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Epson Stylus Pro 9500 Engine, Service Manual

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Epson Stylus Pro 9500 Engine Service Manual Download Page 117

EPSON Stylus Pro 9500

Revision A

Disassembly & Assembly

Disassembly Flow

117

DISASSEMBLING THE I/H ASSEMBLY

1.

Take out the 6 screws (CP(W2) M2 x 4), then remove the I/H assembly 
from the side cover.

2.

Rotate the internal cartridge holder assembly until the lock is released. 
Next, take out the 2 screws (CP(W2) M3 x 6) holding the friction gear 
assembly and remove the friction gear assembly.

Figure 4-59.  Removing the side cover of I/H assembly

Figure 4-60.  Removing the friction gear assembly.

Remove

Friction gear assembly

Summary of Contents for Stylus Pro 9500 Engine

Page 1: ...EPSONStylusPro9500 B0 Wide Format Professional Inkjet Printer SEIJ00005 Service Manual Service Manual Service Manual Service Manual ...

Page 2: ...EIKO EPSON CORPORATION assumes no liability for problems or damages resulting from the use of the information contained herein EPSON is a registered trademark of SEIKO EPSON CORPORATION Other product names used herein are for identification purposes only and may be trademarks of their respective owners EPSON disclaims any and all rights in those marks Copyright 2000 SEIKO EPSON CORPORATION ...

Page 3: ...pair technician Make certain that the source voltage is the same as the rated voltage listed on the serial number rating plate If the EPSON product has a primary AC rating different from the available power source do not connect it to the power source Always verify that the EPSON product has been disconnected from the power source before removing or replacing printed circuit boards and or individu...

Page 4: ...PSON Stylus Pro 9500 Revision A 4 Revision Status Revision Issued Date Description A 31 August 2000 First Established Edition ...

Page 5: ...cuit Board Removal 93 Printer Mechanism Disassembly 96 Conversion Kit 122 ADJUSTMENT Summary 156 Caution 156 Adjustment Tools 156 Adjustment Items 158 Adjustment Steps 161 Parameter Backup 161 Firmware Update 164 Self Diagnostics 166 Adjustment Menu 168 Test Menu 189 Cleaning menu 198 Parameter menu 198 Maintenance Mode 200 Mechanism Adjustment 203 Dip SW setting 218 MAINTENANCE SETUP General Main...

Page 6: ...C H A P T E R PRODUCTDESCRIPTION ...

Page 7: ...CPU and high speed color raster ASIC quickly process detailed print data n A0 Medium Gloss Paper Approx 17 min 720x720dpi Fast A0 Medium Gloss Paper Approx 25 min 720x720dpi Beautiful A0 Medium Gloss Paper Approx 50 min 1440x720dpi Highly detailed Low running cost Six separate ink cartridges so you only have to replace the empty ink cartridge each cartridge holds 220 ml Wide compatibility The foll...

Page 8: ... 30 5m long 44in wide 30 5m long remium Semigloss hoto Paper S041393 S041394 S041395 24in wide 30 5m long 36in wide 30 5m long 44in wide 30 5m long Watercolor Paper adiant White S041396 S041397 S041398 S041352 S041351 24in wide 18m long 36in wide 18m long 44in wide 18m long A3 Wide B A3 Wide B lossy Film S041314 S041313 S041312 610mm wide 20m long 914mm wide 20m long 1118mm wide 20m long ynthetic ...

Page 9: ...ommands are not open to public haracter Specifications n Character Code PC 850 Multilingual PC437 US Standard Europe n Type Faces Bitmap LQ font EPSON Courier IO CPI PAPER FEED SPECIFICATIONS Feeding method Friction feed Line spacing 1 6 or 1 720 programmable Paper loading Roll paper two 2 inch rolls can be loaded at the same time Single sheets loaded one at a time Paper volume 2 core roll paper d...

Page 10: ...5m 28 35 1771 65 Roll Size 2 or 3 spindle paper thickness 103mm or less 4 05 two 2 rolls 150mm or less 5 9 one 3 roll Paper Thickness 0 08 0 11mm 0 003 0 0043 Paper Weight 64 90gf m2 17 24 lb s Paper Quality Normal paper recycled paper 1 Use at normal room temperature 15 25 C 59 77 F 40 60 humidity 2 The printer exerts between 300 500gf to peel off the rear edge of roll paper from the core 3 The e...

Page 11: ...er holder Table 1 3 Special Paper Specifications Paper Code Paper Size Roll Size oubleweight atte Paper S041385 S041386 S041387 24 x 25m 36 x 25m 44 x 25m 2 core paper thickness radius of 103mm or less lossy Paper hoto Weight S041388 S041389 22 x 20m 44 x 20m remium Glossy hoto Paper S041390 S041391 S041392 24 x 30 5m 36 x 30 5m 44 x 30 5m remium emigloss Photo aper S041393 S041394 S041395 24 x 30...

Page 12: ...fuzz tearing or folding of the paper etc 3 This product should be used in a place with a normal room temperature environment Temperature 15 25 C Relative humidity 40 60 Table 1 4 Usable Single Sheet Paper Specifications Size Dimensions W x H Size Dimensions W x H Super B0 1118 x 1580mm A2 329 x 483mm B0 1030 x 1456mm Super A3 B 297 x 483mm B1 728 x 1030mm A3 297 x 420mm B2 515 x 728mm ANSI E 34 x ...

Page 13: ...ed When paper detection setting is OFF the printer may print on the platen te 3 The size of the margin of roll paper can be changed from the panel as shown below Top and Bottom 15 mm Left and Right 3 mm Top Bottom Left and Right 3 mm Top Bottom Left and Right 15 mm Figure 1 1 Printable Area Table 1 7 Printable Area Heading Roll Paper Cut Sheets PW width 297 1118mm 8 27 44 02 297 1118mm 8 27 44 02 ...

Page 14: ...S Model FCC part 15 subpart B class B CSA C108 8 class B European Model EN 55022 CISPR Pub 22 class B EN 61000 3 2 EN 61000 3 3 EN 50082 1 IEC 801 2 IEC 801 3 IEC 801 4 Australian Model AS NZS 3548 class B International Energy Star Compliant EPA MOU2 1 Category Large Format Printer ated voltage range AC100 240V put voltage range AC90 264V ated frequency range 50 to 60Hz put frequency range 49 to 6...

Page 15: ...dges 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 When the temperature drops below 15 C 5 F the ink in the cartridges and printheads freezes The ink thaws completely after three hours at 25 C 77 F C H E C K P O I N T The above service replacement parts are available in...

Page 16: ...260 x 105 3mm WxDxH Weight Approx 370 385g cartridge only Effective period 2 years from production in the sealed packaging plus time used at room temp Storage temperature See the table below Table 1 9 Vibration Shock Resistance Condition Vibration Resistance Shock Resistance Notes Operating 0 15G 10 55Hz 1G less than 1ms X Y Z direction Storage 0 50G 10 55Hz 2G less than 2ms Temp C Humidity Table ...

Page 17: ... Parallel Interface Macintosh Serial Interface Type B Card Slot x1 for optional interface PRINTER DIMENSIONS WEIGHT Dimensions 1688 x 699 x 1259mm WxDxH 66 46 x 27 52 x 49 57 inches Weight 96Kg 211 91 lb s Printer alone 74Kg 163 32 lb s Stand 22Kg 48 59 lb s Figure 1 3 Printer Dimensions C H E C K P O I N T The RAM installed in the form of a SIMM module is a part of system memory and cannot be rep...

Page 18: ...rough 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 logical 0 These signals are used to transfer the 1284 extensibility request values to the printer 10 ACKNLG 28 O When LOW the printer has finished preparing to receive signals and can accept data Pulse width is about 1uS or 3uS Printer clock signal 11 BUSY 29 O ...

Page 19: ... responds in the following manner 00H The printer enters reverse channel mode allowing data to be sent to the host 04H The printer sends the device ID to the host the device ID consists of the following strings device ID 00H 4EH MFG EPSON CMD ESCPL2 BDC MDL Stylus SP Pro SP 9000 CLS PRINTER DES EPSON SP Stylus SP Pro SP 9500 Note SP equals space code 20H Table 1 12 Parallel Interface Timing Parame...

Page 20: ...erse 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 Each signal is at high level when data is logical 1 and low level when data is logical 0 10 PeriphClk 28 O Transmits data to the host computer from the printer 11 PeriphAck PtrBusy 29 O The printer uses this signal for forward direction flow control Also this signal offers ...

Page 21: ...rity bit None Stop bit 1 bit Handshaking X ON X OFF DTR protocol Adaptable connector 8 pin mini DIN Recommended I F cable Apple Genuine Cable 33 GND Ground for twisted pair return 34 NC Not used 35 5V O Normally HIGH state 5 V pull up at 1 0 K Ohm 36 1284 Active 30 I 1284 Active signal HIGH when in the ECP mode Table 1 14 Connector Pin Assignments Reverse Channel Pin No Signal Name Return Pin In O...

Page 22: ...eceiving data via the parallel interface or the optional Type B interface while in a state where no error has occurred including the Pause state if the available capacity of the buffer drops to 4 KB or less the printer receives at 1 byte sec and prevents the host from issuing a time out At the point when the available capacity of the buffer becomes 8 KB or higher 1 byte sec reception is canceled a...

Page 23: ...tus Register MNSTS n After the printer has been initialized or when it is in the idle state with no interface selected the status of each interface is a shown below Parallel Interface READY State Serial Interface DTR SPACE Low State Optional Interface OFF LINE bit of the Main Status Register MNSTS is reset n An interrupt signal like the INIT signal of the parallel interface is disregarded while th...

Page 24: ...xt mode non raster graphics mode rthermore as for the panel settings default settings and remote command orable items their contents in memory are set at the default values 1 3 Control Panel This section describes the control panel the buttons the lights and the way you make settings Figure 1 4 Control Panel Power Operate Sheet Paper Out Roll Cutter Off Roll Auto Cut Cleaning 3 sec Enter Cut Eject...

Page 25: ...rd increases value Paper Feed Feeds paper forward 3 Cycles forward decrease value Paper Source Item Selects paper source Selects item or minor category Cleaning Cleans both heads if pressed for three seconds N A Paper Source Cut Eject Paper Feed N A Maintenance Mode 2 Paper Source Cut Eject Cleaning N A Firmware Update Mode Paper Feed Cut Eject Cleaning N A Self diagnostic Mode Table 1 18 LED Indi...

Page 26: ...rence from the roll paper auto cutting setting It shows that cut sheet paper is set Paper Type Cut Off On Flashing Roll paper with the cutter off is selected Difference between the roll paper and cut sheet paper setting It shows that cut sheet paper is set Paper Type Single Sheet On Flashing Shows that cut sheet paper is selected Difference between the roll paper and cut sheet paper setting It sho...

Page 27: ...operation POWER OFF Preparing to shut down INK OUT Replacing ink cartridge COVER OPEN The cover is open OPTION I F ERROR A Type B interface error has occurred LOWER PAPER SET LVR Paper Release lever is in the release position LOAD xxx PAPER Wrong paper loaded PAPER JAM Paper is caught inside the printer PAPER NOT CUT Printer did not cut the paper when Auto Cut selected PAPER NOT STRAIGHT Paper was...

Page 28: ...ssed once When selecting a menu press the Paper ource button once return to the print ready state press the SelecType button until the Print eady message is displayed in the LCD panel or press the Pause button Menu Selection SelecType Button Selecting a Menu Item Paper Source Button Mode End Pause Button electing a menu provides you with detailed options Table 1 20 Control Panel Settings Menu Item...

