Epson L800, L801 Service Manual

SERVICE MANUAL

Color Inkjet Printer

L800/L801

Confidential

SEMF10-008

Notice:

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 dis-

claims any and all rights in those marks.

I&I CS Quality Assurance Department

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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

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.

WARNING

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.

W A R N I N G

C A U T I O N

C H E C K

P O I N T

Indicates an operating or maintenance procedure, practice or condition that, if not strictly observed, could result in serious injury or loss of life.

Indicates an operating or maintenance procedure, practice, or 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 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.

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)”.

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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

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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

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DISASSEMBLY/REASSEMBLY

CHAPTER

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L800/L801 Revision A

1.1 Overview

C H E C K

P O I N T

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.

Some pictures in this manual are for Epson Stylus Photo R280/ R285/R290; therefore, the shapes of the parts are different from those of L800/L801, but the differences does not affect the disassembly/reassembly procedures.

Table 1-1. List of Tools

1.1.2 Checks and Precautions before Disassembling

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.

Ink Supply Tank Assy

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.

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

Ventilation film

Ink Supply Tank Assy

Do not place the Ink Supply Tank Assy with 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.

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

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

/ Ink Supply Tube Assy from the Joint

Ink Supply Tank Assy

Ink Supply Tank Tube Assy (w/Valve Assy)

Adapter Removing the Ink Supply Tube Assy from

Ink Supply Tube Assy

Note : These parts are indicated with the icon in disassembly/reassembly flowchart. (See

“ 1.2 Disassembly/Reassembly Procedures (p17)”.)

 Removing the tubes of the Ink Supply

Tank Tube Assy from the Joint

 Removing the tubes of the Ink Supply

Tank Tube Assy from the Ink Supply Tank Assy

the Adapter



Removing the Ink Supply Tank Tube Assy / Ink Supply Tube Assy from the Joint

 Removing the Ink Supply Tube Assy

from the Adapter

Ink Supply Tank Assy

A, B

A, C

MEANS DO TO MINIMIZE THE INK SPILL

C A U T I O N

Even observing the points described in this section, ink may 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

C A U T I O N

Do not turn the Valve Lever too much when closing the 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.

Adapter

Joint

Ink Supply Tank Tube Assy Ink Supply Tube Assy

Figure 1-2. Location

Open position

Valve Lever

Choke position

Valve Lever

Figure 1-3. Opening/closing the Choke Valve

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

Valve shaft

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

Disassembly/Reassembly Overview 11

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L800/L801 Revision A

 Adapter is removed

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

C H E C K

P O I N T

The Adapter has an ink valve which cuts off the ink path when removing the Adapter from the Carriage.

DISCHRGING INK FROM THE INK SUPPLY TANK

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 C K

P O I N T

 Discharging procedure

 The photos in the following procedure are for L200/L201, but

the 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.

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)

C H E C K

P O I N T

 It is recommended that the ink in the Ink Supply Tank should

be 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

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.

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 Cap

Air release hole

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.

Ink Supply Tank Assy

Air Release Hole Cap

 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.

Ink Supply

Tank Assy

Strong tape (60 mm x 22 mm)

Figure 1-9. Securing the Ink Supply Tank Assy

Air Release Hole Cap

Top Cover

Strong tape (80 mm x 22 mm)

Strong tape (60 mm x 22 mm)

Fold over the tape edge by 10 mm

Strong tapeCR Unit

Figure 1-8. Securing the CR Unit

Disassembly/Reassembly Overview 14

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 Points to be checked before packing the printer

 The Valve Lever is on the position

shown below (the Choke Valve is

 All the caps of the Ink Supply Tank

Assy are securely closed.

closed). (See Figure 1-3.)

Valve Lever

 The hooks (x2) of the Ink Supply

Tank Assy are securely engaged

 The opened ink bottle is not

included in the box.

with the Housing Upper Assy.

Ink Supply

Tank Assy

Cap

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

Housing Upper Assy

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.

C A U T I O N

 Power the printer and turn it off forcedly by disconnecting the power cable

 Turn the EJ Roller gear on the left side of the printer in the direction of the

[Left side]

PF Roller Gear

Be extremely careful not to damage the EJ Roller gear. Extra care must be taken to avoid injury from sharp metal edges.

when the CR Unit is unlocked and moved away from the home position.

arrow until the carriage is unlocked.

