Epson Stylus Pro 5000 Service Manual
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Epson Stylus Pro 5000 Service Manual

Epson Stylus Pro 5000 Service Manual

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EPSON Stylus Pro 5000

®
TM-STYPRO5000

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Summary of Contents for Epson Stylus Pro 5000

  • Page 1: Epson Stylus Pro

          EPSON Stylus Pro 5000 ® TM-STYPRO5000...

  • Page 2: Fcc Compliance Statement

    Neither Epson America, Inc., nor its affiliates shall be liable to the purchaser of this product or third parties 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.
  • Page 3 EPSON® and ESC/P® are registered trademarks and ESC/P 2™ and EPSON Stylus are trademarks of Seiko Epson Corporation. MicroDot™ and Super MicroDot™ are trademarks of Epson America, Inc. General Notice: Other product names used herein are for identification purposes only and may be trademarks of their respective companies. EPSON disclaims any and all rights in those marks.

  • Page 4: Precautions

    1. Repairs on EPSON products should be performed only by an EPSON-certified repair technician. 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.

  • Page 5: Preface

    PREFACE This manual describes the basic functions, theory of electrical and mechanical operations, maintenance and repair procedures of the EPSON Stylus Pro 5000. The instructions and procedures included herein are intended for experienced repair technicians; attention should be given to the precautions on the preceding page.

  • Page 6: Table Of Contents

    FRONT MATTER ..............FCC Compliance Statement ..........Precautions ................. Preface ................TABLE OF CONTENTS ............CHAP 1-PRODUCT DESCRIPTION ........Overview ................Specifications ..............Printing Specifications ..............Character Specifications ............. Control Codes ................Paper Feed Specifications ............Paper Specifications ..............Ink Cartridge Specifications ............

  • Page 7: Overview

    CHAP 2-OPERATING PRINCIPLES ........Printer Mechanism .............. Printing Mechanism ..............Carriage Mechanism ..............Paper Feed Mechanism .............. Upper Surface Sensor Mechanism ..........Paper Return Mechanism ............Lifter Gear Train ................Stack Lowering Mechanism ............Sub Roller Gear Train ..............Gear Train Disengagement ............
  • Page 8 Main Board Rear Unit Removal ..........Disassembling the Printer Mechanism ........Installing and Removing the Optional Paper Guide .... Installing the Paper Guide Roller ..........Removing the Paper Guide Roller ..........Gear Train Disassembly and Assembly ......Gear Train Disassembly ..............
  • Page 9 Stylus Pro 5000 Table of Contents 1. Product Description ......................1-1 1.1 Overview........................ 1-1 1.2 Specifications......................1-2 1.3 Interfaces....................... 1-7 1.4 Operation ......................1-10 1.5 Advanced Control Panel Functions ..............1-14 2. Operating Principles ......................2-1 2.1 Printer Mechanism ....................2-1 2.2 Electrical Circuits ....................
  • Page 10 Stylus Pro 5000 4.2.5.18 Paper End Sensor Removal..........4-30 4.2.5.19 Paper Registration Sensor Removal ........4-31 4.2.5.20 Paper End Sensor Assembly ..........4-32 4.2.5.21 Home Position Sensor Removal ........... 4-33 4.2.5.22 Paper Width and Encoder Pulse Sensor Removal ....4-33 4.2.5.23 Rear Cover Removal.............

  • Page 11: Product Description

           PRODUCT DESCRIPTION...

  • Page 12: Overview

    1.1 OVERVIEW alternately, as needed. The EPSON Stylus Pro 5000 is a 6-color ink jet printer with professional Paper handling: color output. Its major features include: Two auto-feeding paper cassettes (second cassette optional)

  • Page 13: Specifications

    Printable Area Available Carriage Speed Resolution Dots (inches per Note: The Stylus Pro 5000 can use many different kinds of special media. second) Please see the User’s Guide for more information on media types. 360 dpi 12.7 inches 4578 20 IPS*...

  • Page 14: Character Specifications

    Stylus Pro 5000 Chapter 1 Product Description CHARACTER SPECIFICATIONS PAPER SPECIFICATIONS Character tables: 2 international character sets; Table 1-3. Cut Sheets PC437 (US, Standard Europe) PC850 (Multilingual) Item Description Typefaces: Bitmap LQ font Paper size Super A3 12.9 x 19 in. (327 x 483 mm) EPSON Courier (10 CPI) 11.7 x 16.5 in.

  • Page 15: Ink Cartridge Specifications

    Less than 0.0091 in. (0.23 mm) Lifetime Sealed: 2 years from production date. Paper EPSON Photo Quality Ink Jet Card Installed: Six months at 77 °F (25 °C) EPSON Photo Card Transit: 22 F to 140 F (30 C to 60 C); 120 hours Environmental at 140 F (60 C);...

  • Page 16: Input Data Buffer

    Stylus Pro 5000 Chapter 1 Product Description Rated current: 1.0 A (Max. 1.6 A) Table 1-8. Magenta and Cyan Ink Cartridges Energy Star compliant Item Specifications Power consumption: Approx. 32 W (ISO/IEC 10561 Letter Type Magenta and Light Magenta ink cartridge pattern) (part no.

  • Page 17: Safety Approvals

    Stylus Pro 5000 Chapter 1 Product Description 1 month at 104 F (40 C) SAFETY APPROVALS 120 hours at 140 F (60 C) 120 V version Humidity (without condensation) Safety standards: UL1950 with D3 Operating: 20% to 80% RH CSA22.2 No.950 with D3...

  • Page 18: Physical Specifications

    1. When the printer is not on, make sure that the printhead is capped. 2. When moving the printer, make sure that the printhead is capped and The EPSON Stylus Pro 5000 is equipped with parallel and Macintosh the ink cartridges are installed.

  • Page 19: Parallel

    Stylus Pro 5000 Chapter 1 Product Description Table 1-11. Nibble Mode PARALLEL INTERFACE Item Description Transmission mode IEEE-1284 nibble mode Table 1-10. Compatibility Mode Synchronization Refer to IEEE-1284 specification Item Description Handshaking Refer to IEEE-1284 specification Transmission mode 8-bit parallel, IEEE-1284 compatibility mode...

  • Page 20: Type-B Optional Interface

    ESCPL2, BDC Model : Stylus[SP]Pro[SP]5000 When there is no space left in the buffer, the Stylus Pro 5000 starts PRINTER sending the host a BUSY signal. If the host receives this signal for a long Note: [00H] denotes a hexadecimal value of time, it times out and stops sending data.

  • Page 21: Operation

    INITIALIZATION 2. Line spacing: 1/6 inch 3. Right margin position: 127 columns (at 10 CPI) There are three ways to initialize the Stylus Pro 5000: 4. Left margin position: First column (at 10 CPI) 5. Word pitch: 10 CPI Hardware initialization: 6.

  • Page 22: Control Panel

    Stylus Pro 5000 Chapter 1 Product Description Other things to keep in mind about interface selection: CONTROL PANEL The host checks whether the logic signal is low or high before There are 4 non-locking push buttons and 8 LEDs, described in requesting data through the reverse channel.
  • Page 23 Stylus Pro 5000 Chapter 1 Product Description The following table shows what these buttons do if they are pressed Table 1-13. Control Panel Functions simultaneously with the Operate button while the printer is off. See section Button / Light Function 1.3 for details.