Page 29: ...rticularly low reflection rate and cannot be detected by the photosensor this setting is used Through the Paper Width Sensor OFF setting if an image which is larger than the set paper is printed printing may be done on the platen so the user must take the responsibility for the possible consequences However if detection of the top edge of the paper fails it results in an error Table 1 21 SelecType...

Page 30: ...oximately 10 cm W x approximately 13 cm H Printer ID Head ID xx xx xx xx xx xx In xx the parameters stored in NVRAM are printed out in decimal numbers The order from the left to right is K C M Y Lc Lm Type B Interface Connection Condition The following printer settings Head Gap Border Line perforation line Interface receiving settings Parallel Interface Receiving Speed Code Page Version Firmware v...

Page 31: ... 2 when the waste ink pad replacement operation is performed Note 3 When remainder on the CR motor life counter becomes 0 a fatal error is displayed Concerning the PF motor head units and cleaning unit there is no error display The CR motor life counter is reset in Maintenance Mode 2 CUTTER LIFE Shows the remaining useful life of the cutter TOTAL PRINTS Shows the total number of printed documents ...

Page 32: ...u procedure Cutter Replacement Paper Source button Changing Setting Values or button Setting the Set Values Enter button Mode End Pause button this mode if cutter replacement is carried out the Cutter Life counter in the nt status menu is reset Table 1 25 Cutter Replacement Messages Display Message Item Notes CUT REPLACE EXEC Prepare a replacement cutter and OPEN LOWER COVER Open the front cover R...

Page 33: ...ting Setting Values or button Setting the Set Value Enter button Mode End Pause button Note 1 Values with underlines show default values Table 1 26 Gap Adjustment Menu Display Setting Value Contents PAPER THICK Standard or 0 0 1 6 mm Specify the paper thickness used in the gap adjustment in 0 1 mm units Ordinarily the printer is used with the Standard specification and in this case the paper thick...

Page 34: ... patterns Approx 40 cm ote 2 Always in printing of each pattern 1 block of 15 patterns is printed 6 times Pattern No 8 of the 15 patterns in one block shows the current setting value 1 3 3 Maintenance Call Some of the mechanical units used in this printer have counters which count down the remaining service life based on the proper service life for each unit and when the predetermined value is rea...

Page 35: ... PF Motor encoder check error 00010001 PF Motor Motor out of synch 00010002 PF Motor Overcurrent 00010003 PF Motor In Position Time Out 00010004 CR Motor Encoder check error 00010005 CR Motor Motor out of synch 00010006 CR Motor Overcurrent 00010007 CR Motor In Position Time Out 00010008 Servo interrupt WDT time out error 00010009 System interrupt WDT time out error 0001000A CR home position senso...

Page 36: ...f there is no problem it should be recommended to the user that the parts comprising the CR System periodic replacement parts kit which is scheduled for introduction be replaced If the printer is to be used until CR system periodic replacement parts kit parts are replaced carry out CR Motor Initialization in Maintenance Mode 2 and cancel the error ...

Page 37: ...g control panel service functions and for service and support purposes only none of this information is to be shared with the end user Message Item Explanation HEX DUMP PRINT This prints out print data transferred to the printer in hexadecimal form 16 data items per line are displayed and in addition an ASCII character corresponding to those data is printed on the right side If there are no charac...

Page 38: ...es Enter Button o Setting End Power ON OFF This mode can be roughly divided into the following 3 items For each major item see the following page o Counter Display Menu The items displayed in the Maintenance Mode 2 Counter Display Menu are shown below Table 1 29 Maintenance Mode 2 Setting Items Item Panel Display Counter Display Menu VIEW COUNTERS MENU Counter Initialization Menu CLEAR COUNTERS ME...

Page 39: ...Head Unit M Service Life Counter Value Display HEAD M 0 4294967295 Decimal number ead Unit LC Service Life Counter Value Display HEAD LC 0 4294967295 Decimal number ead Unit LM Service Life Counter Value Display HEAD LM 0 4294967295 Decimal number Head Unit Y Service Life Counter Value Display HEAD Y 0 4294967295 Decimal number Cleaning Unit Life Counter CLEANER 0 4294967295 Decimal number Table 1...

Page 40: ...en changing the setting values ote 3 This sets whether the sensor which detects the I C type identifier on the I C label will detect it or not ote 4 If microbanding which occurs in the 720 x 360 dpi mode and the 720 x 720 dpi mode actually occurs this reduction function acts to reduce banding somewhat when this setting is changed However there may not be any effect even if the setting is set in th...

Page 41: ...ta file to the PC card 2 Remove the access cover on the rear of the printer above paper guide U then insert the memory card Flash memory card where the firmware data for reloading are recorded in the card slot CN20 3 Turn the printer s power ON 4 Reloading of the firmware will start and the following messages will be displayed in order in the LCD panel Flash Erase Flash Write Complete Program Load...

Page 42: ... be changed as shown below For details concerning settings see page 100 DIP Switch Setting DIP SW1 DIP SW2 ASP Board OFF OFF When board installed OFF ON Table 1 34 Printer Status Menu Display message Meaning VERSION Shows the firmware version INK LEFT K 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 Cy...

Page 43: ...C H A P T E R OPERATINGPRINCIPLES ...

Page 44: ...per cutter drive component Carriage guide rail section o CR Motor aper Feed Mechanism Paper feed rail o Grid roller assembly o Secondary roller assembly opposite the grid rollers o PF Motor Rotary Encoder internal part o Paper Suction Fans o P_FRONT Sensor detects front edge o P_REAR Sensor detects rear edge o Paper Thickness Sensor o Paper Release Lever Position Sensor Cleaning Assembly o Pump As...

Page 45: ...er Carriage Including the Print Heads Paper width sensor cutter drive mechanism Cover Open Sensor interlock switch CR Motor CR Lock Mechanism SLID Home Position Detecting Sensor PG home position detecting sensor SLID Motor PG moving Motor Linear Encoder Roll Paper Holders Secondary Roller Assembly P Thick Sensor P Rear Sensor PF Motor Grid Roller Assembly Paper Suction Fans P Front Sensor Paper Re...

Page 46: ...s 46 K SYSTEM COMPONENTS Figure 2 3 Ink System Main Parts ELECTRICAL CIRCUIT BOARDS Figure 2 4 Electrical Circuit Boards I H Assembly F Box L Waste Ink Pads Pump Assembly Cap Assembly CR Lock F Box R Waste Ink Pads R Power Supply Board Main Board C277MAIN Control Panel Relay Board ...

Page 47: ...e from steel e following sensors are used in combination with the CR Guide Rail mponents HP Sensor This optical sensor activates when the CR Guide Rail flag flag enters the space between the light emitter and the light receiver The flag is located just above the home position and the HP sensor sends an On signal when the carriage is in the home position Linear Encoder This encoder is mounted on th...

Page 48: ...ap position ertical movement of the sub carriage with respect to the paper surface is ssible only in the case that the carriage is in the home position HP At that me the SLID motor pinion gear PG moving motor and the SLID gear ounted on the SLID eccentric cam shaft engage and the SLID cam is driven the SLID motor s rotation causing the sub carriage including the print ads to be raised or lowered t...

Page 49: ... the point when the carriage has traveled 10 mm at a stable constant velocity after acceleration control o Stop Control Carriage stop control is executed at the point when acceleration constant velocity deceleration control processing is completed and is controlled by position control through the software servo and a stabilization time in position time at the stop position o CR Motor Trouble Detec...

Page 50: ...tion Modes Figure 2 7 Carriage Unit Paper Width Detection Sensor reflective type photosensor is used and the paper edge paper present or t is judged by the 10 bit A D converted value output by the sensor etection of paper skew occurs in the following case and causes the message et the paper correctly to be displayed in the LCD n If the front edge and back edge of a cut sheet are skewed more than 3...

Page 51: ...centric cam rotates CCW Sub carriage modes up PG becomes wider ote CCW rotation is the rotational direction shown if you are looking from e printer s right side e SLID eccentric cam is eccentric in 3 stages and the following 3 stages of G value setting are enabled by the number of SLID motor CCW rotation steps the above operation able 2 4 SLID Home Position Detection Sensor Detection Mode Figure 2...

Page 52: ...3 Turning Auto Cut on after printing following Auto Cut Off then manual cutting o Cutting Method 1st Stage From a position 60 mm to the left of the paper s center cut to a position 8 mm beyond the paper s left edge from right to left 2nd Stage From a position 30 mm to the left of the paper s right edge cut to a position 8 mm beyond the paper s right edge from left to right 3rd Stage From a positio...

Page 53: ... to left 2nd Stage From a position 60 mm to the right of the paper s center cut to a position 8 mm beyond the paper s left edge from left to right 3rd Stage From a position 68 mm to the right of the paper s center cut to a position 40 mm to the right of paper s center from right to left 4th Stage From a position 68 mm to the left of the paper s center cut to a position 48 mm to the right of the pa...

Page 54: ...ks the rriage s position When the carriage is in the locked state power to the rriage is turned OFF the actuator rises up and a projection engages with the ck surface of the carriage binding the carriage When carriage lock is eased power to the carriage is turned ON the actuator is withdrawn from e carriage and the lock engagement is canceled Figure 2 10 CR Lock Mechanism Carriage Cover Sub Carria...

Page 55: ... are separate its with the loop scale mounted at the left end of and concentric with the PF ler and the encoder sensor also assembled separately in the printer s left ge iving of the PF roller is done by transmission to the PF roller through the lowing channel PF motor pinion gear _ Timing belt _ Reduction pulley _ Grid roller PF roller uction fans are also mounted on the back side of the paper gu...

Page 56: ...r is present and drops when there is no paper Paper Thickness Detection Sensor A transmissive photosensor is used for this sensor which is mounted on the H top guide A detection lever is mounted on the pressurization and follower roller assembly on the HP side and the detection lever position which changes according to the thickness of the paper inserted between the grid roller PF roller and follo...

Page 57: ...guide L pull o the paper from the back side of the sheet The fans are run at a constant velocity during printing but when the paper is set the following control is carried out to improve setting characteristics Suction fan air flow control is carried out based on the paper sensing timing of the P Rear sensor and the P FRONT sensor Detailed control methods are as shown below Figure 2 13 Paper Sucti...

Page 58: ...inting after the first 40 mm of the front edge 100 100 leaning with the paper set 100 100 uring paper cutting 100 Set the maximum moving distance and while detecting the paper level move the CR to the position where the No paper level is detected at the paper s left edge Paper Left Right Edge Detection CR in home position Move the CR to an empty suction position Move the CR to a position where the...

Page 59: ...f the next page to be printed the rear edge position of the previous page and the message Paper is skewed is displayed n Reference Edge position detected during paper left right edge detection n Judgment Standard If there is deviation to the left or right exceeding 3 mm between the front edge and rear edge of the paper the front edge of the next page it is regarded as an error Paper Front Edge Det...

Page 60: ... the dark system head and the light system head This protects the print head nozzles when they are not operating and seal off the head nozzle surfaces during the cleaning operation The cap assembly in the Stylus Pro 9500 uses new tubes to reduce evaporation of the moisture in the ink F Box R This is a receptacle for the ink that is discharged during flushing with the ink being discharged to the wa...

Page 61: ...ame physical shape so they can be serted in each color s ink cartridge slot but in order for the ink cartridge s type be distinguished by the ink ID sensor the message Replace ink cartridge is splayed in the LCD panel and printing is not possible See I H Assembly ensors on page 64 concerning sensor details nother important feature of the ink cartridge holders is the ink valve which is cated on the...

Page 62: ...sor 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 switch open When the I C is not low normal the switch closed Ink ID sensor This optical sensor is located at the side of all six ink cartridge slots and detects the which market the cartridge is for Although not implemented currently the sensor can also detect the ty...

