Epson L120 Service Manual
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Epson L120 Service Manual

Color inkjet printer
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SERVICE MANUAL
Color Inkjet Printer
L120
CONFIDENTIAL
SEIJ13-005
Table of Contents
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Summary of Contents for Epson L120

  • Page 1 SERVICE MANUAL Color Inkjet Printer L120 CONFIDENTIAL SEIJ13-005...
  • Page 2 The contents of this manual are subject to change without notice.  The above not withstanding SEIKO EPSON CORPORATION can assume no responsibility for any errors in this manual or the consequences thereof. EPSON is a registered trademark of SEIKO EPSON CORPORATION.
  • Page 3 Strictly observe the following cautions. Failure to comply may lead to personal injury or damage of the product. 1. Repairs on Epson product should be performed only by an Epson certified repair technician. 2. No work should be performed on this product by persons unfamiliar with basic safety knowledge required for electrician.
  • Page 4 7. In order to protect sensitive microprocessors and circuitry, use static discharge equipment, such as anti-static wrist straps, when accessing internal components. 8. Do not tilt this product immediately after initial ink charge, especially after performing the ink charge several times.

  • Page 5: Chapter 1 Troubleshooting

    About This Manual This manual, consists of the following chapters, is intended for repair service personnel and includes information necessary for properly performing maintenance and servicing the product. CHAPTER 1. TROUBLESHOOTING Describes the step-by-step procedures for the troubleshooting. CHAPTER 2. DISASSEMBLY / REASSEMBLY Describes the disassembly/reassembly procedures for main parts/units of the product, and provides the standard operation time for servicing the product.
  • Page 6 Revision Status Revision Date of Issue Description January 24, 2014 First Release Confidential...

  • Page 7: Table Of Contents

    L120 Revision A Contents Chapter 1 Troubleshooting 1.1 Troubleshooting................................. 9 1.1.1 Troubleshooting Workflow ..........................9 1.2 Power-On Sequence ..............................11 1.3 Fatal Error Code List............................... 13 1.3.1 Printer Fatal Error Code ..........................13 Chapter 2 Disassembly/Reassembly 2.1 Overview ................................. 16 2.1.1 Tools ................................
  • Page 8 CHAPTER 1 TROUBLESHOOTING Confidential...

  • Page 9: Troubleshooting

    L120 Revision A 1.1 Troubleshooting This section describes the troubleshooting workflow and fatal error information. 1.1.1 Troubleshooting Workflow The following page describes the troubleshooting workflow. Follow the flow when troubleshooting problems. Troubleshooting Troubleshooting Confidential...
  • Page 10 Printer check foreign materials / This error may occur in the • Contamination of CR scale [Major Troubleshooting] • Contamination of Printhead • Recommendation of EPSON Cover. parts come-off / parts manual duplex printing if the cover media...

  • Page 11: Power-On Sequence

    L120 Revision A 1.2 Power-On Sequence This section describes the power-on sequences in two conditions. The preconditions are as follows.  Condition 1: Normal power-on sequence (See Table 1-1.)  Turning on the printer after turning it off without an error.
  • Page 12 L120 Revision A  Condition 2: Power-on sequence after recovering from a paper jam error (See Table 1-2.)  Turning on the printer after turning it off with a paper jam fatal error.  There still remains paper on the paper path out of the detecting area of the PE Sensor.

  • Page 13: Fatal Error Code List

    L120 Revision A 1.3 Fatal Error Code List This section describes how to check the fatal error code, description, and the possible causes. 1.3.1 Printer Fatal Error Code This section describes the printer fatal error code and the possible cause for this product.
  • Page 14 L120 Revision A Table 1-3. Fatal Error List (Printer) Error Error type Error name Possible cause code • PF Encoder failure (contaminated/detached scale, Encoder Sensor failure) • Tooth skip of the PF Timing Belt • Improper tension of the PF Timing Belt PF PID reverse error •...

  • Page 15: Chapter 2 Disassembly/Reassembly

    CHAPTER 2 DISASSEMBLY/REASSEMBLY Confidential...

  • Page 16: Overview

    Flathead Precision screwdriver #1 Tweezers Longnose pliers Acetate tape 1003963 Note 1: Some of the tools listed above are commercially available. 2: EPSON provides the tools listed with EPSON part code. 2.1.2 Jigs Name Quantity EPSON Part Code Spring hook jig* Can be made with a commercial item See "...

