EPSON 4900 Field Repair Guide

Pro 4900 Field Repair Guide 8/23/11
Table Of Contents
Table Of Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
Control Panel Map - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7
Component Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - 15
Board (AID) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16
Board (Carriage) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19
Board (Ethernet) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - 23
Board (Ethernet) Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - 30
Board (Main) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 38
Board (Main) Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 45
Board (Power Supply) Removal - - - - - - - - - - - - - - - - - - - - - - - - - 53
Board (Sub-B) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 63
Board (Sub C) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 66
Board (Sub-D) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 68
Cap (Parking) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 72
Cleaning Assembly Removal - - - - - - - - - - - - - - - - - - - - - - - - - - 78
Control Panel Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 92
Cover (Carriage) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - 96
Cover (Cutter Assembly) Removal - - - - - - - - - - - - - - - - - - - - - - - 97
Cover (Left Side) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - 100
Cover (Paper Tray Cavity) Removal - - - - - - - - - - - - - - - - - - - - - - - 102
Cover (Rear) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 110
Cover (Right Side) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - 113
Cover (SpectroProofer Cavity) Removal - - - - - - - - - - - - - - - - - - - - - 117
Cover (Top Right) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - 123
Printer Component, Software Item, LCD Display, Printer Button Page 1.

Ink Bay (Left) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 125

Cutter Assembly Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - 135
Ink Bay (Right) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 138
Maintenance Tank Holder Removal - - - - - - - - - - - - - - - - - - - - - - - 146
Motor (Eject Roller Rotation) Removal - - - - - - - - - - - - - - - - - - - - - 149
Pressure Pump Assembly Removal - - - - - - - - - - - - - - - - - - - - - - - 152
Print Head Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 157
Print Head Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 167
Roller (Pickup) Assembly Removal - - - - - - - - - - - - - - - - - - - - - - - 176
Roller (Pickup) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 180
Selector (Damper) Assembly Removal - - - - - - - - - - - - - - - - - - - - - 184
Sensor (Borderless Waste Ink Tank) Removal - - - - - - - - - - - - - - - - - 196
Sensor (Exit Roller HP) Removal - - - - - - - - - - - - - - - - - - - - - - - - 197
Sensor (Paper Tamper HP) Removal - - - - - - - - - - - - - - - - - - - - - - 206
Sensor (Platen Gap) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - 210
Spindle Assembly Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - 214
Wiper Blade Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 215
Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 219
Printer Error Codes (Maintenance) - - - - - - - - - - - - - - - - - - - - - - - 220
Printer Error Codes (Service) - - - - - - - - - - - - - - - - - - - - - - - - - - 221
Printer Error Codes (SpectroProofer) - - - - - - - - - - - - - - - - - - - - - - 246
AID Function Check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 248
CR Encoder and Scale Check - - - - - - - - - - - - - - - - - - - - - - - - - - 252
Fan Noise Fix - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 256
Ink Mark Sensor Check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 261
Missing Nozzle Diagnosis - - - - - - - - - - - - - - - - - - - - - - - - - - - - 266

PF Encoder and Scale Check - - - - - - - - - - - - - - - - - - - - - - - - - - 269

Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 273
Active Damper Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - 274
APG Motor Counter (Clear) - - - - - - - - - - - - - - - - - - - - - - - - - - - 278
Auto Bi-D Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 283
CR Belt Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 288
CR Motor Counter (Clear) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 290
CR Slant Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 295
CR Speed Auto Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - 302
Cutter Belt Tension Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - 306
Head Cap Counter (Clear) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 308
Head ID Input Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - 313
Initial Ink Charge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 319
Ink Eject and Initial Charge - - - - - - - - - - - - - - - - - - - - - - - - - - - 324
Ink Holder Full Side [L] Counter (Clear) - - - - - - - - - - - - - - - - - - - - - 327
Ink Holder Home Side [R] Counter (Clear) - - - - - - - - - - - - - - - - - - - - 332
Ink Mark Sensor Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - 337
Ink Selector Assy Counter (Clear) - - - - - - - - - - - - - - - - - - - - - - - - 342
IS Unit Counter (Clear) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 347
MAC Address Check & Input - - - - - - - - - - - - - - - - - - - - - - - - - - 352
Media Eject Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 359
Media Feed Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 366
Motor Measurement Adjustment - - - - - - - - - - - - - - - - - - - - - - - - 373
NV-RAM BACKUP UTILITY - - - - - - - - - - - - - - - - - - - - - - - - - - - 377
Paper Thickness Sensor Adjustment - - - - - - - - - - - - - - - - - - - - - - 378
PF Belt Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 381

PF Motor Counter (Clear) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 383

PF Slant Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 388
Printhead Counter (Clear) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 395
PW + T&B&S Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - 400
Rear AD Sensor Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - 409
Roll Feeding Motor Counter (Clear) - - - - - - - - - - - - - - - - - - - - - - - 410
RTC & USB ID Check and Adjustment - - - - - - - - - - - - - - - - - - - - - - 415
Serial Number Check & Input - - - - - - - - - - - - - - - - - - - - - - - - - - 419
Tubes Cleaning (Flushing) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 423
Wiper Counter [For Exchange] (Clear) - - - - - - - - - - - - - - - - - - - - - - 426
Component Pictures - - - - - - - - - - - - - - - - - - - - - - - - - - - 431
Board (AID) Picture - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 432
Board (Carriage) Picture - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 433
Board (Ethernet) Picture - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 434
Board (Main) Picture - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 435
Board (Sub-B) Picture - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 436
Board (Sub-C) Picture - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 437
Board (Sub-D) Picture - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 438
Cap Parking Picture - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 439
Cleaning Assembly Picture - - - - - - - - - - - - - - - - - - - - - - - - - - - 440
Cutter Assembly Picture - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 442
Ink Bay (Right) Pictures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 443
Ink Bay (Right) Pictures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 445
Motor (Exit Roller Rotation) Picture - - - - - - - - - - - - - - - - - - - - - - - 447
Pressure Pump Assembly Picture - - - - - - - - - - - - - - - - - - - - - - - - 448
Print Head Pictures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 449

Roller (Pickup) Assembly Pictures - - - - - - - - - - - - - - - - - - - - - - - 452

Damper (Selector) Assembly Pictures - - - - - - - - - - - - - - - - - - - - - - 456
Sensor (Borderless Waste Ink Tank) Picture - - - - - - - - - - - - - - - - - - 460
Sensor (Paper Tamper HP) Picture - - - - - - - - - - - - - - - - - - - - - - - 461
Sensor (Exit Roller HP) Picture - - - - - - - - - - - - - - - - - - - - - - - - - 462
Sensor (Platen Gap) Picture - - - - - - - - - - - - - - - - - - - - - - - - - - - 463
Spindle Assembly Picture - - - - - - - - - - - - - - - - - - - - - - - - - - - - 464
Wiper Blade Picture - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 465
Reference - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 466
Carriage Release (Auto) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 467
Carriage Release (Manual) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 468
Color Order - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 473
Connectors / Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 475
Consumable/Service Parts List - - - - - - - - - - - - - - - - - - - - - - - - - 481
Firmware History (Ethernet) - - - - - - - - - - - - - - - - - - - - - - - - - - - 483
Firmware History (Printer) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 484
Firmware Update Procedure Using FWUpdate.exe - - - - - - - - - - - - - - - 486
Flushing (Ink System) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 487
Glossary - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 488
Initial Ink Charge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 494
Revision History - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 495
Sensors, Motors, and Fans - - - - - - - - - - - - - - - - - - - - - - - - - - - 498
Service Procedure (recommended) - - - - - - - - - - - - - - - - - - - - - - - 504
Service Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 506
Stress Test (Test Image) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 507
Utilities - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 508

Epson Net Config 2.2b - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 509

FWUpdate.exe - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 514
NV-RAM BACKUP UTILITY - - - - - - - - - - - - - - - - - - - - - - - - - - - 518
Servprog.exe - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 529

Control Panel Map

Paper Check Light Ink Check Light
Power Light
Pause Light
Power Button
Pause and Reset
Paper Feed Paper Release

(Reverse) and Up
Arrow
Paper Source
and Left Arrow Menu and Right Arrow
Nozzle Check, OK (Enter)

Cleaning and Black
Ink Change Menu Paper Cut
Paper Feed (Forward) and Down Arrow

Ink Menu: (Press the Cleaning Button to access)

Cancel:
Auto Cleaning: Clean the head automatically if nozzle clog detected?:
Yes
No
Manual Cleaning:
C/VM: Execute
Execute Powerful
PK (MK) / LK: Execute
Execute Powerful
O/G: Execute
Execute Powerful
LLK/Y: Execute,
Execute Powerful
VLM/LC: Execute,
Execute Powerful
All Colors: This cleaning takes about 10 minutes. Continue? (Yes or No)
All Colors (Powerful): This cleaning takes about 10 minutes. Continue? (Yes or No)
Nozzle Check:
Auto Nozzle Check
Print Check Pattern
Change Black Ink:
Photo Blk to Matte Blk
Matte Blk to Photo BLK

1. Printer Status
2. Platen Gap Setting
3. Paper Source and Roll Paper Auto Cut Setting
4. SpectroProofer Status
5. Ink Levels
6. Black Ink Setting
7. Waste Ink Cartridge Level(s)
8. Roll Paper Counter
9. Roll Paper Margin Setting
SELF TESTING: Down, Right, and OK, at power on

NVRAM (Parameter) Backup Mode: Up, Down, Left, and Right, at power on.
NVRAM (Parameter) Restore Mode: (Disengage 11 Ink Cartridges, remove 1 Maintenance Tank and the Border-
less Waste Ink Tank, hold the Up, Down, Left, and Right buttons and turn on the Printer Wait an
additional 20 seconds after the data is transferred to ensure completion.
F/W DOWNLOAD MODE: Up, Down, Left, and Right, at power on.
Maintenance Mode 1: Pause, at power on.

User Menu: Press the Menu button when

the printer displays Ready
1. PRINTER SETUP. 3. MAINTENANCE
PLATEN GAP: NARROW, *STANDARD, WIDE,
CUTTER ADJUSTMENT: -120mil - 0mil - +120mil
WIDER, WIDEST
CLOCK SETTING: (mm/dd/yy hh:mm)
PAGE LINE: *ON, OFF
ROLL PAPER MARGIN: *DEFAULT, TOP/BOTTOM
15mm, TOP 35/BOTTOM 15mm,
3mm,15mm 4. PRINTER STATUS.
PAPER SIZE CHK: *ON, OFF VERSION: (CURRENT FIRMWARE)
PAPER SKEW CHECK: *ON, OFF INK LEVEL: (FOR EACH COLOR) (E**********F)
REFRESH MARGIN: *ON, OFF MAINTENANCE TANK: 1 (E**********F),
AUTO NOZZLE CHECK: ON:PERIODICALLY*, 2 (E**********F)
ON:EVERY JOB, OFF JOB HISTORY: No.(0-9) INK:(n)ml,
PRINT NOZZLE PATTERN: OFF*, On:Every Page, PAPER:(n)cm2
On:Every 10 Pages TOTAL PRINTS: (n) PAGES
Change Black Ink: *Manual, Auto myEpsonPrinter STATUS: *Disabled,
Auto Roll Feeding: *On, Off Enabled, Last Uploaded (mm/dd/yy hh:mm)
INITIALIZE SETTINGS: EXECUTE
2. TEST PRINT.
STATUS SHEET: PRINT
NETWORK STATUS SHEET: PRINT
JOB INFORMATION: PRINT
CUSTOM PAPER: PRINT
5. PAPER SETUP.
6. Head Alignment.
Roll Paper Remaining:
Remaining Paper Setup: Off, *On(This Menu item is Paper Thickness: Paper Type: (Photo Paper,
only active when paper is not loaded and the Proofing Paper, Fine Art Paper, Matte Paper,
Pinch Rollers are closed) Plain Paper)
Roll Paper Length: (nnn)ft Select Thickness: (N)mil
Roll Length Alert: (nn)ft Alignment: Auto, Uni-D, Bi-D 5-Color, Bi-D All
PAPER TYPE: Photo Paper: (Select the Type) Manual, Uni-D, Bi-D 2-Color,
Proofing Paper: (Select the Type) Bi-D All
Fine Art Paper: (Select the Type)
Matte Paper: (Select the Type)
Plain Paper: 7. Network Setup: (*Hide, Show)
Custom Paper: (Select 1 - 10) IP Address Setting: *Auto, Panel,
No Paper Selected: Bonjour: *On, Off
CUSTOM PAPER (Paper No. 1 - 10): WSD: *Off, On
Paper Type: Init Network Setting: Execute
Photo Paper: (Select the Type)
Note: Manual Ip169.254.1.2 Subnet
Proofing Paper: (Select the Type)
255.255.0.0 Works With Most
Fine Art Paper: (Select the Type)
Computers.
Matte Paper: (Select the Type)
Plain Paper:
8. Spectroproofer: Status Information:
Platen Gap: Narrow, *Standard, Wide, Wider
Device Version:
Thickness Pattern: PRINT
Calibration Tile Serial#: (nnnnnn)
Paper Feed Adjust A: (n.nn)%
Device Temperature: (nn)F
Paper Feed Adjust B: (n.nn)%
Firmware Version:
Drying Time: (n.n)sec
Air Temperature: (nn)F
Paper Suction: *Standard, -1, -2, -3, -4
Backing Color: (White or Black)
Set Roll Paper Tension: *Normal, High, Extra High
Calibration Status: Successful
Remove Skew: *On, Off
NVRAM Data (Parameter) Backup Mode

Hold the Up, Down, Left, and Right buttons and turn on the power. The Printer will display UPDATE FIRMWARE.
NVRAM Data (Parameter) Restore Mode

Disengage 11 Ink Cartridges, remove the 2 Maintenance Tanks, hold the Up, Down, Left, and Right buttons and
turn on the Printer. Wait an additional 20 seconds after the data is transferred to ensure completion.
F/W Download Mode

Hold the Up, Down, Left, and Right buttons and turn on the power. The Printer will display UPDATE FIRMWARE.
Maintenance Mode: Press and hold the Pause button and turn on the Printer.
Language: Japanese, *English, French, Italian, German, Portuguese, Spanish, Dutch, Korean, Chinese (Panel
Language)
Length Units: Metric,*Feet/Inch (Set’s the unit of measure that the printer displays)
Temperature Units: *C, F
Auto Cleaning Times: 1, *2, 3
Maintenance Alert: Disable, Ink, Maintenance Box, Ink or Maint Box, Papers, All
Cut Sheet Remaining: *Off, On
Time to Low Power: 5 Minutes, *15 Minutes, 60 Minutes, 120 Minutes, 180 Minutes
Power Management:
Power Off Timer: *Disable, Enable
Time to Off: (1 - 24) Hours
Default Panel: Execute (Resets to Factory Default all of the User Menus
Custom:*0 (nn)
SELF TESTING: Press and hold the Down, Right, and OK buttons, and turn on the Printer
Mecha Adjustment:
Paper: Paper Thick 00, 01, 10, 11(Displays the output from the Paper Thickness Sensors)
RearAD: [Enter]Start (nnn nnn nnn) (For adjusting the Rear Paper Sensor)
CR Uncap: [Enter Un Cap]
LCD RGB Check: Red, Green Blue
Panel Check:
Sensor Check:
Roll Unit: On, Off
Roll Support: Up, Down
ASF Cassette: On, Off
ASF Paper: On, Off
Front Cover: Open, Close
Life:
CR:
PF:
RLS:
APG:
Cutter:
GS:
Display Count:
Component
Replacement
Board (AID) Removal

1. Remove the Cover (Right Side).
2. Unplug the Printer.
3. Remove 3 Screws and the AID Board Cover.
1. Remove 3 Screws. 2. Remove the AID Board Cover.
Board (AID) Removal Printer Component, Software Item, LCD Display, Printer Button Page 16.
4. Disconnect the AID Grid Wires.

Reassembly Note: It is important to connect the White and Black AID Grid Wires to the correct
terminals.
Remove 2 Screws.
5. Remove the AID Board.
1. Disconnect the AID Control Cable. 2. Remove 3 Screws.
3. Remove the AID Board.
Board (Carriage) Removal

2. Remove the Cover (Side Right).
3. Release the Carriage Lock and move the Carriage Assembly off of the Cleaning Assembly.
3.1 Follow directions located in the Carriage Lock Release (Manual) chapter in the Reference Section.
4. Remove the Cover (Carriage).
1. Remove 6 Screws.
2. Lift off the Carriage Cover.
Board (Carriage) Removal Printer Component, Software Item, LCD Display, Printer Button Page 19.
5. Unplug 1 Foil Cable.
Unplug 1 Foil Cable.
6. Unplug 3 Foil Cables and 3 Connectors.
Unplug 3 Foil Cables and 3 Connectors
7. Remove the Carriage Board.
Remove 2 Screws and lift off the Carriage Board.
Board (Ethernet) Removal

2. Remove the Cover (Rear).
3. Disconnect 1 Cable Fastener.
Squeeze and un-seat 1 Cable Fastener.
Board (Ethernet) Removal Printer Component, Software Item, LCD Display, Printer Button Page 23.
4. Remove 5 Screws.
Remove 5 Screws.
5. Free the Cables from 2 Fastners.
Free the Cables from 2 Fasteners.
6. Disconnect and remove the Main Board / Ethernet Board Assembly.
1. Slide the Board Assembly partially out.
2. Disconnect 10 Foil Cables and 5 Wired Cable Connectors.
3. Remove the Main Board / Ethernet Board Assembly.
7. Disconnect 2 Connectors.
Disconnect 2 Connectors.
8. Remove 2 Screws and move 1 Fan.
1. Remove 2 Screws.
2. Move 1 Fan.
9. Remove 4 Screws, and the Board.
1. Remove 4 Screws. 2. Remove 1 Board.
Board (Ethernet) Installation

1. Install 1 Board and 4 Screws.
1. Install 1 Board. 2. Install 4 Screws.
Board (Ethernet) Installation Printer Component, Software Item, LCD Display, Printer Button Page 30.
2. Place 1 Fan, and install 2 Screws.
1. Place 1 Fan. 2. Install 2 Screws.
3. Connect 2 Connectors.
Connect 2 Connectors.
4. Install and connect the Main Board / Ethernet Board Assembly.
1. Slide the Board Assembly partially in.
2. Connect 10 Foil Cables and 5 Wired Cable Connectors.
5. Route the Cables through the 2 Fastners.
Route the Cables through the 2 Fasteners.
6. Install 5 Screws.
Install 5 Screws.
7. Connect 1 Cable Fastener.
Squeeze and re-seat 1 Cable Fastener.
8. Install the Cover (Rear).
9. Install Ethernet Firmware.
9.1 Use Epson Net Config to install the Ethernet Firmware.
10. Perform the MAC Address Check & Adjustment.
Board (Main) Removal

Main Board Removal (Overview)
• Back up the Printer’s Parameters.
• Remove the Rear Cover.
• Unplug the Cables.
• Remove the Screws.
• Remove the Main Board.
Main Board Removal (Detail)

1. Back up the Printer’s parameters using the NV-Ram Backup Utility feature of the servprog.exe utility.
Board (Main) Removal Printer Component, Software Item, LCD Display, Printer Button Page 38.
5. Remove 5 Screws.
Remove 5 Screws.
7. Disconnect and remove the Main Board / Ethernet Board Assembly.
1. Slide the Board Assembly partially out.
2. Disconnect 10 Foil Cables and 5 Wired Cable Connectors.
3. Remove the Main Board / Ethernet Board Assembly.
8. Remove 8 Screws.
Remove 8 Screws.
9. Remove 1 Screw, 2 Port Fasteners, and remove the Main Board.
1. Remove 2 Port Fasteners.

