Manual de Servicio Epson Stylus Color c67 c68 d68

SERVICE MANUAL
Color Inkjet Printer
EPSON Stylus C67/C68/D68
SEIJI05-003
Notice:
All rights reserved. No part of this manual may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical,
photocopying, recording, or otherwise, without the prior written permission of SEIKO EPSON CORPORATION.
The contents of 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.
Copyright 2005
SEIKO EPSON CORPORATION.

I&I CS/Quality Management & PL Department
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 DISCONNECT THE PRODUCT FROM THE POWER SOURCE AND PERIPHERAL DEVICES PERFORMING ANY MAINTENANCE OR REPAIR
PROCEDURES.
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.
4.
WHEN DISASSEMBLING OR ASSEMBLING A PRODUCT, MAKE SURE TO WEAR GLOVES TO AVOID INJURIER FROM METAL PARTS WITH SHARP EDGES.
WARNING
1.
REPAIRS ON EPSON PRODUCT SHOULD BE PERFORMED ONLY BY AN EPSON CERTIFIED REPAIR TECHNICIAN.
2.
MAKE CERTAIN THAT THE SOURCE VOLTAGES 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 NON-APPROVED COMPONENTS MAY DAMAGE THE PRODUCT AND VOID ANY APPLICABLE EPSON WARRANTY.
6.
WHEN USING COMPRESSED AIR PRODUCTS; SUCH AS AIR DUSTER, FOR CLEANING DURING REPAIR AND MAINTENANCE, THE USE OF SUCH
PRODUCTS CONTAINING FLAMMABLE GAS IS PROHIBITED.
About This Manual

This manual describes basic functions, theory of electrical and mechanical operations, maintenance and repair procedures of the printer. 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.
Manual Configuration
This manual consists of six chapters and 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
Describes the step-by-step procedures for the troubleshooting.
CHAPTER 4.DISASSEMBLY / ASSEMBLY
Describes the step-by-step procedures for disassembling and assembling
the product.
CHAPTER 5.ADJUSTMENT
Provides Epson-approved methods for adjustment.
CHAPTER 6.MAINTENANCE
Provides preventive maintenance procedures and the lists of Epsonapproved lubricants and adhesives required for servicing the product.
APPENDIX Provides the following additional information for reference:
Exploded Diagram
Parts List
Circuit Diagrams
Symbols Used in this Manual

Various symbols are used throughout this manual either to provide additional
information on a specific topic or to warn of possible danger present during a
procedure or an action. Be aware of all symbols when they are used, and always read
NOTE, CAUTION, or WARNING messages.
A D J U S T M E N T
R E Q U IR E D
C A U T IO N
C H E C K
P O IN T
W A R N IN G
Indicates an operating or maintenance procedure, practice or condition

that is necessary to keep the products quality.
Indicates an operating or maintenance procedure, practice, or condition

that, if not strictly observed, could result 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.
Indicates an operating or maintenance procedure, practice or condition
that, if not strictly observed, could result in injury or loss of life.
Indicates that a particular task must be carried out according to a certain

standard after disassembly and before re-assembly, otherwise the quality of the components in question may be adversely affected.
Revision Status
Revision
Date of Issue
Aug 1, 2005
First Release
Jan 18, 2006
CHAPTER 4 DISASSEMBLY/ASSEMBLY
4.3.3.9 CR Cable Head Cover on page 64.
Mar 14, 2006
Description
CHAPTER 5 ADJUSTMENT
5.2.12 PF Torque Check Pattern Print is removed.
Cautions during assembly are added.
Revision C
Contents
Chapter 1 PRODUCT DESCRIPTION
Chapter 3 TROUBLESHOOTING
1.1 Features.................................................................................................................. 9
1.2 Specifications ...................................................................................................... 10
1.2.1 Physical Specification................................................................................. 10
1.2.2 Printing Specification ................................................................................. 10
1.2.3 Paper Feeding ............................................................................................. 11
1.2.4 Input Data Buffer ........................................................................................ 11
1.2.5 Electric Specification.................................................................................. 11
1.2.6 Environmental Condition............................................................................ 12
1.2.7 Reliability ................................................................................................... 12
1.2.8 Safety Approvals ........................................................................................ 12
1.2.9 Acoustic Noise............................................................................................ 13
1.2.10 CE Marking .............................................................................................. 13
1.2.11 Black Ink Save Mode................................................................................ 13
1.3 Operator Controls ................................................................................................ 14
1.3.1 Operate Switch............................................................................................ 14
1.3.2 Panel Functions........................................................................................... 14
1.3.3 Printer Condition and LED Status .............................................................. 15
1.3.4 Errors .......................................................................................................... 15
1.4 Paper .................................................................................................................... 16
1.4.1 Paper Support.............................................................................................. 16
1.5 Ink Cartridge........................................................................................................ 21
1.5.1 Ink Cartridge Specification......................................................................... 21
3.1 Overview .............................................................................................................

3.1.1 Specified Tools ...........................................................................................
3.1.2 Preliminary Checks.....................................................................................
3.2 Troubleshooting With LED Error Indications....................................................
3.2.1 Fatal Error...................................................................................................
3.3 Troubleshooting for Motors and Sensors ............................................................
Chapter 2 OPERATING PRINCIPLES
5.1 Adjustment Items and Overview.........................................................................

5.1.1 Servicing Adjustment Item List..................................................................
5.1.2 Repaired Adjustment ..................................................................................
5.1.3 Replacement Part-Based Adjustment Priorities .........................................
5.2 Adjustment by Using Adjustment Program ........................................................
5.2.1 Market ID Setting .......................................................................................
5.2.2 USB ID Input..............................................................................................
5.2.3 Head ID Input .............................................................................................
5.2.4 Head Angular Adjustment ..........................................................................
5.2.5 Bi-D Adjustment.........................................................................................
5.2.6 PF Adjustment ............................................................................................
2.1 Overview .............................................................................................................

2.2 Printer Mechanism...............................................................................................
2.2.1 Printhead Specifications .............................................................................
2.2.2 Carriage Mechanism ...................................................................................
2.2.3 Paper Feeding Mechanism..........................................................................
2.2.4 Ink System Mechanism...............................................................................
2.3 Electrical Circuit Operating Principles................................................................
2.3.1 C616 PSB/PSE Board.................................................................................
2.3.2 C616 Main Board .......................................................................................
23
23
24
24
25
26
26
27
27
29
29
29
30
32
34
Chapter 4 DISASSEMBLY/ASSEMBLY
4.1 Overview ............................................................................................................. 36
4.1.1 Precautions.................................................................................................. 36
4.1.2 Tools ........................................................................................................... 37
4.1.3 Screws (T.B.D) ........................................................................................... 37
4.1.4 Work Completion Check ............................................................................ 38
4.2 Caution regarding Assembling/Disassembling of the Printer Mechanism, and How
to Ensure of Quality on Re-assembled Product......................................................... 39
4.3 Disassembly Procedures...................................................................................... 41
4.3.1 Removing Housings ................................................................................... 43
4.3.2 Removing Boards ....................................................................................... 52
4.3.3 Disassembling Printer Mechanism ............................................................. 56
Chapter 5 ADJUSTMENT
78
78
80
81
83
83
83
83
84
84
85

5.2.7 First Dot Adjustment ..................................................................................
5.2.8 Top Margin Adjustment .............................................................................
5.2.9 Offset input for CR Motor Calorific Limitation .........................................
5.2.10 A4 Normal Paper print..............................................................................
5.2.11 A4 Photo Quality Inkjet Paper Print........................................................
5.3 Adjustment Except Adjustment Program ............................................................
5.3.1 CR Timing Belt Tension Adjustment .........................................................
Revision C
85
86
86
87
87
88
88
Chapter 6 MAINTENANCE
6.1 Overview ............................................................................................................. 90
6.1.1 Cleaning ...................................................................................................... 90
6.1.2 Service Maintenance................................................................................... 90
6.1.3 Lubrication.................................................................................................. 92
Chapter 7 APPENDIX
7.1 Exploded Diagram............................................................................................... 96
7.2 Parts List............................................................................................................ 102
7.3 Circuit Diagrams ............................................................................................... 103
YCHAPTER
PRODUCT DESCRIPTION
Revision C
1.1 Features
The major features of EPSON Stylus C67/C68/D68 are:
High color print quality
2880 (H) x 1440 (V) dpi printing (Max. resolution)
4 color printing (YMCK)
Built-in auto sheet feeder
Holds 120 cut-sheets (90 g/m2)
Holds 10 envelopes
Built-in 1 I/F
USB 1.1
Windows/Macintosh exclusive
Borderfree
Separate ink cartridge for each color
Figure 1-1. Product Appearance
PRODUCT DESCRIPTION
Features
Revision C
1.2 Specifications
Table 1-2. Raster Graphics Mode
This section covers specifications of the printer.
1.2.1 Physical Specification

Weight:
Horizontal
resolution
Printable area
360 dpi
209.8 mm
(8.26 inch)
3.9 kg (without the ink cartridges)
Available
dot
2976
Dimension
Storage:
447 mm (W) x 240 mm (D) x 189 mm (H)
Printing:
447 mm (W) x 436 mm (D) x 309 mm (H)
720 dpi
1.2.2 Printing Specification

Print method
On demand ink jet
Nozzle configuration
monochrome:
90 nozzles
color:
29 nozzles x 3 (Cyan, Magenta, Yellow)
Bi-direction with logic seeking
Eco
723.9 mm/s (285 CPS)
VSD1
419.1 mm/s (165 CPS)
VSD2
(Color)
609.6 mm/s (240 CPS)
VSD2
609.6 mm/s (240 CPS)
VSD2'
(Black)
609.6 mm/s (240 CPS)
VSD3
(Color)
609.6 mm/s (240 CPS)
209.8 mm
(8.26 inch)
VSD3
609.6 mm/s (240 CPS)
1440 dpi
11904
VSD3
(Black)
609.6 mm/s (240 CPS)
2880 dpi
209.8 mm
(8.26 inch)
23808
VSD3
609.6 mm/s (240 CPS)
ESC/P2 expanded raster graphics code
EPSON Remote command
Character tables
Print speed & Printable columns
Table 1-1. Character Mode

Character Pitch
Printable Columns
CR Speed
10 CPI (Pitch)
80 digits
419.1 mm/s
(165 CPS)
PRODUCT DESCRIPTION
5952
CR speed
Control Code
Print direction
209.8 mm
(8.26 inch)
Dot size
none (ASCII 20H to 7FH code support)
Internal fonts
Specifications
Bit map LQ font

EPSON Courier 10 CPI
10
Revision C
1.2.3 Paper Feeding
220-240 V version
Feeding method
Friction feed with ASF
Paper path
Cut-sheet ASF (Top entry front out)
Feed speed
T.B.D msec (T.B.D mm/sec) (10.16 mm (0.4 inch) feed)
T.B.D msec (T.B.D mm/sec) (Continuous feed)
1.2.4 Input Data Buffer

Input buffer size:
Rated voltage:
AC220-240 V
Input voltage range:
AC198-264 V
Rated frequency range:
50 - 60 Hz
Input frequency range:
49.5 - 60.5 Hz
Rated current:
0.2 A (max. 0.4 A)
Power consumption:
ISO10561 Letter Pattern: 11 W

Sleep Mode: 2.5 W
Power Off Mode: 0.4 W
Dielectric strength:
AC 3000 Vrms for 1 minute

(between AC line and chassis)
32 KB
1.2.5 Electric Specification

100-120 V version
Rated voltage:
AC100 - 120 V
Input voltage range:
AC90 - 132 V
Rated frequency range:
50 - 60 Hz
Input frequency range:
49.5 - 60.5 Hz
Rated current:
0.4 A (max. 0.7 A)
Power consumption:
ISO10561 Letter Pattern: 11W

Sleep Mode: 2.0 W
Power Off Mode: 0.3 W
Dielectric strength:
AC 3000 Vrms for one minute

(between AC line and chassis)
PRODUCT DESCRIPTION
Specifications
11
Revision C
1.2.6 Environmental Condition
1.2.7 Reliability
Table 1-3. Environmental Condition

Temperature*1
Note *1:
*2:
Operating
Non-operating
10~35 C*2
-20~40 C
Humidity
20~80 %
5~85 %
Resistance to shock
1 G, within 1 ms
2 G, within 2 ms
Resistance to vibration
0.15 G
0.50 G
Total print volume:
20,000 pages (A4, Letter) or five years,

whichever comes first.
Print Head Life:
Eight billion shots (per nozzle) or five years,

whichever comes first.
1.2.8 Safety Approvals

100-120 V version
One month at 40C and 120 hours at 60C

Under the following conditions
Safety standards:
UL60950
CSA C22.2 No.60950
EMI:
FCC part15 subpart B class B

CSA C108.8 class B
90
80
70
60
Humidity(%)
220-240V version
50
40
30
Safety standards:
EN 60950
EMI:
EN 55022(CISPR Pub.22) class B

AS/NZS CISPR 22 class B
20
10
20
27 30
35
40
Temperature(C)
Figure 1-2. Temperature/Humidity Range
C A U T IO N
Printhead must be capped during storage.

When transporting the printer, make sure that the printhead is
capped and the ink cartridges are installed in the printer.
If the printhead is not capped when the printer is turned off,
turn the printer on with the ink cartridges installed, cap the
printhead, and turn the power off.
Ink inside the ink cartridges freezes if it is left to stand at
temperature of -4C or less. If this is the case, allow the ink to
stand for about three hours at 25C temperature.
PRODUCT DESCRIPTION
Specifications
12
Revision C
1.2.9 Acoustic Noise

Level:
Approx. 45 dB (A) (According to ISO 7779)
1.2.10 CE Marking
Starts printing in black ink
save mode.
220-240V version
Low Voltage Directive 73/23/EEC:
EN60950
Starts printing in a normal

manner.
EMC Directive 89/336/EEC:
EN55022 Class B
EN61000-3-2
EN61000-3-3
EN55024
Starts printing in a normal

manner. This window will
not be displayed until the
black ink cartridges is
replaced.
Figure 1-3. Black Ink Save Mode Window
1.2.11 Black Ink Save Mode

Black ink save mode allows you to print images with color ink only when the
remaining amount of black ink is low. This mode can be selected when the remaining
amount of color ink is sufficient since black areas of the images are printed with a
mixture of other colors.
Supported OS: Windows NT4.0, 95, 98, ME, 2000, XP
Printing mode: Plain Paper & Text Mode (360 dpi)
Operating procedure
1.
User carries out printing from an application.
2.
The printer driver checks both the printing mode and the amount of remaining ink,
and displays the specific window if the conditions described below are all
satisfied.
Selected printing mode supports black ink save mode.
Remaining amount of black ink is less than 5 %, or the status of the black ink
is ink low.
Remaining amount of all the color ink is more than 10 %, or the status of all
the color ink is NOT ink low.
PRODUCT DESCRIPTION
Specifications
13
Revision C
1.3 Operator Controls
1.3.2 Panel Functions

Table 1-4. Panel Functions
1.3.1 Operate Switch
Switch
Operate switch is located on the control panel.
Function
Loads or ejects paper.

