Epson 4000 Service Manual
Epson 4000 - Stylus Pro Color Inkjet Printer Manual
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- Epson 4000 | Service Manual - Page 1
SERVICE MANUAL Color Large Format Inkjet Printer EPSON Stylus Pro 4000 SEIJ03003 - Epson 4000 | Service Manual - Page 2
in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SEIKO EPSON CORPORATION. „ The contents of this manual are subject to change without notice. „ All effort have been made to ensure the accuracy of the contents of this - Epson 4000 | Service Manual - Page 3
procedures preceded by DANGER Headings. WARNING Signals a precaution performing repair/maintenance procedures. DANGER WITHIN THIS MANUAL, DO NOT CONNECT THE UNIT TO A POWER SOURCE UNTIL INSTRUCTED TO DO EPSON PRODUCT HAS BEEN DISCONNECTED FROM THE POWER SOURCE BEFORE REMOVING OR REPLACING PRINTED - Epson 4000 | Service Manual - Page 4
and mechanical operations, maintenance and repair procedures of the printer. The instructions and procedures included herein are intended for the experienced repair technicians, and attention should be given to the precautions on the preceding page. Manual Configuration This manual consists of six - Epson 4000 | Service Manual - Page 5
30) • Status Printing (Page 55) • Paper Thickness Detection Pattern (Page 68) • Gap Adjustment Print Pattern (Page 72) • Supersonic Cleaning (SSCL) (Page 77) • Maintenance Tank (Page 114) [Chapter 2] • Cutter Solenoid/CR Lock Mechanism (Page 132) [Chapter 3] • Check Before Troubleshooting (Page 156 - Epson 4000 | Service Manual - Page 6
1.7.2 Cleaning cartridge 114 1.7.3 Maintenance Tank 114 Chapter 2 Operating Principles 2.1 Overview 116 2.2 Printer Mechanism Components 117 2.2.1 Printing Mechanism (Print Head 118 2.2.2 Ink Supply Mechanism 119 2.2.3 Cleaning Mechanism 121 2.2.4 Carriage (CR) Mechanism 126 2.2.5 Paper Feed - Epson 4000 | Service Manual - Page 7
EPSON Stylus Pro 4000 Chapter 4 Disassembly & Assembly 4.1 Introductory Information 197 4.1.1 Cautions 197 4.1.2 Paper 377 Revision B 5.3.5 T&B&S (Cut Sheet 379 5.3.6 Cutter Pressure Adjustment 380 5.3.7 Nozzle Bi-D Adjustment 381 5.3.8 Print Head Slant Adjustment (PF 382 5.3.9 Print Head - Epson 4000 | Service Manual - Page 8
EPSON Stylus Pro 4000 6.1.1 Product Life Information 427 6.1.2 Important Maintenance Items During Service Operations 427 6.2 Lubrication 428 Chapter 7 Appendix 7.1 Connectors 432 7.2 Circuit Diagrams 435 7.3 Exploded Diagrams 442 7.4 Parts List 457 Revision B 8 - Epson 4000 | Service Manual - Page 9
PRODUCT DESCRIPTION CHAPTER 1 - Epson 4000 | Service Manual - Page 10
EPSON Stylus Pro 4000 Revision B 1.1 Product Description 1.1.1 Features † Large Format „ Max. paper width: 451.98mm (17.79"), A2 size supported † High-Speed Throughput Table 1-1. Throughput Ink type EPSON media Quality 8-color 4-color Plain Paper Matte Paper Glossy Photo Paper Plain Paper - Epson 4000 | Service Manual - Page 11
EPSON Stylus Pro 4000 † Max Quality High image quality made by various layers of 8-color ink, 2880 x 1440dpi, and minimum of 4pl. † Low Running Cost „ Independent for each color and 110ml ink cartridge † Paper Handling „ Support various media „ Automatic roll paper cutter, manual cutter „ Automatic - Epson 4000 | Service Manual - Page 12
EPSON Stylus Pro 4000 1.2 Basic Specifications 1.2.1 Print Specifications † Printing On-demand ink-jet † Nozzle configuration „ 7-row Lc Lm C M Ink Change 8-row Lk Y Note : Rows below are counted from the front left side of the printer. † Printing direction Bi-direction with logic seeking - Epson 4000 | Service Manual - Page 13
EPSON Stylus Pro 4000 1.2.4 Paper Feed Specification † Paper feeding Friction feed † Line spacing 1/6 inch or programmable at 1440 inch † Paper path „ Roll paper „ Manual (front/back) „ Automatic sheet feeder † Feed speed 6.35mm paper feed: 215 ± 10msec (except front rush, back rush, and hold time) - Epson 4000 | Service Manual - Page 14
EPSON Stylus Pro 4000 1.2.6 Paper Specification 1.2.6.1 Roll Paper CONTAINABLE PAPER The printer accepts following plain paper and EPSON special paper. It is not assured feeding and print quality with any other paper except them. † Paper Size „ 2" core : 203 ~ 432mm (W) x ~ 45m (H) (within roll size - Epson 4000 | Service Manual - Page 15
EPSON Stylus Pro 4000 1.2.6.2 Cut Sheet CONTAINABLE PAPER The printer accepts following plain paper and special paper. It is not assured feeding and print quality with any other paper except plain paper and special paper. † Paper Size Table 1-5. Cut Sheet Size (Containable Paper) Paper Size - Epson 4000 | Service Manual - Page 16
EPSON Stylus Pro 4000 Revision B 1.2.6.3 Special Paper † Cut Sheet Cut Sheet Name Premium Ink Jet Plain Paper (Xerox 4024) Premium Ink Jet Plain Paper (Genuine) Bright White Ink Jet Paper (Recycle paper) Photo Quality Ink Jet Paper Archival Matte Paper Water color paper-Radiant White Smooth Fine - Epson 4000 | Service Manual - Page 17
EPSON Stylus Pro 4000 Revision B † Roll Paper Roll Paper Name Plain Paper Single weight Matte Paper Enhanced Matte Paper Premium Glossy Photo Paper Premium Semigloss Photo Paper Premium Luster Photo Paper Premium Glossy Photo Paper Premium Semigloss Photo Paper Premium Semimatte Photo Paper - Epson 4000 | Service Manual - Page 18
EPSON Stylus Pro 4000 1.2.7 Mechanism Specifications 1.2.7.1 Printable Area Table 1-9. Printable Area Item PW (Paper width) PL (Paper length) TM (Top margin) BM (Bottom margin) LM (Left margin) RM (Right margin) Roll paper / Cut Sheet Dimension Roll paper Cut Sheet 203mm~432mm (17") *1 Roll - Epson 4000 | Service Manual - Page 19
EPSON Stylus Pro 4000 1.2.7.2 Borderless Print Specification By driver's command transmission, supports the following borderless print mode. Supports the following 3 modes. Table 1-10. Borderless Print Specification mode Mode Operation Right and left borderless (default) You can set only the - Epson 4000 | Service Manual - Page 20
EPSON Stylus Pro 4000 1.2.7.3 Paper Set Lever Table 1-12. Paper Set Lever Lever Position Backward Forward Description Position for paper setting (Paper holding is released, and paper can be set.) Ready-to-print position (Paper is fixed, and it becomes ready to be printed.) 1.2.7.4 Cut - Epson 4000 | Service Manual - Page 21
EPSON Stylus Pro 4000 C A U T IO N Make sure to match the leading edge of paper with the paper loading position. If you start printing with the leading edge of paper not reached the loading position, top of the image will be printed directly on the platen instead of the paper. NOTE 1: Auto cutter - Epson 4000 | Service Manual - Page 22
EPSON Stylus Pro 4000 1.2.9 Reliability PRINTER LIFE † Approx. 20,000 pages, 2.6million pass (A2, 360 x 360 M/F, Bi-D) A STANDARD OF PRINT HEAD LIFE † Monochrome/Color: 28 billion shots / nozzle STANDARD OF MAINTENANCE TANK LIFE † 8 color mode: Approx. 2,000 sheets (A2, plain paper, speed mode, - Epson 4000 | Service Manual - Page 23
EPSON Stylus Pro 4000 ink in the print head and ink cartridge freezes. It takes about 3 hours for the frozen ink to be usable under the condition of 25°C. 1.2.10.4 Surrounding Space Provide the printer with an enough surrounding space to ensure proper installation of accessories and replacement - Epson 4000 | Service Manual - Page 24
1105 Figure 1-4. Overall Dimensions of Stylus Pro 4000 † Dimensions of Unit Condition When tray is stored When tray is extended Width (W) x Depth (D) x Height (H) (mm) 848 x 764 x 354 848 x 1099 x 354 † Weight Completed product Approx. 40.2kg (ink cartridge and paper is not included) Product - Epson 4000 | Service Manual - Page 25
2pin „ Exhaust Port Cover „ Software CD-ROM • Printer Driver • EPSON Printer Adjustment Utility 2 „ Spacer for borderless printing 8"/A2 roll paper „ 17 (2"/3") inch normal tension spindle „ Ink cartridges (110ml 1 each PK, MK, LK, C, M, LC, LM, Y) „ Maintenance Tank „ Guarantee Card „ Card holder - Epson 4000 | Service Manual - Page 26
EPSON Stylus Pro 4000 1.3 External View and Parts Names EXTERNAL VIEW Paper Cover Printer Cover Spindle Paper Set Lever Control Panel Type-B Interface Ink Cartridge Box (Right side) Revision B Paper Guide Center Unit (Rear cover) Ink Cartridge Box (Left side) ASF Cassette Maintenance Tank - Epson 4000 | Service Manual - Page 27
EPSON Stylus Pro 4000 1.4 Operating Panel 1.4.1 Buttons and Functions Pause LED Paper Source / Paper Cut LCD 3sec. 1 2 3 4 5 6 7 8 Paper check LED Menu Revision B 1.4.1.1 LED Panel LED types are the following 3 types. The LEDs indicate printer status as follows. Table 1-16. LED LED Color - Epson 4000 | Service Manual - Page 28
EPSON Stylus Pro 4000 Revision B 1.4.1.2 Switch Table 1-17. Panel Functions and Switch Operation Switch Single Function 3 sec. push Function (In panel setting) Function (+ Power ON) Power Power ON/OFF *1 - - - Pause † Pause / Switch Print † Paper feed operation by backside manual - Epson 4000 | Service Manual - Page 29
EPSON Stylus Pro 4000 Revision B Table 1-17. Panel Functions and Switch Operation Switch Single Function 3 sec. push Paper Feed / Eject Paper [∨] † Paper feed for roll paper (forward) *7 † If cut sheet is set, eject sheet † If cut sheet is not set, paper is fed by ASF. † High speed paper - Epson 4000 | Service Manual - Page 30
18. Panel Display Priority Printer Status LCD Display LED Display Paper Check Pause Ink Check Low Printable READY OFF OFF OFF Data processing/ Printing Unable to print *14 Maintenance tank near *7 Ink low *8 PRINTING UNABLE TO PRINT MNT TK NEAR FULL INK LOW OFF - - - Blink - - - OFF - Epson 4000 | Service Manual - Page 31
EPSON Stylus Pro 4000 Priority Printer Status LCD Display Cleaning unavailable Initializing operation Cleaning failure Multi sensor gain error Multi sensor paper recognition error Cut sheet size error Paper eject error *9 Paper out/roll paper out ASF paper out Disable to borderless printing - Epson 4000 | Service Manual - Page 32
EPSON Stylus Pro 4000 Printer Status ASF prohibitions *13 Cleaning Executing ink sequence Initial charging Cutting by cut key Pause while cut *16 Ink out *8 GENUINE error, Wrong model number *8 Wrong dye/pigment, Wrong destination, Wrong 4-color/8-color *8 Ink cartridge failure *8 No ink cartridge - Epson 4000 | Service Manual - Page 33
EPSON Stylus Pro 4000 Priority Printer Status LCD Display Releasing paper lever in operation Replacing ink cartridge *8 Paper jam No maintenance tank Rear cover open Reset F/W updating F/W update completed F/W update failure Executing power off sequence Type-B option I/F error CR lock unlocked - Epson 4000 | Service Manual - Page 34
EPSON Stylus Pro 4000 Note *1: Thick paper is not available. *2: The status becomes no ink or maintenance tank full according to the remaining amount of ink when cleaning is executed. *3: It is assigned to key function in panel setting. *4: Only available when the roll paper is loaded. *5: It is lit - Epson 4000 | Service Manual - Page 35
end Near end Ink out Cartridge error and no cartridge LCD Note "*": Available quantity is displayed for the maintenance tank. 1.4.2.5 Suction Adjustment and Indicator Display Users can adjust paper suction to set paper easily, only when paper set lever is released, and paper is detected with - Epson 4000 | Service Manual - Page 36
EPSON Stylus Pro 4000 1.4.3 Job information † Definition of Job The minimum unit of printer operation is defined as "Job" (*) in this printer. The job print information with character/image can be saved as a record. Basic print job functions are followings; Note "*": Cleaning can be executed during - Epson 4000 | Service Manual - Page 37
EPSON Stylus Pro 4000 1.4.4 Panel Setting 1.4.4.1 Outline † Startup The printer mode is selected by pressing the [Menu] button during print ready, warning, or maintenance call status. The printer is then automatically incapable of printing. † Operation 1. The Printer setting menu can be entered by - Epson 4000 | Service Manual - Page 38
EPSON Stylus Pro 4000 † Panel display „ Level structure of Setting menu READY [< / >] PRINTER SETUP [< / >] [∧ / ∨] [] PRINTER STATUS [< / >] [∧ / ∨] [] [∧ / ∨] [] HEAD ALIGNMENT [< / >] [∧ / ∨] PRINTER SETUP PLATEN - Epson 4000 | Service Manual - Page 39
EPSON Stylus Pro 4000 „ Level structure of Test print menu TEST PRINT [< / >] TEST PRINT NOZZLE CHECK [∧ / ∨] [ - Epson 4000 | Service Manual - Page 40
EPSON Stylus Pro 4000 „ Level structure of User Paper Setup Menu PAPER CONFIG [< / >] PAPER CONFIG PAPER NUMBER [∧ / ∨] [ - Epson 4000 | Service Manual - Page 41
EPSON Stylus Pro 4000 Revision B 1.4.4.2 Panel Setting Menu Item Top menu (Panel display) Printer setting menu (PRINTER SETUP) Test print menu (TEST PRINT) Printer status menu (PRINTER STATUS) Item menu PG Setting Page lines Interface Select Code Page Switching Roll Paper Margin Detect - Epson 4000 | Service Manual - Page 42
EPSON Stylus Pro 4000 Revision B Top menu (Panel display) Printer status menu (PRINTER STATUS) Item menu Table 1-20. Panel Setting Menu Item Panel display 1st row 2nd row 3rd row Ink Remaining 4th row 5th row INK LEFT 6th row 7th row 8th row Maintenance Tank Count Ink counter - Epson 4000 | Service Manual - Page 43
EPSON Stylus Pro 4000 Revision B Top menu (Panel display) User Paper Setup Menu (CUSTOM PAPER) Maintenance menu (MAINTENANCE) Gap Adjustment menu (HEAD ALIGNMENT) Item menu Paper Type Selection PG setting Paper Thickness Detection Pattern Select paper thickness number Table 1-20. Panel Setting - Epson 4000 | Service Manual - Page 44
EPSON Stylus Pro 4000 Revision B Top menu (Panel display) Gap adjustment menu (HEAD ALIGNMENT) Item menu Table 1-20. Panel Setting Menu Item Panel display Select and print adjustment pattern Note *1: Supports value (Underline: Default) Ref. UNI-D *2 MANUAL BI-D BLACK *2 BI-D ALL #1 C : - Epson 4000 | Service Manual - Page 45
EPSON Stylus Pro 4000 Revision B 1.4.4.3 PG Setting Executing this mode allows the user to set the width of platen gap. If paper type other than standard is selected in user paper setting menu, PG specified in user paper setting has the priority. However if the paper thickness sensor detects the - Epson 4000 | Service Manual - Page 46
EPSON Stylus Pro 4000 † Level structure of PG setting menu PRINTER SETUP PLATEN GAP [< / >] PLATEN GAP NARROW [∧ / ∨] [ - Epson 4000 | Service Manual - Page 47
EPSON Stylus Pro 4000 Revision B 1.4.4.7 Roll Paper Margin Setting this panel allows switching roll paper margin, all sides 3mm / all sides 15mm / top and bottom 15mm, right and left 3mm. This setting is only valid for roll paper. It's not valid for cut sheet. This setting changes only margin, and - Epson 4000 | Service Manual - Page 48
EPSON Stylus Pro 4000 † Level structure for roll paper margin setting PRINTER SETUP PAPER MARGIN [< / >] PAPER MARGIN T/B15mm [∧ / ∨] [ - Epson 4000 | Service Manual - Page 49
EPSON Stylus Pro 4000 Revision B 1.4.4.9 Skew Error Detection When this setting is set to "OFF", a paper skew error is not occurred and printing operation is continued. Even if this setting is set to "ON", cut paper skew is not detected after printing. Even if the printing image is outside the - Epson 4000 | Service Manual - Page 50
EPSON Stylus Pro 4000 Revision B 1.4.4.11 Cutter Position Adjustment Cutter position can be adjusted by this mode. Cutter position adjustment pattern is printed, and users entering the cutter position number to adjust the cutter position. NOTE: This adjustment is effective for top/bottom no - Epson 4000 | Service Manual - Page 51
EPSON Stylus Pro 4000 Revision B 1.4.4.12 Auto Margin Refresh When this setting is ON, paper edge is automatically cut and refreshed to prevent print dirt in the situation after 4 sides no margin print in first JOB and with margin print in next JOB. The cutting length depends on the minimum cut - Epson 4000 | Service Manual - Page 52
EPSON Stylus Pro 4000 Revision B 1.4.4.14 Auto Nozzle Check for Each Job This setting is valid only when "Cleaning setting at nozzle check" is ON. By turning this setting on, auto nozzle check can be performed before printing upon receiving data from PC. Trigger for receiving data from PC is when - Epson 4000 | Service Manual - Page 53
EPSON Stylus Pro 4000 Revision B 1.4.4.16 Super Low Speed Cut Mode When this setting is set to "ON", normal cut operation is performed at 20CPS to reduce a noise and paper dust. However when top edge is cut at Top/Bottom borderless printing setting, this setting is not reflected to prevent - Epson 4000 | Service Manual - Page 54
EPSON Stylus Pro 4000 1.4.4.18 Nozzle Check Pattern Printing Selecting this mode allows the user to print the nozzle check pattern, firmware version, used paper/ink, and maintenance tank counter. Nozzle checks method in nozzle check pattern print is switched to either auto or manual by cleaning - Epson 4000 | Service Manual - Page 55
EPSON Stylus Pro 4000 Revision B 1.4.4.19 Status Printing Selecting this mode allows the user to print the current panel settings content. Print status sheet with the following specifications. „ Print paper size : A4 „ Font : Built-in font (Print all in alphanumeric characters) „ Print - Epson 4000 | Service Manual - Page 56
EPSON Stylus Pro 4000 † Explanation of contents: #1: XX-XX-XX-XX-XX-XX-XX #2: XX-XX-XX-XX-XX-XX-XX Type-B Current Setting Printer Status Ink Cartridge *3 Color Adjust ID information (ID1) *4 Color Adjust ID information (ID2M) Whether optional Type-B I/F is mounted or not Setting content of " - Epson 4000 | Service Manual - Page 57
EPSON Stylus Pro 4000 1.4.4.20 Job Information Print With this mode, users can print job information saved in the printer. (Max. 10 Job) Definition of job is followings; † Adjustment patterns and test patterns (Gap adjustment, Nozzle check pattern, Status print, Cutter position, Paper thickness - Epson 4000 | Service Manual - Page 58
EPSON Stylus Pro 4000 1.4.4.21 User Paper Setting Printing With this mode, users print information registered in user paper setting menu. It prints User Paper Setting Printing with following specifications; † Print paper size : A4 † Font : Built-in font (Print all in alphanumeric characters) - Epson 4000 | Service Manual - Page 59
