Service Manual TX 620 W

SERVICE MANUAL
Color Inkjet Printer
WorkForce 635/Epson Stylus Office TX620FWD/Epson Stylus Office BX625FWD/

Epson ME OFFICE 960FWD
Work Force 633/Work Force 630/Epson Stylus SX620FW
Work Force 645/Epson Stylus Office BX635FWD/
WorkForce 545/Epson Stylus Office BX630FW/Epson ME OFFICE 940FW
WorkForce 625/Epson Stylus NX625/TX560WD/SX525WD/
Epson Stylus Office BX525WD/Epson ME OFFICE 900WD
Epson Stylus NX530/SX535WD/NX635/Epson Stylus Office BX535WD
WorkForce 60/T42WD/Epson Stylus Office B42WD/Epson ME OFFICE 82WD
Epson ME OFFICE 85ND
CONFIDENTIAL
SEMF09-016
Notice:
 All rights reserved. No part of this manual may be reproduced, stored in a retrieval system, or transmitted in any form or
by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of
SEIKO EPSON CORPORATION.
 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 registered
trademarks of their respective owners. EPSON disclaims any and all rights in those marks.
Copyright 2011 SEIKO EPSON CORPORATION

I & I CS Quality Assurance Department
Confidential
Safety Precautions
All safety procedures described here shall be strictly adhered to by all parties servicing and maintaining this
product.
DANGER
Strictly observe the following cautions. Failure to comply could result in serious bodily injury or loss of life.
1. Always disconnect the product from the power source and peripheral devices when servicing the product or
performing maintenance.
2. When performing works described in this manual, do not connect to a power source until instructed to do so.
Connecting to a power source causes high voltage in the power supply unit and some electronic components
even if the product power switch is off. If you need to perform the work with the power cable connected to a
power source, use extreme caution to avoid electrical shock.
WARNING
Strictly observe the following cautions. Failure to comply may lead to personal injury or loss of life.
1. Always wear protective goggles for disassembly and reassembly to protect your eyes from ink in working. If
any ink gets in your eyes, wash your eyes with clean water and consult a doctor immediately.
2. When using compressed air products; such as air duster, for 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. In order to protect sensitive microprocessors and circuitry, use static discharge equipment, such as anti-static
wrist straps, when accessing internal components.
6. 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.
7. 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.
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8. When disassembling or assembling this product, make sure to wear gloves to avoid injuries from metal parts
with sharp edges.
9. Use only recommended tools for disassembling, assembling or adjusting the printer.
10. Observe the specified torque when tightening screws.
11. 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
12. 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.
13. Apply the specified amount of grease described in this manual.
14. Make the specified adjustments when you disassemble the printer.
15. When cleaning this product, follow the procedure described in this manual.
16. 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.
17. Make sure to install antivirus software in the computers used for the service support activities.
18. Keep the virus pattern file of antivirus software up-to-date.
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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. 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 2. ADJUSTMENT
Describes the required adjustments for servicing the product.
CHAPTER 3. MAINTENANCE
Describes maintenance items and procedures for servicing the product.
CHAPTER 4. APPENDIX
Provides the following additional information for reference:
 Power-On Sequence
 Connector Diagram
 Troubleshooting
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 1 “Disassembly/Reassembly”, symbols other than indicated above are used to show additional
information for disassembly/reassembly. For the details on those symbols, see "1.2 Disassembly/Reassembly
Procedures (p14)".
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Revision Status
Revision Date of Issue Description
A April 28, 2010 First Release

B August 6, 2010 Revised Contents
 Chapter 1
 "1.1.2 Jigs (p13)" has been added.
 The Stopper Assy has been added and made change in "Table 1-1 Standard Operation
Time (WorkForce 635 series) (p15)" of "1.2.1 Standard Operation Time for servicing
the product (p15)".
 Made change in "Table 1-2 Standard Operation Time (WorkForce 625 series) (p16)" of
"1.2.1 Standard Operation Time for servicing the product (p15)".
 Made change in "1.2.2 Disassembly/Reassembly Flowchart (p19)".
 Made change in "1.3 Detailed Disassembly/Reassembly Procedure for each Part/Unit
(p24)".
• Made change in " Document Pad (WorkForce 635/625 series) (p24)".
• Made change in " Left Housing/Right Housing (WorkForce 635/625 series) (p24)".
• Made change in " Panel Unit (WorkForce 635/625 series) (p24)".
• Made change in " Lower Panel Housing (WorkForce 635/625 series) (p24)".
• Made change in " Panel Board (WorkForce 635/625 series) (p25)".
• Made change in " Ink System Assy (p25)".
• Made change in " FAX Shield Plate/FAX Connector Cover (WorkForce 635 series)
(p25)".
• Made change in " Star Wheel Assy (p25)".
• Made change in " Main Board Unit (WorkForce 635/625 series) (p26)".
• Made change in " Front Frame (p26)".
• Made change in " Main Frame (w/ CR Assy) (p26)".
• Made change in " Printhead (p26)".
• Made change in " ADF Unit (WorkForce 635 series) (1) (p27)".
• Made change in " ADF Unit (WorkForce 635 series) (2) (p27)".
• " Paper Guide Front Assy (installation using the tools) (p28)" has been added.
• " Paper Guide Front Assy (Stopper Holder Idle Roller) (p28)" has been added.
• " LCD (WorkForce 635/625 series) (p28)" has been added.
• Made change in " Front Paper Guide Waste Ink Pad (p28)".
• " Stopper Assy (WorkForce 625 series) (p28)" has been added.
 Made change in "1.4 Routing FFCs/cables (p30)".
• Made change in " Inside the USB Cover (WorkForce 635 series) (p30)".
• Made change in " Panel Unit (WorkForce 635 series) (p30)".
• Made change in " Scanner FFC/Scanner Motor Cable (WorkForce 635/625 series)
(p30)".
• Made change in " P/S Board Assy (WorkForce 635/625 series) (p30)".
• Made change in " FAX Assy (WorkForce 635 series) (p30)".
• Made change in " Head FFC (p31)".
• Made change in " Main Board (WorkForce 635 series) (p31)".
• Made change in " PF Motor (p31)".
• Made change in " PE Sensor (p31)".
• Made change in " Inside the USB Cover (WorkForce 625 series) (p32)".
• Made change in " Main Board (WorkForce 625 series) (p32)".
• Made change in " Panel Unit (WorkForce 625 series) (p31)".
 Chapter 2
 Made change in "2.1 Required Adjustments (p34)".
 "2.2.1 PF Timing Belt Tension Measurement/PF Belt Step Check (p40)" has been
added.
 "2.2.2 Checking the Platen Gap (p43)" has been added.
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B August 6, 2010  Chapter 3

 Made change in "3.1.2 Lubrication (p46)".
 Made change in "3.2 Lubrication Points and Instructions (p48)".
• Made change in "Fig. 3-1 Lubrication of the Driven Pulley Holder (p48)".
• Made change in "Fig. 3-2 Lubrication of the Paper Guide Front Assy (PF Roller) (p48)".
• Made change in "Fig. 3-3 Lubrication of the Paper Guide Front Assy (EJ Roller) (p48)".
• Made change in "Fig. 3-5 Lubrication of the PF Holder (p48)".
• Made change in "Fig. 3-6 Lubrication of the Main Frame (1) (p49)".
• Made change in "Fig. 3-8 Lubrication of the EJ Pulley (p49)".
• Made change in "Fig. 3-9 Lubrication of the Ink System Assy (1) (p49)".
• Made change in "Fig. 3-10 Lubrication of the Ink System Assy (2) (p49)".
• Made change in "Fig. 3-11 Lubrication of the CR Assy (p49)".
• Made change in "Fig. 3-12 Lubrication of the Scanner Unit (WorkForce 635/625 series) (p50)".
• "Fig. 3-15 Lubrication of the Stopper Assy (WorkForce 625 series) (p51)" has been added.
 Chapter 4
 Made change in "4.1 Power-On Sequence (p53)".
 "4.3 Troubleshooting (p57)" has been added.
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C October 12, 2010 Revised Contents

 All chapters
Information of Epson WorkForce 60/T42WD/Epson Stylus Office B42WD/
Epson ME OFFICE 82WD/Epson ME OFFICE 85ND has been added.
 Chapter 1
 Production name has been added in "1.1 Overview (p12)".
 Made change in "1.1.2 Jigs (p13)".
 Made change in "1.2 Disassembly/Reassembly Procedures (p14)".
 Made change in "1.2.1 Standard Operation Time for servicing the product (p15)".
• "1-3 Standard Operation Time (WorkForce 60 series) (p17)" has been added.
 Made change in "1.2.2 Disassembly/Reassembly Flowchart (p19)".
• Made change in "1.2.2.1 Housing Part (WorkForce 635 series/WorkForce 625 series) (p19)".
• "1.2.2.2 Housing Part (WorkForce 60 series) (p21)" has been added.
• Made change in "1.2.2.3 Printer Mechanism Part (p22)".
 Made change in "1.3 Detailed Disassembly/Reassembly Procedure for each Part/Unit (p24)".
• Production name has been added in " USB Cover (WorkForce 635/625 series) (p24)".
• Production name has been added in " Decoration Plate (WorkForce 635/625 series) (p24)".
• Production name has been added in " Document Pad (WorkForce 635/625 series) (p24)".
• Production name has been added in " Left Housing/Right Housing (WorkForce 635/625
series) (p24)".
• Production name has been added in " Panel Unit (WorkForce 635/625 series) (p24)".
• Production name has been added in " Upper Housing (w/ Panel Unit) (WorkForce 635/
625 series) (p24)".
• Production name has been added in " Lower Panel Housing (WorkForce 635/625 series) (p24)".
• Production name has been added in " Panel Board (WorkForce 635/625 series) (p25)".
• Made change in " CR Scale/Extension Spring (p25)".
• Production name has been added in " Shield Plate (w/ Wireless LAN Module)
(WorkForce 635/625 series) (p25)".
• Production name has been added in " Wireless LAN Module (p25)".
• Production name has been added in " Main Board Unit (WorkForce 635/625 series) (p26)".
• Production name has been added in " CIS Unit (WorkForce 635/625 series) (p26)".
• Made change in " Paper Guide Front Assy (installation using the tools) (p28)".
• Made change in " Paper Guide Front Assy (Stopper Holder Idle Roller) (p28)".
• Production name has been added in " LCD (WorkForce 635/625 series) (p28)".
• " Front Cover (WorkForce 60 series) (p29)" has been added.
• " USB Cover (WorkForce 60 series) (p29)" has been added.
• " Upper Housing (WorkForce 60 series) (p29)" has been added.
• " Stacker Assy (WorkForce 60 series) (p29)" has been added.
• " Main Board Unit (WorkForce 60 series) (p29)" has been added.
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C October 12, 2010  Made change in "1.4 Routing FFCs/cables (p30)".
• Production name has been added in " Cover Open Sensor (WorkForce 635/625 series) (p30)".
• Production name has been added in " Scanner FFC/Scanner Motor Cable (WorkForce 635/625
series) (p30)".
• Production name has been added in " P/S Board Assy (WorkForce 635/625 series) (p30)".
• Production name has been added in " PF Encoder Sensor (WorkForce 635/625 series) (p31)".
• " Main Board (WorkForce 60 series) (p32)" has been added.
 Chapter 2
 Made change in "2.2.1 PF Timing Belt Tension Measurement/PF Belt Step Check
(p40)".
 Chapter 3
 Made change in "3.2 Lubrication Points and Instructions (p48)".
• Production name has been added in "3-12 Lubrication of the Scanner Unit (WorkForce
635/625 series) (p50)".
• Production name has been added in "3-13 Lubrication of the Duplex Unit (p50)".
• Production name has been added in "3-15 Lubrication of the Stopper Assy (WorkForce
625 series) (p51)".
 Chapter 4
 Made change in "4.2 Connector Diagram (p56)".
 Made change in "4.3.1 Troubleshooting Workflow (p57)".
 Made change in "4.3.2 Fatal Error Code (p59)".
C November 24,  Chapter 1
2010  1.2.1Standard Operation Time for servicing the product Table 1-1 on page 13-14
Standard Operation Time(WorkForce 635 series) is added.
 1.2.1Standard Operation Time for servicing the product Table 1-2 on page 14-15
 1.2.1Standard Operation Time for servicing the product Table 1-3 on page 15
D December 17,  Add product name(WorkForce630/WorkForce633/StylusNX625/SX620FW).
2010  Delete product name(WorkForce620).
E June 21,2011 Revised Contents
 Chapter 1
 1.2.1Standard Operation Time for servicing the product Table 1-1 on page 15-18
Standard Operation Time(Adjustment & Total time) is added.
 Made change in “Paper guide front supporting tools (A) size for WorkForce625
series(A)”(p28).
 About the directions for a tools (Comment postscript p28).
 All Chapters
 The model name “WorkForce 645/545/Epson Stylus office BX630FW/BX635FWD/
Epson Stylus NX530/SX535WD/BX535WD/NX635/Epson ME OFFICE 940FW” are
added, and revision is changed.
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Epson WorkForce 635/620/60 series Revision E
Contents
Chapter 1 Disassembly/Reassembly
1.1 Overview ................................................................................................................................................................. 12

1.1.1 Tools ............................................................................................................................................................... 12
1.1.2 Jigs .................................................................................................................................................................. 13
1.2 Disassembly/Reassembly Procedures ..................................................................................................................... 14
1.2.1 Standard Operation Time for servicing the product ....................................................................................... 15
1.2.2 Disassembly/Reassembly Flowchart .............................................................................................................. 19
1.2.2.1 Housing Part (WorkForce 635 series/WorkForce 625 series) ............................................................... 19
1.2.2.2 Housing Part (WorkForce 60 series) ..................................................................................................... 21
1.2.2.3 Printer Mechanism Part ......................................................................................................................... 22
1.3 Detailed Disassembly/Reassembly Procedure for each Part/Unit........................................................................... 24
1.4 Routing FFCs/cables ............................................................................................................................................... 30
Chapter 2 Adjustment
2.1 Required Adjustments ............................................................................................................................................. 34

2.2 Details of Adjustments ............................................................................................................................................ 40
2.2.1 PF Timing Belt Tension Measurement/PF Belt Step Check .......................................................................... 40
2.2.2 Checking the Platen Gap ................................................................................................................................ 43
2.2.3 MAC Address Setting..................................................................................................................................... 44
Chapter 3 Maintenance
3.1 Overview ................................................................................................................................................................. 46

3.1.1 Cleaning.......................................................................................................................................................... 46
3.1.2 Lubrication...................................................................................................................................................... 46
3.2 Lubrication Points and Instructions......................................................................................................................... 48
Chapter 4 Appendix
4.1 Power-On Sequence ................................................................................................................................................ 53

4.2 Connector Diagram ................................................................................................................................................. 56
4.3 Troubleshooting....................................................................................................................................................... 57
4.3.1 Troubleshooting Workflow ............................................................................................................................ 57
4.3.2 Fatal Error Code ............................................................................................................................................. 59
10
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CHAPTER 1
DISASSEMBLY/REASSEMBLY
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1.1 Overview
This chapter describes procedures for disassembling the main parts/units of WorkForce 635 series, WorkForce
625 series and WorkForce 60 series. Unless otherwise specified, disassembled parts/units can be reassembled by
reversing the disassembly procedure. See the cautions or tips for disassembly/reassembly described in "1.3
Detailed Disassembly/Reassembly Procedure for each Part/Unit (p24)".
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).
In this chapter, the product names are called as follows:

 WorkForce 635 series:WorkForce 635/Epson Stylus Office TX620FWD/Epson Stylus
Office BX625FWD/Epson ME OFFICE 960FWD
WorkForce 545/Epson Stylus Office BX630FW/Epson ME
OFFICE 940FW
 WorkForce 625 series:WorkForce 625/Epson Stylus NX625/TX560WD/SX525WD/
Epson Stylus NX530/SX535WD/NX635/Epson Stylus Office
BX535WD
 WorkForce 60 series: WorkForce 60/T42WD/Epson Stylus Office B42WD/
Epson ME OFFICE 82WD/Epson ME OFFICE 85ND
1.1.1 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
Nippers O ---
Note 1: Some of the tools listed above are commercially available.

