Epson 4000 - Stylus Pro Color Inkjet Printer User manual

Stylus Pro 4000 Field Repair Guide 4/28/05

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

Table of Contents

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

Control Panel Map - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5

Component Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - 12

Carriage Removal Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - 13

Cartridge Release Lever Repair - - - - - - - - - - - - - - - - - - - - - - - - - 16

Cartridge Release Sensor Repair - - - - - - - - - - - - - - - - - - - - - - - - 17

Damper Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18

Ink Bay Removal (Left) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26

Ink Bay Removal (Right) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 31

Input Roller Assembly, Disassembly - - - - - - - - - - - - - - - - - - - - - - 36

Input Roller Assembly, Re-assembly - - - - - - - - - - - - - - - - - - - - - - 41

Input Roller Assembly Removal - - - - - - - - - - - - - - - - - - - - - - - - - 46

Main Board Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - 51

Paper Exit Roller Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58

Plastic Roller Upgrade - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 61

Print Head Replacement Procedure - - - - - - - - - - - - - - - - - - - - - - - 80

Pump and Cap Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - 87

Pump and Cap Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 93

Side Cover Removal (Left) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 98

Side Cover Removal (Right) - - - - - - - - - - - - - - - - - - - - - - - - - - - 99

Top Cover Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 101

Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 102

Error Codes (Maintenance) - - - - - - - - - - - - - - - - - - - - - - - - - - - 103

Error Codes (Service) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -104

00000088 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -107

00000101 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -108

00000103 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -109

00000105 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -110

00010000 - 00010003 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -111

Color Shift - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 112

Command Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -113

Communication Errors PC - - - - - - - - - - - - - - - - - - - - - - - - - - - - 114

Cover Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -116

Stylus Pro 4000 Field Repair Guide 4/28/05

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

Drop of Ink - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 117

Grainy or Ghosting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 118

Horizontal Banding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 119

Missing Nozzle Diagnosis and Repair - - - - - - - - - - - - - - - - - - - - - - 121

Paper Jam Errors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 124

Paper Not Cut - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -125

Reload Paper - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 126

Random Nozzles - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 128

Scratch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -129

Set Ink Cartridges - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 130

Set Ink Lever - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 131

Smudge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 132

Smear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -133

Vertical Banding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -134

Wrong Ink Cartridge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 135

Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 136

1000mm Feed Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - 137

Auto Bi-D Adjustment [PG 1.2] - - - - - - - - - - - - - - - - - - - - - - - - - 138

Auto Uni-D Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 139

Carriage Timing Belt Tension Adjustment - - - - - - - - - - - - - - - - - - - - 140

Change Model Name - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 141

Check Nozzle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 143

Check Platen Gap - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 144

Cleaning / Charging (Priming) - - - - - - - - - - - - - - - - - - - - - - - - - - 145

Clear PF Micro Feed Adjustment [Bi-D] - - - - - - - - - - - - - - - - - - - - - 146

Copy Bi-D Variables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 147

Copy Uni-D Variables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -148

CR Encoder Sensor Position Adjustment - - - - - - - - - - - - - - - - - - - -149

Head Rank ID - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 150

Initialize Main Board - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -151

Ink Discharge. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 152

Multi Sensor Adjustment for Auto Nozzle Check - - - - - - - - - - - - - - - - 153

Multi Sensor Auto PF Adjustment - - - - - - - - - - - - - - - - - - - - - - - - 154

Multi Sensor Level Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - 155

Multi Sensor Position Adjustment - - - - - - - - - - - - - - - - - - - - - - - - 156

Nozzle Bi-D Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - -158

Paper Feed Timing Belt Adjustment - - - - - - - - - - - - - - - - - - - - - - - 159

Stylus Pro 4000 Field Repair Guide 4/28/05

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

Paper Thickness Sensor Adjustment - - - - - - - - - - - - - - - - - - - - - -161

Platen Gap Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - -164

Platen Position Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - 167

Print Head Slant Adjustment (CR) - - - - - - - - - - - - - - - - - - - - - - - - 169

Print Head Slant Adjustment (PF) - - - - - - - - - - - - - - - - - - - - - - - - 172

RearAD Sensor Calibration - - - - - - - - - - - - - - - - - - - - - - - - - - -175

