Epson Stylus Pro GS6000 User manual

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SERVICE MANUAL
EPSON Confidential
EXCEED YOUR VISION
SEIJ08001

Notice:
• All rights reserved. No part of this manual 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 prior written permission
of SEIKO EPSON CORPORATION.
• The contents
of this manual are subject to change without notice.
• All effort have been made to ensure the accuracy of the contents of this manual. However, should any errors be detected, SEIKO EPSON would greatly
appreciate being informed
of them.
• The above not withstanding SEIKO EPSON CORPORATION can assume no responsibility for any errors in this manual or the consequences thereof.
EPSON is a registered trademark ofSEIKO EPSON CORPORATION.
General Notice: Other product names used herein are for identification purpose only and may be trademarks or registered trademarks
of their
respective owners. EPSON disclaims any and all rights in those marks.
Copyright© 2008 SEIKO EPSON CORPORATION.
Imaging Products CS, PL & Environmental Management
Confidential

PRECAUTIONS
Precautionary notations throughout the text are categorized relative to I) Personal injury and 2) Damage to equipment.
DANGER Signals a precaution which,
if ignored, could result in serious or fatal personal injury. Great caution should be exercised in performing
procedures preceded by DANGER Headings.
WARNING Signals a precaution which,
if ignored, could result in damage to equipment.
The precautionary measures itemized below should always be observed when performing repair/maintenance procedures.
DANGER
1. ALWAYS DISCONNECT THE PRODUCT FROM THE POWER SOURCE AND PERIPHERAL DEVICES PERFORMING ANY MAINTENANCE OR
REPAIR PROCEDURES.
2. NO WORK SHOULD BE PERFORMED ON THE UNIT BY PERSONS UNFAMILIAR WITH BASIC SAFETY MEASURES AS DICTATED FOR ALL
ELECTRONICS TECHNICIANS IN THEIR LINE OF WORK.
3. WHEN PERFORMING TESTING AS DICTATED WITHIN THIS MANUAL, DO NOT CONNECT THE UNIT TO A POWER SOURCE UNTIL
INSTRUCTED TO DO SO. WHEN THE POWER SUPPLY CABLE MUST BE CONNECTED, USE EXTREME CAUTION IN WORKING ON POWER
SUPPLY AND OTHER ELECTRONIC COMPONENTS.
4. WHEN DISASSEMBLING OR ASSEMBLING A PRODUCT, MAKE SURE TO WEAR GLOVES TO AVOID INJURY FROM METAL PARTS WITH
SHARP EDGES.
WARNING
1. REPAIRS ON EPSON PRODUCT SHOULD BE PERFORMED ONLY BY AN EPSON CERTIFIED REPAIR TECHNICIAN.
2. MAKE CERTAIN THAT THE SOURCE VOLTAGES IS THE SAME AS THE RATED VOLTAGE, LISTED ON THE SERIAL NUMBER/RATING
PLATE. IF THE EPSON PRODUCT HAS A PRIMARY AC RATING DIFFERENT FROM AVAILABLE POWER SOURCE, DO NOT CONNECT IT TO
THE POWER SOURCE.
3. ALWAYS VERIFY THAT THE EPSON PRODUCT HAS BEEN DISCONNECTED FROM THE POWER SOURCE BEFORE REMOVING OR
REPLACING PRINTED CIRCUIT BOARDS AND/OR INDIVIDUAL CHIPS.
4. IN ORDER TO PROTECT SENSITIVE MICROPROCESSORS AND CIRCUITRY, USE STATIC DISCHARGE EQUIPMENT, SUCH AS ANTI-STATIC
WRIST STRAPS, WHEN ACCESSING INTERNAL COMPONENTS.
5. REPLACE MALFUNCTIONING COMPONENTS ONLY WITH THOSE COMPONENTS BY THE MANUFACTURE; INTRODUCTION OF SECOND-
SOURCE ICs OR OTHER NON-APPROVED COMPONENTS MAY DAMAGE THE PRODUCT AND VOID ANY APPLICABLE EPSON WARRANTY.
6. WHEN AIR DUSTER IS USED ON THE REPAIR AND THE MAINTENANCE WORK, THE USE OF THE AIR DUSTER PRODUCTS CONTAINING
THE INFLAMMABLE GAS IS PROHIBITED.
Confidential

