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STYLUS PRO 4000
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Table of contents
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Epson Stylus Pro 4000 Service Manual and Field Repair Guide

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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.
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.
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 (Right) Printer Component, Software Item, LCD Display, Printer Button Page 31.
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 4 Screws
Ink Bay Removal (Right) Printer Component, Software Item, LCD Display, Printer Button Page 32.
Remove 1 Screw
Lift off the Cover.
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 the left Side
7. Remove 2 Screws from the front.
1 Screw on the right Side.
2 Screws from the front
Ink Bay Removal (Right) Printer Component, Software Item, LCD Display, Printer Button Page 33.
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.
Cartridge Release Sensor Cable
Ink Bay Removal (Right) Printer Component, Software Item, LCD Display, Printer Button Page 34.
4 CSIC Cables
Re-assembly Note: Cable Order
Top to Bottom Black, Light Cyan, Light Magenta, Light Black
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 35.
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.
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
3. Remove the 2 E-Rings shown below
Remove the E-Ring
Slide off the Cover
Remove the E-Ring
Input Roller Assembly, Disassembly Printer Component, Software Item, LCD Display, Printer Button Page 37.
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.
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.
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.
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.
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.
These two pieces must be pressed tightly together to allow the Paper Separation Assembly too fully compress the Springs.
Input Roller Assembly, Re-assembly Printer Component, Software Item, LCD Display, Printer Button Page 42.
Stylus Pro 4000 Field Repair Guide 4/28/05
5. Study the polarity, and order of the parts below.
Paddles positioned, so that the arrow on the side faces up
The Disks have depressions, that fit the Springs.
Home Position Window faces the oppo­site direction from the flat side of the Roller.
The Right and Left Rollers are different. Pay attention to the position of the Slots.
6. Install the Roller Assembly components into the Base Assembly, following the directions above.
Paddle on the out­side of the Frame.
Paddle on the inside of the Frame.
Cover marked with R
Input Roller Assembly, Re-assembly Printer Component, Software Item, LCD Display, Printer Button Page 43.
Cover marked with L
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.
8. Re-attach the Roller Covers, 3 E-rings, and Gear.
1 E-Ring between the Roller Assembly and the Frame.
1 E-Ring fastening this Gear.
Gear
2 Roller Covers E-Ring
Input Roller Assembly, Re-assembly Printer Component, Software Item, LCD Display, Printer Button Page 44.
Stylus Pro 4000 Field Repair Guide 4/28/05
9. Test the Roller Assembly before installation
Place a piece of paper in the Tray.
Input Roller Assembly, Re-assembly Printer Component, Software Item, LCD Display, Printer Button Page 45.
Rotate the Gear and check for proper operation
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
the Valves
the Valves
4. Remove the Rear Paper Guide Support and the Paper Jam Cover.
Rear Paper Guide Sup­port (directions at step 5)
Remove the Paper Jam Cover (shown removed)
Input Roller Assembly Removal Printer Component, Software Item, LCD Display, Printer Button Page 46.
Stylus Pro 4000 Field Repair Guide 4/28/05
5.
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.
5. Remove the Sensor from the Rear Paper Guide Sup- port
Input Roller Assembly Removal Printer Component, Software Item, LCD Display, Printer Button Page 47.
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.
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.
Back side of the
Waste Ink Tank Slot
3 Screws
Loosen this Screw.
Input Roller Assembly Removal Printer Component, Software Item, LCD Display, Printer Button Page 49.
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.
Left side of the Printer
Input Roller Home Position Sensor
Input Roller Assembly Removal Printer Component, Software Item, LCD Display, Printer Button Page 50.
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.
Push the 2 Grey Tabs and pull out the Cover
4. Remove the 6 Screws fastening the Main Board Housing.
3 Screws
Main Board Replacement Printer Component, Software Item, LCD Display, Printer Button Page 51.
3 Screws
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 Foil Cable corre­sponds to the Con-
nector number
nector Releases, to
release these 3
Cables
Pull up on the Con­nector Release, to release this Cable
Main Board Replacement Printer Component, Software Item, LCD Display, Printer Button Page 52.
