WF-R8590 R8591 R8593 RevF

SERVICE MANUAL
RevisionE Color Ink jet Printer
EPSON WF-R8590
EPSON WF-R8591
EPSON WF-R8593
CONFIDENTIAL
SEMF14-006
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 © 2016 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. In order to protect sensitive microprocessors and circuitry, use static discharge equipment, such as anti-static
wrist straps, when accessing internal components.
6. Do not tilt this product immediately after initial ink charge, especially after performing the ink charge several
times. Doing so may cause ink to leak from the product because it may take some time for the waste ink pads
to completely absorb ink wasted due to the ink charge.
7. Never touch the ink or wasted ink with bare hands. If ink comes into contact with your skin, wash it off with
soap and water immediately. If you have a skin irritation, consult a doctor immediately.
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8. When disassembling or assembling this product, make sure to wear gloves to avoid injuries from metal parts
with sharp edges.
9. Use only recommended tools for disassembling, assembling or adjusting the printer.
10. Observe the specified torque when tightening screws.
11. Be extremely careful not to scratch or contaminate the following parts.
Nozzle plate of the print head
CR Scale
PF Scale
ASF Scale
Coated surface of the PF Roller
Gears
Rollers
LCD
Scanner Sensor
Exterior parts
12. Never use oil or grease other than those specified in this manual. Use of different types of oil or grease may
damage the component or give bad influence on the printer function.
13. Apply the specified amount of grease described in this manual.
14. Make the specified adjustments when you disassemble the printer.
15. When cleaning this product, follow the procedure described in this manual.
16. When transporting this product after filling the ink in the print head, pack the printer without removing the
ink pack in order to prevent the print head from drying out. In addition, make sure to secure the CR Unit with
tape before packing the printer "5.2 Protection for Transportation (p330)".
17. Make sure to install antivirus software in the computers used for the service support activities.
18. Keep the virus pattern file of antivirus software up-to-date.
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About This Manual
This manual, consists of the following chapters, is intended for repair service personnel and includes information
necessary for properly performing maintenance and servicing the product.
CHAPTER 1. 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. 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.
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Revision Status
Revision Date of Issue Description
A July 8th, 2014 First Release

B Jan.9h, 2015 Revise content
Chapter 1
1.1.1 Troubleshooting Workflow
1.2　Power-On Sequence
1.3 　Fatal Error Code List
Chapter 2
2.1.3 Standard Operation Time for servicing the product
2.3.5.4 Main Board
2.3.6.1 Print Head
2.3.6.16 Cap Unit
2.3.7.6 PF Tension Stopper
2.3.7.7 PF Tension Belt
2.3.7.8 PF Motor Assy
2.3.7.13 Sheet Guide
2.3.8.6 Ink Supply CL Assy
2.3.8.9 Tube
Chapter 3
3.2.1.1 PF Timing Belt Tension Measurement
3.2.1.3 ASF Timing Belt Tension Measurement
3.2.3 Ink Leak Check
3.2.3.2 Ink Lake Measurement jig 1
3.2.4 Head Angular Mecha Adjustment
3.2.5 SMAP Run out Adjustment
Chapter 4
4.3 Initialization of Password
C Jun 20,2015 Revise Content
Chapter 1
Fatal Error Code List (p18)
Chapter 2
Disassembly and Assembly Procedure (p59)
Chapter 3
3-3 Required Adjustment List (Adjustment using the Adjustment Program) (2/2) (p275)
Chapter 4
Firmware Update (p317)
Initialization of Password (p318)
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D Dec. 15.2015 Chapter 2

2.1.1 Tools (p.40)
2.1.1.1 Screw types used in the printer (p.41)
2.1.2 Standard Operation Time for servicing the product (p.42)
2.3.1.2 Ink flushing (p.61- p.62)
2.3.1.3 Initial Ink charge (p.62)
2.3.3.14 Front Housing (p.80)
2.3.5.3 Main Board Unit (p.99 - p.101)
2.3.5.8 Power Supply Unit (p.110 - p.111)
2.3.6.1 Print Head (p.113, p.114)
2.3.6.2 CR Waste Ink Pad (p.116)
2.3.6.3 CR Scale
How to install the CR Scale (p.119)
2.3.6.4 PW Sensor (p.120, p.120)
2.3.6.5 Head FFC p.121 - p.127)
2.3.6.7 Taking the ink tubes from the ink supply unit. (p.130 - p.130)
2.3.6.8 CR Unit (p.131, p.131 - p.133)
2.3.6.15 Ink Supply Unit (p.145, p.145 - p.148)
2.3.8.5 Ink Supply BK Assy (p.186)
2.3.8.6 Ink Supply CL Assy (p.188)
2.3.8.7 Ink Pack Holder (BK) (p.192)
2.3.8.8 Ink Pack Holder (Y/M/C) (p.193)
2.3.8.9 Ink Tube (p.194)
2.3.13 Mechanism Unit (p.260)
Chapter 5
5.2.2 Protection of the Ink Supply Needle (p.314)
E Apr. 4.2016 Copyright (p.2)
Chapter 1
Printer fatal error list 0x8A (p.22)
Chapter 2
2.3.1 Preparation for servicing (p.61)
2.3.2.1 Maintenance Box. (p.64)
Chapter 3
Table 3-1 Required Adjustment List (Mechanism adjustment) (p.280)
Table 3-2 Required Adjustment List (Adjustment using the Adjustment Program) (1/2) (p.281)
Table 3-3 Required Adjustment List (Adjustment using the Adjustment Program) (2/2) (p.282)
1.Turn the printer on... (p.306)
12.Turn the printer on... (p.307)
3.2.6 Inspection Mode (p.316)
3.2.6.2 Printer Inspection Mode (p.317)
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F May 24, 2016 Revise the contents.

Chapter 2
Made change description of the disassembly/reassembly procedure in "2.3.6.1 Print
Head (p114)".
Made change description of the disassembly/reassembly procedure in "2.3.6.15 Ink
Supply Unit (p148)".
"2.3.6.19 Print Head / Ink Supply Unit (When the printer cannot perform Ink Flushing
by fatal error) (p168)" is added newly.
Chapter 3
Made change the description of Caution Box in "3.2.2.3 PG adjustment procedure
(p293)".
New procedure is added, and changing the description in "3.2.3 Ink Leak Check
(p296)".
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EPSON WF-R8590 Revision F
Contents
Chapter 1 Troubleshooting
1.1 Troubleshooting....................................................................................................................................................... 14
1.1.1 Troubleshooting Workflow ............................................................................................................................ 14
1.2 Power-On Sequence ................................................................................................................................................ 17
1.3 Fatal Error Code List............................................................................................................................................... 20
1.3.1 FAX Troubleshooting..................................................................................................................................... 32
1.3.1.1 FAX Log ................................................................................................................................................ 32
1.3.1.2 Error Code/Superficial Phenomenon-Based Troubleshooting .............................................................. 37
Chapter 2 DISASSEMBLY/REASSEMBLY
2.1 Overview ................................................................................................................................................................. 40

2.1.1 Tools ............................................................................................................................................................... 40
2.1.1.1 Screw types used in the printer .............................................................................................................. 41
2.1.2 Standard Operation Time for servicing the product ....................................................................................... 42
2.2 Parts Diagram .......................................................................................................................................................... 45
2.3 Disassembly and Assembly Procedure.................................................................................................................... 61
2.3.1 Preparation for servicing ................................................................................................................................ 61
2.3.1.1 Unlocking the CR Unit ......................................................................................................................... 61
2.3.1.2 Ink flushing ............................................................................................................................................ 62
2.3.1.3 Initial Ink charge .................................................................................................................................... 63
2.3.2 Consumables/Accessories .............................................................................................................................. 64
2.3.2.1 Maintenance Box ................................................................................................................................... 64
2.3.3 Housing........................................................................................................................................................... 65
2.3.3.1 Front Cover Assy ................................................................................................................................... 65
2.3.3.2 Paper Support Support ........................................................................................................................... 66
2.3.3.3 Stacker Assy .......................................................................................................................................... 66
2.3.3.4 Rear ASF Document Support Cover ..................................................................................................... 67
2.3.3.5 Left ADF Hinge Cover .......................................................................................................................... 67
2.3.3.6 Right ADF Hinge Cover ........................................................................................................................ 68
2.3.3.7 Paper Support......................................................................................................................................... 69
2.3.3.8 Panel Assy.............................................................................................................................................. 70
2.3.3.9 Speaker................................................................................................................................................... 71
2.3.3.10 Front Cover Microswitch..................................................................................................................... 72
2.3.3.11 Right Upper Front Cover ..................................................................................................................... 73
2.3.3.12 Panel Lower Front Cover..................................................................................................................... 73
2.3.3.13 Panel FFC ............................................................................................................................................ 74
2.3.3.14 Front Housing ...................................................................................................................................... 75
2.3.3.15 Middle Housing ................................................................................................................................... 86
2.3.4 Cover Sensors ................................................................................................................................................. 92
2.3.4.1 Rear Cover Microswitch ........................................................................................................................ 92
2.3.4.2 Rear Cover PF Sensor............................................................................................................................ 93
2.3.4.3 Right Pick Up Roller Sensor.................................................................................................................. 94
2.3.4.4 Left Pick Up Roller Sensor .................................................................................................................... 95
2.3.4.5 Casette Microswitch .............................................................................................................................. 95
2.3.4.6 PE Sensor ............................................................................................................................................... 96
2.3.5 Electric Circuit Components .......................................................................................................................... 97
2.3.5.1 USB/FAX Cover.................................................................................................................................... 97
2.3.5.2 USB Connector Assy ............................................................................................................................. 98
2.3.5.3 Main Board Unit .................................................................................................................................... 99
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2.3.5.4 Main Board .......................................................................................................................................... 107

2.3.5.5 Interface Board .................................................................................................................................... 108
2.3.5.6 Wireless LAN Module......................................................................................................................... 109
2.3.5.7 CSIC Board (BK)................................................................................................................................. 110
2.3.5.8 Power Supply Unit............................................................................................................................... 111
2.3.6 Carriage Mechanism/ Ink System Mechanism ............................................................................................. 114
2.3.6.1 Print Head ............................................................................................................................................ 114
2.3.6.2 CR Waste Ink Pad................................................................................................................................ 119
2.3.6.3 CR Scale .............................................................................................................................................. 120
2.3.6.4 PW Sensor............................................................................................................................................ 123
2.3.6.5 Head FFC............................................................................................................................................. 124
2.3.6.6 CR Motor ............................................................................................................................................. 131
2.3.6.7 Taking the ink tubes from the ink supply unit. ..................................................................... 133
2.3.6.8 CR Unit ................................................................................................................................................ 134
2.3.6.9 Decompression Motor Assy................................................................................................................. 141
2.3.6.10 APG Gear Assy.................................................................................................................................. 142
2.3.6.11 APG Sensor........................................................................................................................................ 143
2.3.6.12 APG Motor Assy ............................................................................................................................... 144
2.3.6.13 CR Solenoid Assy .............................................................................................................................. 146
2.3.6.14 Ink End Board .................................................................................................................................... 147
2.3.6.15 Ink Supply Unit.................................................................................................................................. 148
2.3.6.16 Cap Unit ............................................................................................................................................. 157
2.3.6.17 Pump Unit .......................................................................................................................................... 164
2.3.6.18 Waste Ink Joint Tube Assy ................................................................................................................ 166
2.3.6.19 Print Head / Ink Supply Unit
(When the printer cannot perform Ink Flushing by
fatal error) ......................................................................................................................................................... 168
2.3.7 Paper Feed Mechanism................................................................................................................................. 174
2.3.7.1 Rear Cover Assy/Rear Cover Belt ....................................................................................................... 174
2.3.7.2 Rear Cover Control Lever.................................................................................................................... 174
2.3.7.3 Duplex Unit.......................................................................................................................................... 175
2.3.7.4 PF Encoder Sensor Assy...................................................................................................................... 175
2.3.7.5 Pick Up Roller Motor Assy ................................................................................................................. 176
2.3.7.6 PF Tension Stopper.............................................................................................................................. 178
2.3.7.7 PF Timing Belt..................................................................................................................................... 179
2.3.7.8 PF Motor Assy ..................................................................................................................................... 181
2.3.7.9 PE Sensor ............................................................................................................................................. 182
2.3.7.10 PF Sensor ........................................................................................................................................... 186
2.3.7.11 Star Wheel Assy................................................................................................................................. 187
2.3.7.12 Rear ASF Unit ................................................................................................................................... 188
2.3.7.13 Sheet Guide........................................................................................................................................ 190
2.3.7.14 Rear ASF Solenoid Assy ................................................................................................................... 191
2.3.7.15 Rear ASF Solenoid Gear Assy........................................................................................................... 192
2.3.7.16 Rear ASF PE Sensor .......................................................................................................................... 193
2.3.8 Ink Supply Mechanism ................................................................................................................................. 195
2.3.8.1 Ink Supply BK Cover Assy ................................................................................................................. 195
2.3.8.2 Ink Supply CL Cover Assy ................................................................................................................. 197
2.3.8.3 Ink Supply BK Cover Open Sensor ..................................................................................................... 199
2.3.8.4 Ink Supply CL Cover Open Sensor ..................................................................................................... 200
2.3.8.5 Ink Supply BK Assy ............................................................................................................................ 201
2.3.8.6 Ink Supply CL Assy............................................................................................................................. 203
2.3.8.7 Ink Pack Holder (BK) .......................................................................................................................... 207
2.3.8.8 Ink Pack Holder (Y/M/C) .................................................................................................................... 208
2.3.8.9 Tube ..................................................................................................................................................... 209
2.3.8.10 CSIC FFC .......................................................................................................................................... 211
2.3.8.11 Relay FFC (BK)................................................................................................................................. 213
2.3.8.12 Relay FFC (CL) ................................................................................................................................. 214
2.3.9 ADF/ Scanner Unit ....................................................................................................................................... 216
2.3.9.1 ADF/ Scanner Unit .............................................................................................................................. 216
2.3.9.2 ADF Unit ............................................................................................................................................. 218
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2.3.9.3 ADF Cover Assy.................................................................................................................................. 221

2.3.9.4 Rear ADF Cover/ Rear Sub ADF Cover ............................................................................................. 222
2.3.9.5 Front Sub ADF Cover/ Front Main ADF Cover.................................................................................. 223
2.3.9.6 Document Cover Mat Assy.................................................................................................................. 225
2.3.9.7 ADF Pad Assy ..................................................................................................................................... 225
2.3.9.8 ADF Cover Microswitch ..................................................................................................................... 226
2.3.9.9 ADF PF Encoder Sensor...................................................................................................................... 227
2.3.9.10 ADF LD Assy .................................................................................................................................... 229
2.3.9.11 ADF PF Support Guide...................................................................................................................... 231
2.3.9.12 ADF Side Cover/ ADF Paper End Side Cover .................................................................................. 232
2.3.9.13 ADF PE Sensor A .............................................................................................................................. 233
2.3.9.14 ADF PW Sensor A............................................................................................................................. 235
2.3.9.15 ADF PW Sensor B............................................................................................................................. 236
2.3.9.16 ADF Document Detection Sensor A ................................................................................................. 237
2.3.9.17 ADF Document Detection Sensor B.................................................................................................. 238
2.3.9.18 Right ADF Hinge............................................................................................................................... 239
2.3.9.19 Left ADF Hinge ................................................................................................................................. 240
2.3.9.20 Top ADF Document Support Assy.................................................................................................... 241
2.3.9.21 Bottom ADF Document Support ....................................................................................................... 243
2.3.10 Cassette....................................................................................................................................................... 244
2.3.10.1 Casette Assy....................................................................................................................................... 244
2.3.10.2 Casette End Guide ............................................................................................................................. 244
2.3.11 2nd Cassette ................................................................................................................................................ 245
2.3.11.1 2nd Cassette Unit ............................................................................................................................... 245
2.3.11.2 2nd Cassette Assy .............................................................................................................................. 247
2.3.11.3 2nd Cassette Frame Assy ................................................................................................................... 247
2.3.11.4 2nd Cassette Drive Assy .................................................................................................................... 251
2.3.11.5 Actuator ............................................................................................................................................. 253
2.3.11.6 Sensor................................................................................................................................................. 254
2.3.11.7 Feed Roller......................................................................................................................................... 256
2.3.12 Option Cassette........................................................................................................................................... 257
2.3.12.1 OP Casette Unit ................................................................................................................................. 257
2.3.12.2 OP Cassette Assy ............................................................................................................................... 258
2.3.12.3 OP Casette Retard Roller Assy .......................................................................................................... 258
2.3.12.4 OP Cassette End Guide...................................................................................................................... 259
2.3.12.5 OP Cassette Edge Guide Right .......................................................................................................... 259
2.3.12.6 OP Rear Cover Assy .......................................................................................................................... 261
2.3.12.7 Stopper Belt ....................................................................................................................................... 261
2.3.12.8 OP Right Cover.................................................................................................................................. 262
2.3.12.9 OP Left Cover .................................................................................................................................... 262
2.3.12.10 OP Rear Frame Assy........................................................................................................................ 263
2.3.12.11 OP Cassette Drive Assy ................................................................................................................... 266
2.3.12.12 OP Rear Cover Open Microswitch .................................................................................................. 268
2.3.12.13 OP Rear Frame Cover Assy............................................................................................................. 268
2.3.12.14 OP Cassette Microswitch................................................................................................................. 271
2.3.12.15 OP Cassette PF Sensor..................................................................................................................... 272
2.3.12.16 OP Cassette Paper Sensor ................................................................................................................ 273
2.3.12.17 OP Cassette Hopper Sensor ............................................................................................................. 274
2.3.13 Mechanism Unit ......................................................................................................................................... 275
2.4 Routing the cables and FFC .................................................................................................................................. 277
2.4.1 Around the Main Board................................................................................................................................ 277
Chapter 3 Adjustment
3.1 Required Adjustments ........................................................................................................................................... 279

3.2 Details of Adjustments .......................................................................................................................................... 283
3.2.1 PF/CR/ASF Timing Belt Tension Measurement.......................................................................................... 283
3.2.1.1 PF Timing Belt Tension Measurement ................................................................................................ 284
3.2.1.2 CR Timing Belt Tension Check........................................................................................................... 286
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3.2.1.3 ASF Timing Belt Tension Measurement ............................................................................................. 287

3.2.2 PG Adjustment ............................................................................................................................................. 289
3.2.2.1 PG Adjustment procedure.................................................................................................................... 289
3.2.2.2 Preparation ........................................................................................................................................... 290
3.2.2.3 PG adjustment procedure..................................................................................................................... 293
3.2.2.4 Checking the Platen Gap...................................................................................................................... 295
3.2.3 Ink Leak Check............................................................................................................................................. 296
3.2.3.1 Method of using the Leakage Check PET Chip. ................................................................................. 296
3.2.3.2 Method of using the Ink Leak Measurement jig.................................................................................. 298
3.2.4 Head Angular Mecha Adjustment ................................................................................................................ 306
3.2.5 SMAP Run out Adjustment.......................................................................................................................... 309
3.2.6 Inspection Mode ........................................................................................................................................... 316
3.2.6.1 To enter Inspection Mode................................................................................................... 316
3.2.6.2 Printer Inspection Mode....................................................................................................... 317
3.2.6.3 Touch Panel Adjustment...................................................................................................................... 318
3.2.6.4 To exit the Inspection Mode: ............................................................................................................... 321
Chapter 4 Maintenance
4.1 Overview ............................................................................................................................................................... 323

4.1.1 Cleaning........................................................................................................................................................ 323
4.1.2 Lubrication.................................................................................................................................................... 323
4.2 Lubrication Points and Instructions....................................................................................................................... 324
4.3 Firmware Update................................................................................................................................................... 326
4.4 Initialization of Password...................................................................................................................................... 327
Chapter 5 Appendix
5.1 Revision FConnector Diagram.............................................................................................................................. 329

5.2 Protection for Transportation ................................................................................................................................ 330
5.2.1 Securing the CR Unit.................................................................................................................................... 330
5.2.2 Protection of the Ink Supply Needle............................................................................................................. 331
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CHAPTER 1
TROUBLESHOOTING
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EPSON WF-R8590/WF-R8591/WF-R8593 Revision F
1.1 Troubleshooting
This section describes the troubleshooting workflow.
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.
• Printer Mechanism specification for WF-R8590,WF-R8591 and WF-R8593.
When FAX related error occurs, see " 1.3.1 FAX Troubleshooting (p32)".
Start
Turn on the printer
No
Does printer turn on the
power? 1 (p15)
Printer failure only

Yes What is returned reason?
No ADF/Scanner
Is Power-on sequence 2 (p15) unit failure
finished without error?
Copy an image
Yes
Standby condition
No
Is scanning operation
Print check pattern finished without 5
trouble?
(p16)
Yes
No
Is printing operation
finished without error?
3 (p15)
No
Yes ADF failure?
No
Is printing operation
finished without trouble? 4 (p16) Yes
Yes Copy an image by ADF
No
Is ADF operation finished
Yes trouble? 6
without
(p16)
*: In case of “Not Trouble Found”, check fatal error code. Finish*
Figure 1-1. Troubleshooting Workflow (1)
Troubleshooting Troubleshooting 14
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The power-on Error is indicated during

1 sequence does not 2 power-on sequence (p14)
start (p14)
No Power* LEDs on panel are flashing Fatal error Maintenance error No Maintenance Box error Maintenance Box detection Ink End error Ink pack detection error No Ink pack error Cover open error
error
[Presumable Cause] [Presumable Cause] Please refer to " 1.3 Fatal Error Code [Occurrence Condition] [Occurrence Condition] [Occurrence Condition] [Occurrence Condition] [Occurrence Condition] [Occurrence Condition]
• AC cable is unplugged. • Wi-Fi connector is unplugged List (p20)"for troubleshooting. This error occurs when This error occurs when [Occurrence Condition] This error occurs when ink in Ink This error occurs when Ink pack This error occurs when Ink pack This error occurs when Scanner
• Power shuts down due to • Wi-Fi Board damage maintenance counter in EEPROM Maintenance Box is not installed. This error occurs when pack is empty. data is incorrect or Ink pack is not not installed. Unit (Printer Cover) is open.
scanner error. exceeds the specified value. Maintenance Box data is incorrect recognized correctly.
• Power Supply Unit damage [Major Troubleshooting] [Major Occurrence Timing] [Major Occurrence Timing] or it is not recognized correctly. [Major Occurrence Timing] [Major Occurrence Timing] [Major Occurrence Timing]
• Main Board damage • Plug Wi-Fi connector • Power-on timing • At power-on • Power-on timing [Major Occurrence Timing] At power-on • At power-on
• Detection failure of PW Sensor • Wi-Fi Board replacement CR Fixing Tape error • Print start timing • Maintenance Box monitoring [Major Occurrence Timing] • Print start timing • Power-on timing • During printing
occurred at power-on. • Paper eject timing timing • Power-on timing • Print timing • Print start timing [Major Troubleshooting]
[Occurrence Condition] • Cleaning timing • Maintenance Box replacement • Cleaning timing • Cleaning timing Install Ink pack [Major Troubleshooting]
[Major Troubleshooting] This error occurs if a paper jam • Ink pack replacement timing [Major Troubleshooting] timing • Ink pack replacement timing • Ink pack replacement timing • Close Scanner Unit (Printer
• Plug AC cable. occurs during the power-on • Turn the printer off once and • Maintenance Box monitoring Cover) replacement
• Connect scanner harness. sequence before initial ink charge. [Major Troubleshooting] install Maintenance Box again, timing [Major Troubleshooting] [Major Troubleshooting] • Scanner Unit (Printer Cover)
• Power Supply Unit • Replace Maintenance Box and turn the power on. Ink pack replacement • Remove and reinstall Ink pack. replacement
replacement [Major Occurrence Timing] [Major Troubleshooting] • Ink pack replacement • Cover Open Sensor
Power-on timing • Remove and reinstall [NOTE] • CSIC Terminal replacement Paper Jam error replacement
• Main Board replacement
(before initial ink charge) Maintenance Box If an error occurs during • CSIC FFC replacement • Main Board replacement
• Maintenance Box replacement printing, the page where the error • CR Contact Module Please refer to " Paper Jam error".
[Major Troubleshooting] • Relay Board CSIC Terminal occurred is skipped and the replacement
Open the front cover and remove replacement printing resumes from the next • Main Board replacement
*: If the printer can turn on but turns off right away, the CR fixing tape. • Relay Board Assy replacement page.
the protection circuit may cut off the power due to • Relay Board FFC replacement
• Main Board replacement
an error such as a circuit failure.
3 Error is indicated during printing nozzle check pattern (p14)
Paper Jam error No Paper error Double Feed error No Paper Cassette error Paper Size Unmatch error Manual Tray No Paper error Manual Feed Request error Excessive Manual Feed Error Insufficient Manual Feed
error
[Occurrence Condition] [Occurrence Condition] [Occurrence Condition] [Occurrence Condition] [Occurrence Condition] [Occurrence Condition] [Occurrence Condition] [Occurrence Condition]
This error occurs when top/ This error occurs when top of This error occurs on the following This error occurs if one of the This error occurs when actual When printing from Manual Tray This error occurs if the printer This error occurs when the PE [Occurrence Condition]
bottom of paper is not detected by paper is not detected by PE Sensor cases. cassettes is not installed. paper size is not matched to (MSF unit), this error occurs if cannot receive the manual feed Sensor detects paper before This error occurs during manual
PE Sensor or PW Sensor in the in the specified steps of paper • A paper is ejected without theoretical one. paper is not loaded at the time of request. manual feed or when paper is feed if the PE Sensor detects
specified steps of paper feeding loading operation correctly. printing during paper loading [Major Occurrence Timing] data transmission. inserted too much. paper but the paper is not fed by
operation correctly. operation. Paper loading timing [Major Occurrence Timing] [Major Occurrence Timing] auto loading.
[Major Occurrence Timing] • Actual paper length is longer (Front loading) • Duplex print timing [Major Occurrence Timing] Paper loading timing [Major Occurrence Timing]
[Major Occurrence Timing] Paper loading timing than theoretical one. • FAX data print timing Paper loading timing (Rear loading) Print start timing (Rear loading) [Major Occurrence Timing]
• Power-on timing [Major Troubleshooting] (Rear loading) Print start timing (Rear loading)
• Paper loading timing [Major Troubleshooting] [Major Occurrence Timing] Install the Cassette Assy. [Major Troubleshooting] [Major Troubleshooting] [Major Troubleshooting]
• Paper eject timing 1 Put paper in cassette and push Paper loading timing 1 Put correct sized paper in [Major Troubleshooting] • Send the print data. • Eject paper with panel [Major Troubleshooting]
• Duplex print timing “START” button. cassette, and push “START” • Put paper in the Manual Tray • Main Board replacement operation, and load paper Eject paper with panel operation,
2 If a paper stops before reaching [Major Troubleshooting] button. (MSF unit). again. and load paper again.
[Major Troubleshooting] PE Sensor, remove it and • PE Lever replacement 2 If not resolved by step 1), • PE Sensor replacement • Main Board replacement
1 Remove the jammed paper by check the paper condition. • PE Sensor replacement check the following points. • PE Lever replacement • PE Sensor replacement
opening Printer Cover. 3 A) If no damage on the paper, set • PW Sensor replacement • PE Lever • Main Board replacement • PE Lever replacement
2 Push “Start” button. edge guide correctly after • Main Board replacement • PE Sensor
3 If not resolved by 2), check the putting paper in cassette and • PW Sensor
following. push “PRINT” button again. • Main Board
• Foreign material, bits of B) If damage on the paper, check
paper foreign materials / parts come-
• Part come-off off / parts transformation in
• PE Lever paper path.
• PE Sensor 4 If not resolved by 3-A) & 3-B),
• Main Board check the following.
• PW Sensor • Pickup Roller
• Duplex Unit
[NOTE] • PE Sensor
* If an error occurs during • Main Board
printing, the page where the error • PF Motor
occurred is skipped and the • Casette Assy
printing resumes from the next
page.
* If an error occurs during duplex
printing, the following are
performed.
• If an error occurs during the
front face of duplex printing,
the page where the error
occurred and the next page
are skipped and the printing
resumes from the page after
the next.
• If an error occurs during the
back face of duplex printing,
the page where the error
occurred is skipped and the
printing resumes from the
next page.
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Scanning cannot ADF does

4 Problems related to print result or during printing (p14) 5 be performed 6 not operate
successfully (p14) normally
(p14)
Poor Printing Poor Paper Loading Abnormal Noise Scanner failure ADF failure
[Phenomenon] [Presumable Cause] [Presumable Cause] [Presumable Cause] [Phenomenon]
• Poor printing quality • Use of 3rd party media • Foreign material • Contamination of Scanner • No paper feed
• Ink stain on paper • Edge guide mis-setting • Insufficient grease Glass • Double feed
• Dot missing • Foreign material • Gear damage • Contamination of Document • Paper jam
• Paper eject without printing • Parts come-off • Stopper Holder Idle Roller is Pad • Paper skew
• Contamination of paper feed installed in a wrong place. • CIS Unit bonding failure
[Presumable Cause] roller (Duplex Unit) • CIS Unit damage [Presumable Cause]
• Driver / Panel mis-setting • Cassette Assy damage [Major Troubleshooting] • Scanner Motor damage • Wear of Pickup Roller
• Contamination of CR scale • Pickup Roller deterioration, • Foreign material removal • Wear of ADF Pad Assy
• Contamination of Printhead contamination • Lubrication of grease [Major Troubleshooting] • Gear damage
Cover • Contamination of PF roller • Gear replacement • Scanner Glass cleaning • ADF Motor damage
• Printhead damage • Document Pad cleaning • Contamination of Scanner
• Ink clogging of Printhead [Major Troubleshooting] • Document Pad replacement Glass
• Contamination on Cap Unit / • Recommendation of EPSON • CIS Unit replacement • Foreign material
Wiper of Ink system Assy media • Scanner Motor replacement • Paper Sheet damage
• Ink system Assy damage • Edge guide re-setting • ADF Cover Assy damage
• Narrow PG • Foreign material removal • Wear of EJ Roller
• PE Lever damage • Parts re-installation • ADF Sensors damage
• PE Sensor damage • Pick Up Assy replacement
• PW Sensor damage • Cassette Assy replacement [Major Troubleshooting]
• Printer Mechanism • ADF Cover Assy replacement
[Major Troubleshooting] replacement • ADF Pad Assy replacement
• Driver / Panel re-setting • Rear ASF Unit replacement • Scanner Glass cleaning
• CR Scale replacement • Foreign material removal
• Printhead cover cleaning • ADF Unit replacement
• Printhead cleaning
• Ink pack replacement
• Printhead replacement
• Rubber cleaning of Cap Unit of
Ink system Assy
• Ink system Assy replacement
• PG readjustment
• Printer Mechanism
replacement
• PE Lever replacement
• PE Sensor replacement
• PW Sensor replacement
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1.2 Power-On Sequence

This section describes the power-on sequences for this product. The preconditions are as follows.
The following explains how to use the simplified diagrams in Table 1-1 or Table 1-2. The
diagrams show the movement of each component as seen from the front of the printer.
Carriage movement
The rotation direction of Right-pointing arrow: Moves to the 0-digit side
the ASF Motor Left-pointing arrow: Moves to the 130-digit side
Clockwise: Digit number of CR
The figure shows the carriage is moving to the 0-digit side.
Paper is fed normally
Counterclockwise:
Paper is fed backward
The above shows clockwise
rotation. Carriage
PF Roller
The rotation direction of

the PF Motor
Clockwise:
Paper is fed normally
Counterclockwise:
Paper is fed backward The condition of the CR lock
The above shows clockwise Red: CR lock is set
rotation. White: CR lock is released
The above shows the CR lock is set.
Figure 1-4. Movement of Components

Normal power-on sequence
No error occurred at the last power-on, and the power was turned off normally.
Initial ink charge has finished and every pack has sufficient ink.
No paper on the paper path.
The Printhead is capped by the cap of the Ink System.
CR Lock is engaged normally.
This indicates the Simple Sequence.
PG position is set to PG 1.
Option Cassette Unit is not installed.
Table 1-1. Power-on Sequence
CR PF ASF
Movement of
Operation Motor Motor Motor
Components
rotation rotation rotation
1. APG reset
1-1.If PG is other than 1, the APG Motor rotates to set PG to 1.*9
--- --- ---
2. Printhead initialization and fuse inspection

2-1.Initializes the Printhead, and checks the fuse on the printer control
--- --- ---
circuit board.*1
3. Seeking the home position

3-1.To identify the CR Unit position, the CR Motor rotates
counterclockwise and it confirms the CR Unit touches the Right Frame
CCW --- ---
slowly. It regards the point when the CR Unit touches the Right Frame
as the position specified steps away from the home position, and sets it
as the origin.
3-2.If it judges the CR Unit is in the home position, the PF Motor rotates
clockwise and resets the CR lock.
--- CW ---
3-3.The PF Motor rotates counterclockwise and sets the CR lock.
--- CCW ---
Power-On Sequence 17
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CR PF ASF
Movement of
Components
3-4.The CR Motor rotates clockwise and it confirms the CR Unit touches
the Left Frame.*2
CW --- ---
3-5.The CR Motor and PF Motor stop.
--- --- ---
3-6.The CR Motor rotates clockwise, and the CR Unit moves to the home
position, then the CR lock is set.
CW CCW ---
3-7.The PF Motor rotates clockwise and releases the CR lock.
--- CW ---
4. CR measurement
4-1.The CR Motor rotates counterclockwise, and the CR Unit moves to the
CCW --- ---
0-digit side.*3
4-2.The CR Motor rotates clockwise, and the CR Unit moves to the 130-
digit side. (Measurement drive)
CW --- ---
5. Adjustment of CR acceleration delay