Page 63: ...r cuts off the flow of that current The motors lose their ectromagnetized state when the current is cut off Figure 2 18 Cover Open Sensor e sudden loss of current to the motors can cause problems and may even mage the motors or the printhead To prevent this a discharge from the pacitor connected to the current circuit is used to slow down the current fore it is totally cut off This process ensures...

Page 64: ... 32 bit RISC CPU o Clock speed 33MHz o 128KB PROM internal ASIC E05B61AA IC13 1 Regulates print data o Command handling o Rasterizer image data handling o Head drive regulation DAC o Print timing regulation 2 Memory DRAM SRAM 3 I F Circuit Control o Parallel interface IEEE1284 o Macintosh Serial interface o Type B ASIC TE7751 IC20 Regulates Motor o Pump Motor o PG Motor PG setting o Fan PS Paper S...

Page 65: ...el to be tected is preset at 4 2V When the preset voltage level is detected the Pin 8 nds a reset signal to reset the main logic circuits Figure 2 21 Reset Circuit 2 1 2 2 CR PF Motor Driver Circuit The EPSON Stylus Pro 9500 uses the DC servomotor to drive the CR and PF motors Therefore the encoder is installed to detect the position direction and speed of the carriage and feedback from the encode...

Page 66: ...pulse motor is used for the drive motor and it is driven by the W1 2 ase excitation ased on the preset data received from the IC20 the motor driver IC IC31 termines the current level to be output to the motor and the motor is driven the drive phase switching signal which is input into the Pin 25 18 Figure 2 23 HD_SLID Motor driver circuit 2 1 2 4 Pump Motor Driver Circuit The 4 phase 200 pole HB s...

Page 67: ... e waveform signal is processed at the IC13 Triggered by the input of the TS signal from the CPU IC8 the waveform signal is input into the DAC in e IC37 as 10 bit data synchronizing with the clock signal 20mHz The DAC en converts the head driver voltage waveform data to analog data and tputs it to the trapezoid waveform generation circuit common driver e driver circuit on the printhead nozzle sele...

Page 68: ...y the CPU built in ADC 0 bit and is compared with the standard value for state analysis P_REAR Sensor P_FRONT Sensor P_EDGE Sensor oncerning these sensors since it is necessary that the reference voltage reshold be set at the proper level during AD conversion to match each nsor s characteristics if the main board is replaced or if the sensor boy is placed it is necessary to adjust the level using ...

Page 69: ...C H A P T E R TROUBLESHOOTING ...

Page 70: ...r Message List for Service Technicians table on page 70 or the General Error Message List table on page 71 to determine what and where the problem is as well as where to look for directions on fixing the problem o Errors that Require a Service Man This shows an error state in which it is necessary for a service man to carry out treatment accompanying checking and replacement of the relevant parts ...

Page 71: ...0001000F CR motor PWM output error page 75 00010010 PF motor PWM output error page 75 00020000 NVRAM error page 75 00020001 Internal RAM check error page 75 00020002 SRAM check error page 75 00020003 DRAM check error page 75 10000004 CPU vector 4 General illegal instruction page 75 10000006 CPU vector 6 Slot illegal instruction page 75 10000009 CPU vector 9 CPU address error page 75 1000000A CPU v...

Page 72: ...s not worn out verify no part of the tube shows wear is loose or leaks ink anywhere especially the tube area between the printheads and the ink pipes SERVICE REQ 00010000 o Problem PF motor encoder check error The PF motor makes small revolutions clockwise and counter clockwise When it turns the printer checks the rotary encoder output signals to make sure the motor is turning at the correct speed...

Page 73: ...wise When it turns the printer checks the encoder output signals to make sure the motor is turning at the correct speed distance If the encoder doesn t send the correct signal or output data an error occurs o Solution Make sure there is nothing blocking the carriage If that does not solve the problem check the CR motor encoder connection If there still is a problem try the following n Check the pl...

Page 74: ...elated error Solution n Replace the Main Board SERVICE REQ 0001000A o Problem CR origin sensor malfunction CR home position sensor malfunction o Solution Self diagnostic Function Check CR Home Position in Inspection Sensors n Replace the HP sensor n Replace the Main Board SERVICE REQ 0001000C o Problem PG origin sensor malfunction may indicate PG motor malfunction o Solution Check the sensor surfa...

Page 75: ...ATCHDOG TIME OUT ERROR SERVICE REQ 100000 CPU VECTOR 32 63 o Solution n Write down the error code turn the printer off and back on again to confirm whether the error recurs If the same error recurs replace the Main Board n Send a different print job to make sure the error wasn t due to electrical noise or bad print data 3 1 3 General Errors This section describes the errors that can be solved by t...

Page 76: ...r Check the sensor operation sensor connection and board PAPER JAM o Problem A paper jam occurs when during printing paper feeding or paper cutting the carriage is not able to move properly due to paper catching on some part The printer determines a paper jam has occurred if the P Front sensor and P Rear sensors are in the on state but the CR motor is out of step or has overcurrent o Solution n Ch...

Page 77: ...aper loaded in the printer and properly reload it according to the instructions in the user s guide n For roll paper the edges of the paper may not be lined up remove the paper and carefully squeeze the sides of the roll to make sure the edges are lined up and flat RELOAD PAPER o Problem This error occurs when A The front edge is loaded too far and the paper is not in the loading position after it...

Page 78: ...was interrupted because the lever was pushed to the release position and the paper shifted the print job may be marred n If the lever is down and this error still occurs check the Release Lever position sensor OMPARTMENT OPEN Problem An Ink Holder I H compartment door is open Solution n Push the I H lever down to the lock position n If the lever is down and this error still occurs check the lever ...

Page 79: ...the 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 attempting multiple cleanin...

Page 80: ...er thickness setting the location where the ink strikes the paper may change 3 If after following the above steps the printout quality has not improved verify the following n Head angle adjustment n Head height adjustment SMUDGED OR MARRED PRINTOUT FRONT The front or top side of the paper can become smudged or marred if it rubs against the printhead surface If this happens verify the following 1 I...

Page 81: ...he paper during printing at the point when one page is finished HITE OR BLACK BANDING white or black banding lines across the page appear on your printout try the lowing Cleaning If multiple cleaning cycles don t clear the banding problem try adjusting the heads as described below n Head slant adjustment B head C head If all the nozzles in the B head and C head are not perfectly lined up the raste...

Page 82: ...C H A P T E R DISASSEMBLY ASSEMBLY ...

Page 83: ... safety reasons the front cover position up or down is automatically detected by the cover open sensors which are interlock switches Do not block or modify these sensors n Because the Main Board provides a Lithium battery for memory backup purposes you must keep the following in mind when handling the Main Board Be careful to avoid damaging the Lithium electrodes due to short circuits When replaci...

Page 84: ... connector make sure to pull insert the cable straight Otherwise internal contact of the connector may be damaged and this causes a short circuit to destroy the electrical circuitries n The cutter blade is very hard and can damage or scratch printer parts and it can also be chipped or damaged Be careful when handling or replacing the cutter Table 4 1 Necessary Tools Tool Part Code Notes Phillips s...

Page 85: ...3x6 ex screw silver six sided hex screw 2 5mm Table 4 2 Screws Type Color Description 4 2 1 Remove Housing 4 2 2 Remove Circuit Board Maintenance Cover H Top Cover L R Side Covers Front Cover Roll Cover Lower Paper Guide Upper Paper Guide Power Board C277MAIN Board 4 2 3 Disassemble Printer Mechanism Replace Waste Ink Pads Replace Printheads CR Motor Pulley Assembly PF Motor Pulley Assembly Mainte...

Page 86: ...illustration of the housing parts Figure 4 2 Housing Part Diagram MAINTENANCE COVER REMOVAL 1 Open the Front Cover 2 Remove 2 screws CP W2 M3x6 and then remove the Maintenance Cover Figure 4 3 Maintenance Cover Removal Roll Cover Assembly Upper Paper Guide behind H Top Cover R Side Cover Maintenance Cover Lower Paper Guide H Top Cover Front Cover Assembly L Side Cover L Side Cover ...

Page 87: ...Remove the four screws two silver CP W2 M3x6 and two silver CP W2 M4x6 5 Lift the H Top cover from the rear edge and carefully tilt it forward and lift it away from the printer Figure 4 5 H Top Cover Removal Mounting brackets lower C A U T I O N When lifting the H Top Cover off the printer be careful not to catch the rear edge of the Cover on the P Thick sensor lever which is in the paper path to ...

Page 88: ... the stand and printer Remove the seven screws five silver CP W2 M4x12 screws and two black CP W2 M4x12 securing the Left Side Cover and remove the Left Side Cover Repeat for the Right Side Cover plus remove one cable from the back of the control panel Figure 4 6 L R Side Cover Screw Location Inner Figure 4 7 L R Side Cover Screw Location Outer CP W2 M4x12 silver screws CP W2 M4x12 silver screws C...

Page 89: ... then remove the damper assembly As shown below the Front Cover Assembly is supported by a shaft and brackets on both sides The shaft is secured to these brackets with three screws CP W2 M3x8 two on the right and one on the left Figure 4 8 Locations of Front Cover shaft screws Figure 4 9 Front Cover Removal CP W2 M3x8 screws Left side Right side C H E C K P O I N T The roll assembly parts and guid...

Page 90: ...er L R Assembly mounted on the roll cover rotating shaft on the outside of the left and right side frame Screws 2 each CP W2 M4 x 8 Remove the four screws CP W2 M3x8 two on each side that secure the Roll Cover Shaft From the outer sides of the L R Side Frames remove the Cover Gear Assemblies and then remove the Roll Cover Assembly Figure 4 10 Roll Cover Assembly Removal Left side of Roll CP W2 M3x...

Page 91: ...de Removal J U S T M E N T E Q U I R E D When removing installing the Lower Paper Guide the following adjustment procedure is required n Adjust the paper guide L installation position Refer to page 204 n Check the paper cutting position Refer to page 207 Adjust the cutter mounting position in accordance with the results of the paper cutting position check then adjust the CR cover height Refer to p...

Page 92: ...PAPER GUIDE REMOVAL Remove the Maintenance Cover See 4 2 1 1 Remove the H Top Cover See 4 2 1 2 Open the Roll Cover Remove the seven screws CP W2 M3x6 that secure the Upper Paper Guide and then remove the Upper Paper Guide Figure 4 13 Upper Paper Guide Removal CP W2 M3x6 screws ...

Page 93: ... Paper Guide Removal on page 92 Remove the two cables connected to the Power Board as shown below Remove the one ground screw and five screws that secure the Power Board and then remove the Power Board Five CBF M3x6 screws One CP W2 M4x5 screw Figure 4 14 Power Board Removal A U T I O N If you are removing the power supply board the AC cable should be pulled out then it should be left for approxim...

Page 94: ...ne CBF M3x6 screws I F connector Three CP M2x4 screws Figure 4 15 C277MAIN Board Removal 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 this causes a short circuit to destroy the electrical circuitries J U S T M E N T E Q U I R E D After replacing the main board...

Page 95: ... table above The location of the DIP Switch is as shown in the lowing figure Figure 4 16 C277MAIN DIP Switch Settings OTE Jumpers J1 and J2 should be used with the short setting as is If the setting is changed the printer will cease to operate Table 4 3 C277MAIN Board DIP SW Settings DIP SW1 DIP SW2 Affected Product Mechanical Configuration OFF ON Stylus Pro 9000 PF Roller 3 roller configuration P...

