Page 1: Table Of Contents
Stylus Pro 4880 Field Repair Guide 1/17/08 Table Of Contents Table Of Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1...
Page 2 Stylus Pro 4880 Field Repair Guide 1/17/08 Communication Errors PC - - - - - - - - - - - - - - - - - - - - - - - - - - - - 113 Cover Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 115...
Page 3 Stylus Pro 4880 Field Repair Guide 1/17/08 Paper Feed Timing Belt Adjustment - - - - - - - - - - - - - - - - - - - - - - - 157 Paper Thickness Sensor Adjustment - - - - - - - - - - - - - - - - - - - - - - 159...
Page 4 Stylus Pro 4880 Field Repair Guide 1/17/08 Service Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 219...
Page 5: Control Panel Map
Stylus Pro 4880 Field Repair Guide 1/17/08 Control Panel Map Status Media Feed Sheet Roll / Sheet Roll Auto Cut Ink Quantity Maintenance Tank Level Roll Auto Cut Off Paper Ink Out Paused Pause Power Hold for 3 seconds to reset/clear...
Page 6 Stylus Pro 4880 Field Repair Guide 1/17/08 User Menu: 3. PRINTER STATUS. Press the Menu button when the printer displays Ready VERSION: (CURRENT FIRMWARE) PRINTABLE PG: (FOR EACH COLOR)MK 1. PRINTER SETUP. (nnnnnn)PG ROLL COUNTER: SET ROLL LENGTH nnn.n (If enabled)
Page 7 Stylus Pro 4880 Field Repair Guide 1/17/08 5. MAINTENANCE 6. Head Alignment. CUTTER REPL: EXEC PAPER THKNS: *STD, (n.n)MM BK Ink Change: EXEC (For Changing between Matte ALIGNMENT: AUTO (UNI-D, #3, #2, #1, BI- and Photo Black) D All, BI-D 2-COLOR)
Page 8 Stylus Pro 4880 Field Repair Guide 1/17/08 Maintenance Mode 2: Press and hold the Left, Down, and buttons and turn on the Printer SELF TESTING: Test: Version: (Displays the current firmware version) Panel: (Button tests for the control panel) Sensor:...
Page 9 Stylus Pro 4880 Field Repair Guide 1/17/08 Maintenance Mode 3: Press and hold the Pause, Down, and Right buttons and turn on the Printer SELF TESTING2: TEST: Sensor: (Sensor tests for all sensors) Adjustment: Clean Head: Exec (Evacuates the ink in the Ink Tubes)
Page 10 Stylus Pro 4880 Field Repair Guide 1/17/08 PF BiD Adjust: (+/- n) Uni-D Trap: (On, Off) Display: Address: (Used for displaying data at specific RAM addresses) Custom: Life: CR Motor, PF Motor, CR+PF Motor, Roller, Roller Rel, D/E Chg, Hopper, ASFLoad, Cutter, Head U/D,...
Page 11 Stylus Pro 4880 Field Repair Guide 1/17/08 CUT UNIT MNT: EXEC MAINT INFO: (Page 88 - 98 in the Service Manual) Menu E: (E1 - E17), Menu R: (R1 - R9), Menu S: (S1 - S25), Menu A: (A1 - A32), Menu B: (B1 - B48),...
Page 12: Component Replacement
Stylus Pro 4880 Field Repair Guide 1/17/08 Component Replacement Printer Component, Software Item, LCD Display, Printer Button Page 12.
Page 13: Board (Main) Installation
Stylus Pro 4880 Field Repair Guide 1/17/08 Board (Main) Installation 1. Fasten the New Board to the Housing with 7 Screws (see above) Do not fully tighten. 1. Place the New Board into the Housing. 2. Install 7 Screws (keep them...
Page 14 Stylus Pro 4880 Field Repair Guide 1/17/08 2. Install 1 Screw that fastens the USB Port to the Main Board Housing and tighten the 7 Screws that fasten the Main Board to the Housing. 1. Install 1 Screw. 2. Tighten the 7 Screws that fasten the Main Board to the Housing.
Page 15 Stylus Pro 4880 Field Repair Guide 1/17/08 3. Connect the Cables to the Main Board. Ensure that the Cables are fully seated (straight). Connect the Cables. Note: The numbers on the Foil Cables correspond to the Connector numbers. Printer Component,...
Page 16 Stylus Pro 4880 Field Repair Guide 1/17/08 4. Install 4 Screws that fasten the Main Board Housing to the Printer. Install 4 Screws. Printer Component, Software Item, LCD Display, Printer Button Board (Main) Installation Page 16.
Page 17 Stylus Pro 4880 Field Repair Guide 1/17/08 5. Install 2 Screws that fasten the Cable Cover to the Printer. Install 2 Screws Printer Component, Software Item, LCD Display, Printer Button Board (Main) Installation Page 17.
Page 18 Stylus Pro 4880 Field Repair Guide 1/17/08 6. Write current Firmware to the Main Board. (Detailed directions for writing firmware to the Main Board are in the Firmware Update chapter located in the Reference Section of the Field Repair Guide.
Page 19 Stylus Pro 4880 Field Repair Guide 1/17/08 9.6 Perform the Multi Sensor Level Adjustment. 9.7 Perform the Multi Sensor Adjustment. 9.8 Perform the Auto Bi-D Adjustment. 9.9 Perform the Auto Uni-D Adjustment. 9.10 Perform the Platen Position Adjustment 9.11 Perform the...
Page 20: Board (Main) Removal
Stylus Pro 4880 Field Repair Guide 1/17/08 Board (Main) Removal 1. Back up the Printer’s parameters using the Parameter Backup / Restore Utility (Nvram.exe). Note: If the Printer’s parameters can not be “backed up”, print out the Print Head Calibration value (Head Rank).
Page 21 Stylus Pro 4880 Field Repair Guide 1/17/08 4. Remove the 2 Screws fastening the Cable Cover. Remove 2 Screws Printer Component, Software Item, LCD Display, Printer Button Board (Main) Removal Page 21.
Page 22 Stylus Pro 4880 Field Repair Guide 1/17/08 5. Remove the 4 Screws fastening the Main Board Housing. Remove 4 Screws. Printer Component, Software Item, LCD Display, Printer Button Board (Main) Removal Page 22.
Page 23 Stylus Pro 4880 Field Repair Guide 1/17/08 6. Slide out the Main Board Housing, and disconnect the Cables. Slide out the Main Board Housing, and disconnect the Cables. Note: The numbers on the Foil Cables correspond to the Connector numbers.
Page 24 Stylus Pro 4880 Field Repair Guide 1/17/08 7. Remove the 1 Screw that fastens the USB Port to the Main Board Housing. Remove 1 Screw. Printer Component, Software Item, LCD Display, Printer Button Board (Main) Removal Page 24.
Page 25 Stylus Pro 4880 Field Repair Guide 1/17/08 8. Unplug 2 Cables. Unplug 2 Cables. Printer Component, Software Item, LCD Display, Printer Button Board (Main) Removal Page 25.
Page 26 Stylus Pro 4880 Field Repair Guide 1/17/08 9. Remove 7 Screws, and remove the Main Board from the Housing. 1. Remove 7 Screws. 2. Separate the Board from the Housing. Printer Component, Software Item, LCD Display, Printer Button Board (Main) Removal...
Page 27: Board (Power Supply) Removal
Stylus Pro 4880 Field Repair Guide 1/17/08 Board (Power Supply) Removal 1. Turn off the Printer and UNPLUG from AC. 2. Remove the Rear Paper Guide. Push the 2 Grey Tabs and remove the Rear Paper Guide Printer Component, Software Item,...
Page 28 Stylus Pro 4880 Field Repair Guide 1/17/08 3. Remove the 2 Screws fastening the Cable Cover. Remove 2 Screws Printer Component, Software Item, LCD Display, Printer Button Board (Power Supply) Removal Page 28.
Page 29 Stylus Pro 4880 Field Repair Guide 1/17/08 4. Remove the 4 Screws fastening the Main Board Housing. Remove 4 Screws. Printer Component, Software Item, LCD Display, Printer Button Board (Power Supply) Removal Page 29.
Page 30 Stylus Pro 4880 Field Repair Guide 1/17/08 5. Slide out the Main Board Housing, and disconnect the Cables. Slide out the Main Board Housing, and disconnect the Cables. Note: The numbers on the Foil Cables correspond to the Connector numbers.
Page 31 Stylus Pro 4880 Field Repair Guide 1/17/08 6. Unplug 2 Cables. Unplug 2 Cables. Printer Component, Software Item, LCD Display, Printer Button Board (Power Supply) Removal Page 31.
Page 32 Stylus Pro 4880 Field Repair Guide 1/17/08 7. Remove 6 Screws, and lift the Power Supply off the Housing. 1. Remove 5 Screws. 2. Separate the Power Supply from the Housing. Printer Component, Software Item, LCD Display, Printer Button Board (Power Supply) Removal...
