Epson F4880 Field Repair Guide

Stylus Pro 4880 Field Repair Guide 1/17/08

Table Of Contents

Table Of Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1
Control Panel Map - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
Component Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - 12

Board (Main) Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13
Board (Main) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20
Board (Power Supply) Removal - - - - - - - - - - - - - - - - - - - - - - - - - 27
Carriage Removal Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - 33
Cartridge Release Lever Repair - - - - - - - - - - - - - - - - - - - - - - - - - 36
Cartridge Release Sensor Repair - - - - - - - - - - - - - - - - - - - - - - - - 37
Cover (Left) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 38
Cover (Right) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40
Cover (Top) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 45
Damper Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 46
Ink Bay Removal (Left) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54
Ink Bay Removal (Right) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 59
Input Roller Assembly, Disassembly - - - - - - - - - - - - - - - - - - - - - - 64
Input Roller Assembly, Re-assembly - - - - - - - - - - - - - - - - - - - - - - 69
Input Roller Assembly Removal - - - - - - - - - - - - - - - - - - - - - - - - - 74
Paper Exit Roller Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - 79
Print Head Replacement Procedure - - - - - - - - - - - - - - - - - - - - - - - 82
Pump and Cap Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - 89
Pump and Cap Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 95

Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 100

Error Codes (Maintenance) - - - - - - - - - - - - - - - - - - - - - - - - - - -101
Error Codes (Service) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -102
00000088 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -105
00000101 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -106
00000103 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -107
00000105 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -108
00010000 - 00010003 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -109
0001001B - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -110
Color Shift - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -111
Command Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -112

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

Stylus Pro 4880 Field Repair Guide 1/17/08

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
Smear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -131
Smudge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -132
Vertical Banding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -133
Wrong Ink Cartridge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -134

Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 135

980mm Feed Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - -136
Auto Bi-D Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -137
Auto Uni-D Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - -138
Carriage Timing Belt Tension Adjustment - - - - - - - - - - - - - - - - - - - -139
Check Network Communication - - - - - - - - - - - - - - - - - - - - - - - - -140
Check Nozzle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -142
Check Platen Gap - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -143
Cleaning / Charging (Priming) - - - - - - - - - - - - - - - - - - - - - - - - - -144
Clear PF Micro Feed Adjustment [Bi-D] - - - - - - - - - - - - - - - - - - - - -145
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 - - - - - - - - - - - - - - - - - - - - - - - - - - - -151
Multi Sensor Auto PF Adjustment - - - - - - - - - - - - - - - - - - - - - - - -152
Multi Sensor Level Adjustment - - - - - - - - - - - - - - - - - - - - - - - - -153
Multi Sensor Position Adjustment - - - - - - - - - - - - - - - - - - - - - - - -154
Nozzle Bi-D Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - -156

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

Stylus Pro 4880 Field Repair Guide 1/17/08

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) - - - - - - - - - - - - - - - - - - - - - - - -174
Rear Sensor Calibration - - - - - - - - - - - - - - - - - - - - - - - - - - - - -176
Reset ASF Counter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -177
Reset Paper Ejection Switching / PG Switching Counter - - - - - - - - - - - -178
Reset PF Motor Counter - - - - - - - - - - - - - - - - - - - - - - - - - - - - -179
Reset When Cleaning Unit Change - - - - - - - - - - - - - - - - - - - - - - -180
Reset When CR Unit Change - - - - - - - - - - - - - - - - - - - - - - - - - -181
Reset When Cutter Solenoid Change - - - - - - - - - - - - - - - - - - - - - -182
Reset When Print Head Change - - - - - - - - - - - - - - - - - - - - - - - - -183
RTC & USBID Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - -184
Skew Check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -185
T&B&S [Cut Sheet] Adjustment - - - - - - - - - - - - - - - - - - - - - - - - -186
T&B&S [Roll Paper] Adjustment - - - - - - - - - - - - - - - - - - - - - - - - -187
Writing MAC Address - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -188

