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STYLUS PRO 4000
Service Manual and Field Repair Guide
464 pgs41.83 Mb1
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Product Support Bulletin
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Warranty Statement
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Reference Manual
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Table of contents
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Epson Stylus Pro 4000 Service Manual and Field Repair Guide

Stylus Pro 4000 Field Repair Guide 4/28/05

Table of Contents

Table of Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 Control Panel Map - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 Component Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - 12
Carriage Removal Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - 13 Cartridge Release Lever Repair - - - - - - - - - - - - - - - - - - - - - - - - - 16 Cartridge Release Sensor Repair - - - - - - - - - - - - - - - - - - - - - - - - 17 Damper Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18 Ink Bay Removal (Left) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26 Ink Bay Removal (Right) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 31 Input Roller Assembly, Disassembly - - - - - - - - - - - - - - - - - - - - - - 36 Input Roller Assembly, Re-assembly - - - - - - - - - - - - - - - - - - - - - - 41 Input Roller Assembly Removal - - - - - - - - - - - - - - - - - - - - - - - - - 46 Main Board Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - 51 Paper Exit Roller Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58 Plastic Roller Upgrade - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 61 Print Head Replacement Procedure - - - - - - - - - - - - - - - - - - - - - - - 80 Pump and Cap Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - 87 Pump and Cap Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 93 Side Cover Removal (Left) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 98 Side Cover Removal (Right) - - - - - - - - - - - - - - - - - - - - - - - - - - - 99 Top Cover Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 101
Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 102
Error Codes (Maintenance) - - - - - - - - - - - - - - - - - - - - - - - - - - - 103 Error Codes (Service) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -104 00000088 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 107 00000101 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 108 00000103 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 109 00000105 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 110 00010000 - 00010003 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 111 Color Shift - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 112 Command Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -113 Communication Errors PC - - - - - - - - - - - - - - - - - - - - - - - - - - - - 114 Cover Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 116
Printer Component, Software Item, LCD Display, Printer Button Page 1.
Stylus Pro 4000 Field Repair Guide 4/28/05
Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 136
1000mm Feed Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - 137 Auto Bi-D Adjustment [PG 1.2] - - - - - - - - - - - - - - - - - - - - - - - - -138 Auto Uni-D Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 139 Carriage Timing Belt Tension Adjustment - - - - - - - - - - - - - - - - - - - - 140 Change Model Name - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 141 Check Nozzle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -143 Check Platen Gap - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -144 Cleaning / Charging (Priming) - - - - - - - - - - - - - - - - - - - - - - - - - -145 Clear PF Micro Feed Adjustment [Bi-D] - - - - - - - - - - - - - - - - - - - - -146 Copy Bi-D Variables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 147 Copy Uni-D Variables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 148 CR Encoder Sensor Position Adjustment - - - - - - - - - - - - - - - - - - - - 149 Head Rank ID - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -150 Initialize Main Board - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -151 Ink Discharge. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 152 Multi Sensor Adjustment for Auto Nozzle Check - - - - - - - - - - - - - - - -153 Multi Sensor Auto PF Adjustment - - - - - - - - - - - - - - - - - - - - - - - -154 Multi Sensor Level Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - 155 Multi Sensor Position Adjustment - - - - - - - - - - - - - - - - - - - - - - - - 156 Nozzle Bi-D Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 158 Paper Feed Timing Belt Adjustment - - - - - - - - - - - - - - - - - - - - - - - 159
Printer Component, Software Item, LCD Display, Printer Button Page 2.
