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Epson 9600, 7600 service manual Operating Principles

Models: 9600 7600

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OPERATING PRINCIPLES

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Epson 9600, 7600 service manual Operating Principles

Contents

Epson Stylus Pro 7600/9600 Page Precautions About This Manual Revision Status May 10 First releaseContents Troubleshooting Operating PrinciplesDisassembly & Assembly Adjustment Maintenance AppendixProduct Description Features Epson media Quality Resolution Mode Throughput DpiProduct Description Throughput Stylus ProDifferences between Stylus Pro 7600 and Stylus Pro Differences between Stylus Pro 7600 and Stylus ProStylus Pro Basic Specifications Print SpecificationsCharacter Specification Control CodePaper Specifications Roll PaperAcceptable Paper Plain PaperSheet Borderless Print Roll PaperAcceptable Sheet Sizes Acceptable Paper Paper Size Size W ⋅ HBorderless Print Width Description of units of measure† Roll pigment Special Paper11. Availability with Special Paper Pigment † Roll dye 12. Availability with Special Paper Dye† Sheet pigment 13. Availability with Sheets PigmentMechanism Specifications Roll paper Model Dimension SheetPrintable Area 15. Printable AreaCutting Specification Paper Set LeverAutomatic Cutting of Roll Media Manual Cutting of Roll PaperElectrical Specifications TBD ReliabilityTemperature/Humidity 19. Temperature/HumidityAmbient Conditions VibrationStylus Pro 7600 without stand Surrounding SpaceStylus Pro 7600 with stand/ Stylus Pro Overall Dimensions † Dimensions of UnitModel Condition Weight Accessories and Options for Stylus Pro AccessoriesName Model Number Ml Standard Product Name Model Number Ml Standard Product 220ml Option External View and Parts Names External ViewOperating Panel Buttons and FunctionsFunctions of Buttons Operating panel contains the following buttons21. LEDs LEDsLED color Display Printer Status LED Indications in Normal Mode Indications on the PanelLCD Indications in Normal Mode 27. Indications in Normal ModeFunctions LCD panel display Indicator Setting Functions LCD panel display IndicatorSelecType OutlinePanel Setting Menu Item 28. Panel setting menu itemInkleft See BK ink cartridge replacement Paperthkns PG Setting 29. PG Setting ValuesPaper thickness Panel SN command Actual PG CommandCode Page Switching LinesInterface Select Roll Paper MarginJob Timeout Setting Detect Skew ErrorDetect Paper Width No margin print setting † No margin settingMode Operation No margin mode Right/left no margin Sides no marginCutter position adjustment † Level structure of Cutter position adjustment menuAuto margin refresh „ Number in print pattern and cutter positionPanel Setup Value Initialization Setting item After initializationNozzle Check Pattern Printing Value of ddddd.d-eeeee.e 5.1 figuresStatus Printing 12. Status Sheet Print Pattern Job Information Print 13. Job information print patternMaintenance tank count Firmware versionPrintable pages of each ink cartridge Ink remainingUse counter Clear use counterJob history display Job history clearConsumables life 36. Reference valueDisplay Life These indicationsEpson Stylus Pro 7600/9600 Revision a Load Paper Suction Suction LCD display† Printer status at indicator display † Ink remaining display and fontInk type Panel display position Status LCD panel display37. Job information Job informationInformation Explanation Range Capacity User Paper Setting Paper setting and corresponding operation are as followsDetails of each