Epson WF-2510, WF-2520, WF-2530, WF-2540 Service Manual

SERVICE MANUAL
Color Inkjet Printer
EPSON WF-2540/WF-2548/WF-2541 EPSON WF-2530/WF-2532/WF-2538/WF-2531 EPSON WF-2520/WF-2528/WF-2521 EPSON WF-2510/WF-2511/WF-2512 EPSON WF-2010
CONFIDENTIAL
SEMF12-003
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.
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 contents of this manual are subject to change without notice.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.
Note :Other product names used herein are for identification purpose only and may be trademarks or r egistered
trademarks of their respective owners. EPSON disclaims any and all rights in those marks.
Copyright © 2012 SEIKO EPSON CORPORATION
Printer CS Quality Assurance Department
Confidential
Safety Precautions
All safety procedures described here shall be strictly adhered to by all parties servicing and maintaining this product.
DANGER
Strictly observe the following cautions. Failure to comply could result in serious bodily injury or loss of life.
1. Always disconnect the product from the power source and peripheral devices when servicing the product or performing maintenance.
2. When performing works described in this manual, do not connect to a power source until instructed to do so. Connecting to a power source causes high voltage in the power supply unit and some electronic components even if the product power switch is off. If you need to perform the work with the power cable connected to a power source, use extreme caution to avoid electrical shock.
WARNING
Strictly observe the following cautions. Failure to comply may lead to personal injury or loss of life.
1. Always wear protective goggles for disassembly and reassembly to protect your eyes from ink in working. If any ink gets in your eyes, wash your eyes with clean water and consult a doctor immediately.
2. When using compressed air products; such as air duster, fo r cleaning during repair and maintenance, the use of such products containing flammable gas is prohibited.
PRECAUTIONS
Strictly observe the following cautions. Failure to comply may lead to personal injury or damage of the product.
1. Repairs on Epson product should be performed only by an Epson certified repair technician.
2. No work should be performed on this product by persons unfamiliar with basic safety knowledge required for electrician.
3. The power rating of this product is indicated on the serial number/rating plate. Never connect this product to the power source whose voltages is different from the rated voltage.
4. Replace malfunctioning components only with those components provided or approved by Epson; introduction of second-source ICs or other non-approved components may damage the product and void any applicable Epson warranty.
5. The capacitors on the Main Board may be electrically charged right after the power turns off or after driving motors which generates counter electromotive force such as when rotating the PF Roller or when moving the CR Unit. There is a risk to damage the Main Board if the Head FFC is short-circuited with the capacitors on the Main Board electrically charged, therefore, after the power turns off or after motors are driven, leave the printer untouched for approximately 30 seconds to discharge the capacitors before starting disassembly/ reassembly.
6. To prevent the circuit boards from short-circuiting, be careful about the following when handling FFC or cables.
When handling FFC, take care not to let the terminal section of FFC touch metal parts.
When connecting cables/FFC to the connectors on circuit boards, connect them straight to the connectors to avoid
slant insertion.
Confidential
7. In order to protect sensitive microprocessors and circuitry, use static discharge equipment, such as anti-static wrist straps, when accessing internal components.
8. Do not tilt this product immediately after initial ink charge, especially after performing the ink charge several times. Doing so may cause ink to leak from the product because it may take some time for the waste ink pads to completely absorb ink wasted due to the ink charge.
9. Never touch the ink or wasted ink with bare hands. If ink comes into contact with your skin, wash it off with soap and water immediately. If you have a skin irritation, consult a doctor immediately.
10. When disassembling or assembling this product, make sure to wear gloves to avoid injuries from metal parts with sharp edges.
11. Use only recommended tools for disassembling, assembling or adjusting the printer.
12. Observe the specified torque when tightening screws.
13. Be extremely careful not to scratch or contaminate the following parts.
Nozzle plate of the Printhead
  CR ScalePF ScaleCoated surface of the PF RollerGearsRollersLCDScanner SensorExterior parts
14. Never use oil or grease other than those specified in this manual. Use of different types of oil or grease may damage the component or give bad influence on the printer function.
15. Apply the specified amount of grease described in this manua l .
16. Make the specified adjustments when you disassemble the printer.
17. When cleaning this product, follow the procedure described in this manual.
18. When transporting this product after filling the ink in the printhead, pack the printer without removing the ink cartridges in order to prevent the printhead from drying out.
19. Make sure to install antivirus software in the computers used for the service support activities.
20. Keep the virus pattern file of antivirus software up-to-date.
21. When disassembling/reassembling this product, if you find adhesive power of the double-sided tape which secure the parts or FFC is not enough, replace the tape with new one and attach it correctly to the specified points where the parts or FFC should be secured.
22. Unless otherwise specified in this manual, the labels attached on the returned product should be transferred to the corresponding attachment positions on the new one referring to the labels on the returned product.
Confidential
About This Manual
This manual, consists of the following chapters, is intended for repair service personnel and includes information necessary for properly performing maintenance and servicing the product.
CHAPTER 1. TROUBLESHOOTING
Describes the step-by-step procedures for the troubleshooting.
CHAPTER 2. DISASSEMBLY / REASSEMBLY
Describes the disassembly/reassembly procedures for main parts/units of the product, and provides the standard operation time for servicing the product.
CHAPTER 3. ADJUSTMENT
Describes the required adjustments for servicing the product.
CHAPTER 4. MAINTENANCE
Describes maintenance items and procedures for servicing the product.
CHAPTER 5. REFURBISHMENT
Describes refurbishing work of the product and its purpose.
CHAPTER 6. APPENDIX
Provides the following additional information for reference:
Connector Diagram
Protection for Transportation
Symbols Used in this Manual
Various 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. Pay attention to all symbols when they are used, and always read explanation thoroughly and follow the instructions.
Indicates an operating or maintenance procedure, practice or condition that, if not strictly observed, could result in serious injury or loss of life.
Indicates an operating or maintenance procedure, practice, or condition that, if not strictly observed, could result in bodily injury, damage or malfunction 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.
For Chapter 2 “Disassembly/Reassembly”, symbols other than indicated above are used to show additional information for disassembly/reassembly. For the details on those symbols, see "2.2 Disassembly/Reassembly