  • Page 24: Error Conditons

    Stylus Pro 5000 Chapter 1 Product Description The following table shows what the LEDs mean. ERROR CONDITIONS Table 1-15. LED Messages This section describes the conditions that cause errors in the Stylus Pro Printer Status Indicators (Figure 1-2) 5000. During an error the /ERROR signal is LOW and the BUSY signal is HIGH;...

  • Page 25: Advanced Control Panel Functions

    Stylus Pro 5000 Chapter 1 Product Description Paper jam error 1.5 ADVANCED CONTROL PANEL FUNCTIONS If the PE sensor detects paper on the paper path when there shouldn’t be any, or the printer fails to eject a sheet with the FF command or the Eject button, the printer shows a paper jam error.

  • Page 26: Paper Size/Type Check Mode

    Stylus Pro 5000 Chapter 1 Product Description During the self-test, the printer prints the print nozzle test pattern, the Note: A maintenance error occurs when either ink counter value exceeds firmware version, the ink counter values, and the current setting values.

  • Page 27: Ecp Mode

    Stylus Pro 5000 Chapter 1 Product Description ECP MODE Table 1-16. Conditions under which the platen gap is set wide Settings Conditions Follow the instructions below to set the printer’s parallel interface to ECP Printer driver The A4-size paper (landscape) setting is used.

  • Page 28: Maintenance Mode (Level 1)

    Stylus Pro 5000 Chapter 1 Product Description  Hex Dump Mode MAINTENANCE MODE (LEVEL 1) 1. To enter Hex Dump mode, choose Hex Dump from Maintenance Mode 1. While the printer is off, press the Cleaning, Eject, and Operate buttons simultaneously to enter this mode.

  • Page 29: Maintenance Mode (Level 2) Eeprom Reset

    Stylus Pro 5000 Chapter 1 Product Description  PC437-PC850 Code Page Selection PRINTHEAD ALIGNMENT MODE This adjusts both bi-directional printing and the printhead gap. 1. Choose PC437-PC850 Code Page Selection from Maintenance Mode (level 1) as described above. The Operate and lower tray lights flash.

  • Page 30: Firmware Uploading Mode

    4. Decide which set of lines on the printed sheet is vertically aligned. Press the Reset or Eject button until the printer lights display the If necessary, EPSON will release upgrades to the EPSON Stylus Pro 5000 pattern corresponding to your choice (see Table 1-17). Then press the firmware.
  • Page 31 Stylus Pro 5000 Chapter 1 Product Description 1-20...

  • Page 32: Operating Principles

           OPERATING PRINCIPLES...

  • Page 33: Printer Mechanism

    This chapter explains the mechanical and electrical operating principles Disengagement Gear Train if no paper for the Stylus Pro 5000. Table 2-1 lists the components of the printer tray is installed mechanism and the motors that drive each component. Ink Engage/Disengage...

  • Page 34: Printing Mechanism

    Stylus Pro 5000 Chapter 2 Operating Principles PRINTING MECHANISM Nozzle Configuration for Stylus Pro 5000 The Stylus Pro 5000 uses EPSON’s original MACH printing method. This 320/360" 144/360" printer has two color printheads and includes an automatic color- 32/360" calibration function.

  • Page 35: Carriage Mechanism

    CARRIAGE MECHANISM Unlike previous EPSON ink jet printers, two carriage guide shafts support the whole carriage in the Stylus Pro 5000. Since there are 2 shafts The carriage unit pushes the ink disengage/engage lever. This starts the supporting the carriage, the platen gap can be changed without tilting the pump.

  • Page 36: Paper Feed Mechanism

    PAPER FEED MECHANISM There are four paper feed paths in the Stylus Pro 5000: the standard paper tray, the optional paper cassette, and the front and rear manual feeds. Figure 2-4 shows the paper feed path from the standard paper tray. The other paper feed paths use all of the components in the diagram except for the paper load roller.
  • Page 37 Stylus Pro 5000 Chapter 2 Operating Principles Paper Loading from the Standard Paper Tray Paper Feeding from the Front Manual Feed Slot 1. While the printer is on, the left quantity, paper size and paper type 1. When you insert a sheet into the front manual feed slot, the leading sensors monitor paper in the tray.

  • Page 38: Upper Surface Sensor Mechanism

    Unlike previous ink jet printer models, the lifter in the picked up by the paper load roller to the paper tray. When the paper load Stylus Pro 5000 supports the hopper directly. If the lifter raised the roller rotates, the mechanism raises the Paper Return Lever.

  • Page 39: Lifter Gear Train

    The Lifter Gear Train controls the lifter, which raises the paper hopper. The Stack Lowering Mechanism prevents paper from being creased The Stylus Pro 5000 hopper doesn’t go up automatically when the user when the paper load roller picks up the top sheet in the paper tray.
  • Page 40 Stylus Pro 5000 Chapter 2 Operating Principles Stack Lowering Mechanism Gear Train The stopper lever then prevents the clutch gear from turning. The return The Pump/ASF motor powers the gear train. (See “Lifter Gear Train” for spring turns the gear beneath the clutch gear to the left (see Figure 2-9).
  • Page 41 Stylus Pro 5000 Chapter 2 Operating Principles After the paper load roller loads the paper, the lifter returns to its original The stopper lever then releases the clutch gear. The tension spring position. The stopper lever holds the clutch gear and must be lowered to attached to the semicircular gear that drives the lifter forces the lifter back lower the lifter.

  • Page 42: Sub Roller Gear Train

    Stylus Pro 5000 Chapter 2 Operating Principles SUB ROLLER GEAR TRAIN GEAR TRAIN DISENGAGEMENT The pump/ASF motor drives the sub roller when the motor rotates in To prevent accidents, the lifter gear train is disengaged when the paper reverse. The sub roller is used in all four paper paths. Figure 2-13 shows tray is not installed.
  • Page 43 Stylus Pro 5000 Chapter 2 Operating Principles As a result, Planetary gear 2 In Figure 2-15, the paper tray is not installed. The small cam gear has not Planetary gear 2 moves to the right can drive the next gear in the pushed planetary gear 2 to the right;...

  • Page 44: Ink Engage/Disengage Mechanism

    Stylus Pro 5000 Chapter 2 Operating Principles In Figure 2-18, the pump/ASF motor is driving the pump unit. When the INK ENGAGE/DISENGAGE MECHANISM printer begins to drive the pump, the carriage hits the slider, then the slider moves planetary gear 1 to the left. The carriage also compresses return The ink engage/disengage mechanism (or D/E mechanism) transmits spring 1, which is on the same shaft as planetary gear 1.

  • Page 45: Platen Gap Adjustment Mechanism

    Stylus Pro 5000 Chapter 2 Operating Principles Transmission gear PLATEN GAP ADJUSTMENT MECHANISM and planetary gear 2 after the gear train has disengaged The printer uses the paper type driver setting to automatically adjust the platen gap. Driving the Paper Load/Eject...
  • Page 46 Stylus Pro 5000 Chapter 2 Operating Principles Once the carriage hits the flag, the transmission and PG driver gears Once the transmission gear engages the PG driver gear, the PF motor disengage. When the PF motor turns counterclockwise, the transmission drives the PG driver gear.

