X6	5-7kgf.cm
S15	C.B.S. 3X6	7-9kgf.cm
S16	C.P. 3X4	3-5kgf.cm
S17	C.P. 3X6	3-5kgf.cm
S18	C.P. 3X6	4-6kgf.cm

Disassembly/Reassembly

Disassembling/Reassembling Flowchart

19

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L800/L801

Revision A

B(p 18)

Main Board Unit	“ 1.4.1 Main Board Unit (p27)”	Tube Holder*	*: There are four Tube Holders installed in this printer. Depending on the target parts or units, the number of

Tube Holders you should remove differs.

3

1

̈ When removing the Ink Supply Tank Assy:

The Tube Holder on the home position side (on the Cover Case)

S7

S15

---

S6

1

̈ When removing the Printer Mechanism:

All Tube Holders

Upper Shield

---

Plate M/B

7

---

Ink Supply Tank

Adapter Cover

Adapter Cover

S14 S18

Assy

---

Adapter

---

Tube Guide

Joint

Sheet

Shield Plate M/B

Lower Shield

(p 64)

(p 69)

Ink Supply Tank

---

Sub

Plate M/B

Tube Assy

2

2

Ink Supply Tube

3

---

Assy (W/Clamp)

S13

---

S13

---

(p 66)

---

---

Tube Guide

Sheet Sub

(p 64)

(p 69)

---

---

Tube Guide

(p 67)

(p 69)

1

Main Board

Top Cover

---

(p 66)

1

4

Bottom Cover

---

---

S12

Valve Lever

Right Cover

Screw type/torque list

Left Cover

Symbol

Screw type

Torque

		APG Sensor				Cover Joint		S1	C.B.P. 2.6X8	3.5-4.5kgf.cm
Cover Ink Tube			PF Encoder		PF Scale
		Assy
						Tube Valve		S2	C.B.P. 2.6X8	3-5kgf.cm
Panel Assy		---		1	---	Holder Rear		S3	C.B.P. 3X10	3-5kgf.cm
		2		---	---	Tube Valve		S4	C.B.P. 3X10	5-7kgf.cm
Tube Holder			S1			Holder Front
								S5	C.B.P. 3X6	3-5kgf.cm
Ink Supply Tank		---							C.B.P. 3X8	5-7kgf.cm
								S6
Assy				“ 1.5.10 PF Encoder / PF Scale (p49)”		Ink Supply Tank			C.B.P.(P2) 3X8	5-7kgf.cm
								S7
Adapter Cover		Photo Interrupter						S8	C.B.S 3X6	5-7kgf.cm
								---
									C.B.S. (P2) 3X8	6-8kgf.cm
								S9
Adapter		---						---	C.B.S. (P4) 3X6	7-9kgf.cm
								S10
Tube Guide		2				(p 64)	(p 69)	S11	C.B.S. (P4) 3X6	9-11kgf.cm
Sheet/Tube
Guide Sheet Sub		---						S12	C.B.S. 3X10	4-6kgf.cm
								S13	C.B.S. 3X6	4-6kgf.cm
		“ 1.5.16 APG Sensor Assy						S14	C.B.S. 3X6	5-7kgf.cm
		(p57)”
C	(p 21)								C.B.S. 3X6	7-9kgf.cm
								S15
								S16	C.P. 3X4	3-5kgf.cm
								S17	C.P. 3X6	3-5kgf.cm
								S18	C.P. 3X6	4-6kgf.cm

Disassembly/Reassembly

Disassembling/Reassembling Flowchart

20

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L800/L801	Revision A
C (p 20)	4 (p 21)

				“ 1.5.12 CR Motor (p50)”
Cover Case		Extension Spring		PF Encoder/		Porous Pad	D	(p 22)
				PF Scale		Paper Guide
	1		---			Front
	---		2				---
S6
				PF Motor			---
(p 65)		---
					2	(p 57)
Printer		Driven Pulley		S17	---
Mechanism		Assy		(p 49)	(p 69)
	5	(p 21)	---
	4
S6	4		---	Driven Pulley
			Driven Pulley	Shaft
(p 35)	(p 69)		---	---
			---	---
		CR Motor
			2
		S16	---
			Driven Pulley
			Holder
			---
Housing Lower			---
Assy

