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Epson Stylus Pro 7000 Series Service Manual Download Page 64

EPSON Stylus Pro 7000

Revision B

Operating Principles

Description of Components

64

PAPER-FEEDING-RELATED SENSORS

The following sensors aid in the paper feeding process.

†

P_FRONT sensor
This sensor is attached to the subplaten and is an optical (photo-
reflective) sensor. This sensor detects the front edge of the paper after 
paper has been loaded but before it is set and ready to print.

†

P_REAR sensor
This sensor is attached to the Upper Paper Guide and is an optical 
(photo-reflective) sensor. This sensor detects the rear edge of the 
paper and detects the front edge when the paper is first loaded in the 
paper path. The position of this sensor is stored in EEPROM.

†

P_EDGE sensor
This sensor is attached to the Cutter Housing section on the carriage 
and detects the right and left edges of the paper. This sensor is also 
used to check for paper skew by checking whether the edges are in 
the same location at the top and bottom of a page.

†

P_THICK sensor
This optical sensor physically gauges whether the paper falls into the 
normal/thin category or the thick category. For details, see “Platen 
Gap Mechanism” on page 70.

†

Paper Set Lever sensor
The Paper Set Lever sensor is located on the right side of the printer, 
and this optical sensor determines whether or not the Paper Set lever 
is in the set (print) position.

Figure 2-12.  Paper Feed Sensors

Table 2-2.  Paper Thickness Detection

Detected 

Thickness

Sensor Signal

Output Signal 

Strength

0.6mm or less

On

0.7V or more

0.7mm or more

Off

2.4V or more

Note that the P-Thick and Paper Set Lever sensors as well as 
their corresponding flags are located next to each other. The 
sensors employ the two metal flags on top of the Secondary 
Roller unit (second from the HP side when facing the 
printer). The left flag is used to determine the paper 
thickness and the right flag is used to determine the Paper 
Release Lever position.

P_Front 

sensor

P_Rear 

sensor

Double sensor and flag set:

R = Paper set lever sensor

L = P_Thick sensor

Paper feed 

direction

Paper Set 

lever

Summary of Contents for Stylus Pro 7000 Series

Page 1: ...EPSONStylusPRO7000 Color Large Format Inkjet Printer SEIJ99017 SERVICE MANUAL ...

Page 2: ...e contents of this manual However should any errors be detected SEIKO EPSON would greatly appreciate being informed of them 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 General Notice Other product names used herein are for identification purpose o...

Page 3: ... NOT CONNECT THE UNIT TO A POWER SOURCE UNTIL INSTRUCTED TO DO SO WHEN THE POWER SUPPLY CABLE MUST BE CONNECTED USE EXTREME CAUTION IN WORKING ON POWER SUPPLY AND OTHER ELECTRONIC COMPONENTS WARNING 1 REPAIRS ON EPSON PRODUCT SHOULD BE PERFORMED ONLY BY AN EPSON CERTIFIED REPAIR TECHNICIAN 2 MAKE CERTAIN THAT THE SOURCE VOLTAGES IS THE SAME AS THE RATED VOLTAGE LISTED ON THE SERIAL NUMBER RATING P...

Page 4: ...ES Describes the theory of electrical and mechanical operations of the product CHAPTER 3 TROUBLESHOOTING Provides the step by step procedures for the troubleshooting CHAPTER 4 DISASSEMBLY AND ASSEMBLY Describes the step by step procedures for disassembling and assembling the product CHAPTER 5 ADJUSTMENTS Provides Epson approved methods for adjustment CHAPTER 6 MAINTENANCE Provides preventive maint...

Page 5: ...in injury or loss of life C A U T I O N Indicates an operating or maintenance procedure practice or condition that if not strictly observed could result in damage to or destruction of equipment C H E C K P O I N T May indicate an operating or maintenance procedure practice or condition that is necessary to accomplish a task efficiently It may also provide additional information that is related to ...

Page 6: ...ess detection pg 46 cutter replacement pg 47 maintenance mode 2 description pg 50 transportation mode pg54 Fixed illustrations on pages 60 61 63 71 Fixed paper sensor volume adjustment Added parts list and lubrication points Added troubleshooting information regarding proper gap between cap and printhead Added troubleshooting information regarding the cutter housing and encoder sensor ...

Page 7: ...n Timing 23 Parallel Interface Nibble Mode 26 Parallel interface ECP mode 27 USB 29 TYPE B Optional Interface 30 Preventing Data Transfer Time Outs 30 Interface Selection 31 Physical Specifications 32 Printer Dimensions Weight 32 Setup Guidelines 32 Cutter Specifications 33 Control Panel 34 Buttons 34 LED indicators 35 Indicator Status in Normal Mode 36 Control Panel Messages 37 Panel Display Prio...

Page 8: ...ire a Service Technician 93 Maintenance Call 0100 93 Service Call 00000100 93 Service Call 00000101 93 Service Call 00010000 93 Service Call 00010001 94 Service Call 00010002 94 Service Call 00010003 94 Service Call 00010004 95 Service Call 00010005 95 Service Call 00010006 96 Service Call 00010007 96 Service Call 00010008 96 Service Call 00010009 97 Service Call 0001000A 97 Service Call 0001000B ...

Page 9: ...ameters From PC Card to new Board 160 Backup Download Error Recovery 161 Range of Backed Up Parameters 161 Firmware Update 162 Updating Firmware Via the PC 162 Updating Firmware From a Memory Card 163 Self Diagnostics 164 Self Diagnostic Mode Menus 165 Test Menu 166 Version 167 Control Panel 167 Sensors 168 Sensor Adjustment 169 Encoder 172 Fan 172 Elec 172 D A Revision and Head Signal 173 Adjustm...

Page 10: ...the ID to the New Board 202 Generating New ID Writing It to the New Board 202 Chapter 6 Maintenance General Maintenance Issues 204 Periodic Maintenance Items 206 Product Life Information 206 Important Maintenance Items During Service Operations 207 Lubrication and Glue 207 Chapter 7 Appendix Wiring Diagrams 209 Parts List 211 Exploded View Diagram 215 Component Layout 226 Circuit Diagrams 228 ...

Page 11: ...C H A P T E R 1 PRODUCTDESCRIPTION ...

Page 12: ...ure no paper at the leading edge is wasted Complete Software Compatibility With EPSON Stylus Pro 9000 Latest RIP Technology CPSI Pro software PS Server Large format yet provided as a desktop printer optional stand available Paper Handling Standard roll paper feeder Straight paper path Automatic paper cutter Table 1 1 Throughput Speed EPSON media Slide Bar Resolution Dot Mode Speed Plain Paper Spee...

Page 13: ...Feed Spindle 2 C811092 For two inch diameter roll paper Roll Feed Spindle 3 C811102 For three inch diameter roll paper Glossy Photo Paper S041225 610mm 24 in wide 20 7m long Semigloss Photo Roll Paper S041223 24 in wide 25m long Presentation Matte Roll Paper S041220 24 in wide 25m long Photo Quality Ink Jet Paper S041079 S041068 S041045 S041069 S041043 S041070 S041044 A2 A3 A3 Wide B B Photo Paper...

Page 14: ...1 2 of character matrix is printed at 360dpi 2pass Graphic mode CHARACTER SPECIFICATIONS Control codes ESC P Raster EPSON Remote command Character tables 2 international sets PC 437 US Standard Europe PC 850 Multilingual Typeface Bitmap LQ font EPSON Courier 10 CPI PAPER FEEDING Paper feeding method Friction feed Line spacing 1 6 or programmable at 1 720 Paper path Roll paper manual Feed speed 1 6...

Page 15: ...r edge of roll paper from the core 3 At the point where the rear edge comes free from the core approx last 30 cm print quality is no longer guaranteed 4 If a 3 core is used the EPSON exclusive optional 3 roll paper spindle is required EPSON Special Roll Paper The following special papers meet or exceed EPSON requirements and paper feeding plus printout quality are assured 1 Use at normal room temp...

Page 16: ...EPSON Special Paper The following special papers meet or exceed EPSON requirements and paper feeding plus printout quality are assured Size see the following table Table note 1 Print quality optimized with uni direction printing C A U T I O N Paper must have no wrinkles tears or folds plus the surface should be smooth Paper must be fed short edge first portrait Use at normal room temperature 15 25...

Page 17: ...rea Paper Feed Table 1 7 Printable Area Heading Roll Paper Cut Sheets PW width 210 610mm 8 27 24 210 610mm 8 27 24 PL length Max 90m 298 8 297 915mm 11 8 36 4 LM left margin 3mm 15mm 0 12 0 59 3mm TM top 3mm 15mm 3mm RM right 3mm 15mm 3mm BM bottom 3mm 15mm 14mm There are three margin settings via the control panel 3mm All margins are set to 3mm 15mm All margins are set to 15mm T B 15mm TM and BM ...

Page 18: ...C 22 122 F Less than a month at 40 C 104 F Less than 120 hours at 50 C 122 F Storage 20 40 C 7 6 104 F Less than a month at 40 C 104 F Installed 30 40 C 22 104 F Less than a month at 40 C 104 F Do not refill or reuse cartridges they are consumable items Do not use ink that beyond its expiration date See above To use ink that has been frozen below 15 C 5 F let it thaw at least 3 hours at room tempe...

Page 19: ... to the home position and then switch power off 2 Before transporting the printer remove the ink cartridges and turn the ink valves screws to the closed position Also make sure the printheads are in the home capped position After transporting the printer install new ink cartridges 3 If the temperature drops below 15 C 5 F the ink in the cartridges and printheads freezes The ink thaws completely af...

Page 20: ...he power off when the printheads are capped To thaw frozen ink in the printer or cartridge leave the printer out at a temperature of 25 C 77 F for approximately three hours 1 1 9 Controller CPU Hitachi SH7043 33Mhz RAM 8MB 2MB fixed Interfaces IEEE1284 USB Type B one expansion port Table 1 12 Vibration and Shock Condition Vibration Resistance Shock Resistance Notes Operating 0 15G 10 55Hz 1G maxim...

Page 21: ...rmity Safety Approvals 120V Model Safety Standards UL1950 CSA 22 2 No 950 EMI FCC part 15 subpart B class B CSA C108 8 class B 220 240V Model Safety Standards EN 60950 EMI EN55022 CISPR Pub 22 class B AS NZS 3548 class B 1 1 11 Acoustic Noise Approx 50dB A According to ISO 7779 ...

Page 22: ...23 EEC EN60950 EMC Directive 89 336 EEC EN55022 Class B EN61000 3 2 EN61000 3 3 EN50082 1 IEC801 2 IEC801 3 IEC801 4 1 2 Interfaces The EPSON Stylus Pro 7000 is equipped with parallel and USB interfaces as well as an expansion slot for an optional Type B interface This section provides information on each of these interfaces ...

Page 23: ...ed The ERROR signal is low when there is a Printer hardware error fatal error Paper out error Paper jam error Ink out error NOTE The PE signal is high during paper out errors DATA TRANSMISSION TIMING Figure 1 3 Data Transmission Timing Table 1 13 Parallel Interface Specifications Item Description Transmission mode 8 bit parallel IEEE 1284 compatibility mode Synchronization By STROBE pulse Handshak...

