Page 1 Pro 7900 and 9900 Field Repair Guide 10/6/10 Table of Contents Table of Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 Control Panel Map - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 Component Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - 16 Board (AID) Removal...
Page 2: Table Of Contents
Pro 7900 and 9900 Field Repair Guide 10/6/10 Pressure Pump Assembly Removal - - - - - - - - - - - - - - - - - - - - - - - 146 Print Head Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 148 Print Head Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 159 Sensor (Carriage Encoder) Removal - - - - - - - - - - - - - - - - - - - - - - 170...
Page 3: Table Of Contents
Pro 7900 and 9900 Field Repair Guide 10/6/10 Stuck In Cut Sheet Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - 250 Vertical Banding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 251 Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 252...
Page 4: Table Of Contents
Pro 7900 and 9900 Field Repair Guide 10/6/10 Input Serial Number Adjustment - - - - - - - - - - - - - - - - - - - - - - - - 328 NV-RAM BACKUP UTILITY - - - - - - - - - - - - - - - - - - - - - - - - - - - 331 Paper Thickness Sensor Adjustment - - - - - - - - - - - - - - - - - - - - - - 332 PF Slant Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 335...
Page 5: Table Of Contents
Pro 7900 and 9900 Field Repair Guide 10/6/10 Sensor (Ink Mark) Picture - - - - - - - - - - - - - - - - - - - - - - - - - - - - 383 Sensor (Platen Gap) Picture - - - - - - - - - - - - - - - - - - - - - - - - - - - 384 Wiper Blade Assembly Picture - - - - - - - - - - - - - - - - - - - - - - - - - 385...
Page 6: Table Of Contents
- - - - - - - - - - - - - - - - - - - - - - - - - - - 453 Remote Panel 2 (Epson LFP) - - - - - - - - - - - - - - - - - - - - - - - - - - 464 Servprog.exe - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 466...
Page 7: Control Panel Map
Pro 7900 and 9900 Field Repair Guide 10/6/10 Control Panel Map Paper Source and Left Arrow Power Light Paper Check Light Paper Feed (Reverse) and Up Arrow Ink Check Light Pause Light Black Ink Change Paper Release Ink Cover Open Menu and Right Arrow OK (Enter) Pause and Reset...
Page 8 Pro 7900 and 9900 Field Repair Guide 10/6/10 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.
Page 9 Pro 7900 and 9900 Field Repair Guide 10/6/10 User Menu: Press the Menu button when the printer displays Ready 1. PRINTER SETUP. 3. MAINTENANCE PLATEN GAP: NARROW, *STANDARD, WIDE, CUTTER ADJUSTMENT: EXEC WIDER, WIDEST CUTTER REPLACEMENT: EXEC PAGE LINE: *ON, OFF CLEANING: NORMAL CLEANING: EXECUTE ROLL PAPER MARGIN: *DEFAULT, TOP/BOTTOM CLEAN FOR EACH COLOR: C/VM, PK,...
Page 10 Pro 7900 and 9900 Field Repair Guide 10/6/10 5. PAPER SETUP. 6. Head Alignment. ROLL PAPER REMAINING (This Menu is only active PAPER THICKNESS: SELECT PAPER TYPE: when paper is not loaded and (Photo Paper, Proofing Paper, Fine Art Paper, the Pinch Rollers are closed) Matte Paper, Plain Paper, Others SELECT...
Page 11: Maintenance Mode 1
Pro 7900 and 9900 Field Repair Guide 10/6/10 NVRAM Data (Parameter) Backup Mode Hold the Up, Down, Left, Right buttons and turn on the power. The Printer will display Download. NVRAM Data (Parameter) Restore Mode Disengage 11 Ink Cartridges, remove the 1 (or 2) Maintenance Tank(s), hold the Up, Down, Left, and Right but- tons and turn on the Printer.
Page 12 Pro 7900 and 9900 Field Repair Guide 10/6/10 SELF TESTING: Press and hold the Down, Right, and buttons and turn on the Printer. 1. Down, Right, and OK, and turn on the Printer. Continue to hold the buttons the Down, Right, and buttons.
Page 13 Pro 7900 and 9900 Field Repair Guide 10/6/10 SELF TESTING: Test: Version: F/W: (nnnnnnn,n.nn,n.nnnn) (Displays the current firmware version) Fan: Paper(Duty): (200% - 0%) (Tests the fan suction for all paper suction fans) Paper1: (Fan test for paper suction fan #1 (Right Side Fan)) Paper2: (Fan test for paper suction fan #2 (Left Side Fan Paper3:...
Page 14 Pro 7900 and 9900 Field Repair Guide 10/6/10 Fan: Fan Adjust *0% (-10% to +10%) (Adjusts Suction Fans) Temporary PG: [Enter]Un Cap (Releases the Carriage Mechanism) PF Head Slant: [Enter]Print (Prints the PF Slant adjustment pattern) CR Head Slant: [Enter]Print (Prints the CR Slant adjustment pattern) PG Adj: [Enter]Un Cap (Releases the Carriage Mechanism)
Page 15 Pro 7900 and 9900 Field Repair Guide 10/6/10 Maintenance Tube Exchange: Sequence, Counter Clear Wiper Exchange: Sequence, Counter Clear Pump Exchange: [Enter] Start Press Pump Exchange: [Enter] Start Selector Exchange: Sequence, Counter Clear I/H Exchange: Sequence, Counter Clear Head Exchange: [Enter] Start Cleaning: Std.
Page 16: Component Replacement
Pro 7900 and 9900 Field Repair Guide 10/6/10 Component Replacement Printer Component, Software Item, LCD Display, Printer Button Page 16.
Page 17: Board (Aid) Removal
Pro 7900 and 9900 Field Repair Guide 10/6/10 Board (AID) Removal 1. Remove the Right Side Cover. 2. Remove 2 Screws that fasten the AID Board Assembly to the top of the Cleaning Unit. 1. Remove 2 Screws. 2. Remove the Black Plastic Cover. Printer Component, Software Item, LCD Display,...
Page 18 Pro 7900 and 9900 Field Repair Guide 10/6/10 3. Unplug 2 Cables that connect the AID Board to the Printer. Unplug 2 Cables. Printer Component, Software Item, LCD Display, Printer Button Board (AID) Removal Page 18.
Page 19: Board Carriage Removal
Pro 7900 and 9900 Field Repair Guide 10/6/10 Board Carriage Removal 1. Release the Carriage Mechanism, following the directions found in the Carriage Release Auto) Chapter, located in the Reference Section. Unplug the Printer. 3. Remove the Cover (Top). 4. Remove the Cover (Left Side). 5.
Page 20 Pro 7900 and 9900 Field Repair Guide 10/6/10 6. Remove the Carriage Board Cover. Working from left to right, release 4 Interlocks and remove the Carriage Board Cover. Printer Component, Software Item, LCD Display, Printer Button Board Carriage Removal Page 20.
Page 21 Pro 7900 and 9900 Field Repair Guide 10/6/10 7. Unplug 4 Wired Cables and 7 Foil Cables. Unplug all Cables. Printer Component, Software Item, LCD Display, Printer Button Board Carriage Removal Page 21.
Page 22 Pro 7900 and 9900 Field Repair Guide 10/6/10 8. Remove 4 Screws, and the Carriage Board. 1. Remove 4 Screws. 2. Remove the Carriage Board. Printer Component, Software Item, LCD Display, Printer Button Board Carriage Removal Page 22.
Page 23: Board (Main) Removal
Pro 7900 and 9900 Field Repair Guide 10/6/10 Board (Main) Removal Note: 7900 Main Board Part # 2124160 Note: 9900 Main Board Part # 2124159 Main Board Removal (Overview) • Back up the Printer’s Parameters. • Remove the Rear Cover. •...
Page 24 Pro 7900 and 9900 Field Repair Guide 10/6/10 4. Unplug the 10 Foil Cables that attach the Main Board to the Printer. Unplug 10 Foil Cables and 11 Wire Cables. Printer Component, Software Item, LCD Display, Printer Button Board (Main) Removal Page 24.
Page 25 Pro 7900 and 9900 Field Repair Guide 10/6/10 5. Remove the Main Board from the Printer. 2. Release 4 Interlocks. 3. Lift out the Main Board. 1. Remove 4 Screws. Printer Component, Software Item, LCD Display, Printer Button Board (Main) Removal Page 25.
Page 26: Board (Main) Installation
Pro 7900 and 9900 Field Repair Guide 10/6/10 Board (Main) Installation Note: 7900 Main Board Part # 2124160 Note: 9900 Main Board Part # 2124159 Main Board Installation (Overview) • Install the Main Board. • Install the Screws. • Plug in the Cables. •...
Page 27 Pro 7900 and 9900 Field Repair Guide 10/6/10 2. Install the Main Board into the Printer. 2. Engage the 4 Interlocks. 1. Drop in the Main Board. 3. Install 4 Screws. Printer Component, Software Item, LCD Display, Printer Button Board (Main) Installation Page 27.
Page 28 Pro 7900 and 9900 Field Repair Guide 10/6/10 3. Plug in 11 Wired Cables that attach the Main Board to the Printer. Note: CN5 is not used. Plug in 11 Wired Cables. Printer Component, Software Item, LCD Display, Printer Button Board (Main) Installation Page 28.
Page 29 Pro 7900 and 9900 Field Repair Guide 10/6/10 4. Plug in 10 Foil Cables that attach the Main Board to the Printer. Ensure that the Cables are fully seated (straight). Plug in 10 Foil Cables. Note: The Foil Cables have their Connector Number printed on them. Printer Component, Software Item, LCD Display,...
Page 30 Pro 7900 and 9900 Field Repair Guide 10/6/10 5. Install the Rear Cover. 6. Plug in and turn on the Printer in Firmware Download Mode (depress the Up, Down, Left, and Menu buttons, and turn on the power to the Printer). 7.
Page 31 Pro 7900 and 9900 Field Repair Guide 10/6/10 If the Printer’s Parameters are not available skip step 9, and proceed with step 10. Note: The new board will have a new USB ID. The original driver connection will not work. Allow the driver to connect to a new USB ID.
Page 32 Cleaning PG Adjustment. 11.9 Perform the Gap Adjust: Auto Bi-D Adjustment. 11.10Perform the Gap Adjust: Auto Uni-D Adjustment. 11.11Perform the Colorimetric Calibration (When specifically requested by Epson). Printer Component, Software Item, LCD Display, Printer Button Board (Main) Installation Page 32.
Page 33: Board (Power Supply) Removal
Pro 7900 and 9900 Field Repair Guide 10/6/10 Board (Power Supply) Removal 1. Turn off the Printer and UNPLUG from AC. 2. Remove the Cover (Rear). 3. Unplug the Cables that attach the Power Supply to the Printer. 2. Unplug CN001. 1.
Page 34 Pro 7900 and 9900 Field Repair Guide 10/6/10 4. Remove 9 Screws, and lift out the Power Supply. 1. Remove 9 Screws 2. Lift out the Power Supply. Printer Component, Software Item, LCD Display, Printer Button Board (Power Supply) Removal Page 34.
Page 35: Board (Sub B) Removal
Pro 7900 and 9900 Field Repair Guide 10/6/10 Board (Sub B) Removal 1. Turn off the Printer and UNPLUG from AC. 2. Remove the Cover (Right Side). 3. Unplug the 21 Cables that attach the Sub Board B to the Printer. Unplug 3 Foil Cables and 18 Wire Cables.
Page 36 Pro 7900 and 9900 Field Repair Guide 10/6/10 4. Remove the Sub Board B from the Printer. 2. Remove the Board. 1. Remove 4 Screws. Printer Component, Software Item, LCD Display, Printer Button Board (Sub B) Removal Page 36.
Page 37: Board (Sub C) Removal
Pro 7900 and 9900 Field Repair Guide 10/6/10 Board (Sub C) Removal 1. Turn off the Printer and UNPLUG from AC. 2. Remove the Cover (Left Side). 3. Unplug the 9 Cables (10 Cables on a 9900) that attach the Sub Board C to the Printer. CN308 is not used.
Page 38 Pro 7900 and 9900 Field Repair Guide 10/6/10 4. Remove the Sub Board B from the Printer. 2. Remove the Board. 1. Remove 3 Screws. Printer Component, Software Item, LCD Display, Printer Button Board (Sub C) Removal Page 38.
Page 39: Cleaning Unit Removal
Pro 7900 and 9900 Field Repair Guide 10/6/10 Cleaning Unit Removal 1. Remove the Right Side Cover. 2. Remove the AID Board. 3. Move the Carriage Assembly to the center of the Printer. 3.1 Follow the directions in the Carriage Release (Manual) Chapter found in the Reference Section. Note: The Print Head is very fragile and can be damaged moving it away from the Cleaning Unit.
Page 40 Pro 7900 and 9900 Field Repair Guide 10/6/10 4. Unplug 3 Motors and 6 Sensors from Sub Board B. Unplug: CN213 CN222 CN224 CN223 CN214 CN221 CN216 CN218 CN217 Printer Component, Software Item, LCD Display, Printer Button Cleaning Unit Removal Page 40.
Page 41 Pro 7900 and 9900 Field Repair Guide 10/6/10 5. Free the Waste Ink Tube from the Fastener, Free the Tube from this Fastener. Printer Component, Software Item, LCD Display, Printer Button Cleaning Unit Removal Page 41.
Page 42 Pro 7900 and 9900 Field Repair Guide 10/6/10 6. Remove the Waste Tubes from the Maintenance Tank, and wrap them in a paper towel. Note: This White Nylon Clamp must be transferred to the new Cleaning Unit if the old one is being replaced.
Page 43 Pro 7900 and 9900 Field Repair Guide 10/6/10 7. Remove 1 Screw that fastens the Cleaning Unit to the Printer. Remove 1 Screw. Printer Component, Software Item, LCD Display, Printer Button Cleaning Unit Removal Page 43.
Page 44 Pro 7900 and 9900 Field Repair Guide 10/6/10 8. Remove the Cleaning Unit Support Bracket. 1. Remove 3 Screws. 2. Remove the Cleaning Unit Support Bracket. Printer Component, Software Item, LCD Display, Printer Button Cleaning Unit Removal Page 44.
Page 45 Pro 7900 and 9900 Field Repair Guide 10/6/10 9. Remove the Cleaning Unit. Lift up, and out to remove the Cleaning Unit. Printer Component, Software Item, LCD Display, Printer Button Cleaning Unit Removal Page 45.
Page 46: Cleaning Unit Installation
Pro 7900 and 9900 Field Repair Guide 10/6/10 Cleaning Unit Installation Note: A new Cleaning Unit does not include a Wiper Blade Assembly. Install a Wiper Blade before installing the Cleaning Unit. 1. Put the Cleaning Unit in position. Put the Cleaning Unit in position. Printer Component, Software Item, LCD Display,...
Page 47 Pro 7900 and 9900 Field Repair Guide 10/6/10 2. Install the Cleaning Unit Support Bracket. 2. Install 3 Screws. 1. Install the Cleaning Unit Support Bracket. Printer Component, Software Item, LCD Display, Printer Button Cleaning Unit Installation Page 47.
Page 48 Pro 7900 and 9900 Field Repair Guide 10/6/10 3. Install 1 Screw that fastens the Cleaning Unit to the Printer. Install 1 Screw. Printer Component, Software Item, LCD Display, Printer Button Cleaning Unit Installation Page 48.
Page 49 Pro 7900 and 9900 Field Repair Guide 10/6/10 4. Attach the Waste Tubes to the Maintenance Tank. 1. Put on the Tubes. Note: This White Nylon Clamp must be transferred from the old Cleaning Unit. 2. Fasten the Tubes with the Waste Tube Fastener. Printer Component, Software Item, LCD Display,...
Page 50 Pro 7900 and 9900 Field Repair Guide 10/6/10 5. Fasten the Waste Ink Tube to the Printer Fasten the Waste Ink Tubes. Printer Component, Software Item, LCD Display, Printer Button Cleaning Unit Installation Page 50.
Page 51 Pro 7900 and 9900 Field Repair Guide 10/6/10 6. Plug 3 Motors and 6 Sensors into Sub Board B. Plug in: CN213 CN222 CN224 CN223 CN214 CN221 CN216 CN218 CN217 Printer Component, Software Item, LCD Display, Printer Button Cleaning Unit Installation Page 51.
Page 52 Pro 7900 and 9900 Field Repair Guide 10/6/10 7. Install the AID Board. 8. Connect the Control Panel. 9. Perform Clear Counter [when replacing Wiper]. 10. Perform Clear Counter [when replacing Pump Motor = Cleaning Assy] 11. Perform the Cleaning PG Adjustment.
Page 53: Cover (Cutter Assembly) Removal
Pro 7900 and 9900 Field Repair Guide 10/6/10 Cover (Cutter Assembly) Removal 1. Open the Cover (Front). 2. Remove the Ink Tube Junction Cover. 2. Lift off the Cover. 1. Remove 1 Screw. Printer Component, Software Item, LCD Display, Printer Button Cover (Cutter Assembly) Removal Page 53.
Page 54 Pro 7900 and 9900 Field Repair Guide 10/6/10 3. Remove 3 Screws. Remove 3 Screws. Printer Component, Software Item, LCD Display, Printer Button Cover (Cutter Assembly) Removal Page 54.
Page 55 Pro 7900 and 9900 Field Repair Guide 10/6/10 4. Remove the Cutter Assembly Cover. 1. Remove 4 Screws. 2. Remove 2 Screw and the Black Plastic Cover. 3. Remove the Cutter Assembly Cover. Printer Component, Software Item, LCD Display, Printer Button Cover (Cutter Assembly) Removal Page 55.
Page 56: Cover (Left Side) Removal
Pro 7900 and 9900 Field Repair Guide 10/6/10 Cover (Left Side) Removal 1. Open the Left Ink Bay Door. 2. Push gently to the right to open the Left Ink Door. 1. Place a flat blade screwdriver as shown. Printer Component, Software Item, LCD Display, Printer Button...
Page 57 Pro 7900 and 9900 Field Repair Guide 10/6/10 2. Remove the Left Ink Bay Cover. 1. Remove the 2 Screws that fas- 2. Remove the Left Ink Bay Cover by ten the Left Ink Bay Cover. pulling straight out. Printer Component, Software Item, LCD Display, Printer Button...
Page 58 Pro 7900 and 9900 Field Repair Guide 10/6/10 3. Remove 2 Screws that fasten the inside of the Left Side Cover to the Printer. Remove 2 Screws. Printer Component, Software Item, LCD Display, Printer Button Cover (Left Side) Removal Page 58.
