Epson DFX 8500 Service Manual
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Epson DFX 8500 Service Manual

Epson DFX 8500 Service Manual

Terminal printer
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EPSON
TERMINAL PRINTER
DFX-8500
SERVICE MANUAL
SEIKO EPSON CORPORATION
4009310

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Summary of Contents for Epson DFX 8500

  • Page 1 Volver al INDICE EPSON TERMINAL PRINTER DFX-8500 SERVICE MANUAL SEIKO EPSON CORPORATION 4009310...
  • Page 2 = The contents of this manual are subjects to change without notice. All efforts 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.
  • Page 3 CONNECT THE UNIT TO A POWER SOURCE UNTIL INSTRUCTED TO DO SO. WHEN THE POWER SUPPLY CABLE MUST BE CONNECTED, ON POWER SUPPLY AND OTHER ELECTRONIC COMPONENTS. REPAIRS ON EPSON PRODUCT SHOULD BE PERFORMED ONLY BY EPSON CERTIFIED REPAIR TECHNICIAN. MAKE CERTAIN THAT THE SOURCE VOLTAGE IS THE SAME AS THE RATED VOLTAGE,...

  • Page 4: Specifications

    Describes the theory of printer operation. CHAPTER 3. DISASSEMBLY AND ASSEMBLY Includes a step-by-step guide for product disassembly and assembly. CHAPTER 4. ADJUSTMENT Includes a step-by-step guide for adjustment. CHAPTER 5. TROUBLESHOOTING Provides EPSON-approved techniques for troubleshooting. CHAPTER 6. MAINTENANCE Describes preventive maintenance techniques setice the equipment.
  • Page 5 REVISION SHEET Revision Issued Data Rev. A May l&l998...

  • Page 6: Table Of Contents

    TABLE OF CONTENTS CHAPTER 1. GENERAL DESCRIPTION CHAPTER 2. OPERATING PRINCIPLES CHAPTER 3. DISASSEMBLY AND ASSEMBLY CHAPTER 4. ADJUSTMENT CHAPTER 5. TROUBLESHOOTING CHAPTER 6. MAINTENANCE APPENDIX...

  • Page 7: General Description

    1.4.6.1 Power-on Initialization ... 1.4.6.2 Software Initialization ... 1.4.6.3 Panel lnitiallzatwi ..1.5 MAIN COMPONENT..1.5.1 M-3160 Printer Mechanism..1.52 Main Control Board (C204 MAIN Board) ... 1.5.3 C204 DRV Board ... 1.5.4 C204 DRV-B Board ..
  • Page 8 1.5.5 C204 SUB Board ........................l-41 1.56 C204 PSBIPSE Board .
  • Page 9 1 .I FEATURES The DFX-8500 is a l&pin. serial, dot matrix printer with a maximum speed of 1120 characters per second (cps). It is designed for business use and provides high-speed, high-volume printing and continuous-sheet handling. The main features of the printer are:...
  • Page 10 DFX-8500 The following table shows options. code #8766 #8767 ‘.-x309 1;815OOX C81507X -----w !307^ !308’ !310’ !311’ !312’ !313^ !314’ !315’ WA2357 C82345’ -82362 ^^^_. Table l-1. Option Name Ribbon cartridge Ribbon pack Pull tractor unit sper cutter cutter Pedoratior Serial intelface card (inch screw) Serial inter face card (mm screw)
  • Page 11 The line including special high dufy download characters or bit image data will be printed by one third speed of “High duty” mode. When the print head temperature rises to the upper limit, the printer stops printing. And Notes 3: when the print head temperature falls to the normal level, then the printer starts printing again.
  • Page 12 Note : The international and legal characters are these 12 codes; 23h, 24h, 4Oh, SBh, SCh, SDh, 5Eh, 6Oh, 7Bh. 7Ch, 7Dh, 7Eh. Typeface: Bit map font: EPSON Draft EPSON Roman EPSON Sans Serif Bar code: EAN-13 Interleaved 2 of 5 UPC-E Code 128 Table 1-3.
  • Page 13 PC APTEC PC 720 PC 863.’ BRASCII” IS0 Latin 1 Hebrew 8” OK byte or 128 K bytes (depend on DIP switch settings) GENERAL DESCRIPTION Bitmap Font EPSON Draft EPSON Roman EPSON Sans Serif EPSON Draft EPSON Roman EPSON Sans Serif...

  • Page 14: Environmental Condition

    DFX-8500 1.2.2 Paper Feeding Feeding method: Push tractor feed (front / rear) Push and pull tractor feed (front I rear) Feeder: Front push tractor, rear push tractor, pull tractor (option) Paper path: Tractor (front in, rear in, top out) Line spacing: 1 I6 inches or programmable Feed speed: l/6-inch...

  • Page 15: Safety Approvals

    1.2.6 Safety Approvals 120 V version: Safety standards EMI : 230 V version: Safety standards EMI : 1.2.7 CE Marking 230 V version: Low Voltage Directive 73/23/EEC EMC Directive 89/336/EEC 1.2.8 Acoustic Noise Level: 58 dB(A) (IS0 7779 pattern) Ribbon Cartridge 1.2.9 Fabric Type...

  • Page 16: To Figure L-

    ?--- DFX-Bsoo 1.2.11 Printable area Continuous paper 0 ~ABCD &_ _._.._ . RM (right margin) TM (top margin) BM (bottom margin) area, the paper feeding pitch may be ineguiac Notes 75 mm 1: In tf&e top optional pull tractor is used, the top 720 mm area should not be printed. 2: If the Notes Notes 3: Forms-override printing is available 20 lines after the paper end.
  • Page 17 Labels : T- -_._ PW (width) PL (length) LM (left margin) RM (right margin) TM (top margin) EM (bottom margin) Notes 1: paper Feeding backward Notes 2: tf In the top 75 mm area, the paper feeding pitch may be irregular. if the optional pull tractor is used, the top 120 mm area should not be printed.
  • Page 18 DFX-9500 Continuous forms with labels : &__ ._._ Notes 1: Feeding beckward or paper (PATH) selection are prohibited. Notes 2: ff In the top 75 mm area, the paper feeding pitch may be irregular. If the optional pull tractor is used, the top 120 mm area should not be printed. Notes 3: Notes 4: Forms-override printing is available 20 lines after the paper end.
  • Page 19 Overlapping multi-part forms : -_------_---__- _____ _____ ____ __________. Carrie1 .____-_________________________________ 1 PW (widtl win) rgin) lie area) Notes 1: Feeding backward or paper (PATH) selection are prohibited. Notes 2: if In the top 75 mm wee, the peper feeding pitch may be irregular. If the optional pull tractor is used, the top 120 mm area should not be printed..

  • Page 20: Continuous Paper (Single Sheet And Multi-Part)

    DFX-6500 1.2.12 Paper and Media 1.2.12.1 Continuous paper (Single sheet and multi-part) :opies rotal Thickness iinch) luality dulti-pati binding ‘erforation lotes Figure 1-I. Dotted Paste Positions 7-12 Table 1-5. Continuous Paper Front Entry Maximum Minimum 16.0 17.0 oriqinal + 6 copies 0.021 0.0025 0.065...
  • Page 21 GENERAL DESCRIPTION Figure 1-8. Paper-stapling Height beding dimaion Paper > Fiaure 1-9. Paper-stapling Method 1 Figure l-10. Paper -stapling Method 2 1-13 Rev. A...

