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

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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

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Notice:

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.

Printer CS Quality Assurance Department

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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.

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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 Scale  PF Scale  Coated surface of the PF Roller  Gears  Rollers  LCD  Scanner Sensor  Exterior 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.

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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)".

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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

"2-1 Standard Operation Time (p24)"

"3-2 Required Adjustment List (p56)" "3.2.2.3 PIS Board Check (p62)"

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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

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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

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CHAPTER 1

TROUBLESHOOTING

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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

Yes

Copy an image by ADF

Yes

Is ADF operation

finished without

trouble?

Is scanning operation

finished without

trouble?

What is returned reason?

ADF failure?

Print check pattern

Yes

Is Power-on sequence

finished without error?

Standby condition

Does an error occur

when printing?

Start

Turn on the power

Does printer turn on the

power?

Yes

Is printing operation

finished without trouble?

(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

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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B

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

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)

(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.

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

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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).

Revision B

CR Unit/PF Roller

movement and

position

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.

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

C (41oF) by the thermistor on the Printhead.

Troubleshooting Power-On Sequence 12

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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

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

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

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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 button  OK 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

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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

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Table 1-3. Fatal Error List (Printer)

Revision B

Error type

DC motor error

Motor drive time error

Printhead system 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

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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

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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)

is dirty)

is damaged)

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

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CHAPTER 2

DISASSEMBLY/REASSEMBLY

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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-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 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

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2 3 4

Front

Right

Left

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)

5 Hinge (p30) (Scanner function compatible model) 6 Housing Right (p30)

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) /

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

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8 9 11 12

321

 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

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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series

5 7 8

4 6

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

compatible model)

3 EJ Roller (p31) 7 PF Scale (p34)

Ethernet Board Assy (p31)

(Ethernet function compatible function)

PF Timingbelt (p34)

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

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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

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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series

Table 2-1. Standard Operation Time

Parts/Unit

Replacement

Revision B

Time (mm:ss)

Adjustment/

inspection

ADF Driven Gears

ADF Upper Frame Assy

ADF Pad Assy

ADF Base Assy

Scanner Unit

Scanner Housing Upper CIS Module Unit

Spacer

CIS Module 5:44 Scanner Motor Gear Cover 5:58 Combination Gear 18.4.9.66 6:05 Scanner Carriage Unit 6:09

Scanner Motor 8:25

CIS Holder Unit 8:25 Scanner Housing Lower 6:09

Housing Left Panel FFC Cover Hinge Housing Right Strengthen Plate Upper 4:09 Strengthen Plate Lower 4:10 Cap Assy Cap Lever 5:15 Porous Pad for Cap Assy PIS FFC PIS Shield Plate B 8:05 Star Wheel Holder Assy EJ Roller Panel Unit

Panel Housing Upper Assy 6:01 Panel Board 7:33 LCD Unit 7:56 Panel Button 9:04

Panel Housing Upper Housing Front USB Board Main Board FFC Holder 4:45 Ethernet Board Assy FAX Assy Wireless LAN Module EJ Roller Gear PF Motor Cover

6:42 6:44 7:23 6:15 3:30 2:52 6:22 5:05 5:28 5:44

4:19 3:04 3:02 3:38

5:06

5:21 7:27

8:38

10:34

5:27

9:04 7:00 7:41

5:05 5:23 4:53 4:33 4:28

3:18 11:56 3:18 13:52

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Table 2-1. Standard Operation Time

Parts/Unit

Replacement

Revision B

Time (mm:ss)

Adjustment/

inspection

PS Unit 4:41 PF Scale Sheet PF Encoder Sensor PF Scale PF Grounding Spring 5:02 PF Driven Pulley Assy 5:39 PF Timing Belt 6:26 Hopper LD Roller Assy 7:30

Spur Gear 37.2

Extension Spring 0.137

Clutch

LD Roller Shaft Assy Shield Plate

Main Board

CR Motor PE Sensor Lever CR Scale CR Driven Pulley Assy CR Scale Cover Frame LD Roller Cover FFC Holder Main Frame Assy

Antistatic Cloth

Paper Guide Upper Assy

CR Unit

CR Timing Belt CR Encoder Sensor

Head FFC Frame Base Assy

Pomp Unit

Spur Gear 16.5

PF Roller Unit

PF Motor Assy

Frame Base

EEPROM Data Copy OK EEPROM Data Copy NG 27:58 36:55

4:29 4:43 4:55

5:00

7:34 7:46 7:50 7:50 8:01

8:57

9:26 1:00 10:26

10:23 0:47 11:10

7:22 7:54 3:07 11:01 8:35 8:59

9:06 18:26 11:16 29:42 18:54 23:08 7:21 30:29 21:56 9:52 31:48 22:10 0:40 22:50 22:22 21:56 18:26 21:27 21:36 24:35 5:51 30:26 25:26 1:08 26:34 26:07 6:53 33:00

1:28 6:09

1:10 6:49 1:10 7:36 3:03 8:03 0:47 8:17

1:10 10:07

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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series

START

Multifunction Printer

START

Singlefunction Printer

2.2.2.4

Unit/Assy

2.2.2.1

Multifunction Printer

specific parts

2.2.2.4

Unit/Assy

2.2.2.3

Common Printer

Mechanism

2.2.2.4

Unit/Assy

2.2.2.2

Singlefunction Printer

specific parts

2.2 Disassembly/Reassembly Procedures

This section describes procedures for disassembling the parts/units in a flowchart format. For some parts/units, detailed procedures or precautions are provided (accordingly indicated by icons and cell's color). Refer to the explanations in the example chart below and perform an appropriate disassembling and assembling procedure. (See "2.3 Detailed Disassembly/Reassembly Procedure for each Part/Unit (p40)".) For routing cables, see "2.4 Routing FFCs/cables (p48)".

2.2.1 Configuration

This section describes the configuration of the disassembly flowchart. The disassembly flowchart is divided into the “Multifunction Printer specific parts”, “Singlefunction Printer

specific parts”, “Common Printer Mechanism”, and the “Unit/Assy”. Each section describes the following contents.

No. Item Description Compatible Model

WF-2540 Series

2.2.2.1

2.2.2.2

2.2.2.3

2.2.2.4 Unit/Assy Describes the disassembly flowchart for the Unit/Assy components

Multifunction Printer specific parts

Singlefunction Printer specific parts

Common Printer Mechanism

Describes the disassembly flowchart for the Multifunction Printerspecific parts

Describes the disassembly flowchart for the Singlefunction Printerspecific parts

Describes the disassembly flowchart for the Printer Mechanism common in the Multifunction Printer and Singlefunction Printer

WF-2530 Series WF-2520 Series WF-2510 Series

WF-2010 Series

Common to all models

Revision B

Figure 2-7. Configuration

Disassembly/Reassembly Disassembly/Reassembly Procedures 27

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2.2.2 Disassembly Flowchart

WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series described in this manual have differences in their structure because the same printer mechanism is used for some of them and the composition of housings or functions differs.

The functions and differences according to the models are as follows.

Table 2-2. Function List According to Models

Multifunction Printer Singlefunction Printer

Item

Scanner

ADF

Panel

FAX OOOO --Wireless LAN O O --- O O Ethernet O --- O --- O USB O --- --- --- --Disassembly Flowchart

Start Position

Compatible O O O O --Non-compatible --- --- --- --- O Compatible O O O --- --Non-compatible --- --- --- O O

2.5 inch LCD type O --- --- --- --2Line Bitmap type --- O O O --LED & Button type --- --- --- --- O

WF-2540

Series

p 30 p 30 p 30 p 30 p 32

WF-2530

Series

WF-2520

Series

WF-2510

Series

WF-2010

Revision B

Table 2-3. Components According to Functions

Item Specification

The following part is not mounted on the models without the Scanner.

Scanner

ADF

Panel

FAX The FAX Assy is not mounted on the model without the FAX. Wireless LAN The Wireless LAN Module is not mounted on the models without the Wireless LAN.

• Scanner Unit

• Main Board FFC Holder

 The ADF Unit is not mounted on the models without the ADF.  The Document Cover Assy is mounted on the models without the ADF instead of the ADF Unit.

The shape and unit of components below differ due to the difference of specifications of Panel.

• Panel Unit

• Main Board

• Shield Plate

 The Ethernet Board Assy is not mounted on the models without the Ethernet.

Ethernet

USB The USB Board is not mounted on the models without the USB.

 The shape and unit of components of the Housing Left Assy differ due to the support/unsupport of the

Ethernet.

Therefore, parts and units are colored and classified into 2 types in the flowchart given in this section.



Common parts/unit: Black

 Model-specific parts/unit: Red

Disassembly/Reassembly Disassembly/Reassembly Procedures 28

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Housing Rear

(p22) (p43)

Frame Base Assy

---

(p21) (p27)

Paper Guide

Upper Assy (p29)

CR Timing Belt FFC/ Cable *1

Shows necessary procedures before removing the following parts.*

Black letters indicate a part/ unit not supplied as an ASP.

Item Description Reference

Parts/unit name

White-letter

Part/unit supplied as an ASP ---

Black-letter

Part/unit not supplied as an ASP ---

Icon

Indicates a practice or condition that could result in injury or loss of life if not strictly observed.

Indicates the reference page in blue-letter

Indicates a practice or condition that could result in damage to, or destruction of equipment if not strictly observed.

Indicates the reference page in blue-letter

Indicates the parts that are inevitably broken in the disassembling procedure, and should be replaced with a new one for reassembly.

Indicates the reference page in blue-letter

Indicates necessary check items in the disassembling/ assembling procedure.

Indicates the reference page in blue-letter

Indicates supplementary explanation for disassembly is given.

Indicates the reference page in blue-letter

Indicates particular tasks to keep quality of the units are required.

Indicates the reference page in blue-letter

Indicates particular routing of cables is required.

Indicates the reference page in blue-letter

Indicates particular adjustment(s) is/are required.

Chapter 3 " Adjustment (p52)"

Indicates lubrication is required.

Chapter 4 " Maintenance (p67)"

Indicates the number of screws securing the parts/ units.

---

Indicates the points secured with other than a screw such as a hook, rib, dowel or the like.

---

White letters indicate a part/unit supplied as an ASP.

Shows the screw types and the specified torque on the “Screw type/torque list”.

Reference page

Shows removal/installation as a unit/assy. is available.

The name enclosed in gray indicate a part/unit that must be removed on the way to the target parts.

Note "*": The box with only part names means the removal of the parts. If the name of

FFC or a cable is shown, disconnect the FFC or cable from the connector.

Shows the procedure number on the “FFC/ cable list”.

: Indicates the connection to the disassembly flowchart for the Unit/Assy

: Indicates the connection between the disassembly flowchart

: Indicates the connection to the Common Printer Mechanism

The example below shows how to see the charts on the following pages.

Revision B

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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B

S4S7

S15

S5S6S7

S10

S11

S12

S13

S14

2.2.2.1 Multifunction Printer specific parts

START

Housing Rear

(p 41)

 Scanner FFC  Grounding wire (x2)

ADF/Scanner

Unit

(p 40) (p 48)

Housing Left

Assy

S16

(p 41)

Hinge (p30)

Housing Right

(p30)

Panel FFC Cover

(p30)

Panel Unit (p32)

Housing Front

(p31)

(p 35)

iii

The following parts can be replaced without removing the Scanner Unit. However, the working space for replacement is narrow and dark. Therefore, if you find it difficult to work, remove the Scanner Unit first before replacement.

 Printhead/Holder Board Assy  PIS Board Assy/PIS Shield Plate A  Paper Guide Front Unit/Paper Guide Lower Porous Pad

Paper Support

Sub

---

Tray Front Assy

(p 52)

---

(p 37)

Paper Guide

Front Unit

(p 43)

(p 52)

---

PIS Shield

Plate A

(p 43) (p 50)

Waste Ink Pad

Assy

(p 41) (p 52)

 PIS FFC

Paper Support

---

Paper Guide

Lower Porous

---

Pad

---

(p 44) (p 52)

PIS Board Assy

(p 43) (p 50)

Paper Back

Lever

---

(p 67)

FFC Cover

 CSIC FFC Extension spring (x2)

Holder Board

 Head FFC

Outer

(p 44)

Assy

---

Reflector PIS

Assy

(p 31)

S14

(p 43)

---

(p 37)

(p 36)

Retard Roller

Assy

---

Panel FFC Cover

(p 37)

---

Hinge

---

(p 52)

Screw type/torque list

---

Printhead

---

Common parts/unit

Model-specific parts/unit

(p 44) (p 52)

Symbol Screw Type Torque

C.B.P-TITE (S-P1) SCREW 3x12 F/ZN-3C 6 ± 1 kgf·cm C.B.P-TITE SCREW 2x6 F/ZN-3C 4 ± 1 kgf·cm

Paper Support

Sub (p30)

Paper Support

(p30)

(p 34)

C.B.P-TITE SCREW 2x8 F/ZN-3C 2

Housing Right

(p 34)

(p 31)

(p 41)

C.B.P-TITE SCREW 2x8 F/ZN-3C 2.5 kgf·cm C.B.P-TITE SCREW 2x8 F/ZN-3C 4 C.B.P-TITE SCREW 3x10 F/ZB-3C 6 ± 1 kgf·cm C.B.P-TITE SCREW 3x10 F/ZN-3C 6 C.B.P-TITE SCREW 3x10 F/ZN-3C 5 ± 1 kgf·cm C.B.P-TITE SCREW 3x10 F/ZN-3C 5 C.B.P-TITE SCREW 3x10 F/ZN-3C 7 ± 1 kgf·cm

(p 31)

C.B.P-TITE SCREW 3x8 F/ZN-3C 6

± 0.5 kgf·cm

± 1 kgf·cm

± 0.5 kgf·cm

± 1 kgf·cm

C.B.S-TITE (P2) SCREW 3x6 F/ZN-3C 6 ± 1 kgf·cm C.B.S-TITE (P2) SCREW 3x6 F/ZN-3C 7

± 1 kgf·cm

C.B.S-TITE SCREW 2x4 F/ZN-3C 2 ± 0.5 kgf·cm

S15

S16

S17

S18

S19

S20

S21

C.B.S-TITE SCREW 3x8 F/ZN-3C 6

± 1 kgf·cm

C.B.S-TITE SCREW 3x6 F/ZB-3C 6 ± 1 kgf·cm C.B.S-TITE SCREW 3x6 F/ZN-3C 6

± 1 kgf·cm

C.B.S-TITE SCREW 3x6 F/ZN-3C 8 ± 1 kgf·cm C.B.S-TITE SCREW 3x6 F/ZN-3C 7

± 1 kgf·cm

C.P-TITE SCREW 3x4 F/ZN-3C 4 ± 1 kgf·cm C.B.S-TITE SCREW 3x8 F/ZB-3C 6

± 1 kgf·cm

Flowchart 2-1. Multifunction Printer specific parts (1)

Disassembly/Reassembly Disassembly/Reassembly Procedures 30

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S19

S20

S5S6S7

S10

S11

S12

S13

S14

Document Cover

Assy

---

 FFC/Cable* 1

Main Board FFC

Holder

S15

---

 Cable (CN14)

Ethernet Board

Assy

(p 46)

 FFC/Cable* 3

FAX Assy

(p 45)

(p 30)

---

(p 30)

ADF Paper

Guide Cover

Assy

---

(p 40)

ADF Cable

Cover

---

Paper Support

Cover

---

Document Mat

---

(p 40)

Strengthen Plate

Upper

---

PIS Shield Plate

A (p30)

 Extension spring (x2)  Pump tube

Cap Assy

(p 47)

---

Strengthen Plate

Lower

---

PIS Board Assy

(p30)

Panel FFC Cover

(p30)

 FFC/Cable* 2

Housing Front

---

Panel Unit

(p 42) (p 49)

 USB Board cable (CN2)

(p 37)

(p 41)

USB Board

PIS FFC

---

(p 43) (p 50)

PIS Shield

Plate B

Cap Lever

---

(p 47)

Porous Pad for

Cap Assy

---

Common parts/unit

Model-specific parts/unit

Hinge (p30)

Housing Right

(p30)

(p 45) (p 50)

---

(p 43) (p 50)

Star Wheel

Holder Assy

(p 43) (p 50)

(p 52)

Screw type/torque list

Symbol Screw Type Torque

C.B.P-TITE (S-P1) SCREW 3x12 F/ZN-3C 6 ± 1 kgf·cm C.B.P-TITE SCREW 2x6 F/ZN-3C 4 ± 1 kgf·cm C.B.P-TITE SCREW 2x8 F/ZN-3C 2

± 0.5 kgf·cm

C.B.P-TITE SCREW 2x8 F/ZN-3C 2.5 kgf·cm C.B.P-TITE SCREW 2x8 F/ZN-3C 4

± 1 kgf·cm

C.B.P-TITE SCREW 3x10 F/ZB-3C 6 ± 1 kgf·cm

Housing Left

Assy (p30)

EJ Roller Gear

(p34)

C.B.P-TITE SCREW 3x10 F/ZN-3C 6 C.B.P-TITE SCREW 3x10 F/ZN-3C 5 ± 1 kgf·cm C.B.P-TITE SCREW 3x10 F/ZN-3C 5

± 1 kgf·cm

± 0.5 kgf·cm

C.B.P-TITE SCREW 3x10 F/ZN-3C 7 ± 1 kgf·cm

FFC/cable list

No. FFC/Cable

1 Disconnect the Panel FFC (CN2), and remove the ferrite core.

Remove/disconnect the following.  Panel FFC (CN2)

 Grounding wire( x1) Remove/disconnect the following.