Page 59 Pro 7900 and 9900 Field Repair Guide 10/6/10 4. Remove 2 Screws that fastens the Black Plastic Trim to the top of the Left Side Cover. 1. Remove 1 Screw. 2. Remove 1 Screw. Printer Component, Software Item, LCD Display, Printer Button Cover (Left Side) Removal Page 59.
Page 60 Pro 7900 and 9900 Field Repair Guide 10/6/10 5. Remove the Black Plastic Trim. 1. Lift here. 2. Pull towards the center of the Printer. Printer Component, Software Item, LCD Display, Printer Button Cover (Left Side) Removal Page 60.
Page 61 Pro 7900 and 9900 Field Repair Guide 10/6/10 6. Remove 2 Screws that fastens the top of the Left Side Cover to the Printer. Remove 2 Screws. Printer Component, Software Item, LCD Display, Printer Button Cover (Left Side) Removal Page 61.
Page 62 Pro 7900 and 9900 Field Repair Guide 10/6/10 7. Loosen 6 Screws that fasten the Left Side Cover to the back of the Printer. 2. Remove 2 Screws. 1. Remove 4 Screws. Printer Component, Software Item, LCD Display, Printer Button Cover (Left Side) Removal Page 62.
Page 63 Pro 7900 and 9900 Field Repair Guide 10/6/10 8. Slide off the Left Side Cover. On a 9900, slide out the Left Maintenance Cartridge. 2. Slide off the Left Side Cover. Printer Component, Software Item, LCD Display, Printer Button Cover (Left Side) Removal Page 63.
Page 64: Cover (Rear) Removal
Pro 7900 and 9900 Field Repair Guide 10/6/10 Cover (Rear) Removal 1. Remove the 11 Screws that fasten the Rear Cover to the Printer. Note: The 9900 requires the removal of more Screws. 1. Remove 8 Screws. 2. Remove 3 Screws. Printer Component, Software Item, LCD Display,...
Page 65: Remove The Rear Cover
Pro 7900 and 9900 Field Repair Guide 10/6/10 2. Remove the Rear Cover. Remove the Rear Cover. Printer Component, Software Item, LCD Display, Printer Button Cover (Rear) Removal Page 65.
Page 66: Cover (Rewind Assembly) Removal
Pro 7900 and 9900 Field Repair Guide 10/6/10 Cover (Rewind Assembly) Removal 1. Remove the Cover (Right Side). 2. Remove the media and the Media Holders. Remove the media and the Media Holders. Printer Component, Software Item, LCD Display, Printer Button Cover (Rewind Assembly) Removal Page 66.
Page 67 Pro 7900 and 9900 Field Repair Guide 10/6/10 3. Rotate the Media Cover to expose 1 Screw, and remove 2 Screws. 1. Rotate the Media Cover to expose 1 Screw. 2. Remove 2 Screws. Printer Component, Software Item, LCD Display, Printer Button Cover (Rewind Assembly) Removal Page 67.
Page 68 Pro 7900 and 9900 Field Repair Guide 10/6/10 4. Loosen or remove 1 Screw, and the Rewind Assembly Cover. Back of the Rewind Assembly Cover. Note: This picture shows the Rewind Assembly Cover with the Right Side Cover mounted. At this point in the procedure, the Right Side Cover should be removed.
Page 69: Cover (Right Side) Removal
Pro 7900 and 9900 Field Repair Guide 10/6/10 Cover (Right Side) Removal 1. Open the Right Ink Bay Door. 2. Push gently to the right to open the Right Ink Door. 1. Place a flat blade screwdriver as shown. Printer Component, Software Item, LCD Display, Printer Button...
Page 70 Pro 7900 and 9900 Field Repair Guide 10/6/10 2. Remove the Right Ink Bay Cover. 1. Remove the 2 Screws that fas- 2. Remove the Right Ink Bay Cover by ten the Right Ink Bay Cover. pulling straight out. Printer Component, Software Item, LCD Display, Printer Button...
Page 71 Pro 7900 and 9900 Field Repair Guide 10/6/10 3. Remove 2 Screws that fasten the inside of the Right Side Cover to the Printer. Remove 2 Screws. Printer Component, Software Item, LCD Display, Printer Button Cover (Right Side) Removal Page 71.
Page 72 Pro 7900 and 9900 Field Repair Guide 10/6/10 4. Remove 3 Screws that fastens the Black Plastic Trim to the top of the Right Side Cover. 1. Remove 1 Screw. 2. Remove 2 Screws. Printer Component, Software Item, LCD Display, Printer Button Cover (Right Side) Removal Page 72.
Page 73 Pro 7900 and 9900 Field Repair Guide 10/6/10 5. Remove the Black Plastic Trim. 1. Lift here. 2. Pull towards the center of the Printer. Printer Component, Software Item, LCD Display, Printer Button Cover (Right Side) Removal Page 73.
Page 74 Pro 7900 and 9900 Field Repair Guide 10/6/10 6. Remove 2 Screws that fastens the top of the Right Side Cover to the Printer. Remove 2 Screws. Printer Component, Software Item, LCD Display, Printer Button Cover (Right Side) Removal Page 74.
Page 75 Pro 7900 and 9900 Field Repair Guide 10/6/10 7. Loosen 4 Screws that fasten the Right Side Cover to the back of the Printer. Remove 4 Screws. Printer Component, Software Item, LCD Display, Printer Button Cover (Right Side) Removal Page 75.
Page 76: Remove The Control Panel
Pro 7900 and 9900 Field Repair Guide 10/6/10 8. Remove the Control Panel. 2. Release the Right Interlock. 1. Release the Left Interlock. 3. Lift the Control Panel and unplug the Cable. Printer Component, Software Item, LCD Display, Printer Button Cover (Right Side) Removal Page 76.
Page 77 Pro 7900 and 9900 Field Repair Guide 10/6/10 9. Slide off the Right Side Cover. 1. Slide out the Right Maintenance Cartridge. Note: Ensure that removing the Right Side Cover does not damage the Control Panel Cable. 2. Slide off the Right Side Cover. Printer Component, Software Item, LCD Display,...
Page 78: Cover (Top) Removal
Pro 7900 and 9900 Field Repair Guide 10/6/10 Cover (Top) Removal 1. Remove the Cover (Left Side). 2. Remove the Cover (Right Side). 3. Remove 1 Screw that fastens the Top Cover to the top, right side of the Printer. Remove 1 Screw.
Page 79 Pro 7900 and 9900 Field Repair Guide 10/6/10 4. Remove 6 Screws that fastens the front of the Top Cover to the Printer. 1. Lift the Front Cover. 2. Remove 6 Screws. Note: The 9900 has 7 Screws for this step. Printer Component, Software Item, LCD Display,...
Page 80 Pro 7900 and 9900 Field Repair Guide 10/6/10 5. Close the Cover (Front). Close the Front Cover. Printer Component, Software Item, LCD Display, Printer Button Cover (Top) Removal Page 80.
Page 81 Pro 7900 and 9900 Field Repair Guide 10/6/10 6. Remove the Cover (Top). Lift up on the front of the Top Cover to remove it. 2. Remove the Paper Roll Ramp. Printer Component, Software Item, LCD Display, Printer Button Cover (Top) Removal Page 81.
Page 82: Cutter Assembly Removal
Pro 7900 and 9900 Field Repair Guide 10/6/10 Cutter Assembly Removal 1. Remove the Cover (Left Side). 2. Remove the Cover (Right Side). 3. Remove the Cover (Cutter Assembly). 4. Unplug CN307 from Sub Board C. Unplug 1 Connector (CN307) from Sub Board C. Printer Component, Software Item, LCD Display,...
Page 83 Pro 7900 and 9900 Field Repair Guide 10/6/10 5. Free Cables from the Fasteners. 1. Free the 2 Strand White Wire (CN307) from this Fastener. 2. Free All Wires from this Fastener. Printer Component, Software Item, LCD Display, Printer Button Cutter Assembly Removal Page 83.
Page 84 Pro 7900 and 9900 Field Repair Guide 10/6/10 6. Remove 2 Paper Guides. Carriage at the “capped” position. Release 2 Interlocks and remove 2 Paper Guides. Note: This is the Interlock that holds each Paper Guide in place. Printer Component, Software Item, LCD Display, Printer Button...
Page 85 Pro 7900 and 9900 Field Repair Guide 10/6/10 7. Move the Carriage Assembly fully to the left. Move the Carriage Assembly fully to the left. Printer Component, Software Item, LCD Display, Printer Button Cutter Assembly Removal Page 85.
Page 86 Pro 7900 and 9900 Field Repair Guide 10/6/10 8. Remove the Cutter Motor Cover. 2. Push the Cover up to remove. 1. Lever up the bottom of the Cover to release 1 Interlock. Printer Component, Software Item, LCD Display, Printer Button Cutter Assembly Removal Page 86.
Page 87 Pro 7900 and 9900 Field Repair Guide 10/6/10 9. Remove 2 Screws that fasten the left side of the Cutter Assembly to the Printer. View from below Remove 2 Screws. Printer Component, Software Item, LCD Display, Printer Button Cutter Assembly Removal Page 87.
Page 88 Pro 7900 and 9900 Field Repair Guide 10/6/10 10. Remove 2 Screws that fasten the right side of the Cutter Assembly to the Printer. View from below Remove 2 Screws. Printer Component, Software Item, LCD Display, Printer Button Cutter Assembly Removal Page 88.
Page 89 Pro 7900 and 9900 Field Repair Guide 10/6/10 11. Shift the Cutter Assembly to the right and unplug the Cutter Motor Cable. 1. Shift the Cutter Assembly to the right. 2. Unplug the Cutter Motor Cable. Printer Component, Software Item, LCD Display, Printer Button Cutter Assembly Removal...
Page 90 Pro 7900 and 9900 Field Repair Guide 10/6/10 12. Drop the left side of the Cutter Assembly to remove it. 1. Move the Cutter Blade away from the Side Frame. 2. Drop the left side of the Cutter Assembly to remove it. Printer Component, Software Item, LCD Display,...
Page 91: Damper (Selector) Assembly Removal
Pro 7900 and 9900 Field Repair Guide 10/6/10 Damper (Selector) Assembly Removal 1. (Optional) Drain the ink from the Printer following the directions found in the Ink Draining Procedure chapter located in the reference section. Note: The Ink Draining procedure uses air pressure to force the Ink out of the Ink Lines through the Print Head.
Page 92 Pro 7900 and 9900 Field Repair Guide 10/6/10 8. Move the Carriage Mechanism to the left side of the Printer. Move the Carriage Mechanism to the left side of the Printer. Printer Component, Software Item, LCD Display, Printer Button Damper (Selector) Assembly Removal Page 92.
Page 93 Pro 7900 and 9900 Field Repair Guide 10/6/10 9. Remove the Carriage Board Cover. Working from left to right, release 4 Interlocks and remove the Carriage Board Cover. Printer Component, Software Item, LCD Display, Printer Button Damper (Selector) Assembly Removal Page 93.
Page 94 Pro 7900 and 9900 Field Repair Guide 10/6/10 10. Unplug 2 Wired Cables and 3 Foil Cables. 1. Unplug 2 Wired Cables. 2. Unplug 3 Foil Cables. Printer Component, Software Item, LCD Display, Printer Button Damper (Selector) Assembly Removal Page 94.
Page 95 Pro 7900 and 9900 Field Repair Guide 10/6/10 11. Remove 3 Screws, and 2 Interlocks that fasten the Ink Tube Holder to the Carriage Assembly. 1. Remove 3 Screws. 2. Release 2 Interlocks. Printer Component, Software Item, LCD Display, Printer Button Damper (Selector) Assembly Removal Page 95.
Page 96 Pro 7900 and 9900 Field Repair Guide 10/6/10 12. Remove 2 Tube Braces. Remove 2 Tube Braces Printer Component, Software Item, LCD Display, Printer Button Damper (Selector) Assembly Removal Page 96.
Page 97 Pro 7900 and 9900 Field Repair Guide 10/6/10 13. Mark the Tube polarity and remove 4 Screws. 1. Mark the Tubes, at these locations, to facilitate re-assembly. Reassembly Note: The empty Tube is here. Reassembly Note: The Cyan Tube is here.
Page 98 Pro 7900 and 9900 Field Repair Guide 10/6/10 14. Remove and protect the Tubes. Remove and protect the Tubes. Printer Component, Software Item, LCD Display, Printer Button Damper (Selector) Assembly Removal Page 98.
Page 99 Pro 7900 and 9900 Field Repair Guide 10/6/10 15. Remove and clean 2 O-Ring Chains. Remove and clean 2 O-Ring Chains. Printer Component, Software Item, LCD Display, Printer Button Damper (Selector) Assembly Removal Page 99.
Page 100 Pro 7900 and 9900 Field Repair Guide 10/6/10 16. Remove 8 Screws that fasten the Damper Assembly to the Printer. 1. Remove 5 Screws. 2. Remove 1 Screw. Note: See the next page for additional help in locating the correct Screws to remove in 3.
Page 101 Pro 7900 and 9900 Field Repair Guide 10/6/10 17. Additional reference for the preceding step. Bottom view of the Damper Assembly Location of the 6 Screws Back of the Damper Assembly. Printer Component, Software Item, LCD Display, Printer Button Damper (Selector) Assembly Removal Page 101.
Page 102 Pro 7900 and 9900 Field Repair Guide 10/6/10 18. Free the Damper Assembly Wires. Free these Wires. Printer Component, Software Item, LCD Display, Printer Button Damper (Selector) Assembly Removal Page 102.
Page 103 Pro 7900 and 9900 Field Repair Guide 10/6/10 19. Remove the Damper Assembly. Hold the Damper Assembly here, and “wiggle” the Assembly off. Printer Component, Software Item, LCD Display, Printer Button Damper (Selector) Assembly Removal Page 103.
Page 104: Ink Bay (Left) Removal
Pro 7900 and 9900 Field Repair Guide 10/6/10 Ink Bay (Left) Removal 1. Drain the ink from the Printer following the directions found in the Ink Draining Procedure chapter located in the reference section. Note: The Ink Draining procedure uses air pressure to force the Ink out of the Ink Lines through the Print Head.
Page 105 Pro 7900 and 9900 Field Repair Guide 10/6/10 4. Remove the Sub Board Cover. 1. (View from the front) Release 2 Interlocks. 2. Lift off the Sub Board Cover. Released Interlock. Printer Component, Software Item, LCD Display, Printer Button Ink Bay (Left) Removal Page 105.
Page 106 Pro 7900 and 9900 Field Repair Guide 10/6/10 5. Remove the Ink Tube Guide. 1. Free the Ink Tubes from the Ink Tube Guide. 2. Squeeze in to release 2 Interlocks. 3. Rotate the Ink Tube Guide up to remove. Printer Component, Software Item, LCD Display,...
Page 107 Pro 7900 and 9900 Field Repair Guide 10/6/10 6. Disconnect the Ink Tubes. 1. Remove 2 Screws and disconnect the Tubes. 2. Wrap the Tubes. Note: The Ink Draining procedure uses air pressure to force the Ink out of the Ink Lines through the Print Head. Because of the nature of the hardware the ink in the Lines is replaced by pressurized air.
Page 108 Pro 7900 and 9900 Field Repair Guide 10/6/10 Re-assembly tip. If replacing the Ink Bay, ensure that the O-Ring Chain is transferred to the New Ink Bay. Printer Component, Software Item, LCD Display, Printer Button Ink Bay (Left) Removal Page 108.
Page 109 Pro 7900 and 9900 Field Repair Guide 10/6/10 8. Disconnect the Sub Board Cable. Unplug the Sub Board Cable. Printer Component, Software Item, LCD Display, Printer Button Ink Bay (Left) Removal Page 109.
Page 110 Pro 7900 and 9900 Field Repair Guide 10/6/10 9. Remove 3 Screws. Remove 3 Screws Printer Component, Software Item, LCD Display, Printer Button Ink Bay (Left) Removal Page 110.
Page 111 Pro 7900 and 9900 Field Repair Guide 10/6/10 10. Remove Six Screws and the Left Ink Bay Bracket. 1. Remove 4 Screws. 2. Remove 2 Screws. 3. Remove Bracket. Printer Component, Software Item, LCD Display, Printer Button Ink Bay (Left) Removal Page 111.
Page 112 Pro 7900 and 9900 Field Repair Guide 10/6/10 11. Remove 1 Screw. (View of the bottom) Remove 1 Screw. Printer Component, Software Item, LCD Display, Printer Button Ink Bay (Left) Removal Page 112.
Page 113 Pro 7900 and 9900 Field Repair Guide 10/6/10 12. Free the Carriage Motor Cable from the Tape connecting it to the Left Ink Bay. Free the Tape. Printer Component, Software Item, LCD Display, Printer Button Ink Bay (Left) Removal Page 113.
Page 114 Pro 7900 and 9900 Field Repair Guide 10/6/10 13. Remove the Left Ink Bay. Lift up and out to remove the Left Ink Bay. Printer Component, Software Item, LCD Display, Printer Button Ink Bay (Left) Removal Page 114.
Page 115: Ink Bay Installation (Left)
7900 and 9900 Field Repair Guide 10/6/10 Ink Bay Installation (Left) 1. Place the Left Ink Bay in position. Place the Left Ink Bay in position. Printer Component, Software Item, LCD Display, Printer Button Ink Bay Installation (Left) Page 115.
Page 116 7900 and 9900 Field Repair Guide 10/6/10 2. Install 3 Screws. Install 3 Screws Printer Component, Software Item, LCD Display, Printer Button Ink Bay Installation (Left) Page 116.
Page 117 7900 and 9900 Field Repair Guide 10/6/10 3. Install Six Screws and the Left Ink Bay Bracket. 2. Install 4 Screws. 3. Install 2 Screws. 2. Place the Bracket. Printer Component, Software Item, LCD Display, Printer Button Ink Bay Installation (Left) Page 117.
Page 118 7900 and 9900 Field Repair Guide 10/6/10 4. Install 1 Screw. (View of the bottom) Install 1 Screw. Printer Component, Software Item, LCD Display, Printer Button Ink Bay Installation (Left) Page 118.
Page 119 7900 and 9900 Field Repair Guide 10/6/10 5. Re-tape the Carriage Motor Cable, connecting it to the Left Ink Bay. Re-tape the Cables. Printer Component, Software Item, LCD Display, Printer Button Ink Bay Installation (Left) Page 119.
