Epson Stylus Pro 7900 Assembly instructions

Pro 7900 and 9900 Field Repair Guide 10/6/10

Printer Component, Software Item, LCD Display, Printer Button Page 1.

Table of Contents

Table of Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1

Control Panel Map - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7

Component Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - 16

Board (AID) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17

Board Carriage Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19

Board (Main) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 23

Board (Main) Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26

Board (Power Supply) Removal - - - - - - - - - - - - - - - - - - - - - - - - - 33

Board (Sub B) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 35

Board (Sub C) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 37

Cleaning Unit Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 39

Cleaning Unit Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - 46

Cover (Cutter Assembly) Removal - - - - - - - - - - - - - - - - - - - - - - - 53

Cover (Left Side) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - 56

Cover (Rear) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 64

Cover (Rewind Assembly) Removal - - - - - - - - - - - - - - - - - - - - - - - 66

Cover (Right Side) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - 69

Cover (Top) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 78

Cutter Assembly Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - 82

Damper (Selector) Assembly Removal - - - - - - - - - - - - - - - - - - - - - 91

Ink Bay (Left) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -104

Ink Bay Installation (Left) - - - - - - - - - - - - - - - - - - - - - - - - - - - -115

Ink Bay (Right) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - -126

Ink Bay Installation (Right) - - - - - - - - - - - - - - - - - - - - - - - - - - -136

Pro 7900 and 9900 Field Repair Guide 10/6/10

Printer Component, Software Item, LCD Display, Printer Button Page 2.

Pressure Pump Assembly Removal - - - - - - - - - - - - - - - - - - - - - - -146

Print Head Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -148

Print Head Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -159

Sensor (Carriage Encoder) Removal - - - - - - - - - - - - - - - - - - - - - -170

Sensor (Edge Detector) Removal - - - - - - - - - - - - - - - - - - - - - - - -173

Sensor (Ink Mark) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - -178

Sensor (Platen Gap) Removal - - - - - - - - - - - - - - - - - - - - - - - - - -183

Wiper Blade Assembly Removal - - - - - - - - - - - - - - - - - - - - - - - - -188

Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 191

Printer Error Codes (Maintenance) - - - - - - - - - - - - - - - - - - - - - - -192

Printer Error Codes (Service) - - - - - - - - - - - - - - - - - - - - - - - - - -193

Printer Options Error Codes - - - - - - - - - - - - - - - - - - - - - - - - - -213

1537 Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -218

AID Issue Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - -219

Borderless Printing Errors - - - - - - - - - - - - - - - - - - - - - - - - - - - -221

Color Shift - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -222

Grainy or Ghosting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -223

Horizontal Banding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -224

INK CARTRIDGE ERROR: REPLACE INK CARTRIDGE - - - - - - - - - - - - -226

Missing Nozzle Diagnosis - - - - - - - - - - - - - - - - - - - - - - - - - - - -231

PCU (Plate Curing Unit) Troubleshooting - - - - - - - - - - - - - - - - - - - -235

Random Nozzle Firing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -240

Scratch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -241

Smear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -242

Smudge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -243

SpectroProofer Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - -244

Pro 7900 and 9900 Field Repair Guide 10/6/10

Printer Component, Software Item, LCD Display, Printer Button Page 3.

Stuck In Cut Sheet Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - -250

Vertical Banding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -251

Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 252

AID Check Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -253

Check Network Communication - - - - - - - - - - - - - - - - - - - - - - - - -254

Clear Counter [when replacing AID] - - - - - - - - - - - - - - - - - - - - - - -257

Clear Counter [when replacing Cartridge Holder Ink Pad] - - - - - - - - - - -260

Clear Counter [when replacing CR Motor] - - - - - - - - - - - - - - - - - - - -263

Clear Counter [when replacing Ink holder] - - - - - - - - - - - - - - - - - - -266

Clear Counter [when replacing Ink tube] - - - - - - - - - - - - - - - - - - - -269

Clear Counter [when replacing PF Motor] - - - - - - - - - - - - - - - - - - - -272