  • Page 47: Ink Valve Mechanism

    180 degrees. The purpose of the ink valve mechanism is to prevent ink leaks when transporting the printer. The Stylus Pro 5000 does not have a waste ink sequence like the Stylus Color 3000. Since this printer does not perform...

  • Page 48: Paper Tension Mechanism

    Color 1520 and Stylus Color 3000, this sudden movement could distort sub roller turns, and the cam gear raises the paper feed support roller. the print job. The Stylus Pro 5000 has a mechanism to keep constant When the pump/ASF motor rotates in the other direction, the planetary tension on the paper above the platen, preventing any sudden motion.

  • Page 49: Electrical Circuits

    CN 2 Delay Circuit C228 PSB BOARD The Stylus Pro 5000 uses the C228 PSB board to generate the voltages needed to operate the printer. Table 2-5 shows the voltages generated by the C228 PSB board. Figure 2-27. C228 PSB Board Circuit Block Diagram Table 2-5.
  • Page 50 Stylus Pro 5000 Chapter 2 Operating Principles Delay Circuit If the output of the +42 V line exceeds +48 V, the over voltage protection If the power is turned off at the control panel, the delay circuit provides circuit shuts down the C228 PSB board. The line is monitored by Zener power for the power off sequence.

  • Page 51: C228 Driver Board

    Stylus Pro 5000 Chapter 2 Operating Principles C228 DRIVER BOARD The driver board controls 2 printheads, 3 motors, 2 solenoids, and all the sensors. Figure 2-28 shows a circuit block diagram of the driver board. V H 4 V H 2...

  • Page 52: C228 Main Board

    Stylus Pro 5000 Chapter 2 Operating Principles C228 MAIN BOARD The main board controls the optional SIMMs and the bus. It contains memory control circuits (Flash/DRAM/SRAM/PDRAM) and the printer CPU. Also, this board sends and receives information through the printer interfaces (Parallel/Serial/Type-B).

  • Page 53: Troubleshooting

           TROUBLESHOOTING...

  • Page 54: Cleaning Does Not Improve Poor Print Quality

    If you need to repeat the operation to clean the 2. Start the service program “Stylus Pro 5000.EXE” and select “Head printheads, have extra cartridges ready; ink cleaning” from the Maintenance menu. (Repeat the cleaning five or six usually runs out before the second times, if necessary.

  • Page 55: Printheads Are Misaligned

    Stylus Pro 5000 Chapter 3 Troubleshooting 12. Use a voltmeter to check the change in signal when the printer is on PROBLEM: PRINTER FAILS TO LOAD PAPER. and off. 1. Make sure the type of paper you are using is compatible with the 13.

  • Page 56: The Hopper Isn't Lowered After A Sheet Is Fed

    Stylus Pro 5000 Chapter 3 Troubleshooting PROBLEM: THE HOPPER ISN’T LOWERED AFTER A SHEET IS FED. PROBLEM: LEDS INDICATE “PAPER JAM”. The tension spring is dislocated from the lifter driver gear (a crescent- 1. Make sure the rear cover is securely closed.

  • Page 57: Led's Indicate "Fatal Error

    Stylus Pro 5000 Chapter 3 Troubleshooting Check the internal coil resistance of the CR motor. If the motor doesn’t PROBLEM: LEDS INDICATE “FATAL ERROR”. meet these specifications, replace it.  Specification: 4.3   10% (each phase) The printer indicates a “Fatal Error” condition by turning on all the LEDs.

  • Page 58: Led's Indicate A Maintenance Error

    Between the double clutch gear and the paper return transmission gear (white). If one user uses two or more Stylus Pro 5000 printers, they may notice Between the white and cream paper return transmission gears. differences in color output between the two printers. The printer is...

  • Page 59: Assembly And Disassembly

           ASSEMBLY AND DISASSEMBLY...

  • Page 60: Overview

    Stylus Pro 5000 Chapter 4 Assembly and Disassembly WARNING Do not use solder on any part of the battery. 4.1 OVERVIEW Doing so may result in electrolyte leaks, burning or explosion. This section describes the procedures for disassembling the printer.

  • Page 61: Tools

    Stylus Pro 5000 Chapter 4 Assembly and Disassembly 4.2 DISASSEMBLY 4.1.2 Tools Use only the tools listed in Table 4-1. This section describes the disassembly procedures up to printer Table 4-1. Required Tools mechanism removal and main board rear unit removal. The main board rear unit can be removed without disassembling any other parts.

  • Page 62: Upper Housing Removal

    Stylus Pro 5000 Chapter 4 Assembly and Disassembly 5 CBS Screws(3x8) 4.2.1 Upper Housing Removal 1. Open the rear manual feed slot cover. 2. Release 2 hooks on the printer cover, then remove the cover. (See Figure 4-2.) 2 Hooks Figure 4-3.
  • Page 63 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 2 Hooks 5. Using a standard screwdriver, release 3 hooks located above the paper eject area. (See Figure 4-5.) 3 Hooks Upper Housing Front Housing Figure 4-6. Hooks on top of printer Front Housing Figure 4-5.

  • Page 64: Front Housing Removal

    Stylus Pro 5000 Chapter 4 Assembly and Disassembly 4.2.2 Front Housing Removal 4. Use a standard screwdriver to release 2 hooks securing the front housing. The hooks are on the bottom front of the printer, one on each 1. Remove the upper housing. (See Section 4.2.1.) side.

  • Page 65: Printer Mechanism Removal

    Stylus Pro 5000 Chapter 4 Assembly and Disassembly REMINDER When reassembling the printer mechanism, 4.2.3 Printer Mechanism Removal align the 2 notches on the bottom of the printer 1. Remove the upper housing. (See section 4.2.1.) mechanism with the 2 dimples on the lower housing.

  • Page 66: Main Board Rear Unit Removal

    When installing this unit, push firmly when seating it in the connector on the C228 driver board.   Firmware for the Stylus Pro 5000 has not yet   been installed on replacement main boards. Main Board When replacing the main board, reinstall the Rear Unit proper firmware.

  • Page 67: Disassembling The Printer Mechanism

    Stylus Pro 5000 Chapter 4 Assembly and Disassembly 4.2.5 Disassembling the Printer Mechanism Figure 4-13 shows a flow chart of the remaining printer mechanism disassembly procedures. 4.4 ASF 4.4.1 ASF 4.4.2. ASF Disassembly Disassembly Assembly and Assembly 4.3. Gear Train 4.3.1.

  • Page 68: Discharge Brush Removal

    Stylus Pro 5000 Chapter 4 Assembly and Disassembly 4.2.5.1 Discharge Brush Removal 4.2.5.2 Paper Guide Cover Removal 1. Remove the upper housing. (See section 4.2.1.) 1. Remove the upper housing. (See section 4.2.1.) 2. Remove the front housing. (See section 4.2.2.) 2.