2. Remove 1 Screw.
Board (Main) Installation

1. Set the Board in place, and install 8 Screws.
Install 8 Screws.
Board (Main) Installation Printer Component, Software Item, LCD Display, Printer Button Page 45.
2. Install 1 Screw, and 2 Port Fasteners.
1. Install 2 Port Fasteners.

2. Install 1 Screw.
3. Install and connect the Main Board / Ethernet Board Assembly.
1. Slide the Board Assembly partially in.
2. Connect 10 Foil Cables and 5 Wired Cable Connectors.
4. Route the Cables through the 2 Fastners.
Route the Cables through the 2 Fasteners.
Install 5 Screws.
6. Connect 1 Cable Fastener.
Squeeze and re-seat 1 Cable Fastener.
7. Install the Cover (Rear).
8. Plug in and turn on the Printer in Firmware Download Mode (depress the Up, Down, Left, and
Menu buttons, and turn on the power to the Printer).
9. Download the latest Firmware following the directions found in the Firmware Update Procedure
Using FWUpdate.exe chapter located in the Reference section of the Field Guide.
If the Printer’s Parameters are not available skip step 10, and proceed with step 11.
Note: The new board will have a new USB ID. The original driver connection will not work. Allow the
driver to connect to a new USB ID.
10. Re-Install the Printer’s parameters using the NV-Ram Backup Utility feature of the servprog.exe utility.
10.1 Perform the RTC & USBID Check and Adjustment located in the servprog.exe utility.
Note: After installing the original Boards parameters, the new board will have the original USB ID. Use
the original driver connection for future service operations.
11. Install the appropriate generic NVRAM data (generic Printer parameters) (using the NV-Ram
Backup Utility feature of the servprog.exe utility.
Note: If the new Board does not have any parameters, the Printer will not function well enough to allow
alignments, paper loading, nozzle check, or the rest of step 11. Generic parameters are a set of
working parameters from another printer. They are available for download at: https://
www.epsoninsider.com listed under the Printer name.
Note: Installing generic parameters will introduce a new USB ID. Allow the driver to connect to a new
USB ID.
Note: Install Generic Parameters PKon a Printer that is in photo black mode, or Generic Parameters
MKon a Printer that is in Matte Black Mode. Remove the paper and disconnect all optional devices
(Spectroproofer). This matches the Printer to the Generic Parameters.
12. Perform the following operations in the order listed.
12.1 Perform the RTC & USBID Check and Adjustment.

12.2 Perform the Head ID Check & Input (Print Head calibration values).
12.3 Perform Serial Number Check and Adjustment.
12.4 Perform the Rear AD Adjustment.
12.5 Perform the Media Feed Check & Adjustment.
12.6 Perform the Media Eject Check & Adjustment.
12.7 Perform the Motor Measurement Adjustment.
12.8 Perform the CR Speed Auto Adjustment.
12.9 Perform the Active Damper Adjustment.
12.10Perform the PW + T&B&S Adjustment.
12.11Perform the Auto Bi-D Adjustment.
12.12Perform the Ink Mark Sensor Check & Adjustment.
12.13Perform the Colorimetric Calibration (When specifically requested by Epson).
Board (Power Supply) Removal

3. Remove the Cover (Left).
4. Remove Board (Sub C).
Board (Power Supply) Removal Printer Component, Software Item, LCD Display, Printer Button Page 53.
6. Remove 5 Screws.
Remove 5 Screws.
8. Disconnect CN1.
1. Slide the Board Assembly partially out. 2. Disconnect CN1.
9. Clip 2 Cable Ties.
2. Clip 1 Cable Tie.

1. Clip 1 Cable Tie.
10. Free the Cables fastened to the back of the Power Supply.
1. Release these Cables.
2. Release these Cables.
11. Remove 2 Screws.
Remove 2 Screws.
12. Remove 1 Metal Plate.
1. Remove 3 Screws. 2. Remove 1 Metal Plate.
Remove 2 Screws.
14. Remove the Power Supply
Slide the Power Supply out of the Printer.
Board (Sub-B) Removal

2. Remove 1 Plastic Spacer.
1. Release 2 Interlocks located on the

inside of the Side Frame.
2. Remove the Plastic Spacer.
Board (Sub-B) Removal Printer Component, Software Item, LCD Display, Printer Button Page 63.
3. Disconnect all Cables.

Reassembly Note: CN205 is not used.
Disconnect 4 Foil Cables,

and 29 Wired Connectors.
4. Remove the Board.
1. Remove 4 Screws.
Board (Sub C) Removal

1. Remove the Cover (Left Side).
2. Disconnect all of the Cables.
Disconnect 4 Foil Cables,

and 10 Wired Connectors.
Board (Sub C) Removal Printer Component, Software Item, LCD Display, Printer Button Page 66.
3. Remove Sub Board C.
1. Remove 4 Screws.
Board (Sub C) Removal Printer Component, Software Item, LCD Display, Printer Button Page 67.
Board (Sub-D) Removal

1. Remove the Spindle Assembly.
2. Remove 1 Screw that fastens the Right Side Spindle Assy, Cover.
Remove 1 Screw.
Board (Sub-D) Removal Printer Component, Software Item, LCD Display, Printer Button Page 68.
3. Remove 3 Screws.
1. Remove 1 Screw.
2. Remove 2 Screws.
4. Unplug 7 Connectors.
Unplug 7 Connectors.
5. Remove 4 Screws and 1 Ground Strap.
1. Remove 4 Screws and 1 Ground Strap. 2. Remove the Sub-D Board.
Cap (Parking) Removal

3. Manipulate the Cap Mechanism until the Parking Cap is raised.
Raise the Parking Cap.
Cap (Parking) Removal Printer Component, Software Item, LCD Display, Printer Button Page 72.
4. Remove the Parking Cap.
The Parking Cap is held in position by 3 Black Plastic Tines.
5. Remove the Parking Cap (continued).
1. Push down on this side of the

Cap, and rotate this Tine
free.
2. Parking Cap with 1

Tine free.
3. Push down and rotate the

Cap in the other direction,
and free the other Tine.
4. Lift off the Parking Cap.
Parking Cap Support Springs.
Parking Cap Base.
Cleaning Assembly Removal

Note: If the Cleaning Assembly is to be replaced, ensure that the following counters are cleared (reset).
Wiper Counter [for Exchange], Head Cap Counter, IS Unit Counter.
Cleaning Assembly Removal Printer Component, Software Item, LCD Display, Printer Button Page 78.
3. Disconnect 4 Connectors.
1. Disconnect CN229 and CN228
2. Disconnect CN231 and CN230.
4. Free the Cables with 3 or 4 Wires from 2 Fasteners.
Free the Cables with 3 or 4 Wires from 2 Fasteners.
5. Free the 2 Wire Cable from 3 Fasteners.
Free the 2 Wire Cable from 3 Fasteners.
6. Separate the Waste Ink Tube Junction from the Gray Waste Ink Tube.
Separate the Waste Ink Tube Junction from the Gray Waste Ink Tube.
7. Remove 3 Screws and the AID Board Cover.
1. Remove 3 Screws. 2. Remove the AID Board Cover.
8. Disconnect the AID Grid Wires.

Reassembly Note: It is important to connect the White and Black AID Grid Wires to the correct
terminals.
Remove 2 Screws.
9. Remove 1 Screw and the Bracket.
Remove 1 Screw and the Bracket.
10. Remove 1 Screw.
Remove 1 Screw.
11. Remove 1 Screw.
Remove 1 Screw.
12. Prepare the Waste Ink Tubes and Cable Bundles for Cleaning Assembly Removal.
1. Feed the Waste Ink Tubes through 2. Feed 2” of the Cable Bundles through the hole in
the hole in the Frame. the Frame.
13. Free the Cleaning Assemblies / Side Frame Interlocks.
Slide the Cleaning Assembly slightly away from the

Side Frame to release the Side Frame Interlocks.
14. Remove the Cleaning Assembly.
Rotate the Cleaning Assembly up, and out.
15. Reassembly Note.
White AID Wire.
Black AID Wire.
AID Wires through this

hole.
Waste Ink Tubes and

Wires through this hole.
Control Panel Removal

1. Remove the Cover (SpectroProofer Cavity).
2. Remove the Cover (Top Right).
3. Remove 1 Screw.
Remove 1 Screw.
Control Panel Removal Printer Component, Software Item, LCD Display, Printer Button Page 92.
4. Remove 1 Screw.
Remove 1 Screw.
5. Slide the Control Panel forward, and lift it off.
1. Slide the Control Panel forward. 2. Lift the Control Panel up, and off.
6. Disconnect the Control Panel Cable.
Disconnect the Control Panel Cable.
Cover (Carriage) Removal

1. Remove 6 Screws.
Cover (Carriage) Removal Printer Component, Software Item, LCD Display, Printer Button Page 96.
Cover (Cutter Assembly) Removal

3. Remove the Control Panel.
5. Remove 3 Screws.
Remove 3 Screws.
Cover (Cutter Assembly) Removal Printer Component, Software Item, LCD Display, Printer Button Page 97.
6. Release 1 Interlock.
Release 1 Interlock.
7. Remove the Cutter Assembly Cover.
Bend the top of the Cover out (towards the front of the Printer) to clear 2 parts that are under the metal
frame, and lift the Cutter Assembly Cover up, and off.
Cover (Left Side) Removal

2. Lift the Top Cover and remove 3 Screws.
1. Lift the Top Cover. 2. Remove 3 Screws.
Cover (Left Side) Removal Printer Component, Software Item, LCD Display, Printer Button Page 100.
3. Remove 2 Screws and slide off the Left Side Cover.
1. Remove 2 Screws. 2. Slide off the Left Side Cover.
Cover (Left Side) Removal Printer Component, Software Item, LCD Display, Printer Button Page 101.
Cover (Paper Tray Cavity) Removal

1. Remove the Paper Cassette.
6. Remove the Cover (Cutter Assembly).
7. Remove the Borderless Waste Ink Tank.
1. Release the Interlock Lever. 2. Slide out the Waste Ink Tank.
Cover (Paper Tray Cavity) Removal Printer Component, Software Item, LCD Display, Printer Button Page 102.
8. Remove 1 Screw.
Remove 1 Screw.
9. Remove 1 Screw.
Remove 1 Screw.
10. Remove 1 Screw.
Remove 1 Screw.
11. Open 2 Ink Bay Doors and release 2 Interlocks.
1. Open 2 Ink Bay Doors.
2. Slide the Cover forward slightly to release the 2 Interlocks that fasten the Font Edge.
12. Lift the Front Edge to verify that the 2 Front Edge Interlocks are released.
Lift the Front Edge to verify that the Front Edge Interlocks are released.
13. Remove the Cover.

1. Ensure that the Left Rear Edge of the Cover does not “hang up” on the Sensor located underneath.
2. From the right side, rotate the Cover up and off.
14. Verify that the Borderless Waste Ink Tank Sensor is undamaged.
Verify that the Borderless Waste Ink Tank Sensor is undamaged.
Cover (Rear) Removal

1. Remove the Paper Guide Assembly.
1. Release the Interlocks.
2. Slide out the Paper Guide Assembly.
Cover (Rear) Removal Printer Component, Software Item, LCD Display, Printer Button Page 110.
2. Disconnect the Spindle Assembly Cable and remove 7 Screws.
1. Disconnect the Spindle Assembly Cable.
2. Remove 7 Screws.
Cover (Right Side) Removal

2. Remove the Cover (Top Right)
4. Remove 1 Screw.
Remove 1 Screw.
Cover (Right Side) Removal Printer Component, Software Item, LCD Display, Printer Button Page 113.
5. Remove 1 Screw.
Remove 1 Screw.
6. Remove 2 Screws.
Remove 2 Screws.
7. Remove the Right Side Cover.
1. Lift the top of the Right Side Cover. 2. Slide off the Right Side Cover.
Cover (SpectroProofer Cavity) Removal

1. Open the Top Cover.
Open the Top Cover.
Cover (SpectroProofer Cavity) Removal Printer Component, Software Item, LCD Display, Printer Button Page 117.
2. Remove 2 Screws.
Remove 2 Screws.
3. Open the Left Ink Bay Door, and remove 1 Screw.
1. Open the Left Ink Bay Door. 2. Remove 1 Screw.
4. Open the Right Ink Bay Door, and remove 1 Screw.
1. Open the Left Ink Bay Door. 2. Remove 1 Screw.
5. Remove the SpectroProofer Cavity Cover.
Lift off the SpectroProofer Cavity Cover.
6. View of the SpectroProofer Cavity.
Cover (Top Right) Removal

1. Lift the Top Cover and remove 1 Screw.
Note: It is easier to remove the Top Right Cover if the Spindle Assembly is removed first.
1. Lift the Top Cover. 2. Remove 1 Screw.
Cover (Top Right) Removal Printer Component, Software Item, LCD Display, Printer Button Page 123.
2. Lift up, and slide to the right to remove the Top Right Cover.
1. Release 1 Interlock located under the

Top Right Cover in the front left corner.
2. Slide the Top Right Cover to the

right and remove it.
Cover (Top Right) Removal Printer Component, Software Item, LCD Display, Printer Button Page 124.
Ink Bay (Left) Removal

1. Drain the Ink from the Ink System.
1.1 Follow the Ink Draining Procedure located in the Reference section.
6. Remove the Cover (Paper Tray Cavity).
Ink Bay (Left) Removal Printer Component, Software Item, LCD Display, Printer Button Page 125.
7. Disconnect the Ink Bay (Left).
1. Unplug 2 Cables. 3. Disconnect the

Pressure Hose.
2. Free the White Ink

Door Sensor
Cable from the fas-
teners and tape.
8. Remove the Ink Bay Door (Left).
1. Open the Left Ink Door. 2. Remove 4 Screws. 3. Slide off the Left Ink Door.
9. Remove 8 Screws.
Remove 8 Screws.
10. Remove the SpectroProofer USB Connector.
Remove 2 Screws.
11. Remove the SpectroProofer Power Connector.
Remove 2 Screws.
12. Loosen 2 Screws.
Fully loosen, but do not remove

2 Screws.
13. Mark the Ink Tubes.
Mark the Ink Tubes to aid in reassembly
14. Disconnect the Ink Tubes.
“Lever” off the Ink Tubes.
15. Remove the Ink Bay (Left).
16. Reassembly Note:
If replacing the Ink Bay, ensure that you transfer or replace the O-Ring Chain. Failure to do so will
result in a serious Ink leak.
O-Ring Chain
Cutter Assembly Removal

2. Move the Cutter Blade into the center of the Cutter Assembly.
Move the Cutter Blade into the center of the Cutter Assembly.
Cutter Assembly Removal Printer Component, Software Item, LCD Display, Printer Button Page 135.
3. Remove 2 Screws.
1. Unplug 1 Connector. 2. Remove 2 Screws.
4. Remove 3 Screws, and the Cutter Assemby.
1. Remove 2 Screws. 2. Remove 1 Screw.
3. Remove the Cutter Assembly.
Ink Bay (Right) Removal

1. Drain the Ink from the Ink System.
1.1 Follow the Ink Draining Procedure located in the Reference section.
Ink Bay (Right) Removal Printer Component, Software Item, LCD Display, Printer Button Page 138.
8. Disconnect the Ink Bay (Right).
1. Unplug 2 Cables. 3. Disconnect the 2

Pressure Hoses.
2. Free the White

Ink Door Sensor
Cable from the
fasteners.
4. Free 4 Foil
Cables.
9. Remove the Ink Bay Door (Right).
1. Open the Left Ink Door.

2. Remove the Maintenance Tank. 4. Slide off the Left Ink Door.
2. Remove 4 Screws.
Remove 8 Screws.
11. Loosen 2 Screws.
Fully loosen, but do not remove

2 Screws.
12. Mark the Ink Tubes.
Mark the Ink Tubes to aid in reassembly
13. Disconnect the Ink Tubes.
“Lever” off the Ink Tubes.
14. Remove the Ink Bay (Right).
15. Reassembly Note:
If replacing the Ink Bay, ensure that you transfer or replace the O-Ring Chain. Failure to do so will
result in a serious Ink leak.
Maintenance Tank Holder Removal

2. Disconnect the Maintenance Tank Waste Ink Tube.
Disconnect the Maintenance Tank Waste Ink Tube.

Maintenance Tank Holder Removal Printer Component, Software Item, LCD Display, Printer Button Page 146.
3. Remove 4 Screws.
Remove 4 Screws.
4. Remove the Maintenance Tank Holder.
1. Disconnect and free the

CSIC Cable.
2. Remove the Mainte-

nance Tank Holder.
Motor (Eject Roller Rotation) Removal

2. Remove 3 Screws.
Remove 3 Screws.
Motor (Eject Roller Rotation) Removal Printer Component, Software Item, LCD Display, Printer Button Page 149.
3. Disconnect 1 Connector.
Disconnect 1 Connector.
4. Remove Motor (Exit Roller Rotation).
1. Remove 2 Screws.
2. Remove the Motor (Exit

Roller Rotation).
Pressure Pump Assembly Removal

Disconnect CN232
Pressure Pump Assembly Removal Printer Component, Software Item, LCD Display, Printer Button Page 152.
3. Free the Pressure Pump Motor Cable.
Free the Pressure Pump Cable from 5 Fasteners.
4. Remove 3 Screws.
Remove 3 Screws.
5. Disconnect and free the Pressure Pump Tube.
Disconnect and free the Pressure Pump Tube.
6. Disconnect the Pressure Pump Encoder.
Disconnect the Pressure

Pump Encoder.
Print Head Removal

Note: The Print Head Nozzle Plate on the Pro 4900 is as fragile as tin foil. Any contact with the Nozzle
plate will damage the Print Head.
Note: A long shafted (6”) number 1 phillips screw driver is necessary for this procedure.
Print Head Removal Overview

• Input the New Print Head’s Head Rank ID (if the Print Head is to be replaced).
• Release the Carriage Mechanism.
• Unplug the Printer.
• Remove the Old Print Head.
Print Head Removal Detail

1. If you are replacing the Print Head, run the Servprog.exe and input the new Print Head’s
calibration value (Head Rank ID).
Print Head Removal Printer Component, Software Item, LCD Display, Printer Button Page 157.
1. Remove 6 Screws.
6. Remove 3 Screws.
Remove 3 Screws.
8. Remove 1 Plastic Support.
Release 1 Interlock and remove 1 Plastic Support.
9. Remove 1 Screw.
Remove 1 Screw.
10. Lift off the Selector Assembly.
Lift off the Selector Assembly.
11. Lay the Selector Assembly to the side.
Lay the Selector Assembly to the side.
Remove 3 Screws.
13. Remove the Print Head.
1. Lift out the Print Head.
2. Disconnect 4 Foil Cables.
Print Head Installation

1. Connect the Print Head.
CN1 CN3
CN2 CN4
Connect 4 Foil Cables.
Print Head Installation Printer Component, Software Item, LCD Display, Printer Button Page 167.
2. Install the Print Head.
1. Place the Print Head in position 2. Install 3 Screws.
3. Place the Selector Assembly.
Place the Selector Assembly in position.
Install3 Screws.
5. Install 1 Plastic Support.
Install 1 Plastic Support.
6. Install 1 Screw.
Install 1 Screw.
7. Connect 2 Connectors.
Connect 2 Connectors.
8. Plug in the Printer, and close the Ink Bay Doors.
9. Close the Top Cover.
10. Turn on the Printer, and let it come Ready.
11. Press the Cleaning button and navigate to Manual Cleaning / All colors Powerful.
11.1 Execute 1 or more cleaning cycles.
12. Print a Nozzle Check pattern (Perform additional cleaning cycles if necessary).
13. Perform the following adjustments in sequence.

