Page 1: Table Of Contents
Stylus Pro 4000 Field Repair Guide 4/28/05 Table of Contents Table of Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1...
Page 2 Stylus Pro 4000 Field Repair Guide 4/28/05 Drop of Ink - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 117...
Page 3 Stylus Pro 4000 Field Repair Guide 4/28/05 Paper Thickness Sensor Adjustment - - - - - - - - - - - - - - - - - - - - - - 161 Platen Gap Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 164...
Page 4 4/28/05 Epson Paper Feed Adjuster - - - - - - - - - - - - - - - - - - - - - - - - - - - 223 NVRAM.EXE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 226 PRNprint.exe - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 229...
Page 5: Control Panel Map
Stylus Pro 4000 Field Repair Guide 4/28/05 Control Panel Map Status Media Feed Sheet Roll / Sheet Roll Auto Cut Ink Quantity Maintenance Tank Level Roll Auto Cut Off Paper Ink Out Paused Pause Power Hold for 3 seconds to reset/clear...
Page 6 Stylus Pro 4000 Field Repair Guide 4/28/05 User Menu: Press the Menu button when 3. PRINTER STATUS. the printer displays Ready VERSION: (CURRENT FIRMWARE) PRINTABLE PG: (FOR EACH COLOR)MK 1. PRINTER SETUP. (nnnnnn)PG PLATEN GAP: *STANDARD, NARROW, WIDER, INK LEFT: (FOR EACH COLOR)MK E*****F...
Page 7: Maintenance Mode 1
Stylus Pro 4000 Field Repair Guide 4/28/05 5. MAINTENANCE 6. Head Alignment. CUTTER REPL: EXEC PAPER THKNS: *STD, (n.n)MM CHNG INK SET: EXEC (For Changing between 8 and 4 color) ALIGNMENT: AUTO, MANUAL PWR CLEANING: N CLEANING Y CLOCK SETTING: (mm/dd/yy hh:mm)
Page 8 Stylus Pro 4000 Field Repair Guide 4/28/05 Elec.: Record: Maintenance: (Usage Counters for the following devices) WasteInk, Wiper, Rubbing, Lever, Cover, Ink Lever, Cr Motor, PF Motor, PrintNumber, Cleaning, Fire A, Fire B, Fire C, Fire D, Fire E, Fire F, Fire G, Fire H, Cut, Cute Sole, LockSolen...
Page 9 Stylus Pro 4000 Field Repair Guide 4/28/05 PF Resolution: Initialize OK? (Resets this counter only) Head Record: Initialize OK? (Resets this counter only) Wiping Record: Initialize OK? (Resets this counter only) Rab. Record: Initialize OK? (Resets this counter only) Waste Record: Initialize OK?
Page 10: Maintenance Mode
Stylus Pro 4000 Field Repair Guide 4/28/05 Clear Counters (Clears the usage/life counter information for the following devices/operations) Init All: (Initializes all the following counters at once) NVRAM, RTC: (YY/MM/DD/HH), Cutter, CR Motor, CR Total, PF Motor, Head, Cleaner, Total Pages,...
Page 11 Stylus Pro 4000 Field Repair Guide 4/28/05 Printer Component, Software Item, LCD Display, Printer Button Page 11.
Page 12: Component Replacement
Stylus Pro 4000 Field Repair Guide 4/28/05 Component Replacement Printer Component, Software Item, LCD Display, Printer Button Page 12.
Page 13: Carriage Removal Procedure
Stylus Pro 4000 Field Repair Guide 4/28/05 Carriage Removal Procedure Unplug the Printer. 2. Raise both Ink Levers, closing the Ink Valves. 3. Remove the Left Side Cover. 4. Release the Carriage Lock, and move the Carriage Mechanism away from the capped position.
Page 14 Stylus Pro 4000 Field Repair Guide 4/28/05 6. Carriage Rail Cover (Wheel Track) protection steps. The Carriage Rail Covers will separate and bend when removing the Print Head if not protected. 1. Make a double wall cardboard jig as shown.
Page 15 Stylus Pro 4000 Field Repair Guide 4/28/05 7. Move the Carriage Mechanism at the removal slot as shown. Compress the Tension Springs against the Front Carriage Rail, and lift out the Carriage. Removal Slot Be careful to free the Carriage Timing...
Page 16: Cartridge Release Lever Repair
Stylus Pro 4000 Field Repair Guide 4/28/05 Cartridge Release Lever Repair 1. Remove the Ink Bay. 2. Ensure that the Gears and Spring are in the positions shown. (This is the Cartridge released, and the Valves closed position) Ensure that the Valve Open/Close 3 Gear positions to check.
Page 17: Cartridge Release Sensor Repair
Stylus Pro 4000 Field Repair Guide 4/28/05 Cartridge Release Sensor Repair 1. Remove the Ink Bay Assembly. 2. Remove the Cartridge Release Sensor, and replace. The Sensor is fastened by 2 Interlocks. Cartridge Release Sensor Repair Printer Component, Software Item,...
Page 18: Damper Removal
Stylus Pro 4000 Field Repair Guide 4/28/05 Damper Removal 1. Raise both Ink Levers, closing the Ink Valves. 2. Remove the Left Side Cover. 3. Move the Carriage Mechanism to the left as shown, remove 3 Screws, and remove the Carriage Cover.
Page 19 Stylus Pro 4000 Field Repair Guide 4/28/05 4. Disconnect 4 Cables, remove 1 Screw, and remove the Junction Board 3. Remove the Junction Board. 2. Remove 1 Screw. 1. Disconnect 4 Cables. 5. Remove 4 Screws, 1 Stay Bar, and 1 Spring.
Page 20 Stylus Pro 4000 Field Repair Guide 4/28/05 6. Disconnect the Ink Lines, from the Dampers to be replaced. Disconnect the Lines at the Damper (bottom of the Elbow Joint). Move the Lines to the side, and fasten out of the way.
Page 21 Stylus Pro 4000 Field Repair Guide 4/28/05 8. Lift out the Print Head / Damper Assembly. 9. .Turn over the Print Head / Damper Assembly and remove 3 Screws. Remove 3 Screws. Damper Removal Printer Component, Software Item, LCD Display, Printer Button Page 21.
Page 22 Stylus Pro 4000 Field Repair Guide 4/28/05 10. Disconnect the Print Head from the Damper Assembly. 3. Place the Print Head off to the side 2. Hold the Damper Assembly like 1. Disconnect the Print Head from as shown. this so that ink does not leak.
Page 23 Stylus Pro 4000 Field Repair Guide 4/28/05 12. Install the new Damper(s). 13. Re-connect the Ink Tubes to the new Dampers, and manually prime all the Dampers. With the Damper openings facing up, draw the air out of the each Damper.
Page 24 Stylus Pro 4000 Field Repair Guide 4/28/05 15. Place the Print Head / Damper Assembly back into the Carriage Mechanism. 16. Replace 4 Screws, 1 Stay Bar, and 1 Spring. 1 Stay Bar 1 Spring 4 Screws Damper Removal Printer Component,...
Page 25 Stylus Pro 4000 Field Repair Guide 4/28/05 17. Re-install the Junction Board, fasten with 1 Screw, and reconnect 4 Cables. This Connector has a latch. Install the Junction Board and fasten with 1 Screw. Reconnect 4 Cables. 18. Perform cleaning cycles and nozzle checks until the nozzles are working.
Page 26: Ink Bay Removal (Left)
Stylus Pro 4000 Field Repair Guide 4/28/05 Ink Bay Removal (Left) 1. Remove the Left and Right Side Covers. 2. Remove the 10 Screws fastening the Front Panel. (View from the back) Remove 4 Screws Remove 5 Screws Remove 1 Screw 3.
Page 27: Remove The Front Panel
Stylus Pro 4000 Field Repair Guide 4/28/05 4. Remove the Front Panel. 5. Remove 4 Screws that fasten the Ink Bay Cover, and 1 Screw that fastens the Cartridge Release Handle, and lift off the Cover. Remove 1 Screw This hole in the Cover allows easy access to the Lift off the Cover.
Page 28 Stylus Pro 4000 Field Repair Guide 4/28/05 6. Remove 2 Screws and 2 Brackets 1 Screw and Bracket on the Right Side 1 Screw and Bracket on the Left Side 7. Remove 2 Screws from the front. 2 Screws from the front...
Page 29 Stylus Pro 4000 Field Repair Guide 4/28/05 8. Remove 2 Screws from the back of the Ink Bay Assembly. Blow up of this area Remove 2 Screws Look through this area, on the back of the Printer, to find 2 Screws 9.
Page 30 Stylus Pro 4000 Field Repair Guide 4/28/05 10. Maneuver the Ink Tubes from the Slot. 11. Slide out the Ink Bay Assembly, while assisting the Cables through the Frame. Ink Bay Removal (Left) Printer Component, Software Item, LCD Display, Printer Button...
