Service Manual: Epson PM-520 Epson PM-525

SERVICE MANUAL
Color Inkjet Printer
Epson PM-520
Epson PM-525
CONFIDENTIAL
SEIJ16-001
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 2017 SEIKO EPSON CORPORATION

Printer CS Quality Assurance Department
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Safety Precautions
All safety procedures described here shall be strictly adhered to by all parties servicing and maintaining this
product.
DANGER
Strictly observe the following cautions. Failure to comply could result in serious bodily injury or loss of life.
1. Always disconnect the product from the power source and peripheral devices when servicing the product or
performing maintenance.
2. When performing works described in this manual, do not connect to a power source until instructed to do so.
Connecting to a power source causes high voltage in the power supply unit and some electronic components
even if the product power switch is off. If you need to perform the work with the power cable connected to a
power source, use extreme caution to avoid electrical shock.
WARNING
Strictly observe the following cautions. Failure to comply may lead to personal injury or loss of life.
1. Always wear protective goggles for disassembly and reassembly to protect your eyes from ink in working. If
any ink gets in your eyes, wash your eyes with clean water and consult a doctor immediately.
2. When using compressed air products; such as air duster, 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. The capacitors on the Main Board may be electrically charged right after the power turns off or after driving
motors which generates counter electromotive force such as when rotating the PF Roller or when moving the
CR Unit. There is a risk to damage the Main Board if the Head FFC is short-circuited with the capacitors on
the Main Board electrically charged, therefore, after the power turns off or after motors are driven, leave the
printer untouched for approximately 30 seconds to discharge the capacitors before starting disassembly/
reassembly.
6. To prevent the circuit boards from short-circuiting, be careful about the following when handling FFC or
cables.
 When handling FFC, take care not to let the terminal section of FFC touch metal parts.
 When connecting cables/FFC to the connectors on circuit boards, connect them straight to the connectors to avoid
slant insertion.
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7. In order to protect sensitive microprocessors and circuitry, use static discharge equipment, such as anti-static
wrist straps, when accessing internal components.
8. Do not tilt this product immediately after initial ink charge, especially after performing the ink charge several
times. Doing so may cause ink to leak from the product because it may take some time for the waste ink pads
to completely absorb ink wasted due to the ink charge.
9. Never touch the ink or wasted ink with bare hands. If ink comes into contact with your skin, wash it off with
soap and water immediately. If you have a skin irritation, consult a doctor immediately.
10. When disassembling or assembling this product, make sure to wear gloves to avoid injuries from metal parts
with sharp edges.
11. Use only recommended tools for disassembling, assembling or adjusting the printer.
12. Observe the specified torque when tightening screws.
13. Be extremely careful not to scratch or contaminate the following parts.
 Nozzle plate of the Printhead
 CR Scale
 PF Scale
 Coated surface of the PF Roller
 Gears
 Rollers
 LCD
 Exterior parts
14. Never use oil or grease other than those specified in this manual. Use of different types of oil or grease may
damage the component or give bad influence on the printer function.
15. Apply the specified amount of grease described in this manual.
16. Make the specified adjustments when you disassemble the printer.
17. When cleaning this product, follow the procedure described in this manual.
18. When transporting this product after filling the ink in the printhead, pack the printer without removing the
ink cartridges in order to prevent the printhead from drying out.
19. Make sure to install antivirus software in the computers used for the service support activities.
20. Keep the virus pattern file of antivirus software up-to-date.
21. When disassembling/reassembling this product, if you find adhesive power of the double-sided tape which
secure the parts or FFC is not enough, replace the tape with new one and attach it correctly to the specified
points where the parts or FFC should be secured.
22. Unless otherwise specified in this manual, the labels attached on the returned product should be transferred to
the corresponding attachment positions on the new one referring to the labels on the returned product.
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Safety Instructions for the Optional Battery
1. Use an Epson Li-ion battery model C12C932941 or C12C932951 for this printer according to the directions
in the user documentation. Do not use the battery with non-rechargeable batteries (primary cell batteries) or
with rechargeable batteries (secondary cell batteries) of different capacities or types. Use of batteries not
designed for this printer can cause excessive discharging during use, and an excessive current to flow during
charging. As a result, the battery could become hot, emit smoke, rupture, or catch fire.
2. Do not place the battery in a microwave oven or a high-pressure container. Otherwise, the battery could
become hot, emit smoke, rupture, or catch fire.
3. Do not drop or throw the battery or subject it to strong shocks. Otherwise, the battery could leak or the
protection circuit in the battery could be damaged. As a result, the battery could become hot, emit smoke,
rupture, or catch fire.
4. Do not use or leave the battery in a hot location (more than 50C), such as near a fire or a heater. Otherwise,
the plastic separator could melt and the individual cells could short-circuit. As a result, the battery could
5. Do not leave the battery in a vehicle. Otherwise, the battery could overheat.
6. Do not expose the battery to high humidity.
7. Do not handle the battery with wet hands or use it in locations near water. If the battery gets wet or is
immersed in water, an excessive current will flow during charging. As a result, the battery could become hot,
emit smoke, rupture, or catch fire.
8. Do not incinerate or heat the battery. Otherwise, the battery could become hot, emit smoke, rupture, or catch
fire.
9. Do not allow the battery to come into contact with metals objects, such as coins and keys. Do not carry or
store the battery with metal objects. Otherwise, the battery could short-circuit. As a result, the battery could
10. Do not touch battery terminals.
11. If overheating, discoloration, or deformation occur, remove the battery from the printer and do not use it.
12. Do not connect the battery to an electrical outlet or to an automobile cigarette lighter receptacle. High voltage
to the battery will cause an excessive current to flow. As a result, the battery could become hot, emit smoke,
rupture, or catch fire.
13. Do not short-circuit the battery.
14. Do not remove the outside case of the battery to protect against short circuits.
15. Do not puncture, strike, or step on the battery. If the battery is broken or deformed, it could short-circuit. As
a result, the battery could become hot, emit smoke, rupture, or catch fire.
16. Do not insert objects into any openings as they may touch dangerous voltage points or short-circuit
components.
17. Do not solder any item directly to the battery. Otherwise, the insulator could melt, or the gas vent or the
safety function could be damaged. As a result, the battery could become hot, emit smoke, rupture, or catch
fire.
18. If a battery is swallowed, seek medical treatment immediately.
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19. Do not disassemble or modify the battery. To prevent accidents, the battery is equipped with a safety function
and protection circuit. If the safety function or protection circuit is damaged, the battery could become hot,
20. Do not use the battery if it is leaking or damaged in any way. Otherwise, the battery could become hot, emit
smoke, rupture, or catch fire.
21. If the liquid leaks from the battery (or the battery gives out bad smell), let the battery leave from flammable
objects immediately. Unless do that, the electrolyte leaked from battery will catch fire and it will cause the
smoke, flame or rupture of it.
22. If battery acid gets in your eyes, immediately rinse your eyes thoroughly with fresh water without rubbing
them. And then, see a doctor immediately. Otherwise, permanent eye damage could result.
23. If battery acid gets on your skin, immediately rinse the affected area thoroughly with water. And then, see a
doctor immediately.
24. Use only AC adapter model A461H or A462E to charge the battery and operate the printer.
25. Do not charge or use the battery with devices other than the specified product. Otherwise, the performance
and life of the battery could decrease. In addition, the battery or device could be damaged and cause an
abnormal current to flow. As a result, the battery could become hot, emit smoke, rupture, catch fire, or
explode.
26. Use the specified charger and observe the charging requirements. Otherwise, the battery could become hot,
27. Do not charge the battery near an open flame or in very hot locations. If the protection circuit in the battery is
activated, you will not be able to charge the battery. If the protection circuit is damaged, the battery could
28. If the battery is not fully charged within the specified time, stop charging. Otherwise, the battery could
29. The battery has polarity. Do not forcefully connect the battery to the charger or product even if the battery
cannot be connected easily. Be sure to confirm the polarity of the battery when connecting it. Do not reverse
the polarity of the battery connections (terminals). If the battery is connected incorrectly during charging, the
battery will be reverse-charged and an abnormal chemical reaction could occur in the battery. As a result, the
battery could become hot, emit smoke, rupture, or catch fire.
30. Do not reverse the polarity of the battery connections (terminals). If the battery is connected incorrectly
during charging, the battery will be reverse-charged and an abnormal chemical reaction could occur in the
battery. If the battery is connected incorrectly during discharging, an excessive current could flow. As a
result, the battery could become hot, emit smoke, rupture, or catch fire.
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About This Manual
This manual, consists of the following chapters, is intended for repair service personnel and includes information
necessary for properly performing maintenance and servicing the product.
CHAPTER 1. TROUBLESHOOTING
Describes the step-by-step procedures for the troubleshooting.
CHAPTER 2. DISASSEMBLY / REASSEMBLY

Describes the disassembly/reassembly procedures for main parts/units of the product, and provides the
standard operation time for servicing the product.
CHAPTER 3. ADJUSTMENT
Describes the required adjustments for servicing the product.
CHAPTER 4. MAINTENANCE
Describes maintenance items and procedures for servicing the product.
CHAPTER 5. REFURBISHMENT
Describes refurbishing work of the product and its purpose.
CHAPTER 6. APPENDIX
Provides the following additional information for reference:
 Connector Diagram
 Protection for Transportation
Symbols Used in this Manual

Various symbols are used throughout this manual either to provide additional information on a specific topic or
to warn of possible danger present during a procedure or an action. Pay attention to all symbols when they are
used, and always read explanation thoroughly and follow the instructions.
Indicates an operating or maintenance procedure, practice or condition that, if not strictly observed,
could result in serious injury or loss of life.
Indicates an operating or maintenance procedure, practice, or condition that, if not strictly observed,
could result in bodily injury, damage or malfunction of equipment.
May indicate an operating or maintenance procedure, practice or condition that is necessary to