2: EPSON provides the tools listed with EPSON part code.
Disassembly/Reassembly Overview 12
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1.1.2 Jigs
Name Q’ty EPSON Part Code
Paper guide front supporting tool (A)* 1 WorkForce 635 series: 1543170
WorkForce 625 series: 1543171
Paper guide front supporting tool (B)* 1 WorkForce 635 series: 1543539
Paper guide front supporting tool (C)* 3 WorkForce 635 series: 1543541
Printhead supporting tool 2 1543169
Note *: The required tools differ between WorkForce 635 series, WorkForce 625 series and WorkForce 60 series. Be careful not to mix
up the tools.
Disassembly/Reassembly Overview 13
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1.2 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 "1.3 Detailed Disassembly/Reassembly Procedure for each Part/Unit (p24)".)
For routing cables, see "1.4 Routing FFCs/cables (p30)".
The example below shows how to see the charts on the following pages.
Ref.
White letters indicate a part/
Explanation available in the Ink System Assy unit supplied as an ASP.
Reference Guide
1
Shows the screw types and
S4 1 the specified torque in the
“Screw type/torque list”.
(p 25) (p 49)
Reference page
USB Cover
Black letters indicate a part/
unit not supplied as an ASP. 1
S3 2
(p 24) (p 30) Shows removal/installation

as a unit/assy. is available.
Item Description Reference

White-letter Part/unit supplied as an ASP ---
Parts/unit name
Black-letter Part/unit not supplied as an ASP ---
Indicates a practice or condition that could result in Indicates the reference
injury or loss of life if not strictly observed. page in blue-letter
Indicates a practice or condition that could result in
Indicates the reference
damage to, or destruction of equipment if not strictly
page in blue-letter
observed.
Indicates the parts that are inevitably broken in the
disassembling procedure, and should be replaced with ---
a new one for reassembly.
Indicates necessary check items in the disassembling/ Indicates the reference
assembling procedure. page in blue-letter
Indicates supplementary explanation for disassembly Indicates the reference
is given. page in blue-letter
Icon
Indicates particular tasks to keep quality of the units Indicates the reference
are required. page in blue-letter
Indicates the reference
Indicates particular routing of cables is required.
page in blue-letter
Chapter 2 " Adjustment
Indicates particular adjustment(s) is/are required.
(p33)"
Chapter 3 " Maintenance
Indicates lubrication is required.
(p45)"
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.
Disassembly/Reassembly Disassembly/Reassembly Procedures 14

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1.2.1 Standard Operation Time for servicing the product

The following are the standard operation time for servicing the product. Those are based on the MTTR result
measured using a prototype.
The underlined parts/units are supplied as After Service Parts.
 Standard Operation Time for servicing WorkForce 635 series: See Table 1-1
Table 1-1. Standard Operation Time (WorkForce 635 series)
Time (second) Time (second)
Parts/Unit Replace- Adjust- Parts/Unit Replace- Adjust-
Total Total
ment ment ment ment
USB Cover 32 0 32 Main Frame (w/ CR Assy) 1140 937 2077
ADF Unit/Scanner Unit 272 0 272 Upper Paper Guide 1181 657 1838
Scanner Unit 392 0 392 PE Holder Assy 1230 302 1532
CIS Unit 505 0 505 CR Motor 1255 70 1325
ADF Unit 392 0 392 CR Scale Holder 1164 0 1164
Front ADF Cover 466 0 466 CR Assy 1190 570 1760
Hinge Cover
Top ADF Cover 470 0 470 Cartridge/Cartridge 517 0 517
Cover
Right ADF Cover 505 0 505 I/C Guide 523 0 523
Inner Head Cable
Rear ADF Cover 425 0 425 556 0 556
Cover
ADF Document
402 402 Printhead 646 1152 1798
Support
ADF Cover Assy 12 0 12 Holder Board Assy 508 0 508
ADF Pad Assy 17 0 17 CSIC Terminal 535 0 535
CR Contact
Document Pad 23 0 23 524 0 524
Module
Decoration Plate 34 0 34 Holder Board 551 0 551
Left Housing 61 0 61 Head FFC 1267 0 1267
Hinge 287 0 287 Front Frame 1167 570 1737
Upper Housing
484 0 484 Star Wheel Assy 1192 249 1441
(w/ Panel Unit)
Upper Housing 518 0 518 Paper Guide Front Assy 1304 735 2039
Front Paper Guide
Cover Open Sensor 518 0 518 1308 0 1308
Waste Ink Pad
Duplex Unit 8 411 419 EJ Pulley 1208 43 1251
Right Housing 52 0 52 EJ Roller 1229 454 1683
PF Holder/PF Timing
Panel Unit 183 0 183 1387 43 1430
Belt
Panel Gear 200 0 200 PF Motor 1429 87 1516
Panel Lever 200 0 200 Frame Base Assy 1359 859 2218
Lower Paper Guide
Lower Panel Housing 299 0 299 1363 14 1377
Waste Ink Pad
Panel Board 318 0 318 PE Sensor 1332 53 1385
LCD 366 0 366 Stacker Assy 1327 0 1327
Button 464 0 464 Frame Base 1304 0 1304
Extension Spring
Upper Panel Housing 512 0 512 529 0 529
(Upper Paper Guide)
Cassette Assy 8 135 143 CR Scale 565 0 565
Driven Pulley/Extension
Pickup Assy 24 0 24 641 0 641
Spring
Waste Ink Tray Assy 35 14 49 Cam Holder Assy 503 0 503
Paper Sheet Assy 13 114 127 Extension Spring 566 0 566

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Total Total
ment ment ment ment
FAX Grounding Plate 521 0 521 FAX Assy 560 0 560
FAX Shield Plate/
PF Encoder Sensor 829 0 829 625 0 625
FAX Connector Cover
Main Board Unit 800 1144 1944 Fax Board 625 0 625
Shield Plate
949 0 949 Right Frame 496 0 496
(w/ Wireless LAN Module)
Wireless LAN Module 838 0 838 Ink System Assy 540 0 540
Waste Ink Pad
Main Board 987 0 987 575 0 575
(Bottom of Ink System Assy)
P/S Board Assy 529 0 529

Total Total
ment ment ment ment
Scanner Unit 147 0 147 Upper Paper Guide 1025 527 1552
CIS Unit 236 0 236 PE Holder Assy 1074 402 1476
Document Cover 21 0 21 CR Motor 1099 62 1161
Document Pad 23 0 23 CR Scale Holder 1006 0 1006
Decoration Plate 40 0 40 CR Assy 1032 441 1473
Hinge Cover
Left Housing 67 0 67 Cartridge/Cartridge 396 0 396
Cover
Hinge 162 0 162 I/C Guide 402 0 402
Upper Housing Inner Head Cable
365 0 365 435 0 435
(w/ Panel Unit) Cover
Upper Housing 503 0 503 Printhead 525 1023 1548
Cover Open Sensor 399 0 399 Holder Board Assy 389 0 389
Duplex Unit 8 316 324 CSIC Terminal 440 0 440
CR Contact
Right Housing 58 0 58 401 0 401
Module
Panel Unit 189 0 189 Holder Board 428 0 428
Panel Gear/Panel Lever 216 0 216 Head FFC 1109 0 1109
Lower Panel Housing 286 0 286 Front Frame 1011 441 1452
Panel Board 383 0 383 Star Wheel Assy 1036 201 1237
LCD 431 0 431 Paper Guide Front Assy 1036 634 1670
Front Paper Guide
LCD Cover 433 0 433 1148 0 1148
Waste Ink Pad
Button 447 0 447 EJ Pulley 1207 43 1250
Upper Panel Housing 497 0 497 EJ Roller 1052 359 1411
PF Holder/PF Timing
Cassette Assy 8 115 123 1273 78 1351
Belt
Pickup Assy 24 0 24 PF Motor 1273 78 1351
Waste Ink Tray Assy 35 7 42 Frame Base Assy 1148 892 2040
Lower Paper Guide
Main Board Unit 644 774 1418 1152 7 1159
Waste Ink Pad
Shield Plate
(w/ Wireless LAN 739 0 739 PE Sensor 1176 201 1377
Module)

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Total Total
ment ment ment ment
Wireless LAN Module 682 0 682 Stacker Assy 1171 0 1171
Main Board 739 0 739 Frame Base 1203 709 1912
Extension Spring
PF Encoder Sensor 673 0 673 410 0 410
(Upper Paper Guide)
Right Frame 377 0 377 CR Scale 446 0 446
Driven Pulley/Extension
Ink System Assy. 421 0 421 406 0 406
Spring
Waste Ink Pad
437 0 437 Cam Holder Assy 384 0 384
(Bottom of Ink System Assy)
P/S Board Assy 410 97 507 Extension Spring 379 0 379
Stopper Assy 0

Total Total
ment ment ment ment
Printer Cover 9 0 9 Upper Paper Guide 566 657 1223
Upper Housing
162 0 162 PE Holder Assy 592 302 894
(w/ Printer Cover)
Upper Housing 171 0 171 CR Motor 627 70 697
Duplex Unit 4 411 415 CR Scale Holder 570 0 570
Cassette Assy 4 135 139 CR Assy 601 570 1171
Hinge Cover
Pickup Assy 25 0 25 Cartridge/Cartridge 193 0 193
Cover
Waste Ink Tray Assy 24 14 38 I/C Guide 199 0 199
Inner Head Cable
Stacker Assy 128 0 128 208 0 208
Cover
Front Cover 13 0 13 Printhead 279 1152 1431
Panel Unit 44 0 44 Holder Board Assy 179 0 179
Panel Board 101 0 101 CSIC Terminal 230 0 230
CR Contact
LED Lens 94 0 94 191 0 191
Module
Button 126 0 126 Holder Board 242 0 242
Front Panel Cover 126 0 126 Head FFC 632 0 632
Stacker Open Sensor 56 0 56 Paper Guide Front Assy 716 735 1451
Front Paper Guide
Main Board Unit 348 1144 1492 847 0 847
Waste Ink Pad
Wireless LAN Module 392 0 392 EJ Pulley 616 43 659
Shield Plate
581 0 581 EJ Roller 624 454 1078
(w/ Cover Open Sensor)
PF Holder/PF Timing
Main Board 581 0 581 750 43 793
Belt
Cover Open Sensor 354 0 354 PF Motor 822 87 909
PF Encoder Sensor 361 0 361 Frame Base Assy 716 859 1575
Lower Paper Guide
Front Frame 583 570 1153 721 14 735
Waste Ink Pad

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Total Total
ment ment ment ment
Star Wheel Assy 609 249 858 PE Sensor 768 53 821
CR Scale 195 0 195 Frame Base 773 0 773
Driven Pulley/Extension Extension Spring
252 0 252 201 0 201
Spring (Upper Paper Guide)
Right Frame 170 0 170 Cam Holder Assy 200 0 200
Ink System Assy 223 0 223 Extension Spring 219 0 219
Waste Ink Pad
(Bottom of Ink System 228 0 228 Power Supply Unit 83 0 83
Assy)

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1.2.2 Disassembly/Reassembly Flowchart

1.2.2.1 Housing Part (WorkForce 635 series/WorkForce 625 series)
START
USB Cover Decoration Plate Waste Ink Tray

Duplex Unit Assy Cassette Assy Stacker Assy Paper Sheet Assy ADF Cover Assy ADF Pad Assy
1 --- 3 1 --- --- --- --- ---
S3 2 --- S4 6 S3 4 --- 4 1 2 4
(p 24) (p 30) (p 35) (p 24) (p 35) (p 35) --- --- (p 27) (p 27)
ADF Unit/ Document Pad

Scanner Unit Left Housing Right Housing Pickup Assy Stopper Assy Document Cover Document Pad
Scanner Unit
2 1 1 1 --- 2 --- --- ---
S3 S8 --- S3 --- S4 2 S4 2 1 S4 2 4 --- ---
(p 30) (p 32) (p 24) (p 24) --- (p 28) (p 51) (p 24) (p 24) (p 24)
Hinge Panel Unit Panel Unit

1
1 3 3
(p 20)
S4 --- S4 6 S4 6
--- (p 24) (p 30) (p 24) (p 31)
Decoration Plate
2
Left Housing WorkForce 635 series specific parts/unit
(p 20)
Right Housing WorkForce 625 series specific parts/unit
WorkForce 635 series/