Stylus Pro 4000 Field Repair Guide 4/28/05
Paper Thickness Sensor Adjustment - - - - - - - - - - - - - - - - - - - - - - 161 Platen Gap Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - -164 Platen Position Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - -167 Print Head Slant Adjustment (CR) - - - - - - - - - - - - - - - - - - - - - - - - 169 Print Head Slant Adjustment (PF) - - - - - - - - - - - - - - - - - - - - - - - - 172 RearAD Sensor Calibration - - - - - - - - - - - - - - - - - - - - - - - - - - - 175 Reset ASF Counter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 176 Reset Paper Ejection Switching - - - - - - - - - - - - - - - - - - - - - - - - - 177 Reset PF Motor Counter - - - - - - - - - - - - - - - - - - - - - - - - - - - - -178 Reset When Cleaning Unit Change - - - - - - - - - - - - - - - - - - - - - - - 179 Reset When CR Unit Change - - - - - - - - - - - - - - - - - - - - - - - - - - 180 Reset When Cutter Change - - - - - - - - - - - - - - - - - - - - - - - - - - - 181 Reset When Print Head Change - - - - - - - - - - - - - - - - - - - - - - - - -182 RTC & USB & IEEE1394ID Adjustment - - - - - - - - - - - - - - - - - - - - -183 Skew Check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -187 T&B&S [Cut Sheet] Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - 188 T&B&S [Roll Paper] Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - 189
Reference - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 190
Utilities - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 219
Adjustment Wizard2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 220
Printer Component, Software Item, LCD Display, Printer Button Page 3.
Stylus Pro 4000 Field Repair Guide 4/28/05
Epson Paper Feed Adjuster - - - - - - - - - - - - - - - - - - - - - - - - - - - 223 NVRAM.EXE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 226 PRNprint.exe - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 229
Printer Component, Software Item, LCD Display, Printer Button Page 4.
Stylus Pro 4000 Field Repair Guide 4/28/05

Control Panel Map

Roll Auto Cut Roll Auto Cut Off
Ink Out
Paused
Pause
Power
Roll / SheetSheet
Status
Ink Quantity
Media Feed
Maintenance Tank Level
Paper Out
Hold for 3 seconds to reset/clear Printer
Printer Component, Software Item, LCD Display, Printer Button Page 5.
Hold for 3 seconds to cut roll media
Hold the 4 Arrow Buttons and Power on for F/W Down-
load Mode.
Hold for 3 seconds to clean
Stylus Pro 4000 Field Repair Guide 4/28/05
User Menu: Press the Menu button when
the printer displays Ready
1. PRINTER SETUP.
PLATEN GAP: *STANDARD, NARROW, WIDER,
WIDE
PAGE LINE: *ON, OFF INTERFACE: *AUTO, USB, IEEE1394, OPTION CODE PAGE: *PC437, PC850, PAPER MARGIN: *T/B 15MM, 15MM, 3MM PPR SIZE CHK: *ON, OFF PPR ALIGN CHK: *ON, OFF TIME OUT: *OFF, 30SEC, 60SEC, 180SEC, 300SEC CUTTER ADJ: EXEC REFRESH MRGN: *ON, OFF SHEET SIZE CHK: *ON, OFF AUTO NZL CK: *ON, OFF AUTO CLEANING: *ON, OFF QUIET CUT: *OFF, ON INIT SETTINGS: EXEC
3. PRINTER STATUS.
VERSION: (CURRENT FIRMWARE) PRINTABLE PG: (FOR EACH COLOR)MK
(nnnnnn)PG
INK LEFT: (FOR EACH COLOR)MK E*****F MAINT TANK: E*****F USAGE COUNT: INK (nnnn.n)ML, PPR
(nnnn.n)CM
USE COUNT CLR: EXEC JOB HISTORY: N0.(N) I:(nnn)ML, P:(nnn)CM JOB HISTORY CLR: EXEC TOTAL PRINTS: (nnnn)
4. CUSTOM PAPER.
PAPER NUMBER: *STANDARD, NO. (1-10)
Platen Gap: Standard, Narrow, Wide, Wider Thickness Pat: Print Cut Method: *Standard, Thick (Fast, Slow), Thin
Paper
2. TEST PRINT.
NOZZLE CHECK: PRINT STATUS CHECK: PRINT JOB INFO: PRINT CUSTOM PAPER: PRINT
Printer Component, Software Item, LCD Display, Printer Button Page 6.
