Epson WP-M4595, WF-4525, WF-4521, WF-4095, WF-4015 Service Manual

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SERVICE MANUAL

Mono Inkjet Printer

Epson WP-M4525/4521

Epson WP-M4595

Epson WP-M4015/4011

Epson WP-M4095

CONFIDENTIAL

SEMF12-009

Notice:

by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SEIKO EPSON CORPORATION.

 All effort have been made to ensure the accuracy of the contents of this manual. However, should any errors be

detected, SEIKO EPSON would greatly appreciate being informed of them.

 The contents of this manual are subject to change without notice.  The above not withstanding SEIKO EPSON CORPORATION can assume no responsibility for any errors in this

manual or the consequences thereof.

EPSON is a registered trademark of SEIKO EPSON CORPORATION.

Note :Other product names used herein are for identification purpose only and may be trademarks or r egistered

trademarks of their respective owners. EPSON disclaims any and all rights in those marks.

Printer CS Quality Assurance Department

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Safety Precautions

All safety procedures described here shall be strictly adhered to by all parties servicing and maintaining this product.

DANGER

Strictly observe the following cautions. Failure to comply could result in serious bodily injury or loss of life.

1. Always disconnect the product from the power source and peripheral devices when servicing the product or performing maintenance.

2. When performing works described in this manual, do not connect to a power source until instructed to do so. Connecting to a power source causes high voltage in the power supply unit and some electronic components even if the product power switch is off. If you need to perform the work with the power cable connected to a power source, use extreme caution to avoid electrical shock.

WARNING

Strictly observe the following cautions. Failure to comply may lead to personal injury or loss of life.

1. Always wear protective goggles for disassembly and reassembly to protect your eyes from ink in working. If any ink gets in your eyes, wash your eyes with clean water and consult a doctor immediately.

2. When using compressed air products; such as air duster, fo r cleaning during repair and maintenance, the use of such products containing flammable gas is prohibited.

PRECAUTIONS

Strictly observe the following cautions. Failure to comply may lead to personal injury or damage of the product.

1. Repairs on Epson product should be performed only by an Epson certified repair technician.

2. No work should be performed on this product by persons unfamiliar with basic safety knowledge required for electrician.

3. The power rating of this product is indicated on the serial number/rating plate. Never connect this product to the power source whose voltages is different from the rated voltage.

4. Replace malfunctioning components only with those components provided or approved by Epson; introduction of second-source ICs or other non-approved components may damage the product and void any applicable Epson warranty.

5. The capacitors on he Main Board may be electrically charged right after the power turns off or after driving motors which generates counter electromotive force such as when rotating the PF Roller or when moving the CR Unit. There is a risk to damage the Main Board if the Head FFC is short-circuited with the capacitors on the Main Board electrically charged, therefore, after the power turns off or after motors are driven, leave the printer untouched for approximately 30 seconds to discharge the capacitors before starting disassembly / reassembly.

6. To prevent the circuit boards from short-circuiting, be careful about the following when handling FFC or cables.



When handling FFC, take care not to let the terminal section of FFC touch metal parts.

 When connecting cables/FFC to the connectors on circuit boards, connect them straight to the connectors to avoid

slant insertion.

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7. In order to protect sensitive microprocessors and circuitry, use static discharge equipment, such as anti-static wrist straps, when accessing internal components.

8. Do not tilt this product immediately after initial ink charge, especially after performing the ink charge several times. Doing so may cause ink to leak from the product because it may take some time for the waste ink pads to completely absorb ink wasted due to the ink charge.

9. Never touch the ink or wasted ink with bare hands. If ink comes into contact with your skin, wash it off with soap and water immediately. If you have a skin irritation, consult a doctor immediately.

10. When disassembling or assembling this product, make sure to wear gloves to avoid injuries from metal parts with sharp edges.

11. Use only recommended tools for disassembling, assembling or adjusting the printer.

12. Observe the specified torque when tightening screws.

13. Be extremely careful not to scratch or contaminate the following parts.

Nozzle plate of the printhead

  CR Scale  PF Scale  ASF Scale  Coated surface of the PF Roller  Gears  Rollers  LCD  Scanner Sensor  Exterior parts

14. Never use oil or grease other than those specified in this manual. Use of different types of oil or grease may damage the component or give bad influence on the printer function.

15. Apply the specified amount of grease described in this manua l .

16. Make the specified adjustments when you disassemble the printer.

17. When cleaning this product, follow the procedure described in this manual.

18. When transporting this product after filling the ink in the printhead, pack the printer without removing the ink cartridges in order to prevent the printhead from drying out.

19. Make sure to install antivirus software in the computers used for the service support activities.

20. Keep the virus pattern file of antivirus software up-to-date.

21. When disassembling/reassembling this product, if you find adhesive power of the double-sided tape which secure the parts or FFC is not enough, replace the tape with new one and attach it correctly to the specified points where the parts or FFC should be secured.

22. Unless otherwise specified in this manual, the labels attached on the returned product should be transferred to the corresponding attachment positions on the new one referring to the labels on the returned product.

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About This Manual

This manual, consists of the following chapters, is intended for repair service personnel and includes information necessary for properly performing maintenance and servicing the product.

CHAPTER 1. PRODUCT DESCRIPTIONS

Provides a general overview and specifications of the product.

CHAPTER 2. OPERATING PRINCIPLES

Describes the theory of mechanical operations of the product.

CHAPTER 3. TROUBLESHOOTING

Describes the step-by-step procedures for the troubleshooting.

CHAPTER 4. DISASSEMBLY / REASSEMBLY

Describes the disassembly/reassembly procedures for main parts/units of the product.

CHAPTER 5. ADJUSTMENT

Describes the required adjustments for servicing the product.

CHAPTER 6. MAINTENANCE

Describes maintenance items and procedures for servicing the product.

Symbols Used in this Manual

Various symbols are used throughout this manual either to provide additional information on a specific topic or to warn of possible danger present during a procedure or an action. Pay attention to all symbols when they are used, and always read explanation thoroughly and follow the instructions.

Indicates an operating or maintenance procedure, practice or condition that, if not strictly observed, could result in serious injury or loss of life.

Indicates an operating or maintenance procedure, practice, or condition that, if not strictly observed, could result in bodily injury, damage or malfunction of equipment.

May indicate an operating or maintenance procedure, practice or condition that is necessary to accomplish a task efficiently. It may also provide additional information that is related to a specific subject, or comment on the results achieved through a previous action.

For Chapter 4 “Disassembly/Reassembly”, symbols other than indicated above are used to show additional information for disassembly/reassembly. For the details on those symbols, see "4.2 Disassembly/Reassembly

Procedures (p54)".

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Revision Status

Revision Date of Issue Description

A July 25, 2012 First Release

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Epson WP-M4595/4525/4521/4095/4015/4011 Revision A

Contents

Chapter 1 Product description

1.1 Features ................................................................................................................................................................... 10

1.2 Printing Specifications ............................................................................................................................................ 12

1.2.1 Basic Specifications........................................................................................................................................ 12

1.3 Scanner Specifications (WP-M4595/4525/4521 only)............................................................................................ 13

1.3.1 Basic Specifications........................................................................................................................................ 13

1.4 Control Panel........................................................................................................................................................... 14

1.4.1 O peration Buttons & LEDs ............................................................................................................................ 14

1.4.2 LEDs and LCD Indications ............................................................................................................................ 16

1.5 Various Settings ............................................................................................................ .......................................... 21

1.5.1 Panel Operation .............................................................................................................................................. 21

1.5.1.1 Setup Menu Configuration (WP-M4595/4525/4521 only).................................................................... 21

1.5.1.2 Panel Operation Lock Setting (WP-M4595/4525/4521 only) ............................................................... 22

1.5.1.3 Forced Power OFF................................................................................................................................. 23

1.5.1.4 Printer Status Sheet................................................................................................................................ 23

Chapter 2 Operating Principles

2.1 O verview ................................................................................................................................................................. 25

2.2 Printhead.................................................................................................................................................................. 25

2.3 Motors and Sensors ................................................................................................................................................ 26

2.4 Optical Sensor Control........................... ......................................................................... ........................................ 29

2.5 Ink Supply Mechanism............................................................................................................................................ 30

2.6 Ink System Mechanism ........................................................................................................................................... 31

2.7 Power-On Sequence ................................................................................................................................................ 32

Chapter 3 Troubleshooting

3.1 Troubleshooting....................................................................................................................................................... 40

3.1.1 Fatal Error Code ............................................................................................................................................. 42

3.1.2 FAX Troubleshooting (WP-M4595/4525/4521 only).................................................................................... 45

3.1.2.1 FAX Log ................................................................................................................................................ 45

3.1.2.2 Error Code/Superficial Phenomenon-Based Troubleshooting .............................................................. 50

Chapter 4 Disassembly/Reassembly

4.1 O verview ................................................................................................................................................................. 53

4.1.1 Tools ............................................................................................................................................................... 53

4.1.2 Jigs .................................................................................................................................................................. 53

4.2 D isassembly/Reassembly Procedures ..................................................................................................................... 54

4.2.1 Caution when Replacing the Printhead/Ink Supply Unit................................................................................ 54

4.2.2 Parts/Units Need to be Removed in Advance ................................................................................................ 55

4.2.3 Disassembly Flowchart................................................................................................................................... 56

4.2.3.1 Parts/Units whose Configuration is Different between Models in the Flowchart ................................. 56

4.2.3.2 Exterior Parts ......................................................................................................................................... 58

4.2.3.3 Printer Mechanism.................................... ..................................... ........................................................ 60

4.2.3.4 Printhead/Ink Supply Unit ..................................................................................................................... 62

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Epson WP-M4595/4525/4521/4095/4015/4011 Revision A

4.2.3.5 2nd Cassette Unit ................................................................................................................................... 63

4.3 Detailed Disassembly/Reassembly Procedure for each Part/Unit........................................................................... 64

4.4 Routing FFCs/cables ............................................................................................................................................... 72

4.5 Connector Summary................................................................................................................................................ 76

Chapter 5 Adjustment

5.1 Required Adjustments ............................................................................................................................................. 78

5.2 D etails of Adjustments ............................................................................................................................................ 83

5.2.1 PF Timing Belt Tension Check ...................................................................................................................... 83

5.2.2 Rear ASF Timing Belt Tension Check........................................................................................................... 84

5.2.3 PG Adjustment ............................................................................................................................................... 85

5.2.4 Checking the Platen Gap ................................................................................................................................ 91

5.2.5 MAC Address Setting............................................................................... ...................................................... 92

5.2.6 Ink Leak Check............................................................................................................................................... 93

Chapter 6 Maintenance

6.1 O verview ................................................................................................................................................................. 97

6.1.1 Cleaning.......................................................................................................................................................... 97

6.1.2 Lubrication...................................................................................................................................................... 97

6.2 Lubrication Points and Instructions......................................................................................... ................................ 98

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CHAPTER 1

PRODUCT DESCRIPTION

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Epson WP-M4595/4525/4521/4095/4015/4011 Revision A

1.1 Features

In this manual, the product name is abbreviated to such as “WP-4510 series”, however, the last digit of the actual name may differ. Identify your product with the first three digits and refer to the appropriate sections in this manual.

WP-M4595/4525/4521/4095/4015/4011 are mono inkjet printers made based on WP-4540/4530/4520/4510/ 4020/4010 series. The main features are as follows.

 Common futures

 Printer

• Maximum print speed: 16 ppm (A4, monochrome, draft printing mode)

• F7-Mach Turbo 2 Printhea d (Black: 152 nozzles x 4, Color: 152 nozzles x 1 per color)

• Maximum print resolution: 4800 x 1200 dpi

• Duplex printing available using the Duplex Unit that can be removed/installed by users

• Equipped with a panel operation lock function that improves security

• Auto switching for paper trays

The paper tray to use is automatically selected from the 1st cassette, 2nd cassette* or the Rear MP Tray (rear ASF) depending on the paper size

• Four newly developed independent ink cartridges are installed (pigment inks)

• Borderless printing is not available

 Consumables

• Maintenance box (the user can replace the waste ink pad when maintenance error occurs)

Note"*": When the optional 2nd cassette is installed for WP-M4595/4525/4521/4095/4015/4011.

 Differences between the models

WP-M4595/4525/4521/4095/4015/4011 are different as shown below.

Table 1-1. Differences between the Models

Item WP-M4595

LCD display size 2.5 inch 2.5 inch --- --Panel operation Button Button Button Button Scanner Yes Yes --- --ADF Yes Yes --- --Copy Yes Yes --- --USB host Yes Yes --- --FAX Yes Yes --- --Wi-Fi --- --- --- --Ethernet Yes Yes Yes Yes PCL Yes --- Yes --2nd cassette Option Option Option Option

WP-M4525/

4521

WP-M4095

WP-M4015/

4011

Product description Features 10

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Epson WP-M4595/4525/4521/4095/4015/4011 Revision A

WP-M4595/4525/4521

WP-M4095/4015/4011

Figure 1-1. External View

Table 1-2. Dimensions

Model Dimensions (W x D x H)

Weight

WP-M4595/4525/4521 460.0mm x 419.5mm x 340.9mm 13.77 kg WP-M4095/4015/4011 460.0 mm x 419.5 mm x 28.32 mm 10.87 kg

Note *1: Paper support for rear ASF and stacker are closed. Rubber feet are included.

*2: Excluding the weight of ink cartridges and power cable.

Product description Features 11

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Epson WP-M4595/4525/4521/4095/4015/4011 Revision A

1.2 Printing Specifications

1.2.1 Basic Specifications

Table 1-3. Printer Specifications

Item Specification

Print method On-demand ink jet Nozzle configuration Black: 608 nozzles (152 nozzles x 4)

Color: 456 nozzles (152 nozzles x 1 per color) Color Black only Print direction Bi-directional minimum distance printing, Unidirectional printing Print resolution H oriz ontal x Vertical (dpi)

• 300 x 300

• 600 x 600

• 1200 x 600

Control code • ESC/P Raster command

• ESC/P-R (RGB) command

Input buffer size 132 KBytes Paper feed method Friction feed Paper feed amount

• 1st cassette: 250 pages (plain paper), 30 pages (Legal)

• 2nd cassette

• Rear MP Tray (rear ASF): 80 pages (plain paper)

: 250 pages (plain paper)

• 600 x 300

• 600 x 1200

• 4800 x 1200

Paper path • Front feed, front out

• Rear feed, front out

PF interval 0.01693 mm (1/1500 inch)

Note *1: For paper thickness: 0.10 mm, 75 g/m

*2: When the optional 2nd cassette is installed for WP-M4595/4525/4521.

Product description Printing Specifications 12

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Epson WP-M4595/4525/4521/4095/4015/4011 Revision A

1.3 Scanner Specifications (WP-M4595/4525/4521 only)

1.3.1 Basic Specifications

Table 1-4. Basic Specifications

Item Specification

Scanner type Flatbed, color Scanning method Moving carriage, stationary document Home position The rear left corner Photoelectric device CIS Light source LED Maximum document sizes A4 or US Letter Scanning range 8.5” x 11.7” (216 mm x 297 mm) Maximum resolution Main scan: 1,200 dpi

Sub scan: 2,400 dpi Maximum effective pixels 10,200 x 14,040 pixels (1200 dpi) Pixel depth Color 48 bit per pixel (input) and 24 bit per pixel (output)

Monochrome 16 bit per pixel (input) and 1 bit or 8 bit per pixel (output)

Table 1-5. ADF Speci fications (WP-4540/4530/4520 series only)

Item Specification

Document loading Face-up Maximum document sizes A4, US Letter or Legal Supported paper type Plain paper only Paper thickness 64 to 95 g/m Maximum number of documents which can be set 30 sheets or 3 mm at maximum (A4, US Letter) / 10 sheets (Legal) Document path Feeds from upper tray and ejects to lower tray Document set position Rear

Product description Scanner Specifications (WP-M4595/4525/4521 only) 13

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Epson WP-M4595/4525/4521/4095/4015/4011 Revision A

LCD

1.4 Control Panel

1.4.1 Operation Buttons & LEDs

The operation buttons,LEDs, and LCD are shown below. See Table 1-6 and Table o for the functions.  WP-M4595/4525/4521

Figure 1-2. Control Panel(WP-M4595/4525/4521)

Table 1-6. Operation Buttons, LEDs and LCD (WP-M4595/4525/4521)

Item Icon Name Function

LCD Indicates the printer status, error, and menu screen. Button/

touch panel

Power Turns the power on/off. Copy Enters copy mode. Scan Enters scan mode. Fax Enters fax mode. Auto Answer Turns on/off auto answer mode.

Redial/Pause

• Displays the last number dialed.

• Inserts a pause symbol (-) when entering numbers in fax mode.

LED

Speed Dial Displays speed dial/group dial list in fax mode. Setup Enters setup mode. Help Displays help for solutions to problems.

Arrows

Shows next or previous menus.

• Selects menus.

Arrows

• Specifies the number of copies.

• Moves the cursor in fax mode.

OK Activates the setting you have selected. Menu Displays detailed settings for each mode. Back Cancels/returns to the previous menu.

• Specifies the date/time

Ten key

• Specifies the number of copies

• Specifies fax numbers

Stop/Reset Stops printing/copying/scanning/faxing or resets the setting.

(

Start (B&W) Starts copying/scanning/faxing in black and white.

(

Start (Color) Starts copying/scanning/faxing in color.

Power

• Lights when the printer is on.

• Flashes when the printer is in process.

Error On when error has occurred. Network Indicates the network connection status. Auto Answer On when the fax is in auto answer mode.

Note : See "1.4.2 LEDs and LCD Indications (p16)" for more details about the LCD.

Product description Control Panel 14

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Epson WP-M4595/4525/4521/4095/4015/4011 Revision A

 WP-M4095/4015/4011

Figure 1-3. Control Panel (WP-M4095/4015/4011)

Table 1-7. Operation Buttons, LEDs (WP-M4095/4015/4011)

Item Icon Name Function

Button Power Turns the power on/off.

Network status sheet Prints a network status sheet.

• Loads or ejects paper.

• Resumes printing after a paper out error, multiple page feed error.

• Lights when the printer is on.

• Flashes when the printer is in process.

LED

Paper feed/eject

Head cleaning (monochrome) Starts head cleaning (black only). Printer Status sheet Prints a printer status sheet. Cancel Cancels printing during a print job.

Power

Network Indicates the network connection status. Maintenance box Indicates error status for maintenance box. Paper Indicates error status for paper.

Ink

Note : See "1.4.2 LEDs and LCD Indications (p16)" for more details about the LEDs.

Indicates error status for ink.

Product description Control Panel 15

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1.4.2 LEDs and LCD Indications

Table 1-8. LEDs and LCD Indications

WP-M4095/4015/4011 WP-M4595/4525/4521

Status

O p

PCL Recovery error

e r a t i n g

Printer fatal error

Scanner fatal error

ADF fatal error

Fax error

Maintenance box full Flash

Maintenance box CSIC error

No maintenance box error

Paper jam error

Paper jam error (front cover open)

Paper out error Flash

LED Status

Power Ethernet

Flash at

high

speed

Flash at

high

speed

Flash at

high

speed

Flash at

high

speed

Mainten

ance

Flash at

high

speed

Flash at

high

speed

paper Ink 1 Ink 2 Ink 3 Ink 4

Flash at

high

speed

Flash at

high

speed

Flash at

high

speed

Flash at

high

speed

Flash at

high

speed

Flash at

high

speed

Flash at

high

speed

Flash at

high

speed

--- --- --- --- --- --- --- ---

---- --- --- --- --- --- --- ---

--- --- --- --- --- --- --- ---

Flash

--- ON --- --- --- --- ---

--- --- Flash --- --- --- ---

--- --- ON --- --- --- ---

Flash at

high

speed

Flash at

high

speed

LCD Message

TBD

Printer error. Turn power off and then on again. For details, see your documentation or visit Epson.com.

Paper jam inside, in back, or in ADF. Press [OK] to see to see how to remove jammed paper.

Remove while and orange transportation locks by following instructions.

Scanner error. Turn power off and then on again. If the error is not fixed, visit Epson.com for technical support.

Automatic Document Feeder (ADF) error.

Fax error. Turn power off and then on again.

Maintenance box is at the end of its service life. You need to replace it. <Maintenance Box> XXXXX

Cannot recognize maintenance box. Install it correctly. <Maintenance Box> XXXXX

Paper jam. Press OK to see how to remove jammed paper.

Paper out or paper jam. Check paper size and load paper in paper cassette

Product description Control Panel 16

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Epson WP-M4595/4525/4521/4095/4015/4011 Revision A

Table 1-8. LEDs and LCD Indications

WP-M4095/4015/4011 WP-M4595/4525/4521

Status

Paper out error

cover open)

(front

r a

No paper cassette error

t i n g

Multi-feed error Flash

Paper length mismatch error for duplex printing

Paper size mismatch error

Printer/printer driver mismatch error

Front cover open error

Ink end error Flash

Ink cartridge detection error

Ink cartridge detection error (non-Epson cartridge)

No ink cartridge error Flash

Starting initialization (starting initial filling of ink)

Initializing (during initial filling of ink)

Requiring ink cartridges for initial filling

LED Status

Power Ethernet

Flash

--- --- ON --- --- --- ---

--- ---

Mainten

ance

paper Ink 1 Ink 2 Ink 3 Ink 4

Falsh at

high

speed

Flash at

high

speed

Flash at

high

speed

Flash at

high

speed

Flash at

speed

Flash --- --- Flash2 --- --- --- ---

Flash

--- --- --- Flash Flash Flash Flash

Flash --- --- --- --- --- --- ---

high

LCD Message

Paper out or paper jam. Check paper size and load paper in rear MP tray.

Load Cassette XX*4

(

correctly and press or

(

Multi-page feed error. Remove and reload the

(

paper, then press or

(

Incorrect paper size detected. Load correct paper

(

size and press or

(

No paper source matches paper size setting. Load appropriate paper in Rear

(

MP Tray. Press or

(

Error. Press .

Front cover is open.

You need to replace the following ink cartridge(s). <Ink Cartridges> XXX

Cannot recognize the following cartridge(s). Try installing them again. <Ink Cartridges> XXX

Ink cartridge is not recognized. Please replace the cartridge. <Ink Cartridges> XXX

The cartridge is installed incorrectly. Press it until it clicks into place. <Ink Cartridges> XXX

Install ink cartridges that came with this product. Close front cover. Initialization starts.

Initializing. Please wait... Do not open front cover and do not turn power off until initialization completes.

Open front cover and replace cartridge(s).

Product description Control Panel 17

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Epson WP-M4595/4525/4521/4095/4015/4011 Revision A

Table 1-8. LEDs and LCD Indications

WP-M4095/4015/4011 WP-M4595/4525/4521

Status

Checking ink

cartridges e r

Drying 1st side a

(printing from PC) t

Printing (PC)

n g

Printing nozzle check

pattern

Printing printer status

sheet

Printing (UPNP)

Power Ethernet

Mainten

ance

Flash --- --- --- --- --- --- ---

Flash --- --- --- --- --- --- --- Printing...

Flash --- --- --- --- --- --- ---

Flash Flash --- --- --- --- --- --- Printing...

LED Status

paper Ink 1 Ink 2 Ink 3 Ink 4

Checking the ink cartridges...

Printing 2-sided document. Do not touch the paper in the output tray until printing is complete.

Printing...

Receiving data Flash Flash --- --- --- --- --- --- Receiving data...

Canceling Falsh --- --- --- --- --- --- --- Canceling...

Cleaning print head. Please

Cleaning (PC) Flash --- --- --- --- --- --- ---

wait... Do not open front cover.

Cleaning print head. Please

Print head cleaning Flash --- --- --- --- --- --- ---

wait... Do not open front cover.

Canceling nozzle

check pattern print

Canceling printer

status sheet print

Flash --- --- --- --- --- --- ---

Initializing network Flash

Waiting for network

initialization

Network initialization

(LED ON)

Network initialization

(LED OFF)

Preparing to update

firmware (cancel)

Flash

OFF

Alternate

Flash1

---

OFF

Flash at

high

--- --- --- --- --- ---

--- --- --- --- --- --- Preparing to update...

speed

Canceling...

