Epson 9000 User Manual

Download



Wide-Format Professional Inkjet Printer

EPSON Stylus Pro 9000

TM-PRO9000

Guide to Using This Manual

Before servicing the EPSON Stylus Pro 9000, read the precautions on

CHAPTER 1. Printer Basics

Refer to this chapter for details on control panel operation.

CHAPTER 2. Technical Overview

Read this chapter if you want to know more about how the major systems of this printer work.

CHAPTER 3. Troubleshooting

Use this chapter to troubleshoot typical printer problems.

CHAPTER 4. Disassembly and Assembly

Follow these step-by-step instructions to disassemble and assemble the printer. Refer to the “Maintenance” section of this chapter when you need to replace the Waste Ink Pads and other consumable parts.

CHAPTER 5. Adjustments

When you remove or replace parts, read the beginning of this chapter to find out which adjustments are required and how to perform them.

CHAPTER 6. Maintenance

Follow these routine inspection and maintenance pro ced ures each time you service the printer.

page 5

. Then turn to one of these chapters:

CHAPTER 7 Appendix

Provides the following additional informati on for reference :

• Setup instru ctions

• Detailed product specifications

• Parts list

• Exploded di agrams

• Electrical circuit boards schematics

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the written permission of Epson America, Inc. No patent liability is assumed with respect to use of the information contained herein. Neither is any liability assumed for damages resulting from the use of the information contained herein. While every precaution has been taken in the preparation of this book, Epson America, Inc., assumes no responsibility for errors and omissions.

Neither Epson Americ a, Inc ., nor its affilia tes sh all be liable to the purchaser of this product or third partie s for damages, losses, costs, or expenses incurred by purchaser or third parties as a result of: accident, misuse, or abuse of this product or unauthorized modifications, repairs, or alterations to this product.

Epson America, Inc., shall not be liable against any damages or problems arising from the use of any options or any consumable products other than those designated as Original EPSON Products or EPSON-Approved Products by Seiko Epson Corporation.

TRADEMARKS

EPSON and ESC/P are registered trademarks and ESC/P 2, EPSON Stylus COLOR 900, and EPSON Sylus COLOR 900N are trademarks of Seiko Epson Corporation. Epson Connection is a service mark of Epson America, Inc.

General Notice:

any and all rights in those marks.

Other product names used herein are for identification purposes only and may be trademarks of their respective compani es. EPSON disclaims

July 1999

FCC COMPLIANCE STATEMENT

FOR AMERICAN USERS

This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses, and c an radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio and television reception. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause interference to radio and television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:



Reorient or relocate th e receivin



Increase t he separation between the e



Connect the e



Consult th e dealer or an ex perience d radio/TV t ec hnician fo r help.

WARNING

The connection of a non-shielded equipment interface cable to this equipment will invalidate the FCC Certification of this device and may cause interference levels that exceed the limits established by the FCC for this equipment. It is the responsibility of the user to obtain and use a shielded equipment interface cable with this device. If this equipment has more than one interface connector, do not leave cables connected to unused interfaces.

Changes or modifications not expressly approved by the manufacturer could void the user's authority to operate the printer.

FOR CANADIAN USERS

This Class B digital apparatus meets all requirements of the Canadian Interference-Causing Equipment Regulations. Cet appareil numérique de la classe B respecte toutes les exigences du Règlement sur le materiel brouilleur du Canada.

uipment int o an outlet on a circuit diff erent from that to which t he receiver is co nnected .

antenna.

uipment and receiver.

PRECAUTIONS

Precautionary notes throughout the text are categorized with respect to: (1) personal injury and (2) damage to equipment.

W ARNING

CAUTION

Always observe the precautions listed below when performing repair and maintenance procedures.

Signals a precaution which, if ignored, could result in serious or fatal personal injury. Great caution should be exercised in performing a procedure preceded by a WARNING.

Signals a precaution which, if ignored, could result in damage to equipment.

WARNING

1. Always disconnect the product from both the power source and the host computer before performing any maintenance or repair procedure.

2. No work sh ould be perfo rm ed on the un it by persons u nf am iliar with bas ic s af ety measure s dic t at ed for all elect ronics technicians in th eir line of work.

3. In performin must be co nnected, use extreme ca ut ion in working on the pow er s upply and other electronic c om ponents.

testing describe d in this manu al, do not connec t t he unit to a pow er s ource until instructe d t o do so. When th e power supply cable

CAUTION

1. Repairs o n EPSON pr oducts should be perfo m ed only by an EPSO N -c ertified repair technic ian.

2. 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.

3. Always verify that the EPSON prod uc t has been disconnected f rom t he power source bef ore removing or replacing printed circuit boards or individual chips.

4. To protect se ns it iv e microproc essors an d ot he circuitr components.

5. Replace malfunctioning components only with those components recommended by the manufacturer; introduct ion of second- sour ce ICs or other nonappr ov ed components may damage the product and void any applicable EPSON w arranty.

, use static discharge equipment, such as anti-static wrist straps, when accessing internal

EPSON Stylus Pro 9000 Revision A

1 Printer Basics

Features ...................................................................................................... 11

Control Panel Operations ......................................................................... 12

Control Panel Buttons ............................................................................ 12

Operation in Normal Mode .................................. .......... ....... .. .......... .. 12

Operation at Power On ....................................................................... 13

SelecType Mode .................................................................................... 13

Control Panel Operation in SelecType Mode ..................................... 13

Main Menu Options in SelecType Mode ............................................ 13

Printer Setting Menu........................................................................ 14

Test Print Menu............................................................................... 15

Printer Status Menu......................................................................... 15

Paper Configuration Menu. .............................................................. 16

Cutter Replace Menu....................................................................... 16

Head Alignment Menu..................................................................... 16

Service-Related Modes .......................................................................... 17

Maintenance Mode . ............................................................................ 17

Maintenance Mode 2 .......................................................................... 17

LED Indicators and Error Messages ........................................................ 18

LED Indicators ........................................................................................ 18

LCD Display ........................................................................................... 19

Options and Consumables ....................................................................... 20

2 Technical Overview

Location of Com ponents .......................................................................... 22

Carriage Mechanism ....................................................................... 22

Paper Feed Mechanism .................................................................. 22

Ink System ....................................................................................... 23

Circuit Boards.................................................................................. 23

Operation ................................................................................................... 24

Carriage Mechanism .............................................................................. 24

Carriage (CR) Guide Rail ................................................................ 24

Platen Gap (PG) Mechanism........................................................... 24

Paper Width Sensor........................................................................ 25

Carriage Motor and Position Control............................................... 26

Cutter Mechanism .................................................... .......... .. ....... .... 27

Printheads ....................................................................................... 27

Paper Feed Mechanism ......................................................................... 28

Paper Feed Motor and Rollers . . ...................................................... 28

Paper Feed Sensors ....................................................................... 29

Paper Suction Fan........................................................................... 30

Paper Width Determination (Left and Right edge Detection) . ......... 31

Paper size Determination (Detection of Top edge) ......................... 32

Paper Loading Errors ...................................................................... 33

Carriage Lock Mechanism ..................................................................... 33

Ink Supply Mechanism ........................................................................... 34

Ink-Related Sensors........................................................................ 35

Cover Open Sensor ............................................................................... 36

Control Circuit ........................................................................................ 37

3 Troubleshooting

Overview .................................................................................................... 39

Troubleshooting Usin g LCD Error Messa ges ......................................... 39

LCD Error Messages .................................. ....... ....... ....... ..... ....... ....... .... 40

Errors that require a service technician .................................................. 41

General Errors ........................................................................................ 45

Ink Low............................................................................................ 45

Paper Out........................................................................................ 45

Load xxx Paper ............................................................................... 45

Load Paper...................................................................................... 45

Paper Jam....................................................................................... 46

Cover Open..................................................................................... 46

EPSON Stylus Pro 9000 Revision A

Paper Not Cut . ................................................................................. 46

Paper Not Straight. .......................................................................... 46

Reload Paper................................................................................... 47

Push Lever Down............................................................................ 47

Compartment Open......................................................................... 47

Ink Out............................................................................................. 48

No Ink Cartridge .............................................................................. 48

Remove Paper................................................................................. 48

Option I/F Error................................................................................ 48

Print Quality Troubleshooting .................................................................. 49

Missing Dots or Lines...................................................................... 49

No Ink Output from One or Both Printheads.................................... 50

Uneven Printing or Poor Resolution................................................ 50

Smudged or Marred Printout (Front) ............................................... 51

Smudged or Marred Printout (Reverse side)................................... 51

White or Black Banding ................................................................... 51

Connector-Related Errors ......................................................................... 52

4 Disassembly & Assembly

Overview ..................................................................................................... 55

Precautions ............................................................................................ 55

Tools ....................................................................................................... 56

Screw List ............................................................................................... 56

Order of Disassembly ............................................................................. 57

Housing Parts ......................................................................................... 58

Housing Removal ...................................................................................... 58

Maintenance Cover Removal .......................................................... 58

Top Cover Removal......................................................................... 59

Left and Right Side Cover Removal................................................ 60

Front Cover Removal...................................................................... 61

Roll Cover Removal......................................................................... 62

Lower Paper Guide Removal ................................................... ....... 63

Upper Paper Guide Removal ................................................... ....... 64

Circuit Board Removal .............................................................................. 65

Power Supply Board Removal......................................................... 65

Main Board Removal....................................................................... 66

Maintenance Procedures .......................................................................... 67

Replacing the Waste Ink Pads........................................................ 67

Maintenance Assembly Removal & Disassembly........................... 69

Printer Mechanism Disassembly ............................................................. 71

Replacing the Printheads................................................................ 71

Removing the Carriage Motor Assembly......................................... 75

Removing the PF Motor Assembly.................................................. 76

Removing the Platen Gap Adjustment motor.................................. 78

Removing the Platen Gap Home Position Sensor........................... 78

Removing the Cover open Sensors................................................. 79

Removing the Paper Thickness Sensor.......................................... 80

Removing the Rear Paper Sensor................................................... 80

Removing the Front Paper Sensor.................................................. 81

Removing the Paper Release Sensor............................................. 81

Removing the Carriage Home Position Sensor and Encoder ......... 82

Ink Holder Disassembly ............................................................................ 84

Removing the I/C Holder Assembly ....................................................... 84

Disassembling the I/C Holder ................................................................. 91

Removing the Ink Tubes ........................................................................... 92

Preparation...................................................................................... 92

Removing the Ink Pipe Covers........................................................ 92

Separating the ink pipes and ink tubes ........................................... 92

Removing the CR circuit board........................................................ 93

Disconnecting the ink dampers....................................................... 93

Removing the cable connection plate.............................................. 94

Ink Tubing Reassembly .......................................................................... 95

Installing the new cable connec t ion plate........................................ 95

Positioning the tube guides and FFCs............................................. 95

Connecting the ink tubes to the ink pipes........................................ 96

Securing the the ink tubes and ink pipes......................................... 96

Securing the tube guides on the CR side........................................ 96

Checking the ink tubes.................................................................... 97

Attaching the CR circuit board......................................................... 97

Connecting the carriage FFCs......................................................... 97

Connecting the ink tubes and dampers. .......................................... 98

Confirming the tube guide assembly position.................................. 99

Connecting the carriage FFCs to the relay circuit board. .............. 100

Resetting the printer...................................................................... 100

EPSON Stylus Pro 9000 Revision A

5 Adjustments

Overview ......... ....... ..................... ...................... ..................... ................... 102

Precautio n s ............................ ...................... ..................... ................... 102

Adjustment Tools .................................................................................. 102

Required Adjustments ......................................................... ....... .......... 103

ROM Backup and Updating ........... ..................... ...................... .............. 105

Requirements for Backup.............................................................. 105

Backup Procedure......................................................................... 105

Download Proce d ure............ ............................ ...................... ....... 106

Possible Errors During Backup or Downloading............................ 106

Firmware Update ... ............................................................................... 106

Updating From a PC...................................................................... 106

Updating From a Memory Card..................................................... 107

Self-Diagnostics ........................... ..................... ..................... ................. 107

Using the Self-Diagnostic Mode . .......................................................... 108

Self-Diagnostic Menus ......................................................................... 109

Test Menu ............................................................................................ 110

Version................................... ...................... ............................ ..... 111

Control Panel ................................................................................. 111

Sensors................ ..................... ..................... ..................... .......... 112

Encoder ......................................................................................... 113

Fan ................................ ..................... ...................... ..................... 113

Elec. (Maintenance Records) ........................................................ 113

Adjustment Menu ................................................................................. 115

Cap Position Adjustment............................................................... 116

Check Skew.......................... ..................... ...................... .............. 117

Input Rank (Printhead ID) Adjustment........................................... 117

Check Nozzle....................... ..................... ...................... .............. 118

B Head Slant/C Head Slant Adjustment (Head Angle).................. 119

BC Head Slant Adjustment (Head Height) .................................... 120

Bi-D Adjus tmen t............... ...................... ..................... ................... 121

Head LR Adjustment (Head Gap Timing).... .................................. 123

Flush Point Right and Left Adjustment.......................................... 124

Feed Adjustmen t............. ............................. ..................... ............ 124

Top & Bottom (Margin) Adjustment............................................... 125

Rear Sensor Position Adjustment.................................................. 126

Test Print....................................................................................... 127

Clean Head (Drain Ink).................................................................. 127

Counter Clear ................................................................................ 128

Cleaning menu ...................... ....... .. ....... .......... ....... .. ....... .......... .. ....... .. 128

Print menu ............................................................................................ 128

Parameter menu .................................................... .. ....... .......... .. ....... .. 129

Initialize......................................................................................... 129

Update........................................................................................... 129

Mechanical Adjustments ........................................................................ 130

Carriage Cover Height Adjustment..................................... .. ....... .. 130

Cutter Position Adjustment............................................................ 131

Carriage Belt Tension Adjustment................................................. 132

PF Belt Tension Adjustment.......................................................... 132

Platen Gap Gear Backlash Adjustment......................................... 133

I/H Lever Position Adjustment ....................................................... 133

Paper Thickness Sensor Adjustment............................................ 134

Cover Open Sensor Assembly (Right and left).............................. 135

Sensor Trimmer Adjustment.......................................................... 136

6 Maintenance

Overview .................................................................................................. 138

Physical Inspection and Cleaning ......................................................... 138

Lubrication ............................................................................................... 139

Checking and Clearing Counters ........................................................... 139

Checking Maintenance Counters ......................................................... 140

Clearing Maintenance Counters ........................................................... 140

Service Error Code s and Rep laceabl e Part s ........................................ 143

The Difference Between a ‘Maintenance Call’ and a ‘Service Call’ ...... 143

Ink Cartridge Replacement ..................................................................... 144

Cutter Blade Replacement ...................................................................... 144

EPSON Stylus Pro 9000 Revision A

7 Appendix

Unpacking and Transporting the Printer .......................................... ..... 146

The Packagin g ......... ..................... ...................... ............................ ..... 146

Before Opening the Large & Medium boxes................................. 146

Contents of the Packaging ................................................................... 146

Medium-size b ox.......................................... ..................... ............ 146

Large box....................................................................................... 147

Unpacking and Assembly ..................................................................... 147

From unpacking to assembling the Stand..................................... 147

Assembling the Printer body.......................................................... 151

Repacking and Transporting the Printer ............................................... 155

Before Shipping............................................................................. 155

After Shi ppi n g....... .............. ..................... ............................ .......... 155

Specifications ............ ....... ............................ ...................... ..................... 156

Mechanical .................................... ...................... ..................... ............ 156

Safety Appr ov a ls ................................ ..................... ...................... ....... 157

CE Marking ...... ....... ..................... ..................... ...................... .............. 157

Electrical ............................. ..................... ..................... ...................... .. 158

Environmen ta l ...................... ..................... ...................... ..................... 158

Ink Cartridge ......................................................................................... 158

Controll e r .............................. ..................... ...................... ..................... 159

Cutter .................................................................................................... 159

Paper .................................................................................................... 160

Paper Release Lever ............................................................................ 162

Interface ........................ ..................... ..................... ...................... ....... 162

Paralle l i nt e r fa ce .................... ..................... ..................... ................. 164

Nibble Mode ..................... ..................... ...................... ..................... 166

ECP Mode ........................................................................................ 166

Type-B Interface (Optional) .............................................................. 168

Interface se le ction ............ .............. ..................... ...................... ....... 168

Initialization ........... .............. ............................. ..................... ................... 169

Jumper and DIP Switch Settings ............ ....... ..................... ................... 170

Connector Summary ...... ....... ..................... ............................ ................. 171

Parts List ... ...................... ..................... ..................... ..................... .......... 173

Exploded D ia gram s ..... ....... ...................... ..................... .......................... 179

Main Board Component Layout .................. ...................... ..................... 194

Circuit Diagrams ......................................... ..................... ...................... .. 196

PRINTER BASICS





EPSON Stylus Pro 9000

1.1 Features

The EPSON Stylus Pro 9000 is an ultra-wide, 6-color ink jet printer with professional color o ut put. It provid es t he c olor printin g f eatures listed below. (For addition al details, see

Roll Cover

Top Cover

Specifications

on page 156.)

