Troubleshooting | Epson 7600, 9600 instruction

C H3A P T E R

TROUBLESHOOTING

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Epson 7600, 9600 service manual Troubleshooting

Contents

Epson Stylus Pro 7600/9600 Page Precautions About This Manual May 10 First release Revision Status Contents Operating Principles Troubleshooting Disassembly & Assembly Adjustment Appendix Maintenance Product Description Epson media Quality Resolution Mode Throughput Dpi FeaturesProduct Description Throughput Stylus Pro Differences between Stylus Pro 7600 and Stylus Pro Differences between Stylus Pro 7600 and Stylus ProStylus Pro Print Specifications Basic SpecificationsCharacter Specification Control Code Roll Paper Paper SpecificationsAcceptable Paper Plain Paper Borderless Print Roll Paper SheetAcceptable Sheet Sizes Acceptable Paper Paper Size Size W ⋅ H Description of units of measure Borderless Print Width † Roll pigment Special Paper11. Availability with Special Paper Pigment 12. Availability with Special Paper Dye † Roll dye 13. Availability with Sheets Pigment † Sheet pigment Roll paper Model Dimension Sheet Mechanism SpecificationsPrintable Area 15. Printable Area Paper Set Lever Cutting SpecificationAutomatic Cutting of Roll Media Manual Cutting of Roll Paper Reliability Electrical Specifications TBD 19. Temperature/Humidity Temperature/HumidityAmbient Conditions Vibration Stylus Pro 7600 without stand Surrounding SpaceStylus Pro 7600 with stand/ Stylus Pro † Dimensions of Unit Overall Dimensions Model Condition Weight Accessories and Options for Stylus Pro AccessoriesName Model Number Ml Standard Product Name Model Number Ml Standard Product 220ml Option External View External View and Parts Names Buttons and Functions Operating PanelFunctions of Buttons Operating panel contains the following buttons 21. LEDs LEDsLED color Display Printer Status Indications on the Panel LED Indications in Normal Mode 27. Indications in Normal Mode LCD Indications in Normal ModeFunctions LCD panel display Indicator Setting Functions LCD panel display Indicator Outline SelecType 28. Panel setting menu item Panel Setting Menu Item Inkleft See BK ink cartridge replacement Paperthkns 29. PG Setting Values PG SettingPaper thickness Panel SN command Actual PG Command Lines Code Page SwitchingInterface Select Roll Paper Margin Job Timeout Setting Detect Skew ErrorDetect Paper Width † No margin setting No margin print settingMode Operation No margin mode Right/left no margin Sides no margin † Level structure of Cutter position adjustment menu Cutter position adjustmentAuto margin refresh „ Number in print pattern and cutter position Setting item After initialization Panel Setup Value InitializationNozzle Check Pattern Printing Value of ddddd.d-eeeee.e 5.1 figures Status Printing 12. Status Sheet Print Pattern 13. Job information print pattern Job Information Print Firmware version Maintenance tank countPrintable pages of each ink cartridge Ink remaining Clear use counter Use counterJob history display Job history clear 36. Reference value Consumables lifeDisplay Life These indications Epson Stylus Pro 7600/9600 Revision a Suction LCD display Load Paper Suction † Ink remaining display and font † Printer status at indicator displayInk type Panel display position Status LCD panel display 37. Job information Job informationInformation Explanation Range Capacity Paper setting and corresponding operation are as follows User Paper SettingDetails of each setting item are following Paper setup Operation 15. Level Structure of User Setting Menu Print Paper Thickness Detection Pattern † Printing Specifications Number Pattern Displacement Bottom pattern relative toTop pattern Cutter Blade Replacement Power cleaningGap Adjustment Bi-D Adjustment, Uni-D Adjustment STD Paper thickness sensor PG setting Saving place Setting 18. 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 LCD panel message Insert Cartridge in Correct Slot Insert Draining Cartridge in #XLCD panel message Remove Draining Cartridge LCD panel message Insert ALL INK Cartridges Maintenance Mode 1 Setup Items Maintenance Mode46. Maintenance mode 1 setup items Outline Expir Date M Panel Display Language Selection Hexadecimal Dump Setting D4 Parallel I/F ModeUnit Change INK Information Menu Maintenance Mode 48. Maintenance mode 2 setup items Maintenance Mode 2 Setup Items For 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 Cleaning Unit Life Initialize NVRAM, TIMER, Life COUNTER, Mechanical CounterParameter Backup Maintenance Information Menu † How to change correction values Paper feeding