Page 120 7900 and 9900 Field Repair Guide 10/6/10 6. Connect the Sub Board Cable. Plug in the Sub Board Cable. Printer Component, Software Item, LCD Display, Printer Button Ink Bay Installation (Left) Page 120.
Page 121 7900 and 9900 Field Repair Guide 10/6/10 7. Ensure that the Ink Bay O-Ring Chain is installed. If replacing the Ink Bay, ensure that the O-Ring Chain is transferred to the New Ink Bay. Printer Component, Software Item, LCD Display, Printer Button Ink Bay Installation (Left) Page 121.
Page 122 7900 and 9900 Field Repair Guide 10/6/10 8. Connect the Ink Tubes. Connect the Tubes, and install 2 Screws. Printer Component, Software Item, LCD Display, Printer Button Ink Bay Installation (Left) Page 122.
Page 123 7900 and 9900 Field Repair Guide 10/6/10 9. Install the Ink Tube Guide. 1. Squeeze in to release 2 Interlocks, and rotate the Ink Tube Guide into position. 2. Place the Ink Tubes under the Guides. Printer Component, Software Item, LCD Display, Printer Button Ink Bay Installation (Left)
Page 124 7900 and 9900 Field Repair Guide 10/6/10 10. Install the Sub Board Cover. 1. Place the Sub Board Cover. 2. Engage the Interlocks. Printer Component, Software Item, LCD Display, Printer Button Ink Bay Installation (Left) Page 124.
Page 125 7900 and 9900 Field Repair Guide 10/6/10 11. Connect the Air Pressure Line. Connect the Air Pressure Line, and place it in the Guides. 12. Perform the Ink Holder Assy Adjustment 13. Install Ink Cartridges and turn on the Printer. Note: If the Printer does not start to charge (prime) turn on the Ink Charge Flag.
Page 126: Ink Bay (Right) Removal
Pro 7900 and 9900 Field Repair Guide 10/6/10 Ink Bay (Right) Removal 1. Drain the ink from the Printer following the directions found in the Ink Draining Procedure chapter located in the reference section. Note: The Ink Draining procedure uses air pressure to force the Ink out of the Ink Lines through the Print Head.
Page 127 Pro 7900 and 9900 Field Repair Guide 10/6/10 5. Remove the Sub Board Cover. 1. (View from the front) Release 2 Interlocks. 2. Lift off the Sub Board Cover. Released Interlock. Printer Component, Software Item, LCD Display, Printer Button Ink Bay (Right) Removal Page 127.
Page 128 Pro 7900 and 9900 Field Repair Guide 10/6/10 6. Remove the Ink Tube Guide. 1. Free the Ink Tubes from the Ink Tube Guide. 2. Squeeze in to release 2 Interlocks. 3. Rotate the Ink Tube Guide up to remove. Printer Component, Software Item, LCD Display,...
Page 129 Pro 7900 and 9900 Field Repair Guide 10/6/10 7. Disconnect the Ink Tubes. 1. Remove 2 Screws and disconnect the Tubes. 2. Wrap the Tubes. Note: The Ink Draining procedure uses air pressure to force the Ink out of the Ink Lines through the Print Head. Because of the nature of the hardware the ink in the Lines is replaced by pressurized air.
Page 130 Pro 7900 and 9900 Field Repair Guide 10/6/10 Re-assembly tip. If replacing the Ink Bay, ensure that the O-Ring Chain is transferred to the New Ink Bay. Printer Component, Software Item, LCD Display, Printer Button Ink Bay (Right) Removal Page 130.
Page 131 Pro 7900 and 9900 Field Repair Guide 10/6/10 9. Remove 3 Screws. Remove 3 Screws Printer Component, Software Item, LCD Display, Printer Button Ink Bay (Right) Removal Page 131.
Page 132 Pro 7900 and 9900 Field Repair Guide 10/6/10 10. Remove Six Screws and the Right Ink Bay Bracket. 1. Remove 4 Screws. 2. Remove 2 Screws. 3. Remove Bracket. Printer Component, Software Item, LCD Display, Printer Button Ink Bay (Right) Removal Page 132.
Page 133 Pro 7900 and 9900 Field Repair Guide 10/6/10 11. Remove 1 Screw. (View of the bottom) Remove 1 Screw. Printer Component, Software Item, LCD Display, Printer Button Ink Bay (Right) Removal Page 133.
Page 134 Pro 7900 and 9900 Field Repair Guide 10/6/10 12. Free the Print Head Cables and disconnect the Sub Board Cable. 2. Unplug the Sub Board Cable. 1. Free the Print Head Cables. Printer Component, Software Item, LCD Display, Printer Button Ink Bay (Right) Removal Page 134.
Page 135 Pro 7900 and 9900 Field Repair Guide 10/6/10 13. Remove the Right Ink Bay. Lift up and out to remove the Right Ink Bay. Printer Component, Software Item, LCD Display, Printer Button Ink Bay (Right) Removal Page 135.
Page 136: Ink Bay Installation (Right)
Pro 7900 and 9900 Field Repair Guide 10/6/10 Ink Bay Installation (Right) 1. Install the Right Ink Bay. Place the Right Ink Bay in position. Printer Component, Software Item, LCD Display, Printer Button Ink Bay Installation (Right) Page 136.
Page 137 Pro 7900 and 9900 Field Repair Guide 10/6/10 2. Install 3 Screws. Install 3 Screws Printer Component, Software Item, LCD Display, Printer Button Ink Bay Installation (Right) Page 137.
Page 138 Pro 7900 and 9900 Field Repair Guide 10/6/10 3. Install Six Screws and the Right Ink Bay Bracket. 3. Install 4 Screws. 2. Install 2 Screws. 1. Install the Bracket. Printer Component, Software Item, LCD Display, Printer Button Ink Bay Installation (Right) Page 138.
Page 139 Pro 7900 and 9900 Field Repair Guide 10/6/10 4. Install 1 Screw. (View of the bottom) Install 1 Screw. Printer Component, Software Item, LCD Display, Printer Button Ink Bay Installation (Right) Page 139.
Page 140 Pro 7900 and 9900 Field Repair Guide 10/6/10 5. Fasten the Print Head Cables and connect the Sub Board Cable. 2. Plug in the Sub Board Cable. 1. Fasten the Print Head Cables. Printer Component, Software Item, LCD Display, Printer Button Ink Bay Installation (Right) Page 140.
Page 141 Pro 7900 and 9900 Field Repair Guide 10/6/10 6. Ensure that the Ink Bay O-Ring Chain is installed. If replacing the Ink Bay, ensure that the O-Ring Chain is transferred to the New Ink Bay. Printer Component, Software Item, LCD Display, Printer Button Ink Bay Installation (Right) Page 141.
Page 142 Pro 7900 and 9900 Field Repair Guide 10/6/10 7. Connect the Ink Tubes. Connect the Tubes, and install 2 Screws. Printer Component, Software Item, LCD Display, Printer Button Ink Bay Installation (Right) Page 142.
Page 143 Pro 7900 and 9900 Field Repair Guide 10/6/10 8. Remove the Sub Board Cover. 1. Place the Sub Board Cover. 2. Engage the Interlocks. Printer Component, Software Item, LCD Display, Printer Button Ink Bay Installation (Right) Page 143.
Page 144 Pro 7900 and 9900 Field Repair Guide 10/6/10 9. Install the Ink Tube Guide. 3. Place the Ink Tubes In the Ink Tube Guide. 1. Squeeze in to release 2 Interlocks. 2. Rotate the Ink Tube Guide Into place. Printer Component, Software Item, LCD Display, Printer Button...
Page 145 Pro 7900 and 9900 Field Repair Guide 10/6/10 10. Connect the Air Pressure Line. View from the back. Connect the Air Pressure Line, and place it in the Guide. 11. Install the Cleaning Unit (if it was removed). 12. Perform the Ink Holder Assy Adjustment 13.
Page 146: Pressure Pump Assembly Removal
Pro 7900 and 9900 Field Repair Guide 10/6/10 Pressure Pump Assembly Removal 1. Turn off the Printer and UNPLUG from AC. 2. Remove the Cover (Rear). 3. Disconnect 2 Air Pressure Tubes and remove 3 Screws from the Pressure Pump Assembly. 1.
Page 147 Pro 7900 and 9900 Field Repair Guide 10/6/10 4. Remove the Pressure Pump Assembly. 2. Unplug 2 Cables. 1. Lift out and turn over the Pressure Pump Assembly. Printer Component, Software Item, LCD Display, Printer Button Pressure Pump Assembly Removal Page 147.
Page 148: Print Head Removal
Pro 7900 and 9900 Field Repair Guide 10/6/10 Print Head Removal Note: The Print Head Nozzle Plate on the Pro 79_9900 is as fragile as tin foil. Any contact with the Nozzle plate will damage the Print Head. Note: A long shafted (6”) number 1 phillips screw driver is necessary for this procedure. Print Head Removal Overview •...
Page 149 Pro 7900 and 9900 Field Repair Guide 10/6/10 7. Remove the Cover (Right Side). 8. Remove 1 Screw that fastens 2 Ground Straps to the left side of the Carriage Mechanism. Remove 1 Screw. Printer Component, Software Item, LCD Display, Printer Button Print Head Removal Page 149.
Page 150 Pro 7900 and 9900 Field Repair Guide 10/6/10 9. Move the Carriage Mechanism to the left side of the Printer. Move the Carriage Mechanism to the left side of the Printer. Printer Component, Software Item, LCD Display, Printer Button Print Head Removal Page 150.
Page 151 Pro 7900 and 9900 Field Repair Guide 10/6/10 10. Remove the Carriage Board Cover. Working from left to right, release 4 Interlocks and remove the Carriage Board Cover. Printer Component, Software Item, LCD Display, Printer Button Print Head Removal Page 151.
Page 152 Pro 7900 and 9900 Field Repair Guide 10/6/10 11. Unplug 2 Wired Cables and 3 Foil Cables. 1. Unplug 2 Wired Cables. 2. Unplug 3 Foil Cables. Printer Component, Software Item, LCD Display, Printer Button Print Head Removal Page 152.
Page 153 Pro 7900 and 9900 Field Repair Guide 10/6/10 12. Remove 3 Screws, and 2 Interlocks that fasten the Ink Tube Holder to the Carriage Assembly. 1. Remove 3 Screws. 2. Release 2 Interlocks. Printer Component, Software Item, LCD Display, Printer Button Print Head Removal Page 153.
Page 154 Pro 7900 and 9900 Field Repair Guide 10/6/10 13. Remove 8 Screws that fasten the Damper Assembly to the Printer. 1. Remove 5 Screws. 2. Remove 1 Screw. Note: Remove the Top Screw in this area. Do not remove the bottom one.
Page 155 Pro 7900 and 9900 Field Repair Guide 10/6/10 14. Additional reference for the preceding step. Bottom view of the Damper Assembly Location of the 6 Screws Back of the Damper Assembly. Printer Component, Software Item, LCD Display, Printer Button Print Head Removal Page 155.
Page 156 Pro 7900 and 9900 Field Repair Guide 10/6/10 15. Hang the Damper Assembly. Hang the Damper Assembly on the Front Cover Frame. Use the Hooks located on the back of the Damper Assembly. Hooks located on the back of the Damper Assembly. Printer Component, Software Item, LCD Display,...
Page 157 Pro 7900 and 9900 Field Repair Guide 10/6/10 16. Remove 3 Screws. Remove 3 Screws. Printer Component, Software Item, LCD Display, Printer Button Print Head Removal Page 157.
Page 158 Pro 7900 and 9900 Field Repair Guide 10/6/10 17. Remove the Print Head, and unplug 4 Print Head Cables. 1. Remove the Print Head. 2. Unplug 4 Print Head Cables. Printer Component, Software Item, LCD Display, Printer Button Print Head Removal Page 158.
Page 159: Print Head Installation
Pro 7900 and 9900 Field Repair Guide 10/6/10 Print Head Installation 1. Plug in 4 Print Head Cables and put the Print Head in place. 1. Plug in 4 Print Head Cables. 2. Install the Print Head. Printer Component, Software Item, LCD Display, Printer Button Print Head Installation...
Page 160 Pro 7900 and 9900 Field Repair Guide 10/6/10 2. Fasten with 3 Screws. Install 3 Screws. Printer Component, Software Item, LCD Display, Printer Button Print Head Installation Page 160.
Page 161 Pro 7900 and 9900 Field Repair Guide 10/6/10 3. Put the 2 Ferrite Cores in place. Put the 2 Ferrite Cores in place. Printer Component, Software Item, LCD Display, Printer Button Print Head Installation Page 161.
Page 162 Pro 7900 and 9900 Field Repair Guide 10/6/10 4. Install the Damper Assembly and fasten with 8 Screws. 1. Install 5 Screws. 2. Install 1 Screw. Note: See the next page for additional help in locating the correct Screws to install in this 3.
Page 163 Pro 7900 and 9900 Field Repair Guide 10/6/10 5. Additional reference for the preceding step. Bottom view of the Damper Assembly Location of the 6 Screws Back of the Damper Assembly. Printer Component, Software Item, LCD Display, Printer Button Print Head Installation Page 163.
Page 164 Pro 7900 and 9900 Field Repair Guide 10/6/10 6. Route 5 Wires. Route 5 Wires. Printer Component, Software Item, LCD Display, Printer Button Print Head Installation Page 164.
Page 165 Pro 7900 and 9900 Field Repair Guide 10/6/10 7. Install 3 Screws and fasten the Ink Tube Holder to the Carriage Assembly. Install 3 Screws. Printer Component, Software Item, LCD Display, Printer Button Print Head Installation Page 165.
Page 166 Pro 7900 and 9900 Field Repair Guide 10/6/10 8. Plug in 2 Wired Cables and 3 Foil Cables. 1.Plug in 2 Wired Cables. 2. Plug in 3 Foil Cables. Printer Component, Software Item, LCD Display, Printer Button Print Head Installation Page 166.
Page 167 Pro 7900 and 9900 Field Repair Guide 10/6/10 9. Install the Carriage Board Cover. Install the Carriage Board Cover. Printer Component, Software Item, LCD Display, Printer Button Print Head Installation Page 167.
Page 168 Pro 7900 and 9900 Field Repair Guide 10/6/10 10. Install 1 Screw that fastens 2 Ground Straps to the left side of the Carriage Mechanism. Install 1 Screw. Printer Component, Software Item, LCD Display, Printer Button Print Head Installation Page 168.
Page 169 CR Head Slant Adjustment. 18.4 Perform the Gap: Auto Bi-D Adjustment 18.5 Perform the Gap: Auto Uni-D Adjustment 18.6 Perform the Colorimetric Calibration (When specifically requested by Epson) Printer Component, Software Item, LCD Display, Printer Button Print Head Installation Page 169.
Page 170: Sensor (Carriage Encoder) Removal
Pro 7900 and 9900 Field Repair Guide 10/6/10 Sensor (Carriage Encoder) Removal 1. Release the Carriage Mechanism. 1.1 Enter Self Testing mode: Down, Right, buttons, and turn on the Printer. 1.2 Navigate to SELF TESTING\Mecha Adjustment\IM Sensor Gap 1.3 Press the Right Arrow to display the [Enter]...
Page 171 Pro 7900 and 9900 Field Repair Guide 10/6/10 4. Remove the Top Cover. 5. Remove 1 Screws that fasten the Carriage Encoder in place. Right side of the Carriage Mechanism. Remove 1 Screw. Printer Component, Software Item, LCD Display, Printer Button Sensor (Carriage Encoder) Removal Page 171.
Page 172 Pro 7900 and 9900 Field Repair Guide 10/6/10 6. Unplug the Foil Cable, and remove the Carriage Encoder. Unplug the Foil Cable, and remove the Carriage Encoder. Printer Component, Software Item, LCD Display, Printer Button Sensor (Carriage Encoder) Removal Page 172.
Page 173: Sensor (Edge Detector) Removal
Pro 7900 and 9900 Field Repair Guide 10/6/10 Sensor (Edge Detector) Removal 1. Release the Carriage Mechanism. 1.1 Enter Self Testing mode: Down, Right, buttons, and turn on the Printer. 1.2 Navigate to SELF TESTING\Mecha Adjustment\IM Sensor Gap 1.3 Press the Right Arrow to display the [Enter]...
Page 174 Pro 7900 and 9900 Field Repair Guide 10/6/10 4. Remove 3 Screws that fasten the Sensor Bracket in place. Remove 3 Screws. Printer Component, Software Item, LCD Display, Printer Button Sensor (Edge Detector) Removal Page 174.
Page 175 Pro 7900 and 9900 Field Repair Guide 10/6/10 5. Carefully remove, and rotate the Sensor Bracket exposing the Cables. Expose the Sensor Cables. Printer Component, Software Item, LCD Display, Printer Button Sensor (Edge Detector) Removal Page 175.
Page 176 Pro 7900 and 9900 Field Repair Guide 10/6/10 6. Inspect the end of the Sensor Bracket and remove 1 Screw and 1 Cover. 1. Remove 1 Screw. 2. Remove the Cover. Printer Component, Software Item, LCD Display, Printer Button Sensor (Edge Detector) Removal Page 176.
Page 177 Pro 7900 and 9900 Field Repair Guide 10/6/10 7. Remove the Edge Detector. Lift out the Sensor, and unplug the Cable. Printer Component, Software Item, LCD Display, Printer Button Sensor (Edge Detector) Removal Page 177.
Page 178: Sensor (Ink Mark) Removal
Pro 7900 and 9900 Field Repair Guide 10/6/10 Sensor (Ink Mark) Removal 1. Release the Carriage Mechanism. 1.1 Enter Self Testing mode: Down, Right, buttons, and turn on the Printer. 1.2 Navigate to SELF TESTING\Mecha Adjustment\IM Sensor Gap 1.3 Press the Right Arrow to display the [Enter]...
Page 179 Pro 7900 and 9900 Field Repair Guide 10/6/10 4. Remove 3 Screws that fasten the Sensor Bracket in place. Remove 3 Screws. Printer Component, Software Item, LCD Display, Printer Button Sensor (Ink Mark) Removal Page 179.
Page 180 Pro 7900 and 9900 Field Repair Guide 10/6/10 5. Carefully remove, and rotate the Sensor Bracket exposing the Cables. Expose the Sensor Cables. Printer Component, Software Item, LCD Display, Printer Button Sensor (Ink Mark) Removal Page 180.