accomplish a task efficiently. It may also provide additional information that is related to a specific
subject, or comment on the results achieved through a previous action.
For Chapter 2 “Disassembly/Reassembly”, symbols other than indicated above are used to show additional
information for disassembly/reassembly. For the details on those symbols, see "2.3 Disassembly/Reassembly
Procedures (p35) ".
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Revision Status
Revision Date of Issue Description
A February. 15, 2017 First Release
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Epson PM-520/PM-525 Revision A
Contents
Chapter 1 Troubleshooting
1.1 Troubleshooting....................................................................................................................................................... 10
1.1.1 Troubleshooting Workflow ............................................................................................................................ 10
1.2 Power-On Sequence ................................................................................................................................................ 12
1.3 Fatal Error Code List............................................................................................................................................... 14
1.3.1 Displaying the Fatal Error Code..................................................................................................................... 14
1.3.2 Printer Fatal Error Code ................................................................................................................................. 15
Chapter 2 Disassembly/Reassembly
2.1 Overview ................................................................................................................................................................. 19
2.1.1 Tools ............................................................................................................................................................... 19
2.1.2 Jigs .................................................................................................................................................................. 19
2.1.3 Locations of the Parts/Units ........................................................................................................................... 20
2.1.4 Standard Operation Time for Servicing the Product ...................................................................................... 23
2.2 Common cautions when disassembling/reassembling the Product......................................................................... 26
2.3 Disassembly/Reassembly Procedures ..................................................................................................................... 28
2.3.1 Works before Disassembling/Reassembling the Product............................................................................... 28
2.3.2 Disassembly Flowchart................................................................................................................................... 29
2.3.3 Disassembly Flowchart (Main Board,Sub Board Assy,Battery/Printhead) ................................................... 35
2.4 Detailed Disassembly/Reassembly Procedure for each Part/Unit........................................................................... 36
2.5 Routing FFCs/cables ............................................................................................................................................... 40
Chapter 3 Adjustment
3.1 Required Adjustments ............................................................................................................................................. 44
3.2 Adjustment Program................................................................................................................................................ 48
3.2.1 Operating Environment .................................................................................................................................. 48
3.2.2 Details of the Adjustment Program ................................................................................................................ 48
3.2.2.1 Battery check ......................................................................................................................................... 48
3.2.2.2 Direction Finding Sensor adjustment .................................................................................................... 49
3.3 Mechanism Adjustment / Check ............................................................................................................................. 50
3.3.1 Checking the Platen Gap ................................................................................................................................ 50
3.3.1.1 Preparation ............................................................................................................................................. 51
3.3.1.2 Adjustment procedure............................................................................................................................ 53
3.3.2 Checking the Head FFC position.................................................................................................................... 54
Chapter 4 Maintenance
4.1 Cleaning................................................................................................................................................................... 56
4.1.1 Cleaning the CR Unit ..................................................................................................................................... 56
4.1.2 Cleaning the Exterior Parts/inside of the printer ............................................................................................ 57
4.2 Lubrication .............................................................................................................................................................. 58
4.2.1 Lubrication Points and Instructions................................................................................................................ 59
4.3 Firmware Update..................................................................................................................................................... 60
Chapter 5 Refurbishment
5.1 Overview ................................................................................................................................................................. 62
5.1.1 Ink Discharge.................................................................................................................................................. 62
5.1.1.1 Preparation ............................................................................................................................................. 63
9
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Chapter 6 Appendix
6.1 Connector Diagram ................................................................................................................................................. 66
6.2 Protection for Transportation .................................................................................................................................. 67
6.2.1 Securing the Paper Support Assy ................................................................................................................... 67
6.3 Procedure of battery transportation ......................................................................................................................... 67
10
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CHAPTER 1
TROUBLESHOOTING
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1.1 Troubleshooting
This section describes the troubleshooting workflow and fatal error information.
1.1.1 Troubleshooting Workflow

The following page describes the troubleshooting workflow. Follow the flow when troubleshooting problems.
 This flowchart is compiled based on the following contents.

• Our experience regarding the quality problem.
• ESK’s repair data.
• Printer Mechanism specification for the product.
 If the reason for the return is evident, first check the phenomenon user claims recurs,
then proceed to the troubleshooting.
Start
Turn on the power
No
Does printer turn on the
power? 1
(p 13)
Yes
No
Is Power-on sequence
finished without error? 2
(p 13)
Yes
Standby condition
Print network status sheet

(p 14)
Print check pattern
Yes
Does an error occur
when printing? 3
(p 13)
No
No
Is printing operation
finished without trouble? 4
(p 13)
Yes
Finish*
*: In case of “Not Trouble Found”, check fatal error code.
Figure 1-1. Troubleshooting Workflow (1)
Troubleshooting Troubleshooting Workflow 12

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The power-on sequence Error is indicated during power-on

1 does not start (p 12)
2 sequence (p 12)
No Power* Fatal error Waster ink error Ink End error Ink Cartridge detection error No Ink Cartridge error Paper Jam Fatal error Maintenance Box error
[Presumable Cause] Please refer to " 1.3 Fatal Error [Occurrence Condition] [Occurrence Condition] [Occurrence Condition] [Occurrence Condition] Please refer to " Paper Jam error [Occurrence Condition]
• AC adapter damage Code List (p19) ". This error occurs when This error occurs when ink in Ink This error occurs when Ink This error occurs when Ink (p13) ". This error occurs when the
• Main/Sub Board damage maintenance counter in EEPROM Cartridge is empty. Cartridge has a defect. Cartridge is not installed. Maintenance Box has a defect or
• Panel Unit damage exceeds the specified value. is not set.
[Major Occurrence Timing] [Major Occurrence Timing] [Major Occurrence Timing]
[Major Troubleshooting] [Major Occurrence Timing] • Power-on timing • Power-on timing • Power-on timing [Major Occurrence Timing]
• AC adapter replacement • Power-on timing • Print start timing • Print start timing • Power-on timing
• Main/Sub Board replacement • Print start timing • Cleaning timing • Cleaning timing [Troubleshooting] • Print start timing
• Panel Unit replacement • Paper eject timing • Ink Cartridge replacement • Ink Cartridge replacement • Ink Cartridge installation • Cleaning timing
• Cleaning timing timing timing
*: If the printer can turn on but turns off right • Ink Cartridge replacement [Troubleshooting]
timing [Troubleshooting] [Troubleshooting] • Maintenance Box re-
away, the protection circuit of the AC • Ink Cartridge replacement • Remove and reinstall Ink installation
adapter may cut off the power. [Troubleshooting] Cartridge • Maintenance Box replacement
• Maintenance Box replacement • Ink Cartridge replacement • Main Board replacement
& Maintenance counter reset • Head FFC Assy replacement
• Main board replacement • Main Board replacement
• Ink System Lower Porous Pad
replacement (The pad should
be replaced at every other
replacement of Maintenance
Box Assy.)
3 Error is indicated during power-on sequence (p 12) 4 Problems related to print result or during printing (p 12)
Paper Jam error No Paper error Paper Size Mismatch error Poor Print Quality Paper Loading Failure Abnormal Noise
[Occurrence Condition] [Occurrence Condition] [Occurrence Condition] [Phenomenon] [Presumable Cause] [Presumable Cause]
This error occurs when top/ This error occurs when top of This error occurs when the actual • Poor print quality • Use of 3rd party media • Foreign materials
bottom of paper is not detected by paper is not detected by PE Sensor paper length detected by the PE • Ink stain on paper • Edge guide wrong setting • Insufficient grease
PE Sensor within the specified in the specified steps for Sensor does not match with the • Dot missing • Foreign materials • Gear damage
steps of normal paper loading/ completing paper loading paper size specified in the driver. • Paper eject without printing • Part come-off
ejecting operation. operation. (No paper is set, paper (It occurs when the detected paper • Contamination of LD Roller or [Major Troubleshooting]
fails to be fed, or paper is fed at an length is shorter or longer than the [Presumable Cause] PF Roller • Foreign material removal
[Major Occurrence Timing] angle.) theoretical paper length specified • Driver/Panel wrong-setting • Wrinkled paper • Proper lubrication
• Power-on timing in the driver). • Contamination of CR scale • Gear replacement
• Paper loading timing [Major Occurrence Timing] • Dirty Printhead cover [Major Troubleshooting]
• Paper eject timing • Paper loading timing [Major Occurrence Timing] • Printhead damage • Recommendation of EPSON
• Paper eject timing • Ink clogging of Printhead media
[Troubleshooting] [Troubleshooting] • Contamination on Cap Unit / • Never use wrinkled paper.
1 Perform paper ejecting 1 Set paper in the ASF and [Troubleshooting] Wiper of Ink System • Edge guide re-setting
operation from the control perform paper loading • PE Sensor replacement • Ink System damage • Foreign material removal
panel. operation. • Main board replacement • Looseness of Paper Guide • Part re-installation
Front Porous Pad • Roller replacement
• When it succeeds: 2 When this error occurs before • PE Sensor Lever damage
If the printer has print data, paper reaches the PE Sensor, • PW Sensor damage
paper is fed. remove the paper and check • Air pressure Sensor damage
• When it fails:  the paper condition.
The Paper Jam error occurs 3 A) When paper is OK, set the [Major Troubleshooting]
again. paper in the ASF and adjust the • Driver / Panel re-setting
2 If Step 1 fails, open the Printer edge guide properly and • CR Scale replacement
Cover and remove the jammed perform Step 2 again. • Printhead cover cleaning
paper. B) When paper is NG, check • Printhead cleaning
foreign materials / parts come- • Ink Cartridge replacement
3 Perform paper ejecting • Printhead replacement
operation from the control off / parts damage / parts
deformation in paper path. • Cleaning rubber of Cap Unit
panel again. • Ink System replacement
• When it succeeds: 4 If Step 3-A/B do not work, • Paper Guide Front Porous Pad
If the printer has print data, check the following. re-installation
paper is fed. • Foreign materials • Printer Mechanism
• When it fails:  • Parts come-off replacement
The Paper Jam error occurs • Surface conditions of the LD • PE Sensor Lever replacement
again. Roller or the PF Roller • PW Sensor replacement
• PE Sensor Lever • Main Board replacement
4 If Step 3 fails, check the
following. • PE Sensor
• Main Board
• Foreign materials
• Parts come-off
• PE Sensor Lever
• PE Sensor
• Paper Guide Front Porous
Pad
• Main Board
Figure 1-2. Troubleshooting Workflow (2)
Troubleshooting Troubleshooting Workflow 13

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1.1.2 Printing the network status sheet

The following screen is displayed by pressing the Start button and the Stop button at the same time. Print the
network status sheet with the Print Start button.
Procedure to print the network status sheet
1. Select “Setup” on the Home screen.
Setup
2. Select “Network Settings”.
Network Settings
3. Select “Network Status”.

Network Status
4. On the “Network Status” screen, press the Left or Right button.
Troubleshooting Power-On Sequence 14

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5. On the “Network Status” screen, press the Start button and the Stop button simultaneously.
6. On the confirmation screen for printing the status sheet, press the Start button.
Figure 1-2. Network status sheet print confirmation screen

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7. Printing of the status sheet starts.
Use an A5 sheet (portrait) when printing the status sheet. If letters on the bottom of the sheet
fade or some of them are missing, make a sheet with the A5-portrait width and a longer length
out of an A4 sheet to print the status information fully.
8.
Figure 1-3. Status sheet printout
Troubleshooting Fatal Error Code List 16

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1.2 Power-On Sequence

This section describes the power-on sequences. The preconditions are as follows.
 Condition: Power-on sequence (See Table 1-1.)
 No error occurred when you turned on the printer last time and it has been correctly turned off.
 Initial ink charge has finished and every cartridge has sufficient ink.
 No paper on the paper path.
 The Printhead is capped.
 The Carriage is normally fixed by the CR Lock.
 Maintenance error recovery has never been performed.
 The Cover EJ is opened.
Table 1-1. Condition 1: Normal Power-on Sequence
CR Unit/PF Roller
Operation*1 movement and
position*2
1. Printhead initialization and fuse inspection 80 HP 0
CR Unit
1-1.Initializes the air pressure sensor and reads out the air pressure, and then initializes the Printhead and checks for the
fuse on the circuit boards in the printer.*3
CR Lock
2. Checking for waste ink overflow 80 HP 0
2-1.Checks the waste ink counter if the waste ink overflow is occurring.
3. Sequence of paper eject without printing 80 HP 0
3-1.Acquires information from the Cover Open Sensor and confirms the Cover EJ is opened.
3-2.The ASF Motor rotates clockwise to check whether paper is above the PE Sensor. 80 HP 0
3-3.The PF Motor rotates counterclockwise to eject paper below the PE Sensor. 80 HP 0
4. Unlocking the CR Unit 80 HP 0
4-1.PF Motor drives the PF Roller and the roller rotates clockwise once and counterclockwise once to unlock the CR
Lock.
5. Seeking the home position 80 HP 0
5-1.The CR Unit moves to the 0-digit side slowly and confirms it touches the Right Frame.
5-2.The CR Unit moves to the 80-digit side for about 3 cm and confirms it does not touch any foreign material, such as 80 HP 0
remaining paper.
5-3.To set the Change Lever in the ASF Unit back to the ASF lock position surely, the ASF Motor rotates clockwise. 80 HP 0
5-4.The CR Unit moves to the home position quickly and confirms it touches the right frame again. 80 HP 0
5-5.The distance from the position where the CR Unit touched to the Right Frame is regarded as the standard distance 80 HP 0
from the origin position, and the home position is fixed. From then on, the CR Unit position is monitored according
to the signals from the CR Encoder.
5-6.After the CR Unit moves to the 80-digit side slightly, it moves back to the home position on the 0-digit side. 80 HP 0
6. Low temperature operation sequence *4

