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SERVICE MANUAL

Color Inkjet Printer

EPSON Stylus Photo R800

www.electronicsrepair.net
SEIJ03012
PRECAUTIONS
Precautionary notations throughout the text are categorized relative to 1)Personal injury and 2) damage to equipment.

DANGER Signals a precaution which, if ignored, could result in serious or fatal personal injury. Great caution should be exercised in performing
procedures preceded by DANGER Headings.

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

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

DANGER
1. ALWAYS DISCONNECT THE PRODUCT FROM THE POWER SOURCE AND PERIPHERAL DEVICES PERFORMING ANY MAINTENANCE OR REPAIR
PROCEDURES.
2. NO WORK SHOULD BE PERFORMED ON THE UNIT BY PERSONS UNFAMILIAR WITH BASIC SAFETY MEASURES AS DICTATED FOR ALL
ELECTRONICS TECHNICIANS IN THEIR LINE OF WORK.
3. WHEN PERFORMING TESTING AS DICTATED WITHIN THIS MANUAL, DO NOT CONNECT THE UNIT TO A POWER SOURCE UNTIL INSTRUCTED TO
DO SO. WHEN THE POWER SUPPLY CABLE MUST BE CONNECTED, USE EXTREME CAUTION IN WORKING ON POWER SUPPLY AND OTHER
ELECTRONIC COMPONENTS.

WARNING
1. REPAIRS ON EPSON PRODUCT SHOULD BE PERFORMED ONLY BY AN EPSON CERTIFIED REPAIR TECHNICIAN.
2. MAKE CERTAIN THAT THE SOURCE VOLTAGES IS THE SAME AS THE RATED VOLTAGE, LISTED ON THE SERIAL NUMBER/RATING PLATE. IF THE
EPSON PRODUCT HAS A PRIMARY AC RATING DIFFERENT FROM AVAILABLE POWER SOURCE, DO NOT CONNECT IT TO THE POWER SOURCE.
3. ALWAYS VERIFY THAT THE EPSON PRODUCT HAS BEEN DISCONNECTED FROM THE POWER SOURCE BEFORE REMOVING OR REPLACING
PRINTED CIRCUIT BOARDS AND/OR INDIVIDUAL CHIPS.
4. IN ORDER TO PROTECT SENSITIVE MICROPROCESSORS AND CIRCUITRY, USE STATIC DISCHARGE EQUIPMENT, SUCH AS ANTI-STATIC WRIST
STRAPS, WHEN ACCESSING INTERNAL COMPONENTS.
5. REPLACE MALFUNCTIONING COMPONENTS ONLY WITH THOSE COMPONENTS BY THE MANUFACTURE; INTRODUCTION OF SECOND-SOURCE
ICs OR OTHER NON-APPROVED COMPONENTS MAY DAMAGE THE PRODUCT AND VOID ANY APPLICABLE EPSON WARRANTY.
About This Manual
This manual describes basic functions, theory of electrical and mechanical operations, maintenance and repair procedures of the printer. The instructions and
procedures included herein are intended for the experienced repair technicians, and attention should be given to the precautions on the preceding page.

Manual Configuration Symbols Used in this Manual


This manual consists of six chapters and Appendix. Various symbols are used throughout this manual either to provide additional
CHAPTER 1.PRODUCT DESCRIPTIONS information on a specific topic or to warn of possible danger present during a
Provides a general overview and specifications of the product. procedure or an action. Be aware of all symbols when they are used, and
CHAPTER 2.OPERATING PRINCIPLES always read NOTE, CAUTION, or WARNING messages.
Describes the theory of electrical and mechanical operations of
the product. Indicates an operating or maintenance procedure, practice or
CHAPTER 3.TROUBLESHOOTING condition that is necessary to keep the product’s quality.
Describes the step-by-step procedures for the troubleshooting.
CHAPTER 4.DISASSEMBLY / ASSEMBLY
Describes the step-by-step procedures for disassembling and
Indicates an operating or maintenance procedure, practice, or
assembling the product.
condition that, if not strictly observed, could result in damage to,
CHAPTER 5.ADJUSTMENT
or destruction of, equipment.
Provides Epson-approved methods for adjustment.
CHAPTER 6.MAINTENANCE
Provides preventive maintenance procedures and the lists of May indicate an operating or maintenance procedure, practice or
Epson-approved lubricants and adhesives required for servicing condition that is necessary to accomplish a task efficiently. It may
the product. also provide additional information that is related to a specific
APPENDIX Provides the following additional information for reference: subject, or comment on the results achieved through a previous
• Connector pin assignments action.
• Exploded diagram & Parts List
• Electric circuit boards components layout Indicates an operating or maintenance procedure, practice or
• Electrical circuit boards schematics condition that, if not strictly observed, could result in injury or loss
of life.

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


certain standard after disassembly and before re-assembly,
otherwise the quality of the components in question may be
adversely affected.
Revision Status
Revision Date of Issue Description
A December 16, 2003 First Release
B May 27, 2004 Correction of the misspellings
CONTENTS
Chapter 1 PRODUCT DESCRIPTION 3.1 Overview ............................................................................................... 38
3.1.1 Troubleshooting according to panel messages ............................ 38
1.1 Overview.................................................................................................. 9 3.1.2 Superficial Phenomenon-Based Troubleshooting ......................... 62
1.2 PG Setting ............................................................................................. 10
1.3 Functions .............................................................................................. 11 Chapter 4 DISASSEMBLY & ASSEMBLY
1.3.1 Control Panel ................................................................................ 11
1.3.2 Switches ........................................................................................ 11 4.1 Overview ............................................................................................... 73
1.3.3 Indicators ....................................................................................... 11 4.1.1 Precautions ................................................................................... 73
1.3.4 Switch Functions ........................................................................... 11 4.1.2 Tools to Be Used .......................................................................... 74
1.3.5 Indicator Display in Normal Mode ................................................. 12 4.1.3 Screw List ..................................................................................... 75
1.3.6 Error Status ................................................................................... 13 4.1.4 Pre-Shipment Checks ................................................................... 76
1.4 Casing Specifications .......................................................................... 14 4.2 Disassembly ......................................................................................... 77
4.2.1 Removing the Housings ................................................................ 78
1.5 Accessories .......................................................................................... 14
4.2.2 Stacker Assy. ................................................................................ 82
4.2.3 Waste Ink Pads ............................................................................. 84
Chapter 2 OPERATING PRINCIPLES 4.2.4 ASF Assy. ..................................................................................... 86
4.2.5 Removing the Boards ................................................................... 90
2.1 Overview................................................................................................ 16
4.2.6 Disassembling the Printer Mechanism .......................................... 96
2.2 Printer Mechanism ............................................................................... 16 4.2.7 Removing the Motors .................................................................. 130
2.2.1 Carriage Mechanism ..................................................................... 17 4.2.8 Removing the Sensors ................................................................ 133
2.2.2 Printhead Specifications ................................................................ 20
2.2.3 Paper Feeding Mechanism ........................................................... 20
Chapter 5 ADJUSTMENT
2.2.4 Paper Loading Mechanism ........................................................... 24
2.2.5 Ink System Mechanism ................................................................. 26 5.1 Adjustment Items and Overview ....................................................... 140
2.2.6 Ink Sequence ................................................................................ 28 5.1.1 Servicing Adjustment Item List .................................................... 140
2.2.7 Paper Cutter Mechanism .............................................................. 30 5.1.2 Replacement Part-Based Adjustment Priorities .......................... 143
2.2.8 Power-On Sequence ..................................................................... 32 5.1.3 Required Adjustment Jigs, Tools and Like .................................. 145
2.3 Electrical Circuitry Operating Principles............................................ 33 5.2 Adjustments........................................................................................ 145
2.3.1 Power Supply Circuit Operating Principle ..................................... 33 5.2.1 PF Belt Tension Adjustment ....................................................... 145
2.3.2 C550 MAIN Circuit Operating Principle ......................................... 34 5.2.2 PG Adjustment ............................................................................ 147

Chapter 3 TROUBLESHOOTING Chapter 6 MAINTENANCE


6.1 Overview.............................................................................................. 153
6.1.1 ROM Replacement ...................................................................... 153
6.1.2 Cleaning ...................................................................................... 153
6.1.3 Service Maintenance ................................................................... 154
6.1.4 Lubrication ................................................................................... 155

Chapter 7 APPENDIX
7.1 Connector Summary .......................................................................... 162
7.1.1 Connectors and Pin Layouts ....................................................... 162
7.2 Exploded Diagram .............................................................................. 163
7.3 Parts List for EPSON Stylus Photo R800 ......................................... 170
7.4 Component Layout............................................................................. 172
7.5 Circuit Diagram................................................................................... 174
1
CHAPTER

PRODUCT DESCRIPTION
EPSON Stylus Photo R800 Revision A

1.1 Overview Note"*1": When user performs the "Auto nozzle check and cleaning", Prints
nozzle check pattern and automatically checks print head nozzles. If they are
The Stylus Photo R800 is a photo printer designed for a wide range of users clogged, performs head cleaning. If they are not recovered, and performs head
from individual users to commercial users. As a successor to the Stylus Photo cleaning and detection up to tree times.
950/960, this consumer middle high model is capable of CD-R/DVD-R printing
and roll paper cutter functions.
This product has the following features.

FEATURES
† High Color Print Quality
„ High photo quality thanks to Photo Mach technology
„ Achievement of higher quality using microweaves and super
microweaves
„ High resolution printing of 5760 x 1440dpi, world's minimum dot 1.5pl
MSDT
† High-speed printing
† Two Different Interfaces Supported
„ USB 2.0 (HS compatibility)
Figure 1-1. Product Appearance
„ IEEE-1394
† Compact, space saving
† Windows/Macintosh Exclusive
† Multi-size Capable ASF
ASF equipped as standard supports forms ranging from business cards to
A4.
† CSIC-compatible Independent Ink Cartridge
† Roll paper compatibility
† Fast, 4-side borderless printing compatibility
† Two-sided printing compatibility
† Prevention of platen printing by optical sensor
† CD-R/DVD-R printing compatibility by front loading
† Business card, card photo printing compatibility
† Auto Nozzle Check and Cleaning*1

PRODUCT DESCRIPTION Overview 9


EPSON Stylus Photo R800 Revision A

1.2 PG Setting
As this printer uses an Auto PG (APG), an appropriate PG position is set according to the used paper type.
The following table indicates the PG positions, the main applications of each position, and the relationships between the two sensors used with the APG.

Table 1-1.
PG Position
Application
PG (-) PG (0) PG (+) PG (++) Release
Printing • Special thick paper • Plain paper • Envelope • CD-R/Board paper
• Special thin paper • PG(0) rub avoidance –
• PG(-) rub avoidance
Non-printing • Standby position • Initialization at • Waiting for CD-R/
after power-on (For power-on Board paper to be
– –
bottom stacker) • Cleaning (wiping) fed
• Paper jam removal
PG value 1.2mm 1.7mm 2.1mm 4.5mm –
Sensor PG (-) PG (Typ.) PG (+) PG (++) Release
APG Sensor 1 OFF OFF OFF OFF OFF
APG Sensor 2 ON ON ON OFF OFF

PRODUCT DESCRIPTION PG Setting 10


EPSON Stylus Photo R800 Revision A

1.3 Functions 1.3.4 Switch Functions


FUNCTIONS IN NORMAL STATUS
1.3.1 Control Panel
The appearance of the control panel is shown below. Table 1-2. Normal-status Functions
Switch Function
Ink LED Paper LED Power LED Power switch • Power On/Off
• Loads or Ejects the Paper.
Paper switch
• In the condition of printing, cancel the print job.
• Starts the Cleaning of head with 3 second pushing.
• Moves the Carriage to ink cartridge change position.
Ink switch
• When Carriage is on the ink cartridge change position, return
carriage from ink cartridge change position.
• Loads the Roll paper.
• Back out the roll paper with 3 second pushing.
Ink switch Power switch
• Move to tear off position / Return from tear off position.
Roll paper
Roll paper switch Paper switch switch • When the cutter is set, cuts the paper.
• When the photo album is used, ejects the paper forwards only.
Figure 1-2. Control Panel Appearance (At this mode, the printer can't move the cutter and can't move
backwards.)
Note : When the printer has frozen, hold down the Power switch and Ink switch for 7
seconds to forcibly switch power off.
1.3.2 Switches
† Power switch
† Paper switch FUNCTION AT POWER-ON
† Ink switch
Table 1-3. Power-on Function
† Roll paper switch
Switch Function
Paper switch Starts status printings.*1
1.3.3 Indicators Note "*1": Status printings prints firmware version, ink counter and nozzle check
patterns.
† Power LED : Green
† Paper LED : Red
† Ink LED : Red

PRODUCT DESCRIPTION Functions 11


EPSON Stylus Photo R800 Revision A

1.3.5 Indicator Display in Normal Mode


Table 1-4. Printer Condition and LED Status
Indicators
Printer status Error status
Power Paper Ink Priority
Idle – On – – 20
Data Processing – Blink – – 19
Pause *1 Status 05h – – – 18
Ink Sequence Processing – Blink – – 17
Ink Cartridge Change Mode – Blink – – 16
PG Release Processing – Blink Blink Blink 15
Ink Low (warning) – – – Blink 14
Tear Off Status 11h – – – 13
Paper Mismatch Error 0Ch Fast Blink – 12
Paper Out 06h – On – 11
Ink Out 05h – – On 10
No Ink Cartridge or Ink Cartridge Error 05h – – On 9
Paper Jam Error 04h – Blink – 8
Card Loading Error 2Ah – Fast Blink – 7
Cutter Jam Error 1Dh –| Blink 2 – 6
Cover Open Error 02h – Blink 2 Fast Blink 5
Reset Input – On On On Å|
Fatal Error 00h Off Fast Blink Fast Blink 4
Cutter Position Error 1Ch Off Blink 2 Blink 2 3
Blink Blink
Maintenance Request 10h Off 2
Alternately 1 Alternately 2
Power Off – Fast Blink Off Off 1
Note: • "–" : Don't care
• Blink : 0.5sec on + 0.5sec off repetition
• Blink 2 : 0.2sec on + 0.2sec + 0.2sec on + 0.4sec off repetition
• Fast Blink : 0.1sec on + 0.1sec off repetition
• Blink alternately 1 : 0.5sec on + 0.5sec off repetition
• Blink alternately 2 : 0.5sec off + 0.5sec on repetition
Note"*1": When the Photo album paper is end, the printer goes to this status.

PRODUCT DESCRIPTION Functions 12


EPSON Stylus Photo R800 Revision A

1.3.6 Error Status Table 1-5. General error


Error Status Occurring Condition Resuming Condition
If any of the following states is detected, this printer is put in an error status and
Cutter Jam Error When Cutter can't cut the paper, it Switch power off and
turns the interface signal -ERROR "Low" and BUSY "High" to inhibit data input.
goes Cutter Jam Error. recheck the cutter state.
At this time, the printer is automatically disabled from printing. However, when
When a paper jam has
communication is being made using the IEEE1284.4 protocol, communication occurred, clear the
with the printer is enabled. paper.
† General error Cover Open Error When the cover is opened at Close the cover.
After the cause of this type of error is removed, the printer can resume its Economy printing mode, the printer
operation from where it stopped due to the error goes this error.

Table 1-5. General error


Error Status Occurring Condition Resuming Condition † Fatal error
Paper Mismatch If the paper path specified by the Change the printer's After the cause of this type of error is removed, the printer cannot return to
Error print data is different from the paper path to the one normal unless it is powered off and then on again
printer's real paper path, the printer specified by the data.
goes to this error. Table 1-6. Fatal error
Paper Out When printer fails to load a sheet, it Set the paper to the ASF Error Status Occurring Condition Resuming Condition
goes Paper Out Error. and push the Paper Fatal Error When detecting a Fatal Error such as Turn off and turn on.
switch. a carriage control error, the printer is
Ink Out When the printer runs out the most Install the new Ink placed in an error status.
part of the ink of any one color, it Cartridge. Cutter Position When Cutter can't return to cutter Switch power off and
warns Ink Low and keeps printing. Error home position, it goes Cutter Position recheck the cutter state.
When the printer runs out the whole Error. When a paper jam has
ink of any one color, it stops printing occurred, clear the
and indicates Ink Out Error. User is paper.
requested to install a new Ink- Maintenance When the total quantity of ink wasted Replace the Waste Ink
Cartridge in this state. Request through the cleaning and flushing is Pads in the printer
No Ink Cartridge/ When printer detects that Ink Install the new Ink reaches to the limit, printer indicates enclosure by a service
CSIC Error Cartridge comes off, it goes this error Cartridge. this error and stops. person.
mode.
Paper Jam Error • Failure of ejecting a sheet Remove the jammed
• Failure of loading a sheet to the paper.
loading position
Card Loading When the card was loaded to the Set an A4 paper to the
Error wrong position, the printer goes this ASF, and press the
error. Paper switch. If the card
couldn't eject at your first
try, repeat again the
same method.

PRODUCT DESCRIPTION Functions 13


EPSON Stylus Photo R800 Revision A

1.4 Casing Specifications 1.5 Accessories


EXTERNAL DIMENSIONS STANDARD ACCESSORIES
When tucked : 495 (width) x 305 (depth) x 193 mm (height) † Setup guide : 1 set
When used : 495 (width) x 644 (depth) x 322 mm (height) † Ink Cartridge (one for each of 8 colors) : 1 set
† CD-ROM (Printer driver utility) : 1 set
WEIGHT † CD/DVD tray : 1 set
7.0kg † CD/DVD print position check sheet : 1 set
† 8cm CD/DVD attachment : 1 set
EXTERNAL DIMENSION DIAGRAM
† Roll paper holder : 1 set
† Power cord : 1 set

CONSUMABLES AND OPTIONS


† Ink cartridges
322
„ Gloss Optimizer: T0540
193 „ Black : T0541
„ Cyan : T0542
„ Magenta : T0543
„ Yellow : T0544
305 „ Red : T0547
„ Matte Black : T0548
644
„ Blue : T0549
† Roll paper auto cutter
495
(Cutter, paper support basket, instruction manual) : PMA4RAC3
† USB cable : USBCB2

Figure 1-3. External Dimension Diagram

PRODUCT DESCRIPTION Casing Specifications 14


2
CHAPTER

OPERATING PRINCIPLES
EPSON Stylus Photo R800 Revision A

2.1 Overview The basic structure of the mechanism has the following features.
† The sensor dedicated to Auto Bi-D adjustment and auto nozzle check is
This chapter explains the operating principles of the mechanical sections and installed.
electrical circuits in this product. The main components of this product are as
The following shows the outline of the printer mechanism.
follows.
† Control circuit board : C550 MAIN PF Encoder PF Scale
Sensor
† Power supply circuit board : C550 PSB/PSE
† Control panel board : C550 PNL
Paper Eject
Roller (front)
PG Release APG Sensors
2.2 Printer Mechanism Sensor
PF Motor
Like the conventional model, this product uses DC motors as power sources. Paper Eject
The following table describes the motor types and their applications. Roller (rear)
APG Motor
Table 2-1. Various Motors
Motor Name Type Applications/Functions PF Roller
Timing Belt
Used for carriage driving. Makes little noise CR Encoder
DC motor with
CR Motor during driving. The CR linear scale and CR Sensor
brushes
encoder sensor are used to control the motor.
PW Sensor LD Roller
Power source to drive the Paper loading rollers
at the time of fixed-value paper loading or paper
DC motor with feed/eject operation. To grasp the paper feed Ink Mark
PF Motor Sensor
brushes pitch, the precision gear surface is fitted with the
PF scale and the PF encoder sensor is used to Retard
Carriage Roller
control the motor.
Unit
Power source to drive the Carriage Unit at the
DC motor with time of PG setting. The two APG Sensors and
APG Motor
brushes Carriage Shaft are driven vertically to control the CR Scale
motor. PE Sensor

Performs the paper feed operation of the ASF.


4-phase, 48-pole Ink System
Because of a stepping motor, this motor does ASF Motor
ASF Motor PM type Unit
not require a scale, photo sensor and like to be
stepping motor
fitted to grasp the driving conditions.
Drives the pump, wiper, etc. of the Ink System. Pump Motor CR Motor
4-phase, 48-pole
Because of a stepping motor, this motor does Carriage
Pump Motor PM type Shaft
not require a scale, photo sensor and like to be
stepping motor
fitted to grasp the driving conditions. Figure 2-1. Printer Mechanism Outline

OPERATING PRINCIPLES Overview 16


EPSON Stylus Photo R800 Revision A

2.2.1 Carriage Mechanism † CR measurement sequence


To set the appropriate drive current value according to the variation of the
The Carriage mechanism consists of the Carriage Motor (CR Motor), Carriage CR mechanical load, the mechanical load is measured in a CR
Shafts, Platen Gap Adjustment Mechanism, Carriage Lock Mechanism, and measurement sequence and saved into the EEPROM A4<H>, A5<H> in a
others. power-on or IC change sequence. However, if 46 is saved at the EEPROM
A4<H> and 05 at A5<H>, Fatal error will occur since too large load is
2.2.1.1 Carriage Mechanism applied to the CR drive system.
The following indicates the Carriage driving DC motor specifications. The above control and sequences correct the drive current value of the CR
Table 2-2. CR Motor Specifications Motor according to not only the mechanical load but also the variations of the
motor and like. In addition, the resultant CR drive current value is used to
Item Specifications
calculate a heating value, and when the specified heating value is reached,
Type DC motor with brushes wait time is provided per CR path for printing.
Drive voltage +42V ± 5% (voltage applied to driver)
Winding resistance 24.4Ω ± 15%
Inductance 17.5mH ± 25%
Drive method PWM, constant-current chopping
Drive IC A6615

Closed loop control based on the CR Motor (DC Motor) and CR Encoder
Sensor has advantages in stabilized print quality and silent operation.
† Heat generation control
Using low-cost DC motors, this product grasps the variations of the torque
constants, coil resistances and power supply board output voltages of the
individual DC motors adequately to carry out heat generation control
according to individual differences.
† CR variation measurement sequence
The variations of the torque constant, coil resistance and power supply
board output voltage of the motor are measured in a CR variation
measurement sequence when the CR mechanical load is in the initial
status and saved into the EEPROM (A6<H>). According to the variations
(individual differences) measured in this sequence, the voltage is corrected
to make the drive current value constant (without an individual difference)
according to the variations (individual differences) measured in this
sequence.

OPERATING PRINCIPLES Printer Mechanism 17


EPSON Stylus Photo R800 Revision A

2.2.1.2 Carriage Home Position Detection 2.2.1.3 Sequence Used for PW Detection
As in the conventional model, the Carriage Home Position is detected using the The PW (paper width detection) Sensor installed on the Carriage Unit bottom is
drive current of the CR Motor and the speed/position signal of the CR Linear used to control the printer according to various sequences.
Encoder.
The following briefly describes the PW Sensor operating principle.
The basic home position detection sequence is as described below.
A dark voltage is measured by the PW Sensor in three places on the right end
1. The CR linear encoder pulse counter in the CPU is reset by the plane (area without the absorber) of the Front Paper Guide every time power is
initialization operation performed at power-on. switched on, and the measurement values are saved into the EEPROM as
2. When the CR Motor rotates counterclockwise, the Carriage Unit moves threshold values.
from left to right. When the following conditions are satisfied, the CPU „ Threshold value > detection voltage: Paper present
assumes that the Carriage Unit made contact with the right frame. „ Threshold value < detection voltage: Paper absent
„ The ASIC detects 862/1500 counts or more in the PWM output under The following sequences are performed.
CR Motor load positioning control.
† Off-paper printing prevention control
„ P1 (number of output pulses from when power is switched on until the
Before start of printing (immediately after the end of paper locating), or
Carriage Unit makes contact with the right frame) is 12 steps or less.
during printing, whether paper is present or not is detected to prevent off-
3. When the CR Motor rotates clockwise, the Carriage Unit moves from right paper printing on the Paper Guide by borderless printing used in a wrong
to left. When the following conditions are satisfied, the CPU assumes that way. (This applies to only the left or right end of the paper.)
the Carriage Unit reached the CR lock confirmation position.
This control applies to only the four-side borderless mode.
„ The ASIC detects 483/1500 counts or more in the PWM output under
† CD-R center detection control
CR Motor load positioning control.
When printing is not being performed, the PW detector is used to detect
„ A difference between P1 and P2 (number of output pulses from when
the center of CD-R. Refer to "2.2.3.4 CD-R Printing Mechanism (p.23)" for
the Carriage Unit made contact with the right frame until it reaches the
details.
Carriage lock confirmation position) is 12 steps or less.
† Board paper/roll paper leading edge detection control
4. When the CR Motor rotates counterclockwise to move the Carriage from
Control exercised to detect the user-preset board paper leading edge, or
left to right and the CPU detects 862/1500 counts or more in the PWM
control carried out to detect the roll paper edge. Therefore, the PW sensor
output under CR Motor load positioning control, the printer judges it as
does not detect a paper leading edge at the time of ASF cut sheet feeding.
contact with the frame.
5. When a difference between P1 and P3 (number of output pulses from
when the Carriage Unit reached the Carriage lock confirmation position
until it makes contact with the right frame) is 4 steps or less, the printer
judges that the Carriage Unit is in the home position.
The IC14 (ASIC) sets the drive current value adequate for the Carriage Unit
motion and outputs it to the motor driver.
Based on the signal output from the IC14 (ASIC), the IC5 (Motor Driver)
outputs the CR Motor drive current to the CR Motor.

OPERATING PRINCIPLES Printer Mechanism 18


EPSON Stylus Photo R800 Revision A

† Off-range restriction control 2.2.1.4 APG (Auto PG) Mechanism


At the time of frameless printing, a paper leading edge is detected using
The following indicates the APG DC motor specifications.
the PW Sensor to restrict the frameless off-range amount.
„ Complete frameless mode Table 2-3. APG Motor Specifications
Control is performed to print the print data 3mm larger at top, 5mm Item Specifications
larger at bottom, and 2.5mm lager at left and right than the detected
Type DC motor with brushes
paper size.
Drive voltage +42V ± 5% (voltage applied to driver)
„ Roll paper mode
In the left and right frameless mode, control is performed to print the Winding resistance 64.7Ω ± 15%
print data 2.5mm lager at left and right than the detected paper size. Inductance 37.6mH ± 25%
† PW sensor dark voltage (VH) measurement Drive method PWM, constant-current chopping
PW sensor dark voltage (VH) measurement is performed at the following Drive IC A6615
timings and locations and used to calculate the threshold value of whether
paper is present or not. The APG Motor (DC Motor) and two APG Sensors automatically adjust the PG
„ Cut sheets, Roll paper amount according to the paper.
The dark voltage is measured and updated at every power-on, and the
threshold value (VS) is calculated and saved in the EPROM area as a APG Motor
PW detection level.
• Threshold value > detection voltage: Paper present
• Threshold value < detection voltage: Paper absent
„ CD-R Tray
When a CD-R is used, the dark voltage is measured on the CD-R tray,
and the threshold value (VS) is then calculated and saved in the
EPROM area as a PW detection level. PG Cam
• Threshold value > detection voltage: CD-R present
(tray home position detected)
The measurement voltage in the presence of the CD-R is saved into
the EEPROM as a white level. The white level value is used to check
Carriage Shaft Carriage Unit
the sensor deterioration condition during servicing or like.
• If the measurement value of the white level is close to that of the PW Figure 2-2. APG Mechanism
detection level, it means that the sensor is dirty or deteriorated.

