Epson 4880 C Service Manual

							EPSON Stylus Pro  4400/4450/4800
                                                                4880/4880CColor Large Format Inkjet Printer
SERVICE MANUAL
SEIJ04008 
						

							Notice:
„All rights reserved. No part of this manual may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, 
electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SEIKO EPSON CORPORATION.
„The contents of this manual are subject to change without notice.
„All effort have been made to ensure the accuracy of the contents of this manual. However, should any errors be detected, SEIKO EPSON 
would greatly appreciate being informed of them.
„The above not withstanding SEIKO EPSON CORPORATION can assume no responsibility for any errors in this manual or the consequences 
thereof.
EPSON is a registered trademark of SEIKO EPSON CORPORATION.
General Notice: Other product names used herein are for identification purpose only and may be trademarks or registered trademarks of their 
respective owners. EPSON disclaims any and all rights in those marks.
Copyright © 2007  SEIKO EPSON CORPORATION. 
Imaging Product CS,PL & Environmental Management 
						

							PRECAUTIONS
Precautionary notations throughout the text are categorized relative to 1)Personal injury and 2) damage to equipment.
DANGERSignals a precaution which, if ignored, could result in serious or fatal personal injury. Great caution should be exercised in 
performing procedures preceded by DANGER Headings.
WARNINGSignals a precaution which, if ignored, could result in damage to equipment.
The precautionary measures itemized below should always be observed when performing repair/maintenance procedures.
DANGER
1. ALWAYS DISCONNECT THE PRODUCT FROM THE POWER SOURCE AND PERIPHERAL DEVICES PERFORMING ANY MAINTENANCE 
OR REPAIR PROCEDURES.
2. NO WORK SHOULD BE PERFORMED ON THE UNIT BY PERSONS UNFAMILIAR WITH BASIC SAFETY MEASURES AS DICTATED FOR 
ALL ELECTRONICS TECHNICIANS IN THEIR LINE OF WORK.
3. WHEN PERFORMING TESTING AS DICTATED WITHIN THIS MANUAL, DO NOT CONNECT THE UNIT TO A POWER SOURCE UNTIL 
INSTRUCTED TO DO SO. WHEN THE POWER SUPPLY CABLE MUST BE CONNECTED, USE EXTREME CAUTION IN WORKING ON 
POWER SUPPLY AND OTHER ELECTRONIC COMPONENTS.
WA R N I N G
1. REPAIRS ON EPSON PRODUCT SHOULD BE PERFORMED ONLY BY AN EPSON CERTIFIED REPAIR TECHNICIAN.
2. MAKE CERTAIN THAT THE SOURCE VOLTAGES IS THE SAME AS THE RATED VOLTAGE, LISTED ON THE SERIAL NUMBER/RATING 
PLATE. IF THE EPSON PRODUCT HAS A PRIMARY AC RATING DIFFERENT FROM AVAILABLE POWER SOURCE, DO NOT CONNECT IT 
TO THE POWER SOURCE.
3. ALWAYS VERIFY THAT THE EPSON PRODUCT HAS BEEN DISCONNECTED FROM THE POWER SOURCE BEFORE REMOVING OR 
REPLACING PRINTED CIRCUIT BOARDS AND/OR INDIVIDUAL CHIPS.
4. IN ORDER TO PROTECT SENSITIVE MICROPROCESSORS AND CIRCUITRY, USE STATIC DISCHARGE EQUIPMENT, SUCH AS ANTI-
STATIC WRIST STRAPS, WHEN ACCESSING INTERNAL COMPONENTS.
5. REPLACE MALFUNCTIONING COMPONENTS ONLY WITH THOSE COMPONENTS BY THE MANUFACTURE; INTRODUCTION OF 
SECOND-SOURCE ICs OR OTHER NON-APPROVED COMPONENTS MAY DAMAGE THE PRODUCT AND VOID ANY APPLICABLE EPSON 
WARRANTY.
6. WHEN AIR DUSTRE IS USED ON THE REPAIR AND THE MAINTENANCE WORK, THE USE OF THE AIR DUSTER PRODUCTS 
CONTAINING THE INFLAMMABLE GAS IS PROHIBITED. 
						

