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SERVICE MANUAL Color Inkjet Printer EPSON WF-2540/WF-2548/WF-2541 EPSON WF-2530/WF-2532/WF-2538/WF-2531 EPSON WF-2520/WF-2528/WF-2521 EPSON WF-2510/WF-2511/WF-2512 EPSON WF-2010 CONFIDENTIAL SEMF12-003...
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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.
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.
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7. In order to protect sensitive microprocessors and circuitry, use static discharge equipment, such as anti-static wrist straps, when accessing internal components. 8. Do not tilt this product immediately after initial ink charge, especially after performing the ink charge several times.
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.
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Revision Status Revision Date of Issue Description June 29, 2012 First Release August 28, 2012 Revised Contents □ Chapter 2 ■ Made change in "2-1 Standard Operation Time (p24)" □ Chapter 3 ■ Made change in "3-2 Required Adjustment List (p56)" ■ Made change in "3.2.2.3 PIS Board Check (p62)"...
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WF-2540 / WF-2530 / WF-2520 / WF-2510 /WF-2010 series Revision B Chapter 6 Appendix 6.1 Connector Diagram ..............................76 6.2 Protection for Transportation ..........................77 6.2.1 Securing the CR Unit............................77 6.2.2 Securing the Paper Support/Paper Support Sub ..................... 78...
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B 1.1 Troubleshooting This section describes the troubleshooting workflow and fatal error information. 1.1.1 Troubleshooting Workflow The following page describes the troubleshooting workflow. Follow the flow when troubleshooting problems.
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B Error is indicated during power-on The power-on sequence sequence (p 10) (p 10) does not start Fatal error Maintenance error Ink End error Ink Cartridge error No Ink Cartridge error...
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B 1.2 Power-On Sequence This section describes the power-on sequences in two conditions. The preconditions are as follows. Condition 1: Normal power-on sequence (See Table 1-1.) Turning on the printer after turning it off without an error.
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B Condition 2: Power-on sequence after recovering from a paper jam error (See Table 1-2.) Turning on the printer after turning it off with a paper jam fatal error.
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B 1.3 Fatal Error Code List This section describes how to check the fatal error code, description, and the possible causes. 1.3.1 Displaying the Fatal Error Code The fatal error code is stored in the EEPROM on the Main Board and can be read out using the Adjustment Program.
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B 1.3.2 Printer Fatal Error Code This section describes the printer fatal error code and the possible cause for this product. Table 1-3. Fatal Error List (Printer) Error Error type...
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B Table 1-3. Fatal Error List (Printer) Error Error type Error name Possible cause code • PF Encoder failure (contaminated/detached scale, Encoder Sensor failure) • Tooth skip of the PF Timing Belt •...
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B Table 1-3. Fatal Error List (Printer) Error Error type Error name Possible cause code • Defective Fault Detection Plate (detachment, peeled reflector) Reflector no reflection error • Sensor failure (contaminated Sensor, damaged FFC, PIS Board installation failure) •...
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B 1.3.3 Scanner Fatal Error Code This section describes the scanner fatal error code and the possible cause for this product. Table 1-4. Fatal Error List (Scanner) Error code...
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B 2.1 Overview In this chapter, the product names are called as follows: WF-2540 Series: WF-2540/WF-2548/WF-2541 WF-2530 Series: WF-2530/WF-2532/WF-2538/WF-2531 WF-2520 Series: WF-2520/WF-2528/WF-2521 WF-2510 Series: WF-2510/WF-2511/WF-2512 WF-2010 Series: WF-2010 This chapter describes procedures for disassembling the main parts/units of this product. Unless otherwise specified, disassembled parts/units can be reassembled by reversing the disassembly procedure.
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B 2.1.3 Locations of the Parts/Units This section shows the locations of the main parts/units of this product. The parts/units which can not be seen in the following pictures are indicated in dotted lines...
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B Printer mechanism Name Name CR Driven Pulley Assy (p35) CR Unit (p38) CR Scale (p35) PF Roller Unit (p38) CR Timing Belt (p38) Star Wheel Holder Assy (p31)
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B Name Name FAX Assy (p31) (FAX function compatible model) PF Motor Assy (p38) Wireless LAN Module (p34) (Wireless LAN function PF Timingbelt (p34) compatible model) EJ Roller (p31)
The following are the standard operation time for servicing the product. This standard operation time was determined with the MTTR result measured using the prototype of WF-2540 series which have the most functions. For other models described in this manual, perform the repair work referring to this standard operation time though the time varies due to the structural difference between models.
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B Table 2-1. Standard Operation Time Time (mm:ss) Parts/Unit Adjustment/ Replacement inspection ADF Driven Gears 6:42 ADF Upper Frame Assy 6:44 ADF Pad Assy 7:23 ADF Base Assy 6:15...
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B Table 2-1. Standard Operation Time Time (mm:ss) Parts/Unit Adjustment/ Replacement inspection PS Unit 4:41 1:28 6:09 PF Scale Sheet 4:29 PF Encoder Sensor 4:43 PF Scale 4:55 PF Grounding Spring...