In the condition of printing, cancel the print job.
Paper
1.3.1.1 Switches
Starts the ink cartridge change sequence. Moves the

carriage to cartridge change position.
In the condition of Ink Low, Ink Out or No Ink
Cartridge, moves the carriage to the ink check
position.
When the carriage is on the ink check position, moves
carriage to next ink check position or cartridge change
position.
When carriage is on the ink change position, returns
carriage from ink cartridge change position.
There are three non-lock type push switches and three LEDs.
Ink switch
Paper switch
Power switch
Ink
Ink
(Holding down for three seconds)
Starts the cleaning of head.

In the condition of 'Ink Low', 'Ink Out' or 'No Ink
Cartridge', starts the ink cartridge change sequence.
Table 1-5. Panel functions with power on

Switch
Paper
Paper LED
Ink LED
Power LED
Note *:
Pressing with Power On function*

Starts status printings.
Holding down the [Paper] switch, press [Power].
Figure 1-4. Control Panel
Table 1-6. Panel functions with power off

Switch
1.3.1.2 Indicators
Ink
Power LED [Green]

Lights when the power switch is ON and AC power is supplied.
Note *:
Pressing with Power Off function*

Compulsory power off.
Holding down the [Power] switch, press [Ink] for about seven seconds.
Paper LED [Red]

Lights during the paper-out condition, and flashes during the paper-jam condition.
Ink LED [Red]
Lights during no ink condition, and flashes during the ink low condition.
PRODUCT DESCRIPTION
Operator Controls
14
Revision C
1.3.3 Printer Condition and LED Status
Table 1-7. Error Status

Error
Indicators
Printer status
Power LED
On
-Flashes
--Flashes
Flashes
---
Power on
Ink level low
Data processing
No ink cartridge or ink end
CSIC Error
Ink sequence
Ink cartridge change mode
Paper out
Paper jam condition
Maintenance request
Off
Fatal error
Off
Power off
Flashes on
high speed
On
Reset request*
Note *:
Paper LED
-------On
Flashes
Flashes
alternately
Flashes on
high speed
Off
Ink LED
-Flashes
-On
On
----Flashes
alternately
Flashes on
high speed
Off
On
On
Priority
11
10
9
8
8
7
6
5
4
Maintenance request
Fatal errors
Description
When the total quantity of ink wasted through the cleanings and
flushing is reaches to the limit, printer indicates this error and
stops. The absorber in the printer enclosure is needed to be
replaced with new one by a service person.
Carriage control error.
3
2
1
--
When the reset request (e.g. IEEE 1284.4 rs command, Parallel Init signal)
occurred, the LED indicates for 0.2 sec.
1.3.4 Errors
Table 1-7. Error Status
Error
Ink out
Paper out
Paper jam
No ink-cartridge / CSIC
Error
Description
When the printer runs out the most part of the ink of any one color,
it warns ink-low and keeps printing.When the printer runs out the
whole ink of any one color, it stops printing and indicates ink-out
error. User is requested to install a new ink-cartridge in this state.
When printer fails to load a sheet, it goes paper out error.
When printer fails to eject a sheet, it goes paper jam error.
When printer detects that ink-cartridge comes off, or failed to read
or write CSIC data, it goes this error mode.
PRODUCT DESCRIPTION
Operator Controls
15
Revision C
1.4 Paper
Envelopes
Table 1-9. Envelopes*
1.4.1 Paper Support

Paper type
Cut sheets
#10*1
Table 1-8. Cut sheets

Paper
size
Dimensions
Thickness Weight
Length
(mm)
(g/m2)
(mm)
Width
(mm)
Paper Support
Quality
Stylus Stylus Stylus

C68
D68
C67
Legal
215.9
(8.5)
355.6
(14)
OK
OK
OK
Letter
215.9
(8.5)
279.4
(11)
OK
OK
OK
A4
210
297
OK
OK
OK
B5
182
257
NG
OK
OK
A5
148
210
NG
OK
OK
Half
Letter
139.7
(5.5")
215.9
(8.5")
OK
NG
NG
A6
105
148
OK
OK
OK
User
defined
50.8-329
1271117.6
OK
OK
OK
C A U T IO N
0.08-0.11
64-90
common
paper
recycled
paper
Width
Length
104.8
241.3
DL*1
110
220
C6*1
114
162
Weight
Quality
75-90g/m2
bond paper
PPC paper
air mail
Note *:
Borderless printing is not supported for envelops.
Note *1:
There is flap in the long side part, and it is fold down.

Loading paper under the oblong condition is done.
The flap side is moved to 80-digit side.
Only for Stylus C67/D68.
*2:
C A U T IO N
It is necessary that there is no winkle, nap, tear, fold and so on

in the form.
The curve of form must be five mm or below.
PRODUCT DESCRIPTION
Dimensions (mm)
Paper
Use paper under normal conditions.

Temperature 15 to 25C (59 to 77F)
Humidity 40 to 60% RH
in the form.
The curve and swell of the form must be three mm or below.
Don't use the adhesive envelope.
Don't use sleeve insert envelope and cellophane window
envelope.
As for double-flap envelope, if the envelope is damaged or bent
during printing, load the envelope with its flap facing in the
opposite direction. (Feeding direction should be changed as well
from the printer driver.)
If the printed images are skewed or misaligned from the proper
position, fold four sides of the envelope tightly.
If multi-feed occurs, press the [Paper] switch to feed the
envelope before starting printing again.
16
Revision C
Exclusive papers
Quality: EPSON Exclusive paper
Table 1-10. Exclusive papers

Dimensions
Item
Table 1-10. Exclusive papers

Dimensions
Item
Premium Ink Jet
Plain Paper
Bright White Ink Jet
Paper
Photo Paper
Size
Width Length
(mm) (mm)
Paper Support
Thickness Weight
Stylus
Stylus Stylus
2
(mm)
(g/m )
C68
D68
C67
A4
210
297
0.11
80
NG
OK
OK
A4
210
297
0.13
92.5
NG
OK
OK
210
101.6
215.9
210
203.2
127
101.6
89
215.9
210
101.6
215.9
210
215.9
210
297
152.4
279.4
297
254
178
152.4
127
279.4
297
152.4
279.4
297
279.4
297
NG
NG
OK
OK
OK
OK
OK
NG
OK
NG
NG
OK
NG
OK
NG
OK
OK
NG
OK
NG
OK
OK
NG
NG
OK
OK
NG
OK
NG
OK
NG
NG
NG
OK
NG
NG
OK
OK
NG
OK
OK
NG
OK
NG
OK
210
297
NG
NG
OK
215.9
210
215.9
101.6
279.4
297
279.4
152.4
OK
OK
OK
OK
NG
OK
NG
NG
NG
OK
NG
NG
101.6
152.4
OK
NG
NG
A4
10x15
Premium Glossy
Letter
Photo Paper
A4
8" x 10"
5" x 7"
10 x 15
3R
Premium Semigloss Letter
Photo Paper
A4
10 x 15
Matte PaperLetter
Heavyweight
A4
Double-Sided Matte Letter
Paper
A4
Economy Photo
A4
Paper
Photo Quality Ink Jet Letter
Paper*
A4
Glossy Photo Paper Letter
10 x 15
Premium Glossy
10 x 15
Photo Paper (RC-X)
PRODUCT DESCRIPTION
0.23
0.27
194
255
0.27
250
0.23
167
0.25
178
0.23
188
0.12
102
0.23
188
0.25
238
Size
Ultra Glossy Photo

Paper/
Ultra Premium
Glossy Photo Paper
Note *:
C A U T IO N
Paper Support
Thickness Weight
Stylus
Stylus Stylus
(mm)
(g/m2)
C68
D68
C67
OK
NG
NG
NG
OK
NG
0.29
209
OK
NG
NG
OK
OK
NG
OK
OK
NG
Borderless printing is not supported for Photo Quality Ink Jet Paper.
Paper
Width Length
(mm) (mm)
Letter 215.9 279.4
A4
210
297
8" x 10" 203.2
254
5" x 7" 127
178
10 x 15 101.6 152.4
Use paper under normal conditions.

Temperature 15 to 25C (59 to 77F)
Humidity 40 to 60% RH
in the form.
The curve of form must be five mm or below.
17
Revision C
1.4.1.1 Printable Area
PW
Cut sheet (standard printing)
LM
Printable area
For paper width (PW) and paper length (PL), refer to 1.4.1 Paper Support
(p16).
RM
TM
Table 1-11. Applicable Paper/Printing Area

Paper type
LM
RM
TM
BM
A4
A6
Paper Feed Direction
Cut Sheet
A5
B5
Half Letter
Letter
Legal
User defined
Premium Ink Jet Plain Paper
Bright White Ink Jet Paper
Photo Paper
3mm
3mm
3mm
12.5mm/
3mm*1
PL
Printable area
Exclusive papers
Premium Glossy Photo Paper

Premium Semigloss Photo Paper
Matte Paper-Heavyweight
Double-Sided Matte Paper
BM
Economy Photo Paper

Glossy Photo Paper
(RC-X)
Figure 1-5. Printable Area Cut Sheet (Standard Printing)
Ultra Glossy Photo Paper/

Ultra Premium Glossy Photo Paper
Note *1:
Bottom margin is expanded to 3 mm when paper dimension is defined by using

command (ESC (S and Remote SN), otherwise it is not expanded (12.5 mm).
From a form lower end 3 mm as for 12.5 mm area a printing may scramble.
PRODUCT DESCRIPTION
Paper
18
Revision C
Envelopes
PW
Printable area
(p16).
LM
RM
TM

Paper type
LM
RM
TM
BM
3mm
3mm
3mm
20mm
Printable area
#10
DL
C6
PL
BM
Figure 1-6. Printable Area for Envelopes
PRODUCT DESCRIPTION
Paper
19
Revision C
Cut sheet (border-free printing)
LO
PW
Printable area
(p16).
RO
TO
Size
LO
RO
TO
BO
Premium Ink Jet Plain Paper
Paper type
A4
2.54
2.54
2.96
4.02
Bright White Ink Jet Paper
A4
2.54
2.54
2.96
4.02
A4
2.54
2.54
2.96
4.02
10x15
2.54
2.54
2.82
3.60
Letter
2.54
2.54
2.96
4.02
A4
2.54
2.54
2.96
4.02
8" x 10"
2.54
2.54
2.96
4.02
5" x 7"
2.54
2.54
2.96
4.02
10 x 15
2.54
2.54
2.82
3.60
Photo Paper
Exclusive papers
Premium Semigloss Photo

Paper
Matte Paper-Heavyweight
Double-Sided Matte Paper
Economy Photo Paper
Ultra Glossy Photo Paper/

Ultra Premium Glossy Photo
Paper
2.54
2.54
2.82
3.60
2.54
2.54
2.96
4.02
A4
2.54
2.54
2.96
4.02
10 x 15
2.54
2.54
2.82
3.60
Letter
2.54
2.54
2.96
4.02
A4
2.54
2.54
2.96
4.02
Letter
2.54
2.54
2.96
4.02
A4
2.54
2.54
2.96
4.02
A4
2.54
2.54
2.96
4.02
Printable area
Figure 1-7. Printable Area for Cut Sheet (Border-free Printing)
2.54
2.54
2.96
4.02
2.54
2.54
2.82
3.60
10 x 15
2.54
2.54
2.82
3.60
Letter
2.54
2.54
2.96
4.02
A4
2.54
2.54
2.96
4.02
8" x 10"
2.54
2.54
2.96
4.02
5" x 7"
2.54
2.54
2.96
4.02
10 x 15
2.54
2.54
2.82
3.60
PRODUCT DESCRIPTION
PL
3R
Letter

(RC-X)
Paper size
Letter
10 x 15
Glossy Photo Paper
BO
Paper
20
Revision C
1.5 Ink Cartridge
Dimension:
12.7 mm(W) x 73.46 mm(D) x 55.25 mm(H)
1.5.1 Ink Cartridge Specification

Type:
12.7 mm
Exclusive cartridge
Table 1-14. Ink Cartridge
Color
Black
Cyan
Magenta
Yellow
Size
Stylus C67
Stylus C68
Stylus D68
SS Size
T0631
T0611
S Size
T0621
T0601
SS Size
T0632
T0612
S Size
T0602
SS Size
T0633
T0613
S Size
T0603
SS Size
T0634
T0614
S Size
T0604
Base View
Print Capacity:
Black ink cartridge

Print capacity
S size:
SS size:
73.46 mm
390 pages /A4 (360 dpi, 5% duty each color)

Figure 1-8. Ink Cartridge
Color ink cartridge

Print capacity
S size:
SS size:
Ink life:
C A U T IO N

Two years from production date
Storage temperature
Ink cartridge can not re-fill, only ink cartridge is prepared for
article of consumption.
Do not use the ink cartridge which has expired.
Ink will be frozen under -16 C environment, however it will be
usable after placing it more than three hours at room
temperature.
Table 1-15. Storage Temperature

Situation
Storage
temperature
Limit
When transported in individual boxes
-30C ~ 50C
10 days max. at 50C
When stored in individual boxes
-30C ~ 40C
1 month max. at 40C
When installed in main unit
-20C ~ 40C
PRODUCT DESCRIPTION
Ink Cartridge
21
YCHAPTER
OPERATING PRINCIPLES
Revision C
2.1 Overview
This section describes the operating principles of the printer mechanism and electrical
circuit boards.
2.2 Printer Mechanism
PF timing belt
PF motor
PF roller
Star wheel
rollers
Printer mechanism of Stylus C67/C68/D68 consists of printhead, carriage mechanism,

paper loading mechanism, paper feeding mechanism, and ink system.
As in the case of conventional models, Stylus C67/C68/D68 has two DC motors; one is
for paper loading/feeding mechanism, and the other is for carriage mechanism.
Papers are fed from the backside and ejected from the front side of the printer.
Paper feeding mechanism, which is also similar to conventional models, feeds papers
using the LD roller and the retard roller.
CR timing belt
CR encoder
sensor
Carriage unit
Retard roller
Compression
spring
LD roller
PE sensor
Paper eject
roller
Cam, large
Cam, small
CR lock lever
Clutch
Pump unit
Cap unit
CR motor
Figure 2-1. Printer Mechanism Outline
Overview
23
Revision C
2.2.1 Printhead Specifications
2.2.2 Carriage Mechanism
The Printhead of this product is a D2-CHIPS head.
Main components of the carriage mechanism are carriage unit (including printhead,
CR encoder sensor), CR motor, timing belt, and CR scale.
Nozzle configuration
2.2.2.1 CR Motor Specifications
Monochrome 90 nozzles
Color 29 nozzles x 3 (Cyan, Magenta, Yellow)
Table 2-1. CR Motor Specifications