 USB Board cable (CN9)  FAX FFC (CN1)

S17

EJ Roller

(p 52) (p 67)

C.B.P-TITE SCREW 3x8 F/ZN-3C 6 C.B.S-TITE (P2) SCREW 3x6 F/ZN-3C 6 ± 1 kgf·cm

---

S15

S16

S17

S18

S19

S20

S21

C.B.S-TITE (P2) SCREW 3x6 F/ZN-3C 7 C.B.S-TITE SCREW 2x4 F/ZN-3C 2 ± 0.5 kgf·cm C.B.S-TITE SCREW 3x8 F/ZN-3C 6 C.B.S-TITE SCREW 3x6 F/ZB-3C 6 ± 1 kgf·cm C.B.S-TITE SCREW 3x6 F/ZN-3C 6 C.B.S-TITE SCREW 3x6 F/ZN-3C 8 ± 1 kgf·cm C.B.S-TITE SCREW 3x6 F/ZN-3C 7 C.P-TITE SCREW 3x4 F/ZN-3C 4 ± 1 kgf·cm C.B.S-TITE SCREW 3x8 F/ZB-3C 6

± 1 kgf·cm

Flowchart 2-2. Multifunction Printer specific parts (2)

Disassembly/Reassembly Disassembly/Reassembly Procedures 31

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S15

S5S6S7

S10

S11

S12

S13

S14

2.2.2.2 Singlefunction Printer specific parts

START

 Panel FFC

Panel Unit

(p 42) (p 49)

 FFC/Cable* 4

Housing Upper

Assy

(p 41)

(p 34)

Paper Support

Sub

---

Printer Cover

---

Paper Guide

Front Unit

---

FFC Cover

Outer

---

Reflector PIS

Assy

---

Waste Ink Pad

Assy

PIS Shield

Plate A

---

(p 44)

(p 52)

(p 44)

 CSIC FFC

(p 37)

Paper Guide

Paper Support

---

Lower Porous

Pad

---

(p 44) (p 52)

Holder Board

Assy

---

(p 43)

(p 37)

(p 41) (p 52)

 Extension spring (x2)

Paper Back

Lever

(p 67)

(p 43) (p 50)

 PIS FFC

PIS Board Assy

---

(p 43) (p 50)

 Head FFC

Retard Roller

Assy

Printhead

---

(p 52)

(p 34)

iii

(p 35)

(p 33)

---

Common parts/unit

Model-specific parts/unit

The following parts can be replaced without removing the Housing Upper Assy. However, the working space for replacement is narrow and dark. Therefore, if you find it difficult to work, remove the Housing Upper Assy first before replacement.

 Printhead/Holder Board Assy  PIS Board Assy/PIS Shield Plate A  Paper Guide Front Unit/Paper Guide Lower Porous Pad

Flowchart 2-1. Singlefunction Printer specific parts (1)

(p 44) (p 52)

FFC/cable list

No. FFC/Cable

Remove the double-sided tape of the Panel FFC (CN2) and

remove the FFC/Cable from the Housing Upper Assy hole.

Screw type/torque list

Symbol Screw Type Torque

C.B.P-TITE (S-P1) SCREW 3x12 F/ZN-3C 6 ± 1 kgf·cm C.B.P-TITE SCREW 2x6 F/ZN-3C 4 ± 1 kgf·cm

S15

S16

S17

S18

S19

S20

S21

C.B.P-TITE SCREW 2x8 F/ZN-3C 2 C.B.P-TITE SCREW 2x8 F/ZN-3C 2.5 kgf·cm C.B.P-TITE SCREW 2x8 F/ZN-3C 4 C.B.P-TITE SCREW 3x10 F/ZB-3C 6 ± 1 kgf·cm C.B.P-TITE SCREW 3x10 F/ZN-3C 6 C.B.P-TITE SCREW 3x10 F/ZN-3C 5 ± 1 kgf·cm C.B.P-TITE SCREW 3x10 F/ZN-3C 5 C.B.P-TITE SCREW 3x10 F/ZN-3C 7 ± 1 kgf·cm C.B.P-TITE SCREW 3x8 F/ZN-3C 6 C.B.S-TITE (P2) SCREW 3x6 F/ZN-3C 6 ± 1 kgf·cm C.B.S-TITE (P2) SCREW 3x6 F/ZN-3C 7 C.B.S-TITE SCREW 2x4 F/ZN-3C 2 ± 0.5 kgf·cm C.B.S-TITE SCREW 3x8 F/ZN-3C 6 C.B.S-TITE SCREW 3x6 F/ZB-3C 6 ± 1 kgf·cm C.B.S-TITE SCREW 3x6 F/ZN-3C 6 C.B.S-TITE SCREW 3x6 F/ZN-3C 8 ± 1 kgf·cm C.B.S-TITE SCREW 3x6 F/ZN-3C 7 C.P-TITE SCREW 3x4 F/ZN-3C 4 ± 1 kgf·cm C.B.S-TITE SCREW 3x8 F/ZB-3C 6

± 0.5 kgf·cm

± 1 kgf·cm

± 0.5 kgf·cm

± 1 kgf·cm

Disassembly/Reassembly Disassembly/Reassembly Procedures 32

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S5S6S7

S10

S11

S12

S13

S14

(p 32)

 Pump tube

Cap Assy

Cap Lever

Front Tray Assy/

Front Tray Rail

Left/Right

---

Porous Pad for

Cap Assy

---

 Cable (CN14) Extension spring (x2)

Ethernet Board

Assy

(p 46)

Strengthen Plate

Upper

S19

---

PIS Shield Plate

A (p30)

PIS Board Assy

(p30)

PIS FFC

---

(p 43) (p 50)

PIS Shield

Plate B

Strengthen Plate

Lower

---

Common parts/unit

Model-specific parts/unit

S20

(p 43) (p 50)

Star Wheel

Holder Assy

(p 43) (p 50)

(p 52)

EJ Roller Gear

(p34)

EJ Roller

---

(p 52) (p 67)

Flowchart 2-2. Singlefunction Printer specific parts (2)

Screw type/torque list

Symbol Screw Type Torque

C.B.P-TITE (S-P1) SCREW 3x12 F/ZN-3C 6 ± 1 kgf·cm

S15

S16

S17

S18

S19

S20

S21

C.B.P-TITE SCREW 2x6 F/ZN-3C 4 ± 1 kgf·cm C.B.P-TITE SCREW 2x8 F/ZN-3C 2

± 0.5 kgf·cm

C.B.P-TITE SCREW 2x8 F/ZN-3C 2.5 kgf·cm C.B.P-TITE SCREW 2x8 F/ZN-3C 4

± 1 kgf·cm

C.B.P-TITE SCREW 3x10 F/ZB-3C 6 ± 1 kgf·cm C.B.P-TITE SCREW 3x10 F/ZN-3C 6

± 1 kgf·cm

C.B.P-TITE SCREW 3x10 F/ZN-3C 5 ± 1 kgf·cm C.B.P-TITE SCREW 3x10 F/ZN-3C 5

± 0.5 kgf·cm

C.B.P-TITE SCREW 3x10 F/ZN-3C 7 ± 1 kgf·cm C.B.P-TITE SCREW 3x8 F/ZN-3C 6

± 1 kgf·cm

C.B.S-TITE (P2) SCREW 3x6 F/ZN-3C 6 ± 1 kgf·cm C.B.S-TITE (P2) SCREW 3x6 F/ZN-3C 7

± 1 kgf·cm

C.B.S-TITE SCREW 2x4 F/ZN-3C 2 ± 0.5 kgf·cm C.B.S-TITE SCREW 3x8 F/ZN-3C 6

± 1 kgf·cm

C.B.S-TITE SCREW 3x6 F/ZB-3C 6 ± 1 kgf·cm C.B.S-TITE SCREW 3x6 F/ZN-3C 6

± 1 kgf·cm

C.B.S-TITE SCREW 3x6 F/ZN-3C 8 ± 1 kgf·cm C.B.S-TITE SCREW 3x6 F/ZN-3C 7

± 1 kgf·cm

C.P-TITE SCREW 3x4 F/ZN-3C 4 ± 1 kgf·cm C.B.S-TITE SCREW 3x8 F/ZB-3C 6

± 1 kgf·cm

Disassembly/Reassembly Disassembly/Reassembly Procedures 33

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S17

S15

S5S6S7

S10

S11

S12

S13

S14

2.2.2.3 Common Printer Mechanism

i ii

 PF Encoder FFC

PF Encoder

Sensor

(p 45) (p 49)

PF Scale

(p 45)

PF Driven

Pulley Assy

S13

(p 45) (p 52)

Singlefunction Printer :

---

(p 30)Multifunction Printer : (p 32)

PF Scale Sheet

(p 46)

PF Grounding

Spring

(p 46)

(p 30)Multifunction Printer :

Singlefunction Printer :

(p 32)

FFC/cable list

No. FFC/Cable

PF Motor Cover

---

EJ Roller Gear

---

 Cable (CN4)

Wireless LAN

Module

Hopper

---

(p 45) (p 67)

(p 52) (p 67)

---

 Cable (CN501)

PS Unit

---

(p 42) (p 50)

(p 52)

(p 45)

Main Board FFC

Holder (p31)

Ethernet Board

Assy (p33)

FAX Assy (p31)

 FFC/Cable* 4

Shield Plate

S14

(p 46)

CR Scale (p35)

CR Scale Cover

Frame (p35)

LD Roller Cover

(p35)

LD Roller Assy

---

(p 47) (p 52)

(p 67)

Remove/disconnect the following.  Head FFC (CN102)

 CSIC FFC (CN6)  PF Motor cable (CN13)  PS Unit cable (CN501)

5 Remove/disconnect all FFCs/cables.

Release the CR Motor cable from the hooks of the Main Frame and

Frame Base.

Common parts/unit

(p 38)

Model-specific parts/unit

PF Timingbelt

---

(p 45) (p 52)

When the CR Unit or the Head FFC is removed from the Main Frame Assy, remove the following parts before removing the Main Frame Assy.

 FFC Cover Outer  Holder Board Assy  Printhead

CR Scale (p35)

CR Scale Cover

Frame (p35)

 FFC/Cable* 5

Main Board

LD Roller Cover

(p35)

 Extension spring

(p 46) (p 49)

(p 52)

PE Sensor Lever

---

(p 52)

Flowchart 2-1. Common Printer Mechanism (1)

 FFC/Cable* 6  CR Timingbelt

Screw type/torque list

Symbol Screw Type Torque

C.B.P-TITE (S-P1) SCREW 3x12 F/ZN-3C 6 ± 1 kgf·cm

CR Motor

---

S20

(p 50) (p 52)

---

C.B.P-TITE SCREW 2x6 F/ZN-3C 4 ± 1 kgf·cm C.B.P-TITE SCREW 2x8 F/ZN-3C 2

± 0.5 kgf·cm

C.B.P-TITE SCREW 2x8 F/ZN-3C 2.5 kgf·cm C.B.P-TITE SCREW 2x8 F/ZN-3C 4

± 1 kgf·cm

C.B.P-TITE SCREW 3x10 F/ZB-3C 6 ± 1 kgf·cm C.B.P-TITE SCREW 3x10 F/ZN-3C 6

± 1 kgf·cm

C.B.P-TITE SCREW 3x10 F/ZN-3C 5 ± 1 kgf·cm C.B.P-TITE SCREW 3x10 F/ZN-3C 5

± 0.5 kgf·cm

C.B.P-TITE SCREW 3x10 F/ZN-3C 7 ± 1 kgf·cm C.B.P-TITE SCREW 3x8 F/ZN-3C 6

± 1 kgf·cm

C.B.S-TITE (P2) SCREW 3x6 F/ZN-3C 6 ± 1 kgf·cm C.B.S-TITE (P2) SCREW 3x6 F/ZN-3C 7

± 1 kgf·cm

C.B.S-TITE SCREW 2x4 F/ZN-3C 2 ± 0.5 kgf·cm

S15

S16

S17

S18

S19

S20

S21

C.B.S-TITE SCREW 3x8 F/ZN-3C 6

± 1 kgf·cm

C.B.S-TITE SCREW 3x6 F/ZB-3C 6 ± 1 kgf·cm C.B.S-TITE SCREW 3x6 F/ZN-3C 6

± 1 kgf·cm

C.B.S-TITE SCREW 3x6 F/ZN-3C 8 ± 1 kgf·cm C.B.S-TITE SCREW 3x6 F/ZN-3C 7

± 1 kgf·cm

C.P-TITE SCREW 3x4 F/ZN-3C 4 ± 1 kgf·cm C.B.S-TITE SCREW 3x8 F/ZB-3C 6

± 1 kgf·cm

Disassembly/Reassembly Disassembly/Reassembly Procedures 34

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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B

S17

S19

S5S6S7

S10

S11

S12

S13

S14

iii

Singlefunction Printer :

PF Encoder Sen-

sor (p34)

PF Scale (p34)

CR Scale (p35)

CR Scale Cover

Frame (p35)

CR Driven Pul-

ley Assy (p35)

LD Roller Cover

(p35)

PIS Shield Plate

A (p32)

PIS Board Assy

(p32)

Strengthen Plate

Upper (p31)

PIS FFC (p31)

PIS Shield Plate

B (p31)

Main Board FFC

Holder (p31)

Ethernet Board

Assy (p33)

(p 30)Multifunction Printer : (p 32)

CR Scale

(p 43)

CR Scale Cover

Frame

(p 43)

LD Roller Cover

---

 CR Timingbelt

---

CR Driven

Pulley Assy

---

(p 45) (p 52)

(p 67)

FFC Holder

(p 51)

---

Common parts/unit

Model-specific parts/unit

FAX Assy (p31)

 FFC/Cable* 7  Extension spring (x3)  PF Grounding Spring

Main Frame

Assy

S17

(p 46) (p 52)

(p 67)

Frame Base Assy

(p 52)

---

Screw type/torque list

Symbol Screw Type Torque

C.B.P-TITE (S-P1) SCREW 3x12 F/ZN-3C 6 ± 1 kgf·cm C.B.P-TITE SCREW 2x6 F/ZN-3C 4 ± 1 kgf·cm C.B.P-TITE SCREW 2x8 F/ZN-3C 2 C.B.P-TITE SCREW 2x8 F/ZN-3C 2.5 kgf·cm

C.B.P-TITE SCREW 2x8 F/ZN-3C 4 C.B.P-TITE SCREW 3x10 F/ZB-3C 6 ± 1 kgf·cm C.B.P-TITE SCREW 3x10 F/ZN-3C 6

(p 38)

C.B.P-TITE SCREW 3x10 F/ZN-3C 5 ± 1 kgf·cm C.B.P-TITE SCREW 3x10 F/ZN-3C 5 C.B.P-TITE SCREW 3x10 F/ZN-3C 7 ± 1 kgf·cm C.B.P-TITE SCREW 3x8 F/ZN-3C 6 C.B.S-TITE (P2) SCREW 3x6 F/ZN-3C 6 ± 1 kgf·cm C.B.S-TITE (P2) SCREW 3x6 F/ZN-3C 7 C.B.S-TITE SCREW 2x4 F/ZN-3C 2 ± 0.5 kgf·cm C.B.S-TITE SCREW 3x8 F/ZN-3C 6 C.B.S-TITE SCREW 3x6 F/ZB-3C 6 ± 1 kgf·cm C.B.S-TITE SCREW 3x6 F/ZN-3C 6 C.B.S-TITE SCREW 3x6 F/ZN-3C 8 ± 1 kgf·cm C.B.S-TITE SCREW 3x6 F/ZN-3C 7 C.P-TITE SCREW 3x4 F/ZN-3C 4 ± 1 kgf·cm C.B.S-TITE SCREW 3x8 F/ZB-3C 6

8 (p 38)

FFC/cable list

No. FFC/Cable

Remove/disconnect the following.