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B 2.2 Disassembly/Reassembly Procedures This section describes procedures for disassembling the parts/units in a flowchart format. For some parts/units, detailed procedures or precautions are provided (accordingly indicated by icons and cell's color). Refer to the explanations in the example chart below and perform an appropriate disassembling and assembling procedure.
Revision B 2.2.2 Disassembly Flowchart WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series described in this manual have differences in their structure because the same printer mechanism is used for some of them and the composition of housings or functions differs.
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B The example below shows how to see the charts on the following pages. The name enclosed in gray indicate a part/unit that Paper Guide must be removed on the Upper Assy (p29) way to the target parts.
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B 2.2.2.1 Multifunction Printer specific parts START PIS Shield FFC Cover Reflector PIS Paper Support Paper Guide Waste Ink Pad Housing Rear Tray Front Assy (p 31) Plate A...
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B (p 30) (p 30) ADF Cable Strengthen Plate Extension spring (x2) Strengthen Plate Document Cover ADF Paper Paper Support Document Mat Assy Guide Cover Cover Cover Upper Pump tube...
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B 2.2.2.2 Singlefunction Printer specific parts START Panel FFC FFC Cover Reflector PIS Waste Ink Pad PIS Shield Paper Support Paper Guide Printer Cover Outer Assy Plate A Front Unit...
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B (p 32) Extension spring (x2) Cable (CN14) Strengthen Plate Strengthen Plate Front Tray Assy/ Pump tube Front Tray Rail Upper Lower Left/Right Ethernet Board Cap Assy Assy S1 S19...
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B 2.2.2.4 Unit/Assy (p 30) Common parts/unit Model-specific parts/unit ADF Unit Scanner Unit FFC/cable list FFC/Cable Remove the double-sided tape (x1) and release the Scanner FFC. Grounding wire ADF Paper...
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B Multifunction Printer : (p 30) (p 30) Singlefunction Printer : (p 32) LED&Button Type 2.5LCD Type 2Line Bitmap Type Tray Front Panel Housing Panel Housing Tray Front Panel Board...
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B (p 34) (p 35) (p 35) Cap Assy (p31) Spur Gear 37.2 Shield Plate Antistatic Cloth (p34) Hopper (p39) LD Roller Assy (p34) (p 47) Main Board CR Motor (p34)
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B 2.3 Detailed Disassembly/Reassembly Procedure for each Part/Unit ADF/Scanner Unit (ADF compatible model) ADF Unit (ADF compatible model) ADF Paper Guide Cover Assy (ADF compatible model) ADF Frame Assy (ADF compatible model)
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B Scanner Housing Upper (Scanner compatible model) Scanner Motor Gear Cover Housing Rear (Multifunction Printer) (Scanner compatible model) Scanner Housing Upper Step 2 Section B Scanner Motor Gear Cover...
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B PS Unit Panel Unit Panel Housing Upper Assy (2.5 inch LCD / 2Line Bitmap) (2.5 inch LCD / 2Line Bitmap) Bottom Rear Panel Housing Upper Assy Housing Left Housing Right Widen this rib to release the hook of PS Unit.
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B PIS Board Assy / Star Wheel Holder Assy Reflector PIS Assy CR Scale Reflector PIS Assy Step 1 Reflector PIS Holder Step 2 Secure PIS Shield Plate and CR Cut Section Motor together with Main Frame.
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B CR Driven Pulley Assy / CR Timing Belt Printhead Main Frame CR Unit (ink cartridge exchange position) Protrusion Main Frame Pinion gear of CR Motor Printhead PIS Shield Plate A...
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B USB Board (USB compatible model) EJ Roller Gear Wireless LAN Module FAX Assy (Models with FAX) (Model with wireless LAN) FAX Assy Wireless LAN Module Cable Ferrite core...
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B Ethernet Board Assy (Models with Ethernet) PF Grounding Spring PF Scale Sheet Singlefunction Printer Ethernet Board Assy Left Ethernet Board Assy PF Grounding Spring leg A Spring Cutout...
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B Cap Lever / Cap Assy Pump Unit Step 1, 3-5 Step 2 Cap Slider Step 1-2 Cap Assy Hole of Shaft A Shaft B Frame Base Step 4...
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B 2.4 Routing FFCs/cables ADF Frame Assy / ADF Document Support (ADF compatible model) ADF Hinge Left (ADF compatible model) ADF/Scanner Unit (Multifunction Printer) ADF Hinge Left Grounding wire of the ADF Document Support...
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B Panel FFC (Multifunction Printer) Panel Unit (Multifunction Printer) Panel FFC (Singlefunction Printer) PF Encoder Sensor Panel FFC Main Frame Left side of printer Connector of Panel Board Panel FFC...
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B CR Motor USB Board (USB compatible model) USB Board CR Motor cable Hook D Groove of FFC Holder Hook E Main Board PF Scale Hook C CR Motor cable (red)
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B Head FFC (Routing on the Main Frame) Head FFC (Routing on the CR Unit) Left side of CR Unit Aligning Head FFC with CSIC FFC Head FFC Connector of CR Encoder...