Upper P aper Guide (behind Top Cov er)

Right Side Cover



High-speed printing

64 nozz les per color RISC-CPU and high-speed color raster ASIC quickly process

detailed print data approx. 10 minutes (360 approx. 30 minutes (720 approx. 55 minutes (1440



Low operating costs

× 360 dpi/speed) on A0/normal paper × 720 dpi/quality) on A0/glossy paper

× 720 dpi/superfine) on A0/glossy paper

6 separate ink cartridges so only the empty ink cartridge is replaced Auto Rotate feature saves paper by automatically rotating an image

if the widt h is s horter than th e height

Left Side

Cover

Front Cover

Lower Paper Gui de

Figure 1-1. Exterior View of the EPSON Stylus Pro 9000



Large printing

Up to B0-wide paper (44 inches [1,118 mm]), including print registration marks



Excellent photo-quality printing

1440 (H)

× 720 (V) dpi co m bined with EPSON’s M ic rodot printing

Right Joint Cover

Main tenance

Cover



Alternative interface compatibility

IEEE-1284 bidirectional parallel interface (supports ECP mode) Macintosh serial int erface (approximat ely 1. 8 Mbps) Type-B ex pansion slot f or an optiona l int erface



User friendly

2 roll hold ers f or easily swit c hing between paper types Standard roll paper cutter Optional roll paper take-up reel for automatically winding up your

long prin t outs

Printer Basics 11

EPSON Stylus Pro 9000

1.2 Control Panel Operations

The EPSON Stylus Pro 9000 co nt rol panel dis plays status and error messages , and the lights indicate wh en a problem oc c urs or if any ink cartridge is low or runs out. This section provides inf ormatio n on the control panel buttons, LEDs, and liquid crystal display (LCD).

Ink Out

Paper Source

Pause

Reset

3 sec.

SelecType

Item

Paper Feed

Cut /Eject

Enter

Cleaning

3 sec.

LCD Display

Operate

KC LCMLMY

Paper Out

Roll Auto Cut

Roll Cutter Off

Sheet

Power

1.2.1 Control Panel Buttons

Pressing a control panel button executes the functions listed in

and

Table 1-1

Table 1-2

1.2.1.1 Operation in Normal Mode

Table 1-1. Operation in Normal Mode

Button (Second function) Function

Power Power ON and OFF Pause (Reset) Switches between onl ine and offline.

SelecType Enters SelecType mode (when printer is in

Cut/Eject (Enter)*

Paper Feed Paper Feed Paper Source (Item) Selects paper source:

Cleaning Cleans both heads if pressed for 3 seconds

* Int errupts the ink-drying time, if taking place. ** 1.27 cm/second paper feed for 2 seconds after key is pressed.

7.62 cm/second paper feed if pressed for over 2 seconds. Maximum feed of 20 cm when the button is pressed once.

***1.27 cm/second paper feed for 2 seconds after key is pressed.

7.62 cm/second paper feed if pressed for over 2 seconds.

Resets the printer i f pressed for 3 seconds.

Standby)

• Cuts and ejects paper if Roll Aut o Cut is selected

• Ejects paper if Roll Cutter Off or Sheet is selected

Feeds paper backward** Feeds paper forward***

•Roll Auto Cut

• Roll Cutter Off

• Sheet

Figure 1-2. EPSON Stylus Pro 9000 Control Panel

Printer Basics 12

EPSON Stylus Pro 9000

1.2.1.2 Operation at Power On

Pressing th es e buttons a t po w er on puts the printer in one of th e following service-related modes. See

Service-Related Modes

page 17 for d et ails .

Table 1-2. Operation at Power On

Button (Second function) Function

Power — Pause (Reset) Maintenance Mode

See

Maintenance Mode

SelecType Cut/Eject (Enter) Paper Feed Paper Feed Paper Source (Item) Cleaning Paper Source, Paper Feed

Paper Source, Cut/Eject, Cleaning Firmware Update Mode

Paper Feed

, Cut/Eject Maintenance Mode 2

See

Maintenance Mode 2

See

ROM Backup and Updating

, Cut/Eject, Cleaning Self-Diagnostic Mode

See

Self-Diagnostics

—

page 105

on page 17

on page 107

1.2.2 SelecT ype Mode

The SelecType menus allows y ou to configu re printer set t ings and perform c ert ain maintenance op erations fro m th e c ontrol pane l. To access these menus, press th e SelecType button while the printer is not printing. The printer enters the SelecType mode and cannot print.

1.2.2.1 Control Panel Operation in SelecType Mode

The con tr ol panel buttons have th e f ollowing func t ions in this mode:

Table 1-3. Operation in SelecType Mode

Button (Second function) Function

Power Pause (Reset) SelecType Selects menu Cut/Eject (Enter) Confirms and saves value Paper Feed Paper Feed Paper Source (Item) Selects item within a menu Cleaning —

Increases a value Dec re ases a value

1.2.2.2 Main Menu Options in SelecType Mode

Table 1-4

lists the menus and where to find additional in fo rm ation.

—

Table 1-4. SelecType Menus

Menu Description For more

information

Printer Setting Configure the printer Test Print Print a nozzle check or status check Printer Status Check ink levels and component life

page 14 page 15 page 15

Printer Basics 13

EPSON Stylus Pro 9000

Table 1-4. SelecType Menus (continued)

Menu Description For more

Paper Configuration Register pape r thi ckne ss and dr ying t ime,

and select registered configurations

Cutter Replacement Replace the pap er cut ter blade Head Alignment Align the printhe ad

information

page 16

page 16 page 16

PRINTER SETTING MENU

The bold it em is the default setting.

Table 1-5. Printer Setting Menu

Message Item Explanation

PLATEN GAP

PAGE LINE

INTERFACE

PARA. I/F

CODE PAGE

AUTO

THICK

OFF

AUTO

PARALLEL

MAC

OPTION

COMPAT*

ECP

PC437

PC850

Adjusts the platen gap. Normally leave set to AUTO.

When AUTO CUT OFF is selected on the control panel, this setting determines whether a li ne for ma nual cutting is printed

Determines which interface the print er checks for data. AUTO cont inuously checks all interfaces and is good for normal use. MA C is the serial interface.

Determines the data t ran sfer r ate when using this interface. Normally leave set to COMPAT*.

Character code setting. PC437 is for expanded graphics. PC850 is for multilingual.

ROLL MARG

INIT. PANEL EXEC. Initialize control panel setup values

* The printed image is t he sam e size as the printed image using the 0.12 inch (3 mm)

setting. However , t he printer adds 0.47 inch ( 12 mm) of paper clearance (for a total margin of 0.59 inch [15 mm] ) to t he top and bottom edges to make paper feeding more stable and to preven t the paper from rubbing the printheads.

T/B15MM*

15MM All margins are 0.59 in. (15 m m).

3MM All margins are 0.12 in. (3 mm).

Top and bottom margins are 0. 59 in. (15 mm). The left and right margins ar e

0.12 in. (3 mm).

Printer Basics 14

EPSON Stylus Pro 9000

TEST PRINT MENU

Table 1-6. Test Print Menu

Message Item Explanation

NOZZLE CHECK PRINT Check the printo ut. Any missing lines mean the

nozzle(s) ar e clogged.

STATUS CHECK PRINT Prints the amount of ink lef t or the component life as

follows:

• E*****F = full (or full life remaining)

• E ****F = ¾ full (or ¾ life remaining)

• E ***F = ½ full (or ½ life remaining)

• E **F = ¼ full (or ¼ life re maining)

• E *F = nearly empty (or service life near end)

• E F = empty (or service life ended)

PRINTER STATUS MENU

Use this menu to view the printer status on the contr ol panel display without printing a sta tu s ch eck. While in this m enu, press th e I tem button to view the messages in Table 1-7

Table 1-7. Printer Status Menu

Table 1-7. Printer Status Menu (continued)

Message Explanation

WASTE INK Ink pad maintenance information CR MOTOR Carriage motor maintenance information PF MOTOR Paper feed motor mainten ance information HEAD UNIT Printhead maintenance information CLEANER Maintenance information

Contin ue pressing t he Item button to display the am ount remaining for each of the 6 inks or se rv ic e lif e remainin g f or t he part. The indicator reads as fo llows:

E*****F = full (or full life remaining) E **** F = ¾ full (or ¾ lif e remaining ) E ***F = ½ full (or ½ life remaining) E **F = ¼ full (or ¼ life remaining) E *F = nearly empty (or service life ne ar end) E F = empty (or se rv ic e lif e ended)

Message Explanation

VERSION <number> Shows the firmware version INK LEFT-C Amount of cyan ink remaining INK LEFT-M Amount of magenta ink remaining INK LEFT-LC Amount of light cyan ink remaining INK LEFT-LM Amount of light magen ta ink remaining INK LEFT-Y Amount of yellow in k remaining INK LEFT-K Amount of black ink r em aining CUTTER LIFE Useful life of the cutter remaining TOTAL PRINTS Total num ber of printed documents

Printer Basics 15

EPSON Stylus Pro 9000

PAPER CONFIGURATION MENU

The bold ite m is th e default sett ing.

Table 1-8. Paper Configuration Menu

Message Item Explanation

PAPER NUMBER

THICK. PAT PRINT Prints a pattern t o detec t the paper

PAPER THICK 1 If PAPER NUMBER is set to STD, the

DRYING TIME 0MIN De termines the length of time th e pri nter

STD*

1 Select the appropriate number for thick

Select STD for Epson specia l paper

paper. Use the registered number up to 4.

thickness. If PAPER NUMBER is set to STD, the message does not appear.

message does not app ear. Use the select the reg istered number up to 17.

allows the ink to dry. When printing on roll paper, the print er will wai t the specif ied ti me after printing. Use the registered number up to 30MIN.

or − to select the

or − to

HEAD ALIGNMENT MENU

Table 1-10. Head Alignment Menu

Messages Item Explanation

ADJUST. PATT

PAPER THICK STD Leave on STD for EPSON paper. For other

ALL

Prints a full series of patterns. To print a single pattern, use the registered pattern appears.

media, use the thickness in 0.1-m m increments.

and − until the

and − to select the

CUTTER REPLACE MENU

Follow the order in Table 1-9

to replace the cutter.

Table 1-9. C u tter R eplacement Menu

Step Message Item Explanation

1 CUT. REPLACE EXEC. Prepare a replacement cutter 2 OPEN LOWER COVER — Open the front cover 3 REPLACE CUTTER — Remove the old cutter and instal l

a new one

4 CLOSER LOWER COVER — Close the front cover. READY

appears on the display.

Printer Basics 16

EPSON Stylus Pro 9000

1.2.3 Service-Related Modes

Press and hold down the buttons li sted in enter one of t hes e service- related modes:

Maintenance Mode



Lets you print a hex dum p or change th e language us ed for LCD display messages . S ee

Maintenance Mode 2



Table 1-11

Lets you clear maintenance counters after replacing consumable parts. See

Self-Diagnostic Mode



Table 1-12

on this pag e.

Lets you adjust printer settings, check and reset certain counters, make test prints, a n d cle an th e pri nt head. S ee page 107.

Firmware Update Mode



Lets you update the printer’s firmw are after replacing the Main Board. See

CAUTIO N

ROM Backup and Updating

The operations described in this section a re for s ervic e and support only. Avoid sharing this information with the end us er .

Table 1-2

on this page.

Self-Diagnostics

on page 105.

at power on to

1.2.3.1 Maintenance Mode

Press the

Message Menu Item Explanation

HEX DUMP PRINT Pr int data printed in

LANGUAGE ENGLISH, PORTUGUESE, SPANISH,

Pause

button while turning on the printer.

Table 1-11. Maintenance Mode Menu

GERMAN, ITALIAN, FRENCH

hexadecimal form Determines language used

for LCD display messages

1.2.3.2 Maintenance Mode 2

Press the

Paper Source, Cut/Eject,

turning on the printer.

Table 1-12. Maintenance Mode 2 Menu

Message Menu Item Explanation

INIT. ALL EXEC. Initializes NVRAM, Timer, life counters, and

mechanical coun ters INIT. NVRAM EXEC. Initializes NVRAM INIT. TIMER EXEC. Initializes timer INIT CR MOTOR EXEC. Initialize s CR motor (after r eplacing ink tubes) INIT. PF MOTOR EXEC. Initializes PF motor

Paper Feed

and

D buttons while

INIT. HEAD UNIT EXEC. Initializes head unit

NOTE: In Main te nanc e M ode an d Main te nanc e M ode 2, pre ss t he

Paper Source button to select a menu item, and press Enter save a setting.

INIT CLEANING UNIT

INIT. TOTAL PRINTING

INIT. INK EXEC. Initializes ink counter INIT. WASTE INK EXEC. Initializes waste ink counter DETECT INK LABEL ON

EXEC. Initializes cleaning unit

EXEC. Initializes total print counter

Determines whether the Ink ID sensor checks

OFF

the ink ID label on the ink cartridge.

Printer Basics 17

EPSON Stylus Pro 9000

1.3 LED Indicators and Error Messages

The printe r dis plays stat us m es s ages and e rror codes us ing its LED indicators and LCD panel. Interpret these messages using the tables on the following pages .

Ink Out

Paper Source

Pause

Reset

3 sec.

SelecType

Item

Paper Feed

Cut /Eject

Enter

Cleaning

3 sec.

LCD Display

LED Indicators

Operate

KC LCMLMY

Paper Out

Roll Auto Cut

Roll Cutter Off

Sheet

Power

1.3.1 LED Indicators

Table 1-13. LED Indicators

LED Status Explanation

Operate On Power on

Flashing Receiving data or perfor m ing power-down sequence

Paper Out On No paper loaded

Flashing Paper jam

Pause On Printer ready

Flashing Performing head cleaning. Printer is in ink- drying

phase. Performing ink- charging operation.

Ink Out Y On Ink out (also occurs if no or wrong cartridge is installed)

Flashing Ink low

Ink Out LM O n Ink out (also occurs if no or wrong cartridge is installed)

Flashing Ink low

Ink Out LC On Ink out (also occurs if no or wrong cartridge is installed)

Flashing Ink low

Ink Out M On Ink out (also occurs if no or wrong cartridge is installed)

Flashing Ink low

Ink Out C O n Ink out (also occurs if no or wrong cartridge is installed)

Flashing Ink low

Ink Out K On Ink out (also occurs if no or wrong cartridge is installed)

Flashing Ink low

Paper Source (Auto C u t)

On Roll paper will automa ti ca ll y b e cut

Paper Type (Cut Off)

On Roll paper will not be cut (sel ect th is sett ing when usi ng

the optional take-up Roller)

Figure 1-3. Control Panel Indicators and LCD Display

Paper Type (Sing le Sh ee t)

On Single sheet printi ng m ode

Printer Basics 18

EPSON Stylus Pro 9000

1.3.2 LCD Display

Table 1-14. LCD Display Messages

Message Explanation

COVER OPEN Lower cover is open INK COMPART. OPEN Replacing ink cartridge when the ink compartment

cover is open

INK DRY FOR <number> MIN*

INK LOW Ink cartridge(s) are n early empty. Pri nting continues. INK OUT Ink cartridge(s) are empty. Printing stops. LOAD PAPER Wrong paper is loaded or the paper set lever is up

LOAD ROLL PAPER Paper source set ting i n pri nt options is dif feren t fro m LOAD SHEET PAPER MAINTENANCE REQ. 0100 Waste Ink Pads are nearly ful l. See

NO INK CARTRIDGE Ink cartridge(s) not installed OPTION I/F ERROR Wrong interface card is installed PAPER JAM Paper is jammed inside printer. PAPER NOT CUT Roll pa per was not cut completely ( when Auto Cut is

PAPER NOT STRAIGHT Paper slipped and fed into the printer at an angle.

PAPER OUT No paper is loaded or paper has run out

PAUSE Pause state

Printer is paused for minutes shown to let ink dry

while loading paper

control panel

LCD Error

Messages

selected)

Printing stops.

Cut paper did not fall off The paper detect sensor may have dust or grime

blocking its operation

on page 40.

Table 1-14. LCD Display Messages (continued)

Message Explanation

PRINTING* Printer is receiving data PUSH LEVER DOWN Paper release lever is in the release position READY* Printer is ready to print RELOAD PAPER Pap er could not be reversed into the pri nti ng

position Paper is set out of the printable area or out of the

horizontal cutting area Paper is not fully ejected

PAPER NOT CUT error was not cleared REMOVE PAPER Paper is too thick for head cl eaning RESET Printer is resetting SERVICE REQ. <error

number> SWITCHING POWER OFF Preparing to shut down TURN PWR OFF AND ON Tried to print a test patter n while in an error

WAIT* Resett ing timer IC

WRONG CARTRIDGE Wrong ink cartridge(s) install ed

* If the pl aten gap setting is set to Thic k, a “W” appears in the last space on the

LCD display.

A fatal error has occurred. See

Messages

condition or the ink compartment cove r was open

Clearing NVRAM

Performing res et operation

Performing in k sequence operation

Initializing the printer

Dealing with initi al paper operation

on page 40.

LCD Error

PRESS PAUSE BUTTON Press Pause to continue

For a listing of LCD error m essages and how to read them, see

Error Messages

on page40.

LCD

Printer Basics 19

EPSON Stylus Pro 9000

1.4 Options and Consumables

The table below li sts the co nsumable it ems and options available for the EPSON St y lus Pro 9000 .