---

---

			“ 1.5.7 Left & Right Guide		Waste Ink Pad	Waste Ink Pad
---	Stacker Assy		Stackers / CDR Guide Sensor				P/S Assy		Waste Ink Tray
					Lower	Cap Lower
			(p44)”
	Stacker Cover				---	---		1		2
Waste Ink Pad
Lower					---	---	S4	---	S4	1
Waste Ink Pad							(p 34)	(p 69)	(p 42)	(p 69)
Cap
	Guide Stacker		Guide Stacker
					“ 1.5.6 Waste Ink Pad Lower / Waste Ink Pad Cap Lower (p43)”
P/S Assy	Left		Right Assy
		1		1
	S6	---	S6	---	CDR Guide
						Label CDR
					Sensor
					---	---
					2	---
Housing Lower					---	---
(W/Foot)

---	Guide Stacker
---	Right
	---
---
	---
	---

Screw type/torque list

Symbol	Screw type	Torque
S1	C.B.P. 2.6X8	3.5-4.5kgf.cm
S2	C.B.P. 2.6X8	3-5kgf.cm
S3	C.B.P. 3X10	3-5kgf.cm
S4	C.B.P. 3X10	5-7kgf.cm
S5	C.B.P. 3X6	3-5kgf.cm
S6	C.B.P. 3X8	5-7kgf.cm
S7	C.B.P.(P2) 3X8	5-7kgf.cm
S8	C.B.S 3X6	5-7kgf.cm
S9	C.B.S. (P2) 3X8	6-8kgf.cm
S10	C.B.S. (P4) 3X6	7-9kgf.cm
S11	C.B.S. (P4) 3X6	9-11kgf.cm
S12	C.B.S. 3X10	4-6kgf.cm
S13	C.B.S. 3X6	4-6kgf.cm
S14	C.B.S. 3X6	5-7kgf.cm
S15	C.B.S. 3X6	7-9kgf.cm
S16	C.P. 3X4	3-5kgf.cm
S17	C.P. 3X6	3-5kgf.cm
S18	C.P. 3X6	4-6kgf.cm

Disassembly/Reassembly

Disassembling/Reassembling Flowchart

21

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L800/L801

Revision A

D (p 21)

	“ 1.5.8 Ink System (p45)”		“ 1.5.9 EJ Frame Assy (p46)”
Ink System	APG Unit	Tube Guide	Tube Guide

2

Extension Spring

Cable Holder

Cable Holder

S15

---

Driven Pulley

Frame

Frame

ExtensionSpring

Compression

Assy

2

0.8

Spring 0.98

CR Scale

PF Scale Sheet

---

---

S15

2

2

---

Adapter Cover

---

PF Encoder FFC

---

---

---

Adapter

---

---

Front Frame

---

(p 66)

Cover FFC

CR Lock

2

---

---

Cover FFC Inner

---

PF Scale Cover

S15

---

Holder Contact

1

---

Printhead

S6

1

LD Roller

Guide Assy

EJ Frame Assy

(p 66)

“ 1.5.14 ASF Unit (p54)”

1

---

S10

5

---

5

(p 23)

EJ Frame

EJ Frame

Torsion Spring L

Torsion Spring R

---

---

ASF Unit

---

---

2

S10

S11

2

Screw type/torque list

6

(p 23)

Cable Holder

“ 1.5.13 CR Unit (p52)”

Symbol

Screw type

Torque

Frame

S1

C.B.P. 2.6X8

3.5-4.5kgf.cm

Upper Paper

S2

C.B.P. 2.6X8

3-5kgf.cm

Guide

CR Unit

C.B.P. 3X10

3-5kgf.cm

S3

---

---

S4

C.B.P. 3X10

5-7kgf.cm

---

S5

C.B.P. 3X6

3-5kgf.cm

2

C.B.P. 3X8

5-7kgf.cm

S6

(p 56)

