Chapter 3
Disassembly and Assembly
3.1 Overview................................................................................................................3-1
3.1.1 Precautions for Disassembling the Printer......................................................... 3-1
3.2 Disassembly and Assembly Procedures............................................................3-3
3.2.1 Before Beginning Disassembly........................................................................... 3-4
3.3 C202 MAIN Board Assembly Removal................................................................3-5
3.4 Upper Housing Removal......................................................................................3-6
3.4.1 C202 Panel Board Assembly Removal................................................................ 3-9
3.5 Printhead Removal.............................................................................................3-10
3.6 Paper Eject Frame Assembly Removal.............................................................3-13
3.7 Front Paper Guide Assembly Removal.............................................................3-14
3.8 Home Position (HP) Sensor Removal...............................................................3-15
3.9 C202 PSB/PSE Board Assembly Removal .......................................................3-16
3.10 Carriage Motor (CR Motor) Assembly Removal.............................................3-18
3.11 ASF (Auto Sheet Feeder) Removal..................................................................3-19
3.11.1 ASF Assembly Disassembly- ........................................................................... 3-21
3.11.2 ASF HP Sensor Removal.................................................................................. 3-26
3.12 Paper Feed Motor Assembly Removal............................................................3-28
3.13 Printer Mechanism Removal............................................................................3-30
3.13.1 Cap Assembly Removal....................................................................................3-31
3.13.2 Pump Assembly Removal................................................................................ 3-33
3.13.3 Pump Motor Removal....................................................................................... 3-35
3.13.4 Carriage (CR) Assembly Removal ................................................................... 3-36
3.13.5 Top Frame Removal.......................................................................................... 3-40
3.13.6 Paper Empty (PE) Sensor Assembly Removal................................................ 3-42
3.13.7 I/S (Ink System) Frame Removal...................................................................... 3-44
3.13.7.1 I/S Frame Disassembly (Removing the Pump Motor)............................ 3-47
3.13.8 Paper Feed Roller (PF Roller) Assembly Removal......................................... 3-51
3.13.9 Ink Drain Pad Removal.....................................................................................3-54
Disassembly and Assembly
3.1 Overview
This section describes procedures for disassem bling main components of the EPSON Stylus
COLOR 800. Unless otherwise specified, you can assemble units or components by reversing
disassembly. Therefore, no assembly procedures are included. Pr ecautions for disassembly or
assembly are described under the heading
assembling the unit are described under
3.1.1 Precautions for Disassembling the Printer
See the precaution below when disassembling and assembling EPSON Stylus COLOR 800.
❏ Disconnect the power cable before disassembling or assembling t he pr inter.
❏ Wear goggles to protect your eyes from ink. I f ink gets in your eye, flush it with fresh
water and see a doctor immediately.
❏ If ink comes in contact with your skin, wash it off with soap and water. If irritation occur s,
contact a physician.
POINTS TO NOTE
REQUIRED ADJUSTMENTS
. Adjustments required after
WARNING
.
❏ A lithium battery is installed on the main board of this printer. Be sure to observe the
following instructions when servicing the bat t ery:
Keep the battery away from any m et al or other batteries so that electrodes of the
opposite polarity do not come in contact with each other.
Do not heat the battery or put it near fire.
Do not solder on any part of the batter y. (Doing so may result in leakage of
electrolyte from the batt er y, burning, or explosion.)
Do not charge the battery. (An explosive may be generated inside the battery and
cause burning or explosion.)
Do not dismantle the battery. (The gas inside the battery may hurt your throat .
Leakage, burning, or explosion also may result.)
Do not install the battery in the wr ong direction. (This may cause burning or
explosion.)
CAUTION
❏ Danger of explosion if the battery is incorrectly replaced. Replace only with the same or
equivalent type recommended by the manufact ur er. Dispose of used batter ies accor ding
to government laws and regulations.
ATTENTION
❏ Risque d’esplosion si la pile est remplacée incorrectment. Ne remplacer que par une pile
fu mêmetype ou d’un type équivalent recommandé par le fabricant . Eliminer les piles
déchargées selon lois et les règles de sécurité en vigueur.
