Epson Stylus Pro 7880, Stylus Pro 9880 Field Repair Guide

Pro 7880 / 9880 Field Repair Guide 12/20/07

Table Of Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 Control Panel Map - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 Component Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - 19

Board (Main) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 20 Board (Main) Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22 Board (Power Supply) Removal - - - - - - - - - - - - - - - - - - - - - - - - - 26 Carriage Assembly Replacement Procedure - - - - - - - - - - - - - - - - - - 28 Cartridge Release Lever Repair (Left) - - - - - - - - - - - - - - - - - - - - - - 51 Cartridge Release Lever Repair (Right) - - - - - - - - - - - - - - - - - - - - - 52 Cover (Left Side) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53 Cover (Rear) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58 Cover (Right Side) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - 61 Cover (Right Side) Installation - - - - - - - - - - - - - - - - - - - - - - - - - - 70 Cover (Top) Removal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 84 Damper Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 86 Edge Detector (EdgeAD) Replacement - - - - - - - - - - - - - - - - - - - - - 99 Encoder Disk (Paper Feed) Removal - - - - - - - - - - - - - - - - - - - - - -103 Encoder (Paper Feed) Removal - - - - - - - - - - - - - - - - - - - - - - - - -106 Encoder Strip (Carriage) Replacement - - - - - - - - - - - - - - - - - - - - -109 Ink Bay Removal (Left) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -111 Ink Bay Replacement (Right) - - - - - - - - - - - - - - - - - - - - - - - - - -121 Paper Feed Encoder Scale Replacement - - - - - - - - - - - - - - - - - - - -131 Pressure Pump Assembly Removal - - - - - - - - - - - - - - - - - - - - - - -133 Print Head Replacement Procedure - - - - - - - - - - - - - - - - - - - - - - -141

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

Pro 7880 / 9880 Field Repair Guide 12/20/07

Pulley (Paper Feed) Removal - - - - - - - - - - - - - - - - - - - - - - - - - -154 Pump and Cap Assembly Installation - - - - - - - - - - - - - - - - - - - - - -156 Pump and Cap Assembly Removal - - - - - - - - - - - - - - - - - - - - - - -170 Wiper Blade Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - -178

Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 185

Error Codes (Maintenance) - - - - - - - - - - - - - - - - - - - - - - - - - - -186 Error Codes (Service) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -187 00000088 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -190 00000101 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -191 00000103 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -192 00000105 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -193 00010000 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -194 00010002 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -195 00010004 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -196 00010005 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -197 0001000C - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -198 00010014 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -199 Borderless Printing Errors - - - - - - - - - - - - - - - - - - - - - - - - - - - -200 Color Shift - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -201 Command Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -202 Communication Errors, Macintosh - - - - - - - - - - - - - - - - - - - - - - -203 Communication Errors, PC - - - - - - - - - - - - - - - - - - - - - - - - - - -205 Cover Open - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -207 Drop of Ink - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -208 Grainy or Ghosting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -209 Horizontal Banding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -210

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

Pro 7880 / 9880 Field Repair Guide 12/20/07

Install Ink Cartridge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -212 Invalid Ink Cartridge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -213 Load Paper Properly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -214 Lower Ink Lever - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -216 Missing Nozzle Diagnosis and Repair - - - - - - - - - - - - - - - - - - - - - -217 No Control Panel Display - - - - - - - - - - - - - - - - - - - - - - - - - - - -220 Paper Not Cut - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -221 Paper Jam Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -222 Random Nozzle Firing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -223 Scratch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -224 Smudge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -225 Smear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -226 Stuck In Cut Sheet Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - -227 Vertical Banding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -228

Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 229

980mm Feed Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - -230 Auto Bi-D Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -231 Auto Bi-D [P.G. 0.8/1.6] - - - - - - - - - - - - - - - - - - - - - - - - - - - - -232 Auto Uni-D Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - -233 Carriage Timing Belt Tension Adjustment - - - - - - - - - - - - - - - - - - - -234 Check Alignment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -235 Check Cutting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -236 Check Nozzle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -237 Cleaning / Charging (Priming) - - - - - - - - - - - - - - - - - - - - - - - - - -238 Clear PF Micro Feed Adjustment [Bi-D] - - - - - - - - - - - - - - - - - - - - -239 Copy Bi-D Variables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -240

