Assembling Point

When you install the ribbon feed change lever unit, join the tip of the tractor select lever and the tractor select gear holder correctly. (Refer to Figure 2-12.)

3.2.6.3 Tractor Select Lever (Upper and Lower) Assembly Disassembly

This section describes how to disassemble the tractor select lever assembly, including how to remove the ribbon feed motor and tractor select sensor.

Step 1: Remove the ribbon feed change lever unit. (Refer to Section 3.2.6.2.)

Step 2: Remove the two CP(S-P1)(M3x6) screws, leaf springs, and washers securing the ribbon feed motor to the ribbon feed motor frame and remove the motor. Step 3: Remove the E ring (# 3) securing the upper/lower tractor select levers and remove the levers. Step 4: Remove the E ring (# 3) securing the tractor select cam and remove the cam. Step 5: Remove the CPS(P1)(M2x10) screw securing the tractor select sensor and remove the sensor. Step 6: Using wire cutters, cut the wire band securing the ribbon feed motor and tractor select sensor cables to the ribbon feed motor frame.

Epson Dfx 5000 Disassembly
Figure 3-49. Tractor Select Lever Disassembly

ASSEMBLING POINT

z Attach the tractor select levers to the tractor select cam as shown in Figure 3-50.

(Upper and Lower) Figure 3-50. Tractor Select Lever Installation

3.2.6.4 Ribbon Jam Sensor Removal

Step 1: Remove the right cover. (Refer to Section 3.2.3.2)

Step 2: Disconnect the connector for the sensor from the connector junction board.

Step 3: Remove the CP(S-P1) (M3x6) screw securing the sensor to the bracket, and remove the sensor.

Figure 3-51. Ribbon Jam Sensor Removal

3.2.6.5 Connector Junction Board Assembly and FPC Board Assembly Removal

This section describes how to remove the connector junction board assembly and FPC board assembly.

Step 1: Remove the left side cover. (Refer to Section 3.2.3.2)

Step 2: Disconnect all the cables from the connector junction board assembly. Remove the two CP (S-P1) (M3x6) screws securing the connector junction board assembly to the printer mechanism and then remove the connector junction board assembly.

Step 3: Remove the front/rear tractor select lever assembly. (Refer to Section 3.2.6.2)

Step 4: Disconnect the connector for the CR sensor (encoder) from the FPC board assembly.

Step 5: Remove the 2 CBS (M3x8) screws securing the FPC cover and remove the cover (Refer to Figure 3-10). Then remove the CPS(P-1) (M3x6) screw securing the FPC board assembly to the printer mechanism and remove the FPC board assembly.

Epson Dfx 5000 Fan
Figure 3-52. Connector Junction Board Removal

ASSEMBLING POINT

When you connect the cables to the connector junction board assembly, note that the matching connectors have the same color and number of pins (Refer to APPENDIX Figure A-15.).

3.2.6.6 PG Sensor and PG Motor Removal

^CAUTION

When you remove or install the PG sensor, be careful not to bend the PG motor encoder plate.

Step 1: Remove the connector junction board assembly. (Refer to Section 3.2.6.5)

Step 2: Remove the CBS screw (3X6) securing the PG sensor unit to the left frame. Then take out the unit to the front and remove it. Step 3: Remove the screw securing the PG sensor to the unit, and remove the sensor. Step 4: Remove two CP (S-P1) (M3x6) screws securing the PG motor and remove the motor.

Encoder Plate

Encoder Plate

Encoder Plate
Figure 3-53. PG Sensor and PG Motor Removal

ASSEMBLING POINT

• When you install the PG motor, make sure the backlash between the PG motor and PG motor transmission gear is between 0.05 and 0.15 mm (almost no backlash).

• When you install the PG sensor unit, align the C-cut portion of the unit with the lower shaft securing the PG motor to the frame.

ADJUSTMENT REQUIRED

When you install the PG sensor or PG motor, perform the platen gap motor value (platen gap) adjustment, as described in Section 4.1.7.

3.2.6.7 Plunger and Paper Bail Assembly Removal

This section describes how to remove the plunger (loading solenoid) and paper bail assembly.

Step 1: Disconnect the black, 2-pin plunger connector from the connector junction board assembly, and remove the plunger cable from the connector junction board assembly. Step 2: Remove the two CP(S-P1) (M3x6) screws securing the plunger to the left side frame and remove the plunger.

Step 3: Remove the iron core of the plunger from the paper bail shaft.

Dfx 9000 Ring

Step 4: Remove the left tension roller lever spring.