Page 181 Pro 7900 and 9900 Field Repair Guide 10/6/10 6. Inspect the end of the Sensor Bracket and remove 1 Screw and 1 Cover. 1. Remove 1 Screw. 2. Remove the Cover. Printer Component, Software Item, LCD Display, Printer Button Sensor (Ink Mark) Removal Page 181.
Page 182 Pro 7900 and 9900 Field Repair Guide 10/6/10 7. Remove the Ink Mark Sensor. Lift out the Sensor, and unplug the Foil Cable. Printer Component, Software Item, LCD Display, Printer Button Sensor (Ink Mark) Removal Page 182.
Page 183: Sensor (Platen Gap) Removal
Pro 7900 and 9900 Field Repair Guide 10/6/10 Sensor (Platen Gap) Removal 1. Release the Carriage Mechanism. 1.1 Enter Self Testing mode: Down, Right, buttons, and turn on the Printer. 1.2 Navigate to SELF TESTING\Mecha Adjustment\IM Sensor Gap 1.3 Press the Right Arrow to display the [Enter]...
Page 184 Pro 7900 and 9900 Field Repair Guide 10/6/10 4. Remove 3 Screws that fasten the Sensor Bracket in place. Remove 3 Screws. Printer Component, Software Item, LCD Display, Printer Button Sensor (Platen Gap) Removal Page 184.
Page 185 Pro 7900 and 9900 Field Repair Guide 10/6/10 5. Carefully remove, and rotate the Sensor Bracket exposing the Platen Gap Sensor. Expose the Platen Gap Sensor. Printer Component, Software Item, LCD Display, Printer Button Sensor (Platen Gap) Removal Page 185.
Page 186 Pro 7900 and 9900 Field Repair Guide 10/6/10 6. Turn the Platen Gap Gear until the Home Position Window is aligned with the Sensor. Turn this Gear until the Sensor is in the Window. Sensor in the Window. Printer Component, Software Item, LCD Display, Printer Button...
Page 187 Pro 7900 and 9900 Field Repair Guide 10/6/10 7. Remove the Platen Gap Home Position Sensor. Platen Gap Home Position Sensor 1. Compress the Interlocks and remove the Sensor. 2. Unplug the Cable. Printer Component, Software Item, LCD Display, Printer Button Sensor (Platen Gap) Removal Page 187.
Page 188: Wiper Blade Assembly Removal
Pro 7900 and 9900 Field Repair Guide 10/6/10 Wiper Blade Assembly Removal Note: Wiper Blade Assembly Part # 1504179 1. Remove the Right Side Cover. 2. Move the Carriage Assembly off the Cleaning Unit, towards the center of the Printer. 2.1 Follow the directions in the Carriage Release (Manual) Chapter found in the Reference Section.
Page 189 Pro 7900 and 9900 Field Repair Guide 10/6/10 3. Rotate the Flushing Box/Wiper Blade Motor until the Wiper Blade is exposed. Wiper Blade Assembly. Rotate this Gear counter clockwise..Until the Wiper Blade Assembly is completely exposed Printer Component, Software Item, LCD Display, Printer Button Wiper Blade Assembly Removal...
Page 190 Pro 7900 and 9900 Field Repair Guide 10/6/10 4. Remove the Wiper Blade Assembly. 1. Compress, and release, the Wiper Blade Interlock. 2. Lift out the Wiper Blade Assembly. Wiper Blade Assembly Interlock Wiper Blade Assembly Printer Component, Software Item, LCD Display, Printer Button Wiper Blade Assembly Removal...
Page 191: Troubleshooting
Pro 7900 and 9900 Field Repair Guide 10/6/10 Troubleshooting Printer Component, Software Item, LCD Display, Printer Button Page 191.
Page 192: Printer Error Codes (Maintenance)
Pro 7900 and 9900 Field Repair Guide 10/6/10 Printer Error Codes (Maintenance) 0002 Carriage Motor / Ink Tube is near end of life perform (Clear Counter (when replacing CR motor))and (Clear Counter (when replacing Ink Tube) 0008 RTC error (Replace the Battery and initialize the RTC with the Adjustment Wizard’s RTC &...
Page 193: Printer Error Codes (Service)
Pro 7900 and 9900 Field Repair Guide 10/6/10 Printer Error Codes (Service) 11xx Series Carriage Error Codes Carriage Error Name Description Remedy Error Code 1101 Carriage Motor End Of The Carriage has made Inspect and replace the Ink Tubes if neces- Life Error enough passes to wear out sary, and reset the counters (Clear counter...
Page 194 Pro 7900 and 9900 Field Repair Guide 10/6/10 Carriage Error Name Description Remedy Error Code 113C Carriage Encoder The Carriage Encoder 1. Check the CR Encoder. Reversing Error reports that the Carriage is 2. Check the Main Board. moving in the wrong direction. 113D Carriage Encoder The Carriage Encoder...
Page 195 Pro 7900 and 9900 Field Repair Guide 10/6/10 12xx Series Paper Feed Error Codes Paper Explanation Description Remedy Feed Error Codes 1223 Paper Feed Encoder The Paper Feed Encoder 1. Check the PF Encoder Disk. Check Error signal does not look right to 2.
Page 196 Pro 7900 and 9900 Field Repair Guide 10/6/10 Paper Explanation Description Remedy Feed Error Codes 122A Paper Feed Motor The Paper Feed Motor 1. Check for proper Paper Feed Roller Overload Error Driver Circuit detects abnor- Pressurization (look for binding). mal current draw.
Page 197 Pro 7900 and 9900 Field Repair Guide 10/6/10 Paper Explanation Description Remedy Feed Error Codes 122E Paper Feed Motor The Paper Feed Encoder 1. Check for proper Paper Feed Roller Velocity error. reports that the Paper Feed Pressurization (look for binding). Roller is moving at and irreg- 2.
Page 198: 13Xx Ink Cover Error
Pro 7900 and 9900 Field Repair Guide 10/6/10 13xx Ink Cover Error Ink Cover Explanation Description Remedy Error Codes 131B Thermistor Sensor The Thermistor on the Print 1. Re-seat the Print Head Cables on the Error Head Driver reports an over Main Board side.
Page 199 Pro 7900 and 9900 Field Repair Guide 10/6/10 Ink Sys- Explanation Description Remedy tem Error Codes 141A Over Current Error The Cleaning Pump Motor 1. Check the Ink System. draws too much current 2. Check the Main Board. 141B Over Speed Error The Cleaning Pump Motor 1.
Page 200 Pro 7900 and 9900 Field Repair Guide 10/6/10 Ink Sys- Explanation Description Remedy tem Error Codes 1431 Ink Selector Life Error The PK/MK Ink Selector 1. Replace the Damper (Selector) Assem- Assembly has reached it’s bly. end of life. 2. Reset the counter (Clear Counter when replacing Ink select motor)
Page 201 Pro 7900 and 9900 Field Repair Guide 10/6/10 Ink Sys- Explanation Description Remedy tem Error Codes 143F Under Speed Error The Cap Motor spins too 1. Check the Ink System. slow. 2. Check the Main Board. 144A Over Current Error Air Pressure Motor draws 1.
Page 202 Pro 7900 and 9900 Field Repair Guide 10/6/10 Ink Sys- Explanation Description Remedy tem Error Codes 148C Rotation Direction Error The Flushing Box Motor 1. Check the Ink System. spins in the wrong direction. 2. Check the Main Board. 148D Driving Time Out Error The Flushing Box Motor 1.
Page 203 Pro 7900 and 9900 Field Repair Guide 10/6/10 Ink Sys- Explanation Description Remedy tem Error Codes 1497 Switching Time Out Switching between PK/MK Note: Corrupted or incorrect Parameters Error does not work can cause this error. For example: Selector Sensor set to Photo Black and Parameters set to Matte Black.
Page 204 Pro 7900 and 9900 Field Repair Guide 10/6/10 15xx Series Auto Platen Gap and Ink System Errors Explanation Description Remedy Errors 1501 Release Phase Detection The Pinch Roller Release 1. Check the operation of the Pinch Roller Error Home Position Sensor Release Mechanism.
Page 205 Pro 7900 and 9900 Field Repair Guide 10/6/10 Explanation Description Remedy Errors 151E Velocity Deviation Error The Platen Gap Motor 1. Check the Platen Gap Motor. spins at irregular speeds. 2. Check the Main Board. 151F Under Speed Error The Platen Gap Motor 1.
Page 206 Pro 7900 and 9900 Field Repair Guide 10/6/10 Explanation Description Remedy Errors 1536 Pressure Sensor Error The Air Pressure Sensor 1. Visually check the Pressure sensor on always reports pressure. the Pressure Pump Assembly 2. Replace the Pressure Pump Assembly. 3.
Page 207 Pro 7900 and 9900 Field Repair Guide 10/6/10 Explanation Description Remedy Errors 1540 Cutter Home Position The Cutter Home Position 1. Check the Cutter Motor. Detection Error Sensor does not report to 2. Check the Cutter HP Sensor. the Main Board. 3.
Page 208 Pro 7900 and 9900 Field Repair Guide 10/6/10 Explanation Description Remedy Errors 1551 Paper Thickness Sensor Error 1561 Paper Thickness Sensor Error Printer Component, Software Item, LCD Display, Printer Button Printer Error Codes (Service) Page 208.
Page 209 Pro 7900 and 9900 Field Repair Guide 10/6/10 18xx Series AID (Auto Ink Detection) Error 1800 AID (Auto Ink Detector) The AID circuitry counted 1.Determine why the AID operation is fail- Voltage Error. enough failures to have ing (missing nozzles or bad Aid Compo- reached a counter limit.
Page 210 Pro 7900 and 9900 Field Repair Guide 10/6/10 Main Explanation Description Remedy Board Errors 1A26 RTC Communication Error The RTC circuit on the Main 1. Unplug the Printer. Board is malfunctioning. 2. Remove the Battery for 30 seconds. 3. Re-install the Battery. 4.
Page 211 Pro 7900 and 9900 Field Repair Guide 10/6/10 Main Explanation Description Remedy Board Errors 1A50 Carriage Board Error Carriage Board does not 1. Check the Carriage Board. communicate with the Main 2. Check the Main Board Board. 1A51 Carriage Board Error Carriage Board does not 1.
Page 212 Pro 7900 and 9900 Field Repair Guide 10/6/10 Main Explanation Description Remedy Board Errors 2010 Board Error Board Error 1. Check Ink Bay Cable Connections. 2. Reseat all other Foil Cables. 3. Replace the Main Board 3000 AC Shut Off Error AC Power was interrupted.
Page 213: Printer Options Error Codes
Pro 7900 and 9900 Field Repair Guide 10/6/10 Printer Options Error Codes Error Error Name Description Remedy Code XRITE Head Mount- The XRITE Head Detection 1. Reinstall the Xrite Head. ing Error Sensor does not detect the 2. Check the Detection Sensor. presence of a XRITE Head.
Page 214 Pro 7900 and 9900 Field Repair Guide 10/6/10 Error Error Name Description Remedy Code Carriage Home Posi- The Carriage Home Posi- 1. Check the correct installation of the tion Error tion Sensor does not detect Backing Plate. correct movement of the Car- 2.
Page 215 Pro 7900 and 9900 Field Repair Guide 10/6/10 Error Error Name Description Remedy Code Paper Pressing Plate The Paper Pressing Plate 1. Check for proper Paper Pressing Plate Current Error Motor draws too much cur- movement (binding). rent. 2. Check the Paper Pressing Plate Motor. 3.
Page 216 Pro 7900 and 9900 Field Repair Guide 10/6/10 Error Error Name Description Remedy Code Paper Pressing Plate The Paper Pressing Plate 1. Check for proper Paper Pressing Plate under speed Error Encoder does not detect the movement. correct timing for movement 2.
Page 217 Pro 7900 and 9900 Field Repair Guide 10/6/10 Error Error Name Description Remedy Code Take Up Motor Irregu- The Take Up Motor Encoder 1. Check for proper Gear movement. lar Speed Error does not detect the correct 2. Check the Take Up Motor. timing of the Take Up Motor.
Page 218: Error
Pro 7900 and 9900 Field Repair Guide 10/6/10 1537 Error Note: The 1537 error code indicates that the Ink System Pressure Sensor reports low pressure. Note: This error usually is caused by an Ink Cartridge that leaks pressure. 1. Test each Ink Cartridge for pressure leaks. 1.
Page 219: Aid Issue Troubleshooting
Pro 7900 and 9900 Field Repair Guide 10/6/10 AID Issue Troubleshooting Overview The AID (Auto Ink Detection) feature is designed to perform auto nozzle checks. It has 3 settings that were added with a recent firmware revision. There are 3 options in the: User Menu: Printer Settings AUTO NOZZLE CHECK: ON:PERIODICALLY*, ON:EVERY JOB,...
Page 220 Pro 7900 and 9900 Field Repair Guide 10/6/10 3.4 Press the button to begin the test. 1. The Printer will display Please Wait. 2. The Printer will display 6 OK’s if the AID Circuitry passes the test. 4. If Mode1 has 1 or more NG’s instead of OK’s: 4.1 Clean the AID Grid, or replace the Cleaning Unit (the AID Grid is on the Cleaning Unit).
Page 221: Borderless Printing Errors
Pro 7900 and 9900 Field Repair Guide 10/6/10 Borderless Printing Errors Ensure that the media is one of the supported sizes. The media should be exactly on of the sizes listed below. 7700: 10”, 12”, 13”,16”, 17”,and 24” 9700: 10”, 12”, 13”,16”, 17” ,24”, 36”, and 44”. The image being printed must be at least 1/4”...
Page 222: Color Shift
If the color appears normal, then the user’s “work flow” is the issue. Verify that the Printer is filled with Epson Ink. Non-Epson Ink can cause a color shift. If the color is incorrect using your materials, and the customers, replacing the Main Board and the Print Head at the same time may correct the issue.
Page 223: Grainy Or Ghosting
Using your Computer, Driver, and Application, verify that it is not the users equipment that is causing the print qual- ity issue. • Non-Epson media or improper media settings in the driver can cause grainy images. • Non-Epson Ink can cause Grainy print quality.
Page 224: Horizontal Banding
Use another Computer with the Epson Driver and Epson Media to eliminate the users equipment. Verify that the proper tension setting is being used. Check the Paper Config section of the driver, or Custom Paper section of the Printer’s user menu...
Page 225 Pro 7900 and 9900 Field Repair Guide 10/6/10 If all of the nozzles appear to be functioning properly, the horizontal banding may still be caused by the print head. Missing or deflected Nozzles may be caused by problems with the Cleaning Station. Before attempting to clear Nozzle issues, the Cap, Wiper Blade, Wiper Blade Cleaner, and the Print Head Nozzle Plate should be cleaned.
Page 226: Ink Cartridge Error: Replace Ink Cartridge
Pro 7900 and 9900 Field Repair Guide 10/6/10 INK CARTRIDGE ERROR: REPLACE INK CARTRIDGE Error Message: INK CARTRIDGE ERROR: REPLACE INK CARTRIDGE Explanation of Error: The CSIC Chip reports ink in the Cartridge, but the Ink Out Sensor (located where the ink leaves the Cartridge) reports no ink.
Page 227 Pro 7900 and 9900 Field Repair Guide 10/6/10 2. Prepare to inflate the Ink Cartridge. Attach the hollow tube to the Air Pressure Insert Nipple. Ensure that the paper clip is handy. Place the Ink Cartridge on a flat surface, with this side up.
Page 228 Pro 7900 and 9900 Field Repair Guide 10/6/10 3. Inflate the Cartridge and bleed it. Note: The ink is in a bag, inside of the sealed Ink Cartridge. When the Cartridge is inflated, the air pressure squeezes the bag of ink, placing the ink under pressure. 1.
Page 229 Pro 7900 and 9900 Field Repair Guide 10/6/10 4. Inspect the released ink. This image shows the approximate amount of ink that should be released from the Cartridge. This particular Cartridge did not contain air bubbles in the ink. This Cartridge did contain air bubbles in the ink.
Page 230 Pro 7900 and 9900 Field Repair Guide 10/6/10 5. Clean up the released ink. Use the paper towel to absorb the “frothy” Ink. The Cartridge should now work. INK CARTRIDGE ERROR: REPLACE INK CARTRIDGE Printer Component, Software Item, LCD Display, Printer Button Page 230.
Page 231: Missing Nozzle Diagnosis
Pro 7900 and 9900 Field Repair Guide 10/6/10 Missing Nozzle Diagnosis Note: It is important to completely clean the Printer before following the troubleshooting advice in this chapter. This is because a dirty printer will cause any of the symptoms listed. Follow the cleaning advice in the Service Procedure chapter in the reference section.
Page 232 Pro 7900 and 9900 Field Repair Guide 10/6/10 It can be verified by gently injecting water into the suspected inlet. If the channel accepts water, the Print Head is probably not the issue. Because of the cost of the Print Head, verification is recommended.
Page 233 Pro 7900 and 9900 Field Repair Guide 10/6/10 2. Perform a Cleaning Cycle on the missing nozzles (Color Pair cleaning is the most efficient use of Ink). 3. Perform a Nozzle Check and mark it as #2. 3.1 Compare Nozzle Check 1 to 2. 3.1.1 If the missing nozzles on nozzle check 1 have cleared up, and new ones have appeared: 3.1.1.1...
Page 234 Pro 7900 and 9900 Field Repair Guide 10/6/10 Ink. A cleaning cycle delivers a much stronger demand on the Ink System and will refill the Print Head with Ink. The process of printing will once again “starve” the Print Head. 1.
Page 235: Pcu Troubleshooting
Pro 7900 and 9900 Field Repair Guide PCU (Plate Curing Unit) Troubleshooting Overview The Plate Curing Unit (PCU) is a whole unit exchange. Troubleshooting the PCU consists of testing it’s ability to heat a Plate. If it can not heat a Plate evenly and sufficiently, the unit should be exchanged. Required Equipment 3 Plates 1 package of 10 Thermax Strips.
Page 236 Pro 7900 and 9900 Field Repair Guide 2. Turn on the PCU. Turn on the Power Switch. This switch supplies power to the PCU. The Transport Belt internal to the PCU will start moving. This Switch changes the direction that the Transport Belt travels. Printer Component, Software Item, LCD Display,...