Clear Counter [when replacing Pressurizing motor] - - - - - - - - - - - - - -275

Clear Counter [when replacing Printhead] - - - - - - - - - - - - - - - - - - -278

Clear Counter [when replacing Pump motor = ...] - - - - - - - - - - - - - - - -281

Clear Counter [when replacing Wiper] - - - - - - - - - - - - - - - - - - - - - -284

Cleaning PG Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - -287

CR Head Slant Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - -291

CTP Plate Guide Alignment - - - - - - - - - - - - - - - - - - - - - - - - - - -294

Feed Adj(ustment) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -300

Head Rank Input Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - -302

Initial Ink Charge Flag - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -306

Ink Holder Assy Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - -309

Ink Mark Sensor Position Adjustment - - - - - - - - - - - - - - - - - - - - - -312

Input CR Motor Current Adjustment - - - - - - - - - - - - - - - - - - - - - - -316

Input MAC Address Adjustment - - - - - - - - - - - - - - - - - - - - - - - - -319

Input PF Motor Current Adjustment - - - - - - - - - - - - - - - - - - - - - - -325

Pro 7900 and 9900 Field Repair Guide 10/6/10

Printer Component, Software Item, LCD Display, Printer Button Page 4.

Input Serial Number Adjustment - - - - - - - - - - - - - - - - - - - - - - - -328

NV-RAM BACKUP UTILITY - - - - - - - - - - - - - - - - - - - - - - - - - - -331

Paper Thickness Sensor Adjustment - - - - - - - - - - - - - - - - - - - - - -332

PF Slant Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -335

Rear AD Sensor Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - -343

RTC & USB ID Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - -344

Sensor (Carriage Encoder) Adjustment - - - - - - - - - - - - - - - - - - - - -347

Setting Destination Adjustment - - - - - - - - - - - - - - - - - - - - - - - - -349

TBS Pos Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -352

Component Pictures - - - - - - - - - - - - - - - - - - - - - - - - - - - 354

Board (AID) Picture - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -355

Board Carriage (CA11) Picture - - - - - - - - - - - - - - - - - - - - - - - - -356

Board (Sub-B) Picture - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -357

Board (Sub-C) Picture - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -358

Board (Main) Picture - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -359

Board (Power Supply) Picture - - - - - - - - - - - - - - - - - - - - - - - - - -360

Carriage Assembly Pictures - - - - - - - - - - - - - - - - - - - - - - - - - - -361

Carriage Motor Pictures - - - - - - - - - - - - - - - - - - - - - - - - - - - - -365

Cleaning Unit Pictures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -366

Control Panel Pictures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -370

Cutter Assembly Pictures - - - - - - - - - - - - - - - - - - - - - - - - - - - -371

Damper (Selector) Assembly Pictures - - - - - - - - - - - - - - - - - - - - - -372

Pressure Pump Assembly Pictures - - - - - - - - - - - - - - - - - - - - - - -374

Print Head Pictures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -378

Sensor (Carriage Encoder) Pictures - - - - - - - - - - - - - - - - - - - - - - -381

Sensor (Edge Detector) Picture - - - - - - - - - - - - - - - - - - - - - - - - -382

Pro 7900 and 9900 Field Repair Guide 10/6/10

Printer Component, Software Item, LCD Display, Printer Button Page 5.

Sensor (Ink Mark) Picture - - - - - - - - - - - - - - - - - - - - - - - - - - - -383

Sensor (Platen Gap) Picture - - - - - - - - - - - - - - - - - - - - - - - - - - -384

Wiper Blade Assembly Picture - - - - - - - - - - - - - - - - - - - - - - - - -385

Reference - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 386

Accessories List - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -387

Carriage Release (Auto) - - - - - - - - - - - - - - - - - - - - - - - - - - - - -388

Carriage Release (Manual) - - - - - - - - - - - - - - - - - - - - - - - - - - - -389

Cleaning Cycles (Types and Uses) - - - - - - - - - - - - - - - - - - - - - - -393

Color Order - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -395

Connectors / Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -397

Consumable/Service Parts List - - - - - - - - - - - - - - - - - - - - - - - - -402

