Epson WP-4590 Series Service Manual
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Epson WP-4590 Series Service Manual

Epson WP-4590 Series Service Manual

Color inkjet printer
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SERVICE MANUAL
Color Inkjet Printer
Epson WP-4590 series/ Epson WP-4540 series
Epson WP-4530 series/ Epson WP-4520 series
Epson WP-4510 series/ Epson WP-4090 series
Epson WP-4020 series/ Epson WP-4010 series
CONFIDENTIAL
SEMF11-002

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  • Page 1 SERVICE MANUAL Color Inkjet Printer Epson WP-4590 series/ Epson WP-4540 series Epson WP-4530 series/ Epson WP-4520 series Epson WP-4510 series/ Epson WP-4090 series Epson WP-4020 series/ Epson WP-4010 series CONFIDENTIAL SEMF11-002...
  • Page 2 SEIKO EPSON would greatly appreciate being informed of them. The contents of this manual are subject to change without notice. The above not withstanding SEIKO EPSON CORPORATION can assume no responsibility for any errors in this manual or the consequences thereof.

  • Page 3: Safety Precautions

    Strictly observe the following cautions. Failure to comply may lead to personal injury or damage of the product. 1. Repairs on Epson product should be performed only by an Epson certified repair technician. 2. No work should be performed on this product by persons unfamiliar with basic safety knowledge required for electrician.
  • Page 4 easy-manual.blogspot.com 7. In order to protect sensitive microprocessors and circuitry, use static discharge equipment, such as anti-static wrist straps, when accessing internal components. 8. Do not tilt this product immediately after initial ink charge, especially after performing the ink charge several times.
  • Page 5 easy-manual.blogspot.com About This Manual This manual, consists of the following chapters, is intended for repair service personnel and includes information necessary for properly performing maintenance and servicing the product. CHAPTER 1. PRODUCT DESCRIPTIONS Provides a general overview and specifications of the product. CHAPTER 2.

  • Page 6: Revision Status

    easy-manual.blogspot.com Revision Status Revision Date of Issue Description June 17, 2011 First Release March 12, 2013 Revised Contents All Chapter Description about WP-4590/WP-4090 has been added. Chapter 1 Description about WP-4590/WP-4090 has been added in " Differences between the Models (p10)".

  • Page 7: Table Of Contents

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Contents Chapter 1 Product description 1.1 Features ................................... 10 1.2 Printing Specifications ............................12 1.2.1 Basic Specifications............................12 1.3 Scanner Specifications (WP-4590/4540/4530/4520/4510 series only)..............13 1.3.1 Basic Specifications............................13 1.4 Control Panel................................14 1.4.1 Operation Buttons & LEDs ..........................14 1.4.2 LEDs and LCD Indications ..........................
  • Page 8 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 4.2.3.3 Printer Mechanism ..........................64 4.2.3.4 Printhead/Ink Supply Unit ........................66 4.2.3.5 2nd Cassette Unit ........................... 67 4.3 Detailed Disassembly/Reassembly Procedure for each Part/Unit................68 4.4 Routing FFCs/cables ............................... 77 4.5 Connector ................................81 Chapter 5 Adjustment 5.1 Required Adjustments .............................

  • Page 9: Chapter 1 Product Description

    easy-manual.blogspot.com CHAPTER 1 PRODUCT DESCRIPTION Confidential...

  • Page 10: Features

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 1.1 Features In this manual, the product name is abbreviated to such as “WP-4510 series”, however, the last digit of the actual name may differ. Identify your product with the first three digits and refer to the appropriate sections in this manual.
  • Page 11 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D WP-4540 series WP-4590 series/WP-4530 series/WP-4520 series WP-4090 series/WP-4020 series/WP-4010 series WP-4510 series Figure 1-1. External View Table 1-2. Dimensions Model Dimensions (W x D x H) Weight WP-4540 series 461.0 mm x 419.5 mm x 420.0 mm 16.50 kg...