 Panel FFC (CN2) (double-sided tape)  Grounding wire ( x1)

 PF Motor Cable  PS Unit cable (CN501)  CR Motor cable

S15

S16

S17

S18

S19

S20

S21

± 0.5 kgf·cm

± 1 kgf·cm

± 0.5 kgf·cm

± 1 kgf·cm

Flowchart 2-2. Common Printer Mechanism (2)

Disassembly/Reassembly Disassembly/Reassembly Procedures 35

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S11

S5S6S7

S10

S11

S12

S13

S14

2.2.2.4 Unit/Assy

(p 30)

Common parts/unit

Model-specific parts/unit

ADF Unit

(p 40) (p 52)

---

Scanner Unit

FFC/cable list

---

ADF Paper

Guide Cover

Assy (p31)

 Grounding wire

ADF Hinge

Right

(p 52)

Scanner

Housing Upper

ADF Hinge Left

Cover Gear Assy

S11

---

ADF Cable

Cover (p31)

 Grounding wire

ADF Frame Assy

(p 40) (p 40)

(p 67)

ADF Document

Support (p36)

Combination

Gear 24.9.6 (p36)

ADF Hinge Right (p36)

ADF Base Assy

---

S11

---

Bevel Gear Shaft

(p 48)

---

 Scanner FFC

(p 41)

---

Combination

Gear 24.9.6

---

ADF Paper

Guide Cover

Assy (p31)

ADF Cable

Cover (p31)

 Grounding wire

ADF Document

Support

(p 48)

---

ADF Front

Frame

CIS Module Unit

(p 48)

Scanner Motor

Gear Cover

(p 41)

Combination

Gear 18.4.9.66

---

(p 67)

(p 40)

 FFC/Cable* 8

Spur Gear 20.4 /

Spur Gear 25.8

---

(p 40)

---

ADF Driven

Gears

---

ADF Upper Frame Assy

---

ADF Pad Assy

---

(p 40)

---

Scanner Motor

(p 48) (p 52)

CIS Holder Unit

(p 48)

Scanner

Carriage Unit

---

(p 48) (p 67)

Scanner

Housing Lower

---

(p 48) (p 67)

---

No. FFC/Cable

8 Remove the double-sided tape (x1) and release the Scanner FFC.

Spacer

---

CIS Module

---

Screw type/torque list

Symbol Screw Type Torque

C.B.P-TITE (S-P1) SCREW 3x12 F/ZN-3C 6 ± 1 kgf·cm C.B.P-TITE SCREW 2x6 F/ZN-3C 4 ± 1 kgf·cm

S15

S16

S17

S18

S19

S20

S21

± 0.5 kgf·cm

± 1 kgf·cm

± 0.5 kgf·cm

± 1 kgf·cm

Flowchart 2-1. Unit/Assy (1)

Disassembly/Reassembly Disassembly/Reassembly Procedures 36

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S5S6S7

S10

S11

S12

S13

S14

S15

S16

S17

S18

S19

S20

S21

(p 30)

Tray F ront

---

CR Contact

Module

---

CSIC Connector

---

Holder Board

---

(p 30)

Housing Left

---

Multifunction Printer :

Singlefunction Printer :

---

Tray Front

Support

---

(p 30) (p 32)

Ethernet Cover

---

Singlefunction Printer :

2.5LCD Type 2Line Bitmap Type

Panel Housing

Upper Assy

---

(p 42)

(p 30)Multifunction Printer : (p 32)

 LCD FFC (CN2)

Panel Housing

Upper Assy

(p 42)

LED&Button Type

Panel Board

---

Panel Board

Panel Housing

Lower

---

Panel Board

---

(p 42)

---

Panel Housing

Lower

---

(p 42)

---

Panel Button

---

Panel Button

LCD Unit

---

Panel Button

---

(p 42)

---

(p 42)

Panel Housing

Upper

---

Panel Housing

---

Panel Housing

Upper

---

Screw type/torque list

Symbol Screw Type Torque

C.B.P-TITE (S-P1) SCREW 3x12 F/ZN-3C 6 ± 1 kgf·cm

---

C.B.P-TITE SCREW 2x6 F/ZN-3C 4 ± 1 kgf·cm C.B.P-TITE SCREW 2x8 F/ZN-3C 2

± 0.5 kgf·cm

C.B.P-TITE SCREW 2x8 F/ZN-3C 2.5 kgf·cm C.B.P-TITE SCREW 2x8 F/ZN-3C 4

± 1 kgf·cm

C.B.P-TITE SCREW 3x10 F/ZB-3C 6 ± 1 kgf·cm C.B.P-TITE SCREW 3x10 F/ZN-3C 6

± 1 kgf·cm

C.B.P-TITE SCREW 3x10 F/ZN-3C 5 ± 1 kgf·cm C.B.P-TITE SCREW 3x10 F/ZN-3C 5

± 0.5 kgf·cm

C.B.P-TITE SCREW 3x10 F/ZN-3C 7 ± 1 kgf·cm C.B.P-TITE SCREW 3x8 F/ZN-3C 6

± 1 kgf·cm

C.B.S-TITE (P2) SCREW 3x6 F/ZN-3C 6 ± 1 kgf·cm C.B.S-TITE (P2) SCREW 3x6 F/ZN-3C 7

---

C.B.S-TITE SCREW 2x4 F/ZN-3C 2 ± 0.5 kgf·cm C.B.S-TITE SCREW 3x8 F/ZN-3C 6 C.B.S-TITE SCREW 3x6 F/ZB-3C 6 ± 1 kgf·cm C.B.S-TITE SCREW 3x6 F/ZN-3C 6

Common parts/unit

C.B.S-TITE SCREW 3x6 F/ZN-3C 8 ± 1 kgf·cm C.B.S-TITE SCREW 3x6 F/ZN-3C 7

Model-specific parts/unit

C.P-TITE SCREW 3x4 F/ZN-3C 4 ± 1 kgf·cm C.B.S-TITE SCREW 3x8 F/ZB-3C 6

± 1 kgf·cm

Flowchart 2-2. Unit/Assy (2)

Disassembly/Reassembly Disassembly/Reassembly Procedures 37

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S11

S5S6S7

S10

S11

S12

S13

S14

S15

S16

S17

S18

S19

S20

S21

(p 34)

Spur Gear 37.2

(p 47)

Extension Spring

0.137

(p 47)

Clutch

(p 47)

LD Roller Shaft

(p 47)

(p 35)

Cap Assy (p31)

Shield Plate

---

(p34)

Main Board

(p34)

CR Motor (p34)

Antistatic Cloth

---

Hopper (p39)

---

LD Roller Assy

(p34)

 Pump tube

PE Sensor Lever

(p34)

---

Paper Guide

Upper Assy

---

(p 52)

---

 FFC/Cable* 9

CR Unit

(p 51) (p 52)

Head FFC

(p 51)

Pump Unit

---

CR Timing Belt

---

(p 52)

CR Encoder

Sensor

---

(p 47)

Spur Gear 16.5

---

Common parts/unit

---

Model-specific parts/unit

---

FFC/cable list

No. FFC/Cable

PF Grounding

Spring (p34) Paper Guide

Front Unit (p30)

EJ Roller Gear

(p34)

PF Driven Pul-

ley Assy (p34)

PF Timingbelt

(p34)

PF Roller Unit

(p 52)

PF Motor Cover

(p34)

 PF Motor Cable

---

PF Motor Assy

(p 50) (p 52)

USB Board (p31)

Frame Base

(p 52) (p 67)

---

9 Disconnect the CR Encoder FFC.

Screw type/torque list

Symbol Screw Type Torque

C.B.P-TITE (S-P1) SCREW 3x12 F/ZN-3C 6 ± 1 kgf·cm C.B.P-TITE SCREW 2x6 F/ZN-3C 4 ± 1 kgf·cm C.B.P-TITE SCREW 2x8 F/ZN-3C 2 C.B.P-TITE SCREW 2x8 F/ZN-3C 2.5 kgf·cm C.B.P-TITE SCREW 2x8 F/ZN-3C 4 C.B.P-TITE SCREW 3x10 F/ZB-3C 6 ± 1 kgf·cm C.B.P-TITE SCREW 3x10 F/ZN-3C 6 C.B.P-TITE SCREW 3x10 F/ZN-3C 5 ± 1 kgf·cm C.B.P-TITE SCREW 3x10 F/ZN-3C 5 C.B.P-TITE SCREW 3x10 F/ZN-3C 7 ± 1 kgf·cm C.B.P-TITE SCREW 3x8 F/ZN-3C 6 C.B.S-TITE (P2) SCREW 3x6 F/ZN-3C 6 ± 1 kgf·cm C.B.S-TITE (P2) SCREW 3x6 F/ZN-3C 7 C.B.S-TITE SCREW 2x4 F/ZN-3C 2 ± 0.5 kgf·cm C.B.S-TITE SCREW 3x8 F/ZN-3C 6

± 0.5 kgf·cm

± 1 kgf·cm

± 0.5 kgf·cm

± 1 kgf·cm

C.B.S-TITE SCREW 3x6 F/ZB-3C 6 ± 1 kgf·cm C.B.S-TITE SCREW 3x6 F/ZN-3C 6

± 1 kgf·cm

C.B.S-TITE SCREW 3x6 F/ZN-3C 8 ± 1 kgf·cm C.B.S-TITE SCREW 3x6 F/ZN-3C 7

± 1 kgf·cm

C.P-TITE SCREW 3x4 F/ZN-3C 4 ± 1 kgf·cm C.B.S-TITE SCREW 3x8 F/ZB-3C 6

± 1 kgf·cm

Flowchart 2-3. Unit/Assy (3)

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S14

S17

S15

S5S6S7

S10

S11

S12

S13

S14

S15

S16

S17

S18

S19

S20

S21

2.2.3 Disassembly Flowchart (Printhead/Main Board)

 Printhead

START

FFC Cover

Outer

(p 44)

 CSIC FFC

Holder Board

Assy

---

Printhead

(p 44) (p 52)

 Main Board (Multifunction Printer)

START

Housing Rear

---

(p 41)

Paper Support

Sub

---

 Scanner FFC  Grounding wire (x2)

ADF/

Scanner Unit

---

(p 40) (p 48)

Housing Left

Assy

---

S16

Paper Support

---

Hopper

---

(p 52) (p 67)

 FFC/Cable* 10

(p 41)

Main Board FFC

Hinge

---

Holder

S15

---

 Cable (CN14)

Housing Right

Ethernet Board

Assy

(p 46)

(p 41)

The Printhead can be replaced without removing the ADF/Scanner Unit. However, the working space for replacement is narrow and dark. Therefore, if you find it difficult to work, remove the ADF/Scanner Unit first before replacement.

 FFC/Cable* 11

FAX Assy

 FFC/Cable* 12

Shield Plate

 FFC/Cable* 13

Main Board

(p 46) (p 49)

Flowchart 2-4. Disassembly Flowchart (Printhead/Main Board)

(p 45)

S17

(p 46)

S15

(p 52)

 Main Board (Singlefunction Printer)

START

 Panel FFC

Panel Unit

---

(p 42) (p 49)

 FFC/Cable* 14

Housing Upper

Assy

S15

(p 41)

Hopper

(p 52) (p 67)

FFC/cable list

No. FFC/Cable

---

10 Disconnect the Panel FFC (CN2), and remove the ferrite core.

Remove/disconnect the following.

 USB Board cable(CN9)  FAX FFC(CN1)

Remove/disconnect the following.

 HeadFFC (CN102)  CSIC FFC (CN6)

 PF Motor cable (CN13)  PS Unit cable(CN501)

13 Remove/disconnect all FFCs/ cables.

Remove the double-sided tape of the Panel FFC (CN2) and remove the

FFC/Cable from the Housing Upper Assy hole.

 FFC/Cable* 12

Shield Plate

S14

(p 46)

 FFC/Cable* 13

Main Board

(p 46) (p 49)

(p 52)

---

Common parts/unit

Model-specific parts/unit

Screw type/torque list

Symbol Screw Type Torque

± 0.5 kgf·cm

± 1 kgf·cm

± 0.5 kgf·cm

± 1 kgf·cm

Disassembly/Reassembly Disassembly/Reassembly Procedures 39

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ADF/Scanner Unit

Hinge

C.B.P-TITE SCREW 3x10 F/ZN-3C (6 ± 1 kgf·cm)

ADF Unit

Hook

Precision screwdriver

ADF Hinge hole

Scanner Unit Hook

Scanner Unit

ADF Paper Guide Cover Assy

Hole

ADF Unit

Dowel and hole

ADF Frame AssyGrounding terminal

ADF Base Assy

Square hole

ADF Front Frame

Diagram A

Spur Gear 25.8

Spur Gear 20.4

Diagram B

Spur Gear 20.4

Spur Gear 25.8

ADF Upper Frame Assy

Hook

Bottom

ADF Pad Assy

Dowel

ADF Upper Frame Assy

Document Mat

ADF Unit

Double-sided tape Standard line

Document Mat

Document Cover Assy

Reference (origin)

position

Double-sided tape

Reference position: Align the Document Mat with the front right corner of the document glass. Make sure the gap in yellow above must be less than 1 mm.

2.3 Detailed Disassembly/Reassembly Procedure for each Part/Unit

ADF/Scanner Unit (ADF compatible model)

Tighten the screw of the ADF/Scanner Unit by supporting the ADF/Scanner Unit. Without the support, the ADF/Scanner Unit may drop out from the Hinge by its weight and it may damage the ADF/Scanner Unit.

ADF Unit (ADF compatible model)

 When removing the ADF Unit from the Scanner Unit, remove

the Hinge Left/Right from the Hook on the Scanner Unit.

 Release the hooks (x2) on the Scanner Unit by inserting the

precision screwdriver to the hole of the ADF Unit Left/Right to push the Hook to the rear.

ADF Paper Guide Cover Assy (ADF compatible model)

Remove the ADF Paper Guide Cover Assy by removing the holes (x2) of the dowels (x2) of the ADF Unit.

ADF Frame Assy (ADF compatible model)

When removing the ADF Frame Assy, remove the grounding terminal of the ADF Frame Assy through the square hole of the ADF Base Assy.

ADF Front Frame / Spur Gear 25.8/20.4

ADF Pad Assy (ADF compatible model)

Document Mat (ADF compatible model)

Document Mat (ADF non-compatible model)

(ADF compatible model)

 Install the Spur Gear 25.8/20.4 as shown in the figure A above.  When installing the ADF Front Frame, check that the Spur

Gear 25.8/20.4 is installed on the position shown in the figure B above.

Disassembly/Reassembly Detailed Disassembly/Reassembly Procedure for each Part/Unit 40

Remove the ADF Pad Assy by removing the hooks (x2) and dowels (x2) of the ADF Pad Assy from the ADF Upper Frame Assy.

When attaching the Document Mat to the ADF Unit, follow the procedure below.

1. Attach double-sided tape on the two long sides of the Document Mat.

2. Place the mat on the document glass with double-sided tape attachment side upward while aligning it with the standard line of the document glass shown above.

3. Close the Document Cover and stick the Document Mat to the Document Cover.

4. Open the Document Cover and press the double-sided tape attachment side to secure the Document Mat to the ADF Unit securely.

When attaching the Document Mat to the Document Cover, follow the procedure below.

1. Attach double-sided tape on the two long sides of the Document Mat.

2. Place the mat on the document glass with double-sided tape attachment side upward while aligning it with the reference position of the document glass shown above.

3. Close the Document Cover and press the cover to stick the Document Mat to the Document Cover.

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Bottom

C.B.P-TITE SCREW 3x10 F/ZN-3C (6 ± 1 kgf·cm)

Rib

Scanner Housing Upper

Scanner Motor Gear Cover

C.B.P-TITE SCREW 3x10 F/ZN-3C (6 ± 1 kgf·cm)

Hook

Scanner Motor Gear Cover

C.B.P-TITE SCREW 3x10 F/ZN-3C (6 ± 1 kgf·cm)

Step 2

Section A

Section B

Section D

Section C

Step 3-4

Step 1

Housing Rear

Dowel Rib

Housing Rear

The section enclosed in red dotted line may be interfered with the Hopper or the Scanner Unit.