Rev. A
3-1
EPSON Stylus
2
&2/25
800
CAUTION
❏ Never remove the ink cartridge from t he car riage unless the manual specifies to do so.
❏ When transporting the printer af ter the ink cartridge has been installed, be sure to pack
the printer for transport 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 det ails. )
❏ Make adjustments specified when you disassemble the printer. (See Chapter 4 f or
details.)
3-
Rev. A
Disassembly and Assembly
3
3.2 Disassembly and Assembly Procedures
This section describes disassembly or assembly procedures for pr inter assemblies and parts.
CAUTION
Read precautions in Section 3.1.1 prior to disassembly and assembly.
Start
Pre-disassembling
Operation
C202MAIN Board
Removal
Upper Housing Removal
C202PSB/PSE Board
Removal
Paper Supprt Removal
Stacker Removal
Control Panal Removal
Print Head Removal
Carriage Motor Removal
: If the shaded parts was replaced or removed,
perform the required adjustment which is mentioned
on page 4-1 of the Chapter 4
Paper Eject Frame
Assembly Removal
Paper Guide (Front)
Removal
ASF Assembly Removal
Home Position Sensor
Removal
ASF Assembly
Disassembly
ASF Home Position
Removal
Sensor
Rev. A
Printer Mechanism
Removal
Paper Feed Motor
Removal
Cap Assembly Removal
Pump Assembly Removal
Pump Motor Removal
Carriage Assembly
Removal
Top Frame Removal
Figure 3-1. Printer Disassembly Procedures
Ink Drain Pad Removal
Paper Empty Sensor
Assembly Removal
I/S Frame Removal
Paper Feed Roller
Assembly Removal
I/S Frame Disassembly
3-
EPSON Stylus
4
&2/25
800
3.2.1 Before Beginning Disassembly
Remove the following parts before beg inning disassembly.
Paper Support
Output Tray
To remove the output tray, shift it to the right end, then push the handle on the left edge
inward. This will help you to remo ve it m or e easily.
2. Output Tray
Figure 3-2. Before Beginning Disassembly
1. Paper Support
3-
Rev. A
Disassembly and Assembly
5
3.3 C202 MAIN Board Assembly Removal
1. Remove 2 screws (CBS, 3x8, F/Zn) securing the C202 MAIN board assembly to the back of
the printer. (See Figure 3-3.)
2. Move C202 MAIN board about 5 cm (2”) out from the back of the printer. (See Figure 3-3.)
CAUTION
C202 MAIN board assembly shield plate edges are sharp. So, be caref ul handling t hem.
CBS Scrws (3X8, F/Zn)
Figure 3-3. C202 MAIN Board Assembly Removal
Rev. A
3-
EPSON Stylus
6
&2/25
800
3. Disconnect all cables (CN4, CN6, CN7, CN8, CN11, CN12, and CN13) and FFCs (CN9 and
CN10) from C202 MAIN board assembly. (See Figure 3-4) Use instructions below to
disconnect connectors:
CN11, CN12, CN13: Release the connector lock lever by pulling it up, and
disconnect the cable.
CN4: Release the connector lock lever by pressing it down, and
disconnect the cable.
2
2
1
Disconnecting CN4
1
Disconnecting CN11, CN12, CN13
1
Figure 3-4. Connector Removal
Remove C202 MAIN board from the printer main board slot . (See Figure 3-3.)
❏ Note the direction when connecting cables for CN11, CN12, CN13, and CN4. Be sure to
insert the pin 1 side into the position marked w it h a “ 1” on the board.
❏ Ensure that the locks for CN11, CN12, CN13 are locked after connection.
❏ Hold down the lock lever for CN4 while connecting the cable.
❏ Make sure no cables or FFCs are cut by the shield plates.
❏ Tightening torque for the screws (CBS, 3X8, F/ Zn) is 8 ~10 kg- c m .
3-
Rev. A
Disassembly and Assembly
7
3.4 Upper Housing Removal
1. Remove the parts shown in Figure 3-2.
2. remove 2 screws (CBS, 3X8, F/Zn) securing the C202 MAIN board assembly to the printer.
