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/
LC
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