Page 31: Ink Bay Removal (Right)
Stylus Pro 4000 Field Repair Guide 4/28/05 Ink Bay Removal (Right) 1. Remove the Left and Right Side Covers. 2. Remove the 10 Screws fastening the Front Panel. (View from the back) Remove 4 Screws Remove 5 Screws Remove 1 Screw 3.
Page 32 Stylus Pro 4000 Field Repair Guide 4/28/05 4. Remove the Front Panel. 5. Remove 4 Screws that fasten the Ink Bay Cover, and 1 Screw that fastens the Cartridge Release Handle, and lift off the Cover. Remove 1 Screw Remove 4 Screws Lift off the Cover.
Page 33 Stylus Pro 4000 Field Repair Guide 4/28/05 6. Remove 4 Screws and 2 Brackets 1 Screw and Bracket on the right side 1 Screw and Bracket on the left side 1 Screw on 1 Screw on the the right Side.
Page 34 Stylus Pro 4000 Field Repair Guide 4/28/05 8. Remove 2 Screws from the back of the Ink Bay Assembly. View is from the back of the Printer Pump Assembly Remove 2 Screws 9. Disconnect the 4 Foil CSIC Cables and the Cartridge Release Sensor Cable.
Page 35 Stylus Pro 4000 Field Repair Guide 4/28/05 10. Maneuver the Ink Tubes from the slot. 11. Slide out the Ink Bay Assembly, while assisting the Cables through the Frame. Ink Bay Removal (Right) Printer Component, Software Item, LCD Display, Printer Button...
Page 36: Input Roller Assembly, Disassembly
Stylus Pro 4000 Field Repair Guide 4/28/05 Input Roller Assembly, Disassembly 1. Remove the E-Ring, Gear, and Paddle shown below. Input Roller Assembly, Disassembly Printer Component, Software Item, LCD Display, Printer Button Page 36.
Page 37 Stylus Pro 4000 Field Repair Guide 4/28/05 2. Detach the 3 Interlocks that fasten the Input Roller Cover, and slide the Cover off the Roller. Detach 3 Interlocks Slide off the Cover 3. Remove the 2 E-Rings shown below Remove the E-Ring...
Page 38 Stylus Pro 4000 Field Repair Guide 4/28/05 4. Detach the 3 Interlocks holding the remaining Roller Cover, and slide it off. 3 Interlocks 5. Slide the remaining components off the Shaft. Input Roller Assembly, Disassembly Printer Component, Software Item, LCD Display, Printer Button Page 38.
Page 39 Stylus Pro 4000 Field Repair Guide 4/28/05 6. Release the Interlocks, as shown below. 7. Lift up the Paper Tray Base, and remove the Separation Pad Assembly as shown below. Input Roller Assembly, Disassembly Printer Component, Software Item, LCD Display, Printer Button Page 39.
Page 40 Stylus Pro 4000 Field Repair Guide 4/28/05 8. Maneuver the remaining side of the Paper Tray Base as shown below to free the last Separation Pad Assembly. Input Roller Assembly, Disassembly Printer Component, Software Item, LCD Display, Printer Button Page 40.
Page 41: Input Roller Assembly, Re-Assembly
Stylus Pro 4000 Field Repair Guide 4/28/05 Input Roller Assembly, Re-assembly 1. Assemble the Base Unit until it looks this. 2. Maneuver the Separation Pad Assembly into the slot as shown. Input Roller Assembly, Re-assembly Printer Component, Software Item, LCD Display, Printer Button Page 41.
Page 42 Stylus Pro 4000 Field Repair Guide 4/28/05 3. Re-hook the Interlock / Pivot Points that connect the Separation Pad Assembly to the Base. 4. Press down on the Separation Pad Assembly until the Black Levers lock it in the down position.
Page 43 Stylus Pro 4000 Field Repair Guide 4/28/05 5. Study the polarity, and order of the parts below. Paddles positioned, so that the The Disks have depressions, that fit Home Position Window faces the oppo- arrow on the side faces up the Springs.
Page 44 Stylus Pro 4000 Field Repair Guide 4/28/05 7. Rotate the Input Rollers so that the flat side is down to allow the Roller to interlock with the Roller Frame. Flat side down This part of both Rollers must fit through the Roller Side Frame.
Page 45 Stylus Pro 4000 Field Repair Guide 4/28/05 9. Test the Roller Assembly before installation Place a piece of paper in the Tray. Rotate the Gear and check for proper operation Input Roller Assembly, Re-assembly Printer Component, Software Item, LCD Display, Printer Button Page 45.
Page 46: Input Roller Assembly Removal
Stylus Pro 4000 Field Repair Guide 4/28/05 Input Roller Assembly Removal 1. Remove the Left Side Cover. 2. Remove the Right Side Cover. 3. Remove the Ink Cartridges, and leave the Levers up (closing the Valves). Lever up, closing Lever up, closing...
Page 47 Stylus Pro 4000 Field Repair Guide 4/28/05 1. Remove this Screw on the left. 2. Remove this Screw on the right. 3. Free the Rear Paper Guide Support from the Printer. 4. Remove the Screw that holds the Manual Feed Sensor to the Support.
Page 48 Stylus Pro 4000 Field Repair Guide 4/28/05 6. Rotate the Printer onto it’s back. 7. Remove the 2 screws fastening the Right Side Air Duct to the Frame. 2 Screws Input Roller Assembly Removal Printer Component, Software Item, LCD Display, Printer Button Page 48.
Page 49 Stylus Pro 4000 Field Repair Guide 4/28/05 8. Lift the Right Side Air Duct exposing the 2 Screws noted in step 9. This is 1 of the 2 Screws shown is the picture on the left in step 9. 9. Remove the 3 Screws that fasten the Input Roller Assembly to the Right Side Frame.
Page 50 Stylus Pro 4000 Field Repair Guide 4/28/05 10. Remove the 3 Screws that fasten the Input Roller Assembly to the Left Side Frame. 3 Screws 11. Slide the Input Roller Assembly out about 2 inches, disconnect the Input Roller HP Sensor, and fully remove the Assembly.
Page 51: Main Board Replacement
Stylus Pro 4000 Field Repair Guide 4/28/05 Main Board Replacement 1. Back up the Printer’s parameters using the Parameter Backup / Restore Utility (Nvram.exe) 2. Turn off the Printer and UNPLUG from AC. 3. Remove the Rear Paper Guide Assembly.
Page 52 Stylus Pro 4000 Field Repair Guide 4/28/05 5. Slide out the Main Board Housing until the Cable Connectors are visable. 6. Un-fasten the Cables Pull up on the Con- The number on the nector Releases, to Foil Cable corre- release these 3...
Page 53 Stylus Pro 4000 Field Repair Guide 4/28/05 7. Remove the 5 Screws and Hardware fastening the Ports to the Main Board Housing. Removing the Firewire Hardware 5 Screws is necessary for re-assembly. 8. Remove the 9 Screws fastening the Board to the Housing.
Page 54 Stylus Pro 4000 Field Repair Guide 4/28/05 9. Fasten the new Board to the Housing with 9 Screws (see above) Do not fully tighten. 10. Install the Port Covers and 5 Screws 5 Screws 11. Full tighten the 9 Main Board Screws.
Page 55 Stylus Pro 4000 Field Repair Guide 4/28/05 13. Write down the IEEE (Firewire) ID, if the Printer’s Parameters are not available. The IEEE ID is located in the Main Board Cavity 14. Attach the Board Housing to the Printer and fasten with 6 Screws.
Page 56 Stylus Pro 4000 Field Repair Guide 4/28/05 15. Down load the current firmware version. 15.1 Open the PRNPRINT application, and prepare to send the current firmware version to the Printer. 15.2 Turn on the Printer while depressing the Left, Up,...
Page 57 Stylus Pro 4000 Field Repair Guide 4/28/05 17.12.1Copy Uni-D variables. 17.13Perform the Platen Position Adjustment 17.14Perform the Clear Micro Feed PF Adjustment (Bi-D) 17.15Perform the 1000 mm Feed Adjustment, or Multi Sensor Auto PF Adjustment. 17.16Perform the T&B&S (Roll Paper) Adjustment.
Page 58: Paper Exit Roller Removal
Stylus Pro 4000 Field Repair Guide 4/28/05 Paper Exit Roller Removal 1. Remove the Left and Right Side Covers. 2. Remove the 10 Screws fastening the Front Panel. (View from the back) Remove 4 Screws Remove 5 Screws Remove 1 Screw 3.
Page 59 Stylus Pro 4000 Field Repair Guide 4/28/05 4. Remove the Front Panel. 5. Remove the2 Screws that fasten the Exit Roller. Remove 2 Screws Paper Exit Roller Removal Printer Component, Software Item, LCD Display, Printer Button Page 59.
Page 60 Stylus Pro 4000 Field Repair Guide 4/28/05 6. Remove the Exit Roller. 7. The Exit Roller must be re-installed using the correct polarity.j Gold Spring side, on the top Long end Short end Silver Spring side, on the bottom Paper Exit Roller Removal...