80 HP 0
6-1.The CR Unit moves to the 80-digit side for about 3 cm.
6-2.The CR Unit moves back and forth quickly twice between the position above and near the left frame. 80 HP 0

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

CR Unit/PF Roller
Operation*1 movement and
position*2
7. VH detection sequence 80 HP 0
7-1.The CR Unit moves back and forth quickly between the position above and near the left frame, and detects/
measures the threshold value of the PW Sensor.
8. Detecting ink cartridge and initializing ink system 80 HP 0
8-1.Initializes the air pressure sensor and reads out the air pressure, and then acquires the information of the ink
consumption counter to calculate the amount of the remaining ink.
8-2.The CR Unit moves to the home position. 80 HP 0
8-3.PF Motor rotates clockwise to lock the CR Unit with the CR Lock. 80 HP 0
Note *1 : The rotation directions of the PF Motor and ASF Motor are as follows.
• PF Motor
Counterclockwise: Paper is fed normally
Clockwise: Paper is fed backward
• ASF Motor
Clockwise: Paper is fed normally
Counterclockwise: Paper is fed backward
*2 : The conditions of the CR lock and the APG lever are as follows.
• CR lock
Red: CR lock is set
White: CR lock is released
*3 : The fatal error occurs if there is a problem such as the fuse blew.
*4 : Executed when the detected temperature is under 5 oC (41oF) by the thermistor on the Printhead.

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1.3 Fatal Error Code List

This section describes how to check the fatal error code, description, and the possible causes.
1.3.1 Displaying the Fatal Error Code

The fatal error code can be checked as follows:
 Check the fatal error code displayed on the panel LCD when a printer fatal error occurs.
 read out the fatal error code stored in the EEPROM on the Main Board using the Adjustment Program.
LCD display screen image
Error Code
Figure 1-4. Displaying the Fatal Error Code

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1.3.2 Printer Fatal Error Code

This section describes the fatal error code and the possible cause for this product.
Table 1-2. Fatal Error List
Error Error
Error name Possible cause
type code
Printer 000020 CR PID excess driving time error Main Board failure
• CR Encoder failure (contaminated/detached scale, Encoder Board failure)
• CR Motor failure
000021 CR PID excess load error
• Carriage overload error (paper jam/foreign object)
• Cable disconnection
• Motor driver failure (Main Board failure)
000022 CR PID excess speed error
• Tooth skip of the CR Timing Belt
• Improper tension of the CR Timing Belt
000023 CR PID reverse error
000024 CR PID lock error
000025 CR PID speed fall error
CR load position excess driving time • Tooth skip of the CR Timing Belt
000030
error • Improper tension of the CR Timing Belt
000031 CR load position excess load error
000032 CR load position excess speed error
000033 CR load position reverse error
000040 PF PID driving time error Main Board failure
• PF Encoder failure (contaminated/detached scale, Encoder Board failure)
• PF Motor failure
000041 PF PID excess load error
• PF drive mechanism overload (paper jam/foreign object)
000042 PF PID excess speed error
• Tooth skip of the PF Timing Belt
• Improper tension of the PF Timing Belt
000043 PF PID reverse error
• Paper jam
000044 PF PID lock error

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Error Error
type code
Printer 000050 PF load position excess driving time error Main Board failure
000051 PF load position excess load error
000052 PF load position excess speed error
000053 PF load position reverse error • Tooth skip of the PF Timing Belt
000060 Excess error of ASF PID drive time Main Board failure
• ASF Motor Encoder Sensor failure (contaminated/detached scale, Encoder Board
failure)
000061 ASF PID load excess error • ASF Motor failure
failure)
000062 ASF PID excessive speed error
• Motor Driver failure
• Tooth skip of the ASF/Stacker gears
failure)
000063 ASF PID reversal error
• - Tooth skip of the ASF/Stacker gears
failure)
000064 ASF PID lock error • ASF Motor failure
• Printhead failure
031001 Head hot detect error (pre printing)
• Main Board failure
031002 Head hot detect error (after flushing)
031003 Transistor temperature error
031004 Head temperature error
031005 Head hot detect error (when changing ink) Main Board failure
031006 Blown headfuse error Headfuse has blown.
033003 Other ink device errors
• Paper Sensor failure
033004
033005 Other ink device errors
033008
033009 Inspection mode error None of those will occur except in manufacturing process
033010 CSIC access error (hard factor) CSIC failure
• Ink system failure
034001 Home position error • Deformation of the Main Frame
• Deformation of the CR Guide Frame
• CR Encoder Sensor failure (contaminated/detached scale, Encoder Board failure)

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Error Error
type code
Printer • Paper jam
Contact error at ink replacement timing
034500 • Foreign object
(Power-off)
• Deformation of the Main Frame
System 060002 Driver mismatch error An unsupported driver was used.
060003 PCD verify command error
• Flash ROM failure

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CHAPTER 2
DISASSEMBLY/REASSEMBLY
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2.1 Overview
This chapter describes procedures for disassembling the main parts/units of this product. Unless otherwise
specified, disassembled parts/units can be reassembled by reversing the disassembly procedure. See the cautions
or tips for disassembly/reassembly described in "2.4 Detailed Disassembly/Reassembly Procedure for each Part/
Unit (p47) ".
Read the "Safety Precautions(p3) " before disassembling and reassembling.
When you have to remove units or parts that are not described in this chapter, see the exploded diagrams of SPI
(Service Parts Information).
2.1.1 Tools
Use only specified tools to avoid damaging the printer.
Name Availability EPSON Part Code

(+) Phillips screwdriver #1 O 1080530
(+) Phillips screwdriver #2 O ---
Flathead screwdriver O ---
Flathead Precision screwdriver #1 O ---
Tweezers O ---
Longnose pliers O ---
Acetate tape --- 1003963
SHIPPING CLEANING LIQUID,CR06 --- 6104713 / 6104714
Note 1: Some of the tools listed above are commercially available.
2: EPSON provides the tools listed with EPSON part code.
2.1.2 Jigs
Name Quantity EPSON Part Code
Thickness gauge (1.55 mm) 2 Commercially available
Thickness gauge (1.95 mm) 2 Commercially available
Housing Lower Cover 3 Make ones using commercially available
plastic sheets.
Disassembly/Reassembly Overview 24
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2.1.3 Locations of the Parts/Units

This section shows the locations of the main parts/units of this product.
The parts/units which can not be seen in the following pictures are indicated in dotted lines
( ).
 Exterior parts
Front Right
1
3 2
44
5
6
10
Left Rear
9 8
No. Name No. Name

1 Cover Upper (p37) 6 Housing Lower Assy (p40)
2 Paper Support (p37) 7 Handle (p36)
3 Panel Assy (p39) 8 Maintenance Box Assy (p36)
4 LCD Assy (p39) 9 Cover Bottom (p36)
5 Cover EJ (p36) 10 Cover USB Host (p37)
Figure 2-1. Exterior Parts
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 Printer mechanism
No. Name No. Name
1 Printhead (p42) 3 CRCM (p42)

2 Mech Sub 1 (p41) (ASF Unit) 4 Paper Sensor Assy (p41)
Figure 2-2. Printer Mechanism: Front
No. Name No. Name
1 Pump Assy (p43) 2 Ink System Assy (p41)

Figure 2-3. Printer Mechanism: Right
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1
2
No. Name No. Name
1 PCB Battery (p38) 2 CR Scale (p42)

Figure 2-4. Printer Mechanism: Left
No. Name No. Name
1 PCB Drive (p41) 2 Encoder Board ASF (p43)

Figure 2-5. Printer Mechanism: Rear
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2.1.4 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.
Table 2-1. Standard Operation Time

Time (mm:ss)
Parts/Unit Adjustment/
Replacement Total
inspection
Housing Upper Assy 1 3:19 3:19
Cover Upper Sub 0:38 0:38
Cover ASF 0:08 0:08
Cover EJ 0:10 0:10
Cover Bottom 0:06 0:06
Maintenance Box Assy 0:07 0:07
Handle 0:11 0:11
Housing Bottom Assy 1:56 1:56
Cover DC 2:03 2:03
Cover Battery 1:59 1:59
Rubber Foot 3:00 3:00
Housing Bottom 3:10 3:10
E Ring 4:41 4:41
Shaft Paper Support 5:23 5:23
Paper Support 5:30 5:30
Cover Upper 5:23 5:23
OPT Tube Card 3:47 3:47
Cover USB Host 3:26 3:26
Guide Rail EG 3:37 3:37
EG Sub 3:41 3:41
Housing Upper Assy 2 3:41 3:41
FFC related parts 6:30 6:30
GND Plate Main R 7:11 7:11
DC Board 5:09 5:09
Spring Cover Battery 6:55 6:55
PCB Battery 5:15 5:15
Spring Box Ink Eject 6:58 6:58
Supporter Slider 6:39 6:39
Cover Middle 6:56 6:56
Needle Ink Eject 7:19 7:19
GND Plate WiFi 6:56 6:56
WiFi PCB 5:15 5:15
Panel Assy 7:46 7:46
PCB LED 5:55 5:55
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Time (mm:ss)
Replacement Total
inspection
Bush PNL Right 8:15 8:15
Platespring Bush Panel 1 8:05 8;05
Shaft PNL Right 8:19 8:19
Bush PNL Left 8:15 8:15
Platespring Bush Panel 2 8:05 8:05
Shaft PNL Left 8:19 8:19
Panel Housing Lower 7:51 7:51
Panel Housing Upper Assy 8:50 8:50
LCD Assy 9:05 9:05
Panel Housing Upper 8:01 8:01
Button Start 8:05 8:05
Button PS 8:05 8:05
Button OK 8:05 8:05
Housing Middle Assy 8:50 8:50
Sheet Stopper ASF Center 9:11 9:11
Lock Handle 8:57 8:57
Spring Handle 9:02 9:02
Housing Middle 9:02 9:02
Shield Plate MB 9:18 9:18
PCB Top Main 6:06 11:05 17:11
OPT Tube LED 9:51 9:51
Holder Connector 9:55 9:55
Hsg IS Modify Assy 10:15 10:15
Hsg IS Modify 10:15 10:15
Slider Transfer Haieki 11:16 11:16
Porous Pad Slider 12:28 12:28
CmpSpring Slider Transfer Haieki 11:44 11:44
Slider Transfer Haieki Assy 11:16 11:16
Detector Cord 11:24 11:24
Housing Lower Assy 14:41 14:41
Detector Assy 15:16 15:16
Holder Lock Battery 15:06 15:06
Compression Spring Lock Battery 15:12 15:12
Lock Battery 15:30 15:30
Cover DC 14:48 14:48
Lock Cover Assy 15:07 15:07
Compression Spring Lock Cover 15:17 15:17
Lock Cover 15:25 15:25
Holder Lock Cover 15:17 15:17
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Time (mm:ss)
Replacement Total
inspection
Housing Lower 14:41 14:41
POROUS PAD IS LOWER A 14:51 18 14:51
POROUS PAD IS LOWER B 14:51 18 14:51
POROUS PAD Housing Lower 14:51 18 14:51
POROUS PAD FRAME IS 11:27 18 11:27
Waste ink related 15:05 18 15:05
Harness/FFC related 15:28 18 15:28
Mech Assy 11:24 10:11 21:35
FFC/Cable related 12:07 12:07
Shield Plate Rear 14:06 14:06
PCB Driver 14:39 1:21 16:00
Ink System Assy 13:38 13:38
Hopper Assy 12:55 12:55
Paper Sensor Assy 7:32 7:35
FFC Guide Frame 13:20 13:20
GND Plate DRV L 13:27 13:27
GND Plate Main F 12:28 12:28
Cover Head FFC 12:46 12:46
Head FFC 13:31 13:31
Cable Holder 13:01 13:01
Printhead 9:45 9:14 18:59
Lever I/C 13:59 13:59
Cover CSIC 14:11 14:11
Head Spring 13:39 13:39
GND Head 15:28 15:28
CRCM 16:19 16:19
CRCM Board 16:24 16:24
DTC PW Board 15:39 15:39
CR Scale 8:04 8:04
GND Plate DRV R 13:46 13:46
Holder Scale CR 13:53 13:53
Pump Cover 14:17 14:17
Belt Stopper 15:31 15:31
GND Plate Paper Guide Front 12:54 12:54
CR Driven Pulley 12:55 12:55
Comb Gear PF 13:15 13:15
Mech Sub 1 17:09 17:09
Mech Sub 2 17:09 17:09
Holder PE Assy 17:39 17:39
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Time (mm:ss)
Replacement Total
inspection
PB Lever 18:06 18:06
Holder Retard 18:44 18:44
CR Motor 17:49 17:49
Encoder Board ASF 17:43 17:43
Pump Assy 18:25 18:25
Spur Gear Pump 18:29 18:29
Frame Pump 18:56 18:56
Lever Change Assy 18:33 18:33
Comb Gear 1 19:00 19:00
Comb Gear 2 19:04 19:04
ASF Motor 20:18 20:18
Spur Gear Plate 20:14 20:14
Gear 3 20:18 20:18
Cam PB 20:21 20:21
Clutch 20:28 20:28
LD Roller Assy 20:42 20:42
Frame ASF Assy 20:42 20:42
Idol Gear PF 17:32 17:32
PF Encoder Sensor 18:12 18:12
Comb Gear PF 17:32 17:32
Gear 1 17:55 17:55
Gear 2 18:18 18:18
CR Assy 18:27 18:27
CR 18:33 18:33
CR Frame 18:33 18::33
Board ENC 19:07 19:07
CR Belt 18:43 18:43
Frame FFC 17:45 17:45
Shield Plate Rear ASSY 18:48 18:48
Shield Plate Rear 19:20 19:20
Holder Star Wheel Assy 19:20 19:20
Rodspring 21:44 21:44
Star Wheel 20:40 20:40
Roller EJ 17:57 17:57
Paper Guide Front Assy 17:57 17:57
Flame Left Assy 18:12 18:12
Paper Guide Front 17:57 17:57
Paper Guide Front Porous Pad 18:24 18:24
PF Bush Middle Support 18:01 18:01
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Time (mm:ss)
Replacement Total
inspection
Main Flame Assy 19:12 19:12
Paper Guide Upper Assy 19:47 19:47
Roller Shaft 19:54 19:54
Roller Driven R 19:51 19:51
Roller Driven L 19:51 19:51
Roller Paper Guide Upper 19:51 19:51
Paper Guide Upper 19:47 19:47
Frame Holder Pulley Driven 19:47 19:47
Main Flame 19:12 19:12
Holder Lock CR Assy 19:22 19:22
Lever Lock CR 19:32 19:32
Holder Lock CR 19:22 19:22
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2.2 Common cautions when disassembling/reassembling the Product