5-1.The CR Motor rotates and the CR Unit moves back and forth two CW/
--- ---
times.*4 CCW
6. Measurement of synchronized drive timing correction

6-1.The PF Motor and ASF Motor rotate. CW/ CW/
---
CCW CCW
7. Low temperature operation sequence*5

7-1.The PF Motor rotates clockwise, and the CR lock is unlocked.
--- CW ---
7-2.The CR Motor rotates and the CR Unit moves back and forth two
times.*4 CW/
--- ---
CCW
7-3.The PF Motor rotates counterclockwise and the CR lock is set.
--- CCW ---
8. Setting the PF Roller origin

8-1.The PF Motor rotates clockwise.*6
--- CW ---
9. Sucking supply
9-1.The Decompression Motor Assy 1 rotates in turn (decompresses =>
--- --- ---
vents to atmosphere), and the diaphragm pump sucks ink from the ink
cartridges.*8
9-2.The Decompression Motor Assy 2 rotates in turn (decompresses =>
vents to atmosphere), and the diaphragm pump sucks ink from the ink
cartridges.*8 --- --- ---
10.Ink detection
10-1.Checks the ink consumption counters and the status of ink cartridges.
--- --- ---
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CR PF ASF
Movement of
Components
11.Checking for waste ink overflow
11-1.Checks the waste ink counter of the Maintenance Box if the waste ink
--- --- ---
overflow is occurring.
12.CR lock setting

12-1.The CR Motor rotates clockwise and the CR Unit moves to the home
CW --- ---
position.
12-2.The CR Motor rotates counterclockwise and the CR Unit moves to the

0-digit side.
CCW --- ---
12-3.The PF Motor rotates counterclockwise and the CR lock is set.
--- CCW ---
12-4.The CR Motor rotates clockwise and the CR Unit moves to the home
position.
CW --- ---
13.Set the Hopper up

13-1.The ASF Motor rotates clockwise and the Hopper is set up.*7
--- --- CW
Note : On the premise on this table, PG does not change and the Rear ASF does not operate during the sequence.
Note "*1": If any trouble exists such as the fuse has blown, the fatal error occurs.
"*2": At this point, if the output value of the CR Motor is below the specified value, the paper jam error occurs.
"*3": If, at this point, the output value of the CR Motor is more than the specified value, the fatal error occurs.
"*4": The DC error may occur.
"*5": Executes when the detected temperature is under 5 oC (41oF) by the thermistor on the Printhead.
"*6": If the phase of the PF Roller cannot be detected, the SMAP phase detection error occurs.
"*7": If the sensor cannot detect the Hopper, the cassette damage error occurs.
"*8": If the Front Cover is open, the front cover open error occurs.
"*9": If the sensor cannot detect the APG position, the APG error occurs.
Power-on Sequence after Recovering from a Paper Jam Error

Table 1-2. Power-on Sequence after Recovering from a Paper Jam Error
CR PF ASF
Movement of
Components
Executes No.1 on the power-on sequence (Table 1-1).
1. Detecting remaining paper
1-1.The CR Motor rotates and the CR Unit moves back and forth slowly CW/
--- ---
once. CCW
1-2.The CR Motor rotates clockwise and the CR Unit moves to the 0-digit
side slowly. At this point, if the CR lock lever, APG lever, and Suction
Unit are on the way, it evacuates them. CW --- ---
1-3.The CR Motor rotates and the CR Unit moves back and forth slowly
once.*1 CW/
--- ---
CCW
Note : On the premise on this table, PG does not change and the Rear ASF does not operate during the sequence.
Note *1: At this point, if the output value of the CR Motor is more than the specified value, the paper jam error occurs.
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1.3 Fatal Error Code List

This section describes the fatal error code and the possible cause for this product.
Printer fatal error list
Table 1-3. Fatal Error List (Printer)

Error
Error type Error name Possible cause
code
• Paper jam
0x60 HP (Home Potion) error • Foreign object
• Deformation of the main frame
• Foreign object
0x61 Deadlock Avoidance error • Lock the CR Unit.
• Paper jam
• Foreign object
0x62 Impossible contact detection error
• PW sensor failure
• Paper jam
Contact error at ink replacement timing
0x63 • Foreign object
(Power-off)
• Defective initial operation
• Foreign object
0x64 PW sensor failure error
• Main board failure
• Power On Sequence error
• Paper jam
0x65 PW sensor detected foreign object error
• Foreign object
• APG motor failure
0x67 APG error • APG encoder failure
Printer • Option cassette board failure
0x69 Option Cassette recovery mode error
0x6A SMAP phase detection error • Misalignment of eccentric correction phase
• PF encoder failure
0x6B PF runaway error
• Motor driver failure
0x6C Option Cassette Connected error • Four optional cassettes or more setting error
0x6D Option Cassette Connected error • Option cassette setting error
0x6E Option Cassette Connected error • Option cassette setting error
0x6F Option Cassette Connected error • Option cassette setting error
• Opt1 ASF Encoder failure (contaminated/detached scale, Encoder
Board failure)
0x70 Opt1 ASF excess load error • Opt1 ASF motor failure
• Pickup Roller driven mechanism overload (paper jam/foreign object)
• Cable disconnection
Board failure)
0x71 Opt1 ASF excess speed error • Opt1 ASF motor failure
Board failure)
0x72 Opt1 ASF PID reverse error • Opt1 ASF motor failure
Fatal Error Code List 20

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Error
code
Board failure)
0x73 Opt1 ASF PID lock error • Opt1 ASF motor failure
Board failure)
0x74 Opt1 ASF load position reverse error • Opt1 ASF motor failure
Board failure)
0x75 Opt1 ASF load position excess speed error • Opt1 ASF motor failure
Board failure)
0x76 Opt1 ASF load position excess load error • Opt1 ASF motor failure
• Protection material remains
• Opt1 LFT Motor Failure
0x77 Opt1 LFT PID excess load error
Board failure)
• Opt1 LIFT driven mechanism overload (paper jam/foreign object)
Printer 0x78 Opt1 LFT PID excess speed error Board failure)
Board failure)
0x79 Opt1 LFT PID lock error • Opt1 ASF motor failure
• Opt1 LIFT motor failure
0x7A Opt1 LFT PID driving time error
0x7B Opt2 LFT PID driving time error
0x7C Opt3 LFT PID driving time error
0x7D Option Communication error • Main board failure (UART Parity error/ UART FIFO Overflow)
0x7E Emergency stop error • Emergency cover open error
0x7F Inspection mode error ---
Board failure)
0x80 Opt2 ASF PID excess load error • Opt2 ASF motor failure
Board failure)
0x81 Opt2 ASF PID excess speed error • Opt2 ASF motor failure

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Error
code
Board failure)
0x82 Opt2 ASF PID reverse error • Opt2 ASF motor failure
Board failure)
0x83 Opt2 ASF PID lock error • Opt2 ASF motor failure
Board failure)
0x84 Opt2 ASF load position reverse error • Opt2 ASF motor failure
Board failure)
Board failure)
0x87 Opt2 LFT PID excess load error
Printer Board failure)
0x88 Opt2 LFT PID excess speed error Board failure)
0x89 Opt2 LFT PID lock error Board failure)
• Ink leak at the ink supply route
0x8A Ink Leak error • Printhead failure
• Ink Supply Unit failure
• Communication connector (Drawer Connectors) failure
0x8C Opt Communication error • Cable disconnection
This error occurs if the printer becomes a fatal error status due to a
0x8D Factor Error other than printer driver
failure of parts other than the printer such as the scanner or ADF.
0x8E Driver mismatch error • An unsupported drive was used.
0x8F EEPROM verify error (by command) ---
• PE sensor failure
0x93 PE sensor failure
0x94 PW sensor light value adjust error

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Error
code
• Decompress motor failure
0x96 Decompress pump motor drive time error
• Head FFC failure
0x97 Head drive circuit VBS over-voltage error
0x99 IES (Ink End Sensor) process check error • Main board failure
• Power board failure
0x9A Circuit error (include blowout of a fuse)
• Printhead failure
• Printhead FFC failure
0x9B Transistor temperature error • Main board failure
• Cooling of print head
0x9C X-Hot detect error (pre printing) • Print head failure
0x9D X-Hot detect error (after flushing) • Print head failure
0x9E Head temperature error • Print head failure
0x9F No print inspection mode error ---
Board failure)
0xA0 Opt3 ASF PID excess load error • Opt3 ASF motor failure
Printer Board failure)
0xA1 Opt3 ASF PID excess speed error • Opt3 ASF motor failure
Board failure)
0xA2 Opt3 ASF PID reverse error • Opt3 ASF motor failure
Board failure)
0xA3 Opt3 ASF PID lock error • Opt3 ASF motor failure
Board failure)
0xA4 Opt3 ASF load position reverse error • Opt3 ASF motor failure
Board failure)
0xA5 Opt3 ASF load position excess speed error • Opt3 ASF motor failure
Board failure)
0xA6 Opt3 ASF load position excess load error • Opt3 ASF motor failure

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Error
code
0xA7 Opt3 LFT PID excess load error
Board failure)
0xA8 Opt3 LFT PID excess speed error Board failure)
0xA9 Opt3 LFT PID lock error Board failure)
Board failure)
0xAA Opt1 ASF PID driving time error • Opt1 ASF Motor failure
Board failure)
0xAB Opt2 ASF PID driving time error • Opt2 ASF motor failure
• Pickup Roller drive mechanism overload (paper jam/foreign object)
Board failure)
Printer 0xAC Opt3 ASF PID driving time error • Opt3 ASF motor failure
• Opt1 ASF motor failure
0xAD Opt1 ASF BS driving time error
• Opt1 ASF Drive Board failure
0xAE Opt2 ASF BS driving time error
0xAF Opt3 ASF BS driving time error
Opt Communication error • Communication connector failure
0xB0
(Parameter length abnormality) • Main board failure

0xB1
(Sub function code abnormality) • Main board failure

0xB2
(A lot of numbers of optional cassettes) • Main board failure

0xB3
(Parameter abnormality) • Main board failure

0xB4
(Time-out error) • Main board failure

0xB5
(Function code abnormality) • Main board failure
• Communication connector failure

0xB6 Opt Communication error
Opt Communication error
• Communication connector failure
0xB7 (Number of row for optional cassette
abnormality in power supply ON)

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Error
code
• Ink cartridge failure
• CSIC Loose connection
0xB9 Ink device error • CSIC Terminal failure
• CR Contact Module failure
0xBA Ink device error • CSIC Terminal failure
• CSIC Terminal failure
0xC0 CRCM access error
0xC1 CRCM access error
0xC3 Ink device error
• ASF Encoder failure (contaminated/detached scale, Encoder Board
failure)
0xD1 ASF PID excess load error • ASF motor failure
Printer • ASF Encoder failure (contaminated/detached scale, Encoder Board

0xD2 ASF PID excess speed error failure)
• Motor driver failure (Main board failure)
0xD3 ASF PID reverse error failure)
• Paper jam
failure)
• ASF motor failure
0xD4 ASF PID lock error
• Pickup Roller (2nd cassette) drive mechanism overload (paper jam /
foreign object)
• LFT motor failure
0xD5 LFT PID excess load error
0xD7 LFT PID lock error ---
0xD8 ASF load position reverse error failure)
• Paper jam
0xD9 ASF load position excess speed error failure)
failure)
0xDA ASF load position excess load error • ASF motor failure
0xDB LFT PID driving time error

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Error
code
0xDD LFT PID excess speed error
0xDE ASF PID driving time error • Main board failure
0xDF ASF load position driving time error • Main board failure
• CR Encoder failure (contaminated/detached scale, Encoder Board
failure)
0xE1 CR PID excess load error • CR motor failure
• Carriage overload error (paper jam, foreign object)
failure)
0xE2 CR PID excess speed error • Motor driver failure (Main Board failure)
• Tooth skip of the CR Timing Belt
• Improper tension of the CR Timing Belt
failure)
0xE3 CR PID reverse error • Tooth skip of the CR Timing Belt
• Paper jam
failure)
0xE4 CR PID lock error • CR motor failure
failure)
Printer • Motor Driver failure (Main Board failure)
0xE5 CR PID speed fall error
• Paper jam
• APG encoder failure (contaminated/detached scale, Encoder Board
failure)
0xE6 APG PID lock error
failure)
0xE7 APG PID excess load error
failure)
0xE8 CR load position reverse error • Tooth skip of the CR Timing Belt
• Paper jam
failure)
0xE9 CR load position excess speed error • Motor driver failure (Main board failure)
failure)
0xEA CR load position excess load error • CR motor failure
0xEB APG PID driving time error • Main board failure

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Error
code
0xEC APG PID excess speed error failure)
• Main Board failure
0xED APG PID reverse error
• Motor Driver failure
0xEE CR PID driving time error • Main board failure
0xEF CR load position driving time error • Main board failure
• PF Encoder failure (contaminated/detached scale, Encoder Board
failure)
0xF1 PF PID excess load error • PF motor failure
• PF drive mechanism overload (paper jam, foreign object)
failure)
0xF2 PF PID excess speed error • Motor driver failure (Main Board failure)
• Tooth skip of the PF Timing Belt
• Improper tension of the PF Timing Belt
failure)
0xF3 PF PID reverse error • Tooth skip of the PF Timing Belt
Printer • Paper jam
failure)
0xF4 PF PID lock error • PF motor failure
• PF drive mechanism overload (paper jam, foreign object)
failure)
0xF8 PF load position reverse error
failure)
0xF9 PF load position excess speed error • Motor driver failure (Main board failure)
failure)
0xFA PF load position excess load error • PF motor failure
• PF driver mechanism overload (paper jam/foreign object)
0xFE PF PID driving time error • Main board failure
0xFF PF load position driving time error • Main board failure

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ADF/Scanner fatal error list
Table 1-4. Fatal Error List (ADF/Scanner)

Error type Error code Error name
• ADF Encoder failure (contaminated/detached scale, Encoder Board
0x01 ADF PID excess speed error failure)
• Motor driver failure (SCN Main board failure)
0x02 ADF PID reverse error failure)
• Paper jam
failure)
ADF PID (Proportional Integral Derivative
0x03 • ADF motor failure
Controller) lock error
• Paper jam
failure)
0x04 ADF PID acceleration lock detection error • ADF motor failure
• Paper jam
failure)
0x05 ADF PID excess load error • ADF motor failure
• Paper jam
0x06 ADF PID driving time error • SCN Main board failure
0x09 ADF BS+ excess speed error failure)
0x0A ADF BS+ reverse error failure)
• Paper jam
failure)
0x0B ADF BS+ lock error • ADF Motor failure
• ADF drive overload (paper jam, foreign object)
failure)
0x0D ADF BS+ excess load error • ADF motor failure
• ADF drive overload (paper jam, foreign object)
0x0E ADF BS+ driving time error • SCN Main board failure
• CIS Unit failure
0x10 HP detection error • Scanner Housing failure
• SCN Main board failure
• Scanner Housing failure (Including wrong attachment of the origin mark)
0x11 Contact detection distance exceeded error • SCN Main Board failure
• Scanner FFC failure / Scanner FFC connection failure
• Scanner Motor failure / Scanner Motor connection failure
• Scanner housing failure (Including wrong attachment of the origin mark)
Opposite side contact detection distance
0x12 • SCN Main board failure
exceeded error
• Scanner FFC failure / Scanner FFC connection failure
• Scanner motor failure / Scanner motor connection failure

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• Scanner Housing failure (Including wrong attachment of the origin mark)
Opposite side wrong contact detection distance
0x13 • Scanner FFC failure
error
• Scanner FFC connection failure
• Scanner motor failure
• Scanner motor connection failure
0x14 Measurement failure error • Scanner drive mechanism was overloaded
0x20 LED light error
• ALD motor failure
0x21 ALD PID excess speed error • Motor driver failure
0x22 ALD PID reverse error • Motor driver failure
0x23 ALD PID Lock error • Motor driver failure
0x24 ALD PID acceleration lock • Motor driver failure
0x25 ALD PID excess load error • Motor driver failure
0x26 ALD PID driving time error • Motor driver failure
Option error
0x30 • Connected error between the Main board and SCN Main Board
MAIN-B connection error
• SCN Main Board failure
0x31 MAIN-A connection error
• Scanner FFC connection failure
• Paper jam
0x36 Paper jam error
• Foreign object
failure)
0x41 FB PID excess speed error
• Paper jam
0x42 FB PID reverse error failure)
• Paper jam
failure)
0x43 FB PID lock error • ADF motor failure
• ADF drive mechanism overload (assembling failure, lubrication failure)
failure)
0x44 FB PID acceleration lock • ADF motor failure

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failure)
0x45 FB PID excess load error • ADF motor failure
0x46 FB PID driving time error • SCN Main board failure
0x49 FB BS+ excess sped error failure)
0x4A FB BS+ reverse error failure)
• Paper jam
failure)
0x4B FB BS+ lock error • ADF Motor failure
failure)
0x4D FB BS+ excess load error • ADF motor failure
0x4E FB BS+ driving time error • SCN Main board failure
0x51 Automatic judgement fatal error 1 ---
Table 1-5. Fatal Error List (μSD (PDL))

Match error between Main ROM and μSD
0x5F Mismatch of firmware version of the main and μSD
ROM

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Inspection mode error list
Table 1-6. Inspection mode error list

Error name Error indication Remedy
Fatal error Fatal Error Code: 0xXX Refer to " Fatal Error Code List (p20)".
Printer failure error Fatal Error Code: 0xXX Refer to" Fatal Error Code List (p20)".
Paper jam error Paper Jam Error Remove the jammed paper, close the cover.
No paper error Paper Out Error Set the paper, close the cover.
No tray / cassette error Cassette Nothing Set the cassette.
Rear cover open error Rear Open Error Close the rear cover.
Opt cover open error Opt Cover Open Close the opt cassette cover.
Ink case open error Ink Cover Open Error Close the ink cover.
Cover open error Cover Open Error Close the cover.
Carriage outside error OutSide Carriage Lock the CR Unit.
No ink cartridge error Ink Out Error Replace the ink pack.
ink cartridge abnormal error Ink Out Error Replace the ink pack.
ink cartridge non-genuine error Ink Out Error Replace the ink pack.
Initial charge error Ink Out Error Replace the ink pack.
ink error Ink Out Error Replace the ink pack.
Ink end error Ink Out Error Replace the ink pack.
Print error Ink Out Error Replace the ink pack.
Maintenance box nothing error Maintenance Box Nothing Error Replace the maintenance box.
Maintenance box CSIC error Maintenance Box CSIC Error Replace the maintenance box.
Maintenance box full error Maintenance Box Full Error Replace the maintenance box.
Double feed error Paper Piled out Error Remove the jammed paper, close the cover.
Fax paper length mismatch error Other Error Set the specified paper.
Auto duplex paper length mismatch error Paper Size Error (Duplex) Changes to the paper size of a possible duplex printing.
Paper mismatch error (logical) Other Error Changes to the kind of paper a possible dull ex printing.
Duplex printing error Can’t Duplex Media Set the paper for the duplex printing.
Roller Life End error Roller Life End Replace the roller.
Cassette failure error Cassette Break Replace the cassette.
Memory overflow error Other Error Expand the memory

Manual Feed command error Manual Feed Error Changes to the paper
Driver mismatch error Other Error －
Replace Printhead
<Procedure>
Ink leakage Error 1.Start the adjust program.
Ink Leakage error
Fatal Error 0x8A 1-1. Ink leak error reset
1-2. Ink flushing.
2.Replace Printhead.

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1.3.1 FAX Troubleshooting

1.3.1.1 FAX Log
When an error related to fax occurs, it is not only indicated on the LCD but also saved as a log file. The error
code is recorded in it, and according to this log, the contents of the error can be confirmed.
Table 1-7. FAX Log (1)

Log Name Description Save Destination
*1
Latest log
The latest communication log of sending / polling reception Nonvolatile memory
(Last Transaction)
The following information is stored.
Item Information
Communication start
Year/month/day/hour/minute
date / time
Communication type Sending/receiving/polling reception
Sending/polling reception:
• Destination name of speed dial (first 20 characters)
• Telephone number (last 20 characters)
Communication log Communication ID
• Destination fax ID (20 characters) Nonvolatile memory
(Fax Log)
Receiving:
• Destination fax ID (20 characters)
Airtime Hour/minute/second
Communication pages 0 to 100
Common:
Normal/cancel/error code*
Communication result
No dial tone detected/No fax signal detected/Busy tone detected
Note *: For error codes, see Table 1-9. Error Code List (p.33).
*2
Power failure log The information stored in this log is the same as the communication log. However, since the
Nonvolatile memory
(Fax Log) airtime is “Unknown” in this case, the result of it is recorded as “power failure”.
Note *1: The latest communication log for all destinations are printed in a list form when the sequential broadcast is executed.
Cancellation is treated as a normal termination, therefore, if it is cancelled, the latest log is printed when the auto print setting is
“always print”, and not printed when the setting is “only when an error occurs”. If “only when an error occurs” is selected, the
log is printed even when an error occurs for just one destination.
*2: The power failure log when the sequential broadcast is being executed is not printed for the destinations to which the
transmission log is already complete then. If the power failure occurs before the scheduled sending time when a broadcast is
scheduled, the scheduled sending time is recorded.
The communication log is not stored under the following conditions:

When the sending operation is canceled while storing B&W image or waiting for re-dial i
ng.
In the case of a power failure during the operation of sending/polling reception including
waiting status for redial, or during receive operation.
When the receiving operation is canceled before the fax signal is detected.
If the fax signal is not detected during receiving operation.
If cancelled during the sequential broadcast.
(The log for the destinations of “not dialed yet” or “waiting for re-dial” is not saved except
for those of which the communication is complete.)

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Table 1-8. FAX Log (2)

Log Name Description Save Destination
The following information of the latest communication is stored.
Item Information
Communication start
Year/month/day/hour/minute
date / time
Communication type Sending/receiving/polling reception
• Destination name of speed dial (first 20 characters)
• Telephone number (last 20 characters)
Communication ID
Receiving:
Airtime Hour/minute/second
Protocol trace Communication pages 0 to 100 Volatile memory
Common:
Normal/cancel/error code
Communication result
No dial tone detected/No fax signal detected/Busy tone detected
Diagnosing code 10 bytes
The latest 43 commands/responses*
• Time stamp
• Sending / receiving
Protocol data
• Command /response code
(See Table 1-10. Command/Response Code (p.35))
• FCF/FIF (first 33 octets).
Note *: If a large amount of FIF is received, the recorded command/response may

be less than 40.
Error codes
Table 1-9. Error Code List
Error
Code Phenomenon LCD Display Print Example
(HEX)
000 Successful completion (Monochrome) Complete OK
C000 Successful completion (Color) Complete OK Color
400 Communication error Communication error Error code
Fax signal was not detected during receive operation. (The call was a
420 Not displayed ---
telephone call)

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Error
(HEX)
Talking Talking
630 A busy tone was detected after dialing
(Line Busy) (Line Busy)
634 A fax signal was not detected for a given length of time after dialing No Answer No Answer
637 A dial tone was not detected before dialing No Dial Tone No Dial Tone
638 A power failure occurred during communication Not displayed Power Fail
700 The communication was canceled by an operation Canceled Canceled
706 System error System Error Error code
870 The image memory is full Memory Full Memory Full
871 The maximum number of files was exceeded Error code Error code
928 Collision (A call signal was detected when shifting to dial operation) Not displayed ---
F0B Communication error Communication error Error code
F1E Communication error Communication error Error code
F20 Communication error Communication error Error code

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Error
(HEX)
F21 System error System Error Error code
F2A Communication error Communication error Error code
F2B No image data for reprint exists No Image ---
F2F System error System Error Error code
F3A Communication error Communication error Error code
Same message when a scanner
F60 A scanner fatal error occurs Error code
fatal error occurred*
Same message when a printer
F61 A printer fatal error occurs Error code
F62 Reserved --- Error code
Same message when an ADF
F63 ADF misfeed or paper jam occurred ADF Jam
F64 The memory for printing received image is full Error code Error code
Note *: Confirm the fatal error code with the Adjustment Program to check which error occurred. (See " 1.3 Fatal Error Code List
(p20)".)
Command/response code
Table 1-10. Command/Response Code
FCF value (HEX)
Command/response (LSB first: X=0) Content
code
First Second
DIS 80 - Digital Identification Signal
CSI 40 - Called Subscriber Identification
NSF 20 - Non-Standard Facilities
DTC 81 - Digital Transmit Command
CIG 41 - CallInG subscriber identification
NSC 21 - Non-Standard facilities Command
PWD C1 - PassWorD
SEP A1 - Selective Polling
Reserved (PSA) 61 - Polled Sub Address
Reserved (CIA) E1 - Calling subscriber Internet Address
Reserved (ISP) 11 - Internet Selective Polling address
DCS 82 - Digital Command Signal
TSI 42 - Transmitting Subscriber Identification
NSS 22 - Non-Standard facilities Set-up
SUB C2 - Sub Address
SID A2 - Sender IDentification
TRN E6 - Training
TCF F0 - Training Check
CTC 12 - Continue To Correct
Reserved (TSA) 62 - Transmitting Subscriber internet Address

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Table 1-10. Command/Response Code

FCF value (HEX)
Command/response (LSB first: X=0) Content
code
First Second
Reserved (IRA) E2 - Internet Routing Address
CFR 84 - ConFirmation to Receive
FTT 44 - Failure To Train
CTR C4 - Response for Continue To correct
Reserved (CSA) 24 - Called Subscriber internet Address
EOM 8E - End Of Message
MPS 4E - Multi Page Signal
EOP 2E - End Of Procedure
PRI-EOM 9E - Procedure Interrupt-End Of Message
PRI-MPS 5E - Procedure Interrupt-Multi Page Signal
PRI-EOP 3E - Procedure Interrupt-End Of Procedure
Reserved (EOS) 1E - End Of Selection
PPS-EOM BE 8E Partial Page Signal-End Of Message
PPS-MPS BE 4E Partial Page Signal-Multi Page Signal
PPS-EOP BE 2E Partial Page Signal-End Of Procedure
PPS-PRI-EOM BE 9E Partial Page Signal-Procedure Interrupt- End Of Message
PPS-PRI-MPS BE 5E Partial Page Signal-Procedure Interrupt- Multi Page Signal
PPS-PRI-EOP BE 3E Partial Page Signal-Procedure Interrupt- End Of Procedure
PPS-EOS BE 1E Partial Page Signal-End Of Selection
PPS-NULL BE 00 Partial Page Signal-partial page boundary
EOR-EOM CE 8E End Of Retransmission-End Of Message
EOR-MPS CE 4E End Of Retransmission-Multi Page Signal
EOR-EOP CE 2E End Of Retransmission-End Of Procedure
EOR-PRI-EOM CE 9E End Of Retransmission-Procedure Interrupt-End Of Message
EOR-PRI-MPS CE 5E End Of Retransmission-Procedure Interrupt-Multi Page Signal
EOR-PRI-EOP CE 3E End Of Retransmission-Procedure Interrupt-End Of Procedure
EOR-EOS CE 1E End Of Retransmission-End Of Selection
EOR-NULL CE 00 End Of Retransmission- partial page boundary
RR 6E - Receive Ready
MCF 8C - Message ConFirmation
RTP CC - ReTrain Positive
RTN 4C - ReTrain Negative
PIP AC - Procedure Interrupt Positive
PIN 2C - Procedure Interrupt Negative
PPR BC - Partial Page Request
RNR EC - Receive Not Ready
ERR 1C - Response for End of Retransmission
Reserved (FDM) FC - File Diagnostic Message
DCN FA - DisCoNnect
CRP 1A - Command RePeat
Reserved (FNV) CA - Field Not Valid
PIX FF - PIXel image
Space Other combinations Unknown command/response

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1.3.1.2 Error Code/Superficial Phenomenon-Based Troubleshooting

This section explains the troubleshooting procedures based on the error codes and superficial phenomenon.
When an error occurs, it may be displayed on the LCD panel with a message instead of
an error code. To check the error code, print out a fax log.
If the problem is not solved even after carrying out the remedy shown in the Table 1-11,
print out a protocol trace to analyze the cause of the error.
Table 1-11. Troubleshooting Based on the Error Code/Superficial Phenomenon

Error code (LCD
Description Remedy
Message)/Phenomenon
Turn off v.34 and try again.
Turn off ECM and try again.
Communication Error When using xDSL, check the connection from “Line” jack to the fax
(The error is indicated with Communication error via the xDSL splitter.
error code on the fax log.) When using TAM, check the connection from “Line” jack to the
TAM via the fax.
Check if the telephone line makes any sounds.
Line Busy The line is busy. Try again later.
The other end of the line does not
answer.
No answer The other end of the line Check the number and dial again.
answered but no answer tone is
detected.
Power failure occurred during
Confirm the P/S Board Connector Cable or P/S Board is not
Power fail sending/receiving/printing/redial i
damaged, and retry.
ng.
706,880-884,F21,F27- A system error (fax circuit failure)
Replace the FAX board with a new one.
F28,F2F,F51,F59 occurs
Memory full Out of Memory
Maximum number of files is Ask the sender to re-send the fax in several batches.
871
exceeded
F60 A scanner fatal error occurred • See Table 1-3 "Fatal Error List (Printer)" (p.20).
F61 A printer fatal error occurred • See Table 1-4 "Fatal Error List (ADF/Scanner)" (p.28).
F62 Reserved ---
ADF document mis-feed or paper • Set the documents and try again.
F63
jam occurs • If a paper jam error occurs, remove the jammed paper and try again.
The memory for printing received
F64 Ask the sender to re-send the fax in several batches.
image is full
The telephone cable is not
Connect the telephone cable properly.
connected properly.
The telephone line is not working. Verify if the phone line works by connecting to a phone to it.
Auto answer is set to “N”. Set to “Y”.
Cannot receive faxes
Set the setting to “ALL” and try again. Should other ring patterns be
DRD setting is incorrect.
selected, contact the telephone company.
Contact the telephone company or obtain the fax log for more
Calling signal cannot be detected.
analysis.
The telephone cable is not
Connect the telephone cable properly.
connected properly.
Cannot dial
The telephone line is not working. Verify if the phone line works by connecting to a phone to it.
Pulse/Tone dial setting error Turn the setting to the other one and try again.
Cannot receive/send faxes ECM is set to off. Set to on and try again.
in color Fax mode is set to “B&W only”. Set to “B&W/Color”.

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Table 1-11. Troubleshooting Based on the Error Code/Superficial Phenomenon

Error code (LCD
Description Remedy
Message)/Phenomenon
The size of the memory is 2.0
Cannot print all the
Mbyte. If the data becomes over
received data when Ask the sender to res end the data if necessary because the data
the set threshold, oldest data are
printing data stored in deleted from the memory can not be restored.
deleted to make room for new
memory
ones.
Auto reduction is set to off. Set auto reduction to on and reprint the data.
Paper size setting does not match
Choose the correct setting and reprint the data.
Images run off the paper the size of the received data.
Paper size setting does not match Choose the correct setting or load correct sized papers in the tray and
the size of papers in the tray. reprint the data.

