EPSON Pro 9600, Pro 7600 User Manual

Stylus Pro 7600/9600 Field Repair Guide	7/22/02

Table of Contents

Table of Contents - - - - - - - - - - -							-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	1
Control Panel Map	- -	- - - -	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	2
What Is New About the 7600/9600 -					-	-	- - - - - -						-	-	-	-	-	- - - - - -						-	-	7
Sensors, Motors, Solenoids, and Fans - - - - - - - - - - - - - - - - - - - - 10
Initialization Sequence		- - - -	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- 11
Missing Nozzle Diagnosis and Repair						-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- 15
Image Quality Diagnosis and Repair -						-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- 18
Bi-Directional Adjustment Instructions						-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- 26
Print Head Replacement Procedure					-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- 28
Main Board Replacement - - -			-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- 32
Paper Feed Belt Tension Adjustment						-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- 36
Carriage Belt Tension Adjustment				-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- 37
Paper Feed Encoder Alignment			-	-	-	-	- - - - - -						-	-	-	-	-	-	-	-	-	-	-	-	- 38
Carriage Encoder Alignment - - - - - - - - - - - -													-	-	-	-	-	-	-	-	-	-	-	-	- 39
Cutter Guide Alignment		- - - -	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- 40
Parameter Back-Up Utility (NVRAM.exe)								-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- 41
Adjustment Wizard (Adj_wiz.exe)				-	-	-	- - - - - -						-	-	-	-	-	-	-	-	-	-	-	-	- 44
Updating Firmware From Windows (WinPRN Utility)													-	-	-	-	-	-	-	-	-	-	-	-	- 45
Updating Firmware From DOS			-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- 47
Epson User Print Quality Solutions					-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- 48
Firmware History	- - -	- - - -	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- 50
Ink Cartridge Errors - - - - - - - - -						-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- 52
Error Codes - - - - - - - - - - - - - -							-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- 53
Glossary - - - -	- - -	- - - -	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	-	- 55

Table of Contents

Printer Component, Software Item, LCD Display, Printer Button

Page 1.

Stylus Pro 7600/9600 Field Repair Guide

NOTE: Although this is a guideline to navigate through the Service and User Menus, the Service Manual, Technical Bulletins or Users Guide may still be needed to reference detailed information on a setting or adjustment listed.

7/22/02

Control Panel Map

Settings Available:

1. Printer Setup.

2. Test Print.

SelecType Mode:

3. Printer Status.

While printer LCD shows Ready,

4. Paper Config.

pressing the [SelecType] button

5. Maintenance.

enters this mode.

6. Print Head Alignment.

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.

4.

Parallel I/F.

Maintenance Mode 1:

Press [Pause] button while

5.

IEEE1284.4 Mode.

powering on printer.

6.

Crtg Info. Menu.

7.

SSCL.

8.

SN Menu.

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.

3. Service Config.

Maintenance Mode 2:

Press [Paper Source] + [Cut/Eject] +

4. Parameter Backup Mode.

[Paper Feed -] buttons while

5. Maintenance Info.

powering on printer.

6. Init. Info.

Use the [Paper Feed-] or [Paper

Feed+] to move up or down the menu.

For navigation and details on menu items, go to page 3.

For navigation and details on menu items, go to page 4.

For navigation and details on menu items, go to page 4.

Self Diagnostic Mode:

Press [Paper Feed+] + [Paper Feed - ] + [Cut/Eject] buttons while powering on printer.

** While in this mode, pressing the [Cleaning] button will Auto Cut roll fed media

Settings Available:

1.Check: Test.

2.Check: Adjustment.

3.Check: Cleaning.

4.Check: Print.

5.Check: Parameter.

6.Check: Life.

Use the [Paper Feed-] or [Paper Feed+] to move up or down the menu.

For navigation and details on menu items, go to page 5.

Firmware Download:
Press [Paper Source] + [Cut/Eject] +					Once in this mode, the LCD will display Date Send. At this point send the
					UPG Data file (BN or BWxxxx.UPG) to the printer via the copy command
[Cleaning] buttons while powering on
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

7/22/02

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.

