Epson F4800 Field Repair Guide
Stylus Pro 4800 Field Repair Guide 6/9/05
Table of Contents
Table of Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
Control Panel Map - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
Component Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11
Carriage Removal Procedure - - - - - - - - - - - - - - - - - - - - - 12
Cartridge Release Lever Repair - - - - - - - - - - - - - - - - - - - - 15
Cartridge Release Sensor Repair - - - - - - - - - - - - - - - - - - - 16
Damper Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
Ink Bay Removal (Left) - - - - - - - - - - - - - - - - - - - - - - - - 25
Ink Bay Removal (Right) - - - - - - - - - - - - - - - - - - - - - - - 30
Input Roller Assembly, Disassembly - - - - - - - - - - - - - - - - - - 35
Input Roller Assembly, Re-assembly - - - - - - - - - - - - - - - - - 40
Input Roller Assembly Removal - - - - - - - - - - - - - - - - - - - - 45
Main Board Replacement - - - - - - - - - - - - - - - - - - - - - - - 50
Paper Exit Roller Removal - - - - - - - - - - - - - - - - - - - - - - 57
Plastic Roller Upgrade - - - - - - - - - - - - - - - - - - - - - - - - 60
Print Head Replacement Procedure - - - - - - - - - - - - - - - - - - 79
Pump and Cap Installation - - - - - - - - - - - - - - - - - - - - - - 86
Pump and Cap Removal - - - - - - - - - - - - - - - - - - - - - - - 92
Side Cover Removal (Left) - - - - - - - - - - - - - - - - - - - - - - 97
Side Cover Removal (Right) - - - - - - - - - - - - - - - - - - - - - - 98
Top Cover Removal - - - - - - - - - - - - - - - - - - - - - - - - - 100
Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 101
Error Codes (Maintenance) - - - - - - - - - - - - - - - - - - - - - 102
Error Codes (Service) - - - - - - - - - - - - - - - - - - - - - - - - 103
00000088 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 106
00000101 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 107
00000103 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 108
00000105 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 109
Printer Component, Software Item, LCD Display, Printer Button Page 1.
Stylus Pro 4800 Field Repair Guide 6/9/05
00010000 - 00010003 - - - - - - - - - - - - - - - - - - - - - - - - 110
Color Shift - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 111
Command Error - - - - - - - - - - - - - - - - - - - - - - - - - - - 112
Communication Errors PC - - - - - - - - - - - - - - - - - - - - - - 113
Cover Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 115
Drop of Ink - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 116
Grainy or Ghosting - - - - - - - - - - - - - - - - - - - - - - - - - 117
Horizontal Banding - - - - - - - - - - - - - - - - - - - - - - - - - 118
Missing Nozzle Diagnosis and Repair - - - - - - - - - - - - - - - - 120
Paper Jam Errors - - - - - - - - - - - - - - - - - - - - - - - - - - 123
Paper Not Cut - - - - - - - - - - - - - - - - - - - - - - - - - - - 124
Reload Paper - - - - - - - - - - - - - - - - - - - - - - - - - - - - 125
Random Nozzles - - - - - - - - - - - - - - - - - - - - - - - - - - 127
Scratch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 128
Set Ink Cartridges - - - - - - - - - - - - - - - - - - - - - - - - - - 129
Set Ink Lever - - - - - - - - - - - - - - - - - - - - - - - - - - - - 130
Smudge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 131
Smear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 132
Vertical Banding - - - - - - - - - - - - - - - - - - - - - - - - - - 133
Wrong Ink Cartridge - - - - - - - - - - - - - - - - - - - - - - - - - 134
Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 135
1000mm Feed Adjustment - - - - - - - - - - - - - - - - - - - - - 136
Auto Bi-D Adjustment - - - - - - - - - - - - - - - - - - - - - - - - 137
Auto Uni-D Adjustment - - - - - - - - - - - - - - - - - - - - - - - 138
Carriage Timing Belt Tension Adjustment - - - - - - - - - - - - - - 139
Change Model Name - - - - - - - - - - - - - - - - - - - - - - - - 140
Check Nozzle - - - - - - - - - - - - - - - - - - - - - - - - - - - - 142
Check Platen Gap - - - - - - - - - - - - - - - - - - - - - - - - - 143
Cleaning / Charging (Priming) - - - - - - - - - - - - - - - - - - - - 144
Clear PF Micro Feed Adjustment [Bi-D] - - - - - - - - - - - - - - - 145
Printer Component, Software Item, LCD Display, Printer Button Page 2.