Component Pictures - - - - - - - - - - - - - - - - - - - - - - - - - - - 190

Board (Main) Picture - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -191
Board (Power Suppy) Picture - - - - - - - - - - - - - - - - - - - - - - - - - -192

Reference - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 193

Accessories List - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -194
Cleaning Fluid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -195
Connector Diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -196
Connectors / Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -197
Consumable/Service Parts List - - - - - - - - - - - - - - - - - - - - - - - - -202
Firmware History - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -205
Firmware Update Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - -206
Glossary - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -207
Ink Draining Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - -213
Ink Tube/Color Order - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -214
Prime, On or Off - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -215
Revision History - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -216
Sensors, Motors, Solenoids, and Fans - - - - - - - - - - - - - - - - - - - - -217

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

Stylus Pro 4880 Field Repair Guide 1/17/08

Service Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -219
Service Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -221
Stress Test (Test Image) - - - - - - - - - - - - - - - - - - - - - - - - - - - - -222
User Nozzle Check Order - - - - - - - - - - - - - - - - - - - - - - - - - - - -223

Utilities - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 224

Adjustment Wizard2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -225
FWUpdate.exe - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -229
NVRAM.EXE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -233

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

Stylus Pro 4880 Field Repair Guide 1/17/08

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 4880 Field Repair Guide 1/17/08

User Menu: Press the Menu button when

the printer displays Ready

1. PRINTER SETUP.

ROLL COUNTER: SET ROLL LENGTH nnn.n (If enabled)
SHEET COUNTER: SET SHEET PAGES 0-250PG (If enabled)
PLATEN GAP: *STANDARD, NARROW, WIDEST, WIDER,

WIDE

PAGE LINE: *ON, OFF
INTERFACE: *AUTO, USB, NETWORK I/F
CODE PAGE: *PC437, PC850,
PAPER MARGIN: *DEF AULT, 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
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,

2. TEST PRINT.

NOZZLE CHECK: PRINT
STATUS CHECK: PRINT
JOB INFO: PRINT
CUSTOM PAPER: PRINT

SLOW), THIN PAPER

PPR FEED ADJ: (N.NN)%
EJECT ROLLER: *AUTO, SHEET, ROLL CURLED,

ROLL NORMAL

DRYING TIME: (N.N)SEC

SUCTION: *STANDARD, -4, -3, -2, -1

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

Stylus Pro 4880 Field Repair Guide 1/17/08

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)

7. NETWORK SETUP: (*DISABLE, ENABLE)
IP ADDRESS SETTING: AUTO, PANEL,
BONJOUR: *ON, OFF
INIT NETWORK SETTING: EXECUTE

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, DUTCH, PORTUGUE, SPANISH, GERMAN, ITALIAN, FRENCH (Control panel lan-

guage)

D All, BI-D 2-COLOR)

D 2-COLOR)

Paper Counter: *Off, Roll, Sheet (Enables the tacking of Roll Paper usage, or count down from 250 Sheets

(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)

CRTG INFO MENU: MANUFACTURER,COLOR, INK TYPE, INK CAPACITY, INK LEFT, PRODUCTION

DATE, EXPIRATION DATE, INK LIFE, INK AGE (CSIC

CUSTOM: 0-9 (Enabels custom modes)

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

information, for each ink cartridge)

Stylus Pro 4880 Field Repair Guide 1/17/08

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,

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, Cut Sole

Record: Error: Error (0 - 6) (Displays the last 7 errors)

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 “black level” 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

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

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)
Clean Head2: Exec (?)
Counter Clear: Reset Counter? (?)
Ink Drain:

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 (?)