WorkForce 625 series common parts/unit
Upper Housing
(w/ Panel Unit)
Screw type/torque list
4 3 (p 20)
Symbol Screw type Torque
---
4 1 kgf·cm
S4
S1 C.B.P-TITE SCREW,2.5X8,F/ZN-3C
(p 24) S2 C.B.P-TITE SCREW,2X8,F/ZN-3C 2 0.5 kgf·cm
S3 C.B.P-TITE SCREW,3X10,F/ZB-3C 6 1 kgf·cm
S4 C.B.P-TITE SCREW,3X10,F/ZN-3C 6 1 kgf·cm
A
S5 C.B.S-TITE SCREW,3X10,F/ZN-3C 6 1 kgf·cm
4 0.5 kgf·cm
(p 22) S6 C.B.S-TITE SCREW,3X6,F/ZN-3C
 See "1.2.2.2Housing Part (WorkForce 60 series) (p21)" for S8 C.B.S-TITE SCREW,3X6,F/ZN-3C 8 1 kgf·cm
removing the housing part of WorkForce 60 series. S9 C.P.SCREW,2.5X6,F/ZN-3C 2 0.5 kgf·cm
 When replacing the Printer Mechanism supplied as an ASP, make S10 C.P.SCREW,3X4,F/ZN-3C 2 0.5 kgf·cm
sure to adjust the Stopper Holder Idle Roller in the proper S11 C.P.SCREW,3X4,F/ZN-3C 4 1 kgf·cm
attachment position, and then perform the PF Timing Belt tension S12 C.P.SCREW,2.6X3,F/ZN-3C 4 1 kgf·cm
measurement. See " Paper Guide Front Assy (Stopper Holder Idle S13 C.B.P-TITE SCREW(S-P1),3X12,F/ZN-3C 5 - 6 kgf·cm
Roller) (p28)" and "2.2.1PF Timing Belt Tension Measurement/ S14 C.B.P-TITE SCREW,2.5X8,F/ZN-3C 2 0.5 kgf·cm
PF Belt Step Check (p40)" for the details. S15 C.B.P-TITE SCREW,3X4,F/ZN-3C 6 1 kgf·cm
Flowchart 1-1. Disassembly Flowchart of Housing Part (1)
Disassembly/Reassembly Disassembly/Reassembly Flowchart 19

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1 (p 19) 2 (p 19) 3 (p 19)
Ref. ADF Unit Scanner Unit Scanner Panel Gear/ Cover Open
Panel Lever Panel Unit Sensor
--- --- ---
--- ---
3 3 4
--- 2
(p 27) (p 30) (p 30)
--- (p 30)
Front ADF Rear ADF Cover ADF Document CIS Unit Lower Panel Lower Panel
Cover Support Housing Housing Upper Housing
3 1 --- 6 5 6 ---
S4 8 S4 3 2 S4 2 S4 1 S4 --- ---
(p 27) (p 27) (p 27) (p 26) (p 24) (p 24) ---

(p 30) (p 50)
Top ADF Cover Panel Board Panel Board
--- 4 8
2 S4 --- S4 ---
(p 27) WorkForce 635 series specific parts/unit

(p 25) (p 25)
WorkForce 625 series specific parts/unit

Right ADF
Cover Button LCD Button
WorkForce 635 series/
1 WorkForce 625 series common parts/unit
--- 2 ---
S4 5 --- S2 --- --- Screw type/torque list

(p 27) --- (p 28) --- Symbol Screw type Torque
S1 C.B.P-TITE SCREW,2.5X8,F/ZN-3C 4 1 kgf·cm
S2 C.B.P-TITE SCREW,2X8,F/ZN-3C 2 0.5 kgf·cm
LCD Cover
--- S4 C.B.P-TITE SCREW,3X10,F/ZN-3C 6 1 kgf·cm
--- S5 C.B.S-TITE SCREW,3X10,F/ZN-3C 6 1 kgf·cm

S6 C.B.S-TITE SCREW,3X6,F/ZN-3C 4 0.5 kgf·cm
---
 See "1.2.2.2Housing Part (WorkForce 60 series) (p21)" for S8 C.B.S-TITE SCREW,3X6,F/ZN-3C 8 1 kgf·cm
removing the housing part of WorkForce 60 series. Upper Panel Upper Panel S9 C.P.SCREW,2.5X6,F/ZN-3C 2 0.5 kgf·cm
 When replacing the Printer Mechanism supplied as an ASP, make Housing Housing
S10 C.P.SCREW,3X4,F/ZN-3C 2 0.5 kgf·cm
sure to adjust the Stopper Holder Idle Roller in the proper --- ---
S11 C.P.SCREW,3X4,F/ZN-3C 4 1 kgf·cm
attachment position, and then perform the PF Timing Belt tension --- --- S12 C.P.SCREW,2.6X3,F/ZN-3C 4 1 kgf·cm
measurement. See " Paper Guide Front Assy (Stopper Holder Idle S13 C.B.P-TITE SCREW(S-P1),3X12,F/ZN-3C 5 - 6 kgf·cm
--- ---
Roller) (p28)" and "2.2.1PF Timing Belt Tension Measurement/ S14 C.B.P-TITE SCREW,2.5X8,F/ZN-3C 2 0.5 kgf·cm
PF Belt Step Check (p40)" for the details.

Confidential
1.2.2.2 Housing Part (WorkForce 60 series)
START
Waste Ink Tray USB Cover

Front Cover Printer Cover Duplex Unit Assy Cassette Assy
--- --- --- 1 --- 1
6 2 --- S3 4 --- S4 4
(p 29) --- (p 35) (p 35) (p 35) (p 29)
Panel Unit Pickup Assy P/S Board Assy
1 --- 1
S4 1 1 S4 ---
(p 29) --- (p 39)
Stacker Open
Sensor Panel Board
--- 3
2 S4 2
--- ---
USB Cover LED Lens Button
--- ---
Upper Housing 3 ---
(w/ Printer Cover)
WorkForce 635 series/WorkForce 625 series/
--- --- WorkForce 60 series common parts/unit
4
S4 ---
Printer Cover Front Panel Cover
(p 29)
Sym
--- Screw type Torque
bol
--- S1 C.B.P-TITE SCREW,2.5X8,F/ZN-3C 4 1 kgf·cm
Cover Open
Sensor Stacker Assy Upper Housing S2 C.B.P-TITE SCREW,2X8,F/ZN-3C 2 0.5 kgf·cm
---
--- --- ---
2 4 --- S5 C.B.S-TITE SCREW,3X10,F/ZN-3C 6 1 kgf·cm
--- (p 29) --- S6 C.B.S-TITE SCREW,3X6,F/ZN-3C 4 0.5 kgf·cm
 See "1.2.2.1Housing Part (WorkForce 635 series/WorkForce 625 series) (p19)" for S9 C.P.SCREW,2.5X6,F/ZN-3C 2 0.5 kgf·cm
A disassembly of the Housing Part of WorkForce 635/625 series. S10 C.P.SCREW,3X4,F/ZN-3C 2 0.5 kgf·cm
(p 22)  When replacing the Printer Mechanism supplied as an ASP, make sure to adjust the S11 C.P.SCREW,3X4,F/ZN-3C 4 1 kgf·cm
Stopper Holder Idle Roller in the proper attachment position, and then perform the PF S12 C.P.SCREW,2.6X3,F/ZN-3C 4 1 kgf·cm
Timing Belt tension measurement. See "Paper Guide Front Assy (Stopper Holder Idle S13 C.B.P-TITE SCREW(S-P1),3X12,F/ZN-3C 5 - 6 kgf·cm
Roller) (p28)" and "2.2.1PF Timing Belt Tension Measurement/PF Belt Step Check S14 C.B.P-TITE SCREW,2.5X8,F/ZN-3C 2 0.5 kgf·cm
(p40)" for the details. S15 C.B.P-TITE SCREW,3X4,F/ZN-3C 6 1 kgf·cm

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1.2.2.3 Printer Mechanism Part
WorkForce 635 series/WorkForce 625 series: (p 19)
A WorkForce 60 series: (p 21)
FAX Grounding Extension Spring CR Scale/ Ref.

Cam Holder Right Frame FAX Grounding Hinge Cover Holder Board
Plate (Upper Paper Guide) Plate Cartridge/ P/S Board Assy
Extension Spring Assy Assy
Cartridge Cover*
2 --- --- --- --- --- 1
---
S6 --- 6 3 4 2 2 S4 ---
1
--- --- (p 25) (p 25) --- --- (p 30) (p 39)
---
Driven Pulley/ CSIC Terminal CR Contact

Main Board Unit Main Board Unit Extension Spring Ref. Ink System Assy FAX Assy Module
Extension Spring
3 --- --- 1 2 I/C Guide --- ---

4
1 1 --- 2 S4 1 S3 S4 --- --- 8 2

S4 S6 S4 S6
(p 26) (p 48) --- (p 25) (p 49) (p 30) 1 --- ---

(p 26)
(p 31) (p 35) (p 32) (p 35) ---

Waste Ink Pad FAX Shield Plate/ Holder Board Main Board Unit
(Bottom of Ink FAX Connector
System Assy) Cover
Right Frame 4 (p 23) PF Encoder Sensor
Inner Head Cable
Cover --- 3
--- 3
1 --- --- S4 S6 2 4 (p 23)
Main Frame --- S4 ---
(w/ CR Assy) (p 29)
S14 --- 1 ---
--- (p 25)
4 (p 32) (p 35)
(p 31) ---
S4 S8 S13 --- 5 (p 23) Note "*": Only the Hinge Cover Cartridge is supplied as an ASP.
Fax Board
(p 26) (p 31) Holder Board WorkForce 635 series specific parts/unit
--- Assy
(p 49) (p 36)
--- WorkForce 625 series specific parts/unit
Front Frame ---

2
WorkForce 635 series/WorkForce 625 series/
S4 --- WorkForce 60 series common parts/unit
(p 26) (p 49) (p 37)

Ref. Printhead
Symbol Screw type Torque
Star Wheel Assy
3 S1 C.B.P-TITE SCREW,2.5X8,F/ZN-3C 4 1 kgf·cm
2
S1 --- S2 C.B.P-TITE SCREW,2X8,F/ZN-3C 2 0.5 kgf·cm
S4 --- S3 C.B.P-TITE SCREW,3X10,F/ZB-3C 6 1 kgf·cm

(p 26) (p 39)
(p 25) (p 37) EJ Pulley
--- S6 C.B.S-TITE SCREW,3X6,F/ZN-3C 4 0.5 kgf·cm
Ref. Ink System Assy
--- S7 C.B.S-TITE SCREW,3X6,F/ZN-3C 6 1 kgf·cm
Paper Guide (p 38) (p 49)
Front Assy S9 C.P.SCREW,2.5X6,F/ZN-3C 2 0.5 kgf·cm
When replacing the Printer Mechanism supplied as an ASP, make S10 C.P.SCREW,3X4,F/ZN-3C 2 0.5 kgf·cm
4 EJ Roller
6 (p 23) sure to adjust the Stopper Holder Idle Roller in the proper attachment S11 C.P.SCREW,3X4,F/ZN-3C 4 1 kgf·cm
4 1 kgf·cm
S13 --- position, and then perform the PF Timing Belt tension measurement. S12
--- C.P.SCREW,2.6X3,F/ZN-3C
(p 28) (p 48) (p 37) See " Paper Guide Front Assy (Stopper Holder Idle Roller) (p28)" and S13 C.B.P-TITE SCREW(S-P1),3X12,F/ZN-3C 5 - 6 kgf·cm
---
"2.2.1PF Timing Belt Tension Measurement/PF Belt Step Check S14 C.B.P-TITE SCREW,2.5X8,F/ZN-3C 2 0.5 kgf·cm
(p 38) (p 48) (p40)" for the details. C.B.P-TITE SCREW,3X4,F/ZN-3C 6 1 kgf·cm
B S15
(p 23)
Flowchart 1-4. Disassembly Flowchart of Printer Mechanism Part (1)

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B (p 22) 4 WorkForce 635 series/WorkForce 625 series: (p 22)

WorkForce 60 series: (p 22) 5 (p 22) 6 (p 22)
Waste Ink Tray Shield Plate Shield Plate Wireless LAN Upper Paper
(w/ Wireless LAN (w/ Wireless LAN CR Scale Holder CR Motor EJ Pulley Front Paper Guide
Assy Module*5 Guide Waste Ink Pad
Module) Module)
Cassette Assy 2 --- 1 2 EJ Roller ---
7 6
S7 --- 6 S8 --- S11 --- ---

Pickup Assy S5 S7 S9 S10 --- S5 S7 S10 ---
(p 25) (p 36) --- (p 30) (p 36) (p 28)

(p 25) (p 25)
P/S Board Assy
Waste Ink Pad Hinge Cover Stopper Holder/

(Bottom of Ink Main Board*1 PE Holder Assy Cartridge/ Idle Roller
System Assy) Cartridge Cover
1
--- 1
FAX Assy I/C Guide
S15 ---
--- S8 ---
Inner Head Cable
(p 35)
Cover ---
(p 36)
Holder Board
Assy
PF Holder/
PF Timing Belt
Printhead
---
CR Motor
1
Frame Base
(p 38) (p 48)
Assy*2*3
CR Assy
---
--- PF Motor
---
--- 2
(p 38)
(p 37) (p 49) S12 ---
Lower Paper Guide PE Sensor (p 31) (p 38)