Stylus Pro 4800 Field Repair Guide 6/9/05
Copy Bi-D Variables - - - - - - - - - - - - - - - - - - - - - - - - 146
Copy Uni-D Variables - - - - - - - - - - - - - - - - - - - - - - - - 147
CR Encoder Sensor Position Adjustment - - - - - - - - - - - - - - 148
Head Rank ID - - - - - - - - - - - - - - - - - - - - - - - - - - - - 149
Ink Discharge. - - - - - - - - - - - - - - - - - - - - - - - - - - - 150
Multi Sensor Adjustment for Auto Nozzle Check - - - - - - - - - - - 151
Multi Sensor Auto PF Adjustment - - - - - - - - - - - - - - - - - - 152
Multi Sensor Level Adjustment - - - - - - - - - - - - - - - - - - - 153
Multi Sensor Position Adjustment - - - - - - - - - - - - - - - - - - 154
Nozzle Bi-D Adjustment - - - - - - - - - - - - - - - - - - - - - - - 156
Paper Feed Timing Belt Adjustment - - - - - - - - - - - - - - - - - 157
Paper Thickness Sensor Adjustment - - - - - - - - - - - - - - - - 159
Platen Gap Adjustment - - - - - - - - - - - - - - - - - - - - - - - 162
Platen Position Adjustment - - - - - - - - - - - - - - - - - - - - - 165
Print Head Slant Adjustment (CR) - - - - - - - - - - - - - - - - - - 167
Print Head Slant Adjustment (PF) - - - - - - - - - - - - - - - - - - 171
RearAD Sensor Calibration - - - - - - - - - - - - - - - - - - - - - 174
Reset ASF Counter - - - - - - - - - - - - - - - - - - - - - - - - - 175
Reset Paper Ejection Switching - - - - - - - - - - - - - - - - - - - 176
Reset PF Motor Counter - - - - - - - - - - - - - - - - - - - - - - 177
Reset When Cleaning Unit Change - - - - - - - - - - - - - - - - - 178
Reset When CR Unit Change - - - - - - - - - - - - - - - - - - - - 179
Reset When Cutter Change - - - - - - - - - - - - - - - - - - - - - 180
Reset When Print Head Change - - - - - - - - - - - - - - - - - - - 181
RTC & USB & IEEE1394ID Adjustment - - - - - - - - - - - - - - - 182
Skew Check - - - - - - - - - - - - - - - - - - - - - - - - - - - - 186
T&B&S [Cut Sheet] Adjustment - - - - - - - - - - - - - - - - - - - 187
T&B&S [Roll Paper] Adjustment - - - - - - - - - - - - - - - - - - - 188
Reference - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 189
Accessories List - - - - - - - - - - - - - - - - - - - - - - - - - - 190
Printer Component, Software Item, LCD Display, Printer Button Page 3.
Stylus Pro 4800 Field Repair Guide 6/9/05
Cleaning Fluid - - - - - - - - - - - - - - - - - - - - - - - - - - - 191
Color Order - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 192
Connector Diagram - - - - - - - - - - - - - - - - - - - - - - - - - 193
Consumable/Service Parts List - - - - - - - - - - - - - - - - - - - 194
Firmware History - - - - - - - - - - - - - - - - - - - - - - - - - - 196
Firmware Update Procedure - - - - - - - - - - - - - - - - - - - - 197
Glossary - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 198
Ink Draining Procedure - - - - - - - - - - - - - - - - - - - - - - - 204
Ink Tube Order - - - - - - - - - - - - - - - - - - - - - - - - - - - 205
Prime, On or Off - - - - - - - - - - - - - - - - - - - - - - - - - - 206
Revision History - - - - - - - - - - - - - - - - - - - - - - - - - - 207
Sensors, Motors, Solenoids, and Fans - - - - - - - - - - - - - - - - 208
Service Procedure - - - - - - - - - - - - - - - - - - - - - - - - - 210
Service Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - 212
Stress Test (Test Image) - - - - - - - - - - - - - - - - - - - - - - 213
User Nozzle Check Order - - - - - - - - - - - - - - - - - - - - - - 214
Utilities - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 215
Adjustment Wizard2 - - - - - - - - - - - - - - - - - - - - - - - - - 216
Colorimetric Calibration Procedure - - - - - - - - - - - - - - - - - 219
Epson Paper Feed Adjuster - - - - - - - - - - - - - - - - - - - - - 237
NVRAM.EXE - - - - - - - - - - - - - - - - - - - - - - - - - - - - 240
PRNprint.exe - - - - - - - - - - - - - - - - - - - - - - - - - - - - 243
Printer Component, Software Item, LCD Display, Printer Button Page 4.
