Comprehensive Guide for EPSON 9600 and Stylus Pro 7600 Maintenance

EPSON Stylus Pro 7600/9600

Revision A

4.6.6 Flushing Box ASSY

1.Remove the R Side Cover. (p.160)

2.Remove the Paper Guide L2. (p.168)

3.From the printer body, pull off carefully the waste ink tube (thick) which connects the Flushing Box ASSY to the Maintenance Tank.

4.Remove the one (CUPS: M3⋅6) screw securing the Flushing Box ASSY.

5.Take out the Flushing Box, while pulling off carefully the waste ink tube (thin) coming from the Pump ASSY.

6.Remove the Flushing Box ASSY.

After installing the Flushing Box ASSY, make certain by removing the Paper Guide L2 that the waste ink tube (thick) is set securely on the tube joint of the Maintenance Cartridge Holder.

Waste ink tube

CHECK	Take off the ink tube (thick/thin) carefully so that ink will not spill
POINT	from the ink tube.

Waste ink tube (thin)

Screw (CUPS: M3⋅6)

Flushing Box ASSY

Waste ink tube (thick)

Figure 4-79. Removing the Flushing Box ASSY

Disassembly & Assembly

Disassembly and Assembly of Cleaning Mechanism

204

Image 204

Epson 9600, 7600 service manual Removing the Flushing Box Assy

Contents

Epson Stylus Pro 7600/9600 Page Precautions About This Manual Revision Status May 10 First release Contents Troubleshooting Operating Principles Disassembly & Assembly Adjustment Maintenance Appendix Product Description Features Epson media Quality Resolution Mode Throughput DpiProduct Description Throughput Stylus Pro Differences between Stylus Pro 7600 and Stylus Pro Differences between Stylus Pro 7600 and Stylus ProStylus Pro Basic Specifications Print SpecificationsCharacter Specification Control Code Paper Specifications Roll PaperAcceptable Paper Plain Paper Sheet Borderless Print Roll PaperAcceptable Sheet Sizes Acceptable Paper Paper Size Size W ⋅ H Borderless Print Width Description of units of measure Special Paper † Roll pigment11. Availability with Special Paper Pigment † Roll dye 12. Availability with Special Paper Dye † Sheet pigment 13. Availability with Sheets Pigment Mechanism Specifications Roll paper Model Dimension SheetPrintable Area 15. Printable Area Cutting Specification Paper Set LeverAutomatic Cutting of Roll Media Manual Cutting of Roll Paper Electrical Specifications TBD Reliability Temperature/Humidity 19. Temperature/HumidityAmbient Conditions Vibration Surrounding Space Stylus Pro 7600 without standStylus Pro 7600 with stand/ Stylus Pro Overall Dimensions † Dimensions of Unit Model 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 View Operating Panel Buttons and FunctionsFunctions of Buttons Operating panel contains the following buttons LEDs 21. LEDsLED color Display Printer Status LED Indications in Normal Mode Indications on the Panel LCD Indications in Normal Mode 27. Indications in Normal ModeFunctions LCD panel display Indicator Setting Functions LCD panel display Indicator SelecType Outline Panel Setting Menu Item 28. Panel setting menu item Inkleft See BK ink cartridge replacement Paperthkns PG Setting 29. PG Setting ValuesPaper thickness Panel SN command Actual PG Command Code Page Switching LinesInterface Select Roll Paper Margin Detect Skew Error Job Timeout SettingDetect Paper Width No margin print setting † No margin settingMode Operation No margin mode Right/left no margin Sides no margin Cutter position adjustment † Level structure of Cutter position adjustment menuAuto margin refresh „ Number in print pattern and cutter position Panel Setup Value Initialization Setting item After initializationNozzle Check Pattern Printing Value of ddddd.d-eeeee.e 5.1 figures Status Printing 12. Status Sheet Print Pattern Job Information Print 13. Job information print pattern Maintenance tank count Firmware versionPrintable pages of each ink cartridge Ink remaining Use counter Clear use counterJob history display Job history clear Consumables life 36. Reference valueDisplay Life These indications Epson 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 display Job information 37. Job informationInformation Explanation Range Capacity User Paper Setting Paper setting and corresponding operation are as followsDetails of each setting item are following Paper setup Operation 15. Level Structure of User Setting Menu † Printing Specifications Print Paper Thickness Detection Pattern Pattern 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 STD 18. 