Stacker Assy*4 Waste Ink Pad
Head FFC
--- --- Screw type/torque list
--- 4 --- Symbol Screw type Torque
--- S1 C.B.P-TITE SCREW,2.5X8,F/ZN-3C 4 1 kgf·cm
(p 39) (p 31) (p 39)
S2 C.B.P-TITE SCREW,2X8,F/ZN-3C 2 0.5 kgf·cm
(p 31)
Frame Base*3
Note "*1": Supplied as an ASP only for WorkForce 635 series/WorkForce 625 series. S5 C.B.S-TITE SCREW,3X10,F/ZN-3C 6 1 kgf·cm
--- "*2": Supplied as an ASP only for WorkForce 635 series/WorkForce 60 series.
S6 C.B.S-TITE SCREW,3X6,F/ZN-3C 4 0.5 kgf·cm
"*3": The shape of the parts are different but the procedure is the same between
--- WorkForce 635 series/WorkForce 625 series and WorkForce 60 series. S7 C.B.S-TITE SCREW,3X6,F/ZN-3C 6 1 kgf·cm
"*4": See (p 21) for Stacker Assy of WorkForce 60 series. S8 C.B.S-TITE SCREW,3X6,F/ZN-3C 8 1 kgf·cm
(p 38) WorkForce 635 series specific parts/unit
"*5": This is not mounted on Epson ME OFFICE 85ND. S9 C.P.SCREW,2.5X6,F/ZN-3C 2 0.5 kgf·cm
When replacing the Printer Mechanism supplied as an ASP, make S10 C.P.SCREW,3X4,F/ZN-3C 2 0.5 kgf·cm
sure to adjust the Stopper Holder Idle Roller in the proper attachment S11 C.P.SCREW,3X4,F/ZN-3C 4 1 kgf·cm
position, and then perform the PF Timing Belt tension measurement. WorkForce 60 series specific parts/unit S12 C.P.SCREW,2.6X3,F/ZN-3C 4 1 kgf·cm
See " Paper Guide Front Assy (Stopper Holder Idle Roller) (p28)" and S13 C.B.P-TITE SCREW(S-P1),3X12,F/ZN-3C 5 - 6 kgf·cm
2 0.5 kgf·cm
"2.2.1PF Timing Belt Tension Measurement/PF Belt Step Check WorkForce 635 series/WorkForce 625 series/ S14
WorkForce 60 series common parts/unit C.B.P-TITE SCREW,2.5X8,F/ZN-3C
(p40)" for the details. S15 C.B.P-TITE SCREW,3X4,F/ZN-3C 6 1 kgf·cm
Flowchart 1-5. Disassembly Flowchart of Printer Mechanism Part (2)

Confidential
1.3 Detailed Disassembly/Reassembly Procedure for each Part/Unit

USB Cover (WorkForce 635/625 series) Decoration Plate (WorkForce 635/625 series) Document Pad (WorkForce 635/625 series) Left Housing/Right Housing (WorkForce 635/625 series)
Decoration Plate Right Housing Left Housing

ADF Unit (WorkForce 635 series)
Document Cover (WorkForce 625 series)
USB Cover
Positioning
No gap
hole
Dowel
Hole
Rib
Hook
Left Right
Reference position
1 2 3
Panel FFC
Document Pad
No gap
Standard line
Decoration Plate
Double-sided tape Cover Open Sensor cable
C.B.P-TITE SCREW,3X10,F/ZN-3C (6 ± 1 kgf·cm)
Hook  Be careful not to damage the hooks (x1 each) and ribs (x7
C.B.P-TITE SCREW,3X10,F/ZB-3C (6 ± 1 kgf·cm) Rib Remove the Decoration Plate by rotating it in the direction of the each) that secure the Left Housing/Right Housing.
arrow shown above carefully not to damage the hooks (x2) that  First align one bottom corner of the Document Pad with the  Be careful to remove the Left Housing since the Panel FFC and
secure the Decoration Plate. reference position and attach it with double-sided tape. the Cover Open Sensor cable are routed inside it.
Remove the USB Cover by sliding it in the direction of the arrow
shown above carefully not to damage the hooks (x2) that secure the Tighten the screws in the order indicated in the figure above.  Make sure there is no gap on the left and bottom sides of the When installing the Left/Right Housing, align the positioning holes
USB Cover. Document Pad. with the dowels of the Upper Housing.
Document Cover (WorkForce 625 series) Panel Unit (WorkForce 635/625 series) Upper Housing (w/ Panel Unit) Lower Panel Housing (WorkForce 635/625 series)
(WorkForce 635/625 series)
Document Cover WorkForce 635 series
3 Lower Panel Housing
Upper Housing
1 2 3 1 5
1 2
Upper Housing 6
Panel Unit 2 4
Left Panel Shaft Holder Right Panel Shaft Holder
WorkForce 625 series

Lower Panel Housing
4 3 3 1 5
Hook
C.B.P-TITE SCREW,3X10,F/ZN-3C (6 ± 1 kgf·cm) Panel Unit 6 2 4

Dowel
Remove the screws (x3) with the Panel Unit open, and turn the
Panel Unit in the direction of the arrow to release the hooks of the C.B.P-TITE SCREW,3X10,F/ZN-3C (6 ± 1 kgf·cm)
When removing the Document Cover, follow the procedure below. Panel Shaft Holders from the Upper Housing, then remove the C.B.P-TITE SCREW,3X10,F/ZN-3C (6 ± 1 kgf·cm)
Panel Unit.
1. With the Document Cover open, release the outside dowel on
the right by pushing it from the rear of the printer. Secure the hooks of the Panel Shaft Holders firmly to the Upper
2. Release the outside dowel on the left, and remove the Housing, and tighten the screws in the order indicated in the figure Tighten the screws in the order indicated in the figure above. Tighten the screws in the order indicated in the figure above.
Document Cover. above.
Disassembly/Reassembly Detailed Disassembly/Reassembly Procedure for each Part/Unit 24

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Panel Board (WorkForce 635/625 series) CR Scale/Extension Spring Cam Holder Assy Ink System Assy
WorkForce 635 series Waste Ink Tube

Panel Board
Cut section
1 2
Cam Holder Assy
8 ± 1 mm
Groove
4 D/E Lever
3 Longer leg
Hole of Frame Base
Waste Ink Tube

Panel Board Protrusion
1 2 5 6 Extension spring
CR Scale
4 3 8 7
C.B.P-TITE SCREW,3X10,F/ZN-3C (6 ± 1 kgf·cm) Hook
Tighten the screws in the order indicated in the figure above.  Install the CR Scale with the cut section up. When installing the Cam Holder Assy, insert the protrusion of the When installing the Ink System Assy, insert the Waste Ink Tube
 Attach it to the hook on the left of the printer with the longer D/E Lever into the groove of the Cam Holder Assy. (8 ± 1 mm from the tip) into the hole on the Frame Base.
leg of the extension spring to the front of the printer.
FAX Shield Plate/FAX Connector Cover Star Wheel Assy Shield Plate (w/ Wireless LAN Module) Wireless LAN Module
(WorkForce 635 series) (WorkForce 635/625 series)
Left
7
Star Wheel Assy
1
1 2
FAX Shield Plate
2
2 3

4 WorkForce 60 series
3 2
WorkForce
Grounding Spring
1 635 series only
1
6 5
FAX Connector Cover

Rib C.B.S-TITE SCREW,3X6,F/ZN-3C (6 ± 1 kgf·cm)
C.P SCREW,2.5X6,F/ZN-3C (2 ± 0.5 kgf·cm) C.B.S-TITE SCREW,3X6,F/ZN-3C (6 ± 1 kgf·cm)
C.P-SCREW,3X4,F/ZN-3C (2 ± 0.5 kgf·cm)
C.B.S-TITE SCREW,3X10,F/ZN-3C (6 ± 1 kgf·cm)
Tighten the screws in the order indicated in the figure above. Hook the leg of the grounding spring to the rib and attach the Tighten the screws in the order indicated in the figure above. Tighten the screws in the order indicated in the figure above.
spring as shown in the figure above.

Confidential
Main Board Unit (WorkForce 635/625 series) CIS Unit (WorkForce 635/625 series) Front Frame
PF Encoder Cover Timing Belt Bottom of Front Frame
Cutout
CIS Carriage
2
1.6 mm 1.6 mm
Double-sided Belt clamp
tape
Torsion spring
(27 x 4 mm) MAC Address Label
Antistatic cloth Antistatic cloth
Main Board Unit Label

Rib
3
1
Front Frame
1
PF Encoder Cover Screw hole Main Board Unit C.B.P-TITE SCREW,3X10,F/ZN-3C (6 ± 1 kgf·cm)
C.B.S-TITE SCREW,3X6,F/ZN-3C (4 ± 0.5 kgf·cm) Spacer
Do not damage or contaminate the MAC Address Label. Confirm the label of the CIS Unit, and make sure to install the 2
proper spacers on both ends of the CIS Unit corresponding to the
label. C.B.P-TITE SCREW,3X10,F/ZN-3C (6 ± 1 kgf·cm)
 Align the rib (x1) and screw hole of the PF Encoder Cover with the Main Board Unit as shown above, and secure the PF Encoder Cover with
double-sided tape (x1). • A: Spacer, CIS, A17 (black)  Tighten the screws in the order indicated in the figure above.
 Tighten the screws in the order indicated in the figure above. • B: Spacer, CIS, B19 (white)  When attaching the antistatic cloth, make sure to follow the
• C: Spacer, CIS, C21 (gray) standard below and attach it to the Front Frame.
 When replacing the Main Board, it is necessary to set the MAC address if the EEPROM data cannot be read out from the old Main Board. In such
a case, refer to "2.2.3MAC Address Setting (p44)" and set it.  When installing the Timing Belt, secure the Timing Belt and • Align the antistatic cloth with the edge of the cutout on the
the CIS Carriage with the Belt Clamp, and attach the torsion bottom of the Front Frame.
spring to the location shown above. • Attach it at 1.6 mm away from the edge of the Front Frame.
Main Frame (w/ CR Assy) Printhead

Left Rear Rear Step 2-3 Printhead supporting tool
Cutout Main Frame
Carriage
D/E Lever 1 2
Nozzle plate surface
of Printhead
Right
Step 1 Printhead
Main Frame
C.B.P-TITE SCREW,3X10,F/ZN-3C (6 ± 1 kgf·cm) C.B.P-TITE SCREW,2.5X8,F/ZN-3C (4 ± 1 kgf·cm)

C.B.P-TITE SCREW(S-P1),3X12,F/ZN-3C (5 - 6 kgf·cm)
When removing the Main Frame with the Printhead installed on the Carriage, be careful not to damage the nozzle plate surface of the Printhead.
Printhead supporting tool
When removing the Main Frame, follow the procedure below. When installing the Printhead, use the printhead supporting tools (x2) and follow the procedure below.
1. Slide the D/E Lever toward the 0-digit side to align the D/E Lever with the cutout of the Main Frame, and detach the D/E Lever from the Main Frame. 1. Move the carriage to the center, and from the rear of the printer, insert the supporting tools one each on the 0-digit side and 80-digit side until
2. Release the CR Motor cable from the hooks of the Main Frame and ribs of the Frame Base. (See "CR Motor (p30)".) they touch the Main Frame.
3. Release the Head FFC from the ribs of the Front Frame. (See "Head FFC (p31)".) 2. Move the carriage toward the 80-digit side to the end, and install the Printhead to the carriage.
4. Remove the screws (x4) that secure the Main Frame, and remove the Main Frame from the Frame Base. 3. Tighten the screws in the order indicated in the figure above.

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ADF Unit (WorkForce 635 series) (1) ADF Unit (WorkForce 635 series) (2)
Front ADF Cover
Right ADF Cover Right ADF Cover
ADF Cover Assy
Front ADF Cover
Release hooks that secure Right ADF Cover in the direction of the arrow.
Release hooks that secure Front ADF Cover in the direction of the arrow. ADF Unit
ADF Unit
ADF Document Support ADF Pad Assy
Top ADF Cover Rear ADF Cover
Hook
Dowel
Screw hole
Hook
Dowel
Screw hole
The figures above indicate the hooks, dowels and screws that secure the parts and units. The figures above indicate the hooks, dowels and screws that secure the parts and units.

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Paper Guide Front Assy (installation using the tools) Paper Guide Front Assy (Stopper Holder Idle Roller) LCD (WorkForce 635/625 series)
Left
Fig. 1: Tool positions (bottom) 87 mm
Front of printer Paper guide front A B C
supporting tools PF Timing Belt

for WorkForce 635
series/WorkForce LCD
119 mm 123 mm
60 series 45.5 mm 44 mm
45 mm
C 1
C
186 mm
224 mm
8 mm
PF Holder
12.5 mm 15 mm 33 mm
20 mm 33 mm
B C Paper guide front A B C

supporting tools
for WorkForce 625
89.5 mm series 2
34.5 mm 33 mm 34 mm
315 mm 8 mm
1512.5
mm mm 15 mm 33 mm
Insert the tools into hole of Frame Base. 2025
mmmm 33 mm Stopper Holder Idle Roller
Less than 0.3 mm
Paper Guide Front Assy When installing the Paper Guide Front Assy, C.B.S-TITE SCREW,3X4,F/ZN-3C (6 ± 1 kgf·cm)
use the paper guide front supporting tools (x4)
and follow the procedure below. Attach the Stopper Holder Idle Roller so that the gap between it
and the PF Holder becomes less than 0.3 mm.
1. On a flat table, put the paper guide front If the gap becomes larger than 0.3 mm, replace the Stopper Holder C.B.P-TITE SCREW,2X8,F/ZN-3C (2 ± 0.5 kgf·cm)
supporting tools B and C on the positions Idle Roller with the longer one (the following “1”) or the longest
shown in Fig. 1. one (the following “2”) one by one to until proper gap is obtained. Tighten the screws in the order indicated in the figure above.
2. Put the Frame Base over the paper guide front 1. Stopper Holder Idle Roller, PF;C (Parts code: 1540328)
supporting tools B and C, and confirm that the 2. Stopper Holder Idle Roller, PF;B (Parts code: 1540006)
tools are placed on the correct positions.
3. Install the Paper Guide Front Assy to the
Frame Base.
Front Paper Guide Waste Ink Pad Stopper Assy (WorkForce 625 series)
4. Put the paper guide front supporting tool A on
the position shown in Fig. 2.
C Front Paper Guide Waste Ink Pad Paper Guide Front Assy
5. Tighten the screws (x4) in the order Stopper
indicated in Fig. 3 to secure the Paper Guide
C Front Assy. Cam slider
B Extension spring
6. After securing the Paper Guide Front Assy,
install the PF Holder and the Stopper Holder
C
Idle Roller. (See "Paper Guide Front Assy
Stopper lever
When there is a gap between top of tools (Stopper Holder Idle Roller) (p28)".)
A
Frame Base and Frame base, please put thin things, such 7. Perform "2.2.1PF Timing Belt Tension
as rubber or plastic material, in order to fill Dowel
Measurement/PF Belt Step Check (p40)".
it.
Bottom of Paper Guide Front Assy
Fig. 2: Tool position (80-digit side) Fig. 3: Screws tightening order
Paper Guide Front Assy

2 1
Slider base
Leg of Front Paper Guide Waste Ink Pad
 Install the Front Paper Guide Waste Ink Pad under the ribs Compression spring
4 3
(x12) of the Paper Guide Front Assy without any gap.
 After installing the Front Paper Guide Waste Ink Pad, check if
A all the legs of the Front Paper Guide Waste Ink Pad come out
If any of the parts of the Stopper Assy comes off when removing it,
be sure to assemble the Stopper Assy as shown above.
from the holes of the Paper Guide Front Assy correctly.
C.B.P-TITE SCREW(S-P1),3X12,F/ZN-3C (5 - 6 kgf·cm)