Stylus Pro 4800 Field Repair Guide 6/9/05
Control Panel Map
Roll Auto Cut
Roll Auto Cut Off
Ink Out
Paused
Pause
Power
Roll / SheetSheet
Status
Ink Quantity
Media Feed
Maintenance Tank Level
Paper
Out
Hold for 3 seconds to reset/clear
Printer
Printer Component, Software Item, LCD Display, Printer Button Page 5.
Hold for 3 seconds to cut
roll media
Hold the 4 Arrow Buttons and Power on for F/W Down-
load Mode.
Hold for 3 seconds to clean
Stylus Pro 4800 Field Repair Guide 6/9/05
User Menu: Press the Menu button when
the printer displays Ready
1. PRINTER SETUP.
PLATEN GAP: *STANDARD, NARROW, WIDEST, WIDER,
WIDE
PAGE LINE: *ON, OFF
INTERFACE: *AUTO, USB, IEEE1394, OPTION
CODE PAGE: *PC437, PC850,
PAPER MARGIN: *DEFAULT, T/B15mm, T/B25mm,15mm,
3mm
PPR SIZE CHK: *ON, OFF
PPR ALIGN CHK: *ON, OFF
TIME OUT: *OFF, 30SEC, 60SEC, 180SEC, 300SEC
CUTTER ADJ: EXEC
REFRESH MRGN: *ON, OFF
SHEET SIZE CHK: *ON, OFF
AUTO NZL CK: *ON, OFF
AUTO CLEANING: *ON, OFF
QUIET CUT: *OFF, ON
INIT SETTINGS: EXEC
4. CUSTOM PAPER.
3. PRINTER STATUS.
VERSION: (CURRENT FIRMWARE)
PRINTABLE PG: (FOR EACH COLOR)MK
(nnnnnn)PG
INK LEFT: (FOR EACH COLOR)MK E*****F
MAINT TANK: E*****F
USAGE COUNT: INK (nnnn.n)ML, PPR
(nnnn.n)CM
USE COUNT CLR: EXEC
JOB HISTORY: N0.(N) I:(nnn)ML, P:(nnn)CM
JOB HISTORY CLR: EXEC
TOTAL PRINTS: (nnnn)
SERVICE LIFE: CUTTER, CR MOTOR, PF
MOTOR, HEAD UNIT,CLEANING UNIT,
(E*****F)
PAPER NUMBER: *STANDARD, NO. (1-10)
Platen Gap: Standard, Narrow, Wide, Wider
Thickness Pat: Print
Cut Method: *Standard, Thick (Fast, Slow), Thin
Paper
2. TEST PRINT.
NOZZLE CHECK: PRINT
STATUS CHECK: PRINT
JOB INFO: PRINT
CUSTOM PAPER: PRINT
Printer Component, Software Item, LCD Display, Printer Button Page 6.
PPR Feed Adj: (n.nn)%
Eject Roller: *Auto, Sheet, Roll Curled, Roll Normal
Drying Time: (n.n)sec
Suction: *Standard, -4, -3, -2, -1
M/W ADJ: *Standard,1 , 2
Stylus Pro 4800 Field Repair Guide 6/9/05
5. MAINTENANCE
CUTTER REPL: EXEC
BK Ink Change: EXEC (For Changing between Matte
and Photo Black)
PWR CLEANING: N CLEANING Y
CLOCK SETTING: (mm/dd/yy hh:mm)
6. Head Alignment.
PAPER THKNS: *STD, (n.n)MM
ALIGNMENT: AUTO (UNI-D, #3, #2, #1, BI-
MANUAL (UNI-D, BI-D All, BI-
Maintenance Mode 1: Press and hold the Pause button and turn on the Printers
HEX DUMP: PRINT EXEC (In this mode, the printer prints hexadecimal values received)
LANGUAGE: *ENGLISH, PORTUGUE, SPANISH, GERMAN, ITALIAN, FRENCH (Control panel language)
Paper Counter: *Off, ON (On causes the printer to count down from 250 (full tray))
UNIT: *METER, FEET/INCH (Set’s the unit of measure that the printer displays)
4CMW72: *OFF, ON (?)