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CHAPTER 2
DISASSEMBLY/REASSEMBLY
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2.1 Overview 2.1.1 Tools

Use only specified tools to avoid damaging the printer.
This chapter describes procedures for disassembling the main parts/units of WF-
R8590. Unless otherwise specified, disassembled parts/units can be reassembled by EPSON
reversing the disassembly procedure. See the cautions or tips for disassembly/ Name Availability Remarks
Part Code
reassembly described in2.3 Disassembly and Assembly Procedure (Page 61).
(+) Phillips screwdriver #1 O 1080530 JIS B1012-1985
Read the Safety Precautions (p3) before disassembling and reassembling. (+) Phillips screwdriver #2 O --- JIS B1012-1985
The length of the two hooks on mechanical contact sensor differs. Flathead screwdriver #3 Qty two
See the following and make sure to release the shorter hook first Total length 195mm
when removing the mechanical contact sensor. O --- Shaft length 100mm
Grip diameter 10mm
Shaft diameter 3mm
Mechanical Flathead Precision
contact sensor O ---
screwdriver #1
Hook (short) Hook (long) (+) Stubby screwdriver O --- Total length 47 mm or less
Tweezers O ---
Longnose pliers O ---
Teflon tape NITTO DENKO COPRP.
O ---
No.903UL
Strong tape --- 1032813 Strong tape No.388 Blue
Acetate tape --- 1003963
Back Teflon tape O ---
Hook (long) Mechanical Rope O ---
contact sensor Double-clip O ---
Magnetizer O ---
Hook (short)
Tie-wrap O --- Nylon (length 70mm
Cotton Swab O ---
Cleaning Sheet O ---
Sonic Tension Meter U508 Sonic Tension MetereU507
O 1640645
EPSON Part Code:1294120
DISASSEMBLY/REASSEMBLY Overview 40
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EPSON 2.1.1.1 Screw types used in the printer

Name Availability Remarks
Part Code
The screw types used in the printer are shown in the table below. The screw types used
PHOTO MATTE PAPER ○ --- in each part/unit are indicated as the symbols below in the disassembly procedures with
Needle Cap ---- 1653127
the total number of used screws.
Polyester Swab Tex wipe: Symbol Screw Type Torque

Alpha Swab with Long S1 C.B.(P2)SCREW,3X6,F/ZN-3C 0.6 ± 0.1N·m
○ ---
Handle
(Model number: TX761*) S2 C.B.EP-TITE SCREW,2.6X17(B=14),F/ZN-3C 0.3 ± 0.05N·m
S3 C.B.P(W2)-TITE SCREW,3X8,F/ZN-3C 0.6 ± 0.1N·m
Note 1:Some of the tools listed above are commercially available.
S4 C.B.P-TITE SCREW,2.5X5,F/ZN-3C 0.2 ± 0.05N·m
2: EPSON provides the tools listed with EPSON part code
S5 C.B.P-TITE SCREW,3X10,F/ZN-3C 0.6 ± 0.1N·m
S6 C.C.P-TITE SCREW,3X6,F/ZN-3C 0.6 ± 0.1N·m
S10 C.B.P-TITE(P2)SCREW,3X10,F/ZN-3C 0.6 ± 0.1N·m
S11 C.B.SCREW,2.5X4,F/ZN-3C 0.3 ± 0.05N·m
S12 C.B.SCREW,3X12,F/ZN-3C 0.8 ± 0.1N·m
S13 C.B.SCREW,3X6,F/ZN-3C 0.8 ± 0.1N·m
S14 C.B.S-TITE SCREW,3X4,F/ZN-3C 0.8 ± 0.1N·m
S18 C.B.S-TITE(P4)SCREW,3X6,F/ZN-3C 0.6 ± 0.1N·m
S19 C.C.S-TITE SCREW,3X5,F/ZN-3C 0.8 ± 0.1N·m
S20 C.C.S-TITE SCREW,3X6,F/ZN-3C 0.6 ± 0.2N·m
S21 C.P.SCREW,2.5X6,F/ZN-3C 0.6 ± 0.1N·m
S22 C.P.SCREW,3X4,F/ZN-3C 0.6 ± 0.1N·m
S23 SCREW,MOUNT,HEAD 0.3 ± 0.05N·m
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Symbol Screw Type Torque 2.1.2 Standard Operation Time for servicing the product
S24 SHOULDER BOLT,3X4,RASF 0.8 ± 0.1N·m The following are the standard operation time for servicing the product. The underlined
S25 C.B.S-TITE(P4)SCREW,3X6,F/ZN-3C 0.6 ± 0.1N·m parts/units are supplied as After Service Parts.
S26 C.C.SCREW,3X5,F/ZN-3C 0.8 ± 0.1N·m

Time
S27 C.P.SCREW,3X5,F/ZN-3C 0.4 ± 0.1N·m
Parts/Unit Adjustment/
S28 C.POLYWAVE DELTITE-A SCREW,3X6,F/ZN-3C 0.8 ± 0.1N·m Replacement
Inspection
Total
S29 C.C.P-TITE SCREW,3X8,F/ZN-3C 0.6 ± 0.1N·m Option Cassette 1:04 0:38 1:42
S30 C.B.P-TITE SCREW,2.5X10,F/ZN-3C 0.3 ± 0.05N·m Panel Assy 1:08 0:30 1:38
S31 C.B.S-TITE SCREW,3X8,F/ZN-3C 0.8 ± 0.1N·m Speaker 1:19 0:00 1:19
S32 C.B.P-TITE SCREW,3X10,F/ZN-3C 0.8 ± 0.1N·m Front Cover Assy 0:04 0:00 0:04
S33 C.B.S-TITE(P2)SCREW,3X8,F/ZB-3C 0.8 ± 0.1N·m Paper Support Support 0:14 0:00 0:14
S34 C.POLYWAVE SELITE-A 3X6,F/ZN-3C 0.8 ± 0.1N·m Left ADF Hinge Cover 1:03 0:00 1:03
S35 C.B.P-TITE SCREW,3X8,F/ZN-3C 0.6 ± 0.05N·m Right ADF Hinge Cover 0:50 0:00 0:50
S36 C.B.P-TITE SCREW,4X12,F/ZN-3C 0.8 ± 0.1N·m Stacker Assy 0:05 0:00 0:05
S37 C.C.SCREW,4X12,F/ZN-3C 0.5 ± 0.05N·m Paper Support Assy 2:14 0:00 2:14
S38 C.B.S-TITE SCREW,3X10,F/ZN-3C 0.8 ± 0.1N·m Rear ASF Document Support Cover 0:07 0:00 0:07
Cassette Assy 0:04 0:00 0:04
Casette Retard Roller Assy 0:09 0:00 0:09
Casette End Guide 0:10 0:00 0:10
Cassette Microswitch 0:27 0:00 0:27
PE Sensor 3:16 0:00 3:16
Rear Cover Assy 0:36 0:00 0:36
Rear Cover Belt 1:10 0:00 1:10
Rear Cover Control Lever 0:05 0:00 0:05
Maintenance Box 0:11 0:00 0:11
Duplex Unit 0:06 0:01 0:07
Rear Cover PE Sensor 1:54 0:09 2:03
Right Pick UP Roller Sensor 2:00 0:00 2:00
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Time Time
Parts/Unit Adjustment/ Parts/Unit Adjustment/
Replacement Total Replacement Total
Inspection Inspection
Left Pick Up Roller Sensor 2:00 0:00 2:00 PW Sensor 41:10 5:03 46:13
Rear ADF Cover 3:24 0:00 3:24 Wireless LAN Module 40:24 0:09 40:33
Rear Sub ADF Cover 3:17 0:00 3:17 Wireless LAN Module Cable 39:51 0:09 40:00
ADF Side Cover 3:37 0:00 3:37 CSIC Board 42:18 0:09 42:27
ADF Paper End Side Cover 3:37 0:00 3:37 Ink End Board 41:34 0:09 41:43
Front Sub ADF Cover 0:32 0:00 0:32 Decompression Motor Assy 43:52 0:09 45:01
Front Main ADF Cover 2:55 0:00 2:55 Print Head 44:45 49:21 94:06
ADF PF Encoder Sensor 4:22 0:00 4:22 Print Head Seal 45:11 49:21 94:32
ADF Cover Microswitch 8:07 0:00 8:07 CR Waste Ink Pad 44:55 31:50 76:45
Document Cover Mat Assy 0:48 0:00 0:48 CR Scale/Extension Spring 44:55 0:28 45:33
ADF Pad Assy 0:07 0:00 0:07 Star Wheel Assy 42:10 0:09 42:19
ADF PF Support Guide 0:07 0:00 0:07 Ink Supply Unit 47:33 21:40 69:13
ADF Cover Assy 0:08 0:00 0:08 PF Encoder Sensor Assy 40:47 14:21 55:08
ADF LD Assy 3:25 0:00 3:25 Head FFC 56:11 31:50 88.01
ADF/ Scanner Unit 5: 28 1:11 6:39 Interface Board FFC 42:30 0:09 42:39
ADF/ Scanner Cable Support 20:32 0:00 20:32 Interface Board 43:47 0:30 44:17
ADF Unit 23:30 1:11 24:41 Main Board Unit 32:19 0:09 32:28
Panel Lower Front Cover*1 7:32 0:00 7:32 Main Board 48:58 25:57 74:55
Panel FFC 7:50 0:00 7:50 Cap Unit 42:32 2:16 44:48
Right Upper Front Cover 8:14 0:00 8:14 Pump Unit 55:53 2:16 58:09
Front Cover Microswitch 8:26 0:00 8:26 Waste Ink Joint Tube Assy 50:56 2:16 53:12
Front Housing 29:06 0:00 29:06 Power Supply Unit 40:48 3:12 44:00
Middle Housing 33:39 0:09 33:48 Pick Up Roller Motor Assy 43:03 0:50 43:53
USB/FAX Cover 34:12 0:09 34:21 PF Motor Assy 46:36 6:47 53:23
USB Connector Assy 40:57 0:09 41:06 PF Timing Belt 46:36 6:47 53:23
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Time Time
Parts/Unit Adjustment/ Parts/Unit Adjustment/
Replacement Total Replacement Total
Inspection Inspection
APG Gear Assy 40:59 0:45 41:44 OP Cassette Retard Roller Assy 0:22 0:00 0:22
APG Gear Sensor 41:09 0:09 41:18 OP Cassette End Guide 0:27 0:00 0:27
CR Motor 51:14 7:15 58:29 OP Cassette Edge Guide Right 2:13 0:00 2:13
APG Motor Assy 43:12 0:45 43:57 OP Rear Cover Assy 0:45 0:00 0:45
CR Solenoid Assy 42:58 0:09 43:07 OP Stopper Belt 1:35 0:00 1:35
CR Assy 98:55 21:15 120:10 OP Rear Cover Open Sensor 5:09 0:00 5:09
Rear Cover Microswitch 43:57 0:09 44:06 OP Cassette Sensor 7:59 0:00 7:59
Rear ASF Unit 51:58 1:17 53:15 OP Cassette Paper Sensor 8:02 0:00 8:02
Sheet Guide 51:18 0:44 52:02 OP Cassette PF Sensor 8:02 0:00 8:02
Rear ASF Solenoid Assy 52:59 0:44 53:41 OP Cassette Hopper Sensor 7:56 0:00 7:56
Rear ASF Solenoid Gear Assy 53:05 0:44 53:49
Rear ASF PE Sensor 53:57 0:44 54:41
Machine Unit 74:16 32:50 107:06

2nd Cassette Assy 0:10 0:00 0:10
2nd Cassette Retard Roller Assy 0:22 0:00 0:22
2nd Cassette End Guide 0:27 0:00 0:27
2nd Cassette Edge Guide Right 2:13 0:00 2:13
2nd Rear Cover Assy 0:45 0:00 0:45
2nd Stopper Belt 1:35 0:00 1:35
2nd Rear Cover Open Sensor 33:48 0:35 34:23
2nd Cassette Sensor 36:38 0:35 37:13
2nd Cassette Paper Sensor 36:41 0:35 37:16
2nd Cassette PF Sensor 36:41 0:35 37:16
2nd Cassette Hopper Sensor 36:35 0:35 37:10
OP Cassette Assy 0:10 0:00 0:10
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2.2 Parts Diagram

No. Part/ Unit name No. Part/ Unit name No. Part/ Unit name No. Part/ Unit name
A Left ADF Hinge Cover (p.67) E Paper Support (p.69) I Panel Assy (p.70) M Speaker (p.71)
Rear ASF Document Support Cover
B F Middle Housing (p.86) J Right Upper Front Cover (p.73) N Front Cover Assy (p.65)
(p.67)
C Paper Support Support (p.66) G Panel FFC (p.74) K Stacker Assy (p.66) O Panel Lower Front Cover (p.73)
Open the Front Cover Assy. (P.65)
D Right ADF Hinge Cover (p.68) H L Front Housing (p.75)
(p.72)
A
A
B
A
C
A
O
A
D
A
E
A
N
A
F
M
A
A
L A
G
A
H
A
K
A
I
J
A
Figure 2-1. Housing
DISASSEMBLY/REASSEMBLY Parts Diagram 45

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A Left Pick Up Roller Sensor (p.95) C Rear Cover PF Sensor (p.93) E Casette Microswitch (p.95) F PE Sensor (p.96)
B Right Pick Up Roller Sensor (p.94) D Rear Cover Microswitch (p.92)
A
B
A
C
D
A
A
E
A
F
Figure 2-2. Cover Sensors

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A Power Supply Unit (p.111) C Wireless LAN Module (p.109) E Interface Board (p.108) G Main Board Unit (p.99)
B CSIC Board (BK) (p.110) D USB/FAX Cover (p.97) F Main Board (p.107) H USB Connector Assy (p.98)
B
A
A
A
C
A
D
E
A
F
A
A
G
A
H
Figure 2-3. Electric Circuit Components

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A APG Gear Assy (p.142) D CR Scale (p.120) G PW Sensor (p.123) J CR Unit (p.134)
B APG Motor Assy (p.144) E Head FFC (p.124) H CR Waste Ink Pad (p.119) K CR Solenoid Assy (p.146)
C APG Sensor (p.143) F Print Head (p.114) I CR Motor (p.131)
G
A
AC A
F
A
B D
A
A E
A
K
A
H
A
AI
A
J
Figure 2-4. Carriage Mechanism

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A Ink End Board (p.147) C Maintenance Box (p.64) E Pump Unit (p.164) G Ink End Board (p.147)
B Decompression Motor Assy (p.141) D Waste Ink Joint Tube Assy (p.166) F Cap Unit (p.157) H Ink Supply Unit (p.148)
A
B
A
H
A
C
AG
A
D
A
E
A
F
Figure 2-5. Ink System Mechanism

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Rear Cover Assy/Rear Cover Belt
A PF Tension Stopper (p.178) D G Star Wheel Assy (p.187) J PF Encoder Sensor Assy (p.175)
(p.174)
B Pick Up Roller Motor Assy (p.176) E Duplex Unit (p.175) H PF Sensor (p.186) K PF Timing Belt (p.179)
C Rear Cover Control Lever (p.174) F PE Sensor (p.182) I PF Motor Assy (p.181)
A
A A
B
A
K
A
J A
C
D
A
AI
A
H
A
E
A
G
A
F
Figure 2-6. Paper Feed Mechanism

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A Rear ASF Solenoid Assy (p.191) C Rear ASF PE Sensor (p.193) D Sheet Guide (p.190) E Rear ASF Solenoid Gear Assy (p.192)
B Rear ASF Unit (p.188)
A
A
B
A
C
A
E
A
D
Figure 2-7. Rear ASF Mechanism

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A Ink Supply BK Cover Assy (p.195) C Ink Supply BK Assy (p.201) E Tube (p.209) F CSIC FFC (p.211)
Ink Supply BK Cover Open Sensor
B D Ink Pack Holder (BK) (p.207)
(p.199)
B
A
A
A
A
D
A
C
FA
A
E
Figure 2-8. Ink Supply Mechanism (1)

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A Ink Supply CL Cover Assy (p.197) C Ink Supply CL Assy (p.203) E Tube (p.209) F CSIC FFC (p.211)
Ink Supply CL Cover Open Sensor
B D Ink Pack Holder (Y/M/C) (p.208)
(p.200)
A
C A
B A
D
A A
D
D
A
E
A
F
A
E
A
Figure 2-9. Ink Supply Mechanism (2)

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A ADF Cover Assy (p.221) D ADF Unit (p.218) G Bottom ADF Document Support (p.243) J ADF PF Support Guide (p.231)
Rear ADF Cover/ Rear Sub ADF Cover
B E ADF/ Scanner Unit (p.216) H Top ADF Document Support Assy (p.241)
(p.222)
ADF Side Cover/ ADF Paper End Side Front Sub ADF Cover/ Front Main ADF Cover
C Document Cover Mat Assy (p.225) F I
Cover (p.232) (p.223)
A AB
A
J A
C
A
D
A
I
E
A
A
F
A
H
G
A
Figure 2-10. ADF Unit/ Scanner Mechanism

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A ADF LD Assy (p.229) D ADF PE Sensor A (p.233) G ADF Document Detection Sensor A (p.237) J ADF Cover Microswitch (p.226)
B ADF PW Sensor A (p.235) E ADF PW Sensor B (p.236) H Right ADF Hinge (p.239) K ADF Pad Assy (p.225)
ADF Document Detection Sensor B
C Left ADF Hinge (p.240) F I ADF PF Encoder Sensor (p.227)
(p.238)
A
B A
C
D
A
A E
A
A
F
A
K A
G
A
J H
A
A
I
Figure 2-11. ADF Unit

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A Casette End Guide (p.244) B Casette Assy (p.244)
A A
B
Figure 2-12. Cassette Mechanism

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A OP Cassette End Guide (p.259) C OP Cassette Edge Guide Right (p.259) D OP Casette Unit (p.257) E OP Cassette Assy (p.258)
B OP Casette Retard Roller Assy (p.258)
A
A A
B
CA
A
D
A
E
Figure 2-13. Option Cassette Mechanism (1)

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A OP Left Cover (p.262) D OP Cassette PF Sensor (p.272) G OP Cassette Hopper Sensor (p.274) J OP Right Cover (p.262)
B OP Rear Frame Assy (p.263) E OP Rear Cover Assy (p.261) H OP Rear Cover Open Microswitch (p.268) K OP Rear Frame Cover Assy (p.268)
C OP Cassette Microswitch (p.271) F OP Cassette Paper Sensor (p.273) I Stopper Belt (p.261) L OP Cassette Drive Assy (p.266)
A
C
A
B D
A
A
E
A
F
A
G
A
A
K
A
H
AI
A
L
AJ
Figure 2-14. Option Cassette Mechanism (2)

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A 2nd Cassette Unit (p.245) C 2nd Cassette Frame Assy (p.247) E Actuator (p.253) G Feed Roller (p.256)
B 2nd Cassette Assy (p.247) D 2nd Cassette Drive Assy (p.251) F Sensor (p.254)
E
A A
C
A A
G F
A
D
A
A
B
Figure 2-15. 2nd Cassette Unit

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A Mechanism Unit (p.275)
Figure 2-16. Printer Mechanism

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2.3 Disassembly and Assembly Procedure 16. Rotate the gear shown in the figure in the direction of the arrow to unlock the CR
Unit.
2.3.1 Preparation for servicing Left

The common work used by the repair is described as follows.
Please refer to disassembly and reassembly sequence of the each parts whether
these work are necessary or not.
2.3.1.1 Unlocking the CR Unit

1. Remove the Panel Assy. (P.70) Gear
2. Remove the Paper Support Support. (P.66)
3. Remove the Left ADF Hinge Cover. (P.67)
4. Remove the Right ADF Hinge Cover. (P.68)
5. Remove the ADF/ Scanner Unit. (P.216)
Figure 2-17. 4Unlocking the CR Unit
6. Remove the Panel Lower Front Cover. (P.73)
7. Remove the Right Upper Front Cover. (P.73)
8. Remove the Stacker Assy. (P.66) CR Lock Lever
9. Remove the Cassette Assy. (P.244)
10. Remove the Front Cover Microswitch. (P.72)
11. Remove the Ink Supply BK Cover Assy. (P.195)
12. Remove the Ink Supply CL Cover Assy. (P.197)
13. Remove the Front Housing. (P.75)
14. Remove the Ferrite Core Holder. (P.74)
15. Remove the Middle Housing. (P.86)
CR locked CR unlocked
(The lever is raised) (The Lever is lowered)
Figure 2-18. Status of the CR Lock Lever
DISASSEMBLY/REASSEMBLY Disassembly and Assembly Procedure 61

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When moving the CR Unit, make sure to hold it by the location 2.3.1.2 Ink flushing
shown below. 1. Replace the maintenance box with the one for the repair. (P.64)
Before performing Ink flushing, confirm the Maintenance Box
counter is 60% or less.
CR Unit
2. Open the Ink Supply BK Cover Assy.(P.195)

3. Push and fix the lever of the Ink Supply BK Cover Open Sensor with tape.
Push and Fix the BK

Sensor lever by Tape
Figure 2-19. Moving the CR Unit
Figure 2-20. Fixing the Ink Supply BK Cover Open Sensor

4. Open the Ink Supply CL Cover Assy.(P.197)
5. Push and fix the lever of the Ink Supply CL Cover Open Sensor with tape.
Push and Fix the BK

Sensor lever by Tape
Figure 2-21. Fixing the Ink Supply CL Cover Open Sensor

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6. Turn on the printer and conform the printer becomes ready, then remove the all Ink 2.3.1.3 Initial Ink charge
Packs.
1. Replace maintenance box with the one for the repair. (P.64)
7. Perform the “Ink Flushing” with Adjustment Program.
2. Open the Ink Supply BK Cover Assy. (P.195)
3. Install the BK Ink Pack for the repair.
4. Open the Ink supply CL Cover Assy.(P.197)
5. Install the Y/M/C Ink Packs for the repair.
6. Close the Ink supply BK Cover Assy and the Ink supply CL cover Assy.
7. Plug the AC cable into the AC inlet of the printer.
8. Wait until the printer becomes ready.
9. Perform the “Initial ink charge” with the adjustment program.
Figure 2-22. Perform the ink flushing

Use the latest adjustment program (since Ver.1.06).
8. Unplug the AC Cable from the AC Inlet of the Power Supply Unit.
Power Supply Unit

AC Cable
AC Inlet Figure 2-24. Perform the Initial Ink charge

10. Perform the “Nozzle check print “with the adjustment program.
11. If the nozzle-missing appeared in paper, perform the cleaning.
Figure 2-23. Unplug the AC Cable

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2.3.2 Consumables/Accessories Take care not to drop the screws or the like on the Maintenance
Box. Doing so may damage the film on the Maintenance Box.
2.3.2.1 Maintenance Box
Film
1. Open the Rear Cover Assy. (P.174)

2. Remove the Maintenance Box.

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2.3.3 Housing 4. Disengage the right side hook, and remove the Front Cover Assy.
2.3.3.1 Front Cover Assy
Hook (Right)
For the screw types, see 2.1.1.1 Screw types used in the printer (p41).
1. Open the Front Cover Assy. Figure 2-26. Removing the Front Cover Assy (2)
2. Disengage the both of the Front Cover Assy.

3. Disengage the left side hook using the flatbed screw driver.
The picture of Figure 2-25 and Figure 2-26 is WF-8590 series's
picture.
Both Hook (Left)
Figure 2-25. Removing the Front Cover Assy (1)

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2.3.3.2 Paper Support Support 2.3.3.3 Stacker Assy
For the screw types, see 2.1.1.1 Screw types used in the printer (p41). For the screw types, see 2.1.1.1 Screw types used in the printer (p41).
1. Disengage the two tabs of the Paper Support Support, and remove the Paper 1. Remove the Stacker Assy.
Support Support.
Tab
Tab
Figure 2-27. Removing the Paper Support Support

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2.3.3.4 Rear ASF Document Support Cover 2.3.3.5 Left ADF Hinge Cover
1. Disengage the two tabs of the Rear ASF Document Support Cover, and remove the 1. Remove the Paper Support Support. (P.66)
Rear ASF Document Support Cover. 2. Open the ADF/ Scanner Unit.
3. Remove the two screws (S5).
Tab
Tab
S5
Figure 2-28. Removing the Rear ASF Document Support Cover S5 ADF/ Scanner Unit
Figure 2-29. Removing the Left ADF Hinge Cover (1)

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4. Remove the Left ADF Hinge Cover in the direction of the arrow while lifting the 2.3.3.6 Right ADF Hinge Cover
ADF/ Scanner Unit.
ADF/ Scanner Unit
2. Open the ADF/ Scanner Unit.
Figure 2-30. Removing the Left ADF Hinge Cover (2)
3. Remove the three screws (S5).
ADF/ Scanner
Unit
S5
S5
Figure 2-31. Removing the Right ADF Hinge Cover (1)

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4. Remove the Right ADF Hinge Cover in the direction of the arrow while lifting the 2.3.3.7 Paper Support
ADF/ Scanner Unit.
ADF/ Scanner Unit
3. Remove the Paper Support.
Figure 2-32. Removing the Right ADF Hinge Cover (2)

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2.3.3.8 Panel Assy

Tab Insert position Tab Insert position
Screw Cover
2. Remove the four Screw Cover.
3. Remove the four screws (S5).
4. Insert a flathead screwdriver or a similar tool insert into the two insert potions
shown in Figure 2-33 and release each four tabs.
5. Disengage the five hooks, and remove the Panel Assy. Hook
S5
Figure 2-33. Removing the Panel Assy (1)

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6. Disconnect the Panel FFC, grounding wire and Speaker Cable from the Panel 2.3.3.9 Speaker
Board, and remove the Panel Assy.
Grounding wire Panel Board
Speaker Cable
Panel FFC
Figure 2-34. Removing the Panel Assy (2) For the screw types, see 2.1.1.1 Screw types used in the printer (p41).
Carry out the adjustments referring to "3.1 Required Adjustments" 1. Remove the Panel Assy. (P.70)
(p279) when the Panel Assy is replaced. 2. Remove the Speaker Holder Urethane outward.
3. Slide the Speaker Holder in the direction of the arrow, and remove the Speaker.
Speaker Holder
Urethane
Speaker Holder
Figure 2-35. Removing the Speaker

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2.3.3.10 Front Cover Microswitch 9. Disconnect the cable from the connector.
10. Disengage the two hooks, and remove the Front Cover Microswitch.
Hook Connector
Cable
1. Remove the Panel Assy. (P.70) Hook
Figure 2-36. Removing the Front Cover Microswitch
7. Open the Front Cover Assy. (P.65)
8. Remove the Right Upper Front Cover upward. (P.73)

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2.3.3.11 Right Upper Front Cover 2.3.3.12 Panel Lower Front Cover
1. Remove the Panel Assy. (P.70)
For the screw types, see 2.1.1.1 Screw types used in the printer (p41). 4. Remove the Right ADF Hinge Cover. (P.68)
1. Remove the Panel Assy. (P.70) 5. Remove the ADF/ Scanner Unit. (P.216)
2. Remove the Paper Support Support. (P.66) 6. Release the grounding wire from hooks to prevent cutting.
3. Remove the Left ADF Hinge Cover. (P.67) 7. Remove the Ferrite Core.
4. Remove the Right ADF Hinge Cover. (P.68) 8. Remove the four screws (S5), and remove the Panel Lower Front Cover.
Ferrite Core
7. Open the Front Cover Assy. (P.65) Grounding wire
8. Remove the Right Upper Front Cover upward.
S5
Figure 2-37. Removing the Panel Lower Front Cover

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2.3.3.13 Panel FFC

Grounding Grounding
Plate Plate
For the screw types, see 2.1.1.1 Screw types used in the printer (p41). Ferrite Core Holder
S5
2. Remove the Paper Support Support. (P.66) Ferrite Core Connector
Ferrite Core
6. Disconnect the Panel FFC from the connector of the Main Board.
7. Remove the two screws (S5), and remove the two Grounding Plate.
Ferrite Core
8. Remove the Ferrite Core Holder.
9. Remove the three Ferrite Core from the Middle Housing.
Figure 2-38. Removing the Panel FFC
10. Remove the three Ferrite Core from the Panel FFC.

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2.3.3.14 Front Housing 13. Remove the two screws (S5) that secure the Inner Cover of the Ink Supply BK
Assy.
14. Disengage the two hooks of the Inner Cover.
Press down with your finger.
Hook Hook
5. Remove the ADF/ Scanner Unit. (P.216) Inner
Cover
8. Remove the Stacker Assy. (P.66)
S5
Figure 2-39. Removing the Ink Supply BK Assy (1)

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15. Pull the Inner Cover toward you, and remove it upward. 16. Release the cable of the Ink Supply BK Cover Open Sensor from the hook.
Inner Cover
Cable
Hook

17. Mark the tube at the point shown below.
Figure 2-40. Removing the Ink Supply BK Assy (2) Tube

Make sure you insert two hook of the inner cover in the base of the
Ink Supply BK Assy. The Ink supply BK cover Assy does not open Marking
if the hooks are not well

Hook
Hook

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18. Remove the six screws (S31). 20. Lift the Ink Supply BK Assy to disengage the two hooks.
S31
19. Pull the Ink Supply BK Assy toward you to disengage the two hooks.
Hook Hook
Hook Hook

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21. Slide the Ink Supply BK Assy backward. 22. Remove the three screws (S5) that secure the Inner Cover of the Ink Supply CL
Assy.
23. Disengage the two hooks of the Inner Cover.
Press down with your finger.
Hook Hook
Figure 2-46. Sliding the Ink Supply BK Assy
Inner
Cover
S5
Figure 2-47. Removing the Ink Supply CL Assy (1)

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24. Pull the Inner Cover toward you, and remove it upward.
Make sure you insert two hook of the inner cover in the base of the
Ink Supply CL Assy. The Ink supply CL cover Assy does not open
if the hooks are not well. Inner Cover
Hook
Hook Figure 2-48. Removing the Ink Supply CL Assy (2)

25. Remove the screw (S5).
26. Disengage the hook, and remove the Switch Cover.
Switch Cover Hook
S5
Figure 2-49. Releasing the cable (1)

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27. Disconnect the cable from the connector. 29. Remove the screw (S31), and remove the grounding wire.
Pull out the grounding wire from the hole shown in the figure
below.
Cable 30. Disconnect the FFC from the connector (CN1) of the CSIC Board (CL).
Connector CSIC
Board (CL) Grounding
wire
Figure 2-50. Releasing the cable (2)
Hole
28. Release the cable of the Ink Supply CL Cover Open Sensor. Grounding
wire
S31
CN1 FFC
Cable
31. Mark the tube at the point shown below.
Ferrite Core
Tube (Y/M) Tube (C)
Marking
Marking
Figure 2-51. Releasing the cable (2) Marking
Confirmed that the Ferrite Core is not on the CSIC Board (CL) Figure 2-53. Removing the Ink Supply CL Assy (4)
before turning on the power. Not only the CSIC Board (CL) but
also the main board is damaged if the Ferrite Core is on the CSIC
Board (CL).

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32. Remove the seven screws (S15:2 pcs, S31: 4pcs,S17: 1pice) 34. Pull the Ink Supply CL Assy toward you to disengage the two hooks.
Hook
Hook
S15 S17
S31

33. Loose the screws(x4) and don’t remove it
S38

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35. Lift the Ink Supply CL Assy to disengage the four hooks. 36. Slide the Ink Supply CL Assy backward.
Figure 2-58. Sliding the Ink Supply CL Assy
Hook

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37. Open the Front Cover Assy. 39. Release the two tabs on the upper part in the order from the left to the right. Use a
38. Remove the nine screws (S5:1piece S7:6pcs: S17:2pcs) flat-head screwdriver to release the tab on the right because it is stiff.
Tab (left upper)
Tab (right upper)
S5
Front Cover Figure 2-60. Removing the Front Housing (2)
S7 Assy
S17
Figure 2-59. Removing the Front Housing (1)

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40. On the lower left, insert the flat-head screwdriver (φ 3.5 mm or less) into the hole 43. On the lower right, insert the flat-head screwdriver (φ 3.5 mm or less) into the hole
on the Lower Housing in the direction of the arrow and release the hook. on the Lower Housing in the direction of the arrow and release the hook.
41. By holding the point shown below, pull the Front Housing toward you to make 44. By holding the point shown below, pull the Front Housing toward you to make
some space between the Front Housing and the Lower Housing. some space between the Front Housing and the Lower Housing.
Front Housing Front Housing

Space Space
Hook Hook
Hole Hole
Lower Housing Lower Housing

Figure 2-61. Removing the Front Housing (3) Figure 2-63. Removing the Front Housing (5)
42. Insert the flat-head screwdriver into the space between the Front Housing and the 45. Insert the flat-head screwdriver into the space between the Front Housing and the
Lower Housing, and pull the Front Housing slightly toward you. Lower Housing, and pull the Front Housing slightly toward you.
Figure 2-62. Removing the Front Housing (4) Figure 2-64. Removing the Front Housing (6)

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46. Insert the flat-head screwdriver between the Front Housing and the Lower
When installing the Front Housing, be careful of the following.
Housing, and pull the Front Housing toward you to remove it.
Insert the two hooks on the lower part straight into the holes on
the Lower Housing.
Front Housing Make sure to align the guides on the Front Housing and the
Lower Housing correctly.
Left Right
Guide Guide
Hook
Hook
Lower Housing Lower Housing

Figure 2-65. Removing the Front Housing (7) Insert the rib on the Front Housing into the hole on the Lower
47. Remove the Front Housing while pulling it toward you. Housing.
Right
Rib and hole
Lower Housing
Figure 2-66. Removing the Front Housing (8)

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2.3.3.15 Middle Housing 13. Remove the Front Housing. (P.75)

15. Remove the two screws (S15), and remove the Ink Holder Cover.
Ink Holder
Cover
S15
Figure 2-67. Removing the Ink Holder Cover
16. Release the FFC from the three clamps.
Inside of the Ink
1. Remove the Panel Assy. (P.70) Supply Unit
4. Remove the Right ADF Hinge Cover. (P.68) Clamp
7. Remove the Right Upper Front Cover. (P.73) Clamp
Figure 2-68. Releasing the Tube (BK) and FFC (1)

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17. Release the Tube (BK) and FFC from the clamp.
To prevent the Tube (BK) from being folded, check the state
Clamp of the Tube (BK) shown in the figure below after installing
FFC the Ink Supply BK Assy
No Good OK
Tube (BK)
In the following step, take care not to let the Tube (BK) or FFC get
caught on the clamp.
No Good OK
18. Move the Ink Supply BK Assy in front of the Middle Housing.
Tube (BK)
Ink Supply
BK Assy
FFC
Clamp
Figure 2-70. Moving the Ink Supply BK Assy

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19. Open the Rear Cover Assy. (P.174) 21. Release the two tabs of the Middle Housing from the holes of the Lower Housing.
20. Remove the six screws (S5: 4 pcs, S17: 2 pcs).
Tab and hole
Tab and hole
Lower Housing
Rear Cover Assy
Figure 2-72. Removing the Middle Housing (2)

S5 22. Disconnect the Panel FFC from the connector of the Main Board.
23. Release the grounding wire.
Main Board
Panel FFC
Grounding wire

S17
S5

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24. While releasing the Middle Housing from the USB/FAX Cover, remove the
Take care not to catch the USB Cable and the cable of the
Middle Housing upward. Front Cover Microswitch.
Cable of the Front Cover USB Cable

Microswitch
USB/FAX Cover
Take care not to deform the grounding plate.

