EPSON COLOR INKJET PRINTER

Stylus Pro XL

SERVICE MANUAL

EPSON
4004677

Chapter 1

Product Description

Table of Contents
1.1 FEATURES

1-1

1.2 SPECIFICATIONS
1.2.1 Printing Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.2 Paper Handling Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.3 Paper Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.4 Ink Cartridge Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.5 Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.6 Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.7 Reliability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.8 Safety Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2.9 Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3
1-3
1-5
1-5
1-7
1-8
1-8
1-9
1-9
1-9

1.3 INTERFACE SPECIFICATIONS

1-10
1.3.1 Serial Interface Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.3.2 Parallel Interface Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.4 OPERATIONS
1.4.1 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.2 Panel Operation at Power On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.3 Default settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.3.1 Default Setting Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.3.2 Changing the Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.4 Error Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.5 Printer Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.5.1 Hardware Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.5.2 Software Initialization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.5.3 Panel Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-13
1-13
1-14
1-15
1-15
1-16
1-18
1-18
1-18
1-18
1-18

1.5 MAIN COMPONENTS

1.5.1 Main Control Board (C162 MAIN Board) . . . . . . . . . . . . . . . . . . . . . . . . .
1.5.2 Power Supply Board (C137 PSB/PSE Board) . . . . . . . . . . . . . . . . . . . . .
1.5.3 Control Panel (C137 PNL Board) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5.4 Printer Mechanism (M-4A60) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5.5 Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-19
1-19
1-20
1-20
1-21
1-21

Rev.-A

1-i

List of Figures
Figure 1-1. Exterior View of the Stylus Pro XL
Figure 1-2. Nozzle Configuration
Figure 1-3. Printable Area for Cut Sheet
Figure 1-4. Printable Area for Envelope
Figure 1-5. Adjustment Lever Setting
Figure 1-6. Temperature/Humidity Range
Figure 1-7. Data Transmission Timing
Figure 1-8. Control Panel Appearance
Figure 1-9. C162 MAIN Board Component Layout
Figure 1-10. C137 PSB/PSE Board Component Layout
Figure 1-11. Printer Mechanism (M-4A60)

List of Tables
Table 1-1. Interface Cards
Table 1-2. Print Speed and Printable Columns
Table 1-3. Character Table
Table 1-4. Cut Sheet Paper Specifications
Table 1-5. Envelope Specifications
Table 1-6. Adjust Lever Setting
Table 1-7. Rated Electrical Ranges
Table 1-8. Acceptable Environmental Conditions
Table 1-9. Signal and Connector Pin Assignments for Parallel Interface
Table 1-10. DTR and X-ON/X-OFF Protocol
Table 1-11. Signal and Connector Pin Assignments for Serial Interface
Table 1-12. Printer Condition Panel Status
Table 1-13. Default Setting Items
Table 1-14. Characteristics of Print Direction Mode
Table 1-15. Printing Direction and ESC U Command
Table 1-16. Language Selection
Table 1-17. Feature Selection
Table 1-18. Character Table Selection
Table 1-19. Error Indications

1-ii

Rev.-A

Stylus Pro XL

Product Description

1.1 FEATURES
The Stylus Pro XL is a 64 + 48-nozzle (monochrome and CMY) color ink jet dot matrix printer.
The major features of this printer are:

High-quality color print

-Micro Dot 720 dpi printing
-Plain paper 720 dpi printing
-Special coated paper 720 dpi printing

High print speed

-LQ 200 cps

Built-in auto sheet feeder

-Holds 100 cut sheets (64 g/m2)
-Holds 10 envelopes
-Holds 50 transparency films
-Hold 70 special paper

Built-in 3 I/
-Mac serial I/F
-Parallel I/F
-Type B I/F (option)

Easy setup.
-No dip-switches
-Multi-lingual setting messages (5 languages)

4 scalable fonts and 5 LQ fonts standard.

-Roman T, Sans Serif H, Roman, Sans Serif (scalable)
-Roman, Sans Serif, Courier, Prestige, Script (LQ)

21 character tables
Italic, PC437, PC850, PC860, PC863, PC865, PC437, Greek,
PC852, PC853, PC858, PC857, PC866, PC869, PC861,
BRASCII, Abicomp, MAZOWIA, Code MJK, ISO 8859-7, ISO Latin 1T, Bulgaria

Low running cost

The figure below shows the Stylus Pro XL.

Front
C ov er

Printer
Cov er

Kn ob

Paper Supply
Tray
Serial Interface
Connector

Paper Catch
Tr ay
Interface Card
Cov e r

Control
Pa n el

Parallel Interface
Connector

AC Inlet

Figure 1-1. Exterior View of the Stylus Pro XL

Rev.A

1-1

Product Description

Stylus Pro XL

Table 1-1. Interface Cards

Interface Card

Model Number

Serial interface card

C823051/C823061

32KB serial interface card

C823071/C823081

32KB parallel interface card

C82310

32KB IEEE-488 interface card

C82313

LocalTalk interface card

C82312

Twinax interface card

C82315

Coax interface card

C82314

The asterisk represents the last digit, which varies by country.

1-2

Rev.A

Stylus Pro XL

Product Description

1.2 SPECIFICATIONS
This section provides statistics and other detailed information for the printer.

1.2.1 Printing Specifications

Print system:

On demand ink jet system

Nozzle configuration:

64 nozzles (16 4 staggered): monochrome

48 nozzles (16 3 staggered): color

#1

Magenta

#1

Row D

#1
1/360"

Row C

Row B
72/360"

#2

Row A

#1

#2
#3

1/90"
#2

20/360"

Cyan

2 0/3 60"

Yellow

1/90"

#4

#2

#5

#6
#7
#8
#3

#3

#3

64/360"
#16

#16

#61

#62
#63

#16

#64

Figure 1-2. Nozzle Configuration

Printing direction:

Bidirectional with logic-seeking

Print speed:

See Table 1-2.

Printable columns:

See Table 1-2.

Table 1-2. Print Speed and Printable Columns

Rev.A

Character Pitch

Printable Columns

Print Speed (LQ)

10 cpi (Pica)

127

200 cps

12 cpi (Elite)

152

240 cps

15 cpi

190

300 cps

17 cpi (Pica condensed)

218

340 cps

20 cpi (Elite condensed)

254

400 cps

1-3

Product Description

Stylus Pro XL

Character sets:

Legal and 14 international character sets.

Character tables:

See Table 1-3.

Table 1-3. Character Tables

Bit map font

Character Tables

EPSON Roman
EPSON Sans Serif
EPSON Courier
EPSON Prestige
EPSON Script

EPSON Roman
EPSON Sans Serif

EPSON Roman
EPSON Sans Serif
H

m
m

m
m

m
m
m
m

m
m
m

m
m

m
m

m
m

m
m
m
m

Italic
PC437 (U.S./Standard Europe)
PC850 (Multilingual)
PC860 (Portuguese)
PC861 (Iceland)
PC863 (Canadian-French)
PC865 (Nordic)
Abicomp
BRASCII
PC437 (Greek)
PC852 (East Europe)
PC853 (Turkish)
PC855 (Cyrillic)
PC857 (Turkish)
PC866 (Russian)
PC869 (Greek)
MAZOWIA (Poland)
Code MJK (Czecho/Slovakia)
ISO 8859-7 (Greek)
ISO Latin 1T (Turkish)
Bulgaria (Bulgaria)
Supported
Fonts:

Scalable font

Not supported
[Bitmap LQ fonts]
- EPSON Roman
- EPSON Sans Serif
- EPSON Courier
- EPSON Prestige
- EPSON Script

(10 cpi/12 cpi/15 cpi/Proportional)

(10/12/15/Proportional)
(10/12/15)
(10/12/15)
(10/12/15)

[Scalable fonts]
- EPSON Roman
- EPSON Sans Serif
- EPSON Roman T
- EPSON Sans Serif H

10.5 points, 8 32 points (in units of 2 points)

10.5 points, 8 32 points (in units of 2 points)
10.5 points, 8 32 points (in units of 2 points)
10.5 points, 8 32 points (in units of 2 points)

Control codes:

ESC/P 2 and expanded raster graphics code

Input data buffer:

64KB

1-4

Rev.A

Stylus Pro XL

Product Description

1.2.2 Paper Handling Specifications

Feeding method:

Notes:

Friction feed paper is fed from the built-in auto sheet feeder (ASF).

The following operations are not allowed.

1. Reverse feeding within 3 mm (0.12 in.) from the top edge of the paper or 16 mm
(0.63 in.) from the bottom edge of the paper.
2. Reverse feeding beyond 7.9 mm (0.3 in.).

Line spacing:

1/6 inch feed, 1/8 inch feed, or programmable with a 1/360 inch minimum
increment.

Paper path:

Cut sheet: Built-in auto sheet feeder (ASF) (front entry)

Feeding speed:

89 msec. (at 1/6-inch feed pitch)

1.2.3 Paper Specifications

Table 1-4. Cut Sheet Paper Specifications
A3+/US B+: 329 mm (13.0 in.) 483 mm (19.0 in.)

Size (W L)

A3:

297 mm (11.7 in.) 420 mm (16.5 in.)

US B:

279 mm (11.0 in.) 432 mm (17.0 in.)

Legal:

216 mm (8.5 in.) 356 mm (14.0 in.)

Letter:

216 mm (8.5 in.) 279 mm (11.0 in.)

A4: 210 mm (8.3 in.) 297 mm (11.7 in.)

Executive: 184 mm (7.25 in.) 267 mm (10.5 in.)
Statemrnt: 140 mm (5.5 in.) 216 mm (8.5 in.)
Thickness

0.08 mm (0.003 in.) 0.11 mm (0.004 in.)

Weight

64g/m2 (17 lb.) 90 g/m2 (24 lb.)

Plain paper, Special coated paper for 720dpi, Special coated paper for 360dpi,
Transparency film, High Quality Glossy paper, Glossy paper

Quality

Note:

Special coated paper for 720dpi, Special coated paper for 360dpi, Transparency film
High Quality Glossy paper printing are only available at normal temparature.

Table 1-5. Envelope Specifications

Size (W L)

No. 10:240 mm (9 12 in.) 104 mm (4 18 in.)

DL:220 mm (8.7 in.) 110 mm (4.3 in.)
C5:

229 mm (9.0 in.) 162 mm (6.4 in.)

Thickness
Weight

Less than 0.52 mm (0.020 in.)

Quality

Plain paper

Note:

Rev.A

75 g/m2 (20 lb) 90 g/m2 (24 lb)

Envelope Printing is only available at normal temperature.

Keep the longer side of the envelopes horizontal at setting.

1-5

Product Description
Printable area:

Stylus Pro XL
Cut sheets
B
(Left Margin)

C
(Right Margin)

A
(Top Margin)
Printable Area
D
(Bottom Margin)

Figure 1-3. Printable Area for Cut Sheets

Envelopes
B
(Left Margin)

C
(Right Margin)

Printable Area

A
(Top Margin)

D
(Bottom Margin)

Figure 1-4. Printable Area for Envelopes

Notes:

1-6

A: The minimum top margin = 3 mm (0.12 in.)

B: The minimum left margin = 3 mm (0.12 in.)
C: The minimum right margin is:
A3+/US B+ size: 3mm (0.12 in.)
A3 size:
3 mm (0.12 in.)
A4 size:
3 mm (0.12 in.)
A4
(Landscape)size:3 mm (0.12 in.)
USB size:
9 mm (0.35 in.)
Legal size:
9 mm (0.35 in.)
Letter size:
9 mm (0.35 in.)
Letter size
(Landscape)size:9 mm (0.35 in.)
Executive size: 9 mm (0.35 in.)
Statement size: 9 mm (0.35 in.)
Envelopes:
3 mm (0.12 in.)
D: The minimum bottom margin = 14 mm (0.55 in.)
Rev.A

Stylus Pro XL

Product Description

Setting the
adjust lever:

The adjust lever on the carriage unit must be set to the proper position for
the paper thickness, as shown in Table 1-6.

Table 1-6. Adjust Lever Settings

Lever Position

Paper

Paper Thickness

LEFT
(Vertical)

Cut Sheets

0.08 0.11 mm
(0.003 0.004 in.)

RIGHT
(Horizontal)

Envelopes

Less than 0.5 mm (0.020 in.)

Cut Sheets

Envelopes

Carriage Unit

Figure 1-5. Setting the Adjust Lever

1.2.4 Ink Cartridge Specifications
Black
Type:

Exclusive cartridge

Color:

Black

Print capacity:

1.2 million characters (315 dots/character, Roman 10 cpi)

Life:

The effective life from the indicated production date is 2 years.

Storage temperature:

30 40 C (22 104 F) (Storage: a month or less at 40 C (104 F))

30 60 C (22 140 F) (Transit: a month or less at 40 C (104 F))
30 60 C (22 140 F) (Transit: 120 hours or less at 60 C (140 F))

Dimension (W D H):

26.9 67.4 41.8 mm (1.06 2.65 1.65 in.)

Color
Type:

Exclusive cartridge

Colors:

Cyan, magenta, yellow

Print capacity:

28 sheets/color (A4 or letter, full-image printing at 360 dpi)

Life:

The effective life from the indicated production date is 2 years.

Storage temperature:

30 40 C (22 104 F) (Storage: a month or less at 40 C (104 F))

30 60 C (22 140 F) (Transit: a month or less at 40 C (104 F))
30 60 C (22 140 F) (Transit: 120 hours or less at 60 C (140 F))

Dimension (W D H):

54.0 67.4 41.8 mm (2.13 2.65 1.65 in.)

Notes:

Rev.A

The ink cartridge cannot be refilled; it is the only consumable article.

Do not attempt to use an ink cartridge that has exceeded its ink life.
Ink freezes at 3 C (37 F); however, it can be used after it returns to room temperature.

1-7

Product Description

Stylus Pro XL

1.2.5 Electrical Specifications

Table 1-7. Rated Electrical Ranges
Specification

120 V Version

220 - 240 V Version

120 VAC

220 - 240 VAC

103.5 132 V

198 264 V

Rated frequency range

50 60 Hz

50 60 Hz

Input frequency range

49.5 60.5 Hz

49.5 60.5 Hz

0.6 A

0.4 A

Rated voltage
Input voltage range

Rated current

Approx. 20 W
Approx. 20 W
(self-test with 10-cpi LQ characters) (self-test with 10-cpi LQ characters)

Power consumption

10 M, minimum
10 M, minimum
(applying 500 VDC between AC line (applying 500 VDC between AC line
and chassis)
and chassis)
1000 VAC rms - 1 minute or
1500 VAC rms - 1 minute
1200 VAC rms - 1 second
(between AC line and chassis)
(between AC line and chassis)

Insulation resistance

Dielectric strength

1.2.6 Environmental Conditions

Table 1-8. Acceptable Environmental Conditions
Condition
Temperature
Humidity
Shock resistance

Operating

Non Operating

10 35 C (50 95 F) *1

20 60 C (4 122 F) *2

20 80% RH *1,3

5 85% RH *2,3

1G (within 1 msec.)

2G (within 2 msec.) *2

0.15 G

0.50 G 2

Vibration resistance
*1
*2
*3

: For printer operation, conditions must be in the range shown in the figure below.
: These conditions are applicable when the printer is in its shipping container.
: Without condensation.

Humidity
(% RH)
80%

Guaranteed

55%

20%

(50 F)

27 C 35 C
(80 F) (95 F)

C
( F)

Figure 1-6. Temperature / Humidity Range

1-8

Rev.A

Stylus Pro XL

Product Description

1.2.7 Reliability
Total print volume:

75,000 pages (A4, letter)

Printhead life:

1,000 million dots/nozzle

1.2.8 Safety Approvals

Safety standards:

120 V version:
220-240 V version:

Radio frequency interference (RFI):

120 V version:
220-240 V version:

UL1950 with D3,

CSA22.2 #950 with D3
EN 60950 (TV, SEMKO, DEMKO,
NEMKO, SETI)
FCC Part 15 Subpart B Class B
Vfg.243 (VDE0878 part 3, part 30)
EN55022 (CISPR PUB. 22) class B

1.2.9 Physical Specifications

Dimensions (W D H):

580 597 182 (mm) (22.8 23.5 7.17 in.)

Weight:

About 10 Kg (22 lb)

Rev.A

1-9

Product Description

Stylus Pro XL

1.3 INTERFACE SPECIFICATIONS

The Stylus Pro XL is standard-equipped with an 8-bit parallel and serial interface.

1.3.1 Parallel Interface Specifications

Data format:

8-bit parallel

Synchronization:

By STROBE pulse synchronization

Handshaking:

By BUSY and ACKNLG signals

Signal level:

TTL compatible level

Adaptable connector:

36-pin 57-30360 (Amphenol) or equivalent

Data transmission timing:

See Figure 1-7.

BUSY
ACKNLG

DATA
STROBE
0 sec (minimum)
0 sec
(minimum)

5 sec (typical)

0.5 sec (minimum)

0.5 sec (minimum)
0.5 sec (minimum)

Figure 1-7. Data Transmission Timing

Note:

Transition time (rise time and fall time) of every input signal must be less than 0.2 s.

The Busy signal is active (HIGH) under the following conditions:

During data reception (See Figure 1-7.)
When the input buffer is full
When the INIT input signal is active
During initialization
When the ERROR or PE signal is active
During the self-test mode
During the demonstration mode
During the default setting mode
When a fatal error occurs
The ERROR signal is active (LOW) under the following conditions:
When a paper-out error occurs
When a no ink cartridge error occurs
When a fatal error occurs
The PE signal is active (HIGH) under the following conditions:
When a paper-out error occurs
When a fatal error occurs

1-10

Rev.A

Stylus Pro XL

Product Description

Table 1-9 shows the connector pin assignments and signal functions of the 8-bit parallel interface.

Table 1-9. Signal and Connector Pin Assignments for Parallel Interface
Pin No.

2-9

Signal Name

STROBE

DATA 1-8

I/O*

Description

The STROBE pulse is used to read data from the host

computer. The pulse width must be 0.5 s or more. Normally,
it is HIGH, and data is latched with the rising edge of this
signal.

DATA 1-8 are parallel data bits. When one of these signals is
HIGH, the data bit is 1; when LOW, the data bit is 0. The
most significant bit (MSB) is DATA 8. The signal state must
be maintained for 0.5 s on either side of the STROBE
signals active edge.

10

ACKNLG

ACKNLG is an acknowledge pulse with a width of

approximately 10 s. This signal goes LOW upon the
completion of data reception to indicate that the printer is
ready to receive further data.

11

BUSY

The BUSY signal informs the host computer of the printers

status. When this signal is HIGH, the printer cannot accept
any more data.

12

PE

This signal indicates whether paper is available in the printer

or not. A HIGH level indicates no paper.

13

SLCT

Pulled up to +5 V through a 1.0 K resistor in the printer.

14

AFXT

If this signal is set to LOW, the printer automatically performs

one line feed upon receipt of a CR (carriage return) code. The
status of this signal is checked only at power on and
initialization.

31

INIT

If this signal goes LOW, the printer is initialized. The pulse

width of this signal must be 50 s or more.

32

ERROR

This signal goes LOW if the printer has a fatal error or runs
out of paper.

35

+5 V

Pulled up to +5 V through 1.0 K resistor in the printer.

17

CHASSIS

Chassis ground.

16

GND

Signal ground.

19-30

33,36

Not used.

15,18,34

The I/O column indicates the direction of the signal as viewed from the printer.

Rev.A

1-11

Product Description

Stylus Pro XL

1.3.2 Serial Interface Specifications

Data format:

RS-422 serial

Synchronization:

Asynchronous

Handshaking:

By DTR signal and X-ON/X-OFF protocol

Table 1-10. DTR and X-ON/X-OFF Protocol

State

Buffer Space

Busy

Less than 512 bytes

Off

X-OFF

Ready

More than 1,024 bytes

On

X-ON

DTR

Word length
Start bit:
Data bit:
Parity bit:
Stop bit:

1 bit
8 bit
none
1 bit

Bit rate:

57.6K bps /230.4 Kbps

Adaptable connector:

8-pin mini-circular connector

Recommended I/F cable:

Apple System Peripheral-8 cable

X-ON/X-OFF

Table 1-11. Signal and Connector Pin Assignments for Serial Interface
Pin No.

Signal Name

I/O*

Description

DTR

Out

Data terminal ready

NC

No connection

TXD

Out

Transmit data

SG

In

Signal ground

RXD

In

Receive data

Balanced transmit

TXD

Out

NC

No connection

RXD

In

Balanced receive

1-12

The I/O column indicates the data flow as viewed from the printer.

Rev.A

Stylus Pro XL

Product Description

1.4 OPERATIONS
This section describes the basic operations of the printer.

1.4.1 Control Panel

The control panel for this printer has 1 lock-type, 5 non-lock-type push buttons, and 14 LED indicators for
easy operation of the various printer functions.
Operate

Alt

Fon t
Econ omy/
Condensed
Load/Eject

Pau se

Figure 1-8. Control Panel Appearance

Buttons
Operate

Turns the printer on or off.

Alt

Modifies the function of other buttons. Holding down this button for
3 seconds causes the printer to move the carriage to the ink cartridge
installation position. Pressing Alt again causes the carriage to return to the
home position.

Font

Cycles through the font choices. Pressing the Font button, while holding
down the Alt button causes the carriage to move to the gap adjustment
position. Pressing the Alt button again causes the carriage to return to the
home position.

Economy/Condensed

Selects either economy or condensed printing mode. Pressing the

Economy/Condensed button while holding down the Alt button starts
the color printhead cleaning cycle.

Load/Eject

Either loads a new sheet into the printer or ejects paper currently in the
paper path. Pressing the Load/Eject button while holding down the Alt
button starts the black printhead cleaning cycle.

