EPSON 7600_9600 Field Repair Guide
Contents
1. 00010022 Ink type error Setting on printer body side 00010023 RTC analysis error 00010025 CSIC ROM communication error 00010026 RTC communication error 00010028 Head error 00010029 Unidentified NMI 0001002A CR ASIC ECU error 0001002B PF ASIC ECU error 00020000 NVRAM error 00020002 SDRAM error 00020003 BOOT program SUM error 00020009 Flash memory SUM error 0002000A Program load error 0002000B Internal memory shortage error 0002000C Review error 100000E0 CPU address error load misalignment 10000100 CPU address error storage misalignment 10000180 CPU reserve command code exception error 100001 A0 CPU slot illegal command exception error 100005C0 CPU DMA address error 10000xxx CPU error Error Codes Printer Component Software Item LCD Display Printer Button Page 54 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 Glossary Artifact A defect that is within an image It can mean something on the graphic that was not intended or something missing that was intended All image quality defects are arti facts Bi Directional Adjustment An electronic adjustment that ensures that a printer can coordinate left to right with right to left printing Capped Position The print head at it s stand by position with the cap mechanism sealing the nozzles Coating The top layer of graphics paper media that consists of a special substance d2. Paint Brush Effect Something horizontally across the printed surface that was not intended Usually caused by an ink soaked fiber hanging off the print head Pigment Ink Ink that deposits colored particles pigment on the printed surface to create an image It is more durable than dye based ink but does not have as wide a color range gamut Glossary Printer Component Software Item LCD Display Printer Button Page 58 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 Pixilated An image quality issue that is caused by a low resolution image printed at high reso lution Platen Gap The distance between the print head and the printable surface Rippling A term that refers to a condition caused by over saturated paper warping Saturation The amount of ink applied to the printed surface Screening The dot pattern placed on the printed surface to create and image Also known as dithering Skew Crooked paper in the printer Smear An image that has been rubbed by something causing it to be deformed or smeared The direction or any repetition of the smear should be noted Smudge Something on the printed surface that was not intended Usually transferred to the page because of contact with a dirty roller or the print head Any repetition should be noted and measured Sublimation Ink Ink that is first printed on thermal transfer media and then transferred using h
3. 4 Check Pin 3 N A No information on this adjustment 1 Initialize Initializes specific or all parameter items Refer to the service manual for list 5 Check Parameter 2 Update Allows you to update certain parameter items Refer to the service manual for list 3 Display Displays parameter items Refer to service manual for list 6 Check Life Control Panel Map 7 22 02 Page 6 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 What Is New About the 7600 9600 CSIC Ink Cartridges CSIC Customer Satisfaction Ink Cartridge chips on the Ink Cartridges inform the Printer about e The type of ink dye or pigment e The color of the ink e The quantity of the ink e The vendor date manufactured etc 7 Nozzle Sets Pigment or Dye The 7600 9600 are equipped to handle either pigment or dye ink from the factory The User has three ink combina tions to choose from all combinations include cyan light cyan magenta light magenta and yellow e 7 color pigment black and light black e 7 color pigment matte black and light black e 6 color pigment two matte blacks e 6 color dye 2 photo blacks If the User installs either of the pigment ink sets the Printer recognizes the ink and becomes a pigment Printer The customer can switch from one pigment set to the other but never to dye If the User installs dye inks first the Printer will not accept pigment inks and vice versa 4 Platen gap
4. A type of horizontal banding where multiple print head passes have a space between them The banding looks lighter than the intended image Multiple passes of the print head should place ink on the paper exactly next to earlier passes with no space in between Illusion of Continuous Tone A term that refers to fooling the human eye into perceiving a dot matrix image as a photograph continuous tone image Epson ink jet printers are not continuous tone printers However when working properly their printed images fool the human eye into seeing continuous tone transitions Ink Color Contamination The intended color of the ink supply has been altered Ink Impurities Foreign objects in the ink supply Margin Shift A term that refers to an image with irregular right and left side margins Mechanical Alignments Printer adjustments that requires physically moving parts of the mechanism Media The surface that is being printed on usually paper Metamerism The different appearance of colors caused by different light sources and viewing angles Micro Weave The way an Epson Ink Jet printer interlaces weaves bands of and image during printing Moir Pattern A repetitive pattern within an image which is not intended can appear like a pais ley or herringbone pattern Over Saturation Too much ink has been applied to the printable surface for the media to support
5. Head Gap Adjustment An electronic print head adjustment that ensures that the printer knows the exact distance between nozzle sets on separate heads ae EM hae Ee Head ID The calibration value written on the print head that allows the printers electronics to compensate for the print heads personality inaccuracies Head Linear Adjustment A mechanical print head alignment that ensures that on a two head ink jet printer that all the noz zles are on the same horizontal plane Also known as Head Height and BC Head Slant The right head is moved in relation to the left head Home Position The print head s horizontal reference position as determined by the Home Position Sensor Horizontal Banding An image defect that extends from the left to the right margin parallel to the direc tion of print head movement The defect could be a lighter or darker band than is intended It usually repeats with the same interval from the top margin to the bot tom Horizontal Over lap A type of horizontal banding where multiple print head passes overlap while printing The banding looks darker than the intended image Multiple passes of the print head should place ink on the paper next to but not on top of earlier passes Glossary Printer Component Software Item LCD Display Printer Button Page 57 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 Horizontal Under lap
6. 3 Move the Paper Release Control Panel LCD displays Wait Lever to the Secured Paper Out LED red is OFF position Pause LED green is ON Operate LED green is ON Pause LED will flash for a short period of time then return to solid 1 The Paper Cutter Solenoid is energized releasing the Carriage Assembly 2 The Carriage Assembly moves to the Home Position Sensor to establish the carriage home position If fails Check the Carriage Encoder Strip the Carriage Encoder and the Home Position sensor 3 The Carriage Assembly moves to the right side frame engaging the Pump Motor to set the platen gap If fails Check the Gap Home Position Sensor related gears and outside light on the Gap Home Position Sensor light from an outside source i e sunlight from a window 4 The Paper Cutter Solenoid energizes twice 5 The Carriage Assembly moves to the right side of the media to detect the right edge then returns and parks on the Cap Assembly The Control Panel displays Press Pause Button If not pressed within 5 seconds the initialization process continues Initialization Sequence Printer Component Software Item LCD Display Printer Button Page 12 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 6 Press the Pause button 1 The Paper Cutter Solenoid energizes releasing the Carriage Assembly 2 The Carriage Assembly moves to verify the right edge of the paper 3 The Car
7. Info to page 4 Use the Paper Feed or Paper Feed to move up or down the menu Settings Available Self Diagnostic Mode 1 Check Test Press Paper Feed Paper Feed 2 Check Adjustment Cut Eject buttons while powering 3 Check Cleaning For navigation on printer 4 Check Print and details on SNE 5 Check Parameter menu items 90 While in this mode pressing the 6 Check Life to page 5 Se button will Auto Cut roll fed Use the Paper Feed or Paper media Feed to move up or down the menu Firmware Download Press Paper Source Cut Eject Once in this mode the LCD will display Date Send At this point send the Cleaning buttons while powering on p UPG Data file BN or BWxxxx UPG to the printer via the copy command printer from a DOS prompt using the following syntax COPY B Filename UPG LPT1 Once the download is complete the LCD will display Complete Control Panel Map Page 2 Stylus Pro 7600 9600 Field Repair Guide 1 Use the Paper Feed or Paper Feed to move up or down the menu 2 Pressing the SelecType button will move you into the sub menu 3 Pressing the Paper Source button will move you back one menu item 1 Printer Setup 2 Test Print Menu 3 Printer Status Menu SelecType Menu Options 1 Platen Gap Std Wide Wi