Processing... Please wait .

Updating firmware... Do not

Updating firmware

ON to

Flash

OFF

OFF OFF OFF OFF OFF OFF

turn power off. It turns off and on automatically when complete.

Preparing to update

firmware

Canceling firmware

update

Flash at

high

--- --- --- --- --- --- Preparing to update...

speed

Flash at

high

--- --- --- --- --- --- Canceling...

speed

Flash at

Powering OFF

high

---

--- --- --- --- --- --- Turning off...

speed

LCD Message

---

Product description Control Panel 18

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Epson WP-M4595/4525/4521/4095/4015/4011 Revision A

Table 1-8. LEDs and LCD Indications

WP-M4095/4015/4011 WP-M4595/4525/4521

Status

O p

Resetting e r

Powering ON Flash a

Feeding a paper (load/

eject)

n g

No error ON t

Maintenance box near a

full n

Ink residual quantity

level 1

(Ink residual quantity

≧ 75%)

Ink residual quantity

level 2

(75% > Ink residual

quantity ≧ 50%)

Ink residual quantity

level 3

(50% > Ink residual

quantity ≧ 25%)

Ink residual quantity

level 4

(25% > Ink residual

quantity)

Ink level low ON

Front cover open

error

Maintenance box full

Maintenance box

CSIC error

No maintenance box

error

Ink end error ON

Power Ethernet

Flash at

high

---

speed

---

Flash

---

Flash

---

LED Status

Mainten

ance

paper Ink 1 Ink 2 Ink 3 Ink 4

LCD Message

Restarting product from

--- --- --- --- --- ---

other device...

--- --- --- --- --- --- ---

Flash --- --- --- --- ---

Maintenance box is nearing end of its service life.

--- --- ON ON ON ON ---

--- --- ON ON ON OFF ---

--- --- ON ON OFF OFF ---

--- --- ON OFF OFF OFF ---

--- --- Flash OFF OFF OFF Ink low.

--- Flash2 --- --- --- --- Front cover is open.

Maintenance box is at the end of its service life. You

ON --- --- --- --- ---

need to replace it. <Maintenance Box> XXXXX

Cannot recognize maintenance box. Install it

ON --- --- --- --- ---

correctly. <Maintenance Box> XXXXX

Cannot recognize maintenance box. Install it

ON --- --- --- --- ---

correctly. <Maintenance Box> XXXXX

You need to replace the

--- --- Flash Flash Flash Flash

following ink cartridge(s). <Ink Cartridges> XXX

Product description Control Panel 19

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Table 1-8. LEDs and LCD Indications

WP-M4095/4015/4011 WP-M4595/4525/4521

Status

S t

No ink cartridge error ON

a n d b

Ink cartridge

detection error

Power Ethernet

---

Mainten

ance

--- --- Flash Flash Flash Flash

LED Status

paper Ink 1 Ink 2 Ink 3 Ink 4

The cartridge is installed incorrectly. Press it until it clicks into place. <Ink Cartridges> XXX

Cannot recognize the following cartridge(s). Try installing them again. <Ink Cartridges> XXX

Ink cartridge detection error (non-Epson cartridge)

---

--- --- Flash Flash Flash Flash

Ink cartridge is not recognized. Please replace the cartridge. <Ink Cartridges> XXX

Note : -- No change

Flash: turns on and off at intervals of 1.25 seconds. Flash 2: On for 0.5 sec., Off for 0.5 sec., On for 0.5 sec. and Off for 1.0 sec. Flash at high speed: turns on and off at intervals of 0.5 seconds. Simultaneous Flash: same as “Flash” Alternate flash 1: same as “Flash” Alternate flash 2: turns on and off at intervals of 1.25 seconds.

Note *1: WP-M4595/4525/4521 only.

*2: WP-M4595/4095 only. *3: Flashes if the status arises when printing starts or when the printer starts up, but lights if the status arises when printing is complete. *4: The corresponding maintenance box, ink cartridge product number or cassette number is indicated. *5: Occurs in any paper path. *6: The corresponding ink LED flashes after the ink falls in the ink low status, and lights when it reaches the ink end status.

LCD Message

Product description Control Panel 20

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1.5 Various Settings

1.5.1 Panel Operation

1.5.1.1 Setup Menu Configuration (WP-M4595/4525/4521 only)

The following explains the setup menu structure and the outline of the menu functions.

Table 1-9. Menu Configuration

Menu Description

Setup Ink Levels --- Displays the status of ink cartridges and maintenance box.

Maintenance Nozzle Check Prints a nozzle check pattern.

Head Cleaning Runs a print head cleaning. Head Alignment Adjusts the alignment of the printhead.

Printer Setup Paper Size Loaded Selects the paper size (1st cassette/2nd cassette

Thick Paper Turn this on when printing on thick paper. Dry Time Sets the dry time when duplex printing. Sound Turns the sound on/off. Date/Time Selects display format for data/time. Daylight Saving Time Selects daylight saving time. Country/Region Selects country/region. Language Selects the language displayed on the LCD. Paper Size Notice Checks the paper size and selects whether to alert users when an

error occurs (Off/On).

Network Settings

File Sharing Setup USB

Fax Settings Send Settings Configures fax send settings.

Print Status Sheet --- Prints a printer status sheet. Lock Settings On

Restore Default Settings

Network Setup Network Connection Check • Checks the network connection status.

Network Settings • Displays the network information.

Network

Receive Settings Configures fax receive settings. Communication Configures the details of the fax communication. Check Fax Connection Prints the fax connection settings.

(“Off” when panel operation is locked)

Change Password Changes the password. (See "1.5.1.2 Panel Operation Lock

Fax Send/Receive Settings Initializes the fax send/receive settings. Fax Data Settings Deletes the fax data settings. Network Setting Initializes the network settings. All except Network & Fax

Settings All Settings Initiali ze s the all settings.

Configures the connection setting for networkl setup.

• Prints the connection check result.

• Prints a network status sheet.

Sets the access priority when accessing the storage dev ice connected to the USB host port to USB or Network.

Changes the setting of the panel operation lock. (See "1.5.1.2

Panel Operation Lock Setting (WP-M4595/4525/4521 only) (p22)".)

Setting (WP-M4595/4525/4521 only) (p22)".)

Initializes the settings except network/fax settings.

/Rear MP Tray).

Note *: When the optional 2nd cassette is installed for WP-M4595/4525/4521.

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1.5.1.2 Panel Operation Lock Setting (WP-M4595/4525/4521 only)

For WP-M4595/4525/4521, the panel operation for the following can be locked after setting the password.

 The same password is also required when configuring the printer settings through

EPSON NetConfig.

 All settings will be initialized when resetting the password.

Table 1-10. Panel Operation Lock Setting

ON The password is required for the following settings.

• Lock settings

• Printer setup

• Network settings

• File sharing setup

• Restoration of individual settings such as network setting (except initializing the all settings)

OFF Entering the password is not required to go to the setting screen even the password is registered.

 Password setting method

1. Select “Setup” - “Lock Settings” - “On”, and then press “OK”.

2. Enter the password, and then press “OK”.

3. To verify the password, enter the password again and press “OK”.

Table 1-11. Password Setting

Item

WP-4540 series WP-4530/4520/4510 series

Digit of the password Within 1 to 20 Available characters Space, !”#$%&'()*+,-./, 0-9, ;<=>?@ A-Z, \]^_`, a-z, {|}~ Method Select characters with arrows or ten key. When a

password is already set, the following three password entries are required: “Enter Current Password”, “Enter New Password”, and “Verify New Password”.

Note 1: The password is not set when shipping from the factory.

2: If the entr ies “Enter New Password” a nd “Verify Ne w Password” are diffe rent, the message “Passw ord is in correct. Enter cor rect

password.” is displayed and the menu screen returns to the password entering screen.

3: If the entries up t o “Verify New Password” are com plete successfully, the change will be reflecte d and the LCD display returns to

the setup menu.

4: The password is stored on the EEPROM, and kept even the power is off.

Description

Select characters with the arrow buttons. When a password is already set, the following three password entries are required: “Enter Current Password”, “Enter New Password”, and “Verify New Password”.

 Panel operation lock method

1. Select “Setup” - “Lock Settings” - “On”, and then press “OK”.

2. Enter the password, and then press “OK”.

3. When “Free access limited” displays, press “OK”. Then the panel lock setting becomes valid.

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 Resetting the password/unlocking the panel operation lock

If you need to reset the password or unlock the panel operation because of forgetting the password and such, follow the steps below to reset them.

 Resetting/unlocking method

1. Select “Setup” - “Restore Default Settings” - “All Settings”, and press “OK”.

2. When “Restore all settings to defaults” displays, select “Yes”.  Settings after reset

• Password: Not set

• Panel operation lock: OFF

1.5.1.3 Forced Power OFF

For WP-M4595/4525/4521/4095/4015/4011, the power can be turned off forcibly by the following panel operation. If the power is turned off forcibly, the same process of the normal power-off is executed.

 Operation method

1. Press the power button and then stop button, and hold down the buttons for seven seconds or more.

2. When the LCD display changes, release the buttons.

1.5.1.4 Printer Status Sheet

WP-M4595/4525/4521/4095/4015/4011 print the printer status sheet by the following operation.

Table 1-12. Status Sheet

Model Procedure

WP-M4595/4525/4521 1. Press the setup button.

2. Select “Print Status Sheet” from the setup menu.

3. Press the start button.

WP-M4095/4015/4011 Turn the power on while pressing the paper feed/eject button.

Note : When printing the network status sheet to check the network information, follow the procedure below.

WP-M4595/4525/4521: Select “/Network Settings” - “Confirm Network Settings”, and press or

WP-M4095/4015/4011: Press the “network status sheet” button. (See

(

. (See "1.5.1.1 Setup Menu Configuration (WP-M4595/4525/4521 only) (p21)".)

"1.4.1 Operation Buttons & LEDs (p14)"

(

Product description Various Settings 23

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CHAPTER 2

OPERATING PRINCIPLES

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A#3 A#2 A#1

A#152 A#151

A#150

B#152 B#151

B#150

B#3 B#2 B#1

C#3 C#2 C#1

C#152 C#151

C#150

D#152 D#151

D#150

D#3 D#2 D#1

E#3 E#2 E#1

E#152 E#151

E#150

F#152 F#151

F#150

F#3 F#2 F#1

G#3 G#2 G#1

G#152 G#151

G#150

0.169 ｍｍ 1/150 inch）

5.9267 ｍｍ

(35/150 inch

）

2.3707 ｍｍ

(14/150 inch）

）

0.0423 ｍｍ 1/600 inch）

）

0.0847 ｍｍ 1/300 inch）

）

Black CyanMagenta

Yellow

Column A

Carriage movement direction

Paper feed direction

Column B

Column C

Column D

Column E

Column F Column G

2.1 Overview

This chapter describes the operating principles of WP-M4595/4525/4521/4095/4015/4011 printer mechanism.

2.2 Printhead

This section describes the printhead.  Print method: On-demand inkjet

(F7-Mach Turbo 2)

 Nozzle configuration

Color Bk, C, M, Y (4 colors) Number of nozzles 1064 nozzles (Bk: 152 nozzles x 4, C, M, Y: 152 nozzles per color) Nozzle pitch 0.169 mm (1/150 inch)

The nozzle layout as seen from behind the Printhead is shown below.

Operating Principles Overview 25

Figure 2-1. Nozzle Layout

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Printhead

2.3 Motors and Sensors

The following table lists the motors and sensors of WP-M4595/4525/4521/4095/4015/4011.  Printer Mechanism

Table 2-1. List of Motors & Sensors (Printer Mechanism)

Mechanism Motor or Sensor No.

Printhead --Carriage mechanism CR Motor A

CR Encoder 1 PW Sensor 2

Cover Open Sensor 3 Ink supply mechanism Decompress Pump Motor B Paper loading/feed mechanism PF Motor C

PF Encoder 4

PE Sensor 5

Paper Stopper Lever Sensor 6

Figure 2-2. Motors & Sensors (Printer Mechanism)

Operating Principles Motors and Sensors 26

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 Scanner (WP-M4595/4525/4521 only)

Table 2-2. List of Motors & Sensors (Scanner)

Mechanism Motor or Sensor No.

Scanner mechanism Scanner Motor A

CIS Unit 1

Figure 2-3. Motors & Sensors (Scanner)

 ADF (WP-M4595/4525/4521 only)

Table 2-3. List of Motors & Sensors (ADF)

Mechanism Motor or Sensor No.

ADF mechanism ADF Motor A

PE Sensor 1

Document Sensor 2

ADF Encoder 3

Figure 2-4. Motors & Sensors (ADF)

Operating Principles Motors and Sensors 27

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 Option(2nd Cassette)

Table 2-4. List of Motors & Sensors (2nd Cassette)

Mechanism Motor or Sensor No.

2nd cassette ASF Motor A

Paper Stopper Lever Sensor 1

ASF Encoder 2

Figure 2-5. Motors & Sensors (2nd Cassette)

Operating Principles Motors and Sensors 28

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PF MotorPF Timing Belt

Left side of Printer Mechanism

PF Encoder

With cover

Without cover (light-emitting

and receiving devices)

PF Encoder

Light passes

Light does not pass

PF Scale

2.4 Optical Sensor Control

WP-M4595/4525/4521/4095/4015/4011 uses the optical sensor to control itself. The following describes the operating principles of optical sensor control.

 Control method To ensure accurate printing, each part must be controlled to make an adequate amount (time) of movement. The

optical sensors read the amount (time) of movements as follows to printer to control it for achieving accurate printing.

1. Rotates the motors for control of the printer, and transmits drive force to the each part via the gear or the timing belt.

2. The encoder reads the drive amount of each part from the scale one by one to printer to monitor that the part drives for an adequate amount (time).

 Controlled parts The following table lists where the optical sensor control is used.

Table 2-5. Controlled Parts

Item Motor Scale Encoder Transmission method

 Paper feed/load mechanism

PF Motor PF Scale PF Encoder

 Front ASF mechanism

(1st cassette)

 Rear ASF mechanism

Carriage mechanism CR Motor CR Scale CR Encoder CR Timing Belt Front ASF mechanism

(2nd cassette ADF mechanism

Note *1: Option

)

*2: WP-M4595/4525/4521 only.

ASF Motor ASF Scale ASF Encoder Gear

ADF Motor ADF Scale ADF Encoder Gear

 Operating principles The following describes the paper feed mechanism drive control as an example of the actual operation for the

optical sensor. The PF scale consists of light-passing and light-blocking portions on its surface, and runs through the slit between

the encoder’s light-emitting and light-receiving devices. While the printer is operating, the encoder always emits light from light-emitting device toward the light-receiving device, and the ligh t-receiving dev ice detects light when the light is transmitted through the light-passing portion of the scale, and does not detect light when the light is blocked by the light-blocking portion of the scale. Accord ing to the counts of light-detected and non detected times, the printer controls paper feed drive direction and amount. When the encoder cannot read light-emitting/blocking counts correctly due to the misalignment, broken or contaminated scale, paper jam, foreign object and increasing a load, the fatal error occurs and the printer stops.

 PF Timing Belt  ASF Timing Belt

Figure 2-6. PF Drive Control Section

Operating Principles Optical Sensor Control 29

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Ink Supply Unit

(Ink Cartridge Holder - Ink Supply Tube)

Printhead

Ink Supply TubeInk Cartridge Holder

Buffer

Diaphragm Pump

Decompress Pump Unit

2.5 Ink Supply Mechanism

The following shows configurations of the ink supply mechanism. The ink supply mechanism consists of the Decompress Pump Unit and the Ink Supply Unit composed of the Ink

Supply Tube, Diaphragm Pump, Buffer and Ink Cartridge Holder. As the Decompress Pump Unit reduces the pressure inside the Diaphragm Pump, the Diaphragm Pump can suck

the ink inside the Ink Cartridge, and then the sucked ink is supplied to the Printhead through the Buffer and Ink Supply Tube.

Figure 2-7. Ink Supply Mechanism

Operating Principles Ink Supply Mechanism 30

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Maintenance Box

Pump Unit

Waste Ink Tube

Cap

Ink System

2.6 Ink System Mechanism

The following shows configurations of the ink system mechanism. The ink system mechanism consists of the Ink System Unit composed of the Cap, Pump Unit, Waste Ink Tube

and similar parts, and the Maintenance Box that stores the ink from the Printhead sucked by the Ink System Unit.

Operating Principles Ink System Mechanism 31

Figure 2-8. Ink System Mechanism

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The rotation direction of the PF Motor

Clockwise:

Paper is fed normally

Counterclockwise:

Paper is fed backward

The above shows clockwise rotation.

Carriage

The condition of the CR lock

Red: CR lock is set White: CR lock is released The above shows the CR lock is set.

PF Roller

Carriage movement

Right-pointing arrow:

Moves to the 0-digit side

Left-pointing arrow:

Moves to the 80-digit side

The figure shows the carriage is moving to the 0-digit side.

Digit number of CR

The condition of the APG Trigger Lever

Red: APG Trigger Lever is set White:APG Trigger Lever is released The figure shows the APG Trigger Lever is released.

APG Trigger

Lever

↓

2.7 Power-On Sequence

Initializing operations of this printer at power-on differ between when powered off normally ("Simple Sequence

(p32)") and when powered off abnormally ("Normal Power-On Sequence (p35)"). This section describes how

this printer operates in the simple sequence and in the normal power-on sequence under certain conditions.

The following explains how to use the simplified diagrams in Table 2-6 or Table 2-7. The diagrams show the movement of each component as seen from the front of the printer.

Figure 2-9. Movement of Components

 Condition 1: Simple sequence (Table 2-6)



After powered off normally without any paper jam or fatal error.

 After the ink charge is complete and sufficient ink remains.  No paper is on the paper path.  The Printhead is capped with the Cap of the Ink System.  The Carriage is locked by the CR lock.  No heat control was executed for the CR Motor or the PF Motor at the previous use, or a long time has passed since

the last power off.

 PG position is set to PG 1.

Table 2-6. Simple Sequence

1. Printhead initialization and fuse inspection

1-1. Initializes the Printhead, and checks the fuse on the printer control

circuit board.

2. Seeking the home position

2-1. The carriage moves to the 0-digit side slowly and confirms it touches

the Right Frame.

2-2. Regards the position where the carriage touches the Right Frame as

the position of the specified steps from the home position, and set it as the origin position.

2-3. The carriage slowly moves to the CR lock set position.

Operation

Movement of

Components

Front ASF

drive condition

OFF ---

Decompress

Motor

Operating Principles Power-On Sequence 32

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↓

Table 2-6. Simple Sequence

Operation

2-4. The PF Motor rotates clockwise and releases the CR lock.

2-5. The PF Motor rotates counterclockwise and sets the CR lock.

2-6. The carriage moves to the 80-digit side slowly and confirms it touches

the CR lock.

2-7. The carriage returns to its home position.

2-8. The PF Motor rotates clockwise and releases the CR lock.

3. Switching front ASF drive

3-1. The carriage moves to the 80-digit side slowly up to the position

where the Front ASF turns on.

3-2. The carriage moves to the 0-digit side slowly up to the position where

the Front ASF turns off.

Movement of

Components

Front ASF

drive condition

ON ---

OFF ---

Decompress

Motor

---

3-3. The carriage moves to the 80-digit side slowly and passes by the CR

lock.

4. APG reset

4-1. To reset the APG Trigger Lever, the PF Motor rotates clockwise and

the PF Roller makes one turn.

4-2. The carriage moves to the 80-digit side quickly up to the APG reset

stand-by position.

4-3. To set the APG Trigger Lever, the PF Motor rotates counterclockwise

and the PF Roller makes one turn.

4-4. The carriage moves to the 80-side slowly up to the APG reset

completion position.

4-5. After the carriage slightly moves to the 0-digit side, the PF Motor

rotates clockwise quickly and the PF Roller makes one turn to reset the APG Trigger Lever.

5. PF initialization

5-1. The PF Motor rotates clockwise for approximately one second.

---

OFF ---

5-2. The PE sensor checks if paper exists, and the PF Motor rotates

clockwise for approximately 0.5 seconds.

Operating Principles Power-On Sequence 33

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↓

Table 2-6. Simple Sequence

Operation

6. Low temperature operation sequence

6-1. The carriage slowly moves to the 0-digit side.

6-2. The carriage moves back and forth between CR lock and the Left

Frame two times.

7. Checking waste ink overflow

7-1. Reads out the waste ink counter value of the Maintenance Box to

check waste ink overflow.

8. Detecting ink cartridge and initializing ink system

8-1. The carriage moves slowly to the ink detection position.

8-2. The Decompress Motor is driven and the Diaphragm Pump sucks the

ink in the ink cartridges.

8-3. While monitoring the ink end sensor, the Decompress Motor is driven

again and the Diaphragm Pump sucks the ink.

8-4. Detects the ink remaining.

Movement of

Components

Front ASF

drive condition

Decompress

Motor

---

Decompress and

vent to

atmosphere

Decompress and

vent to

atmosphere

---

8-5. The carriage returns to its home position.

Note : On the premise on this table, PG does not change and the Rear ASF does not operate during the sequence. Note *1:

Executes when the detected temperature is under 5 oC (41oF) by the thermistor on the Printhead. *2: If this occurs when the timer cleaning (once a year) is scheduled, the cleaning (equivalent to CL3) is executed . *3: The Printhead is capped with the Cap of the Ink System but the Carriage is not locked by the CR lock in order to shorten the

time before printing starts. The Carriage is locked when the printer enters the power saving mode without any operation after

it is turned on.

---

Operating Principles Power-On Sequence 34

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↓

 Condition 2: Normal power-on sequence (Table 2-7)



When a paper jam error occurred during the previous power-on, and also the printer could not turn off normally.

 After the ink charge is complete and sufficient ink remains.  No paper is on the paper path.  The Printhead is not capped with the Cap of the Ink System.  The Carriage is not locked by the CR lock, and also the APG Trigger Lever is not set.  PG position is set to PG 1.

Table 2-7. Normal Power-On Sequence

Operation

1. Printhead initialization and fuse inspection

1-1. Initializes the Printhead, and checks the fuse on the printer control

circuit board.

2. Seeking the home position

2-1. The carriage moves to the 0-digit side slowly and confirms it touches

the Right Frame.

2-2. The carriage slowly moves to the 80-digit side.

2-3. To ensure the CR lock and APG Trigger Lever are reset, the PF Motor

rotates clockwise and the PF Roller makes one turn.

2-4. The carriage moves to the 0-digit side slowly and confirms it touches

the Right Frame.

2-5. To engage the I/S Clutch of the Ink System, the PF Motor rotates

clockwise and the PF Roller makes approximately one turn.

2-6. To turn on the clutch of the Ink System, the PF Motor rotates

counterclockwise and the PF Roller makes approximately half turn.

Movement of

Components

Front ASF

drive condition

OFF ---

Decompress

Motor

---

2-7. The carriage returns to its home position.

2-8. The PF Motor rotates clockwise, and releases the CR lock.

2-9. The carriage moves to the 80-digit side slowly up to the position

where the Front ASF turns on.

2-10. The carriage moves to the 0-digit side slowly up to the position where

the Front ASF turns off.

2-11. The carriage moves to the 80-digit side slowly up to the Valve Unit

initialization position.

---

ON ---

OFF ---

---

Operating Principles Power-On Sequence 35

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↓

Table 2-7. Normal Power-On Sequence

Operation

2-12. The carriage slightly moves to the 0-digit side.

2-13. The carriage moves to the 0-digit side slowly and confirms it touches

the Right Frame.

2-14. To turn off the clutch of the Ink System, the PF Motor rotates

clockwise and the PF Roller makes approximately half turn.

2-15. The carriage returns to its home position.

2-16. To release the Pump Unit, the PF Motor rotates clockwise

approximately one second.

2-17. The carriage slowly moves to the 0-digit side to the CR lock set

position.

2-18. The PF Motor rotates counterclockwise and sets the CR lock.