OPERATING PRINCIPLES Printer Mechanism 19


EPSON Stylus Photo R800 Revision A

2.2.2 Printhead Specifications 2.2.3 Paper Feeding Mechanism


The Printhead of this product is a F-Mach head. The paper feeding mechanism indicates the mechanism that feeds paper or
The following shows the arrangement of the nozzles and the color CD-R Tray to the PF Roller Shaft.
arrangement of each nozzle line when they are viewed from behind.
7.620mm 7.620mm 7.620mm
(216/720inch) (216/720inch) (216/720inch) Cut sheet
Roll paper
2.258mm 2.258mm 2.258mm 2.258mm
(64/720inch) (64/720inch) (64/720inch) (64/720inch) PE Sensor
CD-R Tray
Star Wheel Rollers

Paper feeding
Line A Line C Line E Line G direction
Line B Line D Line F Line H
Board Paper

0.071mm 0.141mm
(1/180inch) Paper eject roller (front) Paper eject roller (rear) PF Roller
(1/360inch)

31.89mm
Figure 2-4. Paper Feeding Mechanism
41.66mm

Carriage moving direction


Figure 2-3. Nozzle Rear View

Table 2-4. Relationships between Nozzle Lines and Color Arrangement


Line Ink
A Yellow
B Magenta
C Cyan
D Matte-black
E Photo-black
F Red
G Blue
H Gloss Optimizer

OPERATING PRINCIPLES Printer Mechanism 20


EPSON Stylus Photo R800 Revision A

2.2.3.1 ASF Paper Feeding Mechanism Driven by the ASF Motor, the ASF Assy. performs the following feeding
operation.
The following indicates the ASF Assy. driving stepping motor specifications.
1. When a paper feeding command is issued from the PC or the Paper Switch
Table 2-5. ASF Motor Specifications of the panel is pressed after power-on, the driving force of the ASF Motor
Item Specifications begins to be transmitted to the LD Roller.
Type 4-phase, 48-pole PM type stepping motor 2. The flag of the Paper Back Cam moves away from the home position of the
Drive voltage Bipolar drive/constant-current drive ASF Sensor and the LD Roller rotates.
Winding resistance +42V ± 5% (voltage applied to driver) 3. When the LD Roller rotates one turn and the flag of the Paper Back Cam
Inductance 7.4Ω ± 10% (per phase at 25°C) returns to the home position of the ASF Sensor again, the LD Roller stops
Drive method 12.0mH ± 20% (1kH, 1Vrms) rotating.

The drive of the ASF Motor is transmitted to the LD Roller in the following path.
† LD Roller Drive Transmission Path
2.2.3.2 Manual Paper Feeding Mechanism (Board Paper)
ASF Motor Pinion Gear ⇒ Combination Gear 29, 11 ⇒ Paper Back Cam
⇒ LD Roller To enable direct printing onto thick paper and CD-R label, this product has the
mechanism to feed paper from the printer front manually.
1. When the Stacker is lifted, the close signal of the PG Release Sensor is
transmitted to the APG Assy. in the following order.
„ PG Release Sensor ⇒ Main Board ⇒ Relay Board ⇒ APG Motor
ASF Motor Paper Back Cam
⇒ APG Assy.
2. Driven by the APG Motor, the APG Assy. sets the PG position to PG
release to release the Upper Paper Guide (Driven Roller).
3. Along the Paper Feed Guide of the Stacker, match the leading edge (front
side) of the board paper to the marking position of the Stacker.
After the above operation, press the Paper Switch. When the PE Sensor
detects that the paper is present, it detects the leading edge of the paper, and
Combination Gear 29, 11 the printer performs paper locating and then enters the standby status.
LD Roller Shaft

Figure 2-5. LD Roller Drive Transmission Path

OPERATING PRINCIPLES Printer Mechanism 21


EPSON Stylus Photo R800 Revision A

2.2.3.3 Roll Paper Feeding † When roll paper printing data is received (when cutter is not fitted)
Since panel operation in the roll paper mode differs from the above operation, 1. After end of printing, press the Roll Paper Switch.
the differences of panel operation after roll paper feeding will be described. 2. A tear-off line is printed, and the roll paper is fed to the roll paper
1. When roll paper is fed, the PE Sensor detects the paper, and after 3 cut position.
seconds have elapsed, the paper is fed. 3. After cutting the roll paper with a pair of scissors or like, Press the
2. The PW Sensor check for the leading edge of the paper, and if it detects Roll Paper Switch. This returns the leading edge of the paper to
the paper, the printer operates in the Cutter Self-Cleaning Mode. the print starting position.
3. The printer back-feeds the paper to the paper print starting position.
At this time, panel Switch operation is invalid, and the definitions of the panel
operation and Paper Switch differ between cut sheets and roll paper.
The following describes a difference between Panel Switch operations
performed when roll paper is fed and performed when roll paper printing data is
received from the PC.
† When roll paper is fed
Pressing the Roll Paper Switch for more than 3 seconds back-feeds the
leading edge of the roll paper to the PE Sensor (the Paper LED blinks). In
this state, draw the roll paper and press the Paper Switch to return to the
panel operation that enables paper feeding from the ASF.
† When roll paper printing data is received (when cutter is fitted)
„ When data is "No auto cut"
1. After end of printing, press the Roll Paper Switch. This feeds the
separation position in the print data to the roll paper cut position.
2. After the paper is cut, the leading edge of the paper returns to the
print starting position.
„ When data is "Standard 1 cut" or "Specific 2 cuts"
1. The roll paper is cut automatically at every separation of the print
data.
2. After the paper is cut, the leading edge of the paper returns to the
print starting position.

OPERATING PRINCIPLES Printer Mechanism 22


EPSON Stylus Photo R800 Revision A

2.2.3.4 CD-R Printing Mechanism 9. The Carriage Unit moves to the CD-R Tray HP detectable position
and stops there, and then the CD-R Tray is fed in the ASF
† CD-R tray home position detection sequence
direction.
Lift the Stacker (PG Release Sensor: Close), insert the CD-R Tray into the
specified position, and press the Paper Switch. This starts the following 10. When the CD-R Tray stops operating, the Carriage Unit moves to
operation. the carriage HP and stands by.
When the close signal of the PG Release Sensor is detected, no paper is If the CD-R Tray HP, white marking or CD-R cannot be detected in any
fed from the ASF if the Paper Switch is pressed. In this case, the Paper specified step operation in the CD-R Tray HP detection sequence, the CD-R
Switch executes a CD-R Tray home position detection sequence. Tray is ejected and Paper Out Error is displayed.
1. When the APG Assy. is driven, the PG position is set to "++" and
the Driven Roller of the Upper Paper Guide presses the CD-R PW Sensor
Tray.
2. When the Carriage Unit moves leftward and the PW Sensor
detects the CD-R, the Carriage Unit returns to the carriage home
position (HP).
3. After waiting for about 5 seconds at the carriage HP, the Carriage
Unit moves to the CD-R Tray HP detectable position (right end of
the CD-R Tray).
4. The CD-R Tray is pulled in the ASF direction, the PW Sensor
detects the CD-R Tray HP, and then the Carriage Unit moves to
the center of the CD-R Tray.
5. When the PW Sensor detects the white marking in the center of Carriage Unit
the CD-R Tray, the CD-R Tray is fed in the paper ejection CD-R Tray CD-R home position
direction.
6. The Carriage Unit moves leftward, the PW Sensor detects the left Figure 2-6. CD-R Printing Mechanism
side white marking, then the Carriage Unit moves rightward, and
the PW Sensor detects the right side white marking.
7. The Carriage Unit moves to the center of the CD-R Tray, and the
PW Sensor starts detection in the back-and-forth direction of the
CD-R. After the leading edge of the CD-R is detected, the CD-R
Tray is fed in the paper ejection direction, and the trailing edge of
the CD-R is detected. After that, the CD-R Tray is fed to the center
of the CD-R in the paper ejection direction.
8. The Carriage Unit moves leftward, and the PW Sensor starts
detection in the horizontal direction of the CD-R. After the left end
of the CD-R is detected, the Carriage Unit moves rightward, and
the right end of the CD-R is detected.

OPERATING PRINCIPLES Printer Mechanism 23


EPSON Stylus Photo R800 Revision A

2.2.4 Paper Loading Mechanism The driving force of the PF Motor is transmitted to the PF Roller and Paper
Eject Roller in the following path.
The Paper Loading Mechanism is designed to transfer the paper fed from the
† PF Roller Drive Transmission Path
ASF, Roll Paper Guide or Board Paper Guide or the CD-R fed from the CD-R
PF Motor Pinion Gear ⇒ PF Timing Belt ⇒
Tray according to the print data.
Combination Gear 36.294, 45.5 ⇒ PF Roller Shaft
2.2.4.1 Paper Loading Mechanism † Paper Eject Roller (front) Drive Transmission Path
PF Motor Pinion Gear ⇒ PF Timing Belt ⇒
The following indicates the paper loading driving DC motor specifications.
Combination Gear 36.294, 45.5 ⇒ Spur 31.5 ⇒ Spur 54 ⇒
Table 2-6. PF Motor Specifications Paper Eject Roller (front)
Item Specifications † Paper Eject Roller (rear) Drive Transmission Path
Type DC motor with brushes PF Motor Pinion Gear ⇒ PF Timing Belt ⇒
Combination Gear 36.294, 45.5 ⇒ Spur 31.5 ⇒ Spur 54 ⇒ Spur 18 ⇒
Drive voltage +42V ± 5% (voltage applied to driver)
Spur 15.5 ⇒ Spur 18 ⇒ Paper Eject Roller (rear)
Winding resistance 22.3Ω ± 25%
Inductance 17.3mH ± 25% The following shows the part names and outline of the drive transmission path.
Drive method PWM Paper is transferred in the above driving force transmission path.
Drive IC A6615
Combination Gear
Spur 18 Spur 54
36.294, 45.5
Like the CR Motor, a DC motor is used as the PF Motor in this product.
PF Timing Belt
Closed loop control based on the DC Motor and Rotary Encoder has the Spur 18
following advantages.
† Improved paper feed accuracy
† Paper feed amount control
Pinion Gear Spur 31.5 Spur 15.5

Front Paper
PF Motor Guide

Paper Eject Paper Eject


PF Roller Roller (front) Roller (rear)
Figure 2-7. Paper Loading Mechanism 1

OPERATING PRINCIPLES Printer Mechanism 24


EPSON Stylus Photo R800 Revision A

The fed paper is detected by the PE Sensor, and its leading edge is then 2.2.4.2 PF Measurement Sequence
transferred to the front of the Front Paper Guide.
† The mechanical load in the paper loading path is measured in the following
To eliminate the deflection of the paper, the paper is then returned toward the
cases to perform control so that an adequate current value is set according
ASF Assy. by the specified number of steps according to the paper feed mode.
to the mechanical load.
The paper is transferred again to the specified paper locating position of the
Front Paper Guide. „ When power is switched on
„ When the Ink Cartridge is replaced
Print Head Driven Roller „ When the removal or fitting of the cutter is recognized in the paper feed
sequence
Paper Star Wheel Rollers † When the mechanical load in the paper loading path reaches the specified
value, Fatal Error is displayed. (When the cutter is not fitted)
† When the cutter is fitted, the mechanical load when the cutter is fitted is
measured and reflected on the control since the mechanical load of the
cutter must be taken into consideration to set the adequate current value.

Paper eject roller (front) Paper eject roller (rear) PF Roller

Figure 2-8. Paper Loading Mechanism 2

OPERATING PRINCIPLES Printer Mechanism 25


EPSON Stylus Photo R800 Revision A

2.2.5 Ink System Mechanism 2.2.5.2 Drive Transmission Path to Pump Unit
The Ink System Mechanism consists of the following mechanisms. The drive of the Pump Motor is transmitted to the Pump Unit in the following
path.
† Pump Unit (including the CR Lock Lever)
† Motor Pinion Gear ⇒ Combination Gear 10.2, 21.2 IS
† Cap Unit
⇒ Spur Gear 20.4 IS ⇒ Pump Unit
2.2.5.1 Pump Unit The following shows the internal part names and operation outline of the Pump
Unit.
The Pump Unit is designed to suck ink from the Print Head or Cap Unit. The
Cap Unit has a built-in Head Cleaning Wiper.
<Pump Unit inside>
The following indicates the Pump Unit driving stepping motor specifications. Combination Gear 10.2, 21.2 IS

Table 2-7. Pump Motor Specifications


Item Specifications
Type 4-phase, 48-pole PM type stepping motor
Spur Gear
Drive voltage Bipolar drive/constant-current drive 20.4 IS
Winding resistance +42V ± 5% (voltage applied to driver)
Inductance 10.3Ω ± 10% (per phase at 25°C)
Drive method 13.4mH ± 20% (1kH, 1Vrms)

The following operations are performed when the drive of the Pump Motor is Motor Pinion Gear
transmitted to the Pump Unit.
Figure 2-9. Outline of Pump Unit Inside
Table 2-8. Pump Motor Rotation Directions and Functions
Pump Motor Rotation Direction* Functions
• Cap closing
• Ink suction
CW direction
• Wiper resetting
• CR Lock setting
• Cap opening
• Pump release
CCW direction
• Wiper setting
• CR Lock resetting
Note: As the rotation directions of the motor, CW indicates a clockwise
direction, and CCW indicates a counterclockwise direction, as seen
from the output shaft side of the motor mounting plate.

OPERATING PRINCIPLES Printer Mechanism 26


EPSON Stylus Photo R800 Revision A

The following shows the Pump Unit operating principle. 2.2.5.3 Cap Unit
The Cap Unit is designed to bring the Cap into close contact with the Print
Cap Unit Side
Head surface and suck ink by the driving force of the Pump Unit to secure air
tightness in the Cap.
When the printer is in a standby status or its power is OFF, the Cap Unit
prevents the ink from thickening.
Ink is fed to the Waste Ink Pad in the following path.
† Ink Cartridge ⇒ Head Cavity ⇒ Cap ⇒ Waste Ink Pad
The following diagram shows the outline of Cap Unit operation.

To Waste ink pad


Carriage Unit

Figure 2-10. Pump Unit Operating Principle


Cap

† Ink suction
1. The Pinion Gear of the Pump Motor rotates in the CW direction.
2. The Roller turns and simultaneously presses the tube.
3. Ink is fed from the Cap Unit toward the Waste Ink Pad.
Print Head
Slider cap rises to perform
capping.
† Pump release
1. The Pinion Gear of the Pump Motor rotates in the CCW direction. Figure 2-11. Capping Mechanism

2. The Roller moves away from the tube and releases the tube.
3. Ink is not sucked.

OPERATING PRINCIPLES Printer Mechanism 27


EPSON Stylus Photo R800 Revision A

2.2.6 Ink Sequence „ When current I/C consumption is the same (as ink consumption in
EEPROM)
The following ink sequence is executed according to various timer, counter,
flag and other information saved on the EEPROM. 1. When the initial filling flag is set and the CSIC side ink
consumption is 0, the printer judges that initial filling is not yet
† CSIC-related sequence performed.
The ink type code stored in the CSIC Memory Chip is identical regardless (The printer before initial filling judges that the I/C is fitted in a
of the Japanese domestic or overseas cartridges, and is saved at the Main
power-off status.)
Board EEPROM.
At power-on, data is read from each color CSIC and the CSIC data status 2. Installation count updating, CSIC information replacement, and
is made valid. If the data read from each CSIC has any problem, Ink initial filling are executed in this order.
cartridge error or Ink end error is displayed. 3. If the initial filling flag is not set, the printer judges that I/C change
After CSIC operation is checked, the ink consumption of the I/C currently was not made at power-off and regards the CSIC data as valid.
installed per color is compared with the ink consumption saved in the
Data is written to the CSIC at the following timings.
printer EEPROM, and control is performed under the following conditions.
„ At power-off
„ When current I/C consumption differs (from ink consumption in
EEPROM) „ In the power saving mode
„ At the time of Ink Cartridge replacement
1. On the assumption that the I/C has been changed at power-off, the „ At the time of cleaning
first I/C flag is reset.
1. Data is read from the CSIC and developed in the RAM on the Main
2. The installation count in the printer EEPROM is updated for the
Board.
CSIC. In the CSIC information replacement sequence, the CSIC
side ink consumption data is updated to the ink consumption data 2. The data is compared with the ink consumption in the printer
in the printer EEPROM. EEPROM. If the data are the same, the data is written to the CSIC.
If they are different, only the consumed difference is added and
3. The used model name data on the I/C side is rewritten.
written to the CSIC. When cleaning is performed, the CL count is
Note: Reason why the used model name data is rewritten from the also written, and when the I/C is changed, the installation count is
printer to the I/C: To grasp which printer used the I/C removed. also written.
4. The change flag 2 (flag that indicates change CL) is set and CL is
executed.

OPERATING PRINCIPLES Printer Mechanism 28


EPSON Stylus Photo R800 Revision A

† Initial ink filling † Manual cleaning


When the printer is powered on for the first time after the purchase of the This product provides three different manual cleanings to remove ink
product, the printer executes the initial ink filling operation to fill the ink coagulated by air bubbles, viscous material or foreign matter. Perform the
cavities of the Head with ink. When the initial ink filling operation is following manual CL operations by operating the panel or using the utility
performed properly, the printer clears the flag in the EEPROM so that initial included in the printer driver.
ink filling operation will not be performed when it is powered on next. The Independently of the printing path after the previous CL, perform manual
Stylus Photo R800 requires about 150 seconds to perform the initial ink CL from CL1 to CL3 in order if the cumulative printing timer counter is less
filling operation and consumes about 1/ 7 of the new ink cartridge. than 7min. Only when the cumulative printing timer counter is more than
If the sequence does not end normally during initial filling, the initial filling 7min, execute only CL1.
flag is not cleared and the CL operating flag is set. Because of these flags, „ CL1: 1.704g (0.213g per color)
when powered on next time, the printer assumes that it was powered off for „ CL2: 4.488g (0.561g per color)
some reason during initial filling and executes CL3 instead of the initial „ CL3: 7.120g (0.890g per color)
filling sequence. (On the conventional mode, initial filling was executed „ Wiper operation
again. However, when this operation was performed, ink was wasted and Clean the nozzle surface with the right-half rubber part of the wiper.
therefore CL3 is executed to cover the ink filling performance.)
„ Flushing operation
When the initial filling flag is set and the CL operating flag is not set, the
Prevent color mixture. Stabilize the ink surface inside the nozzles.
printer assumes that the initial filling was not executed at all (power was
switched on but the cartridges were not set), and when the printer is If the remaining ink amount of the I/C is short or the I/C is in an Ink Low/Out
powered on next time, it executes initial filling. status, all manual cleanings are disabled and STM3 shows the condition.

† Change cleaning
Change CL1 is executed when Ink Cartridge change is made.
„ Change CL1: 3.4g (0.425g per color)

OPERATING PRINCIPLES Printer Mechanism 29


EPSON Stylus Photo R800 Revision A

† Timer cleaning 2.2.7 Paper Cutter Mechanism


Ink is consumed depending on the combination of the cumulative printing
timer, cumulative cleaning count and cleaning timer. The Paper cutter mechanism consists of such main parts as the Cutter Motor,
left and right HP Sensors (2 pcs. in all), Relay Board, Paper Eject Roller and
† Flushing
Paper Holddown Flap in the Cutter unit.
Two different flushing operations are executed for the following reasons.
„ Periodic flushing † Operation during printing
This is done to prevent ink viscosity in the Print Head nozzles from „ When the Cutter Blade starts cutting, the Paper Hold-down Flap rises.
increasing during continuous printing. A specific small amount of ink is „ The paper is held and simultaneously cut.
discharged into the Cap according to the Periodic flushing timer. „ The HP Sensors installed on both ends of the Cutter operating area
„ Periodic large-amount flushing detect the Cutter Blade position.
This is done to prevent ink viscosity in the Print Head nozzles from „ The HP Sensors detect whether the Cutter Blade operates properly,
increasing during continuous printing. A large amount of ink is and Cutter Position Error or Cutter Jam Error is displayed according to
discharged into the Cap according to the Periodic large-amount the operating condition.
flushing timer.

Paper Holddown Flap


Right HP Sensor
Left HP
Sensor
Cutter Blade

Cutter Motor Paper Eject Roller Relay Board

Figure 2-12. Paper Cutter Mechanism

OPERATING PRINCIPLES Printer Mechanism 30


EPSON Stylus Photo R800 Revision A

2.2.7.1 Cutter Initialization Sequence Paper cutting by the Cutter consists of the basic cutting sequences 1 and 2.
When the Cutter is fitted, the Cutter initialization sequence is executed if the † Basic cutting sequences 1
printer has confirmed that the Cutter has been fitted (the Power Switch blinks Means movement from the right HP Sensor to the left HP Sensor. At this
about 5 seconds). time, as soon as the Cutter Blade starts moving from the right HP Sensor,
the Timer starts. If the left HP Sensor does not detect the Cutter Blade
† Cutter Initialization Sequence
within 3 seconds, the Cutter initialization sequence is executed and then
The initialization sequence is performed to securely put the Cutter Blade in
Cutter Jam Error or Cutter Position Error occurs.
a standby position detected by the right HP Sensor if the Cutter Blade is
not detected by the right HP Sensor. † Basic cutting sequences 2
The initialization operation is not performed if the Cutter Blade is in the Means movement from the left HP Sensor to the right HP Sensor. At this
right HP Sensor position when the Cutter is fitted. time, if the Cutter Blade cannot move from the left HP Sensor to the right
HP Sensor within 3 seconds, Cutter Position Error occurs.
During Cutter operation, Cutter Position Error or Cutter Jam Error may occur.
These errors are explained below.
† If the Cutter Blade cannot reach the left or right HP Sensor, the Cutter 2.2.7.2 Cutter Self-cleaning
Blade is returned to the HP Sensor located in the motion starting position
(right HP Sensor). This sequence indicates the operation performed to hold down and remove the
ink, which may stick to the Plate above the Paper Hold-down Flap (Plate where
„ Cutter Jam Error
the paper print surface comes into contact), with the leading edge of the fed roll
Indicates that the Cutter Blade can return to the HP Sensor position in
paper.
the motion starting position within 3 seconds.
The Cutter Blade must be operated left-to-right to operate the Paper Hold-
„ Cutter Position Error
down Flap. At this time, the Cutter Blade generates operating noise during
Indicates that the Cutter Blade cannot return to the HP Sensor position
Cutter self-cleaning when the roll paper is fed.
located in the motion starting position within 3 seconds.

2.2.7.3 Cutter Cleaning (Driver Side)


This sequence is executed on the driver side. By cutting the roll paper three
times at intervals of 7cm, the ink that may stick to the Cutter Blade is removed
to clean the Cutter Blade.

OPERATING PRINCIPLES Printer Mechanism 31


EPSON Stylus Photo R800 Revision A

2.2.8 Power-On Sequence CARRIAGE UNIT OUTSIDE HP


The following explains the operation to be performed when the Carriage Unit is
1. When the PG position is other than PG++ after power-on, the drive of the
inside or outside the HP with the printer powered on.
APG Motor is transmitted to the Carriage Shaft, and the PG position
changes to PG++.
CARRIAGE UNIT INSIDE HP (CR LOCKED)
2. The drive of the CR Motor is transmitted to the Carriage Unit, and the
1. After power-on, the drive of the APG Motor is transmitted to the Carriage Carriage Unit returns to the home position at slow speed.
Shaft, and the PG position changes from PG Typ. to PG++. 3. The drive of the PF Motor is transmitted to the PF Roller and Paper Eject
2. The drive of the CR Motor is transmitted to the Carriage Unit, and the Rollers (front and rear), which then rotate for about 2 seconds.
Carriage Unit performs HP detection operation in the following path. 4. After the Carriage Unit has moved leftward by the specified number of
„ Home position ⇒ Right frame ⇒ CR Lock confirmation position steps, the Wiper is set, driven by the Pump.
⇒ Right frame ⇒ Home position 5. After the Carriage Unit has returned to the home position, it moves leftward
3. The drive of the Pump Motor is transmitted to the Cap Unit, the Cap opens again by the specified number of steps. And, driven by the Pump Motor, ink
(lowers), and the CR Lock is released. is sucked for about 4 seconds and then the Wiper is set, and the CR Lock
is placed.
4. After the Carriage Unit has moved leftward by the specified number of
steps, the Wiper is driven by the Pump Motor to perform the following 6. The Carriage Unit performs HP detection operation in the following path.
operation, and during that period, ink is sucked for about 4 seconds. „ Home position ⇒ Right frame ⇒ CR Lock confirmation position
„ Wiper setting ⇒ Wiper resetting ⇒ Right frame ⇒ Home position
5. The Carriage Unit returns to the home position, and the PG position 7. The drive of the Pump Motor is transmitted to the Cap Unit, the Cap opens
returns from PG++ to PG Typ. (lowers), and the CR Lock is released.
6. The drive of the PF Motor is transmitted to the PF Roller and Paper Eject 8. The Carriage Unit returns to the home position, and the PG position
Rollers (front and rear), which then rotate for about 2 seconds. returns from PG++ to PG Type.
7. After moving between the left and right frames twice, the Carriage Unit 9. The drive of the PF Motor is transmitted to the PF Roller and Paper Eject
moves to the right end of the Front Paper Guide. Rollers (front and rear), which then rotate and stop as described below.
8. The PF Roller and Paper Eject Rollers (front and rear) rotate. „ Rotation for about 3 seconds ⇒ Stop for about 0.5 seconds ⇒
Rotation for about 2 seconds
„ Rotation for about 4 seconds (slow speed) ⇒ Rotation for about 2
seconds 10. As soon as the operation in step 9 starts, the drive of the ASF Motor is
transmitted to the LD Roller, and the LD Roller rotates one turn.
9. The Carriage Unit returns to the home position and is fixed by the CR Lock.
11. The operations in Steps 7 to 9 of "Carriage Unit inside HP (CR locked)
(p32)" are performed, and the Carriage Unit is locked.