adjustment conversion tableSystem table † User table initialization Installation with service utility F/W Update function Reload with F/W Download modeCompulsory start F/W Download mode Firmware Reload Initialization Function to prevent irregular printingHardware initialization Software initialization Initial Setting for Operation Default Setup ValuesInk Type Setting Esck Escd MW Printing Adjustment / Setting Values and Printing Modes Valid print mode combination is following Printing Mode Combination Table Controller Specification Compatibility ModeConnector PIN Assignment and Signals Interfaces Parameter Minimum Maximum Parallel Interface Timing Chart 55. Connector Pin Assignment and Signals Nibble Nibble ModePin Return Signal Name In/Out Function MDL Stylus Pro 7600-DYE/Stylus Pro 9600-DYE 56. Connector Pin Assignment and Signals ECP ECP Mode USB interface 57. Connector Pin Assignment and Signals UsbfsCMD MDL Stylus Pro 7600-DYE/Stylus Pro 9600-DYE CLS Optional Interface Reply for Option CommandType-B interface level 2, 1200mA type is supported Reply Message 59. Commands and Sending Timing Supported Main Command and Sending TimingSupplements Prevention Hosts from Data Transfer TIME-OUT Optional Units and Consumables Installation LocationsInk Cartridge Maintenance Tank Cleaning cartridgeCleaning cartridge is the same as the 220-ml ink cartridge Draining cartridge Operating Principles Explanation is composed as follows Overview Printer Mechanism Components Print Mechanism Components Carriage Mechanism Carriage CR Mechanism Assembled to the nearest 1/100 mm at the factory Carriage Moving Unit Relationship between Nozzle Rows and Colors Print HeadPrinting Modes Drive Waveforms Ink Type Nozzle Row Color Carriage Mechanical Unit and PG Adjustment Unit Platen GAP Adjustment Unit Position Gap Width Application Pulse Count from Pulse Positions Reflective 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 11. Paper Feed Mechanism Unit 1/2 Paper Feed Assembly 13. Paper Feed Mechanical Unit Stylus Pro 7600 2/2 Modes Pump Drive Modes Cleaning Mechanism Operation Explanation Explanation of Operation 16. Valve Mechanism Ink Supply Mechanism Others Circuit Board PlacementCover Sensor Major Elements Outline of Control Circuit BoardName/Code Location Function SD-RAM Signal Name Function Outline of Power Supply Circuit BoardFuse Rating Input Voltage Range V AC Fuse Rating 100 +/- 10% AC / 6.3A Troubleshooting Introduction Outline Errors Error DisplayError Indications on LCD Error Indications on LCD Full Maintenance Tank Almost Service Call Fatal Errors Service Call Fatal ErrorsError Code Description Refer to Paper End/End of roll LED Indications for Wrong Setting Roll Paper/SheetWrong paper source is selected on panel Paper set lever is released during operation Paper 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 No Maintenance tank Maintenance tank fullFatal Error Illegal ink cartridge Maintenance tank full warning Troubleshooting for WarningMaintenance request Bit Request object Cause How to recover errors Rsvd Assigned bit Nnnn Cause How to clearMotor 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 in-position time out PF motor overcurrent CR motor out of step CR motor encoder check error CR motor in-position time-out CR motor overcurrent PF home position sensor error 0001000B CR home position sensor error 0001000AServo interrupt watchdog time-out System interrupt watchdog time-out CR motor PWM output faulty 0001000F Head slide PG home position sensor error 0001000C Head driver TG temperature error 0001001B PF motor PWM output faulty PF 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 RTC communication error Csic ROM communication errorHead error CR Asic ECU error 0001002A Flash memory SUM error Sdram errorBoot program SUM error Program load error 0002000A CPU slot illegal command exception error 100001A0 Review error 0002000CCPU address error load misalignment 100000E0 CPU address error storage misalignment Dot Missing Troubleshooting Based on Your Printout Smudged or Marred Printout Front Uneven Printing/Poor Resolution White or Black Banding in the carriage running direction Smudged or Marred Printout Reverse side Banding in the paper feed direction Disassembly & Assembly Summary Precautions Governments law and regulations Manufacture. Dispose the used batteries according toImmediately Edge in the printer mechanism Disassembly & Assembly Summary 154 Screw List ToolsNecessary Tools Following table lists all the screws used in this printer Refer to -2when determining the disassembly flow Disassembly Flow Disassembly & Assembly Summary 157 Housing Part Diagram Removing the Panel Unit and Housing Panel Unit Removal 1/2 Panel Unit R Side Cover Removal 1/5 Side Cover R Side Cover Removal 3/5 R Side Cover Removal 4/5 11. L Side Cover Removal 1/2 13. I/H Cover Removal 4 I/H Cover 14. H Top Cover Removal on left side Top Cover Rear Cover „ Removing and installing the Rear Cover Loosen the screw Main Board Access Cover Remove the screw 18. Paper Guide L2 Removal Paper Guide L2 20. Roll Paper Cover removal Roll Paper Cover Opens and closes Front Cover Print Head Disassembly and Assembly of Carriage CR Mechanism Procedures are required When replacing the print head, the following adjustment Execute ink discharge Ink Blowing before removing Damper AssyDamper Assy Will be expelled, so do not press on this part Connector Type Connected to Connectors on CR BoardCR Board Assy Cutter Section Cutter Holder Assy 33. Removing the Cutter Housing 35. Take Care When Installing the Cutter Holder 36. Cutter Solenoid Removal Cutter Solenoid Made CR Encoder Sensor Assy Pegde Sensor Assy After replacing the Pedge Sensor, the following adjustmentOperation should be performed CR Motor Assy 41. Indicator Position 43. Removing the CR Motor Assy CR Motor, make the following adjustment 44. Removing the Headslide Sensor Assy Headslide Sensor Assy 46. Releasing the Crhp Sensor Assy Harness Crhp Sensor Assy Fastening Spring on the L Side Frame side CR Encoder Scale Timing Fence PF Motor Disassembly and Assembly of Paper Feed Mechanism PF Encoder Sensor Assy Adjustment 53. #F730 tool and PF Loop Scale Base Assembly Procedure for the PF Loop Scale Assy 55. Affixing the Double Sided Tape to the PF Loop Scale PF Loop Scale Assy Affixing Procedure 57. Suction Fan Mounting Position Suction Fans Pthick Sensor/PTHICK Sensor0.3 Assy Adjustment at reassembly† Pthick Sensor Assy † PTHICK0.3 Sensor Assy Window Prear Sensor Assy 1 C472SUB-B Board Disassembly and Assembly of Ink Supply Mechanism Following adjustment should be made When removing and installing the front cover switch holder,2 I/H Ink Holder Assy Discharge 65. 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 When you replace the Maintenance ASSY, ink can spill from Maintenance Assy RemovalDisconnect the connector CN17 of the Pump Motor Assy Carefully so that ink will not spill Cap Assy Pump Motor Assy Once you have replaced the Pump ASSY, execute Clear Pump AssyCounters See p.71 Spring catch 78. Removing the Cleaner Head Cleaner Head Wiper 79. Removing the Flushing Box Assy Flushing Box Assy Power Supply Board Disassembly and Assembly of Circuit BoardsPower left in the boards capacitors Connectors on Power Supply Board 81. Removing the AC Inlet Holder AC Inlet 83. C472MAIN Board Removal Main Board C472 Main CN.No Pins Color Connection Remarks † Main Board Connector List Changing their setting can result in malfunctions DIP Switch and Jumper Setting at Factory before ShipmentDIP Switch Setting at Factory at Shipment Jumper Setting at Factory at Shipment Adjustment Adjustment Tools Adjustment ToolsName Part Code MCSP24R4 Adjustment Items Procedure for Adjustment WorkPrint Head Adjustment Main Board Adjustment PF Motor Adjustment CR Motor AdjustmentRequired Adjustment Items CR Motor Replacement Power OFF → Paper Feed ∆ +Paper Feed ∇ + Cut/Eject Prear Sensor Assy Adjustment Pedge Sensor Assy AdjustmentPTHICK/PTHICK0.3 Sensor Assy Adjustment CR Encoder Sensor Assy Adjustment PF Encoder Sensor Assy Adjustment Cover Sensor Assy Adjustment11. Required Adjustment Items 12. Required Adjustment Items Damper Assy Adjustment Cutter Solenoid Assy or Paper Guide L AdjustmentRelease Sensor I/H Lever Adjustment Battery Parameter Backup Procedure Parameter BackupWork Procedure Others Firmware Installation through ROM-DIMM Firmware ReinstallationFirmware Installation through Interface Check Set the parallel interface in the compatibility mode How to Start Self-diagnostic Function Self-diagnostic Function15. Key Functions in Self-diagnostic Mode Overview Top Menu 16. Self-diagnostic Function List Test is intended to check the circuit boards Test17. Circuit Board Check Items Description See Control Panel Version Menu Transition of Sensor Test Sensors 2.5 Fan EncoderCheck to see if each fan operates. See Figure Record Maintenance Record Csic Record of Errors Internal information on Csic is displayed Internal Information Display of Csic You can operate actuators. See Figure ActuatorCutter Automatically move up 19. Panel Setting Item List Adjustment Adjustment and Checking Procedure Rear AD AdjustmentStart the Self-diagnostic Function Power OFF → Paper Feed ∆+Paper Feed ∇+Cut/Eject → Power on „ Paper to be used A3 plain paper Edge AD Adjustment Input Rank Damper ASSY, select and execute Initial charge in Cleaning 22. Menu Transition of Panel Input Input Line Selection This mode, input a dye code by operating on the panel † Dye code inputRight End Write D/A Value 20. Pattern Check NozzlePattern Description 4BUTWTU Check Skew Feed Correction + T&B Adjustment Coordinate in units of 360 dpi 21. Positions where Vertical Line Patterns Are Drawn Display Adj Feed Adj.