WFP 4010 S 1

SERVICE MANUAL
CONFIDENTIAL
Color Inkjet Printer
Epson WP-4540 series/ Epson WP-4530 series
SEMF11-002
Confidential
Notice:
All rights reserved. No part of this manual may be reproduced, stored in a retrieval system, or transmitted in any form or
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 registered
trademarks of their respective owners. EPSON disclaims any and all rights in those marks.
Copyright 2011 SEIKO EPSON CORPORATION
I&I 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, for 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. In order to protect sensitive microprocessors and circuitry, use static discharge equipment, such as anti-static
wrist straps, when accessing internal components.
6. 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.
7. 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.
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8. When disassembling or assembling this product, make sure to wear gloves to avoid injuries from metal parts
with sharp edges.
9. Use only recommended tools for disassembling, assembling or adjusting the printer.
10. Observe the specified torque when tightening screws.
11. 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
12. 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.
13. Apply the specified amount of grease described in this manual.
14. Make the specified adjustments when you disassemble the printer.
15. When cleaning this product, follow the procedure described in this manual.
16. 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.
17. Make sure to install antivirus software in the computers used for the service support activities.
18. Keep the virus pattern file of antivirus software up-to-date.
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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 (p58)".
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Revision Status
Revision Date of Issue Description
A June 17, 2011 First Release
7
Epson WP-4540/4530/4520/4510/4020/4010 series Revision A
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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-4540/4530/4520/4510 series only)............................................................................ 13
1.3.1 Basic Specifications........................................................................................................................................ 13
1.4 Control Panel ........................................................................................................................................................... 14
1.4.1 Operation Buttons & LEDs ............................................................................................................................ 14
1.4.2 LEDs and LCD Indications ............................................................................................................................ 17
1.5 Various Settings ...................................................................................................................................................... 22
1.5.1 Panel Operation .............................................................................................................................................. 22
1.5.1.1 Setup Menu Configuration (WP-4540/4530/4520/4510 series only) .................................................... 22
1.5.1.2 Panel Operation Lock Setting (WP-4540/4530/4520/4510 series only) ............................................... 23
1.5.1.3 Forced Power OFF................................................................................................................................. 24
1.5.1.4 Printer Status Sheet ................................................................................................................................ 24
Chapter 2 Operating Principles
2.1 Overview................................................................................................................................................................. 26
2.2 Printhead.................................................................................................................................................................. 26
2.3 Motors and Sensors ................................................................................................................................................ 27
2.4 Optical Sensor Control ............................................................................................................................................ 30
2.5 Ink Supply Mechanism............................................................................................................................................ 31
2.6 Ink System Mechanism........................................................................................................................................... 32
2.7 Power-On Sequence ................................................................................................................................................ 33
Chapter 3 Troubleshooting
3.1 Troubleshooting....................................................................................................................................................... 41
3.1.1 Error Message List.......................................................................................................................................... 41
3.1.2 Troubleshooting Workflow............................................................................................................................ 44
3.1.3 Fatal Error Code ............................................................................................................................................. 46
3.1.4 FAX Troubleshooting (WP-4540/4530/4520 series only) ............................................................................. 49
3.1.4.1 FAX Log................................................................................................................................................ 49
3.1.4.2 Error Code/Superficial Phenomenon-Based Troubleshooting .............................................................. 54
Chapter 4 Disassembly/Reassembly
4.1 Overview................................................................................................................................................................. 57
4.1.1 Tools ............................................................................................................................................................... 57
4.1.2 Jigs .................................................................................................................................................................. 57
4.2 Disassembly/Reassembly Procedures ..................................................................................................................... 58
4.2.1 Caution when Replacing the Printhead/Ink Supply Unit................................................................................ 58
4.2.2 Parts/Units Need to be Removed in Advance ................................................................................................ 59
4.2.3 Disassembly Flowchart................................................................................................................................... 60
4.2.3.1 Parts/Units whose Configuration is Different between Models in the Flowchart ................................. 60
4.2.3.2 Exterior Parts ......................................................................................................................................... 62
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4.2.3.3 Printer Mechanism................................................................................................................................. 64
4.2.3.4 Printhead/Ink Supply Unit ..................................................................................................................... 66
4.2.3.5 2nd Cassette Unit ................................................................................................................................... 67
4.3 Detailed Disassembly/Reassembly Procedure for each Part/Unit........................................................................... 68
4.4 Routing FFCs/cables ............................................................................................................................................... 77
4.5 Connector Summary................................................................................................................................................ 81
Chapter 5 Adjustment
5.1 Required Adjustments ............................................................................................................................................. 83
5.2 Details of Adjustments ............................................................................................................................................ 88
5.2.1 PF Timing Belt Tension Check ...................................................................................................................... 88
5.2.2 Rear ASF Timing Belt Tension Check........................................................................................................... 89
5.2.3 PG Adjustment ............................................................................................................................................... 90
5.2.4 Checking the Platen Gap ................................................................................................................................ 96
5.2.5 MAC Address Setting..................................................................................................................................... 97
5.2.6 Touch Panel Adjustment (WP-4540 series only) ........................................................................................... 98
5.2.7 Ink Leak Check............................................................................................................................................. 101
Chapter 6 Maintenance
6.1 Overview............................................................................................................................................................... 105
6.1.1 Cleaning........................................................................................................................................................ 105
6.1.2 Lubrication.................................................................................................................................................... 105
6.2 Lubrication Points and Instructions....................................................................................................................... 106
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CHAPTER 1
PRODUCT DESCRIPTION
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Product description Features 10
1.1 Features
WP-4540/4530/4520/4510/4020/4010 series are color inkjet printers that achieve high quality and high speed
printing with a new printer mechanism. The main features are as follows.
Common futures
Printer
Maximum print speed: 16 ppm (A4, monochrome, draft printing mode)
F7-Mach Turbo 2 Printhead (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-4530/4520/4510/4020/4010 series.
Differences between the models
WP-4540/4530/4520/4510/4020/4010 series are different as shown below.
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.
Table 1-1. Differences between the Models
Item
WP-4540
series
WP-4530
series
WP-4520
series
WP-4510
series
WP-4020
series
WP-4010
series
LCD display size 3.5 inch 2.5 inch 2.5 inch 2.5 inch --- ---
Panel operation Touch panel Button Button Button Button Button
Scanner Yes Yes Yes Yes --- ---
ADF Yes Yes Yes --- --- ---
Copy Yes Yes Yes Yes --- ---
USB host Yes Yes Yes Yes --- ---
FAX Yes Yes Yes --- --- ---
Wi-Fi Yes Yes --- --- Yes ---
2nd cassette Yes Option Option Option Option Option
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Product description Features 11
Figure 1-1. External View
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.
Table 1-2. Dimensions
Model Dimensions (W x D x H)
*1
Weight
*2
WP-4540 series 461.0 mm x 419.5 mm x 420.0 mm 16.50 kg
WP-4530 series
460.0 mm x 419.5 mm x 340.9 mm
11.20 kg
WP-4520 series 13.77 kg
WP-4510 series 460.0 mm x 419.5 mm x 298.5 mm 12.60 kg
WP-4020 series
460.0 mm x 419.5 mm x 283.2 mm
10.90 kg
WP-4010 series 10.87 kg
WP-4540 series WP-4530 series/WP-4520 series
WP-4510 series WP-4020 series/WP-4010 series
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Product description Printing Specifications 12
1.2 Printing Specifications
1.2.1 Basic Specifications
Note *1: For paper thickness: 0.10 mm, 75 g/m
2
*2: When the optional 2nd cassette is installed for WP-4530/4520/4510/4020/4010 series.
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, Cyan, Magenta, Yellow
Print direction Bi-directional minimum distance printing, Unidirectional printing
Print resolution Horizontal x Vertical (dpi)
300 x 300
600 x 600
1200 x 600
600 x 300
600 x 1200
4800 x 1200
Control code ESC/P Raster command
ESC/P-R (RGB) command
Input buffer size 132 KBytes
Paper feed method Friction feed
Paper feed amount
*1
1st cassette: 250 pages (plain paper), 30 pages (Legal)
2nd cassette
*2
: 250 pages (plain paper)
Rear MP Tray (rear ASF): 80 pages (plain paper)
Paper path Front feed, front out
Rear feed, front out
PF interval 0.01693 mm (1/1500 inch)
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Product description Scanner Specifications (WP-4540/4530/4520/4510 series only) 13
1.3 Scanner Specifications (WP-4540/4530/4520/4510 series only)
1.3.1 Basic Specifications
Table 1-4. Basic Specifications
Item Specification
Scanner type Flatbed, color
Scanning method Moving carriage, stationary document
Home position The rear left corner
Photoelectric device 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 Specifications (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
2
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
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Product description Control Panel 14
1.4 Control Panel
1.4.1 Operation Buttons & LEDs
The operation buttons, touch panel (WP-4540 series only), LEDs, and LCD are shown below. See Table 1-6 and
Table 1-7 for the functions.
Figure 1-2. Control Panel
WP-4540 series
WP-4530 series/WP-4520 series
WP-4020 series/WP-4010 series
WP-4510 series
Note 1: The WiFi logo on the control panel is for WP-4540/4530/4020 series only.
2: WP-4010 series do not have the WiFi button.
Touch panel
LCD
LCD
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Note : See "1.4.2 LEDs and LCD Indications (p17)" for more details about the LCD.
Note *1: WP-4540 series only.
*2: WP-4530/4520/4510 series only.
The available buttons and LEDs differ between models. Refer to Figure1-2 for available
buttons and LEDs for your model.
Table 1-6. Operation Buttons, LEDs and LCD (WP-4540/4530/4520/4510 series)
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.