CUT PRESSURE: *100% (0%-150%) (Adjusts the Paper Cutter pressure)
SSCL: EXEC (Super Strong Cleaning)
ROLL PPR FEED: *OFF, ON (On saves leading edge paper)
DEFAULT PANEL: EXEC (Returns Maintenance Mode 1 settings to Factory Default)
D All, BI-D 2-COLOR)
D 2-COLOR)
CRTG INFO MENU: MANUFACTURER,COLOR, INK TYPE, INK CAPACITY, INK LEFT, PRODUCTION
DATE, EXPIRATION DATE, INK LIFE, INK AGE (CSIC
information, for each ink cartridge)
Maintenance Mode 2: Press and hold the Left, Down, and Up buttons and turn on the Printer
SELF TESTING:
Test:
Version: (Displays the current firmware version)
Panel: (Button tests for the control panel)
Sensor: (Sensor tests for all sensors)
Encoder: (Encoder tests for both encoders)
Fan: (Fan tests for all fans)
Elec.: Record: Maintenance: (Usage Counters for the following devices) WasteInk, Wiper, Rubbing,
Printer Component, Software Item, LCD Display, Printer Button Page 7.
Stylus Pro 4800 Field Repair Guide 6/9/05
Lever, Cover, Ink Lever, Cr Motor, PF Motor, PrintNumber, Cleaning, Fire A, Fire B, Fire C, Fire
D, Fire E, Fire F, Fire G, Fire H, Cut, Cute Sole, LockSolen
Record: Error: Error (0 - 6) (Displays the last 7 errors)
D/A Revision: Measure Va: (nn.nnn)v (?)
CSIC: Slot (1 - 8), Maintenance Tank (?)
Actuator: Cutter: [Enter], Start (Tests the cutter assembly)
Actuator2: Cutter Sol, Pump Motor (Tests the following devices)
Adjustment:
Cut Adj.: Pressure: *73% (Adjusts voltage used for the cutter solenoid)
PG ADJ: [Enter], Start: PG Offset *(nn) (Used for adjusting the platen gap)
Rear AD: [Enter], Start: Exc.: RearAD: (nnn nnn nnn) (For adjusting the rear paper sensor)
Edge Sns Lvl: [Enter], Start: (For adjusting the sensitivity of the edge sensor)
Check Nozzle: [Enter] Print: (Service level nozzle check)
Check Skew: Check Skew: (n.n)mm (Default 1.0) (Used for setting the amount of allowable skew)
Print:
Check Ptn.: [Enter] Print (Prints all alignment patterns)
Adj. Variable: [Enter] Print (Prints the numeric adjustment variables currently set)
View Counters (Displays the usage/life counter information for the following devices/operations)
Cutter, Cutter Total, Total Pages, Maint Tank, CR Motor, CR Total, PF Motor, Nozzle A, Nozzle B,
Nozzle C, Nozzle D, Nozzle E, Nozzle F, Nozzle G, FL Box, Cleaner, Sponge, ASF, Feed Roller, PG
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)
Clean Head2: Exec (?)
Counter Clear: Reset Counter? (?)
Ink Drain:
Printer Component, Software Item, LCD Display, Printer Button Page 8.
Stylus Pro 4800 Field Repair Guide 6/9/05
Cleaning:
Std. KK0 (Weakest cleaning cycle (uses less ink))
Std. KK1 (Medium strength cleaning cycle)
Std. KK2 (Stronger cleaning cycle)
Std. KK3 (Strongest cleaning cycle)
Init. Fill (Forces a initial fill (prime))
Parameter:
Initialize:
All: Initialize OK? (Resets all of the following counters at once)
PF Resolution: Initialize OK? (Resets this counter only)
Head Record: Initialize OK? (Resets this counter only)
Wiping Record: Initialize OK? (Resets this counter only)
Rab. Record: Initialize OK? (Resets this counter only)
Waste Record: Initialize OK? (Resets this counter only)
CRmot Record: Initialize OK? (Resets this counter only)
PFmot Record: Initialize OK? (Resets this counter only)
Lever Record: Initialize OK? (Resets this counter only)
Cover Record: Initialize OK? (Resets this counter only)
Ink Lever Record: Initialize OK? (Resets this counter only)
Update: InkParameter: Init. Fill: (Set, Reset) (Reset, turns off the initial fill)
HeadWashFLG (?)
Mask Type: Dispersion, Regular (?)
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,
Head Lock, Cleaning, Print, Total Life, CR+PF+Fire, TotalLife2, TotalLife3, Check (Used for design testing
of these devices and assemblies)
Printer Component, Software Item, LCD Display, Printer Button Page 9.
