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Epson 9600 Disassembly and Assembly of Cleaning Mechanism, Major Parts of Cleaning Mechanism

Models: 9600 7600

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EPSON Stylus Pro 7600/9600

Revision A

4.6Disassembly and Assembly of Cleaning Mechanism

The Maintenance ASSY consists of the major assemblies listed below four of which constitute the Cleaning Unit.

The life of the Cleaning Unit is judged by the life of the Pump Motor. Replace the Cap ASSY, Pump ASSY, Flushing Box and Wiper at the same time.

Parts of the Cleaning Unit are available as individual parts so that each of those parts can be replaced singly.

NOTE: For details, refer to “Table 6-1 Stylus Pro 7600/9600 - Lives of

Periodically Replaced Components and Maintenance (p.277)”.

Table 4-4. Major Parts of Cleaning Mechanism

	Names of Parts			See
	Pump Motor ASSY			p.200

	Cleaning Unit	Pump/Cap ASSY	Cap ASSY	p.200
	* Replace at expiration of Pump Motor		Pump ASSY	p.201
	ASSY life
	ASSY life	Cleaner Head		p.203
		Cleaner Head		p.203
		Flushing Box ASSY		p.204

ADJUSTMENT REQUIRED

Once you have replaced the Cleaning Unit, be sure to execute CLEAR COUNTERS “Initialize cleaning unit (CLEANER) (p.71)” and CLEAR COUNTERS “Initialize flashing box (FL BOX) (p.71)” in Maintenance mode 2.

Disassembly & Assembly

Disassembly and Assembly of Cleaning Mechanism

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Epson 9600, 7600 Disassembly and Assembly of Cleaning Mechanism, Major Parts of Cleaning Mechanism, Names of Parts See