Table 1-15. Optional Items

Item Part Number Description

Paper cutter blade C815131 Consumable item Roll feed spindle 2 in ch C811021* 2 in. diameter roll paper Roll feed spindle 3 in ch C811031** 3 in. diameter roll paper Auto take-up reel unit C81508* Pr inted roll paper option

C815091

(core only)

Glossy photo paper S041225 36 in. (914 mm) wide

68.9 ft (21 m) long

S041224 44 in. (1 ,118 mm) wide

68.9 ft (21 m) long

Semigloss photo ro ll paper S041222 36 in. (914 mm) wide

16.4 ft (5 m) long

S041223 44 in. (1 ,118 mm) wide

82 ft (25 m) long

Matte roll paper S041221 36 in. (914 mm) wide

82 ft (25 m) long

S041220 44 in. (1 ,118 mm) wide

82 ft (25 m) long

Photo quality ink j et paper S041079 A2

S041068/S041045 A3 S041069/S041043 A3 Wide/B S041070/S041044 B

Table 1-15. Optional Items (continued)

Item Part Number Description

Photo paper S041142 A3

S041143 A3 Wide/B S041156 B

Photo quality glossy film S041073 A3

S041074 A3 Wide/B S041075 B

Rip Station 5100 PS Server Series

Multi-protocol Ethernet interface card

100 Mbps multiprotoc ol Ethernet interface card

* Two rolls can be installed at the same time. ** Can be installed only in the upper spindle hold er.

EAI - C850092

Other - C850093

C823622 Type-B 10BaseT

C823632 Type-B 100BaseT

Fiery Adobe

PostScript® 3™ Server

Table 1-16. Consumables

Item Part Number Description

Ink cartridge T407011 Black ink

T410011 Cyan ink T409011 Magenta ink T408011 Yellow ink T412011 Light Cyan ink T411011 Light Magenta ink

Printer Basics 20

TECHNICAL OVERVIEW





EPSON Stylus Pro 9000

2.1 Location of Components

The following figures show the main components of the EPSON Stylus Pro

9000.

CARRIAGE MECHANISM

For more information, see

Car ria ge Mechanism

Guide Rail

on page 24.

HP Sensor/

Encoder

PAPER FEED MECHANISM

For more information, see

PF Motor

Paper Feed Mechanism

Roll Paper

Holders

Paper

Suction

Fans

on page 28.

Paper Pressure Rollers

Paper

ThicknessSensor

Rear Paper

Sensor

Paper Feed

Roller

Carriage

CR Motor

Cover Open Sensor

(interlock switch)

Front P a per Sens or

Paper Release Lever

Figure 2-2. Paper Feed Mechanism

Figure 2-1. Carriage Mechanism

Technical Overview 22

EPSON Stylus Pro 9000

INK SYST EM

For more information, see

Flushing Box (L)

Waste Ink Pads

Ink Supply Mechanism

I/H Assembly

Pump Assembly

Wiper/Clea ner B l ade

Cap Assembly

CR Lock

Flush i ng Box (R)

Waste Ink Pads (R)

on page 34.

CIRCUIT BOARDS

For more information, see

Control Circuit

Power Supply Board

on page 37.

Main Board

(C277MAIN)

Control Panel

Relay

Board

Figure 2-3. Ink System

Figure 2-4. Circuit Boards

Technical Overview 23

EPSON Stylus Pro 9000

2.2 Operation

The following sections describe how the printer’s main components operate .

2.2.1 Carriage Mechanism

The carriage mechanism includes the parts shown in operation is described below.

Figure 2-5

CARRIAGE (CR) GUIDE RAIL

To print on paper as wide as B0, the printhead carriage must be more stable and must travel further than the usual carriage. To make the printheads more stable, EPSON added the CR Guide Rail to the Stylus Pro 9000.

Every EPSON ink jet printer until now has used a carriage guide shaft to stabilize the carriage during printing and horizontal movement. The Stylus Pro 9000 does away with the carriage guide shaft and relies on the printer frame for its stability.

As shown in bearings, and the carriage in turn holds the subcarriage. The subcarriage holds the printheads.

Figure 2-5

, the Carriage attaches to the CR Guide Rail with eight

. Their

Carriage

CR Guide Rail

Bearings

Platen

PG Cam

PG Gear

PLATEN GAP (PG) MECHANISM

Unlike previous models, the Stylus Pro 9000 uses a special system to ensure that the distance between the printhead nozzles and paper remains the same for all supported paper thicknesses. The subcarriage can be moved using the PG Cam which is driven by the PG Gear; this causes the subcarriage and all its components to move slightly nearer to or farther from the platen. The subcarriage moves because the PG Cam is mounted off-center, so one side of the cam pushes the subcarriage closer to the platen than the other side.

Subcarriage

Figure 2-5. CR Guide Rail and PG Mechanism (side view)

Printhead

Technical Overview 24

EPSON Stylus Pro 9000

To maintain a constant distance between the printhead nozzles and the paper, the printer measures the thickness of the paper and adjusts the height of the carriage accordingly. The printhead has three platen gap (height) settings, as described in the table below.

Table 2-1. Platen Gap Settings

Platen Gap Setting Gap Distance

PG “Small” 1.3mm

PG “Medium” 2.2mm

PG “Large” 2.7mm

The actual platen gap position used during printing depends on both the detected paper thickness and the user’s paper thickness setting on the control panel.

Table 2-2. Platen Gap Setting Determination

Control Panel Setting Paper Thickness Sensor Platen Gap Position

Wide Wide PG “Large”

Standard PG “Medium”

Auto Wide PG “Large”

Standard PG “Small”



PG Sensor

This light-reflecting sensor detects whether the subcarriage is in the thick paper position or normal paper position. The PG Gear rotates with the PG Cam, and the PG Sensor determines the subcarriage’s position from the position of the PG Gear, using the hole in the gear’s side as a reference.

PAPER WIDTH SENSOR

This sensor locates the right and left edges of the paper. The light emitted from the sensor is reflected back to the sensor where paper exists. In this way the sensor determines where the paper’s edge is and how wide the paper is.

Carriage

Left

edge

Right

edge

Paper Width

sensor

HP side

The printer uses two sensors in setting the platen gap:



Paper Thickness Sensor This sensor physically gauges whether the paper falls into the normal/thin

Paper

Figure 2-6. Paper Width Sensor

category or the thick category. The Pressure Roller unit closest to home position has a thin metal flag on top. When the Paper Release Lever is in the Lock position and thin paper is loaded, this flag pivots into the space between the sensor’s light emitter and receiver. However, when thick paper is loaded, the flag is forced forward out of the sensor area.

Sensor signal = ON at 0.7 V or less: Normal or thin paper Sensor signal = OFF at 2.4 V or more:Thick paper

Technical Overview 25

EPSON Stylus Pro 9000

CARRIAGE MOTOR AND POSITION CONTROL

For the greatest possible print accuracy and to minimize vibration, the printer uses a DC motor to move the carriage. Because a rubber timing belt would stretch over the long distance the carriage must travel during printing, the Stylus Pro 9000’s timing belt is made from steel.

The following sensors are located on the carriage and control the carriage’s position (see



HP Sensor

Figure 2-7

This optical sensor activates when the CR Guide Rail flag enters the space between the sensor’s light emitter and the light receiver. The flag is located just above home position, and the HP sensor sends an ON signal when the carriage is in home position.



Linear Encoder Sensor This sensor determines the position of the carriage by counting bands on the timing fence (timing strip) while the carriage is in motion. The bands have a distance equal to 180 dpi. For every band the Linear Encoder passes over, it sends a print timing pulse to the software servo system. The software servo forms a closed-loop with the CR motor and Encoder Sensor. It receives feedback from the Encoder Sensor and adjusts the current to the CR motor to maintain constant carriage speed.



CR Motor Motion Failure

During operation, the encoder measures the distance the carriage travels. If the CR speed as determined by the encoder varies too much from the speed set by the Software Servo, a fatal error occurs (Service Call 00010005).

CR Guide Rail flag (projected

Carriage

area)

HP Sensor

No HP signal

HP signa l

Linear

Encoder

Timing Strip

Carriage Speed and Acceleration



Carriage Speed

Carriage

The carriage speed during printing is described below.

Table 2-3. Carriage Speed

Figure 2-7. Carriage Mechanism Sensors

Print Mode Carriage Speed

720 dpi & Normal M/W 200 cps 4 Pass FOL printing 300 cps Unidirectional 400 cps



Carriage Acceleration

Due to the carriage’s quick acceleration, even after the heads reach and maintain normal speed, they are not stable enough to print for the next 10 mm.

Technical Overview 26

EPSON Stylus Pro 9000

CUTTER MECHANISM

To make a paper cut, the cutter solenoid plunges the cutter blade into the paper. To cut the paper evenly, the following method is used:

1)The cutter cuts from the left of center (when facing the printer) to the left edge.

2)The cutter cuts from several centimeters inside the right edge to the right edge.

3)The cutter cuts the remaining center portion, from right to left.

Cutter

Carriage

solenoid

PRINTHEADS

The printheads are the same type used in the EPSON Stylus Pro 5000, and are installed in the same way. Three levers are provided to make sure the heads are lined up vertically and that neither head leans one way or the other.

Cutter

Blade

Paper

Figure 2-8. Cutter Mechanism

Technical Overview 27

EPSON Stylus Pro 9000

2.2.2 Paper Feed Mechanism

The main components of the paper feed mechanism are described below.

PAPER FEED MOTOR AND ROLLERS

When paper is loaded, it’s held against the Paper Feed Roller by the Paper Pressure Rollers. Raising the Paper Release Lever (see the Paper Pressure Rollers away from the Paper Feed Roller, and releases any loaded paper. The Paper Feed Roller Assembly is made up of three equal lengths of rollers and their coupling.

Figure 2-10

) moves

CR Guide

Rail

Speed-

Reduction

Gear

Paper Pressu r e

Roller

Paper Fe ed

Roller

The PF Motor uses a DC motor, which has a built-in optical rotary encoder. The encoder sends signals to the software servo system, which regulates the speed of the motor. Motion is transferred through a timing belt to the SpeedReduction Gear, which improves the accuracy of paper feeding.

Platen

Subplaten

Paper

PF Motor

Figure 2-9. Paper Feed Mechanism

Technical Overview 28

EPSON Stylus Pro 9000

PAPER FEED SENSORS

The printer relies on the following sensors for paper feeding:



Front Paper Sensor This optical sensor is attached to the back side of the Lower Paper Guide, and detects the front edge (top or leading edge) of the paper.



Rear Paper Sensor This optical sensor is attached to the back side of the Lower Paper Guide, and detects the rear edge (bottom or trailing edge) of the paper.



Paper Release Lever Position Sensor The Paper Release Lever is located on the right side of the pri nter, and the sensor attaches to the bottom of the lever, inside the right-side frame. This sensor’s signal is ON when the lever is in down, which allows the printer to print.

Rear Paper

Sensor

Paper Thickness

Sensor

Paper Release

Lever

Front Paper

Sensor

Paper Release Lever

Position Sensor

Figure 2-10. Paper Feed Sensors

Technical Overview 29

EPSON Stylus Pro 9000

PAPER SUCTION FAN

The Paper Suction Fans are located behind the lower paper guide and suck air through the holes in the guide. This keeps the paper from bulging as it feeds through the printer and prevents ink smears. The table below relates fan speed to various printer states and user actions.

Table 2-4. Fan Speeds

Fan speed User action Printer action Sensor state LCD message

Level 1 (low) User begins to load paper —

Level 2 (medium) User continues loading paper —

Rear Paper Sensor ON Front Paper Sensor OFF

Rear Paper Sensor ON Front Paper Sensor ON

“Load Paper” if Paper

Release Lever UP

“Paper Out” if Paper Release

Lever DOWN

“Load Paper” if Paper

Release Lever UP

“Press Pause Button” if Paper

Release Lever DOWN

Fan goes from Level 3 (high) to Off, and then back to Level 3 (high) during paper setting sequence

Off —

Level 3 (high) User sends print data Printing

User lowers Paper Release Lever and presses Pause, or user allows several seconds to pass after lowering Paper Release Lever and prin ter automatically ends “Pause” state

Printer sets paper

Paper loaded and printer waiting for print data

Depends on paper’s location while being set

Rear Paper Sensor ON Front Paper Sensor ON

Depends on paper’s location while printing

“Wait”

“Ready”

“Printing”

Technical Overview 30

EPSON Stylus Pro 9000

PAPER WIDTH DETERMINATION (LEFT AND RIGHT EDGE DETECTION)

Before printing, the printer sets the platen gap and then flushes the printheads to make sure no ink smears the paper. The printer then detects the left and right edges of the paper. Note how “left” and “right” are defined below:

Right Paper Edge

Left Paper Edge

Printable Area

To detect the left and right edges, the printer performs the following steps:

Table 2-5. Left and Right Edge Detection

Purpose Step Action

To make sure

paper is

loaded

correctly

The carriage moves just to t he inside of where the left edge

should be, if the paper is loaded correctly. The Paper Width Sensor checks for paper. If paper is

detected, go to step 3; otherwise report “Reload Paper” error.

Table 2-5. Left and Right Edge Detection (continued)

Purpose Step Action

To determine

position of lef t

edge

To determine

position of right edge

To verify left

edge position

and determine

paper width

The carriage move s to the left paper edge and regi sters its

position.

8 The carriage moves to the right edge of the paper.

The Paper Width Sensor checks for paper. If paper is not

detected, go to step10; otherwise, report “Reload Paper” error.

The printer registers the position of the right edge of the

paper.

11 The carriage returns to th e lef t paper edge.

The Paper Width Sensor checks for paper. If paper is not

detected, go to step13; otherwise, report “Reload Paper” error.

The printer verifies the edge position and registers the

distance from one edge of the paper to the other.

To establish

sensor signal

level

To make sure

paper is

loaded

correctly

To establish

sensor signal

level

The printer registers the sensor’s “paper present” (ON) signal

level.

The carriage moves just to t he outside of where the left edge

should be, if the paper is loaded correctly. The Paper Width Sensor checks for paper. If paper is not

detected, go to step 6; otherwise report “Reload Paper” error.

The printer registers the sensor’s “no paper” (OFF) signal

level.

Technical Overview 31

EPSON Stylus Pro 9000

PAPER SIZE DETERMINATION (DETECTION OF TOP EDGE)

If the printer is in Roll Auto Cut or (Cut) Sheet mode, it determines the location of the top (leading) edge of the paper before printing. Note that the printer skips this procedure if Roll Cutter Off is selected.

The “top-left” and “top-right” edges are as shown below. Note that the top edge may not be straight across.

Printable Area

Top-R i ght Pape r Edge

After determining the position of the left and right edges of the paper (see

Paper Width Determination (Left and Right edge Detection)

the printer performs the following steps to locate the top edge and correctly position the paper for printing:

Top-Left Paper Edge

on page 31),

Table 2-6. Top Edge Detection and Positioning

Purpose Step Action

Printer reverse feeds (pulls paper back up) a maximum

To make sure

paper is

loaded

correctly

To determine

top-left edge

position

To determine

top-right edge

position

To ready

carriage for

printing

distance of 200mm. The Front Paper Sensor checks for paper. If, during rever se

feeding, it detects the top edge of the paper, go to step 3; otherwise, report “Reload Paper” error.

Carriage moves from home posit ion to 30 mm inside lef t edge

of paper.

4 Printer reverse feeds 200 mm max.

The Paper Width Sensor checks for paper. If, duri ng reverse

feeding, it detects the top edge of the paper, go to step 6;

otherwise, report “Reload Paper” error. 6 Printer registers top-left edge position. 7 Carriage moves to 30 mm inside right edge.

The Paper Width Sensor checks for paper. If it det ects paper,

the printer reverse feeds paper until Paper Width Sensor 8

detects top-right edge. If paper n ot detected, printer advances

paper until Paper Width Sensor detects top-right edge.

9 Carriage returns to home position.

To set paper

for printing

Printer advanc es paper so that the shorter of the two edges

(top-left or top-right ) aligns with a position approx imately 1 cm

below the level of the Fr ont Paper Sensor.

Technical Overview 32

EPSON Stylus Pro 9000

PAPER LOADING ERRORS



“Reload Paper” Error After paper is loaded in the printer, the printer performs the left, right, and

leading edge detection operations described above. If the operations fail at any point, a “Reload Paper” error occurs.



“Paper Not Straight” Error To avoid printing on paper that is skewed or fed at a slant too far to the

right or left, the printer detects the right and left edges at the leading edge of each page. If the printer determines that the paper is skewed 3 mm or more from the position previously detected, a “Paper Not Straight” error occurs.

To avoid paper loading errors, make sure the paper’s left edge (near HP) is lined up with the vertical line of holes in the Lower Paper Guide. Paper loaded within 10 mm of the center of the vertical line of holes in the Lower Paper Guide is considered in the printable zone; however, paper loaded outside that 10 mm zone causes an error.

2.2.3 C arriage Lock Mechanism

The printer uses an electromagnetic solenoid to release the carriage lock. When the carriage lock does not receive any signal, the actuator rises into the opening at the bottom of the subcarriage, restricting carriage movement. To release the carriage for printing, the printer signals the actuator which then moves down, releasing the carriage.