Page 33: Carriage Removal Procedure
Stylus Pro 4880 Field Repair Guide 1/17/08 Carriage Removal Procedure Unplug the Printer. 2. Raise both Ink Levers, closing the Ink Valves. 3. Remove the Left Side Cover. 4. Release the Carriage Lock, and move the Carriage Mechanism away from the capped position.
Page 34 Stylus Pro 4880 Field Repair Guide 1/17/08 6. Carriage Rail Cover (Wheel Track) protection steps. The Carriage Rail Covers will separate and bend when removing the Print Head if not protected. 1. Make a double wall cardboard jig as shown.
Page 35 Stylus Pro 4880 Field Repair Guide 1/17/08 7. Move the Carriage Mechanism at the removal slot as shown. Compress the Tension Springs against the Front Carriage Rail, and lift out the Carriage. Removal Slot Be careful to free the Carriage Timing...
Page 36: Cartridge Release Lever Repair
Stylus Pro 4880 Field Repair Guide 1/17/08 Cartridge Release Lever Repair 1. Remove the Ink Bay. 2. Ensure that the Gears and Spring are in the positions shown. (This is the Cartridge released, and the Valves closed position) Ensure that the Valve Open/Close 3 Gear positions to check.
Page 37: Cartridge Release Sensor Repair
Stylus Pro 4880 Field Repair Guide 1/17/08 Cartridge Release Sensor Repair 1. Remove the Ink Bay Assembly. 2. Remove the Cartridge Release Sensor, and replace. The Sensor is fastened by 2 Interlocks. Printer Component, Software Item, LCD Display, Printer Button Cartridge Release Sensor Repair Page 37.
Page 38: Cover (Left) Removal
Stylus Pro 4880 Field Repair Guide 1/17/08 Cover (Left) Removal 1. Remove 2 Screws. 1. Remove 1 Screw 2. Remove 1 Screw Printer Component, Software Item, LCD Display, Printer Button Cover (Left) Removal Page 38.
Page 39 Stylus Pro 4880 Field Repair Guide 1/17/08 2. Remove the Cover (Left) 1. Remove 2 Screws. 2. Slide off the Cover (Left). Printer Component, Software Item, LCD Display, Printer Button Cover (Left) Removal Page 39.
Page 40: Cover (Right) Removal
Stylus Pro 4880 Field Repair Guide 1/17/08 Cover (Right) Removal 1. Remove the Rear Paper Guide Assembly. Remove the Rear Paper Guide Assembly Printer Component, Software Item, LCD Display, Printer Button Cover (Right) Removal Page 40.
Page 41 Stylus Pro 4880 Field Repair Guide 1/17/08 2. Remove 1 Screw that fastens the Cover (Right Side) to the inside of the Printer. Remove 1 Screw Printer Component, Software Item, LCD Display, Printer Button Cover (Right) Removal Page 41.
Page 42 Stylus Pro 4880 Field Repair Guide 1/17/08 3. Remove the Waste Ink Tank and 1 Screw. 1. Remove Waste Ink Tank 2. Remove 1 Screw Printer Component, Software Item, LCD Display, Printer Button Cover (Right) Removal Page 42.
Page 43 Stylus Pro 4880 Field Repair Guide 1/17/08 4. Remove 2 Screws and slide off the Paper Release Lever. Remove 2 Screws and slide off the Paper Release Lever. Printer Component, Software Item, LCD Display, Printer Button Cover (Right) Removal Page 43.
Page 44 Stylus Pro 4880 Field Repair Guide 1/17/08 5. Remove 2 Screws and slide off the Cover (Right Side). 1. Remove 2 Screws 2. Slide off the Cover (Right Side). Printer Component, Software Item, LCD Display, Printer Button Cover (Right) Removal...
Page 45: Cover (Top) Removal
Stylus Pro 4880 Field Repair Guide 1/17/08 Cover (Top) Removal 1. Using a small flat head screw driver, lever the right Top Cover Hinge pivot point out of the Hinge Frame. 2. Using a small flat head screw driver, lever the left Top Cover Hinge pivot point out of the Hinge Frame.
Page 46: Damper Removal
Stylus Pro 4880 Field Repair Guide 1/17/08 Damper Removal 1. Raise both Ink Levers, closing the Ink Valves. 2. Remove the Left Side Cover. 3. Move the Carriage Mechanism to the left as shown, remove 3 Screws, and remove the Carriage Cover.
Page 47 Stylus Pro 4880 Field Repair Guide 1/17/08 4. Disconnect 4 Cables, remove 1 Screw, and remove the Junction Board 3. Remove the Junction Board. 2. Remove 1 Screw. 1. Disconnect 4 Cables. 5. Remove 4 Screws, 1 Stay Bar, and 1 Spring.
Page 48 Stylus Pro 4880 Field Repair Guide 1/17/08 6. Disconnect the Ink Lines, from the Dampers to be replaced. Disconnect the Lines at the Damper (bottom of the Elbow Joint). Move the Lines to the side, and fasten out of the way.
Page 49 Stylus Pro 4880 Field Repair Guide 1/17/08 8. Lift out the Print Head / Damper Assembly. 9. .Turn over the Print Head / Damper Assembly and remove 3 Screws. Remove 3 Screws. Printer Component, Software Item, LCD Display, Printer Button Damper Removal Page 49.
Page 50 Stylus Pro 4880 Field Repair Guide 1/17/08 10. Disconnect the Print Head from the Damper Assembly. 3. Place the Print Head off to the side 2. Hold the Damper Assembly like 1. Disconnect the Print Head from as shown. this so that ink does not leak.
Page 51 Stylus Pro 4880 Field Repair Guide 1/17/08 12. Install the new Damper(s). 13. Reconnect the Print Head to the Damper Assembly. Connect the Print Head and fasten with 3 Screws. 14. Place the Print Head / Damper Assembly back into the Carriage Mechanism.
Page 52 Stylus Pro 4880 Field Repair Guide 1/17/08 15. Replace 4 Screws, 1 Stay Bar, and 1 Spring. 1 Stay Bar 1 Spring 4 Screws 16. Re-install the Junction Board, fasten with 1 Screw, and reconnect 4 Cables. This Connector has a latch.
Page 53 Stylus Pro 4880 Field Repair Guide 1/17/08 17. Perform a Power Cleaning, located in the User: Maintenance menu. 18. Perform a Nozzle Check and cleaning cycles if necessary. 19. Perform the Print Head mechanical adjustments. Perform 19.1 Print Head Slant Adjustment (CR) 19.2 Perform the...
Page 54: Ink Bay Removal (Left)
Stylus Pro 4880 Field Repair Guide 1/17/08 Ink Bay Removal (Left) 1. Remove the Left and Right Side Covers. 2. Remove the 10 Screws fastening the Front Panel. (View from the back) Remove 4 Screws Remove 5 Screws Remove 1 Screw 3.
Page 55 Stylus Pro 4880 Field Repair Guide 1/17/08 4. Remove the Front Panel. 5. Remove 4 Screws that fasten the Ink Bay Cover, and 1 Screw that fastens the Cartridge Release Handle, and lift off the Cover. Remove 1 Screw This hole in the Cover allows easy access to the Lift off the Cover.
Page 56 Stylus Pro 4880 Field Repair Guide 1/17/08 6. Remove 2 Screws and 2 Brackets 1 Screw and Bracket on the Right Side 1 Screw and Bracket on the Left Side 7. Remove 2 Screws from the front. 2 Screws from the front...
Page 57 Stylus Pro 4880 Field Repair Guide 1/17/08 8. Remove 2 Screws from the back of the Ink Bay Assembly. Blow up of this area Remove 2 Screws Look through this area, on the back of the Printer, to find 2 Screws 9.
Page 58 Stylus Pro 4880 Field Repair Guide 1/17/08 10. Maneuver the Ink Tubes from the Slot. 11. Slide out the Ink Bay Assembly, while assisting the Cables through the Frame. Printer Component, Software Item, LCD Display, Printer Button Ink Bay Removal (Left)
Page 59: Ink Bay Removal (Right)
Stylus Pro 4880 Field Repair Guide 1/17/08 Ink Bay Removal (Right) 1. Remove the Left and Right Side Covers. 2. Remove the 10 Screws fastening the Front Panel. (View from the back) Remove 4 Screws Remove 5 Screws Remove 1 Screw 3.
Page 60 Stylus Pro 4880 Field Repair Guide 1/17/08 4. Remove the Front Panel. 5. Remove 4 Screws that fasten the Ink Bay Cover, and 1 Screw that fastens the Cartridge Release Handle, and lift off the Cover. Remove 1 Screw Remove 4 Screws Lift off the Cover.