Speed Dial Displays speed dial/group dial list in fax mode.
Setup Enters setup mode.
Help Displays help for solutions to problems.
Arrows
*1
Shows next or previous menus.
Arrows
*2
Selects menus.
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.
Ten key
Specifies the date/time
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.
LED
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.
- , ,
( (
( (
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Note : See "1.4.2 LEDs and LCD Indications (p17)" for more details about the LEDs.
Note *: The corresponding color LED is indicated.
Table 1-7. Operation Buttons, LEDs (WP-4020/4010 series)
Item Icon Name Function
Button Power Turns the power on/off.
Network status sheet Prints a network status sheet.
Wi-Fi Configures the wireless network.
Paper feed/eject
Loads or ejects paper.
Resumes printing after a paper out error, multiple page feed error.
Head cleaning (monochrome) Starts head cleaning (black only).
Head cleaning (color) Starts head cleaning (all except black).
Cancel Cancels printing during a print job.
LED
Power
Lights when the printer is on.
Flashes when the printer is in process.
Network Indicates the network connection status.
Maintenance box Indicates error status for maintenance box.
Paper Indicates error status for paper.
Ink
*
Indicates error status for ink.
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1.4.2 LEDs and LCD Indications
Table 1-8. LEDs and LCD Indications
Status
WP-4020/4010 series WP-4540/4530/4520/4510 series
LED status
LCD message
*2
Power Wi-Fi
*1
Ethernet
Mainte-
nance
box
Paper
Ink
(BK/C/
M/Y)
Operating
Printer fatal
error
Flash at
high
speed
Flash at
high
speed
Flash at
high
speed
Flash at
high
speed
Flash at
high
speed
Flash at
high
speed
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 fatal
error
*3
--- --- --- --- --- ---
Scanner error. Turn power off and
then on again. If the error is not fixed,
visit Epson.com for technical support.
ADF fatal
error
*4
--- --- --- --- --- ---
Automatic Document Feeder
(ADF) error.
Fax error
*4
--- --- --- --- --- ---
Fax error. Turn power off and then
on again.
Maintenance
box full
Flash
*5
--- --- ON --- ---
Maintenance box is at the end of
its service life. You need to replace
it. <Maintenance Box> XXXXX
*6
Maintenance
box CSIC error
Flash
*5
--- --- ON --- ---
Cannot recognize maintenance
box. Install it correctly.
<Maintenance Box> XXXXX
*6
No
maintenance
box error
Flash
*5
--- --- ON --- ---
*6
Paper jam
error
*7
Flash
*5
--- --- --- Flash ---
Paper jam. Press OK to see how to
remove jammed paper.
Paper jam error
(front cover
open)
*7
Flash
*5
--- --- --- Flash ---
Paper jam. Press OK to see how to
remove jammed paper.
Paper out error Flash
*5
--- --- --- ON ---
Paper out or paper jam. Check
paper size and load paper in paper
cassette XX
*6
.
Paper out error
(front cover
open)
Flash
*5
--- --- --- ON ---
Paper out or paper jam. Check
paper size and load paper in rear
MP tray.
No paper
cassette error
Flash
*5
--- --- --- ON ---
Load Cassette XX
*6
correctly and
press or .
Multi-feed
error
Flash
*5
--- --- --- ON ---
Multi-page feed error. Remove
and reload the paper, then press
or .
Paper length
mismatch error
for duplex
printing
Flash
*5
--- --- --- ON ---
Incorrect paper size detected. Load
correct paper size and press
or .
( ( ( (
( ( ( (
( (
( (
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Operating
Paper size
mismatch error
Flash
*5
--- --- --- ON ---
No paper source matches paper
size setting. Load appropriate
paper in Rear MP Tray. Press
or .
Printer/printer
driver
mismatch error
Flash
*5
--- --- ---
Flash at
high
speed
Flash at
high
speed
Error. Press .
Front cover
open error
Flash --- --- --- Flash2 ---
Front cover is open.
Ink end error Flash
*5
--- --- --- ---
Flash/
ON
*8
You need to replace the following
ink cartridge(s).
<Ink Cartridges> XXX
*6
Ink cartridge
detection error
Flash
*5
--- --- --- ---
Flash/
ON
*8
Cannot recognize the following
cartridge(s). Try installing them
again. <Ink Cartridges> XXX
*6
Ink cartridge
detection error
(non-Epson
cartridge)
Flash
*5
--- --- --- ---
Flash/
ON
*8
Ink cartridge is not recognized.
Please replace the cartridge.
*6
No ink
cartridge error
Flash
*5
--- --- --- ---
Flash/
ON
*8
The cartridge is installed
incorrectly. Press it until it clicks
into place.
*6
Starting
initialization
(starting initial
filling of ink)
Flash --- --- --- --- ---
Install ink cartridges that came
with this product. Close front
cover. Initialization starts.
Initializing
(during initial
filling of ink)
Flash --- --- --- --- ---
Initializing. Please wait... Do not open
front cover and do not turn power off
until initialization completes. This
takes about 12 minutes.
Requiring ink
cartridges for
initial filling
Flash --- --- --- --- ---
Open front cover and replace
cartridge(s).
Checking ink
cartridges
Flash --- --- --- --- ---
Checking the ink cartridges...
Drying 1st side
(printing from
PC)
Flash --- --- --- --- ---
Printing 2-sided document. Do not
touch the paper in the output tray
until printing is complete.
Printing (PC) Flash --- --- --- --- --- Printing...
Printing nozzle
check pattern
Flash --- --- --- --- ---
Printing...
Printing printer
status sheet
Flash --- --- --- --- ---
Printing...
Printing (UPNP) Flash Flash Flash --- --- --- Printing...
Receiving data Flash Flash Flash --- --- --- Receiving data...
Status
LED status
LCD message
*2
Power Wi-Fi
*1
Ethernet
Mainte-
nance
box
Paper
Ink
(BK/C/
M/Y)
( ( ( (
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Operating Canceling Flash --- --- --- --- --- Canceling...
Cleaning (PC) Flash --- --- --- --- ---
Cleaning print head. Please wait...
Do not open front cover.
Print head
cleaning
Flash --- --- --- --- ---
Cleaning print head. Please wait...
Do not open front cover.
Canceling
nozzle check
pattern print
Flash --- --- --- --- ---
Canceling...
Canceling
printer status
sheet print
Flash --- --- --- --- ---
Canceling...
Initializing
network
Flash
*5
Alternate
Flash2
Alternate
Flash1
--- --- ---
Processing... Please wait.
Waiting for
network
initialization
Flash
*5
--- --- --- --- --- ---
Network
initialization
(LED ON)
OFF
*5
ON ON --- --- --- ---
Network
initialization
(LED OFF)
OFF
*5
OFF OFF --- --- --- ---
Configuring
wireless
LAN
*9
ON
Alternate
Flash2
Alternate
Flash1
--- --- ---
Establishing a Wi-Fi connection
with Push-Button mode...
Configuring
PINCODE
*9
ON
Simulta-
neous
Flash
Simulta-
neous
Flash
--- --- ---
Establishing a Wi-Fi connection
with WPS PIN code mode...
PIN Code XXXXXXXX
*10
Preparing to
update
firmware
(cancel)
ON
*5
Simulta-
neous
Flash
Simulta-
neous
Flash
--- --- ---
Preparing to update...
Updating
firmware
ON to
flash
OFF OFF OFF OFF OFF
Updating firmware... Do not turn
power off. It turns off and on
automatically when complete.
Preparing to
update
firmware
ON
*5
Simulta-
neous
Flash
Simulta-
neous
Flash
--- --- ---
Preparing to update...
Canceling
firmware
update
ON
*5
Simulta-
neous
Flash
Simulta-
neous
Flash
--- --- ---
Canceling...
Powering OFF
Flash at
high
speed
--- --- --- --- ---
Turning off...
Status
LED status
LCD message
*2
Power Wi-Fi
*1
Ethernet
Mainte-
nance
box
Paper
Ink
(BK/C/
M/Y)
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Operating
Resetting
Flash at
high
speed
--- --- --- --- ---
Restarting product from other
device...
Powering ON Flash
Alternate
Flash2
Alternate
Flash1
--- --- --- ---
Feeding a paper
(load/eject)
Flash --- --- --- --- --- ---
Standby No error ON --- --- --- --- --- ---
Maintenance
box near full
ON
*5
--- --- Flash --- ---
Maintenance box is nearing end of
its service life.
Ink level low ON
*5
--- --- --- --- Flash
*8
Ink low.
Front cover
open error
Flash --- --- --- Flash2 ---
Maintenance
box full
ON
*5
--- --- ON --- ---
Maintenance box is at the end of its
service life. You need to replace it.
*6
Maintenance
box CSIC error
ON
*5
--- --- ON --- ---
*6
No
maintenance
box error
ON
*5
--- --- ON --- ---
*6
Ink end error ON
*5
--- --- --- --- ON
*8
You need to replace the following
ink cartridge(s).
*6
No ink
cartridge error
ON
*5
--- --- --- --- ON
*8
The cartridge is installed
incorrectly. Press it until it clicks
into place.
*6
Ink cartridge
detection error
ON
*5
--- --- --- --- ON
*8
Cannot recognize the following
cartridge(s). Try installing them
again. <Ink Cartridges> XXX
*6
Ink cartridge
detection error
(non-Epson
cartridge)
ON
*5
--- --- --- --- ON
*8
Ink cartridge is not recognized.
Please replace the cartridge.
*6
Access point
setting error
(security
information
exchange)
*9
ON ---
Flash at
high
speed
--- --- ---
Security error while setting Wi-Fi
with your access point. Try again.
Access point
setting error
(general)
*9
ON --- Flash --- --- ---
Error while setting Wi-Fi with
your access point. Try again.
Status
LED status
LCD message
*2
Power Wi-Fi
*1
Ethernet
Mainte-
nance
box
Paper
Ink
(BK/C/
M/Y)
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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-4020 series only
*2: The message WP-4540 series indicates is different but the meaning is the same.
*3: WP-4540/4530/4520/4510 series only
*4: WP-4540/4530/4520 series only
*5: Flashes if the status arises when printing starts or when the printer starts up, but lights if the status arises when printing is
complete.
*6: The corresponding maintenance box, ink cartridge product number or cassette number is indicated.
*7: Occurs in any paper path.
*8: The corresponding ink LED flashes after the ink falls in the ink low status, and lights when it reaches the ink end status.
*9: WP-4540/4530/4020 series only
*10: The corresponding PIN number is indicated.
Standby
Access point
setting error
(registration)
*9
ON --- Flash --- --- ---
Registration error.
The access point is busy. Try
again.
Access point
setting error
(PINCODE
authentication)
*9
ON --- Flash --- --- ---
PIN code authentication error.
Make sure the PIN code is correct.
Wireless LAN
connection
error
*9
ON --- Flash --- --- ---
The Wi-Fi/network connection
failed.
Print the check report?
Network
connection
time out error
*9
ON --- Flash --- --- ---
The Wi-Fi/network connection
failed.
Status
LED status
LCD message
*2
Power Wi-Fi
*1
Ethernet
Mainte-
nance
box
Paper
Ink
(BK/C/
M/Y)
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Product description Various Settings 22
1.5 Various Settings
1.5.1 Panel Operation
1.5.1.1 Setup Menu Configuration (WP-4540/4530/4520/4510 series only)
The following explains the setup menu structure and the outline of the menu functions.
Note : The setting items for Wi-Fi is for WP-4540/4530 series only.
Note *: When the optional 2nd cassette is installed for WP-4530/4520/4510/4020/4010 series.
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
*
/Rear MP Tray).
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).
Wi-Fi/Network
Settings
Wi-Fi Setup Selects a connection method for wireless LAN.
Manual Wi-Fi/Network Setup Configures the connection setting for manual setup.
Wi-Fi/Network Connection
Check
Checks the network connection status.
Prints the connection check result.
Confirm Wi-Fi/Network
Settings
Displays the network information.
Prints a network status sheet.
File Sharing Setup USB
Sets the access priority when accessing the storage device
connected to the USB host port to USB or Wi-Fi/Network.
Wi-Fi/Network
Fax Settings Send Settings Configures fax send settings.
Receive Settings Configures fax receive settings.
Communication Configures the details of the fax communication.
Check Fax Connection Prints the fax connection settings.
Print Status Sheet --- Prints a printer status sheet.
Lock Settings On
(Off when panel operation
is locked)
Changes the setting of the panel operation lock. (See "1.5.1.2
Panel Operation Lock Setting (WP-4540/4530/4520/4510 series
only) (p23)".)
Change Password Changes the password. (See "1.5.1.2 Panel Operation Lock
Setting (WP-4540/4530/4520/4510 series only) (p23)".)
Restore Default
Settings
Fax Send/Receive Settings Initializes the fax send/receive settings.
Fax Data Settings Deletes the fax data settings.
Wi-Fi/Network Setting Initializes the Wi-Fi/network settings.
All except Wi-Fi/Network &
Fax Settings
Initializes the settings except Wi-Fi/network/fax settings.
All Settings Initializes the all settings.
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1.5.1.2 Panel Operation Lock Setting (WP-4540/4530/4520/4510 series only)
For WP-4540/4530/4520/4510 series, the panel operation for the following can be locked after setting the
password.
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.
Note 1: The password is not set when shipping from the factory.
2: If the entries Enter New Password and Verify New Password are different, the message Password is incorrect. Enter correct
password. is displayed and the menu screen returns to the password entering screen.
3: If the entries up to Verify New Password are complete successfully, the change will be reflected and the LCD display returns to
the setup menu.
4: The password is stored on the EEPROM, and kept even the power is off.
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.
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
Wi-Fi/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.
Table 1-11. Password Setting
Item
Description
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.
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.
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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-4540/4530/4520/4510/4020/4010 series, 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-4540/4530/4520/4510/4020/4010 series print the printer status sheet by the following operation.
Note : When printing the network status sheet to check the network information, follow the procedure below.
WP-4540/4530/4520/4510 series: Select Wi-Fi/Network Settings - Confirm Wi-Fi/Network Settings, and press or
. (See "1.5.1.1 Setup Menu Configuration (WP-4540/4530/4520/4510 series only) (p22)".)
WP-4020/4010 series: Press the network status sheet button. (See "1.4.1 Operation Buttons & LEDs (p14)".)
Table 1-12. Status Sheet
Model Procedure
WP-4540/4530/4520/4510 series 1. Press the setup button.
2. Select Print Status Sheet from the setup menu.
3. Press the start button.
WP-4020/4010 series Turn the power on while pressing the paper feed/eject button.
( (
( (
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CHAPTER 2
OPERATING PRINCIPLES
Operating Principles Overview 26
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2.1 Overview
This chapter describes the operating principles of WP-4540/4530/4520/4510/4020/4010 series printer
mechanism.
2.2 Printhead
This section describes the printhead.
Print method: On-demand inkjet
(F7-Mach Turbo 2)
Nozzle configuration
The nozzle layout as seen from behind the Printhead is shown below.
Figure 2-1. Nozzle Layout
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)
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
1/150 inch
5.9267
(35/150 inch
2.3707
(14/150 inch
0.0423
1/600 inch
0.0847
1/300 inch
Black Cyan Magenta
Yellow
Column A
Carriage movement direction
P
a
p
e
r