Then draw the C202 MAIN board forward about 5 cm.
3. Disconnect the control panel FFC from CN5 on the C202 MAIN board assembly.
(See Figure 3-5.)
Connector CN5
Figure 3-5 Connector for CN5 Removal
Rev. A
3-
EPSON Stylus
8
&2/25
800
4. Remove 4 screws (CCP, 4x12, F/Zn): 2 screws securing the upper housing to the f ront and
2 screws securing the upper housing to the top rear side of the printer.
(Refer to Figure 3-6. )
5. Set the platen g ap lever to the “+” position. Then, pull the front part of the upper housing
forward, and lift it backward to remove.
CCP, 4X12
Upper Case
CCP, 4X12
Figure 3-6. Upper Housing Removal
❏ Before installing the upper housing, set the platen gap lever to the “+” position to make
the job easier. You must set it back to “0” after theu upper housing is securely positioned.
❏ Tightening torque for the screws (CCP, 4x12, F/Zn) = 10 kg-cm.
3-
Rev. A
Disassembly and Assembly
9
3.4.1 C202 Panel Board Assembly Removal
1. Remove the upper housing. (See Section 3.4. )
2. Turn the upper housing up, and release the lock lever f or the FFC connector by pushing it
out. Then disconnect the FFC.
3. Release 2 hooks attaching the C202 panel board assembly to the upper housing. Then
remove the C202 panel board assembly from the upper housing. (See Figure 3-7.)
Control Panel
Figure 3-7. Control Panel Removal
❏ During assembly, be careful not to bend the contact plate m ount ed on the C202 panel
board.
Rev. A
3-
EPSON Stylus
0
&2/25
800
3.5 Printhead Removal
1. Remove the upper housing. (Refer to Section 3.4.)
2. Open the ink cartridg e covers and r em ove the ink cartridges from t he CR assem bly.
3. Using tweezers, release the ink cartridge covers from the pins fixing them to the CR
assembly. Then remove the ink cartridge covers. ( See Figure 3-8.)
Figure 3-8. Cartridge Cover Removal
4. Remove 2 head fixing screws securing the printheads to the CR assembly at the bottom.
5. Remove 2 compression springs (9.9 g) holding each printhead t o the carriag e. (See Figur e
3-9.)
Head Fixing Screw
Compression Spring (9.9)
Figure 3-9. Screw and Spring Removal
3-1
Rev. A
6. Remove 2 FFCs from the printheads. ( See Figure 3-10.)
Head FFCs
Disassembly and Assembly
Figure 3-10. Head FFC Removal
7. Shift the printheads forward. Then remove them by lif t ing upward carefully.
CAUTION
❏ In handling the printheads, note the follow ing:
Ground yourself. The driver IC is att ached dir ectly to the printhead unit.
Do not touch the printhead surface.
❏ Before installing a new printhead in the CR assembly, note the voltage ID stamped on
the right side of the printhead.
❏ When tightening and loosening printhead fixing screws, use your hand t o support the
bottom of the CR assembly.
Rev. A
3-11
EPSON Stylus
2
&2/25
800
❏ Before installing the printhead into the CR assembly, move the carriage to the capping
position to protect the head surface.
❏ Procedures for printhead assembly are described below.
1. Remove the 2 FFCs from the clips used to att ach t hem .
2. Insert the color head FFC through the slit in t he back of the CR assembly with the
exposed terminal facing the rear, and connect it to the color head. Then install the
color head in the CR assembly.
3. Insert the black head in the CR assembly. Then insert the black head FFC through
the slit with the exposed terminal facing t he r ear.
4. Fasten the printheads in the CR assembly with the compression springs (9.9 g)
and head fixing screws.
5. Place both FFCs back into the clips used to hold them. Be sure t hey ar e also
placed in the small clip beside the larger one. Be careful not to disconnect the
FFCs from the printheads while installing t hem int o the clips. (See Figure 3-11.)
❏ Tightening torque for the head fixing screw = 2.5 ~ 3.1 kg-cm.