About This Manual
This manual describes basic functions. theory of electrical and mechanical operations, maintenance and repair procedures of the printer. The instructions and procedures included
herein are intended for the experienced repair technicians, and attention should be given to the precautions on the preceding page.
Manual Configuration
This manual consists of six chapters and Appendix.
CHAPTER !.PRODUCT DESCRIPTIONS
Provides a general overview and specifications of the product.
CHAPTER 2.0PERA TING PRINCIPLES
Describes the theory of electrical and mechanical operations ofthe
product.
CHAPTER 3.TROUBLESHOOTING
Describes the step-by-step procedures for the troubleshooting.
CHAPTER 4.DISASSEMBLY I ASSEMBLY
Describes the step-by-step procedures for disassembling and assembling
the product.
CHAPTER S.ADJUSTMENT
Provides Epson-approved methods for adjustment.
CHAPTER 6.MAINTENANCE
Provides preventive maintenance procedures and the lists of Epson-
approved lubricants and adhesives required for servicing the product.
CHAPTER 7.APPENDIX
Provides the following additional information for reference:
• Connectors
• ASP List
• Exploded Diagrams
Svmhols Used in this Manual
Various symbols are used throughout this manual either to provide additional
information on a specific topic or to warn
of possible danger present during a
procedure
or an action. Be aware of all symbols when they are used, and always read
NOTE, CAUTION, or WARNING messages.
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D
CAUTlON
I
•
Indicates an operating or maintenance procedure. practice or condition
that is necessary to keep the product's quality.
Indicates an operating or maintenance procedure. practice, or condition
that,
if not strictly observed, could result in damage to, or destruction of.
equipment.
May indicate an operating
or maintenance procedure, practice or
condition that
is necessary to accomplish a task efficiently. It may also
provide additional information that
is related to a specific subject, or
comment on the results achieved through a previous action.
Indicates an operating or maintenance procedure, practice
or condition
that, if not strictly observed. could result
in injury or loss of life.
Indicates that a particular task must be carried out according to a certain
standard after disassembly and before
re -assembly, otherwise the quality
ofthe components in question may be adversely affected.
Confidential

Revision Status
Confidential

EPSONStylus Pro GS6000 Revision A
Contents
Chapter 1 PRODUCT DESCRIPTION 3.1.2 Troubleshooting Procedure ........................................................................ 40
1.1 Features ................................................................................................................. 9 3.2 Remedies for Error Messages .............................................................................
41
1.2 Basic Specifications ............................................................................................ 10
1.2.1 Printer Specifications ................................................................................. 10
3.3 Remedies for Service Call Error ........................................................................ 45
3.4 Remedies for Print Quality Troubles .................................................................. 50
1.2.2 Durability ................................................................................................... 13
1.2.3 Paper size/Printable area ............................................................................ 13 Chapter 4 DISASSEMBLY & ASSEMBLY
1.2.4 Print Mode I Print Resolution .................................................................... 14
1.3 Dimensions and Main Components .................................................................... 15
1.3.1 Dimensions and Weight ............................................................................. 15
1.3.2 Part Names ................................................................................................. 16
4.1 Overview ............................................................................................................ 54
4.1.1 Precautions ................................................................................................. 54
4.1.2 Orientation Definition ................................................................................ 56
4.1.3 Recommended Tools ................................................................................. 56
1.4 Control Panel ......................................................................................................
17
1.4.1 Buttons and Indicators ............................................................................... 17
4.2 Parts Diagram ..................................................................................................... 57
1.4.2 Panel Settings .............................................................................................
21
4.3 Disassembly Flowchart ...................................................................................... 66
1.4.3 Maintenance Mode .................................................................................... 28 4.4 Disassembly and Assembly Procedure ...............................................................
73
1.4.4 Serviceman Mode ...................................................................................... 29 4.4.1 Basic Operations ........................................................................................
73
4.4.2 Consumables/Accessories ......................................................................... 74
Chapter 2 OPERATING PRINCIPLES 4.4.3 Housing ......................................................................................................
75
4.4.4 Electric Components .................................................................................. 89
2.1 Glossary .............................................................................................................. 31
4.4.5 Fans ............................................................................................................ 91
2.2 Ink System .......................................................................................................... 32
2.3 Carriage Mechanism ........................................................................................... 33
4.4.6 Boards ........................................................................................................ 99
4.4.7 Sensors .....................................................................................................
113
4.4.8 Heaters/Thermistors ................................................................................. 127
2.4 Paper Feed Mechanism ....................................................................................... 34 4.4.9 Carriage Mechanism ................................................................................ 132
2.5 Heater Mechanism ..............................................................................................
35
4.4.10 Paper Feed Mechanism .......................................................................... 142
2.6 Boards ................................................................................................................. 36 4.4.11 Ink System Mechanism .........................................................................
145
2.7 Sensors ................................................................................................................ 37 4.4.12 Take-Up Reel Unit ................................................................................. 164
2.8 Fans ..................................................................................................................... 38 Chapter 5 ADJUSTMENT
Chapter 3 TROUBLE SHOOTING
5.1 Overview ........................................................................................................ .. 172
5
.1.1 Precautions ............................................................................................... 172
3.1 Overview ............................................................................................................ 40 5.1.2 Adjustment Items and the Order by Repaired Part ................................
.. 173
3 .1.1 Preliminary Check ..................................................................................... 40 5.1.3 Description
of Adjustments ..................................................................... 176