Step 5: Remove the E-ring (6) securing the paper bail shaft to the left frame and remove the platen roller shaft holder and paper bail lever.

E-rings

Shaft Holder

Paper Bail Lever E-ring —

Tension Roller Lever Spring

E-rings

Shaft Holder

Paper Bail Lever E-ring —

Tension Roller Lever Spring

Figure 3-55. Paper Bail Assembly Removal 1/2

Step 6: Disconnect 2 fan harnesses and remove 2 screws (CPS-P1) securing the CR fan duct. Then remove the CR fan duct along with the CR fan. (Refer to Section 3.2.6.1.)

Step 7: Remove the right tension roller lever spring.

Step 8: Remove 2 E-rings to release the release tension lever at the inner side of the left frame.

Step 9: Remove the E-ring (6) at the right end of the paper bail shaft. Then remove the paper bail lever, leaf spring and shaft holder.

Step 10: Slide the shaft left to release the right end of the shaft from the right frame. Then lift up the shaft by the right end and remove it along with the release tension lever.

Paper Bail Assembly

Paper Bail Assembly

Epson Leaf Sensor
Leaf Spring /

Paper Bail Lever Figure 3-56. Paper Bail Assembly Removal 2/2

3.2.6.8 Upper Paper Guide and Top PE Sensor Removal

Step 1: Remove the paper bail assembly. (Refer to Section 3.2.6.7)

Step 2: Disconnect the red, 3-pin, top PE sensor connector from the connector junction board assembly.

Sensor Epson
Figure 3-57. Top PE Sensor Connector Removal

Step 3: Remove the two CBS (M4x6) screws securing the upper paper guide to both frames and remove the paper guide.

Step 4: Remove the two CPS(SP) (M3x8) screws securing the top PE sensor to the upper paper guide and remove the sensor.

Top PE Sensor

Upper Paper Guide

CBS(M4X6)

CBS(M4X6)

Figure 3-58. Top PE Sensor Removal

CBS(M4X6)

Figure 3-58. Top PE Sensor Removal

3.2.6.9 Tension Roller Shaft Removal

This section describes how to remove the tension roller shaft. It is better to remove the tension roller shaft with the paper bail assembly removed; however, removing it is not required. (Refer to Section 3.2.6.7.) for instructions on how to remove the paper bail assembly.)

Step 1: Remove the connector junction board assembly. (Refer to Section 3.2.6.5.) Step 2: Remove the paper bail assembly. (Refer to Section 3.2.6.7.) Step 3: While pushing the tension pulley to the front, remove the CR timing belt. Step 4: Remove the upper paper guide. (Refer to Section 3.2.6.8.)

Step 5: Using tweezers, unlock the locking tab of the tension roller gear at the left end of the tension roller shaft, and remove the gear. Step 6: Remove the E-ring (6) on the left end of the tension roller shaft and remove the shaft holder.

Right

Right

Carriage Belt Roller Tension

Tension Roller Gear

Tension Roller Shaft Assembly

Tension Roller Shaft Holder Figure 3-59. Tension Roller Gear Removal

Tension Roller Gear

Tension Roller Shaft Assembly

Tension Roller Shaft Holder Figure 3-59. Tension Roller Gear Removal

Step 7: Remove the CR motor fan. (Refer to Section 3.2.6.19.)

Step 8: Remove the E-ring (6) at the right end of the tension roller shaft and remove the tension roller shaft holder along with the leaf spring and the washer. Step 9: Remove the tension roller shaft by taking it out from the right frame.

Tension Roller Shaft

Assembly Tension Roller Shaft Holder

Tension Roller Shaft

Assembly Tension Roller Shaft Holder

Assembling Point
Figure 3-60. Shaft Holder Removal
Tension Roller Dfx 9000
Figure 3-61. Tension Roller Shaft Removal

3.2.6.10 Platen Removal

Step 1: Remove the paper bail assembly. (Refer to Section 3.2.6.7.) Step 2: Remove the upper paper guide. (Refer to Section 3.2.6.8.)

Step 3: Remove the four hexagon socket screws securing the platen to the platen holders. Then remove the platen with the lower paper guide composed of 3 parts in it. Step 4: Slide the 3 parts of the lower paper guide to release the notches and remove them one by one from the platen.

Lower Paper Guide Epson P7600
No through

Positionning Tab

Figure 3-63. Platen Positioning

Positionning Tab

Figure 3-63. Platen Positioning

ASSEMBLING POINT

• When you attach the 3 parts of the lower paper guide to the platen, start with the one at the right end and work toward the left.