setting item are following Paper setup Operation15. Level Structure of User Setting Menu † Printing Specifications Print Paper Thickness Detection PatternNumber Pattern Displacement Bottom pattern relative toTop pattern Cutter Blade Replacement Power cleaningGap Adjustment Bi-D Adjustment, Uni-D Adjustment Paper thickness sensor PG setting Saving place Setting STD18. Level Structure of Gap Adjustment Menu „ Each adjustment item GAP Adjustment Print Pattern TBD45. Adjustment Item List Replace with NEW Maintenance Tank BK ink cartridge replacementRelease INK Lever Insert Draining Cartridge in #X LCD panel message Insert Cartridge in Correct SlotLCD panel message Remove Draining Cartridge LCD panel message Insert ALL INK CartridgesMaintenance Mode Maintenance Mode 1 Setup Items46. Maintenance mode 1 setup items OutlineExpir Date M Hexadecimal Dump Panel Display Language SelectionParallel I/F Mode Setting D4Unit Change INK Information MenuMaintenance Mode Maintenance Mode 2 Setup Items 48. Maintenance mode 2 setup itemsFor R4C825P Cleaning times TCL2 Top menu Panel display Item menu 1 Panel display Setup value Each color ink replacement date Black2, 2 times before Each color ink vendor Yellow, this time Menu Print length of each paper size Roll paper width Print mode setting times 360-720 Bi-D Black Menu Service call history6 Type Normal error Menun Normal error history 6 Type Initinfo Initialize NVRAM, TIMER, Life COUNTER, Mechanical Counter Initialize Cleaning Unit LifeParameter Backup Maintenance Information MenuPaper feeding adjustment conversion table † How to change correction valuesSystem table † User table initializationReload with F/W Download mode Installation with service utility F/W Update functionCompulsory start F/W Download mode Firmware ReloadFunction to prevent irregular printing InitializationHardware initialization Software initializationInitial Setting for Operation Default Setup ValuesInk Type Setting MW Printing Adjustment / Setting Values and Printing Modes Esck EscdPrinting Mode Combination Table Valid print mode combination is followingController Compatibility Mode SpecificationConnector PIN Assignment and Signals InterfacesParallel Interface Timing Chart Parameter Minimum MaximumNibble Mode 55. Connector Pin Assignment and Signals NibblePin Return Signal Name In/Out Function MDL Stylus Pro 7600-DYE/Stylus Pro 9600-DYEECP Mode 56. Connector Pin Assignment and Signals ECP57. Connector Pin Assignment and Signals Usbfs USB interfaceCMD MDL Stylus Pro 7600-DYE/Stylus Pro 9600-DYE CLSReply for Option Command Optional InterfaceType-B interface level 2, 1200mA type is supported Reply MessageSupported Main Command and Sending Timing 59. Commands and Sending TimingSupplements Prevention Hosts from Data Transfer TIME-OUTOptional Units and Consumables Installation LocationsInk Cartridge Cleaning cartridge Maintenance TankCleaning cartridge is the same as the 220-ml ink cartridge Draining cartridgeOperating Principles Overview Explanation is composed as followsPrint Mechanism Components Printer Mechanism ComponentsCarriage CR Mechanism Carriage MechanismCarriage Moving Unit Assembled to the nearest 1/100 mm at the factoryPrint Head Relationship between Nozzle Rows and ColorsPrinting Modes Drive Waveforms Ink Type Nozzle Row ColorPlaten GAP Adjustment Unit Carriage Mechanical Unit and PG Adjustment UnitPulse Positions Position Gap Width Application Pulse Count fromReflective paper is greater than the reflection value „ It must be ensured that the reflection value of the leastPlaten Operating Principles Print