Page 96: ... 1 2 3 Remove the L R Side Covers See 4 2 1 3 4 Remove the Front Cover See 4 2 1 4 5 Remove the Lower Paper Guide See 4 2 1 6 Figure 4 17 L R Waste Ink Box Positions A U T I O N This manual only describes the repair and replacement procedures for parts that can be serviced on site Therefore only perform repair or replace procedures that are described here Other service procedures can only be done ...

Page 97: ...nk Boxes and re install the Waste Ink Boxes in the printer C H E C K P O I N T n When replacing the Waste Ink Pads prepare a vinyl bag beforehand for disposing the Pads CP W2 M4x8 screws A D J U S T M E N T R E Q U I R E D n When replacing the Waste Ink Pads following adjustment and setting are required Paper Guide L assembling position adjustment Refer to page 139 Cutter Position adjustment Refer...

Page 98: ...ck Release Figure 4 21 Carriage Cover Removal with H Top removed A U T I O N The printer uses two printheads B Head and C Head and although they are similar you need to make sure you do no 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 n B head Dark system head F055040 Printhead IJ192 OAD n C Head Light sy...

Page 99: ... print head from the carriage briefly 12 Take out the flat cable that is connected to the back of the print head and remove the print head Figure 4 23 Printhead Tension Spring and Screw Removal A U T I O N If you grasp the side of the damper the ink that is filling the inside of the damper will leak out so absolutely do not apply any force to the sides Insert a flat head screwdriver between the bo...

Page 100: ...nsion on the steel belt Figure 4 24 CR Motor Removal CR Steel Belt Loosening 4 Towards the right side of the frame there is one screw securing the steel belt remove this screw Then remove one edge of the steel belt and finally pull out the steel belt to the Right Side Frame Figure 4 25 CR Motor Removal Steel Belt Removal J U S T M E N T E Q U I R E D When removing the CR Motor the following adjust...

Page 101: ... connector CN18 on the relay board 3 Remove the two screws CP W2 M3x8 securing the HD_SLID motor assembly to the side frame Figure 4 27 HD_SLID Motor Assembly Removal A U T I O N During assembly when fastening the Y follower pulley assembly move the carriage to the left and right by hand and set the positioning screw while confirming that the steel belt fits uniformly in the center of the pulley L...

Page 102: ...re 4 29 Removing the PF Encoder Sensor Mounting Plate 5 Loosen the 4 screws CP W2 M4 x 12 blue screws in the figure holding the X Motor Mounting Plate then release the tension on the X deceleration belt 6 Take out the 2 screws CP W2 M3 x 8 red screws in the figure holding the PF motor pulley assembly on the X Motor Mounting Plate then remove the PF motor pulley assembly Figure 4 30 Removing the PF...

Page 103: ...the deceleration pulley support toured the outside Figure 4 33 Removing the X Deceleration Belt 3 X Deceleration Belt Deceleration Support Deceleration Pulley Support Front Arm Deceleration Pulley Support Upper Arm A D J U S T M E N T R E Q U I R E D If you are replacing or removing the X deceleration belt the following adjustment should be made n Paper guide L installation position adjustment Ref...

Page 104: ...cking material from the double sided tape on the PF loop scale base Figure 4 34 F730 tool and PF Loop Scale Base 3 Set the PF loop scale with its printed side downward on the PF loop scale base and affix the PF loop scale carefully to the PF loop scale base Figure 4 35 PF Loop Scale Set PF Loop Scale Base Protective Seal F730 tool C A U T I O N n Care should be taken so as not to damage the intern...

Page 105: ...gn the internal diameter of the PF loop scale with the left end of the grid roller PF roller and set it lightly 2 Press the exclusive tool F731 against the PF loop scale assembly from the outside then insert the grid roller in as far as the base plate carefully and affix it Figure 4 37 Affixing the PF Loop Scale Assembly A U T I O N At this point the PF loop scale assembly should not be fitted on ...

Page 106: ...motor pulley assembly Figure 4 38 Removing the PF Motor Pulley Assembly Push the PF motor inside the printer and remove the PF motor pulley I C H E C K P O I N T At the place where the tension is released workability will be improved if the X motor mounting plate is tightened temporarily A D J U S T M E N T R E Q U I R E D If the PF motor pulley is removed the following adjustments should be made ...

Page 107: ...ce Call 00000100 error occurs you need to replace the Waste Ink Pads and Box R well as replace the Pump Assembly Cap Assembly and Head Cleaner on reset the Maintenance Assembly In addition you need to reset the following counters n INIT WASTE INK see page 38 n INIT CREANER see page 38 You also need to perform the Cutter Position Adjustment J U S T M E N T E Q U I R E D If the Maintenance Assembly ...

Page 108: ...n remove the Pump Assembly along with the Cap Assembly and plate Figure 4 41 Maintenance Assembly disassembled 1 10 If necessary disassemble the Cap Assembly and Pump Assembly remove the ink tubes and remove the Head Cleaner from the Pump Assembly Figure 4 42 Maintenance Assembly disassembled 2 Cap Assembly Pump Assembly Pump Assembly Gear 2 screws C A U T I O N If you plan to re install the Cap A...

Page 109: ...t plate Figure 4 43 Interlock Switch R removal 4 To remove the interlock switch L disconnect the cable from the connector CN27 on the C277MAIN board 5 Remove the two screws CP W2 M3x6 securing the interlock switch mount plate to the side frame and remove the interlock switch L together with the mount plate Figure 4 44 Interlock Switch L removal CN13 A D J U S T M E N T R E Q U I R E D When the int...

Page 110: ...the cable from the connector CN11 on the C277MAIN board 3 Remove the one screws CP W M3x6 securing the sensor assembly and remove the P_REAR sensor together with the mount plate Figure 4 46 P_REAR sensor removal J U S T M E N T E Q U I R E D When replacing the P THICK sensor the following item should be checked n P THICK sensor assembly adjustment Self diagnostic mode Refer to page 215 A D J U S T...

Page 111: ...ard CN17 to HD_SLID HP sensor CN10 to LEVER POSITION sensor 3 Remove the two screws CP W M3x6 securing each sensor assembly and remove the LEVER POSITION HD_SLID HP sensor together with the mount plate Figure 4 48 LEVER POSITION HD_SLID HP sensor removal J U S T M E N T E Q U I R E D When removing the P FRONT sensor the following adjustment should be made since the paper guide L will be removed n ...

Page 112: ...s on the CR RELAY board CN3 to CR HP Sensor CN2 to Linear Encoder Figure 4 49 Disconnect the cables Figure 4 50 Removing the screws L R 4 Take out the 2 CR relay board mounting frame installation screws CR Encoder Sensor connector CR HP Sensor connector P Edge sensor connector Cutter Solenoid connector C A U T I O N Do not damage the timing fence slit film when removing attaching the encoder CR Re...

Page 113: ...sor and encoder from the back of the CR relay board mounting plate igure 4 51 Fig 4 51 Removing the CR HP Sensor and Encoder Sensor J U S T M E N T E Q U I R E D If you have removed the CR encoder sensor the following adjustment is necessary n CR encoder sensor installation position adjustment Refer to page 210 CR HP Sensor CR Encoder Sensor CR HP Sensor Installation Screws CR Encoder Installation...

Page 114: ...ws CP W2 M3x6 securing the ink tube fixing plate and loosen the lock nut securing the ink tubes to the ink pipes ad disconnect the ink tubes from the ink pipes Remove the four screws CP W2 M2x4 securing the access cover attached at the back of the I H assembly Figure 4 52 Disconnecting the ink tubes Figure 4 53 Removing the access cover A U T I O N Removing and re installing the ink system mechani...

Page 115: ...move the hand hold cover Remove the two screws CP W2 M3x6 securing the ink tube holder plate and disconnect the FFC from the connector CN1 on the I H relay board attached at the bottom of the I H assembly Figure 4 54 Removing the fixing plate Figure 4 55 Removing the FFC C H E C K P O I N T To remove two screws securing the ink tube holder plate you need a short neck screwdriver Push to release th...

Page 116: ...the printer mechanism Remove the six screws CP W2 M2x4 securing the side cover of the I H assembly and remove the side cover Slightly rotate the I C holder assembly so that the assembly is released from the lock lever unit Then remove the two screws CP W2 M3x6 securing the friction gear assembly and remove it Figure 4 56 Removing the screws 4 pcs Figure 4 57 Removing the screws 3 pcs Figure 4 58 I...

Page 117: ...he I H assembly from the side cover Rotate the internal cartridge holder assembly until the lock is released Next take out the 2 screws CP W2 M3 x 6 holding the friction gear assembly and remove the friction gear assembly Figure 4 59 Removing the side cover of I H assembly Figure 4 60 Removing the friction gear assembly Remove Friction gear assembly ...

Page 118: ...older fastening plate The I C holders are each independent of the other so they can be removed individually If you are removing one I C holder first take out the 1 screw CP W2 M3 x 4 holding the I C holder to the base frame Overturn the entire cartridge holder assembly then take out the screw CP W2 M3 x 4 holding the I C holder from the bottom surface of the base frame Figure 4 61 Removing the I C...

Page 119: ...g removed from the I H relay board on the bottom of the cartridge holder assembly Figure 4 64 Removing the ink pipe Figure 4 65 Connector location on the I H relay board Lock Nut HOLDER ASSY VALVE A Table 4 4 Connection between each I C holder and relay board I C Holder I C ID sensor I C In sensor Ink low sensor Black Light Cyan CN3 CN4 Cyan Light Magenta CN5 CN6 Magenta Yellow CN7 CN8 CN3 CN5 CN7...

Page 120: ...ly Disassembly Flow 120 Remove the one screw CP W2 M2x4 with a metal bushing securing the I C link to the I C eject lever Remove the I C holder assembly from the I H assembly Figure 4 66 Removing the screw I C link Figure 4 67 Removing the I C holder ...

Page 121: ... C ID sensor board Remove the two screws CP W2 M3x4 securing the HOLDER ASSY VALVE A to a base frame If necessary remove the I C In sensor assembly or the Ink Low sensor assembly Figure 4 68 I C Holder Figure 4 69 I C Holder Disassembly 1 2 I C ID Sensor board Upper I C guide Base frame HOLDER ASSY VALVE A Metal bracket Bottom I C guide Upper I C guide Metal bracket Bottom I C guide I C In sensor ...

Page 122: ...r or Postscript Server system disc so a system disk or materials which are compatible with the customer s use environment should be brought together with this kit 4 2 4 2 Required Adjustment Item In the upgrade service if the necessary parts are assembled the necessary adjustment items are as shown below Table 4 5 Conversion Kit Component Parts Part Name Quantity Maintenance Kit 1 Kit MC Thick Mat...

Page 123: ...ftware package o The results of the nozzle check of the Stylus Pro 9000 currently in use by the user should be checked If missing of dots is occurring carry out head cleaning 3 times and if it still doesn t recover use a light system head regardless of whether the head causing the dot missing is a dark system head or a light system head ASP Code F055050 and this should be brought together with thi...

Page 124: ...GE PROCEDURE 1 Enter the Self diagnostic mode by turning the printer s power switch ON while pressing the following buttons n Paper Feed Button Cut Eject Button Cleaning Button 2 Select Check Adjustments by pressing the SelecType button then press the Enter button After that press the Paper Source button to select Adj Clean Head then press the Enter button 3 In accordance with the instruction Plea...

Page 125: ...ges the S46 transport liquid used to fill the ink supply system from the printer and ends in approximately 4 minutes When the transport liquid discharge sequence is completed the message Adj Counter Clear will be displayed in the LCD When the Enter button is pressed the message Reset Counter will be displayed in the LCD By pressing the Enter button the counters for the following items will be rese...