  • Page 12: Printing Specifications

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 1.2 Printing Specifications 1.2.1 Basic Specifications Table 1-3. Printer Specifications Item Specification Print method On-demand ink jet Nozzle configuration Black: 608 nozzles (152 nozzles x 4) Color: 456 nozzles (152 nozzles x 1 per color)

  • Page 13: Scanner Specifications (Wp-4590/4540/4530/4520/4510 Series Only)

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 1.3 Scanner Specifications (WP-4590/4540/4530/4520/4510 series only) 1.3.1 Basic Specifications Table 1-4. Basic Specifications Item Specification Scanner type Flatbed, color Scanning method Moving carriage, stationary document Home position The rear left corner Photoelectric device Light source...

  • Page 14: Control Panel

    Table 1-7 for the functions. Touch panel WP-4540 series WP-4590 series/WP-4530 series/WP-4520 series WP-4510 series /WP-4090 seriesWP-4020 series/WP-4010 series Note 1: The WiFi logo on the control panel is for WP-4540/4530/4020 series only. 2: WP-4090/4010 series do not have the WiFi button.
  • Page 15 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D The available buttons and LEDs differ between models. Refer to Figure1-2 for available buttons and LEDs for your model. Table 1-6. Operation Buttons, LEDs and LCD (WP-4590/4540/4530/4520/4510 series) Item Icon Name Function Indicates the printer status, error, and menu screen.
  • Page 16 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Table 1-7. Operation Buttons, LEDs (WP-4090/4020/4010 series) Item Icon Name Function Button Power Turns the power on/off. Network status sheet Prints a network status sheet. Wi-Fi Configures the wireless network. • Loads or ejects paper.

  • Page 17: Leds And Lcd Indications

    Scanner error. Turn power off and Scanner fatal then on again. If the error is not fixed, error visit Epson.com for technical support. ADF fatal Automatic Document Feeder error (ADF) error. Fax error. Turn power off and then Fax error on again.
  • Page 18 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Table 1-8. LEDs and LCD Indications WP-4590/4540/4530/4520/4510 WP-4090/4020/4010 series series LED status Status Mainte- LCD message Power Wi-Fi Ethernet nance Paper (BK/C/ M/Y) Operating No paper source matches paper Paper size size setting. Load appropriate...
  • Page 19 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Table 1-8. LEDs and LCD Indications WP-4590/4540/4530/4520/4510 WP-4090/4020/4010 series series LED status Status Mainte- LCD message Power Wi-Fi Ethernet nance Paper (BK/C/ M/Y) Operating Canceling Flash Canceling... Cleaning print head. Please wait... Cleaning (PC) Flash Do not open front cover.
  • Page 20 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Table 1-8. LEDs and LCD Indications WP-4590/4540/4530/4520/4510 WP-4090/4020/4010 series series LED status Status Mainte- LCD message Power Wi-Fi Ethernet nance Paper (BK/C/ M/Y) Operating Flash at Restarting product from other Resetting high device... speed...
  • Page 21 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Table 1-8. LEDs and LCD Indications WP-4590/4540/4530/4520/4510 WP-4090/4020/4010 series series LED status Status Mainte- LCD message Power Wi-Fi Ethernet nance Paper (BK/C/ M/Y) Standby Registration error. Access point setting error Flash The access point is busy. Try (registration) again.

  • Page 22: Various Settings

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 1.5 Various Settings 1.5.1 Panel Operation 1.5.1.1 Setup Menu Configuration (WP-4590/4540/4530/4520/4510 series only) The following explains the setup menu structure and the outline of the menu functions. Table 1-9. Menu Configuration Menu Description Setup Ink Levels Displays the status of ink cartridges and maintenance box.

  • Page 23: Panel Operation Lock Setting (Wp-4590/4540/4530/4520/4510 Series Only)

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 1.5.1.2 Panel Operation Lock Setting (WP-4590/4540/4530/4520/4510 series only) For WP-4590/4540/4530/4520/4510 series, the panel operation for the following can be locked after setting the password. The same password is also required when configuring the printer settings through EPSON NetConfig.