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Front Cover (WorkForce 60 series) USB Cover (WorkForce 60 series) Upper Housing (WorkForce 60 series) Panel Unit (WorkForce 60 series)
Stacker Open Sensor
Back of Front Cover
Upper Housing
Groove
Front Cover Screw boss
Hooks 4 3
Panel Unit
1 2
USB Cover
Hook
Rib
Rib
Stacker Open Sensor
Be careful not to damage the hooks (x2) and ribs (x4) that secure Remove the USB Cover in the direction of the arrow. Be careful Tighten the screws in the order indicated in the figure above. When installing the Panel Unit, route the cable of the Stacker Open
the Front Cover. not to damage the hooks (x2), rib (x1) and screw boss (x1) then. Sensor through the groove of the Upper Housing so as not to catch
the cables in between.
Stacker Assy (WorkForce 60 series) Main Board Unit (WorkForce 60 series)
PF Encoder Cover
Positioning
Rib hole PF Encoder Cover 2
4
Shaft & bearing
Step 1-2 Step 3 Main Board Unit
Cutout MAC Address Label

Stacker Lock 3
Stacker Assy
Bottom 1
Frame Base
Stacker Assy C.B.P-TITE SCREW,3X10,F/ZN-3C (6 ± 1 kgf·cm)
Dowel C.B.S-TITE SCREW,3X6,F/ZN-3C (4 ± 0.5 kgf·cm)
Hooks to secure
Stacker Lock Do not damage or contaminate the MAC Address Label.
Follow the procedure below when removing the Stacker Assy.  Align the rib (x1) and positioning hole (x1) of the PF Encoder Cover with the cutout (x1) and dowel (x1) of the Frame Base.
1. Release the hooks (x2) that secure the Stacker Lock, and lift the Stacker Lock in the direction of the arrow.  Tighten the screws in the order indicated in the figure above.
2. Remove the Stacker Lock from the shaft on the left of the Stacker Assy.  When replacing the Main Board, it is necessary to set the MAC address if the EEPROM data cannot be read out from the old Main Board. In such
3. Remove the shaft on the right of the Stacker Assy from the bearing of the Frame Base, and remove the Stacker Assy from the Frame Base. a case, refer to "2.2.3MAC Address Setting (p44)" and set it.

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1.4 Routing FFCs/cables

Inside the USB Cover (WorkForce 635 series) Panel Unit (WorkForce 635 series) Cover Open Sensor (WorkForce 635/625 series)
Main Board Rear Panel FFC
CN17 Panel Unit
Scanner FFC Cover Open Sensor
Scanner FFC
CN24
CN19 Rib
Groove
CN2
Hole
CN22
Ferrite core Front Panel FFC
CN18
Double-sided tape
Groove of Upper Housing
Grounding
C.B.P-TITE SCREW,3X10,F/ZN-3C (6 ± 1 kgf·cm) FAX Assy wire
When routing the FFCs/cables inside the USB Cover, connect them to the Main Board as shown above. Cover Open Sensor cable
• ADF PE Sensor cable (CN18) • ADF Encoder cable (CN19) Route FFC through hole
with its stiffener outward.
• ADF Document Sensor cable (CN22) • ADF Motor cable (CN24)
• Scanner Motor cable (CN2)
When routing the Panel FFC, be careful of the following. Route the Cover Open Sensor cable through the groove of the Upper Housing.
• Scanner FFC (CN17): Secure the ferrite core to the Upper Housing with double-sided tape.
 Route it through the rib, groove and hole of the Upper Housing as shown
• Grounding wire: Secure to the FAX Assy with screw.
above.
 Facing the FFC stiffener outward, route it through the hole of the Upper
Housing.
Scanner FFC/Scanner Motor Cable P/S Board Assy (WorkForce 635/625 series) CR Motor FAX Assy (WorkForce 635 series)
(WorkForce 635/625 series)
Main Frame
Back of PF Encoder Cover
Screw boss
2 mm or less
Ferrite core
CR Motor cable
P/S Board Assy cable
Scanner FFC CR Motor

FAX FFC
Groove of PF Encoder Cover CN3
CR Motor cable FAX Assy
Double-sided tape
P/S Board Assy cable

Hook Main Board
Ferrite core Section A Rib PF Encoder Cover
Dowel
Scanner Motor cable P/S Board Assy
Groove
 When routing the Scanner FFC, secure it to the housing with double-sided When routing the P/S Board Assy cable, make sure of the following.  When routing the CR Motor cable, route it through the hooks (x7) and ribs When routing the FAX FFC, insert the ferrite core into the groove of the PF
tape (x3).  Insert the ferrite core into the section A of the Frame Base. (x2) as shown above. Encoder Cover, and connect the FFC to the Main Board.
 When routing the Scanner Motor cable, route it through the dowels (x2)  Route the P/S Board Assy cable between the screw boss and P/S Board  Make sure the gap between the CR Motor cable and the Main Frame is
and groove of the housing. Assy in order to prevent the cable from getting caught. less than 2 mm.
Disassembly/Reassembly Routing FFCs/cables 30

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Head FFC Main Board (WorkForce 635 series)

Ferrite core
Carriage Head FFC
Head FFC
FAX FFC
CN15
To CR Encoder CN13
CN3 CN11
Front Frame
PF Encoder FFC CN12
CN14 Double-sided tape
CR Motor cable CN501
Bottom of Main Board Unit
Cutout of PF
Encoder Cover CN6 CN7
To Holder Board Assy

Head FFC
CR Motor cable PF Motor cable
PF Motor cable Rib
Head FFC P/S Board Assy cable
Rib
Rib
When connecting the following cables to the Main Board, connect them as shown above.
 When you do not need to replace the Head FFC, be careful not to disconnect it from the CR encoder connector. Once it is disconnected, you must  Head FFC (CN11, CN12, CN13): Secure the ferrite core to the Main Board with double-sided tape, and connect it confirming the direction of the
disassemble the carriage to reconnect it to the CR encoder. terminals is correct.
 Confirm that the Head FFC is connected to the CR Contact Module and CR Encoder.  PF Motor cable (CN7): Route it through the ribs (x4) of the Frame Base, and connect it to the connector on the Main Board.
 Route the Head FFC through the ribs (x3) of the Carriage.  CR Motor cable (CN6): Route it through the cutout of the PF Encoder Cover, and connect it to the connector on the Main Board. See "CR
 Route the Head FFC through the ribs (x4) of the Front Frame. Motor (p30)" for routing it on the other sections.
 PE Sensor cable (CN15): Route it through the cutout of the PF Encoder Cover, and connect it to the connector on the Main Board. See "PE
Sensor (p31)" for routing it on the other sections.
 PF Encoder FFC (CN14): See "PF Encoder Sensor (WorkForce 635/625 series) (p31)".
 FAX FFC (CN3): See "FAX Assy (WorkForce 635 series) (p30)".
 P/S Board Assy cable (CN501): See "P/S Board Assy (WorkForce 635/625 series) (p30)".
PF Encoder Sensor (WorkForce 635/625 series) PF Motor PE Sensor Panel Unit (WorkForce 625 series)
Bottom of Paper Guide Front Assy Rear Panel Unit
Main Board
Hook A
PF Motor cable
PF Encoder FFC Hole

Panel FFC Rib
PF Encoder Cover PE Sensor cable Groove
Hole
Front
Panel FFC
PE Sensor
PF Motor Boss
Rib
Hook
Rib A
Hook Rib B
Route the PF Encoder FFC through the ribs of the PF Encoder Cover, and Route the PF Motor cable through the hooks (x2) of the Paper Guide Front  Route the PE Sensor cable through the hole of the Frame Base, and route Route FFC through hole
connect it to the Main Board. Assy. Make one turn in the direction of the arrow around the hook A. it through the bosses (x2), hook (x1), and rib A (x1). with its terminal outward.
 When routing the PE Sensor cable, keep it below the rib B.
When routing the Panel FFC, be careful of the following.
 Route it through the rib, groove and hole of the Upper Housing as shown
above.
 Facing the FFC terminal outward, route it through the hole of the Upper
Housing.

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Inside the USB Cover (WorkForce 625 series) Main Board (WorkForce 625 series)
Ferrite core
Head FFC
Main Board Head FFC
Scanner FFC CN17 CN15

CN13
CN11
CN14
Scanner FFC
PF Encoder FFC CN12
CN6 Double-sided tape
CN501
CN8 Cutout of PF CN7 Bottom of Main Board Unit

Encoder Cover
Scanner Motor cable
Ferrite core
PE Sensor cable
Double-sided tape
CR Motor Cable
P/S Board Assy cable PF Motor cable
PF Motor cable Rib
When routing the FFCs/cables inside the USB Cover, connect them to the Main Board as shown above.  Head FFC (CN11, CN12, CN13): Secure the ferrite core to the Main Board with double-sided tape, and connect it confirming the direction of the
• Scanner Motor cable (CN8) terminals is correct.
• Scanner FFC (CN17): Secure the ferrite core to the Upper Housing with double-sided tape.  PF Motor cable (CN7): Route it through the ribs (x4) of the Frame Base, and connect it to the connector on the Main Board.
 CR Motor cable (CN6): Route it through the cutout of the PF Encoder Cover, and connect it to the connector on the Main Board. See "CR
Motor (p30)" for routing it on the other sections.
 PE Sensor cable (CN15): Route it through the cutout of the PF Encoder Cover, and connect it to the connector on the Main Board. See "PE
 PF Encoder FFC (CN14): See "PF Encoder Sensor (WorkForce 635/625 series) (p31)".
 P/S Board Assy cable (CN501): See "P/S Board Assy (WorkForce 635/625 series) (p30)".
Main Board (WorkForce 60 series)
CR Motor Cable PF Encoder Cover CN13 Ferrite core of Head FFC

PF Encoder FFC CN12
CN11 CN5 Panel FFC
Head FFC
Double-sided tape
CN14
CN7 Bottom of Main Board Unit
Ferrite core of P/S
CN6 Board Assy cable
CN501
CN15
PE Sensor cable Rib PF Motor cable
 Head FFC (CN11, CN12, CN13): Secure the ferrite core to the Main Board with double-sided tape, and connect it confirming the direction of the
terminals is correct.
 Panel FFC (CN5): Connect it to the Main Board confirming the direction of the terminals is correct.
 PF Motor cable (CN7): Route it as shown in the above, and connect it to the Main Board.
 CR Motor Cable (CN6): Route it through the ribs (x2) of the PF Encoder Cover, and connect it to the connector on the Main Board. See "CR
Motor (p30)" for routing it on the other sections.
 PE Sensor cable (CN15): Route it through the ribs (x2) of the PF Encoder Cover, and connect it to the connector on the Main Board. See "PE
 PF Encoder FFC (CN14): Route it through the ribs (x1) of the PF Encoder Cover, and connect it to the connector on the Main Board.
 P/S Board Assy cable (CN501): Insert the ferrite core into the position shown above, and connect it to the connector on the Main Board.

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CHAPTER 2
ADJUSTMENT
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2.1 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 Tray 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 and the Printer Mechanism at the same time, the
adjustment should be made after performing the initial setting.
 In this chapter, the product names are called as follows:

• WorkForce 635 series: WorkForce 635/Epson Stylus Office TX620FWD/Epson Stylus
OFFICE 940FW
• WorkForce 625 series: WorkForce 625/Epson Stylus NX625/TX560WD/SX525WD/
BX535WD
• WorkForce 60 series: WorkForce 60/T42WD/Epson Stylus Office B42WD/Epson
ME OFFICE 82WD/Epson ME OFFICE 85ND
 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.
Adjustment Required Adjustments 34

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Table 2-1. Required Adjustment List

Adjustment Type Mechanism adjustment Adjustment using the Adjustment Program
Priority 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
PF Timing
Belt tension First dot PF / EJ CR motor heat PF motor heat
Checking the EEPROM Initialize MAC address Maintenance PE Detector PF / EJ Bi-D Head angular PF band PE Paper Skew
Adjustment Item measurement/ Ink charge Head ID input position / PW deterioration protection protection
Platen Gap data copy Setting setting counter confirmation adjustment adjustment adjustment adjustment adjustment adjustment
PF belt step adjustment offset control control
confirmation
Check if the Check if the PG To copy To write sale- To set the MAC To fill ink To correct To reset the Confirm the PE To correct To correct the To correct print To correct tilt of To correct To correct paper To align print To reset the To measure and To measure and
tension of the is within the adjustment destination- address inside the new characteristic waste ink sensor's variations in print start start timing in the Printhead variations in detection start position at counter or set it correct the correct the
values or the like specific settings (required for Printhead to variation of the counter after chattering after paper feed position in the bidirectional caused at the paper feed position error 0-digit side with to its maximum electrical electrical
PF Timing Belt standard. stored on the old and the serial connecting to make it ready replaced replacing the detecting the accuracy to carriage moving printing through installation accuracy to caused by PE that at 80-digit according to the variation of the variation of the
is within the Main Board to number into the network) when for print after Printhead by Waste Ink Pad. end of the paper achieve higher direction software through achieve higher sensor mounting side in banding replaced parts. motor and the motor and the
Purpose standard. the new board Main Board the Main Board replacing the entering its falls within the print quality. through control. software print quality in position error bi-directional power supply power supply
when the Main after replacing needs to be Printhead. Printhead ID specified software control. band printing. through software printing, timing board. board.
Board needs to it. replaced. (Head ID). period. control. control. of firing ink
be replaced. droplet is
adjusted through
software control.
Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Duplex Unit
Replace --- --- --- --- --- --- --- --- --- O O --- --- O O --- --- --- ---
Cassette Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Assy Replace --- --- --- --- --- --- --- --- --- --- O --- --- --- O --- --- --- ---
Part Name
Waste Ink Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Tray Assy Replace --- --- --- --- --- --- --- O --- --- --- --- --- --- --- --- --- --- ---
Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Main Board Replace --- --- O --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
(Main (Read OK)
Board Unit)
Replace O
(Read NG)
--- --- --- O O --- O *1 --- O O O O O O O Input max. value O O
(10000)
-2 -1 0 1 2
OK
-2 -2
-1 -1 OK
0 0 OK
1 1
NG
2 2 OK NG
Printout pattern --- --- --- --- --- --- --- --- --- -2 -1 0 1 2 --- --- --- ---
NG NG
OK
NG -2 NG OK NG
-1
0 NG
1 NG
NG OK NG 2 NG
The Adjustment See ? 2.2.2 See ? 2.2.3 Examine the PW Examine the Band pattern Examine the Examine the
Program is Checking the MAC Address printout patterns Adjustment printout patterns Enter the values printout patterns printout pattern
needed partly in Platen Gap Setting (p44)? and enter the Examine the for each of the of the most and enter the and enter the
this adjustment. (p43)? for the for the details. value for the misaligned lines four modes, and straight lines. value for the number of the
See ? 2.2.1 PF details. pattern with no printed on top, enter the value Microweave pattern with no one with the
bottom, left, and pattern
Timing Belt overlap and gap right of the for the pattern overlap and gap least gap and
Tension between the two with no gap and Enter the value between the two
paper, and enter for the group of overlap between
Measurement/ rectangles. the number overlap for each rectangles. the two
which the gaps
PF Belt Step beside the line mode. between the 2 different
Check (p40)? that is exactly 5 color bars are
mm away from colored lines.
for the details. the smallest.
How to judge --- --- --- --- --- --- the paper edge --- --- --- ---
for each side.
1st dot
adjustment
Examine the
lines on the left
side of paper,
and enter the
number beside
the line that
overlaps with
the horizontal
line.
Adjustment program O O O O O O O O O O O O O O O O O O O
Tool See p40 See p43 --- --- --- --- --- --- --- --- Ruler --- --- --- --- --- --- --- ---
Note "*1": Replacement of the Waste Ink Tray Assy is necessary.

