Hi
Update on progress....
I followed the instructions in the manual to dismantle the printer. The instructions were good for removing covers, duplex-er, scanner, etc. But when it came to removing the bottom tray for the print mechanics, there were no instructions, apart from how to remove the screw from behind the purge unit. However, it was simple enough to remove half a dozen screws around the outside of printer mechanism - it was fairly obvious which ones need to be removed, and would be screwing into the bottom tray. I hesitated because there were no instructions, but I came that far, so I wasn't stopping there...
Now I didn't take photos, sorry, but there was enough ink everywhere already - didn't need extra on the camera. There are 2 smaller black tubes going in, and 2 larger clear tubes going out , of the purge unit. I found by removing and testing these tubes , I could find what was blocked. I poked and cleaned (Windex) best I could. I completely removed the black tubes, cleaned them, and then also poked and cleaned into the purge unit as best I could, from both inlet and outlet sides. I used a pin, a syringe, and Windex water, and ear bud / cotton tipped cleaners. There are two sides in the purge unit, one for the black and other for colour. The black path was pretty well gummed by ink in most areas of the piping and inlet / outlet of the purge unit.
Now I though that I had done everything that I could, and was ready to put it back together. I wasn't keen to put it back together though, and find out I didn't do a good enough job of cleaning, particularly in the purge unit itself. The meaning pull it all apart again. No thanks. I decided to do a manual test of the purge unit. I filled the black rubber trays which sit under the print head, with water, and I manually operated the purge unit by rotating the plastic gear. Within a couple of turns I could see one of the outlet tubes dribbling liquid, but no the other. LUCKY I TESTED. The black side was still clogged. I cleaned again and finally the black side operated as well. Thereafter, I also found that by using a syringe (without needle) on the outlet side, that you can clean through the purge unit, by sucking and pushing liquid through.
While the printer was apart I also cleaned the absorber pads. I removed them and cleaned under running hot water for 5 mins or so, until the run off was mostly clear, then "rolled" the water out of them, so they were as dry as possible. They didn't really swell or anything, but I didn't soak them wither, just a 5-10 min wash. Chucked them back in, no worries.
My greatest fear was putting it wall back together and then either not working, or one of the those error codes. however, all went well, printer worked when reassembled. The original print head did not print a good test page, but the new print head worked fine. I will clean the old print head again to see if its going or not -good to have a spare I suppose.
I will now Windex the rubber "under the print head pads" every cartridge change - hopefully this will stop the problem reoccurring.
So problem solved. I wanted to sincerely THANK YOU very much ghwellsjr, and other co-contributors, for your assistance.
I fixed my printer for $3.50 myself, instead of forking out another $185-$250 for a tech to do it, or having to buy a new printer. I've learned something, and I'm proud for being able to do it myself - but again, it would have not been possible with out your assistance. Thanks again....