							About This Manual
This manual describes basic functions, theory of electrical and mechanical operations, maintenance and repair procedures of the printer. The instructions and 
procedures included herein are intended for the experienced repair technicians, and attention should be given to the precautions on the preceding page.
Manual Configuration
This manual consists of six chapters and Appendix.
CHAPTER 1.PRODUCT DESCRIPTIONS
Provides a general overview and specifications of the product.
CHAPTER 2.OPERATING PRINCIPLES
Describes the theory of electrical and mechanical operations of 
the product.
CHAPTER 3.TROUBLESHOOTING
Describes the step-by-step procedures for the troubleshooting. 
CHAPTER 4.DISASSEMBLY / ASSEMBLY
Describes the step-by-step procedures for disassembling and 
assembling the product.
CHAPTER 5.ADJUSTMENT
Provides Epson-approved methods for adjustment.
CHAPTER 6.MAINTENANCE
Provides preventive maintenance procedures and the lists of 
Epson-approved lubricants and adhesives required for servicing 
the product.
APPENDIXProvides the following additional information for reference:
• Connector pin assignments
• Electrical circuit boards schematics
• Exploded diagram & Parts List
Symbols Used in this ManualVarious symbols are used throughout this manual either to provide additional 
information on a specific topic or to warn of possible danger present during a 
procedure or an action. Be aware of all symbols when they are used, and 
always read NOTE, CAUTION, or WARNING messages.
Indicates an operating or maintenance procedure, practice or 
condition that is necessary to keep the product’s quality.
Indicates an operating or maintenance procedure, practice, or 
condition that, if not strictly observed, could result in damage to, 
or destruction of, equipment.
May indicate an operating or maintenance procedure, practice or 
condition that is necessary to accomplish a task efficiently. It may 
also provide additional information that is related to a specific 
subject, or comment on the results achieved through a previous 
action.
Indicates an operating or maintenance procedure, practice or 
condition that, if not strictly observed, could result in injury or loss 
of life.
Indicates that a particular task must be carried out according to a 
certain standard after disassembly and before re-assembly, 
otherwise the quality of the components in question may be 
adversely affected. 
						

							 Revision Status
Revision
Date of Issue
Description
A Jun. 2, 2005 First release
B May. 25, 2007 Revised contents:
[Chapter 3]
Recovery (p.163) was changed.
[Chapter 5]
• Procedures were partially changed in 5.1.4 Adjustment Items classified by Part/Unit (p.368).
• 5.8 Installing Firmware for SP 4400 (4-color model) after replacing Main Board with New one (p.445) was added.
C September. 12, 2007 Revised Contents:
[All chapters]
• Information on Stylus 4450/4880/4880C has been added. 
						