  • Page 24: Forced Power Off

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Resetting the password/unlocking the panel operation lock If you need to reset the password or unlock the panel operation because of forgetting the password and such, follow the steps below to reset them. Resetting/unlocking method 1.

  • Page 25: Chapter 2 Operating Principles

    easy-manual.blogspot.com CHAPTER 2 OPERATING PRINCIPLES Confidential...

  • Page 26: Overview

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 2.1 Overview In this manual, the product name is abbreviated to such as “WP-4510 series”, however, the last digit of the actual name may differ. Identify your product with the first three digits and refer to the appropriate sections in this manual.

  • Page 27: Motors And Sensors

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 2.3 Motors and Sensors The following table lists the motors and sensors of WP-4590/4540/4530/4520/4510/4090/4020/4010 series. Printer Mechanism Table 2-1. List of Motors & Sensors (Printer Mechanism) Mechanism Motor or Sensor Printhead Carriage mechanism CR Motor...
  • Page 28 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Scanner (WP-4590/4540/4530/4520/4510 series only) Table 2-2. List of Motors & Sensors (Scanner) Mechanism Motor or Sensor Scanner mechanism Scanner Motor CIS Unit Figure 2-3. Motors & Sensors (Scanner) ADF (WP-4590/4540/4530/4520 series only) Table 2-3. List of Motors & Sensors (ADF)
  • Page 29 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 2nd cassette This unit is installed for WP-4540 series, and option for WP-4590/4530/4520/4510/4090/4020/4010 series. Table 2-4. List of Motors & Sensors (2nd Cassette) Mechanism Motor or Sensor 2nd cassette ASF Motor Paper Stopper Lever Sensor ASF Encoder Figure 2-5.

  • Page 30: Optical Sensor Control

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 2.4 Optical Sensor Control WP-4590/4540/4530/4520/4510/4090/4020/4010 series uses the optical sensor to control itself. The following describes the operating principles of optical sensor control. Control method To ensure accurate printing, each part must be controlled to make an adequate amount (time) of movement. The optical sensors read the amount (time) of movements as follows to printer to control it for achieving accurate printing.

  • Page 31: Ink Supply Mechanism

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 2.5 Ink Supply Mechanism The following shows configurations of the ink supply mechanism. The ink supply mechanism consists of the Decompress Pump Unit and the Ink Supply Unit composed of the Ink Supply Tube, Diaphragm Pump, Buffer and Ink Cartridge Holder.

  • Page 32: Ink System Mechanism

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 2.6 Ink System Mechanism The following shows configurations of the ink system mechanism. The ink system mechanism consists of the Ink System Unit composed of the Cap, Valve Unit, Pump Unit, Waste Ink Tube and similar parts, and the Maintenance Box that stores the ink from the Printhead sucked by the Ink System Unit.

  • Page 33: Power-On Sequence

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 2.7 Power-On Sequence Initializing operations of this printer at power-on differ between when powered off normally ("Simple Sequence (p33)") and when powered off abnormally ("Normal Power-On Sequence (p36)"). This section describes how this printer operates in the simple sequence and in the normal power-on sequence under certain conditions.
  • Page 34 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Table 2-6. Simple Sequence Front Decom- Movement of Operation press Components drive Clutch Motor condition 2-3. The carriage slowly moves to the CR lock set position. 2-4. The PF Motor rotates clockwise and releases the CR lock.
  • Page 35 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Table 2-6. Simple Sequence Front Decom- Movement of Operation press Components drive Clutch Motor condition 5. PF initialization 5-1. The PF Motor rotates clockwise for approximately one second. 5-2. The PE sensor checks if paper exists, and the PF Motor rotates clockwise for approximately 0.5 seconds.
  • Page 36 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Condition 2: Normal power-on sequence (Table 2-7) When a paper jam error occurred during the previous power-on, and also the printer could not turn off normally. After the ink charge is complete and sufficient ink remains.
  • Page 37 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Table 2-7. Normal Power-On Sequence Front Decom- Movement of Operation press Components drive Clutch Motor condition 2-12. The PF Motor rotates counterclockwise, and the Valve Unit goes up. 2-13. To check if the protrusion of the Valve Unit has been set in the groove of the carriage, the carriage slightly moves to the 0-digit side, and then ↓...
  • Page 38 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Table 2-7. Normal Power-On Sequence Front Decom- Movement of Operation press Components drive Clutch Motor condition 2-26. The carriage moves to the 80-digit side slowly and confirms it touches the CR lock. 2-27. The carriage returns to its home position.
  • Page 39 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Table 2-7. Normal Power-On Sequence Front Decom- Movement of Operation press Components drive Clutch Motor condition 6-2. The PE sensor checks if paper exists, and the PF Motor rotates clockwise for approximately 0.5 seconds.
  • Page 40 easy-manual.blogspot.com CHAPTER 3 TROUBLESHOOTING Confidential...

