SEIJ04008
3
CHAPTER
TROUBLESHOOTING
EPSON Stylus Pro 4800/4400 Revision A
3.1 Outline 9. As necessary, initialize the NVRAM on the C593 MAIN Board (return the
individual settings and panel settings to the factory settings).
This section explains procedures for rapid and efficient troubleshooting if Carry out initialization by executing "Panel Initialization" in "Maintenance
trouble occurs in the printer. Mode 1".
3.1.1 Check Before Troubleshooting W A R N IN G Be sure to refer to "4.1.1 Cautions" (p.196) for the detailed
description when handling a lithium battery that is installed
First of all, when performing troubleshooting, the following basic parts should for RTC backup on the MAIN Board.
be checked.
1. Look in the printer for any foreign matter and make sure there is nothing
there to hinder normal operation. C A U T IO N When disassembling/assembling, turn the printer power
switch OFF. After confirming that panel display
2. With the printer in "READY" condition, press the [Menu] key one time, and
disappears, unplug the power cable from the electric
then press the [Paper Feed (∧ / ∨)] keys to select "TEST PRINT". Press the
outlet and then continue operations.
[Menu] key again one time, press the [Paper Feed (∧ / ∨)] keys to select
"STATUS CHECK". After these have been selected, press the [Menu] key Only the specified printer tools should be used so as to
two times to print. maintain the printer's quality.
From the status sheet, you can check to see if the cause of the trouble is Only the specified lubricants and adhesives should be
that the printer (either the printer unit itself or some major unit) is at the end used.
of its service life, and check the user inherent panel settings, etc. The specified adjustments should definitely be carried
(Refer to "Step 9" when in properties panel settings.) out.
3. There should be no market soiling of the outside or the inside of the printer.
If it is extremely soiled, carry out cleaning. 3.1.2 Narrow Down the Trouble
4. Each of the units and parts in the printer should not be missing or To increase the troubleshooting efficiency, follow the flow chart below and
damaged, and should have the normal shape and configuration. narrow down the trouble.
5. Each of the harnesses should be undamaged, and should be correctly
connected to the relevant connector (perpendicularly and in the correct Trouble Occurs
direction).
6. Each cam and gear in the printer mechanism should have no uneven wear
or be overly worn, and the combinations should be correct.
"Troubleshooting Based on Panel "Troubleshooting Based on Your Printout
7. Each type of rubber roller in the printer mechanism should be cleaned and
Messages (p.153)" (p.191)"
it should be ascertained whether the cause of the trouble is because of dirt
or due to some other cause.
8. Each type of rubber roller in the printer mechanism should not be unevenly
worn or excessively worn, and their combinations should be correct. "Corrective Actions for "Corrective Actions for "Corrective Actions for
Displayed Warnings Error Display (p.160)" Service Request Display
(p.157)" (p.170)"
Table 3-2. Service request error list(continued) Table 3-2. Service request error list(continued)
Reference Reference
Error Code Description Error Code Description
Page Page
00000101 CR Motor life p.170 00010032 ASF drive switch error p.184
00010000 PF Motor Encoder check error p.172 00010033 Eject phase detection error p.185
00010001 PF Motor out of step p.173 00010034 Eject movement error p.185
00010002 PF Motor over current p.173 00010035 Pump phase detection error p.185
00010003 PF Motor in-position time-out p.174 00010036 Type-B board installation error p.185
00010004 CR Motor Encoder check error p.174 00010037 Head thermistor error p.185
00010005 CR Motor out of step p.175 00010038 Transistor thermistor error p.185
00010006 CR Motor over current p.175 00010039 PG adjustment value incorrect overwrite error p.186
00010007 CR Motor in-position time-out p.176 0001003A PG adjustment value outside range error p.186
00010008 Servo interrupt watchdog time-out p.176 0001003B Cutter installation error 1 p.186
00010009 System interrupt watchdog time-out p.176 0001003C Cutter installation error 2 p.186