Housing RightHousing Left

Housing Front

C.B.P-TITE SCREW 3x10 F/ZN-3C (6 ± 1 kgf·cm)

Housing Right

Housing Left

Hook

Housing Upper Assy

Hook Rib

C.B.P-TITE SCREW 3x10 F/ZN-3C (6 ± 1 kgf·cm)

Bottom

Hook and holeFrame Base

Waste Ink Pad Assy

Rear

Rib and hole

C.B.P-TITE SCREW 3x10 F/ZN-3C (6 ± 1 kgf·cm)

Scanner Housing Upper (Scanner compatible model)

When removing the Scanner Housing Upper from the Scanner Housing Lower Assy, follow the procedure below.

1. Remove the screws (x6) on the bottom of the Scanner Unit.

2. Release the ribs (x2) of the Scanner Housing Upper, and remove the Scanner Housing Upper in the direction of the arrow with the document glass upward.

Scanner Motor Gear Cover

(Scanner compatible model)

Remove the Scanner Motor Gear Cover by removing the screw securing the Scanner Motor Gear Cover to release the hooks (x2) of the Scanner Motor Gear Cover.

Housing Rear (Multifunction Printer)

When removing the Housing Rear, follow the procedure below.

1. Remove the screw (x1) of the Housing Rear.

2. Press the section A on the Housing Left and release the dowels (x2) of the Housing Left from the Housing Rear, and lift the rear side of the Housing Rear slightly to release the section B from the Housing Left.

3. Pull and turn the section C of the Housing Rear slightly to the front to release it from the gap between the Housing Right and Frame Base.

4. Slide the Housing Rear in the direction of the arrow to release the section D, and remove the Housing Rear while avoiding the Hopper and Scanner Unit.

Housing Front (Multifunction Printer)

Housing Left / Housing Right

Housing Upper Assy (Singlefunction Printer)

Waste Ink Pad Assy

When installing the Waste Ink Pad Assy, follow the procedure below.

1. Place the Waste Ink Pad Assy under the Frame Base.

2. Slide the Waste Ink Pad Assy in the direction of the arrow to align the hole of the Waste Ink Pad Assy with the hook of the

Disassembly/Reassembly Detailed Disassembly/Reassembly Procedure for each Part/Unit 41

Tighten the screws in the order indicated in the figure above.

When releasing the hooks (x14) of the Housing Left/Housing Right, be careful not to damage the hooks (x14).

Release the hooks shown above when removing the Housing Left/

Remove the Housing Upper Assy by releasing the hooks (x3) and ribs (x10) shown in the figure above.

Tighten the screws in the order indicated in the figure above.

Housing Right.

Frame Base.

3. Confirm the following first, and then tighten the screw to secure the Waste Ink Pad Assy.

• The rib of the Waste Ink Pad Assy is correctly inserted into the hole of the Frame Base.

• The Waste Ink Pad Assy is secured firmly with the hook of the Frame Base.

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PS Unit

Hook Rib

Bottom

Widen this rib to release the hook of PS Unit.

PS Unit cable

Panel Unit

Housing RightHousing Left

12 3

C.B.P-TITE SCREW 3x10 F/ZB-3C (6 ± 1 kgf·cm)

Rear

Hook Rib

Panel Housing Upper Assy

Panel Housing Lower Hole

Panel Unit

Bottom

Panel Housing Lower

Hole

123

C.B.P-TITE SCREW 3x10 F/ZB-3C (6 ± 1 kgf·cm)

Panel Board Assy

Grounding wire

C.B.P-TITE SCREW 3x10 F/ZN-3C (6 ± 1 kgf·cm)

Grounding wire terminal

Select Button (back)

Rib

No rib here.

Start button

Stop ButtonSelect ButtonOK ButtonPower Button

The side without any rib must be the side of down arrow.

Panel Housing Upper Assy

Back

Panel Board

Panel FFC

Panel UnitHousing Upper Assy

Hook Rib Dowel and hole

C.B.P-TITE SCREW 3x10 F/ZN-3C (6 ± 1 kgf·cm)

PS Unit

Be careful not to damage the rib of the Frame Base when widen the rib to release the hook of the PS Unit.

When removing the PS Unit, follow the procedure below.

1. Using a precision screwdriver or the like, widen the rib of the Frame Base to release the hook of the PS Unit.

2. Remove the PS Unit from the Frame Base in the direction of the arrow while releasing the rib of the PS Unit.

3. Disconnect the PS Unit cable from the connector on the PS Unit and remove the PS Unit.

Panel Unit

(2.5 inch LCD / 2Line Bitmap)

 Tighten the screws (x3) securing the Panel Unit after installing

the Housing Left/Housing Right.

 Tighten the screws in the order indicated in the figure above.

Panel Housing Upper Assy (2.5 inch LCD / 2Line Bitmap)

When removing the Panel Housing Upper Assy, follow the procedure below.

1. Remove the screw (x3) of the Panel Unit.

2. Rotate and lift the front side of the Panel Housing Upper Assy and remove the hook (x4) and rib (x5) from the Panel Housing Upper Assy.

3. Pull out the grounding wire of the Panel Housing Upper Assy from the hole of the Panel Housing Lower Assy and remove the Panel Housing Upper Assy from the Panel Housing Lower Assy.

Tighten the screws in the order indicated in the figure above.

Panel Board Assy

(2.5 inch LCD / 2Line Bitmap)

 Tighten the screws in the order indicated in the figure above.  Tighten the grounding wire together on the position indicated

in the figure above.

 Tighten the grounding wire with screws on the direction

indicated in the figure above.

Panel Buttons

(2.5 inch LCD / 2Line Bitmap)

When attaching the Select B utton to the Panel Housing Upper Assy, attach the Select Button with its side without any rib downward.

Panel Unit (LED and Button)

When removing the Panel Unit, follow the procedure below.

1. Remove the screw (x2) securing the Panel Unit.

2. Remove the hole (x2) from the dowel(x2) of the Housing Upper Assy.

3. Remove the hook (x2) and rib(x2) on the back of the Panel Board from the Housing Upper Assy.

4. Remove the Panel FFC from the connector (CN1) of the Panel Board and remove the Panel Unit.

Disassembly/Reassembly Detailed Disassembly/Reassembly Procedure for each Part/Unit 42

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Secure PIS Shield Plate and CR

Motor together with Main Frame.

Step 2

Hole

Frame Base

PIS FFC

Turn it

CCW.

Step 4

Section A

PIS Shield Plate B

C.B.P-TITE SCREW 3x10 F/ZN-3C (6 ± 1 kgf·cm)

C.P SCREW 3x4 F/ZN-3C (4 ± 1 kgf·cm)

C.B.P-TITE 2x8 F/ZN-3C (2.5 kgf·cm)

Step 3

Star Wheel Holder Assy

Sensor

PIS Board AssyDowel and cutout

Step 1

Star Wheel Holder Assy

PIS Shield Plate A

PIS Shield Plate B

Step 6, 7

Hole

Positioning hole and dowel Hole and hook

Reflector PIS

Reflector

PIS Holder

Bottom

Reflector PIS

Reflector PIS Holder

Reflector PIS Assy

CR Unit

Cut Section

Slit of CR Encoder Sensor

CR Unit

CR Scale

Extension spring

CR Scale Cover Frame

Cutout

Rib

0-digit side

Inset rib.

80-digit side

Align cutout.

Inset rib.

Main Frame CR Scale Cover Frame

PIS Board Assy / Star Wheel Holder Assy

Reflector PIS Assy

 Do not remove the Reflector PIS Assy from the Reflector PIS

Holder.

 When handling the Reflector PIS Assy, be careful not to

contaminate or damage the Reflector PIS.

When attaching the Reflector PIS Assy to the CR Unit, confirm the Reflector PIS Holder cannot be seen through the hole on the bottom of the CR Unit. Otherwise, the Reflector PIS Assy has not been installed correctly, so make sure to install the Reflector PIS Assy properly again.

CR Scale

 Attach the CR Scale to the hook on the left of the Main Frame

with the black triangle mark upward.

 Make sure to put the CR Scale through the slit of the CR

Encoder Sensor.

 PIS Shield Plate B and CR Motor are secured to the Main Frame together.  If the internal thread of the screw hole on the Star Wheel Holder Assy has been damaged, a fatal error may occur because the PIS Board Assy is

detached due to vibrations during transportation or the like. When securing the PIS Board Assy with the screw, first turn the screw CCW and align the thread of the screw and the internal thread of the screw hole on the Star Wheel Holder Assy, then tighten the screw securely.

 Do not touch the sensor of the PIS Board Assy.  Do not use air-blowing when cleaning the PIS Board Assy. If the board is dirty with ink or similar, wipe it off using a waste cloth.

When installing the PIS Board Assy / Star Wheel Holder Assy, follow the procedure below.

1. Insert the section A of the PIS Shield Plate B into the hole of the Frame Base.

2. Secure the PIS Shield Plate B using the screw together with the CR Motor and Main Frame.

3. Connect the PIS FFC to the connector on the PIS Board Assy, and then align the dowels (x2) of the PIS Board Assy with the positioning hole and cutout of the Star Wheel Holder Assy.

4. Secure the PIS Board Assy with the screw while pressing it to the rear of the printer and supporting the Star Wheel Holder Assy with your hand so as to prevent it from warping.

5. Route the PIS FFC and connect it to the Main Board. (p 50)

6. Align the positioning holes (x2) on the PIS Shield Plate A with the dowels (x2) on the Star Wheel Holder Assy, and engage the hole on the PIS Shield Plate A to the hook on the Star Wheel Holder Assy, then attach the PIS Shield Plate A to the Star Wheel Holder Assy.

7. After confirming the sensor of the PIS Board Assy is set out from the hole on the PIS Shie ld Plate A, secure the PIS Shield Plate A/B and Star Wheel Holder Assy together with the screw.

CR Scale Cover Frame

When installing the CR Scale Cover Frame, install the CR Scale Cover Frame to the Main Frame following the standard below and tighten the screw in the procedure below.

 80-digit side

• Align the protrusions of the Main Frame with the cutout of the CR Scal e Cover Frame.

• Insert the rib of the CR Scale Cover Frame to the hole of the Main Frame.

 0-digit side

• Insert the rib of the CR Scale Cover Frame to the hole of the Main Frame.

Disassembly/Reassembly Detailed Disassembly/Reassembly Procedure for each Part/Unit 43

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Main Frame

Rib

CR Driven Pulley Assy

Dowel

Main Frame

CR Timing Belt

Pinion gear of CR Motor

Compression Spring 20.91

Ink cartridge exchange position: when the protrusion of the CR Unit is on the protrusion of the PIS Shield Plate A.

Do not remove/replace the Printhead other than under this condition in order to prevent the Main Frame from being deformed.

Protrusion of CR Unit

Bottom of CR Unit

PIS Shield Plate A

Protrusion

PIS Shield Plate A

Main Frame

Printhead

CR Unit (ink cartridge exchange position)

C.B.P-TITE SCREW 2.5x8 F/ZN-3C (5 ± 0.5 kgf·cm)

FFC Cover Outer

Left side of CR Unit

Hook Rib

Paper Guide Lower Porous Pad

Frame Base

Rib

Cut Section

Back

Paper Guide Front Unit

Paper Guide Front Porous Pad

Leg

Front

Paper Guide Front Porous Pad

Paper Guide Front Unit

No tab of the pad sticks

out on the frame.

A tab of the pad sticks

out on the frame.

Enlarged figure: a leg of Paper

Guide Front Porous Pad

Anti-disconnect hooks

CR Driven Pulley Assy / CR Timing Belt

Printhead

When installing the CR Driven Pulley Assy and CR Timing Belt, follow the procedure below.

1. Install the CR Driven Pulley Assy to the Main Frame.

2. Attach the Compression Spring 20.91 in the order from the dowel on the CR Driven Pulley Assy to the rib on the Main Frame.

3. Attach the CR Timing Belt to the CR Driven Pulley Assy.

4. Attach the CR Timing Belt on the pinion gear of the CR Motor while pushing the CR Driven Pulley Assy to the 0-digit side.

FFC Cover Outer

Paper Guide Lower Porous Pad

When removing/replacing the Printhead, be sure the CR Unit is at the “ink cartridge exchange position” shown above. Otherwise, the Main Frame may be deformed by applying force perpendicularly when tightening the screws and it may affect print quality.

Tighten the screws of the Printhead in the order indicated in the figure above while pressing the Printhead in the direction of the arrow.

Paper Guide Front Porous Pad

When installing the Paper Guide Front Porous Pad, make sure to wipe off the grease attached on the Paper Guide Front Unit.

Slide and remove the FFC Cover Outer in the direction of the arrow while releasing the hook.

Disassembly/Reassembly Detailed Disassembly/Reassembly Procedure for each Part/Unit 44

 When installing the Paper Guide Lower Porous Pad, set it with

the cut section to the front right of the printer.

 Align the cutout of the Paper Guide Lower Porous Pad with the

rib of the Frame Base.

 The Paper Guide Front Porous Pad is not included in the replacement parts when the maintenance error occurs.  The shapes of the Paper Guide Front Unit and Paper Guide Front Porous Pad differ between models because of the size of the borderless printing.

After installing the Paper Guide Front Porous Pad, make sure of the following.  The entire anti-disconnect hooks on both ends of the legs of the Paper Guide Porous Pad should come out from the holes on the bottom of the

Paper Guide Front Unit.

 The tabs of the Paper Guide Front Porous Pad should be inserted completely into the grooves of the Paper Guide Front Unit.  No parts of the Paper Guide Porous Pad are wavy or lift over the platen surface of the Paper Guide Front Unit.

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USB Board

C.B.P-TITE SCREW 3x10 F/ZN-3C (6 ± 1 kgf·cm) C.B.S-TITE SCREW 3x6 F/ZN-3C (6 ± 1 kgf·cm)

Joint

Main Frame Grounding wire

Can not be reused because the rib of the EJ Roller Gear is deformed once removed from the EJ Roller.

EJ Roller Gear

Wireless LAN Module

Wireless LAN Module Cable

Cover with acetate tape (x2).

Hook

FAX Assy

Ferrite core

CN1FAX FFC

Frame BaseFAX Assy

PF Encoder Sensor

PF Scale

PF Roller

PF Scale

PF Encoder Sensor

PF Roller

Dowel

Hook

PF Motor Frame

Protrusion

Rib

PF Driven Pulley Assy

C.B.S-TITE(P2) SCREW 3x6 F/ZN-3C P.W. 3.4x0.43x7 (7 ± 1 kgf·cm)

Pinion gear of PF Motor PF Timing Belt

Compression Spring 5.07

PF Driven Pulley Assy

Combination Gear 29.2,42

USB Board (USB compatible model)

EJ Roller Gear

Wireless LAN Module

(Model with wireless LAN)

FAX Assy (Models with FAX)

 Tighten grounding wire together on the position indicated in

the figure above.

 Install the grounding wire terminal on the Main Frame side on

the direction indicated in the figure above.

 Tighten the screws in the order indicated in the figure above.

Do not reuse the removed PF Scale and make sure to replace it with a new one when removing it. When installing the PF Scale, it is pressed into the PF Roller, therefore, the removed one is deformed. If it is re-installed to the printer, it does not rotate properly and the paper feed accuracy may be reduced.

 When installing the PF Scale to the PF Roller, press the PF Scale into the PF Roller vertically.  After installing the PF Encoder Sensor, confirm the PF Scale does not touch the PF Encoder Sensor.

Connect the FAX FFC to the connector (CN1) of the Main Board before installing the FAX Assy.

The rib on the contact point of the EJ Roller Gear with the EJ

 Install the hook (x3) of the FAX Assy on the Frame Base.  Put the ferrite core on the position indicated in the figure

above.

PF Encoder Sensor / PF Scale

Roller is deformed when removing the EJ Roller Gear. Therefore, make sure to replace it with a new one when removing it in order to maintain the paper feed accuracy.

Attach two pieces of acetate tape on the Wireless LAN Module cable to cover the cable to protect it as shown above.

PF Driven Pulley Assy / PF Timing Belt

Do not hold the PF Driven Pulley Assy when securing it with the screw in order to prevent applying improper tension to the PF Timing Belt.

