How to Remove and Install Epson Printhead Cable Covers and CR Clips

Replacing or removing a printhead on an Epson printer often looks straightforward until you reach the printhead cable cover. This small plastic component can become surprisingly difficult to remove or reinstall, especially when flexible flat cables, the carriage frame, and nearby gears limit your working space.

The challenge usually does not come from the complexity of the part itself. Instead, the difficulty comes from understanding exactly how the cover locks into the carriage and which direction it must move during removal and installation.

In addition, Epson printers can use different styles of carriage, or CR, cable covers depending on the design of the paper-feed mechanism. Understanding the difference between these covers can prevent broken tabs, damaged cables, and unnecessary frustration during a printhead repair.

In this guide, we will explain how the printhead cable cover works, how to identify the two common CR clip styles, how the PF encoder disk affects the cover design, and how to safely remove and reinstall the cover. We also have a video below to show how it's done so you can see the positioning and movement more clearly.

What Is the Printhead Cable Cover?

The printhead cable cover is a small plastic component located on or around the carriage assembly. Its purpose is to help organize and secure the flexible flat cables, often called FFC cables, that connect the printhead and other carriage components to the printer's electronics.

When replacing a printhead, technicians frequently need to remove this cover before they can access the printhead cables.

Although the cover may appear to simply snap into place, its attachment system is more specific than that. A locking tab fits into a small opening in the carriage assembly. Another section of the cover follows the carriage structure and helps keep the cover aligned.

Therefore, trying to pull the cover directly outward can make removal unnecessarily difficult. Worse, excessive force may break the locking tab.

Once you understand how the tab and opening interact, the process becomes much easier.

The main concept is simple: the cover slides into position rather than simply snapping straight inward.

That distinction is important during both installation and removal.

Understanding Inner and Outer CR Clip Designs

There are two common styles of these carriage cable covers. At BCH Technologies, they can be described as the outer CR clip and the inner CR clip.

The easiest way to distinguish them is by looking at the curved section of the plastic.

On the outer-style clip, the curved portion extends outward. On the inner-style clip, the curved section bends inward toward the carriage.

Although they look slightly different, both clips perform essentially the same job. The difference exists because Epson uses different mechanical layouts around the carriage depending on the printer model.

In particular, the size of the PF encoder disk and nearby gears affects which cover shape the printer needs.

If you are searching for a replacement part, you can visit BCH Technologies and search for CR clip to compare the inner and outer versions.

Before ordering or installing a replacement, compare the original part carefully with the available versions. Do not select a cover based only on the printer's appearance because similar printer families can use slightly different mechanical configurations.

How the PF Encoder Disk Determines the Correct Cover

The PF encoder disk is an important part of the printer's paper-feed positioning system. PF generally refers to paper feed.

The printer monitors this encoder disk to determine how far the paper-feed mechanism has rotated. Accurate feedback from the encoder system allows the printer to advance media in precise increments.

The size of this disk can also influence the shape of the nearby CR cable cover.

A printer with a smaller PF disk, approximately 36 mm, may use the outer-style clip. In this design, the curved section of the cover provides clearance around the smaller disk.

As the carriage travels across the printer, this shape helps keep the cover from interfering with the PF disk.

Printers using a larger PF disk, approximately 68 mm, may instead use the inner-style clip.

In this arrangement, the curve serves a slightly different purpose. Rather than primarily clearing the encoder disk, it helps keep the cover away from the larger gear structure near the carriage.

Therefore, the difference between inner and outer clips is not cosmetic. Epson shaped the covers according to the surrounding mechanical components.

Installing the wrong style may create clearance problems when the carriage moves.

For that reason, always compare the replacement cover with the original part and inspect the PF disk and neighboring gears before installation.

How the Locking Mechanism Works

Understanding the locking mechanism is the most important part of this repair.

When the cable cover is removed and placed flat on a workbench, the design becomes much easier to understand. You can identify the top, bottom, front, and rear portions of the cover without trying to look through cables inside the printer.

One section of the cover contains a small locking tab. The carriage contains a corresponding opening.