  • Page 17: Locations Of The Parts/Units

    L120 Revision A 2.1.3 Locations of the Parts/Units This section shows the locations of the main parts/units of this product. The parts/units which can not be seen in the following pictures are indicated in dotted lines  Exterior parts Right...
  • Page 18 L120 Revision A  Printer mechanism Name Name CR Driven Pulley Assy (p30) Adapter (p31) CR Scale (p30) CR Unit (p32) CR Timing Belt (p32) PF Roller Unit (p32) Printhead (p31) Star Wheel Holder Assy (p31) CR Encoder Sensor (p32)
  • Page 19 L120 Revision A Name Name PF Encoder Sensor* (p29) PF Scale (p29) EJ Roller (p31) PF Timing Belt (p29) EJ Roller Gear (p29) PF Motor Assy (p32) Figure 2-5. Printer Mechanism: Left Name Name CR Motor (p30) PE Sensor Lever (p30)
  • Page 20 L120 Revision A  Ink Supply Tank Assy Name Name Ink Supply Tank Tube Assy (p31) Ink Supply Tank Ink Supply Tank (p31)/Ink Supply Tank (p31)/Ink Ink Supply Tube Assy (p31) Supply Tank (p31)/Ink Supply Tank (p31) Ink Supply Tank Lower Housing (p31) Figure 2-7.

  • Page 21: Standard Operation Time For Servicing The Product

    L120 Revision A 2.1.4 Standard Operation Time for Servicing the Product The following are the standard operation time for servicing the product. Those are based on the MTTR result measured using a prototype. The underlined parts/units are supplied as After Service Parts.
  • Page 22 L120 Revision A Table 2-1. Standard Operation Time Time (mm:ss) Parts/Unit Adjustment/ Replacement Total inspection CR Unit 9:55 9:55 CR Timing Belt 6:28 6:28 CR Encoder Sensor 6:30 6:30 Frame Base Assy 10:21 10:21 Pump Unit 12:23 12:23 Spur Gear 16.5...

  • Page 23: Checks And Precautions Before Disassembling

    L120 Revision A 2.1.5 Checks and Precautions before Disassembling 2.1.5.1 Factors which Affect the Print Quality HOW TO PLACE THE INK TANK ASSY WHEN DISASSEMBLING/REASSEMBLING The Ink Supply Tank Assy of this printer has an air release hole on the upper part.

  • Page 24: Factors Which Affect The Safety Of Service Personnel Such As Ink Leakage During Operation

    2.1.5.2 Factors which Affect the Safety of Service Personnel such as Ink Leakage during Operation Ink may spill when removing the following parts from L120. This section describes the parts that may cause ink spill and the means to minimize the ink spill when removing the parts.
  • Page 25 L120 Revision A MEANS TO MINIMIZE THE INK SPILL Even observing the points described in this section, ink may spill in the following situations. Therefore, be careful not to contaminate the inside of the printer or its surroundings by preparing the container to receive the leaked ink, or the like.
  • Page 26 L120 Revision A DISCHRGING INK FROM THE INK SUPPLY TANK Discharging ink is recommended only when disconnecting the Ink Supply Tank Tube Assy from the Ink Supply Tank. Before performing the above disconnection, discharge ink from the Ink Supply Tank as follows.
  • Page 27 L120 Revision A  It is recommended that the ink in the Ink Supply Tank should be discharged completely before proceeding to disassembling/reassembling.  After all the reassembling work is complete, the discharged ink of each color should be refilled back to the Ink Supply Tank before performing the adjustment. Confirm the colors indicated on the film of the Ink Supply Tank so as not to mistake them, and make sure to refill each ink back to the correct tank from the corresponding ink supply hole.

  • Page 28: Disassembly/Reassembly Procedures

    L120 Revision A 2.2 Disassembly/Reassembly Procedures This section describes procedures for disassembling the parts/units in a flowchart format. For some parts/units, detailed procedures or precautions are provided (accordingly indicated by icons and cell's color). Refer to the explanations in the example chart below and perform an appropriate disassembling and assembling procedure.