Carriage Cover

Locking Actuator

CR Lock

Release

Lever

Figure 2-11. Carriage Lock Mechanism

Technical Overview 33

EPSON Stylus Pro 9000

2.2.4 Ink Supply Mechanism

The two ink cartridge holders each hold three cartridges, K, C, and M on one side and Lc, Lm, and Y on the other side. The design of the holders makes it quite easy to install and replace ink cartridges from the front of the printer. The I/H Lever opens and closes the I/H door, and at the same time it changes the angle of the Ink Cartridge Holder Assembly as shown in page 34. To prevent users from accidently installing a color ink cartridge in the wrong slot, the cartridges have slightly different designs.

Another important feature of the ink cartridge holders is the ink valve, which is located on the outer sides of the ink cartridge holders. It can be used to shut off the flow of ink during printer transportation. The valve is closed when:



the user turns the valve to the “CLOSE” position



the I/H lever is lifted to install cartridges

When the valves are open, the ink flows out of the ink cartridges, through the stainless steel pipes, through the ink tubes, and finally into the printheads.

Figure 2-12

I/H Lever

Ink Cartridge

Holder Assembly

Figure 2-12. Ink Supply Mechanism

Technical Overview 34

EPSON Stylus Pro 9000

INK-RELATED SENSORS

The following sensors are located in the I/H compartment:



I/H Assembly sensor This optical sensor detects the whether the door is open and the I/H Assembly is in the install position or the door is closed and the I/H Assembly is in the print position.

When the I/H door is open, the signal = ON When the I/H door is closed, the signal = OFF



Ink Cartridge sensor This mechanical sensor (microswitch) is built in all six ink cartridge slots.

When the I/C is installed, switch = closed When the I/C is not installed, switch = open



Ink Low sensor This mechanical sensor (microswitch) is at the bottom of all six ink cartridge slots and detects when ink is running out. When the I/C is nearly empty, the switch = open When the I/C is not low (normal), the switch = closed



Ink ID sensor This optical sensor is located on the side of all six ink cartridge slots and detects which market the cartridge is for. Although not currently implemented, the sensor can also detect the type of ink (presently dye only) and any special color (if new colors are introduced in the future). The Ink ID sensor looks for the following marks on the ink cartridge.

Ink Cartridge

Figure 2-13. Ink Cartridge Holder Sensors

Ink ID Sensor

Ink Low Sensor

Ink Cartridge Sensor

Market: No mark, white = Overseas/Global Ink type: No mark, white = dye-based ink Special color: No mark, white = N/A (may be available in future)

Technical Overview 35

EPSON Stylus Pro 9000

2.2.5 Cover Ope n Se ns or

There are two cover open sensors, or safety interlock switches, one on each side of the printer, that detect when the cover is open. When the cover is open, relays that control current to the CR motor and PF motor cut off the flow of current. As shown in from damaging drivers and other circuitry when the relays shut off.

Figure 2-15

Front

Cover

, a bypass capacitor prevents current spikes

Motor

Driver

Front Co v er

open

Cover Open

Sensor

Figure 2-14. Cover Open Sensor

Driver

C126/127

Figure 2-15. Relay Circuit Between Cover Open Sensors and

Printer Motors

Technical Overview 36

EPSON Stylus Pro 9000

2.2.6 Control Circuit

This section summarizes the functions of the (C277MAIN) Main Board.

Motor

drivers

Printer

mechanism

IC8 CPU/C90A08CA (SH7043)

IC13 ASIC/E05B61AA

IC32 ASIC/uPD65802

IC33

Motor

IC35

Motor

IC20 ASIC/TE7751

IC30

Motor

CN7 Control Panel

IC31

Pump Motor

IC39 SRAM/8KB

IC18/19 DRAM/2MB

CN19 RAM-SIMM/16MB

IC1/2 Flash mem./1MB

CN20 PC Card connector

Head data & control signals

IC37 DAC/M65530FP

B head C head

Head-drive voltage common driver

Printheads (B/C)

CN2 Type-B Slot

CN3 Mac Serial I/F

CN1 Parallel I/F

Fixed

-Firmware

-Setting parameters

Head-drive wave generation

Table 2-7. C277MAIN Board Main Components

Name/Code Location Function



CPU (C90A08CA) SH7043

IC8

ASIC (E05B61AA) IC13

ASIC (TE7751) IC20

ASIC (uP D65802) IC32

DAC (M65530FP) IC37

Flash Memory (MBM29F400TC)

IC1/2

DRAM (EDO) IC18/19

SRAM (LC3564SM-

10)

IC39

Driver IC (L6203) IC33/35 CR/PF Motor Driver Driver IC (LB1845) IC30/31 PG/Pump Motor Driver

32 bit RISC-CPU

Clock speed = 33M H z 128KB PROM internal



Regulates print data

Command handling Rasterizer (image da ta handling) Head drive regulation (DAC) Print timing regulation



Memory (DRAM /SR AM)



I/F Circuit Control

Parallel interface (IEEE1284) Macint osh Serial interface Type-B



Regulates Motor

Pump Motor PG Motor (PG setting) Fan (PS, Paper Suction)



Regulates motor (PWM regul ation)

CR Motor PF Motor



3 channel 10 bit DA converter

head-drive voltage control



Fla sh Me mory (1Mbyte)

Save firmware Register setting parameters



EDO RAM

2Mbyte 16Mbtye (CN19 mounted SIMM)



64Kbit SRAM

External da ta ring buffer type

Figure 2-16. C277MAIN Board-Circuit Block Diagram

Technical Overview 37

TROUBLESHOOTING





EPSON Stylus Pro 9000

3.1 Overview

To troubleshoot printer problems, turn to one of these sections:



If the LCD display shows an error message, see

LCD Error Messages



Since an LED or LCD error message may indicate a loose cable connector, see also



If you notice problems with print quality such as missing dots or lines, misaligned vertical lines, or banding (faint white lines), see

Troubleshooting

Connector-Related Errors

on page 39.

on page 52.

on page 49.

Trouble shooting Usi ng

Print Quality

3.2 Troubleshooting Using LCD Error Messages

The EPSON Stylus Pro 9000 performs self-diagnostic tests using the data supplied by its sensors, and if an error is detected by one or more sensors, an error message appears on the control panel display.

When the printer displays an error, look it up in follow the link in the table to the appropriate troubleshooting section of this chapter.

Table 3-1

Table 3-2

and

Troubleshooting 39

EPSON Stylus Pro 9000

3.2.1 LCD Error Messages

When a part reaches the end of its useful life, an error code appears on the printer’s LCD display. For example, MAINTENANCE REQ. 0100 appears on the display to warn that the Waste Ink Pads are about 99% full. The printer continues to print while this message appears. When the Waste Ink counter determines that the Waste Ink Pads are completely full, the printer displays SERVICE REQ. 00000100 and stops printing.

Error codes also alert the user to fatal errors and other printer problems. Refer to the tables below to determine the meaning of each code.

Table 3-1. Error Message List for Service Technicians

Error Code Description Refer to

Maintenance Req. nn

Service Req. nnnnnnnn

0100

0000010 0 Waste Ink pads must be replaced 00000101 Ink Tube wor n out 00010000 PF motor encoder check error 0001000 1 PF motor out of step 00010002 PF motor overcurrent 00010003 PF in-position time-out 00010004 CR motor enco der check error 0001000 5 CR motor out of ste p 00010006 CR motor overcurrent 00010007 CR in-position time-out 00010008 Servo interrupt watchdog time-out error 00010009 System interrupt watchdog time-out error 0001000A CR origin sensor malfunction 0001000C PG origin sensor malfunction 0001000D Cov er sensor m alf un ction (00 ) 000100 0E Cover sens or m alfunct io n (0 1 ) 0001000F CR motor PWM output error 00010010 PF motor PWM output er ror

0002000 0 NVRAM error

Waste Ink pads is almost full (les s than 1% remaining)

page 41 page 41

page 41 page 41 page 41 page 42 page 42 page 42 page 42 page 43 page 43 page 43 page 43 page 43 page 43 page 44 page 44 page 44 page 44

page 44

Table 3-1. Error Message List for Service Technicians (continued)

Error Code Description Refer to

000200 01 Internal RAM check erro r 00020002 SRAM check error 00020003 DRAM check error 0002000B Mail Box receiving error 10000004 CPU vector 4 - General illegal instruction 10000006 CPU ve ctor 6 - Slot illegal in st r uc tion 10000009 CPU vector 9 - CPU address error 1000000A CPU vector 10 - DMAC/DTC address error 1000000B CPU vector 11 - Watchdog time-out error

100000”” CPU vector 32 to 63 - Wrong trap

page 44 page 44 page 44 page 44 page 44 page 44 page 44 page 44 page 44 page 44

Table 3-2. General Error Message List

Error Type Message Refer to

Warning Ink Low

Paper Out Load xxx Paper Load Paper Paper Jam Cover Open Paper Not Cut Paper Not Straight

Error

Reload Paper Push Lever Down Compartment Open Ink Out No Ink Cartridge Remove Paper Option I/F Error

page 45 page 45 page 45 page 45 page 46 page 46 page 46 page 46 page 47 page 47 page 47 page 48 page 48 page 48 page 48

Troubleshooting 40

EPSON Stylus Pro 9000

3.2.2 Errors that require a service technician

This section describes the errors listed in

MAINTENANCE REQ. 0100

Problem



The Waste Ink Pads have absorbed 99% of their ink capacity. The printer can continue printing, but the “Maintenance Req. 0100” message appears instead of the “Ready” or “Printing” messages.



Solution Replace the Waste Ink Pads along with the replaceable parts of the Mainenance Assembly as described in page 67.

SERVICE REQ. 00000100



Problem The waste ink pads are completely full, causing a fatal error. The printer stops printing.



Solution See the solution for Maintenance Req. 0100, above.

SERVICE REQ. 00000101



Problem This error occurs when the CR Motor has reached 2.5 million passes, which indicates that the Ink Tubes should be replaced due to excessive wear and tear.



Solution Replace the Ink Tubes as explained in page 92.

Table 3 - 1

Maintenance Procedures

Removing the Ink Tubes

on page 40 in detail.

SERVI C E R EQ. 00010 000

Problem



PF motor encoder check error When the PF motor turns, the printer checks the rotary encoder output signals to make sure the motor is turning at the correct speed and distance. If the encoder doesn’t send the expected output data, an error occurs.



Solution Make sure there is nothing blocking the PF Roller. If that does not solve the problem, check the PF motor encoder connection. If there still is a problem, try the following:



Check and adjust the PF Belt tension



Replace the PF motor



Replace the Main Board

SERVI C E R EQ. 00010 001

Problem



PF motor out of step The length of the pulse generated by the PF motor’s internal encoder is too long or too short compared to the normal pulse.



Solution See the solution for Service Request 00010000, above.

Troubleshooting 41

EPSON Stylus Pro 9000

SERVICE REQ. 00010002



Problem PF motor overcurrent Feedback from the PF motor driver (IC35) indicates that the PF motor’s current is irregular.



Solution



Replace the PF motor



Replace the Main Board

SERVICE REQ. 00010003



Problem PFin-position time-out The in-position time is the amount of time the printer waits to make sure the PF Roller is not moving when the motor comes to a stop. If the rotary encoder sends a pulse during the in-position time, then the PF Roller is moving even though it’s supposed to be at a full stop, and this generates an error.



Solution



Replace the PF motor



Replace the Main Board

SERVI C E R EQ. 00010 004



Problem CR motor (linear) encoder check error When the CR motor turns, the printer checks the linear encoder output signals to make sure the motor is turning at the correct speed and distance. If the encoder doesn’t send the correct output data, an error occurs.



Solution Make sure there is nothing blocking the carriage. If that does not solve the problem, check the linear encoder’s connections. If there still is a problem, try the following.



Check the plastic encoder strip (timing fence) for soiled areas, obstructions, and damage



Replace the linear encoder sensor



Replace the CR motor



Replace the Main Board

SERVI C E R EQ. 00010 005

Problem



CR motor out of step The length of the CR motor’s pulse is too long or too short compared to the normal pulse.



Solution See the solution for Service Request 0010004, above.

Troubleshooting 42

EPSON Stylus Pro 9000

SERVICE REQ. 00010006



Problem CR mo t or overc urre nt Feedback from the CR motor driver (IC33) indicates that the CR motor’s current is irregular.



Solution



Replace the CR motor



Replace the Main Board

SERVICE REQ. 00010007



Problem CR in-position time-out The in-position time is the amount of time the printer waits to make sure the carriage is not moving when the carriage comes to a stop. If the linear encoder sends a pulse during the in-position time, then the carriage is moving even though it’s supposed to be at a full stop, and this generates an error.



Solution



Replace the linear encoder sensor



Replace the CR motor



Replace the Main Board

SERVICE REQ. 00010008



Problem Servo interrupt watchdog time-out error due to motor-drive control related error



Solution Replace the Main Board

SERVI C E R EQ. 00010 009



Problem System interrupt watchdog time-out error due to sensor-related error



Solution Replace the Main Board

SERVI C E R EQ. 00010 00A



Problem CR origin (home position) sensor malfunction



Solution



Check the HP sensor for obstructions, and clean using compressed air



Replace the HP sensor



Replace the Main Board

SERVI C E R EQ. 00010 00C

Problem



PG origin sensor malfunction (may indicate PG motor malfun ction)



Solution Make sure there is no ink or dust on the surface of the sensor. If this does not solve the problem, check the PG sensor’s connections. If there still is a problem, try the follo w in g:



Replace the PG sensor



Replace the PG motor



Replace the Main Board

Troubleshooting 43

EPSON Stylus Pro 9000

SERVICE REQ. 0001000D SERVICE REQ. 0001000E



Problem Cover sensor malfunction One or both Cover Open sensors (interlock switches) located at either end of the cover shaft is malfunctioning. D: right sensor (HP side) E: left sensor



Solution Make sure each sensor is properly installed. If that does not solve the problem, check the Cover Open sensor’s connections. If there still is a problem, try the following:



Replace the malfunctioning sensor or sensors



Replace the Main Board

SERVICE REQ. 0001000F



Problem CR motor PWM output error



Solution



Replace the Main Board

SERVICE REQ. 00010010

Problem



PF motor PWM output error



Solution



Replace the Main Board

SERVICE REQ. 00020000 (NVRAM ERROR) SERVICE REQ. 00020001 (INTERNAL RAM ERROR) SERVICE REQ. 00020002 (SRAM ERROR) SERVICE REQ. 00020003 (DRAM ERROR) SERVICE REQ. 0002000B (MAIL BOX RECEIVING ERROR)

Problem



Unusual condition detected.



Solution



Write down the error code, and then turn the printer off and back on to confirm that the error recurs. If the error recurs, replace the Main Board.



For “Service Req. 00020003” (DRAM error), replace the SIMM installed in CN19 and then check whether the error recurs.

SERVI C E R EQ. 10000 004 SERVI C E R EQ. 10000 006 SERVI C E R EQ. 10000 009 SERVICE REQ. 1000000A SERVICE REQ. 1000000B SERVI C E R EQ. 10000 0##



Problem Unusual condition detected.



Solution



Write down the error code, and then turn the printer off and back on to confirm that the error recurs. If the error recurs, replace the Main Board.



Send a different print job to make sure the error wasn’t due to electrical noise or bad print data.

(CPU GNRL ILLEGAL INSTRCTNS) (CPU SLOT ILLEGAL INSTRCTNS) (CPU CPU ADDRESS ERROR)

(CPU DMAC/DTC ADDRESS ERROR) (CPU WATCHDOG TIME-OUT ERROR)

(CPU VECTOR 32~63)

Troubleshooting 44

EPSON Stylus Pro 9000

CAUTION

3.2.3 General Errors

This section describes the errors that can be solved by the user.

INK LOW



Problem Each ink cartridge has a mechanical ink level gauge. One of them has detected that the corresponding ink cartridge is almost empty. With the remaining ink, the user can still print at about 100% duty on B1 size paper, but the cartridge should be replaced as soon as possible.



Solution Replace the ink cartridge with a new one. Do not try to reuse the old cartridge; if you re-install an ink cartridge that was detected as being in a “Near End ” sta te, the s tat us w ill im mediately g o to “Ink Ou t . ”

ADJUSTM ENT

REQUIRED

PAPER OUT

If for any reason you replace an ink cartridge before it reaches the ink-low or ink-out state with a new ink cartridge, you need to reset the ink counter from the control panel. See Maintenance Mode 2

on page 17.



Solution



If paper has run out, remove the printer paper and load new paper. If print data remains in the printer, the data will be printed.



If this error occurs even though paper is properly loaded, there may be something on the Rear Paper Sensor’s surface. Clean the sensor’s surface (hole in the Upper Paper Guide) with a clean, dry cloth or using compressed air.

Never use a wet cl oth or soap to clean opti cal s en sors.

LOAD XXX PAPE R



Problem The selected paper source (according to the remote PP command) and the paper type selected on the control panel do not match.



Solution Load the correct paper or change the panel setting to match the type of paper loaded in the printer.

Problem





Paper is not loaded.



The rear edge of roll paper has been detected.



The print job using cut sheets is finished or the rear edge of cut-sheet paper has been detected.

LOAD PAPER

Problem



While paper is loaded, the Paper Release lever was pushed up to the Release position.



Solution



Make sure paper is loaded properly and push down the Release lever to lock the paper in place.



If this error occurs even when the lever is down, in the Lock position, there may be a problem with the Paper Release lever sensor. Check the sensor’s operation and connectors. If that doesn’t work, replace the Main Board.