During installation, the objective is to slide the cover along the carriage until that locking tab enters the opening.

Once the tab reaches the opening, it drops or snaps into position and prevents the cover from sliding backward.

Another upper section of the cover also engages the carriage structure. Together, these contact points keep the cable cover secure.

When you practice the movement outside the printer, the mechanism appears simple because the cover can remain horizontal.

Inside the printer, however, the same movement happens vertically. This change in orientation makes the installation feel much more complicated.

Instead of thinking about pushing the cover straight onto the carriage, think of it as sliding the cover along the carriage until the locking tab reaches its opening.

That mental picture can make the installation significantly easier.

Why Installation Feels Difficult Inside the Printer

Several obstacles make the cover harder to install when the carriage remains inside the printer.

First, the part must usually be positioned vertically rather than horizontally.

Second, flexible flat cables occupy the same area where the cover needs to travel.

Third, visibility is limited. You may not be able to see the locking opening once the cover is positioned between the cables and the carriage.

Finally, the cover must remain properly aligned while it slides into position.

Because of these limitations, many people instinctively try to push the cover directly toward the carriage. However, that approach can prevent the locking tab from reaching its opening.

Instead, concentrate on maintaining the correct orientation first.

Position the cover behind the appropriate cable and between the cables and carriage frame. Keep the cover as vertical as possible.

Once everything is aligned, move the cover upward along the carriage.

As the cover reaches its correct position, the locking tab should enter the opening and secure the cover.

You usually should not need excessive force.

If the cover refuses to move into position, stop and check the alignment rather than pushing harder.

Preparing the Printer Before Removing the Cover

Before working around a printhead, carriage cable, or electrical connector, disconnect power from the printer.

Do not connect or disconnect printhead FFC cables while the printer is powered.

The printhead circuit can carry electrical signals that may damage the printhead or mainboard if a cable becomes partially connected or shorted while power is present.

Whenever possible, move the carriage into an accessible position before disconnecting power. The exact method depends on the printer model.

After disconnecting the power cord, give yourself enough working space around the carriage.

It is also helpful to take several photographs before removing cables or covers. These reference images can help you confirm cable routing during reassembly.

Pay particular attention to:

• Which cable passes in front of the cover

• Which cable passes behind it

• How deeply the FFC cables enter their connectors

• Which direction the exposed cable contacts face

• How the cable cover sits against the carriage

• The location of the locking tab

These details can prevent reassembly mistakes later.

How to Remove the Printhead Cable Cover

Removing the cover involves releasing the locking tab and sliding the cover away from its locked position.

Because the cover sits vertically inside the printer, the direction of movement may initially feel unintuitive.

If the same cover were lying horizontally on a table, you would lift the tab and slide the cover sideways.

Inside the printer, that sideways motion becomes a downward movement.

Start by locating the locking tab.

Use a small suitable tool to gently lift the tab enough to clear the carriage opening. A plastic spudger or small flat tool may work well, depending on the available space.

Avoid aggressively bending the tab. These plastic clips can become brittle with age, ink contamination, heat, or repeated removal.

Once the tab clears the opening, push or slide the cover downward.

Do not yank the cover away from the carriage.

The goal is to disengage the sliding mechanism, not bend the cover until it releases.

As the cover moves downward, it should separate from the carriage and become easier to remove from between the cables.

Take your time around the FFC cables. A damaged carriage cable can create problems ranging from missing colors to complete printer errors or electrical damage.

How to Install the Printhead Cable Cover

Reinstallation works in the opposite direction.

First, identify the correct orientation of the cover.

Then position it behind the appropriate cable and between the cable bundle and the carriage.

Make sure the cover remains completely vertical.

Next, align the side of the cover with the carriage guide.

Slide the cover upward.

As the cover moves upward, the locking tab should approach the small opening in the carriage.

Continue moving the cover gently until the tab enters the opening.

You may feel or hear a small click when the tab locks.

Afterward, lightly check the cover.

It should remain firmly attached without excessive movement. However, do not aggressively pull on it to test the connection.