f
e
e
d

d
i
r
e
c
t
i
o
n
Column B
Column C
Column D
Column E
Column F Column G
Operating Principles Motors and Sensors 27
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2.3 Motors and Sensors
The following table lists the motors and sensors of WP-4540/4530/4520/4510/4020/4010 series.
Printer Mechanism
Figure 2-2. Motors & Sensors (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
A
Printhead
1
2
4
3
5
6
C
B
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Scanner (WP-4540/4530/4520/4510 series only)
Figure 2-3. Motors & Sensors (Scanner)
ADF (WP-4540/4530/4520 series only)
Figure 2-4. Motors & Sensors (ADF)
Table 2-2. List of Motors & Sensors (Scanner)
Scanner mechanism Scanner Motor A
CIS Unit 1
Table 2-3. List of Motors & Sensors (ADF)
ADF mechanism ADF Motor A
PE Sensor 1
Document Sensor 2
ADF Encoder 3
1
A
A
1
2
3
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2nd cassette
This unit is installed for WP-4540 series, and option for WP-4530/4520/4510/4020/4010 series.
Figure 2-5. Motors & Sensors (2nd Cassette)
Table 2-4. List of Motors & Sensors (2nd Cassette)
2nd cassette ASF Motor A
Paper Stopper Lever Sensor 1
ASF Encoder 2
A
1
2
Operating Principles Optical Sensor Control 30
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2.4 Optical Sensor Control
WP-4540/4530/4520/4510/4020/4010 series uses the optical sensor to control itself. The following describes the
operating principles of optical sensor control.
Control method
To ensure accurate printing, each part must be controlled to make an adequate amount (time) of movement. The
optical sensors read the amount (time) of movements as follows to printer to control it for achieving accurate printing.
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.
Note *1: Installed on WP-4540 series, and option for WP-4530/4520/4510/4020/4010 series.
*2: WP-4540/4530/4520 series only.
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 encoders 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 light-receiving device 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. According 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.
Figure 2-6. PF Drive Control Section
Table 2-5. Controlled Parts
Item Motor Scale Encoder Transmission method
Paper feed/load mechanism
Front ASF mechanism
(1st cassette)
Rear ASF mechanism
PF Motor PF Scale PF Encoder PF Timing Belt
ASF Timing Belt
Carriage mechanism CR Motor CR Scale CR Encoder CR Timing Belt
Front ASF mechanism
(2nd cassette
*1
)
ASF Motor ASF Scale ASF Encoder Gear
ADF mechanism
*2
ADF Motor ADF Scale ADF Encoder Gear
PF Motor PF 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
Operating Principles Ink Supply Mechanism 31
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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
Ink Supply Unit
(Ink Cartridge Holder - Ink Supply Tube)
Printhead
Ink Supply Tube Ink Cartridge Holder
Buffer
Diaphragm Pump
Decompress Pump Unit
Operating Principles Ink System Mechanism 32
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2.6 Ink System Mechanism
The following shows configurations of the ink system mechanism.
The ink system mechanism consists of the Ink System Unit composed of the Cap, Valve Unit, Pump Unit, Waste
Ink Tube and similar parts, and the Maintenance Box that stores the ink from the Printhead sucked by the Ink
System Unit.
The caps for color and monochrome are separately mounted and can be sucked individually. The Cap to use is
switched by the Valve Unit.
Figure 2-8. Ink System Mechanism
Maintenance Box
Pump Unit
Waste Ink Tube
Cap
Valve Unit
Ink System
Operating Principles Power-On Sequence 33
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2.7 Power-On Sequence
Initializing operations of this printer at power-on differ between when powered off normally ("Simple Sequence
(p33)") and when powered off abnormally ("Normal Power-On Sequence (p36)"). This section describes how
this printer operates in the simple sequence and in the normal power-on sequence under certain conditions.
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.
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
Table 2-6. Simple Sequence
Operation
Movement of
Components
Front
ASF
drive
condition
Decom-
press
Motor
I/S
Clutch
*1
1. Printhead initialization and fuse inspection
1-1. Initializes the Printhead, and checks the fuse on the printer control
circuit board.
OFF --- OFF
2. Seeking the home position
2-1. The carriage moves to the 0-digit side slowly and confirms it touches
the Right Frame.
--- ON
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.
--- OFF
80 0 HP
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.
Valve Unit position
On PF Roller: Up
Below PF Roller: Down
The above shows the Valve Unit is up.
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
80 0 HP
80 0 HP
80 0 HP