Pause

Stops printing temporarily or resumes printing if it has been stopped

temporarily. Pressing Pause while holding down the Alt button resets the
printer.

Rev.A

1-13

Product Description

Stylus Pro XL

Indicators
Operate

On when the printer is on. Blinks during power on and off sequence.

Data

On when print data is in the input buffer. Data and Pause lights blink if
an error occurs.

Paper Out

On when the printer is out of paper. Blinks when a paper jam occurs.

No Ink Cartridge

On when ink cartridge is out.

Economy

On when economy printing mode is selected.

Condensed

On when condensed printing mode is selected.

Font

These LEDs indicate the selected font.

Pause

On when printing is paused.

1.4.2 Panel Operation at Power On

You can activate the following modes by doing the following:
Self-test mode

Turn on the printer while holding down the Load/Eject button.

Hex dump mode

Turn on the printer while holding down the Font and Load/Eject
buttons. Once this mode is selected, the printer prints all received data in
hexadecimal format.

Demonstration mode

Turn on the printer while holding down the Alt button.

Default setting mode

Turn on the printer while holding down the Economy/ Condensed

button. For more information about the mode, see Section 1.4.3.

Initialize EEPROM

Turn on the printer while holding the Alt, Font, Load/Eject, and Pause
buttons.

Table 1-12. Printer Condition Panel Status

Printer status

Indicators
Operate

Data

Paper
No Ink
Economy Condensed Pause
Out Cartridge

Power on condition

On

Data exit

On

Economy mode

On

Condensed mode

On

Pause condition

On

Power on/off sequence

Blinks

Ink sequence

Blinks

Ink cartridge change mode

Blinks

Head gap adjust mode

Blinks

Paper out

On

No ink cartrdige

On

Paper jam condition

Blinks

Maintenance request

Blinks

Blinks

Blinks

Blinks

Cartidge error

Blinks

Blinks

dont care

1-14

Rev.A

Stylus Pro XL

Product Description

1.4.3 Default Settings

The printer can save some printer setting parameters that define its functions at initialization. You can
change these parameters by using the printers default setting mode.

1.4.3.1 Default Setting Items

You can use the default setting mode to change settings listed in the table below. Activate default-setting
mode by holding down Economy/Condensed while turning on the printer.

Table 1-13. Default Setting Items

Menu Contents

Factory
Setting

Description

Character table

Selects the character table

Print direction

Controls the print direction. (See Tables 1-12 and 1-13)

Auto
Bi-D
Uni-D

Network I/F mode

Off: For normal environments.

On: For network environments.

Off

Auto line feed

On: Valid
Off: Invalid

Loading position

3.0/8.5 mm (0.12/0.33 in.)

3.0 mm

Interface mode

Auto I/F mode

Parallel I/F mode
Serial I/F mode
Optional I/F mode

Auto I/F wait mode

10/30 seconds

10 sec.

Table 1-14. Characteristics of Print Direction Mode

Mode

Black and White Printing

Auto

Throughput and quality is

better.

Throughput is better.
Color quality with special paper is worse.
(Color correction depends on the printing direction.)

Bi-D

Throughput is best.
Print quality may be down.

Throughput is better.
Color quality with special paper is worse.
(Color correction depends on the printing direction.)

Throughput is worse.
Print quality is better.

Uni-D

Color (CMYK) Printing

Throughput is worse.
Color quality is best.

Table 1-15. Printing Direction and ESC U Command

Default Setting
Mode
^

Auto

Bi-D

Uni-D

ESC U0 ESC U1 None ESC U0 ESC U1 None ESC U0 ESC U1 None

Character mode
(for MS-DOS)

Auto

Auto

Auto

Bi-D

Uni-D

Bi-D

Uni-D

Uni-D

Uni-D

Raster graphics
mode
(for Windows)

Bi-D

Uni-D

Auto

Bi-D

Uni-D

Bi-D

Bi-D

Uni-D

Uni-D

Note:

Rev.A

Printing direction is controlled by driver in Windows environment.

1-15

Product Description

Stylus Pro XL

1.4.3.2 Changing the Default Settings

To change the printers default settings:
1.

Hold down the Economy/Condensed button and turn on the printer. The printer prints a sheet
that shows the firmware version and describes how to select the language used to print messages.

2.

Press the Font button until the appropriate font LED is selected. The following table shows which
language corresponds to which font LED.

Table 1-16. Language Selection

Language

Font LED

English

Courier

Franais

Roman T (PS)

Deutsch

Sans Serif H (PS)

Italiana

Roman

Espaol

Sans Serif

3.

Press the Alt button. The printer prints the current settings using the selected language. It also prints a
table showing how to change the printer settings.

4.

Press the Font button to advance through the setting menu. The current printer settings are indicated
by the Courier, Roman T (PS), and San Serif H (PS) LEDs. Each time you press the Font button, you
adance to the next setting, and the three font LEDs change according to the selection.

Table 1-17. Feature Selection

Menu

Setting Value

Feature/Menu

Courier
LED

Roman T
(PS) LED

Sans
Serif H
(PS) LED

Character table

On

On

On

Print direction
^

On

Off

Off

^
Network I/F mode
^
Auto line feed
^
Loading position
^

Off

On

Off

On

On

Off

Off

Off

On

Interface mode
^

On

Off

On

^
Auto I/F wait time
^
5.

Off

On

On

Setting

Operate
LED

+
Data
LED

Paper Out
LED

See Table 1-18

Auto

On

Off

Off

Bi-D

Off

On

Off

Uni-D

On

On

Off

Off

Off

Off

Off

On

On

Off

Off

Off

Off

Off

Off

On

On

Off

Off

3 mm

Off

Off

Off

8.5 mm

On

Off

Off

Auto

On

Off

Off

Parallel

Off

On

Off

Serial

On

On

Off

Option

Off

Off

On

10 sec.

Off

Off

Off

30 sec.

On

Off

Off

Change the setting value by pressing Alt button. Pressing the Alt button changes the setting for the
current menu. The status of the LEDs will be changed as the button is pressed.

1-16

Rev.A

Stylus Pro XL

Product Description

Table 1-18. Character Table Selection

Data LED

Paper Out
LED

Off

Off

Off

On

Off

Off

Blinks

Off

Off

Italic U.K.

Off

On

Off

Italic Denmark 1

On

On

Off

Version

Settings

Common

Italic U.S.A.

Italic France

Italic Germany

^
^
^

Italic Sweden

On

Off

Italic Italy

Off

Blinks

Off

Italic Spain 1

On

Blinks

Off

PC437

Blinks

Blinks

Off

PC850

Off

Off

On

Operate LED

Blinks

Standard

PC860

On

Off

On

PC863

Blinks

Off

On

PC865

Off

On

On

PC861

On

On

On

BRASCII

Blinks

On

On

Abicomp

Off

Blinks

On

NLSP

Off

Off

On

PC853

Blinks

Off

On

PC855

Off

On

On

PC852

On

On

On

On

On

PC437 Greek

PC857

Blinks

PC866

Off

Blinks

On

PC869

On

Blinks

On

MAZOWIA

Blinks

Blinks

On

Code MJK

Off

Off

Blinks

ISO 8859-7

On

Off

Blinks

ISO Latin 1T

Blinks

Off

Blinks

Off

On

Blinks

Bulgaria

6.

Repeat steps 4 and 5 to change other printer settings. The setting menu selection will return to the first
menu after the last menu selection is over.

7.

Turn off the printer. The setting is stored in non-volatile memory.

Rev.A

1-17

Product Description

Stylus Pro XL

1.4.4 Error Conditions

The printer can detect various errors and indicate them with LEDs.

Table 1-19. Error Indications

Paper Out
LED

No Ink
Cartridge
LED

Off

On

Off

Off

Off

Off

No ink cartridge

Off

Off

On

Off

Off

Off

Paper jam

Off

Blinks

Off

Off

Off

Off

Maintenance request

Blinks

Blinks

Blinks

Blinks

Blinks

Blinks

Carriage error

Blinks

Off

Off

Off

Off

Blinks

Error

Data LED

Paper out

Economy Condensed
LED
LED

Pause
LED

1.4.5 Printer Initialization

There are three initialization methods: hardware initialization, software initialization, and panel
initialization.

1.4.5.1 Hardware Initialization

Hardware initialization is performed by:
- Turning on the printer.
- Sending the parallel interface INIT signal.
(If the INIT signal is active when the printer is turned on, hardware initialization is started when the INIT
signal becomes inactive.)
When the hardware initialization is performed:
- The printer mechanism is initialized.
- Input data buffer is cleared.
- Downloaded character definitions are cleared.
- Print buffer is cleared.
- Default values are set.

1.4.5.2 Software Initialization

Software initialization is performed upon receipt of the control code ESC @.
When the software initialization is performed:
- Print buffer is cleared.
- Default values are set.

1.4.5.3 Panel Initialization

This printer is initialized by pressing the Load/Eject button while pressing the Alt button.
When the panel initialization is performed:
- Input data buffer is cleared.
- Print buffer is cleared.
- Default values are set.

1-18

Rev.A

Stylus Pro XL

Product Description

1.5 MAIN COMPONENTS

The main components of the Stylus Pro XL are:

Printer mechanism (M-4A60)

Main control board (C162 MAIN Board)
Power supply unit (C137 PSB/PSE Board)
Control panel board (C137 PNL Board)
Housing

1.5.1 Main Control Board (C162 MAIN Board)

The Main Control Board (C162 MAIN Board) consists of an H8/3003 16-bit CPU, E05A96 gate array, a
program ROM (4M), a dynamic RAM (4M), a mask ROM (4M or 8M), an EEPROM (1K), and a lithium
battery for powering the protect counters. The reset IC (M51955 and PST 592) is equipped with both a logic
system and a power system. The 8M program ROM is used only for the NLSP (National Language Support
Printer) specification.
4M D R AMs
(IC5, 6)

Program
ROM (IC3)

GA E05B09 (IC2)
CPU (IC1)

Mask ROM
M160A69
(IC16)

Mask ROM
M80B00
(IC17)

Figure 1-9. C162 MAIN Board Component Layout

Rev.A

1-19

Product Description

Stylus Pro XL

1.5.2 Power Supply Board (C137 PSB/PSE Board)

The power supply board (C137 PSB/PSE Board) consists of an RCC switching regulator circuit. This board is
equipped with a power switch connected to the secondary circuit. Thus, if the printer is turned off, it can
continue to operate in order to eject the paper and perform the head capping operation. The power on/off
signal is always monitored by the E05A96 gate array on the C162 MAIN Board, and the logic system
recognizes the power switch status.
IC51 (TL494)

CN2

PC1
C82

R2

CN1

Q5 1

Q1

F1
C1
C51
D51 T1

C11

DB1

C3

L1

Figure 1-10. C137 PSB / PSE Board Component Layout

1.5.3 Control Panel (C137 PNL Board)

The 14 LEDs on this board indicate the error status (there is no buzzer system); by using the 6 switches in
combination with one another, the printer can operate in each protect operation (color or black cleaning,
cartridge exchanging, self-test, default setting value exchanging, reset, and EEPROM clear operation).

1-20

Rev.A

Stylus Pro XL

Product Description

1.5.4 Printer Mechanism (M-4A60)

The M-4A60 printer mechanism is equipped with a 64-nozzle black printhead and 48-nozzle color (CMY)
printhead on the carriage unit. Resolution of 720 dpi is possible with special (non-absorbent) paper.
The ink system has both a black pump unit and a color pump unit. Waste ink from each printhead is made to
flow into the individual caps. Power for the pump system and paper feed system is supplied from the paper
feed motor.

Figure 1-11. Printer Mechanism (M-4A60)

1.5.5 Housing
The Stylus Pro XL housing consists of the printer cover, upper case, and the lower case. Attached to the
housing are the front paper support and the ejected paper support with paper separator.

Rev.A

1-21

Chapter 2

Operating Principles

Table of Contents
2.1 OVERVIEW

2-1

2.2 OPERATING PRINCIPLES OF THE PRINTER MECHANISM

2-1
2.2.1 Printer Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2.2 Carriage Drive Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.2.2.1 Platen Gap Adjust Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.2.3 Paper Feed Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.2.4 Imk System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.2.5 Pump Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.2.6 Cap Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.2.7 Wiping Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.3 OPERATING PRINCIPLES OF THE ELECTRICAL CIRCUITS
2.3.1 Operating Principles of the Power Supply Circuit . . . . . . . . . . . . . . . . . .
2.3.2 Operating Principles of the Main Control Circuit . . . . . . . . . . . . . . . . . . .
2.3.2.1 Reset Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.2.2 Sensor Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.2.3 Carriage Motor Drive Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.2.4 Paper Feed Motor Drive Circuit . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.2.5 Printhead Drive Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.2.6 DMA Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3.2.7 D-RAM Refreshment Controller. . . . . . . . . . . . . . . . . . . . . . . . . .

2-13
2-13
2-15
2-16
2-16
2-17
2-19
2-20
2-22
2-23

2.4 INK SYSTEM MANAGEMENT

2.4.1 Ink Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.2 Timer and Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.2.1 Refresh Timer (Monochrome and YMC Head) . . . . . . . . . . . . . .

2-24
2-25
2-27
2-27

Rev.-A

2-i

List of Figures
Figure 2-1. Printer Mechanism Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Figure 2-2. Structure of Printhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Figure 2-3. Principles of the Printing Operation . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Figure 2-4. Carriage Drive Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Figure 2-5. Platen Gap Lever Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Figure 2-6. Paper Feed Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Figure 2-7. Ink System Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Figure 2-8. Pump Mechanism Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Figure 2-9. Switch Lever Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Figure 2-10. Paper Feed Mechanism Block. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Figure 2-11. Switch Lever Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Figure 2-12. Pump Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Figure 2-13. Cap Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Figure 2-14. Wiping Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Figure 2-15. Block Diagram of the Electrical Circuit. . . . . . . . . . . . . . . . . . . . . 2-13
Figure 2-16. Power Supply Circuit Block Diagram . . . . . . . . . . . . . . . . . . . . . . 2-14
Figure 2-17. Main Control Circuit Block Diagram. . . . . . . . . . . . . . . . . . . . . . . 2-15
Figure 2-18. Reset Circuit Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Figure 2-19. Sensor Circuit Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Figure 2-20. Carriage Motor Circuit Block Diagram . . . . . . . . . . . . . . . . . . . . . 2-17
Figure 2-21. Serial Data Transfer Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Figure 2-22. Paper feed Motor Drive Circuit Diagram . . . . . . . . . . . . . . . . . . . 2-19
Figure 2-23. Normal/Micro Dot Mode Switch Block . . . . . . . . . . . . . . . . . . . . . 2-20
Figure 2-24. Trapezoidal Drive Wave Form . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Figure 2-25. Printhead Drive Circuit Block Diagram . . . . . . . . . . . . . . . . . . . . 2-21
Figure 2-26. DMA Controller Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Figure 2-27. D-RAM Cycle Timings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Figure 2-28. Junction Method (CPU-DRAM) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

List of Tables
Table 2-1. Carriage Drive Motor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Table 2-2. Drive Terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Table 2-3. Platen Gap Adjust Lever Position . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Table 2-4. Paper Feed Drive Motor Specifications . . . . . . . . . . . . . . . . . . . . . . 2-6
Table 2-5. Drive Terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Table 2-6. Pump Mechanism Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Table 2-7. DC Voltage Distribution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Table 2-8. Serial Data Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Table 2-9. Paper Feed Motor Drive Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Table 2-10. Junction Method (CPU-2CAS DRAM) . . . . . . . . . . . . . . . . . . . . . 2-23

2-ii

Rev.-A

Stylus Pro XL

Operating Principles

2.1 OVERVIEW
This section describes the operating principles of the printer mechanism and the electrical circuits
of the Stylus Pro XL.

2.2 OPERATING PRINCIPLES OF THE PRINTER MECHANISM

The Stylus Pro XL printer mechanism is composed of the printhead unit, paper feed mechanism,
carriage drive mechanism, pump mechanism, and various sensors. The figure below shows a
functional block diagram of the printer mechanism.

ASF Plunger

Disengage Lever

ASF Pickup Mechanism

Paper Feed Mechanism

Pump Unit Drive Mechanism

Paper Feed Motor

Carriage Unit
Carriage Motor

Color

Black

Figure 2-1. Printer Mechanism Block Diagram

REV.-A

2-1

Operating Principles

Stylus Pro XL

2.2.1 Printer Mechanism

The printer mechanism of this printer uses a drop-on-demand ink jet system similar to the system
used on all other EPSON ink jet printers. However, the printhead in this system is completely
redesigned to make it more compact and ensure a high level of reliability. The figure below shows
the structure of the printhead and ink supply system.
Piezo

When a drive pulse (voltage) is applied, this element pushes the vibration plate,
compressing the cavity for ink injection from the nozzle.

Cavity

Ink supplied from the ink cartridge is stored in this space and is ejected fr
om the nozzles when the vibration plate compresses this area.

Nozzles

These eject ink against the papers surface in response to the application of the
print signal. There are 64 (black head) or 48 (color head) individual nozzles
making up the printhead.
Cartridge Needle

Printhead Driver Board

Ink Supply Tube

Piezo
Nozzle Plate
No zzle
Nozzle Plate

Ink Supply Tank

Cavity

Piezo

Figure 2-2. Structure of Printhead

2-2

REV.-A

Stylus Pro XL

Operating Principles

Principles of the Printing Operation

The printhead operates in one of two modes to eject ink from each nozzle:

Normal state
No electrical charge is applied to the MLP (Multi-Layer Piezoelectric) element attached to the
back of the cavity, and pressure inside the cavity is kept at a constant level.

Ejecting state
The head data signal is applied to the specific nozzle control line to select the active nozzle for
printing, and the MLP element is gradually charged by the drive voltage. By charging the MLP
element, the vibration plate is bent to compress the cavity. Then, ink is ejected from the nozzle.

Cavity

Piezo

Nozzle

Vibration Plate

Normal
State

Cavity

Piezo

Nozzle

Ejecting
State

Ink Dot

Figure 2-3. Principles of the Printing Operation

When the ink charge or printhead cleaning operation is performed, the ink in the cavity is
vacuumed out with the pump mechanism. During printing, on the other hand, the ink is
simultaneously supplied from the ink cartridge and ejected from the nozzle, according to the
change of volume in the cavity.
A thermistor is attached to the side of the color printhead drive board to monitor the temperature,
because the viscosity of the ink varies, depending on the temperature. The detected temperature
level is fed back to the printhead drive voltage control circuit to change the timing of the Tc pulse.
(The Tc pulse is shown in Section 2.3.2.5.)

REV.-A

2-3

Operating Principles

Stylus Pro XL

Micro Dot Printing mode

The Stylus Pro XL printer has a special printing mode, called Micro Dot Printing mode. This
printing mode can be selected by a command from the host computer. Using the Micro Dot
printing mode can improve the quality of output. In Micro Dot Printing mode, the ink dot size
became to be smaller than the normal dot size.

2-4

REV.-A

Stylus Pro XL

Operating Principles

2.2.2 Carriage Drive Mechanism

The timing belt attached to the base of the carriage unit is driven by the carriage motor, causing the
carriage unit to move along the carriage guide shaft left to right, or vice versa. The carriage drive
motor on this printer is a 4-phase, 200-pole, hybrid-type stepping motor mechanism, allowing the
printer to stop the carriage or change the carriage movement at any position. The position of the
carriage is recognized by the home position sensor, and position information is fed back to the
carriage drive control circuit. This carriage motor is driven by the motor driver IC SLA7041 (see
Section 2.3.2.3 for more information).

Table 2-1. Carriage Drive Motor Specifications

Item

Description

Motor Type

4-phase / 200-pole hybrid-type stepping motor

Drive Voltage

+35 VDC 5%

Coil Resistance

10.0 7%

Drive Frequency

960 ~ 4800 PPS

Excitation Mode

Constant current unipolar drive, micro step drive

In the following table, 2 W1-2 phase means the 1/8 2-2 phase drive control. Values in parentheses
( ) are for the 2-2 phase.

Table 2-2. Drive Terms

CR Speed

Frequency

Acceleration/
Deceleration
Step

Phase Drive Method

4800 (2400)

Acceleration/Deceleration Area:
2 W1-2 phase + 1-2 phase
Constant Area: 1-2 phase

Acceleration
40 (5)+110 (55)
Deceleration
32 (4)+112 (56)

Mode 2
(100 CPS)

2400 (1200)

Acceleration/Deceleration Area:
2W1-2 phase + 1-2 phase
Constant Area: 1-2 phase

40 (5)+40 (20)

Mode 3
(40 CPS)

960 (480)

Acceleration/Deceleration Area:
2W1-2 phase
Constant Area: 2 W1-2 phase

16 (2)

Mode 1
(200 CPS)

CR HP Sensor

CR Motor

Carriage Guide Shaft

Belt Pulley

Figure 2-4. Carriage Drive Mechanism

REV.-A

2-5

Operating Principles

Stylus Pro XL

2.2.2.1 Platen Gap Adjust Lever

The platen gap adjust lever, which is attached to the carriage unit, needs to be set to an appropriate
position for the paper thickness. To change the platen gap, put the printer in the PAUSE state; then
press the Font button, while holding down the Alt button. The carriage unit moves the platen gap
position automatically.

Table 2-3. Platen Gap Adjust Lever Position

Paper Type

Lever Position

Cut sheets

Horizontal (A) ( 0 mm)

Envelopes

Vertical (B) (+0.6 mm)

Platen Gap Adjust Lever

(B)

(A)

0.6 mm

Gap

(Plain Paper or Bond Paper)

(Envelope or Transparency)

Figure 2-5. Platen Gap Adjust Lever Operation

2.2.3 Paper Feed Mechanism

This printers paper feed mechanism can feed paper only from the built-in ASF (auto sheet feeder).
The paper feed drive motor is a 4-phase, 96-pole, hybrid-type stepping motor that directly drives
the paper feed mechanism (paper advancing operation, paper pickup operation). This motor also
drives the pump mechanism, but only when the printer is in the cleaning state. The paper feed
drive method is driven by the 2-2 phase drive method, except the paper feed drive sequence
(2 W1-2 phase).