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

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,

Head Lock, Cleaning, Print, Total Life, CR+PF+Fire, TotalLife2, TotalLife3, Check (Used for design testing

of these devices and assemblies)

Service Config

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: EXEC
Init All: EXEC(Initializes all counters in this menu)
NVRAM: EXEC
RTC: (YY/MM/DD/HH): EXEC
Cutter: EXEC
CR Motor: EXEC
CR Total: EXEC
PF Motor: EXEC
Head: EXEC
Cleaner: EXEC
Total Pages: EXEC
SPONGE: EXEC (Sponge = Boarderless Pads)
ASF: EXEC
FEED ROLLER: EXEC
PG: EXEC
CR UNIT MAINT: EXEC
CL UNIT MAINT: EXEC
HEAD MAINT: EXEC

Printer Component, Software Item, LCD Display, Printer Button Page 10.

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),

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.

Firmware Download Mode:

Hold the 4 Arrow Buttons and Power on for F/W Download Mode

: Press and hold the Left, Down, and Up buttons and turn on the Printer

Printer Component, Software Item, LCD Display, Printer Button Page 11.

Stylus Pro 4880 Field Repair Guide 1/17/08

Component

Replacement

Printer Component, Software Item, LCD Display, Printer Button Page 12.

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 loose)

Board (Main) Installation Printer Component, Software Item, LCD Display, Printer Button Page 13.

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.

Board (Main) Installation Printer Component, Software Item, LCD Display, Printer Button Page 14.

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.

Board (Main) Installation Printer Component, Software Item, LCD Display, Printer Button Page 15.

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.

Board (Main) Installation Printer Component, Software Item, LCD Display, Printer Button Page 16.

Stylus Pro 4880 Field Repair Guide 1/17/08

5. Install 2 Screws that fasten the Cable Cover to the Printer.

Install 2 Screws

Board (Main) Installation Printer Component, Software Item, LCD Display, Printer Button Page 17.

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.

6.1 Open the FW/Update.exe, and prepare to send the current firmware version to the Printer.

6.2 Turn on the Printer while depressing the Left, Up, Down, and Right arrow buttons, The Printer will display

UPDATE F/W.

6.3 Send the current firmware to the Printer.

If the Printer’s Parameters are not available skip step 7, and follow step 8 and 9.

7. Re-Install the Printer’s parameters using the Parameter Backup / Restore Utility (Nvram.exe)

7.1 Perform the RTC&USBID&IEEE1394ID Adjustment.

8. Install the appropriate generic Printer parameters using the Parameter Backup / Restore Utility

(Nvram.exe)

Note: If the new Board does not have any parameters, the Printer may not function well enough to allow

alignments, paper loading, nozzle check, or the rest of step 18. Generic parameters are a set of
working parameters from another printer. They are available for download at: https://

www.epsoninsider.com listed under the Printer name, as Generic NVRAM Backup. They come in 2

variations (4880 Matte Black, 4880 Photo Black).

9. Perform the following operations in the order listed.

9.1 Perform the RTC&USBID Adjustment.

9.2 Perform the Rear Sensor Calibration.

9.3 Perform the Cutter Pressure adjustment.

9.4 Perform the Platen Gap adjustment.

9.5 Enter the Head Rank ID (Print Head calibration values).

Board (Main) Installation Printer Component, Software Item, LCD Display, Printer Button Page 18.

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 980mm Feed Adjustment, or Multi Sensor Auto PF Adjustment.

9.12 Perform the T&B&S (Roll Paper) Adjustment.

9.13 Perform the T&B&S (Cut Sheet) Adjustment.

9.14 Perform the Writing MAC Address Adjustment.

Board (Main) Installation Printer Component, Software Item, LCD Display, Printer Button Page 19.

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). The Print Head Calibration value is printed on the Service Level Nozzle Check
(Maintenance Mode 2: Self Testing: Adjustment: Check Nozzle).

2. Turn off the Printer and UNPLUG from AC.

3. Remove the Rear Paper Guide.

Push the 2 Grey Tabs and remove the Rear Paper Guide

Board (Main) Removal Printer Component, Software Item, LCD Display, Printer Button Page 20.