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2-3. The carriage slowly moves to the CR lock set position.
OFF --- OFF
2-4. The PF Motor rotates clockwise and releases the CR lock.
---
2-5. The PF Motor rotates counterclockwise and sets the CR lock.
---
the CR lock.
---
2-7. The carriage returns to its home position.
---
---
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.
ON ---
3-2. The carriage moves to the 0-digit side slowly up to the position where
the Front ASF turns off.
OFF ---
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.
---
Operation
Movement of
Components
Front
ASF
drive
condition
Decom-
press
Motor
I/S
Clutch
*1
80 0 HP
80 0 HP

80 0 HP

80 0 HP

80 0 HP

80 0 HP

80 0 HP
80 0 HP
80 0 HP

80 0 HP

80 0 HP

80 0 HP

80 0 HP

80 0 HP

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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 I/S Clutch is located in the Ink System, and transmits the drive force of the PF Motor to move the Valve Unit up and down.
*2: Executes when the detected temperature is under 5
o
C (41
o
F) by the thermistor on the Printhead.
*3: If this occurs when the timer cleaning (once a year) is scheduled, the cleaning (equivalent to CL3) is executed for black or
color, or for both of them.
*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.
5. PF initialization
5-1. The PF Motor rotates clockwise for approximately one second.
OFF --- OFF
5-2. The PE sensor checks if paper exists, and the PF Motor rotates
clockwise for approximately 0.5 seconds.
---
6. Low temperature operation sequence
*2
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.
Decompress
and vent to
atmosphere
8-3. While monitoring the ink end sensor, the Decompress Motor is driven
again and the Diaphragm Pump sucks the ink.
Decompress
and vent to
atmosphere
8-4. Detects the ink remaining.
*3
---
*4
---
Operation
Movement of
Components
Front
ASF
drive
condition
Decom-
press
Motor
I/S
Clutch
*1
80 0 HP
80 0 HP

80 0 HP

80 0 HP

80 0 HP

80 0 HP

80 0 HP

80 0 HP

80 0 HP

80 0 HP

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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
Movement of
Components
Front
ASF
drive
condition
Decom-
press
Motor
I/S
Clutch
*1
1. Printhead initialization and fuse inspection
1-1. Initializes the Printhead, and checks the fuse on the printer control
circuit board.
OFF --- OFF
2. Seeking the home position
the Right Frame.
---
---
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.
---
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
---
2-6. To turn on the clutch of the Ink System, the PF Motor rotates
counterclockwise and the PF Roller makes approximately half turn.
--- ON
---
2-8. The PF Motor rotates clockwise, and releases the CR lock.
---
ON ---
OFF ---
2-11. The carriage moves to the 80-digit side slowly up to the Valve Unit
initialization position.
---
80 0 HP
80 0 HP

80 0 HP

80 0 HP

80 0 HP

80 0 HP

80 0 HP
80 0 HP

80 0 HP

80 0 HP
80 0 HP
80 0 HP

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2-12. The PF Motor rotates counterclockwise, and the Valve Unit goes up.
OFF --- ON
2-13. To check if the protrusion of the Valve Unit has been set in the groove
of the carriage, the carriage slightly moves to the 0-digit side, and then
returns to its original position.
---
2-14. The PF Motor rotates clockwise, and the Valve Unit goes down.
---
2-15. The carriage slightly moves to the 0-digit side.
---
2-16. The PF Motor rotates counterclockwise, and the Valve Unit goes up.
---
2-17. The carriage moves to the 80-digit side.
---
2-18. The carriage moves to the 0-digit side slightly, and sets the choke
valve of the Valve Unit to the position where the Printhead nozzles for
both color and monochrome can be sucked.
---
2-19. The PF Motor rotates clockwise, and the Valve Unit goes down.
---
the Right Frame.
---
2-21. To turn off the clutch of the Ink System, the PF Motor rotates
clockwise and the PF Roller makes approximately half turn.
--- OFF
---
2-23. To release the Pump Unit, the PF Motor rotates clockwise
approximately one second.
---
2-24. The carriage slowly moves to the 0-digit side to the CR lock set
position.
---
2-25. The PF Motor rotates counterclockwise and sets the CR lock.
---
Operation
Movement of
Components
Front
ASF
drive
condition
Decom-
press
Motor
I/S
Clutch
*1
80
0 HP
80 0 HP

80 0 HP

80 0 HP

80 0 HP

80 0 HP

80 0 HP

80 0 HP

80 0 HP

80 0 HP
80 0 HP

80 0 HP

80 0 HP

80 0 HP

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the CR lock.
OFF --- OFF
---
---
3. Detecting remaining paper
3-1. The carriage moves to the 80-digit side, and check if paper exists.
*3
---
---
4. Switching front ASF drive
ON ---
OFF ---
4-3. The carriage moves to the 80-digit side slowly and passes by the CR
lock.
---
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.
---
Operation
Movement of
Components
Front
ASF
drive
condition
Decom-
press
Motor
I/S
Clutch
*1
80 0 HP
80 0 HP

80 0 HP

80 0 HP

80 0 HP

80 0 HP
80 0 HP
80 0 HP

80 0 HP

80 0 HP

80 0 HP

80 0 HP

80 0 HP

80 0 HP

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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 I/S Clutch is located in the Ink System, and transmits the drive force of the PF Motor to move the Valve Unit up and down.
*2: Initializes the Ink System. This sets the Valve Unit down completely.
*3: 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.
*4: Executes when the detected temperature is under 5
o
C (41
o
F) by the thermistor on the Printhead.
*5: If this occurs when the timer cleaning (once a year) is scheduled, the cleaning (equivalent to CL3) is executed for black or
color, or for both of them.
*6: 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.
6-2. The PE sensor checks if paper exists, and the PF Motor rotates
clockwise for approximately 0.5 seconds.
OFF --- OFF
7. Low temperature operation sequence
*4
---
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.
Decompress
and vent to
atmosphere
9-3. While monitoring the ink end sensor, the Decompress Motor is driven
again and the Diaphragm Pump sucks the ink.
Decompress
and vent to
atmosphere
9-4. Detects the ink remaining.
*5
---
*6
---
Operation
Movement of
Components
Front
ASF
drive
condition
Decom-
press
Motor
I/S
Clutch
*1
80 0 HP
80 0 HP

