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Epson Stylus Pro XL Service manual

1. DB1 C11 C51 Ful 1 S 35 VDC ul wave Smoothing moot ing e Rectifier Circuit Circuit Circuit L1 cona Q1 Y 2051 81 84 Drop Protection me Main Switching 5 Circuit Filter Circuit Circuit E lt xd Y 5 VDC 7 P OFF Detection TL 494 e F1 s and Dely Circuit ZD52 Fuse Gm 2086 Over Voltage 82 Protection Circuit ZD53 vv Over Voltage Photo Protection Circuit Coupler PC1 P OFF Signal Figure 2 16 Power Supply Circuit Block Diagram 1 5 line over voltage protection circuit The output voltage level of 5 V line is monitored by a Zener diode 2053 If the voltage level exceeds 7 V the status is fed back to the primary switching circuit through a photocoupler PC1 to stop the 35 V generation 2 5 VDC line over current over voltage control circuit The output current is monitored by a detection resistor R53 and fed back to the 5 generation switching control IC IC51 which monitors the output voltage This information is input to the internal comparater and outputs the high signal to turn off the transistor Q51 when the voltage or the current becomes abnormal 3 35 line over voltage protection circuit The output level is monitored by a Zener diode ZD36 If the voltage level exceeds 36 V photocoupler PC1 is activated stopping the primary
2. Stylus Pro XL Appendix Table A 14 Part No Reference Table Continued Ref No Description PPL Name 603 EXTENTION SPRING 1 6 g EXTENTION SPRING 1 6 604 COMPRESSION SPRING 90 g COMPRESSION SPRING 90 605 TORSION SPRING 15000 g TORSION SPRING 15000 606 TORSION SPRING 6700 g TORSION SPRING 6700 607 EXTENSION SPRING 102 g EXTENSION SPRING 102 608 COMPRESSION SPRING 1500 g COMPRESSION SPRING 1500 610 EXTENSION SPRING 10 g EXTENSION SPRING 10 612 COMPRESSION SPRING 100 g COMPRESSION SPRING 100 613 COMPRESSION SPRING 485 g COMPRESSION SPRING 485 614 SPUR GEAR 25 mm SPUR GEAR 25 615 COMPRESSION SPRING C 100 g COMPRESSION SPRING 100 C 616 TORSION SPRING 6120 g TORSION SPRING 6120 617 COMPRESSION SPRING 450 g COMPRESSION SPRING 450 618 EXTENSION SPRING 200 g EXTENSION SPRING 200 619 COMPRESSION SPRING 900 g COMPRESSION SPRING 900 620 COMPRESSION SPRING 180 g COMPRESSION SPRING 180 621 EXTENSION SPRING 567 g EXTENSION SPRING 567 622 TORSION SPRING 10400 g TORSION SPRING 10400 625 PLAIN WASHER 4x0 5x8 PLAIN W ASHER 4x0 5x8 626 PLAIN WASHER 3 2x1x7 F ZN PLAIN WASHER 3 2x1x7 F ZN 628 PLAIN WASHER 8x0 5x15 PLAIN WASHER 8x0 5x15 629 PLAIN WASHER 4 2x1x11 PLAIN WASHER 4 2 1 11 630 PLAIN WASHER 6x0 7x12 PLAIN WASHER 6x0 7x12 631 PLAIN WASHER 6 5 1 18 S NA P W 6 5x1x18 S NA 632 PLAIN WASHER 4 2x0 3x8 L
3. 2 17 Table 2 9 Paper Feed Motor Drive Modes 2 19 Table 2 10 Junction Method CPU 2CAS DRAM 2 23 2 ii Rev A Stylus Pro XL Operating Principles 2 1 OVERVIEW This section describes the operating principles of the printer mechanism and the electrical circuits of the Stylus Pro XL 2 2 OPERATING PRINCIPLES OF THE PRINTER MECHANISM The Stylus Pro XL printer mechanism is composed of the printhead unit paper feed mechanism carriage drive mechanism pump mechanism and various sensors The figure below shows a functional block diagram of the printer mechanism ASF Plunger Se y Disengage Lever ASF Pickup Mechanism O_O 20 gt Paper Feed Mechanism Pump Unit Drive Mechanism Carriage Unit ou Color Black Carriage Motor Figure 2 1 Printer Mechanism Block Diagram REV A 2 1 Operating Principles Stylus Pro XL 2 2 1 Printer Mechanism The printer mechanism of this printer uses a drop on demand ink jet system similar to the system used on all other EPSON ink jet printers However the printhead in this system is completely redesigned to make it more compact and ensure a high level of reliability The figure below shows the structure of the printhead and ink supply system Piezo When a drive pulse voltage is applied this element
4. Table 5 Connector Pin Assignments CN5 Table 6 Connector Pin Assignments CN6 4 Table A 7 Connector Pin Assignments 7 4 Table A 8 Connector Pin Assignments CN8 4 Table A 9 Connector Pin Assignments 9 4 Table A 10 Connector Pin Assignments 10 A 4 Table A 11 Connector Pin Assignments CN11 A 5 Table A 12 Connector Pin Assignments CN12 A 5 Table A 13 Connector Pin Assignments CN13 A 5 Table 14 Part No Reference Table A 21 Rev A A i Stylus Pro XL Appendix A 1 CONNECTOR SUMMARY The figure below shows the interconnection between the major components of the Stylus Pro XL Rev A AC Input gt 2 C137 PSB PSE CN2 CN5 Parallel TEES Black ASF Plunger Type B lo oe z Parallel Color z I F Printhead Unit C162 MAIN m RS 422 oS Sl ensor Serial Mz TR I F 2 co d B CN10 CN6 CN7 AN CR Sensor PF Motor C137 PNL N CR
5. REV A 3 1 Disassembly and Assembly Stylus Pro XL 3 2 DISASSEMBLY AND ASSEMBLY WARNING Follow the precautions in Section 3 1 1 when disassembling the printer This section consists of the subheads shown in the diagram below See the exploded view of the printer in the Appendix if necessary Y Printhead Unit Removal Upper Case 3 2 5 1 Page 3 8 Removal 3 2 1 Page 3 3 v Carriage Unit Removal Power Supply Unit 3 2 5 2 Page 3 12 Removal 3 2 2 Page 3 4 v Pump Unit v Removal Main Controller 3 2 5 3 Page 3 13 Removal 3 2 3 Page 3 5 v Clerner Head v Removal Printer Mechanism 3 2 5 4 Page 3 14 Removal 3 2 4 Page 3 7 v CR Motor Removal 3 2 5 5 Page 3 15 v PF Motor Removal 3 2 5 6 Page 3 15 v HP PE Sensor Removal 3 2 5 7 8 Page 3 16 v PF Roller Assembly Removal 3 2 5 9 Page 3 17 v Upper Frame Removal 3 2 5 10 Page 3 18 Figure 3 1 Disassembly Flowchart 3 2 REV A Stylus Pro XL Disassembly and Assmbly 3 2 1 Upper Case Removal 1 Remove the printer cover center of top by releasing the 2 tabs holding it to the upper case 2 Remove the front cover front of top by releasing the 2 tabs holding it to the lower case 3 Remove the paper guide by releasing the 2 tabs holding it to
6. ae N State E Gig Ink Dot Figure 2 3 Principles of the Printing Operation When the ink charge or printhead cleaning operation is performed the ink in the cavity is vacuumed out with the pump mechanism During printing on the other hand the ink is simultaneously supplied from the ink cartridge and ejected from the nozzle according to the change of volume in the cavity A thermistor is attached to the side of the color printhead drive board to monitor the temperature because the viscosity of the ink varies depending on the temperature The detected temperature level is fed back to the printhead drive voltage control circuit to change the timing of the Tc pulse The Tc pulse is shown in Section 2 3 2 5 REV A 3 Operating Principles Stylus Pro XL Micro Dot Printing mode The Stylus Pro XL printer has a special printing mode called Micro Dot Printing mode This printing mode can be selected by a command from the host computer Using the Micro Dot printing mode can improve the quality of output In Micro Dot Printing mode the ink dot size became to be smaller than the normal dot size 2 4 REV A Stylus Pro XL Operating Principles 2 2 2 Carriage Drive Mechanism The timing belt attached to the base of the carriage unit is driven by the carriage motor causing the carriage unit to move along the carriage guide shaft left to right or vice versa The carriage drive motor on this
7. 2 23 2 4 INK SYSTEM MANAGEMENT 2 24 23 1 nk Operations a SE n HU Gero ETa E E 2 25 24 2 Timer and 3 vios E be agua eet ted Bee ad ee ee 2 27 2 4 2 1 Refresh Timer Monochrome and Head 2 27 Rev A 2 i List of Figures Figure 2 1 Printer Mechanism Block 2 1 Figure 2 2 Structure of Printhead 2 2 Figure 2 3 Principles of the Printing Operation 2 3 Figure 2 4 Carriage Drive Mechanism 2 5 Figure 2 5 Platen Gap Lever Operation 2 6 Figure 2 6 Paper Feed Mechanism 2 7 Figure 2 7 Ink System 2 8 Figure 2 8 Pump Mechanism Block 2 9 Figure 2 9 Switch Lever 2 9 Figure 2 10 Paper Feed Mechanism 2 10 Figure 2 11 Switch Lever Reset 2 10 Figure 2 12 Pump 2 11 Figure 2 13 Cap Mechanism 2 12 Figure 2 14 Wiping 2 12 Figure 2 15 Block Diagram of the Electrical Circuit 2 13 Figure 2 16 Power Supply Circuit Block Diagram
8. a recien ni civ ee ee 2 TC 2 t n 4 eis EESE D D EN D D lice potesse n ea eue QUAE ea ee sns s Qi esed 3 3 3 i pos cei pk Qiie 64 360 koc cuta OP Mr 62 gt Yag Vii6 16 Y 16 O O O Figure 1 2 Nozzle Configuration Printing direction Bidirectional with logic seeking Print speed See Table 1 2 Printable columns See Table 1 2 Table 1 2 Print Speed and Printable Columns Character Pitch Printable Columns Print Speed LQ 10 cpi Pica 200 cps 12 cpi Elite 240 cps 15 cpi 300 cps 17 cpi Pica condensed 340 cps 20 cpi Elite condensed 400 cps Rev A 1 3 Product Description Stylus Pro XL Character sets Legal and 14 international character sets Character tables See Table 1 3 Table 1 3 Character Tables Bit map font Scalable font EPSON Roman EPSON Sans Serif EPSON Roman EPSON Roman Character Tables EPSON Courier EPSON Sans Serif EPSON Sans Serif EPSON Prestige H EPSON Script Italic PC437 U S Standard Europe PC850 Multilingual PC860 Portuguese PC861 Iceland PC863 Canadian French PC865 Nordic Abicomp BRASCII PC437 Greek PC852 East Europe PC853 Turkish PC855 Cyrillic PC857 Turkish PC866 Russian PC
9. 3 4 Figure 3 5 Main Controller Removal 3 5 Figure 3 6 Printer Mechanism M 4A60 3 7 Figure 3 7 Ink Cartridge Clamp Removal 3 8 Figure 3 8 Ink Cartridge Holder removal 3 9 Figure 3 9 Printhead Removal 3 9 Figure 3 10 Head Spacer Position 3 11 Figure 3 11 Front Frame Removal 3 12 Figure 3 12 Carriage Unit Removal 3 12 Figure 3 13 Pump Unit 3 13 Figure 3 14 Cleaner Head Replacement 3 14 Figure 3 15 CR Motor Removal 3 15 Figure 3 16 PF Motor 3 15 Figure 3 17 HP Sensor Removal 3 16 Figure 3 18 PE Sensor Removal 3 16 Figure 3 19 Tension Roller Assembly Removal 3 17 Figure 3 20 Paper Feed Roller Assembly Removal 3 17 Figure 3 21 Upper Frame Removal 3 18 Figure 3 22 Attaching the Torsion Spring 3 18 List of Tables Table 3 1 Insert Location of the Block Resistor 3 7 Table 3 2 Insert Location of the
10. ACK lt y 2 162 DMAC Memor BUSY Nun MESE y 128 14 125146 pReoz BAREQ Figure 2 26 DMA Controller Operation 2 22 REV A Stylus Pro XL Operating Principles 2 3 2 7 DRAM Refresh Controller The H8 CPU is equipped with a refresh controller in the internal controller This CPU can contact the 16 bit long IC5 DRAM which is a 2 CAS type The following table lists the junction method between the H8 CPU and the 2 CAS DRAM Table 2 10 Junction Method CPU 2 CAS DRAM 2 CAS DRAM The method of the DRAM refresh is used only for the CAS before RAS cycle method The following figure shows the timing for each cycle d CAS RAS a TE Read Cycle WE WE NER lt Write Cycle ns AS Read Write Cycle Refresh Cycle Figure 2 27 DRAM Cycle Timing CPU H8 IC1 DRAM 105 23 LWR gt 79 CAS R 101 8 _ 3 78 7 RAS D gt WE I O DRAM IC6 Figure 2 28 Junction Method CPU DRAM REV A 2 23 Operating Principles Stylus Pro XL 2 4 INK SYSTEM MANAGEMENT This section explains how the ink system is controlled to protect the printhead and ink supply system and to ensure high quality output Ink system control is composed of the following operations Power
11. 2 14 Figure 2 17 Main Control Circuit Block Diagram 2 15 Figure 2 18 Reset Circuit Block Diagram 2 16 Figure 2 19 Sensor Circuit Block Diagram 2 16 Figure 2 20 Carriage Motor Circuit Block Diagram 2 17 Figure 2 21 Serial Data Transfer Procedure 2 18 Figure 2 22 Paper feed Motor Drive Circuit Diagram 2 19 Figure 2 23 Normal Micro Dot Mode Switch Block 2 20 Figure 2 24 Trapezoidal Drive Wave 2 21 Figure 2 25 Printhead Drive Circuit Block Diagram 2 21 Figure 2 26 DMA Controller 2 22 Figure 2 27 D RAM Cycle Timings 2 23 Figure 2 28 Junction Method CPU DRAM 2 23 List of Tables Table 2 1 Carriage Drive Motor Specifications 2 5 Table 2 2 Drive Terms suu GUAE REIR E ERE nuns 2 5 Table 2 3 Platen Gap Adjust Lever Position 2 6 Table 2 4 Paper Feed Drive Motor Specifications 2 6 Table 2 5 Drive 2 7 Table 2 6 Pump Mechanism Operation 2 11 Table 2 7 DC Voltage Distribution 2 13 Table 2 8 Serial Data
12. Carriage Unit gt Black Head 1 Push N Head Base J O r Angular Spacer Platen Gap 2 Replace Adjust Lever Linear Spacer Angular Spacer Replacement Position Figure 4 6 Removing the Rubber Cap WARNING After replacing the spacer always install new ink cartridges before returning the printer to the user During this adjustment use ink cartridges exclusively for service Monochrome 1020626 CMY 1020627 You can reuse old ink cartridges for other purposes 10 Replace the angular spacer for the black head with a new one referring Figure 4 7 Replace the angular spacer by using tweezers to push the head base toward the rear Rev A 4 7 Adjustments Stylus Pro XL 11 After replacing the angular spacer reassemble the ink cartridge holder and reinstall the ink cartridges Use the BASIC program to verify the angle of the black head Confirm the angle by performing the steps 1 to 6 again and if the angle is wrong perform the adjustment again until the head angle is correct The angular spacer comes five thicknesses Continue performing this adjustment by changing the black head angle is correct When inserting an angular spacer always place the angular spacer on the linear spacer Carriage Unit gt Black Head 1 Push N N
13. Wiper Drive Gear Clutch Wiper Drive Gear Frame Figure 2 14 Wiping Mechanism 2 12 REV A Stylus Pro XL Operating Principles 2 3 OPERATING PRINCIPLES OF THE ELECTRICAL CIRCUITS The Stylus Pro XL contains the following circuit board units C162 MAIN Board main control circuit board C137 PSB PSE Board power supply circuit board B C137 PNL control panel board In addition to the circuit boards above part of the printhead drive circuit is built on a separate circuit board installed in the carriage unit the printhead is attached directly to this board The figure below shows a block diagram of the electrical circuitry C137 PNL C137 PSB C162 MAIN M 4A60 Printer Mechanism p e p gt TOTEM CR PF Motor 35 VDC YMC Head Black Head Driver Driver R T02 Head R T01 Head Figure 2 15 Block Diagram of the Electrical Circuitry 2 3 1 Operating Principles of the Power Supply Circuit The power supply circuitry for this printer is provided either by the C137 PSB Board 120 VAC or the C137 PSE Board 220 240 VAC Both boards are identical in design and functionality except for the components in the primary circuit that accommodate the specified input voltage The input voltage and the application of output voltages are summarized in the table below Table 2 7 DC Voltage Distribution
14. x Head Base e Angular Spacer RS Platen Gap 2 Replace Adjust Lever Linear Spacer Angular Spacer Replacement Position Figure 4 7 Angular Spacer Replacement Method 4 8 Rev A Stylus Pro XL Adjustments 4 1 5 Black Color Head Vertical Adjustment This adjustment calibrates the vertical position between the black head and the color head Align the top nozzles both nozzle 1 on the black head and nozzle 1 on the color head You can make this adjustment by using only the linear spacers for the black head This adjustment is required when the black head or the color head is replaced or disassembled The following figure illustrates this adjustment Adjust Carriage Unit L Color Head Black Head T ele lt Vertical Position Sie trs 2 87 9 Pa 6 9 pe lt Vertical Position Magenta Cyan Yellow 463 62 61 Figure 4 8 Black Color Head Vertical Adjustment Concept 1 Connect the PC to the target printer and turn the printer on 2 Execute BASIC on the PC and run the program 5 1 Destination Setting 2 Head Angle Confirmation Pattern Printing Black Head Spacer Selection 3 Head Vertical Position Confirmation 4 Head Gap Adjustment 5 Bi D Adjustment 6 Internal Timer Reset
15. Wiping Operation 1 Cleaning Selection Wiping Operation 2 Micro Absorbing Cleaning Rubbing Operation l Power Off Disengage On Print Start B Disengage Off Refresh Micro Absorbing Standby 1 Carriage Lock Set LY False Absorbing Carriage Lock Reset Ink Cartridge Replacement B Refresh when loading or ejecting paper Forwarding not described These ink system operations are controlled by the following counters and timers Refresh Timer Monochrome Color Head Timer LY Flushing Counter Ink Level Counter R CL Counter K Protect Counter 2 24 REV A Stylus Pro XL Operating Principles 2 4 1 Ink Operations Various ink operations can be performed selectively by the printer 1 Power On Operation This operation is performed when power is turned on 2 Cleaning Selection Mode This operation cleans each nozzle to ensure that the nozzle fires and that no dots are skipped during printing Cleaning selection is performed by pressing the cleaning switch Alt Load Eject or Economy Condensed while the printer is in PAUSE status 3 Micro Absorbing Cleaning Operation This operation prevents an increase in the viscosity of the ink inside the printhead by ink absorbing discharge 4 Power Off Operation This operation ensures the carriage is in the home position when the printer turns off and prevents the disengage gear from turning continuously when the printer turns off Power of
16. 1 Pump Unit PF Motor b rrt Platen Roller i Ink Absorber Waste Ink Drain Tank Figure 2 7 Ink System Block Diagram REV A Stylus Pro XL Operating Principles 2 2 5 Pump Mechanism The paper feed motor drives the pump mechanism when the transmission gear is moved to the position where the paper feed motor engages the pump mechanism gear trains when the carriage unit is at the ink system home position The figure below shows a block diagram of the pump mechanism Pump system operation depends on the rotational direction of the paper feed drive motor as shown in Table 2 6 Drive Pump Mechanism Carriage Disengage Lever Spring Left Frame NW P u m p Hook Drive Gear Release PI E idi Clutch Platen Drive Gear Sub Frame Right Frame PF Motor Pump Unit Figure 2 8 Pump Mechanism Block Drive Switch Lever Set Carriage D E Set Lever D E Reset Lever D E Lever Figure 2 9 Switch Lever Set REV A 999 Operating Principles Stylus Pro XL Drive Paper Feed Mechanism Figure 2 10 Paper Feed Mechanism Block Diagram Switch Lever Reset Carriage D E Reset Lever D E Lever Figure 2 11 Switch Lever Reset 2
