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Epson DFX-8500 - Impact Printer, Service Manual

The Epson DFX-8500 Impact Printer is a high-performance printing solution designed for those who require fast and reliable printing in demanding work environments. With its robust design and advanced features, this printer delivers exceptional print quality and efficient performance. To ensure proper maintenance and maximize its capabilities, we offer a comprehensive Service Manual available for free download on our website.

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CHAPTER 1

 GENERAL DESCRIPTION

 

1.1 FEATURES.............................................................................................................1-1

 

1.2 SPECIFICATIONS..................................................................................................1-3

 

1.2.1 Printing Specification............................................................................................................. 1-3

 

1.2.2 Paper Feeding ......................................................................................................................... 1-6

 

1.2.3 Electrical Specification .......................................................................................................... 1-6

 

1.2.4 Environmental Condition....................................................................................................... 1-6

 

1.2.5 Reliability................................................................................................................................. 1-6

 

1.2.6 Safety Approvals .................................................................................................................... 1-7

 

1.2.7 CE Marking .............................................................................................................................. 1-7

 

1.2.8 Acoustic Noise........................................................................................................................ 1-7

 

1.2.9 Ribbon Cartridge .................................................................................................................... 1-7

 

1.2.10 Physical Specifications........................................................................................................ 1-7

 

1.2.11 Printable area ........................................................................................................................ 1-8

 

1.2.12 Paper and Media ................................................................................................................. 1-12

 

1.2.12.1 Continuous paper (Single sheet and multi-part).................................................... 1-12

 

1.2.12.2 Labels .................................................................................................................... 1-14

 

1.2.12.3 Continuous Forms with Labels .............................................................................. 1-14

 

1.2.12.4 Overlapping Multi-part Form.................................................................................. 1-16

 

1.2.12.5 Perforation ............................................................................................................. 1-16

 

1.2.12.6 Notes ..................................................................................................................... 1-16

 

1.3 INTERFACES .......................................................................................................1-19

 

1.3.1 Parallel Interface (Forward channel)................................................................................... 1-19

 

1.3.2 Parallel Interface (Reverse channel)................................................................................... 1-21

 

1.3.3 Serial Interface ...................................................................................................................... 1-22

 

1.3.4 Optional Interface ................................................................................................................. 1-22

 

1.3.5 Interface Selection................................................................................................................ 1-23

 

1.3.6 Prevention Hosts from Data Transfer Time-out................................................................. 1-23

 

1.4 OPERATING INSTRUCTIONS.............................................................................1-24

 

1.4.1 Control Panel ........................................................................................................................ 1-24

 

1.4.1.1 Switches .................................................................................................................. 1-25

 

1.4.1.2 Indicators ................................................................................................................. 1-26

 

1.4.2 Errors and Buzzers............................................................................................................... 1-27

 

1.4.3 DIP Switch Settings.............................................................................................................. 1-28

 

1.4.4 Functions .............................................................................................................................. 1-31

 

1.4.4.1 Usual operation ....................................................................................................... 1-31

 

1.4.4.2 Operation at Power On............................................................................................ 1-33

 

1.4.4.3 Built-in Detection ..................................................................................................... 1-34

 

1.4.5 Paper Memory Function....................................................................................................... 1-35

 

1.4.6 Initializations ......................................................................................................................... 1-36

 

1.4.6.1 Power-on Initialization ............................................................................................. 1-36

 

1.4.6.2 Software Initialization............................................................................................... 1-36

 

1.4.6.3 Panel Initialization.................................................................................................... 1-36

 

1.5 MAIN  COMPONENT ...........................................................................................1-37

 

1.5.1 M-3I60 Printer Mechanism ................................................................................................... 1-38

 

1.5.2 Main Control Board (C204 MAIN Board)............................................................................. 1-39

 

1.5.3 C204 DRV Board ................................................................................................................... 1-40

Summary of Contents for DFX-8500 - Impact Printer

Page 1: ...EPSON IMPACT SERIAL DOT MATRIX PRINTER DFX 8500 SERVICE MANUAL SEIKO EPSON CORPORATION 4009310 ...

Page 2: ...al 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 consequences thereof EPSON is a registered trademark of SEIKO EPSON CORPORATION General Notice Other product names used herein are for identification purposes only and may be trademarks or regist...

Page 3: ...ANUAL DO NOT CONNECT THE UNIT TO A POWER SOURCE UNTIL INSTRUCTED TO DO SO WHEN THE POWER SUPPLY CABLE MUST BE CONNECTED USE EXTREME CAUTION IN WORKING ON POWER SUPPLY AND OTHER ELECTRONIC COMPONENTS CAUTION 1 REPAIRS ON EPSON PRODUCT SHOULD BE PERFORMED ONLY BY EPSON CERTIFIED REPAIR TECHNICIAN 2 MAKE CERTAIN THAT THE SOURCE VOLTAGE IS THE SAME AS THE RATED VOLTAGE LISTED ON THE SERIAL NUMBER RATI...

Page 4: ...ts of the printer CHAPTER 2 OPERATING PRINCIPLES 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 techn...

Page 5: ...v REVISION SHEET Revision Issued Data Contents Rev A May 18 1998 First issue Rev B June 25 1998 Second issue due to minor correction on the manual contents ...

Page 6: ...vi 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: ...FACES 1 19 1 3 1 Parallel Interface Forward channel 1 19 1 3 2 Parallel Interface Reverse channel 1 21 1 3 3 Serial Interface 1 22 1 3 4 Optional Interface 1 22 1 3 5 Interface Selection 1 23 1 3 6 Prevention Hosts from Data Transfer Time out 1 23 1 4 OPERATING INSTRUCTIONS 1 24 1 4 1 Control Panel 1 24 1 4 1 1 Switches 1 25 1 4 1 2 Indicators 1 26 1 4 2 Errors and Buzzers 1 27 1 4 3 DIP Switch Se...

