Epson 7600, 9600 service manual

EPSON Stylus Pro 7600/9600

Color Large Format Inkjet Printer

SERVICE MANUAL

SEIJ01017

Contents

Main Notice: PRECAUTIONS DANGER WARNING About This Manual Manual Configuration Symbols Used in this Manual Page EPSON Stylus Pro 7600/9600 Revision A Contents Chapter 1 Product Description EPSON Stylus Pro 7600/9600 Revision A Chapter 2 Operating Principles Chapter 3 Troubleshooting Chapter 4 Disassembly & Assembly EPSON Stylus Pro 7600/9600 Revision A Chapter 5 Adjustment Chapter 6 Maintenance Chapter 7 Appendix Page 1.1 Product Description 1.1.1 Features Product Description Product Description 13 1.1.2 Differences between Stylus Pro 7600 and Stylus Pro 9600 Table 1-3. Di fferences between Stylus Pro 7600 and Stylus Pro 9600 1.2 Basic Specifications 1.2.1 Print Specifications 1.2.2 Character Specification 1.2.3 Control Code 1.2.4 Paper Feed 1.2.5 Paper Specifications 1.2.5.1 Roll Paper 1.2.5.2 Sheet Product Description Basic Specifications 18 1.2.5.3 Special Paper Table 1-11. Availability with Special Paper (Pigment) Product Description Basic Specifications 19 Table 1-12. Availability with Special Paper (Dye) Product Description Basic Specifications 20 1.2.6 Mechanism Specifications 1.2.6.1 Printable Area 1.2.6.2 Paper Set Lever 1.2.6.3 Cutting Specification 1.2.6.4 Acoustic Noise 1.2.7 Electrical Specifications (TBD) 1.2.8 Reliability 1.2.8.1 Total Print Volume 1.2.8.2 Print Head Life 1.2.8.3 Maintenance Tank Life 1.2.9 Ambient Conditions 1.2.9.1 Temperature/Humidity 1.2.9.2 Vibration 1.2.9.3 Shock 1.2.9.4 Surrounding Space 1.2.10 Overall Dimensions Page 1.2.11 Accessories 1.2.11.1 Accessories and Options for Stylus Pro 7600 1.2.11.2 Accessories and Options for Stylus Pro 9600 Product Description External View and Parts Names 30 1.3 External View and Parts Names Note : Shown above is Stylus Pro 7600 Figure 1-6. External View and Parts Names EXTERNAL VIEW Product Description Operating Panel 31 1.4 Operating Panel 1.4.1 Buttons and Functions The operating panel contains the following buttons. Figure 1-7. Panel Design Paper Feed Paper Feed (setup value -) 1.4.1.2 LEDs Table 1-21. LEDs (continued) Product Description Operating Panel 33 1.4.2 Indications on the Panel 1.4.2.1 lED Indications in Normal Mode Table 1-22. Table 1-23. Table 1-24. 1.4.2.2 LCD Indications in Normal Mode NOTE: For details of error display, refer to 3.2.1 Errors (p.123). Table 1-27. Indications (in Normal Mode) Table 1-27. Indications (in Normal Mode) (continued) 1.4.3 SelecType 1.4.3.1 Outline 1. 2. 3. 1.4.3.2 Panel Setting Menu Item Table 1-28. Panel setting menu item Page Page Page Product Description Operating Panel 40 1.4.3.3 PG Setting Table 1-29. PG Setting Values Table 1-29. PG Setting Values (continued) 1.4.3.4 Page Lines 1.4.3.5 Interface Select 1.4.3.6 Code Page Switching 1.4.3.7 Roll Paper Margin 1.4.3.8 Detect Paper Width 1.4.3.9 Detect Skew Error 1.4.3.10 Job Timeout Setting Product Description Operating Panel 43 1.4.3.11 No margin print setting No margin print mode can be switched with these settings. Following 3 modes can be selected; Table 1-31. Table 1-32. 