Page 61 Stylus Pro 4880 Field Repair Guide 1/17/08 6. Remove 4 Screws and 2 Brackets 1 Screw and Bracket on the right side 1 Screw and Bracket on the left side 1 Screw on 1 Screw on the the right Side.
Page 62 Stylus Pro 4880 Field Repair Guide 1/17/08 8. Remove 2 Screws from the back of the Ink Bay Assembly. View is from the back of the Printer Pump Assembly Remove 2 Screws 9. Disconnect the 4 Foil CSIC Cables and the Cartridge Release Sensor Cable.
Page 63 Stylus Pro 4880 Field Repair Guide 1/17/08 10. Maneuver the Ink Tubes from the slot. 11. Slide out the Ink Bay Assembly, while assisting the Cables through the Frame. Printer Component, Software Item, LCD Display, Printer Button Ink Bay Removal (Right)
Page 64: Input Roller Assembly, Disassembly
Stylus Pro 4880 Field Repair Guide 1/17/08 Input Roller Assembly, Disassembly 1. Remove the E-Ring, Gear, and Paddle shown below. Printer Component, Software Item, LCD Display, Printer Button Input Roller Assembly, Disassembly Page 64.
Page 65 Stylus Pro 4880 Field Repair Guide 1/17/08 2. Detach the 3 Interlocks that fasten the Input Roller Cover, and slide the Cover off the Roller. Detach 3 Interlocks Slide off the Cover 3. Remove the 2 E-Rings shown below Remove the E-Ring...
Page 66 Stylus Pro 4880 Field Repair Guide 1/17/08 4. Detach the 3 Interlocks holding the remaining Roller Cover, and slide it off. 3 Interlocks 5. Slide the remaining components off the Shaft. Printer Component, Software Item, LCD Display, Printer Button Input Roller Assembly, Disassembly...
Page 67 Stylus Pro 4880 Field Repair Guide 1/17/08 6. Release the Interlocks, as shown below. 7. Lift up the Paper Tray Base, and remove the Separation Pad Assembly as shown below. Printer Component, Software Item, LCD Display, Printer Button Input Roller Assembly, Disassembly...
Page 68 Stylus Pro 4880 Field Repair Guide 1/17/08 8. Maneuver the remaining side of the Paper Tray Base as shown below to free the last Separation Pad Assembly. Printer Component, Software Item, LCD Display, Printer Button Input Roller Assembly, Disassembly Page 68.
Page 69: Input Roller Assembly, Re-Assembly
Stylus Pro 4880 Field Repair Guide 1/17/08 Input Roller Assembly, Re-assembly 1. Assemble the Base Unit until it looks this. 2. Maneuver the Separation Pad Assembly into the slot as shown. Printer Component, Software Item, LCD Display, Printer Button Input Roller Assembly, Re-assembly...
Page 70 Stylus Pro 4880 Field Repair Guide 1/17/08 3. Re-hook the Interlock / Pivot Points that connect the Separation Pad Assembly to the Base. 4. Press down on the Separation Pad Assembly until the Black Levers lock it in the down position.
Page 71 Stylus Pro 4880 Field Repair Guide 1/17/08 5. Study the polarity, and order of the parts below. Paddles positioned, so that the The Disks have depressions, that fit Home Position Window faces the oppo- arrow on the side faces up the Springs.
Page 72 Stylus Pro 4880 Field Repair Guide 1/17/08 7. Rotate the Input Rollers so that the flat side is down to allow the Roller to interlock with the Roller Frame. Flat side down This part of both Rollers must fit through the Roller Side Frame.
Page 73 Stylus Pro 4880 Field Repair Guide 1/17/08 9. Test the Roller Assembly before installation Place a piece of paper in the Tray. Rotate the Gear and check for proper operation Printer Component, Software Item, LCD Display, Printer Button Input Roller Assembly, Re-assembly...
Page 74: Input Roller Assembly Removal
Stylus Pro 4880 Field Repair Guide 1/17/08 Input Roller Assembly Removal 1. Remove the Left Side Cover. 2. Remove the Right Side Cover. 3. Remove the Ink Cartridges, and leave the Levers up (closing the Valves). Lever up, closing Lever up, closing...
Page 75 Stylus Pro 4880 Field Repair Guide 1/17/08 1. Remove this Screw on the left. 2. Remove this Screw on the right. 3. Free the Rear Paper Guide Support from the Printer. 4. Remove the Screw that holds the Manual Feed Sensor to the Support.
Page 76 Stylus Pro 4880 Field Repair Guide 1/17/08 6. Rotate the Printer onto it’s back. 7. Remove the 2 screws fastening the Right Side Air Duct to the Frame. 2 Screws Printer Component, Software Item, LCD Display, Printer Button Input Roller Assembly Removal...
Page 77 Stylus Pro 4880 Field Repair Guide 1/17/08 8. Lift the Right Side Air Duct exposing the 2 Screws noted in step 9. This is 1 of the 2 Screws shown is the picture on the left in step 9. 9. Remove the 3 Screws that fasten the Input Roller Assembly to the Right Side Frame.
Page 78 Stylus Pro 4880 Field Repair Guide 1/17/08 10. Remove the 3 Screws that fasten the Input Roller Assembly to the Left Side Frame. 3 Screws 11. Slide the Input Roller Assembly out about 2 inches, disconnect the Input Roller HP Sensor, and fully remove the Assembly.
Page 79: Paper Exit Roller Removal
Stylus Pro 4880 Field Repair Guide 1/17/08 Paper Exit Roller Removal 1. Remove the Left and Right Side Covers. 2. Remove the 10 Screws fastening the Front Panel. (View from the back) Remove 4 Screws Remove 5 Screws Remove 1 Screw 3.
Page 80 Stylus Pro 4880 Field Repair Guide 1/17/08 4. Remove the Front Panel. 5. Remove the2 Screws that fasten the Exit Roller. Remove 2 Screws Printer Component, Software Item, LCD Display, Printer Button Paper Exit Roller Removal Page 80.
Page 81 Stylus Pro 4880 Field Repair Guide 1/17/08 6. Remove the Exit Roller. 7. The Exit Roller must be re-installed using the correct polarity.j Gold Spring side, on the top Long end Short end Silver Spring side, on the bottom Printer Component,...
Page 82: Print Head Replacement Procedure
Stylus Pro 4880 Field Repair Guide 1/17/08 Print Head Replacement Procedure 1. Run the Adjustment Wizard and input the new Print Head’s calibration value. Unplug the Printer. 3. Raise both Ink Levers, closing the Ink Valves. 4. Remove the Left Side Cover.
Page 83 Stylus Pro 4880 Field Repair Guide 1/17/08 7. Carriage Rail Cover (Wheel Track) protection steps. The Carriage Rail Covers will separate and bend when removing the Print Head if not protected. 1. Make a double wall cardboard jig as shown.
Page 84 Stylus Pro 4880 Field Repair Guide 1/17/08 8. Move the Carriage Mechanism at the removal slot as shown. Compress the Tension Springs against the Front Carriage Rail, and lift out the Carriage. Removal Slot Be careful to free the Carriage Timing Strip 9.
Page 85 Stylus Pro 4880 Field Repair Guide 1/17/08 10. Remove the Print Head by rotating the top of the Head away from the Carriage. 11. Remove 3 Screws fastening the Head to the Head Case. Remove 3 Screws Separate the Print Head from the Print Head Case.
Page 86 Stylus Pro 4880 Field Repair Guide 1/17/08 12. Disconnect the Print Head Cables Gently remove the Cables. The Top Cable is the 0 Cable. 13. Connect the new Print Head to the Cables. Ensure that the 0 Cable is on top (Nozzle Plate side).
Page 87 Stylus Pro 4880 Field Repair Guide 1/17/08 19. Verify that the Carriage Rail Covers, Carriage Bearings, Carriage Belt and Timing Strip are properly in place. 20. Move the Carriage Mechanism to the capped position. 21. Plug in the Printer, and lower both Ink Cartridge Levers to open the Ink Valves.
Page 88 Stylus Pro 4880 Field Repair Guide 1/17/08 28.1 Perform Reset When Print Head Change 28.2 Perform the Print Head Slant Adjustment (CR) 28.3 Perform the Print Head Slant Adjustment (PF) 28.4 Perform the Auto Bi-D Adjustment 28.5 Perform the Auto Uni-D Adjustment...
Page 89: Pump And Cap Installation
Stylus Pro 4880 Field Repair Guide 1/17/08 Pump and Cap Installation 1. Before installing the Pump and Cap Assembly identify the Tube Receptacles where the Pump Tubes must be inserted. Blow up view Tubes go here 2. Before installing the Pump and Cap Assembly, note this detail.
Page 90 Stylus Pro 4880 Field Repair Guide 1/17/08 3. Insert the Cap Assembly part of the way, through the back of the Printer. If the Ink Tubes are not fully inserted, the Ink may bubble back through the cap. Slide the Cap and Pump...