8. Non Epson Drivers RIPs Support The Stylus Pro 7600 9600 Printers utilize numerous media and ink control features that are accessed by commands built into the Epson Printer Driver The purpose of the control features is to improve print quality and minimize banding and saturation issues Non Epson Drivers and RIPS do not support those control features The SelecType Paper Config menu allows the User to configure the Printer to use a group of custom settings on every job that is received that does not contain Epson Printer control feature commands The following is a list of cus tom settings supported e Paper Number to assign a number to the custom settings e Cut Pressure to control cutter blade pressure e Cut Method to reduce cutting errors on thin media e Paper feed pitch to reduce horizontal banding e Drying time to increase Ink drying time between passes to reduce smearing e Suction Fan power to reduce vertical rippling on thin media Epson User Print Quality Solutions Printer Component Software Item LCD Display Printer Button Page 49 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 Firmware History EPSON Stylus Pro 9600 Current version BW0526 Firmware Version Release Date Description of Changes Backward Compatibility Issues BW3024 4 30 02 Initial release for mass production units N A BW0526 6 05 02 1 Corrected the issue of ink out when the initial in
9. Prints a pattern of all Bi D adjustment patterns 21 Head LR Adj Prints a pattern to allow for adjustment of the Head Gap Head LR 22 Test Print Prints pattern of all adjustment variables 23 Clean Head Performs ink drain function This process should only be done during refurbishment of product 24 Counter Clear Clears ink flag counter to 0 When in the sub menu of each item pressing the Pause button will back up one menu 3 Check Cleaning 4 Check Print 5 Check Parameter p Goto Page 6 6 Check Life Control Panel Map Page 5 Stylus Pro 7600 9600 Field Repair Guide Self Diagnostic Mode Options cont 1 Use the Paper Feed or Paper Feed to move up or down the menu 2 Pressing the SelecType button will move you into the sub menu 3 Pressing the Paper Source button will move you back one menu item 1 KKO Normal Cleaning Cycle is performed volume of ink cleared Low 3 Check Cleaning 2 KK 1 Strong Cleaning Cycle is performed volume of ink cleared Med Rubbing Off 3 KK2 Strong Cleaning Cycle is performed volume of ink cleared High Rubbing On 4 Init Fill Perfoms initial fill cycle 1 Check Ptn Prints out the current adjustment patterns 4 Check Print 2 Adj Variables Prints out the adjustment variables Also lists feed length firmware error information 3 Check Ptn 2 N A No information on this adjustment
10. Procedure Printer Component Software Item LCD Display Printer Button Page 28 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 5 3 5 4 5 5 5 6 5 7 5 8 Ensure the Print Head Cables are fully inserted to avoid damaging the Main Board Install the Print Head onto the Carriage Assembly Place your fingers on the base of the Print Head and slide the Print Head ensuring that it is seated properly Secure the Head Holder with both screws Back off each screw a 1 4 turn and ensure the Print Head still slides using the Adjustment Lever Set the Adjustment Lever 1 4 of an inch from the top back position 6 Installation of the new Dampers 6 1 6 2 6 3 6 4 6 5 6 6 6 7 6 8 6 9 Before installation inspect the Dampers closely Look for cuts in the flexible membrane Inspect the O rings for damage and replace if necessary Place a Joint Screw then an O ring onto an Ink Tube Insert the Tube fully into a Damper Maintain insertion pressure on the Ink Tube and finger tighten the Joint Screw Repeat steps 6 1 through 6 5 for each Damper Install the Dampers into the Damper Holder and reassemble Insert the Ink Cartridges Manually prime the Dampers using a syringe 6 10 Remove the Ink Cartridges closing the Valves 6 11 Install the Damper Assembly onto the Print Head 6 12 Park the Print Head on the Cap Assembly 7 Install the Ink Cartridges and the Waste Ink Tank Note During the next procedures look for leaks f
11. Verify that the platen gap is being set to the proper position by observing the Platen Gap HP Flag 3 3 1 Inspect Thickness Sensor Actuator for proper position 3 3 2 Adjust if required 4 Perform the Head Angular Adjustment 5 Perform the Bi directional Adjustment 6 Perform the Uni directional Adjustment Un sharp Caused by to much dot gain See Vertical Banding Irregular Smear typically caused by one or more of the following reasons 1 Slow dry time caused by 3 party media 1 1 Try with the Epson supplied media image and driver 2 Slow dry time caused by 3 party ink 3 Slow dry time caused by over saturated media 3 1 Try with the Epson supplied media image and driver Debris Image Quality Diagnosis and Repair Printer Component Software Item LCD Display Printer Button Page 22 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 1 Clean the edges metal of the Print Head DO NOT touch Print Head nozzle area 2 Clean the Cap Wiper Blade and Wiper Cleaner Note Look for fibers from cotton or rag based media attracted to the Print Head and saturated with ink It collects and drops onto the media Smudge 1 Clean the Paper Feed Rollers 1 1 Ink or dirt accumulation 2 Ensure Print Head is in the cap position while loading paper 2 1 Paper contact with the Print Head during loading 3 Increase Suction to Normal or feed paper an extra 3 inches 3 1 To much curl on the leading edge of the
12. media for the Suction Fan to over come results in contact between the media and the Print Head Drop of Ink 1 Inspect the Ink Supply Tubes for damage Leakage 2 Inspect Dampers for correct installation or damage Leakage 2 1 Inspect the O ring inside the Joint Screw fitting that joins the Ink Supply Tube to the Damper 2 1 1 Look for a deformed O ring caused by over tightening the Joint Screw Paint Brush Effect Ink saturated fibers on the Printhead being dragged across the media Image Quality Diagnosis and Repair Printer Component Software Item LCD Display Printer Button Page 23 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 3 Clean the edges metal of the Print Head DO NOT touch the Print Head nozzle area 3 1 Clean Cap Wiper Blade and Wiper Cleaner Assembly Note Look for fibers from cotton or rag based media attracted to the Print Head and saturated with ink It collects and drops onto the media Pixilated 1 Use the Epson supplied image to eliminate the following 1 1 Application 1 2 Low quality resolution image 2 Perform a Bi Directional Adjustment 3 Perform a Uni directional Adjustment Ink Color Contamination Note It is caused by a restriction in the ink supply The restriction causes the Damper for the contaminated color to collapse Eventually the collapsed Damper will expand drawing ink from the Cap through the Print Head into the Damper contaminating the color 1 Inspect or rep
13. of Contents Printer Component Software Item LCD Display Printer Button Page 1 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 Control Panel Map NOTE Although this is a guideline to navigate through the ettings Available Service and User Menus the a red Setup Service Manual Technical SENS Made Leie Ea Bulletins or Users Guide may still While printer LCD shows Ready 4 Paper Config and details on be needed to reference detailed pressing the SelecType button 5 Maintenance menu items go information on a setting or enters this mode 6 Print Head Alignment to page 3 adjustment listed Use the Paper Feed or Paper Feed to move up or down the menu Settings Available 1 Hex Dump Mode 2 Language Mode 3 Unit Maintenance Mode 1 4 Parallel I F For navigation Press Pause button while 5 IEEE1284 4 Mode and details on powering on printer gt 6 Crtg Info Menu menu items go i 7 SSCL to page 4 E Opere Eppoi verte E 8 SN Menu Tank Power 9 Default Panel Use the Paper Feed or Paper Feed to move up or down the menu Settings Available 1 View Counters 2 Clear Counters Maintenance Mode 2 3 Service Config For navigation Press Paper Source Cut Eject 4 Parameter Backup Mode and details on Paper Feed buttons while gt 5 Maintenance Info menu items go powering on printer 6 Init