17. DRIVEN E 573 PLATEN SHAFT HOLDER PLATEN SHAFT HOLDER 574 PLATEN SHAFT HOLDER GRAY PLATEN SHAFT HOLDER GRAY 575 TRACTOR REDUCTION GEAR TRACTOR REDUCTION GEAR 576 CLUTCH PAD PAD CLUTCH 577 PFSPRING CAP CAP SPRING PF 578 CAM CAM HOPPER 579 CLUTCH CAM CAM CLUTCH 580 ANTI STATIC BRUSH ANTI STATIC BRUSH 581 PAD HOLDER HOLDER ASSY PAD C 582 EDGE GUIDE EDGE GUIDE 583 EDGE GUIDE PRESSING PLATE PRESSING PLATE EDGE GUIDE 584 HOPPER HOPPER ASSY 585 PAPER LOADING CORK CORK PAPER LOAD 586 GEAR CHANGE GUIDE GUIDE CHANGE GEAR 587 COMBINATION GEAR HOLDER HOLDER COMBINATION GEAR 588 COMBINATION GEAR 13 5 mm 22mm COMBINATION GEAR 13 5 22 589 SPUR GEAR 20 mm SPUR GEAR 20 590 COMBINATION GEAR 16 mm 28 mm COMBINATION GEAR 16 28 591 SPUR GEAR 22 5 mm SPUR GEAR 22 5 592 COMBINATION GEAR 10 mm 50mm COMBINATION GEAR 10 50 593 SPUR GEAR 60 mm SPUR GEAR 60 594 GEAR 24mm SPUR GEAR 24 595 COMBINATION GEAR 17 5 mm 14 mm COMBINATION GEAR 17 5 14 596 GEAR 27 5 mm SPUR GEAR 27 5 598 SPUR GEAR 19 mm SPUR GEAR 19 599 COMBINATION GEAR 21 5 mm 9mm COMBINATION GEAR 21 5 9 600 COMBINATION GEAR 21 5 mm 9 mm COMBINATION GEAR 21 5 9 601 COMBINATION GEAR 28 mm 17 5 mm COMBINATION GEAR 28 17 5 602 EXTENSION SPRING 1937 g EXTENSION SPRING 1937 A 24 Rev A
18. Paper feed 2 2 phase or 2 W1 2 phase 391 or 1600 pps Pump drive 2 2 pha se 300 or 1800 pps E05A96 SLA7041MS IC2 IC14 42 jae 16 P CLKB 43 Mese PFSTB 13 STBA 695788 to DATA A A5 PFB gt DATA B 73 44 48 39 3 Slag na PFVRF gt REFA B 2 34465 PB8 PB13 4 5 57 U REF B 54 O 10 gt RSB C C B E NPN Tr P Q25 26 Figure 2 22 Paper Feed Motor Drive Circuit Diagram REV A CN7 2 19 Operating Principles Stylus Pro XL 2 3 2 5 Printhead Drive Circuit The printhead drive circuit for this printer is composed of the following two parts Common drive circuit trapezoidal drive pulse generation Head drive circuit nozzle control built on the printhead SED5620D the 64 bit thermal head driver in the head drive circuit on the carriage is used as a nozzle selector to drive the printhead nozzles selectively Print data is converted into serial data by gate array E05A96 IC2 and is output from port BSO pin 20 to the black head drive circuit or output from port CSO pin 24 to the color head drive circuit Then head driver SED5620D latches the head data when gate array E05A96BA outputs the BLAT or CLAT signal and the latched data becomes 64 bit parallel data for the black head or 48 bit parallel data for
19. The carriage does not operate at all IC15 is defective Checkpoint Check the output signal at pins 1 8 or at 11 18 of IC15 Troubleshooting Solution Replace IC15 Self test printing is abnormal Self test is not executed IC2 is defective Check the output signal at pin 13 or 14 and pin 15 or 16 of IC2 Replace IC2 Printhead unit is defective Replace printhead unit Paper feed does not operate normally Rev A The paper feed motor does not rotate IC2 is defective Check the serial signals output from pins 39 or 40 of IC2 to the driver IC14 Replace IC2 IC14 is defective Check the output signal at pin 1 8 or 11 18 of IC14 Replace IC14 Troubleshooting Stylus Pro XL 5 5 UNIT REPAIR PRINTER MECHANISM M 4A60 Any problems related to the printer mechanism should be repaired according to the troubleshooting procedures in Table 5 7 Symptom The pump mechanism does not operate Table 5 7 Repair of the Printer Mechanism Condition The PF motor fails to rotate at power on Foreign substances are lodged in the mechanism gears Checkpoint Manually drive the gear train connected to the pump mechanism to check if the motor rotates Solution Remove any foreign substance The PF motor is defective Check the coil resistance of the motor Replace the PF motor Ink is not absorbed or
20. Transmit data Not connected Receive data There is no connector CN4 Table A 5 Connector Pin Assignments CN5 Description Power scan signal Head common driver for common drive circuit Ground Power supply for logic system Rev A A 3 Appendix Stylus Pro XL Table A 6 Connector Pin Assignments CN6 Pin Description CRA Phase A drive signal CRA Phase A drive signal CRB Phase B drive signal CRB Phase B drive signal CRCOM Carriage drive power common voltage Table A 7 Connector Pin Assignments CN7 Pin Description PFA Phase A drive signal PFA Phase A drive signal PFB Phase B drive signal PFB Phase B drive signal PFCOM Carriage drive power common voltage Table A 8 Connector Pin Assignments CN8 Pin Description 1 PE Paper on out state detection signal 2 GND Ground Table A 9 Connector Pin Assignments CN9 Pin Description 2 1 Home position detection signal GND Ground HPV Sensor drive power supply Table A 10 Connector Pin Assignments CN10 Pin Description 1 3 5 7 GND Ground LDATA LED data LCLK Clock signal for LED drive LLAT LED data latch signal LCLR LED data reset signal 5 V LED driver and power SW0 5 Switch 0 5 input signal PSW Power switch PSC Power scan A 4 Rev A Stylus Pro XL Appendix
21. Also this spacer is different from the linear spacer or angular spacer See Chapter 4 Spacer Setting Locations Spacer 4 Head Nose For Black Head Figure 3 10 Head Spacer Position REV A 3 11 Disassembly and Assembly Stylus Pro XL 3 2 5 2 Carriage Unit Removal 1 Remove the printer mechanism see Section 3 2 4 2 Move the carriage to the left side of the printer while pressing the hook that fixes the carriage to the home position 3 Remove the 2 CBN O M3x 6 screws securing the eject frame to both side frames CBS O M3x6 Eject Frame Figure 3 11 Front Frame Removal Remove the cartridge holder with ink cartridge from the carriage unit see Section 3 2 5 1 Release the carriage timing belt from the belt pulley while pressing the pulley lever Remove the grounding wire from the left side frame Remove the 2 parallelism adjustment bushings from both side frames 09 DU gm Lift the carriage unit with the carriage guide shaft out of the printer mechanism Pulley Lever Parallelism Grounding Wire Adjust Bushing Parallelism Adjust Bushing Figure 3 12 Carriage Unit Removal CAUTION Take proper measures to protect the printhead unit from static electricity because the driver IC is directly attached to the printhead unit Never touch the printhead s metallic nozzle cover surface H
22. B 117 PLATE EARTH PLATE PS 118 I F GROUNDING PLATE GROUNDING PLATE I F 119 I F BOARD GUIDE GUIDE I F BOARD 120 UPPER CONNECTOR COVER COVER CONNECTOR UPPER 121 CLAMP CLAMP 122 CBBSCREW M3x12 C B B SCREW M3x12 123 CBS TITESCREW M3x12 C B S TITE SCREW M3x12 124 CBS SCREW M3x8 F UC C B S SCREW M3x8 F UC 125 SCREW 4 8 C B O SCREW M4x8 126 HEXAGON NUT M4 HEXAGON NUT M4 127 CB USCA 3x6 F ZN C B USCA 3x6 F ZN 128 CBSCREW 4x14 F ZN C B SCREW 4x14 F ZN 129 CBBSCREW 3 10 C B B SCREW 3 10 130 EJECT POROUS PAD POROUS PAD INKEJECT 131 FRONT PRINTER COVER COVER PRINTER FRONT 132 PAPER SUPPORT COVER COVER PAPER SUPPORT 133 EDGE GUIDE SLIDER SLIDER EDGE GUIDE 134 SUB EDGE GUIDE EDGE GUIDE SUB 135 GROUNDING PLATE E GROUNDING PLATE E 136 GROUNDING PLATE GROUNDING PLATE F 137 I F UPPER GROUNDING PLATE GROUNDING PLATE I F UPPER 138 CBB SCREW 4 12 SCREW M4x12 139 GROUNDING PLATE GROUNDING PLATE B Rev A A 21 Appendix Stylus Pro XL Table A 14 Part No Reference Table Continued Ref No Description PPL Name 200 MAIN BOARD FOR USA S E ASIA E 200 MAIN BOARD FOR EUROPE EO EUROPE MAIN 300 POWER SUPP
23. LINEAR F BLACK 702 LINEAR SPACER G BLACK SPACER LINEAR G BLACK 702 LINEAR SPACER H BLACK SPACER LINEAR H BLACK 702 LINEAR SPACER I BLACK SPACER LINEAR I BLACK 702 LINEAR SPACER J BLACK SPACER LINEAR J BLACK 702 LINEAR SPACER K BLACK SPACER LINEAR K BLACK A 26 Rev A EPSON
24. 220 240 V Version Rated voltage 120 VAC 220 240 VAC Input voltage range 103 5 132 V 198 264 V Rated frequency range 50 60 Hz 50 60 Hz Input frequency range 49 5 60 5 Hz 49 5 60 5 Hz Rated current 0 6A 04 Approx 20 W Approx 20 W self test with 10 cpi LQ characters self test with 10 cpi LQ characters 10 MO minimum 10 MO minimum Insulation resistance applying 500 VDC between AC line applying 500 VDC between AC line and chassis and chassis 1000 VAC rms 1 minute or Dielectric strength 1200 VAC rms 1 second between AC line and chassis Power consumption 1500 VAC rms 1 minute between AC line and chassis 1 2 6 Environmental Conditions Table 1 8 Acceptable Environmental Conditions Condition Operating Non Operating Temperature 10 35 C 50 95 F 20 60 4 122 Humidity 20 80 RH 3 5 85 RH 23 Shock resistance 1G within 1 msec 2G within 2 msec Vibration resistance 0 15 G 0 50 G For printer operation conditions must the range shown in the figure below 2 2 These conditions are applicable when the printer is in its shipping container 3 Without condensation Humidity 96 RH 8096 je ce mes Guaranteed 55 7 2096 I Figure 1 6 Temperature Humidity Range 1 8 Rev A Stylus Pro XL Product Description 1 2 7 Reliability Total print volume
25. 7 END 3 When the main menu appears choose Head Vertical Position Confirmation by typing 3 and ENTER The printer prints the check pattern along with the sample name When replacing the black head always adjust the black head angle first because the black color head vertical adjustment is based upon the black head angle 2 3 BLACK HEAD SPACER SELECTION Magenta 4 3 2 1 OK 0 s A 1 2 3 4 5 Figure 4 9 Linear Spacer Selection Sample Rev A 4 9 Adjustments Stylus Pro XL 4 InFigure 4 10 the vertical position is correct when both the magenta line and the black line are aligned as shown in position OK 0 If the vertical position is correct turn off the printer If the black and magenta lines are not aligned perform the vertical adjustment as described in steps 5 10 WARNING The number shown in the sample indicates the thickness level compared to the current linear spacer See There are 11 linear spacers with 11 different thicknesses The linear spacer is attached by two pieces one on each side of the head base Therefore when you need to replace one linear spacer always replace both linear spacers at the same time When replacing the linear spacer place it under the angular spacer If necessary replace the linear spacer For instance if your pattern is similar to the pattern shown
26. 75 000 pages A4 letter Printhead life 1 000 million dots nozzle 1 2 8 Safety Approvals Safety standards 120 V version UL1950 with D3 CSA22 2 950 with D3 220 240 V version EN 60950 TUV SEMKO DEMKO NEMKO SETI Radio frequency interference RFI 120 V version FCC Part 15 Subpart B Class B 220 240 V version Vfg 243 VDE0878 part 3 part 30 EN55022 CISPR PUB 22 class B 1 2 9 Physical Specifications Dimensions W x D x H 580 x 597 x 182 mm 22 8 x 23 5 x 7 17 in Weight About 10 Kg 22 Ib Rev A 1 9 Product Description Stylus Pro XL 1 3 INTERFACE SPECIFICATIONS The Stylus Pro XL is standard equipped with an 8 bit parallel and serial interface 1 3 1 Parallel Interface Specifications Data format 8 bit parallel Synchronization By STROBE pulse synchronization Handshaking By BUSY and ACKNLG signals Signal level TTL compatible level Adaptable connector 36 pin 57 30360 Amphenol or equivalent Data transmission timing See Figure 1 7 BUSY ACKNLG DATA STROBE 0 usec minimum L 0 usec 4 ME 0 5 psec minimum 5 usec typical 0 5 usec minimum 0 5 usec minimum Figure 1 7 Data Transmission Timing Note Transition time rise time and fall time of every input signal must be less than 0 2 us The Busy signal is active HIGH under the following conditions During data reception See Fi
27. Adjustments Stylus Pro XL 4 1 7 Platen Gap Adjustment This adjustment is required when the carriage unit is replaced or removed from the printer mechanism Adjust the distance between the printhead nose and the paper surface to 1 1 mm 1 Attach a thickness gauge commercially available to the left side adjustment position on the paper guide plate as shown in the figure below so that one side hooks the paper feed pinch roller unit 2 Move the carriage unit manually onto the thickness gauge Table 4 2 Gap and Adjustment Direction Gap between Head Nose and Gauge Surface Left Bushing Right Bushing 3 Rotate the parallelism adjustment bushing attached to the left and right ends of the carriage guide shaft when the black and color printheads contact the thickness gauge 4 After attaching the printheads to the gauge surface verify that the gap between the carriage roller and the front frame is less than 0 04 mm See Figure 4 16 5 Attach the 1 1 mm thickness gauge to the right side adjustment position on the paper guide plate as shown below so that one side hooks the paper feed pinch roller unit Note When checking the gap between the carriage roller and the front frame use the thickness gauge or the paper guide plate If the gap is correct the gauge cannot be installed into the gap If the gap is incorrect the gauge can be inserted in the gap Attach the thickness gauge Bushin
28. CW Color Pumping Pump Motor CCW Black Pumping LZ No Vacuuming No Vacuumin Pump Motor CW Black Not Pumping Pump Motor CCW Color Not Pumping Figure 2 12 Pump Operation REV A 2 11 Operating Principles Stylus Pro XL 2 2 6 Cap Mechanism The cap mechanism prevents the printhead nozzles from drying and keeps bubbles from forming inside the nozzle while the printer is not in use The printer performs this operation automatically when print data is not received or when the printer power is turned off during printing or ink system operations The secondary circuit for the power switch allows this operation to be performed Also this printer has two caps one for the black head and one for the color head Color Cartridge Black Cartridge Carriage Cap Holder Air Valve Valve Spring Air Tube Figure 2 13 Cap Mechanism 2 2 7 Wiping Mechanism The wiping mechanism cleans the surface of the printhead nose when the printer is in the ink system sequence The wiper drive gear transmits power from the paper feed motor via the clutch gear When the wiper is raised against the printhead surface the hook for securing the carriage to the home position is raised too When the wiper goes down toward the bottom frame the hook goes down too Both black and color heads are cleaned by this wiper lt Hook Lever Wiper Cleaning Blade
29. Points and Adhesive Points 2 6 6 LIST OF TABLES Table 6 1 Recommended 6 3 Table 6 2 Lubrication and Adhesive Points 6 3 Stylus Pro Service Manual Maintenance 6 1 PREVENTIVE MAINTENANCE Although this printer is designed so that no specific maintenance is required on a regular basis it is recommended that you clean the printer thoroughly whenever you get a chance to do so You can clean Outer case Use a soft clean cloth dampened with mild detergent if necessary O Auto sheet feeder If the inside of the auto sheet feeder is dirty dusty carefully brush away all dust and dirt using a soft brush If the pickup roller of the sheet feeder is dirty clean its surface with a soft clean cloth J Inside the printer If you notice any dust or dirt that has accumulated inside the printer when you open the outer case for repair remove all dust and dirt using a small vacuum cleaner designed for such purposes VARNING Never use paint thinner trichloroethylene or ketone based solvents for cleaning These chemicals can damage the components of the printer CAUTION Do not use a hard or abrasive brush for cleaning Be careful not to damage the components of the printer when using a vacuum cleaner A lithium battery is installed on the C164 MAIN board of this printer Be sure to observe the following instructions when servicing
30. ROLLER ROLLER ASSY PAPER LOAD 519 PAPER LOADING ROLLER SUPPORT ROLLER PAPER LOAD SUPPORT A 22 Rev A Stylus Pro XL Appendix Table A 14 Part No Reference Table Continued Ref No Description PPL Name 520 REARPAPER GUIDE PAPER GUIDE ASSY REAR 521 IPF ROLLER SUPPORT ROLLER PF SUPPORT 522 PFHOLDER SUPPORT HOLDER PF SUPPORT 523 TORSION SPRING 5800 TORORSION SPRING 5800 524 HARNESS HARNESS PE 525 PF STEPPING MOTOR STEPPING MOTOR PF 526 HP DETECTOR DETECTOR HP 527 HP HARNESS HARNESS HP 528 PUMPB PUMP ASSY 529 CAP POROUS PAD POROUS PAD UPPER 530 LOWER CAP POROUS PAD POROUS PAD CAP YMC LOWER 531 UPPER BK CAP POROUS PAD POROUS PAD CAP BK UPPER 532 LOWER CAP POROUS PAD POROUS PAD CAP BK LOWER 533 ASP HEAD CLEANER CLEANER HEAD ASP 534 CLEANER LEVER LEVER CLEANER 535 DRIVEN ROLLER HOLDER C HOLDER ROLLER DRIVEN C 536 ICR GUIDE SHAFT SHAFT CR GUIDE 537 OILPAD OIL PAD 538 KNOB LEVER LEVER KNOB 539 ICR STEPPING MOTOR 4 0 VDC 0 4 A STEPPING MOTOR CR DC 4 0V 0 4A 540 CR COVER COVER ASSY CR B 541 CR GUIDE GROUNDING SPRING GROUNDING SPRING CR GUIDE 542 CR STOPPER LEVER LEVER CR STOPPER 543 CR DAMPER DAMPER CR 544 ICR DAMPER SHAFT B SHAFT DAMPER CR B 545 PAPERLOAD LEVER LEVER PAPER LOAD 546
31. Section 4 1 5 Head gap adjustment see Section 4 1 3 Bi D alignment adjustment see Section 4 1 2 When replacing or disassembling the black head board Color head angle adjustment see Section 4 1 6 Black Color head vertical adjustment see Section 4 1 5 Head gap adjustment see Section 4 1 3 Bi D alignment adjustment see Section 4 1 2 When replacing or disassembling the color head board Color head angle adjustment see Section 4 1 6 When replacing or Black head angle adjustment see Section 4 1 4 disassembling both the Black Color head vertical adjustment see Section 4 1 5 color and black head Head gap adjustment see Section 4 1 3 Bi D alignment adjustment see Section 4 1 2 When replacing or disassembling Platen gap adjustment see Section 4 1 7 the carriage unit Rev A 4 1 Adjustments Stylus Pro XL 4 1 1 Destination Data Writing Operation The setup value that specifies the printer destination is stored in the EEPROM on the C162 MAIN board Therefore this setup value must be written into the EEPROM when the MAIN board or EEPROM chip is replaced CAUTION Before writing the destination data writing set the interface to parallel 1 Connectthe IC to the target printer using a parallel interface cable and turn the printer on M Execute BASIC on the PC and run the program VERxxx BAS You see the following menu Desti