Mechanism Components 109 Conditions „ Paper size detection sequence front edgeIs not made by the edge sensors Operating Principles Print Mechanism Components 111 Operating Principles Print Mechanism Components 112 Paper Feed Assembly 11. Paper Feed Mechanism Unit 1/2Modes 13. Paper Feed Mechanical Unit Stylus Pro 7600 2/2Cleaning Mechanism Pump Drive ModesExplanation of Operation Operation ExplanationInk Supply Mechanism 16. Valve MechanismOthers Circuit Board PlacementCover Sensor Outline of Control Circuit Board Major ElementsName/Code Location Function SD-RAMOutline of Power Supply Circuit Board Signal Name FunctionFuse Rating Input Voltage Range V AC Fuse Rating 100 +/- 10% AC / 6.3ATroubleshooting Outline IntroductionError Display ErrorsError Indications on LCD Error Indications on LCDMaintenance Tank Almost FullService Call Fatal Errors Service Call Fatal ErrorsError Code Description Refer to LED Indications for Wrong Setting Roll Paper/Sheet Paper End/End of rollWrong paper source is selected on panel Paper set lever is released during operationPaper Jam Paper set lever is releasedFront Cover Open Paper cutting error Type-B I/F errorPaper Not Straight Paper is too thick for cleaning Paper check error/Paper eject error sheetNot enough ink for cleaning Defective ink cartridge Ink-related ErrorsInk lever released Maintenance tank full No Maintenance tankFatal Error Illegal ink cartridgeTroubleshooting for Warning Maintenance tank full warningMaintenance request Bit Request object Cause How to recover errorsAssigned bit Nnnn Cause How to clear RsvdMotor Clear Counters / RTC„ When the CR motor has still an adequate life remaining Troubleshooting for Service Call ErrorsCR motor life PF Motor out of step PF motor encoder check errorReplace the PF Motor p.185 PF motor overcurrent PF motor in-position time outCR motor encoder check error CR motor out of stepCR motor overcurrent CR motor in-position time-outCR home position sensor error 0001000A PF home position sensor error 0001000BServo interrupt watchdog time-out System interrupt watchdog time-outHead slide PG home position sensor error 0001000C CR motor PWM output faulty 0001000FPF motor PWM output faulty Head driver TG temperature error 0001001BPF servo parameter error 0001001E CR servo parameter error 0001001DClear the cause of paper feed related mechanism out-of-step Ink type error setting on printer body side Csic reed/right errorRTC analysis error Csic ROM communication error RTC communication errorHead error CR Asic ECU error 0001002ASdram error Flash memory SUM errorBoot program SUM error Program load error 0002000AReview error 0002000C CPU slot illegal command exception error 100001A0CPU address error load misalignment 100000E0 CPU address error storage misalignmentTroubleshooting Based on Your Printout Dot MissingUneven Printing/Poor Resolution Smudged or Marred Printout FrontSmudged or Marred Printout Reverse side White or Black Banding in the carriage running directionBanding in the paper feed direction Disassembly & Assembly Precautions SummaryManufacture. Dispose the used batteries according to Governments law and regulationsImmediately Edge in the printer mechanismDisassembly & Assembly Summary 154 Tools Screw ListNecessary Tools Following table lists all the screws used in this printerDisassembly Flow Refer to -2when determining the disassembly flowDisassembly & Assembly Summary 157 Removing the Panel Unit and Housing Housing Part DiagramPanel Unit Panel Unit Removal 1/2Side Cover R Side Cover Removal 1/5R Side Cover Removal 3/5 R Side Cover