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.
5 Screws
4 Screws
Main Board Replacement Printer Component, Software Item, LCD Display, Printer Button Page 53.
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.
12. Connect the Cables to the Board. Ensure that the Cables are fully seated (straight).
Lift the Release Mechanisms on these 4 Connectors
Hold the Cable firmly in place, while locking the Release Mechanism.
Main Board Replacement Printer Component, Software Item, LCD Display, Printer Button Page 54.
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.
Tilt the Board Assembly, while inserting, so that the leading edge drops on to the Printer
Fasten with 6 Screws
Mechanism’s Board Support Ledge.
Main Board Replacement Printer Component, Software Item, LCD Display, Printer Button Page 55.
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, Down, and Right arrow buttons, The Printer will display
UPDATE F/W.
15.3 Send the current firmware to the Printer.
16. Re-Install the Printer’s parameters using the Parameter Backup / Restore Utility (Nvram.exe)
16.1 Perform the RTC&USBID&IEEE1394ID Adjustment.
If the Printer’s Parameters are not available skip step 16, and follow step 17.
17. Perform the following operations in the order listed.
17.1 Stop the Printer from priming (See The Prime ON / Off chapter).
17.1.1 Note: Init.Fill: Reset = The Printer ‘s prime function is turned off.
17.2 Perform the Rear Sensor AD Adjustment.
17.3 Perform the Cutter Pressure adjustment.
17.4 Perform the Platen Gap adjustment.
17.5 Enter the Head Rank ID (Print Head calibration values).
17.6 Perform the Multi Sensor Level Adjustment.
17.7 Perform the Print Head Slant (CR) Adjustment.
17.8 Perform the Print Head Slant (PF) Adjustment.
17.9 Perform the Multi Sensor Adjustment for Auto Nozzle Check.
17.10Perform the Nozzle Bi-D Adjustment.
17.11Perform the Auto Bi-D Adjustment.
17.11.1Copy Bi-D variables
17.12Perform the Auto Uni-D Adjustment.
Main Board Replacement Printer Component, Software Item, LCD Display, Printer Button Page 56.
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.
17.17Perform the T&B&S (Cut Sheet) Adjustment.
17.18Perform the RTC&USBID&IEEE1394ID Adjustment.
Main Board Replacement Printer Component, Software Item, LCD Display, Printer Button Page 57.
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.
Remove 4 Screws
Remove 5 Screws
(View from the back) Remove 1 Screw
3. Remove 2 Screws fastening the Front Panel.
Remove 2 Screws
Paper Exit Roller Removal Printer Component, Software Item, LCD Display, Printer Button Page 58.
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.
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
Long end
Gold Spring side, on the top
Short end
Silver Spring side, on the bottom
Paper Exit Roller Removal Printer Component, Software Item, LCD Display, Printer Button Page 60.
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.
1. Remove the Left Side Cover.
2. Remove the Right Side Cover.
3. Remove the Paper Release Lever Assembly Cover.
1. Remove 1 Screw.
2. Remove the Cover.
Plastic Roller Upgrade Printer Component, Software Item, LCD Display, Printer Button Page 61.
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.
Plastic Roller Upgrade Printer Component, Software Item, LCD Display, Printer Button Page 62.
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.
Rear Paper Guide Sup­port (directions at step 8)
Remove the Paper Jam Cover (shown removed)
Plastic Roller Upgrade Printer Component, Software Item, LCD Display, Printer Button Page 63.
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 that holds the Manual
Feed Sensor to the Support.
5. Remove the Sensor from the Rear Paper Guide Sup- port
Plastic Roller Upgrade Printer Component, Software Item, LCD Display, Printer Button Page 64.
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.
2. Remove the Gear.
Plastic Roller Upgrade Printer Component, Software Item, LCD Display, Printer Button Page 65.
Stylus Pro 4000 Field Repair Guide 4/28/05
11. Remove the Gear shown below.
To r e m o ve t h i s Gear, follow the 4 steps listed below.
