Epson WorkForce 635/620/60 Series Service Manual – 2010 (P/N SEMF09-016)

Epson’s Revision C service manual for the WorkForce 635, 620, 625, and 60 color inkjet printers is dated October 12, 2010 (P/N SEMF09-016). It also covers the Stylus Office TX620FWD, BX625FWD, BX525WD, and B42WD, the Stylus TX560WD and SX525WD, the T42WD, and the ME OFFICE 960FWD, 900WD, 82WD, and 85ND.

Searchable PDF with Chapter Bookmarks

Finding repair details: Search the PDF text for part names and error codes, or use the embedded bookmarks to jump to adjustment procedures, the connector diagram, and troubleshooting. Small connector labels in Figure 4-1 are easiest to read when zoomed in.

The download is one printable PDF with 58 pages, including the cover, eight pages of front matter, and the 10-page appendix.

Printer Disassembly, Adjustments, and Fault Diagnosis

These are selected service topics. The troubleshooting workflow also covers ink cartridge recognition faults and abnormal operating noise.

• Housing and scanner assemblies: Separate housing paths for the WorkForce 635/620 and WorkForce 60 series, with CIS Unit and ADF Unit service where fitted.

• Printer mechanism: Removal and reassembly coverage for the printhead, carriage and frame, CR and PF motors, Paper Guide Front Assy, and Duplex Unit.

• Boards and ink system: Main Board Unit and P/S Board Assy service, FFC and harness routing, and removal references for the Ink System Assy and Waste Ink Tray Assy.

• Post-repair adjustments: PF timing belt tension measurement, PF belt step check, platen gap inspection, and an Adjustment Program matrix keyed to the parts removed or replaced.

• Cleaning and lubrication: Cleaning guidance for the housing, paper path, and feed rollers, plus illustrated grease application points for the printer mechanism and scanner assemblies.

• Startup and fault diagnosis: Normal and post-jam power-on sequence tables, the Figure 4-1 Connector Diagram, and fatal error tables for the printer and applicable ADF and scanner assemblies.

Epson wrote this manual for repair service personnel and specifies that Epson-certified technicians perform the repairs.

Model Differences, Service Parts, and Jigs

Revision C adds the WorkForce 60 family across all four chapters. The WorkForce 635 series has ADF and fax hardware, the 620 series follows the scanner-only configuration, and the 60 series has a separate housing path for its printer-only chassis. The ME OFFICE 85ND configuration omits the wireless LAN module.

Five disassembly flowcharts distinguish shared and series-specific parts. They flag service-part availability and point to the relevant checks, cable routing, lubrication, and adjustments. The screw and torque index has 15 entries. The separate operation-time tables for the three series give prototype replacement figures marked TBD. For units outside Chapter 1, Epson refers technicians to the separate Service Parts Information (SPI) exploded diagrams.

Paper Guide Front supporting tools A/B/C are 1543170/1543539/1543541 for the 635 and 60 series and 1543171/1543544/1543547 for the 620 series. The printhead uses supporting tool 1543169. The detailed plates also show CIS spacer selection, ADF housings, WorkForce 60 stacker and panel parts, and routing for the scanner, motors, PE sensor, fax, panel, and power supply.

Main Board and Printhead Service

The 19-item Required Adjustment List lets technicians identify which settings and checks apply after replacing a specific part. It covers EEPROM data copy, destination and serial initialization, ink charge, Head ID input, maintenance-counter reset, PF/EJ and first-dot/PW alignment, bidirectional and head-angle corrections, paper skew, deterioration offsets, and CR/PF motor heat protection. Dedicated sections cover the mechanical checks and conditional MAC address setting, followed by a final check-pattern print after the required adjustments.

If the old Main Board’s EEPROM data cannot be read, Epson calls for replacing the Waste Ink Tray Assy along with the board. Disconnecting the Head FFC at the CR encoder requires carriage disassembly to reconnect it. The Main Frame removal notes also flag the risk of damaging the printhead nozzle plate.

Lubrication and Fault Isolation

The manual specifies G-45, G-71, G-72, and G-74 grease across 15 illustrated lubrication references. These include the Main Frame, Paper Guide Front Assy, Ink System Assy, CR Assy, Scanner Unit, Duplex Unit, CIS Carriage, and the WorkForce 620 Stopper Assy.

The connector diagram distinguishes scanner-motor connections on the 635 and 620 series so technicians can identify the correct board connector before tracing a fault. The WorkForce 60 series uses LED error indications, and Epson Status Monitor 3 provides the error details. Internal repair exposes the P/S Board and high-voltage circuitry. Epson calls for power isolation and ESD protection before service.

Scanner Fastener and Stopper Lubrication Examples

The WorkForce 620 series housing flowchart identifies an S3 fastener for the Scanner Unit. The accompanying screw index specifies 6 ± 1 kgf·cm for S3.

The WorkForce 620 series Stopper Assy illustration specifies G-72 grease at 0.2–0.3 g per point at the three slider-base grooves that contact the Cam Slider.