Note "*2": When you have just removed and reinstalled the part or unit, you are required to make the adjustments checked in the “Remove” row. However, if you have reinstalled the part or unit without using Epson-specified tools, the adjustments checked in the “Replace” row must be performed.

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Priority 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
PF Timing
confirmation
PF Timing Belt standard. values or the like specific settings (required for Printhead to variation of the counter after chattering after paper feed position in the bidirectional caused at the paper feed position error 0-digit side with to its maximum electrical electrical
stored on the old and the serial connecting to make it ready replaced replacing the detecting the accuracy to carriage moving printing through installation accuracy to caused by PE that at 80-digit according to the variation of the variation of the
adjusted through
software control.
Main Frame Remove --- --- --- --- --- --- --- --- O --- O --- --- --- O --- --- --- ---
(w/ CR Assy) Replace --- O --- --- --- --- O --- O O O O O O O O --- O ---
Upper Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Part Name
Paper Guide Replace --- --- --- --- --- --- --- --- --- O --- O O O --- O --- --- ---
PE Holder Remove --- --- --- --- --- --- --- --- O --- --- --- --- --- O --- --- --- ---
Assy Replace --- --- --- --- --- --- --- --- O O --- --- --- O O --- --- --- ---
Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
CR Motor
Replace --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- O ---
-2 -1 0 1 2
OK
-2 -2
-1 -1 OK
0 0 OK
1 1
NG
2 2 OK NG
NG NG
OK
NG -2 NG OK NG
-1
0 NG
1 NG
NG OK NG 2 NG
See ? 2.2.1 PF details. pattern with no
printed on top,
enter the value Microweave pattern with no one with the
which the gaps
for each side.
1st dot
adjustment
Examine the
lines on the left
side of paper,
and enter the
number beside
the line that
overlaps with
the horizontal
line.


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Priority 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
PF Timing
confirmation
adjusted through
software control.
Remove --- --- --- --- --- --- --- --- --- --- O --- --- --- O --- --- --- ---
CR Assy
Replace --- --- --- --- --- --- --- --- --- --- O O O --- O O --- --- ---
Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Front Frame
Part Name
Replace --- --- --- --- --- --- --- --- --- --- O O O --- O O --- --- ---
Star Wheel Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Assy Replace --- --- --- --- --- --- --- --- --- O --- --- --- O --- --- --- --- ---
Remove O --- --- --- --- --- --- --- --- --- --- O O --- --- O --- --- ---
Paper Guide
*2
Front Assy Replace O
O O --- --- --- --- --- --- --- O --- O O O --- O --- ---
Reset to 0
-2 -1 0 1 2
OK
-2 -2
-1 -1 OK
0 0 OK
1 1
NG
2 2 OK NG
NG NG
OK
NG -2 NG OK NG
-1
0 NG
1 NG
NG OK NG 2 NG
printed on top,
which the gaps
for each side.
1st dot
adjustment
Examine the
lines on the left
side of paper,
and enter the
number beside
the line that
overlaps with
the horizontal
line.


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Priority 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
PF Timing
confirmation
adjusted through
software control.
Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
EJ Pulley
Replace O --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Remove O --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
EJ Roller
Replace O --- --- --- --- --- --- --- --- O O --- --- O O --- --- --- ---
Part Name
PF Holder/ Remove O --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
PF Timing
Belt Replace O --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Remove O --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
PF Motor
Replace O --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- O
Frame Base Remove --- --- --- --- --- --- --- --- O --- --- --- --- --- --- --- --- --- ---
Assy (Frame
Base) Replace --- O --- --- --- --- --- O O O O O O O O O --- --- ---
-2 -1 0 1 2
OK
-2 -2
-1 -1 OK
0 0 OK
1 1
NG
2 2 OK NG
NG NG
OK
NG -2 NG OK NG
-1
0 NG
1 NG
NG OK NG 2 NG
printed on top,
which the gaps
for each side.
1st dot
adjustment
Examine the
lines on the left
side of paper,
and enter the
number beside
the line that
overlaps with
the horizontal
line.


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Priority 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
PF Timing
confirmation
adjusted through
software control.
Lower Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Paper Guide
Waste Ink Replace --- --- --- --- --- --- --- O --- --- --- --- --- --- --- --- --- --- ---
Pad
Remove --- --- --- --- --- --- --- --- O --- --- --- --- --- --- --- --- --- ---
PE Sensor
Replace --- --- --- --- --- --- --- --- O --- --- --- --- --- O --- --- --- ---
Part Name
Remove --- --- --- --- --- --- --- --- --- --- --- O O --- --- O --- --- ---
Printhead*2
Replace --- O --- --- --- O O --- --- O O O O O O O --- --- ---
P/S Board Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Assy Replace --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- O O
Printer O
Replace O O --- --- --- --- --- O O O O O O O O O O O
Mechanism Reset to 0
-2 -1 0 1 2
OK
-2 -2
-1 -1 OK
0 0 OK
1 1
NG
2 2 OK NG
NG NG
OK
NG -2 NG OK NG
-1
0 NG
1 NG
NG OK NG 2 NG
printed on top,
which the gaps
for each side.
1st dot
adjustment
Examine the
lines on the left
side of paper,
and enter the
number beside
the line that
overlaps with
the horizontal
line.


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2.2 Details of Adjustments

This section provides adjustment procedures for which explanation in details is necessary. See "2.1 Required
Adjustments (p34)" for the adjustments not explained here.
2.2.1 PF Timing Belt Tension Measurement/PF Belt Step Check
This section describes PF Timing Belt tension measurement and PF belt step check.
 If you have correctly reassembled the Printer Mechanism using the Epson-specified
tools, the tension of the PF Timing Belt falls within the expected range. However,
deformation of any related part(s) can cause improper tension of the belt. In such case,
replace the Printer Mechanism.
 The standard tension range of the PF Timing Belt Tension is as follows:
• Standard: 3.1-6.2 N
 Tools
 Sonic tension gauge
 Plastic tweezers
 Adjustment Program
 Adjustment procedure
Follow the procedure below.
START
Reassemble the printer

Does the Stopper No completely and execute
Holder Idle " PF Belt Step Check
Roller touch the (p42)" in the
PF Holder? Adjustment Program.
Yes
Perform " PF Timing

Belt Tension
Measurement (p41)".
Are the all

Yes
measured value
within the
standard?
No
Attach Stopper Holder

Idle Roller keeping a Yes
Any value bigger
gap of 0.3 mm or less than 6.2 N?
from the PF Holder*.
No
Replace the Printer FINISH

Mechanism
Note "*": The Stopper Holder Idle Roller's pressure applying to the PF Holder may make the tension of the belt get tighter. See " Paper Guide
Front Assy (Stopper Holder Idle Roller) (p28)" for the position of the Stopper Holder Idle Roller.
Figure 2-1. Flowchart for PF Timing Belt Tension Measurement/PF Belt Step Check
Adjustment Details of Adjustments 40

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PF Timing Belt Tension Measurement
When performing the PF Timing Belt tension measurement, make sure of the following.
 Perform PF Timing Belt tension measurement before installing the Main Board Unit.
 Bring the microphone of the sonic tension gauge 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 gauge can measure it.
 Be careful not to damage the Timing belt when flipping it with the plastic tweezers.
1. Set the following parameters to the sonic tension gauge:
 Weight: 1
 Width: 2.5
 Span: 73
2. Bring the microphone of the sonic tension gauge close to the upper center of the PF Timing Belt as shown in
Figure 2-2.
3. Press the “MEASURE” button of the sonic tension gauge and flip the Timing Belt with plastic tweezers and
measure the tension of the belt three times.
Left side PF Timing Belt
Figure 2-2. Preparation
The following explains how the positional relationship between the PF Holder and the
Stopper Holder Idle Roller affects the tension of the PF Timing Belt.
Left side PF Timing Belt
The tension decreases as the Stopper

Holder Idle Roller goes away from the
PF Holder.
PF Holder
The tension of the belt increases if the Stopper

Holder Idle Roller is pushing the PF Holder.
A gap less than 0.3 mm is required between them Stopper Holder Idle Roller The tension increases as the Stopper
(almost touching but not actually touching). Holder Idle Roller pushes the PF
Holder.
Figure 2-3. PF Holder and Stopper Holder Idle Roller Relationship

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PF Belt Step Check
1. Connect the printer and the PC with the USB cable.

2. Start the Adjustment Program.
3. Select “PF belt step check” from the menu. The check screen appears.
4. Press the “Execute” button to perform the PF Timing Belt step check, and confirm the screen.
 When “OK” is displayed:
the check is complete.
 When “OK” is not displayed:
follow the instructions on the program screens, check that no abnormal noise or fatal error occurs.
If any of them occurs, go to Step 5. If not, the check is complete.
5. Reinstall the Front Paper Guide Assy, and reattach the Stopper Holder Idle Roller correctly.
(See " Paper Guide Front Assy (installation using the tools) (p28)" and " Paper Guide Front Assy (Stopper
Holder Idle Roller) (p28)".)
6. Perform PF Timing Belt Tension Measurement/PF Belt Step Check again by following the " Flowchart for
PF Timing Belt Tension Measurement/PF Belt Step Check (p40)".

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2.2.2 Checking the Platen Gap

This section describes the procedure for checking the platen gap (PG).
 If you have correctly reassembled the Printer Mechanism using the Epson-specified
tools, the PG falls within the expected range. However, deformation of any related part(s)
can cause improper PG. In such case, replace the Printer Mechanism.
 The standard range of the PG is as follows:
• Standard: 1.7 ± 0.2 mm
 Tools
 Thickness gauge: 1.5 mm (x2), 1.9 mm (x2)
 Confirmation procedure
When checking the PG, make sure of the following.

 Check the PG with the ink cartridges installed and the Upper Housing removed.
 Move the carriage by pulling the Timing Belt.
 Be careful not to damage the nozzles of the Printhead with the thickness gauge.
1. Move the carriage to the center of the printer.

2. Place the thickness gauges (1.5 mm) on the positions shown in Figure 2-4.
80-digit side 0-digit side
Thickness gauge Thickness gauge
Figure 2-4. Position of the Thickness Gauge

3. Pull the Timing Belt to move the carriage to both ends and confirm the carriage does not touch the thickness gauges.
If the carriage comes in contact with the thickness gauges, the PG is smaller than the standard value,
therefore, replace the Printer Mechanism.
4. Move the carriage to the center, and replace the thickness gauges (1.5 mm) with the thickness gauges (1.9
mm) on the same positions as Step 2.
5. Pull the Timing Belt to move the carriage to both ends and confirm the carriage touches the thickness gauges.
If the carriage does not come in contact with the thickness gauges, the PG is greater than the standard value,
therefore, replace the Printer Mechanism.

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2.2.3 MAC Address Setting

 This setting is not necessary when the data in EEPROM on the Main Board can be read out.
 To avoid a conflict of MAC address on a network, make sure to correctly follow the MAC
address setting flowchart given on the following.
 The user should be notified of the change of MAC address because of the following
reasons.
• If the user has set the printer’s MAC address on a router, the repaired printer with a
new MAC address cannot be connected to the network.
• The default printer name on a network consists of “EPSON” and the last six digits of the
MAC address. Therefore, the printer name becomes different from the previous one.
 You are required to enter the last six digits of the MAC address (xx:yy:zz) on the
adjustment program.
MAC address example: 00:00:48:xx:yy:zz
(“xx, yy, zz” represents a value unique to each printer)
Last six digits of MAC address
MAC Address Label
Figure 2-5. MAC Address Label
 Setting procedure
1. After replacing the Main Board, note down the MAC address written on a label on the Upper M/B Shield Plate.
2. Connect the printer and the PC with the USB cable.
3. Start the adjustment program.
4. Select the “Initial Setting” from the menu. The initial setting screen appears.
5. Enter the last six digits of MAC address into the MAC address entry field, and click the MAC Address input
button. (Enter the address again into the second entry field to confirm it.)
6. Select the network status sheet print menu on the printer’s control panel, and print the sheet. Check the MAC
address printed on the sheet to see if it is correct.
Figure 2-6. MAC Address Setting Screen

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CHAPTER 3
MAINTENANCE
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3.1 Overview
This section provides information to maintain the printer in its optimum condition.
OFFICE 940FW
BX535WD
 WorkForce 60 series:WorkForce 60/T42WD/Epson Stylus Office B42WD/
3.1.1 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.
 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.
3.1.2 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 " 3.2 Lubrication Points and Instructions (p48)" for the repairing
procedures below, and apply the specified type and amount of the grease to the specified part of the printer
mechanism.
 Grease
Type Name EPSON Part Code Supplier
Grease G-45 1033657 EPSON
 Tools
Maintenance Overview 46
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Name Availability EPSON Part Code

Injector O* ---
Brush O* ---
Flux dispenser O* 1049533
Note *: Use tools whose specifications are specified in " 3.2 Lubrication Points and Instructions (p48)".
Maintenance Overview 47
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3.2 Lubrication Points and Instructions