32. Stop bit 1 bit Bit rate 57 6K bps 230 4 Kbps Adaptable connector 8 pin mini circular connector Recommended I F cable Apple System Peripheral 8 cable Table 1 11 Signal and Connector Pin Assignments for Serial Interface Signal Name Description Data terminal ready No connection Transmit data Signal ground Receive data Balanced transmit No connection 1 2 3 4 5 6 7 8 Balanced receive The I O column indicates the data flow as viewed from the printer 1 12 Rev A Stylus Pro XL Product Description 1 4 OPERATIONS This section describes the basic operations of the printer 1 4 1 Control Panel The control panel for this printer has 1 lock type 5 non lock type push buttons and 14 LED indicators for easy operation of the various printer functions p Courier Operate Alt Operate Data Paper Out No Ink Cartridge Font g Roman PS my Font i p Sans Serif H PS p Roman Sans Serif Prestige i g Script Buttons Operate Alt Font Economy Condensed Load Eject Pause Rev A Economy J Condensed Economy Condensed Load Eject Pause Figure 1 8 Control Panel Appearance Turns the printer on or off Modifies the function of other buttons Holding down this button for 3 seconds causes the printer to move the carriage to the ink cartridge install
33. Voltage Application Motor drive carriage and paper feed Printhead through the drive voltage generation circuit C137 MAIN Board 5 VDC Sensors home position paper end no ink cartridge head thermistor Control panel head nozzle selector 35 VDC REV A 2 13 Operating Principles Stylus Pro XL The figure below shows a block diagram of the power supply circuit C137 PSB PSE The power switch is equipped with a secondary circuit that allows the CPU to remain active for a while after the printer is turned off This allows the printhead to return to the capping position after power is off The CPU mounted on the C137 MAIN Board always monitors the PSC power on off signal If this signal becomes LOW the CPU resets each device after performing the head capping sequence Also this board employs the RCC ringing choke converter switching system This AC voltage is first input to the filter circuit for higher harmonics absorption and then input to the rectification and smoothing circuit converting it into DC voltage This DC voltage is then input to the switching circuit for the switching operation Along with the switching operation on the primary side 35 VDC is generated after passing through the 35 V line voltage detection circuit This 35 VDC output level is stabilized This 35 VDC is also input to the 5 VDC generation circuit to generate a stable 5 VDC
34. is poorly absorbed Used ink does not go through the used ink tube during the cleaning operation The tube is not properly connected to the cap Check that the tube is properly connected to the cap Insert the tube properly The ink tube is damaged Check the ink tube visually Replace the tube The cap is defective Check for any defective part Replace the head cap The pump is defective Replace the pump to see if this causes the ink to be absorbed normally Replace the pump unit The printhead is defective Replace the printhead to see if this causes the ink to be absorbed normally Replace the printhead The carriage motor does not rotate The carriage motor fails to rotate at power on Foreign substances are lodged in the gear of the mechanism Manually drive the timing belt to see if the carriage motor rotates Remove any foreign substances The carriage motor is defective Measure the coil resistance of the CR motor Replace the carriage motor The carriage does not operate normally at power on after the carriage has been manually centered prior to power on 5 12 The carriage motor rotates but the carriage does not move The pulley is defective Check for broken or worn pulley Replace the driven pulley The timing belt is defective Check that the timing belt is properly inserted int
35. nozzles in rows A and D are fired making it is easy to see the angle of the black head Black Head Angle Adjustment Figure 4 4 Black Head Angle Adjustment Sample 5 Inthe figure above pay attention to position A Do not look at position B 6 Using the following flowchart replace the angular spacer for the black head which is under the right linear spacer The procedure for this replacement is explained beginning with step 7 Check position A gt Position A Position A Replace the right Replace the right angular spacer with angular spacer with a thinner one a thicker one Figure 4 5 Spacer Selection 4 6 Rev A Stylus Pro XL Adjustments 7 Turnthe printer power off now 8 Manually move the carriage to the center while pressing the carriage lock lever and remove the two ink cartridges 9 Remove the rubber cap covering the head screw at the side of color ink cartridge Then loosen but do not remove 3 screws Refer to Figure 4 6
36. pushes the vibration plate compressing the cavity for ink injection from the nozzle Cavity Ink supplied from the ink cartridge is stored in this space and is ejected fr om the nozzles when the vibration plate compresses this area Nozzles These eject ink against the paper s surface in response to the application of the print signal There are 64 black head or 48 color head individual nozzles making up the printhead Cartridge Needle Printhead Driver Board nnnm Ink Supply Tube Nozzle Plate Nozzle Plate Ink Su pply Tank Cavity Piezo Figure 2 2 Structure of Printhead 2 2 REV A Stylus Pro XL Operating Principles Principles of the Printing Operation The printhead operates in one of two modes to eject ink from each nozzle Normal state No electrical charge is applied to the MLP Multi Layer Piezoelectric element attached to the back of the cavity and pressure inside the cavity is kept at a constant level Ejecting state The head data signal is applied to the specific nozzle control line to select the active nozzle for printing and the MLP element is gradually charged by the drive voltage By charging the MLP element the vibration plate is bent to compress the cavity Then ink is ejected from the nozzle Cavity _ Piezo 27 Vibration Plate N Piezo Nozzle N SUC Nozzle N
37. sensor is built into the printer mechanism to determine whether there is paper in the printer or not A LOW level from the signal indicates that no paper is loaded The cartridge out CO sensor is micro switch attached to the bottom of each ink cartridge holder in the carriage unit When the ink cartridge is installed these switches are pressed and a LOW level from the signal indicates that the ink cartridge is installed into the ink cartridge holder A thermistor is attached to the color printhead driver board to monitor its temperature by thermister s resistance value at 25 C approx 10kQ The CPU changes the printhead drive signal s pulse width charge pulse width based on the temperature level 5 V V A 2 87 CPU IC1 1 89 10 PEO PANI AN3 4 O TH CN8 2 925 i Hn om2 TN see AN5 4 JO cco gt ANO d CN11 HPO 4 90 O BCO CN9 O ih Figure 2 19 Sensor Circuit Block Diagram REV A Stylus Pro XL Operating Principles 2 3 2 3 Carriage Motor Drive Circuit The carriage motor drive IC SLA7041MS IC15 outputs a constant current to drive the carriage motor for the printer mechanism Gate array E05A96EA IC2 decides the motor phase and speed and then sends a signal to the carriage motor driver IC SLA7041MS using the 4 bit serial transmission line The first bit indicates the direction of the motor rotation The other three bits ar
38. switching circuit operation 4 35 VDC line drop protection circuit The output level of 35 line is monitored by a detection circuit that consists of a Zener diode ZD51 and ZD81 to 84 This circuit feeds back the output voltage level status through a photo coupler to the primary switching circuit to control the ON OFF time of the switching transistor for contast output voltage 2 14 REV A Stylus Pro XL Operating Principles 2 3 2 Operating Principles of the Main Control Circuit The main control circuit of this printer is the C162 MAIN Board This circuit is controlled by the 16 bit CPU H8 3003 IC1 running at 14 7456 MHz This CPU has a unique architecture capable of handling data on the data bus at either an 8 bit or 16 bit bus width Because of this a 16 bit or 8 bit data bus width type ROM is used on this board increasing the internal processing speed Also the CPU has a unique architecture capable of the refresh control function A 4M DRAM 2 CAS method on this board is controlled by the CPU itself The CPU controls the serial interface control RS 422 for Mac Gate array E05A96 IC2 manages printhead drive control external Centronics parallel I F extension CG board and the control panel and the controls that create the 4 bit signal for the carriage or the paper feed motor The carriage and paper feed motor are controlled by the current duty data This board also is equipped with EEPROM 93C46 IC12 to store ce
39. the PAUSE LED is on 2 Hold down the Alt button and press the Load Eject button for black head cleaning Hold down the Alt button and press the Economy Condensed button for color head cleaning When panel button operation is accepted by the printer the PAUSE LED flashes during the cleaning cycle When the cleaning completes the PAUSE LED stops flashing and the printer returns to standby mode 6 2 2 Waste Ink Drain Tank Replacement The printer counts the total amount of ink drained to the waste ink drain tank and this information is stored in the EEPROM on the main board in Protect Counter A This value is used for ink system operation management If the counter value reaches the predetermined value the printer displays an error Waste ink tank overflow see Chapter 1 Section 1 4 4 Error Conditions Table 1 10 When this error is displayed replace the waste ink absorbing materials and reset the protect counter 1 Open the upper case and replace the waste ink absorbing materials from the compartment of the lower case Reassemble the printer 2 Turn the printer while holding down the Alt Font Load Eject Pause buttons This resets the protect counter 6 2 Rev A Stylus Pro Service Manual Maintenance 6 3 LUBRICATION AND ADHESIVES The printer must be lubricated properly when it is disassembled for component replacement or if mechanical noise exceeds a certain level EPSON recommends only the lubricants listed
40. the printer mechanism 4 Move the carriage to the middle of the printer while pressing the hook that fixes the carriage unit to the home position 5 Remove the control panel Release the tab by inserting a screwdriver into the hole in the upper case as shown in the figure below At this time disconnect the connector on the C137 PNL Board C137 PNL Board Carriage Lock Lever Figure 3 2 C137 PNL Control Panel Removal M Remove the 2 CBB M3 x 11 screws securing the upper case to the lower case a Release 1 tab by inserting a flathead screwdriver into the holes at the bottom of the lower case as shown in the figure below 7 Remove the upper case by lifting the front side At the same time release 1 tab located in the center front of the lower case DISASSEMBLY ASSEMBLY POINT Hold the upper case firmly and pull it to remove it while you release the tabs CBB M3x11 N Figure 3 3 Upper Case Removal REV A 3 3 Disassembly and Assembly Stylus Pro XL 3 2 2 Power Supply Unit C137 PSB PSE Board Removal 1 Remove the upper case see Section 3 2 1 2 Disconnect the cables from connectors 1 on the C137 PSB PSE Board and CN5 on the C162 MAIN Board 3 Remove the 2 screws 1 CBN M3x8 and 1 CBB M3x12 securing the shield plate to the lower case via the C137 PSB PSE Board 4 Remove the 3 screws 2 CBB M3x12 and 1 CBN 8 securing the C137 PSB P
41. 10 REV A Stylus Pro XL Operating Principles Table 2 6 Pump Mechanism Operation PF Motor Rotational Direction Operation Clockwise CW LIColor absorption forward rotation LIColor micro absorption LIColor false absorption Wiper reset CICarriage lock reset Counterclockwise CCW LIMonochrome absorption backward rotation LIMonochrome micro absorption Monochrome false absorption Wiper set lock set The pump draws ink from the printhead nozzles and drains it to the waste ink drain tank The printer performs this operation to eliminate dust or bubbles in the nozzles Figure 2 12 illustrates pump operation When the paper feed drive motor rotates CW forward the color pulley pumps in the wheel pump unit rotate in the direction of the arrow while squeezing the ink tube to push the ink inside the tube out to the waste ink drain tank When the motor rotates CCW backward the black pulley pumps in the wheel pump unit rotate in the direction of the arrow while squeezing the ink tube to push the ink inside the tube out to the waste ink drain tank There are two pump rollers in the pump unit and the drive power is supplied from the paper feed motor via the pump drive gear D E gear which is moved by carriage operation In the pump unit the transmission gear drives both the black and color pulley which are rotated by the movement of the other a oF 2 Vacuuming Vacuuming Pump Motor
42. 4 5 Printer is sioe Ba Gye ewe Gee dala eee E E 1 18 1 4 5 1 Hardware 1 18 1 4 5 2 Software Initialization 1 18 1 4 5 3 1 1 18 1 5 MAIN COMPONENTS 1 19 1 5 1 Main Control Board C162 MAIN Board 1 19 1 5 2 Power Supply Board C137 PSB PSE Board 1 20 1 5 3 Control Panel C137 PNL 1 20 1 5 4 Printer Mechanism 4 60 1 21 155 5 IOUS IG eel 1 21 Rev A 1 i Figure 1 1 Figure 1 2 Figure 1 3 Figure 1 4 Figure 1 5 Figure 1 6 Figure 1 7 Figure 1 8 Figure 1 9 List of Figures Exterior View of the Stylus Pro XL Nozzle Configuration Printable Area for Cut Sheet Printable Area for Envelope Adjustment Lever Setting Temperature Humidity Range Data Transmission Timing Control Panel Appearance C162 MAIN Board Component Layout Figure 1 10 C137 PSB PSE Board Component Layout Figure 1 11 Printer Mechanism M 4A60 Table 1 1 Table 1 2 Table 1 3 Table 1 4 Table 1 5 Table 1 6 Table 1 7 Table 1 8 Table 1 9 Table 1 10 Table 1 11 Table 1 12 Table 1 13 Table 1 14 Table 1 15 Table 1 16 Table 1 17 Table 1 18 Table 1 19 List of Tables Interface Cards Print Speed and Printable Columns Cha
43. 869 Greek MAZOWIA Poland Code MJK Czecho Slovakia ISO 8859 7 Greek 3 3 3 13 0 3 43 3 JOJO JOJO JOJO lO lOO JOJO x X X X X X X Xx X x 3 3 3 3 3 3 33 3 3 3 O Supported x Not supported Fonts Bitmap LQ fonts EPSON Roman 10 cpi 12 cpi 15 cpi Proportional EPSON Sans Serif 10 12 15 Proportional EPSON Courier 10 12 15 EPSON Prestige 10 12 15 EPSON Script 10 12 15 Scalable fonts EPSON Roman 10 5 points 8 32 points in units of 2 points EPSON Sans Serif 10 5 points 8 32 points in units of 2 points EPSON Roman T 10 5 points 8 32 points in units of 2 points EPSON SansSerif H 10 5 points 8 32 points in units of 2 points 2 Control codes ESC P 2 and expanded raster graphics code Input data buffer 64KB 1 4 Rev A Stylus Pro XL Product Description 1 2 2 Paper Handling Specifications Feeding method Friction feed paper is fed from the built in auto sheet feeder ASF Notes following operations are not allowed 1 Heverse feeding within 3 mm 0 12 in from the top edge of the paper or 16 mm 0 63 in from the bottom edge of the paper 2 Heverse feeding beyond 7 9 mm 0 3 in Line spacing 1 6 inch feed 1 8 inch feed or programmable with a 1 360 inch minimum increment Paper path Cut sheet Buil
44. AR 12 660 PLUNGER PLUNGER ASSY 661 EXTENSION SPRING 3 35 g EXTENSION SPRING 3 35 662 EXTENSION SPRING 0 196 g EXTENSION SPRING 0 196 663 TORSION SPRING 0 000206 g TORSION SPRING 0 000206 664 SUPPORT EARTHPLATE EARTHPLATE SUPPORT 665 PAPER EJECT ROLLER B ROLLER ASSY PAPER EJECT B 666 PAPER EJECT GUIDE GUIDE PAPER EJECT 667 PAPER EJECT HOLDER C HOLDER ASSY PAPER EJECT C 668 DRIVEN ROLLER HOLDER HOLDER ROLLER DRIVEN 669 DRIVEN HOLDER ROLLER DRIVEN 670 PLUNGER COVER COVER PLUNGER 700 ANGULAR SPACER COLOR SPACER ANGULAR YMC COLOR 700 YMC ANGULAR SPACER B COLOR SPACER ANGULAR YMC B COLOR 700 ANGULAR SPACER C COLOR SPACER ANGULAR YMC C COLOR 700 ANGULAR SPACER D COLOR SPACER ANGULAR YMC D COLOR 700 YMC ANGULAR SPACER E COLOR SPACER ANGULAR YMC E COLOR 701 ANGULAR SPACER BLACK SPACER ANGULAR BK BLACK 701 ANGULAR SPACER B BLACK SPACER ANGULAR BK B BLACK 704 BK ANGULAR SPACER C BLACK SPACER ANGULAR BK C BLACK 701 ANGULAR SPACER D BLACK SPACER ANGULAR BK D BLACK 701 ANGULAR SPACER E BLACK SPACER ANGULAR BK E BLACK 702 LINEAR SPACER BLACK SPACER LINEAR BLACK 702 LINEAR SPACER B BLACK SPACER LINEAR B BLACK 702 LINEAR SPACER C BLACK SPACER LINEAR C BLACK 702 LINEAR SPACER D BLACK SPACER LINEAR D BLACK 702 LINEAR SPACER E BLACK SPACER LINEAR E BLACK 702 LINEAR SPACER F BLACK SPACER
45. Block Resistor 3 10 Rev A Stylus Pro XL Disassembly and Assmbly 3 1 OVERVIEW This section describes procedures for disassembling the main components of this printer Unless otherwise specified disassembled units or components can be reassembled by reversing the disassembly procedure Therefore no assembly procedures are included Precautions for any disassembly or assembly procedure are described under the heading Disassembly Assembly Points Adjustments required after assembling the unit are described under the heading Required Adjustments 3 1 1 Precautions for Disassembling the Printer See the precautions below when disassembling the printer WARNING Disconnect the power cable before disassembling or assembling the printer Wear protective goggles to protect your eyes from ink If ink gets in your eye flush the eye with fresh water and see a doctor immediately T If ink comes into contact with your skin wash it off with soap and water If irritation occurs contact a physician lithium battery is installed on the C162 MAIN Board of this printer Be sure to observe the following instructions when servicing the battery 1 Keep the battery away from any metal or other batteries so that electrodes of the opposite polarity do not come in contact with each other Do not heat the battery or put it near fire Do not solder on any part of the battery Doing so may result in lea