  • Page 22: Perforation

    DFX-8500 1.2.12.2 Labels Label Size Backing Sheet Width (inch) (mm1 (inch) Backing Sheet Length (mm) (inch) Label Thickness (mm) Total Thickness (inch) (mm) Quality AVERY CONTINUOUS AVERY same quality labels Refer to section 1.2.12.5. Perforation Notes The easy-cone-off Every label must be put on the carrier. Each comer of those labels must be rounded.
  • Page 23 1.2.12.3 Continuous Forms with Labels e 1-7. Continuous Label Size Refer to Section 12.122. Width (inch] (mm) Length (inch] JVeiqht :notmulti-part) v&sight (913 ;one sheet of multi-part) abel Thickness (inch) (mm) Total Thickness (inch) (mm) 3uality (Multi-part forms) Plain paper, reclaimed paper. carbonless multi-part forms AVERY CONTINUOUS FORM LABELS, 3uality (Label)
  • Page 24 DFX-8500 1.2.12.4 Overlapping Multi-part Form 1.2.12.5 Perforation Weak horizontal and vertical perforations cause paper jams. v The length ratio of the cut part and uncut part of perforations must be more than 3 to 1 and Less than 5 to 1 (Refer to Figure I-13.). Horizontal perforations must have an uncut part in each end of the paper (Refer to Figure l-14.).
  • Page 25 GENERAL DESCRlpnoN Figure 1-12. Paper Width Overlapping Area uncut _Fpl- /- - paper edse UnCUl Figure 1-13. Perforations 1 Figure l-14. Perforations 2 l-17 Rev. A...
  • Page 26 DFX-8500 Figure l-15. Perforations 3 Figure 1-19. Sprocket Hole 1 /folds Figure l-19. Sprocket Hole creases ---..__ ..___ 9.’ ,“#-- fo’ds Figure 1-17. Unsuitable Paper Figure l-20. Bad Folded Paper l-18 Rev. A...

  • Page 27: Serial Interface

    During test printing or during setting printing During SelecType When the parallel interface is not selected. Notes 2: /ERROR signal is at a low level when the printer is in one of the following states. m Printer hardware error (fatal error) Paper out error...
  • Page 28 Signal Level: Note: A low Iogic level on the logical high signal is 2.0 V or less when the printer is powered off. And this signal is equal or exceeding 3.0 V when the printer is powered on. The receiver shall provide an impedance equivalent to 7.5 K ohms to ground.
  • Page 29 Cl Connector pin assignments: Refer to Table l-11. Table l-11. Signal and Connector Pin Assignment (Reverse channel) Note: *In/Out refers to the direction of signal flow from the printer’s point of view. Rev. A IEEE-1284 nibble mode 57-30360 (AMPHENOL) 36.pin plug or equivalent No Info.

  • Page 30: Optional Interface

    Table 1-12. Signal and Connector 1 GND Other 1 NC Note: *In/Out refers to the diraction of signal flow from the printer’s point of view. 1.3.4 Optional Interface Type-B and Type-B level 2 optional interfaces are available (Refer to Table i-1.). l-22...
  • Page 31 To prevent hosts from this kind of time-out, the printer receives data very slowly, several bytes per minute, even if the printer is in busy state. This slowdown is started when the rest of the input buffer becomes several hundreds of bytes. At last, when the input buffer is full, the printer is in busy state continuously.
  • Page 32 This section describes the functions performed through the control panel, such as test print, hexadecimal dump, and paper memory function. 1.4.1 Control Panel The printer control panel gives you easy control over most common printer operations. The panel consists of indicator lights and buttons. C LEDOff LEDOn Figure l-22.
  • Page 33 Normal Mode Operation at power on: Tuning the printer on while pressing panel switches executes the function shown in Table l-1 4, Table 1-14. Switch Function at Power On Notesl: All of mechanism adjustment values are cleared. Then it requires the printer mechanism adjustment.
  • Page 34 W The LED is on when the printer is powered on, and it is off when the printer is powered off. Paper Out (Red) : The LED is on when the printer is in the paper out status, and it is off when the printer is out of this status.

  • Page 36: Dip Switch Settings

    When power is applied or the printer is reset, the DIP switch selections are treated as the default setup. If the setup is changed, the power should be cycled or the printer should be reset.
  • Page 37 Table l-17. Character Table Setting (Standard) SW l-1 1 SW12 1 SWl-3 1 SW1-4 1 SWl-5 I Off I Off JOfl I off Table 1-16. Character Table Setting (NLSP) GENERAL ~EsGff~P770~ 1 SWl-6 I PC437 (1’” 1 PC850 (...
  • Page 38 DFX-6500 Table 1-19. Front Tractor Page Length Table l-20. Rear Tractor Page Lenoth SW44 Table l-22. Serial UF Parity Setting I sw4-6 sw4-5 , -.. ^ . . Table l-23. Serial l/F Baud Rate Setting sw4-7 sw4-8 l-30 Table l-21. l/F Selection sw4-4 l/F Mode Auto...
  • Page 39 Normal Paper is set and the pull tractor is not used: The printer feeds the paper to the tear off position and cut the paper by the cutter, and feeds backward to paper park position. If the cutter is not used, it goes incomplete changing paper error. So cut the paper at the top of paper and push Pause switch or Front/Rear switch, and the printer feeds the paper backward.
  • Page 40 The printer feeds the paper to the tear-off position and cut the paper by cutter and feeds backward to paper park position. If cutter is not used or the printer fails to feed the paper to paper park position, it goes incomplete changing paper path error.
  • Page 41 Operation at Power On 1.4.4.2 Self test: Prints the self test pattern. To cancel it, make printer pause and turn off the power, DIP switch setting print: Starts the setting printing mode, Data dump: Starts the data dump mode, in which all the input data are printed as hexadecimal corresponding characters.
  • Page 42 When the cover is opened, the printer stops printing and enters the pause mode automatically several beeps. The printer stays at the state until the cover is closed and the “Pause” switch is pressed. Several printer settings loaded at each power-on can be changed in this operation.
  • Page 43 The loading position must be adjusted for overlapping multi-part forms at every loading. If paper position doesn’t correspond with TOF when turn on the printer, paper is to the top of the next page automatically. advanced Cl How to write the information of a paper except “Continuous forms with labels” : 1) Make sure the printer is turns off.

  • Page 44: Initializations

    (remote RS command). This initialization is: to initialize the printer mechanism. to clear the all buffers of data. to cancel the download character definition. to make the printer stand-by state, if no errors occur. to execute software initialization. 1.4.6.2 Software Initialization The initialization of this level is activated by the control code ESC &...

  • Page 45: Main Component

    1.5 MAIN COMPONENT The main components of the DFX-8500 are as follows: M-3160 Printer mechanism: C204 MAIN board Main control board: C204 DRV board Mechanism driver board: C204 DRV-B board % Printhead driver board: G204 SUB board DIP SW. board:...
  • Page 46 LIFX-6500 1.5.1 M-3160 Printer Mechanism The M-3160 printer mechanism is a 18-pin (g-pin two lows), serial impact dot matrix printer mechanism developed for the DFX-8500. It is designed to provide high-speed, high-volume printing. and is especially heavy and durable when compared with existing terminal...
  • Page 47 1.5.2 Main Control Board (C204 MAIN Board) The C204 MAIN board is a main controller l&bit CPU: TMP95C051A; Gate array: E05B36 PROM (including C.G.) 2M-bit (IC5) 4M-bit (IC14) ADM232L RS-232C RESET IC PST391QIC13) EEPROM 93066 There are two types of C204 MAIN board used as after service differences between them.
  • Page 48 PF (paper feed) motor, CR (carriage) feed) motor drive circuits are located on the driver boards. Sensor signals from the printer mechanism Major ICs on the DRV are as follows: CR motor drive IC: PF motor drive IC:...

  • Page 49: C204 Sub Board

    GENERAL DESCRIPTION 1.5.4 C204 DRV-B Board The C204 DRV-B board is the % printhead driver board. The drive part is mainly Consists of the discrete bipolar FETs. Figure 1-28. C204 DRV-B Board 1.5.5 C204 SUB Board The C204 SUB board consists of five DIP switch units.

  • Page 50: C204 Psbipse Board

    1.5.6 C204 PSB/PSE Board C204 PSWPSE board is a power supply circuit board which generates (main control board) and printer mechanism The PSB board is a 100-120 V AC version, the power for the control drive circuit (driver board). It contains...

  • Page 51: Control Panel

    1.5.7 Control Panel The control panel for this printer consists of switches, LED% and buzzers (Refer to Figure l-22 on page l-23.). 1.5.8 Housing The housing for this printer consists of the upper housing, lower housing, printer cover, ink cartridge cover, rear sheet guide, tractor unit, knob, adjust lever and release lever.