  • Page 41: Troubleshooting

    Remove while and orange transportation locks by following instructions. Scanner error. Turn power off and then on again. Scanner fatal If the error is not fixed, visit Epson.com for error technical support. ADF fatal error Automatic Document Feeder (ADF) error.
  • Page 42 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Table 3-1. Error Message List WP-4090/4020/4010 series WP-4590/4540/4530/4520/4510 series LED status Status Mainte- LCD message Power Wi-Fi Ethernet nance Paper (BK/C/ M/Y) Paper length Incorrect paper size detected. Load correct mismatch error paper size and press...
  • Page 43 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Note *1: WP-4020 series only *2: The message WP-4540 series indicates is different but the meaning is the same. *3: WP-4590/4540/4530/4520/4510 series only *4: WP-4590/4540/4530/4520 series only *5: Flashes if the status arises when printing starts or when the printer starts up, but lights if the status arises when printing is complete.

  • Page 44: Troubleshooting Workflow

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 3.1.2 Troubleshooting Workflow The following page describes the troubleshooting workflow. Follow the flow when troubleshooting problems. This flowchart is compiled based on the following contents. • Our experience regarding the quality problem. • Printer Mechanism specification for WP-4590/4540/4530/4520/4510/4090/4020/4010 series "...
  • Page 45 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D The power-on sequence Error is indicated during power-on does not start (p44) sequence (p44) Fatal error Maintenance box full Maintenance box CSIC error No maintenance box error Ink end error Ink cartridge detection error...

  • Page 46: Fatal Error Code

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 3.1.3 Fatal Error Code This section describes the fatal error code and the possible cause for this product. Printer fatal error list Table 3-2. Fatal Error List (Printer) Error Error type Error name Possible cause code •...
  • Page 47 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Table 3-2. Fatal Error List (Printer) Error Error type Error name Possible cause code • ASF Encoder failure (contaminated/detached scale, Encoder Board failure) ASF load position reverse error • Paper jam • ASF Encoder failure (contaminated/detached scale, Encoder Board...
  • Page 48 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Table 3-2. Fatal Error List (Printer) Error Error type Error name Possible cause code Home position error • Paper jam Deadlock avoidance error • Foreign object • Deformation of the Main Frame Impossible contact detection error...

  • Page 49: Fax Troubleshooting (Wp-4590/4540/4530/4520 Series Only)

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 3.1.4 FAX Troubleshooting (WP-4590/4540/4530/4520 series only) 3.1.4.1 FAX Log When an error related to fax occurs, it is not only indicated on the LCD but also saved as a log file. The error code is recorded in it, and according to this log, the contents of the error can be confirmed.
  • Page 50 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Table 3-6. FAX Log (2) Log Name Description Save Destination The following information of the latest communication is stored. Item Information Communication start Year/month/day/hour/minute date / time Communication type Sending/receiving/polling reception Sending/polling reception: • Destination name of speed dial (first 20 characters) •...
  • Page 51 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Table 3-7. Error Code List Error Code Phenomenon LCD Display Print Example (HEX) Communication error Communication error Error code Communication error Communication error Error code Communication error Communication error Error code Communication error Communication error...
  • Page 52 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Table 3-7. Error Code List Error Code Phenomenon LCD Display Print Example (HEX) Communication error Communication error Error code Communication error Communication error Error code Communication error Communication error Error code System error System Error...
  • Page 53 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Table 3-8. Command/Response Code FCF value (HEX) Command/response (LSB first: X=0) Content code First Second Failure To Train Response for Continue To correct Reserved (CSA) Called Subscriber internet Address End Of Message MultiPage Signal...

