All rights reserved. Reproduction of any part of this manual in any form whatsoever without SEIKO
EPSON’s express written permission is forbidden.
The contents of this manual are subjects to change without notice.
All efforts 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 notwithstanding SEIKO EPSON can assume no responsibility for any errors in this manual or
the consequence thereof.
Epson is a registered trademark of Seiko Epson Corporation.
General Notice: Other productnamesused herein are for identication purposes only andmay be trademarks
of their respective campanies.
Precautionary notations throughout the text are categorized relative to 1) personal injury and 2) damage to
equipment.
DANGER
WARNING
The precautionary measures itemized below should always be observed when performing repair/ maintenance procedures.
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.
Signals a precaution which, if ignored, could result in damage to equipment.
DANGER
1.ALWAYS DISCONNECT THE PRODUCT FROM BOTH THE POWER SOURCE AND PERIPHERAL DEVICES PERFORMING ANY MAINTENANCE OR REPAIR PROCEDURE.
2.NO WORK SHOULD BE PERFORMED ON THE UNIT BY PERSONS UNFAMILIAR WITH
BASIC SAFETY MEASURES AS DICTATED FOR ALL ELECTRONICS TECHNICIANS IN
THEIR LINE OF WORK.
3.WHEN PERFORMING TESTING AS DICTATED WITHIN THIS MANUAL, DO NOT CONNECT THE UNIT TO A POWER SOURCE UNTIL INSTRUCTED TO DO SO. WHEN THE
POWER SUPPLY CABLE MUST BE CONNECTED, USE EXTREME CAUTION IN WORKING
ON POWER SUPPLY AND OTHER ELECTRONIC COMPONENTS.
WARNING
1.REPAIRS ON EPSON PRODUCT SHOULD BE PERFORMED ONLY BY AN EPSON CERTIFIED REPAIR TECHNICIAN.
2.MAKE CERTAIN THAT THE SOURCE VOLTAGE IS THE SAME AS THE RATED VOLTAGE,
LISTED ON THE SERIAL NUMBER/RATING PLATE.IF THE EPSON PRODUCT HAS A
PRIMARY AC RATING DIFFERENT FROM AVAILABLE POWER SOURCE, DO NOT CONNECT IT TO THE POWER SOURCE.
3.ALWAYS VERIFY THAT THE EPSON PRODUCT HAS BEEN DISCONNECTED 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 AS ANTI-STATIC WRIST STRAPS, WHEN ACCESSING
INTERNAL COMPONENTS.
5.REPLACE MALFUNCTIONING COMPONENTS ONLY WITH THOSE COMPONENTS BY
THE MANUFACTURE; INTRODUCTION OF SECOND-SOURCE ICs OR OTHER NONAPPROVED COMPONENTS MAY DAMAGE THE PRODUCT AND VOID ANY APPLICABLE
EPSON WARRANTY.
-ii-
PREFACE
This manual describes functions, theory of electrical and mechanical operations, maintenance, and repair of
STYLUS-PRO.
The instructions and procedures included herein are intended for the experience repair technician, and attention
should be given to the precautions on the preceding page. The chapters are organized as follows:
CHAPTER 1. GENERAL DESCRIPTION
Provides a general product overview, lists specifications, and illustrates the main components of the printer.
CHAPTER 2. OPERATING PRINCIPLES
Describes the theory of printer operation.
CHAPTER 3. DISASSEMBLY AND ASSEMBLY
Includes a step-by-step guide for product disassembly and assembly.
CHAPTER 4. ADJUSTMENTS
Includes a step-by-step guide for adjustment.
CHAPTER 5. TROUBLESHOOTING
Provides Epson-approved techniques for adjustment.
CHAPTER 6. MAINTENANCE
Describes preventive maintenance techniques and lists lubricants and adhesives required to service the equipment.
Table 1-18. The Comparison between C164 MAIN and C162 MAIN . . . . . . 1-18
Stylus Pro Service ManualProduct Description
1.1 FEATURE
The Stylus Pro is a high-performance color ink jet printer with a small footprint and low cost. The main
components of this printer are similar to the Stylus Color. The main features are:
r High quality color printSuper dot 720 dpi printing
Plain paper 720 dpi printing
Special coated paper for 720 dpi printing
r High print speedLQ printing at 200 cps
2
r Built-in auto sheet feederHolds 100 cut sheets (55 g/m
Holds 10 envelopes
Holds 50 transparency film sheets
Holds 70 sheets of special paper
r Three built-in I/F typesMacintosh Serial interface
Note:These character tables are not supported for EPSON Roman T and EPSON Sans Serif H
scalable fonts.
