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Epson C117001-N - DFX 5000+ B/W Dot-matrix Printer Service Manual

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EPSON TERM NAL PR
NTER
DFX-5000+

SERVICE MANUAL

EPSON

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  Summary of Contents for Epson C117001-N - DFX 5000+ B/W Dot-matrix Printer

  • Page 1: Service Manual

    EPSON TERM NAL PR NTER DFX-5000+ SERVICE MANUAL EPSON...
  • Page 2 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. The above notwithstanding SEIKO EPSON can assume no responsibility for any errors in this manual or the consequence thereof.
  • Page 3 THE POWER SUPPLY CABLE MUST BE CONNECTED, USE EXTREME CAUTION IN WORKING ON POWER SUPPLY AND OTHER ELECTRONIC COMPONENTS. REPAIRS ON EPSON PRODUCT SHOULD BE PERFORMED ONLY BY AN EPSON CERTIFIED REPAIR TECHNICIAN. MAKE CERTAIN THAT THE SOURCE VOLTAGE IS THE SAME AS THE RATED VOLT- AGE, LISTED ON THE SERIAL NUMBER/RATING PLATE.
  • Page 4 CHAPTER ADJUSTMENTS Includes a step-by-step guide for adjustment. CHAPTER 5. TROUBLESHOOTING Provides Epson-approved techniques for adjustment. CHAPTER 6. MAINTENANCE AND LUBRICATION Describes preventive maintenance techniques and lists Lubricants and adhesives required to service the equipment. APPENDIX Describes connector pin assignments, circuit diagrams, circuit board component layout and exploded diagram.
  • Page 5 REVISION SHEET Issue Data Revision Page Revision 1 st issue Rev.-A February 9, 1994 Page 4-10: Addition the notes Rev.-B April 20, 1994 Page 4-1 1: Addition the notes Page 4-4 to 4-7: Change the explanation Rev.-C November 22, 1994 Whole Revise of the Chap.4 Rev.-D December 15, 1994...
  • Page 6 TABLE OF CONTENTS CHAPTER 1. GENERAL DESCRIPTION CHAPTER 2. OPERATING PRINCIPLES DISASSEMBLY AND ASSEMBLY CHAPTER 3. ADJUSTMENTS CHAPTER TROUBLESHOOTING CHAPTER MAINTENANCE AND LUBRICATION CHAPTER 6. APPENDIX vi -...
  • Page 7: Table Of Contents

    CHAPTER 1 Product Description Table of Contents GENERAL FEATURES 1.2 SPECIFICATIONS 1.2.1 Printer Capabilities......... . l-3 1.2.2 Paper Handling Specifications.
  • Page 8 List of Figures Exterior View of the DFX-5000+......1-1 Figure 1-1. Figure 1-2. Pin Configuration .
  • Page 9: General Features

    - Paper memory function - Automatic paper path changing Cl Eight-bit parallel interface and RS-232C serial interface standard Cl Epson ESC/P-83 (ESC/P version 83) printer driver (compatible with the FX-870/1170 and DFX-5000) D 9 character tables in the standard version...
  • Page 10: Table 1-1. Options And Consumables

    DFX-5000+ Service Manual Product Description Options and Consumables Table 1-1. Description Model #8309 Pull tractor unit #8766 Ribbon cartridge #8767 Ribbon pack I C82305* I Serial I/Fcard, simple serial interface** (SSi), inch screw C82306* Serial I/F card, SSI, mm screw I 32KB intelligent serial l/F card (inch screw) C82307’...
  • Page 11: Specifications

    Product Description DFX-5000+ Service Manual SPECIFICATIONS This section provides detailed information about the DFX-5000+. 1.2.1 Printer Capabilities Serial impact dot matrix Printing method: 9 wires Pin configuration: 0.29 mm (0.01 inches) Pin diameter: (1/72”) 8/72” L 3 - Figure 1-2. Pin Configuration Dot matrix: 9 x 7 (high-speed draft mode) 9 x 9 (draft mode)
  • Page 12: Table 1-3. Printing Speeds

    DFX5000+ Service Manuai Product Description Speeds Table 1-3. Printing High Duty (cps) Type of Letters Print Speed (cps) High-speed draft Draft pica 10@ Draft elite 12 cpi Draft 15 cpi 17 Cpi Draft condensed pica Draft emphasized pica 20cpi NLQ pica NLQ elite 20KB or O bytes (selectable by DIP switch 2-2) Input data buffer:...
  • Page 13: Paper Handling Specifications

    Product Description DFX-5000+ Service Manual 1.2.2 Paper Handling Specifications Push tractor feed (front and rear) Feeding methods: Push-pull feed with the optional pull tractor (front or rear) Paper size: Fanfold paper 101 -406 mm (4 - 16 inches) wide Single sheet paper Not available Roll paper Not available...
  • Page 14: Figure 1-4. Unsuitable Paper

    Product Description DFX-5000+ Service Manual Notes: 1. Horizontal alignment maybe irregular in the top 75 mm (3 inches) of the first page. 2. When using the optional pull tractor, the top 120 mm (4.8 inches) of the first page are unprintable.
  • Page 15: Figure 1-10. Sprocket Holes

    DFX-5000+ Service Manual Product Description Horizontal perforations must have uncut parts on both edges of the paper. Uncut -’/ ——— Paper edge Figure Edge at a Horizontal Perforation 1-7. Paper At the intersection of a horizontal and vertical perforation, the perforation cuts must not cross each other.
  • Page 16: Figure 1-12. Incorrectly Folded Paper

    DFX-50oo+ Service Manual Product Description 12. Any pieces of paper remaining in the sprocket holes must be removed. 13. The paper should be fanfolded at the horizontal perforations. Never use incorrectly folded paper, such as the paper shown below. Figure 1-12. Incorrectly Folded Paper 14.
  • Page 17: Figure 1-14. Dotted Paste Positions

    DFX-5000+ Service Manual Product Description When using overlapping multi-part forms, do not use the paper select (change tractors) or tear offfunction; to avoid a paper jam, it is important not to feed overlapping multi-part forms backward. Notes: Rough multi-part form binding causes paper jams. multi-part form sheets should be bound together with spot gluing (dotted paste), paper 2.
  • Page 18: Figure 1-17. Stapled Area

    DEMO(M+ Servke hisnual Pfvduct Descfiptkm The binding area must be fiat. Figure 1-17 shows a cross section of the stapled area. Figure 1-17. Stapled Area 3 Never use forms joined with metal staples. The binding (dots of paste or paper staples) must be outside the printable area. Overlapping multi-part forms must be bound at the top side by spot gluing.
  • Page 19: Figure 1-20. Printable Area For Labels

    Product Description DFX-5000+ Service Manual Labels Front only Paper path: 2%x 15/16 inches Label size (W x H): 4 x 15/16 inches 4 x 17/16 inches Bottom carrier: Width 4- 16 inches Length 3.5 inches minimum 0.19 mm (0.0075 inches) maximum Total thickness: Differences in thickness must be less than 0.12 mm (0.0047 inches).
  • Page 20: Ribbon Specifications

    DEX-50(W+ Service hWw81 Product Description 4-16” o [ - o .- --------------------------- r-- r ‘T 0’ ‘k’ j i ‘*e’ j r‘7 bb’ i i ‘ab’ j, 0 ~ ~ ----------------------------- Figure 1-21. Label and Carrier 1.2.4 Ribbon Specifications #8766 Ribbon cartridge: Ribbon pack: #8767...
  • Page 21: Electrical Specifications

    DFX-5000+ Service Manual Product DescriMion 1.2.6 Electrical Specifications Table 1-6. Rated Electrical Ranges 120 V Version 220-240 V Version Rated voltage 120 VAC 220-240 Input voltage range 103.5- 132 V 198-264 V Rated frequency range 5 0 - 6 0 tiz 5 0 - 6 0 Input frequency range 49.5 -60.5 Hz...
  • Page 22: Interface Specifications

    LKMO#+ Serukw Mwd Product Description 1.3 INTERFACE SPECIFICATIONS 1.3.1 Parallel Interface 8-bit parallel Data forrmt: By STROBE Synchronization: Pllk Sy’dWXWa “ tion By BUSY and ACKNLG Handshaking: SigdS TT’compatible level Signal level: %-pm 57-30360 (Amphenol) or equivalent Connector: ACKNLG 6!’!? DATA ‘,$ ‘.
  • Page 23 Product Description DFX-5000+ Service Manual Table 1-7 shows the signal functions and connector pin assignments for the 8-bit parallel interface. Table 1-7. Parallel Interface Signals and Connector Pin Assignments Return I/o’ Pin No. Signal Name Description Pin No. STROBE pulse to read the input data. The pulse width must exceed 0.5 @.
  • Page 24: Rs-232C Serial Interface