Page 24: ... time of every input signal Table 1 14 Data transmission times Parameter Minimum Maximum tsetup 500 ns thold 500 ns tstb 500 ns tready 0 tbusy 500 ns tt out 120 ns tt in 200 ns treply 0 tack Typical 2 us tnbusy 0 tnext 0 Table 1 15 Typical tack time Parallel I F mode Time required High speed default 0 5us Normal speed 2us ...

Page 25: ...IGH means the printer cannot receive data This occurs when the printer is receiving data or when the printer is in an error state 12 PE 28 O HIGH means no paper is loaded 13 SLCT 28 O Always HIGH when the printer is on 14 AFXT 30 I Not used 15 NC Not connected 16 GND Ground for twisted pair return 17 Chassis GND Ground for frame body 18 Logic H Pulled up to 5V via 3 9Kohm 19 30 GND Ground for twis...

Page 26: ...00H denotes a hexadecimal value of zero MDL values depend on the EEPROM setting Table 1 18 Connector Pin Assignments Reverse Channel Pin No Signal Name Return Pin In Out Functional Description 1 HostClk 19 I Host clock signal 2 9 Data0 7 20 27 I The DATA0 through DATA7 signals represent data bits 0 to7 respectively Each signal is at high level when data is logical 1 and low level when data is logi...

Page 27: ...nel Data trans timing Refer to IEEE 1284 specification Extensibility request The printer responds affirmatively when the extensibility request values are 10H or 14H 10H Request ECP Mode Reverse Channel Transfer 14H Request Device ID Return Data Using ECP Mode Reverse Channel Transfer Device ID The printer returns the following strings when the device ID is requested 00H 4EH MFG EPSON CMD ESCPL2 BD...

Page 28: ... signal in the forward direction 12 nAckReverse 28 O The printer goes to Low and approves the nReverseRequest Acknowledge data request signal and reverse channel transfer data bit 2 or 6 13 Xflag 28 O X flag signal and reverse channel transfer data bit 1 or 5 14 HostAck 30 I The host uses this signal for flow control in the reverse direction Also used for data bit 9 which indicates command informa...

Page 29: ... cable length 2 meters Figure 1 4 USB Pins Device ID 00H 4EH MFG EPSON CMD ESCPL2 BDC MDL Stylus SP Pro SP 7000 CLS PRINTER DES EPSON SP Stylus SP Pro SP 7000 NOTE To use USB interface set PARA I F COMPAT in the Printer Settings Menu Table 1 21 USB connector pin assignments and signals Pin no Signal name In Out Description 1 VCC Cable power max power consumption is 100mA 2 Data bi directional data...

Page 30: ...PW127cl10cpi PRG B0xxx rev AP1200ma SPD0fast Product name Stylus SP Pro SP 7000 Emulation type ESCPL2 00 Entity type ESPONLQ2 1 2 6 Preventing Data Transfer Time Outs Generally hosts abandon data transfer to peripherals when a peripheral is in the busy state for dozens of seconds continuously To prevent hosts from entering this kind of time out period the printer slows down the data reception rate...

Page 31: ...d As long as the host sends data or the printer interface is in the busy state the interface selection does not change When the host stops transferring data and the printer is in the stand by state for a certain period of time the printer returns to the idle state Interface status and selection When the option interface is selected the parallel USB interface goes into the busy state The LH signal ...

Page 32: ...ensions SETUP GUIDELINES When setting up the printer on a desk or table top refer to the instruction and illustration below When setting up the printer using the optional stand see the setup guide that comes with the stand for details 1 Make sure the printer is 60 80cm 24 32 off the floor 2 Make sure the nearest obstruction in front of the printer is at least 60cm 24 away 60 80cm Floor Nearest obs...

Page 33: ...ade Life The cutter can cut well over 2 000 sheets of paper but the actual wear and tear depends on the type and thickness of the paper used The cutter life can be determined manually attempt to cut a piece of normal paper and if the cutter easily cuts the paper it is OK Unlike the cutter position with the EPSON Stylus Pro 9000 the SP 7000 cutter position is automatically determined by the carriag...

Page 34: ...ed if pressed for over two seconds Table 1 22 Buttons and Functions Button Second function Function Normal SelecType Function Power On Function Power Power on off N A N A Pause Reset Switch pause ready Reset press 3 seconds N A Maintenance Mode SelecType Enters SelecType mode Opens Cutter Replacement Menu press for five seconds Selects menu or major category N A Cut Eject Enter Selects 1 Auto Cut ...

Page 35: ...or Pause On Flashing Paused Performing head cleaning or the printer is in ink drying phase Also flashes during ink charging operation Ink Out Y On Flashing Ink out Ink low Ink Out LM On Flashing Ink out Ink low Ink Out LC On Flashing Ink out Ink low Ink Out M On Flashing Ink out Ink low Ink Out C On Flashing Ink out Ink low Ink Out K On Flashing Ink out Ink low Roll Auto Cut On Flashing Auto cut s...

Page 36: ...er in release position On Paper is too thick to perform cleaning On Paper jam Flashing Paper cutting error Flashing Paper skew Flashing Paper check error Flashing Problem with paper eject sheet Flashing Fatal error Flashing Reset timer IC reset NVRAM clear On Table 1 26 Pause Indicator Printer Status Indicator Ready Off In SelecType mode Off Paused Off Ink drying phase Flashing Ink charging sequen...

Page 37: ...of ink has been consumed after the cartridge has entered the near end condition A near end cartridge has been removed and re installed READY Can receive and print data WAIT Resetting Timer IC Clearing NVRAM Performing reset operation Performing ink sequence operation Initializing the printer Initializing the paper INK CHARGING nnn Initial charging of ink shown in percent completed INK DRY xx MIN P...

Page 38: ...Maintenance required Processing data printer ready Out of paper UNABLE TO PRINT When trying to print a test or adjustment pattern one of the following occurs Paper not loaded Ink cartridge not loaded Paper detection error RELOAD PAPER The paper was loaded too far forward and cannot be backward fed to the proper position The paper s horizontal position exceeds the normal printable area when the pap...

Page 39: ...n it with the paper guideline 4 Pull the paper set lever forward to the set position 5 If the surface of the paper is dirty or indented anywhere use the Paper Feed buttons to skip over that area When that area passes the cut off line press the Cut Eject button This trims the unusable section of paper and the printer is now ready to print 6 Push the Pause button or wait ten seconds to automatically...

Page 40: ...current option or to execute the operation shown in the display Exiting SelecType mode Select one of the following methods to exit SelecType mode Press the Pause button while in SelecType mode the printer is ready to print Perform the printer initialization Print a status sheet Print a nozzle check pattern Replace the cutter Press the SelecType button several times at the top level of SelecType me...

Page 41: ... paper or paper with low reflective qualities such as tracing paper The print area is determined manually and the printheads will fire ink onto the platen if the print area is set larger than the actual paper size Table 1 31 Printer Setting Menu Display Message Options Notes PLATEN GAP Auto Wide Adjusts the platen gap Normally leave set to Auto PAGE LINE ON OFF When Auto Cut Off is selected on the...

Page 42: ...as a percentage 1 6 2 2 Status sheet Head Gap see Platen Gap in Printer Status Menu page 44 Border Line see Page Line in Printer Status Menu page 44 Interface See Table 1 31 Printer Setting Menu on page 41 Parallel I F See Table 1 31 Printer Setting Menu on page 41 Table 1 32 Test Print Menu Display Message Item Notes NOZZLE CHECK Print Check the printout any missing lines mean the nozzle s are cl...

Page 43: ...an 1 remaining Maintenance Req 0100 when the ink pads are calculated to be full Service Req 00000100 occurs and the printer cannot print After replacing the waste ink pads clear the waste ink counter with Maintenance Mode 2 See page 50 CR Motor life Monitors carriage passes to notify when ink tubes need replacing See above for count explanation Service Req 00000101 occurs when the count equals 0 P...

Page 44: ... four If you use EPSON media select STD and proceed to step 4 Table 1 34 Printer Status Menu Display message Meaning VERSION Shows the firmware version INK LEFT K Shows the amount of remaining ink Black INK LEFT C Shows the amount of remaining ink Cyan INK LEFT M Shows the amount of remaining ink Magenta INK LEFT LC Shows the amount of remaining ink Light Cyan INK LEFT LM Shows the amount of remai...

Page 45: ...o replace the cutter If you need to replace the cutter 1 Press the SelecType button until CUTTER REPLACE MENU appears on the LCD You can automatically enter the cutter replacement menu by pressing the SelecType button for five seconds 2 Open the Lower Cover as shown on the LCD 3 While pushing down the cutter the lower of the two extensions on the left slide the cutter actuator extension up and to ...

Page 46: ...etecting Paper Thickness on page 44 if necessary Press Enter 4 Select the pattern 1 12 or patterns ALL that you want to print See the table below for details Press the Enter button to print the test patterns 5 There are twelve sections in the printout and for each section determine which pattern is vertically aligned and enter the corresponding value 1 7 You will notice in the printout that sectio...

Page 47: ...after replacing the maintenance parts Waste Ink Counter Clear See Maintenance Mode 2 on page 50 Cleaner Counter See Maintenance Mode 2 on page 50 Table 1 37 Head Alignment Menu Display Messages Item Notes PAPER THICK STD 0 0 1 6mm Select the thickness to 0 1mm of the paper you are using to check the platen gap Normally leave set to Standard ADJUST PATT All 1 12 Selects which patterns to print All ...

Page 48: ...ead slide error 0001000D Cover sensor error 00 0001000E Cover sensor error 01 0001000F CR motor PWM output error 00010010 PF motor PWM output error 00020000 NVRAM Error 00020001 Internal RAM Check Error 00020002 SRAM Check Error 00020003 DRAM Check Error 0002000B Mail box receiving error 100000004 CPU Vector 4 General illegal instruction 100000006 CPU Vector 6 Slot illegal instruction 100000006 CP...

Page 49: ...0 To exit a mode turn the printer off and on again MAINTENANCE MODE To enter While pressing the Pause button turn the printer on C A U T I O N The following explanations regarding control panel service functions are for service and support purposes only do not share this information with the user Table 1 39 Maintenance Mode Message Item Explanation Hex Dump Print Prints the print data in hexadecim...

Page 50: ...ad Bi D offset setting 1 for Normal Dot 300cps BID OFFSET 2 4 0 4 Right head Bi D offset setting 2 for Micro Dot 300cps CLR HEAD ERROR Exec Clear head error INK K 0 4294967295 Ink remaining value K INK C 0 4294967295 Ink remaining value C INK M 0 4294967295 Ink remaining value M INK LC 0 4294967295 Ink remaining value LC INK LM 0 4294967295 Ink remaining value LM INK Y 0 4294967295 Ink remaining v...