Page 61: Plastic Roller Upgrade
Stylus Pro 4000 Field Repair Guide 4/28/05 Plastic Roller Upgrade Note: This procedure documents the replacement of 9 Plastic Rollers with 9 Rubber Coated Plastic Rollers. These Rollers make contact with the printable side of the media. The old Roller design could scuff the surface of Fine Art Media.
Page 62 Stylus Pro 4000 Field Repair Guide 4/28/05 4. Remove the Top Cover as shown. Lever up both sides of the Top Cover at the Hinges. 5. Remove the Top Cover Component shown below. Remove 1 Screw Remove 1 Screw Lift of the Top Cover Component.
Page 63 Stylus Pro 4000 Field Repair Guide 4/28/05 6. Remove the Paper Thickness Sensor Assembly. Remove these 2 Screws. Remove the 2 Screws accessed through these holes. Lift off the Paper Thickness Sensor Assembly. Do not loosen these 2 Screws. 7. Remove the Rear Paper Guide Support and the Paper Jam Cover.
Page 64 Stylus Pro 4000 Field Repair Guide 4/28/05 8. Paper Guide Support removal 1. Remove this Screw on the left. 2. Remove this Screw on the right. 3. Free the Rear Paper Guide Support from the Printer. 4. Remove the Screw...
Page 65 Stylus Pro 4000 Field Repair Guide 4/28/05 9. Remove the Paper Release Lever Assembly. Remove 2 Screws. Remove the Assembly. 10. Remove the Paper Release Transmission Gear. 1. Note the position of the Gear in rela- tion to this Rubber Stopper.
Page 66 Stylus Pro 4000 Field Repair Guide 4/28/05 11. Remove the Gear shown below. To remove this Gear, follow the 4 steps listed below. 1. Note the Gears’ orientation to this Rubber Stopper. 2. Note the Interlock on 4. Remove the Gear.
Page 67 Stylus Pro 4000 Field Repair Guide 4/28/05 12. Remove the Roller Assembly. Remove the Roller Assembly by finessing the right side of the Assembly out, followed by the left. 13. Place the Roller Assembly on a flat surface. Ensure that the Assembly is in this position...
Page 68 Stylus Pro 4000 Field Repair Guide 4/28/05 14. Remove 4 Screws that fasten the Release Roller to the Assembly, and remove the Roller. 15. Flip up the white Paper Guides so that the Assembly is in this position.l Plastic Roller Upgrade...
Page 69 Stylus Pro 4000 Field Repair Guide 4/28/05 16. Inspect 1 of the 3 Paper Guides and note the items listed below. The Shaft ends here, The Shaft ends and goes next to this here, and goes next Support. to this Support.
Page 70 Stylus Pro 4000 Field Repair Guide 4/28/05 18. Lay out the Assembly Components like this. 19. Attach the Guides to the Frame starting on the right. 1. Under here. 4. Under here. 2. Over here. 5. Over here. 3. Spring in the Notch.
Page 71 Stylus Pro 4000 Field Repair Guide 4/28/05 20. It should look like this when installed correctly. 21. Use the same method to replace the second and third Guide Assemblies. Plastic Roller Upgrade Printer Component, Software Item, LCD Display, Printer Button...
Page 72 Stylus Pro 4000 Field Repair Guide 4/28/05 22. The Assembly should look like this when the 3 Guides are installed. 23. Lay out the remaining Components like this. Square open- ing on this end. Plastic Roller Upgrade Printer Component, Software Item,...
Page 73 Stylus Pro 4000 Field Repair Guide 4/28/05 24. Note these aspects of the Release Roller. Square Hole on the left side. These Notches make contact with the White Guides. 25. Place the Release Roller against the White Guides.j Notches against the White Guides.
Page 74 Stylus Pro 4000 Field Repair Guide 4/28/05 26. Fasten the Release Roller with 1 Bracket in the middle, and then install the remaining Brackets. 27. Spin the Release Roller and verify that the Guides and Notches line up properly. Guides and Notches should look like this.
Page 75 Stylus Pro 4000 Field Repair Guide 4/28/05 28. Install the Roller Assembly. 2. Insert the Right Side second. 3. Install 2 Screws. 1. Insert the Left Side first. Plastic Roller Upgrade Printer Component, Software Item, LCD Display, Printer Button Page 75.
Page 76 Stylus Pro 4000 Field Repair Guide 4/28/05 29. Install the Paper Thickness Sensor Assembly. Fasten with 2 Screws. 30. Install the Gear pictured below. Insert this Gear. It is “keyed’ and will only insert 1 way. Plastic Roller Upgrade Printer Component,...
Page 77 Stylus Pro 4000 Field Repair Guide 4/28/05 31. Attach the Release Transmission Gear and the Release Lever Assembly. 2. Install this Assembly so that the Gear is held in place. 3. Fasten with 2 1. Insert this Gear. Screws. 32. Attach the Manual Feed Sensor to the Paper Guide.
Page 78 Stylus Pro 4000 Field Repair Guide 4/28/05 33. Install the Paper Guide Assembly and fasten with 2 Screws. 1 Screw 1 Screw 34. Perform the Paper Thickness Sensor Adjustment. 35. Install the Plastic Cover pictured below, and fasten with 3 Screws.
Page 79 Stylus Pro 4000 Field Repair Guide 4/28/05 36. Install the Top Cover. Lever the Pivot into the Hinges. 37. Install the Paper Release Lever Assembly Cover. 1. Install the Cover. 2. Fasten with 1 Screw. 38. Replace the Left and Right Side Covers.
Page 80: Print Head Replacement Procedure
Stylus Pro 4000 Field Repair Guide 4/28/05 Print Head Replacement Procedure 1. Run the Adjustment Wizard and input the new Print Head’s calibration value. Unplug the Printer. 3. Raise both Ink Levers, closing the Ink Valves. 4. Remove the Left Side Cover.
Page 81 Stylus Pro 4000 Field Repair Guide 4/28/05 7. Carriage Rail Cover (Wheel Track) protection steps. The Carriage Rail Covers will separate and bend when removing the Print Head if not protected. 1. Make a double wall cardboard jig as shown.
Page 82 Stylus Pro 4000 Field Repair Guide 4/28/05 8. Move the Carriage Mechanism at the removal slot as shown. Compress the Tension Springs against the Front Carriage Rail, and lift out the Carriage. Removal Slot Be careful to free the Carriage Timing Strip 9.
Page 83 Stylus Pro 4000 Field Repair Guide 4/28/05 10. Remove the Print Head by rotating the top of the Head away from the Carriage. 11. Remove 3 Screws fastening the Head to the Head Case. Remove 3 Screws Separate the Print Head from the Print Head Case.
Page 84 Stylus Pro 4000 Field Repair Guide 4/28/05 12. Disconnect the Print Head Cables Gently remove the Cables. The Top Cable is the 0 Cable. 13. Connect the new Print Head to the Cables. Ensure that the 0 Cable is on top (Nozzle Plate side).
Page 85 Stylus Pro 4000 Field Repair Guide 4/28/05 19. Verify that the Carriage Rail Covers, Carriage Bearings, Carriage Belt and Timing Strip are properly in place. 20. Move the Carriage Mechanism to the capped position. 21. Plug in the Printer, and lower both Ink Cartridge Levers to open the Ink Valves.
Page 86 Stylus Pro 4000 Field Repair Guide 4/28/05 28.1 Perform Reset When Print Head Change 28.2 Perform the Print Head Slant Adjustment (CR) 28.3 Perform the Print Head Slant Adjustment (PF) 28.4 Reset (initialize) the user settings using the Epson Paper Feed Adjuster utility.
Page 87: Pump And Cap Installation
Stylus Pro 4000 Field Repair Guide 4/28/05 Pump and Cap Installation 1. Before installing the Pump and Cap Assembly identify the Tube Receptacles where the Pump Tubes must be inserted. Blow up view Tubes go here 2. Before installing the Pump and Cap Assembly, note this detail.
Page 88 Stylus Pro 4000 Field Repair Guide 4/28/05 3. Insert the Cap Assembly part of the way, through the back of the Printer. If the Ink Tubes are not fully inserted, the Ink may bubble back through the cap. Slide the Cap and Pump...
Page 89 Stylus Pro 4000 Field Repair Guide 4/28/05 5. Install the Flushing Box and fasten with 1 Screw Tube into the hole leading to the Waste InkTank 1 Screw 6. Plug in the Pump Home Position Sensor. Plug in Pump and Cap Installation...
Page 90 Stylus Pro 4000 Field Repair Guide 4/28/05 7. Install the Gear and Shaft Assembly, and fasten it with 2 Screws. Install Gear and 2 Screws Shaft Assembly. 8. Install the Platen Gap Motor, and fasten with 2 Screws. Install the Motor...