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 Insert Draining Cartridge in #X LCD panel message Insert Cartridge in Correct SlotLCD panel message Remove Draining Cartridge LCD panel message Insert ALL INK Cartridges Maintenance Mode Maintenance Mode 1 Setup Items46. Maintenance mode 1 setup items Outline Expir Date M Hexadecimal Dump Panel Display Language Selection Parallel I/F Mode Setting D4Unit Change INK Information Menu Maintenance Mode Maintenance Mode 2 Setup Items 48. 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 NVRAM, TIMER, Life COUNTER, Mechanical Counter Initialize Cleaning Unit LifeParameter Backup Maintenance Information Menu Paper feeding adjustment conversion table † How to change correction valuesSystem table † User table initialization Reload with F/W Download mode Installation with service utility F/W Update functionCompulsory start F/W Download mode Firmware Reload Function to prevent irregular printing InitializationHardware initialization Software initialization Default Setup Values Initial Setting for OperationInk Type Setting MW Printing Adjustment / Setting Values and Printing Modes Esck Escd Printing Mode Combination Table Valid print mode combination is following Controller Compatibility Mode SpecificationConnector PIN Assignment and Signals Interfaces Parallel Interface Timing Chart Parameter Minimum Maximum Nibble Mode 55. Connector Pin Assignment and Signals NibblePin Return Signal Name In/Out Function MDL Stylus Pro 7600-DYE/Stylus Pro 9600-DYE ECP Mode 56. Connector Pin Assignment and Signals ECP 57. Connector Pin Assignment and Signals Usbfs USB interfaceCMD MDL Stylus Pro 7600-DYE/Stylus Pro 9600-DYE CLS Reply for Option Command Optional InterfaceType-B interface level 2, 1200mA type is supported Reply Message Supported Main Command and Sending Timing 59. Commands and Sending TimingSupplements Prevention Hosts from Data Transfer TIME-OUT Installation Locations Optional Units and ConsumablesInk Cartridge Cleaning cartridge Maintenance TankCleaning cartridge is the same as the 220-ml ink cartridge Draining cartridge Operating Principles Overview Explanation is composed as follows Print Mechanism Components Printer Mechanism Components Carriage CR Mechanism Carriage Mechanism Carriage Moving Unit Assembled to the nearest 1/100 mm at the factory Print Head Relationship between Nozzle Rows and ColorsPrinting Modes Drive Waveforms Ink Type Nozzle Row Color Platen GAP Adjustment Unit Carriage Mechanical Unit and PG Adjustment Unit Pulse 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 1/2 Modes 13. Paper Feed Mechanical Unit Stylus Pro 7600 2/2 Cleaning Mechanism Pump Drive Modes Explanation of Operation Operation Explanation Ink Supply Mechanism 16. Valve Mechanism Circuit Board Placement OthersCover Sensor Outline of Control Circuit Board Major ElementsName/Code Location Function SD-RAM Outline of Power Supply Circuit Board Signal Name FunctionFuse Rating Input Voltage Range V AC Fuse Rating 100 +/- 10% AC / 6.3A Troubleshooting Outline Introduction Error Display ErrorsError Indications on LCD Error Indications on LCD Maintenance Tank Almost Full Service 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 operation Paper 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 Maintenance tank full No Maintenance tankFatal Error Illegal ink cartridge Troubleshooting for Warning Maintenance tank full warningMaintenance request Bit Request object Cause How to recover errors Assigned bit Nnnn Cause How to clear RsvdMotor Clear Counters / RTC Troubleshooting 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 out CR motor encoder check error CR motor out of step CR motor overcurrent CR motor in-position time-out CR home position sensor error 0001000A PF home position sensor error 0001000BServo interrupt watchdog time-out System interrupt watchdog time-out Head slide PG home position sensor error 0001000C CR motor PWM output faulty 0001000F PF motor PWM output faulty Head driver TG temperature error 0001001B CR 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 Csic ROM communication error RTC communication errorHead error CR Asic ECU error 0001002A Sdram error Flash memory SUM errorBoot program SUM error Program load error 0002000A Review error 0002000C CPU slot illegal command exception