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

• Covers the Epson WorkForce 635, WorkForce 620/625, and WorkForce 60 series together with the TX620FWD, BX625FWD, TX560WD, SX525WD, BX525WD, T42WD, B42WD, and ME OFFICE 960FWD/900WD/82WD/85ND regional variants; 58-page PDF, Epson document code SEMF09-016, Revision C dated October 12, 2010.
• Separates housing and printer-mechanism repair into five disassembly flowcharts, including model-specific paths for the WorkForce 635/620 multifunction chassis and the WorkForce 60 printer-only chassis, plus individual standard-operation-time tables for all three series.
• Maps removal and reassembly of the Main Board Unit and P/S Board Assy, Printhead and carriage/frame assemblies, CIS Unit and ADF Unit, Ink System Assy and Waste Ink Tray Assy, Duplex Unit, Paper Guide Front Assy, and CR/PF motors, with screw/torque references and FFC/cable-routing plates.
• Provides a 19-item required-adjustment matrix for Main Board initialization, Printhead replacement, waste-ink service, paper-feed and print-position correction, head geometry, paper-skew correction, and motor-protection control; named operations include EEPROM copy, MAC address setting, ink charge, Head ID input, and maintenance-counter reset.
• Documents model-specific service jigs, PF Timing Belt tension and step checking, platen-gap inspection, final check-pattern printing, cleaning instructions, and 15 illustrated lubrication procedures for printer, scanner, duplex, ink-system, and carriage components.
• Adds normal and post-paper-jam power-on sequence tables, the Figure 4-1 Connector Diagram, a troubleshooting workflow, and fatal-error tables for the printer and the ADF/scanner hardware used on the WorkForce 635/620 series.

Disassembly, Component Repair, and Model Differences

Revision C adds the WorkForce 60/T42WD/B42WD/ME OFFICE 82WD/85ND family throughout the publication. Epson separates the variants rather than treating them as one generic chassis. WorkForce 635 coverage includes the ADF and FAX hardware; WorkForce 620 coverage follows the scanner configuration; the WorkForce 60 series has its own housing path and no scanner/ADF troubleshooting branch. Figure 4-1 also identifies the ME OFFICE 85ND as the configuration without the Wireless LAN Module.

Chapter 1 uses color-coded flowcharts to show service-part status and the checks, adjustments, lubrication, and cable-routing references that follow removal. Detailed plates cover the Main Board and MAC label, CIS spacer selection, Printhead support, Paper Guide Front installation, ADF housings, WorkForce 60 stacker and panel parts, and routing for the Head FFC, scanner, PF/CR motors, PE sensor, FAX, panel, and power-supply cables. The repeated torque index contains 15 screw/torque entries.

Epson identifies the jigs required for Paper Guide Front and Printhead repair. Paper Guide Front supporting tools A/B/C are 1543170/1543539/1543541 for the WorkForce 635 and 60 series, while the WorkForce 620 series uses 1543171/1543544/1543547. Printhead supporting tool 1543169 is listed separately. The three standard-operation-time tables give prototype replacement times by assembly, but Epson marks them TBD; they are not presented as a finalized flat-rate schedule.

Parts or units not described in Chapter 1 are referred to separate SPI exploded diagrams. This PDF therefore covers the stated disassembly and repair procedures, but it is not a complete illustrated service-parts catalog.

Adjustment, Maintenance, and Diagnostic Scope

The required-adjustment chart links each removed or replaced part to the factory operations that follow. Dedicated procedure sections cover PF Timing Belt tension/PF belt step checking, platen-gap inspection, and MAC address setting. The remaining Adjustment Program functions are organized in the part-by-part matrix, including destination and serial initialization, PF/EJ and first-dot/PW alignment, Bi-D and head-angular correction, paper-skew correction, deterioration offsets, and CR/PF motor heat-protection control. A final check-pattern print is specified after the required adjustments are complete.

Several warnings are specific enough to matter at the bench. If EEPROM data cannot be read from a replaced Main Board, the manual requires the Waste Ink Tray Assy to be replaced with it and the applicable initialization and adjustment work completed. Disconnecting the Head FFC from the CR encoder unnecessarily forces carriage disassembly to reconnect it. Removing the Main Frame with the Printhead still installed can damage the nozzle plate, while incorrect FFC or harness routing can pinch the P/S Board cable or leave motor and sensor connections improperly positioned.

Maintenance coverage identifies G-45, G-71, G-72, and G-74 grease and illustrates application points on the Main Frame, Paper Guide Front, Ink System Assy, CR Assy, Scanner Unit, Duplex Unit, CIS Carriage, and WorkForce 620 Stopper Assy. The appendix then supports fault isolation with carriage/PF movement sequences, CN-number connector mapping, printer fatal codes, and separate ADF/scanner codes. WorkForce 60 error indications are LED-only, so the workflow directs technicians to Epson Status Monitor 3 for the detailed error. Internal repair exposes the P/S Board and high-voltage circuitry; the manual calls for power isolation and ESD protection before service.