46. Color Print capacity Life Storage temperature Dimension W x D x H Color Type Colors Print capacity Life Storage temperature Dimension W x D x H Notes Exclusive cartridge Black 1 2 million characters 315 dots character Roman 10 cpi The effective life from the indicated production date is 2 years 30 40 C 22 104 P Storage month or less at 40 C 104 30 60 C 22 140 P Transit a month or less at 40 C 104 30 60 C 22 140 F Transit 120 hours or less at 60 C 140 26 9 x 67 4 x 41 8 mm 1 06 x 2 65 x 1 65 in Exclusive cartridge Cyan magenta yellow 28 sheets color A4 or letter full image printing at 360 dpi The effective life from the indicated production date is 2 years 30 40 C 22 104 P Storage month or less at 40 C 104 30 60 C 22 140 Transit a month or less at 40 C 104 30 60 C 22 140 P Transit 120 hours or less at 60 C 140 54 0 x 67 4 x 41 8 mm 2 13 x 2 65 x 1 65 in The ink cartridge cannot be refilled it is the only consumable article Do not attempt to use an ink cartridge that has exceeded its ink life Ink freezes at 3 C 37 F however it can be used after it returns to room temperature Rev A 1 7 Product Description Stylus Pro XL 1 2 5 Electrical Specifications Table 1 7 Rated Electrical Ranges Specification 120 V Version
47. DRIVEN ROLLER ROLLER DRIVEN 547 DRIVEN ROLLER HOLDER HOLDER ROLLER DRIVEN 548 DRIVEN ROLLER C ROLLER DRIVEN C 549 DRIVEN PULLEY LEVER LEVER ASSY PULLEY DRIVEN 550 PARALLEL ADJUST BUSHING BUSHING PARALLEL ADJUST 551 DRIVEN ROLLER SUPPORT ROLLER DRIVEN SUPPORT 552 SUB FRAME FRAME ASSY SUB 553 PAPER EJECT HOLDER HOLDER ASSY PAPER EJECT 554 IPAPER HOLDER B HOLDER ASSY PAPER EJECT B 555 PAPER FRAME FRAME PAPER EJECT 556 PAPER EJECT ROLLER ROLLER ASSY PAPER EJECT 557 PAPER EJECT CLUTCH CLUTCH PAPER EJECT 558 EDGE GUIDE SLIDER SLIDER EDGE GUIDE 559 BUSHING 6 mm BUSHING 6 560 HEAD FASTENING PRESSURE PLATE PRESSINGPLATE FASTEN HEAD Rev A A 23 Appendix Stylus Pro XL Table A 14 Part No Reference Table Continued Ref No Description PPL Name 561 BK HEAD BASE BASE HEAD BK 562 HEAD BASE BASE HEAD YMC 563 UPPER HEAD CABLE HOLDER HOLDER HEAD CABLE UPPER 564 LOWER HEAD CABLE HOLDER HOLDER HEAD CABLE LOWER 565 CARTRIDGE LEVER LEVER ASSY CARTRIDGE BK 566 YMC CARTRIDGE LEVER LEVER ASSY CARTRIDGE YMC 567 COVER CAP CAP COVER CR 568 PUMP SPEED UP SHAFT SHAFT SPEED UP PUMP 569 OIL PAD PRESSURE PLATE PRESSING PLATE OIL PAD 570 KNOB KNOB 571 KNOB SHAFT SHAFT KNOB 572 DRIVEN ROLLER E ROLLER ASSY
48. EPSON COLOR INKJET PRINTER Stylus Pro XL SERVICE MANUAL EPSON 4004677 Chapter 1 Product Description Table of Contents 1 4 FEATURES 1 1 1 2 SPECIFICATIONS 1 3 1 2 1 Printing Specifications s nocet ew EE A RR SPEED ERES Ss 1 3 1 2 2 Paper Handling SpecificationSs 1 5 1 2 3 Paper Specifications 1 5 1 2 4 Ink Cartridge Specifications 1 7 1 2 5 Electrical SpecificationSs 1 8 1 2 6 Environmental Conditions 1 8 1 27 Ca DIY oe entertain quos Senes Cad auratus bu mh bet 1 9 1 2 8 Safety 1 9 12 9 Physical Specifications Eu ua ee 1 9 1 3 INTERFACE SPECIFICATIONS 1 10 1 3 1 Serial Interface Specifications 1 10 1 3 2 Parallel Interface Specifications 1 12 1 4 OPERATIONS 1 13 124 3 Gontrob Panels eus s eto Sa huasipi ee exe taya 1 13 1 4 2 Panel Operation at Power On 1 14 14 3 SOUIPIOS ani Ee un ete aye 1 15 1 4 8 1 Default Setting 1 15 1 4 3 2 Changing the Default Settings 1 16 4 4 Error Conditions ice res t iret ae noe Ac ed E em 1 18
49. LY BOARD FOR 120 V PONER SURELY 300 POWER SUPPLY BOARD BOARD ASSY POWER SUPPLY FOR 220 V 240 V FOR 220V 240V 330 HARNESS HARNESS 400 POWER CABLE VD31303SA 10A 230 POWER CABLE VD31303SA 10A V 230V 401 POWER CABLE VD31303SA 10A POWER CABLE BS31303SA SR 10A 240 V 240V 402 AC CABLE 240 V AC CABLE 240V 403 POWER CABLE VD00303SA 10A POWER CABLE VD00303SA 10A 220 V 220V 403 POWER CABLE 220 V POWER CABLE 220V 410 POWER CABLE POWER CABLE ASSY 411 POWER CABLE 100 V POWER CABLE ASSY 100V 412 HARNESS 220 V 240 VAC INLET HARNESS 220V 240V AC INLET 450 PANEL BOARD BOARD ASSY PANEL 500 PRINTER MECHANISM M 4A60 PRINTER MECHANISM M 4A60 501 DRIVEN PULLEY PULLEY DRIVEN 502 BASE FRAME FRAME ASSY BASE 503 PE DETECTOR 0 V 0 A OW DETECTOR PE 0V 0A 0W 504 LEFT FRAME FRAME ASSY LEFT 505 MIDDLE FRAME FRAME ASSY MIDDLE 506 RIGHT MAIN FRAME FRAME MAIN RIGHT 507 BOTTOM MAIN FRAME FRAME MAIN BOTTOM 508 CARRIAGE B CARRIAGE ASSY B 509 GEAR CHANGE LEVER LEVER CHANGE GEAR 510 SUPPORT CHANGE LEVER LEVER CHANGE SUPPORT 511 PAPER LOAD SHAFT SHAFT PAPER LOAD 512 TIMING BELT TIMINGBELT 513 BKHEAD CABLE CABLE HEAD BK 514 YMC HEAD CABLE CABLE HEAD YMC 515 PRINT HEAD IJ48 0CA COLOR PRINT HEAD IJ48 0CA COLOR 516 PRINT HEAD 164 0 BLACK PRINT HEAD IJ64 0A A BLACK 517 FRONT APER GUIDE PAPER GUIDE FRONT 518 PAPER LOADING
50. MJK ISO 8859 7 ISO Latin 1T Bulgaria Low running cost The figure below shows the Stylus Pro XL Front Cover Printer Cover Knob Control Panel Paper Supply Tray Tray Interface Card Serial Interface Cover Connector 4 Parallel Interface Connector AC Inlet Figure 1 1 Exterior View of the Stylus Pro XL Rev A 1 1 Product Description 1 2 Stylus Pro XL Table 1 1 Interface Cards Interface Card Model Number Serial interface card C823051 C823061 32KB serial interface card C823071 C823081 32KB parallel interface card 82310 32KB IEEE 488 interface card C82313 LocalTalk interface card C82312 Twinax interface card C82315 Coax interface card 823142 The asterisk represents the last digit which varies by country Rev A Stylus Pro XL Product Description 1 2 SPECIFICATIONS This section provides statistics and other detailed information for the printer 1 2 1 Printing Specifications Print system On demand ink jet system Nozzle configuration 64 nozzles 16 x 4 staggered monochrome 48 nozzles 16 x 3 staggered color Yellow Cyan Magenta RowD mw RowC Row B Row A lt 72 360 8 UV Dn LU vns I 1 860 A IE E m to eS Peete 2 a E Tis 1 90 on i D D poer sew a re Aere
51. Motor N Printer Mechanism M 4A60 Figure A 1 Interconnection of Major Components Appendix Stylus Pro XL Table A 1 Connector Summary Location i Description Centronics parallel I F Type B parallel I F RS 422 serial I F There is no connector CN4 Power supply from PS board Carriage motor phase output PF PM motor phase output Paper end sensor Carriage home position sensor Control panel to C137 PNL Black head nozzle selector and common driver Color head nozzle selector and common driver ASF plunger AC inlet L N DC output 5 V 35 V to C162 MAIN Description Strobe signal Data strobe signal ACK signal Busy signal Paper end signal Printer select signal Auto line feed signal Not connected Ground Frame ground 5 VDC Ground INIT signal Error signal Ground Not connected 5 VDC Select in signal A 2 Rev A Stylus Pro XL Appendix Table A 3 Connector Pin Assignments CN2 Description Power supply for I F drive Transmit data Ready signal Receive data Not connected Reset signal Inhabit signal Command request signal Write ready signal Read request signal High write signal Read signal Chip select signal Ground Address bus signal 3 0 Data bus signal 15 8 Table A 4 Connector Pin Assignments CN3 Description Data terminal ready Not connected Transmit data Ground Receive data
52. NA P W 4 2x0 3x8 L NA 633 PLAIN WASHER 3x0 5x8 F ZN PLAIN WASHER 3x0 5x8 F ZN 634 PLAIN WASHER 6 1x0 3x12 L N A PLAIN WASHER 6 1x0 3x12 L NA 635 PLAIN WASHER 5 07x0 3x10 L NA PLAIN WASHER 5 07x0 3x10 L NA 637 SPRING WASHER 3x0 7x5 9 F ZN SPRING WASHER 3x0 7x5 9 F ZN 638 SPRING PIN 2x14 SPRING PIN 2x14 639 BEARING BALL BEARING 640 WIRE BAND WIRE BAND 641 WIRE SADDLE WIRE SADDLE 642 CLAMP CLAMP 643 RETAINING RING 3 RETAINING RING TYPE E 3 644 RETAINING RING TYPE E 4 RETAINING RING 4 645 RETAINING RING 5 RETAINING RING TYPE E 5 646 RETAINING RING TYPE E 2 3 RETAINING RING TYPE E 2 3 647 CB SCREW M3x6 C B SCREW M3x6 648 CBSSCREW 3x6 F ZN C B S SCREW 3x6 F ZN 649 SCREW M3x6 C B S O SCREW M3x6 Rev A A 25 Appendix Stylus Pro XL Table A 14 Part No Reference Table Continued Ref No Description PPL Name 650 CBBSCREW M3x12 C B B SCREW M3x12 652 CBS SCREW M3x8 F UC C B S SCREW M3x8 F UC 653 CPB SCREW 3x15 F ZN C P B SCREW 3x15 F ZN 654 HEAD MOUNTING PRESSURE PLATE PRESSING PLATE MOUNTING HEAD 655 PFROLLER ROLLER PF 656 SPURGEAR 9 mm SPUR GEAR 9 657 SPURGEAR 27 mm SPUR GEAR 27 659 SPUR GEAR 12 mm SPUR GE
53. NT When you replace the main board initialize EEPROM contents as follows 1 Reassemble the printer 2 Turn the printer on while holding down the Alt Font Load Eject and Pause buttons on the control panel It is possible to misconnect the cables When reconnecting the cables from connectors CN6 CN7 and connectors CN11 CN12 of the C162 MAIN board see the following instructions 1 CN11 Printhead cable white mark rear direction CN12 Printhead cable blue mark rear direction 2 CN6 Carriage motor cable red mark the red mark indicates pin 1 of CN6 Paper feed motor cable black mark the black mark indicates pin 1 of CN7 REQUIRED ADJUSTMENT When replacing the main controller board adjust both the head gap and the bidirectional adjustment alignment and save the adjusted parameters into the EEPROM on the C162 MAIN Board See Chapter 4 When you replace the main board the parameters in the internal timer are all reset Therefore it is possible for printing to become abnormal At this time perform the cleaning operation using the control panel or command Refer to Chapter 4 until the printing becomes normal CAUTION The shield plates for the C162 MAIN Board and C137 PSB PSE Board have sharp edges so take care in handling them REV A 3 6 Stylus Pro XL Disassembly and Assmbly 3 2 4 Printer Mechanism M 4A10 Removal 1 Rem
54. SE Board to the lower case and remove a CBN O M3x6 screw fixing the earth line from the AC cable to the earth plate 5 Remove the wire harness for the motors in the locking tab on the shield plate and take the shield plate out by pulling upward toward the back of the printer 6 Remove the power supply unit by pulling it upward toward the back of the printer CAUTION The shield plates of C137 PSB PSE and C162 MAIN boards have sharp edges so take care in handling them CBS M3x8 C162 MAIN Board C137 PSB Board CBB M3x12 CBS O M36 Figure 3 4 Power Supply Unit Removal 3 4 REV A Stylus Pro XL Disassembly and Assmbly 3 2 3 Main Controller C162 MAIN Board Removal 1 Remove the upper case see Section 3 2 1 Remove the grounding plate from the shield plate Remove the 4 CBB M3x12 screws securing the shield plate to the lower case Remove the 2 CBB M3x12 screws securing the Type B interface cover to the lower case Disconnect the cables from connectors CN5 CN6 CN7 CN8 CN9 CN10 CN11 CN12 and CN13 of the C162 MAIN Board 6 Remove the 4 CBB screws 2 M3x12 and 2 M3x8 securing the main controller to the lower case and then remove the C162 MAIN Board gr gsm CBB 3 12 Grounding Plate Grounding Plate Shield Plate CBS M3x8 CBB M3x12 Figure 3 5 Main Controller Removal REV A 3 5 Disassembly and Assembly Stylus Pro XL ASSEMBLY POI
55. Table A 11 Connector Pin Assignments CN11 Description Ground Clock signal for black head Ground Latch signal for black head Ground Black head serial data output Ground Black cartridge out sensor Power supply for cartridge out sensor Not connected Ground Common voltage for printhead drive Description Ground Clock signal for color head Ground Latch signal for color head Ground Color head serial data output Ground Color cartridge out sensor 1 2 3 4 5 6 7 8 9 Power supply for cartridge out sensor mn Thermistor signal Re a Ground mn ge N N Common voltage for printhead drive Description Power supply for ASF plunger Paper loading signal Rev A A 5 Stylus Pro XL Appendix Table A 14 Part No Reference Table Ref No Description PPL Name 100 LOWER HOUSING HOUSING LOWER 101 FOOT FOOT 102 LOWER SHIELD PLATE SHIELD PLATE LOWER 103 UPPER SHIELD PLATE SHIELD PLATE UPPER 104 P S SHIELD PLATE SHIELD PLATE P S 105 GROUNDING PLATE GROUNDING PLATE 106 PAPER SUPPORT COVER B COVER PAPER SUPPORT B 107 UPPER HOUSING HOUSING UPPER 108 REAR PRINTER COVER COVER PRINTER REAR 109 PAPER SUPPORT PAPER SUPPORT ASSY 110 EDGE GUIDE EDGE GUIDE 111 GROUNDING PLATE D GROUNDING PLATE D 112 PAPER SUPPORT SUPPORT PLATE SUPPORT PLATE PAPER SUPPORT 115 LOGO PLATE B LOGO PLATE
56. Turn off the printer 4 4 Black Line Head Gap Adjustment No 0 Color Magenta Line Figure 4 1 Head Gap Adjustment Sample Rev A Stylus Pro XL 4 1 4 Black Head Angle Adjustment The black head angle adjustment is required when the black head is replaced or disassembled If this adjustment is not correct a white banding problem may occur or the color head timing may not match the black head timing The following figure illustrates the black head angle adjustment Adjustments The black head angle is adjusted with linear and angular spacers A linear spacer is attached to both sides of the head base and an angular spacer is attached only to the right side of the head base Spacers for the black head come in different shapes for the thickness needed The following figure shows the relationship between the shape and thickness Black Head Angle Adjustment Concept Figure 4 2 Black Head Angular and Linear Spacers Angular Spacers For Black Head Head Base Black Head Reverse Side Carriage N Z NY DE AZ 44 Linear Spacer Spacer Setting Position Angular Spacer Linear Spacers Only Use for Black Head Spacer Name Thickness Shape Spacer Name Thickness Shape CE
57. VIEW 3 1 3 1 1 Precautions for Disassembling the 3 1 3 2 DISASSEMBLY AND ASSEMBLY 3 2 3 2 1 Upper Case Removal 3 3 3 2 2 Power Supply Unit C137 PSB PSE Board Removal 3 4 3 2 3 Main Controller C162 MAIN Board Removal 3 5 3 2 4 Printer Mechanism M 4A60 Removal 3 7 3 2 5 Printer Mechanism Disassembly 3 8 3 2 5 1 Printhead Unit Removal 3 8 3 2 5 2 Carriage Unit Removal 3 12 3 2 5 3 Pump Unit 3 13 3 2 5 4 Cleaner Head Replacement 3 14 3 2 5 5 CR Motor Removal 3 15 3 2 5 6 PF Motor Removal sse oe bie re ayu Q Cth ei 3 15 3 2 5 7 Carriage Home Position HP Sensor Removal 3 16 3 2 5 8 Paper End PE Sensor Removal 3 16 3 2 5 9 Paper Feed Roller Assembly Removal 3 17 3 2 5 10 Upper Frame Removal 3 18 Rev A 3 List of Figures Figure 3 1 Disassembly Flowchart 3 2 Figure 3 2 C137 PNL Control Panel Removal 3 3 Figure 3 3 Upper Case Removal 3 3 Figure 3 4 Power Supply Unit Removal
58. andle it only by holding the edges of the printhead When you replace the printhead or the printer mechanism you must replace the block resistor see Table 3 2 AD USTMENT REQUIRED Platen gap adjustment see Chapter 4 3 12 REV A Disassembly and Assembly Stylus Pro Service Manual 3 2 5 3 Pump Unit Removal 1 2 3 4 Remove the printer mechanism See Section 3 2 4 Remove the carriage unit See Section 3 2 5 2 Remove the CBS M3x6 screw securing the pump unit to the bottom frame Push the pump unit outward while releasing the tab at the bottom side of the pump unit and then lift up the pump unit ag PE CBS M3x6 Bottom Frame Pump Unit Figure 3 14 Pump Unit Removal ev Disassembly and Assembly Stylus Pro XL 3 2 5 4 Cleaner Head Replacement 1 Remove the printer mechanism see Section 3 2 4 2 Use tweezers to unhook the cleaner head from the hook on the cleaning lever CAUTION Keeping the cleaner head clean is extremely important to keep the ink injection system working properly in the printhead and it directly affects printing quality Therefore handle the cleaner head very carefully and observe the following precautions Never touch the cleaner head with your bare hands B When attaching the cleaner head to the pump unit wear gloves and use clean tweezers to handle it C
59. angular spacer BK 0 05 linear spacer K 0 05 angular spacer BK B 0 10 linear spacer J 0 12 angular spacer BK G 0 15 linear spacer I 0 19 angular spacer BK D 0 20 Jex linear spacer 0 26 angular spacer BK E 0 25 linear spacer B 0 33 linear spacer C 0 40 linear spacer D 0 47 linear spacer E 0 54 i linear spacer F 0 61 linear spacer 0 68 linear spacer H 0 75 Figure 4 3 Types of Spacers and Relationship between Shape and Thickness Rev A 4 5 Adjustments Stylus Pro XL 1 Connect the PC to the target printer and turn the printer on 2 Execute BASIC on the PC and run the program VERxxx BAS 1 Destination Setting 2 Head Angle Confirmation Pattern Printing Black Head Spacer Selection Head Vertical Position Confirmation Head Gap Adjustment Bi D Adjustment Internal Timer Reset END NO of OO 3 When the main menu appears choose Head Angle Confirmation Pattern Printing by typing 2 and ENTER The printer prints the check pattern along with the sample name When replacing both the black and color heads always adjust the color head angle first The black head angle is based on the color head angle After you replace the black head and print the black head angle pattern you only have to insert an angular spacer if the pattern is incorrect 4 The printer prints a pattern like one in the following sample Only the
60. aste ink drain tank overflow v NO Replace the waste ink absorbing material and reset the protect counter See Chapter 6 v Check ink cartridge sensor and if bad replace Rev A YES Does the SR YES carriage move smoothly ee y Troubleshooting Check CR motor and drivers If they are OK replace the C162 MAIN board Is the problem corrected Refer to the section describing repair of the printer mechanism 5 5 Troubleshooting 5 2 3 Failure occurs during printing START Run the self test Does the self S test print YES NO Stylus Pro XL Perform the color or black head cleaning ee Is the problem corrected EN YES d Is print t aiy bad d v Adjust the bidirectional print alignment or readjust the head arrangement adjustment See Chapter 4 See the section describing repair of the printer mechanism sthe problem corrected EC 7 YES J 5 6 m Replace the C162 MAIN board p all cables connected to the C162 EN board firmly p Connect the cables correctly we YES Is the problem corrected Check all motors drivers and printhead for shorts If they are OK re