Page 8: ...1 5 4 C204 DRV B Board 1 41 1 5 5 C204 SUB Board 1 41 1 5 6 C204 PSB PSE Board 1 42 1 5 7 Control Panel 1 43 1 5 8 Housing 1 43 ...

Page 9: ...er paper path and paper park Automatic platen gap adjustment for paper thickness Automatic tear off Paper memory function Automatic paper path changing Auto cut mode enables the optional perforation cutter to cut the paper at the perforation Bi directional parallel interface IEEE 1284 nibble and RS 232C serial interface standard EPSON ESC P upper compatible with DFX 8000 and IBM LEXMARK 2381Plus e...

Page 10: ...l interface card mm screw C82307 32 KB intelligent serial I F card inch screw C82308 32 KB intelligent serial I F card mm screw C82310 32 KB intelligent parallel I F card inch screw C82311 32 KB intelligent parallel I F card mm screw C82312 Local Talk I F card C82313 32KB IEEE 488 I F card C82314 Coax I F card C82315 Twinax I F card C82357 Ethernet I F card C82345 IEEE 1284 parallel I F card C8236...

Page 11: ... 800 12 cpi 163 1008 960 15 cpi 204 630 630 Draft condensed 17 cpi 233 720 685 20 cpi 272 840 800 Draft emphasized 10 cpi 136 420 400 NLQ 10 cpi 136 210 200 12 cpi 163 252 240 15 cpi 204 200 200 NLQ condensed 17 cpi 233 171 171 20 cpi 272 200 200 Notes 1 The line including graphic B0h FFh or download characters or bit image data will be printed by High duty mode Notes 2 The line including special ...

Page 12: ...East Europe PC853 Turkish PC855 Cyrillic PC857 Turkish PC866 Russian PC869 Greek MAZOIWA Poland Code MJK CSFR ISO 8859 7 Latin Greek ISO Latin 1T Turkish Bulgaria Bulgarian Estonia Estonia PC 774 LST 1283 1993 ISO 8859 2 ISO Latin 2 PC 866 LAT Latvian PC866 UKR PC 860 PC 861 PC 865 PC APTEC PC 708 PC 720 PC AR864 PC 863 Canadian French Abicomp BRASCII Roman 8 ISO Latin 1 Hebrew 7 Hebrew 8 PC862 No...

Page 13: ... EPSON Roman PC850 Multilingual PC437 Greek EPSON Sans Serif PC852 East Europe PC853 Turkish PC855 Cyrillic PC857 Turkish PC866 Russian PC869 Greek MAZOWIA Poland Code MJK CSFR ISO 8859 7 Latin Greek ISO Latin 1T Turkish Bulgaria Bulgarian Estonia Estonia PC 774 LST 1283 1993 ISO 8859 2 ISO Latin 2 PC 866 LAT Latvian PC 866 UKR PC 860 PC 861 PC 865 PC APTEC PC 708 PC 720 PC AR864 PC 863 1 Abicomp ...

Page 14: ...C Dielectric strength 1000 AC Vrms 1 min or 1200 AC Vrms 1 sec between AC line and chassis 220 240 V version Rated voltage 220 to 240 V AC Input voltage range 198 to 264 V AC Rated frequency range 50 to 60 Hz Input frequency range 49 5 to 60 5 Hz Rated current 1 4 A max 3 5 A Power consumption Approx 160 W ISO IEC10561 Letter pattern Energy Star compliant Insulation resistance 10 M ohms min betwee...

Page 15: ...B 1 2 7 CE Marking 230 V version Low Voltage Directive 73 23 EEC EN60950 EMC Directive 89 336 EEC EN55022 class B EN61000 3 2 EN61000 3 3 EN50082 1 IEC801 2 IEC801 3 IEC801 4 1 2 8 Acoustic Noise Level 58 dB A ISO 7779 pattern 1 2 9 Ribbon Cartridge Type Fabric Color Black Ribbon life 15 million characters draft 10 cpi 14 dots character Dimensions 506 0 mm W x 123 5 mm D x 23 0 mm H 1 2 10 Physica...

Page 16: ...rgin 13 mm or more TM top margin 2 6 mm or more BM bottom margin 4 2 mm or more Notes 1 In the top 75 mm area the paper feeding pitch may be irregular Notes 2 If the optional pull tractor is used the top 120 mm area should not be printed Notes 3 Forms override printing is available 20 lines after the paper end Paper feeding pitch is not guaranteed The end of the printable area is 9 to 15 mm apart ...

Page 17: ...more BM bottom margin 4 2 mm or more Notes 1 Feeding backward or paper PATH selection are prohibited Notes 2 If In the top 75 mm area the paper feeding pitch may be irregular Notes 3 If the optional pull tractor is used the top 120 mm area should not be printed Notes 4 Forms override printing is available 20 lines after the paper end Paper feeding pitch is not guaranteed The end of the printable a...

Page 18: ... or more TFL top margin from label 12 5 mm or more BFL bottom margin from label 12 5 mm or more LOL left margin on label 5 mm or more ROL right margin on label 5 mm or more TOL top margin on label 2 mm or more BOL bottom margin on label 2 mm or more Notes 1 Feeding backward or paper PATH selection are prohibited Notes 2 If In the top 75 mm area the paper feeding pitch may be irregular Notes 3 If t...