Reset ASF Counter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -176

Reset Paper Ejection Switching - - - - - - - - - - - - - - - - - - - - - - - - - 177

Reset PF Motor Counter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 178

Reset When Cleaning Unit Change - - - - - - - - - - - - - - - - - - - - - - - 179

Reset When CR Unit Change - - - - - - - - - - - - - - - - - - - - - - - - - - 180

Reset When Cutter Change - - - - - - - - - - - - - - - - - - - - - - - - - - -181

Reset When Print Head Change - - - - - - - - - - - - - - - - - - - - - - - - -182

RTC & USB & IEEE1394ID Adjustment - - - - - - - - - - - - - - - - - - - - - 183

Skew Check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -187

T&B&S [Cut Sheet] Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - 188

T&B&S [Roll Paper] Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - 189

Reference - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 190

Accessories List - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -191

Cleaning Fluid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 192

Color Order on the Print Head - - - - - - - - - - - - - - - - - - - - - - - - - - 193

Consumable/Service Parts List - - - - - - - - - - - - - - - - - - - - - - - - - 194

Firmware History - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -196

Firmware Update Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - 201

Glossary - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -202

Ink Draining Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 208

Ink Tube Order - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -209

Prime, On or Off - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 210

Revision History - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -211

Sensors, Motors, Solenoids, and Fans - - - - - - - - - - - - - - - - - - - - - 212

Service Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 214

Service Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -216

Stress Test (Test Image) - - - - - - - - - - - - - - - - - - - - - - - - - - - - -217

User Nozzle Check Order - - - - - - - - - - - - - - - - - - - - - - - - - - - - 218

Utilities - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 219

Adjustment Wizard2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -220

Stylus Pro 4000 Field Repair Guide 4/28/05

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

Epson Paper Feed Adjuster - - - - - - - - - - - - - - - - - - - - - - - - - - - 223

NVRAM.EXE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 226

PRNprint.exe - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 229

Stylus Pro 4000 Field Repair Guide 4/28/05

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

Control Panel Map

Hold for 3 seconds to reset/clear

Printer

Hold for 3 seconds to cut

roll media

Hold for 3 seconds to clean

Power

Pause

Roll / SheetSheet

Roll Auto Cut

Roll Auto Cut Off Ink Quantity Maintenance Tank Level

Media Feed

Status

Paper

Out

Ink Out

Paused

Hold the 4 Arrow Buttons and Power on for F/W Down-

load Mode.

Stylus Pro 4000 Field Repair Guide 4/28/05

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

1. PRINTER SETUP.

PLATEN GAP: *STANDARD, NARROW, WIDER,

WIDE

PAGE LINE: *ON, OFF

INTERFACE: *AUTO, USB, IEEE1394, OPTION

CODE PAGE: *PC437, PC850,

PAPER MARGIN: *T/B 15MM, 15MM, 3MM

PPR SIZE CHK: *ON, OFF

PPR ALIGN CHK: *ON, OFF

TIME OUT: *OFF, 30SEC, 60SEC, 180SEC, 300SEC

CUTTER ADJ: EXEC

REFRESH MRGN: *ON, OFF

SHEET SIZE CHK: *ON, OFF

AUTO NZL CK: *ON, OFF

AUTO CLEANING: *ON, OFF

QUIET CUT: *OFF, ON

INIT SETTINGS: EXEC

2. TEST PRINT.

NOZZLE CHECK: PRINT

STATUS CHECK: PRINT

JOB INFO: PRINT

CUSTOM PAPER: PRINT

4. CUSTOM PAPER.

PAPER NUMBER: *STANDARD, NO. (1-10)

Platen Gap: Standard, Narrow, Wide, Wider

Thickness Pat: Print

Cut Method: *Standard, Thick (Fast, Slow), Thin

Paper

PPR Feed Adj: (n.nn)%

Eject Roller: *Auto, Sheet, Roll Curled, Roll Normal

Drying Time: (n.n)sec

Suction: *Standard, -4, -3, -2, -1

M/W ADJ: *Standard,1 , 2

3. PRINTER STATUS.

VERSION: (CURRENT FIRMWARE)