Procedures (p27)".
Confidential
Revision Status
Revision Date of Issue Description
A June 29, 2012 First Release B August 28, 2012 Revised Contents
Chapter 2
 ■ Made change in Chapter 3
 ■ Made change in
 ■ Made change in
"2-1 Standard Operation Time (p24)"
"3-2 Required Adjustment List (p56)" "3.2.2.3 PIS Board Check (p62)"
Confidential
WF-2540 / WF-2530 / WF-2520 / WF-2510 /WF-2010 series
Contents
Chapter 1 Troubleshooting
1.1 Troubleshooting....................................................................................................................................................... 10
1.1.1 Troubleshooting Workflow ............................................................................................................................ 10
1.2 Power-On Sequence ................................................................................................................................................ 12
1.3 Fatal Error Code List............................................................................................................................................... 14
1.3.1 D isplaying the Fatal Error Code..................................................................................................................... 14
1.3.2 Printer Fatal Error Code ................................. ..................................... ........................................................... 15
1.3.3 Scanner Fatal Error Code .................................. ..................................... ........................................................ 18
Chapter 2 Disassembly/Reassembly
2.1 O verview ................................................................................................................................................................. 20
2.1.1 Tools ............................................................................................................................................................... 20
2.1.2 Jigs .................................................................................................................................................................. 20
2.1.2.1 Making the Spring Hook Jig.................................................... ... ........................................................... 20
2.1.3 Locations of the Parts/Units ........................................................................................................................... 21
2.1.4 Standard Operation Time for Servicing the Product ...................................................................................... 24
2.2 D isassembly/Reassembly Procedures ..................................................................................................................... 27
2.2.1 Configuration.................................................................................................................................................. 27
2.2.2 Disassembly Flowchart................................................................................................................................... 28
2.2.2.1 Multifunction Printer specific parts ....................................................................................................... 30
2.2.2.2 S inglefunction Printer specific parts...................................................................................................... 32
2.2.2.3 Common Printer Mechanism ................................................................................................................. 34
2.2.2.4 Unit/Assy ............................................................................................................................................... 36
2.2.3 Disassembly Flowchart (Printhead/Main Board)........................................................................................... 39
2.3 Detailed Disassembly/Reassembly Procedure for each Part/Unit........................................................................... 40
2.4 Routing FFCs/cables ............................................................................................................................................... 48
Revision B
Chapter 3 Adjustment
3.1 Required Adjustments ............................................................................................................................................. 53
3.2 Adjustment Program.................................. ..................................... ......................................................................... 60
3.2.1 O perating Environment .................................................................................................................................. 60
3.2.2 Details of the Adjustment Program ................................................................................................................ 60
3.2.2.1 CR Motor Heat Protection Control / PF Motor Heat Protection Control .............................................. 60
3.2.2.2 S canner Motor Heat Protect ion Control ................................................................................................ 61
3.2.2.3 PIS Board Check.................................................................................................................................... 62
3.3 Mechanism Adjustment / Check ................................................. .................................... ........................................ 63
3.3.1 Checking the Platen Gap ................................................................................................................................ 63
3.3.2 CR/PF Belt Tension Check ............................................................................................................................. 65
Chapter 4 Maintenance
4.1 O verview ................................................................................................................................................................. 68
4.1.1 Cleaning.......................................................................................................................................................... 68
4.1.2 Lubrication...................................................................................................................................................... 68
4.2 Lubrication Points and Instructions......................................................................................... ................................ 69
Chapter 5 Refurbishment
5.1 O verview ................................................................................................................................................................. 74
5.1.1 Ink Discharge.................................................................................................................................................. 74
7
Confidential
WF-2540 / WF-2530 / WF-2520 / WF-2510 /WF-2010 series
Chapter 6 Appendix
6.1 Connector Diagram ................................................................................................................................................. 76
6.2 P rotection for Transportation .................................................................................................................................. 77
6.2.1 Securing the CR Unit.................................................... ... ..................................... .......................................... 77
6.2.2 Securing the Paper Support/Paper Support Sub ............................................................................................. 78
Revision B
8
Confidential
CHAPTER 1