Page 91 Stylus Pro 4000 Field Repair Guide 4/28/05 9. Install the Trigger Shaft. Insert Trigger Shaft into the Right Side Frame Insert Into Flex the Trigger Shaft from the back side of the Socket here Printer, until the end of the Shaft can be inserted...
Page 92 Stylus Pro 4000 Field Repair Guide 4/28/05 10. Replace the Trigger Spring. Spring goes here. Ensure that the Splash Guard is routed as shown. 11. Replace the Trigger Assembly End Piece. Trigger Assembly End Piece here 12. Perform Reset When Cleaning Unit Change (if the Cap/Pump Assembly was changed).
Page 93: Pump And Cap Removal
Stylus Pro 4000 Field Repair Guide 4/28/05 Pump and Cap Removal 1. Remove the Right Side Cover. 2. Remove the Flushing Box. Remove Screw. Lift out the Flushing Box. 3. Remove the Trigger Assembly End Piece and Spring. Trigger Assembly End Piece...
Page 94 Stylus Pro 4000 Field Repair Guide 4/28/05 4. Flex the Trigger Shaft until the end farthest from the Side Frame clears it’s Socket, then remove the Shaft. Flex the Shaft from behind Free the end of the Shaft from it’s...
Page 95 Stylus Pro 4000 Field Repair Guide 4/28/05 6. Remove 2 Screws fastening the Platen Gap Motor, and remove. 2 Screws Remove the Motor 7. Remove 2 Screws fastening the Gear and Shaft Assembly, and remove. Remove Gear and Shaft Assembly.
Page 96 Stylus Pro 4000 Field Repair Guide 4/28/05 9. Unplug the Pump Home Position Sensor. Re-assembly note: The Plastic Tray that the Pump / Cap Assembly covers, sits on top of the Pump / Cap Assembly Frame at this corner. Unplug 10.
Page 97 Stylus Pro 4000 Field Repair Guide 4/28/05 Cap and Pump Assembly Components. Wiper Blade Pump Pump and Cap Removal Printer Component, Software Item, LCD Display, Printer Button Page 97.
Page 98: Side Cover Removal (Left)
Stylus Pro 4000 Field Repair Guide 4/28/05 Side Cover Removal (Left) Remove Screw Remove Screw The Left Side Cover will slide off Remove 2 Screws Side Cover Removal (Left) Printer Component, Software Item, LCD Display, Printer Button Page 98.
Page 99: Side Cover Removal (Right)
Stylus Pro 4000 Field Repair Guide 4/28/05 Side Cover Removal (Right) Remove the Rear Paper Guide Assembly Remove Screw Side Cover Removal (Right) Printer Component, Software Item, LCD Display, Printer Button Page 99.
Page 100: Remove 2 Screws
Stylus Pro 4000 Field Repair Guide 4/28/05 Remove Waste Ink Tank Remove Screw Remove Remove 2 2 Screws Screws and slide off Lever The Right Side Cover will slide off. Side Cover Removal (Right) Printer Component, Software Item, LCD Display, Printer Button Page 100.
Page 101: Top Cover Removal
Stylus Pro 4000 Field Repair Guide 4/28/05 Top Cover Removal 1. Using a small flat head screw driver, lever the right Top Cover Hinge pivot point out of the Hinge Frame. 2. Using a small flat head screw driver, lever the left Top Cover Hinge pivot point out of the Hinge Frame.
Page 102: Troubleshooting
Stylus Pro 4000 Field Repair Guide 4/28/05 Troubleshooting Printer Component, Software Item, LCD Display, Printer Button Page 102.
Page 103: Error Codes (Maintenance)
Stylus Pro 4000 Field Repair Guide 4/28/05 Error Codes (Maintenance) 0002 Carriage Motor / Ink Tube end of life (Clear Carriage Motor Counter) 0004 Nozzle check error 0008 RTC error (Real Time Clock) (Check the Battery and reset the Date and Time)
Page 104: Error Codes (Service)
Stylus Pro 4000 Field Repair Guide 4/28/05 Error Codes (Service) 00000088 RTC (Real Time Clock) data is corrupted 00000101 Carriage Motor life (Reset Carriage Motor Counter, check for leaky ink tubes) 00000103 RTC (Real Time Clock) battery is defective 00000105...
Page 105 Stylus Pro 4000 Field Repair Guide 4/28/05 0001001E Paper feed servo parameter error 00010020 CSIC read / write error 00010022 Ink type error 00010023 RTC (Real TIme Clock) (Reset RTC) 00010025 CSIC ROM communication error 00010026 RTC (Real TIme Clock) communication error...
Page 106 Stylus Pro 4000 Field Repair Guide 4/28/05 00010039 PG adjustment value NVRAM error 0001003A PG adjustment value NVRAM error 0001003B Carriage Lock / Cutter Error 0001003C Carriage Lock / Cutter Error 0001003D Carriage Lock / Cutter Error 00020000 NVRAM error...
Page 107 Stylus Pro 4000 Field Repair Guide 4/28/05 00000088 Note: The 00000088 error code indicates that the RTC (Real Time Clock) data is incorrect. 1. Set the RTC by accessing the Maintenance Mode 2: Clear Counters: RTC counter. 2. Replace the Main Board, if the RTC data can not be set.
Page 108 Stylus Pro 4000 Field Repair Guide 4/28/05 00000101 Note: The 00000101 error code indicates that the Carriage Motor and Ink Tubes have reached their end of life. 1. Inspect the Ink Tubes for leaks or cracks. 2. Inspect the Carriage Motor for wear.
Page 109 Stylus Pro 4000 Field Repair Guide 4/28/05 00000103 Note: The 00000103 error code indicates that the RTC Battery is defective. 1. Replace the RTC Battery located on the Main Board. 2. Replace the Main Board. 00000103 Printer Component, Software Item,...
Page 110 Stylus Pro 4000 Field Repair Guide 4/28/05 00000105 Note: The 00000105 error code indicates that the Print Head has reached it’s end of life. 1. Inspect the Print Heads operation using the Printer’s Maintenance Mode 2: Self Testing: Adjustment: Check Nozzle function.
Page 111 Stylus Pro 4000 Field Repair Guide 4/28/05 00010000 - 00010003 Note: The 00010000 - 00010003 range of error codes indicates that the Paper Feed Motor or Encoder is defective. 1. Manually check the operation (spin) of the Paper Feed Motor.
Page 112: Color Shift
Stylus Pro 4000 Field Repair Guide 4/28/05 Color Shift Note: Most color shift issues are not caused by a printer problem, but by the customers “work flow”. “work flow” refers to the customers color management. Usually the printer will accurately print the image that it is sent.
Page 113: Command Error
Stylus Pro 4000 Field Repair Guide 4/28/05 Command Error Note: Command Error usually is generated by a Printer/Driver ink type mismatch. 1. Remove hubs and other devices on the USB bus. 2. Test the Printer using another Computer and Driver.
Page 114: Communication Errors Pc
Stylus Pro 4000 Field Repair Guide 4/28/05 Communication Errors PC Description: Status Monitor 3 reports a Communication Error. Reason: The Printer and the Driver / Computer are not communicating. Troubleshooting process: 1. Check the Printer’s Control Panel and verify. 1.1 The Printer is turned on.
Page 115: Other Considerations
• Custom Dongles attached to RIP Servers could cause a problem. • Epson Printers use USB 2.0. Computer Ports that use USB 1.0, may cause a problem. • Status Monitor 3 can report an error on a Windows 2000 system, that does not exist. Turn off the Error Monitoring (Printer Driver: Utility: Speed &...
Page 116: Cover Open
Stylus Pro 4000 Field Repair Guide 4/28/05 Cover Open Note: The Cover Open error indicates that the Printer’s Front Cover is open, or the Cover Sensor is defective. 1. The Cover Sensor can be tested in the Maintenance Mode 2: Self Testing: Test: Sensor menu.
Page 117: Drop Of Ink
Stylus Pro 4000 Field Repair Guide 4/28/05 Drop of Ink Note: A Drop of Ink refers to ink dripping onto the media. Ink drips on the media come from two separate causes. The most common reason is a build up of ink on the nose of the Print Head.
Page 118: Grainy Or Ghosting
Intermittent or missing Nozzles may also be a factor. Non-Epson media or improper media settings in the driver can cause grainy images. Use another Computer with the Epson Driver and Epson Media to eliminate the users equipment. The following components occasionally cause the issue.
Page 119: Horizontal Banding
Use another Computer with the Epson Driver and Epson Media to eliminate the users equipment. Verify that the proper Spindle is being used (High Tension or Low Tension Spindle) Verify that the media does not bind coming off the roll.
Page 120 Stylus Pro 4000 Field Repair Guide 4/28/05 Additionally the Borderless Pads and Flushing Box should be checked to verify that they are not out of position or dirty. If a build up of contaminants makes contact with the Nozzle Plate, it will cause reoccurring Nozzle drop out.