CR Guide Shaft

Timing Belt

Head FFC

C.B.P.(P2) 3X8

5-7kgf.cm

S7

(p 69)

---

---

---

C.B.S 3X6

5-7kgf.cm

S8

---

---

---

S9

C.B.S. (P2) 3X8

6-8kgf.cm

Tube Guide

S10

C.B.S. (P4) 3X6

7-9kgf.cm

---

S11

C.B.S. (P4) 3X6

9-11kgf.cm

Cable Holder

Frame

S12

C.B.S. 3X10

4-6kgf.cm

Front Frame

S13

C.B.S. 3X6

4-6kgf.cm

S14

C.B.S. 3X6

5-7kgf.cm

EJ Frame Assy

S15

C.B.S. 3X6

7-9kgf.cm

S16

C.P. 3X4

3-5kgf.cm

S17

C.P. 3X6

3-5kgf.cm

E

(p 23)

S18

C.P. 3X6

4-6kgf.cm

Disassembly/Reassembly

Disassembling/Reassembling Flowchart

22

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L800/L801

Revision A

E (p 22)

EJ Ground

Spring

---

3

Front Paper

Guide Assy

		2
S9	S15	1

CDR Tray

Sensor

---

2

(p 60)

			“ 1.5.17 Front Paper Guide Assy (p57)”
	PE Lever/	Spur Gear 26.5	Porous Pad	Photo Interrupter
	PE Lever		Paper Guide	(PE Sensor)
	Torsion Spring		Front
		---		---
		---
		1		4
		2
	---	---		---

6 (p 22)				“ 1.5.14 ASF Unit (p54)”

Retard Roller		Combination
Holder Assy		Gear 168.32.8
	---	---
	2	1
---		---
5	(p 22)

Torsion Spring

137.7

---

---

---

LD Roller Guide

---

---

---

	Spur Gear 16	LD Roller
		Shaft Assy

---	---
---	2
---

Change Lever
Assy
---
---	Compression
	Spring 2.36
---	---
	---
ASF Assy	---
---
---	Change Lever
---	---
	1
	---

LD Roller

---

---

---

	Screw type/torque list
		Symbol	Screw type	Torque
		S1	C.B.P. 2.6X8	3.5-4.5kgf.cm
		S2	C.B.P. 2.6X8	3-5kgf.cm
		S3	C.B.P. 3X10	3-5kgf.cm
		S4	C.B.P. 3X10	5-7kgf.cm
		S5	C.B.P. 3X6	3-5kgf.cm
		S6	C.B.P. 3X8	5-7kgf.cm
		S7	C.B.P.(P2) 3X8	5-7kgf.cm
		S8	C.B.S 3X6	5-7kgf.cm
		S9	C.B.S. (P2) 3X8	6-8kgf.cm
		S10	C.B.S. (P4) 3X6	7-9kgf.cm
		S11	C.B.S. (P4) 3X6	9-11kgf.cm
		S12	C.B.S. 3X10	4-6kgf.cm
		S13	C.B.S. 3X6	4-6kgf.cm
		S14	C.B.S. 3X6	5-7kgf.cm
		S15	C.B.S. 3X6	7-9kgf.cm
		S16	C.P. 3X4	3-5kgf.cm
		S17	C.P. 3X6	3-5kgf.cm
		S18	C.P. 3X6	4-6kgf.cm
Disassembly/Reassembly	Disassembling/Reassembling Flowchart			23

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L800/L801 Revision A

1.3 Removing Exterior Parts/Components	1.3.2 Paper Support Assy
	¸ Removal procedure

1.3.1 Printer Cover

¸Removal procedure

1.Pull out the left shaft and right shaft of the Printer Cover, and remove the Printer Cover.

1.Open the Paper Support Assy.

2.Disengage the right shaft of the Paper Support Assy from the bushing of the ASF Unit by pushing the bushing outward. Then remove the Paper Support Assy, disengaging the left shaft preventing the Edge Guide projection from hitting against the other parts.