EJ Roller Gear

Turn this gear

Carriage Lock

Locked

Carriage Lock

Unlocked

Figure 1-13. How to Unlock the Carriage

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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 name

Icon

White-letter Parts/units supplied as an ASP --Black-letter Parts/units not supplied as an ASP ---

Indicates a practice or condition that could result in injury or loss of life if not strictly observed.

Indicates a practice or condition that could result in damage to, or destruction of equipment if not 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 when they are removed.

Indicates necessary check items in the disassembling/reassembling procedure.

Indicates supplementary explanation for disassembly is given.

Indicates particular tasks to keep quality of the units are required.

Indicates particular adjustment(s) is/are required.

Indicates lubrication is required.

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.

Indicates the reference page in blue-letter

“ 1.1.2 Checks and Precautions before Disassembling (p10)”

Indicates the reference page in blue-letter

Chapter 2 “ Adjustment (p69)”

Chapter 3 “ Maintenance (p88)”

---

Black letters indicate a part/unit not supplied as an ASP.

Shows the screw types and the specified torque in the “Screw type/torque list”.

White letters indicate a part/unit supplied as an ASP.

Indicates that the disassembly procedure of boxed parts is explained all together and step by step in the section shown as reference page (A).

Main Board Unit

S15

Ink Supply Tank

Tube Assy

(p 20)

Adapter

(p 18)

Reference page

---

Figure 1-14. Example Chart

Reference page (A)

“ 1.5.8 Ink System (p45)”

Front Paper

Guide Assy

S15

Disassembly/Reassembly Disassembly/Reassembly Procedures 17

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1.2.2 Disassembly Flowchart

START

Printer Cover

(p 24)

Paper Support

Assy

Housing Upper

Assy

(p 25)

(p 20)

---

Paper Support

Assy

---

(p 24)

Stacker Assy

---

Stacker Cover

---

Cover Ink Tube

(p 35)

Foot

---

(p 19)

“ 1.3.3 Stacker Assy / Stacker Cover (p25) ”

(p 18)

Cover Open

Sensor

CR Scale

Adapter Cover

Joint

APG Unit

Panel Assy

(p 18)

Housing Right

Housing Upper

---

(p 30)

(p 40)

“ 1.3.4 Housing Upper Assy (p25)”

Decoration Belt

Right

---

(p 68)

(p 65) (p 69)

---

S15

(p 41) (p 88)

---

S14

(p 30)

Screw type/torque list

Adapter

---

(p 19)

(p 68)

(p 69)

---

Holder Contact

---

Cover FFC Inner

---

Cover FFC

---

Printhead

---

“ 1.5.2 Printhead (p37)”

Symbol Screw type Torque

C.B.P. 2.6X8 3.5-4.5kgf.cm

C.B.P. 2.6X8 3-5kgf.cm

C.B.P. 3X10 3-5kgf.cm

C.B.P. 3X10 5-7kgf.cm

C.B.P. 3X6 3-5kgf.cm

C.B.P. 3X8 5-7kgf.cm

C.B.P.(P2) 3X8 5-7kgf.cm

C.B.S 3X6 5-7kgf.cm

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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(p 18)

Top Cover

(p 61)

Bottom Cover

Valve Leve r

Right Cover

(p 63)

(p 18)

Valve Posi t i o n

Label

---

(p 61)

---

Refilling Ink

Label

(p 61)

---

Tube Valve

Holder Rear

(p 62)

Bottom Cover

(p 63)

---

Valve Leve r

---

(p 62)

Cap

---

Top Cover Label

---

(p 61)

Tube Valve

Holder Front

---

Left Cover

---

(p 63)

Left Cover

(p 62)

Valve Le v e r

Right Cover

Cover Joint

---

Panel Cover

Assy

---

(p 18)

---

(p 63)

Panel Unit

---

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

Panel Cover

---

Decoration Belt

Left

---

“ 1.5.4 APG Unit (p41)”