61. ation No Location Normal Monochrome 12 d Color RM5 Micro Monochrome R xx RM11 u Color R xx x RM4 Disassembly and Assembly Stylus Pro XL 3 2 5 Printer Mechanism Disassembly The procedures described in this section explain how to remove the components within the printer mechanism 3 2 5 1 Printhead Unit Removal 1 2 Remove the printer mechanism see Section 3 2 4 Move the carriage to the middle of the printer while pressing the hook that fixes the carriage unit to the home position Pull the ink cartridge clamp toward you and remove the ink cartridge CAUTION When removing the ink cartridge always install a new cartridge immediately after removing the old one When the ink cartridge is replaced the printer performs the ink cartridge replacement operation automatically The exclusive cartridge is Monochrome 1020626 YMC 1020627 Ink cartridges should never be kept longer than 6 months 4 5 Push the 2 hooks from the inside of ink cartridge holder with tweezers and push down the ink cartridge clamp monochrome color to remove the clamps from ink cartridge holder Remove the3 CBB M3x11 screws and 3 plain washers securing the ink cartridge holder to the carriage base and then lift the ink cartridge holder out of the carriage base sliding a little toward left Ink Cartridge Fixing Lever 1 SS Cartridge Holder Figure 3 7 Ink Cartridge C
62. ation position Pressing Alf again causes the carriage to return to the home position Cycles through the font choices Pressing the Font button while holding down the Alt button causes the carriage to move to the gap adjustment position Pressing the Alt button again causes the carriage to return to the home position Selects either economy or condensed printing mode Pressing the Economy Condensed button while holding down the Alt button starts the color printhead cleaning cycle Either loads a new sheet into the printer or ejects paper currently in the paper path Pressing the Load Eject button while holding down the Alt button starts the black printhead cleaning cycle Stops printing temporarily or resumes printing if it has been stopped temporarily Pressing Pause while holding down the All button resets the printer Product Description Stylus Pro XL Indicators Operate On when the printer is on Blinks during power on and off sequence Data On when print data is in the input buffer Data and Pause lights blink if an error occurs Paper Out On when the printer is out of paper Blinks when a paper jam occurs No Ink Cartridge On when ink cartridge is out Economy On when economy printing mode is selected Condensed On when condensed printing mode is selected Font These LEDs indicate the selected font Pause On when printing is paused 1 4 2 Panel Operation at Power On You can activate the following modes by doing the follo
63. ck pattern with the sample name WARNING When replacing both the black head and color head always adjust the color head angle first The black head angle and the black color head vertical position adjustments are based on the color head angle adjustment Stylus Pro XL Adjustments Angular spacers for the color head come in five thicknesses each having its own shape The following figure shows the relationship between the shape and thickness Since the color head is not equipped with a linear spacer the angle adjustment is decided only by the angular spacer specifically designed for the color head which is placed under the left side of the head base Angular Spacer for Color Head Spacer Name Thickness Shape angular spacer YMC 0 30 angular spacer 0 35 angular spacer YMC C 0 40 angular spacer YMC D 0 45 angular spacer YMC E 0 50 Figure 4 14 Relationship between the Shape and Thickness 4 InFigure 4 13 pay attention to the position of A and B while you reset the left angular spacer The replacement procedure is explained beginning in step 5 r Magenta Magenta Cyan Check Cyan positions A B Position A B A B A B Replace the right Replace the right angular spacer angular spacer with a thicker one with a thinner one Figure 4 15 Spacer Se
64. e 5 1 Table 5 3 Sensor Test Points 5 2 Table 5 4 Error Codes se yaa s aha ee ca ee 5 2 Table 5 5 Symptoms and 5 5 3 Table 5 6 Repair of the C137 5 9 Table 5 7 Repair of the C164 5 10 Table 5 8 Repair of the Printer Mechanism Rev A Stylus Pro XL Troubleshooting 5 1 OVERVIEW The printer may exhibit different symptoms for the same problem which makes troubleshooting more difficult However this section provides simple and effective ways to facilitate troubleshooting The following flowchart illustrates the main steps of the troubleshooting process START s UNIT LEVEL TROUBLESHOOTING UNIT REPAIR UNIT REPAIR UNIT REPAIR C137 PSB PSE BOARD C162 MAIN BOARD M 4A60 MECHANISM ASSEMBLY AND ADJUSTMENT END Ae 2 Figure 5 1 Troubleshooting Process Flowchart Table 5 1 Motor Resistances CR Motor 10 00 10 At 25 C 77 F PF Motor 11 50 10 At 25 77 F Table 5 2 Sensor Status Sensor Signal Level CN8 Paper exists PE Sensor Pin 1 PE to Pin 2 GND No paper paper end CN11 Black cartridge exists BCO Sensor Pin 8 BCO to Pin 7 GND No black cartridge CN12 Color cartridge exists CCO Sensor Pin 8 CCO to Pin 7 GND No color cartid
65. e area Cut sheets B C Left Margin Right Margin N A Top Margin Printable Area D Margin N Figure 1 3 Printable Area for Cut Sheets Envelopes B C Left Margin Right Margin A Printable Area EY D Bottom Margin Figure 1 4 Printable Area for Envelopes Notes minimum top margin 3 mm 0 12 in B The minimum left margin 3 mm 0 12 in C The minimum right margin is A3 US B size 3mm 0 12 in size 3 mm 0 12 in A4 size 3 mm 0 12 in A4 Landscape size 3 mm 0 12 in USB size 9 mm 0 35 in Legal size 9 mm 0 35 in Letter size 9 mm 0 35 in Letter size Landscape size 9 mm 0 35 in Executive size 9 mm 0 35 in Statement size 9 mm 0 35 in Envelopes 3 mm 0 12 in D The minimum bottom margin 14 mm 0 55 in 1 6 Rev A Stylus Pro XL Setting the adjust lever Product Description The adjust lever on the carriage unit must be set to the proper position for the paper thickness as shown in Table 1 6 Lever Position LEFT Vertical Table 1 6 Adjust Lever Settings Paper Thickness 0 08 0 11 mm h Cut Sheets 0 003 0 004 in RIGHT Horizontal Envelopes Less than 0 5 mm 0 020 in Envelopes Carriage Unit Figure 1 5 Setting the Adjust Lever 1 2 4 Ink Cartridge Specifications Black Type
66. e current duty data for the motor speed of each printing sequence SLA7041MS can select the reference voltage itself based on these three current duty data Also it receives these signals by 2 serial transmission lines for 2 motor s phases phase A and phase B Due to this the carriage motor can drive the micro step sequence min 1 720 inches E05A96 SLA7041MS I2 C15 29 CRCLK I 13 STBA E STBB e DATA A 820 P DATA B o 90 CRHLD 56 ASA 105 RSB Bj NPN Tr E Q27 m 1 Figure 2 20 Carriage Motor Circuit Block Diagram Four bit serial data is read by the SLA7041MS motor driver with four clock counts from the E05A96 IC2 clock Each bit is read at the falling edges of these clock pulses Due to this received serial data is placed in the shift register and then shifts the latch register When the STROBE pulse becomes active from the E05A96 IC2 the serial data is moved into the reference voltage selection circuit and the voltage is changed Therefore when the printer is in the constant speed mode this STROBE pulse becomes inactive The following table indicates the current duty of each carriage motor speed mode Table 2 8 Serial Data Contents Vref typical Vref x 1 3 Vref 5 V x 55 5 x 10095 REV A 2 17 Operat
67. e of Contents A 1 CONNECTOR SUMMARY A 1 A 2 CIRCUIT DIAGRAM A 7 A 3 CIRCUIT BOARD COMPONENT LAYOUT A 14 A 4 EXPLODED DIAGRAM A 18 List of Figures Figure 1 Interconnection of Major Component A 1 Figure A 2 C162 MAIN Board Circuit Diagram 1 A 7 Figure C162 MAIN Board Circuit Diagram 2 A 9 Figure 4 C137 PSB Board CircuitDiagram A 11 Figure 5 C137 PSE Board CircuitDiagram A 12 Figure 6 C137 PNL Board CircuitDiagram A 13 Figure 7 C162 MAIN Board Component Layout 1 A 14 Figure A 8 C162 MAIN Board Component Layout 2 A 15 Figure A 9 C137 PSB Board Component Layout A 16 Figure A 10 C137 PSE Board Component Layout A 16 Figure A 11 C137 PNL Board Component Layout A 17 Figure 12 Exploded Diagram for Stylus Pro XL 1 A 18 Figure A 13 Exploded Diagram for Stylus Pro XL 2 A 19 Figure 14 Exploded Diagram for Stylus Pro XL 3 A 20 List of Table Table 1 Connector 2 Table 2 Connector Pin Assignments CN1 A 2 Table Connector Pin Assignments CN2 Table 4 Connector Pin Assignments
68. elected for each printhead Refer to Table 3 2 Table 3 2 Insertion Location of the Block Resistors Mode Head Indication No Location Monochrome M xx RM12 Normal Color M xx RM5 Monochrome R xx RM11 Micro Color R xx x RM4 3 10 REV A Stylus Pro XL Disassembly and Assmbly REQUIRED USTMENT When removing or changing the black head the following adjustments are needed 1 Black head angle adjustment see Section 4 1 4 2 Black Color head vertical adjustment see Section 4 1 5 3 Head gap adjustment see Section 4 1 3 4 Bidirectional alignment adjustment see Section 4 1 2 When removing or changing the color head the following adjustments are needed 1 Color head angle adjustment see Section 4 1 6 2 Black Color head vertical adjustment see Section 4 1 5 3 Head gap adjustment see Section 4 1 3 4 Bi D alignment adjustment see Section 4 1 2 When removing or changing both heads the following adjustments are needed 1 Color head angle adjustment see Section 4 1 6 2 Black head angle adjustment see Section 4 1 4 3 Black Color head vertical adjustment see Section 4 1 5 4 Head gap adjustment see Section 4 1 3 5 Bidirection alignment adjustment see Section 4 1 2 When removing the color or black head do not lose the spacer attached to each head This spacer modifies the angle error that occurs during manufacturing
69. elt Pulley mam Figure 2 4 Carriage Drive Mechanism REV A 2 5 Operating Principles Stylus Pro XL 2 2 2 1 Platen Gap Adjust Lever The platen gap adjust lever which is attached to the carriage unit needs to be set to an appropriate position for the paper thickness To change the platen gap put the printer in the PAUSE state then press the Font button while holding down the Alt button The carriage unit moves the platen gap position automatically Table 2 3 Platen Gap Adjust Lever Position Cut sheets Horizontal A 0 mm Envelopes Vertical B 40 6 mm Platen Gap Adjust Lever Cs gt Il B A Y 7 EN Plain Paper or Bond Paper Envelope or Transparency Figure 2 5 Platen Gap Adjust Lever Operation 2 2 3 Paper Feed Mechanism This printer s paper feed mechanism can feed paper only from the built in ASF auto sheet feeder The paper feed drive motor is a 4 phase 96 pole hybrid type stepping motor that directly drives the paper feed mechanism paper advancing operation paper pickup operation This motor also drives the pump mechanism but only when the printer is in the cleaning state The paper feed drive method is driven by the 2 2 phase drive method except the paper feed drive sequence 2 W1 2 phase Table 2 4 Paper Feed Drive Motor S
70. ensor Cable Figure 3 19 PE Sensor Removal ev 15 Stylus Pro XL Disassembly and Assmbly 3 2 5 9 Paper Feed Roller Assembly Removal 1 Remove the printer mechanism see Section 3 2 4 2 Remove the carriage unit see Section 3 2 5 2 3 Remove the pump unit see Section 3 2 5 3 4 Remove the tension spring holding the tension roller assembly to the sub frame 5 Remove the tension wire on the left side frame holding the tension roller assembly to the left side frame 6 Remove a CBB M3x8 screw securing the tension roller assembly to the sub frame and remove the tension roller assembly Tension Wire Tension Roller Eject Paper CBB M3x8 Assembly Roller Figure 3 19 Tension Roller Assembly Removal 7 Release the 2 bushings securing the paper feed roller assembly to both the left side frame and the sub frame Then remove the paper feed roller assembly Paper Feed Roller Figure 3 20 Paper Feed Roller Assembly Removal REV A 3 17 Disassembly and Assembly Stylus Pro XL 3 2 5 10 Upper Frame Removal 1 Remove the printer mechanism see Section 3 2 4 2 Remove the carriage unit see Section 3 2 5 2 3 Remove the E ring securing the knob shaft to the sub frame then remove the knob with the knob shaft from the right side frame 4 Remove the 5 CBN M3x5 screws securing the upper frame to both side frames or the sub frame Then remove the upper frame with 4 PF support rollers 5 Remo
71. es used for controlling ink system operation 2 4 2 1 Protect Counter Protect counter A and Ink Amount Counter R values are stored in the EEPROM on the main board and while the printer is on this data is saved in the RAM on the main board Protect Counter A This counter is used to manage the total amount of drained ink If the counter value is equal to or exceeds 51000 the printer indicates an error on the control panel and maintenance is required This counter is incremented by the following every sequence Values in parentheses mean only the color head 1 point 0 025 cc 1 Power On Micro 40 steps x 6 5 2 points 40 steps x 10 9 3 points 40 steps x 15 12 5 4 points 2 CL 1 3600 4800 steps 16 20 points 40 steps x 12 absorption 4 points 3 CL 2 720 steps 4 points 7800 8200 steps 40 points 40 steps x 12 4 points 4 CL 3 40 steps x 12 4 points 5 I C Replacement 8900 14000 steps 48 72 points 8900 8800 steps 48 44 points 40 steps x 12 4 points 6 Fixed time False Absorption Monochrome and CMY 2 7 Power On Normal 3600 4800 steps 16 20 points 40 steps x 12 4 points Note for Service Also protect counter A resets when 1 The printer is shipped from the factory 2 After the maintenance is performed When the ink drain tank ink eject porous pad part number 130 is replaced REV A 2 27 Chapter 3 Disassembly and Assembly Table of Contents 3 1 OVER
72. f operation is performed when the secondary side switch is turned off 5 Print Start Operation This operation eliminates ink from the nozzle surface and is performed when the printer receives print data while in the standby state 6 Refresh Operation This operation prevents an increase in the viscosity of the head ink 7 Standby Operation This operation prevents an increase in the viscosity of the head ink 8 False Absorbing Operation This operation absorbs ink inside the cap and eliminates ink from the nozzle plate 9 Ink Cartridge Replacement Operation This operation is performed when the Alt button is pressed for more than 3 seconds the carriage then moves to the ink cartridge replacement position 10 Wiping Operation 1 This operation eliminates dust from the nozzle plate before performing the ink absorption 11 Wiping Operation 2 This operation eliminates dust or ink from the nozzle plate after performing the ink absorption 12 Rubbing Operation This operation removes dust or ink that adheres to the head surface 13 Disengage ON Operation This operation sets the switch lever to the position where it transmits the PF motor drive to the pump mechanism It also moves the carriage to the home position where the lever is set to the specified position REV A 2 25 Operating Principles Stylus Pro XL 14 Disengage Off Operation This operation resets the switch lever to the position where it transmits the PF
73. g under the PF pinch roller unit Paper Guide Plate Left Adjustment Position g Right Adjustment Position Eject Frame Thickness Gauge Thickness Gauge Front Frame PF Pinch Roller Unit Attachment Point Front NX Tension Roller Y Tue Figure 4 18 Adjusting the Platen Gap Thickness Gauge Paper Guide 4 16 Rev A Stylus Pro XL Adjustments 6 Move the carriage manually to the right adjustment position and repeat steps 3 and 4 referring to Figures 4 18 and 4 19 Carriage Roller il mmm 0 04 mm N Thickness E Gauge Eject Frame Figure 4 19 Confirming the 4 1 8 Internal Timer Reset Operation This operation is required when the M 4A60 printer mechanism is replaced There are 6 timers in this printer Sy Refresh timer Timer monochrome and CMY Flushing level decision timer False absorbing timer Total print timer PAUSE timer When the printer mechanism is replaced reset the timers as described here 1 2 Connect the PC to the target printer and turn on the printer Execute BASIC on the PC and
74. ge CN9 At home position HP HP Sensor Pin 3 HPV to Pin 2 GND Out of HP CN10 Change the pulse width of TH Sensor Pin 10 SWO0 5 to Analog data the charge pulse for the Pin 1 GND common driver circuit Rev A 5 1 Troubleshooting Paper out Table 5 3 Error Codes LED No Ink Cartridge Economy Condensed Stylus Pro XL Recovery Load paper in the tray press Load Eject and then the Pause button No ink cartridge Install the new ink cartridge and press the Pause button Paper jam Blinks Load paper and press Pause and Load Eject buttons Maintenance request Blinks Blinks Blinks Blinks Blinks Blinks Service maintenance request Change the waste ink drain tank and reset the counter Carriage error 5 2 Blinks Blinks Turn off the printer and turn it on again Rev A Stylus Pro XL Troubleshooting 5 2 UNIT LEVEL TROUBLESHOOTING When a problem occurs you can identify the defective unit based on the symptoms exhibited The table below lists the symptoms of certain problems Once the problem is identified refer to the flowchart that corresponds to the problem Table 5 4 Symptom and Problem Symptom Problem Flowchart No L1 LEDs do not light up Her not perde at power on LJ Printer mechanism does not operate Error is detected LJ Error is indicated by LED indica