  • Page 52: Operating Principles

    PRINTER MECHANISM OPERATION..2.1 .l Printhead Mechanism ... 2.1.2 Carriage Mechanism ... 2.1.3 Platen Gap Adjustment Mechanism ... 2.1.4 Paper Feed Mechanism ... 2.1.4.1 Tractor Wire Operation..2.1.5 Ribbon Feed and Tractor Select Mechanisms..2.1.6 Plunger Mechanism ...
  • Page 53 3160 printer mechanism features a 18-pin, impact dot printhead for serial printing. The printer mechanism is the main component of the printer and is supported by the other components (the power supply and control circuits). Figure 2-l shows the Model 3160 printer mechanism.
  • Page 54 Because the carriage moves at a very high speed, it would be dangerous if a hand or finger were inserted inside the printer mechanism during printing. Therefore, as a safety measure, when the top cover is opened, the interlock switch cuts the drive voltage to the CR motor to slow down the carriage speed and prevent accidents.
  • Page 55 The PF motor drives the paper feed mechanism. The front, rear, and top PE sensors detect whether paper is present in the paper path, and stop the printer from printing when there is no paper. The printer is equipped with three PE sensors: the front PE sensor at the front tractor, the rear PE sensor at the rear tractor, and the top PE sensor at the paper bail.
  • Page 56 DFX-8500 2.1.1 Printhead Mechanism The printhead is a charge-type, impact dot printhead. Figure 2-4 shows its operation. The dot wire is attached to the actuating spring at point A. It is pulled beck (left in the figure) by magnetic force when power is applied and during standby.

  • Page 57: Carriage Mechanism

    The printer does not have a carriage home position sensor; the home position is detected using disordered pulses of the CR motor and CR encoder sensor (linear, bek-type). A gum pad is attached to the left side of the frame.

  • Page 58: Platen Gap Adjustment Mechanism

    DFX-8500 2.1.3 Platen Gap Adjustment Mechanism Figure 2-6 shows the platen gap adjustment the carriage have a vertical section. The rotation shaft through the gears. Counterclockwise rotation reduces it. The encoder plate with equally pitched slits is attached the PC sensor detects it and outputs resolution (horizontal distance).

  • Page 59: Paper Feed Mechanism

    2.1.4 Paper Feed Mechanism Figures 2-7, 2-8, and 2-9 show the paper feed mechanism. After the printer loads the paper, it is fed by the tension roller, platen roller, and front or rear tractor assembly. The PF motor rotates the tension roller and tractor select gear (Figures 2-8 and 2-9) and moves either the front or rear tractor assembly.
  • Page 60 L’FX-8500 Paper Bail Tractor Select Gear Front PE Sensor PF Motor Tractor Sprocket (Front) Pinion Gear PF Tran Figure 2-9. Front Tractor Assembly Operation Paper Paper Bail Tension Roller Tractor Select Gear Rear PE Senso PF Transmission Gear Tractor Sprocket (Rear) Pinion Figure 2-9.

  • Page 61: Tractor Wire Operation

    Point B shows the movement range of the right tractor sprocket when the release lever is engaged or released. If the paper in the printer becomes bubbled, you can pull the tractor wire to the right to stabilize the paper tension between the left and right tractor sprockets.

  • Page 62: Ribbon Feed And Tractor Select Mechanisms

    DFX-8500 2.1.5 Ribbon Feed and Tractor Select Mechanisms The RF motor supplies power to both the ribbon feed and tractor select mechanisms. RF motor pinion swings ribbon feed point. The rotation of the RF motor is transmitted alter the gears are engaged. When the RF motor pinion gear rotates counterclockwise, the motor rotates the ribbon feed mechanism: the motor rotates the tractor select mechanism.
  • Page 63 Tractor select mechanism : Figure 2-12 shows the operation of the tractor select mechanism. transmitted to the tractor select cam through the ribbon feed select gear and tractor select transmission gear, and rotates the tractor select cam clockwise. The tractor select lever contacts the inside curve of the cam due to the spring force;...

  • Page 64: Plunger Mechanism

    2.1.6 Plunger Mechanism Figure 2-13 shows the plunger mechanism. The paper bail assembly is attached to the end of the plunger’s iron core. The paper bail assembly axis is connected to the frame. When the plunger coil is energized, the force of the paper bail spring returns the paper bail assembly to its original position.

  • Page 65: Power Supply Operation

    2.2 POWER SUPPLY OPERATION printer can be powered by either of two power supply boards: the 120 V C204 PSB board or the 220/240 V C204 PSE board. The only diierence supply power to the printer in the same way. The power supply board outputs the DC current required to drive the control circuits and printer driie mechanism.

  • Page 66: Power Supply Overview

    DFX-8500 2.2.1 Power Supply Overview Figure 2-14 shows a block diagram of the C204 PSB/PSE board Figure 2-14. Power Supply Board Block Diagram...
  • Page 67 General The power supply board converts the AC input voltage to the DC voltages required to operate the printer. The AC voltage is input to the AC inlet, and is supplied to the MO4 PSB/PSE board via the power switch and a fuse.
  • Page 68 Control and status signals : The PSBIPSE board receives two control signal from the C204 MAIN board and outputs two status signals to the MAIN board. Refer to Table 2-3 for the each signal and the printer status relationship. q Fatal error recovery When the printer detects the fatal error, the PSB/PSE board cannot recover for APPROX.10 minutes by the...

  • Page 69: Control Circuit Operation Overview

    PD signal. The reset circuit outputs the reset signal when the printer is turned on or off, the voltage level drops, or a reset signal is input from an external device. It resets the control circuit for a certain period directly or via the E05B36.
  • Page 70 ,... , ...., i Optional & Type-B I/F Card ;A .._.__..._._... , Option cutter i ... Panel Unit 9 i ....L------ figure 2-15.
  • Page 71 Contains the program that runs the CPU. Holds the CPU working area and buffers (input,, line,, and image buffers). Memorizes the printer unique parameter during the power is off. EIA to Logic level voltage level converter System reset IC Drives the CR motor.
  • Page 72 DFx-6500 Figure 2-16 shows the data flow for data input via the parallel interface. Although various circuits perform data processing, the control core is the CPU and all operations are executed via the CPU. In this circuit, the E05B36 IC (ICl) provides the interface between the external host computer and the CPU, and all data processing is performed by read/w&e operations to MM10 (Memory Mapped Input I Output).

  • Page 73: Reset Circuit

    2.3.2 Reset Circuit This sectiin describes the hardware reset circuit. When the hardware reset signal is input, all ICs in the control circuit are reset, and the CPU executes the program from the starting address. Figure 2-17 shows the reset circuit block diagram. The circuit is equipped with a reset IC: PTS591(IC13) operation is described below.

  • Page 74: Sensor Circuits

    DFX-8500 2.3.3 Sensor Circuits Figure 2-18 shows the sensor circuits in block diagram form. The printer is equipped with the following sensors: 1. Front and rear PE sensors (use a photo intermpter) 2. Top PE sensor (to detect the TOF position, uses a photo interrupter) 3.
  • Page 75 Each sensor is described below. Front and rear paper end sensors Detection fon: Photo interrupter output form: Open collector (pulled up to 10 K ohms resistor) Logical: Paper present: LOW Paper out: HIGH TOD oaoer end sensor (to detect the TOF position) D&iion fon: Photo reflector...
  • Page 76 To provide information about the CR motor life, the analog port (AN2) of the CPU checks the isolation resistance every time the printer is turned on. If the isolation resistance is equal or less than 2.2 K ohms, a carriage error is detected and the printer beeps.

  • Page 77: Cr Motor Drive Circuit

    (05, Q6, and Q7). When the printer is turned on, CPU analog pod AN2 measures the isolation resistance in the CR motor. If the isolation resistance is equal or less than 2.2 K ohms, the printer change the status to the carriage error.
  • Page 78 This division increases throughput when the carriage is moving and the printer is not printing. The printer has three deceleration control modes. The degree of deceleration is determined by how the CR motor transistors are driven. Table 2-6 describes how the transistors are driven for each mode.
  • Page 79 Until the carriage speed reaches the constant speed set by PI control, acceleration control determines the speed of the carriage. The printer can print while the carriage is accelerating. The carriage speed moves to constant control speed smoothly to prevent the CR motor from exceeding the constant control speed. The EOSB36 gate array controls the motor driver (STK681-050), which performs the current chopping.
  • Page 80 Current speed - SP3 1. The printer uses Deceleration driving mode 2, based on the duty data, and the rest of the time, it uses Deceleration driving mode 1. 2. During this time the control circuit measures time periods using the encoder signal, and controls the following: When duty data becomes Duty,.,...