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 Product Description FeaturesEpson media Quality Resolution Mode Throughput Dpi Throughput Stylus ProDifferences between Stylus Pro 7600 and Stylus Pro Differences between Stylus Pro 7600 and Stylus ProStylus Pro Character Specification Basic SpecificationsPrint Specifications Control CodeAcceptable Paper Paper SpecificationsRoll Paper Plain PaperAcceptable Sheet Sizes Acceptable Paper SheetBorderless Print Roll Paper Paper Size Size W ⋅ HBorderless Print Width Description of units of measureSpecial Paper † Roll pigment11. Availability with Special Paper Pigment † Roll dye 12. Availability with Special Paper Dye† Sheet pigment 13. Availability with Sheets PigmentPrintable Area Mechanism SpecificationsRoll paper Model Dimension Sheet 15. Printable AreaAutomatic Cutting of Roll Media Cutting SpecificationPaper Set Lever Manual Cutting of Roll PaperElectrical Specifications TBD ReliabilityAmbient Conditions Temperature/Humidity19. Temperature/Humidity VibrationSurrounding Space Stylus Pro 7600 without standStylus Pro 7600 with stand/ Stylus Pro Overall Dimensions † Dimensions of UnitModel Condition Weight Accessories Accessories and Options for Stylus ProName Model Number Ml Standard Product Name Model Number Ml Standard Product 220ml Option External View and Parts Names External ViewFunctions of Buttons Operating PanelButtons and Functions Operating panel contains the following buttonsLEDs 21. LEDsLED color Display Printer Status LED Indications in Normal Mode Indications on the PanelFunctions LCD panel display Indicator Setting LCD Indications in Normal Mode27. Indications in Normal Mode Functions LCD panel display IndicatorSelecType OutlinePanel Setting Menu Item 28. Panel setting menu itemInkleft See BK ink cartridge replacement Paperthkns Paper thickness Panel SN command Actual PG PG Setting29. PG Setting Values CommandInterface Select Code Page SwitchingLines Roll Paper MarginDetect Skew Error Job Timeout SettingDetect Paper Width Mode Operation No margin print setting† No margin setting No margin mode Right/left no margin Sides no marginAuto margin refresh Cutter position adjustment† Level structure of Cutter position adjustment menu „ Number in print pattern and cutter positionNozzle Check Pattern Printing Panel Setup Value InitializationSetting item After initialization Value of ddddd.d-eeeee.e 5.1 figuresStatus Printing 12. Status Sheet Print Pattern Job Information Print 13. Job information print patternPrintable pages of each ink cartridge Maintenance tank countFirmware version Ink remainingJob history display Use counterClear use counter Job history clearDisplay Life Consumables life36. Reference value These indicationsEpson Stylus Pro 7600/9600 Revision a Load Paper Suction Suction LCD displayInk type Panel display position † Printer status at indicator display† Ink remaining display and font Status LCD panel displayJob information 37. Job informationInformation Explanation Range Capacity Details of each setting item are following User Paper SettingPaper setting and corresponding operation are as follows Paper setup Operation15. Level Structure of User Setting Menu † Printing Specifications Print Paper Thickness Detection PatternPattern Displacement Bottom pattern relative to NumberTop pattern Power cleaning Cutter Blade ReplacementGap Adjustment Bi-D Adjustment, Uni-D Adjustment Paper thickness sensor PG setting Saving place Setting STD18. Level Structure of Gap Adjustment Menu GAP Adjustment Print Pattern TBD „ Each adjustment item45. Adjustment Item List BK ink cartridge replacement Replace with NEW Maintenance TankRelease INK Lever LCD panel message Remove Draining Cartridge Insert Draining Cartridge in #XLCD panel message Insert Cartridge in Correct Slot LCD panel message Insert ALL INK Cartridges46. Maintenance mode 1 setup items Maintenance ModeMaintenance Mode 1 Setup Items OutlineExpir Date M Hexadecimal Dump Panel Display Language SelectionUnit Change Parallel I/F ModeSetting D4 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 Parameter Backup Initialize NVRAM, TIMER, Life COUNTER, Mechanical CounterInitialize Cleaning Unit Life Maintenance Information MenuSystem table Paper feeding adjustment conversion table† How to change correction values † User table initializationCompulsory start F/W Download mode Reload with F/W Download modeInstallation with service utility F/W Update function Firmware ReloadHardware initialization Function to prevent irregular printingInitialization Software initializationDefault Setup Values Initial Setting for OperationInk Type Setting MW Printing Adjustment / Setting Values and Printing Modes Esck EscdPrinting Mode Combination Table Valid print mode combination is followingController Connector PIN Assignment and Signals Compatibility ModeSpecification InterfacesParallel Interface Timing Chart Parameter Minimum MaximumPin Return Signal Name In/Out Function Nibble Mode55. Connector Pin Assignment and Signals Nibble MDL Stylus Pro 7600-DYE/Stylus Pro 9600-DYEECP Mode 56. Connector Pin Assignment and Signals ECPCMD 57. Connector Pin Assignment and Signals UsbfsUSB interface MDL Stylus Pro 7600-DYE/Stylus Pro 9600-DYE CLSType-B interface level 2, 1200mA type is supported Reply for Option CommandOptional Interface Reply MessageSupplements Supported Main Command and Sending Timing59. Commands and Sending Timing Prevention Hosts from Data Transfer