Stylus Pro 4800 Field Repair Guide 6/9/05
Service Config
Chg DEVICE-ID: *Sty Pro 4800, PX-6500 (Used for choosing the Plug and Play printer name)
MD TBL: ID = (1-7D Hex) (“Modifying parameter of media table is available”)
Clear Counters (Clears the usage/life counter information for the following devices/operations)
Cutter REPL, Init All (Initializes all counters in this menu), NVRAM, RTC: (YY/MM/DD/HH), Cutter, CR
Motor, CR Total, PF Motor, Head, Cleaner, Total Pages, SPONGE, ASF,FEED ROLLER, PG, CR UNIT
MAINT, CL UNIT MAINT, HEAD MAINT, CUT UNIT MAINT (Sponge = Boarderless Pads)
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),
Menu P: (P1 - P42), Menu M: (M1 - M26), Menu O: (O1 - O28), Menu F: (F1 - F28), Menu N: (N1 - N22)
INIT INFO (Resets MAINT INFO menu data)
INIT. MENU E:, INIT. MENU R:, INIT. MENU S:, INIT. MENU A:, INIT. MENU B:, INIT. MENU P:, INIT.
MENU M:, INIT. MENU O:, INIT. MENU F:, INIT. MENU N:
Parameter Backup Mode: (Allows Parameter backup without the Printer being online)
1. Enter Maintenance Mode 2
2. Lift both (2) Ink Levers
3. Remove the Maintenance Tank
4. Move the Paper Release Lever to the released position.
: Press and hold the Left, Down, and Up buttons and turn on the Printer
Firmware Download Mode:
Hold the 4 Arrow Buttons and Power on for F/W Download Mode
Printer Component, Software Item, LCD Display, Printer Button Page 10.
Stylus Pro 4800 Field Repair Guide 6/9/05
Component
Replacement
Printer Component, Software Item, LCD Display, Printer Button Page 11.
Stylus Pro 4800 Field Repair Guide 6/9/05
Carriage Removal Procedure
1. 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.
5. Mark the Carriage Belt Tension Gauge, loosen, and remove the Belt.
Mark Belt Tension Gauge
Carriage Removal Procedure Printer Component, Software Item, LCD Display, Printer Button Page 12.
Loosen Belt tension
Remove Belt from
the Carriage Motor
Stylus Pro 4800 Field Repair Guide 6/9/05
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.
1.75” wide
.5” wide, and1/4” deep V slot
5” long
2. Place the jig so that the
V slots support the Car-
riage Rail Covers
Note:The jig should be placed
so that it supports the
Carriage Rail Covers
beside to the Print
Head, when it is in the
removal position (see
step 8).
Carriage Removal Procedure Printer Component, Software Item, LCD Display, Printer Button Page 13.
Stylus Pro 4800 Field Repair Guide 6/9/05
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
Strip
Carriage Removal Procedure Printer Component, Software Item, LCD Display, Printer Button Page 14.
Stylus Pro 4800 Field Repair Guide 6/9/05
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
Cam is fully seated in the Interlocks.
Cartridge Release Lever Repair Printer Component, Software Item, LCD Display, Printer Button Page 15.
Spring position
3 Gear positions to check.
Stylus Pro 4800 Field Repair Guide 6/9/05
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.
Cartridge Release Sensor Repair Printer Component, Software Item, LCD Display, Printer Button Page 16.
Stylus Pro 4800 Field Repair Guide 6/9/05
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.
Slot
3 Screws
Lift off
Damper Removal Printer Component, Software Item, LCD Display, Printer Button Page 17.
Stylus Pro 4800 Field Repair Guide 6/9/05
4. Disconnect 4 Cables, remove 1 Screw, and remove the Junction Board
1. Disconnect 4 Cables.
2. Remove 1 Screw.
5. Remove 4 Screws, 1 Stay Bar, and 1 Spring.
1 Spring
4 Screws
3. Remove the Junction Board.
1 Stay Bar
Damper Removal Printer Component, Software Item, LCD Display, Printer Button Page 18.
Stylus Pro 4800 Field Repair Guide 6/9/05
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.
7. Remove the Stay Bar that fastens the Dampers to the Assembly.
Remove the Stay Bar.
Damper Removal Printer Component, Software Item, LCD Display, Printer Button Page 19.