  • Page 29: Disassembly Flowchart

    L120 Revision A 2.2.1 Disassembly Flowchart START (p 29) Note "*": Proceed to the next step PF Encoder Paper Support Paper Support Waste Ink Pad Cap Tank Printer Cover with the part detached Assy Joint Assy Sensor* temporarily because the part cannot be removed fully there.
  • Page 30 L120 Revision A (p 29)  Extension spring PF Encoder Paper Support Sensor* (p29) Assy (p29) PF Scale (p29) LD Roller Cover Transistor Cover CR Scale CR Scale (p30) Hopper Transistor Cover (p30) CR Driven Pulley (p 34) (p 39)
  • Page 31 L120 Revision A (p 29) (p 29)  Ink Supply Tube Assy  Ink Supply Tube Assy Cap Tank (p29)  Ink Supply Tank Tube Assy Tube Guide Tube Pressing Adapter Joint Sheet Sub Plate  Ink Supply Tank Tube Assy ...
  • Page 32 L120 Revision A (p 30) (p 30) Cap Assy (p29) Shield Plate (p30)  Pump Tube Pump Unit Main Board Assy CR Motor (p30) Antistatic Cloth (p30) PE Sensor Lever  FFC/Cable* 5 (p30) (p 36) CR Unit Paper Guide...

  • Page 33: Disassembly Flowchart (Printhead/Main Board)

    L120 Revision A 2.2.2 Disassembly Flowchart (Printhead/Main Board)  Printhead  Main Board START START Cap Tank Cap Tank  Head FFC  FFC/Cable* 6 Shield Plate Printhead Ink Supply Tank Ink Supply Tank (p 35) (p 42) Upper Housing...

  • Page 34: Detailed Disassembly/Reassembly Procedure For Each Part/Unit

    L120 Revision A 2.3 Detailed Disassembly/Reassembly Procedure for each Part/Unit Housing Upper Assy CR Scale PS Unit Bottom Right side Right side Ink Supply Black triangle mark Tank Tube Assy Extension spring Housing Upper Assy CR Scale Do not pinch.
  • Page 35 L120 Revision A LD Roller Assy (1) LD Roller Assy (2) Printhead Main Frame Rear of printer CR Unit Change Lever Spur gear Printhead Clutch Main Frame Extension Spring Paper Back Lever LD Roller Shaft C.B.P-TITE SCREW 3x10 F/ZN-3C (7 ± 1 kgf·cm) When removing/replacing the Printhead, do not apply excess downward force when tightening the screws.
  • Page 36 L120 Revision A Main Frame Assy CR Driven Pulley Assy / CR Timing Belt Main Frame Align the screw holes of Main Frame and PF Motor Frame. Pinion gear of CR Motor Section A Main Frame Assy Main Frame Tighten screw while pressing Main...
  • Page 37 L120 Revision A CR Encoder Sensor Ink Supply Tank Upper Housing Ink Tank Label Refilling Ink Label Right side Back side Refilling Ink Label Ink Tank Label Hook Gap exists. No gap Cap Tank CR Encoder Sensor 2 ± 1 mm 20 ±...
  • Page 38 L120 Revision A Ink Supply Tube Assy Joint Step 6 2nd marking Tube clamp Ink Supply Tube Ink Supply Tube Assy: Step 1 Adapter CR Unit 0.5 mm or less 160 ± 1 mm Joint Black Yellow Joint Magenta Grooves...
  • Page 39 L120 Revision A Adapter Transistor Cover Hook Adapter Transistor Cover back side Film Connection of Ink Supply Tubes Ink Supply Tube Transistor Cover Hook Be careful not to damage or peel off the film of the Adapter. Dowel Use a precision screwdriver when releasing the hooks of the When removing the Transistor Cover, release the dowels (x 2) on Adapter.

  • Page 40: Routing Ffcs/Cables

    L120 Revision A 2.4 Routing FFCs/cables Main Board Assy Head FFC (Routing on the Main Frame) Aligning Head FFC with CR Encoder FFC Right side Head FFC Head FFC CN102 CN12 Fold here inside FFC Holder PF Motor cable Main Board...
  • Page 41 L120 Revision A CR Motor Do not apply too Hook C CR Motor cable CR Motor Hook D Groove of FFC Holder Hook E much tension. CR Motor cable CR Motor cable (red) Rib A Dowel of FFC Holder: Route above dowel.

  • Page 42: Chapter 3 Adjustment

    CHAPTER 3 ADJUSTMENT Confidential...