Page 19: ...e OL overlapping length Less than 13 3 mm NA non printable area 25 4 mm or more Notes 1 Feeding backward or paper PATH selection are prohibited Notes 2 If In the top 75 mm area the paper feeding pitch may be irregular Notes 3 If the optional pull tractor is used the top 120 mm area should not be printed Notes 4 Forms override printing is available 20 lines after the paper end Paper feeding pitch i...

Page 20: ...se paper jam The each sheet of multi part paper should normally be put together by spot gluing paper stapling tape stitching Spot gluing is recommended for the better printing quality Spot gluing must be applied on both sides of paper Refer to Figure 1 7 The spot glued parts must be pressed flat There must be no creases in the paper The paper stapling must be applied from the front of paper and th...

Page 21: ...GENERAL DESCRIPTION Rev B 1 13 Figure 1 8 Paper stapling Height Figure 1 9 Paper stapling Method 1 Figure 1 10 Paper stapling Method 2 ...

Page 22: ...I LINE LABELS or the same quality labels Perforation Refer to section 1 2 12 5 Notes The easy cone off label should not be used Every label must be put on the carrier Each comer of those labels must be rounded Each label and backing sheet should not have any folds or creases Between each label there should be the same sheet as those labels The backing sheet must be continuous paper Labels should b...

Page 23: ...ded for the better printing quality Spot gluing must be applied on both sides of paper Refer to Figure 1 7 The spot glued parts must be pressed flat There must be no creases in the paper The paper stapling must be applied from the front of paper and the paper must be flat Refer to Figure 1 8 Paper stapling must be applied for both feeding directions Refer to Figure 1 9 The paper stapling should be...

Page 24: ... Overlapping multi part form should be inserted from front entrance Refer to Section 1 2 12 6 1 2 12 5 Perforation Weak horizontal and vertical perforations cause paper jams D 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 1 13 Horizontal perforations must have an uncut part in each end of the paper Refer to Figure 1 14...

Page 25: ...S p o t g l u e d p s r t P e r f o r a t i o n o f b a s e s h e e t 4 2 o r m o r e 2 1 2 o r m o r e S p o t g l u e d p a r t B a s e s h e e t M u l t i p a r t c u t s h e e t 2 1 2 o r m o r e 1 3 3 1 9 o r m o r e U n i t m m Figure 1 12 Paper Width Overlapping Area Figure 1 13 Perforations 1 Figure 1 14 Perforations 2 ...

Page 26: ...8500 Rev B 1 18 Figure 1 17 Unsuitable Paper a b c Figure 1 15 Perforations 3 Figure 1 18 Sprocket Hole 1 Figure 1 19 Sprocket Hole 2 Figure 1 16 Raised Portion at a Perforation Figure 1 20 Bad Folded Paper ...

Page 27: ...ardware initialization During printer error see ERROR signal 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 Printer hardware error fatal error Paper out error Paper jam error Cover open status Incomplete paper change Paper size error Ribbon jam err...

Page 28: ...dge of this pulse 2 9 DATA 0 7 20 27 In The DATA0 through DATA7 signals represent data bits 0 to 7 respectively Each signal is at high level when data is logical 1 and low level when data is logical 0 10 ACKNLG 28 Out This signal is a negative pulse indicating that the printer can again accept data 11 BUSY 29 Out A high signal indicates that the printer cannot receive data 12 PE 28 Out A high sign...

Page 29: ...ts following values 0000 0100 Request Device ID by nibble mode sending 0000 0000 Request nibble mode 10 ACKNLG OUT PtrCIk Printer data sending clock 11 BUSY OUT PtrBusy Printer sending data bits 3 and 7 during data transfer to the host computer 12 PE OUT AckDataReq Printer sending data bits 2 and 6 during data transfer to the host computer 13 SLCT OUT Xflag Printer sending data bits 2 and 6 during...

Page 30: ...g When parity error is detected the received byte is changed to the character code Overrun error and framing error are ignored Connector 25 pin sub miniature D shell connector female Connector pin assignment and signals Refer to Table 1 12 Table 1 12 Signal and Connector Pin Assignment EIA 232D Pin No Signal Name In Out Functional Description 2 TXD Out Transmit data 20 DTR Out Indicates that the p...

Page 31: ...el interface is not selected the interface got into a busy state When the serial interface is not selected the interface sends X OFF and sets the DTR signal MARK When the optional interface is not selected the printer sends disable commands to the optional interface When the printer is initialized or returned to the idle state the parallel interface got into a ready state the serial interface send...

Page 32: ...inter operations The panel consists of indicator lights and buttons P a p e r S e l e c t P o w e r P a p e r O u t R i b b o n F o n t P i t c h C o p y T o p o f F o r m T e a r O f f L F F F L o a d P a u s e R e s e t 3 s e c T r a c t o r S e l e c t P A P E R S E L E C T F r o n t R e a r S p e r D r a f t D f a f t R o m a n S a n s s e r i f 1 0 c p i 1 2 c p i 1 5 c p i 1 7 c p i 2 0 c p ...

Page 33: ...vances continuous paper to the Tear off position adjustment Copy Alternates copy mode or not Pitch Selects pitch Font Selects font Paper Select Selects paper No Operation at power on Tuning the printer on while pressing panel switches executes the function shown in Table 1 14 Table 1 14 Switch Function at Power On Switch Function LF FF Load Draft self test Tear off NLQ self test Tear off and LF FF...

Page 34: ... position is adjustable Tear Off Green The LED on when the paper is in Tear off position and it is off when the paper is out of the Tear off position Copy Green The LED is on at copy mode and it is off at normal mode Pitch Green The status of Pitch selection is displayed by three Pitch LEDs 10 cpi 12 cpi 15 cpi 17 cpi 20 cpi PS LED off LED on Font Green The status of Font selection is displayed by...