  • Page 69: Printhead Removal

    Stylus Pro 5000 Chapter 4 Assembly and Disassembly 1. Remove the upper housing. (See section 4.2.1.) REMINDER Always install the leaf spring with the concave side facing the paper guide cover. (See Figure 2. Remove the front housing. (See section 4.2.2.) 4-16.)
  • Page 70 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 7. Move the carriage to the center and remove 1 screw (CBP, 3x8) 8. Release 4 hooks on the sides of the front carriage cover, then remove securing the rear carriage cover. Then remove the rear carriage cover.
  • Page 71 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 12. Remove the 2 compression springs (9.9) that press the printheads   against the carriage. (See Figure 4-20.) After replacing the printhead, refer to Table 5-1,   and perform all necessary adjustments.

  • Page 72: Main Board Shield Plate Removal

    Stylus Pro 5000 Chapter 4 Assembly and Disassembly REMINDER As shown in Figure 4-22, the FFC in connector 4.2.5.4 Main Board Shield Plate Removal CN10 is marked with an “O.” This is the FFC for 1. Remove the upper housing. (See section 4.2.1.) the left printhead.

  • Page 73: Fan Removal

    Stylus Pro 5000 Chapter 4 Assembly and Disassembly 4.2.5.5 Fan Removal Table 4-3. C228 Driver Board Connectors 1. Remove the upper housing. (See section 4.2.1.) Connector Color Connected to: 2. Remove the front housing. (See section 4.2.2.) Black Main board...

  • Page 74: Power Supply Removal

    Stylus Pro 5000 Chapter 4 Assembly and Disassembly 4.2.5.6 Power Supply Removal 4.2.5.7 Paper Feed Motor Removal 1. Remove the upper housing. (See section 4.2.1.) 1. Remove the upper housing. (See section 4.2.1.) 2. Remove the front housing. (See section 4.2.2.) 2.

  • Page 75: Carriage Motor Removal

    Stylus Pro 5000 Chapter 4 Assembly and Disassembly Carriage Motor CAUTION When removing the screws from the left frame, don’t touch the teeth on gear (80) or combination gear (9, 6, 36) with the screwdriver. These are precision gears; small impacts may damage them.

  • Page 76: Asf Motor Removal

    Stylus Pro 5000 Chapter 4 Assembly and Disassembly 11. Loosen 3 screws holding 3 dampers to the ASF motor, then remove 4.2.5.9 ASF Motor Removal the motor. (See Figure 4-30.) 1. Remove the upper housing. (See section 4.2.1.) REMINDER Washers are attached to each damper; be 2.

  • Page 77: Carriage Removal

    Stylus Pro 5000 Chapter 4 Assembly and Disassembly CAUTION Paper may not feed correctly if gear (80) is 4.2.5.10 Carriage Removal reused after it has been removed; always 1. Remove the upper housing. (See section 4.2.1.) replace it with a new one during assembly.
  • Page 78 Stylus Pro 5000 Chapter 4 Assembly and Disassembly Parallelism Adjustment Bushing E-ring (#6) REMINDER Combination gear (36, 36) and gear (49) are carefully aligned. During assembly, make sure Screw (CBS, 3×8) the red circles on each gear surface adjoin. (See Figure 4-32.) 11.
  • Page 79 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 17. Carefully remove the timing belt from the clip on the carriage. (See 13. Remove the carriage shaft from the notch in the left parallelism Figure 4-37.) adjustment bushing. Do not lose the 2 leaf springs and 1 flat washer on the right side of the shaft.

  • Page 80: Paper Eject Frame Removal

    Stylus Pro 5000 Chapter 4 Assembly and Disassembly 4.2.5.11 Paper Eject Frame Removal 1. Remove the upper housing. (See section 4.2.1.) 2. Remove the front housing. (See section 4.2.2.) 3. Remove the printer mechanism. (See section 4.2.3.) 4. Remove the printheads. (See section 4.2.5.3.) 5.
  • Page 81 Stylus Pro 5000 Chapter 4 Assembly and Disassembly CAUTION 10. On the right side of the printer mechanism, remove 1 e-ring from the Make sure the tube ends are facing up as you carriage support shaft. remove them; they may be full of ink.
  • Page 82 Stylus Pro 5000 Chapter 4 Assembly and Disassembly Washer 14. Remove 1 screw (CBS, 3×6) securing the ink absorbing tank, then (8.2×0.15×15) remove the tank. 15. Remove 8 screws (CBS, 3×6) securing the paper eject frame, then Carriage Support Shaft remove the paper eject frame.

  • Page 83: Upper Paper Guide Removal

    Stylus Pro 5000 Chapter 4 Assembly and Disassembly 4.2.5.12 Upper Paper Guide Removal Screws (CBP, 3×8) Slider and Notch 1. Remove the upper housing. (See section 4.2.1.) 2. Remove the front housing. (See section 4.2.2.) 3. Remove the printer mechanism. (See section 4.2.3.) 4.
  • Page 84 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 9. Remove 3 screws (CBS, 3×6) securing the pump frame to the right Ink Valve Driver Gear Cap Positioning Pin frame, then remove the pump frame. (See Figure 4-48.) REMINDER During assembly, insert the cap positioning pin and the ink valve driver gear into the corresponding holes.

  • Page 85: Paper Feed Frame Removal

    Stylus Pro 5000 Chapter 4 Assembly and Disassembly 4.2.5.14 Paper Feed Frame Removal Left Frame 1. Remove the upper housing. (See section 4.2.1.) 2. Remove the front housing. (See section 4.2.2.) 3. Remove the printer mechanism. (See section 4.2.3.) 4. Remove the printheads. (See section 4.2.5.3.) 5.

  • Page 86: Print Feed Roller Removal

    Stylus Pro 5000 Chapter 4 Assembly and Disassembly 4.2.5.15 Print Feed Roller Removal 12. Remove 2 screws (CBS, 3×8) holding the front paper guide, then remove the front paper guide. 1. Remove the upper housing. (See section 4.2.1.) 13. Remove 2 screws (CBS, 3×8) holding the middle paper guide to the 2.
  • Page 87 Stylus Pro 5000 Chapter 4 Assembly and Disassembly Washer (4.4×0.5×14) Bushing 14. Remove the e-ring (#3) securing the carriage lock, then remove the Washer (4.4×0.3×10) carriage lock. (See Figure 4-54.) Washer (5.07×0.3×10) Print Feed Roller Spacer E-ring (#3) Compression Spring (5.85) Washer (5.07×0.3×10)

  • Page 88: Auto Sheet Feeder Removal

    Stylus Pro 5000 Chapter 4 Assembly and Disassembly 13. Remove all cables from the cable clip on the left paper quantity sensor. 4.2.5.16 Auto Sheet Feeder Removal (See Figure 4-57.) 1. Remove the upper housing. (See section 4.2.1.) 14. Remove 2 screws (CBS, 3×6) securing the auto sheet feeder to the 2.

  • Page 89: Paper End Sensor Removal

    Stylus Pro 5000 Chapter 4 Assembly and Disassembly 10. Remove the paper feed frame. (See section 4.2.5.14.) 4. Remove the printheads. (See section 4.2.5.3.) 11. Remove the print feed roller. (See section 4.2.5.15.) 5. Remove the carriage motor. (See section 4.2.5.8.) 12.