Movement of

Components

Front ASF

drive condition

Decompress

Motor

---

2-19. The carriage moves to the 80-digit side slowly and confirms it touches

the CR lock.

2-20. The carriage returns to its home position.

2-21. The PF Motor rotates clockwise and releases the CR lock.

3. Detecting remaining paper

3-1. The carriage moves to the 80-digit side, and check if paper exists.

3-2. The carriage returns to its home position.

4. Switching front ASF drive

4-1. The carriage moves to the 80-digit side slowly up to the position

where the Front ASF turns on.

4-2. The carriage moves to the 0-digit side slowly up to the position where

the Front ASF turns off.

OFF ---

---

ON ---

OFF ---

4-3. The carriage moves to the 80-digit side slowly and passes by the CR

lock.

Operating Principles Power-On Sequence 36

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↓

Table 2-7. Normal Power-On Sequence

Operation

5. APG reset

5-1. To reset the APG Trigger Lever, the PF Motor rotates clockwise and

the PF Roller makes one turn.

5-2. The carriage moves to the 80-digit side quickly up to the APG reset

stand-by position.

5-3. To set the APG Trigger Lever, the PF Motor rotates counterclockwise

and the PF Roller makes one turn.

5-4. The carriage moves to the 80-side slowly up to the APG reset

completion position.

5-5. After the carriage slightly moves to the 0-digit side, the PF Motor

rotates clockwise quickly and the PF Roller makes one turn to reset the APG Trigger Lever.

6. PF initialization

6-1. The PF Motor rotates clockwise for approximately one second.

6-2. The PE sensor checks if paper exists, and the PF Motor rotates

clockwise for approximately 0.5 seconds.

Movement of

Components

Front ASF

drive condition

OFF ---

Decompress

Motor

---

7. Low temperature operation sequence

7-1. The carriage slowly moves to the 0-digit side.

7-2. The carriage moves back and forth between CR lock and the Left

Frame two times.

8. Checking waste ink overflow

8-1. Reads out the waste ink counter value of the Maintenance Box to

check waste ink overflow.

9. Detecting ink cartridge and initializing ink system

9-1. The carriage moves slowly to the ink detection position.

9-2. The Decompress Motor is driven and the Diaphragm Pump sucks the

ink in the Ink Cartridges.

9-3. While monitoring the ink end sensor, the Decompress Motor is driven

again and the Diaphragm Pump sucks the ink.

9-4. Detects the ink remaining.

---

Decompress and

vent to

atmosphere

Decompress and

vent to

atmosphere

---

9-5. The carriage returns to its home position.

Operating Principles Power-On Sequence 37

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Note : On the premise on this table, PG does not change and the Rear ASF does not operate during the sequence. Note *1:

The judgment standard is as follows. If judged as “paper exists”, the paper jam occurs again.

Paper exists: The carriage touches paper, or the PW Sensor detects the paper.

Paper does not exist: The carriage does not touch paper, but can move to the Left Frame position and touch the frame. *2: Executes when the detected temperature is under 5 *3: If this occurs when the timer cleaning (once a year) is scheduled, the cleaning (equivalent to CL3) is executed . *4: The Printhead is capped with the Cap of the Ink System but the Carriage is not locked by the CR lock in order to shorten the

time before printing starts. The Carriage is locked when the printer enters the power saving mode without any operation after

it is turned on.

C (41oF) by the thermistor on the Printhead.

Operating Principles Power-On Sequence 38

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CHAPTER 3

TROUBLESHOOTING

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Finish

Turn on the printer

What is returned reason?

Copy an image

Copy an image by ADF

Start

ADF/Scanner

failure

Printer failure only

Yes

Does power-on sequence start?

Is power-on sequence

finished without error?

Yes

Is ADF operation

finished without

trouble?

Standby condition

Is scanning operation

finished without

trouble?

ADF failure?

Print a nozzle check pattern.

Is the print result OK?

Yes

Is printing complete

without an error?

*: In case of “Not Trouble Found”, check fatal error code.

(p41)

Print a nozzle check pattern

3.1 Troubleshooting

This section describes the troubleshooting workflow, fatal error code and FAX Troubleshooting.Troubleshooting Workflow

 This flowchart is compiled based on the following contents.

• Our experience regarding the quality problem.

• Printer Mechanism specification for WP-M4595/4525/4521/4095/4015/4011

 See " 1.4.2 LEDs and LCD Indications (p16)"for the error indication on the control

panel..

 When FAX related error occurs, see " 3.1.2 FAX Troubleshooting (WP-M4595/4525/

4521 only) (p45)".

Figure 3-1. Troubleshooting Workflow (1)

Troubleshooting Troubleshooting 40

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Epson WP-M4595/4525/4521/4095/4015/4011 Revision A

The power-on sequence does not start (p40)

No power

[Presumable Cause]

• Damage to Power Supply Unit

• Damage to Main Board

[Remedy]

• Replace Power Supply Unit

• Replace Main Board

Error is indicated during printing nozzle check pattern. (p40)

Error is indicated during power-on

sequence (p40)

Fatal error

See "3.1.1Fatal Error Code

(p42)".

Maintenance box full

[Occurrence Condition]

This error occurs when maintenance counter in Maintenance Box exceeds the specified value.

[Occurrence Timing]

• At power-on

• When printing starts

• Cleaning

• When closing the Front Cover

[Remedy]

• Replace Maintenance Box

Maintenance box CSIC error

[Occurrence Condition]

This error occurs when Maintenance Box data is incorrect or cannot be recognized correctly.

[Occurrence Timing]

•At power-on

• When printing starts

•Cleaning

• When closing the Front Cover

[Remedy]

• Remove and reinstall Maintenance Box

• Replace Maintenance Box

• Replace CSIC terminal

• Replace Maintenance Box FFC

• Replace Main Board

No maintenance box error

[Occurrence Condition]

This error occurs when Maintenance Box is not installed.

[Occurrence Timing]

• At power-on

• When printing starts

• Cleaning

• When closing the Front Cover

[Remedy]

• Install Maintenance Box

Ink end error

[Occurrence Condition]

This error occurs when ink in Ink Cartridge is empty.

[Occurrence Timing]

• At power-on

• When printing starts

• Cleaning

• When closing the Front Cover

• During printing

[Remedy]

• Replace Ink Cartridge

[Note]

If this error occurs during printing, the paper will be ejected automatically after the current page is printed. If the error occurs during face printing in the automatic duplex printing, the current page will be printed but printing stops before reversing the paper.

Problems related to print result or during printing (p40)

Ink cartridge detection error

[Occurrence Condition]

This error occurs when ink cartridge data is incorrect or Ink Cartridge is not recognized correctly.

[Occurrence Timing]

• At power-on

• When printing starts

• Cleaning

• When closing the Front Cover

• During printing

[Remedy]

• Remove and reinstall Ink Cartridges

• Replace Ink Cartridge

• Replace CSIC terminal

• Replace CSIC Board

• Replace CSIC FFC

• Replace Main Board

No ink cartridge error

[Occurrence Condition]

This error occurs when Ink Cartridge is not installed.

[Occurrence Timing]

• At power-on

• When printing starts

• Cleaning

• When closing the Front Cover

• During printing

[Remedy]

• Install Ink Cartridge

Front cover open error

[Occurrence Condition]

This error occurs when Front Cover is open.

[Occurrence Timing]

• At power-on

• During printing

[Remedy]

• Close Front Cover

• Replace Front Housing Assy

• Replace Cover Open Sensor

• Replace Main Board

Scanning cannot be performed

5 643

successfully (p40)

Paper jam error

See "Paper jam error" which occurs during nozzle check pattern printing.

ADF does not operate normally (p40)

Paper jam error

[Occurrence Condition]

This error occurs when the top/ bottom of paper cannot be detected by PE Sensor or PW Sensor within the specified steps even if the paper has been fed correctly.

[Occurrence Timing]

• At power-on

• During feeding paper

• During ejecting paper

• During duplex printing

• When closing the Front Cover

[Remedy]

1 Press the “Start” button to eject

jammed paper.

• If succeeded Print starts if there is printing data.

• If failed The paper jam error occurs again.

2 If failed at Step 1, open the

Front Cover and remove the Duplex Unit, and then remove jammed paper.

3 Press the “Start” button again.

• If succeeded Paper is fed if there is printing data.

• If failed The paper jam error occurs again.

4 Check the following if failed in

Step 3.

• Foreign object

• Detached parts

• PE Sensor Lever

•PE Sensor

•PW Sensor

• Main Board

• Paper Stopper Assy

Paper out error

[Occurrence Condition]

This error occurs when the top of paper cannot be detected by PE Sensor within the specified steps even if the paper has been fed correctly. (No paper / paper loading failed / paper is fed at slant)

[Occurrence Timing]

• During feeding paper

[Remedy]

1 Set paper to 1st cassette or

Rear MP Tray, and press the “Start” button.

2 If a paper stops before reaching

PE Sensor, remove it and check the paper condition.

3 A)If paper has no damage, set

edge guide correctly after setting paper in 1st cassette or Rear MP Tray, and perform Step 2 again.

B) If paper is damaged, check

for foreign materials / detached parts / deformed parts in the paper path.

4 If the problem is not solved by

3-A) & 3-B), check the following.

• Foreign object

• Detached parts

• Movement of Trigger Lever of Rear ASF

• Tension of ASF Timing Belt

• Surface condition of LD Roller of Rear ASF, Pickup Roller and paper feed rollers in Duplex Unit

• PE Sensor Lever

•PE Sensor

• Main Board

•PF Motor

• Cassette Assy

• Paper Stopper Assy

Multi-feed error

[Occurrence Condition]

This error occurs on the following case.

• A paper is ejected without printing during paper loading operation.

• Actual paper length is longer than theoretical one.

[Occurrence Timing]

• During feeding paper

• During loading paper

• During ejecting paper

[Remedy]

• Replace PE Sensor Lever

• Replace PE Sensor

• Replace PW Sensor

• Replace Main Board

• Perform the operation check and replace Paper Stopper Assy if necessary

Paper length mismatch error

for duplex printing

[Occurrence Condition]

This error occurs when actual paper size is not matched to theoretical one (both shorter and longer).

[Occurrence Timing]

• During auto duplex printing

• During receiving FAX data

[Remedy]

• Replace PE Sensor Lever

• Replace PE Sensor

• Replace PW Sensor

• Replace Main Board

No paper cassette error

[Occurrence Condition]

This error occurs when Cassette Assy 1st cannot be detected. (The error occurs to the Cassette Assy

2nd

in the same way.)

[Occurrence Timing]

• During feeding paper

[Remedy]

• Check connection for Paper Stopper Lever Sensor cable

• Replace Paper Stopper Lever Sensor

Printing failure

[Symptoms]

• Printing failure

• Contamination on paper

• Dot missing

• Paper is ejected without printing

[Presumable Cause]

• Incorrect setting for driver/ panel

• Contamination on CR Scale

• Contamination on Printhead Cover

• Printhead failure

• Dot missing of Printhead

• Contamination on Cap or Wiper of Ink System Unit

• Ink System Unit failure

• PG is narrow

• Damage on PE Sensor Lever

• Damage on PE Sensor

• Damage on APG related parts of Carriage Assy

• APG Lever operation failure

• Connection failure between Decompress Pump Tube and Ink Supply Unit

• Twist or blockade of Decompress Pump Tube

• Decompress Pump Unit operation failure

• Ink Supply Unit operation failure

• Connection failure between Ink Supply Tube and Printhead

[Remedy]

• Check driver or panel setting

• Replace CR Scale

• Clean Printhead Cover

• Perform cleaning

• Replace Ink Cartridge

• Replace Printhead

• Clean rubber part of Cap

• Replace Ink System Unit

• Adjust PG again

• Replace Printer Mechanism

• Replace PE Sensor Lever

• Replace PE Sensor

• Replace Carriage Assy

• Check the attachment condition of APG Lever

• Check the condition of Decompress Pump Tube

• Replace Decompress Pump Unit

• Replace Ink Supply Unit

• Check the condition of the joint section of Ink Supply Tube

Paper feeding failure

[Presumable Cause]

• Use of 3rd party media

• Inappropriate position of edge guide

• Foreign object

• Detached parts

• Contamination on LD Roller of Rear ASF / Retard Roller

• Contamination on Pickup Roller

• Contamination on paper feed rollers in Duplex Unit

• Damage to Cassette Assy

• Rear ASF Timing Belt tension failure

• Damage to Rear ASF Assy

[Remedy]

• Use EPSON-recommended paper

• Set edge guide correctly

• Remove foreign material

• Re-install parts

• Replace Pickup Assy

• Replace Cassette Assy

• Replace Printer Mechanism

• Replace Rear ASF Assy

Note *1: If the printer can turn on but turns off right away, the protection circuit may cut off the power due

Abnormal noise

[Presumable Cause]

• Foreign object

• Insufficient grease

• Damage to gears

[Remedy]

• Remove foreign material

• Apply an appropriate amount of grease

• Replace gears

to an error such as a circuit failure. *2: Only for manual duplex printing *3: WP-M4595/4525/4521 only

Scanner failure

[Presumable Cause]

• Contamination on document glass

• Contamination on Document Pad

• CIS bonding failure

• CIS failure

• Damage to Scanner Motor

[Remedy]

• Clean document glass

• Clean Document Pad

• Replace Document Pad

• Replace CIS Unit

• Replace Scanner Motor

ADF failure

[Symptoms]

• Paper is not fed

• Multi-feed

• Paper jam

• Skewed document

[Presumable Cause]

• Deterioration of Pickup Roller

• Deterioration of ADF Pad Assy

• Damage to gears

•Damage to ADF Motor

• Contamination on document glass

• Foreign object

• Damage to ADF Cover Assy

• Deterioration of Paper Eject Roller

• Damage to ADF Document Sensor / ADF PE Sensor

[Remedy]

• Replace ADF Cover Assy

• Replace ADF Pad Assy

• Clean document glass

• Remove foreign material

• Replace ADF Unit

Troubleshooting Troubleshooting Workflow 41

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3.1.1 Fatal Error Code

This section describes the fatal error code and the possible cause for this product.  Printer fatal error list

Table 3-1. Fatal Error List (Printer)

Error type

DC motor error

Error

code

01H CR PID excess load error

02H CR PID excess speed error

03H CR PID reverse error

04H CR PID lock error

05H CR PID speed degradation error

08H CR load position reverse error

09H CR load position excess speed error

0AH CR load position excess load error

11H ASF PID excess load error

12H ASF PID excess speed error

13H ASF PID reverse error

14H ASF PID lock error

Error name Possible cause

• CR Encoder failure (contaminated/detached scale, Encoder Board failure)

• CR Motor failure

• Carriage overload error (paper jam/foreign object)

• Cable disconnection

• CR Encoder failure (contaminated/detached scale, Encoder Board failure)

• Motor driver failure (Main Board failure)

• Tooth skip of the CR Timing Belt

• Improper tension of the CR Timing Belt

• CR Encoder failure (contaminated/detached scale, Encoder Board failure)

• Tooth skip of the CR Timing Belt

• Improper tension of the CR Timing Belt

•Paper jam

• CR Encoder failure (contaminated/detached scale, Encoder Board failure)

• CR Motor failure

• Carriage overload error (paper jam/foreign object)

• Cable disconnection

• CR Encoder failure (contaminated/detached scale, Encoder Board failure)

• Motor driver failure (Main Board failure)

• Tooth skip of the CR Timing Belt

• Improper tension of the CR Timing Belt

•Paper jam

• CR Encoder failure (contaminated/detached scale, Encoder Board failure)

• Tooth skip of the CR Timing Belt

• Improper tension of the CR Timing Belt

•Paper jam

• CR Encoder failure (contaminated/detached scale, Encoder Board failure)

• Motor driver failure (Main Board failure)

• Tooth skip of the CR Timing Belt

• Improper tension of the CR Timing Belt

• CR Encoder failure (contaminated/detached scale, Encoder Board failure)

• CR Motor failure

• Carriage overload error (paper jam/foreign object)

• Cable disconnection

• ASF Encoder failure (contaminated/detached scale, Encoder Board failure)

• ASF Motor failure

• 2nd Cassette Unit overload error (paper jam/foreign object/inappropriate installation of Pickup Assy 2nd)

• Cable disconnection

• ASF Encoder failure (contaminated/detached scale, Encoder Board failure)

• Motor driver failure (Main Board failure)

• ASF Encoder failure (contaminated/detached scale, Encoder Board failure)

•Paper jam

• ASF Encoder failure (contaminated/detached scale, Encoder Board failure)

• ASF Motor failure

• 2nd Cassette Unit overload error (paper jam/foreign object/inappropriate installation of Pickup Assy 2nd)

• Cable disconnection

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Table 3-1. Fatal Error List (Printer)

Error type

DC motor error

Motor drive time error

Printhead system error

Error

code

18H ASF load position reverse error

19H ASF load position excess speed error

1AH ASF load position excess load error

F1H PF PID excess load error

F2H PF PID excess speed error

F3H PF PID reverse error

F4H PF PID lock error

F8H PF load position reverse error

F9H PF load position excess speed error

FAH PF load position excess load error • PF Encoder failure (contaminated/detached scale, Encoder Board failure)

FCH PF load position error

D1H CR (PID) driving time error D2H CR (load position) driving time error D3H PF (PID) driving time error D4H PF (BS) driving time error D5H ASF (PID) driving time error D6H ASF (BS) driving time error

D8H I/S driving time error

40H Transistor temperature error • Main Board failure 41H X-Hot detect error (pre printing) 42H X-Hot detect error (after flushing) 43H Head temperature error

Error name Possible cause

• ASF Encoder failure (contaminated/detached scale, Encoder Board failure)

•Paper jam

• ASF Encoder failure (contaminated/detached scale, Encoder Board failure)

• Motor driver failure (Main Board failure)

• ASF Encoder failure (contaminated/detached scale, Encoder Board failure)

• ASF Motor failure

• 2nd Cassette Unit overload error (paper jam/foreign object/inappropriate installation of Pickup Assy 2nd)

• Cable disconnection

• PF Encoder failure (contaminated/detached scale, Encoder Board failure)

• PF Motor failure

• PF drive mechanism overload (paper jam/foreign object)

• Cable disconnection

• PF Encoder failure (contaminated/detached scale, Encoder Board failure)

• Motor driver failure (Main Board failure)

• Tooth skip of the PF Timing Belt

• Improper tension of the PF Timing Belt

• PF Encoder failure (contaminated/detached scale, Encoder Board failure)

• Tooth skip of the PF Timing Belt

• Improper tension of the PF Timing Belt

•Paper jam

• PF Encoder failure (contaminated/detached scale, Encoder Board failure)

• PF Motor failure

• PF drive mechanism overload (paper jam/foreign object)

• Cable disconnection

• PF Encoder failure (contaminated/detached scale, Encoder Board failure)

• Tooth skip of the PF Timing Belt

• Improper tension of the PF Timing Belt

• PF Encoder failure (contaminated/detached scale, Encoder Board failure)

• Motor driver failure (Main Board failure)

• Tooth skip of the PF Timing Belt

• Improper tension of the PF Timing Belt

• PF Motor failure

• PF drive mechanism overload (paper jam/foreign object)

• Cable disconnection

• Main Board failure

• PF Motor failure

• PF drive mechanism overload (paper jam/foreign object)

• Cable disconnection

• Printhead failure

• Main Board failure

Troubleshooting 43

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Table 3-1. Fatal Error List (Printer)

Error type

Sequence error

Sensor error

Ink device error

Circuit error 80H Circuit error (include blowout of a fuse) • Main Board failure

Error

code

50H Home position error 51H Deadlock avoidance error 52H Impossible contact detection error

57H

58H

60H PW detector error 61H PW detector confusion error

62H

B0H -

CFH

Valve initialization contact point detection error

I/S clutch operation contact point detection error

Hot-plug disconnection paper jam fatal error

Ink device error

Error name Possible cause

•Paper jam

• Foreign object

• Deformation of the Main Frame

• Carriage overload error (paper jam/foreign object)

• PW Sensor failure

• Main Board failure

• 2nd Cassette Unit has been removed during feeding (when the ASF Motor is operating).

• Contact failure of the connector which connects 2nd Cassette Unit and the printer.

• Ink Cartridge failure

• CSIC terminal failure

• CSIC Board failure

• Main Board failure

• CSIC FFC connection failure

 Scanner fatal error list (WP-M4595/4525/4521 only)

Table 3-2. Fatal Error List (Scanner)

Error code Error name Possible cause

• CIS Unit failure

10H Scanner HP detection error

20H Scanner LED light error

• Scanner Housing failure

• Main Board failure

• CIS Unit failure

• Main Board failure

 ADF fatal error list (WP-M4595/4525/4521 only)

Table 3-3. Fatal Error List (ADF)

Error code Error name Possible cause

01H ADF PID excess speed error

02H ADF PID reverse error

03H ADF PID lock error • ADF Encoder failure (contaminated/detached scale, Encoder Board failure)

05H ADF PID excess load error

06H ADF PID driving time error • Main Board failure 30H ADF option error • Main Board failure 36H ADF paper jam error • Paper jam

• ADF Encoder failure (contaminated/detached scale, Encoder Board failure)

• Motor driver failure (Main Board failure)

• ADF Encoder failure (contaminated/detached scale, Encoder Board failure)

•Paper jam

• ADF Motor failure

• ADF drive mechanism overload (paper jam/foreign object)

• Cable disconnection

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Item Information

Communication start date / time

Year/month/day/hour/minute

Communication type Sending/receiving/polling reception

Communication ID

Sending/polling reception:

• Destination name of speed dial (first 20 characters)

• Telephone number (last 20 characters)

• Destination fax ID (20 characters)

Receiving:

• Destination fax ID (20 characters) Airtime Hour/minute/second Communication pages 0 to 100

Communication result

Common:

Normal/cancel/error code

Sending/polling reception:

No dial tone detected/No fax signal detected/Busy tone detected

3.1.2 FAX Troubleshooting (WP-M4595/4525/4521 only)

3.1.2.1 FAX Log

When an error related to fax occurs, it is not only indicated on the LCD but also saved as a log file. The error code is recorded in it, and according to this log, the contents of the error can be confirmed.

Table 3-4. FAX Log (1)

Log Name Description Save Destination

Latest log (Last Transaction)

The latest communication log of sending / polling reception Nonvolatile memory

The following information is stored.

Communication log (Fax Log)

Note *: For error codes, see Table 3-6. Error Code List (p.46).

Power failure log (Fax Log)

Note *1: The latest communication log for all destinations are printed in a list form when the sequential broadcast is executed. Cancellation is treated as

*2: The power failure log when the sequential broadcast is being executed is not printed for the destinations to which the transmission log is already

a normal termination, therefore, if it is cancelled, the latest log is printed when the auto print setting is “always print”, and not printed when the setting is “only when an error occurs”. If “only when an error occurs” is selected, the log is printed even when an error occurs for just one destination.

complete then. If the power failure occurs before the scheduled sending time when a broadcast is scheduled, the scheduled sending time is recorded.

The information stored in this log is the same as the communication log. However, since the airtime is “Unknown” in this case, the result of it is recorded as “power failure”.

Nonvolatile memory

The communication log is not stored under the following conditions:  When the sending operation is canceled while storing B&W image or waiting for

redialing.

 In the case of a power failure during the operation of sending/polling reception including

waiting status for redial, or during receive operation.

 When the receiving operation is canceled before the fax signal is detected.  If the fax signal is not detected during receiving operation.  If cancelled during the sequential broadcast.

Troubleshooting 45

(The log for the destinations of “not dialed yet” or “waiting for re-dial” is not saved except for those of which the communication is complete.)

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Item Information

Communication start date / time

Year/month/day/hour/minute

Communication type Sending/receiving/polling reception

Communication ID

Sending/polling reception:

• Destination name of speed dial (first 20 characters)

• Telephone number (last 20 characters)

• Destination fax ID (20 characters)

Receiving:

• Destination fax ID (20 characters) Airtime Hour/minute/second Communication pages 0 to 100

Communication result

Common:

Normal/cancel/error code

Sending/polling reception:

No dial tone detected/No fax signal detected/Busy tone detected

Diagnosing code

10 bytes

Protocol data

The latest 43 commands/responses*

• Time stamp

• Sending / receiving

• Command /response code

(See Table 3-7. Command/Response Code (p.48))

• FCF/FIF (first 33 octets).

