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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 printer for any foreign matter and make sure there is nothing there to hinder normal operation. 2. With the printer in "READY" condition, press the [Menu] key one time, and then press the [Paper Feed keys to select "TEST PRINT". Press the [Menu] key again one time, press the [Paper Feed keys to select "STATUS CHECK". After these have been selected, press the [Menu] key two times to print. From the status sheet, you can check to see if the cause of the trouble is that the printer (either the printer unit itself or some major unit) is at the end of its service life, and check the user inherent panel settings, etc. (Refer to "Step 9" when in properties panel settings.) 3. There should be no market soiling of the outside or the inside of the printer. If it is extremely soiled, carry out cleaning. 4. Each of the units and parts in the printer should not be missing or damaged, and should have the normal shape and configuration. 5. Each of the harnesses should be undamaged, and should be correctly connected to the relevant connector (perpendicularly and in the correct direction). 6. Each cam and gear in the printer mechanism should have no uneven wear or be overly worn, and the combinations should be correct. 7. Each type of rubber roller in the printer mechanism should be cleaned and it should be ascertained whether the cause of the trouble is because of dirt or due to some other cause. 8. Each type of rubber roller in the printer mechanism should not be unevenly worn or excessively worn, and their combinations should be correct. 9. As necessary, initialize the NVRAM on the C511 MAIN Board (return the individual customer settings and panel settings to the factory settings). Carry out initialization by executing "NVRAM" from the "CLEAR COUNTERS" in "Maintenance Mode 2". W A R N IN G Be sure to refer to "4.1.1 Cautions" (p197) for the detailed description when handling a lithium battery that is installed for RTC backup on the MAIN Board. C A U T IO N „ When disassembling/assembling, turn the printer power switch OFF. After confirming that panel display disappears, unplug the power cable from the electric outlet and then continue operations. „ Only the specified printer tools should be used so as to maintain the printer's quality. „ Only the specified lubricants and adhesives should be used. „ The specified adjustments should definitely be carried out. 3.1.2 Narrow Down the Trouble To increase the troubleshooting efficiency, follow the flow chart below and narrow down the trouble. Trouble Occurs "Troubleshooting Based on Panel Messages (p157)" "Troubleshooting Based on Your Printout (p192) " "Corrective Actions for Displayed Warnings (p160) " "Corrective Actions for Error Display (p163)" "Corrective Actions for Service Request Display (p172) " Troubleshooting Outline 156