Page 91 Stylus Pro 4880 Field Repair Guide 1/17/08 5. Install the Flushing Box and fasten with 1 Screw Tube into the hole leading to the Waste InkTank 1 Screw 6. Plug in the Pump Home Position Sensor. Plug in Printer Component,...
Page 92 Stylus Pro 4880 Field Repair Guide 1/17/08 7. Install the Gear and Shaft Assembly, and fasten it with 2 Screws. Install Gear and 2 Screws Shaft Assembly. 8. Install the Platen Gap Motor, and fasten with 2 Screws. Install the Motor...
Page 93 Stylus Pro 4880 Field Repair Guide 1/17/08 9. Install the Trigger Shaft. Insert Trigger Shaft into the Right Side Frame Insert Into Flex the Trigger Shaft from the back side of the Socket here Printer, until the end of the Shaft can be inserted...
Page 94 Stylus Pro 4880 Field Repair Guide 1/17/08 10. Replace the Trigger Spring. Spring goes here. Ensure that the Splash Guard is routed as shown. 11. Replace the Trigger Assembly End Piece. Trigger Assembly End Piece here 12. Perform Reset When Cleaning Unit Change (if the Cap/Pump Assembly was changed).
Page 95: Pump And Cap Removal
Stylus Pro 4880 Field Repair Guide 1/17/08 Pump and Cap Removal 1. Remove the Right Side Cover. 2. Remove the Flushing Box. Remove Screw. Lift out the Flushing Box. 3. Remove the Trigger Assembly End Piece and Spring. Trigger Assembly End Piece...
Page 96 Stylus Pro 4880 Field Repair Guide 1/17/08 4. Flex the Trigger Shaft until the end farthest from the Side Frame clears it’s Socket, then remove the Shaft. Flex the Shaft from behind Free the end of the Shaft from it’s...
Page 97 Stylus Pro 4880 Field Repair Guide 1/17/08 6. Remove 2 Screws fastening the Platen Gap Motor, and remove. 2 Screws Remove the Motor 7. Remove 2 Screws fastening the Gear and Shaft Assembly, and remove. Remove Gear and Shaft Assembly.
Page 98 Stylus Pro 4880 Field Repair Guide 1/17/08 9. Unplug the Pump Home Position Sensor. Re-assembly note: The Plastic Tray that the Pump / Cap Assembly covers, sits on top of the Pump / Cap Assembly Frame at this corner. Unplug 10.
Page 99 Stylus Pro 4880 Field Repair Guide 1/17/08 Cap and Pump Assembly Components. Wiper Blade Pump Printer Component, Software Item, LCD Display, Printer Button Pump and Cap Removal Page 99.
Page 100: Troubleshooting
Stylus Pro 4880 Field Repair Guide 1/17/08 Troubleshooting Printer Component, Software Item, LCD Display, Printer Button Page 100.
Page 101: Error Codes (Maintenance)
Stylus Pro 4880 Field Repair Guide 1/17/08 Error Codes (Maintenance) 0002 Carriage Motor / Ink Tube end of life (Clear Carriage Motor Counter) 0004 Nozzle check error 0008 RTC error (Real Time Clock) (Check the Battery and reset the Date and Time)
Page 102: Error Codes (Service)
Stylus Pro 4880 Field Repair Guide 1/17/08 Error Codes (Service) 00000088 RTC (Real Time Clock) data is corrupted 00000101 Carriage Motor life (Reset Carriage Motor Counter, check for leaky ink tubes) 00000103 RTC (Real Time Clock) battery is defective 00000105...
Page 103 Stylus Pro 4880 Field Repair Guide 1/17/08 0001001E Paper feed servo parameter error 00010020 CSIC read / write error 00010022 Ink type error 00010023 RTC (Real TIme Clock) (Reset RTC) 00010025 CSIC ROM communication error 00010026 RTC (Real TIme Clock) communication error...
Page 104 Stylus Pro 4880 Field Repair Guide 1/17/08 00010039 PG adjustment value NVRAM error 0001003A PG adjustment value NVRAM error 0001003B Carriage Lock / Cutter Error 0001003C Carriage Lock / Cutter Error 0001003D Carriage Lock / Cutter Error 00020000 NVRAM error...
Page 105 Stylus Pro 4880 Field Repair Guide 1/17/08 00000088 Note: The 00000088 error code indicates that the RTC (Real Time Clock) data is incorrect. 1. Set the RTC by accessing the Maintenance Mode 3: Clear Counters: RTC counter. 2. Replace the Main Board, if the RTC data can not be set.
Page 106 Stylus Pro 4880 Field Repair Guide 1/17/08 00000101 Note: The 00000101 error code indicates that the Carriage Motor and Ink Tubes have reached their end of life. 1. Inspect the Ink Tubes for leaks or cracks. 2. Inspect the Carriage Motor for wear.
Page 107 Stylus Pro 4880 Field Repair Guide 1/17/08 00000103 Note: The 00000103 error code indicates that the RTC Battery is defective. 1. Replace the RTC Battery located on the Main Board. 2. Replace the Main Board. Printer Component, Software Item, LCD Display,...
Page 108 Stylus Pro 4880 Field Repair Guide 1/17/08 00000105 Note: The 00000105 error code indicates that the Print Head has reached it’s end of life. 1. Inspect the Print Heads operation using the Printer’s Maintenance Mode 2: Self Testing: Adjustment: Check Nozzle function.
Page 109 Stylus Pro 4880 Field Repair Guide 1/17/08 00010000 - 00010003 Note: The 00010000 - 00010003 range of error codes indicates that the Paper Feed Motor or Encoder is defective. 1. Manually check the operation (spin) of the Paper Feed Motor.
Page 110: 0001001B
Stylus Pro 4880 Field Repair Guide 1/17/08 0001001B Note: The 0001001B error code indicates that the Print Head Driver thermistor detects an abnormal temperature. The following list represents the historical causes for the 0001001B error. • Re-seat the Print Head Cables on the Board side.
Page 111: Color Shift
Stylus Pro 4880 Field Repair Guide 1/17/08 Color Shift Note: Most color shift issues are not caused by a printer problem, but by the customers “work flow”. “work flow” refers to the customers color management. Usually the printer will accurately print the image that it is sent.
Page 112: Command Error
Stylus Pro 4880 Field Repair Guide 1/17/08 Command Error Note: Command Error usually is generated by a Printer/Driver ink type mismatch. 1. Remove hubs and other devices on the USB bus. 2. Test the Printer using another Computer and Driver.
Page 113: Communication Errors Pc
Stylus Pro 4880 Field Repair Guide 1/17/08 Communication Errors PC Description: Status Monitor 3 reports a Communication Error. Reason: The Printer and the Driver / Computer are not communicating. Troubleshooting process: 1. Check the Printer’s Control Panel and verify. 1.1 The Printer is turned on.
Page 114 • Custom Dongles attached to RIP Servers could cause a problem. • Epson Printers use USB 2.0. Computer Ports that use USB 1.0, may cause a problem. • Status Monitor 3 can report an error on a Windows 2000 system, that does not exist. Turn off the Error Monitoring (Printer Driver: Utility: Speed &...
Page 115: Cover Open
Stylus Pro 4880 Field Repair Guide 1/17/08 Cover Open Note: The Cover Open error indicates that the Printer’s Front Cover is open, or the Cover Sensor is defective. 1. The Cover Sensor can be tested in the Maintenance Mode 2: Self Testing: Test: Sensor menu.
Page 116: Drop Of Ink
Stylus Pro 4880 Field Repair Guide 1/17/08 Drop of Ink Note: A Drop of Ink refers to ink dripping onto the media. Ink drips on the media come from two separate causes. The most common reason is a build up of ink on the nose of the Print Head.
Page 117: Grainy Or Ghosting
Intermittent or missing Nozzles may also be a factor. Non-Epson media or improper media settings in the driver can cause grainy images. Use another Computer with the Epson Driver and Epson Media to eliminate the users equipment. The following components occasionally cause the issue.
Page 118: Horizontal Banding
Stylus Pro 4880 Field Repair Guide 1/17/08 Horizontal Banding Note: Horizontal Banding is either paper feed related, or Print Head related. Horizontal Banding is caused by vertical dot placement errors. Feed Related Feed related horizontal banding is always spaced at the same interval as the MicroWeave step.
Page 119 Use another Computer with the Epson Driver and Epson Media to eliminate the users equipment. Verify that the proper Spindle is being used (High Tension or Low Tension Spindle) Verify that the media does not bind coming off the roll.
Page 120: Missing Nozzle Diagnosis And Repair
Stylus Pro 4880 Field Repair Guide 1/17/08 Missing Nozzle Diagnosis and Repair Note: Inspect the printer and media for dust or fiber accumulation. Excessive “dirt” will cause missing nozzles. Some Missing Nozzles, one or more colors 1. Check the Printer’s components for mechanical problems and “dirt”.