Page 121: Missing Nozzle Diagnosis And Repair
Stylus Pro 4000 Field Repair Guide 4/28/05 Missing Nozzle Diagnosis and Repair Note: Inspect the printer and media for dust or fiber accumulation. Excessive “dirt” will cause missing nozzles. Some Missing Nozzles, one or more colors 1. Check the Printer’s components for mechanical problems and “dirt”.
Page 122 Stylus Pro 4000 Field Repair Guide 4/28/05 1. Check the following components of the ink supply for a minor restriction, causing partial starvation. Note: Partial Starvation refers to a slight blockage of the ink supply system that slowly starves the Print Head for ink.
Page 123 Stylus Pro 4000 Field Repair Guide 4/28/05 1.1.1 When the Printhead moves off of the Cap, and the Pump is running, inject water into the Cap with a syringe. 1.1.1.1 If the water is drawn through the Cap, the Pump is good.
Page 124: Paper Jam Errors
Stylus Pro 4000 Field Repair Guide 4/28/05 Paper Jam Errors The Paper Jam Error indicates that one of the paper sensors does not detect paper properly. Roll Paper Maintenance Mode 2: Self Testing: Test: Sensor menu Test the following sensors using the •...
Page 125: Paper Not Cut
Stylus Pro 4000 Field Repair Guide 4/28/05 Paper Not Cut Note: The Paper Not Cut error indicates that the Printer detected that the paper did not separate, after cutting. Paper cutting errors occur: •When the Cutter Blade is defective. •When the Cutter Blade does not have white nylon wheels.
Page 126: Reload Paper
Stylus Pro 4000 Field Repair Guide 4/28/05 Reload Paper Note: The Reload Paper error indicates that the Printer recognizes paper in the Printer, but can not sense it’s size or location properly. The reload paper error can be generated if the paper is loaded beyond the alignment marks (paper loading alignment marks).
Page 127: Encoder Menu
Stylus Pro 4000 Field Repair Guide 4/28/05 Encoder menu. Reload Paper Printer Component, Software Item, LCD Display, Printer Button Page 127.
Page 128: Random Nozzles
Stylus Pro 4000 Field Repair Guide 4/28/05 Random Nozzles Note: Random Nozzles refers to Nozzles that fire when they are not commanded to. Random Nozzle firing is caused by 1 of 4 components •Head Cables •Print Head •Main Board •Power Supply Head Cable Inspect the Head Cables for worn insulation.
Page 129: Scratch
Stylus Pro 4000 Field Repair Guide 4/28/05 Scratch Note: A scratch is damage to the media surface caused by contact with a roller or other Printer components. Sometimes scratches occur before the media is inserted into the Printer. Some media is very sensitive to surface abrasions. Contact between the Pinch Rollers, the Paper Feed Roller, and the media is necessary to support and move it.
Page 130: Set Ink Cartridges
Stylus Pro 4000 Field Repair Guide 4/28/05 Set Ink Cartridges Note: The Set Ink Cartridge error indicates that the Printer does not detected one or more Ink Cartridges. The error is usually generated when: •The Ink Cartridge Release Sensor is defective.
Page 131: Set Ink Lever
Stylus Pro 4000 Field Repair Guide 4/28/05 Set Ink Lever Note: The Set Ink Lever message indicates that the Ink Lever is in the up position, or that the Ink Lever Sensor is Defective. 1. Check the position of the Ink Cartridge Release Lever.
Page 132: Smudge
Stylus Pro 4000 Field Repair Guide 4/28/05 Smudge Note: A smudge is a mark left on the media by contact. It can be caused by contact with the Print Head, or contact with a dirty Roller. Dirty Roller A dirty Roller usually leaves a mark that repeats at an interval that is equal to the circumference of the Roller. Plac- ing the image with the smudge back into the paper path, and aligning the smudge with the Printer’s Rollers will indi-...
Page 133: Smear
Note: A smear is caused by something “smearing” the intended image, after the image is printed. Many times smearing is a result of non-Epson media or ink. Non-Epson ink or media may dry to slowly, resulting in a smear after the image leaves the Printer. Adjusting the...
Page 134: Vertical Banding
Computer with the Epson Driver and Epson Media to eliminate the users equipment. Non-Epson drivers effect verti- cal banding if the amount of ink that is applied to the media is too low. Using the Epson driver should look better, if that is the case.
Page 135: Wrong Ink Cartridge
Stylus Pro 4000 Field Repair Guide 4/28/05 Wrong Ink Cartridge Note: The Wrong Ink Cartridge error indicates that the Printer detects an Ink Cartridge that does not match the Ink type expected. 1. Verify that the Maintenance Mode 2: Service Config: NPD value is set to the correct ink type.
Page 136: Adjustments
Stylus Pro 4000 Field Repair Guide 4/28/05 Adjustments Printer Component, Software Item, LCD Display, Printer Button Page 136.
Page 137: 1000Mm Feed Adjustment
Stylus Pro 4000 Field Repair Guide 4/28/05 1000mm Feed Adjustment 1. Load 17” Enhanced Matte roll paper. 2. From the Adjustment Wizard for the Pro 4000, select the 1000mm Feed Adjustment. 1. Click on the Print button. 2. The Printer will print the 1000mm alignment pattern 3.
Page 138: Auto Bi-D Adjustment [Pg 1.2]
Stylus Pro 4000 Field Repair Guide 4/28/05 Auto Bi-D Adjustment [PG 1.2] 1. Load 17” Enhanced Matte roll paper. 2. From the Adjustment Wizard for the Pro 4000, select the Auto Bi-D Adjustment. 1. Click on the button. 2. The Printer will print out these patterns. It will take approximately 15 minutes 3.
Page 139: Auto Uni-D Adjustment
Stylus Pro 4000 Field Repair Guide 4/28/05 Auto Uni-D Adjustment 1. Load 17” Enhanced Matte roll paper. 2. From the Adjustment Wizard for the Pro 4000, select the Auto Uni-D Adjustment. 1. Click on the button. 2. The Printer will print out these patterns. It will take approximately 15 minutes 3.
Page 140: Carriage Timing Belt Tension Adjustment
Stylus Pro 4000 Field Repair Guide 4/28/05 Carriage Timing Belt Tension Adjustment 1. Remove the Left Side Cover. 2. Turn the Adjustment Screw until the Belt Bracket is positioned by the 3rd Mark from the right. Turn the Adjustment Screw.
Page 141: Change Model Name
Stylus Pro 4000 Field Repair Guide 4/28/05 Change Model Name Note: Change Model Name will write Stylus Pro 4000 to the Main Board (Plug and Play name) 1. From the Adjustment Wizard for the Pro 4000, select Change Model Name.
Page 142 Stylus Pro 4000 Field Repair Guide 4/28/05 2. Click on Check to verify the current name. 2. Verify the Printer is named Epson Stylus Pro 4000 1. Click on Check. 3. Click on Finished Change Model Name Printer Component, Software Item,...
Page 143: Check Nozzle
Stylus Pro 4000 Field Repair Guide 4/28/05 Check Nozzle Note: Check Nozzle performs a user Nozzle Check. 1. From the Adjustment Wizard for the Pro 4000, select Check Nozzle. 1. Load paper. 2. Click on to print the pattern. The nozzle check pattern should look like this.
Page 144: Check Platen Gap
Stylus Pro 4000 Field Repair Guide 4/28/05 Check Platen Gap Note: Check Platen Gap allows physical verification of the proper operation (setting) of the Platen Gap Detent Cam. 1. From the Adjustment Wizard for the Pro 4000, select Check Platen Gap.
Page 145: Cleaning / Charging (Priming)
Stylus Pro 4000 Field Repair Guide 4/28/05 Cleaning / Charging (Priming) Note: Cleaning explains the function of the various cleaning cycles accessed with the function keys. 1. From the Adjustment Wizard for the Pro 4000, select Cleaning. F5 forces a Prime.
Page 146: Clear Pf Micro Feed Adjustment [Bi-D]
Stylus Pro 4000 Field Repair Guide 4/28/05 Clear PF Micro Feed Adjustment [Bi-D] Note: The Clear PF Micro Feed Adjustment [Bi-D] resets the user paper feed adjustments that modifies the paper feed tables. It should be reset every time the Feed Length Adjustment is performed.
Page 147: Copy Bi-D Variables
Stylus Pro 4000 Field Repair Guide 4/28/05 Copy Bi-D Variables Note: Copy Bi-D Variables transfers the data from the Manual Bi-D Adjustment at standard platen gap, to the memory locations that correspond to the other 3 platen gaps. The ink must travel different distances for each platen gap, and the timing must be adjusted to compensate for the different “flight...
Page 148: Copy Uni-D Variables
Stylus Pro 4000 Field Repair Guide 4/28/05 Copy Uni-D Variables Note: Copy Uni-D Variables transfers the data from the Manual Uni-D Adjustment at standard platen gap, to the memory locations that correspond to the other 3 platen gaps. The ink must travel different distances for each platen gap, and the timing must be adjusted to compensate for the different “flight...