Page 237 Pro 7900 and 9900 Field Repair Guide 3. Configure the PCU. 1. Turn on the Oven. 2. Set the Temperature to 190.0 (Centigrade). Use the Down Arrows. 3. Press this button to “Lock In” the temperature setting. 4. Turn this Knob to 1.5.
Page 238 Pro 7900 and 9900 Field Repair Guide 4. Insert the Plate with the Thermax Strips. Gently insert the leading edge of the Plate (Landscape) into the front of the PCU . Note: If the Transport does not pick up the Plate, change the direction of the Transportation Belts’s movement.
Page 239 Pro 7900 and 9900 Field Repair Guide 5. Remove the Plate from the rear of the PCU, and inspect the Thermax Strips. 1. Wait for the Plate to be released onto the Exit Tray of the PCU. 2. Inspect the Thermax Strips. There should be no more than a 10% differance between between the 3 Strips.
Page 240: Random Nozzle Firing
Pro 7900 and 9900 Field Repair Guide 10/6/10 Random Nozzle Firing Note: Random Nozzles refers to Nozzles that fire when they are not commanded to. Random Nozzle firing is caused by 1 or more of 6 components •Head Cables •Print Head •Main Board •Power Supply •Carriage Encoder and Encoder Strip...
Page 241: Scratch
Pro 7900 and 9900 Field Repair Guide 10/6/10 Scratch Note: A scratch is damage to the media surface caused by contact with a roller or other Printer components. Sometimes scratches occur before the media is inserted into the Printer. Some media is very sensitive to surface abrasions. Contact between the Pinch Rollers, the Paper Feed Roller, and the media is necessary to support and move it.
Page 242: Smear
Note: A smear is caused by something “smearing” the intended image, after the image is printed. Many times smearing is a result of non-Epson media or ink. Non-Epson ink or media may dry to slowly, resulting in a smear after the image leaves the Printer. Adjusting the...
Page 243: Smudge
Pro 7900 and 9900 Field Repair Guide 10/6/10 Smudge Note: A smudge is a mark left on the media by contact. It can be caused by contact with the Print Head, or contact with a dirty Roller. Dirty Roller A dirty Roller usually leaves a mark that repeats at an interval that is equal to the circumference of the Roller. Plac- ing the image with the smudge back into the paper path, and aligning the smudge with the Printer’s Rollers will indi- cate which Roller is dirty.
Page 244: Spectroproofer Troubleshooting
Pro 7900 and 9900 Field Repair Guide 10/6/10 SpectroProofer Troubleshooting Note: This document is intended to provide a step by step procedure for verifying the correct installation and initialization of the SpectroProofer assembly. Install and Connect the SpectroProofer 1. Unplug the Printer. 2.
Page 245 Pro 7900 and 9900 Field Repair Guide 10/6/10 5. Install the Calibration Tile into the Calibration Tile Holder. 1. Place the Calibration Tile in position. 2. Place the Calibration Tile Fastener in position and lock it in place. Printer Component, Software Item, LCD Display, Printer Button...
Page 246 Pro 7900 and 9900 Field Repair Guide 10/6/10 6. Install the Calibration Tile Holder. 1. Locate the 2 Holes for the Calibration Tile Holder Tabs. 2. Align the Calibration Tile Holder Tabs with the 2 Holes. 3. Place the Calibration Tile Holder Tabs into the 2 Holes.
Page 247 Pro 7900 and 9900 Field Repair Guide 10/6/10 7. Install the ILS Head into it’s correct position. Correct with the Pins in these Holes. Incorrect with the Pins not in these Holes. 8. Plug in the 2 cables to the ILS Head. 9.
Page 248 13.6 The SpectroProofer Carriage will return to it’s home position. 13.7 The SpectroProofer Track will return to it’s raised position. 13.8 The Green Light will stop blinking and remain on. 14. Load Epson Paper (necessary for step 16). 15. Check the Printer’s configuration. 15.1 Verify that Paper Setup/Paper Type is correctly set to match the paper loaded in the previous step.
Page 249 Pro 7900 and 9900 Field Repair Guide 10/6/10 18.1.2.1 Generally this issue requires a new ILS Head to fix. 18.1.2.2 Occasionally this issue requires a new SpectroProofer Mechanism to fix. Printer Component, Software Item, LCD Display, Printer Button SpectroProofer Troubleshooting Page 249.
Page 250: Stuck In Cut Sheet Mode
Pro 7900 and 9900 Field Repair Guide 10/6/10 Stuck In Cut Sheet Mode Note: Stuck In Cut Sheet Mode refers to the Printer always returning to sheet mode after loading paper. Note: Historically, this symptom has been caused by the Paper Thickness Sensor registering very thick media.
Page 251: Vertical Banding
Computer with the Epson Driver and Epson Media to eliminate the users equipment. Non-Epson drivers effect verti- cal banding if the amount of ink that is applied to the media is too low. Using the Epson driver should look better, if that is the case.
Page 252: Adjustments
Pro 7900 and 9900 Field Repair Guide 10/6/10 Adjustments Printer Component, Software Item, LCD Display, Printer Button Page 252.
Page 253: Aid Check Test
Pro 7900 and 9900 Field Repair Guide 10/6/10 AID Check Test Purpose: The AID Check verifies the correct operation of the AID (Auto Ink Detection) circuitry. Note: If the AID Check fails, verify that the Print Head does not have missing nozzles. Missing nozzles on the Print Head will cause the test to fail.
Page 254: Check Network Communication
Pro 7900 and 9900 Field Repair Guide 10/6/10 Check Network Communication Note: The Check Network Communication adjustment item tests the Ethernet Port on the Printer. 1. Prepare the Printer’s Ethernet Port for the test. 1.1 Enter the User Menu on the Printer, and navigate to NETWORK SETUP.
Page 255 Pro 7900 and 9900 Field Repair Guide 10/6/10 1. From the Servprog.exe for the 7900 and 9900, select Adjustments (Individual). Click on Adjustments (Individual) Printer Component, Software Item, LCD Display, Printer Button Check Network Communication Page 255.
Page 256 Pro 7900 and 9900 Field Repair Guide 10/6/10 2. Check the Printer’s Ethernet Port operation. Note: Manual IP169.254.1.2 Subnet 255.255.0.0 works with most computers. 1. Enter the Printer’s IP Address. 2. Click on the button to start the test. 3. The Printer will print out a Status Sheet (test print).
Page 257: Clear Counter [When Replacing Aid]
Pro 7900 and 9900 Field Repair Guide 10/6/10 Clear Counter [when replacing AID] Note: Clear Counter [when replacing AID board] resets the AID Board Life Counter. 1. From the Servprog.exe for the 7900 and 9900, select FLAG CHANGE & COUNTER RESET Click on FLAG CHANGE &...
Page 258 Pro 7900 and 9900 Field Repair Guide 10/6/10 2. From the menu, select FLAG CHANGE & COUNTER RESET Clear Counter [when replacing AID board] 1. Click on Clear Counter [when replac- ing AID board]. 2. Click on OK. Printer Component, Software Item, LCD Display, Printer Button...
Page 259 Pro 7900 and 9900 Field Repair Guide 10/6/10 3. Reset the AID Board life counter. 1. Click on Run. 2. Click on Finish. Printer Component, Software Item, LCD Display, Printer Button Clear Counter [when replacing AID] Page 259.
Page 260: Clear Counter [When Replacing Cartridge Holder Ink Pad]
Pro 7900 and 9900 Field Repair Guide 10/6/10 Clear Counter [when replacing Cartridge Holder Ink Pad] Note: Clear Counter [when replacing Cartridge holder Ink Pad] resets the Ink Bay Drip Pad Life Counter. Note: Clear this counter when replacing either Ink Bay. 1.
Page 261 Pro 7900 and 9900 Field Repair Guide 10/6/10 2. From the menu, select FLAG CHANGE & COUNTER RESET Clear Counter [when replacing Cartridge holder ink Pad] 1. Click on Clear Counter [Cartridge holder ink Pad]. 2. Click on OK. Clear Counter [when replacing Cartridge Holder Ink Pad] Printer Component, Software Item, LCD Display, Printer Button...
Page 262 Pro 7900 and 9900 Field Repair Guide 10/6/10 3. Reset the Drip Pad in the Ink Bay life counter. 1. Click on Run. 2. Click on Finish. Clear Counter [when replacing Cartridge Holder Ink Pad] Printer Component, Software Item, LCD Display, Printer Button Page 262.
Page 263: Clear Counter [When Replacing Cr Motor]
Pro 7900 and 9900 Field Repair Guide 10/6/10 Clear Counter [when replacing CR Motor] Note: Clear Counter [when replacing CR motor] resets the Carriage Motor Life Counter. 1. From the Servprog.exe for the 7900 and 9900, select FLAG CHANGE & COUNTER RESET Click on FLAG CHANGE &...
Page 264 Pro 7900 and 9900 Field Repair Guide 10/6/10 2. From the menu, select FLAG CHANGE & COUNTER RESET Clear Counter [when replacing CR motor] 1. Click on Clear Counter [when replac- ing CR motor]. 2. Click on OK. Printer Component, Software Item, LCD Display, Printer Button...
Page 265 Pro 7900 and 9900 Field Repair Guide 10/6/10 3. Reset the Carriage Motor life counter. 1. Click on Run. 2. Click on Finish. Printer Component, Software Item, LCD Display, Printer Button Clear Counter [when replacing CR Motor] Page 265.
Page 266: Clear Counter [When Replacing Ink Holder]
Pro 7900 and 9900 Field Repair Guide 10/6/10 Clear Counter [when replacing Ink holder] Note: Clear Counter [when replacing Ink holder] resets the Ink Bay Life Counter. Note: Clear this counter even if 1 Ink Bay is replaced. 1. From the Servprog.exe for the 7900 and 9900, select FLAG CHANGE &...
Page 267 Pro 7900 and 9900 Field Repair Guide 10/6/10 2. From the menu, select FLAG CHANGE & COUNTER RESET Clear Counter [when replacing Ink holder] 1. Click on Clear Counter [when replac- ing Ink holder]. 2. Click on OK. Printer Component, Software Item, LCD Display, Printer Button...
Page 268 Pro 7900 and 9900 Field Repair Guide 10/6/10 3. Reset the Ink Bay life counter. 1. Click on Run. 2. Click on Finish. Printer Component, Software Item, LCD Display, Printer Button Clear Counter [when replacing Ink holder] Page 268.
Page 269: Clear Counter [When Replacing Ink Tube]
Pro 7900 and 9900 Field Repair Guide 10/6/10 Clear Counter [when replacing Ink tube] Note: Clear Counter [when replacing Ink tube] resets the Ink tube’s Life Counter. 1. From the Servprog.exe for the 7900 and 9900, select FLAG CHANGE & COUNTER RESET Click on FLAG CHANGE &...
Page 270 Pro 7900 and 9900 Field Repair Guide 10/6/10 2. From the menu, select FLAG CHANGE & COUNTER RESET Clear Counter [when replacing Ink tube] 1. Click on Clear Counter [when replac- ing Ink tube]. 2. Click on OK. Printer Component, Software Item, LCD Display, Printer Button...
Page 271 Pro 7900 and 9900 Field Repair Guide 10/6/10 3. Reset the Ink Tube life counter. 1. Click on Run. 2. Click on Finish. Printer Component, Software Item, LCD Display, Printer Button Clear Counter [when replacing Ink tube] Page 271.
Page 272: Clear Counter [When Replacing Pf Motor]
Pro 7900 and 9900 Field Repair Guide 10/6/10 Clear Counter [when replacing PF Motor] Note: Clear Counter [when replacing PF motor] resets the Paper Feed Motor Life Counter. 1. From the Servprog.exe for the 7900 and 9900, select FLAG CHANGE & COUNTER RESET Click on FLAG CHANGE &...
Page 273 Pro 7900 and 9900 Field Repair Guide 10/6/10 2. From the menu, select FLAG CHANGE & COUNTER RESET Clear Counter [when replacing PF motor] 1. Click on Clear Counter [when replac- ing PF motor]. 2. Click on OK. Printer Component, Software Item, LCD Display, Printer Button...
Page 274 Pro 7900 and 9900 Field Repair Guide 10/6/10 3. Reset the Paper Feed Motor life counter. 1. Click on Run. 2. Click on Finish. Printer Component, Software Item, LCD Display, Printer Button Clear Counter [when replacing PF Motor] Page 274.
Page 275: Clear Counter [When Replacing Pressurizing Motor]
Pro 7900 and 9900 Field Repair Guide 10/6/10 Clear Counter [when replacing Pressurizing motor] Note: Clear Counter [when replacing Pressurizing motor] resets the Pressure Pump Life Counter. 1. From the Servprog.exe for the 7900 and 9900, select FLAG CHANGE & COUNTER RESET Click on FLAG CHANGE &...
Page 276 Pro 7900 and 9900 Field Repair Guide 10/6/10 2. From the menu, select FLAG CHANGE & COUNTER RESET Clear Counter [when replacing Pressurizing motor] 1. Click on Clear Counter [when replac- ing Pressurizing motor. 2. Click on OK. Clear Counter [when replacing Pressurizing motor] Printer Component, Software Item, LCD Display, Printer Button...
Page 277 Pro 7900 and 9900 Field Repair Guide 10/6/10 3. Reset the Pressure Pump life counter. 1. Click on Run. 2. Click on Finish. Clear Counter [when replacing Pressurizing motor] Printer Component, Software Item, LCD Display, Printer Button Page 277.
Page 278: Clear Counter [When Replacing Printhead]
Pro 7900 and 9900 Field Repair Guide 10/6/10 Clear Counter [when replacing Printhead] Note: Clear Counter [when replacing Printhead] resets the Print Head Life Counter. 1. From the Servprog.exe for the 7900 and 9900, select FLAG CHANGE & COUNTER RESET Click on FLAG CHANGE &...
Page 279 Pro 7900 and 9900 Field Repair Guide 10/6/10 2. From the menu, select FLAG CHANGE & COUNTER RESET Clear Counter [when replacing Printhead] 1. Click on Clear Counter [when replac- Printhead]. 2. Click on OK. Printer Component, Software Item, LCD Display, Printer Button Clear Counter [when replacing Printhead] Page 279.
Page 280 Pro 7900 and 9900 Field Repair Guide 10/6/10 3. Reset the Print Head life counter. 1. Click on Run. 2. Click on Finish. Printer Component, Software Item, LCD Display, Printer Button Clear Counter [when replacing Printhead] Page 280.
Page 281: Clear Counter [When Replacing Pump Motor
Pro 7900 and 9900 Field Repair Guide 10/6/10 Clear Counter [when replacing Pump motor = ...] Note: Clear Counter [when replacing Pump motor = Cleaning Assy] resets the Cleaning Units Life Counter. 1. From the Servprog.exe for the 7900 and 9900, select FLAG CHANGE &...
Page 282 Pro 7900 and 9900 Field Repair Guide 10/6/10 2. From the menu, select FLAG CHANGE & COUNTER RESET Clear Counter [when replacing Pump motor = Cleaning Assy] 1. Click on Clear Counter [when replac- ing Pump motor = Cleaning Assy]. 2.
Page 283 Pro 7900 and 9900 Field Repair Guide 10/6/10 3. Reset the Cleaning Unit life counter. 1. Click on Run. 2. Click on Finish. Printer Component, Software Item, LCD Display, Printer Button Clear Counter [when replacing Pump motor = ...] Page 283.
Page 284: Clear Counter [When Replacing Wiper]
Pro 7900 and 9900 Field Repair Guide 10/6/10 Clear Counter [when replacing Wiper] Note: Clear Counter [when replacing Wiper] resets the Wiper Blade Life Counter. 1. From the Servprog.exe for the 7900 and 9900, select FLAG CHANGE & COUNTER RESET Click on FLAG CHANGE &...
Page 285 Pro 7900 and 9900 Field Repair Guide 10/6/10 2. From the menu, select FLAG CHANGE & COUNTER RESET Clear Counter [when replacing Wiper] 1. Click on Clear Counter [when replac- Wiper]. 2. Click on OK. Printer Component, Software Item, LCD Display, Printer Button Clear Counter [when replacing Wiper] Page 285.
Page 286 Pro 7900 and 9900 Field Repair Guide 10/6/10 3. Reset the Wiper Blade life counter. 1. Click on Run. 2. Click on Finish. Printer Component, Software Item, LCD Display, Printer Button Clear Counter [when replacing Wiper] Page 286.
Page 287: Cleaning Pg Adjustment
Pro 7900 and 9900 Field Repair Guide 10/6/10 Cleaning PG Adjustment Purpose: The Cleaning PG adjustment measures the gap between the Print Head’s Nozzle Plate and the AID Grid located on the Flushing Box. Note: There are 2 possible settings for the Cleaning PG adjustment. (2.2 Stop Stop) Overview...
Page 288 Pro 7900 and 9900 Field Repair Guide 10/6/10 Stop. 1. Enter Self Testing mode: Down, Right, buttons, and turn on the Printer. 2. Navigate to SELF TESTING\Mecha Adjustment\Cleaning PG\Adjustment\ 3. Press the Right Arrow to begin the adjustment. 3.1 The Printer will display Please Wait.
Page 289 Pro 7900 and 9900 Field Repair Guide 10/6/10 Stop. 1. Enter Self Testing mode: Down, Right, buttons, and turn on the Printer. 2. Navigate to SELF TESTING\Mecha Adjustment\Cleaning PG\Check\ 2.1 Press the Right Arrow to begin the adjustment. 3. Select Stop.
Page 290 Pro 7900 and 9900 Field Repair Guide 10/6/10 5. Select Stop. 2. Press the button. 1. Highlight Stop. 6. The Printer will display OK. 7. Press the Pause button to complete the adjustment. Printer Component, Software Item, LCD Display, Printer Button Cleaning PG Adjustment Page 290.
Page 291: Cr Head Slant Adjustment
Pro 7900 and 9900 Field Repair Guide 10/6/10 CR Head Slant Adjustment Note: The CR Head Slant adjusts the Print Head rotation, ensuring that Nozzle 1 for black is linear with Nozzle 1 for yellow (same vertical position). 1. Load 24” Doubleweight Matte roll paper. 2.
Page 292 Pro 7900 and 9900 Field Repair Guide 10/6/10 3. Inspect the printed pattern. This is what the correct pattern looks like. If the pattern looks like this, move the CR Slant Dial Clock Wise. Paper feed Leading Edge direction If the pattern looks like this, move the CR Slant Dial Counter Clock Wise.