13.1 Perform Counter Reset after replacing the Print Head.
13.2 Perform Head ID Check & Input (if you did not do it before removing the old Print Head).
13.3 Perform the CR Head Slant Adjustment.
13.4 Perform the Auto Bi-D Adjustment
13.5 Perform the Colorimetric Calibration (When specifically requested by Epson)
14. Install the Cover (Carriage).
Place the Cover and install 6

Screws.
15. Install the Cover (Right Side).
16. Install the Control Panel.
1. Install the Cover (Top Right)
Roller (Pickup) Assembly Removal

1. Remove the Paper Cassette.
2. Locate the Roller (Pickup) Assembly.
Roller (Pickup) Assembly Removal Printer Component, Software Item, LCD Display, Printer Button Page 176.
3. Free the Shaft closest to the front of the Printer.
1. Release the Left White Plastic Bush-

ing by pulling out the Handle and rotat-
ing it until it is straight down.
2. Release the Hook on the right side of

the Shaft fastened by the Bushing
released in step 1. Slide the Shaft
fully to the right.
4. Free the Nylon Interlock that fastens the rear of the Assembly to the Printer.
Slide this Nylon Interlock to the right to release the

rear of the Assembly from the Printer.
5. Slide out the Roller (Pickup) Assembly.
Slide out the Roller (Pickup) Assembly.
Roller (Pickup) Removal

1. Remove the Roller (Pickup) Assembly.
Roller (Pickup) Removal Printer Component, Software Item, LCD Display, Printer Button Page 180.
2. Remove 1 Gear.
2. Slide off this Gear.

1. Release 1 Interlock.
3. Free the Pickup Rollers.
1. Push the Spring Loaded White Nylon Roller down to make room for the Pickup Roller Shaft.
2. Slide the Pickup Roller Shaft to the left.
4. Remove the Pickup Roller.
Lift the Pickup Roller up, and off.
Selector (Damper) Assembly Removal

Note: A new Selector Assembly’s part # is 1541331
Note: New Selector Assemblies come with the O-Ring Chain that supplies a “seal” between the
Selector Assembly and in Ink Tubes.
Note: The 4900 Ink System is pressurized. It will remain under pressure after the Printer is turned off.
Failure to bleed off the Ink System Pressure will cause an ink spill, if the Ink System is opened.
1. Bleed off the Ink System pressure.

1. Clamp the Ink System Pressure Vacuum
Hose.
2. Run 2 powerful cleaning cycles to bleed

of residual pressure. (Cleaning Button:
Manual Cleaning, All Colors (Power-
ful))
Selector (Damper) Assembly Removal Printer Component, Software Item, LCD Display, Printer Button Page 184.
4.1 Follow directions located in the Carriage Release (Manual) chapter in the Reference Section.
5. Prepare 1 Rubber Band Chain.
1. Remove 6 Screws.
7. Remove 3 Screws.
Remove 3 Screws.
9. Remove 1 Plastic Support.
Release 1 Interlock and remove 1 Plastic Support.
10. Remove 1 Screw.
Remove 1 Screw.
11. Prepare to secure the Ink Tubes (once they are removed from the Selector Assembly).
Prepare to secure the Ink Tubes (once they are removed from the Selector Assembly)
12. Lift off the Selector Assembly.
1. Lift off the Selector Assembly and expose 3 Screws. 2. Remove 3 Screws.
13. Remove 1 Screw.
Note: There is serious potential

for an ink spill when the Ink
System is opened in this
step. Be prepared to
capture the leaking ink.
1. Rotate the Selector Assembly 90 degrees. 2. Remove 1 Screw.
14. Secure the Ink Tubes.
Secure the Ink Tubes.
15. Reassembly Note.
New Selector Assemblies come with an O-Ring Chain. Remove the O-Ring Chain from the old Selector
Assembly, if necessary, to use on the replacement Selector Assembly.
Failure to use a O-Ring Chain during reassembly will result in a serious Ink leak.
Sensor (Borderless Waste Ink Tank) Removal

7. Remove the Sensor.
1. Release the Interlocks that

fasten the Sensor.
2. Unplug the
Sensor (Borderless Waste Ink Tank) Removal Printer Component, Software Item, LCD Display, Printer Button Page 196.
Sensor (Exit Roller HP) Removal

2. Release the Carriage Lock

3. Move the Carriage Assembly to the left side of the Printer.
Move the Carriage Assembly to the left side of the Printer.
Sensor (Exit Roller HP) Removal Printer Component, Software Item, LCD Display, Printer Button Page 197.
4. Remove 1 Screw.
Carriage Motor
Remove 1 Screw.
5. Remove the Black Plastic Component.
Slide to the right and remove the Black Plastic Component.
6. Free 1 section of the Carriage Cable Cover.
1. Release 1 Interlock. 2. Slide the Cover in this direction to release it.
7. Free 1 more section of the Carriage Cable Cover.
1. Release 1 Interlock. 2. Slide the Cover in this direction to release it.
8. Remove 1 Screw.
1. Lift 1 Cable Cover to expose 1 Screw. 2. Remove 1 Screw.
9. Remove 1 Screw.
1. Lift 1 Cable Cover to expose 1 Screw. 2. Remove 1 Screw.
10. Disconnect 1 Cable.
Disconnect 1 Cable.
11. Remove the Sensor (Exit Roller HP).
Release 4 Interlocks and remove the

Sensor.
Sensor (Paper Tamper HP) Removal

2. Remove 3 Screws.
Remove 3 Screws.
Sensor (Paper Tamper HP) Removal Printer Component, Software Item, LCD Display, Printer Button Page 206.
5. Remove the Sensor (Paper Tamper HP).
Release 4 Interlocks, and remove

the Sensor.
Sensor (Platen Gap) Removal

1. Remove 6 Screws.
Sensor (Platen Gap) Removal Printer Component, Software Item, LCD Display, Printer Button Page 210.
5. Spin the Platen Gap Mechanism until the “Window” is centered on the Sensor.
Spin the Platen Gap Mechanism until the “Window” is centered on the Sensor.
6. Remove the Platen Gap Sensor.
Release 4 Interlocks and remove the Sensor.
7. Unplug the Sensor.
Unplug the Sensor.
Spindle Assembly Removal

2. Remove 2 Screws and rotate up, and off, the Spindle Assembly.
1. Remove 2 Screws.
2. Rotate the Spindle Assembly up, and off.
Spindle Assembly Removal Printer Component, Software Item, LCD Display, Printer Button Page 214.
Wiper Blade Removal

3. Manipulate the Cap Mechanism until the Wiper Blade is exposed.
Move the Wiper Blade until it is

exposed.
Wiper Blade Removal Printer Component, Software Item, LCD Display, Printer Button Page 215.
4. Remove the Wiper Blade.
1. Push the Wiper Blade down.
5. Remove the Wiper Blade (continued).
2. Release 1 Interlock, and

remove the Wiper Blade.
6. Remove the Wiper Blade (continued).
Wiper Blade
Troubleshooting
Printer Error Codes (Maintenance)

0002 Carriage Motor / Ink Tube is near end of life perform CR Motor Counter (Clear)
0008 RTC error (Replace the Battery and initialize the RTC with the Servprog.exe ‘s RTC & USB
ID Check and Adjustment routine.
0010 AID error.
0040 Cleaning Unit near end of life. Perform IS Unit Counter (Clear).
0080 Date is not set (initialize the RTC with the Servprog.exe ‘s RTC & USB ID Check and
Adjustment routine.)
0088 RTC Battery low (Replace the battery, initialize the RTC with the Servprog.exe ‘s RTC &
USB ID Check and Adjustment routine
0800 An Ink Bay is near end of life. Perform Ink Holder Full [L] and Ink Holder Home [R] Coun-
ter (clear)
1000 The PK/MK Ink Selector is near end of life. Perform Ink Selector Assy Counter (Clear)
4000 After 2 attempts, the AID circuitry can detect no nozzles. Technician Required to repair.
Printer Error Codes (Maintenance) Printer Component, Software Item, LCD Display, Printer Button Page 220.
Printer Error Codes (Service)
Carriage Error Name Description Remedy

Error Code
1101 Carriage Motor End Of The Carriage has made Inspect and replace the Ink Tubes if neces-
Life Error enough passes to wear out sary, and perform CR Motor Counter
the Ink Tubes. (Clear)
1125 Carriage Home Posi- The Carriage Home Posi- 1. Check the CR HP Sensor.
tion Error tion Sensor does not detect 2. Check for proper Carriage movement.
the Carriage Assembly. 3. Check the Main Board.
1138 Over Current Error The Carriage Motor Driver 1. Check for proper Carriage movement.
Circuit detects abnormal cur- 2. Check for proper Carriage Belt Tension.
rent draw. 3. Check the Carriage Motor.
113A Over Current Error The Carriage Motor Driver 1. Check for proper Carriage movement.
Circuit detects abnormal cur- 2. Check for proper Carriage Belt Tension.
rent draw. 3. Check the Carriage Motor.
113B Carriage Over Speed The Carriage Encoder signal 1. Check the CR Encoder Strip.
Error does not look right to the 2. Check the CR Encoder.
Main Board. 3. Check the Carriage Motor.
4. Check Sub Board B.
113C Carriage Encoder The Carriage Encoder 1. Check the CR Encoder.
Reversing Error reports that the Carriage is 2. Check the Main Board.
moving in the wrong direction.
Printer Error Codes (Service) Printer Component, Software Item, LCD Display, Printer Button Page 221.
Carriage Error Name Description Remedy

Error Code
113D Carriage Encoder The Carriage Encoder 1. Check the CR Encoder.
Movement Error reports that the Carriage is 2. Check the CR Encoder Strip.
not moving or moving slow. 3. Check the Main Board.
113E Carriage Encoder The Carriage Encoder 1. Check the CR Encoder Strip.
Velocity Error reports that the Carriage is 2. Check the CR Encoder.
moving at an irregular speed. 3. Check the Carriage Motor.
5. Check the Main Board.
113F Carriage Encoder The Carriage Encoder 1. Check Carriage Movement.
Velocity Error reports that the Carriage is 2. Check the CR Encoder Strip.
moving at an irregular speed. 3. Check the CR Encoder.
4. Check the Carriage Motor.
Paper Explanation Description Remedy

Feed Error
Codes
1223 Paper Feed Encoder The Paper Feed Encoder 1. Check the PF Encoder Disk.
Check Error signal does not look right to 2. Check the PF Encoder.
the Main Board. 3. Check the Paper Feed Motor.

Feed Error
Codes
122A Paper Feed Motor The Paper Feed Motor 1. Check for proper Paper Feed Roller
Overload Error Driver Circuit detects abnor- Pressurization (look for binding).
mal current draw. 2. Check for proper Paper Feed Belt Ten-
sion.
3. Check the Paper Feed Encoder.
4. Check the Paper Feed Encoder Disk.
5. Check the Paper Feed Motor
122B Paper Feed Motor The Paper Feed Encoder 1. Check the Paper Feed Encoder.
overspeed error. reports that the Paper Feed 2. Check Sub Board C.
Roller is moving to fast. 3. Check the Main Board.
122C Paper Feed Encoder The Paper Feed Encoder 1. Check the Paper Feed Encoder.
Reversing Error reports that the Paper Feed 2. Check the Main Board.
Roller is moving in the wrong
direction.
123D Paper Feed Motor The Paper Feed Encoder 1. Check for proper Paper Feed Roller
Driving Time Out Error reports that the Paper Feed movement.
Motor is moving irregularly. 2. Check for proper Paper Feed Belt ten-
sion.
5. Check the Paper Feed Motor
6. Check Sub Board C.

Feed Error
Codes
122E Paper Feed Motor The Paper Feed Encoder 1. Check for proper Paper Feed Roller
Velocity error. reports that the Paper Feed Pressurization (look for binding).
Motor is moving irregularly. 2. Check for proper Paper Feed Belt Ten-
sion.
5. Check the Paper Feed Motor.
122F Paper Feed Motor The Paper Feed Encoder 1. Check for proper Paper Feed Roller
Velocity error. reports that the Paper Feed Pressurization (look for binding).
Motor is moving irregularly. 2. Check for proper Paper Feed Belt Ten-
sion.
5. Check the Paper Feed Motor.
Ink Cover Explanation Description Remedy

Error
Codes
131B Thermistor Sensor The Thermistor on the Print 1. Re-seat the Print Head Cables on the
Error Head Driver reports an over Main Board side.
temperature condition 2. Re-seat the Print Head Cables on the
Print Head side.
3. Replace the Main Board.
4. Replace the Print Head.
Ink Sys- Explanation Description Remedy

tem Error
Codes
1412 Cleaning Pump end of The Cleaning Pump has 1. Replace the Cleaning Assembly.
life error reached end of life. 2. Perform IS Unit Counter (Clear).
141A Over Current Error The Cleaning Pump Motor 1. Check the Cleaning Assembly.
draws too much current 2. Check the Main Board.
141B Over Speed Error The Cleaning Pump Motor 1. Check the Cleaning Assembly.
spins too fast. 2. Check the Main Board.
141C Rotation Direction Error The Cleaning Pump Motor 1. Check the Cleaning Assembly.
spins in the wrong direction. 2. Check the Main Board.

tem Error
Codes
141D Driving Time Out Error The Cleaning Pump Motor 1. Check the Cleaning Assembly.
does not spin, or spins too 2. Check the Main Board.
long.
141E Velocity Deviation Error The Cleaning Pump Motor 1. Check the Cleaning Assembly.
spins at irregular speeds. 2. Check the Main Board.
141F Under Speed Error The Cleaning Pump Motor 1. Check the Cleaning Assembly.
spins too slow. 2. Check the Main Board.
1431 Ink Selector Life Error The PK/MK Ink Selector 1. Replace the Damper (Selector) Assem-
Assembly has reached it’s bly.
end of life. 2. Perform Ink Selector Assy Counter
(Clear)
1432 Cartridge Holder End of One of the Ink Cartridge 1. Determine which cartridge has reached it’s
Life Error Holders has reached it’s end of life (maybe both of them).
end of life. 2. Replace the Ink Holder(s).
3. Perform Ink Holder Full [L] and Ink
Holder Home [R] Counter
(clear)
1433 Cleaning Assembly (Ink One of the Cleaning 1. Check the Sensors on the Cleaning
System) Sensor Error Assembly Sensors is Assembly.
reporting conflicting data. 2. Replace the Cleaning Assembly.
1494 Ink Selector Error Switching between PK/MK 1. Replace the Damper (Selector) Assem-
does not work bly.

tem Error
Codes
1496 Ink Selector Error Switching between PK/MK 1. Replace the Damper (Selector) Assem-
does not work bly.
1497 Switching Time Out Switching between PK/MK Note: Corrupted or incorrect Parameters
Error does not work can cause this error. For example:
Selector Sensor set to Photo Black and
the Parameters set to Matte Black.
1. Test the Selector Assembly using the
Self Testing/Mecha Adjusment/Selec-
tor Check function.
2. Install Generic Parameters that match the
Printers current mode (ie: Photo Black
Paramenters on a Printer in photo black
mode etc.)
3. Replace the Damper (Selector) Assem-
bly.
149D Driving Time Out Error Switching between PK/MK 1. Check the Damper (Selector) Assembly.
takes too long. 2. Check the Main Board.
APG Explanation Description Remedy

and
ASF
Errors
150C Platen Gap Home Position The Platen Gap Home 1. Check the operation of the Platen Gap
Detection Error Position Sensor does not Mechanism.
report to the Main Board. 2. Check the Platen Gap Home Position
Sensor.
3. Check the Platen Gap Motor.
151A Over Current Error The Platen Gap Motor 1. Check the operation of the Platen Gap
draws too much current Mechanism.
2. Check the Platen Gap Home Position
Sensor.
151B Over Speed Error The Platen Gap Motor 1. Check the operation of the Platen Gap
spins too fast. Mechanism.
Sensor.

and
ASF
Errors
151C Rotation Direction Error The Platen Gap Motor 1. Check the operation of the Platen Gap
spins in the wrong direction. Mechanism.
Sensor.
151D Driving Time Out Error The Platen Gap Motor 1. Check the operation of the Platen Gap
does not spin, or spins too Mechanism.
long. 2. Check the Platen Gap Home Position
Sensor.
151E Velocity Deviation Error The Platen Gap Motor 1. Check the operation of the Platen Gap
spins at irregular speeds. Mechanism.
Sensor.

and
ASF
Errors
151F Under Speed Error The Platen Gap Motor 1. Check the operation of the Platen Gap
spins too slow. Mechanism.
Sensor.
1521 Roll Lock Sensor Detection The Roll Lock Sensor does 1. Check the Roll Lock Sensor.
Error not detect properly 2. Check Sub Board D.
1522 Roll Feeding Sensor The Roll Feeding Sensor 1. Check the Roll Feeding Sensor.
Detection Error does not detect Properly. 2. Check Sub Board D.
1523 Roll Paper End Sensor The Roll Paper End Sen- 1. Check the Roll Feeding Sensor.
sor does not detect Prop- 2. Check Sub Board D.
erly.
152A Roll Feeding Motor Over The Roll Feeding Motor 1. Check the Roll Feeding Motor.
Current Error draws too much current 2. Check Sub Board D.
152B Roll Feeding Motor Over The Roll Feeding Motor 1. Check the Roll Feeding Motor.
Speed Error spins too fast. 2. Check Sub Board D.
152C Roll Feeding Motor Rota- The Roll Feeding Motor 1. Check the Roll Feeding Motor.
tion Direction Error spins in the wrong direction. 2. Check Sub Board D.

and
ASF
Errors
152D Roll Feeding Motor Driving The Roll Feeding Motor 1. Check the Roll Feeding Motor.
Time Out Error does not spin, or spins too 2. Check Sub Board D.
long. 3. Check the Main Board.
152E Roll Feeding Motor Veloc- The Roll Feeding Motor 1. Check the Roll Feeding Motor.
ity Deviation Error spins at irregular speeds. 2. Check Sub Board D.
152F Roll Feeding Motor Under The Roll Feeding Motor 1. Check the Roll Feeding Motor.
Speed Error spins too slow. 2. Check Sub Board D.
1530 Pinch Roller Release The Pinch Roller Assy 1. Check the Pinch Roller Assy Motor.
Home Position Detection Home Position Sensor 2. Check the Pinch Roller HP Sensor.
Error does not report to the Main 3. Check the Main Board.
Board.
1531 Pinch Roller Release The Pinch Roller Assy 1. Check the Pinch Roller Assy Motor.
Home Position Detection Home Position Sensor 2. Check the Pinch Roller HP Sensor.
Error does not report to the Main 3. Check the Main Board.
Board.
153A Pinch Roller Release Over The Pinch Roller Assy 1. Check the Pinch Roller Assy Motor.
Current Error Motor draws too much cur- 2. Check the Main Board.
rent
153B Pinch Roller Release Over The Pinch Roller Assy 1. Check the Pinch Roller Assy Motor.
Speed Error Motor spins too fast. 2. Check the Main Board.