Page 51: ... printer parts and adjustment operations For details see Chapter 5 Adjustment 1 9 Firmware Update The firmware contained on the Main Board is Flash ROM therefore if you need to update the firmware or replace the Main Board see Parameter Backup on page 159 and Firmware Update on page 162 for details C H E C K P O I N T The information contained in this section is not to be shared publicly ...

Page 52: ...nitialization When the Pause button is pressed for more than two seconds or the printer receives an INIT signal negative pulse from the parallel interface the printer If a single sheet is loaded the printer ejects the sheet If roll paper is loaded and Auto Cut is selected the printer cuts the printed area off and reverse feeds the paper If roll paper is loaded and Cutter Off is selected the printe...

Page 53: ...in the printer will perform an initial ink charge C H E C K P O I N T For long distance trips where the printheads will be dry for more than two or three days 1 Insert six transportation fluid cartridges 1045585 x six to charge with fluid 2 When the charge is finished turn off the printer and then remove the cartridges 3 Properly prepare and ship the printer 4 Set up the printer at the next locati...

Page 54: ...C H A P T E R 2 OPERATINGPRINCIPLES ...

Page 55: ...n PG HP unreflected out of PG HP P_Edge sensor 5VDC Photo reflector over threshold paper exists under threshold no paper Cutter solenoid 28VDC solenoid cutter drive Paper feed components PF motor 42VDC DC Servo motor PF encoder sensor 5VDC Rotary encoder two channel A phase B phase in PF motor Paper suction fans x2 28VDC DC motor fan P_Front sensor 5VDC Photo reflector over threshold paper exists ...

Page 56: ...56 Other components Cover open sensor 5VDC Mechanical switch Open cover open Closed cover closed Panel unit 5VDC C299MAIN board 42VDC 28VDC 5VDC 2VDC Printer control drive circuit board Power supply board Table 2 1 Printer Mechanism Components continued Part Drive voltage Description ...

Page 57: ...PRO 7000 BODY STAND Figure 2 1 Panel and AC inlet CARRIAGE COMPONENTS The carriage component functions are described in detail on page 60 Figure 2 2 Carriage Components Main Parts Control Panel AC inlet P Edge sensor underneath carriage Home position sensor Platen gap HP sensor Linear encoder sensor ...

Page 58: ... Figure 2 3 Paper Feed Components 1 Figure 2 4 Paper Feed Components 2 PF Motor belt Secondary Roller Assembly Paper Set Lever Second assembly from right R Paper Width flag L Paper Set Lever flag Frontal view of sensor flags Sideways view of sensor flags Paper suction fans Roll paper P Rear sensor P Front sensor ...

Page 59: ... Illustrations 59 INK SYSTEM COMPONENTS Figure 2 5 Ink System Main Parts ELECTRICAL CIRCUIT BOARDS Figure 2 6 Electrical Circuit Board locations Ink cartridge Ink cartridge holder Waste ink pads Maintenance assembly Flushing box Pump motor Main board Power supply board ...

Page 60: ...oftware servo NOTE CR motor errors such as overcurrent and encoder sensor malfunctions can be caused by simple problems for example dust ink on the T Fence or the T Fence is out of the sensor The following sensors are used in combination with the carriage components Home Position Sensor This optical sensor activates when the CR Guide Rail flag enters the space between the light emitter and the lig...

Page 61: ...are replaced in the same way Therefore after replacing the printheads hardware and software adjustments are necessary to make sure the nozzles are lined up and to make sure ink dots are fired in the correct places See Chapter 5 for details Other sensors and components attached to or related to the carriage are P EDGE sensor This sensor measures the distance between the right and left edges of the ...

Page 62: ...drives the cutter toward the paper The spring drives the cutter back away from the paper Also the cutter solenoid is used to release the carriage lock In order to cut roll paper evenly the following method is used 1 The cutter cuts from the left of center when facing the printout to the left edge 2 The cutter cuts from several centimeters inside the right edge to the right edge 3 The cutter cuts t...

Page 63: ...mbly is made up of three equal lengths of rollers and their coupling The PF Motor is a DC Motor that is controlled by the software servo system and the servo receives a pulse from the built in optical rotary encoder This rotary encoder allows for minute paper feeding The PF Roller torque is transferred through the PF Roller shaft edge left frame and turns the PF motor pinion gear and timing belt F...

Page 64: ...ion at the top and bottom of a page P_THICK sensor This optical sensor physically gauges whether the paper falls into the normal thin category or the thick category For details see Platen Gap Mechanism on page 70 Paper Set Lever sensor The Paper Set Lever sensor is located on the right side of the printer and this optical sensor determines whether or not the Paper Set lever is in the set print pos...

Page 65: ...ead cleaner The head cleaner has felt on one side and rubber on the other and is used to wipe or rub off ink and foreign materials from the nozzle surface Pump motor Clockwise rotation pump assembly drive for cleaning and so on Counter clockwise rotation platen gap adjustment Cap assembly one pad for each printhead When not printing the printheads should rest on the cap assembly to make sure the n...

Page 66: ...the opening at the bottom of the subcarriage when the carriage is in the home position However when the CR Motor is running the solenoid prevents the lock from engaging the carriage To release the carriage from the capping position the printer activates the cutter solenoid which pushes down the CR lock releasing the carriage To manually release the carriage when it is locked in the home position p...

Page 67: ...ing sensors are located in the ink cartridge compartments Ink Cartridge sensor This optical sensor is built in all six ink cartridge slots When a cartridge is installed switch closed When a cartridge is not installed switch open Ink Low sensor This mechanical sensor microswitch is at the bottom of all six ink cartridge slots and detects when ink is running out When the I C is nearly empty the swit...

Page 68: ... flow of that current When this happens the motors lose their electromagnetized state Figure 2 15 Cover Open Sensor The sudden loss of current to the motors can cause problems and may even damage the motors or the printhead To prevent this a discharge from the capacitor connected to the current circuit is used to slow down the current before it is totally cut off This process ensures that printing...

Page 69: ...stable enough to print for the next 10mm Stop Control stop position The encoder determines the carriage position by counting the dark stripes on the Step Ruler When the carriage reaches the predetermined position depends on paper width the carriage stops To make sure the carriage has come to a complete stop the printer checks the encoder for a certain time in position time out to make sure no sign...

Page 70: ... main carriage which is secured to the CR guide rail via bearings and the subcarriage which holds the printheads The subcarriage is secured with a cam and due to the cam s shape the subcarriage can be raised or lowered depending on the rotation of the cam See Figure 2 17 The platen gap adjustment is linear the nozzle surface is constantly parallel to the paper surface Figure 2 17 Platen Gap Contro...

Page 71: ...he control panel Platen Gap setting NOTE You can manually set the platen gap See Platen Gap in Printer Setting Menu on page 41 for information on making this setting The three platen gap height settings as described in the table below Table 2 4 Determining PG Settings Control Panel Setting Command Setup Paper Thickness Sensor Actual Platen Gap Position Wide Wide PG Wide Wide Thin Wide Default PG W...

Page 72: ...12 Paper Feed Sensors on page 64 Another important point to remember about the paper feed mechanism is the paper suction fans The paper suction fans are located behind the lower paper guide and are necessary to keep the roll paper flat against the lower paper guide which prevents ink smears The fans create a vacuum through the holes in the lower paper guide pulling the paper flat against the guide...

Page 73: ...y or plain paper Next the carriage moves from the home position toward the opposite frame and measures the distance from the home position to the opposite right edge of the paper according to the brightness high and low levels If the paper edge has not been determined by a certain point outside of the printheads print range the paper is loaded too far to the right and a Reload Paper error occurs O...

Page 74: ...e Dotted line Left top edge Right top edge Leading edge detection Perform regular flushing Stop suction fans stop CR moves to 30mm inside left edge Max reverse feed 200mm P Front sensor on Max reverse feed P Front sensor Reverse feed 40mm Before beginning this procedure the printer must determine the sensor s high and low reflection levels see page 73 CR moves to preset position P Width sensor Rig...

Page 75: ...rea Paper loaded within 10mm of the center of the vertical line of holes in the Lower Paper Guide is considered in the printable zone however paper loaded outside that 10mm zone causes an error Paper skew In order to avoid printing on paper that is skewed or fed at a slant too far to the right or left the printer detects the right and left edges at the leading edge of every page If the printer det...

Page 76: ...IC39 SRAM 8KB IC73 74 75 76 DRAM 8MB IC81 82 DRAM 2MB IC1 2 Flash ROM 1MB Firmware D A adjustment setting parameters CN20 PCMCIA CARD Socket IC32 ASIC uPD65802 IC20 ASIC TE7751 IC37 DAC M65530FP IC33 Head drive voltage common driver Printheads B C CR Motor PF Motor Pump Motor Fan Motor x2 Printer mechanism Motor drivers B head C head Head drive wave generation Head data control signals IC35 IC30 I...

Page 77: ...n Paper suction x2 ASIC uPD65802 IC32 Motor regulation PWM regulation CR Motor PF Motor DAC M65530FP IC37 3 channel 10 bit DA converter head drive voltage control Flash Memory MBM29F400TC IC1 IC2 Flash Memory 1Mbyte Save firmware Register D A user defined and factory default setting parameters DRAM EDO IC81 IC82 IC73 76 EDO RAM 10Mbyte onboard SRAM LC3564SM 10 IC39 64Kbit SRAM External data ring b...

Page 78: ...vent ink from clogging the nozzles Always turn off the printer using the power switch do not remove the power cable from the wall outlet while the printer is on or while internal parts are moving Table 2 7 PS Board Signal Summary Signal Name Condition Function 28V 42V REM_ON MAIN PS During operation The On Off status is controlled from the C299MAIN board Printer off When this terminal is released ...

Page 79: ...C H A P T E R 3 TROUBLESHOOTING ...

Page 80: ...n freely The rubber pads on the rollers are not dirty Clean if necessary The rubber pads on the rollers are not worn not wearing out unevenly and are connecting properly turn freely If necessary reset the NVRAM parameters to the factory default parameters Maintenance Mode 2 Counter Init Menu NVRAM Init 3 1 2 Remember Before beginning disassembly turn the printer off wait for a few seconds after th...

Page 81: ... message However when the waste ink counter determines the Waste Ink pads are 100 full the Service Req 00000100 message appears and the printer can no longer print To clear this condition perform the following Replace The following items must be replaced Waste Ink Pads Pump Assembly Cap Assembly Flushing Box Cleaner Head Required Adjustments Perform the following adjustments after replacing the ma...

Page 82: ... Cover sensor error 00 00010000E Cover sensor error 01 00010000F CR motor PWM output error 000100010 PF motor PWM output error 000200000 NVRAM Error 000200001 Internal RAM Check Error 000200002 SRAM Check Error 000200003 DRAM Check Error 0002000B Memory Mail Box reception error 100000004 CPU Vector 4 General illegal instruction 100000006 CPU Vector 6 Slot illegal instruction 100000006 CPU Vector 9...