0001000A CR axis detection error p.177 0001003D Cutter installation error 3 p.186
0001000C PG axis detection error p.177 00020000 NVRAM error p.187
0001000F CR Motor PWM output faulty p.178 00020002 SDRAM error p.187
00010010 PF Motor PWM output faulty p.178 00020003 BOOT program SUM error p.187
00010012 CR overload (high sensitivity) error p.179 00020009 Flash memory SUM error p.187
00010013 PR overload (high sensitivity) error p.179 0002000A Program load error p.188
0001001B Head driver (TG) temperature error p.180 0002000B Internal memory shortage error p.188
0001001D CR servo parameter error p.180 100000E0 CPU address error (load misalignment) p.188
0001001E PF servo parameter error p.181 10000100 CPU address error (storage misalignment) p.188
00010020 CSIC reed/right error p.181 10000180 CPU reserve command code exception error p.189
00010022 Ink type error (setting on printer body side) p.181 100001A0 CPU slot illegal command exception error p.189
00010023 RTC analysis error p.182 100001C0 AC disruption p.189
00010025 CSIC ROM communication error p.182 100005C0 CPU DMA address error p.189
00010026 RTC communication error p.183 10000xxx CPU error p.190
00010028 Head error p.183 0003xxxx Debug error code p.190
00010029 Unidentified NMI p.183 0Dxxxxxx Debug error code p.190
0001002A CR ASIC ECU error p.183 0Exxxxxx RTC timer off error p.190
0001002B PF ASIC ECU error p.183
0001002D Cleaning Unit work life error p.184
0001002F 360 DPI writing time out error p.184
00010030 Multi Sensor failure p.184
00010031 ASF phase detection error p.184
Explanation
Generated when the life of maintenance- required part expires shortly or
an error related to a lithium battery for RTC backup has occurred.
Recovery
Remedy
nnnn Cause Replacement part/unit
(how to recover errors)
The number of CR movement cycles has Refer to "SERVICE REQ. 00000101 (p.170)." Refer to "SERVICE REQ. 00000101 (p.170)."
0002
reached predetermined value.
RTC backup battery shut off / uninstalled RTC backup battery Replace RTC backup battery, turn on the printer in Maintenance Mode 2, and execute
0008
"RTC&USB ID&IEEE1394 ID" to set the date using basic adjustment in adjustment program.
Pump counter has reached predetermined Box Assy., Flushing Replace parts/ units listed in the left column, and execute “Reset When Cleaning Unit Change”
amount. Pump Unit using Reset Counters in adjustment program.
Cleaner, Head, A, ASP
0040
Cleaner, Head, B, ASP
Porous Pad, Box, FL, Upper
Porous Pad, Box, FL, Lower
Date is not set Turn on the printer in Maintenance Mode 2, and execute “RTC&USB ID&IEEE1394 ID” to set
0080 ---
the date using basic adjustment in adjustment program.
RTC backup battery is not installed. Install RTC battery, turn on the printer in Maintenance Mode 2, and execute “RTC&USB
0088 ---
ID&IEEE1394 ID” to set the date using basic adjustment in adjustment program.
RTC backup battery pressure is temporally Wait for a while.
0100 ---
low.
The number of ASF paper feeding has Roller Assy, LD, Right Replace parts/ units listed in the left column, and execute “Reset ASF Counter” and “Reset
0200 reached predetermined value. Roller Assy, LD, Left Paper ejection switching / PG switching counter” using Reset Counters in adjustment program.
Mount Assy., Plate, Motor, ASF, SP
C H E C K Replace the following parts when replacing the Cleaning CONVERSION CARTRIDGE LIFE NEAR END
P O IN T Unit.
Item Description
CLEANER, HEAD, B, ASP LCD Panel message TIMES REMAINING
CLEANER, HEAD, A, ASP Ink check LED: On
POROUS PAD, BOX, FL, UPPER LED display
Pause LED: On
Explanation The number of usable time of the conversion cartridge is
less than ten.
Recovery Press the [Pause] key.
POROUS PAD,
BOX, FL, LOWER
BOX ASSY.,
FLUSHING
Item Description
LCD Panel message PAPER LOW
LED display Paper check LED: Blink
Explanation Occurs when the current remaining paper counter value is
less than the near end setting value while the remaining
paper detection is on with roll paper or cut paper loaded.
Execute one of the following:
• Set the near end setting value so that it is more than the
current remaining paper counter value, using roll or cut
Recovery paper menu of the remaining paper detection in the
printer setting menu.See "Remaining paper detection
(p.46)"
• Reload paper.