							EPSON Stylus Pro 4400/4450/4800/4880/4880CRevision C
6
Contents
Chapter 1 Product Description1.1 Product Description .............................................................................................  10
1.1.1 Comparison with Stylus Pro 4000 ..............................................................  10
1.1.2 Features .......................................................................................................  11
1.2 Basic Specifications.............................................................................................  13
1.2.1 Print Specifications .....................................................................................  13
1.2.2 Character Specification...............................................................................  14
1.2.3 Control Code...............................................................................................  14
1.2.4 Paper Feed Specification ............................................................................  14
1.2.5 Paper Feeder Specification .........................................................................  14
1.2.6 Paper Specification .....................................................................................  15
1.2.7 Mechanism Specifications ..........................................................................  19
1.2.8 Electrical Specification ...............................................................................  22
1.2.9 Reliability ...................................................................................................  23
1.2.10 Environmental Conditions ........................................................................  23
1.2.11 Quality Standards for Completed Products ..............................................  25
1.2.12 Overall Dimensions ..................................................................................  25
1.2.13 Accessories ...............................................................................................  26
1.3 External View and Parts Names ..........................................................................  28
1.4 Operating Panel ...................................................................................................  30
1.4.1 Buttons and Functions ................................................................................  30
1.4.2 Panel Display ..............................................................................................  33
1.4.3 Job information ...........................................................................................  39
1.4.4 Panel Setting ...............................................................................................  40
1.4.5 Maintenance Mode 1 ..................................................................................  83
1.4.6 Maintenance Mode 2 ..................................................................................  90
1.4.7 MIB Function............................................................................................  102
1.4.8 Function to Prevent Irregular Printing ......................................................  103
1.4.9 Initialization ..............................................................................................  104
1.4.10 Default Setup Values ..............................................................................  104
1.5 Controller...........................................................................................................  105
1.6 Interface .............................................................................................................  106
1.6.1 USB interface............................................................................................  1061.6.2 IEEE1394 Interface ..................................................................................  107
1.6.3 Optional Interface .....................................................................................  108
1.6.4 Supplements..............................................................................................  110
1.7 Optional Units and Consumables ......................................................................  111
1.7.1 Ink Cartridge .............................................................................................  111
1.7.2 Cleaning cartridge.....................................................................................  112
1.7.3 Maintenance Tank ....................................................................................  112
Chapter 2 Operating Principles2.1 Overview ...........................................................................................................  114
2.2 Printer Mechanism Components .......................................................................  115
2.2.1 Printing Mechanism (Print Head) .............................................................  116
2.2.2 Ink Supply Mechanism .............................................................................  118
2.2.3 Cleaning Mechanism ................................................................................  120
2.2.4 Carriage (CR) Mechanism ........................................................................  125
2.2.5 Paper Feed Mechanism.............................................................................  131
2.2.6 Paper Eject/Release Mechanism...............................................................  140
2.2.7 Multi Sensor .............................................................................................  145
2.2.8 Others........................................................................................................  151
2.3 Outline of Control Circuit Board.......................................................................  152
2.4 Outline of Power Supply Circuit Board ............................................................  154
2.5 Colorimetric Calibration (Color ID) Overview .................................................  155 
						