PPR Feed Adj: (n.nn)% Eject Roller: *Auto, Sheet, Roll Curled, Roll Normal Drying Time: (n.n)sec
Suction: *Standard, -4, -3, -2, -1
M/W ADJ: *Standard,1 , 2
Stylus Pro 4000 Field Repair Guide 4/28/05
5. MAINTENANCE
6. Head Alignment.
CUTTER REPL: EXEC CHNG INK SET: EXEC (For Changing between 8 and 4 color) PWR CLEANING: N CLEANING Y CLOCK SETTING: (mm/dd/yy hh:mm)
PAPER THKNS: *STD, (n.n)MM ALIGNMENT: AUTO, MANUAL
Maintenance Mode 1: Press and hold the Pause button and turn on the Printers
HEX DUMP: PRINT EXEC (In this mode, the printer prints hexadecimal values received)
LANGUAGE: *ENGLISH, PORTUGUE, SPANISH, GERMAN, ITALIAN, FRENCH (Sets the control panel lan-
guage)
UNIT: *METER, FEET/INCH (Set’s the unit of measure that the printer displays)
4CMW72: *OFF, ON (?) CUT PRESSURE: *100% (0%-150%) (Adjusts the Paper Cutter pressure) SSCL: EXEC (Super Strong Cleaning) DEFAULT PANEL: EXEC (Returns Maintenance Mode 1 settings to Factory Default)
CRTG INFO MENU: MANUFACTURER,COLOR, INK TYPE, INK CAPACITY, INK LEFT, PRODUCTION DATE,
EXPIRATION DATE, INK LIFE, INK AGE (CSIC
information, for each ink cartridge)
Maintenance Mode 2: Press and hold the Left, Down, and Up buttons and turn on the Printer
SELF TESTING:
Test:
Version: (Displays the current firmware version) Panel: (Button tests for the control panel) Sensor: (Sensor tests for all sensors) Encoder: (Encoder tests for both encoders) Fan: (Fan tests for all fans)
Printer Component, Software Item, LCD Display, Printer Button Page 7.
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
Record: Error: Error (0 - 6) (Displays the last 7 errors)
D/A Revision: Measure Va: (nn.nnn)v (?)
CSIC: Slot (1 - 8), Maintenance Tank (?)
Actuator: Cutter: [Enter], Start (Tests the cutter assembly)
Actuator2: Cutter Sol, Pump Motor (Tests the following devices)
Adjustment:
Cut Adj.: Pressure: *73% (Adjusts voltage used for the cutter solenoid) PG ADJ: [Enter], Start: PG Offset *(nn) (Used for adjusting the platen gap) Rear AD: [Enter], Start: Exc.: RearAD: (nnn nnn nnn) (For adjusting the rear paper sensor) Edge Sns Lvl: [Enter], Start: (For adjusting the sensitivity of the edge sensor) Check Nozzle: [Enter] Print: (Service level nozzle check) Check Skew: Check Skew: (n.n)mm (Default 1.0) (Used for setting the amount of allowable skew) Clean Head: (Used for draining the ink system) Counter Clear: Reset Counter? (Resets all counters, DO NOT USE) Ink Drain: (Used for draining the ink system)
Cleaning:
Std. KK0 (Weakest cleaning cycle (uses less ink))
Std. KK1 (Medium strength cleaning cycle)
Std. KK2 (Strongest cleaning cycle)
Init. Fill (Forces a initial fill (prime))
Print:
Check Ptn.: [Enter] Print (Prints all alignment patterns) Adj. Variable: [Enter] Print (Prints the numeric adjustment variables currently set)
Parameter:
Initialize:
All: Initialize OK? (Resets all of the following counters at once)
Printer Component, Software Item, LCD Display, Printer Button Page 8.