OPERATING PRINCIPLES Printer Mechanism 32


EPSON Stylus Photo R800 Revision A

2.3 Electrical Circuitry Operating Principles 2.3.1 Power Supply Circuit Operating Principle
The power supply circuit board of this product is the C550 PSB/PSE.
The electrical circuitry of Stylus Photo R800 consists of the following circuits.
† Basic circuit structure
† Control circuit board : C550 MAIN
„ RCC switching regulator system
† Power supply circuit board : C550 PSB/PSE „ +42VDC and +3.3VDC are supplied to the Printer Mechanism and
† Control panel board : C550 PNL Control Board
The following indicates the applications of the voltages generated in this power
The following shows how the three circuit boards are connected. supply circuit.

Table 2-9. Supplied Power


Printer Voltage Applications
PNL Board Mechanism +42VDC • CR Motor
Rated output current: 0.45A • PF Motor
CR Motor • PG Motor
• ASF Motor
PF Motor
• Pump Motor
APG Motor • Head drive voltage
+3.3VDC • Logic sensor circuit
MAIN Board ASF Motor
Rated output current: 0.5A • Sensor circuit
Pump Motor • Nozzle selection circuit (above Print Head)
• Interface control circuit
Head drive circuit

Sensors

Power OFF +3.3VDC +42VDC


PSB/PSE
Power Supply
Board

Figure 2-13. Electrical Circuitry Block Diagram

OPERATING PRINCIPLES Electrical Circuitry Operating Principles 33


EPSON Stylus Photo R800 Revision A

The following is the block diagram of the power supply circuit. 2.3.2 C550 MAIN Circuit Operating Principle
The C550 MAIN Board consists of the following circuits and sensors.
† Logic Circuits (CPU-ASIC 2 in 1, PROM, SDRAM)
† Motor control/Drive circuits
(CR Motor, PF Motor, APG Motor, ASF Motor, Pump Motor)
† Head control/Drive circuit
† Interface Circuits
USB 2.0, IEEE1394
† Sensor circuits
† Reset circuits
† EEPROM circuit
† D/A converter circuit

Figure 2-14. Power Supply Circuit Block Diagram

OPERATING PRINCIPLES Electrical Circuitry Operating Principles 34


EPSON Stylus Photo R800 Revision A

The following indicates differences between the control circuits of this product
and conventional model.
† Adoption of 1.5V drive logic circuit components
The 1.5V voltage is generated by the Regulator IC installed on the C550
MAIN Board that reduces +3.3VDC generated by the C550 PSB/PSE
Board, and is used to drive multiple components.
This is done to reduce the power of the logic circuit.
The following table indicates the 3.3V drive components and 1.5V drive
components.

Table 2-10. 3.3V and 1.5V Drive Components


3.3V 1.5V
• Nozzle selection circuit • CPU-ASIC 2 in 1
(above Print Head) • PROM
• CR Encoder Sensor • SDRAM
• PE Sensor • Motor circuit
• PG Release Sensor • Panel LED
• CSIC • Interface circuit
• USB 2.0
• Sensors
(other than CR Encoder Sensor, PE
Sensor, PG Release Sensor)

OPERATING PRINCIPLES Electrical Circuitry Operating Principles 35


EPSON Stylus Photo R800 Revision A

The following is the block diagram of the C550 MAIN control board.

CR Motor

IEEE 1394 IEEE 1394 PROM


CN3 (IC1) (IC4, IC15) Motor
Driver PF Motor
(IC5)
Data
Address DAC
CN4 APG Motor
(IC2)
SDRAM CPU-ASIC
(IC12) 2 in 1 Motor
(IC14) Driver ASF Motor
(IC6)
USB
CN2
Pump Motor

Reset
(IC13)
CN5 Relay Board PF Encoder Sensor

Reset PE Sensor
CR Encoder Sensor (IC16)

PW Sensor PG Release Sensor


EEPROM
(IC3)
ASF Sensor
Ink Mark Sensor CN4
APG Sensor 1

C550 PSB/PSE Board CN7 APG Sensor 2

C550 Panel Board CN8 CN11

Head CN12
CSIC Board CN10 Driver Q13, Q14
(IC7) CN13

Cutter Unit CN6


CN14 Print Head

Figure 2-15. C550 MAIN Control Board Block Diagram

OPERATING PRINCIPLES Electrical Circuitry Operating Principles 36


3
CHAPTER

TROUBLESHOOTING
EPSON Stylus Photo R800 Revision A

3.1 Overview
This chapter describes unit-level troubleshooting.

3.1.1 Troubleshooting according to panel messages


After checking the printer LED and EPW3 error indications, you can grasp the fault location using the check list in this section. When you have found the fault
location, refer to Chapter 4 "Disassembly and Reassembly" and change the corresponding part and/or unit. The following table indicates the check point reference
tables corresponding to the error states (LED and EPW3).

Table 3-1. Reference Tables of Error States


Error State Reference Table
Communication Error Refer to Table 3-2 "Phenomenon-Based Communication Error Check Points" on page 39
Model Difference Refer to Table 3-2 "Phenomenon-Based Communication Error Check Points" on page 39
Cover Open Error Refer to Table 3-3 "Phenomenon-Based Cover Open Error Check Points" on page 42
Paper Out Error Refer to Table 3-4 "Phenomenon-Based Paper Out Error Check Points" on page 43
Paper Jam Error Refer to Table 3-5 "Phenomenon-Based Paper Jam Error Check Points" on page 48
Card Loading Error Refer to Table 3-6 "Phenomenon-Based Card Loading Error Check Points" on page 49
Paper Mismatch Error Refer to Table 3-7 "Phenomenon-Based Paper Mismatch Error Check Points" on page 50
Ink Low Refer to Table 3-8 "Phenomenon-Based Ink Low Check Points" on page 50
Ink Out Error Refer to Table 3-9 "Phenomenon-Based Ink Out Error Check Points" on page 50
No Ink Cartridge/CSIC Error Refer to Table 3-10 "Phenomenon-Based No Ink Cartridge/Ink Cartridge Error Check Points" on page 51
Cutter Jam Error Refer to Table 3-11 "Phenomenon-Based Cutter Jam Error Check Points" on page 53
Cutter Position Error Refer to Table 3-12 "Phenomenon-Based Cutter Position Error Check Points" on page 54
Maintenance Request Refer to Table 3-13 "Phenomenon-Based Maintenance Request Check Points" on page 55
Fatal Error Refer to Table 3-14 "Phenomenon-Based Fatal Error Check Points" on page 56

TROUBLESHOOTING Overview 38
EPSON Stylus Photo R800 Revision A

Table 3-2. Phenomenon-Based Communication Error Check Points


Occurrence Faulty Part/
Phenomenon Detail Check Point Remedy
Timing Part Name
At power-on The printer does not operate Panel FFC 1. Check that the Panel FFC is securely connected to the 1. Connect the Panel FFC to the Panel
at all. Panel Board connector and Main Board connector (CN8). Board and Main Board connectors.

Panel FFC

Panel FFC

Main Board Panel Board


connector connector

2. Check the Panel FFC for damage. 2. Change the Panel FFC for a new one.
Panel Board 1. Check the Panel Board for damage. 1. Change the Panel Board for a new one.
Power Supply 1. Check that the Connector cable of the Power Supply 1. Connect the Connector cable of the
Board Board is securely connected to the Main Board (CN7). Power Supply Board.

Blue line

Connector cable
of the Power
Supply Board
1Pin side

2. Check that the blue line side pin of the Power Supply 2. Match and connect the blue line of the
Board Connector cable is inserted into the 1 Pin. (Refer to Power Supply Board Connector cable
the above photo.) into the 1 Pin.

TROUBLESHOOTING Overview 39
EPSON Stylus Photo R800 Revision A

Table 3-2. Phenomenon-Based Communication Error Check Points


Occurrence Faulty Part/
Phenomenon Detail Check Point Remedy
Timing Part Name
At power-on The printer does not operate Power Supply 3. Check that the Fuse (F1) on the Power Supply Board is not 3. Change the Power Supply Board for a
at all. Board blown. new one.

Fuse (F1)

4. Check the devices on the Power Supply Board for 4. Change the Power Supply Board for a
damage. new one.
After the power-on sequence Main Board 1. Check that the Relay connector of the ASF Motor and the 1. Change the Main Board for a new one.
has started, the LED turns off Relay connector of the Pump Motor are not connected to
and the printer does not cause a short circuit.
operate.
Relay Connector
of the ASF Motor

Relay Connector
of the Pump Motor

TROUBLESHOOTING Overview 40
EPSON Stylus Photo R800 Revision A

Table 3-2. Phenomenon-Based Communication Error Check Points


Occurrence Faulty Part/
Phenomenon Detail Check Point Remedy
Timing Part Name
At operation Operation at power-on is Interface cable 1. Check that the Interface cable is connected between the 1. Connect the Interface cable to the PC
normal, but the error appears PC and printer. and printer.
when the print jog is sent to
2. Check the Interface cable for wire break. 2. Change the Interface cable for a new
the printer.
one.
EPSON 1. When USB is used, check that the EPSON USB driver has 1. Install the EPSON USB driver.
USB driver been installed in the PC.
USB 1. Check that the PC and printer are connected via the USB 1. Enter the USB serial No. indicated on the
hub. product nameplate.
(Refer to Chapter 5 "ADJUSTMENT".)
IEEE1394 1. Check that the same code as the IEEE1394 QR label code 1. Input the code given as the IEEE1394
is saved at BA<H> to BE<H> of the EEPROM. QR label code.
(Refer to Chapter 5 "ADJUSTMENT".)
Printer driver 1. Check that the Stylus Photo R800 printer driver has been 1. Install the Stylus Photo R800 printer
installed. driver.
2. Check that the connected printer is the Stylus Photo R800. 2. Connect the Stylus Photo R800 printer.
Main Board 1. Check that a wrong model name has not been input to the 1. Using the Adjustment Program, enter the
EEPROM address (E0<H>) on the Main Board. correct model name (save 02 into
E0<H>).
(Refer to Chapter 5 "ADJUSTMENT".)

TROUBLESHOOTING Overview 41
EPSON Stylus Photo R800 Revision A

Table 3-3. Phenomenon-Based Cover Open Error Check Points


Occurrence Faulty Part/
Phenomenon Detail Check Point Remedy
Timing Part Name
During printing Cover Open Error is Printer Cover 1. Check that the Printer Cover is not open. 1. Close the Printer Cover.
displayed during printing in
the "Economy" mode.
The Printer Cover is in a Cover Open 1. Check that the Connector cable of the Cover Open Sensor 1. Connect the Connector cable of the
closed state but Cover Open Sensor is securely connected to the connectors of the Cover Open Cover Open Sensor to the connectors of
Error is displayed. Sensor and Panel Board. the Cover Open Sensor and Panel
Board.
Panel Board

Cover Open Sensor

2. Check the Cover Open Sensor for damage. 2. Change the Cover Open Sensor for a
new one.

TROUBLESHOOTING Overview 42
EPSON Stylus Photo R800 Revision A

Table 3-4. Phenomenon-Based Paper Out Error Check Points


Occurrence Faulty Part/
Phenomenon Detail Check Point Remedy
Timing Part Name
At operation When the Paper Switch was ASF Assy. 1. Check the LD Roller or Retard Roller of the ASF Assy. for 1. Using a cleaning sheet, clean the LD
pressed, the LD Roller paper dust and foreign matter. Roller and Retard Roller. The procedure
attempt to feed paper but the is as follows.
paper is not fed. (1) Place the cleaning sheet upside
down and put it into the ASF Assy.
(2) Press the Paper Switch to start
paper feed.
(3) Repeat the above steps several
times.
* To remove persistent contamination,
staple an alcohol-dampened cloth to a
postcard and clean the rollers in the
following method.
Cleaning sheet Postcard used
as mount

Non-adhesive part

Adhesive part

Stapling
This side down
Cloth damped
with alcohol
(1) Place the alcohol-dampened cloth
toward the LD Roller surface of the
ASF Assy.
(2) Hold the mount top end securely
and press the Paper Switch.
(3) Repeat the paper feed sequence
several times to clean the LD Roller
surface of the ASF Assy.

TROUBLESHOOTING Overview 43
EPSON Stylus Photo R800 Revision A

Table 3-4. Phenomenon-Based Paper Out Error Check Points


Occurrence Faulty Part/
Phenomenon Detail Check Point Remedy
Timing Part Name
At operation Paper is not fed. ASF Motor 1. Check that the Connector cable of the ASF Motor is 1. Connect the Connector cable of the ASF
connected to the Relay Connector. Motor to the Relay Connector.

ASF Motor

Relay Connector

2. Using a tester, check the resistance value of the ASF 2. If the resistance value is abnormal,
Motor. change the ASF Motor for a new one.
Resistance value: 7.4Ω ± 10%
3. Check the ASF Motor connector cable for damage. 3. Change the ASF Motor for a new one.

TROUBLESHOOTING Overview 44
EPSON Stylus Photo R800 Revision A

Table 3-4. Phenomenon-Based Paper Out Error Check Points


Occurrence Faulty Part/
Phenomenon Detail Check Point Remedy
Timing Part Name
At operation Though paper is fed from the PE Sensor 1. Check that the Connector cable of the PE Sensor is 1. Connect the Connector cable of the PE
ASF Assy., it stops near the securely connected to the PE Sensor and Relay Board Sensor to the PE Sensor and Relay
PE Sensor Lever. Connector (CN3). Board Connector.

Relay Board Connector

PE Sensor

2. Check that the Sensor Holder is mounted to the 2. Install the Sensor Holder correctly.
Mechanical frame correctly.

Sensor Holder

Detection Lever

Torsion Spring

3. Move the Detection Lever actively by hand in the same 3. Change the PE Sensor Holder Unit for a
state as when the paper passes, and check that the new one.
Detection Lever is returned to the original position
automatically by the Torsion Spring when released.
(Refer to the above photo.)
4. Using a tester, check that the PE Sensor is normal. 4. Change the PE Sensor Holder Unit for a
⋅ Paper present : 2.4V or more new one.
⋅ Paper absent : 0.4V or less

TROUBLESHOOTING Overview 45
EPSON Stylus Photo R800 Revision A

Table 3-4. Phenomenon-Based Paper Out Error Check Points


Occurrence Faulty Part/
Phenomenon Detail Check Point Remedy
Timing Part Name
The Paper Switch The CD-R Tray HP detection CD-R Tray 1. Check the HP detection position or white markings of the 1. Remove paper dust and/or foreign matter
was pressed at the sequence stops and the Tray CD-R Tray for paper dust and foreign matter. from the detection portion.
setting of the CD-R is ejected.
Tray.

White Markings HP detection


position

2. Check the Driven Roller surface for contamination such as 2. Pass plain paper of A4 width from the
paper dust and CD-R coating. ASF Assy. several times to remove
contamination.
3. Check that the HP detection position or white markings of 3. Change the CD-R Tray for a new one.
the CD-R Tray are not chipped.
The Paper Switch The CD-R Tray or board PW Sensor 1. Check the PW Sensor for paper dust, ink, etc. 1. Clean the PW Sensor surface.
was pressed at the paper is fed toward the ASF
PW Sensor
setting of the CD-R Assy., but is ejected
Tray or board paper immediately.

Carriage Unit bottom

2. Compare the EEPROM values in two places (50<H> and 2. Change the PW Sensor for a new one.
51<H>) and check that they are not approximate to each
other.

TROUBLESHOOTING Overview 46
EPSON Stylus Photo R800 Revision A

Table 3-4. Phenomenon-Based Paper Out Error Check Points


Occurrence Faulty Part/
Phenomenon Detail Check Point Remedy
Timing Part Name
The Paper Switch The trailing edge of the CD-R PW Sensor 1. Check that the PW Sensor FFC is placed in the specified 1. Place the PW Sensor FFC in the
was pressed at the Tray is fed toward the ASF routing positions and does not make contact with any specified routing positions.
setting of the CD-R Assy. up to the Driven Roller parts.
Tray or board paper of the Upper Paper Guide,
and is then fed in an attempt CR Encoder Board PW Sensor
Connector Connector
to move it farther, but the
Tray is ejected.

FFC

2. Check that the PW Sensor FFC is not disconnected from 2. Connect the FFC to the CR Encoder
the CR Encoder Board and PW Sensor Connectors. (Refer Board and PW Sensor Connectors.
to the above photo.)
3. Check the PW Sensor or PW Sensor FFC for damage. 3. Change the PW Sensor for a new one.

TROUBLESHOOTING Overview 47
EPSON Stylus Photo R800 Revision A

Table 3-5. Phenomenon-Based Paper Jam Error Check Points


Occurrence Faulty Part/
Phenomenon Detail Check Point Remedy
Timing Part Name
At operation At the time of paper ejection, – 1. Check that the size of the fed paper is not larger than that 1. Since the paper length is larger than the
the PF Roller advances the of the paper set on the driver side. specifications, notify the user.
paper but cannot eject it
completely.
Paper is not ejected ASF Assy. 1. Check that the paper is fed along the Right Edge Guide. 1. Feed the paper along the Right Edge
completely and causes a jam Guide.
near the Paper Eject Frame.
Paper EJ Frame 1. Check that the Star Wheel Units have not come off the 1. Securely install the Star Wheel Units to
Assy. Paper EJ Frame Assy. the Paper EJ Frame Assy.

Paper EJ Frame Assy. Star Wheel Units

2. Check the Paper EJ Frame Assy. for deformation or 2. Change the Paper EJ Frame Assy. for a
damage. new one.
Spur Gear 54 1. Check the Spur Gear 54 or Spur Gear 18 for damage. 1. Change the Front (or Rear) Paper EJ
and Spur Gear Roller Assy. for a new one.
18 (Paper EJ
Spur Gear 18
Roller Assy.
Rear Paper EJ
(front/rear)) Roller Assy.

Front Paper EJ
Roller Assy.

Spur Gear 54

TROUBLESHOOTING Overview 48
EPSON Stylus Photo R800 Revision A

Table 3-6. Phenomenon-Based Card Loading Error Check Points


Occurrence Faulty Part/
Phenomenon Detail Check Point Remedy
Timing Part Name
During printing Printing starts but paper is – 1. Check that the card size paper is loaded in the portrait 1. Load the cards of the same size correctly,
not fed. orientation. and press the Paper Switch to eject the
jammed paper.
The card size paper is loaded PW Sensor 1. Check that the PW Sensor FFC is not disconnected from 1. Connect the FFC to the CR Encoder
correctly, but Card Loading the CR Encoder Board or PW Sensor Connector. Board or PW Sensor.
Error is displayed.
CR Encoder Board PW Sensor
Connector Connector

FFC

2. Check the PW Sensor or PW Sensor FFC for damage. 2. Change the PW Sensor for a new one.

TROUBLESHOOTING Overview 49
EPSON Stylus Photo R800 Revision A

Table 3-7. Phenomenon-Based Paper Mismatch Error Check Points


Occurrence Faulty Part/
Phenomenon Detail Check Point Remedy
Timing Part Name
At operation When print data are sent, an Stacker Assy. 1. Check that the Stacker Assy. setting position and paper 1. Correctly combine the Stacker Assy.
error is displayed on the LED size set on the driver side are combined correctly. setting position and paper size.
and EPW3.
PG Release 1. Check that the Connector cable of the PG Release Sensor 1. Connect the Connector cable of the PG
Sensor is securely connected to the PG Release Sensor and Release Sensor to the PG Release
Relay Board Connector (CN7). Sensor and Relay Board.

Relay Board Connector

PG Release Sensor

2. Check the PG Release Sensor or Connector cable for 2. Change the PG Release Sensor for a
damage. new one.

Table 3-8. Phenomenon-Based Ink Low Check Points


Occurrence Faulty Part/
Phenomenon Detail Check Point Remedy
Timing Part Name

At operation or A message is displayed on Ink Cartridge 1. Look at the remaining ink indication of the EPW3 to check 1. Prepare a new Ink Cartridge.
during printing the LED and EPW3 during the amount of the ink remaining in the Ink Cartridge.
printing.

Table 3-9. Phenomenon-Based Ink Out Error Check Points


Occurrence Faulty Part/
Phenomenon Detail Check Point Remedy
Timing Part Name

During printing After the Carriage has Ink Cartridge 1. Look at the remaining ink indication of the EPW3 to check 1. Change the Ink Cartridge for a new one.
detected the HP, an error is whether the ink remains in the Ink Cartridge.
displayed on the LED and
EPW3.

TROUBLESHOOTING Overview 50
EPSON Stylus Photo R800 Revision A

Table 3-10. Phenomenon-Based No Ink Cartridge/Ink Cartridge Error Check Points


Occurrence Faulty Part/
Phenomenon Detail Check Point Remedy
Timing Part Name
At power-on After the Carriage has Ink Cartridge 1. Check that the Ink Cartridge is fitted properly. 1. Fit the Ink Cartridge properly.
detected the HP, an error is
2. Check that the Hook of the Ink Cartridge is not broken. 2. Change the Ink Cartridge for a new one.
displayed on the LED and
EPW3.

Hook

3. Check that the Memory Chip is not disconnected or not 3. Change the Ink Cartridge for a new one.
chipped.

Memory Chip

TROUBLESHOOTING Overview 51
EPSON Stylus Photo R800 Revision A

Table 3-10. Phenomenon-Based No Ink Cartridge/Ink Cartridge Error Check Points


Occurrence Faulty Part/
Phenomenon Detail Check Point Remedy
Timing Part Name
At power-on After the Carriage has Carriage Unit 1. Check that the Electrodes in the Carriage, which make 1. Change the Carriage Unit for a new one.
detected the HP, an error is contact with the CSIC Board, are not bent.
displayed on the LED and
EPW3.

Electrodes

CSIC FFC 1. Check that the CSIC FFC is connected to the CSIC Board 1. Connect the FFC to the CSIC Board and
Connector and Main Board Connector (CN10). Main Board Connectors.

CSIC FFC
Main Board
CSIC Board Connector Connector

2. Check the CSIC FFC for damage. 2. Change the CSIC FFC for a new one.
CSIC Board 1. Check the CSIC Board for damage. 1. Change the CSIC Board for a new one.

CSIC Board

TROUBLESHOOTING Overview 52
EPSON Stylus Photo R800 Revision A

Table 3-11. Phenomenon-Based Cutter Jam Error Check Points


Occurrence Faulty Part/
Phenomenon Detail Check Point Remedy
Timing Part Name
At roll paper feeding When the paper roll is fed, Cutter Unit 1. Check the rail groove of the Cutter for paper dust, foreign 1. Remove the paper dust, foreign matter,
the Cutter produces matter, etc. etc. from the rail groove of the Cutter.
operating noise.

Rail Groove

After end of printing The roll paper is not cut after Cutter Motor 1. Check that the Connector cable of the Cutter Motor is 1. Connect the Connector cable of the
end of printing. connected to the Relay Board Connector (CN2). Cutter Motor to the Relay Board
Connector.

CN2

Cutter Motor

2. Check the Cutter Motor or Connector cable for damage. 2. Change the Cutter Motor for a new one.
At roll paper The roll paper is cut only Cutter Unit 1. Check that the paper used is not other than the EPSON 1. Use the EPSON special media.
cutting halfway. special media.
2. Check the Cutter for damage. 2. Change the Cutter Unit for a new one.

TROUBLESHOOTING Overview 53
EPSON Stylus Photo R800 Revision A

Table 3-12. Phenomenon-Based Cutter Position Error Check Points


Occurrence Faulty Part/
Phenomenon Detail Check Point Remedy
Timing Part Name
At Cutter unit fitting At power-on, an error is Cutter Motor 1. Check that the Connector cable of the Cutter Motor is 1. Connect the Connector cable of the Cutter
(At power-on) displayed on the Paper LED connected to the Relay Board Connector (CN2). Motor to the Relay Board Connector.
and EPW3. (When the Cutter position is other than the HP)

CN2

Cutter Motor

2. Check the Cutter Motor or Connector cable for damage. 2. Change the Cutter Motor for a new one.
(When the Cutter position is other than the HP)
The Cutter produces Cutter HP 1. Check the Cutter HP Sensor (right) or the rail groove of the 1. Remove the paper dust, foreign matter,
operating noise. Sensor (right) Cutter for paper dust, foreign matter, etc. etc. from the Cutter HP Sensor (right) or
the rail groove of the Cutter.
Cutter HP Sensor (right)

CN4

2. Check that the Connector cable of the Cutter HP Sensor 2. Connect the Connector cable of the Cutter
(right) is connected to the Cuter HP Sensor (right) and HP Sensor (right) to the Cuter HP Sensor
Relay Board Connector (CN4). (right) and Relay Board Connector.
3. Check the Cutter HP Sensor (right) for damage. 3. Change the Cutter HP Sensor (right) for a
new one.

TROUBLESHOOTING Overview 54
EPSON Stylus Photo R800 Revision A

Table 3-13. Phenomenon-Based Maintenance Request Check Points


Occurrence Faulty Part/
Phenomenon Detail Check Point Remedy
Timing Part Name
At power-on At power-on, the printer does Waste Ink Pads 1. Using the Adjustment Program, check that the Protection 1. Change the Waste Ink Pads and reset
not operate at all. Counter A+B value is the following count or more. the Protection Counter A+B value with
„ Home side : 14787 count or more the Adjustment Program.
„ Opposite-to-home side : 17115 count or more „ Home side: 24<H>, 25<H>
„ Opposite-to-home side: 26<H>,
27<H>

TROUBLESHOOTING Overview 55
EPSON Stylus Photo R800 Revision A

Table 3-14. Phenomenon-Based Fatal Error Check Points


Occurrence Faulty Part/
Phenomenon Detail Check Point Remedy
Timing Part Name
At power-on At power-on, the CR Motor CR Motor 1. Check that the CR Motor connector cable is connected to 1. Connect the CR Motor connector to the
does not operate at all. the Relay Connector. Relay Connector.

CR Motor

Relay Connector

2. Using a tester, check the resistance value of the CR Motor. 2. If the resistance value is abnormal,
Resistance value: 24.4Ω ± 15% change the CR Motor for a new one.
3. Check the CR Motor connector cable for damage. 3. Change the CR Motor for a new one.
Relay 1. Check that the Relay Connector Cable is connected to the 1. Connect the Relay Connector Cable to
Connector Main Board Connector (CN4). the Main Board.
Cable

Connector

2. Check the Relay Connector Cable for damage. 2. Change the Relay Connector Cable for a
new one.

TROUBLESHOOTING Overview 56
EPSON Stylus Photo R800 Revision A

Table 3-14. Phenomenon-Based Fatal Error Check Points


Occurrence Faulty Part/
Phenomenon Detail Check Point Remedy
Timing Part Name
At power-on The power-on sequence is CR drive 1. Check that the Carriage Shaft is lubricated with grease. 1. Wipe the surface of the Carriage Shaft
executed but Fatal error is system with a dry, soft cloth, and lubricate the
displayed. Carriage Shaft with grease G-70. (Refer
to Chapter 6 "MAINTENANCE".)
Carriage Shaft

At power-on, the PF Motor PF Motor 1. Check that the PF Motor connector cable is connected to 1. Connect the PF Motor connector cable to
does not operate at all. the Relay Connector. the Relay Connector.