• When you mount the platen to the platen holders, space between the platen and positioning tab on the both sides must be less than 0.03mm. (Refer to Figure 3-63.)

ADJUSTMENT REQUIRED

When you install the platen, perform the following adjustments:

• Carriage guide shaft parallelism adjustment (described in Section 4.1.5 and Section 4.1.6)

• Platen angle (right angle) adjustment (described in Section 4.1.6)

• Platen gap motor value (platen gap) adjustment (described in Section 4.1.7)

3.2.6.11 Paper Jam Sensor Removal

Step 1: Remove the platen along with the lower paper guide composed of 3 parts. (Refer to Section 3.2.6.10.)

Step 2: Remove the CPN(SP)(M4x8) screw securing the left part of the lower paper guide to the platen. Step 3: Remove the part from the platen.

Epson Multifunction Printer Sensor Jam

Step 4: Unhook the paper jam sensor (magnetic transistor) cover to remove it. Step 5: Remove the paper jam sensor.

Epson Paper Jam Sensor
Figure 3-65. Paper Jam Sensor Removal

ASSEMBLING POINT

When you attach the paper jam sensor, make sure it is oriented correctly (front to back).

3.2.6.12 Pull Tractor Sensor Removal

Step 3:

Assembling Point

Remove the upper paper guide. (Refer to Section 3.2.6.8)

Disconnect the red 2-pin pull tractor sensor connector from the connector junction board assembly.

Remove the CP(S) (M2x14) screw securing the pull tractor sensor (a micro-switch type sensor) to the left side frame and remove the sensor.

3.2.6.13 Paper Width (PW) Sensor Removal

Step 1: Disconnect the connector for the PW sensor.

Step 2: Remove the CP(S-P1) (M2.5x6) screw securing the PW sensor to the ribbon mask holder.

Epson Dfx 8500 Ribbon

Paper Width Sensor Connector Figure 3-67. PW Sensor Removal

Paper Width Sensor ^»j

Paper Width Sensor Connector Figure 3-67. PW Sensor Removal

3.2.6.14 PG Home Sensor Removal

Step 1: Remove the front/rear tractor select lever assembly. (Refer to Section 3.2.6.2.)

Step 2: Remove the E-ring securing the carriage guide shaft gear to the rear carriage guide shaft.

Epson Artisan 810 Gears

Carriage Guide Shaft (Rear)

Carriage Guide Shaft Gear

E-ring

Figure 3-68. Carriage Guide Shaft Gear Removal

Carriage Guide Shaft (Rear)

Carriage Guide Shaft Gear

E-ring

Figure 3-68. Carriage Guide Shaft Gear Removal

Step 3: Disconnect the white, 2-pin, PG home sensor connector from the connector junction board assembly.

Step 4: Detach the hook securing the PG home sensor and remove the sensor.

Motor Gap Platen

PG Home Sensor

J7 i) J^-^ J HIIIH V--^Platen Gap (PG) Motor Figure 3-69. PG Home Sensor Removal

PG Home Sensor

J7 i) J^-^ J HIIIH V--^Platen Gap (PG) Motor Figure 3-69. PG Home Sensor Removal

ASSEMBLING POINT

When you install the CR guide shaft gear, align the rib in the CR guide shaft gear with the PG adjustment transmission gear as shown in the figure below, then rotate the CR guide shaft gear 10 mm in CCW.

Flat Part of CR Guide Shaft (Rear) Frame Left

CR Guide Shaft Gear

CR Guide Shaft Gear

Transmission Gear

■ Advance 10 mm Stopper

Figure 3-70. CR Guide Shaft Gear Phase Alignment

■ Advance 10 mm Stopper

Figure 3-70. CR Guide Shaft Gear Phase Alignment

3.2.6.15 PF Motor Removal

Step 1: Remove the connector junction board assembly. (Refer to Section 3.2.6.5.)

Step 2: Remove the three CP (SP-1) (M4x8) screws securing the PF motor to the left side frame.

Step 3: Remove the PF motor from the inside of the left side frame.

Figure 3-71. PG Home Sensor Removal

3.2.6.16 Left Side Frame Gear Removal

Step 1: Remove the front/rear tractor select lever assembly. (Refer to Section 3.2.6.2.) Step 2: Remove the connector junction board assembly. (Refer to Section 3.2.6.5.) Step 3: Remove the PG motor. (Refer to Section 3.2.6.6.)