    DEX401W+ Servka Mm&# Product Lkscription 1.3.2 RS-232C Serial Interface RS-232C serial Data format: Asynchronous Synchronization: By DTR signal or X-ON/X-OFF protocol Handshaking: Word length: 1 bit S t a r t b i t Data bit 8 bits Odd, even, or no parity Parity bit 1 bit or more Stop bit...
  • Page 25: Printer Operation

    Product Description DFX-5000+ Service Manual 1.4 PRINTER OPERATION This section describes the basic operation of the printer. 1.4.1 Control Panel The printer’s control panel contains eight non-lock type push buttons and twelve LED indicators for easy use of the various printer functions. PAPER SELECT Cl POWER PAUSE...
  • Page 26: Self-Test

    DFX-5009+ Servkm MwnuJ Product Descrhtion LED Indicators Lit when the printer is turned on. POWER (green): Lit when the printer is out of paper. PAPER OUT (red): Flashes when there is a paper jam. Lit when the printer is in pause mode. PAUSE (orange): Lit when the printer is in tear off mode.
  • Page 27: Paper Width Detection

    Product Description DFX-5000+ Service Manual 1.4.6 Paper Width Detection The printer detects the right paper edge and determines the right end of the printable area. This disables printing in areas where there is no paper. 1.4.7 Automatic Paper Thickness Adjustment The printer measures the paper thickness each time paper is loaded.
  • Page 28: Using The Paper Memory Function

    DFX-5000+ Servke Manual Product Description Function 1.4.8.1 Using the Paper Memory To use the paper memory function, you must first save paper format and thickness information for up to two different types of paper as described in fktion 1.4.8.2, below. To turn on the paper memo~ function after saving your paper format and thickness information, hold down one of the buttons below and turn on the printer.
  • Page 29: Automatic Tear Off Function

    Product Description DFX-5000+ Service Manual Use DIP switches 3-5 and 3-6 to set the paper type. Table 1-11. Setting the Paper Type Paper Type Normal paper Forms with a label Overlapping forms Overlapping forms with a label Hold down both MICRO FEED buttons and turn on the printer. If you are using forms with a label, indicate the label’s position by following these steps: (1) Open the printer cover.
  • Page 30: Skip Binding Function

    Mmual DEW(W)+ Service Product Dascrfption 1.4.13 Skip Binding Function The skip binding for printing on multi-part forms with binding that could scratch function is used the printhead during paper feeding. When this function is head parks away from the used, the binding during paper feeding to avoid paper jams.
  • Page 31: Dip Switch Settings

    Product Description DFX-5000+ Service Manual 1.5 DIP SWITCH SEITINGS This section describes the functions of the DIP switches. After settimz one or more DIP switches, turn on the printer to put your settings into effect. Table 1-12. DIP Switch Settings Factory SW No.
  • Page 32: Table 1-14. Esc/P Mode Selection

    Product Description DEW50tM+ Swvke Manual Table 1-14. ESC/P Mode Selection Character Table Sw 1-4 Sw l-a Sw l-e Sw Sw 14 Standard NLSP Italic Us. Italh France Italk Germany Itzk U.K. Italic Denmark Italic Sweden Italic Italy Italii Spain PC437 PC437 PC850 PC850...
  • Page 33: Table 1-15. Interface Selection

    Product Description DFX-5000+ Service Manual Table 1-15. Interface Selection Sw 2-4 Interface SW 2-5 Sw 2-6 Automatic selection, serial interface, odd parity (30 seconds*) Automatic selection, serial interface, odd parity (10 seconds*) Automatic selection, serial interface, no parity (30 seconds*) Automatic selection, serial interface, no parity (10 seconds*) Parallel interface Serial interface, odd parity...
  • Page 34: Main Components

    DEX4i’W+ Swvice Msnusl Pfvduct Dwcription 1.6 MAIN COMPONENTS main components of the DFX-5000+ are designed fix easy removal and replacement. These main components are: Printer mechanism (M-3C11) Main control board (C117 MAIN board assembly) Power supply board ( C117 PSB/PSE board assembly) Control panel (C117 PNL board assembly) Housing Connector Junction Board...
  • Page 35: Figure 1-27. M-3C11 Printer Mechanism

    DFX-5000+ Service Manual Product Description 1.6.1 M-3CI 1 Printer Mechanism The M-3C11 printer mechanism is a 9-pin, serial, dot matrix printer mechanism developed for the DFX-5000+. It is designed to provide high-speed, high-volume printing, and is especially heavy and durable when compared with existing terminal printer mechanisms. Its paper feeding mechanism uses fanfold paper, and an automatic mechanism is included to provide enhanced paper handling.
  • Page 36: Main Control Board (Cl 17 Main Board Assembly)

    Manual Product LA9ecriotkn DEX-45000+ Service 1.6.2 Main Control Board (C117 MAIN Board Assembly) The C117 MAIN board assembly cxmsists ofi a TA4P96C14 8-bit CPU, an E05A87 gate array, a PROM (2 megabit including the CG ROM), a PS-RAM (256K), an EEPROM, an SLA7026M for the paper feed motor, an SLA5007 for the CR motor, each driver’s IC, and the parallel and serial interface control circuits.
  • Page 37: Control Panel Board (C117 Pnl Board Assembly)

    DFX-5000+ Service Manual Product Description 1.6.4 Control Panel Board (C117 PNL Board Assembly) The C117 PNL board assembly is the operator control panel. It contains the buttons, indicator LEDs, and buzzer. Figure 1-30. C117 PNL Board Assembly 1.6.5 Housing The housing consists of many parts. The lower case is the main frame which holds the printer mechanism and circuits.
  • Page 38 CHAPTER 2 Operating Principles Table of Contents 2.1 OVERVIEW OF PRINTER MECHANISM OPERATION 2.1.1 Printhead Mechanism ........2-3 2.1.2 Carriage Mechanism .
  • Page 39 List of Figures Figure 2-1. Mode13Cll Printer Mechanism......2-1 Figure 2-2. Printer Mechanism Operation ......2-2 Figure 2-3.
  • Page 40: Overview Of Printer Mechanism Operation

    DFx-5tW(h Sewka Manual Oparathg Prfncipka 2.1 OVERVIEW OF PRINTER MECHANISM OPERATION This section describes the Model 3C11 printer mechanism and explains how the printer works. The Model 3C11 printer mechanism features a 9-pin, impact dot printhead for serial printing. The printer mechanism is the main component of the printer and is supported by the other mmponents (the power supply and control arcuits).
  • Page 41 DFX-5000+ Service Manual Operating Principles Cl Ribbon feed mechanism The printer’s ribbon cartridge contains an endless ribbon. The ribbon feed mechanism takes up the ribbon so that the portion hit by the pins is constantly changing. The RF motor drives the ribbon feed mechanism.
  • Page 42: Printhead Mechanism

    Manual Opating Princ@ha DEX-4XXW Service Paper TRACTOR ASSY., PULL \.fi- SENSOR ASSY., PE, UPPER PRINTHEAD - S E N S O R ASSY., P A P E R J A M TRASCOTR SELECT SENSOR SENSOR ASSY., PE, REAR SENSOR ASSY., FRONT Rear Tractor Sprocket Front Tractor...
  • Page 43: Carriage Mechanism

    DFX4000+ Service Manual Operating Principles 2.1.2 Carriage Mechanism Figure 2-5 shows the carriage mechanism. The front and rear carriage guide shafts support the carriage. The rotation of the CR motor is transmitted to the carnage timing belt through the carriage belt pulleys at the right and left sides. The printhead is mounted on the carriage, which is attached to the carriage timing belt and moves horizontally.
  • Page 44: Platen Gap Adjustment Mechanism

    Oparathg Prlnclpks Man(ml DEX-5Uk Servic@ 2.1.3 Platen Gap Adjustment Mechanism Figure 2-6 shows the platen gap adjustment mechanism. The front and rear carriage guide shafts supporting the carriage have a vertical wtion. The rotation of the PG motor is transmitted to the rear carriage guide shaft through the gears.
  • Page 45: Paper Feed Mechanism