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

Pro 7880 / 9880 Field Repair Guide 12/20/07

Copy Uni-D Variables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -241 CR Encoder Sensor Position Adjustment - - - - - - - - - - - - - - - - - - - -242 Cutter Blade Position Adjustment - - - - - - - - - - - - - - - - - - - - - - - -243 Head Rank ID - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -245 Input Serial Number - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -246 Ink Discharge - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -247 Ink Mark Sensor Level Adjustment - - - - - - - - - - - - - - - - - - - - - - -248 IM (Ink Mark) Sensor Position Adjustment - - - - - - - - - - - - - - - - - - -249 Ink Mark Sensor Adjustment for Auto Nozzle Check - - - - - - - - - - - - - -251 Nozzle Bi-D Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - -252 Paper Feed Belt Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - -253 Paper Feed Encoder Alignment - - - - - - - - - - - - - - - - - - - - - - - - -255 Paper Thickness Sensor Adjustment - - - - - - - - - - - - - - - - - - - - - -257 Platen Position Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - -260 Print Head Slant Adjustment (CR) - - - - - - - - - - - - - - - - - - - - - - - -262 Print Head Slant Adjustment (PF) - - - - - - - - - - - - - - - - - - - - - - - -265 RearAD Sensor Calibration - - - - - - - - - - - - - - - - - - - - - - - - - - -269 Reset PF Motor Counter - - - - - - - - - - - - - - - - - - - - - - - - - - - - -270 Reset PG Switching Counter - - - - - - - - - - - - - - - - - - - - - - - - - -271 Reset When Cleaning Unit Change - - - - - - - - - - - - - - - - - - - - - - -272 Reset When CR Unit Change - - - - - - - - - - - - - - - - - - - - - - - - - -273 Reset When Cutter Solenoid - - - - - - - - - - - - - - - - - - - - - - - - - - -274 Reset When Print Head Change - - - - - - - - - - - - - - - - - - - - - - - - -275 Reset When Pressure Motor Change - - - - - - - - - - - - - - - - - - - - - -276 RTC & USBID Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - -277 Skew Check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -278

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

Pro 7880 / 9880 Field Repair Guide 12/20/07

T&B&S + 980mm Feed Adjustment - - - - - - - - - - - - - - - - - - - - - - -279 T&B&S (Roll Paper) Adjustment - - - - - - - - - - - - - - - - - - - - - - - - -280 Washing Head - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -281 Writing MAC Address - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -282

Component Pictures - - - - - - - - - - - - - - - - - - - - - - - - - - - 285

Carriage Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -286 Carriage Board Picture - - - - - - - - - - - - - - - - - - - - - - - - - - - - -291 Cleaning Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -292 Encoder Disk (Paper Feed) Picture - - - - - - - - - - - - - - - - - - - - - - -294 Ink System Pressurization Assembly Components - - - - - - - - - - - - - - -295 Main Board Picture - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -296 Power Supply Picture - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -297 Pressure Pump Assembly Picture - - - - - - - - - - - - - - - - - - - - - - - -298 Print Head Pictures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -299 Pulley (Paper Feed) Picture - - - - - - - - - - - - - - - - - - - - - - - - - - -301 Sub Board B - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -302 Sub Board C - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -303

Reference - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 304

Accessories List - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -305 Cleaning Fluid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -306 Color Order - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -307 Connectors / Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -309 Consumable/Service Parts List - - - - - - - - - - - - - - - - - - - - - - - - -313 Firmware History (7880) - - - - - - - - - - - - - - - - - - - - - - - - - - - - -315 Firmware History (9880) - - - - - - - - - - - - - - - - - - - - - - - - - - - - -316 Firmware Update Procedure Using FWUpdate.exe - - - - - - - - - - - - - - -317

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

Pro 7880 / 9880 Field Repair Guide 12/20/07

Glossary - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -318 Ink Draining Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - -324 Ink System Flushing Procedure - - - - - - - - - - - - - - - - - - - - - - - - -325 Ink Tube Order - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -327 Prime, On or Off - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -328 Revision History - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -329 Sensors, Motors, Solenoids, and Fans - - - - - - - - - - - - - - - - - - - - -330 Service Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -332 Service Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -334 Stress Test (Test Image) - - - - - - - - - - - - - - - - - - - - - - - - - - - - -335

Utilities - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 336

Adjustment Wizard2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -337 FWUpdate.exe - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -340 NVRAM.EXE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -344

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

Pro 7880 / 9880 Field Repair Guide 12/20/07

Control Panel Map

Sheet Roll Auto Cut Roll Auto Cut Off

Status

Paused light

Custom Paper Number

Power Button

Paper Out

Ink Out

Ink Levels

Maintenance Tank Level

Roll Counter

Paper Source Button

User Menu Button

Hold for 3 seconds to clean

Media Feed

Hold for 3 seconds to reset/clear

SERVICEMAN MODE: Down, Right, Pause, at power on.