PRINTABLE PG: (FOR EACH COLOR)MK

(nnnnnn)PG

INK LEFT: (FOR EACH COLOR)MK E*****F

MAINT TANK: E*****F

USAGE COUNT: INK (nnnn.n)ML, PPR

(nnnn.n)CM

USE COUNT CLR: EXEC

JOB HISTORY: N0.(N) I:(nnn)ML, P:(nnn)CM

JOB HISTORY CLR: EXEC

TOTAL PRINTS: (nnnn)

User Menu: Press the Menu button when

the printer displays Ready

Stylus Pro 4000 Field Repair Guide 4/28/05

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

Maintenance Mode 1: Press and hold the Pause button and turn on the Printers

HEX DUMP: PRINT EXEC (In this mode, the printer prints hexadecimal values received)

LANGUAGE: *ENGLISH, PORTUGUE, SPANISH, GERMAN, ITALIAN, FRENCH (Sets the control panel lan-

guage)

UNIT: *METER, FEET/INCH (Set’s the unit of measure that the printer displays)

4CMW72: *OFF, ON (?)

CUT PRESSURE: *100% (0%-150%) (Adjusts the Paper Cutter pressure)

SSCL: EXEC (Super Strong Cleaning)

DEFAULT PANEL: EXEC (Returns Maintenance Mode 1 settings to Factory Default)

CRTG INFO MENU: MANUFACTURER,COLOR, INK TYPE, INK CAPACITY, INK LEFT, PRODUCTION DATE,

EXPIRATION DATE, INK LIFE, INK AGE (CSIC information, for each ink cartridge)

Maintenance Mode 2: Press and hold the Left,Down,and Up buttons and turn on the Printer

SELF TESTING:

Test:

Version: (Displays the current firmware version)

Panel: (Button tests for the control panel)

Sensor: (Sensor tests for all sensors)

Encoder: (Encoder tests for both encoders)

Fan: (Fan tests for all fans)

5. MAINTENANCE

CUTTER REPL: EXEC

CHNG INK SET: EXEC (For Changing between 8 and 4 color)

PWR CLEANING: N CLEANING Y

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

6. Head Alignment.

PAPER THKNS: *STD, (n.n)MM

ALIGNMENT: AUTO, MANUAL

Stylus Pro 4000 Field Repair Guide 4/28/05

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

Elec.: Record: Maintenance: (Usage Counters for the following devices) WasteInk, Wiper, Rubbing,

Lever, Cover, Ink Lever, Cr Motor, PF Motor, PrintNumber, Cleaning, Fire A, Fire B, Fire C, Fire

D, Fire E, Fire F, Fire G, Fire H, Cut, Cute Sole, LockSolen

Record: Error: Error (0 - 6) (Displays the last 7 errors)

D/A Revision: Measure Va: (nn.nnn)v (?)

CSIC: Slot (1 - 8), Maintenance Tank (?)

Actuator: Cutter: [Enter], Start (Tests the cutter assembly)

Actuator2: Cutter Sol, Pump Motor (Tests the following devices)

Adjustment:

Cut Adj.: Pressure: *73% (Adjusts voltage used for the cutter solenoid)

PG ADJ: [Enter], Start: PG Offset *(nn) (Used for adjusting the platen gap)

Rear AD: [Enter], Start: Exc.: RearAD: (nnn nnn nnn) (For adjusting the rear paper sensor)

Edge Sns Lvl: [Enter], Start: (For adjusting the sensitivity of the edge sensor)

Check Nozzle: [Enter] Print: (Service level nozzle check)

Check Skew: Check Skew: (n.n)mm (Default 1.0) (Used for setting the amount of allowable skew)

Clean Head: (Used for draining the ink system)

Counter Clear: Reset Counter? (Resets all counters, DO NOT USE)

Ink Drain: (Used for draining the ink system)

Cleaning:

Std. KK0 (Weakest cleaning cycle (uses less ink))

Std. KK1 (Medium strength cleaning cycle)

Std. KK2 (Strongest cleaning cycle)

Init. Fill (Forces a initial fill (prime))

Print:

Check Ptn.: [Enter] Print (Prints all alignment patterns)

Adj. Variable: [Enter] Print (Prints the numeric adjustment variables currently set)

Parameter:

Initialize:

All: Initialize OK? (Resets all of the following counters at once)