Troubleshooting 45

EPSON Stylus Pro 9000

PAPER JAM



Problem A paper jam occurs when during printing, paper feeding, or paper cutting, and 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 Front and Rear Paper sensors are ON but the carriage motor is out of step or drawing too much current.



Solution



After removing the jammed paper, turn the printer off and back on again.



If a paper jams occurs again after removing the original paper jam, check to make sure nothing is blocking the feed path or blocking the carriage.

COVER OP EN



Problem The front cover is open. This error occurs when the cover is opened during carriage operation or a cleaning operation, causing printer operation to stop. If the carriage is not in home position and the cover is left open too long, the printheads may dry out and become damaged. (To avoid this problem, press the Pause button before opening the cover. Note that if you continue printing, a stripe or band may appear where printing resumes; this is because the previously printed section has had more time to dry than the freshly deposited ink.)



Solution



Close the cover as soon as possible.



If the cover is fully closed when this error occurs, make sure the left and right cover-open sensors are correctly installed and are operating properly.

PAPER NOT CUT



Problem The paper that was supposed to be cut was not cut completely, or the paper wa s c ut but is still in front of the Fr ont Paper Sen so r .



Solution



Remove the cut paper if it is on or near the Front Cover and Lower Paper Guide.



Replace the cutter if it is worn out.



If the paper was cut, but not cut straight across, you may need to adjust the cutter position. See page 131 for details.

Cutter Position Adjustment

PAPER NOT STRAIGHT



Problem This error occurs when the printer detects that the paper is skewed (loaded at an angle) by more than 3 mm. If the printer prints on paper that is loaded at a slant, the printer may print outside of the printable area and may fire ink onto the platen. If this happens, the next sheets loaded in the printer may be marred on the back.



Solution



Remove the paper loaded in the printer and properly reload it so that it’s edge is aligned with the vertical line of holes in the Lower Paper Guide.



If using roll paper, remove the roll and carefully squeeze the sides of the roll to make sure they’re lined up and flat.

Troubleshooting 46

EPSON Stylus Pro 9000

RELOAD PAPER



Problem This error occurs when:

1) The user loads the paper too far down (more than 200 mm below the Front Paper Sensor).

2) The paper was loaded in such a way that the left edge is not within 10 mm of the vertical line of holes in the Lower Paper Guide.

3) The right edge is outside the printable area (due to mis-loading or because the paper is too wide).

4) After printing has finished, the right or left edge is outside the area where the cutter can cut the paper.

5) The loaded paper was longer than the selected paper, and the paper was not fully ejected. (For example, roll paper is loaded in the printer but cut sheet is selected on the control panel.)

6) A cutter error occurred after the paper was ejected.



Solution



for 1 through 4, above Reload paper properly. If the front edge of the paper is not straight and clean, cut the paper.



for 5 and 6, above Cut off the ejected portion of the paper and reload the rest of the paper. For paper that is automatically cut, lift up the Release Lever (the “Load Paper” message appears), fix the position of the paper, and lower the Release Lever. If you select the “Roll Auto Cut” setting, you can cut off the ejected portion of the paper using the Cut button.



If the error recurs even after reloading the paper, make sure the Rear Paper Sensor is installed correctly and working properly.

PUSH LEVER DOWN



Problem The printer cannot operate because the lever is in the release position.



Solution



Push the lever down. Note that if printing was interrupted because the lever was pushed to the release position and the paper shifted, the print job may be marred.



If the lever is down and this error still occurs, check the Release Lever Position Sensor.

COMPARTMENT OPEN



Problem An Ink Holder (I/H) compartment door is open.



Solution



Push the I/H lever down to the lock position.



If the lever is down and this error still occurs, check the Lever Position Sensor.

Troubleshooting 47

EPSON Stylus Pro 9000

INK OUT



Problem One or more ink cartridges have run out of ink, a near-end cartridge has been reinstalled, or an unsupported ink cartridge has been installed.



Solution



Replace the empty ink cartridge.

CAUTION

When replacing an empty ink cartridge, alway s replace it with a new ink cartridge; otherwise the printer cannot tell how much ink remains in the cartridge.



Make sure the ink cartridge is the proper type of cartridge for the printer and the proper color for that slot.



If the proper cartridge is installed and this error still occurs, check the Ink Out and Ink ID sensors.

NO INK CARTRIDGE



Problem An ink cartridge is not installed or is not installed properly.



Solution



Install the proper ink cartridge in the empty slot.

CAUTION

When replacing an empty ink cartridge, alway s replace it with a new ink cartridge; otherwise the printer cannot determine how much ink remains in the cartridge.

REMOVE PAPER



Problem Printer cannot perform cleaning because thick paper is installed, causing the printheads to be too far away from the Capping Assembly. This error occurs under the following conditions.



Thick paper is loaded when an automatic cleaning operation is supposed to begin.



The printer attempts to print on thick paper when an automatic cleaning operation is supposed to begin.



You turn on the printer and the thick paper is loaded.



You attempt to perform a manual cleaning operation when thick paper is loaded.



Solution Remove thick paper and push the Release Lever down (this causes the cleaning operation to start and “Wait” appears on the display). After the cleaning operation is finished, “Paper Out” appears. Reload thick paper and continue printing as usual.

OPTION I/F ERROR

Problem



An unsupported Type-B interface card is installed.



Solution Turn off the printer, remove the unsupported card, and install a card with the correct specifications.



If the proper cartridge is installed and this error still occurs, check the Ink Cartridge sensor.

Troubleshooting 48

EPSON Stylus Pro 9000

CAUTION

3.3 Print Quality Troubleshooting

Use this section to solve the following problems if they appear in your printouts:

Table 3-3. Print Quality Problems

Description Refer to

Missing dot or dot s

No ink output from one or both pri ntheads

Uneven printing or poor resolution

Smudged or marred printo ut on fr ont side

Smudged or marred printo ut on reverse side

White or black bandin g

If you need to print a nozzle check pattern, press the SelecType button while the printer is on but not printing. Press the Paper Source button until “Test Print” appears, and then press Enter to select “Nozzle Check.” The nozzle check pattern prints.

MISSING DOTS OR LINES

When the printer is not used for a long period of time, the ink in the nozzles can dry up and clog the nozzles. You can clean the nozzles in both printheads from the printer’s control panel. While the printer is on but not printing, press the Cleaning button and hold it for 3 seconds. This starts the cleaning operation.

If the printhead nozzles don’t clear after attempting multiple cleaning operations, check the following:

1. If there is no output at all or only some of the colors print, check the ink valves on either side of the printer I/H Assemblies to make sure the knobs are set to “Open.” If the valves are open but there is still no output, see

Ink Output from One or Both Printheads

on page 50.

page 49 page 50 page 50 page 51 page 51 page 51

2. Perform ink charging again Select the “Cleaning” function on the control panel’s Self-Diagnostic menu. See

Cleaning menu

printheads and forces out the old ink that is clogging the nozzles.

on page 128. This sends a lot of ink into the

Do not clean the printheads unnecessarily, as doing so consumes a lot of ink. Each head consumes about 90 ml per operation.

3. If the cleaning operation does not clear the clogged nozzles, check the following:



Is there damage to or foreign material in the rubber seal of the Capping Assembly?



Is the Capping Assembly valve operating normally?



Is the Capping Assembly retention spring working properly?



Are the ink tubes and pipes between the ink cartridges and printheads properly connected and undamaged? (Check the nuts for tightness, the O-rings for warping, and the tubes and pipes for ink leakage.)

4. If after following the above steps the printout still shows missing dots, replace one of the parts listed below and recheck the printout:



Main Board



Printhead(s)



Before you uninstall the Main Board or a printhead, make sure the printer is unplugged from the wall outlet.



After installing the new components, make sure all cables are properly connected; if cable connectors not completely inserted, they can damage circuits or the printheads when power is turned on.



Make sure you replace the correct pri nthead: He ad B (left) or H ead C (right).

Troubleshooting 49

EPSON Stylus Pro 9000

CAUTION

NO INK OUTPUT FROM ONE OR BOTH PRINTHEADS

If there is no ink output from one or both printheads, try each of these steps in succession until the problem is resolved:

1. Make sure the ink valve on the outer side of each I/H assembly is open. (The small arrow should point to “OPEN.”) Then perform an initial ink charge as described in check for output.

2. There may be a problem with the ink valve or tubing. To test, place a syringe on the end of one of the dampers (see Try to draw ink through it. If ink cannot be drawn through the damper, the ink valves may be defective or the ink tubing blocked. Service these parts as needed.

3. The Capping Assembly may be damaged or clogged. Remov e the Capping Assembly and rinse it in cold water. Inspect the edges of the rubber seal. If damaged, replace the Capping Assembly.

Place a syringe on the tubing leading from the bottom of the Capping Assembly and try to draw water through it. If water cannot be pulled through, replace the Capping Assembly.

4. Reinstall the Capping Assembly, Pump Mechanism, and tubing in the printer. Make sure the tubing from the Capping Assembly isn’t pinched or crimped. Then move the carriage to home position.

Place a syringe on the end of the tubing that leads to the Flushing Box (Right). Slowly (to avoid damaging the printhead) try to draw ink through the tubing. If ink cannot be drawn through the tubing, there is a problem with the seal between the Capping Assembly and the printhead.

5. The Pump Mechanism may be defective. Turn the printer on and perform the capping position adjustment. See page 116. Turn the printer off, turn it back on, and then run a cleaning cycle as described in cycle is running, watch the end of the tubing leading to the Flushing Box (Right). If ink does not flow through the tubing, replace the Pump Mechanism.

Cleanin g m e nu

Cleaning menu

on page 128. Run a test print and

Figure 4-27

Cap Position Adjustment

on page 128. While the cleaning

on page 73).

If these steps do not restore printhead operation, the problem is probably not mechanical. Check the electrical connections between the Main Board and the printheads. Check that the Main Board is producing printhead driving signals and that the signals are reaching the printheads. Replace the Main Board or printheads as needed.

UNEVEN PRINTING OR POOR RESOLUTION

If printout quality suffers from unevenness, poor quality, or similar problems, check the following:

1. Perform the Head Gap and Bi-D Adjustments See

Head LR Adjustment (Head Gap Timing)

Adjustment

2. If the printing problem occurs only when the user prints on thick paper, press the SelecType button until the “Paper Configuration” menu appears and set the correct paper thickness. (Depending on the paper-thickness setting, the location where the ink strikes the paper may change.) See

Paper Configuration Menu

3. If the printout quality still has not improved, perform the following adjustments in the order listed below:



B Head Slant/C Head Slant Adjustment (Head Angle)



BC Head Slant Adjustment (Head Height)



Head LR Adj ustment (He ad Ga p Timi ng)



Bi-D Adjustment

on page 121.

on page 16.

on page 121

on page 123 and

on page 119

on page 120

on page 123

Bi-D

Even if you performed the Head Gap and Bi-D Adjustments in step 1, you must perform them again after doing the Head Angle and Head Height Adjustments in step 3.

Troubleshooting 50

EPSON Stylus Pro 9000

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, check the following:

1. If the smudged area is just around the front or rear edge of roll paper, make sure the margins (top and bottom) are set to 15 mm on the control panel. (If a print job uses heavy ink coverage and the top and bottom margins are set to 3 mm, the high volume of ink can cause the paper to warp and rub against the printhead surface.)

2. If this problem recurs, check the Capping Assembly retention spring. If the spring is broken or comes off its hook, the Capping Assembly cannot clean ink off the printhead properly, and the ink will smudge the printout. Fix or replace the spring.

SMUDGED OR MARRED PRINTOUT (REVERSE SIDE)

The reverse side of the paper can become smudged or marred if there is ink on the printer parts. Make sure there is no ink on the following parts, and if there is ink, wipe off the affected parts:



Sub-platen



Paper Feed Roller



Paper Pressure Rollers



Lower Paper Guide

WHITE OR BLACK BANDING

If white or black banding (lines across the page) appear on your printout, try the following:

1. Run a printhead cleaning cycle. Press the Cleaning button and hold it for 3 seconds. For more intensive cleaning procedures, see on page 128.

2. If multiple cleaning cycles don’t eliminate the banding, perform the following adjustments in the order listed below:



B Head Slant/C Head Slant Adjustment (Head Angle)



BC Head Slant Adjustment (Head Height)



Head LR Adj ustment (He ad Ga p Timi ng)



Bi-D Adjustment

on page 121

on page 120

on page 123

Cleaning menu

on page 119

If the problem is not caused by ink on these parts, most likely the paper jammed in the printer or curled up after being ejected.

Troubleshooting 51

EPSON Stylus Pro 9000

3.4 Connector-Related Errors

If you suspect a loose connector or faulty cable, you can use the following table to isolate the specific problem:

Table 3-4. Connector-Related Errors

LCD errors LED errors Symptom

(display is blank) — CN7 ribbon cable Main Board Control Panel

Connector

description

From To

— —

— — Printhead comes in contact with edge of paper CN14 Relay Board Suction Fan — — Printhead comes in contact with edge of paper CN16 Relay Board Suction Fan

——

— — Poor print quality due to incorrect platen gap CN12 Relay Board Paper Thickness Sensor

——

May see “Paper Not Cut”

error

—— CN10 Main Board PSB Fan (Left) — — CN15 Main Board Relay Board CN3

—— CN26 Main Board PSB Fan (Right) Ink Compart. Open C, M, K=Solid CN21 Main Board Ink Housing (Left) Ink Compart. Open LC, LM, Y=Solid CN8 Relay Board Ink Housing (Right)

Ink Compart. Open

Load Paper

LC, LM, Y=Solid and Paper Out=Solid

LC, LM, Pause, Paper Out=Solid

— Paper doesn’t cut CN6 Printhead Board Cutter Solenoid

Printhead comes in contact with middle of paper and smears ink

Little or no ink output during printi ng; dry cappi ng sponge

Poor print qualit y, or little or no ink output, due to priming or cleaning problem

No carriage movement

CN15 Relay Board Suction Fan

CN7 ribbon cable

(blue end)

CN19

(white cable)

CN9 flat cable

(blue end)

CN8 flat cable

(white)

Relay Board Printhead Board

Relay Board Pump Motor

Main Board Relay Board CN7

Main Board Relay Board CN6

Load Paper — Release Lever doesn’t change display CN10 Relay Board Paper Release Lever Sensor

Paper Out — Suction fans don’t begin CN11 Main Board Rear Paper Sensor Paper Out — Suction fans don’t go from low to medium speed CN11 Relay Board Front Paper Sensor

Troubleshooting 52

EPSON Stylus Pro 9000

Table 3-4. Connector-Related Errors (continued)

LCD errors LED errors Symptom

Reload Paper — CN5 Printhead Board Paper Width Sensor Service Req. 00010000 — (Error code doesn’t match problem) CN27 Main Board Left Cover Open Service Req. 00010000 — (Error code doesn’t match problem) CN13 Relay Board Right Cover Open Service Req. 00010000 — CN13 Main Board PF Encoder Service Req. 00010000 — CN14 Main Board Relay Board CN5 Service Req. 00010000 — CN18 Main Board PF Motor Service Req. 00010004 — CN17 Main Board CR Motor Service Req. 00010004 — Carriage sl am s ri ght CN2 Printhead Board CR Linear Encoder Sensor

Connector

description

From To

Service Req. 00010004 — Carriage slams right

Service Req. 0001000A — CN4 Printhead Board Home Position Sensor Service Req. 0001000C — CN17 Relay Board Platen Gap Origin Sensor Service Req. 0001000C — CN18 (light blue cable) Relay Board Platen Gap Motor Service Req. 0001000C — CN24 Main Board Relay Board CN4 Service Req. 0001000F — Carriage doesn’t move out of home positi on CN9 Relay Board CR Lock Solenoid

CN6 ribbon cable

(white)

Relay Board Printhead Board

Troubleshooting 53

DISASSEMBLY & ASSEMBLY





EPSON Stylus Pro 9000

CAUTION

4.1 Overview

This section provides disassembly and assembly instructions for the EPSON Stylus Pro 9000. Except as otherwise noted, you can reassemble the printer by reversing the order in which you took it apart.

4.1.1 Precautions

In addition to reading the precautions that appear throughout this chapter, read and keep in mind the following:



W ARNING

To prevent electric shock or damage to the printer, always turn off the power switch and unplug the power cable before servicing the printer.



If you have to remove the printer housing while the printer is on to view internal operations, be very careful around moving parts such as the fans, gears, carriage, and carriage drive belt.



Keep in mind that the steel carriage drive belt and cutter blade have sharp edges and can be dangerous .



The printer is very heavy (about 200 lbs). If you need to separate the printer from its stand or lift the printer, four people are needed.



For safety reasons, the front cover’s position, up or down, is detected by the cover-open sensors, located under the left and right side covers of the printer. Do not block or modify these sensors.



If ink gets on your hands, wash them thoroughly with soap and water. If ink gets in your eyes, rinse them immediately with water.



Because the main board includes a lithium battery for memory backup purposes, keep the following in mind: —Avoid shorting the battery, which can make it very hot or cause it to explode. —When replacing the battery, make sure the positive and negative sides are correctly installed.



Because ink may leak from the printer when servicing inkrelated parts, remove the paper hammock and put a sheet or cloth under the printer when performing such repairs.



Static electricity can damage sensitive printer components, especially on the main board. Use an anti-stati c wri s t band or similar grounding de v ice to prevent static electricity buildup.