SELF TESTING: Down, Right, Enter, at power on.

F/W DOWNLOAD MODE: Up, Down, Left, Right, at power on.

Maintenance Mode 1: Pause, at power on.

Press to pause the Printer.

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

Enter / Select

Hold for 3 seconds

Button

to cut roll media

Pro 7880 / 9880 Field Repair Guide 12/20/07

3. PRINTER STATUS.

User Menu: Press the Menu button when

the printer displays Ready

1. PRINTER SETUP.

ROLL PAPER COUNTER: 15ft - 300ft PLATEN GAP: *STANDARD, NARROW, WIDE, WIDER,

WIDEST

PAGE LINE: *ON, OFF INTERFACE: *AUTO, USB, NETWORK CODE PAGE: *PC437, PC850, ROLL PAPER MARGIN: *DEFAULT, TOP/BOTTOM 15mm,

TOP 35/BOTTOM 15mm,15mm, 3mm

PAPER SIZE CHK: *ON, OFF PAPER SKEW CHECK: *ON, OFF TIME OUT: *OFF, 30SEC, 60SEC, 180SEC, 300SEC CUTTER ADJUSTMENT: EXEC REFRESH MARGIN: *ON, OFF AUTO NOZZLE CHECK: *OFF, ON AUTO CLEANING: *ON, OFF QUIET CUT: *OFF, ON INITIALIZE SETTINGS: EXEC

2. TEST PRINT.

NOZZLE CHECK: PRINT NETWORK STATUS SHEET: PRINT STATUS SHEET: PRINT JOB INFORMATION: PRINT

4. CUSTOM PAPER.

PAPER NUMBER: *STANDARD, NO. (1-10)

VERSION: (CURRENT FIRMWARE) PRINTABLE PAGES: (FOR EACH COLOR)

(nnnnnn)PAGES

INK LEVEL: (FOR EACH COLOR) E*****F MAINTENANCE TANK: L E*****F, R E*****F USAGE COUNT: INK (nnnn.n)ML, PAPER (nnnn.n)FT CLEAR USAGE COUNT: INK:EXEC PAPER:EXEC JOB HISTORY: N0.(n) INK:(n)ml, PAPER:(nnn)sqft TOTAL PRINTS: (n) PA GES

SERVICE LIFE: CUTTER, CR MOTOR, PF MOTOR,

HEAD UNIT,CLEANING UNIT, PRESSURE MOTOR (E*****F)

PLATEN GAP: NARROW, STANDARD, WIDE, WIDER THICKNESS PATTERN: PRINT CUT METHOD: *STANDARD, THIN PAPER, THICK

PAPER FAST, THICK PAPER SLOW

PAPER FEED ADUST: (n.nn)% DRYING TIME: (n.n)sec

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

M/W ADJ: *STANDARD,1, 2

CUSTOM PAPER: PRINT

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

Pro 7880 / 9880 Field Repair Guide 12/20/07

5. MAINTENANCE

CUTTER REPLACEMENT: EXEC BK Ink Change: EXEC (For Changing between Matte and

Photo Black)

POWER CLEANING: “YOU MUST MOVE INK LEVERS

WHEN CLEANING”, EXECUTE, CANCEL (102ml)

CLOCK SETTING: (mm/dd/yy hh:mm)

CONTRAST ADJUSTMENT: (nn)

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

Parameter Backup and Restore Mode

6. Head Alignment.

PAPER THICKNESS: *STANDARD, (n.n)mm ALIGNMENT: AUTO (UNI-D, BI-D 2-COLOR,

BI-D All, BI-D #1, BI-D #2, BI-D #3)

MANUAL (UNI-D, BI-D 2-

COLOR, BI-D All,)

Release the Paper Lever, lift 2 Ink Levers, remove the Maintenance Tank, hold the Down, Right, and Pause but- tons and turn on the Printer.