14. to 0 to get the printer to initialize Make sure the customer has the UltraChrom inks installed then switch the NPD value to 0 1 Power Off the printer Press Paper Source Paper Feed down Cut Eject buttons then power On the printer 2 Navigate to Service Config mode then change the NPD value to 0 Ink Cartridge Errors Printer Component Software Item LCD Display Printer Button Page 52 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 Error Codes 00000101 CR motor life 00010000 PF motor encoder check error 00010001 PF motor out of step 00010002 PF motor overcurrent 00010003 PF motor in position time out 00010004 CR motor encoder check error 00010005 CR motor out of step 00010006 CR motor overcurrent 00010007 CR motor in position time out 00010008 Servo interrupt watchdog time out 00010009 System interrupt watchdog time out 0001000A CR home position sensor error 0001000B PF home position sensor error 0001000C Head slide PG home position sensor error 0001 000F CR motor PWM output faulty 00010010 PF motor PWM output faulty 0001001B Head driver TG temperature error 0001001D CR servo parameter error 0001001E PF servo parameter error 00010020 CSIC reed right error Error Codes Printer Component Software Item LCD Display Printer Button Page 53 Stylus Pro 7600 9600 Field Repair Guide 7 22 02
15. Advancement The 7600 9600 printers feature an expanded Paper Config options found in the SelecType Menu One of the new additions to this feature allows the User to adjust paper feed steps to minimize horizontal banding It is effective with Non Epson RIPS Drivers This paper feed adjustment is global and will affect every job sent to the Printer Epson User Print Quality Solutions The Epson Printer Service Utility is a utility that allows the User to adjust e Paper Feed Step e Ink Saturation e Suction Fan e Platen Gap e Ink Dry Time e Cut Method It can also be used to update firmware and perform electronic adjustments For details see the Epson User Print Quality Solutions document in the 7600 9600 Field Repair Guide What Is New About the 7600 9600 Printer Component Software Item LCD Display Printer Button Page 9 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 Sensors Motors Solenoids and Fans Home Position Sensors Carriage HP Sensor Gap HP Sensor HD Slide Origin Maintenance Waste Ink Tank Sensor Waste Ink ID CSIC Ink Cartridge Sensors Cartridge CSIC s Customer Satisfaction Ink Cartridge 7 Ink Cartridge Lock Lever Sensor Encoders Carriage Encoder Paper Feed Encoder Paper Sensors Rear Sensor Edge Sensor for width and leading edge Paper Thickness Sensor also registers paper release Cover Sensors Cover Sensor Temperature Sensors Head Temperat
16. Horizontal Banding 1 Perform a Nozzle Check from the Adjustment menu within Self Diagnostic Mode 1 1 Inspect printed pattern for missing deflected or sympathetic nozzle s 1 1 1 Perform 2 Cleaning Cycles then reprint Nozzle Check 1 1 1 1 Missing or deflected nozzle s 1 1 1 1 1 Clean the Cap Wiper and Wiper Cleaner and repeat cleaning cycles 1 1 1 1 2 Inspect the Cap Assembly and replace if it is damaged 1 1 1 1 3 Replace the Print Head 1 1 1 2 Sympathetic nozzle s 1 1 1 2 1 Replace the Print Head 2 Verify that paper is not binding 2 1 While loading 2 2 While ejecting 2 3 On the spindle 3 Verify the Head Slant alignment is correct Head Angular 3 1 Print and inspect the pattern 3 2 Perform adjustment if required 4 Verify Platen Gap with the Printer Settings section of the SelecType Menu 4 1 Four settings are available Standard Narrow Wide Wider 4 2 Set to the appropriate setting to match the media default is Standard Image Quality Diagnosis and Repair Printer Component Software Item LCD Display Printer Button Page 18 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 O pP Aa p 10 4 3 Verify that the platen gap is being set to the proper position by observing the Platen Gap HP Flag 4 3 1 Inspect Thickness Sensor Actuator for proper position 4 3 2 Adjust if required Verify Printer Driver settings Note Non Epson drivers may need to have a custom profile created to ensure optimum pr
17. Not used for Stylus Pro 7600 9600 3 Service Config 4 Change Device ID Sty Pro 9600 Sty Pro 9600D PX 9000 5 NPD 1 UltraChrome 2 Dye 0 Neutral 6 ED Mode X all CSIC info is read O all CSIC info is read except market N no CSIC info is read 4 Parameter Back Mode xec Pressing the Cut Eject button will execute the command 5 Maint Info Options in this menu are for Factory Use ONLY Control Panel Map Page 4 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 Self Diagnostic Mode Options 1 Use the Paper Feed or Paper Feed to move up or down the menu 2 Pressing the SelecType button will move you into the sub menu 3 Pressing the Paper Source button 1 Version Checks firmware version dip sw settings and control panel amp main board versions will move you back one menu item 2 Panel Checks control panel buttons LCD display and LED indicators 3 Sensor Checks all optical and physical switches On Off Open Close 4 Encoder Checks CR and PF motor encoders 5 Fan Checks fans On Off 6 Elec Checks maintenance record and fatal error history 7 D A Revision Factory Use Only head voltage correction 8 Head Signal Factory Use Only head pulse check 9 CSIC Checks the CSIC information for the ink cartridges and maintenance tank 10 Actuator Checks the cutter actuator 11 Actuator 2 Checks the cutter solenoid and p
18. Step 4 Ppr Feed Adj 0 00 range is 1 00 1 00 5 Drying Time 0 0sec range is 0 0sec 10 0sec 6 Suction Normal Low 7 Print Adj 5 range is 1 9 DENOTES Default Values Use Paper Feed or Paper Feed to change a value Use Cut Eject to confirm save or execute the item T Pwr Cleaning Executes a power head cleaning cycle 2 Bk Ink Change Executes the Bk Ink Change process This allows the user to change from PhotoK Light K to Matte K Light K or Dual Matte K inks 3 Cutter Repl Executes the cutter replacement process When in these menus you want to follow the LCD Display for instructions 1 Ppr Thkns Std On 3N x xmm where x 0 0mm 1 6mm 1a Once the thickness has been set you can choose the head alignment pattern you want to perform The options are a Bi D Black b Bi D All c Uni D All Use Paper Feed or Paper Feed to change a value Use Cut Eject to confirm save or execute the item 7 22 02 Page 3 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 Maintenance Mode 1 Options T PRINT Prints data in Hexadecimal format for troubleshooting control codes 2 English Potuguese Spanish German Italian French Determines the language used for the LCD Display 3 Meier Feet Inch This allows measurements to be displayed printed in format selected 4 ECP Compat 5 Off On 6 C
19. Stylus Pro 7600 9600 Field Repair Guide 7 22 02 Table of Contents Tableof Gonlenis c c t ss e282 eee eee See eee Control Panel Map meme mme What Is New About the 7600 9600 Sensors Motors Solenoids and Fans Initialization Sequence Missing Nozzle Diagnosis and Repair Image Quality Diagnosis and Repair Bi Directional Adjustment Instructions Print Head Replacement Procedure Main Board Replacement e Paper Feed Belt Tension Adjustment Carriage Belt Tension Adjustment Paper Feed Encoder Alignment Carriage Encoder Alignment Cutter Guide Alignment Parameter Back Up Utility NVRAM exe Adjustment Wizard Adj wiz exe gt Updating Firmware From Windows WinPRN Utility Updating Firmware From DOS Epson User Print Quality Solutions Firmware History eee eee eee Ink Cartridge Errors eee ee eee Emor Codes 4s te s a ee Hee Sees ee Gee eeees eee SEE Glossary eee eee ee eee ee eee eee Table
20. ard Set the Dip Switch settings on New Board to match the Old Board Install the New Board Ensure that the Foil Cables are inserted correctly or the new board will be damaged Update the Firmware on New Board Main Board Replacement Printer Component Software Item LCD Display Printer Button Page 32 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 8 1 Plug in the Printer and connect to your PC via Parallel or USB 8 2 Turn on the Printer the Printer must be in Ready mode 8 3 Send the Firmware file using the DOS or Windows Firmware Update Method 9 Re install the parameters 9 4 Execute the NVRAM EXE program Parameter Backup Utility 9 5 Select Printer 9 6 Select Open 9 6 1 Open the file that your previously created and named I E 9600 00058 bin 9 7 Select Write Caution Do not turn off Printer until the control panel lights stop flashing they flash very subtly The utility indicates that the data has transferred but the printer requires twenty more minutes to process the data 9 8 Click Quit to close the application 9 9 Turn the Printer off and then on Note If Parameters can not be reloaded proceed to Step 10 for the adjustment procedures Adjustments procedure if the Parameter Backup was successful 9 10 Execute the Adjustment Wizard adj_wiz exe the Printer must be in Ready mode 9 10 1 Select Printer Name from the drop down menu 9 10 2 Select select Main Board Backup OK from the Part