  • Page 90: Paper Registration Sensor Removal

    Stylus Pro 5000 Chapter 4 Assembly and Disassembly Press these two hooks together, 12. Release 2 hooks securing the paper end sensor to the frame, then then pull the sensor out. remove the paper end sensor. (See Figure 4-61.) Hooks...

  • Page 91: Paper End Sensor Assembly

    Stylus Pro 5000 Chapter 4 Assembly and Disassembly Paper End Sensor Lever B Torsion Spring (0.089) 4.2.5.20 Paper End Sensor Assembly Torsion Spring (0.089) Paper End Sensor 1. Remove 10 small screws from the rear frame and 9 torsion springs Lever (189), then separate the rear frame from the upper paper guide.

  • Page 92: Home Position Sensor Removal

    Stylus Pro 5000 Chapter 4 Assembly and Disassembly 5. Connect the paper end sensor lever B to the upper paper guide as Connector shown in Figure 4-66. Torsion Spring Push 2 hooks in Home Position the direction of Sensor these arrows Figure 4-67.

  • Page 93: Rear Cover Removal

    Stylus Pro 5000 Chapter 4 Assembly and Disassembly 7. Remove 2 small screws (2.5×5) securing the encoder pulse sensor and 6. Remove the power supply. (See section 4.2.5.6.) 1 screw (CBP, 3×8) securing the paper width sensor, then remove both 7.

  • Page 94: Installing And Removing The Optional Paper Guide

    A3- or Super A3/B-size glossy paper. The paper guide roller is available from EPSON (part number 1040445). 4.3.1 Installing the Paper Guide Roller 1. Insert the left side of the roller into the corresponding space in the...

  • Page 95: Gear Train Disassembly And Assembly

    Large Hook Flathead Screwdriver ASSEMBLY The Stylus Pro 5000 gear train is complicated and precisely aligned. These alignments must be maintained during assembly if the printer is to operate correctly. See section 4.4.1 for disassembly instructions, and section 4.4.2 for assembly instructions.
  • Page 96 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 11. Remove the tension spring (8.49). (See Figure 4-73.) Reinforcing Board Rotary Damper Set Gear (67.8) Arm Lifter Shaft: Gear (67.6) Convex side should face Tension Spring (8.49) Screw (CBS, 3×6) front during installation.
  • Page 97 Stylus Pro 5000 Chapter 4 Assembly and Disassembly Gear (17.4) Gear (27) Place gear (27.6) on the lifter clutch, hanging the bent leg of the torsion spring (1.77) on the hook located at the back of gear (27.6). (See Figure 4-77.)
  • Page 98 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 15. Disconnect and remove the tension spring (0.588) connected to the 16. Disconnect and remove the torsion spring (25.5) connected to the hopper lever. (See Figure 4-79.) hopper lever lock. (See Figure 4-79.) 17.
  • Page 99 Stylus Pro 5000 Chapter 4 Assembly and Disassembly Belt Tension Roller 19. Remove gear (11.4), gear (31.8) and gear (35.4). (See Figure 4-81.) Gear (35.4) Torsion Spring (1.27) Belt Tension Lever Roller Belt Figure 4-82. Lever Belt Tension Parts 22. Remove the e-ring (#2.3) from the ASF planetary lever, then remove the ASF planetary lever.
  • Page 100 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 25. Remove 2 screws (CBS, 3×6) from the lifter gear train cover, then REMINDER Gear (12.8) is precisely aligned with the frame remove the lifter gear train cover. (See Figure 4-83.) gear shown in Figure 4-85. To install, push the 26.
  • Page 101 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 31. Remove the hopper timing belt between the hopper lock transmission gear and combination gear (18.144, 24). (See Figure 4-86.) IMPORTANT The hopper lock transmission gear is precisely aligned. See section 4.4.2 for assembly ASF Cam instructions.

  • Page 102: Gear Train Assembly

    Stylus Pro 5000 Chapter 4 Assembly and Disassembly 2. Place gear (12.8) on the shaft. This gear is precisely aligned with the 4.4.2 Gear Train Assembly frame gear shown in Figure 4-88. To install, push the frame gear to the Gear train assembly requires precise alignment of several gears.
  • Page 103 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 3. If the hopper lock transmission gear has been separated into gear 4. Push the paper return camshaft about a half-inch in the direction of the (18.144) and the hopper lock transmission, align the 2 slots on the arrow in Figure 4-90, then place the hopper lock transmission gear on hopper lock transmission with the 2 tabs on gear (18.144) and press...
  • Page 104 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 5. Loop the hopper timing belt around the hopper lock transmission gear, 6. Install the lifter gear train cover, then place a bushing on the same and temporarily loop the other end around shaft A. (See Figure 4-91.) shaft as the hopper lock transmission gear.
  • Page 105 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 10. Press the hopper release lever to the right and rotate combination gear 8. Make sure the hopper lever is directly under the lifter clutch lever. (See (18.144, 24) until the three holes on the gear are in the position shown Figure 4-93.)
  • Page 106 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 12. Turn the hopper lock transmission gear until the hole in the gear can be seen through the hole in the lifter gear train cover. Insert a positioning pin through both holes. (See Figure 4-96.)
  • Page 107 Stylus Pro 5000 Chapter 4 Assembly and Disassembly Gear (32) 13. Loop the hopper timing belt around combination gear (18.144, 24). E-ring (See Figure 4-99.) Hopper Timing Belt Set ribs at the 10:35 position. Combination Gear Combination Gear (18.144, 24) (18.144, 24)
  • Page 108 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 17. Place a washer (6.2×0.5×17, S/Na) on shaft “A.” 18. Place a leaf spring on shaft “A.” The convex side of the spring should ASF Cam face the frame. (See Figure 4-102.) Leaf Spring Shaft "A"...
  • Page 109 Stylus Pro 5000 Chapter 4 Assembly and Disassembly E-ring 23. Place the ASF stopper lever on the same shaft as gear (32), then hang the long leg of the torsion spring (3.92) on the hook on the right frame. (See Figure 4-105.)
  • Page 110 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 29. Secure the ASF planetary lever with an e-ring (#2.3). (See Figure 27. Place the planetary lever lifter on shaft “B” and secure it with a c-ring. 4-109.) (See Figure 4-108.) Planetary Lever Lifter 30.
  • Page 111 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 31. Place gear (31.8) on the same shaft as combination gear (18.144, 24), 32. Position the 2 holes on the ASF gear train cover over the ASF then place gear (17.4) on the next shaft to the right. (See Figure planetary lever shaft and gear (17.4) shaft and install the cover.
  • Page 112 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 35. Check the operation of the gear train. Follow the instructions in the box 36. Push the ASF stopper lever in the direction of the green arrow in below and refer to Figure 4-113.
  • Page 113 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 39. Check the operation of the ASF following the instructions below. (See ASF Alignment Figure 4-115.) If the ASF check fails, or if the gears will not rotate, try 1. Remove the e-rings securing gear (24), combination gear (24, 24) the ASF alignment procedure below.
  • Page 114 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 41. Rotate the paper feed roller until it appears as shown in Figure 7. Place gear (10) on its shaft, and secure it with an e-ring. (See 4-118. This allows the ASF to be installed easily.
  • Page 115 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 43. Seat the paper feed roller shaft in the U-shaped slot on the left tray 44. Lift up the gear side of the ASF, then rotate combination gear mounting board. (See Figure 4-119.) (24, 24) or the paper feed roller until the paper feed roller faces up.
  • Page 116 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 45. The positioning holes in combination gear (24, 24) and the right paper 47. There is a fishhook-shaped protrusion on the surface of gear (24). feed roller lever should now be aligned. Insert a positioning pin. (See When the ASF is installed correctly, the knob on the back frame should Figure 4-121.)
  • Page 117 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 48. Secure the ASF with 2 screws (CBS, 3×6), then remove the 3 4. Press the ASF stopper lever and rotate gear (35.4) clockwise for 1 positioning pins shown in Figure 4-123.
  • Page 118 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 51. Install the hopper lever, then the tension spring (0.588). (See Section 56. Install gear (27). (See Figure 4-127.) 4.4.1, Figure 4-79.) Make sure the planetary gear below the hopper lever remains free.