When installing the PF Driven Pulley Assy, follow the procedure below.

1. Align the rib of the PF Driven Pulley Assy with the hook of the PF Motor Frame, and instal l the PF Driven Pulley Assy.

2. Attach the Compression Spring 5.07 to the protrusion of the PF Driven Pulley Assy and the dowel of the PF Motor Frame.

3. Attach the PF Timing Belt in the order of the pinion gear of the PF Motor, PF Driven Pulley and Combination Gear 29.2,42.

4. Rota te the Combination Gear 29.2,42 clockwise three times to confirm the PF Timing Belt is correct ly at tached, and then secure the PF Driven Pulley Assy with the screw and washer to the PF Motor Frame.

Disassembly/Reassembly Detailed Disassembly/Reassembly Procedure for each Part/Unit 45

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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B

Ethernet Board Assy

Rib

Hook

Multifunction Printer

Singlefunction Printer

Ethernet Board Assy

Hook

Rib

Frame BaseGroove Frame BaseGroove

Ethernet Board Assy

Insert spring leg

A into groove.

PF Grounding

Spring

Main Frame

Left

Cutout

Spring leg B

Spring leg A

Spring leg B

PF Grounding

Spring

Frame Base

Assy

Hole

Main FramePF Scale Sheet

Double-sided tape

Align the corner of Main Frame.

Align the edge of Frame Base. Insert the outside the

rib of Frame Base.

PF Motor Frame

Main Frame

Align the screw holes of Main

Frame and PF Motor Frame.

Section A

Main Frame Assy

Change Lever must not

interfere with Main Frame.

C.B.P-TITE SCREW 3x10 F/ZN-3C (6 ± 1 kgf·cm) C.B.S-TITE SCREW 3x6 F/ZN-3C (6 ± 1 kgf·cm)

Rib and groove

Positioning hole and dowel

MAC Address LabelShield Plate

Main Board

PE Sensor Lever

PE Sensor

C.B.S-TITE SCREW 3x6 F/ZN-3C (6 ± 1 kgf·cm) C.B.S-TITE SCREW 2x4 F/ZN-3C (2 ± 0.5 kgf·cm)

Ethernet Board Assy (Models with Ethernet)

 When installing the Ethernet Board Assy, hang the hook of the Ethernet Board Assy on the Frame Base and align the rib of the Ethernet Board

Assy to the groove of the Frame Base.

 Put the ferrite core on the position indicated in the figure above (only Singlefunction Printer).

PF Grounding Spring

When installing the PF Grounding Spring, follow the procedure below.

1. From the left side of the printer, insert the spring leg A of the PF Grounding Spring into the hole of the Frame Base.

2. Insert the spring leg B of the PF Grounding Spring into the groove of the Frame Base.

3. Attach the spring leg B of the PF Grounding Spring to the cutout of the Main Frame to install the PF Grounding Spring.

PF Scale Sheet

Attach the PF Scale Sheet to the Main Frame according to the standard indicated in the figure above.

Main Frame Assy

Disassembly/Reassembly Detailed Disassembly/Reassembly Procedure for each Part/Unit 46

 Before installing the Main Frame Assy, shift the Change Lever back to the rear.  When installing the Main Frame Assy, make sure of the following.

• The Change Lever must not interfere with the Main Frame.

• The above shown ribs and grooves, positioning holes and dowels are correctly aligned.

• The section A of the Main Frame Assy is not deformed.

 Tighten the screws in the order indicated in the figure above.

Do not damage or contaminate the MAC Address Label.

 Install the Main Board with the PE Sensor Lever to the rear. After installing the Main Board, make sure the lever part of the PE Sensor Lever is

aligned with the slit of the PE Sensor.

 Attach the MAC Address Label to the Shield Plate on the position indicated in the figure above.  Tighten the screws of the Shielded Plate in the order indicated in the figure above.

Main Board/Shield Plate

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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B

Cap Lever

Extension Spring 1.329

Cap Assy

Extension Spring 0.65

Hook of Cap Assy

Hook of Frame Base

Step 6

Shaft BShaft A

Shaft C

Cap Assy

Step 2

Make sure the marking (10 ± 1 mm from the tube end) on the tube cannot be seen when viewed from the side.

Cap Slider

CutoutHole B

Cap Lever

Frame

Base

Hole A

Hole C

Step 1, 3-5

Hook of Frame Base

Hook of Cap Lever

Step 7

Step 4

Pump

Tube B

Marking

8 ± 1 mm

Hole of Frame Base

Hole of

Frame Base

Pump

Tube A

Step 1-2

Pump Unit

Route Pump Tube A through ribs of Frame

Base with their dashed line facing upward.

Insert Pump Tube B up to the marking (8 ± 1 mm

from tube end) to the hole of Frame Base.

C.B.P-TITE SCREW 3x10 F/ZN-3C (6 ± 1 kgf·cm)

Step 3

Frame Base

Rib

LD Roller Assy

Paper Back Lever

Change Lever

Cam

Main Frame

Rear of printer

Extension Spring 0.137

Clutch

Spur gear

LD Roller Shaft

LD Roller

Cap Lever / Cap Assy

When installing the Cap Lever/Cap Assy, follow the procedure below.

1. Attach the Cap Lever to the Frame Base, and attach one end of the Extension Spring 0.65 to the hook of the Frame Base.

2. Connect the tube of the Pump Unit to the joint on the bottom of the Cap Assy. Then, viewing from the side, confirm the marking (10 ± 1 mm from the tube end) on the tube is covered by the Cap Slider.

3. Insert the shaft A of the Cap Assy through the hole of the Cap Lever to the hole A of the Frame Base.

4. Insert the shaft B of the Cap Assy through the cutout of the Frame Base and to the hole B of the Frame Base.

5. Insert the shaft C of the Cap Assy to the hole C of the Frame Base.

6. Using a “spring hook jig” (p 20), attach the other end of the Extension Spring 0.65 to the hook of the Cap Assy.

7. Attach the Extension Spring 1.329 to the hooks of the Cap Lever and Frame Base.

Pump Unit

When installing the Pump Unit, follow the procedure below in order to prevent ink suction failure.

1. Route the Pump Tube A through the hole of the Frame Base.

2. Install the Pump Unit to the Frame Base, and route the Pump Tube A through the ribs of the Frame Base with their dashed line facing upward.

3. Secure the Pump Unit to the Frame Base with the screw (x1).

4. Route the Pump Tube B through the ribs of the Pump Unit and Frame Base, and insert it to the hole of the Frame Base up to the marking

± 1 mm from tube end).

LD Roller Assy (1)

Spur gear / Extension Spring 0.137 /

Clutch / LD Roller shaft

Install the LD Roller Assy with the following condition in order to avoid the Change Lever and Paper Back Lever.

 Using a screw driver or the like, hold the Paper Back Lever to the rear as shown above not to let it touch the LD Roller Assy.  Push the Change Lever to the front to keep it in the hole of the Main Frame.

Disassembly/Reassembly Detailed Disassembly/Reassembly Procedure for each Part/Unit 47

Install Spur gear/Extension Spring 0.137/Clutch/LD Roller shaft as shown in the figure above.

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Grounding wire of the ADF Document Support

ADF Document Support

Bottom

Grounding wire of the ADF Document Support

ADF Base

Rib A Rib B Dowel

Hole

Grounding wire of the ADF Frame AssyHook

ADF Frame Assy

ADF Document Support

Grounding wire

Hole

ADF Hinge Left

Bottom

Hole

ADF Base

ADF Hinge Left

Rib

Route the Scanner FFC inserting the hole of the Housing Left.

Housing Left

Frame of FAX Assy

Ferrite core

Bottom of Scanner Carriage

Connector of Relay Board

Connector of CIS Module

Standard for attaching double-sided tape

7.5 mm

5 mm

20 mm

Scanner Carriage

Scanner FFC

Hole

Rib

Double-sided tape

Relay Board

Scanner Motor cable

C.B.P-TITE SCREW 3x10 F/ZN-3C (5 ± 1 kgf·cm)

Grounding wire

Scanner Motor

Screw it with

grounding terminal

Scanner Motor

Scanner Carriage

2.4 Routing FFCs/cables

ADF Frame Assy / ADF Document Support (ADF compatible model)

Rotate the grounding wire of the ADF Frame Assy and ADF Document Support(x2) as follows.  Grounding wire of the ADF Frame Assy

Hang the grounding wire the dowel (x3) and route through the hole of the ADF Base.

 Grounding wire of the ADF Document Support

1. Route along the rib A of the ADF Base and hang the dowel on the bottom of the ADF Base.

2. Route along the inside the hook and rib B of the ADF Base and route through the hole of the ADF Base.

ADF Hinge Left (ADF compatible model)

Route the grounding wire (x2) of the ADF Frame Assy/ADF Document Support through the ADF Hinge Left as follows.

1. Route the grounding wire (x2) through the hole (x2) of the ADF Hinge Left.

2. Install the ADF Hinge Left to the ADF Base. Hang the grounding wire (x2) on the rib (x2) of the ADF Hinge Left and route.

ADF/Scanner Unit (Multifunction Printer)

 Scanner FFC

Insert the hole of the Housing Left and connect the connector (CN11) of the Main Board through the ferrite core.

 Grounding wire (only ADF compatible model)

Insert the hole of the Housing Left and connect the frame of the FAX Assy.

Scanner FFC (Multifunction Printer)

Route the Scanner FFC as follows.

1. Insert the Scanner FFC through the hole of the Scanner Housing Lower in the direction shown above, and then secure the FFC with double-sided tape on position with the standard shown in the figure above.

2. Route the FFC through the ribs (x7) of the Scanner Housing Lower taking care not to damage the FFC.

3. Route the FFC through the ribs (x5) on the bottom of the Scanner Carriage taking care not to damage the FFC.

4. Connect the Scanner FFC to the Relay Board and CIS Module as shown above.

Disassembly/Reassembly Routing FFCs/cables 48

 Route the Scanner Motor cable through the hooks (x4) of the Scanner Motor as shown above.  Secure the grounding wire of the Relay Board and the Scanner Motor together with the screw as show above.

Scanner Motor (Multifunction Printer)

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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B

Housing Front

Main FramePanel FFC

Frame Base

Hole

Double-sided tape

Hole

Connector of

Panel Board

Main Frame

Panel FFC

Grounding wire

Housing Front

Panel Unit

C.B.S-TITE SCREW 3x6 F/ZN-3C (6 ± 1 kgf·cm)

Rib Double-sided tape

Panel FFC

Frame Base Main Frame

Housing Upper Assy

Panel FFC

Hole

Left side of printer

PF Encoder Sensor

PF Encoder FFC

Rib

Double Side Tape

CN7

Ribs

CN11

CN2

CN9

CN4

CN7

CN13

CN501

CN1

CN14

Wireless LAN Module Cable

FFC Holder MB Ferrite core

Panel FFC

PF Encoder

FFC

Singlefunction Printer

CN14

CN13

CN2

CN4

CN7CN501

USB Board cable

Multifunction Printer

PF Motor cable FAX FFC

PS Unit cable

Ethernet Board cable

Main Board

CN12

CN102

Head FFC

CSIC FFC

CN61

CR Motor cable

CN23

PIS FFC

Main Board

CN12

CN102

Head FFC

CSIC FFC

CN61 CR Motor cable

CN23

PIS FFC

Double-sided tape

Panel FFC (Multifunction Printer)

 Route the Frame Base and Main Frame along the folded line and secure

with the double-sided tape on the position shown in the above.

 After installing the Housing Front, route the Panel FFC through the hole

of the Housing Front.

Panel Unit (Multifunction Printer)

 Route the Panel FFC and grounding wire as follows before installing the

Panel Unit.

• Route the Panel FFC through the hole of the Panel Unit and connect the connector of the Panel Board.

• Route the grounding wire through the hole of the Housing Front.

 After installing the Panel Unit, secure the grounding wire to the Main

Frame on the position indicated in the figure above with screw (x1).

Panel FFC (Singlefunction Printer)

 Route the Panel FFC through the rib of the Frame Base and Main Frame

along the folded line and secure with the double-sided tape on the position shown above.

 Route through the hole of the Housing Upper Assy and secure with the

double-sided tape on the position shown above.

PF Encoder Sensor

Route the PF Encoder through ribs of the Main Frame and connect the connector (CN7) of the Main Board. Then secure with the double-sided tape (x2) on the position shown in above.

Left side of Main Board

Connect the following cables/FFCs to the Main Board as shown above.

• PF Motor cable (CN13) • PS Unit cable (CN501)

• Wireless LAN Module Cable (CN4: only for Wireless LAN compatible model) • PF Encoder FFC (CN7)

• USB Board cable (CN9: only for USB compatible model) • FAX FFC (CN1: only for FAX compatible model)

• Ethernet Board cable (CN14: only for Ethernet compatible model)

• Panel FFC (CN2) : Secure the ferrite core of the FFC Holder MB and connect to the Main Board through the ferrite core.

Disassembly/Reassembly Routing FFCs/cables 49

(Singlefunction Printer has no FFC Holder MB and ferrite core.)

Right side of Main Board (Multifunction Printer)

Connect the following cables/FFCs to the Main Board as shown in the figure above.

• CR Motor cable (CN12)

• CSIC FFC (CN6)

• Head FFC (CN102)

• PIS FFC (CN23) Route the PIS FFC over the Head FFC and CSIC FFC.

Right side of Main Board (Singlefunction Printer)

Connect the following cables/FFCs to the Main Board as shown in the figure above.

• CR Motor cable (CN12)

• CSIC FFC (CN6)

• Head FFC (CN102) Secure with the double-sided tape on the position shown above.

• PIS FFC (CN23) Route the upper side of the Head FFC and CSIC FFC.

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CR Motor cable (red)

Rib A

CR Motor cable (b lack)

Hook C

Rib B

CR Motor

Hook EGroove of FFC HolderCR Motor cable Hook D

Frame Base

Main Board PF Scale

Rib

USB BoardCN2

USB Board cable

Bottom of Frame Base

PS Unit cable

Ferrite core

PS Unit cableFrame Base

Hole

Rib

Bottom of Frame Base

PF Motor

Route PF Motor

cable through rib.

Secure PF Motor

cable (black) with rib.

PF Motor cable

Hole

Rib

Frame Base

H: Fold back

Align the fold on PIS FFC with

the corner of Frame Base

Protrusion

PIS Shield

Plate B

H: Fold back

PIS FFC

Star Wheel Holder Assy

PIS Shield Plate B

C: 20 x 4 mm

Standard line

Double-sided tape

CR Motor

Route the CR Motor cable as follows before installing the Shield Plate.

1. Route the CR Motor cable (black) around the rib A of the Frame Base (two turns).

2. Route the CR Motor cable (red) through the rib B of the Frame Base, and then route it through the rib A taking care not to let the CR Motor cable (red) come over the CR Motor cable (black).

3. Twist the CR Motor cable (black) and CR Motor cable (red) twice, and then route them through the hook C of the Main Frame.

4. Route the CR Motor cable (black) and CR Motor cable (red) in the order of hook D of the Main Frame, groove of the FFC Holder, and hook E of the Main Frame.

USB Board (USB compatible model)

 When routing the USB Board cable, be careful not to damage the PF Scale.  Route the USB Board cable through the ribs (x4) of the Frame Base.  Connect the connectors on both ends of the USB Board cable to the Card Slot Board (CN3) and Main Board (CN9) firmly. (p 49)

PS Unit

 Pull out the PS Unit cable from the hole of the Frame Base first, and then

route it through the rib of the Frame Base.

 Put the ferrite core into the position shown in the figure above.

Disassembly/Reassembly Routing FFCs/cables 50

Route the PF Motor cable as follows.

1. Pull out the PF Motor cable from the hole of the Frame Base.

2. Install the PF Motor, and secure the PF Motor cable (black) with the rib of the Frame Base, and then route it through the rib of the Frame Base.

PF Motor

PIS FFC

Route the PIS FFC/cable as follows

1. Align the PIS FFC to the standard line on the PIS Shield Plate B, and route it in the direction of arrow (1) taking care not to let it cover th e protrusion of the Star Wheel Holder Assy, then secure the FFC with double sided tape in the order from A to C shown above.

2. Align the fold on the PIS FFC with the corner of the Frame Base, and route the FFC along the standard line on the Main Frame in the direction of arrow (2), then secure the FFC with double sided tape in the order of D and E shown above.