Page 121 Stylus Pro 4880 Field Repair Guide 1/17/08 1. Check the following components of the ink supply for a minor restriction, causing partial starvation. Note: Partial Starvation refers to a slight blockage of the ink supply system that slowly starves the Print Head for ink.
Page 122 Stylus Pro 4880 Field Repair Guide 1/17/08 1.1.1 When the Printhead moves off of the Cap, and the Pump is running, inject water into the Cap with a syringe. 1.1.1.1 If the water is drawn through the Cap, the Pump is good.
Page 123: Paper Jam Errors
Stylus Pro 4880 Field Repair Guide 1/17/08 Paper Jam Errors Note: The Paper Jam Error indicates that one of the paper sensors does not detect paper properly. Roll Paper Maintenance Mode 2: Self Testing: Test: Sensor menu Test the following sensors using the •...
Page 124: Paper Not Cut
Stylus Pro 4880 Field Repair Guide 1/17/08 Paper Not Cut Note: The Paper Not Cut error indicates that the Printer detected that the paper did not separate, after cutting. Paper cutting errors occur: •When the Cutter Blade is defective. •When the Cutter Blade does not have white nylon wheels.
Page 125: Reload Paper
Stylus Pro 4880 Field Repair Guide 1/17/08 Reload Paper Note: The Reload Paper error indicates that the Printer recognizes paper in the Printer, but can not sense it’s size or location properly. The reload paper error can be generated if the paper is loaded beyond the alignment marks (paper loading alignment marks).
Page 126 Stylus Pro 4880 Field Repair Guide 1/17/08 Encoder menu. Printer Component, Software Item, LCD Display, Printer Button Reload Paper Page 126.
Page 127: Random Nozzles
Stylus Pro 4880 Field Repair Guide 1/17/08 Random Nozzles Note: Random Nozzles refers to Nozzles that fire when they are not commanded to. Random Nozzle firing is caused by 1 of 4 components •Head Cables •Print Head •Main Board •Power Supply Head Cable Inspect the Head Cables for worn insulation.
Page 128: Scratch
Stylus Pro 4880 Field Repair Guide 1/17/08 Scratch Note: A scratch is damage to the media surface caused by contact with a roller or other Printer components. Sometimes scratches occur before the media is inserted into the Printer. Some media is very sensitive to surface abrasions. Contact between the Pinch Rollers, the Paper Feed Roller, and the media is necessary to support and move it.
Page 129: Set Ink Cartridges
Stylus Pro 4880 Field Repair Guide 1/17/08 Set Ink Cartridges Note: The Set Ink Cartridge error indicates that the Printer does not detected one or more Ink Cartridges. The error is usually generated when: •The Ink Cartridge Release Sensor is defective.
Page 130: Set Ink Lever
Stylus Pro 4880 Field Repair Guide 1/17/08 Set Ink Lever Note: The Set Ink Lever message indicates that the Ink Lever is in the up position, or that the Ink Lever Sensor is Defective. 1. Check the position of the Ink Cartridge Release Lever.
Page 131: Smear
Note: A smear is caused by something “smearing” the intended image, after the image is printed. Many times smearing is a result of non-Epson media or ink. Non-Epson ink or media may dry to slowly, resulting in a smear after the image leaves the Printer. Adjusting the...
Page 132: Smudge
Stylus Pro 4880 Field Repair Guide 1/17/08 Smudge Note: A smudge is a mark left on the media by contact. It can be caused by contact with the Print Head, or contact with a dirty Roller. Dirty Roller A dirty Roller usually leaves a mark that repeats at an interval that is equal to the circumference of the Roller. Plac- ing the image with the smudge back into the paper path, and aligning the smudge with the Printer’s Rollers will indi-...
Page 133: Vertical Banding
Computer with the Epson Driver and Epson Media to eliminate the users equipment. Non-Epson drivers effect verti- cal banding if the amount of ink that is applied to the media is too low. Using the Epson driver should look better, if that is the case.
Page 134: Wrong Ink Cartridge
Stylus Pro 4880 Field Repair Guide 1/17/08 Wrong Ink Cartridge Note: The Wrong Ink Cartridge error indicates that the Printer detects an Ink Cartridge that does not match the Ink type expected. 1. Verify that the Maintenance Mode 2: Service Config: NPD value is set to the correct ink type.
Page 135: Adjustments
Stylus Pro 4880 Field Repair Guide 1/17/08 Adjustments Printer Component, Software Item, LCD Display, Printer Button Page 135.
Page 136: 980Mm Feed Adjustment
Stylus Pro 4880 Field Repair Guide 1/17/08 980mm Feed Adjustment Note: The 980mm Feed Adjustment calibrates the Paper Feed Mechanism. 1. Load 17” Enhanced Matte roll paper. 2. From the Adjustment Wizard for the Pro 4880, select the 1000mm Feed Adjustment.
Page 137: Auto Bi-D Adjustment
Stylus Pro 4880 Field Repair Guide 1/17/08 Auto Bi-D Adjustment Note: This adjustment automatically performs all Bi-Directional Adjustments. 1. Load 17” Enhanced Matte roll paper. 2. From the Adjustment Wizard for the Pro 4880, select the Auto Bi-D Adjustment. 1. Click on the button.
Page 138: Auto Uni-D Adjustment
Stylus Pro 4880 Field Repair Guide 1/17/08 Auto Uni-D Adjustment Note: This adjustment automatically performs all Uni-Directional Adjustments. 1. Load 17” Enhanced Matte roll paper. 2. From the Adjustment Wizard for the Pro 4880, select the Auto Uni-D Adjustment. 1. Click on the button.
Page 139: Carriage Timing Belt Tension Adjustment
Stylus Pro 4880 Field Repair Guide 1/17/08 Carriage Timing Belt Tension Adjustment Note: This mechanical adjustment sets the Carriage Belt Tension. 1. Remove the Left Side Cover. 2. Turn the Adjustment Screw until the Belt Bracket is positioned by the 3rd Mark from the right.
Page 140: Check Network Communication
Pro 4880 Field Repair Guide 1/17/08 Check Network Communication Note: The Check Network Communication adjustment item tests the Ethernet Port on the Printer. 1. Prepare the Printer’s Ethernet Port for the test. 1.1 Enter the User Menu on the Printer, and navigate to NETWORK SETUP.
Page 141 Pro 4880 Field Repair Guide 1/17/08 5. From the Adjustment Wizard for the Pro 4880, select Check Network Communication 1. Enter the Printer’s IP Address. 2. Click on the button to start the test. 3. The Printer will print out a Status Sheet (test print).
Page 142: Check Nozzle
Stylus Pro 4880 Field Repair Guide 1/17/08 Check Nozzle Note: Check Nozzle performs a user Nozzle Check. 1. From the Adjustment Wizard for the Pro 4880, select Check Nozzle. 1. Load paper. 2. Click on to print the pattern. The nozzle check pattern should look like this.
Page 143: Check Platen Gap
Stylus Pro 4880 Field Repair Guide 1/17/08 Check Platen Gap Note: Check Platen Gap allows physical verification of the proper operation (setting) of the Platen Gap Detent Cam. 1. From the Adjustment Wizard for the Pro 4880, select Check Platen Gap.
Page 144: Cleaning / Charging (Priming)
Stylus Pro 4880 Field Repair Guide 1/17/08 Cleaning / Charging (Priming) Note: Cleaning explains the function of the various cleaning cycles accessed with the function keys. 1. From the Adjustment Wizard for the Pro 4880, select Cleaning. forces a Prime.
Page 145: Clear Pf Micro Feed Adjustment [Bi-D]
Stylus Pro 4880 Field Repair Guide 1/17/08 Clear PF Micro Feed Adjustment [Bi-D] Note: The Clear PF Micro Feed Adjustment [Bi-D] resets the user paper feed adjustments that modifies the paper feed tables. It should be reset every time the Feed Length Adjustment is performed.
Page 146: Copy Bi-D Variables
Stylus Pro 4880 Field Repair Guide 1/17/08 Copy Bi-D Variables Note: Copy Bi-D Variables transfers the data from the Manual Bi-D Adjustment at standard platen gap, to the memory locations that correspond to the other 4 platen gaps. The ink must travel different distances for each platen gap, and the timing must be adjusted to compensate for the different “flight times”.
Page 147: Copy Uni-D Variables
Stylus Pro 4880 Field Repair Guide 1/17/08 Copy Uni-D Variables Note: Copy Uni-D Variables transfers the data from the Manual Uni-D Adjustment at standard platen gap, to the memory locations that correspond to the other 4 platen gaps. The ink must travel different distances for each platen gap, and the timing must be adjusted to compensate for the different “flight times”.