21. ckness Sensor Actuator for proper position 4 3 2 Adjust if required Vertical Banding Irregular Paper Rippling 1 Verify Printer Driver settings Note Non Epson drivers may need to have a custom profile created to ensure optimum print quality Non Epson drivers may not support MicroWeave 1 1 1 2 1 3 1 4 Set Resolution 1440 High Speed OFF for best quality 1 1 1 Slight banding may occur at lower resolutions That is within the printer s specifications Verify that MicroWeave is enabled Verify Screening Method Error Diffusion is the best choice Verify Paper settings 1 4 1 Type Plain Semi Gloss Luster etc 1 4 2 Configuration Paper Thickness Suction etc Note Very High humidity may contribute to the issue wet paper Use the Epson driver supplied media and image to eliminate customer media driver and application issues 2 Verify correct Head ID Print Head calibration value 2 4 1 Compare Label on print head with Value indicated by Adjustment program Over or Under Saturation See Vertical Banding Irregular Image Quality Diagnosis and Repair Printer Component Software Item LCD Display Printer Button Page 21 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 Grainy 3 Verify Platen Gap with the Printer Settings section of the SelecType Menu 3 1 Four settings are available Standard Narrow Wide Wider 3 2 Set to the appropriate setting to match the media default is Standard 3 3
22. der Narrow 2 Page Line Off On 3 Interface Auto Parallel USB Option 4 Code Page PC437 PC850 5 Paper Margin T B 15mm 15mm 3mm 6 Ppr Size Chk On Off 7 Ppr Align Chk On Off 8 Timeout Off 30 sec 60 sec 180 sec 300 sec 9 No Margin L R Only 1 Cut 2 Cut 10 Cutter Adj Exec this will print an adjustment pattern for the built in cutter and cut down the middle 11 Refresh Margin On Off 12 Init Settings Exec This will reset the Printer Setup options to default values DENOTES Default Values Use Paper Feed or Paper Feed to change a value Use Cut Eject to confirm save or execute the item T Nozzle Check Print press Cut Eject to execute 2 Status Check Print press Cut Eject to execute 3 Job Info Print press Cut Eject to execute Use Paper Feed or Paper Feed to change a value Use Cut Eject to confirm save or execute the item This menu allows you fo view all the Status Check ifems on the LCD display without printing the Status Check page from the Test Print menu Use Paper Feed or Paper Feed to move up or down the menu 4 Paper Config Menu 5 Maintenance Menu 6 Head Alignment Menu Control Panel Map 1 Paper Number Standard range is 1 10 2 Cut Pressure 100 range is 0 150 3 Cut Method 3 Step 4
23. e for mass production units N A BN0526 6 05 02 1 Corrected the issue of ink out when the initial ink charge is performed and the user interrupts the process by doing the following 1 Opening the front cover 2 Releasing the paper release lever 3 Releasing the ink holder lever 4 Turning the printer off The printer will not stop the initial ink charge when any of the above acts are performed and the unit will continue to prime the ink delivery system However if the waste ink tank or ink cartridges are removed during the initial fill the ink flag will stop and generate an ink out condition 2 Corrected Svc Req 1000C error when the front cover is open and closed again during printing 3 Corrected Bi d shift when printing at 1440dpi Super Microweave mode 4 Corrected paper jam issue when printing on A4 or Letter size media when paper is back fed prior to printing 5 Corrected issue where printing hangs up if the cover is opened during printing 6 Corrected rare issue where Svc Req 10009 error occurs when turning on printer 7 Corrected issue where Bi d adjustment for VSD4 is changed when performing VSD2 using the EPSON Printer Service Utility User Utility None Firmware History Printer Component Software Item LCD Display Printer Button Page 51 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 Ink Cartridge Errors APS FYI Bulletin 07 18 02 1 Quest
24. eat to another surface Sympathetic Nozzle A nozzle that is not intended to fire firing in conjunction with an intended nozzle Tone The specific shade of a color Under Saturation Not enough ink has been applied to the printable surface to properly saturate the media UN sharp Fuzzy qualities in an image usually caused by too much dot gain Vertical Banding Irregular Vertical bands perpendicular to the direction of print head movement that are not lin ear Usually created by paper rippling caused by over saturation Glossary Printer Component Software Item LCD Display Printer Button Page 59 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 Vertical Banding Linear An image defect that extends from the top to the bottom margin perpendicular to the direction of print head movement It usually repeats with the same interval from the left margin to the right White Specks A term that indicates that the intended image has small missing areas where no ink has been deposited Glossary Printer Component Software Item LCD Display Printer Button Page 60
25. esigned to trap ink and keep it from being absorbed into the paper fibers Non paper based ink jet media uses coating to allow the ink to bond with the surface A coatings purpose is to minimize dot gain and control saturation Color Shift An unintended change of a gradient or tone Continuous Tone The qualities of a photograph that makes an image appear real The smooth and life like transition from one color shade to the next like in a photograph Epson Ink Jet printers are not continuous tone printers But when working properly their printed images fool the human eye into seeing continuous tone transitions Debris A term that refers to unintended ink on the page deposited by debris dropping from the print head Deflected Nozzle A nozzle is firing but the ink drop is not landing where it is intended too Irregular spacing on the nozzle check pattern indicates this condition Dithering The dot pattern placed on the printed surface to create and image Also known as screening Dot Gain A drop of ink tends to travel out from its point of impact as the media absorbs it The purpose of the coating on the media is to minimize dot gain Glossary Printer Component Software Item LCD Display Printer Button Page 55 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 Drop of Ink Ink that appears to have dripped from the print head or any other component of the ink supply Dye Ink Ink that col
26. ge File Type to Updating Firmware From Windows WinPRN Utility Printer Component Software Item LCD Display Printer Button Page 45 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 3 2 Highlight Firmware file BW3024 upg 3 3 Click on Open 4 Turnon the Printer while holding down the Cleaning Paper Source Cut Eject buttons 4 1 The display will read F W Download 5 Click START PRINT to copy file to printer File to print open DiTraining CDs Prographics G2 SP Progress idle About Sta rt Pri nt oo Time Elapsed s Total Bytes 0 5 1 Once completed the display will read Update Complete and all Control Panel LED s will be ON 6 Turn off the Printer Updating Firmware From Windows WinPRN Utility Printer Component Software Item LCD Display Printer Button Page 46 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 Updating Firmware From DOS Caution 7600 and 9600 firmware files are not compatible BW3024 upg 9600 and BN3024 upg 7600 is the correct file format for this method BW3024_q upg 9600 and BN3024_q upg 7600 is the correct file format for the Epson Printer Service Utility 1 2 3 4 5 Connect the Printer to the PC via a Parallel Printer Cable Copy the firmware file to the ROOT directory of you Hard Drive Boot your Computer in DOS mode Ensure that you are logged to C Type copy name of firmware file extension Ipt1 b do not press the Enter key 5 1 E
27. h Speed OFF within the printer driver 12 Replace the Paper Feed Motor very rare Vertical Banding Linear 1 Print with High Speed turned off Uni directional 1 1 If the quality improves perform a Bi directional adjustment 2 Verify the Printer Driver settings Note Non Epson drivers may need to have a custom profile created to ensure optimum print quality Non Epson drivers may not support MicroWeave Use the Epson driver supplied media and image to eliminate customer media driver and application issues 2 1 Set Resolution 1440 High Speed OFF for best quality 2 1 1 Slight banding may occur at lower resolutions That is within the printer s specifications 2 2 Verify that MicroWeave is enabled 2 3 Verify Screening Method Error Diffusion is the best choice 2 4 Verify Paper settings 2 4 1 Type Plain Semi Gloss Luster etc 2 4 2 Configuration Paper Thickness Suction etc 3 Perform the Uni directional Adjustment Image Quality Diagnosis and Repair Printer Component Software Item LCD Display Printer Button Page 20 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 4 Verify Platen Gap with the Printer Settings section of the SelecType Menu 4 1 4 2 4 3 Four settings are available Standard Narrow Wide Wider Set to the appropriate setting to match the media default is Standard Verify that the platen gap is being set to the proper position by observing the Platen Gap HP Flag 4 3 1 Inspect Thi