Table 2-4. Paper Feed Drive Motor Specification

Item

2-6

Description

Motor Type

4-phase, 96-pole, hybrid-type

Drive Voltage

+35 VDC 5%

Coil Resistance

11.5 1.1

Drive Frequency

300 ~ 1800 PPS

Excitation Mode

Paper feed / pump drive: 2-2 phase, 2 W1-2 phase

REV.-A

Stylus Pro XL

Operating Principles

Table 2-5. Drive Terms

Current Value (mA)
Frequency
(pps)

Mode

Acceleration/
Deceleration

Constant

Rush

Hold

Paper loading

1600

970/750

750

750

240

ASF feed

1600

970/750

750

750

240

Paper feed

391

970

240

Pump drive 1

1800

1380/1380

1380

750

240

Pump drive 2

300

1380

240

PF Pinch Roller Unit

Quenching Roller

PF Transmission Gear
Pickup Roller
Pape r

PF Motor Pinion Gear

Platen Drive Gear

Left Side Frame

Paper Pickup Lever

Tension Spring

Plunger

Hopper Frame

Figure 2-6. Paper Feed Mechanism

REV.-A

2-7

Operating Principles

Stylus Pro XL

2.2.4 Ink System

This printers ink system is composed of the following mechanisms:

Ink cartridge
Pump mechanism
Cap mechanism
Waste ink drain tank
Wiping mechanism

The figure below shows a diagram of the ink system.

Color Head

Black Head

Cleaning Blade
(for Color / Black Head)
Friction Clutch
Disengage Unit

Air Valve

Pump 1

Pump Unit
PF Motor

Platen Roller
Pump 2

Ink Absorber

Waste Ink Drain Tank

Figure 2-7. Ink System Block Diagram

2-8

REV.-A

Stylus Pro XL

Operating Principles

2.2.5 Pump Mechanism

The paper feed motor drives the pump mechanism when the transmission gear is moved to the
position where the paper feed motor engages the pump mechanism gear trains, when the carriage
unit is at the ink system home position. The figure below shows a block diagram of the pump
mechanism. Pump system operation depends on the rotational direction of the paper feed drive
motor, as shown in Table 2-6.

Left Frame

Carriage

Dis e nga ge
Le ver
S prin g
Pump
Driv e Gear

Ho o k

Right Frame

Re le as e
Clutch

P la ten

Sub Frame

Platen Drive Gear

Drive: Pump Mechanism

PF Motor

P ump Unit

Figure 2-8. Pump Mechanism Block

Drive: Switch Lever Set

Carriage
D/E Set Lever
D/E Reset Lever
D/E Lever

Figure 2-9. Switch Lever Set

REV.-A

2-9

Operating Principles

Stylus Pro XL

Drive: Paper Feed Mechanism

Carriage

Figure 2-10. Paper Feed Mechanism Block Diagram

Switch Lever: Reset

Carriage

D/E Reset Lever

D/E Lever

Figure 2-11. Switch Lever Reset

2-10

REV.-A

Stylus Pro XL

Operating Principles

Table 2-6. Pump Mechanism Operation

PF Motor Rotational Direction

Operation

Clockwise (CW)
forward rotation

Color absorption
Color micro absorption
Color false absorption
Wiper reset
Carriage lock reset

Counterclockwise (CCW)
backward rotation

Monochrome absorption
Monochrome micro absorption
Monochrome false absorption
Wiper set
Carriage lock set

The pump draws ink from the printhead nozzles and drains it to the waste ink drain tank. The
printer performs this operation to eliminate dust or bubbles in the nozzles. Figure 2-12 illustrates
pump operation. When the paper feed drive motor rotates CW (forward), the color pulley pumps
in the wheel pump unit rotate in the direction of the arrow while squeezing the ink tube to push the
ink inside the tube out to the waste ink drain tank. When the motor rotates CCW (backward), the
black pulley pumps in the wheel pump unit rotate in the direction of the arrow while squeezing the
ink tube to push the ink inside the tube out to the waste ink drain tank.
There are two pump rollers in the pump unit, and the drive power is supplied from the paper feed
motor via the pump drive gear (D/E gear), which is moved by carriage operation. In the pump
unit, the transmission gear drives both the black and color pulley, which are rotated by the
movement of the other.

Ink Draining

Ink Draining

Va cuu mi ng

Va cuu mi ng

Pump Motor (CW): Color Pumping

No Ink Draining

Pump Motor (CCW): Black Pumping

No Ink Draining

No Vac uum ing

No V acuu ming

Pump Motor (CW): Black Not Pumping

Pump Motor (CCW): Color Not Pumping

Figure 2-12. Pump Operation

REV.-A

2-11

Operating Principles

Stylus Pro XL

2.2.6 Cap Mechanism

The cap mechanism prevents the printhead nozzles from drying and keeps bubbles from forming
inside the nozzle while the printer is not in use. The printer performs this operation automatically
when print data is not received or when the printer power is turned off during printing or ink
system operations. (The secondary circuit for the power switch allows this operation to be
performed.) Also this printer has two caps, one for the black head and one for the color head.
Color Cartridge

Carriage

Black Cartridge

1'
1

Cap Holder

Cap 2

Air Tube

Cap 1

Air Valve
Valve Spring

Figure 2-13. Cap Mechanism

2.2.7 Wiping Mechanism

The wiping mechanism cleans the surface of the printhead nose when the printer is in the ink
system sequence. The wiper drive gear transmits power from the paper feed motor via the clutch
gear. When the wiper is raised (against the printhead surface), the hook for securing the carriage to
the home position is raised, too. When the wiper goes down toward the bottom frame, the hook
goes down, too. Both black and color heads are cleaned by this wiper.
Hook

Hook Lever

Wiper (Cleaning Blade)

Wiper Drive Gear

Pl a te n
C lu tc h
Wip er Drive Gear Frame

Figure 2-14. Wiping Mechanism

2-12

REV.-A

Stylus Pro XL

Operating Principles

2.3 OPERATING PRINCIPLES OF THE ELECTRICAL CIRCUITS

The Stylus Pro XL contains the following circuit board units:

C162 MAIN Board (main control circuit board)

C137 PSB/PSE Board (power supply circuit board)
C137 PNL (control panel board)

In addition to the circuit boards above, part of the printhead drive circuit is built on a separate
circuit board installed in the carriage unit; the printhead is attached directly to this board. The
figure below shows a block diagram of the electrical circuitry.

C137 PNL

C1 3 7 P SB

C1 6 2 MA IN

M-4 A60 Printer Mechanism

+5 VDC

CR/PF Moto r

+ 3 5 VD C

YMC H ead Black Head

Driver
Driver
R-T02 Head

R-T01 Head

Figure 2-15. Block Diagram of the Electrical Circuitry

2.3.1 Operating Principles of the Power Supply Circuit
The power supply circuitry for this printer is provided either by the C137 PSB Board (120 VAC) or
the C137 PSE Board (220-240 VAC). Both boards are identical in design and functionality, except for
the components in the primary circuit that accommodate the specified input voltage. The input
voltage and the application of output voltages are summarized in the table below.

Table 2-7. DC Voltage Distribution

Voltage

Application

+35 VDC

Motor drive (carriage and paper feed)

Printhead (through the drive voltage generation circuit)

+5 VDC

C137 MAIN Board

Sensors (home position, paper end, no ink cartridge, head thermistor)
Control panel, head nozzle selector

REV.-A

2-13

Operating Principles

Stylus Pro XL

The figure below shows a block diagram of the power supply circuit (C137 PSB/PSE). The power
switch is equipped with a secondary circuit that allows the CPU to remain active for a while after
the printer is turned off. This allows the printhead to return to the capping position after power is
off. The CPU mounted on the C137 MAIN Board always monitors the PSC (power on/off) signal. If
this signal becomes LOW, the CPU resets each device after performing the head capping sequence.
Also, this board employs the RCC (ringing choke converter) switching system. This AC voltage is
first input to the filter circuit for higher harmonics absorption, and then input to the rectification
and smoothing circuit, converting it into DC voltage. This DC voltage is then input to the switching
circuit for the switching operation. Along with the switching operation on the primary side, +35
VDC is generated after passing through the +35 V line voltage detection circuit. This +35 VDC
output level is stabilized. This +35 VDC is also input to the +5 VDC generation circuit to generate a
stable +5 VDC.

C11

Full-wave
Rectifier Circuit
L1, R1 C1-C4
Filter Circuit

T1

Smoothing
Circuit

Q1
Main Switching
Circuit

T ra ns fo rm er

DB1

F1
F use

Feedback
Circuit

C51

+35 VDC

Smoothing
Circuit
ZD51, 81-84 Drop Protection
Circuit

+ 5 VD C

TL 494

P-OFF Detection
and Delay Circuit

ZD52
Over Voltage
Protection Circuit

ZD8 6 ,
C82

Photo
Coupler
PC 1

Z D53
Over Voltage
Protection Circuit

P-OFF Sign al

Figure 2-16. Power Supply Circuit Block Diagram

1) +5 VDC line over voltage protection circuit

The output voltage level of +5 V line is monitored by a Zener diode (ZD53). If the voltage level
exceeds +7 V, the status is fed back to the primary switching circuit through a photocoupler (PC1)
to stop the +35 V generation.
2) +5 VDC line over current / over voltage control circuit.
The output current is monitored by a detection resistor (R53) and fed back to the +5 VDC
generation switching control IC (IC51), which monitors the output voltage. This information is
input to the internal comparater and outputs the high signal to turn off the transistor (Q51) when
the voltage or the current becomes abnormal.
3) +35 VDC line over voltage protection circuit
The output level is monitored by a Zener diode (ZD36). If the voltage level exceeds +36 V, a
photocoupler (PC1) is activated; stopping the primary switching circuit operation.
4) +35 VDC line drop protection circuit
The output level of +35 VDC line is monitored by a detection circuit that consists of a Zener diode
(ZD51 and ZD81 to 84). This circuit feeds back the output voltage level status through a photocoupler to the primary switching circuit to control the ON/OFF time of the switching transistor for
contast output voltage.

2-14

REV.-A

Stylus Pro XL

Operating Principles

2.3.2 Operating Principles of the Main Control Circuit

The main control circuit of this printer is the C162 MAIN Board. This circuit is controlled by the
16-bit CPU H8/3003 (IC1), running at 14.7456 MHz. This CPU has a unique architecture capable of
handling data on the data bus at either an 8-bit or 16-bit bus width. Because of this, a 16-bit or 8-bit
data bus width-type ROM is used on this board, increasing the internal processing speed. Also, the
CPU has a unique architecture capable of the refresh control function. A 4M DRAM (2 CAS
method) on this board is controlled by the CPU itself. The CPU controls the serial interface control
(RS-422 for Mac).
Gate array E05A96 (IC2) manages printhead drive control, external Centronics parallel I/F,
extension CG board and the control panel, and the controls that create the 4-bit signal for the
carriage or the paper feed motor. (The carriage and paper feed motor are controlled by the current
duty data.)
This board also is equipped with EEPROM 93C46 (IC12) to store certain parameters, such as the
printer mechanism control parameter, default setting parameters, as well as a special counter value
used for printhead (ink management) protection.
The timer, IC NJU6355E (IC7), counts each time the printer is cleaned and keeps track of how long
the printer is not used, thereby allowing the printer to be cleared only when necessary.
Note 2

Note 1
PROM (4M)
(IC3)

PROM (8M)
(IC4)

DRAM (4M)
(IC5)

DRAM (4M)
(IC6)

CG-ROM (4M)
(IC16)

CG-ROM (8M)
(IC17)

Data Bus

Type B I/F

Address Bus

Refresh

EEPROM

(IC12)
9 3C4 6

Reset
(Power)

(IC8)
M51955B

CPU
H8/3003
(IC1)

Panel

DMAREQ
To A
B lack / Color H ead
Com m on and Nozzle
S elector Drive Signal

From A

C arriage / Paper Feed

D rive S ignal

NJU6355E
(Timer
Counter)

P arallel I/F
(Centronics)

Battery

C162 MAIN Board

To B

CLK

SD I/O

Vx

(IC7)

RS-422 Serial I/F

(IC13)
Reset
PST592D (Logic)

E0 5A96
(IC2)

Carriage

Black / Color Head

Common Driver Circuit

S ED5 62 0
(U1,U2)

Black 64 Nozzles
Color 48 Nozzles

SLA7041MS (IC14, 15)

From B

Carriage / Paper Feed

Motor Driver

Note 1: IC4 is a 32-pin IC socket only.

Note 2: IC17 is an IC socket only.

(IC17 is only installed in JAPAN version.)

Figure 2-17. Main Control Circuit Block Diagram

REV.-A

2-15

Operating Principles

Stylus Pro XL

2.3.2.1 Reset Circuits

The C162 MAIN Board contains 2 reset circuits: the +5 V monitor reset circuit and the +35 V
monitor reset circuit. The +5 V monitor reset circuit monitors the voltage level of the +5 V line,
using reset IC PST592D (IC12), and outputs a reset signal to the E05A96 gate array (IC2) when the
voltage level drops below +4.2 V. The +35 V monitor reset circuit monitors the voltage level of the
+35 V line, using reset IC M51955B (IC8), and outputs a reset signal to the CPU. The reset signal is
generated when the voltage level drops below +28 V, and this causes a non-maskable interrupt
(NMI).
+35 V

+5 V
CPU (IC1)
M5 195 5B
(IC8)

+5 V

72

NMI

68

P62

71

RES
E05A96 (IC2)

PST5 92D
(IC13)
1

135

RESET

PA8

55

RST
Typ e B

Figure 2-18. Reset Circuit Block Diagram

2.3.2.2 Sensor Circuits

The following sensor circuits enable the C162 MAIN Board to monitor printer mechanism status:
HP sensor

The photocoupler-type home position (HP) sensor is attached to the surface of the
printer mechanism to detect the carriage home position. A LOW level from the
signal indicates that the carriage is in home position.

PE sensor

The mechanical switch paper end (PE) sensor is built into the printer mechanism to
determine whether there is paper in the printer or not. A LOW level from the signal
indicates that no paper is loaded.

BCO sensor,
CCO sensor

The cartridge out (CO) sensor is micro switch attached to the bottom of each ink
cartridge holder in the carriage unit. When the ink cartridge is installed, these
switches are pressed and a LOW level from the signal indicates that the ink
cartridge is installed into the ink cartridge holder.

Thermistor

A thermistor is attached to the color printhead driver board to monitor its

temperature by thermisters resistance value (at 25C approx. 10k). The CPU
changes the printhead drive signals pulse width (charge pulse width) based on the
temperature level.
+5 V

PE

(CN8)

+5 V
CPU (IC1 )

87
AN1

AN3

89

HP

(CN9)

1
2
3

10

TH

9
A N5

86
AN0

AN4

91

8
9

90

(CN12)
CCO
(CN11)
BCO

Figure 2-19. Sensor Circuit Block Diagram

2-16

REV.-A

Stylus Pro XL

Operating Principles

2.3.2.3 Carriage Motor Drive Circuit

The carriage motor drive IC SLA7041MS (IC15) outputs a constant current to drive the carriage
motor for the printer mechanism. Gate array E05A96EA (IC2) decides the motor phase and speed
and then sends a signal to the carriage motor driver IC (SLA7041MS) using the 4-bit serial
transmission line.
The first bit indicates the direction of the motor rotation. The other three bits are current duty
data for the motor speed of each printing sequence. SLA7041MS can select the reference voltage
itself based on these three current duty data. Also, it receives these signals by 2 serial
transmission lines for 2 motors phases (phase A and phase B). Due to this, the carriage motor
can drive the micro step sequence (min. 1/720 inches).

E05A96
(IC2)

SLA7 0 41MS
(IC15)
CRCLK 2 9
CR S TB 3 0

CR HL D 5 6

A 1
A 8
B 11
B 18
+35 V

CRA 28
CRB 25
31-38
C RV R F
(PB0-PB7)

5 CLKA
16
2 CL K B
1 3 STBA
STBB
6
DATA A
17
DATA B
3 REF A
1 4 REF B
9 RSA
10 RSB
C
C
B NPN Tr E
(Q27, 28)

1
2
3
4
5

(CN6 )

Figure 2-20. Carriage Motor Circuit Block Diagram

Four-bit serial data is read by the SLA7041MS motor driver with four clock counts from the
E05A96 (IC2) clock. Each bit is read at the falling edges of these clock pulses. Due to this,
received serial data is placed in the shift register and then shifts the latch register. When the
STROBE pulse becomes active from the E05A96 (IC2), the serial data is moved into the reference
voltage selection circuit, and the voltage is changed. Therefore, when the printer is in the
constant speed mode, this STROBE pulse becomes inactive. The following table indicates the
current duty of each carriage motor speed mode.

Table 2-8. Serial Data Contents

REV.-A

Mode

c b a

0 0 0

0%

0 0 1

20%

0 1 0

Vref (typical)

Vref 1/3
(Vref = +5 V)

40 %
55.5%

0 1 1

1 0 0

71.4%

1 0 1

83%

1 1 0

91%

1 1 1

100%

2-17

Operating Principles

Stylus Pro XL

The following figure shows the contents of the four-bit serial data and how this data transacts
with the SLA7041MS driver. The step time of the reference voltage is determined by the interval
time of the STROBE pulse.
Vref
+5 V
SL A7 04 1 M S

Vref

To Mot or
(Phase Signal)
STRB

4-bit Serial Data

Vref Voltage Selection

Circuit

1-bit

2-bit

3-bit

4-bit

Phase

1-bit

2-bit

3-bit

4-bit

Phase

Latch

4-bit Shift Register

CL K

CL K

STRB

Reading of serial data from the

Phase signal in order
At this time, the reference voltage selection
circuit checks phase signal outputs

Figure 2-21. Serial Data Transfer Procedure

2-18

REV.-A

Stylus Pro XL

Operating Principles

2.3.2.4 Paper Feed Motor Drive Circuit

The paper feed motor for this printer drives the following mechanisms:

Paper feed mechanism

Paper pickup mechanism
Pump mechanism

Driver IC SLA7041MS (IC14) drives the paper feed motor by a constant current. Its principle of
operation is same as for the carriage motor drive circuit. But the driving method is different for
paper feed and the pump.

Table 2-9. Paper Feed Motor Drive Modes

Mode

Phase Excitation

Drive Frequency

Paper feed

2-2 phase or 2 W1-2 phase

391 or 1600 pps

Pump drive

2-2 phase

300 or 1800 pps

E05A96
(IC2)

SLA7041MS
(IC14)
P FCLK
P FS TB

P FA
P FB

42

5
16
2
13

43
41

40
44-48, 39

17
3

PFH LD

14
57

9
10

DA TA A

DA TA B

11

RE F A

18

RE F B
RSA

+3 5 V

PFV RF
(PB8-PB13)

CLKA
CLKB
S TB A
STBB

(CN 7)

RSB

C
B

NPN Tr E
(Q25, 26)

Figure 2-22. Paper Feed Motor Drive Circuit Diagram

REV.-A

2-19

Operating Principles

Stylus Pro XL

2.3.2.5 Printhead Drive Circuit

The printhead drive circuit for this printer is composed of the following two parts:

Common drive circuit (trapezoidal drive pulse generation)

Head drive circuit (nozzle control built on the printhead)

SED5620D, the 64-bit thermal head driver in the head drive circuit on the carriage, is used as a
nozzle selector to drive the printhead nozzles selectively. Print data is converted into serial data by
gate array E05A96 (IC2) and is output from port BSO (pin 20) to the black head drive circuit or
output from port CSO (pin 24) to the color head drive circuit. Then, head driver SED5620D latches
the head data when gate array E05A96BA outputs the BLAT or CLAT signal, and the latched data
becomes 64-bit parallel data for the black head, or 48-bit parallel data for the color head. One bit
corresponds to each nozzle.
When data transfer and nozzle selection is complete, gate array E05A96 outputs the common drive
pulse BPWC or CPWC (charge pulse) and BPWD or CPWD (discharge pulse) to the common drive
circuit. The common drive circuit then generates the trapezoidal pulse and applies it to the
printhead as a common drive pulse. After this, the nozzle selected by the head data is activated to
inject ink.
In the Micro Dot Printing mode, the gate array E05B09 arranges the puise width of CPWC and
CPWD to became small size of injection ink dot.
SELM Pulse
Block Resistor

Normal
Common Driver
Drive Pulse

Normal Dot Mode

Drive Waveform

Hea d
Micro

Micro Dot Mode

Drive Waveform

SELN Pulse

Figure 2-23. Normal / Micro Dot Mode Switch Block

2-20

REV.-A

Stylus Pro XL

Operating Principles

Micro Dot Printing Mode

The Stylus Pro XL printer has a special printing mode, called Micro Dot Printing Mode. This
printing mode can be selected by command from computer. Using Micro Dot Printing Mode can
improve the quality of output. In Micro Dot Printing Mode, the ink dot size becomes smaller than
the normal dot size.