Table 3-5. FAX Log (2)

Log Name Description Save Destination

The following information of the latest communication is stored.

Protocol trace

Error codes



Note *: If a large amount of FIF is received, the recorded command/response may be less than

40.

Table 3-6. Error Code L is t

Volatile memory

Error

Code

Phenomenon LCD Display Print Example

(HEX)

000 Succe ssful completion (Monochrome) Complete OK

C000 Successful completion (Color) Complete OK Color

400 Communication error Communication error Error code 401 Communication error Communication error Error code 402 Communication error Communication error Error code 403 Communication error Communication error Error code 404 Communication error Communication error Error code

Troubleshooting 46

405 Communication error Communication error Error code 407 Communication error Communication error Error code 408 Communication error Communication error Error code 409 Communication error Communication error Error code 410 Communication error Communication error Error code 412 Communication error Communication error Error code 416 Communication error Communication error Error code 417 Communication error Communication error Error code 418 Communication error Communication error Error code

420

421 Communication error Communication error Error code 422 Communication error Communication error Error code 427 Communication error Communication error Error code 433 Communication error Communication error Error code

Fax signal was not detected during receive operation. (The call was a telephone call)

Not displayed ---

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Epson WP-M4595/4525/4521/4095/4015/4011 Revision A

Table 3-6. Error Code L is t

Error

Code

(HEX)

434 Communication error Communication error Error code 436 Communication error Communication error Error code 459 Communication error Communication error Error code 490 Communication error Communication error Error code 494 Communication error Communication error Error code 495 Communication error Communication error Error code 496 Communication error Communication error Error code 501 Communication error Communication error Error code 502 Communication error Communication error Error code 503 Communication error Communication error Error code 504 Communication error Communication error Error code 505 Communication error Communication error Error code 540 Communication error Communication error Error code 541 Communication error Communication error Error code 542 Communication error Communication error Error code 543 Communication error Communication error Error code 544 Communication error Communication error Error code 550 Communication error Communication error Error code 554 Communication error Communication error Error code 620 Communication error Communication error Error code 621 Communication error Communication error Error code 623 Communication error Communication error Error code 624 Communication error Communication error Error code

630 A busy tone was detected after dialing

631 Communication error Communication error Error code 632 Communication error Communication error Error code 633 Communication error Communication error Error code 634 A fax signal was not detected for a given length of time after dialing No Answer No Answer 637 A dial tone was not detected before dialing No Dial Tone No Dial Tone 638 A power failure occurred during communication Not displayed Power Fail 700 The communication was canceled by an operation Canceled Canceled 706 System error System Error Error code 709 Communication error Communication error Error code 815 Communication error Communication error Error code 870 The image memory is full Memory Full Memory Full 871 The maximum number of files was exceeded Error code Error code 873 Communication error Communication error Error code 874 Communication error Communication error Error code 875 Communication error Communication error Error code 880 System error System Error Error code 881 System error System Error Error code 882 System error System Error Error code 883 System error System Error Error code 884 System error System Error Error code

928 Collision (A call signal was detected when shifting to dial operation) Not displayed --F0B Communication error Communication error Error code F1E Communication error Communication error Error code F20 Communication error Communication error Error code F21 System error System Error Error code

Phenomenon LCD Display Print Example

Talking

(Line Busy)

Talking

(Line Busy)

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Table 3-6. Error Code L is t

Error

Code

(HEX)

F23 Communication error Communication error Error code F24 Communication error Communication error Error code F25 Communication error Communication error Error code F27 System error System Error Error code F28 System error System Error Error code F29 Communication error Communication error Error code

F2A Communication error Communication error Error code

F2B No image data for reprint exists No Image --F2F System error System Error Error code

F3A Communication error Communication error Error code

F51 System error System Error Error code F57 Communication error Communication error Error code F58 Communication error Communication error Error code F59 System error System Error Error code

F60 A scanner fatal error occurs

F61 A printer fatal error occurs

F62 Reserved --- Error code

F63 ADF misfeed or paper jam occurred

F64 The memory for printing received image is full Error code Error code

Note *: Confirm the fatal error code with the Adjustment Program to check which error occurred. (See " 3.1.1 Fatal Error Code (p42)".)

Phenomenon LCD Display Print Example

Same message when a scanner

fatal error occurred

Same message when a printer

fatal error occurred

Same message when an ADF

fatal error occurred

Error code

ADF Jam

 Command/response code

Table 3-7. Command/Response Code

Command/response

code

DIS 80 - Digital Identification Signal

CSI 40 - Called Subscriber Identification

NSF 20 - Non-Standard Facilities

DTC 81 - Digital Transmit Command

CIG 41 - CallInG subscriber identification

NSC 21 - Non-Standard facilities Command

PWD C1 - PassWorD

SEP A1 - Selective Polling Reserved (PSA) 61 - Polled SubAddress Reserved (CIA) E1 - Calling subscriber Internet Address

Reserved (ISP) 11 - Internet Selective Polling address

DCS 82 - Digital Command Signal

TSI 42 - Transmitting Subscriber Identification NSS 22 - Non-Standard facilities Set-up SUB C2 - SUBaddress

SID A2 - Sender IDentification TRN E6 - Training TCF F0 - Training Check CTC 12 - Continue To Correct

Reserved (TSA) 62 - Transmitting Subscriber internet Address Reserved (IRA) E2 - Internet Routing Address

CFR 84 - ConFirmation to Receive

FCF value (HEX)

(LSB first: X=0)

First Second

Content

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Table 3-7. Command/Response Code

Command/response

code

FTT 44 - Failure To Train CTR C4 - Response for Continue To correct

Reserved (CSA) 24 - Called Subscriber internet Address

EOM 8E - End Of Message

MPS 4E - MultiPage Signal EOP 2E - End Of Procedure

PRI-EOM 9E - Procedure Interrupt-End Of Message PRI-MPS 5E - Procedure Interrupt-MultiPage Signal

PRI-EOP 3E - Procedure Interrupt-End Of Procedure

Reserved (EOS) 1E - End Of Selection

PPS-EOM BE 8E Partial Page Signal-End Of Message

PPS-MPS BE 4E Partial Page Signal-MultiPage Signal

PPS-EOP BE 2E Partial Page Signal-End Of Procedure PPS-PRI-EOM BE 9E Partial Page Signal-Procedure Interrupt- End Of Message PPS-PRI-MPS BE 5E Partial Page Signal-Procedure Interrupt- MultiPage Signal

PPS-PRI-EOP BE 3E Partial Page Signal-Procedure Interrupt- End Of Procedure

PPS-EOS BE 1E Partial Page Signal-End Of Selection

PPS-NULL BE 00 Partial Page Signal-partial page boundary EOR-EOM CE 8E End Of Retransmission-End Of Message EOR-MPS CE 4E End Of Retransmission-MultiPage Signal

EOR-EOP CE 2E End Of Retransmission-End Of Procedure

EOR-PRI-EOM CE 9E End Of Retransmission-Procedure Interrupt-End Of Message

EOR-PRI-MPS CE 5E End Of Retransmission-Procedure Interrupt-MultiPage Signal

EOR-PRI-EOP CE 3E End Of Retransmission-Procedure Interrupt-End Of Procedure

EOR-EOS CE 1E End Of Retransmission-End Of Selection

EOR-NULL CE 00 End Of Retransmission- partial page boundary

RR 6E - Receive Ready

MCF 8C - Message ConFirmation

RTP CC - ReTrain Positive RTN 4C - ReTrain Negative

PIP AC - Procedure Interrupt Positive PIN 2C - Procedure Interrupt Negative PPR BC - Partial Page Request

RNR EC - Receive Not Ready

ERR 1C - Response for End of Retransmission

Reserved (FDM) FC - File Diagnostic Message

DCN FA - DisCoNnect

CRP 1A - Command RePeat

Reserved (FNV) CA - Field Not Valid

PIX FF - PIXel image

Space Other combinations Unknown command/response

FCF value (HEX)

(LSB first: X=0)

First Second

Content

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3.1.2.2 Error Code/Superficial Phenomenon-Based Troubleshooting

This section explains the troubleshooting procedures based on the error codes and superficial phenomenon.

 When an error occurs, it may be displayed on the LCD panel with a message instead of

an error code. To check the error code, print out a fax log.

 If the problem is not solved even after carrying out the remedy shown in the Table 3-8,

print out a protocol trace to analyze the cause of the error.

Table 3-8. Troubleshooting Based on the Error Code/Superficial Phenomenon

Error code (LCD

Message)/Phenomenon

Communication Error (The error is indicated with error code on the fax log.)

Line Busy The line is busy. Try again later.

No answer

Power fail

706,880-884,F21,F27F28,F2F,F51,F59

Memory full Out of Memory 871 F60 A scanner fatal error occurred

F61 A printer fatal error occurred F62 Reserved ---

F63

F64

Cannot receive faxes

Cannot dial

Cannot receive/send faxes in color

Communication error

The other end of the line does not answer.

The other end of the line answered but no answer tone is detected.

Power failure occurred during sending/receiving/printing/ redialing.

A system error (fax circuit failure) occurs

Maximum number of files is exceeded

ADF document mis-feed or paper jam occurs

The memory for printing received image is full

The telephone cable is not connected properly.

The telephone line is not working. Verify if the phone line works by connecting to a phone to it. Auto answer is set to “N”. Set to “Y”.

DRD setting is incorrect.

Calling signal cannot be detected. The telephone cable is not

connected properly. The telephone line is not working. Verify if the phone line works by connecting to a phone to it. Pulse/Tone dial setting error Turn the setting to the other one and try again. ECM is set to off. Set to on and try again. Fax mode is set to “B&W only”. Set to “B&W/Color”.

Description Remedy

Turn off v.34 and try again. Turn off ECM and try again. When using xDSL, check the connection from “Line” jack to the fax

via the xDSL splitter. When using TAM, check the connection from “Line” jack to the

TAM via the fax. Check if the telephone line makes any sounds.

Check the number and dial again.

Confirm the P/S Board Connector Cable or P/S Board is not damaged, and retry.

Replace the FAX board with a new one.

Ask the sender to resend the fax in several batches.

•See Table 3-1 "Fatal Error List (Printer)" (p.42).

•See Table 3-2 "Fatal Error List (Scanner)" (p.44).

• Set the documents and try again.

• If a paper jam error occurs, remove the jammed paper and try again.

Ask the sender to resend the fax in several batches.

Connect the telephone cable properly.

Set the setting to “ALL” and try again. Should other ring patterns be selected, contact the telephone company.

Contact the telephone company or obtain the fax log for more analysis.

Connect the telephone cable properly.

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Table 3-8. Troubleshooting Based on the Error Code/Superficial Phenomenon

Error code (LCD

Message)/Phenomenon

Cannot print all the received data when printing data stored in memory

Images run off the paper

The size of the memory is 2.0 Mbyte. If the data becomes over the set threshold, oldest data are deleted to make room for new ones.

Auto reduction is set to off. Set auto reduction to on and reprint the data. Paper size setting does not match

the size of the received data. Paper size setting does not match

the size of papers in the tray.

Description Remedy

Ask the sender to resend the data if necessary because the data deleted from the memory can not be restored.

Choose the correct setting and reprint the data. Choose the correct setting or load correct sized papers in the tray and

reprint the data.

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CHAPTER 4

DISASSEMBLY/REASSEMBLY

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4.1 Overview

This chapter describes procedures for disassembling the main parts/units of WP-M4595/4525/4521/4095/4015/

4011. Unless otherwise specified, disassembled parts/units can be reassembled by reversing the disassembly procedure. See the cautions or tips for disassembly/reassembly described in "4.3 Detailed Disassembly/

Reassembly Procedure for each Part/Unit (p64)".

Read the "Safety Precautions (p3)" before disassembling and reassembling. When you have to remove units or parts that are not described in this chapter, see the exploded diagrams of SPI (Service Parts Information).

4.1.1 Tools

Use only specified tools to avoid damaging the printer.

Name Availability EPSON Part Code

(+) Phillips screwdriver #1 O 1080530 (+) Phillips screwdriver #2 O --Flathead screwdriver O --Flathead Precision screwdriver #1 O --Tweezers O --Longnose pliers O --Acetate tape --- 1003963

Note 1: Some of the tools listed above are commercially available.

2: EPSON provides the tools listed with EPSON part code.

4.1.2 Jigs

Name Quantity EPSON Part Code

Thickness gauge (2 mm) 1 --Ink Leak Measurement Jig 1 1430064 Ink Leak Check Cartridge 1 1565785 I/S Supply Unit Support Jig 1 1568075

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Joint section of the Printhead

and Ink Supply Unit

Printhead

Ink tubes

Carriage Assy

4.2 Disassembly/Reassembly Procedures

4.2.1 Caution when Replacing the Printhead/Ink Supply Unit

For stable ink supply, this product employs a mechanism where the ink in the ink path is pressurized even the power is off. Therefore, if the joint section of the printhead and the Ink Supply Unit is simply disconnected, the ink in the ink tube will spill over.

Figure 4-1. Joint Section of the Printhead and Ink Supply Unit

To prevent this from happening, before separating the Printhead and Ink Supply Unit to replace the Printhead or the Ink Supply Unit, make sure to release the pressure inside the ink path using the Adjustment Program. The following explains the procedure.

 This is not necessary when replacing the Printhead and Ink Supply Unit together with

the Ink System Supply Assy supplied as an ASP.

 Approximately six minutes are required to release the applied pressure.  The ink in the ink path is pressurized in the power-off sequence again, therefore, make

sure not to turn the power off by the power button after the applied pressure is released.

 Tools

 Ink Cartridges

Do not use user’s ink cartridges since the ink in the ink cartridges is consumed when releasing the pressure. Prepare ink cartridges supplied as consumables for this procedure. (Hereafter, an ink cartridge for this purpose is called as an “ink cartridge (for service use)”.

 Maintenance box

Do not use user’s maintenance box since the ink the ink path flows to the maintenance box when releasing the pressure. Prepare maintenance box supplied as a consumable for this procedure. (Hereafter, a maintenance box for this purpose is called as a “maintenance box (for service use)”.

 Procedure

1. Remove the ink cartridges and maintenance box in the returned unit, and install the ink cartridges

use)

and maintenance box (for service use).

(for service

2. Connect the printer and the PC installed the Adjustment Program with the USB cable, and turn the power on.

3. Start the Adjustment Program, and select the “Ink Pressure Release” from the menu.

4. Click “Execute” in the displayed screen to release the applied pressure.

5. When the completion message appears, unplug the computer power cable. Afterward, remove the parts referring to "4.2.2 Parts/Units Need to be Removed in Advance (p55)" and replace

them referring to "4.2.3 Disassembly Flowchart (p56)".

 When separating the Printhead and the Ink Supply Unit, make sure to perform "5.2.6

Ink Leak Check (p93)" to check if ink is leaking.

 After disconnecting the Printhead and the Ink Supply Unit, ink may spill over even if the

pressure is released. Therefore, be careful not to contaminate the surroundings.

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4.2.2 Parts/Units Need to be Removed in Advance

In Chapter 4 "Disassembly Flowchart (p56)", the procedures are indicated on the premise that some parts/units are removed in advance. Make sure to remove the following parts/units before starting disassembly.

Note "*": .

 Ink Cartridges (x4)  Maintenance Box

 Cassette Assy 1st  Duplex Unit

 Cassette Assy 2nd

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4.2.3 Disassembly Flowchart

This section describes procedures for disassembling the parts/units in a flowchart format. For some parts/units, detailed procedures or precautions are provided (accordingly indicated by icons and cell's color). Refer to the explanations in the example chart below and perform an appropriate disassembling and assembling procedure. (See "4.3 Detailed Disassembly/Reassembly Procedure for each Part/Unit (p64)".) For routing cables, see "4.3 Routing FFCs/cables (p72)".

4.2.3.1 Parts/Units whose Configuration is Different between Models in the Flowchart

The models describe in this manual employ the same printer mechanism but they have different printing related functions and structures shown in Chapter 1 "Product description (p9)". Therefore, the parts/units vary and the shape of them differs even they have the same parts name.

In the flowchart in this section, the parts are in two colors: black for the common parts or units, and blue for the parts or units which differ between models. For the parts or units which differ between models, confirm the composition of the parts for the printer whose disassembly procedure you want to check, and then see the disassembly flowchart.

Table 4-1. Parts/Units whose Configuration is Different between Models

Model Name Exterior Parts

WP-M4595/ 4525/4521

WP-M4095/ 4015/4011

 "Scanner Unit (p59)"  "ADF Unit (p59)"

 "ADF Cover Assy (p59)"

• "ADF Cover Housing

Upper (p59)"

• "LD Cover (p59)"

• "LD Shaft (p59)"

• "Extension Spring 0.99

(p59)"

• "ADF LD Assy (p59)"

 "ADF Rear Cover (p59)"  "ADF Document Support

Assy (p59)"

 "ADF Pad Assy (p58)"

 "FAX Cover (p58)"

 "Housing Upper Assy (p58)"  "USB Cover (p58)"

Main Board

Related Parts

 "Main Board Shield Plate

Upper Assy (p61)"

 "Interface Board Shield

Plate (p61)"

 "FAX FFC (p61)"  "Interface Board (p61)"

---

Control Panel

Components

 "Panel FFC (p58)"  "Panel Assy (p58)"

 "Panel Board (p59)"  "Sub Board Assy (p59)"

• "Sub Board (p59)"

• "Sub Board FFC (p59)"

• "LCD Cover (p59)"

• "LCD Module (p59)"

 "Panel Housing Upper Assy

(p59)"

 "Panel FFC (p58)"  "Panel Assy (p58)"

 "Panel Board (p59)"  "Panel Housing Upper Assy

(p59)"

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USB Cover

(p 68) (p 77)

Ink System Unit

(p 71)

Ref.

Item Description Reference

Parts/unit name

White-letter Part/unit supplied as an ASP --Black-letter Part/unit not supplied as an ASP ---

Icon

Indicates a practice or condition that could result in injury or loss of life if not strictly observed.

Indicates the reference page in blue-letter

Indicates a practice or condition that could result in damage to, or destruction of equipment if not strictly observed.

Indicates the reference page in blue-letter

Indicates the parts that are inevitably broken in the disassembling procedure, and should be replaced with a new one for reassembly.

---

Indicates necessary check items in the disassembling/ assembling procedure.

Indicates the reference page in blue-letter

Indicates supplementary explanation for disassembly is given.

Indicates the reference page in blue-letter

Indicates particular tasks to keep quality of the units are required.

Indicates the reference page in blue-letter

Indicates particular routing of cables is required.

Indicates the reference page in blue-letter

Indicates particular adjustment(s) is/are required.

Chapter 5 "Adjustment (p77)"

Indicates lubrication is required.

Chapter 6 "Maintenance (p96)"

Indicates the number of screws securing the parts/ units.

---

Indicates the points secured with other than a screw such as a hook, rib, dowel or the like.

---

Shows removal/installation as a unit/assy. is available.

Reference page

Shows the screw types and the specified torque in the “Screw type/torque list”.

Explanation available in the Reference Guide

White letters indicate a part/ unit supplied as an ASP.

Black letters indicate a part/ unit not supplied as an ASP.

The example below shows how to see the charts on the following pages.

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4.2.3.2 Exterior Parts

START

WP-M4095/4015/4011

Panel Assy

WP-M4595/4525/4521

Panel Assy

---

(p 65)

WP-M4095/4015/4011

Panel FFC

WP-M4595/4525/4521

(p 65)

Panel FFC

---

WP-M4095/4015/4011 WP-M4595/4525/4521

Go to the next step

Housing Rear

Assy

FAX Cover

---

Housing Rear

Assy

(p 59)

(p 64)

Rear Housing

---

Paper Support

---

Metal Plate

(w/ Paper

Stopper Assy)

(p 72)

Pickup Assy 1st

---

WP-M4095/4015/4011

USB Cover

WP-M4595/4525/4521

FAX Cover

Paper Stopper

Assy

(p 70)

Document Cover

---

ADF Pad Assy

---

(p 71)

---

WP-M4095/4015/4011

Housing Upper

Assy

WP-M4595/4525/4521

ADF Unit /

Scanner Unit

---

(p 64)

(p 70) (p 72)

Front Housing

Assy

(p 64)

WP-M4095/4015/4011 WP-M4595/4525/4521

Housing Rear

Assy

Go to the next step

USB Cover

(p 60)

(p 64)

(p 64) (p 72)

Common parts/units

(p 59)

Parts/units whose composition or shape differ between models

Screw type/torque list

Stacker Assy

---

 The removed parts/units differ between models when the name of each model is indicated and

enclosed in a box. If “Go to the next step” is indicated for a specific model in the box, skip the step for the model and go to the next step.

 This flowchart is made on the premise that the parts/units instructed in "4.2.2 Parts/Units Need

to be Removed in Advance (p55)" are already removed in advance.

 See "4.2.3.4 Printhead/Ink Supply Unit (p62)" for disassembly of the Printhead and Ink Supply

Unit.

 See "4.2.3.5 2nd Cassette Unit (p63)" for disassembly of the 2nd Cassette Unit.

Symbol Screw Type Torque

C.B.P-TITE SCREW 2x6-F/ZN-3C 2 ± 1 kgf·cm

C.B.P-TITE SCREW 3x10-F/ZN-3C 6 ± 1 kgf·cm

C.B.S-TITE SCREW 3x6-F/ZN-3C 6

C.P.SCREW 3x6-F/ZN-3C 6 ± 1 kgf·cm

C.P.SCREW 3x6-F/ZN-3C 2

C.B.P-TITE (P2) SCREW 3x10-F/ZN-3C 6 ± 1 kgf·cm

C.B.P-TITE SCREW 3x8-F/ZN-3C 6

C.P.SCREW 2.5x6-F/ZN-3C 2 ± 5 kgf·cm

C.P.SCREW 3x5-F/ZN-3C 6

S10

C.B.S-TITE (P4) SCREW 3x8-F/ZN-3C 6 ± 1 kgf·cm

S11

C.B.P-TITE SCREW 2.5x8-F/ZN-3C 6

S12

C.B.P-TITE SCREW 2x10-F/ZN-3C 3 ± 0.5 kgf·cm

S13

C.B.P-TITE (S-P1) SCREW 3x12-F/ZN-3C 6

S14

C.B.S-TITE (P4) SCREW 3x10-F/ZN-3C 6 ± 1 kgf·cm

S15

C.P.SCREW 3x4-F/ZN-3C 6

S16

C.B.EP-TITE SCREW 2x16 (B=10) F/ZN-3C 2.5 ± 0.4 kgf·cm

± 1 kgf·cm

± 5 kgf·cm

± 1 kgf·cm

Flowchart 4-1. Disassembling Flowchart of Exterior Parts (1)

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(p 58)

WP-M4095/ 4015/4011

Panel Board

Panel Housing

(p 65)

Upper Assy

---

WP-M4595/4525/ 4521

Panel Board

(p 65)

Sub Board Assy

---

(p 65)

Panel Housing

Upper Assy

---

Sub Board

---

Sub Board FFC

---

LCD Cover

---

LCD Module

---

ADF Unit

(p 71) (p 72)

Scanner Unit

(p 72)

---

ADF Rear Cover

(p 71)

ADF Cover Assy

(p 71)

ADF Cover

Housing Upper

---

(p 70)

LD Shaft

---

Extension Spring

0.99

---

LD Cover

ADF Document

Support Assy

ADF LD Assy

---

Flowchart 4-2. Disassembling Flowchart of Exterior Parts (2)

(p 71)

Common parts/units

Parts/units whose composition or shape differ between models

---

Screw type/torque list

Symbol Screw Type Torque

C.B.P-TITE SCREW 2x6-F/ZN-3C 2 ± 1 kgf·cm

C.B.P-TITE SCREW 3x10-F/ZN-3C 6 ± 1 kgf·cm

C.B.S-TITE SCREW 3x6-F/ZN-3C 6

C.P.SCREW 3x6-F/ZN-3C 6 ± 1 kgf·cm

C.P.SCREW 3x6-F/ZN-3C 2

C.B.P-TITE (P2) SCREW 3x10-F/ZN-3C 6 ± 1 kgf·cm

C.B.P-TITE SCREW 3x8-F/ZN-3C 6

C.P.SCREW 2.5x6-F/ZN-3C 2 ± 5 kgf·cm

C.P.SCREW 3x5-F/ZN-3C 6

S10

C.B.S-TITE (P4) SCREW 3x8-F/ZN-3C 6 ± 1 kgf·cm

S11

C.B.P-TITE SCREW 2.5x8-F/ZN-3C 6

S12

C.B.P-TITE SCREW 2x10-F/ZN-3C 3 ± 0.5 kgf·cm

S13

C.B.P-TITE (S-P1) SCREW 3x12-F/ZN-3C 6

S14

C.B.S-TITE (P4) SCREW 3x10-F/ZN-3C 6 ± 1 kgf·cm

S15

C.P.SCREW 3x4-F/ZN-3C 6

S16

C.B.EP-TITE SCREW 2x16 (B=10) F/ZN-3C 2.5 ± 0.4 kgf·cm

± 1 kgf·cm

± 5 kgf·cm

± 1 kgf·cm

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S11

S10

S14

4.2.3.3 Printer Mechanism

Middle Housing

(p 64)

Main Board Unit

(p 65)

(p 74) (p 77)

(p 58)

 The removed parts/units differ between models when the name of each model is indicated and

enclosed in a box. If “Go to the next step” is indicated for a specific model in the box, skip the step for the model and go to the next step.