Page 83: ...nnot Print There is a problem Error 91 Printing Printing the current print job Status Option I F Error Type B interface error Error 91 No Cartridge One or more ink cartridges not installed Error 91 Cover Open The cover is open Error 88 Turn off on The printer needs to re initialize Status Service Call nnnnnnnn Fatal error occurred Error 92 Please Wait Initializing printer initializing paper chargi...

Page 84: ...Servo interrupt watchdog time out error page 96 00010009 System interrupt watchdog time out error page 97 0001000A CR origin sensor malfunction page 97 0001000C PG origin sensor malfunction page 97 0001000D Cover sensor malfunction 00 page 97 0001000E Cover sensor malfunction 01 page 97 0001000F CR motor PWM output error page 97 00010010 PF motor PWM output error page 97 00020000 NVRAM error page ...

Page 85: ... 99 Load xxx Paper page 100 Load Paper page 100 Paper Jam page 100 Cover Open page 100 Paper Not Cut page 101 Paper Not Straight page 101 Reload Paper page 101 Push Lever Down page 102 Ink Out page 102 No Ink Cartridge page 102 Remove Paper page 103 Option I F Error page 103 Table 3 5 Ink Low Item Description LCD message Ink Low LEDindicator status The LED indicator for the ink cartridge that is l...

Page 86: ...nd reset the corresponding counters Waste Ink and Cleaning Table 3 7 No Paper Loaded Item Description LCD message No Paper Loaded LEDindicator status Paper Check indicator is on Details No paper loaded or the end of the roll paper When printing on roll paper if the Paper End sensor detects the end of the roll paper paper feeding stops and the paper is held in place When printing on cut sheets if t...

Page 87: ... Table 3 10 Please Load Paper Item Description LCD message Please Load Paper LEDindicator status The Paper Check indicator in on Details The Paper Set Lever is in the release position While loading paper the Paper Set Lever was pushed to the release position Recovery Pull the Lever forward to the paper set position to clear the error If the error doesn t clear check the Paper Set lever position se...

Page 88: ...ersely affecting printout quality If this error occurs even though both sides of the cover are securely closed check the cover open sensor interlock switch on the left side for proper operation and position Table 3 13 Paper Not Cut Item Description LCD message Paper Not Cut LEDindicator status Paper Check indicator flashes Details Paper cut error occurred The page was not cut entirely or the page ...

Page 89: ...ich can happen under the following conditions 1 The user loaded the leading edge of the paper too far into the printer The printer can only reverse feed the paper a set distance and if the paper is loaded too far it will not reverse feed far enough 2 The printer detected that the paper was loaded outside of the printable area carriage path 3 After printing the printer detected that the paper is ou...

Page 90: ...ring ink cartridge replacement Recovery Finish replacing the ink cartridge s and close the ink cartridge holder door The printer automatically returns to the pre error state i e Ready or Paused Table 3 18 Replace Ink Cartridge Item Description LCD message Replace Ink Cartridge LEDindicator status The Ink End indicator for the incorrect slot if an ink cartridge is installed in the wrong slot or emp...

Page 91: ...card and turn the printer back on Install a supported option card if necessary Table 3 21 Remove Paper Item Description LCD message Remove Paper LEDindicator status Paper Check LED is on Details Paper is too thick to allow for head cleaning The currently loaded paper is too thick to allow for timed cleaning Recovery Move the Paper Set Lever to the release position remove the paper and return the L...

Page 92: ... their predetermined 93 00010000 PF motor encoder check error out of step error 93 00010001 PF motor motor out of step 94 00010002 PF motor overcurrent 94 00010003 PF motor in position time out error 94 00010004 CR motor encoder check error out of step error 95 00010005 CR motor motor out of step 95 00010006 CR motor overcurrent 96 00010007 CR motor in position time out error 96 00010008 Servo wat...

Page 93: ...and Cleaning counter SERVICE CALL 00000101 Problem A printer part has exceeded its useful life and to prevent damage to other parts as well as abnormal operations printouts an error occurs This error occurs when the CR Motor has reached 2 5 million passes and this indicates the ink tubes should be replaced due to excessive wear and tear Solution To make sure the ink tubes are not worn out verify n...

Page 94: ...lace the Main Board SERVICE CALL 00010002 Problem PF motor overcurrent Feedback from the PF motor IC35 driver s 10 pin output sensor signal indicates that the PF motor s current is irregular Solution Replace the PF motor Replace the Main Board SERVICE CALL 00010003 Problem PF in position time out The in position time is the amount of time the printer waits to make sure the carriage is not moving w...

Page 95: ...amage Make sure no foreign material or ink tubes from pump assembly are blocking the carriage path see Removing the Maintenance Assembly on page 143 for reassembly points Replace the encoder sensor Replace the CR motor Replace the Main Board SERVICE CALL 00010005 Problem CR motor out of step the length of the CR motor s pulse is too long or too short compared to the regular pulse Solution Make sur...

Page 96: ...e Assembly on page 143 for reassembly points Replace the CR motor Replace the Main Board SERVICE CALL 00010007 Problem CR in position time out The in position time is the amount of time the printer waits to make sure the carriage is not moving when the carriage comes to a stop The linear encoder is activate for the predetermined in position time and if the encoder sends a pulse this means the carr...

Page 97: ...n Solution Make sure there is no ink or dust on the surface of the sensor If this does not solve the problem check the PG sensor connection If there still is a problem try the following Replace the PG sensor Replace the PG motor Replace the Main Board SERVICE CALL 0001000D SERVICE CALL 0001000E Problem Cover sensor malfunction one or both cover open sensors interlock switch located at either end o...

Page 98: ...r have a nice day Make sure no machines that share the same power supply with the PC or printer are turned on while the print job is being sent Make sure the interface cable is within specifications for this printer Replace the interface cable it may be worn out To make sure an errant command code is not the cause try sending a different print job or send the print job from another application or ...

Page 99: ...ob using cut sheets is finished or the rear edge of cut sheet paper has been detected Solution If paper has run out remove the printer paper and load new paper If print data remains in the printer the data will be printed If this error occurs even though paper is properly loaded there may be something on the P Rear sensor s surface Clean the sensor s surface hole in the Paper Guide Upper with a cl...

Page 100: ...ont sensor and P Rear sensors are in the on state but the CR motor is out of step or has overcurrent Solution After removing the paper stuck in the printer the TURN OFF AND ON message appears on the display The printer is ready after you turn the printer off and back on again If a paper jams occurs again after removing the original paper jam check to make sure nothing is blocking the feed path or ...

Page 101: ...aper and carefully squeeze the sides of the roll to make sure the edges are lined up and flat RELOAD PAPER Problem This error occurs when 1 The front edge is loaded too far and the paper is not in the loading position after it is reverse fed 2 The paper was loaded in such a way that the left and or right edge is out of the printable area due to mis loading or because the paper is too wide 3 After ...

Page 102: ...on sensor INK OUT Problem One or more ink cartridges have run out of ink a near end cartridge has been reinstalled or an unsupported ink cartridge has been installed Solution Replace the empty ink cartridge Make sure the ink cartridge is the proper type of cartridge for the printer and the proper color for that slot If the proper cartridge is installed and this error still occurs check the Ink End...

Page 103: ...This section describes conceivable print quality problems that may occur with this printer and the troubleshooting points for those errors DOT MISSING When the printer is not used for a long period of time the ink in the nozzles can dry up and clog the nozzles Clogged nozzles cannot fire ink and cause the dot missing problem in printed documents If the printhead nozzles do not clear after attempti...

Page 104: ...s listed below and check the print out Main Board Printhead s UNEVEN PRINTING POOR RESOLUTION If printout quality suffers from unevenness poor quality or similar problems check the following 1 Perform platen gap adjustment Using the control panel setting or the diagnostic program function check the platen gap bi directional printing position as well as PG adjustment 2 If this error occurs only whe...

Page 105: ...problem recurs check the Cap Assembly retention spring If this spring is broken or comes off its hook the Cap Assembly cannot wipe ink off the printhead surface and that ink will smudge the printout Fix or replace this spring SMUDGED OR MARRED PRINTOUT REVERSE SIDE The reverse side of the paper can become smudged or marred if there is ink on the printer parts Make sure there is no ink on the follo...

Page 106: ...C H A P T E R 4 DISASSEMBLY ASSEMBLY ...

Page 107: ...g the disassembly instructions in reverse order and where special instructions are necessary reassembly points are provided Where Caution and Reassembly notes are given be sure to confirm these contents BEFORE starting the corresponding procedure Where adjustment procedures are necessary Adjustment Required notes describe what you need do to These adjustment procedures are absolutely necessary and...

Page 108: ...or other batteries so that electrodes of the opposite polarity do not come in contact with each other Do not heat the battery or put it near fire Do not solder on any part of the battery Doing so may result in leakage of electrolyte from the battery burning or explosion The leakage may affect other devices close to the battery Do not charge the battery An explosion may be generated inside the batt...

Page 109: ...ake sure all parts are secured otherwise you re going to be in big trouble Ink may leak onto other printer parts or the printer basket when removing printer parts so it is recommended to put a sheet or cloth under the printer especially when working on or near ink related parts When working on the electrical circuit boards be careful concerning static electricity which can cause damage to the boar...

Page 110: ...harge with the fluid Enter the transportation mode again to remove the fluid user can do and then perform initial ink charge with ink The directional instructions in this chapter are given as if viewing the printer from the front See the illustration below Top Bottom Rear Front R L Table 4 1 Necessary Tools Tool Part Code Notes Phillips screwdriver 2 commonly available tools no special tools neces...

Page 111: ...ight CUPS M4x8 white Cup S tight CUPS M3x6 white Cup S tight CPP M3 x8 white Crosshead Pan P tight CPS M3x12 white Crosshead Pan S tight CP M3x6 white Crosshead Pan CP W M2x12 silver Crosshead Pan washer CP W M2x8 silver Crosshead Pan washer CP W M3x6 silver Crosshead Pan washer CP W M3x8 silver Crosshead Pan washer CP W M3x25 silver Crosshead Pan washer CP W M4x8 silver Crosshead Pan washer CP W ...

Page 112: ...Process Flowchart 4 2 1 Remove Panel Housing 4 2 2 Remove Circuit Board Panel Unit L R Side Covers H Top Cover Front Cover Roll Cover Lower Paper Guide Rear Panel Power Supply Board C299MAIN Board 4 2 3 Disassemble Printer Mechanism Replace Waste Ink Pads Replace Printheads CR Motor Pulley Assembly PF Motor Pulley Assembly Maintenance Assembly Sensors 4 2 4 Disassemble Ink System Mechanism ...

Page 113: ...of the control panel unit and pull slightly away from the R Side Cover Figure 4 4 Panel Unit Removal 1 2 Roll Cover Assembly Upper Paper Guide behind H Top Cover R Side Cover H Top Cover Lower Paper Guide Front Cover Assembly L Side Cover C H E C K P O I N T You may find it easy to remove the control panel if you stand on the side of the printer and use both hands to pull squeeze the panel towards...