80 0 HP

80 0 HP

80 0 HP

80 0 HP

80 0 HP

80 0 HP

80 0 HP

Confidential
CHAPTER 3
TROUBLESHOOTING
Confidential
Troubleshooting Troubleshooting 41
3.1 Troubleshooting
This section describes the error message list, troubleshooting workflow, fatal error code and FAX
Troubleshooting.
3.1.1 Error Message List
Table 3-1. Error Message List
Status
LED status
LCD message
*2
Power Wi-Fi
*1
Ethernet
Mainte-
nance
box
Paper
Ink
(BK/C/
M/Y)
Printer fatal error
Flash at
high
speed
Flash at
high
speed
Flash at
high
speed
Flash at
high
speed
Flash at
high
speed
Flash at
high
speed
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 fatal
error
*3
--- --- --- --- --- ---
Scanner error. Turn power off and then on again.
If the error is not fixed, visit Epson.com for
technical support.
ADF fatal error
*4
--- --- --- --- --- --- Automatic Document Feeder (ADF) error.
Fax error
*4
--- --- --- --- --- --- Fax error. Turn power off and then on again.
Maintenance box
full
ON
*5
--- --- ON --- ---
Maintenance box is at the end of its service
life. You need to replace it.
*6
Maintenance box
CSIC error
ON
*5
--- --- ON --- ---
Cannot recognize maintenance box. Install it
correctly.
*6
No maintenance
box error
ON
*5
--- --- ON --- ---
Cannot recognize maintenance box. Install it
correctly.
*6
Paper jam error
*7
Flash
*5
--- --- --- Flash ---
Paper jam. Press OK to see how to remove
jammed paper.
Paper jam error
(front cover
open)
*7
Flash
*5
--- --- --- Flash ---
Paper jam. Press OK to see how to remove
jammed paper.
Paper out error Flash
*5
--- --- --- ON ---
Paper out or paper jam. Check paper size and
load paper in paper cassette XX
*6
.
Paper out error
(front cover open)
Flash
*5
--- --- --- ON ---
Paper out or paper jam. Check paper size and
load paper in rear MP tray.
No paper cassette
error
Flash
*5
--- --- --- ON ---
Load Cassette XX
*6
correctly and press
or .
Multi-feed error Flash
*5
--- --- --- ON ---
Multi-page feed error. Remove and reload the
paper, then press or .
( ( ( (
( ( ( (
Confidential
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.
Paper length
mismatch error
for duplex
printing
Flash
*5
--- --- --- ON ---
Incorrect paper size detected. Load correct
paper size and press or .
Paper size
mismatch error
*8
Flash
*5
--- --- --- ON ---
No paper source matches paper size setting.
Load appropriate paper in Rear MP Tray.
Press or .
Printer/printer
driver mismatch
error
*9
Flash
*5
--- --- ---
Flash at
high
speed
Flash at
high
speed
Error. Press .
Front cover open
error
Flash --- --- --- Flash2 ---
Ink end error ON
*5
--- --- --- --- ON
*10
You need to replace the following ink
cartridge(s).
*6
No ink cartridge
error
ON
*5
--- --- --- --- ON
*10
The cartridge is installed incorrectly. Press it
until it clicks into place.
*6
Ink cartridge
detection error
ON
*5
--- --- --- --- ON
*10
Cannot recognize the following cartridge(s).
Try installing them again. <Ink Cartridges>
XXX
*6
Ink cartridge
detection error
(non-Epson
cartridge)
ON
*5
--- --- --- --- ON
*10
Ink cartridge is not recognized. Please
replace the cartridge.
*6
Access point
setting error
(security
information
exchange)
*11
ON ---
Flash at
high
speed
--- --- ---
Security error while setting Wi-Fi with your
access point. Try again.
Access point
setting error
(general)
*11
ON --- Flash --- --- ---
Error while setting Wi-Fi with your access
point. Try again.
Access point
setting error
(registration)
*11
ON --- Flash --- --- ---
Registration error.
The access point is busy. Try again.
Wireless LAN
connection
error
*11
ON --- Flash --- --- ---
The Wi-Fi/network connection failed.
Network
connection time
out error
*11
ON --- Flash --- --- ---
The Wi-Fi/network connection failed.
Table 3-1. Error Message List
Status
LED status
LCD message
*2
Power Wi-Fi
*1
Ethernet
Mainte-
nance
box
Paper
Ink
(BK/C/
M/Y)
( ( ( (
( ( ( (
Confidential
Note *1: WP-4020 series only
*2: The message WP-4540 series indicates is different but the meaning is the same.
*3: WP-4540/4530/4520/4510 series only
*4: WP-4540/4530/4520 series only
*5: Flashes if the status arises when printing starts or when the printer starts up, but lights if the status arises when printing is
complete.
*6: The corresponding maintenance box, ink cartridge product number or cassette number is indicated.
*7: Occurs in any paper path.
*8: If this error occurs, set the correct paper size from Printer Setup - Paper Size Loaded to solve this error.
*9: If this error occurs, install the appropriate printer drive to solve the error.
*10: The corresponding ink LED flashes after the ink falls in the ink low status, and lights when it reaches the ink end status.
*11: WP-4540/4530/4020 series only
Confidential
3.1.2 Troubleshooting Workflow
The following page describes the troubleshooting workflow. Follow the flow when troubleshooting problems.
Figure 3-1. Troubleshooting Workflow (1)
This flowchart is compiled based on the following contents.
Our experience regarding the quality problem.
Printer Mechanism specification for WP-4540/4530/4520/4510/4020/4010 series
See " 3.1.1 Error Message List (p41)" for the error indication on the control panel.
WP-4020/4010 series are not equipped with the Scanner / ADF unit, therefore, the
troubleshooting related to the Scanner / ADF unit is not applied.
WP-4510 series are not equipped with the ADF unit, therefore, the troubleshooting
related to the ADF unit is not applied.
When FAX related error occurs, see " 3.1.4 FAX Troubleshooting (WP-4540/4530/4520
series only) (p49)".
Finish
*
Turn on the printer
2
What is returned reason?
Copy an image
Copy an image by ADF
Start
ADF/Scanner
failure
Printer failure only
Yes
Yes
Yes
No
Does power-on
sequence start?
Is power-on sequence
finished without error?
Yes
No
Is ADF operation
finished without
trouble?
Standby condition
Is scanning operation
finished without
trouble?
ADF failure?
1
No
Print a nozzle check pattern.
Is the print result OK?
Yes
Yes
Is printing complete
without an error?
4
No
3
No
5
No
6
No
*: In case of Not Trouble Found, check fatal error code.
(p45)
(p45)
(p45)
(p45)
(p45)
(p45)
Print a nozzle check pattern
Confidential
Troubleshooting Troubleshooting Workflow 45
Fatal error
See 3.1.3Fatal Error Code
(p46).
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
Ink end error
This error occurs when ink in Ink
Cartridge is empty.
[Occurrence Timing]
At power-on
Cleaning
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.
Ink cartridge detection error
This error occurs when ink
cartridge data is incorrect or Ink
Cartridge is not recognized
correctly.
[Occurrence Timing]
At power-on
Cleaning
During printing
[Remedy]
Remove and reinstall Ink
Cartridges
Replace CSIC terminal
Replace CSIC Board
Replace CSIC FFC
Replace Main Board
No ink cartridge error
This error occurs when Ink
Cartridge is not installed.
[Occurrence Timing]
At power-on
Cleaning
During printing
[Remedy]
Install Ink Cartridge
Front cover open error
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
Paper jam error
See Paper jam error which
occurs during nozzle check
pattern printing.
Paper jam error
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
[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
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]
[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
*2
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 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
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
*3
[Remedy]
Replace PE Sensor
Replace PW Sensor
Replace Main Board
No paper cassette error
This error occurs when Cassette
Assy 1st cannot be detected. (The
error occurs to the Cassette Assy
2nd
*4
in the same way.)
[Occurrence Timing]
[Remedy]
Check connection for Paper
Stopper Lever Sensor cable
Replace Paper Stopper Lever
Sensor
No power
*1
[Presumable Cause]
Damage to Power Supply Unit
Damage to Main Board
[Remedy]
Replace Power Supply Unit
Replace Main Board
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
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 Printhead
Clean rubber part of Cap
Replace Ink System Unit
Adjust PG again
Replace Printer Mechanism
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
Abnormal noise
[Presumable Cause]
Foreign object
Insufficient grease
Damage to gears
[Remedy]
Apply an appropriate amount
of grease
Replace gears
Note *1: If the printer can turn on but turns off right away, the protection circuit may cut off the power due
to an error such as a circuit failure.
*2: Only for manual duplex printing
*3: WP-4540/4530/4520 series only
*4: Installed on WP-4540 series, and option for WP-4530/4520/4510/4020/4010 series.
No maintenance box error
Maintenance Box is not installed.
[Occurrence Timing]
At power-on
Cleaning
[Remedy]
Install Maintenance Box
Maintenance box CSIC error
Maintenance Box data is incorrect
or cannot be recognized correctly.
[Occurrence Timing]
At power-on
Cleaning
[Remedy]
Remove and reinstall
Maintenance Box
Replace Maintenance Box
Replace CSIC terminal
Replace Maintenance Box FFC
Replace Main Board
2 1
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
Replace ADF Unit
5 6 4 3
The power-on sequence
does not start (p44)
Error is indicated during power-on
sequence (p44)
Error is indicated during printing nozzle check pattern. (p44) Problems related to print result or during printing (p44)
Scanning cannot be
performed
successfully (p44)
ADF does not
operate
normally (p44)
Confidential
Troubleshooting 46
3.1.3 Fatal Error Code
This section describes the fatal error code and the possible cause for this product.
Printer fatal error list
Table 3-2. Fatal Error List (Printer)
Error type
Error
code
Error name Possible cause
DC motor
error
01H CR PID excess load error
CR Encoder failure (contaminated/detached scale, Encoder Board failure)
CR Motor failure
Carriage overload error (paper jam/foreign object)
Cable disconnection
02H CR PID excess speed error
Motor driver failure (Main Board failure)
Tooth skip of the CR Timing Belt
Improper tension of the CR Timing Belt
03H CR PID reverse error
Paper jam
04H CR PID lock error
CR Motor failure
Cable disconnection
05H CR PID speed degradation error
Paper jam
08H CR load position reverse error
Paper jam
09H CR load position excess speed error
0AH CR load position excess load error
CR Motor failure
Cable disconnection
11H ASF PID excess load error
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
12H ASF PID excess speed error
failure)
13H ASF PID reverse error
failure)
Paper jam
14H ASF PID lock error
failure)
ASF Motor failure
Cable disconnection
Confidential
Troubleshooting 47
DC motor
error
18H ASF load position reverse error
failure)
Paper jam
19H ASF load position excess speed error
failure)
1AH ASF load position excess load error
failure)
ASF Motor failure
Cable disconnection
F1H PF PID excess load error
PF Encoder failure (contaminated/detached scale, Encoder Board failure)
PF Motor failure
PF drive mechanism overload (paper jam/foreign object)
Cable disconnection
F2H PF PID excess speed error
Tooth skip of the PF Timing Belt
Improper tension of the PF Timing Belt
F3H PF PID reverse error
Paper jam
F4H PF PID lock error
PF Motor failure
Cable disconnection
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)
PF Motor failure
Cable disconnection
FCH PF load position error
Motor drive
time error
D1H CR (PID) driving time error
Main Board failure
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
PF Motor failure
Cable disconnection
Printhead
system error
40H Transistor temperature error Main Board failure
41H X-Hot detect error (pre printing)
Printhead failure
Main Board failure
42H X-Hot detect error (after flushing)
43H Head temperature error
Error type
Error
code
Confidential
Troubleshooting 48
Note *: When the optional 2nd cassette is installed for WP-4530/4520/4510/4020/4010 series.
Scanner fatal error list (WP-4540/4530/4520/4510 series only)
ADF fatal error list (WP-4540/4530/4520 series only)
Sequence
error
50H Home position error
Paper jam
Foreign object
Deformation of the Main Frame
51H Deadlock avoidance error
52H Impossible contact detection error
57H
Valve initialization contact point detection
error
58H
I/S clutch operation contact point
detection error
Sensor error
60H PW detector error
PW Sensor failure
Main Board failure
61H PW detector confusion error
62H
*
Hot-plug disconnection paper jam fatal
error
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 device
error
B0H -
CFH
Ink device error
Ink Cartridge failure
CSIC terminal failure
CSIC Board failure
Main Board failure
CSIC FFC connection failure
Circuit error 80H Circuit error (include blowout of a fuse) Main Board failure
Table 3-3. Fatal Error List (Scanner)
Error code Error name Possible cause
10H Scanner HP detection error
CIS Unit failure
Scanner Housing failure
Main Board failure
20H Scanner LED light error
CIS Unit failure
Main Board failure
Table 3-4. Fatal Error List (ADF)
Error code Error name Possible cause
01H ADF PID excess speed error
ADF Encoder failure (contaminated/detached scale, Encoder Board failure)
02H ADF PID reverse error
ADF Encoder failure (contaminated/detached scale, Encoder Board failure)
Paper jam
03H ADF PID lock error ADF Encoder failure (contaminated/detached scale, Encoder Board failure)
ADF Motor failure
ADF drive mechanism overload (paper jam/foreign object)
Cable disconnection
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
Error type
Error
code
Confidential
Troubleshooting 49
3.1.4 FAX Troubleshooting (WP-4540/4530/4520 series only)
3.1.4.1 FAX Log
When an error related to fax occurs, it is not only indicated on the LCD but also saved as a log file. The error
code is recorded in it, and according to this log, the contents of the error can be confirmed.
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
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.
*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
complete then. If the power failure occurs before the scheduled sending time when a broadcast is scheduled, the scheduled sending time is
recorded.
Table 3-5. FAX Log (1)
Log Name Description Save Destination
Latest log
*1
(Last Transaction)
The latest communication log of sending / polling reception Nonvolatile memory
Communication log
(Fax Log)
The following information is stored.
Note *: For error codes, see Table 3-7. Error Code List (p.50).
Nonvolatile memory
Power failure log
*2
(Fax Log)
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.
(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.)
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:
Airtime Hour/minute/second
Communication pages 0 to 100
Communication result
Common:
Normal/cancel/error code
*
No dial tone detected/No fax signal detected/Busy tone detected
Confidential
Troubleshooting 50
Error codes