EPSON Stylus Pro 4000 1.4.4.22 Firmware Version Firmware version is displayed as following; VERSION Ixxxx P Note 1: xxxx : Firmware version (4 letters) 2: P : means mass product model 3: Ix : "x" shows the specific version 1.4.4.23 Printable Pages per Ink Cartridge Printable sheets (estimation) - Epson 4000 | Service Manual - Page 60
EPSON Stylus Pro 4000 1.4.4.24 Ink Remaining Table 1-26. Ink Remaining Ink remaining 100 ~ 81% remaining 80 ~ 61% remaining 60 ~ 41% remaining 40 ~ 21% remaining 20% ~ just before near end After near end ~ just before ink out Ink out Panel display E F E F E∗∗∗ F E∗∗ F E∗ F nn% 0% Ink check - Epson 4000 | Service Manual - Page 61
EPSON Stylus Pro 4000 1.4.4.25 Maintenance Tank Count † Calculate method Current available rate of maintenance tank is displayed. (Total capacity 1300g) † Display Available printer is cleared. Ink usage and paper usage of job history are displayed "---". 1.4.4.30 Total Print Pages Total prints - Epson 4000 | Service Manual - Page 62
EPSON Stylus Pro 4000 1.4.4.31 Consumable Life † Cutter life „ Calculate method Counter that is calculated by accumulating total of cutter used is initialized by cutter replacement „ Maintenance call Life is less than 4%. „ Fatal error Considering tube damage, when life reaches to 0, service call - Epson 4000 | Service Manual - Page 63
EPSON Stylus Pro 4000 † PF motor life „ Calculate method There are no parts that need to be replaced within product life period of PF motor and paper feed mechanical drive system. Therefore it is used as failure diagnosis when used over product life. Display life by accumulating distance of PF - Epson 4000 | Service Manual - Page 64
EPSON Stylus Pro 4000 † Cleaning unit life „ Calculate method Cleaning unit life is judged by pomp motor life. When in service, replace cap assembly, pomp assembly, flashing box, and wiper at the same time. „ Display (Life) 100 ~ 81% E F 80 ~ 61% E F 60 ~ 41% E∗∗∗ F 40 ~ 21% E∗∗ F 20% ~ - Epson 4000 | Service Manual - Page 65
EPSON Stylus Pro 4000 † Paper setting and corresponding operation Table 1-27. Paper setting and operation Paper setup Operation Standard When each setting item values are set by commands, it follows the command settings. 1 ~ 10 User defined paper is used and even if settings are set by - Epson 4000 | Service Manual - Page 66
EPSON Stylus Pro 4000 † Print quality setup values set by MW print adjustment. Table 1-29. Print quality setup value list Mode ESC (i n1 n2 Raster resolution ESC (D Number of POL Print Feed amount Panel Number setting of pass 00H 03H 0 1-359/360" 1 2 01H 00H 360x360 61 119/360" 1 - Epson 4000 | Service Manual - Page 67
EPSON Stylus Pro 4000 † Level structure of user paper menu CUSTOM PAPER CUSTOM PAPER PAPER NUMBER [∧ / ∨] CUSTOM PAPER PLATEN GAP [∧ / ∨] CUSTOM PAPER THICKNESS PAT [∧ / ∨] PLATEN GAP NARROW STANDARD STANDARD WIDE WIDER THICKNESS PAT PRINT CUSTOM PAPER THICKNESS NUM [∧ / ∨] [< / >] - Epson 4000 | Service Manual - Page 68
EPSON Stylus Pro 4000 † Paper Thickness Detection Pattern „ Print Specification Head speed 240 cps Pattern height 96 dots Dot size VSD2 Large Color Black Print direction Uni-D Pattern interval Upper patterns: Equal intervals Lower patterns: Centered on base position for gap adjustment - Epson 4000 | Service Manual - Page 69
EPSON Stylus Pro 4000 Revision B 1.4.4.33 Cutter Blade Replacement Selecting this mode allows the user to replace the cutter blade. The procedure for cutter blade replacement is as follows: 1. Select the cutter replacement menu from the panel. 2. Open the cover by following cover open guide. 3. - Epson 4000 | Service Manual - Page 70
EPSON Stylus Pro 4000 † Adjustment The adjustment values set above are saved in NVRAM as 4 types of adjustment value depending on PG height (0.7mm/1.2mm/2.2mm/2.6mm). To calculate adjustment value, PG height and paper thickness are necessary. Saving place of adjustment value is selected as - Epson 4000 | Service Manual - Page 71
EPSON Stylus Pro 4000 Revision B „ Level structure of gap adjustment menu HEAD ALIGNMENT HEAD ALIGNMENT [< / >] PAPER THKNS PAPER THKNS STD 0.1mm ~ 1.6mm [∧ / ∨] STD [] ALIGNMENT ALIGNMENT AUTO MANUAL AUTO [< / >] [∧ / ∨] [] MANUAL - Epson 4000 | Service Manual - Page 72
EPSON Stylus Pro 4000 † Gap Adjustment Print Pattern „ Print specifications (not mentioned in the manual) Print specifications of gap adjustment print pattern Adjusting items Adjustment pattern height Others 3 items Bi-D Black (#1, #2, #3, #4) Bi-D All (#1, #2, #3, #4) Uni-D All (#1, #2, #3, #4) - Epson 4000 | Service Manual - Page 73
EPSON Stylus Pro 4000 Revision B 1.4.5 Maintenance Mode 1 OUTLINE † Startup The maintenance mode 1 is displayed by switching menu select mode by pushing [Paper Source] button in the setting item select menu. † Termination 1. The printer is ready for printing following reset after selecting the - Epson 4000 | Service Manual - Page 74
EPSON Stylus Pro 4000 MAINTENANCE MODE 1 SETUP ITEMS Table 1-32. Maintenance Mode 1 Setup Items Top menu Panel display Item menu 1 (Panel display) Item menu 2 (Panel display) Setup value Print hexadecimal HEX DUMP dump (-) (PRINT) EXEC *1 Panel display language LANGUAGE select (-) - Epson 4000 | Service Manual - Page 75
EPSON Stylus Pro 4000 Table 1-32. Maintenance Mode 1 Setup Items Top menu Ink information menu Panel display Item menu 1 (Panel display) Item menu 2 (Panel display) Manufacture logo (MANUFACT Y) Ink color (CARTRIDGE Y) Ink type (INK TYPE Y) Ink capacity (INK CAP Y) Ink information (Y4) (Y - Epson 4000 | Service Manual - Page 76
EPSON Stylus Pro 4000 Revision B Table 1-32. Maintenance Mode 1 Setup Items Top menu Ink information menu Panel display Item menu 1 (Panel display) Item menu 2 (Panel display) Manufacture logo (MANUFACT Lk) Ink color (CARTRIDGE Lk) Ink type (INK TYPE Lk) Ink capacity (INK CAP Lk) CRTG - Epson 4000 | Service Manual - Page 77
EPSON Stylus Pro 4000 Revision B CUTTING PRESSURE Changes cutting pressure, which is set in the printer. Adjustment value (calculated by spring balance / input value) in the process is set to 100% (printer default), input / setting range by the user is set to between 0% ~ 150%. The value entered - Epson 4000 | Service Manual - Page 78
EPSON Stylus Pro 4000 † Level structure of ink information menu Ink Information Items CRTG INFO MENU [< / >] CRTG INFO MENU MK INFO [∧ / ∨] [ - Epson 4000 | Service Manual - Page 79
EPSON Stylus Pro 4000 1.4.6 Maintenance Mode 2 This mode includes the following menus and is intended for use by a service engineer in maintaining the printer. † Self Testing Menu (SELF TESTING) (p80) † Adjustment Setting Menu (SERVICE one after another by pushing [Paper Feed] buttons once in the - Epson 4000 | Service Manual - Page 80
menu is mainly intended to adjustment the printer mechanism and determination any adjustment parameters in the firmware. CHECK P O IN T „ It is possible the adjustment program to perform the same functions. „ Ink cartridge and maintenance tank remaining are not detected while executing this - Epson 4000 | Service Manual - Page 81
RearGuide Rear cover Rear Det Rear det POUT Det Paper out P Det P det MainteTank Maintenance tank K/C/M/Y/k/c/m/y Cartridge status EdgeAD Edge AD Edge2AD Edge AD2 RearAD Rear AD Head Temp Head temperature Drv. Temp Driver temperature Encoder Encoder CR CR encoder PF PF - Epson 4000 | Service Manual - Page 82
EPSON Stylus Pro 4000 Top Menu Panel Display Item TEST Test Revision B Table 1-35. Self Testing Menu List 1st hierarchy 2nd hierarchy Panel Display Item Panel Display Item Elec. Electric Maintenance Counter display Error Register occurred error D/A Revision Register voltage error - Epson 4000 | Service Manual - Page 83
EPSON Stylus Pro 4000 SLOT6 Slot6 SLOT7 Slot7 SLOT8 Slot8 MntTank Maintenance tank Actuator Actuator Cutter Cutter Actuator2 Actuator2 print --- --- Check Skew Confirm paper skew --- --- Clean Head Clean head --- --- Clean Counter * Counter clear --- --- Ink Drain Ink - Epson 4000 | Service Manual - Page 84
EPSON Stylus Pro 4000 Top Menu Panel Display Item Print Print Parameter Parameter Revision B Table 1-35. PF Resolution PF resolution initialization Head Record Discharging times initialization Wiping counter initialization Waste Record Waste ink counter initialization CRMot Record CR - Epson 4000 | Service Manual - Page 85
EPSON Stylus Pro 4000 Top Menu Panel Display Item Parameter Parameter Life Lasting Revision B Table 1-35. Self Testing Menu List 1st hierarchy 2nd hierarchy Panel Display Item Panel Display Item Update Update InkParameter Ink parameter update MntTank Maintenance parameter update - Epson 4000 | Service Manual - Page 86
EPSON Stylus Pro 4000 Top Menu Panel Display Item Life Lasting Table 1-35. Self Testing Menu List 1st hierarchy 2nd hierarchy Panel Display Item Panel Display Item Cutter Cutter Paper Pre. Cutter stab force Pressure Cutter pressure PaperSize Paper length LifeCount Lasting times - Epson 4000 | Service Manual - Page 87
EPSON Stylus Pro 4000 Top Menu Panel Display Item Life Lasting Table 1-35. Self Testing Menu D/E Chg Disengage Hopper Hopper AsfLoad ASF paper feed Cutter Cutter Head U/D Head UP/DOWN Head Lock Head lock Cleaning Cleaning Print Printing TotalLife Total lasting CR+PF+Fire CR+ - Epson 4000 | Service Manual - Page 88
EPSON Stylus Pro 4000 Note "*": Initialize the following counter. Table 1-36. Clean Counter Counter Type CSIC control flag Maintenance menu ink reference Maintenance tank ink consumption (CSIC) Head hot error flag Borderless ink counter a1 Timer CL2 cumulative counter Pump counter P Maintenance - Epson 4000 | Service Manual - Page 89
EPSON Stylus Pro 4000 1.4.6.2 Adjustment Setting Menu (SERVICE CONFIG) Modify setting value for maintenance. Table 1-37. Adjustment setting menu item list Top menu Adjustment/ setting menu Panel display Item menu SERVICE CONFIG Device ID switching Ink cartridge type setting Detection level - Epson 4000 | Service Manual - Page 90
EPSON Stylus Pro 4000 initialized (initial value 0) when replacing cutter. Cutter life cumulative counter paper eject operation. Maintenance tank value display MAINT TANK Display maintenance tank A row to H row. Head unit life counter is counted every ink discharging. ... Flashing box counter - Epson 4000 | Service Manual - Page 91
EPSON Stylus Pro 4000 Revision B 1.4.6.4 Counter Initialization Menu (CLEAR COUNTERS) Menu, which targets initialization of each counter value for maintenance. Table 1-42. Counter Initialization Menu Item menu Panel display Setting value Initialization item NVRAM/life counter/mechanic - Epson 4000 | Service Manual - Page 92
EPSON Stylus Pro 4000 Item menu PG switching counter value initialization Initialization when replacing carriage unit Initialization when replacing cleaning unit Initialization when replacing head unit Initialization when replacing cutter solenoid unit Revision B Table 1-42. Counter Initialization - Epson 4000 | Service Manual - Page 93
EPSON Stylus Pro 4000 Revision B 1.4.6.5 Maintenance Information Menu (MAINT INFO) Targets maintenance and display life counter value in the following item list and value which registers environment status in NVRAM. Table 1-43. Maintenance Information Menu List Top menu Maintenance information - Epson 4000 | Service Manual - Page 94
EPSON Stylus Pro 4000 Top menu Maintenance information menu Panel display Item menu 1 MAINT INFO Ink system related 1 Revision B Table 1-43. Maintenance Information Menu List Panel display Item menu 2 Panel display Setting value Unit MENU S Cumulative waste ink counter (absorbent - Epson 4000 | Service Manual - Page 95
EPSON Stylus Pro 4000 Top menu Maintenance information menu Panel display Item menu 1 MAINT INFO Ink related 1 Revision B Table 1-43. Maintenance Information Menu List Panel display Item menu 2 Panel display Setting value Unit MENU A Total amount of ink used (EPSON Genuine) P-K A1 < - Epson 4000 | Service Manual - Page 96
EPSON Stylus Pro 4000 Top menu Maintenance information menu Panel display Item menu 1 MAINT INFO Ink related 2 Table 1-43. Maintenance Information Menu List Panel display MENU B Item menu 2 Each color ink replacing date (Slot 1 current) Each color ink vender (Slot 1 current) Each color ink - Epson 4000 | Service Manual - Page 97
EPSON Stylus Pro 4000 Top menu Maintenance information menu Panel display Item menu 1 MAINT INFO Ink related 2 Revision B Table 1-43. Maintenance Information Menu List Panel display Item menu 2 Panel display Setting value Unit MENU B Each color ink replacing date (Slot 7, 1 times before) - Epson 4000 | Service Manual - Page 98
EPSON Stylus Pro 4000 Top menu Maintenance information menu Panel display Item menu 1 MAINT INFO Paper information Revision B Table 1-43. Maintenance Information Menu List Panel display MENU P Item menu 2 Roll paper set execution times Manual cut paper set execution times Printout length - Epson 4000 | Service Manual - Page 99
EPSON Stylus Pro 4000 Top menu Maintenance information menu Panel display Item menu 1 MAINT INFO Paper information Revision B Table 1-43. Maintenance Information Menu List Panel display Item menu 2 Panel display Setting value Unit MENU P Printout length according to paper size 0 - Epson 4000 | Service Manual - Page 100
EPSON Stylus Pro 4000 Top menu Maintenance information menu Panel display Item menu 1 MAINT INFO Print mode related Revision B Table 1-43. Maintenance Information Menu List Panel display Item menu 2 Panel display Setting value Unit MENU M Print mode specified times 1 2880x1440 4pass Uni - Epson 4000 | Service Manual - Page 101
EPSON Stylus Pro 4000 Revision B Top menu Maintenance information menu Panel display Item menu 1 MAINT INFO Panel setting information Table 1-43. Maintenance Times Paper feed adjustment modified times O21 Times Suction modified times O22 Times Printing adjustment - Epson 4000 | Service Manual - Page 102
EPSON Stylus Pro 4000 Top menu Maintenance information menu Panel display Item menu 1 MAINT INFO Fatal error Table 1-43. Maintenance Information Menu List Panel display MENU F Item menu 2 Service call occurred history 1 (type) Service call occurred history 1 (date) Service call occurred - Epson 4000 | Service Manual - Page 103
EPSON Stylus Pro 4000 Top menu Maintenance information menu Panel display Item menu 1 MAINT INFO Normal error related Table 1-43. Maintenance Information Menu List Panel display MENU N Item menu 2 Normal error occurred history 1 (type) Normal error occurred history 1 (date) Normal error - Epson 4000 | Service Manual - Page 104
EPSON Stylus Pro 4000 † Following are the error factor registered in normal error and its registered value. Table 1-44. Registered value and Error factor Registered value Error factor 00h Reserve 01h CSIC contact error 02h Ink cartridge failure 03h Wrong ink cartridge 04h Wrong ink - Epson 4000 | Service Manual - Page 105
EPSON Stylus Pro 4000 1.4.7 MIB Function The printer corresponds to the following MIB; you can receive printer information (specification/status/commodity/job information etc.) from Global MIB via N/W. Also according to Type-B Level 3 Packet Mode support, corresponds to the following Local MIB. † - Epson 4000 | Service Manual - Page 106
EPSON Stylus Pro 4000 Revision B 1.4.9 Initialization The printer performs initialization operation by the following method. 1.4.9.1 Hardware Initialization This printer is initialized when power to the printer is turned on. † The following are the initialization operation performed when turning - Epson 4000 | Service Manual - Page 107
EPSON Stylus Pro 4000 1.5 Controller † CPU : SH7709A, 100MHz † Code ROM : 2MB † Font ROM : None † RAM : 32MB † Interface „ USB (HS, FS) „ IEEE 1394 „ Type-B interface † Operating System : Hitachi HI7700 (µITRON 3.0 compatible) Revision B Product Description Controller 107 - Epson 4000 | Service Manual - Page 108
length : 2m † Device ID „ (Character strings may vary by Model Name.) „ MFG: EPSON; „ CMD: ESCPL2, BDC, D4; „ MDL: ; „ CLS: PRINTER; „ DES: EPSONT; (: space code) Revision B SIGNAL ASSIGNMENT AND SIGNAL DEFINITION OF INPUT CONNECTOR PIN Table - Epson 4000 | Service Manual - Page 109
EPSON Stylus Pro 4000 1.6.2 IEEE1394 Interface FEATURES † IEEE Std.1394-1995, 1394a-2000 compliant † power. „ Bi-directional data communication between the IEEE 1394 equipped host and the printer. SPECIFICATIONS † Data transmission : Half-duplex, Data/Strobe differential † Synchronization : DS - Epson 4000 | Service Manual - Page 110
EPSON Stylus Pro 4000 Revision B 1.6.3 Optional Interface Type-B interface (level 3, MIB, 1200mA type) is supported. REPLY MESSAGE † Main-Type „ MT48p, PW240cl10cpi, PRG (I0xxxx) rev, AP1000ma, SPD0fast, GDI NOTE: xxxx is F/W version. † Product-Name : - Epson 4000 | Service Manual - Page 111
EPSON Stylus Pro 4000 TYPE-B LEVEL 3 PACKET MODE Communication between Type-B I/F card and Printer corresponds to Type-B Level 3 (Packet Mode) Type-B sends error. † Supported Channel Assigning Service and Channel applies the chart below. Table 1-53. Supported Channel Service Socket ID Use - Epson 4000 | Service Manual - Page 112
EPSON Stylus Pro 4000 1.6.4 Supplements RECEIVED BUFFER FULL OPERATION When data is received from the USB interface or the 1394 interface while no error has occurred (including the pause condition), the printer receives data a rate of 2 byte/second when free space of buffer is less than 16 KB. When - Epson 4000 | Service Manual - Page 113
EPSON Stylus Pro 4000 1.7 Optional Units and Consumables 1.7.1 Ink Cartridge Selection of ink types, detection of cartridges and the amount of remaining ink are controlled by CSIC. CHECK P O IN T When installing the pigment ink cartridges, shake them gently a couple of times beforehand to ensure - Epson 4000 | Service Manual - Page 114