28. he adjustments 8 3 5 12 2 Inspect and repeat any necessary adjustments by clicking the back button Click Finish if patterns are acceptable Printer Component Software Item LCD Display Printer Button Page 30 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 9 Print atest image 10 Re assemble the Printer 10 1 Turn off the Printer and unplug from AC 10 2 Remove the Waste Ink Tank 10 3 Install the Side Cover 10 4 Install the Waste Ink Tank 10 5 Install the Control Panel 11 Plug in the Printer and turn it on 12 Perform a Nozzle Check from the Self Diagnostic Adjustment menu Print Head Replacement Procedure Printer Component Software Item LCD Display Printer Button Page 31 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 2 3 4 5 6 7 8 Main Board Replacement Note The 7600 and 9600 use different Main Boards The 7600 Main Board has no optional take up reel connector CN 30 The 9600 Main Board has the optional take up reel connector CN 30 Parameter Backup 1 1 Connect PC to printer Parallel or USB 1 2 Turn the Printer ON 1 3 Execute the NVRAM EXE program Parameter Backup Utility 1 4 Select Printer 1 5 Select Read it takes approximately 20 minutes 1 6 Select Save 1 6 1 Create name for file and save to your hard drive I E 9600 00058 bin 00058 Last 5 digits of Serial Number Remove the Main Board Housing Turn off the Printer and UNPLUG from AC Remove the Main Bo
29. int quality Non Epson drivers may not support Micro Weave 5 1 Set Resolution 1440 High Speed OFF for best quality 5 1 1 Slight banding may occur at lower resolutions That is within the printer s specifications 5 2 Verify that MicroWeave is enabled 5 3 Verify Screening Method Error Diffusion is the best choice 5 4 Verify Paper settings 5 4 1 Type Plain Semi Gloss Luster etc 5 4 2 Configuration Paper Thickness Suction etc Inspect Paper Feed Encoder Disc for cleanliness Perform Paper Feed Belt Tension Adjustment Perform Feed Length Adjustment Perform Banding Adjustment for Fine tuning NOTE This adjustment is the responsibility of the User Adjustment must be performed from the customer s computer The compensation value is attached to the driver Verify correct Head ID Print Head calibration value 10 1 Compare the label on the Print Head and Head ID value located in the Adjustment section of the Self Diagnostic Mode Image Quality Diagnosis and Repair Printer Component Software Item LCD Display Printer Button Page 19 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 11 Verify that the printer doesn t pause during printing caused by a slow computer 11 1 If the printer pauses it can create a horizontal band especially on pigment ink printers To minimize the problem 11 1 1 Set Spool Settings within the Driver Properties 11 1 1 1 Select Start printing after last page is spooled 11 1 2 Set Hig
30. ion I just purchased an UltraChrome Stylus Pro 7600 9600 printer and intend to use it with Matte Black ink only Could I initialize and perform initial ink charge of the printer with Matte Black ink 1 Answer No you will not be able to initialize the printer and perform initial ink charge with Matte Black inks You must first ini tialize the printer with the UltraChrome Black LBlack ink that was shipped with the printer Once the printer has been initialized then perform the ink switch as described in the SP 7600 9600 User s Guide under Switching Between Black Ink Modes section This switching process will take about 10 minutes and it will take of up to 180 215 ml of ink total across all 7 ink cartridges 2 Question I have already installed the Matte Black inks into my Stylus Pro 7600 9600 printer as part of the initial charge cycle and now I am getting Wrong Cartridge error and the printer will not initialize even after placing the UltraChrom Black LBlack inks into the printer What is wrong and how should I recover from this 2 Answer You must remove the Matte Black ink and initialize the printer using the UltraChrome Black LBlack ink that shipped with the printer If this does not work contact technical support for assistance If the ink initialization flag data is cor rupted the printer may not be able to recognize the UltraChrom Black LBlack ink cartridges and it may be required to change the NPD value under Maintenance Mode 2
31. isplay Printer Button Page 15 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 All Nozzles Missing One Color Only The color comes back after a cleaning cycle but drops out again 1 Check the following components of the ink supply for a minor restriction causing partial starvation Note Partial Starvation refers to a slight blockage of the ink supply system that slowly starves the Print Head for ink 1 1 Remove corresponding Damper and attempt to draw ink with a syringe The ink should draw easily 1 1 1 If ink can not be drawn easily remove Damper and attempt to draw ink through the Tube If ink can be drawn easily replace the Damper 1 1 2 If Ink can not be drawn easily through the Tube check the Ink Valve on the Cartridge Bay for correct operation 1 1 3 If the Ink Valve is working properly replace the Tube All Nozzles Missing One Color Only The color does not comes back after a cleaning cycle 1 Check the following components of the ink system for full starvation 1 1 Remove corresponding Damper and attempt to draw ink with a syringe 1 1 1 If the Damper is empty check for air leaks in the Tubes Joints O rings and Fittings or Dampers 1 1 2 If ink can not be drawn remove Damper and attempt to draw ink through the Tube If ink can be drawn replace the Damper 1 1 3 If Ink can not be drawn through the Tube check the Ink Valve on the Cartridge Bay for correct operation 1 1 4 Ifthe Ink Valve is working p
32. k charge is performed and the user interrupts the process by doing the following 1 Opening the front cover 2 Releasing the paper release lever 3 Releasing the ink holder lever 4 Turning the printer off The printer will not stop the initial ink charge when any of the above acts are performed and the unit will continue to prime the ink delivery system However if the waste ink tank or ink cartridges are removed during the initial fill the ink flag will stop and generate an ink out condition 2 Corrected Svc Req 1000C error when the front cover is open and closed again during printing 3 Corrected Bi d shift when printing at 1440dpi Super Microweave mode 4 Corrected paper jam issue when printing on A4 or Letter size media when paper is back fed prior to printing 5 Corrected issue where printing hangs up if the cover is opened during printing 6 Corrected rare issue where Svc Req 10009 error occurs when turning on printer 7 Corrected issue where Bi d adjustment for VSD4 is changed when performing VSD2 using the EPSON Printer Service Utility User Utility None Firmware History Printer Component Software Item LCD Display Printer Button Page 50 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 EPSON Stylus Pro 7600 Current version BN0526 Firmware Version Release Date Description of Changes Backward Compatibility Issues BN3024 4 30 02 Initial releas
33. l displays Ready The Operate LED green and one of three Paper Option LED s green are on Technician Tech Tips The initialization process described above is defined by the firmware version installed on the printer Slight variations can be observed depending on the firmware version installed To observe the final steps again release the Paper Lever then lock it into the Secured position The Vacuum Fans will come back on the carriage home and head gap will be reset Up and down paper movement will occur as the printer verifies all it s settings again Initialization Sequence Printer Component Software Item LCD Display Printer Button Page 14 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 Missing Nozzle Diagnosis and Repair Note Inspect the printer and media for dust or fiber accumulation Excessive dirt will cause missing nozzles Some Missing Nozzles One or more Colors 1 Check Cap Assembly for mechanical problems and dirt 1 1 Clean Cap 1 2 Check Wiper Blade for correct installation and flaws 1 3 Clean Wiper Blade 1 4 Clean Wiper Blade Cleaner 2 Puddle the Cap and park the Print Head for 30 minutes 2 1 Fill the Cap with as much water as possible 2 2 Park the Printhead on the Cap 3 Perform 2 cleaning cycles 3 1 Re test nozzles 3 2 Repeat 4 Replace the Print Head and Dampers Missing Nozzle Diagnosis and Repair Printer Component Software Item LCD D
34. lace the following components 1 1 The related Damper for a clog replace if required 1 2 Supply Tubes for crimps or clogs replace if required 1 3 A 3 party or damaged ink cartridge 2 Clean the Cap Wiper Blade and Wiper Cleaner Assembly Image Quality Diagnosis and Repair Printer Component Software Item LCD Display Printer Button Page 24 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 Ink Impurities Poor quality control in the manufacture of 3 party ink Ghosting 1 Perform the Bi D Adjustment 2 Perform the Uni Directional Adjustment White Specks Note Caused by particles that flaked off Epson Premium Luster Paper during cutting The particles attach themselves to the leading edge of the remaining paper and absorb some of the ink from the next image Latter the particles drop off leaving white specks where there is no ink Margin Shift Note Caused by incorrect horizontal positioning information from the Carriage Encoder device Clean or replace the Timing Fence most likely Clean and adjust the Carriage Encoder Clean the Carriage Rail e PN Perform the CR Belt Tension adjustment Image Quality Diagnosis and Repair Printer Component Software Item LCD Display Printer Button Page 25 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 Bi Directional Adjustment Instructions The 7600 9600 Printers have multiple ways to perform Bi Directional adjustments The Service Technician ha