Remove the EXT Connector Cover if it is installed.

If it is difficult to release the cover, insert the flat-head
screwdriver to release fixing points on the Middle Housing.
Grounding plate
EXT Connector Cover
Install the Middle Housing taking care not to let it interfere

with the Front Frame and Rear ASF Unit.
Flat-head screwdriver

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Route the cable of Ink Supply Cover Open Sensor through the Route the Tube (Y/M/C) and the grounding wire inside the
two hooks on the Right Lower Tube Guide. Right Lower Tube Guide, and insert them in the lower section
of the Right Lower Tube Guide.
Right side
Right side Right Lower
Right Lower
Tube Guide Tube Guide
Grounding
wire
Hook
Cable of the Ink Supply

Cover Open Sensor
Tube (Y/M/C)

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Route the Tube (Y/M/C) as shown below.
Right Upper Tube Guide
Left Tube Clip
Ink Supply Unit

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2.3.4 Cover Sensors 16. Remove the USB/FAX Cover. (P.97)

17. Slide the Main Board Unit. (P.99)
2.3.4.1 Rear Cover Microswitch
18. Disengage the two hooks, and remove the Rear Cover Microswitch.
19. Disconnect the cable from the connector.
Cable
Connector
For the screw types, see 2.1.1.1 Screw types used in the printer (p41). Hooks
1. Remove the Panel Assy. (P.70) Figure 2-75. Removing the Rear Cover Microswitch
14. Remove the Ferrite Core Holder.(P.74)

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2.3.4.2 Rear Cover PF Sensor 3. Disengage the four hooks, and remove the Rear Cover PE Sensor.
Hooks
Cable
Connector
Figure 2-77. Removing the Rear Cover PE Sensor
1. Remove the Duplex Unit. (P.175)
When removing the screws in the next step, use a 40 mm-long or

shorter stubby screwdriver.
2. Remove the three screws (S5), and open the Lower Paper Guide.
Lower Paper Guide
S5
Figure 2-76. Opening the Lower Paper Guide

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2.3.4.3 Right Pick Up Roller Sensor 3. Disengage the four hooks, and remove the Right Pick Up Roller Sensor.
Hooks Cable
Connector
1. Remove the Duplex Unit. (P.175) Figure 2-79. Removing the Right Pick Up Roller Sensor
2. Remove the four screws (S5), and remove the Lower Paper Guide.
Lower Paper Guide
S5
Figure 2-78. Opening the Lower Paper Guide

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2.3.4.4 Left Pick Up Roller Sensor 2.3.4.5 Casette Microswitch
For the screw types, see 2.1.1.1 Screw types used in the printer (p41). 1. Remove the Cassette Assy. (P.244)
1. Remove the Duplex Unit. (P.175) 2. Disengage the two hooks, and remove the Casette Microswitch.
2. Open the Lower Paper Guide. (refer to (p94)) 3. Disconnect the cable from the connector.
3. Disengage the four hooks, and remove the Left Pick Up Roller Sensor.
4. Disconnect the cable from the connector. Bottom
Hook
Hooks Cable
Cable
Hook
Connector
Connector
Figure 2-81. Removing the Casette Microswitch
Figure 2-80. Removing the Left Pick Up Roller Sensor

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2.3.4.6 PE Sensor
2. Disengage the four hooks, and remove the PE Sensor.
Bottom
Hooks
Cable
Connector
Figure 2-82. Removing the PE Sensor

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2.3.5 Electric Circuit Components 16. Remove the two screws (S1), and remove the USB/FAX Cover.
2.3.5.1 USB/FAX Cover
S1
Figure 2-83. Removing the USB/FAX Cover

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2.3.5.2 USB Connector Assy 13. Remove the Front Housing. (P.75)
16. Disconnect the USB Cable from the connector of the Main Board.
17. Release the USB Cable from the two clamps.
18. Remove the screw (S17), and remove the USB Connector Assy.
Connector
Main Board
Clamp
Clamp
USB Cable
S17
Figure 2-84. Removing the USB Connector Assy

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Route the USB Cable through the hook on the USB Connector 2.3.5.3 Main Board Unit
Assy.
USB Cable
Hook

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14. Remove the Ferrite Core Holder.(P.74) 18. Release the Ink Tube (Y,M,C) from the Tube Clamp.
16. Remove the USB/FAX Cover. (P.97)
17. Release the Ink Tube (Y,M,C) from the Left Tube Clip.
Tube (M)
Tube Clamp
Tube (Y)
Tube (C)
Figure 2-86. Release the Ink Tube (Y,M,C)
Left Tube Clip

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19. Release the Tube (Y/M/C) from three Tube Clips. 20. Disengage the two hooks, and remove the Right Upper Tube Guide.
21. Release the Tube from the groove of the Right Upper Tube Guide.
Tube Clip
Right Upper Groove
Tube Guide
Tube
Hooks
Figure 2-88. Releasing the Tube (Y/M/C) (4)
22. Release the Cable of the Ink Supply CL Cover Open Sensor from the Right Lower
Tube Guide.
Right Lower
Tube Guide
Figure 2-87. Releasing the Tube (Y/M/C)
Hook
Cable of the Ink Supply CL
Cover Open Sensor

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23. Remove the Right Lower Tube Guide, and release the Tube (Y/M/C).
Ink Supply CL Assy Rope
Right Lower
Tube Guide

Figure 2-91. Securing the Ink Supply CL Assy
Before releasing the tube, make sure to mark it at the points shown
in the figure below.
Tube Clip Marking
24. Move the Ink Supply CL Assy in front of the Middle Housing, and secure it to the
printer with a piece of rope.

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25. Disconnect the cables from the connectors (CN2, CN5) of the Main Board. 27. Disconnect the cables and FFCs from the connectors (CN30, CN32, CN77,
CN701, CN702, CN703, CN704, CN705) of the Main Board.
26. Remove the six screws (S17), and remove the Main Board Shield Plate and the
fixing plate. 28. Release the PF Encoder FFC from the rib and hole of the Ferrite Core Holder.
29. Pull off the cables for the ink supply system and the FFC of the CSIC Board from
Screw the grounding wire together as shown below. the Ferrite Core Holder.
CSIC Board FFC Cables for the ink

Grounding wire supply system
Ferrite Core
CN32 CN77
Holder CN705
Rib
CN5 CN2 Hole
PF Encoder FFC
CN30
CN701, CN702,
CN703, CN704
Main Board Shield
Plate Figure 2-93. Removing the Main Board Unit (1)
S17 Fixing plate

Figure 2-92. Removing the Main Board Shield Plate

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30. Remove the Ferrite Core Holder in the direction of the arrow. 31. Disengage the hook, and remove the Ferrite Core from the Ferrite Core Holder.
32. Remove the Head FFC from the Ferrite Core Holder.
Ferrite Core Holder

Head FFC
Ferrite Core Holder
Ferrite Core
Hook
Figure 2-95. Removing the Ferrite Core Holder

33. Disconnect the cables and FFC from the connectors (CN38, CN39, CN45, CN69,
When removing the Main Board Unit to replace the Main Board, it CN74, CN75, CN78, CN79, CN707) of the Main Board.
is not necessary to perform Step 31 (P.104) and 32 (P.104).
Connect the cables and FFC in the following order.
Order Connector Order Connector

1 CN78 6 CN39
2 CN79 7 CN74
3 CN69 8 CN707
4 CN75 9 CN38
5 CN45

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34. Release the CR Motor Cable and Ferrite Core from the Cable Holder. 37. Disengage the two hooks, and remove the Cable Holder.
35. Release the FFC from the wire saddle.
36. Remove the three Ferrite Core from the Cable Holder. Cable Holder Hooks
Install the Ferrite Core referring to Routing the cables and FFC
(p277).
CR Motor Cable
Cable Holder
Figure 2-97. Removing the Cable Holder
Ferrite Core
Ferrite Core Cable Holder
CN74
CN38
CN707
CN78 CN45 CN39 FFC

CN79 CN69 CN75
Wire saddle
Figure 2-96. Removing the Main Board Unit (2)

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38. Disconnect the cables from the connectors (CN61, CN81, CN501) of the Main
Route the CR Motor Cable through the groove on the Cable
Holder. Board.
Route the CR Motor Cable through the hook on the Cable 39. Remove the Cable Cover.
Holder.
40. Release the PF Encoder FFC from the wire saddle.
CR Motor Cable 41. Remove the four screws (S25), and remove the Main Board Unit.
Groove
Cable Holder Hook
Upper
Insert the Cable Holder into the cutout on the frame.
Cutout Cable Holder CN501 Cable Cover

CN81
Wire saddle
Groove
PF Encoder FFC
CN61
S25
Figure 2-98. Removing the Main Board Unit (3)
Carry out the adjustments referring to "3.1 Required

Adjustments" (p279) when the Main Board Unit is replaced.

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2.3.5.4 Main Board 14. Remove the Front Housing. (P.75)

17. Remove the USB/FAX Cover.(P.97)
18. Remove the Main Board Unit. (P.99)
19. Disconnect the FFC from the connector (CN20) of the Main Board.
20. Remove the three screws (S15), and remove the Interface Board Lower Shield
Plate.
FFC
CN20
1. Execute backup in EEPROM data copy before the main board is replaced.
"3.1 Required Adjustments" (p279)
5. Remove the Right ADF Hinge Cover. (P.68) Interface Board Lower
S15 Shield Plate
Figure 2-99. Removing the Interface Board Lower Shield Plate
21. Remove the eight screws (S15: 6 pcs, S21: 1 piece, S22: 1piece).
22. Release the two positioning holes on the Main Board from the two cutouts on the
9. Remove the Stacker Assy. (P.66) frame, and remove the Main Board.
10. Remove the Cassette Assy. (P.244) 23. Do the following three 1. Replace the μSD card, 2. Restore (EEPOM Data
11. Remove the Front Cover Microswitch. (P.72) Copy...Adjust Program), 3 makes to latest FW
12. Remove the Ink Supply BK Cover Assy. (P.195) 24. If the main board does not work, it makes it to a new μSD card.

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2.3.5.5 Interface Board

Cutout
Cutout
S15 S21 S22 For the screw types, see 2.1.1.1 Screw types used in the printer (p41).
Figure 2-100. Removing the Main Board 1. Remove the Panel Assy. (P.70)
Align the two cutouts on the frame with the two positioning holes
on the Main Board. (Figure 2-100) 3. Remove the Left ADF Hinge Cover. (P.67)
Adjustments" (p279) when the Main Board is replaced. 7. Remove the Right Upper Front Cover. (P.73)

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15. Remove the Middle Housing. (P.86) 2.3.5.6 Wireless LAN Module
16. Remove the USB/FAX Cover.(P.97)
17. Remove the Main Board Shield Plate.(p103)
18. Disconnect the Interface Board FFC from the connector of the Interface Board.
19. Remove the five screws (S15), and remove the Interface Board and Interface
Board Shield Plate.
Interface Board FFC
Connector
Interface Board Shield Plate 7. Remove the Right Upper Front Cover. (P.73)
S15
Figure 2-101. Removing the Interface Board
Adjustments" (p279) when the Interface Board is replaced. 10. Remove the Front Cover Microswitch. (P.72)
16. Disconnect the cable from the connector of the Wireless LAN Module.
17. Remove the two screws (S15), and remove the Wireless LAN Module.

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2.3.5.7 CSIC Board (BK)

Connector
Cable
S15
Figure 2-102. Removing the Wireless LAN Module

Adjustments" (p279) when the Wireless LAN Module is replaced. For the screw types, see 2.1.1.1 Screw types used in the printer (p41).

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16. Disconnect the Relay FFC (BK) from the connector (CN1) of the CSIC Board (BK). 2.3.5.8 Power Supply Unit
17. Peel off the Relay FFC (BK).
18. Disengage the six hooks, and remove the CSIC Board Cover.
Hooks
CN1
Hooks
CSIC Board Cover
Relay FFC (BK)
Hook
Figure 2-103. Removing the CSIC Board Cover 1. Remove the Panel Assy. (P.70)
19. Disconnect the FFC from the four connector (CN2) of the CSIC Board (BK). 2. Remove the Paper Support Support. (P.66)
20. Remove the four screws (S11), and remove the CSIC Board (BK). 3. Remove the Left ADF Hinge Cover. (P.67)
CN2
S11
Figure 2-104. Removing the CSIC Board (BK) 14. Remove the Ferrite Core Holder. (P.74)

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15. Release the FFC from the three clamps.

18. Move the Ink Supply BK Assy forward.
Inside of the Ink Supply Unit
Tube (BK) Ink

Supply
Clamp
Clamp
FFC
Figure 2-107. Moving the Ink Supply BK Assy

16. Release the Tube (BK) and FFC from the clamp.
Clamp
FFC
Tube (BK)


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19. Disconnect the cable from the connector of the Power Supply Unit.
Engage the two ribs with the two positioning holes on the Power
20. Release the cable from the clamp.Remove the three screws (S17), and remove the
Supply Unit (refer to Figure 2-108).
Power Supply Unit.
Ribs Carry out the adjustments referring to "3.1 Required

Adjustments" (p279) when the Power Supply Unit is replaced.
S17
Connector
Cable
Clamp
S17
Figure 2-108. Removing the Power Supply Unit

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2.3.6 Carriage Mechanism/ Ink System Mechanism 11. Remove the Front Cover Microswitch. (P.72)
2.3.6.1 Print Head
14. Remove the Ink Supply BK Cover Open Sensor.(P.199)
15. Release the Ink Supply BK Assy.(P.201)
16. Release the Ink Supply CL Assy.(P.203)
18. Remove the Panel FFC. (P.74)
19. Remove the Middle Housing.(P.86)
20. Move the CR Unit to the hole position for access to the screws.
Hole
If Printer can not perform Ink Flushing by fatal error, refer to

repair procedure of "2.3.6.19 Print Head / Ink Supply Unit (When
the printer cannot perform Ink Flushing by fatal error)" (p168).
1. Perform the “Ink Flushing” with Adjustment Program.(P.62) CR Unit
2. Remove the Panel Assy. (P.70) Figure 2-109. Removing the Print Head (1)
3. Remove the Paper Support Support. (P.66) 21. Disconnect the FFC from the connector of the CR Encoder Sensor
4. Remove the Left ADF Hinge Cover. (P.67) FFC

Connector
FFC
Spacer
Figure 2-110. Removing the Print Head (2)

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22. Remove four screws (S23 (w/ spring, washer): 3pcs, S30: 1pcs), and remove the 23. Disconnect the four Head FFC from the connectors of the Print Head.
Print Head.
Take care not to drop the spring and the washer. If they are not Print Head
attached, short-circuiting or similar trouble may result and
Head FFC
which may affect the product quality adversely.
If the spring and washer drop, make sure to search for them
and pick them up.
Head FFC
Screw Spring Washer
Figure 2-112. Removing the Print Head (4)

Magnetizing the screwdriver will make the work easier.
When disconnecting the Head FFC, make sure to pull them straight
off one by one from their connector terminals.
Screwdriver
24. Remove two screws (S2), and remove the Ink tube.
Ink Tube
S23
S30 S2
Figure 2-111. Removing the Print Head (3) Figure 2-113. Removing the Print Head (5)

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Performing the Reassembly, Adjustment and Inspection according 3. Install the Print Head to CR Unit, and fix it by three
to the following procedure, after removing the Print Head. screws (S23).
When installing the Print Head, do it while pressing

the Print Head in the directions of the arrows in the
following order.
Reassembly Procedure of the Print Head. Tighten the three screws in the order given in Figure
1. Wipe out the Ink Tube by Polyester Swab. 2-110.
Make sure to wipe out the ink on the ink tube due to
influence on the Ink leakage check result.
Wiping area
2
1
Figure 2-114. Cleaning the Ink Tube Figure 2-115. Installing the Print Head
2. Connect the Head FFC to Print head. 4. Connect the FFC to CR Encoder.

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5. Install the Leakage Check PET Chip. 5-1. Set the PET Chip (x2) at the Ink Tube connected position of
Print head.
kind of the Leakage Check PET Chip.
Take care that the PET Chip is different between the
Name Part Code Picture Remark PET Chip for rear side and the PET Chip for front
LEAK 1684353 Put it to Front side in length.
TESTER side Set the PET Chip with contacting the smoked face of
SHEET the PET Chip.
FRONT
10mm
Rear Side LEAK TESTER SHEET REAR
LEAK 1684354 Put it to Rear
TESTER side
SHEET
REAR
15mm The Smoked face of
two PET Chip are put
15mm toward the upside
10mm
Making method of the Leakage Check PET Chip.
Press folded part (2 position) and align the PET Chip by
forming folded angle at 90 degrees. LEAK TESTER SHEET FRONT
Front Side
90° Figure 2-116. Setting position of the Leakage Check PET Chip (1)
5-2. Install the Ink Tube to Print Head.
LEAK TESTER SHEET REAR
90°
LEAK TESTER SHEET FRONT
Figure 2-117. Setting position of the Leakage Check PET Chip (2)

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6. Secure the three screws (S2: 2pcs, S30: 1pcs), and fix the Perform the Adjustment in the following procedure when you
Ink Tube. detach/exchange the Print Head.
Make sure to use the new Printhead Seal. If you check the Ink Leak by using the Ink Leak
(ASP Single Part) Measurement jig, perform it after Mechanism
Make sure to check the Printhead Seal is completely Adjustment.
inserted. (Perform it between “procedure 1” and “procedure 2”
Make sure to check the foreign material is not
adhering to the Printhead Seal. 1. Perform the Mechanism Adjustment.
Do not install the Printhead Seal doubly. (Refer to "3-1 Required Adjustment List (Mechanism
adjustment)" (p280))
Printhead Seal 2. Install the following parts by the following procedure.
2-1. Connect the Ink Supply BK Cover Open Sensor Cable to Ink
Supply BK Cover Open Sensor.
2-2. Wrap the Ink Supply BK Cover Open Sensor with tape, and
disable the sensor function.
2-3. Connect the FFC to Connector (CN1) of CSIC Board (CL).
2-4. Connect the Cable to Front Cove Microswitch.
2-5. Wrap the Front Cover Microswitch with tape, and disable
the sensor function.
2-6. Connect the Panel FFC to Main Board.
2-7. Connect the Panel FFC to Panel Assy.
Make sure to put paper to under the Panel Assy to

7. Move the CR Unit to the Home position. prevent the Panel Assy shorting.
Figure 2-118. State of the Printer.

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3. Power on the Printer. 2.3.6.2 CR Waste Ink Pad

Connect the Power Cable to Power Supply Unit, and push the
Power button when blinking the Power LED.
Start the Printer in “Inspection Mode”.(P.316)
4. Perform the Head ID Input.
5. Perform the CR Check.
6. Perform the CR Scale Check.
7. Perform the Ink Charge.
8. Perform the Ink Leak Check. (P.296)
(Using the Leakage Check PET Chip)
9. Perform the Head Angular Mecha Adjustment. (P.306)
10. Reassemble the Printer.
11. Perform the Adjustment using the Adjustment Program.
(Refer to "3-2 Required Adjustment List (Adjustment using
the Adjustment Program) (1/2)" (p281),
"3-3 Required Adjustment List (Adjustment using the
Adjustment Program) (2/2)" (p282)) For the screw types, see 2.1.1.1 Screw types used in the printer (p41).
1. Perform the “Ink Flushing” with Adjustment Program.(P.62)

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16. Remove the Middle Housing. (P.86) 2.3.6.3 CR Scale

17. Remove the Print Head. (P.114)
18. Remove the Pad Film.
19. Remove the CR Waste Ink Pad.
Pad Film
CR Waste Ink Pad
The CR Scale is made of SUS and very fragile. Therefore, take

extreme care when handling one.
Figure 2-119. Removing the CR Waste Ink Pad If you disassemble the CR scale, exchange it for the new CR
scale.
Perform the Adjustment using the Adjustment Program
"3.1 Required Adjustments" (p279)
Do not touch the CR Scale. If you touch the CR Scale, perform
the “CR scale check” on the adjustment program.


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12. Remove the Ink Supply CL Cover Assy. (P.197) 19. Pull out the CR Scale from the slit of the CR Unit.
14. Remove the Ferrite Core Holder.(P.74) Side view
CR Unit
16. Slide the Ink Supply Unit. (refer to (p148))
17. At the full side, disengage the Extension Spring from the hook of the frame. CR Scale
Hook
Extension Spring
Slit
Figure 2-122. Removing the CR Scale (3)

20. Turn the CR Scale 90 degrees upward at the full side and disengage it from the
hook on the frame.
18. At the home side, remove the CR Scale from the hook of the frame.
Hook
Hook

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Do not use the CR scale with chip and dirt.

How to install the CR Scale Do not wipe the dirt off the CR scale, replace a new CR scale.
2.Turn the CR Scale -90
1. Put the CR scale on the
degrees upward at the full side.
3. Install the spring with the 4.The CR scale is inserted in the slit of
frame at the full side by using the CR unit.
long-nose pliers and so on.
5.At the home side, engage

CR Scale with the hook.

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2.3.6.4 PW Sensor 14. Remove the Front Housing. (P.75)

17. Unlock the CR Unit. (P.61)
18. Remove the screw (S4), and remove the Sensor Cover.
19. Remove the PW Sensor using the long nose pliers or the similar tool.
20. Disconnect the FFC from the connector of the PW Sensor.
Sensor Cover
Be careful not to touch the CR Shaft. Otherwise, the grease is

attached on the PW Sensor and the sensor may be damaged. FFC

PW Sensor
S4 Connector
Figure 2-124. Removing the PW Sensor
6. Remove the ADF/ Scanner Unit. (P.216) Carry out the adjustments referring to "3.1 Required
Adjustments" (p279) when the PW Sensor is removed or replaced.

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2.3.6.5 Head FFC 15. Remove the Middle Housing. (P.86)

When removing the Print Head, do not remove the Ink Tube.

17. Release the Ink Tube (Y,M,C) from the Left Tube Clip.
Tube (M)
Tube (Y)
3. Remove the Left ADF Hinge Cover. (P.67) Tube (C)
9. Remove the Cassette Assy. (P.244) Left Tube Clip

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18. Release the Ink Tube (Y,M,C) from the Tube Clamp. Tube Clip
Tube Clamp

19. Release the Tube (Y/M/C) from three Tube Clips.

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20. Disengage the two hooks, and remove the Right Upper Tube Guide. 23. Remove the Right Lower Tube Guide, and release the Tube (Y/M/C).
Right Lower
Right Upper Groove Tube Guide
Tube Guide
Tube
Hooks
22. Release the Cable of the Ink Supply CL Cover Open Sensor from the Right Lower
Tube Guide.
Right Lower
Tube Guide
Hook
Cable of the Ink Supply CL
Cover Open Sensor

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25. Disconnect the cables from the connectors (CN2, CN5) of the Main Board.
26. Remove the six screws (S17), and remove the Main Board Shield Plate and the
fixing plate.
Tube Clip Marking

Screw the grounding wire together as shown below.
Grounding wire
CN5 CN2
Main Board Shield

Plate
S17 Fixing plate

Figure 2-131. Securing the Ink Supply CL Assy Figure 2-132. Removing the Main Board Shield Plate

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27. Disconnect the cables and FFCs from the connectors (CN30, CN32, CN77, 30. Remove the Ferrite Core Holder in the direction of the arrow.
CN701, CN702, CN703, CN704, CN705) of the Main Board.
28. Release the PF Encoder FFC from the rib and hole of the Ferrite Core Holder.
29. Pull off the cables for the ink supply system and the FFC of the CSIC Board from Ferrite Core Holder
the Ferrite Core Holder.
CSIC Board FFC Cables for the ink

supply system
Ferrite Core
CN32 CN77
Holder CN705
Rib

When removing the Main Board Unit to replace the Main Board, it
Hole is not necessary to perform Step31 (P.128) and32 (P.128).
PF Encoder FFC
CN30
CN701, CN702,
CN703, CN704 31. Disengage the hook, and remove the Ferrite Core from the Ferrite Core Holder.
Figure 2-133. Removing the Main Board Unit (1) 32. Remove the Head FFC from the Ferrite Core Holder.
Head FFC
Ferrite Core Holder
Ferrite Core
Hook

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33. Remove the Tube Clamps (x4). 35. Disconnect the FFC from the connector of the CR Encoder Sensor.Remove four
screws (S23 (w/ spring, washer):3pcs, S30: 1piece)
FFC
Ink Tube
Tube Clamp
Spacer
S23
Figure 2-136. Releasing the Tube Clamps S30
34. Move the Print Head at the position of (Figure 2-137).
Figure 2-137. Removing the Print Head

When removing/installing the Ink Tube, place the Spacer (about 5
mm) between the Carriage Assy and Star Wheel Assy in order to
prevent the CR Guide Frame and Main Frame from being
deformed.
When it is not possible to prepare place the Spacer, you may
support the CR unit by the finger.
36. Disconnect the four Head FFC from the connectors of the Print Head.
37. Slide the Head FFC. Sli
Print Head
Head FFC
Head FFC

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39. Disengage the hook, slide the Upper Supply Tube Holder in the direction of the
arrow.Pull out the Head FFC Assy from the frame.
Slide the Head FFC
Upper Supply Tube Holder
Frame
Hook
Disconnect the Head FFC
Print Head
Figure 2-138. Removing the Head FFC

When disconnecting the Head FFC, make sure to pull them straight
off one by one from their connector terminals.
Figure 2-140. Removing the Upper Supply Tube Holder

38. Remove the three FFC clamps.
FFC clamp
FFC clamp
FFC clamp
Figure 2-139. Removing the FFC clamp

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40. Pull the Head FFC Assy from the Upper Supply Tube Holder. 2.3.6.6 CR Motor
Upper Supply Tube Holder

Tube clamps
Tube clamp
Figure 2-141. Removing the Head FFC Assy 2. Remove the Paper Support Support. (P.66)
41. Remove the support parts from the Head FFC Assy. 3. Remove the Left ADF Hinge Cover. (P.67)
16. Remove the APG Gear Assy. (P.142)

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17. Remove the USB Connector Assy. (P.98) 24. Remove the two screws (S27), and remove the CR Motor.
19. Remove the Main Board Shield Plate and Cable Holder. (p99) Pinion gear
20. Disconnect the CR Motor Cable from the connector of the Main Board. (refer CR Timing Belt
to(p99))
22. Disengage the Extension Spring on the CR Driven Pulley Assy from the hook and
release the tension of the CR Timing Belt.
CR Driven Pulley Assy
Hook
S27
Figure 2-143. Removing the CR Motor
Extension Spring Carry out the adjustments referring to "3.1 Required

Adjustments" (p279) when the CR Motor is removed or replaced.
Figure 2-142. Removing the CR Driven Pulley Assy

23. Remove the CR Timing Belt from the pinion gear of the CR Motor.

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2.3.6.7 Taking the ink tubes from the ink supply unit.
1. Rotate the joint 90 degrees counterclockwise and disconnect the Tube (BK) from When removing the tube. Replace to new Packing.
the Ink Supply Unit. Keep the ends of tube up after removal. There is the packing in the tube or on the ink supply unit.
packing
Wide
Tube(BK)
Ink Supply Unit
Figure 2-144. Releasing the Tube (BK)

2. Rotate the joint 90 degrees counterclockwise and disconnect the Tube (CL) from
the Ink Supply Unit. Keep the ends of tubes up after removal.
Tube (Y/M/C)

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2.3.6.8 CR Unit 18. Remove the USB Connector Assy. (P.98)

20. Take the Ink Tubes from the Ink Supply Unit.(P.133)
21. Release the Ink Tube (Y,M,C) from the Tube Clamp.
2. Remove the Panel Assy. (P.70) Tube Clamp

5. Remove the Right ADF Hinge Cover. (P.68) Figure A2-146. Removing the FFC)
6. Remove the ADF/ Scanner Unit. (P.216) 22. Remove the screw (S16), and remove the Color Tube Holder from the Ink Supply
Unit. (Put the Tube with Holder)
Color Tube Holder
15. Remove the Ferrite Core Holder.(P.74) S16
17. Remove the USB/FAX Cover. (P.97) Figure A2-147. Removing the Color Tube Holder

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23. Remove the Head FFC. (P.124) 29. Releasing the cable from the Ink Supply Unit.
24. Disconnect the Relay FFC (BK) from the connector (CN1) of the CSIC Board
(BK). Cable
25. Remove the screw (S5), and remove the fixing plate.
CN1 Fixing plate

CSIC Board
(BK)
Figure 2-150. Releasing the cable

30. Pull the two tubes of the Decompression Motor Assy.
Relay FFC (BK) 31. Remove the four Ferrite Core from the Ink Supply Unit.
S5 32. Disengage the four hooks, and remove the four Ink End Board.
Figure 2-148. Releasing the FFC (1)
26. Peel off the Relay FFC (BK). Ink End Board
27. Remove the Ferrite Core from the Relay FFC (BK).
Tubes of the
Decompression Motor Assy
Ferrite Core

Ferrite Core
28. Release the Tube (Y/M/C) from the Left Tube Clip and clamp.
Figure 2-151. Removing the Ink End Board
33. Disconnect the FFC from the connector of the CSIC Board.

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34. Disengage the hook, and release the Ink Tube from the Upper Supply TUbe 36. Remove the Ink Supply Unit by sliding it toward you.
Holder.
Upper Supply Tube Holder Clamp

FFC
Clamp
Hook Ink Tube
CSIC Board
Clamp
Figure 2-152. Releasing the Ink Tube Figure 2-154. Removing the Ink Supply Unit (2)
35. 2Remove the two screws (S15). 37. Remove the Ink Supply Unit with the Print Head together.
S15
Figure 2-153. Removing the Ink Supply Unit (1)
Figure 2-155. Removing Ink Supply Unit and Print Head
38. Remove the CR Scale. (P.120)
39. Remove the APG Gear Assy.(P.142)
40. Remove the CR Driven Pulley Assy. (P.131)
41. Remove the USB Connector Assy. (P.98)

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42. Remove the CR Motor. (P.131)

43. At the full side, remove the CR Support Spring.
Right PG Adjust Lever
44. Remove the screw (S15), remove the CR Support Plate.
45. Remove the E-ring and bush, and remove the APG Gear and parallel pin.
When removing the APG Gear, be careful not to touch the PF

Scale.
Be careful not to drop the parallel pin.
Rib Marking
Figure 2-157. Marking on the Right PG Adjust Lever
47. Remove the CR Support Spring.
48. Remove the screw (S15), and remove the CR Support Plate.
CR Support Spring
49. Remove the plastic ring, and remove the CR bearing and parallel pin.
50. Remove the screw (S26), and remove the Right PG Adjust Lever.
CR Support Plate Be careful not to drop the parallel pin.
APG Gear
E-ring and bush
Parallel pin
PF Scale
S15
Figure 2-156. Removing the APG Gear
46. At the home side, put a marking at the point where the rib on the frame is in
contact with the Right PG Adjust lever.

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Set the CR Bearing with “6” exactly on the bottom.

CR Support Spring
Plastic Ring
CR Bearing
CR Bearing
Parallel pin
CR Support Plate
6 Right PG
Adjust Lever
Align the marking on the Right PG Adjust lever with the rib on
the frame. S15
S26
Figure 2-158. Removing the Right PG Adjust lever
51. Remove the plastic ring and spacer that secure the CR Shaft.
52. Remove the E-ring and plastic washer, and remove the CR Assembly Plate.
53. Remove the seven screws (S15), and remove the CR Guide Frame.
Rib Marking CR Guide Frame E-ring and plastic washer
CR Assembly Plate Plastic ring and spacer

CR Shaft
S15
Figure 2-159. Removing the CR Guide Frame

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54. Pull out the tubes of the Decompression Motor Assy from the wire saddle. 57. Remove the two screws (S15), and remove the CR Guide Frame upward.
55. Release the cables from the six clamps.
56. Remove the ten screws (S15), and remove the Upper Support Frame.
Upper Support Frame Wire saddle

Tubes of the
Decompression
Motor Assy S15 S15
Clamp CR Guide Frame
S15
Figure 2-160. Removing the Upper Support Frame
Figure 2-161. Removing the CR Guide Frame

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58. Pull the CR Shaft from the printer.
When installing the CR Unit, engage the shaft on the CR Assembly When removing the CR Unit, take care not to scratch the CR Shaft.
Plate into the hole on the frame.
Shaft
Frame
59. Remove the CR Shaft from the CR Unit.
CR Assembly Plate CR Unit
CR Shaft
CR Assembly Plate
CR Unit
CR Shaft Figure 2-163. Removing the CR Unit (2)
Lubricate the parts referring to "4.1.2 Lubrication" (p323) when

the CR Unit is replaced.

Figure 2-162. Removing the CR Unit (1) Adjustments" (p279) when the CR Unit is removed or replaced.