 See "4.2.3.4 Printhead/Ink Supply Unit (p62)" for disassembly of the Printhead and Ink Supply

Unit.

---

Rear ASF Assy

(p 61)

(p 69) (p 77)

---

CSIC FFC

---

(p 73)

Rear ASF Guide

Upper Assy

Metal Plate Left

(p 67) (p 72)

PF Encoder

---

PF Tension

Stopper Holder

Decompress

Pump Unit

S6S3

(p 69) (p 73)

Power Supply

Unit

---

(p 61)

Decompress Pump

Unit

CR Cover

Ink Supply Unit Grounding Plate

Ink Supply Unit/

Printhead

(p 61)

Maintenance Box

Ink Eject Joint

---

CR Scale /

Extension Spring

3.23

(p 69) (p 77)

---

(p 69) (p 73)

(p 67)

PF Encoder FFC

Ink System Unit

(p 66) (p 73)

(p 73)

(p 77)

PF Timing Belt

---

(p 67) (p 77)

---

(p 69)

(p 73) (p 77)

---

Common parts/units

---

Parts/units whose

---

composition or shape differ between models

Screw type/torque list

Symbol Screw Type Torque

C.B.P-TITE SCREW 2x6-F/ZN-3C 2 ± 1 kgf·cm

Option

Connector

---

Spur Gear 11.2

---

ASF Drive Change

Lever Assy

---

Compound Gear

16,10.4

ASF Drive Change

Lever Holder

---

Spur Gear 11.2

---

Extension Spring

0.63

---

C.B.P-TITE SCREW 3x10-F/ZN-3C 6 ± 1 kgf·cm

C.B.S-TITE SCREW 3x6-F/ZN-3C 6

C.P.SCREW 3x6-F/ZN-3C 6 ± 1 kgf·cm

C.P.SCREW 3x6-F/ZN-3C 2

C.B.P-TITE (P2) SCREW 3x10-F/ZN-3C 6 ± 1 kgf·cm

C.B.P-TITE SCREW 3x8-F/ZN-3C 6

C.P.SCREW 2.5x6-F/ZN-3C 2 ± 5 kgf·cm

C.P.SCREW 3x5-F/ZN-3C 6

S10

C.B.S-TITE (P4) SCREW 3x8-F/ZN-3C 6 ± 1 kgf·cm

S11

C.B.P-TITE SCREW 2.5x8-F/ZN-3C 6

S12

C.B.P-TITE SCREW 2x10-F/ZN-3C 3 ± 0.5 kgf·cm

S13

C.B.P-TITE (S-P1) SCREW 3x12-F/ZN-3C 6

S14

C.B.S-TITE (P4) SCREW 3x10-F/ZN-3C 6 ± 1 kgf·cm

S15

C.P.SCREW 3x4-F/ZN-3C 6

S16

C.B.EP-TITE SCREW 2x16 (B=10) F/ZN-3C 2.5 ± 0.4 kgf·cm

± 1 kgf·cm

± 5 kgf·cm

± 1 kgf·cm

Flowchart 4-1. Disassembling Flowchart of Printer Mechanism (1)

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(p 60)

CR Cover

(p 64)

Decompress Pump

Unit

Ink Supply Unit

Grounding Plate

(p 68)

Ink System Supply

(p 67) (p 73)

Assy

S12

Fasten Plate

Center

(p 73)

---

Metal Plate Left

Fasten Plate Left

(p 73)

---

(p 60)

Power Supply

Unit

Metal Plate Left

Rear ASF Assy

Rear ASF Guide

Upper Assy

Stacker Assy

Head FFC

---

Ink System Unit

ASF Drive Change

Lever Assy

Front Frame Assy

(p 69) (p 73)

(p 77)

---

*1 If you find it difficult to connect the Head

(p 68) (p 74)

FFC to the Printhead when connecting it, it will make the procedure easier to remove the Printhead and the Ink Supply Unit together without disconnecting the joint section.

Frame Base Assy

(p 73) (p 77)

(p 96)

---

Main Frame

Mounting Plate

---

Star Wheel Assy

(p 69) (p 77)

PF T ension

Stopper Holder

PF Timing Belt

EJ Roller

(p 69)

(p 77) (p 96)

---

Main Board Cable

Main Board

Shield Plate Upper

Main Board

(p 60)

Holder

(p 74)

Assy

(p 66)

Common parts/units

Parts/units whose composition or shape differ between models

---

Interface Board

Shield Plate

(p 66)

---

FAX FFC

---

However, once the Printhead is removed from

the Carriage Assy, performing "Checking the

Platen Gap (p91)" is necessary.

*2 The Ink System Supply Assy is an ASP

composed of the Printhead and Ink Supply Unit connected together.

Main Frame Assy

(w/CR Guide

Frame)

(p 67) (p 73)

(p 77) (p 96)

Paper Guide

Upper

PE Lever Holder

Assy

---

(p 66)

Main Board Shield Plate Lower Assy

(p 66)

---

CR Scale/

Driven Pulley

Assy

(p 96)

CR Motor

S15

(p 73) (p 77)

---

Extension Spring

3.23

Driven Pulley

Assy

Support Plate

Right/Left

---

CR Guide Frame

(w/ Carriage Assy)

---

(p 77)

CR Guide Frame

(p 96) (p 77)

---

(p 77)

Carriage Assy

(p 68) (p 96)

(p 77)

---

Screw type/torque list

Symbol Screw Type Torque

C.B.P-TITE SCREW 2x6-F/ZN-3C 2 ± 1 kgf·cm

C.B.P-TITE SCREW 3x10-F/ZN-3C 6 ± 1 kgf·cm

C.B.S-TITE SCREW 3x6-F/ZN-3C 6

C.P.SCREW 3x6-F/ZN-3C 6 ± 1 kgf·cm

C.P.SCREW 3x6-F/ZN-3C 2

C.B.P-TITE (P2) SCREW 3x10-F/ZN-3C 6 ± 1 kgf·cm

C.B.P-TITE SCREW 3x8-F/ZN-3C 6

C.P.SCREW 2.5x6-F/ZN-3C 2 ± 5 kgf·cm

C.P.SCREW 3x5-F/ZN-3C 6

S10

C.B.S-TITE (P4) SCREW 3x8-F/ZN-3C 6 ± 1 kgf·cm

S11

C.B.P-TITE SCREW 2.5x8-F/ZN-3C 6

S12

C.B.P-TITE SCREW 2x10-F/ZN-3C 3 ± 0.5 kgf·cm

S13

C.B.P-TITE (S-P1) SCREW 3x12-F/ZN-3C 6

S14

C.B.S-TITE (P4) SCREW 3x10-F/ZN-3C 6 ± 1 kgf·cm

S15

C.P.SCREW 3x4-F/ZN-3C 6

S16

C.B.EP-TITE SCREW 2x16 (B=10) F/ZN-3C 2.5 ± 0.4 kgf·cm

---

Interface Board

---

(p 66)

± 1 kgf·cm

± 5 kgf·cm

± 1 kgf·cm

Flowchart 4-2. Disassembling Flowchart of Printer Mechanism (2)

Disassembly/Reassembly 61

Confidential

Epson WP-M4595/4525/4521/4095/4015/4011 Revision A

4.2.3.4 Printhead/Ink Supply Unit

The disassembling and reassembling procedure of the Printhead/Ink Supply Unit requires additional steps before and during the procedure. Therefore, the whole flow from disassembling to reassembling is provided below.

Note: The black arrows ( ) indicate disassembling, and the red arrows ( ) show reassembling.

Printhead / Ink Supply Unit START

Releasing the pressure

(p 54)

WP-M4095/4015/4011 WP-M4595/4525/4521

Panel Assy

---

(p 65)

WP-M4095/4015/4011

Panel FFC

WP-M4595/4525/4521

(p 65)

Panel FFC

---

WP-M4095/4015/4011

Go to the next step

WP-M4595/4525/4521

---

Housing Rear

Assy

FAX Cover

WP-M4095/4015/4011 WP-M4595/4525/4521

Housing Upper

Assy

ADF Unit/

Scanner Unit

(p 64)

---

Front Housing

Assy

(p 70) (p 72)

(p 64)

---

WP-M4095/4015/4011

Housing Rear

Assy

WP-M4595/4525/4521

Go to the next step

Checking the platen gap

(p 91)

USB Cover

CR Cover

Middle Housing

Ink leak check

(p 93)

---

(p 64)

Reassemble the printer and perform the

required adjustment

(p 78)

CR Cover

---

(p 64)

Decompress Pump

Unit

Ink Supply Unit

Grounding Plate

(p 68)

Ink Supply Unit

S16

(p 68)

(p 73) (p 77)

Printhead

S12 S16

(p 67)

(p 73) (p 77)

---

Screw type/torque list

Symbol Screw Type Torque

C.B.P-TITE SCREW 2x6-F/ZN-3C 2 ± 1 kgf·cm

C.B.P-TITE SCREW 3x10-F/ZN-3C 6 ± 1 kgf·cm

C.B.S-TITE SCREW 3x6-F/ZN-3C 6

C.P.SCREW 3x6-F/ZN-3C 6 ± 1 kgf·cm

C.P.SCREW 3x6-F/ZN-3C 2

C.B.P-TITE (P2) SCREW 3x10-F/ZN-3C 6 ± 1 kgf·cm

C.B.P-TITE SCREW 3x8-F/ZN-3C 6

C.P.SCREW 2.5x6-F/ZN-3C 2 ± 5 kgf·cm

C.P.SCREW 3x5-F/ZN-3C 6

S10

C.B.S-TITE (P4) SCREW 3x8-F/ZN-3C 6 ± 1 kgf·cm

S11

C.B.P-TITE SCREW 2.5x8-F/ZN-3C 6

S12

C.B.P-TITE SCREW 2x10-F/ZN-3C 3 ± 0.5 kgf·cm

S13

C.B.P-TITE (S-P1) SCREW 3x12-F/ZN-3C 6

S14

C.B.S-TITE (P4) SCREW 3x10-F/ZN-3C 6 ± 1 kgf·cm

S15

C.P.SCREW 3x4-F/ZN-3C 6

S16

C.B.EP-TITE SCREW 2x16 (B=10) F/ZN-3C 2.5 ± 0.4 kgf·cm

Common parts/units

Parts/units whose composition or shape differ between models

± 1 kgf·cm

± 5 kgf·cm

± 1 kgf·cm

Flowchart 4-1. Disassembling Flowchart of Printhead/Ink Supply Unit

Disassembly/Reassembly 62

Confidential

Epson WP-M4595/4525/4521/4095/4015/4011 Revision A

4.2.3.5 2nd Cassette Unit

2nd Cassette Unit START

Cassette Assy

2nd

---

(p 96)

Cassette Cover

---

2nd Cassette

Cover Left

(p 70)

2nd Cassette

Cover Right

(p 70)

2nd Cassette

Housing Assy

2nd Cassette Cover Front

---

Paper Stopper

Assy

---

(p 70)

---

(p 75)

Frame Pickup

Assy

(p 70) (p 75)

Screw type/torque list

---

Pickup Assy 2nd

---

Symbol Screw Type Torque

C.B.P-TITE SCREW 2x6-F/ZN-3C 2 ± 1 kgf·cm

C.B.P-TITE SCREW 3x10-F/ZN-3C 6 ± 1 kgf·cm

C.B.S-TITE SCREW 3x6-F/ZN-3C 6

C.P.SCREW 3x6-F/ZN-3C 6 ± 1 kgf·cm

C.P.SCREW 3x6-F/ZN-3C 2

C.B.P-TITE (P2) SCREW 3x10-F/ZN-3C 6 ± 1 kgf·cm

C.B.P-TITE SCREW 3x8-F/ZN-3C 6

C.P.SCREW 2.5x6-F/ZN-3C 2 ± 5 kgf·cm

C.P.SCREW 3x5-F/ZN-3C 6

S10

C.B.S-TITE (P4) SCREW 3x8-F/ZN-3C 6 ± 1 kgf·cm

S11

C.B.P-TITE SCREW 2.5x8-F/ZN-3C 6

S12

C.B.P-TITE SCREW 2x10-F/ZN-3C 3 ± 0.5 kgf·cm

S13

C.B.P-TITE (S-P1) SCREW 3x12-F/ZN-3C 6

S14

C.B.S-TITE (P4) SCREW 3x10-F/ZN-3C 6 ± 1 kgf·cm

S15

C.P.SCREW 3x4-F/ZN-3C 6

S16

C.B.EP-TITE SCREW 2x16 (B=10) F/ZN-3C 2.5 ± 0.4 kgf·cm

± 1 kgf·cm

± 5 kgf·cm

± 1 kgf·cm

Flowchart 4-1. Disassembling Flowchart of 2nd Cassette Unit

Disassembly/Reassembly 63

Confidential

Epson WP-M4595/4525/4521/4095/4015/4011 Revision A

Rib A

C.B.P-TITE SCREW 3x10 F/ZN-3C (6 ± 1 kgf·cm)

FAX Cover/

USB Cover

Rear right

Rear left

C.B.P-TITE SCREW 3x10 F/ZN-3C (6 ± 1 kgf·cm)

Housing Upper Assy

Rib B Hook

Inside Front Cover

Front Cover

Rib A

C.B.P-TITE SCREW 3x10 F/ZN-3C (6 ± 1 kgf·cm)

Cross-section

Middle Housing

Rib A

Front

Housing Assy

Bottom left

Hook

Bottom right

Hook

Front

Housing Assy

Middle Housing

C.B.P-TITE SCREW 3x10 F/ZN-3C (6 ± 1 kgf·cm)

Rear left

Ribs of Frame Base

Rear right

Ribs of Frame Base

Housing Rear Assy

C.B.P-TITE SCREW 3x10 F/ZN-3C (6 ± 1 kgf·cm)

Rear left

Rear right

Hook

Right side of Carriage Assy

Carriage Assy

CR Cover

4.3 Detailed Disassembly/Reassembly Procedure for each Part/Unit

FAX Cover/USB Cover

The name and the shape of this part differ, but the disassembly procedure for this part is the same. The names are FAX Cover for WP-M4595/4525/4521 and USB Cover for WP-M4095/4015/

4011. Remove the FAX Cover/USB Cover by sliding it in the direction of

the arrow shown above carefully not to damage the rib A (x4) that secure the FAX Cover/USB Cover.

Housing Upper Assy (WP-M4095/4015/4011)

Tighten the screws in the order indicated in the figure above.

Front Housing Assy

The structure of the rib A on the Front Housing Assy is as shown in the cross-section above, and it is extremely fragile. Therefore, be careful not to damage the rib A when removing the Front Housing Assy.

 The positions of the rib A (x3) and rib B (x7) of the Front Housing Assy are shown in the figure above.

When releasing the hooks (x2) of the Front Housing Assy, insert a screw driver or the like from the hole on the bottom of the printer and release them.



Tighten the screws in the order indicated in the figure above.

Middle Housing

Disassembly/Reassembly Detailed Disassembly/Reassembly Procedure for each Part/Unit 64

 After reassembling the Middle Housing, make sure the ribs of the Frame Base are aligned and fit in with the Middle Housing without any gap.  Tighten the screws in the order indicated in the figure above.

Tighten the screws in the order indicated in the figure above.

Housing Rear Assy

CR Cover

After installing the CR Cover to the Carriage Assy, make sure the CR Cover is firmly secured with the hooks (x3) shown above.

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Epson WP-M4595/4525/4521/4095/4015/4011 Revision A

Hook A Hook B

Back of Panel Assy

Panel Assy

Bottom left of Scanner Unit

Scanner

Unit

Scanner

Unit

Bottom right of Scanner Unit

Panel Assy

Scanner

Unit

Front

Cover

Hook C Rib

Panel Assy

Bottom of Panel Assy

Bottom of Housing Upper Assy

Housing Upper Assy

Hook A Hook B

Rib A Rib B

Housing Upper Assy

Front

Cover

Panel Assy

WP-M4595/4525/4521

Panel Board Panel Housing Upper

Panel Housing Upper

Panel Board

WP-M4095/4015/4011

C.B.P-TITE SCREW 3x10 F/ZN-3C (6 ± 1 kgf·cm) C.B.P-TITE SCREW 3x8 F/ZN-3C (6 ± 1 kgf·cm)

Positioning hole and dowel

Locked

LCD FPC

Connector lock

C.B.P-TITE SCREW 2x6 FZN-3C (2 ± 1 kgf·cm)

Unlocked

LCD FPC

Connector lock

Main

Board Unit

Legs

Left

Main Frame

Rib and hole

C.B.S-TITE SCREW 3x6 F/ZN-3C (6 ± 1 kgf·cm) C.P.SCREW 3x5 F/ZN-3C (6 ± 1 kgf·cm)

Main Board Unit

MAC Address Label

Main Board Unit Bracket Front

Main Board Unit Bracket Rear

Panel Assy (WP-M4595/4525/4521)

Panel Assy (WP-M4095/4015/4011)

When removing the Panel Assy, follow the procedure below.

1. Open the Front Cover, and release the hook A (x2) of the Panel Assy from the bottom of the Scanner Unit.

2. Release the hook B (x5) of the Panel Assy.

3. Lift the Panel Assy in the direction of the arrow and release the ribs (x5) and hook C (x2) on the top of the Panel Assy, and then remove the Panel Assy.

Panel Board (WP-M4595/4525/4521/4095/4015/4011)

Sub Board Assy (WP-M4595/4525/4521)

When removing the Panel Assy, follow the procedure below.

1. Open the Front Cover, and release the hook A of the Panel Assy from the bottom of the Housing Upper Assy.

2. Release the hook B (x5) and rib A (x3) of the Panel Assy.

3. Slide the Panel Assy slightly in the direction of the arrow and release the rib B (x2), and remove the Panel Assy.

Main Board Unit

Before removing the Sub Board Assy, unlock the connector lock on the Sub Board Assy that secures the LCD FPC.

 Tighten the screws in the order indicated in the figure above.  When connecting the LCD FPC, make sure to insert the LCD

FPC into the connector to the full and secure it with the connector lock.

Be careful not to damage or contaminate the MAC Address Label.

 When installing the Main Board Unit, insert the ribs of the Main Board Unit Bracket Fro n t/Ma in Board Unit Bracket Rear into the holes of the

Main Board Unit.

 Tighten the screws in the order indicated in the figure above.  After installing the Main Board Unit, make sure the legs of the Main Board Unit Grounding Plate touch the Main Frame.

Confidential

 Tighten the screws in the order indicated in the figure above.  When installing the Panel Board, align the positioning holes

(WP-M4595/4525/4521: x3, WP-M4095/4015/4011: x2) of the Panel Board with the dowels (WP-M4595/4525/4521: x3, WPM4095/4015/4011: x2) of the Panel Housing Upper.

 After installing the Panel Board, press all buttons on the Panel

Board Assy to check if they click and do not come off.

Disassembly/Reassembly Detailed Disassembly/Reassembly Procedure for each Part/Unit 65

Epson WP-M4595/4525/4521/4095/4015/4011 Revision A

Back

C.B.S-TITE SCREW 3x6 F/ZN-3C (6 ± 1 kgf·cm) C.P.SCREW 3x6 F/ZN-3C (2 ± 5 kgf·cm)

Main Board Shield

Plate Upper Assy

Inside

Interface Board

FFC

C.P.SCREW 2.5x6 F/ZN-3C (2 ± 5 kgf·cm)

Main Board

Main Board Shield

Plate Lower Assy

C.P.SCREW 3x6 F/ZN-3C (6 ± 1 kgf·cm)

C.B.S-TITE SCREW 3x6 F/ZN-3C (6 ± 1 kgf·cm)

Interface Board Grounding Plate

Step 1

Main Board Shield Plate Upper Assy

Interface Board

Step 2

Step 3-4

Interface Board Shield Plate

Positioning hole and dowel

Screw hole

Ink System Unit

Dowel Hole

Ink System Unit

A BEDC

Maintenance

Box Ink Eject

Joint

Frame Base

Ink System

Tube

clamp

Hole of Frame Base

C.B.P-TITE SCREW 3x10 F/ZN-3C (6 ± 1 kgf·cm)

Groove

Acetate tape

Ink System

Tube

clamp

Main Board Shield Plate Upper Assy

Main Board / Main Board Shield Plate Lower Assy

Ink System Unit

The Interface Board FFC is connected to the back of the Main Board Shield Plate Upper Assy, therefore, be careful of it when removing the Main Board Shield Plate Upper Assy.

Tighten the screws in the order indicated in the figure above.

Interface Board (WP-M4595/4525/4521)

Tighten the screws in the order indicated in the figure above.

When connecting the Ink System Tube to the Maintenance Box Ink Eject Joint, make sure to insert the end of the tube into the socket on the Maintenance Box Ink Eject Joint up to the full to its base in order to prevent the waste ink from leaking.

When installing the Interface Board, follow the procedure below.

Disassembly/Reassembly Detailed Disassembly/Reassembly Procedure for each Part/Unit 66

1. Place the Interface Board Grounding Plate on the Main Board Shield Plate Upper Assy aligning the positioning hole of the Interface Board Grounding Plate with the dowel on the Main Board Shield Plate Upper Assy.

2. Place the Interface Board on the Interface Board Grounding Plate aligning the screw holes on the Interface Board, Interface Board Grounding Plate and Main Board Shield Plate Upper Assy.

3. Place the Interface Board Shield Plate on the Interface Board aligning the screw holes on the Interface Board Shield Plate and the Interface Board.

4. Tighten the screws (x3) in the order indicated in the figure above to secure the Interface Board Grounding Plate, Interface Board and Interface Board Shield Plate together.

When installing the Ink System Unit, follow the procedure below.

1. Route the Ink System Tube through the hole of the Frame Base.

2. Align the dowels A to dowel E of the Ink System Unit with the hole A to hole E of the Frame Base, and install the Ink System Unit to the Frame Base.

3. Insert the end of the Ink System Tube into the socket on the Maintenance Box Ink Eject Joint to the full up to its base, and secure the tube with the tube clamp.

4. Route the Ink System Tube through the groove of the Frame Base, and secure it with acetate tape.

5. Tighten the screws (x2) in the order indicated in the figure above to secure the Ink System Unit to the Frame Base.

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Epson WP-M4595/4525/4521/4095/4015/4011 Revision A

Cutout

Metal Plate Left

Align cutout with rib.