Page 35: ...rmal it goes Measurement seeking error Illegal panel operation Note 1 The descriptions and show how the beeper sounds Beeper sounds 100 ms and interval is 100 ms Beeper sounds 500 ms and interval is 100 ms Table 1 15a Fatal Error Information Fatal Error 7 segment LED Indication 1 Beeper 2 Description 3 CR motor circuit shortage error 1 Auto power off after 12 seconds Cutter error 2 Auto power off ...

Page 36: ...or front tractor Refer to Table 1 19 All Off 2 5 to 2 8 Page length for rear tractor Refer to Table 1 20 All Off 3 1 Auto tear off Inactive Active Off 3 2 Zero slash Inactive Active Off 3 3 Auto line feed Inactive Active Off 3 4 Buzzer Active Inactive Off 3 5 Auto CR IBM 2381 Plus Inactive Active Off 3 6 IBM character table Table 2 Table 1 Off 3 7 Auto cut mode Inactive Active Off 3 8 Software ESC...

Page 37: ...On PC850 Multilingual Off Off Off Off On Off PC437 Greek Off Off Off Off On On PC852 East Europe Off Off Off On Off Off PC853 Off Off Off On Off On PC855 Cyrillic Off Off Off On On Off PC857 Turkish Off Off Off On On On PC866 Russian Off Off On Off Off Off PC869 Greek Off Off On Off Off On MAZOWIA Poland Off Off On Off On Off Code MJK CSFR Off Off On Off On On ISO 8859 7 Latin Greek Off Off On On ...

Page 38: ... 4 Page length for rear tractor Off Off Off Off 11 inches Off Off Off On 3 inches Off Off On Off 3 5 inches Off Off On On 4 inches Off On Off Off 5 5 inches Off On Off On 6 inches Off On On Off 7 inches Off On On On 8 inches On Off Off Off 8 5 inches On Off Off On 70 6 inches On Off On Off 12 inches On Off On On 14 inches On On Off Off 17 inches On On Off On Others Others 11 inches Table 1 21 I F ...

Page 39: ...ackwards by 1 216 inch step LF FF Load Pressing it loads continuous paper when the printer is out of paper Pressing it shortly executes line feed Holding it down for a few seconds executes form feed Top of Form Advances the paper so that the characters base line can be adjusted at the mark of ribbon mask holder and enters the Top of form adjustment mode The Top of Form LED turns on and the TOF pos...

Page 40: ...mediately Cut the bottom of paper at current page and push Pause switch then the printer feeds the paper forward After the paper is out the printer loads the selected paper If incomplete changing paper error is occurred set the selected paper and push Pause switch Current paper No is a or b The printer feeds the paper forward If the printer can t aware out of paper status it goes incomplete changi...

Page 41: ...This function is for emergency and service Clear Driving Line count for ribbon change timing Resets the printer to the standard factory setting only driving line count for ribbon change timing Paper memory setting This makes it possible to print properly on the forms which contain two areas having different thickness in a form and paper type Mechanism adjustment Starts the mechanism parameter adju...

Page 42: ...to the paper thickness Skip over binding This function is used to print on a multi part form with the binding which scratches the print head during paper feeding If this function is used the print head parks apart from those bindings during paper feeding to avoid paper jam This function can be selected by DIP switch and the through put will be reduced at that time Auto cut mode The printer cuts th...

Page 43: ...e printer paper is advanced to the top of the next page automatically How to write the information of a paper except Continuous forms with labels 1 Make sure the printer is turns off 2 Select the memory you want to write the information See DIP SW setting 3 Select the page length See DIP SW setting 4 Select the paper type See DIP SW setting 5 Turn the printer on while both sides of Paper Select sw...

Page 44: ...e 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 for ESC P or ESC K for IBM LEXMARK2381 Plus This initialization is to make the printer setting to default 1 4 6 3 Panel Initialization The initialization performed by the contro...

Page 45: ... C204 DRV B board DIP SW board C204 SUB board Power supply board C204 PSB PSE board unit Control Panel Panel unit Housing C 2 0 4 M A I N B o a r d C 2 0 4 D R V B o a r d C 2 0 4 D R V B B o a r d a n d C 2 0 4 S U B B o a r d C 2 0 4 P S B P S E B o a r d P a n e l U n i t H e a d C a b l e B o a r d C R C o n n e c t o r J u n c t i o n B o a r d C o n n e c t o r J u n c t i o n B o a r d Figu...

Page 46: ...is included to provide enhanced paper handling The structural differences between the DFX 8500 and the DFX 8000 are DFX 8500 includes a CR motor isolation resistance sensor DFX 8500 includes a paper jam sensor DFX 8500 includes a ribbon jam sensor To prevent paper jams the DFX 8500 includes a tractor wire at the front and rear tractors The detection method of the carriage encoder sensor has been c...

Page 47: ...e array E05B36 IC1 PROM including C G 2M bit IC5 RAM 4M bit IC14 ADM232L RS 232C level converter IC9 RESET IC PST391D IC13 EEPROM 93C66 IC11 There are two types of C204 MAIN board used as after service parts The following Table shows differences between them Table 1 24 Color Attribute For USA and Pacific For Europe Serial I F Hexagonal head screw type Inch Metric Figure 1 26 C204 MAIN Board ...