Stylus Pro 4000 Field Repair Guide 4/28/05

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

PF Resolution: Initialize OK? (Resets this counter only)

Head Record: Initialize OK? (Resets this counter only)

Wiping Record: Initialize OK? (Resets this counter only)

Rab. Record: Initialize OK? (Resets this counter only)

Waste Record: Initialize OK? (Resets this counter only)

CRmot Record: Initialize OK? (Resets this counter only)

PFmot Record: Initialize OK? (Resets this counter only)

Lever Record: Initialize OK? (Resets this counter only)

Cover Record: Initialize OK? (Resets this counter only)

Ink Lever Record: Initialize OK? (Resets this counter only)

Update: InkParameter: Init. Fill: (Set, Reset) (Reset, turns off the initial fill)

MntTank: (On, Off) (Turn on or off the Maintenance Tank CSIC)

Mask Type: Dispersion, Regular (?)

PF BiD Adjust: (+/- n) (?)

Uni-D Trap: (On, Off) (?)

Display: Address: (Used for displaying data at specific RAM addresses)

Life: CR Motor, PF Motor, CR+PF Motor, Roller, Roller Rel, D/E Chg, Hopper, ASFLoad, Cutter, Head U/D,

Head Lock, Cleaning, Print, Total Life, CR+PF+Fire, TotalLife2, TotalLife3, Check (Used for design testing

of these devices and assemblies)

Service Config

Chg DEVICE-ID: *Sty Pro 4000, PX-6000 (Used for choosing the Plug and Play printer name)

NPD: *1, 0, 2 (Defines the ink type (1= pigment, 0 = new/undefined, 2 = dye))

EDMODE: *X, O,N (X=CSIC used fully, N=Non-USA Cartridges are OK, O=CSIC is disabled)

MD TBL: ID = (1-7D Hex) (“Modifying parameter of media table is available”)

View Counters (Displays the usage/life counter information for the following devices/operations)

Cutter, Cutter Total, Total Pages, Maint Tank, CR Motor, CR Total, PF Motor, Nozzle A, Nozzle B,

Nozzle C, Nozzle D, Nozzle E, Nozzle F, Nozzle G, FL Box, Cleaner, Sponge, ASF, Feed Roller, PG

Stylus Pro 4000 Field Repair Guide 4/28/05

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

Clear Counters (Clears the usage/life counter information for the following devices/operations)

Init All: (Initializes all the following counters at once)

NVRAM, RTC: (YY/MM/DD/HH), Cutter, CR Motor, CR Total, PF Motor, Head, Cleaner, Total Pages,

MAINT TANK, SPONGE, ASF,FEED ROLLER, PG, CR UNIT MAINT, CL UNIT MAINT, HEAD MAINT,

CUT UNIT MAINT (Sponge = Boarderless Pads)

MAINT INFO: (Page 88 - 98 in the Service Manual)

Menu E: (E1 - E17), Menu R: (R1 - R9), Menu S: (S1 - S25), Menu A: (A1 - A32), Menu B: (B1 - B48),

Menu P: (P1 - P42), Menu M: (M1 - M26), Menu O: (O1 - O28), Menu F: (F1 - F28), Menu N: (N1 - N22)

INIT INFO (Resets MAINT INFO menu data)

INIT. MENU E:, INIT. MENU R:, INIT. MENU S:, INIT. MENU A:, INIT. MENU B:, INIT. MENU P:, INIT.

MENU M:, INIT. MENU O:, INIT. MENU F:, INIT. MENU N:

Maintenance Mode 3: Press and hold the Pause,Down,and Right buttons and turn on the Printer

Shipment:

ADJ.Variable: Exec (Prints out the current adjustment settings)

Clean Head: Exec (Evacuates the ink in the Ink Tubes)

Clean Counter: Exec (Resets counters?)

Default Panel: Exec (Resets the Control Panel Settings to factory default)

Parameter Backup Mode: (Allows Parameter backup without the Printer being online)

1. Enter Maintenance Mode 2:Press and hold the Left,Down,and Up buttons and turn on the Printer

2. Lift both (2) Ink Levers

3. Remove the Maintenance Tank

4. Move the Paper Release Lever to the released position.

Firmware Download Mode:

Hold the 4 Arrow Buttons and Power on for F/W Download Mode

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