Th

Td

Tc

VH
COM
GND
BPWC
C P WC

Ph

Pc

BPWD
C P WD

Pd

Tc: Charge Time

Th: I dle Time
Td: D ischarge Time

Pc: C harge Pulse

Ph: Idle Pulse
Pd: Dischar ge Pulse

Figure 2-24. Trapezoidal Drive Waveform

E 05 A9 6 (IC2 )

CPWC
CPWD

19
18
17

SE D5 6 2 0D (U1)
CN1

Common Driver

15
16

4 68

L A T D O6 4 -4 9

Row A

2 69

C L K D O4 8 -3 3
DO 32- 17
SI
DO16-1

Row B

6 67

20

18-22

23

22
21
24

2
6

C162 MAIN

Row C
R ow D

C O M 1 -6

Common Driver

SED 5620D (U 2)
CN12

CLAT
CCLK
CCLKIN
CSO

COM1-8

17- 22

CN11

BLAT
BCLK
BCLKIN
BSO

13
14

4 68
CN2

BPWC
BPWD

2 69
67

L A T D O6 4 -4 9
D O4 8 -3 3
CL K
DO 32- 17
SI
DO 1 6 -1

N ot C onne ct ed
Row R (Magenta)
Row S (Cyan)
Row T (Yellow)

On Carriage (Head Driver Board)

Figure 2-25. Printhead Drive Circuit Block Diagram

REV.-A

2-21

Operating Principles

Stylus Pro XL

2.3.2.6 DMA Controller

Data from the host computer is received automatically by the STB signal via the external Centronics
interface. The data is input to the input buffer on the DRAM (IC5). At this time, E05A96 detects the
rising edge of the external STB signal and outputs the STBDMA (strobe DMA request) signal to the
CPU. When the CPU detects this signal, the DMA controller in the CPU sends a bus request to the
bus controller in the CPU, and then the CPU releases the bus line. Due to this, external data is
transported into the memory, bypassing the CPU.

E05A96 (IC2)
16 6
STB
ACK
BUSY

STB DMA

CPU H8 (IC1)
129

16 1
162

DRE Q 1
DMAC

DMARQ

128 14

DRE Q 2

BA C

Memory

BA RE Q

Figure 2-26. DMA Controller Operation

2-22

REV.-A

Stylus Pro XL

Operating Principles

2.3.2.7 DRAM Refresh Controller

The H8 CPU is equipped with a refresh controller in the internal controller. This CPU can contact
the 16-bit-long IC5 DRAM, which is a 2 CAS type. The following table lists the junction method
between the H8 CPU and the 2 CAS DRAM.

Table 2-10. Junction Method (CPU 2 CAS DRAM)

CPU

2 CAS DRAM

HWR

UCAS

LWR

LCAS

CS3

RAS

RD

WR

The method of the DRAM refresh is used only for the CAS before RAS cycle method. The following
figure shows the timing for each cycle.

CA S

CA S

RAS

RA S
Re ad Cyc le
WE

WE
Write Cycle
AS

AS

(Read / Write Cycle)

(Refresh Cycle)

Figure 2-27. DRAM Cycle Timing

CPU H8 (I C1)

DR AM (I C5)
80

CS3
RD

79
1 01
78

23
CAS

8
7
22

RAS
WE
OE
DRAM (IC6 )

23
8

7
22

CAS
RAS
WE
OE

Figure 2-28. Junction Method (CPU DRAM)

REV.-A

2-23

Operating Principles

Stylus Pro XL

2.4 INK SYSTEM MANAGEMENT

This section explains how the ink system is controlled to protect the printhead and ink supply
system and to ensure high-quality output. Ink system control is composed of the following
operations:

Power On
Cleaning Selection
Micro Absorbing Cleaning
Power Off
Print Start
Refresh
Standby
False Absorbing
Ink Cartridge Replacement

Wiping Operation 1
Wiping Operation 2
Rubbing Operation
Disengage On
Disengage Off
Micro Absorbing
Carriage Lock Set
Carriage Lock Reset
Refresh (when loading or ejecting paper)
Forwarding (not described)

These ink system operations are controlled by the following counters and timers:

Refresh Timer
Flushing Counter
CL Counter K

2-24

Monochrome / Color Head Timer

Ink Level Counter R
Protect Counter

REV.-A

Stylus Pro XL

Operating Principles

2.4.1 Ink Operations

Various ink operations can be performed selectively by the printer.

1 Power On Operation
This operation is performed when power is turned on.

2 Cleaning Selection Mode

This operation cleans each nozzle to ensure that the nozzle fires and that no dots are skipped
during printing. Cleaning selection is performed by pressing the cleaning switch (Alt +
Load/Eject or Economy/Condensed) while the printer is in PAUSE status.

3 Micro Absorbing Cleaning Operation

This operation prevents an increase in the viscosity of the ink inside the printhead by ink
absorbing discharge.

4 Power Off Operation

This operation ensures the carriage is in the home position when the printer turns off, and
prevents the disengage gear from turning continuously when the printer turns off. Power off
operation is performed when the secondary side switch is turned off.

5 Print Start Operation

This operation eliminates ink from the nozzle surface, and is performed when the printer
receives print data while in the standby state.

6 Refresh Operation
This operation prevents an increase in the viscosity of the head ink.

7 Standby Operation
This operation prevents an increase in the viscosity of the head ink.

8 False Absorbing Operation

This operation absorbs ink inside the cap, and eliminates ink from the nozzle plate.

9 Ink Cartridge Replacement Operation

This operation is performed when the Alt button is pressed for more than 3 seconds; the carriage
then moves to the ink cartridge replacement position.

10 Wiping Operation 1
This operation eliminates dust from the nozzle plate before performing the ink absorption.

11 Wiping Operation 2
This operation eliminates dust or ink from the nozzle plate after performing the ink absorption.

12 Rubbing Operation
This operation removes dust or ink that adheres to the head surface.

13 Disengage ON Operation
This operation sets the switch lever to the position where it transmits the PF motor drive to the
pump mechanism. It also moves the carriage to the home position where the lever is set to the
specified position.
REV.-A

2-25

Operating Principles

Stylus Pro XL

14 Disengage Off Operation

This operation resets the switch lever to the position where it transmits the PF motor drive to the
pump mechanism. It also moves the carriage to the flushing position, where the lever is reset to
the specified position.

15 Micro Absorbing Operation

When the cartridge is removed, it is possible for a small amount of air to form small air bubbles
that can block the ink from the nozzle. This operation eliminates small air bubbles from the
cavity of the printhead.

16 Carriage Lock Set

This operation prevents the carriage from moving out of the home position if the printer is
turned off or is pauesd. This operation is performed when the carriage is in the ink system home
position and no paper is loaded.

17 Carriage Lock Reset

This operation resets the carriage lock lever.

18 Refresh Operation (Performed when Loading or Ejecting Paper)

This operation prevents an increase in the viscosity of ink inside the black head while paper is
being loaded or ejected. When paper is loaded or ejected, just the black head is ready, and the
color head is capped. The refresh flushes the black head only.

19 Adjust Lever Position Moving Sequence

This operation is performed when the Alt and Font buttons are pressed simultaneously while the
printer is paused.

20. Transportation Sequence

This sequence is performed to clean the printhead when the printer is transported to the market.

2-26

REV.-A

Stylus Pro XL

Operating Principles

2.4.2 Timer and Counter

EEPROM LE93C46 (IC12) on the main board stores certain counter and timer values used for
controlling ink system operation.

2.4.2.1 Protect Counter

Protect counter A and Ink Amount Counter R values are stored in the EEPROM on the main
board, and while the printer is on, this data is saved in the RAM on the main board.
Protect Counter A

1. Power On
(Micro):

This counter is used to manage the total amount of drained ink. If

the counter value is equal to or exceeds 51000, the printer indicates
an error on the control panel and maintenance is required. This
counter is incremented by the following every sequence. (Values
in parentheses ( ) mean only the color head. 1 point = 0.025 cc.)
40 steps 6 (5)
40 steps 10 (9)
40 steps 15 (12)

2 points
3 points
5 (4) points

2. CL 1:

3600 (4800) steps

16 (20) points
40 steps 12 absorption 4 points

3. CL 2:

720 steps
7800 (8200) steps
40 steps 12

4 points
40 points
4 points

4. CL 3:

40 steps 12

4 points

5. I/C Replacement:

8900 (14000) steps

8900 (8800) steps
40 steps 12

48 (72) points
48 (44) points
4 points

6. Fixed time
False Absorption:
7. Power On
(Normal):

Monochrome and CMY = 2

3600 (4800) steps
40 steps 12

16 (20) points
4 points

Note for Service

Also, protect counter A resets when:
1. The printer is shipped from the factory.
2. After the maintenance is performed.
(When the ink drain tank (ink-eject porous pad, part number 130) is replaced.)

REV.-A

2-27

Chapter 3

Disassembly and Assembly

Table of Contents
3.1 OVERVIEW
3-1
3.1.1 Precautions for Disassembling the Printer . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 DISASSEMBLY AND ASSEMBLY
3-2
3.2.1 Upper Case Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.2.2 Power Supply Unit (C137 PSB/PSE Board) Removal . . . . . . . . . . . . . . . . 3-4
3.2.3 Main Controller (C162 MAIN Board) Removal . . . . . . . . . . . . . . . . . . . . . . 3-5
3.2.4 Printer Mechanism (M-4A60) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.2.5 Printer Mechanism Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.2.5.1 Printhead Unit Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3.2.5.2 Carriage Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3.2.5.3 Pump Unit Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.2.5.4 Cleaner Head Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3.2.5.5 CR Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.2.5.6 PF Motor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.2.5.7 Carriage Home Position (HP) Sensor Removal . . . . . . . . . . . . . 3-16
3.2.5.8 Paper End (PE) Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3.2.5.9 Paper Feed Roller Assembly Removal . . . . . . . . . . . . . . . . . . . . 3-17
3.2.5.10 Upper Frame Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

Rev.-A

3-i

List of Figures
Figure 3-1. Disassembly Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Figure 3-2. C137 PNL Control Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Figure 3-3. Upper Case Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Figure 3-4. Power Supply Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Figure 3-5. Main Controller Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Figure 3-6. Printer Mechanism (M-4A60) Removal . . . . . . . . . . . . . . . . . . . . . . 3-7
Figure 3-7. Ink Cartridge Clamp Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Figure 3-8. Ink Cartridge Holder removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Figure 3-9. Printhead Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Figure 3-10. Head Spacer Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Figure 3-11. Front Frame Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Figure 3-12. Carriage Unit Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Figure 3-13. Pump Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Figure 3-14. Cleaner Head Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Figure 3-15. CR Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Figure 3-16. PF Motor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Figure 3-17. HP Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Figure 3-18. PE Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Figure 3-19. Tension Roller Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . 3-17
Figure 3-20. Paper Feed Roller Assembly Removal . . . . . . . . . . . . . . . . . . . . 3-17
Figure 3-21. Upper Frame Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Figure 3-22. Attaching the Torsion Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

List of Tables
Table 3-1. Insert Location of the Block Resistor . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Table 3-2. Insert Location of the Block Resistor . . . . . . . . . . . . . . . . . . . . . . . 3-10

3-ii

Rev.-A

Stylus Pro XL

Disassembly and Assmbly

3.1 OVERVIEW
This section describes procedures for disassembling the main components of this printer. Unless
otherwise specified, disassembled units or components can be reassembled by reversing the
disassembly procedure. Therefore, no assembly procedures are included. Precautions for any
disassembly or assembly procedure are described under the heading Disassembly/Assembly
Points. Adjustments required after assembling the unit are described under the heading Required
Adjustments.

3.1.1 Precautions for Disassembling the Printer

See the precautions below when disassembling the printer.

WARNING
Disconnect the power cable before disassembling or assembling the printer.
Wear protective goggles to protect your eyes from ink. If ink gets in your eye, flush the
eye with fresh water and see a doctor immediately.
If ink comes into contact with your skin, wash it off with soap and water. If irritation
occurs, contact a physician.
A lithium battery is installed on the C162 MAIN Board of this printer. Be sure to observe
the following instructions when servicing the battery:
1. Keep the battery away from any metal or other batteries so that electrodes of the
opposite polarity do not come in contact with each other.
2. Do not heat the battery or put it near fire.
3. Do not solder on any part of the battery. (Doing so may result in leakage of electrolyte
from the battery, burning, or explosion. The leakage may affect other devices close to
the battery.)
4. Do not charge the battery. (An explosive gas may be generated inside the battery, and
cause burning or explosion.)
5. Do not dismantle the battery. (The gas inside the battery may hurt your throat.
Leakage, burning, or explosion may also result.)
6. Do not install the battery in the wrong direction. (This may cause burning or explosion.)

CAUTION
Danger of explosion if battery is incorrectly replaced. Replace only with the same or
equivalent type recommended by the manufacturer. Dispose of used batteries according to
governments laws and regulations.

ATTENTION
Risque dexplosion si la pile est remplace incorrectement. Ne remplacer que par une pile
du mme type ou dun type quivalent recommand par le fabricant. Elminer les piles
dcharges selon les lois et les rgles de scurit en vigueur.

CAUTION
Never remove the ink cartridge from the carriage unless manual instructions specify to
do so.
When transporting the printer after installing the ink cartridge, be sure to pack the
printer for transportation without removing the ink cartridge.
Use only recommended tools for disassembling, assembling, or adjusting the printer.
Apply lubricants and adhesives as specified. (See Chapter 6.)
Make specified adjustments when you disassemble the printer. (See Chapter 4.)

REV.-A

3-1

Disassembly and Assembly

Stylus Pro XL

3.2 DISASSEMBLY AND ASSEMBLY

WARNING
Follow the precautions in Section 3.1.1 when disassembling the printer.
This section consists of the subheads shown in the diagram below. See the exploded view of the
printer in the Appendix, if necessary.
START

Printhead Unit
Remo va l
Upper Case
Remo va l
3.2.1

3.2.5.1

Page 3-8

Page 3-3
Carriage Unit
Remo va l

Power Supply Unit

Remo va l

3.2.2

3.2.5.2

Page 3-12

Page 3-4
Pump Unit
Remova l

Main Controller
Removal
3.2.3

Page 3-13

Page 3-5

Printer Mech anism

Re mova l

3.2.4

3.2.5.3

Clerner Head
Remo va l
Page 3-14
3.2.5.4

Page 3-7
CR Motor
Remo va l
3.2.5.5

Page 3-15

PF Motor
Re mo va l

3.2.5.6

Page 3-15

HP,PE
Sensor Removal
3.2.5.7-8 Page 3-16

PF Roller Assembly
Re mo va l
Page 3-17
3.2.5.9

Upper Frame
Re mo va l
3.2.5.10

Page 3-18

Figure 3-1. Disassembly Flowchart

3-2

REV.-A

Stylus Pro XL

Disassembly and Assmbly

3.2.1 Upper Case Removal

1.

Remove the printer cover (center of top) by releasing the 2 tabs holding it to the upper case.

2.

Remove the front cover (front of top) by releasing the 2 tabs holding it to the lower case.

3.

Remove the paper guide by releasing the 2 tabs holding it to the printer mechanism.

4.

Move the carriage to the middle of the printer while pressing the hook that fixes the carriage
unit to the home position.

5.

Remove the control panel. (Release the tab by inserting a screwdriver into the hole in the upper
case, as shown in the figure below.) At this time, disconnect the connector on the C137 PNL
Board.
C137 PNL Board

Cable

Carriage Lock Lever

Figure 3-2. C137 PNL Control Panel Removal

5.

Remove the 2 CBB (M3 11) screws securing the upper case to the lower case.

6.

Release 1 tab by inserting a flathead screwdriver into the holes at the bottom of the lower case,
as shown in the figure below.

7.

Remove the upper case by lifting the front side. At the same time release 1 tab, located in the
center front of the lower case.

DISASSEMBLY/ASSEMBLY POINT
Hold the upper case firmly and pull it to remove it, while you release the tabs.
CBB (M3x11)

Figure 3-3. Upper Case Removal

REV.-A

3-3

Disassembly and Assembly

Stylus Pro XL

3.2.2 Power Supply Unit (C137 PSB/PSE Board) Removal

1.

Remove the upper case (see Section 3.2.1).

2.

Disconnect the cables from connectors CN1 on the C137 PSB /PSE Board and CN5 on the C162
MAIN Board.

3.

Remove the 2 screws, 1 CBN (M38) and 1 CBB (M312), securing the shield plate to the lower
case via the C137 PSB/PSE Board.

4.

Remove the 3 screws, 2 CBB (M312) and 1 CBN (M38), securing the C137 PSB/PSE Board to
the lower case, and remove a CBN (O) (M36) screw fixing the earth line from the AC cable to
the earth plate.

5.

Remove the wire harness for the motors in the locking tab on the shield plate, and take the
shield plate out by pulling upward toward the back of the printer.

6.

Remove the power supply unit by pulling it upward toward the back of the printer.

CAUTION
The shield plates of C137 PSB/PSE and C162 MAIN boards have sharp edges, so take care
in handling them.

CBS (M3x8)

C162 MAIN Board

C137 PSB Board

CBB (M3x12)

CBS(O) (M3x6)

Figure 3-4. Power Supply Unit Removal

3-4

REV.-A

Stylus Pro XL

Disassembly and Assmbly

3.2.3 Main Controller (C162 MAIN Board) Removal

1.

Remove the upper case (see Section 3.2.1).

2.

Remove the grounding plate from the shield plate.

3.

Remove the 4 CBB (M312) screws securing the shield plate to the lower case.

4.

Remove the 2 CBB (M312) screws securing the Type-B interface cover to the lower case.

5.

Disconnect the cables from connectors CN5, CN6, CN7, CN8, CN9, CN10, CN11, CN12, and
CN13 of the C162 MAIN Board.

Remove the 4 CBB screws, 2 (M312) and 2 (M38), securing the main controller to the lower
case and then remove the C162 MAIN Board.

CBB (M3x12)

Grounding Plate

Grounding Plate

Shield Plate

CBS (M3x8)

CBB (M3x12)

Figure 3-5. Main Controller Removal

REV.-A

3-5

Disassembly and Assembly

Stylus Pro XL

ASSEMBLY POINT
When you replace the main board, initialize EEPROM contents as follows:
1. Reassemble the printer.
2. Turn the printer on while holding down the Alt, Font , Load/Eject , and Pause buttons
on the control panel.
It is possible to misconnect the cables. When reconnecting the cables from connectors
CN6, CN7 and connectors CN11, CN12 of the C162 MAIN board, see the following
instructions.
1. CN11: Printhead FFC cable (white mark: rear direction)
CN12: Printhead FFC cable (blue mark: rear direction)
2. CN6: Carriage motor cable (red mark: the red mark indicates pin 1 of CN6.)
CN7: Paper feed motor cable (black mark: the black mark indicates pin 1 of CN7.)

REQUIRED ADJUSTMENT
When replacing the main controller board, adjust both the head gap and the
bidirectional adjustment alignment, and save the adjusted parameters into the
EEPROM on the C162 MAIN Board. (See Chapter 4.)
When you replace the main board, the parameters in the internal timer are all reset.
Therefore, it is possible for printing to become abnormal. At this time, perform the
cleaning operation using the control panel or command (Refer to Chapter 4) until the
printing becomes normal.

CAUTION
The shield plates for the C162 MAIN Board and C137 PSB/PSE Board have sharp edges,
so take care in handling them.

3-6

REV.-A

Stylus Pro XL

Disassembly and Assmbly

3.2.4 Printer Mechanism (M-4A10) Removal

1.

Remove the upper case (see Section 3.2.1).

2.

Remove the power supply unit (see Section 3.2.2).

3.

Remove the main controller (see Section 3.2.3).

4.

Remove the 4 CBN (M413) screws and take out the printer mechanism.

DISASSEMBLY/ASSEMBLY POINT
Wipe off any ink around the end of the ink drain tube when you remove the printer
mechanism.
When reinstalling the printer mechanism, check that the waste ink drain tube is properly
inserted between the lower case and the waste ink absorbing material.
CBB (M4x13 )

Figure 3-6. Printer Mechanism (M-4A60) Removal

CAUTION
When you replace the printhead or printer mechanism, you must replace the block
resistor at location RM4 (for Micro Mode - Color (R-No.)), RM5 (for Normal Mode Color (M-No.)), RM11 (for Micro Mode - Monochrome (R-No.)), and RM12 (for Normal
Mode - Monochrome (M-No.)) on the C162 MAIN Board. (Every spare printhead or
spare printer mechanism comes with a block resistor that is specifically selected for
each printhead.) Refer to Table 3-1.
Adjust both the head gap and bidirectional alignment when replacing the printer
mechanism.

Table 3-1. Insertion Location for Block Resistors

Mode
Normal
^
Micro
^

REV.-A

Head
Monochrome
Color
Monochrome
Color

Indication No.

Location

M-

RM12

M-

RM5

R-

RM11

R-

RM4

3-7

Disassembly and Assembly

Stylus Pro XL

3.2.5 Printer Mechanism Disassembly

The procedures described in this section explain how to remove the components within the
printer mechanism.

3.2.5.1 Printhead Unit Removal

1.

Remove the printer mechanism (see Section 3.2.4).

2.

Move the carriage to the middle of the printer while pressing the hook that fixes the carriage
unit to the home position.

3.

Pull the ink cartridge clamp toward you and remove the ink cartridge.

CAUTION
When removing the ink cartridge, always install a new cartridge immediately after
removing the old one.
When the ink cartridge is replaced, the printer performs the ink cartridge replacement
operation automatically.
The exclusive cartridge is: Monochrome: 1020626
YMC:
1020627
Ink cartridges should never be kept longer than 6 months.
4.

Push the 2 hooks from the inside of ink cartridge holder with tweezers, and push down the
ink cartridge clamp (monochrome/color) to remove the clamps from ink cartridge holder.

5.

Remove the 3 CBB (M311) screws and 3 plain washers securing the ink cartridge holder to
the carriage base, and then lift the ink cartridge holder out of the carriage base sliding a little
toward left.
Ink Cartridge
Fixing Lever

Cartridge Holder

Figure 3-7. Ink Cartridge Clamp Removal

Note:

3-8

The head flexible flat cables (FFCs) are secured to the ink cartridge holder with adhesive
tape. Tear the cables off the ink cartridge holder before removing the ink cartridge
holder from the cartridge base.

