Epson stylus 777 schematic

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SERVICE MANUAL

Color Inkjet Printer

EPSON STYLUSCOLOR680/777/777i

SEIJ00010

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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, or otherwise, without the prior written permission of SEIKO EPSON CORPORATION.

All effort have been made to ensure the accuracy of the contents of this manual. However, should any errors be detected, SEIKO EPSON would greatly appreciate being informed of them.

The contentsof this manual are subject to change without notice.

All effort have been made to ensure the accuracy of the contents of this manual. However, should any errors be detected, SEIKO EPSON would greatly appreciate being informed of them.

The above not withstanding SEIKO EPSON CORPORATION can assume no responsibility for any errors in this manual or the consequences thereof.

EPSON is a registered trademark of SEIKO EPSON CORPORATION.

General Notice: Other product names used herein are for identification purpose only and may be trademarks or registered trademarks of their

respective owners. EPSON disclaims any and all rights in those marks.

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PRECAUTIONS

Precautionary notations throughout the text are categorized relative to 1)Personal injury and 2) damage to equipment. DANGER Signals a precaution which, if ignored, could result in serious or fatal personal injury. Great caution should be exercised in performing

procedures preceded by DANGER Headings.

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

The precautionary measures itemized below should always be observed when performing repair/maintenance procedures.

DANGER

1. ALWAYS DISC ONNECT THE PRODUCT FROM THE POWER SOURCE AND PERIPHERAL DEVICES PERFORMING ANY MAINTENANCE OR RE PAIR PROCEDURES.

2. NO WORK SHOULD BE PERFORMED ON THE UNIT BY PERSONS UNFAMILIAR WITH BASIC SAFETY MEASURES AS DICTATED FOR A LL ELECTRONICS TECHNICIANS IN THEIR LINE OF WORK.

3. WHEN P ERFORMING TESTING AS DICTATED WITHIN THIS MANUAL, DO NOT CONNECT THE UNIT TO A POWE R SOURCE UNTIL INSTRUCTED TO DO SO. WHEN THE POWER SUPPLY CABLE MUST BE CONNECTED, USE EXTREME CAUTION IN WORKING ON POWER S UPPLY AND OTHER ELECTRONIC COMPONENTS.

WARNING

1. REPAIRS ON EPSON PRODUCT SHOULD BE PERFORMED ONLY BY AN EPSON CERTIFIED REPAIR TECHNICIAN.

2. MAKE CE RTAIN THAT THE SOURCE VOLTAGES IS THE SAME AS THE RATED VOLTAGE, LISTED ON THE SER IAL NUMBER/ RATING PLATE. IF THE EPSON PRODUCT HAS A PRIMARY AC RATING DIFFERENT FROM AVAILABLE POWER S OURC E, DO NOT CONNECT IT TO THE POWER SOURCE.

3. ALWAYS V ERIFY THAT THE EPSON PRODUCT HAS BEEN DISCONNECTED FROM THE POWER SOURCE BEFORE REMOVING OR REPLACING PRINTED CIRCUIT BOARDS AND/OR INDIVIDUAL CHIPS.

4. IN ORDER TO PROTECT SENSITIVE MICROPROCESSORS AND CIRCUITRY, USE STATIC DISCHARGE EQUIPMENT, SUCH A S

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About This Manual

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

Contents

This manual consists of six chapters and one Appendix.

CHAPTER 1.PRODUCT DESCRIPTIONS

Provides a general overview and specifications of the product.

CHAPTER 2.OPERATING PRINCIPLES

Describes the theory of electrical and mechanical operations of the product.

CHAPTER 3.TROUBLESHOOTING

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

CHAPTER 4.DISASSEMBLY AND ASSEMBLY

Describes the step-by-step procedures for dissaembling and assembling the product.

CHAPTER 5.ADJUSTMENTS

Provides Epson-approved methods for adjustment.

CHAPTER 6.MAINTENANCE

Provides preventive maintenance procedures and the lists of Epson-approved lubricants and a dhesives required for servicing the product.

APPENDIXProvides the following additional information for reference:

• Connector pin assignments

• Electric circuit boards c omponents layout

• Exploded diagram

• Electricalcircuitboardsschematics

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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 a ction. B e aware of all symbols when they are used, and always read W ARNI NG, CAUTION or NOTE messages.

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 injury or loss of life.

Indicates an operating or maintenance procedure, practice, or condition that, if not strictly observed, could re sult in damage to, or destruction of, equipment.

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

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Revision Status

Revision Issued Date Description

A August 10, 2000 First Release

Revision:

B August 31, 2000

Added disassembly and reassembly caution to 4.2.1 Housing Removal

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

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Chapter 1 PRODUCT DESCRIPTION

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

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

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

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

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

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

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

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

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

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

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

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

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

1.3.1 Parallel Interface (Forward Channel) ....................................... 14

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

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

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

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

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

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

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

1.4.2 Control P anel............................................................................ 20

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

2.2 Electrical CircuitO perating Principles................................................ 40

2.2.1 C383 PSB/PS E board.............................................................. 40

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

Chapter 3 Troubleshooting

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

3.2 Troubleshooting with LED Error Indications....................................... 51

Chapter 4 Disassembly and Assembly

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Chapter 2 Operating Principles

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

Chapter 5 Adjustment

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

Page 8

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Chapter 6 Maintenance

6.1 Overview...........................................................................................1 18

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

6.1.2 Service Maintenance.............................................................. 119

6.1.3 Lubrication..............................................................................1 19

Chapter 7 Appendix

7.1 Connector Sum mary......................................................................... 124

7.1.1 Major Component Unit ........................................................... 124

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

7.2 C omponent L ayout........................................................................... 1 31

7.3 Expl oded Diagram.. .......................................................................... 133

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

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

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PRODUCTDESCRIPTION

CHAPTER

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EPSON Stylus COLOR 680/777/777i Revision B

1.1 FEATURES

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

High Color Print Qua lity

2880 (H) X 720 (V) dpi printing

Four Color Printing (YMCK)

Traditional and New Microweave

Built-inAutoSheetFeeder

Holds 100 cut-sheets(64g/m2)

Holds 10 envelopes

Holds 1 transparency films

Two Built-in Interfaces

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

USB

Windows/Macintosh exclusive

Figure 1-1. External View

PRODUCT DESCRIPTION

EATURES 10

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EPSON Stylus COLOR 680/777/777i Revision B

1.2 SPECIFICATIONS

This section covers specifications of the printers.

1.2.1 Physical Specification

Weight: 4.1kg (without ink cartridges)

Dimension:

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

1.2.2 Printing Specification

Print Method

On demand ink jet

Nozzle Configuration

Monochrome 144 noz zles (48 x 3 staggered)

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

Print Direction

Bi-direction with logic seeking

Control Code

ESC/P Raster command

EPSON Remote command

Character Tables

Two international character sets:

- PC 437 (US, Standard Europe)

Typeface

Bit map LQ font: EPSON Courier 10 CPI

Table1-2. RasterGraphicsMode

Horizontal Resolution

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

1440 dpi 8.26 inches 11904 20 IPS

Printable Area AvailableDot CR Speed

Print Speed & Printable Columns

Table 1-1. Character Mode

CharacterPitch PrintableColumn LQ Speed

10 CPI (Pica) 80 238 CPS*

*This value is the speed of normal-dot printing.

PRODUCT DESCRIPTION

PECIFICATIONS 11

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EPSON Stylus COLOR 680/777/777i Revision B

1.2.3 Paper Feeding

Feed Method

Friction feed with ASF

Paper Path

Cut-sheet ASF (Top entry, Front out)

Feed Speed

2.36 inch/sec (Normal, Continuous feed)

4.5 inch/sec (Fast, Continues feed)

1.2.4 Input Data Buffer

32KB

1.2.5 Electric Specification

[120V Version]

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

Approx. 2.5W in standby m ode Energy Star compliant

Insulation Resistance: 100M ohms min.

(between AC line and chassis, DC 500V)

Dielectric Strength: AC 1000V rms. 1 minutes or

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

[220 ∼ 240V Version]

Rated Voltage: AC220V∼240V Input Voltage Range: AC198∼264V Rated Frequency R ange: 50∼60Hz Input Frequency Range: 49.5∼60.5Hz Rated Current: 0. 2 A (for Stylus Color 860)

0.2 A (for Stylus Color 1160)

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

Approx. 2.5W in standby mode Energy Star compliant

Insulation Resistance: 100M ohms min.

(between AC line and chassis, DC 500V)

Dielectric Strength: AC 1500V rms. 1 minute

(between AC line and chassis)

PRODUCT DESCRIPTION

PECIFICATIONS 12

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EPSON Stylus COLOR 680/777/777i Revision B

1.2.6 Environmental Condition

Temperature

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

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

1monthat40°C and 120 hours at 60°C

Humidity

Operating: 20 to 80% RH

(without c ondensation / see the figure below for condition)

Non-operating: 5 to 85% RH

(without c ondensation / with shipment container)

Resistance to Shock

Operating: 1G, within 1 ms

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

Resistance to Vibration

Operating: 0.15G

Non-operating: 0.50G (with s hipment container)

90 80 70

Humidity (%)

50 40 30 20

Temperature (°C)

1.2.7 Reliability

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

or 5 years although less than 50.000 pages printing

Print Head Life: 3 billion dots/nozzle

1.2.8 Safety Approvals

[120V Version]

Safety Standards: UL1950

CSA22.2 No.950

EMI: FCC part 15 subpart B Class B

CSA C108.8 Class B

[220∼240V Version]

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

AS/NZS 3548 Class B

1.2.9 Acoustic Noise

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

-Used media : Plain Paper

- Print Quality: Fine

1.2.10 CE Marking

[220∼240V Version]

Low Voltage Directive 73/23/EEC: EN60950 EMC Directive 89/336/EEC: EN55022 Class B

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

35 40

IEC801-2 IEC801-3 IEC801-4

Figure 1-2. Temperature/Humidity Range

PRODUCT DESCRIPTION

PECIFICATIONS 13

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EPSON Stylus COLOR 680/777/777i Revision B

1.3 INTERFACE

The EPSON Stylus COLOR 680/777/777i provide USB and parallel interface as standard.

1.3.1 Parallel Interface (Forward Channel)

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

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

BUSY signal is at high level in t he following cases:

During data entry (see data transmission timing).

When input data buffer is full.

During -INIT signal is at low level or during hardware initialization.

During printer error (see -ERROR signal).

When the parallel interface is not selected.