Frame Base Assy

C.B.P-TITE SCREW 2.5x8 F/ZN-3C (6 ± 1 kgf·cm)

PF Encoder

PF Scale

PF Encoder

PF Scale

Left

APG Lever

APG Change Lever

Bottom left

Rib

Cutout

Right

Left

PF Scale Sheet

Bottom right

Rib

Cutout

Hole and rib Hole and hook

C.B.S-TITE SCREW 3x6 F/ZN-3C (6 ± 1 kgf·cm)

Frame Base Assy

Main Frame Assy

Do not remove.

Section A

C.B.P-TITE SCREW 2x10 F/ZN-3C (3 ± 0.5 kgf·cm)

C.B.S-TITE SCREW 3x6 F/ZN-3C (6 ± 1 kgf·cm)

Positioning hole and dowel

Section A

C.B.P-TITE SCREW 2x10 F/ZN-3C (3 ± 0.5 kgf·cm)

Thickness gauge (2 mm)

Printhead

Carriage Assy

Star Wheel Assy

Position for thickness

gauge (2 mm)

Attach tape on the yellow box to

protect the area from ink.

Metal Plate Left

 When installing the Metal Plate Left to the Frame Base Assy,

align the cutout of the Metal Plate Left with the rib of the Frame Base Assy.

 Tighten the screws in the order indicated in the figure above.

PF Encoder / PF Timing Belt



When installing the PF Encoder, set the encode r ov er th e PF Scale with the scale in the slit as shown in the figure above. After installing PF Encoder, make sure it does not touch the PF Scale.

 Install the PF Timing Belt as shown above and make sure the

belt is correctly attached to the gears and pulley.

Main Frame Assy (w / CR Guide Frame)

 When installing the Main Frame Assy to the Frame Base Assy, make sure of the following.

• Align the holes (x2) of the Main Frame Assy with the ribs (x2) of the Frame Base Assy shown above.

• Align the cutout on the bottom of the Main Frame Assy with the rib of the Frame Base Assy.

• Engage the APG Lever with the APG Change Lever properly.

• Align the hook of the PF Scale Sheet with the hole of the Main Frame Assy.

 Tighten the screws in the order indicated in the figure above.

Ink System Supply Assy (Ink Supply Unit w/ Printhead)

Printhead

 To replace the Printhead, it is necessary to disconnect the joint section of the Printhead and the ink tubes of the Ink Supply Unit. Before

disconnecting the joint section, perform “Ink Pressure Release” in advance. (See "4.2.1 Caution when Replacing the Printhead/Ink Supply Unit

(p54)" and " Ink Supply Unit (p68)".)

 When disconnecting the joint section of the ink tubes of the Ink Supply Unit and the Printhead, ink may slightly spill over from the ink tubes

even if “Ink Pressure Release” has been performed. To protect the Printhead from the d am age caused by the spille d ink if the ink reaches up to the control board of the Printhead, make sure to attach tape over the connectors to protect them beforehand, then disconnect the joint section of the ink tubes of the Ink Supply Unit and the Printhead.

 When disconnecting the ink tubes of the Ink Supply Unit from the Printhead to replace the Printhead, make sure to replace the rubber packing

Disassembly/Reassembly Detailed Disassembly/Reassembly Procedure for each Part/Unit 67

 When removing/installing the Printhead, move the Carriage Assy to the center of the printer, and place the thickness gauge (2 mm) between the

Carriage Assy and Star Wheel Assy in order to prevent the CR Guide Frame and Main Frame from being deformed. (See " Printhead (p67)".)

 To prevent ink leakage, make sure not to separate the ink tubes from the I/C Holder Unit by removing the screws (x2) in section A shown above.

Loosening the screws even just once will cause ink leakage, therefore, make sure to replace the Ink System Supply Assy with a new one.

When installing the Ink System Supply Assy, see " Printhead (p67)" and " Ink Supply Unit (p68)".

between the ink tubes and the Printhead with a new one in order to prevent ink leakage. (See " Ink Supply Unit (p68)".)

 When removing/installing the Printhead, move the Carriage Assy to the center of the printer, and place the thickness gauge (2 mm) between the

Carriage Assy and Star Wheel Assy in order to prevent the CR Guide Frame and Main Frame from being deformed.

 Tighten the screws in the order indicated in the figure above.  After installing the Printhead, make sure to connect the ink tubes to the Printhead. (See " Ink Supply Unit (p68)".)

When replacing the Printhead, make sure to perform "5.2.6 Ink Leak Check (p93)".

Confidential

Epson WP-M4595/4525/4521/4095/4015/4011 Revision A

End of ink tube

Rubber packing

Holes of Printhead

Joint section

C.B.S-TITE SCREW 3x6 F/ZN-3C (6 ± 1 kgf·cm)

Positioning hole and dowel

C.B.EP-TITE SCREW 2x16(B=10) F/ZN-3C (2.5 ± 0.4 kgf·cm)

I/C Holder Unit

Ink tube

Rubber packing

Tube Holder A

Step 2

Step 1

Tube Spacers

Ink tube

Attachment positions of Tube Holder B

Step 5

Tube Holder B

Carriage Assy

Align Tube Holder C with

groove of Carriage Assy.

Step 4

I/S Supply Unit

Support Jig

Step 2

Head FFC Holder

Rib B and hole A Rib C and cutout Hook and hole B

Rib A

Front Frame

Rib of Front Frame

Step 1

Head FFC Holder

Head FFC

Front Tube Guide

Tube

Holders

Step 3: Back of Front Frame

Cross-section of

Tube Holder

Front Tube

Guide

Head

FFC

C.B.S-TITE SCREW 3x6 F/ZN-3C (6 ± 1 kgf·cm)

Rib

Ink Supply Unit

Grounding Plate

Front Frame Assy

Hook

Bottom

APG Slider

Rear

APG Slider

Carriage Assy

CR Guide Frame

Ink Supply Unit

Head FFC

When installing the Head FFC, follow the procedure below.

1. Fit in the rib of the Front Frame to the space between the rib A (x3).

2. Align the rib B (x3), rib C (x2) and hook of the Head FFC Holder with the hole A (x3), cutouts (x2) and the hole B of the Front Frame, and slide the Head FFC Holder in the direction of the arrow to secure it to the Front Frame.

3. Insert the Front Tube Guide between the Tube Holder and Head FFC.

 Before disconnecting the joint section of the Printhead and the ink tubes of the Ink Supply Unit, it is necessary to p erform “Ink Pressure Release”

in advance. Make sure to perform “Ink Pressure Release”, otherwise, the ink in the ink tube will spill over. (See "4.2.1 Caution when Replacing

Ink Supply Unit Grounding Plate

Carriage Assy

the Printhead/Ink Supply Unit (p54)".)

 When disconnecting the joint section of the ink tubes of the Ink Supply Unit and the Printhead, ink may slightly spill over from the ink tubes

even if “Ink Pressure Release” has been performed. To protect the Printhead from the damage caused by the spilled ink if the ink reaches up to the control board of the Printhead, make sure to attach tape over the connectors to protect them beforehand, then disconnect the joint section of the ink tubes of the Ink Supply Unit and the Printhead. (See " Printhead (p67)".)

 When disconnecting the ink tubes from the Printhead, make sure to replace the rubber packing between the ink tubes and the Printhead with a

new one in order to prevent ink leakage.

 When connecting the ink tubes to the Printhead, place the thickness gauge (2 mm) between the Carriage Assy and Star Wheel Assy in order to

prevent the CR Guide Frame and Main Frame from being deformed. (See " Printhead (p67)".)

 When Ink Supply Unit Fixed, I/S Supply Unit SUpport Jig put on between Ink Supply Unit and Front Flame to prevent the defect of reading

CSIC caused by transformation of Main Flame and I/S Supply Unit.

When installing the Ink Supply Unit, follow the procedure below.

1. Align the positioning holes (x2) and dowels (x2) shown above, and tighten the screws (x4) of the I/C Holder Unit in the order indicated in the figure above.

3. Move the Carriage Assy to the center of the printer.

4. While aligning the Tube Holder C attached on the ink tubes with the groove of the Carriage Assy, insert the joint section on the end of the ink tubes into the holes of the Printhead, and then secure the end of the ink tubes with the screws (x2).

5. Secure the ink tubes with the Tube Holder B (x3), and then adjust their attachment positions to between the Tube Spacers.

Once you loosen the screws on the joint section of the ink tubes to the Printhead, make sure to perform "5.2.6 Ink Leak Check (p93)".

Disassembly/Reassembly Detailed Disassembly/Reassembly Procedure for each Part/Unit 68

2. Secure the ink tubes with the Tube Holder A (x3).

When installing the Ink Supply Unit Grounding Plate, secure it with the hook of the Ink Supply Unit and rib of the Front Frame, and tighten the screws (x2) in the order indicated in the figure above.

Before installing the Carriage Assy to the CR Guide Frame, make sure the APG Slider is correctly installed to the Carriage Assy as shown above.

Confidential

Epson WP-M4595/4525/4521/4095/4015/4011 Revision A

C.B.P-TITE SCREW 3x10 F/ZN-3C (6 ± 1 kgf·cm) C.B.S-TITE SCREW 3x6 F/ZN-3C (6 ± 1 kgf·cm)

Front Frame Assy

Front

Front Frame Assy

Top

Frame Base

Assy

Dowel and positioning hole

C.B.P-TITE SCREW 3x10 F/ZN-3C (6 ± 1 kgf·cm)

Rear ASF

Assy

Rear right

Trigger Lever Clutch Lever

Rear ASF

Assy

Rear left

C.B.P-TITE SCREW 3x10 F/ZN-3C (6 ± 1 kgf·cm)

Rib Dowel and

positioning hole

Rear ASF Guide Upper Assy

Step 1

Step 2

Holes of Frame Driven Assy

Black mark

Carriage Assy

Slit of CR

Encoder

CR Scale

Carriage Assy

1 2

C.B.P-TITE(S-P1) SCREW 3x12 F/ZN-3C (6 ± 1 kgf·cm)

Paper Guide Front Assy Star Wheel Assy

Dowel and positioning hole

C.B.S-TITE SCREW 3x6 F/ZN-3C (6 ± 1 kgf·cm) C.B.P-TITE SCREW 3x10 F/ZN-3C (6 ± 1 kgf·cm)

Power Supply Unit

C.B.P-TITE(P2) SCREW 3x10 F/ZN-3C (6 ± 1 kgf·cm) C.B.P-TITE SCREW 3x10 F/ZN-3C (6 ± 1 kgf·cm) C.B.S-TITE SCREW 3x6 F/ZN-3C (6 ± 1 kgf·cm)

Joint of Ink

Supply Unit

Hooks

Ink Supply Unit

Back

Decompress

Pump Unit

EJ Roller

Grounding spring

Dowel

EJ Roller

Bush, 5

Front Frame Assy

Tighten the screws in the order indicated in the figure above.

Rear ASF Assy

 When installing the Rear ASF Assy to the Frame Base Assy,

move the Trigger Lever in the direction of the arrow to prevent it from touching the Clutch Lever, and align the positioning holes (x2) of the Rear ASF Assy with the dowels (x2) of the Frame Base Assy.

 Tighten the screws in the order indicated in the figure above.

Rear ASF Guide Upper Assy

When installing the Rear ASF Guide Upper Assy, follow the procedure below.

1. Insert the ribs (x2) on the 80-digit side of the Rear ASF Guide Upper Assy into the holes (x2) of the Frame Driven Assy.

2. Align the positioning hole on the 0-digit side of the Rear ASF Guide Upper Assy with the dowel of the Frame Base Assy, and secure the Rear ASF Guide Upper Assy with the screw.

CR Scale

 Install the CR Scale with the black mark section up.  Make sure to put the CR Scale through the slit of the CR

Encoder.

Star Wheel Assy

Disassembly/Reassembly Detailed Disassembly/Reassembly Procedure for each Part/Unit 69

When installing the Star Wheel Assy, align the positioning holes (x2) on the bottom of the Star Wheel Assy with the dowels (x2) of the Paper Guide Front Assy, and tighten the screws (x2) in the order indicated in the figure above.

When removing the Power Supply Unit, the Power Supply Unit cable may touch the Frame. Be careful not to damage the Power Supply Unit cable then.

Tighten the screws in the order indicated in the figure above.

Power Supply Unit

Decompress Pump Unit

 Tighten the screws in the order indicated in the figure above.  Route the Decompress Pump Tube through the hooks (x2) of

the Ink Supply Unit, and insert the end of the tube into the joint on the Ink Supply Unit to the full up to its base.

EJ Roller

Release the dowel of the Bush, 5, and detach it from the frame by rotating it in the direction of the arrow, and t hen remov e the E J Roller.

Make sure the grounding spring touches the EJ Roller on the position shown above.

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Epson WP-M4595/4525/4521/4095/4015/4011 Revision A

Metal Plate Paper Stopper Assy 1st

Dowel and positioning hole

C.B.S-TITE SCREW 3x6 F/ZN-3C (6 ± 1 kgf·cm)

2nd Cassette Unit

C.B.P-TITE SCREW 3x8 F/ZN-3C (6 ± 1 kgf·cm)

Paper Stopper Assy 2nd

Dowel and positioning hole

Cam Slider

Slider Base

Slider Cassette

Paper Stopper

Compression Spring 0.9

Compression Spring 0.188

Secure springs (x4) with dowels.

2nd Cassette Cover Left

Hole

C.B.P-TITE SCREW 3x10 F/ZN-3C (6 ± 1 kgf·cm)

Cross-section

Hook

2nd Cassette

Cover Left

FrontRear

2nd Cassette Cover Right

Hole

C.B.P-TITE SCREW 3x10 F/ZN-3C (6 ± 1 kgf·cm)

Hook

2nd Cassette

Cover Right

Cross-section

Front Rear

Dowel and positioning hole

Frame Pickup Assy

2nd Cassette Housing Assy

C.B.P-TITE SCREW 3x10 F/ZN-3C (6 ± 1 kgf·cm)

Rear left

Rear right

C.B.P-TITE SCREW 3x10 F/ZN-3C (6 ± 1 kgf·cm) C.B.S-TITE-SCREW 3x6 F/ZN-3C (6 ± 1 kgf·cm)

Scanner Unit

C.B.P-TITE SCREW 3x10 F/ZN-3C (6 ± 1 kgf·cm)

Hook Rib

ADF Cover Housing Upper

Paper Stopper Assy 1st

When installing the Paper Stopper Assy 1st, align the positioning holes (x2) of the Paper Stopper Assy 1st with the dowels (x2) of the Metal Plate, and tighten the screws (x2) in the order indicated in the figure above.

Paper Stopper Assy 2nd

When installing the Paper Stopper Assy 2nd, align the

positioning holes (x2) of the Paper Stopper Assy 2nd with the dowels (x2) of the 2nd Cassette Unit, and tighten the screws (x2) in the order indicated in the figure above.

Paper Stopper Assy 1st / 2nd

If any of the parts of the Paper Stopper Assy 1st/2nd comes off when removing it, be sure to reassemble the Paper Stopper Assy 1st/2nd as shown above.

2nd Cassette Cover Left

When releasing the hooks (x3) of the 2nd Cassette Cover Left, release them in the order from the front side to the rear side of the printer by inserting a screw driver or the like into the holes of the 2nd Cassette Cover Left and then pushing the hooks in the direction of the arrow.

Tighten the screws in the order indicated in the figure above.

2nd Cassette Cover Right

When releasing the hooks (x3) of the 2nd Cassette Cover Right, release them in the order from the front side to the rear side of the printer by inserting a screw driver or the like into the holes of the 2nd Cassette Cover Right and then pushing the hooks in the direction of the arrow.

Tighten the screws in the order indicated in the figure above.

Disassembly/Reassembly Detailed Disassembly/Reassembly Procedure for each Part/Unit 70

 When installing the Frame Pickup Assy to the 2nd Cassette

Housing Assy, align the positioning holes (x2) of the Frame Pickup Assy with the dowels (x2) of the 2nd Cassette Housing Assy.

 Tighten the screws in the order indicated in the figure above.

Frame Pickup Assy

ADF Unit / Scanner Unit (WP-M4595/4525/4521)

Tighten the screws in the order indicated in the figure above.

ADF Cover Housing Upper (WP-M4595/4525/4521)

The figures above indicate the hooks (x2), ribs (x3) and screws (x4) that secure the ADF Cover Housing Upper.

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Epson WP-M4595/4525/4521/4095/4015/4011 Revision A

Hook Dowel

ADF Pad Assy

ADF Cover Assy

Screw hole

ADF Rear Cover

ADF Document Support Assy

ADF Unit

C.B.P-TITE SCREW 3x10 F/ZN-3C (6 ± 1 kgf·cm)

ADF Pad Assy

ADF Cover Assy

ADF Document Support Assy

ADF Rear Cover

ADF Unit (WP-M4595/4525/4521)

The figures above indicate the hooks, dowels and screws that secure the parts and units.

Disassembly/Reassembly Detailed Disassembly/Reassembly Procedure for each Part/Unit 71

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Rib

C.B.S-TITE-SCREW-3 x 6-F/ZN-3C (6 ± 1kgf·cm)

Ferrite core

Shield plate of Main Board Assy

Scanner grounding wire

Metal Plate

Hook

Hole of Frame Base

Clamp

Paper Stopper Lever Sensor cable

Bottom

Hook

Secure ferrite core with hook.

Rib

Scanner Motor cable

Scanner FFC

Pull out ADF

cables (x5) here.

Pull out Scanner

FFC here.

Pull out Scanner

Motor cable here.

Scanner Unit

CN37

Scanner FFC

Scanner Motor cable

CN55

CN# Name

CN37 Scanner FFC CN38 ADF PE Sensor cable CN39 Document Sensor cable CN40 ADF Encoder cable CN54 ADF Motor cable CN55 Scanner Motor cable

CN39

CN38

CN40

CN54

ADF Motor cable/ADF Document Sensor cable/ADF grounding wire

Route them through rib on the left side of screw boss on Middle Housing.

ADF grounding wire

C.B.S-TITE-SCREW-3 x 6-F/ZN-3C (6 ± 1kgf·cm)

Scanner

Unit

Middle Housing

ADF PE Sensor cable

ADF Encoder cable

ADF Motor cable

ADF Document Sensor cable

ADF Encoder cable/ADF PE Sensor cable

Route them through rib on the right side of screw boss on Middle Housing.

Rear

Metal Plate Left

Bottom left

Front

Frame

PF Motor

cable

Hook Rib

ASF Motor relay cable

Clamp

PF Motor cable

Frame Base

PF Motor cable

Front Frame

4.3 Routing FFCs/cables

Top of the Scanner Unit

(WP-M4595/4525/4521)

Route the Scanner grounding wire through the ribs (x4) of the Sc an ne r U n it and insert the ferrite core of it into the position shown above, and then secure the end of the grounding wire to the shield plate of the Main Board Assy with the screw.

Bottom of the Frame Base

Route the Paper Stopper Lever Sensor cable through the hooks (x3) and clamp of the Metal Plate, and then route it through the hole of the Frame Base.

Bottom of the Scanner Unit

(WP-M4595/4525/4521)

 Pull out the Scanner Motor cable from the hole of the Scanner Unit as shown above, and then route it through the hooks (x4) of the Scanner Unit.  Pull out the Scanner FFC from the hole of the Scanner Unit as shown above, and then route it through the hooks (x4) of the Scanner Unit.  Secure the ferrite core of the Scanner FFC on the position shown above with the hook.  Route the following cables related to the ADF through the space between the ribs and the rim on the rear side of the printer as shown above, and secure

them with the hooks (x4). (WP-M4595/4525/4521 only)

• ADF PE Sensor cable • ADF Document Sensor cable • ADF Motor cable

• ADF Encoder cable • ADF grounding wire

Inside the FAX Cover (WP-M4595/4525/4521)

 Route the Scanner FFC and Scanner Motor cable as shown above, and connect them to the connectors on the Main Board as indicated in the above table.  Route the following cables related to the ADF as shown above, and connect them to the connectors on the Main Board as indicated in the above table.

(WP-M4595/4525/4521 only)

• ADF PE Sensor cable • ADF Motor cable • ADF grounding wire (secure it to the shield plate on the Main Board with the screw)

• Document Sensor cable • ADF Encoder cable

Disassembly/Reassembly Routing FFCs/cables 72

 PF Motor cable Route it through the hooks (x2) of the Frame Base and the hooks (x2) of the Metal Plate Left, and then route it through the

hooks (x7), rib and clamp of the Front Frame.

 ASF Motor relay cable Route it under the rib of the Frame Base and rib of the Front Frame, and then route it through the clamp.

Front of the Printer

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Epson WP-M4595/4525/4521/4095/4015/4011 Revision A

Left

PF Encoder FFC

Fasten Plate Left

Double-sided tape

Hook Rib

Acetate tape

Rear

Fasten Plate Center

Ink Supply Unit

Main Frame

CSIC FFC

Decompress Pump cable

Decompress Pump Unit

Decompress Pump cable

Make one turn

Power Supply Unit cable

Rear ASF Guide Upper Assy

Decompress Pump Unit

Ink Supply Unit

Main Frame

CSIC FFC

PF Encoder FFC

Fasten Plate Center

Hook

Main Frame Assy

Hole of Holder Cam

Rear right

Paper Stopper Lever

Sensor cable

Paper Guide Front Assy

PE Sensor cable

Hole of Frame Base

Acetate tape

Frame Base

ASF Encoder relay cable

Top of the Printer

Bottom of the Ink System Unit

Route the Paper Stopper Lever Sensor cable, PE Sensor cable and ASF Encoder relay cable as follows, and then route them under the Main Frame Assy and pull them out from the hole of the Holder Cam Assy.

 Paper Stopper Lever Sensor cable Pull it out from the hole of the Frame Base, and secure it on the position shown above with acetate tape.  PE Sensor cable Pull it out under the Paper Guide Front Assy and route it through the hooks (x2) of the Frame Base, and then secure

it on the position shown above with acetate tape.

 ASF Encoder relay cable Route it through the hooks (x3) of the Frame Base, and then secure it on the position shown above with acetate tape.

 Power Supply Unit cable Route it through the ribs (x5) of the Rear ASF Guide Upper Assy.  Decompress Pump cable Route it through the ribs (x3) and hooks (x2) of the Decompress Pump Unit, hooks (x3) of the Ink Supply Unit, and the

hooks (x8) of the Fasten Plate Center.

 CSIC FFC Form the CSIC FFC back by folding it on the original fold lines, and route it on the Ink Supply Unit and Main Frame, and

then secure it on the positions shown above with acetate tape and double-sided tape.

 PF Encoder FFC Form the PF Encoder FFC back by folding it on the original fold lines, and route it on the Fasten Plate Left and Fasten Plat e

Disassembly/Reassembly Routing FFCs/cables 73

Center, and then secure it on the position shown above with double-sided tape.

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Clamp D

Clamp A

Clamp B

Clamp C

Clamp E

Clamp F

Clamp G

Rib A

Double-sided tape (1)

Double-sided tape (2)

PE Sensor cable

Paper Stopper

Lever Sensor cable

Power Unit cable

CR Motor cable

PF Encoder FFC

CSIC FFC

Top of Main Board Assy

ASF Encoder

relay cable

Decompress Pump cable

CN8 CN13CN501 CN9

CN20 CN11

CN22 CN35

Connector positions on Main Board Assy

CN# Name

CN8 PF Encoder FFC CN9 PE Sensor cable CN11 ASF Encoder relay cable CN13 Paper Stopper Lever Sensor cable CN20 CR Motor cable CN22 Decompress Pump cable CN35 CSIC FFC CN501 Power Unit cable

CN# Name

CN8 PF Encoder FFC CN9 PE Sensor cable CN11 ASF Encoder relay cable CN13 Paper Stopper Lever Sensor cable CN20 CR Motor cable CN22 Decompress Pump cable CN35 CSIC FFC CN501 Power Unit cable

Main Board Cable Holder

PF Motor cable

ASF Motor

relay cable

CR Encoder FFC

Head FFC

Front right of Main Board Assy

Double-sided tape

Rib

CN30

CN31 CN32 CN33 CN34

CN12 CN51

CN# Name CN# Name

CN30 CR Encoder FFC CN34 Head FFC CN31 Head FFC CN12 ASF Motor relay

cable

CN32 Head FFC CN33 Head FFC CN51 PF Motor cable

Connector positions on Main Board Assy

Maintenance

Box FFC

Main Board Assy

Acetate tape

Right side of Main Board Assy

Carriage Assy

CR Encoder FFC

Connector of CR Encoder Board

Head FFC

Hook

Main Board Assy (1)

Main Board Assy (2)

 ASF Motor relay cable (CN12)/

Route them through the ribs (x5) of the Main Board Cable Holder, and then connect them to the connectors on the

PF Motor cable (CN51) Main Board.