							EPSON Stylus Pro 4400/4450/4800/4880/4880CRevision C
7Chapter 3 Troubleshooting3.1 Outline ...............................................................................................................  157
3.1.1 Check Before Troubleshooting .................................................................  157
3.1.2 Narrow Down the Trouble ........................................................................  157
3.2 Troubleshooting Based on Panel Messages ......................................................  158
3.2.1 Message Table ..........................................................................................  158
3.2.2 Corrective Actions for Displayed Warnings.............................................  162
3.2.3 Corrective Actions for Error Display .......................................................  165
3.2.4 Corrective Actions for Service Request Display ......................................  175
3.3 Troubleshooting Based on Your Printout ..........................................................  196Chapter 4 Disassembly & Assembly4.1 Introductory Information ...................................................................................  201
4.1.1 Cautions ....................................................................................................  201
4.1.2 Tools .........................................................................................................  203
4.1.3 Screws .......................................................................................................  204
4.1.4 Difference Between 8-color And 4-color Models In Disassembly/Assembly  
205
4.2 Disassembly Procedures ....................................................................................  206
4.2.1 Basic Operations .......................................................................................  207
4.2.2 Consumable Parts/ASF Cassette Removal ...............................................  209
4.2.3 Panel Unit/Housing Removal ...................................................................  214
4.2.4 Circuit Board Removal .............................................................................  226
4.2.5 Printer Mechanism Disassembly ..............................................................  241
4.2.6 ASF ...........................................................................................................  246
4.2.7 Carriage Mechanism .................................................................................  266
4.2.8 Ink System ................................................................................................  285
4.2.9 Paper Feed Mechanism .............................................................................  343
4.2.10 Harness Routing......................................................................................  358
4.2.11 Disassembly/Assembly Unique to 4-color Model (Stylus Pro 4000).....  362
Chapter 5 Adjustment5.1 Overview ...........................................................................................................  367
5.1.1 Cautions ....................................................................................................  367
5.1.2 Advance of Adjustment ............................................................................  367
5.1.3 The Part/Unit that Requires Adjustment ..................................................  367
5.1.4 Adjustment Items classified by Part/Unit .................................................  368
5.1.5 Adjustment Item .......................................................................................  371
5.1.6 Adjustment Tools .....................................................................................  374
5.1.7 Adjustment Program Basic Operation ......................................................  375
5.2 Mechanical Adjustment.....................................................................................  376
5.2.1 CR Timing Belt Tension Adjustment .......................................................  376
5.2.2 PF Timing Belt Tension Adjustment ........................................................  378
5.2.3 Paper Thickness Sensor Adjustment ........................................................  380
5.2.4 CR Encoder Sensor Position Adjustment .................................................  382
5.2.5 PG Adjustment .........................................................................................  383
5.2.6 Multi Sensor Position Adjustment............................................................  385
5.3 Basic Adjustment ..............................................................................................  387
5.3.1 RTC&USB ID&IEEE1394 ID.................................................................  387
5.3.2 Head Rank ID ...........................................................................................  388
5.3.3 Multi Sensor Level Adjustment................................................................  389
5.3.4 T&B&S (Roll Paper) ................................................................................  390
5.3.5 T&B&S (Cut Sheet) .................................................................................  391
5.3.6 Cutter Pressure Adjustment ......................................................................  392
5.3.7 Nozzle Bi-D Adjustment ..........................................................................  393
5.3.8 Print Head Slant Adjustment (PF) ............................................................  394
5.3.9 Print Head Slant Adjustment (CR) ...........................................................  397
5.3.10 Auto Uni-d Adjustment ..........................................................................  401
5.3.11 Multi Sensor Adjustment for Auto Nozzle Check..................................  402
5.3.12 Skew Check ............................................................................................  404
5.3.13 Platen Position Adjustment ....................................................................  405
5.3.14 1000mm Feed Adjustment......................................................................  407
5.3.15 Initial Ink charge flag ON/OFF ..............................................................  408
5.3.16 NVRAM Back Up and Write .................................................................  409
5.3.17 Check Platen Gap ...................................................................................  410
5.3.18 Ink Discharge..........................................................................................  411
5.3.19 Initial Ink Charge ....................................................................................  412
5.3.20 Cleaning ..................................................................................................  412
5.3.21 Rear Sensor Adjustment .........................................................................  413
5.3.22 Colorimetric Calibration (Color ID).......................................................  414 
						

							EPSON Stylus Pro 4400/4450/4800/4880/4880CRevision C
85.4 Advanced Adjustment .......................................................................................  430
5.4.1 Auto Bi-d Adjustment...............................................................................  430
5.4.2 Manual Bi-D Adjustment .........................................................................  431
5.4.3 Destination Setting....................................................................................  434
5.4.4 PF Micro Feed Adjustment (Bi-D) (TBD) ...............................................  435
5.5 Check Results ....................................................................................................  436
5.5.1 Check Nozzle ............................................................................................  436
5.5.2 Check Alignment ......................................................................................  437
5.5.3 Print Adjustment Check Pattern ...............................................................  438
5.5.4 Image Printing ..........................................................................................  439
5.5.5 Check Cutting ...........................................................................................  440
5.6 Reset Counters ...................................................................................................  441
5.6.1 Reset Paper Ejection Switching/PG Switching Counter ..........................  441
5.6.2 Reset PF Motor Counter ...........................................................................  441
5.6.3 Reset ASF Counter ...................................................................................  442
5.6.4 Reset When CR Unit Change ...................................................................  442
5.6.5 Reset When Cleaning Unit Change ..........................................................  443
5.6.6 Reset When Printhead Change .................................................................  443
5.7 Installing Firmware ...........................................................................................  444
5.8 Installing Firmware for SP 4400 (4-color model) after replacing Main Board with 
New one ...................................................................................................................  445
5.9 Device ID Setting ..............................................................................................  446
5.10 Writing MAC Address ....................................................................................  447
Chapter 6 Maintenance6.1 Overview ...........................................................................................................  449
6.1.1 Product Life Information ..........................................................................  450
6.1.2 Important Maintenance Items During Service Operations .......................  450
6.2 Lubrication ........................................................................................................  451Chapter 7 Appendix7.1 Connectors .........................................................................................................  458
7.2 Exploded Diagrams ...........................................................................................  463
7.3 Parts List ............................................................................................................  481 
						