Printer Cover
Shaft (left)	Shaft (right)

Figure 1-15. Removing the Printer Cover

Paper Support Assy				Edge Guide
				Projection

Push

:Shaft

Bushing of the ASF

Figure 1-16. Removing the Paper Support Assy

When reinstalling the Paper Support Assy, match the projection and hole of the Edge Guide, then attach the right shaft and the left shaft in that order. (Put the shafts at the front side in the bushing and then push them rearward.) After reinstalling, check that the Paper Support Assy moves smoothly.

Paper Support Assy

Convex Portion

2

1

Mounting Direction	Hole
(from front side to rear side)		: Shaft

Figure 1-17. Reinstalling the Paper Support Assy

Disassembly/Reassembly	Printer Cover	24
		CONFIDENTIAL

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L800/L801	Revision A

1.3.3 Stacker Assy / Stacker Cover

¸Removal procedure

1.Open the Stacker Cover.

2.Remove the Stacker Assy.

3.Release the Stacker Cover from the two shafts and remove the Stacker Cover.

		Shaft
Shaft

Stacker Assy		Stacker Cover

Figure 1-18. Removing the Stacker Assy / Stacker Cover

When installing the Stacker Assy, insert the guide pins of the Stacker Assy into the lower grooves of the Guide Stacker Assy. (The upper grooves are used when CDR is printed.)

Groove

Guide Pin

Groove

Guide Pin

Figure 1-19. Installing the Stacker Assy

1.3.4 Housing Upper Assy

¸Removal procedure

1.Remove the four screws and remove the Upper Housing upward.

•Screw C.B.P. M3x10 (tightening torque: 5-7 kgf.cm)

(The numbers shown in the figure indicate the order of tightening the screws.)

[Rear Side]

4

3

1

2

Upper Housing

Groove

Groove

Figure 1-20. Removing the Upper Housing

Disassembly/Reassembly	Stacker Assy / Stacker Cover	25
		CONFIDENTIAL

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L800/L801	Revision A

2.Slide the Front Housing in the direction of the arrow and remove the Front Housing from the Upper Housing.

	Grooves
Front Housing	[Rear Side]
	Ribs

Figure 1-21. Removing the Front Housing

When installing the Upper Housing, be careful of the following:

̈Do not pinch the cables.

̈Tighten the screws in the order given in Fig.1-20 (p.25).

̈Match the ribs of the Upper Housing shown in Fig.1-20 (p.25) with the grooves of the Housing Lower.

̈As shown in Fig.1-22, match the A part of the Front Housing with the screw box of the Housing Lower.

Front Housing

Screw box of Housing Lower

A part of Front Housing

Figure 1-22. Installing Upper Housing

Disassembly/Reassembly	Housing Upper Assy	26
		CONFIDENTIAL

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L800/L801	Revision A

1.4 Removing Control Boards

1.4.1 Main Board Unit

¸ Removal procedure

̈Main Board Unit removal

1.Disconnect all connectors on the Main Board Unit.

2.Peel off the double-sided tape that secures the Panel FFC to the Holder Frame and release the Panel FFC. (Fig.1-29 (p.30))

CN3

CN17

CN6

CN7

Main Board Unit

CN4

CN13

CN14

CN16

CN12

CN11

CN10

CN8

CN5

Figure 1-23. Connector layout of the Main Board

Table 1-3. List of Connectors and their Destinations

CN No.@

Color

Destination

Number of pins

CN3

White

P/S Assy

3pin

CN4

White

CDR Guide Sensor / CDR Tray Sensor

4pin

CN5

FFC

Panel Board

8pin

CN6

White

PE Sensor

3pin

CN7

Black

APG Sensor

3pin

CN8

FFC

PF Encoder

5pin

CN10

FFC

13pin

Head FFC

CN11

FFC

13pin

CN12

FFC

9pin

CN13

Black

PF Motor

2pin

CN14

White

CR Motor

2pin

CN16

FFC

PW Sensor / CR Encoder Sensor

6pin

CN17

White

Cover Open Sensor

2pin

3.Peel off the four acetate tapes that secures the following cables on the back of the Main Board Unit.