+T&B Feed Correction + T&B AdjustmentPaper Feed ∇ → SelecType → Paper Feed ∆ To be placed 34. Menu Transition for Top & Bottom Adjustment Top & Bottom Adjustment Rear 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 40. Menu Transition for Platen Position Checking Platen Position Checking Head Slant Checking † Adjustment Range 38 stepsCheck the print result to see if the head is slanting Head Slant Adjustment Mechanical Adjustment Head Slant Checking ProcedureHead motion by Head Adjustment Lever operation Lever Up Magenta → lower / Black → rise 22. Adjustment Item List Round Trip Print Position Adjustment Bi-D AdjustmentContents † K Black Line Adjustment Procedure BI-D Adjustment ProcedureDisplay Adj Bi-d SelecType → SelecType → Enter Adjustment Self-diagnostic Function 250 Bi-D3 Adjustment PG=2.1mm Bi-D2 Adjustment PG=0.7mmParameter Copying 52. Menu Transition for Bi-D Adjustment Checking Round Trip Print Position Bi-D Adjustment Checking 23. Head Gap Adjustment Items Head Gap Adjustment Uni-D AdjustmentCorrect the print position for one-way printing † If out of alignment Procedure for Head GAP Adjustment UNI-D AdjustmentDisplay the menu for an relevant item by means of SelecType Therefore, there is no need of outputting the comprehensive 56. Menu Transition for Test Pattern Printing Test Pattern Printing 57. Menu Transition for Head Cleaning Clean Head 24. Counters to be Cleared and Their Initial Values Counter ClearCounters to be Cleared Initial Value Adjustment Self-diagnostic Function 258 25. Cleaning Items CleaningPrint Charge in this menu 27. Parameter Items Parameter Execute 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 65. PF Belt Tension Adjustment PF Timing Belt Tension Adjustment Display Test Sensor PTHICK0.3/PTHICK Sensor Mounting Plate Position AdjustmentSelecType → Paper Feed ∇ Display Sen Paper LCD Mounting Plate Gauge Condition 31. Cover Sensor Assembly Check Cover Sensor Assy Mounting Position AdjustmentSensor is installed correctly and check the operation again Display Sen Cover Use with Stylus Pro 7600 / 9600 do not use the CR Encoder CR Encoder Sensor Mounting Position AdjustmentMounting jig designed for any other printer models For adjustments at replacing the Cover Sensor ASSY, make Cutter Positioning AdjustmentPaper Guide L up and down adjustment first and then make Cutter Holder Assy height adjustment Positioning jig designed for any other printer models Use with Stylus Pro 7600 / 9600 do not use the cutter Paper Cutting Position Check Front edge of the paper where it was actually cut should beWithin 0.5 mm +0.1/-0.2mm Use with Stylus Pro 7600 / 9600 do not use the PF Encoder PF Encoder Sensor Installation Position Adjustment USB ID Writing Maintenance Power cable from the AC plug socket to prevent electric Power supply circuit, unless otherwise specified, alwaysShock or circuit damage during service operations Device. Therefore, it is prohibited to turn off this switch Periodic Maintenance Items and Product Life Information 00000101 0040 0002 0020 Maintenance Overview 278 Items to be Checked During Maintenance/Service Important Maintenance Items During Service OperationsItems Check Points Remedy Lubrication and Glue Check Before applying lubricant, clean the surfaceLubricating the CR Guide Rail Grease and Glue Application Appendix Main Board Connectors List ConnectorsPanel Unit Connectors List C472 CR Board Connectors List † Power Supply Board C472 SUB-B Board Connectors ListPower Supply Board Connector List † C472 SUB-B Board Appendix Connectors 284 Will be established by the next revision Component Layout Circuit 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 for Stylus Pro ASP List Parts ListASP List for Stylus Pro Ref No Part Name Adjust Lever Adjust Lever BConnecting Screw Paper Guide Wire Flushing BOX Assy CleanerPump Moter Janction Cable TR Connecter Vacuum FAN1 Cable ASSY.2 HandleVacuum FAN2 Cable ASSY.2 Vacuum FAN3 Cable ASSY.2 Partition Plate L CR Moter Cable ASSY.2FFC2 Packing BOX ASSY.W Cover SW Cable ASSY.2Stand L Assy Caster NON Stopper