Fonts:Bitmap LQ fonts
r EPSON Roman(10 cpi/12 cpi/15 cpi/Proportional)
r EPSON Sans Serif(10/12/15/Proportional)
r EPSON Courier(10/12/15)
r EPSON Prestige(10/12/15)
r EPSON Script(10/12/15)
Scalable fonts
r EPSON Roman10.5 points, 8 ∼ 32 points (in units of 2 points)
r EPSON Sans Serif10.5 points, 8 ∼ 32 points (in units of 2 points)
r EPSON Roman T10.5 points, 8 ∼ 32 points (in units of 2 points)
r EPSON Sans Serif H 10.5 points, 8 ∼ 32 points (in units of 2 points)
Control codes:ESC/P 2 and expanded raster graphics codes
Input data buffer:64K bytes
Rev.B1-3
Product DescriptionStylus Pro Service Manual
1.2.2 Paper Handling Specifications
Feeding method:Friction feed paper is fed from the built-in auto sheet feeder (ASF).
Notes:The following operations are not allowed:
1. Reverse feeding within 3 mm (0.12 in.) from the top edge of the paper or 16 mm
(0.63 in.) from the bottom edge of the paper.
2. Reverse feeding beyond 7.9 mm (0.3 in.).
Line spacing:
1
⁄6-inch feed,1⁄8-inch feed, or programmable in1⁄
-inch minimum increments.
360
Paper path:Cut sheets: Built-in auto sheet feeder (ASF). Front entry.
Feeding speed:
89 msec. (at
1
⁄6-inch feed pitch).
1.2.3 Paper Specifications
Table 1-3. Cut Sheet Paper Specifications
Legal:216 mm (8.5 in.) × 356 mm (14.0 in.)
Letter:216 mm (8.5 in.) × 279 mm (11.0 in.)
Size (W × L)
Thickness0.08 mm (0.003 in.) ∼ 0.11 mm (0.004 in.)
Weight55 g/m
Quality
Note :Printing on special coated paper for 720 dpi, special coated paper for 360 dpi,
transparency film, and high-quality glossy paper is only available at normal temperatures.
A4:210 mm (8.3 in.) × 297 mm (11.7 in.)
Executive: 184 mm (7.25 in.) × 267 mm (10.5 in.)
Statement :140 mm (5.5 in.) × 216 mm (8.5 in.)
2
(17 lb) ∼ 90 g/m2(24 lb)
Plain paper, special coated paper for 720 dpi, special coated paper for
360 dpi, transparency film, high-quality glossy paper
Table 1-4. Envelope Specifications
C5:229 mm (9 in.) × 162 mm (6.4 in.)
Size (W × L)
No. 10:240 mm (9
DL:220 mm (8.7 in.) × 110 mm (4.3 in.)
ThicknessLess than 0.52 mm (0.020 in.)
Weight75 g/m
2
(20 lb) ∼ 90 g/m2(24 lb)
QualityPlain paper
Note:Printing of envelopes is supported only at room temperature. When inserting envelopes,
keep the longer side horizontal.
1
⁄2in.) × 104 mm (41⁄8in.)
1-4Rev.B
Top mar gin
3 mm (0.12 in.)
Left margin
3 mm (0.12 in.)
Right margin
3 mm (0.12 in.)
Bottom margin
14 mm (0.55 in.)
Printable area
Stylus Pro Service ManualProduct Description
Printable area:
Cut sheets
B
(Left margin)
C
(Right margin)
Printable area
A
(Top margin)
D
(Bottom margin)
Figure 1-3. Printable Area for Cut Sheets
Note:A: Mnimum top margin = 3 mm (0.12 in.)
B: Minimum left margin = 3 mm (0.12 in.)
C:Minimum right margin is:
A4 size:3 mm (0.12 in.)
Letter size: 9 mm (0.35 in.)
Legal size: 9 mm (0.35 in.)
Envelopes: 3 mm (0.12 in.)
D:Minimum bottom margin = 14 mm (0.55 in.)
Envelopes
Figure 1-4. Printable Area for Envelopes
Rev.B1-5
Product DescriptionStylus Pro Service Manual
Adjust lever settings:The adjust lever on the carriage unit must be set to the proper position for the
paper thickness, as shown in Table 1-5.