Page 148: Cr Encoder Sensor Position Adjustment
Stylus Pro 4880 Field Repair Guide 1/17/08 CR Encoder Sensor Position Adjustment Purpose: The Carriage Encoder Sensor Position Adjustment is used to ensure that the Carriage Encoder Timing Strip is centered in the Carriage Encoder Sensor across the entire length of the Printer Mechanism.
Page 149: Head Rank Id
Stylus Pro 4880 Field Repair Guide 1/17/08 Head Rank ID Note: Enter the Head Rank ID before installing the 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.
Page 150: Ink Discharge
Stylus Pro 4880 Field Repair Guide 1/17/08 Ink Discharge. Note: Ink Discharge allows the evacuation of the ink in the Tubes. 1. From the Adjustment Wizard for the Pro 4880, select Ink Discharge. 1. Remove the Ink Cartridges 2. Click on Run.
Page 151: Multi Sensor Adjustment
Stylus Pro 4880 Field Repair Guide 1/17/08 Multi Sensor Adjustment Note: The Multi Sensor Adjustment for Auto Nozzle Check calibrates the Auto Nozzle Check function. 1. Load 17” Enhanced Matte roll paper. 2. From the Adjustment Wizard for the Pro 4880, select the Mulit Sensor Adjustment for Auto Nozzle Check.
Page 152: Multi Sensor Auto Pf Adjustment
Stylus Pro 4880 Field Repair Guide 1/17/08 Multi Sensor Auto PF Adjustment Note: This adjustment automatically calibrates the Paper Feed mechanism. 1. Load 17” Enhanced Matte roll paper. 2. From the Adjustment Wizard for the Pro 4880, select the Multi Sensor Auto PF Adjustment.
Page 153: Multi Sensor Level Adjustment
Stylus Pro 4880 Field Repair Guide 1/17/08 Multi Sensor Level Adjustment Note: This adjustment sets the “White Level” for the Multi Sensor (sensitivity calibration). 1. Load 17” Enhanced Matte roll paper. 2. From the Adjustment Wizard for the Pro 4880, select the Multi Sensor Level Adjustment 1.
Page 154: Multi Sensor Position Adjustment
Stylus Pro 4880 Field Repair Guide 1/17/08 Multi Sensor Position Adjustment Note: This mechanical adjustment fixes the physical position of the Multi Sensor. 1. Rotate the Rear Carriage Rail until the Platen Position Stopper is in the first Detent. First Detent.
Page 155 Stylus Pro 4880 Field Repair Guide 1/17/08 3. Move the Multi Sensor over the thickness gauge. 1. Move the Multi Sensor over the thickness gauge. 2. Loosen 2 Screws and move the Multi Sensor in the direction of the arrows 3.
Page 156: Nozzle Bi-D Adjustment
Stylus Pro 4880 Field Repair Guide 1/17/08 Nozzle Bi-D Adjustment Note: This adjustment calibrates the Auto Nozzle Check Function. 1. Load 17” Enhanced Matte roll paper. 2. From the Adjustment Wizard for the Pro 4880, select the Nozzle Bi-D Adjustment.
Page 157: Paper Feed Timing Belt Adjustment
Stylus Pro 4880 Field Repair Guide 1/17/08 Paper Feed Timing Belt Adjustment Note: This adjustment sets the Paper Feed Belt tension. 1. Remove the Left Side Cover. 2. Remove 2 Screws to free the Flexible Cable Support, and move it down, (out of the way).
Page 158 Stylus Pro 4880 Field Repair Guide 1/17/08 apply tension to the Belt. Loosen this screw. This spring will apply tension to the belt. 4. Tighten the Screw, then check the Belt tension with your finger. There should be a deflection of approximately 1/8”...
Page 159: Paper Thickness Sensor Adjustment
Stylus Pro 4880 Field Repair Guide 1/17/08 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”...
Page 160 Stylus Pro 4880 Field Repair Guide 1/17/08 3. Remove the Top Cover. 4. Remove the Paper Thickness Sensor Cover. 1. Remove 3 Screws 2. Lift up, and off. 5. Press and hold the Left, Down, and buttons, and turn on the Printer (Maintenance Mode 2).
Page 161 Stylus Pro 4880 Field Repair Guide 1/17/08 9. Insert the thickness gauges into the paper path as shown, and engage the pressure rollers (Paper Release Lever down). Insert thickness gauge as shown. direction Right digit Left digit direction 1. Insert the 4 gauges and check that the 3 condi- tions listed in step 9 are true.
Page 162: Platen Gap Adjustment
Stylus Pro 4880 Field Repair Guide 1/17/08 Platen Gap Adjustment Note: The Platen Gap Adjustment sets the physical platen gap to the correct distance. 1. Remove the Left Side Cover. 2. Open the Top Cover, and defeat the Top Cover Sensor by wedging something (paper) against the Sensor.
Page 163 Stylus Pro 4880 Field Repair Guide 1/17/08 4. Press and hold the Left, Down, and buttons, and turn on the Printer (Maintenance Mode 2). 5. Using the Down button, navigate to Self Testing: Adjustment: and press the Menu button. 6. Using the...
Page 164 Stylus Pro 4880 Field Repair Guide 1/17/08 10. Place the Platen Position Detent device in the position shown below, and tighten the 2 Screws. Turn until the Stopper is resting in the first Detent (the detent has an arrow pointing at it).
Page 165: Platen Position Adjustment
Stylus Pro 4880 Field Repair Guide 1/17/08 Platen Position Adjustment Note: This Adjustment Calibrates “Borderless” printing. 1. Load 17” Enhanced Matte roll paper. 2. From the Adjustment Wizard for the Pro 4880, select the Platen Position Adjustment. 1. Click on the Print button.
Page 166 Stylus Pro 4880 Field Repair Guide 1/17/08 7. Click on the Check button. 8. The Printer will print and alignment check sheet. 9. Verify that the alignment marks are centered over the Borderless Printing Pads. (If they are not click on the Back button and repeat steps 1 - 5.
Page 167: Print Head Slant Adjustment (Cr)
Stylus Pro 4880 Field Repair Guide 1/17/08 Print Head Slant Adjustment (CR) Note: This adjustment impacts Nozzle Array linearity (Print Head rotation) 1. From the Adjustment Wizard for the Pro 4880, select the Print Head Slant Adjustment (CR). Printer Component,...
Page 168 Stylus Pro 4880 Field Repair Guide 1/17/08 2. Move the Carriage to the position shown below, remove 3 Screws, and remove the Carriage Cover. Move the Carriage to Remove 3 Screws Remove the Carriage Cover this position (align with the notch)
Page 169 Stylus Pro 4880 Field Repair Guide 1/17/08 3. Loosen the 4 indicated Screws 1/4 turn. Loosen these 4 Screws 1/4 turn. 4. Move the Carriage back to the capped position. Printer Component, Software Item, LCD Display, Printer Button Print Head Slant Adjustment (CR)
Page 170 Stylus Pro 4880 Field Repair Guide 1/17/08 5. Click on the Print and the alignment pattern will be printed. Click on Print. Printer Component, Software Item, LCD Display, Printer Button Print Head Slant Adjustment (CR) Page 170.
Page 171 Stylus Pro 4880 Field Repair Guide 1/17/08 6. Using a lens, inspect the printed pattern. The pattern should look like this Move this lever down to rotate the Print Head clockwise. Printer Component, Software Item, LCD Display, Printer Button Print Head Slant Adjustment (CR)
Page 172 Stylus Pro 4880 Field Repair Guide 1/17/08 7. Click on the Next button 3 times until the following screen is displayed, then click on the button to return the Carriage to the capped position. Click on the button to return the Carriage to the capped position.
Page 173 Stylus Pro 4880 Field Repair Guide 1/17/08 8. Adjust, and reprint, until the alignment pattern is correct. 9. Tighten the 4 Screws, and reprint the pattern to verify that the pattern is still correct. 10. Re-install the Carriage Cover. Printer Component,...
Page 174: Print Head Slant Adjustment (Pf)
Stylus Pro 4880 Field Repair Guide 1/17/08 Print Head Slant Adjustment (PF) Note: This adjustment impacts the Print Heads “heel / toe” positioning to the media. 1. From the Adjustment Wizard for the Pro 4880, select the Print Head Slant Adjustment (PF).
Page 175 Stylus Pro 4880 Field Repair Guide 1/17/08 4. Adjust if necessary.. The Lever employs detentes to lock it in place. Flex the top portion of the Lever in the direction of the pivot point to release the detentes. 1. Loosen 1 Screw that fastens the Adjustment Lever 2.
Page 176: Rear Sensor Calibration
Stylus Pro 4880 Field Repair Guide 1/17/08 Rear Sensor Calibration Note: This adjustment sets the “White Level” for the RearAD Sensor (sensitivity calibration). Note: This adjustment can be performed using the customer’s media if it is non-standard (transparent, etc.). 1. Place paper in the paper path. Ensure that the paper is inserted past the Pinch Rollers and the Paper Feed Roller.