REV.-A

Stylus Pro XL
6.

Disassembly and Assmbly

Remove the CBB (M311) screw (under the CR cap cover) and plain washer securing the
monochrome and color printheads to the carriage base.

Rubber Cap

CBB (M3x11)

Head Fixing Sczew

CBB (M3x11)

Figure 3-8. Ink Cartridge Holder Removal

7

Pull the black or color head toward you, and disconnect the head FFC cable on the head driver
board (nozzle selector). Then remove the black or color head.

Color Head

Black Head

Figure 3-9. Printhead Removal

REV.-A

3-9

Disassembly and Assembly

Stylus Pro XL

CAUTION
Take proper measures to protect the printhead unit from static electricity, because the
driver IC is directly attached to the printhead unit.
Never touch the printheads metallic nozzle cover surface. Handle it only by holding the
edges of the printhead.
When you replace the printhead or the printer mechanism, you must replace the block
resistor at location RM4 (for Micro Mode - Color (R-No.)), RM5 (for Normal Mode Color (M-No.)), RM11 (for Micro Mode - Monochrome (R-No.)), and RM12 (for Normal
Mode - Monochrome (M-No.)) on the C162 MAIN Board. (Every spare printhead or
spare printer mechanism comes
with a block resistor that is specifically selected for each printhead. (Refer to Table 3-2.)

Table 3-2. Insertion Location of the Block Resistors

Mode

Head

Indication No.

Location

Monochrome

M-

RM12

Color

M-

RM5

Monochrome

R-

RM11

Color

R-

RM4

Normal

Micro

3-10

REV.-A

Stylus Pro XL

Disassembly and Assmbly

REQUIRED ADJUSTMENT
When removing or changing the black head, the following adjustments are needed.
1. Black head angle adjustment (see Section 4.1.4).
2. Black - Color head vertical adjustment (see Section 4.1.5).
3. Head gap adjustment (see Section 4.1.3).
4. Bidirectional alignment adjustment (see Section 4.1.2).
When removing or changing the color head, the following adjustments are needed.
1. Color head angle adjustment (see Section 4.1.6).
2. Black - Color head vertical adjustment (see Section 4.1.5).
3. Head gap adjustment (see Section 4.1.3).
4. Bi-D alignment adjustment (see Section 4.1.2).
When removing or changing both heads, the following adjustments are needed.
1. Color head angle adjustment (see Section 4.1.6).
2. Black head angle adjustment (see Section 4.1.4).
3. Black - Color head vertical adjustment (see Section 4.1.5).
4. Head gap adjustment (see Section 4.1.3).
5. Bidirection alignment adjustment (see Section 4.1.2).

WARNING
When removing the color or black head, do not lose the spacer attached to each head.
This spacer modifies the angle error that occurs during manufacturing. Also, this spacer
is different from the linear spacer or angular spacer. (See Chapter 4.)

Spacer Setting Locations

Spacer

Head Nose

(For Black Head)

Figure 3-10. Head Spacer Position

REV.-A

3-11

Disassembly and Assembly

Stylus Pro XL

3.2.5.2 Carriage Unit Removal

1.

Remove the printer mechanism (see Section 3.2.4).

2.

Move the carriage to the left side of the printer while pressing the hook that fixes the carriage
to the home position.

3.

Remove the 2 CBN (O) (M3 6) screws securing the eject frame to both side frames.
CBS(O) (M3x6)

CBS(O) (M30x11)
Eject Frame

Figure 3-11. Front Frame Removal

4.

Remove the cartridge holder with ink cartridge from the carriage unit (see Section 3.2.5.1).

5.

Release the carriage timing belt from the belt pulley while pressing the pulley lever.

6.

Remove the grounding wire from the left side frame.

7.

Remove the 2 parallelism adjustment bushings from both side frames.

8.

Lift the carriage unit with the carriage guide shaft out of the printer mechanism.

Pulley Lever

Parallelism
Adjust Bushing

Grounding Wire
Parallelism
Adjust Bushing

Figure 3-12. Carriage Unit Removal

CAUTION
Take proper measures to protect the printhead unit from static electricity, because the
driver IC is directly attached to the printhead unit.
Never touch the printheads metallic nozzle cover surface. Handle it only by holding the
edges of the printhead.
When you replace the printhead or the printer mechanism, you must replace the block
resistor. (see Table 3-2).

ADJUSTMENT REQUIRED
Platen gap adjustment (see Chapter 4).
3-12

REV.-A

Disassembly and Assembly

Stylus Pro Service Manual

3.2.5.3 Pump Unit Removal

1.

Remove the printer mechanism. (See Section 3.2.4.)

2.

Remove the carriage unit. (See Section 3.2.5.2.)

3.

Remove the CBS (M36) screw securing the pump unit to the bottom frame.

4.

Push the pump unit outward while releasing the tab at the bottom side of the pump unit, and then lift
up the pump unit.

CBS (M3x6)

(2 )
(1 )

Bottom Frame

(2)
Pump Unit

Figure 3-14. Pump Unit Removal

3-12

Rev.A

Disassembly and Assembly

Stylus Pro XL

3.2.5.4 Cleaner Head Replacement

1.

Remove the printer mechanism (see Section 3.2.4).

2.

Use tweezers to unhook the cleaner head from the hook on the cleaning lever.

CAUTION
Keeping the cleaner head clean is extremely important to keep the ink injection system
working properly in the printhead, and it directly affects printing quality.
Therefore, handle the cleaner head very carefully, and observe the following precautions.
Never touch the cleaner head with your bare hands.
When attaching the cleaner head to the pump unit, wear gloves and use clean tweezers
to handle it.

Cleaner Head

Ho o k

Cleaner Lever

Figure 3-14. Cleaner Head Replacement

3-14

REV.-A

Stylus Pro XL

Disassembly and Assmbly

3.2.5.5 CR Motor Removal

1.

Remove the printer mechanism (see Section 3.2.4).

2.

Release the timing belt (see section 3.2.5.2).

3.

Remove the 3 screws securing the CR motor to the upper frame, and then remove the CR
motor.
Screws

CR Motor

Figure 3-15. CR Motor Removal

3.2.5.6 PF Motor Removal

1.

Remove the printer mechanism (see Section 3.2.4).

2.

Remove the 2 CBN (M36) screws and then remove the PF motor.

CBS (M3x6)
PF Motor

Figure 3-16. PF Motor Removal

REV.-A

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Stylus Pro Service Manual

Disassembly and Assembly

3.2.5.7 Carriage Home Position Sensor Removal

1.

Remove the printer mechanism. (See Section 3.2.4.)

2.

Disconnect the sensor cable from the carriage home position sensor.

3.

Unhook the 3 notches securing the carriage home position sensor to the upper frame. Then remove
the carriage home position sensor.

Se nsor Cable
Ca rriage Home
Position Sensor

Figure 3-18. Carriage Home Position Sensor Removal

3.2.5.8 PE Sensor Removal
1.

Remove the printer mechanism. (See Section 3.2.4.)

2.

Disconnect the connector for the PE sensor.

3.

Rotate the printer mechanism upside down; use tweezers to release the 2 hooks securing the PE sensor
to the paper feed roller assembly. Then remove the PE sensor.
Bo ttom Fra me

PE Sensor

Sensor Cable

Figure 3-19. PE Sensor Removal

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Stylus Pro XL

Disassembly and Assmbly

3.2.5.9 Paper Feed Roller Assembly Removal

1.

Remove the printer mechanism (see Section 3.2.4).

2.

Remove the carriage unit (see Section 3.2.5.2).

3.

Remove the pump unit (see Section 3.2.5.3).

4.

Remove the tension spring holding the tension roller assembly to the sub frame.

5.

Remove the tension wire on the left side frame holding the tension roller assembly to the left
side frame.

6.

Remove a CBB (M38) screw securing the tension roller assembly to the sub frame and remove
the tension roller assembly.

Tension
Wi re
Tension
Wi re

Tension Rol ler

Assembly

Eject Paper
Roller

C BB (M3x8)

Figure 3-19. Tension Roller Assembly Removal

7.

Release the 2 bushings securing the paper feed roller assembly to both the left side frame and
the sub frame. Then remove the paper feed roller assembly.

Paper Feed Roller

Figure 3-20. Paper Feed Roller Assembly Removal

REV.-A

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Disassembly and Assembly

Stylus Pro XL

3.2.5.10 Upper Frame Removal

1.

Remove the printer mechanism (see Section 3.2.4).

2.

Remove the carriage unit (see Section 3.2.5.2).

3.

Remove the E-ring securing the knob shaft to the sub frame; then remove the knob with the
knob shaft from the right side frame.

4.

Remove the 5 CBN (M35) screws securing the upper frame to both side frames or the sub
frame. Then remove the upper frame with 4 PF support rollers.

5.

Remove the upper frame with 4 PF support rollers.

Upper Frame

CBS (M3x5)

E-ring

CBS (M3x5)
Tension Spring

K no b

Figure 3-21. Upper Frame Removal

ASSEMBLY POINT
Assemble each straight end of torsion spring 6700s to attach to the center of the driven
roller support.
Base Frame

PF Support Roller

Tension Spring

Figure 3-22. Attaching the Torsion Spring

3-18

REV.-A

Chapter 4

Adjustments

Table of Contents
4.1 OVERVIEW
4-1
4.1.1 Destination Data Writing Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.1.2 Bi-D (Bidirectional Printing) Alignment Adjustment . . . . . . . . . . . . . . . . . . 4-3
4.1.3 Head Gap Adjustment (Black and Color Head) . . . . . . . . . . . . . . . . . . . . . 4-4
4.1.4 Black Head Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.1.5 Black-Color Head Vertical Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.1.6 Color Head Angle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.1.7 Platen Gap Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4.1.8 Internal Timer Reset Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

List of figures
Figure 4-1. Head Gap Adjustment Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Figure 4-2. B-Head Angle and Linear, Angular Spacer. . . . . . . . . . . . . . . . . . . . 4-5
Figure 4-3. Spacer Kinds & Relation of the Shape and Thickness . . . . . . . . . . . 4-5
Figure 4-4. Black Head Angle Adjustment Sample . . . . . . . . . . . . . . . . . . . . . . . 4-6
Figure 4-5. Spacer Slection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Figure 4-6. Removing the Rubber Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Figure 4-7. Spacer Angular Replacement Method . . . . . . . . . . . . . . . . . . . . . . . 4-8
Figure 4-8. Black-Color Head Vertical Adjust Conception . . . . . . . . . . . . . . . . . 4-9
Figure 4-9. Spacer Linear Selection Sample. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Figure 4-10. Removing the Rubber Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Figure 4-11. Spacer Linear replacement Method . . . . . . . . . . . . . . . . . . . . . . . 4-11
Figure 4-12. C-Head Angle and Spacer Angular Position. . . . . . . . . . . . . . . . . 4-12
Figure 4-13. Color Head Angle Confirmation Sample . . . . . . . . . . . . . . . . . . . . 4-12
Figure 4-14. Relationship of the Shape and Thickness . . . . . . . . . . . . . . . . . . 4-13
Figure 4-15. Spacer Select judgement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Figure 4-16. Removing the Rubber Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Figure 4-17. Spacer Angular Replacement Method (YMC) . . . . . . . . . . . . . . . 4-15
Figure 4-18. Adjusting the Paper Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Figure 4-19. Confirming the Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

List of Table
Table 4-1. Required Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Table 4-2. Gap and Adjustment Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

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Stylus Pro XL

Adjustments

4.1 OVERVIEW
This section describes adjustments required when the printer is disassembled and assembled after
repair. Since this printer has both a black and color head, it needs new adjustments not required for
previous printers. Refer to the following table to perform the appropriate adjustments.

WARNING
Always perform the adjustments in the order indicated.
After performing steps 1-5, perform a cleaning operation for the black and color
printheads. the cleaning operation is needed because printing sample patterns for the
head angle, Bi-D alignment, and the head gap increases the viscosity of the ink, and the
printer will not print the correct value. For instance if you replace the black head, you
must do the following adjustments in the order shown:
(1) Black head angle, (2) black-color head vertical, (3) head gap, (4) Bi-D alignment.
After removing an ink cartridge, always install a new cartridge immediately. During
adjustments and testing, use cartridges designed exclusively for service
(Monochrome: 1020626, CMY: 1020627).

Table 4-1. Required Adjustments

Service Performed

Adjustment Needed

When replacing the

M-4A60 printer mechanism

1. Bi-D alignment adjustment (see Section 4.1.2).

2. Head gap adjustment (see Section 4.1.3).
3. Internal timer reset operation (see Section 4.1.8).

When replacing or
disassembling the
C162 MAIN board or
printer mechanism

1. Destination data writing operation (see Section 4.1.1).

2. Bi-D alignment adjustment (see Section 4.1.2).
3. Head gap adjustment (see Section 4.1.3).

When replacing or
disassembling the
black head (board)

1. Black head angle adjustment (see Section 4.1.4).

2. Black - Color head vertical adjustment (see Section 4.1.5).
3. Head gap adjustment (see Section 4.1.3).
4. Bi-D alignment adjustment (see Section 4.1.2).

When replacing or
disassembling
the color head (board)

1. Color head angle adjustment (see Section 4.1.6).

2. Black - Color head vertical adjustment (see Section 4.1.5).
3. Head gap adjustment (see Section 4.1.3).
4. Bi-D alignment adjustment (see Section 4.1.2).

When replacing or
disassembling both the
color and black head

1. Color head angle adjustment (see Section 4.1.6).

2. Black head angle adjustment (see Section 4.1.4).
3. Black - Color head vertical adjustment (see Section 4.1.5).
4. Head gap adjustment (see Section 4.1.3).
5. Bi-D alignment adjustment (see Section 4.1.2).

When replacing or
disassembling
the carriage unit

1. Platen gap adjustment (see Section 4.1.7).

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Adjustments

Stylus Pro XL

4.1.1 Destination Data Writing Operation

The setup value that specifies the printer destination is stored in the EEPROM on the C162 MAIN
board. Therefore, this setup value must be written into the EEPROM when the MAIN board or
EEPROM chip is replaced.

CAUTION
Before writing the destination data writing, set the interface to parallel.
1.

Connect the PC to the target printer using a parallel interface cable and turn the printer on.

2.

Execute BASIC on the PC, and run the program VERxxx.BAS. You see the following menu.

1. Destination Setting
2. Head Angle Confirmation Pattern Printing
(Black Head Spacer Selection)
3. Head Vertical Position Confirmation
4. Head Gap Adjustment
5. Bi-D Adjustment
6. Internal Timer Reset
7. END

3.

When the main menu appears, choose Destination Setting by typing 1 and Enter.

4.

The main menu immediately disappears briefly and then reappears. (At this time, specific
destination parameters, including the destination, interface mode, TOF value, and
economy/condensed, are automatically written to the EEPROM.)

5.

Choose END by typing 7 and ENTER. The next message appears on the display.

All parameters that you have specified so far

are written to EEPROM upon power off.
Turn the printer OFF, Now!

6.

4-2

Turn off the printer.

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Stylus Pro XL

Adjustments

4.1.2 Bi-D (Bidirectional Printing) Alignment Adjustment

The bidirectional alignment is required when the printer mechanism, main board, or printhead
(board) is replaced. Performing this adjustment determines a compensation value to rectify any
deviation in the print position. This deviation could be caused by the different print speeds, which
are due to tolerances in the mechanical components, or to differences in print timing between
odd-numbered lines and even-numbered lines in bidirectional printing. The printer stores the
compensation data in the EEPROM on the C162 MAIN board and refers to this data when
performing bidirectional printing.
1.

Connect the PC to the target printer, and turn the printer on.

2.

Execute BASIC on the PC and run the program VERxxx.BAS.

1. Destination Setting
2. Head Angle Confirmation Pattern Printing
(Black Head Spacer Selection)
3. Head Vertical Position Confirmation
4. Head Gap Adjustment
5. Bi-D Adjustment
6. Internal Timer Reset
7. END

3.

When the main menu appears, choose Bi-D Adjustment by typing 5 and ENTER. (The printer
prints a check pattern with a sample compensation value.)

4.

The next menu appears on the display.

Input Bi-D value No. (-30= No. =30,If O.K, input [Y] key.)? _

5.

If the sample print is not vertically aligned for both the odd-numbered and even-numbered
lines, enter a compensation value in the range from 30 to +30.
Positive compensation value:
Shifts the 2nd line to the left
Negative compensation value: Shifts the 2nd line to the right
When the sample print becomes vertically aligned for both lines, press Y and ENTER; this
returns you to the main menu.

6.

Choose END by typing 7 and ENTER. The next message appears on the display.

All parameters that you have specified so far

are written to EEPROM upon power off.
Turn the printer OFF, Now!

7.

Turn off the printer.

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Adjustments

Stylus Pro XL

4.1.3 Head Gap Adjustment (Black and Color Head)

The head gap adjustment is required when the printer mechanism, main board, or printhead
(board) is replaced or diassembled. This adjustment calibrates the head drive timing between the
black and color head. If this adjustment is not made, the vertical alignment will not be completed.
1.

Connect the PC to the target printer, and turn the printer on.

2.

Execute BASIC on the PC and run the program VERxxx.BAS.

1. Destination Setting
2. Head Angle Confirmation Pattern Printing
(Black Head Spacer Selection)
3. Head Vertical Position Confirmation
4. Head Gap Adjustment
5. Bi-D Adjustment
6. Internal Timer Reset
7. END

3.

When the main menu appears, choose Head Gap Adjustment by typing 4 and ENTER. (The
printer prints a check pattern with a sample compensation value.)

4.

The printer prints a sample like the one shown in Figure 4-1.

5.

If the sample print is not vertically aligned for both odd-numbered lines (black lines) and
even-numbered lines (magenta lines), enter a compensation value in the range from 16 to
+16.
Positive compensation value:
Shifts the 2nd line to the left
Negative compensation value: Shifts the 2nd line to the right
When both the black and magenta lines are vertically aligned, press Y and ENTER; this returns
you to the main menu.

6.

Choose END by typing 7 and ENTER. The next message appears on the display.

All parameters that you have specified so far

are written to EEPROM upon power off.
Turn the printer OFF, Now!

7.

Turn off the printer.

Black Line
Head Gap Adjustment No. 0

Color (Magenta) Line

Figure 4-1. Head Gap Adjustment Sample

4-4

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Stylus Pro XL

Adjustments

4.1.4 Black Head Angle Adjustment

The black head angle adjustment is required when the black head is replaced or disassembled. If
this adjustment is not correct, a white banding problem may occur, or the color head timing may
not match the black head timing. The following figure illustrates the black head angle adjustment.
The black head angle is adjusted with linear and angular spacers. A linear spacer is attached to both
sides of the head base, and an angular spacer is attached only to the right side of the head base.
Spacers for the black head come in different shapes for the thickness needed. The following figure
shows the relationship between the shape and thickness.
Black Head
Black Head
(Reverse Side)

Head Base
Angular Spacer
Carriage

Linear Spacer
(Spacer Setting Position)

(Angle Adjustment Concept)

Figure 4-2. Black Head Angular and Linear Spacers

Angular Spacers (For Black Head)

Linear Spacers (Only Use for Black Head)

Spacer Name

Thickness

angular spacer BK

0.05

linear spacer K

0.05

angular spacer BK:B

0.10

linear spacer J

0.12

angular spacer BK:C

0.15

linear spacer I

0.19

angular spacer BK:D

0.20

linear spacer

0.26

angular spacer BK:E

0.25

linear spacer B

0.33

linear spacer C

0.40

linear spacer D

0.47

linear spacer E

0.54

linear spacer F

0.61

linear spacer G

0.68

linear spacer H

0.75

Shape

Spacer Name

Thickness

Shape

Figure 4-3. Types of Spacers and Relationship between

Shape and Thickness
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4-5

Adjustments

Stylus Pro XL

1.

Connect the PC to the target printer, and turn the printer on.

2.

Execute BASIC on the PC and run the program VERxxx.BAS.

1. Destination Setting
2. Head Angle Confirmation Pattern Printing
(Black Head Spacer Selection)
3. Head Vertical Position Confirmation
4. Head Gap Adjustment
5. Bi-D Adjustment
6. Internal Timer Reset
7. END

3.

When the main menu appears, choose Head Angle Confirmation Pattern Printing by typing
2 and ENTER. (The printer prints the check pattern, along with the sample name. )

WARNING
When replacing both the black and color heads, always adjust the color head angle first.
The black head angle is based on the color head angle.
After you replace the black head and print the black head angle pattern, you only have
to insert an angular spacer if the pattern is incorrect.
4.

The printer prints a pattern like one in the following sample. Only the nozzles in rows A and
D are fired (making it is easy to see the angle of the black head).

Black Head Angle Adjustment

Figure 4-4. Black Head Angle Adjustment Sample

5.

In the figure above, pay attention to position A. (Do not look at position B.)

6.

Using the following flowchart, replace the angular spacer for the black head, which is under
the right linear spacer. The procedure for this replacement is explained beginning with step 7.

Check position A.
Position A

Replace the right

angular spacer with
a thinner one.

Position A

Replace the right

angular spacer with
a thicker one.

Figure 4-5. Spacer Selection

4-6

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Stylus Pro XL

Adjustments

7.

Turn the printer power off now.

8.

Manually move the carriage to the center while pressing the carriage lock lever, and remove
the two ink cartridges.

9.

Remove the rubber cap covering the head screw at the side of color ink cartridge. Then loosen
(but do not remove) 3 screws. (Refer to Figure 4-6.)