Page 149: Cr Encoder Sensor Position Adjustment
Stylus Pro 4000 Field Repair Guide 4/28/05 CR Encoder Sensor Position Adjustment Purpose: The Carriage Encoder Sensor Position Adjustment is used to ensure that the Carriage Encoder Timing Strip is centered in the Carriage Encoder Sensor across the entire length of the Printer Mechanism.
Page 150: Head Rank Id
Stylus Pro 4000 Field Repair Guide 4/28/05 Head Rank ID Note: Enter the Head Rank ID before installing the Print Head. This way it is possible to enter the data directly off the Print Head. Otherwise, it is necessary to write down the data before installing the Print Head.
Page 151: Initialize Main Board
Stylus Pro 4000 Field Repair Guide 4/28/05 Initialize Main Board Note: Initialize Main Board will reset all settings. Do not use. 1. From the Adjustment Wizard for the Pro 4000, select Initialize Main Board. 1. Click on to reset all the set- tings on the Main Board.
Page 152: Ink Discharge
Stylus Pro 4000 Field Repair Guide 4/28/05 Ink Discharge. Note: Ink Discharge allows the evacuation of the ink in the Tubes. 1. From the Adjustment Wizard for the Pro 4000, select Ink Discharge. 1. Remove the Ink Cartridges 2. Click on Run.
Page 153: Multi Sensor Adjustment For Auto Nozzle Check
Stylus Pro 4000 Field Repair Guide 4/28/05 Multi Sensor Adjustment for Auto Nozzle Check 1. Load 17” Enhanced Matte roll paper. 2. From the Adjustment Wizard for the Pro 4000, select the Mulit Sensor Adjustment for Auto Nozzle Check. 1. Click on the button.
Page 154: Multi Sensor Auto Pf Adjustment
Stylus Pro 4000 Field Repair Guide 4/28/05 Multi Sensor Auto PF Adjustment 1. Load 17” Enhanced Matte roll paper. 2. From the Adjustment Wizard for the Pro 4000, select the Multi Sensor Auto PF Adjustment. 1. Click on Run. 2. The Printer will print a test pattern. (It takes about 15 minutes).
Page 155: Multi Sensor Level Adjustment
Stylus Pro 4000 Field Repair Guide 4/28/05 Multi Sensor Level Adjustment Note: This adjustment sets the “White Level” for the Multi Sensor (sensitivity calibration). 1. Load 17” Enhanced Matte roll paper. 2. From the Adjustment Wizard for the Pro 4000, select the Multi Sensor Level Adjustment 1.
Page 156: Multi Sensor Position Adjustment
Stylus Pro 4000 Field Repair Guide 4/28/05 Multi Sensor Position Adjustment Note: This mechanical adjustment fixes the physical position of the Multi Sensor. 1. Rotate the Rear Carriage Rail until the Platen Position Stopper is in the first Detent. First Detent.
Page 157 Stylus Pro 4000 Field Repair Guide 4/28/05 3. Move the Multi Sensor over the thickness gauge. 1. Move the Multi Sensor over the thickness gauge. 2. Loosen 2 Screws and move the Multi Sensor in the direction of the arrows 3.
Page 158: Nozzle Bi-D Adjustment
Stylus Pro 4000 Field Repair Guide 4/28/05 Nozzle Bi-D Adjustment 1. Load 17” Enhanced Matte roll paper. 2. From the Adjustment Wizard for the Pro 4000, select the Nozzle Bi-D Adjustment. 1. Click on the Print button. 2. The Printer will print out this pattern.
Page 159: Paper Feed Timing Belt Adjustment
Stylus Pro 4000 Field Repair Guide 4/28/05 Paper Feed Timing Belt Adjustment 1. Remove the Left Side Cover. 2. Remove 2 Screws to free the Flexible Cable Support, and move it down, (out of the way). 1 Screw 1 Screw 3.
Page 160 Stylus Pro 4000 Field Repair Guide 4/28/05 apply tension to the Belt. Loosen this screw. This spring will apply tension to the belt. 4. Tighten the Screw, then check the Belt tension with your finger. There should be a deflection of approximately 1/8”...
Page 161: Paper Thickness Sensor Adjustment
Stylus Pro 4000 Field Repair Guide 4/28/05 Paper Thickness Sensor Adjustment Purpose: The Paper Thickness Sensor Adjustment calibrates the Paper Thickness Sensor so that it correctly rec- ognizes 3 different thickness ranges of media. The Paper Thickness Sensor does not measure the thick- ness of inserted media, it determines the “thickness range”...
Page 162 Stylus Pro 4000 Field Repair Guide 4/28/05 3. Remove the Top Cover. 4. Remove the Paper Thickness Sensor Cover. 1. Remove 3 Screws 2. Lift up, and off. 5. Press and hold the Left, Down, and buttons, and turn on the Printer (Maintenance Mode 2).
Page 163 Stylus Pro 4000 Field Repair Guide 4/28/05 9. Insert the thickness gauges into the paper path as shown, and engage the pressure rollers (Paper Release Lever down). Insert thickness gauge as shown. direction Right digit Left digit direction 1. Insert the 4 gauges and check that the 3 condi- tions listed in step 9 are true.
Page 164: Platen Gap Adjustment
Stylus Pro 4000 Field Repair Guide 4/28/05 Platen Gap Adjustment Purpose: The Platen Gap Adjustment sets the physical platen gap to the correct distance. 1. Remove the Left Side Cover. 1. Open the Top Cover, and defeat the Top Cover Sensor by wedging something (paper) against the Sensor.
Page 165 Stylus Pro 4000 Field Repair Guide 4/28/05 3. Press and hold the Left, Down, and buttons, and turn on the Printer (Maintenance Mode 2). 4. Using the Down button, navigate to Self Testing: Adjustment: and press the Menu button. 5. Using the...
Page 166 Stylus Pro 4000 Field Repair Guide 4/28/05 9. Place the Platen Position Detent device in the position shown below, and tighten the 2 Screws. Turn until the Stopper is resting in the first Detent (the detent has an arrow pointing at it).
Page 167: Platen Position Adjustment
Stylus Pro 4000 Field Repair Guide 4/28/05 Platen Position Adjustment 1. Load 17” Enhanced Matte roll paper. 2. From the Adjustment Wizard for the Pro 4000, select the Platen Position Adjustment. 1. Click on the Print button. 2. The Printer will print the alignment pattern 3.
Page 168 Stylus Pro 4000 Field Repair Guide 4/28/05 7. Click on the Check button. 8. The Printer will print and alignment check sheet. 9. Verify that the alignment marks are centered over the Borderless Printing Pads. (If they are not click on the Back button and repeat steps 1 - 5.
Page 169: Print Head Slant Adjustment (Cr)
Stylus Pro 4000 Field Repair Guide 4/28/05 Print Head Slant Adjustment (CR) 1. From the Adjustment Wizard for the Pro 4000, select the Print Head Slant Adjustment (CR). 2. Move the Carriage to the position shown below, remove 3 Screws, and remove the Carriage Cover.
Page 170 Stylus Pro 4000 Field Repair Guide 4/28/05 3. Loosen the 4 indicated Screws 1/4 turn. Loosen these 4 Screws 1/4 turn. 4. Move the Carriage back to the capped position. 5. Click on the Print Button, the alignment pattern will be printed.
Page 171 Stylus Pro 4000 Field Repair Guide 4/28/05 6. Using a lens, inspect the printed pattern. The pattern should look like this Move this lever down to rotate the Print Head clockwise. 7. Adjust, and reprint, until the alignment pattern is correct.
Page 172: Print Head Slant Adjustment (Pf)
Stylus Pro 4000 Field Repair Guide 4/28/05 Print Head Slant Adjustment (PF) 1. From the Adjustment Wizard for the Pro 4000, select the Print Head Slant Adjustment (CR). 2. Move the Carriage to the position shown below, remove 3 Screws, and remove the Carriage Cover.
Page 173 Stylus Pro 4000 Field Repair Guide 4/28/05 3. Loosen the 5 indicated Screws 1/4 turn. Loosen 1 Screw that fastens the Adjustment Lever Loosen 4 Screws that fasten the Print Head 4. Move the Carriage back to the capped position.
Page 174 Stylus Pro 4000 Field Repair Guide 4/28/05 6. Using a lens, inspect the printed pattern. The Lever employs detentes to lock it in place. Flex the top portion of the Lever in the direction of the pivot point to release the detentes.
Page 175: Rearad Sensor Calibration
Stylus Pro 4000 Field Repair Guide 4/28/05 RearAD Sensor Calibration Note: This adjustment sets the “White Level” for the RearAD Sensor (sensitivity calibration). Note: This adjustment can be performed using the customer’s media if it is non-standard (transparent, etc.). 1. Place paper in the paper path. Ensure that the paper is inserted past the Pinch Rollers and the Paper Feed Roller.