The cutter blade is very hard and can damage or scratch printer parts. Also, it can be easily chipped or damaged. Be careful when handling or replacing the cutter.

Disassembly & Assembly 55

EPSON Stylus Pro 9000

4.1.2 Tools

This section lists the tools necessary to disassemble or assemble the printer.

Table 4-1. Necessary Tools

Tool Part Code Notes

(+) Phillips screwdriver (-) Standard screwdriver — Needle-nosed pliers — Tweezers —

Hex (Allen) wrench

Regular, every-day

tools are OK, no

special tools needed

No. 1 and no. 2 sizes needed

• 1.5 mm (CR motor)

• 2.5 mm (PF motor and CR belt)

• 4.0 and 5.0 mm for setting up printer only

4.1.3 Screw List

The following table lists all the screws used in this printer.

Table 4-2. Screws

Type Color Description

CP(W2)M3x6 black (+) Crosshead Pan, spring washer, flat washer CP(W2)M4x12 silver (+) Crosshead Pan, spring washer, flat washer CP(W2)M4x6 silver (+) Crosshead Pan, spring washer, flat washer CP(W2)M4x12 black (+) Crosshead Pan, spring washer, fl at washer CP(W2)M3x8 silver (+) Crosshead Pan, spring washer, flat washer CP(W2)M3x6 silver (+) Crosshead Pan, spring washer, flat washer CP(W2)M4x5 silver (+) Crosshead Pan, spring washer, flat washer CBF3x6 silver (+) Bind screw, flange CPM2x4 silver (+) Crosshead Pan CBM3x6 silver (+) Bind screw Hex screw silver Six-sided hex screw, 1.5 and 2.5 mm

Disassembly & Assembly 56

EPSON Stylus Pro 9000

4.1.4 Order of Disassembly

For efficient disassembly and assembly, refer to the following flowchart.

Mainte nance Cover Removal

page 58

Top Cover Removal

Upper Paper Guide Removal

Left an d Right Side Cover

Removal

Front Cover Removal

Roll Cover Removal

Lower Paper Guide Removal

page 63

Replacing the Waste Ink Pads

Removin g t h e Fr on t Pa pe r Sens or

on page81

on page 70

page 64

on page60

page 67

on pag e61

on page 62

Power Supply Board Removal

Main Board Removal

Removing the Rear Paper Sensor

Removing the Carr iage Motor

Assembly

Removing the Platen Gap

Adjustment moto r

Removing the Platen Gap Home

Position Sensor

Removing the Paper Thickness

Sensor

on page 75

on page 78

on pag e80

on page 80

page 65

on page 66

Position Sensor and Encoder

Removing the Cover open

Removing the P F Mo to r Asse mbl y

Sensors

on page 76

on pag e79

To access the Left I/L Switch, you also need to remove the Upper Paper Guide

To access the PF Motor, you also need to remove the Lower Paper Guide

Removing the Car riage H ome

page 82

Replacing the Printheads

page 71

To access these parts, you need to remove only the

Right

Side Cover

Removing the Paper Releas e

Sensor

on page81

Maintenance Assembly Removal

& Disassembly

on page 69

To access the Maintenance Assembly, you also need to remove the Lower Paper Guide and Right Waste Ink Box

Figure 4-1. Disassembly Process Flowchart

Disassembly & Assembly 57

EPSON Stylus Pro 9000

4.1.5 Housing Parts

Refer to the figure below to locate the housing parts described throughout this chapter.

Upper P aper Guide (behind Top Cov er)

Right Side Cover

Right Joint Cover

Main tenance

Cover

Top Cover

Left Side

Cover

Front Cover

Roll Cover

Lower Paper Gui de

4.2 Housing Removal

Follow the steps below to remove the printer’s housing.

MAINTENANCE COVER REMOVAL

1. Open the Front Cover.

2. Remove 2 screws, CP(W2) M3x6, and then remove the Maintenance Cover.

Figure 4-2. Housing Parts

CP(W2) M3x6 screw (x2)

Figure 4-3. Maintenance Cover Removal

Disassembly & Assembly 58

EPSON Stylus Pro 9000

CAUTION

TOP COVER REMOVAL

Preparation: Remove the Maintenance Cover. See Maintenance Cover

Removal on page 58.

1. Remove the four screws, CP(W2) M4x12, that secure the left-side lower mounting bracket (spindle holder) and remove the bracket. Repeat for the right-side lower mounting bracket.

Mounting brackets

(lower)

2. Remove the four screws securing the Top Cover to the printer.

CP(W2) M4x6 screws

CP(W2) M3x6 screws

Paper Thickness Sensor

Figure 4-5. Top Cover Removal

3. Lower the Paper Release Lever.

4. Slide the Top Cover slightly forward to free it from its mounting brackets in

Figure 4-4. Lower Mounting Bracket Removal

back. Then lift the Top Cover from the rear, tilting it forward, and lift it away from the printer.

When removing the Top Cover, avoiding catch ing its rear edge on the Paper Thickness sensor, which may kn ock it out of adjustment. The sensor’s approximate location is shown in the figure above. You can also flex the back side of the Top Cover slightly outward, toward the rear of the printer, while removing the cove r.

Disassembly & Assembly 59

EPSON Stylus Pro 9000

LEFT AND RIGHT SIDE COVER REMOVAL

Preparation:



Remove the Maintenance Cover as described in Maintenance Cover

Removal on page 58.



Remove the Top Cover as described in Top Cover Removal on page 59.

1. Remove the left and right Joint Covers, as shown in Figure 4-7

2. Remove the seven screws (five silver CP(W2) M4x12 and two black CP(W2) M4x12) securing the Left Side Cover, and remove the Left Side Cover. Repeat for the Right Side Cover.

NOTE:

The control panel is attached to the Right Side Cover. When removing the Right Side Cover, detach the flat cable from the control panel.

CP (W2) M4x12 silver screws

Right Side

Cover

CP (W2) M4x12 silver screws

CP (W2) M4x12 black screws

Joint Cover

Figure 4-7. L/R Side Cover Outer Screw Location

Figure 4-6. L/R Side Cover Inner Screw Location

Disassembly & Assembly 60

EPSON Stylus Pro 9000

CAUTION

FRONT COVER REMOVAL

Preparation:



Remove the Maintenance Cover as described in Maintenance Cover

Removal on page 58.



Remove the Top Cover as described in Top Cover Removal on page 59.



Remove the Left and Right Side Covers as described in Left and Right

Side Cover Removal on page 60.

1. Remove the two screws (CP(W2) M3x8) securing the damper assembly on the left side of the printer, and then remove the damper assembly.

Damper Assembly

2. The Front Cover Assembly hinges on a mounting pin at each end. Remove the four screws securing the mounting pins as shown below.

Left side

CP(W2) M3x8 screws

Right side

Figure 4-9. Locations of Front Cover Shaft Screws

When removing the Front Cover, avoid tilting it down to the

Figure 4-8. Removing the Damper Assembly

3. While supporting the Front Cover, pull out the mounting pins, and then remove the Front Cover from the printer.

left. The little wheels mounted on the cover’s shaft are not secured and may slide off.

Disassembly & Assembly 61

EPSON Stylus Pro 9000

ROLL COVER REMOVAL

Preparation:



Remove the Maintenance Cover as described in Maintenance Cover

Removal on page 58.



Remove the Top Cover as described in Top Cover Removal on page 59.



Remove the Left and Right Side Covers as described in Left and Right

Side Cover Removal on page 60.

1. Remove the two screws securing each damper assembly, and then remove the damper assemblies.

2. Remove the four screws (CP(W2) M3x8), two on each end, that secure the mounting pins to the Roll Cover shaft.

3. While supporting the Roll Cover, pull out the mounting pins, and then remove the Roll Cover from the printer.

Mounting

Damper

Assembly

Left side of R ol l Cover

Right side

CP(W2) M3x8 screws

CP(W2) M4x8 screws

Figure 4-10. Roll Cover Removal

Disassembly & Assembly 62

EPSON Stylus Pro 9000

REASSEMBLY

LOWER PAPER GUIDE REMOVAL

ADJUSTM ENT

REQUIRED

Preparation: Remove the Maintenance Cover as described in Maintenance

Cover Removal on page 58.

1. Remove the eight screws (CP(W2) M3x6) securing the Lower Paper Guide.

After reinstalling the Lower Paper Guide, you must perform the Cutter Position Adjustment.

2. While supporting the Front Cover with your hands, lower the Lower Paper Guide as shown below. You may find it helpful to move the Front Cover up and down while removing the Lower Paper Guide.

When installing the Lower P ape r Guide, pus h it all the way up before tightening the screws; this is most likely the correct position for the Guide in relation to the cutter blade. However, you should also veri fy its position by perform ing the Cutter Position Adjustment as described in Chapter 5.

Disassembly & Assembly 63

Lower Paper Guide

Figure 4-12. Lower Paper Guide Removal

CP(W2) M3x6

Figure 4-11. Lower Paper Guide Screws

EPSON Stylus Pro 9000

Figure 4-14. Paper

Release Lever

UPPER PAPER GUIDE REMOVAL

Preparation:



Remove the Maintenance Cover as described in Maintenance Cover

Removal on page 58.



Remove the Top Cover as described in Top Cover Removal on page 59.

1. Open the Roll Cover.

2. Remove the seven screws (CP(W2) M3x6) that secure the Upper Paper Guide to the printer frame, and then remove the Upper Paper Guide.

Access Plate

NOTE:

When removing or re-installing the Upper Paper Guide, be sure the Paper Release lever is set to the lower position as shown; otherwise the paper pressure rollers will get in the way.

CP(W2) M3x6 screws

Figure 4-13. Upper Paper Guide Removal

Disassembly & Assembly 64

EPSON Stylus Pro 9000

4.3 Circuit Board Removal

Follow the steps below to remove the power supply board (C277PSU) and the main board (C277MAIN).

POWER SUPPLY BOARD REMOVAL

Preparation:



Remove the Maintenance Cover as described in Maintenance Cover

Removal on page 58.



Remove the Top Cover as described in Top Cover Removal on page 59.



Remove the Upper Paper Guide as described in Upper Paper Guide

Removal on page 64.

1. Remove the two cables connected to the Power Supply Board as shown.

2. Remove the five screws that secure the Power Supply Board, and then remove the board.

CBF M3x6 screw

Figure 4-15. Power Supply Board Removal

(viewed from in back of printer)

Disassembly & Assembly 65

EPSON Stylus Pro 9000

MAIN BOARD REMOVAL

Preparation:



Remove the Maintenance Cover as described in Maintenance Cover

Removal on page 58.



Remove the Top Cover as described in Top Cover Removal on page 59.



Remove the Upper Paper Guide as described in Upper Paper Guide

Removal on page 64.

1. Disconnect all cables from the C277MAIN Board. During reassembly, it may help to note that CN10 is the connector for the power supply fan.

2. Remove the two screws securing the Type-B Interface Cover, and remove the cover.

3. Remove the twelve screws securing the Main Board: — from overhead: nine CBF M 3x6 screws — from the back: three CP M2x4 screws

Then remove the Main Board.

CBF M3x6 CP M2x4

Figure 4-16. C277MAIN Board Removal

(viewed from behind the printer)

Disassembly & Assembly 66

EPSON Stylus Pro 9000

4.4 Maintenance Procedures

ADJUSTM ENT

REQUIRED

When the service call error occurs, you need to replace the following parts:



the Waste Ink Pads in the left and right Waste Ink Boxes



the Flushing Boxes (right and left)



the Pump As sembly



the Capping Assem bly



the Head Cleaner Blade

In addition to replacing these parts, you also need to do the following:



perform the Cutter Position Adjustme nt after reinst alling the Lower Paper Guide, as described in Cutter Position Adjustment



reset the waste ink counter (“Init. Waste Ink”) as described in Maintenance

Mode 2 on page 17



reset the cleaning unit counter (“Init. Cleaning Unit”) as described in

Maintenance Mode 2

Refer to the steps below to replace the Waste Ink Pads and other parts that are mounted on the Maintenance Assembly.

To keep the printhead clean and maintain print quality, the printer periodically flushes ink through the printhead, and the flushed ink drains into one of two Waste Ink Boxes. Once a predetermined amount of ink has drained into the Waste Ink Boxes, the printer displays the service call error—“00000100.”

on page 131

on page 17

REPLACING THE WASTE INK PADS

Refer to the figure below to locate the left and right Waste Ink Boxes:

Left Waste Ink Box

Right Waste

Ink Box

Figure 4-17. Waste Ink Box Locations

Preparation:



Remove the Maintenance Cover as described in Maintenance Cover

Removal on page 58.



Remove the Lower Paper Guide as described in Lower Paper Guide

Removal on page 63.

Disassembly & Assembly 67

EPSON Stylus Pro 9000

CAUTION

ADJUSTM ENT

REQUIRED

1. Remove the screws that secure the Waste Ink Boxes to the printer (see the figures below), and then remove the Waste Ink Boxes.

Waste Ink Box L

CP(W2) M4x8

Figure 4-18. Left Waste Ink Box

Waste Ink Box R

CP(W2) M4x8 screws

Figure 4-19. Right Waste Ink Box

2. Remove the Waste Ink Pads from the left and right Waste Ink Boxes.

Disassembly & Assembly 68

Prepare a viny l bag beforehand for dispo si ng of t he pads.

After replacing the Waste Ink Pads, perform the following adjustments:



reset the waste ink counter



reset the initial cleaning flag [???right name???]



perform the Cutter Position Adjustment

EPSON Stylus Pro 9000

MAINTENANCE ASSEMBLY REMOVAL & DISASSEMBLY

When replacing the Waste Ink Pads, you also have to replace other parts (see

Maintenance Procedures

following:



Right Flushing Box



Pump Mechanism



Capping Mechanism



Head Cleaning Blade

Preparation:



Remove the Maintenance Cover as described in Maintenance Cover

Removal on page 58.



Remove the Top Cover as described in Top Cover Removal on page 59.



Remove the Right Side Cover as described in Left and Right Side Cover

Removal on page 60.



Remove the Lower Paper Guide as described in Lower Paper Guide

Removal on page 63.



Remove the right-side Waste Ink Box as described in Replacing the Waste

Ink Pads on page 67.

on page 67). Refer to the steps below to replace the

1. Disconnect CN9 and CN19 from the relay board on the right side of the printer. See Figure 4-21

2. Remove two screws (CP(W2) M4x6) securing the Maintenance Assembly to the printer as shown below. Access the screws from underneath the Maintenance Assembly. (The screw on the right is hidden, so you may have to get down very low to see it.)

Two screws (the one on the right is hidden)

Figure 4-20. Maintenance Assembly Removal - 1

Disassembly & Assembly 69

EPSON Stylus Pro 9000

3. From the right side of the printer, remove the one remaining screw (CP(W2) M3x6) securing the Maintenance Assembly to the printer, and then remove the Maintenance Assembly.

CAUTION

When removing the Maintenance Assembly, the tubes that drain ink into the Waste Ink Pads may leak or drip ink. It’s a good idea to wipe off the ends of these tubes before removing the Maintenance Assembly.

One screw

Relay Board

4. Remove the two screws (CP(W2) M3x6) securing the Carriage Lock to the Maintenance Assembly, and then remove t he Carriage Lock.

Capping Mechanism

Pump

Mechanism

Carriage

Lock

Screws securing

capping mechanism

to frame

Right Flushing B ox

Figure 4-22. Disassembling the Maintenance Assembly - 1

5. Remove the two screws (CP(W2) M3x6) securing the Capping Mechanism to the frame of the Maintenance Assembly. Lift the Capping Mechanism off the frame (it’s still attached to the Pump Mechani s m by the ink tubing).

Figure 4-21. Maintenance Assembly Removal - 2

6. Remove the Pump Drive Shaft.

7. Remove the screw (CP(W2) M3x6) securing the Pump Mechanism to the frame of the Maintenance Assembly, and then remove the Pump Mechanism along with the Capping Mechanism.

8. Remove the screw securing the Flushing Box to the frame of the Maintenance Assembly, and then remove t he Flushing Box.

Disassembly & Assembly 70

EPSON Stylus Pro 9000

CAUTION

ADJUSTM ENT

REQUIRED

REASSEM BLY

Pump

Mechanism

Carriage

Lock

If you re-install the same Capping Mechanism, be sure to check the following:



After re-installing the springs that hold the Capping Mechanism in place, try sliding the mechanism by hand to make sure it operates smoothly.



Make sure the air bleed valve seals properly when the Capping Mechanism pushes all the way ag ainst it.

Flushing B ox

Pump Motor

Capping

Mechanism

Pump Drive

Shaft

4.5 Printer Mechanism Disassembly

Follow the steps below to remove the main components of the printer mechanism.

Do not attempt to disassemble any components other than those described below. Certain repairs can be done onl y at the factory and can permanently damage the printer if not done correctly.

REPLACING THE PRINTHEADS

The printer uses two printheads, Head B and Head C. Although they are similar, the y are no t int erch angeable . One is for dark ink, the other for light ink. Make sure you install the correct replacement head accordingly:



Head B (f or dark ink; go es on the left) F055040: “Printhead, IJ192-OA D”



Head C (for light ink; goes on the right) F055050: “Printhead, IJ192- OAE”

ADJUSTM ENT

Disassembly & Assembly 71

Bleed Valve

Figure 4-23. Disassembling the Maintenance Assembly - 2

REQUIRED

When replacing the Lower Pap er Guide, you need to perform the Cutter Position Adjustment.