  • Page 119: Asf Disassembly And Assembly

    Stylus Pro 5000 Chapter 4 Assembly and Disassembly 59. Install gear (67.6). (See Figure 4-128.) 4.5 ASF DISASSEMBLY AND ASSEMBLY 60. Install the tension spring (8.49) between gear (67.6) and the ASF gear train cover. (See Figure 4-128.) The gears in the auto sheet feeder (ASF) are precisely aligned. Follow 61.
  • Page 120 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 15. Remove the paper feed roller shaft. (See Figure 4-131.) 13. Remove 3 e-rings from the ASF, then remove gear (10), combination gear (24, 24), gear (11) and gear (24). (See Figure 4-129.)
  • Page 121 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 19. Remove 1 e-ring (2, F/Uc) from the curler transmission shaft through IMPORTANT the cutout in the frame. (See Figure 4-134.) Before installing compression spring (0.98), put some lock-tite on the left paper feed roller lever.

  • Page 122: Curler Disassembly

    Stylus Pro 5000 Chapter 4 Assembly and Disassembly 21. Remove 1 screw (CBP, 3×8) and a leaf spring securing the upper 22. Remove 5 screws (CBP, 3×6) securing the 5 curlers, then remove the surface sensor, then remove the sensor. (See Figure 4-136.) curlers.
  • Page 123 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 2. Remove the tension spring (1.11) from the curler. (See Figure 5. Move the curler lever as far as it will go in the direction of the yellow 4-139.) arrow in Figure 4-140, then remove the lever. (See Figure 4-140.)

  • Page 124: Asf Assembly

    Stylus Pro 5000 Chapter 4 Assembly and Disassembly Positioning Pin 4.5.2 ASF Assembly Follow the steps below to assemble the ASF. Do not attempt to assemble the ASF by following the disassembly procedures in reverse. 1. Attach gear (10) to the curler lever plate, positioning the eccentric shaft as shown in Figure 4-142.
  • Page 125 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 6. Remove the positioning pin. Marks 7. Move the curler lever as far as it will go in the direction of the arrow in Figure 4-147. The knob on gear (24) should pass freely through the lever.
  • Page 126 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 8. Put one end of compression spring (0.399) over the post marked “A” in Figure 4-148, then push the other end into the lever cutout until it fits Metal Curler Cover Checkpoint 3 snugly against the shaft (marked “B”...
  • Page 127 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 11. Pull the curler lever in the direction of the yellow arrow in Figure 4-151, then release it. Make sure the spring returns the lever to its original position. If it doesn’t, disassemble and assemble the curler again.
  • Page 128 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 20. If it isn’t already attached, attach the upper surface sensor to the upper CAUTION surface sensor mounting board. (See Figure 4-156.) Do not use the hole marked “Sensor” in Figure 4-154 to attach a curler to the ASF.
  • Page 129 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 24. Secure the upper surface sensor mounting board with the screw you 22. Place a leaf spring over the tip of the screw, making sure the convex inserted through the frame in step 20. (See Figure 4-159.) side of the leaf spring faces the ASF frame.
  • Page 130 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 29. Pull the curler transmission shaft as far as it will go in the direction of 26. Insert the curler transmission shaft through the curler transmission the blue arrow in Figure 4-162.
  • Page 131 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 31. Insert the paper feed roller shaft into the right paper feed roller lever. 34. Insert the other end of the paper feed roller shaft into the left paper (See Figure 4-164.) feed roller lever.
  • Page 132 Stylus Pro 5000 Chapter 4 Assembly and Disassembly Left Paper Feed 36. Insert the paper feed mounting shaft into the left paper feed roller lever, Roller Lever gently through all 5 curlers, and into the right paper feed roller lever.
  • Page 133 Stylus Pro 5000 Chapter 4 Assembly and Disassembly Right Paper Feed 39. Place gear (24) on the paper feed roller shaft, then secure it with an e- Roller Lever ring (4, F/Uc). The fishhook-shaped protrusion should face away from the ASF. (See Figure 4-170.)
  • Page 134 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 42. Insert a positioning pin through the curler closest to the left paper feed 44. Insert a positioning pin into the large-toothed side of combination gear roller lever. This will prevent gear (10) from moving during the following (24, 24).
  • Page 135 Stylus Pro 5000 Chapter 4 Assembly and Disassembly 46. Secure combination gear (24, 24) with an e-ring (4, F/Uc). 47. Make sure that gear (10) is still in the proper position, as shown in Figure 4-177, and that the positioning pins are still in combination gear (24, 24), gear (24), and the leftmost curler.

  • Page 136: Adjustments

           ADJUSTMENTS...

  • Page 137: Overview

    EEPROM has been cleared. (Data may be even damage the lever. cleared, for example, when you replace the Be sure to run the Stylus Pro 5000 service driver board.) Press Alt-E to enter input mode, program on a computer running DOS 5.0 or then type the following exactly as shown: above.

  • Page 138: Adjustments

    Stylus Pro 5000 Chapter 5 Adjustments 5.2 ADJUSTMENTS CAUTION Be sure to replace the waste ink pad before you clear the waste ink pad counter. Failure to do so Table 5-1. Required Adjustments may cause ink to leak from the lower case.

  • Page 139: Resetting The Initial Ink Charge Flag

    4. If the correct printer name displays, select Yes and press Enter. (If the correct name does not display, press the Alt and E keys simultaneously to enter input mode, then type the following: Stylus Pro 5000.) The following screen appears.
  • Page 140 Stylus Pro 5000 Chapter 5 Adjustments * * * * * * S t y l u s P r o 5 0 0 0 S E R V I C E P R O G R A M V e r s i o n 1 . 0 * * * * * *...

  • Page 141: Entering The Printer Id

    Stylus Pro 5000 Chapter 5 Adjustments ENTERING THE PRINTER ID IMPORTANT The service program may hang at this point for You must reenter the printer ID whenever you replace the driver board, one of the following reasons: since the printer name is registered as character data in the EEPROM.