 Head FFC (CN31, CN32, CN33, CN34)/ Fold them on the fold lines of the FFCs, and route and connect them to the connectors on the Main Board.

CR Encoder FFC (CN30)

Main Board Assy (3)

 Power Unit cable (CN501)

 CR Motor cable (CN20) Route it through the clamp B and clamp E as shown above, and then connect it to the connector on the Main Board.  PF Encoder FFC (CN8) Secure it on the double-sided tape (1) as shown above with a piece of double-sided tape and fold it on the fold lines

 CSIC FFC (CN35) Secure it on the double-sided tape (2) as shown above with double-sided tape (x2) and fold it on the fold lines of the



 Decompress Pump cable (CN22)

Disassembly/Reassembly Routing FFCs/cables 74

Paper Stopper Lever Sensor cable (CN13)/ PE Sensor cable (CN9)/ connectors on the Main Board. ASF Encoder relay cable (CN11)

Route it through the clamp A, clamp C and clamp D as shown above, and then connect it to the connector on the Main Board.

of the FFCs, and then route and connect it to the connector on the Main Board.

FFCs, and then route and connect it to the connector on the Main Board. Route them through the rib A, clamp F and clamp G of the Main Board Assy, and then connect them to the

Route it through the rib A and clamp F of the Main Board Assy, and then connect it to the connector on the Main Board.

Secure the Maintenance Box FFC on the position shown above with acetate tape, and then connect it to the connector (CN1) on the Main Board.

 Route the Head FFC as shown above.  Connect the CR Encoder FFC to the connector on the CR Encoder Board,

and then route it under the hooks (x2) of the Carriage Assy.

Head FFC

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Epson WP-M4595/4525/4521/4095/4015/4011 Revision A

Bottom

Paper Stopper Lever Sensor cable

Groove AHole C

2nd Cassette Housing Assy

ASF Motor cable

ASF Encoder

cable

Hole A

Ferrite core

Route this outside rib.

Left

ASF Motor

ASF Motor cable

ASF Encoder cable

Relay connector

Ferrite core

Hole B

Front

Rear left

Paper Stopper

Lever Sensor cable

Groove B

Hole C

ASF Encoder Board

Hook Rib

ASF Motor cable and ASF Encoder cable

ASF Encoder cable

Connect to Relay connector

ASF Motor cable

Connect to connector on ASF Encoder Board

ASF Motor

2nd Cassette Housing Assy



  When connecting the Paper Stopper Lever Sensor cable to the ASF Encoder Board, follow the procedure below.

Disassembly/Reassembly Routing FFCs/cables 75

Insert the ferrite core of the ASF Motor cable into the hole A of the 2nd Cassette Housing Assy, and route the cable through the hooks and ribs as shown above. Insert the ferrite core of the ASF Encoder cable in the hole B of the 2nd Cassette Housing Assy, and route the cable through the hooks and ribs as shown above.

1. Route it through the groove A of the 2nd Cassette Housing Assy, and then route it through the hook and ribs as shown above.

2. Pull it out from the hole C of the 2nd Cassette Housing Assy, and route it through the groove B of the 2nd Cassette Housing Assy.

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Epson WP-M4595/4525/4521/4095/4015/4011 Revision A

4.4 Connector Summary

Cable connections of this printer are shown below.

Figure 4-2. Connector Diagram

Disassembly/Reassembly 76

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CHAPTER 5

ADJUSTMENT

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Epson WP-M4595/4525/4521/4095/4015/4011 Revision A

5.1 Required Adjustments

The table from the following page lists the required adjustments depending upon the parts being repaired or replaced. Find the part(s) you removed or replaced, and check which adjustment(s) must be carried out.

 After all required adjustments are complete, use the “Final check pattern print” function

to print all adjustment patterns for final check. If you find a problem with the printout patterns, carry out the adjustment again.

 When replacing the Main Board and the Printer Mechanism (Frame Base Assy) at the

same time, the adjustment should be made after performing the initial setting.

 The table items and marks used in the “Required Adjustment List” provided on the

following pages have the following meanings.

• “O” indicates that the adjustment must be carried out.

• “---” indicates that the adjustment is not required.

• The “Mechanism Adjustment” should be performed just after reinstalling or reassembling the part or unit. (See "Table 5-1 Required Adjustment List (Mechanism

adjustment) (p79)".)

• The “Adjustments using the Adjustment Program” need to be performed after reassembling the printer completely. (See "Table 5-2 Required Adjustment List

(p80)".)

 If you have removed or replaced multiple parts, make sure to check the required

adjustments for the all parts. And when multiple adjustments must be carried out, be sure to carry them out in the order given in the “Priority” row.

Adjustment Required Adjustments 78

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Epson WP-M4595/4525/4521/4095/4015/4011 Revision A

Table 5-1. Required Adjustment List (Mechanism adjustment)

Adjustment Type Mechanism adjustment

Priority 1 2 3 4 5

Adjustment Item

Purpose

Touch Panel

Panel Board

Sub Board

Main Board

Carriage Assy

Printhead

Ink Supply Unit

Part Name

Frame Base Assy

EJ Roller

Main Frame

PF Motor

Front Frame Assy

Paper Guide Front Assy

PF Holder / PF Timing Belt

How to judge

Adjustment program

Tool

Remove Replace Remove Replace Remove Replace Remove Replace

(Read OK) Replace

(Read NG) Remove Replace Remove Replace Remove Replace

Replace

Remove Replace Remove Replace Remove Replace Remove Replace Remove Replace Remove Replace

PF Timing Belt

tension check

Check if the tension of the PF Timing Belt is within the standard.

--- --- --- --- ---

--- --- O --- ---

--- --- --- O ---

--- --- --- O O

--- --- --- --- ---

--- --- --- --- O

OOOO---

O --- --- --- --O --- --- --- ---

--- --- O --- ---

--- --- O --- --O --- --- --- --O --- --- --- ---

--- --- --- --- ---

------OOO O --- --- --- --O---OOO O --- --- --- --O --- --- --- ---

See "5.2.1 PF

Timing Belt

Tension Check

(p83)" for the

details.

--- --- --- --- ---

Sonic tension

gauge

Note 1: The mechanism adjustment is not necessary for the parts which are not mentioned above.

2: After the mechanism adjustment is performed, make sure to execute the adjustment using the Adjustment Program.

(See "Table 5-2 Required Adjustment List (p80)".)

Rear ASF Timing

Belt tension check

Check if the tension of the Rear ASF Timing Belt is within the standard.

See "5.2.2 Rear

ASF Timing Belt

Tension Check

(p84)"for the

details.

Sonic tension

gauge

PG adjustment

Adjusts the PG to within the standard.

See "5.2.3 PG

Adjustment (p85)"

for the details.

Thickness gauge Thickness gauge

Checking the

platen gap

Check if the PG is within the standard.

See "5.2.4

Checking the

Platen Gap (p91)"

for the details.

Ink leak check

Check if ink is leaking.

See "5.2.6 Ink Leak

Check (p93) " for

the details.

Ink Leak

Measurement Jig/

Ink Leak Check

Cartridge

Adjustment Required Adjustments 79

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Epson WP-M4595/4525/4521/4095/4015/4011 Revision A

OK NGG

-2

-1

0 1 2

-2 -1 0 1 2

-2

-1

0 1 2

-2

-1

0 1 2

-8-7-6-5-4-3-2-1012345678

Table 5-2. Required Adjustment List

Adjustment Type Adjustment using the Adjustment Program

Priority 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Adjustment Item

LCD Module

Panel Board

Sub Board

Main Board

Part Name

Power Supply Unit

Carriage Assy

Printhead

Purpose

First dot position /

PW adjustment

Rear ASF

Front ASF

(1st cassette)

To correct the print start

position in the carriage

moving direction through

software control.

Bi-D

adjustment

To correct print start timing in bidirectional printing through software control.

Head

angular

adjustment

To correct tilt of the Printhead caused at the installation through software control.

Rear ASF

(Top edge)

To correct the paper detection positions and the mounting positions of the PE Sensor by software control.

EEPROM

data copy

To copy adjustment values or the like stored on the old Main Board to the new board when the Main Board

Initialize

Setting (MAC

address

setting)

To write saledestinationspecific settings and the serial number into the Main Board after replacing it.

Maintenance

counter

To reset the tube durability counter after replacing the Ink Supply Unit.

Ink charge

To fill ink throughout the ink path to make all the nozzles ready for printing.

Head ID

input

To correct characteristic variation of the replaced Printhead by entering its Printhead ID (Head ID).

PF / EJ

adjustment

To correct variations in paper feed accuracy to achieve higher print quality.

needs to be replaced.

Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --Replace --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --Replace --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --Replace --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --Remove O --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --Replace

(Read OK) Replace

(Read NG)

O --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

---OO---OOOOOOOOOOOO*O---OO O

Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --Replace --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- O O O Remove --- --- --- --- --- --- O O --- --- O O O --- --- --- O --- --- --- --Replace --- --- --- --- --- --- O O O O O O O O --- O O --- O --- --Remove --- --- --- O --- --- --- --- O O --- --- --- O --- --- O --- --- --- --Replace --- --- --- O O --- O O O O O O O O --- --- --- --- --- --- ---

PE adjustment

Rear ASF

(Rear edge)

Front ASF

(1st

Cassette)

Paper skew adjustment

To align print start position at 0-digit side with that at 80-digit side in bidirectional band printing, timing of firing ink droplet is adjusted through software control.

PF / EJ

deterioration

offset

To reset the counter or set it to its maximum according to the replaced parts.

deterioration

offset

To reset the counter according to the replaced parts.

PF band

adjustment

To correct variations in paper feed accuracy to achieve higher print quality in band printing.

adjustment

detection

check

To confirm the chattering ends within the specified time after the PE Sensor detects the rear edge.

CR motor

heat

protection

control

To measure and correct the electrical variation of the CR Motor and the Power Supply Board.

PF motor

heat

protection

control

To measure and correct the electrical variation of the PF Motor and the Power Supply Board.

ASF motor

heat

protection

control

To measure and correct the electrical variation of the ASF Motor and the Power Supply Board.

Printout pattern

How to judge

--- --- --- --- --- --- --- --- --- --- ---

--- --- --- --- ---

Examine the printout patterns and enter the value for the pattern with no overlap and gap between the two rectangles.

PW Adjustment

Examine the misaligned lines printed on top, bottom, left, and right of the paper, and enter the number beside the line that is exactly 5 mm away from the paper edge for each side.

1st dot adjustment

Examine the lines on the left side of paper, and enter the number beside the line that overlaps with the horizontal line.

Examine the printout patterns for each of the four modes, and enter the value for the pattern with no gap and overlap for each mode.

NGOK



Band pattern

Enter the values of the most straight lines.

Microwea

ve pattern

Enter the value for the group of which the gaps between the two color

Examine the misaligned lines printed on top and bottom of the paper, and enter the number beside the line that is exactly 5 mm away from the paper edge for each side.

OK NGNG

Examine the printout pattern and enter the number of the one with the least gap and overlap between the two different colored lines.

--- ---

Examine the printout patterns and enter the value for the pattern with no overlap and gap between the two rectangles.

--- --- --- ---

bars are the

smallest. Adjustment program Tool

OOOOOO O OO O OOOOOOOO

--- --- --- --- --- ---

Ruler

--- ---

Ruler --- ---

--- --- --- --- --- ---

Note *: When the data in EEPROM on the Main Board cannot be read out and the Main Board is replaced, the PW deterioration offset is reset. Therefore, replacing the Carriage Assy (PW Sensor) is required with a new one.

Adjustment Required Adjustments 80

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Epson WP-M4595/4525/4521/4095/4015/4011 Revision A

OK NGG

-2

-1

0 1 2

-2 -1 0 1 2

-2

-1

0 1 2

-2

-1

0 1 2

-8-7-6-5-4-3-2-1012345678

Table 5-2. Required Adjustment List

Adjustment Type Adjustment using the Adjustment Program

Priority 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Adjustment Item

Duplex Unit

CR Scale

Cassette Assy 1st

Frame Base Assy

Rear ASF Assy

Part Name

Ink Supply Unit

EJ Roller

Main Frame

Paper Guide Upper

Purpose

First dot position /

PW adjustment

Rear ASF

Front ASF

(1st cassette)

To correct the print start

position in the carriage

moving direction through

software control.

Bi-D

adjustment

To correct print start timing in bidirectional printing through software control.

Head

angular

adjustment

To correct tilt

of the

Printhead

caused at the

installation

through

software

control.

Rear ASF

(Top edge)

To correct the paper detection positions and the mounting positions of the PE Sensor by software control.

EEPROM

data copy

To copy adjustment values or the like stored on the old Main Board to the new board when the Main Board

Initialize

Setting (MAC

address

setting)

To write saledestinationspecific settings and the serial number into the Main Board after replacing it.

Maintenance

counter

To reset the tube durability counter after replacing the Ink Supply Unit.

Ink charge

To fill ink throughout the ink path to make all the nozzles ready for printing.

Head ID

input

To correct characteristic variation of the replaced Printhead by entering its Printhead ID (Head ID).

PF / EJ

adjustment

To correct variations in paper feed accuracy to achieve higher print quality.

needs to be replaced.

Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --Replace --- --- --- --- --- O O O --- --- O O O --- --- --- --- --- --- --- --Remove --- --- --- --- --- --- O O --- --- --- --- --- --- --- --- --- --- --- --- --Replace --- --- --- --- --- --- O O O --- --- --- --- O --- --- --- --- --- --- --Remove --- --- --- --- --- --- --- O --- --- --- O O --- --- --- --- --- --- --- --Replace --- --- --- --- --- --- --- O --- --- --- O O --- --- --- --- --- --- --- --Remove --- --- --- --- --- --- O O O O O O O O --- --- O --- --- --- --Replace --- --- --- --- --- O O O O O O O O O O O O O O O O Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --Replace --- --- --- --- --- --- O --- --- --- O O --- --- --- --- --- --- --- --- --Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --Replace --- --- O O --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --Replace --- --- --- --- --- O O O --- --- O O O O O --- --- --- --- O --Remove --- --- --- --- --- --- O O --- --- O O O --- --- --- --- --- --- --- --Replace --- --- --- --- --- O O O O O O O O O --- --- --- --- O --- --Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --Replace --- --- --- --- --- O --- --- O O --- --- --- O --- --- --- --- --- --- ---

PE adjustment

Rear ASF

(Rear edge)

Front ASF

(1st

Cassette)

Paper skew adjustment

To align print start position at 0-digit side with that at 80-digit side in bidirectional band printing, timing of firing ink droplet is adjusted through software control.

PF / EJ

deterioration

offset

To reset the counter or set it to its maximum according to the replaced parts.

deterioration

offset

To reset the counter according to the replaced parts.

PF band

adjustment

To correct variations in paper feed accuracy to achieve higher print quality in band printing.

adjustment

detection

check

To confirm the chattering ends within the specified time after the PE Sensor detects the rear edge.

CR motor

heat

protection

control

To measure and correct the electrical variation of the CR Motor and the Power Supply Board.

PF motor

heat

protection

control

To measure and correct the electrical variation of the PF Motor and the Power Supply Board.

ASF motor

heat

protection

control

To measure and correct the electrical variation of the ASF Motor and the Power Supply Board.

Printout pattern

How to judge

--- --- --- --- --- --- --- --- --- --- ---

--- --- --- --- ---

Examine the printout patterns and enter the value for the pattern with no overlap and gap between the two rectangles.

PW Adjustment

Examine the misaligned lines printed on top, bottom, left, and right of the paper, and enter the number beside the line that is exactly 5 mm away from the paper edge for each side.

1st dot adjustment

Examine the lines on the left side of paper, and enter the number beside the line that overlaps with the horizontal line.

Examine the printout patterns for each of the four modes, and enter the value for the pattern with no gap and overlap for each mode.

NGOK



Band pattern

Enter the

values of the

most straight

lines.

Microwea

ve pattern

Enter the

value for the

group of

which the

gaps between

the two color

Examine the misaligned lines printed on top and bottom of the paper, and enter the number beside the line that is exactly 5 mm away from the paper edge for each side.

OK NGNG

Examine the printout pattern and enter the number of the one with the least gap and overlap between the two different colored lines.

--- ---

Examine the printout patterns and enter the value for the pattern with no overlap and gap between the two rectangles.

--- --- --- ---

bars are the

smallest. Adjustment program Tool

Adjustment Required Adjustments 81

OOOOOO O OO O OOOOOOOO

--- --- --- --- --- ---

Ruler

--- ---

Ruler --- ---

--- --- --- --- --- ---

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OK NGG

-2

-1

0 1 2

-2 -1 0 1 2

-2

-1

0 1 2

-2

-1

0 1 2

-8-7-6-5-4-3-2-1012345678

Table 5-2. Required Adjustment List

Adjustment Type Adjustment using the Adjustment Program

Priority 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Adjustment Item

Purpose

PE Sensor Holder Assy

PE Sensor

CR Motor

PF Motor

Front Frame Assy

Part Name

Star Wheel Assy

Paper Guide Front Assy

PF Holder / PF Timing Belt

First dot position /

PW adjustment

Rear ASF

Front ASF

(1st cassette)

To correct the print start

position in the carriage

moving direction through

software control.

Bi-D

adjustment

To correct print start timing in bidirectional printing through software control.

Head

angular

adjustment

To correct tilt

of the

Printhead

caused at the

installation

through

software

control.

Rear ASF

(Top edge)

To correct the paper detection positions and the mounting positions of the PE Sensor by software control.

EEPROM

data copy

To copy adjustment values or the like stored on the old Main Board to the new board when the Main Board

Initialize

Setting (MAC

address

setting)

To write saledestinationspecific settings and the serial number into the Main Board after replacing it.

Maintenance

counter

To reset the tube durability counter after replacing the Ink Supply Unit.

Ink charge

To fill ink throughout the ink path to make all the nozzles ready for printing.

Head ID

input

To correct characteristic variation of the replaced Printhead by entering its Printhead ID (Head ID).

PF / EJ

adjustment

To correct variations in paper feed accuracy to achieve higher print quality.

needs to be replaced.

Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --Replace --- --- --- --- --- O --- --- --- --- O O O --- --- --- --- O --- --- --Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --Replace --- --- --- --- --- --- --- --- --- --- O O O --- --- --- --- O --- --- --Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --Replace --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- O --- --Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --Replace --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- O --- --- O --Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --Replace --- --- --- --- --- --- O O O O O O O O --- --- --- --- --- --- --Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --Replace --- --- --- --- --- O --- --- --- --- --- --- --- --- --- --- --- --- --- --- --Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --Replace --- --- --- --- --- O --- --- O O --- --- --- O --- --- --- --- --- O --Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --Replace --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- O ---

PE adjustment

Rear ASF

(Rear edge)

Front ASF

(1st

Cassette)

Paper skew adjustment

To align print start position at 0-digit side with that at 80-digit side in bidirectional band printing, timing of firing ink droplet is adjusted through software control.

PF / EJ

deterioration

offset

To reset the counter or set it to its maximum according to the replaced parts.

deterioration

offset

To reset the counter according to the replaced parts.

PF band

adjustment

To correct variations in paper feed accuracy to achieve higher print quality in band printing.

adjustment

detection

check

To confirm the chattering ends within the specified time after the PE Sensor detects the rear edge.

CR motor

heat

protection

control

To measure and correct the electrical variation of the CR Motor and the Power Supply Board.

PF motor

heat

protection

control

To measure and correct the electrical variation of the PF Motor and the Power Supply Board.

ASF motor

heat

protection

control

To measure and correct the electrical variation of the ASF Motor and the Power Supply Board.

Printout pattern

How to judge

--- --- --- --- --- --- --- --- --- --- ---

--- --- --- --- ---

Examine the printout patterns and enter the value for the pattern with no overlap and gap between the two rectangles.

PW Adjustment

Examine the misaligned lines printed on top, bottom, left, and right of the paper, and enter the number beside the line that is exactly 5 mm away from the paper edge for each side.

1st dot adjustment

Examine the lines on the left side of paper, and enter the number beside the line that overlaps with the horizontal line.

Examine the printout patterns for each of the four modes, and enter the value for the pattern with no gap and overlap for each mode.

NGOK



Band pattern

Enter the

values of the

most straight

lines.

Microwea

ve pattern

Enter the

value for the

group of

which the

gaps between

the two color

Examine the misaligned lines printed on top and bottom of the paper, and enter the number beside the line that is exactly 5 mm away from the paper edge for each side.

bars are the

smallest. Adjustment program Tool

OOOOOO O OO O OOOOOOOO

--- --- --- --- --- ---

Ruler

--- ---

Ruler --- ---

OK NGNG

Examine the printout pattern and enter the number of the one with the least gap and overlap between the two different colored lines.

--- ---

--- --- --- --- --- ---

Examine the printout patterns and enter the value for the pattern with no overlap and gap between the two rectangles.

--- --- --- ---

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PF Timing Belt

Left side

Measurement position EJ Pulley

5.2 Details of Adjustments

This section provides adjustment procedures for which explanation in details is necessary. See "5.1 Required

Adjustments (p78)" for the adjustments not explained here.

5.2.1 PF Timing Belt Tension Check

This section describes PF Timing Belt tension check.

 This printer is designed so that the tension of the PF Timing Belt falls within the expected

range if you correctly reassemble the unit according to this manual. However, deformation of any related part(s) can cause improper tension of the belt. In such case, replace the Printer Mechanism (Frame Base Assy).

 The standard tension range of the PF Timing Belt is as follows:

• Standard: 5.0 ± 1.0 N

Tools

 Sonic tension gauge  Plastic tweezers

Adjustment procedure

When performing the PF Timing Belt tension measurement, make sure of the following.

 Perform PF Timing Belt tension measurement before installing the Metal Plate Left.  Bring the microphone of the sonic tension gauge within 5 mm from the PF Timing Belt

but do not let it touch the belt.

 Flip the PF Timing Belt as weak as the sonic tension gauge can measure it.  Be careful not to damage the PF Timing belt when flipping it with the plastic tweezers.

1. Set the following parameters to the sonic tension gauge:



Weight: 0.0096 kg/m

 Width: 2.5 mm  Span: 51 mm

2. Bring the microphone of the sonic tension gauge clos e to th e lower center of the PF Timing Belt as shown in

Figure 5-1.

3. Press the “MEASURE” button of the sonic tension gauge and flip the PF Timing Belt with plastic tweezers and measure the tension of the belt.

4. Rotate the EJ Pulley a half turn in the direction of the arrow, and measure the tension of the belt. Repeat the same measurement five times (including the first one). After measuring it six times in total, check the average of the measured values falls within the standard range.

Figure 5-1. PF Timing Belt Tension Check

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Rear ASF Timing Belt

Rear

Measurement position

PF Pulley

Left side

5.2.2 Rear ASF Timing Belt Tension Check

This section describes Rear ASF Timing Belt tension check.

 This printer is designed so that the tension of the Rear ASF Timing Belt falls within the

expected range if you correctly reassemble the unit according to this manual. However, deformation of any related part(s) can cause improper tension of the belt. In such case, replace the Printer Mechanism (Frame Base Assy).