4.Paper Config. Menu.

5.Maintenance Menu.

6.Head Alignment Menu.

SelecType Menu Options

1.[Platen Gap] - *Std, Wide, Wider, 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.

1.[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 to view all the Status Check items 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.

1.[Paper Number] - *Standard (range is 1-10)

2.[Cut Pressure] - *100% (range is 0% - 150%)

3.[Cut Method] - *3 Step, 4 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.

1.[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.

Control Panel Map

Page 3.

Stylus Pro 7600/9600 Field Repair Guide

7/22/02

Maintenance Mode 1 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 will move you back one menu item.

1.[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.[*Meter, Feet/Inch] - This allows measurements to be displayed/printed in format selected.

4.[*ECP, Compat]

5.[*Off, On]

6.[Crtg 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.

[Paper Feed] + or [Paper Feed -] to change value. Use [Cut/Eject] to Confirm, Save or Execute the item/value.

Maintenance Mode 2 Options

1.View Counters

2.Clear Counters

3.Service Config.

4.Parameter Back Mode

5.Maint. Info.

While in this menu option, you are capable of viewing all the counter information for the following components:

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.

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

3.[XXS] - Reserved for future use. Not used for Stylus Pro 7600/9600

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)

[Exec] - Pressing the [Cut/Eject] button will execute the command.

Options in this menu are for Factory Use ONLY.

6. Init. 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.

1.

[Version] - (Checks firmware version, dip sw. settings and control panel & main board versions.

3. Pressing the [Paper Source] button

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)

1. Check: Test

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 pump 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&B] - Prints a pattern and allows adjustment for 1000mm feed length, top, bottom and left margin.

9.

[Top & 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).

2. Check: Adjustment

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] - 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

Go to Page 6

5: Check: Parameter

6. Check: Life

Control Panel Map

Page 5.

Stylus Pro 7600/9600 Field Repair Guide

7/22/02

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.

3.Check: Cleaning

4.Check: Print

5.Check: Parameter

1.[KK0] - Normal Cleaning Cycle is performed, volume of ink cleared = Low.

2.[KK1] - 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.

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).

4.[Check Ptn 3] - N/A (No information on this adjustment).

1.[Initialize] - Initializes specific or all parameter items. Refer to the service manual for list.

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

							THIS MENU IS FOR FACTORY USE ONLY. This menu tests the operation of printer components and should not be performed during field ser-
6. Check: Life							vice.

Control Panel Map

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:

•The type of ink (dye or pigment).

•The color of the ink.

•The quantity of the ink.

•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 combinations to choose from (all combinations include cyan, light cyan, magenta, light magenta, and yellow).

•7 color pigment (black and light black)

•7 color pigment (matte black and light black)

•6 color pigment (two matte blacks)

•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 gaps

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 (Narrow 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 Adjustments

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 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:

•Paper Feed Step

•Ink Saturation

•Suction Fan

•Platen Gap

•Ink Dry Time

•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
1.
	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 Temperature Sensors
2.
	Motors	Carriage Motor (5.8 ohm)
		Paper Feed Motor (5.8ohm)
		Pump Motor (Head Slide / Platen Gap Motor) (9.2ohm)
	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	Control Panel (if button sequence is pressed).
	performed prior to	Maintenance Tank status (CSIC).
	observable initialization	Ink Cartridge status (CSIC).
	activities.	Ink Cartridge Lock Lever status.
		Paper Release Lever status.
		Front Cover Sensor status
	1. Turn on power with the	Control Panel displays Set Paper Lever.
	Paper Release Lever in	The Operate LED (green) is ON.
	the “Released” position.	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	When paper is first inserted, the Vacuum Fans turn ON.
	Paper Alignment Guides for	Note: If the Fans do not turn on, Perform “Rear AD” sensor
	reference.	adjustment.

Initialization Sequence

Printer Component, Software Item, LCD Display, Printer Button

Page 11.