  • Page 142: Adjusting The Printhead Id

    Stylus Pro 5000 Chapter 5 Adjustments Follow these steps: 6. Press Enter to register the character data to EEPROM. 1. Connect the printer to the PC, then turn on both the printer and the PC. 7. Press ESC to go back to the main menu. Press ESC repeatedly to quit the service program.
  • Page 143 Stylus Pro 5000 Chapter 5 Adjustments 6. Select Head Voltage ID Input and press Enter. The following screen 4. If the correct printer name displays, select Yes, then press Enter. The appears. following screen appears. H e a d a c t u a t o r v o l t a g e I D a d j u s t m e n t * * * * * * S t y l u s P r o 5 0 0 0 S E R V I C E P R O G R A M V e r s i o n 1 .

  • Page 144: Performing A Printhead Angle Adjustment

    PERFORMING A PRINTHEAD ANGLE ADJUSTMENT the printheads are accessible. (See Chapter 4.) The printhead angle mechanism for the Stylus Pro 5000 is the same as 3. Loosen the screws securing the printheads. (See Figure 5-1.) that for the Stylus Color 800. The adjustment aligns the horizontal lines of the first nozzle in the right printhead with the horizontal lines of the first nozzle in the left printhead by adjusting the angle of the printheads.
  • Page 145 Stylus Pro 5000 Chapter 5 Adjustments S t a r t i n g S E R V I C E P R O G R A M P r i n t e r m o d e l n a m e i s S t y l u s P r o 5 0 0 0...
  • Page 146 Stylus Pro 5000 Chapter 5 Adjustments * * * * * * S t y l u s P r o 5 0 0 0 S E R V I C E P R O G R A M V e r s i o n 1 . 0 * * * * * *...
  • Page 147 Stylus Pro 5000 Chapter 5 Adjustments 12. Turn the printer off and release the carriage lock. (See Figure 5-4.) No adjustment Note: The carriage lock is made up of 2 levers. When you push down on needed Adjustment the lower lever, the upper lever automatically falls to the side, allowing you needed to move the carriage.
  • Page 148 Stylus Pro 5000 Chapter 5 Adjustments 13. Remove the 3 screws securing the paper eject cover with the discharge IMPORTANT If you fail to return the carriage to the home brush to the front case, then remove the frame. Locate the 2 windows position, the printer will detect that the carriage that allow you to change the lever position.
  • Page 149 Stylus Pro 5000 Chapter 5 Adjustments Figure 5-7 shows how the printing pattern changes when you move a lever to the right or left. IMPORTANT You must perform the printhead height adjustment after the printhead angle When you move the adjustment lever to the right adjustment.

  • Page 150: Performing A Printhead Height Adjustment

    Stylus Pro 5000 Chapter 5 Adjustment Follow these steps: PERFORMING A PRINTHEAD HEIGHT ADJUSTMENT 1. Make sure the mounting screw for the right printhead is loosened. (See Like the printhead angle adjustment, the printhead height adjustment Figure 5-8.) aligns the horizontal lines of the first nozzle in the right printhead with the horizontal lines of the first nozzle in the left printhead.
  • Page 151 Stylus Pro 5000 Chapter 5 Adjustment Printhead Height * * * * * * S t y l u s P r o 5 0 0 0 S E R V I C E P R O G R A M V e r s i o n 1 .

  • Page 152: Performing A Printhead Gap Adjustment

    Stylus Pro 5000 Chapter 5 Adjustment 8. Press Enter again to print another test pattern. (The printhead height 6. Locate the printhead height adjustment lever on the right side of the adjustment screen should still be displayed.) Press Eject on the control printer.
  • Page 153 Stylus Pro 5000 Chapter 5 Adjustment Follow these steps: 4. If the correct printer name displays, select Yes and press Enter (if the correct printer name does not appear, reenter the printer ID.) The 1. If you’re already running the service program, skip to step 5.
  • Page 154 Stylus Pro 5000 Chapter 5 Adjustment 6. Select Head Gap Timing Adjustment and press Enter. The following 8. Press Enter to begin printing the test patterns. A message appears screen appears. indicating that the head gap pattern is printing. Three test patterns similar to the following are printed.
  • Page 155 Stylus Pro 5000 Chapter 5 Adjustment 9. Select Adjustment on the Head Gap Adjustment screen and press 10. Press Enter. The following screen appears. Enter. 2 0 0 C P S H e a d G a p a d j u s m e n t...

  • Page 156: Performing A Bi-D (Bi-Directional) Adjustment

    Stylus Pro 5000 Chapter 5 Adjustment PERFORMING A BI-D (BI-DIRECTIONAL) ADJUSTMENT 13. On the Head Gap Adjustment screen, select Adjustment again. Press Enter, then press Enter again to display the screen where you enter the The procedure for the bi-directional adjustment is similar to the procedure adjustment value.
  • Page 157 Stylus Pro 5000 Chapter 5 Adjustment 2. At the DOS prompt, type the following (if you’ve inserted the service * * * * * * S t y l u s P r o 5 0 0 0 S E R V I C E P R O G R A M V e r s i o n 1 .
  • Page 158 Stylus Pro 5000 Chapter 5 Adjustment The program prints 9 test patterns similar to those in Figure 5-14: B i - d i r e c t i o n a l a d j u s t m e n t 3 test patterns for Normal Dot, 3 for MicroDot, and 3 for Super MicroDot.
  • Page 159 Stylus Pro 5000 Chapter 5 Adjustment The second test pattern represents the current Normal Dot bidirectional value: the first test pattern represents a value offset from the current N o r m a l D o t B i - d a d j u s t m e n t printhead gap adjustment value by –20, the second test pattern is...

  • Page 160: Uploading The Firmware

    Stylus Pro 5000 Chapter 5 Adjustment 13. Press the ESC key twice to return to the Bidirectional Adjustment UPLOADING THE FIRMWARE screen. You need to upload firmware whenever you replace the C228 Main Board, since firmware has not been input to flash memory in the replacement B i - d i r e c t i o n a l a d j u s t m e n t board.

  • Page 161: Performing A Parallelism Adjustment

    Stylus Pro 5000 Chapter 5 Adjustment O p e r a t e E j e c t R e s e t C l e a n i n g E j e c t C l e a n i n g...
  • Page 162 1. Remove the printer’s upper housing unit. (See Chapter 4 for Left Parallelism Adjustment Bushing instructions.) 2. Insert a sheet of EPSON Super A3 glossy paper in the rear manual feed slot. (Move the lever illustrated in Figure 5-19 toward the rear of Narrows gap...
  • Page 163 Stylus Pro 5000 Chapter 5 Adjustment Paper guide roller Paper Mounting screw Decreases PG Feed the paper an additional 1 cm Paper guide roller at point of ejection Increases PG Figure 5-21. Position of paper at beginning of adjustment Figure 5-22. Right Parallelism Adjustment Bushing...

  • Page 164: Performing An Upper Surface Sensor Position Adjustment

    IMPORTANT When you perform this adjustment, you must use the upper surface sensor adjustment tool designed specifically for the Stylus Pro 5000 paper load roller (part number 103983200). upper surface sensor mounting screw...
  • Page 165 Stylus Pro 5000 Chapter 5 Adjustment 4. Install the paper tray in the printer. 5. Tighten the mounting screw until the LED for the upper surface sensor signal turns on. 6. Slowly continue tightening the screw just until the LED turns off.
  • Page 166 Stylus Pro 5000 Chapter 5 Adjustment 5-30...