Step 4: Remove the series of gears in the order indicated by the numbers in Figure 3-72.

Epson Dfx 8500 Tractor

3.2.6.17 Front Tractor Assembly Removal

This section describes how to remove the front tractor assembly.

Step 1: Disconnect the connector white 3-pin front PE sensor from the connector junction board.

Step 2: Remove the connector junction board assembly. (Refer to Section 3.2.6.5.)

Step 3: Lay the mechanism on its back.

Step 4: Remove the screw securing the tractor wire holder to the left side frame and remove the holder.

Step 5: Loosen the flange nut securing the front tractor assembly to the left side frame by the left end, and remove the tractor transmission gear.

Step 6: Remove the flange nut on the right side and remove the right tractor wire spring holder set.

Step 7: Remove the E-ring (6) securing the rear shaft of the front tractor assembly to the left side frame and remove the shaft holder.

Step 8: Move the assembly to left to release the right end of the shaft, then release the left side of the shaft from the left side frame and remove the assembly.

Tractor Wire Holder (L)

Carriage Motor

Tractor Wire

Holder (R) Tractor

Wire Spring

Tractor Wire

Holder (R) Tractor

Wire Spring

Carriage Motor

Figure 3-73. Tractor Wire Removal

Tractor Transmission Gear

Flange Nut

Figure 3-73. Tractor Wire Removal

Tractor Transmission Gear

Flange Nut

Epson Leaf Sensor

Flange Nut E-ring (6)

Shaft Holder Leaf Spring

Washer

Tractor Assembly (Front) Figure 3-74. Front Tractor Assembly Removal

Shaft Holder

Flange Nut E-ring (6)

Shaft Holder Leaf Spring

Washer

Tractor Assembly (Front) Figure 3-74. Front Tractor Assembly Removal

ADJUSTMENT REQUIRED

• When you install the front tractor assembly, perform the tractor wire spring adjustment, as described in Section 4.1.3.

3.2.6.18 Rear Tractor Assembly Removal

This section describes how to remove the rear tractor assembly.

Step 1: Disconnect the connector white 3-pin rear PE sensor from the connector junction board. Step 2: Remove the connector junction board assembly. (Refer to Section 3.2.6.5.) Step 3: Remove the flange nut securing the wire holder spring set to the right side frame, and remove the set.

Step 4: Loosen the flange nut securing the rear tractor assembly to the left side frame. Step 5: Remove the CBS(M4x8) screw securing the tractor wire holder and remove the holder. Step 6: Remove the rear tractor gear.

Step 7: Remove the E-ring and release the shaft holder from the left side frame.

Step 8: To remove the rear tractor assembly, first move it to the left to release the right end of the shaft from the right side frame. Then release the left end of the shaft and remove the assembly.

Image Epson Left Rear Tractor
Figure 3-75. Rear Tractor Assembly Removal

ADJUSTMENT REQUIRED

When you install the rear tractor assembly, perform the tractor wire spring adjustment, as described in Section 4.1.3.

3.2.6.19 CR Motor Fan Removal

Step 1: Disconnect the cable for the motor from the relay connector. Step 2: Remove 2 fan fixing screws and remove the fan.

Fan Removal Carriages
Figure 3-76. CR Motor Fan Removal

3.2.6.20 CR Motor Removal

Step 1: Remove the right cover. (Refer to Section 3.2.3.2.)

Step 2: Disconnect the red and black cables from the terminals on the CR motor. (two cables for each terminal)

Step 3: Remove the three CP(S) (M4x10) screws securing the CR motor to the right side frame and remove the motor.

CR Motor Figure 3-77. CR Motor Removal

ADJUSTMENT REQUIRED

• When you install the CR motor, perform the carriage timing belt tension adjustment, as described in Section 4.1.2.

• When you install the printhead, perform the platen gap motor value (platen gap) adjustment, as described in Section 4.1.7.

3.2.6.21 CR (Carriage Encoder) Sensor Removal

Step 1: Remove the printhead. (Refer to Section 3.2.2.)

Step 2: Disconnect the red 4-pin CR sensor connector from the carriage connector junction board. Step 3: Remove the two CP(S-P1) (M2.6 x 5) screws securing the CR sensor to the carriage and remove the sensor.

Carriage Encoder Sensor

Carriage 4-pin Connector

Carriage Encoder Sensor

Encoder Sensor

Carriage 4-pin Connector

Figure 3-78. CR Sensor Removal 1/2

Carriage Connector Junction Board

Figure 3-78. CR Sensor Removal 1/2

Dfx 5000 Encoder Sensor
Figure 3-79. CR Sensor Removal 2/2

3.2.6.22 Carriage Mechanism Disassembly

This section describes how to disassemble the carriage mechanism, including removing the carriage, CR timing belt, and front and rear carriage guide shafts.