error 100001A0CPU address error load misalignment 100000E0 CPU address error storage misalignment Troubleshooting Based on Your Printout Dot Missing Uneven Printing/Poor Resolution Smudged or Marred Printout Front Smudged or Marred Printout Reverse side White or Black Banding in the carriage running direction Banding in the paper feed direction Disassembly & Assembly Precautions Summary Manufacture. Dispose the used batteries according to Governments law and regulationsImmediately Edge in the printer mechanism Disassembly & Assembly Summary 154 Tools Screw ListNecessary Tools Following table lists all the screws used in this printer Disassembly Flow Refer to -2when determining the disassembly flow Disassembly & Assembly Summary 157 Removing the Panel Unit and Housing Housing Part Diagram Panel Unit Panel Unit Removal 1/2 Side Cover R Side Cover Removal 1/5 R 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 Removal Top Cover 14. H Top Cover Removal on left side „ Removing and installing the Rear Cover Rear Cover Loosen the screw Main Board Access Cover Remove the screw Paper Guide L2 18. Paper Guide L2 Removal Roll Paper Cover 20. Roll Paper Cover removal Front Cover Opens and closes Disassembly and Assembly of Carriage CR Mechanism Print Head When replacing the print head, the following adjustment Procedures are required Damper Assy Execute ink discharge Ink Blowing before removingDamper Assy Will be expelled, so do not press on this part Connectors on CR Board Connector Type Connected toCR Board Assy 33. Removing the Cutter Housing Cutter Section Cutter Holder Assy 35. Take Care When Installing the Cutter Holder Cutter Solenoid 36. Cutter Solenoid Removal CR Encoder Sensor Assy Made After replacing the Pedge Sensor, the following adjustment Pegde Sensor AssyOperation should be performed 41. Indicator Position CR Motor Assy CR Motor, make the following adjustment 43. Removing the CR Motor Assy Headslide Sensor Assy 44. Removing the Headslide Sensor Assy Crhp Sensor Assy 46. Releasing the Crhp Sensor Assy Harness CR Encoder Scale Timing Fence Fastening Spring on the L Side Frame side Disassembly and Assembly of Paper Feed Mechanism PF Motor Adjustment PF Encoder Sensor Assy Assembly Procedure for the PF Loop Scale Assy 53. #F730 tool and PF Loop Scale Base PF Loop Scale Assy Affixing Procedure 55. Affixing the Double Sided Tape to the PF Loop Scale Suction Fans 57. Suction Fan Mounting Position Adjustment at reassembly Pthick Sensor/PTHICK Sensor0.3 Assy† Pthick Sensor Assy † PTHICK0.3 Sensor Assy Prear Sensor Assy Window Disassembly and Assembly of Ink Supply Mechanism 1 C472SUB-B Board When removing and installing the front cover switch holder, Following adjustment should be made2 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 Cover Sensor Assy operates coupled with the opening/closingFront Cover Disassembly and Assembly of Cleaning Mechanism Major Parts 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 spill Pump Motor Assy Cap Assy Pump Assy Once you have replaced the Pump ASSY, execute ClearCounters See p.71 Spring catch Cleaner Head Wiper 78. Removing the Cleaner Head Flushing Box Assy 79. Removing the Flushing Box Assy Disassembly and Assembly of Circuit Boards Power Supply BoardPower left in the boards capacitors Connectors on Power Supply Board AC Inlet 81. Removing the AC Inlet Holder Main Board C472 Main 83. C472MAIN Board Removal † Main Board Connector List CN.No Pins Color Connection Remarks DIP 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 Shipment Adjustment Adjustment Tools Adjustment ToolsName Part Code MCSP24R4 Procedure for Adjustment Work Adjustment ItemsPrint Head Adjustment Main Board Adjustment CR Motor Adjustment PF Motor AdjustmentRequired Adjustment Items CR Motor Replacement Power OFF → Paper Feed ∆ +Paper Feed ∇ + Cut/Eject Pedge Sensor Assy Adjustment Prear Sensor Assy AdjustmentPTHICK/PTHICK0.3 Sensor Assy Adjustment CR Encoder Sensor Assy Adjustment Cover Sensor Assy Adjustment PF Encoder Sensor Assy Adjustment11. Required Adjustment Items 12. Required Adjustment Items Cutter Solenoid Assy or Paper Guide L Adjustment Damper Assy AdjustmentRelease Sensor I/H Lever Adjustment Battery Parameter Backup Parameter Backup ProcedureWork Procedure Others Firmware Reinstallation Firmware Installation through ROM-DIMMFirmware