Page 177: Reset Asf Counter
Stylus Pro 4880 Field Repair Guide 1/17/08 Reset ASF Counter Note: Reset ASF Counter is used to reset the Automatic Sheet Feeder counter. 1. From the Adjustment Wizard for the Pro 4880, select Reset ASF Counter. 1. Click on to reset the ASF counter.
Page 178: Reset Paper Ejection Switching / Pg Switching Counter
Stylus Pro 4880 Field Repair Guide 1/17/08 Reset Paper Ejection Switching / PG Switching Counter Note: Reset Paper Ejection Switching is used to reset the Paper Exit Roller counter. 1. From the Adjustment Wizard for the Pro 4880, select Reset Paper Ejection Switching.
Page 179: Reset Pf Motor Counter
Stylus Pro 4880 Field Repair Guide 1/17/08 Reset PF Motor Counter Note: Reset PF Motor Counter is used to reset the Paper Feed Motor counter. 1. From the Adjustment Wizard for the Pro 4880, select Reset PF Motor Counter. 1. Click on to reset the Paper Feed Motor counter.
Page 180: Reset When Cleaning Unit Change
Stylus Pro 4880 Field Repair Guide 1/17/08 Reset When Cleaning Unit Change Note: Rest When Cleaning Unit Change is used to reset the Cleaning Unit counter. 1. From the Adjustment Wizard for the Pro 4880, select Check Nozzle. 1. Click on to reset the Cleaning Unit counter.
Page 181: Reset When Cr Unit Change
Stylus Pro 4880 Field Repair Guide 1/17/08 Reset When CR Unit Change Note: Reset When CR Unit Change is used to reset the Carriage Unit counter. 1. From the Adjustment Wizard for the Pro 4880, select Reset When CR Unit Change.
Page 182: Reset When Cutter Solenoid Change
Stylus Pro 4880 Field Repair Guide 1/17/08 Reset When Cutter Solenoid Change Note: Reset When Cutter Solenoid Change is used to reset the Cutter Solenoid life counter. 1. From the Adjustment Wizard for the Pro 4880, select Reset When Cutter Change.
Page 183: Reset When Print Head Change
Stylus Pro 4880 Field Repair Guide 1/17/08 Reset When Print Head Change Note: Reset When Print Head Change is used to reset the Print Head life counter. 1. From the Adjustment Wizard for the Pro 4880, select Reset When Print Head Change.
Page 184: Rtc & Usbid Adjustment
Pro 4880 Field Repair Guide 1/17/08 RTC & USBID Adjustment Note: The RTC & USBID Adjustment is used to write the correct time and USB ID to the Main Board. Note: The Printer’s USB ID will be changed by this operation. Note: Sometimes the Printer must be in Serviceman Mode for the RTC &...
Page 185: Skew Check
Stylus Pro 4880 Field Repair Guide 1/17/08 Skew Check Note: This function checks the amount of skew the printer exhibits. 1. Load 17” Enhanced Matte roll paper. 2. From the Adjustment Wizard for the Pro 4880, select the Skew Check.
Page 186: T&B&S [Cut Sheet] Adjustment
Stylus Pro 4880 Field Repair Guide 1/17/08 T&B&S [Cut Sheet] Adjustment Note: This function sets the top, bottom, and side margins for cut sheet paper. 1. Load A4 Enhanced Matte cut sheet paper. 2. From the Adjustment Wizard for the Pro 4880, select the T&B&S [Cut Sheet].
Page 187: T&B&S [Roll Paper] Adjustment
Stylus Pro 4880 Field Repair Guide 1/17/08 T&B&S [Roll Paper] Adjustment Note: This function sets the top, bottom, and side margins for roll paper. 1. Load 17” Enhanced Matte roll paper. 2. From the Adjustment Wizard for the Pro 4880, select the T&B&S [Roll Paper].
Page 188: Writing Mac Address
Pro 4880 Field Repair Guide 1/17/08 Writing MAC Address Note: Writing MAC Address writes the unique number, located on a label on the inside of the Printer by the Main Board, to the Main Board. 1. From the Adjustment Wizard for the Pro 4880, select Writing MAC Address.
Page 189 Pro 4880 Field Repair Guide 1/17/08 After approximately 2 minutes, the utility will display this mes- sage. 3. Click on OK. 4. Click on Cancel finish. Printer Component, Software Item, LCD Display, Printer Button Writing MAC Address Page 189.
Page 190: Component Pictures
Stylus Pro 4880 Field Repair Guide 1/17/08 Component Pictures Printer Component, Software Item, LCD Display, Printer Button Page 190.
Page 191: Board (Main) Picture
Stylus Pro 4880 Field Repair Guide 1/17/08 Board (Main) Picture CN52 CN10 CN54 CN20 CN48 CN19 CN51 CN53 CN56 CN59 CN57 CN15 CN18 CN16 CR2032 Battery CN14 CN60 Ethernet CN50 CN61 CN12 USB Port CN55 Port Printer Component, Software Item,...
Page 192: Board (Power Suppy) Picture
Stylus Pro 4880 Field Repair Guide 1/17/08 Board (Power Suppy) Picture CN1 to AC Power CN2 to Main Board Printer Component, Software Item, LCD Display, Printer Button Board (Power Suppy) Picture Page 192.
Page 193: Reference
Stylus Pro 4880 Field Repair Guide 1/17/08 Reference Printer Component, Software Item, LCD Display, Printer Button Page 193.
Page 194: Accessories List
Stylus Pro 4880 Field Repair Guide 1/17/08 Accessories List Accessories Sales Part Number Description C4800STAND Printer Stand C12C811171 2”/3”, 17” Normal Tension Media Spindle C12C811191 2”/3”, 17” High Tension Media Spindle C12C815291 Cutter Blade C12C8890071 Maintenance Tank C4800TUMI TUMI Stylus Pro 4800 (also fits 4880) Printer Cover...
Page 195: Cleaning Fluid
Stylus Pro 4880 Field Repair Guide 1/17/08 Cleaning Fluid Note: Cleaning fluid for the Pro 4000 series is unique. It is an improved formula for pigmented ink. Note: 8 Cartridges are required to flush the system. Part #: 1243924 Description: Cleaning Liquid Cartridge.
Page 196: Connector Diagram
Stylus Pro 4880 Field Repair Guide 1/17/08 Connector Diagram Printer Component, Software Item, LCD Display, Printer Button Connector Diagram Page 196.
Page 197: Connectors / Wiring
Stylus Pro 4880 Field Repair Guide 1/17/08 Connectors / Wiring Main Board Connectors Connector #: Connected To: Pins: Power Supply CN2 Carriage Board (C593 Sub Board D) CN1 Carriage Board (C593 Sub Board D) CN2 Carriage Board (C593 Sub Board D) CN3 CN12 USB 2.0...
Page 198 Stylus Pro 4880 Field Repair Guide 1/17/08 Connector #: Connected To: Pins: CN54 Sub Board B CN100 CN56 Rear Cover Sensor CN57 Power Supply Fan CN62 Ethernet Port C511 Sub Board B Connectors Connector #: Connected To: Pins: CN22 Top Cover Sensor...
Page 199 Stylus Pro 4880 Field Repair Guide 1/17/08 Connector #: Connected To: Pins: CN46 Maintenance Tank CSIC CN55 Pump Home Position Sensor CN100 Main Board CN54 CN101 Main Board CN51 CN102 Main Board CN48 CN103 Control Panel CN1 C594 Sub-C Board...
Page 200 Stylus Pro 4880 Field Repair Guide 1/17/08 C593 Sub Board D Connector #: Connected To: Pins: Main Board CN7 Main Board CN8 Main Board CN9 Carriage Board CN1 Print Head Print Head C593 Carriage Board Connector #: Connected To: Pins:...
Page 201 Stylus Pro 4880 Field Repair Guide 1/17/08 Control Panel Connector #: Connected To: Pins: Main Board CN103 Printer Component, Software Item, LCD Display, Printer Button Connectors / Wiring Page 201.
Page 202: Consumable/Service Parts List
Stylus Pro 4880 Field Repair Guide 1/17/08 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 #...
Page 203 Stylus Pro 4880 Field Repair Guide 1/17/08 Service Part # Sales Part # Paper Type ECCC Cost after 40% discount WAS041603 S041603 Enhanced Matte Paper size A4 (250 sheets) $106.32 WAS041725 SO41725 Enhanced Matte Paper 17” x 100’ roll $38.50...
Page 204 Stylus Pro 4880 Field Repair Guide 1/17/08 Sales Part Number 220 ML (Pro 4880) T606900 UltraChrome K3 Light Light Black Printer Component, Software Item, LCD Display, Printer Button Consumable/Service Parts List Page 204.