and
ASF
Errors
153C Pinch Roller Release Rota- The Pinch Roller Assy 1. Check the Pinch Roller Assy Motor.
tion Direction Error Motor spins in the wrong 2. Check the Main Board.
direction.
153D Pinch Roller Release Driv- The Pinch Roller Assy 1. Check the Pinch Roller Assy Motor.
ing Time Out Error Motor does not spin, or 2. Check the Main Board.
spins too long.
153E Pinch Roller Release The Pinch Roller Assy 1. Check the Pinch Roller Assy Motor.
Velocity Deviation Error Motor spins at irregular 2. Check the Main Board.
speeds.
153F Pinch Roller Release The Pinch Roller Assy 1. Check the Pinch Roller Assy Motor.
Under Speed Error Motor spins too slow. 2. Check the Main Board.
1540 Cutter Home Position The Cutter Home Position 1. Check the Cutter Motor.
Detection Error Sensor does not report to 2. Check the Cutter HP Sensor.
the Main Board. 3. Check the Main Board.
1541 Cutter Return Error The Cutter does not return 1. Check the Cutter Motor.
to “Home Position” properly. 2. Check the Cutter HP Sensor.
1549 Cutter Motor Error The Cutter Motor draws no 1. Check the Cutter Motor.
current 2. Check the Main Board.
154A Cutter Motor Over Current The Cutter Motor draws too 1. Check the Cutter Motor.
Error much current 2. Check the Main Board.

and
ASF
Errors
154B Cutter Motor Over Speed The Cutter Motor spins too 1. Check the Cutter Motor.
Error fast. 2. Check the Main Board.
154C Cutter Motor Rotation The Cutter Motor spins in 1. Check the Cutter Motor.
Direction Error the wrong direction. 2. Check the Main Board.
154D Cutter Motor Driving Time The Cutter Motor does not 1. Check the Cutter.
Out Error spin, or spins too long. 2. Check the Main Board.
154E Cutter Motor Velocity Devi- The Cutter Motor spins at 1. Check the Cutter.
ation Error irregular speeds. 2. Check the Main Board.
154F Cutter Motor Under Speed The Cutter Motor spins too 1. Check the Cutter Motor.
Error slow. 2. Check the Main Board.
1551 Paper Thickness Sensor The Paper Thickness Sen- 1. Check the Paper Thickness Sensors.
Error sors do not detect Properly.
155A DCP Motor Over Current The Decompression Motor 1. Check the Decompression Assembly.
Error draws too much current. 2. Check the Main Board.
155B DCP Motor Over Speed The Decompression Motor 1. Check the Decompression Assembly.
Error spins too fast. 2. Check the Main Board.
155C DCP Motor Reversing The Decompression Motor 1. Check the Decompression Assembly.
Error spins in the wrong direction. 2. Check the Main Board.
155D DCP Motor Drive Time Out The Decompression Motor 1. Check the Decompression Assembly.
Error does not spin, or spins too 2. Check the Main Board.
long.

and
ASF
Errors
155E DCP Motor Irregular Veloc- The Decompression Motor 1. Check the Decompression Assembly.
ity Error spins at irregular speeds. 2. Check the Main Board.
155F DCP Motor Under Speed The Decompression Motor 1. Check the Decompression Assembly.
Error spins too slow. 2. Check the Main Board.
1561 Paper Thickness Sensor The paper Thickness Sen- 1. Check the Paper Thickness Sensors.
Power On Error sor detects more that 2. Check the Main Board.
2.2mm at power on.
1562 ASF Motor Abnormal Load The ASF Motor draws too 1. Check the ASF Motor
Error much current 2. Check Sub Board C
156A ASF Motor Over Current The ASF Motor draws too 1. Check the ASF Motor
Error much current 2. Check Sub Board C
156B ASF Motor Over Speed The ASF Motor spins too 1. Check the ASF Motor
Error fast. 2. Check Sub Board C
156C ASF Motor Reversing Error The ASF Motor spins in the 1. Check the ASF Motor
wrong direction 2. Check Sub Board C
156D ASF Motor Drive Time Out The ASF Motor does not 1. Check the ASF Motor
Error spin, or spins too long. 2. Check Sub Board C

and
ASF
Errors
156E ASF Motor Over Irregular The ASF Motor spins at 1. Check the ASF Motor
Velocity Error irregular speeds. 2. Check Sub Board C
156F ASF Motor Under Speed The ASF Motor spins too 11. Check the ASF Motor
Error slow. 2. Check Sub Board C
1571 ASF Retard Roller Sensor The ASF Retard Roller 1. Check the ASF Retard Roller Sensor.
Error Sensor is not operating cor- 2. Check the ASF Sub Motor Assembly.
rectly. 3. Check Sub Board B
1572 ASF Pickup Roller Opera- ASF Pickup Roller is not 1. Check the Pickup Roller HP Sensor.
tion Error operating correctly. 2. Check the ASF Sub Motor Assembly.
3. Check Sub Board B
1573 ASF Assist Roller Opera- ASF Assist Roller is not 1. Check the ASF Assist Roller Sensor.
tion Error operating correctly. 2. Check the ASF Sub Motor Assembly.
157A ASF Sub Motor Overload The ASF Sub Motor draws 1. Check the ASF Sub Motor
Error. too much current. 2. Check Sub Board B

and
ASF
Errors
157B ASF Sub Motor Over The ASF Sub Motor spins 1. Check the ASF Sub Motor
Speed Error. too fast. 2. Check Sub Board B
157C ASF Sub Motor Reversing The ASF Sub Motor spins 1. Check the ASF Sub Motor
Error. in the wrong direction 2. Check Sub Board B
157D ASF Sub Motor Drive Time The ASF Sub Motor does 1. Check the ASF Sub Motor
Out Error. not spin, or spins too long. 2. Check Sub Board B
157E ASF Sub Motor Velocity The ASF Sub Motor spins 1. Check the ASF Sub Motor
Deviation Error. at irregular speeds. 2. Check Sub Board B
157F ASF Sub Motor Under The ASF Sub Motor spins 1. Check the ASF Sub Motor
Speed Error too slow. 2. Check Sub Board B
1581 Paper Eject Roller Posi- The Paper Eject Roller 1 Check the Eject Roller Assembly Home
tion Error Assembly can not change Position Sensor#2.
position correctly. 2. Check the Edge Guide Motor

and
ASF
Errors
1582 ASF Edge Guide Home The ASF Edge Guide 1 Check the ASF Edge Guide Home Posi-
Position Sensor Error Home Position Sensor #1 tion Sensor #1.
is not working correctly. 2. Check the Edge Guide Motor
158A ASF Edge Guide Motor The ASF Edge Guide 1. Check the ASF Edge Guide Motor
Overload Error. Motor draws too much cur- 2. Check Sub Board B
rent. 3. Check the Main Board.
158B ASF Edge Guide Motor The ASF Edge Guide 1. Check the ASF Edge Guide Motor
Over Speed Error. Motor spins too fast. 2. Check Sub Board B
158C ASF Edge Guide Motor The ASF Edge Guide 1. Check the ASF Edge Guide Motor
Reversing Error. Motor spins in the wrong 2. Check Sub Board B
direction 3. Check the Main Board.
158D ASF Edge Guide Motor The ASF Edge Guide 1. Check the ASF Edge Guide Motor
Drive Time Out Error. Motor does not spin, or 2. Check Sub Board B
spins too long. 3. Check the Main Board.
158E ASF Edge Guide Motor The ASF Edge Guide 1. Check the ASF Edge Guide Motor
Velocity Deviation Error. Motor spins at irregular 2. Check Sub Board B
speeds. 3. Check the Main Board.
158F ASF Edge Guide Motor The ASF Edge Guide 1. Check the ASF Edge Guide Motor
Under Speed Error Motor spins too slow. 2. Check Sub Board B

and
ASF
Errors
159A ATC Motor Overload Error. The ATC Motor draws too 1. Check the ATC Motor
much current. 2. Check Sub Board D
159B ATC Motor Over Speed The ATC Motor spins too 1. Check the ATC Motor
Error. fast. 2. Check Sub Board D
159C ATC Motor Reversing The ATC Motor spins in the 1. Check the ATC Motor
Error. wrong direction 2. Check Sub Board D
159D ATC Motor Drive Time Out The ATC Motor does not 1. Check the ATC Motor
Error. spin, or spins too long. 2. Check Sub Board D
159E ATC Motor Velocity Devia- The ATC Motor spins at 1. Check the ATC Motor
tion Error. irregular speeds. 2. Check Sub Board B
159F ATC Motor Under Speed The ATC Motor spins too 1. Check the ATC Motor
Error slow. 2. Check Sub Board D
1801 AID (Auto Ink Detector) The Aid Circuitry is not 1.Check that the AID Grid is clean
Communication Error. working properly. 2. Check the AID Board.
3. Check the Print Head.
Main Explanation Description Remedy

Board
Errors
1A23 RTC Analysis error The RTC data on the Main 1. (initialize the RTC with the
Board is invalid. Servprog.exe ‘s RTC & USB ID Check
and Adjustment routine.
2. Check the Battery.
1A26 RTC Communication Error The RTC circuit on the Main 1. Unplug the Printer.
Board is malfunctioning. 2. Remove the Battery for 30 seconds.
3. Re-install the Battery.
4. (initialize the RTC with the
Servprog.exe ‘s RTC & USB ID Check
and Adjustment routine.
1A37 Thermistor Sensor Error The Thermistor on the 1. Re-seat the Print Head Cables on the
Print Head reports tempera- Main Board side.
ture out of range. 2. Re-seat the Print Head Cables on the
Print Head side.

Board
Errors
1A38 Transistor Environment The Thermistor on the 1. Re-seat the Print Head Cables on the
Temperature Error Print Head reports tempera- Main Board side.
ture out of range. 2. Re-seat the Print Head Cables on the
Print Head side.
1A39 Print Head Error The Print Head reports an 1. Re-seat the Print Head Cables on the
error. Main Board side.
2. Re-seat the Print Head Cables on the
Print Head side.
1A40 IC22 Error The Destination Setting 1. Correct the destination setting.
(Country Setting) on the 2. Replace the Main Board.
Main Board is wrong
1A41 Head Rank Id Input Error Head Rank Data is wrong 1. Perform the Head ID Input and Adjust-
ment.
1A50 Main Board Error Main Board error 1. Check the Main Board
1A51 Carriage Board Error Carriage Board does not 1. Check the Carriage Board.
communicate with the Main 2. Check the Main Board
Board.
1AB0 Main Board Communica- IC failure on the Main 1.Replace the Main Board
tion Error Board.

Board
Errors
tion Error Board.
tion Error Board.
tion Error Board.
tion Error Board.
tion Error Board.
tion Error Board.
tion Error Board.
1F80 ILS Control Error (1) A fuse located on the Main 1.Replace the Main Board.
Board (protecting the Ink
Limit Sensor) is not func-
tioning properly.
1FB8 ILS Error (2) The Ink Limit Sensor and 1. Check the Ink Cartridges.
the Main Board are not 2. Check the Ink Holders.
communicating properly. 3. Check the Main Board.

Board
Errors
1FB9 CSIC Error (1) The Main Board can not 1. Check the Main Board.
interpret CSIC data cor-
rectly.
1FBE CSIC Error (2) CSIC data can not be read 1. Check in Ink Cartridge CSIC.
correctly. 2. Check the CSIC Contacts for the Car-
tridge Slot.
3. Check the CSIC Sub Board on the Ink
Holder.
5. Check the Ink Bay.
1FBF CSIC Error (3) CSIC data can not be read 1. Check in Ink Cartridge CSIC.
tridge Slot.
Holder.
1FC0 CSIC Error (4) CSIC data can not be read 1. Check in Ink Cartridge CSIC.
tridge Slot.
Holder.

Board
Errors
tridge Slot.
Holder.
tridge Slot.
Holder.
tridge Slot.
Holder.
1FC4 ILS Error (3) The ILS and the Main ?
Board are not communicat-
ing properly.

Board
Errors
ing properly.
ing properly.
ing properly.
ing properly.
1A39 Print Head Error The Head Rank is not cor- 1. Re-enter the Head Rank.
rectly stored on the Main 2. Check the Main Board.
Board.
1A41 Head Rank ID Error Board Error Replace the Main Board
1A50 Main Board Communica- Main Board Error 1. Replace the Main Board
tion Error
1A51 Main Board to Sub Board The Main Board and a Sub 1. Check all Sub Board Cables.
Communication Error Board are not communicat- 2. Check the Sub Boards.
ing correctly. 3. Check the Main Board.
1AB0 Main Board Communica- Main Board Error 1. Replace the Main Board
tion Error (0)

Board
Errors
tion Error (1)
tion Error (2)r
tion Error (3)
tion Error (4)
tion Error (5)
Printer Error Codes (SpectroProofer)

Error Error Name Description Remedy
Code
01 SpectroProofer Instal- The SpectroProofer or the 1. Check the Backing Plate.
lation Error Backing Plate is not installed 2. Check the SpectroProofer.
correctly.
02 Paper Eject Support The Paper Eject Support is 1. Check the Paper Eject Support.
installation Error not installed correctly.
13 Paper Pressing Plate The Paper Pressing Plate 1. Check for proper Paper Pressing Plate
Movement Error does not move correctly. movement (binding).
2. Check the Paper Pressing Plate Motor.
14 Paper Pressing Plate The Paper Pressing Plate 1. Verify movement of the Paper Pressing
Home Position Error Home Position Sensor does Plate.
not detect correct movement 2. Check the Paper Pressing Plate Home
of the Plate. Position Sensor.
15 Carriage Home Posi- The Carriage Home Posi- 1. Check the correct installation of the
tion Error tion Sensor does not detect Backing Plate.
correct movement of the Car- 2. Check the correct installation of the Cali-
riage Mechanism. bration Tile.
3. Check for proper Carriage Mechanism
movement (binding).
4. Check for proper Paper Pressing Plate
movement (binding).
Printer Error Codes (SpectroProofer) Printer Component, Software Item, LCD Display, Printer Button Page 246.
Error Error Name Description Remedy

Code
16 Paper Pressing Plate The Paper Pressing Plate 1. Check for proper Paper Pressing Plate
Movement Error does not move correctly. movement (binding).
2. Check the Paper Pressing Plate Motor.
65 Drying Fan Error. The Drying Fan does not 1. Check for proper Drying Fan.
move correctly.
80 ILS Calibration Error The ILS (SpectroProofer 1. Check the Calibration Tile.
Head) can not calibrate. 2. Check the ILS.
3. Check the SpectroProofer.
D5 SpectroProofer Car- The SpectroProofer Car- 1. Check for proper Carriage movement
riage Error riage does not initialize cor- (binding).
rectly.
D6 Paper Pressing Plate The Paper Pressing Plate 1. Check for proper Paper Pressing Plate
Operation Error Encoder does not detect the movement (binding).
correct timing for movement 2. Check the Paper Pressing Plate Motor.
of the Plate. 3. Check the Main Board.
Printer Error Codes (SpectroProofer) Printer Component, Software Item, LCD Display, Printer Button Page 247.
AID Function Check

Note: The AID Function Check tests the Printer’s Auto Ink Detection (AID) operation.
Note: This check / test requires that all nozzles on the printer are functional.
1. AID Function Check.
1. From the Servprog.exe for the

4900,Select Adjustments (Indi-
vidual).
AID Function Check Printer Component, Software Item, LCD Display, Printer Button Page 248.
2. AID Function Check (continued).
2. Expand the Boards Related

Checks & Adjustments menu.
3. Select AID Function Check.
4. Click on OK.
3. AID Function Check (continued).
5. Select AID Function

Check.
6. Click on Run.
4. Serial Number (continued).
7. Ok.
8. Click on Finish.
CR Encoder and Scale Check

Note: The CR Encoder and Scale Check tests the operation of the Carriage Encoder and Scale (Timing
Strip).
1. CR Encoder and Scale Check.

vidual).
CR Encoder and Scale Check Printer Component, Software Item, LCD Display, Printer Button Page 252.
2. CR Encoder and Scale Check (continued).
2. Expand the CR Related Check &

Adjustments menu.
3. Select CR Encoder and Scale Check.
4. Click on OK.
3. CR Encoder and Scale Check (continued)
5. Click on Run.
6. The Printer will move the Carriage for a time analyzing the operation of the Carriage Encoder.
4. CR Encoder and Scale Check (continued)
7. Click on OK.
8. Click on Finish.
Note: If the test is not successful:

1. Clean or replace the Encoder Strip, and test again.
2. Replace the Carriage Encoder, and test again.
Fan Noise Fix

Fan Noise Fix Printer Component, Software Item, LCD Display, Printer Button Page 256.
4. Remove 5 Screws.
Remove 5 Screws.
6. Slide out the left side of the Board Assembly exposing the Print Head Driver Cooling Fan.
Remove 3 Screws that fasten the Print Head Driver Cooling Fan
7. Place 3 O-rings on the 3 Screws.
Place 3 O-rings onto the 3 Screws that fasten the Fan to the Board.
8. Re-install the Fan, with the O-rings installed, to dampen vibration noise.
9. Re-install the Board Assembly and replace the Rear Cover.
Ink Mark Sensor Check

Note: The Ink Mark Sensor Check tests the Ink Mark Sensor’s operation.
1. Ensure that cut sheet media is loaded in the Paper Cassette.
2. Ink Mark Sensor Check.

vidual).
Ink Mark Sensor Check Printer Component, Software Item, LCD Display, Printer Button Page 261.
3. Ink Mark Sensor Check (continued).

Adjustments menu.
3. Select Ink Mark Sensor Check and

Adjustment.
4. Click on OK.
4. Ink Mark Sensor Check (continued)
5. Select IMS Sensibil-

ity Check.
6. Click on Run.
Note: Cut sheet media in the Paper Cassette is necessary to perform this test.
7. The Printer will test the Ink Mark Sensor and print the results.
8. This OK indicates the test was successful.
9. Click on Finish.
Missing Nozzle Diagnosis

Note: It is important to completely clean the Printer before following the troubleshooting advice in this
chapter. This is because a dirty printer will cause any of the symptoms listed. Follow the cleaning
advice in the Service Procedure chapter in the reference section.
Definitions
Channel: a column of 360 nozzles.
Color Pair: 2 channels that clean simultaneously. There are 5 color pairs on the 4900.
Reverse Flow: a term describing a condition that exists after a strong cleaning cycle. The Ink System pulls back-
wards drawing air into the Print Head’s Nozzle Plate. The air in the Nozzle Plate causes missing
nozzles until the air is expelled.
Overview
There are 4 categories of Missing Nozzles. Read them all, and decide which scenario fits the issue.
1 or More Channel Missing (completely, or almost completely).

The most likely cause is an Ink supply issue. The ink is not reaching the Print Head effectively.
1. Perform a CL3 using Servprog.exe (Strongest cleaning from the service utility).
The purpose of the CL3 cleaning cycle is to remove any air in the Dampers that might restrict ink flow.
2. Replace the related Damper. It is recommended that you replace all 5 Dampers.
3. Replace the related Ink Cartridge(s).
4. Replace the Print Head. (Perform steps 4 and 5 in the order that makes economic sense to you.
Both steps 3 and 4 are “long shots”.
Missing Nozzle Diagnosis Printer Component, Software Item, LCD Display, Printer Button Page 266.
Note: If this symptom is caused by the Print Head, then the ink inlet for the missing channel is clogged.
It can be verified by gently injecting water into the suspected inlet. If the channel accepts water,
the Print Head is probably not the issue. Because of the cost of the Print Head, verification is
recommended.
5. Replace the related Ink Bay.
All Channels Missing (completely, or almost completely)

This symptom can be caused by Ink Supply issues, Main Board issues, or Cleaning Issues.
1. Execute a “color pair” cleaning (try multiple color pairs), and observe the Waste Ink Tube (Ink Exit
Tube) from the Cleaning Unit.
1.1 If the ink flow in the Waste Ink Tube looks normal, replace the Main Board.
1.2 If the ink flow in the Waste Ink Tube does not look normal, replace the Cleaning Unit.
Some Nozzles Missing (but not all) (1 or more channels)

This condition is normal after a period of inactivity. It can also indicate a defective Print Head. It is
complicated by “reverse flow”. This procedure describes how to differentiate the issue.
1. Perform a Nozzle Check and mark it as #1.
2. Perform a “color pair” cleaning cycle on the missing nozzles.
3. Perform a Nozzle Check and mark it as #2.