Page 293 Pro 7900 and 9900 Field Repair Guide 10/6/10 4. Adjust until correct. Note: This view is shown without the Damper Assembly to make it easier to see the screws that must be loosened. 1. Loosen these 2 Screws. 2. Loosen these 4 Screws. 4.
Page 294: Ctp Plate Guide Alignment
Pro 7900 and 9900 Field Repair Guide CTP Plate Guide Alignment 1. Verify that the Plate Guide is attached correctly. 5mm Hex (Allen) 2.5mm Hex (Allen) Ensure that the Plate Guide is flush with the Black Plastic Edge of the Roll Cover.
Page 295 Pro 7900 and 9900 Field Repair Guide 2. Verify that the Plate Guide is supported correctly. The Plate Guide Support “Nut” should make light, but repeatable con- tact between the Black Plastic Cover Component. Raise and lower the Roll Cover to verify this. Printer Component, Software Item, LCD Display,...
Page 296 Pro 7900 and 9900 Field Repair Guide 3. Load a Plate into the Printer. 1. Press the Pinch Roller Release button to open the Pinch Rollers. 2. Press the button to set the suction to maximum. 4. Ensure that the Plate is held against 2 3.
Page 297 Pro 7900 and 9900 Field Repair Guide 4. Wait for the Printer to finish loading the Plate. 5. Use the utility to send to the printer. FWUpdate.exe AlignmentSheet.prn 6. After the is printed remove the Plate. AlignmentSheet.prn Hold the Plate and press the Down but- ton to release the Plate.
Page 298 Pro 7900 and 9900 Field Repair Guide 7. Measure the alignment pattern on the Plate. 1. Accurately measure the distance between the line at Point A and the side of the Plate. Write down the value. 2. Accurately measure the distance between the line at Point B and the side of the Plate.
Page 299 Pro 7900 and 9900 Field Repair Guide 8. Repeat steps 3 through 7 until Point A = Point 9. Verify the Plate Guides alignment. 9.1 Load a blank Plate and print AlignmentSheet.prn. 9.2 Reload the same Plate and print AlignmentSheet.prn again over the first print.
Page 300: Feed Adj(Ustment)
Pro 7900 and 9900 Field Repair Guide 10/6/10 Feed Adj(ustment) Note: The Feed Adj(ustment) calibrates the Paper Feed Mechanism. This Adjustment requires Epson Doubleweight Matte paper. 1. Enter Self Testing Mode. 1.1 Self Testing Mode: Down, Right, buttons, and turn on the Printer.
Page 301 Pro 7900 and 9900 Field Repair Guide 10/6/10 4. Measure the pattern. Measure the distance between the 2 horizontal lines. Note: The Feed Adjustment for the 7900 and 9900 is based on 990.6mm (not 980.0 mm like other Printers). 5. Input the measurements. 5.5 Navigate to SELF TESTING\Mecha Adjustment\Feed Adj\Input: Press the...
Page 302: Head Rank Input Adjustment
Pro 7900 and 9900 Field Repair Guide 10/6/10 Head Rank Input Adjustment Note: Head Rank Input writes the Print Head Calibration Value (Head ID / Head Rank) to the Main Board. Note: Enter the Head Rank before installing a new Print Head. This way it is possible to enter the data directly off the Print Head.
Page 303 Pro 7900 and 9900 Field Repair Guide 10/6/10 1. From the Servprog.exe for the 7900 and 9900, select Adjustments (Individual). Click on Adjustments (Individual) Printer Component, Software Item, LCD Display, Printer Button Head Rank Input Adjustment Page 303.
Page 304 Pro 7900 and 9900 Field Repair Guide 10/6/10 2. From the menu, select Adjustments (Individual) Head Rank Input 1. Click on Head Rank Input. 2. Click on OK. Printer Component, Software Item, LCD Display, Printer Button Head Rank Input Adjustment Page 304.
Page 305 Pro 7900 and 9900 Field Repair Guide 10/6/10 3. Write the Head Rank to the Main Board. 1. Enter the Head Rank data located on the Print Head. 2. Click on the Write but- ton. Note: If the utility dis- plays: Head Rank ID Input contains...
Page 306: Initial Ink Charge Flag
Pro 7900 and 9900 Field Repair Guide 10/6/10 Initial Ink Charge Flag Note: The Initial Ink Charge Flag menu item allows the setting or canceling an initial charge (prime). 1. From the Servprog.exe for the 7900 and 9900, select FLAG CHANGE & COUNTER RESET Click on FLAG CHANGE &...
Page 307 Pro 7900 and 9900 Field Repair Guide 10/6/10 2. From the menu, select FLAG CHANGE & COUNTER RESET Initial Ink Charge Flag 1. Click on Initial Ink Charge Flag. 2. Click on OK. Printer Component, Software Item, LCD Display, Printer Button Initial Ink Charge Flag Page 307.
Page 308 Pro 7900 and 9900 Field Repair Guide 10/6/10 3. Turn on or off the Initial Ink Charge Flag. Select turn on prime at power on. Select cancel prime at power on. 2. Click on Run. 3. Click on Finish. Printer Component, Software Item, LCD Display, Printer Button...
Page 309: Ink Holder Assy Adjustment
Pro 7900 and 9900 Field Repair Guide 10/6/10 Ink Holder Assy Adjustment Note: The Ink Holder Assy Adjustment coordinates the Ink Bay CSIC Board with U.S. Market Ink Cartridges. 1. From the Servprog.exe for the 7900 and 9900, select Adjustments (Individual). Click on Adjustments (Individual) Printer Component,...
Page 310 Pro 7900 and 9900 Field Repair Guide 10/6/10 2. From the menu, select Adjustments (Individual) Ink Holder Assy Adjustment 1. Click on Ink Holder Assy Adjustment. 2. Click on OK. Printer Component, Software Item, LCD Display, Printer Button Ink Holder Assy Adjustment Page 310.
Page 311 Pro 7900 and 9900 Field Repair Guide 10/6/10 3. Initialize the Ink Bay CSIC board to match the U.S. market Ink Cartridges.. 1. Click on Run. 2. Click on Finish. Printer Component, Software Item, LCD Display, Printer Button Ink Holder Assy Adjustment Page 311.
Page 312: Ink Mark Sensor Position Adjustment
Note: If the Ink Mark Sensor Position Jig is not available, move the Ink Mark Sensor as close as possible to the Platen. Ensure that the Ink Mark Sensor is not closer than the Print Head Nozzle Plate. Special Tools: Ink Mark Sensor Position Jig (2.6mm and 2.7mm) Epson Part # 1424365 1. Release the Carriage Mechanism.
Page 313 Pro 7900 and 9900 Field Repair Guide 10/6/10 3. Place the 2.6mm Jig in place. 6th Pinch Roller from the right side of the Printer. Thick side of the Jig. Place the 2.6mm Jig in place under the 6th Pinch Roller from the right. Printer Component, Software Item, LCD Display,...
Page 314 Pro 7900 and 9900 Field Repair Guide 10/6/10 4. Loosen 3 Screws that fasten the Ink Mark Sensor Bracket in place. Loosen 3 Screws. Printer Component, Software Item, LCD Display, Printer Button Ink Mark Sensor Position Adjustment Page 314.
Page 315 Pro 7900 and 9900 Field Repair Guide 10/6/10 5. Rest the Ink Mark Sensor on the Jig, and tighten 3 Screws. 2. Tighten 3 Screws. 1. Rest the Ink Mark Sensor on the Jig. Printer Component, Software Item, LCD Display, Printer Button Ink Mark Sensor Position Adjustment Page 315.
Page 316: Input Cr Motor Current Adjustment
Pro 7900 and 9900 Field Repair Guide 10/6/10 Input CR Motor Current Adjustment Note: The Input CR Motor Current adjustment writes the CR Motor’s Calibration Values to the Main Board. 1. From the Servprog.exe for the 7900 and 9900, select Adjustments (Individual).
Page 317 Pro 7900 and 9900 Field Repair Guide 10/6/10 2. From the menu, select Adjustments (Individual) Input CR Motor Current 1. Click on Input CR Motor Current. 2. Click on OK. Printer Component, Software Item, LCD Display, Printer Button Input CR Motor Current Adjustment Page 317.
Page 318 Pro 7900 and 9900 Field Repair Guide 10/6/10 3. Write the Carriage Motor calibration values to the Printer. Note: New Motors will have the 2 calibration values on a sticker. 1. Enter the voltage value (Fuka_kc). 2. Input the resistance value (Fuka_kd) 3.
Page 319: Input Mac Address Adjustment
Printer’s Ethernet Port Printer’s MAC Address sticker Note: Epson Recommends that you follow the following steps 3 - 8 exactly. 2. Disable all firewall protection on the computer being used. 3. Connect the printer by USB and verify the connection.
Page 320 Pro 7900 and 9900 Field Repair Guide 10/6/10 5. Load paper and turn on the Printer and verify that it is “Ready”. 6. Run , and set the following manual IP address. Epson Net Config 1. Set Manual IP:169.254.1.2 SM:255.255.0.0 DG:255.255.255.255...
Page 321 Pro 7900 and 9900 Field Repair Guide 10/6/10 8. From the Servprog.exe for the 7900 and 9900, select Adjustments (Individual). Click on Adjustments (Individual) Printer Component, Software Item, LCD Display, Printer Button Input MAC Address Adjustment Page 321.
Page 322 Pro 7900 and 9900 Field Repair Guide 10/6/10 9. From the menu, select Adjustments (Individual) Input MAC Address 1. Click on Input MAC Address. 2. Click on OK. Printer Component, Software Item, LCD Display, Printer Button Input MAC Address Adjustment Page 322.
Page 323 Pro 7900 and 9900 Field Repair Guide 10/6/10 10. Adjust the displayed data. 1. Place cursor to the right of the 4. 2. Hit the Left Arrow key on your keyboard to display the 8. Printer Component, Software Item, LCD Display, Printer Button Input MAC Address Adjustment Page 323.
Page 324 If it fails, try again. 4. Click on to com- plete. 5. Run Epson Net Con- and reset the Printer’s IP settings to the users preference. reboot the Printer, verify that it is “Ready”, and retry. Note: if the procedure fails,...
Page 325: Input Pf Motor Current Adjustment
Pro 7900 and 9900 Field Repair Guide 10/6/10 Input PF Motor Current Adjustment Note: The Input PF Motor Current adjustment writes the Paper Feed Motor’s Calibration Values to the Main Board. 1. From the Servprog.exe for the 7900 and 9900, select Adjustments (Individual).
Page 326 Pro 7900 and 9900 Field Repair Guide 10/6/10 2. From the menu, select Adjustments (Individual) Input PF Motor Current 1. Click on Input PF Motor Current. 2. Click on OK. Printer Component, Software Item, LCD Display, Printer Button Input PF Motor Current Adjustment Page 326.
Page 327 Pro 7900 and 9900 Field Repair Guide 10/6/10 3. Write the Paper Feed Motor calibration values to the Printer. Note: New Motors will have the 2 calibration values on a sticker. 1. Enter the voltage value. 2. Input the resistance value 3.
Page 328: Input Serial Number Adjustment
Pro 7900 and 9900 Field Repair Guide 10/6/10 Input Serial Number Adjustment Note: The Input Serial Number adjustment writes the Printer’s Serial Number to the Main Board. 1. From the Servprog.exe for the 7900 and 9900, select Adjustments (Individual). Click on Adjustments (Individual) Printer Component, Software Item,...
Page 329 Pro 7900 and 9900 Field Repair Guide 10/6/10 2. From the menu, select Adjustments (Individual) Input Serial Number 1. Click on Input Serial Number. 2. Click on OK. Printer Component, Software Item, LCD Display, Printer Button Input Serial Number Adjustment Page 329.
Page 330 Pro 7900 and 9900 Field Repair Guide 10/6/10 3. Write the Serial Number to the Printer. Read button will dis- play the Printer’s cur- rent serial number. 1. Enter the Printer’s Serial Number. 2. Click on Write. Printer Component, Software Item, LCD Display, Printer Button Input Serial Number Adjustment...
Page 331: Nv-Ram Backup Utility
Pro 7900 and 9900 Field Repair Guide 10/6/10 NV-RAM BACKUP UTILITY Note: The NV-RAM BACKUP UTILITY “backs up” and restores the unique data that is on each Printer’s Main Board, and should be transferred to a new Main Board. Note: For a detailed description of the NV-RAM Backup Utility see the NVRAM Utility chapter in the Utility section.
Page 332: Paper Thickness Sensor Adjustment
Pro 7900 and 9900 Field Repair Guide 10/6/10 Paper Thickness Sensor Adjustment Purpose: The Paper Thickness Sensor Adjustment calibrates the Paper Thickness Sensor so that it correctly rec- ognizes 3 different thickness ranges of media. The Paper Thickness Sensor does not measure the thick- ness of inserted media, it determines the “thickness range”...
Page 333 Pro 7900 and 9900 Field Repair Guide 10/6/10 5. Using the Pinch Roller Release button, place the 0.4mm thickness gauge in position. 1. Press the Pinch Roller 2. Place the .4mm thickness gauge between the 2nd from Release button to open the the right Pinch Rollers and the Paper Feed Roller.
Page 334 Pro 7900 and 9900 Field Repair Guide 10/6/10 6. Adjust until the conditions are true for each of the 4 gauges. direction Left digit Right digit direction = When the 0.4mm thickness gauge is inserted. = When the 0.5mm thickness gauge is inserted. = When the 0.8mm thickness gauge is inserted.
Page 335: Pf Slant Adjustment
Pro 7900 and 9900 Field Repair Guide 10/6/10 PF Slant Adjustment Note: The Print Head Slant Adjustment (PF) adjusts the Print Head’s “heel / toe” parallelism (for each color, Nozzle 1 and Nozzle 360 are equal distance from the media). About the 7900 and 9900 PF Slant Adjustment Historically the PF Slant adjustment has been primarily a Print Head adjustment.
Page 336 Pro 7900 and 9900 Field Repair Guide 10/6/10 3. Click on Open Click on Open. Printer Component, Software Item, LCD Display, Printer Button PF Slant Adjustment Page 336.
Page 337 Pro 7900 and 9900 Field Repair Guide 10/6/10 4. Load PF Slant.prn 1. Navigate to, and select Slant.prn. 2. Click on Open. Printer Component, Software Item, LCD Display, Printer Button PF Slant Adjustment Page 337.
Page 338 Pro 7900 and 9900 Field Repair Guide 10/6/10 5. Select the correct Printer. Select the correct Printer. Printer Component, Software Item, LCD Display, Printer Button PF Slant Adjustment Page 338.
Page 339 Pro 7900 and 9900 Field Repair Guide 10/6/10 6. Print the adjustment pattern. Click on Print to print the adjustment pattern. Printer Component, Software Item, LCD Display, Printer Button PF Slant Adjustment Page 339.
Page 340 Pro 7900 and 9900 Field Repair Guide 10/6/10 7. This adjustment pattern will be printed. Paper Feed Direction This is what a good pattern looks like. Slight overlap Slight underlap Slight underlap Each of these 3 lines are equal distant from the top to the bottom. Compare each line to itself, not to each other. Printer Component, Software Item, LCD Display,...
Page 341 Pro 7900 and 9900 Field Repair Guide 10/6/10 Right side of Carriage Mechanism. Lever too far down Lever just right. Lever too far up. PF Slant Lever Printer Component, Software Item, LCD Display, Printer Button PF Slant Adjustment Page 341.
Page 342 Pro 7900 and 9900 Field Repair Guide 10/6/10 9. Unlock the Carriage Mechanism. 9.1 ServiceMan Mode: Down, Right, buttons, and turn on the Printer. 9.2 Navigate to SELF TESTING\Mecha Adjustment\Temporay PG: [Enter] Uncap. 9.2.1 Press the button to uncap the Carriage Mechanism. 10.
Page 343: Rear Ad Sensor Adjustment
Pro 7900 and 9900 Field Repair Guide 10/6/10 Rear AD Sensor Adjustment Purpose: The Rear AD Sensor Adjustment calibrates the RearAD Sensor so that it correctly recognizes media. The RearAD Sensor detects media in the Printer. It also reports the end of the media. Special Tools: Special media is not required.
Page 344: Rtc & Usb Id Adjustment
Pro 7900 and 9900 Field Repair Guide 10/6/10 RTC & USB ID Adjustment Note: The RTC & USB ID sets the Printer’s System Clock and/or resets the USB ID. 1. From the Servprog.exe for the 7900 and 9900, select Adjustments (Individual). Click on Adjustments (Individual) Printer Component,...
Page 345 Pro 7900 and 9900 Field Repair Guide 10/6/10 2. From the menu, select Adjustments (Individual) RTC & USB ID 1. Click on RTC & USB 2. Click on OK. Printer Component, Software Item, LCD Display, Printer Button RTC & USB ID Adjustment Page 345.
Page 346 Pro 7900 and 9900 Field Repair Guide 10/6/10 3. Set or reset the Real Time Clock and/or the USB ID. To Set the Printer’s Sys- tem Clock: 1. Verify the date and time information provided by your computer. 2. Click on Write RTC.
Page 347: Sensor (Carriage Encoder) Adjustment
Pro 7900 and 9900 Field Repair Guide 10/6/10 Sensor (Carriage Encoder) Adjustment 1. Release the Carriage Mechanism. 1.1 Enter Self Testing mode: Down, Right, buttons, and turn on the Printer. 1.2 Navigate to SELF TESTING\Mecha Adjustment\IM Sensor Gap 1.3 Press the Right Arrow to display the [Enter]...
Page 348 Pro 7900 and 9900 Field Repair Guide 10/6/10 4. Remove the Top Cover. 5. Adjust the Carriage Encoder. Right side of the Carriage Mechanism. 1. Loosen 1 Screw. 2. Center the Carriage Encoder on the Encoder Strip. Ensure that the Carriage Encoder does not make contact with the Encoder Strip.
Page 349: Setting Destination Adjustment
Pro 7900 and 9900 Field Repair Guide 10/6/10 Setting Destination Adjustment Note: The Setting Destination adjustment configures a new Main Board for the Americas. 1. From the Servprog.exe for the 7900 and 9900, click on the top, left corner Icon. Click here.
Page 350 Pro 7900 and 9900 Field Repair Guide 10/6/10 2. Click on Check printer port(P) Click on Check printer port(P). Printer Component, Software Item, LCD Display, Printer Button Setting Destination Adjustment Page 350.