•Power Supply Cable

•CR Motor Cable

•PF Motor Cable

•PE Motor Cable

•APG Sensor Cable

Main Board Unit

Acetate Tape

Acetate Tape

Figure 1-24. Removing the Main Board Unit (1)

Disassembly/Reassembly	Main Board Unit	27
		CONFIDENTIAL

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L800/L801	Revision A

4.Remove the three screws and remove the Main Board Unit.

• Screw	(2 pcs.): C.B.P.(P2) M3x8 (tightening torque: 5-7 kgf.cm)
• Screw	(1 pc.): C.B.S. M3x6 (tightening torque: 7-9 kgf.cm)

(The numbers shown in the figure indicate the order of tightening the screws.)

[Upper Side]	[Left Side]
	3
2	Rib
Positioning Holes
and Guide Pins

1

Main Board Unit

Figure 1-25. Removing the Main Board Unit (2)

A D J U S WheneverT M E NtheT Main Board Unit is replaced, the required adjustment

R E Q U IR E D

must be carried out.

• Refer to "2.1.2 Required Adjustments" (p.74)

When installing the Main Board Unit, be careful of the following:

̈Match the positioning holes with guide pins shown in Fig.1-25.

̈Insert the rib of the Main Board Unit into the positioning hole of the Cable Holder Frame as shown in Fig.1-25.

̈Tighten the screws in the order given in Fig.1-25.

After connecting the cables, secure them with acetate tape following the procedures below.

1.Route the Power Supply Cable closely along the Lower Shield Plate M/B, and secure the cable with acetate tapes at the positions A, B, and C (30 mm each) as shown in Fig.1-26.

2.Avoiding the sharp edge shown in Fig.1-26, secure the following cables with the acetate tape D (50 mm).

•Power Supply Cable

•CR Motor Cable

•PF Motor Cable

•PE Motor Cable

•APG Sensor Cable

Positions of Acetate tape A, B, C

A

B

Power Supply Cable Main Board Unit

C

Lower Shield Plate

M/B

A

D

B

D

Edge of Lower

Shield Plate

C

Sharp edge

Align the upper left end of acetate tape D with the edge of the Lower Shield Plate M/B.

Figure 1-26. Routing the Cables

Disassembly/Reassembly	Main Board Unit	28
		CONFIDENTIAL

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L800/L801	Revision A

̈Disassembling the Main Board Unit

1.Remove the Main Board Unit (p.27).

̈Do not apply unnecessary force on the screw receiving parts of

C A U T IO N

the Lower Shield Plate M/B, as they are easy to deform.

̈When assembling or disassembling the Upper Shield Plate M/B,

be careful of its sharp edges.

2.Remove the seven screws and remove the Upper Shield Plate M/B.

•Screw (6 pcs.): C.B.S. M3x6 (tightening torque: 5-7 kgf.cm)

•Screw (1 pc.): C.P. M3x6 (tightening torque: 4-6 kgf.cm)

(The numbers shown in the figure indicate the order of tightening the screws.)

Be careful of the sharp edges shown in the figure below when

C A U T IO N

assembling or reassembling.

3.Remove the two screws and remove the Shield Plate M/B Sub.

•Screw (2 pcs.): C.B.S. M3x6 (tightening torque: 4-6 kgf.cm)

(The numbers shown in the figure indicate the order of tightening the screws.)

4.Remove the screw and remove the Main Board Unit.

•Screw C.B.S. M3x10 (tightening torque: 4-6 kgf.cm)

Upper Side: Main Board

Lower Side: Lower Shield Plate M/B

5		Lower Shield Plate
		M/B
		Upper Shield Plate
		M/B
			ShieldPlate
			M/B Sub
3	2
			[Rear Side]
			1
		Screw Receiving Part
7		1
4			2
Screw Receiving Part
	6
		Sharp edge	Positioning Hole and
			Guide Pin

Figure 1-27. Removing the Upper Shield Plate M/B	Figure 1-28. Removing the Main Board

̈ When installing the Main Board, match the positioning hole with the guide pin shown in Fig.1-28.

̈ Tighten the screws in the order given in Fig.1-27 (p.29), Fig.1-28.

Disassembly/Reassembly	Main Board Unit	29

CONFIDENTIAL

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