							CHAPTER
1
PRODUCT DESCRIPTION 
						

							EPSON Stylus Pro 4400/4450/4800/4880/4880CRevision CProduct Description Product Description 101.1  Product DescriptionThe Stylus Pro 4400/4450/4800/4880/4880C is a large-format printer based on the Stylus Pro 4000.
The Stylus Pro 4800/4880/4880C is the exclusive model for 8-color inks and the Stylus Pro 4400/4450 is the exclusive model for 4-color inks.
The following table shows the major changes from the Stylus Pro 4000.1.1.1  Comparison with Stylus Pro 4000 Note * : PK=Photo Black, MK=Matte Black, LK=Light Black, LLK=Light Light Black, C=Cyan, M=Magenta, LC=Light Cyan, LM=Light Magenta, Y=Yellow, VM=Vivid Magenta, 
VLM=Vivid Light Magenta
Table 1-1. Comparative Table
No.
Comparative Point
Stylus Pro 4400/4450/4800
/4880/4880C
Stylus Pro 4000
Remark
1 Difference between 
8-color model and 
4-color modelHardware The 4-color model is not equipped with 
an ink holder on the right side.Common ---
2 Printer driver Differs between the 8-color model and 
the 4-color model.Common ---
3 Ink set 
configuration8-color model
†
Stylus Pro 4800
K (PK/MK),C,M,Y,LK,LC,LM,LLK
*
†
Stylus Pro 4880/4880C
K (PK/MK),C,VM,Y,LK,LC,VLM,LLK
*
MK,C,M,Y,PK,LC,LM,LK
*
---
4-color model MK,C,M,Y
*
MK,C,M,Y
*
4 Calibration function Colorimetric Calibration:
Corrects the amount of dot generation 
based on the individual difference 
between the following parts:
„
Printhead
„
MAIN Board
„
Power Supply BoardHead ID:
Corrects the amount of dot 
generation based on the individual 
difference between the following 
part:
„
PrintheadCalibration accuracy is improved by taking electrical 
variable factor into consideration.
5 PG setting 5 levels:
0.7mm/1.2mm/1.5mm
/2.2mm/2.6mm4 levels:
0.7mm/1.2mm/2.2mm/2.6mmAdded 1.5 mm of PG setting to prevent thin paper from 
being damaged. (Lock bush design is changed according 
to the added PG setting.)
6 Harness connection for CR Motor Connected by connectors Connected by soldering Harnesses are made easier to connect/disconnect.
7 Connection between Printhead and 
Main BoardAdded a relay board between 
“Printhead, Harness”and the MAIN 
Board.The Printhead is connected to the 
MAIN Board by “Head, Harness” 
only.An additional relay board prevents head drive waveform 
being deteriorated when transmitting data form the MAIN 
Board to the Printhead.
8 Material for roll paper guide roller Rubber (elastomer) Plastic (POM) Reduce roller marks traced when roll paper passes 
through the roller.
9 Cooling fan Added a cooling fan --- Cools the MAIN Board and the Power Supply Board, and 
ventilates the board container.