    DFX-5000+ Service Manual Operating Principles 2.1.4 Paper Feed Mechanism Figures 2-7, 2-8, and 2-9 show the paper feed mechanism. After you load paper, it is fed by the tension roller, PF roller, and front or rear tractor assembly. The PF motor rotates the tension roller and tractor select gear (Figure 2-7) and moves either the front or rear tractor assembly.
  • Page 46 Paper PAPER BAIL LEVER TENSION ROLLER TRACTOR SELECT TRANSMISSION GEAR SENSOR ASSY., PE, FRONT Tractor Sprocket (Front) PAPER FEED MOTOR Pinion Gear Figure 2-8. Front Tractor Assembly Operation , Paper PAPER BAIL LEVER TENSION ROLLER SENSOR ASSY., PE, FRONT ~ \ TRACTOR SELECT GEAR k-i-l U.!!xtw”...
  • Page 47: Tractor Wire Operation

    Operating Principles DFX-5000+ Service Manual 2.1.4.1 Tractor Wire Operation The printer is equipped with a tractor wire (white line) to prevent paper jams when continuous paper is loaded from the front or rear entrance. The tractor tension spring on the right side frame pulls the wire and releases the stress on the continuous paper being fed.
  • Page 48 DEX-5000+ Service Manual operating #%’fnclphe Tractor Select 2.1.5 Ribbon Feed and Mechanisms The RF motor supplies power to both the ribbon feed and tractor select mechanisms. The rotaticm .J& of the RF motor pinion swings the ribbon feed select gear like a pendulum, using the lever axis as a support point.
  • Page 49 DFX4000+ Service Manual Operating Principles Figure 2-12 shows the operation of the tractor select mechanism. Clockwise rotation of the RF motor is 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 50: Plunger Mechanism

    Operating Prfnc@laa DFX-5LXXI+ Service Manual 2.1.6 Plunger Mechanism Figure 2-13 shows the plunger mechanism. The paper bail assembly is attached to the tmd 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 ik original position.
  • Page 51: Power Supply Operation

    DEW5000+ Service Manual Omratinf7 Principles 2.2 POWER SUPPLY OPERATION The printer can be powered by either of two power supply boards: the 120 V C117 PSB board assembly or the 220/240 V PSE C117 board assembly. The only difference in the operation of these two boards is in the primary circuitry.
  • Page 52 DFX-5000+ Sendee Mama! O~atfng Princi@aa The power supply board converts the AC voltage to the DC voltages required to operate the printer. The AC voltage is input to the AC inlet, and is supplied to the C117 power supply board assembly via the power switch and fuse.
  • Page 53: Vdcline Regulatorcircuk

    DFX-5000+ Service Manual Operating Principles VDC Line Regulator Circuit 2.2.2 +5 VDC line regulator circuit uses a ringing choke coil (RCC) system DC/DC converter. +35VIX C,, I’.,. +3VUL, IC151 (TL494) ZD153 HZS7B-2 PRIMERY CIRCUIT Figure 2-15. +5 VDC Line Regulator Circuit The rectified and smoothed DC voltage turns on the +5 VDC line first.
  • Page 54 operating Principbe DFX-5000+ Service Manual 2.2.3 +35 VDC Line Regulator Circuit C117 MAIN When the printer is turned on and the board assembly sends the WC signal, the +35 VDC line rises from +13 V to +35 V. The +35 VDC line arcuit uses a ringing choke mnvertor (RCC) AC input switching power circuit.
  • Page 55: 12 Vdc Half-Wave Rectifier Smoothing Circuit

    Dl%Y4iOOO+ Service Manual Operating Principles VDC regulator circuit includes the following: The +35 D Input voltage line over-current protection arcuit (primary side) IC101 and IC201 detect the input voltage of the primary circuit. When the input voltage is normal, the current does not flow into the shunt regulator. When the over-current flows to the input voltage line, the shunt regulator is turned on, Q103 (Q203) and Q102 (Q202) are turned on, and Q101 (Q201) is turned off.
  • Page 56: Control Circuit

    *“ncipba Manual @wating DEX-5000+ Servics 2.3 CONTROL CIRCUIT Figure 2-18 shows a block diagram of the control arcuit with the C117 MAIN board assembly at the center. 2.3.1 Control Circuit Operation Overview The core of the control circuit is the TMP96C14 CPU (IC1). This CPU is driven using a 14.74 MHz external clock (CRU1).
  • Page 57: Figure 2-18. Control Circuit Block Diagram

    DEX4000+ Service Manual Operating Principles -’l MOTOR, RF Q28 - Q31 TM P96CI 41 (lCl) -’i SLA7026M P-ROM MOTOR, PF (Icll) (IC4) Each Sensors Circuit 1.PE(top) 2. PE(front) 3. PE(rear) ~ Address Bus 4. Paper Jam 5.PG Home position 6.PuII Tractor 7. Tractor Select = Data Bus 8.
  • Page 58 Mimml 0per8thg Ffinchl&e DFX-5000+ Servics Figure 2-19 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 gate array IC (IC7) provides the interface between the external heat computer and the CPU, and all data processing is performed by read/write operations to MMIO (Memory Mapped Input/Output).
  • Page 59 DEX4000+ Service Manual Operating Principles 5. The print data is stored in the line buffer in units of one line of data. The CPU reads the print data stored in the line buffer byte by byte, accesses the CG (Character Generator), and expands the data in the image buffer (in the case of download characters, in the download CG).
  • Page 60: Reset Circuit

    Optuating Prfncipka hfimual OEX-5000+ %rvica Reset Circuit 2.3.2 This section 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 2-20 shows the reset arcuit block diagram.
  • Page 61: Sensor Circuits

    DFX-5000+ Service Manual Operating Principles 2.3.3 Sensor Circuits Figure 2-21 shows the sensor circuits in block diagram form. The printer is equipped with the following sensors: Front and rear PE sensors (use a photo interrupter) Top PE sensor (to detect the TOF position, uses a photo interrupter) Paper jam sensor (uses a magnetic transistor) Tractor select sensor (uses a micro mechanical switch) Pull tractor sensor (uses a micro mechanical switch)
  • Page 62 C)pmWng Pn”nc@&a DEX-5000+ Setvice Manual Each sensor is described below. 1. Front and rear paper end sensors Photo interrupter L1 Detection form: Q output form: Open collector (pulled up to 10 Kfi2 resistance) LI Input circuit: CR filter circuit (10 Kfil and 39 pF) Paper present: LOW Cl Logical: Paper out: HIGH...
  • Page 63 DFX-5000+ Service Manual Operating Principles Paper thickness sensor D Detection form: Photo interrupter Cl Input circuit: Rectangle wave (2 channels, TTL level) CR filter circuit (10 KQ and 390 pF) Cl PG ability: 0.015 mm/pulse D Sensing range: O to 0.7 mm Platen gap home position sensor Micro mechanical switch D Detection form:...
  • Page 64: Cr Motor Driver Circuit

    Manual Opwatfng DEX-5000+ Sawka Prh@aa CR Motor Driver Circuit 2.3.4 Figure shows the internal circuit for the CR motor, and Figure a block diagram fir 2-22 2-23 shows the CR motor driver circuit. An SLA5007 bipolar driver IC drives the CR motor. It has built-in bipolar switching transistors and a current limiter.
  • Page 65: Table 2-4. Cr Motor Drive Modes

    DEWOOO+ Service Manual Omwatina Principles Table 2-4. CR Motor Drive Modes Constan M%!or Acceleration/Deceleration Division Drive Mode Speed Control Curve ~r~me Control Super draft 1680 1600 Super drafi-HD Acceleration or deceleration control cutve. Draft 1260 Draft-HD 1200 Bit image 1 1050 Carriage Bit image 1–HD...
  • Page 66: Table 2-5. Cr Motor Drive Sequence

    DFX-5000+ Service Manual Operating Pdncipbs Table 2-5. CR Motor Drive Sequence Driver (Refer to Figure 2-22.) Carria#~T~;sfer Driving Mode Acceleration Deceleration 1 Left -+ Right Deceleration 2 Deceleration 3 Acceleration Deceleration 1 Right + Left Deceleration 2 Deceleration 3 LI PI control ..-.
  • Page 67: Figure 2-25. Deceleration Control Curve