Table 1-5. Adjust Lever Setting
Lever Position
LEFT
(Vertical)
RIGHT
(Horizontal)
1.2.4 Ink Cartridge Specifications
PaperPaper Thickness
Cut Sheets
EnvelopesLess than 0.5 mm (0.020 in.)
Cut Sheets
Carriage Unit
Figure 1-5. Adjustment Lever Settings
Black
0.08 ∼
(0.003
0.11 mm
∼
0.004 in.)
Envelopes
Type:Exclusive cartridge
Color:Black
Print capacity:1.2 million characters (315 dots/character, Roman 10 cpi)
Life:The effective life from the indicated production date is 2 years.
Storage temperature:
Dimension (W × D × H):26.9 × 67.4 × 41.8 mm (1.06 × 2.65 × 1.65 in.)
–30 ∼ 40° C (−22 ∼ 104° F) Storage under a month at 40° C (104° F)
−30 ∼ 60° C(−22 ∼ 140° F) Transit under a month at 40° C (104° F)
−30 ∼ 60° C(−22 ∼ 140° F) Transit under 120 hours at 60° C (140° F)
Color
Type:Exclusive cartridge
Color:Cyan, magenta, yellow
Print capacity:
Life:The effective life from the indicated production date is 2 years.
Storage Temperature:
Dimension (W × D × H):54.0 × 67.4 × 41.8 mm (2.13 × 2.65 × 1.65 in.)
Notes:
r
Ink cartridge cannot be refilled; it is the only consumable article.
r
Do not use an ink cartridge that has exceeded the ink life.
r
Ink freezes below−3°C; however, it can be used after it returns to room
temperature.
28 sheets/color (A4, full image printing at 360 dpi)
–30 ∼ 40° C (−22 ∼ 104° F) Storage under a month at 40° C (104° F)
−30 ∼ 60° C(−22 ∼ 140° F) Transit under a month at 40° C (104° F)
−30 ∼ 60° C(−22 ∼ 140° F) Transit under 120 hours at 60° C (140° F)
Less than 512 bytesOffX-OFF
More than 1,024 bytesOnX-ON
1 bit
8 bit
none
1 bit
®
System peripheral-8 cable
Table 1-10. Signal and Connector Pin Assignments for Serial Interface
Pin No.
1
2
3
4
5
6
7
8
Signal NameI/O*Description
DTROutData terminal ready
NC—No connection
TXDOutTransmit data
SGInSignal ground
RXDInReceive data
TXDOutBalanced transmit
NC—No connection
RXDInBalanced receive
*The I/O column indicates the data flow as viewed from the printer.
Rev.B1-11
Product DescriptionStylus Pro Service Manual
1.4 OPERATIONS
This section describes the basic operations of the printer.
1.4.1 Control Panel
The control panel for this printer has 1 lock-type and 5 non lock-type pushbuttons, and 15 LED
indicators for easy operation of the various printer functions.
OperateAlt
Font
Economy/
Condensed
Load/Eject
Pause
Figure 1-8. Control Panel Appearance
Buttons
OperateTurns the printer on or off.
AltModifies the function of other buttons. Holding down this button for
3 seconds turns the Pause light to come on, and causes the printer to
move the carriage to the ink cartridge installation position. Pressing Alt
again causes the carriage to return to the home position.
FontCycles through the font choices. Pressing the Font button, while holding
down the Alt button in pause mode causes the carriage to move to the
gap adjustment position. Pressing the Alt button again causes the
carriage to return to the home position.
Economy/CondensedSelects either economy printing or condensed printing mode. Pressing
the Economy/Condensed button while holding down the Alt button turns
the Pause light on and starts the color printhead cleaning cycle.
Load/EjectEither loads a new sheet into the printer or ejects paper currently in
the paper path. Pressing the Load/Eject button while holding down the
Alt button starts the black printhead cleaning cycle.
PauseStops printing temporarily or resumes printing if it has been stopped
temporarily. Pressing Pause while holding down the Alt button for
about three seconds, or until all LEDs light, resets the printer.
1-12Rev.B
Stylus Pro Service ManualProduct Description
Indicators
OperateOn when the printer is on. Blinks during power on and off.
DataOn when print data is in the input buffer. Data and Pause lights blink if
an error occurs.
Paper OutOn when the printer is out of paper. Blinks when a paper jam occurs.
No Ink CartridgeOnwhen the ink is out.