TROUBLESHOOTING

Confidential
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series
ADF/Scanner failure
Printer failure only
*1: If the Hopper of ASF on the returned product touches the LD Roller, the
initial ink charge has not been completed for the product yet.
*2: In case of “Not Trouble Found”, check fatal error code.
Finish
*2
Yes
Copy an image by ADF
Yes
Yes
No
Is ADF operation
finished without
trouble?
6
No
No
5
Is scanning operation
finished without
trouble?
What is returned reason?
ADF failure?
2
Print check pattern
Yes
No
Yes
No
Yes
No
Is Power-on sequence
finished without error?
Standby condition
3
Does an error occur
when printing?
Start
Turn on the power
*1
1
No
Does printer turn on the
power?
Yes
4
Is printing operation
finished without trouble?
(p 11)
(p 11)
(p 11)
(p 11)
(p 11)
(p 11)
Copy an image

1.1 Troubleshooting

This section describes the troubleshooting workflow and fatal error information.

1.1.1 Troubleshooting Workflow

The following page describes the troubleshooting workflow. Follow the flow when troubleshooting problems.
In this chapter, the product names are called as follows:
• WF-2540 Series: WF-2540/WF-2548/WF-2541
• WF-2530 Series: WF-2530/WF-2532/WF-2538/WF-2531
• WF-2520 Series: WF-2520/WF-2528/WF-2521
• WF-2510 Series: WF-2510/WF-2511/WF-2512
• WF-2010 Series: WF-2010
This flowchart is compiled based on the following contents.
• Our experience regarding the quality problem.
• ESK’s repair data.
• Printer Mechanism specification for the product.
WF-2510 series are not equipped with the ADF unit, therefore, the troubleshooting
related to the ADF unit is not applied.
WF-2010 series are not equipped with the ADF/Scanner unit, therefore, the
troubleshooting related to the ADF/Scanner unit is not applied.
If the reason for the return is evident, first check the phenomenon user claims recurs,
then proceed to the troubleshooting.
Revision B
Figure 1-1. Troubleshooting Workflow (1)
Troubleshooting Troubleshooting Workflow 10
Confidential
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B
1
No Power
[Presumable Cause]
• PS Unit damage
• Main Board damage
[Major Troubleshooting]
• PS Unit replacement
• Main Board replacement
*
The power-on sequence does not start
(p 10)
Please refer to " 1.3 Fatal Error
Code List (p14)".
Fatal error
Error is indicated during power-on
2
sequence
*: If the printer can turn on but turns off right away, the protection
circuit may cut off the power due to an error such as a circuit failure.
Error is indicated during printing nozzle check pattern.(p 10)
3
(p 10)
Maintenance error
[Occurrence Condition]
This error occurs when maintenance counter in EEPROM exceeds the specified value.
[Major Occurrence Timing]
• Power-on timing
• Print start timing
• Cleaning timing
• Ink Cartridge replacement timing
[Troubleshooting]
• Porous Pad replacement & Maintenance counter reset
Ink End error
[Occurrence Condition]
This error occurs when ink in Ink Cartridge is empty.
[Major Occurrence Timing]
• Power-on timing
• Print start timing
• Cleaning timing
• Ink Cartridge replacement timing
[Troubleshooting]
• Ink Cartridge replacement
Ink Cartridge error
[Occurrence Condition]
This error occurs when the Ink Cartridge failed.
[Major Occurrence Timing]
• Power-on timing
• Print start timing
• Cleaning timing
• Ink Cartridge replacement timing
[Major Troubleshooting]
• Remove and reinstall Ink Cartridge
• Ink Cartridge replacement
• CSIC Terminal (Holder Board Assy) replacement
• Holder Board Assy replacement
• Head FFC replacement
• Main Board replacement
• Porous Pad replacement & Maintenance counter reset
Problems related to print result or during printing (p 10)
4 5 6
No Ink Cartridge error
[Occurrence Condition]
This error occurs when Ink Cartridge is not installed.
[Major Occurrence Timing]
• Power-on timing
[Troubleshooting]
• Ink Cartridge installation
Paper Jam Fatal error
[Occurrence Condition]
This error occurs when CR Unit is blocked by jammed paper.
[Major Occurrence Timing]
• Power-on timing
[Major Troubleshooting]Åz
• Remove jammed paper ?On this product, if CR Unit
touches jammed paper, CR Unit moves back in the opposite direction so that customer can remove the paper. However, if CR Unit cannot move in this sequence, this error occurs.
Scanning cannot be performed successfully
(p 10)
ADF does not operate normally
(p 10)
Paper Jam error
[Occurrence Condition]
This error occurs when top/ bottom of paper is not detected by PE Sensor in the specified steps of paper loading / ejecting operation correctly.
[Major Occurrence Timing]
• Power-on timing
• Paper loading timing
• Paper eject timing
[Major Troubleshooting]
1 Perform paper eject operation
from operation panel.
• Success Starts paper feeding operation again if printer has print data.
•Fail Occurs paper jam error again.
2 If fail in the above 1, remove
the paper by opening Scanner Unit.