    Operating Principle DFX-5000+ Service Manuai SpeeciO - SP1 It causes the carriage to accelerate. Because the control circuit measures time periods with the encoder signal, when the carriage speed reaches SP1, it changes to the next sequence (SP1 - SP2). - SP2 The DFX-5000+ printer has a table programmed into its main program ROM to determine the duration of the acceleration pulses.
  • Page 68 Current speed - SP3 1. The duty data for deceleration control is determined for each printing mode beforehand and programmed into a table in the main program ROM. Duty data is divided into 19 sections, plus Dutytil. Section 1 is the largest, and Dutytil represents the minimum duty data for deceleration amtml.
  • Page 69: Pf Motor Driver Cimuit

    DEX-5000+ Service Manual Operating Principles Carrige transfer direction Carrige transfer direction Right ~ Left ‘“---””””””--””” SP2 ““””””””””-””””- SP2 Figure 2-26. Measurement Sequence 2.3.5 PF Motor Driver Circuit Stepping motor driver SLA7026 (IC1l) drives the PF motor. Figure 2-27 shows the PF motor driver circuit block diagram, and Table 2-6 provides the PF motor specifications.
  • Page 70: Rf Motor Driver Circuit

    DEX-5000+ Sarvice Manual Oparatfng Phc@ba Table 2-6. PF Motor Specifications tkaaoription Specification Form 4-phase, 200-pole, HB* pulse motor Supply voltage 35 VDC t 6% (applied to the driver circuit) Internal coil resistance I 2.65 f2 +0.32 Llperphaseat 25°C (77°F) 4274 pps~ (normal mode, constant driving): 9.9 ipe”” Frequency 2610 pps (middle speed mode, constant driving): 6 ips Driving: 1.95 Aj 0.20A per phase (average)
  • Page 71: Pg Motor Driver Circuit

    Operating Principles DFX4000+ Service Manual 2.3.7 PG Motor Driver Circuit Figure 2-29 shows a block diagram of the PG motor driver circuit, and Table 2-8 provides PG motor specifications. The motor phase switching signals are output from the PGA port and input to the PGBN port of the gate array.
  • Page 72: Plunger Driver Circuit

    Dperating Ptinciphs DEX-5000+ Servb Manual 2.3.8 Plunger Driver Circuit Figure 2-30 shows a block diagram of the plunger driver arcuit, and Table 2-9 provides the plunger switching pattern. The plunger is driven using three switching patterns. Gate array general purpose ports PLP and PLN output the plunger coil drive signals. The CPU latches the switching data in the gate array.
  • Page 73 DEHOOO+ Service Manual Operating Principle FANA > > FANAN +’ -1”1 -z-x u-lo) > co’”’ HEAD FAN thermistor data — HEAD thermistor data Figure 2-31. Printhead Driver Circuit Rev. A 2-34...
  • Page 74 CHAPTER 3 Disassembly and Assembly Table of Contents 3.1 BEFORE STARTING 3.1.1 Tools ........... . 3-3 3.1.2 Small Parts .
  • Page 75 List of Figures Figure 3-1. Attaching the Packing Materials ......3-1 Figure 3-2. Packing the DFX-5000+ ....... . . 3-2 Figure3-3.
  • Page 76 Figure 3-51. Removing the Left Side Frame Gears ....3-38 Figure 3-52. Removing the Front Tractor Assembly..: ..3-39 Figure 3-53.
  • Page 77: Before Starting

    LKX-5000+ Servica Manual LXsassembly and Assembty 3.1 BEFORE STARTING Read this section before you disassemble, assemble, or transport the printer. Because the DFX-5000+ weighs 29.0 kg (63.8 lb) and is much larger and heavier than most printers, you must be carefil when handling it. Whenever it needs to be moved, two or more persons must carry it, supporting itfrom the botiom.
  • Page 78: Figure 3-2. Packing The Dfx

    DFX-5000+ Service Manual Disassembly and Assembly After attaching the packing materials, pack the printer in its container as shown in Figure 3-2. If you do not pack the printer properly, it may be damaged during transportation. Figure 3-2. Packing the DFX-5000+ Before disassembling the printer, turn it off and discomect the power cord from the printer and the wall outlet.
  • Page 79: Tools

    Dial gauges #F610 1019466 Dial gauge base #F611 1019467 Dial gauge master #F612 1019468 Thickness gauge #F616 1020471 ‘ . . Motor screwdriver — (Phillips head, toque adjustable) O: Commeraally available E: EPSON exclusive A: Mandatory B: Recommended f..‘ Rev. C...
  • Page 80 DEX-51UW+ Seffice Manual Disassembly andilsaembly B1019466OO Part number: 0 ..Dial gauges #F610 Catalog number: Figure 3-3. Dial Gauges B1019467OO Part number: Dial gauge base #F611 Catalog number: Figure 34 Dial Gauge Base Part number: B1019468OO Dial gauge master #F612 Catalog number: :: ::...
  • Page 81: Figure 3-6. Thickness Gauge

    B102O47NXI Part number: l’hickness gauge #F616 Catalog number Figure 3-6. Thickness Gauge 3.1.2 Smail Parts Tabie 3-2. Abbreviations for Smaii Parts Part Name Abbreviation Cross-Bind head, B-tight screw CBS (0) Cress-Bind head, S-tight screw with Outside-toothed lock washer washer + Cross-Bind Plane washer CBS (SP)
  • Page 82: Table 3-3. Screw Names And Illustrations

    DFX-5000+ Service Manual Disassembly and Assembly Table 3-3. Screw Names and Illustrations Head Washer Body Side 1. Plain washer 1. Normal 1. Bind 1. Cross-recessed head 2. S-tight 2. Outside toothed I \ \, (with fjotch) lock washer 2. Pan 3.
  • Page 83: Disassembly And Assembly

    and blssainbly Disassamhiy DEX-5iWO+ Samica Manual 3.2 DISASSEMBLY AND ASSEMBLY Before you disassemble or assemble the printer, be sure to read and follow the instmctions in Section 3.1, “BEFORE STARTING.” This section describes how to disassemble the printer. See the Appendix for an exploded diagram of the printer.
  • Page 84: Figure 3-8. Removing The Printhead

    DFX-5000+ Service Manual Disassembly and Assembly 5. Remove the 2 CPN (M3 x 8) screws securing the FPC cover to the bottom plate of the printer mechanism. 6. Remove the 2 FPC printhead cables from the connector junction board on the bottom plate and remove the CP (PS) (M4 x 7) screws securing the pnnthead to the carriage.
  • Page 85: Replacing The Rom

    Service Manual ~“sassambly and Assembiy DFX-5000+ 3.2.2 Replacing the ROM You can replace the ROM without disassembling the printer. il Zt is best to remove the top cover before you tilt back theprz”nter as described in the steps below. Refer to Section 3.2.3.lfor instructions on remooing the top cover. ~ If you tilt back the printer with the top cover attached, be carejid not to put too much weight on the top cover or any other ptinter components.
  • Page 86: Removing The Housing

    DFX-5000+ Service Manual Disassembly and Assembly 3.2.3 Removing the Housing This section describes how to remove the housing. the Top Cover 3.2.3.1 Removing Two people are required to remove the top cover; one person must hold the top cover while the other person removes the screws.
  • Page 87: Removing The Left, Right, And Front Covers And

    Disassamb@ and Assambly DEX-&MO+ Service Manual Removing the Left, Right, and Front Covers and Replacing the 3.2.3.2 Fuse 1. Remove the 4 CBB (M4 x screws securing the left side cover and remove the cover. 2. Remove the right side cover in the same way as you removed the left side cover. Also remove the 4 cables from the main switch on the right side cover.
  • Page 88 DEX-5000+ Service Manual Disassembly and Assembly 3. After you remove the right side cover, you can replace the input fuse for the C117 power supply board assembly. Make sure the new fuse meets the printer’s AC power specifications. ,CARRIAGE MOTOR Grounding Harries (RIGHT Side) Figure 3-13.
  • Page 89: Removing The Front Panel

    Dkassamb(y andAssamb& DFX-5000+ Service Manml 3.2.3.3 Removing the Front Panel Remove the left and right side covers. (Refer to Section 3.23.2) 2. Open the top rover and disconnect connector CN8 (the control panel mnnector). 3. Remove the2 CBB (M4 x 16) screws from the front panel and rernovethe panel with the Cl17 PNL board assembly and its cable.
  • Page 90: Removing Thecoveropen Sensor