 The standard tension range of the Rear ASF Timing Belt is as follows:

• Standard: 4.3 ± 2.5 N

Tools

 Sonic tension gauge  Plastic tweezers

Adjustment procedure

When performing the Rear ASF Timing Belt tension measurement, make sure of the following.

 Perform Rear ASF Timing Belt tension measurement before installing the Rear ASF

Assy.

 Bring the microphone of the sonic tension gauge within 5 mm from the Rear ASF Timing

Belt but do not let it touch the belt.

 Flip the Rear ASF Timing Belt as weak as the sonic tension gauge can measure it.



Be careful not to damage the Rear ASF Timing belt when flipping it with the plastic tweezers.

1. Set the following parameters to the sonic tension gauge:



Weight: 0.0013 kg/m

 Width: 4 mm  Span: 73.4 mm

Bring the microphone of the sonic tension gauge close to the Rear ASF Timing Belt on the position shown in

Figure 5-2.

3. Press the “MEASURE” button of the sonic tension gauge and flip the

Rear ASF

Timing Belt with plastic

tweezers and measure the tension of the belt.

4. Rotate the PF Roller one turn in the direction of the arrow, and measure the tension of the belt. Repeat the same measurement four times (including the first one). After measuring it five times in total, check the average of the measured values falls within the standard range.

Figure 5-2. Rear ASF Timing Belt Tension Check

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Position PG (mm) Application

PG 1 1.60 Printing plain paper/EPSON special paper, PG adjustment, Bi-d adjustment PG 2 1.85 Select when PG 1 is too narrow, printing envelopes/matte paper PG 3 2.50 Select when PG 2 is too narrow PG 4 3.00 Printing envelopes

5.2.3 PG Adjustment

This section describes the procedure for the platen gap (PG) adjustment.

When performing the PG adjustment, make sure of the following.

 Move the Carriage Assy by pulling the Timing Belt.  Be careful not to damage the nozzle surface of the Printhead with the thickness gauge.  Be careful not to damage the PF Scale when removing/installing the PG Cam Left.

 The PG position of this printer can be set to four points, from PG 1 to PG 4. Perform the

PG adjustment with the PG position set to PG 1.

 The standard range of the PG and the adjustment pitch are as follows.

• Standard: 1.6 ± 0.1 mm (PG position: PG 1)

• Adjustment pitch: 0.05 mm (distance between notches on the PG Cam)

 When performing the PG adjustment, install the Printhead to the Carriage Assy, and

remove the following parts beforehand.

• Exterior parts

• Main Board Unit

• Ink Supply Unit

• Metal Plate Left

• CR Cover

 When replacing the Ink System Supply Assy (Ink Supply Unit with Printhead), perform

the PG adjustment with the Ink Supply Unit connected to the Printhead.

Tools

 Thickness gauge: 1.5 mm (x2), 1.7 mm (x2)

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Carriage Assy

APG Cam

Right side of Carriage Assy

PG 1 When the APG Cam is the nearest to the 0-digit side.

PG 4 When the APG Cam is the nearest to the 80-digit side.

APG Lever

Check before the adjustment

Perform the following to check if the PG position is surely set to PG 1.

1. Move the Carriage Assy to the center of the printer.

2. From the 0-digit side between the Main Frame and Carriage Assy, check the APG Cam is as shown in “PG 1” in Figure 5-3.



When PG position is set to PG 1: Go to "Adjustment procedure (p87)".

 If PG position is not set to PG 1: Go to Step 3. (p 86).

Figure 5-3. PG Position

3. Move the Carriage Assy to the 0-digit side.

4. Rotate the PF Roller counterclockwise to move the APG Lever out of the hole of the Main Frame.

5. Move the Carriage Assy to the 80-digit side until it touches the APG Lever.

6. Return the Carriage Assy to the center of the printer.

Figure 5-4. APG Lever

7. Confirm the PG position is set to “PG 1” (see Step 2. (p 86)), and go to "Adjustment procedure (p87)".

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Left side

Right side

C.B.P-TITE (P2) SCREW 3x10-F/ZN-3C (6 ± 1kgf·cm)

PG Cam Left

PG Cam Right

C.B. SCREW 3 x 6 F/ZN-3C (8 ± 1kgf·cm) P.W. 3 x 0.5 x 8 F/ZN-3C

Do not loosen these screws.

CR Guide Frame

Right side

Dowel of

Frame Base

Left side

Dowel of Paper

Guide Front

Assy

PG: narrower

PG: wider

PG: narrower

PG: wider

Rib

Dowel

Align “+” (notch for the widest PG) on the PG Cam with the rib.

PG Cam Left

PG Cam Right

Adjustment procedure

1. Remove the screws (one each) that secure the PG Cam Left and PG Cam Right on both sides of the printer, and remove the PG Cam Left and PG Cam Right.

Figure 5-5. PG Cam Left/PG Cam Right

2. Loosen the screws (x3) that secure the CR Guide Frame.

Figure 5-6. CR Guide Frame

3. Set the PG Cam Left to the dowel of the Paper Guide Front Assy, and set the PG Cam Right to the dowel of the Frame Base.

4. Align the “+” marked notches of the PG Cams with the ribs of the F rame Base so as to make the PG the widest.

Figure 5-7. Installing the PG Cam Left/PG Cam Right

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PG Cam Left

Left side

Confirm PG Cam Left

touches CR Guide Frame.

PG Cam Right

Right side

Confirm PG Cam Right

touches CR Guide Frame.

Press here (x2) down vertically.

Top

Carriage Assy

CR Guide Frame

Make sure from here that the Carriage Assy

is not loosened from the CR Guide Frame.

Right side

To avoid performing the PG adjustment with the Carriage Assy loosened from the CR Guide Frame, press down the two points in the direction of the arrow.

5. Press the two points down vertically on the Carriage Assy shown in Figure 5-3 simultaneously, and make sure of the following.



The Carriage Assy is installed correctly without any gap between the Carriage Assy and CR Guide Frame.

 The PG Cam Right/PG Cam Left touch the CR Guide Frame.

Figure 5-8. The PG Cam Right/PG Cam Left and CR Guide Frame

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Thickness gauge Thickness gauge

Right

PG Cam Right

PG: narrower

Left

PG Cam Left

PG: narrower

Adjust three notches each for both PG Cam

Right/Left to make the PG narrower.

6. Place the thickness gauges (1.7 mm) on the positions shown in Figure 5-9.

Figure 5-9. Position of the Thickness Gauge

When adjusting the PG Cam Right/PG Cam Left in the following steps, make sure to adjust the same amount for both right and left.

7. With the Carriage Assy in the center of the printer, adjust three notches each for both PG Cam Right and PG Cam Left to make the PG narrower.

8. Pull the Timing Belt to move the Carriage Assy to 0-digit side and 80-digit side and check if the Carriage Assy touches the thickness gauges. If the Carriage Assy does not come in contact with the thickness gauges, adjust the PG Cam Right and PG Cam Left to make the PG narrower until the Carriage Assy touches the thickness gauges.

Figure 5-10. PG Adjustment

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START

Move the Carriage Assy to

the 0-digit side.

Yes

Move the Carriage Assy to

the center of the printer.

Move the Carriage Assy to

the center, and adjust one

notch for PG Cam Right to

make the PG wider.

Yes

Remove the PG Cam Right/

Left once, and attach them back on the same positions

as shown in Step 1. (p 87).

Return to Step 7.

(p 89) and

perform the

adjustment again.

END

Change the thickness gauges

(x2) to 1.5 mm ones.

Adjusts the PG to more than

1.5 mm on the 0-digit side.

Move the Carriage Assy to

the center of the printer.

Move the Carriage Assy to

the 80-digit side.

Move the Carriage Assy to

the 0-digit side.

Move the Carriage Assy to

the center of the printer.

Change the thickness gauges

(x2) to 1.7 mm ones.

Move the Carriage Assy to

the 0-digit side and to the

80-digit side.

Does the Carriage

Assy touch the

thickness gauges?

Does the Carriage

Assy touch the

thickness gauges?

Does the Carriage

Assy touch the

thickness gauges?

Does the Carriage

Assy touch the

thickness gauges?

Adjusts the PG to more than

1.5 mm on the 80-digit side.

Confirms the PG is more than

1.5 mm on the 0-digit side.

Confirms the PGs are less than 1.7 mm on the 0-digit side and 80-digit side.

Secure the CR Guide Frame

with the screws (x3).

(See Figure 5-6 (p 87).)

Move the Carriage Assy to

the center, and adjust one

notch for PG Cam Left to

make the PG wider.

Move the Carriage Assy to

the center, and adjust one

notch for PG Cam Right to

make the PG wider.

In the following steps, make sure the PG Cam Right/PG Cam Left always touch the CR Guide Frame. (See Figure 5-8 (p 88).)

9. Follow the flowchart below to perform the PG adjustment.

Figure 5-11. PG Adjustment Flow

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5.2.4 Checking the Platen Gap

This section describes the procedure for checking the platen gap (PG) necessary when removing the Printhead or in a similar case.

When checking the PG, make sure of the following.

 Move the Carriage Assy by pulling the Timing Belt.  Be careful not to damage the nozzle surface of the Printhead with the thickness gauge.

Tools

 Thickness gauge: 1.5 mm (x2), 1.7 mm (x2)

Checking procedure

1. Check the PG position is set to PG 1. (See "Check before the adjustment (p86)".)

2. Move the Carriage Assy to the center of the printer.

3. Place the thickness gauges (1.5 mm) on the positions shown in Figure 5-9 (p 89).

4. Pull the Timing Belt to move the Carriage Assy to both ends and confirm the Carriage Assy does not touch the thickness gauges. If the Carriage Assy comes in contact with the thickness gauges, the PG is narrower than the standard value, therefore, perform "5.2.3 PG Adjustment (p85)".

5. Move the Carriage Assy to the center, and replace the thickness gauges (1.5 mm) with the thickness gauges (1.7 mm) on the same positions as Step 3.

6. Pull the Timing Belt to move the Carriage Assy to both ends and confirm the Carriage Assy touches the thickness gauges. If the Carriage Assy does not come in contact with the thickness gauges, the PG is wider than the standard value, therefore, perform "5.2.3 PG Adjustment (p85)".

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MAC Address Label

Last six digits of MAC address

5.2.5 MAC Address Setting



This setting is not necessary when the data in EEPROM on the Main Board can be read out.

 To avoid a conflict of MAC address on a network, make sure to correctly follow the MAC

address setting flowchart given on the following.

 The user should be notified of the change of MAC address because of the following

reasons.

• If the user has set the printer’s MAC address on a router, the repaired printer with a new MAC address cannot be connected to the network.

• The default printer name on a network consists of “EPSON” and the last six digits of the MAC address. Therefore, the printer name becomes different from the previous one.

 You are required to enter the last six digits of the MAC address (xx:yy:zz) on the

Adjustment Program. MAC address example: 00:00:48:xx:yy:zz (“xx, yy, zz” represents a value unique to each printer)

Figure 5-12. MAC Address Label

Setting procedure

1. After replacing the Main Board, note down the MAC address written on a label on the Main Board Shield Plate Upper Assy.

2. Reassemble the printer, and connect the printer and the PC with the USB cable.

3. Start the Adjustment Program.

4. Select the “Initial Setting” from the menu. The initial setting screen appears.

5. Enter the last six digits of MAC address into the MAC address entry field, and click the MAC Address input button. (Enter the address again into the second entry field to confirm it.)

6. Select the network status sheet from the printer’s control panel, and print the sheet. Check the MAC address printed on the sheet to see if it is correct.

Figure 5-13. MAC Address Setting Screen

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Ink Leak Measurement Jig

Regulator

Regulator protection plate

Pressure gauge GC66 (The battery can be replaced from the hole on the rear.)

Syringe

Valve C

Valve A

Connection part for Ink

Leak Check Cartridge

Valve B

Valve status

Closed Open

Power button of pressure gauge

Ink Leak Check Cartridge

5.2.6 Ink Leak Check

This section describes the procedure for ink leak check necessary when disconnecting the Ink Supply Unit from the Printhead or in a similar case.

Tools

 Ink Leak Measurement Jig (with digital pressure gauge GC66) (Parts code: TBD)

Battery type: CR2016 (3 V) x1

Figure 5-14. Ink Leak Measurement Jig

 Ink Leak Check Cartridge (Parts code: TBD)

Figure 5-15. Ink Leak Check Cartridge

Do not touch or press the regulator located under the regulator protection plate of the Ink Leak Measurement Jig.

 The Ink Leak Measurement Jig applies pressure by sending air using a syringe into the

ink path, and detects the variation of pressure in the ink path between the self-sealing valve in the Printhead and the ink supply holes of the ink cartridges to check the presence of ink leakage. If air leak occurs in the Ink Leak Measurement Jig, the leak check itself cannot be done. Therefore, before performing the leak check, perform

"Checking procedure (p94)" without inserting the Ink Leak Check Cartridge to the

printer to test air leak from the Ink Leak Measurement Jig itself. (If the Ink Leak Check Cartridge is not loaded to the printer, the valve in the cartridge is shut. Therefore, the air leak check from the Ink Leak Measurement Jig itself becomes possible.)

 The ink leak check should be done with the ink tubes secured with the tube clamps and

the CR Cover attached after the joint section of the Printhead and the Ink Supply Unit has been secured. (See "Ink Supply Unit (p68)".)

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Connect tube while pressing here.

Tube of Ink Leak Check Cartridge

Pull the plunger up to the 20 mark.

Checking procedure

1. Turn each valve of the Ink Leak Measurement Jig as follows:

Valve A: Open

  Valve B: Open  Valve C: Open

2. Connect the Ink Leak Check Cartridge to the Ink Leak Measurement Jig.

Figure 5-16. Ink Leak Check (1)

3. Install the Ink Leak Check Cartridge into the ink cartridge slot of the printer to check.

4. Press the power button of the pressure gauge.

5. Confirm the value on the pressure gauge is 0.0 kPa. Otherwise, restart the pressure gauge.

6. Pull the plunger up to the 20 mark.

Figure 5-17. Ink Leak Check (2)

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Valve C

Valve A

Valve B

7. Close the valve C of the Ink Leak Measurement Jig.

8. Push the plunger to inject all the air out, and confirm the pressure gauge indicates 30 kPa or more, then after the value has stabilized, shut the valve A. If the value is less than 30 kPa, open the valve A and pull out and push in the plunger several times until the value reaches 30 kPa or more, then after the value has stabilized, shut the valve A.

Figure 5-18. Ink Leak Check (2)

9. Close the valve B, and after waiting 30 seconds for the pressure to stabilize, record the value displayed on the pressure gauge.

10. After about 10 seconds have passed, check the value on the pressure gauge, and compare it with the recorded value.



Difference is less than 1 kPa: No problem. Go to Step 11.

 Difference is 1 kPa or more: Air may be leaking. Disconnect the ink tubes of the Ink Supply Unit from the

Printhead, and connect them again correctly. (See "Ink Supply Unit (p68)".) Then, start the check again from Step 3.

11. Open the valve C to release the air pressure in the jig.

12. After confirming the value on the pressure gauge is 0.0 kPa, remove the Ink Leak Check Cartridge from the printer.

13. Repeat from Step 3.

to Step 12. for the rest of the ink cartridge slots to check.

14. After checking all the ink cartridge slots, press and hold the power button of the pressure gauge for about four to five seconds to turn off.

Adjustment Details of Adjustments 95

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CHAPTER 6

MAINTENANCE

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Epson WP-M4595/4525/4521/4095/4015/4011 Revision A

6.1 Overview

This section provides information to maintain the printer in its optimum condition.

6.1.1 Cleaning

Except for the printhead, there are no other mechanical parts or units that require periodic cleaning. However, if need arises, clean the component observing the following instructions.

 Instructions for cleaning



Exterior parts such as housing Wipe dirt off with a soft clean cloth moistened with water. For glossy or transparent parts, use of unwoven cloth is recommended to avoid scratching those parts.

 Inside of the printer

Remove paper dust with a vacuum cleaner.

 Rubber or plastic rollers such as an LD roller/Pickup Roller used to feed paper

If paper dust adhered to the rollers decreases the frictional force of the rollers and the rollers cannot properly feed paper, wipe off the paper dust with a soft cloth moistened with diluted alcohol.

 Instructions for cleaning ink stains

Wipe the stains off with a cloth wrung out of diluted alcohol.

 Do not use alcohol for cleaning the transparent parts. Doing so may cause them to get

cloudy.

 When wiping paper dust off the LD roller/Pickup Roller, be careful not to rub against the

surface asperity.

 To minimize the effect on the parts, use diluted alcohol such as 70% diluted ether.  After using alcohol for cleaning, make sure to wipe the part off with a soft dry dust-free

cloth to remove alcohol traces fully.

6.1.2 Lubrication

The type and amount of the grease used to lubricate the printer parts are determined based on the results of the internal evaluations. Therefore, refer to "6.2 Lubrication Points and Instructions (p98)" for the repairing procedures below, and apply the specified type and amount of the grease to the specified part of the printer mechanism.

 Grease

Type Name EPSON Part Code Supplier

Grease G-71 1304682 EPSON Grease G-74 1409257 EPSON

 Tools

Name Availability EPSON Part Code

Injector O * ---

Brush O * ---

Note *: Use tools whose specifications are specified in "6.2 Lubrication Points and Instructions (p98)".

The new Printer Mechanism (Frame Base Assy) supplied as an ASP is not lubricated on the two points described in "6-3 Lubrication of the Main Frame (p98)" and "6-4 Lubrication of

the CR Guide Frame (p98)" of "6.2 Lubrication Points and Instructions (p98)". Therefore,

make sure to lubricate the Printer Mechanism (Frame Base Assy) on the specified points when replacing it.

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Cassette Assy

Application point

Driven Pulley

Application point

Main Frame

7.5 mm

Application point

Carriage Assy

CR Guide Frame

15 mm

3.5

3 mm

CR Guide Frame

Application point

Paper Guide Front Assy

EJ Roller

Application points 1

Contact point with EJ Roller

Apply all over the upper side.

Application point 3

Application point 4

Contact point with

grounding spring

Grounding spring

EJ Roller

Before installing EJ Roller

Application point 2

After installing EJ Roller

6.2 Lubrication Points and Instructions

<Lubrication Point> Edges on the rear of the

Cassette Assy 1st / 2nd <Type>

G-74 <Application Amount>

Appropriate amount <Remarks>

Apply with brush.

<Lubrication Point> Shaft hole of the Driven

Pulley <Type>

G-71 <Application Amount>

φ 1 mm x 1 mm <Remarks>

Apply with injector.

<Lubrication Point> Contact point on the Main

Frame with the Carriage Assy

<Type> G-71

0.3 g <Remarks>

Using brush, apply grease on the Main Frame 7.5 mm from the edge as shown in the figure.

Figure 6-1. Lubrication of the Cassette Assy 1st / 2nd Figure 6-2. Lubrication of the Driven Pulley Assy

<Lubrication Point> Contact points (x3) on the

CR Guide Frame with the Carriage Assy

<Type> G-71

1. φ 2 mm x 420.7 mm

2. φ 2 mm x 420.7 mm

3. φ 2 mm x 420.7 mm <Remarks>

Maintenance Lubrication Points and Instructions 98

Figure 6-4. Lubrication of the CR Guide Frame

 Apply as follows using

injector. 1

. Move the Carriage

Assy to the 0-digit side, and apply grease on the CR Guide Frame from the center to the 80-digit side.

2. Move the Carriage Assy to the 80-digit side, and apply grease on the CR Guide Frame from the center to the 0-digit side.

Figure 6-3. Lubrication of the Main Frame

Figure 6-5. Lubrication of the EJ Roller

1. Contact points (x2) on the EJ Roller with the Paper Guide Front Assy

2. Contact points (x3) on the Paper Guide Front Assy with the EJ Roller

3. Contact point between the bushings of the Paper Guide Front Assy and EJ Roller

4. Contact point on the EJ Roller with the grounding spring

<Type> 1, 2. G-74 3, 4. G-71

<Application Amount> 1, 2. Appropriate amount

3. φ 2 mm x appropriate amount

4. φ 1 mm x appropriate amount <Remarks>

 1, 2. Apply with brush.  3. Using injector, apply

grease all over the upper side of the bearing.



4. Using injector, apply grease on the whole circumference evenly while rotating the EJ Roller.

 Stir G-74 before use.

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Bottom

APG Slider

Application point 3

CR Rear Slider

CR Front Slider Right

Application point 6

Right

Application point 5

Contact surface of Carriage

Assy with CR Guide Frame

CR Front Slider Left

Application point 6

Apply on steps

APG Cam

Application point 2

Apply on projections

Application point 1

Contact surface of Carriage

Assy with CR Guide Frame

Left

Application point 5

Carriage Assy

CR Sub Slider

Application point 7

CR Rear Slider

Application point 4

CR Front Slider Right

1. Contact surfaces (x2) of the Carriage Assy with the APG Cam

2. Contact points (x2) on the APG Cam with the APG slider

3. Contact points (x4) on the APG Slider with the CR Guide Frame

4. Contact point on the CR Sub Slider with the Main Frame

5. Contact surfaces (x2) of the Carriage Assy with the CR Guide Frame

6. Contact points (x2) on the CR Front Slider Left/Right with the CR Guide Frame

7. Contact points (x2) on the CR Rear Slider with the CR Guide Frame

<Type> G-71

1. 0.02 g

2. 0.02 g

3. 0.05 g

4. 0.02 g

5. φ 1 mm x 0.05 g

6. 0.05 g

7. 0.05 g

 Apply with injector.  For 1, 2, 3, 4, 6 and 7,

spread grease with brush as shown in the figure after application with injector.

Figure 6-6. Lubrication of the Carriage Assy

Maintenance Lubrication Points and Instructions 99

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Epson WP-M4595, WF-4525, WF-4521, WF-4095, WF-4015 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

PRODUCT DESCRIPTION

1.1 Features

1.2 Printing Specifications

1.2.1 Basic Specifications

1.3 Scanner Specifications (WP-M4595/4525/4521 only)

1.3.1 Basic Specifications

1.4 Control Panel

1.4.1 Operation Buttons & LEDs

1.4.2 LEDs and LCD Indications

1.5 Various Settings

1.5.1 Panel Operation

1.5.1.1 Setup Menu Configuration (WP-M4595/4525/4521 only)

1.5.1.2 Panel Operation Lock Setting (WP-M4595/4525/4521 only)

1.5.1.3 Forced Power OFF

1.5.1.4 Printer Status Sheet

OPERATING PRINCIPLES

2.1 Overview

2.2 Printhead

2.3 Motors and Sensors

2.4 Optical Sensor Control

2.5 Ink Supply Mechanism

2.6 Ink System Mechanism

2.7 Power-On Sequence

TROUBLESHOOTING

3.1 Troubleshooting

3.1.1 Fatal Error Code

3.1.2 FAX Troubleshooting (WP-M4595/4525/4521 only)

DISASSEMBLY/REASSEMBLY

4.1 Overview

4.1.1 Tools

4.1.2 Jigs

4.2 Disassembly/Reassembly Procedures

4.2.1 Caution when Replacing the Printhead/Ink Supply Unit

4.2.2 Parts/Units Need to be Removed in Advance

4.2.3 Disassembly Flowchart

4.2.3.1 Parts/Units whose Configuration is Different between Models in the Flowchart

4.2.3.2 Exterior Parts

4.2.3.3 Printer Mechanism

4.2.3.4 Printhead/Ink Supply Unit

4.2.3.5 2nd Cassette Unit

4.3 Detailed Disassembly/Reassembly Procedure for each Part/Unit

4.3 Routing FFCs/cables

4.4 Connector Summary

ADJUSTMENT

5.1 Required Adjustments

5.2 Details of Adjustments

5.2.1 PF Timing Belt Tension Check

5.2.2 Rear ASF Timing Belt Tension Check

5.2.3 PG Adjustment

5.2.4 Checking the Platen Gap

5.2.5 MAC Address Setting

5.2.6 Ink Leak Check

MAINTENANCE

6.1 Overview

6.1.1 Cleaning

6.1.2 Lubrication

6.2 Lubrication Points and Instructions