3. From the fold on the PIS FFC aligned in Step 2, route the FFC in the direction of arrow (3), and secure it with double sided tape at F shown above.

4. Route the PIS FFC in the direction of arrow (4), and secure it with double sided tape in the order of G and H shown above.

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Aligning Head FFC with CSIC FFC

Head FFC

CSIC FFC

Fold here inside FFC Holder

Stack the Head FFC over the CSIC

FFC to keep the Head FFC on top.

Head FFC/CSIC FFC

FFC Holder

Rear

FFC HolderMain Frame

Head FFC/CSIC FFC

Double-sided tape

CSIC FFC

Connector of Printhead

Left side of CR Unit

Connector of CR Encoder

Rib B

Head FFC

CR Unit

Rib A

Rib C

Connector of CR

Contact Module

Head FFC (Routing on the Main Frame)

Head FFC (Routing on the CR Unit)

Align the Head FFC and CSIC FFC, and then route them through the FFC Holder as shown in the figure above.

 Route the CSIC FFC through the rib A and rib B, and then connect it to

the connectors of the CR Encoder and CR Contact Module.

 Route the Head FFC through the rib B and C, and then connect it to the

connector of the Printhead.

Disassembly/Reassembly Routing FFCs/cables 51

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CHAPTER 3

ADJUSTMENT

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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series

3.1 Required Adjustments

The table from the following page lists the required adjustments depending upon the parts being repaired or replaced. Find the part(s) you removed or replaced, and check which adjustment(s) must be carried out.

 If the EEPROM data cannot be read out from the old Main Board using the Adjustment

Program when replacing the Main Board is required, the Waste Ink Pad Assy must be replaced with the Main Board at the same time.

 After all required adjustments are completed, use the “Final check pattern print”

function to print all adjustment patterns for final check. If you find a problem with the printout patterns, carry out the adjustment again.

 When replacing the Main Board, the adjustment should be made after performing the

initial setting.

 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

 The table items and marks used in the “Required Adjustment List” provided on the

following pages have the following meanings.

• “O” indicates that the adjustment must be carried out.

• “---” indicates that the adjustment is not required.

• The “Mechanism Adjustment” should be performed just after reinstalling or reassembling the part or unit.

• The “Adjustments using the Adjustment Program” need to be performed after reassembling the printer completely.

 If you have removed or replaced multiple parts, make sure to check the required

adjustments for the all parts. And when multiple adjustments must be carried out, be sure to carry out them in the order given in the “Priority” row.

Revision B

Adjustment Required Adjustments 53

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Table 3-1. Required Adjustment List

Adjustment Type Mechanism adjustment

Priority

Adjustment Item

Purpose

Tray Front Assy

Star Wheel Holder Assy

Paper Guide Front Unit

Paper Guide Lower Porous Pad

Printhead

Waste Ink Pad Assy

Retard Roller Assy

Scanner Unit

Part Name

Scanner Motor

ADF Unit

PS Unit

PF Driven Pulley Assy

PF Timing Belt

EJ Roller

Hopper

Printout pattern

How to judge

Adjustment program Tool See p63 See p65 See p65

Note 1: Necessary when the part is replaced at a point in the disassembly procedures other than specified in this manual.

2: Replacement of the Paper Guide Lower Porous Pad and Waste Ink Pad Assy is necessary.

Remove Replace Remove Replace Remove Replace Remove Replace Remove Replace Remove Replace Remove Replace Remove Replace Remove Replace Remove Replace Remove Replace Remove Replace Remove Replace Remove Replace Remove Replace

1 2 3

Checking the Platen

Gap

Check if the PG is within the standard.

--- --- ---

--- --- --O --- ---

--- --- ---

--O --- ---

--- --- ---

--- --- O

--- --- ---

See " 3.3.1 Checki ng the

Platen Gap (p63)" for

the details.

--- --- ---

Revision B

CR Belt tension check PF Belt tension check

Check the tension of the CR Timing Belt

--- ---

See " 3.3.2 CR/PF Belt

Tension Check (p65)"

for the details.

Check the tension of the PF Timing Belt

See " 3.3.2 CR/PF Belt

Tension Check (p65)"

for the details.

Adjustment Required Adjustments 54

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Table 3-1. Required Adjustment List

Adjustment Type Mechanism adjustment

Revision B

Priority

Adjustment Item

Purpose

LD Roller Assy

CR Motor

PE Sensor Lever

Main Board

CR Driven Pulley

Main Frame Assy

Paper Guide Upper Assy

Part Name

CR Unit

CR Timing Belt

Frame Base Assy Replace

PF Roller Unit

PF Motor Assy

Frame Base Replace

PIS Board

Printout pattern

How to judge

Adjustment program Tool See p63 See p65 See p65

Remove Replace Remove Replace Remove Replace Remove Replace (Read OK) Replace (Read NG) Remove Replace Remove Replace Remove Replace Remove Replace Remove Replace

Remove Replace Remove Replace

Remove Replace

Checking the Platen

Check if the PG is within the standard.

See " 3.3.1 Checki ng the

Platen Gap (p63)" for

the details.

1 2 3

Gap

CR Belt tension check PF Belt tension check

Check the tension of the CR Timing Belt

Check the tension of the PF Timing Belt

--- --- ---

--- O ---

--- --- --OO---

--- --- ---

--- --- --O --- ---

--- --- ---

--- O ---

--- --- O

--- --- ---

See " 3.3.2 CR/PF Belt

Tension Check (p65)"

for the details.

See " 3.3.2 CR/PF Belt

Tension Check (p65)"

for the details.

--- --- ---

Note 1: Necessary when the part is replaced at a point in the disassembly procedures other than specified in this manual.

2: Replacement of the Paper Guide Lower Porous Pad and Waste Ink Pad Assy is necessary.

Adjustment Required Adjustments 55

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-2

-1

0 1 2

-2-1012

NGOK

OK NGNG

Table 3-2. Required Adjustment List

Adjustment Type Adjustment using the Adjustment Program

Priority 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Adjustment Item

Purpose

Tray Front Assy

Star Wheel Holder Assy

Paper Guide Front Unit

Paper Guide Lower Porous Pad

Part Name

Printhead

Waste Ink Pad Assy

Retard Roller Assy

Remove Replace Remove Replace Remove Replace Remove Replace Remove Replace Remove Replace Remove Replace

EEPROM

data copy

To copy adjustment values or the like stored on the old Main Board to the new board when the Main Board needs to be replaced.

Initialize Setting Head ID input Ink charge

To write saledestination-specific settings and the serial number into the Main Board after replacing it. And also to set the MAC address as necessary.

To correct characteristic variation of the replaced Printhead by entering its Printhead ID (Head ID).

To fill ink inside the new Printhead to make it ready for print after replacing the Printhead.

Maintenance

counter

To reset the waste ink counter after replacing the Waste Ink Pad Assy.

First dot position

adjustment

To correct the print start position in the CR Unit moving direction through software control.

TOP margin

adjustment

This corrects top margin of printout.

Head angular

adjustment

To correct tilt of the Printhead caused at the installation through software control.

Bi-D adjustment

To correct print start timing in bidirectional printing through software control.

PF/EJ

adjustment

To correct variations in paper feed accuracy to achieve higher print quality.

PF band

adjustment

To correct variations in paper feed accuracy to achieve higher print quality in band printing.

PF deterioration

offset

To reset the counter according to the replaced parts.

CR motor heat

protection

control

To measure and correct the electrical variation of the motor and the power supply board.

--- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

--- --- --- --- --- --- --- --- --- O --- --- --- --- --- ---

--- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

--- --- --- --- --- --- --- --- --- O O --- --- --- --- ---

--- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

--- --- --- --- --- --- --- --- O O O --- --- --- --- ---

--- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

--- --- --- --- O --- --- --- --- --- --- --- --- --- --- ---

--- --- --- --- --- --- --- O O --- --- --- --- --- --- ---

--- --- O O --- O O O O --- O --- --- --- --- O

--- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

--- --- --- --- O --- --- --- --- --- --- --- --- --- --- ---

--- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

--- --- --- --- --- --- O --- --- --- --- --- --- --- --- ---

PF motor heat

protection

control

To measure and correct the electrical variation of the motor and the power supply board.

Scanner motor heat protection

control

To measure and correct the electrical variation of the motor.

PIS board Check

Determine whether the PIS Board is needed to be replaced when the Printhead and the Main Board are replaced.

Printout pattern

How to judge

Adjustment program Tool

Note "*1": Perform before the final check pattern since the degraded status of the PIS Board by ink mist or other status are checked other than when the Printhead/Main Board are replaced. (T he fault of the PIS Board may not be detected without the PIS Board check.)

"*2": Replacement of the Paper Guide Lower Porous Pad and Waste Ink Pad Assy is necessary.

--- --- --- --- --- --- --- --- --- ---

Examine the misaligned lines printed on the left side of the paper, and enter the number beside the line that is exactly 5 mm away from the paper edge.

Examine the misaligned lines printed on top of the paper, and enter the number beside the line that is exactly 5 mm away from the paper edge.

Enter the values of the most straight lines.

Examine the printout patterns for each of the four modes, and enter the value for the pattern with no gap and overlap for each mode.

--- --- --- --- ---

OOOOOOOOOOOOOOOO

--- --- --- --- --- Ruler Ruler --- --- --- --- --- --- --- --- ---

Normal area

pattern

Examine the printout patterns and enter the value for the pattern with fewest lines.

Bottom area

pattern

Examine the printout patterns and enter the value for the pattern with no overlap and gap between the two rectangles.

See " 3.2.2.1 CR

Motor Heat Protection Control / PF Motor Heat Protection Control (p60)" for the

details.

---

See " 3.2.2.1 CR

Motor Heat Protection Control / PF Motor Heat Protection Control (p60)" for the

details.

See " 3.2.2.2

Scanner Motor Heat Protection Control (p61)" for

the details.

See " 3.2.2.3 PIS

Board Check (p62)" for the

details.

Adjustment Required Adjustments 56

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-2

-1

0 1 2

-2-1012

NGOK

OK NGNG

Table 3-2. Required Adjustment List

Adjustment Type Adjustment using the Adjustment Program

Priority 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Adjustment Item

Purpose

Scanner Unit

Scanner Motor

ADF Unit

PS Unit

Part Name

PF Driven Pulley Assy

PF Timing Belt

EJ Roller

Hopper

Remove Replace Remove Replace Remove Replace Remove Replace Remove Replace Remove Replace Remove Replace Remove Replace

EEPROM

data copy

To copy adjustment values or the like stored on the old Main Board to the new board when the Main Board needs to be replaced.

Initialize Setting Head ID input Ink charge

To write saledestination-specific settings and the serial number into the Main Board after replacing it. And also to set the MAC address as necessary.

To correct characteristic variation of the replaced Printhead by entering its Printhead ID (Head ID).

To fill ink inside the new Printhead to make it ready for print after replacing the Printhead.

Maintenance

counter

To reset the waste ink counter after replacing the Waste Ink Pad Assy.

First dot position

adjustment

To correct the print start position in the CR Unit moving direction through software control.

TOP margin

adjustment

This corrects top margin of printout.

Head angular

adjustment

To correct tilt of the Printhead caused at the installation through software control.

Bi-D adjustment

To correct print start timing in bidirectional printing through software control.

PF/EJ

adjustment

To correct variations in paper feed accuracy to achieve higher print quality.

PF band

adjustment

To correct variations in paper feed accuracy to achieve higher print quality in band printing.

PF deterioration

offset

To reset the counter according to the replaced parts.

CR motor heat

protection

control

To measure and correct the electrical variation of the motor and the power supply board.

--- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

--- --- --- --- --- --- --- --- --- --- --- --- --- --- O ---

--- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

--- --- --- --- --- --- --- --- --- --- --- --- --- --- O ---

--- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

--- --- --- --- --- --- --- --- --- --- --- --- O O --- ---

--- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

--- --- --- --- --- --- --- --- --- O O --- --- --- --- ---

--- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

--- --- --- --- --- O O --- O --- --- --- --- --- --- ---

PF motor heat

protection

control

To measure and correct the electrical variation of the motor and the power supply board.

Scanner motor heat protection

control

To measure and correct the electrical variation of the motor.

PIS board Check

Determine whether the PIS Board is needed to be replaced when the Printhead and the Main Board are replaced.

Printout pattern

How to judge

Adjustment program Tool

Adjustment Required Adjustments 57

"*2": Replacement of the Paper Guide Lower Porous Pad and Waste Ink Pad Assy is necessary.

--- --- --- --- --- --- --- --- --- ---

Examine the misaligned lines printed on the left side of the paper, and enter the number beside the line that is exactly 5 mm away from the paper edge.

Examine the misaligned lines printed on top of the paper, and enter the number beside the line that is exactly 5 mm away from the paper edge.

Enter the values of the most straight lines.

Examine the printout patterns for each of the four modes, and enter the value for the pattern with no gap and overlap for each mode.

--- --- --- --- ---

OOOOOOOOOOOOOOOO

--- --- --- --- --- Ruler Ruler --- --- --- --- --- --- --- --- ---

Normal area

pattern

Examine the printout patterns and enter the value for the pattern with fewest lines.

Bottom area

pattern

Examine the printout patterns and enter the value for the pattern with no overlap and gap between the two rectangles.

See " 3.2.2.1 CR

Motor Heat Protection Control / PF Motor Heat Protection Control (p60)" for the

details.

---

See " 3.2.2.1 CR

Motor Heat Protection Control / PF Motor Heat Protection Control (p60)" for the

details.

See " 3.2.2.2

Scanner Motor Heat Protection Control (p61)" for

the details.

See " 3.2.2.3 PIS

Board Check (p62)" for the

details.

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Table 3-2. Required Adjustment List

Adjustment Type Adjustment using the Adjustment Program

Priority 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Adjustment Item

LD Roller Assy

CR Motor

PE Sensor Lever

Part Name

Main Board

CR Driven Pulley

Main Frame Assy

Purpose

Remove Replace Remove Replace Remove Replace Remove Replace

(Read OK) Replace

(Read NG) Remove Replace Remove Replace

EEPROM

data copy

To copy adjustment values or the like stored on the old Main Board to the new board when the Main Board needs to be replaced.

Initialize Setting Head ID input Ink charge

To write saledestination-specific settings and the serial number into the Main Board after replacing it. And also to set the MAC address as necessary.

To correct characteristic variation of the replaced Printhead by entering its Printhead ID (Head ID).

To fill ink inside the new Printhead to make it ready for print after replacing the Printhead.

Maintenance

counter

To reset the waste ink counter after replacing the Waste Ink Pad Assy.

First dot position

adjustment

To correct the print start position in the CR Unit moving direction through software control.

TOP margin

adjustment

This corrects top margin of printout.

Head angular

adjustment

To correct tilt of the Printhead caused at the installation through software control.

Bi-D adjustment

To correct print start timing in bidirectional printing through software control.

PF/EJ

adjustment

To correct variations in paper feed accuracy to achieve higher print quality.

PF band

adjustment

To correct variations in paper feed accuracy to achieve higher print quality in band printing.

PF deterioration

offset

To reset the counter according to the replaced parts.

CR motor heat

protection

control

To measure and correct the electrical variation of the motor and the power supply board.

--- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

--- --- --- --- --- --- O --- --- --- --- --- --- --- --- ---

--- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

--- --- --- --- --- --- --- --- --- --- --- --- O --- --- ---

--- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

--- --- --- --- --- --- O --- --- --- --- --- --- --- --- ---

O --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

--- O O --- O

OOOOOO---OOOO

--- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

--- --- --- --- --- O --- O O O O --- --- --- --- ---

PF motor heat

protection

control

To measure and correct the electrical variation of the motor and the power supply board.

Scanner motor heat protection

control

To measure and correct the electrical variation of the motor.

PIS board Check

Determine whether the PIS Board is needed to be replaced when the Printhead and the Main Board are replaced.

Printout pattern

How to judge

Adjustment program Tool

"*2": Replacement of the Paper Guide Lower Porous Pad and Waste Ink Pad Assy is necessary.

--- --- --- --- --- --- --- --- --- ---

Examine the misaligned lines printed on the left side of the paper, and enter the number beside the line that is exactly 5 mm away from the paper edge.

Examine the misaligned lines printed on top of the paper, and enter the number beside the line that is exactly 5 mm away from the paper edge.

Enter the values of the most straight lines.

Examine the printout patterns for each of the four modes, and enter the value for the pattern with no gap and overlap for each mode.