    DFX-5000+ Sarvice Manual Disassembly and Assembly 3.2.3.5 Removing the Cover Open Sensor 1. Remove the uppercase. (Refer to Section 3.2.3.4) 2. Tum over tie upper case. Remove the 2 CPB (M2 from the case op~ sensor and x 8) screws remove the sensor.
  • Page 91: Removing Thecircuitboards

    DEX-5tNW+ Sarvica Manual Disassembly and blssambly 3.2.4 Removing the Circuit Boards This section describes how to remove the circuit boards. 3.2.4.1 Removing the Bottom Panel Assembly Q It is best to remove the top cover before you tilt back the~”nter as describedin thesteps below.
  • Page 92 DFX-5000+ Service Manual Disassembly and Assembly While supporting the top cover to protect it from scratches, tilt back the printer and lay it on its back. 5. Remove the 8 CPB (M4 x 16) screws securing the bottom panel assembly. Slowly return the printer to its upright position before you remove the screws for the bottom panel assembly.
  • Page 93 Disasaam6/y and Assamb/y Manual DFX-5000+ Sarvica 9. On the right side of the printer mechanism, remove the green and yellow earth cable from the earth plate on the bottom panel assembly. Then slowly lift up the bottom panel assembly. 10. Remove the CBS (0) (M4 x 8) screw securing earth plate. Earth Cable CBS(O) ‘M4X8)
  • Page 94: Removing The Cl 17 Main Board Assembly

    Disassembly and Assembly DFX-5000+ Service Manual Removing the Cooling Fan and CI17 Power Supply Board Assembly 3.2.4.2 Remove the bottom panel assembly. (Refer to Section 3.2.4.1) 2. If you need to remove the cooling fan, remove the 4 CCN (M3 x 30) screws securing it and remove the fan.
  • Page 95: Removing The Ac Inlet

    Disassembly and Assemb& DFX-5000+ Sarvica Mamml 3.2.4.4 Removing the AC Inlet Remove the C117 power supply board assembly. (Refer to Section 3.2.4.2) 2. Remove the Cl17MAINboard assembly. (RAertoSection3 Q.43) 3. Remove the 3 CPS(M3 x8) screws and 1 CPB (0) (M4 x5) screw securing the earth plate to the bottom panel assembly and remove the earth plate.
  • Page 96: Removing The C117 Pnl Board Assembly

    DFX-5000+ Service Manual Disassembly and Assembly 3.2.4.5 Removing the CI17 PNL Board Assembly Remove the front panel. (Refer to Section 3.2.3.3) Discomect connectors CN1 and CN2 on the C117 PNL board assembly. 3. Remove the CPB (M4 x 9) screw securing the C117 PNL board assembly to the front cover and remove the board.
  • Page 97: Removing The Interlock Switch Assembly

    and Asaambly D/aaaaambly DFX-5tWO+ Sarvica Marwal 3.2.5 Removing the Interlock Switch Assembly Remove the upper case. (Refer to Section 3.23.4) 2. Di SCQMeCt the interlock assembly cable CN9 on the C117 MAIN from junction comector board assembly. 3. Remove the CBB (M4 x 10) screw securing the interlock switch assembly to the lower case and remove the interlock switch assembly.
  • Page 98: Removing The Printer Mechanism

    DFX-5000+ Service Manual Disassembly and Assembly 3.2.6 Removing the Printer Mechanism This section describes how to remove the printer mechanism. Because the printer mechanism is large and heavy, you must be careful when you remove it. When you lift or lower the printer mechanism, follow these precautions: Ll Two people are required to remove or install the printer mechanism.
  • Page 99: Figure 3-29. Lifting The Printer Mechanism

    Disassembly and Assambly DFX-5000+ Sarvica Manual 5. Install the lift handles from the inside of the printer mechanism. Insert each handle through the 2 holes in the side frames of the printer mechanism. Then slowly lift the printer mechanism using the handles and remove it from the lowercase. Figure 3-29.
  • Page 100: Printer Mechanism Disassembly

    DFX-5000+ Service Manual Disassembly and Assembly 3.2.7 Printer Mechanism Disassembly This section describes how to disassemble the printer Before following the steps in this mechanism. section, remove the printer mechanism from the printer as described in Section 3.2.6. 3.2.7.1 Removing the Front/Rear Tractor Select Lever Assembly Remove the head damper from the left side frame.
  • Page 101: Figure 3-33. Disassembling The Tractor Select Lever

    llsassembty and Assamb& DFX-5000+ Service Manual 3.2.7.2 Disassembling the Front/Rear Tractor Select Lever Assembly This describes how to disassemble the front/rear tractor select lever assembly, including section how to remove the RF motor and tractor select sensor. Remove the front/rear tractor select lever assembly. (Refer to Section 3.2.7.1) CP (PS) (M3 x 6) screws securing the RF motor to the front/rear tractor select Remove the lever assembly and remove the motor.
  • Page 102 DFX-5000+ Service Manual Disassembly and Assembly T=a- RIBBON FEED MOTOR FRAME ~~ \ –TRACTOR SELECT CAM TRACTOR SELECT GEAR HOLDER I l l TRACTOR SELECT LEVER (UPPER and LOWER) Figure 3-34. Tractor Select Lever Mounting Position Rev. A 3-26...
  • Page 103: Fpc Board Assembly

    Disassembly and Assembly DFX-5000+ SeWica Manual 3.2.7.3 Removing Connector Junction Board Aasembly and FPC Board Aeaembly This section describes how to remove the comector junction board assembly (also died the relaying board) and FPC board assembly. Remove the left side cover. (Refer to Section 3.2.3.2) 2.
  • Page 104: Removing The Pg Sensor And

    DFX-5000+ Service Manual Disassembly and Assembly 3.2.7.4 Removing the PG Sensor and PG Motor When you remove or install the PG sensor, be careful not to bend the PG motor detection board. Remove the connector junction board assembly. (Refer to Section 3.2.7.3) 2.
  • Page 105: Removing The Plunger And Paper Bail Assembly

    Disassembly and Assembly DFX-5000+ Sawica Manua! 3.2.7.5 Removing the Plunger and Paper Bail Asaembly l%is section describes how to remove the plunger (loading solenoid) and paper bail assembly. black, 2-pin plunger connector from the connector junction board assembly, Discomect the and remove the plunger cable from the connector junction board assembly.
  • Page 106: Figure 3-38. Removing The Paper Bail Assembly

    DFX-5000+ Service Manual Disassembly and Assembly 4. Remove the left tension roller lever spring. 5. Remove the E-ring securing the paper bail shaft to the right side frame and remove the shaft holder. 6. Remove the right tension roller lever spring, and then remove the shaft holder with its washer. 7.
  • Page 107: Removing The Upper Paper Guide And Top Pe Sensor

    Disassembly and Assembly DFX-5000+ Service Manual 3.2.7.6 Removing the Upper Paper Guide and Top PE Sensor Remove the paper bail assembly. (Refer to Section 3.2.7.5) Disconnect the red, 3-pin, top PE sensor connector from the comector junction board assembly. (Refer to 3.2.73) Section 3.
  • Page 108: Figure 3-42. Removing The Tension Roller Shaft

    DFX-5000+ Service Manual Disassembly and Assembly 5. Remove the E-ring on the right side of the tension roller shaft and pull out the platen roller shaft holder with its leaf spring and washer. Figure 3-41. Removing the Shaft Holder 6. Remove the E-ring on the left side of the tension roller shaft and pull out the shaft holder. Then remove the tension roller shaft by pulling it right.
  • Page 109: Removing The Platen

    Disassembly and Assambiy DFX-5000+ Sarvica Manual 3.2.7.8 Removing tha Platen Remove the paper bail assembly. (Refer to Section 3Q.7.5) 2. Remove the upper paper guide. (Refer to Section 32.7.6) 3. Remove the 4 hexagon screws securing the platen to both holders. Then remove the platen with the lower paper guide.
  • Page 110: Removing The Paper Jam Sensor

    DFX-5000+ Service Manual Disassembly and Assembly 3.2.7.9 Removing the Paper Jam Sensor Remove the platen along with the lower paper guide. (Refer to Section 3.2.7.8) 2. Remove the left part of the lower paper guide. (The lower paper guide consists of three parts.) 3.
  • Page 111: Removifig The Pull Tractor Sensor