  • Page 81: Pf Motor Drive Circuit

    2.3.5 PF Motor Drive Circuit Stepping motor driver STK67138MK4 circuit block diagram, and Table 2-9 provides the PF motor specifications. Driving: 1.75 A, + 0.20 A Current Consumption ‘HE .._. Hybrid “pps . . . pulses per second “‘ips . . . inches per second The motor pulse switching signals are transmitted from CPU ports PGOO to PG03.

  • Page 82: Rf Motor Drive Circuit

    DFX-0500 2.3.6 RF Motor Drive Circuit Figure 2-24 shows a block diagram of the RF motor driie circuit, and Table 2-10 provides the RF motor specifications. The RF motor is a stepping motor. The control circuit performs open-loop phase switching control according to the timing data for acceleration, constant speed, and deceleration.

  • Page 83: Pg Motor Drive Circuit

    2.3.7 PG Motor Drive Circuit Figure 2-25 shows a block diagram of the PG motor drive circuit, and Table 2-11 provides PG motor specifications. The PG motor is a stepping motor. The motor phase switching signals are output from the E05B36 ports PGA to PGD.

  • Page 84: Plunger Drive Circuit

    2.3.8 Plunger Drive Circuit Figure 2-26 shows a block diagram of the plunger drive circuit, Table 2-12 provides the plunger specification, and Table 2-13 provides the plunger switching pattern. The plunger is driven using three switching patterns. Gate array E05826 ports PLP and PLN output the plunger coil drive signals.

  • Page 85: C204 Drv-B Board

    FET shorts, CPU (IC2) port PDRERR (P-channel) I NDRERR (N-channel) detects HIGH level and the E05B36 (IGl) sends the DRERR (Driver Error) signal to the C204 PSBiPSE board. When the C204 PSB/PSE board receives this signal, it stops the output voltage and the printer beeps. MAlNBOd Figure 2-27.
  • Page 86 2. When the printhead temperature exceeds equal or more than 110 ‘C, the printer performs intewal printing (Carriage rest time at the sides is little bi longer than the normal.) 3. When the printhead temperature exceeds equal or more than 120 ‘C. the printer stops printing until the temperature goes down to 100 ‘C or less.

  • Page 87: Disassembly And Assembly

    3.2.6 Printer Mechanism Removal ........

  • Page 88: Overview

    29.0 kg (63.8 lb) and is much larger and heavier than most printed you must be careful when handling it. Whenever carry it, supporting it from the bottom. Never lift the printer by holding the front cover: because it ma! coma off.
  • Page 89 Foam packing for paper bail Figure 3-l. Packing Material Attaching After attaching the packing materials, pack the printer in its container as shown in Figure 3-2. Figure 3-2. DFX-85W Packing the paper and ribbon cartridge. Then attach the following packing Rev.

  • Page 90: Tools

    3.1.2 Tools This section describes the tools required for assembling, disassembling, or adjusting the printer. Note : Refer lo CHAPTER 4 for adjustment CHAPTER 6 for tools for maintenance, Table 3-1. Recommended E: EPSON exclusive A: Mandatory B: Recommended Rev. A...
  • Page 91 DFX-8500 Figure 3-3. Dial Gauges Figure 3-4. Dial Gauge Base Figure 3-5. Thickness Gauge Figure 3.6. Dial Gauge Master Rev. A...

  • Page 92: Specification For Screws

    3.1.3 Specification for Screws the following sections, abbreviations are used for small parts such as screws and washers. Table 3-2 lists these abbreviations. Table 3-3 lists screw and washer types. Table 3-Z. Screw Abbreviations Table 3-3. Screw Names and llluatrations Head SidS Bind...

  • Page 93: Service Checks After Repair

    DFX-6600 3.1.4 Service Checks After Repair B&Ore returning the printer after service, use the check list in Table 3-4, which provides a record to make sewicing and shipping more efficient. Table 34. Inspection Check List for the Reoaired Printer Category...

  • Page 94: Disassembly And Assembly

    Before you disassemble or assemble the printec be sure to read and follow the instructions in Sectiion 3.7, “OVERVIEW ” Before you disassemb/e the printer; be sure to turn the printer power off and disconnect AC cab/e. This section describes how to disassemble the printer. See the APPENDIX for an exploded diagram of the printer.

  • Page 95: Rom Replacement

    Refer to Section 323.1 for instructions on removing the top coveK If you tilt back tha printer with the top cover attached, be careful not to put too much weight on the to, cover or any other printer components. Spread a thick, soft cloth under the printer before you follow the steps below...

  • Page 96: Printhead And Ribbon Mask Assembly Removal

    3.2.2 Printhead and Ribbon Mask Assembly Removal The printhead can be changed without disassembling the entire unit. Use the exclusive printhead kit for printhead exchange on the DFX-8500. When you receive the kit, check that all of the following are included. Ptinthead Unit ::.::;::;...
  • Page 97 Step 1: Open the top cover and remove the ribbon cartridge. Step 2: Remove the hvo CBS (M3x8) screws securing the FPC cover to the bottom plate of the printer mechanism. Step 3: Disconnect the three printhead cables and a ground cable from the connector junction board on me bottom plate.
  • Page 98 Step Disconnect the narrow FPC cable from white connector (lock-type). Step 6: Move the cartiage to around 90’” column, remove the two CP(S-Pl)(M4X7) printhead and remove the CP(S-Pi)(M3X6) printhead. CP(S-Pl)(M4X7) Figure 3-12. Step Disconnect the white connector for the paper width sensor on the ribbon mask. Step 6: Remove the two shafts securing the ribbon mask to the carriage using a slotted screwdriver, then remove the ribbon mask.
  • Page 99 DFX-8500 Confim, that the cables are connected correctly (Refer to Figure 3- 12.) Tighten the screws while pulling the printhead as shown below to secure the printhead firm/y Figure 314. Printhead Installation Step 12: install the heed cable cover and the connector cover. Step 13: Wipe off any stains from the carriage guide shaft, lubricate both ends of the carriage guide shaft with the included oil (O-2).

  • Page 100: Housing Removal

    3.2.3 Housing Removal This section describes how to remove the housing. 3.2.3.1 Top Cover Removal Two people are required to remove the top cover; one person must hold the top cover wf~;k the other person removes the screws. M the top cover is not supported while the screws are removed, the weight of the top cover may damage the rear hinges.

  • Page 101: Left, Right, And Front Covers Removal And Fuse Replacement

    DFX-8500 3.2.3.2 Left, Right, and Front Covers Removal and Fuse Replacement Step 1: Remove the four CBB (M4x16) screws securing Step 2: Remove the right side cover in the same way as you removed four cables from the main switch on the right side cover. CBB(M4X16) CBB(M4X16 Right and Lefl Covers...
  • Page 102 DISASSEMBLY AND ASSEMBLY Step 3: After you remove the right side cover, you can replace the input fuse for the C204 power supply board unit. Make sure the new fuse meets the printeis ACpower specifications. Carriage Motor (Right Side) Figure 3-19. Fuse Removal Step 4: Remove the three CBS (M4x16) screws securing the left side of the front cover to the lower cover.

  • Page 103: Front Panel Unit Removal

    DFX-8500 3.2.3.3 Front Panel Unit Removal Step 1: Remove the left and right side covers. (Refer to Section 3.2.3.2) Step 2: Open the top cover and disconnect connector CN5 (the panel unit connector). Step 3: Remove the two CBB (M4x16) screws from the front panel unit and remove the panel unit along with the panel connector cable.

  • Page 104: Upper Case Removal

    DISASSEMBLY AND ASSEMBLY Upper Case Removal 3.2.3.4 Step 1: Remove the front panel unit. (Refer to Section 3.2.3.3) Step 2: Remove the six CBB (M4x16) screws, and two CBB (M3xlO) screws from the upper case. Then remove the upper case. CBB(M3XlO) Figure 3-22.

  • Page 105: Circuit Boards Removal

    Refer to section for instructions on removing the top Cover. 3.2.3.7 E3 tf back the printer with the top cover attached, be careful not to put too much weight on the toI you tin cover or any other components. printer...
  • Page 106 Step From the left side, remove the two CPB(O)(M4X6) screws securing the green and yellow earth cable between the bottom plate of the printer mechanism and the earth on the bottom panel assembly. Step 4: Disconnect the 6 connectors, (1) through (6)
  • Page 107 DFX-8500 Step 7: While supporting the top cover to pmtect it from scratches, tilt back the printer and lay it on its back. Step 6: Remove the eight CBB (M4x16) screws securing the bottom panel assembly, and slowly remove the bottom panel unit assembly.