EconomyOnwhen economy printing mode is selected.
CondensedOn when condensed printing mode is selected.
FontThese LEDs indicate the selected font.
PauseOn when printing is paused.
1.4.2 Panel Operation at Power On
You can activate the modes below by doing the following:
Self-test modeTurn on the printer while holding down the Load/Eject button.
Hex dump modeTurn on the printer while holding down the Font and Load/Eject
buttons. Once this mode is selected, the printer prints all received data
in hexadecimal format.
Default setting modeTurn on the printer while holding down the Economy/ Condensed
button. For more information about the mode, see Section 1.4.3.
Initialize EEPROMTurn on the printer while holding the Alt, Font, Load/Eject, and Pause
buttons.
Rev.B1-13
Product DescriptionStylus Pro Service Manual
1.4.3 Default Settings
The printer can save some printer setting parameters that define its functions at initialization. You can
change these parameters using the printer’s default-setting mode.
1.4.3.1 Default Setting Items
In default-setting mode, you can change settings listed in the table below. Activate default-setting mode
by holding down the Economy/Condensed button while turning on the printer.
Table 1-11. Default Setting Items
Menu
Contents
Character table
Print direction
Network I/F mode
Auto line feed
Loading position
Interface mode
Auto I/F wait mode
Table 1-12. Characteristics of Print Direction Mode
Item
Auto
Bi-D
Uni-D
Black and White PrintingColor (CMYK) Printing
Throughput and quality is
Print quality may be down.
Selects the character table—
Controls the print direction. (See Tables 1-12 and 1-13)
Auto
Bi-D
Uni-D
Off: For normal environments.
On: For network environments.
On: Valid
Off: Invalid
3.0/8.5 mm (0.12/0.33 in.)3.0 mm
Auto I/F mode
Parallel I/F mode
Serial I/F mode
Optional I/F mode
10/30 seconds10 sec.
better.
Throughput is best.
Throughput is worse.
Print quality is better.
Description
Throughput is better.
Color quality with special paper is worse.
(Color correction depends on the printing direction.)
Throughput is better.
Color quality with special paper is worse.
(Color correction depends on the printing direction.)
Note:Printing direction is controlled by driver in Windows environment.
1.4.3.2 Changing the Default Settings
To change the printer’s default settings:
1-14Rev.B
AutoBi-DUni-D+
Stylus Pro Service ManualProduct Description
a.Hold down the Economy/Condensed button and turn on the printer. The printer prints a sheet that
shows the firmware version and describes how to select the language used to print messages.
b.Press the Font button until the appropriate font LED is selected. The following table shows which
language corresponds to which font LED.
Table 1-14. Language Selection
Language
English
Français
Deutsch
Italiana
Español
c.Press the Alt button. The printer prints the current settings using the selected language. It also
prints a table showing how to change the printer settings.
d.Press the Font button to advance through the setting menu. The current printer settings are
indicated by the Courier, Roman T (PS), and San Serif H (PS) LEDs. Each time you press the Font
button, you adance to the next setting, and the three font LEDs change according to the selection.
Font LED
Courier
Roman T (PS)
Sans Serif H (PS)
Roman
Sans Serif
Table 1-15. Feature Selection
Menu
Feature/Menu
Character tableOnOnOnSee Table 1-16+
Print direction
Network I/F mode
Auto line feed
Loading position
Interface mode
Auto I/F wait time
e.Change the setting value by pressing Alt button. Pressing the Alt button changes the setting for the
current menu. The status of the LEDs will be changed as the button is pressed.
The printer can detect the various errors and indicate them with LEDs.
Table 1-17. Error Indications
ErrorData LED
Paper outOffOnOffOffOffOff
No ink cartridgeOffOffOnOffOffOff
Paper jamOffBlinksOffOffOffOff
Maintenance requestBlinksBlinksBlinksBlinksBlinksBlinks
Carriage errorBlinksOffOffOffOffBlinks
Paper Out
LED
No Ink
Cartridge
LED
Economy
LED
Condensed
LED
Pause
LED
1.4.5 Printer Initialization
There are three initialization methods: hardware initialization, software initialization, and panel initialization.
1.4.5.1 Hardware Initialization
Hardware initialization is performed by:
rTurning on the printer.
rSending the parallel interface
(If the
INIT signal is active when the printer is turned on, hardware initialization is started when the INIT
signal becomes inactive.)