---

Open Sensor

Holder

Spur Gear 12.8

---

APG Holder

---

Spur Gear 28.8

---

Spur Gear 33.6

---

Combination

Gear 14.22

---

Panel Shield

Plate

Compression

Spring 2.25

---

Compression

Spring 0.97

---

Combination

Gear 12.8.27

---

Panel Board

---

Housing Panel

Assy

---

Screw type/torque list

Symbol Screw type Torque

C.B.P. 2.6X8 3.5-4.5kgf.cm

C.B.P. 2.6X8 3-5kgf.cm

C.B.P. 3X10 3-5kgf.cm

C.B.P. 3X10 5-7kgf.cm

C.B.P. 3X6 3-5kgf.cm

C.B.P. 3X8 5-7kgf.cm

C.B.P.(P2) 3X8 5-7kgf.cm

C.B.S 3X6 5-7kgf.cm

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

Confidential

L800/L801 Revision A

(p 18)

Main Board Unit

S15

“ 1.4.1 Main Board Unit (p27) ”

Tube H o l d e r*

*: 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.

---

Upper Shield

Plate M/B

---

S14 S18

Shield Plate M/B

Sub

S13

---

Lower Shield

Plate M/B

---

S13

---

Ink Supply Tank

Assy

(p 64) (p 69)

Main Board

S12

---

 When removing the Ink Supply Tank Assy: The Tube Holder on the home position side (on the Cover Case)  When removing the Printer Mechanism: All Tube Holders

Adapter CoverAdapter Cover

---

Ink Supply Tank

Tube Assy

---

(p 64) (p 69)

Top Cover

Adapter

Joint

Ink Supply Tube Assy (W/Clamp)

(p 67) (p 69)

Tube Guide

Sheet

---

(p 66)

---

Tube Guide

Sheet Sub

---

(p 66)

Bottom Cover

---

Valve Le v e r

Cover Ink Tube

Panel Assy

Tube Holder

Ink Supply Tank

Assy

Adapter Cover

Adapter

Tube Guide

Sheet/Tube

Guide Sheet Sub

(p 21)

APG Sensor

Assy

---

Photo Interrupter

---

“ 1.5.16 APG Sensor Assy

(p57)”

PF Encoder

PF Scale

---

“ 1.5.10 PF Encoder / PF Scale (p49)”

Right Cover

Left Cover

Cover Joint

Tube Valve

Holder Rear

Tube Valve

Holder Front

Ink Supply Tank

(p 64) (p 69)

Screw type/torque list

Symbol Screw type Torque

C.B.P. 2.6X8 3.5-4.5kgf.cm

C.B.P. 2.6X8 3-5kgf.cm

C.B.P. 3X10 3-5kgf.cm

C.B.P. 3X10 5-7kgf.cm

C.B.P. 3X6 3-5kgf.cm

C.B.P. 3X8 5-7kgf.cm

C.B.P.(P2) 3X8 5-7kgf.cm

---

C.B.S 3X6 5-7kgf.cm

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 20

Confidential

L800/L801 Revision A

(p 20) (p 21)

Cover Case

(p 65)

Printer

Mechanism

(p 35) (p 69)

Extension Spring

---

Driven Pulley

Assy

(p 21)

---

Driven Pulley

CR Motor

S16

---

Driven Pulley

Holder

“ 1.5.12 CR Motor (p50) ”

Driven Pulley

Shaft

---

PF Encoder/

PF Scale

Porous Pad

Paper Guide

Front

(p 22)

---

PF Motor

S17

(p 49) (p 69)

---

(p 57)

---

Housing Lower

Assy

---

Waste Ink Pad

Lower

Waste Ink Pad

Cap

P/S Assy

Housing Lower

(W/Foot)

---

“ 1.5.7 Left & Right Guide

Stacker Assy

Stackers / CDR Guide Sensor (p44)”

Stacker Cover

Guide Stacker

Left

---

Guide Stacker

Right Assy

“ 1.5.6 Waste Ink Pad Lower / Waste Ink Pad Cap Lower (p43)”

---

Waste Ink Pad

Lower

CDR Guide

Sensor

---

Guide Stacker

Right

---

Waste Ink Pad

Cap Lower

---

P/S Assy

(p 34) (p 69)

---

Label CDR

---

Waste Ink Tray

(p 42) (p 69)