Removal 4/5 11. L Side Cover Removal 1/2 4 I/H Cover 13. I/H Cover RemovalTop Cover 14. H Top Cover Removal on left side„ Removing and installing the Rear Cover Rear CoverLoosen the screw Main Board Access Cover Remove the screw Paper Guide L2 18. Paper Guide L2 RemovalRoll Paper Cover 20. Roll Paper Cover removalFront Cover Opens and closesDisassembly and Assembly of Carriage CR Mechanism Print HeadWhen replacing the print head, the following adjustment Procedures are requiredDamper Assy Execute ink discharge Ink Blowing before removingDamper Assy Will be expelled, so do not press on this partConnector Type Connected to Connectors on CR BoardCR Board Assy 33. Removing the Cutter Housing Cutter Section Cutter Holder Assy35. Take Care When Installing the Cutter Holder Cutter Solenoid 36. Cutter Solenoid RemovalCR Encoder Sensor Assy MadePegde Sensor Assy After replacing the Pedge Sensor, the following adjustmentOperation should be performed 41. Indicator Position CR Motor AssyCR Motor, make the following adjustment 43. Removing the CR Motor AssyHeadslide Sensor Assy 44. Removing the Headslide Sensor AssyCrhp Sensor Assy 46. Releasing the Crhp Sensor Assy HarnessCR Encoder Scale Timing Fence Fastening Spring on the L Side Frame sideDisassembly and Assembly of Paper Feed Mechanism PF MotorAdjustment PF Encoder Sensor AssyAssembly Procedure for the PF Loop Scale Assy 53. #F730 tool and PF Loop Scale BasePF Loop Scale Assy Affixing Procedure 55. Affixing the Double Sided Tape to the PF Loop ScaleSuction Fans 57. Suction Fan Mounting PositionPthick Sensor/PTHICK Sensor0.3 Assy Adjustment at reassembly† Pthick Sensor Assy † PTHICK0.3 Sensor Assy Prear Sensor Assy WindowDisassembly and Assembly of Ink Supply Mechanism 1 C472SUB-B BoardWhen removing and installing the front cover switch holder, Following adjustment should be made2 I/H Ink Holder Assy Discharge65. I/H Frame Removal 2/2 67. Csic Relay Board Removal 69. Disassembling the Ink Holder Assy 1/2 Cover Sensor Assy operates coupled with the opening/closing Cover Sensor AssyFront Cover Major Parts of Cleaning Mechanism Disassembly and Assembly of Cleaning MechanismNames of Parts See Maintenance Assy Removal When you replace the Maintenance ASSY, ink can spill fromDisconnect the connector CN17 of the Pump Motor Assy Carefully so that ink will not spillPump Motor Assy Cap AssyOnce you have replaced the Pump ASSY, execute Clear Pump AssyCounters See p.71 Spring catch Cleaner Head Wiper 78. Removing the Cleaner HeadFlushing Box Assy 79. Removing the Flushing Box AssyDisassembly and Assembly of Circuit Boards Power Supply BoardPower left in the boards capacitors Connectors on Power Supply BoardAC Inlet 81. Removing the AC Inlet HolderMain Board C472 Main 83. C472MAIN Board Removal† Main Board Connector List CN.No Pins Color Connection RemarksDIP Switch and Jumper Setting at Factory before Shipment Changing their setting can result in malfunctionsDIP Switch Setting at Factory at Shipment Jumper Setting at Factory at ShipmentAdjustment Adjustment Tools Adjustment ToolsName Part Code MCSP24R4Adjustment Items Procedure for Adjustment WorkPrint Head Adjustment Main Board Adjustment CR Motor Adjustment PF Motor AdjustmentRequired Adjustment Items CR Motor Replacement Power OFF → Paper Feed ∆ +Paper Feed ∇ + Cut/EjectPedge Sensor Assy Adjustment Prear Sensor Assy AdjustmentPTHICK/PTHICK0.3 Sensor Assy Adjustment CR Encoder Sensor Assy AdjustmentCover Sensor Assy Adjustment PF Encoder Sensor Assy Adjustment11. Required Adjustment Items 12. Required Adjustment ItemsCutter Solenoid Assy