TIME-OUTInstallation Locations Optional Units and ConsumablesInk Cartridge Cleaning cartridge is the same as the 220-ml ink cartridge Cleaning cartridgeMaintenance Tank 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 factoryPrinting Modes Drive Waveforms Print HeadRelationship between Nozzle Rows and Colors Ink Type Nozzle Row ColorPlaten GAP Adjustment Unit Carriage Mechanical Unit and PG Adjustment UnitPulse Positions Position Gap Width Application Pulse Count from„ It must be ensured that the reflection value of the least Reflective paper is greater than the reflection valuePlaten Operating Principles Print Mechanism Components 109 „ Paper size detection sequence front edge ConditionsIs 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 MechanismCircuit Board Placement OthersCover Sensor Name/Code Location Function Outline of Control Circuit BoardMajor Elements SD-RAMFuse Rating Outline of Power Supply Circuit BoardSignal Name Function Input Voltage Range V AC Fuse Rating 100 +/- 10% AC / 6.3ATroubleshooting Outline IntroductionError Indications on LCD Error DisplayErrors Error Indications on LCDMaintenance Tank Almost FullService Call Fatal Errors Service Call Fatal ErrorsError Code Description Refer to Wrong paper source is selected on panel LED Indications for Wrong Setting Roll Paper/SheetPaper End/End of roll Paper set lever is released during operationPaper set lever is released Paper JamFront Cover Open Type-B I/F error Paper cutting errorPaper Not Straight Paper check error/Paper eject error sheet Paper is too thick for cleaningNot enough ink for cleaning Ink-related Errors Defective ink cartridgeInk lever released Fatal Error Maintenance tank fullNo Maintenance tank Illegal ink cartridgeMaintenance request Troubleshooting for WarningMaintenance tank full warning Bit Request object Cause How to recover errorsMotor Assigned bit Nnnn Cause How to clearRsvd Clear Counters / RTCTroubleshooting for Service Call Errors „ When the CR motor has still an adequate life remainingCR motor life PF motor encoder check error PF Motor out of stepReplace 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-outServo interrupt watchdog time-out CR home position sensor error 0001000APF home position sensor error 0001000B 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 0001001BCR servo parameter error 0001001D PF servo parameter error 0001001EClear the cause of paper feed related mechanism out-of-step Csic reed/right error Ink type error setting on printer body sideRTC analysis error Head error Csic ROM communication errorRTC communication error CR Asic ECU error 0001002ABoot program SUM error Sdram errorFlash memory SUM error Program load error 0002000ACPU address error load misalignment 100000E0 Review error 0002000CCPU slot illegal command exception error 100001A0 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 SummaryImmediately Manufacture. Dispose the used batteries according toGovernments law and regulations Edge in the printer mechanismDisassembly & Assembly Summary 154 Necessary Tools ToolsScrew List 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 Damper AssyExecute ink discharge Ink Blowing before removing Will be expelled, so do not press on this partConnectors on CR Board Connector Type Connected toCR 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 MadeAfter replacing the Pedge Sensor, the following adjustment Pegde Sensor AssyOperation 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 PositionAdjustment at reassembly Pthick Sensor/PTHICK Sensor0.3 Assy† Pthick Sensor Assy † PTHICK0.3 Sensor Assy Prear Sensor Assy WindowDisassembly and Assembly of Ink Supply Mechanism 1 C472SUB-B Board2 I/H Ink Holder Assy When removing and installing the front cover switch holder,Following adjustment should be made Discharge65. I/H Frame Removal 2/2 67. Csic Relay Board Removal 69. Disassembling the Ink Holder Assy 1/2 Cover Sensor Assy Cover Sensor Assy operates coupled with the opening/closingFront Cover Disassembly and Assembly of Cleaning Mechanism Major Parts of Cleaning MechanismNames of Parts See Disconnect the connector CN17 of the Pump Motor Assy Maintenance Assy RemovalWhen you replace the Maintenance ASSY, ink can spill from Carefully so that ink will not spillPump Motor Assy Cap AssyPump Assy Once you have replaced the Pump ASSY, execute ClearCounters See p.71 Spring catch Cleaner Head Wiper 78. Removing the Cleaner HeadFlushing Box Assy 79. Removing the Flushing Box AssyPower left in the boards capacitors Disassembly and Assembly of Circuit BoardsPower Supply Board 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 Setting at Factory at Shipment DIP Switch and Jumper Setting at Factory before ShipmentChanging their setting can result in malfunctions Jumper Setting at Factory at ShipmentAdjustment Name Part Code Adjustment ToolsAdjustment Tools MCSP24R4Procedure for Adjustment Work Adjustment ItemsPrint Head Adjustment Main Board Adjustment Required Adjustment Items CR Motor Replacement CR Motor AdjustmentPF Motor Adjustment Power OFF → Paper Feed ∆ +Paper Feed ∇ + Cut/EjectPTHICK/PTHICK0.3 Sensor Assy Adjustment Pedge Sensor Assy AdjustmentPrear Sensor Assy Adjustment CR Encoder Sensor Assy Adjustment11. Required Adjustment Items Cover Sensor Assy AdjustmentPF Encoder Sensor Assy Adjustment 12. Required Adjustment ItemsRelease Sensor I/H Lever Adjustment Cutter Solenoid Assy or Paper Guide L AdjustmentDamper