Page 48: ...d motor CR carriage motor CR fan PG platen gap motor and RF ribbon feed motor drive circuits are located on the driver boards Sensor signals from the printer mechanism are connected to the main board via these boards Major ICs on the DRV are as follows CR motor drive IC STK561 IC1 PF motor drive IC STK5713B IC2 Comparator IC uPC393C IC3 Figure 1 27 C204 DRV Board ...

Page 49: ...rd is the printhead driver board The drive part is mainly consists of the discrete bipolar FETs 1 5 5 C204 SUB Board The C204 SUB board consists of five DIP switch units It is located behind the front paper cover Figure 1 28 C204 DRV B Board Figure 1 29 C204 SUB Board Unit ...

Page 50: ...pply circuit board which generates the power for the control circuit main control board and printer mechanism drive circuit driver board It contains cooling fan on the top The PSB board is a 100 120 V AC version and the PSE board is for 220 240 VAC Figure 1 30 C204 PSB PSE Board ...

Page 51: ...many more components than previous designs The lower case is used as the main frame which holds the mechanism and circuits and they are covered by the upper case bottom plate and side cover each of which has various covers The housing large openings in both the front and rear for paper entrance and exit It also has a lid on the both plate to enable the PROM on the main board to be easily replaced ...

Page 52: ......

Page 53: ...nd Tractor Select Mechanisms 2 10 2 1 6 Plunger Mechanism 2 12 2 2 POWER SUPPLY OPERATION 2 13 2 2 1 Power Supply Overview 2 14 2 3 CONTROL CIRCUIT 2 13 2 3 1 Control Circuit Operation Overview 2 17 2 3 2 Reset Circuit 2 21 2 3 3 Sensor Circuits 2 22 2 3 4 CR Motor Drive Circuit 2 25 2 3 5 PF Motor Drive Circuit 2 29 2 3 6 RF Motor Drive Circuit 2 30 2 3 7 PG Motor Drive Circuit 2 31 2 3 8 Plunger...

Page 54: ......

Page 55: ... a vertical line against the surface of the paper and the ribbon A character is printed by repeating this printing operation in the horizontal direction as the printhead moves The printhead includes a head fan and temperature sensor The head fan also has a thermistor When the printhead or fan is too hot the printer stops printing until it cools Refer to Section 2 3 9 Printhead Drive Circuit Plunge...

Page 56: ...ols CR motor driver deceleration Refer to Section 2 3 4 CR Motor Drive Circuit Printing resumes when the top cover is closed Auto platen gap adjustment mechanism The printer mechanism has an automatic platen gap adjustment function that measures the thickness of the paper and provides the appropriate gap between the platen and printhead The platen gap is adjusted by moving the carriage and printhe...

Page 57: ...ts whether the optional pull tractor unit is installed The printer is also equipped with a paper jam sensor The control circuit reads the signals from the sensors and indicates when an error occurs Tractor select mechanism The printer mechanism has two paper entrances one at the front tractor and one at the rear tractor By controlling the RF motor the tractor select mechanism chooses which tractor...

Page 58: ...etic force when power is applied and during standby The magnetic force holds back the actuating spring When current flows through the coil a counter magnetic field is induced in the coil Then the actuating spring ejects the dot wire forward against the ink ribbon printing a dot on the paper Actuating Spring Mask Holder Cutting Platen Assembly Ribbon Dot Wire Printhead Drive Coil Iron Core GND 35 V...

Page 59: ...dumpers are attached to the left and right sides of the frame These pads are used for the absorbs the carriage hit shock for both side The control circuit monitors the CR motor s pulse when it is disordered the control circuit recognizes the carriage home position The encoder belt has equally pitched slits and is mounted under the timing belt A photo interrupter CR encoder surrounds the encoder be...

Page 60: ...e with equally pitched slits is attached coaxially to the motor axis When the motor rotates the PC sensor detects it and outputs the pulses Each pulse corresponds to detection of a 0 0025 mm resolution horizontal distance The system range is 0 35 to 0 84 mm P l a t e n A s s e m b l y R i b b o n M a s k H o l d e r P l a t e n R o l l e r G e a r P l a t e n G a p M o t o r P l a t e n G a p E n ...

Page 61: ...fer to Section 2 1 5 Ribbon Feed and Tractor Select Mechanisms The front and rear PE sensors are incorporated in the tractor sprocket When paper is loaded the paper pushes the leaf spring and blocks the photo interrupter When no paper is loaded the photo interrupter is not blocked The top PE sensor is attached to the upper paper guide and is used with the reflection plate on the paper bail assembl...

Page 62: ...et Front PF Motor Pinion Gear Tractor Select Gear PF Transmission Gear Figure 2 8 Front Tractor Assembly Operation Paper Tension Roller Paper Bail Tractor Select Gear PF Motor Pinion Tractor Sprocket Rear Rear PE Sensor PF Transmission Gear Figure 2 9 Rear Tractor Assembly Operation ...

Page 63: ...long the tractor shafts When the tractor release lever is released the sprocket can move smoothly side to side along the tractor shafts When the tractor release lever is engaged the sprocket can move along the tractor shafts but it cannot move smoothly because the tractor wire tension is valid In the Figure 2 10 point A shows the movement range of the left tractor sprocket when the tractor release...

Page 64: ...wise the motor rotates the ribbon feed mechanism when it rotates clockwise the motor rotates the tractor select mechanism Ribbon feed mechanism Figure 2 11 shows the ribbon feed mechanism The ribbon is fed in only one direction Counterclockwise rotation of the RF motor is transmitted to the ribbon feed gear through the ribbon feed select gear and ribbon feed transmission gear The ribbon feed drive...