  • Page 43: Required Adjustments

    L120 Revision A 3.1 Required Adjustments The table from the following page lists the required adjustments depending upon the parts being repaired or replaced. Find the part(s) you removed or replaced, and check which adjustment(s) must be carried out.  If the EEPROM data cannot be read out from the old Main Board using the Adjustment Program when replacing the Main Board is required, the Waste Ink Pad Assy must be replaced with the Main Board at the same time.
  • Page 44 L120 Revision A Table 3-1. Required Adjustment List Adjustment Type Mechanism adjustment Adjustment using the Adjustment Program Priority Initialize Setting Checking the CR/PF Belt EEPROM Maintenance Head angular First dot position TOP margin PF deterioration CR motor heat PF motor heat...
  • Page 45 L120 Revision A Table 3-1. Required Adjustment List Adjustment Type Mechanism adjustment Adjustment using the Adjustment Program Priority Initialize Setting Checking the CR/PF Belt EEPROM Maintenance Head angular First dot position TOP margin PF deterioration CR motor heat PF motor heat...
  • Page 46 L120 Revision A Table 3-1. Required Adjustment List Adjustment Type Mechanism adjustment Adjustment using the Adjustment Program Priority Initialize Setting Checking the CR/PF Belt EEPROM Maintenance Head angular First dot position TOP margin PF deterioration CR motor heat PF motor heat...

  • Page 47: Adjustment Program

    L120 Revision A 3.2 Adjustment Program This section provides the operating environment, functions related to safety and privacy policy, and the adjustment item newly added of the Adjustment Program. See "3.1 Required Adjustments (p43)" for the adjustments not explained here.

  • Page 48: Mechanism Adjustment / Check

    (including using the Epson-specified jigs) according to this manual. If the PG cannot fall within the standard range after performing the platen gap check described in this section, first check if the unit is correctly reassembled following the instructions in this manual.
  • Page 49 L120 Revision A 1. Move the CR Unit to the center of the printer. 2. Place the thickness gauges (1.5 mm) on the position A shown in Figure 3-1. 80-digit side 0-digit side Figure 3-1. Position of the Thickness Gauge 3.

  • Page 50: Cr/Pf Belt Tension Check

    L120 Revision A 3.3.2 CR/PF Belt Tension Check This section describes the CR/PF Belt tension check.  This printer is designed so that the each tension of the CR Timing Belt and PF Timing Belt fall within the expected range if you correctly reassemble the unit according to this manual.
  • Page 51 L120 Revision A Checking the PF Timing Belt Tension Perform the PF Belt tension check before installing the PF Scale and the PF Encoder Sensor. 1. Set the following parameters to the sonic tension meter:  Weight: 1.1 g/m ...

  • Page 52: Chapter 4 Maintenance

    CHAPTER 4 MAINTENANCE Confidential...

  • Page 53: Overview

    ASP and the lubrication status when supplied as ASP. For the parts which are not supplied as ASP, if their movement is not smooth enough, check their lubrication status and lubricate them if necessary.  Grease Type Name EPSON Part Code Supplier Grease G-45 1033657 EPSON...

  • Page 54: Lubrication Points And Instructions

    L120 Revision A 4.2 Lubrication Points and Instructions None None supplied as ASP> Ribs (x12) and hooks (x6)
  • Page 55 L120 Revision A supplied as ASP> supplied as ASP>...

  • Page 56: Chapter 5 Appendix

    CHAPTER 5 APPENDIX Confidential...

  • Page 57: Connector Diagram

    L120 Revision A 5.1 Connector Diagram Cable connections of this printer are shown below. CR Unit CR Encoder Printhead CN102 Main Board PE Sensor CN12 CN13 CN501 PF Encoder PS Board CR Motor PF Motor AC in Figure 5-1. Connector Diagram 5.2 Points to be checked before packing the printer...

  • Page 58: Protection For Transportation

    L120 Revision A 5.3 Protection for Transportation This section describes the cautions for packing the printer before returning it to the user. 5.3.1 Securing the CR Unit  Purpose To prevent damaging the Change Lever by shock during transportation.  Risks if it is not performed Fatal error caused by the damage of the Change Lever.

  • Page 59: Securing The Printer Cover

    L120 Revision A 5.3.2 Securing the Printer Cover  Purpose To prevent damaging the Printer Cover by the shock during transportation.  Risks if it is not performed The Printer Cover will be scratched and the abrasion powder will be produced due to the shock during transportation.

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