Page 126: ...Figure 4 70 Removing the Maintenance Cover Take out the 4 screws CP W2 M3 x 6 2 pcs CP W2 M4 x 6 2 pcs holding the H top cover then remove the H top cover Figure 4 71 Removing the H Top Cover 3 Take out the 7 screws CP W2 M4 x 12 holding the right side cover then remove the right side cover At this time carefully pull out the panel FFC from the control panel that is incorporated into the right sid...

Page 127: ...he paper eject guide out from the paper support L Figure 4 74 Removing the Paper Eject Guide 6 Take out the 9 screws holding paper guide L then carefully pull the paper guide L down and off the printer Figure 4 75 Removing the Paper Guide L 1 7 Close the front cover fasten it with adhesive tape etc then pull the paper guide L completely off the printer in the downward direction Figure 4 76 Removin...

Page 128: ...er guide L is removed it becomes possible to perform the following removal procedures more smoothly 1 Push the bottom end portion of the paper guide L toward the rear then let the front part of paper guide L float free toward the front of the printer 2 Pull paper guide L gradually out and downward 3 First pull out the right side of paper guide L then pull it out toward the front of the printer Aft...

Page 129: ...ft F box as shown in the figure below Figure 4 79 Removing the Left F Box 11 11 Take out the 1 screw CP W2 M4 x 8 holding the left waste ink pad box then remove the left waste ink pad box Figure 4 80 Removing the Left Waste Ink Pad Box C H E C K P O I N T When installing the left and right waste ink pad boxes make sure that the F box tubes are set securely in the groove in the metal frame Waste In...

Page 130: ...ce a total of 7 pads After replacing the pads place the left and right waste ink pad boxes off to the side where they will not be in the way while the rest of the operation is being completed 14 Pull the CR lock cable out of the CN9 connector on the relay board on the right side of the printer Figure 4 82 Removing the CN9 Connector Cable 15 Release the CR lock lever manually and move the CR unit f...

Page 131: ...mbly as shown in the figure below Figure 4 84 Removing the Maintenance Assembly 1 Figure 4 85 Removing the Maintenance Assembly 2 17 If the maintenance assembly is gradually pulled out of the printer mechanism the pump motor on the maintenance assembly will catch on the bottom of the front cover so at this point rotate the maintenance assembly clockwise as shown in the figure below then pull the m...

Page 132: ...left side as shown in the figure below Figure 4 90 Fig 4 90 Assembling the Head Cleaner 22 Assemble the new pump assembly 1 screw and side frame 2 screws the cap assembly 1 screw and maintenance assembly following the procedure in steps 18 19 and 20 in reverse order 23 Assemble the maintenance assembly in the printer 3 screws 24 Insert CN9 in the relay board s connector 25 Assemble the right waste...

Page 133: ...aste ink pad box then carefully push the box into position After that tighten the screws to fasten the box in place C H E C K P O I N T n Make sure the waste ink tubes of the pump assembly are routed securely around the right side of the maintenance assembly n Make sure the waste ink tube to the right F box is fitted securely to the tube attachment position on the maintenance assembly n Make sure ...

Page 134: ...es form the damper holder Slide the damper holder to the right side and remove it Figure 4 93 Removing the Damper Holder 31 Pull out the 6 dampers from the print heads carefully wrapping each one in a soft piece of cloth etc to prevent transport liquid from leaking out Figure 4 94 Removing the Dampers 32 Loosen the hex nuts used to fasten the ink tubes to the dampers then remove them 33 Take off t...

Page 135: ...ssemble the damper holder 1 screw 37 Set each ink tube in the damper holder then assemble the CR cover 2 screws 38 Assemble the right side cover 7 screws and H top cover 4 screws 39 Assemble the maintenance cover 2 screws C H E C K P O I N T n When installing the O rings take adequate care in handling and do not touch them with bare hands n When installing the O rings on the ends of the ink tubes ...

Page 136: ...t ink cartridge Model No label over top the dye based ink label Left Ink Cartridge Model No Label Affix the left ink cartridge Model No label over top the dye based ink label r details see the figure below Figure 4 97 Label Affixing Positions PIGMENT INK INITIAL FILLING 1 Take the 6 pigment ink cartridges from the conversion kit and set them in the I H holders Lower the ink lever securely 2 Insert...

Page 137: ...D During this time all the ink LED s on the panel will blink repeatedly This operation will be completed in approximately 2 minutes n Data Send _ Flash Erase _ Flash Write _ Complete _ Program Load End 6 When the above LCD display ends turn the printer s power switch Off A U T I O N n Whichever method is used a PC card or the parallel interface cable if the power is turned off during the firmware ...

Page 138: ...e Self diagnostic mode n Paper Feed Button Cut Eject Button Cleaning Button 2 Press the Paper Source button and select Check Print then press the Enter button 3 Select Print Nozzle Check by pressing the Paper Source button then press the Enter button and print the nozzle check patter The following items are printed out in this nozzle check pattern printout n Nozzle Check Pattern n Firmware Version...

Page 139: ...p direction tighten the 4 screws that fasten the left side of the paper guide L Figure 4 98 Adjusting the Paper Guide L Assembly Position 1 2 Table 4 8 Adjustment Items Adjustment Item Required Jigs 1 Paper Guide L Assembly Position Adjustment F755 2 Cutter Position Adjustment F756 3 Paper Cutting Position Check Gauge 4 CR Cover Installation Position Adjustment F724 5 Bi D Adjustment Since this ad...

Page 140: ... sub platen on paper guide L n To assemble the cutter assembly in the correct position with respect to the cutter groove position on the sub platen on paper guide L 1 Take out the 2 screws holding the CR Cover then remove the CR cover 2 Insert the projections on tool 759 in the row of holes in the 2nd level of the sub platen on the right side of the sub platen installing the tool Figure 4 100 Asse...

Page 141: ...sitioning Adjustment 1 Set paper minimum size 10 cm wide x 20 cm in the paper path along the paper setting position on the right side of the printer then move the paper set lever back and set the paper 2 Move the CR manually to the right edge of the paper then lower the cutter manually 3 While holding the bottom edge of the paper with one hand cut the paper with the cutter 4 Set a gauge with minim...

Page 142: ...ndard loosen about 2 of the screws holding the paper guide L and carry out fine adjustment of the paper guide L s assembly position C H E C K P O I N T n The length from the edge of the cutter level difference to the front edge of the paper where it was actually cut should be within 0 5 mm _ 0 2 mm n If you are adjusting the assembly position of the paper guide L the installation screws that are l...

Page 143: ...etting Position Move the CR unit manually over the tool and set the cutter holder in the groove on the tool shown in the figure at left At this time check if the tool is securely in contact with the sub platen Tighten the CR cover installation screws while lightly pushing the CR cover toward the sub platen 5 Move the CR to the carriage position Figure 4 104 CR Cover Height Adjustment C H E C K P O...

Page 144: ...terns No 1 to No 3 press the Paper Source button 3 times and proceed to the printing pattern No 4 adjustment menu Proceed to Step 8 Confirm that Bi D 300 N C is displayed in the LCD o If there is pattern deviation in printing patterns No 1 to No 3 press the Paper Source button several times to proceed to the adjustment menu for the affected pattern then press the Paper Feed or button to input the ...

Page 145: ...roper printing pattern can be confirmed 11 ND LC XX will be displayed in the LCD In this menu input the pattern No of the pattern among the 8 light cyan printed patterns which was confirmed to be proper using the Paper Feed or buttons The pattern No on the printed pattern has the numbers printed in hexadecimal with each number increased by 2 from the number of the pattern to its left but in this m...

Page 146: ...lue input from the panel the adjustment results are printed out so it is possible to check the adjustment results visually but for Bi D adjustment pattern No 4 even if you decide a value to input from the panel a printing pattern that reflects the adjustment results is not printed so the adjustment results cannot be checked visually Therefore if you are confirming the adjustment results for adjust...

Page 147: ...ent menu then input the appropriate numerical values using the Paper Feed buttons After inputting the correction value press the Enter button to print the results of the input correction values The relationship between the inputs using the Paper Feed buttons and the printing results is as shown below n Adjustment value minimum resolution 1 2880 Inch n Correction Direction Paper Feed Button Moves t...

Page 148: ...tion sensor adjustment range is low and it is difficult for them to detect special papers such as tracing paper Type 2 models have undergone the following improvements and their paper detection capacity has been improved to where they can even detect special papers such as tracing paper n The adjustment range of VR1 VR2 and VR3 which determine the paper detection sensor adjustment range is broad n...

Page 149: ...rinting should always be done with the printer covers securely in place n If the specified paper is set in the printer for each sensor adjustment the paper set lever should be moved to the paper set position securely so as to stabilize the paper over the sensors A U T I O N The papers used for this adjustment PPC Kimoto Tracing Paper 300 should be replaced periodically If there is any dirt ink for...

Page 150: ...Source button and select Test Sensors then press the Enter button 4 Press the Paper Source button and select Sen Edge AD At that time make sure that the LCD displays Sen Edge AD ttt vvv NOTE NOTE ttt or vvv is a hexadecimal number that changes depending on the printer s state 5 As necessary the access cover on the paper guide should be removed Open the front cover release the CR lock then move the...

Page 151: ...vv is displayed in the LCD and that the front cover is in the closed state 2 Confirm that the following is displayed in the LCD n LCD Display Sen FRONT AD ttt vvv n ttt value The numerical value is not related to anything n vvv value Should be a value 025 H or lower If the vvv value is higher than 025 H adjust the VR2 element so that the vvv value is 025 H or lower 3 Raise the paper set lever then...

Page 152: ...he sheet of paper is at the paper front edge setting position on paper guide L Close the front cover halfway At this time if the vvv value in the LCD display does not change the subsequent operation can be performed with the front cover in the open state If the vvv value changes use adhesive tape etc to fix the front cover in the half closed state OTE Move the CR unit over the paper so that the CR...

Page 153: ...A isassembly Assembly Disassembly Flow 153 YPE 2 PRINTER MECHANISM SENSOR ADJUSTMENT case the Conversion base mechanism is Type2 sensor adjustment is not quired because the Main board Sensor Firmware level is same as Stylus RO 9500 ...

Page 154: ...was printed out Confirm that the value has gotten smaller OTE If initial filling has been exceptionally performed several times during this operation the counter value that is printed out may actually be higher than the value printed out during the preparations n Vertical Nozzle Alignment Check Pattern In this pattern it should be confirmed that no irregular color dark portions light portions are ...

Page 155: ...C H A P T E R ADJUSTMENT ...

Page 156: ...le 5 1 Adjustment Tools Name Part Code Notes Tension Gauge B747700300 standard tool acceptable Max 4000g Tension Gauge F712 1047744 standard tool acceptable Max 200g Straight edge ruler 1000mm F713 1047746 standard tool acceptable Length 1000mm Scale Stopper 714 1047745 standard tool acceptable Used in combination with F713 0 1mm scale Paper Guide L Installation Position Adjustment tool F755 Exclu...

Page 157: ...ry Card F727 1050073 standard PC card acceptable Type 2MB Flash memory card Standard Type II PCMCIA Rel 2 1 JEIDA Ver 4 2 Voltage 5V Read Write moto Micro Trace aper F751 ASP Code 1057723 Used for sensor adjustments Table 5 1 Adjustment Tools Name Part Code Notes ...

Page 158: ...n Position Adjustment CR Cover Height Adjustment Paper Cutting Position Check page 170 page 171 page 172 page 173 page 175 page 177 page 180 page 198 page 201 page 205 page 208 page 207 Main Board replacement Caution If it is possible to implement the adjustment sequence in the table at right it is not necessary to perform any adjustments after item 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Parameter ...