Cover Sensor (Front) Bypass Procedure - - - - - - - - - - - - - - - - - - - -404

Cover Sensor (Ink) Bypass Procedure - - - - - - - - - - - - - - - - - - - - -405

CTP(7900) (Computer to Plate) Explanation - - - - - - - - - - - - - - - - - - -406

Firmware History (Ethernet) - - - - - - - - - - - - - - - - - - - - - - - - - - -410

Firmware History (Printer) (7900) - - - - - - - - - - - - - - - - - - - - - - - -411

Firmware History (Printer) (9900) - - - - - - - - - - - - - - - - - - - - - - - -415

Firmware Update Procedure Using FWUpdate.exe - - - - - - - - - - - - - - -419

Ink Draining Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - -420

Media Feed Step (about) - - - - - - - - - - - - - - - - - - - - - - - - - - - - -422

Glossary - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -423

Prime, On or Off - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -429

Revision History - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -430

Sensors, Motors, Solenoids, and Fans - - - - - - - - - - - - - - - - - - - - -436

Service Procedure (recommended) - - - - - - - - - - - - - - - - - - - - - - -439

Service Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -441

Pro 7900 and 9900 Field Repair Guide 10/6/10

Printer Component, Software Item, LCD Display, Printer Button Page 6.

Stress Test (Test Image) - - - - - - - - - - - - - - - - - - - - - - - - - - - - -442

Utilities - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 443

Epson Net Config 2.2b - - - - - - - - - - - - - - - - - - - - - - - - - - - - -444

FWUpdate.exe - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -449

NV-RAM BACKUP UTILITY - - - - - - - - - - - - - - - - - - - - - - - - - - -453

Remote Panel 2 (Epson LFP) - - - - - - - - - - - - - - - - - - - - - - - - - -464

Servprog.exe - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -466

Pro 7900 and 9900 Field Repair Guide 10/6/10

Printer Component, Software Item, LCD Display, Printer Button Page 7.

Control Panel Map

Power Light Paper Check Light

Ink Check Light

Paper Source and Left Arrow

Paper Feed (Reverse) and Up Arrow

Pause and Reset Paper Feed (Forward) and Down Arrow

Pause Light Black Ink Change

Power Button

OK (Enter)

Ink Cover Open

Paper Release

Menu and Right Arrow

Paper Cut

Pro 7900 and 9900 Field Repair Guide 10/6/10

Printer Component, Software Item, LCD Display, Printer Button Page 8.

Printers LCD Display

1. Printer Status

2. Platen Gap Setting

3. Paper Type and Roll Paper Auto Cut Setting

4. Enabled Options

5. Ink Levels

6. Black Ink Setting

7. Waste Ink Cartridge Level(s)

8. Roll Paper Counter

9. Roll Paper Margin Setting

10. Custom Paper Setting

Maintenance Mode 1: Pause, at power on.

F/W DOWNLOAD MODE: Up, Down, Left, and Right, at power on.

NVRAM (Parameter) Backup Mode: Up, Down, Left, and Right, at power on.

SELF TESTING: Down, Right, and OK, at power on (Hold the buttons until the Ink Cartridge Icons appear).

NVRAM (Parameter) Restore Mode: Disengage 11 Ink Cartridges, remove the 1 (or 2) Maintenance Tank(s),

hold the Up, Down, Left, and Right buttons and turn on the Printer. Wait an additional 20 sec-

onds after the data is transferred to ensure completion.

Pro 7900 and 9900 Field Repair Guide 10/6/10

Printer Component, Software Item, LCD Display, Printer Button Page 9.