ERROR signal is at low le vel when the printer is in one of the following states:

Printer hardware error (fatal error)

Paper-out e rror

Paper-jam error

Ink-out error

PE signal is at high level during paper-out e rror.

DATA

-STROBE tsetup

BUSY

tready

-ACKNLG

databyte n

thold

tbusy

treply

tstb

tack

tnbusy

Figure 1-3. Data Transmission Timing

Table 1-3.

Parameter Minimum Maximum

tsetup 500ns -

thold 500ns -

tstb 500ns -

tready 0 -

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

treply 0 -

tack 500ns 10us

tnbusy 0 -

tnext 0 -

databyte n+1

tnext

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

PRODUCT DESCRIPTION INTERFACE 14

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EPSON Stylus COLOR 680/777/777i Revision B

Table 1-4. Typical Time of tack

Parallel I/F Mode TypicalTime of tack

High Speed 0.5us

Normal Speed 2us

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

Parameter Minimum Maximum Condition

VOH* - 5.5V VOL* -0.5V -

IOH* - 0.32mA VOH = 2. 4V IOL* - 12mA VOL = 0.4V

CO - 50pF

VIH - 2.0V

VIL 0.8V -

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

CI - 50pF

* A low logic level on the Logic H signal is 2.0V or less when the printer

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

Table 1-6. Connector Pin Assignment and Signals

Pin No. Signal Name

1 -STROBE 19 In

2 DATA0 20 In 3 DATA1 21 In 4 DATA2 22 In 5 DATA3 23 In 6 DATA4 24 In 7 DATA5 25 In 8 DATA6 26 In 9 DATA7 27 In

10 -ACKNLG 28 Out

11 BUSY 29 Out

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

13 SLCT 28 Out

14 -AFXT 30 In Not used.

Return

GND Pin

In/Out Functional Description

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

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

Each signali s at high level when datais logical 1 and low level when data is logical0.

This signal is a negative pulse indicating that the printer can accept data again.

A high signal indicates that the printer cannot receive data.

Always at high level when the printer is powered on.

The falling edge of a negative pulse or a

31 -INIT 30 In

32 -ERROR 29 Out

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

low signal on this line causes the printer to initialize. Minimum 50us pulse is necessary.

A low signal indicatesprinter error condition.

PRODUCT DESCRIPTION INTERFACE 15

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EPSON Stylus COLOR 680/777/777i Revision B

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

Pin No. SignalName

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

16,33,

19-30 15,34 NC - - Not connected

GND - - Signal GND

Return

GND Pin

In/Out Functional Description

NOTE: In/Out refers to the direction of signal flow seen f rom the printer side.

PRODUCT DESCRIPTION INTERFACE 16

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EPSON Stylus COLOR 680/777/777i Revision B

1.3.2 Parallel Interface (Reserve Channel)

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

See forward channel.

Table 1-7. Connector Pin Assignment and Signals

Pin No. Signal Name

1 HostClk 19 In Host clock signal. 2 DATA0 20 In 3 DATA1 2 1 In 4 DATA2 22 In 5 DATA3 2 3 In 6 DATA4 24 In 7 DATA5 2 5 In 8 DATA6 26 In 9 DATA7 2 7 In

10 PtrClk 28 Out Printer clock signal.

Return

GND Pin

In/Out Functional Description

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

Each signal is at high level when data is logical1 and low level when data is logical0.

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

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

Pin No. Signal Name

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

16,33,

19-30 15,34 NC - - Not connected

-DataAvail / DataBit-0,4

GND - - Signal GND

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

view.

Extensibility Request:

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

00H: Request Nibble Mode Reverse C hannel Transfer. 04H: Request Device ID;

Return Data Using Nibble Mode Rev Channel T ransfer.

Return

GND Pin

29 Out

In/Out Functional Description

Dataavailablesignaland reversechannel transfer data bit 0 or 4.

14 HostBusy 30 In Host busy signal. 31 -INIT 30 In Not used.

PtrBusy /

DataBit-3,7

AckDataReq / DataBit-2,6

Xflag /

DataBit-1,5

29 Out

28 Out

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

Acknowledge data request signal and reverse channel transfer data bit 2 or 6.

X-flag signal and reverse channel transferdata bit 1 or 5.

PRODUCT DESCRIPTION INTERFACE 17

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EPSON Stylus COLOR 680/777/777i Revision B

Device ID:

The printer s ends the following device ID string when requested.

When IEEE1284.4 is enabled,

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

When IEEE1284.4 is disabled,

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

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

1.3.3 USB Interface

Standard: Based on:

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

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

Table 1-8. Connector Pin Assignment and Signals

Pin No. Signal Name I/O Function Description

1 VCC - Cable power. Max.power consumption is 2mA. 2 -Data Bi-D Da ta 3 +Data Bi-D Data, pull up to +3.3 V via 1.5K ohm resistor. 4 Ground - Cable ground

Pin #2

Pin #1

Pin #3

Pin #4

Figure 1-4. USB Pin Assignment

PRODUCT DESCRIPTION INTERFACE 18

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EPSON Stylus COLOR 680/777/777i Revision B

1.3.4 Prevention of Data Transfer Time-out

Generally,hosts abandon data transfer to peripherals when the peripheral is in the busy state for dozens of seconds continuously. To prevent this kind of time-out, the printer receives data very slowly, several bytes per minute, even if the printer is in the busy state. The slowdown starts when the remaining input buffer becomes several hundreds of bytes, and the printer finally gets into the busy state continuously when the input buffer is full. USB and IEEE1284.4 on the parallel interface do not require such function.

On An initial state is IEEE1284.4communication and data that received it by thetime it is able to take synchronization by magic string (1284.4 synchronous commands) is discarded.

Off An initial state is compatible interface and never starts IEEE1284.4 communication even if magic strings (1284.4 synchronous commands) are received.

1.3.5 Interface Selection

The printer ha s two built-in interfaces: the USB and parallel interface. These interfaces are selected automatically.

Automatic Selection In thisautomatic interface selection mode, the printer is initialized to the idle state while scanning which interface receives data when it is powered on. Then the interface which received data first is selected. Whe n the host stops data transfer and the printer is in the s tand-by statefor seconds,the printer is returned to the idle state.As long as the host sends data or the printer interface is in the busy state, the selected interface is let as it is.

Interface State and Interface Selection When the parallel interface is not selected, the interface gets into the busy state. When the printer is initialized or returned to the idle state, the parallel interface gets into the ready state. Note that the interrupt signal such as the -INIT signal on the parallel interface is not effective while that interface is not selected.

1.3.6 IEEE1284.4 Protocol

The packet protocol described by IEEE1284.4 standard allows a device to carry on multiple exchanges or conversations which contain data and/or control information with another device at the same timeacross a singlepoint-to-pointlink. The protocol is not, however, a device control language. It does provide basic transport-level flow controland multiplexingservices. The multiplexedlogical channels are independent of each other a nd blocking of one has no effect on the others. The protocol operates over IEEE1284.

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

PRODUCT DESCRIPTION INTERFACE 19

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EPSON Stylus COLOR 680/777/777i Revision B

1.4 OPERATOR CONTROLS

1.4.1 Operating Switch

Operating switch is located on the control panel.

1.4.2 Control Panel

1.4.2.1 Switches

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

Power

Maintenance

1.4.2.2 Indicators

(1) Power

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

(2) Error

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

Ink Cartridge replacement

Figure 1-5. Control Panel

PRODUCT DESCRIPTION

PERATOR CONTROLS 20

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EPSON Stylus COLOR 680/777/777i Revision B

1.4.3 Panel Functions

Table 1-9. Panel Functions

Switch Function

Maintenance

Ink Cartridge replacement

* This function is not available in printing status.

Switch Function

Maintenance

Ink Cartridge

replacement

Maintenance

Ink Cartridge

replacement

• Loads or Ejects the Paper (Pushing within 3seconds).

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

• When carriage is on t he Ink Cartridgechange position, return carriage from Ink Cartridge change position.

• Starts the Ink Cartridge change sequence. *

Table 1-10. Panel Functions with Power On

• Start status printings.

• Select IEEE 1284.4 mode for parallel I/F. *1

• Enters the special setting mode (Factory use only). *3

Table 1-11. Special S etting Mod e

Switch Function

Maintenance

Ink Cartridge replacement

(10 seconds)

• Initialize EEPROM.

• Reset the ink overflow counterin the EEPROM.

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

PRODUCT DESCRIPTION

PERATOR CONTROLS 21

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EPSON Stylus COLOR 680/777/777i Revision B

1.4.4 Printer Condition and Panel Status

Table 1-12. Printer Condition and LED S tatus

Printer Status

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

(Black and Color) No Ink Cartridge

(Black and Color) Reset, Timer IC reset,

EEPROM clear Ink Overflow Counter reset On (2s) On (2s) Maintenance request

(Ink Overflow Counter error)

Power Er ror

- Blink -> Blink 8

- On 7

On (1s) On (1s) -

Alt Blink Alt Blink 2

Indicators

Priority

1.4.5 Printer Initialization

There are three kinds of initialization m ethods, and the following explains each initialization.

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

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

2. Operator Initialization This printer is initialized when turning the printerpower on again within 10 seconds from last power off, or printer recognized the -INIT signal (negative pulse) of parallel interface.

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

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

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

Fatal error Off On 1 Specialsetting Blink Blink -

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

B is a indicator conditionin Ink exchange sequence.

PRODUCT DESCRIPTION

PERATOR CONTROLS 22

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EPSON Stylus COLOR 680/777/777i Revision B

1.4.6 Errors

Ink Out

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

Paper Out

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

Paper Jam

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

No Ink-Cartridge

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

Maintenance Request

When the total amount of ink wastedthrough cleanings and flushing reachesto the limit, printer indicates this error and stops. In such a case, the absorber in the printer enclosure needs to be replaced with new one by service personnel.

Fatal Errors

Carriage control error.

PRODUCT DESCRIPTION

PERATOR CONTROLS 23

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EPSON Stylus COLOR 680/777/777i Revision B

1.5 PAPER

1.5.1 Paper Handling

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

1.5.2 Paper Specification

1.5.2.1 Cut Sheet

[Size]

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

[Thickness]

0.08mm (0.003”) - 0.11mm (0.004”)

[Weight]

64g/m

[Quality]

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

1.5.2.2 Transparency, Glossy Paper

[Size]

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

[Thickness]

0.075mm (0.003”) - 0.085mm (0.0033”)

[ASF hopper availablecapacity]

1sheets

Note: Transparency printing is available only at normal temperature.