Page 176: Reset Asf Counter
Stylus Pro 4000 Field Repair Guide 4/28/05 Reset ASF Counter Note: Reset ASF Counter is used to reset the Automatic Sheet Feeder counter. 1. From the Adjustment Wizard for the Pro 4000, select Reset ASF Counter. 1. Click on to reset the ASF counter.
Page 177: Reset Paper Ejection Switching
Stylus Pro 4000 Field Repair Guide 4/28/05 Reset Paper Ejection Switching Note: Reset Paper Ejection Switching is used to reset the Paper Exit Roller counter. 1. From the Adjustment Wizard for the Pro 4000, select Reset Paper Ejection Switching. 1. Click on to reset the Paper Exit Roller counter.
Page 178: Reset Pf Motor Counter
Stylus Pro 4000 Field Repair Guide 4/28/05 Reset PF Motor Counter Note: Reset PF Motor Counter is used to reset the Paper Feed Motor counter. 1. From the Adjustment Wizard for the Pro 4000, select Reset PF Motor Counter. 1. Click on to reset the Paper Feed Motor counter.
Page 179: Reset When Cleaning Unit Change
Stylus Pro 4000 Field Repair Guide 4/28/05 Reset When Cleaning Unit Change Note: Rest When Cleaning Unit Change is used to reset the Cleaning Unit counter. 1. From the Adjustment Wizard for the Pro 4000, select Check Nozzle. 1. Click on to reset the Cleaning Unit counter.
Page 180: Reset When Cr Unit Change
Stylus Pro 4000 Field Repair Guide 4/28/05 Reset When CR Unit Change Note: Reset When CR Unit Change is used to reset the Carriage Unit counter. 1. From the Adjustment Wizard for the Pro 4000, select Reset When CR Unit Change.
Page 181: Reset When Cutter Change
Stylus Pro 4000 Field Repair Guide 4/28/05 Reset When Cutter Change Note: Reset When Cutter Change is used to reset the Cutter Solenoid life counter. 1. From the Adjustment Wizard for the Pro 4000, select Reset When Cutter Change. 1. Click on to reset the Cutter Sole- noid life counter.
Page 182: Reset When Print Head Change
Stylus Pro 4000 Field Repair Guide 4/28/05 Reset When Print Head Change Note: Reset When Print Head Change is used to reset the Print Head life counter. 1. From the Adjustment Wizard for the Pro 4000, select Reset When Print Head Change.
Page 183: Rtc & Usb & Ieee1394Id Adjustment
Stylus Pro 4000 Field Repair Guide 4/28/05 RTC & USB & IEEE1394ID Adjustment 1. From the Adjustment Wizard for the Pro 4000, select the RTC & USB & IEEE1394ID Adjustment. Note: The order that is indicated by the following steps is important. The utility will not acti-...
Page 184 Stylus Pro 4000 Field Repair Guide 4/28/05 2. Click on the Check button to display the IEEE1394 I.D. RTC & USB & IEEE1394ID Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 184.
Page 185 Stylus Pro 4000 Field Repair Guide 4/28/05 3. Write down the IEEE1394 I.D. 4. Click on the button. 5. Click on the Back button. RTC & USB & IEEE1394ID Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 185.
Page 186 Stylus Pro 4000 Field Repair Guide 4/28/05 6. Verify that the Date and Time information is correct. It can be adjusted if necessary. 7. Enter the IEEE1394 I.D. 8. Enter the Printer’s serial number. 9. Click on the Write button to send the data to the printer.
Page 187: Skew Check
Stylus Pro 4000 Field Repair Guide 4/28/05 Skew Check 1. Load 17” Enhanced Matte roll paper. 2. From the Adjustment Wizard for the Pro 4000, select the Skew Check. 1. Click on the button. 2. The Printer will feed 1 meter of paper.
Page 188: T&B&S [Cut Sheet] Adjustment
Stylus Pro 4000 Field Repair Guide 4/28/05 T&B&S [Cut Sheet] Adjustment 1. Load A4 Enhanced Matte cut sheet paper. 2. From the Adjustment Wizard for the Pro 4000, select the T&B&S [Cut Sheet]. 1. Click on the Print button. 2. The Printer will print out this pattern, and mea- sure the side margin using the Multi Sensor.
Page 189: T&B&S [Roll Paper] Adjustment
Stylus Pro 4000 Field Repair Guide 4/28/05 T&B&S [Roll Paper] Adjustment 1. Load 17” Enhanced Matte roll paper. 2. From the Adjustment Wizard for the Pro 4000, select the T&B&S [Roll Paper]. 1. Click on the Print button. 2. The Printer will print out this pattern, and mea-...
Page 190: Reference
Stylus Pro 4000 Field Repair Guide 4/28/05 Reference Printer Component, Software Item, LCD Display, Printer Button Page 190.
Page 191: Accessories List
Stylus Pro 4000 Field Repair Guide 4/28/05 Accessories List Sales Part Number Description C4000STAND Printer Stand C12C811171 2”/3”, 17” Normal Tension Media Spindle C12C811191 2”/3”, 17” High Tension Media Spindle C12C815291 Cutter Blade C12C824052 Multi-protocol 10/100 Base-T Type B Ethernet Interface Card...
Page 192: Cleaning Fluid
Stylus Pro 4000 Field Repair Guide 4/28/05 Cleaning Fluid Note: Cleaning fluid for the Pro 4000 is unique. It is an improved formula for pigmented ink. Part #: 1243924 Description: Cleaning Liquid Cartridge. Cleaning Fluid Printer Component, Software Item, LCD Display, Printer Button Page 192.
Page 193: Color Order On The Print Head
Stylus Pro 4000 Field Repair Guide 4/28/05 Color Order on the Print Head User Nozzle Check Color Order (Stair Step) (Listed Left to Right) 1. Matte Black 2. Cyan 3. Magenta 4. Yellow 5. Photo Black 6. Light Cyan 7. Light Magenta 8.
Page 194: Consumable/Service Parts List
Stylus Pro 4000 Field Repair Guide 4/28/05 Consumable/Service Parts List Ink is intended as a service tool (Warranty Service Only), and is not for sale. Use the Service Part Number, and claim it on a warranty form. Service Part #...
Page 195 Stylus Pro 4000 Field Repair Guide 4/28/05 Service Part # Sales Part # Roll Paper ECCC Cost after 40% discount WAS041725 SO41725 Enhanced Matte 17” x 100’ roll $35.97 WAS041387 SO41387 Double Weight Matte 44” x 82’ roll $59.40 WAS041385 SO41385 Double Weight Matte 24”...
Page 196: Firmware History
Firmware History This chart explains the meaning of the firmware version characters. Stylus Pro 4000 Current Firmware Ver. I02552.upg Release date: 02/25/05 1. The Exit Roller setting was changed to minimize “Pizza Wheel” marks when printing on cut sheet paper and/or using the front manual feed.
Page 197 Stylus Pro 4000 Field Repair Guide 4/28/05 Tracing Paper, Single Weight Matte Paper, and Plain Paper. 3. The SSCL (Super Strong Cleaning Cycle) was modified to increase the ultrasonic portion of the cleaning cycle. The ultrasonic portion (strong piezo vibration) assists in disolving deposits on the nozzle plate.
Page 198 Stylus Pro 4000 Field Repair Guide 4/28/05 Release date: June 21, 2004 1. “Communication Errors” via a FireWire IEEE1394 connection under Mac OS X and Windows XP are corrected. 2. The message “DRIVER INK SETTING IS WRONG” is displayed if their is a mismatch between the printers panel ink setting and the driver setting.
Page 199 12. Corrects Service Request 00010007 (carriage motor timing) when the printer is powered on. 13. When loading media eliminates damage to the leading edge of the media. 14. The “Auto Nozzle Check” from the EPSON Service Utility 2 now functions correctly and ejects the media.
Page 200 Stylus Pro 4000 Field Repair Guide 4/28/05 19. An additional Yellow test pattern was added to the auto nozzle. 20. Erroneous paper eject service request 00010033 error is corrected by reducing chatter in the paper eject system. 21. The Dual CMYK ink set change function is removed. (Dual CMYK is not a supported model in the 22.
Page 201: Firmware Update Procedure
Stylus Pro 4000 Field Repair Guide 4/28/05 Firmware Update Procedure Note: This procedure is used to update or install firmware. It is the service method because it does not require the Printer to be “Online” to work. 1. Turn on the Printer while depressing the Up, Down,...
Page 202: Glossary
The qualities of a photograph that makes an image appear real. The smooth and life- like transition from one color shade to the next, like in a photograph. Epson Ink Jet printers are not continuous tone printers. But when working properly, their printed images fool the human eye into seeing continuous tone transitions.