Note: If the backup procedure fails, try re-booting the Printer and letting it come Ready. Then try the

backup / restore procedure.

F/W Download Mode

Hold the Up, Down, Left, and Right buttons and turn on the power.

Maintenance Mode 1: Press and hold the Pause button and turn on the Printer.

HEX DUMP: PRINT EXEC (In this mode, the printer prints hexadecimal values received)

LANGUAGE: *ENGLISH, FRENCH, ITALIAN, GERMAN, SPANISH, PORTUGUE, DUTCH (Panel Language)

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

Pro 7880 / 9880 Field Repair Guide 12/20/07

REMAINING PPR SETUP: *ROLL, OFF (Roll enables the ROLL PAPER COUNTER) UNIT: *FEET/INCH, METER (Set’s the unit of measure that the printer displays)

CUT PRESSURE: *100% (0%-150%) (Adjusts the Paper Cutter pressure) SS CLEANING: EXEC (Super Strong Cleaning)(255 time limit without replacing print head and resetting life

counter)

PWR ON ROLL PPR FEED: *ON, OFF (On = Feeds the paper 3” lower, when auto cut is off)

(Off = Does not feed the paper 3” lower, when auto cut is off)

DEF AULT PANEL: EXEC (Resets to Factory Default the following User Menus: Printer Setup, Printer St atus,

Custom Paper, Head Alignment)

INK INFO MENU: (FOR EACH COLOR) MANUF ACTURER, COLOR, INK TYPE, INK CAPACITY, INK LEVEL,

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

ink cartridge

)

information, for each

Custom:*0 (0 - 9)

SERVICEMAN MODE: Press and hold the Down, Right, and Pause buttons, and turn on the Printer

Note: SERVICEMAN MODE turns on the USB Port even if there is an error condition. Note: SERVICEMAN MODE must be displayed on the LCD to turn on the USB Port.

SELF TESTING:

Test:

Version: F/W: T(N or W)(nnnnnnnn.nn.nnnn) (Displays the current firmware version) Panel: Key, LCD, LED (Button, LCD, and LED tests for the control panel) Sensor: CR Origin: On, Off (Carriage Home Position Sensor test)

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

Pro 7880 / 9880 Field Repair Guide 12/20/07

INK NOT: 1,2,3,4,5,6,7,8 (Ink Cartridge Sensor test for 8 Ink Bays) EdgeAD: (nnn nnn) (Paper Edge Sensor test) Edge2AD: (nnn nnn) (Ink Mark Sensor Test) RearAD: (nnn nnn) (Rear Paper Sensor test) Head Temp: (nn)C (Displays the current Print Head temperature in degrees centigrade) Drv. Temp: (nn)C (Displays the current Print Head Driver temperature in degrees centigrade)

Ink Press: Off, On (Pressure Sensor test) Take Up: (9880 Only) (Tests the absence, or presence of the Optional Take Up Reel)

Encoder: CR (nnnn) (Carriage Encoder test. Counts up, moving away from home position)

PF (nnnn) (Paper Feed Encoder test. Counts up, as the paper advances.)

Fan: Paper(ALL): (Fan test for all paper suction fans)

Paper(Duty): (200% - 0%) (Tests the fan suction for all paper suction fans) Paper1: (Fan test for paper suction fan #1 (Right Side Fan)) Paper2: (Fan test for paper suction fan #2 (Left Side Fan (Center Fan on 9800))) Paper3: (9880 only)(Fan test for paper suction fan #3 (Left Side Fan)) Head Drv: (Fan test for the Head Driver Cooling Fan)

Elec.: Maintenance: WasteInk: (Right Side Maintenance Tank Counter)

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

Pro 7880 / 9880 Field Repair Guide 12/20/07

Fire D: (Light Black Nozzle Array Counter) Fire E: (Photo/Matte Black Nozzle Array Counter) Fire F: (Cyan Black Nozzle Array Counter) Fire G: (Magenta Nozzle Array Counter) Fire H: (Yellow Nozzle Array Counter) Cut: (Paper Cutting Operations Counter) Cute Sole: (Cutter Solenoid Counter)

Error: Error (0 - 6) (Displays the last 7 errors) Cut Adj: Cutter: 55% Actuator2: Cutter Sol: [Enter], Start (Tests the Cutter Solenoid)