1.5.2.3 Envelope

[Size]

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

[Thickness]

0.16mm (0.006”) - 0.52mm (0.02”)

[Weight]

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

Exclusive paper, Bond paper, PPC

[ASF hopper available capacity]

100 sheets

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

PRODUCT DESCRIPTION PAPER 24

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EPSON Stylus COLOR 680/777/777i Revision B

[Quality]

Bond paper, Plain paper, Air mail

Note1: Envelope printing is available only at normal temperature. Note 2: Keep the longer side of the envelope horizontally at setting. Note 3: Envelope printing is available only in t he normal temperature. Note 4: No wrinkled,scuffing, torn or folded paper be used. Note 5: No curled paper more than 5mm be used. Note 6: No paper with glue on flap be used. Note 7: No double envelops nor with window envelops be used. Note 8: Do not print on the back.

1.5.2.4 Index Card

[Size]

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

[Thickness]

Less than 0.23mm (0.0091”)

[ASF hopper available capacity]

30 sheets

PRODUCT DESCRIPTION PAPER 25

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EPSON Stylus COLOR 680/777/777i Revision B

1.5.3 Printing Area

1.5.3.1 Cut Sheet

See the figure be low and tables on the right for printable areas.

Printable Area

Table 1-13. Printing Area

Left Margin

Paper Size

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

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

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

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

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

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

(min.)

* Bottom margin can be reduced to 3mm when paper dimension is

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

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

(paper length).

Right Margin

(min.)

Top Margin

(min.)

14 mm (0.54”)/ 3mm (0.12”) *

Bottom Margin

(min.)

Figure 1-6. Printable Area for Cut S heet

PRODUCT DESCRIPTION PAPER 26

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EPSON Stylus COLOR 680/777/777i Revision B

1.5.3.2 Envelopes

Printable Area

Figure 1-7. Printable Area for Envelopes

Table 1-14. Envelope Margin

Size

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

Left M a rgin

(min.)

Right M argin

(min.)

Top Margin

(min.)

Bottom Margin

(min.)

DL 3 mm (0.12”) 7 mm (0.28”) 3 mm (0.12”) 14 mm (0.55”)

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

PRODUCT DESCRIPTION PAPER 27

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EPSON Stylus COLOR 680/777/777i Revision B

1.6 INK CARTRIDGE

1.6.1 Black Ink Cartridge

Type: Exclusive Cartridge Color: Black Print Capacity: 600 pages/A4

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

Storage: -20 Packing: -30 Transit: -30

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

Cto40oC (within a month at 40oC)

Cto60oC (within 120 hours at 60oC

and within a month at 40

1.6.2 Color Ink Cartridge

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

Storage: -20 Packing: -30 Transit: -30

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

Cto40oC (within a month at 40oC)

Cto60oC (within 120 hours at 60oC

and within a month at 40

Figure 1-9. Color Ink Cartridge

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

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

C environment; however, it will be

usable after being left at room temperature for more than three

Figure 1-8. Black Ink Cartridge

hours.

PRODUCT DESCRIPTION INK CARTRIDGE 28

Page 29

OPERATINGPRINCIPLES

CHAPTER

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EPSON Stylus COLOR 680/777/77i Revision B

2.1 Overview

This section describes the operating principles of the printer m echanism and electrical circuit boards.The Stylus COLOR 680/777/777i has the following boards:

Main board: C383 MAIN (C383 MAIN-B)

NOTE: C383 MAIN-B is compatible with C383 MAIN. Only some chips or parts

are differentfrom each other due to different producers.

Power supply board: C383 PSB/PSE

Panel board: C383 PNL

2.1.1 Printer Mechanism

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

Like other E PSON ink jet printers, the Stylus COLOR 680/777/777i is equipped with two stepping motors; one for ASF, Paper feeding/ Pump m echanism, and one for CR mechanism.ASF unit uses rear entry front eject system. This ASF unit is also designed newly and single LD roller loads the paper to the printer mechanism.

PF Motor

Star Wheel Roller

CR unit

Paper Eject Roller

PF Roller

CR Timingbelt

HP/PE/IC Sensor sensor

LD Roller

Paper feed back plate

Paperseparationpad

ASF Hopper Spring

For cap assembly,Stylus COLOR680/777/777iuses valvelessmechanism;new design

CR lock lever

for this model.

Clutch mechanism

Pump Assembly

Cap Assembly

CR Motor

Figure 2-1. Printer Mechanism block diagram

Operating Principles

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EPSON Stylus COLOR 680/777/77i Revision B

2.1.2 Printhead

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

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

The basic operating principles of the printhead, which plays a major role in printing, are the same as previous models; on-demand m ethod which uses PZT (Piezo Electric Element). In order to uniform the amount of ejecting ink, the printhead has its own head ID (6 digits for this printhead) which adjust PZT voltage drive features. The printhead stores the head ID to EEPROM and generates appropriate PZT drive voltage to prevent amount of ink from varying by printheads.

Following explains printhead basic components.

PZT PZT is an abbreviation of Piezo Electric Element. Certain amount of voltage expandsand contracts PTZ. The drive wave generated on MAIN board drives PZT and P ZT pushes the top c avity which has ink stored to discharge the ink from each nozzle on the nozzle plate.

Ink Cavity The ink absorbed from the ink cartridge goes through the filter and then is stored temporarily in this tank called “cavity” until PZT is driven.

Nozzle Plate

Ink Cartridge

PZT

CSIC

Needle

Cavity

Nozzle Selector Board

CSIC Connection Circuit

Filter

Figure 2-2. Printhead S ectional Drawing

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

CSIC Connection Circuit This circuit connects the CSIC mounted on the ink cartridge and the main board. One end of the wire harness connectswith the print head cable to the main board.

Filter When the ink cartridgeis installed, if any dirt or dust aroundthe cartridgeneedle is absorbed into the head, there is a great possibility of causing nozzle clog and disturbance of ink flow, and finally causing alignment failure and dot missing. To prevent this problem, a filter is setbelow the cartridge needle,where ink is filtered.

Operating Principles

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EPSON Stylus COLOR 680/777/77i Revision B

2.1.2.1 Printing Process

This section explainsthe processin which the printheads of On-Demand inkjet printers eject ink from each nozzle.

1. Normal State:

When no printing signal is sent from PC, or no PZT drive voltage is applied, PZT does not change s hape, therefore PZT does not squeeze the cavity. Ink pressure inside the cavity is kept normal. (Refer to Figure 2-3.)

2) Ejecting State:

When the print signal is output from the C383 MAIN board, IC (Nozzle Selector) located on the printhead unitlatches data once by 1-byte unit. An a ppropriate PZT latched by the nozzle selectoris pushed into the cavity by the common voltage applied from the m ain board. By this operation, ink stored in the cavity spurts out from nozzles.(Refer to Figure 2.1.2.2.)

Ink Path

Nozzle

PZT

Ink Cavity

Nozzle plate

2.1.2.2 Printing Method

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

Multiple shot printing

Variable dot printing

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

Multiple shot printing This printing mode is de veloped to improve the print quality on plain paper or transparencies in low resolution.The multiple shot printing mode uses normal dot and the number of dot shots varies from 1 shot to maximum 4 shots depending on the print data to enable s harp image output even in a low resolution.

Variable dot printing This printing mode is de veloped to improve the print quality on e xclusive paper. This mode is basically the same as variable dot printing mode used on other products /; micro dot, m iddle dot, and large dot compose this mode. Print dot size varies according to print data and this mode enables even sharper image output on exclusive paper.

PZT drive voltage

Figure2-3. Printhead printing process

Operating Principles

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EPSON Stylus COLOR 680/777/77i Revision B

2.1.3 Carriage Mechanism

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

Table 2-1. Carriage Motor Specification

Items Specifications

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

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

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

HP detection Lever

CR HP detection plate

Low signal

Right side view

CR HP detection plate

HP/IC detection Lever

High signal

Figure 2-5. CR home position

CR unit

HP/PE Sensor

CR Guide shaft

CR Motor

CR Timing belt

Figure 2-4. Carriage M echanism (Top view)

Operating Principles

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EPSON Stylus COLOR 680/777/77i Revision B

2.1.4 Paper Feeding Mechanism

The paper feeding mechanism consists of Paper feed motor (PF motor), PF roller, Paper eject roller, Star wheel roller, and so on. The paper feeding mechanism feeds paper loaded from ASF using the PF roller and Paper E ject Roller & Star wheel roller. For this mechanism, the PF motor mentioned in the right Table 2-2 is used on this product.

The drive of the PF motor is transfer to the PF roller and the Paper Eject R oller as following Figure 2-6. Following shows you how to transfer the PF motor drive to the PF rollerand the Paper E ject Roller.

PF motor drive transmission path

PF Motor PinionGear (CW)

(CW) → Spur Gear 15 (CCW) → (CCW) →

Spur gear 35.2(CW)

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

Combination Gear 37.6, 44.4 (W) → Spur Gear 23.2

Table 2-2. PF Motor Specifications

Item Description

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

Spur Gear 35.2

PF roller

Spur Gear 23.2

Spur Gear 15

Combination gear

37.6, 44.4

Figure 2-6. Paper Feeding Mechanism

Paper loaded from ASF is advanced by the following roller.

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

eject roller & Star wheel roller (assembled on the Paper eject frame).

Operating Principles

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

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EPSON Stylus COLOR 680/777/77i Revision B

2.1.5 Paper Loading Mechanism (ASF Uni t)

The Paper loading mechanism is positioned at the printer rear. The Paper loading mechanism loads paper at the ASF unit and fe eds paper to the PF roller.

This ASF unit was designed newly for t his product and consists of LD roller, Pad holder (Paper return plate), ASF Frame, Hopper, and so on. For the major feature of this ASF unit, ASF HP s ensor is not used and the single LD roller is built in the ASF unit. Drive sent from the PF motor is always transmitted to the ASF unit side. But, the Change leverand the Clutch mechanism switch ON/OFF the PF motor drive to t he LD roller with the motor rotational direction.

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

Switch the PF moto r drive to ASF unit side

PF Motor pinion gear rotatesCCW direction with a specific steps Gear 16, 21.6 (CW)

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

Combination Gear 37.6, 44.4 (CCW) → Change Lever rotates (CCW) → Release

the Clutch mechanism lock position

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

→ Combination

Transfer the PF motor drive to LD roller

PF Motor pinion gear rotates CW direction

→ Spur Gear 73.6 (CW) → Spur Gear 15 (CCW) → Combination Gear 37.6, 44.4

(CW)

→ Change Lever rotates (CW) → Spur Gear 23.2 (CCW) → Spur Gear35.2

→ Combination Gear 16, 21.6 (CCW)

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

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

35.2 is assembled.