Page 65: ...e rear tractor assembly When the tractor select lever is set to the right the tractor select gear engages the front tractor assembly The tractor Select sensor contacts the cam and closes when it reaches the convex portion The ribbon jam sensor is used to detect ribbon jam condition and to count ribbon life T r a c t o r D r i v e D e a r T r a c t o r S e l e c t G e a r H o l d e r T r a c t o r ...

Page 66: ...ached 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 Paper Bail ASSY Lever Plunger Iron Core Coil Tension Spring Figure 2 13 Plunger Mechanism ...

Page 67: ...PSB board 120 VAC 12 A 125 VAC C204 PSE board 220 240 VAC 6 3 A 250 VAC Table 2 2 Power Supply Board Output Specification 37 VDC Line 5V DC Line Item VP1 VP2 VP3 Rating Output Voltage 37 0 VDC 5 0 VDC Available Output Voltage Fluctuation 35 5 37 5 VDC 4 75 5 25 VDC Rating Output Current 1 5 A 2 0 A Available Output Current Fluctuation 0 0 4 5 A 1 0 0 5 0 A 1 0 0 2 0 A Over Current Protection Yes Y...

Page 68: ...PC101 Power Down Control 37V VP1 VP2 PC102 Constant Voltage Control Current Limit Monitoring Over Current Protection GP1 GP2 GP1 GP2 CL PD PC1 Over Voltage Protection 5V Regulator Smoothing Circuit PC201 Constant Voltage Control Current Limit Monitoring 37V VP3 GP3 DRERR Fan Driver GP3 FANDR 5V Regulator Circuit 5V GL GP GL Abnormal Current VP1 VP2 Monitoring GP VP3 Down Monitoring SD CN3 CN4 CN2 ...

Page 69: ...s supplied to the motors and plunger on the printer mechanism it also supplied to the 5VDC regulator circuit and it output 5V DC is supplied to the logic circuit on the main circuit Cooling fan The C204 PSB PSE board includes a cooling fan that is driven by the 37 VDC The fan lowers the temperature of the PSB PSE board circuit components and it also lowers the CR motor temperature because the moto...

Page 70: ...recover for APPROX 10 minutes by the DRERR signal of the C204 MAIN board after the power is turned off Therefore you must wait more than 10 minutes turn the power on again Table 2 4 PSB PSE Board Control Signals Signal In Out 1 Signal Logic Function Level Block 1 2 Block 2 3 PD Power Down In TTL High Low 37 VDC 0 VDC 37 VDC 5 VDC 37 VDC 5 VDC DRERR Head coil driver error In TTL High Low 0 VDC 37 V...

Page 71: ... Chip Select signal creation address decoding printhead driver control carriage driver control encoder pulse circuit control PG and HF phase signal creation interface control CR and PF motor driver abnormal sensor circuit monitoring reset signal creation control of the PSB PSE board control of the panel unit and reading the DIP switch settings on the C204 SUB board Signals such as DRERR driver err...

Page 72: ...rive Circuit IC2 RF Motor Drive Circuit AB DB Control Optional Type B I F Card P ROM IC5 RAM IC14 Level Converter IC9 Serial I F EEPROM IC11 24 57MHz CRU1 HPSENS HNSENS CPU TMP95C061 IC2 Printhead 2 2 Printhead 1 2 Cover Open Sensor DRV B Board DRV Board RF Motor PF Motor Interlock SW CR Motor CR Encoder PG Motor Plunger Drive Circuit Head Fan Drive Circuit Fan Drive Circuit Fan Head Fan Plunger H...

Page 73: ...r control CR motor driver control CR and PG motor pulse encoder I O input output Encoder pulse I O Phase signal creation for the motors I O port control Interface control Abnormal CR and PF motor detection RESET signal creation PROM IC5 Contains the program that runs the CPU RAM IC14 Holds the CPU working area and buffers input line and image buffers EEPROM IC11 Memorizes the printer unique parame...

Page 74: ...H and executes printing 4 The CPU reads the data from the input data buffer analyzes each byte to determine whether it is a character or a command and converts it to print data The print data consists of 1 byte character codes and 2 byte attributes Character data is stored as character codes and commands or character types are stored as attributes 5 The print data is stored in the line buffer in u...

Page 75: ...ors the 5 VDC line on the C204 MAIN board If it drops to 4 2 VDC or smaller the reset IC outputs a LOW signal to the CPU IC2 and E05B36 IC1 gate array Forced Reset The gate array outputs the RSTOUTX or ERRCRPFX signals to the XRESET of the CPU and also to the gate array itself INIT Signal Reset When the gate array receives the INIT signal from the host computer the signal is transferred to the INT...

Page 76: ...pen sensor uses a micro mechanical switch 11 Printhead temperature sensor uses a thermistor 12 Head fan temperature sensor uses a thermistor 13 Paper width sensor uses a photo reflector 14 CR motor isolation resistance sensor monitored by the analog port of the CPU 15 PSB PSE board power off sensor signal interface E05B36 IC1 CN4 ENCA ENCB CR Encoder 3 4 CN14 PGENCA PGENCB 35 34 148 149 ENCA ENCB ...

Page 77: ...Rear tractor HIGH open 5 Pull tractor sensor Detection form Micro mechanical switch Logical Pull tractor installed LOW closed Pull tractor not installed HIGH open 6 Carriage encoder sensor Detection form Photo reflector Transaction Rectangle wave A and B phases respectively 7 Platen Gap encoder sensor Detection form Photo interrupter Output form Rectangle wave 2 channel PG ability T 0 015 mm pulse...

Page 78: ...ce sensor monitored by port AN2 of the CPU 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 15 PSB PSE Board power off sensor signal interface When the 37 VDC line voltage drops the PSB PSE b...

