Why Is My Epson DTF Printer Still Grinding After Replacing the Ink Waste Pump?

Question

I purchased your video about replacing the ink waste pump and followed the instructions to line up the notches on the new pump. However, the printer is still making a grinding noise. I am not sure what else to do, and I am very frustrated because I still depend on this machine and am still paying for it. I also have a video of the issue and some WICReset error codes. Can you help me figure out what may be causing the grinding noise?

Answer

From what I observed, the printhead did not appear to error out until the very last second of the movement. Before that point, the capping station seemed to be doing its cleaning cycle correctly. The cap moved as expected, and the wiper appeared to flip up and retract back down properly. That tells us the waste ink pump itself may not be the only thing involved, especially if the pump was installed with the notches lined up correctly.

The key moment appears to happen at the end, when the printhead tries to move left and is stopped by the white lever in the back. When that happens, the printer may make a grinding or ratcheting sound because the carriage motor is trying to move the printhead, but something is physically blocking the carriage path. In this type of situation, the grinding sound is usually not caused by the pump gear alone. It is often caused by the capping station or a lever associated with the capping station sitting slightly too high or failing to return fully to its home position.

A common cause is a worn retriever or lifting mechanism inside the capping station. When that internal part becomes worn, the white lever may remain just a little higher than it should be. Even a small height difference can be enough to block the printhead carriage when it tries to move across the printer. The printhead may then hit the lever, the carriage motor continues trying to move, and that creates the grinding noise.

If WICReset is reporting error codes, those codes can help confirm whether the printer is detecting a carriage movement problem, a CR motor overload, a paper feed issue, or a maintenance station-related failure. For example, many Epson-based DTF printers may report general service or fatal errors when the carriage cannot move freely. If the code points to a carriage error, CR motor error, or obstruction-related fault, that would match what we are seeing: the printhead is being physically stopped near the capping station area. Even if the original repair focused on the ink waste pump, the printer may now be showing that the larger maintenance/capping assembly is worn or misaligned.

In our shop, when we see this behavior, we usually replace the capping station rather than continue adjusting individual pieces. The reason is that the capping station is not just one part. It includes the cap top, pump connection, wiper mechanism, lift/retract mechanism, levers, springs, and internal timing pieces. If one part is worn enough to hold the white lever too high, other parts in the station may also be worn. Replacing the full capping station is often more reliable than replacing only the pump or trying to repair the lever mechanism inside the old station.

If you want to attempt a repair before replacing the capping station, one possible adjustment is to increase the printhead height slightly. On many Epson-based DTF setups, this can be done by adjusting the large "D" wheel on the right side of the main carriage rod. After that, you may also need to adjust the parallelism bar on the left side so the carriage remains level across the platen. The goal would be to raise the printhead just enough so it clears the white lever without striking it.

However, I would be very cautious with this method. Raising the printhead can create new print-quality problems. If the printhead sits too high above the film or paper, the ink droplets have farther to travel before reaching the print surface. This can cause overspray, fuzzy edges, misting, poor registration, banding, or what many DTF users call "floating spray." In other words, the printer might stop grinding, but the print quality may become worse. That is why we usually prefer replacing the capping station and salvaging any usable parts from the old one rather than changing the printhead height to compensate for a worn station.

Before replacing more parts, I would also check the following:

Make sure the printhead carriage can move freely by hand when the printer is powered off and unplugged. Do not force it if it is locked, but once it is released, it should move smoothly across the carriage rail. Any point where it catches or bumps near the capping station is important.

Inspect the white lever at the back of the capping station. It should retract fully and should not remain in the carriage path. If it is staying slightly raised, the printhead can hit it during startup or cleaning.

Check the capping station timing. Since the ink waste pump was replaced, the gears and notches must be aligned correctly, but the capping station also has to return to the correct parked position. If the timing is off by even one tooth, the wiper, pump, or lever may move at the wrong time.

Look for dried ink buildup around the cap, wiper, pump gears, and lever area. DTF ink can dry into a rubbery or sticky mass, and that can prevent the maintenance station from retracting completely.

Check whether the wiper is retracting all the way down. You mentioned the wiper appears to flip up and retract, which is good, but it should not drag against the printhead carriage after the cleaning cycle.

Watch the final second of the startup or cleaning cycle closely. If the printhead moves normally until it reaches the capping station area and then suddenly grinds, that strongly suggests a physical obstruction rather than an electronic board problem.

Based on what you described and what I observed, I would not assume the new ink waste pump is defective right away. The pump may be installed correctly, but the capping station may still be worn or mechanically out of position. The most practical repair would be to replace the capping station assembly. If you choose to adjust the printhead height instead, do so very carefully and understand that it may solve the collision while creating print-quality issues.

Addressing printer issues can be a complicated affair because many of these problems require hands-on inspection. For that reason, we are not able to provide remote troubleshooting, detailed repair guidance, or ongoing support for printer repairs. We do offer an in-person evaluation and repair service through our local diagnostic facility: BCH Technologies Printer Repair Service [https://bchtechnologies.com/printer-repair-service]. Because demand is high, we operate on a first-come, first-served basis, so it may take a few weeks before we can accept your printer for drop-off. Our services are structured to repair either a complete printer or specific parts, with instructions provided for how to proceed. However, we understand that our rates may not be the most economical option for every customer. For that reason, we highly recommend self-help through online research. A good place to start is YouTube, including our channel homepage: BCH Technologies on YouTube [https://youtube.com/@bchtechnologies]. You can search for specific repair videos by using the search icon next to "About" on the right-hand side of the channel menu bar. I receive dozens of questions every day asking for videos on specific topics, and after making videos for the past nine years, it is difficult to remember every single one. Using YouTube's search function is usually the most efficient way to find the right video, and YouTube may also recommend helpful videos from other creators.

Thank you again for reaching out and for supporting BCH Technologies. I know this kind of issue is frustrating, especially when you rely on the printer, but based on the symptoms, the next area I would focus on is the capping station and the white lever that appears to be stopping the printhead movement.