When the hardware initialization is performed:
rThe printer mechanism is initialized.
rInput data buffer is cleared.
rDownloaded character definitions are cleared.
rPrint buffer is cleared.
rDefault values are set.
INIT signal.
1.4.5.2 Software Initialization
Software initialization is performed upon receipt of the control code ESC @.
When the software initialization is performed:
rPrint buffer is cleared.
rDefault values are set.
The last panel settings are kept.
1.4.5.3 Panel Initialization
This printer is initialized by pressing the Load/Eject button while pressing the Alt button.
When the panel initialization is performed:
rInput data buffer is cleared.
rPrint buffer is cleared.
rDefault values are set.
The last panel settings are kept.
Rev.B1-17
Product DescriptionStylus Pro Service Manual
1.5 MAIN COMPONENTS
The main components of the Stylus Pro are:
oMain control board (C164 MAIN Board)
oPower supply unit (C137 PSB/PSE Board)
oControl panel board (C137 PNL Board)
oPrinter mechanism (M-4A10)
oHousing
1.5.1 Main Control Board (C164 MAIN Board)
The main control board (C164 MAIN Board) consists of an H8/3003 16-bit CPU, E05A09 gate array, a
program ROM (1/2/4Mb), a program/CG ROM (1/2/4/8Mb), 1 DRAM (4Mb), a mask ROM (4/8Mb), an
EEPROM (1Kb), and a lithium battery for powering the protect counters. The reset IC (M51955 and PST 592)
is equipped with both a logic system and a power system. The C164 MAIN Board is almost the same as the
C162 MAIN Board, except that the C164 board has no solenoid driving circuit for the ADF. (The C162
MAIN Board has a solenoid driver to operate the document feeder. )
Table 1-18. Comparison between C164 MAIN and C162 MAIN
Main BoardC164 MAIN BoardC162 MAIN Board
DRAMs12
ADF Plunger
Driving Circuit *
NoneEquipped
*The ADF plunger switches the PF motor operation from paper feed to paper pickup.
CPU (H8/3003)
RAM
Program ROM
Head Common Drive Tansistors
Lithium Battery
164
Gate Array (E05B09)
EEPROM
PF Motor Driver IC
CR Motor Driver IC
CG ROM
Figure 1-9. C164 MAIN Board Component Layout
1-18Rev.B
L1
C1
R2
CN1
CN2
F1
IC51 (TL494)
T1
Q1
C11
C51
C82
PC1
C3
Q51
DB1
D51
SW6
LED1
/
LED4
LED8
/
LED14
LED5
LED6
LED7
SW4
/
SW0
Stylus Pro Service ManualProduct Description
1.5.2 Power Supply Board (C137 PSB/PSE Board)
The power supply board (C137 PSB/PSE Board) consists of an RCC switching regulator circuit. This board is
equipped with a power switch, connected to the secondary circuit. Thus, if the printer is turned off, it can
continue to operate to eject the paper and perform the head-capping operation. The power on/off signal is
always monitored by the E05A09 gate array on the C164 MAIN Board, and the logic system recognizes the
power switch status.
Figure 1-10. C137 PSB/PSE Component Layout
1.5.3 Control Panel (C137 PNL Board)
The 15 LEDs on this board indicate error status (there is no buzzer system). By using the 6 buttons in
combination with one another, you can operate the printer in each protected mode (cleaning color or black ink
systems, exchanging ink cartridges, running a self-test, setting default values, resetting the printer, and
EEPROM clearing).
Figure 1-11. C137 PNL Board Component Layout
Rev.B1-19
Product DescriptionStylus Pro Service Manual
1.5.4 Printer Mechanism (M-4A11)
The M-4A11 printer mechanism is equipped with a 64-nozzle black printhead and 48-nozzle color (CMY)
printhead on the carriage unit. A resolution of 720 dpi is possible with special (non-absorbent) paper.
The ink system has both a black pump unit and a color pump unit. Waste ink from each printhead flows into
individual caps. Power for the pump system and paper feed system is supplied by the paper feed motor. This
printer mechanism is based on Stylus Color’s (M-4A10).
1.5.5 Housing
The Stylus Pro’s housing consists of the printer cover, upper case, and the lower case.
Attached to the housing is the front paper tray, with paper separator.
1-20Rev.B
Chapter 2 Operating Principles
Table of Contents
2.1 OVERVIEW2-1
2.2 OPERATING PRINCIPLES OF THE PRINTER MECHANISM2-1