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