1.4.3.12 Cutter position adjustment 1.4.3.13 Auto margin refresh 1.4.3.14 Panel Setup Value Initialization 1.4.3.15 Nozzle Check Pattern Printing 1.4.3.16 Status Printing 1. 2. 3. 4. 5. Product Description Operating Panel 47 Figure 1-12. Status Sheet Print Pattern 1.4.3.17 Job Information Print 1.4.3.18 Firmware version 1.4.3.19 Printable pages of each ink cartridge 1.4.3.20 Ink remaining 1.4.3.21 Maintenance tank count 1.4.3.22 Use counter 1.4.3.23 Clear use counter 1.4.3.24 Job history display 1.4.3.25 Job history clear 1.4.3.26 Total prints 1.4.3.27 Consumables life Page Page Product Description Operating Panel 54 After detection of Ink Low, the display is changed from a graph to a% indication. Product Description Operating Panel 55 1.4.3.30 Job information Figure 1-14. Printing Job Transition This printer saves following job information (68byte 10job) in NVRAM. Table 1-37. Job information 1.4.3.31 User Paper Setting 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Product Description Operating Panel 57 Figure 1-15. Level Structure of User Setting Menu Page 1.4.3.32 Power cleaning 1.4.3.33 Cutter Blade Replacement 1.4.3.34 Gap Adjustment (Bi-D Adjustment, Uni-D Adjustment) Product Description Operating Panel 61 Table 1-44. Product Description Operating Panel 62 Figure 1-18. Level Structure of Gap Adjustme nt Menu Product Description Operating Panel 63 GAP ADJUSTMENT PRINT PATTERN (TBD) Print specifications of gap adjustment print pattern 1.4.3.35 BK ink cartridge replacement 1. 2. 3. 4. 2. 1. 2. 1. 2. 3. 4. 1.4.4 Maintenance Mode 1 1. 2. Each setting menu is displayed one after another by pressing Paper Feed 3. The setting menu is displayed one after another by pressing Paper Feed 4. 5. (EXPIR DATE M) Product Description Operating Panel 68 Note *1 : When hexadecimal dump mode is executed, PRINT is displayed. 1.4.5 Maintenance Mode 2 Product Description Operating Panel 71 MAINTENANCE MODE 2 SETUP ITEMS Table 1-48. Maintenance mode 2 setup items For R4C825P StylusPro9600 StylusPro9600D PX-9000 Page Page Page EPSON Stylus Pro 7600/9600 Revision A Page Page Page Page Page Page Page 1.4.6 Paper feeding adjustment conversion table 1.4.7 Firmware Reload 1.4.7.1 Reload from ROM-DIMM 1.4.7.2 Reload with F/W DOWNLOAD mode 1.4.7.3 Installation with service utility (F/W Update function) 1.4.7.4 Compulsory start F/W DOWNLOAD mode 1.4.8 Function to prevent irregular printing 1.4.9 Initialization 1.4.9.1 Hardware initialization 1.4.9.2 Software initialization 1.4.9.3 Panel initialization 1.4.10 Default Setup Values 1.4.10.1 Initial Setting for Operation 1.4.10.2 Ink Type Setting 1.4.10.3 MW Printing Adjustment / Setting Values and Printing Modes Table 1-51. MW Printing Adjustment / Setting Values and Printing Modes Product Description Operating Panel 89 1.4.10.4 Printing Mode Combination Table Valid print mode combination is following; Table 1-52. 1.5 Controller 1.6 Interfaces 1.6.1 Parallel Interface 1.6.1.1 Compatibility Mode Product Description Interfaces 92 PARALLEL INTERFACE TIMING CHART Figure 1-19. Timing Chart Table 1-54. 