Spur Gear 35.2

ChangeLever

Spur Gear 15

Spur Gear 23.2

CombinationGear

37.6, 44.4

Figure 2-8. PF motor drive transmission path

Spur Gear 35.2

Change Lever

Spur Gear 23.2

Spur Gear 15

Combination Gear

37.6, 44.4

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

Table2-3. ASF unit function & PF Motor rotational direction

Directions Corresponding Functions

Clockwise (*1) Counterclockwise (*1)

• Picks up and loads paper

• Release the DE lever & Clutch mechanism

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

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

Clutch Mechanism

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

Operating Principles

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EPSON Stylus COLOR 680/777/77i Revision B

NOTE:

TheClutchgearismoldedon thebacksideoftheSpurgear

35.2such as Combinationgear.

Spur gear 35.2

Clutch lever

Step1

Change Lever

Clutch gear

Clutch

Figure 2-9. Disengage & Clutch mechanism

The Clutch mechanism transmits the PF motor drive to the LD roller shaft only when the Clutch gear rotates CW direction after the Change lever releases the Clutch lever. If the Clutch gear rotates CCW direction, the PF motor drive is not transmitted to the LD roller. This is due to the combination of the shape of the Clutch gear and the C lutch lock tooth such as described on the figure.

1. When the paper is advanced with the P F roller, the Change lever is set on the

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

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

Change lever moves to the left direction with the CCW rotation of Combination gear 37.6, 44.4. The Clutch turns back to the engagement position by the tension force of the Tension spring 0.143 and the Clutch gear is engaged with the Clutch lock tooth as above Step2’s center figure.

3. When the PF pinion gear rotates CW direction in the above Step3’s figure, the

Change lever moves to the right direction with the CW rotation of the Combination gear 37.6, 44.4. Andthe drive from the PF motor is transmittedto the LD roller shaft via C lutch gear and Clutch lock tooth.

4. The LD roller shaft rotates about 360 degree and the Change lever push the Clutch

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

Step2

Tension spring 0.143

Clutch lock tooth

Step3

LD roller shaft

Unlike the previous products, The Paper return plate is built in the ASF frame instead of the Paper return lever. The Paper s eparation pad is also stacked on the plate. It works with the spring force of the Torsion spring 25.7 (mounted in the ASF frame) as following figure.

Hopper

Compression spring 4.80

ASF frame

LD roller

Paper Return

Plate

Torsion spring 25.7

Figure 2-10. Paper R eturn Plate

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

Following figures show you the ASF paper loading sequence and the operation of the each mechanism.

Paper Return Plate (Pad hold er)

Operating Principles

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EPSON Stylus COLOR 680/777/77i Revision B

When the paper is advanced with the PF roller, Change lever push down the Clutch lever as right figure and the Clutch lock tooth is disengaged from theClu tch gear. As the result, the drive from the PF motor is interrupted and the LD roller dose not rotate. This position is the ASF home position. The Paper return plate is set to avoidthat the paper is slipped down from the paper set position.

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

4.80 and the paper is pickedup with theASF LD roller.

LD roller

LD roller shaft

Paper return plate

PF motor pinion

gearCW rotation

ASF Hopper release lever

Clutch lever

Step 1

Changelever

Step 3

Clutch gear

Clutch lock tooth

Clutch

LD roller shaft

Hopper

Compression

spring 4.80

Printer front side

PF motor pinion

gear CCW rotation

ASF Frame

Step 2

Tension spring 0.143

Step 4

Paper return plate

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

The ASF LD roller rotates CW direction moreover and the Paper return plate is stored under the ASF frame. The paper is ad vanced up to the PF roller. and the ASF LD roller & the clutch rotate to the “Step1” position. The Clutch lever is locked with the Change lever. The drive from the PF motor is interrupted and the drive is transmitted to the PF roller side.

PF motor pinion

gearCW rotation

ASF hopper

releaselever

PF motor pinion

gear CW rotation

Figure2-11. ASF Paper Loading Sequence

Operating Principles

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EPSON Stylus COLOR 680/777/77i Revision B

2.1.6 Ink System Mech anism

Ink system mechanism consists of pump unit (include the CR lock lever) and c apping mechanism. Ink system mechanism drives the pump unit that presses cap to the printhead and ejects ink from ink cartridge, head cavity and cap to the waste ink pad.

2.1.6.1 Pump Unit & Wiper mechanism

The pumpunit is driven by PF motor. PF motor drive is always transmitted to the paper feeding mechanism and pump unit through the following gears. Refer to the Figure 2-13.

PF Motor Pinion Gear (CW)

→ Spur Gear 15 (CCW) → Combination Gear 37.6, 44.4 (CW) → Spur Gear 36.8 (CCW) → Combination Gear 9.6,24 (CW)→ Pump Unit Gear (CCW)

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

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

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

Directions Functions

• Sets the wiper.

Counterclockwise (*1)

Clockwise (*1)

• Absorbs ink by the pump unit

• Set the CR lock lever

• Resets the wiper.

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

Figure 2-12. Pump mechanism

Capunit

Wiper

Pumpunit

CR lock lever

Spur Gear 15

Combination Gear 9.6, 24

Pump Unit Gear

SpurGear36.8

Combination Gear

37.6, 44.4

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

Operating Principles

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EPSON Stylus COLOR 680/777/77i Revision B

2.1.6.2 Capping Mechanism

The capping mechanismcovers the printheadswith thecap holderto preventthe nozzle from increasing viscosity when the printer is in stand-by mode or w hen the printer is off. This product has valveless cap system. Air valve function used for the previous models pumps and ejects ink only inside the cap by absorbing ink with the valve open. By openingthe Air valve, the negative pressureis decreasedand only the ink insidethe cap is ejected. (the ink is not absorbed from Ink cartridge or head cavity.) But, valveless cap system, this operation is done out side of the capping area. The CR moves to left side of the Cap assembly and the pump absorbs the ink inside the cap.

Viewed from front side

CR uni t

Slider cap

Printhead

Cap

Waste Ink tube

Slide up

Figure 2-14. Cap Mechanism

Operating Principles

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EPSON Stylus COLOR 680/777/77i Revision B

2.2 Electrical Circuit Operating Principles

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

Main board: C383 MAIN Board

Power supply board: C383 PSB/PSE Board

Panel board: C383 PNL Board

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

2.2.1 C383 PSB/PSE board

The power supply boards of Stylus COLOR 680/777/777i use a RCC (Ringing Chalk Converter)circuit,which generates+42VDC for drive lineand +5VDC for logic line to drive the printer. The application of the output voltage is described below.

Table 2-5. Application of the DC Voltages

Voltage Application

• Motors (CR Motor, PF Motor)

+42VDC

+5VDC

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

• Printhead commonvoltage

• Printhead nozzle selector 42V drive voltage

• C383MAIN control circuit logic

•Sensor

Figure 2-15. Electric Circuit

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

2. The AC is full-wave rectified by the diode bridge DB1, and converted to x

AC in voltage by the smoothing electrolytic capacitor C11.

3. The pressured up direct current turns Q1 on through the starting resistor R31 and starts the primary side of the circuit.

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

5. When the energy which is charged in the trans i s reaching the saturated state, the voltage which makes Q1 on becomes weak gradually.At the point that this voltage drops at the certain voltage, C13 absorbs the current in the opposite direction and Q1 is quickly shut off by the resulting sharp drop.

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

7. +5VDC is generated by pressured down this +42VDC as power supply. IC51

Figure 2-16. C383PSB/PSE Board Block Diagram

The C383 PSB/PSE board has the various control circuits to stop voltage output if a malfunctionoccurs on the power supply board or the main board while the printer mechanism is on duty. Following explains each control and protection circuit.

pressures down the +42VDC and generates precise +5VDC by chopping off the output, forming the standard santooth wave form by the outer RC integration circuit.

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

+42V Line Constant Voltage Control Circuit: The output level of the +42V line is monitored by a detection circuit composed of the seven Zener diodes. This circuit prevents the voltage from dropping for a constant level of the output voltage.

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+5V line over voltage protection circuit: This protection circuit is in the same line as the +42V over voltage protection circuit is located. The output voltage level of the +5V line is monitored by a Zener diode. This circuit shuts down the +5V line forcefully when the voltage level exceeds +9V.

+42VDC line drop limitation circuit: This protection circuit is in the same line as +42V over voltageprotectioncircuit is located. The output voltage level of the +42V line is monitored by a Zener diode. This circuit shuts down the +42V line forcefully when the voltage level drops to +36V.

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

+5V line constant voltage/constant current control circuit: The output current is m onitored by the +5VDC generation switching control IC (IC51), which also m onitors the output voltage. T his information is input to the internal comparator and stabilizes +5V line. The operations of the secondary side switch are explained below.

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

Thissignalturns Q84on andit becomes possible to dischargeenergy between the terminals8 and 9 of T1. At this time, even if the powe r is turned off, the electrolytic capacitor keeps Q84 on for a while, and by this electrolytic capacitor, voltage output is held at least 30 seconds. This time helps the printer to complete a power-off operation.

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2.2.2 C383 MAIN Board

Use of the 3.3V chips in the logic circuit The 3.3 V regulator (IC11) on the C383MAIN produces3.3 V by pressuring down

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

the 5.5 VDC, also generated on this board, to drive several chips. See the table below that separately shows the chips driven by the +5V and +3V.

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

+5V 3.3V

Sensors I/F Circuit PNL Board

CPU P-ROM D-RAM

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

Following shows you the major characteristic of this main board.

Timer IC & Lithium battery are notmounted Unlike the previous products, the Timer IC and the Lithium battery are not mounted on the Main board. So, this product perform the Power-on cleaning or Timer cleaning based on the time command which is sent from the printer driver.

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

One CPU controls the all function on the main board.

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2.2.2.1 Main elements

Table 2-7 shows the function of the each main elements on C383 MAIN.

Table 2-7. Main Elements

IC Location Function

CPU E01A15CA

PROM IC1

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

EEPROM IC15

Reset IC IC16

Common Driver IC10

Motor Driver IC12 CR motor drive IC Motor Driver IC13 PF motor drive IC Parallel I/F IC IC6 IEEE1284 parallel I/F transceiver IC. USB IC IC2, IC3 USB transceiver IC

IC9

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

• Capacity 8/16/32/64MB, Bus= 16 bit

•ProgramforCPU

1kbit EEPROM

• Default value setting

• Parameter backup Reset IC

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

• For +42V, reset when +33.2 is detected Head drive control HIC

• Generates head common voltage.