This section describes common cautions when disassembling/reassembling the product.
Before disassembling/reassembling the printer including this product, be sure to read "Safety Precautions(p3) "
and this section.
Item Content Photo/Illustration
When 1. When handling new parts for replacement, take care not to
handling contaminate or damage them. 2. 3. 3.
parts 2. When disassembling/reassembling the parts, take care not to damage
the FFCs/cables/Ink tube if there is a possibility of coming into
contact with them. Printer
Panel Unit Ink System Mechanism
3. When reassembling the product, take care not to let components of the
unit come off.
When When installing parts, take care not to damage them when securing them Main Board Sub Board
reassembling by tightening screws.
When Do not lubricate any part other than those specified. If grease is applied
applying on such a part, wipe it off completely. ---
grease
External Confirm visually that there are no scratches, dirt, and gaps.
---
parts
Moving parts After reassembling, confirm that there are no abnormal noises and they
---
work smoothly.
Timing belts 1. Take care not to broke them. 2. 2.
2. Confirm that it is installed properly onto the transmissive sections of
the pinion gear/driven roller.
Motors Take care not to damage them. ---

Sensors 1. Take care not to touch the detector sections.
2. 3.
2. As for the encoder Sensor used with a circular scale, the photo sensor
section should be set over the encoded area of the circular scale.
3. Take care not to get injured by the sharp ends of the board terminal on
the back of the circuit boards when handling the sensors or the
peripheral parts.
Scales 1. Take care not to touch the encoded area. 2. 4.

2. Install it with the black triangular section up. (CR Scale only)
3. Wipe off alcohol before installing. (CR Scale only)
4. Confirm that they do not touch the photo sensors after installation.
Waste ink 1. Take care not to stain your hands with the waste ink soaked in the ink
pads pads. If ink comes into contact with your hands, wash it off with water 2. 2.
immediately.
2. Take care not to stain the printer's parts with the waste ink soaked in
the ink pads. If ink comes into contact with the parts, wash it off.
(Especially, pay attention to Maintenance Box Assy)
Disassembly/Reassembly Common cautions when disassembling/reassembling the Product 33

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Item Content Photo/Illustration
FFCs 1. Be sure to insert them to their connectors on the boards as far as they
will go without any loose connection such as a half-way or slant
connection.
2. Route them along their routing paths. ---
3. If the double-sided tape that secures the FFCs is not strong enough to
secure them, make sure to replace the tape and secure the FFCs
firmly.
Gears When installing gears, pay attention to the following:
• The gear section should not be damaged.
---
• No foreign material is attached.
• No grease is attached on any parts other than those specified.
PF rollers Do not touch rollers for paper feeding when handling them.
One Time After removing One Time parts specified in this manual, do not reuse
One Time icon:
parts them, but be sure to replace them with new ones.
Rubber Foots Rubber Foots, which are removed in the disassembling or reassembling
procedure, can be basically reused. Note that if the double-sided tapes
that secure Rubber Foots are not strong enough to secure them, replace
the tapes with new ones when installing Rubber Foots. Foot
Ink System 1. Take care not to stain your hands with ink.
2. When you connect the ink tube to another part, insert the ink tube up
to the root of the joint to prevent ink leakage and secure the tube with
---
the tube clamp.
3. If it's hard to insert the ink tube to the joint, apply CR06 to the
inserting part of the ink tube.
MAC 1. Take care not to stain or damage it. 2.
Address 2. When replacing the printer mechanism, attach the Main Board and the
Label part with the MAC address label to the new printer mechanism.
Card Slot Board Shield Plate
Disassembly/Reassembly Common cautions when disassembling/reassembling the Product 34

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2.3 Disassembly/Reassembly Procedures

2.3.1 Disassembly Flowchart
This section describes procedures for disassembling the parts/units in a flowchart format. For some parts/units,
detailed procedures or precautions are provided (accordingly indicated by icons and cell's color). Refer to the
explanations in the example chart below and perform an appropriate disassembling and assembling procedure.
(See "2.4 Detailed Disassembly/Reassembly Procedure for each Part/Unit (p47) ".)
For routing cables, see "2.5 Routing FFCs/cables (p52) ".
The example below shows how to see the charts on the following pages.
The name enclosed in gray

indicate a part/unit that
must be removed on the PS Board (p29)
way to the target parts.
Shows necessary
procedures before
CR Timing Belt Shows the procedure
removing the following FFC/ Cable *1 number on the “FFC/
parts.* cable list”.
Black letters indicate a part/ White letters indicate a

Panel Board Card Slot Cover part/unit supplied as an
unit not supplied as an ASP.
ASP.
--- 1
Shows the screw types and
--- S4 4 the specified torque on the
“Screw type/torque list”.
(p21) (p27) (p22) (p43)
Shows removal/installation Reference page

as a unit/assy. is available.
Note "*" : The box with only part names means the removal of the parts. If the name of
FFC or a cable is shown, disconnect the FFC or cable from the connector.
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
page in blue-letter
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 particular routing of cables is required.
page in blue-letter
Chapter 3 " Adjustment
Indicates particular adjustment(s) is/are required.
(p54) "
Chapter 4 " Maintenance
Indicates lubrication is required.
(p62) "
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 35

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START
Housing Upper Cover Bottom Housing Bottom Cover Upper Cover ASF Cover EJ Handle
Assy 1 Assy Sub
7 --- 5 2 --- --- ---
--- --- --- --- 2 2 2
(p 51) --- --- --- --- (p 50) (p 47)
Maintenance
Box Assy Cover DC Rubber Foot Cover Battery
--- --- --- ---
4 1 1 1
--- --- --- ---

A (p 37)
Rubber Foot
(p36)
Cover Battery
(p36)
Screw type/torque list

Symbol Screw Type Torque
S1 C.B.F.P-TITE SCREW 1.7x5 F /ZN-3C 2 ± 0.5 kgf·cm
Housing Bottom
S2 C.B.P-TITE SCREW 2.5x10 F/ZN-3C 5 ± 1 kgf·cm
--- S3 C.B.P-TITE SCREW 2.5x6 F/ZN-3C 4 ± 1 kgf·cm
--- S4 C.B.P-TITE SCREW 2.5x6 F/ZN-3C 6.5 ± 0.5 kgf·cm
---
S6 C.B.P-TITE SCREW 2.5x8 F/ZN-3C 4.5 ± 0.5 kgf·cm
S9 C.B.P-TITE SCREW 2x6 F/ZN-3C 5 ± 1 kgf·cm
S10 C.B.S-TITE SCREW 2.5x5 F/ZN-3C 5 ± 1 kgf·cm
S12 C.P.SCREW 3x3 F/ZN-3C 4 ± 0.5 kgf·cm
S13 C.P.SCREW 3x4 F/ZB-3C 4 ± 0.5 kgf·cm
S15 C.T.P-TITE SCREW 2.6x8 F/ZN-3C 4.5 ± 0.5 kgf·cm
S16 C.T.P-TITE SCREW 2.6x8 F/ZN-3C 5 ± 1 kgf·cm
S17 C.T.SCREW M2x6 F/ZN-3C 2 ± 0.5 kgf·cm
S18 C.T.S-TITE SCREW 2.5x8 F/ZN-3C 5 ± 1 kgf·cm
Flowchart 2-1. Disassembly/Reassembly Flowchart (1)

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A (p 36)
Housing Bottom
Assy (p36) E Ring Cover USB Host OPT Tube Card Guide Rail EG
--- --- 1 1
--- 1 1 2
 Cable Head Upper
 Cable CRCM 1 --- --- --- ---
 FFC Ink Eject
 FFC PCB
 FFC Panel
 Cable CRCM 2
 Cable Head Lower
Shaft Paper
Support EG Sub
--- ---
--- 1
B (p 38)
--- ---
Paper Support Cover Upper Housing Upper

Assy 2
--- --- ---
--- --- ---
--- --- (p 51)


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B (p 37)
GND Plate Spring Cover Spring Box Ink

Main R WiFi PCB DC Board Battery
PCB Battery Needle Ink Eject Eject C (p 39)
2 2 1 1 2 2 1
--- --- 3 --- 2 --- ---
--- (p 53) --- --- --- --- ---
Housing Middle
Assy GND Plate WiFi
4 1
1 2
(p 47) (p 53)
Needle Ink Eject Sheet Stopper