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17. Disconnect the cable of the Decompression Motor Assy from the relay connector.
18. Remove the four screws (S10: 2pcs, S5: 1piece, S15: 1piece), and remove the
2.3.6.9 Decompression Motor Assy Decompression Motor Assy.
Relay connector
Tube
1. Remove the Panel Assy. (P.70) S5
2. Remove the Paper Support Support. (P.66) S10 S15
3. Remove the Left ADF Hinge Cover. (P.67) Figure 2-164. Removing the Decompression Motor Assy
16. Pull out the tube of the Decompression Motor Assy from the Ink Supply Unit.

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2.3.6.10 APG Gear Assy 16. Remove the three screws (S15), and remove the APG Gear Assy.

2. Remove the Paper Support Support. (P.66) Figure 2-165. Removing the APG Gear Assy (1)
3. Remove the Left ADF Hinge Cover. (P.67) 17. Disconnect the cable from the connector of the sensor.

5. Remove the ADF/ Scanner Unit. (P.216) Connector
6. Remove the Panel Lower Front Cover. (P.73) Cable
9. Remove the Cassette Assy. (P.244) Pin of Upper
Paper Guide
12. Remove the Ink Supply CL Cover Assy. (P.197) Groove of the
Release Shaft Holder
14. Remove the Ferrite Core Holder.(P.74) Figure 2-166. Removing the APG Gear Assy (2)

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Align the triangular mark on the Left APG Cam with the 2.3.6.11 APG Sensor
triangular mark on the Spur Gear 14.4 on the APG Gear Assy.
At this point, make sure the rectangular mark on the
Combination Gear can be seen through the hole on the APG
Gear Assy.
Spur Gear 14.4

Rectangular
Left APG Cam
mark
Hole
Triangle mark
Combination Gear
Insert the pin on the Upper Paper Guide into the groove on the 3. Remove the Left ADF Hinge Cover. (P.67)
Release Shaft Holder of the APG Gear Assy. (refer to Figure
2-166) 4. Remove the Right ADF Hinge Cover. (P.68)
Carry out the adjustments referring to "3.1 Required 6. Remove the Panel Lower Front Cover. (P.73)
Adjustments" (p279) when the APG Gear Assy is removed or 7. Remove the Right Upper Front Cover. (P.73)
replaced.

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17. Disengage the four hooks, and remove the APG Sensor. 2.3.6.12 APG Motor Assy
Hooks

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16. Remove the APG Gear Assy. (P.142) 21. Remove the two screws (S15), and remove the APG Motor Assy.
17. Remove the Power Supply Unit. (P.111)
18. Disconnect the cable from the connector of the APG Encoder Sensor.
19. Disconnect the cable from the connector of the APG Motor.
20. Release the cable of the APG Motor from the clamp.
Cable of the APG Motor
Clamp
S15
Figure 2-168. Removing the APG Motor Assy (2)
Connector
Connector
Adjustments" (p279) when the APG Motor Assy is replaced.
Cable of the APG
Encoder Sensor
Figure 2-167. Removing the APG Motor Assy (1)

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2.3.6.13 CR Solenoid Assy 17. Remove the Power Supply Unit. (P.111)
18. Release the cable of the CR Solenoid Assy from the clamp.
19. Disconnect the cable from the relay connector.
20. Remove the two screws (S15), and remove the CR Solenoid Assy.
Cable
2. Remove the Paper Support Support. (P.66) Relay connector S15
Clamp
Figure 2-169. Removing the CR Solenoid Assy

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2.3.6.14 Ink End Board 16. Disengage the hook, and remove the Ink End Board.
17. Disconnect the cables from the connectors of the Ink End Board.
Hook
Connector
Cable
Figure 2-170. Removing the Ink End Board

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2.3.6.15 Ink Supply Unit 12. Remove the Ink Supply BK Cover Assy. (P.195)
14. Remove the Ink Supply BK Cover Open Sensor. (P.199)
15. Remove the Ink Supply BK Assy. (P.201)
16. Remove the Ink Supply CL Assy. (P.203)
18. Remove the Panel FFC. (P.74)
19. Remove the Middle Housing. (p86)
(BK).
21. Remove the screw (S5), and remove the fixing plate.　
CN1 Fixing plate
If Printer can not perform Ink Flushing by fatal error, refer to
repair procedure of "2.3.6.19 Print Head / Ink Supply Unit (When CSIC Board
the printer cannot perform Ink Flushing by fatal error)" (p168). (BK)

4. Remove the Left ADF Hinge Cover. (P.67) Relay FFC (BK)
S5

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22. Peel off the Double side tape of Relay FFC (BK). 25. Disconnect the FFC from Connector (CN5) of CSIC Board (BK) Cover.
Double Side Tape FFC
Relay FFC (BK)
CN5
Ferrite Core
Figure 2-174. Disconnecting the FFC from CSIC Board (BK).
Figure 2-172. Releasing the FFC (2) 26. Release the Clamp (x2) and put the FFC in the Ink Supply BK Assy side.
24. Remove the CISC Board (BK) Cover. 27. Release the Ink Tube (Y/M/C) from Tube Clamp.
FFC
Clamp
Hook
Tube Clamp
Remove the Ink Tube
from cut line of the Tube
Clamp.
CSIC Board (BK) Cover
Figure 2-173. Removing the CSIC Board (BK) Cover

Ink Tube (Y/M/C)
Figure 2-175. Releasing the Ink Tube

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28. Releasing the cable from hooks of the Ink Supply Unit.　 30. Rotate the connector of the Ink Tube in the direction of the counterclockwise,
and remove the Ink Tube (x4) from the Ink Supply Unit.
Cable
Ink Tube
Figure 2-176. Releasing the cable　 Figure 2-178. Removing the Ink tube
29. Remove the screw (S16), and remove the Left Tube Clip from the Ink Supply 31. Ink is sealed by tube clip at the tip of removed Ink Tube.
Unit. (Put the Ink Tube with Left Tube Clip)
Tube Clip
Left Tube Clip
Ink Tubes Ink Tubes

(BK/Y) (M/C)
Figure 2-177. Removing the Left Tube Clip. Figure 2-179. Clipping the Ink Tube

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32. Remove the Connector from the Ink End Board. 35. Disengage the hook, and release the Ink Tube from the Upper Supply Tube
Holder.

FFC
Clamp
Hook Ink Tube
CSIC Board
Ink End Board
Clamp
Figure 2-180. Removing the Ink End Connector Figure 2-182. Releasing the Ink Tube
33. Remove the Pump Tube (x2). 36. Remove the three screws (S2:2 pcs, S30:1piece) and the Ink Tube Connector.
34. Remove the Ferrite Cores (x4) from the Ink Supply Unit.
Pump Tube
Ferrite Core
S2
S30
Figure 2-181. Removing the Ferrite Core and Pump Tube Figure 2-183. Removing the Ink Tube Connector

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37. Release both of hooks by Flat-head screwdriver and remove the Tube Holder. 39. Remove the Ink Supply Unit by sliding it toward you.
Tube Holder
Tube Holder
Figure 2-186. Removing the Ink Supply Unit (2)

Figure 2-184. Removing the Tube Holder 40. Check the separation of the Ink Supply Connector, and remove the Ink Supply
38. Remove the two screws (S15). Unit.
S15
Figure 2-185. Removing the Ink Supply Unit (1) Figure 2-187. Ink Supply Unit
Prepare for a plastic bag due to ink leakage from the Ink Tube
Connector.

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Performing the Reassemble, Adjustment and Inspection according 2. Prepare the New Ink Supply Unit.
to the following procedure, after removing the Print Head.
The Jig Tube and Cover Joint is attached in New Ink
Supply Unit.
Therefore, disassemble these parts before installing the
New Ink Supply Unit to Printer.
Reassembly procedure of the Print Head.
Remove the Jig Tube.
1. Wipe out the Print Head by Polyester Swab.
Rotate the Jig Tube in the direction of the counterclockwise, and
Make sure to wipe out the ink on the ink tube due to remove the Jig Tube from the New Ink Supply Unit.
influence on the Ink leakage check result.
Take care the Shipping Liquid may drop when
removing the Jig Tube from the New Ink Supply
Unit.
Rear face Right face Make sure to use the new Seal Supply Hole.
(Do not use the Seal Supply Hole attached to New Ink
Supply Unit.)
Make sure not to use the Jig Tube.
Jig Tube
Bottom face
Left face Front face
Figure 2-188. Cleaning the Print Head Figure 2-189. Removing the Jig Tube

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Remove the Cover Joint 3. Install the New Ink Supply Unit, and secure the two screws
Remove the Cover Joint from the Ink Tube Connector of New Ink (S16).
Supply Unit (ASP). 4. Connect the each colored connector (x4) to the Ink End Board,
and attach the Ferrite Core to the hooks of the Ink Supply Unit.
The New Ink Supply Unit has two type Cover Joint.
Cover Joint is fixed by screw. Black Yellow Red White
Cover Joint is not fixed by screw.
If Cover Joint is fixed by screw, remove the screw and
Cover Joint.
Make sure to put down plastic sheet or cloth, because

shipping liquid may drop from Ink tube when
removing the Cover Joint and screw.
If you remove the Cover Joint to an upward
direction, Ink Supply Unit and other parts may
dirty by dropped shipping liquid from Ink Tube
Connector. Ink End Connector
Therefore, make sure to remove the Cover Joint to a
downward direction.
Perform the following operation after removing the Figure 2-191. Installing the Connector and Ferrite Core
Cover Joint and install the Ink Supply Unit to 5. Install the two Pump Tube to the Ink Supply Unit.
printer. 6. Install the Left Tube Clip to Ink Supply Unit, and secure the
″ Confirm the shipping liquid is not dropped from screw(S16).
ink Tube Connector. 7. Route the Ink Supply BK Cover Open Sensor Cable.
″ Clean the Ink Tube Connector. 8. Route the FFC of the Ink Supply BK Assy, and connect it to the
Relay Board.
Ink Tube Connector Install the Clamps (x2).
9. Install the CSIC Board (BK) Cover.
10. Route the Relay FFC(BK) and connect it to the Relay Board.
11. Install the Fixing Plate, and secure the screw(S16).
12. Connect the Ink Tube(x4) to Ink Supply Unit.
Cover Joint
Figure 2-190. Removing the Cover Joint

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13. Install the Leakage Check PET Chip. 13-1. Set the PET Chip (x2) at the Ink tube connected position of
Print head.
kind of the Leakage Check PET Chip.
Take care that the PET Chip is different between the
Name Part Code Picture Remark PET Chip for rear side and the PET Chip for front
LEAK 1684353 Put it to Front side in length.
TESTER side Set the PET Chip with contacting the smoked face of
SHEET the PET Chip.
FRONT
10mm
Rear Side LEAK TESTER SHEET REAR
LEAK 1684354 Put it to Rear
TESTER side
SHEET
REAR
15mm The Smoked face of
15mm
two PET Chip are put
toward the upside
10mm
Making method of the Leakage Check PET Chip.
Press folded part (2 position) and align the PET Chip by
forming folded angle at 90 degrees. LEAK TESTER SHEET FRONT
Front Side
90°
13-2. Install the Ink Tube Connector to Print Head.
90°


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14. Secure the three screws (S2: 2pcs, S30: 1pcs), and fix the Perform the Adjustment in the following procedure when you
Ink Tube Connector. detach/exchange the ink Supply Unit.
The Print Head might be attaching to the New Ink If you check the Ink Leak by using the Ink Leak
Supply Unit (ASP). However, it is used item. Measurement jig, perform it after Mechanism
Therefore, make sure to replace it to the new one. Adjustment.
Make sure to check the Printhead Seal is completely (Perform it before Procedure 1.)
inserted.
Make sure to check the foreign material is not 1. Install the following parts by the following procedure.
adhering to the Printhead seal. 1-1. Connect the Ink Supply BK Cover Open Sensor Cable to ink
Do not install the Printhrad Seal doubly. Supply BK Cover Open Sensor.
1-2. Wrap the Ink Supply Bk Cover Open Sensor with tape, and
disable the sensor function.
Printhead Seal 1-3. Connect the FFC to Connector (CN1) of CSIC Board (CL).
1-4. Connect the Cable to Front Cover Microswitch.
1-5. Wrap the Front Cover Microswitch with tape, and disable
the sensor function.
1-6. Connect the Panel FFC to Main Board.
1-7. Connect the Panel FFC to Panel Assy.
Make sure to put paper to under the Panel Assy to

Prevent the Panel Assy shorting.
15. Fix the Ink Tube by the Upper Supply Tube Holder and three
Tube Clamps.
16. Move the CR Unit to Home Position.
Figure 2-194. State of the Printer

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2. Install the Ink Pack (All Colors). 2.3.6.16 Cap Unit

3. Power on the Printer.
Connect the AC cable to Power Supply Unit, and push the Power
button when blinking the Power LED.
Start the Printer in “Inspection Mode”(P.316)
4. Perform the CR Scale Check.
6. Perform the Ink Leak Check.
7. Reassemble the Printer.
1. Perform Waste Ink Flushing of the Adjustment Program to drain the waste ink in
the Cap Unit and Pump Unit into the Maintenance Box (P.279).
Figure 2-195. Removing the Cap Unit

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2. Remove the Panel Assy. (P.70) 17. Release the Tube (Y/M/C) from the clamp.
3. Remove the Paper Support Support. (P.66) 18. Release the Tube (Y/M/C) from the Left Tube Clip.
5. Remove the Right ADF Hinge Cover. (P.68) Clamp
6. Remove the ADF/ Scanner Unit. (P.216) Tube (M)
9. Remove the Stacker Assy. (P.66) Tube (Y)
Tube (C)
Left Tube Clip

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19. Release the Tube (Y/M/C) from the three tube clips. 20. Remove the Right Lower Tube Guide, and release the Tube (Y/M/C).
Tube Clip Marking

Right Lower
Tube Guide
Tube Clip
Image when the tubes are released

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21. Disengage the two hooks, and Right Upper Tube Guide. 24. Unlock the CR Unit. (P.61)
22. Release the Tube from the groove of the Right Upper Tube Guide. 25. Move the CR Unit to the center.
26. At the home side, put a marking at the point where the rib on the frame is in
Right Upper Groove contact with the Right PG Adjust lever.
Tube Guide Tube
Align the marking on the Right PG Adjust lever with the rib on the
frame (refer to Figure 2-201).
Hooks

Rib Marking
Figure 2-201. Marking on the Right PG Adjust Lever
27. Loosen the screw, slide the Right PG Adjust Lever to the front.
28. Pull out the two Waste Ink Tube from the Waste Ink Joint Tube Assy.
When connecting the two Waste Ink Tubes to the Waste Ink Joint
Tube Assy, it is OK to connect them to either of the joints because
of no specific designation.
29. Route the Waste Ink Tube into the Tube Cover.
Figure 2-200. Securing the Ink Supply CL Assy
30. Remove the screw (S15), and remove the Cap Unit Support.

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Screw Right PG Adjust Lever
Tube Cover
Waste Ink Joint

Cap Unit Support Tube Assy
S15
Waste Ink Tube
S15
Figure 2-202. Removing the Cap Unit (1)
S15
In the following steps, waste ink may spill from the Cap Unit.
Prepare waste cloths or similar in advance so as not to
contaminate the surroundings.please in Insert the cotton bud
into the tube for prevention dripping ink.
Be careful not to let the gears on the Cap Unit come off when
removing the Cap Unit.

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32. Remove the Cap Unit with the gears aligned as shown below.
If any gears come off when removing the Cap Unit, restore the
original state referring to the figure below.
The CR lock Cam and Spur Gear 17.6 very easily come off, so make
sure to hold them with your hands.
Head Cleaner Cam CR Lock
Spur Gear 17.6 CR Lock Cam

If gears of the Cap Unit are disengaged, refer to the following
when reassembling them.
1. Insert the pin on the CR Lock into the groove on the CR Lock
Cam, and rotate the cam clockwise.
CR Lock
Groove
Pin
CR Lock Cam

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2. Align the first tooth on the Head Cleaner Cam with the mark. 3. Pull out the Waste Ink Tube. (refer to figure 2-202)
4. Connect the Waste Ink Tube to the Waste Ink Joint Tube Assy.
Head Cleaner Cam (refer to figure 2-202)
5. Route the Waste Ink Tube on the Waste Ink Joint Tube Holder
as shown below.
Waste Ink Tube
First tooth Waste Ink Joint

Tube Holder
Mark
Install the Cap Unit as follows.
6. Make sure the gear on the PF Roller engages with the Cap Gear.
1. Insert the Cap Unit as shown below (put the Waste Ink Tube
first.)
Gear of the
PF Roller Cap Gear
2. Puts edge of the Cap Unit out from the hole of the frame. and
pinch the tube out from the hole.

Adjustments" (p279) when the Cap Unit is removed or
replaced.
cotton bud

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2.3.6.17 Pump Unit 2. Remove the Panel Assy. (P.70)

1. Perform Waste Ink Flushing of the Adjustment Program to drain the waste ink in
the Cap Unit and Pump Unit into the Maintenance Box (P.279).
20. Remove the Cap Unit. (P.157)
Figure 2-205. Removing the Pump Unit (1)

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21. At the home side, put a marking at the point where the rib on the frame is in 24. Release the cables from the wire saddle of the Waste Ink Joint Tube Assy.
contact with the Right PG Adjust lever.
Do not route the cables of the PF/ASF/Pick UP Roller Motor/
Align the marking on the Right PG Adjust lever with the rib on the Solenoid through the wire saddle on the Waste Ink Joint Support.
frame (refer to Figure 2-206).
25. Remove the two screws (S15) that secure the Waste Ink Joint Support.
Waste Ink Joint Support PF / ASF / Pick UP Roller

Right PG Adjust Lever Wire saddle Motor / Solenoid cable
Rib Marking
Figure 2-206. Marking on the Right PG Adjust Lever S15
22. Loosen the screw, slide the Right PG Adjust Lever to the front.
Figure 2-208. Removing the Waste Ink Joint Support
23. Remove the three screws (S15), and remove the Pump Unit Support.
Pump Unit Support

Screw

S15
Figure 2-207. Removing the Pump Unit Support

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26. Remove the three screws (S15), and remove the Pump Unit. 2.3.6.18 Waste Ink Joint Tube Assy
27. Peel off a piece of the acetate tape.
28. By holding the Tube Clamp, disconnect the Waste Ink Tube connected to the
Waste Ink Joint Tube Assy from the Pump Unit.
29. Remove the Waste Ink Joint.
Acetate tape
Tube Clamp Waste Ink Tube
Waste Ink Joint 1. Remove the Panel Assy. (P.70)

Waste Ink Joint 6. Remove the Panel Lower Front Cover. (P.73)
Tube Assy
S15
Figure 2-209. Removing the Pump Unit
Carry out the adjustments referring to "3.1 Required 14. Remove the Ferrite Core Holder.(P.74)
Adjustments" (p279) when the Pump Unit is removed or replaced.
16. Remove the Maintenance Box. (P.64)

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17. Remove the USB/FAX Cover. (P.97) 20. Pull out the Waste Ink Tube of the Waste Ink Joint Tube Assy from the Pump
18. Remove the Main Board Unit. (P.99) Unit.
19. Remove the three screws (S5), and remove the Waste Ink Joint Tube Assy. Insert the Waste Ink Tube into the Waste Ink Joint Tube Assy
according to the standard below.
Upper
Waste Ink Tube
0~5mm
Waste Ink Tube
S5
Figure 2-210. Removing the Waste Ink Joint Tube Assy
Figure 2-211. Removing the Waste Ink Tube

Adjustments" (p279) when the Waste Ink Joint Tube Assy is
removed or replaced.

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2.3.6.19 Print Head / Ink Supply Unit 18. Disconnect the Relay FFC (BK) from the connector (CN1) of the CSIC Board
(When the printer cannot perform Ink Flushing by (BK).
fatal error) 19. Remove the screw (S5), and remove the Fixing plate.
When replacing the Print Head / Ink Supply Unit, you must
perform the Ink Flushing to prevent the Ink dropping from Ink CN1 Fixing Plate
Tube Connector. CSIC Board
However, Printer can not perform Ink Flushing when Printer is (BK)
error condition.
Therefore, when Printer can not perform Ink Flushing by fatal
error, perform the repair operation by the following procedure.

4. Remove the Right ADF Hinge Cover. (P.68) Relay FFC (BK)
5. Remove the ADF/Scanner Unit. (P.216) S5
6. Remove the Panel Lower Front Cover. (P.73) Figure 2-212. Releasing the FFC / Removing the Fixing Plate
7. Remove the Right Upper Front Cover. (P.73) 20. Peel off the Double side tape of Relay FFC (BK).

13. Release the Ink Supply BK Assy. (P.201)
14. Release the Ink Supply CL Assy. (P.203)
16. Remove the Panel FFC.(P.74) Double Side Tape
Figure 2-213. Releasing the Relay FFC (BK)

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21. Remove the CSIC Board (BK) Cover. 23. Release the Clamp (x2) and put the FFC in the Ink Supply BK Assy Side.
24. Release the Ink Tube (Y/M/C) from Tube Clamp.
FFC
Clamp
Tube Clamp
Remove the Ink Tube from
cut line of the Tube Clamp.
CSIC Board (BK) Cover
Ink Tube (Y/M/C)
Figure 2-214. Removing the CSIC Board (BK) Cover.
22. Disconnect the FFC from Connector (CN5) of the CSIC Board (BK).
25. Rotate the connector of the Ink Tube in the direction of the counterclockwise, and
FFC
remove the Ink Tube (x4) from the Ink Supply Unit.
Ink Tube
CN5
Figure 2-215. Disconnecting the FFC from CSIC Board (BK).
Figure 2-217. Removing the Ink Tube

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26. Ink is sealed by tube clip at the tip of removed Ink Tube. 28. Releasing the Cable from hooks of the Ink Supply Unit.
Tube Clip
Cable
Ink Tube Ink Tube

(BK/Y) (M/C)
Figure 2-218. Clipping the Ink Tube Figure 2-220. Releasing the Cable
27. Remove the screw (S16), and remove the Left Tube Clip from the Ink Supply 29. Remove the connector from the Ink End Board.
Unit.
Left Tube Clip
Ink End Board
Figure 2-221. Removing the Ink End Connector

S16
Figure 2-219. Removing the Left Tub Clip

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30. Remove the Pump Tube (x2). 33. Remove the two screws (S15).
31. Remove the Ferrite Core (x4) from the Ink Supply Unit.
Pump Tube
Ferrite Core
S15
Figure 2-222. Removing the Ferrite Core and Pump Tube Figure 2-224. Removing the Ink tube Connector
32. Disengage the hook, and release the Ink Tube from the Upper Supply Tube 34. Remove the FFC from connector of the CR Encoder Sensor.
Holder. 35. Remove the four screws (S23: 3pcs, S30: 1pcs), and remove the Print Head from
CR Unit.
FFC
Clamp
Hook Ink Tube

FFC
CSIC Holder
Clamp

S23
S30
Figure 2-225. Removing the Print Head

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36. Remove the Head FFC from Print Head. 38. Remove the Ink Supply Assy (Ink Supply Unit and Print Head).
Print Head
Head FFC
Head FFC Figure 2-228. Removing the Ink Supply Assy
Regarding next procedure, make sure to put down plastic sheet or

cloth, because ink may drop from Connector of Ink Tube and Print
Head.
Figure 2-226. Removing the Head FFC
37. Release the Clamp, and slide the FFC Holder in the direction of arrow.
39. Clip the Ink Tube by the Tube Clip like the following picture.
Tube Clip
Ink Tube
FFC Holder
Figure 2-227. Removing the FFC Holder.
Figure 2-229. Removing the Ink Tube Connector (1)

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40. Remove the two screws (S2), and remove the Ink Tube Connector.
Make sure not to adhere the ink to the Connector of the Print
Head, because ink may drop when removing the Ink Tube
Connector from Print Head.
S2
Figure 2-230. Removing the Ink Tube Connector (2)
Regarding the procedure of the reassembly and adjustment after

disassembly, refer to following procedure.
"2.3.6.1 Print Head" (p114)
"2.3.6.15 Ink Supply Unit" (p148)

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2.3.7 Paper Feed Mechanism 2.3.7.2 Rear Cover Control Lever
2.3.7.1 Rear Cover Assy/Rear Cover Belt
Rear Cover Belt
Rear Cover Belt
Rear Cover Assy 2. Disengage the hook, and remove the Rear Cover Control Lever.
1. Open the Rear Cover Assy. Hook
2. Remove the four screws (S5), and remove the two Rear Cover Belt.
3. Disengage the two tabs of the Rear Cover Assy, and remove the Rear Cover Assy.
Tab
Figure 2-232. Removing the Rear Cover Control Lever
Tab
S5
Figure 2-231. Removing the Rear Cover Assy/Rear Cover Belt

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2.3.7.3 Duplex Unit 2.3.7.4 PF Encoder Sensor Assy

2. Remove the Duplex Unit. 1. Remove the Panel Assy. (P.70)
Carry out the adjustments referring to "3.1 Required 2. Remove the Paper Support Support. (P.66)
Adjustments" (p279) when the Duplex Unit is replaced. 3. Remove the Left ADF Hinge Cover. (P.67)

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16. Remove the screw (S16). 2.3.7.5 Pick Up Roller Motor Assy
S16
Figure 2-233. Removing the PF Encoder Sensor Assy (1)
17. Disconnect the FFC from the connector of the PF Encoder Sensor Assy.
18. Press the tab on the PF Encoder Sensor Assy, and remove the PF Encoder Sensor For the screw types, see 2.1.1.1 Screw types used in the printer (p41).
Assy by sliding it in the direction of the arrow to remove it.
Inner
Tab 4. Remove the Right ADF Hinge Cover. (P.68)
Figure 2-234. Removing the PF Encoder Sensor Assy (2) 12. Remove the Ink Supply CL Cover Assy. (P.197)

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15. Remove the Middle Housing. (P.86) 18. Disconnect the motor cable from the relay connector.
16. Remove the Power Supply Unit. (P.111) 19. Disconnect the sensor cable from the connector.
17. Remove the Pick UP Roller Gear. 20. Release the Ferrite Core.
Sensor cable
Pick UP Roller Gear
Relay connector
Ferrite Core
Ferrite Core
Motor cable
Figure 2-235. Removing the Pick UP Roller Gear
Figure 2-236. Releasing the cables

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21. Remove the four screws (S15), and remove the Pick Up Roller Motor Assy. 2.3.7.6 PF Tension Stopper
S15 2. Remove the Paper Support Support. (P.66)
Figure 2-237. Removing the Pick Up Roller Motor Assy
Carry out the adjustments referring to "3.1 Required 4. Remove the Right ADF Hinge Cover. (P.68)
Adjustments" (p279) when the Pick Up Roller Motor Assy is
15. Remove the Middle Housing. (P.86).

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2.3.7.7 PF Timing Belt

PF Drive Pulley Holder
Figure 2-238. PF Tension Stopper

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PF Roller
PF Timing Belt
Figure 2-239. Marking on the PF Tension Stopper PF Tension Lever

16. Loosen the screw that secures the PF Tension Stopper. Figure 2-241. Removing the PF Timing Belt
17. Disengage the leg on the PF Tension Stopper from the frame, and slide the PF
The tension adjustment of the PF timing belt is a self
Tension Stopper to the rear.
adjustment.when the PF Timing Belt is removed or replaced, the
adjustment is not necessary.
Screw Leg
Figure 2-240. Sliding the PF Tension Stopper

18. Press down the PF Tension Lever to release the tension of the PF Timing Belt.
19. Remove the PF Timing Belt from the PF Roller.

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2.3.7.8 PF Motor Assy 15. Remove the Middle Housing. (P.86)

17. Remove the Pick Up Roller Motor Assy. (P.176)
For the screw types, see 2.1.1.1 Screw types used in the printer (p41). Figure 2-242. Marking on the PF Tension Stopper
18. Loosen the screw that secures the PF Tension Stopper.
19. Disengage the leg on the PF Tension Stopper from the frame, and slide the PF
Tension Stopper to the rear.
20. Remove the PF Timing Belt from the PF Drive Pulley Holder.
5. Remove the ADF/ Scanner Unit. (P.216) PF Drive Pulley Holder
PF Timing Belt
12. Remove the Ink Supply CL Cover Assy. (P.197) Screw Leg
13. Remove the Front Housing. (P.75) Figure 2-243. Releasing the PF Timing Belt

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21. Disconnect the cables from the two relay connectors, and release them from the 2.3.7.9 PE Sensor
clamp.
22. Remove the four screws (S15), and remove the PF Motor Assy.
Front
S15
Cable
Clamp
Relay Connectors
S15 12. Remove the Ink Supply CL Cover Assy. (P.197)

Figure 2-244. Removing the PF Motor Assy
Adjustments" (p279) when the PF Motor Assy is removed or 15. Remove the Middle Housing. (P.86)
replaced. 16. Remove the USB/FAX Cover. (P.97)
18. Remove the Rear ASF Unit. (P.188)

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19. Remove the Power Supply Unit. (P.111) 26. Remove the four screws (S15).
20. Disconnect the two tubes of the Decompression Motor Assy.
21. Pull out the two tubes of the Decompression Motor Assy from the wire saddle.
22. Release the motor cable from the clamp (Yellow).
23. Disconnect the sensor cable from the relay connector, and release the two clamps
Relay
(Magenta).
24. Disconnect the Decompression Motor Assy Cable and relay cable from the three
relay connectors.
25. Release the Decompression Motor Assy Cable and relay cable from the three
clamps (Green). Motor cable
Sensor
Wire saddle
Tubes of the Decompression

Motor Assy
Relay
connector
Relay connector
Relay connector
Pump Fixing Plate Assy
Decompression Motor
Clamp Assy Cable and relay cable S15
Figure 2-245. Removing the Pump Fixing Plate Assy (1)

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27. Slide the Pump Fixing Plate Assy. 29. Remove the four screws (S15), and remove the four Upper Paper Guide Holder.
30. Remove the two E-ring that secure the bushes of the Upper Paper Guide Roller.
31. Release the tab (one each) on the two bushes from the positioning holes on the
frame.
Bush
Positioning hole
E-ring
Pump Fixing Plate Assy
Figure 2-246. Removing the Pump Fixing Plate Assy (2)
Upper Paper
Guide Holder
Upper Paper Upper Paper

Guide Holder Guide Holder S15
Figure 2-247. Removing the Upper Paper Guide Holder

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32. Remove the pin part of the Upper Paper Guide Roller from the groove of the 35. Remove the Front Paper Guide Cover by sliding it in the direction of the arrow.
Release Shaft Holder.
33. Remove the Upper Paper Guide Roller.
Front Paper Guide Cover

Pin part
Upper Paper Guide Roller
Release Shaft
Holder
Figure 2-250. Removing the Front Paper Guide Cover
36. Disconnect the cable from the connector of the sensor.
Figure 2-248. Removing the Upper Paper Guide Roller
37. Disengage the four hooks, and remove the PE Sensor.
34. Remove the ten screws (S19), and remove the two Left Paper Guide, Middle Paper
Guide and two Right Paper Guide.
Middle Paper Guide Left Paper Guide Connector

Cable
Right Paper Guide
Hooks
Figure 2-251. Removing the PE Sensor
S19 Carry out the adjustments referring to "3.1 Required

Adjustments" (p279) when the PE Sensor is removed or replaced.
Figure 2-249. Removing the Left Paper Guide / Middle Paper Guide / Right Paper Guide

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2.3.7.10 PF Sensor 17. Disconnect the cable from the connector.
Connector
Cable
Figure 2-252. Removing the PF Sensor Holder (1)
3. Remove the Left ADF Hinge Cover. (P.67) Remove the PF Sensor Holder in the direction of the arrow while pushing the tab of the
PF Sensor Holder.
6. Remove the Panel Lower Front Cover. (P.73) Tab
14. Remove the Ferrite Core Holder.(P.74) PF Sensor Holder
15. Remove the Middle Housing. (P.86) Figure 2-253. Removing the PF Sensor Holder (2)

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18. Disengage the four hooks, and remove the PF Sensor. 2.3.7.11 Star Wheel Assy
Hooks
Figure 2-254. Removing the PF Sensor

Adjustments" (p279) when the PF Sensor is removed or replaced. 1. Remove the Panel Assy. (P.70)

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14. Remove the Ferrite Core Holder.(P.74) 2.3.7.12 Rear ASF Unit
17. Remove the two screws (S15), and remove the Star Wheel Assy.

S15
Figure 2-255. Removing the Star Wheel Assy
Adjustments" (p279) when the Star Wheel Assy is removed or 5. Remove the ADF/ Scanner Unit. (P.216)
replaced. 6. Remove the Panel Lower Front Cover. (P.73)

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16. Remove the USB/FAX Cover. (P.97) Sensor
cable
Relay
connector
19. Release the Tube (Y/M/C), and secure the Ink Supply CL Assy. (P.157)
20. Disconnect the ASF Sensor Cable, relay cable 1, and relay cable 2 from the two Relay cable 2
relay connectors.
21. Release the relay cable 2 from the Rear ASF Unit.
22. Remove the two screws (S5), and remove the two Cable Clamp.
23. Remove the four screws (S15: 2 pcs, S24: 2 pcs), and remove the Rear ASF Unit. S24
Place the Rear ASF Unit as shown below to prevent the damage of
the Sheet Guide.
Relay
connector
Cable Clamp
Relay cable 2
Sheet Guide S5
Cable Clamp
S15
Figure 2-256. Removing the Rear ASF Unit

Adjustments" (p279) when the Rear ASF Unit is removed or
replaced.
When replacing should initialize it with Maintenance counter of
adjustment Program.