<Lubrication Point> <Lubrication Point>
Front Driven Pulley Holder Back Driven Pulley Holder
1. Bearing of the Driven Ribs (x3) on the Paper
Pulley Holder (x2). Guide Front Assy
2. Contact points (x8) with (Contact points with the PF
the Main Frame. Roller and Spur Gear 12)
3. Shaft hole of the Driven <Type>
Pulley. G-71
<Type> <Application Amount>
G-71 3 mm x 17 mm x 1 mm
<Application Amount> <Remarks>
1.  2 mm x appropriate  Apply  1 x 17 mm
amount Paper Guide Front Assy each with injector on
Driven Pulley 2.  1 mm x 2 mm the three points to make
3.  1 mm x 1 mm the application amount.
 Lubricate along the
<Remarks> grease grooves and
Apply with injector. wipe the grease that run
off the grooves.
 Do not touch section A
before/during/after
lubrication.
1. Application Point
2. Application Point Section A
3. Application Point 1. Application Point
Figure 3-1. Lubrication of the Driven Pulley Holder Figure 3-2. Lubrication of the Paper Guide Front Assy (PF Roller)
<Lubrication Point> <Lubrication Point> <Lubrication Point>

Ribs (x8) on the Paper Contact point between the PF Holder (x4)
Guide Front Assy PF Roller and the PF
<Type>
(Contact points of the EJ Roller Grounding Spring
Roller) G-71
<Type>
EJ Roller PF Roller Grounding Spring <Application Amount>
<Type> G-71
1. G-74 PF Holder
 0.5 mm x 0.5 mm
<Application Amount>
2. G-71 <Remarks>
 3 mm x 7 mm
<Application Amount> Apply with injector.
<Remarks>
1. 0.04 g
Apply with injector.
2.  1 mm x 4 mm
<Remarks>
 1. Apply with brush.
Paper Guide Front Assy 2. Apply with injector.
 Stir G-74 before use.
 Do not touch
application points after PF Roller
lubrication.
 Install the EJ Roller
soon after lubrication.
Application Point
1. Application Point Application Point

Figure 3-3. Lubrication of the Paper Guide Front Assy (EJ Roller) Figure 3-4. Lubrication of the PF Roller Grounding Spring Figure 3-5. Lubrication of the PF Holder
Maintenance Lubrication Points and Instructions 48

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Main Frame 1. Contact points (x4) on Contact points (x4) Shaft of the EJ Pulley (x3)
Main Frame
2.02 mm the Main Frame with the between the Main Frame
<Type>
2.7 mm CR Assy and the D/E Lever
G-71
1.35 mm
2. Contact point on the <Type>
Front Frame with the <Application Amount>
G-71
CR Assy EJ Pulley  1 mm x appropriate
2 mm Main Frame <Application Amount> amount
<Type>
350 mm
4.2 mm  0.5 mm x 10 mm
9.3 mm G-71 <Remarks>
<Remarks>  Using injector, apply
Apply with brush. grease on the thick part
 1.5 mm x 350 mm
of the shaft only from
(165 mg)
the root to the top edge.
<Remarks>  Lubricate along the
Front Frame  Apply with injector. grease grooves on the
Front Frame
EJ Pulley.
D/E Lever
3 mm
350 mm
Application Point
3.6 mm
Application Point
Application Point
Figure 3-7. Lubrication of the Main Frame (2) Figure 3-8. Lubrication of the EJ Pulley
Figure 3-6. Lubrication of the Main Frame (1)

Sliding surface of the Cap Valve Unit (x2) CR Assy 1. Rail Guide Pressurizing
Slider (x4) Plate (x2)
<Type>
<Type> 2. Contact points (x2) with
G-74
the Valve Cam
G-74
Ink System Assy <Application Amount>
<Type>
<Application Amount> 2 mm x 12 mm
G-71
1 mm x 15 mm
<Remarks>
<Remarks>  Apply with brush.
1.  3 mm x appropriate
 Apply with brush.  Stir G-74 before use.
amount
 Stir G-74 before use.
amount
<Remarks>
1. Apply with injector.
2. Lubricate along the rib
CR Assy Bottom of CR Assy
on the bottom of the CR
Assy with injector.
Bottom of CR Assy
Valve Unit
Application Point
Rail Guide Pressurizing Plate
Application Point 2. Application Point
Figure 3-9. Lubrication of the Ink System Assy (1) Figure 3-10. Lubrication of the Ink System Assy (2) Figure 3-11. Lubrication of the CR Assy

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<Lubrication Point> <Lubrication Point>

Shaft of the Scanner Contact points on the CIS
Housing (x4)/Rail area (x1) Carriage (x6) with the CIS
Unit
<Type>
G-45 <Type>
G-74
1.  1 mm x 2 mm <Application Amount>
2. 0.03 g x 2 points Appropriate amount
<Remarks> <Remarks>
1. After lubricating with Apply with Flux Dispenser.
injector, use brush to
spread the grease all
over the shaft.
2. Spread it with brush
after application with
injector.
Scanner Housing 1. Application Point

Figure 3-12. Lubrication of the Scanner Unit (WorkForce 635/625 series)

CIS Unit
<Lubrication Point>
Shaft of the Middle Shaft
Middle Shaft Assy
Assy (x3)
<Type>
G-71
<Application Amount> CIS Carriage
1.  2 mm x 4 mm
amount
<Remarks>
Apply with injector.
Application Point
Duplex Unit
Figure 3-13. Lubrication of the Duplex Unit Figure 3-14. Lubrication of the CIS Carriage (WorkForce 635/625 series)

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<Lubrication Point>
Grooves of the slider base
(contact points with the
Cam Slider)
<Type>
G-72
0.2 - 0.3 g x 3 points
<Remarks>
Apply with brush.
Cam Slider
Slider base
Application Point
Stopper Assy
Figure 3-15. Lubrication of the Stopper Assy (WorkForce 625 series)

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CHAPTER 4
APPENDIX
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4.1 Power-On Sequence

This section describes the power-on sequences for this product. The preconditions are as follows.

OFFICE 940FW
BX535WD
 WorkForce 60 series: WorkForce 60/T42WD/Epson Stylus Office B42WD/
 Condition 1: Normal power-on sequence (See Table 4-1.)

 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 of the Ink System Assy.
 The Carriage is normally fixed by the CR Lock.
 Condition 2: Power-on sequence after recovering from a paper jam error (See Table 4-2.)
 Turning on the printer after turning it off with a paper jam error.
 There still remains paper on the paper path out of the detecting area of the PE sensor.
Table 4-1. Condition 1: Normal Power-on Sequence *1
Carriage/PF Roller
Operation*2 movement and
position*3
1. Printhead initialization ࠠࡖ࡝࠶ࠫࡠ࠶ࠢ ࠠࡖ࡝࠶ࠫ
1-1.Initializes the Printhead, and checks for the fuse on the board in the Printhead.*4
2. Checking for waste ink overflow

2-1.Checks the waste ink counter if the waste ink overflow is occurring.
3. Avoiding deadlock sequence *5

3-1.The carriage moves to the 0-digit side slowly and confirms it touches the Right Frame.
3-2.The carriage slightly moves to the 80-digit side slowly.
3-3.The PF Motor rotates clockwise, and releases the CR lock.

ࠠࡖ࡝࠶ࠫࡠ࠶ࠢ⸃㒰
4. Seeking the home position

4-1.The carriage moves to the 0-digit side slowly and confirms it touches the Right Frame. The position when it
touches the Right Frame is set as the origin position temporarily.
4-2.The carriage slowly moves to the CR lock set position.
4-3.The PF Motor rotates counterclockwise, and sets the CR lock.
Appendix Power-On Sequence 53

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Table 4-1. Condition 1: Normal Power-on Sequence *1

Carriage/PF Roller
Operation*2 movement and
position*3
4-4.The carriage moves to the 80-digit side slowly and confirms it touches the CR lock.
4-5.The carriage slowly moves toward the 0-digit side and reaches the CR lock set position.
4-6.The PF Motor rotates clockwise, and releases the CR lock.
4-7.The carriage moves to the 80-digit side slowly and confirms it does not touch the CR lock.
4-8.The carriage slowly moves to its home position, and the origin position is fixed.
Afterward, the carriage position is monitored according to the signals from the CR Encoder.
5. PF initialization
5-1.The PF Motor rotates clockwise for approx. one second.
5-2.The PE sensor detects if paper exists and the PF Motor rotates clockwise for approx. 0.5 second.*6
6. Low temperature operation sequence*7

6-1.The carriage moves back and forth between the CR lock and the 80-digit side for two times.
7. PF measurement and PW sensor initialization

7-1.The carriage slowly moves to the 80-digit side.
7-2.The carriage moves to the VHCheck position quickly and stops; meanwhile the voltage values detected by the PW
sensor at the specified three points are recorded. At the same time, the PF Motor rotates clockwise and its load is
measured.
7-3.The carriage detects the voltage of the PW sensor at the carriage stop position (the black area at the Paper Guide
Front).
7-4.The carriage returns near its home position. At the same time, the PF Motor rotates clockwise and its load is
measured.
8. Detecting ink cartridge and initializing ink system*8

8-1.After the carriage slightly moves to the 80-digit side and checks the ink end sensor, detects the ink remaining.
8-2.The carriage slowly returns to its home position.
8-3.The carriage slowly moves to the 0-digit side to the CR lock set position.
8-4.The PF Motor rotates counterclockwise and sets the CR lock.
8-5.The carriage slowly returns to its home position.
Note *1: The PF motor drive is not transmitted to the Pickup Assy during this power-on sequence.
*2: The rotation directions of the PF Motor are as follows.
Clockwise: Paper is fed normally
Counterclockwise: Paper is fed backward

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*3: The conditions of the CR lock are as follows.

Red CR lock is set
White CR lock is released
*4: The fatal error occurs if there is a problem such as the fuse blew.
*5: Confirm that the CR lock is not get stuck in the gap of the carriage or any other parts preventing the carriage from moving.
*6: Eject paper if any.
*7: Executed when the detected temperature is under 5 oC (41oF) by the thermistor on the Printhead.
*8: The empty suction operation may occur depending on situations.
Table 4-2. Condition 2: Power-on Sequence after Recovering from a Paper Jam Error
Carriage/PF Roller
Operation movement and
position
Executes No.1 to No.5 on the normal power-on sequence (Table 4-1).
6. Detecting remaining paper
6-1.The carriage moves to the 80-digit side and confirms there is no paper.*1
6-2.The carriage quickly returns to its home position, and displays on the LCD 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 4-1) is executed
again.*2
Note *1: “Paper exists” is detected when the carriage touches the paper. When “paper does not exist” is detected, the power-on sequence
of condition 1 (Table 4-1) is executed from No.6.
*2: If the paper jam error cannot be solved after repeating the power-on sequence on condition 2 (Table 4-2) twice, the printer turns
into the paper jam fatal error for the third time.

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4.2 Connector Diagram

Cable connections of this printer are shown below.
CR Unit
CSIC
B M Y C
PW Sensor
Printhead CR Contact Module CN2

CN1 CR Encoder Board
CN1
Workforce 635 series
FAX Board
CN1 CN3
CN13
CN12 CN11
CN17 Stacker Open Sensor (Workforce 60 series)
Workforce 635/620 series
CN16 Cover Open Sensor
CN2 (Workforce 635 series)
Scanner Motor
Scanner Unit CN8 (Workforce 620 series) CN15 PE Sensor
CIS Module CN17 CN14 PF Encoder
Workforce 635 series CN6 CR Motor
Main Board
ADF PE Sensor CN18 CN7 PF Motor
ADF Encoder CN19
ADF Unit CN1 USB
ADF Document Sensor CN22
CN20 USB Host (Workforce 635/620 series)
ADF Motor CN24
CN4 Ethernet
CN5 CN501 CN21
CN9/10 Memory Card (Workforce 635/620 series)
Workforce Workforce Workforce

635 series 620 series 60 series J1
CN2
PS Board Wireless LAN Module*
CN1 CN1 CN1
Panel Board Panel Board Panel Board
CN2 CN2 AC in
CN1
Panel Sub
Board
CN2
LCD
Note "*": This is not mounted on Epson ME OFFICE 85ND.

Panel Unit
Figure 4-1. Connector Diagram
Appendix Connector Diagram 56

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4.3 Troubleshooting
This section describes the troubleshooting workflow and fatal error information.
4.3.1 Troubleshooting Workflow

The following page describes the troubleshooting workflow. Follow the flow when troubleshooting problems.
Appendix Troubleshooting 57
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Epson WorkForce 635/625/60 series Revision D
Start 1
Major problem with error message
Turn on the printer
Fatal error Maintenance error Ink End error Ink Cartridge error No Ink Cartridge error Scanner Open error Paper Jam error
No
Does printer turn on the Please refer to " 4.3.2 Fatal Error [Occurrence Condition] [Occurrence Condition] [Occurrence Condition] [Occurrence Condition] [Occurrence Condition] Please refer to " Paper Jam error"
power? Code (p59)"for troubleshooting. This error occurs when This error occurs when ink in Ink This error occurs when Ink This error occurs when Ink This error occurs when Scanner of “Error occurs in printing
maintenance counter in EEPROM Cartridge is empty. Cartridge data is incorrect or Ink Cartridge is not installed. Unit is in open condition. operation”.
Major problem without exceeds the specified value. Cartridge is not recognized
Yes error message [Major Occurrence Timing] correctly. [Major Occurrence Timing] [Major Occurrence Timing]
[Major Occurrence Timing] • Power-on timing • Power-on timing • Power-on timing
• Power-on timing • Print start timing [Major Occurrence Timing]
Is Power-on sequence
No No Power*1 • Print start timing • Cleaning timing • Power-on timing [Troubleshooting] [Major Troubleshooting]
finished without error?