3.1 Compare Nozzle Check 1 to 2.
3.1.1 If the missing nozzles on nozzle check 1 have cleared up, and new ones have appeared:
3.1.1.1 Stop Cleaning, this is reverse flow.
3.1.1.1.1 Print a sample print (Stress Test is recommended) that uses all colors to “print
out” the air that is in the Nozzle Plate.
3.1.2 If one or more nozzles have not cleared up:
3.1.2.1 Repeat steps 1 - 3.
3.1.2.1.1 If 3 cleaning cycles does not clear up 1 or more of the same nozzles, replace
the Print Head.
Note: If the same nozzle or nozzles are always missing, this indicates that the Print Head has a problem
mechanically or electrically.
Some Nozzles Drop Out While Printing (1 or more channels)

Nozzle drop out while printing indicates a ink supply issue. The Print Head demands ink during the
printing process, and the Ink System does not deliver it properly. The Print Head slowly “starves” for
Ink. A cleaning cycle delivers a much stronger demand on the Ink System and will refill the Print Head
with Ink. The process of printing will once again “starve” the Print Head.
1. Determine the amount of printing that it takes for the Nozzles to drop out.
1.1 Note that interval.
2. Perform a CL3 using Servprog.exe (Strongest cleaning from the service utility).
2.1 Perform a nozzle check and ensure that all of the nozzles are working.
The purpose of the CL3 cleaning cycle is to remove any air in the Dampers that might restrict ink flow.
3. Print until the interval in step 1 has been exceeded (2 times the interval is recommended).
4. If the issue persists, replace the related Damper. It is recommended that you replace all 5
Dampers.
PF Encoder and Scale Check

Note: The PF Encoder and Scale Check tests the operation of the Paper Feed Encoder and Scale
(Timing Disk).
1. Ensure that roll media is not loaded.
2. PF Encoder and Scale Check.

vidual).
PF Encoder and Scale Check Printer Component, Software Item, LCD Display, Printer Button Page 269.
3. PF Encoder and Scale Check (continued).
2. Expand the Media Feed Related

Checks and Adjustments menu.
3. Select PF Encoder and Scale Check.
4. Click on OK.
4. PF Encoder and Scale Check (continued)
5. Select Auto Check.
6. Click on Run.
7. The Printer will rotate the Paper Feed Roller for a time, analyzing the operation of the PF Encoder.
5. PF Encoder and Scale Check (continued)
8. Click on OK.
9. Click on Finish.
Note: If the test is not successful:

1. Clean or replace the Encoder Disk, and test again.
2. Replace the Paper Feed Encoder, and test again.
Adjustments
Active Damper Adjustment

Note: The Active Damper Adjustment calibrates the Carriage Motor to minimize Carriage vibration and
limit vertical banding.
1. Active Damper Adjustment.

vidual).
Active Damper Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 274.
2. Active Damper Adjustment (continued).

Adjustments menu.
3. Select Active Damper Adjustment.
4. Click on OK.
3. Active Damper Adjustment (continued)
5. Click on Run.
6. The Printer will move the Carriage for a time analyzing the current draw of the Carriage Motor.
4. Active Damper Adjustment (continued)
7. Click on OK.
8. Click on Finish.
APG Motor Counter (Clear)

Note: APG Motor Counter (Clear) resets the Auto Platen Gap Motor Life Counter.
1. APG Motor Counter.

4900,Select FLAG CHANGE &
COUNTER RESET.
APG Motor Counter (Clear) Printer Component, Software Item, LCD Display, Printer Button Page 278.
2. APG Motor Counter (continued).
2. Expand the Printer Mecha Parts

Related Counters menu.
3. Select APG Motor Counter.
4. Click on OK.
This is the current

value of the life coun-
ter.
5. Click on Run.
4. APG Motor Counter (continued)
6. Click on OK.
7. Click on OK.
7. Click on Finish.
Auto Bi-D Adjustment

Note: The Auto Bi-Di Adjustment calibrates the Printer’s horizontal dot placement when printing bi-
directionally (printing when the carriage is traveling right to left, and left to right).
1. Load high quality coated media (photo media is recommended).
2. Auto Bi-D Adjustment.

vidual).
Auto Bi-D Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 283.
3. Auto Bi-D Adjustment (continued).
2. Expand the Head Related Check &

Input menu.
3. Select Auto Bi-D Adjustment.
4. Click on OK.
4. Auto Bi-D Adjustment (continued)
5. Click on Run.
6. The utility will display

this while it is adjust-
ing the Printer.
7. Click on OK.
8. Click on Finish.
CR Belt Adjustment
Note: The CR Belt Adjustment ensures the proper tension on the Carriage Belt.
Note: This adjustment procedure requires a Sonic Tension Meter to measure the “pitch” of the Belt
when it is at the correct tension.
2. Input the following values into the Sonic Tension Meter.

2.1 Mass: 000.9 g/m
2.2 Width: 005.5 mm/R
2.3 Span: 0710 mm
CR Belt Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 288.
3. Adjust the CR Belt Tension.

1. Place the Sonic Tension Meter Micro-
phone as shown.
2. Press the Measure button on the Ten-

sion Meter.
3. Gently “pluck” the CR Belt to cause it to

vibrate.
4. Check the value displayed / Measured

by the Tension Meter. The correct value
is 14.5 plus or minus 1N
5. Loosen 3 Screws that fasten CR Belt

Tension Assembly.
6. Adjust the CR Belt tension using the

Tension Adjustment Screw.
7. Repeat steps 2 - 6 until correct.
8. Tighten the 3 Screws that fasten CR

Belt Tension Assembly.
CR Belt Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 289.
CR Motor Counter (Clear)

Note: CR Motor Counter (Clear) resets the Carriage Motor Life Counter.
1. CR Motor Counter.

COUNTER RESET.
CR Motor Counter (Clear) Printer Component, Software Item, LCD Display, Printer Button Page 290.
2. CR Motor Counter (continued).

3. Select PF Motor Counter.
4. Click on OK.
This is the current

ter.
5. Click on Run.
4. CR Motor Counter (continued)
6. Click on OK.
7. Click on OK.
7. Click on Finish.
CR Slant Adjustment
Note: The CR Slant Adjustment corrects the Print Head’s rotation, ensuring that Nozzle 1 for black is
linear with Nozzle 1 for Magenta (same vertical position).
1. Load media (roll or cut sheet).
2. CR Slant Adjustment.

vidual).
CR Slant Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 295.
3. CR Slant Adjustment (continued).

Input menu.
3. Select CR & PF Direction Slant

Adjustment.
4. Click on OK.
4. CR Slant Adjustment (continued)
5. Select CR Direction
Slant Check Pattern
Print.
6. Click on Run.
7. Click on OK.

This is what the correct pattern looks like. If the pattern looks like this, move the CR Slant Dial
Clock Wise.
Paper feed
direction
Leading Edge
If the pattern looks like this, move the CR Slant Dial

Counter Clock Wise.
Leading Edge
Leading Edge
8. Inspect the pattern and determine which direction to turn the CR Slant Dial.
7. CR Slant Adjustment (continued.
10. Turn the CR Slant Dial in the direction

9. Loosen 3 Screws 1/4 turn each. Leave the 3 Screws
determined in Step 8.
loose until fully adjusted.
11. Repeat Steps 4 - 10 until the alignment pattern is 12. Tighten the 3 Screws loosened in Step 9.
correct.
13. Reprint the alignment pattern to verify that the CR Slant Adjustment did not change when the 3
Screws were tightened.
8. CR Slant Adjustment (continued).
14. Click on Finish.
Pro 4900 Field Repair Guide
CR Speed Auto Adjustment

Note: The CR Speed Auto Adjustment analyses the combined characteristics of the Carriage Motor, CR
Encoder, and the Carriage Mechanism. A value is written to the Board and used to increase
Carriage movement accuracy.
1. CR Speed Auto Adjustment.

vidual).
CR Speed Auto Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 302.
2. CR Speed Auto Adjustment (continued).

Adjustments menu.
3. Select CR Speed Auto Adjustment.
4. Click on OK.
3. CR Speed Auto Adjustment (continued)
5. Click on Run.
4. CR Speed Auto Adjustment (continued)
7. Click on OK.
8. Click on Finish.
Cutter Belt Tension Adjustment

Note: The Cutter Belt Tension Adjustment ensures the proper tension for the Cutter Belt.
1. Remove the Cutter Assembly.

2.1 Mass: 001.1 g/m
2.2 Width: 004.0 mm/R
2.3 Span: 0620 mm
Cutter Belt Tension Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 306.
3. Adjust the Cutter Belt Tension.

phone as shown.

sion Meter.
3. Gently “pluck” the Cutter Belt to cause it

to vibrate.

is 14.5 plus or minus 1N
5. Loosen 1 Screws that fastens Cutter

Belt Tension Assembly.
6. Adjust the Cutter Belt tension and

tighten 1 Screw.
Cutter Belt Tension Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 307.
Head Cap Counter (Clear)

Note: Head Cap Counter (Clear) resets the Print Head “parking” Cap Life Counter.
1. Head Cap Counter.

COUNTER RESET.
Head Cap Counter (Clear) Printer Component, Software Item, LCD Display, Printer Button Page 308.
2. Head Cap Counter (continued).
2. Expand the Printer Ink Parts

3. Select Head Cap Counter.
4. Click on OK.
This is the current

ter.
5. Click on Run.
4. Head Cap Counter (continued)
6. Click on OK.
7. Click on OK.
8. Click on Finish.
Head ID Input Adjustment

Note: Head Rank Input writes the Print Head Calibration Value (Head ID / Head Rank) to the Main Board.
Note: Enter the Head Rank before installing a new Print Head. This way it is possible to enter the data
directly off the Print Head. Otherwise, it is necessary to write down the data before installing the
Print Head.
1. Identify the Head ID.
Use only the 45 digits within the red lines. Enter the 45 digits within the red lines in this order.
Head ID Input Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 313.
2. Head ID Input Adjustment.

vidual).
3. Head ID Input Adjustment (continued).

Input menu.
3. Select Head ID Check and Input.
4. Click on OK.
4. Head ID Input Adjustment (continued)
5. Enter the Head ID.
6. Click on Write.
Note: If the utility dis-

plays:
Head Rank ID
Input contains
wrong charac-
ters)..., one or more
of the digits entered
is incorrect. Check
that an Zero was not
entered as a O, etc.
5. Head ID Input Adjustment (continued).
7. Click on OK.
8. Click on Finish.
Note: Additional
information
on the next
page.
6. Head ID Input Adjustment (continued)
Note: Click on Read to display the current Head ID. The utility will read it from the Main Board.
Initial Ink Charge

Note: Initial Ink Charge initiates or cancels the priming of the Printers Ink System.
1. Initial Ink Charge.

COUNTER RESET.
Initial Ink Charge Printer Component, Software Item, LCD Display, Printer Button Page 319.
2. Initial Ink Charge (continued).
2. Expand the Flag Status Modifica-

tion menu.
3. Select Initial Ink Charge.
4. Click on OK.
3. Initial Charge (continued).
Select ON to initiate
an initial charge the
next time the Printer
is turned on.
Select OFF to Cancel
an initial charge the
next time the Printer is
turned on.
5. Click on Run.
4. Initial Charge (continued)
6. Click on OK.
5. Initial Charge (continued).
7. Click on OK.
8. Turn the Printer off,

and then on to start the
charge.
9. Click on Finish.
Ink Eject and Initial Charge

Note: The Ink Eject Procedure is used to remove ink from the Ink System.
Note: The Initial Charge Procedure is used to fill the Ink System with ink.
1. Turn on the Printer in Self Testing Mode (Down, Right, and OK, at power on).
2. Ink Eject and Initial Charge.

vidual).
Ink Eject and Initial Charge Printer Component, Software Item, LCD Display, Printer Button Page 324.
3. Ink Eject and Initial Charge (continued).
2. Expand the Ink Supply Related

3. Select Ink Eject and Initial Charge.
4. Click on OK.
4. Ink Eject and Initial Charge (continued)
5. Select Ink Eject or Ink

Charge.
6. Select the Right, Left,

or both Ink Holders.
7. Click on Run and follow

the directions dis-
played.
8. Click on Finish when

completed.
Ink Holder Full Side [L] Counter (Clear)

Note: The Ink Holder Full Side [L] Counter (Clear) resets the Left Ink Holder Life Counter.
1. Ink Holder [L] Counter.

COUNTER RESET.
Ink Holder Full Side [L] Counter (Clear) Printer Component, Software Item, LCD Display, Printer Button Page 327.
2. Ink Holder [L] Counter (continued).

3. Select Ink Holder Full Side [L] Coun-

ter.
4. Click on OK.
This is the current

ter.
5. Click on Run.
4. Ink Holder [L] Counter (continued)
6. Click on OK.
7. Click on OK.
8. Click on Finish.
Ink Holder Home Side [R] Counter (Clear)

Note: The Ink Holder Home Side [R] Counter (Clear) resets the Right Ink Holder Life Counter.
1. Ink Holder [R] Counter.

COUNTER RESET.
Ink Holder Home Side [R] Counter (Clear) Printer Component, Software Item, LCD Display, Printer Button Page 332.
2. Ink Holder [R] Counter (continued).

3. Select Ink Holder Home Side [R]

Counter.
4. Click on OK.
This is the current

ter.
5. Click on Run.
4. Ink Holder [R] Counter (continued)
6. Click on OK.
7. Click on OK.
8. Click on Finish.
Ink Mark Sensor Adjustment

Note: The Ink Mark Sensor Adjustment calibrates the Ink Mark Sensor’s operation.
1. Ensure that cut sheet media is loaded in the Paper Cassette.
2. Ink Mark Sensor Adjustment.

vidual).
Ink Mark Sensor Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 337.
3. Ink Mark Sensor Adjustment (continued).

Adjustments menu.
3. Select Ink Mark Sensor Check and

Adjustment.
4. Click on OK.
4. Ink Mark Sensor Adjustment (continued)
5. Select IMS Position

Auto Correction.
6. Click on Run.
Note: Cut sheet media in the Paper Cassette is necessary to perform this Adjustment.
7. The Printer will print this pattern and read it with the Ink Mark Sensor.
Note: This pattern will be used to set levels and horizontal

positioning data, calibrating the Ink Mark Sensor.
8. Click on Finish.
Ink Selector Assy Counter (Clear)

Note: The Ink Selector Assy Counter (Clear) resets the Ink Selector (Damper Assembly) Life Counter.
1. In Selector Counter.

COUNTER RESET.
Ink Selector Assy Counter (Clear) Printer Component, Software Item, LCD Display, Printer Button Page 342.
2. Ink Selector Counter (continued).

3. Select Ink Selector Assy Counter.
4. Click on OK.
This is the current

ter.
5. Click on Run.
4. Ink Selector Counter (continued)
6. Click on OK.
7. Click on OK.
8. Click on Finish.
IS Unit Counter (Clear)

Note: IS Unit Counter (Clear) resets the Cleaning Unit Life Counter.
1. IS Unit Counter.

COUNTER RESET.
IS Unit Counter (Clear) Printer Component, Software Item, LCD Display, Printer Button Page 347.
2. IS Unit Counter (continued).

3. Select IS Unit Counter.
4. Click on OK.
This is the current

ter.
5. Click on Run.
4. IS Unit Counter (continued)
6. Click on OK.
7. Click on OK.
8. Click on Finish.
MAC Address Check & Input

Note: The Mac Address Check & Input adjustment writes the Printer’s MAC Address to the Main Board.
1. Locate the Printer’s MAC Address.

This view is of the inside of the
printer, by the Ink Tubes that run
from the Left Ink Bay to the Print
Head.
Printer’s MAC Address sticker
Note: Epson Recommends that you follow the following steps 2 - 8 exactly.
2. Disable all firewall protection on the computer being used.
MAC Address Check & Input Printer Component, Software Item, LCD Display, Printer Button Page 352.
3. Connect the printer by USB and verify the connection.
4. Connect the Printer directly (standard ethernet cable, no hub or router). Do not disconnect the
USB connection.
5. Load paper and turn on the Printer and verify that it is “Ready”.
6. Run Epson Net Config, and set the following manual IP address.
1. Set Manual
2. IP:169.254.1.2
3. SM:255.255.0.0
4. DG:255.255.255.255
5. Send
7. Reboot the Printer, and verify that it is “Ready”.
8. From the Servprog.exe for the 4900, select ADJUSTMENTS (Individual).
Click on Adjustments (Individual)
9. From the Boards Related Checks and Adjustments menu, select MAC Address Check & Input.
1. Click on MAC Address Check &

Input.
2. Click on OK.
10. Adjust the displayed data.
1. Place cursor to the

right of the 4.
2. Hit the Left Arrow

key on your key-
board to display the
11. Write the MAC Address to the Printer.
1. Enter the last 6 digits

of the Printer’s MAC
Address here.
2. Click on Write. It will

take a few minutes
to complete. If it
fails, try again.
12. Write the MAC Address to the Printer (continued).
4. Click on OK to com-
plete.
5. Click on Finish.
Note: if the procedure fails, reboot the Printer, verify that it is “Ready”, and retry.
6. Run Epson Net Config and reset the Printer’s IP settings to the users preference.
Media Eject Adjustment

Note: The Media Feed Adjustment calibrates the Media Feed Mechanism. It requires the use of A4
Enhanced Matte cut sheet media.
1. Ensure that A4 Enhanced Matte media is loaded in the Paper Cassette.
2. Media Eject Adjustment.

vidual).
Media Eject Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 359.
3. Media Eject Adjustment (continued).

Check and Adjustments menu.
3. Select Media Eject Correction Check

& Adjustments.
4. Click on OK.
4. Media Eject Adjustment (continued)
5. Click on Print.
5. Media Eject Adjustment (continued)
6. Click on OK.

Note: A4 Enhanced Matte cut sheet media is necessary for this adjustment.
7. The Printer will print this pattern. 0 represents the current adjustment value.
The numbers in
brackets repre-
sent choices
between the
printed rectan-
gles.
8. Identify the pattern that has the least overlap ore underlap and note the
value that corresponds to it.
Over Lap
Under Lap
Note: If none of the patterns are acceptable,
pick the best one and reprint the
pattern.
7. Media Feed Adjustment (continued).
9. Enter the number that

represents the “best”
pattern.
10. Click on Write.
11. Click on OK.
Media Feed Adjustment

Note: The Media Feed Adjustment calibrates the Media Feed Mechanism. It requires the use of A4
Enhanced Matte cut sheet media.
1. Ensure that Enhanced Matte cut sheet media is loaded in the Paper Cassette.
2. Media Feed Adjustment.

vidual).
Media Feed Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 366.

3. Select Media Feed Correction Check

& Adjustments.
4. Click on OK.
4. Media Feed Adjustment (continued)
5. Click on Print.
5. Media Feed Adjustment (continued)
6. Click on OK.