3 Perform paper eject operation
from operation panel again.
• Success Starts paper feeding operation again if printer has print data.
•Fail Occurs paper jam error again.
4 Check the following if failed in
Step 3.
• Foreign object
• Detached parts
• PE Sensor Lever
• PE Sensor
• Porous Pad on Paper Guide Front
• Main board
No Paper error
[Occurrence Condition]
This error occurs when top of paper can not be detected correctly by PE Sensor in the specified steps up to completion of the paper loading operation. (No paper / No loading / large paper skew)
[Major Occurrence Timing]
• Paper loading timing
[Major Troubleshooting]
1 Set paper in ASF and perform
paper feed operation.
2 If the paper stops before
reaching PE Sensor, remove it and check the paper condition.
3
A)
If paper is OK, set paper in ASF and move edge guides to appropriate position, and perform 2 again. B)If damage in the above 2, check foreign materials / parts come-off / parts transformation in paper path.
4 If the problem is not solved by
3-A) & 3-B), check the following.
• Foreign object
• Detached parts
• Surface condition of LD Roller or PF Roller
• PE Sensor Lever
•PE Sensor
• Main Board
•PF Motor
Double Feed err or
[Occurrence Condition]
When manual duplex printing is selected using the printer driver, this error occurs if the actual paper length detected by PE Sensor does not match with the paper length specified in the printer driver. (The error occurs when the actual length is longer than the theoretical length specified in the driver.)
[Major Occurrence Timing]
• Paper loading timing
• Paper eject timin g
[Troubleshooting]
• PE Sensor Lever replacement
• PE Sensor replacement (Main Board replacement)
• Main Board replacement
?This error may occur in the manual duplex printing if the inverted sheet printed on the first side sticks to the second sheet when the first side printing is complete and the sheet is inverted and set to ASF to print on the other side.
Paper Size Unmatch error
[Occurrence Condition]
This error occurs if the actual paper length detected by PE Sensor does not match with the paper length specified in the printer driver. (The error occurs no matter when the actual length is longer or shorter than the theoretical length specified in the driver.)
[Major Occurrence Timing]
• Paper eject timing
[Troubleshooting]
• PE Sensor Lever replacement
• PE Sensor replacement (Main Board replacement)
• Main Board replacement
Poor Printing
[Phenomenon]
• Poor printing quality
• Ink stain on paper
• Dot missing
• Paper eject without printing
[Presumable Cause]
• Driver / Panel mis-setting
• Contamination of CR scale
• Contamination of Printhead cover
• Printhead damage
• Ink clogging of Printhead
• Contamination on Cap Unit / Wiper of Ink System Assy
• Ink System Assy damage
• Float of Porous Pad on Paper Guide Front
• Narrower/Wider PG (out of standard)
• PE Sensor Lever damage
• PE Sensor damage
[Major Troubleshooting]
• Driver / Panel re-setting
• CR Scale replacement
• Printhead cover cleaning
• Printhead cleaning
• Ink Cartridge replacement
• Printhead replacement
• Rubber cleaning of Cap Unit
• Ink System Assy replacement
• Porous Pad re-installation
• Printer replacement
• PE Sensor Lever replacement
• PE Sensor replacement (Main Board replacement)
Poor Paper Loading
[Presumable Cause]
• Use of 3rd party media
• Edge guide mis-setting
• Foreign material
• Part come-off
• Contamination of LD Roller or PF roller
[Major Troubleshooting]
• Recommendation of EPSON media
• Edge guide re-setting
• Foreign material removal
• Part re-installation
• Roller replacement
Abnormal Noise
[Presumable Cause]
• Foreign material
• Insufficient grease
• Gear damage
[Major Troubleshooting]
• Foreign material removal
• Lubrication of grease
• Gear replacement
Scanner failure
[Presumable Cause]
• Contamination of Scanner Glass
• Contamination of Document Pad
• CIS Unit bonding failure
• CIS Unit damage
• Scanner Motor damage
• Insufficient grease
[Major Troubleshooting]
• Scanner Glass cleaning
• Document Pad cleaning
• Document Pad replacement
• CIS Unit replacement
• Scanner Motor replacement
• Lubrication of grease
ADF Unit failure
[Phenomenon]
• Paper is not fed
• Multi-feed
• Paper jam
• Skewed document
[Presumable Cause]
• Deterioration of Pickup Roller
• Deterioration of ADF Pad Assy
• Damage to gears
• Damage to Scanner Motor
• Contamination on document glass
• Foreign object
• Damage to ADF Paper Guide Cover Assy
• Deterioration of Paper Eject Roller
• Scanner Carriage
[Major Troubleshooting]
• Replace ADF Paper Guide Cover Assy
• Replace ADF Pad Assy
• Clean document glass
• Remove foreign material
• Replace ADF Unit
• Replace Scanner Unit
failure
Figure 0-1. Troubleshooting Wo rkflow (2)
Troubleshooting Troubleshooting Workflow 11
Confidential
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series