1.6.1.2 Nibble Mode 1.6.1.3 ECP Mode 1.6.2 USB interface EPSON Stylus Pro 7600/9600 Revision A 1.6.3 Optional Interface 1.6.4 Supplements 1.7 Optional Units and Consumables 1.7.1 Ink Cartridge 1.7.2 Cleaning cartridge 1.7.3 Draining cartridge 1.7.4 Maintenance Tank Page 2.1 Overview Operating Principles Print Mechanism Components 102 2.2 Print Mechanism Components Table 2-1. Prin ter Mechanism Components (continued) 2.2.1 Carriage (CR) Mechanism Page Page Page Operating Principles Print Mechanism Components 109 Figure 2-7. Paper Size Detection Sequence (Left and Right Edges) Set the paper correctly Page 2.2.2 Paper Feed Assembly 2.2.3 Cleaning Mechanism Page 2.2.4 Ink Supply Mechanism 2.2.5 Others Operating Principles Outline of Control Circuit Board 119 2.3 Outline of Control Circuit Board Figure 2-20. C472MAIN Board-Circuit Block Diagram Table 2-8. M ajor Elements 2.4 Outline of Power Supply Circuit Board Page 3.1 Outline 3.1.1 Introduction Troubleshooting Error Display 123 3.2 Error Display 3.2.1 Errors Errors, Warnings and service call errors (fatal errors) are described below. 3.2.1.1 Error Indications on LCD Table 3-1. Error Indications on LCD 3.2.1.2 Warning Indications on LCD Troubleshooting Error Display 125 3.2.1.3 Service Call (Fatal) Errors Table 3-3. Service Call (Fatal) Errors Table 3-3. Service Call (Fatal) Errors (continued) Troubleshooting Error Display 126 3.2.2 Errors 3.2.2.1 Paper End/End of roll 3.2.2.3 Paper set lever is released during operation 3.2.2.2 Wrong paper source is selected on panel Table 3-4. 3.2.2.4 Paper set lever is released 3.2.2.5 Paper Jam 3.2.2.6 Front Cover Open Table 3-8. Table 3-9. 3.2.2.7 Type-B I/F error 3.2.2.8 Paper cutting error 3.2.2.9 Paper Not Straight Table 3-11. Table 3-12. 3.2.2.10 Paper check error/Paper eject error (sheet) 3.2.2.11 Paper is too thick for cleaning 3.2.2.12 Not enough ink for cleaning Table 3-14. Table 3-15. Table 3-16. 3.2.2.13 Ink-related Errors 3.2.2.15 Ink lever released 3.2.2.14 Defective ink cartridge Troubleshooting Error Display 131 3.2.2.16 Illegal ink cartridge 3.2.2.17 Maintenance tank full 3.2.2.20 Fatal Error 3.2.2.18 No Maintenance tank 3.2.2.19 Wrong IK designation 3.2.3 Troubleshooting for Warning 3.2.3.1 Ink Low 3.2.3.2 Maintenance tank full warning 3.2.3.3 Maintenance request Page 3.2.4 Troubleshooting for Service Call Errors 3.2.4.1 CR motor life (00000101) 3.2.4.2 PF motor encoder check error (00010000) 3.2.4.3 PF Motor out of step (00010001) 3.2.4.4 PF motor overcurrent (00010002) 3.2.4.5 PF motor in-position time out (00010003) 3.2.4.6 CR motor encoder check error (00010004) 3.2.4.7 CR motor out of step (00010005) 3.2.4.8 CR motor overcurrent (00010006) 3.2.4.9 CR motor in-position time-out (00010007) 3.2.4.10 Servo interrupt watchdog time-out (00010008) 3.2.4.11 System interrupt watchdog time-out (00010009) 3.2.4.12 CR home position sensor error (0001000A) 3.2.4.13 PF home position sensor error (0001000B) 3.2.4.14 Head slide (PG) home position sensor error (0001000C) 3.2.4.15 CR motor PWM output faulty (0001000F) 3.2.4.16 PF motor PWM output faulty (00010010) 3.2.4.17 Head driver (TG) temperature error (0001001B) 3.2.4.18 CR servo parameter error (0001001D) 3.2.4.19 PF servo parameter error (0001001E) 3.2.4.20 CSIC reed/right error (00010020) 3.2.4.21 Ink type error (setting on printer body side) (00010022) 3.2.4.22 RTC analysis error (00010023) 3.2.4.23 CSIC ROM communication error (00010025) 3.2.4.24 RTC communication error (00010026) 3.2.4.25 Head error (00010028) 3.2.4.26 Unidentified NMI (00010029) 3.2.4.27 CR ASIC ECU error (0001002A) 3.2.4.30 SDRAM error (00020002) 3.2.4.31 BOOT program SUM error (00020003) 3.2.4.32 Flash memory SUM error (00020009) 3.2.4.33 Program load error (0002000A) 3.2.4.34 Internal memory shortage error (0002000B) 3.2.4.35 Review error (0002000C) 3.2.4.36 CPU address error (load misalignment) (100000E0) 3.2.4.37 CPU address error (storage misalignment) (10000100) 3.2.4.38 CPU reserve command code exception error (10000180) 3.2.4.39 CPU slot illegal command exception error (100001A0) 3.3 Troubleshooting Based on Your Printout 3.3.1 Dot Missing 3.3.2 Uneven Printing/Poor Resolution 3.3.3 Smudged or Marred Printout (Front) 3.3.4 Smudged or Marred Printout (Reverse side) 3.3.5 White or Black Banding in the carriage running direction 3.3.6 Banding in the paper feed direction Page 4.1 Summary 4.1.1 Precautions Page Page Disassembly & Assembly Summary 155 4.1.2 Tools This section lists the tools necessary to disassemble or assemble the printer. 4.1.3 Screw List The following table lists all the screws used in this printer. Table 4-1. Necessary Tools Table 4-2. Screws 4.1.4 Disassembly Flow Disassembly & Assembly Summary 157 Figure 4-2. Disassembly Process Flowchart 4.2 Removing the Panel Unit and Housing 4.2.1 Panel Unit 4.2.2 R Side Cover Page Page 4.2.3 L Side Cover 4.2.4 I/H Cover 4.2.5 H Top Cover 4.2.6 Rear Cover Page 4.2.7 Paper Guide L2 4.2.8 Roll Paper Cover 4.2.9 Front Cover 4.3 Disassembly and Assembly of Carriage (CR) 4.3.1 Print Head Page 4.3.2 Damper ASSY 4.3.3 CR Board ASSY 4.3.4 Cutter Section 4.3.4.1 Cutter Holder ASSY Page 4.3.4.2 Cutter Solenoid 4.3.5 CR Encoder Sensor ASSY 4.3.6 P_EGDE Sensor ASSY 4.3.7 CR Motor ASSY Page 4.3.8 HEAD_SLIDE Sensor ASSY 4.3.9 CR_HP Sensor ASSY 4.3.10 CR Encoder Scale (Timing Fence) 4.4 Disassembly and Assembly of Paper Feed 4.4.1 PF Motor 4.4.2 PF Encoder Sensor ASSY Page 4.4.3.2 PF Loop Scale ASSY Affixing Procedure 4.4.4 Suction Fans 4.4.5 P_THICK Sensor/P_THICK Sensor_0.3 ASSY 4.4.6 P_REAR Sensor ASSY 4.5 Disassembly and Assembly of Ink Supply 4.5.1 C472_SUB-B Board 4.5.2 I/H (Ink Holder) ASSY Page Page Page 4.5.3 Cover Sensor ASSY 4.6 Disassembly and Assembly of Cleaning 4.6.1 Maintenance ASSY Removal 2. 4.6.2 Pump Motor ASSY 4.6.3 Cap ASSY 4.6.4 Pump ASSY Page 4.6.5 Cleaner Head (Wiper) 4.6.6 Flushing Box ASSY 4.7 Disassembly and Assembly of Circuit Boards 4.7.1 Power Supply Board 4.7.2 AC Inlet 4.7.3 MAIN Board (C472 MAIN) Disassembly & Assembly Disassembly and Assembly of Circuit Boards 208 Figure 4-85. Connector Locations CN.No. Pins Color Connection Remarks Disassembly & Assembly Disassembly and Assembly of Circuit Boards 209 4.7.4 DIP Switch and Jumper Setting at Factory before Shipment Table 4-7. Jumper Setting at Factory at Shipment Page 5.1 Overview 5.1.1 Cautions 5.1.2 Adjustment Tools 5.1.3 Procedure for Adjustment Work 5.1.4 Adjustment Items 5.1.4.1 Print Head Adjustment 5.1.4.2 Main Board Adjustment 1. 