Carriage Unit
Black Head
1: Push

Head Base

Angular Spacer

Platen Gap
Adjust Lever

2: Replace
Linear Spacer
(Angular Spacer
Replacement Position)

Figure 4-6. Removing the Rubber Cap

WARNING
After replacing the spacer, always install new ink cartridges before returning the printer to
the user. During this adjustment, use ink cartridges exclusively for service (Monochrome:
1020626, CMY: 1020627). You can reuse old ink cartridges for other purposes.
10. Replace the angular spacer for the black head with a new one, referring Figure 4-7.
(Replace the angular spacer by using tweezers to push the head base toward the rear.)

Rev. A

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Stylus Pro XL

11. After replacing the angular spacer, reassemble the ink cartridge holder and reinstall the ink
cartridges. Use the BASIC program to verify the angle of the black head. Confirm the angle by
performing the steps 1 to 6 again, and if the angle is wrong, perform the adjustment again
until the head angle is correct.

WARNING
The angular spacer comes in five thicknesses. Continue performing this adjustment, by
changing the black head angle is correct.
When inserting an angular spacer, always place the angular spacer on the linear spacer.

Carriage Unit
Black Head
1: Push

Head Base

Angular Spacer

Platen Gap
Adjust Lever

2: Replace
Linear Spacer
(Angular Spacer
Replacement Position)

Figure 4-7. Angular Spacer Replacement Method

4-8

Rev. A

Stylus Pro XL

Adjustments

4.1.5 Black - Color Head Vertical Adjustment

This adjustment calibrates the vertical position between the black head and the color head. Align
the top nozzles (both nozzle #1 on the black head and nozzle #1 on the color head). You can make
this adjustment by using only the linear spacers for the black head. This adjustment is required
when the black head or the color head is replaced or disassembled. The following figure illustrates
this adjustment.
Adjust
Carriage Unit
Blac k Head

Colo r Head

#2

#1

#3
#7

#2

#16
Ma g en ta C y a n Yellow

#1
#6

#4
#8

Vertical Position

#5

#9

Vertical Position

#63 #62

#61
#64

Figure 4-8. Black-Color Head Vertical Adjustment Concept

1.

Connect the PC to the target printer, and turn the printer on.

2.

Execute BASIC on the PC and run the program VERxxx.BAS.

1. Destination Setting
2. Head Angle Confirmation Pattern Printing
(Black Head Spacer Selection)
3. Head Vertical Position Confirmation
4. Head Gap Adjustment
5. Bi-D Adjustment
6. Internal Timer Reset
7. END

3.

When the main menu appears, choose Head Vertical Position Confirmation by typing 3 and
ENTER. (The printer prints the check pattern, along with the sample name.)

WARNING
When replacing the black head, always adjust the black head angle first, because the blackcolor head vertical adjustment is based upon the black head angle.

2-3 BLA CK HE AD S PA CER S ELE CTION

Magenta

-5

-4

-3

-2

-1

+1

+2

+3

+4

+5

OK (0)

Black

Figure 4-9. Linear Spacer Selection Sample

Rev. A

4-9

Adjustments
4.

Stylus Pro XL

In Figure 4-10, the vertical position is correct when both the magenta line and the black line
are aligned (as shown in position OK (0)). If the vertical position is correct, turn off the
printer. If the black and magenta lines are not aligned, perform the vertical adjustment as
described in steps 5-10.

WARNING
The number shown in the sample indicates the thickness level compared to the current
linear spacer. (See * .) There are 11 linear spacers with 11 different thicknesses.
The linear spacer is attached by two pieces, one on each side of the head base. Therefore,
when you need to replace one linear spacer, always replace both linear spacers at the
same time.
When replacing the linear spacer, place it under the angular spacer.
*

If necessary, replace the linear spacer. For instance, if your pattern is similar to the pattern
shown under 2, replace the linear spacer with a thinner linear spacer. If your pattern is similar
to the pattern shown under 2, replace the linear spacer with a thicker spacer.

5.

Turn the printer off.

6.

Move the carriage to the center while pressing the carriage lock lever, and remove the two ink
cartridges.

Rubber Cap

Screw 1

Screw 2

Screw 3

Figure 4-10. Removing the Rubber Cap

7.

Remove the rubber cap that covering a head screw at the side of color ink cartridge and then
loosen (but do not remove) 3 screws. (Refer to the figure below.)

WARNING
After replacing the spacer, always install new ink cartridges before returning the printer to
the user. During adjustment, use the ink cartridges exclusively for service (Monochrome:
1020626, CMY: 1020627). You can reuse the old ink cartridges for other purposes.

4-10

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Stylus Pro XL
8.

Adjustments

Change the linear spacers (2 spacers for the monochrome head only) with new ones, referring
the figure below. (Replace linear spacers using tweezers to push the head base toward the
rear.)

Carriage Unit
Black Head

1: Push

He ad B ase

Angu lar Spacer

Platen Gap
Adjust Lever

Linear Spacer x 2

2: Replace

(Linear Spacer
Rep lacement Position)

Figure 4-11. Linear Spacer Replacement Method

9.

Rerun the BASIC program, and choose the Head Vertical Position Confirmation by typing 3
and ENTER; then confirm that the sample print is correct. If the sample is incorrect, change the
thickness of the linear spacer and perform this adjustment again until the two black and
magenta lines are aligned at the position OK (0).

10. When you complete this adjustment, exit the BASIC program and turn off the printer.

Rev. A

4-11

4.1.6 Color Head Angle Adjustment

The color head angle adjustment is required when the color head is replaced or disassembled.
If this adjustment is not correct, a white banding problem may occur, or the black head timing may
not match the color head timing. The following figure illustrates the color head angle adjustment.
The color head angle is adjusted by the angular spacer. The angular spacer is attached only to the
left side of the head base.

1.

Connect the PC to the target printer, and turn the printer on.

2.

Execute BASIC on the PC and run the program VERxxx.BAS.

1. Destination Setting
2. Head Angle Confirmation Pattern Printing
(Black Head Spacer Selection)
3. Head Vertical Position Confirmation
4. Head Gap Adjustment
5. Bi-D Adjustment
6. Internal Timer Reset
7. END

3.

When the main menu appears, choose Head Angle Confirmation Pattern Printing by typing
2 and ENTER. (The printer prints the check pattern with the sample name.)

WARNING
When replacing both the black head and color head, always adjust the color head angle
first. The black head angle and the black-color head vertical position adjustments are based
on the color head angle adjustment.

Stylus Pro XL

Adjustments

Angular spacers for the color head come in five thicknesses, each having its own shape. The
following figure shows the relationship between the shape and thickness. Since the color head is
not equipped with a linear spacer, the angle adjustment is decided only by the angular spacer
(specifically designed for the color head), which is placed under the left side of the head base.

Angular Spacer (for Color Head)

Spacer Name

Thickness

angular spacer YMC

0.30

angular spacer YMC-B

0.35

angular spacer YMC-C

0.40

angular spacer YMC-D

0.45

angular spacer YMC-E

0.50

Shape

Figure 4-14. Relationship between the Shape and Thickness

4.

In Figure 4-13, pay attention to the position of A and B while you reset the left angular spacer.
The replacement procedure is explained beginning in step 5.

Magenta

Magenta
Cy an

Position A, B

(A)

Cy an

Che c k
positions A, B

(B)

Position A, B

(A)

Replace the right

angular spacer
with a thicker one.

(B)

Replace the right

angular spacer
with a thinner one

Figure 4-15. Spacer Selection

5.

Turn off the printer now.

6.

Move the carriage to the center manually, and loosen (but do not remove) the screw securing
the color head to the carriage.

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Stylus Pro XL

7.

Ru bber Cap

Screw 1

Screw 2
Screw 3

Figure 4-16. Removing the Rubber Cap

Remove the rubber cap covering the head screw at one side of color ink cartridge. Then loosen
(but do not remove) 3 screws. (Refer to the figure below.)
8.

Replace the angular spacer on the left side with a new one, referring the figure below. (Replace
the angular spacer using tweezers to push the head base toward the rear.)

4-14

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Stylus Pro XL
9.

Adjustments

Rerun the BASIC program and choose Head Angle Confirmation Pattern again by typing 2
and ENTER. Then verify that the confirmation sample is correct.

Carriage Unit

Color Head

1: Push

Head Base

Platen Gap Adjust Lever

Angular Spacer
(one side only)

2: Replace

Figure 4-17. YMC Angular Spacer Replacement

10. If the sample is incorrect, repeat steps 5-9 until the upper lines in the sample are aligned with
one another and the lower lines in the sample are exactly equidistant to one another (as shown
at B in Figure 4-15).
11. When you complete this adjustment, turn off the printer.

Rev. A

4-15

Adjustments

Stylus Pro XL

4.1.7 Platen Gap Adjustment

This adjustment is required when the carriage unit is replaced or removed from the printer
mechanism. Adjust the distance between the printhead nose and the paper surface to 1.1 mm.
1.

Attach a thickness gauge (commercially available) to the left side adjustment position on the
paper guide plate, as shown in the figure below, so that one side hooks the paper feed pinch
roller unit.

2.

Move the carriage unit manually onto the thickness gauge.

Table 4-2. Gap and Adjustment Direction

Gap between Head Nose and Gauge Surface

Left Bushing

Right Bushing

Narrow

CW

CCW

Spread

CCW

CW

3.

Rotate the parallelism adjustment bushing, attached to the left and right ends of the carriage
guide shaft, when the black and color printheads contact the thickness gauge.

4.

After attaching the printheads to the gauge surface, verify that the gap between the carriage
roller and the front frame is less than 0.04 mm. (See Figure 4-16.)

5.

Attach the 1.1 mm thickness gauge to the right side adjustment position on the paper guide
plate, as shown below, so that one side hooks the paper feed pinch roller unit.

Note:

When checking the gap between the carriage roller and the front frame, use the thickness
gauge or the paper guide plate. If the gap is correct the gauge cannot be installed into the
gap. If the gap is incorrect, the gauge can be inserted in the gap.
Attach the thickness gauge
under the PF pinch roller unit.
Left Adjustment Position

Bushing
Paper Guide Plate
Right Adjustment Position

Pump Unit

Eject Frame

Thickness Gauge

Front Frame

Thickness Gauge
PF Pinch Roller
Unit

Attachment Point

Front
Tension Roller
Thickness Gauge
Paper Guide
Platen

Figure 4-18. Adjusting the Platen Gap

4-16

Rev. A

Stylus Pro XL
6.

Adjustments

Move the carriage manually to the right adjustment position and repeat steps 3 and 4,
referring to Figures 4-18 and 4-19.
Carriage Roller

Gap

0.04 mm
Thickness
Gauge

Eject Frame

Figure 4-19. Confirming the Gap

4.1.8 Internal Timer Reset Operation

This operation is required when the M-4A60 printer mechanism is replaced. There are 6 timers in
this printer:
1.
2.
3.
4.
5.
6.

Refresh timer
Timer (monochrome and CMY)
Flushing level decision timer
False absorbing timer
Total print timer
PAUSE timer

When the printer mechanism is replaced, reset the timers as described here:
1.

Connect the PC to the target printer, and turn on the printer.

2.

Execute BASIC on the PC and run the VERxxx.BAS program.

1. Destination Setting
2. Head Angle Confirmation Pattern Printing
(Black Head Spacer Selection)
3. Head Vertical Position Confirmation
4. Head Gap Adjustment
5. Bi-D Adjustment
6. Internal Timer Reset
7. END

3.

When the main menu appears, choose Internal timer reset by typing 6 and ENTER. This
resets the internal timer. The following message then appears.
All parameters of the internal timer
are now reset. Press Y and ENTER
to return to the main menu.

4.

Press Y and ENTER.

5.

Press 7 and ENTER.

6.

Turn off the printer.

Rev. A

4-17

Chapter 5 Troubleshooting
Table of Contents
5.1 OVERVIEW

5-1

5.2 UNIT LEVEL TROUBLESHOOTING

5.2.1 Printer Does Not Operate at Power on . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2 Error is Detected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.3 Failure Occurs During Printing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.4 Printer Does Not Feed the Paper Correctly . . . . . . . . . . . . . . . . . . . . . .
5.2.5 Control Panel Operation is Abnormal . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3
5-4
5-5
5-6
5-7
5-8

5.3 UNIT REPAIR - C137 PSB/PSE BOARD

5-9

5.4 UNIT REPAIR - C164 MAIN BOARD

5-10

5.5 UNIT REPAIR - PRINTER MECHANISM (M-4A11)

5-12

LIST OF FIGURES
Figure 5-1. Troubleshooting Process Flowchart. . . . . . . . . . . . . . . . . . . . . . . 5-1

LIST OF TABLES
Table 5-1. Motor Coil Resistance Test Points. . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Table 5-2. Sensor Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Table 5-3. Sensor Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Table 5-4. Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Table 5-5. Symptoms and Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Table 5-6. Repair of the C137 PSB/PSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Table 5-7. Repair of the C164 MAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Table 5-8. Repair of the Printer Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Rev.-A

5-i

Stylus Pro XL

Troubleshooting

5.1 OVERVIEW
The printer may exhibit different symptoms for the same problem, which makes troubleshooting
more difficult. However, this section provides simple and effective ways to facilitate
troubleshooting. The following flowchart illustrates the main steps of the troubleshooting process.
STAR T

UNIT LEVEL TROUBLESHOOTING

UNIT REPAIR
[C137 PSB/PSE BOARD]

UNIT REPAIR
[C162 MAIN BOARD]

UNIT REPAIR
[M -4A60 MECHANISM]

ASSEM BLY
AND
ADJUSTMENT

END

Figure 5-1. Troubleshooting Process Flowchart

Table 5-1. Motor Resistances
Motor

Resistance Range

Temperature

CR Motor
PF Motor

10.0 10%
11.5 10%

At 25 C (77 F)
At 25 C (77 F)

Table 5-2. Sensor Status

Sensor
PE Sensor

Rev. -A

Point

Signal Level

Status

CN8
Pin 1 (PE) to Pin 2
(GND)

H (5 V)

Paper exists

L (GND)

No paper (paper end)

CN11
Pin 8 (BCO) to
Pin 7 (GND)

L (GND)

Black cartridge exists

BCO Sensor

H (5 V)

No black cartridge

CN12
Pin 8 (CCO) to
Pin 7 (GND)

L (GND)

Color cartridge exists

CCO Sensor

H (5 V)

No color cartidge

CN9
Pin 3 (HPV) to
Pin 2 (GND)

At home position (HP)

HP Sensor

Out of HP

TH Sensor

CN10
Pin 10 (SW0-5) to
Pin 1 (GND)

Analog data

Change the pulse width of

the charge pulse for the
common driver circuit

5-1

Troubleshooting

Stylus Pro XL

Table 5-3. Error Codes

LED
Error
Status

Data

Paper out

Paper No Ink
Economy Condensed Pause
Out Cartridge

On

No ink
cartridge

On

Paper jam

Carriage
error

5-2

On

Load paper in the

tray, press Load/
Eject, and then the
Pause button.

On

Install the new ink

cartridge and press
the Pause button.
Load paper and
press Pause and
Load/Eject buttons.

Blinks

Maintenance
Blinks Blinks
request

Blinks

Recovery

Blinks

Blinks

Blinks

Blinks

Service maintenance
request. (Change the
waste ink drain tank
and reset the counter.)

Blinks

Turn off the printer

and turn it on again.

Rev. -A

Stylus Pro XL

Troubleshooting

5.2 UNIT LEVEL TROUBLESHOOTING

When a problem occurs, you can identify the defective unit based on the symptoms exhibited. The
table below lists the symptoms of certain problems. Once the problem is identified, refer to the
flowchart that corresponds to the problem.

Table 5-4. Symptom and Problem

Symptom

Problem

Flowchart No.

Printer does not operate at power on

LEDs do not light up.

Printer mechanism does not operate.

5.2.1

Error is detected

Error is indicated by LED indication.

5.2.2

Failure occurs during printing

Printing is not performed.

Abnormal printing (missing dots, etc.)
Print quality is poor

5.2.3

Printer does not feed the paper

correctly

No paper is fed.
Paper feed is irregular.
Paper jam occurs.

5.2.4

Control panel operation is abnormal

No response to button access.

5.2.5

Rev. -A

5-3

Troubleshooting

Stylus Pro XL

5.2.1 Printer does not operate at power on.

START

Is the AC
input voltage
correct?

NO

Use the correct

input voltage.

YE S

Has fuse
(F1) on the C137
PSB/PSE
blown ?

YE S

R epl ace the fuse

and di s connec t
C N 5 on t he C 162
MAIN b oard.
NO

NO

YE S

Check the output

voltage of the C137
PSB/PSE at CN2.

Is the output
voltage correct?

NO

YE S

Replace the
C137 PSB/PSE
boar d

R epl ac e the C 1 62
MAIN b oard.

Is the probl em
corre cted
YE S

Does the
fuse blow again
at power on?

NO
Check motors and drivers.
Refer to the section describing
repair of the printer mechanism.

END

5-4

Rev. -A

Stylus Pro XL

Troubleshooting

5.2.2 Error is detected.

START

Identify the type

of error indicated.
(See Table 5-3.)

Carriage err or

YES

Turn the printer

off and try to
move the carriage
manu ally.
Does the
carriage move
smoothly?

NO

No ink cartriage

YES

Replace the ink

cartridge with a
new o ne.

YES

NO

Waste ink drain

tank overflow

YES

NO

Check CR motor
and drivers. If they
are OK, replace the
C162 M AIN board.

Does error
occur again?

NO
Replace the waste
ink absorbing
material, and reset
the protect counter.
(See Chapter 6.)

YES

NO

Refer to the section

describing repair of
the printer mechanism.

Check ink cartridge

sensor and, if bad,
replace.

END

Rev. -A

Is the
problem
corrected?

END

5-5

Troubleshooting

Stylus Pro XL

5.2.3 Failure occurs during printing.

START

Run the
self-test .

Does the selftest print?

NO

YES

Is print
quality bad?

Are all cables

connected to the C162
MAIN board firmly?
NO

Perform the color or

black head cleaning.

Is the problem
corrected?

YES

NO
Connect the cables
correctly.

Adjust the
bidirectional
print alignment or
readjust the head
arrangement
adjustment .
(See Chapter 4.)

YES

YES

YES

Is the problem
corrected?

NO

NO

Check all motors,

drivers, and printhead
for shorts. If they are
OK, replace the C162
MAIN board.

See the section

describing repair of
the printer mechanism.

Is the problem
corrected?
NO
YES

END

Replace the C162

MAIN board.

END

5-6

Rev. -A

Stylus Pro XL

Troubleshooting

5.2.4 Printer does not feed the paper correctly.

START

Is paper loaded
in the sheet feeder
correctly?

NO

Load the paper

correctly.

YES

Does a
paper jam
occur?

YES

NO

Verify that the

paper path is clear.
Also confirm that
there are no foreign
objects that may
interfere with paper
movement.
Is the problem
corrected?

Check the PF motor

and driver. If OK,
replace the C162
MAIN board.

Is the problem
corrected?

YES

NO

NO

Perform the PF
roller cleaning with
the cleaning sheet.

YES
YES

Is the problem
corrected?
NO

END

Rev. -A

See the section

describing
repair of the
printer mechanism.

END

5-7

Troubleshooting

Stylus Pro XL

5.2.5 Control panel operation is abnormal.

START

Is the control
panel connected
properly?

NO

Connect the control

panel correctly.

YES

Is the problem
corrected?

YES

NO

Replace the
control panel.

Is the problem
corrected?
YES

END

NO

Replace the C162

MAIN board.

END

5-8

Rev. -A

Stylus Pro XL

Troubleshooting

5.3 UNIT REPAIR - C137 PSB/PSE BOARD

This section describes problems related to the power supply board (C137 PSB/PSE). The table
below provides various symptoms, likely causes, and checkpoints. The checkpoints refer to
waveforms, resistances, and other values to check to evaluate the operation of each component.

Table 5-5. Repair of the C137 PSB/PSE

Symptom

Condition

Cause

Checkpoint

Solution

Transformer coilsCheck the transformer coils using a

Replace T1.
are open.
multimeter.
Check the waveform at the drain
of Q1.
+35 V line is
dead.

+35 V line is
abnormal.

Switching FET
(Q1).

ZD52, Q83, or
PC1 is dead.
+35 V line is dead.

The printer
does not
operate at all.

Replace Q1.

Check the voltage level of the

collector side. The correct
voltage is as follows:
Power Switch Off = +1.8 VDC
Power Switch On = 0 VDC

Replace
ZD52, Q82,
or PC1.

Check the +35 V line.

Check the oscillation waveform
and switching waveform of IC51.

+5 V line is
dead.
IC51 is dead.

Oscillation waveform (IC51, pin 5)

Replace
IC51.

Switching waveform (IC51, pin 8)

Auto capping
operation is
invalid.

Rev. -A

+35 V line is
invalid when
power is off.

IC81 is dead.

Turn off the printer and check the

Replace
voltage at pin 1 of IC81.
IC81.
Normal voltage = 0 VDC

C82 is dead or
R88 is short.

Turn off the printer and check the

voltage at plus side of C82.
Replace
Normal voltage = 2.5 VDC
C82 or R88.
R88 resistance = 100 ohms

5-9

Troubleshooting

Stylus Pro XL

5.4 UNIT REPAIR - C162 MAIN BOARD

This section describes the problems related to the main controller board (C162 MAIN). The table
below provides various symptoms, likely causes, and checkpoints. The checkpoints refer to
waveforms, resistance, and other values to be checked to evaluate the operation of each component

Table 5-6. Repair of the C162 MAIN

Symptom

Condition

Cause

Checkpoint

Solution

Check the waveform of the +5 V

line and that of the RESET signal.

The
printer
does not
operate at
all.