1.2 Power-On Sequence

This section describes the power-on sequences in two conditions. The preconditions are as follows.
Condition 1: Normal power-on sequence (See Table 1-1.)
Turning on the printer after turning it off without an error.
Initial ink charge has finished and every cartridge has sufficient ink.No paper on the paper path.The Printhead is capped with the Cap Assy.The CR Unit is normally fixed by the Change Lever.Maintenance error recovery has never been performed.
Table 1-1. Condition 1: Normal Power-on Sequence
Operation
1. Printhead initialization and fuse inspection
1-1.Initializes the Printhead, and checks for the fuse on the circuit boards in the printer.
2. Checking for waste ink overfl ow
2-1.Checks the waste ink counter if the waste ink overflow is occurring.
3. Seeking the home position
3-1.The CR Unit moves to the 80-digit side slowly and confirms it touches the Change Lever (CR lock).
*1
*3
Revision B
CR Unit/PF Roller
movement and
position
*2
3-2.The CR Unit moves to the 0-digit side slowly.
3-3.After the PE Sensor checks if paper exists, the PF Motor rotates clockwise for one second and releases the CR lock.
3-4.While checking if the CR Unit does not touch the Change Lever (CR lock) or the foreign material, the CR Unit
moves to the 80-digit side slowly until it touches the Left Frame.
3-5.The distance from the position where the CR Unit touched to the Left Frame is regarded as the standard distance
from the origin position, and the home position is fixed. From then on, the CR Unit position is monitored according to the signals from the CR Encoder.
3-6.The CR Unit moves to near its home position quickly.
4. Detecting ink cartridge and initializing ink system
4-1.To check the operation of the PIS Sensor and to detect ink, the CR Unit moves back and forth over the PIS Sensor
two times.
4-2.The CR Unit returns to its home position.
5. Low temperature operation sequence
5-1.The CR Unit quickly moves back and forth between near the Change Lever and near the Left Frame for two times.
*5
*4
Note 1: The rotation directions of the PF Motor are as follows.
Clockwise: Paper is fed normally Counterclockwise: Paper is fed backward
*2: The conditions of the CR lock are as follows.
Red CR lock is set
White CR lock is released *3: The fatal error occurs if there is a problem such as the fuse blew. *4: The empty suction operation may occur depending on the situation. *5: Executed when the detected temperature is under 5
o
C (41oF) by the thermistor on the Printhead.
Troubleshooting Power-On Sequence 12
Confidential
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series
Condition 2: Power-on sequence after recovering from a paper jam error (See Table 1-2.)
Turning on the printer after turning it off wi th a paper jam fatal error.
There still remains paper on the paper path out of the detecting area of the PE Sensor.Maintenance error recovery has never been performed.
Revision B
Table 1-2. Condition 2: Power-on Sequence after Recovering from a Paper Jam Error
Operation
Executes No.1 to No.3 on the normal power-on sequence (Table 1-1).
4. Detecting remaining paper
4-1.5.The CR Unit returns to its home position.
4-2.The CR Unit moves to the 80-digit side and confirms there is no paper.
4-3.The CR Unit quickly returns to its home position, and displa ys on the LCD or with flashing LEDs that the paper jam
error occurs.
When the user removes the paper and releases the paper jam error by panel operation, the normal power-on sequence from No.1 (Table 1-1) is executed
*2
again.
Note *1: “Paper exists” is detected when the CR Unit touches the paper. When “paper does not exist” is detected, the power-on sequence
of condition 1 (Table 1-1) is executed from No.4. *2: If the paper jam error cannot be solved after repeating the power-on sequence on condition 2 (
into the paper jam fatal error for the third time.
CR Unit/PF Roller
movement and
position
*1
Table 1-2) twice, the printer turns
To recover from the maintenance error, the dedicated software that can be downl oaded
from the web site which can be accessed from STM3 is required.
The printer operation related to the maintenance error recovery is as follows.
• When the waste ink counter reaches the threshold value (1) for the first time and the maintenance error occurs, the counter threshold of the maintenance error is changed to threshold value 2 after performing recovery from the maintenance error.
• After the threshold value (2) is enabled, the warning; to notify the possibility of ink leakage out of the printer, is displayed every time the waste ink counter increases by 1%.
• If the waste ink counter reaches the threshold value (2), the maintenance error occurs. Then, the waste ink counter is changed back to the threshold value (1) after recovering from the maintenance error, and the warning is displayed repeatedly according to the increment of the waste ink counter until the maintenance error occurs when the threshold value (2) is reached. (Recovery from the maintenance error can be performed up to the specified number of times.)
Troubleshooting Power-On Sequence 13
Confidential
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series
Menu button
OK button
Stop button
FATAL CODE:0x02
Fatal error code
LCD display

1.3 Fatal Error Code List

This section describes how to check the fatal error code, description, and the possible causes.

1.3.1 Displaying the Fatal Error Code

The fatal error code is stored in the EEPROM on the Main Board and can be read out using the Adjustment Program. The code can be displayed on the LCD of the control panel by a special panel operation.
Only the printer fatal error code can be displayed by this panel operation.For the fatal error codes, descriptions, and their possible causes, see" 1.3.2 Printer Fatal
Error Code (p15)".
The following describes the panel operation for the product to display the fatal error code.
Method of displaying the fatal error code
1. Press the following buttons simultaneously while the fatal error is occurring.
Menu button
  Stop buttonOK button
Revision B
Figure 1-2. Displaying the Fatal Error Code (1)
2. Check the displayed fatal error code.
Figure 1-3. Displaying the Fatal Error Code (2)
Troubleshooting Fatal Error Code List 14
Confidential
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series