--- --- --- --- ---

OOOOOOOOOOOOOOOO

--- --- --- --- --- Ruler Ruler --- --- --- --- --- --- --- --- ---

Normal area

pattern

Examine the printout patterns and enter the value for the pattern with fewest lines.

Bottom area

pattern

Examine the printout patterns and enter the value for the pattern with no overlap and gap between the two rectangles.

See " 3.2.2.1 CR

Motor Heat Protection Control / PF Motor Heat Protection Control (p60)" for the

details.

---

See " 3.2.2.1 CR

Motor Heat Protection Control / PF Motor Heat Protection Control (p60)" for the

details.

See " 3.2.2.2

Scanner Motor Heat Protection Control (p61)" for

the details.

See " 3.2.2.3 PIS

Board Check (p62)" for the

details.

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0 1 2

-2-1012

NGOK

OK NGNG

Table 3-2. Required Adjustment List

Adjustment Type Adjustment using the Adjustment Program

Priority 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Adjustment Item

Purpose

Paper Guide Upper Assy

CR Unit

CR Timing Belt

Frame Base Assy Replace

Part Name

PF Roller Unit

PF Motor Assy

Frame Base Replace

PIS Board

Remove Replace Remove Replace Remove Replace

Remove Replace Remove Replace

Remove Replace

EEPROM

data copy

To copy adjustment values or the like stored on the old Main Board to the new board when the Main Board needs to be replaced.

Initialize Setting Head ID input Ink charge

To write saledestination-specific settings and the serial number into the Main Board after replacing it. And also to set the MAC address as necessary.

To correct characteristic variation of the replaced Printhead by entering its Printhead ID (Head ID).

To fill ink inside the new Printhead to make it ready for print after replacing the Printhead.

Maintenance

counter

To reset the waste ink counter after replacing the Waste Ink Pad Assy.

First dot position

adjustment

To correct the print start position in the CR Unit moving direction through software control.

TOP margin

adjustment

This corrects top margin of printout.

Head angular

adjustment

To correct tilt of the Printhead caused at the installation through software control.

Bi-D adjustment

To correct print start timing in bidirectional printing through software control.

PF/EJ

adjustment

To correct variations in paper feed accuracy to achieve higher print quality.

PF band

adjustment

To correct variations in paper feed accuracy to achieve higher print quality in band printing.

PF deterioration

offset

To reset the counter according to the replaced parts.

CR motor heat

protection

control

To measure and correct the electrical variation of the motor and the power supply board.

--- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

--- --- --- --- --- --- O --- O O O --- --- --- --- ---

--- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

--- --- --- --- --- O O O O --- O --- --- --- --- ---

--- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

--- --- --- ------ --- --- --- --- --- --- --- --- --- --- --- ---

--- --- --- --- --- O O --- O O O --- --- --- --- ---

--- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

--- --- --- --- --- --- O --- --- O O --- --- --- --- ---

--- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---

--- --- --- --- --- --- --- --- --- O --- --- --- O --- ---

--- --- --- --- --- O O --- O --- --- --- --- --- --- ---

--- --- --- --- --- O O --- O --- --- --- --- --- --- O

PF motor heat

protection

control

To measure and correct the electrical variation of the motor and the power supply board.

Scanner motor heat protection

control

To measure and correct the electrical variation of the motor.

PIS board Check

Determine whether the PIS Board is needed to be replaced when the Printhead and the Main Board are replaced.

Printout pattern

How to judge

Adjustment program Tool

"*2": Replacement of the Paper Guide Lower Porous Pad and Waste Ink Pad Assy is necessary.

--- --- --- --- --- --- --- --- --- ---

Examine the misaligned lines printed on the left side of the paper, and enter the number beside the line that is exactly 5 mm away from the paper edge.

Examine the misaligned lines printed on top of the paper, and enter the number beside the line that is exactly 5 mm away from the paper edge.

Enter the values of the most straight lines.

Examine the printout patterns for each of the four modes, and enter the value for the pattern with no gap and overlap for each mode.

--- --- --- --- ---

OOOOOOOOOOOOOOOO

--- --- --- --- --- Ruler Ruler --- --- --- --- --- --- --- --- ---

Normal area

pattern

Examine the printout patterns and enter the value for the pattern with fewest lines.

Bottom area

pattern

Examine the printout patterns and enter the value for the pattern with no overlap and gap between the two rectangles.

See " 3.2.2.1 CR

Motor Heat Protection Control / PF Motor Heat Protection Control (p60)" for the

details.

---

See " 3.2.2.1 CR

Motor Heat Protection Control / PF Motor Heat Protection Control (p60)" for the

details.

See " 3.2.2.2

Scanner Motor Heat Protection Control (p61)" for

the details.

See " 3.2.2.3 PIS

Board Check (p62)" for the

details.

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Execute button

Check the check box of the replaced parts.

Execute button

Check the check box of the replaced parts.

3.2 Adjustment Program

This section provides the operating environment, functions related to safety and privacy policy, and the adjustment item newly added of the Adjustment Program. See "3.1 Required Adjustments (p53)" for the adjustments not explained here.

3.2.1 Operating Environment

The operating environment for the Adjustment Program is as follows.

 OS: Windows XP, Vista  Interface: USB

3.2.2 Details of the Adjustment Program

Refer to the guide in the Adjustment Program for the details of the procedure.

3.2.2.1 CR Motor Heat Protection Control / PF Motor Heat Protection Control

Revision B

Purpose To measure the manufacturing variations of the DC motors (CR Motor/PF Motor), Main Board and Power

Supply Board to determine the correction value used for estimating the current values of the motors.

Risks if the adjustment is not correctly made

Procedure 1. Select from the menu of the Adjustment Program. Check the check box of the replaced parts and press the

Adjustment Program screen

The printer cannot measure the current value of motor correctly, then the heat generation caused by motor drive cannot be estimated accurately either, and which may results in trouble such as incorrect control of motors when allotting a cool down period according to each heat generation.

In the worst case, excessive heat generation may cause smoke or ignition.

“Execute” button to measure the correction value.

2. The correction value is automatically measured and the measurement value is written to the EEPROM on the Main Board.

Remarks ---

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Perform button

Check button

3.2.2.2 Scanner Motor Heat Protection Control

Purpose To measure the manufacturing variation of the DC motor (Scanner) to determine the correction value used for

estimating the current value of the motor.

Risks if the adjustment is not cor-

rectly made

Procedure 1. Select from the menu of the Adjustment Program and press the “Perform” button to measure the correction

Adjustment Program screen

Because the printer cannot measure the current value of the motor accurately, even if just a mechanical load with which the Scanner Carriage can operate without any problem is applied, the printer cannot control the drive of the motors correctly, which may resu lt in occur ren ce o r generatio n of scanner fatal error, vibr ation, or noises.

value.

2. Turn off the printer and turn it back on. After the Scanner Carriage is operated, the correction value is automatically measu red and the measurement value is written to the EEPROM on the Main Board.

3. Press the “Check” button to confirm the written value in the EEPROM is within the standard range.

Revision B

Remarks ---

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Check button

3.2.2.3 PIS Board Check

Purpose Photo Ink Sensor degradation and failure check. Risks if the adjust-

ment is not correctly made

Procedure 1. Set the ink cartridges.(The cartridges which is not ink end condition is used.)

Adjustment Program screen

If number of printing sheets increases, ink mist adheres to a sensor and the quantity of light of a sensor falls off by becoming dirty, so that it is necessary to exchange PIS Board Assy (BOARD ASSY,.SUB). By checking with a adjustment program, it is judged whether it is necessary to exchange PIS Board Assy (BOARD ASSY,.SUB) simultaneously at the time of head exchange.

2. Close the scanner & Printer Cover.

3. Carry out a Photo Ink Sensor inspection with a Adjustment program.

4. If the message to which exchange of a PIS board Assy (BOARD ASSY., SUB) is urged is displayed, it is judged that Photo Ink Sensor is in a degradation state.

Revision B

Remarks

If “PIS Board Check” is implemented with SCN open condition, you cannot get correct check result because of the effects of the ambient light. Therefore, implement this with SCN close condition surely.

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3.3 Mechanism Adjustment / Check

This section provides the procedure for the mechanism adjustment and check.

3.3.1 Checking the Platen Gap

This section describes the procedure for checking the platen gap (PG).



This printer does not have any PG adjustment mechanism, however, it is designed so that the platen gap can fall within the expected range if you correctly reassemble the unit (including using the Epson-specified jigs) according to this manual. If the PG cannot fall within the standard range after performing the platen gap check described in this section, first check if the unit is correctly reassembled following the instructions in this manual. Even if the unit is correctly reassembled but the PG still cannot fall within the standard range, replace the unit with a new/refurbished one.

 The standard range of the PG is as follows:

• Standard: 1.8 ± 0.2 mm

 Tools



Thickness gauge: 1.6 mm (x2), 2.0 mm (x2)

 Confirmation procedure

Revision B

When checking the PG, make sure of the following.  Check the PG with new ink cartridges installed to the CR Unit, and also with all parts

related to the PG installed to the printer (p 53).

 Move the CR Unit by pulling the CR Timing Belt.  Be careful not to damage the nozzles of the Printhead with the thickness gauge.

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80-digit side

0-digit side

Thickness gauges

1. Move the CR Unit to the center of the printer.

2. Place the thickness gauges (1.6 mm) on the position A shown in Figure 3-1.

Figure 3-1. Position of the Thickness Gauge

3. Pull the CR Timing Belt to move the CR Unit to both ends and confirm the CR Unit does not touch the thickness gauges.

4. Move the CR Unit to the center, and place the thickness gauges (1.6 mm) on the position B shown in Figure

3-1.

5. Pull the CR Timing Belt to move the CR Unit to both ends and confirm the CR Unit does not touch the thickness gauges.

6. Move the CR Unit to the center, and place the thickness gauges (2.0 mm) on the position A shown in Figure

3-1.

Revision B

7. Pull the CR Timing Belt to move the CR Unit to both ends and confirm the CR Unit touches the thickness gauges.

8. Move the CR Unit to the center, and place the thickness gauges (2.0 mm) on the position B shown in Figure

3-1.

9. Pull the CR Timing Belt to move the CR Unit to both ends and confirm the CR Unit touches the thickness gauges.

Note "*1":If the CR Unit comes in contact with the thickness gauges, the PG is smaller than the standard value, therefore, check if the

"*2":If the CR Unit does not come in contact with the thickness gauges, the PG is greater than the standard value, therefore, check

unit is correctly reassembled. If not, reassemble the unit and perform PG check again. (If the unit is correctly reassembled, replace the unit with a new/refurbished one.)

if the unit is correctly reassembled. If not, reassemble the unit and perform PG check again. (If the unit is correctly reassembled, replace the unit with a new/refurbished one.)

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CR Timing Belt Measurement position

3.3.2 CR/PF Belt Tension Check

This section describes the CR/PF Belt tension check.

 This printer is designed so that the each tension of the CR Timing Belt and PF Timing

Belt fall within the expected range if you correctly reassemble the unit according to this manual. However, deformation of any related part(s) can cause improper tension of the belt. In such case, replace the unit with a new/refurbished one.

 The standard tension range is as follows:

• CR Timing Belt: 9 ± 1 N

• PF Timing Belt: 5 ± 2.5 N

 Tools



Sonic tension meter (Parts code: 1294120)

 Plastic tweezers

 Confirmation procedure

When performing the CR/PF Belt tension check, make sure of the following.  Bring the microphone of the sonic tension meter within 5 mm from the timing belt but do

not let it touch the belt.

 Flip the timing belt as weak as the sonic tension meter can measure it.  Be careful not to damage the timing belt when flipping it with the plastic tweezers.

Revision B

Checking the CR Timing Belt Tension

Perform the CR Belt tension check after performing " 3.3.1 Checking the Platen Gap (p63)".

1. Move the CR Unit to 0-digit side.

2. Set the following parameters to the sonic tension meter:

Weight: 1.1 g/m

  Width: 3 mm  Span: 326 mm

3. Bring the microphone of the sonic tension meter close to the position shown in Figure 3-2.

4. Press the “MEASURE” button of the sonic tension meter and flip the upper of the CR Timing Belt with plastic tweezers and measure the tension of the belt three times.

5. Check the average of the measured values falls within the standard range.



Within the standard range: the CR Timing Belt tension check is complete.

 Out of the standard range: replace the unit with a new/refurbished one.

Figure 3-2. Checking the CR Timing Belt Tension

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PF Driven Pulley Assy PF Timing Belt

Left side

Measurement position

Checking the PF Timing Belt Tension

Perform the PF Belt tension check before installing the PF Scale and the PF Encoder Sensor.

1. Set the following parameters to the sonic tension meter:

Weight: 1.2 g/m

  Width: 3.2 mm  Span: 29 mm

2. Bring the microphone of the sonic tension meter close to the position shown in Figure 3-3.

3. Press the “MEASURE” button of the sonic tension meter and flip the lower of the PF Timing Belt with plastic tweezers and measure the tension of the belt three times.

4. Check the average of the measured values falls within the standard range.



Within the standard range: the PF Timing Belt tension check is complete.

 Out of the standard range: reinstall the " PF Driven Pulley Assy / PF Timing Belt (p45)", and then perform the PF

Timing Belt Tension Check again.

Revision B

Figure 3-3. Checking the PF Timing Belt Tension

If not within the standard though performing the PF Timing Belt Tension Check twice, replace the unit with a new/refurbished one.

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CHAPTER 4

MAINTENANCE

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4.1 Overview

This section provides information to maintain the printer in its optimum condition.

4.1.1 Cleaning

Except for the Printhead, there are no other mechanical parts or units that require periodic cleaning. However, if need arises, clean the component observing the following instructions.

 Instructions for cleaning



Exterior parts such as housing Wipe dirt off with a soft clean cloth moistened with water. For glossy or transparent parts, use of unwoven cloth is recommended to avoid scratching those parts.

 Inside of the printer

Remove paper dust with a vacuum cleaner.

 Rubber or plastic rollers such as an LD roller used to feed paper

If paper dust adhered to the rollers decreases the frictional force of the rollers and the rollers cannot properly feed paper, wipe off the paper dust with a soft cloth moistened with diluted alcohol.

 Instructions for cleaning ink stains

Wipe the stains off with a cloth wrung out of diluted alcohol.

Revision B

 Do not use alcohol for cleaning the transparent parts. Doing so may cause them to get

cloudy.

 When wiping paper dust off the LD Roller, be careful not to rub against the surface

asperity.

 To minimize the effect on the parts, use diluted alcohol such as 70% diluted ether.  After using alcohol for cleaning, make sure to wipe the part off with a soft dry dust-free

cloth to remove alcohol traces fully.

4.1.2 Lubrication

The type and amount of the grease used to lubricate the printer parts are determined based on the results of the internal evaluations. Therefore, refer to "4.2 Lubrication Points and Instructions (p69)" for the repairing procedures below, and apply the specified type and amount of the grease to the specified part of the printer mechanism.

"4.2 Lubrication Points and Instructions (p69)" also provides information about whether or not the parts which

require lubrication are supplied as ASP and the lubrication status when supplied as ASP. For the parts which are not supplied as ASP, if their movement is not smooth enough, check their lubrication status and lubricate them if necessary.

 Grease

Type Name EPSON Part Code Supplier

Grease G-45 1033657 EPSON Grease G-71 1304682 EPSON Grease G-74 1409257 EPSON

 Tools

Name Availability EPSON Part Code

Injector O * ---

Brush O * ---

Flux dispenser O * 1049533

Note *: Use tools whose specifications are specified in "4.2 Lubrication Points and Instructions (p69)".

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ADF Base

(1)Application Point

ADF Frame Assy

(2)Application Point

1. Application Point

Cross-section

Combination gear 19.2,10.8

Combination gear 18.4.9.66

4 mm

6 mm

2. Application Point

Scanner Carriage

Section A (See Cross-section view.)

Cross-section of section A

Scanner Carriage

CIS Module Unit

Application Point

4.2 Lubrication Points and Instructions

<Part supply as ASP> Supplied as the

ADF Unit

Lubricated <Lubrication Point>

1. Contact points (x2) on the ADF Base with the Combination Gear

24.9.6.

2. Shaft on the ADF Frame Assy (x9)

<Type> G-71

1. 4 mm

2. Appropriate amount

 Ap ply with injector.  After applying with

injector, spread it with brush for whole shaft.