  • Page 108: Cooling Fan And C204 Power Supply Board Unit Removal

    3.2.4.2 Cooling Fan and C204 Power Supply Board Unit Removal Step 1: Remove the bottom panel assembly. (Refer to Section 3.2.4.1) Step 2: If You need to remove the cooling fan, disconnect connector CN5 and remove the four CCN (M3x30) screws securing it, and remove the fan.

  • Page 109: C204 Sub Board Unit Removal

    DFX-8500 3.2.4.3 C204 SUB Board Unit Removal Step 1: Remove the bottom panel assembly. (Refer to Section 3.2.4.1) Step 2: Disconnect connectors CN15 and CN16 on the C204 MAIN board. Step 3: Remove the two CBB (M3x8) screws securing the C204 SUB board assembly and remove the board.

  • Page 110: C204 Drv-B And C204 Drv Board Units Removal

    DISASSEMBLY AND ASSEMBLY 3.2.4.4 C204 DRV-B and C204 DRV Board Units Removal Step 1: Remove the bottom panel assembly. (Refer to Section 3.2.4.1) Step 2: Disconnect connector CN3 and cable connector CN14 for the C204 DRV board. Step 3: Disconnect connectors CNl and CN2 on the C204 DRV-B board. C204 DRV Board C204 DRV-B Board C204 MAIN board...

  • Page 111: C204 Main Board Unit Removal

    DFX-8500 3.2.4.5 C204 MAIN Board Unit Removal Step 1: Remove the bottom panel assembly. (Refer to Section 3.2.4.1) Step 2: Remove the C204 SUB board unit (Refer to Section 3.2.4.3.) Step 3: Remove the C204 DRV-B board and C204 DRV board units (Refer to Section 324.4.) Step 4: Disconnect connectors CN6, CN7, CN6, and CNlO.
  • Page 112 Step 5: Remove the four CBS (M3x12) screws and two CBS (0) (M3x8) screw securing the C204 MAIN board unit and remwe the board. : CBS(O)(M3X6) X 2 : CBB(M3X12) X 4 Figure 3-34. C204 MAIN Board Removal 414 When you install the C204 MAIN board assembly, perform the following adjusrents: Platen gap motor value (platen gap) adjustment (described in Section 4.1.7).

  • Page 113: Ac Inlet Removal

    DFX-8500 3.2.4.6 AC Inlet Removal Step 1: Remove the C204 power supply board assembly. (Refer to Section 32.42) Step 2: Remove the C204 MAIN board assembly. (Refer to Section 3.2.4.5) Step 3: Remove the three CBB (M3x6) screws and one CB (0) (M4x6) screw securing the grounding plate to the bottom panel assembly and remove the grounding plate.

  • Page 114: C204 Pnl Board Removal

    DISASSEMBLY AND ASSEMBLY 3.2.4.7 C204 PNL Board Removal 3.2.3.3) Step 1: Remove the front panel unit. (Refer to Section CN2 on C204 Step Disconnect connectors CNI and PNL board. Step 3: Remove the CBB (M4xlO) screw securing the C204 PNL board to the front panel unit and remove the board.

  • Page 115: Interlock Switch And Cover Open Sensor Assembly Removal

    DFX-8500 3.2.5 Interlock Switch and Cover Open Sensor Assembly Removal Step 1: Remove the upper case. (Refer to Section 3.2.3.4) Step 2: Disconnect the interlock switch cable from junction board connector (5) and remove the cover open sensor cable (6) on the C204 MAIN board. Interlock SWL Cover Open_ Sensor...

  • Page 116: Printer Mechanism Removal

    Section 3.2.6. Because the printer mechanism is large and heavy, you must be careful when you remove it. When yor, lift or lower the printer mechanism, follow these precautions: Two people are required to remove or install the printer mechanism.
  • Page 117 Figure 3-44. Printer Mechanism Removal CC/Z When you install the pdnter mechanism, KU? the cables as shown in Figures ths cables do not ga? caught between the printer mechanism and lower case. When you install the printer mechanism, pefiom~ the following a@ustments: Platen gap motor value (platen gap) a&stment (described in Section...

  • Page 118: Fan Removal

    3.2.6.1 Fan Removal Step 1: Remove the upper case unit. (Refer to Section 323.4.) Step 2: Remove the right cover. (Refer to Section 3.2.3.2.) Step 3: Disconnect the connector for the fan from the relay connector. Step 4: Remove the CP(0) screw securing the fan duct to the left frame and the CC screw securing the fan and the fan duct to the shaft on the left frame.

  • Page 119: Ribbon Feed Change Lever Unit Removal

    3.2.6.2 Ribbon Feed Change Lever Unit Removal Step 1: Release the three hooks securing the ribbon feed gear cover to the ribbon feed motor frame and remove the cover and the ribbon feed gear. Step 2: Disconnect the three connectors Step 3: Remove the head damper from the left side frame.
  • Page 120 DISASSEMBLY AND ASSEMBLY To RF Motor To Tractor Select Sensor Ribbon Jam Connector Junction Board Removing Connectors Figure 3-48. When you &tall the ribbon feed change lever unit, the tip of the tractor select lever and the tractor select gear holder correctiy (Refer to Figure Z- 12.) 3-33 Rev.
  • Page 121 DFX-8500 3.2.6.3 Tractor Select Lever (Upper and Lower) Assembly Disassembly This section describes how to disassemble ribbon feed motor and tractor select sensor. Step 1: Remove the ribbon feed change Step 2: Remove the two CP(.%Pl)(M3x6) motor to the ribbon feed motor frame and remove Remove E ring (# 3) securing step 3:...

  • Page 122: Ribbon Jam Sensor Removal

    3.2.6.4 Ribbon Jam Sensor Removal right cover. (Refer to Section 3.2.3.2) Step 1: Remove Step 2: Disconnect the connector for the sensor from the connector Step 3: Remove the CP(S-Pl) (M3x6) screw securing the sensor to the bracket, Front/Rear Tractor Select Lever Assembly Figure 551.

  • Page 123: Connector Junction Board Assembly And Fpc Board Assembly Removal

    Step 1: Remove the left side cover. (Refer to Section 3.2.3.2) Step 2: Disconnect all the cables from the connector junction board assembly. Remove the two CP (S- Pl) (M3x6) screws securing the connector junction board assembly to the printer mechanism and then remove the connector junction board assembly.

  • Page 124: Pg Sensor And Pg Motor Removal

    3.2.6.6 PG Sensor and PG Motor Removal When you remove or install the PG sensor, be careful not to bend the PG motor detection boa&. Step 1: Remove the connector junction board assembly. (Refer to Section 3.265) Step 2: Remove the CBS screw (3X6) securing the PG sensor unit to the left frame.

  • Page 125: Plunger And Paper Bail Assembly Removal

    DFX-8500 3.2.6.7 Plunger and Paper Bail Assembly Removal This section describes how to remove the plunger (loading solenoid) Step 1: Disconnect the black, 2-pin plunger remove the plunger cable from the connector Step 2: Remove the two CP(S-Pl) (M3x6) screws securing the plunger.
  • Page 126 step 4 Remove the left tension roller lever spring. Step 5 Remove the E-ring securing the paper bail shaft to the left frame and remove the platen roller shaft holder and paper bail lever. Shaft Holder Tension Roller Figure 3-55. Paper Bail Assembly Removal l/2 Step 6: Disconnect 2 fan harnesses...

  • Page 127: Upper Paper Guide And Top Pe Sensor Removal

    DFX-8500 3.2.6.6 Upper Paper Guide and Top PE Sensor Removal Step 1: Remove the paper bail assembly. Step 2: Disconnect the red. 3-pin, top PE sensor connector Lefl Side Frame Figure 3-57. Top PE Sensor Connector Removal Step 3: Remove the two CBS (M4x6) screws securing the upper paper guide to both frames the paper guide.