CLEANING FAILURE
CLEANING UNAVAILABLE
COMMAND ERROR
WRONG ROLL PAPER PATH / WRONG ASF PAPER PATH / WRONG MANUAL PAPER PATH
ASF PROHIBITIONS
WRONG MK / PK
INK END
WRONG DESTINATION
NO INK CARTRIDGE
PAPER JAM(ASF)
PAPER JAM(CR)
NO MAINTENANCE TANK
FATAL ERROR
The printer has failed. Because this cannot be recovered by the user, resolve by following "3.2.4 Corrective Actions for Service Request Display" (p.170).
Ink leakage through cracks in Ink Tube. Ο : Replacement required/ ∆ : Check the part/ Χ : No arrangement requried
Poor movement of Carriage Unit due to CR Motor internal wear.
Remedy
1. Check for dirt, paper dust or damage to the Loop Scale.
2. Perform the PF Timing Belt Tension Adjustment (p.372)
3. Replace the PF Encoder Sensor (p.352)
4. Replace the Motor Assy., PF (p.344)
5. Replace the C593 MAIN Board (p.221)
Cause of trouble
Defective circuit board.
Defective SDRAM.
Defective Flash memory.
Faulty ASIC soldering.
Faulty CPU soldering.
Program trouble
Generation error.
Remedy
1. Installing Firmware (p.436)
2. Replace the C593 MAIN Board (p.221)
3.3 Troubleshooting Based on Your Printout C H E C K In Initial Ink Charge, a large amount of ink will be
P O IN T discharged into the Maintenance Tank. Therefore, check
This section describes conceivable print quality problems that may occur with the counter indication (remaining value) beforehand. (If
this printer and the troubleshooting points for those errors. deemed necessary, prepare another Maintenance Tank
as a spare.)
Table 3-4. Diagnosing trouble based on printout Check the amount of ink remaining before starting Initial
Item Description Reference Page Ink Charge. If the remaining ink is less than 50%, replace
1 Dot missing p.191
the ink cartridge with a new one and then start the
procedure.
2 Uneven printing/poor resolution p.192
3 Smudged or marred printout on front side p.192 If the power cleaning does not recover the printer, check the following
points.
4 Smudged or marred print out on reverse side p.193
5 White/black banding p.193 If trouble occurs in all the ink colors.
6 Banding p.194 •
Are the Print Head and Cap Unit sealed during Ink Charge?
•
If the Cap Unit / Pump Tubes have come off.
DOT MISSING •
If the life of the Cleaning Unit has expired.
•
If the Cap Unit has failed.
Auto cleaning is performed by dot missing inspection of the Multi Sensor, but (The cap rubber is damaged, etc.)
dot missing can be generated by increased congealing of ink on Print Head • If the Pump Unit has failed.
nozzle surfaces or in nozzles due to drying when dot missing inspection is OFF (The tubes are crushed, etc.)
or printer has not been used for a long period. Check the following particulars. • If the Printhead has failed.
Execute head cleaning or initial ink charge. • If the fuse on the Main Board has blew.
• Head FFC contact failure.
1. Execute head cleaning or initial ink charge by one of the following
methods.
If the trouble occurs with a specific ink color.
• Head Cleaner is dirty.
Cleaning Execution Method • Abnormal connections between the Ink Cartridge, Ink Holder, Tube,
Cleaning Maintenance Mode 1: SSCL Damper, Print Head.
Adjustment Program: CL3
(Fastening nuts loose, or the O-ring deformed or damaged, causing
ink to leak, etc. could occur.)
Power cleaning Panel Setting menu/Maintenance Menu: Power
• Print Head failure
Cleaning
• Execute power cleaning again.
Adjustment Program: CL4
Initial ink charge Adjustment Program: Initial Ink Charge If the trouble still occur even after checking the items listed above, replace
the following parts and check again.
2. Nozzle Check Pattern Printing (p.56) • Printhead (p.280)
Execute Nozzle Check Pattern Printing in the Panel Setting menu. • C593 MAIN Board (p.221)
("Panel Setting" → "TEST PRINT" → "NOZZLE CHECK")
If the print quality is abnormal (uneven printing, diffused image, etc.), the If smudging or marring occurs due to rubbing by the head, etc. on the paper's
following items should be checked. printed surface, check the following items.