(p38) Lock Handle Shield Plate MB
ASF center
1 --- 1
2 1 2
D (p 40) (p 47) --- (p 51)

Spring Handle PCB Top Main
--- 1 S3 C.B.P-TITE SCREW 2.5x6 F/ZN-3C 4 ± 1 kgf·cm
3 ---
--- (p 50) (p 51) S6 C.B.P-TITE SCREW 2.5x8 F/ZN-3C 4.5 ± 0.5 kgf·cm
Housing Middle S10 C.B.S-TITE SCREW 2.5x5 F/ZN-3C 5 ± 1 kgf·cm
---
---
--- S14 C.P.SCREW 3x4 F/ZN-3C 4 ± 0.5 kgf·cm

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C (p 38) E (p 39)
Bush PNL Right Platespring Bush Bush PNL Left Platespring Bush Panel Housing
Cover Middle Supporter Slider Panel 1 Panel 2 Lower
1 --- 1 --- 1 --- ---
--- 1 2 --- 2 --- ---
--- (p 48) --- --- --- --- ---
Panel Assy Shaft PNL Right Shaft PNL Left
2 --- ---
4 1 1
--- --- ---
Panel Housing
PCB LED Upper Assy
--- 3
1 ---
--- ---

E (p 39) LCD Assy
1 S3 C.B.P-TITE SCREW 2.5x6 F/ZN-3C 4 ± 1 kgf·cm
6
---
Panel Housing
Button Start Button PS Button OK C.B.S-TITE SCREW 2.5x5 F/ZN-3C 5 ± 1 kgf·cm
Upper S10
--- --- --- ---

--- 2 2 4
--- --- --- --- S14 C.P.SCREW 3x4 F/ZN-3C 4 ± 0.5 kgf·cm

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D (p 38)
Hsg IS Modify Holder OPT Tube LED

Assy Connector
4 --- ---
--- --- 1
--- --- ---
Slider Transfer
DC Board (p38) Hsg IS Modify
Haieki Assy
PCB Battery --- ---

(p38)
--- 1
 ditector コード --- ---
Housing Lower Porous Pad CmpSpring Slider Slider Transfer

Mech Assy Slider Transfer Haieki
Assy Haieki
--- 6 --- --- ---
--- --- 1 --- ---
(p 48) (p 48) --- --- ---
 Harness Detector Cover EJ Holder Lock Screw type/torque list

Detector Assy Cover DC Lock Cover Assy Housing Lower
 Cable ENC ASF Battery
 Harness Motor ASF Symbol Screw Type Torque
 Harness UL3443 1 1 --- 1 ---
 FFC ENC PF
 Harness PE TEMP --- 3 1 3 --- S2 C.B.P-TITE SCREW 2.5x10 F/ZN-3C 5 ± 1 kgf·cm
--- --- --- --- ---

F (p 41) S6 C.B.P-TITE SCREW 2.5x8 F/ZN-3C 4.5 ± 0.5 kgf·cm
Compression Spring Compression
Lock Battery Spring Lock Cover
--- ---
--- --- S10 C.B.S-TITE SCREW 2.5x5 F/ZN-3C 5 ± 1 kgf·cm

Holder Lock
Lock Battery Lock Cover Cover S15 C.T.P-TITE SCREW 2.6x8 F/ZN-3C 4.5 ± 0.5 kgf·cm
--- --- ---
1 1 ---
--- --- --- S19 C.T.S-TITE SCREW 2.6x5 F/ZN-3C 5 ± 1 kgf·cm

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F (p 40)
CR Driven Paper Sensor FFC Guide GND Plate

Pulley
Shield Plate Rear Ink System Assy Hopper Assy
Assy Frame Main F G (p 42)
1 4 1 --- 1 2 1
2 --- 4 2 2 --- ---
--- --- (p 49) --- --- --- ---
GND Plate
Comb Gear PF PCB Drive DRV L
--- 1 ---
1 --- 1
--- --- ---
Pump Cover
Mech Sub 1
2 Screw type/torque list

--- 1 (p 43) Symbol Screw Type Torque
Mech Sub 2 S4 C.B.P-TITE SCREW 2.5x6 F/ZN-3C 6.5 ± 0.5 kgf·cm
--- S5 C.B.P-TITE SCREW 2.5x8 F/ZN-3C 5 ± 1 kgf·cm

---
---
2 (p 44) S8 C.B.P-TITE SCREW 2.6x8 F/ZN-3C 5 ± 1 kgf·cm

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G (p 41)
GND Plate Paper

CR Scale Guide Front Cover Head FFC
--- 2 ---
2 1 3
--- --- (p 51)
GND Plate
Head FFC Cable Holder
DRV R
1 --- ---
1 3 3
--- --- ---
Holder Scale CR Printhead Cover CSIC Head Spring Lever I/C
--- 3 --- --- ---
1 --- 3 --- 2
--- (p 50) (p 47) (p 50) (p 47)

Belt Stopper GND Head
--- ---
--- 1 S2 C.B.P-TITE SCREW 2.5x10 F/ZN-3C 5 ± 1 kgf·cm
--- --- S3 C.B.P-TITE SCREW 2.5x6 F/ZN-3C 4 ± 1 kgf·cm

CRCM DTC PW Board S7 C.B.P-TITE SCREW 2.5x8 F/ZN-3C 4 ± 1 kgf·cm

2 ---

CRCM Board S15 C.T.P-TITE SCREW 2.6x8 F/ZN-3C 4.5 ± 0.5 kgf·cm
---
---
--- S19 C.T.S-TITE SCREW 2.6x5 F/ZN-3C 5 ± 1 kgf·cm

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1 (p 41)
Pump Assy Holder PE Assy PB Lever CR Motor Encoder Board

ASF
4 1 --- 2 1
--- 2 --- --- ---
(p 47) --- --- --- (p 48)
Spur Gear Pump Holder Retard
--- ---
1 ---
(p 47) ---
Frame Pump
---
---
Comb Gear 1 Lever Change Gear 3 Cam PB Clutch

Assy
--- --- 2 2 ---
2 2 1
1 ---
(p 49) (p 49) (p 49) (p 49) (p 49)
Comb Gear 2 LD Roller Assy
--- --- S5 C.B.P-TITE SCREW 2.5x8 F/ZN-3C 5 ± 1 kgf·cm
1 2
(p 49) (p 49)
Encoder Board
Spur Gear Plate Frame ASF Assy S11 C.B.S-TITE SCREW 2.5x6 F/ZN-3C 5 ± 1 kgf·cm
ASF (p43)
2
2
ASF Motor
(p 49) S15 C.T.P-TITE SCREW 2.6x8 F/ZN-3C 4.5 ± 0.5 kgf·cm
1 S16 C.T.P-TITE SCREW 2.6x8 F/ZN-3C 5 ± 1 kgf·cm
--- S17 C.T.SCREW M2x6 F/ZN-3C 2 ± 0.5 kgf·cm

---

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2 (p 41)
Frame FFC Idol Gear PF Comb Gear PF CR Assy
1 --- --- 3
--- 1 1 ---
--- --- --- ---
Shield Plate Rear PF Encoder

Roller EJ Assy Gear 1 CR CR Frame Board ENC CR Belt
Sensor
3 3 --- --- --- --- 2 1
1 1 --- 1 --- --- --- ---
--- --- --- --- --- --- --- ---
Shield Plate Rear Holder Star Gear 2

Wheel Assy
H (p 45)
--- --- ---
9 --- 1
--- --- ---
Rodspring Star Wheel
--- ---
2 ---
--- ---

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H (p 44)
Paper guide front

Main Frame Assy Assy Frame Left Assy
3 --- ---
1 --- 2
--- --- (p 49)
Paper Guide Upper Frame Holder Holder Lock CR Paper Guide Front PF Bush Middle
Main Frame Paper Guide Front
Assy Pulley Driven Assy Porous Pad Support
--- 2 --- --- --- --- ---
--- 1 --- 1 --- 4 ---
--- --- --- (p 47) --- --- ---
Lever Lock CR Holder Lock CR
--- ---
--- ---
(p 47) (p 47)
Roller shaft Roller Driven R Roller Driven L Roller Paper Guide Paper Guide Upper
Upper
--- --- --- --- --- Screw type/torque list

--- --- --- --- --- Symbol Screw Type Torque
--- --- --- --- ---

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2.4 Detailed Disassembly/Reassembly Procedure for each Part/Unit

Handle Lever I/C / Torsion Spring 7.32 CR Lock Assy / Torsion Spring 1.16
Handle position A (during installation) CR Lock Assy

Engage leg A with
Left hook on I/C lever. Torsion Spring 1.16
Lever I/C Step 1:

Insert vertically. Step 3:
Turn toward you.
Bearing shape
Engage leg B with

inner slot on CR.
CR Lock Assy
Torsion Spring 7.32

Hole A and protrusion
Hole B and rib
Since the CR Lock Assy is slightly loose and easily comes off, be careful not to detach the CR Lock Assy when working around it. If it has come off,
Handle position B (After reassembly) reassemble it correctly as shown below.
Leg A  Reassemble the Torsion Spring 1.16 as shown above.
Leg B  Reassemble the CR Lock Assy as follows.
 Reassemble the Handle in position A as shown above so as to
align the bearing with the hole. 1. Orient the CR Lock Assy vertically and insert the protrusion on the CR Lock Assy into hole A on the Main Frame.
 After reassembly, set the Handle in position B. Reassemble the Torsion Spring 7.32 as shown above. 2. Align the shape of the protrusion with hole A on the Main Frame and slide the CR Lock Assy to the bottom of the printer.
3. Turn the CR Lock Assy to the front of the printer and align the rib on it with hole B on the Main Frame.
Caution after removing Housing Middle Assy Cover CSIC Paper Retard lever / Torsion Spring 1.19 Pump Assy
Pump Assy
OK Sheet Stoper ASF Center
Housing Middle Assy
Cover CSIC
ASF Unit
Pump Cam
Spur Gear Pump

Engage with hook on
Paper Retard lever.
Hook
Pump Pulley
Engage on ASF Unit.
NG
Torsion Spring 1.19
Pump Assy
Housing Middle Assy NG: Sheet will get bent out of shape!! Cover CSIC Lever I/C
Paper Retard lever

After removing the Housing Middle Assy, place it in the If the components of the Pump Assy (Pump Cam, Pump Pulley,
orientation with OK above. Otherwise, the Sheet Stoper ASF Before removing the Cover CSIC, disengage the hooks (x2) on Reassemble the Torsion Spring 1.19 as shown above. Spur Gear Pump) have come apart, reassemble them as shown
Center will be damaged. both sides shown above. above.
Disassembly/Reassembly Detailed Disassembly/Reassembly Procedure for each Part/Unit 47

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Housing Lower Assy/Mech Assy Supporter Slider
Step 1 Housing Lower Assy

Slider Transfer Haieki Supporter Slider Slider Transfer Haieki
Step 2 Step 1 Step 2 Step 3