Page 114: ...black screws CBP M4x10 from the lever handle and remove the handle 4 Using a driver or similar tool remove the lever opening cap The cap may fall through the hole so it is recommend you secure the cap between your finger and the driver as you remove the cap Figure 4 6 Paper Set Lever Handle Removal When replacing the control panel and FFC make sure you push the FFC cable slack inside and towards t...

Page 115: ...and from the right side remove two white screws CUPS M4x8 Figure 4 8 R Side Cover Removal 2 4 7 Open the front cover and remove one black screw CPP M4x12 Figure 4 9 R Side Cover Removal 3 4 8 Return the Paper Set Lever to the set position and pull off the R Side Cover to the right Figure 4 10 R Side Cover Removal 4 4 Roll Cover One screw R Side Cover Three screws One screw on inside of right cover...

Page 116: ...PS M4x8 and from the left side remove two white screws CUPS M4x8 Figure 4 12 L Side Cover Removal 2 2 4 Pull off the L Side Cover to the left 4 2 1 4 I C Holder Cover Removal 1 Remove the L Side cover as described in 4 2 1 3 L Side Cover Removal 2 Open the I C Holder Cover 3 Remove two white screws CBS M3x10 Figure 4 13 I C Holder Cover Removal 4 Remove the cover and frame One screw Roll Cover Thr...

Page 117: ...1 3 L Side Cover Removal 3 Remove the I C Holder Cover as described in 4 2 1 4 I C Holder Cover Removal 4 Open the Front Cover 5 From the right side remove two screws CUPS M4x8 and from the left side remove three screws CUPS M4x8 Figure 4 14 H Top Cover Removal on right side Figure 4 15 H Top Cover Removal on left side 6 Remove the cover by pulling up and toward the rear H Top Cover Two screws H T...

Page 118: ...ng the parallel interface and remove the one white screw CBS M3x6 securing the USB interface 3 Remove the one white screw CBS M3x6 securing the AC inlet Figure 4 17 Rear Cover Removal 4 Remove three white screws CBS M4x8 securing the lower section of the cover and remove three white screws CBS M4x8 securing the upper section of the cover 5 Remove the Rear Cover by pulling to the rear lift and pull...

Page 119: ... right side Figure 4 19 Paper Guide L2 removal on left side Two screws Paper Guide L2 Paper Guide L2 Two screws When replacing the Paper Guide L2 make sure the five tabs at the top of the guide slide in between the metal and black cushion Then secure with the screws If just one of the tabs is not inserted properly roll paper will most likely still feed normally but cut sheets might not Paper Guide...

Page 120: ...e the spindle support Figure 4 20 Roll Paper Cover removal on left side 3 Remove two white screws CPS M4x8 securing the gray spindle support on the right and then remove the spindle support Figure 4 21 Roll Paper Cover removal on right side 4 Remove the cover brake pin from either the left or right side and remove the cover Two screws Spindle support Brake pin Roll Paper Cover Two screws Spindle s...

Page 121: ...t the front cover spring L and Front Cover come free at this time Figure 4 24 Front Cover Removal 3 3 5 Remove the Front Cover and front cover spring R from the front cover support shaft Spring catch E ring Frontcover spring L Front shaft cover Shaft cover hooks x2 Front cover support shaft Front cover support shaft Frontcover spring R E ring Spring catch Push the front cover support shaft back to...

Page 122: ... to the Power Board as shown below 3 Remove the four white screws CPS M4x8 securing the Power Board and then remove the Power Board Figure 4 25 Power Supply Board Removal W A R N I N G Unplug the AC power cable and wait at least five minutes before removing the power supply board to make sure there is no residual power left in the board s condensers Table 4 3 Power Supply Board Connectors Connecto...

Page 123: ...ed 1 PG_HP snsr Head_Slide CN39 4 yellow 2 P_Front snsr CN11 4 red 2 P_Front snsr CN13 5 white 3 PF Motor encoder CN32 4 blue 3 ink snsr M CN35 5 red 3 ink snsr Y CN9 30 white special CR board Assy 2 lock type CN8 30 white special CR board Assy 1 lock type CN31 4 yellow 4 ink snsr C CN34 5 red 3 ink snsr LM CN30 4 white 4 ink snsr Bk CN33 5 blue 3 ink snsr LC CN10 2 white 4 PS fan CN24 4 white 3 P...

Page 124: ...bly of the AC inlet 1 Remove the holder from the printer as described in AC Inlet Removal on page 124 2 Remove two white screws Dish M3x6 securing the AC inlet and remove the inlet Figure 4 28 AC Inlet Removal C A U T I O N When removing re inserting the flat cable FFC from to a connector make sure to pull insert the cable straight Otherwise internal contact of the connector may be damaged and thi...

Page 125: ...T I O N Do not remove or loosen the screws that secure the CR guide rail also do not remove the carriage These parts are adjusted to 1 100th of a mm at the factory Do not attempt any kind of service or adjustment to the frame or parts attached directly to the frame See the Parts List in Chapter 7 for a list of parts that you can service replace Other parts can only be assembled and adjusted at the...

Page 126: ... L2 Removal on page 119 2 Remove the two waste ink tubes white small diameter and the one flushing tube clear large diameter from the tubes clamps Figure 4 29 Remove the tubes 3 Remove the Waste Ink Box by sliding it forward so the hooks on both sides release and then pull up Figure 4 30 Waste Ink Box C A U T I O N When the waste ink counter indicates the ink pads need to be replaced the following...

Page 127: ...ode 2 on page 50 INIT WASTE INK INIT CLEANING Waste ink box clamp Four layers of pads Six layers of pads Three hooks To reassemble the waste ink box and related parts follow the above steps in reverse order and make sure you keep the following in mind Four pads in the lower side six pads in the upper side The waste ink tubes should be inserted into the box so that the ends are about 20mm a little ...

Page 128: ...from the printer as described in steps 1 to 3 only of Replacing the Waste Ink Pads on page 126 3 Remove the two screws CP W M4x8 and one screw CP W M4x40 securing the fan duct and then remove the fan duct Figure 4 32 Suction Fan Removal 4 Disconnect the fan connector and harness 5 Remove the one screw CP W M4x8 securing the fan and remove the fan Suctions fans One screw One screw Fan duct Two scre...

Page 129: ...o make sure you do not mix the heads One is for dark inks and the other is for light inks Therefore make sure you prepare and install the correct replacement head B head F055040 Printhead IJ192 OAD damper order B C M C head F055050 Printhead IJ192 OAE damper order LC LM Y The printheads are the same for the EPSON Stylus Pro 9000 and EPSON Stylus Pro 7000 Before replacing the printheads you will ne...

Page 130: ... a damper and steady the damper with the forefinger of your other hand Gently but firmly pull the damper straight out Figure 4 35 Damper Removal Ink tubes Ink tubes Damper holder One screw C H E C K P O I N T If you only need to replace one head you only need to perform the following steps in regards to that printhead B head left side B C M C head right side LC LM Y C A U T I O N Do not squeeze th...

Page 131: ...h 9 for the B head Tension Spring 9 9 H Spacer screw Printhead voltage ID FFC C head C H E C K P O I N T When replacing the printheads fold the flat cable behind the printhead and make sure the printhead snaps fully into place When properly installed the printhead ID will be directly behind and at the same height as the PG Cam Shaft If the PG Cam Shaft does not partially block the line of sight of...

Page 132: ... CR board guide Figure 4 38 CR Board Guide Removal 6 While holding down the CR Board left edge remove two FFC cables from the FFC lock type connectors Figure 4 39 CR Board FFC Removal 7 While holding down the CR Board left edge remove three connectors from the CR Board Figure 4 40 Connector and CR Board Removal 8 Remove two screws CPP M3x8 then remove the CR Board You may find it helpful to manual...

Page 133: ...o make sure the sensor clears the carriage wall as you pull the cutter housing to the left to remove it C H E C K P O I N T Before each step in this operation take a good look at the relative parts and where they are or how they are housed This is not an easy procedure and reassembly is even harder if you do not pay strict attention to how the parts fit together Read this entire section and become...

Page 134: ...rriage side which warps the cutter housing Since the encoder sensor is attached to the cutter housing the encoder may have problems trust me If you run into the following or similar errors after replacing the cutter housing loosen the screws a little and try again Service Req 0001000F Service Req 00010006 Cutter guide height lock Cutter guide P_EDGE sensor Hole shaped like T slide over correspondi...

Page 135: ...lenoid core and cutter solenoid spring Figure 4 46 Cutter Solenoid Removal 4 Remove two screws CP W M3x6 securing the cutter solenoid and then using a driver or similar tool push the solenoid out from underneath the Cutter Assembly After reassembly of the cutter housing perform an auto cut operation to make sure 1 the cutter correctly disengages the CR lock and 2 the cutter correctly cuts the pape...

Page 136: ... securing the CR Encoder Sensor ground and washer M3 Then remove the CR Encode Sensor Figure 4 47 CR Encoder Sensor Removal 4 2 3 8 Removing the P_Edge Sensor 1 Remove the cutter housing as described in Removing the Cutter Housing on page 133 2 Remove one screw CBP M3x6 securing the P_Edge sensor and remove the sensor Figure 4 48 P_Edge Sensor Removal CR Encoder Sensor One screw One screw Inner Fa...

Page 137: ...r cable and six Ink Cartridge sensor cables from the C299MAIN board refer to Table 4 4 C299MAIN Board Connectors on page 123 for details and then remove the cables from their harness clamps 7 Pull out the cables through the opening in the L Side frame and remove the cables from the four clamps Figure 4 49 Ink Sensor Harness Removal 8 Remove two screws CPP M3x8 securing the ink tube cover and remov...

Page 138: ...lder Frame on the right side 11 Remove one screw CUPS M3x6 and one screw CUPS M4x6 securing the I C Holder Frame on the left side Figure 4 52 Holder Frame Removal L side 12 Remove six screws CUPS M3x6 and two screws CUPS M4x6 securing the I C Holder Frame on the top Figure 4 53 Holder Frame Removal top 13 Remove the Ink Cartridge sensor cables from their harness connectors and separate them I C Ho...

Page 139: ... and ink cartridge holder slots Also remove the O rings Figure 4 54 Disconnecting the Ink Pipes 15 For the slot you want to remove remove the corresponding two screws CPS M3x12 securing the slot frame to the base Remove that slot frame Figure 4 55 Slot Frame Removal top view Ink pipes Ink tube screws and O rings Two screws Slot frame ...

Page 140: ...he cable completely through the bottom Figure 4 56 Ink Cartridge Sensor Cable Removal 3 Remove the screw CBS M3x10 securing the Ink Low sensor and remove the sensor Figure 4 57 Ink Low Sensor Removal 4 Remove two screws CUPS M3x6 securing the needle frame and remove the frame 5 Remove one screw CBS M2x8 securing the I C sensor to the needle frame and remove the I C sensor Figure 4 58 I C Sensor Re...

Page 141: ... printer to release the tension on the CR Timing belt Figure 4 59 Loosening the CR Tension Belt 7 Pull off the CR Timing Belt from the CR Motor pulley on the left side of the printer 8 Remove the four screws CP W M4x10 securing the CR motor and remove the CR motor Figure 4 60 CR Motor Removal C H E C K P O I N T Before loosening the CR timing belt tension confirm and write down the current tension...