The CPU
does not
operate.
(Drive
system does
not operate
normally
when you
turn the
printer on or
off.)

The reset circuit

does not operate.

Replace IC13
or IC8.

Check pin 2 of IC3 for a change

in the signal HIGH/LOW.

Selection of
control ROM is
abnormal.

Replace IC1.

Either CG or
RAM is defective.

Replace CG
or RAM.
Check the oscillator signal at
either pin 75 or 74 of the CPU.
If signal is
detected,
replace CPU.
Otherwise
replace CR1.

CPU is defective.

Check the serial signal output

from pin 25 or 27 of IC2 to
the driver IC15.
The
carriage
does not
operate
normally.

5-10

The carriage
motor does
not operate
at all.

IC2 is defective.

Replace IC2.

CPU is defective.

Replace CPU.

Rev. -A

Stylus Pro XL

Troubleshooting

Table 5-6. Repair of the C162 MAIN (Cont.)

Symptom

Condition

Cause

Checkpoint

Solution

Check the output signal at pins 1,

8 or at 11, 18 of IC15.

Carriage
does not
operate
normally.

The carriage
does not
IC15 is defective.
operate at all.

Replace IC15.

Check the output signal at pin 13

or 14 and pin 15 or 16 of IC2.

Self-test
printing is
abnormal.

Self-test is
not executed.

IC2 is defective.

Replace IC2.

Printhead unit is
defective.

Replace
printhead unit.
Check the serial signals output
from pins 39 or 40 of IC2 to the
driver IC14.

Replace IC2.

IC2 is defective.

Paper
feed does
not
operate
normally.

The paper
feed motor
does not
rotate.

Check the output signal at pin 1,

8 or 11, 18 of IC14.

IC14 is defective.

Rev. -A

Replace IC14.

5-11

Troubleshooting

Stylus Pro XL

5.5 UNIT REPAIR - PRINTER MECHANISM (M-4A60)

Any problems related to the printer mechanism should be repaired according to the
troubleshooting procedures in Table 5-7.

Table 5-7. Repair of the Printer Mechanism

Symptom

The pump
mechanism
does not
operate.

Ink is not
absorbed or
is poorly
absorbed.

The carriage
motor does
not rotate.

The carriage
does not
operate
normally at
power on
(after the
carriage has
been
manually
centered
prior to
power on).

5-12

Condition

The PF motor
fails to rotate at
power on.

Used ink does

not go through
the used ink
tube during the
cleaning
operation.

The carriage
motor fails to
rotate at power
on.

The carriage
motor rotates,
but the carriage
does not move.

The carriage
moves slightly
and then stops.

Cause

Checkpoint

Solution

Foreign
substances are
lodged in the
mechanism gears.

Manually drive the gear

Remove any
train connected to the
foreign
pump mechanism to check
substance.
if the motor rotates.

The PF motor is
defective.

Check the coil resistance

of the motor.

Replace the
PF motor.

The tube is not

properly
connected to the
cap.

Check that the tube is

properly connected to the
cap.

Insert the tube

properly.

The ink tube is

damaged.

Check the ink tube visually.

Replace the
tube.

The cap is
defective.

Check for any defective

part.

Replace the
head cap.

The pump is
defective.

Replace the pump to see if

Replace the
this causes the ink to be
pump unit.
absorbed normally.

The printhead is
defective.

Replace the printhead to

see if this causes the ink
to be absorbed normally.

Replace the
printhead.

Foreign
Manually drive the timing
substances are
belt to see if the carriage
lodged in the gear
motor rotates.
of the mechanism.

Remove any
foreign
substances.

The carriage
motor is defective.

Measure the coil

Replace the
resistance of the CR motor. carriage motor.

The pulley is
defective.

Check for broken or worn

pulley.

Replace the
driven pulley.

Check that the timing belt

is properly inserted into
the bottom of the carriage.

Reinsert the
timing belt.

Check the timing belt for

any damage.

Replace the
timing belt.

Check whether the

carriage moves smoothly
when moved manually.

Clean and
lubricate the
carriage.

Check tension of the

timing belt.

Adjust tension
of the timing
belt.

The timing belt is

defective.

Carriage
movement is not
smooth.

Rev. -A

Stylus Pro Service Manual

Troubleshooting

Table 5-8. Repair of the Printer Mechanism (Continued)

Symptom

Printing is
not
performed.

Condition

Paper is not
fed normally.

Rev.A

Checkpoint

Solution

The head cable is

disconnected.

Check whether the head

cable is disconnected.

Reconnect the
head cable.

The head cable is

defective.

Replace the head cable to

see if operation is normal.

Replace the
head cable.

The printhead is
defective.

Replace the printhead to

see if the printhead
operates normally.

Replace the
printhead.

Ink absorption is
poor.

See Ink is not absorbed

on the previous page.

Printhead surface
is not clean.

Perform the cleaning

operation.

Clean.

The head cable is

disconnected.

Check whether the head

cable is disconnected.

Reconnect the
head cable.

The head cable is

defective.

Replace the head cable to

see if operation is normal.

Replace the
head cable.

The printhead is
defective.

Replace the printhead.

Replace the
printhead.

Printhead surface
is not clean.

Check the front of the

printhead.

Clean.

The ink cartridge

is used up.

Check whether the ink

cartridge is empty.

Replace the
ink cartridge.

Check whether the cable

is properly plugged into
the connector.

Plug the cable

into the
connector
properly.

Check whether the

printhead is clean.

Clean.

The printhead is
defective.

Replace the printhead to

see if this causes printing
to be performed normally.

Replace.

Ink is poorly
absorbed.

Check whether the used

ink goes through the used
ink tube.

See Ink is not

absorbed.

Printhead
characters are
not aligned.

The platen gap is

not adjusted.

Check the platen gap.

Adjust the gap.

The intervals
between the
characters are
irregular.

The timing belt is

defective.

Check that the timing belt

is properly inserted into
the bottom of the carriage.

Insert the
timing belt
properly.

Vertical line is
not aligned.

Bidirectional
alignment is not
adjusted.

Check it with bidirectional

alignment program.

Adjust the
bidirectional
alignment.

Character or
dot pitch is
abnormal.

Character or dot
pitch is abnormal.

Check for head inclination, Make each

distance front/rear position. adjustment.

The carriage
moves, but no
printing is
performed.

A particular dot
is not printed.

Abnormal
printing.

Cause

A dot is not
printed
occasionally.

Insufficient head
cable contact.

5-13

Troubleshooting

Stylus Pro XL

Table 5-7. Repair of the Printer Mechanism (Cont.)

Symptom

Condition

Cause
Foreign
substances are
lodged in the
paper path.

Paper is not
fed normally.

Paper is not fed. Paper feeding

gears are
defective.
The paper feed
motor is defective.
Particles of power
Paper top of
residue from
form position
coating on glossy
slips (comes
paper are sticking
out too narrow).
to the PF roller.

Checkpoint

Solution

Visually check the paper

path.

Remove any
foreign
substances.

Visually check the gears.

Replace
defective
gears.

Measure the coil

Replace the
resistance of the PF motor. PF motor.
Check that particles of the
power residue from the
coating on glossy paper
are not sticking to the PF
roller.

Perform the
PF roller
cleaning with
the cleaning
sheet
(See Note)

Note: Cleaning sheets are available as service parts.

5-14

Rev. -A

Chapter 6 Maintenance
Table of Contents
6.1 PREVENTIVE MAINTENANCE

6-1

6.2 SERVICE MAINTENANCE

6-2
6.2.1 Printhead Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2.2 Waste Ink Drain Tank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.3 LUBRICATION AND ADHESIVE

6-3

LIST OF FIGURES
Figure 6-1. Lubrication Points and Adhesive Points (1). . . . . . . . . . . . . . . . . 6-5
Figure 6-2. Lubrication Points and Adhesive Points (2). . . . . . . . . . . . . . . . . 6-6

LIST OF TABLES
Table 6-1. Recommended Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Table 6-2. Lubrication and Adhesive Points . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Stylus Pro Service Manual

Maintenance

6.1 PREVENTIVE MAINTENANCE

Although this printer is designed so that no specific maintenance is required on a regular basis, it is
recommended that you clean the printer thoroughly whenever you get a chance to do so. You can clean:

Outer case
Use a soft, clean cloth, dampened with mild detergent, if necessary.

Auto sheet feeder

If the inside of the auto sheet feeder is dirty (dusty), carefully brush away all dust and dirt using a soft
brush. If the pickup roller of the sheet feeder is dirty, clean its surface with a soft, clean cloth.

Inside the printer

If you notice any dust or dirt that has accumulated inside the printer when you open the outer case for
repair, remove all dust and dirt using a small vacuum cleaner designed for such purposes.

WARNING
Never use paint thinner, trichloroethylene, or ketone-based solvents for cleaning. These
chemicals can damage the components of the printer.

CAUTION

Do not use a hard or abrasive brush for cleaning.

Be careful not to damage the components of the printer when using a vacuum cleaner.
A lithium battery is installed on the C164 MAIN board of this printer. Be sure to observe
the following instructions when servicing the printer or storing the after-service parts:
1. Keep the battery away from any metal or other batteries so that electrodes of opposite
polarity do not come in contact with each other.
2. Do not heat the battery and place it near fire.
3. Do not solder on any part of the battery. (Doing so may result in leakage of electrolyte
from the battery, burning, or explosion. The leakage may damage devices close to the
battery.)
4. Do not charge the battery. (An explosive gas may be generated inside the battery, and
cause burning or explosion.)
5. Do not dismantle the battery. (The gas inside the battery may hurt your throat. Leakage,
burning, or explosion may also result.)
6. Do not install the battery in the wrong direction. (This may cause burning or explosion.)

Rev.A

6-1

Maintenance

Stylus Pro Service Manual

6.2 SERVICE MAINTENANCE

Certain maintenance is required when the printer detects an error or when a decline in print quality is
observed.

6.2.1 Printhead Cleaning

If print quality deteriorates, clean the printhead using the built-in printhead cleaning function. The printer also
has an automatic printhead cleaning cycle to ensure the proper nozzle operation for ink injection as well as to
preserve its best condition. Therefore, perform this printhead cleaning operation only if print quality declines
to avoid wasting ink.
1.

Turn the printer on and press the Pause button to pause the printer. Make sure that the PAUSE LED is
on.

2.

Hold down the Alt button and press the Load/Eject button for black head cleaning.
Hold down the Alt button and press the Economy/Condensed button for color head cleaning.

When panel button operation is accepted by the printer, the PAUSE LED flashes during the cleaning cycle.
When the cleaning completes, the PAUSE LED stops flashing and the printer returns to standby mode.

6.2.2 Waste Ink Drain Tank Replacement

The printer counts the total amount of ink drained to the waste ink drain tank and this information is stored in
the EEPROM on the main board (in Protect Counter A). This value is used for ink system operation
management. If the counter value reaches the predetermined value, the printer displays an error (Waste ink
tank overflow, see Chapter 1, Section 1.4.4, Error Conditions, Table 1-10). When this error is displayed,
replace the waste ink absorbing materials and reset the protect counter.
1.

Open the upper case and replace the waste ink absorbing materials from the compartment of the lower
case. Reassemble the printer.

2.

Turn the printer while holding down the Alt, Font, Load/Eject, Pause buttons. This resets the protect
counter.

6-2

Rev.A

Stylus Pro Service Manual

Maintenance

6.3 LUBRICATION AND ADHESIVES

The printer must be lubricated properly when it is disassembled for component replacement, or if mechanical
noise exceeds a certain level. EPSON recommends only the lubricants listed in the table below for this
printer, both of which have been tested extensively and comply with the requirements of this printer
mechanism. Figure 6-1 shows the lubrication and adhesive points.

Table 6-1. Recommended Lubricants

Type

Name

Quantity

Part No.

Availability

Oil

O-5
G-20
G-36
Neji Lock #2 (G)

40 cc
40 gm
40 gm
1000 g

1010513
B700000001
B703600001
B730200200

E
E
E
E

Grease
Adhesive

Note:

E = EPSON Exclusive product (Not commercially available)

Table 6-2. Lubrication and Adhesive Points

Ref. No.

Lubrication/Adhesive Point

Lubricant

1
2
3
4
5
6
7

G-36 (1-3 mg)

G-36 (1-3 mg)
G-36 (1-3 mg)
G-36 (1-3 mg)
G-36 (1-3 mg)
G-36 (1-3 mg)

18
19
20
21
22
27
28
30

The teeth of gear 60

The teeth of combination gear 10, 50
End point of shaft securing sub frame assembly
Cutout for the CR motor in the base frame assembly (2 points)
Shaft located in the center frame assembly
Shaft located in the center frame assembly
Surface of the eject roller assembly
Contact surface of the right side of the front paper guide and the
eject roller assembly
Right end point of the eject roller assembly
Contact surfaces of the shaft and combination gear 13.5, 22 and
the combination gear holder on the sub frame assembly
The teeth of gear 22.5
The teeth of combination gear 28, 17.5
End points of the pump speed-up shaft (both sides)
Cut point for knob on the right main frame
Contact points of gear 60, the platen roller shaft, and the PF cap
spring.
2 points on the combination gear holder.
Oil pad on the carriage
Contact surface of gear 25 and the plain washer
Contact surface of the platen shaft bushing and plain washer
Cutout in the platen roller shaft
Contact point of the pressure spring and washer
Combination gear 13.5, 22
The teeth of gear 24

(1)

Angular spacer for the black head and the cartridge base

Neji Lock #2
(1-3 mg)

(2)

Angular spacers for the color head and the cartridge base

Neji Lock #2
(1-3 mg)

(3)

The screw and washer attaching the ink cartridge holder to the
carriage base.

Neji Lock #2
(1-3 mg)

8
9
10
11
12
14
16
17

Rev.A

G-36 (1-3 mg)

G-20 (1-3 mg)
G-36 (1-3 mg)
G-36 (1-3 mg)
G-36 (1-3 mg)
G-36 (1-3 mg)
G-36 (1-3 mg)
G-36 (1-3 mg)
O5 (1-3 mg)
G-36 (1-3 mg)
G-36 (1-3 mg)
G-20 (1-3 mg)
G-36 (1-3 mg)
G-36 (1-3 mg)
G-36 (1-3 mg)

6-3

Maintenance

Stylus Pro Service Manual

CAUTION
Do not apply too much lubricant, as it may stain the mechanism as well as a cause a
mechanism malfunction.

6-4

Rev.A

Stylus Pro Service Manual

Maintenance

11

20
12

5
4 4

22

9
30

17

17

21

27

2
1

Figure 6-1. Lubrication Points and Adhesive Points (1)

Rev.A

6-5

Maintenance

Stylus Pro Service Manual

19
16

2
2
2

11
3

10

(3)
28
14

18
18
14

Lubrication Point
Adhesive Point

Figure 6-2. Lubrication Points and Adhesive Points (2)

6-6

Rev.A

Appendix
Table of Contents
A.1 CONNECTOR SUMMARY

A-1

A.2 CIRCUIT DIAGRAM

A-7

A.3 CIRCUIT BOARD COMPONENT LAYOUT

A-14

A.4 EXPLODED DIAGRAM

A-18

List of Figures
Figure A-1. Interconnection of Major Component . . . . . . . . . . . . . . . . . . . . . . . A-1
Figure A-2. C162 MAIN Board Circuit Diagram (1) . . . . . . . . . . . . . . . . . . . . . . A-7
Figure A-3. C162 MAIN Board Circuit Diagram (2) . . . . . . . . . . . . . . . . . . . . . . A-9
Figure A-4. C137 PSB Board CircuitDiagram . . . . . . . . . . . . . . . . . . . . . . . . . A-11
Figure A-5. C137 PSE Board CircuitDiagram . . . . . . . . . . . . . . . . . . . . . . . . . A-12
Figure A-6. C137 PNL Board CircuitDiagram . . . . . . . . . . . . . . . . . . . . . . . . . A-13
Figure A-7. C162 MAIN Board Component Layout (1) . . . . . . . . . . . . . . . . . . A-14
Figure A-8. C162 MAIN Board Component Layout (2) . . . . . . . . . . . . . . . . . . A-15
Figure A-9. C137 PSB Board Component Layout. . . . . . . . . . . . . . . . . . . . . . A-16
Figure A-10. C137 PSE Board Component Layout. . . . . . . . . . . . . . . . . . . . . A-16
Figure A-11. C137 PNL Board Component Layout. . . . . . . . . . . . . . . . . . . . . A-17
Figure A-12. Exploded Diagram for Stylus Pro XL (1) . . . . . . . . . . . . . . . . . . A-18
Figure A-13. Exploded Diagram for Stylus Pro XL (2) . . . . . . . . . . . . . . . . . . A-19
Figure A-14. Exploded Diagram for Stylus Pro XL (3) . . . . . . . . . . . . . . . . . . A-20

List of Table
Table A-1. Connector Summay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Table A-2. Connector Pin Assignments - CN1 . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Table A-3. Connector Pin Assignments - CN2 . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Table A-4. Connector Pin Assignments - CN3 . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Table A-5. Connector Pin Assignments - CN5 . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Table A-6. Connector Pin Assignments - CN6 . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Table A-7. Connector Pin Assignments - CN7 . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Table A-8. Connector Pin Assignments - CN8 . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Table A-9. Connector Pin Assignments - CN9 . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Table A-10. Connector Pin Assignments - CN10 . . . . . . . . . . . . . . . . . . . . . . . A-4
Table A-11. Connector Pin Assignments - CN11 . . . . . . . . . . . . . . . . . . . . . . . A-5
Table A-12. Connector Pin Assignments - CN12 . . . . . . . . . . . . . . . . . . . . . . . A-5
Table A-13. Connector Pin Assignments - CN13 . . . . . . . . . . . . . . . . . . . . . . . A-5
Table A-14. Part No. Reference Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-21

Rev.-A

A-i

Stylus Pro XL

Appendix

A.1 CONNECTOR SUMMARY

The figure below shows the interconnection between the major components of the Stylus Pro XL.
CN1

AC I nput

C137 PSB/PSE
CN2

CN
HP S en sor

CN10

CN8

CN9

CN3

CN1

CN11

Printhead Unit
C162 MAI N

RS -4 22
Serial
I/F

CN

CN13

CN 2

Color

ASF Plunger

CN2

CN1

Type B
Parallel
I/F

Black

CN12

CN5
Parallel
I/F

CN6

CN7
CR Senso r

PF Mot or
C137 PNL
CR Mot or

Printer Mechanism
(M-4A60)

Figure A-1. Interconnection of Major Components

Rev. A

A-1

Appendix

Stylus Pro XL

Table A-1. Connector Summary

Board

Location

Pin

CN1

36

Centronics parallel I/F

CN2

36

Type B parallel I/F

CN3

RS-422 serial I/F

CN4

There is no connector CN4

CN5

Power supply from PS board

CN6

Carriage motor phase output

CN7

PF/PM motor phase output

CN8

Paper end sensor

CN9

Carriage home position sensor

CN10

20

Control panel (to C137 PNL)

CN11

22

Black head nozzle selector and common driver

CN12

22

Color head nozzle selector and common driver

CN13

ASF plunger

CN1

AC inlet (L/N)

CN2

DC output (+5 V / +35 V)

CN1

20

(to C162 MAIN)

C162 MAIN

C137 PSB/PSE
C137 PNL

Description

Table A-2. Connector Pin Assignments CN1

Pin

I/O

Name

Description

2-9

10

ACK

ACK signal

11

BUSY

Busy signal

12

PE

Paper end signal

13

SLCT

Printer select signal

14

Auto line feed signal

15

AFXT
NC

16

GND

Ground

17

FG

Frame ground

18

+5 V

+5 VDC

19-30

GND

Ground

STB
DATA1-8

Strobe signal
Data strobe signal

Not connected

31

INIT

INIT signal

32

ERR

Error signal

33

GND

Ground

34

NC

Not connected

35

+5 V

+5 VDC

36

A-2

SLIN

Select in signal

Rev. A

Stylus Pro XL

Appendix

Table A-3. Connector Pin Assignments CN2

Pin

I/O

Name

Description

1-6

+5 V

Power supply for I/F drive

TXD

Transmit data

Ready signal

READY
RXD

10

NC

Not connected

11

Reset signal

12

RESET
INH

13

CMREQ

Command request signal

14

WRRDY

Write ready signal

15

RDREQ

Read request signal

16

HWR

High write signal

17

RD

Read signal

18

CS

Chip select signal

19-24

GND

Ground

25-28

I/O

A3-A0

Address bus signal 3-0

29-36

I/O

D15-D8

Data bus signal 15-8

Receive data

Inhabit signal

Table A-4. Connector Pin Assignments CN3

Pin

I/O

Name

Description

DTR

Data terminal ready

NC

Not connected

TXD+

Transmit data +

NC

Not connected

RXD+

Receive data +

TXD GND
RXD -

Transmit data Ground

Receive data -

There is no connector CN4.