Page 159: ...acement CR Sensor 1 CR Encoder Sensor Installation Position Adjustment page 210 Sensor placement Cover R L Sensor 1 Self Diagnostic Function o From the Test menu select Sensor and then Cover page 215 Table 5 2 Service Parts Required Adjustments continued Service Operation Step Number Adjustment Items Refer to Sensor Replacement o Removal and replacement of the PF encoder sensor 1 2 PF ENC Installa...

Page 160: ...stallation Position Adjustment 2 page 211 page 211 When removing nd installing the R cover Replacing the int heads Replacing the utter solenoid ssembly etc 1 2 3 Cutter Installation Position Adjustment CR Cover Height Adjustment Paper Cutting Position Check page 205 page 208 page 207 Table 5 2 Service Parts Required Adjustments continued Service Operation Step Number Adjustment Items Refer to ...

Page 161: ... II compatible PC card should be used Recommended Fujitsu Model No MB98A81183 15 o A PC which uses PC cards or a PC card writer o PC Card Writing Tool Example ADTEC CardUT97 o IPL Data Separately supplied data should be written to a PC card in advance for use in backing up Data File Name BACKUP EXE Self extracting format file The generated files are written to the PC card after extracting C H E C ...

Page 162: ...cess cover is removed from the top of the Upper Paper Guide add make sure the Control Panel is attached 2 Insert the PC card containing the backup data 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 fol...

Page 163: ... LCD you see the message above one of the following errors has occurred Using different PC card try the operation again using a different PC card does not solve the problem there is a problem with e flash memory on the Main Board and a backup is not possible n Flash memory write error n Flash memory erase error n PC card write error n PC card erase error End Error ...

Page 164: ...printer as follows Parallel Connection From the DOS prompt type copy filename prn and press Enter 4 Reloading of the firmware will start and the following messages will be displayed in order in the LCD panel Flash Erase _ Flash Write _ Complete _ Program Load End 5 Turn the printer off and then back on A U T I O N n When the printer s power is turned on immediately after reloading the firmware the...

Page 165: ...rite _ Complete _ Program Load End Turn the printer s power Off then after removing the memory card turn the power on again A U T I O N n Whichever method is used if update processing is interrupted midway through the process by the power being turned off etc it is possible to recover by starting the operation again n It is possible to use the following PC cards and card writers their operation ha...

Page 166: ...re 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 item or increases the value of the item shown on the LCD Paper ...

Page 167: ... parameter list heck Parameter Updates or clears all of the adjustment parameters heck Life Tests the operation of the printer components A U T I O N n The Check Life menu contains tests that should only be performed at the factory so do not attempt to use this menu n In Self Diagnostic mode all of the tests except for one Rear Sensor adjustment assume that you have loaded roll paper Even if you l...

Page 168: ...ifies the B C Head nozzles are at the same height mechanism adj D Print Position Verifies the printed lines match up when performing bi directional printing ead Gap Adjusts the B C Head Gap as well as sets the left margin Flush Point Adjusts the flush position on the HP side Flush Point Adjusts the flush position on the opposite side eed Correction Checks paper feeding w ruler op Bottom Checks the...

Page 169: ...ind 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 ...

Page 170: ...ected value for the paper edge position to determine if the paper is feeding at a slant This adjustment is for service printouts and does not affect user printouts 1 Make sure Adj Check Skew appears on the LCD and press the Enter button 2 If the paper is not loaded correctly Reload Paper appears indicating you need to properly load the paper If the paper is set correctly the printer initializes th...

Page 171: ...ton again to write the printhead ID value to the Main Board and begin the initial ink charge in the heads Please Set Paper Paper initializes Check Skew 1 0m Press Enter Press Paper Feed or to change the skew check distance 0 1m increments Exc Skew Paper edges detected Skew Result 0 0100m After entering B C head ID s Enter Key appears on the LCD To avoid wasting ink if you do not replace the printh...

Page 172: ... cyan magenta yellow light magenta and light cyan n Also after the above patterns the following items are printed at the same time n Firmware version n Waste ink counter remaining capacity n Vertical nozzle alignment check pattern n Horizontal nozzle alignment check pattern 3 When the check pattern is finished printing Nozzle Check End appears on the LCD If the pattern printed all six colors prope...

Page 173: ...ead Adjuster A to correct the inclination Then tighten the head installation screws The movement direction of the head adjuster at this time is as follows depending on the degree of inclination The check pattern color will differ during C head adjustment After finishing the slant adjustment procedure for both heads move the carriage back to the capping position by hand and close the front cover 4 ...

Page 174: ...ustment Steps 174 J U S T M E N T E Q U I R E D The CR cover is removed in this adjustment so the following adjustment and check should be carried out n CR Cover Height Adjustment Refer to page 208 n Paper Cutting Position Check Refer to page 207 ...

Page 175: ...crews in the affected head then correct the Head Adjuster B to correct the inclination Then tighten the head installation screws The movement direction of the head adjuster at this time is as follows depending on the degree of inclination After finishing the slant adjustment procedure for both heads move the carriage back to the capping position by hand and close the front cover 4 Make sure BC Sla...

Page 176: ...on A djustment Adjustment Steps 176 J U S T M E N T E Q U I R E D The CR cover is removed in this adjustment so the following adjustment and check should be carried out n CR Cover Height Adjustment n Paper Cutting Position Check ...

Page 177: ... several times to proceed to the adjustment menu for the affected pattern then press the Paper Feed or button to input the appropriate numerical value After inputting the correction value press the Enter button The printer will then print out the pattern with the results of the input correction value The relationship between the inputs using the Paper Feed or button and the printing results is as ...

Page 178: ...ed to be proper using the Paper Feed and buttons The pattern No on the printed pattern has the numbers printed in hexadecimal with each number increased by 2 from the number of the pattern to its left but in this menu it is possible to input each of the 16 numbers from 0 H to F H in hexadecimal After inputting a value press the Enter button 10 ND LM XX will be displayed in the LCD In this menu inp...

Page 179: ...not be checked visually Therefore if you are confirming the adjustment results for adjustment values by printing pattern the following DOS program becomes necessary Program Transfer Utility Pout3 Exe Program Name Bid333 prn The program transfer method is as follows 1 Confirm that the printer is in the Pause state 2 Move to the DOS prompt 3 Input POUT__BID333 PRN 4 Press the Enter key Through the a...

Page 180: ... message Gap End is displayed in the LCD Proceed to Step 16 o If there is deviation in the patterns in printing patterns No 5 or No 6 press the Paper Type button to move to the corresponding pattern adjustment menu then input the appropriate numerical values using the Paper Feed keys After inputting the correction value press the Enter button to print the results of the input correction values The...

Page 181: ...g is finished Point x NNN x R or L 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 Dir...

Page 182: ...ler or a 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 After entering the measurement press the Enter button to finish Figure 5 10 Feed Distance Check Pattern Printing Pattern V Length 1000 0mm Use the item select Paper Feed or button to adjust the flushing pos...

Page 183: ...time also carry out the operation with the panel s auto cut setting Off 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 when prompted After entering the measurements press the SelecType or Item button until Bottom Length xx xmm appears and then pr...

Page 184: ... is because this item could not be detected in the top and bottom detection in the previous item Make sure Adj Rear Sensor Pos appears and press the Enter button 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 After printing is finished measure the distance from th...

Page 185: ...PSON Stylus Pro 9500 Revision A djustment Adjustment Steps 185 Figure 5 12 Rear Sensor Position Adjustment Measurement Measure this value and enter it Feed direction ...

Page 186: ...r Table 5 8 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 Item The printer prints the adjustment parameter list ejects the paper and proceeds to next menu E...

Page 187: ...at their remaining capacity is low they should be replaced with new ones after this operation is completed n If this product is transported again or moved after installation ink discharge should also be carried out in this function n After ink discharge at the point when the necessary operation is completed be sure to carry out Initial Filling See item 5 3 4 ...

Page 188: ...ear Counter Reset Value Protection Counter A B 0 Ink Volume Counter Rb Ry Rx Rz 0 Consumed Ink Counter Cb Cy Cm Cc Cml Ccl 0 Power Cutoff Timer T2 0 Accumulated Prints Timer 0 CL Timer 0 CL Timer 3 0 CL Flag 0 Initial Charge Flag 1 Periodic Pseudo Vacuum Flag 0 A U T I O N Since the counter for the remaining ink holding capacity of the waste ink pads and the ink consumption counter etc are cleared...

Page 189: ...n ersion o Program o Backup parameters o DIP SW o Board Rev Control Panel o Panel buttons o LCD panel display o LED indicators ensors HP Cover Open Release Lever P_FRONT P_Rear Paper Thickness PG Thermistor I C Holder Levers Ink ID I C and Ink Low ncoder CR Motor PF Motor an On Off confirmation lec o Maintenance Record o Fatal Error Record D A Revision Factory use for Head voltage correction do no...

Page 190: ...t the Panel Key function o LCD check All dots turn on If a dot is not on the LCD is not working properly o LED check The LED indicators turn on in the following order and the name of the indicator appears in the LCD when it 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 Pause returns you to previous menu Ver Firm XXXXXX Ver Parameter Pn...

Page 191: ... state Lever Shows the paper release lever s state Lock Release Paper Edge AD Paper Front AD Paper Rear AD Shows the state detected by the paper sensors P_EDGE P_FRONT P_REAR Paper Thickness Shows the state detected by the paper thickness detection sensor Head Slide Shows the state detected by the PG cam home position detection sensor Temperature B C Shows the temperature detected by the Thermisto...

Page 192: ...paper n If you are turning the VR1 VR2 and VR3 volume resistors on the main board to make adjustments care should be taken not to touch the other elements on the board or the frame etc It is recommended that a screwdriver that is not conductive be used for this adjustment n It is easy for each sensor to be influenced by stray light from the sun or from the room lighting etc The P FRONT sensor in p...

Page 193: ...ed firmware is written to the flash ROM by this upgrade service implementation the display in the sensor adjustment mode s LCD display is as shown below The meaning of each value is also shown below Panel Display Sen Sensor Name A D ttt vvv ttt Difference between the sensing level when there is no paper and when there is paper This numerical value is shown in Hexadecimal and changes depending on t...

Page 194: ...per is present If adjustment is impossible replace the sensor Raise the paper set lever then after removing the paper return the paper set lever to the paper set position o P_FRONT Sensor Adjustment 1 Press the Paper Source button and select Sen Front AD At that time make sure that the LCD displays Sen Front AD ttt vvv If the vvv value is lower than 01C H when no paper is set then adjustment is im...

Page 195: ...nt operation can be performed with the front cover in the open state If the vvv value changes use adhesive tape etc to fix the front cover in the half closed state Confirm that the LCD displays the following n LCD Display Sen Rear AD ttt vvv n ttt value 40 H or higher n vvv value 95 H or lower If the above conditions are not met adjust the VR3 element while checking the display in the LCD and adju...

Page 196: ...rns on Press the Pause button to turn the fan off and oceed to the next item ELEC This function allows you to check the operation record information and the fatal error record stored in the control circuit o Record Error menu The errors listed here do not include CPU errors service call errors and the printer lists a maximum of the most recent seven fatal errors Error 0 6 Pause returns you to prev...

Page 197: ...umber of times cutter solenoid has operated Lock Solenoid Number of times CR lock solenoid has been used 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 been used Head Rubbing R L Number of times B C head rubbing operation has occurred Rubbing Number of times rubbing pad has been used Lever Number of ...

Page 198: ...t Print tion on the Adjustment menu For details see Test Pattern Print on ge 186 5 2 7 Parameter menu Using this menu you can reset or change the parameters for the printer mechanism controls However the parameters on this menu can also be modified from the Adjust menu When servicing the printer you do not need to separately update or reset the parameters from this menu INITIALIZE ITEMS The items ...