    Disassembly and Assambly DFX-SOOO+ Sarvica Manual 3.2.7.10 Removing the Pull Tractor Sensor Remove the upper paper guide. (Refer to Section 3.2.7.6) 2. Disconnect the red, 2-pin, pull tractor sensor comector from the connector junction board assembly. 3. Remove the CPN (SP) (M2 x 14) screw securing the pull tractor sensor (a micro-switch type sensor) to the left side frame and remove the sensor.
  • Page 112: Removing The Pg Home Sensor

    DFX-5000+ Service Manual Disassembly and Assembly 3.2.7.12 Removing the PG Home Sensor Remove the front/rear tractor select lever assembly. (Refer to Section 3.2.7.2) Remove the E-ring securing the carriage guide shaft gear to the rear carnage guide shaft. Figure 3-48. Removing the Carriage Guide Shaft Gear 3.
  • Page 113: Removing The Pf Motor

    Disassembly and Assambly DFX-5000+ Sarvica Manual 3.2.7.13 Removing the PF Motor Remove the connector junction board assembly. (Refer to Section 3.2.7.3) 2. Remove the 3 CP (PS) (M4 x 8) sc~ws securing the PF motor to the left side frame. 3.
  • Page 114: Removing The Left Side Frame Gears

    DFX-5000+ Service Manual Disassembly and Assembly 3.2.7.14 Removing the Left Side Frame Gears 1. Remove the front/rear tractor select lever assembly. (Refer to Section 3.2.7.2) 2. Remove the connector junction board assembly. (Refer to Section 3.2.7.3) 3. Remove the PG motor. (Refer to Section 3.2.7.4) 4.
  • Page 115: Removing The Front Tractor Assembly

    DEX-5000+ Service Manual Disassembly and Assembly 3.2.7.15 Removing the Front Tractor Assembly This section describes how to remove the front tractor assembly. You need to remove the front tractor assembly before removing the white, 3-pin, front PE sensor connector from the mnnector junction board assembly.
  • Page 116: Removing The Rear Tractor Assembly

    DEX-5000+ Service Manual Disassembly and Assembly 3.2.7.16 Removing the Rear Tractor Assembly This section describes how to remove the rear tractor assembly. You need to remove the rear tractor assembly before removing the black, 3-pin, rear PE sensor connector from the connector junction board assembly.
  • Page 117: Removing The Cr Motor

    Disassembly and Assambly DFX-5000t Service Manual 3.2.7.17 Removing the CR Motor Remove the printhead. (Refer to Section 3.2.1) 2. Remove the printer mechanism. (Refer to Section 3.2.6) 3. Remove the CP (PS) (M3 x 6) screw securing the timing belt holder and timing belt. Figure 3-54.
  • Page 118: Removing The Cr (Carriage Encoder) Sensor

    DFX-5000+ Service Manual Disassembly and Assembly 3.2.7.18 Removing the CR (Carriage Encoder) Sensor Remove the printhead. (Refer to Section 3.2.1) Disconnect the red, 4-pin, CR sensor connector from the connector junction board assembly. 3. Remove the CPN (M3 x 5) screw securing the CR sensor to the carriage and remove the sensor. (M3x5) ;onnector Junction Board CARRIAG...
  • Page 119: Disassembling The Carriage Mechanism

    and Aeaambly Dhwaaambly DFX4000+ Service Manual 3.2.7.19 Disassembling the Carriage Mechanism This section describes how to disassemble the carriage mechanism including removing the carriage, CR timing belt, and front and rear carriage guide shafts. 1. Remove the CRmotor. (Refer to Section 3.2.7.17) Remove the belt pulley from the belt pulley holder.
  • Page 120 DFX-5000+ Service Manual Disassembly and Assembly the carriage damper from therightside frame, and remove the 3 CBS (0) (M4x 8) 7. Remove screws securing the carnage motor holder to the right side frame. Remove the right guide shaft holder lever. Remove the 2 CP (PS) (M4 securing the rear carriage guide parallelism adjust lever x 6) screws...
  • Page 121: Removing The Paper Guide Suppoft Plate

    Disassembly and Assembly DFX-5000+ Service Manual Removing the Paper Guide Support Plate 3.2.7.20 1. Disassemble the carriage mechanism and remove all the parts related to the carriage. (Refer to Section 3.2.7.19) 2. Referring to the exploded diagram in the Appendix, remove the paper guide support plate. When you install the paper guide support plate, perform the following adjustments: Cl Carriage timing belt tension adjustment (described in Section 4.1.2) Cl Carriage guide shaflparallelism adjustment (described in Section 4.1.5)
  • Page 122 CHAPTER Adjustments Table of Contents 4.1 PRINTER MECHANISM ADJUSTMENTS 4.1.1 PG Motor Backlash Adjustment ....... . 4-1 4.1.2 Carriage Timing Belt Tension Adjustment .
  • Page 123: Printer Mechanism Adjustments

    Adjustments DFX-5000 Service Manual 4.1 PRINTER MECHANISM ADJUSTMENTS DFX-5000+. Whenever the printer This section describes the printer mechanism adjustments for the is disassembled and the printer parts mentioned in this section are replaced or repaired, perform the appropriate adjustments to ensure proper printer operation. Perform adjustments before assembling the printer.
  • Page 124: Carriage Timing Belt Tension Adjustment

    Manual Adjustment DFX-5000+ Sanka 4.1.2 Carriage Timing Belt Tension Adjustment CR motor timing belt tension must be adjusted when any carriage mechanism part (such as the pulley, or carriage timing belt) is disassembled. Remove the printer mechanism motor, belt before performing this adjustment. (Refer to Section 3.2.6) performing this adjustment, carefilly secure the printer mechanism because a 4 kg(8.8 lb) Before force is applied to it when the tension leoer is pulled in the horizontal direction.
  • Page 125: Tractor Wire Spring Tension Adjustment

    DFX-5000+ Service Manual Adjustment 4.1.3 Tractor Wire Spring Tension Adjustment describes the tractor wire spring tension adjustment. If the spring is not adjusted section This properly, paper jams may occur, because the continuous paper tension (in the horizontal direction) is incorrect. When you remove the front or rear tractor assembly, perform this adjustment. Remove the printer mechanism.
  • Page 126: Carriage Guide Shaft Parallelism Adjustment

    Since this value is extremely small, you must use the 2 dial gauges, dial gauge base, and dial gauge master supplied by Epson. Do not adjust the parallelism using any other method. i Dial gauge #F610 (Part No. B1019466) Q Dial gauge base #F611 (Part No.
  • Page 127 Adjustment DFX-5000+ Service Manual Remove the paper bail assembly. (Refer to Section 3.2.7.5) 4. Remove the tension roller shaft. (Refer to Section 3.2.7.7) 5. Remove the p-inthead with the masklessholder. (Refer to Section 3.2.1) Attach the dial gauge base with the dial gauge in the same way as you attach the print head. When you attach this tool to the carriage, tighten the two thumb saews while you pulling by the tie bandtoward you.
  • Page 128 DFX-5000+ Servicw Manual Adjustment If the side, move distance measured at the left side is greater than that measured at the right the parallelism adjust lever in the direction shown by the white arrow in Figure 4-9. If the distance measured at the left side is less than that measured at the right side, move the lever in the direction shown by the black arrow.
  • Page 129: Platen Angle Adjustment (Right Angle)

    Since this value is extremely small, you must use the 2 dial gauges, dial gauge base, and dial gauge master supplied by Epson. Do not adjust the parallelism using any other method. Ll Dial gauge #F610 (Part No. B1019466) L1 Dial gauge base #F611 (Part No.
  • Page 130 DFX-5000+ Service Manual Adjustment Attach the another needle to the master surface, then correspond to the another gauge measure, and tighten the hexagonal screw. Tighten the hexagonal screw. Attach the gauge needle to the master surface. Figure 4-12. Attaching the Another Dial Gauge 4.
  • Page 131 Adjustment DFX-5000+ Service Manual 6. Remove a CP(PS)(M3X6) screw securing the timing belt holder and timing belt, then remove the carriage plate. (Refer to Figure 4-2.) 7. Remove the paper bail assernbly.(Refer to Section 3.2.7.5.) Remove the tension roller shaft. (Refer to Section 3.2.7.7.) Remove the pull tractor sensor.(Refer to Section 3.2.7.10.)) 10.
  • Page 132 DFX-5000+ Semke Manual Adjustment 13. Reset the black marker to the “O” position. 14. Measure the angle difference about three position such as figure below.(Using the carriage motor pu IIy to move the carriage with the dial gauge toward the right side.) Platen (Angle Adjustment Operation) Measuring the Angle Difference...
  • Page 133: Platen Gap Motor Value Adjustment