1.3.2 Printer Fatal Error Code

This section describes the printer fatal error code and the possible cause for this product.
Table 1-3. Fatal Error List (Printer)
Revision B
Error type
DC motor error
Error
code
01H CR PID excess load error
02H CR PID excess speed error
03H CR PID reverse error
04H CR PID lock error
08H CR load position reverse error
09H CR load position excess speed error
0AH CR load position excess load error
F1H PF PID exc ess load error
F2H PF PID exc ess speed error
Error name Possible cause
• CR Motor failure
• CR Unit drive mechanism overload (paper jam, foreign object, insufficient grease, deformation of the Main Frame)
• Some part may be detached. (Paper Guide Upper Assy, Cap Assy)
• Tooth skip of the CR Timing Belt
• Improper tension of the CR Timing Belt
• Cable disconnection
• Main Board failure (Motor driver failure)
• CR Encoder failure (contaminated/detached scale, Encoder Sensor failure)
• Main Board failure (Motor driver failure)
• CR Encoder failure (contaminated/detached scale, Encoder Sensor failure)
• Some external force is applied to the printer such as stopping the CR Unit during printer operation, vibration or the like.
• Tooth skip of the CR Timing Belt
• Paper jam
• Main Board failure (Motor driver failure)
• CR Encoder failure (contaminated/detached scale, Encoder Sensor failure)
• CR Motor failure
• CR Unit drive mechanism overload (paper jam, foreign object, insufficient grease, deformation of the Main Frame)
• Some part may be detached. (Paper Guide Upper Assy, Cap Assy)
• Cable disconnection
• Main Board failure (Motor driver failure)
• CR Encoder failure (contaminated/detached scale, Encoder Sensor failure)
• Main Board failure (Motor driver failure)
• CR Encoder failure (contaminated/detached scale, Encoder Sensor failure)
• Tooth skip of the CR Timing Belt
• Improper tension of the CR Timing Belt
• Paper jam
• Main Board failure (Motor driver failure)
• CR Motor failure
• CR Unit drive mechanism overload (paper jam, foreign object, Change Lever failure)
• Cable disconnection
• Main Board failure (Motor driver failure)
• PF Motor failure
• PF drive mechanism overload (paper jam, foreign object, insufficient grease, deformation of the Main Frame)
• Tooth skip of the PF Timing Belt
• Improper tension of the PF Timing Belt
• Cable disconnection
• Main Board failure (Motor driver failure)
• PF Encoder failure (contaminated/detached scale, Encoder Sensor failure)
• Tooth skip of the PF Timing Belt
• Improper tension of the PF Timing Belt
• Main Board failure (Motor driver failure)
Troubleshooting Fatal Error Code List 15
Confidential
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series
Table 1-3. Fatal Error List (Printer)
Revision B
Error type
DC motor error
Motor drive time error
Printhead system error
Sequence error
Sequence error
Ink device error
Circuit error 80H Circuit error (include blowout of a fuse) • Main Board failure
Error
code
F3H PF PID reverse error
F4H PF PID lock error
F8H PF load position reverse error
F9H PF load position excess speed error
FAH PF load position excess load error
D1H CR (PID) driving time error • Main Board failure (Firmware failure)
D2H CR (load position) driving time error
D3H PF (PID) driving time error • Main Board failure (Firmware failure)
D4H PF (BS) driving time error
40H Transistor temperature error • Main Board failure 41H X-Hot detect error (pre printing) 42H X-Hot detect error (after flushing) 43H Head temperature error
50H Home position error
56H
5BH Insoluble paper jam error
B0H -
CFH
Contact error at ink replacement timing (Power-off)
Ink device error
Error name Possible cause
• PF Encoder failure (contaminated/detached scale, Encoder Sensor failure)
• Tooth skip of the PF Timing Belt
• Improper tension of the PF Timing Belt
• Paper jam
• Paper is pulled out from the ASF side when paper is fed
• Main Board failure (Motor driver failure)
• PF Encoder failure (contaminated/detached scale, Encoder Sensor failure)
• PF Motor failure
• PF drive mechanism overload (paper jam, foreign object, insufficient grease, deformation of the Main Frame)
• Cable disconnection
• Main Board failure (Motor driver failure)
• PF Encoder failure (contaminated/detached scale, Encoder Sensor failure)
• Tooth skip of the PF Timing Belt
• Improper tension of the PF Timing Belt
• PF Encoder failure (contaminated/detached scale, Encoder Sensor failure)
• Tooth skip of the PF Timing Belt
• Improper tension of the PF Timing Belt
• Main Board failure (Motor driver failure)
• PF Motor failure
• PF drive mechanism overload (paper jam, foreign object)
• Tooth skip of the PF Timing Belt
• Improper tension of the PF Timing Belt
• Cable disconnection
• Change Lever failure
• CR Motor failure
• Main Board failure (Motor driver failure)
• Change Lever failure
• CR Motor failure
• Main Board failure (Motor driver failure)
• Printhead failure
• Main Board failure
• Foreign object
• Deformation of the Main Frame
• Change Lever failure
• Paper jam
• Foreign object
• Ink Cartridges are not installed correctly
• Paper jam
• Foreign object
• Deformation of the Main Frame
• Change Lever failure
• Paper jam
• Ink Cartridge failure
• Holder Board Assy failure (CSIC Terminal failure/CR Contact Module failure)
• Main Board failure
Troubleshooting Fatal Error Code List 16
Confidential
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series
CR Unit
Fault Detection Plate
Table 1-3. Fatal Error List (Printer)
Revision B
Error type
PIS Board device error
Error
code
83H Reflector no reflection error
88H Excessive Light error
89H Insuffic i ent Light error
Error name Possible cause
• Defective Fault Detection Plate
• Sensor failure (contaminated Sensor, damaged FFC, PIS Board installation failure)
• Abnormal sensor output (Sensor failure, PIS Board failure)
• Unexpected excessive amount of light such as too much diffused light from outside is shed on the sensor because the housings are removed. (When used outdoors or near the window where direct sunlight comes in)
• Sensor failure (PIS Board installation failure, contaminated Sensor)
• Abnormal sensor output (Break of FFC during printer operation, PIS Board failure)
• Unable to accurately detect where the fault detection plate is because too much diffused light from outside is shed on the sensor. (When used outdoors or near the window where direct sunlight comes in)
• Ink Cartridge failure (contaminated/damaged prism)
Note *: Fault Detection Plate is a reflector attached on the CR Unit. (See Fig. 1-4)
*
(detachment, peeled reflector)
Figure 1-4. Fault Detection Plate
Troubleshooting Fatal Error Code List 17
Confidential
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series
Scanner Housing Lower
Rack section