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2.3.7.13 Sheet Guide 13. Remove the Front Housing. (P.75)

20. Peel off the Sheet Guide.
For the screw types, see 2.1.1.1 Screw types used in the printer (p41). No cutout Hooks
Peel off the backing sheet of the sheet guide . paste the No cutout
sheet guide under the hook according to the reamer
reference position . Base line

Figure 2-257. Removing the Sheet Guide
6. Remove the Panel Lower Front Cover. (P.73) Apply the Sheet Guide with the side without any cutout to the
hooks. (refer to (Figure 2-257))

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2.3.7.14 Rear ASF Solenoid Assy 18. Remove the two screws (S5), and remove the Rear ASF Solenoid Assy.
Relay connector
Cable
2. Remove the Paper Support Support. (P.66) Figure 2-258. Removing the Rear ASF Solenoid Assy
17. Disconnect the Rear ASF Solenoid Assy Cable from the relay connector.

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2.3.7.15 Rear ASF Solenoid Gear Assy
Tab
Hook
Figure 2-259. Removing the Rear ASF Solenoid Gear Assy
17. Disengage the hook and while releasing the tab on the actuator, remove the Rear
ASF Solenoid Gear Assy.

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2.3.7.16 Rear ASF PE Sensor 18. Remove the Power Supply Unit. (P.111)
19. Remove the Rear ASF Solenoid Assy. (P.191)
22. Press down the Hopper, and remove the Rear ASF Frame Assy.
Hopper
4. Remove the Right ADF Hinge Cover. (P.68) Rear ASF
Frame Assy
6. Remove the Panel Lower Front Cover. (P.73) S5
7. Remove the Right Upper Front Cover. (P.73) Figure 2-260. Removing the Rear ASF Frame Assy
23. Disconnect the cable from the connector of sensor.
24. Disengage the four hooks, and remove the Rear ASF PE Sensor.

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Connector
Cable
Hooks
Figure 2-261. Removing the Rear ASF PE Sensor

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2.3.8 Ink Supply Mechanism

2.3.8.1 Ink Supply BK Cover Assy Stopper
Stopper
S5
Inner
For the screw types, see 2.1.1.1 Screw types used in the printer (p41). Cover
1. Open the Ink Supply BK Cover Assy.
3. Remove the two Stopper from the two tabs of the Inner Cover. Tab
Figure 2-262. Removing the Ink Supply BK Cover Assy (1)

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4. Remove the four screws (S5), and remove the two Cover Hinge. 5. Remove the Ink Supply BK Cover Assy upward.
Take extra care not to lose the Cover Hinge.
Cover Hinge
Cover Hinge
S5

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2.3.8.2 Ink Supply CL Cover Assy

Stopper
Stopper
S5
For the screw types, see 2.1.1.1 Screw types used in the printer (p41). Inner
Cover
1. Open the Ink Supply CL Cover Assy.
3. Remove the two Stopper from the two tabs of the Inner Cover.
Tab
Figure 2-265. Removing the Ink Supply CL Cover Assy (1)

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4. Remove the four screws (S5), and remove the two Cover Hinge. 5. Remove the Ink Supply CL Cover Assy upward.
Take extra care not to lose the Cover Hinge.
Cover Hinge
Cover Hinge
S5

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2.3.8.3 Ink Supply BK Cover Open Sensor 4. Disengage the hook of the sensor using the flat-head screwdriver.
5. Disengage the cable from the connector.
Cable
Hook Connector
For the screw types, see 2.1.1.1 Screw types used in the printer (p41). Figure 2-269. Removing the Ink Supply BK Cover Open Sensor (2)
1. Open the Ink Supply BK Cover Assy. (P.195)

3. Disengage the hook, remove the Switch Cover.
Switch Cover Hook
S5
Figure 2-268. Removing the Ink Supply BK Cover Open Sensor (1)

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2.3.8.4 Ink Supply CL Cover Open Sensor 4. Disengage the hook of the sensor using the flat-head screwdriver.
5. Disengage the cable from the connector.
Cable
Hook Connector
For the screw types, see 2.1.1.1 Screw types used in the printer (p41). Figure 2-271. Removing the Ink Supply CL Cover Open Sensor (2)
1. Open the Ink Supply CL Cover Assy. (P.197)

3. Disengage the hook, remove the Switch Cover.
Switch Cover Hook
S5
Figure 2-270. Removing the Ink Supply CL Cover Open Sensor (1)

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2.3.8.5 Ink Supply BK Assy 13. Remove the Ink Supply CL Cover Assy. (P.197)
17. Rotate the joint 90 degrees counterclockwise and disconnect the Tube (BK) from
the Ink Supply Unit. Keep the ends of tube up after removal.
Tube (BK)

2. Remove the Panel Assy. (P.70) Figure 2-272. Releasing the Tube (BK)
4. Remove the Left ADF Hinge Cover. (P.67) When removing the tube. Replace to new Packing.
5. Remove the Right ADF Hinge Cover. (P.68) There is the packing in the tube or on the ink supply unit.
6. Remove the ADF/ Scanner Unit. (P.216) packing
Wide
Ink Supply Unit

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18. Disconnect the FFC from the connector (CN1) of the CSIC Board (BK), and peel 22. Disengage the two hooks of the Inner Cover.
off the Relay FFC (BK).
To prevent the Tube (BK) from being folded, check the state of the
19. Disengage the six hooks, and remove the CSIC Board Cover. Tube (BK) shown in the figure below after installing the Ink
Supply BK Assy.
Hooks
Guide
CN1
Hooks
CSIC Board Cover
No Good OK
Relay FFC (BK)

Guide
Hook

20. Disconnect the CSIC FFC (BK) from the connector (CN2) of the CSIC Board
(BK).
No Good OK
CSIC Board (BK)

No Good OK
CN2
? 2-274. Releasing the FFC (2)
21. Remove the two screws (S5) that secure the Inner Cover of the Ink Supply BK
Assy.

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2.3.8.6 Ink Supply CL Assy
No Good OK
No Good OK


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13. Remove the Ink Supply CL Cover Assy. (P.197) 18. Release the Tube (Y/M/C) from the clamp.
14. Remove the Front Housing. (P.75) 19. Release the Tube (Y/M/C) from the Left Tube Clip.
16. Remove the Middle Housing. (P.86) Clamp
17. Rotate the joint 90 degrees counterclockwise and disconnect the Tube (CL) from Tube (M)
the Ink Supply Unit. Keep the ends of tubes up after removal.
Tube (Y)
Tube (Y/M/C)
Tube (C)
Left Tube Clip
When removing the tube. Replace to new Packing.

There is the packing in the tube or on the ink supply unit.
packing
Wide
Ink Supply Unit

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20. Release the Tube (Y/M/C) from the three tube clips. 21. Disengage the two hooks, and remove the Right Upper Tube Guide.
Right Upper Groove
Tube Guide
Tube Clip Marking Tube
Hooks
23. Remove the Right Lower Tube Guide, and release the Right Lower Tube Guide
(Y/M/C).
Tube Clip
Right Lower
Tube Guide

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24. Disconnect the FFC from the connector (CN1) of the CSIC Board (CL).
Route the Tube (CL) as sown below.
Right Upper Tube Guide
CSIC Board (CL)
CL1
Left Tube Clip
FFC Ink Supply Unit
Do not install FFC pressing it.
To prevent the Tube (CL) from being folded, check the state of
the Tube (CL) shown in the figure below after installing the
Ink Supply CK Assy.
25. Remove the Ink Supply CL Assy.
No Good OK

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2.3.8.7 Ink Pack Holder (BK)
S16
S33
Figure 2-281. Removing the Ink Pack Holder

3. Remove the Inner Cover. (P.75)
4. Remove the Tube (BK) and CSIC FFC (BK) from the Ink Supply Unit. (P.201)
5. Remove the four screws (S16: 2 pcs, S33: 2 pcs), and remove the Ink Pack Holder
(BK).

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2.3.8.8 Ink Pack Holder (Y/M/C) 5. Disconnect the FFC from the connector of the CSIC Board (CL).
Y CSIC Board (CL)
Figure 2-282. Removing the Ink Pack Holder (1)
The following explains how to disassemble the Ink Pack Holder (Y).
The Ink Pack Holder (M/C) can be disassembled in the same
manner.

3. Remove the Inner Cover. (P.75)
4. Release the Tube (Y/M/C) from the printer. (P.203)

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6. Remove the four screws (S16: 2 pcs, S33: 2 pcs), and remove the Ink Pack holder 2.3.8.9 Tube
(Y) upward.
S16 For the screw types, see 2.1.1.1 Screw types used in the printer (p41).
S33 1. Perform the “Ink Flushing” with Adjustment Program.(P.62)

2. Remove the Ink Supply Cover Assy. (P.195, P.197)
3. Remove the Inner Cover. (P.75, P.78)
4. Remove the Ink Pack Holder. (P.207, P.208)
5. Press the joint as shown below as far as it will go.
Joint
Figure 2-283. Removing the Ink Pack Holder (2)
Figure 2-284. Removing the Tube (1)

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6. Remove the screw (S5), and remove the Ink Supply Tube Assy vertically. 7. The tube is removed from the tube folder.
1→2:The elbow holder is turned and it removes.
Attach the two tabs to the two positioning holes of the Ink Supply 3→4:Needle ASSY is turned and it separates with the ink tube.
Tube Assy. (Figure 2-285)
Hook
1 2 Hook
Spring
Tab and
3 4
positioning hole
フック 8. The direction of packing

S5 Replace new the packing according to the under figure.
Figure 2-285. Removing the Tube (2) Packing
Tube
Φnarrow Φwide
Needle Assy

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2.3.8.10 CSIC FFC 4. Remove the three screws (S35).
For the CSIC FFC (BK), remove the four screws (S35).
S35
1. Remove the Ink Supply Cover Assy. (P.195, P.197)

2. Remove the Inner Cover.(P.75, P.78)
3. Remove the Ink Pack Holder. (P.207, P.208)
S35
Figure 2-286. Removing the CSIC FFC (1)

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In the following step, take extra care because the three springs will
pop out then.
Frame Slider Plate

5. Insert the flat-head screwdriver, and lift the frame.
6. Remove the Slider Plate.
Set the three springs as shown in the figure below.
Springs

7. Disengage the hook, and remove the CSIC FFC.
Hook

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2.3.8.11 Relay FFC (BK) 17. Remove the (S5), and remove the Fixing Plate.
CN1 Fixing Plate

CSIC Board
(BK)
Relay FFC (BK)


2. Remove the Paper Support Support. (P.66) Figure 2-289. Removing the Relay FFC (BK) (1)

(BK).

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18. Peel off the Relay FFC (BK). 2.3.8.12 Relay FFC (CL)
Ferrite Core
Figure 2-290. Removing the Relay FFC (BK) (2)

20. Remove the Gasket, pull out the Relay FFC (BK) from the hole of the frame.
21. Disconnect the Relay FFC (BK) from the connector (CN2) of the Relay Board.
22. Peel off the Relay FFC (BK).
Relay Board Hole
CN2 8. Remove the Stacker Assy. (P.66)
Gasket 9. Remove the Cassette Assy. (P.244)
Figure 2-291. Removing the Relay FFC (BK) (2)

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16. Pull the FFC from the Ferrite Core. 17. Disconnect the Relay FFC (CL) from the connector (CN3) of the Relay Board.
Relay Board
CN3
Figure 2-293. Removing the Relay FFC (CL) (2)
Ferrite Core
Figure 2-292. Removing the Relay FFC (CL) (1)

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2.3.9 ADF/ Scanner Unit

2.3.9.1 ADF/ Scanner Unit
S5
Back
1. Open ASF Unit

2. Remove the Paper Support. (P.66)
4. Remove the Right ADF Hinge Cover. (P.68) S5
Figure 2-294. Removing the ADF/ Scanner Unit (1)

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6. Narrow the Paper Guide of the Rear ASF Unit.

Align with this line.
Paper Guide
ADF Unit

7. Place the ADF/Scanner Unit as shown below. Main Board
8. Disconnect the FFC of the ADF/ Scanner Unit from the connector of the Main FFC
Board.
9. Remove the ADF/ Scanner Unit.
110mm
When placing the ADF/Scanner Unit, be careful of the following.

Close the ADF Unit, and place it horizontally.
Make sure not to damage the cables and FFC on the bottom of
the ADF/Scanner Unit.

Adjustments" (p279) when the ADF/ Scanner Unit is removed or
replaced.

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2.3.9.2 ADF Unit 6. Disconnect the ADF/SCN FFC from the connector of the ADF/ Scanner Board.
ADF/SCN FFC
ADF/ Scanner Board
Figure 2-297. Removing the ADF/SCN FFC

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7. Disconnect the cables and FFC from the connectors on the ADF/Scanner Board. 8. Release the cables and FFC from the ADF/ Scanner Cable Support.
9. Remove the three screws (S5), and remove the ADF/ Scanner Cable Support.
Cables FFC
CN21 CN31 CN36 CN38 CN42
CN22 CN32 CN37 CN130 CN43
CN37 CN22 CN21 CN32

CN38 CN31
CN130
CN36
CN42
ADF/ Scanner
Board
ADF/ Scanner
Cable Support
CN43
Figure 2-298. Removing the ADF Unit (1)
S5

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10. Open the ADF Unit.

When installing the ADF/Scanner Cable Support, be careful of the
11. Release the hooks that secure the Left Hinge and the Right Hinge with the flat- following.
head screwdriver from the bottom of the Scanner Unit, and remove the ADF Unit Route the cables through the guide on the Lower Cable Holder.
upward.
Guide
Bottom of the
Scanner Unit Cable
Flat-head
Hook screwdriver
Lower Cable Holder
ADF Unit Before installing the ADF/Scanner Cable Support, route the
FFC (CN42) on the Scanner Unit.
FFC (CN42)
Left Hinge
Scanner Unit
Right Hinge
Scanner Unit

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Pull out the FFC (CN42) from the slit on the ADF/Scanner 2.3.9.3 ADF Cover Assy
Cable Support.
Slit
FFC (CN42)
ADF/ Scanner
Cable Support
1. Open the ADF Cover Assy.

2. Disengage the two tabs, and remove the ADF Cover Assy.
Tab
Tab
Figure 2-301. Removing the ADF Cover Assy

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2.3.9.4 Rear ADF Cover/ Rear Sub ADF Cover
Rear Sub ADF Cover
S15
Rear ADF Cover
For the screw types, see 2.1.1.1 Screw types used in the printer (p41). S5
1. Open the Top ADF Document Support Assy. (P.241) Figure 2-302. Removing the Rear ADF Cover/ Rear Sub ADF Cover (1)
2. Open the ADF Cover Assy. (P.221) 4. Disengage the three hooks, and remove the Rear ADF Cover and Rear Sub ADF
Cover.
3. Remove the three screws (S5: 2 pcs, S15: 1 piece).
Left Right
Hooks
Hook
Figure 2-303. Removing the Rear ADF Cover/ Rear Sub ADF Cover (2)

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5. Remove the screw (S5), and remove the Rear Sub ADF Cover from the Rear ADF 2.3.9.5 Front Sub ADF Cover/ Front Main ADF Cover
Cover.
Front Sub ADF Cover
S5 Front Main ADF Cover
Figure 2-304. Removing the Rear Sub ADF Cover For the screw types, see 2.1.1.1 Screw types used in the printer (p41).
1. Open the ADF Unit.
2. Remove the screw (S5), and remove the Front Sub ADF Cover.
ADF Unit
S5
Figure 2-305. Removing the Front Sub ADF Cover

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3. Open the ADF Cover Assy. 5. Disengage the four hooks, and remove the Front Main ADF Cover.
4. Remove the four screws (S3: 1 pcs, S5: 3 pcs) that secure the Front Main ADF
Cover. Hooks
ADF Cover Hooks

Assy
S3
Hook
S5
Figure 2-306. Removing the Front Main ADF Cover (1) Hooks
Figure 2-307. Removing the Front Main ADF Cover (2)

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2.3.9.6 Document Cover Mat Assy 2.3.9.7 ADF Pad Assy
1. Disengage the two hooks and the two tabs, and remove the ADF Pad Assy.
2. Peel off the Document Cover Mat Assy.
Tabs
Hook
Hook
Figure 2-308. Removing the ADF Pad Assy

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2.3.9.8 ADF Cover Microswitch 3. Remove the two screws (S5: 1 piece, S8: 1 piece) that secure the Right ADF Base
Gear Cover to the Base Plate.
Right ADF Base Gear Cover
S8
Base Plate S5
Figure 2-310. Removing the ADF Cover Microswitch (2)
4. Remove the three screw (S1: 1 piece, S8: 2 pcs) while pulling up the Right ADF
For the screw types, see 2.1.1.1 Screw types used in the printer (p41). Base Gear Cover.
1. Remove the Front Sub ADF Cover/ Front Main ADF Cover. (P.223)
2. Remove the two screws (S5). Right ADF Base Gear Cover
S8
S1
S5

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5. Disconnect the cable from the connector of the sensor. 2.3.9.9 ADF PF Encoder Sensor
In the next step, be careful not to drop gears.
6. While moving the Right ADF Base Gear Cover aside slightly and remove the ADF
Cover Microswitch.
Gear
Right ADF Base
Gear Cover
1. Remove the Front Sub ADF Cover/ Front Main ADF Cover. (P.223)
Cable
Connector
Cable Connector
Figure 2-313. Removing the ADF PF Encoder Sensor (1)

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3. While moving Right ADF Base Gear Cover aside and hold it there, remove the 4. Remove the ADF PF Encoder Sensor.
Encoder Holder by disengaging the hook on it.
Set the sensor with the encoder in between. (refer to (Figure
2-315))
Set the sensor into the groove on the Encoder Holder.
Encoder Holder
Set the Encoder Holder into the groove on the Right ADF Base
Gear Cover.
Groove of the
Hook Encoder Holder
Right ADF Base
Gear Cover
Right ADF Base Gear Cover
Figure 2-314. Removing the Encoder Holder Encoder Holder
Encoder
Figure 2-315. Removing the ADF PF Encoder Sensor (2)

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2.3.9.10 ADF LD Assy 2. Remove the four screws (S5).

3. Remove the ADF Pick Up Roller Assy from the six hooks of the ADF Housing
Upper.
ADF Pick Up Hook

ADF Housing Upper
Roller Assy
Hook
1. Remove the ADF Cover Assy. (P.221) Hooks
Hooks S5
Figure 2-316. Removing the ADF LD Assy (1)

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4. Pull out the LD Shaft in the direction of the arrow. 6. Remove the ADF LD Assy from the hole of the ADF Pick Up Roller Assy.
5. Remove the Extension Spring.
Extension ADF Pick Up

Spring Roller Assy
LD Shaft
Hole
Figure 2-318. Removing the ADF LD Assy
Figure 2-317. Removing the LD Shaft

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Set the shaft of the ADF Cover Open Lever into the bearing. 2.3.9.11 ADF PF Support Guide
Bearing
ADF Cover Open Lever
1. Open the ADF Cover Assy. (P.221)

Shaft
2. Disengage the two tabs, and remove the ADF PF Support Guide.
Tab
Tab
Figure 2-319. Removing the ADF PF Support Guide

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2.3.9.12 ADF Side Cover/ ADF Paper End Side Cover

Back
ADF Paper End Side Cover
S5
ADF Side Cover S15

S5
For the screw types, see 2.1.1.1 Screw types used in the printer (p41). Figure 2-320. Removing the ADF Side Cover
4. Disengage the two tabs, and remove the ADF Paper End Side Cover.
1. Remove the Rear ADF Cover. (P.222)
2. Open the ADF Paper End Side Cover.
Tab
3. Remove the three screws (S5: 2 pcs, S15: 1 piece) and remove the ADF Side
Cover and ADF Paper End Side Cover.
Tab
Figure 2-321. Removing the ADF Paper End Side Cover

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2.3.9.13 ADF PE Sensor A
S5 ADF Base Unit
Bottom
2. Remove the Paper Support Support. (P.66) S8
S5
Figure 2-322. Removing the ADF Base Unit
6. Remove the ADF Unit. (P.218)
7. Remove the Top ADF Document Support Assy. (P.241)
8. Remove the five screws (S5: 4 pcs, S8: 1 piece), and remove the ADF Base Unit.

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9. Remove the three screws (S1: 1piece, S8: 2 pcs). 15. Disengage the two ribs, and remove the Left ADF Base Gear Cover.
10. Remove the E-ring and spacer.
11. Disconnect the cable from the connector of the sensor. Back Rib
Left ADF Base

E-ring and spacer Gear Cover
Connector
Left ADF Base Gear Cover
Rib
S8
Cable S1
Figure 2-323. Removing the Left ADF Base Gear Cover (1)
12. Peel off the two FFCs.
13. Peel off the acetate tape.
14. Release the cables from the hook of the Left ADF Base Gear Cover. Figure 2-325. Removing the Left ADF Base Gear Cover (3)
16. Remove the ADF PE Sensor A.
Left ADF Base Gear Cover
Cable
Hook
FFC
Acetate tape Figure 2-326. Removing the ADF PE Sensor A
Figure 2-324. Removing the Left ADF Base Gear Cover (2)

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2.3.9.14 ADF PW Sensor A

Hooks
Connector
Cable
Figure 2-327. Removing the ADF PW Sensor A
8. Remove the Bottom ADF Document Support. (P.243)
9. Disengage the four hooks, and remove the ADF PW Sensor A.

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2.3.9.15 ADF PW Sensor B
Connector
Cable
Hooks
Figure 2-328. Removing the ADF PW Sensor B
9. Disengage the four hooks, and remove the ADF PW Sensor B.

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2.3.9.16 ADF Document Detection Sensor A
Connector
Cable
Hooks
For the screw types, see 2.1.1.1 Screw types used in the printer (p41). Figure 2-329. Removing the ADF Document Detection Sensor A
10. Disengage the four hooks, and remove the ADF Document Detection Sensor A.

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2.3.9.17 ADF Document Detection Sensor B
Connector
Cable
Hooks
Figure 2-330. Removing the ADF Document Detection Sensor B
10. Disengage the four hooks, and remove the ADF Document Detection Sensor B.

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2.3.9.18 Right ADF Hinge 8. Remove the four screws (S9).
S9
Figure 2-331. Removing the Right Hinge (1)
9. Remove the four screws (S12), and remove the Right Hinge from the Right ADF
1. Remove the Panel Assy. (P.70) Hinge Frame.
Right ADF
Hinge Frame
S12
Figure 2-332. Removing the Right Hinge (2)

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2.3.9.19 Left ADF Hinge 8. Remove the five screws (S9: 4 pcs, S13: 1 piece).
S9
S13
Figure 2-333. Removing the Left Hinge (1)
9. Remove the four screws (S12), and remove the Left Hinge from the Left ADF
Hinge Frame.
3. Remove the Left ADF Hinge Cover. (P.67) Left ADF
Hinge Frame
S12
Figure 2-334. Removing the Left Hinge (2)

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2.3.9.20 Top ADF Document Support Assy
Hook
Hook
Lower Cable Holder
Figure 2-335. Removing the Lower Cable Holder
For the screw types, see 2.1.1.1 Screw types used in the printer (p41). 11. Release the cables of the Top ADF Document Support Assy.

6. Remove the ADF Unit. (P.218) Cables of the Top ADF
Document Support Assy
7. Remove the ADF Cover Assy. (P.221)
9. Remove the Front Main ADF Cover. (P.223)
10. Disengage the two hooks, and remove the Lower Cable Holder.
When installing the Lower Cable Holder, route the cables without
excess slack.
Figure 2-336. Releasing the cables

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12. Remove the screw (S14), and remove the grounding wire. 17. Disengage the shaft of the Top ADF Document Support Assy from the hole of the
13. Peel off the acetate tape. Right ADF Base Gear Cover.
14. Release the grounding wire and Top ADF Document Support Assy Cable from the 18. Pull out the cables and grounding wire from the holes on the ADF Base Unit, and
remove the Top ADF Document Support Assy.
Cable Holder.
15. Remove the screw (S8), and remove the Cable Holder. Right ADF Base
Shaft Gear Cover
Grounding wire Hole
Top ADF Document
Support Assy Cable
Cable Holder
ADF Base Unit

Grounding wire
S14 ADF Document

Acetate tape Support Assy Cable Hole
S8
Figure 2-337. Removing the Cable Holder Figure 2-339. Removing the Top ADF Document Support Assy (2)
S8
Figure 2-338. Removing the Top ADF Document Support Assy (1)

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2.3.9.21 Bottom ADF Document Support
S5
Figure 2-340. Removing the Bottom ADF Document Support
Route the cable of Top ADF Document Support Assy on the Upper
1. Remove the Panel Assy. (P.70) ADF Document Support as shown below.
Upper ADF Document
3. Remove the Left ADF Hinge Cover. (P.67) Support
8. Remove the three screws (S5), and remove the Bottom ADF Document Support.
Top ADF Document
Support Assy Cable

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2.3.10 Cassette 2.3.10.2 Casette End Guide
2.3.10.1 Casette Assy

2. Lift the Hopper and remove the Cassette End Guide from the rail on the Cassette
Assy.
1. Remove the Cassette Assy.

Hopper
Rail
Rail
Figure 2-341. Removing the Casette End Guide

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2.3.11 2nd Cassette 15. Remove the Middle Housing. (P.86)

16. Fix the Ink Supply BK Assy with two ropes.
2.3.11.1 2nd Cassette Unit
Figure 2-342. Moving BK Rips Unit

17. Secure the Ink Supply CL Assy. to the printer with a piece of rope.
11. Remove the Ink Supply BK Cover Assy. (P.195) Figure 2-343. Moving CL Rips Unit

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18. Remove the four screws (S36: 2 pcs, S37: 2pcs), and remove the 2nd Cassette
. 19. The handling part is lifted with two people and remove 2nd cassette unit.
Unit.
Front
handling part handling part
Figure 2-345. Remove 2nd Cassette Unit
S36 Make sure to execute the lubricating oil of the second cassette
Unit.
Back
S37
Figure 2-344. Removing the 2nd Cassette Unit.

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2.3.11.2 2nd Cassette Assy 2.3.11.3 2nd Cassette Frame Assy
1. Remove the 2nd Cassette Assy.

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16. Remove the 2nd Cassette Unit. (P.245)

17. Remove the 2nd Cassette Assy. (P.247)
Right Rear Hook
18. Remove the eight screws (S5), and remove the Cassette Top Cover Left and
Cassette Top Cover Right.
Cassette Top Cassette Top

Cover Left Cover Right
Grounding Plate Assy
S5
Figure 2-346. Removing the 2nd Cassette Frame Assy (1) S5
19. Remove the two screws (S6: 1 piece, S29: 1piece), and remove the Grounding
S6
Plate Assy.
S29
20. Remove the two screws (S5), and remove the Right Rear Hook.
Figure 2-347. Removing the 2nd Cassette Frame Assy (2)

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21. Open the Rear Cover. 23. Disconnect the cables from the connectors (CN5) of the board.
Rear Cover
Board
CN5
Cable
Figure 2-348. Removing the 2nd Cassette Frame Assy (3) Figure 2-350. Removing the 2nd Cassette Frame Assy (5)
22. Remove the five screws (S5).
Cassette Drawer Assy
S5

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24. Remove the five screws (S34: 4pcs, S29: 1piece). 25. Remove the Cassette frame Assy and the Cassette Drawer Assy together.
Figure 2-352. Remove Cassette frame Assy and Cassette Drawer Assy
26. Disconnect CN1 and CN2, and remove the Cassette Drawer Assy.
CN1 CN2 Cassette Drawer Assy
S29
S34
Figure 2-353. Remove Cassette Drawer Assy

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2.3.11.4 2nd Cassette Drive Assy 15. Remove the Middle Housing. (P.86)
18. Remove the 2nd Cassette Frame Assy. (P.247)
19. Disconnect the cable from the connector (CN6,CN7) of the board.
20. Release the cable from the Cable Holder.
Cable Holder CN7

CN6

2. Remove the Paper Support Support. (P.66) Board
Figure 2-354. Removing the 2nd Cassette Drive Assy (1)

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21. Remove the two screws (S16), and remove the 2nd Cassette Drive Assy.
S16
2nd Cassette 2nd Cassette Frame

Drive Assy Rear Assy
Figure 2-355. Removing the 2nd Cassette Drive Assy (2)
Make sure to execute the lubricating oil of the second cassette

Unit."Lubrication of the 2nd Cassette Unit (p325)"
Execute the FW UP date according to TI when exchanging 2nd
Cassette Drive Assy.
Adjustments" (p279) when 2nd Cassette Drive Assy or 2nd
Cassette Frame Rear Assy is replaced.

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2.3.11.5 Actuator 17. Remove the 2nd Cassette Assy. (P.247)

19. Remove the 2nd Cassette Drive Assy. (P.251)
20. Remove the two screw (S16), and remove the Cassette PE Sensor Cover from the
2nd Casette Frame Rear Assy in the direction of the arrow.
2nd Casette Frame Rear Assy Cassette PE Sensor Cover
For the screw types, see 2.1.1.1 Screw types used in the printer (p41). S16
1. Remove the Panel Assy. (P.70) Figure 2-356. Removing the Actuator (1)
2. Remove the Paper Support Support. (P.66) 21. Remove the Spring Leg (short) from the hook.
3. Remove the Left ADF Hinge Cover. (P.67) 22. Remove the Actuator in the direction of the arrow.

5. Remove the ADF/ Scanner Unit. (P.216) Spring Leg (short) Hook

Figure 2-357. Removing the Actuator (2)

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2.3.11.6 Sensor 18. Remove the 2nd Cassette Frame Assy. (P.247)
20. Remove the Actuator. (P.253)
21. Remove the screw (S16), and remove the grounding plate.
Grounding plate

4. Remove the Right ADF Hinge Cover. (P.68) S16
5. Remove the ADF/ Scanner Unit. (P.216) Figure 2-358. Removing the Sensor (1)
6. Remove the Panel Lower Front Cover. (P.73) 22. Remove the two screws (S6).
7. Remove the Right Upper Front Cover. (P.73) 23. Disengage the six hooks, and remove the Cassette Rear Frame Cover.

Cassette Rear Frame Cover
9. Remove the Cassette Assy. (P.244) Hook
S6
Figure 2-359. Removing the Sensor (2)
24. Disconnect the cable from the connectors of the three Sensor.

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25. Remove the three Sensor from the Pickup Holder Cover.
Sensor Sensor
Pickup Holder Cover
Figure 2-360. Removing the Sensor (3)

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2.3.11.7 Feed Roller 20. Remove the Cassette Rear Frame Cover. (P.254)
21. Remove the E-ring, and remove the Feed Roller.
22. Remove the E-ring, and remove the Gear from the Feed Roller.
23.
Cassette Rear Frame Cover

Gear
8. Remove the Stacker Assy. (P.66) E-ring
9. Remove the Cassette Assy. (P.244) E-ring
10. Remove the Front Cover Microswitch. (P.72) Figure 2-361. Removing the Feed Roller

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2.3.12 Option Cassette 3. Release the hooks (one each) on the two OP Cassette unit Fixing Plates.
4. Remove the 2nd Cassette Assy and remove two screw.
2.3.12.1 OP Casette Unit 5.
Front
Screw Screw
S36
1. Loosen the two screws. Figure 2-363. Removing the OP Casette unit
2. Release the hooks (one each) on the two OP Cassette unit Fixing Plates.
When lifting the printer, it must be carried by two or more people.

Back
Hooks
6. Lift the printer, and remove the OP Casette unit from the printer.

Adjustments" (p279) when the OP Casette unit is removed.
Screw
OP Casette unit Fixing Plate Screw
Figure 2-362. Removing the OP Casette unit

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2.3.12.2 OP Cassette Assy 2.3.12.3 OP Casette Retard Roller Assy
1. Remove the OP Cassette Assy. (P.258)

1. Remove the OP Cassette Assy.
2. Release the two hooks and remove the OP Cassette Retard Roller Assy from the
two tabs on the OP Cassette Assy.
OP Cassette Assy Tabs
Hooks
Figure 2-364. Removing the OP Casette Retard Roller Assy

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2.3.12.4 OP Cassette End Guide 2.3.12.5 OP Cassette Edge Guide Right

2. Lift the Hopper and insert the flat-head screwdriver into the OP Cassette End
Guide, and remove the OP cassette Assy by releasing it from the rails.
2. Remove the two screws (S5), and disengage the two hooks and then remove the
Hopper OP Cassette Bottom Cover.
Bottom of the OP Cassette Assy
OP Cassette Bottom Cover
Rail
Hooks
Rail S5
Figure 2-365. Removing the OP Cassette End Guide Figure 2-366. Removing the OP Cassette Bottom Cover

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3. Move the OP Cassette Edge Guide Right aside.

Make sure to align the OP Cassette Edge Guide Right with the joint
4. While widening the rail on the bottom of the OP Cassette Assy in the direction of on the Edge Guide Rack when installing OP Cassette Edge Guide
arrow (1), remove the OP Cassette Edge Guide Right by pulling it upward. Right.