    ~ This measurement is important because it determines theplatengap, so be sure to use the exclusive thickness gauge set and tension gauge supplied by EPSON. Thickness gauge set (0.39 mm): #F616 (Part No. B102O472W Tension gauge (200g): #F545 (Part No.
  • Page 134 Sewice Manual Adjustment DFX-5000+ print Remove the ribbon cartridge, and the paper from the printer. Then remove the head for confirm the ALPHA value written on the print head surface. After you confirm the ALPHA value remount the print head. Close the top cover.
  • Page 135: Bi-Directional Printing Adjustment

    Adjustment DFX-5000+ Service Manual Platen Figure 4-19. Pulling the Thickness Gauge 12. Set the BETA value when the tension gauge indicates the 150gf, the tension gauge can move to right in a degree.(Refer to under CAUTION.) 13. After complete this adjustment, turn the printer off, and rotate the PG drive gear manually toward you and remove the thickness gauge.
  • Page 136 DFX-5000+ Service Manual Adjustment Mount the ribbon cartridge. LF/FF, 2. Set the continuous paper to the front tractor and turn the printer on while pressing the mode MICRO FEED FRONT/REAR switches. (At this time, the printer shifts the standby (A), state.) and the paper...
  • Page 137 CHAPTER Troubleshooting Table of Contents 5.1 TROUBLESHOOTING INFORMATION 5.1.1 Error Messages..........5-1 5.1.2 Bypassing the lnterlockSwitch and Cover Sensor .
  • Page 138: Troubleshooting Information

    Troubleshooting DFX-5000+ Service Manual 5.1 TROUBLESHOOTING INFORMATION The information in this chapter makes troubleshooting easier to perform by listing various problems that can occur and p~oviding possible solutions. Note: For this printer; no special tools are necessary for troubleshooting to the unit level, with the exception of a digital multimeter.
  • Page 139 DFX4W@+ Service Manual Troubleshooting 5.1.2 Bypassin9 the 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 autornatidy disable printing when the top cover is open. To bypass the interlock switch, remove the top cover and close the left cover hinge.
  • Page 140: Coil Resistance

    Troubleshooting DFX-5000+ Service Manual 5.1.3 Coil Resistance The following table provides the coil resistances for the motor, head fan, plunger, and pnnthead. Table 5-2. Motor, Fan, Plunger, and Printhead Coil Resistances Coil Resistance Part CR motor 6.2 ohms f 0.45 ohms at 25°C (77”F) PF motor 2.85 ohms f 0.3 ohms at 25°C (77°F) 150 ohms *10 ohms at 25°C (77°F)
  • Page 141: Repair By Unit Replacement

    Troubleshooting DEW5tXM+ Service Msnual 5.2 REPAIR BY UNIT REPLACEMENT You can correct most problems by replaang the unit and adiusting the printer when necessary. Refer to Table 5-3, identib the problem, and&n follow the steps in &e flowchart indicated. Table 5-3. Symptoms and Reference Pages Symptom Problem Chert...
  • Page 142 1. The printer does not operate when power is turned on. START Use the correct voltage. the fuse and Replace disconnect CN 1 and CN3 on + the Cl 17 MAIN board. Measure the output voltage from the Cl 17 power supply board. Replace the Cl 17 power supply board.
  • Page 143 DEX-5000+ Service Msnua{ Troubleshooting 2. Carriage operation is abnormal. Reinsert the connectors. inserted securely? ‘= [ S m o o t h Refer to Section 5.5, Repair of the Printer Mechanism. Perform repair necessary. If the motor is bad, replace. If drivers are bad, replace at ,.->, the same time.
  • Page 144 Troubleshooting DFX-5000+ Service Manual Carriage operation is normal, but the self-testis printed incorrectly. START Perform the self-test. Are the connectors inserted securely? Check printhead cable continuity. Visually check printhead pins. Replace any bad part. Y e s fault corrected? I Perform the bidirectional E N D the followin connectors: NOTE 1: Check...
  • Page 145 DEK5tXUl+ Sertdce Manual Troubieahooting 3. Carriage operation is normal, but the self-testis printed incomectly (continued). Check the printhead resistance. Check printhead drivers. Check the printhead drivers. No If the printhead drivers are OK, replace the printhead. If the printhead drivers are OK, replace the ‘Replace the printhead and Cl 17 \ MAIN board.
  • Page 146 Troubleshooting DFX-5000+ Service Manual 3. Camiage incorrectly (continued). operation is normal, but the self-testis printed Perform bidirectional adjustment. Go back to Section 5.5, Repair of the Printer Mechanism, and check for other problems. Rev. A...
  • Page 147 DIZX-5000+ Servke Manual Troubleshooting Printing is normal, but paper feeding is abnormal. START ; Load the paper correctly. Refer to Section 5.5, Repair of the motor manually, does i ~ Printer Mechanism. ($-) .“:i Check the resistance of the PF motor “;L ‘...
  • Page 148 Troubleshooting DFX.5000+ Service Manual Control panel operation is abnormal. START between the C 117 MAIN Reinsert connector CN8 correctly. Using a m ultim eter, check the switches on the PNL board. Replace the Cl 17 MAIN board. Replace the Cl 17 PN L board. Replace the Cl 17 PNL board.
  • Page 149 DEWiXXl+ Servke Manual Ttvubleshooting 6. Data sent by the host cmnputeris printed incorrectly. Note: flowchart below assumes the host computer is operating normally. START Run the self-test. Troubleshoot printer using the previous flowcharts. Built-in Parallel ‘, J , i Check the cable connection from the host computer.
  • Page 150: Repair Of The Power Supply Circuit

    Troubleshooting DFX-5000+ Service Manual 5.3 REPAIR OF THE POWER SUPPLY CIRCUIT This section provides detailed troubleshooting methods to isolate components in the power supply or on the main board. This information is for use by servicers who repair to the component level. U.S.
  • Page 151 Troubleshooting IX%5tXM+ *vice Manual Table 5-5. C117 PSB/PSE Board Assembly Component Repair (continued) Symptom Checkpoint Cause Solution The +35 The main switching Check voltage waveform between Replace VDC line is FETs (Q101 or the drain side and GND. Q101 or dead.
  • Page 152 DFX-5000+ Service Manual Troubleshooting Table 5-5. C117 PSB/PSE Board Assembly Component Repair (continued) 5-15 Rev. A...
  • Page 153 mx-60@+ Serv#ce Ahmu8J Ttvublestmting Table 5-5. C117 PSBIPSE Board Assembly Component Repair (continued) Rev. A 6-16...
  • Page 154: Repair Of The C117 Main Board Assembly

    DFX-5000+ Service Manual Troubleshooting 5.4 REPAIR OF THE C117 MAIN BOARD ASSEMBLY This section provides detailed troubleshooting methods to isolate components in the C117 MAIN board. This information is for use by servicers who repair to the component level. U.S. servicers repair to the unit leveI only, and may ignore this section.
  • Page 155 Service Wnual DlW50#+ Troubleshooting Table 5-6. C117 MAIN Board Assembly Component Repair (continued) u - . , , .., . , Rev. A 5-18...
  • Page 156 DFX-5000+ Service Manual Troubleshooting Table 5-6. CI17 MAIN Board Assembly Component Repair (continued) Symptom Cause Checkpoint Solution The carriage Check the signals for the carriage Replace IC7. IC7 is defective. operates motor phases at pins 108, 109, 110, abnormally. and 111 of IC7. QM1 is defective.
  • Page 157 DEX50W+ Sarvica Manual Troubleshooting Table 5-6. Cl 17 MAIN Board Assembly Component Repair (continued) Checkpoint Solution Symptom Cause The carriage The carriage encode Observe the carriage encoder sensor Replace the operates sensor is defective. output signal at pins 3 and 4 of CN1 O. carriage abnormally.
  • Page 158 Troubleshooting DFX-5000+ Service Manual Table 5-6. C117 MAIN Board Assembly Component Repair (continued) S-21 Rev. A...
  • Page 159 DF%50tM+ Service Manual Troubleshooting Table 5-6. C117 MAIN Board Assembly Component Repair (continued) . . --,, ‘~ (.”; ‘ L > > , f--.., Rev. A s-22...
  • Page 160 Troubleshooting DFX-5000+ Service Manual Repair (continued) Table 5-6. C117 MAIN Board Assembly Component Solution Cause Checkpoint Symptom Observe the output signal at pins Replace IC7. The self-test IC7 is defective. 129-137 of IC7. is printed incorrectly. Replace the The head driver Observe the voltage waveform at the abnormal FETs are defective.
  • Page 161: Printer Mechanism