Housing Lower Assy
Secure it in place.
Ink System Assy PF gears
A B
Front
Installation jig
Hole
Paper Guide Front Porous Pad Paper Guide Front Porous Pad Tweezers
Bottom
Housing Lower Assy
The Supporter Sliders cannot be reused once they are removed. Whenever the Supporter Sliders are removed, make sure to attach new ones.
1 2
5 Reassemble the Supporter Sliders as follows.
6
1. Pull out the Paper Guide Front Porous Pad from hole A and B for the Supporter Sliders as shown above.
Mech Assy
2. Pull the Slider Transfer Haieki in hole A in the direction of the arrow and keep pulling it, and then insert the Supporter Slider into hole A.
3. Do the same for hole B.
4. While pulling the Slider Transfer Haieki in hole A in the direction of the arrow, secure the Supporter Slider by pushing it fully in place
A Step 4-1 with the Paper Guide Front Porous Pad.
5. Do the same for hole B.
3 A
Ink Tube 4
2
B 1
Ink Tube
Encoder Board ASF Clutch
Hole
ASF Motor Scale
C.T.P-TITE SCREW 2.5x8 F/ZN-3C (5 ± 1 kgf·cm)
Hole Clutch SE
Step 4-2
Torsion Spring 0.325
PCB Battery harness
B
Encoder Board ASF Driver LD
ASF Motor
Dowel
PCB Battery harness
Torsion Spring 0.325 Driver LD
 When disassembling the Printer Mechanism, be careful not to damage the cables/FFCs or hooks of the Mech Assy by catching them with the
hooks and similar inside the Housing Lower Assy.
 When reassembling the Mech Assy into the Housing Lower Assy, be careful not to catch the Ink Tube of the Pump Unit in between.
When reassembling the Printer Mechanism into the Housing Lower Assy, use the installation jigs (as shown above) to make the work easier.
Make the installation jigs out of commercially available plastic sheets.
 Reassemble the Mech Assy into the Housing Lower Assy as follows.
1. Set the installation jigs (x3) on the sides shown above of the Housing Lower Assy. C.P.F.B-TITE SCREW 1.7x5 F/ZN-3C (2 ± 0.5 kgf·cm)
2. Insert the Mech Assy into the Housing Lower Assy from the side with the Ink System Assy (not the side with PF gears) first while pressing it Clutch SE Hook
to the Housing Lower Covers (x3) as shown above.  Make sure the Encoder Board ASF and ASF Motor Scale are
3. Pull out the Ink tube from Hole A, Make sure no cables/FFCs are caught in between, and then remove the installation jigs. not in contact with each other.
4. Secure the Mech Assy on the Housing Lower Assy with six screws in the order shown above.  Make sure the ASF Motor Scale is positioned in the center of If the components of the Clutch (Clutch SE, Torsion Spring 0.325,
the slit on the Encoder Board ASF. Driver LD) have come apart, reassemble them as shown above.

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LD Roller Gear/Cam PB/ Spur Gear Plate / Gear 3/ PF Roller (Frame Left Assy) / PF Roller Grounding Spring
Clutch / Comb Gear 1 / Comb Gear 2 / Lever Change Assy
Spur Gear Plate
Comb Gear 2
Gear 3 (outer) Clutch
Main Frame Assy
Washer 4.2x0.5x8.L/Na
LD Roller Gear Longer leg

Lever Change Assy
Comb Gear 1 PF ローラ
Cam PB (inner)
PF Roller
Bush
C.B.P-TITE SCREW 2.5x8 F/ZN-3C (5 ± 1 kgf·cm) Spur Gear 8

C.P.SCREW 3x4 F/ZN-3C (4 ± 0.5 kgf·cm)
Compression Spring 4.02
PF Roller Grounding Spring
Reassemble the following parts as shown above:
LD Roller Gear, Cam PB, Spur Gear Plate, Spur Gear 10, Clutch, Comb Gear 1, Comb Gear 2, Lever Change Assy

  When installing the PF Roller of the Frame Left Assy on the Main Frame, reassemble the components (Spur Gear 8, Washer 4.2x0.5x8.L/Na,
 Compression Spring 4.02, bush) as shown above.
 When installing the PF Roller Grounding Spring, engage the longer leg on the PF Roller of the Frame Left Assy.
Ink System Assy Mech Sub 1 (ASF Unit)
Step 3, 4 Main Frame Assy

Pump Assy Mech Sub 1 (ASF Unit)
Left
Ink Tube Tube Guide
2 Ink System Assy
1
1
2
Step 5 Ink Tube Joint 3
Hook A
Hook B
Hook C
Groove
C.B.P-TITE SCREW 2.5x6 F/ZN-3C (6.5 ± 0.5 kgf·cm)
Remove the Ink System as follows:

1. Remove the screw that secures the Ink System.
2. Disconnect the Ink Tube (x2) of the Pump Assy from the Ink Tube Joint on the Ink System and the Tube Guide. Positioning hole and dowel
3. Disengage hook A on the Ink System and slide the Ink System in the direction of arrow (1). C.B.P-TITE SCREW 2.5x6 F/ZN-3C (4 ± 1 kgf·cm)
4. Disengage hook B (x2) by lifting the side of the Ink System in the direction of arrow (2).
5. Disengage hook C (x2) by lifting the Ink System and remove the Ink System.
 Align the dowels (x2) on the Mech Sub 1 (ASF Unit) and the positioning holes (x2) on the Main Frame Assy when reassembling them.
 Make sure to connect the Ink Tubes of the Pump Assy and Ink System Assy fully without any gaps.  Tighten the screws in the order shown above.
 Secure the Ink Tube of the Ink System Assy with the grooves (x2) on the Ink System Assy after the tube is connected with the Ink Tube of the Pump Assy.

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PF Encoder Sensor Cover EJ PF Drive Gears
PF Scale
PF Roller
1
PF Encoder Sensor
2
PF Scale
PF Roller Gear Combination Gear 18.5,16.49

Spur Gear 20.5
PF Encoder Sensor Cover EJ
Dowel A
Dowel B Combination Gear 18.5,15.5
Spur Gear 26.5
C.B.S-TITE SCREW 2x5 F/ZN-3C (5 ± 1 kgf·cm)
Combination Gear 18,10.5
 When removing the Cover EJ, disengage dowel A and dowel B
 Never touch the PF Roller Gear or PF Scale when tightening shown above in that order.
the screws.  First release dowel A by warping the Cover EJ, and then pull
 After screwing the PF Encoder Sensor, make sure the PF Scale out dowel B from the hole on the Housing Lower Assy. Reassemble the following parts as shown above:
is positioned in the center of the slit on the PF Encoder Sensor. Combination Gear 18.5,16.49, Spur Gear 26.5, Combination Gear 18,10.5, Combination Gear 18.5,15.5, Spur Gear 20.5.
Insulator FFC Guide Frame Printhead / Head Spring
FFC Guide Frame
Standard position PCB Top Main

1 Hole on CR side
Printhead
3
Head Spring
Nut
2 1
Insulator 2
C.T.S-TITE SCREW 2.6x5 F/ZN-3C (5 ± 1 kgf·cm)

C.T.P-TITE SCREW 2.6x8 F/ZN-3C (5 ± 1 kgf·cm) Leg
C.T.SCREW M2x6 F/ZN-3C (5 ± 1 kgf·m)
Tighten the screws in the order shown above.
Since the Insulator is not included in the PCB Top Main supplied as an Nuts (x3) are set on the sides of the CR for securing the fixing screws of the Printhead. After the Printhead is removed, the nuts become loose and
ASP, make sure to transfer it from the old board to the new board. easily come off. Therefore, be careful not to lose them, and if any of them come off, put them back in the original positions.
Align the Insulator with the standard position on the PCB Top  Reassemble the Head Spring with the leg facing the 80 digit side.
Main shown above.  Tighten the screws in the order shown above.

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Housing Upper Assy Cover Head FFC
Front Left Front right Hook Cover Head FFC

Housing Upper Assy
Housing Upper Assy
Cover Head FFC 1

Head FFC Assy
EG Sub A
A
B
3 2
Engaged state of EG Sub
Blade (A) and EG Main (B)
EG Main Hook
Slit Rib
Housing Lower Assy
When removing the Cover Head FFC, disengage the ribs (x3). First press rib (1) downward and warp section A toward you to disengage rib (2) and
Release the hooks (x6) shown above when removing the Housing Upper Assy. rib (3). Take special care not to weaken (whiten) section A when warping it.
Since the Cover Head FFC is tightly assembled, it is difficult to remove it. Therefore, be careful not to damage the related parts such as the CR
When reassembling the Housing Upper Assy, align the blade on the EG Sub with the slit on the EG Main (Hopper Assy). Unit and ribs.
When reassembling the Cover Head FFC, engage the hook on the Head FFC Assy.
PCB Top Main / Shield Plate MB GND Plate Paper Guide Front
Step 1 Step 2
Step 2
Shield Plate MB
PCB Top Main
C.C.P-TITE SCREW,2.5X5,F/ZN-3C (4 ± 1 kgf·cm) 2
Step 3
FFC connector with a lock
1 1
PCB Top Main
2
GND Plate Paper Guide Front
Unlock the connectors with a lock before disconnecting FFCs. C.B.P-TITE SCREW 2.5x6 F/ZN-3C (4 ± 1 kgf·cm)
C.B.SCREW, 2.5x5,F/ZN-3C (5 ± 1 kgf·cm)
Reassemble the PCB Top Main as follows.
1. Secure the PCB Top Main and the Housing Middle with the screw. Tighten the screws in the order shown above.
2. Secure the Shield Plate MB with three screws shown above.
3. Screw the GND Plate Main R in the order shown above.

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2.5 Routing FFCs/cables

PCB Top Main/PCB Drive Shield Plate Rear/GND Plate Paper Guide Front
PCB Top Main
Top
Connector type FFC PCB
(w/ lock)
Paper Sensor
CN3 CN7 for FFC
ASF Encoder
for FFC w/Lock Detector PE
SD Card
for lead wire PF Encoder
on backface
PCB Drive
Bottom Cover Open

Sensor
CN4
CN22 CN23
CN2
ASF Encoder
CN21 CN12 CN24 CN10 3
CR/PF Motor
2 Relay Cable
# Connected to Cable Name
ASF Motor
CN2 USB Device --- DRV-SUB-B
1 GND Plate Paper
Guide Front Harness
CN3 WLAN Module (BtoB) ---
CN4 USB-Host ---
CN7 Panel Assy FFC Panel  After screwing the Shield Plate Rear at three points ( ) on the PCB Drive, screw the GND Plate Paper Guide Front in the order shown above.
CN10 PCB Driver FFC PCB  Connect the cables and FFCs to theo PCB Drive as shown above.
CN12 CR Encoder  Make sure to unlock the connector ( ) before disconnecting the FFC, and lock it after connecting the FFC.
CN21 Printhead
Head FFC
CN22 Printhead
CN23 CRCM
Panel FFC (1) / Panel FFC (2) / PCB LED
CN24 Maintenance Box Assy FFC Ink Eject
Housing Upper Assy (Rear) Housing Upper Assy (Front)
PCB Drive
CN7
Connector type
for FFC
CN8
CN1
for FFC w/Lock

CN6
for lead wire FFC Panel (2)
on backface Hole B
CN4
CN5 CN10 FFC Panel (2)

CN11 CN2 CN10 FFC Panel (1)
PCB
HoleLED
B
# Connected to Cable Name

CN1 PCB Top Main FFC PCB PCB LED
CN2 PCB Battery PCB Battery harness
Housing Upper Assy
CN4 PF Encoder PE Sensor cable
Slit
CN5 ASF Encoder Cable ENC ASF
CN6 PE Detector FFC ENC PF
 FFC Panel (1)
CN7 Paper Sensor Assy Paper Sensor FFC • Connect to the PCB Top Main.
CN8 Cover Open Sensor Cover Open Sensor FFC  FFC Panel (2)
CN10 CR Motor / PF Motor CR/PF Motor Relay Cable • Fold back and route through the hole to the front side, and then route as shown above to the PCB LED.
 PCB LED
CN11 ASF Motor ASF Motor cable
• Align with the slit as shown above.
Disassembly/Reassembly Routing FFCs/cables 52

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Paper Sensor FFC PE Sensor cable CR Motor cable / PF Motor cable WiFi PCB
Paper Sensor Holder Paper Sensor Paper Sensor FFC PE Sensor Step 1 Step 2 WiFi PCB
PE sensor cable route
(black & white cable)
ASF Unit
WiFi PCB
GND Plate WiFi 1

Securing point
B A
Hook and positioning hole
CN7
CR/PF Motor Relay
Cable connectors Reassemble the WiFi PCB as follows.
1. Set the GND Plate WiFi in the orientation shown above while aligning
PF Motor cable route
the hook with the positioning hole on the plate.
ASF Unit ASF Unit
CR Motor cable route 2. Set the WiFi PCB as shown and secure it with two screws in the order
shown above.
PCB Driver
Double-sided tape 
Slit
Hook 
 Route CR Motor cable and PF Motor cable through the slits and along 
PCB Driver 
 Connect to the connector (CN7) on PCB Driver and route according to the the routes (slots) for them shown above on ASF Unit, and then connect
Double-sided tape
them to the connectors of CR/PF Motor Relay Cable. 
folds of the FFC.