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2.2.2.2 Printhead Driver Circuit

The printhead drivercircuit consists of the following t wo c omponents:

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

Nozzle selector IC on the head board.

The common driver (IC10:E09A14RA) generatesa reference drive waveform according to t he output signals from the C383MAIN board. The reference drive waveform is amplified by the transistorsQ2 and Q3and then transferred to the nozzle selector IC on the head board. Print data is converted to serial data by the CPU (IC9) and then sent to the nozzle selector IC on the head board. Based on the serial data, the nozzle selector IC determines the nozzles to be actuated. The selected nozzles are driven by the drive waveforms p roduced by the common driver. See Figure 2-18 for the printhead driver circuit block diagram.

Head common driver circuit The reference head drive waveform is produced in the common driver (IC10:E09A14RA)based on the following 12 signal lines output from the ASIC (IC8 E05B70CD); A0-A4, CLK1, CLK2, RST, FLOOR, DATA, DCLK, and E. By the DATA signal output from the CPU (IC9), the original data for the head drivewaveform iswritten inthe memoryin the IC10. The addressesfor the written data are determined by the A0 - A4 signals, and, of among,data used to determine the waveform angles is selected. Then, setting the selected data, producing trapezoid waveform value, and canceling the data are performed by the rising edgesoftheCLK1andCLK2signals.

Head nozzle selectorcircuit Printing data is converted into serial data by the CPU (IC9). T hen the converted data is allocated to the six rows, the number of the head nozzle rows, to be transferredto thenozzle selectorthrough the six signallines (HS01to HS06). Data transmission from the CPU (IC9) to the nozzle selector synchronizes with the LAT signal and SCK clock signal. Referring to the transferred da ta, nozzles to be activatedare selected, andthe PZTs of the selectednozzles are driven by the drive waveform output from the head common driver.

Figure 2-18. Printhead Driver Circuit

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

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

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

The current value on each phase is determined by CPU (IC9) and outputs from port 104, 105, 107, 108, 109, 110 to driver IC (IC13). Motor driver IC generates motor driverwaveform based on these inputsignals and controls themotor. If the printer dose not receive any data from PC for 5 minutes, CPU set the motor drive current to 0 via port 104, 105, 107, 108, 109, 110 and the motor drive is turned off to save the power consumption.

2.2.2.4 CR Motor Driver Circuit

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

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

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

Figure 2-19. PF Motor Driver Circuit B lock Diagram

Figure 2-20. CR Motor Driver Circuit Block Diagram

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2.2.2.5 Reset Circuit

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

Unlike the previous products, the timer IC is not built in the reset IC a nd the Lithium battery also is not equipped on the main board.

2.2.2.6 EEPROM Control Circuit

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

Information stored in EEPROM is listed below.

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

Mechanical setting value (Head ID, Bi-D adjustment, USB ID, etc.)

See Table 7-9, “EEPROM Address Map,” on page 127 that provides detailed information on t he values stored in EEPROM.

Figure 2-22. EEPROM Circuit Diagram

Figure 2-21. Reset Circuit Block Diagram

Main signal lines are explained below;

OUT1: Interrupt signal

OUT2: Reset line

IN: +42V line monitoring line

VCC: +5V line monitoring line

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

CS: Chip selection signal

CK: Data synchronism clock pulse

DI: Data writingline (serial data) at power off.

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

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2.2.2.7 Sensor Circuit

C383 MAIN is equipped with the followingtwo sensors to detect the status of the printer. Unlike the previous product, ASF HP sensor is not equipped on the ASF and the ASF HP is determined with the clutch mechanism (2.1.4 Paper Feeding Mechanism).

HP/PE Sensor

This sensor uses photo interrupter method and detects the following three status. The photo interrupt component and two detection levers consists of this sensor.

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

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

Thermistor(THM)

The thermistor is attached directly on the printhead driver board. It monitors the temperature around the printhead and determines the proper head drive voltage according to t he ink viscosity that varies by the temperature. This information is fed back to the CPU analog port. When the temperature rises, the head drive circuit lowers the drive voltage: When the temperature lowers, the head drive circuit rises the drive voltage.

Figure 2-23. Sensor Circuit Diagram

The block diagram for the sensor circuit is shown below

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TROUBLESHOOTING

CHAPTER

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3.1 Overview

This chapter describes how to identify troubles in two levels: unit level repair and component level repair. Refer to the flowchart in this chapter to identify the defective unit and perform component level repair if necessary.This chapter also explains motor coil resistance, sensor specification and error indication.

START

Unit level T roubleshooting

Unit repair

Assemble & Adjustment

END

Table 3-1. Motor, Coil Resistance

Motor Location Check Point Resistance

CR Motor CN12

PF Motor CN7

Pin1and3 Pin2and4

7.8 Ohms (at 25

7.8 Ohms ±10% (at 25

± 10%

°C/ phase)

Table 3-2. Sensor Check Point

Sensor Name Check Point Signal Level Switch Mode

Off

• Out of HP range

•Nopaper

•DetecttheI/C On

• Within HP range

• Detect the paper

• Notdetects the I/C

HP/PE Sensor CN4/Pin 1 and 2

Thermistor (THM)

TH1 (on the Head driverboard)

Less than 0.7V

More than 2.4V

Analog signal 10 K (at 24

°C)

Figure 3-1. Troubleshooting Flowchart

Troubleshooting

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3.2 Troubleshooting with LED E rror Indications

This section describes how to troubleshoot the problem when the printer indicates an error at power on and can not print. The Stylus COLOR 680/777/777i can detect the following six errors and seven status, and indicates t hem with the LEDs, as shows below.

Table 3-3. Error Indicator of Operation Panel

PrinterStatus

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

(Ink Overflow Counter error) Fatal error Off On 1

Power Error

Alt Blink Alt Blink 2

" - " : Indicator status don't change.

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

B is a indicator condition in Ink exchange sequence.

Indicators

Priority

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

Table 3-4. Error Condition and possible cause

Symptom Possible Cause Check table

• The frictionof the LD roller is lowered due to the paper dust.

Paper out error indication (Paper is not loaded correctly)

Paper jam error indication

No I/C or I nk Out error indication

Multiple papers are always loaded

Paper is always loaded without any print job

Fatal error indication

• The clutch mechanism is broken.

• Tension spring 0.143 comeoff in the clutch mechanism.

• Compression spring 0.98 comes off.

• Tip of Change lever has any damage.

• PF motor is broken.

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

• The Spur gear 15 is not assembled correctly.

• The paper guide front is not assembled correctly or has any damage.

• The PE detectionlever dose not move smoothly.

•

• The paper return plate dose not work correctly.

• The Change lever is broken in the Clutch mechanism.

• HP sensor lever or PE sensor lever dosenot move smoothly.

• HP/PE sensor is defective.

• CR motor is defective.

• PF motor is defective.

• Main board is defective.

• Printer Housingdose not secured with screw on -the printer mechanism.

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

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

Table 3-12

Table 3-13

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

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

Symptom Possible Cause Check table

Any error indication is not displayed. But, the paper is not ejected completely. Paper jam dose not occur.

Dot missing occur and it i s not recovered with CL

Print quality is not good

• Vertical banding

• Horizontal banding

• Printing is blurred

• Ink stains the paper

• Paper eject roller gear is disengaged from the pump’s gears.

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

• Pump unit dose not absorb the ink from the printhead.

• Cap unit dose notstick on thesurfaceof the printhead completely.

• The printhead is broken.

• The head FFC has any damage.

• The main board is defective.

• The accuracy of the CR motoris lowered.

• The lack of the lubricant around the CR unit.

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

• The Paper eject frame is deformed.

• Any foreign material is sticking around the printhead.

• Paper feed accuracy is lowered.

• Printer driver setting is not suitable.

• Paper path has ink stain somewhere.

Figure 3-17

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

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

If the problem fits to the detail phenomenon in the table, makesure the check point and repair the product following the corresponding remedy mentioned in the table when you find the defective parts in the check point.

Table 3-5. Paper out error indication

Step

No.

Detail phenomenon Check point Remedy

• Check the surface of

• Set a cleaning sheet in the LD roller if the micropearl or severe smear is adhered.

ASF LD r oller attempt to load the paper. But, paper is not

loaded at all. The LD roller seems slipping.

If it is no problem, proceed the next step.

LD roller

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

the A SF up side down. Then holding the top edge, try to load the paper from the Printer driver. The micro pearl on the LD roller surface is removed. To remove severe smear, staple a cloth moistened with alcohol to a post card and clean the roller in the same manner.

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

C L S h e e t

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

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

S t a p l e r s

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

• If the problem is not

solved, replace the LD roller with new one.

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Step

No.

Detail phenomenon Check point Remedy

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

35.2 is rotating.

Spur gear 35.2

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

35.2 is rotating.

Table 3-6. Paper out error indication

• Check if the clutch tooth is broken.

Clutch tooth

If it is no problem, proceed the next step.

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

Tension spring

0.143

• Replace the clutch mechanism with new one.

1. Se the tension spring

0.143 in the clutch mechanism.

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

Step

No.

Detail phenomenon Check point Re me dy

When the print data is sentto the printer,ASF LD roller continue to load the paper even if thefirstpaperis loaded

to the PF roller and the paper is ejected while the ASF hopper is flapping.

Whenthe printer is turnedon, ASF hopper dose not operate at all

in the power on sequence.

Table 3-7. Paper out error indication

1. Check if the tip of t he Change lever has any damage.

Change lever

comp. spring 1.47

2. Check if the Compression spring

1.47 comes off from theChangelever.

If it is no problem, proceed the next step.

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

2. Check if the PF motor coil resistanceis about

7.8 ohm by using tester Refer to Table 3-1.

1. Replace the Change lever with new one.

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

1. Connect the PF motor connector to the CN7 on the Main board.

2. Replace the PF motor with new one.

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

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Step

No.

Paper is not ejected completely and

jammed around the Paper eject frame.

2 Ditto

Table 3-8. Paper jam error indication

Detail phenomenon Check point Remedy

• Check if the star wheel assemblyis assembled in the Paper eject frame.

Star wheel assy

If it is no problem, proceed the next step.

• Check if the Paper eject roller is rotating correctly.

Paper eject roller

Spur gear 25.6

If it is no problem, proceed the next step.

• Remove the jammed paper and assemble the Star wheel assemblyin the Paper eject frame completely. If the hook portion of the Star wheel assemblyis broken, replace the Star wheel assembly with new one.