Section	Page
EPSON Stylus Pro 4000	1
Product Description	9
1.1 Product Description	10
1.1.1 Features	10
1.2 Basic Specifications	12
1.2.1 Print Specifications	12
1.2.2 Character Specification	12
1.2.3 Control Code	12
1.2.4 Paper Feed Specification	13
1.2.5 Paper Feeder Specification	13
1.2.6 Paper Specification	14
1.2.6.1 Roll Paper	14
1.2.6.2 Cut Sheet	15
1.2.6.3 Special Paper	16
1.2.7 Mechanism Specifications	18
1.2.7.1 Printable Area	18
1.2.7.2 Borderless Print Specification	19
1.2.7.3 Paper Set Lever	20
1.2.7.4 Cut Specification	20
1.2.8 Electrical Specification	21
1.2.9 Reliability	22
1.2.10 Environmental Conditions	22
1.2.10.1 Temperature/Humidity	22
1.2.10.2 Vibration	23
1.2.10.3 Shock	23
1.2.10.4 Surrounding Space	23
1.2.11 Overall Dimensions	24
1.2.12 Accessories	25
1.3 External View and Parts Names	26
1.4 Operating Panel	27
1.4.1 Buttons and Functions	27
1.4.1.1 LED	27
1.4.1.2 Switch	28
1.4.2 Panel Display	30
1.4.2.1 Panel Display in Operation (LCD and LED Display)	30
1.4.2.2 Paper Type Icon Display	35
1.4.2.3 PG Setting Display	35
1.4.2.4 Ink Remaining Indicator Display	35
1.4.2.5 Suction Adjustment and Indicator Display	35
1.4.3 Job information	36
1.4.4 Panel Setting	37
1.4.4.1 Outline	37
1.4.4.2 Panel Setting Menu Item	41
1.4.4.3 PG Setting	45
1.4.4.4 Page Lines	46
1.4.4.5 Interface Select	46
1.4.4.6 Code Page Switching	46
1.4.4.7 Roll Paper Margin	47
1.4.4.8 Paper Width Detection	48
1.4.4.9 Skew Error Detection	49
1.4.4.10 Job Time-out Setting	49
1.4.4.11 Cutter Position Adjustment	50
1.4.4.12 Auto Margin Refresh	51
1.4.4.13 Cut Sheet Size Error	51
1.4.4.14 Auto Nozzle Check for Each Job	52
1.4.4.15 Cleaning Setting for Nozzle Check	52
1.4.4.16 Super Low Speed Cut Mode	53
1.4.4.17 Printer Setup Value Initialization	53
1.4.4.18 Nozzle Check Pattern Printing	54
1.4.4.19 Status Printing	55
1.4.4.20 Job Information Print	57
1.4.4.21 User Paper Setting Printing	58
1.4.4.22 Firmware Version	59
1.4.4.23 Printable Pages per Ink Cartridge	59
1.4.4.24 Ink Remaining	60
1.4.4.25 Maintenance Tank Count	61
1.4.4.26 Consumption Counter	61
1.4.4.27 Clear consumption counter	61
1.4.4.28 Job History Display	61
1.4.4.29 Clear Job History	61
1.4.4.30 Total Print Pages	61
1.4.4.31 Consumable Life	62
1.4.4.32 User Paper Setting	64
1.4.4.33 Cutter Blade Replacement	69
1.4.4.34 Ink Replacement Method (8-color, 4-color)	69
1.4.4.35 Power Cleaning	69
1.4.4.36 Date Setting	69
1.4.4.37 Gap Adjustment (Bi-D Adjustment, Uni-D Adjustment)	69
1.4.5 Maintenance Mode 1	73
1.4.6 Maintenance Mode 2	79
1.4.6.1 Self Testing Menu (SELF TESTING)	80
1.4.6.2 Adjustment Setting Menu (SERVICE CONFIG)	89
1.4.6.3 Counter Display Menu (VIEW COUNTERS)	90
1.4.6.4 Counter Initialization Menu (CLEAR COUNTERS)	91
1.4.6.5 Maintenance Information Menu (MAINT INFO)	93
1.4.6.6 Maintenance Information Initialization Menu (INIT INFO)	104
1.4.6.7 Parameter Backup Mode Menu (PARAMETER BACKUP MODE)	104
1.4.7 MIB Function	105
1.4.8 Function to Prevent Irregular Printing	105
1.4.9 Initialization	106
1.4.9.1 Hardware Initialization	106
1.4.9.2 Software Initialization	106
1.4.9.3 Panel Initialization	106
1.4.10 Default Setup Values	106
1.4.10.1 Operation Default Setting	106
1.5 Controller	107
1.6 Interface	108
1.6.1 USB interface	108
1.6.2 IEEE1394 Interface	109
1.6.3 Optional Interface	110
1.6.4 Supplements	112
1.7 Optional Units and Consumables	113
1.7.1 Ink Cartridge	113
1.7.2 Cleaning cartridge	114
1.7.3 Maintenance Tank	114
Operating Principles	115
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
2.2.4.1 Carriage Unit Movement Components	127
2.2.4.2 Platen Gap Adjustment Components	129
2.2.4.3 Cutter Solenoid/CR Lock Mechanism	132
2.2.5 Paper Feed Mechanism	132
2.2.5.1 ASF Paper Feed Mechanism	135
2.2.6 Paper Eject/Release Mechanism	141
2.2.6.1 Paper Eject Mechanism	141
2.2.6.2 Release Mechanism	144
2.2.7 Multi Sensor	146
2.2.7.1 Overview	146
2.2.7.2 Operations/Functions	147
2.2.8 Others	152
2.3 Outline of Control Circuit Board	153
2.4 Outline of Power Supply Circuit Board	154
Troubleshooting	155
3.1 Outline	156
3.1.1 Check Before Troubleshooting	156
3.1.2 Narrow Down the Trouble	156
3.2 Troubleshooting Based on Panel Messages	157
3.2.1 Message Table	157
3.2.2 Corrective Actions for Displayed Warnings	160
3.2.3 Corrective Actions for Error Display	163
3.2.4 Corrective Actions for Service Request Display	172
3.3 Troubleshooting Based on Your Printout	192
Disassembly & Assembly	196
4.1 Introductory Information	197
4.1.1 Cautions	197
4.1.2 Tools	199
4.1.3 Screws	200
4.2 Disassembly Procedures	201
4.2.1 Basic Operations	202
4.2.1.1 Release of the Transport Retaining Lever	202