<Part supply as ASP> Supplied as the Scanner

Unit <Lubrication status when

supplied as ASP> Lubricated

<Lubrication Point> Contact points (x6) on the

Scanner Carriage with the CIS Module Unit

<Type> G-74

<Application Amount> Appropriate amount (x6)

 Apply with flux

dispenser.

 Stir G-74 before use.  For section A, apply

grease over the area shown in the Crosssection view.

Figure 4-1. Lubrication of the ADF Frame Assy

<Part supply as ASP> Supplied as the Scanner Unit <Lubrication status when

supplied as ASP> Lubricated

Gear sections (x2) on the

1. Pinion Gear of the Combinatio n G e ar 18 .4 .9. 66

Shaft hole of the Combinatio n G e ar 18 .4 .9. 66

Shaft hole of the Combinatio n G e ar 19 .2 .10 .8

<Type> G-45

1. 0.01 g x 2 points

2.3. 0.01 g

1. Apply with injector.

2.3. After applying with

injector, spread it over the entire inner surface the shaft hole shown in the figure.

 Be careful not to let

grease flow over.

Figure 4-2. Lubrication of Combination Gear 14.4.9.66/Combination Gear 19.2.10.8

Maintenance Lubrication Points and Instructions 69

Figure 4-3. Lubrication of the Scanner Carriage (1)

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Scanner Carriage

Apply on the groove

Enlarged figure

Application Point

Origin position side

Drive Gear side

Guide rail

Scanner Housing Lower

Application Point

Guide rail Cross-section: Application Point

Head

Front side Rear side

 Grease spreading procedur e

After applying the grease, follow the procedure below to spread it with brush.

1. Spread the grease from the center of the Guide rail to the origin position side with brush.

2. Spread the grease for the Guide rail A from the Drive Gear side to the origin position side with brush.

3. Spread the grease for the Guide rail B from the origin position side to the Drive Gear side with brush.

4. Spread the grea se for the Guide rail C from the Drive Gear si de to the origin position side with brush.

Guide rail Cross-section: Spreading procedure

Section A

Section B Section C

Front side Rear side

Rear side: Hook

Front side: Rib

Frame Base

Application Point

Apply grease on the groove

Frame Base

Application Point

<Part supply as ASP> Supplied as the Scanner

Unit <Lubrication status when

supplied as ASP> Lubricated

<Lubrication Point> On gap (x4) on the bottom

of the Scanner Carriage <Type>

G-45 <Application Amount>

0.01 g x 4 points <Remarks>

 Apply grease on inner

on the groove

 Be careful not to let

grease flow over.

<Part supply as ASP> Supplied as the Scanner

Unit <Lubrication status when

supplied as ASP> Lubricated

<Lubrication Point> Guide rail of the Scanner

Housing Lower (x6) <Type>

G-45 <Application Amount>

0.03 g x 6 points <Remarks>

 Do not apply directly on

the head of the Guide rail.

 Apply with injector.  Be careful not to let

grease flow over.

 Keep the grease

spreading procedures.

Figure 4-4. Lubrication of the Scanner Carriage (2)

<Part supply as ASP> Supplied as the Printer

Mechanism <Lubrication status when

supplied as ASP> Lubricated

<Lubrication Point> Ribs (x12) and hooks (x6)

on the Frame Base (Contact points of the EJ Roller)

<Type> G-74

<Application Amount> Appropriate amount

 Apply with flu x

dispenser.

 Stir G-74 before use.

Figure 4-5. Lubrication of the Scanner Housing Lower

<Part supply as ASP> Supplied as Printer

Mechanism <Lubrication status when

supplied as ASP> Lubricated

<Lubrication Point> Contact point (x3) on the

EJ Roller with the Frame Base

<Type> G-71

<Application Amount> Appropriate amount

 Apply with injector.  Apply grease along the

groove on the Frame Base.

Figure 4-6. Lubrication of the Frame Base (1)

Figure 4-7. Lubrication of the Paper Back Lever

Maintenance Lubrication Points and Instructions 70

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Apply grease on ribs

Top: Multifunction Printer

Apply grease on ribs

Bottom: Multifunction Printer

Apply grease on both sides of dowels

Apply grease on sides.

Frame Base

2. Application Point

1. Application Point

Apply inside the groove

Rear left

Apply grease on rib

Rear right

Apply inside the groove

Apply grease on rib

Frame Base

Application Point

Main Frame Assy

Frame Base

CR Unit

Application Point

<Part supply as ASP> Supplied as the Printer

Mechanism <Lubrication status when

supplied as ASP> Lubricated

1. Contact points (x2) on the Frame Base with the Hopper

2. Contact points (x7: only Multifunction Printer) on the Frame Base with the Stacker Assy

<Type>

1. G-71

2. G-74

<Application Amount> Appropriate amount

 Apply with flux

dispenser.

 Stir G-74 befor e use.

<Part supply as ASP> Supplied as the Printer

Mechanism <Lubrication status when

supplied as ASP> Lubricated

<Lubrication Point> Contact points (x4) on the

Frame Base with the Paper Support Assy

<Type> G-74

<Application Amount> Appropriate amount

 Apply with flux

dispenser.

 Stir G-74 before use.

Figure 4-9. Lubrication of the Frame Base (4)

<Part supply as ASP> Supplied as the Printer

Mechanism <Lubrication status when

supplied as ASP> Lubricated

1. Contact point (x1) on the upper side of the Main Frame Assy with the CR Unit

2. Contact points (x4) on the lower side of the Main Frame Assy with the CR Unit

<Type> G-71

<Application Amount> Appropriate amount

<Remarks> Apply with injector.

Figure 4-8. Lubrication of the Frame Base (3)

Maintenance Lubrication Points and Instructions 71

Figure 4-10. Lubrication of the Main Frame Assy

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Hopper

Application Point

CR Driven Pulley Holder

2. Application Point

1. Application Point

LD Roller Assy

EJ Roller Gear

Application Point

Frame Base

EJ Roller

Application Point

EJ Roller Gear

Application Point

Paper Back Lever

Application Point

Bevel Gear Shaft 10.4

Application Point

<Part supply as ASP> Yes <Lubrication status when

supplied as ASP> Not lubricated

<Lubrication Point> Contact point on the

Hopper with the Frame Base

<Type> G-74

<Application Amount> Appropriate amount

 Apply with flu x

dispenser.

 Stir G-74 before use.

<Part supply as ASP> None <Lubrication status when

supplied as ASP>

--<Lubrication Point>

On the bearings (x2) of the

1. CR Driven Pulley on the CR Driven Pulley Holder

2. Contact points (x6) on the groove of the CR Driven Pulley Holder with the Main Frame

<Type> G-71

<Application Amount> Appropriate amount

 Apply with injector.  Check the lubrication

condition and apply grease if necessary.

<Part supply as ASP> Supplied as the LD Roller

Shaft <Lubrication status when

supplied as ASP> Not lubricated

<Lubrication Point> Cam of the contact point

with the Hopper/Paper Back Lever (x2)

<Type> G-71

<Application Amount> φ 1 mm x Appropriate

amount <Remarks>

 Apply with injector.  Apply before attaching

the LD Roller Assy.

 After applying to the

specified position, rotate the EJ Roller Gear to spread the grease.

Figure 4-11. Lubrication of the Hopper

<Part supply as ASP> Yes <Lubrication status when

supplied as ASP> Not lubricated

<Lubrication Point> Contact point (x1 on the

shaft) on the EJ Roller with the Frame Base

<Type> G-71

0.06 g <Remarks>

 Apply with injector.  Lubricate before

attaching the part.

Figure 4-12. Lubrication of the CR Driven Pulley Assy

<Part supply as ASP> Yes <Lubrication status when

supplied as ASP> Not lubricated

<Lubrication Point> Shaft on the EJ Roller

Gear <Type>

G-71 <Application Amount>

φ 1 mm x 1 circle <Remarks>

 Using in jector, apply

grease along the tier on the shaft.

 Lubricate bef ore

attaching the part.

Figure 4-13. Lubrication of the LD Roller Assy

<Part supply as ASP> Yes <Lubrication status when

supplied as ASP> Not lubricated

<Lubrication Point> Contact points (x2) on the

Paper Back Lever with the Frame Base

<Type> G-71

0.06 g x 2 points <Remarks>

 Apply with injector.  Lubricate before

attaching the part.

<Part supply as ASP> Yes <Lubrication status when

supplied as ASP> Not lubricated

<Lubrication Point> Shaft on the Bevel Gear

Shaft 10.4 <Type>

G-71 <Application Amount>

Appropriate amount <Remarks>

 Apply with injector.  Lubricate before

attaching the part.

Figure 4-14. Lubrication of the EJ Roller Figure 4-15. Lubrication of the EJ Roller Gear

Maintenance Lubrication Points and Instructions 72

Figure 4-16. Lubrication of the Paper Back Lever Figure 4-17. Lubrication of the Bevel Gear Shaft 10.4

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CHAPTER 5

REFURBISHMENT

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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series

5.1 Overview

This chapter provides the refurbishing work of the printer and its purpose.

5.1.1 Ink Discharge

 Purpose To clean the ink path inside the Printhead to restore its condition identical to the factory default.

 Jigs Required jigs and cleaning liquid for cleaning the ink path is as follows.

Name Category EPSON Part Code

Ink Supply Jig Jig 20MJ11206

CSIC Chip (Bk) Jig 2011900JP1

CSIC Chip (C) Jig 2011900JP2 CSIC Chip (M) Jig 2011900JP3 CSIC Chip (Y) Jig 2011900JP4

Shipping Liquid (CR06, 18kg) Cleaning Liquid 6104714

Shipping Liquid (CR06, 1kg) Cleaning Liquid 6104713

I/P, DPIC009BSP, 110, PRINTING Ink Pack 1462531

Revision B

 Operation of the Adjustment Program for refurbishment when performing the ink discharge Ink discharge can be done by selecting and running “Ink Discharge” from the Adjustment Program for

refurbishment with the jig set on the printer. At this point, the factory default values except the adjustment-related setting values are written on the EEPROM

on the Main Board of the printer. This is performed in order to erase the personal information including the network settings and the operating information of the printer before refurbishment, etc.

This default value restoration is automatically done when performing the ink discharge by the Adjustment Program for refurbishment automatically.

 For the details of how to set the jigs for refurbishment and how to use the Adjustment

Program (for refurbishment), see guide in the Adjustment Program (for refurbishment).

 Approximately four minutes are necessary for completing the Ink Discharge.

Refurbishment Overview 74

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CHAPTER 6

APPENDIX

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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series

CN501 CN1 CN14

CN2

CN9 CN7CN13CN12

CN61 CN11

CN102

Printhead

CIS

PE Sensor

CR Motor

SCN Motor

PF Motor

USB

CN3

CN2

CN4

PF Encoder

CR Encoder

WiFi Board

AC in

PS Board

CN3

USB Board

Main Board

ADF / Scanner Unit

CN1

Panel Board

LCD

CN1

Panel Board

CN1

Panel Board

CN1

CN2

CSIC

CR Contact Module

CR Unit

Panel Unit

2.5 inch LCD type

2 Line Bitmap type

LCD & Button type

Ethernet Board

FAX Board

CN5

PIS Board

6.1 Connector Diagram

Cable connections of this printer are shown below. For the function differences of each model, refer to " Function List According to Models (p28)".

Revision B

Figure 6-1. Connector Diagram

Appendix Connector Diagram 76

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Align the bottom

of the CR Unit.

CR Unit

Multifunction Printer

2 ± 1 mm

Ink replacement label

Strong tape

CR UnitChange Lever

Housing Right

Strong tape

6.2 Protection for Transportation

This section describes the cautions for packing the printer before returning it to the user.

6.2.1 Securing the CR Unit

 Purpose

To prevent damaging the Change Lever by shock during transportatio n.

 Risks if it is not performed

Fatal error caused by the damage of the Change Lever.

 Preparation

Prepare a piece of strong tape

Multifunction Printer



Length: 180 mm, width: 14 mm, fold one end 5 ± 2 mm.

 Singlefunction Printer

Length: 180 mm, width: 22 mm, fold one end 5 ± 2 mm.

 Method

 In order to prevent damaging the Change Lever, the CR Unit should be secured at the

position indicated in Step 2. Therefore, when securing the CR Unit with strong tape, hold the Timing Belt to keep the position of the CR Unit as is and avoid the CR Unit from moving to the 0-digit side.

 When securing the CR Unit of the multifunction printer, attach the strong tape so that the

gap between the strong tape and ink replacement label attached on the Housing Right is 2 ± 1 mm.

Revision B

1. Turn off the printer to set the CR Unit to its home position.

2. Pull the CR Timing Belt, and move the CR Unit to the 80-digit side slightly so that the CR Unit can touch the side of the tip on the Change Lever.

3. Attach the not-folded end of strong tape on the bottom of the CR Unit.

4. Attach the strong tape on to the Housing Right, and secure the CR Unit.

Figure 6-2. Securing the CR Unit

Appendix Protection for Transportation 77

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Diagram B

Paper Support Sub

Folded ends

Diagram A

Folded ends

Paper Support

Housing Left

Strong tape

6.2.2 Securing the Paper Support/Paper Support Sub

 Purpose

To prevent damaging the Paper Support/Paper Support Sub by the shock during transportation.

 Risks if it is not performed

The Paper Support/Paper Support Sub will be scratched and the abrasion powder will be produced due to the shock during transportation.

 Preparation

Prepare two pieces of strong tape



Multifunction Printer

• 1) Length: 60 mm, width: 22 mm, fold one end 5 ± 2 mm.

• 2) Length: 50 mm, width: 22 mm, fold one end 5 ± 2 mm.



Singlefunction Printer (3 tapes)

• Length: 80 mm, width: 16 mm, fold one end 5 ± 2 mm.

 Method



Multifunction Printer

1. Attach the strong tape 1) to the position on the following diagram A and secure the Paper Support Sub.

2. Attach the strong tape 2) to the position on the following diagram B and secure the Paper Support.

Revision B

Figure 6-3. Securing the Paper Support/Paper Support Sub (Multifunction Printer)

Appendix Protection for Transportation 78

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Rear

Paper Support/ Paper

Support Sub

Folded ends

Paper Support/ Paper

Support Sub

Strong tape

Singlefunction Printer



Attach the strong tape (3 tapes) to the position on the following diagram and secure the Paper Support/ Paper Support Sub on the Housing Upper Assy.

Revision B

Figure 6-4. Securing the Paper Support/Paper Support Sub (Singlefunction Printer)

Appendix Protection for Transportation 79

Confidential

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

Specifications and Main Features

Frequently Asked Questions

User Manual

TROUBLESHOOTING

1.1 Troubleshooting

1.1.1 Troubleshooting Workflow

1.2 Power-On Sequence

1.3 Fatal Error Code List

1.3.1 Displaying the Fatal Error Code

1.3.2 Printer Fatal Error Code

1.3.3 Scanner Fatal Error Code

DISASSEMBLY/REASSEMBLY

2.1 Overview

2.1.1 Tools

2.1.2 Jigs

2.1.2.1 Making the Spring Hook Jig

2.1.3 Locations of the Parts/Units

2.1.4 Standard Operation Time for Servicing the Product

2.2 Disassembly/Reassembly Procedures

2.2.1 Configuration

2.2.2 Disassembly Flowchart

2.2.2.1 Multifunction Printer specific parts

2.2.2.2 Singlefunction Printer specific parts

2.2.2.3 Common Printer Mechanism

2.2.2.4 Unit/Assy

2.2.3 Disassembly Flowchart (Printhead/Main Board)

2.3 Detailed Disassembly/Reassembly Procedure for each Part/Unit

2.4 Routing FFCs/cables

ADJUSTMENT

3.1 Required Adjustments

3.2 Adjustment Program

3.2.1 Operating Environment

3.2.2 Details of the Adjustment Program

3.2.2.1 CR Motor Heat Protection Control / PF Motor Heat Protection Control

3.2.2.2 Scanner Motor Heat Protection Control

3.2.2.3 PIS Board Check

3.3 Mechanism Adjustment / Check

3.3.1 Checking the Platen Gap

3.3.2 CR/PF Belt Tension Check

MAINTENANCE

4.1 Overview

4.1.1 Cleaning

4.1.2 Lubrication

4.2 Lubrication Points and Instructions

REFURBISHMENT

5.1 Overview

5.1.1 Ink Discharge

APPENDIX

6.1 Connector Diagram

6.2 Protection for Transportation

6.2.1 Securing the CR Unit

6.2.2 Securing the Paper Support/Paper Support Sub