 Secure at the points shown above on ASF Unit with double-sided tape (x2). 1. CR Motor cable: Red & Black, in the outer slot and connect to A.

 Connect to the connector on Paper Sensor and route through the hook on Route along the route on ASF Unit, and secure with double sided tape on the 2. PF Motor cable: Orange & White, in the inner slot and connect to B 
Paper Sensor Holder. frame corner of ASF Unit as shown above.  Secure the connectors of CR/PF Motor Relay Cable into the position 
shown above and secure the cable with the slit on ASF Unit as shown.
DC Board/PCB Battery
PCB Battery harness
DC Board
PCB Battery
PCB Battery harness
DC Board
Route the PCB Battery harness under the DC Board before screwing the DC
Board.
Disassembly/Reassembly Routing FFCs/cables 53

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CHAPTER 3
ADJUSTMENT
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3.1 Required Adjustments

The table from the following page lists the required adjustments depending upon the parts being repaired or
replaced. Find the part(s) you removed or replaced, and check which adjustment(s) must be carried out.
 If the EEPROM data cannot be read out from the old Main Board using the Adjustment
Program when replacing the Main Board is required, the Maintenance Box Assy must be
replaced with the Main Board at the same time.
 After all required adjustments are completed, use the “Final check pattern print”
function to print all adjustment patterns for final check. If you find a problem with the
printout patterns, carry out the adjustment again.
 When replacing the Main Board, the adjustment should be made after performing the
initial setting.
 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 55

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Epson PM-520/525 Revision A
Table 3-1. Required Adjustment List

Mechanism
Adjustment Type Adjustment using the Adjustment Program
adjustment
Priority 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
PF deterioration CR motor heat PF motor heat ASF Motor heat
EEPROM Initialize Setting Head ID Maintenance PE (TOF) 1st dot position PF/EJ Head angular Bi-D PW deterioration
Adjustment Item PG check Ink charge PW adjustment correction protection protection protection
data copy (MAC address write) input counter reset adjustment adjustment adjustment adjustment adjustment correction counter
counter control control control
Check if the To copy To write sale destination To correct To fill ink To reset the To correct the To correct the mounting To correct first To correct To correct tilt of To correct print To reset the Corrects the amount To measure the manufacturing variations of the DC
PG is within adjustment specific settings, the characteristic inside the new waste ink paper detection position of the PW Sensor on a dot print start variations in the Printhead start timing in counter or set it to of light using motors (CR/PF/ASF Motor), Main Board and PS
the standard. values and such serial number and the variation of Printhead to counter after positions and software basis to adjust the position through paper feed caused at the bidirectional its maximum software to adjust Board to determine the correction value used for
stored on the old adjustment initial value the replaced make it ready replacing the the mounting detection position and Nozzle software control. accuracy to installation printing through according to the the deterioration of estimating the current values of the motors.
Purpose
Main Board to into the Main Board Printhead by for print after waste ink pad. positions of the position dispersion. achieve higher through software control. replaced parts. the sensor by mist or
the new board after replacing it. And entering its replacing the PE Sensor by print quality. software control. similar causes.
when it needs to also to set the MAC Printhead ID Printhead. software
be replaced. address as necessary. (Head ID). control
Porous Pad IS
Lower A
Replace --- --- --- --- --- O --- --- --- --- --- --- --- --- --- --- ---
Porous Pad IS
Lower B
Replace --- --- --- --- --- O --- --- --- --- --- --- --- --- --- --- ---
Porous Pad Housing

Lower
Replace --- --- --- --- --- O*1 --- --- --- --- --- --- --- --- --- --- ---
Porous Pad Frame

IS
Replace --- --- --- --- --- O*1 O O O --- --- --- --- --- --- --- ---
Remove O --- --- --- --- --- O O O --- O O --- --- --- --- ---
Part Name
Printhead
Replace O --- --- O O --- --- O O --- O O --- --- --- --- ---
Remove --- --- --- --- --- --- --- O O --- --- --- --- --- --- --- ---
PW Sensor
Replace --- --- --- --- --- --- --- --- --- --- --- --- --- O --- --- ---
Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Paper Sensor
Replace --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Remove
(Read OK)
--- O --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Main Board Remove

(Read NG)
--- --- O O --- O O O O O O O O --- O O O
Replace --- --- --- --- --- --- O --- --- --- --- --- --- --- --- --- ---
-2 -1 0 1 2
-2 -2 OK
-1 -1
0 0
1 1
2 2 NG OK
-2 -1 0 1 2
Printout pattern --- --- --- --- --- --- --- --- NG --- --- --- --- ---
-2 NG
-1
0 OK NG
NG OK NG
1
2 NG
See " 3.3.1 PW Adjustment Enter the value Enter the values Examine the See " 3.2.2.1 CR Motor/PF Motor/ASF Motor heat
PG Check Examine the misaligned lines for the pattern of the most printout patterns protection control (p58) " for the details.
(p60) " for printed on top, bottom, left, with no overlap straight lines. for each of the
the details. and right of the paper, and or gap between four modes, and
enter the number beside the the two enter the value
line that is exactly 5 mm away rectangles. for the pattern
from the paper edge for each with no gap and
How to judge --- --- --- --- --- --- side.
--- overlap for each --- ---
Left/right margin adjustment mode.
Examine the lines on the left
side and enter the number
beside the line that overlaps
with the vertical line 5mm
from the left.
Adjustment program --- O O O O O O O O O O O O O O O O
Thickness
Tool --- --- --- --- --- --- --- --- Ruler --- --- --- --- --- --- ---
gauge
Note "*1": Replace at every other Porous PAD IS LOWER A & B replacement.

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Table 3-1. Required Adjustment List
Mechanism
Adjustment Type Adjustment using the Adjustment Program
adjustment
Priority 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
PF deterioration CR motor heat PF motor heat ASF Motor heat
EEPROM Initialize Setting Head ID Maintenance PE (TOF) 1st dot position PF/EJ Head angular Bi-D PW deterioration
Adjustment Item PG check Ink charge PW adjustment correction protection protection protection
data copy (MAC address write) input counter reset adjustment adjustment adjustment adjustment adjustment correction counter
counter control control control
Check if the To copy To write sale destination To correct To fill ink To reset the To correct the To correct the mounting To correct first To correct To correct tilt of To correct print To reset the Corrects the amount To measure the manufacturing variations of the DC
PG is within adjustment specific settings, the characteristic inside the new waste ink paper detection position of the PW Sensor on a dot print start variations in the Printhead start timing in counter or set it to of light using motors (CR/PF/ASF Motor), Main Board and PS
the standard. values and such serial number and the variation of Printhead to counter after positions and software basis to adjust the position through paper feed caused at the bidirectional its maximum software to adjust Board to determine the correction value used for
stored on the old adjustment initial value the replaced make it ready replacing the the mounting detection position and Nozzle software control. accuracy to installation printing through according to the the deterioration of estimating the current values of the motors.
Purpose
Main Board to into the Main Board Printhead by for print after waste ink pad. positions of the position dispersion. achieve higher through software control. replaced parts. the sensor by mist or
the new board after replacing it. And entering its replacing the PE Sensor by print quality. software control. similar causes.
when it needs to also to set the MAC Printhead ID Printhead. software
be replaced. address as necessary. (Head ID). control
Remove --- --- --- --- --- --- O --- --- --- --- --- --- --- --- --- ---
PE Sensor
Replace --- --- --- --- --- --- O --- --- --- --- --- --- --- --- --- ---
Remove --- --- --- --- O --- O --- --- --- --- --- --- --- --- --- ---
Part Name
Inksystem
Replace --- --- --- --- O --- O --- --- --- --- --- --- --- --- --- ---
Remove --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Drive Board
Replace --- --- --- --- --- --- O --- --- --- --- --- --- --- O O O
Printer Mechanism Replace O --- --- --- --- O O O O O O O O O O O O
-2 -1 0 1 2
-2 -2 OK
-1 -1
0 0
1 1
2 2 NG OK
-2 -1 0 1 2
Printout pattern --- --- --- --- --- --- --- --- NG --- --- --- --- ---
-2 NG
-1
0 OK NG
NG OK NG
1
2 NG
See " 3.3.1 PW Adjustment Enter the value Enter the values Examine the See " 3.2.2.1 CR Motor/PF Motor/ASF Motor heat
PG Check Examine the misaligned lines for the pattern of the most printout patterns protection control (p58) " for the details.
(p60) " for printed on top, bottom, left, with no overlap straight lines. for each of the
the details. and right of the paper, and or gap between four modes, and
enter the number beside the the two enter the value
line that is exactly 5 mm away rectangles. for the pattern
from the paper edge for each with no gap and
How to judge --- --- --- --- --- --- side.
--- overlap for each --- ---
Left/right margin adjustment mode.
Examine the lines on the left
side and enter the number
beside the line that overlaps
with the vertical line 5mm
from the left.
Adjustment program --- O O O O O O O O O O O O O O O O
Thickness
Tool --- --- --- --- --- --- --- --- Ruler --- --- --- --- --- --- ---
gauge
Note "*1": Replace at every other Porous PAD IS LOWER A & B replacement.