Page 79: ...ch The ENCA pulse that the carriage encoder outputs is input to general purpose port CRENCA of the gate array and the ENCB pulse that the carriage encoder outputs is input to general purpose port CRENCB of the gate array The gate array counts these pulses using the internal counter and determines the amount and direction of motor rotation Table 2 6 CR Motor Specifications Specification Description...

Page 80: ...eek 0 2100 Logical seek 1 1050 Logical seek 2 333 Measurement seek Notes 1 Refer to Table 2 8 Notes 2 This division applies to all printing modes PI control oversees the constant speed Refer to page 2 27 for more information on PI control For increased throughput the division Super Draft to Draft HD allows printing during acceleration and deceleration Notes 3 This division increases throughput whe...

Page 81: ...g Figure 2 21 shows the acceleration control curve Speed 0 SP1 1 It causes the carriage to accelerate 2 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 SP1 SP2 1 When the carriage speed reaches SP1 the printer uses the acceleration driving mode based on the duty data and the rest of the time it us...

Page 82: ...the carriage speed reaches SP3 When the carriage speed reaches SP3 before duty data becomes Dutymin1 the next sequence SP3 Speed 0 takes effect SP3 Speed 0 1 When the carriage speed reaches SP3 Deceleration driving mode 3 takes effect This control method is the inverse continuity break method 2 During this time the control circuit measures time periods using the encoder signal When the rising edge...

Page 83: ... When the PF motor is held the phase driving method is 1 phase excitation The CPU selects the most suitable driving mode from the modes below according to conditions such as the paper feed length and the pull tractor condition Micro feed adjust mode 20 432 inches Middle speed mode 20 432 inches and 60 432 inches or with optional pull tractor Normal speed mode 60 432 inches Each phase switching FET...

Page 84: ...quipped with a hold circuit for changing the motor phase The RF motor rotates when the carriage moves Table 2 10 RF Motor Specifications Specification Description Form 4 phase 48 pole PM pulse motor Supply Voltage 37 VDC applied to the drive circuit Internal Coil Resistance 150 ohms 10 per phase at 25 o C Frequency 720 pps Current Consumption Driving 0 10 A average Driving Method Constant voltage ...

Page 85: ...and the phase B output pulse from the platen gap encoder ENCB is input to port ENCB of E05B36 The E05B36 counts these pulses using the internal counter and determines the amount and direction of motor rotation Table 2 11 PG Motor Specifications Specification Description Form 4 phase 48 pole PM pulse motor Supply Voltage 37 VDC applied to the drive circuit Internal Coil Resistance 250 18 ohms per p...

Page 86: ...he plunger coil When switching transistor Q30 is turned off Q31 is turned off and the hold voltage 5 V flows into the plunger coil via Q32 using the port PLN of the E05B36 Table 2 12 Plunger Specifications Specification Description Form DC solenoid Supply Voltage 37 VDC applied to the drive circuit Internal Coil Resistance 9 ohms 5 at 25 o C Current Consumption Driving 3 7 A MAX Holding 0 4 A Tabl...

Page 87: ...by the VP1 GP1 line CN1 on the C204 DRV B board The CPU monitors the printhead temperature and head fan HF temperature When the temperature rises abnormally printing stops at once until the temperature cools The CPU also monitors the printhead driver status P channel and N channel FET respectively If the printhead driver FET shorts CPU IC2 port PDRERR P channel NDRERR N channel detects HIGH level ...

Page 88: ...al 3 When the printhead temperature exceeds equal or more than 120 o C the printer stops printing until the temperature goes down to 100 o C or less 4 When the printhead temperature returns less than 100 o C the printer performs normal printing again HF temperature feedback operation The printer supports the printhead fan HF temperature detection sequence which consists of the following steps 1 Wh...

Page 89: ...Removal 3 28 3 2 6 Printer Mechanism Removal 3 29 3 2 6 1 Fan Removal 3 31 3 2 6 2 Ribbon Feed Change Lever Unit Removal 3 32 3 2 6 3 Tractor Select Lever Upper and Lower Assembly Disassembly 3 34 3 2 6 4 Ribbon Jam Sensor Removal 3 35 3 2 6 5 Connector Junction Board Assembly and FPC Board Assembly Removal 3 36 3 2 6 6 PG Sensor and PG Motor Removal 3 37 3 2 6 7 Plunger and Paper Bail Assembly Re...

Page 90: ......

Page 91: ... to protect your hands when handling the printer Handle frame edges with care since this printer has a considerable amount of metal materials To prevent damage to ICs from static electricity do not touch the ICs on the circuit board or the terminals of peripheral electrical components with your hands Use only the recommended tools to ensure safe and efficient maintenance work Inappropriate tools m...

Page 92: ...ing packing materials as shown in Figure 3 1 Transport locking bracket Carriage guide shaft support bar Printhead protector Foam packing for paper bail Figure 3 1 Packing Material Attaching After attaching the packing materials pack the printer in its container as shown in Figure 3 2 Figure 3 2 DFX 8500 Packing ...

Page 93: ...ver 7 mm 0 28 inches across o A B741700200 E ring holder No 3 o A B740800500 E ring holder No 6 o A B740800800 Round nose pliers o A B740400100 Diagonal wire cutters o A B740500100 Tweezers o A B741000100 Electric soldering iron o A B740200100 Tension gauge 7000 g o A B777200301 Tension gauge 200 g o A B765114601 Lift handles E656 E A B765111001 Dial gauges F610 E A B101946600 Figure 3 3 Dial gaug...