Page 203 Printer adjustments, which are performed using software routines that, allow the printer to compensate for physical variations in its mechanism. Error Diffusion: The type of dithering (screening) proprietary to Epson, that employs a random dot pattern to ensure that the human eye can discern no pattern. Flight Time: The time it takes a drop of ink to travel from the print head to the printable surface.
Page 204 Stylus Pro 4000 Field Repair Guide 4/28/05 Head Gap Adjustment: An electronic print head adjustment that ensures that the printer knows the exact distance between nozzle sets on separate heads. Also known as Head L/R and Uni-Di... Head ID: The calibration value written on the print head that allows the printers electronics to compensate for the print heads “personality”...
Page 205 The different appearance of colors caused by different light sources and viewing angles Micro Weave: The way an Epson Ink Jet printer interlaces (weaves) bands of and image during printing. Moiré Pattern: A repetitive pattern, within an image, which is not intended. I can appear like a pais- ley or herringbone pattern.
Page 206 Stylus Pro 4000 Field Repair Guide 4/28/05 Pixilated: An image quality issue that is caused by a low-resolution image printed at high reso- lution. Platen Gap: The distance between the print head, and the printable surface. Rippling: A term that refers to a condition caused by over saturated paper warping.
Page 207 Stylus Pro 4000 Field Repair Guide 4/28/05 Vertical Banding, Linear: An image defect that extends from the top, to the bottom margin (perpendicular to the direction of print head movement). It usually repeats, with the same interval, from the left margin to the right.
Page 208: Ink Draining Procedure
Stylus Pro 4000 Field Repair Guide 4/28/05 Ink Draining Procedure 1. Press and hold the Left, Down, and buttons, and turn on the Printer (Maintenance Mode 2). 2. Using the Down button, navigate to Self Testing: Adjustment: and press the Menu button.
Page 209: Ink Tube Order
Stylus Pro 4000 Field Repair Guide 4/28/05 Ink Tube Order Note: This chapter documents the order that the Ink Tubes are connected to the Print Head. The Ink Tube/Print Head color order is listed left to right. 1. Light Black 2.
Page 210: Prime, On Or Off
Stylus Pro 4000 Field Repair Guide 4/28/05 Prime, On or Off Prime, Initial Fill, and Charge mean the same thing. They all refer to filling the Ink System with ink. Controlling the Prime function requires Setting, or Resetting the Init.Fill Flag.
Page 211: Revision History
Stylus Pro 4000 Field Repair Guide 4/28/05 Revision History April 28, 2005 The Firmware History chapter was updated. April 1, 2005 1. 24 troubleshooting chapters were added. 2. A chapter listing service tool part numbers was added. 3. A chapter listing accessory part numbers was added.
Page 212: Sensors, Motors, Solenoids, And Fans
Stylus Pro 4000 Field Repair Guide 4/28/05 Sensors, Motors, Solenoids, and Fans Home Position Sensors: Carriage HP Sensor Origin) Gap HP Sensor (Head Slide) Pump HP Sensor(Pump) Exit Roller HP Sensor (POUT) ASF Roller HP Sensor Maintenance/Waste Ink Tank Sensor...
Page 213 Stylus Pro 4000 Field Repair Guide 4/28/05 Motors Carriage Motor Paper Feed Motor: turns the Paper Feed Roller, Sub Roller and the Eject Roller Pump Motor: also turns the Input Roller Platen Gap Motor: also sets the Eject Roller position,...
Page 214: Service Procedure
Stylus Pro 4000 Field Repair Guide 4/28/05 Service Procedure 1. Observe the customer’s service issue. 2. Update the firmware to the current version if necessary. 3. Repair the customer’s service issue. 4. Clean the Carriage Rails with a dry cloth or paper towel 5.
Page 215 Stylus Pro 4000 Field Repair Guide 4/28/05 12. Perform the 1000 mm Feed Adjustment, or Multi Sensor Auto PF Adjustment. 13. Perform the Nozzle Bi-D Adjustment 14. Perform the Auto Bi-D Adjustment 14.1 Perform Copy Bi-D variables 15. Perform the Auto Uni-D Adjustment 15.1 Perform...
Page 216: Service Tools
Stylus Pro 4000 Field Repair Guide 4/28/05 Service Tools Service Part Number Description 1243924 Cleaning Liquid Cartridge (Requires 8 Cartridges) 1047746 1000 mm Scale (meter stick) 1282354 Multi Sensor Position Tool 1282355 Paper Thickness Sensor calibration tools 1080614 G-26 Grease...
Page 217: Stress Test (Test Image)
There is always some horizontal and vertical banding. Use: 1. Use it to compare Non-Epson Drivers against the Epson Driver. 2. Use it to look for image quality variances across the entire printable area of the printer. Is the vertical banding consistent across the entire image?
Page 218: User Nozzle Check Order
Stylus Pro 4000 Field Repair Guide 4/28/05 User Nozzle Check Order User Nozzle Check Color Order (Stair Step) (Listed Left to Right) 1. Matte Black 2. Cyan 3. Magenta 4. Yellow 5. Photo Black 6. Light Cyan 7. Light Magenta 8.
Page 219: Utilities
Stylus Pro 4000 Field Repair Guide 4/28/05 Utilities Printer Component, Software Item, LCD Display, Printer Button Page 219.
Page 220: Adjustment Wizard2
Stylus Pro 4000 Field Repair Guide 4/28/05 Adjustment Wizard2 Note: The Adjustment Wizard is the utility that enables electronic and mechanical alignments of the Pro 4000. 1. Ensure that the Pro 4000 Printer Driver Status Monitor 3 is installed on the system that will...
Page 221 Stylus Pro 4000 Field Repair Guide 4/28/05 4. Pick the correct printer driver/port, Color, Individual, and click Start. Printer Driver and Port. 8 color Individual Start Adjustment Wizard2 Printer Component, Software Item, LCD Display, Printer Button Page 221.
Page 222 Stylus Pro 4000 Field Repair Guide 4/28/05 5. The utility will look like this. 6. Double click on the individual line items to perform each adjustment. Adjustment Wizard2 Printer Component, Software Item, LCD Display, Printer Button Page 222.
Page 223: Epson Paper Feed Adjuster
Stylus Pro 4000 Field Repair Guide 4/28/05 Epson Paper Feed Adjuster Note: The Epson Paper Feed Utility is a user utility designed to customize the Printer, to increase it’s print quality. Technicians can use it to reset user settings. Ensure that the...
Page 224 Stylus Pro 4000 Field Repair Guide 4/28/05 3. Run the Epson Paper Feed Adjuster from the Windows Start Menu. 1. Click On Initialize Adjust- ment Values. 2. Click on OK. Epson Paper Feed Adjuster Printer Component, Software Item, LCD Display, Printer Button Page 224.
Page 225 Stylus Pro 4000 Field Repair Guide 4/28/05 3. Click on Initialize. 4. Click on OK. Epson Paper Feed Adjuster Printer Component, Software Item, LCD Display, Printer Button Page 225.
Page 226: Nvram.exe
Stylus Pro 4000 Field Repair Guide 4/28/05 NVRAM.EXE Note: NVRAM.EXE is the utility that enables the backup and re-installation of parameters (settings), necessary when exchanging the Main Board of a Pro 4000. Installation: 1. Ensure that the Pro 4000 Printer Driver...
Page 227 Stylus Pro 4000 Field Repair Guide 4/28/05 Parameter Backup:. 1. Pick the Pro 4000 printer driver. The port that the driver is associated with, will be displayed. 3.Click on Read. The Printer LCD will toggle between Ready and Printing. The utility will display this, until it is fin- ished transferring data.
Page 228 Stylus Pro 4000 Field Repair Guide 4/28/05 Parameter Restore. 1. Pick the Pro 4000 printer driver. The port that the driver is associated with, will be displayed. 3.Click on Write to send previously loaded Parameters to the Printer. (If the Parameters...
Page 229: Prnprint.exe
Stylus Pro 4000 Field Repair Guide 4/28/05 PRNprint.exe Note: PRNprint.exe is the utility that is used to copy Firmware to the Printer. 1. Ensure that the Pro 4000 Printer Driver is installed on the system that will be running the PRNprint.exe.
Page 230 Stylus Pro 4000 Field Repair Guide 4/28/05 3. Select the correct firmware and load it into the utility. 1.Change the file type to Files 2. Navigate to, and click on the correct firmware file. 3. Click on Open PRNprint.exe Printer Component,...
Page 231 Stylus Pro 4000 Field Repair Guide 4/28/05 4. Send the firmware to the Printer. 1. Select the correct printer driver. 2. Click on Print. PRNprint.exe Printer Component, Software Item, LCD Display, Printer Button Page 231.

Epson Stylus Pro 4000 Field Repair Manual

Table of Contents

Control Panel Map

Component Replacement

Troubleshooting

Reference

Utilities

Quick Links

Table of Contents

Related Manuals for Epson Stylus Pro 4000

Summary of Contents for Epson Stylus Pro 4000

Table of Contents