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3.2 Adjustment Program

This section provides the operating environment, functions related to safety and privacy policy, and the
adjustment item newly added of the Adjustment Program. See "3.1 Required Adjustments (p55) " for the
adjustments not explained here.
3.2.1 Operating Environment

The operating environment for the Adjustment Program is as follows.
 OS: Windows XP, Vista, 7, 8
 Interface: USB
3.2.2 Details of the Adjustment Program

Refer to the guide in the Adjustment Program for the details of the procedure.
3.2.2.1 CR Motor/PF Motor/ASF Motor heat protection control
Purpose To measure the manufacturing variations of the DC motors (CR/PF/ASF Motor), Main Board and PS Board to
determine the correction value used for estimating the current values of the motors.
Risks if the Since the printer cannot measure the current value of motors correctly, heat generation caused by driving motors
adjustment is not cannot be estimated accurately, which may results in trouble such as incorrect control of motors when allotting a
correctly made cool down period according to heat generation. In the worst case, excessive heat generation may cause smoke or
ignition.
Procedure 1. Select from the menu of the Adjustment Program, turn on the check box of the replaced parts and press the
“Perform” button to measure the correction value.
2. The correction value is automatically measured and the measurement value is written to the EEPROM on
the Main Board.
Adjustment
Program screen
Perform button Perform button

Select the check boxes of the replaced parts. Select the check boxes of the replaced parts.
Perform button
Select the check boxes of the replaced parts.
Remarks ---

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3.2.2.2 Initialize PW deterioration offset
Purpose Initializes the counter to reset the soft counter saved on the EEPROM (PW deterioration offset soft counter) to
fit the PW sensor deterioration condition by ink mist.
Risks if the Mismatch between the PW sensor deterioration condition and the soft counter may result, which may cause non-
adjustment is not uniformity of paper margins.
correctly made
Procedure 1. Select from the menu of the Adjustment Program and press the “Initialization” button to initialize the PW
deterioration offset.
2. After pressing the button, the PW deterioration correction value is automatically initialized and the initial
value is written to the EEPROM on the Main Board.
Adjustment
Program screen
Initialize button
Remarks ---

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3.3 Mechanism Adjustment / Check

This section provides the procedure for the mechanism adjustment and check.
3.3.1 PG Check
This section describes the procedure for checking the platen gap (PG)
 This printer does not have any PG adjustment mechanism, however, it is designed so that the
platen gap can fall within the expected range if you correctly reassemble the unit according to
the instructions for reassembling in this manual.
If the PG does not fall within the standard range after performing the PG check described in
this section, first check if the unit is correctly reassembled following the instructions in this
manual. If the PG still cannot fall within the standard range even though the unit is correctly
reassembled, replace the Printer Mechanism.
 The standard range of the PG is as follows:
• Standard: 1.75 ± 0.25 mm
 Tools
 Thickness gauge for PG adjustment:
• Thickness: 1.55 mm (x2), 2.00 mm (x2)
• Size (for reference): 50 mm (L) x13 mm (W)

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3.3.1.1 Adjustment procedure

When performing the PG adjustment, make sure of the following.
 Move the CR Unit by pulling the upper portion of the CR timing belt.
 Be careful not to damage the nozzle surface of the Printhead with a thickness gauge.
 Carry out the PG Check with the new ink cartridge installed on the CR Unit.
1. Move the CR Unit to the center of the printer.

2. Place the thickness gauges (1.55 mm) on the positions shown in Figure 3-1.
80-digit side 0-digit side
Thickness gauge
Figure 3-1. Position of the Thickness Gauge
3. Move the CR Unit between both ends by pulling the CR Timing Belt and confirm the CR Unit DOES NOT
TOUCH the thickness gauges. If the CR Unit comes in contact with the thickness gauges, the PG is smaller
than the standard value, therefore, check if the unit is correctly reassembled. If not, reassemble the unit and
perform PG check again. (If the unit is correctly reassembled, replace the Printer Mechanism with a new
one.)
4. Move the CR Unit back to the center, and replace the thickness gauges (1.55 mm) with the thickness gauges
(2.0 mm) on the same positions as Step2.
5. Move the CR Unit between both ends by pulling the CR Timing Belt and confirm the CR Unit TOUCHES
the thickness gauges. If the CR Unit does not touch the thickness gauges, the PG is greater than the standard
value, therefore, check if the unit is correctly reassembled. If not, reassemble the unit and perform PG check
again. (If the unit is correctly reassembled, replace the Printer Mechanism with a new one.)

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CHAPTER 4
MAINTENANCE
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4.1 Cleaning
4.1.1 Cleaning the CR Unit
In this product, ink may be attached on the CR Unit due to the structure of Printhead and CR Unit.
So, head short circuit may arise due to ink attachment on the terminal of the head FFC when replacing the
printhead.
 This cleaning should be carried out only when replacing the printhead.
 When installing the Printhead, make sure the Head FFC is not contaminated with ink
beforehand.
 Tool: Cotton swab or soft dry dust-free cloth

 Cleaning procedure
1. Disconnect the Head FFC from the CR Unit and hold the Printhead, check whether ink is attached on the CR
Unit.
2. If any ink is attached on the CR Unit, wipe it off with a cotton swab (or a soft dry dust-free cloth).
Maintenance Cleaning 63
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4.1.2 Cleaning the Exterior Parts/inside of the printer

This section describes how to clean the sections other than the carriage.
 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 rollers, 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.
Maintenance Cleaning 64
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4.2 Lubrication
The type and amount of the grease used to lubricate the printer parts are determined based on the results of the
internal evaluations. Therefore, refer to "4.2.1 Lubrication Points and Instructions (p66) " for the repairing
procedures below, and apply the specified type and amount of the grease to the specified part of the printer
mechanism.
"4.2.1 Lubrication Points and Instructions (p66) " also provides information about whether or not the parts which
require lubrication are supplied as ASP and the lubrication status when supplied as ASP. For the parts which are
not supplied as ASP, if their movement is not smooth enough, check their lubrication status and lubricate them if
necessary.
 Grease
Type Name EPSON Part Code Supplier

Grease G-97 1635441 EPSON
 Tools
Name Availability EPSON Part Code

Injector O* ---
Brush O* ---
Note *: Use tools whose specifications are specified in "4.2.1 Lubrication Points and Instructions (p66) ".
Maintenance Lubrication 65
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4.2.1 Lubrication Points and Instructions
<Part supply as ASP> <Part supply as ASP>

Supplied as the Printer Supplied as the Printer
Mechanism Mechanism
<Lubrication status when <Lubrication status when
supplied as ASP> supplied as ASP>
Lubricated Lubricated
Star Wheel Holder Assy CR Unit
<Lubrication Point> <Lubrication Point>
1.
2. Contact surface (x3) Contact surface between
between the CR Guide the Star Wheel Holder
Frame and the CR Unit Assy and the CR Unit
2.1mm <Type> <Type>
CR Guide Frame G-97 G-97
<Application Amount> Star Wheel Holder Assy <Application Amount>
1. 0.2g 0.2g
2. 0.2g <Remarks>
<Remarks>  Apply with injector.
 Apply with injector.
CR Guide Frame CR Unit

Application Point 6 to 7mm Application Point
Figure 4-1. Lubrication of the CR Guide Frame Figure 4-2. Lubrication of the Star Wheel Holder Assy
<Part supply as ASP>

Supplied as the Printer
Mechanism
<Lubrication status when
supplied as ASP>
Lubricated
<Lubrication Point>
Contact points (x5) with
the gears on the left side of
the Printer Mechanism
<Type>
G-97
<Application Amount>
0.18g
<Remarks>
 After applying with
injector, spread it over
the entire shafts with a
brush.
 Make sure not to attach
grease on the PF Scale
Printer Mechanism or Spur Gear 2.3.
Application Point
Figure 4-3. Lubrication of the Printer Mechanism
Maintenance 66
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CHAPTER 5
APPENDIX
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5.1 Connector Diagram

Cable connections of this printer are shown below.
CN1 LCD
Wireless CN2
board
LAN Module Panel Board
CN1 CN4 LED
CN1 CN3
board
CN3 CN7
SD card in
Main Board
CN22 CN23
USB-Host USB Device
CN21 CN12 CN2
CN24 CN10
Carriage
Maintenance Box
Printhead
CR Contact Module
CN1
ASF Motor
CN5 CN1 CN11
Ink cartridge B M Y C
Battery
PW sensor
DRV Board DRV Board CN2
CN2
(Front face) (Back face)
CR Encoder Sensor
CN10
CN1 CN4 CN6 CN7 CN8 CR Motor
CN3
PF Motor
PE Sensor Cover Open Sensor
PF Encoder Sensor CN2 AC in
ASF Encoder Sensor Paper Sensor PS Board
Figure 5-1. Connector Diagram
Appendix Connector Diagram 68

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5.2 Protection for Transportation

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

 Purpose
To prevent the fingers from getting into spaces such as the space between the Cover EJ and the main body when
removing the product from the individual box.
 Risks if the product is not protected
The product may be damaged if it is forcibly pulled out from the individual box while holding it with the fingers in the
spaces explained above.
 Preparation
Prepare three pieces of strong tape A, B, and C (L: 110/160/260 mm, W: 22 mm; fold back 5mm from the end.).
[Tape A]
22 mm Fold 5 mm
160 mm
[Tape B]
22 mm Fold 5 mm
110 mm
[Tape C]
22 mm Fold 5 mm
260 mm
Figure 5-2. Preparing strong tape (Tape A/B/C)
Appendix Protection for Transportation 69

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 Application standards of tape A, B, C

 Start application with the foldless end of the tape.
 Apply the tape fully to the folded end as shown below following the standard of each tape.
[Tape A Application Standard]

Front 1: Apply from the bottom edge.
2: Apply fully as shown below over on to
Tape A the right side.
Step 2
Apply fully over
onto the right side.
Step 1
Top left [Tape B Application Standard]

1. Start application at the point 60
mm from the left side and 30 mm
from the top surface.
30 mm 2. Apply upward fully over on to the
60 mm top surface.
Bottom [Tape C Application Standard]

Tape B Tape C
1. Apply from the left foot to the right foot.
2. Fold downward as shown below.
3. Fold again as shown and apply to the top.
Step 2
Step 1-1 Step 1-2
Glue side
Step 3
Figure 5-3. Securing the Covers
Appendix Protection for Transportation 70

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Service Manual: Epson PM-520 Epson PM-525

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SERVICE MANUAL

Color Inkjet Printer

Copyright 2017 SEIKO EPSON CORPORATION

CHAPTER 2. 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 February. 15, 2017 First Release

1.1.1 Troubleshooting Workflow

 This flowchart is compiled based on the following contents.

Turn on the power

Print network status sheet

Print check pattern

*: In case of “Not Trouble Found”, check fatal error code.

Figure 1-1. Troubleshooting Workflow (1)

Troubleshooting Troubleshooting Workflow 12

The power-on sequence Error is indicated during power-on

Figure 1-2. Troubleshooting Workflow (2)

Troubleshooting Troubleshooting Workflow 13

1.1.2 Printing the network status sheet

Procedure to print the network status sheet

1. Select “Setup” on the Home screen.

2. Select “Network Settings”.

3. Select “Network Status”.

4. On the “Network Status” screen, press the Left or Right button.

Troubleshooting Power-On Sequence 14

Figure 1-2. Network status sheet print confirmation screen

Troubleshooting Power-On Sequence 15

7. Printing of the status sheet starts.

Figure 1-3. Status sheet printout

Troubleshooting Fatal Error Code List 16

1.2 Power-On Sequence

2. Checking for waste ink overflow 80 HP 0

3. Sequence of paper eject without printing 80 HP 0

3-3.The PF Motor rotates counterclockwise to eject paper below the PE Sensor. 80 HP 0

4. Unlocking the CR Unit 80 HP 0

6. Low temperature operation sequence *4

Troubleshooting Fatal Error Code List 17

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

8. Detecting ink cartridge and initializing ink system 80 HP 0

Troubleshooting Fatal Error Code List 18

1.3 Fatal Error Code List

1.3.1 Displaying the Fatal Error Code

LCD display screen image

Figure 1-4. Displaying the Fatal Error Code

Troubleshooting Fatal Error Code List 19

1.3.2 Printer Fatal Error Code

Troubleshooting Power-On Sequence 20

Table 1-2. Fatal Error List

Troubleshooting Power-On Sequence 21

Table 1-2. Fatal Error List

Troubleshooting Power-On Sequence 22

Name Availability EPSON Part Code

2.1.3 Locations of the Parts/Units

No. Name No. Name

No. Name No. Name

1 Printhead (p42) 3 CRCM (p42)

No. Name No. Name

1 Pump Assy (p43) 2 Ink System Assy (p41)

No. Name No. Name

1 PCB Battery (p38) 2 CR Scale (p42)

No. Name No. Name

1 PCB Drive (p41) 2 Encoder Board ASF (p43)