Item
The following shows the arrangement of the nozzles and the color arrangement of each
nozzle line when viewed the printhead from behind.
Type
Drive voltage
2.822mm
(40/360 inch)
Electric resistance
Inductance
Motor with DC brush

+42 V
5% (applied voltage to the driver)

28.4 10%
20.1 mH 25%
Drive method
PWM, constant-current chopping
Drive IC
A6628
K#90
K#89
Specification
C#29
Cyan: 29nozzles
C#1
Black
Color
M#29
Paper Loading Direction
Magenta: 29nozzles
M#1
Y#29
K#3
0.2117mm
(1/120 inch)
K#2
K#1
Y#3
Yellow: 29nozzles
Y#2
Y#1
Carriage Moving Direction
Figure 2-2. Nozzle Rear View
Printer Mechanism
24
Revision C
2.2.3 Paper Feeding Mechanism
2.2.3.2 Drive Process
Paper loading/feeding mechanism consist of CR lock lever inside the ink system,
holder shaft unit (including clutch mechanism), and ASF unit.
1.
Drive of the PF motor is transmitted to the paper eject roller and the PF roller via
the PF timing belt, however, it is not transmitted to the LD roller and the retard
roller owing to the clutch of the holder shaft unit.
2.
The carriage unit moves to the ASF trigger position once the paper loading
command is received.
3.
PF motor is rotated counter clockwise, and the clutch is released by the PF motor
lever.
4.
After the clutch is released, the PF motor rotates clockwise. Drive is transmitted to
the LD roller and the paper loading operation begins.
5.
During paper loading operation, papers are fed from the ASF unit to inside the
printer by the rotating movement of the two cams of the LD roller.
CR lock lever and clutch mechanism play an important role in paper loading
mechanism. Refer to 2.2.3.2 Drive Process (p25) for details.
2.2.3.1 PF Motor Specifications (For both ASF and Pump motor)

Table 2-2. PF Motor Specification
Item
Specification
Type
4-phase, 200-pole HB stepping motor
Drive voltage
+42 V
Wire wound
resistance
5 % (applied voltage to the driver)
3.0
10% (per one phase at 25 C)
Inductance
3.5 mH 20% (1KH, 1Vrms)
Drive method
Bipolar drive
2-2 phase, 1-2 phase, W1-2, 2W1-2, 4W1-2 phase constant-current drive
Drive IC
A6628
Cam, large: releases hopper
Cam, small:releases paper back lever
6.
Once a sheet of paper is fed, the hopper and the paper back lever bring back rest of
the papers to the position in readiness by the rotating movement of the two cams
mentioned above.
7.
When the LD roller is turned a full circle, the CR lock lever release the clutch and
the drive to the LD roller is interfered.
Printer Mechanism
25
Revision C
2.2.4 Ink System Mechanism
2.3 Electrical Circuit Operating Principles
The Ink system mechanism consists of pump mechanism and capping mechanism with
wiper mechanism.
The electric circuit of the Stylus C67/C68/D68 consists of the following boards.
2.2.4.1 Pump Unit Mechanism

With this printer, when the PF motor turns, power is always transmitted to the ink
system.
Table 2-3. PF Motor Rotational Direction & Ink System Mechanism
Directions*
Counterclockwise
Clockwise
Note *:
Main board:
C616 MAIN Board
Power supply board:
C616 PSB/PSB board
Panel board:
C616 PNL board
This section provides block diagram of both C616 MAIN Board and C616 PSB/PSE
Board, C616 PNL board.
Functions
Absorbs the ink by the Pump Unit
C616 PNL Board
Release pump.
Printer Mechanism
The PF Motor rotational direction = seen from the left side of the printer.
CR Motor
2.2.4.2 Capping Mechanism
PF Motor
The Capping mechanism covers the printhead with the cap to prevent the nozzle from
increasing viscosity when the printer is in stand-by state or when the printer is off.
C616 Main Board
Head Driver Board

Sensors
CSIC Unit
+42V
PowerOFF
C616PSB/C616PSE Board
Figure 2-3. Electrical Circuit Block Diagram
Electrical Circuit Operating Principles
26
Revision C
2.3.1 C616 PSB/PSE Board
Table 2-4. C616 MAIN Board Major Components and Primary Functions
In the PSB/PSE Board of Stylus C67/C68/D68, the simulated oscillating stimulation

flyback converter circuit method is used, and it supplies +42 VDC to the drive line.
The application of the output voltage is described below.
IC
Location
FLASHROM
IC3
3.3 V drive 4 M bit flash ROM that stores the program.
Function
Reset Regulator
IC1
3.3V/1.5V generate regulator, 2 ch reset circuit
C616PSB Board: 100-120V
EEPROM
IC4
Makes back up of default setting values and parameters
C616PSE Board: 220-240V
Motor Driver
IC6
Drives CR/PF motors, controls PWM by the program timer,

adjusts 5 V, drives 42 V
Head Driver
IC7
Generates trapezoidal waveform, drives 5 V
ASIC
IC10
Drives CPU (H8S/2674 base), internal 8 K byte x 4 RAM, 24

Mhz, 3.3 V/1.5V
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 led 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.
2.3.2 C616 Main Board

The logic circuit of the C616 Main Board is composed of the following;
Logic line (CPU-ASIC 2 in 1, Flash-ROM and so on)
Motor control/drive circuit (CR Motor, PF Motor)
Head control/drive circuit
Sensor circuit
Reset circuit, EEPROM circuit

Figure 2-4. C616 Main Board Block Diagram
Electrical Circuit Operating Principles
27
CHAPTER
TROUBLESHOOTING
Revision C
3.1 Overview
3.1.2 Preliminary Checks
This chapter describes how to solve problems.
Before starting troubleshooting, be sure to verify that the following conditions

are all met:
W A R N IN G
C H E C K
P O IN T
Be careful to avoid electric shocks when checking the electrical

circuit boards (C616 MAIN, PSE and B circuit boards) while
the power is turned on.
Touching an FET, transistor or heat sink with one hand while
touching a metal part of the mechanism with the other hand
could result in an electric shock, so carefully avoid this.
After initial filling of ink has been repeated several times,
immediate moving or tilting of the printer could result in
leaking of ink that has not been completely absorbed by the
Waste Ink Pad. When initial filling of ink has been repeated
several times, check the ink remaining in the tip of the Waste
Ink Tube and the waste ink not absorbed by the Waste Ink Pad
before moving the printer.
Disassembly and reassembly of parts is often required when
identifying the causes of problems. The parts should be
disassembled and re-assembled correctly while referring to
DISASSEMBLY/ASSEMBLY (p35) so that the operation and
status of each check item can be correctly verified.
Some individual part and units may require adjustment once
they are removed or replaced. If removing or replacing parts
which have specific instructions for adjustment included in
DISASSEMBLY/ASSEMBLY (p35), be sure to make these
adjustments after repairing the problem location.
The power supply voltage must be within the specification limits. (Measure the
voltage at the wall socket.)
The power code must be free from damage, short circuit or breakage, or miswiring
in the power code.
The printer must be grounded properly.
The printer should not be located in a place where it can be exposed to too high or
low temperature, too high or low humidity, or abrupt temperature change.
The printer should not be located near waterworks, near humidifiers, near heaters
or near flames, in a dusty atmosphere or in a place where the printer can be
exposed to blast from an air conditioner.
The printer should not be located in a place where volatile or inflammable gases
are produced.
The printer should not be located in a place where it can be exposed to direct rays
of the sun.
The printer must be located in a well-ventilated place.
The printer must be placed on a strong and steady level table (without an
inclination larger than five degrees).
The paper used must conform to the specification.
There is no error in handling of the printer.
3.1.1 Specified Tools
Check the inside of the printer, and remove foreign matters if any, such as paper
clips, staples, bits of paper, paper dust or toner.
This printer does not require any specified tools for troubleshooting.
Clean the inside of the printer and the rubber rolls.
TROUBLESHOOTING
Overview
29
Revision C
3.2 Troubleshooting With LED Error Indications

LED error display, cause, and remedy are explained here.
Table 3-1. Troubleshooting With LED Error Indications
Error
LED status
Power
Paper
Cause
Remedy
On
Ink inside Bk, Y, M, C ink cartridges has run out.

Ink cartridge(s) is not installed.
Non-genuine ink cartridge(s) is installed.
Check the ink cartridge(s) and reinstall it

correctly.
Replace the ink cartridge(s) with a genuine one.
---
Paper loading operation is executed when there

is no paper.
Papers stopped before the PE Snesor or could not
be fed.
Papers are fed without being placed against the
right edge guide.
Connector of the PE sensor is disconnected.
1. If there is no paper on the paper tray, load papers.

2. If the paper has stopped halfway, remove the
paper, check if the paper is not bent, fan the
paper, and load it against the edge guide.
3. Press the [Paper] switch to release the error.
---
When performing duplex printing, blank paper is

ejected.
The printer detected that the paper is too long
upon ejection.
1. Remove the blank paper, or check the paper size.

2. Press the [Paper] switch to eject the paper and
release the error.
Ink
Ink end/ No ink cartridge/ CSIC error

---
---
yPaper Out
---
On
Multi-feed error
---
TROUBLESHOOTING
On
Troubleshooting With LED Error Indications
30
Revision C
Table 3-1. Troubleshooting With LED Error Indications
Error
LED status
Power
Paper
Ink
Paper jam
Maintenance request
(Waste ink overflow)
---
Flashes
---
Off
Flashes
alternately
Flashes
alternately
Fatal error
Remedy
Even though paper feeding operation is carried out

for predetermined times, leading edge or back-end
of the paper could not be detected.
1. Press the [Paper] switch on the panel.

2. If paper jam occurred again after pressing the
switch, open the printer cover and remove all the
papers inside the printer and papers set on the
hopper.
3. Making sure there is no paper inside the printer,
load paper on the hopper and press [Paper].
As a result of cleaning and flushing, total emission

of ink has exceeded the specific level.
Replace the waste ink pad, and reset the waste ink
counter (protection counter A) using the adjustment
program. Refer to Chapter5 ADJUSTMENT
(p.77) for details.
Home position of the carriage could not be

detected.
Abnormal external pressure is applied to the
printer when the power is on.
Carriage movement is interfered during printing.
Off
TROUBLESHOOTING
Cause
Flashes on
high speed
Flashes on
high speed
1. Turn the power off, wait for a few seconds, and

turn the power back on again.
2. If the fatal error still appears, turn the power off,
remove the papers on the hopper, and check the
following:
Open the printer cover, check the ink cartridges,
and reinstall them correctly.
Check is there is no foreign material or papers
inside the printer. If there is any, remove them.
3. Turn the printer power on.
4. If the fatal error appears again, refer to
3.2.1 Fatal Error (p32) and examine/replace the
parts.
31
Revision C
3.2.1 Fatal Error

C H E C K
P O IN T
As the most recent fatal error (fatal error code) is stored in the
EEPROM (Address: 0AH), it is possible to check the error by using
the adjustment program.
Check the parts according to the contents of the fatal error, and replace the parts as necessary.
Classification
DC Error
Item
Description
PID aveTi max Error
Something is wrong with the CR motor.
Load Positioning Overspeed Error
Abnormal carriage movement speed is detected during load

positioning control.
Load Positioning Lock Error
It is detected that the carriage has been locked for a certain

period of time during load positioning control.
Remedy
Check the parts listed below, and replace them as necessary.

CR Motor
PID Overspeed Error
Carriage movement speed is abnormal.
CR Encoder
PID Lock Error
Carriage has been locked for a certain period of time due to
CR Encoder Scale
external factors.
PID Reverse Rotation Detection Error
The number of the carriage reverse rotation has exceeded the Timing Belt
Main Board
predetermined times due to external factors.
Connectors and harnesses of each motor or encoder
Encoder Abnormality Error (CR Driving One-pass movement cannot be completed though the CR
Time Over Error)
motor has been driving longer than the specified time.
Load Positioning Cumulative Movement The cumulative movement distance during the load
Distance Error
positioning control has exceeded the given level
Head Error
Transistor Environment Temperature

Abnormality Error
Pre-printing X-HOT Detection Error
Post-flushing X-HOT Detection Error
TROUBLESHOOTING
The environment temperature of the transistor that generates

head driving waveform on the Main board is abnormal.
Check the parts listed below, and replace them as necessary.

Printhead
During pre-printing X-Hot detection, the temperature of the
Head FFC
head driver IC has exceeded the given level for more than two Main Board
seconds.
During post-printing X-Hot detection, the temperature of the
head driver IC has exceeded the given level for more than two
seconds.
32
Classification
Sequence Error
Revision C
Item
Left Frame Shock Detection Error
Between Left Frame and [TF] Shock
Detection Error
Description
Abnormal pressure has being added to the carriage due to
external factors.
Between [TF] and [HOME] Shock

Detection Error
Motor Driving
Time Error
PF Driving Time Over Error
TROUBLESHOOTING
Remedy
Make sure that there is no obstruction on the carriage moving
path, check the parts listed below, and replace them as necessary.
CR Motor
CR Encoder
CR Encoder Scale
Timing Belt
Main Board
Paper feed cannot be completed though the PF motor has been Check the parts listed below, and replace them as necessary.
driving longer than the specified time.
PF motor
Main board
Connectors and harnesses of each motor or encoder
33
Revision C
3.3 Troubleshooting for Motors and Sensors

Motor
Table 3-2. Motor Resistance and Check Points
Location
Check point
CR motor
Motor name
Motor with DC brush
Type
CN5
Pin 1&2
28.4 10%
Resistance
PF motor
4-phase, 200-pole HB stepping

motor
CN6
Pin 1&3
Pin 2&4
3.0 10%
Sensor
Table 3-3. Sensor Check
Sensor name
PE sensor
Detecting system
Transmission photo
interrupter
TROUBLESHOOTING
Location
CN9 pin 1&2
Signal level
Sensor status
2.4 V or more
Paper loaded
0.4 V or less
No paper
Troubleshooting for Motors and Sensors
34
CHAPTER
DISASSEMBLY/ASSEMBLY
Revision C
4.1 Overview
C A U T IO N
This section describes procedures for disassembling the main components of the
product. Unless otherwise specified, disassembled units or components can be
reassembled by reversing the disassembly procedure.
Procedures which, if not strictly observed, could result in personal injury are described
under the heading WARNING.
CAUTION signals a precaution which, if ignored, could result in damage to

equipment.
Important tips for procedures are described under the heading CHECK POINT.
If the assembly procedure is different from the reversed disassembly procedure, the
correct procedure is described under the heading REASSEMBLY.
Make sure that there is enough work space for disassembly/

reassembly.
Use only recommended tools for disassembling, assembling or
adjusting the printer.
Observe the specified torque when tightening screws.
Apply lubricants as specified.
(See "6.1.3 Lubrication" (p92) for details.)
The printer disassembled/assembled to make this manual is a
test production, and the colors or configurations may differ
from the finished product. However, these differences have no
effect for disassembling/assembling the product.
When using compressed air products; such as air duster, for
cleaning during repair and maintenance, the use of such
products containing flammable gas is prohibited.
Any adjustments required after reassembly of components or parts are described under
the heading ADJUSTMENT REQUIRED.
When you have to remove any components or parts that are not described in this
chapter, refer to the exploded diagrams in the appendix.
4.1.1 Precautions
See the precautions given under the handling WARNING and CAUTION in the
following columns when disassembling or assembling EPSON Stylus C67/C68/D68.
W A R N IN G
Disconnect the power cable before disassembling or assembling

the printer. If you need to work on the printer with power
applied, strictly follow the instructions in this manual.
Always wear gloves for disassembly and reassembly to avoid
injury from sharp metal edges.
To protect sensitive microprocessors and circuitry, use static
discharge equipment, such as anti-static wrist straps, when
accessing internal components.
Overview
36
Revision C
4.1.2 Tools
Table 4-2. Screws

No.
Use only specified tools to avoid damaging the printer.