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? (Resets this counter only) CRmot Record: Initialize OK? (Resets this counter only) PFmot Record: Initialize OK? (Resets this counter only) Lever Record: Initialize OK? (Resets this counter only) Cover Record: Initialize OK? (Resets this counter only) Ink Lever Record: Initialize OK? (Resets this counter only)
Update: InkParameter: Init. Fill: (Set, Reset) (Reset, turns off the initial fill)
MntTank: (On, Off) (Turn on or off the Maintenance Tank CSIC) Mask Type: Dispersion, Regular (?) PF BiD Adjust: (+/- n) (?) Uni-D Trap: (On, Off) (?)
Display: Address: (Used for displaying data at specific RAM addresses)
Life: CR Motor, PF Motor, CR+PF Motor, Roller, Roller Rel, D/E Chg, Hopper, ASFLoad, Cutter, Head U/D,
Head Lock, Cleaning, Print, Total Life, CR+PF+Fire, TotalLife2, TotalLife3, Check (Used for design testing
of these devices and assemblies)
Service Config
Chg DEVICE-ID: *Sty Pro 4000, PX-6000 (Used for choosing the Plug and Play printer name) NPD: *1, 0, 2 (Defines the ink type (1= pigment, 0 = new/undefined, 2 = dye)) EDMODE: *X, O,N (X=CSIC used fully, N=Non-USA Cartridges are OK, O=CSIC is disabled) MD TBL: ID = (1-7D Hex) (“Modifying parameter of media table is available”)
View Counters (Displays the usage/life counter information for the following devices/operations)
Cutter, Cutter Total, Total Pages, Maint Tank, CR Motor, CR Total, PF Motor, Nozzle A, Nozzle B, Nozzle C, Nozzle D, Nozzle E, Nozzle F, Nozzle G, FL Box, Cleaner, Sponge, ASF, Feed Roller, PG
Printer Component, Software Item, LCD Display, Printer Button Page 9.
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,
MAINT TANK, SPONGE, ASF,FEED ROLLER, PG, CR UNIT MAINT, CL UNIT MAINT, HEAD MAINT, CUT UNIT MAINT (Sponge = Boarderless Pads)
MAINT INFO: (Page 88 - 98 in the Service Manual)
Menu E: (E1 - E17), Menu R: (R1 - R9), Menu S: (S1 - S25), Menu A: (A1 - A32), Menu B: (B1 - B48),
Menu P: (P1 - P42), Menu M: (M1 - M26), Menu O: (O1 - O28), Menu F: (F1 - F28), Menu N: (N1 - N22)
INIT INFO (Resets MAINT INFO menu data)
INIT. MENU E:, INIT. MENU R:, INIT. MENU S:, INIT. MENU A:, INIT. MENU B:, INIT. MENU P:, INIT.
MENU M:, INIT. MENU O:, INIT. MENU F:, INIT. MENU N:
Maintenance Mode 3: Press and hold the Pause, Down, and Right buttons and turn on the Printer
Shipment:
ADJ.Variable: Exec (Prints out the current adjustment settings) Clean Head: Exec (Evacuates the ink in the Ink Tubes) Clean Counter: Exec (Resets counters?) Default Panel: Exec (Resets the Control Panel Settings to factory default)
Parameter Backup Mode: (Allows Parameter backup without the Printer being online)
1. Enter Maintenance Mode 2
2. Lift both (2) Ink Levers
3. Remove the Maintenance Tank
4. Move the Paper Release Lever to the released position.
: Press and hold the Left, Down, and Up buttons and turn on the Printer
Firmware Download Mode:
Hold the 4 Arrow Buttons and Power on for F/W Download Mode
Printer Component, Software Item, LCD Display, Printer Button Page 10.
Stylus Pro 4000 Field Repair Guide 4/28/05
Printer Component, Software Item, LCD Display, Printer Button Page 11.
Stylus Pro 4000 Field Repair Guide 4/28/05
Component
Replacement
Printer Component, Software Item, LCD Display, Printer Button Page 12.
Stylus Pro 4000 Field Repair Guide 4/28/05

Carriage Removal Procedure

1. 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.