Installation through Interface Check Set the parallel interface in the compatibility mode Self-diagnostic Function How to Start Self-diagnostic Function15. Key Functions in Self-diagnostic Mode Overview 16. Self-diagnostic Function List Top Menu Test Test is intended to check the circuit boards17. Circuit Board Check Items Description See Version Control Panel Sensors Menu Transition of Sensor Test Encoder 2.5 FanCheck to see if each fan operates. See Figure Maintenance Record Record Record of Errors Csic Internal Information Display of Csic Internal information on Csic is displayed Actuator You can operate actuators. See FigureCutter Automatically move up Adjustment 19. Panel Setting Item List Rear AD Adjustment Adjustment and Checking ProcedureStart the Self-diagnostic Function Power OFF → Paper Feed ∆+Paper Feed ∇+Cut/Eject → Power on Edge AD Adjustment „ Paper to be used A3 plain paper Damper ASSY, select and execute Initial charge in Cleaning Input Rank Input Line Selection 22. Menu Transition of Panel Input † Dye code input This mode, input a dye code by operating on the panelRight End Write D/A Value Check Nozzle 20. PatternPattern Description 4BUTWTU Check Skew Feed Correction + T&B Adjustment 21. Positions where Vertical Line Patterns Are Drawn Coordinate in units of 360 dpi Feed Correction + T&B Adjustment Display Adj Feed Adj.+T&BPaper Feed ∇ → SelecType → Paper Feed ∆ To be placed Top & Bottom Adjustment 34. Menu Transition for Top & Bottom Adjustment Rear 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 Slant Checking Procedure Head Slant Adjustment Mechanical AdjustmentHead motion by Head Adjustment Lever operation Lever Up Magenta → lower / Black → rise Round Trip Print Position Adjustment Bi-D Adjustment 22. Adjustment Item ListContents BI-D Adjustment Procedure † K Black Line Adjustment ProcedureDisplay Adj Bi-d SelecType → SelecType → Enter Adjustment 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 Checking Head Gap Adjustment Uni-D Adjustment 23. Head Gap Adjustment ItemsCorrect 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 comprehensive Test Pattern Printing 56. Menu Transition for Test Pattern Printing Clean Head 57. Menu Transition for Head Cleaning Counter Clear 24. Counters to be Cleared and Their Initial ValuesCounters to be Cleared Initial Value Adjustment Self-diagnostic Function 258 Cleaning 25. Cleaning ItemsPrint Charge in this menu Parameter 27. Parameter Items Parameter 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 Adjustment PTHICK0.3/PTHICK Sensor Mounting Plate Position Adjustment Display Test SensorSelecType → Paper Feed ∇ Display Sen Paper Mounting Plate Gauge Condition LCD Cover Sensor Assy Mounting Position Adjustment 31. Cover Sensor Assembly CheckSensor is installed correctly and check the operation again Display Sen Cover CR Encoder Sensor Mounting Position Adjustment Use with Stylus Pro 7600 / 9600 do not use the CR EncoderMounting 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 adjustment Use with Stylus Pro 7600 / 9600 do not use the cutter Positioning jig designed for any other printer models Front 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 Encoder USB 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 switch Periodic Maintenance Items and Product Life Information 0040 0002 0020 00000101 Maintenance Overview 278 Important Maintenance Items During Service Operations Items to be Checked During Maintenance/ServiceItems Check Points Remedy Check Before applying lubricant, clean the surface Lubrication and GlueLubricating the CR Guide Rail Grease and Glue Application Appendix Connectors Main Board Connectors ListPanel Unit Connectors List C472 CR Board Connectors List C472 SUB-B Board Connectors List † Power Supply BoardPower Supply Board Connector List † C472 SUB-B Board Appendix Connectors 284 Component Layout Will be established by the next revision 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 Parts List ASP List for Stylus ProASP List for Stylus Pro Ref No Part Name Adjust Lever B Adjust LeverConnecting Screw Paper Guide Wire Cleaner Flushing BOX AssyPump Moter Janction Cable TR Connecter Handle Vacuum FAN1 Cable ASSY.2Vacuum FAN2 Cable ASSY.2 Vacuum FAN3 Cable ASSY.2 CR Moter Cable ASSY.2 Partition Plate LFFC2 Cover SW Cable ASSY.2 Packing BOX ASSY.WStand L Assy Caster NON Stopper