Table 3-6. FAX Log (2)
Log Name Description Save Destination
Protocol trace
The following information of the latest communication is stored.
Note *: If a large amount of FIF is received, the recorded command/response may be less than
40.
Volatile memory
Table 3-7. Error Code List
Error
Code
(HEX)
Phenomenon LCD Display Print Example
000 Successful completion (Monochrome) Complete OK
C000 Successful completion (Color) Complete OK Color
400 Communication error Communication error Error code
420
Fax signal was not detected during receive operation. (The call was a
telephone call)
Not displayed ---
Item Information
Communication start
date / time
Year/month/day/hour/minute
Communication type Sending/receiving/polling reception
Communication ID
Destination name of speed dial (first 20 characters)
Telephone number (last 20 characters)
Receiving:
Airtime Hour/minute/second
Communication pages 0 to 100
Communication result
Common:
Normal/cancel/error code
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 3-8. Command/Response Code (p.52))
FCF/FIF (first 33 octets).
Confidential
Troubleshooting 51
630 A busy tone was detected after dialing
Talking
(Line Busy)
Talking
(Line Busy)
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
870 The image memory is full Memory Full Memory Full
871 The maximum number of files was exceeded Error code 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
Error
Code
(HEX)
Confidential
Troubleshooting 52
Note *: Confirm the fatal error code with the Adjustment Program to check which error occurred. (See " 3.1.3 Fatal Error Code (p46)".)
Command/response 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
F60 A scanner fatal error occurs
Same message when a scanner
fatal error occurred
*
Error code
F61 A printer fatal error occurs
Same message when a printer
*
Error code
F62 Reserved --- Error code
F63 ADF misfeed or paper jam occurred
Same message when an ADF
*
ADF Jam
F64 The memory for printing received image is full Error code Error code
Table 3-8. Command/Response Code
Command/response
code
FCF value (HEX)
(LSB first: X=0)
Content
First Second
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
Error
Code
(HEX)
Confidential
Troubleshooting 53
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
Table 3-8. Command/Response Code
Command/response
code
FCF value (HEX)
(LSB first: X=0)
Content
First Second
Confidential
Troubleshooting 54
3.1.4.2 Error Code/Superficial Phenomenon-Based Troubleshooting
This section explains the troubleshooting procedures based on the error codes and superficial phenomenon.
When an error occurs, it may be displayed on the LCD panel with a message instead of
an error code. 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 3-9,
print out a protocol trace to analyze the cause of the error.
Table 3-9. Troubleshooting Based on the Error Code/Superficial Phenomenon
Error code (LCD
Message)/Phenomenon
Description Remedy
Communication Error
(The error is indicated with
error code on the fax log.)
Communication error
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.
Line Busy The line is busy. Try again later.
No answer
The other end of the line does not
answer.
Check the number and dial again.
The other end of the line
answered but no answer tone is
detected.
Power fail
Power failure occurred during
sending/receiving/printing/
redialing.
Confirm the P/S Board Connector Cable or P/S Board is not
damaged, and retry.
706,880-884,F21,F27-
F28,F2F,F51,F59
A system error (fax circuit failure)
occurs
Replace the FAX board with a new one.
Memory full Out of Memory
Ask the sender to resend the fax in several batches.
871
Maximum number of files is
exceeded
F60 A scanner fatal error occurred See Table 3-2 "Fatal Error List (Printer)" (p.46).
See Table 3-3 "Fatal Error List (Scanner)" (p.48). F61 A printer fatal error occurred
F62 Reserved ---
F63
ADF document mis-feed or paper
jam occurs
Set the documents and try again.
If a paper jam error occurs, remove the jammed paper and try
again.
F64
The memory for printing received
image is full
Ask the sender to resend the fax in several batches.
Cannot receive faxes
The telephone cable is not
connected properly.
Connect the telephone cable 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.
Set the setting to ALL and try again. Should other ring patterns be
selected, contact the telephone company.
Calling signal cannot be detected.
Contact the telephone company or obtain the fax log for more
analysis.
Cannot dial
The telephone cable is not
connected properly.
Connect the telephone cable 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.
Cannot receive/send faxes
in color
ECM is set to off. Set to on and try again.
Fax mode is set to B&W only. Set to B&W/Color.
Confidential
Troubleshooting 55
Cannot print all the
received data when
printing data stored in
memory
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.
Ask the sender to resend the data if necessary because the data
deleted from the memory can not be restored.
Images run off the paper
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.
Choose the correct setting and reprint the data.
Paper size setting does not match
the size of papers in the tray.
Choose the correct setting or load correct sized papers in the tray and
reprint the data.
Table 3-9. Troubleshooting Based on the Error Code/Superficial Phenomenon
Error code (LCD
Message)/Phenomenon
Description Remedy
Confidential
CHAPTER 4
DISASSEMBLY/REASSEMBLY
Confidential
Disassembly/Reassembly Overview 57
4.1 Overview
This chapter describes procedures for disassembling the main parts/units of WP-4540/4530/4520/4510/4020/
4010 series. 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 (p68)".
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.
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 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
Name Quantity EPSON Part Code
Thickness gauge (2 mm) 1 ---
Ink Leak Measurement Jig 1 TBD
Ink Leak Check Cartridge 1 TBD
Confidential
Disassembly/Reassembly Disassembly/Reassembly Procedures 58
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.
Tools
Ink Cartridges (four colors: cyan, magenta, yellow, black)
Do not use users 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 users 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 (for service
use) and maintenance box (for service use).
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 (p59)" and replace
them referring to "4.2.3 Disassembly Flowchart (p60)".
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.
When separating the Printhead and the Ink Supply Unit, make sure to perform "5.2.7
Ink Leak Check (p101)" 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.
Joint section of the Printhead
and Ink Supply Unit
Printhead
Ink tubes
Carriage Assy
Confidential
4.2.2 Parts/Units Need to be Removed in Advance
In Chapter 4 "Disassembly Flowchart (p60)", the procedures are indicated on the premise that some parts/units
are removed in advance. Make sure to remove the following parts/units before starting disassembly.
Note "*": When the optional Cassette Assy 2nd is installed for WP-4530/4520/4510/4020/4010 series.
Ink Cartridges (x4) Maintenance Box
Cassette Assy 1st Duplex Unit
Cassette Assy 2nd
*
Confidential
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 (p68)".)
For routing cables, see "4.4 Routing FFCs/cables (p77)".
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.
Note: The 2nd Cassette Unit is installed for WP-4540 series, and option for WP-4530/4520/4510/4020/4010 series.
Table 4-1. Parts/Units whose Configuration is Different between Models
Model
Name
Exterior Parts
Main Board
Related Parts
Control Panel
Components
Wireless LAN
Related Parts
WP-4540
series
"Scanner Unit (p63)"
"ADF Unit (p63)"
"ADF Cover Assy
(p63)"
"ADF Cover Housing
Upper (p63)"
"LD Cover (p63)"
"LD Shaft (p63)"
"Extension Spring
0.99 (p63)"
"ADF LD Assy
(p63)"
"ADF Rear Cover
(p63)"
"ADF Document
Support Assy (p63)"
"ADF Pad Assy (p62)"
"FAX Cover (p62)"
"Main Board Shield
Plate Upper Assy
(p65)"
"Interface Board Shield
Plate (p65)"
"FAX FFC (p65)"
"Interface Board
(p65)"
"Panel FFC (p62)"
"Panel Assy (p62)"
"Panel Board (p63)"
"Panel Housing Upper
Assy (p63)"
"Touch Panel (p63)"
"Panel Sheet (p63)"
"LCD Module (p63)"
"Panel Frame (p63)"
"Panel Optical Plate
(p63)"
"Wireless LAN Module
(p64)"
WP-4520
series
"Panel FFC (p62)"
"Panel Assy (p62)"
"Panel Board (p63)"
"Sub Board Assy
(p63)"
"Sub Board (p63)"
"Sub Board FFC
(p63)"
"LCD Cover (p63)"
"LCD Module
(p63)"
Assy (p63)"
---
WP-4530
series
(p64)"
WP-4510
series
"Document Cover
(p62)"
"Scanner Unit (p62)"
"FAX Cover (p62)"
---
---
WP-4010
series
"Housing Upper Assy
(p62)"
"USB Cover (p62)"
"Panel FFC (p62)"
"Panel Assy (p62)"
"Panel Board (p63)"
Assy (p63)"
---
WP-4020
series
(p64)"
Confidential
The example below shows how to see the charts on the following pages.
USB Cover
1
2
(p 68) (p 77)
S3
Ink System Unit
1
1
(p 71)
Ref.
S4
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.
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.
page in blue-letter
Indicates supplementary explanation for disassembly
is given.
page in blue-letter
Indicates particular tasks to keep quality of the units
are required.
page in blue-letter
Indicates particular routing of cables is required.
page in blue-letter
Indicates particular adjustment(s) is/are required.
Chapter 5 "Adjustment
(p82)"
Indicates lubrication is required.
Chapter 6 "Maintenance
(p104)"
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.
Confidential
Disassembly/Reassembly 62
Screw type/torque list
Symbol Screw Type Torque
C.B.P-TITE SCREW 2x6-F/ZN-3C 2 1 kgfcm
C.B.S-TITE SCREW 3x6-F/ZN-3C 6 1 kgfcm
C.P.SCREW 3x6-F/ZN-3C 6 1 kgfcm
C.B.P-TITE (P2) SCREW 3x10-F/ZN-3C 6 1 kgfcm
C.P.SCREW 2.5x6-F/ZN-3C 2 5 kgfcm
C.B.S-TITE (P4) SCREW 3x8-F/ZN-3C 6 1 kgfcm
C.B.P-TITE SCREW 2.5x8-F/ZN-3C 6 1 kgfcm
C.B.P-TITE SCREW 2x10-F/ZN-3C 3 0.5 kgfcm
C.B.P-TITE (S-P1) SCREW 3x12-F/ZN-3C 6 1 kgfcm
C.B.EP-TITE SCREW 2x16 (B=10) F/ZN-3C 2.5 0.4 kgfcm
S1
S2
S3
S4
S5
S6
S7
S8
S9
S10
S11
S12
S13
S14
S15
S16
4.2.3.2 Exterior Parts
Flowchart 4-1. Disassembling Flowchart of Exterior Parts (1)
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 (p59)" are already removed in advance.
See "4.2.3.4 Printhead/Ink Supply Unit (p66)" for disassembly of the Printhead and Ink Supply
Unit.
See "4.2.3.5 2nd Cassette Unit (p67)" for disassembly of the 2nd Cassette Unit.
START
A
Metal Plate
(w/ Paper
Stopper Assy)
6
---
(p 77)
S2 S3
1
(p 64)
(p 63)
Parts/units whose
composition or shape
differ between models
Common parts/units
Housing Rear
Assy
4
2
(p 68)
S2
Rear Housing
---
---
---
Stacker Assy
---
4
---
WP-4020/4010 series WP-4530/4520/4510 series
Panel Assy
---
9
(p 69)
Panel Assy
---
7
(p 69)
Go to the next step
Housing Rear
Assy
FAX Cover
Housing Upper
Assy
5
---
(p 68)
S2
ADF Unit /
Scanner Unit
7
2
(p 75) (p 77)
S2 S3
Front Housing
Assy
3
2
(p 68)
S2
WP-4010 series WP-4520 series
Go to the next step
Housing Rear
Assy
USB Cover
2
(p 63)
Paper Support
---
2
---
Paper Stopper
Assy
2
2
(p 74)
S3
Pickup Assy 1st
---
2
---
WP-4540/4530/4520/4510 series
USB Cover
2
4
(p 68)
S2
FAX Cover
2
4
(p 68) (p 77)
S2
Panel FFC
---
---
---
ADF Pad Assy
---
4
(p 76)
WP-4510 series
Scanner Unit
6
2
(p 75) (p 77)
S2 S3
Document Cover
---
2
---
Panel FFC
---
---
---
WP-4540 series
Panel Assy
---
7
(p 69)
WP-4020/4010 series
Confidential
Flowchart 4-2. Disassembling Flowchart of Exterior Parts (2)
LCD Module
---
---
---
1
2
(p 62)
(p 62)
Panel Board
6
3
(p 69)
S2
WP-4020/
4010 series
Panel Board
4
2
(p 69)
S7
Panel Housing
Upper Assy
---
---
---
WP-4530/4520/
4510 series
Sub Board Assy
2
---
(p 69)
S1
Panel Housing
Upper Assy
---
---
---
Sub Board
---
3
---
Sub Board FFC
---
---
---
LCD Cover
---
---
---
Scanner Unit
---
---
(p 77)
ADF Unit
---
2
(p 76) (p 77)
ADF Document
Support Assy
---
2
(p 76)
ADF Cover
Housing Upper
4
5
(p 75)
S2
LD Shaft
---
1
---
Extension Spring
0.99
---
---
---
ADF LD Assy
---
2
---
Panel Optical
Plate
---
---
---
Panel Board
2
3
(p 69)
(p 78) (p 82)
S7
Panel Frame
---
---
(p 78)
Touch Panel
---
---
(p 70)
(p 78) (p 82)
WP-4540
series
Panel Housing
Upper Assy
6
---
(p 69)
S7
LD Cover
1
---
---
S2
LCD Module
2
---
(p 70)
(p 78) (p 82)
S1
Panel Sheet
---
---
(p 70)
S1
S2
S3
S4
S5
S6
S7
S8
S9
S10
S11
S12
S13
S14
S15
S16
Parts/units whose
Common parts/units
ADF Rear Cover
1
3
(p 76)
S2
ADF Cover Assy
---
2
(p 76)
Confidential
Parts/units whose
Common parts/units
4.2.3.3 Printer Mechanism
Flowchart 4-1. Disassembling Flowchart of Printer Mechanism (1)
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 (p66)" for disassembly of the Printhead and Ink Supply
Unit.
Rear ASF Assy
4
---
(p 73) (p 82)
S2
CSIC FFC
---
---
(p 78)
Decompress Pump
Unit
CR Cover
Ink Supply Unit
Grounding Plate
Ink Supply Unit/
Printhead
Metal Plate Left
3
---
(p 71) (p 77)
S3
PF Encoder
1
2
(p 71)
S11
PF Tension
Stopper Holder
1
---
(p 82)
S10
A
(p 62)
Main Board Unit
3
3
(p 70)
(p 79) (p 82)
S4 S9
Middle Housing
4
---
(p 68)
S2
Rear ASF Guide
Upper Assy
1
2
(p 73) (p 78)
S2
PF Encoder FFC
---
---
(p 78)
PF Timing Belt
---
---
(p 71) (p 82)
Decompress
Pump Unit
4
---
(p 74) (p 78)
S6 S3 S2
Power Supply
Unit
2
---
(p 74)
(p 78) (p 82)
S3 S2
Wireless LAN
Module
3
---
(p 75) (p 78)
S3
B
(p 65)
3
(p 65)
Ink System Unit
2
1
(p 71) (p 78)
S2
ASF Drive Change
Lever Assy
---
1
---
Spur Gear 11.2
---
---
---
Compound Gear
16,10.4
---
---
---
ASF Drive Change
Lever Holder
---
---
---
Spur Gear 11.2
---
---
---
Extension Spring
0.63
---
---
---
C
(p 65)
Option
Connector
---
2
---
Maintenance Box
Ink Eject Joint
2
---
---
S14
CR Scale /
Extension Spring
3.23
---
---
(p 73) (p 82)
S1
S2
S3
S4
S5
S6
S7
S8
S9
S10
S11
S12
S13
S14
S15
S16
Confidential
Parts/units whose
Common parts/units
Flowchart 4-2. Disassembling Flowchart of Printer Mechanism (2)
Main Board
3
---
(p 70)
S4 S8
3
Frame Base Assy
---
---
(p 78) (p 82)
(p 104)
CR Cover
---
3
(p 68)
Front Frame Assy
5
---
(p 73) (p 78)
(p 82)
S3 S2
Interface Board
Shield Plate
3
---
(p 70)
S3
(p 64) B (p 64)
Power Supply
Unit
Rear ASF Assy
Rear ASF Guide
Upper Assy
Stacker Assy
Ink System Unit
ASF Drive Change
Lever Assy
Metal Plate Left
Decompress Pump
Unit
Ink Supply Unit
Grounding Plate
2
2
(p 73)
S3
Ink System Supply
Assy
*2
8
---
(p 72) (p 78)
S12 S3
Head FFC
*1
---
8
(p 73) (p 79)
Fasten Plate
Center
3
---
(p 78)
S3
Metal Plate Left
Fasten Plate Left
2
---
(p 78)
S2
Driven Pulley
Assy
---
---
(p 104)
CR Motor
2
---
(p 78) (p 82)
S15
C (p 64)
EJ Roller
---
1
(p 74)
(p 82) (p 104)
Star Wheel Assy
2
2
(p 74) (p 82)
S2
PF Tension
Stopper Holder
PF Timing Belt
CR Scale/
Extension Spring
3.23
Driven Pulley
Assy
Paper Guide
Upper
---
6
(p 82)
PE Lever Holder
Assy
1
---
(p 82)
S3
CR Guide Frame
(w/ Carriage Assy)
5
---
(p 82)
S3
CR Guide Frame
---
---
(p 104) (p 82)
Carriage Assy
---
---
(p 73) (p 104)
(p 82)
Main Frame
Mounting Plate
1
2
---
S3
Main Frame Assy
(w/CR Guide
Frame)
5
6
(p 71) (p 78)
(p 82) (p 104)
S3
Main Board Cable
Holder
---
3
(p 79)
Main Board
Shield Plate Upper
Assy
7
3
(p 70)
S5 S3
Main Board
Shield Plate
Lower Assy
---
---
(p 70)
Interface Board
---
---
(p 70)
S1
S2
S3
S4
S5
S6
S7
S8
S9
S10
S11
S12
S13
S14
S15
S16
FAX FFC
---
---
---
*1 If you find it difficult to connect the Head
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.
However, once the Printhead is removed from
the Carriage Assy, performing "Checking the
Platen Gap (p96)" is necessary.
*2 The Ink System Supply Assy is an ASP
composed of the Printhead and Ink Supply
Unit connected together.
Support Plate
Right/Left
2
4
---
S3
Confidential
Parts/units whose
Common parts/units
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.
Flowchart 4-1. Disassembling Flowchart of Printhead/Ink Supply Unit
Printhead / Ink Supply Unit START
S1
S2
S3
S4
S5
S6
S7
S8
S9
S10
S11
S12
S13
S14
S15
S16
Middle Housing
4
---
(p 68)
S2
CR Cover
---
3
(p 68)
Decompress Pump
Unit
Ink Supply Unit
Grounding Plate
2
2
(p 73)
S3
Ink Supply Unit
6
---
(p 72)
(p 78) (p 82)
S3 S16
Printhead
6
---
(p 72)
(p 78) (p 82)
S12 S16
Front Housing
Assy
3
2
(p 68)
S2
Go to the next step
Housing Rear
Assy
USB Cover
CR Cover
Ink leak check (p 101)
Checking the platen gap (p 96)
Reassemble the printer and perform the
required adjustment (p 83).
Panel Assy
---
9
(p 69)
Panel Assy
---
7
(p 69)
Go to the next step
Housing Rear
Assy
FAX Cover
Housing Upper
Assy
5
---
(p 68)
S2
ADF Unit/
Scanner Unit
7
2
(p 75) (p 77)
S2 S3
Panel FFC
---
---
---
WP-4510 series
Scanner Unit
6
2
(p 75) (p 77)
S2 S3
Panel FFC
---
---
---
WP-4540 series
Panel Assy
---
7
(p 69)
Releasing the pressure (p 58)
Confidential
4.2.3.5 2nd Cassette Unit
This unit is installed for WP-4540 series, and option for WP-4530/4520/4510/4020/4010 series.
Flowchart 4-1. Disassembling Flowchart of 2nd Cassette Unit
2nd Cassette Unit START
Cassette Assy
2nd
---
---
(p 104)
Frame Pickup
Assy
4
---
(p 75) (p 80)
S2
2nd Cassette
Housing Assy
---
---
(p 80)
2nd Cassette
Cover Left
4
3
(p 74)
S2
Cassette Cover
---
---
---
2nd Cassette
Cover Right
4
3
(p 75)
S2
2nd Cassette
Cover Front
2
---
---
S2
Paper Stopper
Assy
2
---
(p 74)
S7
Pickup Assy 2nd
---
1
---
S1
S2
S3
S4
S5
S6
S7
S8
S9
S10
S11
S12
S13
S14
S15
S16