1. Note the Gears’ orientation to this Rubber Stopper.
2. Note the Interlock on the back side of the Gear.
Plastic Roller Upgrade Printer Component, Software Item, LCD Display, Printer Button Page 66.
3. Rotate the Gear so that the Interlock is in this position.
4. Remove the Gear.
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
Plastic Roller Upgrade Printer Component, Software Item, LCD Display, Printer Button Page 67.
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 Printer Component, Software Item, LCD Display, Printer Button Page 68.
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, and goes next to this Support.
Note the way that the Shaft is behind some Supports, and under others.
These are the Rollers to be replaced.
17. Remove the 3 Paper Guide Assemblies, and install the new Rollers.
The Shaft ends here, and goes next to this Support.
The Hook on the Springs goes to the right.
Old Rollers
Plastic Roller Upgrade Printer Component, Software Item, LCD Display, Printer Button Page 69.
New Rollers.
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.
6. Spring in the Notch.
Plastic Roller Upgrade Printer Component, Software Item, LCD Display, Printer Button Page 70.
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 71.
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 open­ing on this end.
Plastic Roller Upgrade Printer Component, Software Item, LCD Display, Printer Button Page 72.
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
Square Hole on this side.
Notches against the White Guides.
Plastic Roller Upgrade Printer Component, Software Item, LCD Display, Printer Button Page 73.
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.
Plastic Roller Upgrade Printer Component, Software Item, LCD Display, Printer Button Page 74.
Stylus Pro 4000 Field Repair Guide 4/28/05
28. Install the Roller Assembly.
1. Insert the Left Side first.
3. Install 2 Screws.
2. Insert the Right Side second.
Plastic Roller Upgrade Printer Component, Software Item, LCD Display, Printer Button Page 75.
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, Software Item, LCD Display, Printer Button Page 76.
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.
1. Hold in place on the back side of the Guide.
2. Route the Wire through the Fas- teners.
3. Fasten with 1 Screw.
Plastic Roller Upgrade Printer Component, Software Item, LCD Display, Printer Button Page 77.
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.
1 Small Head Screw.
2 Big Head Screws.
Plastic Roller Upgrade Printer Component, Software Item, LCD Display, Printer Button Page 78.
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.
Plastic Roller Upgrade Printer Component, Software Item, LCD Display, Printer Button Page 79.
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.
2. Unplug the Printer.
3. Raise both Ink Levers, closing the Ink Valves.
4. Remove the Left Side Cover.
5. Release the Carriage Lock, and move the Carriage Mechanism away from the capped position.
6. Mark the Carriage Belt Tension Gauge, loosen, and remove the Belt.
Mark Belt Tension Gauge
Print Head Replacement Procedure Printer Component, Software Item, LCD Display, Printer Button Page 80.
Loosen Belt Tension
Remove Belt from the Carriage Motor
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.
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).
Print Head Replacement Procedure Printer Component, Software Item, LCD Display, Printer Button Page 81.
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. Turn over the Carriage Mechanism, and support it with one hand (ensure that the Nozzles and
the Carriage Encoder are not damaged).
Remove 3 Screws
Print Head Replacement Procedure Printer Component, Software Item, LCD Display, Printer Button Page 82.
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.
Print Head Replacement Procedure Printer Component, Software Item, LCD Display, Printer Button Page 83.
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).
14. Attach the Print Head to the Head Case.
15. Attach the Head Case to the Carriage Mechanism.
16. Re-install the Carriage Mechanism.
16.1 Ensure that the Timing Strip is routed through the Sensor.
16.2 Use the Carriage Rail Cover protection jig.
17. Place the Carriage Belt on the Carriage Motor Pulley.
18. Tighten the Carriage Belt until the Gauge reaches the mark that represents the proper tension.
Print Head Replacement Procedure Printer Component, Software Item, LCD Display, Printer Button Page 84.
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.
