How to Fix Grinding Noise and Fatal Error After Replacing a Capping Station

Question:
I recently purchased a replacement capping station because my old one was squirting ink. After installing the new unit, everything seems fine until the end of the cycle when the printer tries to seat. At that point, it runs ink through, makes a loud grinding noise, shakes the drive belt, and then gives a fatal error code. The last time I heard this grinding sound was when the old capping station was stuck underneath, but that was solved by cleaning. Since this is a new unit, why would it still be grinding, and is there something I can do to fix it?

Answer:

The problem you are describing-grinding noise, shaking drive belt, and fatal error after capping station replacement-usually points to an alignment or obstruction issue within the capping station or its surrounding components. Here are the key things to check:

1. Check the APG Platen Height

   • During installation, the platen height adjustment (APG) may have been changed without noticing. If the platen sits too high, the capping station mechanism won't align correctly with the printhead. This misalignment causes resistance, which the printer compensates for by forcing the drive belt-leading to the grinding noise and ultimately a fatal error.

2. Inspect for Caught Tubes or Obstructions

   • Look closely at the ink tubing around the capping station. A tube may have been caught, bent, or pinched during reinstallation. When the carriage moves, this can block the capping station's motion, causing the grinding.

   • Even though the capping station itself is new and clean, an external obstruction can mimic the same "locked" effect you experienced with your old one.

3. Manual Gear Rotation Test

   • If adjusting the platen height and checking tubes doesn't solve the problem, try this:

     • Stop the printer at the point just before the grinding begins.

     • Place your hand under the capping station assembly and manually rotate the gears.

     • Start the printer again, but this time keep the rubber wiper raised to see if the mechanism resets properly without resistance.

   • This test helps confirm whether the issue is mechanical binding or a misalignment of gears.

4. Fatal Error Codes

   • Many Epson-style printers display a "Fatal Error" message (sometimes logged as 0x9A or 0x97 error codes) when the carriage, capping, or drive system experiences too much resistance.

   • Since you specifically hear grinding before the error, the problem is mechanical rather than electronic-most likely a height or gear issue.

5. Other Considerations

   • Ensure that the capping station you purchased matches your printer model exactly. Even small design variations between units can result in alignment issues.

   • Double-check that the capping station is seated firmly and level in its mount. A slight tilt can cause gear slippage or excessive pressure.

Addressing printer issues can be a complicated affair due to the hands-on nature of the problems. So, we're not able to provide remote troubleshooting, suggestions, or support for printer repairs. We offer an in-person evaluation and repair service via our local diagnostic facility (https://bchtechnologies.com/printer-repair-service). Because of high demand, we work on a first-come, first-served basis, and it may take a few weeks before we can accept your printer. Our services can address either complete printer repairs or specific part issues, with clear instructions provided for customers. That said, our pricing may not be the lowest available, so we encourage you to also consider self-help. You can start by exploring our YouTube channel (https://youtube.com/@bchtechnologies) for guides-just use the search icon next to "About" to find videos on capping station repairs, fatal error troubleshooting, or drive belt issues. YouTube may also suggest other creators' content that could provide additional step-by-step help.

Thank you again for your question and for trusting us with your repair concerns. Your engagement motivates us to continue sharing detailed printer repair solutions.