  • Page 54: Error Code/Superficial Phenomenon-Based Troubleshooting

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 3.1.4.2 Error Code/Superficial Phenomenon-Based Troubleshooting This section explains the troubleshooting procedures based on the error codes and superficial phenomenon. When an error occurs, it may be displayed on the LCD panel with a message instead of an error code.
  • Page 55 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Table 3-9. Troubleshooting Based on the Error Code/Superficial Phenomenon Error code (LCD Description Remedy Message)/Phenomenon The size of the memory is 2.0 Cannot print all the Mbyte. If the data becomes over received data when...

  • Page 56: Chapter 4 Disassembly/Reassembly

    easy-manual.blogspot.com CHAPTER 4 DISASSEMBLY/REASSEMBLY Confidential...

  • Page 57: Overview

    Flathead Precision screwdriver #1 Tweezers Longnose pliers Acetate tape 1003963 Note 1: Some of the tools listed above are commercially available. 2: EPSON provides the tools listed with EPSON part code. 4.1.2 Jigs Name Quantity EPSON Part Code Thickness gauge (2 mm)

  • Page 58: Disassembly/Reassembly Procedures

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 4.2 Disassembly/Reassembly Procedures 4.2.1 Caution when Replacing the Printhead/Ink Supply Unit For stable ink supply, this product employs a mechanism where the ink in the ink path is pressurized even the power is off. Therefore, if the joint section of the printhead and the Ink Supply Unit is simply disconnected, the ink in the ink tube will spill over.

  • Page 59: Parts/Units Need To Be Removed In Advance

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 4.2.2 Parts/Units Need to be Removed in Advance Chapter 4 "Disassembly Flowchart (p60)", the procedures are indicated on the premise that some parts/units are removed in advance. Make sure to remove the following parts/units before starting disassembly.

  • Page 60: Disassembly Flowchart

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 4.2.3 Disassembly Flowchart This section describes procedures for disassembling the parts/units in a flowchart format. For some parts/units, detailed procedures or precautions are provided (accordingly indicated by icons and cell's color). Refer to the explanations in the example chart below and perform an appropriate disassembling and assembling procedure.
  • Page 61 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D The example below shows how to see the charts on the following pages. White letters indicate a part/ Ref. Ink System Unit Explanation available in the unit supplied as an ASP. Reference Guide Shows the screw types and the specified torque in the “Screw type/torque list”.

  • Page 62: Exterior Parts

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 4.2.3.2 Exterior Parts START WP-4090/4020/4010 series WP-4590/4530/4520/4510 series WP-4540 series Panel Assy Panel Assy Panel Assy Metal Plate Paper Stopper Housing Rear ADF Pad Assy (w/ Paper Assy Assy Stopper Assy) (p 63) (p 69)
  • Page 63 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D (p 62) (p 62) WP-4540 WP-4090/4020/ WP-4590/4530/ series 4010 series 4520/4510 series Panel Board Panel Board Panel Board ADF Unit (p 69) (p 69) (p 69) (p 76) (p 77) (p 78) (p 82)

  • Page 64: Printer Mechanism

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 4.2.3.3 Printer Mechanism The removed parts/units differ between models when the name of each model is indicated and (p 62) enclosed in a box. If “Go to the next step” is indicated for a specific model in the box, skip the step for the model and go to the next step.
  • Page 65 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D (p 64) (p 64) (p 64) Common parts/units Parts/units whose composition or shape differ between models CR Cover Main Board Cable Power Supply PF Tension Metal Plate Left Stopper Holder Holder Unit Rear ASF Assy...