35. ng e Paper feed pitch to reduce horizontal banding e Suction Fan power to reduce vertical rippling on thin media e Cut Method to reduce cutting errors on thin media e Ink density to increase or reduce saturation e Turn off MicroWeave to increase speed but cause horizontal banding e Update Firmware e Perform Bi Directional and Head Gap Adjustments e Perform a strong Print Head Cleaning The Epson Printer Service Utility consists of menu choices and test prints that allow the User to adjust the custom settings The adjusted custom settings are named and saved They can be loaded from the Custom menu on the Printer Driver at the User s discretion A Technician should use his media image and driver computer to bypass all User settings If the Epson User Print Quality Solutions Printer Component Software Item LCD Display Printer Button Page 48 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 Printer is aligned properly and works with the Technician s media image and Printer Driver the issue should be referred back to Epson Phone Support Epson Printer Driver Paper Config Section This Section of the Printer Driver does essentially what the Epson Printer Service Utility does It can be used to adjust and save custom settings They can be loaded from the Custom menu on the Printer Driver at the User s discretion This method has no test print support and requires more experimentation and User knowledge
36. o will result in very poor print quality with some media and resolutions Bi Directional Adjustment Instructions Printer Component Software Item LCD Display Printer Button Page 27 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 Print Head Replacement Procedure 1 Place a sheet of paper drop cloth under Printer work area 2 Remove the Ink Cartidges to close the Ink Valves 3 Removal of the Damper Assembly 3 1 Turn off the Printer and UNPLUG from AC 3 2 Remove the Control Panel Waste Ink Tank and the Right Side Cover 3 3 Re connect the Control Panel to the cable 3 4 Gently press on the Cutter Assembly to release the Carriage Mechanism from the capped position 3 5 Loosen the screw securing the middle of the Damper Holder 3 6 Separate the Damper Assembly from the Printhead 3 7 Disengage the three hooks to separate the Damper Assembly into two pieces 3 8 Note the order that the Ink Tubes are connected to the Dampers K LK DC LC DM LM Y 3 9 Disconnect the Joint Screws and separate the Dampers from the Tubing 4 Removal of the Print Head 4 1 Loosen the left screw of the Head Holder 4 2 Remove the right screw and release the Head Holder downward 4 3 Gently remove the Print Head by lifting on the inner side 4 4 Disconnect the two Foil Cables from the Print Head 5 Installation of the Print Head 5 1 Write Down the Head Rank Print Head Calibration Value 5 2 Insert the Print Head Cables Print Head Replacement
37. omponent Software Item LCD Display Printer Button Page 43 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 Adjustment Wizard Adj wiz exe Purpose To assist in performing all the necessary adjustments after replacing a part or parts Location Epson Resource CD Adjustment Software 76_9600 Adjustment Wizard SP7600 or SP9600 File Name Adj_wiz exe Note The Printer Driver for the Printer must be loaded on the PC To Use 1 Replace the part s on the Printer Turn on the Printer and load paper Printer must be Ready Open Adj_wiz exe 2 3 4 Select the name of the Printer being serviced 5 Select the appropriate part s from the Change Parts menu 6 Select OK and follow the prompts Adjustment Wizard Adj_wiz exe Printer Component Software Item LCD Display Printer Button Page 44 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 Updating Firmware From Windows WinPRN Utility Caution 7600 and 9600 firmware files are not compatible BW3024 upg 9600 and BN3024 upg 7600 is the correct file format for this method BW3024_q upg 9600 and BN3024_q upg 7600 is the correct file format for the Epson Printer Service Utility 1 Execute WINPRN EXE Located in the Utilities folder on your Epson Resource CD 2 Click Open OPEN File to print Open Frogresa ide Time Elapsed 5 Total Bytes 3 Locate Firmware File Firmware File BW3024 upg File Type Open 3 1 Chan
38. ors the printed surface with dye It is less durable than pigment ink but has a wider color range gamut Electronic Alignments Printer adjustments which are performed using software routines that allow the printer to compensate for physical variations in its mechanism Error Diffusion The type of dithering Screening proprietary to Epson that employs a random dot pattern to ensure that the human eye can discern no pattern Flight Time The time it takes a drop of ink to travel from the print head to the printable surface Gamut The range of colors that a printer can produce Ghosting A term that refers to components of an image that are intended to be on top of each other or adjacent but are offset Gradient A smooth transition between one color shade and the next A continuous tone image requires a smooth gradient for all its tonal shifts Grainy A breakdown of the illusion of continuous tone A printed image that does not have smooth tonal transition and sharp detail Head Angular Adjustment A term that refers to a mechanical print head alignment that ensures that an ink jet s print heads nozzles are on the same vertical plane Also Known as the B head slant or the C head slant The head is rotated until it is vertically linear Glossary Printer Component Software Item LCD Display Printer Button Page 56 Stylus Pro 7600 9600 Field Repair Guide 7 22 02
39. r Position Printer Component Software Item LCD Display Printer Button Page 34 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 10 1 5 17Write USB ID 10 1 6 Click on the Print button to print all the adjustment patterns 10 1 7 Inspect and repeat any adjustments by clicking the Back button 10 1 8 Click Finish if the patterns are acceptable 11 Turn off the Printer and UNPLUG from AC 12 Re install the Main Board Housing 13 Plug in the Printer and turn it on 14 Perform a Nozzle Check from the Self Diagnostic Check Adjustment menu Main Board Replacement Printer Component Software Item LCD Display Printer Button Page 35 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 Paper Feed Belt Tension Adjustment Note The following instructions are for the purpose of performing the belt tension adjustment when the 4000g Tension Gauge is not available Recommended tension is 2200g 1 Remove the Left Side Cover 4 Screws 2 Loosen the 4 screws on the Fixing Bracket indicated in FIG 1 3 Slide the Fixing Bracket in the direction indicated in FIG 1 4 While holding the Bracket in place tighten the bottom left and top right screws to secure Bracket evenly Di Secure remaining 2 screws 6 Inspect the Belt tension by pressing with your finger as shown in FIG 2 7 The Belt will flex approximately a 1 8 Refer to red circle in FIG 2 Fig 1 Fig 2 NOTE If the Paper Feed Timing belt tension is to loose Hori
40. riage Assembly moves to the right side frame engaging the Pump Motor to set the platen gap 4 The Carriage Assembly moves from right to left across the paper using the Paper Edge Sensor to measure the paper width If fails Perform the Edge AD sensor adjustment 5 The Carriage Assembly moves back to the right edge of the paper 6 The paper is backed up until the leading edge of paper reaches the Paper Width Sensor establishing the TOP of Form reference 7 The Carriage Assembly moves from right to left across the leading edge of the paper checking for any evidence of paper skewing If fails Control Panel displays Reload Paper Reload the paper verifying the paper is aligned with the paper guide holes If fails again Check to see if the paper edge is uneven or there is ink on the paper Also check the Carriage Timing Strip and Carriage Encoder Initialization Sequence Printer Component Software Item LCD Display Printer Button Page 13 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 Press the Pause button contin 8 The Carriage Assembly moves to the right side frame ued engaging the Pump Motor which resets the platen gap 9 The Carriage Assembly moves back to the carriage lock position and is locked in place 10 The paper is advanced to the Top of Form position 11 The Vacuum Fans turn off until printing or paper movement is initiated 12 The Control Pane