4.2.1.2 Carriage Unit Lock Release/Lock Set Method	203
4.2.2 Consumable Parts/ASF Cassette Removal	204
4.2.2.1 Ink Cartridges	204
4.2.2.2 Maintenance Tank (Porous Pad Assy., Ink Eject)	205
4.2.2.3 Cutter Assembly	206
4.2.2.4 ASF Cassette	207
4.2.2.5 Spindle	208
4.2.3 Panel Unit/Housing Removal	209
4.2.3.1 Holder, Roller, Unit	209
4.2.3.2 Paper Guide Assy., M, SP	210
4.2.3.3 Cover, Side, Left	211
4.2.3.4 Cover, Side, Right	212
4.2.3.5 Panel, Front/Panel Unit	214
4.2.3.6 Cover, Printer	216
4.2.3.7 Cover, Rear	218
4.2.3.8 P Cover Open Sensor	219
4.2.3.9 Rear Cover Sensor	220
4.2.4 Circuit Board Removal	221
4.2.4.1 C511 MAIN Board	221
4.2.4.2 Power Supply Board	228
4.2.4.3 C511_SUB Board	229
4.2.4.4 C511_SUB-B Board	231
4.2.4.5 C511_SUB-C Board	233
4.2.5 Printer Mechanism Disassembly	235
4.2.5.1 Printer Mechanism (SP)	236
4.2.5.2 Fan, Blower	238
4.2.6 ASF	240
4.2.6.1 ASF Unit	240
4.2.6.2 Roller Assy., LD, Left / Roller Assy., LD, Right	248
4.2.6.3 Mount Assy., Plate, Motor, ASF, SP	253
4.2.6.4 ASF Phase Sensor	257
4.2.6.5 ASF Paper Sensor	259
4.2.7 Carriage Mechanism	260
4.2.7.1 Carriage Unit	260
4.2.7.2 Motor Assy., CR	264
4.2.7.3 Motor Assy., PG	267
4.2.7.4 CR_HP Sensor	269
4.2.7.5 Multi Sensor	270
4.2.7.6 PG Phase Sensor	271
4.2.7.7 CR Encoder Sensor	273
4.2.7.8 Scale, CR	274
4.2.7.9 Pulley, Driven/Shaft, Pulley	275
4.2.7.10 Solenoid, CR	277
4.2.8 Ink System	278
4.2.8.1 Printhead	278
4.2.8.2 Valve Assy., Head	284
4.2.8.3 Gutter, Ink	287
4.2.8.4 I/H Left Unit / I/H Lever Sensor (Left)	289
4.2.8.5 I/H Right Unit / I/H Lever Sensor (Right)	298
4.2.8.6 Box Assy., Flushing / Pump Unit	309
4.2.8.7 Guide, Waste Ink	315
4.2.8.8 Pump Phase Sensor	316
4.2.8.9 Holder, FFC	318
4.2.8.10 Holder, FFC; B	321
4.2.8.11 Harness, Head, Intermit / Harness, Head	324
4.2.8.12 Tube, Supply, Ink (Y/M/C/MK) on the Left Side of the Main Unit	327
4.2.8.13 Tube, Supply, Ink (LK(Y)/LM(M)/LC(C)/PK(MK)) on the Right side of the Main Unit	331
4.2.9 Paper Feed Mechanism	335
4.2.9.1 Release Unit	335
4.2.9.2 Paper Eject Unit	340
4.2.9.3 Motor Assy., PF	341
4.2.9.4 P_THICK Sensor (0.8) / P_THICK Sensor (0.3)	343
4.2.9.5 PE Sensor	344
4.2.9.6 Rear Manual Insertion Sensor	346
4.2.9.7 Paper Eject Phase Sensor	348
4.2.9.8 Paper Eject Release Sensor	348
4.2.9.9 PF Encoder Sensor	349
4.2.10 Harness Routing	350
4.2.10.1 Harnesses on Left Side of Printer	350
4.2.10.2 Harnesses on Right Side of Printer	352
Adjustment	354
5.1 Overview	355
5.1.1 Cautions	355
5.1.2 Advance of Adjustment	355
5.1.3 The Part/Unit that is required Adjustment	355
5.1.4 Adjustment Items classified by Part/Unit	356
5.1.5 Adjustment Item	358
5.1.6 Adjustment Tools	361
5.1.7 Adjustment Program Basic Operation	362
5.2 Mechanical Adjustment	363
5.2.1 CR Timing Belt Tension Adjustment	363
5.2.2 PF Timing Belt Tension Adjustment	365
5.2.3 Paper Thickness Sensor Adjustment	367
5.2.4 CR Encoder Sensor Position Adjustment	369
5.2.5 PG Adjustment	370
5.2.6 Multi Sensor Position Adjustment	372
5.3 Basic Adjustment	374
5.3.1 RTC&USB ID&IEEE1394 ID	374
5.3.2 Head Rank ID	375
5.3.3 Multi Sensor Level Adjustment	376
5.3.4 T&B&S (Roll Paper)	377
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 Slant Adjustment (CR)	384
5.3.10 Auto Uni-d Adjustment	387
5.3.11 Multi Sensor Adjustment for Auto Nozzle Check	388
5.3.12 Skew Check	390
5.3.13 Platen Position Adjustment	391
5.3.14 1000mm Feed Adjustment	393
5.3.15 Initial Ink charge flag ON/OFF	394
5.3.16 NVRAM Back Up and Write	395
5.3.17 Check Platen Gap	396
5.3.18 Ink Discharge	397
5.3.19 Initial Ink Charge	398
5.3.20 Cleaning	398
5.3.21 Rear Sensor Adjustment	399
5.3.22 Adjustment Image (for 8-color model)	400
5.3.22.1 PF Micro Feed Adjustment Bi-D	401
5.3.22.2 Dot Shift Adjustment	406
5.3.22.3 Image Print (Tanzaku)	408
5.3.23 Adjustment Image (for 4-color model)	409
5.3.23.1 4-color Dot Shift	409
5.3.23.2 Microweave Adjustment	411
5.4 Advanced Adjustment	413
5.4.1 Auto Bi-d Adjustment	413
5.4.2 Manual Bi-D Adjustment	414
5.4.3 Destination Setting	416
5.5 Check Results	417
5.5.1 Check Nozzle	417
5.5.2 Check Alignment	418
5.5.3 Print Adjustment Check Pattern	419
5.5.4 Check Cutting	420
5.6 Reset Counters	421
5.6.1 Reset Paper Ejection Switching/PG Switching Counter	421
5.6.2 Reset PF Motor Counter	421
5.6.3 Reset ASF Counter	422
5.6.4 Reset When CR Unit Change	422
5.6.5 Reset When Cleaning Unit Change	423
5.7 Installing Firmware	424
Maintenance	425
6.1 Overview	426
6.1.1 Product Life Information	427
6.1.2 Important Maintenance Items During Service Operations	427
6.2 Lubrication	428
Appendix	431
7.1 Connectors	432
7.2 Circuit Diagrams	435
7.3 Exploded Diagrams	442