5. Mark the Carriage Belt Tension Gauge, loosen, and remove the Belt.
Mark Belt Tension Gauge
Carriage Removal Procedure Printer Component, Software Item, LCD Display, Printer Button Page 13.
Loosen Belt tension
Remove Belt from the Carriage Motor
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.
1.75” wide
.5” wide, and1/4” deep V slot
5” long
2. Place the jig so that the V slots support the Car-
riage Rail Covers
Note:The jig should be placed
so that it supports the
Carriage Rail Covers beside to the Print Head, when it is in the
removal position (see step 8).
Carriage Removal Procedure Printer Component, Software Item, LCD Display, Printer Button Page 14.
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 Strip
Carriage Removal Procedure Printer Component, Software Item, LCD Display, Printer Button Page 15.
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 Cam is fully seated in the Interlocks.
Cartridge Release Lever Repair Printer Component, Software Item, LCD Display, Printer Button Page 16.
Spring position
3 Gear positions to check.
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, LCD Display, Printer Button Page 17.
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.
Slot
3 Screws
Lift off
Damper Removal Printer Component, Software Item, LCD Display, Printer Button Page 18.
Stylus Pro 4000 Field Repair Guide 4/28/05
4. Disconnect 4 Cables, remove 1 Screw, and remove the Junction Board
1. Disconnect 4 Cables.
2. Remove 1 Screw.
5. Remove 4 Screws, 1 Stay Bar, and 1 Spring.
1 Spring
4 Screws
3. Remove the Junction Board.
1 Stay Bar
Damper Removal Printer Component, Software Item, LCD Display, Printer Button Page 19.
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.
7. Remove the Stay Bar that fastens the Dampers to the Assembly.
Remove the Stay Bar.
Damper Removal Printer Component, Software Item, LCD Display, Printer Button Page 20.
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.
Stylus Pro 4000 Field Repair Guide 4/28/05
10. Disconnect the Print Head from the Damper Assembly.
1. Disconnect the Print Head from the Damper Assembly.
2. Hold the Damper Assembly like this so that ink does not leak.
3. Place the Print Head off to the side as shown.
11. Release the Interlock that corresponds to the Damper(s) to be replaced, and lift out the Damper(s)
Damper Interlock
Damper Removal Printer Component, Software Item, LCD Display, Printer Button Page 22.
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.
14. Reconnect the Print Head to the Damper Assembly.
Connect the Print Head and fasten with 3 Screws.
Damper Removal Printer Component, Software Item, LCD Display, Printer Button Page 23.
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 Spring
4 Screws
Damper Removal Printer Component, Software Item, LCD Display, Printer Button Page 24.
1 Stay Bar
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.
19. Perform the Print Head mechanical adjustments.
19.1 Perform the Print Head Slant Adjustment (CR)
19.2 Perform the Print Head Slant Adjustment (PF)
Damper Removal Printer Component, Software Item, LCD Display, Printer Button Page 25.
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.
Remove 4 Screws
Remove 5 Screws
(View from the back) Remove 1 Screw
3. Remove 2 Screws fastening the Front Panel.
Remove 2 Screws
Ink Bay Removal (Left) Printer Component, Software Item, LCD Display, Printer Button Page 26.
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
Remove 4 Screws
Cartridge Release Handle
Lift off the Cover.
Screw
Ink Bay Removal (Left) Printer Component, Software Item, LCD Display, Printer Button Page 27.
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
Ink Bay Removal (Left) Printer Component, Software Item, LCD Display, Printer Button Page 28.
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
Look through this area,
Remove 2 Screws
on the back of the Printer, to find 2 Screws
9. Disconnect the 4 Foil CSIC Cables and the Cartridge Release Sensor Cable.
Cartridge Release Sensor Cable
4 CSIC Cables
Re-assembly Note: Cable Order
Yellow-Magenta-Cyan-Matte Black
Ink Bay Removal (Left) Printer Component, Software Item, LCD Display, Printer Button Page 29.
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 30.
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