Stylus Pro 4800 Field Repair Guide 6/9/05
8. Lift out the Print Head / Damper Assembly.
9. .Turn over the Print Head / Damper Assembly and remove 3 Screws.
Remove 3 Screws.
Damper Removal Printer Component, Software Item, LCD Display, Printer Button Page 20.
Stylus Pro 4800 Field Repair Guide 6/9/05
10. Disconnect the Print Head from the Damper Assembly.
1. Disconnect the Print Head from
the Damper Assembly.
2. Hold the Damper Assembly like
this so that ink does not leak.
3. Place the Print Head off to the side
as shown.
11. Release the Interlock that corresponds to the Damper(s) to be replaced, and lift out the
Damper(s)
Damper Interlock
Damper Removal Printer Component, Software Item, LCD Display, Printer Button Page 21.
Stylus Pro 4800 Field Repair Guide 6/9/05
12. Install the new Damper(s).
13. Re-connect the Ink Tubes to the new Dampers, and manually prime all the Dampers.
With the Damper openings facing
up, draw the air out of the each
Damper.
14. Reconnect the Print Head to the Damper Assembly.
Connect the Print Head and
fasten with 3 Screws.
Damper Removal Printer Component, Software Item, LCD Display, Printer Button Page 22.
Stylus Pro 4800 Field Repair Guide 6/9/05
15. Place the Print Head / Damper Assembly back into the Carriage Mechanism.
16. Replace 4 Screws, 1 Stay Bar, and 1 Spring.
1 Spring
4 Screws
Damper Removal Printer Component, Software Item, LCD Display, Printer Button Page 23.
1 Stay Bar
Stylus Pro 4800 Field Repair Guide 6/9/05
17. Re-install the Junction Board, fasten with 1 Screw, and reconnect 4 Cables.
This Connector
has a latch.
Install the Junction Board and fasten with 1 Screw.
Reconnect 4 Cables.
18. Perform cleaning cycles and nozzle checks until the nozzles are working.
19. Perform the Print Head mechanical adjustments.
19.1 Perform the Print Head Slant Adjustment (CR)
19.2 Perform the Print Head Slant Adjustment (PF)
Damper Removal Printer Component, Software Item, LCD Display, Printer Button Page 24.
Stylus Pro 4800 Field Repair Guide 6/9/05
Ink Bay Removal (Left)
1. Remove the Left and Right Side Covers.
2. Remove the 10 Screws fastening the Front Panel.
Remove 4 Screws
Remove 5 Screws
(View from the back)
Remove 1 Screw
3. Remove 2 Screws fastening the Front Panel.
Remove 2 Screws
Ink Bay Removal (Left) Printer Component, Software Item, LCD Display, Printer Button Page 25.
Stylus Pro 4800 Field Repair Guide 6/9/05
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
Remove 4 Screws
Cartridge Release Handle
Lift off the Cover.
Screw
Ink Bay Removal (Left) Printer Component, Software Item, LCD Display, Printer Button Page 26.
Stylus Pro 4800 Field Repair Guide 6/9/05
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
Ink Bay Removal (Left) Printer Component, Software Item, LCD Display, Printer Button Page 27.
Stylus Pro 4800 Field Repair Guide 6/9/05
8. Remove 2 Screws from the back of the Ink Bay Assembly.
Blow up of
this area
Look through this area,
Remove 2 Screws
on the back of the
Printer, to find 2 Screws
9. Disconnect the 4 Foil CSIC Cables and the Cartridge Release Sensor Cable.
Cartridge Release Sensor Cable
4 CSIC Cables
Re-assembly Note: Cable Order
Yellow-Magenta-Cyan-Matte Black
Ink Bay Removal (Left) Printer Component, Software Item, LCD Display, Printer Button Page 28.
Stylus Pro 4800 Field Repair Guide 6/9/05
10. Maneuver the Ink Tubes from the Slot.
11. Slide out the Ink Bay Assembly, while assisting the Cables through the Frame.
Ink Bay Removal (Left) Printer Component, Software Item, LCD Display, Printer Button Page 29.
Stylus Pro 4800 Field Repair Guide 6/9/05
Ink Bay Removal (Right)
1. Remove the Left and Right Side Covers.
2. Remove the 10 Screws fastening the Front Panel.
Remove 4 Screws
Remove 5 Screws
(View from the back)
Remove 1 Screw
3. Remove 2 Screws fastening the Front Panel.
Remove 2 Screws
Ink Bay Removal (Right) Printer Component, Software Item, LCD Display, Printer Button Page 30.
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