EPSONStylus Pro GS6000 Revision A
5.1.4 Tools for Adjustments ............................................................................. 178
6.4 Cleaning ............................................................................................................ 225
5.1.5 Service Program Basic Operations ..........................................................
179
6.4.1 Cleaning Wiper ........................................................................................ 226
5.1.6 Cautions and Preparation for Pattern Printing ......................................... 184 6.4.2 Around the Print head .............................................................................. 228
5.2 NV-RAM BACKUP UTILITY ........................................................................
185
6.4.3 Cleaning the Pressure Rollers and Platen ................................................ 229
5.3 CR Related Adjustments .................................................................................. 186
5.3.1 CR Belt Tension Adjustment ................................................................... 186
6.4.4 Cleaning and Lubricating the CR rail ......................................................
231
6.5 Lubrication ....................................................................................................... 232
5.3.2 CR Reduction Belt Tension Adjustment ................................................. 188
5.3.3 CR Height Adjustment ............................................................................ 189 Chapter 7 APPENDIX
5.3.4 Media Side Margin Adjustment ............................................................... 191
5.4 Head Related Adjustments ............................................................................... 192
5.4.1 Head Rank Input ...................................................................................... 192
7.1 Block Wiring Diagram ..................................................................................... 237
7.2 Panel Menu Map .............................................................................................. 238
5.4.2 Nozzle Check Pattern ..............................................................................
193
7.3 Parts List ........................................................................................................... 241
5.4.3 Cleaning and Washing ............................................................................. 194 7.4 Exploded Diagram ............................................................................................ 246
5.4.4 Ink Discharge ...........................................................................................
195
5.4.5 Initial Ink Charge Flag ............................................................................. 196
5.4.6 Head Slant and Alignment Adjustment ................................................... 197
5.4.7 Head Nozzles Alignment Adjustment ..................................................... 202
5.4.8 Head Uni-D/Bi-D Low Gap Adjustment ................................................. 203
5.5 PF Related Adjustments ................................................................................... 206
5.5.1 PF Reduction Belt Tension Adjustment .................................................. 206
5.5.2 Paper Feed Adjustment ............................................................................ 207
5.6 Other Adjustments ............................................................................................ 208
5.6.1 RTC and USB ID ..................................................................................... 208
5.6.2 Firmware Update ..................................................................................... 209
5.6.3 Washing Sequence ON/OFF Flag ........................................................... 211
5.7 Clear Counters .................................................................................................. 212
5.8 Tests .................................................................................................................. 213
5.8.1 Network Test ...........................................................................................
213
5.8.2 Skew Test ................................................................................................. 214
5.8.3 Electric Components Test ........................................................................ 215
Chapter 6 MAINTENANCE
6.1 Overview .......................................................................................................... 220
6.2 Setting up and Transportation .......................................................................... 221
6.2.1 Setting up ................................................................................................. 221
6.2.2 Transportation .......................................................................................... 222
6.3 Maintenance ..................................................................................................... 223