41. rig Info Menu Gives details about ink cartridges type and usage 7 SSCL Super Strong Cleaning cycles Perform when normal cleanings do not work This should be last option as a lot of ink of consumed during the process 8 SN Menu For Factory Use only 9 Default Panel This will reset all Maintenance Mode 1 settings to factory defaults 1 Use the Paper Feed or Paper Paper Feed or Paper Feed to change value Use Cut Eject to Confirm Save or Execute the item value Feed to move up or down the menu 2 Pressing the SelecType button will z move you into the sub menu Maintenance Mode 2 Options 3 Pressing the Paper Source button will move you back one menu item While in this menu option you are capable of viewing all the counter information for the following components 1 View Counters lt _ __ gt Cutter Cutter Total Total Pages Maint Tank CR Motor CR Motor Total PF Motor Head K1 Head K2 Head C Head M Head LC Head LM Head Y Flushing Box Head Cleaner and Sponge 3 Clear Counters While in this menu option you are capable of initializing the following items Init All NVRAM RTC Cutter CR Motor CR Total PF Motor Head Head Cleaner Total Pages Maint Tank and Sponge 1 XXD Reserved for future use Not used for Stylus Pro 7600 9600 2 XXP Reserved for future use Not used for Stylus Pro 7600 9600 z 3 XXS Reserved for future use
42. rom the dampers If the damper leaks from the outlet check for proper installation If the damper leaks from the fitting remove fitting and inspect the O ring Re fasten with less pressure Print Head Replacement Procedure Printer Component Software Item LCD Display Printer Button Page 29 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 8 Perform the required adjustments 8 1 Plug in the Printer and connect to your PC via Parallel or USB 8 2 Turn on the Printer the Printer must be in Ready mode 8 3 Execute the Adjustment Wizard adj wiz exe the Printer must be in Ready mode 8 3 1 Select Printer Name from the drop down menu 8 3 2 Select Printhead from the Parts Replaced During Service list 8 3 3 Click on the Right Arrow button to select Print Head and click Next 8 3 4 A list of adjustments will appear 8 3 5 Click Next and complete the adjustments using the instructions provided 8 3 5 1 8 3 5 2 8 3 5 3 8 3 5 4 8 3 5 5 8 3 5 6 8 3 5 7 8 3 5 8 8 3 5 9 8 3 5 10 8 3 5 11 8 3 5 12 8 3 5 13 Print Head Replacement Procedure Head Rank Clear Print Head Counter Input Rank Ink Charge Do Not perform proceed to Nozzle Check Nozzle Check 8 3 5 5 1 Cleaning cycles and then nozzle check until all nozzles are working Head Slant Top Bottom Side Margin Platen Position Adjustment Bi D Adjustment Uni d Adjustment Head Gap Leak Check Test Print 8 3 5 12 1 Confirmation patterns for all t
43. roperly replace the Tube Missing Nozzle Diagnosis and Repair Printer Component Software Item LCD Display Printer Button Page 16 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 All Nozzles Missing Note Steps 1 and 2 must be run in sequence 1 Check the Pump s operation 1 1 Runacleaning cycle 1 1 1 When the Printhead moves off of the Cap and the Pump is running inject water into the Cap with a syringe 1 1 1 1 If the water is drawn through the Cap the Pump is good 1 1 1 2 If water is not drawn through the Cap check the Pump Tube connections to the Cap 1 1 1 3 If the two preceding steps reveal no problems replace the Pump 2 Check the Cap s seal with the Printhead 2 1 Check the amount of ink in the Cap it should be clean because of step 1 2 2 Runacleaning cycle 2 3 Check the amount of ink in the Cap there should be clear signs of ink compared to step 2 1 2 3 1 If there is no ink 2 3 1 1 The Cap is not sealing with the Printhead 2 3 1 1 1 Check the Cap Assembly for mechanical problems 2 3 1 1 2 Check the Air Valve on the Cap Assembly for proper operation 3 Check Printhead Fuses on Main Board F6 and F7 3 1 Ifthe Fuses are blown replace the Main Board 3 2 If the Fuses are good replace the Printhead Missing Nozzle Diagnosis and Repair Printer Component Software Item LCD Display Printer Button Page 17 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 Image Quality Diagnosis and Repair
44. s The Printer has a Paper Thickness Sensor like the other Epson Large Format Printers This sensor recognizes two thickness of paper and sets the platen gap accordingly Standard or Wide There are two additional gaps Nar row and Wider These gaps must be set through the Driver or SelecType User Waste Ink Tank Replacement The Waste Ink Cartridge is designed for the User to remove It has a CSIC like chip attached to it and is easily slid out of the right side of the printer The quantity of ink contained by the Waste Ink Cartridge is stored on the CSIC What Is New About the 7600 9600 Printer Component Software Item LCD Display Printer Button Page 7 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 chip Consequently a new cartridge will also reset the Cartridge Counter Easy Removal of the Cap and Pump After the Right Side Cover has been removed only 4 more screws must be removed to remove the Cap and Pump Assembly All 4 screws are removed from the back side of the Printer One Print Head 7 nozzle sets on a one piece Print Head One Print Head mechanical adjustment head rotation Back Light on LCD The back lit LCD is easy to read Auto Open Valves in the Ink Bays Inserting an Ink Cartridge opens a spring loaded Valve located on the inside of each Ink Bay No Front Paper Sensor The Front Paper Sensor has been eliminated The Paper Edge Sensor is used for Leading Edge detection Electronic Paper Sensor Adjustment
45. s The Rear Paper Sensor and the Edge Sensor adjustments are performed from the Self Diagnostic Check Adjust menu The Printer senses the paper and writes the appropriate level to the Main Board On earlier Epson Large Format Printers a potentiometer was used to set the level Edge to Edge Printing The 7600 9600 Printers can print with no top bottom or side margins All margin adjustments are critical for this type of printing The printer also has many foam screened openings in the Platen area to catch over spray Automatic Cap Adjustment What Is New About the 7600 9600 Printer Component Software Item LCD Display Printer Button Page 8 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 There is no Cap Position Adjustment It is performed automatically when the Printer is turned on Parameter Back up Utility The main board parameters can be backed up with a PC and stored as a file Read the Parameter Back up Utility NVRAM exe section of the 7600 9600 Field Repair Guide for details Adjustment Wizard Utility The Adjustment Wizard Utility is designed to assist with component replacement After replacing a component boot the utility and highlight the component replaced The utility will prompt you to perform the necessary adjustments in the proper order Most adjustments can be performed from the PC Read the Adjustment Wizard Adj wiz exe section of the 7600 9600 Field Repair Guide for details Selectype Control Over Paper
46. s Replaced During Service list 9 10 3 Click on the Right Arrow button to select Main Board Backup OK and click Next 9 10 4 A list of adjustments will appear 9 10 5 Click Next and complete each adjustment as directed 9 10 5 1 Edge AD 9 10 5 2 Rear AD Main Board Replacement Printer Component Software Item LCD Display Printer Button Page 33 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 9 10 5 3 Write RTC 10 Adjustments if the Parameter Backup failed 10 1 Execute the Adjustment Wizard adj wiz exe the Printer must be in Ready mode 10 1 1 10 1 2 10 1 3 10 1 4 10 1 5 Main Board Replacement Select Printer Name from the drop down menu Select Main Board Backup NG from the Parts Replaced During Service list Click on the Right Arrow button to select Main Board Backup NG and click Next A list of adjustments will appear Click Next and complete each adjustment as directed 10 1 5 1 Edge AD 10 1 5 2 Rear AD 10 1 5 3 Clear Initial Ink Charge Cancels Initial Charge 10 1 5 4 Write RTC 10 1 5 5 Confirm Rank Write down value from print head 10 1 5 6 Input Rank 10 1 5 7 Ink Charge Do Not perform proceed to Nozzle Check 10 1 5 8 Nozzle Check 10 1 5 9 Clean as necessary 10 1 5 10Head Slant 10 1 5 111000mm Feed Length Adjustment 10 1 5 12Top Bottom Side Margin Adjustment 10 1 5 13Platen Position Adjustment 10 1 5 14Bi d Adjustment 10 1 5 15Uni d Adjustment Head Gap 10 1 5 16Rear Senso