Relay Connector

PF Motor

2. Using a tester, check the resistance value of the PF Motor. 2. If the resistance value is abnormal,
Resistance value: 22.3Ω ± 25% change the PF Motor for a new one.
3. Check the PF Motor connector cable for damage. 3. Change the PF Motor Cable for a new
one.

TROUBLESHOOTING Overview 57
EPSON Stylus Photo R800 Revision A

Table 3-14. Phenomenon-Based Fatal Error Check Points


Occurrence Faulty Part/
Phenomenon Detail Check Point Remedy
Timing Part Name
At power-on At power-on, the APG Motor APG Motor 1. Check that the APG Motor connector cable is connected to 1. Connect the APG Motor connector cable
does not operate at all. the Relay Connector. to the Relay Connector.
Relay Connector
APG Motor

2. Using a tester, check the resistance value of the APG 2. If the resistance value is abnormal,
Motor. change the APG Motor for a new one.
Resistance value: 64.7Ω ± 15%
3. Check the APG Motor connector cable for damage. 3. Change the APG Motor Cable for a new
one.
At power-on, the Pump Motor Pump Motor 1. Check that the Pump Motor connector cable is connected 1. Connect the Pump Motor connector cable
does not operate at all. to the Relay Connector. to the Relay Connector.

Relay Connector

2. Using a tester, check the resistance value of the Pump 2. If the resistance value is abnormal,
Motor. change the Ink System Unit for a new
Resistance value: 10.3Ω ± 10% one.
3. Check the Pump Motor connector cable for damage. 3. Change the Ink System Unit Cable for a
new one.

TROUBLESHOOTING Overview 58
EPSON Stylus Photo R800 Revision A

Table 3-14. Phenomenon-Based Fatal Error Check Points


Occurrence Faulty Part/
Phenomenon Detail Check Point Remedy
Timing Part Name
At power-on While the power-on APG Sensor 1. Check that the APG Sensor Connector cables are 1. Connect the APG Sensor Connector
sequence is being executed, connected to the APG Sensors and Relay Board cables to the APG Sensors and Relay
Fatal error is displayed. Connectors (CN5 and CN6). Board Connectors.

APG Sensors
CN6

CN5

2. Check the APG Sensors for damage. 2. Change the APG Sensors for new ones.
Relay FFC 1. Check that the Relay FFC is connected to the Relay Board 1. Connect the Relay FFC to the Relay
Connector (CN1) and Main Board Connector (CN5). Board and Main Board Connectors.

Main Board Connector Relay Connector

2. Check the Relay FFC for damage. 2. Change the Relay FFC Cable for a new
one.

TROUBLESHOOTING Overview 59
EPSON Stylus Photo R800 Revision A

Table 3-14. Phenomenon-Based Fatal Error Check Points


Occurrence Faulty Part/
Phenomenon Detail Check Point Remedy
Timing Part Name
At power-on At power-on, the Carriage CR Scale 1. Check that the CR Scale is inserted in the slit of the CR 1. Insert the CR Scale into the slit of the CR
Unit moves away from the Encoder Sensor. Encoder Sensor.
home position and collides
CR Scale
with the left of the Frame.

CR Encoder
Sensor

2. Check the CR Scale for damage and contamination. 2. Wipe contamination completely or
change the CR Scale for a new one.
CR Encoder 1. Check the CR Encoder Sensor for paper dust, etc. 1. Remove the paper dust, etc. from the CR
Sensor Encoder Sensor.
2. Check the CR Encoder Sensor for damage. 2. Change the CR Encoder Sensor Cable
for a new one.
At power-on, the PF Roller PF Encoder 1. Check that the PF Encoder Sensor is mounted correctly. 1. Install the PF Encoder Sensor correctly.
rotates fast about a half turn. Sensor
2. Check that the FFC of the PF Encoder Sensor is securely 2. Connect the PF Encoder Sensor FFC to
connected to the PF Encoder Sensor Connector and Relay the PF Encoder Sensor and Relay Board
Board Connector (CN9). Connectors.

Relay Board Connector

PF Encoder Sensor
Connector

3. Check the PF Encoder Sensor for paper dust, etc. 3. Remove the paper dust, etc. from the PF
Encoder Sensor.
4. Check the PF Encoder Sensor for damage. 4. Change the PF Encoder Sensor Cable for
a new one.

TROUBLESHOOTING Overview 60
EPSON Stylus Photo R800 Revision A

Table 3-14. Phenomenon-Based Fatal Error Check Points


Occurrence Faulty Part/
Phenomenon Detail Check Point Remedy
Timing Part Name
At power-on At power-on, the PF Roller PF Scale 1. Check that the PF Scale is inserted in the slit of the PF 1. Install the PF Scale in the slit of the PF
rotates fast about a half turn. Encoder Sensor. Encoder Sensor correctly.

Slit
PF Scale

2. Check the PF Scale for damage or contamination. 2. Change the PF Scale for a new one.
During printing Before start of printing, Initial Head FFC 1. Check that the Head FFC is securely connected to the 1. Connect the Head FFC to the Print Head
Filling is executed and Print Head Connectors and Main Board Connectors and Main Board Connectors.
printing is then started. Ink is (CN11, CN12, CN13, CN14).
not delivered and paper stops
midway. Head FFC

Print Head
Main Board Connectors Connectors

2. Check the Head FFC for damage. 2. Change the Head FFC for a new one.
Ink is not delivered from most Print Head 1. Check for occurrence of Head Hot. 1. Change the Print Head for a new one.
nozzles.

TROUBLESHOOTING Overview 61
EPSON Stylus Photo R800 Revision A

3.1.2 Superficial Phenomenon-Based Troubleshooting


This section applies to the fault locations of the error states (print quality fault and abnormal noise) other than the error states (LED and EPW3) in the previous
section.

Table 3-15. Print Quality Fault Check Points


Faulty Part/
Print Quality State Phenomenon Detail Check Point Remedy
Part Name

Dot missing and [Phenomenon 1] Ink System Unit 1. Check for foreign matter around the Seal Rubber on the 1. Remove the foreign matter around the
mixed colors • In the cleaning (Cap Unit) Cap Unit. Seal Rubber securely.
sequence, the Ink
System Unit operates Seal Rubbers
properly but ink is not
ejected to the Waste
ink pads.
• Ink is not sucked from
the Print Head into the
Cap at all.
Hence, printing is not
executed if a print command Extension Spring 1.19 IS
is given to the printer. (Dot
missing)
2. Check that the Ink Tube is connected to the Pump Tube. 2. Connect the Ink Tube to the Pump Tube
securely.

Ink Tube Pump Tube

Connection Portion

3. Check that the Extension Spring 1.19 IS is correctly 3. Change the Ink System Unit for a new
installed to the Cap Unit. one.

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EPSON Stylus Photo R800 Revision A

Table 3-15. Print Quality Fault Check Points


Faulty Part/
Print Quality State Phenomenon Detail Check Point Remedy
Part Name
Dot missing and [Phenomenon 2] Print Head 1. Check that each segment is printed correctly in the Nozzle 1. Perform Head Cleaning and check the
mixed colors In the cleaning sequence, ink Check Pattern Nozzle Check Pattern.
(Continued) is ejected to the Waste Ink 2. Check that the Head FFC is securely connected to the 2. Connect the Head FFC to the Print Head
Pads. However, Dot missing/ Print Head Connectors and Main Board Connectors and Main Board Connectors.
displacement occurs in all (CN11, CN12, CN13, CN14).
nozzles during printing and
this problem is not resolved
Head FFC
after several times of
cleaning. (Dot missing)

Print Head
Main Board Connectors Connectors

3. Check the Head FFC for damage. 3. Change the Head FFC for a new one.
If the problem still persists, also change
the Print Head.
Main Board 1. Check the Main Board for damage. 1. Change the Main Board for a new one.

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EPSON Stylus Photo R800 Revision A

Table 3-15. Print Quality Fault Check Points


Faulty Part/
Print Quality State Phenomenon Detail Check Point Remedy
Part Name
Dot missing and [Phenomenon 3] Ink Cartridge 1. Look at the remaining ink indication of the EPW3 to check 1. Change the Ink Cartridge for a new one.
mixed colors In the cleaning sequence, ink for the ink remaining in the Ink Cartridge.
(Continued) is ejected to the Waste Ink Ink System Unit 1. Check that the Cleaner Blade is mounted on the Cleaning 1. Change the Cleaner Blade for a new one.
Pads. (This means that the (Cap Unit) Lever correctly.
Pump Unit and Cap Unit
operate properly.) However,
Dot missing is not resolved in
indefinite nozzles after
cleaning has been executed
several times. (Dot missing/
mixed colors)

[Phenomenon 4]
In the cleaning sequence, ink Cleaner Blade
is ejected to the Waste Ink
Pads. However, drawing
operation is not performed 2. Check for foreign matter around the Seal Rubber on the 2. Change the Ink System Unit for a new
properly, resulting in mixture Cap Unit. one.
of colors. (Mixed colors)
Seal Rubbers

Extension Spring 1.19 IS

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EPSON Stylus Photo R800 Revision A

Table 3-15. Print Quality Fault Check Points


Faulty Part/
Print Quality State Phenomenon Detail Check Point Remedy
Part Name
White streak/color Vertical stripes appear Adjustment 1. For printing in the Bi-D mode, check that the Bi-D 1. Perform Bi-D Adjustment to eliminate
unevenness relative to the CR moving Adjustment has been performed properly. displacements between the upper and
occurrence direction and printing is lower rules.
uneven. (Refer to Chapter 5 "ADJUSTMENT".)
Print Head 1. Check that each segment is printed correctly in the Nozzle 1. Perform Head Cleaning and check the
CR moving Check Pattern. Nozzle Check Pattern.
direction (Refer to Chapter 5 "ADJUSTMENT".)
If the problem is not solved, change the
Print Head for a new one.
Carriage Shaft 1. Check the surfaces of the Carriage Shaft for foreign 1. Remove foreign matter from the Carriage
matter. Shaft.
* If the problem is not solved, 2. Check that the Carriage Shaft is fully lubricated with 2. Wipe the grease applied to the Carriage
change the CR Motor for a grease. Shaft with a dry, soft cloth, and then
new one. apply grease (G-70).
(Refer to Chapter 6 "MAINTENANCE".)
3. Check that the Carriage Shaft are mounted horizontally. 3. Reassemble the Carriage Shaft correctly.
4. Check the Carriage Shaft for damage. 4. Change the Carriage Shaft for a new one.
Narrow stripes of the same Printer Driver 1. Check that adequate paper is used according to the setting 1. Use adequate paper according to the
width appear horizontally and Exclusive of the Printer Driver. setting of the Printer Driver.
relative to the CR moving Paper
direction.
Print Head 1. Check that each segment is printed correctly in the Nozzle 1. Perform Head Cleaning and check the
Check Pattern. Nozzle Check Pattern.
CR moving (Refer to Chapter 5 "ADJUSTMENT".)
direction If the problem is not solved, change the
Print Head for a new one.
PF Roller 1. Check the surface of the PF Roller for foreign matter. 1. Clean the PF Roller surface carefully.
2. Check the PF Roller for damage. 2. Change the PF Roller for a new one.

* If the problem is not solved,


change the PF Motor for a
new one.

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EPSON Stylus Photo R800 Revision A

Table 3-15. Print Quality Fault Check Points


Faulty Part/
Print Quality State Phenomenon Detail Check Point Remedy
Part Name
White streak/color White streaks/color Adjustment 1. Check that PF Adjustment is executed properly. 1. Perform PF Adjustment properly. (Refer
unevenness unevenness occurs to Chapter 5 "ADJUSTMENT".)
occurrence horizontally in a fixed cycle
2. Check for Dot missing. 2. Change the Ink System Unit for a new
(Continued) during 360dpi printing.
one.
Star Wheel Rollers traces Paper EJ Frame 1. Check that the Star Wheel Units have not come off or the 1. Install the Star Wheel Units to the Paper
appear relative to the CR Assy. Star Wheel Rollers turn. EJ Frame Assy. correctly.
moving direction.
Star Wheel Units

Star Wheel Roller

Printing is executed but blur Printer Driver 1. Check that adequate paper is used according to the setting 1. Use adequate paper according to the
occurs. and Exclusive of the Printer Driver. setting of the Printer Driver.
Paper
Print Head 1. Using the Adjustment Program, check that the correct Head 1. Using the Adjustment Program, enter the
ID has been written to the EEPROM. 31- digit code of the Head ID to the
EEPROM.
(Refer to Chapter 5 "ADJUSTMENT".)
Occurrence of Paper EJ Roller traces occur Printer Driver 1. Check that adequate paper is used according to the setting 1. Use adequate paper according to the
Paper EJ Roller during printing of print paper and Exclusive of the Printer Driver. setting of the Printer Driver.
traces or CD-R. Paper

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EPSON Stylus Photo R800 Revision A

Table 3-15. Print Quality Fault Check Points


Faulty Part/
Print Quality State Phenomenon Detail Check Point Remedy
Part Name
Ink stain of paper Ink stain occurs at the back Front Paper 1. Check that heaps of ink are not formed on the Front Paper 1. If heaps of ink are formed, replace the
or end of the print paper. Guide Pad Guide Pad and that the Front Paper Guide Pad is installed Front Paper Guide. If it has been
securely and evenly in the setting position. confirmed that the Ink pads have risen,
reinstall the Front Paper Guide Pad
correctly.

Front Paper Guide Pad Front Paper Guide

When the paper size in the PW Sensor 1. Check that the PW Sensor FFC is connected. 1. Connect the PW Sensor FFC.
sent print data is larger than
2. Check that the PW Sensor is not faulty. 2. Change the PW Sensor for a new one.
the size of the fed paper, data
are printed on the Front
Paper Guide, extending off
the paper.
Ink sticks to other than the Paper EJ Frame 1. Check the Star Wheel Rollers for ink stain. 1. Clean the Star Wheel Rollers with a soft
print area of the paper, Assy. cloth.
resulting in contamination.
Front Paper 1. Check the Front Paper Guide for ink stain. 1. Clean the Front Paper Guide with a soft
Guide cloth.
Front Paper 1. Check that ink heaps are formed on the Front Paper Guide 1. Change the Front Paper Guide for a new
Guide Pad Pad. one.

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EPSON Stylus Photo R800 Revision A

Table 3-15. Print Quality Fault Check Points


Faulty Part/
Print Quality State Phenomenon Detail Check Point Remedy
Part Name
Ink stain of paper Ink sticks to other than the Lower Paper 1. Check the Lower Paper Guide for ink stain. 1. Clean the Lower Paper Guide with a soft
(Continued) print area of the paper, Guide cloth.
resulting in contamination.
Rear Paper EJ Roller Assy.

Lower Front Paper EJ Roller Assy.


Paper Guide

Paper EJ Roller 1. Check the Paper EJ Roller Assy. (front/rear) for ink stain. 1. Clean the Paper EJ Roller Assy. (front/
Assy. rear) with a soft cloth.
(front/rear)
Driven Rollers 1. Check the Driven Rollers for ink stain. 1. Clean the Driven Rollers with a soft cloth.

Driven Rollers

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EPSON Stylus Photo R800 Revision A

Table 3-15. Print Quality Fault Check Points


Faulty Part/
Print Quality State Phenomenon Detail Check Point Remedy
Part Name
Ink stain of paper Ink sticks to other than the Ink System Unit 1. Check that wiping operation was performed properly. 1. Install the Cleaner blade correctly or
(Continued) print area of the paper, change it for a new one.
resulting in contamination.

Cleaner Blade

PF Roller 1. Check the PF Roller for ink stain. 1. Clean the PF Roller with a soft cloth.

PF Roller

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EPSON Stylus Photo R800 Revision A

Table 3-15. Print Quality Fault Check Points


Faulty Part/
Print Quality State Phenomenon Detail Check Point Remedy
Part Name
Image graininess The image graininess is poor Improper 1. Check that PG, Bi-D and Head Angular Adjustments have 1. Make adjustments according to the
in all print modes or the adjustment, been made properly. specified adjustment priority. (Refer to
image looks rough. Main Board or Chapter 5 "ADJUSTMENT".)
Print Head
2. Print the adjustment check patterns and check how rough 2. If the image graininess is not improved
the image looks. after adjustment, change the Main Board
for a new one.
The image graininess is poor Improper 1. After making sure that PG, Bi-D and Head Angular 1. Make adjustments according to the
only in the 2880dpi print adjustment, Adjustments have been made correctly, check whether specified adjustment priority. (Refer to
modes or the image looks Main Board or PW Sensor has been performed properly. Chapter 5 "ADJUSTMENT".)
rough. Print Head
2. Print the adjustment check patterns and check how rough 2. If the image graininess is not improved
the image looks. after adjustment, change the Print Head
and Main Board in this order, and check
the image graininess.
Color of image The whole image is reddish. Improper 1. Check that the PG Adjustment value is proper. 1. Make adjustments according to the
adjustment or specified adjustment priority. (Refer to
Print Head Chapter 5 "ADJUSTMENT".)
2. Check that Bi-D and Head Angular Adjustments have been 2. Make adjustments according to the
made properly. specified adjustment priority. (Refer to
Chapter 5 "ADJUSTMENT".)
3. Print the adjustment check patterns and check the image 3. If the image color does not change after
color. adjustment, change the Print Head for a
new one.
Borderless Printing Bordered printing is executed PW Sensor 1. Check if the paper powder or scrap of the paper is on the 1. Remove the paper powder or scrap of the
for borderless printing. Front Paper Guide. paper.
2. Check that the PW Sensor is operating normally. 2. Change the PW Sensor for a new one if it
Print the adjustment check patterns with the Adjustment has been confirmed in the adjustment
Program, and check that the clip function is executed check patterns of the Adjustment
normally. (The clip function is executed normally if an Program that the clip function is not
about 5mm margin is provided on the left of the first gray executed. (Refer to Chapter 5
band pattern in the patterns.) "ADJUSTMENT".)

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EPSON Stylus Photo R800 Revision A

Table 3-16. Phenomenon-Based Abnormal Noise Check Point


Faulty Part/
Print Quality State Phenomenon Detail Check Point Remedy
Part Name
– Printing operation is Carriage Shaft 1. Check that the Carriage Shaft is fully lubricated with 1. Wipe the grease applied to the Carriage
performed normally but grease. Shaft with a dry, soft cloth, and then
abnormal noise is produced apply grease (G-70).
at power-on or between (Refer to Chapter 6 "MAINTENANCE".)
operations.

TROUBLESHOOTING Overview 71
4
CHAPTER

DISASSEMBLY & ASSEMBLY


EPSON Stylus Photo R800 Revision A

4.1 Overview 4.1.1 Precautions


Before starting the disassembling/reassembling work of this product, always
This chapter describes procedures for disassembling and assembling this
read the descriptions under the following headings "WARNING" and
product. Unless otherwise specified, the disassembled units or main
"CAUTION" carefully.
components can be reassembled by reversing the disassembling procedure.
† WARNING W A R N IN G „ Before starting the disassembling/reassembling work of
Procedures that could result in injury or loss of life, if cautions are not this product, always disconnect the power cable.
taken, are described under the heading "WARNING". However, if you cannot disconnect the power cable for
voltage measurement or like, be extremely careful not to
† CAUTION
get an electric shock and follow the procedures in this
Precautions for any disassembly or assembly procedures are described
manual to do your work.
under the heading "CAUTION".
„ Always wear goggles to protect your eyes from ink. If ink
† CHECK POINT gets in your eyes, wash your eyes with clean water and
Tips for disassembling procedures are described under the heading see the doctor.
"CHECK POINT". „ To prevent injury from sharp metal edges, always wear
† REASSEMBLY gloves for disassembly and reassembly.
If the assembling procedure is different from the reverse procedure of „ If ink has adhered to your skin, wash it with soap and
disassembling, it is described under the heading "REASSEMBLY". water. If it has caused skin irritation, see the doctor.
„ To protect the microprocessors and circuitry, use static
† ADJUSTMENT REQUIRED
discharge equipment, such as anti-static wrist straps,
Any adjustments required after disassembling or assembling are described
and handle them carefully when accessing the internal
under the heading "ADJUSTMENT REQUIRED".
components.
When you need to disassemble any units or parts that are not described in this
chapter, refer to the exploded diagrams in the Appendix.
Before starting your work, always read the precautions described in the next
section.

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EPSON Stylus Photo R800 Revision A

C A U T IO N „ When the printer model uses the HAV Ink Cartridges, 4.1.2 Tools to Be Used
transport it after removing the Ink Cartridges. Especially The following table indicates the tools recommended for use for disassembly,
for air transportation, always remove the Ink Cartridges reassembly and adjustment.
before transportation since ink will flow into the Cap Unit .

via the Print Head with the reduction of the atmospheric Table 4-1. Tool List
pressure, causing ink leakage.
Tool Name Supplier Code
„ Use only the recommended tools for disassembly,
reassembly and adjustment. (Refer to Table 4-1"Tool Phillips Screw Driver (No.1) { 1080530
List".) Phillips Screw Driver (No.2) { 1080532
„ Tighten screws to the specified torques.
Standard Screwdriver { 1080527
„ Use the specified lubricants and adhesives.
Make the necessary adjustments under the instructions Tweezers { 1080561
given for disassembling. Needle nose pliers { 1080564
(Refer to Chapter 5 "Adjustment".)
Acetate Tape { 1003963
Sonic Tension Meter { 1231678
{: Available in the market

DISASSEMBLY & ASSEMBLY Overview 74


EPSON Stylus Photo R800 Revision A

4.1.3 Screw List Table 4-2. Used Screw List

The following table lists the screws used in this product. When disassembling Appearance Specifications Appearance Specifications
and reassembling the printer, refer to the following table and use the specified
screws in the specified positions. The screw numbers given in this manual
correspond to the screw numbers in this table. 11) C.B.S (P4) 3x6 12) C.C 3x4

Table 4-2. Used Screw List


Appearance Specifications Appearance Specifications

13) C.P.B (P1) 1.7x5 14) C.B.P 2.6x5


1) C.B.S 3x10 2) C.B.S 3x6

3) C.B.P 3x6 4) C.B.S 3x8

5) C.B.P 3x12 6) C.B.P 3x8

7) C.B.S (P4) 3x8 8) CR Mount Shaft

9) C.P 3x4 10) C.B.P 2.6x8

DISASSEMBLY & ASSEMBLY Overview 75


EPSON Stylus Photo R800 Revision A

4.1.4 Pre-Shipment Checks


When returning this product to the user after completion of printer repair, check that the work is complete using the following table.

Table 4-3. Servicing Completion Pre-Shipment Check List


Class Component Check Item Check Field
Main Unit Self-test Is the operation normal? … Checked / … Not necessary
On-line Test Is the printing successful? … Checked / … Not necessary
Print Head Is ink discharged normally from all the nozzles? … Checked / … Not necessary
Carriage Mechanism Does it move smoothly? … Checked / … Not necessary
Is there any abnormal noise during its operation? … Checked / … Not necessary
Is there any dirt or foreign objects on the CR Shaft? … Checked / … Not necessary
Is the CR Motor at the correct temperature? … Checked / … Not necessary
Paper Feeding Mechanism Is paper advanced smoothly? … Checked / … Not necessary
No paper jamming? … Checked / … Not necessary
No paper skew? … Checked / … Not necessary
No multiple feeding? … Checked / … Not necessary
No abnormal noise? … Checked / … Not necessary
Is the PF Motor at correct temperature? … Checked / … Not necessary
Is the paper path free of any obstructions? … Checked / … Not necessary
Adjustment Specified Adjustment Are all the adjustment done correctly? … Checked / … Not necessary
Lubrication Specified Lubrication Are all the lubrication made at the specified points? … Checked / … Not necessary
Is the amount of lubrication correct? … Checked / … Not necessary
Function ROM Version Version: … Checked / … Not necessary
Packing Ink Cartridge Have the ink cartridges been removed? … Checked / … Not necessary
Protective Materials Have all relevant protective materials been attached to the … Checked / … Not necessary
printer?
Others CD-R Tray Is the operation normal? … Checked / … Not necessary
Cutter Unit Is the operation normal? … Checked / … Not necessary
Attachments, Accessories Have all the relevant items been included in the package? … Checked / … Not necessary

DISASSEMBLY & ASSEMBLY Overview 76


EPSON Stylus Photo R800 Revision A

4.2 Disassembly
A disassembling flowchart is shown below. When disassembling any unit, refer to the page number shown in the following flowchart.
START

"Rear Housing"
4.2.1.1 Page 78

"Upper Housing"
4.2.1.2 Page 78

"Lower Housing/ "Cover Open "PF Encoder "Paper EJ Frame


"Panel Board" "CR Scale" "CSIC Board" "CR Motor" "ASF Assy." "Print Head" "APG Assy."
Printer Mechanism" Sensor Holder" Sensor Holder" Assy."
4.2.5.3 Page 94 4.2.6.3 Page 99 4.2.6.6 Page 111 4.2.7.1 Page 130 4.2.4 Page 86 4.2.6.2 Page 97 4.2.6.4 Page 101
4.2.1.3 Page 80 4.2.8.1 Page 133 4.2.8.6 Page 138 4.2.6.8 Page 116

"PG Release "Carriage Shaft/ "PE Sensor


"ASF Assy." "Waste Ink Pads" "Stacker Assy." "PF Motor" "Main Board" "PS Board" "CR Scale" "ASF Assy."
Sensor" Carriage Unit" Holder"
4.2.4 Page 86 4.2.3 Page 84 4.2.2 Page 82 4.2.7.2 Page 131 4.2.5.1 Page 90 4.2.5.2 Page 93 4.2.6.3 Page 99 4.2.4 Page 86
4.2.8.2 Page 134 4.2.6.5 Page 103 4.2.8.3 Page 135

"Ink System Unit" "Paper EJ Frame "APG Assy." "FLAG Release


4.2.6.7 Page 114 Assy." 4.2.6.4 Page 101 Assy."
4.2.6.8 Page 116 4.2.6.9 Page 117

"Front Paper "Carriage Shaft/ "Upper Paper


Guide" Carriage Unit" Guide Assys."
4.2.6.11 Page 120 4.2.6.5 Page 103 4.2.6.10 Page 119

"PF Encoder "Ink Mark Sensor/ "CR Encoder


Sensor Holder" PW Sensor" Board"
4.2.8.6 Page 138 4.2.8.4 Page 136 4.2.8.5 Page 137

"Rear Paper EJ "ASF Assy."