22. Defeat the Cover Sensor, and turn on the Printer.
23. Turn on the Printer, and let it come Ready.
24. Press the Menu button and navigate to Maintenance.
25. Press the Menu button and navigate PWR CLEANING.
26. Press the Menu button to execute.
27. Print a Nozzle Check Pattern (Perform standard cleanings if necessary).
28. Perform the following adjustments in sequence.
Print Head Replacement Procedure Printer Component, Software Item, LCD Display, Printer Button Page 85.
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.
28.5 Perform the Nozzle Bi-D Adjustment
28.6 Perform the Auto Bi-D Adjustment
28.7 Perform Copy Bi-D variables
28.8 Perform the Auto Uni-D Adjustment
28.9 Perform Copy Uni-D variables
Print Head Replacement Procedure Printer Component, Software Item, LCD Display, Printer Button Page 86.
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.
The Plastic Tray that sits under the Pump, and that the Tubes are inserted into, has one corner that sits on top of the Pump / Cap Assembly Frame.
View from the bottom. Note the
Plastic Tray is on top of the Frame Mount.
View from the back of the Printer. The Plastic is on top of the Frame.
Pump and Cap Installation Printer Component, Software Item, LCD Display, Printer Button Page 87.
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 Assembly, part of the way in
Feed the Tubes into the receptacle
Assist the Tubes fully into the receptacle, while sliding in the Assembly.
4. Install the 4 Screws securing the Cap and Pump Assembly. Ensure that the Assembly is
correctly seated to avoid carriage errors.
2 Screws
Ensure that the Flushing Box Screw Hole is correctly
aligned before tightening the
Assembly screws.
2 Screws
Pump and Cap Installation Printer Component, Software Item, LCD Display, Printer Button Page 88.
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 Printer Component, Software Item, LCD Display, Printer Button Page 89.
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
Shaft Assembly.
2 Screws
8. Install the Platen Gap Motor, and fasten with 2 Screws.
Install the Motor
2 Screws
Pump and Cap Installation Printer Component, Software Item, LCD Display, Printer Button Page 90.
Stylus Pro 4000 Field Repair Guide 4/28/05
9. Install the Trigger Shaft.
Insert Trigger Shaft into the
Right Side Frame
Flex the Trigger Shaft from the back side of the Printer, until the end of the Shaft can be inserted into the Socket
Insert Into Socket here
Pump and Cap Installation Printer Component, Software Item, LCD Display, Printer Button Page 91.
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).
Pump and Cap Installation Printer Component, Software Item, LCD Display, Printer Button Page 92.
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
Trigger Spring
Pump and Cap Removal Printer Component, Software Item, LCD Display, Printer Button Page 93.
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 Socket
Slide out the Trigger Shaft
5. Remove 4 Screws securing the Cap and Pump Assembly.
2 Screws
2 Screws
Pump and Cap Removal Printer Component, Software Item, LCD Display, Printer Button Page 94.
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.
2 Screws
8. Slide the Cap and Pump Assembly to the right, to separate the Assembly from the Gear.
Separate the Assembly from the Gear
Slide the Cap and Pump Assembly this way.
Pump and Cap Removal Printer Component, Software Item, LCD Display, Printer Button Page 95.
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. Slide the Cap and Pump Assembly out the back of the Printer.
Remove from the back of the Printer
Slide the Assembly to the back
Pump and Cap Removal Printer Component, Software Item, LCD Display, Printer Button Page 96.
Stylus Pro 4000 Field Repair Guide 4/28/05
Cap and Pump Assembly Components.
Cap
Wiper Blade
Pump
Pump and Cap Removal Printer Component, Software Item, LCD Display, Printer Button Page 97.
Stylus Pro 4000 Field Repair Guide 4/28/05

Side Cover Removal (Left)

Remove Screw
Remove 2 Screws
Side Cover Removal (Left) Printer Component, Software Item, LCD Display, Printer Button Page 98.
Remove Screw
The Left Side Cover will slide off
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.
Stylus Pro 4000 Field Repair Guide 4/28/05
Remove Waste Ink Tank
Remove 2
Screws
The Right Side Cover will slide off.
Remove Screw
Remove 2 Screws and slide off Lever
Side Cover Removal (Right) Printer Component, Software Item, LCD Display, Printer Button Page 100.
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