EPSON Stylus Pro 4000 1.7.2 Cleaning cartridge CHECK P O IN T The cleaning cartridge is the same as the 110ml ink cartridge in shape except that it does not have the projection for a color block. † Type : Exclusive cleaning cartridge † Dimension : Same as 110ml exclusive ink cartridge † - Epson 4000 | Service Manual - Page 115
OPERATING PRINCIPLES CHAPTER 2 - Epson 4000 | Service Manual - Page 116
and operating principles for the EPSON Stylus Pro 4000. The explanation is composed as follows: † 2.2 Printer Mechanism Components (p.117) „ 2.2.1 Printing Mechanism (Print Head) (p.118) „ 2.2.2 Ink Supply Mechanism (p.119) „ 2.2.4 Carriage (CR) Mechanism (p.126) „ 2.2.5 Paper Feed Mechanism (p.132 - Epson 4000 | Service Manual - Page 117
nozzles: 180 nozzles x 8 rows p.118 Head Thermistor +3.3V Incorporated in the Print Head - Ink Supply Mechanism (p.119) Release Sensor (I/H lever) +5V Reverse tension switch (mechanical contact) p.120 ASF/Pump Motor +42V Stepping motor p.124 Maintenance Tank +3.3V/+5V CSIC p.124 Pump - Epson 4000 | Service Manual - Page 118
EPSON Stylus Pro 4000 Revision B Paper Feed Direction 2.2.1 Printing Mechanism (Print Head) The printing method uses the unique EPSON MACH method of previous models. The Print Head incorporates a thermistor. According to the temperature around the head detected by the thermistor, the CPU on the - Epson 4000 | Service Manual - Page 119
EPSON Stylus Pro 4000 2.2.2 Ink Supply Mechanism This printer has ink cartridges for 8 colors held by Ink holders (I/H) located on the left and right sides of the printer. There are protruding tabs and markings on the top of each color ink cartridge to prevent mistaken installation. † Explanation - Epson 4000 | Service Manual - Page 120
EPSON Stylus Pro 4000 † Dumper The dumper is equipped with a valve to prevent reverse flow of ink, and when this valve opens the ink inside the ink storage space within the dumper flows and is supplied to the Print Head. Front 1 Back Revision B † I/H lever sensor The left I/H and right I/H each - Epson 4000 | Service Manual - Page 121
EPSON Stylus Pro 4000 2.2.3 Cleaning Mechanism Cleaning mechanism components are located at the right side of the printer. Waste ink from the cleaning components is sent through a tube to the Waste Ink Absorber (Maintenance Tank) at the bottom right. Main cleaning mechanism components and their - Epson 4000 | Service Manual - Page 122
EPSON Stylus Pro 4000 CLEANING MECHANISM DRIVE ASF/Pump Motor Planetary Lever (Spur Gear, 15.2) Combination Gear, 15.2, 25.6 Spur Gear , 15.2, 25.6 Combination Gear, 13.6, 28.8 Pump Unit Figure 2-10. Cleaning Mechanism Drive Components Operating Principles Printer Mechanism Components 122 - Epson 4000 | Service Manual - Page 123
EPSON Stylus Pro 4000 DRIVE TRANSMISSION TO PUMP UNIT 1. The DE Lock Lever is moved to the right end by moving the Carriage Unit to through Step 4, drive power of ASF/Pump Motor is transferred to the Pump Unit by the path shown in Figure 2-8. Operating Principles Printer Mechanism Components 123 - Epson 4000 | Service Manual - Page 124
EPSON Stylus Pro 4000 † ASF/Pump Motor (Stepping motor) When the transmission path is switched to the Pump Unit side by Carriage Unit movement and the DE Lock Lever, the ASF/Pump Motor can drive the ink maintenance system such as pump and wiper, etc. Movements of the ASF/Pump Motor drive - Epson 4000 | Service Manual - Page 125
EPSON Stylus Pro 4000 NOTE: The table below explains Ink System terminology. Operation Initial Ink Charge Flushing Wiping Operation Rubbing Operation Capping Table 2-6. Explanation of Operation Explanation • This is the operation where the head is filled with ink for the first time. When the - Epson 4000 | Service Manual - Page 126
EPSON Stylus Pro 4000 2.2.4 Carriage (CR) Mechanism This printer has a unique carriage mechanism for stable and high precision movement/printing of the on-carriage head for the print area of A2 paper width. The Carriage mechanism is formed of the following components. † Carriage Unit † Carriage - Epson 4000 | Service Manual - Page 127
EPSON Stylus Pro 4000 2.2.4.1 Carriage Unit Movement Components Two Carriage Shafts, each covered with a linear plate, and eight rollers (bearings) form the structure supporting the carriage. C A 2-16. Carriage Mechanism Drive Components Operating Principles Printer Mechanism Components 127 - Epson 4000 | Service Manual - Page 128
EPSON Stylus Pro 4000 control circuit to perform feedback speed control. The control maintains high printing speed. Drive transmission from the CR Motor to the Carriage Unit position) This is a transmissive photosensor installed at the printer right side. Insertion of the flag (a protrusion) on - Epson 4000 | Service Manual - Page 129
EPSON Stylus Pro 4000 2.2.4.2 Platen Gap Adjustment Components The Carriage Unit (= Print Head) installation position must always maintain a fixed distance from the paper surface in order to preserve printing precision. The Carriage Unit is supported Principles Printer Mechanism Components 129 - Epson 4000 | Service Manual - Page 130
EPSON Stylus Pro 4000 Revision B DRIVE TRANSMISSION TO CARRIAGE SHAFT 1. The Planetary Lock Lever (along with the DE Lock Lever) are moved to Step 4, PG/PO Motor drive is transferred to the Carriage Shaft by the path shown in Figure 2-18. Operating Principles Printer Mechanism Components 130 - Epson 4000 | Service Manual - Page 131
EPSON Stylus Pro 4000 † PG/PO Motor (Stepping motor) When the transmission path is Sensor This is a transmissive sensor installed on the left side of the printer that detects the PG position (height of head from paper surface) and machine home position (home) at the time of adjustment movements - Epson 4000 | Service Manual - Page 132
EPSON Stylus Pro 4000 Revision B 2.2.4.3 Cutter Solenoid/CR Lock Mechanism Installed on the front of the Carriage Unit, this is a DC solenoid for controlling cutter pressure of the cutter used for roll paper and then the CR Lock is released. The printer is also equipped with the mechanism to lock - Epson 4000 | Service Manual - Page 133
EPSON Stylus Pro 4000 Revision B PAPER FEED MECHANISM DRIVE PF Motor PF Timing Belt Speed-Reduction Pulley PF Roller Sub Roller Drive PF Pulley Sub Roller Drive Belt Paper Eject Roller Belt Sub Roller Drive Pulley Paper Eject Roller Pulley Sub Roller Unit Paper Eject Roller Figure 2-26 - Epson 4000 | Service Manual - Page 134
EPSON Stylus Pro 4000 † PF Motor (DC motor) With drive from the PF Motor, the grid of the loop scale installed above both PF Rollers is read by the Encoder Sensor, and feedback control is based on the output pulse. This control maintains high printing precision. † Suction Fans Suction Fans are - Epson 4000 | Service Manual - Page 135
EPSON Stylus Pro 4000 † Rear Manual Insertion Sensor This reverse tension switch sensor (mechanical contact) is mounted at the rear surface of the printer. The sensor detects paper being fed from the manual insertion slot. P_THICK_0.3 Sensor P_THICK_0.8 Sensor Revision B 2.2.5.1 ASF Paper Feed - Epson 4000 | Service Manual - Page 136
EPSON Stylus Pro 4000 ASF PAPER FEED MECHANISM DRIVE ASF/Pump Motor Planetary Lever (Spur Gear, , 44.8) Combination Gear, 16.8, 24 Figure 2-34. ASF Paper Feed Mechanism Drive Components Figure 2-33. ASF Paper Feed Mechanism Drive Layout Operating Principles Printer Mechanism Components 136 - Epson 4000 | Service Manual - Page 137
EPSON Stylus Pro 4000 TRANSMISSION OF DRIVE TO ASF UNIT 1. The DE Lock Lever is moved to the right end by moving the Carriage Unit to through Step 4, drive power of ASF/Pump Motor is transferred to the ASF Unit by the path shown in Figure 2-32. Operating Principles Printer Mechanism Components 137 - Epson 4000 | Service Manual - Page 138
EPSON Stylus Pro 4000 † ASF/Pump Motor (Stepping motor) When the transmission path is photosensor is mounted at the right lower side of the printer. The Detector Wheel at the left side of the LD Roller and LD Roller Shaft is rotated by paper feed movement from the ASF Unit. There is a notch - Epson 4000 | Service Manual - Page 139
EPSON Stylus Pro 4000 Revision B LIFTER MOVEMENT (RAISING THE HOPPER) 1. When a print command is received from the PC, the LD Roller which has been in standby condition first rotates to the paper feed side (counterclockwise) by the required step number and then rotates in the opposite direction - Epson 4000 | Service Manual - Page 140
EPSON Stylus Pro 4000 „ Skew Correction Mode 2 1. The paper hits against the Gate Roller and Sub Roller. The Gate Roller and Sub Roller are stopped at this time. Stops Contact Location 2. Skew is corrected by the LD Roller pushing forward the unfed paper. 4. After feeding the paper paper remaining - Epson 4000 | Service Manual - Page 141
EPSON Stylus Pro 4000 2.2.6 Paper Eject/Release Mechanism This printer has a paper eject mechanism that switches eject according to the paper feed device and media used and has a release mechanism that applies pressure/release by the driven roller. Operating principles of the eject mechanism and - Epson 4000 | Service Manual - Page 142
EPSON Stylus Pro 4000 Revision B TRANSMISSION OF DRIVE TO PAPER EJECT UNIT 1. The Planetary Lock Lever (along with the DE 1 through Step 4, drive power of PG/PO Motor is transferred to the Paper Eject Unit by the path shown in Figure 2-38. Operating Principles Printer Mechanism Components 142 - Epson 4000 | Service Manual - Page 143
EPSON Stylus Pro 4000 Revision B † PG/PO Motor (Stepping motor) When the transmission path is switched to the Paper Eject Unit side by the Carriage Unit movement and DE Lock Lever, counterclockwise rotation of the PG/PO Motor performs eject switching movement as shown - Epson 4000 | Service Manual - Page 144
EPSON Stylus Pro 4000 2.2.6.2 Release Mechanism RELEASE MECHANISM DRIVE PG/PO Motor Spur Gear, 16 Planetary Holder (Spur Gear, 20, 21.6, Release Spur Gear, 20 Combination Gear, 36, 8.8 Figure 2-47. Release Mechanism Drive Components Operating Principles Printer Mechanism Components 144 - Epson 4000 | Service Manual - Page 145
EPSON Stylus Pro 4000 RELEASE MECHANISM MOVEMENT When the drive transmission path of the PG/PO Motor is switched by carriage movement, the driving force of the PG/PO Motor is transmitted to the Gate Roller by the path shown in Figure 2-45. (Refer to " Transmission of Drive to Paper † Paper Pressure - Epson 4000 | Service Manual - Page 146
EPSON Stylus Pro 4000 2.2.7 Multi Sensor 2.2.7.1 Overview This printer is equipped with a Multi Sensor that paper (white) or platen (black), specifying the edge of the paper. „ PW2 (diffused light receiver) Prints a special pattern and detects differences in concentration for paper (white) and ink - Epson 4000 | Service Manual - Page 147
EPSON Stylus Pro 4000 Revision B 2.2.7.2 Operations/Functions SENSOR SENSITIVITY ADJUSTMENT Before performing any function/adjustment, the sensor sensitivity level must be set for use as a standard. Specifically, paper gets fed and the LED light emission quantity should be adjusted to 3V that - Epson 4000 | Service Manual - Page 148
EPSON Stylus Pro 4000 Revision B PAPER WIDTH DETECTION When paper is fed, the paper and platen are scanned and the change points of the detected reflective light levels (paper present level paper absent level) are confirmed as the paper edges. The diagrams below show scan/detection timing. At - Epson 4000 | Service Manual - Page 149
EPSON Stylus Pro 4000 Revision B DOT MISSING DETECTION A pattern for dot missing detection is printed and dot missing is detected by scanning the pattern. The pattern is printed by all the nozzles, with 1 nozzle printing 1 block, and a block for a abnormal nozzle will not print. If dot missing is - Epson 4000 | Service Manual - Page 150
EPSON Stylus Pro 4000 AUTOMATIC BI-D ADJUSTMENT A pattern for adjustment is printed, the pattern is scanned and acceptable values are calculated from the collected values, and then adjustment is automatically executed. Two types of patterns are printed paper margin Printer Mechanism Components 150 - Epson 4000 | Service Manual - Page 151
EPSON Stylus Pro 4000 † Fine Adjustment Pattern This is a pattern for calculating the exact correction value. It uses all nozzles and 3 Bi-D patterns are printed after being Scanning Position Figure 2-59. Fine Adjustment Pattern Detection Operating Principles Printer Mechanism Components 151 - Epson 4000 | Service Manual - Page 152
EPSON Stylus Pro 4000 2.2.8 Others P-COVER OPEN SENSOR This sensor is mounted at the Printer Cover right side open/close components to detect the open or closed condition of the Printer at the printer right rear side to detect the removed/ installed condition of the Paper Guide Unit. Detecting - Epson 4000 | Service Manual - Page 153
EPSON Stylus Pro 4000 2.3 Outline of Control Circuit Board This section describes the operation of C511 MAIN Board, which controls and drives the Printer Mechanism of Stylus Pro 4000 formation IC21 Custom ASICC 1. Print data processing • Rasterizer • Head drive control 2. Mechanism control - Epson 4000 | Service Manual - Page 154
EPSON Stylus Pro 4000 not stop operating immediately, but power is kept on until the ink system ending sequence is completed. Do not disconnect the Power Cable or power by turning off any power switch other than that on the printer. There are three control signals between the C511 MAIN Board and - Epson 4000 | Service Manual - Page 155
TROUBLESHOOTING CHAPTER 3 - Epson 4000 | Service Manual - Page 156
EPSON Stylus Pro 4000 Revision B 3.1 Outline This section explains procedures for rapid and efficient troubleshooting if trouble occurs in the printer. 3.1.1 Check Before Troubleshooting First of all, when performing troubleshooting, the following basic parts should be checked. 1. Look in the - Epson 4000 | Service Manual - Page 157
EPSON Stylus Pro 4000 Revision B 3.2 Troubleshooting Based on Panel Messages This printer conducts self testing based on output conditions of each sensor. Any error detected by self testing is displayed by an LCD message and LED indicators. This section explains corrective actions for errors and - Epson 4000 | Service Manual - Page 158
I/F ERROR UNLOCK PRINT HEAD Table 3-1. Displayed Error Messages Displayed Error Paper Check ASF prohibitions *5 ON Ink out *1 GENUINE error, Wrong model number *1 Wrong dye/pigment, Wrong destination, Wrong 4-color/8-color*1 Ink Cartridge failure *1 No Ink Cartridge*1 Maintenance Tank full - Epson 4000 | Service Manual - Page 159
EPSON Stylus Pro 4000 Table 3-2. Service request error list(continued) Error Code Description Reference Page 00000101 CR Motor life p.172 00010000 PF Motor Encoder check error p.174 00010001 PF Motor out of step p.175 00010002 PF Motor over current p.175 00010003 PF Motor in-position - Epson 4000 | Service Manual - Page 160
EPSON Stylus Pro 4000 Revision B 3.2.2 Corrective Actions for Displayed Warnings Warnings replace the "READY"/"PRINTING" message in the LCD to notify the user of the condition, but printing may continue because printer operations are not affected. A warning message cannot be cleared until the - Epson 4000 | Service Manual - Page 161
EPSON Stylus Pro 4000 Revision B † Recovery nnnn Cause 0002 The number of CR movement cycles has reached predetermined value. RTC backup battery shut off 0008 Pump counter has reached predetermined amount. 0040 Date is not set 0080 RTC backup battery is not installed. 0088 0100 RTC - Epson 4000 | Service Manual - Page 162
EPSON Stylus Pro 4000 CHECK P O IN T Replace the following parts when replacing the Cleaning Unit. CLEANER, HEAD, B, ASP POROUS PAD, BOX, FL, UPPER CLEANER, HEAD, A, ASP POROUS PAD, BOX, FL, LOWER BOX ASSY., FLUSHING PUMP CAP ASSY Revision B Troubleshooting Troubleshooting Based on Panel - Epson 4000 | Service Manual - Page 163
EPSON Stylus Pro 4000 Revision B 3.2.3 Corrective Actions for Error Display Error messages replace the "READY"/"PRINTING" message in the LCD to notify the user of the condition. The following explains corrective actions for when the errors are displayed. CLEANING FAILURE LCD NOZZLES STILL - Epson 4000 | Service Manual - Page 164
EPSON Stylus Pro 4000 Revision B PAPER EJECT ERROR LCD REMOVE PAPER Explanation After paper eject, paper is left in paper route and ASF Paper Sensor has turned ON. After paper eject, paper is left in paper route and PE Sensor has turned ON. Or paper eject was done without the Paper Eject Roller ( - Epson 4000 | Service Manual - Page 165
EPSON Stylus Pro 4000 Revision B PAPER RECOGNITION ERROR LCD RELOAD PAPER Explanation When setting paper by front loading or roll paper cutter ON, surpassed back feed critical mass by top edge detection. When paper which the paper width is less than 8inch is set. When detecting paper width, the - Epson 4000 | Service Manual - Page 166
EPSON Stylus Pro 4000 Revision B PAPER SKEW ERROR LCD PAPER NOT STRAIGHT PAPER CUT ERROR LCD PAPER NOT CUT Explanation Generated when position of left/right edges changes more than 3mm between start and finish of print. When this error is generated, it is necessary to check print results because - Epson 4000 | Service Manual - Page 167
EPSON Stylus Pro 4000 Revision B ASF PROHIBITIONS LCD FORBIDDEN MEDIA FROM P. TRAY FEED SHEET PAPER MANUARY Explanation ASF is designated paper tray when command is received for printing of media that is prohibited from being supplied by ASF, such as Water Color Paper. Recovery Reset panel by - Epson 4000 | Service Manual - Page 168
EPSON Stylus Pro 4000 Revision B NO INK CARTRIDGE LCD NO INK CRTG Explanation There is no Ink Cartridge installed. There detected any Ink Cartridge slot without cartridge. Recovery Open I/H Cover and properly install the Ink Cartridge indicated by the LCD panel. Or insert a new Ink Cartridge and - Epson 4000 | Service Manual - Page 169
EPSON Stylus Pro 4000 RELEASING PAPER LEVER LCD LOAD PAPER (Except roll paper) LOAD PAPER SUCTION (Roll paper only) Explanation Paper Lever was released during standby. RELEASING PAPER LEVER IN OPERATION LCD SET PAPER LEVER Explanation Paper Lever was released during one of the movements. - Epson 4000 | Service Manual - Page 170