Stylus Pro 7600/9600 Field Repair Guide	7/22/02

3. Move the Paper Release Lever to the “Secured” position.

Control Panel LCD displays Wait. Paper Out LED (red) is OFF.

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 Carriage 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 Panel 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

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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”.

1.1Clean Cap.

1.2Check Wiper Blade for correct installation and flaws.

1.3Clean Wiper Blade.

1.4Clean Wiper Blade Cleaner.

2.Puddle the Cap and park the Print Head for 30 minutes.

2.1Fill the Cap with as much water as possible.

2.2Park the Printhead on the Cap.

3.Perform 2 cleaning cycles.

3.1Re-test nozzles.

3.2Repeat.

4.Replace the Print Head and Dampers.

Missing Nozzle Diagnosis and Repair

Printer Component, Software Item, LCD Display, Printer Button

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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.

1.1Remove corresponding Damper and attempt to draw ink with a syringe. The ink should draw easily.

1.1.1If 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.

1.1.2If Ink can not be drawn easily through the Tube, check the Ink Valve on the Cartridge Bay for correct operation.

1.1.3If 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

1.1Remove corresponding Damper and attempt to draw ink with a syringe.

1.1.1If the Damper is empty, check for air leaks in the Tubes, Joints (O-rings and Fittings), or

Dampers.

1.1.2If ink can not be drawn, remove Damper and attempt to draw ink through the Tube. If ink can be drawn, replace the Damper.

1.1.3If Ink can not be drawn through the Tube, check the Ink Valve on the Cartridge Bay for correct operation

1.1.4If the Ink Valve is working properly, replace the Tube.

Missing Nozzle Diagnosis and Repair

Printer Component, Software Item, LCD Display, Printer Button

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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.

1.1Run a cleaning cycle.

1.1.1When the Printhead moves off of the Cap, and the Pump is running, inject water into the Cap with a syringe.

1.1.1.1If the water is drawn through the Cap, the Pump is good.

1.1.1.2If water is not drawn through the Cap, check the Pump Tube connections to the Cap.

1.1.1.3If the two preceding steps reveal no problems, replace the Pump.

2.Check the Cap’s seal with the Printhead

2.1Check the amount of ink in the Cap (it should be clean because of step 1).

2.2Run a cleaning cycle

2.3Check the amount of ink in the Cap (there should be clear signs of ink compared to step 2.1).

2.3.1If there is no ink:

2.3.1.1The Cap is not sealing with the Printhead.

2.3.1.1.1Check the Cap Assembly for mechanical problems.

2.3.1.1.2Check the Air Valve on the Cap Assembly for proper operation.

3.Check Printhead Fuses on Main Board (F6 and F7).

3.1If the Fuses are blown, replace the Main Board.

3.2If the Fuses are good, replace the Printhead.

Missing Nozzle Diagnosis and Repair

Printer Component, Software Item, LCD Display, Printer Button

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Stylus Pro 7600/9600 Field Repair Guide	7/22/02

Image Quality Diagnosis and Repair

Horizontal Banding:

1.Perform a Nozzle Check from the Adjustment menu within Self-Diagnostic Mode.

1.1Inspect printed pattern for missing, deflected or sympathetic nozzle(s).

1.1.1Perform 2 Cleaning Cycles then reprint Nozzle Check.

1.1.1.1Missing or deflected nozzle(s)

1.1.1.1.1Clean the Cap, Wiper, and Wiper Cleaner and repeat cleaning cycles.

1.1.1.1.2Inspect the Cap Assembly and replace if it is damaged.

1.1.1.1.3Replace the Print Head.

1.1.1.2Sympathetic nozzle(s)

1.1.1.2.1Replace the Print Head.

2.Verify that paper is not binding:

2.1While loading.

2.2While ejecting.

2.3On the spindle.

3.Verify the Head Slant alignment is correct (Head Angular)

3.1Print and inspect the pattern.

3.2Perform adjustment if required.

4.Verify Platen Gap, with the Printer Settings section, of the SelecType Menu.

4.1Four settings are available: Standard, Narrow, Wide, Wider.

4.2Set 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.