Table 4-1. Tools
Name
(+) Phillips screwdriver #1
(+) Phillips screwdriver #1
Flathead screwdriver
Tweezer
Hex wrench (T.B.D)
Name
Type
C.B.P. 3 x 8
C.B.P-TITE SCREW
C.B.P. 3 x 10
C.B.P-TITE SCREW
C.B.P.(P2) 3 x 8
C.B.P-TITE (P2) SCREW
C.P. 3 x 4
C.P. SCREW
C.P.B (P1) 1.7 x 5
T.B.D
Supplier
Parts No.
EPSON
EPSON
EPSON
EPSON
(T.B.D)
1080530
1080532
1080527
1080561
(T.B.D)
4.1.3 Screws (T.B.D)

Screws used on the Stylus C67/C68/D68 are shown below.
Table 4-2. Screws
No.
Image
Image
Name
C.B.S. 3 x 6
9
Type
C.B.S-TITE SCREW
10
1
C.B.S. 3 x 8
Hexagon nut, normal, M3 T.B.D
C.B.P-TITE SCREW
11
2
C.B.S. 3 x 14
C.B.S-TITE SCREW
C.B.S.(P4) 3 x 6
C.B.P-TITE (P4) SCREW
C.B.P. 2.5 x 8
C.B.S-TITE SCREW
Overview
37
Revision C
4.1.4 Work Completion Check
Table 4-3. 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.
Classification
Function
Table 4-3. Work Completion Check

Classification
Item
Self-test
Is the operation normal?
ON-line Test
Is the printing successful
Checked
Not necessary
Printhead
Is ink discharged normally from all

the nozzles?
Checked
Not necessary
Does it move smoothly?
Checked
Not necessary
Is there any abnormal noise during

its operation?
Checked
Not necessary
Is there any dirt or foreign objects on

the CR Guide Shaft?
Checked
Not necessary
Is the CR Motor at the correct

temperature? (Not too hot to touch?)
Checked
Not necessary
Is paper advanced smoothly?

No paper jamming?
No paper skew?
No multiple feeding?
No abnormal noise?
Checked
Not necessary
Is the PF Motor at correct

temperature?
Checked
Not necessary
Is the paper path free of any

obstructions?
Checked
Not necessary
Are all the adjustment done

correctly?
Checked
Not necessary
Are all the lubrication made at the

specified points?
Checked
Not necessary
Is the amount of lubrication correct?
Checked
Not necessary
Main Unit
Paper Feeding
MEchanism
Lubrication
Status
Checked
Not necessary
Carriage
Mechanism
Adjustment
Check Point
Specified
Adjustment
Specified
Lubrication
Packing
Others
Overview
Item
Check Point
Status
ROM Version
Version:
Checked
Not necessary
Ink Cartridge
Are the ink cartridges installed

correctly?
Checked
Not necessary
Protective
materials
Have all relevant protective

materials been attached to the
printer?
Checked
Not necessary
Attachments,
Accessories
Have all the relevant items been

included in the package?
Checked
Not necessary
38
Revision C
4.2 Caution regarding Assembling/Disassembling

of the Printer Mechanism, and How to Ensure of
Quality on Re-assembled Product
On current low end models, weve basically forbidden to remove Housing, Lower from
Printer mechanism in your repair. This is because there is a possibility of main frame
deformation when a part (such as Ink system) is removed from Printer mechanism
without Housing, Lower.
For this reason, if you want to replace Ink system/PF motor, we recommend to replace
with new Printer mechanism with Housing, Lower. On these models, you have to
remove Housing, Lower from printer mechanism when replacing Waste Ink Pad with a
new one.
Therefore, we clarify caution regarding assembling/disassembling of the printer
mechanism without Housing, Lower, and how to ensure of quality on repaired products
in this section.
[Caution regarding assembling/disassembling of the printer mechanism]
[Z-axis direction]
- Make sure that there is no gap between main frame and Housing, Lower.
- Make sure that the left side of Printer mechanism is correctly fixed by two
tabs.
(b) Control of vertical level of guide rail (Guide rail means the portion latched by
hooks of IC holder & Print head assy.)
[Reason]
There is a possibility that printing failure/operation failure occurs by guide
rail deformation.
[Service treatment]
- Do not remove [Mounting Plate, M/B] from Printer mechanism.
- Hold up the specified position of main frame to avoid the deformation.
(c) How to assemble of ASF unit/Circuit board/Paper guide upper
[Reason]
There is a possibility that main frame deformation is caused extra force in
assembling. As the result, printing failure/operation failure occurs.
1) Main frame
(a) Control of assembled standard position.
[Reason]
[Service treatment]
Hold the opposite side with hand while you are installing the above parts.
The assembled accuracy of each part composed of Printer mechanism is based

on Housing, Lower.
[Service treatment]
Confirm that there is no gap between main frame and Housing, Lower.
[Reference]
To ensure the assembled accuracy, you have to control the assembled
standard position of main frame against X/Y/Z-axis direction.
[X-axis direction]
- Make sure that main frame is correctly placed on the groove of Housing,
Lower.
- Make sure that there is no gap between main frame and Housing, Lower.
[Y-axis direction]
Make sure that cut-out portion of main frame is correctly placed on the square
protrusion of Housing, Lower.
Caution regarding Assembling/Disassembling of the Printer Mechanism, and How to Ensure of Quality on Re-assembled
Revision C
2) Front frame
(a) Control of vertical level
[Reason]
There is a possibility that printing failure occurs by front frame deformation.
[Service treatment]
Handle Front frame in assembling/disassembling carefully.
3) IC holder
(a) Handling of IC holder
[Reason]
If IC holder is damaged in assembling/disassembling of your repair, there is a
possibility that vital problem occurs in users further operation.
[Service treatment]
Released two hooks of IC holder from the inside of IC holder by the tweezer.
[How to ensure of quality on re-assembled product]
We judge that the quality of re-assembled product is ensured if there is no
problem about the print result by adjustment program.
Caution regarding Assembling/Disassembling of the Printer Mechanism, and How to Ensure of Quality on Re-assembled
Revision C
4.3 Disassembly Procedures

This section explains the procedures for disassembling the product.
Unless otherwise stated, reassembly should be carried out in the reverse order of the disassembly procedure.
For detailed engagement relations among main components, refer to the exploded diagrams in the Appendix.
When disassembling each unit, refer to the pages described in the chart below.
START
"Housing, Upper"
4.3.1.1 (p. 43)
"Stacker Assy."
4.3.1.2 (p. 44)
"ASF Unit"
4.3.1.3 (p. 44)
"CR Timing Belt"

4.3.3.5 (p. 60)
"CR Motor"
4.3.3.6 (p. 61)
"Front Frame"
4.3.3.7 (p. 62)
"CR Encoder Scale"

4.3.3.8 (p. 63)
"CR Cable Head

Cover"
4.3.3.9 (p. 64)
"Paper Guide, Upper

Assy."
4.3.3.14 (p. 71)
"Eject Roller"
4.3.3.15 (p. 71)
"Paper Guide, Front

Assy."
4.3.3.16 (p. 73)
"Hopper/Retard Roller
Unit"
4.3.1.4 (p. 45)
"Main Board"
4.3.2.1 (p. 52)
"Panel Board"
4.3.2.2 (p. 54)
"PS Board"
4.3.2.3 (p. 55)
Figure 4-1. Disassembling Flowchart (1)
Disassembly Procedures
41
Revision C
* Procedure in the broken-line is NOT the

shortest removing procedure, but the
passing point for the next removing
procedure.
START
"Panel Board"
4.3.2.2 (p. 54)
"PS Board"
4.3.2.3 (p. 55)
"Holder Shaft Unit"4.3.3.2

(p. 56)
4.3.3.2 (p. 56)
"Front Frame"
4.3.3.7 (p. 62)
"Stacker Assy."
4.3.1.2 (p. 44)
"Spool Gear 36.8/Extension

Spring 0.143/Clutch"
4.3.3.3 (p. 58)
"CR Encoder Scale"

4.3.3.8 (p. 63)
"Paper Guide, Front

Assy."
4.3.3.16 (p. 73)
"PE Sensor Board/PE

Detection Lever/Idle
Roller"
4.3.3.4 (p. 59)
"CR Cable Head

Cover"
4.3.3.9 (p. 64)
"Housing, Lower Assy."

4.3.1.5 (p. 47)
"CR Unit"
4.3.3.10 (p. 65)
"Waste Ink Pad"

4.3.1.6 (p. 51)
"Printhead Assy."
4.3.3.11 (p. 68)
"CR Encoder Sensor

Board"
4.3.3.12 (p. 69)
"CSIC Board"
4.3.3.12 (p. 69)
"PF Motor"
4.3.3.18 (p. 76)
"Holder Shaft Unit"

4.3.3.2 (p. 56)
"Pump Unit/Cap Unit"

4.3.3.17 (p. 74)
Figure 4-2. Disassembling Procedure (2)
42
Revision C
4.3.1 Removing Housings
C A U T IO N
Do not damage the tabs in removing the Housings.

Do not tilt the printer too much when removing the Housings
because ink may flow if the Carriage unit is not at the home
position.
4.3.1.1 Housing, Upper
C.B.P. 3x8
Tabs
C.B.P. 3x8
1) Remove the two screws on backside of the Housing, Upper.
C.B.P. 3 x 8:
2) Insert a flathead screwdriver into the two tabs on upper backside of the
Housing, and release the tabs.
3) Open the Stacker Assy. (See 4.3.1.2 Removing Stacker Assy. Step 2).
Tabs
4) Having your hands on the grooves of the Housing, Lower, press the parts
toward the direction of the arrows a shown in Figure 4-3, and remove the
Housing, Upper.
Figure 4-3. Removing Housing, Upper
43
Revision C
4.3.1.2 Stacker Assy.
4.3.1.3 ASF Unit
1) Remove the Housing, Upper. (p43)
2) Open the Stacker assy.
2) Open the Stacker Assy. (See 4.3.1.2 Removing Stacker Assy. Step 2)
3) Push the shaft located on the left side of the Stacker Assy. with a flathead
screwdriver or a similar tool, release the shaft from the slot of the Housing,
Lower, and remove the Stacker Assy.
3) Remove the three screws that secure the ASF Unit to the main unit, and
remove the ASF unit.
C.B.S. 3 x 6:
C.B.S. (P4) 3 x 6:
C.B.P. 3 x 8:
1
1
1
ASF Unit
C.B.S. 3 x 6
1
Stacker Assy.
C.B.S.(P4) 3 x 6
3
Shaft
C.B.P. 3 x 8
Figure 4-4. Removing Stacker Assy.

Figure 4-5. Removing ASF Unit
44
Revision C
When installing the ASF Unit to the main unit, follow the steps
described below.
1. Make sure to match the guide pin of the ASF Unit with the
positioning hole of the main unit.
2. Make sure to match the shaft of the ASF Unit with the
bearing of the Pump Unit.
3. Secure the screws in the order shown in Figure 4-5.
4.3.1.4 Hopper/Retard Roller Unit

C A U T IO N
Do not touch the cork on the Retard Roller and the Hopper.
1) Remove the ASF Unit. (p44)

2) Lift up the Hopper toward the direction of the arrow, release the two tabs, and
remove the spring and the hopper from the ASF Frame.
Side Surface of the

ASF Unit
Hopper Side
Guide Pin
ASF Frame Side
Shaft
Tab
Shaft
Shaft and Bearing

Guide Pin and Positioning Hole
Figure 4-6. Installing ASF Unit

Cork
A D J U S T M E N T
R E Q U IR E D
When you replace the ASF unit with a new one, lubricate it as
specified. See "6.1.3 Lubrication" (p92) for details.
When ASF unit is removed or replaced with new one, the
following adjustment must be performed in the order below.
1. Top Margin Adjustment
2. First Dot Adjustment
Hopper
Spring
Retard Roller
ASF Frame
Figure 4-7. Removing Hopper
45
Revision C
3) Remove Extension Spring 0.585 from both the ASF Frame and the Paper back
Lever.
4) Remove the Paper Back Lever from the bearing of the ASF frame.
5) Remove Compression Spring 1.88 from the ASF Frame, and remove the
Retard Roller Unit.
Paper Back Lever
Extension Spring 0.585
Compression Spring 1.88
When installing the Retard Roller or the Paper Back Lever,

attach the two springs as described below.
Attach the spring to the tab of the ASF Frame and the one of
the Paper Back Lever.
Attach the spring to the boss of the ASF Frame and the one
of the Retard Roller Unit.
Bosses
Tabs
Bearing
ASF Frame
Compression Spring1.88
Figure 4-9. Attaching the Springs
When installing the spring between the Hopper and the ASF
Frame, match the spring with the positioning hole (circular
dent) of the Hopper and the one of the ASF Frame.
Retard Roller Unit

ASF Frame Side
Figure 4-8. Removing Retard Roller Unit
Hopper Side
Positioning Hole
Positioning Hole
Figure 4-10. Attaching the Springs
46
Revision C
4.3.1.5 Housing, Lower Assy.

C A U T IO N
C A U T IO N
Do not remove the Housing, Lower Assy. more than is necessary.
When removing the Waste Ink Tube from the Waste Ink Pad, pay
attention not to spill the ink.
6) Remove the Waste Ink Tube from the Waste Ink Pad.
1) Remove the Stacker Assy.. (p44)
2) Remove the PS Board. (p55)
3) Remove the Paper Guide, Front Assy.. (p73)
4) Move the CR unit to the center of the printer.
(See 4.3.3.2 Removing Holder Shaft Unit Step 3)
Tab
5) Remove the two rubber feet located on the PF Motor side.