Page 205: Firmware History
Example A01354 SP4800 DAY YEAR MONTH 2005 April Example: I0154B SP4000 DAY YEAR MONTH 2004 Stylus Pro 4880 Current Firmware Ver. B0057A.upg Release date: 10/05/07 1. Initial Release Printer Component, Software Item, LCD Display, Printer Button Firmware History Page 205.
Page 206: Firmware Update Procedure
Stylus Pro 4880 Field Repair Guide 1/17/08 Firmware Update Procedure 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,...
Page 207: Glossary
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.
Page 208 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.
Page 209 Stylus Pro 4880 Field Repair Guide 1/17/08 Head Gap Adjustment: An electronic print head adjustment that ensures that the printer knows the exact distance between nozzle sets on separate heads. Also known as Head L/R and Uni-Di... Head ID: The calibration value written on the print head that allows the printers electronics to compensate for the print heads “personality”...
Page 210 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.
Page 211 Stylus Pro 4880 Field Repair Guide 1/17/08 Pixilated: An image quality issue that is caused by a low-resolution image printed at high reso- lution. 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.
Page 212 Stylus Pro 4880 Field Repair Guide 1/17/08 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.
Page 213: Ink Draining Procedure
Stylus Pro 4880 Field Repair Guide 1/17/08 Ink Draining Procedure 1. Press and hold the Pause, Down, and Menu buttons, and turn on the Printer (Maintenance Mode 2. Press the Menu button once to enter the Self Testing2 menu. 3. Using the...
Page 214: Ink Tube/Color Order
Stylus Pro 4880 Field Repair Guide 1/17/08 Ink Tube/Color Order Note: This chapter documents the order that the Ink Tubes are connected to the Print Head. The Ink Tube/Print Head color order is listed left to right. 1. Light Light Black 2.
Page 215: Prime, On Or Off
Stylus Pro 4880 Field Repair Guide 1/17/08 Prime, On or Off Prime, Initial Fill, and Charge mean the same thing. They all refer to filling the Ink System with ink. Controlling the Prime function requires Setting, or Resetting the Init.Fill Flag.
Page 216: Revision History
Stylus Pro 4880 Field Repair Guide 1/17/08 Revision History January 16, 2007 1. Initial release. Printer Component, Software Item, LCD Display, Printer Button Revision History Page 216.
Page 217: Sensors, Motors, Solenoids, And Fans
Stylus Pro 4880 Field Repair Guide 1/17/08 Sensors, Motors, Solenoids, and Fans Home Position Sensors: Carriage HP Sensor Origin) Gap HP Sensor (Head Slide) Pump HP Sensor(Pump) Exit Roller HP Sensor (POUT) ASF Roller HP Sensor Maintenance/Waste Ink Tank Sensor...
Page 218 Stylus Pro 4880 Field Repair Guide 1/17/08 Motors Carriage Motor Paper Feed Motor: turns the Paper Feed Roller, Sub Roller and the Eject Roller Pump Motor: also turns the Input Roller Platen Gap Motor: also sets the Eject Roller position,...
Page 219: Service Procedure
Stylus Pro 4880 Field Repair Guide 1/17/08 Service Procedure Note: Because of the large amount of ink that some service procedures require, please use your Ink and Waste Tank, not the customers. 1. Observe the customer’s service issue. 2. Update the firmware to the current version if necessary.
Page 220 Stylus Pro 4880 Field Repair Guide 1/17/08 11. Perform the 980mm Feed Adjustment, or Multi Sensor Auto PF Adjustment. 12. Perform the Auto Bi-D Adjustment. 13. Perform the Auto Uni-D Adjustment. 14. Perform the T&B&S [Roll Paper] adjustment. 15. Perform the T&B&S [Cut Sheet]...
Page 221: Service Tools
Stylus Pro 4880 Field Repair Guide 1/17/08 Service Tools Service Part Number Description 1418585 Cleaning Liquid Cartridge (Package of 4) 1303211 Ink Conversion Cartridge (Cyan) 1303212 Ink Conversion Cartridge ( Vivid Magenta) 1303213 Ink Conversion Cartridge (Yellow) 1047746 1000mm Scale (meter stick)
Page 222: Stress Test (Test Image)
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?
Page 223: User Nozzle Check Order
Stylus Pro 4880 Field Repair Guide 1/17/08 User Nozzle Check Order User Nozzle Check Color Order (Stair Step) (Listed Left to Right) 1. Photo Black/Matte Black 2. Cyan 3. Vivid Magenta 4. Yellow 5. Light Black 6. Light Cyan 7. Light Vivid Magenta 8.
Page 224: Utilities
Stylus Pro 4880 Field Repair Guide 1/17/08 Utilities Printer Component, Software Item, LCD Display, Printer Button Page 224.
Page 225: Adjustment Wizard2
Stylus Pro 4880 Field Repair Guide 1/17/08 Adjustment Wizard2 Note: The Adjustment Wizard will only run on a computer that has been registered with Epson. Note: The Adjustment Wizard is the utility that enables electronic and mechanical alignments of the Pro 4880.
Page 226 Stylus Pro 4880 Field Repair Guide 1/17/08 4. Click on to accept the license agreement.j Click on to accept the license agreement. Printer Component, Software Item, LCD Display, Printer Button Adjustment Wizard2 Page 226.
Page 227 Stylus Pro 4880 Field Repair Guide 1/17/08 5. Ignore this message if it occures, and click on OK. Click on 6. Pick the correct printer driver/port, Individual, and click Start. Printer Driver and Port. Individual Start Printer Component, Software Item,...
Page 228 Stylus Pro 4880 Field Repair Guide 1/17/08 7. The utility will look like this. 8. Double click on the individual line items to perform each adjustment. Printer Component, Software Item, LCD Display, Printer Button Adjustment Wizard2 Page 228.
Page 229: Fwupdate.exe
Stylus Pro 4880 Field Repair Guide 1/17/08 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 utility Icon. FWUpdate.exe Double Click on this Icon. 2. The utility will open and look like this.
Page 230 Stylus Pro 4880 Field Repair Guide 1/17/08 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 firmware. Note: Stylus Pro 7400 is the Japanese model name for the Stylus Pro 7800.
Page 231 Stylus Pro 4880 Field Repair Guide 1/17/08 5. Select the correct Firmware File 1. Select the correct Firmware File. 2. Click on 6. Click on to upload the to the Printer. Send Firmware Click on Send to upload the Firmware.
Page 232 Stylus Pro 4880 Field Repair Guide 1/17/08 7. The utility will display this, click on Click on Printer Component, Software Item, LCD Display, Printer Button FWUpdate.exe Page 232.
Page 233: Nvram.exe
Stylus Pro 4880 Field Repair Guide 1/17/08 NVRAM.EXE Note: NVRAM.EXE is the utility that enables the backup and re-installation of parameters (settings), necessary when exchanging the Main Board of a Pro 4880. Installation: 1. Ensure that the Pro 4880 Printer Driver...
Page 234 Stylus Pro 4880 Field Repair Guide 1/17/08 5. Click on to accept the license agreement.j Click on to accept the license agreement. Printer Component, Software Item, LCD Display, Printer Button NVRAM.EXE Page 234.
Page 235 Stylus Pro 4880 Field Repair Guide 1/17/08 Parameter Backup 1. Pick the appropriate printer driver. The port that the driver is associated with, will be displayed. 2. Click on Information. The utility will display this, until it is fin- ished transferring data.
Page 236 Stylus Pro 4880 Field Repair Guide 1/17/08 Parameter Backup (continued) The utility will display the Printer’s serial number when finished transfer- ring the parameters. 3. Click on Save to save the parame- ters, and assign the file a name. The utility assigns the Printer’s serial number as the default name for the file.
Page 237 Stylus Pro 4880 Field Repair Guide 1/17/08 Parameter Backup (continued) The utility will display this screen after saving the file. Printer Component, Software Item, LCD Display, Printer Button NVRAM.EXE Page 237.
Page 238 Stylus Pro 4880 Field Repair Guide 1/17/08 Parameter Restore. 1. Pick the appropriate printer driver. The port that the driver is associated with, will be displayed. Printer Component, Software Item, LCD Display, Printer Button NVRAM.EXE Page 238.
Page 239 Stylus Pro 4880 Field Repair Guide 1/17/08 Parameter Restore (Continued) 2. Select the parameter file to be restored to the Printer. 3. Click on Open load the parameter file to be restored to the Printer. Printer Component, Software Item, LCD Display, Printer Button NVRAM.EXE...
Page 240 Stylus Pro 4880 Field Repair Guide 1/17/08 Parameter Restore (Continued) 4. Click on Write to send previously loaded Parameters to the Printer. The utility will display this screen while it is transmitting the Parameters to the Printer. Do not turn the printer off until the utility displays this screen.

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