the movements. Recovery Set the Maintenance Tank. REAR COVER OPEN LCD REAR COVER OPEN Explanation Generated when Paper Guide Unit is not installed. Under this error, all of CR motion and ink sequences are halted. Therefore it may give damages to printing head if this situation continues very long - Epson 4000 | Service Manual - Page 171
EPSON Stylus Pro 4000 CR LOCK UNLOCKED ERROR LCD UNLOCK PRINT HEAD Explanation Print head (Carriage Unit) may be locked. Revision B Recovery Turn off the printer, release the lock of print head (Carriage Unit), and turn the printer back on p.202. FATAL ERROR The printer has failed. Because this - Epson 4000 | Service Manual - Page 172
EPSON Stylus Pro 4000 3.2.4 Corrective Actions for Service Request Display Service request errors are displayed in the LCD panel with the intention of notifying the user of the need for a service engineer to check/replace corresponding parts. This section describes service request errors and - Epson 4000 | Service Manual - Page 173
EPSON Stylus Pro 4000 2. The product-life cycle is the same as CR Motor-life cycle, so check and maintain all over the printer mechanism. Specially check points are shown below. „ Check for bending or damage to the Head FFC. „ Check for damage to the CR timing belt and PF timing belt. „ Check for - Epson 4000 | Service Manual - Page 174
EPSON Stylus Pro 4000 SERVICE REQ. 00010000 † Error meaning: PF Motor Encoder check error † Explanation During initial operation at power on or during PF Motor operation, there may be a case where the encoder pulse signal can not be recognized - Epson 4000 | Service Manual - Page 175
EPSON Stylus Pro 4000 Revision B SERVICE REQ. 00010001 † Error "Maintenance problem causing a short circuit to the frame. † Remedy 1. Check for dirt, paper dust or damage to the Loop Scale. 2. Replace the Motor Assy., PF (p341) 3. Replace the C511 MAIN Board (p221) Troubleshooting Troubleshooting - Epson 4000 | Service Manual - Page 176
EPSON Stylus Pro 4000 Revision B SERVICE REQ. 00010003 † Error meaning: PF Motor in-position time-out † Explanation At PF stop processing in PF Motor control, there may be a case where the paper can not move to the final target position within a specified period of time. In such a case, this - Epson 4000 | Service Manual - Page 177
EPSON Stylus Pro 4000 Revision B SERVICE REQ. 00010005 † Error meaning: CR Motor out of step † Explanation During CR Motor operation, there may be a case where the encoder pulse signal within the specified range is - Epson 4000 | Service Manual - Page 178
EPSON Stylus Pro 4000 Revision B SERVICE REQ. 00010007 † Error meaning: CR Motor in-position time-out printer stops operating. † Remedy If not cleared by turning the power OFF and back ON, the CPU or ASIC is deemed defective, so replace the C511 MAIN Board (p221). Troubleshooting Troubleshooting - Epson 4000 | Service Manual - Page 179
EPSON Stylus Pro 4000 Revision B SERVICE REQ. 0001000A † Error meaning: CR home position sensor error † Explanation During initial operation at power on or during printing operation, there may be a case where the home position can not be detected at the home position detection timing or within a - Epson 4000 | Service Manual - Page 180
EPSON Stylus Pro 4000 Revision B SERVICE REQ. 0001000F † Error meaning: CR Motor PWM output faulty † Explanation There may be a case where a current exceeding the specified value flows during CR Motor operation. In such a case, this message is displayed and the printer stops operating. This error - Epson 4000 | Service Manual - Page 181
EPSON Stylus Pro 4000 Revision B SERVICE REQ. 0001001B † Error meaning: Head driver (TG) temperature error † Explanation During printing operation (empty jetting of ink), there may be a case where the temperature inside the Print Head has risen above the specified value and the thermistor in the - Epson 4000 | Service Manual - Page 182
EPSON Stylus Pro 4000 Revision B SERVICE REQ. 0001001E † Error meaning: PF servo parameter error † Explanation There may be a case where a voltage exceeding the specified value is about to be applied to the PF Motor. In such a case, this message is displayed and the printer stops operating. † - Epson 4000 | Service Manual - Page 183
EPSON Stylus Pro 4000 Revision B SERVICE REQ. 00010023 † Error meaning: RTC analysis error † Explanation There may be a case where the absolute time data stored on NVRAM indicates an impossible date or hour. In such a case, this message is displayed and the printer stops operating. † Remedy „ - Epson 4000 | Service Manual - Page 184
on the printer in Maintenance Mode 2, execute "RTC&USBID&IEEE1394ID" and enter date of "RTC." SERVICE REQ. 00010028 † Error meaning: Head error † Explanation Print Head has been damaged or undefined NMI was detected at CPU. † Remedy Replace the Printhead (p278) SERVICE REQ. 00010029 † Error meaning - Epson 4000 | Service Manual - Page 185
EPSON Stylus Pro 4000 SERVICE REQ. 0001002D † Error meaning: Cleaning Unit work life error † Cause of trouble Pump counter (8P x 1000 = 8,000P) has reached its regulated value. † Remedy Replace the Cleaning Unit and reset the Cleaning Unit work life counter. (Reset When Cleaning Unit Change (p423).) - Epson 4000 | Service Manual - Page 186
EPSON Stylus Pro 4000 Revision B SERVICE REQ. 00010033 † Error meaning: Paper eject phase detection error † Cause of trouble Home position for paper eject switching cannot be detected even though PG Motor turns at designated amount, or Paper eject phase sensor is damaged. † Remedy 1. Check if the - Epson 4000 | Service Manual - Page 187
EPSON Stylus Pro 4000 Revision B SERVICE REQ. 00010039 † Error meaning: PG adjustment value incorrect overwrite error † Explanation Writing to the PG adjustment value area of NVRAM was done improperly, or an improper value was read. † Cause of trouble „ Defective circuit board „ Faulty CPU - Epson 4000 | Service Manual - Page 188
EPSON Stylus Pro 4000 Revision B SERVICE REQ. 00020000 † Error meaning: NVRAM error † Explanation There may be a case where the parameter data in NVRAM is broken. In such a case, this message is displayed and the printer stops operating. † Cause of trouble „ NVRAM erase error „ Write error (Check - Epson 4000 | Service Manual - Page 189
EPSON Stylus Pro 4000 SERVICE REQ. 0002000A † Error meaning: Program load error † Explanation SUM check error for program area on RAM. † Cause of trouble „ Program problem „ SDRAM failure † Remedy 1. Installing Firmware (p424) 2. Replace the C511 MAIN Board (p221) SERVICE REQ. 0002000B † Error - Epson 4000 | Service Manual - Page 190
EPSON Stylus Pro 4000 SERVICE REQ. 10000180 † Error meaning: CPU reserve command code exception error † Cause of trouble „ Defective circuit board „ Faulty CPU soldering „ Program trouble „ Generation error † Remedy 1. Installing Firmware (p424) 2. Replace the C511 MAIN Board (p221) SERVICE REQ. - Epson 4000 | Service Manual - Page 191
EPSON Stylus Pro 4000 SERVICE REQ. 10000XXX † Error meaning: CPU error † Cause of trouble „ Defective circuit board „ Faulty CPU soldering „ Program trouble „ Generation error † Remedy 1. Installing Firmware (p424) 2. Replace the C511 MAIN Board (p221) SERVICE REQ. 0003XXXX SERVICE REQ. 0DXXXXXX † - Epson 4000 | Service Manual - Page 192
EPSON Stylus Pro 4000 Revision B 3.3 Troubleshooting Based on Your Printout This section describes conceivable print quality problems that may occur with this printer and the troubleshooting points for those errors. Item 1 2 3 4 5 6 Table 3-5. Diagnosing trouble based on printout Description - Epson 4000 | Service Manual - Page 193
is not improved by the above items (adjustments), replace the following parts. „ Printhead (p278) „ Printer Mechanism (SP) (p236) SMUDGED OR MARRED PRINTOUT (FRONT SIDE) If smudging or marring occurs due to rubbing by the head, etc. on the paper's printed surface, check the following items. 1. If - Epson 4000 | Service Manual - Page 194
EPSON Stylus Pro 4000 Revision B SMUDGED OR MARRED PRINTOUT (REVERSE SIDE) If smudging or marring of the paper back surface with ink occurs, the following items should be checked. 1. Check if the paper is bent or curled, and replace the paper with new one if abnormal. 2. Check to see if there isn - Epson 4000 | Service Manual - Page 195
EPSON Stylus Pro 4000 BANDING IN THE PAPER FEED DIRECTION If banding (uneven density, rough image) in parallel with the paper feed direction is found on the print, perform the following adjustment: † Bi-D adjustment The Bi-D adjustment can be executed by any of the following methods. „ "HEAD - Epson 4000 | Service Manual - Page 196
DISASSEMBLY & ASSEMBLY CHAPTER 4 - Epson 4000 | Service Manual - Page 197
EPSON Stylus Pro 4000 Revision B 4.1 Introductory Information This chapter describes disassembly/reassembly steps for the Stylus Pro 4000. When no special instructions are given, reassembly is done by reversing the order for disassembly steps. † WARNING Dangers that could cause injury or death are - Epson 4000 | Service Manual - Page 198
EPSON Stylus Pro 4000 W A R N IN G C A U T IO N • Wear gloves while performing disassembly/ reassembly to prevent accidental cuts. • If ink contacts the eyes, rinse eyes with clean water and consult a physician. • If ink contacts the skin, wash with soap and water. Consult a physician if the skin - Epson 4000 | Service Manual - Page 199
screws Hex wrench Ink cartridge Maintenance Tank HEAD EXCHANGE SUPPORT TOOL CUTTER CAP CR SUS PLATE SUPPORT TOOL ASF EXCHANGE SUPPORT TOOL Commercial Tool ICxx24* PXMT1 1294672 1401456 1400023 1401458 For roll paper feeder - - Used in Print Head replacement Used in Print Head replacement Used in - Epson 4000 | Service Manual - Page 200
EPSON Stylus Pro 4000 4.1.3 Screws Screws used on the Stylus Pro 4000 are shown below. Name Decorative Screw C.B.S. 3x6 C.B.S. 3x6 C.C.P. 4x10 C.B.P. 3x8 C.B.S. (O) 3x6 C.B.S. (O) 3x6 Shaft, Installation, CR C.B.S. 3x8 C.B.S. 3x10 C.B.P. 3x6 C.B. 3x4 C.B.P. (P2) 3x8 C.P.P. 2.6x8 C.B.P. 3x12 - Epson 4000 | Service Manual - Page 201
EPSON Stylus Pro 4000 4.2 Disassembly Procedures C A U T IO N „ Because this printer is assembled with precise measurements of Chapter 7. (Disassembly of parts other than those listed could result in problems that cannot be repaired except at the factory.) „ Disassembly/reassembly operations for - Epson 4000 | Service Manual - Page 202
EPSON Stylus Pro 4000 4.2.1 Basic Operations 4.2.1.1 Release of the Transport Retaining Lever 1. Open "Cover, Printer". (Refer to Figure 4-2.) 2. Grasp and pull the "Transport Retaining Lever" (green) located on the left side of the "Carriage Unit" to release the locked condition - Epson 4000 | Service Manual - Page 203
EPSON Stylus Pro 4000 4.2.1.2 Carriage Unit Lock Release/Lock Set Method CARRIAGE UNIT LOCK RELEASE 1. Open "Cover, Printer". 2. Push in "Holder, Solenoid" to release carriage lock. (Refer to Figure 4-4.) Revision B Holder, Solenoid CARRIAGE UNIT LOCK SET 1. Move "Carriage Unit" to the right until - Epson 4000 | Service Manual - Page 204
EPSON Stylus Pro 4000 4.2.2 Consumable Parts/ASF Cassette Removal 4.2.2.1 Ink Cartridges 1. Open "Cover, I/H, Left (Right)". (Refer to Figure 4-6.) 2. Lift "IC, Lock Lever, Knob, Left (Right)" to release "Ink Cartridge" lock. (Refer to Figure 4-6.) 3. Remove the eight "Ink Cartridges" from the - Epson 4000 | Service Manual - Page 205
EPSON Stylus Pro 4000 4.2.2.2 Maintenance Tank (Porous Pad Assy., Ink Eject) C A U T IO N Do not touch the IC chip while performing the following steps. Doing so could disrupt normal operation/printing. 1. Insert the fingers of your right hand into the hole of the "Maintenance Tank" and pull - Epson 4000 | Service Manual - Page 206
EPSON Stylus Pro 4000 4.2.2.3 Cutter Assembly 1. Enter cutter replacement mode using the panel setting with printer power on. 2. The carriage unit moves and stops at the cutter replacement position. 3. Open "Cover, Printer". C A U T IO N When pressing the "Cutter Assembly" tab in the following - Epson 4000 | Service Manual - Page 207
EPSON Stylus Pro 4000 4.2.2.4 ASF Cassette 1. Remove the "ASF Cassette" from the printer. CHECK P O IN T The disassembly steps described on the following pages require prior removal of the "ASF Cassette". Revision B ASF Cassette Figure 4-11. ASF Cassette Removal - Epson 4000 | Service Manual - Page 208
EPSON Stylus Pro 4000 4.2.2.5 Spindle SPINDLE REMOVAL 1. Open "Cover, Roll Paper". 2. Remove "Spindle". Spindle Revision B Cover, Roll Paper 1 2 SPINDLE DISASSEMBLY 1. Remove "Spindle" (p208). 2. Remove "Flange, Left" (black) along with "Adapter" from the "Spindle". 3. Release hooks (4 each, 8 - Epson 4000 | Service Manual - Page 209
EPSON Stylus Pro 4000 4.2.3 Panel Unit/Housing Removal This section describes steps for removing housing 14.) „ Decorative screw : 4 pcs. 3. Slide the "Holder, Roller, Unit" upward from the printer rear surface and remove it outward. (Refer to Figure 4-15.) Revision B Screws Holder, Roller, Unit - Epson 4000 | Service Manual - Page 210
EPSON Stylus Pro 4000 4.2.3.2 Paper Guide Assy., M, SP 1. Pull the left and right levers that secures the "Paper Guide Assy., M, SP" inward, and then pull out the "Paper Guide Assy., M, SP". Paper Guice Assy., M, SP Securing Lever Figure 4-16. Paper Guide Assy., M, SP Removal Disassembly & Assembly - Epson 4000 | Service Manual - Page 211
EPSON Stylus Pro 4000 4.2.3.3 Cover, Side, Left 1. Remove "Holder, Roller, Unit" (p209). 2. Remove "Paper Guide Assy., M, SP" (p210). 3. Open "Cover, Printer". 4. Remove the four screws securing "Cover, Side, Left". „ C.B.S. 3x6 „ C.B.S. 3x8 „ C.C.P. 4x10 : 2 pcs. : 1 pc. : 1 pc. 5. While - Epson 4000 | Service Manual - Page 212
EPSON Stylus Pro 4000 4.2.3.4 Cover, Side, Right 1. Remove "Maintenance Tank (Porous Pad Assy., Ink Eject)" (p205). 2. Remove "Holder, Roller, Unit" (p209). 3. Remove "Paper Guide Assy., M, SP" (p210). 4. Move "Paper Lever" until two screws can be seen and hold the lever in the place. 5. Remove the - Epson 4000 | Service Manual - Page 213
EPSON Stylus Pro 4000 6. Open "Cover, Printer". 7. Remove the four screws securing "Cover, Side, Right". printer. C A U T IO N When removing the "Cover, Side, Right", ink may leak or splatter. So have cleaning rags ready and prevent ink from getting on the work area. Install the "Maintenance Tank - Epson 4000 | Service Manual - Page 214
EPSON Stylus Pro 4000 4.2.3.5 Panel, Front/Panel Unit 1. Remove "Cover, Side, Left" (p211). 2. Remove "Cover, with positioning hole in frame. (Refer to Figure 4-20.) „ Install "Panel, Front" to printer by tightening screws in the order shown by number in Figure 4-21. Step 3 Panel Unit Revision - Epson 4000 | Service Manual - Page 215
EPSON Stylus Pro 4000 7. Remove the three screws securing the "Panel Unit", and remove the "Panel Unit" from "Panel, Front". (Refer to Figure 4-22.) „ C.B.S. (O) 3x6 : 3 pcs. Panel Unit Revision B C.B.S. (O) - Epson 4000 | Service Manual - Page 216
EPSON Stylus Pro 4000 4.2.3.6 Cover, Printer 1. Remove "Cover, Side, Left" (p211). 2. Remove the two screws securing "Plate, P Cover, Left". Then remove "Plate, P Cover, Left" by sliding it to the left side while supporting "Cover Printer" with your hand. „ C.B.S. 3x6 : 2 pcs. Follow the steps - Epson 4000 | Service Manual - Page 217
EPSON Stylus Pro 4000 3. Remove "Cover, Printer" upward by sliding to left side. Insert the right shaft of "Cover, Printer" into the shaft hole on "Plate, P Cover, Right". Shaft Hole Shaft of Cover, Printer Plate, P Cover, Right Revision B Cover, Printer 2 1 Figure 4-24. Cover, Printer Removal - Epson 4000 | Service Manual - Page 218
EPSON Stylus Pro 4000 4.2.3.7 Cover, Rear 1. Remove "Cover, Printer" (p216). 2. Remove "Cover, Side, Right" (p212). 3. Remove the three screws securing "Cover, Rear" and remove "Cover, Rear" upward. „ Shaft, Installation, CR :2 pcs. „ C.B.S. 3x6 :1 pc. Align - Epson 4000 | Service Manual - Page 219
EPSON Stylus Pro 4000 4.2.3.8 P Cover Open Sensor 1. Remove "Panel, Front/Panel Unit" (p214). 2. Release the two tabs securing "P Cover Open Sensor" and then release the "P Cover Open Sensor". 3. Disconnect - Epson 4000 | Service Manual - Page 220
EPSON Stylus Pro 4000 4.2.3.9 Rear Cover Sensor 1. Remove "Paper Guide Assy., M, SP" (p210). 2. Remove the screw securing "Rear Cover Sensor Unit" to the printer frame. (Refer to Figure 4-27.) „ C.B.B. 2x10 : 1 pc. 3. Release the tab securing the "Rear Cover Sensor Unit" to the printer frame and - Epson 4000 | Service Manual - Page 221
EPSON Stylus Pro 4000 4.2.4 Circuit Board Removal This section describes steps for removing "C511 MAIN Board cause damage to circuit board components.) 1. Remove "Holder, Roller, Unit" (p209). 2. Remove "Paper Guide Assy., M, SP" (p210). 3. Remove the two screws securing "Cover, Harness". (Refer to - Epson 4000 | Service Manual - Page 222
EPSON Stylus Pro 4000 C A U T IO N Be careful not to pull the "PCB Unit" too hard and stretch the harness when performing the following steps. 6. Remove the four screws securing - Epson 4000 | Service Manual - Page 223
EPSON Stylus Pro 4000 7. Disconnect all connectors/harnesses from "C511 MAIN Board". 30 C511_SUB-B Board (CN100) 4 CN9 - 30 C511_SUB Board (CN1) 5 CN7 - 30 Print Head Board (CN2) 6 CN8 - 30 Print Head Board (CN1) 7 CN53 - 28 C511_SUB-C Board (CN201) 8 CN52 - 15 C511_SUB-C Board - Epson 4000 | Service Manual - Page 224
EPSON Stylus Pro 4000 „ The connector number is marked on each connector on the board. When connecting the FFCs, match the connector numbers with the ones on the board with the number printed side of the FFCs facing toward the printer rear. Connector Numbers „ The wires should be bundled with - Epson 4000 | Service Manual - Page 225
EPSON Stylus Pro 4000 8. Remove the screw securing USB connector. (Refer to Figure 4-34.) „ C.P. 3x6 : 1 pc. 9. Remove the two screws securing "Cover, Connector, Upper; B" and then remove "Cover, Connector, - Epson 4000 | Service Manual - Page 226