Stylus Pro 4880 Field Repair Guide 1/17/08

4. Remove the 2 Screws fastening the Cable Cover.

Remove 2 Screws

Board (Main) Removal Printer Component, Software Item, LCD Display, Printer Button Page 21.

Stylus Pro 4880 Field Repair Guide 1/17/08

5. Remove the 4 Screws fastening the Main Board Housing.

Remove 4 Screws.

Board (Main) Removal Printer Component, Software Item, LCD Display, Printer Button Page 22.

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.

Board (Main) Removal Printer Component, Software Item, LCD Display, Printer Button Page 23.

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.

Board (Main) Removal Printer Component, Software Item, LCD Display, Printer Button Page 24.

Stylus Pro 4880 Field Repair Guide 1/17/08

8. Unplug 2 Cables.

Unplug 2 Cables.

Board (Main) Removal Printer Component, Software Item, LCD Display, Printer Button Page 25.

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.

Board (Main) Removal Printer Component, Software Item, LCD Display, Printer Button Page 26.

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

Board (Power Supply) Removal Printer Component, Software Item, LCD Display, Printer Button Page 27.

Stylus Pro 4880 Field Repair Guide 1/17/08

3. Remove the 2 Screws fastening the Cable Cover.

Remove 2 Screws

Board (Power Supply) Removal Printer Component, Software Item, LCD Display, Printer Button Page 28.

Stylus Pro 4880 Field Repair Guide 1/17/08

4. Remove the 4 Screws fastening the Main Board Housing.

Remove 4 Screws.

Board (Power Supply) Removal Printer Component, Software Item, LCD Display, Printer Button Page 29.

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.

Board (Power Supply) Removal Printer Component, Software Item, LCD Display, Printer Button Page 30.

Stylus Pro 4880 Field Repair Guide 1/17/08

6. Unplug 2 Cables.

Unplug 2 Cables.

Board (Power Supply) Removal Printer Component, Software Item, LCD Display, Printer Button Page 31.

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.

Board (Power Supply) Removal Printer Component, Software Item, LCD Display, Printer Button Page 32.

Stylus Pro 4880 Field Repair Guide 1/17/08

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 33.

Loosen Belt tension

Remove Belt from
the Carriage Motor

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.

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 34.

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
Strip

Carriage Removal Procedure Printer Component, Software Item, LCD Display, Printer Button Page 35.

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
Cam is fully seated in the Interlocks.

Cartridge Release Lever Repair Printer Component, Software Item, LCD Display, Printer Button Page 36.

Spring position

3 Gear positions to check.

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.

Cartridge Release Sensor Repair Printer Component, Software Item, LCD Display, Printer Button Page 37.

Stylus Pro 4880 Field Repair Guide 1/17/08

Cover (Left) Removal

1. Remove 2 Screws.

1. Remove 1 Screw

2. Remove 1 Screw

Cover (Left) Removal Printer Component, Software Item, LCD Display, Printer Button Page 38.

Stylus Pro 4880 Field Repair Guide 1/17/08

2. Remove the Cover (Left)

1. Remove 2 Screws.

2. Slide off the Cover (Left).

Cover (Left) Removal Printer Component, Software Item, LCD Display, Printer Button Page 39.

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

Cover (Right) Removal Printer Component, Software Item, LCD Display, Printer Button Page 40.

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

Cover (Right) Removal Printer Component, Software Item, LCD Display, Printer Button Page 41.

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

Cover (Right) Removal Printer Component, Software Item, LCD Display, Printer Button Page 42.

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.

Cover (Right) Removal Printer Component, Software Item, LCD Display, Printer Button Page 43.

Stylus Pro 4880 Field Repair Guide 1/17/08

5. Remove 2 Screws and slide off the Cover (Right Side).

1. Remove 2 Screws

Cover (Right) Removal Printer Component, Software Item, LCD Display, Printer Button Page 44.

2. Slide off the Cover (Right Side).

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.