Table A-5. Connector Pin Assignments CN5

Pin

I/O

Name

Description

PSC

Power scan signal

2, 3

+35V

Head common driver for common drive circuit

4-6

GND

Ground

7, 8

+5V

Power supply for logic system

Rev. A

A-3

Appendix

Stylus Pro XL

Table A-6. Connector Pin Assignments CN6

Pin

I/O

Name

Description

CRA

Phase A drive signal

CRA

Phase A drive signal

CRB

Phase B drive signal

CRB

Phase B drive signal

CRCOM

Carriage drive power (common voltage)

Table A-7. Connector Pin Assignments CN7

Pin

I/O

Name

Description

PFA

Phase A drive signal

PFA

Phase A drive signal

PFB

Phase B drive signal

PFB

Phase B drive signal

PFCOM

Carriage drive power (common voltage)

Table A-8. Connector Pin Assignments CN8

Pin

I/O

Name

Description

PE

Paper on/out state detection signal

GND

Ground

Table A-9. Connector Pin Assignments CN9

Pin

I/O

2
3

Name

Description

HP

Home position detection signal

GND

Ground

HPV

Sensor drive power supply

Table A-10. Connector Pin Assignments CN10

Pin

I/O

Name

Description

1, 3, 5, 7

GND

Ground

LDATA

LED data

LCLK

Clock signal for LED drive

LLAT

LED data latch signal

LCLR

LED data reset signal

9, 11, 19, 20

+5 V

LED driver and power

10, 12-16

SW0-5

Switch 0-5 input signal

17

PSW

Power switch

18

PSC

Power scan

A-4

Rev. A

Stylus Pro XL

Appendix

Table A-11. Connector Pin Assignments CN11

Pin

I/O

Name

Description

GND

Ground

BCLK

Clock signal for black head

GND

Ground

BLAT

Latch signal for black head

GND

Ground

BSI

Black head serial data output

GND

Ground

BCO

Black cartridge out sensor

+5 V

Power supply for cartridge out sensor

10

NC

Not connected

11-16

GP

Ground

17-22

COM

Common voltage for printhead drive

Table A-12. Connector Pin Assignments CN12

Pin

I/O

Name

Description

GND

Ground

CCLK

Clock signal for color head

GND

Ground

CLAT

Latch signal for color head

GND

Ground

CSI

Color head serial data output

GND

Ground

CCO

Color cartridge out sensor

+5 V

Power supply for cartridge out sensor

10

TH

Thermistor signal

11-16

GP

Ground

18-22

COM

Common voltage for printhead drive

Table A-13. Connector Pin Assignments CN13

Pin

I/O

Name

Description

+35 V

Power supply for ASF plunger

PL

Paper loading signal

Rev. A

A-5

Stylus Pro XL

Appendix

Table A-14. Part No. Reference Table

Ref.No.

Description

PPL Name

100

LOWER HOUSING

HOUSING, LOWER

101

FOOT

FOOT

102

LOWER SHIELD PLATE

SHIELD PLATE, LOWER

103

UPPER SHIELD PLATE

SHIELD PLATE, UPPER

104

P/S SHIELD PLATE

SHIELD PLATE, P/S

105

GROUNDING PLATE

GROUNDING PLATE

106

PAPER SUPPORT COVER B

COVER, PAPER SUPPORT; B

107

UPPER HOUSING

HOUSING, UPPER

108

REAR PRINTER COVER

COVER, PRINTER, REAR

109

PAPER SUPPORT

PAPER SUPPORT, ASSY.

110

EDGE GUIDE

EDGE GUIDE

111

GROUNDING PLATE D

GROUNDING PLATE; D

112

PAPER SUPPORT SUPPORT PLATE

SUPPORT PLATE, PAPER SUPPORT

115

LOGO PLATE B

LOGO PLATE; B

117

PS EARTH PLATE

EARTH PLATE, PS

118

I/F GROUNDING PLATE

GROUNDING PLATE, I/F

119

I/F BOARD GUIDE

GUIDE, I/F BOARD

120

UPPER CONNECTOR COVER

COVER, CONNECTOR, UPPER

121

CLAMP

CLAMP

122

CBB SCREW (M312)

C.B.B. SCREW (M312)

123

CBS-TITE SCREW (M312)

C.B.S.-TITE SCREW (M312)

124

CBS SCREW M38 F/UC

C.B.S. SCREW M38, F/UC

125

CB(O) SCREW (M48)

C.B.(O) SCREW (M48)

126

HEXAGON NUT (M4)

HEXAGON NUT (M4)

127

CB USCA 36 F/ZN

C.B. USCA, 36, F/ZN

128

CB SCREW 414 F/ZN

C.B. SCREW, 414, F/ZN

129

CBB SCREW (M310)

C.B.B. SCREW (M310)

130

INK EJECT POROUS PAD

POROUS PAD, INKEJECT

131

FRONT PRINTER COVER

COVER, PRINTER, FRONT

132

PAPER SUPPORT COVER

COVER, PAPER SUPPORT

133

EDGE GUIDE SLIDER

SLIDER, EDGE GUIDE

134

SUB EDGE GUIDE

EDGE GUIDE, SUB

135

GROUNDING PLATE E

GROUNDING PLATE; E

136

GROUNDING PLATE F

GROUNDING PLATE; F

137

I/F UPPER GROUNDING PLATE

GROUNDING PLATE, I/F, UPPER

138

CBB SCREW (M412)

C.B.B. SCREW (M412)

139

GROUNDING PLATE B

GROUNDING PLATE; B

Rev. A

A-21

Appendix

Stylus Pro XL

Table A-14. Part No. Reference Table (Continued)

Ref.No.

Description

PPL Name

200

MAIN BOARD (FOR USA, S.E. ASIA)

BOARD ASSY., MAIN

(FOR USA, S.E. ASIA)

200

MAIN BOARD (FOR EUROPE)

BOARD ASSY., MAIN

(FOR EUROPE)

300

POWER SUPPLY BOARD (FOR 120 V)

BOARD ASSY., POWER SUPPLY

(FOR 120V)

300

POWER SUPPLY BOARD

(FOR 220 V / 240 V)

BOARD ASSY., POWER SUPPLY

(FOR 220V/240V)

330

HARNESS

400

POWER CABLE (VD31303SA-10A)

V)

401

POWER CABLE (VD31303SA-10A)

(240 V)

402
403

AC CABLE (240 V)
POWER CABLE (VD00303SA-10A)
(220 V)

HARNESS
(230 POWER
(230V)

CABLE

(VD31303SA-10A)

POWER CABLE (BS31303SA-SR-10A)

(240V)
AC CABLE (240V)
POWER CABLE (VD00303SA-10A)
(220V)

403

POWER CABLE (220 V)

POWER CABLE (220V)

410

POWER CABLE

POWER CABLE ASSY.

411

POWER CABLE (100 V)

POWER CABLE ASSY. (100V)

412

HARNESS (220 V / 240 VAC INLET)

HARNESS (220V/240V AC INLET)

450

PANEL BOARD

BOARD ASSY., PANEL

500

PRINTER MECHANISM (M-4A60)

PRINTER MECHANISM (M-4A60)

501

DRIVEN PULLEY

PULLEY, DRIVEN

502

BASE FRAME

FRAME ASSY., BASE

503

PE DETECTOR (0 V, 0 A, 0 W)

DETECTOR, PE (0V, 0A, 0W,)

504

LEFT FRAME

FRAME ASSY., LEFT

505

MIDDLE FRAME

FRAME ASSY., MIDDLE

506

RIGHT MAIN FRAME

FRAME, MAIN, RIGHT

507

BOTTOM MAIN FRAME

FRAME, MAIN, BOTTOM

508

CARRIAGE B

CARRIAGE ASSY.; B

509

GEAR CHANGE LEVER

LEVER, CHANGE, GEAR

510

SUPPORT CHANGE LEVER

LEVER, CHANGE, SUPPORT

511

PAPER LOAD SHAFT

SHAFT, PAPER LOAD

512

TIMING BELT

TIMINGBELT

513

BK HEAD CABLE

CABLE, HEAD, BK

514

YMC HEAD CABLE

CABLE, HEAD, YMC

515

PRINT HEAD, IJ48-0CA (COLOR)

PRINT HEAD, IJ48-0CA (COLOR)

516

PRINT HEAD, IJ64-0AA (BLACK)

PRINT HEAD, IJ64-0AA (BLACK)

517

FRONT APER GUIDE

PAPER GUIDE , FRONT

518

PAPER LOADING ROLLER

ROLLER ASSY., PAPER LOAD

519

PAPER LOADING ROLLER SUPPORT

ROLLER, PAPER LOAD, SUPPORT

A-22

Rev. A

Stylus Pro XL

Appendix

Table A-14. Part No. Reference Table (Continued)

Ref.No.

Description

PPL Name

520

REAR PAPER GUIDE

PAPER GUIDE ASSY., REAR

521

PF ROLLER SUPPORT

ROLLER, PF, SUPPORT

522

PF HOLDER SUPPORT

HOLDER, PF, SUPPORT

523

TORSION SPRING, 5800

TORORSION SPRING, 5800

524

PE HARNESS

HARNESS, PE

525

PF STEPPING MOTOR

STEPPING MOTOR, PF

526

HP DETECTOR

DETECTOR, HP

527

HP HARNESS

HARNESS, HP

528

PUMP B

PUMP ASSY.; B

529

UPPER YMC CAP POROUS PAD

POROUS PAD, CAP, YMC, UPPER

530

LOWER YMC CAP POROUS PAD

POROUS PAD, CAP, YMC, LOWER

531

UPPER BK CAP POROUS PAD

POROUS PAD, CAP, BK, UPPER

532

LOWER BK CAP POROUS PAD

POROUS PAD, CAP, BK, LOWER

533

ASP HEAD CLEANER

CLEANER, HEAD, ASP

534

CLEANER LEVER

LEVER, CLEANER

535

DRIVEN ROLLER HOLDER C

HOLDER, ROLLER, DRIVEN; C

536

CR GUIDE SHAFT

SHAFT, CR, GUIDE

537

OIL PAD

OIL PAD

538

KNOB LEVER

LEVER, KNOB

539

CR STEPPING MOTOR (.4.0 VDC, 0.4 A)

STEPPING MOTOR, CR (DC.4.0V,0.4A)

540

CR COVER B

COVER ASSY., CR; B

541

CR GUIDE GROUNDING SPRING

GROUNDING SPRING, CR, GUIDE

542

CR STOPPER LEVER

LEVER, CR, STOPPER

543

CR DAMPER

DAMPER, CR

544

CR DAMPER SHAFT B

SHAFT, DAMPER, CR; B

545

PAPER LOAD LEVER

LEVER, PAPER LOAD

546

DRIVEN ROLLER

ROLLER, DRIVEN

547

DRIVEN ROLLER HOLDER

HOLDER, ROLLER, DRIVEN

548

DRIVEN ROLLER C

ROLLER, DRIVEN; C

549

DRIVEN PULLEY LEVER

LEVER ASSY., PULLEY, DRIVEN

550

PARALLEL ADJUST BUSHING

BUSHING, PARALLEL, ADJUST

551

DRIVEN ROLLER SUPPORT

ROLLER, DRIVEN, SUPPORT

552

SUB FRAME

FRAME ASSY., SUB

553

PAPER EJECT HOLDER

HOLDER ASSY., PAPER EJECT

554

PAPER EJECT HOLDER, B

HOLDER ASSY., PAPER EJECT; B

555

PAPER EJECT FRAME

FRAME, PAPER EJECT

556

PAPER EJECT ROLLER

ROLLER ASSY., PAPER EJECT

557

PAPER EJECT CLUTCH

CLUTCH PAPER EJECT

558

EDGE GUIDE SLIDER

SLIDER, EDGE GUIDE

559

BUSHING 6 mm

BUSHING, 6

560

HEAD FASTENING PRESSURE PLATE

PRESSINGPLATE, FASTEN, HEAD

Rev. A

A-23

Appendix

Stylus Pro XL

Table A-14. Part No. Reference Table (Continued)

Ref.No.

Description

PPL Name

561

BK HEAD BASE

BASE, HEAD, BK

562

YMC HEAD BASE

BASE, HEAD, YMC

563

UPPER HEAD CABLE HOLDER

HOLDER, HEAD CABLE, UPPER

564

LOWER HEAD CABLE HOLDER

HOLDER, HEAD CABLE, LOWER

565

BK CARTRIDGE LEVER

LEVER ASSY., CARTRIDGE, BK

566

YMC CARTRIDGE LEVER

LEVER ASSY., CARTRIDGE, YMC

567

CR COVER CAP

CAP, COVER, CR

568

PUMP SPEED UP SHAFT

SHAFT, SPEED UP, PUMP

569

OIL PAD PRESSURE PLATE

PRESSING PLATE, OIL PAD

570

KNOB

KNOB

571

KNOB SHAFT

SHAFT, KNOB

572

DRIVEN ROLLER E

ROLLER ASSY., DRIVEN; E

573

PLATEN SHAFT HOLDER

PLATEN SHAFT HOLDER

574

PLATEN SHAFT HOLDER (GRAY)

PLATEN SHAFT HOLDER (GRAY)

575

TRACTOR REDUCTION GEAR

TRACTOR REDUCTION GEAR

576

CLUTCH PAD

PAD, CLUTCH

577

PF SPRING CAP

CAP, SPRING, PF

578

HOPPER CAM

CAM, HOPPER

579

CLUTCH CAM

CAM, CLUTCH

580

ANTI-STATIC BRUSH

ANTI-STATIC BRUSH

581

PAD HOLDER C

HOLDER ASSY., PAD; C

582

EDGE GUIDE

EDGE GUIDE

583

EDGE GUIDE PRESSING PLATE

PRESSING PLATE, EDGE GUIDE

584

HOPPER

HOPPER ASSY.

585

PAPER LOADING CORK

CORK, PAPER LOAD

586

GEAR CHANGE GUIDE

GUIDE, CHANGE, GEAR

587

COMBINATION GEAR HOLDER

HOLDER, COMBINATION GEAR

588

COMBINATION GEAR, 13.5 mm, 22 mm

COMBINATION GEAR, 13.5,22

589

SPUR GEAR, 20 mm

SPUR GEAR, 20

590

COMBINATION GEAR, 16 mm, 28 mm

COMBINATION GEAR, 16,28

591

SPUR GEAR, 22.5 mm

SPUR GEAR, 22.5

592

COMBINATION GEAR, 10 mm, 50 mm

COMBINATION GEAR, 10,50

593

SPUR GEAR, 60 mm

SPUR GEAR, 60

594

SPUR GEAR, 24 mm

SPUR GEAR, 24

595

COMBINATION GEAR, 17.5 mm, 14 mm

COMBINATION GEAR, 17.5, 14

596

SPUR GEAR, 27.5 mm

SPUR GEAR, 27.5

598

SPUR GEAR, 19 mm

SPUR GEAR, 19

599

COMBINATION GEAR, 21.5 mm, 9 mm

COMBINATION GEAR, 21.5, 9

600

COMBINATION GEAR, 21.5 mm, 9 mm

COMBINATION GEAR, 21.5,9

601

COMBINATION GEAR, 28 mm, 17.5 mm

COMBINATION GEAR, 28,17.5

602

EXTENSION SPRING 1937 g

EXTENSION SPRING, 1937

A-24

Rev. A

Stylus Pro XL

Appendix

Table A-14. Part No. Reference Table (Continued)

Ref.No.

Description

PPL Name

603

EXTENTION SPRING, 1.6 g

EXTENTION SPRING, 1.6

604

COMPRESSION SPRING, 90 g

COMPRESSION SPRING, 90

605

TORSION SPRING, 15000 g

TORSION SPRING, 15000

606

TORSION SPRING, 6700 g

TORSION SPRING, 6700

607

EXTENSION SPRING, 102 g

EXTENSION SPRING, 102

608

COMPRESSION SPRING, 1500 g

COMPRESSION SPRING, 1500

610

EXTENSION SPRING, 10 g

EXTENSION SPRING, 10

612

COMPRESSION SPRING, 100 g

COMPRESSION SPRING, 100

613

COMPRESSION SPRING, 485 g

COMPRESSION SPRING, 485

614

SPUR GEAR, 25 mm

SPUR GEAR, 25

615

COMPRESSION SPRING C, 100 g

COMPRESSION SPRING,100; C

616

TORSION SPRING, 6120 g

TORSION SPRING, 6120

617

COMPRESSION SPRING, 450 g

COMPRESSION SPRING, 450

618

EXTENSION SPRING, 200 g

EXTENSION SPRING, 200

619

COMPRESSION SPRING, 900 g

COMPRESSION SPRING, 900

620

COMPRESSION SPRING,180 g

COMPRESSION SPRING,180

621

EXTENSION SPRING, 567 g

EXTENSION SPRING, 567

622

TORSION SPRING, 10400 g

TORSION SPRING, 10400

625

PLAIN WASHER (40.58)

PLAIN WASHER (40.58)

626

PLAIN WASHER (3.217, F/ZN)

PLAIN WASHER, 3.217, F/ZN

628

PLAIN WASHER (80.515)

PLAIN WASHER (80.515)

629

PLAIN WASHER (4.2111)

PLAIN WASHER (4.2111)

630

PLAIN WASHER (60.712)

PLAIN WASHER (60.712)

631

PLAIN WASHER (6.5118 S/NA)

P.W., 6.5118, S/NA

632

PLAIN WASHER (4.20.38 L/NA)

P.W., 4.20.38, L/NA

633

PLAIN WASHER (30.58 F/ZN)

PLAIN WASHER, 30.58 F/ZN

634

PLAIN WASHER (6.10.312 L/NA)

PLAIN WASHER, 6.10.312, L/NA

635

PLAIN WASHER (5.070.310 L/NA)

PLAIN WASHER, 5.070.310, L/NA

637

SPRING WASHER (30.75.9 F/ZN)

SPRING WASHER, 30.75.9, F/ZN

638

SPRING PIN (214)

SPRING PIN (214)

639

BALL BEARING

BALL BEARING

640

WIRE BAND

WIRE BAND

641

WIRE SADDLE

WIRE SADDLE

642

CLAMP

CLAMP

643

RETAINING RING (TYPE-E (3))

RETAINING RING (TYPE-E(3))

644

RETAINING RING (TYPE-E (4))

RETAINING RING (TYPE-E(4))

645

RETAINING RING (TYPE-E (5))

RETAINING RING (TYPE-E(5))

646

RETAINING RING (TYPE-E (2.3))

RETAINING RING (TYPE-E(2.3))

647

CB SCREW (M36)

C.B. SCREW (M36)

648

CBS SCREW (36 F/ZN)

C.B.S. SCREW 36 F/ZN

649

CBS (O) SCREW (M36)

C.B.S. (O) SCREW (M36)

Rev. A

A-25

Appendix

Stylus Pro XL

Table A-14. Part No. Reference Table (Continued)

Ref.No.

Description

PPL Name

650

CBB SCREW (M312)

C.B.B. SCREW (M312)

652

CBS SCREW (M38 F/UC)

C.B.S. SCREW (M38 F/UC)

653

CPB SCREW (315 F/ZN)

C.P.B. SCREW, 315, F/ZN

654

HEAD MOUNTING PRESSURE PLATE

PRESSING PLATE, MOUNTING, HEAD

655

PF ROLLER

ROLLER, PF

656

SPUR GEAR, 9 mm

SPUR GEAR, 9

657

SPUR GEAR, 27 mm

SPUR GEAR, 27

659

SPUR GEAR, 12 mm

SPUR GEAR, 12

660

PLUNGER

PLUNGER ASSY.

661

EXTENSION SPRING, 3.35 g

EXTENSION SPRING, 3.35

662

EXTENSION SPRING, 0.196 g

EXTENSION SPRING, 0.196

663

TORSION SPRING, 0.000206 g

TORSION SPRING, 0.000206

664

SUPPORT EARTHPLATE

EARTHPLATE, SUPPORT

665

PAPER EJECT ROLLER B

ROLLER ASSY., PAPER EJECT; B

666

PAPER EJECT GUIDE

GUIDE, PAPER EJECT

667

PAPER EJECT HOLDER C

HOLDER ASSY., PAPER EJECT; C

668

DRIVEN ROLLER HOLDER

HOLDER, ROLLER, DRIVEN

669

DRIVEN HOLDER

ROLLER, DRIVEN

670

PLUNGER COVER

COVER, PLUNGER

700

YMC ANGULAR SPACER (COLOR)

SPACER, ANGULAR, YMC (COLOR)

700

YMC ANGULAR SPACER B (COLOR)

SPACER, ANGULAR, YMC; B (COLOR)

700

YMC ANGULAR SPACER C (COLOR)

SPACER, ANGULAR, YMC; C (COLOR)

700

YMC ANGULAR SPACER D (COLOR)

SPACER, ANGULAR, YMC; D (COLOR)

700

YMC ANGULAR SPACER E (COLOR)

SPACER, ANGULAR, YMC; E (COLOR)

701

BK ANGULAR SPACER (BLACK)

SPACER, ANGULAR, BK (BLACK)

701

BK ANGULAR SPACER B (BLACK)

SPACER, ANGULAR, BK; B (BLACK)

701

BK ANGULAR SPACER C (BLACK)

SPACER, ANGULAR, BK; C (BLACK)

701

BK ANGULAR SPACER D (BLACK)

SPACER, ANGULAR, BK; D (BLACK)

701

BK ANGULAR SPACER E (BLACK)

SPACER, ANGULAR, BK; E (BLACK)

702

LINEAR SPACER (BLACK)

SPACER, LINEAR (BLACK)

702

LINEAR SPACER B (BLACK)

SPACER, LINEAR; B (BLACK)

702

LINEAR SPACER C (BLACK)

SPACER, LINEAR; C (BLACK)

702

LINEAR SPACER D (BLACK)

SPACER, LINEAR; D (BLACK)

702

LINEAR SPACER E (BLACK)

SPACER, LINEAR; E (BLACK)

702

LINEAR SPACER F (BLACK)

SPACER, LINEAR; F (BLACK)

702

LINEAR SPACER G (BLACK)

SPACER, LINEAR; G (BLACK)

702

LINEAR SPACER H (BLACK)

SPACER, LINEAR; H (BLACK)

702

LINEAR SPACER I (BLACK)

SPACER, LINEAR; I (BLACK)

702

LINEAR SPACER J (BLACK)

SPACER, LINEAR; J (BLACK)

702

LINEAR SPACER K (BLACK)

SPACER, LINEAR; K (BLACK)

A-26

Rev. A

EPSON