Page 351 Pro 7900 and 9900 Field Repair Guide 10/6/10 3. Click on Click on Yes. Printer Component, Software Item, LCD Display, Printer Button Setting Destination Adjustment Page 351.
Page 352: Tbs Pos Adjustment
Pro 7900 and 9900 Field Repair Guide 10/6/10 TBS Pos Adjustment Note: The TBS Pos Adjustment sets the correct margins. This Adjustment requires A3 paper. 1. Enter Self Testing Mode. 1.1 Self Testing Mode: Down, Right, buttons, and turn on the Printer. 2.
Page 353 Pro 7900 and 9900 Field Repair Guide 10/6/10 4. Release the paper. 4.1 Navigate to the Main Menu (displays ink levels). 4.2 Release the paper with the Pinch Roller Release Button. 5. Measure the Top, Bottom, and Side Margings. Rear Sens Pos Side Home Margin Top Margin 6.
Page 354: Component Pictures
Pro 7900 and 9900 Field Repair Guide 10/6/10 Component Pictures Printer Component, Software Item, LCD Display, Printer Button Page 354.
Page 355: Board (Aid) Picture
Pro 7900 and 9900 Field Repair Guide 10/6/10 Board (AID) Picture Located above the Cap Assembly CN1 to CN23 on Main Board CN2 To Flushing Box Grid Printer Component, Software Item, LCD Display, Printer Button Board (AID) Picture Page 355.
Page 356: Board Carriage (Ca11) Picture
Pro 7900 and 9900 Field Repair Guide 10/6/10 Board Carriage (CA11) Picture Located on the Carriage Mechanism CN101 to Main Board (CN101) CN114 to Carriage Encoder CN118 to Ink Selector Motor (PK/MK) CN111 to Platen Gap HP Sensor CN113 to Ink Mark Sensor CN100 to Main CN112 to...
Page 357: Board (Sub-B) Picture
Pro 7900 and 9900 Field Repair Guide 10/6/10 Board (Sub-B) Picture Located on the Right Side Frame CN224 Cap CN222 Wiper CN207 PE CN219 Rewind CN227 APG CN206 Maintenance Tank Motor Encoder Motor Encoder Sensor Motor Encoder Encoder CN229 CR HP Sensor CN205 P Thick 2 Sensor CN213...
Page 358: Board (Sub-C) Picture
Pro 7900 and 9900 Field Repair Guide 10/6/10 Board (Sub-C) Picture Located on the Left Side Frame CN300 to Main Board CN308 (not (CN300) used) CN301 to Main Board (CN301) CN310 Pinch Roller HP Sensor. CN309 Cutter Motor CN311 Cutter Motor Encoder CN303 Paper Feed Motor...
Page 359: Board (Main) Picture
Pro 7900 and 9900 Field Repair Guide 10/6/10 Board (Main) Picture CN36 CN20 CN22 CN904 CN14 CN23 CN19 CN21 CN400 CN200 CN201 CN300 CN500 CN100 CN101 CN104 CN501 CN202 CN25 CN301 CN28 CN10 CN37 Printer Component, Software Item, LCD Display, Printer Button Board (Main) Picture Page 359.
Page 360: Board (Power Supply) Picture
Pro 7900 and 9900 Field Repair Guide 10/6/10 Board (Power Supply) Picture (CN301) to Main Board (CN001) AC input (F001) 8 amp, 250 Volt Fuse Printer Component, Software Item, LCD Display, Printer Button Board (Power Supply) Picture Page 360.
Page 361: Carriage Assembly Pictures
Pro 7900 and 9900 Field Repair Guide 10/6/10 Carriage Assembly Pictures Left Side View Felt Bushing (Left) Platen Gap Adjustment Lever Ink Mark Sensor Carriage Encoder Printer Component, Software Item, LCD Display, Printer Button Carriage Assembly Pictures Page 361.
Page 362: Right Side View
Pro 7900 and 9900 Field Repair Guide 10/6/10 Right Side View Platen Gap Adjustment Lever Felt Bushing (Right) PF Slant Adjustment Lever Carriage Lock Carriage Encoder Printer Component, Software Item, LCD Display, Printer Button Carriage Assembly Pictures Page 362.
Page 363: Top View
Pro 7900 and 9900 Field Repair Guide 10/6/10 Top View Carriage Board (CA11 Sub Board) Print Head Ground Strap CR Slant Adjustment Dial Printer Component, Software Item, LCD Display, Printer Button Carriage Assembly Pictures Page 363.
Page 364 Pro 7900 and 9900 Field Repair Guide 10/6/10 Bottom View Carriage Encoder Ink Mark Sensor Print Head Ground Strap Edge Detector Sen- sor (Edge AD Sen- sor) Printer Component, Software Item, LCD Display, Printer Button Carriage Assembly Pictures Page 364.
Page 365: Carriage Motor Pictures
Pro 7900 and 9900 Field Repair Guide 10/6/10 Carriage Motor Pictures Induced Voltage Value Motor Resistance Value Printer Component, Software Item, LCD Display, Printer Button Carriage Motor Pictures Page 365.
Page 366: Cleaning Unit Pictures
Pro 7900 and 9900 Field Repair Guide 10/6/10 Cleaning Unit Pictures Front View 5 Caps (1 Cap for each Color Pair) Retracted Flushing Box is under here. Carriage Lock Wiper Blade Cleaner Printer Component, Software Item, LCD Display, Printer Button Cleaning Unit Pictures Page 366.
Page 367 Pro 7900 and 9900 Field Repair Guide 10/6/10 Wiper Blade and Flushing Box Flushing Box 1 Wiper Blade (for cleaning 1 color pair at a time). Wiper Blade Cleaner Printer Component, Software Item, LCD Display, Printer Button Cleaning Unit Pictures Page 367.
Page 368: Rear View
Pro 7900 and 9900 Field Repair Guide 10/6/10 Rear View Cap Motor and Encoder Flushing Box Motor and Encoder AID Grid Wire Waste Ink Tube Flushing Box HP Sensor (not shown) Pump Motor and Encoder Cap HP Sensor Pump Valve Assembly HP Sensor Valve Assembly (directs suction to the appropriate Cap(s)).
Page 369 Pro 7900 and 9900 Field Repair Guide 10/6/10 Pump Assembly Pump Motor Valve Assembly (directs suction to the appropriate Cap(s)). Pump Printer Component, Software Item, LCD Display, Printer Button Cleaning Unit Pictures Page 369.
Page 370: Control Panel Pictures
Pro 7900 and 9900 Field Repair Guide 10/6/10 Control Panel Pictures Printer Component, Software Item, LCD Display, Printer Button Control Panel Pictures Page 370.
Page 371: Cutter Assembly Pictures
Pro 7900 and 9900 Field Repair Guide 10/6/10 Cutter Assembly Pictures Cutter Assembly Cutter Home Position Sensor Cutter Blade Cutter Motor and Encoder Printer Component, Software Item, LCD Display, Printer Button Cutter Assembly Pictures Page 371.
Page 372: Damper (Selector) Assembly Pictures
Pro 7900 and 9900 Field Repair Guide 10/6/10 Damper (Selector) Assembly Pictures Top View Printer Component, Software Item, LCD Display, Printer Button Damper (Selector) Assembly Pictures Page 372.
Page 373 Pro 7900 and 9900 Field Repair Guide 10/6/10 Bottom View 5 Damper Assemblies (Included with Damper Assembly) Photo/Matte Black Valve Printer Component, Software Item, LCD Display, Printer Button Damper (Selector) Assembly Pictures Page 373.
Page 374: Pressure Pump Assembly Pictures
Pro 7900 and 9900 Field Repair Guide 10/6/10 Pressure Pump Assembly Pictures Top View Pressure Sensor Tube for the Left Ink Bay Tube for the Right Ink Bay Not Used Air Pump Printer Component, Software Item, LCD Display, Printer Button Pressure Pump Assembly Pictures Page 374.
Page 375 Pro 7900 and 9900 Field Repair Guide 10/6/10 Bottom View Pump Motor Pressure Pump Motor Encoder Printer Component, Software Item, LCD Display, Printer Button Pressure Pump Assembly Pictures Page 375.
Page 376 Pro 7900 and 9900 Field Repair Guide 10/6/10 Pressure Pump View from the top. View from the bottom. 4 Diaphragms This Actuator depresses each Diaphragm in sequence, generating pressurized Printer Component, Software Item, LCD Display, Printer Button Pressure Pump Assembly Pictures Page 376.
Page 377 Pro 7900 and 9900 Field Repair Guide 10/6/10 Pressure Regulator and Release Mechanism Pressure Sensor Flag Pressure Sensor Front View Pressure Release Valve Printer Component, Software Item, LCD Display, Printer Button Pressure Pump Assembly Pictures Page 377.
Page 378: Print Head Pictures
Pro 7900 and 9900 Field Repair Guide 10/6/10 Print Head Pictures 4 Cable Connectors Ink inlets Printer Component, Software Item, LCD Display, Printer Button Print Head Pictures Page 378.
Page 379 Pro 7900 and 9900 Field Repair Guide 10/6/10 7900 and 9900 Head Rank Sticker A Head Rank Sticker with black letters on a white background is intended for a 7900 or 9900 only. A Head Rank Sticker with white letters on a black background is intended for a 7700, 9700, 7900, or 9900.
Page 380 Pro 7900 and 9900 Field Repair Guide 10/6/10 2 Channels (colors) per Nozzle Plate 5 Nozzle Plates Note: the Nozzle Plates are very fragile and will be damaged with a minimum of force. Printer Component, Software Item, LCD Display, Printer Button Print Head Pictures Page 380.
Page 381: Sensor (Carriage Encoder) Pictures
Pro 7900 and 9900 Field Repair Guide 10/6/10 Sensor (Carriage Encoder) Pictures Printer Component, Software Item, LCD Display, Printer Button Sensor (Carriage Encoder) Pictures Page 381.
Page 382: Sensor (Edge Detector) Picture
Pro 7900 and 9900 Field Repair Guide 10/6/10 Sensor (Edge Detector) Picture Printer Component, Software Item, LCD Display, Printer Button Sensor (Edge Detector) Picture Page 382.
Page 383: Sensor (Ink Mark) Picture
Pro 7900 and 9900 Field Repair Guide 10/6/10 Sensor (Ink Mark) Picture Printer Component, Software Item, LCD Display, Printer Button Sensor (Ink Mark) Picture Page 383.
Page 384: Sensor (Platen Gap) Picture
Pro 7900 and 9900 Field Repair Guide 10/6/10 Sensor (Platen Gap) Picture Printer Component, Software Item, LCD Display, Printer Button Sensor (Platen Gap) Picture Page 384.
Page 385: Wiper Blade Assembly Picture
Pro 7900 and 9900 Field Repair Guide 10/6/10 Wiper Blade Assembly Picture Wiper Blade Printer Component, Software Item, LCD Display, Printer Button Wiper Blade Assembly Picture Page 385.
Page 386: Reference
Pro 7900 and 9900 Field Repair Guide 10/6/10 Reference Printer Component, Software Item, LCD Display, Printer Button Page 386.
Page 387: Accessories List
Pro 7900 and 9900 Field Repair Guide 10/6/10 Accessories List Accessories Sales Part Number Description C12C815331 Replacement l Cutting Blade C12C811241 Replacement Roll Media Adapters (qty. 2) C12C890191 Maintenance Tank C12C815321 Auto Take Up Reel Assembly SPECTRO24 24” SpectroProofer SPECTRO24UV 24”...
Page 388: Carriage Release (Auto)
Pro 7900 and 9900 Field Repair Guide 10/6/10 Carriage Release (Auto) Note: Releasing the Carriage Mechanism is a delicate operation. It is extremely easy to damage the Print Head if a mistake is made. Auto Carriage Release Method 1. Enter Self Testing mode: Down, Right,...
Page 389: Carriage Release (Manual)
Pro 7900 and 9900 Field Repair Guide 10/6/10 Carriage Release (Manual) Note: Releasing the Carriage Mechanism is a delicate operation. It is extremely easy to damage the Print Head if a mistake is made. Manual Carriage Release Method 1. Unplug the Printer. 2.
Page 390 Pro 7900 and 9900 Field Repair Guide 10/6/10 3. Rotate the White Gear counter clockwise to unlock the Carriage. Condition 1 - Carriage Locked. Rotate the White Gear counter clockwise until the Carriage is un-locked. Condition 2 - Carriage Locked. Printer Component, Software Item, LCD Display,...
Page 391 Pro 7900 and 9900 Field Repair Guide 10/6/10 Manual Carriage Lock 1. Center the Carriage Assembly over the Cap Assembly. Center the Carriage Assembly over the Cap Assembly. Printer Component, Software Item, LCD Display, Printer Button Carriage Release (Manual) Page 391.
Page 392 Pro 7900 and 9900 Field Repair Guide 10/6/10 2. Rotate the White Gear clockwise and lock the Carriage Mechanism. 1. Center the Carriage Stop over the Carriage Lock. 2. Rotate the White Gear CW. 3. Guide the Carriage Lock into the Carriage Stop. 4.
Page 393: Cleaning Cycles (Types And Uses)
Pro 7900 and 9900 Field Repair Guide 10/6/10 Cleaning Cycles (Types and Uses) About All Cleaning Cycles The Ink System is tuned to the gentle ink flow demand generated by printing. All Cleaning cycles employ a much stronger ink demand than printing. It is not unusual for the Ink System to “pull back”...
Page 394 Pro 7900 and 9900 Field Repair Guide 10/6/10 Color Pair Cleaning: User Menu/MAINTENANCE/CLEANING/CLEAN FOR EACH COLOR Color pair cleaning is the cleaning method with the most efficient use of ink. How to use effectively: 1. Print an nozzle check, and identify the color pair with the most missing nozzles. 2.
Page 395: Color Order
Pro 7900 and 9900 Field Repair Guide 10/6/10 Color Order Color Order For installed Cartridges (Listed Left to Right) 1. Cyan 2. Orange 3. Yellow 4. Light Cyan 5. Matte Black 6. Photo Black 7. Vivid Magenta 8. Light Black 9.
Page 396 Pro 7900 and 9900 Field Repair Guide 10/6/10 Color Pairs on the Print Head (Listed Left to Right) 1. Cyan and Vivid Magenta 2. Photo Black (Matte Black) and Light Black 3. Orange and Green 4. Light Light Black and Yellow O / G LLK / Y VLM / LC C / VM PK&MK / LK...
Page 397: Connectors / Wiring
Pro 7900 and 9900 Field Repair Guide 10/6/10 Connectors / Wiring Main Board Connectors Connector #: Connected To: Pins: Power Supply CN301 Suction Fan Suction Fan Suction Fan CN10 Ink System Pressure Motor CN14 Ink System Pressure Motor Encoder CN19 Control Panel CN20 Pressure Sensor...
Page 398 Pro 7900 and 9900 Field Repair Guide 10/6/10 Connector #: Connected To: Pins: CN200 Sub Board B CN200 CN201 Sub Board B CN201 CN202 Sub Board B CN202 CN300 Sub Board C CN300 CN301 Sub Board C CN301 CN400 Right Ink Bay Sub Board D CN400 CN500 Left Ink Bay Sub Board D CN400 CN501...
Page 399 Pro 7900 and 9900 Field Repair Guide 10/6/10 Connector #: Connected To: Pins: CN216 Suction Valve Home Position Sensor CN217 Cap Home Position Sensor CN218 Flushing Box (Wiper) Home Position Sensor CN219 Rewind Motor Encoder CN220 Rewind Motor CN221 Flushing Box / Wiper Motor CN222 Flushing Box / Wiper Encoder CN223...
Page 400 Pro 7900 and 9900 Field Repair Guide 10/6/10 Connector #: Connected To: Pins: CN305 Left Maintenance Tank (9900 only) CN309 Cutter Motor CN310 Pinch Roller Release Home Position Sensor CN311 Cutter Motor Encoder Carriage Board (CA11 Sub Board) Connector #: Connected To: Pins: CN100...
Page 401: Power Supply
Pro 7900 and 9900 Field Repair Guide 10/6/10 Power Supply Connector #: Connected To: Pins: CN001 AC Power CN301 Main Board CN1 Printer Component, Software Item, LCD Display, Printer Button Connectors / Wiring Page 401.
Page 402: Consumable/Service Parts List
Pro 7900 and 9900 Field Repair Guide 10/6/10 Consumable/Service Parts List Ink is intended as a service tool (Warranty Service Only), and is not for sale. Use the Service Part Number, and claim it on a warranty form. Service Part # Sales Part # Ink Cartridges ECCC Cost after 40% discount WAT642100...
Page 403 Pro 7900 and 9900 Field Repair Guide 10/6/10 Service Part # Sales Part # Paper Type ECCC Cost after 40% discount WAS041393 S041393 Premium Semimatte Photo Paper(170) 24” x 100” roll $69.96 WAS041395 S041395 Premium Semimatte Photo Paper(170) 44” x 100” roll $123.00 WAS041603 S041603...
Page 404: Cover Sensor (Front) Bypass Procedure
Pro 7900 and 9900 Field Repair Guide 10/6/10 Cover Sensor (Front) Bypass Procedure Wedge 2 Cover Sensors with paper to defeat the Front Cover Sensors. Printer Component, Software Item, LCD Display, Printer Button Cover Sensor (Front) Bypass Procedure Page 404.
Page 405: Cover Sensor (Ink) Bypass Procedure
Pro 7900 and 9900 Field Repair Guide 10/6/10 Cover Sensor (Ink) Bypass Procedure Lever Up = Ink Door Closed Left Ink Door Sensor Lever Down = Ink Door Open Printer Component, Software Item, LCD Display, Printer Button Cover Sensor (Ink) Bypass Procedure Page 405.
Page 406: Ctp(7900) (Computer To Plate) Explanation
CTP(7900) (Computer to Plate) Explanation What is the 7900CTP The Epson 7900CTP system is designed to create Press Plates for offset printing. It requires the use of Epson Directplate Aluminum Plates. The Epson Directplate Aluminum Plates have a coating that accept ink until they are cured (heated).
Page 407 Pro 7900 and 9900 Field Repair Guide The PCU is a whole unit exchange. Directions on how to test/diagnosis the PCU are in the Troubleshooting Section of the Field Repair Guide. Component Pictures Thermax Strips Plate Guide Teflon Tape Strip Printer Component, Software Item, LCD Display,...