Disassembly/Reassembly Detailed Disassembly/Reassembly Procedure for each Part/Unit 68
Confidential
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-4540/4530/4520/4510 series and USB Cover for WP-4020/
4010 series.
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.
Rib A
C.B.P-TITE SCREW 3x10 F/ZN-3C (6 1 kgfcm)
FAX Cover/
USB Cover
Housing Upper Assy (WP-4020/4010 series)
Tighten the screws in the order indicated in the figure above.
Rear right
4
1
2 3
5
Rear left
Housing Upper Assy
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.
Rib B
Hook
1
2
3
Inside Front Cover
Front Cover
Front Cover
Rib A
Cross-section
Middle Housing
Rib A
Front
Housing Assy
Bottom left
Hook
Bottom right
Hook
Front
Housing Assy
Middle Housing
When removing the Middle Housing on the way to the target parts, remove it also by removing the screw securing the grounding wire, but leave the
grounding wire attached on the Middle Housing with the acetate tape then. (WP-4510 series only)
When replacing the Middle Housing, remove the grounding wire from the Middle Housing. After replacing the Middle Housing, route the
grounding wire as shown in the figure above and secure it with acetate tape (x3). (WP-4510 series only)
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.
Middle Housing
1
2
4
Rear left
Ribs of Frame Base
3
Rear right
Top: WP-4510 series only
Screw to secure grounding wire
Acetate tape
Grounding wire
Ribs of Frame Base
Housing Rear Assy
1
4
Housing Rear Assy
2
3
Rear left
Rear right
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.
Hook
Right side of Carriage Assy
Carriage Assy
CR Cover
Confidential
Panel Assy (WP-4540/4530/4520/4510 series)
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.
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 (WP-4020/4010 series)
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.
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
Panel Board (WP-4530/4520/4510/4020/4010 series)
When installing the Panel Board, align the positioning holes
(WP-4530/4520/4510 series: x3, WP-4020/4010 series: x2) of
the Panel Board with the dowels (WP-4530/4520/4510 series:
x3, WP-4020/4010 series: 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.
WP-4530/4520/4510 series
1
2
3 4
5 6
Panel Board Panel Housing Upper
Panel Housing Upper
1 2
3
4
Panel Board
WP-4020/4010 series
Positioning hole and dowel
Sub Board Assy (WP-4530/4520/4510 series)
Before removing the Sub Board Assy, unlock the connector lock
on the Sub Board Assy that secures the LCD FPC.
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.
Locked
LCD FPC
Connector lock
1
2
C.B.P-TITE SCREW 2x6 FZN-3C (2 1 kgfcm)
Unlocked
LCD FPC
Connector lock
Panel Board (WP-4540 series)
Before removing the Panel Board, unlock the connector lock on the
Panel Board that secures the Touch Panel FPC.
When connecting the Touch Panel FPC, make sure to insert the
Touch Panel FPC into the connector to the full and secure it
with the connector lock.
Panel Board
Touch Panel FPC
Locked
Connector lock
Touch Panel FPC
Unlocked
Connector lock
2
1
3
4
5
2
1
3
Panel Housing Upper (WP-4540 series)
When attaching the Panel Cushioning Materials, align them
with the reference lines shown above, and attach them keeping
the gap between the lines and materials less than 1 mm.
Attach the Panel Frame by engaging the hooks (x4) on the
upper side first of the Panel Housing Upper and the hooks (x4)
on the lower side next, then tighten the screws (x6) in the order
indicated in the figure above.
Panel Cushioning Materials
Panel Cushioning Materials
2
1
3
4
6
5
Reference line
Hook
Panel Frame
Panel Housing Upper
Confidential
LCD Module / Panel Sheet / Touch Panel (WP-4540 series)
When attaching the Panel Sheet, make sure to hold the edges of it and do not touch the surface of the sheet.
When installing the LCD Module, Panel Sheet and Touch Panel, follow the procedure below.
1. Install the LCD Module to the Panel Frame, and tighten the screws (x2) in the order indicated in the figure above to secure the LCD Module to the Panel Frame.
2. Peel off the protection sheet from the Panel Sheet, and attach the Panel Sheet aligning the ribs (x3) of it with the section A (x3) of the Panel Frame.
3. Route the Touch Panel FPC through the hole on the Panel Frame, then attach the Touch Panel aligning it with the frame of the Panel Frame.
LCD Module
1 2
LCD Module
Rib
Section A
Touch Panel FPC
Touch Panel
Hole of Panel Frame
Panel Frame
Panel Sheet
Touch Panel
LCD
Module
Hole of Panel Frame
Panel Frame
Main Board Unit
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 Front/Main Board Unit Bracket Rear into the holes of the
Main Board Unit.
After installing the Main Board Unit, make sure the legs of the Main Board Unit Grounding Plate touch the Main Frame.
Main
Board Unit
1
Legs
Left
Main Frame
Rib and hole
2
3
C.B.S-TITE SCREW 3x6 F/ZN-3C (6 1 kgfcm)
C.P.SCREW 3x5 F/ZN-3C (6 1 kgfcm)
Main Board Unit
MAC Address Label
Main Board Unit Bracket Front
Main Board Unit Bracket Rear
Main Board Shield Plate Upper Assy
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.
1
Back
2
3
4 5
6
7
Main Board Shield
Plate Upper Assy
Inside
Interface Board
FFC
Main Board / Main Board Shield Plate Lower Assy
2
1
C.P.SCREW 2.5x6 F/ZN-3C (2 5 kgfcm)
Main Board
Main Board Shield
Plate Lower Assy
3
Interface Board (WP-4540/4530/4520 series)
When installing the Interface Board, follow the procedure below.
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.
Interface Board Grounding Plate
Step 1 Main Board Shield Plate Upper Assy
Interface Board Step 2 Step 3-4 Interface Board Shield Plate
1
2
3
Screw hole
Confidential
Ink System Unit
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 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.
Ink System Unit
1
2
Dowel
Hole
A
B
C
D
Ink System Unit
E
A B
E D
C
Maintenance
Box Ink Eject
Joint
Frame Base
Ink System
Tube
Tube
clamp
Hole of Frame Base
Groove
Acetate tape
Ink System
Tube
Tube
clamp
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.
Cutout
Metal Plate Left
3
1
Align cutout with rib.
2
Frame Base Assy
PF Encoder / PF Timing Belt
When installing the PF Encoder, set the encoder over the 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.
C.B.P-TITE SCREW 2.5x8 F/ZN-3C (6 1 kgfcm)
PF Encoder
PF Scale
PF Encoder
PF Scale
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.
Left
APG Lever
APG Change Lever
Bottom left
Rib
Cutout
3
4 5
Right
1
2
Left
PF Scale Sheet
Bottom right
Rib
Cutout
Hole and rib
Hole and hook
Frame Base Assy
Main Frame Assy
Confidential
Ink System Supply Assy (Ink Supply Unit w/ Printhead)
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 (p72).)
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 (p72) and Ink Supply Unit (p72).
Do not remove.
Section A
C.B.P-TITE SCREW 2x10 F/ZN-3C (3 0.5 kgfcm)
Section A
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
(p58) and Ink Supply Unit (p72).)
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.
When disconnecting the ink tubes of the Ink Supply Unit from the Printhead to replace 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. (See Ink Supply Unit (p72).)
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.
After installing the Printhead, make sure to connect the ink tubes to the Printhead. (See Ink Supply Unit (p72).)
When replacing the Printhead, make sure to perform 5.2.7 Ink Leak Check (p101).
C.B.P-TITE SCREW 2x10 F/ZN-3C (3 0.5 kgfcm)
Thickness gauge (2 mm)
1
2
3
4
Printhead
Carriage Assy
Star Wheel Assy
Position for thickness
gauge (2 mm) Attach tape on the yellow box to
protect the area from ink.
Ink Supply Unit
Before disconnecting the joint section of the Printhead and the ink tubes of the Ink Supply Unit, it is necessary to perform 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
the Printhead/Ink Supply Unit (p58).)
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 (p72).)
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 (p72).)
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.
2. Secure the ink tubes with the Tube Holder A (x3).
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 5.2.7 Ink Leak Check (p101).
End of ink tube
Rubber packing
Holes of Printhead
Joint section
C.B.EP-TITE SCREW 2x16(B=10) F/ZN-3C (2.5 0.4 kgfcm)
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
1 2
3
4
Confidential
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.
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
Ink Supply Unit Grounding Plate
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.
Rib
1
Ink Supply Unit
Ink Supply Unit
Grounding Plate
2
Front Frame Assy
Hook
Carriage Assy
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.
Bottom
APG Slider
Rear APG Slider
Carriage Assy
CR Guide Frame
Front Frame Assy
2
1
5
3 4
Front Frame Assy
Front
Front Frame Assy
Top
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.
Frame Base
Assy
1
2 Dowel and
positioning hole
3
4
Rear ASF
Assy
Rear right
Trigger Lever Clutch Lever
Rear ASF
Assy
Rear left
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.
Rib
Dowel and
positioning hole
Step 1
Step 2
Holes of Frame Driven Assy
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.
Black mark
Carriage Assy
Slit of CR
Encoder
CR Scale
Carriage Assy
Confidential
Star Wheel Assy
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.
1 2
C.B.P-TITE(S-P1) SCREW 3x12 F/ZN-3C (6 1 kgfcm)
Paper Guide Front Assy Star Wheel Assy
Dowel and positioning hole
Power Supply Unit
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.
1
2
Power Supply Unit
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.
2
1
C.B.P-TITE(P2) SCREW 3x10 F/ZN-3C (6 1 kgfcm)
3
4
Joint of Ink
Supply Unit
Hooks
Ink Supply Unit Back
Decompress
Pump Unit
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 then remove the EJ Roller.
Make sure the grounding spring touches the EJ Roller on the
position shown above.
EJ Roller Grounding spring
Dowel
EJ Roller
Bush, 5
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.
Metal Plate Paper Stopper Assy 1st
1 2
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.
2nd Cassette Unit
1 2
Paper Stopper Assy 2nd
Note "*": When the optional 2nd cassette is installed for WP-4530/4520/4510/4020/
4010 series.
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.
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*
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.
1
2nd Cassette Cover Left
Hole
2
3
4
Cross-section
Hook
2nd Cassette
Cover Left
Front Rear
Confidential
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.
2
2nd Cassette Cover Right
Hole
1
3
4
Hook
2nd Cassette
Cover Right
Cross-section
Front Rear
Frame Pickup Assy
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.
1
2
3
4
Frame Pickup Assy
2nd Cassette Housing Assy
Wireless LAN Module (WP-4540/4530/4020 series)
When installing the Wireless LAN Module, make sure of the
following.
Align the cutout of the Wireless LAN Module with the rib of
the Wireless LAN Module Mounting Plate.
Align the positioning hole of the Wireless LAN Module with
the dowel of the Wireless LAN Module Mounting Plate.
1
2
C.B.P-TITE(S-P1) SCREW 3x12 F/ZN-3C (6 1 kgfcm)
Wireless LAN Module
Align cutout
with rib.
Align positioning
hole with dowel.
Front right of printer Wireless LAN Module
Mounting Plate
ADF Unit / Scanner Unit (WP-4540/4530/4520/4510 series)
WP-4510 series do not have the ADF Unit but the disassembly/
reassembly procedure is the same as that for the others.
1
Rear left
4
2 3
6
Rear right
5
C.B.S-TITE-SCREW 3x6 F/ZN-3C (6 1 kgfcm)
Scanner Unit
ADF Cover Housing Upper (WP-4540/4530/4520 series)
The figures above indicate the hooks (x2), ribs (x3) and screws
(x4) that secure the ADF Cover Housing Upper.
Hook
Rib
ADF Cover Housing Upper
Note"*":When the optional 2nd cassette is installed for WP-4530/4520/4510/4020/4010 series.
Confidential
ADF Unit (WP-4540/4530/4520 series)
The figures above indicate the hooks, dowels and screws that secure the parts and units.
Hook
Dowel
ADF Pad Assy
ADF Cover Assy
Screw hole
ADF Rear Cover
ADF Document Support Assy
ADF Unit
ADF Pad Assy
ADF Cover Assy
ADF Document Support Assy
ADF Rear Cover
Disassembly/Reassembly Routing FFCs/cables 77
Confidential
4.4 Routing FFCs/cables
Top of the Scanner Unit
(WP-4540/4530/4520/4510 series)
Route the Scanner grounding wire through the ribs (x4) of the Scanner Unit 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.
Rib
C.B.S-TITE-SCREW-3 x 6-F/ZN-3C (6 1kgfcm)
Ferrite core Shield plate of Main Board Assy
Scanner grounding wire
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.
Metal Plate
Hook
Hole of Frame Base
Clamp
Paper Stopper Lever Sensor cable
Bottom
Bottom of the Scanner Unit
(WP-4540/4530/4520/4510 series)
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-4540/4530/4520 series only)
ADF PE Sensor cable ADF Document Sensor cable ADF Motor cable
ADF Encoder cable ADF grounding wire
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
Inside the FAX Cover (WP-4540/4530/4520/4510 series)
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-4540/4530/4520 series 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
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 1kgfcm)
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
Front of the Printer
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.
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
Confidential
Top of the Printer
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 Plate
Center, and then secure it on the position shown above with double-sided tape.
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
Make one turn
Power Supply Unit cable
Ink Supply Unit
Main Frame
CSIC FFC
PF Encoder FFC
Fasten Plate Center
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.
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
Wireless LAN Module (WP-4540/4530/4020 series)
Route the Wireless LAN Module cable through the hole of the Front Frame,
and then connect it to the connector on the Main Board. (TBD)
Wireless LAN Module
Hole of Front Frame
Main Board
Assy
Wireless LAN
Module cable
Back
Wireless LAN
Module cable
Right
LCD FFC / Touch Panel FPC (WP-4540 series)
Route the LCD FFC and Touch Panel FPC as shown above, and then connect
them to the connectors on the Panel Board.
Route under the cables
connecting the two boards.
Pull it out from hole
of Panel Board.
Panel Board
Touch Panel FPC
LCD FFC
LCD FFC
Pull them out from hole of Panel Frame.
Touch Panel FPC
Panel Frame
Confidential
Main Board Assy (1)
Power Unit cable (CN501) 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.
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
of the FFCs, and then route and connect it to the connector on the Main Board.
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
FFCs, and then route and connect it to the connector on the Main Board.
Paper Stopper Lever Sensor cable (CN13)/ Route them through the rib A, clamp F and clamp G of the Main Board Assy, and then connect them to the
PE Sensor cable (CN9)/ connectors on the Main Board.
ASF Encoder relay cable (CN11)
Decompress Pump cable (CN22) 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.
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
CN8 CN13 CN501 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 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 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
Main Board Assy (3)
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.
Maintenance
Box FFC
Main Board Assy
Acetate tape
Right side of Main Board Assy
Head FFC
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.
Carriage Assy
CR Encoder FFC
Connector of CR Encoder Board
Head FFC
Head FFC
Hook
Confidential
Note "*": When the optional 2nd cassette is installed for WP-4530/4520/4510/4020/4010 series.
*
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.
When connecting the Paper Stopper Lever Sensor cable to the ASF Encoder Board, follow the procedure below.
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.
Bottom
Paper Stopper Lever Sensor cable
Groove A Hole C
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
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
Confidential
4.5 Connector Summary
Cable connections of this printer are shown below.
Figure 4-2. Connector Diagram
Model ADF Unit Scanner Unit
Wireless LAN
Module
FAX Board USB Host
Panel Unit
type
WP-4540 series Yes Yes Yes Yes Yes B
WP-4530 series Yes Yes Yes Yes Yes C
WP-4520 series Yes Yes --- Yes Yes C
WP-4510 series --- Yes --- --- Yes C
WP-4020 series --- --- Yes --- --- A
WP-4010 series --- --- --- --- --- A
B
Maintenance Box
M Y C
Touch panel
3.5 inch LCD Module
CB32 PNL
CB27 PNL
CB32 PNL-B 2.5 inch LCD Module
CB28 PNL
CA70 SUB
PW Sensor
CR Encoder Board
ADF Motor
ADF PE Sensor
Wireless LAN Module
Cover Open Sensor CN10
CN3 CN36
CN1
CN32 CN33
CN27 CN501
AC in
J1
CN31 CN34
CN1
Printhead
CSIC
CSIC
CR Contact Module
CN30 CN35 CN1
CN23
CN37
CN54
Scanner Motor
CIS Module
ADF Unit
2nd Cassette Unit
CN55
CN38
ADF Encoder CN40
ADF Document Sensor CN39
CN1
PE Sensor CN9
Paper Stopper Lever Sensor CN13
CR Motor CN20
PF Motor
USB
USB Host
Ethernet
CN51
Decompression Motor CN22
CN4
CN28
CN29
PF Encoder CN8
CA28 PSH
CN1
CN1
Option
Connector
CN2
CN2
CA28 Main
Scanner Unit
FAX Board
Carriage Assy
ASF Motor