2. 3. 5.1.4.3 CR Motor Adjustment 5.1.4.4 PF Motor Adjustment 5.1.4.5 P_EDGE Sensor ASSY Adjustment 5.1.4.6 P_REAR Sensor ASSY Adjustment 5.1.4.7 P_THICK/P_THICK_0.3 Sensor ASSY Adjustment 5.1.4.8 CR Encoder Sensor ASSY Adjustment 5.1.4.9 Cover Sensor ASSY Adjustment 5.1.4.10 PF Encoder Sensor ASSY Adjustment 5.1.4.11 Cutter Solenoid ASSY or Paper Guide L Adjustment 5.1.4.12 Damper ASSY Adjustment 5.1.4.13 Release Sensor (I/H Lever) Adjustment 5.1.4.14 Battery 5.1.5 Parameter Backup 5.1.5.1 Parameter Backup Procedure 5.1.5.2 Work Procedure 5.1.6 Firmware Reinstallation 5.1.6.1 Firmware Installation through ROM-DIMM 5.1.6.2 Firmware Installation through Interface 5.2 Self-diagnostic Function 5.2.1 Overview 5.2.1.1 How to Start Self-diagnostic Function 5.2.1.2 Functions of Keys during Self-diagnosis Adjustment Self-diagnostic Function 221 5.2.1.3 Top Menu Figure 5-2. Top Menu Transition Table 5-16. Self-diagnostic Function List Adjustment Self-diagnostic Function 222 5.2.2 Test Figure 5-3. Inspection Menu Transition Test is intended to check the circuit boards. Table 5-17. Circui t Board Check Items 5.2.2.1 Version 5.2.2.2 Control Panel 5.2.2.3 Sensors 5.2.2.4 Encoder 5.2.2.5 Fan Adjustment Self-diagnostic Function 226 5.2.2.6 Record Figure 5-10. Menu Transition of Maintenance Record Note"*": Not used Figure 5-9. Menu Transition of Record Table 5-18. 5.2.2.7 CSIC Adjustment Self-diagnostic Function 228 Figure 5-13. Menu Transition for Internal Information Display of CSIC 5.2.2.8 Actuator 5.2.2.9 Actuator 2 Adjustment Self-diagnostic Function 230 5.2.3 Adjustment Figure 5-17. Adjustment Menu Transition Make the mechanism adjustment (head slant) and the firmware parameter adjustment. Table 5-19. Panel Setting Item List Table 5-19. Panel Setting Item List (continued) 5.2.3.1 Rear AD Adjustment 5.2.3.2 Edge AD Adjustment 5.2.3.3 Input Rank 5.2.3.3.1 QR Code Input 5.2.3.3.2 Input on Panel Page 5.2.3.4 Write D/A Value 5.2.3.5 Check Nozzle 5.2.3.6 Check Skew 5.2.3.7 Feed Correction + T&B Adjustment Page 5.2.3.8 Top & Bottom Adjustment 5.2.3.9 Rear Sensor Position 5.2.3.10 Platen Position (Sponge Position) Adjustment 5.2.3.11 Platen Position Checking 5.2.3.12 Head Slant Checking Page 5.2.3.13 Round Trip Print Position Adjustment (Bi-D Adjustment) 1. 2. 3. 4. Page 5.2.3.14 Parameter Copying 5.2.3.15 Bi-D2 Adjustment (PG=0.7mm) 5.2.3.16 Bi-D3 Adjustment (PG=2.1mm) 5.2.3.17 Round Trip Print Position (Bi-D Adjustment) Checking 5.2.3.18 Head Gap Adjustment (Uni-D Adjustment) 1. 2. 3. 5.2.3.19 Test Pattern Printing Adjustment Self-diagnostic Function 256 5.2.3.20 Clean Head Draining Cartridge. Figure 5-57. M enu Transition for Head Cleaning When replacing the print head, execute ink discharge (Ink Blowing) by using this function. If transition in the sequence can not take place for some reason, the display shows Reset ** I/C. 5.2.3.21 Counter Clear Counters to be Cleared Initial Value C A U T IO N This function is to be used to initialize each counter value at the Counters to be Cleared Initial