Page 199: ...turned on Dot Shift Mode This mode sets an offset for the adjustment value in Bi D adjustment pattern No 4 The initial setting is Single Print C H E C K P O I N T The parameters will update and be stored in the Flash memory on the Main Board the next time the printer is turned off A U T I O N If Pair is set based on the evaluation results it will be judged that there is shifting of the adjustment ...

Page 200: ...m Explanation HEX DUMP PRINT This prints out print data transferred to the printer in hexadecimal form 16 data items per line are displayed and in addition an ASCII character corresponding to those data is printed on the right side If there are no characters such as print or control codes which correspond to the data a period is printed The panel settings cannot be set while the printer is in this...

Page 201: ...C counter Value Display INK LC 0 4294967295 Decimal number Remaining Ink LM counter Value Display INK LM 0 4294967295 Decimal number Remaining Ink Y counter Value Display INK Y 0 4294967295 Decimal number Cutter Life Counter Value Display CUTTER 0 4294967295 Decimal number Total Printed Sheet Counter Value Display TTL PAGES 0 4294967295 Decimal number Waste Ink Counter A Value Display WAST INKA 0 ...

Page 202: ...ct it or not Note 4 If microbanding which occurs in the 720 x 360 dpi mode and the 720 x 720 dpi mode actually occurs this reduction function acts to reduce banding somewhat when this setting is changed However there may not be any effect even if the setting is set in the desired value by this function so exercise caution when changing the setting value Table 5 17 Counter Initialization Menu Item ...

Page 203: ... confirm by sight page 214 ower Paper uide o Paper guide L installation position adjustment o Cutter Position o Paper guide L installation position adjustment tool F755 Code 1059434 confirm by sight or by measuring with a ruler page 204 H Assembly I H Handle Gear position match confirm by sight page 214 THICK sensor Self diagnostic mode test Paper Thickness page 215 R Encoder ensor CR encoder sens...

Page 204: ...ter s right side as shown in the figure below While pushing up the paper guide L toward the sub platen upward tighten the 5 screws on the right side of the paper guide L to fasten it Figure 5 15 Paper Guide L Assembly Position Adjustment 2 2 3 Set tool No F755 between the paper guide L and platen on the printer s left side again then confirm that the tool cannot be inserted smoothly If the tool ca...

Page 205: ...ove the CR unit so as to cover tool No F759 set on the sub platen At this time the rib on the tool should pass between the cutter assembly and solenoid 4 Loosen the 2 screws holding the cutter solenoid and cutter assembly then push the cutter assembly to the rib on the tool Figure 5 17 Cutter Position Adjustment 5 Tighten the 2 screws holding the cutter solenoid and cutter assembly 6 Tighten the 2...

Page 206: ...lus Pro 9500 Revision A djustment Adjustment Steps 206 C H E C K P O I N T n After performing this adjustment be sure to perform the following adjustments Paper Cutting Position Check CR Cover Height Adjustment ...

Page 207: ...ults are outside the standard loosen about 2 of the screws holding the paper guide L then carry out fine adjustment of the paper guide L s assembly position 6 In the same way set paper on the left side of the printer cut the paper manually and measure the length from the cutter level difference to the front edge of the paper If the measurement results are not within the standard loosen about 2 of ...

Page 208: ... difference in the tool and check if the cutter blade enters the groove Fasten the CR cover with it pushed down so the cutter pushes against the tool Since the position will change only as much as the amount of looseness in the installation screw holes position it so that it will hit against the tool Standard 9 75 0 25 mm Using tool F724 Figure 5 18 Checking the tool Setting Position C H E C K P O...

Page 209: ...PSON Stylus Pro 9500 Revision A djustment Adjustment Steps 209 Carriage Cover Cutter The plastic part is the front end Sub platen CR Cover Position Adjustment tool F724 ...

Page 210: ...in the figure below Push the CR encoder sensor toward the tool lightly then tighten the 2 CR encoder installation screws Figure 5 20 CR Encoder Sensor Installation Position Adjustment A U T I O N n The CR encoder sensor used in the Stylus Pro 9500 differs in its shape from the CR encoder sensor used in the Stylus Pro 9000 when using tool 766 in this adjustment it should be used only after confirmi...

Page 211: ...nt PF ENCODER SENSOR INSTALLATION POSITION ADJUSTMENT 2 This adjustment shifts and adjusts the PF encoder sensor on each installation frame so that the loop scale on the PF roller shaft is positioned virtually in the center between the PF encoder sensor s receptor and emitter Through this adjustment it becomes possible to read the slits on the loop scale more accurately 1 Loosen the 2 PF encoder a...

Page 212: ...5 23 Check Points C H E C K P O I N T Due to sensor characteristics the reading accuracy of the sensor has a tendency to drop if the scale makes contact with the sensor s emitter side outside Adjust so that the scale does not make contact with the tool Exclusive tool F765 ...

Page 213: ...CR Rail Figure 5 24 CR Steel Belt Tension PF 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 3500g 10 Figure 5 25 PF Belt Tension Driven Pulley Carriage Assembly CR Motor 2 Test the tension in the center 1 Move to ...

Page 214: ... andard At the level where the slide idler gear slides smoothly in the axial direction Figure 5 26 PG Motor Backlash Adjustment I H LEVER POSITION ADJUSTMENT This adjustment is necessary for service operations that require you to remove the I H subassembly which is located inside the Ink Cartridge Holder The I H Lever controls the I H subassembly position up or down and when the I H lever is prope...

Page 215: ... Thick appears in the LCD Insert a schema gauge 0 6mm 0 7mm between the PF Grid Rollers and Driven Rollers nearest the HP Lower the Release lever to the Lock position The LCD message will vary according to the schema gauge as shown in the table below If the correct message does not appear or any other message appears verify the P THICK sensor is installed correctly and check the operation again Fi...

Page 216: ... 2 screws used to install the cover R L sensor assembly then adjust the sensor s position forward and backward and tighten the installation screws n The cover R L sensor assembly s switch lever is pressed by the front cover flag to such an extent that it bends n The cover R L sensor assembly switch is not turned ON by the front cover flag 3 Set tool 754 on the left edge of the front cover then clo...

Page 217: ...eaning Press the SelecType or Item button until Check Test appears in the LCD then press the Enter button to select the Test menu Press the SelecType or Item button until Test Sensor appears in the LCD then press the Enter button to select the Test Item menu Press the SelecType or Item button until Sen Cover xxxx appears Open and close the Front Cover checking the LCD to make sure the message chan...

Page 218: ...ion of the DIP Switch is as shown in the lowing figure Figure 5 30 C277MAIN DIP Switch Settings OTE Jumpers J1 and J2 should be used with the short setting as is If the setting is changed the printer will cease to operate Table 5 22 C277MAIN Board DIP SW Settings DIP SW1 DIP SW2 Affected Product Mechanical Configuration OFF ON Stylus Pro 9000 PF Roller 3 roller configuration PF Motor Built in enco...

Page 219: ...C H A P T E R MAINTENANCE SETUP ...

Page 220: ...s or your skin If ink gets in your eye flush the eye with water and see a doctor if you feel discomfort in your eye C A U T I O N n Due to the printer s size when performing any service or maintenance operations confirm there is plenty of space for the operation n Due to the printer s size and weight make sure the area you move and place the printer is stable n Since the EPSON Stylus Pro 9500 is v...

Page 221: ...Solution Replace the following parts Waste Ink Pads R L Pump Assembly Cap Assembly F Box R L Cleaner Head o Required Adjustments Cleaner Counter See Maintenance Mode on page 37 Cutter Position Adjustment See CR Encoder Sensor Installation Position Adjustment on page 210 k Tubes Service Call 00000101 Solution o Check the ink tube The printer indicates this error when the useful life ends for the sp...

Page 222: ... 000 pages B1 paper No rintheads 2 billion dots Each nozzle No Waste Ink Pads Right 132 000 points Left 6 600 points 1 point 0 02ml Yes R Motor 2 500 000 passes 1 pass 1 round trip Ink tube life is monitored based on this counter value Yes F Motor 23 000 meters Paper feed distance No utter 2 000 operations 1 operation cut one page No Table 6 3 Items to be Checked During Maintenance Service Items C...

Page 223: ...the equipment Also if the printer needs to be repacked and transported again after it is installed perform necessary packing procedures after checking the service operations and packing conditions written here 6 2 1 The Packaging The printer comes from the factory packed in a large box printer body and accessories and is delivered with a smaller box on top for the stand and lower accessories BEFOR...

Page 224: ...ttached inside Tray Hooks x 2 one each for right and left Pins x 2 Hexagon Allen wrench x 2 large 5mm small 4mm Bolts 4 kinds n For assembling the stand 8 bolts with hexagon hole M6 x 30 6 bolts with hexagon hole M6 x 10 n For connecting the printer body and stand 2 washer bolts with hexagon hole M6 x 12 2 flange bolts with hexagon hole M6 x 12 LARGE BOX The following parts are in the large box o ...

Page 225: ...lts M6 x 10 Repeat for the left side leg Turn over the stand so that the bottom faces up Then connect the bottom support and secure the support with the hexagonal bolts M6 x 30 Turn over the assembled stand again and completely secure the top support bolts Figure 6 2 Stand Assembly 1 Figure 6 3 Stand Assembly 2 A U T I O N n It is recommended at least two people four for printer body unpack and as...

Page 226: ...es of the stand Figure 6 4 Stand Assembly 3 7 Insert the eject tray pins into the holes located toward the rear of the right and left legs Figure 6 5 Stand Assembly C H E C K P O I N T When installing the tray hooks the sides with the plastic resin caps should be toward the rear of the printer and should face inward See the figure below ...

Page 227: ... the pins and push down securely Figure 6 6 Stand Assembly 5 9 Move the other three Paper Eject Tray shafts which are all in the cloth in front of the stand and hang them on the hooks located at the tips of the right and left Tray Arms Figure 6 7 Stand Assembly 6 A U T I O N When installing the Paper Eject Tray cloth make sure the seam folded fabric side faces the floor rear as shown below otherwi...

Page 228: ...rotecting the printer body on the right and left Take out the four box panels one on each side of the box and remove the Documentation box Figure 6 8 Body Assembly 1 Figure 6 9 Body Assembly A R N I N G n When lifting or moving the printer body make sure to do so with at least 4 people The printer weighs approximately 74kg n When removing the large box be sure that there is enough space overhead 2...

Page 229: ... box and store it As shown in the figure below place the assembled stand in front of the printer body and lock the front right and left casters Then lower the right and left leveling screws until you are sure they are secure against the floor Figure 6 10 Body Assembly 3 Figure 6 11 Body Assembly 4 ...

Page 230: ...he stand then place the bottom rear of the body so that the coupling guide pins on the stand insert into the body Figure 6 12 Body Assembly Figure 6 13 Body Assembly 6 A R N I N G n Lifting the printer requires four people and all four people need to lift the printer by the hand position while supporting steadying the printer with their free hands n After placing the printer on the stand one perso...

Page 231: ...stened securely with bolts Figure 6 14 Body Assembly 7 7 Install the stand covers on the stand couplings 8 After assembly is completed release the casters and leveling screws on the stand and install the printer in its designated location During installation the casters and leveling screws should be locked again Figure 6 15 Body Assembly 8 ...

Page 232: ...C H A P T E R APPENDIX ...

Page 233: ...Sensor C Head B Head Pump Motor PG Motor PG Origin Sensor Suction Fan P_FRONT Sensor I H Assy R CR Lock Solenoid Release Lever Suction Fan Suction Fan P_THICK Sensor Cover R CN9 BLE Relay CN2 CN8 WHT Relay CN1 CN7 Control Panel CN11 P_REAR Sensor CN13 PF Encoder CN19 RAM SIMM CN20 PC Card CN1 Parallel CN3 Macintosh Serial CN18 PF Motor CN17 CR Motor CN6 Power CN10 P S Fan L CN21 I H Assy L CN24 Re...