3. Lift off the Top Cover.

Cover (Top) Removal Printer Component, Software Item, LCD Display, Printer Button Page 45.

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.

Slot

3 Screws

Lift off

Damper Removal Printer Component, Software Item, LCD Display, Printer Button Page 46.

Stylus Pro 4880 Field Repair Guide 1/17/08

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 47.

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.

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 48.

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.

Damper Removal Printer Component, Software Item, LCD Display, Printer Button Page 49.

Stylus Pro 4880 Field Repair Guide 1/17/08

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 50.

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.

Damper Removal Printer Component, Software Item, LCD Display, Printer Button Page 51.

Stylus Pro 4880 Field Repair Guide 1/17/08

15. Replace 4 Screws, 1 Stay Bar, and 1 Spring.

1 Spring

1 Stay Bar

4 Screws

16. 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.

Damper Removal Printer Component, Software Item, LCD Display, Printer Button Page 52.

Reconnect 4 Cables.

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.

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 53.

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.

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 54.

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

Remove 4 Screws

Cartridge Release Handle

Lift off the Cover.

Screw

Ink Bay Removal (Left) Printer Component, Software Item, LCD Display, Printer Button Page 55.

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

Ink Bay Removal (Left) Printer Component, Software Item, LCD Display, Printer Button Page 56.

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

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 57.

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.

Ink Bay Removal (Left) Printer Component, Software Item, LCD Display, Printer Button Page 58.

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.

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 59.

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 4 Screws

Ink Bay Removal (Right) Printer Component, Software Item, LCD Display, Printer Button Page 60.

Remove 1 Screw

Lift off the Cover.

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 the
left Side

7. Remove 2 Screws from the front.

1 Screw on
the right Side.

2 Screws from the front

Ink Bay Removal (Right) Printer Component, Software Item, LCD Display, Printer Button Page 61.

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.

Cartridge
Release Sensor
Cable

Ink Bay Removal (Right) Printer Component, Software Item, LCD Display, Printer Button Page 62.

4 CSIC Cables

Re-assembly Note: Cable Order

Top to Bottom
Black, Light Cyan, Light
Magenta, Light Black

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.

Ink Bay Removal (Right) Printer Component, Software Item, LCD Display, Printer Button Page 63.

Stylus Pro 4880 Field Repair Guide 1/17/08

Input Roller Assembly, Disassembly

1. Remove the E-Ring, Gear, and Paddle shown below.

Input Roller Assembly, Disassembly Printer Component, Software Item, LCD Display, Printer Button Page 64.

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

3. Remove the 2 E-Rings shown below

Remove the E-Ring

Slide off the Cover

Remove the E-Ring

Input Roller Assembly, Disassembly Printer Component, Software Item, LCD Display, Printer Button Page 65.

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.

Input Roller Assembly, Disassembly Printer Component, Software Item, LCD Display, Printer Button Page 66.

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.

Input Roller Assembly, Disassembly Printer Component, Software Item, LCD Display, Printer Button Page 67.

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.

Input Roller Assembly, Disassembly Printer Component, Software Item, LCD Display, Printer Button Page 68.

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.

Input Roller Assembly, Re-assembly Printer Component, Software Item, LCD Display, Printer Button Page 69.

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.

These two pieces must be pressed tightly together to allow
the Paper Separation Assembly too fully compress the
Springs.

Input Roller Assembly, Re-assembly Printer Component, Software Item, LCD Display, Printer Button Page 70.

Stylus Pro 4880 Field Repair Guide 1/17/08

5. Study the polarity, and order of the parts below.

Paddles positioned, so that the
arrow on the side faces up

The Disks have depressions, that fit
the Springs.

Home Position Window faces the oppo­site direction from the flat side of the
Roller.

The Right and Left Rollers are different. Pay
attention to the position of the Slots.

6. Install the Roller Assembly components into the Base Assembly, following the directions above.

Paddle on the out­side of the Frame.