1. PRINTER SETUP.

PLATEN GAP: NARROW, *STANDARD, WIDE,

WIDER, WIDEST

PAGE LINE: *ON, OFF

ROLL PAPER MARGIN: *DEFAULT, TOP/BOTTOM

15mm, TOP 35/BOTTOM 15mm,

3mm,15mm

PAPER SIZE CHK: *ON, OFF

PAPER SKEW CHECK: *ON, OFF

REFRESH MARGIN: *ON, OFF

AUTO NOZZLE CHECK: ON:PERIODICALLY*,

ON:EVERY JOB, OFF

PRINT NOZZLE PATTERN: OFF*, ON:EVERY PAGE,

ON EVERY 10 PAGES,

INITIALIZE SETTINGS: EXECUTE

2. TEST PRINT.

NOZZLE CHECK: PRINT

STATUS SHEET: PRINT

NETWORK STATUS SHEET: PRINT

JOB INFORMATION: PRINT

CUSTOM PAPER: PRINT

User Menu: Press the Menu button when

the printer displays Ready

3. MAINTENANCE

CUTTER ADJUSTMENT: EXEC

CUTTER REPLACEMENT: EXEC

CLEANING: NORMAL CLEANING: EXECUTE

CLEAN FOR EACH COLOR: C/VM, PK,

(MK)/LK, O/G, LLK/Y,VLM/

POWER CLEANING: EXECUTE

CLOCK SETTING: (mm/dd/yy hh:mm)

4. PRINTER STATUS.

VERSION: (CURRENT FIRMWARE)

INK LEVEL: (FOR EACH COLOR) (nnn%)

MAINTENANCE TANK: LEFT (nnn%), CENTER

REAR (nnn%), RIGHT (nnn%)

JOB HISTORY: N0.(n) INK:(n)ml, PAPER:(nnnn)cm2

TOTAL PRINTS: (n) PAGES

EDM STATUS: ENABLED, LAST UPLOADED (mm/

dd/yy hh:mm)

Pro 7900 and 9900 Field Repair Guide 10/6/10

Printer Component, Software Item, LCD Display, Printer Button Page 10.

6. Head Alignment.

PAPER THICKNESS: SELECT PAPER TYPE:

(Photo Paper, Proofing Paper, Fine Art Paper,

Matte Paper, Plain Paper, Others SELECT

THICKNESS: (N)mil

ALIGNMENT: AUTO (UNI-D, BI-D 2-COLOR,

BI-D All, BI-D #1, BI-D #2,

BI-D #3, BI-D #3, BI-D #4)

MANUAL (UNI-D, BI-D 2-

COLOR, BI-D ALL)

7. NETWORK SETUP: (*DISABLE, ENABLE)

IP ADDRESS SETTING: AUTO, PANEL,

BONJOUR: *ON, OFF

INIT NETWORK SETTING: EXECUTE

Note: Manual IP169.254.1.2 Subnet

255.255.0.0 works with most

computers.

5. PAPER SETUP.

ROLL PAPER REMAINING (This Menu is only active

when paper is not loaded and

the Pinch Rollers are closed)

REMAINING PPR SETUP: *OFF, ON:PRINT EVERY

PAGE, ON: AT ROLL EXCHANGE

ROLL PAPER LENGTH: (nnn)ft (REMAINING PPR

SETUP must be on to enable)

ROLL LENGTH ALERT: (nn)ft (REMAINING PPR

SETUP must be on to enable)

PAPER TYPE: Photo Paper, Proofing Paper, Fine Art

Paper, Matte Paper, Plain Paper, Others,

Custom Paper, No Paper Selected

CUSTOM PAPER: Paper NO. (1-10)

PAPER TYPE: Photo Paper, Proofing Paper, Fine Art

Paper, Matte Paper, Plain Paper, Others

PLATEN GAP: NARROW, STANDARD, WIDE,

WIDER, WIDEST

THICKNESS PATTERN: PRINT

PAPER FEED ADJUST: (n.nn)%

DRYING TIME: (n.n)sec

PAPER SUCTION: *STANDARD, -1, -2, -3, -4

SET ROLL PAPER TENSION: *STANDARD, HIGH,

HIGHER

8. OPTIONS SETUP:

SPECTROPROOFER:

STATUS INFORMATION: DEVICE

VERSION, CALIBRATION TILE

SERIAL#,DEVICETEMPERATURE,

FIRMWARE VERSION, AIR TEM-

PERATURE, BACKING COLOR

Device Alignment: EXECUTE

TAKE UP REEL: Version

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