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B 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.
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B Table 3-1. Required Adjustment List Adjustment Type Mechanism adjustment Priority Checking the Platen Adjustment Item CR Belt tension check PF Belt tension check Check if the PG is within...
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B Table 3-1. Required Adjustment List Adjustment Type Mechanism adjustment Priority Checking the Platen Adjustment Item CR Belt tension check PF Belt tension check Check if the PG is within...
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B Table 3-2. Required Adjustment List Adjustment Type Adjustment using the Adjustment Program Priority CR motor heat PF motor heat Scanner motor EEPROM Maintenance First dot position TOP margin...
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B Table 3-2. Required Adjustment List Adjustment Type Adjustment using the Adjustment Program Priority CR motor heat PF motor heat Scanner motor EEPROM Maintenance First dot position TOP margin...
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B Table 3-2. Required Adjustment List Adjustment Type Adjustment using the Adjustment Program Priority CR motor heat PF motor heat Scanner motor EEPROM Maintenance First dot position TOP margin...
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B Table 3-2. Required Adjustment List Adjustment Type Adjustment using the Adjustment Program Priority CR motor heat PF motor heat Scanner motor EEPROM Maintenance First dot position TOP margin...
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B 3.2 Adjustment Program This section provides the operating environment, functions related to safety and privacy policy, and the adjustment item newly added of the Adjustment Program. See "3.1 Required Adjustments (p53)"...
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B 3.2.2.2 Scanner Motor Heat Protection Control Purpose To measure the manufacturing variation of the DC motor (Scanner) to determine the correction value used for estimating the current value of the motor.
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B 3.2.2.3 PIS Board Check Purpose Photo Ink Sensor degradation and failure check. Risks if the adjust- If number of printing sheets increases, ink mist adheres to a sensor and the quantity of light of a sensor falls off ment is not cor- by becoming dirty, so that it is necessary to exchange PIS Board Assy (BOARD ASSY,.SUB).
(including using the Epson-specified jigs) according to this manual. If the PG cannot fall within the standard range after performing the platen gap check described in this section, first check if the unit is correctly reassembled following the instructions in this manual.
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B 1. Move the CR Unit to the center of the printer. 2. Place the thickness gauges (1.6 mm) on the position A shown in Figure 3-1. 80-digit side...
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B 3.3.2 CR/PF Belt Tension Check This section describes the CR/PF Belt tension check. This printer is designed so that the each tension of the CR Timing Belt and PF Timing Belt fall within the expected range if you correctly reassemble the unit according to this manual.
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B Checking the PF Timing Belt Tension Perform the PF Belt tension check before installing the PF Scale and the PF Encoder Sensor. 1. Set the following parameters to the sonic tension meter: Weight: 1.2 g/m...
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B 4.1 Overview This section provides information to maintain the printer in its optimum condition. 4.1.1 Cleaning Except for the Printhead, there are no other mechanical parts or units that require periodic cleaning. However, if need arises, clean the component observing the following instructions.
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B 4.2 Lubrication Points and Instructions <Part supply as ASP> <Part supply as ASP> Cross-section section Supplied as the Scanner Supplied as the ADF Unit ADF Base Unit <Lubrication status when <Lubrication status when...
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B <Part supply as ASP> <Part supply as ASP> Grease spreading procedure Guide rail Cross-section: Application Point After applying the grease, follow the procedure below to spread it with brush.
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B <Part supply as ASP> <Part supply as ASP> Supplied as the Printer Supplied as the Printer Rear right Rear left Apply grease on rib Apply inside the groove...
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B <Part supply as ASP> <Part supply as ASP> <Part supply as ASP> None Supplied as the LD Roller Shaft <Lubrication status when <Lubrication status when supplied as ASP>...
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B 5.1 Overview This chapter provides the refurbishing work of the printer and its purpose. 5.1.1 Ink Discharge Purpose To clean the ink path inside the Printhead to restore its condition identical to the factory default.
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B 6.1 Connector Diagram Cable connections of this printer are shown below. For the function differences of each model, refer to " Function List According to Models (p28)". Panel Unit...
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B 6.2 Protection for Transportation This section describes the cautions for packing the printer before returning it to the user. 6.2.1 Securing the CR Unit Purpose To prevent damaging the Change Lever by shock during transportation.
WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B 6.2.2 Securing the Paper Support/Paper Support Sub Purpose To prevent damaging the Paper Support/Paper Support Sub by the shock during transportation. Risks if it is not performed The Paper Support/Paper Support Sub will be scratched and the abrasion powder will be produced due to the shock during transportation.
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WF-2540 / WF-2530 / WF-2520 / WF-2510 / WF-2010 series Revision B Singlefunction Printer Attach the strong tape (3 tapes) to the position on the following diagram and secure the Paper Support/ Paper Support Sub on the Housing Upper Assy.