Page 142: ... from the reduction gear by moving the belt inward 7 Remove the two CP W M3x8 screws securing the PF Motor Assembly to the PF motor bracket and then remove the PF motor bearing PF motor spacer and PF motor in that order Figure 4 62 Removing the PF Motor Assembly Clamp L Side Frame PF Motor Connector for Drive PF Motor Connector for encoder signals C A U T I O N When assembling the PF Motor Assembl...

Page 143: ...ntenance Base Assembly respectively Figure 4 64 Removing the Harnesses 2 A D J U S T M E N T R E Q U I R E D If you replace the waste ink absorbers because the service call error 0000100 occurs you need to replace the specified parts in the Maintenance Assembly After replacing them be sure to initialize the following counters Waste ink counter Cleaning unit counter Parts to be replaced Pump Motor ...

Page 144: ...intenance Base Assembly 1 Figure 4 66 Removing the Maintenance Base Assembly 2 Figure 4 67 Removing the Maintenance Base Assembly 3 8 Shift the Maintenance Base Assembly to the left to release the joint with the R Side Frame Then watching out for the harnesses lower the Maintenance Base Assembly and remove it Figure 4 68 Maintenance Base Assembly Screw M4x6 Screw Driver Screw M4x6 Screw Driver Scr...

Page 145: ...y Cause damage to the nozzle surface by scraping the nozzle surface on the capping flag no error message Cause clogged nozzles and or cause the printer to leak ink if the cap and nozzle surface do not form a good seal in the capping position make sure both caps are tightly sealed like the one on the left no error message Good seal No good you can see through the space between the nozzle surface an...

Page 146: ...as described in Removing the Maintenance Assembly on page 143 2 Release the harness for the Pump Motor Assembly from the cable clamp 3 Remove the three CP W M3x8 screws securing the Pump Motor Assembly to the Maintenance Base Assembly and remove the Pump Motor Assembly Figure 4 69 Removing the Pump Motor Assembly Pump Motor Assembly Clamp Screws M3x8 ...

Page 147: ...e Frame Sub Assembly 3 Remove the one CUPS M3x6 screw securing the Cap Assembly disconnect the two tubes from the Pump Assembly and remove the Cap Assembly Figure 4 71 Removing the Cap Assembly Figure 4 72 Cap Assembly R Side Frame Sub Assembly Screws M4x6 Screws M4x6 Cap Assembly Screw M3x6 Tubes connect here C A U T I O N Check for the points below when removing mounting the Cap Assembly Push th...

Page 148: ...ing the Pump Assembly and remove the Pump Assembly Figure 4 73 Removing the Pump Assembly 4 2 3 17 Removing the Cleaner Head 1 Remove the Maintenance Assembly as described in Removing the Maintenance Assembly on page 143 2 Remove the Cap Assembly as described in Removing the Cap Assembly on page 147 3 Using tweezers release the joint for the concave part of the Cleaner Head and the convex part of ...

Page 149: ...43 2 Using tweezers remove the Cleaner Head from the Pump Assembly NOTE Make sure the Cleaner Head surface is free from any dirt dust or grease Also when mounting it use tweezers to keep the wiping side of the Cleaner Head clean 3 Remove the one CUPS M3x6 screw securing the Flushing Box Assembly and remove the Flushing Box Assembly Figure 4 75 Removing the Flushing Box Assembly Screw M3x6 Flushing...

Page 150: ...ss out from the hole in the R Side Frame 4 Push the carriage lock using your finger to unlock the carriage and move the carriage from the home position to the left 5 Remove the one CP W M3x6 screw securing the HEAD_SLIDE Sensor Assembly and remove the HEAD_SLIDE Sensor Assembly 6 Release the harness for the HEAD_SLIDE Sensor Assembly from the four cable clamps on the Maintenance Assembly and CR Ra...

Page 151: ...n R Side Cover Removal on page 114 2 Push the carriage lock using your finger to unlock the carriage and move the carriage from the home position to the left 3 Disconnect the harness from the CR_HP Sensor connector 4 Release the hook fixing the CR_HP Sensor and remove the CR_HP Sensor Figure 4 77 Removing the CR_HP Sensor Connector Hooks CR_HP Sensor ...

Page 152: ...al on page 117 5 Push the paper hold lever down to the rear 6 Remove the one CUPS M3x6 screw securing the sensor bracket and remove the bracket along with the both sensors NOTE Sensor bracket position is adjusted at factory Therefore be sure to mark its current position before removing the screw 7 Remove the harness from the connector of the Release P_THICK Sensor 8 Unhook the sensor from the sens...

Page 153: ... harness in the hole on the right 8 Push the paper hold lever down to the front 9 Remove the three CUPS M4x6 screws securing the Paper Guide L and remove the Paper Guide L by slowly taking it out toward upper front NOTE To remove the left screw insert a screw driver from the space of the I H Assembly the third one from the right 10 Remove the two CP W M2x8 screws securing the P_FRONT Sensor Assemb...

Page 154: ... Remove the five CBS M4x6 screws securing the Paper Guide U and remove the Paper Guide U by slowly taking it out toward the upper front NOTE When removing installing the Paper Guide U be careful not to mar the P_REAR Sensor Assembly with the edge of the sensor inspection window 9 Remove the two CP W M2x8 screws securing the P_REAR Sensor Assembly and remove the P_REAR Sensor Assembly NOTE P_REAR S...

Page 155: ...r and harness bundle for the Cover Sensor Assembly 3 Remove the two CP W M2x12 screws securing the Cover Sensor Assembly and Cover SW Holder and remove the Cover Sensor Assembly Figure 4 83 Removing the Cover Sensor Assembly A D J U S T M E N T R E Q U I R E D Perform the necessary adjustment listed in Table 5 2 in Chapter 5 This adjustment is required to make the Cover Sensor Assembly work interl...

Page 156: ...C H A P T E R 5 ADJUSTMENT ...

Page 157: ... not function properly if it is operated under such conditions When replacing the following always install a new ink cartridge Printheads Main Board Holder Assembly Valve Table 5 1 Adjustment Tools Name Part Code Notes Tension Gauge 1054053 standard tool acceptable Max 10 000g Tension Gauge F712 B747700300 standard tool acceptable Max 2500g Straight edge ruler 1000mm F713 1047746 standard tool acc...

Page 158: ... Value 4 Paper Related Sensor adjustment 5 Head rank input 6 Misc adjustments see Range of Backed Up Parameters on page 161 7 Test print 8 Generate new USB ID 9 Replace waste ink pads 10 Reset waste ink counter 123 162 159 177 169 161 202 126 194 CR Motor replacement 1 Replace CR Motor 2 CR belt tension adjustment Required tool 8 000g Tension Gauge 3 Bi D adjustment 4 Flush point adjustment R 5 To...

Page 159: ...r 4 download the parameters as described in the following pages upload the firmware as described on page 162 adjust the sensors as described on page 169 REQUIREMENTS FOR PARAMETER BACKUP F727 Flash Memory Card 1050073 Conforms to PCMCIA Rel 2 1 JEIDA Ver 4 2 Type II 5V Read Write operation Part 1050073 Fujitsu MB98A81183 15 Memory card writing utility i e Adtech CardUT97 PC with memory card writer...

Page 160: ...printer into the PC card slot connector on the Main Board and turn on the printer 3 Make sure the following message appears on the LCD 4 Press any button on the Control Panel to start the download procedure 5 When the download procedure is finished the following message appears 6 After making sure the printer is finished turn off the printer and remove the PC card 7 Replace the access cover on the...

Page 161: ...te error PC card erase error Using a different PC card try the operation again If a different PC card does not solve the problem there is a problem with the flash memory on the Main Board and a backup is not possible Replace the Main Board RANGE OF BACKED UP PARAMETERS The following parameters on the C299 Main Board are backed up during the back up operation Flash ROM addresses 000 5FF except for ...

Page 162: ...9c ipl lpt1 The data transfer operation takes between five and seven minutes and the ink out plus Pause indicators flash during the transfer FLASH ERASE FLASH WRITE PROGRAM LOAD END 5 Turn the printer off and then back on 6 Verify the firmware version according to the directions in step 1 turn off the printer and see the Caution at the top of this page C A U T I O N After updating the firmware the...

Page 163: ... the access cover from the rear of the printer and insert the prepared firmware card xxxxxxxx ROM into slot CN20 The top surface of the card faces the outside of the printer The card is EPSON service tool F727 Flash memory card 4 Turn on the printer 5 Update Complete appears when the firmware update has finished 6 Turn off the printer remove the memory card and then turn on the printer 7 Verify th...

Page 164: ... Self Diagnostic function as described in the table below Figure 5 1 Self Diagnostic Controls Table 5 3 Self Diagnostic Mode Controls Normal Function Self Diagnostic Function Meaning Pause Return up one level Moves up one level without selecting at item SelecType Next menu Displays the next menu Paper Source Previous menu Displays the previous menu Paper Feed Next item or value Displays the next i...

Page 165: ...rameter Updates or clears all of the adjustment parameters Check Life Tests the operation of the printer components C A U T I O N The Check Life menu contains tests that should only be performed at the factory so do not attempt to use this menu accept where written in this manual In Self Diagnostic mode all of the tests except for one Rear Sensor adjustment assume that you have loaded roll paper B...

Page 166: ...R P_EDGE P_THICK PG Thermistor I C Holder Levers Ink ID I C and Ink Low Encoder CR Motor PF Motor Fan On Off confirmation Elec Maintenance Record Fatal Error Record D A Revision Factory use for Head voltage correction do not attempt Head Signal Factory use for Head pulse check do not attempt C A U T I O N Do not attempt the D A Revision or Head Signal test These tests are only performed with speci...

Page 167: ...hat is pressed appears Press the Pause button twice to exit the Panel Key function LCD check All dots turn on If a dot is not on the LCD is not working properly LED check The LED indicators turn on in the following order and the name of the indicator appears on the LCD when that indicator turns on Power Pause Ink End K C Lc M Lm and Y Paper Out Roll Auto Cut Roll Cut Off and Sheet Item SelecType P...

Page 168: ...d the ID number appears as 0 7 Sensor on 1 and sensor off 0 X Ink NOT yy Describes which cartridge is not installed if a missing cartridge is detected X B or C head and yy ink color such as Lc X Ink END yy Describes which cartridge is empty if an empty cartridge is detected X B or C head and yy ink color such as Lc Figure 5 6 Sensor Menu Options C H E C K P O I N T You need to perform the Sensor A...

Page 169: ...r These sensors are light sensitive and may not function properly under such conditions It is recommended to remove the housing before performing this adjustment to ensure light is reflected evenly off the paper Make sure there is no dust or foreign substance on both the paper and sensor When performing sensor adjustment make sure paper is loaded and parked above the sensor above the guide lines a...