Step 1: Remove the CR motor. (Refer to Section 3.2.6.20.) Step 2: Remove the belt pulley from the belt pulley holder.

How Replace Belt Epson

Step 3: Unhook the spring securing the encoder belt to the right side frame. (Refer to Figure 2-5.) Step 4: Loosen the two flange nuts securing the front carriage guide shaft to the left and right side frames.

Shaft Guide Front Dfx8500

Step 5: Remove the front carriage guide shaft by pulling it through the hole in the right side frame. (When you remove the front carriage guide shaft, move the carriage to the left side.)

Step 6: On the left side frame, remove the E-ring (6) securing the carriage guide shaft gear to the rear carriage guide shaft, then remove the carriage guide shaft gear and paper thickness sensor holder.

Step 7: Unhook the spring securing the paper thickness sensor assembly and remove the sensor assembly.

Rear Carriage Guide Shaft

Paper Thickness Sensor

Carriage Guide Shaft Gear

Rear Carriage Guide Shaft

Paper Thickness Sensor

Carriage Guide Shaft Gear

Hexagon 125 Motor

PG Motor

Figure 3-82. Rear Carriage Guide Shaft Removal

PG Motor

Figure 3-82. Rear Carriage Guide Shaft Removal

Step 8: Remove the PG motor. (Refer to Section 3.2.6.6.)

Step 9: Remove the carriage damper (solid rubber) from the inner side of the right side frame, and remove the three CBS (M4x8) screws securing the carriage motor holder to the right side frame.

Step 10: Remove the guide shaft holding spring and the E-ring, then remove the right guide shaft holder lever.

Step 11: Remove the two CP(S-P1) (M4x6) screws securing the parallelism adjust lever and remove the lever.

Step 12: Remove the rear carriage guide shaft with the carriage base from the right side frame.

Rear Carriage Guide Shaft

Parallelism Adjustment Lever CP(S-P1)(M4X6)

Rear Carriage Guide Shaft

Carriage Guide Epson 1170

Guide Shaft Holder Lever (Right)

Guide Shaft Holding Spring

Carriage Motor Holder

Figure 3-83. Right Side Frame Removal

Guide Shaft Holder Lever (Right)

Guide Shaft Holding Spring

Carriage Motor Holder

Figure 3-83. Right Side Frame Removal

ASSEMBLING POINT

When you install the front carriage guide shaft, tighten the screws while pushing the shaft toward the platen.

ADJUSTMENT REQUIRED

When you assemble the carriage mechanism, perform the following adjustments:

• Carriage timing belt tension adjustment (described in Section 4.1.2)

• Carriage guide shaft parallelism adjustment (described in Section 4.1.5 and Section 4.1.6)

• Platen gap motor value (platen gap) adjustment (described in Section 4.1.7)

• Bidirectional printing adjustment (described in Section 4.1.8)

3.2.6.23 Paper Support Assembly Removal

Step 1: Disassemble the carriage mechanism and remove all the parts related to the carriage. (Refer to Section 3.2.6.22.)

Step 2: Referring to the exploded diagram in the Appendix, remove the paper support assembly.

ADJUSTMENT REQUIRED

When you install the paper support assembly, perform the following adjustments:

• Carriage timing belt tension adjustment (described in Section 4.1.2)

• Carriage guide shaft parallelism adjustment (described in Section 4.1.5 and Section 4.1.6)

• Platen gap motor value (platen gap) adjustment (described in Section 4.1.7)

• Bidirectional printing adjustment (described in Section 4.1.8)

3.2.6.24 3.2.6.21 PF Drive Roller Removal

Step 2: Remove the CR motor. (Refer to Section 3.2.6.20)

Step 3: Remove the left side frame gears. (Refer to Section 3.2.6.16)

Step 4: Referring to the exploded diagram in the Appendix, remove the PF driver roller.

ADJUSTMENT REQUIRED

When you install the PF drive roller, perform the following adjustments:

• Carriage timing belt tension adjustment (described in Section 4.1.2)

• Carriage guide shaft parallelism adjustment (described in Section 4.1.5 and Section 4.1.6)

• Platen gap motor value (platen gap) adjustment (described in Section 4.1.7)

• Bidirectional printing adjustment (described in Section 4.1.8)

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