Roller Assy." 4.2.4 Page 86
4.2.6.12 Page 123

"Ink System Unit" "PF Roller"


4.2.6.7 Page 114 4.2.6.14 Page 127

"Stacker Assy."
4.2.2 Page 82 * The step for the unit or discrete part within
the broken line is not the shortest removal
"Front Paper EJ
step but is the step necessary for
Roller Assy." removing the next unit or discrete part.
4.2.6.13 Page 124

Figure 4-1. Disassembling Procedure Flowchart

DISASSEMBLY & ASSEMBLY Disassembly 77


EPSON Stylus Photo R800 Revision A

4.2.1 Removing the Housings 4.2.1.2 Upper Housing


1. Remove the Rear Housing. (p.78)
4.2.1.1 Rear Housing
2. Open the Printer Cover, Stacker and Paper Support.
1. Remove the three screws 1) C.B.S 3x10 that secure the Rear Housing,
and remove the Rear Housing from the printer. 3. Remove the three screws 2) C.B.S 3x6 and two screws 3) C.B.P 3x6 that
secure the Upper Housing.
1) C.B.S 3x10
(6±1 kgf.cm) 2) C.B.S 3x6
(6±1 kgf.cm)
Upper Housing

2 3 5 4
3

1) C.B.S 3x10
1
Rear Housing (6±1 kgf.cm)

Figure 4-2. Removing the Rear Housing

Tighten the screws in the order shown in Figure 4-2.

3) C.B.P 3x6
(6±1 kgf.cm)

1
2
Dowels
Left Rear Side Right Rear Side

Figure 4-3. Screws That Secure the Upper Housing

Tighten the screws in the order shown in Figure 4-3.

DISASSEMBLY & ASSEMBLY Disassembly 78


EPSON Stylus Photo R800 Revision A

4. Disconnect the Panel FFC from the Main Board Connector. 6. Insert a Standard Screwdriver, etc. into each of the notches in the left and
right of the front bottom of the Lower Housing, and push it in the direction
of arrow to release the two Hooks that secure the Upper Housing.
7. Remove the Upper Housing upward.

Panel FFC

Connector

Upper Housing
Figure 4-4. Disconnecting the Panel FFC

5. Pull each Hook on the rear side of the Upper Housing toward the outside of
the printer, and insert a thickness gauge, etc. into the holes of the Lower
Housing to disengage the Hooks one by one.

Notch

Notch
Notch
Notch

Figure 4-6. Removing the Upper Housing


Hole and Hook Hole and Hook
Figure 4-5. Hooks That Secure the Upper Housing Match the Positioning Holes and Dowels of the Upper
Housing. (Refer to Figure 4-3)

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EPSON Stylus Photo R800 Revision A

4.2.1.3 Lower Housing/Printer Mechanism 5. Hold the grips of the Printer Mechanism with both hands, and remove the
Printer Mechanism from the Lower Housing.
1. Remove the Upper Housing. (p.78)
2. Hold both ends of the two fasteners with your fingers, and shift the 5) C.B.P 3x12 6) C.B.P 3x8
fasteners in the direction of arrow. (6±1 kgf.cm) (6±1 kgf.cm)
4
1
C H E C K The 0 digit side (lower) Waste Ink Tube is marked red.
P O IN T However, when ink flows in the tube, the marking becomes
difficult to identify. Refer to Figure 4-7 and mark the Waste
Ink Tube with a red magic marker before pulling it out of the
Ink Tube.

0 Digit Side Waste Ink Tube 10mm 5mm

Figure 4-7. Marking the Waste Ink Tube

5) C.B.P 3x12
3. Pull the Waste Ink Tubes from the two Ink Tubes. (6±1 kgf.cm)
4. Remove the two screws 4) C.B.S 3x8, three screws 5) C.B.P 3x12, and
one screw 6) C.B.P 3x8 that secure the Printer Mechanism. Ink Tubes

C A U T IO N Always hold the grips when handling the Printer Mechanism. Fastener
Failure to do so can deform the Frame. 3
5) C.B.P 3x12
(6±1 kgf.cm)
Grips Step 2
Waste Ink Tubes

4) C.B.S 3x8
(6±1 kgf.cm)

Figure 4-8. Handling the Printer Mechanism

5
6
Figure 4-9. Screws That Secure the Printer Mechanism

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EPSON Stylus Photo R800 Revision A

„ Align the Ink Tube lined green with the Waste Ink Tube „ Fit the 0 digit side Ink Tube, which comes out of the
marked red. Pump, to the lower side of the Hook.
„ Fit the Waste Ink Tube of longer tip to the 0 digit side Ink „ Fit the 0 digit side Waste Ink Tube to the lower side of the
Tube, and the one of shorter tip to the 80 digit side. Hook.

80 Digit Side Ink Tube 0 Digit Side Ink Tube

80 Digit Side Waste Ink Tube 80 Digit Side Ink Tube

Hook
Hook
0 Digit Side Ink Tube

0 Digit Side Waste Ink Tube


Figure 4-12. Ink Tube Fitting Positions
Figure 4-10. Installing the Ink Tubes
„ Make sure that the Waste Ink Tubes are not caught in the
„ After inserting the tip of the Waste Ink Tube into the Ink Printer Mechanism.
Tube by about 10mm, refer to Figure 4-11 and secure the „ Tighten the screws in the order shown in Figure 4-9.
Waste Ink Tube with the fastener.
A D J U S T M E N T After replacing the Printer Mechanism, always make the
Fastener R E Q U IR E D
following adjustments.
1. PG Adjustment
2. Head Angular Adjustment
3. Ink Mark Sensor Adjustment
4. Auto Bi-D Adjustment
5. Ink Mark Sensor Check
6. First Dot Position
1±0.5 mm 1±0.5 mm 7. PW Sensor Adjustment
Figure 4-11. Securing Position of Fastener 8. PF Deterioration Compensation Counter Reset
9. PF Adjustment
10. PF Adjustment (Bottom Margin)
11. CR Motor Drive Dispersion
Refer to "CHAPTER 5 ADJUSTMENT" for details of the
adjustments.

DISASSEMBLY & ASSEMBLY Disassembly 81


EPSON Stylus Photo R800 Revision A

4.2.2 Stacker Assy. 4. Remove the two screws 2) C.B.S 3x6 that secure the Stacker Shaft
Brackets (Left/Right).
1. Remove the Printer Mechanism. (Refer to 4.2.1.3 Lower Housing/Printer
Mechanism (p.80)) 5. Slide the Stacker Shaft Bracket (Left) upward to disengage the Hook and
Dowel.
2. Remove the Torsion Spring 105.84 from the Stacker Assy. Shaft with a
pair of long-nose pliers. 6. Remove the Stacker Assy. to the front together with the Stacker Shaft
Brackets (Left/Right).

Torsion Spring 105.84

Dowel

Hook
2) C.B.S 3x6
(6±1 kgf.cm)

Figure 4-13. Removing the Torsion Spring 105.84

3. Disengage the Paper EJ Lock Lever from the Paper EJ Release Lever,
and remove the Paper EJ Lock Lever from the Stacker Assy. Shaft.

Stacker Shaft Bracket (Left) Stacker Shaft Bracket (Right)

Paper EJ Release Lever Figure 4-15. Removing the Stacker Shaft Brackets (Left/Right)

Paper EJ Lock Lever

Stacker Assy. Shaft

Figure 4-14. Removing the Paper EJ Lock Lever

DISASSEMBLY & ASSEMBLY Disassembly 82


EPSON Stylus Photo R800 Revision A

7. Remove the Stacker Shaft Brackets (Left/Right) from the Stacker Assy.
„ Put the lever of the PG Release Sensor under the shaft
Shaft, and remove the Stacker Assy.
on the right of the Stacker Assy. (Refer to Figure 4-16)
„ Set the engagement positions of the Gears at both ends
of the Stacker Assy. to the same height.

Stacker Assy. Shaft


Figure 4-17. Gear Engagement Positions

„ Engage the Shaft Support of the Paper EJ Release Link


with the Shaft of the Paper EJ Transmission Lock Lever.

Paper EJ Transmission Lock Lever

Paper EJ Release Link

Stacker Assy. Shaft

Shaft Support
Figure 4-16. Removing the Stacker Assy.
Figure 4-18. Installing the Stacker Shaft Bracket (Right).

DISASSEMBLY & ASSEMBLY Disassembly 83


EPSON Stylus Photo R800 Revision A

8. Disconnect the Connector from the PG Release Sensor, and remove the 4.2.3 Waste Ink Pads
Stacker Shaft Bracket (Left).
1. Remove the Lower Housing. (Refer to 4.2.1.3 Lower Housing/Printer
Mechanism (p.80))
2. Remove the 11 Waste Ink Pads from the Lower Housing.

Connector

Figure 4-19. Removing the Stacker Shaft Bracket (Left). Waste Ink Pad

Figure 4-20. Removing the Waste Ink Pads

DISASSEMBLY & ASSEMBLY Disassembly 84


EPSON Stylus Photo R800 Revision A

„ Refer to Figure 4-21, and install the Waste Ink Pads „ Confirm that the Waste Ink Tubes are installed in the
correctly. correct top and bottom positions.
0 digit side : Bottom side
80 digit side : Top side
4 4 „ Match the markings at the tip of the Waste Ink Tubes with
the locators of the Lower Housing.
3 3
Waste Ink Tubes
Installation Order Installation Order
2 2

7mm
1 1

80 Digit Side 0 Digit Side

Figure 4-22. Positions of Waste Ink Tubes

„ Refer to Figure 4-23, and make certain that the Protective


Sheet is applied in the correct position.

Protective Sheet

Figure 4-21. Installing the Waste Ink Pads

Figure 4-23. Position of Protective Sheet

A D J U S T M E N T After replacing or removing the Waste Ink Pads, always


R E Q U IR E D
make the following adjustment.
„ Waste Ink Counter Reset
Refer to "CHAPTER 5 ADJUSTMENT" for details of the
adjustment.

DISASSEMBLY & ASSEMBLY Disassembly 85


EPSON Stylus Photo R800 Revision A

4.2.4 ASF Assy. „ Always screw the two Earth Cables together.
1. Remove the Upper Housing. (p.78) „ Place the Ferrite Core of the Relay Connector Cable in
the recess on the left side of the ASF Assy. as viewed
2. Remove the one screw 4) C.B.S 3x8 that secures the Earth Cables, and from the printer rear.
remove the Earth Cables. „ After placing the Ferrite Core of the Relay Connector
3. Disconnect the ASF Motor Connector from the Relay Connector. Cable in the recess of the Ink System Unit, secure it with
the Acetate Tape.
4. Release the two Relay Connector Cables from the clamp of the ASF.
5. Peel off one Acetate Tape to release the ASF Motor Connector Cable.
6. Disconnect all Connectors and FFCs from the Relay Board.
7. Disconnect the APG Motor Connector from the Relay Connector.
8. Release the Relay Connector Cable and PF Motor Connector Cable.
4) C.B.S 3x8 Relay Connector Cables
(6±1 kgf.cm) Clamp Relay Board Relay Connector

Recess

Relay Connector Cable

Earth Cables Relay Connector Ferrite Core

Ferrite Core
ASF Motor Connector Cable PF Motor Connector Cable

Figure 4-25. Releasing the Cables (2)

Refer to Figure 4-25, and route the Relay Connector Cable


Recess and PF Motor Connector Cable correctly.

Acetate Tape

Figure 4-24. Releasing the Cables (1)

DISASSEMBLY & ASSEMBLY Disassembly 86


EPSON Stylus Photo R800 Revision A

9. Release the ASF Sensor Connector Cable from the three Hooks of the
„ Refer to Figure 4-26, and route the ASF Sensor
Main Frame and the right side of the ASF Assy. as viewed from the printer
Connector Cable correctly.
rear.
„ When the ASF Assy. is removed, the ASF Sensor
Connector Cable may have come off from the right side
Hooks of the ASF Assy. If it has come off, refer to Figure 4-27
and route it correctly.

Connector Cable
Figure 4-26. Releasing the Cables (3)

Connector Cable

Figure 4-27. Routing the Cable

DISASSEMBLY & ASSEMBLY Disassembly 87


EPSON Stylus Photo R800 Revision A

10. Remove the one screw 2) C.B.S 3x6 that secure the LD Roller Guide. 12. Remove the two screws 7) C.B.S (P4) 3x8 and one screw 8) CR Mount
Shaft that secure the ASF Assy., and remove the ASF Assy. from the
11. Slide the LD Roller Guide to the right to disengage the two Dowels, and
Printer Mechanism.
while simultaneously moving away the Connector Cables, remove the LD
Roller Guide from the Printer Mechanism.
8) CR Mount Shaft
(8±1 kgf.cm)
Front

LD Roller Guide

Dowels

2) C.B.S 3x6
(8±1 kgf.cm) 7) C.B.S (P4) 3x8
(8±1 kgf.cm)

ASF Assy.
ASF Assy.

Figure 4-29. Removing the ASF Assy.

Figure 4-28. Removing the LD Roller Guide

DISASSEMBLY & ASSEMBLY Disassembly 88


EPSON Stylus Photo R800 Revision A

Engage the one Dowel and four Hooks of the ASF Assy. with A D J U S T M E N T After replacing or removing the ASF Assy., always make the
R E Q U IR E D
the locators of the Main Frame to eliminate a clearance following adjustment.
between the ASF Assy. and Main Frame. „ First Dot Position
Refer to "CHAPTER 5 ADJUSTMENT" for details of the
Hook adjustments.
Dowel

Hook

Hook

Hook

Figure 4-30. Installing the ASF Assy.

DISASSEMBLY & ASSEMBLY Disassembly 89


EPSON Stylus Photo R800 Revision A

4.2.5 Removing the Boards 3. Remove the two screws 2) C.B.S 3x6 that secure the Board Assy.

4.2.5.1 Main Board


1. Remove the Printer Mechanism. (Refer to 4.2.1.3 Lower Housing/Printer 2) C.B.S 3x6
(6±1 kgf.cm) Screwed Frame
Mechanism (p.80))
2. Peel the Acetate Tape from the Board Assy. Screwed Frame

C A U T IO N Once peeled, never stick the Acetate Tape again.

Board Assy.

Figure 4-32. Screws That Secure the Board Assy.

C A U T IO N In the following step, be careful not to scratch the FFCs and


Connector Cables with the Screwed Frame.

4. Disconnect the FFCs and Connectors connected to the Board Assy. in


order of front to rear, and avoiding the interference with the Mechanism
Acetate Tape Frame and Power Cord, pull out the Board Assy. from the printer.

Figure 4-31. Peeling the Acetate Tape

DISASSEMBLY & ASSEMBLY Disassembly 90


EPSON Stylus Photo R800 Revision A

Point of Interference „ Paying attention to the burrs of the Shield Plate, insert
the FFCs and Connectors into the Main Board.
„ The Board Assy. should not ride on the PS Grounding
Plates (3 pcs.).

PS Grounding Plates

Figure 4-34. Installing the Board Assy.

FFCs and Connectors


5. In order of the numbers shown in Figure 4-35, unlock the Lock-type
Figure 4-33. Removing the Board Assy. Connector of the Main Board and disconnect the Connector Cable of the
PS Board.

Blue Line
Connector Cable
2
1 1

Lock-type Connector
1 Pin Side

Figure 4-35. Disconnecting the PS Board Connector Cable

DISASSEMBLY & ASSEMBLY Disassembly 91


EPSON Stylus Photo R800 Revision A

7. Remove the one screw 2) C.B.S 3x6 that secures the Grounding Plate,
„ Put the Blue Line on the 1 pin side, and connect the pins
and remove the Grounding Plate.
one after another correctly into the corresponding ports
of the Lock-type Connector. (Refer to Figure 4-35) 8. Remove the Main Board from the Board Assy.
„ After inserting the Connector Cable, securely lock the
Connector Lock Mechanism. (Refer to Figure 4-35)
2) C.B.S 3x6
(6±1 kgf.cm)
Grounding Plate
6. Remove the four screws 2) C.B.S 3x6 and one screw 9) C.P 3x4 that
secure the Main Board.

9) C.P 3x4
(6±1 kgf.cm)

2) C.B.S 3x6 2) C.B.S 3x6


(6±1 kgf.cm) (6±1 kgf.cm)

Figure 4-37. Removing the Main Board

Main Board

Figure 4-36. Screws That Secure the Main Board

DISASSEMBLY & ASSEMBLY Disassembly 92


EPSON Stylus Photo R800 Revision A

A D J U S T M E N T After replacing the Main Board, always make the following 4.2.5.2 PS Board
R E Q U IR E D
adjustments. 1. Remove the Board Assy. (Refer to 4.2.5.1 Main Board, Step 4 (p.90))
„ When data can be read from the old board.
2. Remove the four screws 2) C.B.S 3x6 that secure the PS Board.
1. Main Board Data Read/Write Function
„ When data cannot be read from the old board. 2) C.B.S 3x6
1. Main Board Data Read/Write Function (6±1 kgf.cm)
2. Initial Value Write
3. USB ID Input
4. IEEE-1394 ID Input
5. Head ID Input
6. Head Angular Adjustment
7. Ink Mark Sensor Adjustment
8. Auto Bi-D Adjustment
9. Ink Mark Sensor Check
10. First Dot Position
11. PW Sensor Adjustment
PS Board
12. PF Deterioration Compensation Counter Reset
(Maximum value write) Figure 4-38. Screws That Secure the PS Board
13. PF Adjustment
14. PF Adjustment (Bottom Margin)
15. CR Motor Drive Dispersion
Refer to "CHAPTER 5 ADJUSTMENT" for details of the
adjustments.

DISASSEMBLY & ASSEMBLY Disassembly 93


EPSON Stylus Photo R800 Revision A

3. Disconnect the PS Board Connector. (Refer to 4.2.5.1 Main Board, Step 5 4.2.5.3 Panel Board
(p.91))
1. Remove the Upper Housing. (p.78)
4. Remove the Power Cable from the notch of the Board Frame, and remove
2. Remove the two screws 6) C.B.P 3x8 that secure the Upper Housing
the PS Board.
Support, and remove the Upper Housing Support from the Upper Housing.

Notch Upper Housing Support 6) C.B.P 3x8


(6±1 kgf.cm)

Power Cable

Figure 4-39. Removing the PS Board


Figure 4-40. Removing the Upper Housing Support
A D J U S T M E N T After replacing the PS Board, always make the following
R E Q U IR E D 3. Disconnect the Panel FFC and Cover Open Sensor Connector from the
adjustment.
Panel Board.
„ CR Motor Drive Dispersion
Refer to "CHAPTER 5 ADJUSTMENT" for details of the
adjustment.

Panel FFC

Cover Open Sensor Connector

Figure 4-41. Disconnecting the Panel FFC and Connector

DISASSEMBLY & ASSEMBLY Disassembly 94


EPSON Stylus Photo R800 Revision A

4. Remove the two screws 2) C.B.S 3x6 that secure the Panel Assy., and 5. Remove the two screws 6) C.B.P 3x8 and two screws 3) C.B.P 3x6 that
remove the Panel Assy. from the Upper Housing. secure the Panel Board, and remove the Panel Board.

3) C.B.P 3x6
(6±1 kgf.cm)
Panel Board

2) C.B.S 3x6
(6±1 kgf.cm) 6) C.B.P 3x8
(6±1 kgf.cm)
Figure 4-43. Removing the Panel Board

Panel Assy.

Figure 4-42. Removing the Panel Assy.

DISASSEMBLY & ASSEMBLY Disassembly 95


EPSON Stylus Photo R800 Revision A

4.2.6 Disassembling the Printer Mechanism RELEASING THE CARRIAGE LOCK 2

4.2.6.1 Releasing the Carriage Lock 1. Power ON the printer.


Two methods of releasing the Carriage Lock will be explained below. 2. Push the Ink SW. When the Carriage Unit has moved to the left,
disconnect the Power Cable from the receptacle.

C A U T IO N Always disconnect the Power Cable before adjustments


RELEASING THE CARRIAGE LOCK 1 made by the Adjustment Program.
1. Remove the Printer Mechanism. (Refer to 4.2.1.3 Lower Housing/Printer
Mechanism (p.80))
2. Insert a Standard Screwdriver into the hole on the right side of the Frame,
and turn the white Shaft of the Ink System Unit 1.5 turns to release the
Carriage Lock.

White Shaft

Figure 4-44. Releasing the Carriage Lock

DISASSEMBLY & ASSEMBLY Disassembly 96


EPSON Stylus Photo R800 Revision A

4.2.6.2 Print Head 5. Remove the three screws 10) C.B.P 2.6x8 that secure the Print Head, and
vertically lift and remove the Print Head.
1. Remove the Upper Housing. (p.78)
2. Release the Carriage Lock, and move the Carriage Unit to the center of the Print Head
printer. (Refer to 4.2.6.1 Releasing the Carriage Lock (p.96))
3. Open the Ink Cartridge Cover.
4. Disengage the three Hooks that secure the FFC Guide, and remove the
FFC Guide from the Carriage Unit.

FFC Guide

10) C.B.P 2.6x8


(3±0.5 kgf.cm)

Figure 4-46. Removing the Print Head

6. Disconnect the two FFCs from the Print Head.

Hooks

Figure 4-45. Removing the FFC Guide

FFCs

Figure 4-47. Disconnecting the FFCs

DISASSEMBLY & ASSEMBLY Disassembly 97


EPSON Stylus Photo R800 Revision A

„ Make sure that the Absorber is applied in the position „ Hold down the Print Head in the direction of arrow and
shown in Figure 4-48. tighten the screws.

Absorber

Figure 4-48. Applying the Absorber

„ Install the Print Head after matching the Dowels of the


Carriage Unit with the Positioning Holes of the Print
Head.

Figure 4-50. Installing the Print Head (2)

A D J U S T M E N T After replacing or removing the Print Head, always make the


R E Q U IR E D
following adjustments.
Dowels 1. PG Adjustment
2. Head ID Input (for replacement only)
Positioning Holes 3. Head Angular Adjustment
4. Ink Mark Sensor Adjustment
5. Auto Bi-D Adjustment
6. First Dot Position
7. PW Sensor Adjustment
Refer to "CHAPTER 5 ADJUSTMENT" for details of the
adjustments.

Figure 4-49. Installing the Print Head (1)

DISASSEMBLY & ASSEMBLY Disassembly 98


EPSON Stylus Photo R800 Revision A

4.2.6.3 CR Scale 5. With tweezers, disengage the coil part of the Torsion Spring 24.7 from the
Hook of the CR Shaft Mounting Plate (Left).
1. Remove the Upper Housing. (p.78)
2. Release the Carriage Lock, and remove the Carriage Unit to the center of
the printer. (Refer to 4.2.6.1 Releasing the Carriage Lock (p.96)) Hook

C A U T IO N In the following steps, be careful not to break both ends of CR Shaft Mounting
Plate (Left)
the CR Scale.

Torsion Spring 24.7

3. Pull the right end of the CR Scale in the direction of arrow, and disengage
it from the Hook of the CR Shaft Mounting Plate (Right).
4. Pull the right end of the CR Scale to the left out of the rear side of the Figure 4-52. Removing the Torsion Spring 24.7 (1)
Carriage Unit.
6. Remove the Torsion Spring 24.7 from the CR Scale in the following
CR Shaft Mounting Plate (Right)
procedure.

Step 3 6-1. Raise the coil part.


6-2. Push it down, and disengage the Foot 1 from the notch of the CR
Shaft Mounting Plate (Left).
Step 4
6-3. Turn it counterclockwise.
6-4. Remove the Torsion Spring 24.7 from the hole of the CR Scale.
CR Scale Hook
Step 6-1

Step 6-3
Foot 1

Figure 4-51. Pulling the CR Scale Out


Notch
Step 6-2

Figure 4-53. Removing the Torsion Spring 24.7 (2)

DISASSEMBLY & ASSEMBLY Disassembly 99


EPSON Stylus Photo R800 Revision A

7. Turn the CR Scale 90 degrees, and remove the CR Scale from the Hook of
„ Pass the CR Scale into the slit of the CR Encoder Sensor.
the CR Shaft Mounting Plate (Left).

CR Encoder
Sensor

Hook

CR Scale

Figure 4-55. Installing the CR Scale (1)

„ Install the left end of the CR Scale with the beveled


Figure 4-54. Removing the CR Scale
portion up.

Beveled Portion

CR Scale

Figure 4-56. Installing the CR Scale (2)

„ Install the right end of the CR Scale securely so that it is


not engaged with the hooked portion of the CR Shaft
Mounting Plate (Right).

OK
CR Scale
NG
Hooked Portion

Figure 4-57. Installing the CR Scale (3)

DISASSEMBLY & ASSEMBLY Disassembly 100


EPSON Stylus Photo R800 Revision A

4.2.6.4 APG Assy. 4. Remove the three screws 2) C.B.S 3x6 that secure the APG Assy.
1. Remove the Upper Housing. (p.78) 5. Peel off the Acetate Tape, and remove the APG Assy. from the Main
Frame.
2. Disconnect the APG Motor Connector from the Relay Connector.
3. Disconnect the Connectors from the two APG Sensors. 2) C.B.S 3x6
1 (8±1 kgf.cm)

Relay Connector
Ferrite Core

2
Connectors 3
APG Assy.
Acetate Tape

Figure 4-59. Removing the APG Assy.

Figure 4-58. Disconnecting the connectors

DISASSEMBLY & ASSEMBLY Disassembly 101


EPSON Stylus Photo R800 Revision A

„ When reinstalling the APG Assy., make sure that the „ Match the phase of the APG Assy. in the following
FLAG Release Assy. is not released (Upper Paper Guide procedure.
Assys. are not raised). 1. Match the delta marks of the Spur Gear 16 and
Combination Gear 22, 28.8, 32.4.

Delta Marks

Spur Gear 16

Combination Gear
FLAG Release Assy. 22, 28.8, 32.4

2. In the position where the Rib can be identified


through the notch of the PG Frame, match the delta
marks of the Spur Gear 16 and PG Cam (Left).

Spur Gear16 PG Cam (Left)


Rib

Released Not Released

Figure 4-60. Installing the APG Assy.

Delta Marks

Figure 4-61. Phase Matching

„ Secure the Ferrite Core with the Acetate Tape in the


position shown in Figure 4-59.
„ Tighten the screws in the order shown in Figure 4-59.