  • Page 128: Tension Roller Shaft Removal

    3.2.6.9 Tension Roller Shaft Removal This section describes how to remove the tension roller shaft. It is better to remove the tension roller shaft with the paper bail assembly removed; however, removing it is not required. (Refer to Section 326.7.) instructions on how to remove the paper bail assembly.) Step 1: Remove the connector junction board assembly.
  • Page 129 DFX-6500 Step 7: Remove the CR motor fan. (Refer to Section 3.2.6.19.) Remove the E-ring (6) at the right end of the tension roller shaft and remove the tension roller shaft Step 8: holder along with the leaf spring and the washer. Remove the tension roller shaft by taking it out from the right frame.

  • Page 130: Platen Removal

    3.2.6.10 Platen Removal Step 1: Remove the paper bail assembly. Step 2: Remove the upper paper guide. (Refer to Section Step 3: Remove the four hexagon socket screws the platen with the lower paper guide composed Step 4: Slide the 3 parts of the lower paper guide to release from the platen.

  • Page 131: Paper Jam Sensor Removal

    DFX-8500 3.2.6.11 Paper Jam Sensor Removal Step 1: Remove the platen along with the lower paper guide composed of 3 parts (Refer to Section 3.2.6.10.) Step 2: Remove the CPN(SP)(M4xB) screw securing the left part of the lower paper guide to the platen. Step 3: Remove the part from the platen.

  • Page 132: Pull Tractor Sensor Removal

    3.2.6.12 Pull Tractor Sensor Removal Step 1: Remove the upper paper guide. (Refer to Section 3.2.6.8) Step2: Disconnect the red 2-pin pull tractor sensor connector assembly. Step 3: Remove the CP(S) (M2x14) screw securing the pull tractor sensor (a micro-switch type sensor) to the left side frame and remove the sensor.

  • Page 133: Paper Width (Pw) Sensor Removal

    DFX-8500 3.2.6.13 Paper Width (PW) Sensor Removal Step 1: Disconnect the connector for the PW sensor. Step 2: Remove the CP(S-PI) (M2.56) screw securing the PW sensor to the mask-less holder. Paper Width Sensor Connector Figure 3-67. PW Sensor Removal 3-46 Rev.

  • Page 134: Pg Home Sensor Removal

    3.2.6.14 PG Home Sensor Removal Step 1: Remove the frontlrear tractor select lever assembly. (Refer to Section 3.2.6.2) Step 2: Remove the E-ring securing the carriage guide shaft gear to the rear carriage guide shaft. Figure 3-68. Carriage Guide Shaft Gear Removal Step3: Diiconnect the whiie, 2-p%...
  • Page 135 DFX-8500 Flat Part of CR Guide Shaft (Rear) Advance 10 mm Transmission Gear Figure 3-70. CR Guide Shaft Gear Phase Alignment Rev. A...

  • Page 136: Pf Motor Removal

    3.2.6.15 PF Motor Removal Step 1: Remove the connector junction board assembly. (Refer to Section 3.2.6.5) Step 2: Remove the three CP (SP-1) (M4x8) screws securing the PF motor to the left side frame. Step 3: Remove the PF motor from the inside of the left side frame. Figure 3-71.

  • Page 137: Left Side Frame Gear Removal

    DFX-8500 3.2.6.16 Left Side Frame Gear Removal Step 1: Remove the front/rear tractor select lever assembly. Step 2: Remove the connector junction Step 3: Remove the PG motor. (Refer to Section Step 4: Remove the series of gears in the order indicated by the numbers Figure 3-50 ..,,,.

  • Page 138: Front Tractor Assembly Removal

    3.2.6.17 Front Tractor Assembly Removal This section describes how to remove the front tractor assembly. Step 1: Disconnect the connector white 3-pin front PE sensor from the connector Step 2: Remove the connector junction Step 3: Lay the mechanism on its back. Step 4: Remove the screw securing the tractor wire holder to the left side frame and remove Step 5: Loosen...

  • Page 139: Rear Tractor Assembly Removal

    DFX-&700 3.2.6.18 Rear Tractor Assembly Removal This section describes how to remove the rear tractor assembly. Step 1: Disconnect the connector white 3-pin rear PE sensor from the connector junction board. Step 2: Remove the connector junction board assembly. (Refer to Section 326.5) Step 3: Remove the flange nut securing the wire holder spring set to the right side frame, and remove the set.

  • Page 140: Cr Motor Fan Removal

    DISASSEMBLY AND ASSEMBLY 3.2.6.19 CR Motor Fan Removal Step 1: Disconnect the cable for the motor from the relay connector. Step 2: Remove 2 fan fixing screws and remove the fan. Removal Figure 3-76. CR Motor Fan Rev.

  • Page 141: Cr Motor Removal

    DFX-8500 3.2.6.20 CR Motor Removal Step 1: Remove the right cover. (Refer to Section Step 2: Disconnect the red and black cables terminal) Step 3: Remove the three CP(S) (M4xlO) the motor. CP(S)(M4XlO) Figure When you install the CR motor, perfom Section 4.12.

  • Page 142: Cr (Carriage Encoder) Sensor Removal

    DISASSEMBLY AND ASSEMBLY 3.2.6.21 CR (Carriage Encoder) Sensor Removal Step 1: Remove the printhead. (Refer to Section 3.2.2.) Step 2: Disconnect the red 4-pin CR sensor connector from the carriage connector junction board. Step 3: Remove the two CP(S-Pl) (M2.6 x 5) screws securing the CR sensor to the carriage and remove the sensor.

  • Page 143: Carriage Mechanism Disassembly

    DFX-6500 3.2.6.22 Carriage Mechanism Disassembly This section describes how to disassemble the carriage mechanism, carriage timing belt, and front and rear guide shafts. Step 1: Remove the CR motor. (Refer to Section 3.2.6.20) Step 2: Remove the belt pulley from the belt pulley holder. Figure 3-60.
  • Page 144 Remove the front carriage guide shaft by pulling it through the hole in the right side frame. (When Step 5: you remove the front carriage guide shaft move the carriage to the left side.) Step 6: On the left side frame, remove the E-ring (6) securing the carriage guide shaft gear to the rear carriage guide shaft, then remove the carriage guide shaft gear and paper thickness sensor holder.
  • Page 145 DFX-8500 When you install front carriage guide shaft, tighten the screws while pushing the shaff toward the platen. When you assemble the caniage mechanism, perform the folowikg adjustments: Carriage timrig belt tension adjustment (described in Section 4.1.2) Cardage guide shaftpara/Msm adjustment (d&scribed in Section 4.1.5) Platen gap motor value (platen gap) adjustment (described in Section 4.1.7) Bk?ctiona/...

  • Page 146: Paper Guide Support Plate Removal

    3.2.6.23 Paper Guide Support Plate Removal Step 1: Disassemble the carriage mechanism and remove all the parts related to the carriage. (Refer to Section 3.2.6.22.) Step 2: Referring to the exploded diagram in the Appendix, remove the paper guide support plate. guide support paper...
  • Page 147 DFX-8500 3.2.6.21 Platen Roller Removal Step 1: Remove the platen. (Refer to 326.10) Step 2: Remove the CR motor. (Refer to Section 3.2620) Step 3: Remove the left side frame gears. (Refer to Section 3.2616) Step 4: Refening to the exploded diagram in the Appendix, remove the platen roller. When you install the platen roller.