Also verify that no FFC cable has become trapped, sharply folded, or pinched between the cover and carriage.

The cables should follow their intended routing and retain smooth bends.

Protecting the FFC Cables During Reassembly

The flexible flat cables deserve special attention during this repair.

These cables contain thin conductive traces laminated into a flexible material. Although they can bend, they are not designed to tolerate sharp creases.

A hard fold may crack the internal traces.

Similarly, repeated bending at the same point can eventually weaken the cable.

When reinstalling the CR cover, make sure the cables remain relaxed and follow their original route.

Never force the cover into place while an FFC cable is underneath the locking tab or trapped against the carriage.

If something feels unusually tight, remove the cover and inspect the cable routing again.

Also examine the ends of the FFC cables before reconnecting them.

Look for:

• Bent or torn contacts

• Burn marks

• Ink contamination

• Corrosion

• Sharp creases

• Delamination

• Cracked cable material

Even minor cable damage can cause unusual printer behavior after a printhead replacement.

Common Mistakes to Avoid

One of the most common mistakes is pulling the cover directly outward.

Because the cover uses a sliding locking system, pulling outward may place unnecessary stress on the plastic tab.

Another common mistake is installing the wrong CR clip style.

If the printer uses a different PF disk or gear configuration, the incorrect cover may interfere with moving components.

Cable routing also causes frequent problems.

If a cable runs on the wrong side of the cover, the carriage may pull against it during operation.

Additionally, avoid using excessive force.

These parts are small and inexpensive compared with the damage that can occur if a cable connector, carriage component, or encoder system becomes damaged.

Finally, never reconnect the printer and immediately start moving components manually without first inspecting the entire carriage area.

Before powering the printer, verify that the cover is secure and that nothing enters the path of the carriage.

Check Carriage Movement Before Powering the Printer

After reinstalling the cable cover, inspect the carriage path carefully.

If the printer design allows safe manual carriage movement while powered off, gently check whether the carriage can travel without the cover contacting the PF encoder disk, gear assembly, cable bundle, or another component.

Do not force the carriage against the parking or locking mechanism.

You are simply checking for obvious interference.

Pay close attention to the curved section of the CR clip.

On printers with the smaller PF disk, confirm that the outer-style curve clears the disk.

On printers with the larger disk and gear configuration, make sure the inner-style clip clears the nearby gear.

Also verify that the FFC cables move naturally with the carriage.

They should not pull tightly at either end of carriage travel.

If anything appears incorrect, resolve the mechanical issue before reconnecting power.

A Simple Way to Understand the Installation

The easiest way to learn this process is to remove the cover and study it outside the printer.

Place the cover flat on a table.

Identify the locking tab and imagine the corresponding opening in the carriage.

Then visualize sliding the cover horizontally until the tab falls into the opening.

Once you understand that motion, rotate the entire concept 90 degrees.

Inside the printer, the cover follows essentially the same sliding movement, but it travels vertically.

To remove it, release the tab and slide downward.

To install it, align the cover and slide upward until the tab locks.

This simple visualization removes much of the confusion from the process.

Making Printhead Repairs Easier

Small mechanical details often determine whether a printer repair feels straightforward or frustrating.

The printhead cable cover is an excellent example. It looks like a simple plastic clip, but without understanding its locking direction and surrounding components, technicians can spend unnecessary time trying to remove or reinstall it.

Remember these key points: identify whether your printer uses an inner or outer CR clip, examine the PF encoder disk and surrounding gears, protect the FFC cables, release the locking tab before removal, and slide the cover rather than forcing it outward.

When reinstalling the cover, keep it vertical, position it correctly between the cables and carriage, and slide it upward until the locking tab enters its opening.

Most importantly, never use excessive force around printhead cables or carriage electronics.

Once you understand how the locking mechanism works, removing and reinstalling this cover becomes a much more predictable part of printhead replacement and carriage repair.

For additional printer repair information, replacement parts, and troubleshooting resources, visit BCH Technologies. We also have a video below to show how it's done, including how to identify the cover orientation, release the locking tab, and reinstall the CR clip correctly.