1. Perform the adjustment below with Adjustment Program. 1. If smudging is occurring at the front end of the roll paper or at the rear end,
1. Nozzle Bi-D Adjustment (p.387) widen the margins at the front end and rear end. (Set the "PAPER
MARGIN" front end and rear end on "15mm".)
2. Auto Bi-d Adjustment (p.423)
(If high duty printing was done close to the front end and rear end (margin
3. Auto Uni-d Adjustment (p.394)
= 3mm), the paper will contain a large amount of ink and deformation of the
4. Check Platen Gap (p.403) paper will be accelerated, and depending on the case, the paper will touch
Execute Nozzle Check (p.428) and Alignment Check (p.429) above the head.)
adjustment. If print quality is still abnormal, go to next step. 2. If paper with weak edges which cannot move smoothly along the paper
2. If the trouble occurs only when the user is using a specific type of paper path is being used, Select "-4" for "SUCTION" in the "CUSTOM PAPER",
(thick paper), carry out "User Paper Setting" using the panel setting which is in the "Panel Setting".
procedure. (By setting the information concerning the thickness of the 3. If there is rubbing and smudging due to slow drying in printing of user
paper the user is using and correcting the print position (correction of paper.
changes in the position where ink hits the paper surface due to differences In the item "DRYING TIME" in the "CUSTOM PAPER", in "Panel Setting"
in paper thickness), avoid influencing the print position.) set the drying time (the time until auto paper cutting is carried out after
3. If this problem occurs after replacing the C593 Main Board with a new one: printing is finished. (Default: 0 second; Maximum: 10 seconds)
Transfer the parameters on the old Main Board to the new board. 4. If the trouble cannot be resolved by the above methods, check the
(p.402) following.
4. If the printer's condition is not improved by the above items (adjustments), Pump Unit failure
replace the following parts. Check to see if dust containing ink, foreign matters or paper is
Printhead (p.280) adhering to the side surface of the head.
Printer Mechanism (SP) (p.237) 5. Extend platen gap.
NOTE: Be careful to decreasing image quality, if the platen gap is
extended.
SMUDGED OR MARRED PRINTOUT (REVERSE SIDE) WHITE OR BLACK BANDING IN THE CARRIAGE RUNNING DIRECTION
If smudging or marring of the paper back surface with ink occurs, the following If white or black banding (uneven density) in parallel with the Carriage Unit
items should be checked. running direction appears on your printout, check the following points:
1. Check if the paper is bent or curled, and replace the paper with new one if 1. Nozzle Check Pattern Printing (p.56)
abnormal. Execute Nozzle Check Pattern printing in the panel setting menu. If dot
missing is found, perform the head cleaning or initial ink charge by
2. Check to see if there isn't ink adhering to the paper feed path. If there is ink
following method
adhering, it should be wiped off.
PF Roller surface "Cleaning" (p.405) of adjustment program.
Front Eject Paper Guide surface
"Power Cleaning" (p.75) in Panel Setting Mode.
Rear Paper Guide surface (including switching ribs)
"Initial Ink Charge" (p.405) of adjustment program.
Paper Eject Roller surface 2. Adjustment
If dot missing is not found, perform the following adjustment and check for
improvement.
C A U T IO N If the user's paper size setting is not correct when "PPR SIZE
CHK" / "PPR ALIGN CHK" of panel setting menu has been Check Alignment (p.429)
set to OFF, then printing will be done onto platen surface. If it has trouble, execute "Power Cleaning" (p.75) or "Initial Ink
Charge" (p.405).
1000mm Feed Adjustment (p.400)
3. Check if ink absorbing sponge for borderless printing, and correct if it is
abnormal.
Deformation
Embossment (installation failure)
Accumulation of ink
If banding (uneven density, rough image) in parallel with the paper feed
direction is found on the print, perform the following adjustment:
Bi-D adjustment
The Bi-D adjustment can be executed by any of the following methods.
"HEAD ALIGNMENT" in the Panel setting menu
Printer Driver
Adjustment Program
If the adjustment above does not work to improve the print quality, you may
improve it by adjusting the "THICKNESS NUM" setting value (± 0.1 ~ 0.2mm)
in "CUSTOM PAPER" of the panel setting menu.