1.3.3 Scanner Fatal Error Code

This section describes the scanner fatal error code and the possible cause for this product.
Table 1-4. Fatal Error List (Scanner)
Error code Error name Possible cause
Revision B
10H Home position detection error
14H Measurement error
20H LED lightning error
36H Paper jam error
• CIS Module failure
• Scanner Housing Upper failure (h ome seek pattern
• Scanner Housing Lower failure (the rack section
• Scanner Motor failure
• Insufficient grease
• Foreign object
• FFC disconnection/failure
• Main Board failure
• Scanner Motor failure
• Insufficient grease
• Foreign object
• Gear failure
• Deformation of the shaft
• CIS Module failure
• Foreign object
• Scanner Housing Upper failure (white standard pattern
• Main Board failure
•Paper jam
• Loading/ejecting papers out of the standard range or curled papers
• Using long papers (Legal or longer)
*1
is dirty)
*2
is damaged)
*1
is dirty)
Note *1: The home seek pattern and the white standard pattern are attached on the back of the Scanner Housing Upper near the home
position.
*2: The rack section is the linearly-arranged toothed area on the Scanner Housing Lower. (See Fig. 1-5.)
Figure 1-5. Rack section
Troubleshooting Fatal Error Code List 18
Confidential
CHAPTER 2

DISASSEMBLY/REASSEMBLY

Confidential
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series
Before folding
Fold here
Clip
40 mm or more
After folding
Fold appropriate length
to hitch a spring.
Clip

2.1 Overview

In this chapter, the product names are called as follows:
WF-2540 Series: WF-2540/WF-2548/WF-2541WF-2530 Series: WF-2530/WF-2532/WF-2538/WF-2531WF-2520 Series: WF-2520/WF-2528/WF-2521WF-2510 Series: WF-2510/WF-2511/WF-2512WF-2010 Series: WF-2010
This chapter describes procedures for disassembling the main parts/units of this product. Unless otherwise specified, disassembled parts/units can be reassembled by reversing the disassembly procedure. See the cautions or tips for disassembly/reassembly described in "2.3 Detailed Disassembly/Reassembly Procedure for each Part/
Unit (p40)".
Read the "Safety Precautions(p3)" before disassembling and reassembling. When you have to remove units or parts that are not described in this chapter, see the exploded diagrams of SPI (Service Parts Information).

2.1.1 Tools

Use only specified tools to avoid damaging the printer.
Name Availability EPSON Part Code
(+) Phillips screwdriver #1 O 1080530 (+) Phillips screwdriver #2 O --­Flathead screwdriver O --­Flathead Precision screwdriver #1 O --­Tweezers O --­Longnose pliers O --­Acetate tape --- 1003963
Note 1: Some of the tools listed above are commercially available.
2: EPSON provides the tools listed with EPSON part code.
Revision B

2.1.2 Jigs

Name Quantity EPSON Part Code
Spring hook jig* 1 Can be made with a commercial item See " Making the Spring Hook Jig (p20)". Thickness gauge (1.5 mm) 2 Commercially available Thickness gauge (2.0 mm) 2 Commercially available Sonic tension meter 1 1294120
Note *: If perf orming the disassembling/reassembling procedure is difficult using tweezers such a s when reassembli ng " Cap Lever / Cap
Assy (p47)", the spring hook jig helps you to remove/attach the spring easier.
2.1.2.1 Making the Spring Hook Jig
Fold a clip (commercial item) as shown in Fig. 2-1.
Figure 2-1. Making the Spring Hook Jig
Disassembly/Reassembly Overview 20
Confidential
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series
1
2 3 4
Front
5
6
Right
7
8
Left
9
10
Rear

