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    							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. 
    						
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