❏ When mounting a head fixing screw, screw carefully with force while supporting the
bottom of the carriage so not to st rip the screw head.
❏ Ensure the head fixing screw washers do not tur n after tightening head fixing screws.
FFC Fixing Clip
Head FFC
Figure 3-11. Head FFC and FFC Clips
REQUIRED ADJUSTMENT
❏ After replacing or removing the print head, perform the specified adjustment. ( See
Chapter 4.)
3-1
Rev. A
Disassembly and Assembly
3
3.6 Paper Eject Frame Assembly Removal
1. Remove the upper housing. (See Section 3.4. )
2. Release the CR lock lever using tweezers. Then shift the CR to the left of the FFC holder.
3. Release 2 hooks for the FFC holder, and remove the FFC holder. (See Figure 3-12.)
FFC Holder
Paper Eject Frame
Figure 3-12. FFC Holder Removal
4. Remove the printhead FFCs from the sub holder, and remove the sub holder. Then remove
2 screws (CBS, 3x6, F/Zn) securing the paper eject frame. (See Figure 3-13.)
Paper Eject Frame CBS Screw (3X&, F/Zn) Head FFC
Figure 3-13. Screws Securing t he Paper Eject Frame
5. Hold down FFC along the paper eject frame, and shift the CR back to the capping position.
Then lift the paper eject frame assembly up about 3 mm (0.12”) and slide it forward.
❏ In mounting FFCs, be careful not to damage or catch them while sliding the CR unit.
❏ Make sure the FFC holder is securely hooked to the paper eject fr am e assembly.
❏ Tightening torque for the screws (CBS, 3x6, F/Zn) = 8 ~ 10 kg-cm .
Rev. A
3-1
EPSON Stylus
4
&2/25
800
3.7 Front Paper Guide Assembly Removal
1. Remove the paper eject fram e assem bly. (See Section 3.6.)
2. Lift up the front paper guide assembly slightly, and shift it forward while sliding it t o the left
to release the pins from the cut out s in the right frame. (See Figure 3-14.)
Front Paper Guide Assembly
Figure 3-14. Front Paper Guide Removal
❏ There are 4 pins, 2 on each edge. Be sure to fit them int o the cutouts in the right and left
frame when installing the front paper guide assem bly.
❏ When engaging the gear (19 mm) on the left edge of the front paper guide assembly
and the gear (17 mm) on the left edge of the paper feed roller, be careful not to damage
them.
3-1
Rev. A
Disassembly and Assembly
5
3.8 Home Position (HP) Sensor Removal
1. Remove the upper housing. (See Section 3.4. )
2. Using tweezers, release 2 hooks fixing the HP sensor to t he sub pum p f r ame. T hen rem ove
the HP sensor by pulling it downward. (See Figure 3-15.)
Home Postion Sensor
Figure 3-15. HP Sensor Removal
3. Disconnect the HP sensor connector cable from the HP sensor.
Sub Pump Frame
❏ Note the direction in which the HP sensor is att ached. Place t he cable side down.
❏ Tightening torque for the screws (CBS, 3x8, F/Zn) = 8 ~ 10 kg-cm .
Rev. A
3-1
EPSON Stylus
6
&2/25
800
3.9 C202 PSB/PSE Board Assembly Removal
1. Remove the upper housing. (See Section 3.4. )
2. Remove 2 screws (CBS, 3x6, F/Zn) securing the C202 PSB/PSE board assembly to the
printer mechanism. (See Figure 3- 16.)
Carriage Motor
CBS Screw (3X6, F/Zn)
ASF Frame
C202PSB/PSE Board Assembly
Figure 3-16. C202 PSB/PSE Board Removal
3. Hold down the lock lever for CN4 on the C202 MAIN board assembly, and disconnect the
connector cable for the C202 PSB/PSE board.
4. Remove all connectors from the clamp attached to the C202 PSB/PSE board assembly.
(See Figure 3-17.)
C202 PSB/PSE Board
Assembly
Cable Clump
Home Position Sensor
Figure 3-17. Connector Cable Removal
5. Lift up the C202 PSB/PSE board, and remove it from the printer mechanism.
3-1
Rev. A