Pump Motor: [Enter], Start (Tests the Cutter Solenoid) Regulator Sol: [Enter], Start (Tests the Ink System Pressure Release Solenoid)

Ink Press Motor: [Enter], Start (Ink System Pressure Motor) Edge Sns Lvl: [Enter], Start (Sets the black level of the Edge Detector) Auto Gap Adj: Auto Uni-D: [Enter] Print (Performs and Auto Uni-D Adjustment)

Auto Bi_d PG1.6: [Enter] Print (Performs and Auto Bi-D for Platen Gap 1.6 (WIDE)) Auto Bi_d PG0.8: [Enter] Print (Performs and Auto Bi-D for Platen Gap 0.8 (NARROW))

Adjustment:

Fan: Paper(ALL)(Runs all Suction Fans), Fan Adjust *0% (-10% to +10%) (Adjusts Suction Fans) Paper: 00, 01, 10, 11(Displays the output from the Paper Thickness Sensors) RearAD: [Enter], Start: Exc.: RearAD: (nnn nnn nnn) (For adjusting the Rear Paper Sensor) Check Nozzle: [Enter] Print: (Service nozzle check, displays Firmware Version, displays Head Rank) Cutter: [Enter], Start:(Cut position check) IM Sensor: (Adjusts sensitivity of the Edge Detector Sensor and the Ink Mark Sensor) PlatenPos: (n.n)mm(Calibrates the Borderless Pad Positions) PlatenPos.Chk.: (Checks the Borderless Pad Position calibration) Rear Sens.Pos: (Calibrates the EOF position for cut sheet media) CR Head Slant: (Performs the CR Head Slant adjustment) PF Head Slant: PF Head BiD Adj (Pk or MK Bi-D adjustment), PF Head Slant (PF Head Slant adjust-

ment)

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

Pro 7880 / 9880 Field Repair Guide 12/20/07

Gap Adj: All, Uni-D, Bi-D PG1.6,Bi-D PG0.8, (Manual Bi-D and Uni-D) Gap Adj: VSD1C: Print (Manual Bi-D and Uni-D PG 1.2) Check Skew: (n.n)mm (Default 1.0) (Used for testing and setting the amount of allowable skew) Feed Adj.+T&B: (Performs the 980mm, Top and Bottom Margin adjustments) IM Thresh: IM PosAdj, IM Loss Pattern, IM Full Pattern (Calibrates the IM Sensor for Auto Nozzle Check) Adj. Variable: [Enter] Print (Prints the numeric adjustment variables currently set) Pump Cnt: NG(?)

VIEW COUNTERS:

CUTTER: (Count for the Cutter Blade) CUTTER TOTAL: (Count for the Cutter Assembly) TOTAL PAGES: (Page count for the Printer) CR MOTOR: (Count for the Carriage Motor) CR TOTAL: (Count for the Carriage Mechanism) PF MOTOR: (Count for the Paper Feed Motor) PRESSURE MOTOR: (Count for the Pressure Motor) NOZZLE A: (Light Light Black Nozzle Array Counter) NOZZLE B: (Light Magenta Nozzle Array Counter) NOZZLE C: (Light Cyan Nozzle Array Counter) NOZZLE D: (Light Black Nozzle Array Counter) NOZZLE E: (Photo/Matte Black Nozzle Array Counter) NOZZLE F: (Cyan Black Nozzle Array Counter) NOZZLE G: (Magenta Nozzle Array Counter) NOZZLE H: (Yellow Nozzle Array Counter)

FL BOX: (Count for the Flushing Box) CLEANER: (Count for the Pump and Cap Assembly) SPONGE: (?) PG: (Count for the Platen Gap Assembly)

MAINT INFO:

MENU E: E1 - E17 (?) MENU R: R1 - R9 (?)

Printer Component, Software Item, LCD Display, Printer Button Page 13.

Pro 7880 / 9880 Field Repair Guide 12/20/07

MENU S: S1 - S26 (?) MENU A: A1 - A32 (?) MENU B: B1 - B48 (?) MENU P: P1 - P46 (?) MENU M: M1 - M26 (?) MENU O: 01 - 026 (?) MENU F: F1- F20 (?) MENU N: N1 - N22 (?)

SELF TESTING: Press and hold the Down, Right, and Enter buttons and turn on the Printer.