Edge Guide Rack
Rail
Joint
OP Cassette Assy
Figure 2-367. Removing the OP Cassette Edge Guide Right

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2.3.12.6 OP Rear Cover Assy 2.3.12.7 Stopper Belt
1. Open the OP Rear Cover Assy. 1. Open the OP Rear Cover Assy. (P.261)
2. Remove the two screws (S5). 2. Remove the four screws (S5).
3. Release the two tabs in the order given below, and remove the OP Rear Cover 3. Remove the two Stopper Belt.
Assy.
Back
Back Tabs
S5
S5 Figure 2-369. Removing the Stopper Belt
Figure 2-368. Removing the OP Rear Cover Assy

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2.3.12.8 OP Right Cover 2.3.12.9 OP Left Cover
1. Remove the OP Cassette Unit. (P.257)
3. Remove the OP Left Cover.
3. Remove the OP Right Cover.
S5
S5
Figure 2-371. Removing the OP Left Cover
Figure 2-370. Removing the OP Right Cover

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2.3.12.10 OP Rear Frame Assy 4. Remove the OP Cassette Assy (P.262).
Right Rear Hook
For the screw types, see 2.1.1.1 Screw types used in the printer (p41). Grounding Plate Assy
2. Remove the OP Right Cover. (P.262)
3. Remove the OP Left Cover. (P.262)
S5
S6
S29
Figure 2-372. Removing the OP Rear Frame Assy (1)

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5. Open the OP Rear Cover Assy. (P.261) 7. Disconnect the cables from the connectors (CN5) of the board.
Rear Cover
Board
CN5
Cable

6. Remove the five screws (S5).
S5

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8. Remove the five screws (S34: 4pcs, S29: 1piece). 9. Remove the Cassette frame Assy and the Cassette Drawer Assy together.
OP Rear Frame Assy
Figure 2-377. Remove Cassette frame Assy and Cassette Drawer Assy
10. Disconnect CN1 and CN2, and remove the Cassette Drawer Assy.
CN1 CN2 Cassette Drawer Assy
S29
S34
Figure 2-378. Remove Cassette Drawer Assy

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2.3.12.11 OP Cassette Drive Assy
For the screw types, see 2.1.1.1 Screw types used in the printer (p41). Figure 2-379. Removing the OP Cassette Drive Assy (1)

4. Remove the OP Cassette Assy (P.262)
5. Remove OP Rear Frame Assy(P.263)
6. Disconnect the cable from the connector (CN6,CN7) of the board.
7. Release the cable from the Cable Holder.

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8. Remove the two screws (S16), and remove the 2nd Cassette Drive Assy.
S16
OP Cassette OP Cassette Frame

Drive Assy Rear Assy
Figure 2-380. Removing the OP Cassette Drive Assy (2)
Execute the FW UP date according to TI when exchanging 2nd

Cassette Drive Assy.
Adjustments" (p279) when OP Cassette Drive Assy or OP
Cassette Frame Rear Assy is replaced.

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2.3.12.12 OP Rear Cover Open Microswitch 2.3.12.13 OP Rear Frame Cover Assy
1. Remove the OP Cassette Unit. (P.257) For the screw types, see 2.1.1.1 Screw types used in the printer (p41).
2. Remove the OP Right Cover. (P.262) 1. Remove the OP Cassette Unit. (P.257)
3. Remove the OP Left Cover. (P.262) 2. Remove the OP Right Cover. (P.262)
4. Remove the OP Rear Frame Assy. (P.263) 3. Remove the OP Left Cover. (P.262)
5. Disengage the two hooks, and remove the OP Rear Cover Open Microswitch. 4. Remove the OP Rear Frame Assy. (P.263)
6. Disconnect the cable from the connector. 5. Remove the two screws (S15), and remove the OP Cassette PF Sensor Cover.
OP Cassette PF Sensor Cover

Hook
S15
Cable Connector
Figure 2-382. Removing the OP Cassette PF Sensor Cover
Figure 2-381. Removing the OP Rear Cover Open Microswitch

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6. Disengage the two tabs, and remove the OP Cassette PF Sensor Lever and Torsion 7. Remove the screw (S15), and remove the Rear Frame Grounding Plate.
Spring.
Rear Frame Grounding Plate
Tab
OP Cassette PF Sensor Lever
Tab
S15
Torsion Spring
Figure 2-384. Removing the Rear Frame Grounding Plate
Figure 2-383. Removing the OP Cassette PF Sensor Lever / Torsion Spring
9. Disengage the six hooks, and remove the OP Rear Frame Cover Assy.
Attach the Torsion Spring as shown below.
Hooks
Engage short leg here.
Engage long leg here.
Hooks S29
Figure 2-385. Removing the OP Rear Frame Cover Assy

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When installing the OP Rear Frame Cover Assy, be careful of the

following.
Make sure that the legs of the Torsion Spring on the OP Rear
Frame Cover Assy are engaged with the cutout on the shaft and
the hook on the frame.
Cutout
Torsion Spring
Hook
Make sure that the OP Cassette Paper Sensor Lever is installed
in the position shown below.
OP Cassette Paper Sensor Lever

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2.3.12.14 OP Cassette Microswitch Carry out the adjustments referring to "3.1 Required
Adjustments" (p279) when the OP Cassette Microswitch is
4. Remove the OP Rear Frame Assy. (P.263)
5. Remove the OP Rear Frame Cover Assy. (P.268)
6. Disengage the two hooks, and remove the OP Cassette Microswitch.
Back Connector
Hooks
Cable
Figure 2-386. Removing the OP Cassette Microswitch

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2.3.12.15 OP Cassette PF Sensor Carry out the adjustments referring to "3.1 Required
Adjustments" (p279) when the OP Cassette PF Sensor is removed
or replaced.
6. Disengage the four hooks, and remove the OP Cassette PF Sensor.
Cable
Connector Hooks
Figure 2-387. Removing the OP Cassette PF Sensor

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2.3.12.16 OP Cassette Paper Sensor Carry out the adjustments referring to "3.1 Required
Adjustments" (p279) when the OP Cassette Paper Sensor is
6. Disengage the four hooks, and remove the OP Cassette Paper Sensor.
Connector
Cable
Hooks
Figure 2-388. Removing the OP Cassette Paper Sensor

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2.3.12.17 OP Cassette Hopper Sensor Carry out the adjustments referring to "3.1 Required
Adjustments" (p279) when the OP Cassette Hopper Sensor is
6. Disengage the four hooks, and remove the OP Cassette Hopper Sensor.
Connector
Cable
Hooks
Figure 2-389. Removing the OP Cassette Hopper Sensor

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2.3.13 Mechanism Unit 17. Remove the Rear Cover Assy/ Rear Cover Belt. (P.174)
18. Remove the Maintenance Box. (P.64)
25. Remove the USB Connector Assy. (P.98)
When removing the Print Head, do not remove the Ink Tube.
26. Remove Ink Supply BK Assy.(P.201)
27. Remove Ink Supply CL Assy.(P.203)
28. Remove the Print Head. (P.114)
29. Remove the Ink End Board. (P.147)
When removing the Ink Supply Unit, do not remove the Ink Tube.
10. Remove the Cassette Assy. (P.244) 30. Remove the Ink Supply Unit. (P.148)

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31. Remove the two screws (S15), and remove the Left Rear ASF Cover Holder. 33. Remove the screw (S26) that secures the Left PG Adjust Lever.
Left Rear ASF

Cover Holder Left PG
Adjust Lever
S26
Figure 2-392. Removing the Mechanism Unit (2)
S15
Figure 2-390. Removing the Left Rear ASF Cover Holder
Adjustments" (p279) when the Mechanism Unit is removed or
32. Remove the screw (S26) that secures the Right PG Adjust Lever. replaced.
S26
Figure 2-391. Removing the Mechanism Unit (1)

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2.4 Routing the cables and FFC
2.4.1 Around the Main Board

1. Set the four Ferrite Cores on the lower part of the Main Board as shown below.
Ferrite Core Ferrite Core
Figure 2-393. Installing the Ferrite Core

2. Connect the cables and FFC to their connectors (CN38, CN39, CN45, CN74, and
CN707). (Route the cables through the hook on the Cable Holder.)
Cable Holder
Hook CN74
CN38
CN45
CN39 CN707
Figure 2-394. Connecting the cables and FFC
DISASSEMBLY/REASSEMBLY Routing the cables and FFC 277

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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.
After all required adjustments are complete, use the “Final check pattern print” function
to print all adjustment patterns for final check. If you find a problem with the printout
patterns, carry out the adjustment again.
When replacing the Main Board and the Printer Mechanism (Frame Base Assy) at the
same time, 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. (See Table 3-1 Required Adjustment List (Mechanism
adjustment) (p280).)
• The “Adjustments using the Adjustment Program” need to be performed after
reassembling the printer completely. (See Table 3-2 Required Adjustment List
(Adjustment using the Adjustment Program) (1/2) (p281) to Table 3-3 Required
Adjustment List (Adjustment using the Adjustment Program) (2/2) (p282).)
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 them out in the order given in the “Priority” row.
Adjustment Required Adjustments 279

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Table 3-1. Required Adjustment List (Mechanism adjustment)

Adjustment Type Mechanism adjustment
Priority 1 2 3 4 5 6 7
Adjustment Item CR Timing Belt Tension Check PF Timing Belt Tension Check ASF Timing Belt Tension Check Ink Leak Check PG Adjustment Checking the Platen Gap Touch Panel Adjustment
Re-Install --- --- --- --- --- --- ---
Panel Assy
Replace --- --- --- --- --- --- O
Re-Install --- --- --- --- --- --- ---
Speaker
Replace --- --- --- --- --- --- ---
Re-Install --- --- --- --- --- --- ---
Main Board Replace (Read OK) --- --- --- --- --- --- ---
Replace (Read NG) --- --- --- --- --- --- O
Re-Install --- O --- --- --- --- ---
PF Motor Assy
Replace --- O --- --- --- --- ---
Re-Install --- O --- --- --- --- ---
PF Tension Stopper
Replace --- O --- --- --- --- ---
Part Name
Re-Install --- O --- --- --- --- ---

PF Timing Belt
Replace --- O --- --- --- --- ---
Re-Install --- --- --- O* --- --- ---
Ink Supply Unit
Replace --- --- --- O --- --- ---
Re-Install --- --- --- O* O O ---
Print Head
Replace --- --- --- O O O ---
Re-Install O --- --- --- O O ---
CR Motor
Replace O --- --- --- O O ---
Re-Install O --- --- --- O O ---
CR Holder
Replace O --- --- --- O O ---
Re-Install --- --- --- --- --- --- ---
Mechanism Unit
Replace O O O --- --- --- O
Re-Install --- --- --- --- --- --- ---
OP Casette
Replace --- --- --- --- --- --- ---
See " 3.2.1.3 ASF Timing Belt
See " 3.2.1.2 CR Timing Belt See " 3.2.1.1 PF Timing Belt Tension See " 3.2.3 Ink Leak Check (p296)" See " 3.2.2 PG Adjustment (p289)" See " 3.2.2.4 Checking the Platen See " 3.2.6.3 Touch Panel
How to judge Tension Measurement (p287)" for the
Tension Check (p286)" for the details. Measurement (p284)" for the details. for the details. for the details. Gap (p295)" for the details. Adjustment (p318)" for the details.
details.
Tool Sonic tension gauge Sonic tension gauge Sonic tension gauge Ink Leak Measurement Jig Thickness gauges Thickness gauges ---
Note "*": If Ink tube is not disconnect from the Printhead, this process is not needed
Note: After the mechanism adjustment is performed, make sure to execute the adjustment using the Adjustment Program.
(See Table 3-2 Required Adjustment List (Adjustment using the Adjustment Program) (1/2)(p281) to Table 3-3 Required Adjustment List (Adjustment using the Adjustment Program) (2/2)(p282))
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Table 3-2. Required Adjustment List (Adjustment using the Adjustment Program) (1/2)
Adjustment Type Adjustment using the Adjustment Program
Priority 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Initialize
EEPROM Data CR Motor Heat PF Motor Heat ASF Motor Heat Synchro Head Angular PW Sensor Initial
Adjustment Item Ink flushing Waste Ink flushing Initial Setting Head ID Input Deterioration APG Check CR Check CR Scale Check Ink Charge
Copy Protection Control Protection Control Protection Control Adjustment Mecha Adjustment Setting
Counter
To copy adjustment To minimize the To minimize the To write sale To correct To reset the PF To measure and correct the electrical variation of each motor and the To synchronize the To confirm the APG To confirm the CR To confirm the CR To fill ink To correct tilt of To reset the counter
values or the like amount of ink spilling amount of ink spilling destination specific characteristic deterioration counter power supply board. PF drive and the change work is movement is movement failure throughout the ink the Printhead according to the
stored on the old when removing the when removing the settings and the serial variation of the or ASF deterioration ASF drive by correctly. correctly. by deforming the replaced parts.
Main Board to the printhead, discharge related parts of the ink number into the Main replaced Printhead counter according to software control. CR scale. path to make all caused at the
Porpose new board when the ink in the ink tube to system, discharge ink Board after replacing by entering its the replaced parts. the nozzles ready installation
Main Board needs the Ink System. in the waste ink tube. it. Printhead ID (Head for printer through
to be replace. ID). mechanism
control.
Re-Install --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Panel Assy
Replace --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Re-Install --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Dup Assy.
Replace --- --- --- --- --- O --- --- --- --- --- --- --- --- --- ---
ADF/Scanner Re-Install --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Unit Replace --- --- --- --- --- --- --- --- --- --- --- --- --- --- --- ---
Re-Install --- --- --- --- --- --- --- --- --- --- --- --- O --- --- ---
Rear ASF Unit
Replace --- --- --- --- --- --- --- --- O --- --- --- O --- --- ---
Re-Install --- --- --- --- --- --- --- --- --- --- --- --- O --- --- ---
Main Board
Assy. Replace (Data Copy OK) O --- --- --- --- --- --- --- --- --- --- --- O --- --- ---
Replace (Data Copy NG) --- --- --- O O --- O O O O --- --- O --- --- O
Re-Install --- --- --- --- --- --- --- --- --- --- --- --- O --- --- ---
Power Unit
Replace --- --- --- --- --- --- O O O O O --- O --- --- ---
Re-Install --- --- --- --- --- --- --- --- --- --- --- --- O --- O ---
Print Head Make sure
Replace --- O --- --- O --- --- --- --- --- --- O O to O O ---
perform the “CR
Re-Install --- --- --- --- --- --- --- --- --- --- --- --- O --- --- ---
CR Motor Scale Check”
Replace --- --- --- --- --- --- O --- --- --- --- O O --- --- ---
when the Middle
Re-Install --- --- --- --- --- --- --- --- --- --- --- --- O --- --- ---
PF Motor Housing is
Part Name
Replace --- --- --- --- --- --- --- O --- O --- --- O --- --- ---
removed.
Re-Install --- --- --- --- --- --- --- --- --- --- --- --- O --- --- ---
ASF Motor
Replace --- --- --- --- --- --- --- --- O O --- --- O --- --- ---
Re-Install --- --- --- --- --- --- --- --- --- --- --- --- O --- --- ---
APG Motor
Replace --- --- --- --- --- --- --- --- --- --- O --- O --- --- ---
Re-Install --- --- --- --- --- --- --- --- --- --- --- --- O --- --- ---
LIFT Motor
Replace --- --- --- --- --- --- --- --- O --- --- --- O --- --- ---
Ink Supply Re-Install --- --- --- --- --- --- --- --- --- --- --- --- O --- --- ---
Unit Replace --- O --- --- --- --- --- --- --- --- --- --- O O --- ---
Re-Install --- --- O --- --- --- --- --- --- --- --- --- O --- --- ---
INK System
Replace --- --- O --- --- --- --- --- --- --- --- --- O --- --- ---
Re-Install --- --- --- --- --- --- --- --- --- --- --- --- O --- --- ---
PW Sensor
Replace --- --- --- --- --- --- --- --- --- --- --- --- O --- --- O
Re-Install --- --- --- --- --- --- --- --- --- --- --- --- O --- --- ---
PE Sensor
Replace --- --- --- --- --- --- --- --- --- --- --- --- O --- --- ---
Re-Install --- --- --- --- --- --- --- --- --- --- --- --- O --- O ---
CR Holder
Replace --- --- --- --- --- --- --- --- --- --- --- O O --- O ---
Re-Install --- O O --- --- --- --- --- --- --- --- --- O O --- ---
Mecha Unit
Replace --- O O --- --- O O O O O O O O O O O
Re-Install --- --- --- --- --- --- --- --- --- --- --- --- ---
Casette2 - 4
Replace --- --- --- --- --- --- --- --- O --- --- --- --- --- --- ---
Printout pattern
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Table 3-3. Required Adjustment List (Adjustment using the Adjustment Program) (2/2)
Adjustment Type
Priority 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Scanner/ADF Moter
SMAP Runout Haed Angular PW/First Dot PF-EJ Band Paper Skew Maintenance Final Check Pattern Ink Leak Error
Adjustment Item PW Sensor Check PE Sensor Check PF/EJ Adjustment PE Adjustment Bi-D Adjsutment Heat Protection Head Cleaning
Adjustment Adjustment Postion Adjustment Adjustment Adjutment Counter Print Reset
Control
To confirm the PW To check the PE To correct To correct the gap To correct tilt of To correct the To correct the paper To correct print To correct To align print start To measure and To reset the --- Reset a 0x8A error to To repair a clogging
shutter work to detector sensor. variations in paper of the paper feed the Printhead paper detection detection positions start timing in variations in paper position at 0-digit correct the Maintenance operate the nozzles of the
adjustment program. printhead.
prevent the ink feed accuracy to by eccentricity caused at the positions and the and the mounting bidirectional feed accuracy to side with that at 80- electrical variation counter of the Rear
mist attaching the achieve higher print element of the installation mounting positions positions of the PE printing through achieve higher print digit side in of each motor and ASF Unit and
Porpose PW Sensor is quality. SMAP Roller and through software of the PW sensor sensor by soft ware software control. quality in band bidirectional ban the power supply check the counter
correctly. the PF encoder control. by software control control. print. printing, timing of board. of the Maintenance
scale by Software firing ink droplet is Box
control. adjusted through
software control.
Re-Install --- --- --- --- --- --- --- --- --- --- --- --- O --- ---
Panel Assy
Replace --- --- --- --- --- --- --- --- --- --- --- --- O --- ---
Re-Install --- --- --- --- --- --- --- --- --- --- --- --- O --- ---
Dup Assy.
Replace --- --- --- --- --- --- --- --- --- --- --- --- O --- ---
ADF/Scanner Re-Install --- --- --- --- --- --- --- --- --- --- --- --- O --- ---
Unit Replace --- --- --- --- --- --- --- --- --- --- O --- O --- ---
Re-Install --- --- --- --- --- --- --- --- --- --- --- --- O --- ---
Rear ASF Unit
Replace --- --- --- --- --- --- --- --- --- --- --- O O --- ---
Re-Install --- --- --- --- --- --- --- --- --- --- --- --- O --- ---
Main Board
Assy. Replace (Data Copy OK) --- --- --- --- --- --- --- --- --- --- --- --- O --- ---
Replace (Data Copy NG) --- --- O O O O O O O O --- --- O --- ---
Re-Install --- --- --- --- --- --- --- --- --- --- --- --- O --- ---
Power Unit
Replace --- --- --- --- --- --- --- --- --- --- O --- O --- ---
Re-Install --- --- --- --- --- O O O O O --- --- O O O
Print Head
Replace --- --- --- --- O O O O O O --- --- O O O
Re-Install --- --- --- --- --- --- --- --- --- --- --- --- O --- ---
CR Motor
Replace --- --- --- --- --- O --- --- --- O --- --- O --- ---
Re-Install --- --- O --- --- O --- --- --- --- --- --- O --- ---
PF Motor
Replace --- --- O --- --- O --- --- O --- --- --- O --- ---
Part Name
Re-Install --- --- --- --- --- --- --- --- --- --- --- --- O --- ---
ASF Motor
Replace --- --- --- --- --- --- --- --- --- --- --- --- O --- ---
Re-Install --- --- --- --- --- --- --- --- --- --- --- --- O --- ---
APG Motor
Replace --- --- --- --- --- --- --- --- --- --- --- --- O --- ---
Re-Install --- --- --- --- --- --- --- --- --- --- --- --- O --- ---
LIFT Motor
Replace --- --- --- --- --- --- --- --- --- --- --- --- O --- ---
Ink Supply Re-Install --- --- --- --- --- --- --- --- --- --- --- --- O O ---
Unit Replace --- --- --- --- --- --- --- --- --- --- --- --- O O ---
Re-Install --- --- --- --- --- --- --- --- --- --- --- --- O --- ---
INK System
Replace --- --- --- --- --- --- --- --- --- --- --- --- O --- ---
Re-Install O --- --- --- --- O O --- --- --- --- --- O --- ---
PW Sensor
Replace --- --- --- --- --- O O --- --- --- --- --- O --- ---
Re-Install --- --- --- --- --- --- O --- --- --- --- --- O --- ---
PE Sensor
Replace --- O --- --- --- --- O --- --- --- --- --- O --- ---
Re-Install O --- --- --- O O --- O O O --- --- O --- ---
CR Holder
Replace O --- --- --- O O --- O O O --- --- O --- ---
Re-Install --- --- --- --- --- --- --- --- --- --- --- --- O --- ---
Mecha Unit
Replace --- O O O O O O O O O --- --- O --- ---
Casette2 - 4 Re-Install --- --- --- --- --- --- --- --- --- --- --- --- O --- ---
Replace --- --- --- --- --- --- --- --- --- --- --- --- O --- ---
Upper
OK -2 -1 0 1 2
part
-2 -1 0 1 2
-2 -2
-1 -1 OK OK
NG
0 0 -2 -2
1 1 -1 -1
2 2 0 0 NG
Printout pattern --- --- NG

-2 -1 0 1 2
1
2
1
2
NG --- --- --- --- ---
-2 -1 0 1 2 NG
-2
NG OK NG OK NG -1
NG Lower
0
1 part
2 NG OK NG
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3.2 Details of Adjustments

This section provides adjustment procedures for which explanation in details is necessary. See "Required
Adjustments (p279)"for the adjustments not explained here.
3.2.1 PF/CR/ASF Timing Belt Tension Measurement

This section describes PF/CR/ADF Timing Belt tension measurement.
Tools
“3.1
Sonic tension gauge

Plastic tweezers
Adjustment procedure
When PF/CR/ASF Timing Belt tension measurement, make sure of the following.
Bring the microphone of the sonic tension gauge within 5 mm from the PF Timing Belt
but do not let it touch the belt.
Flip the PF Timing Belt as weak as the sonic tension gauge can measure it.
Be careful not to damage the PF Timing belt when flipping it with the plastic tweezers.
Details of Adjustments 283

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3.2.1.1 PF Timing Belt Tension Measurement
If you have correctly reassembled the Printer Mechanism, the tension of the PF Timing
Belt falls within the expected range. If the result of measurement of the PF Timing Belt
tension explained in this section is out of standard, readjust the tension as instructed
below.
The standard tension range of the PF Timing Belt: 6.5 ± 2.0 N
Measurement procedure
1. Set the following parameters to the sonic tension meter:
Weight: 1.0 g/m
Width: 4.0 mm
Span: 44 mm
2. Bring the microphone of the sonic tension meter close to the position shown in Figure 3-1
3. Press the “MEASURE” button of the sonic tension meter and flip the upper of the PF Timing Belt with
plastic tweezers and measure the tension of the belt.
4. Rotate the gear 60 degrees, and measure the tension of the belt.
9. Checks whether the average of the values measured in Step 3. to Step 8. is within the standard.
measurement value is within the standard: PF Timing Belt Tension Measurement is completed.
measurement value is out of the standard: Perform the “PF Timing Belt Tension Adjustment (p244)“.
Left side
Measurement position
Within 5 mm
PF Timing Belt
Figure 3-1. PF Timing Belt Tension Measurement

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PF Timing Belt Tension

1. There is not the PF timing belt tension adjustment mechanism. Figure 3-2
PF Timing Belt
Figure 3-2. PF Timing Belt Tension

2. Disassemble and assemble the PF timing belt and go back to the measurement procedure.
3. Exchange the PF timing belt if the tension is not in the standard.

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3.2.1.2 CR Timing Belt Tension Check
This printer is designed so that the each tension of the CR Timing Belt fall within the
expected range if you correctly reassemble the unit. However, deformation of any related
part(s) can cause improper tension of the belt. In such case, replace the Mechanism Unit
with a new/refurbished one.
The standard tension range of the CR Timing Belt: 14.1 ± 3 N
1. Move the CR Unit back and forth between the 0-digit side and 130-digit side three times.
2. Move the CR Unit to the position on the left of the Ink System on the 0-digit side shown in Figure 3-3.
3. Set the following parameters to the sonic tension gauge:
Weight: 1.0 g/m
Width: 4 mm
Span: 476 mm
4. Bring the microphone of the sonic tension meter close to the position shown in Figure 3-3.
5. Press the “MEASURE” button of the sonic tension meter and flip the upper of the CR Timing Belt with
Within the standard range: CR Timing Belt tension measurement is complete.
Out of the standard range: go to Step 6.
6. Measure the belt tension twice in the same way as described in Step 5.
Within the standard range two times in a row
CR Timing Belt tension check is complete.
Either of the results is out of the standard range
Any of the related parts may be deformed. Replace the Mechanism Unit, and then perform the CR Timing Belt
tension Check again.
Measurement
CR Unit
position
CR Timing Belt
Within 5 mm
Figure 3-3. CR Timing Belt Tension Check

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3.2.1.3 ASF Timing Belt Tension Measurement
If you have correctly reassembled the Printer Mechanism, the tension of the ASF Timing
Belt falls within the expected range.If the result of measurement of the ASF Timing Belt
tension explained in this section is out of standard, readjust the tension as instructed
below.
The standard tension range of the ASF Timing Belt: 6.0 ± 2.0 N
Measurement procedure
1. Set the following parameters to the sonic tension meter:
Weight: 1.0 g/m
Width: 4.0 mm
Span: 31 mm
2. Bring the microphone of the sonic tension meter close to the position shown in Figure 3-4.
3. Press the “MEASURE” button of the sonic tension meter and flip the upper of the ASF Timing Belt with
9. Checks whether the average of the values measured in Step 3. to Step 8. is within the standard.
measurement value is within the standard: ASF Timing Belt Tension Measurement is completed.
measurement value is out of the standard: Perform the “ASF Timing Belt Tension Adjustment (p247)“.
Left side
ASF Timing Belt Within 5 mm
Measurement position
Figure 3-4. ASF Timing Belt Tension Measurement

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ASF Timing Belt Tension Adjustment

1. There is not the ASF timing belt tension adjustment mechanism. Figure 3-5.
DRIVE ASF Assy
Figure 3-5. Timing Belt Tension

2. Disassemble and assemble DRIVE ASF Assy and go back to the measurement procedure.
3. Exchange DRIVE ASF Assy if the tension is not in the standard.

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3.2.2 PG Adjustment
This section describes the procedure for the platen gap (PG) adjustment.
The standard range of the PG is as follows:

1.3 ± 0.5 mm
This adjustment should be carried out with the mechanism in the minimum PG position
(PG1) before installing the CR Scale.
Tools
Thickness gauge for PG adjustment
Teflon tape
Commercially available tape (thickness: 0.08 mm)
3.2.2.1 PG Adjustment procedure
START
“Preparation (p249)“
“Adjustment of the 0-digit side (p252)“
“Checking the Platen Gap (p254)“
No
Is PG within standard?
Yes
PG adjustment is finished.
Figure 3-6. PG Adjustment Flow

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3.2.2.2 Preparation
This section describes how and what to prepare for the preparation before starting the PG adjustment.
Modification of the thickness gauges
The Print head of this printer has an integral structure of the Print head Cover and Print
head nozzle surface. Therefore, if the thickness gauge touches the nozzle surface in the
same way as performed in the traditional procedure, the nozzle surface may be damaged.
When performing the PG Adjustment or checking the platen gap, make sure to apply
Teflon tape (thickness: 0.08 mm) on all the thickness gauge (1.00 mm) used for the
adjustment or check in advance.
Use commercially available Teflon tape of 0.08 mm in thickness.
When applying Teflon tape on the thickness gauges, make sure no bubbles or foreign
material remain under the tape.
Application procedure of Teflon tape
1. Clean the surfaces of the thickness gauge using alcohol, and make sure no dirt or contamination remains on the
surfaces.
2. Apply Teflon tape on the thickness gauge (1.00 mm) as shown below.
Teflon tape
Thickness gauge (1.00 mm)
Figure 3-7. Modification of Thickness Gauge (1)

3. Fold the excess portions of Teflon tape along the edges of the thickness gauge, and trim the portions at about
the center in the thickness direction of the sides.
4. Make sure any tears or burrs on the applied Teflon tape, then the modification of thickness gauges is complete.
Before trimming Teflon tape
Thickness gauge
After trimming
Fold the tape at the edges and trim it at the center in the thickness direction.
Teflon tape
Thickness gauge
Figure 3-8. Modification of Thickness Gauge (2)

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Relationship between thickness gauges and adjustment values

When performing the PG adjustment, use three thickness gauges by stacking them together. Make sure to take the
thickness of teflon tape attached on them into consideration. The judging criteria and the relationship between
thickness gauges and teflon tape are shown below.
Perform the following because the thickness of teflon tape varies.

1. Apply teflon tape on the thickness gauge (1.00 mm) and measure the thickness with a
micrometer.
2. Subtract 1.00 mm from the measured value and compare the result with the value in the
“Teflon tape (d)” on Table 3-4 and correct it, and then correct the values in the
“Thickness ((a)+(b)+(c)+(d))” column.
Table 3-4. adjustment value and judgement (unit: mm)

Position
Thickness 1st thickness 2nd thickness 3rd thickness Teflon tape
Judge against CR
((a)+(b)+(c)+(d)) gauge (a) gauge (b) gauge (c) (d)
Unit
1.37 1.00 0.20 0.09 0.08

NG
In contact 1.36 1.00 0.20 0.08 0.08
1.35 1.00 0.20 0.07 0.08
1.34 1.00 0.20 0.06 0.08
1.33 1.00 0.20 0.05 0.08
1.32 1.00 0.20 0.04 0.08
1.31 1.00 0.20 0.03 0.08
OK 1.30 1.00 0.20 0.02 0.08
1.29 1.00 0.20 0.01 0.08
1.28 1.00 0.10 0.10 0.08
1.27 1.00 0.10 0.09 0.08
1.26 1.00 0.10 0.08 0.08
1.25 1.00 0.10 0.07 0.08
Not in contact 1.24 1.00 0.10 0.06 0.08
NG
1.23 1.00 0.10 0.05 0.08

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APG position check

Confirm the APG position is set to [PG1].
Check method
“1” on the CR Bearing is exactly on the bottom.
CR Bearing
1
Hole
Figure 3-9. APG position check

If not, insert a pin or a similar tool into the hole on the CR Bearing and adjust it until “1” comes exactly on
the bottom.
Position check of the PG Adjustment Lever
Confirm the center of the notches on the PG Adjustment Lever located on the side of the printer is set to the
rib on the frame.
Right PG Adjustment Left PG Adjustment Lever

Lever (0-digit side) (130-digit side)
PG: Max.
Rib
PG: Min.
PG: Max. PG: Min.
Rib
Figure 3-10. PG Adjustment Lever

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3.2.2.3 PG adjustment procedure

When performing the PG adjustment, make sure of the following.
Perform the PG adjustment before installing the CR Scale.
Move the CR Unit by pulling the top of the CR timing belt.
Be careful not to damage the nozzle surface of the Print head with the thickness gauge.
When make the Print head touch the thickness gauge, be careful not to let the Print head
run onto the gauge.
Adjustment of the 0-digit side
1. Loosen the two PG Adjustment Lever (Left/Right) on the right and the left of the printer. (refer to Figure
3-10)
2. Move the CR Unit in the middle of the printer, and place the 1.35 mm-thick thickness gauge shown in Table
3-4 on position A in Figure 3-11.
130-digit side 0-digit side
B
A
Thickness gauge
Figure 3-11. Placement of the Thickness Gauge

3. Move the CR Unit to the thickness gauge and check whether the CR Unit touches the thickness gauge or not.
If the CR Unit touches the gauge, adjust it as follows. If not, proceed to the next step.
1. Move the CR Unit back in the middle of the printer, and place the 1.25 mm-thick thickness gauge shown in
Table 3-4 on position A in Figure 3-11.
• If the CR Unit does not touch the thickness gauge
Tighten the screw of the PG Adjustment Cam on the 0-digit side, and go to “Adjustment of the 130-digit side
(p253)“.
• If the CR Unit touches the thickness gauge
Rotate the PG Adjustment Cam on the 0-digit side by one notch in the - direction and check whether the CR
Unit touches the thickness gauge or not (refer to Figure 3-10). Repeat the adjustment until the CR Unit does
not touch the thickness gauge any more.
4. Adjust the CR Unit as follows.
1. Move the CR Unit in the middle of the printer, and rotate the PG Adjustment Cam on the 0-digit side by one
notch in the + direction. (refer to Figure 3-10)
Tighten the screw of the PG Adjustment Cam, and go to Step 4-3.