Note: A4 Enhanced Matte cut sheet media is necessary for this adjustment.
7. The Printer will print this pattern. This rectangle represents the current adjustment value.
The numbers in
brackets represent
choices between the
printed rectangles.
8. Identify the rectangle that is the “most solid”, and

note the corresponding number.
Note: If none of the rectangles are

acceptable, pick the best one and
reprint the pattern.
Correct Pattern Incorrect Pattern
9. Enter the number that

represents the “best”
rectangle.
10. Click on Write.
11. Click on OK.
Motor Measurement Adjustment

Note: The Motor Measurement Adjustment analyzes the electrical characteristics of the Carriage Motor,
the Paper Feed Motor, and/or the Ink System Motor and writes the appropriate data to the Main
Board.
1. Motor Measurement Adjustment.

vidual).
Motor Measurement Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 373.
2. Motor Measurement Adjustment (continued).
2. Expand the Other Printer Checks

and Adjustments menu.
3. Select Motor Measurement Adjust-

ment.
4. Click on OK.
5. Select CR Motor Mea-

surement Adj, (or PF
Motor Measurement
Adj, or IS Motor Mea-
surement Adj).
6. Click on Run.
7. The Printer will run the

Motor, analyze it’s
electrical characteris-
tics, and write the
appropriate data to the
Main Board.
8. Ok.
9. Click on Finish.
NV-RAM BACKUP UTILITY

Note: The NV-RAM BACKUP UTILITY “backs up” and restores the unique data that is on each Printer’s
Main Board, and should be transferred to a new Main Board.
Note: For a detailed description of the NV-RAM Backup Utility see the NVRAM Utility chapter in the
Utility section.
NV-RAM BACKUP UTILITY Printer Component, Software Item, LCD Display, Printer Button Page 377.
Paper Thickness Sensor Adjustment

Purpose: The Paper Thickness Sensor Adjustment calibrates the Paper Thickness Sensor so that it correctly rec-
ognizes 3 different thickness ranges of media. The Paper Thickness Sensor does not measure the thick-
ness of inserted media, it determines the “thickness range” of the media.
Special Tools: The Paper Thickness Sensor Adjustment requires 3 thickness gauges.
.4mm .5mm .8mm
1. Remove the Cover (Top).
2. Enter Self Testing mode: Down, Right, and OK buttons, and turn on the Printer.
3. Navigate to SELF TESTING\Mecha Adjustment\Paper
4. Press the Right Arrow to display the Sensor data.

4.1 Navigate to ServiceMan Mode: SELF TESTING\Adjustment\Paper\Paper Thick 00.
Currently the Sensor data = 00
Paper Thickness Sensor Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 378.
5. Using the Pinch Roller Release button, place the 0.4mm thickness gauge in position.
1. Press the Pinch Roller

Release button to open the
Pinch Rollers.
2. Place the .4mm thickness gauge under the 5th and 6th Pinch Rollers
from the right, and the Paper Feed Roller.
3. Press the Pinch Roller

Release button to close the 4. The Printer will close the Pinch Rollers on the gauge.
Pinch Rollers.
6. Adjust until the conditions are true for each of the 4 gauges.
0 direction
Left digit Right digit
1 direction
00 = When the 0.4mm thickness gauge is inserted.

11 = When the 0.4+0.8 thickness gauges combined are inserted.
10 = When the Pinch Roller Release Mechanism is open.
1. Insert the gauges and check that the 4 conditions listed above are true.
2. If the conditions listed are not true, loosen the fastening screws, and move the sensor
positions until they are true.
PF Belt Adjustment
Note: The PF Belt Adjustment ensures the proper tension on the Paper Feed Belt.

2.1 Mass: 001.4 g/m
2.2 Width: 006.0 mm/R
2.3 Span: 0093 mm
PF Belt Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 381.
3. Adjust the PF Belt Tension.

phone as shown.

sion Meter.
3. Gently “pluck” the PF Belt to cause it to

vibrate.

is 13 plus or minus 1.5N
5. Loosen 2 Screws and adjust the PF

Belt Tension as necessary.
7. Rotate the Paper Feed Gear (with the

Encoder Disk) 180 degrees and measure
again. Re-adjust tension if necessary.
PF Belt Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 382.
PF Motor Counter (Clear)

Note: PF Motor Counter (Clear) resets the Paper Feed Motor Life Counter.
1. PF Motor Counter.

COUNTER RESET.
PF Motor Counter (Clear) Printer Component, Software Item, LCD Display, Printer Button Page 383.
2. PF Motor Counter (continued).

3. Select PF Motor Counter.
4. Click on OK.
This is the current

ter.
5. Click on Run.
4. PF Motor Counter (continued)
6. Click on OK.
7. Click on OK.
8. Click on Finish.
PF Slant Adjustment
Note: The Print Head Slant Adjustment (PF) adjusts the Print Head’s “heel / toe” parallelism (for each
color, Nozzle 1 and Nozzle 360 are equal distance from the media).
Note: The PF Slant adjustment is not impacted by Print Head exchange. It is impacted by Carriage
exchange.
1. Load media (roll or cut sheet).
2. PF Slant Adjustment.

vidual).
PF Slant Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 388.
3. PF Slant Adjustment (continued).

Input menu.
3. Select CR & PF Direction Slant

Adjustment.
4. Click on OK.
4. PF Slant Adjustment (continued)
5. Select PF Direction
Slant Check Pat-
tern Print.
6. Click on Run.
7. Click on OK.

If the pattern looks like this, move the PF Adjust-
ment Lever to the Left.
Paper feed
direction
This is what the correct pattern looks like.
Leading Edge
If the pattern looks like this, move the PF

Adjustment Lever Right.
Equal Gap.
Leading Edge
Leading Edge
8. Inspect the pattern and determine which direction to move the PF Adjustment Lever.
7. PF Slant Adjustment (continued.
9. Move the PF Adjustment Lever in the direction determined in Step 8.
10. Repeat Steps 4 - 9until the alignment pattern is correct.
8. PF Slant Adjustment (continued).
Printhead Counter (Clear)

Note: Printhead Counter (Clear) resets the Print Head Life Counter.
1. Print Head Counter.

COUNTER RESET.
Printhead Counter (Clear) Printer Component, Software Item, LCD Display, Printer Button Page 395.
2. Print Head Counter (continued).

3. Select Head Cap Counter.
4. Click on OK.
This is the current

ter.
5. Click on Run.
4. Print Head Counter (continued)
6. Click on OK.
7. Click on OK.
8. Click on Finish.
PW + T&B&S Adjustment
Note: The PW + T&B&S Adjustment calibrates the Edge Detector Sensor, and ensures that the media
margins are correct. The Edge Detector Sensor measures media and detects the leading edge. It
requires the use of A4 Enhanced Matte cut sheet media.
1. Ensure that A4 Enhanced Matte cut sheet media is loaded in the Paper Cassette.
2. PW + T&B&S Adjustment.

vidual).
PW + T&B&S Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 400.
3. PW + T&B&S Adjustment (continued).

3. Select Media Eject Correction Check

& Adjustments.
4. Click on OK.
4. PW + T&B&S Adjustment (continued)
5. Click on PW Adjust.
6. The Printer will load a

sheet of media and
measure it, calibrat-
ing the Edge Detec-
tor.
7. Click on OK
8. Click on OK
9. Click on OK
Right Side Margin

Left Side Margin
10. Measure and note the 4 margins shown above.
11. Enter the 4 values

measure in Step 10.
12. Click on Write.
11. Click on OK.
Rear AD Sensor Adjustment

Purpose: The Rear AD Sensor Adjustment calibrates the RearAD Sensor so that it correctly recognizes media. The
RearAD Sensor detects media in the Printer. It also reports the end of the media.
Special Tools: Special media is not required. Non-reflective media works well. It is acceptable to use the customers
media if they are having trouble with the Printer recognizing it. Do not use glossy (reflective)
media.
2. Navigate to SELF TESTING\Mecha Adjustment\RearAD
3. Press the Right Arrow to display the [Enter] Start.
4. Place media in to position and sample it to adjust the Rear AD Sensor.

Note: This picture shows the Printer without
the Top Cover. It is not necessary to
remove the Top Cover.
1. Place the media in the paper path of the Printer.
2. Press the OK button to sample the media.
3. The Printer’s LCD will display a value when

finished.
Rear AD Sensor Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 409.
Roll Feeding Motor Counter (Clear)

Note: Roll Feeding Motor Counter (Clear) resets the Roll Feed Motor Life Counter.
1. Roll Feeding Motor Counter.

COUNTER RESET.
Roll Feeding Motor Counter (Clear) Printer Component, Software Item, LCD Display, Printer Button Page 410.
2. Roll Feeding Motor Counter (continued).

3. Select Roll Feeding Motor Counter.
4. Click on OK.
This is the current

ter.
5. Click on Run.
4. Roll Feeding Motor Counter (continued)
6. Click on OK.
7. Click on OK.
8. Click on Finish.
RTC & USB ID Check and Adjustment

Note: The RTC & USB ID Check and Adjustment sets the Printer’s System Clock and/or resets the USB
ID.
1. RTC & USB Adjustment.

vidual).
RTC & USB ID Check and Adjustment Printer Component, Software Item, LCD Display, Printer Button Page 415.
2. RTC & USB Adjustment (continued).

3. Select RTC & USB ID Check &

Adjustment.
4. Click on OK.
3. RTC & USB Adjustment (continued)
To Set the Printer’s Sys-

tem Clock:
A. Verify the date and time
information provided by
your computer.
B. Click on Write RTC.
To Set the Printer’s USB

ID:
A. Enter the Printer’s
Serial Number.
B. Click on Write USB ID.
4. RTC & USB Adjustment (continued)
5. Click on OK.
6. Click on Finish.
Serial Number Check & Input

Note: The Serial Number Check & Input writes the Printer’s Serial Number to the Main Board.
1. Serial Number Adjustment.

vidual).
Serial Number Check & Input Printer Component, Software Item, LCD Display, Printer Button Page 419.
2. Serial Number Adjustment. (continued).

3. Select Serial Number Check & Input.
4. Click on OK.
3. Serial Number Adjustment (continued).
The Read button will dis-

play the Printer’s cur-
rent serial number.
5. Enter the Printer’s

Serial Number.
6. Click on Write.
4. Serial Number (continued).
7. Ok.
8. Click on Finish.
Tubes Cleaning (Flushing)

Note: The Tubes Cleaning is used to flush out the Ink System with cleaning fluid.
Note: The procedure is performed 1 Color Pair at a time, so 2 cartridges could be sufficient to complete
the flush. Each Cartridge is good for 5 cleanings. 2 times 5 is 10, but the 4900 is a 11 channel
printer. Consequently, 4 Cartridges is recommended (part # 1537913 quantity 1).
1. Turn on the Printer in Self Testing Mode (Down, Right, and OK, at power on).
2. Tubes Cleaning.

vidual).
Tubes Cleaning (Flushing) Printer Component, Software Item, LCD Display, Printer Button Page 423.
3. Tubes Cleaning (continued).
2. Expand the Ink Supply Related

3. Select Tubes Cleaning.
4. Click on OK.
4. Tubes Cleaning (continued)
5. Select Tubes Cleaning.
6. Select the appropriate

Color Pair or All Col-
ors.
7. Click on Run and follow

the directions dis-
played.
8. Click on Finish when

completed.
Wiper Counter [For Exchange] (Clear)

Note: Wiper Counter [For Exchange] (Clear) resets the Wiper Blade Life Counter.
1. Wiper Motor Counter.

COUNTER RESET.
Wiper Counter [For Exchange] (Clear) Printer Component, Software Item, LCD Display, Printer Button Page 426.
2. Wiper Counter (continued).

3. Select Wiper Counter [For

Exchange}.
4. Click on OK.
This is the current

ter.
5. Click on Run.
4. Wiper Counter (continued)
6. Click on OK.
7. Click on OK.
8. Click on Finish.
Component Pictures
Board (AID) Picture
White Wire to AID Grid
Black Wire to AID Grid
CN1 to CN8 on Main Board
Board (AID) Picture Printer Component, Software Item, LCD Display, Printer Button Page 432.
Board (Carriage) Picture

CN104 to Platen CN101 to Ink CN103 to Edge CN102 to Car- CN106 to Ink Selec-
Gap HP Sensor Mark Sensor Detector Sensor riage Encoder tor HP Sensor
CN100 to CN100 on Main Board CN105 to Ink Selector Motor
Board (Carriage) Picture Printer Component, Software Item, LCD Display, Printer Button Page 433.
Board (Ethernet) Picture
CN702 Ethernet Port
CN700 to CN701 on
Main Board
CN701 to CN701 on
Main Board
Board (Ethernet) Picture Printer Component, Software Item, LCD Display, Printer Button Page 434.
Board (Main) Picture
CN11
CN9 CN202 CN8 CN500 CN904 CN7 CN701 CN700
CN300
CN100 CN201 CN301 CN600 CN1 CN2 CN10

CN102 CN200 CN6
CN101 CN400 CN200
CN400
Board (Main) Picture Printer Component, Software Item, LCD Display, Printer Button Page 435.
Board (Sub-B) Picture
CN210
CN226 CN229 CN228 CN221 CN211 CN207 CN206
CN212 CN233 CN232 CN217 CN209 CN205 CN204
CN231 CN225 CN227 CN216 CN208 CN214 CN213
CN230 CN220 CN215 CN219 CN218
CN235 CN223 CN222 CN202
CN236
CN200 CN201
Board (Sub-B) Picture Printer Component, Software Item, LCD Display, Printer Button Page 436.
Board (Sub-C) Picture

CN316 CN307 to Release Sensor CN315 to Cutter HP Sensor CN308 to Ejected Media Tray Sensor.
to
Maint.
Tank CN313 to
Paper
Cassette
CN306 to Sensor
Pinch
Roller
CN309 to
Assy
Bord.
Motor
Maint
Encoder
Tank
CN303 to Sens.
PF Motor CN305 to
Encoder Pinch
Roller
Assy
Motor
CN312 to
ASF CN302 to
Motor PF Motor
Encoder
CN300 to CN300 on Main Board CN311 to ASF Motor CN301 to CN301 on CN314 to Rear
Main Board Cover Sensor.
Board (Sub-C) Picture Printer Component, Software Item, LCD Display, Printer Button Page 437.
Board (Sub-D) Picture

CN600 to CN600 on Main Board CN603 to ATC Motor CN604 ATC Motor Encoder
CN605 to Roll Sensor

CN606 to Roll Feeding Sensor
CN601 to Roll Motor CN602 to Roll Motor Encoder CN607 to Roll Lock Sensor
Board (Sub-D) Picture Printer Component, Software Item, LCD Display, Printer Button Page 438.
Cap Parking Picture
Cap Parking Picture Printer Component, Software Item, LCD Display, Printer Button Page 439.
Cleaning Assembly Picture
Manual Carriage
Release Knob
Carriage Lock
Wiper Blade
AID Grid and

Flushing Box Pump/Cap
Motor
Wiper Blade
Cleaner
Capping Caps
Cleaning Cap
Cleaning Assembly Picture Printer Component, Software Item, LCD Display, Printer Button Page 440.
Cleaning Assembly Picture (cont.)
Flushing Box
Cover
Cleaning Assembly Picture Printer Component, Software Item, LCD Display, Printer Button Page 441.
Cutter Assembly Picture
Cutter Assembly Picture Printer Component, Software Item, LCD Display, Printer Button Page 442.
Ink Bay (Right) Pictures
CN1 to CN500 on Main Board.
CN8 to Ink Door Sensor
Ink Tube Connection
Ink Bay (Right) Pictures Printer Component, Software Item, LCD Display, Printer Button Page 443.
Interior View
CSIC Contact
Ink Cartridge Key
Cartridge Alignment Pins Cartridge Lock Ink Needle
Ink Bay (Right) Pictures
CN1 to CN500 on Main Board.
CN8 to Ink Door Sensor
Ink Tube Connection
Interior View
CSIC Contact
Ink Cartridge Key
Ink Needle
Cartridge Alignment Pins Cartridge Lock
Motor (Exit Roller Rotation) Picture
Motor (Exit Roller Rotation) Picture Printer Component, Software Item, LCD Display, Printer Button Page 447.
Pressure Pump Assembly Picture
Pressure Pump Assembly Picture Printer Component, Software Item, LCD Display, Printer Button Page 448.
Print Head Pictures

4 Cable Connectors
Ink inlets
Print Head Pictures Printer Component, Software Item, LCD Display, Printer Button Page 449.
4900 Head Rank Sticker
2 Channels (colors) per Nozzle Plate 5 Nozzle Plates
Note: the Nozzle Plates are very fragile and will be damaged with a minimum of force.
Roller (Pickup) Assembly Pictures

Top View
Interlock
Interlock
Roller (Pickup) Assembly Pictures Printer Component, Software Item, LCD Display, Printer Button Page 452.
Bottom View
Interlock
Interlock
Interlocks
Interlock
Interlock
Pickup Rollers
Damper (Selector) Assembly Pictures

Top View
Damper (Selector) Assembly Pictures Printer Component, Software Item, LCD Display, Printer Button Page 456.
Bottom View
5 Damper Assemblies (Included with Damper Assembly)
Photo/Matte Black Valve
Right Side View
Photo/Matte Black Selector Motor O-Ring Chain (Gasket)
Left Side View
Sensor (Borderless Waste Ink Tank) Picture
Sensor (Borderless Waste Ink Tank) Picture Printer Component, Software Item, LCD Display, Printer Button Page 460.
Sensor (Paper Tamper HP) Picture
Sensor (Paper Tamper HP) Picture Printer Component, Software Item, LCD Display, Printer Button Page 461.
Sensor (Exit Roller HP) Picture
Sensor (Exit Roller HP) Picture Printer Component, Software Item, LCD Display, Printer Button Page 462.
Sensor (Platen Gap) Picture
Sensor (Platen Gap) Picture Printer Component, Software Item, LCD Display, Printer Button Page 463.
Spindle Assembly Picture
Spindle Assembly Picture Printer Component, Software Item, LCD Display, Printer Button Page 464.
Wiper Blade Picture
Wiper Blade Picture Printer Component, Software Item, LCD Display, Printer Button Page 465.
Reference
Carriage Release (Auto)

Note: Manually releasing the Carriage Mechanism is a delicate operation. It is extremely easy to
damage the Print Head if a mistake is made. It is safer to use the Auto Carriage Release procedure
described in this chapter.
Auto Carriage Release

2. Navigate to SELF TESTING\Mecha Adjustment\CR Uncap
3. Press the Right Arrow to display the [Enter] Start.
4. Press the OK button to release the Carriage.
5. The Printer will display: CR Uncap / Enter to Cap.