EPSON Stylus Pro 4000 11. Release the four hooks securing the "Guide Rail" and remove the "Guide Rail". (Refer to Figure 4-36.) Secure the two "Guide Rail" hooks to the two "C511 MAIN Board" installation holes. Hooks Guide Rail 3 Revision B Installation Holes 12. Remove the two screws securing - Epson 4000 | Service Manual - Page 227
EPSON Stylus Pro 4000 directly on a conductive surface. „ Circuit boards supplied as service parts have been equipped with lithium battery. Do not place Chapter 5 "Adjustment" (p.354) and perform specified adjustments after replacing the "C511 MAIN Board". C.B.S. 3x8 Revision B IEEE1394 Connector - Epson 4000 | Service Manual - Page 228
EPSON Stylus Pro 4000 4.2.4.2 Power Supply Board W A R N IN G When removing the "Power Supply Board", wait 5 minutes after unplugging the AC power cord before starting work to allow discharge of - Epson 4000 | Service Manual - Page 229
EPSON Stylus Pro 4000 4.2.4.3 C511_SUB Board 1. Open "Cover, Printer". C A U T IO N When performing the following steps, remove protective equipment if it is installed and make sure to release the Carridge Unit lock with the "Transport - Epson 4000 | Service Manual - Page 230
EPSON Stylus Pro 4000 4. Disconnect all connectors/harnesses on the "C511_SUB Board". (Refer to Figure 4-42.) Table 4-5. Connectors/Harnesses Connected to C511_SUB Board Connector No. Color Number of Pins - Epson 4000 | Service Manual - Page 231
EPSON Stylus Pro 4000 4.2.4.4 C511_SUB-B Board Panel Unit (CN1) 2 CN46 - 7 Porous Pad Assy., Ink Eject 3 CN39 PK 7 CSIC_R1 Board (Photo Black) 4 CN42 Sensor (Right) 9 CN26 Black 2 Paper Eject Release Sensor 10 CN25 Red 2 ASF Paper Sensor 11 CN27 Yellow 2 Rear Hand Insertion - Epson 4000 | Service Manual - Page 232
EPSON Stylus Pro 4000 3. Remove the four screws securing "C511_SUB-B Board" and remove "C511_SUB-B Board". „ C.B.P. 3x6 : 4 pcs. C.B.P. 3x6 Revision B Figure 4-44. C511_SUB-B Board Removal Disassembly & Assembly Disassembly Procedures 232 - Epson 4000 | Service Manual - Page 233
EPSON Stylus Pro 4000 4.2.4.5 C511_SUB-C 9 CN30 Yellow 3 ASF Phase Sensor 10 CN28 White 2 Paper Eject Phase Sensor 11 CN32 Red 3 PG Phase Sensor Note is marked with its corresponding ink name. Refer to Table 4-7 and connect the harnesses properly. Ink Names Clamps Revision B FFC - Epson 4000 | Service Manual - Page 234
EPSON Stylus Pro 4000 4. Remove the three screws securing "C511_SUB-C Board" and remove "C511_SUB-C Board". „ C.B.S. 3x6 : 3 pcs. Revision B C.B.S. 3x6 Figure 4-47. SUB-C Board Removal Disassembly & Assembly Disassembly Procedures 234 - Epson 4000 | Service Manual - Page 235
EPSON Stylus Pro 4000 4.2.5 Printer Mechanism Disassembly This section describes disassembly steps for main components of the printer mechanism. C A U T IO N For the following reasons, replaceable parts are limited to defined components. Therefore removal or replacement of parts that cannot be - Epson 4000 | Service Manual - Page 236
parts removal/installation procedure and remedy after replacement. 1. Remove the following parts from the old printer, and attach the removed parts except consurmables to "Printer Mechanism (SP)". „ Consumables (ink cartridge, maintenance tank) „ C511MAIN Board (Refer to "4.2.4.1 C511 MAIN Board - Epson 4000 | Service Manual - Page 237
EPSON Stylus Pro 4000 5. Enter Maintenance Mode 2 (panel display: "SELF TESTING") Power OFF → Press "Paper Select ( - Epson 4000 | Service Manual - Page 238
EPSON Stylus Pro 4000 4.2.5.2 Fan, Blower 1. Remove the four screws securing the two "Paper Guide, Eject, Stacker"s and then remove the two "Paper Guide, Eject, Stacker"s. (Refer to Figure 4-49.) „ Installation Plate, Shaft, CR : 2 pcs. „ C.B.S. 3x8 : 2 pcs. 2. Release relay harness connected - Epson 4000 | Service Manual - Page 239
EPSON Stylus Pro 4000 4. Peel off the acetate tape attached to the gap between the "Frame, Fan, Unit" and the main unit. 5. Remove the two screws securing "Frame, Fan, - Epson 4000 | Service Manual - Page 240
EPSON Stylus Pro 4000 4.2.6 ASF This section discribes the "ASF Unit" removal and the assembly and disassembly of the main components comprising the ASF. 4.2.6.1 ASF Unit C A U T IO N This section explains the working procedure using the "ASF EXCHANGE SUPPORT TOOL". Always prepare the tool before - Epson 4000 | Service Manual - Page 241
EPSON Stylus Pro 4000 4. Insert the tab of the "Joint Plate" to the slit of the "Base, Left". 5. Insert the "Base, Left" with the "Joint Plate" set in the Step 4 under the left bottom of the main unit until the notches hit the rubber feet of the printer. Revision B Figure 4-52. "Joint Plate" - Epson 4000 | Service Manual - Page 242
EPSON Stylus Pro 4000 6. Insert the "Base, Right" under the right bottom of the main unit until the noches hit the rubber feet of the printer. CHECK P O IN T After the "Base, Left", "Base, Right", and the "Joint Plate" are set up. Revision B Figure 4-54. "Base, Right" Setting Disassembly & - Epson 4000 | Service Manual - Page 243
EPSON Stylus Pro 4000 C A U T IO N When lifting the printer in the steps given below, pay attention to the followings: „ Hold the front panel section of the printer. Holding other section could cause the malfunction of the printer. „ This printer is heavy (approximately 40 kg). Hold the front - Epson 4000 | Service Manual - Page 244
EPSON Stylus Pro 4000 8. Hold the front panel section of the printer, lift the printer upward and keep it there, and then set the "Stand" in both the rubber foot on the bottom of the printer and the "Base, Left", following the steps below. 8-1. Fit the rubber foot of the printer into the foot - Epson 4000 | Service Manual - Page 245
EPSON Stylus Pro 4000 10. Remove the two screws that secure the "ASF Unit" on the right side of the printer and the two screws that secure "Duct, Air, C, Assy". „ C.B.S. 3x6 : 4 pcs. C A U T IO N When performing the following work, do not keep the "Duct, Air, C, Assy" too far from the printer - Epson 4000 | Service Manual - Page 246
EPSON Stylus Pro 4000 12. While holding the "ASF Unit", remove the three screws that secure the "ASF Unit" on the left side of the printer. „ C.B.S. 3x6 : 3 pcs. Revision B C.B.S. 3x6 Disassembly & Assembly Figure 4-58. Screws Securing "ASF Unit" Disassembly Procedures 246 - Epson 4000 | Service Manual - Page 247
EPSON Stylus Pro 4000 13. Remove the "ASF Unit" downward from the printer. When installing the "ASF Unit" to the printer sure to refer to Chapter 5 "Adjustment" (p.354) and perform specified adjustments after replacing the "ASF Unit". ASF Unit Figure 4-59. "ASF Unit" Removal Disassembly & Assembly - Epson 4000 | Service Manual - Page 248
EPSON Stylus Pro 4000 4.2.6.2 Roller Assy., LD, Left / Roller Assy., LD, Right 1. Remove "ASF Unit" (p240). 2. Remove the "E-ring, 6", and pull out the "Gear, 44.74" and "Lever, Hopper, - Epson 4000 | Service Manual - Page 249
EPSON Stylus Pro 4000 3. Remove the three screws that secure the "Frame, ASF, Right" Hopper Revision B 4. Push down and release the tab that secures the "Wheel, Detector" using a precision driver or a similar tool, and then remove the "Wheel, Detector".(Refer to Figure 4-63.) C.B.P. 3x8 Figure - Epson 4000 | Service Manual - Page 250
EPSON Stylus Pro 4000 5. Rotate the "Bushing, Lock, 11.4" to the direction shown in Figure 4-64 to match the rib with the frame hole, release the boss at the - Epson 4000 | Service Manual - Page 251
EPSON Stylus Pro 4000 6. Detach the resin plate that is attached on the "Holder, Edge Guide, Left", release the tab that secures "Holder, Edge Guide, Left" to the "Cover, Roller, LD, Left", and then remove the "Holder, Edge Guide, Left" to the right. (Refer to Figure 4-65.) 7. Release the tab that - Epson 4000 | Service Manual - Page 252
EPSON Stylus Pro 4000 8. Remove the "E-ring, 6" from the "Shaft, Roller, LD". 9. Draw out the , refering the Figure 4-67. Revision B Roller Assy., LD, Right Compression Spring, 0.407 Holder, Edge Guide, Left Roller Assy., LD, Left Shaft, Roller, LD Compression Spring, 0.4 Roller, Sub, LD, Middle - Epson 4000 | Service Manual - Page 253
EPSON Stylus Pro 4000 4.2.6.3 Mount Assy., Plate, Motor, ASF, SP 1. Remove "Box Assy., Flushing / Pump Unit" (p309). 2. Disconnect relay connector. (Refer to Figure 4-68.) 3. Detach E-ring and then remove " - Epson 4000 | Service Manual - Page 254
EPSON Stylus Pro 4000 4. Insert screwdriver through hole at lower right of "Spur Gear, 16" removed in Step 3 and remove the screw securing "Mount Assy., Plate, Motor, ASF, SP". „ C.B. - Epson 4000 | Service Manual - Page 255
EPSON Stylus Pro 4000 Install "Mount Assy., Plate, Motor, ASF, SP" following the steps below. 1. "Combination Gear 12, 22.4" may fall from the "Mount Assy., Plate, Motor, ASF, SP" - Epson 4000 | Service Manual - Page 256
EPSON Stylus Pro 4000 5. Tighten screws so that there are no gaps at the locations Q U IR E D Be sure to refer to Chapter 5 "Adjustment" (p.354) and perform specified adjustments after replacing the "Mount Assy., Plate, Motor, ASF, SP". Disassembly & Assembly Disassembly Procedures Revision B 256 - Epson 4000 | Service Manual - Page 257
EPSON Stylus Pro 4000 4.2.6.4 ASF Phase Sensor 1. Remove "Cover, Side, Left" (p211). 2. Remove the four screws securing "Cover, Motor, PF" and then remove "Cover, Motor, PF" in the upward - Epson 4000 | Service Manual - Page 258
EPSON Stylus Pro 4000 4. Use a tool such as a precision screwdriver to press down on and release the hook securing the "Wheel, Detector", and remove the "Wheel, Detector". (Refer to - Epson 4000 | Service Manual - Page 259
EPSON Stylus Pro 4000 4.2.6.5 ASF Paper Sensor 1. Remove PCB Unit. (Refer to "4.2.4.1 C511 MAIN Board" (p221).) 2. Release "ASF Paper Sensor" harness from clamp. 3. Release the two tabs securing "ASF Paper Sensor" and then release "ASF Paper Sensor". 4. Disconnect connector from "ASF Paper Sensor". - Epson 4000 | Service Manual - Page 260
EPSON Stylus Pro 4000 4.2.7 Carriage Mechanism 4.2.7.1 Carriage Unit CHECK P O IN T This section explains the working procedure using the "CR SUS PLATE SUPPORT TOOL" shown in the figure below. The "CR SUS PLATE SUPPORT TOOL" is a tool that holds and fixes the SUS plate which is on the CR guide - Epson 4000 | Service Manual - Page 261
EPSON Stylus Pro 4000 When installing the "Ink Tube Unit", be sure to check the followings. „ Release the "Belt, CR" tension (Refer to "4.2.7.2 Motor Assy., CR" (p264).), and sandwich the "Belt, CR" with the "Carriage Unit" and the "Ink Tube" at between the two red lines marked on the reverse side - Epson 4000 | Service Manual - Page 262
EPSON Stylus Pro 4000 5. Remove the "Tension Spring, 3.81" from the hooks of both the "Head Unit" and the "Lever, Inclination 4-79, and move the "Carriage Unit" toward you. 9. Lift the "Head Unit" together with the "Ink Tube Unit" to remove from the"CarriageUnit". (Refer to Figure 4-80.) Extension - Epson 4000 | Service Manual - Page 263
EPSON Stylus Pro 4000 10. Set the "CR SUS PLATE SUPPORT TOOL" on the both sides of the "Carriage Unit" as shown in Figure 4-81. Place the "CR SUS PLATE SUPPORT TOOL" with after replacing or removing the "Carriage Unit". Shaft, Rear Carriage Unit 2 Revision B 1 Shaft, Front CR SUS PLATE SUPPORT - Epson 4000 | Service Manual - Page 264
EPSON Stylus Pro 4000 4.2.7.2 Motor Assy., CR 1. Remove "Release, Lever Unit". (Refer to "4.2.9.1 Release Unit" ( (Refer to "4.2.4.1 C511 MAIN Board" (p221).) 5. Release "Motor Assy., CR" harness from "Paper Guide, Lower" tab and the two channels. (Refer to Figure 4-82.) 6. Peel two pieces of - Epson 4000 | Service Manual - Page 265
EPSON Stylus Pro 4000 8. Release the "Motor Assy., CR" harness from the four cramps, four pieces of acetate tape and the tab on the frame. (Refer to Figure 4-84.) - Epson 4000 | Service Manual - Page 266
EPSON Stylus Pro 4000 CHECK P O IN T When performing the following Q U IR E D Be sure to refer to Chapter 5"Adjustment" (p.354) and perform specified adjustments after installing or replacing the "Motor Assy., CR". Lever, Lock, PG Screw Figure 4-85. Releasing Tension of Belt, CR Belt, CR - Epson 4000 | Service Manual - Page 267
EPSON Stylus Pro 4000 4.2.7.3 Motor Assy., PG 1. Remove "Cover, Side, Right" (p212). 2. Peel off the acetate tape and release the tab at the lower part of the "Sheet, Ink, Stopper, C" from the U-shaped cutout of the "Frame, Base, Side, Right". (Refer to Figure 4-87.) 3. Disconnect relay connector. ( - Epson 4000 | Service Manual - Page 268
EPSON Stylus Pro 4000 7. Remove the two screws securing "Motor Assy., PG". (Refer to Figure 4-89.) „ C.C. 3x6 : 2 pcs. C A U T IO N When performing the following steps, be careful not to scratch the frame with "Motor Assy., PG" pinion gear. 8. Seen from the right side of the printer, slide the - Epson 4000 | Service Manual - Page 269
EPSON Stylus Pro 4000 4.2.7.4 CR_HP Sensor 1. Remove "Cover, Side, Right" (p212). 2. Move "Carriage Unit" to center of printer. (Refer to "4.2.4.3 C511_SUB Board" (p229).) 3. Release "CR_HP Sensor" harness from clamp. 4. Unfasten the two upper hooks securing "CR_HP Sensor", release the lower tab and - Epson 4000 | Service Manual - Page 270
EPSON Stylus Pro 4000 4.2.7.5 Multi Sensor 1. Remove "Cover, Side, Left" (p211). 2. Move "Carriage Unit" to center of printer. (Refer to to refer to Chapter 5 "Adjustment" (p.354) and perform specified adjustments after replacing or installing a "Multi Sensor". C.B. (P2) 3x6 Revision B Figure - Epson 4000 | Service Manual - Page 271
EPSON Stylus Pro 4000 4.2.7.6 PG Phase Sensor 1. Remove "Cover, Side, Left" (p211). 2. Remove "Cover, Side, Right" (p212). CHECK P O IN T As the PG Cam (Bush, Shaft, Rear) and PG Detection - Epson 4000 | Service Manual - Page 272
EPSON Stylus Pro 4000 4. Remove "Extension Spring, 2.58" from the frame and the two tabs of the "Installation Plate, Detector, HP". (Refer to Figure 4-95.) 5. Disconnect the connector from - Epson 4000 | Service Manual - Page 273
EPSON Stylus Pro 4000 4.2.7.7 CR Encoder Sensor 1. Remove "Cover, Rear" (p218). 2. Move "Carriage Unit" to center of printer the two positioning holes on the "Ink Tube Unit". Positioning holes Revision B 354) and perform specified adjustments after replacing or installing the "CR Encoder Sensor - Epson 4000 | Service Manual - Page 274
EPSON Stylus Pro 4000 4.2.7.8 Scale, CR 1. Remove "Cover, Side, Left" (p211). 2. Remove "Cover, Side, Right" (p212). 3. Move the "Carriage Unit" to the center of the printer. (Refer to "4.2.4.3 C511_SUB Board" (p229).) 4. At the left side of the printer, remove the "Tension Spring, 3.86" hitched to - Epson 4000 | Service Manual - Page 275
EPSON Stylus Pro 4000 4.2.7.9 Pulley, Driven/Shaft, Pulley 1. Remove "Cover, Side, Left" (p211). 2. Remove the E-ring that secures the "Shaft, Pulley" on the left back of the printer, and then remove the plain washer. (Refer to Figure 4-99.) 3. While pressing the "Lever, Rock, PG", loosen the CR - Epson 4000 | Service Manual - Page 276
EPSON Stylus Pro 4000 4. Pull the "Holder, Pulley" toward you, and then remove the "Shaft, Driven" and "Shaft, Pulley" with the grooved end of the "Shaft, Pulley" facing the rear of the printer. Assemble Groove Revision B Belt, CR 2 Pulley, Driven Shaft, Pulley 1 Holder, Pulley Figure 4-101. - Epson 4000 | Service Manual - Page 277
EPSON Stylus Pro 4000 4.2.7.10 Solenoid, CR 1. Remove "Carriage Unit" (p260). 2. Attach IR E D Be sure to refer to Chapter 5 "Adjustment" (p.354) and perform specified adjustments after replacing the "Solenoid, CR". Revision B Tabs CUTTER CAP Solenoid, CR Disassembly & Assembly C.B.P.(P2) 3x8 - Epson 4000 | Service Manual - Page 278
EPSON Stylus Pro 4000 4.2.8 Ink System 4.2.8.1 Printhead CHECK P O IN T „ Figures below shows the required tools in replacing the "Printhead". CUTTER CAP Revision B CHECK P O IN T „ Be sure to install the "Adjust Plate" to the rear of the "HEAD EXCHANGE SUPPORT TOOL" before removing the " - Epson 4000 | Service Manual - Page 279
EPSON Stylus Pro 4000 1. Remove "Scale, CR" (p274). 2. Move the "Carriage Unit" to match the sensor section on the rear of the "Carridge Unit" with the cutout of the "Cover, Rear". (Refer to Figure 4-104.) 3. Place the "CR SUS PLATE SUPPORT TOOL" on both sides of the "Carriage Unit" as shown in - Epson 4000 | Service Manual - Page 280
EPSON Stylus Pro 4000 5. Remove the "Carriage Unit" following the order below. (Refer to Figure a temporarily unstable state. 7. Set the "HEAD EXCHANGE SUPPORT TOOL" on the printer at the position as shown in Figure 4-107. Set the "HEAD EXCHANGE SUPPORT TOOL" with its front holes macthing with the - Epson 4000 | Service Manual - Page 281
EPSON Stylus Pro 4000 8. Set the "Carriage Unit" on the "HEAD EXCHANGE SUPPORT TOOL". (Refer to Figure 4-108.) CHECK P O IN T „ When setting the "Carriage Unit" on the "HEAD EXCHANGE SUPPORT TOOL", take care not to bend the "Tube, Supply, Ink". If it get bend, replace with a new one. „ Make sure - Epson 4000 | Service Manual - Page 282
EPSON Stylus Pro 4000 C A U T IO N When performing the following work, do not keep the "Carriage, C" , C Figure 4-109. "Carriage, C" Removal Carriage, B Carriage, C Disassembly & Assembly Headrank ID Label Printhead Figure 4-110. Separation from Carriage, B Disassembly Procedures 282 - Epson 4000 | Service Manual - Page 283
EPSON Stylus Pro 4000 12. Remove the three screws that secure the "Printhead", and then remove the "Printhead" from the "Carriage, C". (Refer to Figure 4-111.) „ C.P.P. 2.6x8 : 3 pcs. If the "Absorber, CR" comes off when removing the "Printhead" form the "Carriage, C", reattach the "Absorber, CR - Epson 4000 | Service Manual - Page 284
EPSON Stylus Pro 4000 4.2.8.2 Valve Assy., Head A D JU S TM E N T R E Q U IR E D When performing the following work, remove ink out of the ink route before removing the "Valve Assy., Head". Refer to Chapter 5 "Adjustment" (p.354) to know how to remove ink. 1. Remove the "Carriage Cover". (Refer - Epson 4000 | Service Manual - Page 285