75. gure 1 7 When the input buffer is full When the INIT input signal is active During initialization When the ERROR or PE signal is active During the self test mode L1 During the demonstration mode During the default setting mode When a fatal error occurs The ERROR signal is active LOW under the following conditions When a paper out error occurs When a no ink cartridge error occurs When a fatal error occurs The PE signal is active HIGH under the following conditions When a paper out error occurs When a fatal error occurs 1 10 Rev A Stylus Pro XL Product Description Table 1 9 shows the connector pin assignments and signal functions of the 8 bit parallel interface Table 1 9 Signal and Connector Pin Assignments for Parallel Interface Signal Name STROBE Description The STROBE pulse is used to read data from the host computer The pulse width must be 0 5 us or more Normally itis HIGH and data is latched with the rising edge of this signal DATA 1 8 are parallel data bits When one of these signals is HIGH the data bit is 1 when LOW the data bit is 0 The most significant bit MSB is DATA 8 The signal state must be maintained for 0 5 us on either side of the STROBE signal s active edge ACKNLG ACKNLG is an acknowledge pulse with a width of approximately 10 us This signal goes LOW upon the completion of data reception to indicate that the printer i
76. harge Time Pd Discharge Pulse Figure 2 24 Trapezoidal Drive Waveform E05A96 IC2 COM1 8 BPWG Pic Bier S T SED5620D U1 BPWD y Common Driver m U1 5 Spl LAT 0064 49 _ Row A BLAT 8 22 69 0048 33 371 Bloc RUM D ME Row BCLKIN 6 6 67 Row BSO 0016 1 gt Row D 5 18 22 CPWC M 5 COM1 6 CPWD 6 gt Common Driver C 02 23 4 2j j S LAT 0064 49 Not Connected Z z 69 211 gt 6 2 59 CLK 0048 33 Row R Magenta CSO 24 6 6 875 5 0032 17 J3 Row S Cyan 0016 1 3 Row T Yellow C162 MAIN 4 On Carriage Head Driver Board Figure 2 25 Printhead Drive Circuit Block Diagram REV A 2 21 Operating Principles Stylus Pro XL 2 3 2 6 DMA Controller Data from the host computer is received automatically by the STB signal via the external Centronics interface The data is input to the input buffer on the DRAM IC5 At this time E05A96 detects the rising edge of the external STB signal and outputs the STBDMA strobe DMA request signal to the CPU When the CPU detects this signal the DMA controller in the CPU sends a bus request to the bus controller in the CPU and then the CPU releases the bus line Due to this external data is transported into the memory bypassing the CPU E05A96 1 2 CPU H8 IC1 c 108 129 9 STB gt STBDMA DREQ
77. in the table below for this printer both of which have been tested extensively and comply with the requirements of this printer mechanism Figure 6 1 shows the lubrication and adhesive points Table 6 1 Recommended Lubricants Part No 1010513 Quantity Oil O 5 Availability Grease G 20 B700000001 G 36 B703600001 Note Adhesive E EPSON Exclusive product Not commercially available Neji Lock 2 G B730200200 Table 6 2 Lubrication and Adhesive Points Lubrication Adhesive Point The teeth of gear 60 Lubricant G 36 1 3 mg The teeth of combination gear 10 50 G 36 1 3 mg End point of shaft securing sub frame assembly Cutout for the CR motor in the base frame assembly 2 points G 36 1 3 mg G 36 1 3 mg Shaft located in the center frame assembly G 36 1 3 mg Shaft located in the center frame assembly G 36 1 3 mg Surface of the eject roller assembly IN O Q Contact surface of the right side of the front paper guide and the eject roller assembly G 36 1 3 mg Right end point of the eject roller assembly Contact surfaces of the shaft and combination gear 13 5 22 and the combination gear holder on the sub frame assembly G 36 1 3 mg The teeth of gear 22 5 G 20 1 3 mg G 36 1 3 mg The teeth of combination gear 28 17 5 End points of the
78. ing Principles Stylus Pro XL The following figure shows the contents of the four bit serial data and how this data transacts with the SLA7041MS driver The step time of the reference voltage is determined by the interval time of the STROBE pulse Vref 5 V lt AN V V Ex SLA7041MS Vref Voltage Selection Vref lt Circuit To Motor bit 2 bit 3 bit 4 bit Phase Signal 4 b T STRB gt eS i NA O Q 1 bit 2 bit 3 bit 4 bit 4 bit Serial Data Phase a b C 4 bit Shift Register 0 O A CLK m fl ges r v STRB 2 18 Reading of serial data from the Phase signal in order At this time the reference voltage selection circuit checks phase signal outputs Figure 2 21 Serial Data Transfer Procedure REV A Stylus Pro XL 2 3 2 4 Paper Feed Motor Drive Circuit The paper feed motor for this printer drives the following mechanisms Paper feed mechanism Paper pickup mechanism Pump mechanism Operating Principles Driver IC SLA7041MS IC14 drives the paper feed motor by a constant current Its principle of operation is same as for the carriage motor drive circuit But the driving method is different for paper feed and the pump Table 2 9 Paper Feed Motor Drive Modes Phase Excitation Drive Frequency
79. ism main board or printhead board is replaced or diassembled This adjustment calibrates the head drive timing between the black and color head If this adjustment is not made the vertical alignment will not be completed 1 2 Connect the PC to the target printer and turn the printer on Execute BASIC on the PC and run the program VERxxx BAS 1 Destination Setting 2 Head Angle Confirmation Pattern Printing Black Head Spacer Selection Head Vertical Position Confirmation Head Gap Adjustment Bi D Adjustment Internal Timer Reset END O of When the main menu appears choose Head Gap Adjustment by typing 4 and ENTER The printer prints a check pattern with a sample compensation value The printer prints a sample like the one shown in Figure 4 1 If the sample print is not vertically aligned for both odd numbered lines black lines and even numbered lines magenta lines enter a compensation value in the range from 16 to 16 Positive compensation value Shifts the 2nd line to the left Negative compensation value Shifts the 2nd line to the right When both the black and magenta lines are vertically aligned press Y and ENTER this returns you to the main menu Choose END by typing 7 and ENTER The next message appears on the display All parameters that you have specified so far are written to EEPROM upon power off Turn the printer OFF Now 7
80. ject the paper and perform the head capping operation The power onloff signal is always monitored by the E05A96 gate array on the C162 MAIN Board and the logic system recognizes the power switch status IC51 TL494 C1 ii A DB1 C3 L1 Figure 1 10 C137 PSB PSE Board Component Layout 1 5 3 Control Panel C137 PNL Board The 14 LEDs on this board indicate the error status there is no buzzer system by using the 6 switches in combination with one another the printer can operate in each protect operation color or black cleaning cartridge exchanging self test default setting value exchanging reset and EEPROM clear operation 1 20 Rev A Stylus Pro XL Product Description 1 5 4 Printer Mechanism M 4A60 The M 4A60 printer mechanism is equipped with a 64 nozzle black printhead and 48 nozzle color CMY printhead on the carriage unit Resolution of 720 dpi is possible with special non absorbent paper The ink system has both a black pump unit and a color pump unit Waste ink from each printhead is made to flow into the individual caps Power for the pump system and paper feed system is supplied from the paper feed motor Figure 1 11 Printer Mechanism M 4A60 1 5 5 Housing The Stylus Pro XL housing consists of the printer cover upper case and the lower Attached to the housing are the front paper support a
81. kage of electrolyte from the battery burning or explosion The leakage may affect other devices close to the battery Do not charge the battery An explosive gas may be generated inside the battery and cause burning or explosion Do not dismantle the battery The gas inside the battery may hurt your throat Leakage burning or explosion may also result Do not install the battery in the wrong direction This may cause burning or explosion CAUTION Danger of explosion if battery is incorrectly replaced Replace only with the same or equivalent type recommended by the manufacturer Dispose of used batteries according to government s laws and regulations ATTENTION Risque d explosion si la pile est remplac e incorrectement Ne remplacer que par une pile du m me type ou d un type quivalent recommand par le fabricant Elminer les piles d charg es selon les lois et les r gles de s curit en vigueur CAUTION Never remove the ink cartridge from the carriage unless manual instructions specify to do so When transporting the printer after installing the ink cartridge be sure to pack the printer for transportation without removing the ink cartridge Use only recommended tools for disassembling assembling or adjusting the printer Apply lubricants and adhesives as specified See Chapter 6 Make specified adjustments when you disassemble the printer See Chapter 4
82. lace the head cable The printhead is defective Replace the printhead Replace the printhead A dot is not printed occasionally Printhead surface is not clean Check the front of the printhead Clean The ink cartridge is used up Check whether the ink cartridge is empty Replace the ink cartridge Insufficient head cable contact Check whether the cable is properly plugged into the connector Plug the cable into the connector properly Check whether the printhead is clean Clean The printhead is defective Replace the printhead to see if this causes printing to be performed normally Replace Ink is poorly absorbed Check whether the used ink goes through the used ink tube See Ink is not absorbed Printhead characters are not aligned The platen gap is not adjusted Check the platen gap Adjust the gap The intervals between the characters are irregular The timing belt is defective Check that the timing belt is properly inserted into the bottom of the carriage Insert the timing belt properly Vertical line is not aligned Bidirectional alignment is not adjusted Check it with bidirectional alignment program Adjust the bidirectional alignment Paper is not fed normally ev Character or dot pitch is abnormal Character or dot pitch is abnormal Check for head inclina
83. lamp Removal Note The head flexible flat cables FFCs are secured to the ink cartridge holder with adhesive tape Tear the cables off the ink cartridge holder before removing the ink cartridge holder from the cartridge base 3 8 REV A Stylus Pro XL Disassembly and Assmbly 6 Remove the CBB M3x11 screw under the CR cap cover and plain washer securing the monochrome and color printheads to the carriage base Q Rubber Cap CBB 3 11 Figure 3 8 Ink Cartridge Holder Removal 7 Pull the black or color head toward you and disconnect the head FFC cable on the head driver board nozzle selector Then remove the black or color head Color Head Black Head Figure 3 9 Printhead Removal REV A 3 9 Disassembly and Assembly Stylus Pro XL CAUTION Take proper measures to protect the printhead unit from static electricity because the driver IC is directly attached to the printhead unit Never touch the printhead s metallic nozzle cover surface Handle it only by holding the edges of the printhead When you replace the printhead or the printer mechanism you must replace the block resistor at location RM4 for Micro Mode Color R No 5 for Normal Mode Color M No RM11 for Micro Mode Monochrome R No and RM12 for Normal Mode Monochrome M No on the C162 MAIN Board Every spare printhead or spare printer mechanism comes with a block resistor that is specifically s
84. leaner Head Cleaner Lever Figure 3 14 Cleaner Head Replacement 3 14 REV A Stylus Pro XL Disassembly and Assmbly 3 2 5 5 CR Motor Removal 1 Remove the printer mechanism see Section 3 2 4 2 Release the timing belt see section 3 2 5 2 3 Remove the 3 screws securing the CR motor to the upper frame and then remove the CR motor Screws CR Motor Figure 3 15 CR Motor Removal 3 2 5 6 PF Motor Removal 1 Remove the printer mechanism see Section 3 2 4 2 Remove the 2 CBN M3x6 screws and then remove the PF motor CBS M3x6 4 W Figure 3 16 PF Motor Removal PF Motor REV A 3 15 Stylus Pro Service Manual Disassembly and Assembly 3 2 5 7 Carriage Home Position Sensor Removal 1 Remove the printer mechanism See Section 3 2 4 2 Disconnect the sensor cable from the carriage home position sensor 3 Unhook the 3 notches securing the carriage home position sensor to the upper frame Then remove the carriage home position sensor Sensor Cable e Position Sensor SP DIPL A en CEE Figure 3 18 Carriage Home Position Sensor Removal 3 2 5 8 PE Sensor Hemoval 1 Remove the printer mechanism See Section 3 2 4 2 Disconnect the connector for the PE sensor 3 Rotate the printer mechanism upside down use tweezers to release the 2 hooks securing the PE sensor to the paper feed roller assembly Then remove the PE sensor Bottom Frame S
85. lection 5 Turn off the printer now 6 Move the carriage to the center manually and loosen but do not remove the screw securing the color head to the carriage Rev A 4 13 Adjustments Stylus Pro XL 7 Figure 4 16 Removing the Rubber Cap Remove the rubber cap covering the head screw at one side of color ink cartridge Then loosen but do not remove 3 screws Refer to the figure below 8 Replace the angular spacer on the left side with a new one referring the figure below Replace the angular spacer using tweezers to push the head base toward the rear 4 14 Rev A Stylus Pro XL Adjustments 9 Rerun the BASIC program and choose Head Angle Confirmation Pattern again by typing 2 and ENTER Then verify that the confirmation sample is correct Carriage Unit gt Color Head 1 Push Head Base Platen Gap Adjust Lever Angular Spacer one side only 2 Replace Figure 4 17 YMC Angular Spacer Replacement 10 If the sample is incorrect repeat steps 5 9 until the upper lines in the sample are aligned with one another and the lower lines in the sample are exactly equidistant to one another as shown at B in Figure 4 15 11 When you complete this adjustment turn off the printer Rev A 4 15
86. med Input data buffer is cleared Print buffer is cleared Default values are set 1 18 Rev A Stylus Pro XL Product Description 1 5 MAIN COMPONENTS The main components of the Stylus Pro XL are Printer mechanism M 4A60 Main control board C162 MAIN Board Power supply unit C137 PSB PSE Board Control panel board C137 PNL Board Housing O O O 1 5 1 Main Control Board C162 MAIN Board The Main Control Board C162 MAIN Board consists of an H8 3003 16 bit CPU E05A96 gate array a program ROM 4M a dynamic RAM 4M a mask ROM 4M or 8M an EEPROM 1K and a lithium battery for powering the protect counters The reset IC M51955 and PST 592 is equipped with both a logic system and a power system The 8M program ROM is used only for the NLSP National Language Support Printer specification 4M DRAMs 1 5 6 M p Program 4 ROM IC3 GA E05B09 IC2 Mask ROM Mask ROM M160A69 M80B00 161 1616 IC17 Figure 1 9 C162 MAIN Board Component Layout Rev A 1 19 Product Description Stylus Pro XL 1 5 2 Power Supply Board C137 PSB PSE Board The power supply board C137 PSB PSE Board consists of an RCC switching regulator circuit This board is equipped with a power switch connected to the secondary circuit Thus if the printer is turned off it can continue to operate in order to e
87. mm AN 8 5 mm Interface mode Auto Parallel Serial Option Auto I F wait time 10 sec A 30 sec 5 Change the setting value by pressing Alt button Pressing the Alt button changes the setting for the current menu The status of the LEDs will be changed as the button is pressed 1 16 Rev A Stylus Pro XL Product Description Table 1 18 Character Table Selection Paper Out LED Version Settings Operate LED Data LED Italic U S A Off Italic France On Italic Germany Blinks Italic U K Off Italic Denmark 1 On Italic Sweden Blinks Italic Italy Off Blinks Italic Spain 1 On Blinks PC437 Blinks Blinks PC850 Off Off PC860 On Off PC863 Blinks Off PC865 Off On PC861 On On BRASCII Blinks On Abicomp Off Blinks PC437 Greek Off Off PC853 Blinks PC855 Off PC852 On PC857 Blinks PC866 Off Blinks PC869 On Blinks MAZOWIA Blinks Blinks Code MJK Off Blinks ISO 8859 7 On Off Blinks ISO Latin 1T Blinks Off Blinks Bulgaria Off On Blinks 6 Repeat steps 4 and 5 to change other printer settings The setting menu selection will return to the first menu after the last menu selection is over 7 Turn off the printer The setting is stored in non volatile memory Rev A 1 17 Product Description Stylus Pro XL 1 4 4 Error Conditions The
88. motor drive to the pump mechanism It also moves the carriage to the flushing position where the lever is reset to the specified position 15 Micro Absorbing Operation When the cartridge is removed it is possible for a small amount of air to form small air bubbles that can block the ink from the nozzle This operation eliminates small air bubbles from the cavity of the printhead 16 Carriage Lock Set This operation prevents the carriage from moving out of the home position if the printer is turned off or is pauesd This operation is performed when the carriage is in the ink system home position and no paper is loaded 17 Carriage Lock Reset This operation resets the carriage lock lever 18 Refresh Operation Performed when Loading or Ejecting Paper This operation prevents an increase in the viscosity of ink inside the black head while paper is being loaded or ejected When paper is loaded or ejected just the black head is ready and the color head is capped The refresh flushes the black head only 19 Adjust Lever Position Moving Sequence This operation is performed when the Alt and Font buttons are pressed simultaneously while the printer is paused 20 Transportation Sequence This sequence is performed to clean the printhead when the printer is transported to the market 2 26 REV A Stylus Pro XL Operating Principles 2 4 2 Timer and Counter EEPROM LE93C46 IC12 on the main board stores certain counter and timer valu