2.1.3 Locations of the Parts/Units

This section shows the locations of the main parts/units of this product.
The parts/units which can not be seen in the following pictures are indicated in dotted lines ().
Exterior parts
Revision B
No. Name No. Name
1 Housing Rear (p30) 2 Tray Front Assy (p30) 3 Frame Base Assy (p35)
Panel Unit (p32)
4
5 Hinge (p30) (Scanner function compatible model) 6 Housing Right (p30)
7
Panel Board (p37) / Panel Button (p37) / LCD Unit (p37) / Panel Housing Upper Assy (p37)
Housing Left Assy (p30)
Housing Left (p37)
Ethernet Cover (p37) (Ethernet function non­compatible model)
ADF/Scanner Unit (p30)
ADF Unit (p36) (ADF function compatible model)
ADF Paper Guide Cover Assy (p31) / Paper Support Cover (p31) / Bevel Gear Shaft (p36) / Combination Gear 24.9.6 (p36) / ADF Document Support (p36) /
8
9 Paper Support (p30)
10 Paper Support Sub (p30)
ADF Pad Assy (p36)
Scanner Unit (p36) (Scanner function compatible model)
Scanner Housing Upper (p36) / Scanner Carriage Unit (p36) / Scanner Housing Lower (p36) / CIS Module Unit (p36) / Scanner Motor (p36)
Figure 2-2. Exterior Parts
Disassembly/Reassembly Overview 21
Confidential
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series
1
2
3
5
6
8 9 11 12
7
10
4
7
8
10
5
4
321
6
9
Printer mechanism
No. Name No. Name
1 CR Driven Pulley Assy (p35) 7 CR Unit (p38) 2 CR Scale (p35) 8 PF Roller Unit (p38)
Revision B
3 CR Timing Belt (p38) 9 Star Wheel Holder Assy (p31) 4 Printhead (p30) 10 Paper Guide Front Unit (p30) 5 CR Encoder Sensor (p38) 11 Paper Guide Lower Porous Pad (p30) 6 Holder Board Assy (p30) 12 Paper Guide Upper Assy (p38)
Figure 2-3. Printer Mechanism: Front
No. Name No. Name
1 LD Roller Cover (p35) 6 PIS Board Assy (p30) 2 LD Roller Assy (p34) 7 Cap Lever (p31) 3 Hopper (p39) 8 Cap Assy (p31) 4 Retard Roller Assy (p30) 9 Porous Pad for Cap Assy (p33) 5 Paper Back Lever (p30) 10 Pump Unit (p38)
Figure 2-4. Printer Mechanism: Right
Disassembly/Reassembly Overview 22
Confidential
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series
2
3
9
5 7 8
1
4 6
10
1
2
3
5 64
No. Name No. Name
1 FAX Assy (p31) (FAX function compatible model) 5 PF Motor Assy (p38)
Revision B
Wireless LAN Module (p34) (Wireless LAN function
2
compatible model)
3 EJ Roller (p31) 7 PF Scale (p34)
Ethernet Board Assy (p31)
4
(Ethernet function compatible function)
PF Timingbelt (p34)
6
8 PF Encoder Sensor (p34) 9 EJ Roller Gear (p34)
10 USB Board (p31) (USB function compatible model)
Figure 2-5. Printer Mechanism: Left
No. Name No. Name
1 CR Motor (p34) 4 Waste Ink Pad Assy (p30) 2 Head FFC (p38) 5 PE Sensor Lever (p34) 3 Main Board (p34) 6 PS Unit (p34)
Figure 2-6. Printer Mechanism: Rear
Disassembly/Reassembly Overview 23
Confidential
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series

2.1.4 Standard Operation Time for Servicing the Product

The following are the standard operation time for servicing the product. This standard operation time was determined with the MTTR result measured using the prototype of WF-2540 series which have the most functions. For other models described in this manual, perform the repair work referring to this standard operation time though the time varies due to the structural difference between models.
The underlined parts/units are supplied as After Service Parts.
Table 2-1. Standard Operation Time
Time (mm:ss)
Parts/Unit
Replacement
Adjustment/
inspection
Revision B
Housing Rear Paper Support Paper Support Sub Tray Front Assy
Tray Front
Tray Front Support Paper Guide Front Unit Paper Guide Lower Porous Pad PIS Shield Plate A PIS Board Assy Waste Ink Pad Assy Paper Back Lever Retard Roller Assy FFC Cover Outer Holder Board Assy
CR Contact Module
CSIC Connector
Holder Board Printhead Reflector PIS Assy ADF Paper Guide Cover Assy ADF Cable Cover Paper Support Cover Document Mat ADF/Scanner Unit
ADF Unit
ADF Hinge Left ADF Document Support ADF Hinge Right Cover Gear Assy
Bevel Gear Shaft Combination Gear 24.9.6 ADF Frame Assy
ADF Front Frame
Spur Gear 20.4 / 25.8
0:36 1:31 2:07 0:09 0:23 0:15 0:15 0:22 0:49 7:44 8:33 0:54 0:45 1:39 0:33 1:11 0:42 0:45 1:27 1:52 2:00 0:47 2:47 0:26 0:56 1:35 1:46 1:46 2:20 17:39 19:59 0:37 0:25 0:27 0:06 0:13 2:46 2:52 5:38 3:32 2:52 6:24 5:28 7:06 3:53 4:29 4:34 4:33 5:04 6:00 6:04
Disassembly/Reassembly Overview 24
Confidential
Loading...
+ 55 hidden pages