When replacing the printheads, you have to perform various adjustments. See Required Adjustments

Preparation:



Remove the Maintenance Cover as described in Maintenance Cover

Removal on page 58.



Optional:

page 59. Although t his is an extra step, it provides more light and room.

Remove the Top Cover as described in Top Cover Removal on

on page 103.

EPSON Stylus Pro 9000

1. Turn the ink valve knob located on the sides of the Ink Cartridge Holders to the “Close” position, or depress and then lift up the I/C Holder levers. Both operations perform the same function of shutting off the flow of ink from the ink cartr i d g es.

2. Manually release the Carriage Lock by pulling up on the release lever as shown below, and then move the carriage away from the capping position.

Carriage Lock Release

3. Remove two screws (CB M3x6) as shown below, and remove the carriage cover.

CB M3x6 screw

Figure 4-25. Carriage Cover Removal

Figure 4-24. Carriage Lock Release

Disassembly & Assembly 72

EPSON Stylus Pro 9000

CAUTION

4. Unhook the ink tubes from the damper holder.

Damper Holder

Figure 4-26. Damper Holder Removal

6. Pull out the dampers. To remove them, place the tip of a flat-head screwdriver under rear-most (or upper-most) portion of each damper as shown, and gently pry it out.

Avoid squeezing the dampers. Handle them only by their edges. If pressure is applied to the middle of the dampers, the ink inside will squirt out.

Damper

5. Remove the screw (CP(W2) M3x6) securing the damper holder and ground wire. Then remove the Damper Holder by first pulling its left side out toward you (forward), and then sliding the whole unit out toward the right.

REASSEM BLY

The ground wire connector attaches to the carriage between the head of the screw and the plastic Damper Holder.

Disassembly & Assembly 73

Figure 4-27. Damper Removal

EPSON Stylus Pro 9000

CHECK

PO INT

7. Using needle-nosed pliers, remove the Tension Spring.

Tension S pri ng

CB M3x6

10. Repeat steps 10 and 11 for the other printhead if necessary.



When replacing the printheads, fold the flat cable behind the printhead and make sure the printhead snaps fully into place. When properly installed, the printhead ID is directly behind and at the same height as the PG Cam Shaft. If the PG Cam Shaft does not partially block the line of sight of the printhead ID (when looking at the ID from straight in front), the printhead is not installed properly.



When attaching the dampers to the printhead, follow the same orde r, l ef t to righ t, a s shown on the con tr ol panel : K, C, M, LC, LM, Y.

Figure 4-28. Printhead Tension Spring and Screw Removal

8. Remove the CB M3x6 screw, and then remove the printhead from the carriage.

9. Remove the flat cable from the back of the printhead.

Disassembly & Assembly 74

EPSON Stylus Pro 9000

W ARNING

REMOVING THE CARRIAGE MOTOR ASSEMBLY

Preparation:



Remove the Maintenance Cover as described in Maintenance Cover

Removal on page 58.



Remove the Top Cover as described in Top Cover Removal on page 59.



Remove the Left and Right Side Covers as described in Left and Right

Side Cover Removal on page 60.

1. Manually release the Carriage Lock and move the carriage away from the capping position, as shown in Figure 4-24

2. On the Left Side Frame, loosen the two screws shown below to reduce tension on the CR Drive Belt.

CR Drive Belt Pulley

3. Remove the hex screw that secures the CR Drive Belt to the right side of the carriage assembly.

CR Drive Belt

Remove one Hex Screw: 2.5mm

Figure 4-30. Removing the CR Drive Belt

4. Pull the loose end of the Carriage Drive Belt out through the Right Side Frame.

The edges of the CR drive belt may be sharp. Exercise caution when remov ing the belt.

Loosen these two screws.

Figure 4-29. Loosening the CR Drive Belt

Disassembly & Assembly 75

EPSON Stylus Pro 9000

5. Remove the four screws securing the CR Motor Assembly to the Right Side Frame, and then remove the CR Motor Assembly.

Four CP(W2) M4x8

Figure 4-31. CR Motor Removal

REMOVING THE PF MOTOR ASSEMBLY

Preparation:



Remove the Maintenance Cover as described in Maintenance Cover

Removal on page 58.



Remove the Top Cover as described in Top Cover Removal on page 59.



Remove the Left Side Cover as described in Left and Right Side Cover

Removal on page 60.



Remove the Lower Paper Guide as described in Lower Paper Guide

Removal on page 63.

1. Loosen the four screws (CP(W2) M4x12) on the PF Motor Mounting Bracket as shown below to reduce the tension on the timing belt.



REASSEM BLY

ADJUSTM ENT

REQUIRED

When re-assembling the CR Motor Assembly, move the

carriage back and forth by hand, and adjust the screws in

Figure 4-29

(The belt must be within 1 mm of the center of the pulley.)



The white CR Motor lead connects to the terminal marked

“+” and the black lead connects to the terminal marked “-”.

After removing the CR Motor, you must perform the CR Drive Belt Tension Adjustment.

until the CR Drive Belt is centered on the pulley.

PF Motor Cable Connector (black and white wires)

CP(W2) M4x12 screws: only loosen

Figure 4-32. Loosening the Timing Belt

2. Disconnect the PF Motor cable connector as shown in the figure above (black and white wires).

Disassembly & Assembly 76

EPSON Stylus Pro 9000

ADJUSTM ENT

REQUIRED

3. Disconnect the PF Motor Encoder cable connector (black, gray, and white wires).

4. Remove the two CP(W2) M3x8 screws securing the PF Motor to the PF Motor Mounting Bracket, and then remove the PF Motor. If necessary, raise up the PF Motor Mounting Bracket to reduce belt tension while removing the motor.

5. If you need to remove the timing belt, remove the four screws (CP(W2) M4x8) securing the Speed-Reduction Gear Fram e, and then remove the frame and the belt.

Speed-Reduction

Gear Frame

CP(W2) M4x8

Disassembly & Assembly 77

CP(W2) M3x8

Figure 4-33. PF Motor Removal

Figure 4-34. Timing Belt Removal

After reinstalling the Lower Paper Guide, perform the Cutter Position Adjustment.

EPSON Stylus Pro 9000

ADJUSTM ENT

REQUIRED

REMOVING THE PLATEN GAP ADJUSTMENT MOTOR

Preparation:



Remove the Maintenance Cover as described in Maintenance Cover

Removal on page 58.



Remove the Top Cover as described in Top Cover Removal on page 59.



Remove the Right Side Cover as described in Left and Right Side Cover

Removal on page 60.

1. Disconnect the cables from CN17 and CN18 on the relay board.

2. Remove the two screws (CP(W2) M3 x8) se cu ri n g the PG Motor to the side frame, and then remove the motor.

After reinstalling the PG Motor, perform the gear backlash adjustment.

REMOVING THE PLATEN GAP HOME POSITION SENSOR

Preparation:



Remove the Maintenance Cover as described in Maintenance Cover

Removal on page 58.



Remove the Top Cover as described in Top Cover Removal on page 59.



Remove the Right Side Cover as described in Left and Right Side Cover

Removal on page 60.

1. Disconnect the cable from CN17 on the relay board on the right side of the printer.

2. Remove the two screws securing the Platen Gap HP Sensor to the PG Adjustment Motor mounting plate, and then remove the sensor.

Disassembly & Assembly 78

Figure 4-35. PG Motor Removal

NOTE:

A No. 1 (small) Phillips screwdriver is needed to remove these screws.

Platen Gap HP Sensor

Figure 4-36. Removing the Platen Gap HP Sensor

EPSON Stylus Pro 9000

ADJUSTM ENT

REQUIRED

REMOVING THE COVER OPEN SENSORS

The Cover Open Sensors (interlock switches) are a safety feature to detect the position of the Front Cover (open or closed). There are two switches (right and left). Printing stops when the cover is open.

Preparation (to remove the right interlock switch):



Remove the Maintenance Cover as described in Maintenance Cover

Removal on page 58.



Remove the Top Cover as described in Top Cover Removal on page 59.



Remove the Right Side Cover as described in Left and Right Side Cover

Removal on page 60.

To remove the left interlock switch, also do the following:



Remove the Left Side Cover as described in Left and Right Side Cover

Removal on page 60.



Remove the Upper Paper Guide as described in Upper Paper Guide

Removal on page 64.

1. To remove the Right Interlock Switch, disconnect the cable from CN13 on the relay board as shown below.

2. Remove the two screws (CP(W2) M3x6) securing the Interlock Switch mounting plate to the side frame, and remove the Interlock Switch together with the plate.

3. To remove the Left Interlock Switch, disconnect the cable from CN27 on the C277MAIN board.

4. Remove the two screws (CP(W2) M3x6) securing the Interlock Switch mounting plate to the side frame, and remove the Interlock Switch together with the plate.

Disassembly & Assembly 79

CN13

Switch

Figure 4-37. Interlock Switch (R) Removal

Figure 4-38. Interlock Switch (L) Removal

Perform the adjustment for the

(Right and left)

on page 135.

Cover Open Sensor Assembly

EPSON Stylus Pro 9000

ADJUSTM ENT

REQUIRED

REMOVING THE PAPER THICKNESS SENSOR

Preparation:



Remove the Maintenance Cover as described in Maintenance Cover

Removal on page 58.



Remove the Top Cover as described in Top Cover Removal on page 59.



Remove the Right Side Cover as described in Left and Right Side Cover

Removal on page 60.

1. Disconnect the cable from CN12 on the relay board on the right side of the printer.

2. Remove the two screws (CP(W) M3x6) securing the Paper Thickness Sensor, and remove the sensor.

REMOVING THE REAR PAPER SENSOR

Preparation:



Remove the Maintenance Cover as described in Maintenance Cover

Removal on page 58.



Remove the Top Cover as described in Top Cover Removal on page 59.



Remove the Upper Paper Guide as described in Upper Paper Guide

Removal on page 64.

1. Disconnect the cable from CN11 on the C277MAIN board.

2. Remove the screw (CP(W) M3x6) securing the Rear Paper Sensor, and remove the sensor.

ADJUSTM ENT

Disassembly & Assembly 80

REQUIRED

Figure 4-39. Paper Thickness Sensor Removal

Perform the

Paper Thickness Sensor Adjustment

on page 134.

Figure 4-40. Rear Paper Sensor Removal

Perform th e

Rear Sensor Position Adjustment

on page126.

EPSON Stylus Pro 9000

REMOVING THE FRONT PAPER SENSOR

Preparation:



Remove the Maintenance Cover as described in Maintenance Cover

Removal on page 58.



Remove the Lower Paper Guide as described in Lower Paper Guide

Removal on page 63.

1. Disconnect the cable from CN11 on the relay board.

2. Remove the screw (CP(W) M3x6) securing the Front Paper Sensor, and remove the sensor.

REMOVING THE PAPER RELEASE SENSOR

The Paper Release Sensor detects the position of the Paper Release Lever. Preparation:



Remove the Maintenance Cover as described in Maintenance Cover

Removal on page 58.



Remove the Top Cover as described in Top Cover Removal on page 59.



Remove the Right Side Cover as described in Left and Right Side Cover

Removal on page 60.

1. Disconnect the cable from CN10 on the relay board.

2. Remove the two screws (CP(W) M3x6) securing the Paper Release Sensor, and remove the sensor.

Paper Release Sens or

One screw

(behind the sensor board)

Figure 4-41. Front Paper Sensor Removal

ADJUSTM ENT

REQUIRED

After reinstalling the Lower Paper Guide, you need to perform the

Cutter Position Adjustment

on page 131.

Figure 4-42. Paper Release Sensor Removal

Disassembly & Assembly 81

EPSON Stylus Pro 9000

REMOVING THE CARRIAGE HOME POSITION SENSOR AND ENCODER

Preparation:



Remove the Maintenance Cover as described in Maintenance Cover

Removal on page 58.



Remove the Top Cover as described in Top Cover Removal on page 59.

1. Disconnect the cables from CN2 (Encoder) and CN4 (HP Sensor) on the carriage circuit board.

2. Remove the two screws (CP(W2) M3x6) securing the circuit board mounting frame to the carriage assembly.

Screw

Figure 4-43. Disconnecting the Cables

Figure 4-44. Removing the Circuit Board Mounting Frame Screws

Disassembly & Assembly 82

EPSON Stylus Pro 9000

CAUTION

3. Separate the circuit board and its mounting frame from the carriage assembly by lifting them up as shown below.

4. Remove the two screws (CP(W2) M3x6) securing each sensor to the back of the circuit board mounting frame, and remove the sensors.

Avoid scratching the timing fence when removing the Encoder.

Carriage HP Sensor

Encoder Sensor

Figure 4-45. Removing the Carriage HP Sensor and Encoder Sensor

Disassembly & Assembly 83

EPSON Stylus Pro 9000

4.6 Ink Holder Disassembly

This section describes how to remove and disassemble the Ink Holder Assembly.



CAUTION

4.6.1 Removing the I/C Holder Assembly

1. Perform the ink discharge operation to eject inks from all ink paths. See

Clean Head (Drain Ink)

Before removing the Ink Holder Assembly, you have to discharge all ink from the ink system. See step 1 below.



After reassembling the Ink Holder Assembly, install new ink cartridges and perform the Initial Ink Charge operation.

Cleaning menu

See

on page 127.

on page128.

2. Remove the side covers (L/R). See Left and Right Side Cover Removal page 60.

3. Remove the four screws (CP(W2) M3x6) secureing 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.

4. Remove the four screws (CP(W2) M2x4) securing the access cover attached at the back of the I/H assembly.

Ink tube fixing plate

Figure 4-46. Disconnecting the ink tubes

Figure 4-47. Removing the access cover

Disassembly & Assembly 84

EPSON Stylus Pro 9000

5. Loosen two screws securing the fixintg plate that holding the ink tubes and a FFC inside the I/H assembly. And unhook two tabs and remove the hand hold cover.

6. Remove the two screws (CP(W2) M3x6) securing the ink tube holder plate, and disconnect the FFC from the connector on the I/H relay board attached at the bottom of the I/H assembly as shown at right.

CHECK

PO INT

To remove two screws securin g the ink tube holder plate, you need a short-neck screwdriver .

Figure 4-49. Removing the FFC

Push to release the tabs

Figure 4-48. Removing the fixing plate

Disassembly & Assembly 85

EPSON Stylus Pro 9000

7. Remove the seven screws (CP(W2) M4x6) securing the I/H assembly to the printer mechanism, and slightly push it up as to unhook the assembly from the side frame of the printer mechanism.

Push to unhook

Figure 4-51. Removing the screws (4 pcs)

Figure 4-50. Removing the screws (3 pcs)

Figure 4-52. I/H Assembly

Disassembly & Assembly 86

EPSON Stylus Pro 9000

8. Remove the six screws (CP(W2) M2x4) securing the side cover of the I/H assembly and remove the side cover.

9. 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 the assembly.

Remove

Figure 4-53. Removing the side cover of I/H assembly

Figure 4-54. Removing the friction gear assembly.

Disassembly & Assembly 87

EPSON Stylus Pro 9000

10. Remove the I/C holder assembly from the I/H assembly frame.

11. Remove the two screws (CP(W2) M3x4) securing the I/C cover to the I/C holder assembly. Then, remove the five screws (2 pcs=CP(W2) M3x4, 3 pcs=P-Tight M3x4) securing the I/C holder fixing plate.

12. The I/C holder for each color can be removed individually. To remove one of the I/C holder assembly, remove the one screw (CP(W2) M3x12) securing the I/C holder assembly to a base frame of the I/H assembly.

13. Turn the I/C holder assembly upside down and remove the one screw (CP(W2) M3x4) securing the I/C holder from the back of the base frame.

I/C Cover

Figure 4-56. Removing the screw (from the top)

I/C Holder Fixing Plate

Figure 4-55. Removing the I/C cover and the fixing plate

Figure 4-57. Removing the screw (from the bottom)

Disassembly & Assembly 88

EPSON Stylus Pro 9000

14. Loosen the lock nut and remove the ink pipe from “HOLDER ASSY., VALVE, A” of th e I/ C hold e r .

15. Remove the two cables corresponding to the I/C holder to be removed from the connector on the I/H relay board.

Table 4-3. Connection between each I/C holder and relay board

I/C Holder I/C ID senso r

I/C sensor

and Ink low sensor

Lock Nut

HOLDER ASSY., VALVE,A

Figure 4-58. Removing the ink pipe

Black (Light Cyan)

Cyan (Light Magenta)

Magenta (Yellow)

CN4

CN6

CN7

CN5

CN3 CN4

CN5 CN6

CN7 CN8

Magenta / Yellow Holder Cyan / LM Holder

Black / LC Holder

CN3

CN1

FFC

CN8

CN2

I/H position sensor

Figure 4-59. Connector location on the I/H relay board

Disassembly & Assembly 89

EPSON Stylus Pro 9000

16. Remove the one screw (CP(W2) M2x4 with a metal bushing) securing the I/C link to the I/C eject lever.

17. Remove the I/C holder assembly from the I/H assembly.

Figure 4-61. Removing the I/C holder

Figure 4-60. Removing the screw (I/C link)

Disassembly & Assembly 90

EPSON Stylus Pro 9000

4.6.2 Disassembling the I/C Holder

1. Unhook the hooks fixing the upper I/C guide and slide it backward. Then slide out the metal bracket that holds the I/C ID sensor board.