Paddle on the inside
of the Frame.

Cover marked with R

Input Roller Assembly, Re-assembly Printer Component, Software Item, LCD Display, Printer Button Page 71.

Cover marked with L

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.

8. Re-attach the Roller Covers, 3 E-rings, and Gear.

1 E-Ring between the
Roller Assembly and the
Frame.

1 E-Ring fastening
this Gear.

Gear

2 Roller Covers E-Ring

Input Roller Assembly, Re-assembly Printer Component, Software Item, LCD Display, Printer Button Page 72.

Stylus Pro 4880 Field Repair Guide 1/17/08

9. Test the Roller Assembly before installation

Place a piece of paper in the Tray.

Input Roller Assembly, Re-assembly Printer Component, Software Item, LCD Display, Printer Button Page 73.

Rotate the Gear and check for proper operation

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

the Valves

the Valves

4. Remove the Rear Paper Guide Support and the Paper Jam Cover.

Rear Paper Guide Sup­port (directions at step 5)

Remove the Paper Jam
Cover (shown removed)

Input Roller Assembly Removal Printer Component, Software Item, LCD Display, Printer Button Page 74.

Stylus Pro 4880 Field Repair Guide 1/17/08

5.

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.

5. Remove the Sensor from
the Rear Paper Guide Sup-
port

Input Roller Assembly Removal Printer Component, Software Item, LCD Display, Printer Button Page 75.

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

Input Roller Assembly Removal Printer Component, Software Item, LCD Display, Printer Button Page 76.

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.

Back side of the

Waste Ink Tank Slot

3 Screws

Loosen this Screw.

Input Roller Assembly Removal Printer Component, Software Item, LCD Display, Printer Button Page 77.

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

1 1. Slide the Input Roller Assembly out about 2 inches, disconnect the Input Roller HP Sensor , and
fully remove the Assembly.

Left side of the Printer

Input Roller Home
Position Sensor

Input Roller Assembly Removal Printer Component, Software Item, LCD Display, Printer Button Page 78.

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.

Remove 4 Screws

Remove 5 Screws

(View from the back)
Remove 1 Screw

3. Remove 2 Screws fastening the Front Panel.

Remove 2 Screws

Paper Exit Roller Removal Printer Component, Software Item, LCD Display, Printer Button Page 79.

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

Paper Exit Roller Removal Printer Component, Software Item, LCD Display, Printer Button Page 80.

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

Long end

Gold Spring side, on the top

Short end

Silver Spring side, on the bottom

Paper Exit Roller Removal Printer Component, Software Item, LCD Display, Printer Button Page 81.

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.

2. Unplug the Printer.

3. Raise both Ink Levers, closing the Ink Valves.

4. Remove the Left Side Cover.

5. Release the Carriage Lock, and move the Carriage Mechanism away from the capped position.

6. Mark the Carriage Belt Tension Gauge, loosen, and remove the Belt.

Mark Belt Tension Gauge

Print Head Replacement Procedure Printer Component, Software Item, LCD Display, Printer Button Page 82.

Loosen Belt Tension

Remove Belt from
the Carriage Motor

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.

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).

Print Head Replacement Procedure Printer Component, Software Item, LCD Display, Printer Button Page 83.

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. Turn over the Carriage Mechanism, and support it with one hand (ensure that the Nozzles and

the Carriage Encoder are not damaged).

Remove 3 Screws

Print Head Replacement Procedure Printer Component, Software Item, LCD Display, Printer Button Page 84.

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.

Print Head Replacement Procedure Printer Component, Software Item, LCD Display, Printer Button Page 85.

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).

14. Attach the Print Head to the Head Case.

15. Attach the Head Case to the Carriage Mechanism.

16. Re-install the Carriage Mechanism.

16.1 Ensure that the Timing Strip is routed through the Sensor.

16.2 Use the Carriage Rail Cover protection jig.

17. Place the Carriage Belt on the Carriage Motor Pulley.

18. Tighten the Carriage Belt until the Gauge reaches the mark that represents the proper tension.

Print Head Replacement Procedure Printer Component, Software Item, LCD Display, Printer Button Page 86.