  • Page 167: Maintenance

           MAINTENANCE...

  • Page 168: Overview

    Wear protective goggles to protect your This chapter provides information on how to maintain the Stylus Pro 5000. eyes from ink. If ink does get in your eyes, Be sure to read the warnings and cautions on this page before beginning flush them immediately and see a doctor.

  • Page 169: Cleaning The Printheads

    Stylus Pro 5000 Chapter 6 Maintenance Printhead Cleaning Methods CAUTION Never apply thinner, trichloroethylene, or other organic solvents to any part of the printer. Use a soft, dry cloth to clean the printer. For stains, use a cloth with mild detergent.

  • Page 170: Resetting The Waste Ink Counter

    Stylus Pro 5000 Chapter 6 Maintenance assembling the printer. Adhere all specified parts when assembling the printer or replacing the parts. Use an adequate amount of adhesive, and 6.3 RESETTING THE WASTE INK COUNTER let it dry thoroughly. Overflows of surplus adhesive may cause malfunctions in nearby parts.
  • Page 171 Stylus Pro 5000 Chapter 6 Maintenance Table 6-3. Lubrication Points (continued) Table 6-3. Lubrication Points (continued) Lubricating Points Type/Amount Lubricating Points Type/Amount 12 points on the front paper guide. G-26 (=2 mm) The gearshaft on the right frame (shown in G-26 (=25 mm) 4 points on the paper eject grounding plate.
  • Page 172 Stylus Pro 5000 Chapter 6 Maintenance Table 6-4. Adhesive Points Adhesive points Amount Under compression spring 0.98 on the Just enough to left paper feed roller lever. adhere the spring to the lever. The screw securing the upper surface Moisten 1/3 of the sensor to the ASF.
  • Page 173 Stylus Pro 5000 Chapter 6 Maintenance Lifter Clutch Lever ASF Cam Lifter Gear Train Cover Gear (24) (10) Note: There are 3 other Lubrication Point places to lubricate: they look similar to those depicted here. (10) Figure 6-2. Lubrication Points 1-10...
  • Page 174 Stylus Pro 5000 Chapter 6 Maintenance (13) Rotary Damper Mounting Board (16) (19) Rotary Damper (13) (12) (15) (14) (11) (14) (11) (17) Base Reinforcing Plate Pump Frame (20) (20) (20) (20) (20) (20) (20) (20) (20) (20) (20) (18)
  • Page 175 Stylus Pro 5000 Chapter 6 Maintenance Rear Paper Eject Roller (23) (23) (21) (21) (21) (21) (22) (22) Paper Eject Roller (31) (31) (24) (24) (26) (26) (32) (25) (32) (25) Lubrication Point Do not lubricate the carriage support shaft.
  • Page 176 Stylus Pro 5000 Chapter 6 Maintenance (28) Adhesion Point (27) (29) (30) (34) (33) Figure 6-6. Adhesion Points Lubrication Point (34) Do not lubricate here. Figure 6-5. Lubrication Points 27-30, 33, 34...
  • Page 177 Stylus Pro 5000 Chapter 6 Maintenance 6-10...

  • Page 178: Appendix

    APPENDIX...

  • Page 179: Connector Summary

    Stylus Pro 5000 Appendix A.1 CONNECTOR SUMMARY Table A-1. C228 Driver Board Connections The following tables show the connections and connector pin Connector Connected To: assignments of the C228 driver board. Assignments Main board — Power supply board Table 7-2...
  • Page 180 Stylus Pro 5000 Appendix Table A-2. Connector Pin Assignment - CN2 Table A-6. Connector Pin Assignment - CN6 Signal Name Function Signal Name Function 1, 2 +42 V Motor power source Paper type data 3 Ground Paper type data 2...
  • Page 181 Stylus Pro 5000 Appendix Table A-9. Connector Pin Assignment - CN9 Table A-10. Connector Pin Assignment - CN10 Signal Name Function Signal Name Function Ground Not used Ground Printhead temperature signal OPTPk3 Paper type data 3 3,5,7,9, Ground OPTPk2 Paper type data 2...
  • Page 182 Stylus Pro 5000 Appendix Table A-11. Connector Pin Assignment - CN11 Table A-13. Connector Pin Assignment - CN13 Signal Name Function Signal Name Function Not used Operate switch state detection signal Printhead temperature signal 2,4,6 Ground 3,5,7,9, Ground 11,13,15 Operate switch...
  • Page 183 Stylus Pro 5000 Appendix Table A-16. Connector Pin Assignment - CN16 Table A-21. Connector Pin Assignment - CN21 Signal Name Function Signal Name Function Phase drive signal (A) ASF/Pump Motor Phase A CO-C Cyan Cartridge In/Out signal Phase drive signal (B)

  • Page 184: Eeprom Address Map

    Stylus Pro 5000 Appendix A.2 EEPROM ADDRESS MAP Table A-25. EEPROM Address Map (continued) Address Explanation Setting QPIT Factory settings settings Table A-25. EEPROM Address Map CPSI License Address Explanation Setting QPIT Factory Password settings settings CPSI License EEPROM data...
  • Page 185 Stylus Pro 5000 Appendix Table A-25. EEPROM Address Map (continued) Table A-25. EEPROM Address Map (continued) Address Explanation Setting QPIT Factory Address Explanation Setting QPIT Factory settings settings settings settings Panel Masking Bit 2: Mask Head Actuator (continued) cleaning switch...
  • Page 186 Stylus Pro 5000 Appendix Table A-25. EEPROM Address Map (continued) Table A-25. EEPROM Address Map (continued) Address Explanation Setting QPIT Factory Address Explanation Setting QPIT Factory settings settings settings settings Reserved Ink counter Cy 1 count = (total) 100 ng...
  • Page 187 Stylus Pro 5000 Appendix Table A-25. EEPROM Address Map (continued) Table A-25. EEPROM Address Map (continued) Address Explanation Setting QPIT Factory Address Explanation Setting QPIT Factory settings settings settings settings Ink counter Rb 1 count = Head Driver (total) 100 ng...

  • Page 188: Component Layout Diagrams

    Stylus Pro 5000 Appendix A.3 COMPONENT LAYOUT DIAGRAMS Figure A-1. C228 PSB Board Figure A-2. C228 PSE Board A-10...
  • Page 189 Stylus Pro 5000 Appendix Figure A-4. C228 Main Board (Soldering side) Figure A-3. C228 Main Board (Component side) A-11...
  • Page 190 Stylus Pro 5000 Appendix Figure A-5. C228 Driver Board (Component side) Figure A-6. C228 Driver Board (Soldering side) A-12...

  • Page 191: Circuit And Exploded Diagrams

     C228 PSB Board (Power supply unit for 120 VAC input)  C228 PSE Board (Power supply unit for 220-240 VAC input)  C228 Main Board  C228 Driver Board  C228 Control Panel Board  Stylus Pro 5000 Exploded Diagrams A-13...
  • Page 192 Stylus Pro 5000 Appendix Figure A-7. C228 PSB Circuit Diagram A-14...
  • Page 193 Stylus Pro 5000 Appendix Figure A-8. C228 PSE Circuit Diagram A-15...

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