89. nation Setting Head Angle Confirmation Pattern Printing Black Head Spacer Selection Head Vertical Position Confirmation Head Gap Adjustment Bi D Adjustment Internal Timer Reset END N NOOR When the main menu appears choose Destination Setting by typing 1 and Enter The main menu immediately disappears briefly and then reappears At this time specific destination parameters including the destination interface mode TOF value and economy condensed are automatically written to the EEPROM 5 Choose END by typing 7 and ENTER The next message appears on the display All parameters that you have specified so far are written to EEPROM upon power off Turn the printer OFF Now 6 Turn off the printer 4 2 Rev A Stylus Pro XL Adjustments 4 1 2 Bi D Bidirectional Printing Alignment Adjustment The bidirectional alignment is required when the printer mechanism main board or printhead board is replaced Performing this adjustment determines a compensation value to rectify any deviation in the print position This deviation could be caused by the different print speeds which are due to tolerances in the mechanical components or to differences in print timing between odd numbered lines and even numbered lines in bidirectional printing The printer stores the compensation data in the EEPROM on the C162 MAIN board and refers to this data when performing bidirectional
90. nd the ejected paper support with paper separator Rev A 1 21 Chapter 2 Operating Principles Table of Contents 2 1 OVERVIEW 2 1 2 2 OPERATING PRINCIPLES OF THE PRINTER MECHANISM 2 1 Printer Mechanism rti Ru di ori PP eerte S 2 2 2 2 2 Carriage Drive Mechanism 2 5 2 2 2 1 Platen Gap AdjustLever 2 6 2 2 3 Paper Feed 2 6 224 Im System o Z i Dit re du i biu as a one bia s p 2 8 2 2 5 PutmMSOcCHhalsltiz suos xat IF u MP SW UU e SSS 2 9 2 2 6 Cap Mechanisms case eee ee ee Adm 2 12 2 2 7 Wiping Mechanism 2 12 2 3 OPERATING PRINCIPLES OF THE ELECTRICAL CIRCUITS 2 13 2 3 1 Operating Principles of the Power Supply Circuit 2 13 2 3 2 Operating Principles of the Main Control Circuit 2 15 2 3 2 1 Reset sg nd Ses hoe aree buds E 2 16 2 3 2 2SeriSOr CUCU sur Bettas eee ce ud RA 2 16 2 3 2 3 Carriage Motor Drive Circuit 2 17 2 3 2 4 Paper Feed Motor Drive Circuit 2 19 2 3 2 5 Printhead Drive Circuit 2 20 2 3 2 6 DMA 2 22 2 3 2 7 D RAM Refreshment Controller
91. o the bottom of the carriage Reinsert the timing belt Check the timing belt for any damage Replace the timing belt The carriage moves slightly and then stops Carriage movement is not smooth Check whether the carriage moves smoothly when moved manually Clean and lubricate the carriage Check tension of the timing belt Adjust tension of the timing belt Rev A Stylus Pro Service Manual Troubleshooting Table 5 8 Repair of the Printer Mechanism Continued Symptom Printing is not performed Condition The carriage moves but no printing is performed The head cable is disconnected Checkpoint Check whether the head cable is disconnected Solution Reconnect the head cable The head cable is defective Replace the head cable to see if operation is normal Replace the head cable The printhead is defective Replace the printhead to see if the printhead operates normally Replace the printhead Ink absorption is poor See Ink is not absorbed on the previous page Abnormal printing A particular dot is not printed Printhead surface is not clean Perform the cleaning operation Clean The head cable is disconnected Check whether the head cable is disconnected Reconnect the head cable The head cable is defective Replace the head cable to see if operation is normal Rep
92. oting 5 4 UNIT REPAIR C162 MAIN BOARD This section describes the problems related to the main controller board C162 MAIN The table below provides various symptoms likely causes and checkpoints Stylus Pro XL The checkpoints refer to waveforms resistance and other values to be checked to evaluate the operation of each component Symptom The printer does not operate at all Condition The CPU does not operate Drive system does not operate normally when you turn the printer on or off The reset circuit does not operate Table 5 6 Repair of the C162 MAIN Checkpoint Check the waveform of the 5 V line and that of the RESET signal Solution Replace IC13 or IC8 Selection of control ROM is abnormal Check pin 2 of IC3 for a change in the signal HIGH LOW Replace IC1 Either CG or RAM is defective Replace CG or RAM CPU is defective Check the oscillator signal at either pin 75 or 74 of the CPU If signal is detected replace CPU Otherwise replace CR1 The carriage does not operate normally 5 10 The carriage motor does not operate at all IC2 is defective Check the serial signal output from pin 25 or 27 of IC2 to the driver IC15 Replace IC2 CPU is defective Replace CPU Rev A Stylus Pro XL Symptom Carriage does not operate normally Table 5 6 Repair of the C162 MAIN Cont Condition
93. ove the upper case see Section 3 2 1 2 Remove the power supply unit see Section 3 2 2 3 Remove the main controller see Section 3 2 3 4 Remove the 4 CBN M4x13 screws and take out the printer mechanism DISASSEMBLY ASSEMBLY POINT Wipe off any ink around the end of the ink drain tube when you remove the printer mechanism When reinstalling the printer mechanism check that the waste ink drain tube is properly inserted between the lower case and the waste ink absorbing material CBB M4x13 d FEN Y NE g 2m Figure 3 6 Printer Mechanism M 4A60 Removal CAUTION When you replace the printhead or printer mechanism you must replace the block resistor at location RM4 for Micro Mode Color R No RM5 for Normal Mode Color M No RM11 for Micro Mode Monochrome R No and RM12 for Normal Mode Monochrome M No on the C162 MAIN Board Every spare printhead or spare printer mechanism comes with a block resistor that is specifically selected for each printhead Refer to Table 3 1 Adjust both the head gap and bidirectional alignment when replacing the printer mechanism Table 3 1 Insertion Location for Block Resistors REV A Mode Head Indic
94. pecification Item Description Motor Type 4 phase 96 pole hybrid type Drive Voltage 35 VDC 596 Coil Resistance 11 5 0 t 1 10 Drive Frequency 300 1800 PPS Excitation Mode Paper feed pump drive 2 2 phase 2 W1 2 phase 2 6 REV A Stylus Pro XL Operating Principles Table 2 5 Drive Terms Current Value mA Frequency pps Acceleration Deceleration Constant Rush Paper loading 970 750 ASF feed 970 750 Paper feed Pump drive 1 1380 1380 Pump drive 2 PF Pinch Roller Unit Quenching Roller PF Transmission Gear Pickup Roller Paper PF Motor Pinion Gear Platen Drive Gear Left Side Frame Plunger Hopper Frame Figure 2 6 Paper Feed Mechanism REV A 7 Operating Principles Stylus Pro XL 2 2 4 Ink System This printer s ink system is composed of the following mechanisms Ink cartridge Pump mechanism Cap mechanism Waste ink drain tank m Wiping mechanism The figure below shows a diagram of the ink system Color Head Black Head Cleaning Blade Air Valve gt for Color Black Head Friction Clutch UEM 25 Disengage Unit 2 8 f E o U Z Tom pM E
95. place the C162 MAIN board gt Rev A Stylus Pro XL Troubleshooting 5 2 4 Printer does not feed the paper correctly START E NO botas the sheet feeder correctly lt me Ps Load the paper YES correctly lt Verify that the paper path is clear Also confirm that there are no foreign objects that may interfere with paper movement Pd Is the problem Check the PF motor corrected 2 and driver If OK M replace the C162 NO MAIN board paper jam occur NO uU Perform the PF A n NO p gt oller cleaning with Is the problem roller cleaning wi corrected the cleaning sheet odd YES YES Pi DS Is the problem jouet lt 3X 3A 3 p corrected NO See the section describing repair of the printer mechanism Rev A 5 7 Troubleshooting Stylus Pro XL 5 2 5 Control panel operation is abnormal Is the control panel connected properly NO Y Connect the control YES panel correctly YES Is the problem all NO v Replace the control panel Is the problem NO corrected Replace the C162 MAIN board 5 8 Rev A Stylus Pro XL Troubleshooting 5 3 UNIT REPAIR C137 PSB PSE BOARD This section describes problems related to the power
96. previous printers Refer to the following table to perform the appropriate adjustments Always perform the adjustments in the order indicated After performing steps 1 5 perform a cleaning operation for the black and color printheads the cleaning operation is needed because printing sample patterns for the head angle Bi D alignment and the head gap increases the viscosity of the ink and the printer will not print the correct value For instance if you replace the black head you must do the following adjustments in the order shown 1 Black head angle 2 black color head vertical 3 head gap 4 Bi D alignment After removing an ink cartridge always install a new cartridge immediately During adjustments and testing use cartridges designed exclusively for service Monochrome 1020626 1020627 Table 4 1 Required Adjustments Service Performed Adjustment Needed Bi D alignment adjustment see Section 4 1 2 Head gap adjustment see Section 4 1 3 Internal timer reset operation see Section 4 1 8 When replacing the M 4A60 printer mechanism When replacing or disassembling the C162 MAIN board or printer mechanism Destination data writing operation see Section 4 1 1 Bi D alignment adjustment see Section 4 1 2 Head gap adjustment see Section 4 1 3 Black head angle adjustment see Section 4 1 4 Black Color head vertical adjustment see
97. printer can detect various errors and indicate them with LEDs Table 1 19 Error Indications No Ink Cartridge LED Paper Out LED Economy Condensed Data LED LED LED Paper out Off On Off Off Off No ink cartridge Off Off Off Off Off Paper jam Off Blinks Off Off Off Maintenance request Blinks Blinks Blinks Blinks Blinks Blinks Carriage error Blinks Off Off Off Off Blinks 1 4 5 Printer Initialization There are three initialization methods hardware initialization software initialization and panel initialization 1 4 5 1 Hardware Initialization Hardware initialization is performed by Turning on the printer Sending the parallel interface INIT signal T If the INIT signal is active when the printer is turned on hardware initialization is started when the INIT signal becomes inactive When the hardware initialization is performed The printer mechanism is initialized Input data buffer is cleared Downloaded character definitions are cleared Print buffer is cleared Default values are set 1 4 5 2 Software Initialization Software initialization is performed upon receipt of the control code ESC When the software initialization is performed Print buffer is cleared Default values are set 1 4 5 3 Panel Initialization This printer is initialized by pressing the Load Eject button while pressing the Alf button When the panel initialization is perfor
98. printer is a 4 phase 200 pole hybrid type stepping motor mechanism allowing the printer to stop the carriage or change the carriage movement at any position The position of the carriage is recognized by the home position sensor and position information is fed back to the carriage drive control circuit This carriage motor is driven by the motor driver IC SLA7041 see Section 2 3 2 3 for more information Table 2 1 Carriage Drive Motor Specifications Item Description Motor Type 4 phase 200 pole hybrid type stepping motor Drive Voltage 35 5 Coil Resistance 10 0 O 796 Drive Frequency 960 4800 PPS Excitation Mode Constant current unipolar drive micro step drive In the following table 2 W1 2 phase means the 1 8 2 2 phase drive control Values in parentheses are for the 2 2 phase Table 2 2 Drive Terms Acceleration CR Speed Frequency Phase Drive Method Deceleration Step Mode 1 Acceleration Deceleration Area WO es 200 CPS 4800 2400 2 W1 2 phase 1 2 phase Deceleration Constant Area 1 2 phase 32 4 112 56 Acceleration Deceleration Area 2400 1200 2W1 2 phase 1 2 phase 40 5 40 20 9 Constant Area 1 2 phase Mode 2 100 CPS Acceleration Deceleration Area 960 480 2W1 2 phase 16 2 Constant Area 2 W1 2 phase Mode 3 40 CPS CR Motor CR HP Sensor t Carriage Guide Shaft B
99. printing 1 Connect the PC to the target printer and turn the printer on 2 Execute BASIC on the PC and run the program VERoox BAS k Destination Setting Head Angle Confirmation Pattern Printing Black Head Spacer Selection Head Vertical Position Confirmation Head Gap Adjustment Bi D Adjustment Internal Timer Reset END NOOR 3 When the main menu appears choose Bi D Adjustment by typing 5 and ENTER The printer prints a check pattern with a sample compensation value 4 Thenext menu appears on the display Input Bi D value No 30 lt No lt 30 If O K input Y key _ 5 If the sample print is not vertically aligned for both the odd numbered and even numbered lines enter a compensation value in the range from 30 to 30 Positive compensation value Shifts the 2nd line to the left Negative compensation value Shifts the 2nd line to the right When the sample print becomes vertically aligned for both lines press Y and ENTER this returns you to the main menu 6 Choose END by typing 7 and ENTER The next message appears on the display All parameters that you have specified so far are written to EEPROM upon power off Turn the printer OFF Now 7 Turn off the printer Rev A 4 3 Adjustments Stylus Pro XL 4 1 3 Head Gap Adjustment Black and Color Head The head gap adjustment is required when the printer mechan
100. pump speed up shaft both sides G 36 1 3 mg Cut point for knob on the right main frame goman points of gear 60 the platen roller shaft and the PF cap G 36 1 3 mg G 36 1 3 mg 2 points on the combination gear holder G 36 1 3 mg Oil pad on the carriage O5 1 3 mg Contact surface of gear 25 and the plain washer G 36 1 3 mg Contact surface of the platen shaft bushing and plain washer G 36 1 3 mg Cutout in the platen roller shaft G 20 1 3 mg Contact point of the pressure spring and washer G 36 1 3 mg Combination gear 13 5 22 G 36 1 3 mg The teeth of gear 24 G 36 1 3 mg Angular spacer for the black head and the cartridge base Neji Lock 2 1 3 mg Angular spacers for the color head and the cartridge base Neji Lock 2 1 3 mg Rev A The screw and washer attaching the ink cartridge holder to the carriage base Neji Lock 2 1 3 mg 6 3 Maintenance Stylus Pro Service Manual CAUTION O Do not apply too much lubricant as it may stain the mechanism as well as a cause a mechanism malfunction 6 4 Rev A Stylus Pro Service Manual Maintenance Maintenance Stylus Pro Service Manual Hb lubrication Point D Adhesive Point Figure 6 2 Lubrication Points and Adhesive Points 2 6 6 Rev A Appendix Tabl
101. racter Table Cut Sheet Paper Specifications Envelope Specifications Adjust Lever Setting Rated Electrical Ranges Acceptable Environmental Conditions Signal and Connector Pin Assignments for Parallel Interface DTR and X ON X OFF Protocol Signal and Connector Pin Assignments for Serial Interface Printer Condition Panel Status Default Setting Items Characteristics of Print Direction Mode Printing Direction and ESC U Command Language Selection Feature Selection Character Table Selection Error Indications Rev A Stylus Pro XL Product Description 1 1 FEATURES The Stylus Pro XL is 64 48 nozzle monochrome and CMY color ink jet dot matrix printer The major features of this printer are High quality color print Micro Dot 720 dpi printing Plain paper 720 dpi printing Special coated paper 720 dpi printing B High print speed 200 cps Built in auto sheet feeder Holds 100 cut sheets 64 g m2 Holds 10 envelopes Holds 50 transparency films Hold 70 special paper Built in3I Mac serial I F Parallel I F Type B I F option Easy setup No dip switches Multi lingual setting messages 5 languages 4scalable fonts and 5 LO fonts standard Roman T Sans Serif H Roman Sans Serif scalable Roman Sans Serif Courier Prestige Script LO 21 character tables Italic PC437 PC850 PC860 PC863 PC865 PC437 Greek PC852 PC853 PC858 PC857 PC866 PC869 PC861 BRASCII Abicomp MAZOWIA Code
102. re 4 6 Removing the Rubber Cap 4 7 Figure 4 7 Spacer Angular Replacement Method 4 8 Figure 4 8 Black Color Head Vertical Adjust Conception 4 9 Figure 4 9 Spacer Linear Selection 5 4 9 Figure 4 10 Removing the Rubber 4 10 Figure 4 11 Spacer Linear replacement Method 4 11 Figure 4 12 C Head Angle and Spacer Angular Position 4 12 Figure 4 13 Color Head Angle Confirmation 4 12 Figure 4 14 Relationship of the Shape and Thickness 4 13 Figure 4 15 Spacer Select juidgement 4 13 Figure 4 16 Removing the Rubber 4 14 Figure 4 17 Spacer Angular Replacement Method YMC 4 15 Figure 4 18 Adjusting the Paper 4 16 Figure 4 19 Confirming the 4 17 List of Table Table 4 1 Required Adjustments 4 1 Table 4 2 Gap and Adjustment Direction 4 16 Rev A Stylus Pro XL Adjustments 4 1 OVERVIEW This section describes adjustments required when the printer is disassembled and assembled after repair Since this printer has both a black and color head it needs new adjustments not required for
103. rtain parameters such as the printer mechanism control parameter default setting parameters as well as a special counter value used for printhead ink management protection The timer IC NJU6355E IC7 counts each time the printer is cleaned and keeps track of how long the printer is not used thereby allowing the printer to be cleared only when necessary Note 1 Note 2 PROM 4M PROM 8M DRAM 4M DRAM 4M CG ROM 4M CG ROM 8M IC3 C4 IC5 IC6 IC 16 IC17 Data Bus Address Bus Type B I F Refresh lt EEPROM 1012 CPU E05A96 lt 1013 Reset H8 3003 1 2 PST592D Logic C1 Reset IC8 p P gt Power M51955B lt DMAREQ zi 2 x Vx w P A OX EQ Ou RS 422 Serial 1 G Sa Battery 35 2332 5 So NJU6355E 523 9 9 Timer s za Counter 2 7 EN 4 o SN D o C162 MAIN CI acon From Black Color Head gt SED5620 gt Black 64 Nozzles Common Driver Circuit U1 U2 gt Color 48 Nozzles SLA7041MS IC14 15 fox From Carriage Paper Feed Motor Driver M s Note 1 IC4 is a 32 pin IC socket only Note 2 1 17 is an IC socket onl
104. run the program 1 Destination Setting Head Angle Confirmation Pattern Printing Black Head Spacer Selection Head Vertical Position Confirmation Head Gap Adjustment Bi D Adjustment Internal Timer Reset END O of C When the main menu appears choose Internal timer reset by typing 6 and ENTER This resets the internal timer The following message then appears All parameters of the internal timer are now reset Press Y and ENTER to return to the main menu Press Y and ENTER Press 7 and ENTER Turn off the printer Rev A 4 17 Chapter 5 Troubleshooting Table of Contents 5 1 OVERVIEW 5 1 5 2 UNIT LEVEL TROUBLESHOOTING 5 3 5 2 1 Printer Does Not Operate at 5 4 5 2 2 Error is Detected a dn RC RR 5 5 5 2 3 Failure Occurs During Printing 5 6 5 2 4 Printer Does Not Feed the Paper Correctly 5 7 5 2 5 Control Panel Operation is Abnormal 5 8 5 3 UNIT REPAIR C137 PSB PSE BOARD 5 9 5 4 UNIT REPAIR C164 MAIN BOARD 5 10 5 5 UNIT REPAIR PRINTER MECHANISM M 4A11 5 12 LIST OF FIGURES Figure 5 1 Troubleshooting Process Flowchart 5 1 LIST OF TABLES Table 5 1 Motor Coil Resistance Test Points 5 1 Table 5 2 Sensor Status ii ccd din oe ee Wee wae he ee ee er