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

36.8 and assemble it correctly.

Step

No.

Detail phenomenon Check point Remedy

The paper is jammed

around the Frontpaper guide.

Paper is loaded correctly from ASF.

But, after complete the print job, paper jam indicatedon thescreen without any paper jam.

If you send the new print job in this condition, the General error is indicated on the screen.

Table 3-9. Paper jam error indication

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

2. Check if there is any damage around the rear edge of the each ribontheFrontpaper guide.

Front paper guide

If it is no problem, proceed the next step.

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

Tensionspring

0.22

PE sensor lever

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

PF grounding spring

2. Replace the Front paper guide with new one.

• I f the Torsion spring

0.22 is not set on the correct position, set it correctly. If any paper dust is placedaroundthe PE sensor l ever, remove it.

• I f it is no problem, proceed the next step.

Front Paper guide

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Table 3-10. Paper jam error indication

Step

No.

Detail phenomenon Check point Remedy

When the paperis loadedfrom theASF and ejected without any printing. After eject the paper, paper eject sequence

is continued. If any print job is

sent to the printer, General error is

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

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

1. Connect the CN4

2. Replace the HP/PE

3. Ifthe problem is not

displayed.

connector cable to the CN4ontheMainboard.

sensor with new one.

solved, replace the Main board with new one.

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

Step

No.

Detail phenomenon Check point Remedy

A[No Ink Cartridge] or [Ink Out Error] message isdisplayed when the power to the printer is switched on.

1. Check to ascertainthat

an ink cartridge has been set in place.

2. Check the remaining

ink with the printer driver or STM3.

3. Check to ascertainthat

the head FFC is been attached correctly to the head.

4. Check to ascertainthat

the head FFC has been attached correctly to the main board.

1. Set the ink cartridge in

2. Remove and then reset

3. Replace the i nk cartridge

4. Replace the i nk cartridge

place.

the ink cartridge in place.

(faulty CSIC.)

Table 3-12. Multiple papers are always loaded

Step

No.

Detail phenomenon Check point Remedy

• Assemble the torsion

Any error indication is not displayed on the monitor. But, multiple

papers are always loaded from ASF.

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

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

Step

No.

Detail phenomenon Check point Remedy

Paperisalwaysloaded from ASF without any print job.

ASF hopper

1. Check if the tip of t he Change lever has any damage.

Change lever

1. Replace the Change

continueto flapping when the printeris turned on.

comp. spring 1.47

2. Check if the Compression spring

1.47 comes off from theChangelever.

2. Set the Compression

spring 25.7 in the ASF frame.

Torsion spring 25.7

lever with new one.

spring 1.47 in the Change lever.

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Step

No.

Detail phenomenon Check point Remedy

When the printer is turned on, the printer

continuethe paper eject sequence even if the paper is not in the paper path.

Table3-14. FatalErrorindication

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

HP sensor lever

Torsionspring

0.22

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

Tensionspring

0.22

1. Set the Torsion spring

0.22 on the HP sensor lever.

2. Set the Torsion spring

0.22 on the PE sensor lever.

Step

No.

Detail phenomenon Check point Remedy

When the printer is turned on, the CR unit

dose not move at all in the power on sequence.

When the printer is turned on, PF roller

dose not rotate at all in the power on sequence.

Table 3-15. Fastal Error indication

1. Check i f the CR motor connector is connected CN12 on the Main board.

2. Check if the coil resistance of the CR motor is about7.8ohm by using the tester. Refer to Table 3-1.

1. Checkif the PF motor connectorisconnected to the CN7.

2. Checkif the PF motor coilresistance is about

7.8 ohm by using tester.

1. Connect the CR motor connector to the CN12 on the Main board.

2. Replace the CR motor with new one.

3. Ifthe problem is not solved,replacethe M ain board with new one.

1. Connect the PF motor connector to the CN7 on the Main board.

2. Replace the PF motor with new one.

3. Ifthe problem is not solved,replacethe M ain board with new one.

PE sensorlever

3. Check if the CN4 connector cableis connected on the CN4 on the Main board or sensor.

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

Troubleshooting

3. Connect the CN4 connector cable to the CN4ontheMainboard.

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

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

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Step

No.

Detail phenomenon Check point Remedy

When the printer is turned on, it sounds strangenoise and the

CR unit is stopped around the CR lock lever.

Table3-16. FatalErrorindication

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

Top housing

2. Check if the Change leverisplacedtothe printer front side.

Change lever

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

2. Turn back the Change lever to the printerback side with the tweezer or small screw driver.

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

Step

No.

Detail phenomenon Check point Remedy

1. Assemble the Spur gear

2. Secure the Paper eject

Printing is normal. But, the paper is not ejected completely and the

bottom area stay around the Paper eject frame.

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

2. Check if the Paper eject frame is secured with the three fixing screws to the Main frame.

Paper eject frame

25.6 to the Combination gear 11.6, 36.8.

Spur gear 25.6

frame witt the two fixing screws to the Main frame.

3. Check if the PF motor is operated. Check the CN7 connectorand the coil resistance for PF motor.

4. If the CR lock lever is not released even if the PF motor rotate in the power on sequence, check if one of t he gears has any damage in the PF motor torque transportation path. Refer to Figure 2-13.

Troubleshooting

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

4. Change the damaged gear with new one.

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

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EPSON Stylus COLOR 680/777/777i Revision B

Table 3-18. Dot missing occur and it is not recovered with CL

Step

No.

Detail phenomenon Check point Remedy

1. If ink is not ejected at all

2. Remove the foreign

3. Replace the Cap

In the CL sequence, the pump unit seems work correctly. But, inkisnotejectedtothe waste i n k pad at all.

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

1. Check i f ink is ejected to the waste ink pad via pump unit in t he CL sequence.

2. Check if there is any foreign material around the seal rubber parts on the cap assembly.

Cap seal rubber

parts

3. Check if any damage is observed around the seal rubber parts on the cap assembly.

to the waste ink pad in the CL sequence, proceed the following check point 2).

material around the seal rubber parts.

assembly with new one.

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

Step

No.

Detail phenomenon Check point Remedy

7. Connect the Pump tube

8. Pump unit may coil the

In the CL sequence, the pump unit seems work correctly.But, any ink is not ejected to wasteink pad.

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

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

Pumptube

connectionpoint

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

Tube

Cap assy.

to the bottom of the Cap assemblydeeply.

pump tube inside the unit. Inthiscase, pulloutthe coiled tube from the pump unitcarefully. After that, connect the pump tube to the Cap assemblyafter placing thetubecorrectly.

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

Compression

spring

Troubleshooting

4. Set the Compression spring into the Cap assembly.

Pumpunit

9. Ifthe problem is not solved,replacethe Pump unit with new one.

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Table 3-20. Dot missing occur and it is not recovered with CL

Table 3-21. Print quality is not good

Step

No.

Detail phenomenon Check point Remedy

In the CL sequence, ink is ejected to the Waste ink pad (this means pump unit & cap unit are working correctly). But, the dot missing is not solved at the specific nozzles even if the several CLs are performed.

In the CL sequence, ink is ejected to the Waste inkpad.But,dot missingisoccurredon allnozzlei n theprinting and is not solved in the severalCLs.

1. Check if the segment in the nozzle check patter is reduced every CL & Nozzle check pattern printing.

2. Check if any damage is observed on the Head FFC.

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

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

2. Replace the Head FFC with the new one.

3. Replace the printhead with new one.

1. Connect the Head FFC securely to the CN8 and CN9 on theMain board or Printhead.

2. Replace the Printhead with new one.

3. Replace the Main board with new one.

Step

No.

Detail phenomenon Check point Remedy

Vertical banding is appeared againstt he CR movement direction. Andi t lookslike uneven printing.

CR movement

direction

1. Check if each segment is printed correctly in the nozzle check pattern.

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

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

G26 lubrication

4. Check if the CR guide shaftis assembledin the correctportion securely.

1. Perform the CLand check the nozzle check pattern.

2. Cleanthe surface of the CR guide shaft with the dry soft cloth and lubricateG-55 inside the CR guide shaft.

3. Cleanthe surface of the CR sliding portion on the Paper ejectframe and lubricatespecific amount of the G-26.

4. Reassemble the CR guide shaft into the mounting slaton the bothside frame and secure it with Rod spring.

5. Replace t he CR guide shaft with new one.

5. Check if the surface of

Troubleshooting

the CR guide shaftis flat.

6. Check if the surface of the Paper eject frame is flat.

roubleshooting with LED Error Indications 59

6. Replace the Paper eject frame with new one.

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EPSON Stylus COLOR 680/777/777i Revision B

Step

No.

Detail phenomenon Check point Remedy

1 Ditto

Microbanding appears horizontallyagainstthe paperfeeding direction anditappearswiththe same width.

Table 3-22. Print quality is not good

1. Check if eachsegment is printed correctly in the nozzle check pattern.

2. Check if the suitable

paper is used accordingto the printerdriver setting.

3. Check if the Paper

feed roller is dirty.

4. Check if the following

parts do not have any damage.

CR movement

direction

• Combination gear 16,

21.6

• Combination gear

11.6, 36.8

• Spurgear 73.6

• Spurgear 25.6

7. Replace the following parts.

• CR motor

•CRtimingbelt

• Compression spring 19.6

1. Perform the CL and

check the nozzle check pattern.by using the Adjustment program.

2. Use the suitable paper according to the printer driver setting.

3. Clean the surface of the PF rollercarefully with the soft brush

4. Replace the damaged parts with new one.

5. Replace the Printhead with new one.

Table 3-23. Print quality is not good

Step

No.

Detail phenomenon Check point Remedy

3 Printing is blurred

4 Ink stains the paper

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

2. Check if the correct headID is storedin the EEPROM by using the Adjustment program.

1. Check if the following parts are stained with ink.

• Upper paper driven roller

•PFroller

• Paper guide front

• Paper eject roller.

2. Check if there is some ink drops around the backsideof the printhead.

3. If the bottom area of the printed paper has ink stain, check if the Paper eject frame is secured withthree screws.

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

1. Use the suitable paper accordingtothedriver setting.

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

1. Clean the ink stained parts with soft cloth.

2. Wipe off the ink drop with the soft cloth carefully.

3. Securethescrews fixing the Paper eject frame.

4. Replace the Paper eject frame with new one.

Troubleshooting

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DISASSEMBLYANDASSEMBLY

CHAPTER

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EPSON Stylus COLOR 680/777/777i Revision B

4.1 Overview

This section describesproceduresfor disassembling themain components of the Stylus COLOR 680/777/777i. Unless otherwise s pecified, disassembly units or components can be reassembled by reversing the disassembly procedure. Things, if not strictly observed, that could result in injury or loss of life are described under the heading “Warning”. Precautions for any disassembly or assembly procedures are described under the heading “CAUTION”. Chips for disassembling procedures are described under the heading “CHECK POINT”. If the assembling procedure i s different from the reversed procedure of the disassembling, the procedure is described under the heading “REASSEMBLY”. Any adjustments requiredafter disassembling the units are describedunder the heading “ADJUSTMENT REQUIRED”. When you have to remove any units or parts that are not described in this chapter, refer to the exploded diagrams in the appendix.