DISASSEMBLY & ASSEMBLY Disassembly 102


EPSON Stylus Photo R800 Revision A

4.2.6.5 Carriage Shaft/Carriage Unit 5. Disengage the Foot of the Torsion Spring 411.77 from the Hook A,
disengage its coil part from the Hook B, and remove the Torsion Spring
1. Remove the Print Head. (p.97) 411.77 from the Main Frame.
2. Remove the CR Scale. (p.99)
3. Remove the APG Assy.. (p.101)
4. Remove the two screws 2) C.B.S 3x6 that secure the Frame Support Plate Hook A
(Left), and remove the Frame Support Plate (Left) from the Main Frame. Torsion Spring 411.77

Frame Support Plate (Left)


1

2) C.B.S 3x6
(8±1 kgf.cm)
Hook B

2
Figure 4-63. Removing the Torsion Spring 411.77

6. Disengage the Foot of the Torsion Spring 411.61 from the Hook A,
Notches and Ribs disengage its coil part from the Hook B, and remove the Torsion Spring
411.61 from the Main Frame.

Figure 4-62. Removing the Frame Support Plate (Left)

Hook A
„ Match the two ribs of the Main Frame with the notches of Torsion Spring 411.61
the Frame Support Plate (Left). (Refer to Figure 4-62)
„ The ribs of the Frame Support Plate (Left) should be on
the outside of the CR Shaft Mounting Plate (Left). (Refer
to Figure 4-62)
„ Tighten the screws in the order shown in Figure 4-62.
Hook B

Figure 4-64. Removing the Torsion Spring 411.61

DISASSEMBLY & ASSEMBLY Disassembly 103


EPSON Stylus Photo R800 Revision A

8. Disengage the Extension Spring 25.2 from the Hooks of the Main Frame
Put the Feet of the Torsion Spring 411.77 and Torsion Spring
and Driven Pulley Holder.
411.61 on the Carriage Shaft.

Extension Spring 25.2


Driven Pulley Holder

Foot
Foot

Hooks

Figure 4-65. Installing the Torsion Springs


Figure 4-67. Removing the Extension Spring 25.2

7. Disengage the CR Shaft Mounting Plate Fixed Spring from the rib of the 9. Slide the Driven Pulley Holder to the right end of the notch in the Main
Main Frame, and pull it out in the direction of arrow. Frame, and then remove it to the front.

Rib

Driven Pulley Holder

CR Shaft Mounting Plate Fixed Spring

Figure 4-66. Removing the CR Shaft Mounting Plate Fixed Spring Figure 4-68. Removing the Driven Pulley Holder

DISASSEMBLY & ASSEMBLY Disassembly 104


EPSON Stylus Photo R800 Revision A

10. Remove the CR Timing Belt from the Pinion Gear of the CR Motor.
„ Match the five ribs of the Main Frame with the
positioning holes of the CR Guide Plate. (Refer to Figure
4-70)
CR Motor Pinion Gear „ Tighten the screws in the order shown in Figure 4-70.

12. Remove the one screw 11) C.B.S (P4) 3x6 that secures the Adjust Parallel
Bushing (Left), and turn and move away the Adjust Parallel Bushing (Left)
to the front so that its gear will not interfere with the PG Cam (Left).

Adjust Parallel Bushing (Left) 11) C.B.S (P4) 3x6


CR Timing Belt (5±0.5 kgf.cm)
Figure 4-69. Removing the CR Timing Belt PG Cam (Left)

11. Remove the five screws 2) C.B.S 3x6 that secure the CR Guide Plate, and
remove the CR Guide Plate from the Main Frame.

2) C.B.S 3x6 2) C.B.S 3x6


CR Guide Plate (8±1 kgf.cm) (8±1 kgf.cm)

5
2 3 4 1
Figure 4-71. Turning the Adjust Parallel Bushing (Left)

Ribs and Positioning Holes Ribs and Positioning Holes

Figure 4-70. Removing the CR Guide Plate

DISASSEMBLY & ASSEMBLY Disassembly 105


EPSON Stylus Photo R800 Revision A

13. Slide the CR Shaft Mounting Plate (Left) upward, move away the Hook of 15. Turn the CR Shaft Mounting Plate (Left) to the front, disengage the Shaft
the CR Shaft Mounting Plate (Left) from the notch of the Main Frame, and Support of the CR Shaft Mounting Plate (Left) from the Carriage Shaft, and
turn the CR Shaft Mounting Plate (Left) to the front. remove the CR Shaft Mounting Plate (Left).

Hook CR Shaft Mounting Plate (Left)

Shaft Support

CR Shaft Mounting Plate (Left)

Figure 4-72. Turning the CR Shaft Mounting Plate (Left) Figure 4-74. Removing the CR Shaft Mounting Plate (Left)

14. Lift up the Carriage Shaft, and remove the Carriage Shaft Spacer from the 16. Remove the Polyslider from the Carriage Shaft, and remove the PG Cam
Carriage Shaft with a flat-blade screwdriver. (Left).

PG Cam (Left)

Carriage Shaft Spacer

Carriage Shaft

Polyslider

Figure 4-73. Removing the Carriage Shaft Spacer Figure 4-75. Removing the PG Cam (Left)

DISASSEMBLY & ASSEMBLY Disassembly 106


EPSON Stylus Photo R800 Revision A

17. Remove the Polyslider from the Carriage Shaft, and remove the PG Cam 18. Move the CR Shaft Mounting Plate (Right) away from the rib of the Main
(Right). Frame, and turn it to the front.

CR Shaft Mounting Plate (Right)

PG Cam (Right)

Rib

Polyslider

Figure 4-76. Removing the PG Cam (Right) Figure 4-78. Turning the CR Shaft Mounting Plate (Right)

Install the PG Cam (Right) with any of "0", "+" and "++"
facing down, among its four markings.

Figure 4-77. Orientation of Installing the PG Cam (Right)

DISASSEMBLY & ASSEMBLY Disassembly 107


EPSON Stylus Photo R800 Revision A

C A U T IO N In the following step, be careful not to scratch the Carriage „ Put the longer Bushing of the Carriage Shaft on the left
Shaft. side.
„ As the right side Leaf Spring and Plain Spring come off
when the Carriage Shaft is removed, refer to Figure 4-80
and reinstall them correctly.

19. Lift the Carriage Shaft into the Escape Hole along the notch of the Main Carriage Shaft Leaf Spring Plain Spring
Frame, and pull it out of the Main Frame and Carriage Unit.

Carriage Shaft Right


Carriage Unit Left Side Side
Escape Hole

Longer Shorter

Figure 4-80. Installing the Carriage Shaft

20. Remove the CR Timing Belt from the Carriage Unit.

Figure 4-79. Removing the Carriage Shaft Carriage Unit

CR Timing Belt

Figure 4-81. Removing the CR Timing Belt

DISASSEMBLY & ASSEMBLY Disassembly 108


EPSON Stylus Photo R800 Revision A

22. Remove the Belt Holder from the Carriage Unit.


Refer to Figure 4-82 and install the CR Timing Belt with the
right side out.

With Tooth Surface

Belt Holder

Without Tooth Surface

Figure 4-82. Installing the CR Timing Belt

21. Turn the Belt Holder Fixed Plate in the direction of arrow, and remove it
from the Carriage Unit.
Figure 4-84. Removing the Belt Holder

23. Release the three Hooks, and remove the CR Encoder Board Holder from
the Carriage Unit.

Belt Holder Fixed Plate Hole

Hooks

Figure 4-83. Removing the Belt Holder Fixed Plate


CR Encoder Board Holder

Figure 4-85. Removing the CR Encoder Board Holder

DISASSEMBLY & ASSEMBLY Disassembly 109


EPSON Stylus Photo R800 Revision A

24. Disconnect the CSIC FFC from the CSIC Board Connector.
„ When the Carriage Unit is removed from the Printer
Mechanism, the CR Pad and Head Grounding Plate may
come off. If they have come off, refer to Figure 4-88 and
reinstall them correctly.

Head Grounding Plate


CSIC FFC

Figure 4-86. Disconnecting the CSIC FFC CR Pad

25. Disconnect the CSIC FFC from the CR Encoder Board Connector, pull the
CSIC FFC from the Carriage Unit, and remove the Carriage Unit.

FFC Head Grounding Plate

CSIC FFC

CR Encoder Board Figure 4-88. Installing the CR Pad and Head Grounding Plate

Figure 4-87. Disconnecting the CSIC FFC

DISASSEMBLY & ASSEMBLY Disassembly 110


EPSON Stylus Photo R800 Revision A

A D J U S T M E N T After replacing any of the following parts, always coat the 4.2.6.6 CSIC Board
R E Q U IR E D
predetermined place with grease G-26 or G-70. 1. Remove the Upper Housing. (p.78)
„ Adjust Parallel Bushing (Left/Right):
2. Release the Carriage Lock, and move the Carriage Unit to the center of the
Chapter 6 Figure 6-2 (p.155)
printer. (Refer to 4.2.6.1 Releasing the Carriage Lock (p.96))
„ CR Shaft Mounting Plate (Left/Right):
Chapter 6 Figure 6-3 (p.155) 3. Open the Ink Cartridge Cover.
„ PG Cam (Left/Right): 4. With a flat-blade screwdriver, disengage from the Carriage Unit the Dowels
Chapter 6 Figure 6-5 (p.156) that secure the Ink Cartridge Cover, and remove the Ink Cartridge Cover.
„ Torsion Spring 411.77 and Torsion Spring 411.61:
Chapter 6 Figure 6-6 (p.156)
„ CR Guide Plate:
Carriage Unit
Chapter 6 Figure 6-7 (p.156)
„ Carriage Shaft :
Chapter 6 Figure 6-4 (p.156), 6.1.4.1 (p.158)

A D J U S T M E N T After replacing or removing the Carriage Shaft and the


R E Q U IR E D
Carriage Unit, always make the following adjustments. Ink Cartridge Cover
1. PG Adjustment
2. Head Angular Adjustment Dowel
3. Ink Mark Sensor Adjustment
4. Auto Bi-D Adjustment
5. First Dot Position Figure 4-89. Removing the Ink Cartridge Cover
6. PW Sensor Adjustment
Refer to "CHAPTER 5 ADJUSTMENT" for details of the
adjustments.

DISASSEMBLY & ASSEMBLY Disassembly 111


EPSON Stylus Photo R800 Revision A

5. With a flat-blade screwdriver, release the four Hooks that secure the CSIC
„ When replacing the Ink Cartridge Cover, refer to Figure
Board Cover, and remove the CSIC Board Cover from the Carriage Unit.
4-90 and reapply the Label to the new Ink Cartridge
Cover.

CSIC Board Cover


0-1mm
0-1mm

Figure 4-90. Label Application Position


Hooks
„ Match the two Dowels of the Ink Cartridge Cover with the Figure 4-92. Removing the CSIC Board Cover
corresponding installation holes of the Carriage Unit.
„ The Shaft in the center of the Ink Cartridge Cover should 6. Disconnect the CSIC FFC from the CSIC Board Connector. (Refer to
be fitted in the Shaft Support of the Carriage Unit. 4.2.6.5 Carriage Shaft/Carriage Unit, Step 24 (p.110))

Ink Cartridge Cover

Dowels

Installation Holes

Figure 4-91. Installing the Ink Cartridge Cover

DISASSEMBLY & ASSEMBLY Disassembly 112


EPSON Stylus Photo R800 Revision A

C A U T IO N In the following step, pay attention to the following points. Install the CSIC Board between the Grounding Plate and
„ Do not push up the CSIC Board too fast to prevent the Electrodes.
Hook from being broken.
„ Do not insert the flat-blade screwdriver into the notch
too far to prevent the Electrodes from being scratched.

Electrode
7. While simultaneously releasing the Hook that secures the CSIC Board with
your fingers, gradually push up the CSIC Board through the notch in the CSIC Board
front of the Carriage Unit with the flat-blade screwdriver to remove it from
the Carriage Unit.

Grounding Plate
Figure 4-94. Installing the CSIC Board

Notch

Hook

CSIC Board

Hook

Notch

Figure 4-93. Removing the CSIC Board

DISASSEMBLY & ASSEMBLY Disassembly 113


EPSON Stylus Photo R800 Revision A

4.2.6.7 Ink System Unit 4. Remove the three screws 4) C.B.S 3x8 that secure the Support Frame
(Lower), tilt the Printer Mechanism to the rear, and remove the Support
1. Remove the Printer Mechanism. (Refer to 4.2.1.3 Lower Housing/Printer Frame (Lower).
Mechanism (p.80))
2. Remove the ASF Assy.. (p.86)
3. Disconnect the Pump Motor Connector from the Relay Connector.
2

4) C.B.S 3x8
(8±1 kgf.cm)
3

4) C.B.S 3x8 1
(8±1 kgf.cm)

Figure 4-96. Screws That Secure the Support Frame (Lower)

Relay Connector

Figure 4-95. Disconnecting the Relay Connector Support Frame (Lower)

Bottom

Figure 4-97. Removing the Support Frame (Lower)

Tighten the screws in the order shown in Figure 4-96.

DISASSEMBLY & ASSEMBLY Disassembly 114


EPSON Stylus Photo R800 Revision A

5. Remove the two screws 2) C.B.S 3x6 that secure the Ink System Unit. 6. Remove the two screws 2) C.B.S 3x6 that secure the Support Frame
(Right), and remove the Support Frame (Right) from the Main Frame.

2
1
2

1
Top Support Frame (Right)
2) C.B.S 3x6
(6±1 kgf.cm)
2) C.B.S 3x6
2) C.B.S 3x6 (6±1 kgf.cm)
Figure 4-98. Screws That Secure the Ink System Unit (6±1 kgf.cm)

Tighten the screws in the order shown in Figure 4-98. Figure 4-99. Removing the Support Frame (Right)

„ Match the Dowels of the Main Frame with the Positioning


Holes of the Support Frame (Right).

Dowels and Positioning Holes

Figure 4-100. Installing the Support Frame (Right)

„ Tighten the screws in the order shown in Figure 4-99.

DISASSEMBLY & ASSEMBLY Disassembly 115


EPSON Stylus Photo R800 Revision A

7. Tilt the Printer Mechanism to the rear, and remove the Ink System Unit 4.2.6.8 Paper EJ Frame Assy.
from under the Main Frame.
1. Remove the Upper Housing. (p.78)
2. Release the Carriage Lock, and remove the Carriage Unit to the center of
the printer. (Refer to 4.2.6.1 Releasing the Carriage Lock (p.96))
3. Disengage the Paper EJ Lock Lever from the Paper EJ Release Lever.
Ink System Unit

Paper EJ Release Lever

Figure 4-101. Removing the Ink System Unit


Paper EJ Lock Lever
When the Ink System Unit is removed from the Printer Figure 4-103. Disengaging the Paper EJ Lock Lever
Mechanism, the Paper EJ Lock Release Cam may come off.
If it has come off, refer to the figure and reinstall it correctly.
4. Remove the four screws 2) C.B.S 3x6 that secure the Paper EJ Frame
Assy., and remove the Paper EJ Frame Assy. from the Printer Mechanism
to the front.

2) C.B.S 3x6
(8±1 kgf.cm)

Paper EJ Lock Release Cam


1
2
Figure 4-102. Installing the Paper EJ Lock Release Cam 3 4
Paper EJ Frame Assy.

Figure 4-104. Removing the Paper EJ Frame Assy.

DISASSEMBLY & ASSEMBLY Disassembly 116


EPSON Stylus Photo R800 Revision A

„ Engage both ends in the rear of the Paper EJ Frame 4.2.6.9 FLAG Release Assy.
Assy. with the Hooks of the Main Frame. 1. Remove the APG Assy.. (p.101)
„ Match the positioning holes and ribs.
2. Remove the ASF Assy.. (p.86)

Hooks
3. Disengage the Dowel of the Driven Release Holder from the Main Frame
with tweezers, and slide the Driven Release Holder to the left, and release
the three Hooks of the Driven Release Holder.

Driven Release Holder

Ribs and Positioning Holes Hooks

Figure 4-105. Installing the Paper EJ Frame Assy.

„ Tighten the screws in the order shown in Figure 4-104.


Dowel

A D J U S T M E N T After replacing or removing the Paper EJ Frame Assy., Figure 4-106. Removing the Driven Release Holder
R E Q U IR E D
always make the following adjustments.
1. Ink Mark Sensor Adjustment
2. PW Sensor Adjustment
3. PF Adjustment
4. PF Adjustment (Bottom Margin)
Refer to "CHAPTER 5 ADJUSTMENT" for details of the
adjustments.

DISASSEMBLY & ASSEMBLY Disassembly 117


EPSON Stylus Photo R800 Revision A

4. Push down with your fingers the three Upper Paper Guide Assys. on the 6. Push down with your fingers the two Upper Paper Guide Assys. on the left
right side as seen from the printer rear, and remove the right side of the side as seen from the printer rear, and remove the FLAG Release Assy.
FLAG Release Assy. to the front. downward.

Upper Paper Guide Assys.


Upper Paper Guide Assys.

FLAG Release Assy.

Figure 4-107. Removing the Right Side of the FLAG Release Assy.
Figure 4-109. Removing the FLAG Release Assy.
5. Move the Carriage Unit to the side opposite to the home.
A D J U S T M E N T After replacing the following part, always coat the
R E Q U IR E D
predetermined place with grease G-26.
„ Driven Release Shaft:
Chapter 6 Refer to Figure 6-8 (p.157), Figure 6-9 (p.157)

Figure 4-108. Moving the Carriage Unit

DISASSEMBLY & ASSEMBLY Disassembly 118


EPSON Stylus Photo R800 Revision A

4.2.6.10 Upper Paper Guide Assys. 3. Disengage the four Torsion Springs 161.6 from the Hooks of the Main
Frame, and pull the Torsion Springs 161.6 out of the four Upper Paper
1. Remove the FLAG Release Assy.. (p.117) Guide Assys. to the front.
2. Pass a sheet of A4 size paper into the clearance between the Upper Paper
Guide Assys. and Rear Paper Guide.

Upper Paper Guide Assys.

A4 Paper

Figure 4-110. Passing Paper


Hook

Torsion Spring 161.6

Figure 4-111. Removing the Torsion Spring 161.6

DISASSEMBLY & ASSEMBLY Disassembly 119


EPSON Stylus Photo R800 Revision A

Make certain that the tip of the Torsion Spring 161.6 is 4.2.6.11 Front Paper Guide
identified through the hole of the Upper Paper Guide Assy. 1. Remove the Printer Mechanism. (Refer to 4.2.1.3 Lower Housing/Printer
Mechanism (p.80))
2. Remove the Carriage Unit. (Refer to 4.2.6.5 Carriage Shaft/Carriage Unit
Torsion Spring 161.6 (p.103))
3. Remove the Paper EJ Frame Assy.. (p.116)
4. Tilt the Printer Mechanism to the rear, and remove the Guide Ink Eject
secured with the double-faced tape from the Front Paper Guide.

Guide Ink Eject

Hole

Figure 4-112. Installing the Torsion Spring 161.6

4. Remove the four Upper Paper Guide Assys. from the Main Frame.

Upper Paper Guide Assys. Figure 4-114. Removing the Guide Ink Eject

Figure 4-113. Removing the Upper Paper Guide Assys.

DISASSEMBLY & ASSEMBLY Disassembly 120


EPSON Stylus Photo R800 Revision A

3. Turn the Release Spur Gear in the direction of arrow shown in Figure
„ When the Guide Ink Eject is removed, the Protective
4-117 to release the Upper Paper Guide Assys.
Sheets and Absorber of the Guide Ink Eject may come
off. If they have come off, refer to the following
procedure and assemble them.
1. Insert the tabs of Protective Sheet Front into the
holes of the Absorber.
2. Insert the notches of the Protective Sheet Rear into
the notches of the Protective Sheet Front.

Tabs Protective Sheet


Rear

Absorber
Notches Release Spur Gear

Figure 4-116. Releasing the Upper Paper Guide Assys.

Protective Sheet
4. Pass a sheet of A4 size paper into the clearance between the PF Roller's
Front coating part and Front Paper Guide.

Notches

Holes
A4 Paper
„ After installing the Front Paper Guide, install the Guide
Ink Eject.

PF Roller

Front Paper Guide

Figure 4-117. Passing Paper

Double-Faced Tape Application Position


Home Side Tabs
Figure 4-115. Installing the Guide Ink Eject

DISASSEMBLY & ASSEMBLY Disassembly 121


EPSON Stylus Photo R800 Revision A

5. Push up the front of the Front Paper Guide from its bottom to release the
„ Check the conditions of the tabs of the Front Paper
three front Hooks, push the right side of the Front Paper Guide to the front
Guide Pads and Front Paper Guide Absorber Protection.
to release the rear Hook, and then remove the Front Paper Guide.
• The folded-over portions of all tabs should come out
of the holes of the Front Paper Guide completely.
• The tabs should not have been broken.
Front Paper Guide
• The opposite-to-home side tabs of the Front Paper
Rear Paper EJ Roller Guide Absorber Protection should be warped to the
inside each other. The home side tabs should be
straight as shown in Figure 4-115.

Hooks

Figure 4-118. Removing the Front Paper Guide

„ Match the rib of the Frame with the right side locator of Front Paper Guide Absorber
the Front Paper Guide.

Front Paper Guide

Opposite-to-Home Side Tabs


Locator

Figure 4-119. Installing the Front Paper Guide Figure 4-120. Tab Conditions

A D J U S T M E N T After replacing the following part, always coat the


R E Q U IR E D
predetermined place with grease G-45.
„ Front Paper Guide: Chapter 6 Figure 6-11 (p.157)

DISASSEMBLY & ASSEMBLY Disassembly 122


EPSON Stylus Photo R800 Revision A

4.2.6.12 Rear Paper EJ Roller Assy. 4. Disengage from the Main Frame the Dowels of the Bushes 5 at both ends
of the Rear Paper EJ Roller Assy., turn the Bushes 5 in the direction of
1. Remove the Front Paper Guide. (p.120) arrow in Figure 4-122, and match the Bushes 5 with the notches of the
2. Remove the PF Encoder Sensor Holder. (p.138) Main Frame.
3. Release the EJ Grounding Spring from the Hook of the Main Frame, and
remove the EJ Grounding Spring from the Front Paper EJ Roller Assy.

EJ Grounding Spring
Hook Bush 5 Dowel Bush 5
Dowel

Left Side Face Right Side Face

Figure 4-122. Turning the Bushes


Front Paper EJ Roller Assy.
5. Remove the Rear Paper EJ Roller Assy. along the notches of the Main
Frame.
Figure 4-121. Removing the EJ Grounding Spring

Rear Paper EJ Roller Assy.


Notch

Notch

Figure 4-123. Removing the Rear Paper EJ Roller Assy.

DISASSEMBLY & ASSEMBLY Disassembly 123


EPSON Stylus Photo R800 Revision A

A D J U S T M E N T After replacing the following part, always coat the 4.2.6.13 Front Paper EJ Roller Assy.
R E Q U IR E D
predetermined place with grease G-45. 1. Remove the Ink System Unit. (p.114)
„ EJ Grounding Spring: Chapter 6 Figure 6-10 (p.157)
2. Remove the Stacker Assy.. (p.82)
3. Remove the Rear Paper EJ Roller Assy.. (p.123)
4. Remove the Spacer that secures the Spur Gear 31.5, and remove the Spur
A D J U S T M E N T After replacing or removing the Rear Paper EJ Roller Assy., Gear 31.5 from the Printer Mechanism.
R E Q U IR E D
always make the following adjustments.
1. Ink Mark Sensor Adjustment
2. PW Sensor Adjustment
3. PF Adjustment
4. PF Adjustment (Bottom Margin) Spacer
Refer to "CHAPTER 5 ADJUSTMENT" for details of the
adjustments.

Spur Gear 31.5

Figure 4-124. Removing the Spur Gear 31.5

DISASSEMBLY & ASSEMBLY Disassembly 124


EPSON Stylus Photo R800 Revision A

5. Remove the three screws 3) C.B.P 3x6 that secure the Lower Paper Guide 7. Disengage the right end of the Lower Paper Guide Assy. from the two ribs
Assy. of the Main Frame, and remove the Front Paper EJ Roller Assy. along the
notches of the Main Frame, together with the Lower Paper Guide Assy.

Notches

3) C.B.P 3x6 3) C.B.P 3x6


(6±1 kgf.cm) Left Front Face Side (6±1 kgf.cm) Right Side Face Side
Lower Paper Guide Assy.
Figure 4-125. Screws That Secure the Lower Paper Guide Assy.

Front Paper EJ Roller Assy.


6. Disengage from the Main Frame the Dowels of the Bushes 5 at both ends
of the Front Paper EJ Roller Assy., turn the Bushes 5 in the direction of
arrow in Figure 4-122, and match the Bushes 5 with the notches of the
Main Frame.
Positioning Holes and Ribs

Dowel

Dowel

Bush 5
Bush 5
Left Side Face Right Side Face
Figure 4-127. Removing the Lower Paper Guide Assy. and Front Paper EJ
Figure 4-126. Turning the Bushes Roller Assy.

DISASSEMBLY & ASSEMBLY Disassembly 125


EPSON Stylus Photo R800 Revision A

8. Disconnect the two Cutter Connectors from the Lower Paper Guide Assy. 10. Release the Front Paper EJ Roller Assy. from the Hooks at both ends of
the Lower Paper Guide Assy., and then release it from the center Hook to
remove the Front Paper EJ Roller Assy.
Cutter Connectors

Hooks

Front Paper EJ Roller Assy.

Lower Paper Guide Assy.

Lower Paper Guide Assy.


Figure 4-128. Disconnecting the Cutter Connectors

9. Release the two Hooks of the Lower Paper Guide Assy., and remove the Figure 4-130. Removing the Front Paper EJ Roller Assy.
Paper EJ Frame from the Lower Paper Guide Assy.
A D J U S T M E N T After replacing the following part, always coat the
Paper EJ Frame R E Q U IR E D
predetermined place with grease G-26.
„ Lower Paper Guide Assy.: Chapter 6 Figure 6-12 (p.157)
Hooks

A D J U S T M E N T After replacing or removing the Front Paper EJ Roller Assy.,


R E Q U IR E D
always make the following adjustments.
1. Ink Mark Sensor Adjustment
2. PW Sensor Adjustment
Lower Paper Guide Assy. 3. PF Adjustment
4. PF Adjustment (Bottom Margin)
Refer to "CHAPTER 5 ADJUSTMENT" for details of the
adjustments.

Figure 4-129. Removing the Paper EJ Frame

DISASSEMBLY & ASSEMBLY Disassembly 126


EPSON Stylus Photo R800 Revision A

4.2.6.14 PF Roller 4. Release the PF Grounding Spring from the notch of the Main Frame, and
remove the PF Grounding Spring from the PF Roller.
1. Remove the Front Paper Guide. (p.120)
2. Loosen the two screws 12) C.C 3x4 that secure the PF Motor, and remove
Rear Side
the PF Timing Belt from the Pinion Gear of the PF Motor.