  • Page 148: Adjustment

    PRINTER MECHANISM ADJUSTMENTS.. 4.1 .I PG Motor Backlash Adjustment..4.1.2 Carriage Timing Belt Tension Adjustment..4.1.3 Tractor Wire Spring Tension Adjustment..4.1.4 Pull Tractor Sensor Position Adjustment ... 4.15 Carriage Guide Shaft Parallelism Adjustment..4.1.6 Platen Angle Adjustment ...
  • Page 149 In the PG motor backlash adjustment, the PG motor pinion gear must mesh smoothly with the PG transmission gear cog. lt the pinion gear is poorly aligned or the pinion gear and cog are too tight, printer operation is noisy or the character density is incorrect.
  • Page 150 Remove the printer mechanism before pertoning adjustment. (Referto Section 3.2.6) Before performing this adjustment, carefulry secure the printer mechanism because a 7 kg (15.4 lb.) force is applied to ii when the tension lever is pukd in the horizontal direction.
  • Page 151 (in the horizontal direction) is incorrect. When you remove the front or rear tractor assembly, perform this adjustment. Step 1: Remove the printer mechanism. (Refer to Section 3.2.6) Step 2: Release the release levers for the tractor sprockets on the front.
  • Page 152 4.1.4 Pull Tractor Sensor Position Adjustment This section describes the pull tractor sensor position adjustment. If the sensor position is incorrect, the sensor is always on. When you replace or disassemble the platen, rear paper guide, platen roller shaft, tension roller shaft, or pull tractor sensor, perform this adjustment. Figure 4-4 illustrates the pull tractor sensor position adjustment.
  • Page 153 Do not remove the printer mechanism (if remove the printer mechanism from the lower case, the adjust value will be out of order when you reassemble the printer mechanism to the lower case.) performing this adjustment.
  • Page 154 DFX-8500 Step 3: Attach the another needle to the master surface. APPROX, I .DO mm depth, then correspond to the another gauge measure, and tighten the hexagonal screw. 3. Tighten the hexagonal screw. 2. Attach the gauge needle to the master surface, then correspond to the another gauge measure.
  • Page 155 Step 6: Remove a CP(PS)(M3X6) screw securing the timing belt holder to the timing beit, then remwe the timing belt holder. Figure 4-9. Carriage Step 7: Remove the paper bail assembly. (Refer to Section 3.2.6.5) Step 8: Remove the tension roller shaft. (Refer to Sactiin 3.2.6.7) Step 9: Remove the printhead with the mask-less holder.
  • Page 156 DFX-8500 Step 12: Measure the distance between the platen and the carriage guide shaft on the left side. Then measure the distance between the platen and the rear carriage guide shaft on the right side, and compare these values.(Figure4-11 shows the measurement position and the parallelism adjust lever operation.) Note: When you shift the carriage manually, do not touch the both dialgauges.
  • Page 157 Do not remove the printer mechanism from the lower case. (If remove the printer mechanism from the lower case, the adjust value will be out of order when you reassemble the pnnter mechanism to the lower case.) Also, it is necessary to remove the tension roller shaft be fore performing this adjustment.
  • Page 158 DFX-8500 Step 4: Using the carriage guide shaft gear, attach the both dial gauge needles to the platen surface.(The needle doesn’t reach the end of the stroke). Side Frame (L) Shaft Figure 4-14. Attaching Two Needles to Platen Surface Step 5: Measure the angle difference about three postiion such as figure below.(Using the CR motor pulley to move the carriage with the dial gauge toward the right side.
  • Page 159 Platen Adjustment (Angle Method) Figure 4-16. Measuring Angle Diierence ‘2 Step 6: If the angle diierence of two values are more than + 0.015 mm, loosen (but do not remove) the two hexagonal screws securing the platen stay to both side frames, then change the platen angle slowlly and manually.) Step 7: lIghten two hexagonal screws securing the platen stay to both side frames.
  • Page 160 !hicknees gauge set and fension gauge. Thickness gauge (0.43 mm) : #F616 (EPSON Part No. SlOZO47lCO) Thickness gauge (0.80 mm) Tension gauge (200 g) : #F545 (EPSON Part No. B765114601) Do not turn the printer off during adjustment.
  • Page 161 ALPHA Value Write Mode : Step 3: Turn the printer on while pressing the Tear Off, Micro Feed (v), and Front/Rear switches. At this time the printer perfons PG home position seek. and the carriage moves to the 15 column.
  • Page 162 DFX-8500 Figure 4-19. Thickness Gauge Setting Method Beta No. Reference Thickness Gauge BETA 3 BETA 2 BETA 3 BETA 4 ‘1: When EEPROM is reset. 4-14 Platen I-Q~~ Thickness Gauge (BETA3’ = 0.43mm) Table 4-l. BETA Values Adjustment Allowed Value Default Value’l) 0.43 mm with 15Ogf pull 0.00 mm 367-419...
  • Page 163 4.1.8 Bi-directional Printing Adjustment The purpose of this adjustment is to correct the printer mechanism parameters which control bi-directional printing. Be sure to peltorm this adjustment when required. If this adjustment is not performed correctly, bi- directional printing may be miss-aligned, or, in the worst case, the carriage might operate incorrectly. Before performing this adjustment, be sure to that the following adjustment are completed correctly.
  • Page 164 ‘PG Alpha=&&” 1. ‘PG Betal=BBB, PG BetaZ=CCC. 2. Panel diplays the current flight time adjustment value The printer prims the test print pa,,em wi,h Change the Right time adjustment value. fkclement 10 steps: Top of Form SW once. Dedement 1 step: Push MicmFeed n SW once Inclement 10 steps: Tear OR SW once.
  • Page 165 Fright Time = xxx ___ ____ __ ________ rrTTT-rrT ________________ _________________ &-&+#+r*; _________-____^_ 40 COL. Figure 4-21, Table 4-2. LED indication and Adjustment Value Comparison Rihhon Top of Form Tear Off COPY Pitch n nD ‘2) Indicates 1’ ______________ _________________ __________________ , , , , , (J-1 , , , ITT...
  • Page 166 1. Panel dipkvs the current Bi-D. adiustment value. 2. Printer p&t; “Speed = AAA BBB’I) is the current adjustment value. The printer prints the test print pattern with the cwrent adjustment value. 4th) lines vertical alignment Change the Bi-D. adjustment value. Deckment 10 steps: Top of Form SW once.