105. s ready to receive further data The BUSY signal informs the host computer of the printer s status When this signal is HIGH the printer cannot accept any more data PE This signal indicates whether paper is available in the printer or not A HIGH level indicates no paper SLCT Pulled up to 5 V through a 1 0 resistor in the printer AFXT If this signal is set to LOW the printer automatically performs one line feed upon receipt of a CR carriage return code The status of this signal is checked only at power on and initialization 31 INIT If this signal goes LOW the printer is initialized The pulse width of this signal must be 50 us or more 32 ERROR This signal goes LOW if the printer has a fatal error or runs out of paper 35 5 V Pulled up to 5 V through 1 0 resistor in the printer 17 CHASSIS Chassis ground 16 Signal ground 19 30 33 36 Not used 15 18 34 Rev A The column indicates the direction of the signal as viewed from the printer Product Description Stylus Pro XL 1 3 2 Serial Interface Specifications Data format RS 422 serial Synchronization Asynchronous Handshaking By DTR signal and X ON X OFF protocol Table 1 10 and X ON X OFF Protocol Busy Less than 512 bytes X OFF Ready More than 1 024 bytes On X ON Word length Start bit 1 bit Data bit 8 bit Parity bit none
106. supply board C137 PSB PSE The table below provides various symptoms likely causes and checkpoints The checkpoints refer to waveforms resistances and other values to check to evaluate the operation of each component Table 5 5 Repair of the C137 PSB PSE Symptom The printer does not operate at all Condition 35 V line is dead ransformer coils are open Checkpoint Check the transformer coils using a Solution Replace T1 Switching FET Q1 Check the waveform at the drain of Q1 Replace Q1 35 V line is abnormal ZD52 Q83 or PC1 is dead Check the voltage level of the collector side The correct voltage is as follows Power Switch Off 41 8 VDC Power Switch On 0 VDC Replace ZD52 Q82 or PC1 5 V line is dead 35 V line is dead Check the 35 V line IC51 is dead Check the oscillation waveform and switching waveform of IC51 Oscillation waveform IC51 pin 5 Switching waveform IC51 pin 8 Replace IC51 Auto capping operation is invalid Rev A 35 V line is invalid when power is off C81 is dead Turn off the printer and check the voltage at pin 1 of IC81 Normal voltage 0 VDC Replace IC81 C82 is dead or R88 is short Turn off the printer and check the voltage at plus side of C82 Normal voltage 2 5 VDC R88 resistance 100 ohms Replace C82 or R88 5 9 Troublesho
107. t in auto sheet feeder ASF front entry Feeding speed 89 msec at 1 6 inch feed pitch 1 2 3 Paper Specifications Table 1 4 Cut Sheet Paper Specifications A34 US B 329 mm 13 0 in x 483 mm 19 0 in A3 297 mm 11 7 in x 420 mm 16 5 in US B 279 mm 11 0 in x 432 mm 17 0 in Legal 216 mm 8 5 in x 356 mm 14 0 in Letter 216 mm 8 5 in x 279 mm 11 0 in A4 210 mm 8 3 in x 297 mm 11 7 in Executive 184 mm 7 25 in x 267 mm 10 5 in Statemrnt 140 mm 5 5 in x 216 mm 8 5 in Thickness 0 08 mm 0 003 in 0 11 mm 0 004 in Weight 64g m 17 Ib 90 g m 24 Ib Quality Plain paper Special coated paper for 720dpi Special coated paper for 360dpi Transparency film High Quality Glossy paper Gloss Size W x L Note Special coated paper for 720dpi Special coated paper for 360dpi Transparency film High Quality Glossy paper printing are only available at normal temparature Table 1 5 Envelope Specifications Size W x L No 10 240 mm 9 1 in x 104 mm 4 in DL 220 mm 8 7 in x 110 mm 4 3 in C5 229 mm 9 0 in x 162 mm 6 4 in Thickness Less than 0 52 mm 0 020 in 75 g m 20 Ib 90 g m 24 Ib Note Envelope Printing is only available at normal temperature e Keep the longer side of the envelopes horizontal at setting Rev A 1 5 Product Description Stylus Pro XL Printabl
108. te X Printing direction is controlled by driver in Windows environment Rev A 1 15 Product Description Stylus Pro XL 1 4 3 2 Changing the Default Settings To change the printer s default settings 1 Hold down the Economy Condensed button and turn on the printer The printer prints a sheet that shows the firmware version and describes how to select the language used to print messages 2 Press the Font button until the appropriate font LED is selected The following table shows which language corresponds to which font LED Table 1 16 Language Selection Language Font LED English Courier Francais Roman T PS Deutsch Sans Serif H PS Italiana Roman Espa ol Sans Serif 3 Press the Alt button The printer prints the current settings using the selected language It also prints a table showing how to change the printer settings 4 Press the Font button to advance through the setting menu The current printer settings are indicated by the Courier Roman T PS and San Serif H PS LEDs Each time you press the Font button you adance to the next setting and the three font LEDs change according to the selection Table 1 17 Feature Selection Setting Value Sans Serif H Setting PS LED Courier Roman T LED PS LED Operate Feature Menu LED Character table See Table 1 18 Print direction Auto Bi D A Uni D Network I F mode Off AN On Auto line feed Off A On Loading position 3
109. the BASIC program and choose the Head Vertical Position Confirmation by typing 3 and ENTER then confirm that the sample print is correct If the sample is incorrect change the thickness of the linear spacer and perform this adjustment again until the two black and magenta lines are aligned at the position OK 0 10 When you complete this adjustment exit the BASIC program and turn off the printer Rev A 4 11 4 1 6 Color Head Angle Adjustment The color head angle adjustment is required when the color head is replaced or disassembled If this adjustment is not correct a white banding problem may occur or the black head timing may not match the color head timing The following figure illustrates the color head angle adjustment The color head angle is adjusted by the angular spacer The angular spacer is attached only to the left side of the head base i j J 7 N X N N 1 Connectthe to the target printer and turn the printer on 2 Execute BASIC on the PC and run the program VEIbox BAS 1 Destination Setting 2 Head Angle Confirmation Pattern Printing Black Head Spacer Selection 3 Head Vertical Position Confirmation 4 Head Gap Adjustment 5 Bi D Adjustment 6 Internal Timer Reset 7 END 3 When the main menu appears choose Head Angle Confirmation Pattern Printing by typing 2 and ENTER The printer prints the che
110. the color head One bit corresponds to each nozzle When data transfer and nozzle selection is complete gate array E05A96 outputs the common drive pulse BPWC or CPWC charge pulse and BPWD or CPWD discharge pulse to the common drive circuit The common drive circuit then generates the trapezoidal pulse and applies it to the printhead as a common drive pulse After this the nozzle selected by the head data is activated to inject ink In the Micro Dot Printing mode the gate array E05B09 arranges the puise width of CPWC and CPWD to became small size of injection ink dot SELM Pulse ERN Normal Dot Mode Common Drive Drive Waveform Drive Pulse Head THEE Micro Dot Mode d Mich Drive Waveform SELN Pulse Figure 2 23 Normal Micro Dot Mode Switch Block 2 20 REV A Stylus Pro XL Operating Principles Micro Dot Printing Mode The Stylus Pro XL printer has a special printing mode called Micro Dot Printing Mode This printing mode can be selected by command from computer Using Micro Dot Printing Mode can improve the quality of output In Micro Dot Printing Mode the ink dot size becomes smaller than the normal dot size COM GND BPWG Ph CPWC Pc BPWD CPWD Pd Tc Charge Time Pc Charge Pulse Th Idle Time Ph Idle Pulse Td Disc
111. the printer or storing the after service parts 1 Keep the battery away from any metal or other batteries so that electrodes of opposite polarity do not come in contact with each other 2 Do not heat the battery and place it near fire 3 Do not solder on any part of the battery Doing so may result in leakage of electrolyte from the battery burning or explosion The leakage may damage devices close to the battery 4 Do not charge the battery An explosive gas may be generated inside the battery and cause burning or explosion 5 Do not dismantle the battery The gas inside the battery may hurt your throat Leakage burning or explosion may also result 6 Do not install the battery in the wrong direction This may cause burning or explosion Rev A 6 1 Maintenance Stylus Pro Service Manual 6 2 SERVICE MAINTENANCE Certain maintenance is required when the printer detects an error or when a decline in print quality is observed 6 2 1 Printhead Cleaning If print quality deteriorates clean the printhead using the built in printhead cleaning function The printer also has an automatic printhead cleaning cycle to ensure the proper nozzle operation for ink injection as well as to preserve its best condition Therefore perform this printhead cleaning operation only if print quality declines to avoid wasting ink 1 Turn the printer on and press the Pause button to pause the printer Make sure that
112. ting Items You can use the default setting mode to change settings listed in the table below Activate default setting mode by holding down Economy Condensed while turning on the printer Table 1 13 Default Setting Items Factory Menu Contents Description Setting Character table Selects the character table Controls the print direction See Tables 1 12 and 1 13 Auto Bi D Uni D Print direction Network IE mode Off For normal environments On For network environments On Valid Off Invalid Loading position 3 0 8 5 mm 0 12 0 33 in Auto mode Parallel I F mode Serial I F mode Optional mode Auto I F wait mode 10 30 seconds Auto line feed Interface mode Table 1 14 Characteristics of Print Direction Mode Black and White Printing Color CMYK Printing Throughput is better Color quality with special paper is worse Color correction depends on the printing direction Throughput and quality is better Throughput is better Color quality with special paper is worse Color correction depends on the printing direction Throughput is best Print quality may be down Throughput is worse Throughput is worse Print quality is better Color quality is best Table 1 15 Printing Direction and ESC U Command Default Setting Mode Character mode for MS DOS Raster graphics mode for Windows No
113. tion L1 Printing is not performed Failure occurs during printing Abnormal printing missing dots etc LJ Print quality is poor l No paper is fed Paper feed is irregular LJ Paper jam occurs Printer does not feed the paper correctly Control panel operation is abnormal No response to button access Rev A 5 3 Troubleshooting 5 2 1 Printer does not operate at power on 1 the AC input voltage correct Use the correct input voltage Replace the fuse and disconnect Has fuse Stylus Pro XL F1 on the C137 PSB PSE blown m Check the output voltage of the C137 PSB PSE at CN2 v Is the output CN5 on the C162 MAIN board NO NO Does the fuse blow again at power on YES voltage correct Replace the C162 MAIN board Is the problem corrected Replace the C137 PSB PSE board Check motors and drivers Refer to the section describing repair of the printer mechanism Rev A Stylus Pro XL 5 2 2 Error is detected START Identify the type of error indicated See Table 5 3 Turn the printer off and try to move the carriage manually Carriage error Replace the ink cartridge with a new one No ink cartriage YES 2 Does error occur again W
114. tion distance front rear position Make each adjustment 5 1 Troubleshooting Table 5 7 Repair of the Printer Mechanism Cont Symptom Paper is not fed normally Condition Foreign substances are lodged in the paper path Checkpoint Visually check the paper path Stylus Pro XL Solution Remove any foreign substances Paper is not fed Paper feeding gears are defective Visually check the gears Replace defective gears The paper feed motor is defective Measure the coil resistance of the PF motor Replace the PF motor Paper top of slips comes Note Cleaning sheets are available as service parts form position out too narrow Particles of power residue from coating on glossy paper are sticking to the PF roller Check that particles of the power residue from the coating on glossy paper are not sticking to the PF roller Perform the PF roller cleaning with the cleaning sheet See Note Rev A Chapter 6 Maintenance Table of Contents 6 1 PREVENTIVE MAINTENANCE 6 1 6 2 SERVICE MAINTENANCE 6 2 6 2 1 Printhead 6 2 6 2 2 Waste Ink Drain Tank 6 2 6 3 LUBRICATION AND ADHESIVE 6 3 LIST OF FIGURES Figure 6 1 Lubrication Points and Adhesive Points 1 6 5 Figure 6 2 Lubrication
115. under 2 replace the linear spacer with a thinner linear spacer If your pattern is similar to the pattern shown under 2 replace the linear spacer with a thicker spacer Turn the printer off Move the carriage to the center while pressing the carriage lock lever and remove the two ink cartridges Rubber Cap Screw 3 Figure 4 10 Removing the Rubber Cap 7 Remove the rubber cap that covering a head screw at the side of color ink cartridge and then loosen but do not remove 3 screws Refer to the figure below WARNING After replacing the spacer always install new ink cartridges before returning the printer to the user During adjustment use the ink cartridges exclusively for service Monochrome 1020626 CMY 1020627 You can reuse the old ink cartridges for other purposes 4 10 Rev A Stylus Pro XL Adjustments 8 Change the linear spacers 2 spacers for the monochrome head only with new ones referring the figure below Replace linear spacers using tweezers to push the head base toward the rear Carriage Unit gt Black Head n 1 Push e E Head Base T Angular Spacer m je Platen Gap Adjust Lever Linear Spacer x 2 2 Replace Linear Spacer Replacement Position Figure 4 11 Linear Spacer Replacement Method 9 Rerun
116. ve the upper frame with 4 PF support rollers 27 Upper Frame 222 CBS M3x5 Figure 3 21 Upper Frame Removal ASSEMBLY POINT Assemble each straight end of torsion spring 6700s to attach to the center of the drioen roller support Base Frame PF Support Roller Tension Spring Figure 3 22 Attaching the Torsion Spring 3 18 REV A Chapter 4 Adjustments Table of Contents 4 1 OVERVIEW 4 1 4 1 1 Destination Data Writing Operation 4 2 4 1 2 Bi D Bidirectional Printing Alignment Adjustment 4 3 4 1 3 Head Gap Adjustment Black and Color 4 4 4 1 4 Black Head Angle Adjustment 4 5 4 1 5 Black Color Head Vertical Adjustment 4 9 4 1 6 Color Head Angle Adjustment 4 12 4 1 7 Platen Gap Adjustment 4 16 4 1 8 Internal Timer Reset Operation 4 17 List of figures Figure 4 1 Head Gap Adjustment Sample 4 4 Figure 4 2 B Head Angle and Linear Angular 4 5 Figure 4 3 Spacer Kinds amp Relation of the Shape and Thickness 4 5 Figure 4 4 Black Head Angle Adjustment Sample 4 6 Figure 4 5 Spacer Slection 4 6 Figu
117. wing Self test mode Turn on the printer while holding down the Load Eject button Hex dump mode Turn on the printer while holding down the Font and Load Eject buttons Once this mode is selected the printer prints all received data in hexadecimal format Demonstration mode Turn on the printer while holding down the Alt button Default setting mode Turn on the printer while holding down the Economy Condensed button For more information about the mode see Section 1 4 3 Initialize EEPROM Turn on the printer while holding the Alt Font Load Eject and Pause buttons Table 1 12 Printer Condition Panel Status Printer status Indicators Operate Paper No Ink pata Out Cartridge Economy Condensed Power on condition Data exit Economy mode Condensed mode Pause condition Power on off sequence Blinks Ink sequence Blinks Ink cartridge change mode Blinks Head gap adjust mode Blinks Paper out On No ink cartrdige On Paper jam condition Blinks Maintenance request Blinks Blinks Blinks Blinks Cartidge error Blinks Blinks don t care 1 14 Rev A Stylus Pro XL Product Description 1 4 3 Default Settings The printer can save some printer setting parameters that define its functions at initialization You can change these parameters by using the printer s default setting mode 1 4 3 1 Default Set
118. y 17 is only installed in JAPAN version Figure 2 17 Main Control Circuit Block Diagram REV A 2 15 Operating Principles Stylus Pro XL 2 3 2 1 Reset Circuits The C162 MAIN Board contains 2 reset circuits the 5 V monitor reset circuit and the 35 V monitor reset circuit The 5 V monitor reset circuit monitors the voltage level of the 5 V line using reset IC PST592D IC12 and outputs a reset signal to the E05A96 gate array IC2 when the voltage level drops below 4 2 V The 435 V monitor reset circuit monitors the voltage level of the 35 V line using reset IC M51955B 1 8 and outputs a reset signal to the CPU The reset signal is generated when the voltage level drops below 28 V and this causes a non maskable interrupt NMI 35 V 45V CPU IC1 M51955B 6 72 NMI 68 P62 5 V 717 RES 05 96 1 2 PST592D IC13 1 135 RESET PAS RST 55 Type B Figure 2 18 Reset Circuit Block Diagram 2 3 2 2 Sensor Circuits The following sensor circuits enable the C162 MAIN Board to monitor printer mechanism status HP sensor PE sensor BCO sensor CCO sensor Thermistor 2 16 The photocoupler type home position HP sensor is attached to the surface of the printer mechanism to detect the carriage home position A LOW level from the signal indicates that the carriage is in home position The mechanical switch paper end PE

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