EPSON Stylus Pro 4000 „ Make sure that the "O-ring, Coupling M7" is attached approximately 2mm away from the end point of the "Tube, Supply, Ink". O-ring, coupling M7 Approximately 2mm „ The ink color marked on the "Tube, Supply, Ink Revision B „ To prevent from both ink leak and damage on the joint - Epson 4000 | Service Manual - Page 286
EPSON Stylus Pro 4000 3. Remove the "Head Unit" from the "Carriage Unit". (Refer to "4.2.7.1 Carriage Unit" (p260).) 4. Separate the "Carriage, C" from the "Carriage, B". (Refer to "4.2.8.1 Printhead" (p278).) 5. Draw out the "Plate, Damper" with a plier or a similar tool. (Refer to Figure 4-114.) - Epson 4000 | Service Manual - Page 287
EPSON Stylus Pro 4000 4.2.8.3 Gutter, Ink C A U T IO N When removing the "Gutter, Ink", prepare pieces of cloth in case the waste ink leaks or splatter inside the printer. Make sure that the ink is not ejected from the ink ejection route during the work. 1. Remove "Fan, Blower" (p238). 2. Remove - Epson 4000 | Service Manual - Page 288
EPSON Stylus Pro 4000 6. Remove the screw securing "Gutter, Ink". (Refer to Figure 4-118.) „ C.B. (P1) 3x4 : 1 pc. 7. Remove "Gutter, Ink" by following the steps below. (Refer to Figure 4-119.) 7-1. Slide "Gutter, Ink" to left side. 7-2. Move "Gutter, Ink" right side downward. 7-3. Pull out " - Epson 4000 | Service Manual - Page 289
EPSON Stylus Pro 4000 4.2.8.4 I/H Left Unit / I/H Lever Sensor (Left) C A U T IO N When performing the following work, remove ink out of the the ink path before removing the "IH Left Unit". Refer to Chapter 5 "Adjustment" (p.354) to know how to remove ink. 1. Remove "Panel, Front/Panel Unit" ( - Epson 4000 | Service Manual - Page 290
EPSON Stylus Pro 4000 5. Remove the four screws securing "Guide, I/H, Left" and remove "Guide, I/ H, Left" by pulling forward. (Refer to Figure 4-122.) „ C.B.S. 3x6 : 4 pcs. 6. Remove the screw securing "Installation Plate, I/H Guide, A" and remove "Installation Plate, I/H Guide, A". (Refer to - Epson 4000 | Service Manual - Page 291
EPSON Stylus Pro 4000 7. Remove the screw securing "Installation Plate, I/H Guide, C" and remove "Installation Plate, I/H Guide, C". „ C.B.S. 3x6 : 1 pc. „ The shapes of "Installation Plate, I/H Guide, A" and "Installation Plate, I/H Guide, C" differ, so be careful when installing them. - Epson 4000 | Service Manual - Page 292
EPSON Stylus Pro 4000 C A U T IO N When performing the following step, be careful not to bend the "Tube, Supply, Ink" or scratch it with the edge of the frame. 8. Peel acetate tape and release the four "Tube, Supply, Ink" from the notch of the frame. (Refer to Figure 4-125.) C A U T IO N The - Epson 4000 | Service Manual - Page 293
EPSON Stylus Pro 4000 10. Remove the six screws securing the "I/H Left Unit" to the pinter. „ C.B.S. 3x8 : 6 pcs. 11. Peel off the acetate tape that attaches the FFC to the Printer Frame. 12. Remove the FFC from the printer frame. (The FFC is attached to the printer frame with double-sided tape.) 13 - Epson 4000 | Service Manual - Page 294
EPSON Stylus Pro 4000 15. Disconnect "Harness, CSIC"s (4 connectors: CN38, CN40, CN41, CN44) and "I/H Lever Sensor ( )"s harness. (Refer to Figure 4-129.) 17. Pull the "I/H Left Unit" forward from the printer while pulling the four "Harness, CSIC" and "I/H Lever Sensor (Left)" harness from the hole - Epson 4000 | Service Manual - Page 295
EPSON Stylus Pro 4000 „ Make the rear side screw stop tabs stay under the "Cover, Motor, PF". Cover, Motor, PF Screw Stop Tabs „ The four grounding springs on the top of the "I/H Left Unit" make contact with the printer frame, so install the "I/H Left Unit" while lightly holding down the grounding - Epson 4000 | Service Manual - Page 296
EPSON Stylus Pro 4000 18. Pick up and release the two tabs securing the "I/H Lever and remove "Cover, Holder, IC, Left". (Refer to Figure 4-132.) „ C.B.S. 3x6: 2pcs. „ When the "Ink Lever" is installed against the angle set location as shown in the illustration, confirm that the two holes of "Fan - Epson 4000 | Service Manual - Page 297
EPSON Stylus Pro 4000 C A U T IO N When performing the following steps, be careful of the points below. „ As ink may leak or splatter, have cleaning rags ready and prevent ink from getting on the surrounding work area. „ Prevent dust and dirt from getting inside the "Tube, Supply, Ink , Ink" has - Epson 4000 | Service Manual - Page 298
EPSON Stylus Pro 4000 4.2.8.5 I/H Right Unit / I/H Lever Sensor (Right) C A U T IO N When performing the following work, remove ink out of the ink path before removing the "IH Right Unit". Refer to Chapter 5 "Adjustment" (p.354) to know how to remove ink. 1. Remove "Panel, Front/Panel Unit" ( - Epson 4000 | Service Manual - Page 299
EPSON Stylus Pro 4000 5. Remove the four screws securing "Guide, I/H, Right" and remove "Guide, I/ H, Right" by pulling forward. (Refer to Figure 4-136.) „ C.B.S. 3x6 : 4 pcs. 6. Remove the screw securing "Installation Plate, I/H Guide, B" and then remove "Installation Plate, I/H Guide, B". (Refer - Epson 4000 | Service Manual - Page 300
EPSON Stylus Pro 4000 7. Remove the screw securing "Installation Plate, I/H Guide, C" and remove "Installation Plate, I/H Guide, C". „ C.B.S. 3x6 :1 pc. „ The shapes of "Installation Plate, I/H Guide, B" and "Installation Plate, I/H Guide, C" differ, so be careful when installing them. Installation - Epson 4000 | Service Manual - Page 301
EPSON Stylus Pro 4000 C A U T IO N When performing the following step, be careful not to bend the "Tube, Supply, Ink" or scratch it with the edge of the frame. 8. Peel acetate tape and release the four "Tube, Supply, Ink" from the notch of the frame. (Refer to Figure 4-139.) C A U T IO N The - Epson 4000 | Service Manual - Page 302
EPSON Stylus Pro 4000 9. Disconnect "Harness, CSIC"s (5 connectors: CN39, CN42, CN43, CN45, CN461) and "I/H Lever Sensor (Right)" harness (CN36: white, 2 pin) from "C511_SUB-B Board". (Refer to "4.2.4.4 C511_SUB-B Board" (p231).) - Epson 4000 | Service Manual - Page 303
EPSON Stylus Pro 4000 11. Remove the four clamps securing the harnesses. (The "Sheet Ink Stopper" will be released at the same time.) "Sheet Ink Stopper, D" should be attached to the printer frame with the three tabs of the clamps inside the printer as shown in Figure 4-142. 12. Release both the FFC - Epson 4000 | Service Manual - Page 304
EPSON Stylus Pro 4000 13. Peel off the acetate tape binding the FFC to release the FFC. (Refer to Figure 4-144.) 14. Release the four "Harness, CSIC"s and the "I/H - Epson 4000 | Service Manual - Page 305
EPSON Stylus Pro 4000 15. Move "Carriage Unit" to center of printer. (Refer to "4.2.4.3 C511_SUB Board" (p229).) 16. Remove the two screws securing rear side of "I/H Right Unit". (Refer to Figure 4-146.) „ C.B.S. 3x6 : 2 pcs. 17. Remove the - Epson 4000 | Service Manual - Page 306
EPSON Stylus Pro 4000 18. Pull the "I/H Right Unit" forward from the printer following the order below while pulling the "Harness, CSIC" and "I/H Lever Sensor (Right)" harness from the hole in the frame. (Refer to Figure 4-148.) 18-1. 18-2. To avoid interference of the printer 2 Paper Eject - Epson 4000 | Service Manual - Page 307
EPSON Stylus Pro 4000 21. Remove the two screws securing "Cover, Holder, IC, Right" and remove "Cover, Holder, IC, Right". (Refer to Figure 4-150.) „ C.B.S. 3x6 : 2 pcs. „ When the "Ink Lever" is installed against the angle set location as shown in the illustration, confirm that the two holes of " - Epson 4000 | Service Manual - Page 308
EPSON Stylus Pro 4000 C A U T IO N When performing the following steps, be careful of the points below. „ Ink may leak or splatter, so have cleaning rags ready and prevent ink from getting on the surrounding work area. „ Prevent dust and dirt from getting inside the "Tube, Supply, Ink". 22. - Epson 4000 | Service Manual - Page 309
EPSON Stylus Pro 4000 4.2.8.6 Box Assy., Flushing / Pump Unit C A U T IO N When removing the "Box Assy., Flushing" and "Pump Unit", ink may leak from the "Box Assy., Flushing" ink discharge port or the "Pump Unit" waste ink tube. Have cleaning rags ready and prevent ink from getting on the - Epson 4000 | Service Manual - Page 310
EPSON Stylus Pro 4000 6. Remove the two screws securing the "Shaft, Transmission, PG Unit" and then remove the "Shaft, Transmission, PG Unit" by pulling it out of the hole - Epson 4000 | Service Manual - Page 311
EPSON Stylus Pro 4000 C A U T IO N When performing the following steps, be careful of the points below. „ Do not lose "Extension Spring, 0.262". „ Use care not to pull "Extension Spring, 0.262" too much, or it may loose the spring force. „ Do not touch the "Cleaner, Head" or allow it to contact - Epson 4000 | Service Manual - Page 312
EPSON Stylus Pro 4000 9. Remove the "Lever, Lock, DE" by following the steps below. (Refer to Figure 4-156.) 9-1. Slide it to the right. 9-2. Bend it toward the center. 9-3. Remove - Epson 4000 | Service Manual - Page 313
EPSON Stylus Pro 4000 10. Disconnect the connector from the "Pump Phase Sensor" from behind the printer. (Refer to Figure 4-157.) 11. Free all the harnesses from the U-shaped notch of the "Frame, Base, Side, Right". (Refer to Figure 4-157.) 12. Remove - Epson 4000 | Service Manual - Page 314
EPSON Stylus Pro 4000 Revision B The "Pump Unit" must be reassembled properly. An incorrect assembly may cause malfunction of the printer and lower the print quality due to poor pumping. „ Align the five ribs and front side dowel of the "Pump Unit" with the six frame positioning holes. „ Slip the - Epson 4000 | Service Manual - Page 315
EPSON Stylus Pro 4000 4.2.8.7 Guide, Waste Ink 1. Remove "Pump Unit". (Refer to "4.2.8.6 Box Assy., Flushing / Pump Unit" (p309).) 2. Remove the "Guide, Waste Ink" by following the steps below. 2-1. Push up the "Guide, Waste Ink" from the printer bottom surface to free the dowel from the frame. 2-2. - Epson 4000 | Service Manual - Page 316
EPSON Stylus Pro 4000 4.2.8.8 Pump Phase Sensor 1. Remove "Pump Unit". (Refer to "4.2.8.6 Box Assy., Flushing / Pump Unit" (p309).) 2. Remove the two screws securing the "Pump Cover". (Refer to Figure 4- - Epson 4000 | Service Manual - Page 317
EPSON Stylus Pro 4000 4. Peel off acetate tape. 5. Release tabs securing "Pump Phase Sensor" and then remove "Pump Phase Sensor". The "Shield Plate" inside the "Pump Cover" may come - Epson 4000 | Service Manual - Page 318
EPSON Stylus Pro 4000 4.2.8.9 Holder, FFC 1. Move the "Carriadge Unit" depending on " position Home position Left end 2. Pinch the upper and lower end of the two "Harness, Head"s and the "Harness, Head, Intermit" with your fingers to make their central parts bowed, and release them from the upper - Epson 4000 | Service Manual - Page 319
EPSON Stylus Pro 4000 3. Release the top and bottom tabs of the "Holder, FFC", and open the "Holder, FFC". Revision B 4. Release the top tab of the "Holder, FFC" from the "Guide Plate, Tube", and remove the "Holder, FFC" backward. 1 2 Figure 4-166. Holder, FFC Tabs Release Figure 4-167. "Holder, - Epson 4000 | Service Manual - Page 320
EPSON Stylus Pro 4000 Check the followings after installing the "Holder, FFC". „ Each part should be properly installed in its prescribed space of the "Holder, FFC". Y M C MK PK (MK) LC (C) LM (LM) LK (Y) Harness, Head (x2) Harness, Head, Intermit Tube, Supply, Ink Sheet, SUS Guide Plate, Tube Sheet - Epson 4000 | Service Manual - Page 321
EPSON Stylus Pro 4000 4.2.8.10 Holder, FFC; B 1. Move the "Carriadge Unit" depending " position Home position Left end 2. Pinch the upper and lower end of the two "Harness, Head"s and the "Harness, Head, Intermit" with your fingers to make their central parts bowed, and release them from the upper - Epson 4000 | Service Manual - Page 322
EPSON Stylus Pro 4000 3. Release the top tab of the "Holder, FFC; B" to open the "Holder, FFC; B". Revision B 4. Release the top tab of the "Holder, FFC; B" from the "Guide Plate, Tube", and remove the "Holder, FFC; B" backward. 1 2 Figure 4-170. Holder, FFC; B Tab Release Figure 4-171. "Holder - Epson 4000 | Service Manual - Page 323
EPSON Stylus Pro 4000 Check the followings after installing the "Holder, FFC; B". „ Each part should be properly installed in its prescribed space of the "Holder, FFC; B". Y M C MK PK (MK) LC (C) LM (LM) LK (Y) Harness, Head (x2) Harness, Head, Intermit Tube, Supply, Ink Sheet, SUS Guide Plate, Tube - Epson 4000 | Service Manual - Page 324
EPSON Stylus Pro 4000 4.2.8.11 Harness, Head, Intermit / Harness, Head 1. Remove the "Panel, Front". (Refer to "4.2.3.5 Panel, Front/Panel Unit" (p214).) 2. Disconnect the "Harness, Head, Intermit" and the two "Harness, Head is on the backside of the printer. Cutout Revision B Ferrite Core Clamps - Epson 4000 | Service Manual - Page 325
EPSON Stylus Pro 4000 6. Release the FFC from the tabs of the "Cover, Tube" and draw out the FFC from the hole on the front frame of the printer. (Refer to Figure 4-174.) 7. Release the FFC from the tabs of the "Cover, Tube". (Refer to Figure 4-175.) 8. Remove the five "Holder, FFC" ("Holder, FFC; - Epson 4000 | Service Manual - Page 326
EPSON Stylus Pro 4000 11. Release the FFC from the tab of the "Holder, Tube, A" and then disconnect the "Harness, Head, Intermit" from the slot on the "C511_SUB Board". (Refer to Figure 4-177.) 12. Peel off the three pieces of acetate tape that bundle the FFCs, then remove the "Harness, Head, - Epson 4000 | Service Manual - Page 327
EPSON Stylus Pro 4000 Revision B 4.2.8.12 Tube, Supply, Ink (Y/M/C/MK) on the Left Side of the Main Unit C A U T IO N When performing the following work, remove ink out of ink path before removing the "Tube, Supply, Ink". Refer to Chapter 5 "Adjustment" (p.354) to know how to remove ink. Some - Epson 4000 | Service Manual - Page 328
EPSON Stylus Pro 4000 5. Remove the two omega locks to release the "Tube, Supply, Ink" s. (Refer to Figure 4-182.) For the attachment positions of the omega locks, refer to "I/H Left Unit / I/H Lever Sensor (Left)" (p.289). 6. Loosen the "Coupling Screw, M7"s that secure the "Tube, Supply, Ink"s to - Epson 4000 | Service Manual - Page 329
EPSON Stylus Pro 4000 11. Remove the screw that secures both the "Holder, Tube, A" and "Holder, Tube, B", and separate the "Holder, Tube, A" from the "Holder, Tube, B". „ C.B.P. 3x8 : 1 pc. Holder, Tube, B Revision B 12. Release the "Tube, Supply, Ink" from the tabs of the "Holder, Tube, A". Tabs - Epson 4000 | Service Manual - Page 330
EPSON Stylus Pro 4000 13. Remove the three screws that secures the "Cover, Tube" to the printer frame, lift it upward, release the three upper tabs, and then remove the "Cover, Tube". „ C.B.P. 3x8 : 3 pcs. „ Hitch the three tabs on the "Cover, Tube" to the "Guide, Tube, CR" before tightening the - Epson 4000 | Service Manual - Page 331
EPSON Stylus Pro 4000 Revision B 4.2.8.13 Tube, Supply, Ink (LK(Y)/LM(M)/LC(C)/PK(MK)) on the Right side of the Main Unit C A U T IO N 7 When performing the following work, remove ink out of the ink path befoe removing the "Tube, Supply, Ink". Refer to Chapter 5 "Adjustment" (p.354) to know how - Epson 4000 | Service Manual - Page 332
EPSON Stylus Pro 4000 5. Remove the two omega locks to release the "Tube, Supply, Ink"s. (Refer to Figure 4-190.) For the attachment positions of the omega locks, refer to "I/ H Left Unit / I/H Lever Sensor (Left)" (p.289). 6. Loosen the "Coupling Screw, M7"s that secure the "Tube, Supply, Ink"s to - Epson 4000 | Service Manual - Page 333
EPSON Stylus Pro 4000 11. Remove the screw that secures both the "Holder, Tube, A" and "Holder, Tube, B", and separate the "Holder, Tube, A" from the "Holder, Tube, B". „ C.B.P. 3x8 : 1 pc. Holder, Tube, B Revision B 12. Release the "Tube, Supply, Ink" from the tabs of the "Holder, Tube, A". Tabs - Epson 4000 | Service Manual - Page 334
EPSON Stylus Pro 4000 13. Remove the three screws that secures the "Cover, Tube" to the printer frame, lift it upward, release the three upper tabs, and then remove the "Cover, Tube". „ C.B.P. 3x8 : 3 pcs. „ Hitch the three tabs on the "Cover, Tube" to the "Guide, Tube, CR" before tightening with - Epson 4000 | Service Manual - Page 335
EPSON Stylus Pro 4000 4.2.9 Paper Feed Mechanism 4.2.9.1 Release Unit 1. Remove "Cover, Rear" (p218). 2. Remove the screw securing "Cover, Inner, Release". (Refer to Figure 4-196.) „ C.B.S. 3x8 : 1 pc. 3. Slide "Cover, Inner, Release" - Epson 4000 | Service Manual - Page 336
EPSON Stylus Pro 4000 5. Remove the two screws securing "Release, Lever Unit". (Refer to Figure 4- positioning rib and then install "Release, Lever Unit" and "Spur Gear, 18" onto the printer body. Position Locator and Positioning Rib Intermittent Gear, 40 3. Secure with screw after aligning "Release - Epson 4000 | Service Manual - Page 337
EPSON Stylus Pro 4000 7. Confirm that gears of "Intermittent Gear, 40" and "Release, Planetary to align the hook and cut-out. (Refer to Figure 4-200.) 9. Remove "Intermittent Gear, 40" from printer body. (Refer to Figure 4-200.) CHECK P O IN T If "Intermittent Gear, 40" is difficult to remove - Epson 4000 | Service Manual - Page 338
EPSON Stylus Pro 4000 C A U T IO N When performing the following step, be careful not to careful not to pull the "Guide, Roll Paper" too much because a harness is connected. 11. Remove the two screws securing the "Guide, Roll Paper" and remove the "Guide, Roll Paper" along with "Installation Plate - Epson 4000 | Service Manual - Page 339
EPSON Stylus Pro 4000 12. Remove the two screws securing "Release Unit". (Refer to Figure 4-203.) „ C.B.S. 3x6 : 2 pcs. 13. Pull right side of "Release Unit" toward you, completely remove the right side of "Release Unit" while freeing the "Release Unit" ribs from the printer frame cut-out, and then - Epson 4000 | Service Manual - Page 340
EPSON Stylus Pro 4000 4.2.9.2 Paper Eject Unit 1. Remove "Panel, Front/Panel Unit" (p214). C A U T IO N When performing the following steps, be careful not to take hold of the Star Wheels of the "Paper Eject Unit". 2. Turn the "Paper Eject Unit" until the screws that secure the "Paper Eject Unit - Epson 4000 | Service Manual - Page 341