Bottom Face
Waste Ink Tube
Figure 4-12. Removing Waste Ink Tube

7) Remove the Cap Unit from the two guide pins of the Housing, Lower Assy.
Rubber Feet
Guide Pin
Figure 4-11. Removing Rubber Feet

Guide Pin
Cap Unit
Figure 4-13. Removing Cap Unit
47
Revision C
8) Remove the four screws that secure the Housing, Lower Assy
to the main unit.
C A U T IO N
C.B.P. 3 x 8:
3
C.B.P.(P2) 3 x 8: 1
9) Release the two tabs on the PF Motor side of the Housing, Lower assy, and
remove the Housing, Lower Assy.
3
C.B.P. (P2) 3 x 8
When performing the following work, be sure to hold the places

indicated with dotted circles to avoid deformation of the Main Unit
Frame.
Holding Position
2
1
C.B.P. 3 x 8
Figure 4-14. Removing Housing Lower Assy. (1)
Housing, Lower Assy.
PF Motor Assy.
Tab
Figure 4-15. Removing Housing Lower Assy. (2)
48
Revision C
To ensure the assembling accuracy, you have to control the

assembled standard position of the Main Frame against X/Y/Zaxis direction as follows.
[X-axis direction]
Make sure that main frame is correctly placed on the
groove of Housing (Lower).
Make sure that there is no gap between main frame and
Housing (Lower).
[Y-axis direction]
Make sure that cut-out portion of main frame is correctly
placed on the square protrusion of Housing, Lower.
[Z-axis direction]
Make sure that there is no gap between main frame and
Housing, Lower.
Make sure that the left side of Printer Mechanism is
correctly fixed with two tabs.
Z-axis Assembled Standard Position
X-axis Assembled Standard Position

Y-axis Assembled Standard Position
Z-axis Assembled Standard Position

Tabs
Figure 4-16. X and Y-axis Assembled Standard Position
Figure 4-17. Z-axis Assembled Standard Position
49
Revision C
When installing the Cap Unit, pay attention to the following

instructions:
Route the Ink Tube underneath the Cap Unit.
Make sure that the two bosses of the Cap Unit are located
under the Main Unit Frame.
A D J U S T M E N T
R E Q U IR E D
Bosses
When Housing (Lower) is removed or replaced with new one, the

2. PF Adjustment
3. Bi-D Adjustment
4. Head Angular Adjustment
Ink Tube
Figure 4-18. Installing Cap Unit
When installing the Cap Unit, route the Waste Ink Tube as
shown below, and place it under the protective sheet.
Tab
Protective Sheet
Waste Ink Tube
Figure 4-19. Routing Waste Ink Tube

When installing the Main Frame to the Housing, Lower Assy,
secure the screws as shown in Figure 4-14.
50
Revision C
4.3.1.6 Waste Ink Pad
Attach the Waste Ink Pads correctly with reference to Figure 4-21.
1) Remove the Housing, Lower Assy.. (p47)

2) Remove the eight Waste Ink Pad and the protective sheet from the Housing,
Lower.
Installation Order
Installation Order
4
1
1
Waste Ink Pad
Figure 4-20. Removing Waste Ink Pad

Double-sided Tape
Attachment Areas
Figure 4-21. Attaching Waste Ink Pads
51
Revision C
4.3.2 Removing Boards
3) Disconnect all the connectors from the Main Board.
4.3.2.1 Main Board

2) Remove the Clump Core from the Main Unit.
Clump Core
CN2:
CN4:
CN5:
CN6:
CN7:
CN8:
CN9:
Power Supply Cable

Panel Board Connector
CR Motor Connector
PF Motor Connector
CR Encoder FFC
Head FFC
PF Sensor Cable
CN7
CN8
Figure 4-22. Removing Clump Core

CN9
CN5
CN6
CN2
CN4
Figure 4-23. Removing Main Board (1)
52
Revision C
4) Remove the four screws that secure the Main Board Unit to the Main Unit,
and remove the Main Board Unit.
C.B.S. 3 x 14:
C.B.S. 3 x 6:
5) Remove the Main Board Cover from the Main Board Unit.
2
2
Main Board
Main Board Cover
Main Board Unit
C.B.S. 3 x 14
4
C.B.S. 3 x 6
When installing the Main Board Unit to the Main Unit, Secure
the screws in the order shown in Figure 4-24.
When attaching the Clump Core, pay attention not to confuse
left and right. The side with two portions should be facing to the
left.
Portions
Figure 4-26. Attaching Clump Core
53
A D J U S T M E N T
R E Q U IR E D
Revision C
When replacing the Main board with new one, perform the
following service items.
If the read-out operation succeeds by adjustment program
from defective main board, replace with new board and
write the read out data to new one.
1. Ink consumption counter
2. Waste drain ink pad counter
3. Head ID Input
4. Bi-D Adjustment
7. USB ID Input
8. Market ID Setting
10. PF Adjustment
11. CR motor drive torque dispersion measurement
If the read-out operation is not able to succeed by
adjustment program from defective main board, perform
the following service items after replacing main board with
new one.
1. Replace the Waste drain ink pad with a new one.
2. Head ID Input
3. Bi-D Adjustment
6. USB ID Input
7. Market ID Setting
9. PF Adjustment
10. Offset input for CR Motor Calorific Limitation
4.3.2.2 Panel Board

2) Disconnect the Panel Board Connector (CN4) from the Main Board.
(See 4.3.2.1 Removing Main Board Step 3)
3) Release the Panel Board from the two tabs and the notch of the Holder Shaft
Unit.
Holder Shaft Unit
Notch
Panel Board
Tabs
Figure 4-27. Removing Panel Board

When installing the Panel Board, make sure to hitch the Panel
Board Connector to the tab of the Holder Shaft Unit.
Holder Shaft Unit
Tab
Figure 4-28. Routing Panel Board Connector
54
Revision C
4.3.2.3 PS Board
5) Remove the four screws that secure the PS Board to the PS Board Frame,
Lower, and remove the PS Board.
2) Disconnect the Power Supply Cable (CN2) from the Main Board.
C.B.S 3 x 6:
4
C.B.S. 3 x 6
(61 kgf.cm)
3) Remove the three screws that secure the PS Board Unit to the Main Unit, and
remove the PS Board Unit.
C.B.P. 3 x 10:
C.B.S. 3 x 6:
2
1
PS Board Unit
C.B.S. 3 x 6
(81 kgf.cm)
2
C.B.P. 3 x 10
(61 kgf.cm)
3
Figure 4-31. Removing PS Board
C.B.P. 3 x 10
(61 kgf.cm)
Figure 4-29. Removing PS Board
4) Release the two tabs on both sides of the PS Board Unit, and remove the PS
Board Frame, Upper.
PS Board Frame, Upper
A D J U S T M E N T
R E Q U IR E D
Tab
Tab
When installing the PS Board to the PS Board Frame, Lower,

secure the screws in the order shown in Figure 4-31.
When installing PS Board Unit to the Main Unit, secure the
screws in the order shown in Figure 4-29.
When PS board unit is removed or replaced with new one,

the following adjustment must be performed in the order
below.
2. PF Adjustment
Figure 4-30. Removing PS Board Frame, Upper
55
Revision C
4.3.3 Disassembling Printer Mechanism
4.3.3.2 Holder Shaft Unit

1) Remove the Panel Board. (p54)
4.3.3.1 Printer Mechanism

C A U T IO N
When handling the Printer Mechanism, do not hold the Front

Frame with your hands.
2) Remove the Clump Core from the Main Unit.

3) Press down the CR Lock Lever toward the direction of the arrow, and move
the CR unit to the other side of the home position.
Follow the following steps to bring out the Printer Mechanism.
CR Lock Lever
1) Remove the Stacker Assy.. (p44)

2) Remove the Main Board. (p52)
4) Remove the PS Board. (p55)
CR Unit
Figure 4-32. Moving CR Unit
56
Revision C
4) Disconnect the four connectors from the Main Board.

CN5:
CN7:
CN8:
CN9:
7) Slide the concave portion of the Pump Unit toward the direction of the arrow,
and release the convex portion of the Holder Shaft Unit.
CR Motor Connector
CR Encoder FFC
Head FFC
PF Sensor Cable
Concave and Convex Portions
5) Release both the CR Encoder FFC and the Head FFC from the tab of the
Holder Shaft Unit.
6) Disconnect the CR Motor Cable from the Holder Shaft Unit.
CR Encoder FFC/
Head FFC
Tab
Pump Unit
Figure 4-34. Removing Holder Shaft Unit (2)

Holder Shaft Unit
8) Releasing two tab As that secure the Holder Shaft Unit to the Main Unit,
Remove the Holder Shaft Unit upward.
CR Motor Cable
Tab As
57
Revision C
When installing the CR Motor Cable to the Holder Shaft Unit, be

sure to route the cable as shown below.
Tab
4.3.3.3 Spool Gear 36.8/Extension Spring 0.143/Clutch

C A U T IO N
Notch
Never touch the LD Roller.

When removing the LD Roller Shaft Unit, pay attention not to
drop the Spool Gear 36.8, Extension Spring, and Clutch.
1) Remove the Holder Shaft Unit. (p56)

2) Remove the LD Roller Shaft Unit from the Holder Shaft Frame.
Holder Shaft Unit
3) Remove the Spool Gear 36.8 from the LD Roller Shaft Unit.
CR Motor Cable
4) Release the Extension Spring 0.143 that joins the LD Roller Shaft Unit and
the Clutch, and remove the Clutch.
Holder Shaft Frame
LD Roller Shaft Unit
LD Roller
Figure 4-36. Routing CR Motor Cable

A D J U S T M E N T
R E Q U IR E D
When Holder shaft unit is removing or replacing Holder shaft Unit

with new one, the following adjustment must be performed in the
order below.
Clutch
Spool Gear
36.8
Extension Spring
0.143
Figure 4-37. Removing LD Roller Shaft Unit
58
Revision C
The LD Roller Shaft Unit should be reassemble as shown below.
4.3.3.4 PE Sensor Board/PE Detection Lever/Idle Roller

1) Remove the Spool Gear 36.8/Extension Spring 0.143/Clutch. (p58)
2) Release the tab that secures the PE Sensor Board to the Holder Shaft Frame.
3) Release the cable from the Holder Shaft Frame, and remove the PE Sensor
Board.
4) Release the shaft of the PE Detection Lever from the bearings of the Holder
Shaft Frame, and remove Torsion Spring 0.22 from the PE Detection Lever.
Clutch
LD Roller
Shaft
5) Release the Idle Roller from the bearings of the Holder Shaft Frame.
Spool Gear 36.8
Figure 4-38. Assembling LD Roller Shaft Unit
PE Sensor Cable
PE Detection Lever
Idle Roller
PE Sensor Board
Torsion Spring 0.22
Tab
Bearings
Figure 4-39. Removing PE Sensor Board/PE Detection Lever/Idle Roller
59
Revision C
When installing the PE Detection Lever, attach Torsion Spring

0.22 as shown below.
4.3.3.5 CR Timing Belt

2) Move the CR Unit toward the center of the printer.
3) Loosen the screw that secures the Drive Pulley Holder Stopper to the Main
Unit.
4) Press the Drive Pulley Holder toward the direction of the arrow, pull the CR
Timing Belt toward you, and remove the belt from the Drive Pulley Holder.
Torsion Spring 0.22
C.B.S. (P4) 3 x 6:
Figure 4-40. Attaching Torsion Spring 0.22

When installing the PE Sensor Cable to the Holder Shaft
Frame, route the cable as shown below.
Tab
Holder Shaft Frame
CR Timing Belt
C.B.S. (P4) 3 x 6
Notch
Drive Pulley Holder
Drive Pulley
Holder Stopper
Figure 4-42. Removing CR Timing Belt
PE Sensor Cable
5) Remove the CR Unit. (p65)

When installing the CR Timing Belt to the CR Unit, make sure to
attach the belt to the positioning jag as shown in Figure 4-58.
Figure 4-41. Routing PE Sensor Cable
60
Revision C
4.3.3.6 CR Motor
When installing the CR Motor, follow the steps described below.

1. Positioning hole of the CR Motor should be on the
downside.
1) Remove the CR Timing Belt.

(4.3.3.5 Removing CR Timing Belt Step 2 through Step 4)
2) Disconnect the CR Motor Connector (CN5) from the Main Board.
Threaded Holes
3) Remove the CR Motor Cable from the Holder Shaft Unit.

Make sure to support the CR Motor with your hands when
removing the screws.
C A U T IO N
Positioning
Hole
4) Remove the two screws that secure the CR Motor to the Main Unit, and
remove the CR Motor.
C.P. 3 x 4:
2
Positioning Hole
C.P. 3 x 4
(41 kgf.cm)
2.
3.
1
A D J U S T M E N T
R E Q U IR E D
CR Motor
Figure 4-43. Removing CR Motor
Figure 4-44. Installing CR Motor

Secure the screws in the order shown in Figure 4-43.
When installing the CR Motor Cable to the Holder
Shaft Unit, route the cable as shown in Figure 4-36.
When CR timing belt is removed or replaced with new one,

tension adjustment of CR timing belt must be performed by the
degital tension gauge.
When CR motor is removed or replaced with new one, the
2. PF Adjustment
3. Bi-D Adjustment
4. Head ID Input
61
Revision C
4.3.3.7 Front Frame
2) Move the CR Unit to the center of the printer. (See 4.3.3.2 Removing Holder
Shaft Unit Step 3)
3) Remove both the two screws that secure the Front Frame to the Main Unit and
the Front Frame Stopper.
C.B.S. 3 x 6:
A D J U S T M E N T
R E Q U IR E D
4) Lift up the CR Unit, and remove the Front Frame.
Front Frame
Match the positioning hole with the rib as shown in Figure 4-45
when installing the Front Frame.
Secure the screws in the order shown in Figure 4-45.
When you replace Front frame with new one, lubricate it as

specified. See "6.1.3 Lubrication" (p92) for details.
When Front frame is removed or replaced with new one, the
1. PF Adjustment
2. Bi-D Adjustment
CR Unit
C.B.S. 3 x 6
(81 kgf.cm)
C.B.S. 3 x 6
(81 kgf.cm)
Positioning
Hole and Rib
Positioning
Hole and Rib
Front Frame Stopper
Front Frame Stopper
Figure 4-45. Removing Front Frame
62
Revision C
4.3.3.8 CR Encoder Scale
5) Release Extension Spring 1.494 on the left side of the CR Encoder Scale from
the tab of the Main Unit, turn the CR Encoder Sensor 90 degrees as shown in
the figure, and remove the CR Encoder sensor.

2) Move the CR Unit toward the center of the printer. (See 4.3.3.2 Removing
Holder Shaft Unit Step 3)
3) Release the slit on the right side of the CR Encoder Scale from the tab of the
Main Unit.
Tab
Slit and Tab
CR Encoder
Scale
CR Encoder Scale
Figure 4-46. Removing CR Encoder Scale (1)

4) Remove the CR Encoder Scale from the CR Unit.
When installing the CR Encoder Scale, place the scale so that the
chipped part is facing upper left as shown in the figure below.
CR Unit
CR Encoder Scale
Chipped Part
CR Encoder Scale
Extension Spring
1.494
Figure 4-49. Installing CR Encoder Scale
63
Revision C
4.3.3.9 CR Cable Head Cover

2) When removing the CR Cable Head Cover, follow the steps mentioned below.
1. Slide the CR Cable Head Cover downward, and release tab As.
2. Release tab B, slide the CR Cable Head Cover upward, and remove the
CR Cable Head Cover.
Follow the following procedure to install the CR Cable Head Cover.