Page 234: ...Board CN4 CN26 Printer Mechanism P S Fan R CN27 Printer Mechanism Cover Sensor L Relay Junction Board CN1 From C277MAIN CN9 CN2 From C277MAIN CN8 CN3 From C277MAIN CN15 CN4 From C277MAIN CN24 CN5 From C277MAIN CN14 CN6 To CR Board CN1 WHT CN7 To CR Board CN7 BLE CN8 Printer Mechanism I H Assembly R CN9 Printer Mechanism CR Lock Solenoid CN10 Printer Mechanism Release Lever CN11 Printer Mechanism P...

Page 235: ...y 42 V Pin Signal Name Explanation FG Ground Chassis FG Ground Chassis POWER_SW Power Switch Signal P REV OE OE Output Enable Signal 6 RESET Reset Signal 7 RD Read Signal 8 WRL Write Signal 9 10 11 BA2 12 BA1 13 PD7 Data Signal bit 8 14 PD6 Data Signal bit 7 15 PD5 Data Signal bit 6 16 PD4 Data Signal bit 5 17 PD3 Data Signal bit 4 18 PD2 Data Signal bit 3 19 PD1 Data Signal bit 2 20 PD0 Data Sign...

Page 236: ...ensor Signal 2 6 COVER2 PG Home Position Detection Sensor Signal 8 19 HD_SLIDE CR Lock Solenoid Control Signal 0 21 HD_SOL Cutter Solenoid Control Signal 2 CUT_SOL LED Control Signal 3 P_EDGE P_EDGE Sensor Output 4 CR_ORG HP Sensor Output 5 Not used 6 CRENC_A B CR Encoder Output Pin Signal Name Explanation Pin Signal Name Explanation 1 VCC Power Supply 2 N C 3 P S_FAN1 2 Fan Control Signal Pin Sig...

Page 237: ...nation Drive Signal NC Not Used Drive Signal Pin Signal Name Explanation 4 Drive Signal 5 NC Not Used 6 Drive Signal Table 7 2 Pin Signal Name Explanation 1 GND Ground 2 ENG_STAR Energy Star Mode Control Signal 3 INKS7 I H Assembly Sensor Information 4 INKS6 I H Assembly Sensor Information 5 INKS5 I H Assembly Sensor Information 6 INKS4 I H Assembly Sensor Information 7 INKS3 I H Assembly Sensor I...

Page 238: ...Explanation 28V Power Supply 28V Power Supply A SLID Motor A Phase A SLID Motor A Phase B SLID Motor B Phase B SLID Motor B Phase A PUMP Motor A Phase A PUMP Motor A Phase B PUMP Motor B Phase 0 B PUMP Motor B Phase Pin Signal Name Explanation Cover Closed Signal Common Signal Cover Open Signal ...

Page 239: ...EN AND SHUT LIGHT 193 1045249 LABEL VALVE OPEN AND SHUT LEFT 194 1057535 LABEL PAPER EJECT CLOTH SET 195 1046639 LABEL CAUTION CUTER B 196 1046641 LABEL CAUTION PAPER COVER B 198 1058864 LABEL ACCESSORY B 199 1058866 LABEL MANUAL CUTTER 3 B CONTROL CIRCUIT BOARD 200 2035331 BOARD ASSY MAIN 201 2032855 SIMM B1 2025669 BEADS CORE B10 2025669 BEADS CORE B11 2025669 BEADS CORE B12 2025669 BEADS CORE B...

Page 240: ...CAPACITOR C157 2025212 ALMINIUM ELECTROLYTIC CAPACITOR Table 7 3 Parts List for Stylus PRO 9500 Block Name Ref No Sales Part Code Description C158 2026271 ALMINIUM ELECTORLYTIC CAPACITOR C159 2026271 ALMINIUM ELECTORLYTIC CAPACITOR C197 2026271 ALMINIUM ELECTORLYTIC CAPACITOR C198 2026271 ALMINIUM ELECTORLYTIC CAPACITOR C199 2026271 ALMINIUM ELECTORLYTIC CAPACITOR C28 2026211 ELECTROLYTIC CAPACITO...

Page 241: ...NNECTOR CN27 2022864 CONNECTOR CN3 2024322 CONNECTOR CN6 2015587 CONNECTOR Table 7 3 Parts List for Stylus PRO 9500 Block Name Ref No Sales Part Code Description CN7 2033826 CONNECTOR CN8 2033825 CONNECTOR CN9 2033825 CONNECTOR CR1 2029053 QUARTZ OSCILLATOR CR2 X504013500 QUARTZ OSCILLATOR CRU1 2025626 QUARTZ OSCILLATOR D1 X325010309 DIODE D10 X325010309 DIODE D14 2021266 DIODE D15 2021266 DIODE D...

Page 242: ...2021049 I F IC SN75LBC775 IC26 2021165 TTL IC SN74ACT1284NS EL IC27 2021165 TTL IC SN74ACT1284NS EL Table 7 3 Parts List for Stylus PRO 9500 Block Name Ref No Sales Part Code Description IC28 2021165 TTL IC SN74ACT1284NS EL IC30 2022234 HIC IC31 2022234 HIC IC32 2029041 GATE ARRAY IC33 2029045 DRIVER IC34 X422350749 TTL IC IC35 2029045 DRIVER IC36 X440003394 COMPARATOR IC37 2027732 D A CONVERTER I...

Page 243: ...k Name Ref No Sales Part Code Description Q9 2026214 TRANSISTOR QM1 2022823 TRANSISTOR SWD1 2029069 DIP SWITCH TH1 2026536 CHIP THERMISTOR TH2 2026536 CHIP THERMISTOR VR1 2035328 POTENTIOMETERS VR2 2035329 POTENTIOMETERS VR3 2035329 POTENTIOMETERS CABLE BLOCK 400 2032091 P S CABLE EAI 120V PRINTER MECHANISM 101 1044247 X REDUCTION BELT 102 1044248 ROLL SUPPORT L ASSY 103 1044249 ROLL SUPPORT R ASS...

Page 244: ...SSY A 208 1044279 DETECTOR ARM Table 7 3 Parts List for Stylus PRO 9500 Block Name Ref No Sales Part Code Description 209 1044285 STEEL BELT 210 1059459 F BOX L ASSY 211 2037041 P FRONT SENSOR ASSY 302 1056149 DAMPER ASSY 304 1044288 HEAD TAPE CABLE 306 1044290 P EDGE ASSY 307 1044291 HEAD ADJUSTOR A 308 1044292 HEAD ADJUSTOR B 309 1044293 CUTTER CAP 310 1044294 SOLONOID SPRING 311 1044295 CUTTER ...

Page 245: ...ETECTOR ASSY D 522 2030102 NOT DETECTOR ASSY L Table 7 3 Parts List for Stylus PRO 9500 Block Name Ref No Sales Part Code Description 523 1044336 I H LEVER L 524 1044337 I H LEVER KNOB L 525 1044338 I H LEVER R 526 1044339 I H LEVER KNOB R 527 1044343 BULB KNOB 528 1044344 BULB MANUAL CAM 530 1044346 OIL DAMPER 531 1044347 I H SPACER 532 1044348 I H IDLE GEAR 533 1044349 LATCH 534 1044350 FLANGE 2...

Page 246: ...NEL ASSY OVERSEAS 802 1057018 LOGO PLATE30X30 Table 7 3 Parts List for Stylus PRO 9500 Block Name Ref No Sales Part Code Description 805 1059727 R SIDE COVER 806 1059728 R STAND COVER 807 1059731 ROLL COVER ASSY 808 1044378 FRONT COVER ASSY 809 1051808 NEW TYPE SUB PLATEN 810 1051809 NEW TYPE SUB PLATEN A 811 1051810 NEW TYPE SUB PLATEN B 812 1059729 L SIDE COVER 813 1059730 L STAND COVER 814 1059...

Page 247: ...N INDIVIDUAL BOX LMG L OVERSEAS NON FIG 1056544 INK CARTRIDGE WITHIN INDIVIDUAL BOX LCG L OVERSEAS NON FIG 1058462 MAINTENANCE KIT STYLUS PRO 9500 NON FIG 4010221 SUPPLEMENT NON FIG 4012670 UNPACKING SHEET Table 7 3 Parts List for Stylus PRO 9500 Block Name Ref No Sales Part Code Description ...

Page 248: ...to the illustration mbers in Table 7 3 Parts List for Stylus PRO 9500 on page 239 No 1 PF L Frame Assembly Fan Bracket Assembly No 2 R Frame Assembly No 3 PF Rail Assembly No 4 CR Rail Assembly No 5 Carriage Assembly No 6 Maintenance Assembly No 7 I H Assembly 1 LEFT No 8 I H Assembly 1 RIGHT No 9 I H Assembly 1 IH Assembly No 10 I H Assembly 2 Holder No 11 Tube Assembly 2 No 12 Board Assembly No ...

Page 249: ...PSON Stylus Pro 9500 Revision A ppendix Exploded view Diagram 249 Figure 7 2 PF L Frame Assembly Fan Bracket Assembly ...

Page 250: ...PSON Stylus Pro 9500 Revision A ppendix Exploded view Diagram 250 Figure 7 3 R Frame Assembly ...

Page 251: ...PSON Stylus Pro 9500 Revision A ppendix Exploded view Diagram 251 Figure 7 4 PF Rail Assembly ...

Page 252: ...PSON Stylus Pro 9500 Revision A ppendix Exploded view Diagram 252 Figure 7 5 CR Rail Assembly ...

Page 253: ...PSON Stylus Pro 9500 Revision A ppendix Exploded view Diagram 253 Figure 7 6 CR Assy ...

Page 254: ...PSON Stylus Pro 9500 Revision A ppendix Exploded view Diagram 254 Figure 7 7 Maintenance Assy ...

Page 255: ...PSON Stylus Pro 9500 Revision A ppendix Exploded view Diagram 255 Figure 7 8 I H Assy Left ...

Page 256: ...PSON Stylus Pro 9500 Revision A ppendix Exploded view Diagram 256 Figure 7 9 I H Assy Right ...

Page 257: ...PSON Stylus Pro 9500 Revision A ppendix Exploded view Diagram 257 Figure 7 10 I H Assy 1 ...

Page 258: ...PSON Stylus Pro 9500 Revision A ppendix Exploded view Diagram 258 Figure 7 11 I H Assy 2 ...

Page 259: ...PSON Stylus Pro 9500 Revision A ppendix Exploded view Diagram 259 Figure 7 12 Tube Assembly ...

Page 260: ...PSON Stylus Pro 9500 Revision A ppendix Exploded view Diagram 260 Figure 7 13 Board Assembly ...

Page 261: ...PSON Stylus Pro 9500 Revision A ppendix Exploded view Diagram 261 Figure 7 14 Cover Assembly ...

Page 262: ...ndix Component Layout 262 5 Component Layout is illustrations below show the C277 Main board component layout The illustrations below show the C277 MAIN Board component layout Figure 7 15 C277MAIN Board Component Layout of Component side ...

Page 263: ...PSON Stylus Pro 9500 Revision A ppendix Component Layout 263 Figure 7 16 C277MAIN Board Component Layout of Soldering Side ...

Page 264: ...PSON Stylus Pro 9500 Revision A ppendix Circuit Diagrams 264 6 Circuit Diagrams e circuit diagrams for the C277MAIN Board are provided in the following ges C277MAIN 1 2 C277MAIN 2 2 ...

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