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.

22. Defeat the Cover Sensor, and turn on the Printer.

23. Turn on the Printer, and let it come Ready.

24. Press the Menu button and navigate to Maintenance.

25. Press the Menu button and navigate to PWR CLEANING.

26. Press the Menu button to execute.

27. Print a Nozzle Check Pattern (Perform standard cleanings if necessary).

28. Perform the following adjustments in sequence.

Print Head Replacement Procedure Printer Component, Software Item, LCD Display, Printer Button Page 87.

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

Print Head Replacement Procedure Printer Component, Software Item, LCD Display, Printer Button Page 88.

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.

The Plastic Tray that sits under
the Pump, and that the Tubes
are inserted into, has one corner
that sits on top of the Pump /
Cap Assembly Frame.

View from the bottom. Note the

Plastic Tray is on top of the
Frame Mount.

View from the back of the Printer.
The Plastic is on top of the
Frame.

Pump and Cap Installation Printer Component, Software Item, LCD Display, Printer Button Page 89.

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
Assembly, p art of the way in

Feed the Tubes into the receptacle

Assist the Tubes fully into the receptacle,
while sliding in the Assembly.

4. Install the 4 Screws securing the Cap and Pump Assembly. Ensure that the Assembly is

correctly seated to avoid carriage errors.

2 Screws

Ensure that the Flushing
Box Screw Hole is correctly

aligned before tightening the

Assembly screws.

2 Screws

Pump and Cap Installation Printer Component, Software Item, LCD Display, Printer Button Page 90.

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

Pump and Cap Installation Printer Component, Software Item, LCD Display, Printer Button Page 91.

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

Shaft Assembly.

2 Screws

8. Install the Platen Gap Motor, and fasten with 2 Screws.

Install the Motor

2 Screws

Pump and Cap Installation Printer Component, Software Item, LCD Display, Printer Button Page 92.

Stylus Pro 4880 Field Repair Guide 1/17/08

9. Install the Trigger Shaft.

Insert Trigger Shaft into the

Right Side Frame

Flex the Trigger Shaft from the back side of the
Printer , until the end of the Shaft can be inserted
into the Socket

Insert Into
Socket here

Pump and Cap Installation Printer Component, Software Item, LCD Display, Printer Button Page 93.

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).

Pump and Cap Installation Printer Component, Software Item, LCD Display, Printer Button Page 94.

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

Trigger Spring

Pump and Cap Removal Printer Component, Software Item, LCD Display, Printer Button Page 95.

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
Socket

Slide out the Trigger
Shaft

5. Remove 4 Screws securing the Cap and Pump Assembly.

2 Screws

2 Screws

Pump and Cap Removal Printer Component, Software Item, LCD Display, Printer Button Page 96.

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.

2 Screws

8. Slide the Cap and Pump Assembly to the right, to separate the Assembly from the Gear.

Separate the Assembly
from the Gear

Slide the Cap and Pump
Assembly this way.

Pump and Cap Removal Printer Component, Software Item, LCD Display, Printer Button Page 97.

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. Slide the Cap and Pump Assembly out the back of the Printer.

Remove from the back of the Printer

Slide the Assembly to the back

Pump and Cap Removal Printer Component, Software Item, LCD Display, Printer Button Page 98.

Stylus Pro 4880 Field Repair Guide 1/17/08

Cap and Pump Assembly Components.

Cap

Wiper Blade

Pump

Pump and Cap Removal Printer Component, Software Item, LCD Display, Printer Button Page 99.

Stylus Pro 4880 Field Repair Guide 1/17/08

Troubleshooting

Printer Component, Software Item, LCD Display, Printer Button Page 100.