Read precautionsdescribed in the next section before starting.

4.1.1 Precautions

See the precautions given under the handling “WARNING” and “CAUTION” in the following column when disassemblingor assembling EPSON Stylus COLOR 680/777/ 777i.

W A R N I N G

Disconnect the power c able before disassembling or assembling the printer.

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

Always wear gloves for disassembly and r eassembly.

If ink comes into contact with your skin, wash it off with soap and water. If irritation occurs, contact a physician.

A lithium batteryis installed onthe main board of thisprinter. Be sure to observe the following instructions when serving the battery:

1. Keep the batteryaway from any metalor other batteriesso that electrodes ofthe oppositepolaritydo notcome in contact witheach other.

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

3. Do not solder on any part of the battery. (Doing so may result in leakage of e lectrolyte from the battery, burning or explosion. The leakage may affect other devices close to the battery.)

4. Do not charge the ba ttery. (An explosion may be generated inside the battery, and cause burning or explosion.)

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

6. Do not install the ba ttery in the wrong direction. (This may cause burning or explosion.)

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

Wear gloves wh en disassembly and reassembl y to protect sharp metal edges.

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4.1.2 Tools

C A U T I O N

Risque d’explosion si la pile est remplacée incorrectment. Ne remplacerqueparunepiledumêmetypeoud’untypeéquivalent recommandé par le fabricant. Eliminer les pilesdéchargéesselon les lois et les règles de sécurité en vigueur.

Never remove the ink cartridge fromthe carriage unless this manualspecifiestodoso.

When transporting the printer after installing the ink cartridge, be sure to pack the printer for transportation without removing the ink cartridge.

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

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

Make thespecified adjustments when you disassemble the printer. (See Chapter 5 for details.)

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

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

2. If an ink cartridgein use is removed and is reinstalled, ink quantity will not be detected correctly since the counter to check ink consumption is cleared.

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

Use only specified tools to avoid damaging the printer.

Name Supplier Parts No.

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

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4.1.3 Work Completion Check

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

Table 4-1. Work Completion Check

Classifi-

cation

MainUnit

Adjustment

Item Check Point Status

Self-test Is the operation normal?

On-line Test Isthe printing successful?

Printhead

Carriage Mechanism

Paper Feeding Mechanism

Specified Adjustment

Isinkdischargednormallyfrom all the nozzles?

Does it move smoothly?

Is there any abnormal noise during its operation?

Is there any dirtor foreign objects on the CR Guide Shaft?

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

Is paper advanced smoothly?

• No paper jamming?

• No paper skew?

• No multiple feeding?

• No abnormal noise? Is the PF Motor at correct

temperature? Is the paper path free of any

obstructions? Arealltheadjustmentdone

correctly?

Checked

Not necessary

Checked

Not necessary

Checked

Not necessary

Checked

Not necessary

Checked

Not necessary

Checked

Not necessary

Checked

Not necessary

Checked

Not necessary

Checked

Not necessary

Checked

Not necessary

Checked

Not necessary

Table 4-1. Work Completion Check (continued)

Classifi-

cation

Lubrication

Function ROM Version Version:

Packing

Others

Item Check Point Status

Areallthelubricationmadeat

Specified Lubrication

Ink Cartridge

Protective Materials

Attachments, Accessories

the specified points? Is the amount of lubrication

correct?

Are the ink cartridges installed correctly?

Have all relevant protective materialsbeenattachedtothe printer?

Have all the relevant items been includedin thepackage?

Checked

Not necessary

Checked

Not necessary

Checked

Not necessary

Checked

Not necessary

Checked

Not necessary

Checked

Not necessary

Disassembly and Assembly

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EPSON Stylus COLOR 680/777/777i Revision B

4.2 Disassembly

The flowchart be low shows step-by-step disassembly procedures. When disassembling each unit, refer t o the pa ge number shown in the figure.

Figure 4-1. Disassembling Flowchart

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EPSON Stylus COLOR 680/777/777i Revision B

4.2.1 Housing removal

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

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

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

C.B.S 3x6 F/Zn screws

Figure 4-3. Removing 2scews for Housing

Figure 4-2. Removing 2screws for Housing

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

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EPSON Stylus COLOR 680/777/777i Revision B

4.2.2 Operation Panel removal

C A U T I O N

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

Fasten Portion

Tightening Torque for s crew

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

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

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

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

The panel board equipped with printer is as follows:

- Stylus COLOR 680: C383PNL

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

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

C.B.S 3x6 F/Zn

Figure 4-4. Removing 2 screws for Operation Panel

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3. Remove2 screws (C.B.P-TITE 3x8 F/Zn) and detach the Sub RightPanel Housing from the Operation P anel Assembly.

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

Figure 4-5. Removing 2 screws for C383PNL board

4.2.3 Printhead removal

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

2. Open the Cover Cartridge and remove the both black and color ink cartridge.

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

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

Hooks

4. Remove the Panel Shield Plate and the C383PNL board from the Operation Panel Assembly.

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

C H E C K

P O I N T

Removing the Operation Panel Assembly also sepa rates the stacker assembly f rom the Printer Mechanism, since the Stacker Assembly is held with Operation Panel.

Figure 4-6. Removing t he Head FFC Holder

5. Disconnect the Printhead'sFFC from the connector on the Printhead.

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6. Remove two screws (C.B.P-TITE 3x6 F/Zn and +Bind B-TITE SEMS W2 2.5x5 F/Zn) tighiening the Printhead.

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

+BindB-TITESEMSW22.5x5F/Zn

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

7. Remove the Printheadfrom the CR unit.

C H E C K

P O I N T

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

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

Make sure that two holes of the Printhead correctly fit in the installing position pins. Fi g ure 4-9.

Figure 4-8. Placing the Printhead’s FFC

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EPSON Stylus COLOR 680/777/777i Revision B

Headinstalling positionpins

Head grounding plate

Figure 4-9.

Printhead installing the position pin & the grounding plate.

Tightening Torque for s crew

• C.B.P-TITE 3x6 s crew for printhead: 6+/1kgf.cm

A D J U S T M E N T

R E Q U I R E D

When the P rinthead is replaced with a ne w one, following adjustments must be performed in the order below:

1. Initial ink charge

2. Printhead ID input

3. Bi-d adjustment When the Printheadis removed and reinstalled, only the following adjustment is r equired.

1. Head cleaning

2. Bi-d adjustment

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4.2.4 CR motor removal

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

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

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

CR Timing belt

Step 2

Figure 4-10. Removing the Timing Belt

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EPSON Stylus COLOR 680/777/777i Revision B

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

Hexagonnuts

Figure 4-11. Removing t he CR m otor

5. Take the CR motor's cable out from the cable hook in the Waste drain inkpad unit.

6. Disconnect the CR motor connector cable from the CN12 on the Main board with tweezers.

A D J U S T M E N T

R E Q U I R E D

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

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

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EPSON Stylus COLOR 680/777/777i Revision B

4.2.5 Waste drain ink pad unit removal

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

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

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

3. Remove two screws (C.B.P- TITE 3x8 F/Zn) and take some cables off from the cable hook in the Waste drain ink pad unit as s hown in the following figure.

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

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

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

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

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

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EPSON Stylus COLOR 680/777/777i Revision B

C H E C K

P O I N T

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

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

Waste drain ink pad

Ink tube

Figure 4-14. Drain ink tube setting position

A D J U S T M E N T

R E Q U I R E D

WhentheWastedraininkpadisreplacedwithanewone, followingservice item is required.

Wastedrain ink counter resetoperation.

Tightening torque for screw

• C.B.P-TITE 3x8 screw for Waste drain ink pad unit : 9+/1 kgf.cm

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EPSON Stylus COLOR 680/777/777i Revision B

4.2.6 Circuit board remova l

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

2. Remove three screws (C.B.S3x6 F/Zn) securing the Circuit board unitat the front side of the Printer mechanism.

C.B.S 3x6 F/Zn

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

C.B.S 3x6 F/Zn

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

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

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EPSON Stylus COLOR 680/777/777i Revision B

4. Holding the Left housing lightly, pull down the Circuit board unit. T hen disconnect the following four cables from the corresponding connectors on the Main board.

CR motor connectorcable : CN12

PFmotorconnectorcable :CN7

Printhead FFC : CN8, CN9

HP/PE sensor cable : CN4

5. Remove the following screws securing each circuit board to the Shield plate. Figure Figure 4 -17.

C383 MAIN : Remove five screws.

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

connector)

C383PSB/E : Remove five screws.

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

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

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

C383 MAIN Board

C383 PSE/PSE board

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

A D J U S T M E N T

R E Q U I R E D

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

Before removing the Main board, connect the parallel I/F or USB Cable and try to read out the following data by using the Adjustment program. If this operat ion succeeds, replace the Main boardand writethe read out data to the new Main board through the Adjustm ent program.

1) I/C Ink consumption counter.

2) Waste ink drain pad counter.

3) Printhead ID i nput.

4) Gap adjustment (Bi-d adjus tment) In case the above mentioned data are not able to be read out from the defective M ain board, perform the following service items.

Replace the both ink cartridgeswith a b rand new one.

Replace the Wa ste ink drain pad with a new one.

Input the Printhead ID.

Adjust the Bi-d alignment.

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EPSON Stylus COLOR 680/777/777i Revision B

Since the cable between C383 MAIN board and C 383 PSB/E board are directly soldered, take the following steps when replacing only one circuit board in the service activity.

1. Take off the cable on the Main board by removing the s older by heating it with the soldering iron.

2. Replace the defective circuit board with new one.

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

Tightening Torque for s crew

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

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

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

• C.P. 3x6 F/Zn screw for Parallel I/F connector : 6+/- 1kgf.cm

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

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

C H E C K

P O I N T

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

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

Figure 4-18. PS board fixing screws

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

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

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EPSON Stylus COLOR 680/777/777i Revision B

C H E C K

P O I N T

Check the Earth terminal and wire position. Refer to the following figure. The earth wire for 120V must be placed back side of the Heat sinkerHT1. Be sure toleave at least2.5 mm of space between heat sink HT1 and thewi re . If this is not possible, secure the wire with tape or o ther methodto be sure tha t a minimum of 2.5 mm spacing is preserved.And the earth wire for 220V must be placed in front of the Heat sinker HT1 as following figure.