Assy Adjustment BatteryWork Procedure Parameter BackupParameter Backup Procedure OthersFirmware Installation through Interface Firmware ReinstallationFirmware Installation through ROM-DIMM Check Set the parallel interface in the compatibility mode15. Key Functions in Self-diagnostic Mode Self-diagnostic FunctionHow to Start Self-diagnostic Function Overview16. Self-diagnostic Function List Top Menu17. Circuit Board Check Items TestTest is intended to check the circuit boards Description SeeVersion Control PanelSensors Menu Transition of Sensor TestEncoder 2.5 FanCheck to see if each fan operates. See Figure Maintenance Record RecordRecord of Errors CsicInternal Information Display of Csic Internal information on Csic is displayedCutter ActuatorYou can operate actuators. See Figure Automatically move upAdjustment 19. Panel Setting Item ListStart the Self-diagnostic Function Rear AD AdjustmentAdjustment and Checking Procedure 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 InputRight † Dye code inputThis mode, input a dye code by operating on the panel EndWrite D/A Value Pattern Description Check Nozzle20. Pattern 4BUTWTUCheck Skew Feed Correction + T&B Adjustment 21. Positions where Vertical Line Patterns Are Drawn Coordinate in units of 360 dpiPaper Feed ∇ → SelecType → Paper Feed ∆ Feed Correction + T&B AdjustmentDisplay Adj Feed Adj.+T&B To be placedTop & Bottom Adjustment 34. Menu Transition for Top & Bottom AdjustmentRear Sensor Position Adjustment Procedure Rear Sensor PositionDisplay Adj Rear Sensor Pos Platen Position Sponge Position Adjustment Platen Position Sponge Position Adjustment ProcedureDisplay Adj Sponge Pos Platen Position Checking 40. Menu Transition for Platen Position Checking† Adjustment Range 38 steps Head Slant CheckingCheck the print result to see if the head is slanting Head motion by Head Adjustment Lever operation Head Slant Checking ProcedureHead Slant Adjustment Mechanical Adjustment Lever Up Magenta → lower / Black → riseRound Trip Print Position Adjustment Bi-D Adjustment 22. Adjustment Item ListContents Display Adj Bi-d BI-D Adjustment Procedure† K Black Line Adjustment Procedure SelecType → SelecType → EnterAdjustment Self-diagnostic Function 250 Bi-D2 Adjustment PG=0.7mm Bi-D3 Adjustment PG=2.1mmParameter Copying Round Trip Print Position Bi-D Adjustment Checking 52. Menu Transition for Bi-D Adjustment CheckingHead Gap Adjustment Uni-D Adjustment 23. Head Gap Adjustment ItemsCorrect the print position for one-way printing Display the menu for an relevant item by means of SelecType Procedure for Head GAP Adjustment UNI-D Adjustment† If out of alignment Therefore, there is no need of outputting the comprehensiveTest Pattern Printing 56. Menu Transition for Test Pattern PrintingClean Head 57. Menu Transition for Head CleaningCounter Clear 24. Counters to be Cleared and Their Initial ValuesCounters to be Cleared Initial Value Adjustment Self-diagnostic Function 258 Print Cleaning25. Cleaning Items Charge in this menuParameter 27. Parameter ItemsParameter Initialize Execute parameter initializationWith the condition of the printer mechanism Adjustment Self-diagnostic Function 262 Mechanism Adjustment CR Timing Belt Tension Adjustment29. Required Mechanism Adjustments PF Timing Belt Tension Adjustment 65. PF Belt Tension AdjustmentSelecType → Paper Feed ∇ PTHICK0.3/PTHICK Sensor Mounting Plate Position AdjustmentDisplay Test Sensor Display Sen PaperMounting Plate Gauge Condition LCDSensor is installed correctly and check the operation again Cover Sensor Assy Mounting Position Adjustment31. Cover Sensor Assembly Check Display Sen CoverCR Encoder Sensor Mounting Position Adjustment Use with Stylus Pro 7600 / 9600 do not use the CR EncoderMounting jig designed for any other printer models Paper Guide L up and down adjustment first and then make Cutter Positioning AdjustmentFor adjustments at replacing the Cover Sensor ASSY, make Cutter Holder Assy height adjustmentUse with Stylus Pro 7600 / 9600 do not use the cutter Positioning jig designed for any other printer modelsFront edge of the paper where it was actually cut should be Paper Cutting Position CheckWithin 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 Shock or circuit damage during service operations Power supply circuit, unless otherwise specified, alwaysPower cable from the AC plug socket to prevent electric Device. Therefore, it is prohibited to turn off this switchPeriodic Maintenance Items and Product Life Information 0040 0002 0020 00000101Maintenance Overview 278 Important Maintenance Items During Service Operations Items to be Checked During Maintenance/ServiceItems Check Points Remedy Lubricating the CR Guide Rail Check Before applying lubricant, clean the surfaceLubrication and Glue Grease and Glue ApplicationAppendix Panel Unit Connectors List ConnectorsMain Board Connectors List C472 CR Board Connectors ListPower Supply Board Connector List C472 SUB-B Board Connectors List† Power Supply Board † 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 for Stylus Pro ASP List Parts ListASP List for Stylus Pro Ref No Part NameConnecting Screw Adjust Lever BAdjust Lever Paper Guide WirePump Moter Janction Cable CleanerFlushing BOX Assy TR ConnecterVacuum FAN2 Cable ASSY.2 HandleVacuum FAN1 Cable ASSY.2 Vacuum FAN3 Cable ASSY.2CR Moter Cable ASSY.2 Partition Plate LFFC2 Stand L Assy Cover SW Cable ASSY.2Packing BOX ASSY.W Caster NON Stopper