  • Page 66: Printhead/Ink Supply Unit

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 4.2.3.4 Printhead/Ink Supply Unit The disassembling and reassembling procedure of the Printhead/Ink Supply Unit requires additional steps before and during the procedure. Therefore, the whole flow from disassembling to reassembling is provided below. Note: The black arrows ( ) indicate disassembling, and the red arrows ( ) show reassembling.

  • Page 67: 2Nd Cassette Unit

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 4.2.3.5 2nd Cassette Unit This unit is installed for WP-4540 series, and option for WP-4590/4530/4520/4510/4090/4020/4010 series. 2nd Cassette Unit START Cassette Assy (p 104) Cassette Cover 2nd Cassette 2nd Cassette 2nd Cassette Paper Stopper...

  • Page 68: Detailed Disassembly/Reassembly Procedure For Each Part/Unit

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 4.3 Detailed Disassembly/Reassembly Procedure for each Part/Unit FAX Cover/USB Cover Housing Upper Assy (WP-4090/4020/4010 series) Front Housing Assy Front Cover Rear right Rear left Inside Front Cover Front Housing Assy Front Cover Bottom left...
  • Page 69 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Panel Assy (WP-4590/4540/4530/4520/4510 series) Panel Assy (WP-4090/4020/4010 series) Panel Assy Back of Panel Assy Housing Upper Assy Bottom of Panel Assy Panel Assy Panel Assy Panel Assy Front Scanner Cover Unit Front Cover Bottom of Housing Upper Assy...
  • Page 70 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D LCD Module / Panel Sheet / Touch Panel (WP-4540 series) Main Board Unit Touch Panel Left MAC Address Label Main Board Unit Touch Panel FPC Main LCD Module Panel Sheet Board Unit Legs Module...
  • Page 71 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D PCL Sub Board( WP-4590/4090 series ) Metal Plate Left Ink System Unit PCL Sub Board Tube Ink System clamp Tube Frame Base Cutout Maintenance Box Ink Eject Ink System Unit Joint Metal Plate Left...
  • Page 72 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Ink System Supply Assy (Ink Supply Unit w/ Printhead) Ink Supply Unit Step 4 Section A Section A I/C Holder Unit Align Tube Holder C with groove of Carriage Assy. I/S Supply Unit End of ink tube...
  • Page 73 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Head FFC PF Encoder / PF Timing Belt Ink Supply Unit Grounding Plate Ink Supply Unit Tube Step 3: Back of Front Frame Holders Head FFC PF Encoder Ink Supply Unit Grounding Plate Front Frame...
  • Page 74 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D CR Scale Star Wheel Assy Power Supply Unit Decompress Pump Unit Ink Supply Unit Back Carriage Assy Joint of Ink Supply Unit Slit of CR Black mark Encoder Hooks Power Supply Unit Decompress Pump Unit...
  • Page 75 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 2nd Cassette Cover Left* Frame Pickup Assy Wireless LAN Module (WP-4540/4530/4020 series) 2nd Cassette Cover Right Rear Front Wireless LAN Module Front right of printer Front Rear 2nd Cassette Cover Right Mounting Plate 2nd Cassette Cover Left...
  • Page 76 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D ADF Unit (WP-4540/4530/4520 series) ADF Document Support Assy ADF Cover Assy ADF Cover Assy ADF Document Support Assy ADF Pad Assy ADF Unit ADF Rear Cover ADF Rear Cover ADF Pad Assy Hook Dowel Screw hole C.B.P-TITE SCREW 3x10 F/ZN-3C (6 ±...