Match case Limit results 1 per page

EPSON Stylus Pro 4000

Revision B

Troubleshooting

Outline

156

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.

Look in the printer for any foreign matter and make sure there is nothing

there to hinder normal operation.

With the printer in "READY" condition, press the [Menu] key one time, and

then press the [Paper Feed (

∧

∨

)] keys to select "TEST PRINT". Press the

[Menu] key again one time, press the [Paper Feed (

∧

∨

)] keys to select

"STATUS CHECK". After these have been selected, press the [Menu] key

two times to print.

From the status sheet, you can check to see if the cause of the trouble is

that the printer (either the printer unit itself or some major unit) is at the end

of its service life, and check the user inherent panel settings, etc.

(Refer to "Step 9" when in properties panel settings.)

There should be no market soiling of the outside or the inside of the printer.

If it is extremely soiled, carry out cleaning.

Each of the units and parts in the printer should not be missing or

damaged, and should have the normal shape and configuration.

Each of the harnesses should be undamaged, and should be correctly

connected to the relevant connector (perpendicularly and in the correct

direction).

Each cam and gear in the printer mechanism should have no uneven wear

or be overly worn, and the combinations should be correct.

Each type of rubber roller in the printer mechanism should be cleaned and

it should be ascertained whether the cause of the trouble is because of dirt

or due to some other cause.

Each type of rubber roller in the printer mechanism should not be unevenly

worn or excessively worn, and their combinations should be correct.

As necessary, initialize the NVRAM on the C511 MAIN Board (return the

individual customer settings and panel settings to the factory settings).

Carry out initialization by executing "NVRAM" from the "CLEAR

COUNTERS" in "Maintenance Mode 2".

3.1.2

Narrow Down the Trouble

To increase the troubleshooting efficiency, follow the flow chart below and

narrow down the trouble.

Be sure to refer to

"4.1.1 Cautions" (p197)

for the detailed

description when handling a lithium battery that is installed

for RTC backup on the MAIN Board.

When disassembling/assembling, turn the printer power

switch OFF. After confirming that panel display

disappears, unplug the power cable from the electric

outlet and then continue operations.

Only the specified printer tools should be used so as to

maintain the printer's quality.

Only the specified lubricants and adhesives should be

used.

The specified adjustments should definitely be carried

out.

Trouble Occurs

"Troubleshooting Based on Panel

Messages (p157)"

"Corrective Actions for

Displayed Warnings

(p160)"

"Corrective Actions for

Error Display (p163)"

"Troubleshooting Based on Your Printout

(p192)"

"Corrective Actions for

Service Request Display

(p172)"