ASF Encoder Board
CB28 IF
CN11
CN12
CN2
CN3
CN1
CN2
CN2
CN1
CN1
Paper Stopper Lever Sensor
Panel Unit (A)
Panel Unit (B) Panel Unit (C)
Confidential
CHAPTER 5
ADJUSTMENT
Adjustment Required Adjustments 83
Confidential
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.
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.
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) (p84).)
The Adjustments using the Adjustment Program need to be performed after
reassembling the printer completely. (See Table 5-2 Required Adjustment List
(p85).)
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.
Confidential
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 (p85).)
Note *: WP-4540 series only
Table 5-1. Required Adjustment List (Mechanism adjustment)
Adjustment Type Mechanism adjustment
Priority 1 2 3 4 5 6
Adjustment Item
PF Timing Belt
tension check
Rear ASF
Timing Belt
tension check
PG adjustment
Checking the
platen gap
Touch Panel
adjustment
*
Ink leak check
Purpose
Check if the
tension of the PF
Timing Belt is
within the
standard.
Check if the
tension of the
Rear ASF
Timing Belt is
within the
standard.
Adjusts the PG
to within the
standard.
Check if the PG
is within the
standard.
Adjusts the
relative positions
between the
Touch Panel
detection points
and displayed
positions on the
Control Panel.
Check if ink is
leaking.
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Touch Panel
Remove --- --- --- --- O ---
Replace --- --- --- --- O ---
Panel Board
Remove --- --- --- --- --- ---
Replace --- --- --- --- --- ---
Sub Board
Remove --- --- --- --- --- ---
Replace --- --- --- --- --- ---
Main Board
Remove --- --- --- --- --- ---
Replace
(Read OK)
--- --- --- --- --- ---
Replace
(Read NG)
--- --- --- --- O ---
Carriage
Assy
Remove --- --- O --- --- ---
Replace --- --- O --- --- ---
Printhead
Remove --- --- --- O --- ---
Replace --- --- --- O --- O
Ink Supply
Unit
Remove --- --- --- --- --- ---
Replace --- --- --- --- --- O
Frame Base
Assy
Replace O O O O --- ---
EJ Roller
Remove O --- --- --- --- ---
Replace O --- --- --- --- ---
Main Frame
Remove --- --- O --- --- ---
Replace --- --- O --- --- ---
PF Motor
Remove O --- --- --- --- ---
Replace O --- --- --- --- ---
Front Frame
Assy
Remove --- --- --- --- --- ---
Replace --- --- O O --- O
Paper Guide
Front Assy
Remove O --- --- --- --- ---
Replace O --- O O --- O
PF Holder / PF
Timing Belt
Remove O --- --- --- --- ---
Replace O --- --- --- --- ---
How to judge
See 5.2.1 PF
Timing Belt
Tension Check
(p88) for the
details.
See 5.2.2 Rear
ASF Timing Belt
Tension Check
(p89)for the
details.
See 5.2.3 PG
Adjustment
(p90) for the
details.
See 5.2.4
Checking the
Platen Gap
(p96) for the
details.
See 5.2.6 Touch
Panel
Adjustment
(WP-4540 series
only) (p98) for
the details.
See 5.2.7 Ink
Leak Check
(p101) for the
details.
Adjustment program --- --- --- --- --- ---
Tool
Sonic tension
gauge
Sonic tension
gauge
Thickness gauge Thickness gauge Touch pen
Ink Leak
Measurement
Jig/Ink Leak
Check Cartridge
Confidential
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
EEPROM
data copy
Initialize
Setting (MAC
address
setting)
Maintenance
counter
Ink charge
Head ID
input
PF / EJ
adjustment
First dot position /
PW adjustment
Bi-D
adjustment
Head
angular
adjustment
PE adjustment
Paper skew
adjustment
PF / EJ
deterioration
offset
PW
deterioration
offset
PF band
adjustment
PE
adjustment
detection
check
CR motor
heat
protection
control
PF motor
heat
protection
control
ASF motor
heat
protection
control
Rear ASF
Front ASF
(1st cassette)
Rear ASF
(Top edge)
Rear ASF
(Rear edge)
Front ASF
(1st
Cassette)
Purpose
To copy
adjustment
values or the
like stored on
the old Main
Board to the
new board
when the
Main Board
needs to be
replaced.
To write sale-
destination-
specific
settings and
the serial
number into
the Main
Board after
replacing it.
To reset the
tube
durability
counter after
replacing the
Ink Supply
Unit.
To fill ink
throughout
the ink path
to make all
the nozzles
ready for
printing.
To correct
characteristic
variation of
the replaced
Printhead by
entering its
Printhead ID
(Head ID).
To correct
variations in
paper feed
accuracy to
achieve
higher print
quality.
To correct the print start
position in the carriage
moving direction through
software control.
To correct
print start
timing in
bidirectional
printing
through
software
control.
To correct tilt
of the
Printhead
caused at the
installation
through
software
control.
To correct the paper detection positions and
the mounting positions of the PE Sensor by
software control.
To align print
start position at
0-digit side with
that at 80-digit
side in bi-
directional band
printing, timing
of firing ink
droplet is
adjusted
through
software
control.
To reset the
counter or set
it to its
maximum
according to
the replaced
parts.
To reset the
counter
according to
the replaced
parts.
To correct
variations in
paper feed
accuracy to
achieve
higher print
quality in
band
printing.
To confirm
the chattering
ends within
the specified
time after the
PE Sensor
detects the
rear edge.
To measure
and correct
the electrical
variation of
the CR Motor
and the Power
Supply Board.
To measure
and correct
the electrical
variation of
the PF Motor
and the Power
Supply Board.
To measure
and correct
the electrical
variation of
the ASF
Motor and the
Power Supply
Board.
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LCD Module
Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Replace --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Touch Panel
Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Replace --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Panel Board
Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Replace --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Sub Board
Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Replace --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Main Board
Remove O --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Replace
(Read OK)
O --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Replace
(Read NG)
--- O O --- O O O O O O O O O O O O
*
O --- O O O
Power Supply Unit
Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Replace --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- O O O
Carriage Assy
Remove --- --- --- --- --- --- O O --- --- O O O --- --- --- O --- --- --- ---
Replace --- --- --- --- --- --- O O O O O O O O --- O O --- O --- ---
Printhead
Remove --- --- --- O --- --- --- --- O O --- --- --- O --- --- O --- --- --- ---
Replace --- --- --- O O O O O O O O O O O --- --- O --- O --- ---
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.
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
bars are the
smallest.
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.
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.
--- --- --- ---
Adjustment program O O O O O O O O O O O O O O O O O O
Tool --- --- --- --- --- --- 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.
OK NG G
OK
NG
NG
-2
-1
0
1
2
-2 -1 0 1 2
-2 -1 0 1 2
-2
-1
0
1
2
-2
-1
0
1
2
OK
NG
NG
NG OK
NG
OK
-8
-7
-6
-5
-4
-3
-2
-1
0
1
2
3
4
5
6
7
8
-8
-7
-6
-5
-4
-3
-2
-1
0
1
2
3
4
5
6
7
8
OK NG NG
OK
NG
NG
Confidential
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N
a
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Duplex Unit
Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Replace --- --- --- --- --- O O O --- --- O O O --- --- --- --- --- --- --- ---
CR Scale
Remove --- --- --- --- --- --- O O --- --- --- --- --- --- --- --- --- --- --- --- ---
Replace --- --- --- --- --- --- O O O --- --- --- --- O --- --- --- --- --- --- ---
Cassette Assy 1st
Remove --- --- --- --- --- --- --- O --- --- --- O O --- --- --- --- --- --- --- ---
Replace --- --- --- --- --- --- --- O --- --- --- O O --- --- --- --- --- --- --- ---
Frame Base Assy
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
Rear ASF Assy
Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Replace --- --- --- --- --- --- O --- --- --- O O --- --- --- --- --- --- --- --- ---
Ink Supply Unit
Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Replace --- --- O O --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
EJ Roller
Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Replace --- --- --- --- --- O O O --- --- O O O O O --- --- --- --- O ---
Main Frame
Remove --- --- --- --- --- --- O O --- --- O O O --- --- --- --- --- --- --- ---
Replace --- --- --- --- --- O O O O O O O O O --- --- --- --- O --- ---
Paper Guide Upper
Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Replace --- --- --- --- --- O --- --- O O --- --- --- O --- --- --- --- --- --- ---
Priority 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Adjustment Item
EEPROM
data copy
Initialize
Setting (MAC
address
setting)
Maintenance
counter
Ink charge
Head ID
input
PF / EJ
adjustment
PW adjustment
Bi-D
adjustment
Head
angular
adjustment
PE adjustment
Paper skew
adjustment
PF / EJ
deterioration
offset
PW
deterioration
offset
PF band
adjustment
PE
adjustment
detection
check
CR motor
heat
protection
control
PF motor
heat
protection
control
ASF motor
heat
protection
control
Rear ASF
Front ASF
(1st cassette)
Rear ASF
(Top edge)
Rear ASF
(Rear edge)
Front ASF
(1st
Cassette)
Purpose
To copy
adjustment
values or the
like stored on
the old Main
Board to the
new board
when the
Main Board
needs to be
replaced.
To write sale-
destination-
specific
settings and
the serial
number into
the Main
Board after
replacing it.
To reset the
tube
durability
counter after
replacing the
Ink Supply
Unit.
To fill ink
throughout
the ink path
to make all
the nozzles
ready for
printing.
To correct
characteristic
variation of
the replaced
Printhead by
entering its
Printhead ID
(Head ID).
To correct
variations in
paper feed
accuracy to
achieve
higher print
quality.
software control.
To correct
print start
timing in
bidirectional
printing
through
software
control.
To correct tilt
of the
Printhead
caused at the
installation
through
software
control.
software control.
To align print
start position at
0-digit side with
that at 80-digit
side in bi-
directional band
printing, timing
of firing ink
droplet is
adjusted
through
software
control.
To reset the
counter or set
it to its
maximum
according to
the replaced
parts.
To reset the
counter
according to
the replaced
parts.
To correct
variations in
paper feed
accuracy to
achieve
higher print
quality in
band
printing.
To confirm
the chattering
ends within
the specified
time after the
PE Sensor
detects the
rear edge.
To measure
and correct
the electrical
variation of
the CR Motor
and the Power
Supply Board.
To measure
and correct
the electrical
variation of
the PF Motor
and the Power
Supply Board.
To measure
and correct
the electrical
variation of
the ASF
Motor and the
Power Supply
Board.
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
for each side.
1st dot adjustment
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.
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
bars are the
smallest.
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.
--- --- --- ---
Tool --- --- --- --- --- --- Ruler --- --- Ruler --- --- --- --- --- --- --- ---
OK NG G
OK
NG
NG
-2
-1
0
1
2
-2 -1 0 1 2
-2 -1 0 1 2
-2
-1
0
1
2
-2
-1
0
1
2
OK
NG
NG
NG OK
NG
OK
-8
-7
-6
-5
-4
-3
-2
-1
0
1
2
3
4
5
6
7
8
-8
-7
-6
-5
-4
-3
-2
-1
0
1
2
3
4
5
6
7
8
OK NG NG
OK
NG
NG
Confidential
P
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N
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PE Sensor Holder Assy
Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Replace --- --- --- --- --- O --- --- --- --- O O O --- --- --- --- O --- --- ---
PE Sensor
Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Replace --- --- --- --- --- --- --- --- --- --- O O O --- --- --- --- O --- --- ---
CR Motor
Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Replace --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- O --- ---
PF Motor
Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Replace --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- O --- --- O ---
Front Frame Assy
Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Replace --- --- --- --- --- --- O O O O O O O O --- --- --- --- --- --- ---
Star Wheel Assy
Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Replace --- --- --- --- --- O --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Replace --- --- --- --- --- O --- --- O O --- --- --- O --- --- --- --- --- O ---
PF Holder / PF Timing
Belt
Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Replace --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- O ---
Priority 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Adjustment Item
EEPROM
data copy
Initialize
Setting (MAC
address
setting)
Maintenance
counter
Ink charge
Head ID
input
PF / EJ
adjustment
PW adjustment
Bi-D
adjustment
Head
angular
adjustment
PE adjustment
Paper skew
adjustment
PF / EJ
deterioration
offset
PW
deterioration
offset
PF band
adjustment
PE
adjustment
detection
check
CR motor
heat
protection
control
PF motor
heat
protection
control
ASF motor
heat
protection
control
Rear ASF
Front ASF
(1st cassette)
Rear ASF
(Top edge)
Rear ASF
(Rear edge)
Front ASF
(1st
Cassette)
Purpose
To copy
adjustment
values or the
like stored on
the old Main
Board to the
new board
when the
Main Board
needs to be
replaced.
To write sale-
destination-
specific
settings and
the serial
number into
the Main
Board after
replacing it.
To reset the
tube
durability
counter after
replacing the
Ink Supply
Unit.
To fill ink
throughout
the ink path
to make all
the nozzles
ready for
printing.
To correct
characteristic
variation of
the replaced
Printhead by
entering its
Printhead ID
(Head ID).
To correct
variations in
paper feed
accuracy to
achieve
higher print
quality.
software control.
To correct
print start
timing in
bidirectional
printing
through
software
control.
To correct tilt
of the
Printhead
caused at the
installation
through
software
control.
software control.
To align print
start position at
0-digit side with
that at 80-digit
side in bi-
directional band
printing, timing
of firing ink
droplet is
adjusted
through
software
control.
To reset the
counter or set
it to its
maximum
according to
the replaced
parts.
To reset the
counter
according to
the replaced
parts.
To correct
variations in
paper feed
accuracy to
achieve
higher print
quality in
band
printing.
To confirm
the chattering
ends within
the specified
time after the
PE Sensor
detects the
rear edge.
To measure
and correct
the electrical
variation of
the CR Motor
and the Power
Supply Board.
To measure
and correct
the electrical
variation of
the PF Motor
and the Power
Supply Board.
To measure
and correct
the electrical
variation of
the ASF
Motor and the
Power Supply
Board.
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
for each side.
1st dot adjustment
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.
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
bars are the
smallest.
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.
--- --- --- ---
Tool --- --- --- --- --- --- Ruler --- --- Ruler --- --- --- --- --- --- --- ---
OK NG G
OK
NG
NG
-2
-1
0
1
2
-2 -1 0 1 2
-2 -1 0 1 2
-2
-1
0
1
2
-2
-1
0
1
2
OK
NG
NG
NG OK
NG
OK
-8
-7
-6
-5
-4
-3
-2
-1
0
1
2
3
4
5
6
7
8
-8
-7
-6
-5
-4
-3
-2
-1
0
1
2
3
4
5
6
7
8
OK NG NG
OK
NG
NG
Confidential
Adjustment Details of Adjustments 88
5.2 Details of Adjustments
This section provides adjustment procedures for which explanation in details is necessary. See 5.1 Required
Adjustments (p83) for the adjustments not explained here.
5.2.1 PF Timing Belt Tension Check
This section describes PF Timing Belt tension check.
Tools
Sonic tension gauge
Plastic tweezers
Adjustment procedure
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 close to the 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
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
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.
PF Timing Belt
Left side
Measurement position EJ Pulley
Confidential
5.2.2 Rear ASF Timing Belt Tension Check
This section describes Rear ASF Timing Belt tension check.
Tools
Sonic tension gauge
Plastic tweezers
1. Set the following parameters to the sonic tension gauge:
Weight: 0.0013 kg/m
Width: 4 mm
Span: 73.4 mm
2. 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
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
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.
Rear ASF Timing Belt
Rear
Measurement position
PF Pulley
Left side
Confidential
5.2.3 PG Adjustment
This section describes the procedure for the platen gap (PG) adjustment.
Tools
Thickness gauge: 1.5 mm (x2), 1.7 mm (x2)
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.
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
Confidential
Check before the adjustment
Perform the following to check if the PG position is surely set to PG 1.
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 (p92)".
If PG position is not set to PG 1: Go to Step 3. (p 91).
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.
Figure 5-4. APG Lever
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.
7. Confirm the PG position is set to PG 1 (see Step 2. (p 91)), and go to "Adjustment procedure (p92)".
Carriage Assy
APG Cam
OK
NG
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.
OK
APG Lever
NG
Confidential
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 Frame Base so as to make the PG the widest.
Figure 5-7. Installing the PG Cam Left/PG Cam Right
Left side
Right side
C.B.P-TITE (P2) SCREW 3x10-F/ZN-3C (6 1kgfcm)
PG Cam Left
PG Cam Right
C.B. SCREW 3 x 6 F/ZN-3C (8 1kgfcm)
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.
Align + (notch for the widest PG) on the
PG Cam with the rib.
PG Cam Left
PG Cam Right
Confidential
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
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.
Confidential
6. Place the thickness gauges (1.7 mm) on the positions shown in Figure 5-9.
Figure 5-9. Position of the Thickness Gauge
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
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.
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.
Confidential
9. Follow the flowchart below to perform the PG adjustment.
Figure 5-11. PG Adjustment Flow
In the following steps, make sure the PG Cam Right/PG Cam Left always touch the CR Guide
Frame. (See Figure 5-8 (p 93).)
START
Move the Carriage Assy to
the 0-digit side.
Yes
No
the center of the printer.
the center, and adjust one
notch for PG Cam Right to
make the PG wider.
Yes
No
Yes
No
Yes
No
Remove the PG Cam Right/
Left once, and attach them
back on the same positions
as shown in Step 1. (p 92).
Return to Step 7.
(p 94) 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.
the 80-digit side.
the 0-digit side.
Change the thickness gauges
(x2) to 1.7 mm ones.
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
Confirms the PG is more than
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 92).)
notch for PG Cam Left to
make the PG wider.
notch for PG Cam Right to
make the PG wider.
Confidential
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.
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 (p91).)
3. Place the thickness gauges (1.5 mm) on the positions shown in Figure 5-9 (p 94).
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 (p90).
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 (p90).
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.
Confidential
5.2.5 MAC Address Setting
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 printers 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
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 printers 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
MAC Address Label
Last six digits of MAC address
Confidential
5.2.6 Touch Panel Adjustment (WP-4540 series only)
This section describes Touch Panel adjustment.
Purpose
This adjustment is made to adjust the relative positions between the Touch Panel detection points and
displaying positions on the Control Panel.
Tools
Touch pen (without a sharp end such as a plastic stick)
1. Press and keep pressing the Copy, , and Stop buttons, then press the Power button to start WP-4540 series
in the inspection mode.
Figure 5-14. Touch Panel Adjustment (1)
2. Select Touch Screen Inspection and press the Color button.
While in the inspection mode, you can operate selection of each menu, etc. by pressing the
following buttons.
Figure 5-15. Panel Operation in Special Inspection Mode
(2) Press this button.
(1) Keep pressing these buttons.
Power: Quit the Inspection mode / Power off
1: Menu forward
2: Menu backward
Color: OK/Menu selection
Stop: Back
Inspection Mode
Run:Color / Select:[UP:1][DOWN:2]
1. Mechanism Inspection
2. Special Inspection
3. Fax Inspection
3. Touch Screen Inspection
Confidential
3. Select Touch Screen Calibration and press the Color button.
4. Press LCD to display the adjustment screen. When aborting the adjustment, press the Stop button.
5. Press + displayed on the four corners in order using the touch pen.
Touch Screen Inspection
Run:Color / Select:[UP:1][DOWN:2]
1. Touch Screen Calibration
2. Touch Screen Coordinates
Touch panel to coordinate them.
Push [Color] Button.[OK]
Push [Stop] Button.[Cancel]
+ << Please Touch
Confidential
6. If you retry the adjustment, press the Stop button and start from Step 5 once again. When saving the result of
adjustment, press the Color button.
7. When the confirmation pattern appears, press + displayed in the middle of the panel.
8. When Complete! appears on LCD, press the Color button to return to the menu, and press the Color
button to complete the adjustment.
If Retry Check is displayed, press Color button and start from Step 5 once again.
Calibration Check
Push [Color] Button.[Save]
Push [Stop] Button.[Retry]
Press the [Stop] button to retry.
+
Complete!
Push [Color] Button
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5.2.7 Ink Leak Check
This section describes the procedure for ink leak check necessary when disconnecting the Ink Supply Unit from
the Printhead or in a similar case.
Tools
Ink Leak Measurement Jig (with digital pressure gauge GC66) (Parts code: TBD)
Battery type: CR2016 (3 V) x1
Figure 5-23. Ink Leak Measurement Jig
Ink Leak Check Cartridge (Parts code: TBD)
Figure 5-24. 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 (p102)" 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 (p72).)
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
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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 5-25. 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.
Connect tube while pressing here.
Tube of Ink Leak Check Cartridge
Pull the plunger up to the 20 mark.
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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.
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 (p72).)
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.
Valve C
Valve A
Valve B
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CHAPTER 6
MAINTENANCE
Confidential
Maintenance Overview 105
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.
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 (p106)" for the repairing
procedures below, and apply the specified type and amount of the grease to the specified part of the printer
mechanism.
Grease
Tools
Note *: Use tools whose specifications are specified in "6.2 Lubrication Points and Instructions (p106)".
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.
Type Name EPSON Part Code Supplier
Grease G-71 1304682 EPSON
Grease G-74 1409257 EPSON
Name Availability EPSON Part Code
Injector O * ---
Brush O * ---
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 (p106)" and "6-4 Lubrication of
the CR Guide Frame (p106)" of "6.2 Lubrication Points and Instructions (p106)". Therefore,
make sure to lubricate the Printer Mechanism (Frame Base Assy) on the specified points
when replacing it.
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Maintenance Lubrication Points and Instructions 106
6.2 Lubrication Points and Instructions
Figure 6-1. Lubrication of the Cassette Assy 1st / 2nd Figure 6-2. Lubrication of the Driven Pulley Assy
<Lubrication Point>
Edges on the rear of the
Cassette Assy 1st / 2nd
<Type>
G-74
<Application Amount>
Appropriate amount
<Remarks>
Apply with brush.
Cassette Assy
Application point
<Lubrication Point>
Shaft hole of the Driven
Pulley
<Type>
G-71
1 mm x 1 mm
<Remarks>
Apply with injector.
Driven Pulley
Application point
Figure 6-3. Lubrication of the Main Frame
<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.
Main Frame
Main Frame
7.5 mm
Application point
Figure 6-4. Lubrication of the CR Guide Frame
<Lubrication Point>
Contact points (x3) on the
CR Guide Frame with the
Carriage Assy
<Type>
G-71
1. 2 mm x 420.7 mm
2. 2 mm x 420.7 mm
3. 2 mm x 420.7 mm
<Remarks>
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.
Carriage Assy
CR Guide Frame 15 mm
3.5
mm
3 mm
CR Guide Frame
1
2
3
Application point
Figure 6-5. Lubrication of the EJ Roller
<Lubrication Point>
1. Contact points (x2) on
the EJ Roller with the
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
1, 2. Appropriate amount
3. 2 mm x appropriate amount
4. 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.
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
Application point 2
After installing EJ Roller
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Maintenance Lubrication Points and Instructions 107
Figure 6-6. Lubrication of the Carriage Assy
<Lubrication Point>
1. Contact surfaces (x2)
of the Carriage Assy
with the APG Cam
the APG Cam with the
APG slider
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
the CR Front Slider
Left/Right with the CR
Guide Frame
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. 1 mm x 0.05 g
6. 0.05 g
7. 0.05 g
<Remarks>
Apply with injector.
For 1, 2, 3, 4, 6 and 7,
spread grease with
brush as shown in the
figure after application
with injector.
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

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SERVICE MANUAL

Operating Principles Power-On Sequence 34

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