Page 170: ...that the vvv signal level indicated on the LCD is over 040 and the ttt signal level indicated on the LCD is between 0E0 0E8 7 Through the access cover adjust the volume on VR1 rough adjustment and VR5 precise adjustment so that vvv 0E0 0E8 However if ttt less than 040 adjust vvv to 0E8 Figure 5 7 VR1 VR6 Positions Viewed Through Access Cover NOTE If the signal level cannot be adjusted properly che...

Page 171: ...remove the access cover on the rear cover and enter the Test Menu in the self diagnostic mode Select Sensors check mode 2 Select Sen RearAD from the sensor menu and make sure the front cover is closed Remove any paper from the printer 3 Write down the volume shown on the LCD You will need to refer to this number and Table 5 8 to complete the volume adjustment 4 Open the cover Push the Paper Set Le...

Page 172: ...C This function allows you to check the maintenance record and fatal error record stored in the control circuit See the Table 3 3 Messages That Indicate Service is Necessary on page 84 for details on the error messages Figure 5 10 Record Menu Options Record Error menu Figure 5 11 Error Record Function The errors listed here do not include CPU errors service call errors and the printer lists a maxi...

Page 173: ...n Fire x Amount of ink fired from nozzles in number of megadots x which color Cut Number of times cutter has been used Cutter Solenoid Number of times cutter solenoid has been activated Lock Solenoid Number of times CR lock solenoid has been activated Waste Ink R L Amount of waste ink right or left Head Wiper R L Number of times head wiping operation has occurred Wiper Number of times wiper has be...

Page 174: ...ame height mechanism adj Bi D Print Position Verifies the printed lines match up when performing bi directional printing Head Gap Adjusts the B C Head Gap as well as sets the left margin R Flush Point Adjusts the flush position on the HP side L Flush Point Do not use there is no left flush point and this function will generate a fatal error Feed Correction Checks paper feeding w ruler Top Bottom C...

Page 175: ... of menu Pause SelecType Paper Source Adj Counter Clear Adj Cap Position Adj B Head Slant Adj Check Nozzle Adj Input Rank Adj Check Skew Adj Flush Point L Adj Flush Point R Adj Head LR Adj Adj Bi D Adj BC Head Slant Adj C Head Slant Adj Clean Head Adj Test Print Adj Rear Sensor Pos Adj Top Bottom Adj Feed Write D A Value ...

Page 176: ... the P EDGE sensor This value is compared to the originally detected value for the paper edge position to determine if the paper is feeding at a slant Any change you make to the Check Skew distance only affects service related printouts the skew check operation for user printouts does not change 1 Make sure Adj Check Skew appears on the LCD and press the Enter button 2 If the paper is not loaded c...

Page 177: ...the Enter button and Enter Key appears on the LCD 5 Press the Enter button again to write the printhead ID value to the Main Board and begin the initial ink charge in the heads Figure 5 16 Head ID Input Process C A U T I O N This operation must be performed before sending a print job otherwise print quality will most likely suffer If an out of range error Error Rank Input occurs at any time during...

Page 178: ...ing check pattern Figure 5 17 Head Nozzle Check Pattern The pattern includes the following colors from left to right black cyan magenta yellow light magenta and light cyan 3 When the check pattern is finished printing Nozzle Check End appears on the LCD If the pattern printed all six colors properly with no lines or dots missing press the Enter button to end this adjustment procedure If lines or d...

Page 179: ... the carriage cap position Figure 5 19 Head Slant Check Printout 3 Loosen the screw securing the head that is printing at a slant and move the Head Adjust Lever A left or right depending on the slant direction See Figure 5 21 for reference 4 Using tweezers or a similar tool push in the head toward the back of the printer and then tighten the screw 5 After making sure both heads are correctly insta...

Page 180: ...Stylus Pro 7000 Revision B Adjustment Self Diagnostic Mode Menus 180 Figure 5 21 B C Head Skew Adjust Lever Head Adjust Lever A in front of B C heads Push in here with tweezers to correctly set the printhead ...

Page 181: ...igure 5 22 Head Parallelism Check Printout 3 Press Enter if the level is OK like the top row If there is a slant open the front cover release the carriage lock by hand and move the carriage away from the carriage cap position 4 If necessary loosen the screw securing the printhead on the right Move the Head Height Lever up or down to match the height of the two heads B C Height Adjust Lever Figure ...

Page 182: ... pattern again to make sure the heads are lined up Adjust again if necessary If there is no slant press Enter Figure 5 24 Head Parallelism Check Operation Printing Pattern Check the pattern for offset lines or segments and change the adjust lever position if necessary BC Slant Check End Print Adj Pattern Enter SelecType Item End adjustment next menu ...

Page 183: ...page 184 1 Enter the Self Diagnostics mode by holding down the Paper Feed Paper Feed and Enter buttons while turning on the printer 2 Press the Item button until Check Print appears on the display and then press Enter 3 Make sure Print Nozzle Check appears and then press Enter The printer prints all adjustment patterns related to the physical and logical printhead positioning Figure 5 25 New 6 and...

Page 184: ...t Print appears and press Enter The printer prints the Bi D adjustment patterns and BiD 200 N B y appears on the display when finished y adjustment value Figure 5 27 Bi D Adjustment Operation 5 Determine which patterns are incorrect and need adjustment You judge patterns 1 5 and 7 the same as always they are correct if they line up vertically See Figure 5 25 for details on judging the correct item...

Page 185: ...time press Item 8 Press Item and xD LC y appears on the display Press Paper Feed or Paper Feed to change the Light Cyan value Press Enter 9 xD LM y appears and press Paper Feed or Paper Feed to change the Light Magenta value Press Enter 10 xD LM y appears and press Paper Feed or Paper Feed to change the Light Magenta value Press Enter to finish Repeat from step 3 until all Bi D adjustment items ar...

Page 186: ...D and press the Enter button to finish If some lines are not aligned select the numbered pattern using the Paper Feed buttons Correction increment 1 2880 inch Correction direction toward HP and away from HP Aim 1 5 7 Align the lines vertically 6 8 Make sure light cyan and light magenta are equal width without overlapping see the illustration below After you finish correcting a pattern press the En...

Page 187: ...ample make sure Gap Check End appears in the LCD and press the Enter button to finish If some lines are not aligned select the numbered pattern using the Paper Feed buttons Correction distance One press 1 2880 inch Correction direction toward HP and away from HP Aim Black and light cyan lines are vertically aligned After you finish correcting a pattern press the Enter button to print another test ...

Page 188: ...shing is finished Point R NNN NNN numeric position appears Check the piece of paper you put over the flushing box to confirm the ink is ejected into the flushing box If the ink flushing position is correct press the Enter button to finish Otherwise press the SelecType or Item button to correct the flushing position The settings increment as follows Correction distance One press 1 720 inch Directio...

Page 189: ...nted V Length 1000 0mm appears Using a regular ruler and the Scale Stopper code number 1047746 1047745 measure the printed pattern from the top line to the bottom line Then enter this measurement using the item select buttons in 0 1mm increments 4 After entering the measurement press the Enter button to finish Figure 5 33 Feed Distance Check Operation Figure 5 34 Feed Distance Check Pattern Printi...

Page 190: ... fixed distance 3 After the printing operation is finished measure the top bottom and right HP side margins using a ruler Press the item select Paper Feed buttons to enter each of these measurements in 0 1mm increments 4 After entering the measurements press the SelecType or Item button until Bottom Length xx xmm appears and then press the Enter button Figure 5 35 Margin Adjustment Operation Figur...

Page 191: ...d press the Enter button 2 Load A3 size paper in portrait short edge first orientation when you see the Please Set CutSheet message After the paper initializes press the Enter button to print the check pattern 3 After printing is finished measure the distance from the rear edge of the printed pattern to the rear edge of the paper Press the Enter button until you see RearSen Pos xx xmm and then ent...

Page 192: ... on the back of the printer next to the power connector Figure 5 39 Test Pattern Printing Operation Table 5 13 Printed Items in the Test Pattern Item Description Nozzle Check Prints all of the check test patterns that are available from the Adjustment menu Adjustment Variables Prints a list of all the adjustable items from the Adjustment menu Print Nozzle Check Enter Enter SelecType Item SelecType...

Page 193: ...quires approx 6 minutes Set Cleaning Jig Cleaning Insert transportation fluid cartridges Requires approx 6 minutes Remove transportation fluid cartridges Cleaning Proceed to next Adjustment menu Requires approx 6 minutes C A U T I O N After draining the ink and performing any necessary operation and or moving the printer be sure to perform the initial ink charge as described in Cleaning Menu on pa...

Page 194: ...g cycle Volume of ink cleared medium rubbing off Std KK2 CL2 Strong cleaning cycle Volume of ink cleared high rubbing on Init Fill Perform Initial charge sequence Table 5 14 Counters Reset by Counter Clear Counter Reset Value Protection Counter A B 0 Ink Volume Counter Rb Ry Rx Rz 0 Consumed Ink Counter Cb Cy Cm Cc Cll Clc 0 Power Cutoff Timer T2 0 Accumulated Prints Timer 0 CL Timer 0 CL Timer 3 ...

Page 195: ...menu are described below Capping Position see Adj Cap Position on page 176 Paper Feed Distance see Feed Adjustment on page 189 Serial No see Test Pattern Print on page 192 for more information Maintenance Record see Table 5 9 Maintenance Record Items on page 173 UPDATE ITEMS The items you can update are described below Capping Position see Adj Cap Position on page 176 Head Rank voltage see Adj Inp...

Page 196: ...n reset the Initial Ink Charge flag causing the printer to perform the initial ink charge the next time the printer is turned on Figure 5 43 Ink Parameter Update Operation Update Ink Parameter Paper Feed Init Ink Charge Flag SET Init Ink Charge Flag RESET Update Parameter Updating Parameter Enter ...

Page 197: ...rresponding adjustments are as follows Table 5 15 Necessary Mechanism Adjustments Parts Adjustment Necessary Tools Refer to CR Motor CR Steel Belt Tension Tension Gauge F712 code 1047744 Standard 8 000g page 198 PF Motor PF Belt Tension Tension Gauge code B747700300 Standard 4 000g page 198 P THICK sensor Self diagnostic test Paper Thickness 6 7mm schema gauge s page 199 Cover Open sensor Self dia...

Page 198: ...the CR Rail Figure 5 44 CR Timing Belt Tension Adjustment PF TIMING BELT TENSION ADJUSTMENT This adjustment is necessary for service operations that require you to remove loosen the PF Motor or PF Belt When replacing or re installing the PF Belt you need to confirm the tension of the PF Belt Standard 2 200g 10 Figure 5 45 PF Belt Tension CR Tension Bracket CR Timing Belt CR Tension Screw Hook the ...

Page 199: ...e position and verify that Sen Paper Thick appears in the LCD 7 Insert a schema gauge 6mm 7mm between the set of PF Grid Rollers and Driven Rollers nearest the HP Return the Paper Set Lever to the Set position The LCD message will vary according to the schema gauge as shown in the table below 8 If the correct message does not appear or any other message appears verify the P THICK sensor is install...