12) C.C 3x4


(4±0.5 kgf.cm)

Notch

PF Grounding Spring
PF Roller

Figure 4-132. Removing the PF Grounding Spring


Pinion Gear
PF Timing Belt
5. Turn the Adjust Parallel Bushing (Left) in the direction of arrow to prevent it
Figure 4-131. Removing the PF Timing Belt from engaging the notch of the Main Frame.

3. Remove the Spur Gear 31.5. (Refer to 4.2.6.13 Front Paper EJ Roller
Adjust Parallel Bushing (Left)
Assy., Step 4 (p.124))

Notch

Figure 4-133. Turning the Adjust Parallel Bushing (Left)

DISASSEMBLY & ASSEMBLY Disassembly 127


EPSON Stylus Photo R800 Revision A

6. Disengage the Dowel of the Bush 8 (Left) from the Main Frame with 8. Hold the rear side of the Upper Paper Guide Assys. with your hand to lift
tweezers, and turn the Bush 8 (Left) upward to match the Bush 8 (Left) with their front side, lower the right side of the Upper Support Lever, and pass a
the notch of the Main Frame. sheet of A4 size paper into the clearance between the PF Roller and Under
Driven Roller.

Dowel

Bush 8 (Left)

Figure 4-134. Turning the Bush 8 (Left)

C A U T IO N In the following step, be careful not to mislay the E-Ring.


Upper Paper Guide Assys.

7. Remove the E-Ring from the PF Roller with a flat-blade screwdriver, and
remove the Bush 8 (Left) to the inside of the Printer Mechanism.

E-Ring

Figure 4-136. Lifting the Upper Paper Guide Assys.

PF Roller

Figure 4-135. Removing the Bush 8 (Left)

DISASSEMBLY & ASSEMBLY Disassembly 128


EPSON Stylus Photo R800 Revision A

9. Shift the PF Roller to the left to remove it from the Bush 8 (Right), remove it
from the Rear Paper Guide and Main Frame Shaft Support, and remove
the PF Roller along the notch of the Main Frame.
Under Driven Roller

Under Support Lever


Rear Paper Guide

Bush 8 (Right)

Figure 4-137. Passing Paper


Shaft Support

C A U T IO N In the following step, pay attention to the following points.


„ Do not scratch the coating of the PF Roller. Figure 4-139. Removing the PF Roller
„ Do not touch the coating of the PF Roller with bare
hands. After the PF Roller is removed, note that the Compression
C A U T IO N
Spring 4, Leaf Spring, etc. on the left side of the PF Roller
Coating Part may move to the coating part.

Compression Spring 4

Leaf Spring
Figure 4-138. Handling the PF Roller

Figure 4-140. Left Side of PF Roller

DISASSEMBLY & ASSEMBLY Disassembly 129


EPSON Stylus Photo R800 Revision A

A D J U S T M E N T After replacing the following parts, always coat the 4.2.7 Removing the Motors
R E Q U IR E D
predetermined place with grease G-45.
„ PF Roller : Chapter 6 Figure 6-13 (p.158) 4.2.7.1 CR Motor
„ Rear Paper Guide : Chapter 6 Figure 6-14 (p.158) 1. Remove the Upper Housing. (p.78)
„ PF Grounding Spring : Chapter 6 Figure 6-15 (p.158) 2. Release the Carriage Lock, and move the Carriage Unit to the center of the
printer. (Refer to 4.2.6.1 Releasing the Carriage Lock (p.96))
3. Disconnect the CR Motor Connector from the Relay Connector.
A D J U S T M E N T After replacing or removing the PF Roller, always make the
R E Q U IR E D
following adjustments.
1. PF Belt Tension Adjustment CR Motor
2. Ink Mark Sensor Adjustment
3. PW Sensor Adjustment
4. PF Deterioration Compensation Counter Reset Relay Connector
5. PF Adjustment
6. PF Adjustment (Bottom Margin)
Refer to "CHAPTER 5 ADJUSTMENT" for details of the
adjustments.

CR Motor Connector
Figure 4-141. Disconnecting the CR Motor Connector

4. Remove the CR Timing Belt from the CR Motor Pinion Gear.


(Refer to 4.2.6.5 Carriage Shaft/Carriage Unit, Step 10 (p.105))

DISASSEMBLY & ASSEMBLY Disassembly 130


EPSON Stylus Photo R800 Revision A

5. Remove the two screws 12) C.C 3x4 that secure the CR Motor, and 4.2.7.2 PF Motor
remove the CR Motor from the Main Frame.
1. Remove the Printer Mechanism. (Refer to 4.2.1.3 Lower Housing/Printer
Mechanism (p.80))
2. Peel off the Acetate Tape to release the Ferrite Core. (Refer to 4.2.6.4
12) C.C 3x4
(4±0.5 kgf.cm)
APG Assy., Step 5 (p.101))
3. Remove the screw 2) C.B.S 3x6 that secures the PF Motor Cover, and
remove the PF Motor Cover from the Main Frame.

2 1 2) C.B.S 3x6
PF Motor Cover (6±1 kgf.cm)

Figure 4-142. Removing the CR Motor

„ Install the CR Motor with its Lot No. print surface up.

Print Surface
Figure 4-144. Removing the PF Motor Cover

Figure 4-143. Installing the CR Motor

„ Tighten the screws in the order shown in Figure 4-142.

A D J U S T M E N T After replacing the CR Motor, always make the following


R E Q U IR E D
adjustment.
„ CR Motor Drive Dispersion
Refer to "CHAPTER 5 ADJUSTMENT" for details of the
adjustments.

DISASSEMBLY & ASSEMBLY Disassembly 131


EPSON Stylus Photo R800 Revision A

4. Disconnect the PF Motor Connector from the Relay Connector.


„ Match the positioning holes of the Main Frame with the
Hooks of the PF Motor Cover. 5. Remove the two screws 12) C.C 3x4 that secure the PF Motor.
„ Pass the PF Motor Connector Cable into the notch of the 6. Peel off the Acetate Tape to release the PF Motor Connector Cable.
PF Motor Cover.
7. Remove the PF Timing Belt from the Pinion Gear of the PF Motor, and
remove the PF Motor from the Printer Mechanism.

Acetate Tape

PF Motor Connector Cable

PF Timing Belt
Hooks

Positioning
Holes 1

Notch Relay Connector


2 12) C.C 3x4
(4±0.5 kgf.cm)
PF Motor

Figure 4-145. Installing the PF Motor Cover Figure 4-146. Removing the PF Motor

DISASSEMBLY & ASSEMBLY Disassembly 132


EPSON Stylus Photo R800 Revision A

„ Install the PF Motor with its Lot No. print surface facing 4.2.8 Removing the Sensors
as shown in Figure 4-147.
4.2.8.1 Cover Open Sensor Holder
1. Remove the Upper Housing. (p.78)
2. Disconnect the Cover Open Sensor Connector from the Cover Open
Sensor Holder.
3. Release the Hook of the Upper Housing, and remove the Cover Open
Print Surface Sensor Holder upward from the Upper Housing.

„ Make certain that the two Hooks of the Upper Housing


secure the Cover Open Sensor Holder tightly.
„ Refer to Figure 4-148, and route the Connector Cable so
Figure 4-147. Installing the PF Motor that it is not caught in the Printer Mechanism.

„ Secure the PF Motor Connector Cover with the Acetate


Cover Open Sensor Connector
Tape.
„ Tighten the screws in the order shown in Figure 4-146.

A D J U S T M E N T After replacing or removing the PF Motor, always make the


R E Q U IR E D
following adjustments.
1. PF Belt Tension Adjustment
Hook
2. PF Adjustment
3. PF Adjustment (Bottom Margin)
Refer to "CHAPTER 5 ADJUSTMENT" for details of the
adjustments. Hook

Figure 4-148. Removing the Cover Open Sensor Holder

DISASSEMBLY & ASSEMBLY Disassembly 133


EPSON Stylus Photo R800 Revision A

4.2.8.2 PG Release Sensor 4. Remove the Stacker Shaft Bracket (Left) from the Stacker Assy. Shaft.
1. Remove the Torsion Spring 105.84. (Refer to 4.2.2 Stacker Assy. (p.82)) 5. Disconnect the Connector from the PG Release Sensor, and remove the
Stacker Shaft Bracket (Left).
2. Remove the screw 2) C.B.S 3x6 that secures the Stacker Shaft Bracket
(Left). (Refer to 4.2.2 Stacker Assy. (p.82))
3. Slide the Stacker Shaft Bracket (Left) upward to disengage the Hook and
Dowel.

Connector

Dowel
Step 5

Hook Step 4 Stacker Shaft Bracket (Left)

Figure 4-150. Removing the Stacker Shaft Bracket (Left) (2)

6. Release the two Hooks that secure the PG Release Sensor, and remove
the PG Release Sensor.
Figure 4-149. Removing the Stacker Shaft Bracket (Left) (1)

Hooks

PG Release Sensor

Figure 4-151. Removing the PG Release Sensor

DISASSEMBLY & ASSEMBLY Disassembly 134


EPSON Stylus Photo R800 Revision A

„ Put the lever of the PG Release Sensor under the shaft 4.2.8.3 PE Sensor Holder
on the right of the Stacker Assy. (Refer to Figure 4-42) 1. Remove the ASF Assy.. (p.86)
„ Set the engagement positions of the Gears at both ends
2. Release the Connector Cable of the PE Sensor from the three Hooks of
of the Stacker Assy. to the same height.
the Main Frame.

Connector Cable

Figure 4-152. Gear Engagement Positions Hooks

Figure 4-153. Releasing the Cable

DISASSEMBLY & ASSEMBLY Disassembly 135


EPSON Stylus Photo R800 Revision A

3. Remove the one screw 2) C.B.S 3x6 that secures the PE Sensor Holder. 4.2.8.4 Ink Mark Sensor/PW Sensor
4. Push the Hook of the PE Sensor Holder with tweezers, slide the PE Sensor 1. Remove the Carriage Unit. (Refer to 4.2.6.5 Carriage Shaft/Carriage Unit
Holder upward, and then remove it to the front. (p.103))
2. Remove the one screw 13) C.P.B (P1) 1.7x5 that secures the PW Sensor
Front Face Holder, and remove the PW Sensor Holder from the Carriage Unit.

PE Sensor Holder
PW Sensor Holder

Hook

2) C.B.S 3x6
(8±1 kgf.cm)
13) C.P.B (P1) 1.7x5
Carriage Unit (1±0.2 kgf.cm)
Bottom
Figure 4-154. Removing the PE Sensor Holder
Figure 4-156. Removing the PW Sensor Holder

Engage the four Hooks of the PE Sensor Holder with the 3. Disconnect the FFC from the Connectors of the Ink Mark Sensor and PW
Main Frame securely to eliminate a clearance between the Sensor, and remove the Ink Mark Sensor and PW Sensor.
PE Sensor Holder and Main Frame.

Hooks
PW Sensor

Connectors

Ink Mark Sensor

Figure 4-155. Installing the PE Sensor


Figure 4-157. Removing the Ink Mark Sensor and PW Sensor

DISASSEMBLY & ASSEMBLY Disassembly 136


EPSON Stylus Photo R800 Revision A

Make sure that the FFC is routed as shown in Figure 4-157. 4.2.8.5 CR Encoder Board
1. Remove the Carriage Unit. (Refer to 4.2.6.5 Carriage Shaft/Carriage Unit
(p.103))
2. Remove the two screws 14) C.B.P 2.6x5 that secure the CR Encoder
Board.
3. Disconnect the FFC of the PW Sensor and Ink Mark Sensor from the CR
A D J U S T M E N T After replacing or removing the Ink Mark Sensor and PW
R E Q U IR E D Encoder Board Connector, and remove the CR Encoder Board.
Sensor, always make the following adjustments.
„ Ink Mark Sensor
1. Ink Mark Sensor Adjustment
2. Ink Mark Sensor Check
3. PW Sensor Adjustment
FFC
„ PW Sensor
1. Ink Mark Sensor Adjustment
2. PW Sensor Adjustment
Refer to "CHAPTER 5 ADJUSTMENT" for details of the
adjustments. CR Encoder Board
14) C.B.P 2.6x5
(3±0.5 kgf.cm)

Figure 4-158. Removing the CR Encoder Board

DISASSEMBLY & ASSEMBLY Disassembly 137


EPSON Stylus Photo R800 Revision A

4.2.8.6 PF Encoder Sensor Holder 5. After pushing the Dowel of the PF Encoder Sensor Holder with tweezers,
shift the PF Encoder Sensor Holder upward to disengage the three Hooks,
1. Remove the Upper Housing. (p.78) and remove the PF Encoder Sensor Holder.
2. Remove the one screw 2) C.B.S 3x6 that secures the PF Encoder Sensor
Holder.
3. Disconnect the FFC from the PF Sensor Board Connector.

PF Encoder Sensor Holder


FFC

2) C.B.S 3x6
(4±0.5 kgf.cm)
Dowel
Connector

Hooks

Figure 4-160. Removing the PF Encoder Sensor Holder

The PF Scale should have been entered in the slit of the PF


Figure 4-159. Removing the Screw that Secures the PF Encoder Sensor Encoder Sensor.
Holder and Disconnecting the FFC

4. Remove the Frame Support Plate (Left). (Refer to 4.2.6.5 Carriage Shaft/
Carriage Unit, Step 4 (p.103)) PF Scale

PF Encoder Sensor

Figure 4-161. Installing the PF Encoder Sensor Holder

DISASSEMBLY & ASSEMBLY Disassembly 138


5
CHAPTER

ADJUSTMENT
EPSON Stylus Photo R800 Revision A

5.1 Adjustment Items and Overview


This chapter describes adjustments to be made after the disassembly/reassembly of this product.

5.1.1 Servicing Adjustment Item List


The items, purposes and outlines of the Adjustment Program are given in the following table.

Table 5-1. Main Adjustment Items


Function Item Purpose Method Outline
Main Board Data Necessary data are read from within the EEPROM of the 1. Select this function in the Adjustment Program.
Read/Write Function faulty Main Board by the D4 function to reduce the 2. Read data from the faulty product.
ancillary adjustment items for of board replacement. 3. After replacing the Main Board, write the read data to the new board.
Market & Initial At the time of Main Board replacement, the board- 1. Select and execute this function in the Adjustment Program.
Settings common information is written on a market basis. 2. Write the market-by-market settings and initial settings to the EEPROM.
„ Market-by-market settings
Market ID
CSIC Printer ID
USB ID Input The USB ID is written to identify the connection of the 1. Select this function in the Adjustment Program and enter the serial number of the
same model. printer.
2. The correction value is saved to the specific EEPROM address of the Main Board.
IEEE1394 ID Input When multiple printers of the same model are connected 1. Read the 10-digit unique ID from the label applied to the rear of the Board Unit.
to the PC in a daisy chain, etc., this adjustment is made to 2. Enter the ID in the Adjustment Program to save it into the EEPROM.
allow the PC to recognize the connected printers
individually.
Head ID Input At the time of Print Head replacement, this adjustment is 1. Enter the ID of the Head QR Code Label, which is applied to the Print Head, into the
made to correct head manufacturing variations and program.
eliminate the individual differences of print quality. 2. The ID is saved into the EEPROM of the Main Board.
(Supplement: Read the QR code label from left to right on the top row and from top to
bottom in due order.)
Head Angular This adjustment is made to correct the error in the Print 1. Select this function in the Adjustment Program and print the adjustment pattern.
Adjustment Head mounting position (Head angle) to make the nozzle 2. After checking the displacement amount of the pattern, enter the pattern number whose
line straight relative to the paper feeding direction. Angular displacement amount is the smallest.
displacement is also checked for.
Multi Sensor This adjustment is made to correct a detection position 1. Select and execute this function in the Adjustment Program.
Adjustment error, which is caused by the displacement of the Ink Mark 2. Pattern printing and adjustment are automatically executed.
(Ink Mark Sensor Sensor mounting position, on a software basis. Supplement: Note that you must confirm there are no dots missing before execution of this
Adjustment) adjustment.

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EPSON Stylus Photo R800 Revision A

Table 5-1. Main Adjustment Items


Function Item Purpose Method Outline
Auto Bi-D Adjustment This adjustment is made to correct the print timing in the 1. Select and execute this function in the Adjustment Program.
go and return paths in bi-directional printing. 2. Pattern printing and adjustment are automatically executed.
Supplement: Note that you must confirm there are no dots missing before execution of this
adjustment.
Ink Mark Sensor This check is made to test whether the Ink Mark Sensor 1. Print a pattern with no dots missing, and check it with the Sensor.
Check can detect patterns properly. 2. Print a pattern with five dots missing, and check it with the Sensor.
3. The check result is OK if the two patterns are detected correctly.
Before execution of pattern printing, however, you must confirm that there are no dots
missing.
First Dot Position This function adjusts the print starting position in the CR 1. Select this function in the Adjustment Program and print the adjustment pattern.
main scanning direction. 2. Select the pattern number 5mm away from each edge, and enter that number in the
program.
3. The correction value is saved to the specific EEPROM address of the Main Board.
PW Sensor This adjustment is made to correct the PW Sensor 1. Select this function in the Adjustment Program and print the adjustment pattern.
Adjustment mounting position on a software basis to improve a paper 2. Select the pattern number 5mm away from each edge, and enter that number in the
detection error caused by the variation of the mounting program.
position. 3. The correction value is saved to the specific EEPROM address of the Main Board.
PF Deterioration The deterioration amount of the PF Roller Shaft is added 1. Select and execute this function in the Adjustment Program.
Compensation to the paper feed correction amount. Every time a sheet of 2. Reset the PF deterioration counter.
Counter Reset paper is fed, the deterioration amount is counted on the
basis of the original counter value setting.
When the PF Roller Shaft or Printer Mechanism has been
replaced during repair, the PF deterioration counter must
be reset.
PF Deterioration The PF deterioration compensation counter can be reset 1. Select and execute this function in the Adjustment Program.
Compensation only when the PF Roller Shaft is new. To reduce the 2. Reset the PF deterioration counter.
Counter Reset ancillary work in servicing, enter the maximum value
(Maximum value write) (value for which deterioration compensation is not made) if
the PF Roller Shaft has not been replaced.
PF Adjustment This correction is made when the actual feed amount 1. Select this function in the Adjustment Program and print the adjustment pattern.
differs greatly from the theoretical value due to paper slip, 2. Select or measure the adjustment value, and write it to the specific EEPROM address
PF roller tolerances, etc. during paper feed for printing. on the Main Board.
PF Adjustment This correction is made when the actual feed amount 1. Select this function in the Adjustment Program and print the adjustment pattern.
(Bottom Margin) differs greatly from the theoretical value due to paper slip, 2. Select or measure the adjustment value, and write it to the specific EEPROM address
exit roller tolerances, etc. during exit paper feed for bottom on the Main Board.
printing.

ADJUSTMENT Adjustment Items and Overview 141


EPSON Stylus Photo R800 Revision A

Table 5-1. Main Adjustment Items


Function Item Purpose Method Outline
CR Motor Drive This adjustment is made to measure the manufacturing 1. Select/execute this function in the Adjustment Program.
Dispersion variations of the CR Motor and PS Board to make the 2. After execution, the variations are automatically measured and the measurement
most of the motor capabilities for motor heat generation values are written to the EEPROM of the Main Board.
control.
CR Motor Drive CR Dispersion Measurement can be performed only when 1. Select/execute this function in the Adjustment Program.
Dispersion the Carriage Shaft is new. To reduce the ancillary work in 2. After execution, the dispersions are automatically measured and the worst value is
(Maximum value) servicing, enter the worst value (on which heat generation written to the EEPROM of the Main Board.
limit is easily imposed) if the Carriage Shaft has not been
replaced.

Table 5-2. Maintenance Function


Function Item Purpose Method Outline

Ink Charge This function is used for Print Head replacement to drain 1. Select this function in the Adjustment Program.
Shipping Liquid of the after-sales service part in the head 2. Transfer the factory-set command (CL execution command (Initial Ink Charge) is used
flow path and simultaneously fill ink in the head flow path as the command) to the printer to make the printer perform Initial Ink Charge operation.
to make all nozzles printable and stabilize the ink in the
Print Head.
Refurbishment This function is used to refurbish the initially returned 1. Select this function in the Adjustment Program.
Function product. Specifically, clean the inside of the Head, and
(Shipping Liquid charge and replace the Shipping Liquid.
replacement)

Cleaning This function is used to execute cleaning 3 (CL3) when ink 1. Select this function in the Adjustment Program.
is not delivered from the Print Head properly, e.g. dot 2. Execute CL3.
missing or skewed injection.
Waste Ink Counter This function is used to read and reset the Waste Ink 1. In the Adjustment Program, select data read or reset from this function.
Reset Counters. Before executing this function, replace both the 0 digit and 80 digit side Waste Ink Pads.

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EPSON Stylus Photo R800 Revision A

5.1.2 Replacement Part-Based Adjustment Priorities


The following table indicates the replacement part-based adjustment item and priority list.

NOTE: The replacement part adjustment item indicates the adjustment to be made when the corresponding replacement part is removed singly, and does not include
adjustment accompanied by ancillary work.

Note : Symbol explanation


~: When part is replaced or removed
{: When part is replaced
Table 5-3. Replacement Part-Based Adjustment Item and Priority List (1)
Waste Ink Ink Mark
Adjustment Item Priority Print Head Main Board *1 Main Board *2 PS Board PW sensor CR Motor
Pads Sensor
PG Adjustment 1 ~ – – – – – – –
PF Belt Tension Adjustment 2 – – – – – – – –
Main Board Data Read/Write 3 – { { – – – – –
Initial Value Write 4 – – { – – – – –
USB ID Input 5 – – { – – – – –
IEEE-1394 ID Input 6 – – { – – – – –
Head ID Input 7 { – { – – – – –
Head Angular Adjustment 8 ~ – { – – – – –
Ink Mark Sensor Adjustment 9 *3 ~ – { – – ~ ~ –
Auto Bi-D Adjustment 10 *3 ~ – { – – – – –
Ink Mark Sensor Check 11 *3 – – { – – ~ – –
First Dot Position 12 ~ – { – – – – –
PW Sensor Adjustment 13 ~ – { – – ~ ~ –
PF Deterioration 14 – – – – – – – –
Compensation Counter Reset
PF Deterioration 14 – – { – – – – –
Compensation Counter Reset
(Maximum value)
PF Adjustment 14 – – { – – – – –
PF Adjustment 15 – – { – – – – –
(Bottom Margin)
Waste Ink Counter Reset 16 – – – – ~ – – –
CR Motor Drive Dispersion 17 – – { { – – – {
Note "*1": When data can be read from the old board. "*3": Nozzle check patterns must be printed for confirmation.
"*2": When data cannot be read from the old board. "*4": Perform this adjustment when replacing the mechanical unit with a rebuilt
one whose PF Roller is not new.

ADJUSTMENT Adjustment Items and Overview 143


EPSON Stylus Photo R800 Revision A

Note : Symbol explanation


~: When part is replaced or removed
{: When part is replaced

Table 5-4. Replacement Part-Based Adjustment Item and Priority List (2)
Paper EJ ASP
Carriage Paper EJ
Adjustment Item Priority Carriage Unit PF Motor PF Roller Roller (Front/ Mechanism ASF Assy.
Shaft Frame Assy.
Rear) Assy. Unit
PG Adjustment 1 ~ ~ – – – – { –
PF Belt Tension Adjustment 2 – – ~ – ~ – – –
Main Board Data Read/Write 3 – – – – – – – –
Initial Value Write 4 – – – – – – – –
USB ID Input 5 – – – – – – – –
IEEE-1394 ID Input 6 – – – – – – – –
Head ID Input 7 – – – – – – – –
Head Angular Adjustment 8 { { – – – – – –
Ink Mark Sensor Adjustment 9 *3 { { – { { { { –
Auto Bi-D Adjustment 10 *3 { { – – – – { –
Ink Mark Sensor Check 11 *3 – – – – – – { –
First Dot Position 12 { { – – – – { ~
PW Sensor Adjustment 13 { { – { { { { –
PF Deterioration 14 – – – – { – { –
Compensation Counter Reset
PF Deterioration 14 – – – – – – – –
Compensation Counter Reset
(Maximum value)
PF Adjustment 15 – – { { { { { –
PF Adjustment 16 – – { { { { { –
(Bottom Margin)
Waste Ink Counter Reset 17 – – – – – – – –
CR Motor Drive Dispersion 18 – – – – – – { –
Note "*1": When data can be read from the old board.
"*2": When data cannot be read from the old board.
"*3": Nozzle check patterns must be printed for confirmation.
"*4": Perform this adjustment when replacing the mechanical unit with a rebuilt
one whose PF Roller is not new.

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EPSON Stylus Photo R800 Revision A

5.1.3 Required Adjustment Jigs, Tools and Like 5.2 Adjustments


The following table indicates the adjustment jigs, tools and like necessary for
This section explains the adjustments that do not use the Adjustment Program.
the adjustments of this product.

Table 5-5. Adjustment Tools 5.2.1 PF Belt Tension Adjustment


No. Name Parts code Category Outline When either of the following parts has been removed or replaced, this
1 Adjustment -- Software Unlike the conventional adjustment must be performed to reduce load on the PF Motor and to secure
Program Adjustment Program, this paper feed accuracy.
Adjustment Program is
designed to display the † PF Motor
requested adjustment items
† PF Roller
in proper order of priorities
when the part to be replaced The PF Tension Measuring Tool is used for this adjustment.
is selected, providing the
worker with precise
adjustment priorities.
2 G-26 1080614 Grease For the Adjust Parallel
Bushing, Lower Paper
Guide, Driven Release Shaft,
etc.
3 G-45 1033657 For the PF Roller, Front
Paper Guide, Rear Paper
Guide, etc.
4 G-70 1275684 For the Carriage Unit and
Carriage Shaft.
5 PG Adjustment 1276333 Gauge Gauge exclusively used to
Gauge make PG Adjustment.
Confirm the adjustment value
by energization. There is one Figure 5-1. PF Tension Measuring Tool
gauge.
6 PF Tension 1231678 Measuring Used to check whether the
Measuring Tool Equipment tension of the PF Timing Belt
is within the specified value
or not. If load is greater than
the specified value, the PF
Motor may generate heat,
burning off the coil.
Reversely, if load is less than
the specified value, the paper
feed position may shift.