EPSON Stylus Pro 4000 4.2.9.3 Motor Assy., PF 1. Remove "Cover, Side, Left" (p211). 2. Disconnect " "Motor Assy., PF" harness and other harnesses from the two tabs and the three grooves on "Paper Guide, Lower". (Refer to Figure 4-206.) 4. Peel off the pieces of acetate tape to release "Motor - Epson 4000 | Service Manual - Page 342
EPSON Stylus Pro 4000 6. Release "Motor Assy., PF" harness from clamp shown in Figure IR E D Be sure to refer to Chapter 5 "Adjustment" (p.354) and perform specified adjustments after installing or replacing the "Motor Assy., PF". Revision B C.B.S. (P2) 3x6 Hooks Clamp Scale, PF Belt, Motor, PF - Epson 4000 | Service Manual - Page 343
EPSON Stylus Pro 4000 4.2.9.4 P_THICK Sensor (0.8) / P_THICK Sensor (0.3) 1. Remove "Cover, Rear" (p218). 2. to refer to Chapter 5 "Adjustment" (p.354) and perform specified adjustments after replacing or installing a "P_THICK Sensor". Revision B Connector Tabs Connector P_THICK Sensor (0.8) - Epson 4000 | Service Manual - Page 344
EPSON Stylus Pro 4000 4.2.9.5 PE Sensor 1. Remove "Release Unit" (p335). 2. As seen from the printer rear surface, release the two left "Extension Spring, 8.08"s from hooks on the frame. (Refer to Figure 4-212.) 3. Peel off acetate tape securing the FFC. ( - Epson 4000 | Service Manual - Page 345
EPSON Stylus Pro 4000 6. Release the two tabs securing "PE Sensor" and remove "PE IR E D Be sure to refer to Chapter 5 "Adjustment" (p.354) and perform specified adjustments after replacing the "PE Sensor". Revision B FFC PE Sensor Tabs Figure 4-214. PE Sensor Removal Disassembly & Assembly - Epson 4000 | Service Manual - Page 346
EPSON Stylus Pro 4000 4.2.9.6 Rear Manual Insertion Sensor 1. Remove "Holder, Roller, Unit" (p209). 2. Remove "Paper Guide Assy., M, SP" (p210). 3. Release "Rear Manual Insertion Sensor" harness from the two tabs. (Refer to Figure 4-215.) 4. Release "Guide, Roll Paper" along with "Rear Manual - Epson 4000 | Service Manual - Page 347
EPSON Stylus Pro 4000 6. Release the two tabs securing "Rear Manual Insertion Sensor" and remove "Rear Manual Insertion Sensor" from "Installation Plate, Detector, Rear". (Refer to Figure 4-217.) 7. Disconnect the connector from "Rear Manual Insertion Sensor". (Refer to Figure 4-218.) „ Route "Rear - Epson 4000 | Service Manual - Page 348
EPSON Stylus Pro 4000 4.2.9.7 Paper Eject Phase Sensor 1. Pull out "I/H Left Unit" from printer. (Refer to "4.2.8.4 I/H Left Unit / I/H Lever Sensor (Left)" (p289).) 2. Release the two tabs securing "Paper Eject Phase Sensor" and remove "Paper Eject Phase Sensor". 3. Disconnect the connector from " - Epson 4000 | Service Manual - Page 349
EPSON Stylus Pro 4000 4.2.9.9 PF Encoder Sensor 1. Remove "Cover, Side, Left" (p211). C A U IR E D Be sure to refer to Chapter 5 "Adjustment" (p.354) and perform specified adjustments after replacing the "PF Encorder Sensor". „ Do not bend condenser. (Refer to Figure 4-221.) „ After installing - Epson 4000 | Service Manual - Page 350
EPSON Stylus Pro 4000 Revision B 4.2.10 Harness Routing This section explains cautions is not described here, refer to the corresponding diassembly/assembly procedures. 4.2.10.1 Harnesses on Left Side of Printer PG Sensor • Harness † Should be secured with the parts below. „ Clamp : 1 pc. „ - Epson 4000 | Service Manual - Page 351
EPSON Stylus Pro 4000 Harness, Head / Harness, R1 / Harness, R2 † Should be routed along the outside of the two "Harness, Head"s and the "Harness, Head, Intermit" from the " C511_MAIN Board" until they reach the point where the "Harness, R1" and "Harness, R2" are connected to the "C511_SUB-C Board - Epson 4000 | Service Manual - Page 352
EPSON Stylus Pro 4000 4.2.10.2 Harnesses on Right Side of Printer Routing on the right frame † Should be secured with the parts below. „ Clamp : 4 pcs. „ Acetate tape : 6 pcs. Acetate tapes Clamps Acetate tapes Figure 4-227. Routing - Epson 4000 | Service Manual - Page 353
EPSON Stylus Pro 4000 Routing on the "Duct, Air, C" † Route the harness via the tabs on the "Duct, Air, C" Tabs Revision B † Bundle the harnesses and secure them to the - Epson 4000 | Service Manual - Page 354
ADJUSTMENT CHAPTER 5 - Epson 4000 | Service Manual - Page 355
EPSON Stylus Pro 4000 Revision B 5.1 Overview This section describes the adjustment procedures necessary after replacing certain MAIN Board (p221)) Cleaning Unit*2 (p.309) Printhead (p278) Damper (Valve Assy., Head (p.284)) AS Mechanical Unit (Printer Mechanism (SP) (p.236)) ASF Unit (p. - Epson 4000 | Service Manual - Page 356
EPSON Stylus Pro 4000 5.1.4 Adjustment Items classified by Part/Unit Required adjustment items and execution order for each part/unit that has been replaced or removed is shown in the table below. Note "*1": RP = Replacement with new part "*2": RM = Removal only "*3": Refer to "P.400 and P.409" - Epson 4000 | Service Manual - Page 357
EPSON Stylus Pro 4000 Table 5-2. Required Adjustment Items/Execution Order Name Adjustment Item RP*1 RM*2 Ref. Damper 1 Ink Discharge { { P.397 2 CR Timing Belt Tension Adjustment { { P.363 3 CR Encoder Sensor Position Adjustment { { P.369 4 Initial Ink Charge { { P.398 5 Head Rank ID - Epson 4000 | Service Manual - Page 358
EPSON Stylus Pro 4000 Revision B 5.1.5 Adjustment Item Printer adjustment items and their adjustment classification descriptions are shown in the tables below. Note "*1": AU = Adjustment program (utility) "*2": M2 = Maintenance Mode 2 (Refer to "1.4.6 Maintenance Mode 2 (p79)" ) "*3": AT = - Epson 4000 | Service Manual - Page 359
EPSON Stylus Pro 4000 Revision B Adjustment Item Auto Uni-d Adjustment Multi Sensor Adjustment for Auto Nozzle Check Skew Check Rear Sensor Adjustment Platen Position Adjustment 1000mm Feed Adjustment Initial Ink charge flag ON/OFF NVRAM Back Up and Write Check Platen Gap Ink Discharge Initial Ink - Epson 4000 | Service Manual - Page 360
EPSON Stylus Pro 4000 Adjustment Item Copy Bi-D variables Manual Uni-D Adjustment Copy Uni-D variables Table 5-5. Advanced of misalignment. Prints all adjustment patterns and adjustment parameters and checks content. Performs paper feed ? eject from ASF and checks feed operation. Prints an image - Epson 4000 | Service Manual - Page 361
Color Banding Sample 1288094 --- Ink cartridge (x8)*3 Maintenance Tank*3 Refer to Table Consumable 5-9. PXMT1 Option Proofing Paper Commercial Semimatte (Roll) PXMC17R7 Genuine Paper Premium Semimatte Photo Paper [250] (Roll) PXMC16R4 Genuine Paper Premium Glossy Photo Paper [250] (Roll - Epson 4000 | Service Manual - Page 362
„ Port: USB port „ Printer driver and ESM3 have to be installed. † Start-up 1. Double-click [adjwiz2.exe] to start the adjustment program. 2. Select the following items after the startup screen appears. z Printer name Stylus Pro 4000 z Ink Config. Select the ink type currently installed. z Adju - Epson 4000 | Service Manual - Page 363
EPSON Stylus Pro 4000 5.2 Mechanical Adjustment 5.2.1 CR Timing Belt Tension Adjustment This adjustment applies to all operations that have resulted in removal or replacement Holder at the same position it had before removal. 2. Manually move the Carriage Unit through a return and back 5 times - Epson 4000 | Service Manual - Page 364
EPSON Stylus Pro 4000 7. Turn the CR tension installation screw to adjust tension until the measurement value reaches the standard value. 8. After adjustment is complete, check the results by - Epson 4000 | Service Manual - Page 365
EPSON Stylus Pro 4000 5.2.2 PF Timing Belt Tension Adjustment This adjustment applies to all operations that have loosened the PF Timing Belt, such as "Motor Assy., PF" removal. This - Epson 4000 | Service Manual - Page 366
EPSON Stylus Pro 4000 4. No adjustment is necessary if the measurement value is within the standard value. If the value is outside the standard value, use the following procedure - Epson 4000 | Service Manual - Page 367
EPSON Stylus Pro 4000 5.2.3 Paper Thickness Sensor Adjustment When the paper thickness sensor has been replaced, it check from the condition in which [Paper Lever] is lowered. 1. Enter Maintenance Mode 2. Power off → Press "Paper Source ( - Epson 4000 | Service Manual - Page 368
EPSON Stylus Pro 4000 † Adjustment Procedure Adjusts position of "Paper Thickness Sensor Holder" for when [Paper Lever] is lowered with adjustment tool 0.3/0.4 or "Paper Lever" is lowered with no adjustment tool and when "Paper Lever" is lowered with adjustment jig 0.8/0.9 or "Paper Lever" is - Epson 4000 | Service Manual - Page 369
EPSON Stylus Pro 4000 5.2.4 CR Encoder Sensor Position Adjustment This is intended to keep the CR Encoder Sensor and CR Scale at a suitable space. † Procedure 1. Move the Carriage Unit - Epson 4000 | Service Manual - Page 370
EPSON Stylus Pro 4000 5.2.5 PG Bushing, Shaft, Rear 2. Enter Maintenance Mode 2. Power off → Press "Paper Source( - Epson 4000 | Service Manual - Page 371
EPSON Stylus Pro 4000 C A U T IO N Always move the "Carriage Unit" by pulling the "Belt, the "Paper Feed (∆)" to move the "Carriage Unit" upward and widen the PG. Slowly move the "Carriage Unit" upward to the position where the "Carriage Unit" does not hit the thickness gauge. 12. Replace the - Epson 4000 | Service Manual - Page 372
EPSON Stylus Pro 4000 5.2.6 Multi Sensor Position Adjustment This adjustment sets a suitable Print Head contact the thickness gauge. Position Tool Carriage Unit Printhead Lever, Lock, PG Revision B Bushing, Shaft, Rear Figure 5-14. Multi Sensor Position Adjustment_1 Paper Guide Assy., Paper - Epson 4000 | Service Manual - Page 373
EPSON Stylus Pro 4000 4. Set the CR Lock Tool. Set the CR Lock Tool into the 2 holes on the printer frame, and then fix the tool by pinching with the bearings of the Carriage Unit. 5. Loosen the two screws securing the "Multi Sensor Holder". 6. Set - Epson 4000 | Service Manual - Page 374
EPSON Stylus Pro 4000 of the main unit right frame when replacing the Main Board. 2. Turn the printer power on after replacing the Main Board. 3. Start up the If you turn the printer OFF/ON after the USB ID has been changed, Windows recognizes the USB as another port and creates a driver of xxxx (Copy - Epson 4000 | Service Manual - Page 375
EPSON Stylus Pro 4000 5.3.2 Head Rank ID Sets/Inputs the information unique to each print head as the Head Rank ID for the best driving voltage setup after replacing the print head. (It can be read from and written to a file.) † Procedure for Writing - Epson 4000 | Service Manual - Page 376
EPSON Stylus Pro 4000 5.3.3 Multi Sensor Level Adjustment Paper is fed into the printer, the Multi Sensor emits light onto the paper and platen, the reflected light is received by the Multi Sensor, and detection level is corrected automatically. Then the detection result is printed. † Paper Used „ - Epson 4000 | Service Manual - Page 377
EPSON Stylus Pro 4000 5.3.4 T&B&S (Roll Paper) This adjusts the printing position that includes the cut position on the surface of the paper and corrects a bend of emission axis of the main scanning direction in the multi sensor. † Paper Used „ Size: 17" „ Type: Enhanced Matte Roll Paper † - Epson 4000 | Service Manual - Page 378
EPSON Stylus Pro 4000 7. Input each of the following value into its corresponding edit box. † The values measured in Step 6 „ Top Margin „ Bottom Margin „ Side Margin (Side Margin Adjust) † The values printed in the pattern lower part „ Multi Sensor Left „ Multi Sensor Right 8. Click the [Write] - Epson 4000 | Service Manual - Page 379
EPSON Stylus Pro 4000 5.3.5 T&B&S (Cut Sheet) This prints a special pattern and adjusts the printing position on the surface of the paper. † Paper Used „ Size: A4 „ Type: Enhanced Matte Cut Sheet † Procedure 1. Start the adjustment program and select [T&B&S (Cut Sheet)]. 2. Click the [Print] button - Epson 4000 | Service Manual - Page 380
EPSON Stylus Pro 4000 5.3.6 Cutter Pressure Adjustment Adjusts the pressure to cut papers after replacing the cutter solenoid. † Required Tools „ Tension Gauge (10N) † Specifications „ 500-600g „ Pressure: Less than 85% † Procedure 1. Enter Maintenance Mode2. Power off → Press "Paper Source( - Epson 4000 | Service Manual - Page 381
EPSON Stylus Pro 4000 5.3.7 Nozzle Bi-D Adjustment Performs standard adjustment of matte black nozzle columns. Adequately adjusts matte black Bi-D before performing Bi-D adjustment for all nozzles. † Paper Used „ Size: 17" „ Type: Enhanced Matte Roll Paper † Procedure 1. Turn the printer power on. - Epson 4000 | Service Manual - Page 382
EPSON Stylus Pro 4000 5.3.8 Print Head Slant Adjustment (PF) † Papers Required „ Size: 16" „ Type: Premium Glossy Photo Paper † Procedure 1. Remove the "Carriage Cover". (Refer to 4.2.4.4 C511_SUB-B Board (p231)) 2. Turn the printer power on. 3. Start up the adjusting program and select [Print Head - Epson 4000 | Service Manual - Page 383
EPSON Stylus Pro 4000 6. Open the top cover and move the "Carriage Unit" to the center of the printer. 7. Loosen the four screws (A, B, C, and D) shown in figure 5-34 that secure the head. 8. Move the "Cam, Inclination, R" vertically and adjust the slant of the print head. z If the upper side of the - Epson 4000 | Service Manual - Page 384
EPSON Stylus Pro 4000 Revision B 5.3.9 Print Head Slant Adjustment (CR) † Papers Required „ Size: 16" „ Type: Premium Glossy Photo Paper † † Procedure 1. Remove the "Carriage Cover". (Refer to 4.2.4.4 C511_SUB-B Board (p231)) 2. Turn the printer power on. 3. Start up the adjusting program, select - Epson 4000 | Service Manual - Page 385
EPSON Stylus Pro 4000 5. Seeing the pattern in the direction shown in Step 5-36, check the on any of the columns: Adjustment needed → Proceed to Step 6. 6. Click [Next] (Proceed to Screen 3). Revision B Paper Feed Direction Adjustment Figure 5-36. Adjustment Pattern Basic Adjustment 385 - Epson 4000 | Service Manual - Page 386
EPSON Stylus Pro 4000 7. Open the top cover and loosen the three head fixing screws shown in Figure 5-37. 8. Move the "Lever, Cam" vertically and adjust the slant of the print head. z Gap on the left column : Lower the "Lever, Cam". z Gap on the right column : Raise the "Lever, Cam". C A U T IO N - Epson 4000 | Service Manual - Page 387
EPSON Stylus Pro 4000 5.3.10 Auto Uni-d Adjustment Performs Auto Uni-D Adjustment with the Multi Sensor. When the adjustment pattern is printed, the adjustment; from scanning the pattern to correcting, is executed automatically. The pattern is printed at PG=1.2, and the correction value is - Epson 4000 | Service Manual - Page 388
EPSON Stylus Pro 4000 5.3.11 Multi Sensor Adjustment for Auto Nozzle Check This adjustment prints a special pattern and scans it no dot missing pattern are printed and the automatic dot missing function is checked. † Paper Used „ Size: 17" „ Type: Enhanced Matte Roll Paper † Procedure 1. Start the - Epson 4000 | Service Manual - Page 389
EPSON Stylus Pro 4000 3. Selecting [Print Check Pattern] and clicking the [Run] button will print the confirmation pattern. Two patterns are printed (dot missing/no dot missing) and read by the Multi Sensor, and then the results are printed along with the patterns. 4. Click the [Finish] button. - Epson 4000 | Service Manual - Page 390
EPSON Stylus Pro 4000 5.3.12 Skew Check † Paper Used „ Size: 17" „ Type: Enhanced Matte Roll Paper † Procedure 1. Start the adjustment program and select [Skew Check]. 2. When the [Run] button is clicked, the paper will be ejected and the paper skew amount will be measured by the Multi Sensor. C A - Epson 4000 | Service Manual - Page 391
EPSON Stylus Pro 4000 5.3.13 Platen Position Adjustment This adjusts the printing position for the sponge position used during borderless printing. † Paper Used „ Size: 17" „ Type: Enhanced Matte Roll Paper ] button to write the adjustment value to the printer. 5. Click the [Next] button. Revision B - Epson 4000 | Service Manual - Page 392
EPSON Stylus Pro 4000 † Check Procedure 1. Click the [Check] button to print the check pattern. 2. Refer to Figure 5-48 and check the positions of the printed adjustment line and the platen tab. If there is no slip, click the [Finish] button. If the position has slipped, click the [Back] button to - Epson 4000 | Service Manual - Page 393
EPSON Stylus Pro 4000 5.3.14 1000mm Feed Adjustment † Paper Used „ Size: 17" „ Type: Enhanced Matte Roll Paper † Procedure 1. Start the adjustment program and select [1000mm Feed Adjustment]. 2. Click the [Print] button and the adjustment pattern will be printed. 3. Use a ruler (1000mm) and scale - Epson 4000 | Service Manual - Page 394
EPSON Stylus Pro 4000 5.3.15 Initial Ink charge flag ON/OFF † Procedure 1. Enter Maintenance Mode 2. Power off → Press "Paper Source ( - Epson 4000 | Service Manual - Page 395
EPSON Stylus Pro 4000 5.3.16 NVRAM Back Up and Write Reads and saves each parameter stored in NVRAM on the Main Board before replacement and writes them to the new Main Board or when replacement of the "Printer Mechanism (SP)", write the parameter stored in the CD-ROM which is included in "Printer - Epson 4000 | Service Manual - Page 396
EPSON Stylus Pro 4000 5.3.17 Check Platen Gap This checks whether or not "Lever, Lock, PG" (used for fixing the PG position) is fixing "Bushing, Shaft, Rear" in a suitable position. † Procedure 1. Turn the printer power on. After printer initialization is complete, check that "Lever, Lock, PG" is in - Epson 4000 | Service Manual - Page 397
EPSON Stylus Pro 4000 5.3.18 Ink Discharge Before removing the Damper (Valve Assy., Head), discharge the ink remaining in the equipment by following the procedure below. † Procedure 1. Turn the printer power on. 2. Start up the adjustment program and select [Ink Discharge]. 3. Click the [Run] tab. - Epson 4000 | Service Manual - Page 398