or Paper Guide L Adjustment Damper Assy AdjustmentRelease Sensor I/H Lever Adjustment BatteryParameter Backup Parameter Backup ProcedureWork Procedure OthersFirmware Reinstallation Firmware Installation through ROM-DIMMFirmware Installation through Interface Check Set the parallel interface in the compatibility modeSelf-diagnostic Function How to Start Self-diagnostic Function15. Key Functions in Self-diagnostic Mode Overview16. Self-diagnostic Function List Top MenuTest Test is intended to check the circuit boards17. Circuit Board Check Items Description SeeVersion Control PanelSensors Menu Transition of Sensor Test2.5 Fan EncoderCheck to see if each fan operates. See Figure Maintenance Record RecordRecord of Errors CsicInternal Information Display of Csic Internal information on Csic is displayedActuator You can operate actuators. See FigureCutter Automatically move upAdjustment 19. Panel Setting Item ListRear AD Adjustment Adjustment and Checking ProcedureStart the Self-diagnostic Function Power OFF → Paper Feed ∆+Paper Feed ∇+Cut/Eject → Power onEdge AD Adjustment „ Paper to be used A3 plain paperDamper ASSY, select and execute Initial charge in Cleaning Input RankInput Line Selection 22. Menu Transition of Panel Input† Dye code input This mode, input a dye code by operating on the panelRight EndWrite D/A Value Check Nozzle 20. PatternPattern Description 4BUTWTUCheck Skew Feed Correction + T&B Adjustment 21. Positions where Vertical Line Patterns Are Drawn Coordinate in units of 360 dpiFeed Correction + T&B Adjustment Display Adj Feed Adj.+T&BPaper Feed ∇ → SelecType → Paper Feed ∆ To be placedTop & Bottom Adjustment 34. Menu Transition for Top & Bottom AdjustmentRear Sensor Position Rear Sensor Position Adjustment ProcedureDisplay Adj Rear Sensor Pos Platen Position Sponge Position Adjustment Procedure Platen Position Sponge Position AdjustmentDisplay Adj Sponge Pos Platen Position Checking 40. Menu Transition for Platen Position CheckingHead Slant Checking † Adjustment Range 38 stepsCheck the print result to see if the head is slanting Head Slant Checking Procedure Head Slant Adjustment Mechanical AdjustmentHead motion by Head Adjustment Lever operation Lever Up Magenta → lower / Black → rise22. Adjustment Item List Round Trip Print Position Adjustment Bi-D AdjustmentContents BI-D Adjustment Procedure † K Black Line Adjustment ProcedureDisplay Adj Bi-d SelecType → SelecType → EnterAdjustment Self-diagnostic Function 250 Bi-D3 Adjustment PG=2.1mm Bi-D2 Adjustment PG=0.7mmParameter Copying Round Trip Print Position Bi-D Adjustment Checking 52. Menu Transition for Bi-D Adjustment Checking23. Head Gap Adjustment Items Head Gap Adjustment Uni-D AdjustmentCorrect the print position for one-way printing Procedure for Head GAP Adjustment UNI-D Adjustment † If out of alignmentDisplay the menu for an relevant item by means of SelecType Therefore, there is no need of outputting the comprehensiveTest Pattern Printing 56. Menu Transition for Test Pattern PrintingClean Head 57. Menu Transition for Head Cleaning24. Counters to be Cleared and Their Initial Values Counter ClearCounters to be Cleared Initial Value Adjustment Self-diagnostic Function 258 Cleaning 25. Cleaning ItemsPrint Charge in this menuParameter 27. Parameter ItemsExecute parameter initialization Parameter InitializeWith the condition of the printer mechanism Adjustment Self-diagnostic Function 262 CR Timing Belt Tension Adjustment Mechanism Adjustment29. Required Mechanism Adjustments PF Timing Belt Tension Adjustment 65. PF Belt Tension AdjustmentPTHICK0.3/PTHICK