Page 408 Pro 7900 and 9900 Field Repair Guide Plate Curing Unit (PCU) Printer Component, Software Item, LCD Display, Printer Button CTP(7900) (Computer to Plate) Explanation Page 408.
Page 409 Pro 7900 and 9900 Field Repair Guide Optional Plate Guide Picture Optional Plate Guide for use with large Plate sizes. Printer Component, Software Item, LCD Display, Printer Button CTP(7900) (Computer to Plate) Explanation Page 409.
Page 410: Firmware History (Ethernet)
Pro 7900 and 9900 Field Repair Guide 10/6/10 Firmware History (Ethernet) 7700 and 9700 Current Ethernet Firmware Ver. 1.05 Firmware File Name: lpe2105.efu 1. Improves Ethernet functionality. Printer Component, Software Item, LCD Display, Printer Button Firmware History (Ethernet) Page 410.
Page 411: Firmware History (Printer) (7900)
2005 ExampleSN00157 SP7800 DAY YEAR MONTH 2005 Example: YEAR MONTH Stylus Pro 7900 Current Firmware Ver. HN003A9.upg Release date: 09/03/10 1. Improved support for the “Job Cancel Command”. 2. SpectroProofer functionality was improved. Printer Component, Software Item, LCD Display, Printer Button Firmware History (Printer) (7900) Page 411.
Page 412 4. Improve firmware support for the Ink Selector Assembly. Stylus Pro 7900 Firmware Ver. HN0239A.upg Release date: 10/23/09 1. The Auto Uni-Directional adjustment was improved. Stylus Pro 7900 Current Firmware Ver. HN01699.upg Printer Component, Software Item, LCD Display, Printer Button Firmware History (Printer) (7900) Page 412.
Page 413 3. The Carriage Life Counter value has been extended (2x). 4. Sleep mode “awakening” issues have been improved. Stylus Pro 7900 Firmware Ver. HN02995.upg Release date: 05/29/09 1. Compatible with the new Main Board configuration, and downward compatible with the old Main Board.
Page 414 Pro 7900 and 9900 Field Repair Guide 10/6/10 Release date: 02/16/09 1. Disables AID Nozzle Check when the printer is turned on. All other AID functions are retained. Stylus Pro 7900 Firmware Ver. HN0148A.upg Release date: 11/14/08 1. Initial Release Printer Component,...
Page 415: Firmware History (Printer) (9900)
Pro 7900 and 9900 Field Repair Guide 10/6/10 Firmware History (Printer) (9900) Epson firmware version is The values are represented as: represented in Model and the Release Date. Hexadecimal This chart explains the meaning of = Decimal SN00458 Example the firmware version characters.
Page 416 Pro 7900 and 9900 Field Repair Guide 10/6/10 Stylus Pro 9900 Firmware Ver. HW028A4.upg Release date: 04/28/10 1. Improved support for the “Job Cancel Command” used by RIPS. 2. AID functionality was improved. 3. Changed the AID missing nozzle message to “Clogged Nozzles Detected Cleaning Recommended”.
Page 417 Pro 7900 and 9900 Field Repair Guide 10/6/10 Stylus Pro 9900 Firmware Ver. HW0239C.upg Release date: 12/23/09 1. The operation of the SpectroProofer in conjunction with the Take Up Reel was improved. Note: This firmware version is for the 9900 only because there is no Take Up Reel for the 7900. Stylus Pro 9900 Firmware Ver.
Page 418 Pro 7900 and 9900 Field Repair Guide 10/6/10 Stylus Pro 9900 Firmware Ver. HW02995.upg Release date: 05/29/09 1. Compatible with the new Main Board configuration, and downward compatible with the old Main Board. The new Main Board uses a new Flash ROM chip. This release of firmware is necessary for that reason.
Page 419: Firmware Update Procedure Using Fwupdate.exe
2.1 The Printer will display UPDATING FIRMWARE. 2.2 The Printer will display FIRMWARE UPDATE COMPLETE. 2.3 The Printer will display ENERGYSTAR. 2.4 The Printer will re-initialize and display EPSON. 2.5 The Printer will display PRESS PAUSE BUTTON. 2.6 The Printer will display PLEASE WAIT.
Page 420: Ink Draining Procedure
Pro 7900 and 9900 Field Repair Guide 10/6/10 Ink Draining Procedure Note: This procedure requires 11 Draining Cartridges Part # 1500853 (order 11 of this part # to receive 11 Draining Cartridges) Note: This procedure requires a new Maintenance Tank Sales Part # C12C890191 Note: Each step of this procedure must be followed exactly for the procedure to work.
Page 421 Pro 7900 and 9900 Field Repair Guide 10/6/10 5.1 Turn off the Printer. 5.2 Remove 11 Draining Cartridges. Note: The Ink Draining procedure uses air pressure to force the Ink out of the Ink Lines through the Print Head. Because of the nature of the hardware the ink in the Lines is replaced by pressurized air.
Page 422: Media Feed Step (About)
Media Feed Step (about) Paper Feed Adjustment (990.6mm service adjustment)(calibrates the paper feed mechanism) Media Feed Tables (media feed offset for each Epson media type) LFP Remote Panel 2 media feed adjustment (writes the offset value to the printer modifying the Media Feed Table value for the specified media.
Page 423: Glossary
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.
Page 424 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.
Page 425 Pro 7900 and 9900 Field Repair Guide 10/6/10 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 CR Slant.) The head is rotated until it is ver- tically linear.
Page 426 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...
Page 427 Pro 7900 and 9900 Field Repair Guide 10/6/10 Micro Weave: The way an Epson Ink Jet printer interlaces (weaves) bands of and image during printing. Moiré Pattern: A repetitive pattern, within an image, which is not intended. I can appear like a pais- ley or herringbone pattern.
Page 428 Pro 7900 and 9900 Field Repair Guide 10/6/10 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 heat to another surface.
Page 429: Prime, On Or Off
Pro 7900 and 9900 Field Repair Guide 10/6/10 Prime, On or Off Prime, Initial Fill, and Charge mean the same thing. They all refer to filling the Ink System with ink. Controlling the Prime function requires Setting, or Resetting the Init.Fill Flag. Init.Fill: Reset = The Printer is already primed.
Page 430: Revision History
Pro 7900 and 9900 Field Repair Guide 10/6/10 Revision History October 6, 2010 1. The Firmware History chapters were updated. 2. A chapter titled PCU (Plate Curing Unit) Troubleshooting was added to the Troubleshooting Section. 3. A chapter titled CTP Alignment was added to the Adjustment Section. 4.
Page 431 Address. 2. A chapter titled Remote Panel was added to the Utility Section. 3. A chapter titled Epson Net Config was added to the Utility Section. 4. A chapter titled Service Procedure (recommended) was added to the Reference Section. 5. A chapter titled Media Feed Step (about) was added to the Reference Section.
Page 432 1. The ServProg.exe chapter located in the Utility section was modified to reflect the change in utility security policy. Servprog.exe is no longer ASI enabled, and is available for download on Epson Insider. November 03, 2009 1. The Printer Error Codes (Maintenance) chapter was updated.
Page 433 Pro 7900 and 9900 Field Repair Guide 10/6/10 June 18, 2009 1. The Printer Error Codes (Service) chapter was updated to reflect new data on the 1497 Error. 2. The Board (Main) installation chapter was modified to reflect new information on Generic Parameter installation.
Page 434 Pro 7900 and 9900 Field Repair Guide 10/6/10 10. A chapter titled Option Error Codes was added to the Troubleshooting section. 11. A chapter titled PF Slant Adjustment was added to the Adjustment section. 12. A chapter titled Ink Draining Procedure was added to the Reference section. 13.
Page 435 Pro 7900 and 9900 Field Repair Guide 10/6/10 9. The Error Code chapter was updated to reflect new information regarding the 2010 error code. February 24, 2009 1. The Firmware History chapters were updated. 2. Multiple Component Replacement chapters were added. 3.
Page 436: Sensors, Motors, Solenoids, And Fans
Pro 7900 and 9900 Field Repair Guide 10/6/10 Sensors, Motors, Solenoids, and Fans Home Position Sensors: Carriage HP Sensor (Detects the Home Position of the Carriage Mechanism) Platen Gap HP Sensor (Detects platen gap home posi- tion) Pump Valve HP Sensor (Detects the position of the Suction Valves) Cap Home Position Sensor (detects the home position of the Cap Assembly)
Page 437 Pro 7900 and 9900 Field Repair Guide 10/6/10 Encoders: Carriage Encoder (CR Encoder)(Carriage position and dot timing) Paper Feed Encoder (PF Encoder) (Paper advance timing). Pressure Pump Encoder (Detects the rotation of the Pressure Pump Motors) Platen Gap Encoder (Detects the rotation of the Platen Gap Motor) Pinch Roller Encoder (Detects the rotation of the Pinch Roller Motor)
Page 438 Pro 7900 and 9900 Field Repair Guide 10/6/10 Temperature Sensors: Head Temperature Sensor (Detects the temperature of the Head Driver Heat Sink) Head Driver Temperature Sensor (Detects the temper- ature of the Print Head Nozzle Plate) Motors Carriage Motor: Moves the Carriage Assembly. Paper Feed Motor: Moves the Paper Feed Roller Pump Motor: (Pump Motor) Runs the Cleaning Pump, switches the Pump Valves...
Page 439: Service Procedure (Recommended)
Pro 7900 and 9900 Field Repair Guide 10/6/10 Service Procedure (recommended) 1. Observe the customer’s service issue. 2. Clean or replace the Cleaning Station 2.1 Perform the Clear Counter [When replacing Pump Motor]. 3. Clean or replace the Wiper Blade, and Wiper Blade Cleaner. 3.1.1 Clean the Print Head Nozzle Plate if necessary.
Page 440 Pro 7900 and 9900 Field Repair Guide 10/6/10 13. Perform the Gap Adjust: Auto Bi-D Adjustment. 14. Perform the Gap Adjust: Auto Uni-D Adjustment. Printer Component, Software Item, LCD Display, Printer Button Service Procedure (recommended) Page 440.
Page 441: Service Tools
Pro 7900 and 9900 Field Repair Guide 10/6/10 Service Tools Service Part Number Description 1047746 1000mm Scale (meter stick) 1033657 Grease G-45 1480655 Grease G-71 1409257 Grease G-74 1516265 Grease G-84 1500853 Draining Cartridge (qty-1) 5 required to drain the Printer 1500854 Cleaning Cartridge (qty-1) 5 required to clean the Printer 1507278...
Page 442: Stress Test (Test Image)
There is always some horizontal and vertical banding. Use: 1. Use it to compare Non-Epson Drivers against the Epson Driver. 2. Use it to look for image quality variances across the entire printable area of the printer. Is the vertical banding consistent across the entire image?
Page 443: Utilities
Pro 7900 and 9900 Field Repair Guide 10/6/10 Utilities Printer Component, Software Item, LCD Display, Printer Button Page 443.
Page 444: Epson Net Config 2.2B
10/6/10 Epson Net Config 2.2b Note: Epson Net Config is a user utility that allows the user to upgrade an Epson Printer’s ethernet firmware, and configure TCPIP settings. Additionally it will display all of the Epson Printers on the same network as the host computer.
Page 445: Main Screen
Pro 7900 and 9900 Field Repair Guide 10/6/10 main screen. Epson Net Config Displays all of the Epson Printers on the network. Printer Component, Software Item, LCD Display, Printer Button Epson Net Config 2.2b Page 445.
Page 446 Pro 7900 and 9900 Field Repair Guide 10/6/10 5. To Update a Printer’s Ethernet Firmware. Click on Tool: Firmware Update to start the Update Wizard. Printer Component, Software Item, LCD Display, Printer Button Epson Net Config 2.2b Page 446.
Page 447 Pro 7900 and 9900 Field Repair Guide 10/6/10 6. To Configure a Printer’s TCPIP settings. Double Click on the Printer to be configured. Printer Component, Software Item, LCD Display, Printer Button Epson Net Config 2.2b Page 447.
Page 448 Pro 7900 and 9900 Field Repair Guide 10/6/10 7. To Configure a Printer’s TCPIP settings (continued) Click on Basic to access the TCPIP configuration screen. Printer Component, Software Item, LCD Display, Printer Button Epson Net Config 2.2b Page 448.
Page 449: Fwupdate.exe
Pro 7900 and 9900 Field Repair Guide 10/6/10 FWUpdate.exe Note: FWUpdate.exe is used to copy Firmware to the Printer and works without the printer driver being installed. 1. Double Click on the utility Icon. FWUpdate.exe Double Click on this Icon. 2.
Page 450 Pro 7900 and 9900 Field Repair Guide 10/6/10 3. Choose a Port/Printer. 1. Click on the Down Arrow to open up the list of Ports. 2. Select the Port that is connected to the Printer that requires firm- 4. Click on and navigate to the to be uploaded to the Printer.
Page 451 Pro 7900 and 9900 Field Repair Guide 10/6/10 5. Select the correct Firmware File 1. Select the correct Firmware File. 2. Click on 6. Click on to upload the to the Printer. Send Firmware Click on Send to upload the Firmware. Printer Component, Software Item, LCD Display,...
Page 452 Pro 7900 and 9900 Field Repair Guide 10/6/10 7. The utility will display this, click on Click on Printer Component, Software Item, LCD Display, Printer Button FWUpdate.exe Page 452.
Page 453 Pro 7900 and 9900 Field Repair Guide 10/6/10 NV-RAM BACKUP UTILITY Note: The NV-RAM BACKUP UTILITY “backs up” and restores the unique data that is on each Printer’s Main Board, and should be transferred to a new Main Board. Uses for the NV-RAM BACKUP UTILITY.
Page 454 Pro 7900 and 9900 Field Repair Guide 10/6/10 2.5 If there is no change in the Printer’s symptom, restore the Printer’s unique NVRAM Data. 2.6 If there is change in the Printer’s symptom, leave the Generic NVRAM Data on the Printer, and follow the procedure documented in the Main Board Installation Chapter for using Generic NVRAM Data (Generic...
Page 455 Pro 7900 and 9900 Field Repair Guide 10/6/10 Enabling NVRAM Viewer 1. Open with a text editor ( used for this example). ServProg.ini Note Pad Open ServProg.ini with a text editor. Printer Component, Software Item, LCD Display, Printer Button NV-RAM BACKUP UTILITY Page 455.
Page 456 Pro 7900 and 9900 Field Repair Guide 10/6/10 2. Modify ServProg.in 1. Change this to 1. 2. Save and close ServProg.ini. Printer Component, Software Item, LCD Display, Printer Button NV-RAM BACKUP UTILITY Page 456.
Page 457: Nvram Backup
Pro 7900 and 9900 Field Repair Guide 10/6/10 NVRAM Backup 1. From Servprog.exe for the 7900 and 9900, select NV-RAM BACKUP UTILITY. Click on NV-RAM BACKUP UTILITY. Printer Component, Software Item, LCD Display, Printer Button NV-RAM BACKUP UTILITY Page 457.
Page 458 Pro 7900 and 9900 Field Repair Guide 10/6/10 2. To “back up” NVRAM Data. 1. Start the Printer in NVRAM Data Backup Mode: (Hold the Up, Down, Left, Right buttons and turn on the power. The Printer will display Download). 2.
Page 459 Pro 7900 and 9900 Field Repair Guide 10/6/10 5. The Printer’s Serial # will be displayed here. 6. Click on Save. 7. The utility will enter the date and serial number for the default file name. Change the name if desired. 8.
Page 460 Pro 7900 and 9900 Field Repair Guide 10/6/10 10. If enabled, NVRAM Viewer will display this screen. Printer Component, Software Item, LCD Display, Printer Button NV-RAM BACKUP UTILITY Page 460.
Page 461 Pro 7900 and 9900 Field Repair Guide 10/6/10 NVRAM Restore 1. From Servprog.exe for the 7900 and 9900, select NV-RAM BACKUP UTILITY. Click on NV-RAM BACKUP UTILITY. Printer Component, Software Item, LCD Display, Printer Button NV-RAM BACKUP UTILITY Page 461.
Page 462 Pro 7900 and 9900 Field Repair Guide 10/6/10 2. To “restore” NVRAM Data. 1. Start the Printer in NVRAM Data Restore Mode: (Disengage 11 Ink Cartridges, remove the 1 (or 2) Main- tenance Tank(s), hold the Up, Down, Left, and Right buttons and turn on the Printer).
Page 463 Pro 7900 and 9900 Field Repair Guide 10/6/10 5. The utility will display the Printer’s serial #. 7. The utility will display this while writing to the Printer. 8. Click on to finish. 6. Click on Write to begin. Note: After the utility displays “complete”, wait an additional 20 seconds before turning off the Printer.
Page 464: Remote Panel 2 (Epson Lfp)
Pro 7900 and 9900 Field Repair Guide 10/6/10 Remote Panel 2 (Epson LFP) Note: Remote Panel 2 is a user utility that allows the user to upgrade firmware, adjust paper feed, monitor printer status, and setup custom paper. 1. Install Remote Panel 2 2.
Page 465 Custom Paper Setup locations. Facilitates the naming and setup of custom paper types. These custom media types are accessed from the control panel on the printer. Printer Component, Software Item, LCD Display, Printer Button Remote Panel 2 (Epson LFP) Page 465.
Page 466: Servprog.exe
7900 and 9900 Field Repair Guide 10/6/10 Servprog.exe Note: Servprog.exe is no longer an ASI enabled service utility. It is available for download on Epson Insider. Note: Servprog.exe is the utility that enables counter resets, and some electronic alignments for the 7900 and 9900.
Page 467 7900 and 9900 Field Repair Guide 10/6/10 3. Double Click on Servprog.exe to start the utility. 4. Click on to accept the license agreement. Click on Ok. Printer Component, Software Item, LCD Display, Printer Button Servprog.exe Page 467.
Page 468 7900 and 9900 Field Repair Guide 10/6/10 5. (Optional but recommended) Click on to download the Printers NVRAM data. 1. Click on to open the NVRAM Click on to open Servprog.exe. BACKUP UTILITY. (See the next page). 2. Select the correct Printer. 3.
Page 469 7900 and 9900 Field Repair Guide 10/6/10 Servprog.exe main menu. Opens the NVRAM Backup Utility. Opens the individ- ual adjustment Opens a firmware update menu. Opens a menu for sending a PRN print job to the Printer. Opens the counter reset menu.

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Stylus pro 9900

Epson Stylus pro 7900 Repair Manual

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Component Replacement

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