47. s access to the primary Bi Directional adjustment All other methods depend on the accuracy of the primary adjustment The following explains the primary method of adjustment 1 Enter Self Diagnostic Mode 1 1 Turn on the Printer while holding the Paper Feed Paper Feed and the Cut Eject buttons 2 Enter the Check Adjustment menu 3 Load Double Weight Matte paper 4 Execute Bi D adjustment 4 1 Print the black pattern the printer will print the colored patterns also 4 1 1 Adjust the black pattern 4 1 2 Reprint the black pattern 4 1 3 Repeat steps 4 1 1 and 4 1 2 if necessary 4 2 Print the 6 corresponding colored patterns 4 2 1 Identify the correct value for each color and enter the value 4 3 Repeat 4 1 through 4 2 for the next two groups of seven colors There are 21 adjustment patterns The patterns are divided into 3 groups of 7 It is necessary to align the black pattern the first pattern for every group of 7 before aligning the 6 colored patterns that correspond The six corresponding colored patterns are relational to the black pattern Changing the black pattern changes the colored patterns Bi Directional Adjustment Instructions Printer Component Software Item LCD Display Printer Button Page 26 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 5 After completing all 21 patterns 5 1 Execute Copy Param the next menu item following Bi D Copy Param Copy Parameters initializes Bi D2 and Bi D3 Failure to do s
48. ump motor When in the sub menu of each item pressing the Pause button will back up one menu 1 Rear AD Allows for adjustment of the Rear AD Sensor 2 Edge AD Allows for adjustment of the Edge AD 3 Front AD N A No Front AD to adjust on the SP7600 9600 4 Input Rank Allows you to input the Head Rank 5 Edge Sns Lvl Factory use only 6 Check Nozzle Prints a detailed nozzle check horizontal and vertical pattern 7 Check Skew Checks for paper skew 8 Feed Adj T amp B Prints a pattern and allows adjustment for 1000mm feed length top bottom and left margin 9 Top amp Bottom Prints a pattern to allow adjustment for top and bottom margin 10 AT Mecha Adj Factory use only 11 Rear Sen Pos Allows for adjustment of rear sensor adj in mm 12 Platen Pos Centers print head on foam pads for edge to edge printing 13 Platen Pos Chk Verifies adjustment 12 Platen Position Adjustment 14 Cut Adj Allows adjustment of cutter pressure 15 Head Slant Prints a pattern to allow slant adjustment of the entire head 16 Bi D Prints a pattern to allow for adjustment for Bi D Double Weight Matte VSD1 17 Copy Param Copies parameters to backup area of NVRAM 18 Bi D2 Prints a pattern to allow for adjustment for Bi D2 Photo Glossy Paper VSD2 19 Bi D3 Prints a pattern to allow for adjustment for Bi D Double Weight Matte VSD4 20 Bi D Chk
49. ure Sensors Motors Carriage Motor 5 8 ohm Paper Feed Motor 5 80hm Pump Motor Head Slide Platen Gap Motor 9 20hm Solenoids Cutter Blade Solenoid 29 ohm Fans Head Drive Cooling Fan 7600 Paper Suction Fans 2 9600 Paper Suction Fans 3 Sensors Motors Solenoids and Fans Printer Component Software Item LCD Display Printer Button Page 10 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 Initialization Sequence Technician Action What You Should Observe NOTE These steps are performed prior to observable initialization activities Control Panel if button sequence is pressed Maintenance Tank status CSIC Ink Cartridge status CSIC Ink Cartridge Lock Lever status Paper Release Lever status Front Cover Sensor status 1 Turn on power with the Paper Release Lever in the Released position Control Panel displays Set Paper Lever The Operate LED green is ON Paper Out LED red is ON Pause LED green is ON One of the three Paper Options LED s is ON No Vacuum Fans are running 2 Load paper using the Paper Alignment Guides for reference When paper is first inserted the Vacuum Fans turn ON Note If the Fans do not turn on Perform Rear AD sensor adjustment Initialization Sequence Printer Component Software Item LCD Display Printer Button Page 11 Stylus Pro 7600 9600 Field Repair Guide 7 22 02
50. xample copy BW3024 upg Ipt1 b Note Step 4 prepares the computer to send the firmware It is important to send the file quickly after preparing the printer to receive it At this point when the Enter key is pressed the file will be sent Turn on the Printer while holding down the Cleaning Paper Source Cut Eject buttons 6 1 The display will read F W Download Press the Enter key on the PC key to start the firmware update 7 1 Once completed the display will read Update Complete and all Control Panel LED s will be ON Turn off the Printer Updating Firmware From DOS Printer Component Software Item LCD Display Printer Button Page 47 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 Epson User Print Quality Solutions The Stylus Pro 7600 9600 provide the Printer User with three methods for tuning their Printer to their job specifica tions media and ink The print quality solutions discussed in this document are the responsibility of the User and the Epson User Phone Support Group to implement The purpose of this document is to inform the Service Technician of the User solutions only The three methods for tuning the User s Printer fall into two groups e Methods that work with the Epson Printer Driver e Methods that work with Non Epson Printer Drivers and RIPs Epson Printer Driver Support Epson Printer Service Utility This utility allows the User to control e Ink drying time between passes to reduce smeari
51. y The utility indicates that the data has transferred but the printer requires twenty more minutes to process the data To Restore Printer in Error State 1 Open NVRAM exe Select the name of the Printer being serviced Select Open Select the File that was previously created I E 9600 00058 bin a ae V N Turn on the Printer while holding Power On Paper Source Paper Down Cut Eject Maintenance Mode 2 oe 6 Scroll and select Parameter Backup mode and execute 7 Select Write Display will indicate nothing Wait 30 minutes for printer to complete Turn Printer OFF If Parameter Back Up fails and the Printer will not Store Parameter Settings 1 Open NVRAM exe 2 Select the name of the Printer being serviced Parameter Back Up Utility NVRAM exe Printer Component Software Item LCD Display Printer Button Page 42 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 3 Select Open 4 Select the appropriate recover File for the printer E 9600recovery bin 5 Turn on the Printer while holding Power On Paper Source Paper Down Cut Eject Maintenance Mode 2 6 Scroll and select Parameter Backup mode and execute 7 Select Write Display will indicate nothing Wait 30 minutes for printer to complete Turn Printer OFF 8 Load ADJ_WIZ EXE 9 Select Main Board Back up NG 10 Follow the instructions to perform all necessary adjustments Parameter Back Up Utility NVRAM exe Printer C
52. ylus Pro 7600 9600 Field Repair Guide 7 22 02 Cutter Guide Alignment Special Tool Will be provided by Epson when necessary on a case by case basis Cutter Guide Alignment Printer Component LCD Display Printer Button Page 40 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 Parameter Back Up Utility NVRAM exe Purpose Back up and restore all parameters for the Printer Location Epson Resource CD Adjustment Software 76_9600 Backup Utility SP7600 or SP9600 File Name NVRAM exe Note The Printer Driver for the Printer must be loaded on the PC To Back up 1 Turn on the Printer and load paper Printer must be Ready 2 Open NVRAM exe 3 Select the name of the Printer being serviced 4 Select Read Wait approximately 20 minutes for printer to complete 5 Select Save Give the file a unique name I E 9600 00058 bin Model Serial To Restore 1 Turn on the Printer and load paper Printer must be Ready 2 Open NVRAM exe 3 Select the name of the Printer being serviced 4 Select Open Parameter Back Up Utility NVRAM exe Printer Component Software Item LCD Display Printer Button Page 41 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 5 Select the File that was previously created I E 9600 00058 bin 6 Select Write Wait approximately 20 minutes for printer to complete Caution Do not turn off Printer until the control panel lights stop flashing they flash very subtl
53. zontal Banding will appear Refer to the Image Quality Diagnosis Document for more details on Horizontal Banding Paper Feed Belt Tension Adjustment Printer Component Software Item LCD Display Printer Button Page 36 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 Carriage Belt Tension Adjustment The following instructions explain how to perform the belt tension adjustment when the 10000g Tension Gauge is not available Recommended tension is 8000g 1 Remove the Right Side cover 4 Screws 2 Turn the adjustment screw so that the Tension Gauge is set to the middle position of the Scale Adjustment Screw Middle Position NOTE If the CR Timing Belt tension is loose you may encounter carriage errors Also a slight vibration may occur when printing resulting in vertical banding Carriage Belt Tension Adjustment Printer Component Software Item LCD Display Printer Button Page 37 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 Paper Feed Encoder Alignment Special Tool Will be provided by Epson when necessary on a case by case basis Paper Feed Encoder Alignment Printer Component Software Item LCD Display Printer Button Page 38 Stylus Pro 7600 9600 Field Repair Guide 7 22 02 Carriage Encoder Alignment Special Tool Will be provided by Epson when necessary on a case by case basis Carriage Encoder Alignment Printer Component Software Item LCD Display Printer Button Page 39 St
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