EPSON Stylus Pro 4000 5.3.19 Initial Ink Charge C A U T IO N Check the amount of ink remaining before starting Initial Ink Charge. If the remaining ink is less than 50%, replace the ink cartridge with a new one and then start the procedure. † Procedure 1. Start the adjustment program and select [ - Epson 4000 | Service Manual - Page 399
EPSON Stylus Pro 4000 5.3.21 Rear Sensor Adjustment When the rear sensor has been replaced, the AD value for setting a paper detection standard must be acquired and stored in the Main Board. † Required Tool „ Microtrace #300 (A4) † Procedure 1. Enter Maintenance Mode 2. Power off → Press "Paper - Epson 4000 | Service Manual - Page 400
EPSON Stylus Pro 4000 Revision B 5.3.22 Adjustment Image (for 8-color model) Following operations should be performed on each type of paper. „ PF Micro Feed Adjustment Bi-D „ Dot Shift Adjustment „ Print Image (Tanzaku) NOTE: Three kinds of PF Micro Feed Adjustment Bi-D are provided to - Epson 4000 | Service Manual - Page 401
EPSON Stylus Pro 4000 5.3.22.1 PF Micro Feed Adjustment Bi-D Three types of PF Micro Feed Adjustment are provided to correspond several types of papers. PF MICRO FEED ADJUSTMENT BI-D TYPE-A † Procedure 1. Turn the printer be made easily by comparing the printed pattern with the Banding Standard - Epson 4000 | Service Manual - Page 402
EPSON Stylus Pro 4000 Check the gray sections at both sides of the printed pattern. START EMP720*720_7A&7F&84&89&8E PG1.2 [ Vertical Alignment VSD 2 ] end Pattern Value EMP720*720_7A&7F&84&89&8E Figure 5-62. Adjustment Pattern Adjustment Basic Adjustment Revision B 402 - Epson 4000 | Service Manual - Page 403
EPSON Stylus Pro 4000 PF MICRO FEED ADJUSTMENT BI-D TYPE-B † Procedure 1. Turn the printer on. 2. Start up the adjustment program and select [Image Adjustment]. 3. Select the type of paper and click the [Next] Button. 4. Select the pattern value specified in Procedure 5 of the " PF Micro Feed - Epson 4000 | Service Manual - Page 404
EPSON Stylus Pro 4000 PF MICRO FEED ADJUSTMENT BI-D TYPE-C † Procedure 1. Turn the printer on. 2. Start up the adjustment program and select [Image Adjustment]. 3. Select the type of paper and click the [Next] Button. 4. Select "74_79_7E_83_88" and click [Print] to print adjustment patterns. 5. - Epson 4000 | Service Manual - Page 405
EPSON Stylus Pro 4000 Check the gray sections at both sides of the printed pattern. PGPP250 :0A:6F 6F 6F PPS Offset :07 0A 07 0A:7F 7F 7F 7F Revision B PPS720 74_79_7E_83_88 Pattern Value PPS720 74_79_7E_83_88 Figure 5-65. Adjustment Pattern Adjustment Basic Adjustment 405 - Epson 4000 | Service Manual - Page 406
EPSON Stylus Pro 4000 5.3.22.2 Dot Shift Adjustment † Procedure 1. Tick the circle beside "Dot Shift1, 2" and click [Print] to print adjustment patterns. 2. Check the gray sections at both ends of the printed can be made easily by comparing the printed pattern with the Banding Standard Sample. „ - Epson 4000 | Service Manual - Page 407
EPSON Stylus Pro 4000 Check the gray sections at both sides of the printed pattern. Adjustment pattern for C511 DOT SHIFT CHECK FILE PPS 031122 F/W Version :I03043 P [ Vertical Alignment VSD 2 ] ^^^^ 66-65 ^^^^Dot Shift 1_-4 ^^^^Dot Shift 1_-2 ^^^^Dot - Epson 4000 | Service Manual - Page 408
EPSON Stylus Pro 4000 5.3.22.3 Image Print (Tanzaku) C A U T IO N „ Select the paper size from the printer driver setting before printing following the procedure below. „ With 4-color machine, use Singleweight Matte Paper. † Procedure 1. Click the [Refer] button and select any image file (bmp) - Epson 4000 | Service Manual - Page 409
EPSON Stylus Pro 4000 5.3.23 Adjustment Image (for 4-color model) Following adjustments are performed as a series of operations. „ 4-color dot shift „ Microweave Adjustment „ Image Print (Tanzaku) NOTE: Refer to "5.3.22.3 Image Print (Tanzaku) (p408)" for details of the Image Print (Tanzaku). - Epson 4000 | Service Manual - Page 410
EPSON Stylus Pro 4000 Check the gray sections at both sides of the printed pattern. START Dot Shift 1 Dot Shift 2 Dot Shift 3 Dot Shift 4 ^^^^Dot Shift 2_0 SWMP720*720_4c_DS1_-2&DS1_+2&DS2_-4&DS2_-2&DS2_0&DS2_+2&DS2_+4&DS3_-3&DS3_0&DS3_+3&DS4 - Epson 4000 | Service Manual - Page 411
EPSON Stylus Pro 4000 5.3.23.2 Microweave Adjustment † Papers Required „ Size: 17" „ Type: Singleweight Matte Paper † Procedure 1. Turn the printer power on. 2. Start up the adjusting program and select [Image Adjustment]. 3. Click [Print] to print the adjustment pattern. 4. Check the gray sections - Epson 4000 | Service Manual - Page 412
EPSON Stylus Pro 4000 Check the gray sections at both sides of the printed pattern. START Microweave 1 Microweave 2 Microweave 3 Microweave 4 ^^^^Dot Shift 2_0 SWMP1440*720_4c_M/W1&M/W2&M/W3&M/W4 PG1.2 [ Vertical Alignment VSD 2 end ∗ Explanation: • M/W=Microweave M/W1&M/W2&M/W3&M/ - Epson 4000 | Service Manual - Page 413
EPSON Stylus Pro 4000 5.4 Advanced Adjustment 5.4.1 Auto Bi-d Adjustment Performs Auto Bi-D Adjustment with the Multi Sensor. When the adjustment pattern is printed, this is automatically executed from scanning of the pattern to correction. The pattern is printed at PG=0.7/1.2, and the correction - Epson 4000 | Service Manual - Page 414
EPSON Stylus Pro 4000 5.4.2 Manual Bi-D Adjustment Adjusts Bi-D by inspecting visually. † Papers required „ Size: 17" „ Type: Enhanced Matte Roll Paper † Procedure 1. Turn the printer power on. 2. Start up the adjustment program and select [Manual Bi-D Adjustment]. 3. Select the PG that requires - Epson 4000 | Service Manual - Page 415
EPSON Stylus Pro 4000 9. Click [Print] to print the color adjustment patterns consist of four rows (VSD1, VSD2, to the printer is finished normally, and then click [OK]. ( ) 12. Click [Finish].( ) Revision B 8 9 10 12 Figure 5-78. Color Adjustment Pattern 11 Figure 5-77. Manual Bi-D Adjustment - Epson 4000 | Service Manual - Page 416
EPSON Stylus Pro 4000 5.4.3 Destination Setting † Procedure 1. Start the adjustment program and select [Change Model Name]. 2. Select the "Others" and click the [Run] button to set the destination to - Epson 4000 | Service Manual - Page 417
EPSON Stylus Pro 4000 5.5 Check Results 5.5.1 Check Nozzle This checks whether or not each of the head nozzles is jetting ink normally. If nozzle ink jetting is abnormal, execute cleaning and check the nozzles again. † Paper Used „ Size: 17" „ Type: Enhanced Matte Roll Paper and then print the check - Epson 4000 | Service Manual - Page 418
EPSON Stylus Pro 4000 5.5.2 Check Alignment This checks for presence/absence of alignment slip. Check all of the printing modes VSD1, VSD2, VSD3 and ECO. If alignment is slipped, execute cleaning and check the alignment again. † Paper Used „ Size: 17" „ Type: Enhanced Matte Rool Paper † Procedure 1. - Epson 4000 | Service Manual - Page 419
EPSON Stylus Pro 4000 5.5.3 Print Adjustment Check Pattern This prints all of the adjustment patterns and the adjustment parameters stored in the printer. † Paper Used „ Size: 17" „ Type: Enhanced Matte Rool Paper † Procedure 1. Start the adjustment program and select [Print Adjustment Check - Epson 4000 | Service Manual - Page 420
EPSON Stylus Pro 4000 5.5.4 Check Cutting This cuts the paper and checks for cutter adjustment and cutter wear. † Paper Used „ Size: 17" „ Type: Enhanced Matte Roll Paper † Procedure 1. Start the adjustment program and select [Cut Check]. 2. Input the number of times to execute the test cut into the - Epson 4000 | Service Manual - Page 421
EPSON Stylus Pro 4000 5.6 Reset Counters 5.6.1 Reset Paper Ejection Switching/PG Switching Counter † Procedure 1. Turn the printer power on. 2. Start up the adjustment program and select [Reset Paper Ejection Switching/PG Switching Counter]. 3. Click [Run] to clear the Paper Ejection Switching/PG - Epson 4000 | Service Manual - Page 422
EPSON Stylus Pro 4000 5.6.3 Reset ASF Counter † Procedure 1. Turn the printer power on. 2. Start up the adjustment program and select [Reset ASF Counter]. 3. Click [Run] to clear the ASF Counter. 4. Click [Finish]. Revision B 5.6.4 Reset When CR Unit Change † Procedure 1. Turn the printer power on. - Epson 4000 | Service Manual - Page 423
EPSON Stylus Pro 4000 5.6.5 Reset When Cleaning Unit Change † Procedure 1. Turn the printer power on. 2. Start the adjustment program and select [Reset When Cleaning Unit Change]. 3. Click the [Run] button to clear the Cleaning Unit change counter. 4. Click - Epson 4000 | Service Manual - Page 424
EPSON Stylus Pro 4000 Revision B 5.7 Installing Firmware Firmware for the printer is written to the Flash ROM on the Main Board. Use the following procedure to write the firmware to the Flash ROM when the Main Board is replaced. C A U T IO N Turning on the printer immediately after uploading - Epson 4000 | Service Manual - Page 425
MAINTENANCE CHAPTER 6 - Epson 4000 | Service Manual - Page 426
EPSON Stylus Pro 4000 6.1 Overview This chapter describes maintenance operations that are required during servicing. Most servicing/maintenance of this printer will need to be done by visiting the site where the printer will actually be used by the customer (on-site service). Carefully observe - Epson 4000 | Service Manual - Page 427
2.6 million passes). However, if this printer continues to be used after the product work life, service call errors will be displayed before part failures occur and messages will be presented to advise part replacement. (This excludes the Maintenance Tank and Cutter consumable parts.) Corresponding - Epson 4000 | Service Manual - Page 428
EPSON Stylus Pro 4000 6.2 Lubrication Lubricate as needed during servicing. Use lubricants specified below. Table 6-2. Grease Application Name G-26 G-46 Amount 40 g --- Company EPSON EPSON Part No. 1080614 1039172 C A U T IO N When lubricating printer ASF Unit Maintenance Lubrication 428 - Epson 4000 | Service Manual - Page 429
EPSON Stylus Pro 4000 • Lubrication Point "Plate, Linear, Front (Rear)" and "Ball Bearing S/NA" intervening parts. (16 places) • Lubrication Type G-26 • # or equivalent), spread it using a brush or other utensil. Figure 6-7. Shaft, Release, Roller Driven (right side) Maintenance Lubrication 429 - Epson 4000 | Service Manual - Page 430
EPSON Stylus Pro 4000 • Lubrication Point Cam part of "Intermittent Gear, 40" • Lubrication Type G-26 • Lubrication Amount φ1mm x approximately x 1/2 circumference • Remarks Use a syringe/needle (JIS 17# or equivalent) for application. Figure 6-10. Motor assembly, PG Maintenance Lubrication 430 - Epson 4000 | Service Manual - Page 431
APPENDIX CHAPTER 7 - Epson 4000 | Service Manual - Page 432
EPSON Stylus Pro 4000 7.1 Connectors † C511 Main Board Table 7-1. C511 Main Board Connectors List CN.No. CN1 CN3 CN7 CN8 CN9 CN11 CN12 CN13 CN14 CN15 CN16 CN18 CN19 - Epson 4000 | Service Manual - Page 433
EPSON Stylus Pro 4000 † C511_SUB-B Board Table 7-5. C511_SUB-B Board Connectors List CN.No. CN22 CN25 CN26 CN27 CN29 CN31 CN33 CN34 CN36 CN39 CN42 CN43 CN45 CN46 CN55 CN100 - Epson 4000 | Service Manual - Page 434
EPSON Stylus Pro 4000 Revision B Panel Board PG Phase Sensor CN32 CN28 Paper Eject Phase Sensor CN1 ASF Phase Sensor CN30 CN37 I/H Lever Sensor (Left) CN24 CN200 CN201 PF Encoder Paper Eject Release Sensor I/H Lever Sensor (Right) Paper Thickness Sensor (0.8) CR_HP Sensor CN38 Matte - Epson 4000 | Service Manual - Page 435
EPSON Stylus Pro 4000 7.2 Circuit Diagrams The circuit diagrams of the following circuit boards are shown on the following pages: † C511 MAIN BOARD „ C511 MAIN BOARD (1) „ C511 MAIN BOARD (2) „ - Epson 4000 | Service Manual - Page 436
Model: PX-6000 / StylusPro 4000 Board: C511Main Sheet: 1 of 3 Revision: G - Epson 4000 | Service Manual - Page 437
Model: PX-6000 / StylusPro 4000 Board: C511Main Sheet: 2 of 3 Revision: G - Epson 4000 | Service Manual - Page 438
Model: PX-6000 / StylusPro 4000 Board: C511Main Sheet: 3 of 3 Revision: H - Epson 4000 | Service Manual - Page 439
Model: PX-6000 / StylusPro 4000 Board: C511Sub Sheet: 1 Revision: B - Epson 4000 | Service Manual - Page 440
Model: PX-6000 / StylusPro 4000 Board: C511Sub-B Sheet: 1 Revision: E - Epson 4000 | Service Manual - Page 441
Model: PX-6000 / StylusPro 4000 Board: C511Sub-C Sheet: 1 Revision: C - Epson 4000 | Service Manual - Page 442
EPSON Stylus Pro 4000 7.3 Exploded Diagrams Revision B Appendix Exploded Diagrams 442 - Epson 4000 | Service Manual - Page 443
112 111 111 111 110 117 113 100 108 108 101 109 105 103 106 118 107 104 103 108 102 108 116 114 115 PX-6000 / EPSON STYLUS PRO 4000 119 Rev.02 C511-CASE-012 - Epson 4000 | Service Manual - Page 444
158 152 153 155 159 154 150 G 151 156 157 PX-6000 / EPSON STYLUS PRO 4000 Rev.02 C511-CASE-022 - Epson 4000 | Service Manual - Page 445
300 302 301 G P Q1 AH1 I R Q2 V2 V4 U4 AE1 D AD1 AF1 AG1 N 200 PX-6000 / EPSON STYLUS PRO 4000 Rev.01 C511-ELEC-011 - Epson 4000 | Service Manual - Page 446
501 509 542 507 505 526 506 522 521 520 510 527 508 511 502 503 500 504 524 516 503 A2 519 518 517 515 514 513 525 512 PX-6000 / EPSON STYLUS PRO 4000 Rev.04 C511-MECH-014 - Epson 4000 | Service Manual - Page 447
567 AB 571 594 Y8 568 562 577 590 578 578 577 579 595 561 561 AC 567 560 553 555 560 570 PX-6000 / EPSON STYLUS PRO 4000 Rev.01 C511-MECH-021 - Epson 4000 | Service Manual - Page 448
AH2 AG2 633 632 AH1 AD2 AD1 635 634 AE2 AG1 AF2 AE1 AF1 619 608 620 609 638 638 636 610 612 611 616 618 617 AC 613 615 614 638 607 639 606 606 627 628 629 621 622 623 625 624 626 Z2 630 631 PX-6000 / EPSON STYLUS PRO 4000 Rev.03 C511-MECH-033 - Epson 4000 | Service Manual - Page 449
672 686 694 668 O 664 692 657 665 663 Q2 666 Q1 692 657 669 667 AI2 662 AI1 670 AI1 661 x17 PX-6000 / EPSON STYLUS PRO 4000 694 693 Rev.03 674 676 N 677 679 678 694 675 652 680 682 681 683 652 684 685 C511-MECH-043 - Epson 4000 | Service Manual - Page 450
V3 738 739 729 745 730 727 723 726 746 722 746 723 722 723 746 722 722 746 723 735 732 736 PX-6000 / EPSON STYLUS PRO 4000 Rev.05 C511-MECH-055 740 U3 741 U2 - Epson 4000 | Service Manual - Page 451
785 787 789 789 789 788 789 789 759 760 790-A 790-B 790-C 790-D 790-E S 791 790-A 790-B 790-C 790-D 790-E 770 772 PX-6000 / EPSON STYLUS PRO 4000 Rev.05 C511-MECH-065 - Epson 4000 | Service Manual - Page 452
817 818 814 822 817 826 825 815 827 828 832 833 818 829 834 831 835 830 839 810 836 837 803 PX-6000 / EPSON STYLUS PRO 4000 Rev.03 840 847 845 C511-MECH-073 846 817 848 849 - Epson 4000 | Service Manual - Page 453
x6 878 x3 877 x6 881 x7 890 J 892 893 856 857 858 859 I 887 888 887 888 883 884 H 894 885 860 PX-6000 / EPSON STYLUS PRO 4000 Rev.02 886 889 C511-MECH-083 - Epson 4000 | Service Manual - Page 454
926 927 W 909 908 928 929 900 902 903 905 904 924 924 912 913 911 925 914 915 916 920 918 919 924 924 917 923 923 923 910 923 923 921 924 923 924 923 923 923 923 923 922 907 930 906 x16 PX-6000 / EPSON STYLUS PRO 4000 Rev.06 C511-MECH-096 - Epson 4000 | Service Manual - Page 455
950 953 952 954 955 956 957 958 960 961 960 961 975 978 979 952 985 986 962 963 964 965 966 963 962 967 974 971 970 971 976 977 973 982 977 975 968 974 987 979 983 991 990 987 992 988 989 PX-6000 / EPSON STYLUS PRO 4000 Rev.02 C511-MECH-102 - Epson 4000 | Service Manual - Page 456
18 16 17 16 17 15 14 11 08 07 08 08 02 08 06 05 12 10 12 03 04 04 04 04 13 13 01 09 PX-6000 / EPSON STYLUS PRO 4000 Rev.01 13 13 13 13 13 13 C511-PACK-011 - Epson 4000 | Service Manual - Page 457
EPSON Stylus Pro 4000 7.4 Parts List Table "GUIDE,STACKER" "STACKER,SUPPORT" TRAY ASSEMBLY;B "LABEL,MODEL NAME" "LABEL,ULTRA CHROME INK" "LABEL,ASF SET" "LABEL,ROLLPAPER SET,2/3 INCH" "LABEL,INK N-CH FET P-CH FET "PRINTER MECHANISM(SP),M-AB60-103" "COVER ASSY.,SIDE,L,SP" "COVER,I/H,LEFT" "LATCH,COVER - Epson 4000 | Service Manual - Page 458
EPSON Stylus Pro 4000 Table 7-7. Parts List for C511001N-EAI Fig. No. 504 505 506 507 508 509 510 511 512 513 514 515 516 517 518 519 520 521 522 524 525 526 527 542 550 551 552 553 554 555 556 557 558 559 560 Parts Name "GUIDE,I/H,LEFT" "PANEL,FRONT" "COVER,REAR" "STOPPER - Epson 4000 | Service Manual - Page 459
EPSON Stylus Pro 4000 Table 7-7. Parts List for C511001N-EAI Fig. No. 606 607 608 609 610 611 612 613 614 615 616 617 618 619 620 621 622 623 624 625 626 627 628 629 630 631 632 633 634 635 636 638 639 650 651 Parts Name "POROUS PAD,INK,GUTTER,B" "GUTTER ASSY.,INK EJECT - Epson 4000 | Service Manual - Page 460
EPSON Stylus Pro 4000 Table 7-7. Parts List for C511001N-EAI Fig. No. 689 690 691 692 693 694 700 701 701 702 703 704 705 706 706 707 708 709 710 711 712 713 714 715 716 717 718 719 720 721 722 723 725 726 727 Parts Name "DETECTOR,LEAF,B2" "COVER,DETECTOR,PAPER GUIDE,MIDDLE - Epson 4000 | Service Manual - Page 461
EPSON Stylus Pro 4000 Table 7-7. GUIDE PLATE,TUBE" "SHEET,SUS" "HOLDER,FFC;B" "SPACER,MIDDLE,0.05" "SPACER,MIDDLE,0.1" "SPACER,MIDDLE,0.2" "SPACER,MIDDLE,0.5" "SPACER,MIDDLE,0.08" "HARNESS,DETECTOR,HP" BALL BEARING(B210151490) "DETECTOR,LEAF,B2" "HARNESS,PAPER EJECT PHASE,LEFT" "LEVER,CHANGE PAPER - Epson 4000 | Service Manual - Page 462
EPSON Stylus Pro 4000 Table 7-7. Parts List for C511001N-EAI PAPER EJECT ROLLER" "PAPER GUIDE ASSY.,PAPER EJECT,FRONT,LEFT" "POROUS PAD,I" "POROUS PAD,H" "POROUS PAD,G" "POROUS PAD,F" "POROUS PAD,E" "PAPER GUIDE ASSY.,PAPER EJECT,FRONT,RIGHT" "POROUS PAD,C2" "POROUS PAD,B2" "PAPER GUIDE ASSY.,PAPER - Epson 4000 | Service Manual - Page 463
EPSON Stylus Pro 4000 Table 7-7. Parts List for C511001N-EAI Fig. No. 956 957 958 960 961 962 963 964 965 966 967 968 970 971 973 974 975 976 977 978 979 982 983 985 986 987 988 989 990 991 992 Parts Name "COMPRESSION SPRING,0.46" "COMPRESSION SPRING,3.23" "SLIDER,EDGE GUIDE" "GUIDE,LOWER" " - Epson 4000 | Service Manual - Page 464
EPSON Stylus Pro 4000 Table 7-7. Parts List for C511001N-EAI Fig. No. NON FIG NON PRESS TOOL FOR CUTTER PLATE ASF EXCHANGE SUPPORT TOOL BOXWRENCH(SPECIAL PROCESSING) CUTTER PLATE DITCH POSITION TOOL KEEP STAND FOR CUTTER PLATE&PLATEN CALIBRATE BLOCK&TOOL STAND TENSION GAUGE(5N;STD) TENSION GAUGE(
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EPSON Stylus Pro 4000
Color Large Format Inkjet Printer
SERVICE MANUAL
SEIJ03003