    DEX-50iW+ Service hbnual Tivubtastmoting 5.5 PRINTER MECHANISM REPAIR The table below describes how to isolate problems with the printer mechanism. To repiaa? or adjust printer mechanism parts, refer to Chapter 3, Dkaswmb ly and Assembly, and Chapter 4, Adjusfrnenfs. symptom If a recurs following a repair attempt, look for other possible causes and table b&low.
  • Page 162 Troubleshooting DFX-5000+ Service Manual Table 5-7. Printer Mechanism Repair (continued) Cause Checkpoint Solution Symptom The printhead is Replace the printhead. A particular dot does Measure the defective. not print. printhead coil resistance. (Refer to Figure 5-4 for details.) The printhead is Check whether a Replace the printhead.
  • Page 163 DEK50QO+ Service Manual Tmub/eshooting Table 5-7. Printer Mechanism Repair (continued) Cause Checkpoint Solution Symptom Perform the The parallelism value The RF motor does Check whether the parallelism is incorred. carriage moves not operate. adjustment, as smoothly when described in moved manually. (Check that foreign Section 4.1.5.
  • Page 164 DFX-5000+ Service Manual Troubleshooting Table 5-7. Printer Mechanism Repair (continued) Cause Checkpoint Symptom Solution The PW sensor is Printing occurs Check the PWsensor. ‘eplace’he ‘ defective. sensor. outside the paper width. The paper bail The plunger is Check the coil Replace the plunger.
  • Page 165 CHAPTER Maintenance and Lubrication Table of Contents 6.1 PREVENTIVE MAINTENANCE 6.2 LUBRICATION AND ADHESIVE APPLICATION List of Figures Figure 6-1. Correct Adhesive Application......6-3 Figure 6-2.
  • Page 166: Preventive Maintenance

    Adhesive application is necessary at the points indicated in Table 6-3 when parts are disassembled or replaced. EPSON recommends Neji Lock #2 (G) adhesive be applied to the points indicated in Figures 6-2,6-3, and 6-4. Avoid allowing excess adhesive to overflow onto related parts.
  • Page 167 Table 6-2. Lubrication Points Lubrication Points Lubrksni Caniage oil pad ring (on both left and right s“- of carriage) Carriage oil pad (under the carriage head cable holder) Hole holdin thetipofthe rear carriage guide shaft (in both left and right s“ e frames) Both edges of the rear carriage guide shaft Parallelism adjustment lever (contact point with the rear carriage gude shaft)
  • Page 168 Maintenance and Lubrication DFX-5000+ Sewice Manual Figure 6-1. Correct Adhesive Application (11) (12) Figure 6-2. Lubrication and Adhesive Diagram 1 Rev. A...
  • Page 169 Rev. A...
  • Page 170 Maintenance and Lubrication DFX-5000+ Sewice Manual —- -— ‘/ Figure 6-4. Lubrication and Adhesive Diagram 3 Rev. A...
  • Page 171 Appendix Table of Contents A.1 CONNECTOR SUMMARY A.2 CIRCUIT DIAGRAMS A-13 A.3 CIRCUIT BOARD COMPONENT LAYOUT A-15 A.4 EXPLODED DIAGRAM A-1a A.5 CASE OUTLINE DRAWING List of Figures Cable Connections ......Figure A-1.
  • Page 172 1. Plunger Vcc (+35V) 1. GND 2. PGA 3. PGB 1. Pull tractor signal 4. +5V 1. PG COMMON 1. Paper jam signa; 2. PG COMMON 2. GND 3. PG phase D 1. Tractor select signal 4. PG phase C 5.
  • Page 173 Appendix DFX-5000+ Service Manual A.1 CONNECTOR SUMMARY FiWre A-1 illustrates the interconnection of the primary components, and Table A-1 summarizes - - - functions sizes connectors. Cl 17 PNL Board Assembly 11 pins 11 pins Case Open sensor Interlock Switch CR Motor +35 VDC ON/OFF *%%1...
  • Page 174 oi%~ Service Manual Appendix Table A-1. Connector Summary p,n~ Re~Ipk- Unit Connector Description Receives the +5 VDC and t12 VDC voltages &2 from connector CN3 on the Cl 17 PSB/PSE board. Standard serial interface; receives serial data from the external computer. Receives the +35 VDC voltage from connector CN2 on the Cl 17 PSIYPSE board.
  • Page 175 Appendix DFX-5000+ Service Manual Table A-2. CN1, C117 MAIN Board Assembly Name Description Pin No. \ OK for +35 VDC voltage output (used in conjunction with DRERR) DRERR Driver error signal to drop voltage to the head driver IC I CLIMIT Power supply board voltage drop signal +12 VDC input for serial interface VDC input for serial interface...
  • Page 176 DEHOtXl+ Service Manual Appendix Table A-5. CN4, C117 MAIN Board Assembly Oesoription Name Pin No. Power source for Type B optional interface Serial transmission data READY Ready to receive data Serial receiving data input Not connected Reset signal for Type B interface card Inhibit signal output CMREQ Command request signal input...
  • Page 177 Appendix DFX-5000+ Service Manual Table A-7. CN6, Cl 17 MAIN Board Assembly Name Description Pin No. 13,21,15, HDI HD9 Head driver signal output 25,20,23, 16,9,18 HDCOM1 Head common (HD2,4,6) 11,12,14 HDCOM2 Head common (HD1 ,3,5,7,8,9) 5-8,10 HTMP Head temperature detection data input 59,61 CR motor driver signal output CR motor driver signal output...
  • Page 178 Table A-8. CN7, C117 MAIN Board Assernbty Pin No. I/O Deeoriptlon Name I COVER I Cover open sensordata input Ground Table A-9. CN8, C117 MAIN Board Assembly Pin No. Name Description Ol@Jt TEARLP TEAR OFF LED Buzzer signal output BUZZER REGLP REAR LED paper loaded output (green) 17CPI...
  • Page 179 Appendix DFX-5000+ Service Manual Table A-1 1. CN1O, Cl 17 MAIN Board Assembly Name Description Pin No. Ground Power source for CR sensor (encoder) ENC-A Encoder pulse phase A input ENC-B Encoder pulse phase B input Table A-12. CN1, Cl 17 Power Supply Board Assembly PSB/PSE Description...
  • Page 180 Appendix DFX-5000+ Service Manual Figure A-3. C117 PSB Board Assembly Circuit Diagram Rev. A...
  • Page 181 DFX+OOO+ Service Manual Appendix P I I Figure A-4. C117 PSE Board Assembly Circuit Diagram Rev. A A-1 2...
  • Page 182 Appendix DFX-5000+ Service Manual A.3 CIRCUIT BOARD COMPONENT LAYOUT CI06 ....<~ HMZ7CIO!AG-12 - - - - - - - - - - - - - - - .
  • Page 183 DFX-5000+ Service Manual Appendix -’--- ,mTN ,15, ,,54 ~ : C>eo’---” MODEL EPS-1 S CflK-C2X~ A C I i 7 PSE _ ,D;N4 Figure A-6. C117 PSB/PSE Board Assembly Component Layout Rev. A A-14...
  • Page 184 Dl%5000+ Service Manual Appendix A.5 CASE OUTLINE DRAWING — — — — — A-10. DFX-5000+ Case Outline Drawing Figure Rev. A A-1a...
  • Page 185 EPSON OVERSEAS MARKETING LOCATIONS EPSON AMERICA, INC. EPSON DEUTSCHLAND GmbH ZiYpicher StraBe 6,4000 Dkseldorf 11 20770 Madrona Avenue, P.O. 2842 F.R. Germany Phone: 0211-56030 Torrance, CA 90509-2842 Phone: (800) 922-8911 Fax : 0211-504-7787 (310) 782-5220 Fax: EPSON UK LTD. EPSON FRANCE S.A.
  • Page 186 EPSON...

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