5.1 Press the OK button to re-cap the Carriage.
Note: Turning off the Printer will not cap the Carriage.
Note: Turning on the Printer will cap the Carriage.
Carriage Release (Auto) Printer Component, Software Item, LCD Display, Printer Button Page 467.
Carriage Release (Manual)

Note: Manually releasing the Carriage Mechanism is a delicate operation. It is extremely easy to
damage the Print Head if a mistake is made. It is safer to use the Auto Carriage Release procedure
described in the Carriage Release (Auto) chapter.
Manual Carriage Release Method

3. Remove the Cover (Top Right)
Carriage Release (Manual) Printer Component, Software Item, LCD Display, Printer Button Page 468.
6. Locate the Carriage Lock / Unlock Wheel.
Carriage Lock / Unlock Wheel
7. Unlock the Carriage Mechanism
1. Rotate the Carriage Lock

/ Unlock Wheel 3 com-
plete turns in the direc-
tion shown.
2. The Carriage Lock

3. The Cap should be retracted. should be retracted.
Manual Carriage Lock

1. Center the Platen Gap Gears.
Align these Platen Gap Gears.
2. Lock the Carriage Mechanism.
1. Rotate the Carriage

Lock / Unlock
Wheel 6 or more
complete turns in the
direction shown.
2. The Carriage Lock should

3. The Cap should be raised. be raised.
Color Order
Color Order For installed Cartridges (Listed Left to Right)
1. Green
2. Light Light Black
3. Yellow
4. Light Cyan
5. Vivid Light Magenta
6. Orange
7. Matte Black
8. Vivid Magenta
9. Light Black
10. Cyan
11. Photo Black
Color Order Printer Component, Software Item, LCD Display, Printer Button Page 473.
User Nozzle Check Color Order (Stair Step) (Listed Left to Right)
1. Cyan
2. Vivid Magenta
3. Matte/Photo Black
4. Light Black
5. Orange
6. Green
7. Light Light Black
8. Yellow C / VM PK&MK / LK O / G LLK / Y VLM / LC
9. Vivid Light Magenta
10. Light Cyan
Color Pairs on the Print Head (Listed Left to Right)

1. Cyan and Vivid Magenta
2. Photo Black (Matte Black) and Light Black
3. Orange and Green
4. Light Light Black and Yellow
5. Vivid Light Magenta and Light Cyan.
Color Order Printer Component, Software Item, LCD Display, Printer Button Page 474.
Connectors / Wiring
Main Board Connectors
Connector #: Connected To: Pins:
CN1 Power Supply CN1 20
CN2 SpectroProofer Power ?
CN6 USB 4
CN7 SpectroProofer USB 4
CN8 AID Board CN1 2
CN9 Control Panel 25
CN10 Board Cavity Cooling Fan 2
CN11 Head Driver Cooling Fan 2
CN100 Sub Board B CN100 40
CN101 Print Head 40
CN102 Print Head 40
CN300 Sub Board C CN300 34
CN301 Sub Board C CN301 8
CN400 Head B Board (Right CSIC Board) CN1 23
Connectors / Wiring Printer Component, Software Item, LCD Display, Printer Button Page 475.

CN500 Head C Board (Left CSIC Board) CN1 23
CN600 Sub Board D (Spindle Assembly) CN600 26
CN700 Network Board CN700 16
CN701 Network Board CN701 5
Carriage Board
CN100 Main Board CN100 40
CN101 Ink Mark Sensor 4
CN102 Carriage Encoder 5
CN103 Edge Detector Sensor 3
CN104 Platen Gap Home Position Sensor 3
CN105 Ink Selector Motor (PK/MK) 2
CN106 Ink Selector HP Sensor (PK/MK) 2
Sub-B Board

CN204 CR Motor 2
CN205 Not Used 4
CN206 Platen Gap Motor 2
CN207 Platen Gap Motor Encoder 4
CN208 Paper Thickness Sensor #1 3
CN209 Paper Thickness Sensor #2 3
CN210 Paper Empty (Rear AD) Sensor 3
CN211 Paper Empty (Jam) Sensor 3
CN212 Suction Fan 3
CN213 ASF Sub Motor (lowers Pickup Roller and dis- 2
engages and engages transport friction)
CN214 ASF Sub Motor Encoder 4
CN215 Pickup Roller HP Sensor 3
CN216 ASF Sub Assy HP Sensor #1 (Retard Roller) 3
CN217 ASF Sub Assy HP Sensor #1 (Assist Roller) 3
CN218 ASF Edge Guide Motor 2
CN219 ASF Edge Guide Motor Encoder 4
CN220 ASF Edge Guide HP Sensor 3
CN221 Cassette Paper Empty Sensor 3
CN222 Cutter Motor 4
CN223 Cutter Motor Encoder 4

CN225 SpectroProofer Cover Sensor 4
CN226 Top Cover Sensor 4
CN227 Roll Unit Sensor 4
CN228 Cleaning Pump Motor 2
CN229 Cleaning Pump Encoder 4
CN230 Wiper and Cap HP Sensor #1 5
CN231 Wiper and Cap HP Sensor #2 5
CN232 Decompression Pump Motor 2
CN233 Decompression Pump Motor Encoder 4
CN235 Eject Star Wheels assy HP Sensor 5
CN236 Maintenance Tank CSIC 7
Sub-C Board
CN302 Paper Feed Motor 2
CN303 Paper Feed Motor Encoder 4
CN305 Pinch Roller Assy Motor 2
CN306 Pinch Roller Assy Motor Encoder 6

CN307 Pinch Roller Assy HP Sensor 3
CN308 Ejected Media Tray Sensor 3
CN309 Borderless Maintenance Tank Lock Sensor 3
CN311 ASF Motor (Sheet Feeder and Pickup Roller) 2
CN312 ASF Motor Encoder 4
CN313 Paper Cassette Sensor 2
CN314 Rear (Jam) Media Guide Sensor 2
CN315 Cutter HP Sensor 2
CN316 Borderless Maintenance Tank CSIC 7
Sub-D Board
CN601 Roll Motor 2
CN602 Roll Motor Encoder 4
CN603 ATC Motor 2
CN604 ATC Motor Encoder 4
CN605 Roll Sensor 3
CN606 Roll Feeding Sensor 3
CN607 Roll Lock Sensor 3
Power Supply
CN001 AC Power 2
Consumable/Service Parts List

Ink is intended as a service tool (Warranty Service Only), and is not for sale. Use the Service Part
Number, and claim it on a warranty form.
Service Part # Sales Part # Ink Cartridges

WAT653100 T653100 UltraChrome HDR Photo Black Warranty use only
WAT653200 T653200 UltraChrome HDR Cyan Warranty use only
WAT653300 T653300 UltraChrome HDR Vivid Magenta Warranty use only
WAT653400 T653400 UltraChrome HDR Yellow Warranty use only
WAT653500 T653500 UltraChrome HDR Light Cyan Warranty use only
WAT653600 T653600 UltraChrome HDR Vivid Light Magenta Warranty use only
WAT653700 T653700 UltraChrome HDR Light Black Warranty use only
WAT653800 T653800 UltraChrome HDR Matte Black Warranty use only
WAT653900 T653900 UltraChrome HDR Light Light Black Warranty use only
WAT653A00 T653A00 UltraChrome HDR Orange Warranty use only
WAT653B00 T653B00 UltraChrome HDR Green Warranty use only
Service Part # Sales Part # Paper Type ECCC Cost

after 40%
discount
WAS041385 SO41385 Double Weight Matte Paper 24” x 82’ roll $42.00
WAS041387 SO41387 Double Weight Matte Paper 44” x 82’ roll $64.64
Consumable/Service Parts List Printer Component, Software Item, LCD Display, Printer Button Page 481.
Service Part # Sales Part # Paper Type ECCC Cost

after 40%
discount
WAS041393 S041393 Premium Semimatte Photo Paper(170) 24” x 100” roll $69.96
WAS041395 S041395 Premium Semimatte Photo Paper(170) 44” x 100” roll $123.00
WAS041603 S041603 Enhanced Matte Paper size A4 (250 sheets) $106.32
WAS041725 SO41725 Enhanced Matte Paper 17” x 100’ roll $38.50
WAS041737 SO41737 Premium Luster Photo Paper(250) 16” x 100’ roll $66.00
WAS041779 S041779 Photo Semigloss 16.5” x 100” roll $59.97
WAS041827 S041827 Premium Semimatte Photo Paper 17” x 22” (25 sheets) $53.97
Maintenance Tank and Cutter Blades are available through Sales Channels only.
Sales Part Number Description

T619000 Maintenance Tank
T619100 Borderless Maintenance Tank
C12C815331 Cutter Blade
Consumable/Service Parts List Printer Component, Software Item, LCD Display, Printer Button Page 482.
Firmware History (Ethernet)

4900 Current Ethernet Firmware Ver. 1.0
Firmware File Name: lpe7100.efu
1. Initial Release
Firmware History (Ethernet) Printer Component, Software Item, LCD Display, Printer Button Page 483.
Firmware History (Printer)

Epson firmware version is The values are
represented as: represented in
Model and the Release Date. Hexadecimal
This chart explains the meaning of HEX = Decimal
the firmware version characters. Example SN00458 1 = 1
SN0 04 5 8 2 = 2
SP7800 DAY YEAR MONTH 3 = 3
4 2005 Aug 4 = 4
5 = 5
ExampleSN00157 6 = 6
SN0 01 5 7 7 = 7
SP7800 DAY YEAR MONTH 8 = 8
01 2005 Jul 9 = 9
A = 10
Example: B = 11
C = 12
DAY YEAR MONTH D = 13
E = 14
F = 15
Stylus Pro 4900 Current Firmware Ver. M028B7.upg

Release date: 07/28/11
1. The “wake up time” from “sleep mode” has been improved.
Stylus Pro 4900 Firmware Ver. M028B2.upg
Firmware History (Printer) Printer Component, Software Item, LCD Display, Printer Button Page 484.

1. Improves the detection of paper width.
2. Improves the use of dry time.
3. Improves optional SpectroProofer operations.
Stylus Pro 4900 Firmware Ver. M014AC.upg

1. The “wake up time” from “sleep mode” has been reduced.
2. The “double feed” error message from the paper cassette has been changed from “Paper Jam” to
“Paper Load Error”.
3. Remaining ink calculation, before a cleaning cycle, has been improved.
Stylus Pro 4900 Current Firmware Ver. M0010A9.upg

Firmware History (Printer) Printer Component, Software Item, LCD Display, Printer Button Page 485.
Firmware Update Procedure Using FWUpdate.exe

Note: This procedure is used to update or install firmware. It is the service method because it does not
require the Printer to be “Online” to work.
1. Turn on the Printer while depressing the Up, Down, Left, and Right buttons.
1.1 The Printer will display UPDATE FIRMWARE
2. Using FWUpdate.exe transmit the current firmware to the Printer.

2.1 The Printer will display UPDATING FIRMWARE.
2.1.1 *************** will appear to illustrate the progress of the update.
2.2 The Printer will display FIRMWARE UPDATE COMPLETE.
2.3 The Printer will re-boot.
Firmware Update Procedure Using FWUpdate.exe Printer Component, Software Item, LCD Display, Printer Button Page 486.
Flushing (Ink System)

Note: Flushing (Ink System) refers to cleaning out residual ink from the Ink System by flushing with
cleaning fluid.
1. See the Tubes Cleaning (Flushing) chapter in the Adjustment section.
Flushing (Ink System) Printer Component, Software Item, LCD Display, Printer Button Page 487.
Glossary
Artifact A defect, that is within an image. It can mean something on the graphic that was not
intended, or something missing that was intended. All image quality defects are arti-
facts.
Bi-Directional Adjustment: An electronic adjustment, that ensures that a printer can coordinate left to right, with
right to left, printing.
Capped Position: The print head at it’s stand by position, with the cap mechanism sealing the nozzles.
Coating: The top layer of graphics paper (media) that consists of a special substance
designed to trap ink and keep it from being absorbed into the paper fibers. Non-paper
based ink jet media uses coating to allow the ink to bond with the surface. A coatings
purpose is to minimize dot gain, and control saturation.
Color Shift: An unintended change of a gradient or tone.
Continuous Tone: The qualities of a photograph that makes an image appear real. The smooth and life-
like transition from one color shade to the next, like in a photograph. Epson Ink Jet
printers are not continuous tone printers. But when working properly, their printed
images fool the human eye into seeing continuous tone transitions.
CR Slant A term that refers to a mechanical print head alignment that ensures that an ink jet’s print heads
nozzles are on the same vertical plane. (Also known as CR Slant.) The head is rotated until it is ver-
tically linear.
Debris: A term that refers to unintended ink on the page deposited by Ink soaked debris
dropping from the print head.
Glossary Printer Component, Software Item, LCD Display, Printer Button Page 488.
Deflected Nozzle: A nozzle is firing, but the ink drop is not landing where it is intended too. Irregular
spacing on the nozzle check pattern indicates this condition.
Dithering: The dot pattern placed on the printed surface to create and image. Also known as
screening.
Dot Gain: A drop of ink tends to travel out from its point of impact, as the media absorbs it. The
purpose of the coating (on the media) is to minimize dot gain.
Drop of Ink: Ink that appears to have dripped from the print head, or any other component of the
ink supply.
Dye Ink: Ink that colors the printed surface with dye. It is less durable than pigment ink, but
has a wider color range (gamut).
Electronic Alignments: Printer adjustments, which are performed using software routines that, allow the
printer to compensate for physical variations in its mechanism.
Error Diffusion: The type of dithering (screening) proprietary to Epson, that employs a random dot
pattern to ensure that the human eye can discern no pattern.
Flight Time: The time it takes a drop of ink to travel from the print head to the printable surface.
Gamut: The range of colors that a printer can produce.
Ghosting: A term that refers to components of an image that are intended to be on top of each
other (or adjacent), but are offset.
Gradient: A smooth transition between one color shade, and the next. A continuous tone image
requires a smooth gradient for all its tonal shifts.
Grainy: A breakdown of the “illusion of continuous tone”. A printed image that does not have
smooth tonal transition, and sharp detail.
Head Angular Adjustment: A term that refers to a mechanical print head alignment that ensures that an ink jet’s print heads
nozzles are on the same vertical plane. (Also known as CR Slant.) The head is rotated until it is ver-
tically linear.
Head Gap Adjustment: An electronic print head adjustment that ensures that the printer knows the exact distance between
black and the other color nozzle sets. Also known as Uni-Di.
Head ID: The calibration value written on the print head that allows the printers electronics to
compensate for the print heads “personality” (inaccuracies).
Head Linear Adjustment: A mechanical print head alignment that ensures that on a two-head ink jet printer that all the noz-
zles are on the same horizontal plane. (Also known as Head Height and BC Head Slant.) The right
head is moved in relation to the left head.
Home Position: The print head’s horizontal reference position, as determined by the Home Position
Sensor
Horizontal Banding: An image defect that extends from the left, to the right margin (parallel to the direction
of print head movement). The defect could be a lighter or darker “band” than is
intended. It usually repeats, with the same interval, from the top margin to the bot-
tom.) Horizontal banding is caused by vertical dot placement errors (print head or
paper feed related).
Horizontal Over-lap: A type of horizontal banding, where multiple print head passes overlap while printing.
The banding looks darker than the intended image. Multiple passes of the print head
should place ink on the paper next to, but not on top of earlier passes.
Horizontal Under-lap: A type of horizontal banding, where multiple print head passes have a space
between them. The banding looks lighter than the intended image. Multiple passes of
the print head should place ink on the paper exactly next to earlier passes with no
space in between.
Illusion of Continuous Tone. A term that refers to “fooling” the human eye into perceiving a dot matrix image as a
photograph (continuous tone image). Epson ink jet printers are not continuous tone
printers. However, when working properly, their printed images fool the human eye
into seeing continuous tone transitions
Ink Color Contamination: The intended color of the ink supply has been altered.
Ink Impurities: Foreign objects in the ink supply.
Leading Edge The first part of the media to leave the printer.
Margin Shift: A term that refers to an image with irregular right and left side margins.
Mechanical Alignments: Printer adjustments, that requires physically moving parts of the mechanism.
Media: The surface that is being printed on, usually paper.
Metamerism: The different appearance of colors caused by different light sources and viewing
angles
Micro Weave: The way an Epson Ink Jet printer interlaces (weaves) bands of and image during
printing.
Moiré Pattern: A repetitive pattern, within an image, which is not intended. I can appear like a pais-
ley or herringbone pattern.
Nozzle Plate The portion of the Print Head that faces the media. The print head nozzles are drilled
in the nozzle plate.
Over Saturation: Too much ink has been applied to the printable surface for the media to support.
Paint Brush Effect: Something horizontally across the printed surface, that was not intended. Usually
caused by an ink soaked fiber hanging off the print head.
Pigment Ink: Ink that deposits colored particles (pigment) on the printed surface to create an
image. It is more durable than dye based ink, but does not have as wide a color
range (gamut).
Pixilated: An image quality issue that is caused by a low-resolution image printed at high reso-
lution.
PF Slant The heal/toe (camber) adjustment of the Print Head. It ensures that nozzle 1 and
nozzle 360 are equal distance from the media.
Platen Gap: The distance between the print head, and the printable surface.
Rippling: A term that refers to a condition caused by over saturated paper warping.
Saturation: The amount of ink applied to the printed surface.
Screening: The dot pattern placed on the printed surface to create and image. Also known as
dithering.
Skew: Crooked paper in the printer.
Smear: An image that has been rubbed by something, causing it to be deformed, or
smeared. The direction or any repetition of the smear should be noted.
Smudge: Something on the printed surface, that was not intended. Usually transferred to the
page because of contact with a dirty roller or the print head. Any repetition should be
noted and measured.
Sublimation Ink: Ink that is first printed on thermal transfer media, and then transferred using heat to
another surface.
Sympathetic Nozzle: A nozzle that is not intended to fire, firing in conjunction with an intended nozzle.
Tone: The specific shade of a color.
Trailing Edge The last part of the media to leave the printer.
Under Saturation: Not enough ink has been applied to the printable surface to properly saturate the
media.
Uni-D Adjustment: An electronic print head adjustment that ensures that the printer knows the exact distance between
black and the other color nozzle sets. Also known as Head Gap.
UN-sharp: “Fuzzy “qualities in an image usually caused by too much dot gain.
Vertical Banding, Irregular: Vertical bands perpendicular to the direction of print head movement, that are not lin-
ear. Usually created by paper “rippling”, caused by over saturation.
Vertical Banding, Linear: An image defect that extends from the top, to the bottom margin (perpendicular to the
direction of print head movement). It usually repeats, with the same interval, from the
left margin to the right.
White Specks: A term that indicates that the intended image has small missing areas where no ink
has been deposited.
Initial Ink Charge

Note: Initial Ink Charge initiates or cancels the priming of the Printers Ink System.
1. See the Initial Ink Charge chapter in the Adjustment section, or see the Ink Eject and Initial Charge
chapter in the Adjustment Section.
Revision History
August 23, 2011
1. The Firmware History (Printer) chapter was updated.
July 15, 2011

1. A chapter titled Roller (Pickup) Assembly Removal was added.
2. A chapter titled Roller (Pickup) Removal was added.
3. A chapter titled Roller (Pickup) Assembly Picture was added.
4. A chapter titled Tubes Cleaning (Flushing) was added.
5. A chapter titled Ink Eject and Initial Charge was added to the Adjustment Section.
6. A chapter titled PF Belt Tension Adjustment was added to the Adjustment Section.
7. A chapter titled CR Belt Tension Adjustment was added to the Adjustment Section.
8. A chapter titled CR Speed Auto Adjustment was added to the Adjustment Section.
9. A chapter titled Cutter Belt Tension Adjustment was added to the Adjustment Section.
April 6, 2011
1. A chapter titled Firmware History (Ethernet) was added to the Reference Section.
Revision History Printer Component, Software Item, LCD Display, Printer Button Page 495.
2. A chapter titled Consumable Service Parts List was added to the Reference Section.
3. A chapter titled Service Tools was added to the Reference Section.
4. A chapter titled Mac Address Check & Input was added to the Adjustment Section.
5. The Firmware History (Printer) chapter was updated.
6. A chapter titled Cap (Parking) Removal was added to the Component Removal Section.
7. A chapter titled Wiper Blade Removal was added to the Component Removal Section.
8. A chapter titled Cap (Parking) Picture was added to the Component Picture Section.
9. A chapter titled Wiper Blade Picture was added to the Component Picture Section.
10. A chapter titled Missing Nozzle Diagnosis was added to the Troubleshooting Section.
11. A chapter titled Service Procedure was added was added to the Reference Section.
12. A chapter titled Fan Noise Fix was added to the Troubleshooting Section.
March 4, 2011
1. A chapter titled Revision History was added.
1. The Firmware History chapter was updated.
2. The Selector (Damper) Assembly Removal was updated.
3. A chapter titled Carriage Release (Manual) was added.