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Start over from Step 4-1. Repeat the adjustment until the CR Unit touches the thickness gauge.
Table 3-4 on position A in Figure 3-11.
Tighten the screw of the PG Adjustment Cam on the 0-digit side, and go to “Adjustment of the 130-digit side
(p253)“.
Adjustment of the 130-digit side
1. Loosen the two PG Adjustment Lever (Left/Right) on the right and the left of the printer. (refer to Figure
3-10)
2. Move the CR Unit in the middle of the printer, and place the 1.35 mm-thick thickness gauge shown in Table
3-4 on position B in Figure 3-11.
If the CR Unit touches the gauge, adjust it as follows. If not, proceed to the next step.
Table 3-4 on position B in Figure 3-11.
Tighten the screw of the PG Adjustment Cam on the 130-digit side, and confirm the PG on the 0-digit side is
appropriate according to the procedure in “Adjustment of the 0-digit side (p252)“, then go to “3.2.2.4
Checking the Platen Gap (p254)“.
4. Adjust the CR Unit as follows.
1. Move the CR Unit in the middle of the printer, and rotate the PG Adjustment Cam on the 130-digit side by one
notch in the + direction. (refer to Figure 3-10)
Tighten the screw of the PG Adjustment Cam, and go to Step 4-3.
Start over from Step 4-1. Repeat the adjustment until the CR Unit touches the thickness gauge.
Table 3-4 on position B in Figure 3-11.
Tighten the screw of the PG Adjustment Cam on the 0-digit side, and confirm the PG on the 0-digit side is
appropriate according to the procedure in “Adjustment of the 0-digit side (p252)“, then go to “3.2.2.4
Checking the Platen Gap (p254)“.

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3.2.2.4 Checking the Platen Gap

This section describes the procedure for checking the platen gap (PG) necessary when removing the Print head or
in a similar case.
When checking the PG, make sure of the following.

Move the CR Unit by pulling the top of the CR timing belt.
Be careful not to damage the nozzle surface of the Print head with the thickness gauge.
When make the Print head touch the thickness gauge, be careful not to let the Print head
run onto the gauge.
1. Confirm the PG position is set to position 1. (refer to “APG position check (p251) “)
2. Move the CR Unit to the center.
3. Place the 1.25 mm-thick thickness gauge shown in Table 3-4 on the position shown below.
Thickness gauge
Figure 3-12. Checking the Platen Gap

4. Move the CR Unit to the right and to the left and make sure the CR Unit does not touch the thickness gauges
on both sides. If the CR Unit touches the thickness gauge, the PG is narrower than the standard value;
therefore, perform “3.2.2.3 PG adjustment procedure (p252)“.
Table 3-4 on the same position as in Step 3.
6. Move the CR Unit to the right and to the left and make sure the CR Unit touches the thickness gauges on both
sides. If the CR Unit does not touch the thickness gauge, the PG is wider than the standard value; therefore,
perform “3.2.2.3 PG adjustment procedure (p252)“.

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3.2.3 Ink Leak Check

This section describes the procedure for ink leak check necessary when disconnecting the Ink Supply Unit from
the Print head or in a similar case.
Ink leak Check has the following two inspection methods.
Method of using the Leakage Check PET Chip.
(Purpose)
Detect the minute ink leakage from the connecting parts of the Print Head and ink Tube.
Method of using the Ink Leak Measurement Jig.
(Purpose)
Detect the ink leakage due to assembly mistake.
3.2.3.1 Method of using the Leakage Check PET Chip.

This inspection is necessary when removing the Ink Tube from the Print Head.
Refer to the following for the setting method of the Leakage Check PET Chip.
"2.3.6.1 Print Head (p114)"
"2.3.6.15 Ink Supply Unit (p148)"
Ink Leak Check procedure
1. Pull out the Leakage Check PET Chip.
Figure 3-13. Ink Leak Check Procedure (1)

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2. Visually check if ink spot is observed at the 2mm from front edge of the smoked face of the Leakage Check
PET Chip.
Criterion of the Ink Leak Check.
Pass condition
Ink spot is observed at the position less than 2mm from the front edge of the smoked face of the PET Chip.
Fail condition
Ink spot is observed at the position more than 2mm from the front edge of the smoked face of the PET Chip.
2mm
PET Chip
Front edge
Smoked face
Fail Pass
Figure 3-14. Criterion of the Ink Leak Check
If Ink Leak Check result is failed, reassemble the printer in the following procedure, and
perform the Ink Leak Check again.
1. Perform the Ink discharge.
2. Remove the Ink Tube from Print Head.
3. Replace the Print head Seal to new one.
4. Set the Leakage Check PET Chip.
5. Install the Ink Tube to Print Head.
7. Perform the Ink Leak Check.

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3.2.3.2 Method of using the Ink Leak Measurement jig.
Tools
This product can use the following two type Ink Leak Measurement Jig.
As for Leak Check method, refer to
(Current tool) Ink Leak Measurement Jig
Battery type: CR2016(3V) x1
Ink Leak Measurement Jig

Syringe Muffler
Connection part for Ink
Leak Check Cartridge Power button of
pressure gauge
Valve Status
Pressure gauge GC66

(The battery can be replaced from
Valve B Valve A the hole on the rear.)
Close Open
Figure 3-15. (Current tool) Ink Leak Measurement Jig

(Previous tool) Ink Leak Measurement Jig
Battery type: CR2016(3V) x1
Ink Leak Measurement Jig Pressure gauge GC66 (The battery can
Valve C be replaced from the hole on the rear.)
Power button of pressure gauge

Connection part for Ink
Leak Check Cartridge
Valve B
Valve status Regulator protection plate
Regulator
Closed Open Valve A Syringe
Figure 3-16. (Previous tool) Ink Leak Measurement Jig

Ink Leak Check Adapter
Ink Leak Check Adapter
Figure 3-17. Ink Leak Check Adapter

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Do not touch or press the regulator located under the regulator protection plate of the Ink
Leak Measurement Jig.
The Ink Leak Measurement Jig applies pressure by sending air using a syringe into the
ink path, and detects the variation of pressure in the ink path between the self-sealing
valve in the Printhead and the ink supply holes of the ink cartridges to check the
presence of ink leakage. If air leak occurs in the Ink Leak Measurement Jig, the leak
check itself cannot be done. Therefore, before performing the leak check, perform the
test air leak from the Ink Leak Measurement Jig itself. (The air leak test from Leak
Measurement Jig itself is possible by closing the connection port of the Leak Check
Adapter with a finger.)
The ink leak check should be done with the ink tubes secured with the tube clamps and
the CR Cover attached after the joint section of the Print head and the Ink Supply Unit
has been secured. (See.” Ink Supply Unit (p125)“)

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Preparation
Tools
Ink Tube, CY (Part Code: 163329500 or 163554100)
Joint Tube (Outside diameter: 4mm, Inside Diameter: 2.5mm) * It is band led to Ink Leak Measurement Jig.
Banding Band (Width: 2 mm ~ 5mm) * Commercially available goods
Seal Supply Hole Assy (Part code: 123219100)
Making Procedure
1. Cut out the needle connection portion of the Ink Tube,CY
Figure 3-18. Making procedure of Ink Leak Check Adapter (1)

2. Install the Joint Tube to the cutting portion of the Ink Tube, CY by from 7 to 10mm.
from 7 to 10mm

3. Clamp the connection portion of the Joint Tube and the Ink Tube, CY by the Banding Band.
Remaining band is cut off.

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4. Install the Seal Supply Hole Assy to the Ink Tube, CY.
(Make sure to install the Seal Supply Hole Assy in the correct direction.)
.
OK NG
Figure 3-21. Making procedure Ink Leak Check Adapter (4)
Make sure to clamp the banding band by hand, and do not use the industrial tool when
clamping the banding band.
The Seal Supply Hole Assy deteriorates by repeating the installation and removal of the
Ink Leak Check Adapter.
If the air leak is occurred frequently in the Ink Leak Check, replace the packing, and
performing the Ink Leak check again.

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Ink leakage Inspection Condition

Air pressure power: 48 ± 2 kPa
Air pressure hold time: 30 sec
Air pressure judgment standard: Less than 0.4 kPa
Checking procedure
Make sure to pressurize the pressure of the specified value (48±2Kpa), and do not
pressurize the pressure of more than specified value.
If you pressurized the pressure of the more than the specified value, it can not lower the
pressure by pulling the syringe.
(Because, the ink supply Jig has valve to prevent back flow of the ink. If you lower the
pressure by pulling the syringe, the valve is closed and can not perform the reliable test)
If you pressurized the pressure of the more than the specified value, reassemble the
connection parts of print Head and the Ink supply Unit to lower the pressure of the Ink
tube of the Ink Supply Unit.
Checking procedure of the “(Current tool) Ink Leak Check Measurement Jig”
1. Turn each valve of the Ink Leak Measurement Jig as follows:
Valve A: Open
Valve B: Open
2. Connect the Ink Leak Check Adapter to the Ink Leak Measurement Jig.
3. Install the Ink Leak Check Adapter into the Ink Supply Unit of the printer to check.
Connect the while pressing here
Tube of Ink Leak Check Adapter
Figure 3-22. Ink Leak Check (1)

4. Press the power button of the pressure gauge.
5. Confirm the value on the pressure gauge is 0.0 kPa. Otherwise, restart the pressure gauge.

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6. Pull the plunger up.
Pull the plunger up

7. Close the valve B of the Ink Leak Measurement Jig.
8. Push the plunger to inject the air out, and confirm the pressure gauge indicates 48±2 kPa, then after the
value has stabilized, shut the valve A.
9. If the value is less than 48±2kpa, shut the valve A and pull the plunger, and open the valve A and push the
plunger several times until the valve reaches 48±2kpa, then after valve has stabilized, shut the valve A.
10. Close the valve A, and after waiting 10 seconds for the pressure to stabilize, record the value displayed on the
pressure gauge.
11. After about 30 seconds have passed, check the value on the pressure gauge, and compare it with the recorded
value.
Difference is less than 0.4 kPa: No problem. Go to Step 12.
Difference is 0.4 kPa or more: Air may be leaking. Disconnect the ink tubes of the Ink Supply Unit from the Print
head, and connect them again correctly. (See "2.3.6.15 Ink Supply Unit (p148)".)
Then, start the check again from Step 3.
12. Open the valve B to release the air pressure in the jig.
13. After confirming the value on the pressure gauge is 0.0 kPa, remove the Ink Leak Check Adapter from the
printer.
14. Repeat from Step 3 to Step 13 for the rest of the ink cartridge slots to check.
15. After checking all the ink cartridge slots, press and hold the power button of the pressure gauge for about
four to five seconds to turn off.
Make sure not to open the period of the Ink Charge from the Ink Leak Check for three
days or more.
After the Ink Leak Check, perform the Head Cleaning (CL1) before the initial charge.
If you need open the period of the Ink Charge from the Ink Leak Check for three days or
more, make sure to disconnect the connect part of Print Head and the Ink Supply Unit.
Additionally, make sure to perform the Ink Leak Check again if the Ink Charge
performs.

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Checking procedure of (Previous tool) Ink Leak Check Measurement Jig

1. Turn each valve of the Ink Leak Measurement Jig as follows:
Valve A: Open
Valve B: Open
Valve C: Open
2. Connect the Ink Leak Check Adapter to the Ink Leak Measurement Jig.
Connect tube while pressing here.
Tube of Ink Leak Check Adapter

3. Install the Ink Leak Check Adapter into the ink cartridge slot of the printer to check.
4. Press the power button of the pressure gauge.
5. Confirm the value on the pressure gauge is 0.0 kPa. Otherwise, restart the pressure gauge.
6. Pull the plunger up.
Pull the plunger up.

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7. Close the valve C of the Ink Leak Measurement Jig.

8. Push the plunger to inject the air out, and confirm the pressure gauge indicates 48±2 kPa, then after the
value has stabilized, shut the valve A. If the value is less than 48±2 kPa, open the valve A and pull out and
push in the plunger several times until the value reaches 48±2 kPa, then after the value has stabilized,
shut the valve A.
Valve C
Valve B
Valve A

9. Close the valve B, and after waiting 10 seconds for the pressure to stabilize, record the value displayed on the
pressure gauge.
10. After about 30 seconds have passed, check the value on the pressure gauge, and compare it with the recorded
value.
Difference is less than 0.4 kPa: No problem. Go to Step 11.
Difference is 0.4 kPa or more: Air may be leaking. Disconnect the ink tubes of the Ink Supply Unit from the Print
head, and connect them again correctly. (See "2.3.6.15 Ink Supply Unit (p148)".)
Then, start the check again from Step 3.
11. Open the valve C to release the air pressure in the jig.
12. After confirming the value on the pressure gauge is 0.0 kPa, remove the Ink Leak Check Cartridge from the
printer.
13. Repeat from Step 3. to Step 12. for the rest of the ink cartridge slots to check.
14. After checking all the ink cartridge slots, press and hold the power button of the pressure gauge for about
four to five seconds to turn off.
Make sure not to open the period of the Ink Charge from the Ink Leak Check for three
days or more.
After the Ink Leak Check, perform the Head Cleaning (CL1) before the initial charge.
If you need open the period of the Ink Charge from the Ink Leak Check for three days or
more, make sure to disconnect the connect part of Print Head and the Ink Supply Unit.
Additionally, make sure to perform the Ink Leak Check again if the Ink Charge
performs.

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The following explains the Head Angular Mecha Adjustment.
Adjustment Procedure
1. Turn the printer on in the Inspection Mode (P.316).)

2. Select the “Head Angular Mecha Adjustment” on the adjustment program.
3. Click the [Print], and print the adjustment pattern.
(Paper feed: Rear ASF Unit / Paper: Matte Paper (A4))
Figure 3-27. Head Angular Mecha Adjustment (1)

4. Check the Adjustment pattern, and forecast the adjustment value when the line space becomes equal
【OK】
【NG】
【NG】

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5. Turn the printer off.

7. Move the Print Head to the center.
8. While supporting the bottom of the CR Unit, loosen the four screws that secure the Print Head (by rotating
them 90 degrees counterclockwise).
9. Turn the Head Angular Adjustment Dial by the amount of the value selected in Step 4.
10. Turn the Head Angular Adjustment Dial by one step in the same direction (+ or -) in which the head is
misaligned.
Print Head
Head Angular Adjustment Dial
Screws
+5
-5
+ direction
- direction
Screw
-5
+5
Screw

11. Tighten the four screws, and move the CR Unit to the home position.
12. Turn the printer on in the Inspection Mode (P.316).)
13. print the adjustment pattern, and check it.
14. Repeat Step 1 to Step 13 until the spaces between the adjustment patterns of the Scan sheet are uniformly
distributed.

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Operation after the adjustment
In this printer, the cap of the Cap Unit follows the inclination of the Print Head. However, if hardened ink is
accumulated on the cap, capping may not be done properly and printing failure may result. After the adjustment
is complete, make sure to perform the operation check of the cap following the procedure below.
1. Push the cap of the Cap Unit to the rear and confirm the cap surely returns to the original position.
2. Push the cap of the Cap Unit to the home position and confirm the cap surely returns to the original position.
3. Repeat Step 1 to Step 2 a few times. If the action of the cap is too slow or awkward, or does not return to the
original position, replace the Cap Unit with a new one.
Step 1 Cap Step 2
Cap Unit
Figure 3-30. Operation check of the cap

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3.2.5 SMAP Run out Adjustment

This section describes SMAP Run out Adjustment.
Purpose
Correct the banding by the paper feed speed difference.
Preparation
1.Paper ?Photo Matte Paper
2.Paper feed entrance: Rear ASF
3.The number of sheets: 2-10 pieces
Flow Chart (outline)
Figure 3-31. Flow chart (outline)

PF/EJ Adjustment (Initialize PF value and EJ value)
(1)?Input & Check
Smap set 0 & Eject set 0
(2) Push “Input” button.
(3) Push “Finish” button
（1）（2）
0
0
0 （1）
（3）
（1）
Figure 3-32. Initialize Smap and EJ

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SMAP run out adjustment

Flow Chart (outline)
Figure 3-33. Flow chart (Set the Value)

Decided the value from the Adjustment pattern
Print Adjustment pat tan
(1).Check “Adjustment pattern”.
(2).Click “Print” button and print Adjustment pat tankeep the printing result.
（2）
（1）
Figure 3-34. Print Adjustment pattern

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Fix the Block Number

1. Find block number (A) that is the longest space between the upper block and the under block. and find block number(B)
that is the longest overlap between the upper block and the under block.
2. Compare length of the (A) and length of the (B).
3. When length of the (A) is longer than length of the (B),decide “White”. When length of the (B) is longer than (A),decide
“Black”.
0
1 A djustment pattern print result
2
（A)
9
10
11
（B)
PF Count
Figure 3-35. Adjustment pattern print result
There might be only space or only overlap by the printer.

If all are the spaces, fix “White” and find block number (A) that is the longest space
between the upper block and the under block.
If all are the overlap, fix “Black” and find block number (B) that is the longest overlap
between the upper block and the under block.

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Input of confirmation pattern parameter
1. Input “White” and “Black” And, the block number

2. Input 0 to Factor
3. Input the value of PF Count. See “Figure3-35 (p311)“
4. Click Input button
5. Click Confirmation pattern.
6. Click “Print” button and print out confirmation pattern sheet. keep the print result.
7. Repeat from step 3) to step 5) and input Factor as following individual value 5,10,15,20.keep the printing
result.
6
5
Figure 3-36. Print Adjustment pattern

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8. Decision of SMAP run out adjustment parameter

The standard of “OK” is as follows.
The density of all pattern A areas is lower than that of pattern B area. or The density of pattern A area in one
place is the same as the one in pattern B area, and another density of pattern A area is lower than pattern B area.
Pattern B 　 Pattern A
A djustment pattern print resul
Factor=5
Factor =0
Factor=10 Factor=15 Factor=20
Figure 3-37. Comparison by Factor difference

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Judgment by confirmation pattern

　　 Compare density differences of pattern A and pattern B .
　　Judgment 1: When the density of all pattern A areas is lower than that of pattern B area.it makes it to OK.
Judgment 2: When the part where the density of pattern A is higher than that of pattern B is one or less,
it makes it to OK.
When the density of pattern A is higher than that of pattern B, it is judged NG.
if there is no OK in five confirmation patterns. It does over again from the decision of the block
number. see " Fix the Block Number (p311)"
Figure 3-38. Judgment by confirmation pattern

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Input of SMAP run out adjustment parameters

Should input the following values that have been decided. The parameter is memorized and when the printer
prints and it is reflected.
1. Input the value of PF Count. See “Figure3-35 (p311)“

2. Input “White” and “Black” And, the block number
3. Input Factor. see "8 Decision of SMAP run out adjustment parameter (p313)"
4. Click Input button
4
2
Figure 3-39. Input of SMAP run out adjustment parameters
Do PF/EJ adjustment again after it completely assembles printer because the PF/EJ
regulation has been initialized.

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3.2.6 Inspection Mode

This chapter describes the inspection mode.
Purpose
To start the adjustment program without connecting the printer with ADF/Scaner Unit.
To adjust the origin of the Touch Panel.
3.2.6.1 To enter Inspection Mode

During in the Inspection mode, operations such as menu selection can be done by pressing the
following buttons on the panel.
[3] [6]
Power Moves up menu selection. Moves down menu selection
[Color]
Enter
Figure 3-40. Panel Operation in Inspection Mode

Procedure
1. Start the printer in Inspection mode by turning it on with the [HOME] button (1), [*] (2), [Stop] (3), and
[Power] button (4) on the panel simultaneously.
1 2
Figure 3-41. Shift to Inspection Mode(1)

2. When shifting to Inspection mode, the display of the panel is as follows.
Run : Color / Select [3][6]
1. Mechanism Inspection
2. Sepcial Inspection
3. FAX Inspection
4. Touch Screen Inspection
5. Development Inspection
6. FAX Development Insepction
7. Normal Mode
Figure 3-42. Shift to Inspection Mode(2)

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3.2.6.2 Printer Inspection Mode
1. On the displayed menu screen, select “1. Mechanism Inspection” and select “1.Printer Inspection Mode”.
As a result, the adjustment program operates only by the printer.
Run : Color / Select [3][6] Run : Color / Select [3][6]
1. Mechanism Inspection 1. Printer Inspection Mode

2. Sepcial Inspection 2. SCN/ADF FT Mode
3. FAX Inspection 3. SCN Endurance Model
4. Touch Screen Inspection 4. ADF Endurance Mode
5. Development Inspection
6. FAX Development Insepction
7. Normal Mode
Figure 3-43. Printer Inspection Mode

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3.2.6.3 Touch Panel Adjustment

This section describes the Touch Panel adjustment
Tools
Touch pen (without a sharp end such as a plastic stick)
1. On the displayed menu screen, select “4. Touch Screen Inspection” and press the [Color] button.
Inspection Mode
Run:Color / Select:[3][6]
1.Mechanism Inspection
2.Special Inspection
3.FAX Inspection
4.Touch Screen Inspection
5.Development Mode
6.FAX Development Mode

7.Status Sheet Print Mode
8.Nomal Mode
Figure 3-44. Touch Panel Adjustment (2)

2. On the displayed menu screen, select “1. Touch Screen Calibration” and press the [Color] button.
Touch Screen Mode

1.Touch Screen Calibration
2.Touch PNL Measurement Mode

3. Press “Push this Area. [OK]” to display the adjustment screen. To abort the adjustment, press “Push [Stop]
button. [Cancel]”.
Touch Panel to coordinate them.
Push this Area. [OK]
Push [Stop] button. [Cancel]

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4. Press “+” displayed on the four corners in order using the touch pen.
+ << Please Touch
5. When performing the adjustment again, press “Push this Area. [Cancel]” and start from Step 4 again. To save
the adjustment result, press “Push this Area. [Save]”.
Calibration Check
Push this Area. [Save]
Push this Area. [Cancel]
6. Press the red boxes (x 5) being displayed in the order given below with the Touch Pen.
Touch Red Area

1 3
2 4

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7. When “Complete!” appears on the Touch Panel, press the [Color] button to finish the adjustment.
Complete !
Push [Color] Button.
8. If “Retry Check” appears on the Touch Panel, press “Push this Area. [OK]” to start from Step 5 again.
Retry Check
Push this Area. [OK]

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3.2.6.4 To exit the Inspection Mode:

1. Press the [Stop] button to display the screen shown in Figure 3-52.
2. Press the [Power] button to display the screen below.
3. Press the [Power] button one more time to exit the Inspection Mode.
Flag Check
Initial Charge Flag: OFF

Inspection Flag: OFF
Push [Power] button.

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CHAPTER 4
MAINTENANCE
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4.1 Overview
This section provides information to maintain the printer in its optimum condition.
4.1.1 Cleaning
Except for the print head, there are no other mechanical parts or units that require periodic cleaning. However, if
need arises, clean the component observing the following instructions.
Instructions for cleaning
Exterior parts such as housing
Wipe dirt off with a soft clean cloth moistened with water. For glossy or transparent parts, use of unwoven cloth is
recommended to avoid scratching those parts.
Inside of the printer
Remove paper dust with a vacuum cleaner.
Rubber or plastic rollers such as an LD roller/Pickup Roller used to feed paper
If paper dust adhered to the rollers decreases the frictional force of the rollers and the rollers cannot properly feed
paper, wipe off the paper dust with a soft cloth moistened with diluted alcohol.
Instructions for cleaning ink stains
Wipe the stains off with a cloth wrung out of diluted alcohol.
Do not use alcohol for cleaning the transparent parts. Doing so may cause them to get
cloudy.
When wiping paper dust off the LD roller/Pickup Roller, be careful not to rub against the
surface asperity.
To minimize the effect on the parts, use diluted alcohol such as 70% diluted ether.
After using alcohol for cleaning, make sure to wipe the part off with a soft dry dust-free
cloth to remove alcohol traces fully.
4.1.2 Lubrication
The type and amount of the grease used to lubricate the printer parts are determined based on the results of the
internal evaluations. Therefore, refer to "4.2 Lubrication Points and Instructions (p324)" for the repairing
procedures below, and apply the specified type and amount of the grease to the specified part of the printer
mechanism.
Grease
Type Name EPSON Part Code Supplier
Grease G-96 1590700 EPSON

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 Lubrication Points and Instructions (p324)".
Maintenance Overview 323

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4.2 Lubrication Points and Instructions <Lubrication Point>

CR Shaft
<Lubrication Point>
<Type>
CR Guide Frame
CR Shaft G-97
<Type>
<Application Amount>
G-97
Appropriate amount
<Remarks>
Appropriate amount
Apply with brush.
<Remarks>
Lubricate with injector on
the contact surface
between CR Guide Frame
and CR Unit.
CR Guide Frame
Application point
Application point
Figure 4-2. Lubrication of the CR Shaft
Figure 4-1. Lubrication of the CR Guide Frame
<Lubrication Point> <Lubrication Point>

Right PG Adjustment Left PG Adjustment Lever
Lever
Right PG Adjustment Lever <Type>
<Type> G-97
G-97
<Application Amount> Appropriate amount
Appropriate amount
<Remarks>
Left PG Adjustment Lever
<Remarks> Lubricate with brush on
Lubricate with brush on the contact surface
the contact surface between Left PG
between Right PG Adjustment Lever and
Adjustment Lever and CR APG Gear.
Bearing.
Application point Application point
Figure 4-3. Lubrication of the Right PG Adjustment Lever Figure 4-4. Lubrication of the Left PG Adjustment Lever
324
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<Lubrication Point> <Lubrication Point>

Transmission Gear CR Driven Pulley
<Type> <Type>
G-96 G-97
<Application Amount> <Application Amount>
0.1g φ 1 mm × 1 mm
<Remarks> <Remarks>
Lubricate with brush on Lubricate with injector on
the entire circumference of the hole on CR Driven
Transmission Gear. Pulley.
CR Driven Pulley
Transmission Gear Application point Application point
Figure 4-5. Lubrication of the Transmission Gear Figure 4-6. Lubrication of the CR Driven Pulley
<Lubrication Point>
Two bosses of the 2nd
Cassette Unit
<Type>
G-97
φ2 mm × 3 points
<Remarks>
Lubricate with injector.
Boss Application point
Figure 4-7. Lubrication of the 2nd Cassette Unit
325
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4.2 Firmware Update

Perform the firmware update as follows.
Required items
PC (Windows 7, Windows Vista or Windows XP)
USB Cable
Procedure
Epson Firmware Up dater
Firmware Update 326

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4.3 Initialization of Password

The following explains how to initialize the password.
Adjustment procedure
1. Push the [#] button and [Power] button simultaneously.
[3] [6]
Power Moves up menu selection. Moves down menu selection.
[#]
Figure 4-1. Initialization of Password (1)

2. On the displayed menu screen, select “2. Password initialization” and press the [Color] button.
User Special Mode
1.Touch Screen Calibration
2.NW Setting
3.Password Initialization
4.Wifi Disabling
5.Ethenet Disabling
6.USB ID Setting
7.FAX to PC
8.FAX to Memory

3. Press the [Stop] button for Yes or press the [Power] button for No.
Password Initialization
Initialize the Admin Password?
Yes : Press [Stop] Button
No : Press [Power] Button

4. Press the [Power] button.
Initialization of Password 327

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CHAPTER 5
APPENDIX
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5.1 Revision FConnector Diagram
Ink End Sensor
WIreless LAN Module Ink End Sensor
Ink End Sensor

USB Ink End Sensor
ADF/ Scanner Unit APG Encoder Sensor
APG Phase Sensor
Front Cover Microswitch

Speaker
Panel Board
Power Supply Unit
PF Encoder Sensor CN32

CN9 CN3 CN5 CN2 CN77 CN81 CN501
CSIC Board (BK) Relay Board

CN2
CSIC B
CN1
CN2
CN1
CN3 CN705
Y CN5
CSIC M CN6 CN1
C CN7
CSIC Board (CL) CN701
CN702
Print Head
CN703
CN704 Main Board
CR Encoder Sensor CN30
CR Unit PW Sensor
CN4 USB
CC97 IF CN20 CN1 USB

CN1
CN10 Ethernet
CR Motor CN61
PF Motor CN78
ASF Motor CN79 CN69 CN38 CN75 CN45 CN39 CN707 CN74
Pick Up Roller Motor
Solenoid Rear Cover End Sensor

Cassette Detection Sensor
Back Tray Paper Detection Sensor
Decompression Motor
Maintenance Box CSIC
Decompression Motor
PE Sensor
APG Motor
Front Manual Feed Detection Sensor
Solenoid
Printer Feed Detection Sensor
Option Cassete
Ink Supply BK Cover
Cassette Paper Detection Sensor
Open Sensor
Ink Supply CL Cover SMAP Phase Paper Detection Sensor
Open Sensor
Pick Up Roller Motor Phase Detection Sensor
Hopper Detection Sensor
ASF Encoder Sensor
Figure 5-1. Connector Diagram
Revision FConnector Diagram 329

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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 CR Unit

Purpose
To prevent damaging the CR Unit by shock during transportation.
Risk if it is not performed.
Fatal error caused by the damage of the CR Unit.
Preparation
Strong tape (Length: 150 mm, width: 30 mm, fold on end: 5 mm)
Method
1. Turn off the printer to set the CR Unit to its home position.
2. Move the CR Unit until it hits the right frame from the home position.
3. Attach the strong tape on the CR Unit as shown below to secure the CR Unit.
CR Unit Strong tape
Middle Housing
Figure 5-2. Securing the CR Unit
Protection for Transportation 330

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5.2.2 Protection of the Ink Supply Needle

Purpose
To prevent ink from leaking from the Ink Supply Needle due to the shocks during transportation.
Method 1
Preparation
　Needle Cap 　(ASP Code:1653127)
Needle Cap
Figure 5-3. Needle Cap

Procedure
1. Remove each Ink pack from each Ink Pack holder.
2. Attach each Needle Cap to each Ink Pack holder.
Ink Pack Holder
Needle Cap
Figure 5-4. Attach Needle Cap

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Method2
Preparation
Strong tape
Paper (pain paper: A4 size)
Procedure
1. Open the Ink Supply CL Cover Assy.
2. Cut the paper in half.
3. Fold one piece of paper in half lengthwise and then fold it in half width-wise to fold it into fourths.
4. Put the folded piece of paper over the Ink Supply Needle (C/M/Y) and secure it with strong tape as
shown below.
5. Do the same to the left side for the Ink Supply Needle (BK).
Strong tape
38 mm
Paper
52.5 mm
Figure 5-5. Protection of the Ink Supply Needle

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SERVICE MANUAL

RevisionE Color Ink jet Printer

Copyright © 2016 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 July 8th, 2014 First Release

D Dec. 15.2015 Chapter 2

F May 24, 2016 Revise the contents.

2.1 Overview ................................................................................................................................................................. 40

2.3.5.4 Main Board .......................................................................................................................................... 107

2.3.9.3 ADF Cover Assy.................................................................................................................................. 221

3.1 Required Adjustments ........................................................................................................................................... 279

3.2.1.3 ASF Timing Belt Tension Measurement ............................................................................................. 287

4.1 Overview ............................................................................................................................................................... 323

5.1 Revision FConnector Diagram.............................................................................................................................. 329

1.1.1 Troubleshooting Workflow

 This flowchart is compiled based on the following contents.

Turn on the printer

Printer failure only

Yes Copy an image by ADF

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

Figure 1-1. Troubleshooting Workflow (1)

The power-on Error is indicated during

3 Error is indicated during printing nozzle check pattern (p14)

Figure 1-2. Troubleshooting Workflow (2)

Scanning cannot ADF does

Figure 1-3. Troubleshooting Workflow (3)

1.2 Power-On Sequence

The rotation direction of

Figure 1-4. Movement of Components

2. Printhead initialization and fuse inspection

3. Seeking the home position

3-3.The PF Motor rotates counterclockwise and sets the CR lock.

--- CCW ---

Table 1-1. Power-on Sequence

3-5.The CR Motor and PF Motor stop.

--- --- ---

3-7.The PF Motor rotates clockwise and releases the CR lock.

5. Adjustment of CR acceleration delay

6. Measurement of synchronized drive timing correction

7. Low temperature operation sequence*5

7-3.The PF Motor rotates counterclockwise and the CR lock is set.

--- CCW ---

8. Setting the PF Roller origin

Table 1-1. Power-on Sequence

12.CR lock setting

12-2.The CR Motor rotates counterclockwise and the CR Unit moves to the

12-3.The PF Motor rotates counterclockwise and the CR lock is set.

--- CCW ---

13.Set the Hopper up

 Power-on Sequence after Recovering from a Paper Jam Error

1.3 Fatal Error Code List

Table 1-3. Fatal Error List (Printer)

Fatal Error Code List 20

Table 1-3. Fatal Error List (Printer)

Fatal Error Code List 21

Table 1-3. Fatal Error List (Printer)

Fatal Error Code List 22

Table 1-3. Fatal Error List (Printer)

Fatal Error Code List 23

Table 1-3. Fatal Error List (Printer)

This flowchart is compiled based on the following contents.

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

Power-on Sequence after Recovering from a Paper Jam Error

ADF/Scanner fatal error list

Inspection mode error list