1. Insert the rib of the CR Cable Head Cover shown in Figure
4-52 into the hole of CR Unit, and fix tab B on the CR Unit.
2. While holding the three portions ( ) shown in Figure 4-67
with your fingers, slide the CR Cable Head Cover until tab
As are securely fixed on the hole of CR Unit.
Tab As
Tab As
Tab B
Rib
CR Cable Head Cover
Figure 4-50. Removing CR Cable Head Cover

When installing the CR Cable Head Cover, make sure that the Head FFC is;
firmly bent.
secured under the tabs.
not overlapped with the rib of the CR Unit.
Otherwise the CR Cable Head Cover may come off.
Figure 4-52. Installing CR Cable Head Cover (2)

Confirm the following points after installing the CR Cable Head Cover.
Tab As should be securely fixed.
The Tab of the CR Cable Head Cover shown below ( )
should be securely fixed on the rib of the CR Unit.
CR Cable Head Cover should not come off from the CR Unit
when you push down C-part shown in Figure 4-53 with
tweezers.
Tab and Rib
Tabs
Tab B
Tab As
Rib
C-part
Head FFC
64
Revision C
4.3.3.10 CR Unit
8) Remove the Shield Plate FFC from the Main Unit Frame.

2) Remove the Front Frame. (p62)
C A U T IO N
Shield Plate FFC
As the Head FFC and the CR Encoder FFC is attached to each

other with glue, be careful not to remove them separately.
Double-sided tape
attaching location
3) Disconnect the two connectors from the Main Board.

(4.3.2.1 Removing Main Board Step 1 through Step 3)
CN7:
CN8:
Figure 4-54. Removing Shield Plate FFC
CR Encoder FFC
Head FFC
9) Remove the CSICFFC from the CSIC Board.
4) Disconnect the CR Encoder FFC and the Head FFC from the Holder Shaft
Unit. (See 4.3.3.2 Removing Holder Shaft Unit Step 5)
5) Disconnect the CR Timing Belt.
(4.3.3.5 Removing CR Timing Belt Step 3 through Step 4)
10) Disconnect the CR Encoder FFC (CN1) from the CR Encoder Sensor Board.
11) Release the three FFCs from the three notches.
Rear
6) Remove the CR Encoder Scale. (p63)
CN1
7) Remove the CR Cable Head Cover. (p64)
CR Encoder Sensor Board
Notches
CR Encoder FFC
CSIC Board
CSICFFC
Figure 4-55. Removing FFC
65
C A U T IO N
Revision C
Make sure to support the CR Unit with your hands so as not to drop
it, or the nozzle surface of the printhead may be damaged.
When installing the CR Timing Belt to the CR Unit, make sure

to attach the belt to the positioning jag as shown below.
Positioning Jag
12) Release the two tabs of the IC Holder, slide the holder toward you, and
remove both the CR Unit and the CR Timing Belt from the Main Unit.
CR Unit
CR Timing Belt
CR Unit
Tab
Tab
Figure 4-58. Installing CR Timing Belt

When installing the CR Unit to the Main Unit Frame, engage
them as shown in Figure 4-55.
Figure 4-56. Removing CR Unit (1)

13) Remove the CR Timing Belt from the CR Unit.
Main Unit Frame
Figure 4-59. Installing CR Unit

Route the three FFCs as shown in Figure 4-55.
The Shield Plate FFC should be attached to the location shown
in Figure 4-54 with double-sided tape.
CR Timing Belt
CR Unit
Figure 4-57. Removing CR Unit (2)
66
A D J U S T M E N T
R E Q U IR E D
Revision C
When you replace Holder pulley driven, Front Frame, Pulley

driven shaft, or Pulley driven holder with new a one, lubricate it
as specified. See "6.1.3 Lubrication" (p92) for details.
When IC holder/PW sensor/CR encoder sensor is removed or
replaced with new one, the following adjustment must be
performed in the order below.
2. PF Adjustment
3. Bi-D Adjustment
When Print head assy. is removed or replaced with new one, the
1. Head ID Input
3. PF Adjustment
4. Bi-D Adjustment
When CR timing belt is removed or replaced with new one,
tension adjustment of CR timing belt must be performed by the
degital tension gauge.
67
Revision C
4.3.3.11 Printhead Assy.
4) Remove the Head FFC from the Printhead Assy.

C H E C K
P O IN T
Before starting the following work, make sure that the two tabs
shown in Figure 4-56 are already released.
Head FFC
2) Release the tab from the notch of the IC Holder, and remove the printhead
cover.
3) Turn the Printhead Assy. toward the direction of the arrow, and remove the
Printhead Assy.
Printhead Assy.
IC Holder
Printhead Assy.
Figure 4-61. Removing Printhead Assy. (2)
Printhead Cover
Tab and Notch
Figure 4-60. Removing Printhead Assy. (1)
68
Revision C
When installing the Printhead Assy. to the IC Holder, match the

tabs with the notches, and tilt the Printhead as shown below.
4.3.3.12 CR Encoder Sensor Board

2) Remove the two screws that secure the CR Encoder Sensor Board to the IC
Holder, and remove the CR Encoder Sensor Board.
Tab and Notch
C.P.B. (P1) 1.7 x 5 :2
C.P.B. (P1) 1.7 x 5

Tab and Notch
CR Encoder Sensor Board
Figure 4-63. Removing CR Encoder Sensor Board

Figure 4-62. Installing Printhead Assy.
69
Revision C
4.3.3.13 CSIC Board
3) Insert a flathead screwdriver or a similar tool into the six A sections located
on bottom of the IC Holder, and remove the CSIC Board.

2) Remove the two screws that secure the IC Holder Cover to the IC Holder,
release the tab, and remove the IC Holder Cover.
C.B.P. 2.5 x 8:
CSIC Board
Tab
IC Holder Cover
C.B.P. 2.5 x 8
Bottom
A Sections
Figure 4-64. Removing IC Holder Cover
Figure 4-65. Removing CSIC Board
70
Revision C
4.3.3.14 Paper Guide, Upper Assy.
4.3.3.15 Eject Roller
2) Push the two guide pins on the Paper Guide, Upper Assy. with a flathead
screwdriver or a similar tool, and remove the Paper Guide, Upper Assy.
toward you.
2) Remove the Front Frame. (p62)

3) Move the CR Unit to the home position.
4) Remove the PF Timing Belt from the PF Drive Pulley.
Guide Pins
5) Remove the Eject Drive Pulley from the Eject Roller.

PF Drive Pulley
PF Timing Belt
Eject Roller
Paper Guide, Upper Assy.

Eject Drive Pulley
Figure 4-66. Removing Paper Guide, Upper Assy.

3) Repeat the steps above, and remove all the Paper Guide, Upper Assys.
A D J U S T M E N T
R E Q U IR E D
Figure 4-67. Removing Eject Drive Pulley
When Paper guide upper is removed or replaced with new one, the
2. PF Adjustment
3. Bi-D Adjustment
71
C A U T IO N
Revision C
Be careful not to damage the rubber area when performing the

following work.
A D J U S T M E N T
R E Q U IR E D
6) Release the Eject Roller from the four tabs of the Paper Guide, Upper Assy.,
and remove the Eject Roller.
Tabs
When you replace Paper eject roller with new one, lubricate it
aws specified. See "6.1.3 Lubrication" (p92) for details.
When Paper eject roller is removed or replaced with new one,
the following adjustment must be performed in the order
below.
2. PF Adjustment
3. Bi-D Adjustment
Figure 4-68. Removing Eject Roller

When installing the Eject Roller, make sure to match the notch of
the Eject Drive Pulley with the tab of the Eject roller as shown
below.
Eject Drive Pulley

Eject Roller
Notch
Tab
Figure 4-69. Installing Eject Drive Pulley
72
Revision C
4.3.3.16 Paper Guide, Front Assy.

C A U T IO N
1) Remove the Eject Roller. (p71)

2) Remove the screw that secures the Paper Guide, Front Assy. to the Main Unit.
Never touch the rib on the Paper Guide, Front Assy.
C.B.S. 3 x 8:
3) Follow the steps below when removing the Paper Guide, Front Assy.
1.
Lift up the left side of the Paper Guide, Front Assy.
2.
Slide the Paper Guide, Front Assy. toward left, and release the two
convex portions on the right.
Lift up the right side of the Paper Guide, Front Assy, slide it toward
right, and remove the Paper Guide, Front Assy.
3.
Rib
Left
Right
C.B.S. 3 x 8
Convex Portion
and Notch
Paper Guide, Front Assy.
Figure 4-70. Rib on Paper Guide, Front Assy.

Be careful not to bent the four Paper Guide, Front Absorbent
Protections.
Convex Portion
and Notch
Convex Portion
and Hole
Convex Portion
and Hole
Paper Guide, Front Assy.
Figure 4-72. Removing Paper Guide, Front Assy.

Paper Guide, Front
Absorbent Protections
Figure 4-71. Paper Guide, Front Absorbent Protections
When installing the Paper Guide, Front Assy. to the Main Unit,
make sure to match each convex portion with the notches and the
holes as shown in Figure 4-72.
73
A D J U S T M E N T
R E Q U IR E D
Revision C
When Paper guide front is removed or replaced with new one, the
2. PF Adjustment
3. Bi-D Adjustment
4.3.3.17 Pump Unit/Cap Unit

C A U T IO N
When removing the Pump Unit and the Cap Unit, pay attention not
to drop the CR Lock Lever and the Gear.

2) Remove the Holder Shaft Unit. (p56)
3) Release the three tabs that secure the Pump Unit to the Main Unit, and remove
both the Pump Unit and the Cap Unit.
Tabs
Figure 4-73. Removing Pump Unit/Cap Unit (1)
74
Revision C
4) Remove the Ink Tube that connects the Pump Unit and the Cap Unit.
Cap Unit
Pump Unit
A D J U S T M E N T
R E Q U IR E D
When you replace Pump Unit/Cap Unit with new one, lubricate
it as specified. See "6.1.3 Lubrication" (p92) for details.
When Pump Unit/Cap Unit is removed or replaced with new
one, the following adjustment must be performed in the order
below.
2. PF Adjustment
3. Bi-D Adjustment
Ink Tube Joint
Figure 4-74. Removing Pump Unit/Cap Unit (2)

Be sure to assemble the Pump Unit as shown below.
Compound Gear 27.2, 19.2
CR Lock Lever
Compound Gear 21, 24
Spool Gear 27.2
Figure 4-75. Assembling Pump Unit
75
Revision C
4.3.3.18 PF Motor
5) Remove Compression Spring 1.53, and remove the PF Motor.

2) Disconnect the PF Motor Connector from the Main Board.
PF Motor
3) Remove the PF Timing Belt, Idle Roller Assy, and Compression Spring from
the Main Unit.
PF Timing Belt
Figure 4-78. Removing PF Motor (3)
Compression Spring
1.13
Idle Roller Assy.
When installing the PF Motor, make sure to attach

Compression Spring 1.53 to the part shown in Figure 4-78.
When installing the PF Motor, secure the hexagon nuts in the
order shown in Figure 4-77.

4) Remove the four hexagon nuts that secure the PF Motor to the Main Unit.
A D J U S T M E N T
R E Q U IR E D
HEXAGON NAT NORMAL M3

(6 1 kgf.cm)
When PF motor is removed or replaced with new one, the

2. PF Adjustment
3. Bi-D Adjustment
3
2
76
CHAPTER
ADJUSTMENT
Revision C
5.1 Adjustment Items and Overview

This chapter describes adjustments to be made after the disassembly/reassembly of this product.
5.1.1 Servicing Adjustment Item List

The adjustment items of this product are as follows. For details of the adjustment items, refer to the detailed procedures and sketches of the adjustment items.
Table 5-1. Servicing Adjustment Items
Main adjustment items
Function Item
Used
Media
Purpose
Method Outline
Tool
Market
setting
At the time of Main board replacement, this adjustment is made

to write the board common information on a destination basis.
Select and execute this function in the exclusive servicing program to save
the following data into the EEPROM.
Market ID, CSIC printer ID, D4 setting (USB, parallel), First Dot
adjustment fixed value.
Exclusive servicing
program
Non-target
Head ID
input
At the time of head replacement, this adjustment is made to

correct head manufacturing variations and eliminate the
individual differences of print quality.
Enter the ID of the head QR code label applied to the Printhead into the
exclusive servicing program to save it to the EEPROM on the Main board.
(Supplement: Read the QR code label from left to right on the top row and
from top to bottom in due order.)
Exclusive servicing
program
Non-target
Offset input
for CR motor
calorific
limitation.
When the Main board, CR motor, PS board or Print head assy is

changed individually, this adjustment is made to write the
maximum offset to prevent the occurrence of damage to the
motor at the time of CR motor heat generation.
Select and execute this function in the exclusive servicing program to save
the offset into the EEPROM.
Exclusive servicing
program
Non-target
Head angular
adjustment
This adjustment is made to correct the error in the Head

mounting position (angle of the Head to the paper surface) to
keep the nozzle intervals uniform in the CR main scanning
direction.
Select this function in the exclusive servicing program and print the
adjustment pattern. Check the displacement amount of the pattern. Print
the exclusive pattern again and adjust the displacement amount.
Exclusive servicing
program
Photo
Quality Ink
Jet Paper
(A4)
PF
adjustment
This adjustment is made to correct the variations of paper feed

accuracy in the band printing mode to improve print quality.
adjustment patterns (9 patterns). Select and enter the pattern that has the
smallest gap and overlap. The correction value is saved to the specific
EEPROM address on the Main Board.
Exclusive servicing
program
Photo
Quality Ink
Jet Paper
(A4)
Bi-D
adjustment
This adjustment is made to correct the print timing in the go and

return paths in bi-directional printing.
adjustment patterns to check the displacement amounts of the patterns.
Select/enter the pattern number that has the smallest displacement amount
in the program. Print the exclusive patterns again and adjust the
displacement amount. The correction value is saved into the EEPROM.
Exclusive servicing
program
Plain paper
(A4)
ADJUSTMENT
Adjustment Items and Overview
78
Revision C
Table 5-1. Servicing Adjustment Items
Main adjustment items
Function Item
Purpose
Method Outline
Tool
Used
Media
USB ID
input
This adjustment is made to allow the PC to recognize the

Select this function in the exclusive servicing program and enter the serial
connected printers individually when multiple printers of the
numbers of the printers. The correction value is saved to the specific
same model are connected and used with the PC via a USB hub. EEPROM address on the Main board.
Exclusive servicing
program
Non-target
First Dot
adjustment
This adjustment is made to correct the first dot position in the