  • Page 77: Routing Ffcs/Cables

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 4.4 Routing FFCs/cables Top of the Scanner Unit Bottom of the Frame Base Bottom of the Scanner Unit (WP-4590/4540/4530/4520/4510 series) (WP-4590/4540/4530/4520/4510 series) Hole of Frame Base Ferrite core Shield plate of Main Board Assy...
  • Page 78 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Top of the Printer Bottom of the Ink System Unit Paper Guide Front Assy Rear right Rear Ink Supply Unit Main Frame Main Frame Assy Hole of Frame Base CSIC FFC Decompress Pump Unit...
  • Page 79 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Main Board Assy (1) Main Board Assy (2) Connector positions on Main Board Assy Front right of Main Board Assy PF Motor cable Main Board Cable Holder CN12 CN51 Clamp E Double-sided tape (1)
  • Page 80 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 2nd Cassette Housing Assy Rear left Bottom Paper Stopper Lever Sensor cable ASF Encoder Board Groove B Paper Stopper Lever Sensor cable Hole C Groove A Groove B Hole C Left ASF Motor 2nd Cassette Housing Assy...

  • Page 81: Connector

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 4.5 Connector Cable connections of this printer are shown below. Wireless PCL Sub Panel Unit Model ADF Unit Scanner Unit FAX Board USB Host LAN Module Board type WP-4590 series WP-4540 series WP-4530 series...

  • Page 82: Chapter 5 Adjustment

    easy-manual.blogspot.com CHAPTER 5 ADJUSTMENT Confidential...

  • Page 83: Required Adjustments

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 5.1 Required Adjustments The table from the following page lists the required adjustments depending upon the parts being repaired or replaced. Find the part(s) you removed or replaced, and check which adjustment(s) must be carried out.
  • Page 84 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Table 5-1. Required Adjustment List (Mechanism adjustment) Adjustment Type Mechanism adjustment Priority Rear ASF PF Timing Belt Checking the Touch Panel Adjustment Item Timing Belt PG adjustment Ink leak check tension check platen gap...
  • Page 85 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Table 5-2. Required Adjustment List Adjustment Type Adjustment using the Adjustment Program Priority First dot position / PE adjustment Initialize CR motor PF motor ASF motor PW adjustment Head PF / EJ EEPROM Setting (MAC...
  • Page 86 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Table 5-2. Required Adjustment List Adjustment Type Adjustment using the Adjustment Program Priority First dot position / PE adjustment Initialize CR motor PF motor ASF motor PW adjustment Head PF / EJ EEPROM Setting (MAC...
  • Page 87 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Table 5-2. Required Adjustment List Adjustment Type Adjustment using the Adjustment Program Priority First dot position / PE adjustment Initialize CR motor PF motor ASF motor PW adjustment Head PF / EJ EEPROM Setting (MAC...

  • Page 88: Details Of Adjustments

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 5.2 Details of Adjustments This section provides adjustment procedures for which explanation in details is necessary. See "5.1 Required Adjustments (p83)" for the adjustments not explained here. 5.2.1 PF Timing Belt Tension Check This section describes PF Timing Belt tension check.

  • Page 89: Rear Asf Timing Belt Tension Check

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 5.2.2 Rear ASF Timing Belt Tension Check This section describes Rear ASF Timing Belt tension check. This printer is designed so that the tension of the Rear ASF Timing Belt falls within the expected range if you correctly reassemble the unit according to this manual. However, deformation of any related part(s) can cause improper tension of the belt.

  • Page 90: Pg Adjustment

    PG adjustment with the PG position set to PG 1. Position PG (mm) Application PG 1 1.60 Printing plain paper/EPSON special paper, PG adjustment, Bi-d adjustment PG 2 1.85 Select when PG 1 is too narrow, printing envelopes/matte paper PG 3 2.50...
  • Page 91 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Check before the adjustment Perform the following to check if the PG position is surely set to PG 1. 1. Move the Carriage Assy to the center of the printer. 2. From the 0-digit side between the Main Frame and Carriage Assy, check the APG Cam is as shown in “PG 1”...
  • Page 92 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Adjustment procedure 1. Remove the screws (one each) that secure the PG Cam Left and PG Cam Right on both sides of the printer, and remove the PG Cam Left and PG Cam Right.
  • Page 93 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 5. Press the two points down vertically on the Carriage Assy shown in Figure 5-3 simultaneously, and make sure of the following. The Carriage Assy is installed correctly without any gap between the Carriage Assy and CR Guide Frame.
  • Page 94 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 6. Place the thickness gauges (1.7 mm) on the positions shown in Figure 5-9. Thickness gauge Thickness gauge Figure 5-9. Position of the Thickness Gauge When adjusting the PG Cam Right/PG Cam Left in the following steps, make sure to adjust the same amount for both right and left.
  • Page 95 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D In the following steps, make sure the PG Cam Right/PG Cam Left always touch the CR Guide Frame. (See Figure 5-8 (p 93).) 9. Follow the flowchart below to perform the PG adjustment. START Adjusts the PG to more than 1.5 mm on the 0-digit side.

