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7600, 9600 service manual
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322 pages, 18.43 Mb
Revision Status
Revision
Date of Issue
Description
A
May 10, 2002
First release
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
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EPSON Stylus Pro 7600/9600 Revision A
Page
Page
Page
Page
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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