CR main scanning direction.
Select and execute this function in the exclusive servicing program. Enter
the correction value in the program using the rule position of the print
pattern as a reference. The correction value is saved to the specific
EEPROM address on the Main board.
Exclusive servicing
program
Plain paper
(A4)
Top Margin
adjustment
This adjustment is made to correct the printout position in the
Select and execute this function in the exclusive servicing program. Enter
the correction value in the program using the rule position of the print
pattern as a reference. The correction value is saved to the specific
EEPROM address on the Main board.
Exclusive servicing
program
Plain paper
(A4)
Tool
Used
Media
paper feeding direction.
Table 5-2. Maintenance Functions
Others
Maintenance items
Function Item
Purpose
Adjustment Outline
Head
Cleaning
This function is used to execute CL efficiently when ink is not

delivered from the Head properly, e.g. dot missing or skewed
injection. This function is used together with the nozzle check
pattern to confirm the CL effects.
Select this function in the exclusive servicing program, and execute

CL 3.
Exclusive servicing
program
Non-target
Ink Charge
This function is used to drain the Shipping Liquid in the ASP head
flow path and simultaneously fill ink in the head flow path to make
all nozzles printable and stabilize the ink in the Head.
Select this function in the exclusive servicing program, and execute

the ink sucking operation equivalent to the initial charge.
Exclusive servicing
program
Non-target
Select this function in the exclusive servicing program, read/display

the current data from the specific EEPROM address on the Main
board, and check whether the current counter value is close to the
upper limit or not.
For the reset function, select this function in the exclusive servicing
program after Waste ink pad replacement, and reset the corresponding
data at the specific address in the EEPROM on the Main board.
Exclusive servicing
program
Non-target
Waste ink
pad counter
This function is used after repair to read the Waste ink counter, and
if the value is close to the predetermined near-end value or end
value, to recommend Pad replacement to the user in order to prevent
the repaired printer from being returned again for repair in a short
time. The reset function is used to reset the Waste ink counter from
the exclusive program after Waste ink pad replacement.
EEPROM
data copy
This function is used to read the above necessary information from

the EEPROM of the faulty Main board using the D4 function to
reduce the auxiliary adjustment items at the time of Board
replacement.
Select this function in the exclusive servicing program, and read the
data from the faulty board. After that, change the Main board and then
write the read data to a new board.
Exclusive servicing
program
Non-target
Save all
EEPROM
data
This function is used to analyze defective products.
Save the data of all EEPROM addresses.
Exclusive servicing
program
Non-target
ADJUSTMENT
79
Revision C
Table 5-3. Check Pattern Printing
Check pattern items
Function Item
Purpose
Adjustment Outline
Tool
Used
Media
A4 Photo Quality Ink

Jet Paper print
This pattern is used to check whether all adjustment

results are normal.
Select this function in the exclusive servicing program, print the

print patterns, and check the adjustment result in each pattern.
Exclusive servicing
program
Photo Quality Ink

Jet Paper (A4)
A4 Normal Paper print
This pattern is used to check whether all adjustment

results are normal.
Select this function in the exclusive servicing program, print the

print patterns, and check the adjustment result in each pattern.
Exclusive servicing
program
Plain paper (A4)
Nozzle check pattern

print
This pattern is used to check simply whether all nozzles

deliver ink or not.
This pattern is used to make a simple print check at the EPSON

service company.
Exclusive servicing
program
Plain paper (A4)
5.1.2 Repaired Adjustment

If you remove or replace the specific part in your service/repair, you have to perform the appropriate adjustment as listed Table 2-4 below.
In this printer, it is necessary to perform appropriate adjustment in order to maintain consistent printing function and quality, eliminate differences of each printer mechanisms
characteristics.Therefore, in case that the combination between the printer mechanism and the main board changes or the Printhead is replaced during the repair service, you must
input the correct adjustment value into the EEPROM on the Main board by using the Adjustment program.
C H E C K
P O IN T
In case that any parts are removed and assembled on the repair
product while running the Adjustment program, make sure to
turn off the printer.
ADJUSTMENT
80
Revision C
5.1.3 Replacement Part-Based Adjustment Priorities
Note: applicable in this table indicates the adjustment

items required after removing/replacing the parts.
The following table indicates the adjustment items and priorities on a replacement part basis.
Performance Priority
Adjustment item
Replaced part
EEPROM Market
data copy setting
USB ID
input
Waste ink
pad counter
5
Ink
charge
Head ID
input
Top margin
adjustment
Removal/Replacement
Head
First dot
angular
adjustment
adjustment
10
11
12
Offset input for

Bi-D
PF
CR motor
adjustment adjustment calorific
limitation
ASF unit removal
---
---
---
---
---
---
applicable
applicable
---
---
applicable
---
ASF unit replacement
---
---
---
---
---
---
applicable
applicable
---
---
applicable
---
CR motor removal
---
---
---
---
---
---
---
applicable
applicable
applicable
---
---
CR motor replacement
---
---
---
---
---
---
---
applicable
applicable
applicable
---
applicable
Paper guide upper removal
---
---
---
---
---
---
applicable
---
---
---
applicable
---
Paper guide upper replacement
---
---
---
---
---
---
applicable
---
---
---
applicable
---
Frame front (only) removal
---
---
---
---
---
---
---
applicable
applicable
applicable
---
---
Frame front (only) replacement
---
---
---
---
---
---
---
applicable
applicable
applicable
---
---
I/C holder removal
---
---
---
---
---
---
applicable
applicable
applicable
applicable
applicable
---
I/C holder replacement
---
---
---
---
---
---
applicable
applicable
applicable
applicable
applicable
---
Print Head assy. removal
---
---
---
---
---
---
applicable
applicable
applicable
applicable
applicable
---
Print Head assy. replacement
---
---
---
---
applicable
applicable
applicable
applicable
applicable
applicable
applicable
applicable
Main board removal
---
---
---
---
---
---
---
---
---
---
---
---
Main board replacement (Read OK)
applicable
---
---
---
---
---
---
---
---
---
---
---
Main board replacement (Read NG)
---
applicable
applicable
---
applicable
applicable
applicable
applicable
applicable
applicable
applicable
Holder shaft unit removal
---
---
---
---
---
---
applicable
---
---
---
---
---
Holder shaft unit replacement
---
---
---
---
---
---
applicable
---
---
---
---
---
ADJUSTMENT
--- (Pad
replacement)
81
Performance Priority
Adjustment item
Replaced part
Revision C
EEPROM Market
data copy setting
USB ID
input
Waste ink
pad counter
Ink
charge
6
Head ID
input
7
Top margin
adjustment
Removal/Replacement
10
11
12
Offset input for

Head
First dot
Bi-D
PF
CR motor
angular
adjustment
adjustment adjustment calorific
adjustment
limitation
Paper eject roller removal
---
---
---
---
---
---
---
---
---
---
applicable
---
Paper eject roller replacement
---
---
---
---
---
---
---
---
---
---
applicable
---
PS board removal
---
---
---
---
---
---
---
---
---
---
---
---
PS board replacement
---
---
---
---
---
---
---
---
---
---
---
applicable
Paper guide front removal
---
---
---
---
---
---
applicable
applicable
applicable
applicable
applicable
---
Paper guide front replacement
---
---
---
---
---
---
applicable
applicable
applicable
applicable
applicable
---
PF motor removal
---
---
---
---
---
---
applicable
---
---
---
applicable
---
PF motor replacement
---
---
---
---
---
---
applicable
---
---
---
applicable
---
Waste ink pad removal
---
---
---
---
---
---
---
---
---
---
---
---
Waste ink pad replacement
---
---
---
applicable
---
---
---
---
---
---
---
---
PW sensor removal
---
---
---
---
---
---
---
---
---
---
---
---
PW sensor replacement
---
---
---
---
---
---
---
---
---
---
---
---
Printer mechanism removal
---
---
---
---
---
---
---
---
---
---
---
---
Printer mechanism replacement
---
---
---
---
---
---
---
---
---
---
---
---
Ink system removal
---
---
---
---
---
---
---
---
---
---
---
---
Ink system replacement
---
---
---
---
---
---
---
---
---
---
---
---
ADJUSTMENT
82
Revision C
5.2 Adjustment by Using Adjustment Program

The procedures of the adjustment items will be explained here. The intended item is
as follows.
5.2.1 Market ID Setting

[Adjustment Procedure]
1.
Select the Market ID of the adjustment program.
Market setting
2.
Click the [OK] button to write the specific data into EEPROM.
USB ID input
3.
Click the [Check] button to check market and model name.
Head ID input
Head angular adjustment
5.2.2 USB ID Input
Bi-d adjustment
PF adjustment
1.
Select USB ID input in the adjustment program.
First dot adjustment
2.
Enter the 10-digits serial number from the label applied to the bottom side of the
Upper housing.
Top margin adjustment

Offset input for CR motor calorific limitation
A4 Normal Paper print
A4 Photo Quality Inkjet Paper print
ADJUSTMENT
5.2.3 Head ID Input

1.
Select the Head ID of the adjustment program.
2.
Enter the 16-digits code of the Head ID label applied to the Printhead. Enter the
Head ID from left to right on the top row and from top to bottom in due order.
Adjustment by Using Adjustment Program
83
Revision C
5.2.4 Head Angular Adjustment
5.2.5 Bi-D Adjustment
1.
Select Head Angular adjustment in the adjustment program.
1.
Select Bi-D adjustment in the adjustment program.
2.
Click the [Print] button to print Head Angular adjustment pattern of checked
items.
2.
Click the [Print] button to print Bi-D adjustment pattern of checked items.
3.
3.
Select the pattern value of straight line in the printed lines.
Select the pattern that has the smallest displacements in each variable dot, and
click the [Go to print page] button in the adjustment program.
4.
Click the [Input] button to write the adjustment value of checked items.
(Note: The range of the adjustment value is -4 to 4.)
4.
5.
Click [Go to print page].
[Treatment procedure for NG product]
Step1) Replace the print head with new one again.

Step2) Print the check pattern, and check the adjustment result.
Step3) If the result is NG level, confirm the installation condition of removed parts
during disassembly.
Step4) Perform step2) again.
OK pattern
NG pattern
[Judging Standard]
- The printed line should be straight line.
[Reference:Standard value in manufactory]
- Standard : 50m
Step1) Replace the print head with new one again.

during disassembly.
OK pattern
NG pattern
Figure 5-2. Bi-D Adjustment Pattern
Figure 5-1. Head Angular Printing Pattern

C A U T IO N
ADJUSTMENT
[Judging Standard]
- No gap/overlap between short block
pattern and long one.
- VSD1:60m, VSD2:60m, VSD3:
40m, VSD4:40m, ECO:85m.
Please perform Bi-d adjustment keeping all Housing attached.
84
Revision C
5.2.6 PF Adjustment
5.2.7 First Dot Adjustment
1.
Select PF adjustment in the adjustment program.
1.
Select First Dot adjustment in the adjustment program.
2.
Click the [Print] button to PF adjustment pattern.
2.
Click the [Print] button to print First Dot adjustment pattern.
3.
Select the pattern that has the smallest displacements in each variable dot,
3.
4.
Determine the adjustment value in the shifting direction for the pattern printed on
the left margin. Input can be made in 0.0176mm increments for the adjustment
value of 1.
5.
If the smallest displacements is [*] or [**], and click the corresponded button.
4.
6.
Check that [*] or [**] is best of the three, input 4 in case of [*] and
-4 in case of [**].

Step1) Replace the repaired (replaced) part with new one.
during disassembly.
OK pattern
NG pattern

during disassembly.
[Judging Standard]
- Standard : 3.6 1.0 mm away from top edge.
[Judging Standard]
- No gap/overlap between short block
pattern and long one.
- Standard : 35m
Figure 5-4. First Dot Pattern
Figure 5-3. PF Adjustment Pattern
ADJUSTMENT
85
Revision C
5.2.8 Top Margin Adjustment
5.2.9 Offset input for CR Motor Calorific Limitation
1.
Select Top Margin adjustment in the adjustment program.
1.
Select Offset input for CR motor calorific limitation in the adjustment program.
2.
Click the [Print] button to print Top Margin adjustment pattern.
2.
Click the [Input] button to write the specific data in EEPROM.
3.
Determine the adjustment value in the shifting direction for the pattern printed on
the top margin. (Note: [+] input < 2.6mm, 4.6mm < [-] input )
4.

during disassembly.
[Judging Standard]
- Standard : 3 1.5 mm away from left edge.
Figure 5-5. Top Margin Pattern
ADJUSTMENT
86
Revision C
5.2.10 A4 Normal Paper print
5.2.11 A4 Photo Quality Inkjet Paper Print
1.
Select A4 Normal Paper print in the adjustment program.
1.
Select A4 Photo Quality Inkjet Paper print in the adjustment program.
2.
Click the [Print] button to print A4 Normal Paper print pattern.
2.
Click the [Print] button to print A4 Photo Quality Inkjet Paper print pattern.
3.
Check the adjustment result in each pattern.
[Judging Standard]
- PW Sensor adjustment
Top / Bottom : 5.0+0.5/-1.0mm
Right / Left : 5.0+0.3/-1.0mm
- Beta pattern
[Judging Standard]
- Bi-D adjustment
Make sure that X is the best pattern of the
three.
- Top Margin adjustment
3 1mm from top edge.
( This standard is different from that of
individual Top Margin adjustment. The
standard of individual Top Margin adjustment
is added about 0.6mm by the circumstance.)
- First Dot adjustment
3 1.5mm from left edge.
- Head Angular adjustment
three.
- PF adjustment
three.
- Accumulated Pitch Line
259.5 1mm from top line.
No uneven printing / white line.

- Vertical alignment
No thin dot or thick dot / vertical

alignment.
- Horizontal alignment
No displacement between the vertical

rules of each VSD.
Figure 5-6. A4 Normal Paper Print Pattern
Figure 5-7. A4 Photo Quality Inkjet Paper Print Pattern
ADJUSTMENT
87
Revision C
5.3 Adjustment Except Adjustment Program
[Treatment for NG product]

Step1) Replace the CR timing belt with new one again.
Step2) Check the adjustment result again.
during disassembly.
Following is adjustment except adjustment program.
5.3.1 CR Timing Belt Tension Adjustment

[Purpose]
This adjustment is to optimize the timing belt tension for preventing tooth skip between
the pinion of CR motor and the CR timing belt. This adjustment must be made when
the CR timing belt is removed.
Sensor cable
[Judging Standard]
- CR Timing Belt Tension : 9 1.5N
1.
Install the CR timing belt to the printer mechanism.
2.
Check the CR timing belt tension by using Digital Tension Gauge.