Screw type/torque list

Symbol Screw type Torque

S10

S11

S12

S13

S14

S15

S16

S17

S18

C.B.P. 2.6X8 3.5-4.5kgf.cm

C.B.P. 2.6X8 3-5kgf.cm

C.B.P. 3X10 3-5kgf.cm

C.B.P. 3X10 5-7kgf.cm

C.B.P. 3X6 3-5kgf.cm

C.B.P. 3X8 5-7kgf.cm

C.B.P.(P2) 3X8 5-7kgf.cm

C.B.S 3X6 5-7kgf.cm

C.B.S. (P2) 3X8 6-8kgf.cm

C.B.S. (P4) 3X6 7-9kgf.cm

C.B.S. (P4) 3X6 9-11kgf.cm

C.B.S. 3X10 4-6kgf.cm

C.B.S. 3X6 4-6kgf.cm

C.B.S. 3X6 5-7kgf.cm

C.B.S. 3X6 7-9kgf.cm

C.P. 3X4 3-5kgf.cm

C.P. 3X6 3-5kgf.cm

C.P. 3X6 4-6kgf.cm

Disassembly/Reassembly Disassembling/Reassembling Flowchart 21

Confidential

L800/L801 Revision A

(p 21)

Ink System

S15

LD Roller

Guide Assy

S10

---

Extension Spring

CR Lock

“ 1.5.14 ASF Unit (p54)”

0.8

---

(p 23)

“ 1.5.8 Ink System (p45)”

Compression

Spring 0.98

---

APG Unit

Tube Guide

“ 1.5.9 EJ Frame Assy (p46)”

Tube G u i d e

Extension Spring

Driven Pulley

Assy

Cable Holder

Frame

Cable Holder

Frame

---

CR Scale

Adapter Cover

S15

---

Adapter

Front Frame

PF Encoder FFC

---

Cover FFC

---

Cover FFC Inner

Holder Contact

S15

---

Printhead

EJ Frame Assy

PF Scale Sheet

(p 66)

PF Scale Cover

(p 66)

---

EJ Frame

Torsion Spring L

---

EJ Frame

Torsion Spring R

---

ASF Unit

S10 S11

Upper Paper

Guide

(p 56)

(p 69)

Tube G u i d e

Cable Holder

Frame

Front Frame

EJ Frame Assy

(p 23)

---

(p 23)

Cable Holder

Frame

“ 1.5.13 CR Unit (p52)”

CR Unit

---

CR Guide Shaft

---

Timing Belt

---

Head FFC

---

Screw type/torque list

Symbol Screw type Torque

C.B.P. 2.6X8 3.5-4.5kgf.cm

C.B.P. 2.6X8 3-5kgf.cm

C.B.P. 3X10 3-5kgf.cm

C.B.P. 3X10 5-7kgf.cm

C.B.P. 3X6 3-5kgf.cm

C.B.P. 3X8 5-7kgf.cm

C.B.P.(P2) 3X8 5-7kgf.cm

C.B.S 3X6 5-7kgf.cm

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 22

Confidential

L800/L801 Revision A

EJ Ground

Spring

Front Paper

Guide Assy

S15

CDR Tray

Sensor

(p 60)

(p 22)

Retard Roller

Holder Assy

---

“ 1.5.17 Front Paper Guide Assy (p57)”

---

Combination

Gear 168.32.8

---

Spur Gear 16

---

LD Roller

Shaft Assy

“ 1.5.14 ASF Unit (p54)”

---

LD Roller

---

(p 22)

PE Lever/

PE Lever

Torsion Spring

---

Spur Gear 26.5

---

Porous Pad

Paper Guide

Front

Photo Interrupter

(PE Sensor)

---

Torsion Spring

137.7

---

LD Roller Guide

---

Change Lever

Assy

---

ASF Assy

---

Compression

Spring 2.36

---

Change Lever

---

Screw type/torque list

Symbol Screw type Torque

C.B.P. 2.6X8 3.5-4.5kgf.cm

C.B.P. 2.6X8 3-5kgf.cm

C.B.P. 3X10 3-5kgf.cm

C.B.P. 3X10 5-7kgf.cm

C.B.P. 3X6 3-5kgf.cm

C.B.P. 3X8 5-7kgf.cm

C.B.P.(P2) 3X8 5-7kgf.cm

C.B.S 3X6 5-7kgf.cm

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

Confidential

L800/L801 Revision A

1.3 Removing Exterior Parts/Components

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.