1 • Cleaning timing
• Ink Cartridge replacement
• Ink Cartridge replacement
timing
• Print start timing
• Cleaning timing
• Ink Cartridge installation • Scanner Unit close
• Scanner Unit replacement
[Presumable Cause]
• Power Supply Board damage timing • Print timing • Ink Cartridge replacement • Scanner Open Sensor
• Main Board damage timing replacement
Yes [Troubleshooting] [Troubleshooting] • Main Board replacement
[Major Troubleshooting] • Porous Pad replacement • Ink Cartridge replacement [Major Troubleshooting]
• Power Supply Board • Maintenance counter reset • Remove and reinstall Ink
Standby condition [NOTE] Cartridge
replacement
• Main Board replacement If this error occurs during auto • Ink Cartridge replacement
duplex print operation, printer • CSIC Terminal replacement
stops and eject the paper • CR Contact Module
Perform “Flow A” Flow A automatically even if the printing replacement
Start is not completed. • Head FFC replacement
• Main Board replacement
Print check pattern

Printer failure only
What is returned reason?
Is printing operation No
ADF/Scanner
unit failure finished without error?
Copy an image
Yes
No Paper Jam error No Paper error Double Feed error*2 Paper Size Unmatch error Paper Size error*3
Is printing operation
No finished without trouble? [Occurrence Condition] [Occurrence Condition] [Occurrence Condition]
Is scanning operation [Occurrence Condition] [Occurrence Condition]
finished without This error occurs when top/ This error occurs when top of This error occurs on the following This error occurs when actual This error occurs when actual
bottom of paper is not detected by paper is not detected by PE Sensor case. paper size is not matched to paper size is not matched to
trouble? Yes PE Sensor in the specified steps of in the specified steps of paper theoretical one. (Detect both
• A paper is ejected without theoretical one. (Detect shorter
Scanner failure paper feeding operation correctly. loading operation correctly. printing during paper loading shorter and longer) only)
Return previous flow (No paper / No loading / No operation.
Yes [Presumable Cause] [Major Occurrence Timing] cassette / large paper skew) • Actual paper length is longer [Major Occurrence Timing] [Major Occurrence Timing]
• Contamination of Scanner Glass • Power-on timing than theoretical one. • Duplex print timing • Paper loading timing
• Contamination of Document Pad • Paper loading timing [Major Occurrence Timing] • Paper feed timing
• CIS Unit bonding failure Major problem without error message • Paper eject timing • Paper loading timing [Major Occurrence Timing] [Troubleshooting] • Paper eject timing
No • CIS Unit damage • Duplex print timing • Paper loading timing • PE Sensor Lever replacement
• Contamination of Scanner Motor Encoder [Major Troubleshooting] • Paper feed timing • PE Sensor replacement [Troubleshooting]
ADF failure? • Scanner Motor Encoder Sensor damage [Major Troubleshooting] 1 Put papers in cassette and push • PW Sensor replacement
• Paper eject timing • PE Sensor Lever replacement
• Scanner Motor damage 1 Push “Start” button to eject the “Start” button. • Main Board replacement • PE Sensor replacement
Poor Printing Poor Paper Loading paper. 2 If a paper stops before reaching [Troubleshooting] • PW Sensor replacement
[Major Troubleshooting] • Success PE Sensor, remove it and • PE Sensor Lever replacement • Main Board replacement
[Phenomenon] [Presumable Cause] Start paper feeding operation check the paper condition.
Yes • Scanner Glass cleaning • Poor printing quality • Use of 3rd party media • PE Sensor replacement
• Document Pad cleaning again if printer has print data. 3 A) If no damage in the above 2), • PW Sensor replacement
• Ink stain on paper • Edge guide mis-setting • Fail set edge guide correctly after
• Document Pad replacement • Dot missing • Foreign material • Main Board replacement
Copy an image by ADF • CIS Unit replacement Occur paper jam error again. putting papers in cassette and
• Paper eject without printing • Part come-off 2 If fail in the above 1), remove retry.
• Scanner Motor Encoder cleaning • Contamination of Pickup
• Scanner Motor Encoder Sensor the paper by opening Scanner B) If damage in the above 2),
[Presumable Cause] Roller or paper feed roller Unit or taking off Duplex Unit. check foreign materials /
replacement • Driver / Panel mis-setting (Duplex Unit)
• Scanner Motor replacement 3 Push “Start” button again. parts come-off / parts
No • Contamination of CR scale • Cassette Assy damage • Success transformation in paper
Is ADF operation finished • Contamination of Printhead Start paper feeding operation path.
cover [Major Troubleshooting] again if printer has print data. 4 If not resolved by 3-A) & 3-B),
without trouble? • Printhead damage • Recommendation of EPSON • Fail check foreign material / Part
• Ink clogging of Printhead media Occur paper jam error again. come-off / surface condition of
ADF failure
Yes • Contamination on Cap Unit /
Wiper of Ink System Assy
• Edge guide re-setting
• Foreign material removal
4 If fail in the above 3), check Pickup Roller or Paper Feed  This flowchart is compiled based on the following
[Phenomenon] foreign material / part come- Roller (Duplex Unit) / PE
• Ink System Assy damage • Part re-installation
• No paper feed • Float of Porous Pad on Paper • Roller replacement
off / PE Sensor Lever / PE Sensor Lever / PE Sensor / contents.
• Double feed Sensor / Porous Pad on Paper Main Board / PF Motor /
Guide Front • Cassette Assy replacement Guide Front / Main board / Cassette Assy / Stopper Assy.
• Paper jam • Narrow PG Stopper Assy.
• Our experience regarding the quality problem.
• Paper skew • PE Sensor Lever damage
[Presumable Cause]
• PE Sensor damage
Abnormal Noise [NOTE] • ESK’s repair data on FY08 / FY09 models.
• Wear of Pickup Roller If this error occurs during auto
[Major Troubleshooting] duplex print operation, printer • Printer Mechanism specification for Epson
• Wear of ADF Pad Assy • Driver / Panel re-setting [Presumable Cause]
• Gear damage • Foreign material stops and eject the paper
• CR Scale replacement automatically even if the printing WorkForce 635/625/60 series.
• ADF Motor damage • Printhead cover cleaning • Insufficient grease
• Contamination of Scanner Glass • Gear damage is not completed. (print data of
• Paper Sheet Assy damage
• Printhead cleaning
• Ink Cartridge replacement • “Stopper Holder Idle Roller” adverse side & reverse side is
eliminated.)
 WorkForce 60 series does not have the Scanner/ADF
• Foreign material • Printhead replacement mis-setting
• ADF Cover Assy damage • Rubber cleaning of Cap Unit unit, so the troubleshooting for the Scanner/ADF unit
• Wear of EJ Roller • Ink System Assy replacement [Major Troubleshooting]
• ADF Sensor damage • Porous Pad re-installation • Foreign material removal is not applicable to this series.
• PG readjustment • Lubrication of grease *1: If the printer can turn on but turns off right away, the protection
[Major Troubleshooting] • Printer Mechanism • Gear replacement
• “Stopper Holder Idle Roller” circuit may cut off the power due to an error such as a circuit failure.  Error indications of WorkForce 60 series are LED
• ADF Cover Assy replacement replacement
• ADF Pad Assy replacement • PE Sensor Lever replacement re-setting *2: Only for manual duplex print only. So, check the details on errors with the EPSON
Finish*4 • Scanner Glass cleaning • PE Sensor replacement *3: Only for fax print
• Paper Sheet Assy replacement *4: In case of “Not Trouble Found”, check fatal error code. Status Monitor 3.
• Foreign material removal
• ADF unit replacement
Appendix Troubleshooting Workflow 58

Confidential
4.3.2 Fatal Error Code

This section describes the fatal error code and the possible cause for this product.
WorkForce 60 series does not have the Scanner/ADF unit, so Table 4-4 is not applicable to
this series.
 Printer fatal error list
Table 4-3. Fatal Error List (Printer)

Error
Error type Error name Possible cause
code
• CR Encoder failure (contaminated/detached scale, Encoder Board failure)
• CR Motor failure
01H CR PID excess load error
• Carriage overload error (paper jam/foreign object)
• Cable disconnection
• Motor driver failure (Main Board failure)
02H CR PID excess speed error
• Tooth skip of the CR Timing Belt
• Improper tension of the CR Timing Belt
03H CR PID reverse error
• Paper jam
04H CR PID lock error
05H CR PID speed degradation error • Tooth skip of the CR Timing Belt
DC motor • Paper jam
error
08H CR load position reverse error
• Paper jam
09H CR load position excess speed error
0AH CR load position excess load error
• PF Encoder failure (contaminated/detached scale, Encoder Board failure)
• PF Motor failure
F1H PF PID excess load error
• PF drive mechanism overload (paper jam/foreign object)
F2H PF PID excess speed error
• Tooth skip of the PF Timing Belt
• Improper tension of the PF Timing Belt
Appendix Fatal Error Code 59

Confidential
Table 4-3. Fatal Error List (Printer)

Error
Error type Error name Possible cause
code
F3H PF PID reverse error
• Paper jam
F4H PF PID lock error
• PF drive mechanism overload (paper jam/foreign object)
F6H PF PID excess torque limitation error ---*
DC motor • PF Encoder failure (contaminated/detached scale, Encoder Board failure)
error F8H PF load position reverse error • Tooth skip of the PF Timing Belt
F9H PF load position excess speed error
FAH PF load position excess load error • PF Encoder failure (contaminated/detached scale, Encoder Board failure)
FCH PF load position error • PF drive mechanism overload (paper jam/foreign object)
D1H CR (PID) driving time error
Motor drive D2H CR (load position) driving time error

• Main Board failure
time error D3H PF (PID) driving time error
D4H PF (BS) driving time error
Command error 30H EEPROM verify error (by command) ---*
40H Transistor temperature error • Main Board failure
Printhead 41H X-Hot detect error (pre printing)

system error • Printhead failure
42H X-Hot detect error (after flushing)
43H Head temperature error
50H Home position error
51H Deadlock avoidance error • Paper jam
52H Impossible contact detection error • Foreign object
• Deformation of the Main Frame
Sequence Contact error at ink replacement timing
error 56H
(Power-off)
• Paper jam
5BH Insoluble paper jam error
• Foreign object
7EH No print inspection mode error ---*
60H PW detector error
• PW Sensor failure
Sensor error 61H PW detector confusion error
63H PE detector error
• Ink Cartridge failure
Ink device B0H - • CSIC Terminal failure
Ink device error
error CFH • CR Contact Module failure
Circuit error 80H Circuit error (include blowout of a fuse) • Main Board failure
Note "*": Not occurs except in manufacturing process.

Confidential
 ADF/Scanner fatal error list (WorkForce 635/625 series)
Table 4-4. Fatal Error List (ADF/Scanner)

Error code Error name Possible cause
• ADF Encoder failure (contaminated/detached scale, Encoder Board failure)
01H ADF PID excess speed error
• ADF Encoder failure (contaminated/detached scale, Encoder Board failure)
02H ADF PID reverse error
• Paper jam
03H ADF PID lock error • ADF Encoder failure (contaminated/detached scale, Encoder Board failure)
• ADF Motor failure
05H ADF PID excess load error • Paper jam
06H ADF PID driving time error • Main Board failure
• CIS Unit failure
10H Scanner HP detection error • Scanner Housing failure
• CIS Unit failure
20H Scanner LED light error
30H ADF option error • Main Board failure
36H ADF paper jam error • Paper jam

Confidential

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SERVICE MANUAL

Color Inkjet Printer

WorkForce 635/Epson Stylus Office TX620FWD/Epson Stylus Office BX625FWD/

Copyright 2011 SEIKO EPSON CORPORATION

CHAPTER 1. DISASSEMBLY / REASSEMBLY

Symbols Used in this Manual

May indicate an operating or maintenance procedure, practice or condition that is necessary to

Revision Date of Issue Description

A April 28, 2010 First Release

B August 6, 2010  Chapter 3

C October 12, 2010 Revised Contents

1.1 Overview ................................................................................................................................................................. 12

2.1 Required Adjustments ............................................................................................................................................. 34

3.1 Overview ................................................................................................................................................................. 46

4.1 Power-On Sequence ................................................................................................................................................ 53

In this chapter, the product names are called as follows:

Name Availability EPSON Part Code

Note 1: Some of the tools listed above are commercially available.

1.2 Disassembly/Reassembly Procedures

(p 24) (p 30) Shows removal/installation

Item Description Reference

Disassembly/Reassembly Disassembly/Reassembly Procedures 14

1.2.1 Standard Operation Time for servicing the product

Disassembly/Reassembly Disassembly/Reassembly Procedures 15

Table 1-1. Standard Operation Time (WorkForce 635 series)

Table 1-2. Standard Operation Time (WorkForce 625 series)

Disassembly/Reassembly Disassembly/Reassembly Procedures 16

Table 1-2. Standard Operation Time (WorkForce 625 series)

Table 1-3. Standard Operation Time (WorkForce 60 series)

Disassembly/Reassembly Disassembly/Reassembly Procedures 17

Table 1-3. Standard Operation Time (WorkForce 60 series)

Disassembly/Reassembly Disassembly/Reassembly Procedures 18

1.2.2 Disassembly/Reassembly Flowchart

USB Cover Decoration Plate Waste Ink Tray

1 --- 3 1 --- --- --- --- ---

ADF Unit/ Document Pad

2 1 1 1 --- 2 --- --- ---

S3 S8 --- S3 --- S4 2 S4 2 1 S4 2 4 --- ---

Hinge Panel Unit Panel Unit

--- (p 24) (p 30) (p 24) (p 31)

Right Housing WorkForce 625 series specific parts/unit

WorkForce 635 series/

Disassembly/Reassembly Disassembly/Reassembly Flowchart 19

1 (p 19) 2 (p 19) 3 (p 19)

(p 27) (p 27) (p 27) (p 26) (p 24) (p 24) ---

Top ADF Cover Panel Board Panel Board

(p 27) WorkForce 635 series specific parts/unit

WorkForce 625 series specific parts/unit

S4 5 --- S2 --- --- Screw type/torque list

--- S5 C.B.S-TITE SCREW,3X10,F/ZN-3C 6 1 kgf·cm

Disassembly/Reassembly Disassembly/Reassembly Flowchart 20

Waste Ink Tray USB Cover

--- --- --- 1 --- 1

(p 29) --- (p 35) (p 35) (p 35) (p 29)

Panel Unit Pickup Assy P/S Board Assy

(p 29) --- (p 39)

USB Cover LED Lens Button

Disassembly/Reassembly Disassembly/Reassembly Flowchart 21

FAX Grounding Extension Spring CR Scale/ Ref.

Driven Pulley/ CSIC Terminal CR Contact

3 --- --- 1 2 I/C Guide --- ---

1 1 --- 2 S4 1 S3 S4 --- --- 8 2

(p 26) (p 48) --- (p 25) (p 49) (p 30) 1 --- ---