Test:

Paper: 00, 01,10,11 (Paper Thickness Sensor test) Lever: Down, Up (Paper Release Sensor test) HeadSlide: On, Off (Platen Gap Home Position Sensor test) Pump: On, Off (Pump Home Position Sensor test) InkLvr: Down/Down, Up/Down, Down/Up, UP/Up (Right and Left Ink Lever Sensor test) Cover: Close, Open (Cover Sensor test) MainteTank: On, Off (CSIC Contact Test) INK NOT: 1,2,3,4,5,6,7,8 (Ink Cartridge Sensor test for 8 Ink Bays) EdgeAD: (nnn nnn) (Paper Edge Sensor test) Edge2AD: (nnn nnn) (Ink Mark Sensor Test) RearAD: (nnn nnn) (Rear Paper Sensor test) Head Temp: (nn)C (Displays the current Print Head temperature in degrees centigrade) Drv. Temp: (nn)C (Displays the current Print Head Driver temperature in degrees centigrade)

Ink Press: Off, On (Pressure Sensor test) Take Up: (9800 Only) (Tests the absence, or presence of the Optional Take Up Reel)

Encoder: CR (nnnn) (Carriage Encoder test. Counts up, left to right)

Printer Component, Software Item, LCD Display, Printer Button Page 14.

Pro 7880 / 9880 Field Repair Guide 12/20/07

PF (nnnn) (Paper Feed Encoder test. Counts up, as the paper advances.)

Fan: Paper(ALL): (Fan test for all paper suction fans)

Paper(Duty): (200% - 0%) (Tests the fan suction for all paper suction fans) Paper1: (Fan test for paper suction fan #1 (Right Side Fan)) Paper2: (Fan test for paper suction fan #2 (Left Side Fan (Center Fan on 9800))) Paper3: (9800 only)(Fan test for paper suction fan #3 (Left Side Fan)) Head Drv: (Fan test for the Head Driver Cooling Fan)

Elec.: Maintenance: WasteInk: (Right Side Maintenance Tank Counter)

WasteInk2: (9880 Only)(Left Side Maintenance Tank Counter) Wiper: (Wiping Counter) Rubbing: (Rubbing Counter) Lever: (Paper Release Lever Counter) Cover: (Cover Sensor Counter) Ink Lever: (Left and Right Ink Lever Counter) Cr Motor: (Carriage Motor Usage Counter) PF Motor: (Paper Feed Motor Usage Counter) PrintNumber: (Number of printed pages) Cleaning: (Cleaning Operations Counter) Fire A: (Light Light Black Nozzle Array Counter) Fire B: (Light Magenta Nozzle Array Counter) Fire C: (Light Cyan Nozzle Array Counter) Fire D: (Light Black Nozzle Array Counter) Fire E: (Photo/Matte Black Nozzle Array Counter) Fire F: (Cyan Black Nozzle Array Counter) Fire G: (Magenta Nozzle Array Counter) Fire H: (Yellow Nozzle Array Counter) Cut: (Paper Cutting Operations Counter) Cute Sole: (Cutter Solenoid Counter)

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

CSIC: Slot (1 - 8), Maintenance Tank (?)

Printer Component, Software Item, LCD Display, Printer Button Page 15.

Pro 7880 / 9880 Field Repair Guide 12/20/07

Cut Adj: Cutter: 55% Actuator2: Cutter Sol: [Enter], Start (Tests the Cutter Solenoid)

Pump Motor: [Enter], Start (Tests the Cutter Solenoid) Regulator Sol: [Enter], Start (Tests the Ink System Pressure Release Solenoid)

Auto Bi_d PG1.6: [Enter] Print (Performs the Auto Bi-D for Platen Gap 1.6 (WIDE)) Auto Bi_d PG0.8: [Enter] Print (Performs the Auto Bi-D for Platen Gap 0.8 (NARROW))

Adjustment:

Input HeadRank: (Does not function) Fan: Paper(ALL)(Runs all Suction Fans), Fan Adjust *0% (-10% to +10%) (Adjusts Suction Fans) Paper: 00, 01, 10, 11(Displays the output from the Paper Thickness Sensors) Rear AD: [Enter], Start: Exc.: RearAD: (nnn nnn nnn) (For adjusting the Rear Paper Sensor) Init.Fill: (Starts an initial fill) Check Nozzle: [Enter] Print: (Service nozzle check, displays Firmware Version, displays Head Rank) Cutter: (Cut position check) IM Sensor: (Adjusts sensitivity of the Edge Detector Sensor) PlatenPos: (n.n)mm(Calibrates the Borderless Pad Positions) PlatenPos.Chk.: (Checks the Borderless Pad Position calibration) Rear Sens.Pos: (Calibrates the EOF position for cut sheet media) CR Head Slant: (Performs the CR Head Slant adjustment) PF Head Slant: PF Head Slant (PF Head Slant adjustment), PF Head BiD Adj (Pk or MK Bi-D adjust-

ment)

Gap Adj: All, Uni-D, Bi-D PG1.6,Bi-D PG0.8, (Manual Bi-D and Uni-D) Gap Adj: VSD1C: Print (Manual Bi-D and Uni-D PG 1.2) Check Skew: (n.n)mm (Default 1.0) (Used for testing and setting the amount of allowable skew) Feed Adj.+T&B: (Performs the 980mm, Top and Bottom Margin adjustments) IM Thresh: IM PosAdj, IM Full Pattern, IM Loss Pattern (Calibrates the IM Sensor for Auto Nozzle Check) Adj. Variable: [Enter] Print (Prints the numeric adjustment variables currently set)

Printer Component, Software Item, LCD Display, Printer Button Page 16.

Pro 7880 / 9880 Field Repair Guide 12/20/07

Clean Head: (Evacuates the ink system) Pump Cnt: NG(?) Counter Clear: (Clears a variety of counters)(Do not use)

Cleaning:

Std. CL1 (5.3ml) Std. CL2 (6.3ml) Std. CL3 (10.4ml) Std. CL6 (?) Init.Fill

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) Cutter Record: Initialize OK? (Resets this counter only) Cleaner Record: Initialize OK? (Resets this counter only)

Update: JM: Init. Fill: (Set, Reset) (Reset, turns of f the initial fill)

InkParameter: Init. Fill: (Set, Reset) (Reset, turns off the initial fill) HeadWash(?) Mask Type: Dispersion, Regular (?) PF BiD Adjust: (+/- n) (?) Uni-D Trap: (On, Off) (?)

Printer Component, Software Item, LCD Display, Printer Button Page 17.

Pro 7880 / 9880 Field Repair Guide 12/20/07

Display: Address: (nnnn)(Used for displaying data at specific RAM addresses)

Life: CR Motor (Carriage Motor Life Counter)

PF Motor (Paper Feed Motor Life Counter) CR+PF Motor(Carriage and Paper Feed Motor Life Counter) Cutter (Cutter Assembly Life Counter) Head U/D (?) Head Lock (Head Lock Assembly Life Counter) Cleaning (Cleaning Unit Life Counter) Print (Print Head Life Counter) Total Life (?) TotalLife2 (?) CSIC (?) Check (?)

Printer Component, Software Item, LCD Display, Printer Button Page 18.

Pro 7880 / 9880 Field Repair Guide 12/20/07

Component

Replacement

Printer Component, Software Item, LCD Display, Printer Button Page 19.

Pro 7880 / 9880 Field Repair Guide 12/20/07

Board (Main) Removal

Note: 7880 Main Board Part # 2117093 (the part # is stamped on the board)

9880 Main Board Part # 2117078 (the part # is stamped on the board)

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 (ServiceMan Mode: Self Testing: Adjustment: Check Nozzle).

2. Turn off the Printer and UNPLUG from AC.

3. Remove the Cover (Rear).

4. Unplug the Cables that attach the Main Board to the Printer..

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

Pro 7880 / 9880 Field Repair Guide 12/20/07

5. Remove 7 Screws, and lift out the Main Board.

1. Remove 7 Screws

2. Lift out the Main Board.

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

Pro 7880 / 9880 Field Repair Guide 12/20/07

Board (Main) Installation

Note: 7880 Main Board Part # 2117093 (the part # is stamped on the board)

9880 Main Board Part # 2117078 (the part # is stamped on the board)

1. Compare the New Main Board to the Old Main Board. Verify that the Components, Brackets, and Part Numbers match.

2. Fasten the new Board to the Housing with 7 Screws (see above).

1. Drop In the New Main Board.

2. Install 7 Screws.

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

Pro 7880 / 9880 Field Repair Guide 12/20/07

3. Connect the Cables to the Board. Ensure that the Cables are fully seated (straight).

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

Pro 7880 / 9880 Field Repair Guide 12/20/07

4. Install the Rear Cover.

5. Plug in and turn on the Printer in Firmware Download Mode (depress the Up, Down, Left, and

Menu buttons, and turn on the power to the Printer).