Sensor Mounting Plate Position Adjustment Display Test SensorSelecType → Paper Feed ∇ Display Sen PaperMounting Plate Gauge Condition LCDCover Sensor Assy Mounting Position Adjustment 31. Cover Sensor Assembly CheckSensor is installed correctly and check the operation again Display Sen CoverUse with Stylus Pro 7600 / 9600 do not use the CR Encoder CR Encoder Sensor Mounting Position AdjustmentMounting jig designed for any other printer models Cutter Positioning Adjustment For adjustments at replacing the Cover Sensor ASSY, makePaper Guide L up and down adjustment first and then make Cutter Holder Assy height adjustmentUse with Stylus Pro 7600 / 9600 do not use the cutter Positioning jig designed for any other printer modelsPaper Cutting Position Check Front edge of the paper where it was actually cut should beWithin 0.5 mm +0.1/-0.2mm PF Encoder Sensor Installation Position Adjustment Use with Stylus Pro 7600 / 9600 do not use the PF EncoderUSB ID Writing Maintenance Power supply circuit, unless otherwise specified, always Power cable from the AC plug socket to prevent electricShock or circuit damage during service operations Device. Therefore, it is prohibited to turn off this switchPeriodic Maintenance Items and Product Life Information 0040 0002 0020 00000101Maintenance Overview 278 Items to be Checked During Maintenance/Service Important Maintenance Items During Service OperationsItems Check Points Remedy Check Before applying lubricant, clean the surface Lubrication and GlueLubricating the CR Guide Rail Grease and Glue ApplicationAppendix Connectors Main Board Connectors ListPanel Unit Connectors List C472 CR Board Connectors ListC472 SUB-B Board Connectors List † Power Supply BoardPower Supply Board Connector List † C472 SUB-B BoardAppendix Connectors 284 Component Layout Will be established by the next revisionCircuit Diagrams Page Page Page Page Page Exploded Diagrams 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 PX-7000 / Epson Stylus PRO 7600 No.3 Rev.01 C472-ELEC-011 PX-7000 / Epson Stylus PRO 7600 No.4 Rev.01 C472-POWE-011 PX-7000 / Epson Stylus PRO 7600 No.5 Rev.01 C472-MECH-011 PX-7000 / Epson Stylus PRO 7600 No.6 Rev.01 C472-MECH-021 PX-7000 / Epsonstylus PRO 7600 No.7 Rev.01 C472-MECH-031 PX-7000 / Epson Stylus PRO 7600 No.8 Rev.01 C472-MECH-041 PX-7000 / Epson Stylus PRO 7600 No.9 Rev.01 C472-MECH-051 PX-7000 / Epson Stylus PRO 7600 No.10 Rev.01 C472-MECH-061 PX-7000 / Epson Stylus PRO 7600 No.11 Rev.01 C472-MECH-071 PX-7000 / Epson Stylus PRO 7600 No.12 Rev.01 C472-MECH-081 PX-9000 / Epson Stylus PRO 9600 No.1 Rev.01 C473-CASE-011 PX-9000 / Epson Stylus PRO 9600 No.2 Rev.01 C473-CASE-021 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 PX-9000 / Epson Stylus PRO 9600 No.5 Rev.01 C473-MECH-011 PX-9000 / Epson Stylus PRO 9600 No.6 Rev.01 C473-MECH-021 PX-9000 / Epsonstylus PRO 9600 No.7 Rev.01 PX-9000 / Epson Stylus PRO 9600 No.8 Rev.01 C473-MECH-041 PX-9000 / Epson Stylus PRO 9600 No.9 Rev.01 C473-MECH-051 PX-9000 / Epson Stylus PRO 9600 No.11 Rev.01 C473-MECH-071 PX-9000 / Epson Stylus PRO 9600 No.12 Rev.01 C473-MECH-081 PX-9000 / Epson Stylus PRO 9600 No.13 Rev.01 C473-MECH-091 ASP List Parts List ASP List for Stylus ProASP List for Stylus Pro Ref No Part NameAdjust Lever B Adjust LeverConnecting Screw Paper Guide WireCleaner Flushing BOX AssyPump Moter Janction Cable TR ConnecterHandle Vacuum FAN1 Cable ASSY.2Vacuum FAN2 Cable ASSY.2 Vacuum FAN3 Cable ASSY.2Partition Plate L CR Moter Cable ASSY.2FFC2 Cover SW Cable ASSY.2 Packing BOX ASSY.WStand L Assy Caster NON Stopper