Epson Stylus Pro 7880/9880 Field Workshop Repair manual

Pro 7880 / 9880 Field Repair Guide 12/20/07 Printer Component, Software Item, LCD Display, Printer Button Page 1. Table Of Contents 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

Pro 7880 / 9880 Field Repair Guide 12/20/07 Printer Component, Software Item, LCD Display, Printer Button Page 2. 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

Pro 7880 / 9880 Field Repair Guide 12/20/07 Printer Component, Software Item, LCD Display, Printer Button Page 3. 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

Pro 7880 / 9880 Field Repair Guide 12/20/07 Printer Component, Software Item, LCD Display, Printer Button Page 4. 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

Pro 7880 / 9880 Field Repair Guide 12/20/07 Printer Component, Software Item, LCD Display, Printer Button Page 5. 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

Pro 7880 / 9880 Field Repair Guide 12/20/07 Printer Component, Software Item, LCD Display, Printer Button Page 6. 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

Pro 7880 / 9880 Field Repair Guide 12/20/07 Printer Component, Software Item, LCD Display, Printer Button Page 7. Control Panel Map Hold for 3 seconds to reset/clear Hold for 3 seconds to cut roll media Hold for 3 seconds to clean Power Button Sheet Roll Auto Cut Roll Auto Cut Off Ink Levels Maintenance Tank Level Media Feed Status Paper Out Ink Out Paused light Paper Source Button User Menu Button Enter / Select Button Press to pause the Printer. Roll Counter Custom Paper Number 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.

Pro 7880 / 9880 Field Repair Guide 12/20/07 Printer Component, Software Item, LCD Display, Printer Button Page 8. 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 CUSTOM PAPER: PRINT 4. CUSTOM PAPER. PAPER NUMBER: *STANDARD, NO. (1-10) 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 3. PRINTER STATUS. 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) PAGES SERVICE LIFE: CUTTER, CR MOTOR, PF MOTOR, HEAD UNIT,CLEANING UNIT, PRESSURE MOTOR (E*****F) User Menu: Press the Menu button when the printer displays Ready

Pro 7880 / 9880 Field Repair Guide 12/20/07 Printer Component, Software Item, LCD Display, Printer Button Page 9. Parameter Backup and Restore Mode Release the Paper Lever , lift 2 Ink Levers, remove the Maintenance Tank, hold the Down, Right, and Pause buttons 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) 7. NETWORK SETUP: (*DISABLE, ENABLE) IP ADDRESS SETTING: AUTO, PANEL, BONJOUR: *ON, OFF INIT NETWORK SETTING: EXECUTE 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) 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,)

Pro 7880 / 9880 Field Repair Guide 12/20/07 Printer Component, Software Item, LCD Display, Printer Button Page 10. 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) DEFAULT PANEL: EXEC (Resets to Factory Default the following User Menus: Printer Setup, Printer Status, Custom Paper, Head Alignment) INK INFO MENU: (FOR EACH COLOR) MANUFACTURER, COLOR, INK TYPE, INK CAPACITY, INK LEVEL, PRODUCTION DATE, EXPIRATION DATE, INK LIFE, INK AGE (CSIC information, for each ink cartridge) 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) 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, ON (CSIC Contact Test)

Epson Stylus Pro 7880/9880 Field Workshop Repair manual

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