4. A chapter titled Carriage Release (Auto) was added.
5. A chapter titled Connectors / Wiring was added.
6. The Board (Sub-B) Picture chapter was modified.
7. The Board (Sub-C) Picture chapter was modified.
8. A chapter titled Board (Carriage) Removal was added.
9. A chapter titled Board (Sub-D) Removal was added.
10. A chapter titled Board (Sub-D) Picture was added.
December 3, 2010
1. Initial Release
Sensors, Motors, and Fans

1.
Auto Alignment Sensor: Ink Mark Sensor (Used for Auto Bi-D and Auto Uni-D).
Encoders: ASF Motor Encoder (ASF Motor Assy Encoder)
Encoders report on distance and direction traveled by ASF Sub Motor Encoder (ASF Sub Motor Assy
devices with moving parts. Encoder)
1. Rotational distance and direction ASF Edge Guide Motor Encoder (Edge Release Assy
2. Linear distance and direction Encoder)
Note: The magenta text represents the name of ATC Motor Encoder (ATC Motor Encoder)
the related sensor in the Encoder Check Carriage Encoder (CR Encoder)
section of Serprog.exe. Cleaning Pump Motor Encoder (IS Motor Assy
Encoder)
Cutter Motor Encoder (Cutter Motor Assy Encoder)
Decompression Pump Motor Encoder
Paper Feed Motor Encoder (PF Encoder)
Pinch Roller Assy Motor Encoder (Release Motor
Encoder)
Platen Gap Motor Encoder (Decompression
Encoder)
Roll Feed Motor Encoder (Paper Press Motor
Encoder)
Fans Board Cavity Cooling Fan
Head Driver Cooling Fan
Paper Suction Fans
Power Supply Cooling Fan
Sensors, Motors, and Fans Printer Component, Software Item, LCD Display, Printer Button Page 498.
Home Position Sensors: ASF Sub Assy HP Sensor #1 (Retard Roller Sensor)
(Position of the Retard Rollers).
Home Position Sensors are used to set a reference posi- ASF Sub Assy HP Sensor #2 (Assist Roller Sensor)
tion for devices with moving parts. (Position of the Assist Rollers).
Note: The magenta text represents the name of Cutter Assy HP Sensor (Cutter HP Sensor) (Position
the related sensor in the Sensor Check of the Cutter Blade).
section of Serprog.exe. Eject Star Wheel Assy HP Sensor (Eject Star Wheels
Position Sensor) (Position of the Eject Star Wheel
assy).
ASF Edge Guide HP Sensor (Edge Release Sensor)
(Position of the ASF Edge Guide).
Ink Selector HP (PK/MK) Sensor (Position of the PK/
MK Ink Selector).
Pickup Roller HP Sensor (Pickup Unit Sensor) (Posi-
tion of the Pickup Roller).
Pinch Roller Assy HP Sensor (Release Sensor) (Posi-
tion of the Pinch Roller Assy).
Platen Gap HP Sensor (Position of the Platen Gap
Assy).
Wiper and Cap HP Sensor #1 (IS Unit HP Sensor 1
and Wiper & Cap Sensor 1) (Position of the Wiper and
Cap).
Wiper and Cap HP Sensor #2 (IS Unit HP Sensor 2
and Wiper & Cap Sensor 2) (Position of the Wiper
and Cap).
Motors ASF Motor (Turns the Pickup Roller / Advances media

until it reaches the Paper Feed Roller).
ASF Sub Motor (Engages the Pickup Roller / Engages
the PF Sub Assembly)
ASF Edge Guide Motor (Moves the ASF Edge Guide)
ATC Motor (Engages the roll Feed Gears / Locks the
Spindle into the Roll Assy).
Decompression Pump Motor (Runs the Ink System
Vacuum Pump to pressurize the Ink System).
Carriage Motor (Moves the Carriage Assy.).
Cleaning Pump Motor (Runs the Cleaning Pump /
Moves the Wiper Blade / Moves the Flushing Box).
Cutter Motor (Moves the Cutter Blade).
Ink Selector (PK/MK) Motor (Moves the PK/MK Ink
Selector Valve).
Paper Feed Motor (Turns the Paper Feed Roller / Turns
the Eject Roller Assy.).
Pinch Roller Assy Motor (Engages the Pinch Roller
Assy.).
Platen Gap Motor (Moves the Platen Gap)
Roll Feed Motor (Winds and un-winds the Paper Roll
Spindle / Creates “Roll Paper Back Tension”)
Paper Sensors: Cassette Paper Empty Sensor (Paper Empty Sensor)

(Monitors paper in the Cassette).
Paper sensors report on: Paper Thickness Sensor #1 (Paper Thickness Sen-
1. Paper present or not. sor 1) (Monitors Paper Thickness).
2. Size of Paper. Paper Thickness Sensor #2 (Paper Thickness Sen-
3. Paper path being used. sor 2) (Monitors Paper Thickness).
Note: The magenta text represents the name of Paper Edge Detector (Measures Media Width / Detects
the related sensor in the Sensor Check the leading edge / Checks for media skew).
section of Serprog.exe. Paper Empty (Rear AD) Sensor (PE Sensor) (Detects
Media at the Paper Feed Roller / Detects the trailing
edge of media).
Paper Empty (Jam) Sensor (2nd PE Sensor) (Detects
the correct movement / timing of media
between the “pick up roller and the Paper
Empty (Rear AD) Sensor).
Roll Sensor (Roll Sensor) (Detects the Insertion of Roll
Paper)
Status Sensors: Borderless Maintenance Tank Lock Sensor (Mainte-

nance Box 2 Lever Sensor) (Detects the position
Status sensors report on the condition of a component. of the Maintenance Tank Lock Lever).
1. Door open or close. Ejected Media Tray Sensor (Detects the presence of
2. Device installed or not installed. the Ejected Media Tray).
3. ETC. Ink Door (Left) Sensor (Left IC Cover Sensor)
Note: The magenta text represents the name of (Reports on the condition of the ink door).
the related sensor in the Sensor Check Ink Door (Right) Sensor (Right IC Cover Sensor)
section of Serprog.exe. (Reports on the condition of the ink door).
Paper Cassette Sensor (Paper Cassette Sensor)
(Reports on the presence of the Paper Cassette).
Rear (Jam) Media Guide Sensor (Rear Unit Sensor)
(Reports on the presence of the Rear (Jam) Media
Guide).
Roll Feed Engaged Sensor (Roll Feeding Sensor)
(Detects the condition of the friction rollers on
the Roll Unit).
Roll Lock Sensor (Roll Lock Sensor) (Reports on the
condition of the Spindle Lock Mechanism on the
Roll Unit)
Roll Unit Sensor (Roll Unit Sensor) (Reports on the
presence of the Roll Unit)
SpectroProofer Cover Sensor (Front Cover Sensor)
(Reports on the presence of the Spectro-
Proofer Cover or the SpectroProofer).
Top Cover Sensor (Printer Cover Sensor) (Reports on
the condition of the Top
Cover).
Temperature Sensors: Head Temperature Sensor (Thermistor [Printhead])

(Reports on the Nozzle Plate Tempera-
ture (Print Head).
Head Driver Temperature Sensor (Thermistor [Main
Board]) (Reports on the Temperature of the Head
Driver Heat Sink (Main Board).
Service Procedure (recommended)

1. Observe the customer’s service issue.
2. Clean or replace the Wiper Blade, and the Wiper Blade Cleaner.
2.0.1 Clean the Print Head Nozzle Plate if necessary.
2.0.2 Clear (reset) the Wiper Counter [for Exchange].
3. Clean or replace the Cap (Parking).

3.0.1 Clean the Print Head Nozzle Plate if necessary.
3.0.2 Clear (reset) the Head Cap Counter.
4. Clean the Cleaning Cap

4.1 Clear (reset) the IS Unit Counter.
5. Clear (reset) the CR Motor Counter.
6. Clean and check the Borderless Pads. Replace if necessary.
7. Clean the Carriage Encoder Strip (Timing Strip) with a damp soft cloth (Encoder Strip)
8. Update the Printer Firmware to the current version if necessary.
9. Update the Ethernet Firmware to the current version if necessary.
10. Repair the customer’s service issue, if cleaning did not fix it.
11. Perform the Media Feed Correction Check & Adjustment.
Service Procedure (recommended) Printer Component, Software Item, LCD Display, Printer Button Page 504.
12. Perform the Media Eject Correction Check & Adjustment.
13. Perform the PW +T&B&S Check and Adjustment.
14. Perform the Auto Bi-D Adjustment.
Service Procedure (recommended) Printer Component, Software Item, LCD Display, Printer Button Page 505.
Service Tools
Service Part Number Description

1047746 1000mm Scale (meter stick)
1080614 Grease G-26
1480655 Grease G-71
1516265 Grease G-84
1521154 Oil O-17
1537913 Cleaning Cartridge (qty-1) 4 required to clean all 11 Channels. 2 required to
clean a color pair.
1543007 PG Height Adjustment Jig (1.55)
1424364 Paper Thickness Sensor Position Jig #1
1282355 Paper Thickness Sensor Position Jig #2
1294120 Sonic Tension Meter
Service Tools Printer Component, Software Item, LCD Display, Printer Button Page 506.
Stress Test (Test Image)

Purpose:
The Printer Stress Test was designed to amplify any print quality issues. It is for diagnosis purposes only. It never
looks perfect. There is always some horizontal and vertical banding.
Use:
1. Use it to compare Non-Epson Drivers against the Epson Driver.
2. Use it to look for image quality variances across the entire printable area of the printer.
Is the vertical banding consistent across the entire image?

Is the horizontal banding consistent across the entire image?
Is the density consistent across the entire image?
If the answer to any of the above questions is no, Contact Epson. It may be
a parallelism issue.
Stress Test (Test Image) Printer Component, Software Item, LCD Display, Printer Button Page 507.
Utilities
Epson Net Config 2.2b

Note: Epson Net Config is a user utility that allows the user to upgrade an Epson Printer’s ethernet
firmware, and configure TCPIP settings. Additionally it will display all of the Epson Printers on the
same network as the host computer.
1. Install Epson Net Config.
2. Ensure that the host computer is on the same network as the Printer(s) to be accessed.
3. Launch Epson Net Config.

Launch Epson Net Config.
Epson Net Config 2.2b Printer Component, Software Item, LCD Display, Printer Button Page 509.
4. Epson Net Config main screen.
Displays all of the Epson Printers on the network.
5. To Update a Printer’s Ethernet Firmware.

Click on Tool: Firmware Update to start the Update Wizard.
6. To Configure a Printer’s TCPIP settings.
Double Click on the Printer to be configured.
7. To Configure a Printer’s TCPIP settings (continued)
Click on Basic to access the TCPIP configuration screen.
FWUpdate.exe
Note: FWUpdate.exe is used to copy Firmware to the Printer and works without the printer driver being
installed.
1. Double Click on the FWUpdate.exe utility Icon.
Double Click on this Icon.
2. The utility will open and look like this.
FWUpdate.exe Printer Component, Software Item, LCD Display, Printer Button Page 514.
3. Choose a Port/Printer.
1. Click on the Down Arrow to open

up the list of Ports.
2. Select the Port that is connected

to the Printer that requires firm-
4. Click on Browse and navigate to the Firmware File to be uploaded to the Printer.
Click on Browse.
5. Select the correct Firmware File.
1. Select the correct Firmware File.
2. Click on OK.
6. Click on Send to upload the Firmware to the Printer.
Click on Send to upload the Firmware.
7. The utility will display this, click on Ok.
Click on OK
NV-RAM BACKUP UTILITY

Note: The NV-RAM BACKUP UTILITY “backs up” and restores the unique data that is on each Printer’s
Main Board, and should be transferred to a new Main Board.
Uses for the NV-RAM BACKUP UTILITY.

1. At Main Board exchange
1.1 Backing up the unique data resident on each Printer’s Main Board.
1.2 Restoring the unique data onto the Printer’s New Main Board.
Note: When installing a New Main Board, use Generic NVRAM Data (Generic Parameters) if the Printer’s
unique NVRAM data is not available. Follow the procedure documented in the Main Board Installation
Chapter.
Note: Install Photo Black Generic Parameters on a Printer that is in photo black mode, or Matte Black
Generic Parameters on a Printer that is in Matte Black Mode. Remove the paper and disconnect all
optional devices (Take Up Reel and Spectroproofer). This matches the Printer to the Generic
Parameters.
2. Troubleshooting
2.1 Note the Printer’s symptom.
2.2 Backup and store the Printer’s unique NVRAM Data.
2.3 Load Generic NVRAM Data onto the Printer’s Main Board.
2.4 Note any change in the Printer’s symptom.
Note: A change in the printers symptom indicates that the Printer’s unique NVRAM Data is contributing
to the symptom.
2.5 If there is no change in the Printer’s symptom, restore the Printer’s unique NVRAM Data.
2.6 If there is change in the Printer’s symptom, leave the Generic NVRAM Data on the Printer, and follow
the procedure documented in the Main Board Installation Chapter for using Generic NVRAM Data
(Generic Parameters).
3. Restore point(s)
3.1 Backup and save NVRAM Data to create restore points when experimenting with electronic adjustments.
About NVRAM Viewer

Note: NVRAM Viewer is a feature of the NV-RAM BACKUP UTILITY. It allows the viewing of selected
information from the “backed up” NVRAM data. When enabled, it automatically allows viewing of
the NVRAM data prior to saving the NVRAM data.
Enabling NVRAM Viewer.

1. Open ServProg.ini with a text editor (Note Pad used for this example).
Open ServProg.ini with a text editor.
2. Modify ServProg.ini
1. Change this 0 to 1.
2. Save and close ServProg.ini.
NVRAM Backup
1. From Servprog.exe for the 4900, select NV-RAM BACKUP UTILITY.
Click on NV-RAM BACKUP

UTILITY.
2. To “back up” NVRAM Data.

1. Start the Printer in NVRAM Data Backup Mode: (Hold the Up, Down, Left, and Right buttons and turn on
the power. The Printer will display F/W Download).
2. Select the correct Printer/Driver connection.
3. Click here to start the “backup”
4. The utility will display this while “backing up”

the data.
5. The Printer’s Serial # will be displayed here.
6. Click on Save.
7. The utility will enter the date and serial

number for the default file name.
Change the name if desired.
8. Navigate to the appropriate location to

save the file (Desktop recommended).
9. Click on Save.
3. Display NVRAM Data
Click on Display Info to display relevant NVRAM data.
4. Display Data (Continued)
NVRAM Restore
1. From Servprog.exe for the 4900, select NV-RAM BACKUP UTILITY.
Click on NV-RAM BACKUP

UTILITY.
2. To “restore” NVRAM Data.

1. Start the Printer in NVRAM Data Restore Mode: (Disengage 11 Ink Cartridges, remove the 1 Mainte-
nance Tank and the Borderless Waste Ink Tank, hold the Up, Down, Left, and Right
buttons and turn on the Printer).
2. Click on Open File.
3. Highlight the appropriate NVRAM file.
4. Click on Open.
5. The utility will display the Printer’s serial #.

7. The utility will display this while writing to the Printer.
8. Click on OK to finish.
6. Click on Write File to begin. Note: After the utility displays “complete”, wait an
additional 20 seconds before turning off the Printer.
Servprog.exe
Note: Servprog.exe is the utility that enables counter resets, and some electronic alignments for the
4900.
Note: Servprog.exe will work when the Printer is in Ready mode, or in Self Testing mode.
Note: Self Testing mode will allow the Servprog.exe to function with the Printer, when the Printer is in
an error condition.
1. Ensure that the 4900 Printer Driver is installed on the system that will be running the Servprog.exe.
1.1 Verify that the Printer Driver can read the Printer’s ink quantities.
2. Ensure that the Servprog files listed below are all in the same folder.
Servprog.exe Printer Component, Software Item, LCD Display, Printer Button Page 529.
3. Double Click on Servprog.exe to start the utility.
4. Click on Ok to accept the license agreement.
Click on Ok.
5. (Optional but recommended) Click on Yes to download the Printers NVRAM data.
1. Click on Yes to open the NVRAM

BACKUP UTILITY. Click on No to open Servprog.exe.
(See the next page).
2. Select the correct Printer.
3. Click on Get Information

to download the Printer’s
NVRAM data.
4. Click on Exit to open the Adjustment Utility.
6. Servprog.exe main menu.
Opens the NVRAM

Backup Utility.
Opens the individ-

ual adjustment
Opens a firmware
update menu.
Opens a menu for

sending a PRN print
job to the Printer.
Opens the counter

reset menu.
Opens a menu that will dis-

play a wiring diagram and a
menu map.

EPSON 4900 Field Repair Guide

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Pro 4900 Field Repair Guide 8/23/11

Printer Component, Software Item, LCD Display, Printer Button Page 1.

Ink Bay (Left) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 125

Printer Component, Software Item, LCD Display, Printer Button Page 2.

PF Encoder and Scale Check - - - - - - - - - - - - - - - - - - - - - - - - - - 269

Printer Component, Software Item, LCD Display, Printer Button Page 3.

PF Motor Counter (Clear) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 383

Printer Component, Software Item, LCD Display, Printer Button Page 4.

Roller (Pickup) Assembly Pictures - - - - - - - - - - - - - - - - - - - - - - - 452

Printer Component, Software Item, LCD Display, Printer Button Page 5.

Epson Net Config 2.2b - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 509

Printer Component, Software Item, LCD Display, Printer Button Page 6.

Control Panel Map

Paper Feed Paper Release

Nozzle Check, OK (Enter)

Printer Component, Software Item, LCD Display, Printer Button Page 7.

Ink Menu: (Press the Cleaning Button to access)

Printer Component, Software Item, LCD Display, Printer Button Page 8.

2. Platen Gap Setting

3. Paper Source and Roll Paper Auto Cut Setting

6. Black Ink Setting

7. Waste Ink Cartridge Level(s)

8. Roll Paper Counter

9. Roll Paper Margin Setting

SELF TESTING: Down, Right, and OK, at power on

Printer Component, Software Item, LCD Display, Printer Button Page 9.

User Menu: Press the Menu button when

NVRAM Data (Parameter) Backup Mode

NVRAM Data (Parameter) Restore Mode

F/W Download Mode

Board (AID) Removal

2. Unplug the Printer.

3. Remove 3 Screws and the AID Board Cover.

1. Remove 3 Screws. 2. Remove the AID Board Cover.

4. Disconnect the AID Grid Wires.

5. Remove the AID Board.

1. Disconnect the AID Control Cable. 2. Remove 3 Screws.

3. Remove the AID Board.

Board (Carriage) Removal

2. Remove the Cover (Side Right).

4. Remove the Cover (Carriage).

2. Lift off the Carriage Cover.

5. Unplug 1 Foil Cable.

Unplug 1 Foil Cable.

6. Unplug 3 Foil Cables and 3 Connectors.

Unplug 3 Foil Cables and 3 Connectors

7. Remove the Carriage Board.

Remove 2 Screws and lift off the Carriage Board.

Board (Ethernet) Removal

2. Remove the Cover (Rear).

3. Disconnect 1 Cable Fastener.

Squeeze and un-seat 1 Cable Fastener.

5. Free the Cables from 2 Fastners.

Free the Cables from 2 Fasteners.

6. Disconnect and remove the Main Board / Ethernet Board Assembly.

1. Slide the Board Assembly partially out.

2. Disconnect 10 Foil Cables and 5 Wired Cable Connectors.

3. Remove the Main Board / Ethernet Board Assembly.

8. Remove 2 Screws and move 1 Fan.

9. Remove 4 Screws, and the Board.

1. Remove 4 Screws. 2. Remove 1 Board.

Board (Ethernet) Installation

1. Install 1 Board. 2. Install 4 Screws.

2. Place 1 Fan, and install 2 Screws.