Page 200: ...s the Enter button to select the Test Item menu 4 Press the SelecType or Item button until Sen Cover xxxx appears 5 Open and close the Front Cover checking the LCD to make sure the message changes depending on the Front Cover position 6 If the correct message does not appear or any other message appears verify the Cover Sensor is installed correctly and check the operation again If necessary loose...

Page 201: ...am as well as PC with MS DOS or Windows 95 Parallel interface connection compatible mode EXTRACTING THE USB ID COPY PROGRAM SP7000 USB ID Copy Program Found on the F733 Self Training Kit P N 1053426 File AD_PRO_E Spro7000 exe self extracting file extract the file to a folder you make on the root directory of your hard drive example C SP7000 PC equipped with Windows 95 or MS DOS6 2 or above Paralle...

Page 202: ...USB ID from the menu that appears 9 Select Write the USB ID on EEPROM 10 Enter the name of the file you created in step 4 and press the Enter key After about 85 seconds the The USB ID message finishes and the USB ID is written to the new board 11 Press the ESC key to return to the previous menu and select Set the USB configuration item NOTE The USB configuration item contains the packet and addres...

Page 203: ...C H A P T E R 6 MAINTENANCE ...

Page 204: ...pen close condition of the front cover has an interlock switch that functions as a safety device Therefore it is prohibited to turn off this switch A lithium battery is installed on the MAIN Board of this printer Be sure to observe the following instructions when servicing the battery Keep the battery away from any metal or other batteries so that electrodes of the opposite polarity do not come in...

Page 205: ...or lower sections of the printer Therefore spread a sheet or similar object when removing ink related parts When handling the electric circuit boards do not touch the elements on the board by your bare hands to prevent the elements from being damaged by static electricity Wearing an earth band is highly recommended If it is necessary to turn on the printer after removing various covers be especial...

Page 206: ... the Maintenance Kit Waste Ink Pads Pump Assembly Cap Assembly Flushing Box Cleaner Head Required Adjustment Waste Ink Counter Clear See Counter Clear on page 194 Ink Tubes Service Call 00000101 Solution Check the ink tube The printer indicates this error when the carriage has made a predetermined number of passes this indicates the ink tubes should be replaced before they wear out causing air to ...

Page 207: ...n the capped position look from above Loosen the maintenance bracket screws push up the bracket and secure the screws T Fence Step ruler Make sure no dust or foreign objects are attached or have accumulated and make sure it is not ripped bent or stained 1 Cleaning 2 Replace if there are any rips or stains Rail on the CR guide frame Make sure there are no foreign objects attached Cleaning P_REAR se...

Page 208: ...C H A P T E R 7 APPENDIX ...

Page 209: ...CN13 CN41 CN43 CN11 CN39 CN42 CN37 CN44 CN31 CN34 CN32 CN35 CN33 C299Main Board Carriage Board CN2 CN5 Cutter solenoid Printheads CN3 CN8 CN7 CN1 Power Supply Board CN001 AC inlet Panel Unit Fan Fan Lever sensor P Thick sensor F cover sensor CN22 CR HP sensor Head Slide sensor P Front sensor P Rear sensor PF mtr encoder sensor Ink sensor M Ink sensor Y Ink sensor C Ink sensor LM Ink sensor LC Ink ...

Page 210: ...CN24 Pump motor CN30 Ink sensor black CN31 Ink sensor cyan CN32 Ink sensor magenta CN33 Ink sensor light cyan CN34 Ink sensor light magenta CN35 Ink sensor yellow CN36 Lever sensor CN37 P_Thick sensor C299Main Board continued CN38 Front cover sensor CN39 P_Front sensor CN41 CR HP sensor CN42 Head slide PG sensor CN43 Paper Suction Fan CN44 Paper Suction Fan Panel Unit Board CN22 From and to C299MA...

Page 211: ...NK MODEL NUMBER C B 1 187 LABEL INK MODEL NUMBER M B 1 188 LABEL INK MODEL NUMBER LC B 1 189 LABEL INK MODEL NUMBER LM B 1 190 LABEL INK MODEL NUMBER Y B 1 200 BOARD ASSY MAIN 1 300 P S BOARD ASSY 1 400 P S CABLE 1 101 RUBBER FOOT 4 102 VACUUM FAN 2 103 VACUUM FAN 1 CABLE 1 104 VACUUM FAN 2 CABLE 1 105 P REAR SENSOR ASSY 1 151 PF MOTOR PULLEY ASSY 1 152 SPECER X MOTOR 1 153 BEARING PF MOTOR 1 154 ...

Page 212: ...CABLE ASSY 1 363 CR HP CABLE ASSY 1 401 P FRONT SENSOR ASSY 1 402 WASTE INK BOX 1 Table 7 2 Parts List cont Ref Part Name Quantity 403 POROUS PAD INK EJECT 10 404 SUB PLATEN A 1 405 SUB PLATEN B 4 406 PAPER OUTLET ROLLER ASSY 7 407 COVER SENSOR ASSY 1 408 CLAMP 2 409 PAPER GUIDE TRAY 2 410 WASTE INK TANK STOPPER 1 451 MOTOR ASSY ASF 1 452 PUMP REDUCTION GEAR 3 1 453 PUMP REDUCTION GEAR 4 1 454 PUM...

Page 213: ...603 TUBE SUPPLY INK M 1 604 TUBE SUPPLY INK LM 1 605 TUBE SUPPLY INK Y 1 606 TUBE SUPPLY INK LC 1 607 STEEL BEAR 1 Table 7 2 Parts List cont Ref Part Name Quantity 608 CR TAPE CABLE 1 609 TUBE GUIDE 1 610 BOARD ASSY SUB 1 611 JOINT SCREWS M6 12 612 O RING TUBE FASTEN 12 613 JOINT BK 6 614 TUBE CUSHION 1 701 GROUNDING PLATE I F UPPER 1 702 INLET ASSY 1 703 DC CABLE ASSY 1 801 H TOP COVER ASSY 1 802...

Page 214: ...SY 1 819 PANEL SHEET ENGLISH 1 820 PANEL TAPE CABLE 1 821 PRESS LEVER KNOB 1 822 PANEL UNIT ASSY OVERSEAS 1 901 FLANGE 2 INCH R 1 901 FLANGE 3 INCH R 1 902 FLANGE 2 INCH 1 902 FLANGE 3 INCH L 1 NO FIG MAINTENANCE KIT STYLUS PRO 7000 1 NO FIG ROLL BAND 1 NO FIG UNPACKING SHHEET 1 NO FIG SUPPLEMENT 1 Table 7 2 Parts List cont Ref Part Name Quantity ...

Page 215: ... components and arrangement The part numbers in the illustrations refer to the illustration numbers in Table 7 2 page 162 No 1 Frame Assembly No 2 Paper Feed Assembly No 3 Head Assembly No 4 Carriage Assembly No 5 Frame Assembly No 6 Maintenance Assembly No 7 Ink Cartridge Holder Assembly No 8 Cable Guide No 9 Board Base Assembly No 10 Cover Assembly ...

Page 216: ...EPSON Stylus Pro 7000 Revision B Appendix Exploded View Diagram 216 Figure 7 2 Frame Assembly A 101 A PM 7000C No 1 Rev 01 10180 103 102 104 105 102 101 RAME ASS EPSON Stylus Pro 7000 ...

Page 217: ...EPSON Stylus Pro 7000 Revision B Appendix Exploded View Diagram 217 Figure 7 3 Paper Feed Assembly 153 155 156 151 152 154 PM 7000C No 2 Rev 01 10180 P ASS EPSON Stylus Pro 7000 ...

Page 218: ...x Exploded View Diagram 218 Figure 7 4 Head Assembly 315 313 314 312 310 316 301 304 303 306 307 305 311 308 307 305 306 307 305 306 304 303 306 307 305 307 305 306 307 305 306 302 309 PM 7000C No 3 Rev 01 10180 EAD ASS EPSON Stylus Pro 7000 ...

Page 219: ...lus Pro 7000 Revision B Appendix Exploded View Diagram 219 Figure 7 5 Carriage Assembly B B 355 351 360 356 359 358 363 357 362 358 358 361 353 351 352 354 PM 7000C No 4 Rev 01 10180 CR ASS EPSON Stylus Pro 7000 ...

Page 220: ...00 Revision B Appendix Exploded View Diagram 220 Figure 7 6 Frame Accessory 406x7 407 4082 402 410 403x4 403x6 409 401 x5 409 404 405x4 172 173 176 175 184 PM 7000C No 5 Rev 01 10180 RAME ACCESSR 400 EPSON Stylus Pro 7000 ...

Page 221: ...7000 Revision B Appendix Exploded View Diagram 221 Figure 7 7 Maintenance Assembly 457 455 454 461 460 460 460 459 453 458 459 452 451 464x3 465x3 463x3 462 PM 7000C No 6 Rev 01 10180 MENTE ASS 456 EPSON Stylus Pro 7000 ...

Page 222: ...ion B Appendix Exploded View Diagram 222 Figure 7 8 Ink Cartridge Holder Assembly 503 508 515x6 501x6 516x6 514x6 510x6 511x6 509x6 512x6 513x6 502x6 503 504 505 506 507 508 PM 7000C No 7 Rev 01 10180 I ASS EPSON Stylus Pro 7000 ...

Page 223: ...N Stylus Pro 7000 Revision B Appendix Exploded View Diagram 223 Figure 7 9 Cable Guide 604 605 606 601 602 603 61212 6136 61112 609 608 607 614 610 PM 7000C No 8 Rev 01 10180 CABLE IDE EPSON Stylus Pro 7000 ...

Page 224: ...ON Stylus Pro 7000 Revision B Appendix Exploded View Diagram 224 Figure 7 10 Board Base Assembly 702 300 202 201 701 200 including 201 202 703 PM 7000C No 9 Rev 01 10180 BARD BASE ASS EPSON Stylus Pro 7000 ...

Page 225: ...gram 225 Figure 7 11 Cover Assembly CER ASS 183 811 818 813 177 170 805 185 186 187 188 189 190 806 180 807 178 179 902 174 901 821 810 822 182 808 809 171 814 819 802 801 804 804 803 803 815 817 820 816 180 181 PM 7000C No 10 Rev 01 10180 EPSON Stylus Pro 7000 ...

Page 226: ...N Stylus Pro 7000 Revision B Appendix Component Layout 226 7 4 Component Layout The illustrations below show the C299MAIN Board component layout Figure 7 12 C299MAIN Board Component Layout of Component side ...

Page 227: ...EPSON Stylus Pro 7000 Revision B Appendix Component Layout 227 Figure 7 13 C299MAIN Board Component Layout of Soldering Side ...

Page 228: ...ix Circuit Diagrams 228 Figure 7 14 C299SUB Board Component Side Figure 7 15 C299SUB Board Soldering Side 7 5 Circuit Diagrams The circuit diagrams for the C299MAIN Board are provided in the following pages C299MAIN 1 2 C299MAIN 2 2 C299SUB ...

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