Earth terminal

120V Type

2.5mm

Heat sinker

Earth terminal

220V Type

Heat sinker

Figure 4-19. Earth terminal and wire position

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4.2.7 LD Roller removal

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

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

Head FFC holder

LD roller shaft holder

3. Remove two screws (C.B.S 3x6 F/Zn) securing the LD roller holder to the Main frame.

C.B.S 3x6 F/Zn screws

Figure 4-21. Removing two screws securing the LD roller holder

Figure 4-20. Taking Head FFC ou t from the FFC holder

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

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

Two hooks for LD roller holder

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

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

LD Roller shaftholderunit

Clutch mechanism

LD Roller

Washer

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

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

C A U T I O N

Do not damage the tooth of the Spur gear 35.2 and the Spur gear

23.2 when assembling the LD roller shaft holder unit.

Spur gear 35.2

Spur gear 23.2

Figure 4-24.

Spur Gear 23.2 and Spur G ear 35.2

round hole on the Clutch

Protrusion on the LD roller shaft

Figure 4-25. Assembling the Clutch

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

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

Changel ever

Figure 4-26. LD Roller shaft holder assembling

procedure (1)

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

Paper return p late

Figure 4-27. LD Roller shaft holder assembling

procedure (2)

Fasten the LD roller shaft holder with two C.B.S 3x6 F/Zn screws in the order indicated in the following figure.

Figure 4-28. Fastening the LD roller sh aft holder

Tightening torque for screw

C.B.S 3x6 F/Zn screw for LD roller shaft holder unit : 9+/1 kgf.cm

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4.2.8 HP/PE Sensor removal

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

2. Remove the LD roller from the L D roller shaft holder. (Refer to Section 4.2.7.)

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

HP/IC detection lever

HP/PE sensor

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

Two fixing hooks

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

Figure 4-29. Removing t he HP detection lever

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Tor

C H E C K

P O I N T

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

Torsion spring 0.22

PE sensor lever

C H E C K

P O I N T

Make sure that theHP/PE sensorcable is placed tothe suitable groove on the LD roller shaft holder.

HP/PE sensor cable

HP/PE sensor

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

HP/IC sensor lever

Torsion spring 0.22

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

HP/PE sensor cable

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

Make sure that the each sensor lever turn back smoothly by

Figure 4-32. Torsion spring 0. 22 for HP detection lever

moving it after the sensor was assembled to the LD roller sha ft holder.

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4.2.9 Ink system unit removal (Cap & Pump unit )

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

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

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

4. Remove three screws (C.B.S3x6 F/Zn) securing the Ink system frame and the Cap assembly to the frame.

C.B.S3x6 F/Znscrews

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

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

C A U T I O N

Since the compression spr ing is include d in the Pump assembly, watch out for the spring and the gear that pop out from the unit when the Pum p assembly is rem oved from the Ink system unit.

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

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

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

When installing the C leaner head, setthe rubber side (black side) facing toward the right side of the frame.

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

Cleaner head

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

5. Remove the Ink system unit (Cap and Pump unit) carefully along w ith the Ink system frame.

C A U T I O N

When the Ink system unitis removed,be carefulthat the gearsdo not come off from each shaft on the Ink system frame.

When replacing the Cap Assembly, do not touch the sealing rubber portion of the Cap Assembly.

The component parts in the Pump Assembly are not individually supplied as ASP. So please replace the w ho le Pump Assem bly when replacing the Pump Assembly.

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

hook & cutoff

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C H E C K

P O I N T

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

Combination gear

9.6, 24

Combination gear

37.6, 44.4

Tightening torque for sc rew

• C.B.S 3x6 F/Zn screw for I nk system frame & Cap assy.:9+/1 kgf.cm

Figure 4-36. Gear engagement on the In k system frame

Make sure that the ink tube is pl a ce d along the following position.

Pumpunit

Cap assembly

Ink tube

Figure 4-37. Ink tube placing position

After installing the Pump Assembly, ensure that the cleaner parts move back a nd forth by rotating the Gear.

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4.2.10 Paper Eject Roller removal

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

2. Remove three screws (C.B.S 3x6 F/Zn) securing the Front frame to the Main frame.

C.B.S3x6 F/Znscrew

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

Combination gear 11.6,36.8

Plainwasher

Figure 4-39.

Figure 4-38. Removing the Front frame

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

C A U T I O N

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

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5. Open the spur gear 25.6 hookwith a pair of tweezers and then slide the paper eject roller to the right while pulling it toward to remove it.

Spur gear 25.6

A D J U S T M E N T

R E Q U I R E D

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

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

Assemble the Paper eject roller in the following procedure.

1. Set the Spur Gear 25.6 to the cut out hole in the Main frame.

2. Align the shape with the spur gear 25.6 hole, insert the paper eject roller shaft, an d t hen press the spur g ear 25.6 hook until it is closed.

3. Slide the paper eject roller and then insert it in the s haft guide holder.

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

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

Paper eject roller

Tightening torque for sc rew

• C.B.S 3x6 F/Zn screw for Frontframe : 9+/-1 kgf.cm

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4.2.11 PF motor removal

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

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

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

4. Remove the Plain washer and then remove the Combination gear 11.6, 36.8 carefully. Refer to Figure 4-38.

Combination gear 11.6,36.8

Plainwasher

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

Hexagon Nut M3

PF motor

Figure 4-41. Removing two screws securing the PF motor

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

7. Remove the PF motor from the left frame.

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

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C H E C K

P O I N T

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

PF motor cable

Figure 4-42. PF motor cable

Since the CN 7 is not located near t he rear edge of the Main board, it is eas ier to use the twee ze rs or pincers to connect the cable to the CN7.

Tightening torque for screw

• Hexagon Nut M 3 for PF motor : 9+/1 kgf.cm

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4.2.12 CR unit removal

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

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

3. Release the Printhead FFC from the cable holders on the LD roller shaft holder. And disconnectthe Printhead FFC fromthe connectors CN8 and CN9 on the Main board.

Figure 4-43. Taking Printhead FFC off

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

Left CR guide shaftrod spring

Figure 4-44. Release Left Rod spring f or CR shaft

RightCRguideshaftrodspring

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

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

CR guide shaft

Figure 4-46. Removing the CR gu ide shaft

C A U T I O N

Remove the CR guide shaft while holding the CR unit by hand. If you remove the CR guide shaft without holding the CR unit, the nozzle surface of the Printhead may come in contact with the Paper guide fron t, which causes the dot missing probl em .

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C H E C K

P O I N T

Unlike the previous pr oducts, the oil pa d is not built in the CR unit.

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

Make sure tha t the CR guide shaft rod spring s are correctly set in the suitable position. Re fer to Figure 4-44,Figure 4-45.

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

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

CR Grounding plate

C H E C K

P O I N T

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

Assembling groove

CR timing belt

CR sl ider

A D J U S T M E N T

R E Q U I R E D

Figure 4-48. CR timing belt setting position

When you rep lace the CR unit with a new one, lub ricate it with the suitable amount of the G-55 grease by the spe cified position. Refer to Chapter 6 Figure 6-4.

When you rep lace the CR Pulley shaft with new one, lubricate it with the suitable amount of G-26 g rea se by the specific position.

Figure 4-47. Grounding plate assembling position

Refer to Chapter 6 Figure6-3.

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

the Gap (Bi-d).

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

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

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4.2.13 Paper feed roller removal

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

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

3. Remove the CR unit. (Refer to Section 4.2.12.)

4. Release the PF grounding spring from the Main frame.

PF groundingspring

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

hook

Frontpaper guide

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

Figure4-49. Releasing the PF groundingspring

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6. Lift up the left edge of the Front paper guide while slanting the Front paper guide by pulling up its front edge, and then slide the Front paper guide to the left s ide after releasing the right hook on the Front paper guide.

Step1

Paper guide front

Step1

Step2

Figure 4-51. Remove t he Front paper gu ide

7. Fit the protrusions of the Left PF roller bushing to the notches in the frames as shown in the following figure and remove the PF roller fasten spacer with tweezer.

Left PF roller bushing

PF roller fastenspacer

Figure 4-52.

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

8. Slide the Left PF roller bushing to right side as above figure Step 2.

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

Right PF roller bushing

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

notches

C H E C K

P O I N T

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

After assemble the Front paper guide to the printer mechanism, make sure that the hooks and the dowel pins on the Front paper guide is set to the fitting positions secure. Slide the Front paper guide to the r ight si de by pushing it a nd make sure that the right hook on the Front paper guide is locked to the frame securely. If the Front paper guide is not fixed securely to the suitable position, it may cause thepaperjam problem.

Right hook

Two dowel pins

10. Slide the PF roller t o the left s ide along with the both PF roller bushings and

Figure 4-54. Front paper guide assembling notice

remove the PF roller from the printer mechanism.

A D J U S T M E N T

R E Q U I R E D

When youreplace the PF rollerwith new one, be sure to lubricate a specific amount of G-26 between the Left PF roller bushing holder and the left edge of the PF roller. Refer to Chapter 6 Figure.

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

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4.2.14 Disassembling ASF frame unit

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

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

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

Spur gear 23.2

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

ASF Fram e unit

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

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

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

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

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5. Remove the CompressionSpring 2.67 located between the ASF Frame and the Hopper, and remove the Hopper from the ASF frame.

ASFHopper

Compression spr ing 2.67

ASFFrame

Figure 4-57. Removing the Compression spring 2.67

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

Torsionspring 25.7

ASF Frame

Figure 4-58. Removing t he Torsion spring 25.7

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

Pad holder

ASF Frame

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

When you replace the ASF frame or Hopper with the new one, make sure to l ubricate the specific a mount of G26 into the groove on ASF frame. Refer to Figure 6-2 Figure 6-3 & Figure6-4 in the Chapter 6.

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

C H E C K

P O I N T

Make surethat the each tip of the Torsionspring 25.7is set in the slot of the Pad holder and ASF frame. Refer to Figure 4-57.

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

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

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

Figure4-60. ASF fixing screwsfastening order

Tightening torque for sc rew

(rightscrew in above figure)

(left screw in abovefigure)

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ADJUSTMENT

CHAPTER