Epson 9000 User Manual
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
COPYRIGHT NOTICE
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.
Copyright © 1999 Epson America, Inc.
20770 Madrona Avenue
Torrance, CA 90509-2842
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
g
q
q
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
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y
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
Contents
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
6
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
7
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
8
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
9
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.
U
D
.
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
U
D
, Cut/Eject Maintenance Mode 2
D
See
Maintenance Mode 2
See
ROM Backup and Updating
, Cut/Eject, Cleaning Self-Diagnostic Mode
D
See
Self-Diagnostics
—
page 105
on
on page 17
on page 17
on page 107
on
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 —
U
D
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
ON
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 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
on
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
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