6. Download the latest Firmware following the directions found in the Firmware Update Procedure

Using FWUpdate.exe chapter located in the Reference section of the Field Guide.

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

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

7.1 Perform the RTC&USBID&IEEE1394ID Adjustment.

7.2 Perform the Colorimetric Calibration (When specifically requested by Epson).

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 will not function well enough to allow

alignments, paper loading, nozzle check, or the rest of step 16. 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 4

variations (7880 Matte Black, 7880 Photo Black, 9880 Matte Black, and 9880 Photo Black)

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

Pro 7880 / 9880 Field Repair Guide 12/20/07

9. Perform the following operations in the order listed.

9.1 Perform the RTC&USBID Adjustment.

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

9.3 Perform Input Serial Number.

9.4 Perform the Rear Sensor Adjustment.

9.5 Perform the 980mm Feed Adjustment

9.6 Perform the Ink Mark Sensor Level Adjustment.

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

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

9.9 Perform the Platen Position Adjustment

9.10 Perform the Ink Mark Sensor Adjustment for Auto Nozzle Check.

9.11 Perform the Auto Bi-D Adjustment.

9.12 Perform the Auto Uni-D Adjustment.

9.13 Perform the Cutter Pressure Adjustment.

9.14 )Perform the Writing MAC Address Adjustment.

9.15 Perform the Colorimetric Calibration (When specifically requested by Epson).

10. Turn the Printer off, and then back on, to ensure that the new data from step 16 is loaded into the

Printer’s memory.

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

Pro 7880 / 9880 Field Repair Guide 12/20/07

Board (Power Supply) Removal

1. Turn off the Printer and UNPLUG from AC.

2. Remove the Cover (Rear).

3. Unplug the Cables that attach the Power Supply to the Printer..

1. Unplug CN301.

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

2. Unplug CN001.

Pro 7880 / 9880 Field Repair Guide 12/20/07

4. Remove 8 Screws, and lift out the Power Supply..

1. Remove 8 Screws

2. Lift out the Power Supply.

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

Pro 7880 / 9880 Field Repair Guide 12/20/07

Carriage Assembly Replacement Procedure

Required Parts: New Carriage, Part # 1291960 & Cutter Alignment tool, Part # 1212928

1. Unplug the Printer.

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

3. Remove the Top Cover, Left Side Cover, and Right Side Cover.

4. Release the Carriage Lock, and move the Carriage Mechanism to the center of the Printer.

5. Remove the Pump Cap Assembly.

6. Remove the Carriage Board Cover.

Loosen 1 Screw.

Carriage Assembly Replacement Procedure Printer Component, Software Item, LCD Display, Printer Button Page 28.

Lift off the Carriage Board Cover.

Pro 7880 / 9880 Field Repair Guide 12/20/07

7. Remove 2 Screws that fasten the Carriage Board Assembly.

Remove 2 Screws.

8. Disconnect 5 Cables

Disconnect 2 foil cables and 3 connectors. Remove 1 screw that fastens the Ground Stra

Carriage Assembly Replacement Procedure Printer Component, Software Item, LCD Display, Printer Button Page 29.

Wire.

Pro 7880 / 9880 Field Repair Guide 12/20/07

9. Lift and suspend the Carriage Board Assembly.

Loosen one of the Screws that fasten a cover to support the Carriage Board Assem- bly.

Lift up the Carriage Board Assembly, and suspend it from the loosened Screw. (Shown with rubber bands in the picture).

Carriage Assembly Replacement Procedure Printer Component, Software Item, LCD Display, Printer Button Page 30.

+ 320 hidden pages

Epson Stylus Pro 7880, Stylus Pro 9880 Field Repair Guide

Specifications and Main Features

Frequently Asked Questions

User Manual

Table Of Contents

Control Panel Map

Board (Main) Removal

Board (Main) Installation

Board (Power Supply) Removal

Carriage Assembly Replacement Procedure