  • Page 96: Checking The Platen Gap

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 5.2.4 Checking the Platen Gap This section describes the procedure for checking the platen gap (PG) necessary when removing the Printhead or in a similar case. When checking the PG, make sure of the following.

  • Page 97: Mac Address Setting

    • If the user has set the printer’s MAC address on a router, the repaired printer with a new MAC address cannot be connected to the network. • The default printer name on a network consists of “EPSON” and the last six digits of the MAC address. Therefore, the printer name becomes different from the previous one.

  • Page 98: Touch Panel Adjustment (Wp-4540 Series Only)

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 5.2.6 Touch Panel Adjustment (WP-4540 series only) This section describes Touch Panel adjustment. Purpose This adjustment is made to adjust the relative positions between the Touch Panel detection points and displaying positions on the Control Panel.
  • Page 99 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 3. Select “Touch Screen Calibration” and press the Color button. Touch Screen Inspection Run:Color / Select:[UP:1][DOWN:2] 1. Touch Screen Calibration 2. Touch Screen Coordinates Figure 5-17. Touch Panel Adjustment (3) 4. Press LCD to display the adjustment screen. When aborting the adjustment, press the Stop button.
  • Page 100 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 6. If you retry the adjustment, press the Stop button and start from Step 5 once again. When saving the result of adjustment, press the Color button. Calibration Check Push [Color] Button.[Save] Push [Stop] Button.[Retry]...

  • Page 101: Ink Leak Check

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 5.2.7 Ink Leak Check This section describes the procedure for ink leak check necessary when disconnecting the Ink Supply Unit from the Printhead or in a similar case. Tools Ink Leak Measurement Jig (with digital pressure gauge GC66) (Parts code: 1430064)
  • Page 102 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D Ink Leakage inspection Condition Air pressure power : 48 ± 2 Kpa Air pressure time : 10 sec Air pressure hold time : 30 sec Air pressure judgement standard : Less than 0.4 Kpa Checking procedure 1.
  • Page 103 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 7. Close the valve C of the Ink Leak Measurement Jig. 8. Push the plunger to inject the air out, and confirm the pressure gauge indicates 48 ± 2 kPa, then after the value has stabilized, shut the valve A. If the value is less than 48 ± 2 kPa, open the valve A and pull out and push in the plunger several times until the value reaches 48 ±...

  • Page 104: Chapter 6 Maintenance

    easy-manual.blogspot.com CHAPTER 6 MAINTENANCE Confidential...

  • Page 105: Overview

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 6.1 Overview In this manual, the product name is abbreviated to such as “WP-4510 series”, however, the last digit of the actual name may differ. Identify your product with the first three digits and refer to the appropriate sections in this manual.

  • Page 106: Lubrication Points And Instructions

    Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D 6.2 Lubrication Points and Instructions <Lubrication Point> <Lubrication Point> <Lubrication Point> Main Frame Edges on the rear of the Shaft hole of the Driven Contact point on the Main Cassette Assy 1st / 2nd...
  • Page 107 Epson WP-4590/4540/4530/4520/4510/4090/4020/4010 series Revision D <Lubrication Point> Left Application point 5 Application point 6 1. Contact surfaces (x2) of the Carriage Assy Contact surface of Carriage CR Front Slider Left with the APG Cam Assy with CR Guide Frame 2.

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