[Note]
Before this adjustment, the following data should be inputted into Digital Tension
Gauge.
[UNITTA : Setting of Digital Tension Gauge]
- Weight
: Input 0.4
- Width
: Input 8
- Span
: Input 377
C A U T IO N
Dont damage timing belt while pushing it with the tail plastic of
ballpoint pen / plastic tweezers.
Perform this adjustment in quiet environment in order to avoid

that the measured result affects by other frequency.
Sensor should be set vertically on CR timing belt.
3.
Return to CR unit to have position.
4.
Set the sensor cable to the center of the timing belt vertically.
(This time, the distance between the surface of the sensor cable on the timing belt
is 10 5mm.)
5.
Push the upside of the timing belt with the tail plastic of ballpoint pen / plastic
tweezers and check the timing belt tension on display of Digital Tension Gauge.
6.
Check the result of tension value on the display.
ADJUSTMENT
Figure 5-8. CR Timing Belt Tension adjustment
Adjustment Except Adjustment Program
88
CHAPTER
MAINTENANCE
Revision C
6.1 Overview
6.1.2 Service Maintenance

If any abnormal print (dot missing, white line, etc.) has occurred or the printer indicates
the "Maintenance request error" (This error is displayed as "Maintenance call error" in
the STM3), take the following actions to clear the error.
This section provides information to maintain the printer in its optimum condition.
6.1.1 Cleaning
Printhead cleaning
This printer has no mechanical components which require regular cleaning except the
Printhead. Therefore, when returning the printer to the user, check the following parts
and perform appropriate cleaning if stain is noticeable.
.
C A U T IO N
Never use chemical solvents, such as thinner, benzine, and
acetone to clean the exterior parts of the printer like the

Housing. These chemicals may deform or deteriorate the
components of the printer.
Be careful not to damage any components when you clean
inside the printer.
Do not scratch the coated surface of the PF roller. Use soft
brush to wipe off any dusts. Use a soft cloth moistened with
alcohol to remove the ink stain.
Do not use cleaning sheet included in the media for normal
usage. It may damage the coated surface of PF roller.
If the adhesive surface of the cleaning sheet is set to the LD
roller shaft side and used to clean the LD roller surface, it is no
problem.
When using compressed air products; such as air duster, for
cleaning during repair and maintenance, the use of such
products containing flammable gas is prohibited.
When dot missing or banding phenomenon has occurred, you need to perform the
printhead cleaning operation*1 by using the printhead cleaning function. This
function can be performed by the control panel operation, the printer driver utility
and the Adjustment program.
In case that the cleaning sequence is performed by the control panel operation,
confirm that the printer is in stand-by state (the Power LED is lighting), and hold
down the Error reset button on the control panel for more than 3 seconds. Then,
the printer starts the cleaning sequence (the Power LED blinks during this
sequence).
In case that you select and perform the manual cleaning by the printer driver
utility, the most appropriate cleaning mode is selected. The following is the
process to perform the printhead cleaning from the printer driver utility.
As for the operation of the Adjustment program, refer to
Chapter5 ADJUSTMENT (p.77).
*1: The Stylus C67/C68/D68 has four modes for manual cleaning, and even during
printing, the appropriate cleaning mode is automatically selected and performed
according to various conditions. Therefore the ink consumption amount for
manual cleaning varies depending on each mode.
Exterior parts
Use a clean soft cloth moistened with water, and wipe off any dirt. If the exterior
parts are stained by the ink, use a cloth moistened with neutral detergent to wipe it
off.
Inside the printer

Use a vacuum cleaner to remove any paper dust.
LD Roller
When paper loading function does not operate because friction of the LD roller is
lowered by any paper dust, set the adhesive side up of the cleaning sheet (included
in the media) to remove any paper dust. Repeat loading the cleaning sheet several
times.
MAINTENANCE
Overview
90

1.
Revision C
Select the EPSON Status Monitor 3 in the printer driver utility, and make sure
that the printer is in stand-by state by using the Status monitor 3. If the printer is in
stand-by state, the following figure is indicated on the monitor.
Maintenance request error (Maintenance call error)

Ink is used for the printhead cleaning operation as well as the printing operation.
When the ink is used for the printhead cleaning operation, the ink is drained to the
Waste drain ink pad and the amount of the waste ink is stored as the waste ink
counter into the EEPROM on the Main board. Due to this, when the waste ink max
counter has reached the limit of the absorbing capability of the Waste drain ink
pad*,) the Maintenance call error is indicated on Status monitor 3 as following
figure. But waste ink max counter is chenged by usage, therefore waste ink max
counter is not necessarily right.
*): The range of the waste ink counter is
8100 ~ 16900. ( means initial maximam value of mon-used printer.)
Figure 6-1. Status monitor 3 indication

2.
Select the Head Cleaning in the printer driver utility, and perform the printhead
cleaning. After performing the printhead cleaning operation, print a nozzle check
pattern by selecting the Nozzle Check. If you repeat the printhead cleaning
operation without selecting the Nozzle Check, CL1, the weakest cleaning, will
be repeated.
Figure 6-3. Maintenance error indication in STM3

In this case, replace to new Waste drain ink pad and clear the waste ink counter stored
into the EEPROM. The waste ink counter can be reset only from the Adjustment
program because this printer dose not have the waste ink counter reset function by the
control panel SW. As for the procedure, refer to Chapter5 ADJUSTMENT (p.77).
In your repair activity, check the waste ink counter along with the firmware version,
Main board checker program version and nozzle check pattern on the nozzle check
pattern printing. If the waste ink counter is closed to its limit, recommend that the
Waste drain ink pad will be replaced with new one. This is because the "Maintenance
request error" will may occur after returning the repaired product to the customer.
Figure 6-2. Head cleaning function in the printer driver utility
MAINTENANCE
Overview
91
Revision C
Refer to the following figures for the lubrication points.
6.1.3 Lubrication
The characteristics of the grease have great affects on the mechanical function and
durability, especially does the characteristics about temperature environment. The type
and amount of the grease used to lubricate the printer parts are determined based on the
results of the internal evaluations. Therefore, be sure to apply the specified type and
amount of the grease to the specified part of the printer mechanism during servicing.
<Lubrication Point>
Paper Back Lever Surface
ASF Unit
<Lubrication Type>
G-26
Paper Back Lever
C A U T IO N
C H E C K
P O IN T
Never use oil or grease other than those specified in this
<Lubrication Amount>
1 x 1 mm
<Remarks>
G-26 must not be adhered to
other parts.
manual. Use of different types of oil or grease may damage the

component or give bad influence on the printer function.
Never apply larger amount of grease than specified in this
manual.
Figure 6-4. Lubrication on Paper Back Lever
G-58 / G-26 / G-71 is already on the printer mechanism for

service part in the manufactory.
<Lubrication Point>
Front Frame Surface
Type
Name
EPSON code
Supplier
Grease
G-26
1080614
EPSON
Grease
G-58
1082176
EPSON
Grease
G-71
1304682
EPSON
<Lubrication Type>
G-58
Front Frame
35mm
1mm x 365mm
20mm
<Remarks>
the printer mechanism and
other parts.
Figure 6-5. Lubrication on Front Frame
MAINTENANCE
Overview
92
Revision C
<Lubrication Point>
Front and rear faces of the Main
Frame Carriage Slide
Rear side view
<Lubrication Point>
Back side slit of I/C Holder
<Lubrication Type>
G-71
<Lubrication Type>
G-58
I/C Holder
<Lubrication Point>
3mm x 3mm
360 mm x 2 face
<Remarks>
G-58 moust not be adhered to
other parts.
<Remarks>
other parts.
Main Frame
Figure 6-6. Lubrication on Main Frame
Roller Unit
Roller Guide
Figure 6-8. Lubrication on I/C Holder
<Lubrication Point>
Contact point between Roller
Guide and Roller Unit
<Lubrication Point>
EJ drive pulley Shaft Surface
<Lubrication Type>
G-58
<Lubrication Type>
G-58
Upper side view
PrintHead
Bottom side view
1 mm x diameter of EJ drive
pulley
1 mm x 4 points
<Remarks>
Use a injector to apply.
other parts.
EJ drive pulley
Figure 6-7. Lubrication on Roller Guide
MAINTENANCE
<Remarks>
other parts.
Figure 6-9. Lubrication on EJ drive pulley
Overview
93
Revision C
<Lubrication Point>
Contact point between the PF
Grounding Spring and the PF
Roller Unit
PF Grounding Spring
PF Roller Unit
<Lubrication Type>
G-58
<Lubrication Point>
1 mm x 0.5 mm
<Remarks>
Use a brush to apply.
other parts.
Figure 6-10. Lubrication on PF Roller Unit
Idle roller assy
<Lubrication Point>
U-shaped part for the Idle roller
assy
<Lubrication Point>
G-58
U-shaped part : 1 mm x 2 points
<Remarks>
other parts such as pinion face
of the PF Motor or the Timing
Belt
Figure 6-11. Lubrication on Idle Roller Assy
MAINTENANCE
Overview
94
CHAPTER
APPENDIX
Revision C
7.1 Exploded Diagram

The exploded diagram of this product are shown on the following pages.
APPENDIX
Exploded Diagram
96
400 Without ESP(Iinter),EURO

104
No.1
Rev.01
C616-ACCE-001
105
106
102
101
100
103
No.2
Rev.01
C616-CASE-001
200
300
No.3
Rev.01
C616-ELEC-001
513
508
505 505
501
501
500
502
512
510
507
509
541
504
514
515
503
511
542
No.4
Rev.01
C616-MECH-001
702
708
704
716
710
701
706
709
711
707
714
700
703
No.5
Rev.01
C616-MECH-002
Revision C
7.2 Parts List
Ref No.
Parts list for the EPSON Stylus C67/C68/D68

Ref No.
Part Name
Part Name
701
SCALE, CR
702
ASF UNIT
703
GROUNDING PLATE, HEAD
100
HOUSING, UPPER; EDG2
704
TORSION SPRING, LEVER, CARTRIDGE
101
COVER, INK TUBE; EDG2
706
SHIELD PLATE, CABLE HEAD ASSY., C616
102
COVER, I/F; EDG2
707
BOARD ASSY., ENCODER
103
STACKER ASSY.
708
BOARD ASSY., PANEL
104
PAPER SUPPORT ASSY.; EFS3
709
LABEL, POSITION, CARTRIDGE
105
COVER, PRINTER; EFS3; C67
710
LEVER, CARTRIDGE
106
BUTTON, SW ASSY., A
711
HOLDER, I/C ASSY.
200
BOARD ASSY., MAIN
714
PLATE, SLIDER
300
POWER SUPPLY ASSY.
716
TIMING BELT; E
400
POWER CABLE
NON FIG
INK CART.UNBOXED, BK-SS, PIG'T; G38K, A/A, AS
500
PRINTER MECHANISM(ASP)MAD13-100
NON FIG
INK CART.UNBOXED, C-SS, PIG'T; G38K, A/A, AS
501
FOOT
NON FIG
INK CART.UNBOXED, M-SS, PIG'T; G38K, A/A, AS
502
POROUS PAD, INK EJECT, UPPER, LARGE
NON FIG
INK CART.UNBOXED, Y-SS, PIG'T; G38K, A/A, AS
503
POROUS PAD, INK EJECT, LOWER, BIG; D
NON FIG
INTERFACE CABLE; USB2.0
504
POROUS PAD, INK EJECT, FB
NON FIG
SOFTWARE CD, EAI-LATIN
505
INSULATOR, FRAME, MAIN
NON FIG
USER'S GUIDE
507
ROLLER, EJECT
NON FIG
USER'S GUIDE
508
INKSYSTEM ASSY.
NON FIG
SETTING UP MANUAL
509
PAPER GUIDE, FRONT ASSY.
510
POROUS PAD, INK EJECT, LOWER, SMALL
511
PROUS PAD, CAP, LOWER, SMALL
512
POROUS PAD, TUBE, FASTEN
513
HOLDER, SHAFT ASSY.; B
514
FRAME, FRONT ASSY.
515
POROUS PAD, PAPER GUIDE FRONT, LOWER
541
SHEET, POROUS PAD, COVER
542
DIFFUSION SHEET, INK EJECT, LOWER, ASP
700
PRINT HEAD ASSY.
APPENDIX
Parts List
102
Revision C
7.3 Circuit Diagrams

The control electrical circuit diagrams of this product are shown on the following pages.
APPENDIX
Circuit Diagrams
103
Model
Board
Rev.
Sheet
: Stylus C67/C68/D68
: C616 MAIN
:B
: 1/1
Model
Board
Rev.
Sheet
: C616 PNL
:A
: 1/1
Model
Board
Rev.
Sheet
: C616 PSB
:B
: 1/1
Model
Board
Rev.
Sheet
: C616 PSE
:A
: 1/1

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SERVICE MANUAL

Color Inkjet Printer

EPSON Stylus C67/C68/D68

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

EPSON is a registered trademark of SEIKO EPSON CORPORATION.

SEIKO EPSON CORPORATION.

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

About This Manual

Symbols Used in this Manual

Indicates an operating or maintenance procedure, practice or condition

Indicates an operating or maintenance procedure, practice, or condition

Indicates that a particular task must be carried out according to a certain

Jan 18, 2006

Mar 14, 2006

Cautions during assembly are added.

EPSON Stylus C67/C68/D68

3.1 Overview .............................................................................................................

Chapter 2 OPERATING PRINCIPLES

5.1 Adjustment Items and Overview.........................................................................

2.1 Overview .............................................................................................................

EPSON Stylus C67/C68/D68

EPSON Stylus C67/C68/D68

2880 (H) x 1440 (V) dpi printing (Max. resolution)

4 color printing (YMCK)

Built-in auto sheet feeder

Holds 120 cut-sheets (90 g/m2)

EPSON Stylus C67/C68/D68

Table 1-2. Raster Graphics Mode

This section covers specifications of the printer.

1.2.1 Physical Specification

3.9 kg (without the ink cartridges)

447 mm (W) x 240 mm (D) x 189 mm (H)

447 mm (W) x 436 mm (D) x 309 mm (H)

1.2.2 Printing Specification

On demand ink jet

29 nozzles x 3 (Cyan, Magenta, Yellow)

Bi-direction with logic seeking

723.9 mm/s (285 CPS)

419.1 mm/s (165 CPS)

609.6 mm/s (240 CPS)

609.6 mm/s (240 CPS)

609.6 mm/s (240 CPS)

609.6 mm/s (240 CPS)

609.6 mm/s (240 CPS)

609.6 mm/s (240 CPS)

609.6 mm/s (240 CPS)

ESC/P2 expanded raster graphics code

EPSON Remote command

Print speed & Printable columns

Table 1-1. Character Mode

none (ASCII 20H to 7FH code support)

Bit map LQ font

EPSON Stylus C67/C68/D68

1.2.3 Paper Feeding

Friction feed with ASF

Cut-sheet ASF (Top entry front out)

T.B.D msec (T.B.D mm/sec) (10.16 mm (0.4 inch) feed)

T.B.D msec (T.B.D mm/sec) (Continuous feed)

1.2.4 Input Data Buffer

Input voltage range:

Rated frequency range:

Input frequency range:

0.2 A (max. 0.4 A)