  • Page 167: Troubleshooting

    5.1 PROBLEM ISOLATION ... 5.2 SELF DIAGNOSTIC FUNCTION ... 5.3 TROUBLESHOOTING CHAPTER 5 TROUBLESHOOTING...
  • Page 169 The information in this chapter makes troubleshooting easier to perform by listing various problems that can occur and providing possible solutions. Note: For this printer no special took are necessa~ for troubleshooting to the unit level, with the exception of a digital multi-meter. oscilloscope.
  • Page 170 LYFX-8500 5.1.2 Bypassing Interlock Switch and Cover Open Sensor To print with the top cover open or removed, you need to bypass the interlock switch and cover open sensor because these sensors automatically disable i ..................Interlock SW.
  • Page 171 5.1.3 Coil Resistance The following table provides the coil resistance for the motor, head fan, plunger, and printhead. Table 5-2. Motor, Fan, Plunger, and Printhead Coil Resistance Pall CR motor PF motor RF motor PG motor Head fan Plunger Printhead Shield Cable Head Cable Board Figure 5-3.
  • Page 172 13%8500 FPC A FPC 6 FPC C 1 .18 : Head coil GNO side fT- @ Head coil P/S side : Head thermistor Paper width sensor :+5VDC ENCA: Encoder A : Head themfistor Fan motor phase A Fan motor phase B Fan motor common Fan motor thermistor Power supply (~37 VDC)
  • Page 173 START Check all motors, solenoid, printhead. and drivers using a multimeter. N” \/’ power is turned on. Use the correct AC voltage. N4 on the C204 power and turn on the ce the c2w Replace bad motor. solenoid, or printhead.
  • Page 174 If drivers are bad, replace at the same time. Reinsert the connectors. Refer to Section 5.3, Repair of the Printer Mechanism. Perform repair necessary. NOTE 1: Check the following connectors: Junction board connector to intwlock switch Junction board connector to CR motor...
  • Page 175 1: Check the following connecton: Three head junction board mnnecton to printhead CNl of C204 MAIN board to head junction boam CN2 of C2W MAIN board to C204 DRV-B board CNI of CZM DRV-B board to printer mechanism Rev. A...
  • Page 176 DEX-&iOl? 3. Carriage operation is normal, but the self-test is printed incorrectly (2/3). Replace the C204 MAIN and./or CZO4 DRV-Ei board. coil resistance. Check the printhead drivers. Check the printhead drivers. Replace the C2C4 MAIN and/or Rev. A...
  • Page 177 TROUBLESHOOTING 3. Carriage operation is normal, but the self-test is printed incorrectly (3n). Go back to Section 5.3 Repair of the Printer Mechanism. check for other problems.
  • Page 178 DFX-8500 Printing is normal, but paper feeding START Refer to Section 5.5. Repair of the Printer Mechanism. Perform final printing of self-test. and perform the PG motor backlash is abnormal. Load the paper correctly. Refer to Section 5.3 Repair of the Printer Mechanism.
  • Page 179 TROllBLESHOOTlNG Panel unit operation is abnormal. START and C204 PNL board Reinsert connector CN5 correctly. Using a multimeter, check the switches on the C204 PNL board. Replace the C204 PNL board. 5-11 Rev. A...
  • Page 180 DFX-6’500 6. Data sent by the host computer is printed incorrectly. Note : The flowchart below assumes the host computer is operating normally Run the self-test. 5-12 Troubleshoot printer using the previous flowchatts. Rev.
  • Page 181 By referring to the checkpoints, determine the defective component. Then perform the proper repair. The table provides the following four columns: Symptom: Check this column for a list of common printer problems. D Cause: Use this column to identify possible causes that could produce this symptom.
  • Page 182 DFX-8500 (FB) must be HI waveform behvee Rev. A...
  • Page 183 Table 5-5. C204 line 37 VDC (VP3) I ‘SI 3lPSE Board Component Repair 3/3 Checkpoint Check the voltage level at pin 10 (Vl) and pin5 (GP). Observe the drive waveform at pin 6 (VO) and pin 5 (GP). When the input voltage of the minus port (pin 6 for VP1 and pin2 for VP2) is less than u VDC, the comparator...
  • Page 184 Table 5-6 indicates major components which is used for the C204 MAIN/DRV/DRV-B boards and Table 5-7 shows the C204 MAINiDRWDRV-B boards component level troubleshooting. rable 6-6. C204 MAWDRWDRV-6 Symptom Cause The printer does The DRERR signal lot operate at all. was sent to the C204 sent to the C204...
  • Page 185 Table 56. C204 MANDRVIDRV-B Symptom Cause The printer does The control ROM is not operate at all. defective. The gate array (El) is defective. The CPU (IC2) is defective The DRAM (IC14) is defective Rev. A TROUBLESHOOTlNG boards Component Repair 2/1...
  • Page 186 DFX-8500 Table 5-6. C204 MAfN/DRV/DRV-S Symptom cause The carriage IC1 on the C204 operates MAIN board is abnormally. defective. Q16,Q17,Q18, 019 on the C204 MAIN board is defective. ICl is doesn’t work. ICl on the C204 DRV board is defective. IC3 on the C204 DRV board is defective.
  • Page 187 Table 56. C204 MAINIDRVIDRV-B boards Component Repair W Symptom Cause The carriage The carriage encoder operates sensor is defective. abnormally. Carriage operation is unstable (due to a lack of motor torque). Rev. A Checkpoint Observe the carriage encoder sensor output signal at pins 4 (ENCA) and 3 (ENCB) of CN4 on the C204 MAfN board Check the switching waveform for Q5,...
  • Page 188 DFX-85w GE04 MAINIDRVIDRV-B boards Component Tsbk 5-6. Symptom cause Paper feeding is The CPU IC2) on the abnormal. C204 MAIN board is defective. IC2 on the C204 DRV board is defective. Ribbon feeding is The CPU IC2) on the abnormal. C204 MAIN board is defeciie.
  • Page 189 (PG home = LOW level; other = HIGH level.) Check if fuse F3 is defective. When paper is loaded into the printer, look at the switching signal at pins 16 (PLP) and 17 (PLN)of ICl. Obsewe the 031 collector voltage at paper loading.
  • Page 190 DFX-8500 Table 56. CZO4 MAINIDRVIDRV-B boards Component Repair 717 Symptom Cause The self-test is ICl on the C204 MAIN board is printed incorrectly defective. The head driver FETs on the C204 MAIN an&or C204 WV-6 boards are defective. The CPU (IC2) on the C204 MAIN board is Checkpoint Observe the output signal at pins 136.
  • Page 191 5.2.3 Printer Mechanism Repair The table below describes how to isolate problems with the printer mechanism. To replace or adjust printer mechanism parts, refer to Chapter 3, Disassembly and Assembly, and Chapter 4, Adjustments. SyT!IptOm recurs fOIlOWing a repair attempt, look for other possible causes and solutions in the table below.
  • Page 192 DFX-8500 Table 5-7 sympml cause A particular dot The printhead is does not print. defective. The print is too The printhead is iight or print defective. jensity is not miform The parallelism value is incorrect. The platen gap MIW is incorrect. ‘Wing Foreign objects are ~rformad, but the...
  • Page 193 Table 57. Printer Mechanism Repair 3 I4 Symptom cause The RF motor 1 The parallelism value does not operate. 1 is incorrect. The RF motor The RF motor is 3oes not operate ~ defective. The PG motor The backlash value is joes not operate, incorrect.
  • Page 194 DFX-6500 Table 5-7. Printer Mechanism Symptom cause Printing occurs The PW sensor is outside the paper defective. width. The paper bail The plunger is assembly does defective. not work. The tension value of Continuous paper becomes the tractor wire spring crumpled at the is incorrect.
  • Page 195 6.1 PREVENTIVE MAINTENENCE ... 6.2 LUBRICATION AND ADHESIVE APPLICATION ... CHAPTER 6 MAINTENENCE...

  • Page 196: Maintenance

    6.2 LUBRICATION AND ADHESIVE EPSON recommends that the printer be lubricated at the points illustrated in Figures 6-2, 6-3, and 6-4 using EPSON lubricants 02 and G26. These lubricants have been extensively tested and found to comply with needs of the printer. Refer to Table 6-l for information on lubricants 02 and G26. Table 6-2 lists the appropriate lubricant for each point.
  • Page 197 DFX-8500 Table 6-Z. Lubrication Points Table 6-3. Adhesive Application Points Ref. No. 1 Ref. Figure Adhesive Application Point Adhesive (25) Tractor tension tire 1 Neji Lock #2 (G) Figure 6-1. Correct Adhesive Application Rev.
  • Page 198 (11) 111) Figure 6-Z. Lubrication and Adhesive Diagram 1 Rev.
  • Page 199 DFX-BSM) Figure 6-3. Lubrication and Adhesive Diagram 2 Rev.
  • Page 200 Figure 6-4. Lubrication and Adhesive Diagram 3 Rev.
  • Page 201 APPENDIX A-1. CONNECTOR PIN ASSIGNMENTS ..............A-l A.2.
  • Page 202 APPENDIX CONNECTOR PIN ASSIGNMENTS Figure A-l illustrates the interconnection of the primary components Table A-l summarize the description and sizes of the connectors. Input open COVW se”SN Printer Mechanism Figure A-l. Cable Connection Rev. A...
  • Page 203 DFX-0500 Table A-l. Board Connector Summary connector /Connection MAIN Baarrl => Mechal I=> C204 DRV-B board CNlO => C204 PSBIPSE CNll => Optional Type-B I/F card CN12 => IEEE-1264 ^.._^ LNIS => EIA 232D I/F CN14 => C204 DRV board CN15 =>...
  • Page 204 Table A-2. C20.4 MAIN Board Connector CNl Signal Name Table A-3. C204 MAtN Board Connector CN2 Pi” c:___, .I___ ” ,I zR9N IHRZN Table A-4. CX4 MAIN Board Connector CN3 Signal Name COPEN Rev. Function I ~~~~~~ ‘D-‘-‘kad pin #I 0 lead pin #12 lead pin #16 ead pin #17...
  • Page 205 DFX-8500 Table A-5. C204 MAIN Board Connector CN4 Signal Name ^. ._ ENCB ENCA Table A-7. C204 MAIN Board Connector CN6 Signal Name 1, 2% 4, 5, 6 Table A-8. C204 MAIN Board Connector CN7 Signal Name 1,293 4, 5, 6 Table A-g.
  • Page 206 APPENDIX...
  • Page 207 OFX-6500 Rev. A...
  • Page 208 Table A-16. C204 DRV Board Connector Signal Name Function 1.3,s.a +37 VDC...
  • Page 209 LXX-8500 Table A-17. C204 DRV Board Connector CN3 Signal Name4 1,2,3 4,516 Table A-18. C204 DRV-B Board Connector CNl Table A-19. C204 PSB/PSE Board Connector CNl Signal Name4 Table A-20. C204 PSB/PSE Board Connector CN5 Signal Name4 iFANDR Fan motor drive Function +37 VDC GND for VP3...
  • Page 210 A.2 CIRCUIT DIAGRAMS the following pages for the figures below: Figure A-2. C204 MAIN Board Exploded Diagram Figure A-3. CL04 DRV Board Exploded Diagram Figure A-4. C204 DRV-B Board Exploded Diagram Figure A-5. C204 PSB Board Exploded Diagram Figure A-6. C204 PSE Board Exploded Diagram...

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