Printer Cover

Shaft (left)

Figure 1-15. Removing the Printer Cover

Shaft (right)

1.3.2 Paper Support Assy

 Removal procedure

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.

Paper Support Assy

Push

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.

Edge Guide

Projection

Paper Support Assy

:Shaft

Convex Portion

Mounting Direction

(from front side to rear side)

Hole

: Shaft

Figure 1-17. Reinstalling the Paper Support Assy

Disassembly/Reassembly Printer Cover 24

Confidential

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

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

Shaft

Groove

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]

1 2

Upper Housing

Guide Pin

Groove

Figure 1-19. Installing the Stacker Assy

Figure 1-20. Removing the Upper Housing

Disassembly/Reassembly Stacker Assy / Stacker Cover 25

Confidential

L800/L801 Revision A

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

Front Housing

Grooves

[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

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))

CN6 CN7CN3

CN17

CN4

CN13

CN14

CN12

CN11

CN16

CN10

CN5CN8

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

CN4 White

CN5 FFC

CN6 White

CN7 Black

CN8 FFC

CN10 FFC

CN11 FFC 13pin

CN12 FFC 9pin

CN13 Black

CN14 White

CN16 FFC

CN17 White

P/S Assy CDR Guide Sensor / CDR Tray Sensor

Panel Board

PE Sensor

APG Sensor

PF Encoder

Head FFC

PF Motor

CR Motor

PW Sensor / CR Encoder Sensor

Cover Open Sensor

Main Board Unit

3pin

4pin

8pin

3pin

5pin

13pin

2pin

6pin

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

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

Disassembly/Reassembly Main Board Unit 27

Confidential

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]

Positioning Holes and Guide Pins

Main Board Unit

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

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

Rib

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

Power Supply Cable

Main Board Unit

Lower Shield Plate M/B

A D J U S T M E N T

R E Q U I R E D

Whenever the Main Board Unit is replaced, the required adjustment must be carried out.

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

Sharp edge

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.

Edge of Lower Shield Plate M/B

Figure 1-26. Routing the Cables

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

Disassembly/Reassembly Main Board Unit 28

Confidential

L800/L801 Revision A

 Disassembling the Main Board Unit

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

C A U T I O N

 Do not apply unnecessary force on the screw receiving parts of

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.)

Lower Shield Plate M/B

Upper Shield Plate M/B

Screw Receiving Part

C A U T I O N

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

[Rear Side]

Shield Plate M/B Sub

Screw Receiving Part

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

Sharp edge

Positioning Hole and Guide Pin

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

L800/L801 Revision A

1.4.2 Panel Assy/ Cover Open Sensor

 Removal procedure

 Panel Assy removal

1. Disconnect the Panel FFC from the connector (CN5) on the Main Board and peel the Panel FFC off the Cable Holder Frame.

2. Disconnect the CDR Sensor Cable and Cover Open Sensor Cable from the connectors (CN4, CN17) on the Main Board.

3. Release the CDR Sensor Cable and Cover Open Sensor Cable from the two hooks of the Cable Holder Frame.

4. Peel off the acetate tape A, B to separate the CDR Sensor Cable from the Cover Open Sensor Cable.

Hooks and Acetate Tape A, B

CN4CN17

Cover Open Sensor and CDR Sensor Cable

C A U T I O N

When removing the screw (2) shown in Fig.1-30, be careful not to damage the Cover Open Sensor Cable and CDR Sensor Cable.

5. Remove the two screws.

• Screw (3 pcs.): C.B.P. M3x6 (tightening torque: 5-7 kgf.cm)

• Screw (3 pcs.): C.B.P. M3x10 (tightening torque: 5-7 kgf.cm)

6. From the bottom of the Printer, insert a flathead screwdriver into the hole to disengage the tab, and remove the Panel Assy.

Panel Assy

[Front side]

Open Sensor Holder

Tab

CN5

Main Board

Panel FFC

Figure 1-29. Removing the Panel Assy (1)

Cable Holder Frame

Double sided Tape

Figure 1-30. Removing the Panel Assy (2)

Disengage direction

Housing Lower

Disassembly/Reassembly Panel Assy/ Cover Open Sensor 30

Confidential

+ 75 hidden pages