Value Table 5-24. Counters to be Cleared and Their Initial Values (continued) Page Adjustment Self-diagnostic Function 259 5.2.4 Cleaning Figure 5-61. Printing Menu Transition 5.2.5 Print Figure 5-60. Cleaning Menu Transition Table 5-25. Cleaning Items 5.2.6 Parameter Adjustment Self-diagnostic Function 261 5.2.6.1 Parameter Initialize Item Contents Execute parameter initialization. Item Contents Table 5-28. Adjustment Self-diagnostic Function 262 Figure 5-63. Menu Transition for Parameter Initialization 5.3 Mechanism Adjustment 5.3.1 Overview 5.3.2 CR Timing Belt Tension Adjustment 5.3.3 PF Timing Belt Tension Adjustment 5.3.4 P_THICK_0.3/P_THICK Sensor Mounting Plate Position Adjustment Page 5.3.5 Cover Sensor ASSY Mounting Position Adjustment 5.3.6 CR Encoder Sensor Mounting Position Adjustment 5.3.7 Cutter Positioning Adjustment Page 5.3.7.1 Paper Cutting Position Check 5.3.8 PF Encoder Sensor Installation Position Adjustment 5.3.9 USB ID Writing Page 6.1 Overview 6.1.1 Periodic Maintenance Items and Product Life Information Maintenance Overview 277 Table 6-1. Stylus Pro 7600/9600 - Lives of Periodically Replaced Components and Maintenance Print Volume (# of sheet) Product Life (Specification) Page Maintenance Overview 279 6.1.2 Important Maintenance Items During Service Operations Maintenance Lubrication and Glue 280 6.2 Lubrication and Glue 6.2.1 Lubricating the CR Guide Rail Page Appendix Connectors 282 7.1 Connectors Table 7-1. Main Board Connectors List Table 7-2. Panel Unit Connectors List Table 7-3. C472 CR Board Connectors List Page Page Page 7.3 Circuit Diagrams Page Page Page Page Page Page PX-7000 / EPSON STYLUS PRO 7600 No.1 Rev.01 C472-CASE-011 PX-7000 / EPSON STYLUS PRO 7600 No.2 Rev.01 C472-CASE-021 Rev.01 C472-ELEC-011 PX-7000 / EPSON STYLUS PRO 7600 No.3 Rev.01 C472-POWE-011 PX-7000 / EPSON STYLUS PRO 7600 No.4 PX-7000 / EPSON STYLUS PRO 7600 No.5 Rev.01 C472-MECH-011 Rev.01 C472-MECH-021 PX-7000 / EPSON STYLUS PRO 7600 No.6 Rev.01 C472-MECH-031 PX-7000 / EPSONSTYLUS PRO 7600 No.7 PX-7000 / EPSON STYLUS PRO 7600 No.8 Rev.01 C472-MECH-041 Rev.01 C472-MECH-051 PX-7000 / EPSON STYLUS PRO 7600 No.9 PX-7000 / EPSON STYLUS PRO 7600 No.10 Rev.01 C472-MECH-071 PX-7000 / EPSON STYLUS PRO 7600 No.11 Page PX-9000 / EPSON STYLUS PRO 9600 No.1 Rev.01 C473-CASE-011 Rev.01 C473-CASE-021 PX-9000 / EPSON STYLUS PRO 9600 No.2 PX-9000 / EPSON STYLUS PRO 9600 No.3 Rev.01 C473-ELEC-011 PX-9000 / EPSON STYLUS PRO 9600 No.4 Rev.01 C473-POWE-011 Rev.01 C473-MECH-011 PX-9000 / EPSON STYLUS PRO 9600 No.5 PX-9000 / EPSON STYLUS PRO 9600 No.6 Rev.01 C473-MECH-021 PX-9000 / EPSONSTYLUS PRO 9600 No.7 Rev.01 C473-MECH-031 PX-9000 / EPSON STYLUS PRO 9600 No.8 Rev.01 C473-MECH-041 Rev.01 C473-MECH-051 PX-9000 / EPSON STYLUS PRO 9600 No.9 Rev.01 C473-MECH-071 PX-9000 / EPSON STYLUS PRO 9600 No.11 Page PX-9000 / EPSON STYLUS PRO 9600 No.13 Rev.01 C473-MECH-091 Appendix ASP List (Parts List) 317 7.5 ASP List (Parts List) 7.5.1 ASP List for Stylus Pro 7600 Table 7-6. ASP List for Stylus Pro 7600 Page Page Appendix ASP List (Parts List) 320 7.5.2 ASP List for Stylus Pro 9600 Table 7-7. ASP List for Stylus Pro 9600