2. Remove the two screws (CP(W2) M3x4) se cu r i n g the “ HOLDER ASSY., VALVE, A” to a base frame.

3. If necessary, remove the I/C In sensor assembly or the Ink Low sensor assembly.

Upper I/C guide

Metal bracket

Base frame

“HOLDER ASSY., VALVE,A”

Figure 4-62. I/C Holder

Upper I/C guide

Bottom I/C guide

I/C ID Sensor board

Metal bracket

Figure 4-63. I/C Holder Disassembly (1)

Ink low sensor

Bottom I/C guide

I/C In sensor

Figure 4-64. I/C Holder Disassembly (2)

Disassembly & Assembly 91

EPSON Stylus Pro 9000

4.7 Removing the Ink Tubes

This section describes how to remove the ink tubes connected to the printhead on the carriage assembly.

CAUTION

PREPARATION

1. Remove the Maintenance cover, Top Cover, and Right Side Cover.

2. Make sure both I/H Levers are raised to close the ink valves.

REMOVING THE INK PIPE COVERS

1. Remove two CR cable fixing plates, two tube fixing plates (C), and the tube guide fixing plate.

2. Remove the two center-most ink tube fixing devices (B); one for each set of ink pipes.

After reassembling the Ink Tubing, install new ink cartridges and perform the Initial Ink Charge operation. See

Cleaning menu

Joint screw

on page 128.

Tube guide fixing plate

CR cable fixing plate

SEPARATING THE INK PIPES AND INK TUBES

1. Loosen the screws securing the ink tubes to the ink pipes, and separate the tubes from the pipes. The screw and O-rings should remain on the tube ends.

NOTE:

You need one black joint for each tube and pipe connection. If the replacement tubes do not come with the joints, make sure the joints stay in the screws on the pipe side.

Tube fixing device B

Tube fixing plate C

Disassembly & Assembly 92

EPSON Stylus Pro 9000

REMOVING THE CR CIRCUIT BOARD

1. Remove the CR circuit board guide plate, cut the insulation (plastic) lock tie next to the Ferrite core, and remove the cable support.

CR circuit board guide plate

Cable support

Ferrite core

NOTE:

2. Remove two printhead FFCs and four connectors. (CN9 is not in use.)

You may dispose of the CR circuit board guide and cable support.

CR circuit board assembly

3. Remove 4 flat core pieces from the tape wires (two from the FFCs to the printheads and two from the FFCs to the junction board). Remove the metal snaps securing the ferrite core and then remove the ferrite core pieces.

4. Remove the CR circuit board.

DISCONNECTING THE INK DAMPERS

1. While holding down the cutter, remove the carriage cove r.

2. Remove the cutter and cutter solenoid.

3. Cut the insulation (plastic) lock ties that hold the ink tubes in place.

4. Loosen the damper joint screws and remove the ink tubes from the dampers.

Cable connection plate

Damper joint screw

5. Remove the H cable pressing plate (black) that secures the printhead FFCs to the inside of the cable connection plate.

CR tape wire 1 CR tape wire 2

Disassembly & Assembly 93

EPSON Stylus Pro 9000

REMOVING THE CABLE CONNECTION PLATE

1. Insert a screwdriver through one of the holes in the ink t ube support f rame, loosen the two screws securing the tube guide fixing plate on the underside of the cable connection plate, and remove the plastic ink tube guide protector on the top-right side of the cable connection plate. (Use a 100 mm to 150 mm length plus/cross head (Phillips) driver.)

CHECK

PO INT

NOTE:

2. Carefully remove the cable connection plate so as not to scratch or catch the timing fence. The carriage FFCs, tube guides, and tube guide fixing plate will come off with the cable connection plate.

3. Disconnect the FFCs from the junction board, and remove the FFCs.

If the printer has been used, there is a chance the screws at either end of the ink tube support frame may be worn. The ink tube guides and cables rub these screws ever y time they make a pass. If the heads of the screws are worn, replace the screws.

If the replacement ink tubes do not have a O-rings and screws, remove the O-rings and screws from the old tubes and put them aside for re-use later.

4. Remove the HP position (head origin) and Linear Encoder (CR ENC) sensor as s e m b lies fro m the ba c k o f th e cab l e con n ec ti o n p lat e ; yo u w ill use them again.

CR ENC assembly Head origin detector assembly

Cable connection plate

Reverse side of cable connection plate

Disassembly & Assembly 94

EPSON Stylus Pro 9000

CHECK

PO INT

CHECK

PO INT

Dark color

tubes

Light color

tubes

LMYLooking at the tubes from the ink pipes’

point of view

4.7.1 Ink Tubing Reassembly

This section describes how to re-assemble the ink tubes and related components.

INSTALLING THE CABLE CONNECTION PLATE

1. Attach the HP position and Linear Encoder sensor assemblies to the cable connection plate.

2. Re-attach the cable connection plate while making sure the Timing Fence is in the middle of the Linear Encoder sensor. Lightly secure the cable connection plate with two screws, and connect the ground to the screw on the left. While looking through the hole on the right side frame to make sure the timing fence is exactly in the middle of the sensor, tighten the cable connection plate screws.

POSITIONING THE TUBE GUIDES AND FFCS

1. Line up the new FFCs and make sure their folds overlap; one FFC will fit into the fold of the other. The double-sided tape (white) on one of the FFC cables must be showing on top.

2. Lay down the FFCs in the H Top frame with the multi-folded end protruding through the hole in the right-side frame. With the double-sided tape facing the front wall of the H Top frame, put the FFCs in the clips. The fold in the middle of the FFCs should be right in the middle of the printer.

3. Lay the left-side bottom layer protective film down on the left side and put the new FFCs on top of that film. Lay the next left-side protective film on top of the FFCs, and then lay the new tube guide for the light ink on top of the film.

The side of the tube guide that has only four joints must attach to the ink pipes in the center. The side with seven joints must attach to the ink dampers in the carriage.

4. Lay down the right side protective film, and put the new tube guide for the dark inks on top of the film. Make sure there are only four joints on the ink pipe end of the tube guide.

Make sure the three ink tubes in the tube guides are straight and in a const ant tr i angle throughout the tube guides to prevent the tubes from overlapping, twisting, or pinching.

Look throug h th is hol e to line up t he encoder

sensor and the timing fence.

3. Pull the printhead FFCs through the uppper-rear slot in the cable connection plate. While pulling the ends of the FFCs to remove any slack, secure the printhead FFCs and the H cable plate with two screws.

4. Fold the right FFC slightly in the middle so the lengths of the two FFCs are the same.

Disassembly & Assembly 95

EPSON Stylus Pro 9000

Align the

edge of the

tube guid e

here.

Tube guid e

fixing p lat er

Protective

film

CONNECTING THE INK TUBES TO THE INK PIPES

1. Make sure the ink tubes on the ink pipe side are uncovered for about 45 mm.

2. Make sure there is a screw and O-ring on the end of each ink tube. If some are missing, use ones from the old ink tubes.

3. Insert the inner clear tube into the corresponding color ink pipe as far as it will go. Repeat for all six tubes.

4. Secure the joint screws by hand temporally, and use the torque wrench (1.75Å}0.25kgf/cm) to fasten the screws completely. The ink tube must be inserted completely, and the O-ring must not be twisted.

CHECK

PO INT

Make sure the end of the tube guide that attaches to the ink pipes has only FOUR joints.

CR cable

fixing plate

CR fixing plate C

(underneath)

Tube guid e fixing plate

SECURING THE THE INK TUBES AND INK PIPES

1. Slide the UL tube adjuster (on the end of each tube) towards the joint screw side.

2. Place the CR fixing plate over the ink tubes and carefully but firmly press down until all three tubes are secure. Repeat for the other side.

3. Secure the tube guides and ink tubes with the CR cable fixing plates and tube guide fixing plate, then insert and close two screw(3Å~20) to secure the CR cable fixing plates. At this time, the tube guide sticks out about 6mm from the tube guide fixing plate.

4. Place the black tube fixing plate over the ink pipes (over the black pad), and press down to make sure all the pipes are secured by the plate. Secure the plate with a screw (3Å~16), and repear for the other side.

SECURING THE TUBE GUIDES ON THE CR SIDE

1. Place both tube guides on the cable connection plate, aligning the ends of both tube guides with the far edges of the cable connection plate.

2. Put the right-side protective film on top of the cable connection plate and tube guide. Make sure the protective film is not too loose or too tight.

3. Put the new tube guide fixing plate on top of the tube guides and protective film, and secure all with three screws.

4. Make sure there is no gap between the protective film and the tube guide.

6mm

Tube guid e

Disassembly & Assembly 96

EPSON Stylus Pro 9000

CHECKING THE INK TUBES

Move the carriage all the way back and forth to make sure the tubes do not come loose from the open section of the tube guide when the CR is moving.

CHECK

PO INT

If a tube sticks out as far as the top of tube guide, check the twisting of the ink tube in the tube guide, and fix as needed.

Wrong

CONNECTING THE CARRIAGE FFCS

1. Make sure the FFCs are properly overlapped; the one with the shorter end should be underneath and the one with the longer end should be on top.

2. Slide the ferrite core pieces onto the FFCs.

3. Put the FFCs on the tube guide fixing plate, and make sure the fold of the FFCs lines up with the FFC connectors on the CR board. Also, make sure there is no gap between the tube guide, FFCs, and protective film sheets.

4. Attach the new cable support.

ATTACHING THE CR CIRCUIT BOARD

1. Secure the CR circuit board assembly to the cable connection plate with two screws.

2. Slide the flat core pieces onto the two printhead FFCs and connect the FFCs to the circuit board.

3. Insert the other 4 connectors into the corresponding CR board connectors. CN9 is not used.

Cable support

Disassembly & Assembly 97

EPSON Stylus Pro 9000

The order of the ink tubes is shown on the

control pan el .

CONNECTING THE INK TUBES AND DAMPERS

1. Return the carriage to the home position.

2. Arrange the dark series ink tubes from the tube guide to the dampers. The ink tubes should pass through the slot on the left side of the cable connection plate. Be sure not to twist the three tubes.

3. Make sure the tubes all have screws and O-rings on the ends.

4. Take one ink tube and apply cleaning liquid to the O-ring.

5. Insert the ink tube into the corresponding color damper as far as it will go, and close the screw by hand for now.

6. Make sure the ink tube is not twisted or bent and the O-ring is not twisted. Use the torque wrench (1.75Å}0.25kgf•cm) to tighten the screw completely.

7. Slide down the UL tube adjuster to the screw, and press down the tube to make sure it is fully inserted into the screw and damper. The ink tube should be covered completely.

8. Repeat steps four through seven for all dark color ink tubes.

9. Shift the carriage all the way to the left.

10. Arrange the dark series ink tubes from the tube guide to the dampers. The ink tubes should pass through the slot on the right side of the cable connection plate. Be sure not to twist the three tubes.

11. Connect the light color ink tubes as described in steps 3 through 8, substituting light for dark.

12. Secure the light-colored ink tubes to the cable connect ion plate with the plastic insulation lock (KI-100M).

Insulation lock (KI-100M)

Disassembly & Assembly 98

EPSON Stylus Pro 9000

Make sure nothing touches the left-side

frame.

13. Secure the dark-colored ink tubes and ferrite core to the cable connection plate with the plastic insulation lock (KI-100M).

Ferrite core

NOTE:

Insulation lock (KI-100M)

At this point in re-assembly, the tube guide assembly (tube guide, FFCs, and protective film) is attached to the cable connection plate with the cable support.

CONFIRMING THE TUBE GUIDE ASSEMBLY POSITION

1. Move the carriage all the way from one side to the other to make sure the tube guide assemblies stay centered in the carriage path.

If any part of the tube guide assembly on the left moves laterally (towards the front or back of the printer), loosen the ink pipe fixing side of the tube guide fixing plate and CR cable pressing plate. Then adjust the tube guide assembly so that it is centered, and secure the tube guide fixing plate and CR cable fixing plate.

If any part of the tube guide assembly on the right moves laterally, loosen the tube guide cover and CR cable fixing plate. Then adjust the tube guide assembly so that it is centered, and secure the tube guide cover and CR cable fixing plate.

2. Squeeze the FFC ferrite core and the cable support together, and secure them with the plastic insulation lock (T18L).

3. Move the carriage to the left so that the left edge of t he CR board i s 43 mm from the left-side frame. Make sure the ferrite core and cable support do not touch the frame or screw. Also, make sure the FFC and protective film do not touch or rub against the frame. If there is a problem, loosen the tube guide fixing plates in the center and adjust the position of the edge of the tube guide.

4. Attach the new CR board cover.

Disassembly & Assembly 99

EPSON Stylus Pro 9000

CONNECTING THE CARRIAGE FFCS TO THE RELAY CIRCUIT BOARD

1. Peel off the backing of the double-sided adhesive tape at two places: the wall surface toward the right frame and the folded section near the center.

2. Make sure the FFCs are aligned and peel off the backing of the doublesided adhesive tape on the second FFC. Attach the second FFC to the back of the first one.

3. Fold the FFCs into three sections as shown below, and attach acetate rayon tape.

4. Connect the FFCs to the relay board connectors.

Acetate rayon tape

RESETTING THE PRINTER

1. Install new ink cartridges in the printer.

2. Enter the Self-Diagnostic Mode (see Using the Self-Diagnostic Mode page 108) and adjust the capping position (see Cap Position Adjustment on page 116). After the printer automatically adjusts the cap position (a number appears on the LCD), press the Enter button on the control panel.

3. Perform an initial ink charge (“Init. Fill” in the Cleaning menu of the Self-Diagnostic Mode). Check the ink discharge condition as well as the amount of ink in the dampers. Make sure there are no bubbles, which would indicate a leak in the ink delivery system.

4. Attach the carriage cover and perform the carriage cover height adjustment. See Carriage Cover Height Adjustment

5. Lower the Paper Release Lever to prevent damage to the Paper Thickness Sensor, and then re-attach the Top Cover, being careful not to bump the sensor.

6. Load 44 inch roll paper and print a test pattern (see Check Nozzle page 118). Check the operation of the printer, and make sure the order of printed colors in the check nozzle pattern is B, C, M, Y, LM, LC from the left.

7. Enter Maintenance Mode 2 as described in Maintenance Mod e 2 page 17. Then reset the Ink Counter (“Init. Ink”) and CR Motor Counter (“Init. CR Motor”).

on page 130.

on page 128

CHECK

PO INT

As shown in the photo above, make sure the FFC does not block the tube guide assembly from movi ng all the way to the right.

Disassembly & Assembly 100

Epson 9000 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

EPSON Stylus Pro 9000

Guide to Using This Manual

FCC COMPLIANCE STATEMENT

PRECAUTIONS

Contents

1.1 Features

1.2 Control Panel Operations

1.2.1 Control Panel Buttons

1.2.2 SelecT ype Mode

PRINTER SETTING MENU

TEST PRINT MENU

PRINTER STATUS MENU

PAPER CONFIGURATION MENU

HEAD ALIGNMENT MENU

CUTTER REPLACE MENU

1.2.3 Service-Related Modes

1.3 LED Indicators and Error Messages

1.3.1 LED Indicators

1.3.2 LCD Display

1.4 Options and Consumables

2.1 Location of Components

CARRIAGE MECHANISM

PAPER FEED MECHANISM

INK SYST EM

CIRCUIT BOARDS

2.2 Operation

2.2.1 Carriage Mechanism

CARRIAGE (CR) GUIDE RAIL

PLATEN GAP (PG) MECHANISM

PAPER WIDTH SENSOR

CARRIAGE MOTOR AND POSITION CONTROL

CUTTER MECHANISM

PRINTHEADS

2.2.2 Paper Feed Mechanism

PAPER FEED MOTOR AND ROLLERS

PAPER FEED SENSORS

PAPER SUCTION FAN

PAPER WIDTH DETERMINATION (LEFT AND RIGHT EDGE DETECTION)

PAPER SIZE DETERMINATION (DETECTION OF TOP EDGE)

PAPER LOADING ERRORS

2.2.3 C arriage Lock Mechanism

2.2.4 Ink Supply Mechanism

INK-RELATED SENSORS

2.2.5 Cover Ope n Se ns or

2.2.6 Control Circuit

3.1 Overview

3.2 Troubleshooting Using LCD Error Messages

3.2.1 LCD Error Messages

3.2.2 Errors that require a service technician

MAINTENANCE REQ. 0100

SERVICE REQ. 00000100

SERVICE REQ. 00000101

SERVI C E R EQ. 00010 000

SERVI C E R EQ. 00010 001

SERVICE REQ. 00010002

SERVICE REQ. 00010003

SERVI C E R EQ. 00010 004

SERVI C E R EQ. 00010 005

SERVICE REQ. 00010006

SERVICE REQ. 00010007

SERVICE REQ. 00010008

SERVI C E R EQ. 00010 009

SERVI C E R EQ. 00010 00A

SERVI C E R EQ. 00010 00C

SERVICE REQ. 0001000D SERVICE REQ. 0001000E

SERVICE REQ. 0001000F

SERVICE REQ. 00010010

3.2.3 General Errors

INK LOW

PAPER OUT

LOAD XXX PAPE R

LOAD PAPER

PAPER JAM

COVER OP EN

PAPER NOT CUT

PAPER NOT STRAIGHT