ADJUSTMENT Adjustments 145


EPSON Stylus Photo R800 Revision A

5.2.1.1 PF Belt Tension Adjustment Method 7. Bring the Microphone as close as possible to the center of the Timing Belt.

C A U T IO N Proper measurement may be interrupted by sounds picked


up from around. Make measurement in silent environment. Microphone of
Measuring Tool

1. Secure the PF Motor to the Printer Mechanism, and install the Timing Belt
on the Gear of the PF Scale and the Pinion Gear of the PF Motor. Timing Belt

2. Press the [POWER] button. (The LCD of the Measuring Tool displays No. 0
and No. 1.)
3. From among No. 0 to No. 9, select the channel you want to store its setting
by pressing the [SELECT] button. (The initial value may be selected as the Figure 5-2. Microphone Position
channel.)
4. Press the [WEIGHT] button. Though the initial value is displayed, type from
the ten-key pad so that "1.2g/m" is displayed. C A U T IO N As the Timing Belt is flipped with the tip of tweezers in the
following steps, carefully choose the flipping position so
5. Press the [WIDTH] button. Though the initial value is displayed, type from that the Belt will not make contact with the Microphone by
the ten-key pad so that "5.0mm" is displayed. reaction of flipping.
6. Press the [SPAN] button. Though the initial value is displayed, type from
the ten-key pad so that "48mm" is displayed.

8. Press the [MEASURE] button. ("----" is displayed on the LCD screen.)


9. Put the tip of the tweezers on the Timing Belt, and flip it downward in that
position. The "----" line on the LCD screen becomes wavy, and the
measurement result is indicated by "repeated beeps" and "N" (Newton)
displayed on the LCD screen. This jig can pick up and measure sounds
accurately, regardless of the flipping force.
10. Repeating Step 8 and 9, delicately shift the variable part of the PF Motor
mounting position to adjust the tension until the tension falls within the
allowable standard value.

ADJUSTMENT Adjustments 146


EPSON Stylus Photo R800 Revision A

A D J U S T M E N T Standard value: 9.0 ± 2N (7.0 ~ 11.0N) 5.2.2 PG Adjustment


R E Q U IR E D
When any of the following parts has been removed or replaced, this adjustment
must be performed to secure the specified clearance between the print surface
of the Print Head and paper.
† Print Head

C A U T IO N „ Even if the Timing Belt is flipped, the LCD screen may † Carriage Unit
not change at all. In this case, flip the Timing Belt again † Carriage Shaft
after a few seconds have passed.
† Adjust Parallel Bushing (Including the case where positions have been
„ If measurement results differ greatly from each other,
shifted)
acoustic sounds may not be picked up properly in any of
the measurements. Therefore, flip the Timing Belt again In this adjustment, use the same Adjustment Gauge on the left and right sides.
with the tweezers, and record the value at which two
measurement results are approximate. Displaying errors Adjustment Gauge Plate (Top face) Continuity measurement portion
in the range 1/100 to 5/100, the Measuring Tool has high
reliability.

Figure 5-3. Adjustment Gauge Appearance

C A U T IO N „ Do not touch the Adjustment Gauge Plate surface with


bare hands.
„ If the Adjustment Gauge Plate surface is stained by ink or
like, wipe it with a soft cloth or like.

ADJUSTMENT Adjustments 147


EPSON Stylus Photo R800 Revision A

5.2.2.1 PG Adjustment Method 3. Load virgin Ink Cartridges of all colors into the Carriage Unit.
4. Loosen the screw that secures the Adjust Parallel Bushing.
C A U T IO N „ Before starting PG adjustment, completely wipe drops of 5. Turn the Adjust Parallel Bushing upward to match the frame edge and the
ink from around the Print Head. Remaining drops of ink bottom of the Adjust Parallel Bushing gear.
will stick to the continuity measurement portion of the
Adjustment Gauge, and generate continuity before the
continuity measurement portion makes contact with the Adjust Parallel Match Position Adjust Parallel Bushing
Bushing
metal frame around the Print Head, interrupting accurate
PG Adjustment.
„ As the ink in the Print Head may stick fast and damage
the Print Head during PG Adjustment, make the
continuity time detected with a tester as short as
possible. (Within 3 minutes)
Screw

1. Install the printer on a level base. Match Position Screw

C H E C K Place the printer on a level, warp-free table. Normal PG


P O IN T Adjustment cannot be performed on a warped table.

2. Connect the Tester to the printer frame and Adjustment Gauge.

Frame

Figure 5-5. Setting the Adjust Parallel Bushings


Tester

Adjustment Gauge

Figure 5-4. Connecting the Tester

ADJUSTMENT Adjustments 148


EPSON Stylus Photo R800 Revision A

6. With its conductor connection portion up, set the Adjustment Gauge in the 7. Move the Carriage Unit onto the Adjustment Gauge.
specified position (on the left side of the Front Paper Guide). „ Moving position
„ Setting position Match the left end of the Gauge with the left end of the Carriage Unit.
Rear direction : Match the rear end of the Gauge with the Driven
Roller Shaft of the Upper Paper Guide.
Left direction : Match the left end of the Gauge with the rib of the
Front Paper Guide in Figure 5-6.

Conductor Connection Portion


Setting Position

Rib
Setting Position Figure 5-7. Moving the Carriage Unit

8. In order to set the PG position to - (minus), turn the PG Cam mounted on


the Carriage Shaft right end clockwise (CW) to direct the position marked -
(minus) to the bottom.
Figure 5-6. Setting the Adjustment Gauge

PG Cam

Figure 5-8. Markings of the PG Cam

ADJUSTMENT Adjustments 149


EPSON Stylus Photo R800 Revision A

9. Lower the Gear of the Adjust Parallel Bushing on the left side of the frame 11. With its conductor connection portion up, set the Adjustment Gauge in the
step by step, and confirm continuity. When continuity could be confirmed, specified position (on the right side of the Front Paper Guide).
define the position, where the Gear was raised one step up from the „ Setting position
continuity position (where continuity is lost), as the left side PG position. Rear direction : Match the rear end of the Gauge with the Driven
Move the Adjust Parallel Bushing at least twice to confirm that the Roller Shaft of the Upper Paper Guide.
continuity position and the non-continuity position are the same.
Right direction : Match the right end of the Gauge with the rib of the
C H E C K The following figure shows the states of the Adjust Parallel Front Paper Guide in Figure 5-10.
P O IN T Bushing of the left side of the frame and the PG. (This also
applies to the Adjust Parallel Bushing on the right side of
the frame.)

Wider PG

Adjust Parallel Bushing

Rib

Setting Position

Narrower PG Conductor Connection Portion

Figure 5-10. Setting the Adjustment Gauge


Figure 5-9. Relationship between Adjust Parallel Bushing
and PG

10. In order to set the PG position to 0 or more, turn the PG Cams mounted on
both ends of the Carriage Shaft counterclockwise (CCW) to direct the
position marked 0 (or +, ++) to the bottom.

ADJUSTMENT Adjustments 150


EPSON Stylus Photo R800 Revision A

12. Move the Carriage Unit onto the Adjustment Gauge.


„ Moving position
Match the right end of the Gauge with the right end of the Carriage
Unit.

Setting Position

Figure 5-11. Moving the Carriage Unit

13. Return the PG position to - (minus).


14. As in Step 9, move the Adjust Parallel Bushing on the right side of the
frame to set the right side PG position.
15. Set the PG position to 0 or more.
16. Set the Adjustment Gauge on the left side of the Front Paper Guide.
17. Move the Carriage Unit onto the left side Adjustment Gauge.
18. Return the PG position to - (minus).
19. Confirm continuity in the left side PG position again. If the PG position has
not shifted, terminate the adjustment. If it has shifted, restart adjustment
from Step 9.

ADJUSTMENT Adjustments 151


6
CHAPTER

MAINTENANCE
EPSON Stylus Photo R800 Revision A

6.1 Overview 6.1.2 Cleaning


This printer has no mechanical components which require regular cleaning
This section provides information to maintain the printer in its optimum
except the Print Head. Therefore, when returning the printer to the user, check
condition.
the following parts and perform appropriate cleaning if stain is noticeable.

6.1.1 ROM Replacement C A U T IO N „ Never use chemical solvents, such as thinner, benzine,
and acetone, to clean the exterior parts of the printer like
This printer may require the ROM to be replaced when program changes or
the housing. These chemicals may degrade or
additions are made. In such cases, use the special tool (ROM puller: 2035659
deteriorate the quality of this product.
(#F749)) to replace the ROM. The position of the ROM is shown in the figure
below. „ Be careful not to damage any components when you
clean inside the printer.
„ Do not scratch the surface of the PF Roller assembly.
Use a soft brush to wipe off dust.
„ Use a soft cloth moistened with dilute alcohol to remove
ink stain.
„ Do not use the supplied cleaning sheet for normal
usage. It may damage the coated surface of the PF
Roller. If the adhesive surface of the cleaning sheet is
set to the ASF LD Roller side and used to clean the ASF
ROM LD Roller surface, it is no problem.

† Housing
C550 Main Board Use a clean soft cloth moistened with water and wipe off any dirt. If the
Figure 6-1. ROM Location Housings are stained with ink, use a cloth moistened with neutral detergent
to wipe it off.

† Inside the printer


Use a vacuum cleaner to remove any paper dust.

MAINTENANCE Overview 153


EPSON Stylus Photo R800 Revision A

6.1.3 Service Maintenance 6.1.3.2 Maintenance Request


If print irregularity (missing dot, white line, etc.) has occurred or the printer Ink is used for printing and Head Cleaning. Waste ink is drained into the Waste
indicates "Maintenance Error", take the following actions to clear the error. Ink Pads via the Cap Unit, and its amount is stored into the Protection Counters
A and B (Waste Ink Counters) set in the EEPROM on the control board. When
6.1.3.1 Head Cleaning the preset value is reached, the Waste Ink Counters detect that the Waste Ink
Pads have reached the absorption limit. The printer displays "Maintenance
The printer has a built-in head cleaning function, which is activated by
Request" to request the Waste Ink Pads to be replaced.
operating the control panel.
† Protection Counter A+B Limit
1. Confirm that the printer is in stand-by state.
„ Home side : Up to 14787
The Power LED is not blinking.
„ Opposite-to-home side : Up to 17115
2. Hold down the Ink Switch on the control panel for more than 3 seconds.
The Power LED blinks during the cleaning sequence. † Timing for Replacing the Waste Ink Pads
„ When the Protection Counters A and B (either the home side or
C H E C K For Head Cleaning, it is recommended to alternate the opposite-to-home side) reach the above level, Maintenance Request is
P O IN T nozzle check pattern and cleaning to minimize ink displayed and no switch inputs are accepted with the exception of the
consumption. Power Switch.
„ Since the Protection Counter A+B value can be confirmed in the
adjustment program, confirm the Counters independently of the work
done for product repair. If the Protection Counter A+B value of that
printer is close to its limit, contact the user and replace the Waste Ink
Pads and reset the Counters after acknowledgement of the user. (If the
Waste Ink Pads are not replaced at that time, it is expected that the
printer will be returned for repair in the near future due to a
Maintenance Request error.)
„ Under the specific conditions, the limit level of the counter is preset to
25000 pages for black ink or to 10000 pages for color ink. We assume
that the limit level will be reached in about 3 years in normal use.
† Replacement Procedure
Replacement of Waste Ink Pads in Disassembly and Assembly
(Refer to 4.2.3 "Waste Ink Pads" (p.84).)
† After the Replacement
Reset the Protection Counter A+B
(Refer to Chapter 5 "ADJUSTMENT")

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EPSON Stylus Photo R800 Revision A

6.1.4 Lubrication <Lubrication Point>


The lubrication used for the components of the printer has been decided on Shaft support (outer circumference
part) of Adjust Parallel Bushing
based on evaluation carried out by Epson. As a result, the specified amount of
lubricant should be applied in the places specified when carrying out repair and <Lubrication Type>
maintenance work. G-26
<Lubrication Amount>
C A U T IO N „ Never use oil or grease other than those specified in this φ1mm x 2mm
manual. Use of different types of oil or grease may
<Remarks>
damage the components or affect the printer functions.
• Apply with a syringe.
„ Never apply a larger amount of oil or grease than (Pin Head: φ1mm)
Right Side Face
specified in this manual.
• After lubrication, install and turn
the PG Cam Bush to lubricate
the grease evenly.
Table 6-1. Grease Applied to the Stylus Photo R800
Type Name EPSON CODE Supplier
Grease G-26 1080614 EPSON
Grease G-45 1033657 EPSON
Grease G-70 1275684 EPSON

Left Side Face

Figure 6-2. Lubrication (1)

<Lubrication Point>
Place of contact between CR
Scale Mounting Plate (Left/Right)
and main frame
<Lubrication Type>
G-26
<Lubrication Amount>
Apply evenly.
<Remarks>
Left Right
Side Side
Apply with a brush.

Figure 6-3. Lubrication (2)

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EPSON Stylus Photo R800 Revision A

<Lubrication Point> <Lubrication Point>


Place of contact between main Place of contact between Torsion
frame and Carriage Shaft Spring 411.77 (Torsion Spring
<Lubrication Type> 411.61) and Carriage Shaft
G-26 <Lubrication Type>
<Lubrication Amount> G-26
A little at 4 points <Lubrication Amount>
<Remarks> φ1mm x 2mm x 2 points
Apply with a brush. <Remarks>
Left Side Face Right Side Face Apply with a syringe.
(Pin Head: φ1mm)

Right Side Face Left Side Face

Figure 6-4. Lubrication (3) Figure 6-6. Lubrication (5)

<Lubrication Point> <Lubrication Point>


Left Side Right Side Shaft support (inner circumference Place of contact between rear side
part) of PG Cam (Left/Right) of CR Guide Plate and slider of
<Lubrication Type> Carriage Unit
G-26 30mm 30mm <Lubrication Type>
<Lubrication Amount> G-70
1mm diameter of circumference <Lubrication Amount>
part 150 ± 50mg
<Remarks> <Remarks>
• Apply with a brush. • Apply with a brush.
• Grease should not stick to the • Do not apply grease to the
PF Scale. 30mm areas from both ends.
Figure 6-5. Lubrication (4) Figure 6-7. Lubrication (6)

MAINTENANCE Overview 156


EPSON Stylus Photo R800 Revision A

<Lubrication Point> <Lubrication Point>


Place of contact between Driven Shaft support of Front Paper Guide
Release Shaft and main frame <Lubrication Type>
<Lubrication Type> G-45
G-26 <Lubrication Amount>
<Lubrication Amount> 1 1. φ1mm x 1mm
φ1mm x 2mm x 7 points 2. φ1mm x 2mm
<Remarks> <Remarks>
Apply with a syringe. Apply with a syringe.
(Pin Head: φ1mm) 1 Right Rear Side (Pin Head: φ1mm)
Figure 6-8. Lubrication (7)

<Lubrication Point>
Place of contact between Driven
Release FLAG and Upper Paper
Guide
<Lubrication Type>
2
G-26
<Lubrication Amount>
φ1mm x 4mm x 4 points 2 Left Rear Side
<Remarks>
Apply with a syringe. Figure 6-11. Lubrication (10)
(Pin Head: φ1mm)
Figure 6-9. Lubrication (8) <Lubrication Point>
Shaft support of Lower Paper
<Lubrication Point> Guide
Place of contact between EJ <Lubrication Type>
Grounding Spring and Paper EJ G-26
Roller (Front and Rear) <Lubrication Amount>
<Lubrication Type> φ1mm x 3 points
G-45 <Remarks>
<Lubrication Amount> • Apply with a syringe.
φ1mm x 2mm x 2 points (Pin Head: φ1mm)
<Remarks> • Grease should not stick to the
Apply with a syringe. pull rollers of the Paper EJ
(Pin Head: φ1mm) Roller.
Figure 6-10. Lubrication (9) Figure 6-12. Lubrication (11)

MAINTENANCE Overview 157


EPSON Stylus Photo R800 Revision A

<Lubrication Point> 6.1.4.1 Lubrication of Carriage Shaft


Left shaft side of PF Roller 1. Fit the Carriage Unit onto the Carriage Shaft, and move it to the center of
<Lubrication Type> the Shaft.
G-45
<Lubrication Amount> C A U T IO N In the following step, do not bring the needle of a syringe
into contact with the Carriage Shaft.
Approx. φ1mm x 5mm
<Remarks>
Apply with a syringe.

Right Side Face 2. Using a syringe, lubricate the holes (2 places) at both ends of the Carriage
Figure 6-13. Lubrication (12) Unit rear side with grease.

<Lubrication Point> Lubrication Type Lubrication Amount


Shaft support of Rear Paper Guide G-70 140mg x 2 points
<Lubrication Type>
G-45
<Lubrication Amount>
Carriage Unit
φ1mm x 2mm x 2 points
<Remarks>
Carriage Shaft
Apply with a syringe. Holes
(Pin Head: φ1mm)

Figure 6-14. Lubrication (13)

<Lubrication Point>
Place of contact between PF
Grounding Spring and PF Roller
<Lubrication Type>
G-45
<Lubrication Amount>
φ1mm x 2mm
<Remarks>
Apply with a syringe.
(Pin Head: φ1mm)

Figure 6-15. Lubrication (14)


Figure 6-16. Lubricating the Carriage Shaft (1)

MAINTENANCE Overview 158


EPSON Stylus Photo R800 Revision A

3. Hold the Carriage Unit, and while turning the Carriage Shaft clockwise and 5. Hold the Carriage Unit, and while turning the Carriage Shaft, move the
counterclockwise, move the Carriage Unit to lubricate the grease evenly. Carriage Unit to the left end of the Carriage Shaft to lubricate the grease
evenly.
6. Lubricate grease with the syringe at the point shown in Figure 6-19.

Lubrication Type Lubrication Amount


G-70 70mg

Figure 6-17. Lubricating the Carriage Shaft (2) Lubrication Point

4. Move the Carriage Unit to the right end of the Carriage Shaft with the
Carriage Unit seen from the rear side, and lubricate grease with the syringe
at the point shown in Figure 6-18.

Lubrication Type Lubrication Amount


Figure 6-19. Lubricating the Carriage Shaft (4)
G-70 70mg

Lubrication Point

Figure 6-18. Lubricating the Carriage Shaft (3)

MAINTENANCE Overview 159


EPSON Stylus Photo R800 Revision A

7. Hold the Carriage Unit, and while turning the Carriage Shaft, move the
Carriage Unit to the right end of the Carriage Shaft to lubricate the grease
evenly.

Figure 6-20. Lubricating the Carriage Shaft (5)

8. Repeat Steps 4 to 7.

MAINTENANCE Overview 160


7
CHAPTER

APPENDIX
EPSON Stylus Photo R800 Revision A

7.1 Connector Summary 7.1.1 Connectors and Pin Layouts


See the following tables for the connector summary for the C550 MAIN Board
This section shows the connections between the main components of the
and each connector's pin alignment.
printer.
Table 7-1. Connector Summary for C550 MAIN
Connector Function
CN4 Motor (CR Motor, PF Motor, Pump Motor, PG Motor, ASF Motor)
CN5 Sensor 1 (PF Encoder Sensor, PG Release Sensor, PE Sensor,
ASF Sensor, APG Sensor)
CN6 Cutter Unit
CN7 Power Supply
CN8 Control Panel
CN9 Sensor 2 (Ink Mark Sensor, CR Encoder Sensor, PW Sensor)
CN10 CSIC
CN11 Print Head 1-2 (including head temperature)
CN12 Print Head 1-1
CN13 Print Head 2-2
CN14 Print Head 2-1 (including thermistor)

Table 7-1. Connection of the Major Components

APPENDIX Connector Summary 162


EPSON Stylus Photo R800 Revision A

7.2 Exploded Diagram


Following pages show exploded diagram.
† Exploded Diagram 1
† Exploded Diagram 2
† Exploded Diagram 3
† Exploded Diagram 4
† Exploded Diagram 5
† Exploded Diagram 6

APPENDIX Exploded Diagram 163


EPSON Stylus Photo R800 Revision A

09( Only EHC )

12

13

08

732

11

10

400 except EHC & EAI

PX-G900 Stylus photo R800 No.1 Rev.04 C550-ACCE-0014


Figure 7-2. PX-G900 Exploded Diagram 1

APPENDIX Exploded Diagram 164


EPSON Stylus Photo R800 Revision A

110

111

105

106

113

102

112

101

104

100
109

107

103

PX-G900 Stylus photo R800 No.2 Rev.01 C550-CASE-0011


Figure 7-3. PX-G900 Exploded Diagram 2

APPENDIX Exploded Diagram 165


EPSON Stylus Photo R800 Revision A

300

200

PX-G900 Stylus photo R800 No.3 Rev.01 C550-ELEC-0011


Figure 7-4. PX-G900 Exploded Diagram 3

APPENDIX Exploded Diagram 166


EPSON Stylus Photo R800 Revision A

519

518
550

517

524
509 513

510

549
514
A

512

511

502
505 515 500

516
504

503
A
506

501

PX-G900 Stylus photo R800 No.4 Rev.03 C550-MECH-0013


Figure 7-5. PX-G900 Exploded Diagram 4

APPENDIX Exploded Diagram 167


EPSON Stylus Photo R800 Revision A

540

526
528
541

527

531
508

507
546
523

530
547
533

522

532

525

545

521

PX-G900 Stylus photo R800 No.5 Rev.01 C550-MECH-0021


Figure 7-6. PX-G900 Exploded Diagram 5

APPENDIX Exploded Diagram 168


EPSON Stylus Photo R800 Revision A

701

724
733
713

703
722

705
712

730( For EHC only)


709 731
732

711

704
708

710

707

716
714 706

718
721

PX-G900 Stylus photo R800 No.6 Rev.01 C550-MECH-0031


Figure 7-7. PX-G900 Exploded Diagram 6

APPENDIX Exploded Diagram 169


EPSON Stylus Photo R800 Revision A

7.3 Parts List for EPSON Stylus Photo R800 Table 7-2. Parts List for EPSON Stylus Photo R800
Code Parts Name
Table 7-2. Parts List for EPSON Stylus Photo R800 508 BOARD ASSY., ENCORDER, PF
Code Parts Name 509 COVER, IC ASSY., CR, ASP
8 ADAPTOR, CDR 510 LABEL, INK POSITION
9 ADAPTOR, PHOTO ALBUM 511 SHAFT, CR, GUIDE
10 ROLL PAPER ASSY., LEFT, ASP 512 SCALE, CR
11 ROLL PAPER ASSY., RIGHT, ASP 513 TORSION SPRING, 24.7
12 TRAY, CDR 514 MOTOR ASSY., CR
13 SHEET, CD, DAMMY 515 CABLE, HEAD
100 HOUSING, UPPER ASSY., ASP 516 CABLE, HEAD; B
101 PANEL ASSY., ASP 517 DETECTOR, LEAF, B2
102 COVER, PRINTER ASSY., ASP 518 HARNESS, DETECTOR, STACKER
103 HOUSING, LOWER ASSY., ASP 519 AUTO PG ASSY., ASP
104 HOUSING, UPPER, SUPPORT; ENM3 521 INK SYSTEM ASSY., ASP
105 SWITCH, COVER OPEN 522 PAPER GUIDE, UPPER ASSY., ASP
106 HOLDER, CASE OPEN SW; ENN8 523 TORSION SPRING, 161.16
107 STACKER ASSY., ASP 524 MOTOR ASSY., PF
109 HOUSING, REAR; EPAG 525 FRAME, PAPER EJECT ASSY., ASP
110 DAMPER, SUPPORT, L; NATURAL 526 ROLLER, PF ASSY., ASP
111 DAMPER, SUPPORT, R; NATURAL 527 ROLLER, EJ, REAR ASSY., ASP
112 SHEET, MOTOR 528 PAPER GUIDE, FRONT ASSY., ASP
113 LABEL, INSTRUCTION 530 GUIDE, INK EJECT
200 BOARD ASSY., MAIN 531 ROLLER, EJ, FRONT ASSY., ASP
300 BOARD ASSY., POWER SUPPLY 532 PAPER DETECTOR ASSY., ASP
400 POWER CABLE 533 PF ENCORDER ASSY; ASP
500 PRINTER MECHANISM (ASP) M-AH10-101 540 HARNESS, COVER OPEN
501 CARRIAGE ASSY., ASP 541 HARNESS, ENCORDER, PF
502 BOARD ASSY., CSIC 545 CLEANER, HEAD; C, ASP
503 HOLDER, DETECTOR, PW 546 GUIDE, INK EJECT; B
504 BOARD ASSY., INK MARK 547 POROUS PAD, GUIDE, INK EJECT
505 BOARD ASSY., ENCORDER, CR 550 PF STIFFENING PLATE
506 BOARD ASSY., DETECTOR, PH 701 PRINT HEAD
507 HOLDER, BOARD ASSY., ENCORDER, PF 703 ASF UNIT, ASP

APPENDIX Parts List for EPSON Stylus Photo R800 170


EPSON Stylus Photo R800 Revision A

Table 7-2. Parts List for EPSON Stylus Photo R800


Code Parts Name
704 MOTOR ASSY., ASF
705 PAPER SUPPORT ASSY., ASP
706 PAPER GUIDE, MANUAL
707 POROUS PAD, INK EJECT, RIGHT; A
708 POROUS PAD, INK EJECT, RIGHT; B
709 POROUS PAD, INK EJECT, RIGHT; C
710 POROUS PAD, INK EJECT, LEFT; A
711 POROUS PAD, INK EJECT, LEFT; B
712 POROUS PAD, INK EJECT, LEFT; C
713 POROUS PAD, INK EJECT, LEFT; D
714 POROUS PAD, IS, LOWER; B
716 POROUS PAD, TUBE; A
718 POROUS PAD, TUBE; B
721 POROUS PAD, INK EJECT; H
722 POROUS PAD, INK EJECT, RIGHT; D
723 POROUS PAD, CABLE, HEAD
724 SHEET, STOPPER, IS
730 LABEL, PAPER SUPPORT
731 LABEL, GUIDE, ROLL PAPER INSERT
732 LABEL, GUIDE, ROLL PAPER
733 POROUS PAD, CABLE, HEAD

APPENDIX Parts List for EPSON Stylus Photo R800 171


EPSON Stylus Photo R800 Revision A

7.4 Component Layout † C550 PSB Component Layout

Following pages show Component Layout.


† C550 MAIN Component Layout

APPENDIX Component Layout 172


EPSON Stylus Photo R800 Revision A

† C550 PSB Component Layout


† C550 PANEL Component Layout

APPENDIX Component Layout 173


EPSON Stylus Photo R800 Revision A

7.5 Circuit Diagram


Following pages show Circuit Diagram.
† C550 MAIN control circuit board 1
† C550 MAIN control circuit board 2
† C550 PSB power supply circuit board
† C550 PSE power supply circuit board
† C550 PNL circuit board

APPENDIX Circuit Diagram 174

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