Page 94: ...DFX 8500 Rev B 3 4 P E A C O C K P E A C O C K Figure 3 3 Dial Gauges Figure 3 4 Dial Gauge Base Figure 3 5 Thickness Gauge Figure 3 6 Dial Gauge Master ...

Page 95: ...FS Cross Flat head S tight screw CP SP Cross Pan head with Spring lock washer Plane washer CP PS Cross Pan head with Plane washer Spring lock washer CPB Cross Pan head B tight screw CPB O Cross Pan head B tight screw with Outside toothed lock washer CPS Cross Pan head S tight screw CPS P Cross Pan head S tight screw with Plain washer CPS SP Cross Pan head S tight screw with Spring lock washer Plai...

Page 96: ...on are correct Refer to CHAPTER 6 Checked Not necessary Operation At the operate switch turns on does the printer perform power on initialization correctly Checked Not necessary Does the printer work exactly with using the attached utility program Checked Not necessary ROM Grade up What it the ROM version up dated Checked Not necessary Cleaning Is any dust removed from the inside of the printer Ch...

Page 97: ...s how to disassemble the printer See the APPENDIX for an exploded diagram of the printer Use this diagram for simple disassembly procedures not described here To assemble the printer follow the disassembly instructions in this chapter in reverse Any extra information you need to assemble printer components is provided in notes labeled ASSEMBLING POINT Adjustments required before assembly are descr...

Page 98: ...u follow the steps below Remove the ROM carefully to avoid damaging the board Before you install a new ROM check the INDEX mark on the socket to be sure the ROM is oriented correctly Insert the ROM carefully to avoid damaging the ROM pins and the board When transporting the printer a long distance pack it using the original packing material Step 1 Tilt back the printer and lay it on its back Hold ...

Page 99: ...for printhead exchange on the DFX 8500 When you receive the kit check that all of the following are included P r i n t h e a d U n i t O i l O 2 H e a d C a b l e P r o t e c t i o n S h e e t R i b b o n M a s k A s s e m b l y Figure 3 8 Printhead Kit The description hereafter is the same as the above instruction Manual so you may refer to this section or to the Instruction Manual ...

Page 100: ...m the FPC board on the bottom plate Note 1 When disconnect the cables hold the cable close to the connector Note 2 When disconnect the cable hold the connector to prevent it from being pulled off the board Note 3 When disconnect the cable pull it slowly and horizontally to the right as viewed from the front side C B S M 3 X 8 F P C C o v e r P r i n t h e a d C a b l e s F P C B o a r d Figure 3 9...

Page 101: ...ribbon mask Step 8 Remove the two shafts securing the ribbon mask to the carriage using a hexagon head screw wrench then remove the ribbon mask P W S e n s o r C o n n e c t o r R i b b o n M a s k S h a f t s Figure 3 13 Ribbon Mask Removal Step 9 Install the new printhead ribbon mask and cable protection sheet by following Steps1 to 9 in the reverse order Step 10 Replace the ribbon mask with a n...

Page 102: ...tep 12 Install the cable cover and the FPC cover Step 13 Wipe off any stains from the carriage guide shaft lubricate both ends of the carriage guide shaft with the included oil 0 2 and spread the oil over the shaft by moving the carriage manually Figure 3 15 Lubricating to Carriage Guide Shafts z When you install the printhead perform the platen gap motor value adjustment ALPHA value write operati...

Page 103: ...d the top cover while the other person removes the screws If the top cover is not supported while the screws are removed the weight of the top cover may damage the rear hinges Step 1 Open the top cover Step 2 While someone supports the top cover remove the four screws two on the right and two on the left securing the top cover to the hinges and remove the cover T o p C o v e r Figure 3 16 Top Cove...

Page 104: ... R i g h t a n d L e f t C o v e r s Figure 3 17 Left and Right Side Covers Removal ASSEMBLING POINT z When you attach the right side cover connect the cable from connector CN1 on the C204 power supply board unit and the cable from the AC inlet to the main switch on the right side cover as shown below M a i n S w i t c h R e v e r s e s i d e o f t h e s i d e c o v e r R A C I n l e t S e t C 2 0...

Page 105: ...nter s AC power specifications C a r r i a g e M o t o r C N 1 C 2 0 4 P S B P S E B o a r d G r o u n d i n g H a r n e s s R i g h t S i d e F u s e Figure 3 19 Fuse Removal Step 4 Remove the three CBB M4x16 screws securing the left side of the front cover to the lower cover Then remove the front cover along the left hinge C B B M 4 X 1 6 F r o n t C o v e r Figure 3 20 Front Cover Removal ...

Page 106: ...r 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 C B B M 4 X 1 6 F r o n t P a n e l U n i t Figure 3 21 Front Panel Removal ...

Page 107: ...emoval 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 M3x10 screws from the upper case Then remove the upper case C B B M 4 X 1 6 C B B M 3 X 1 0 U p p e r C a s e Figure 3 22 Upper Case Removal ...

Page 108: ... other printer components Spread a thick soft cloth under the printer before you follow the steps below When you attach the bottom panel make sure the parallel interface cable latch is not caught between the lower case and bottom panel Step 1 Remove the left and right side covers Refer to Section 3 2 3 2 Step 2 On the right side of the printer mechanism remove the CBS O screw securing the green an...

Page 109: ...n e c t o r C N 9 7 p i n O p t i o n C u t t e r F l a t C a b l e C o n n e c t o r 5 0 p i n P r i n t h e a d C N 3 2 p i n C o v e r O p e n S e n s o r C N 5 1 4 p i n P a n e l U n i t 1 2 3 6 5 4 Figure 3 24 Connector and Earth Cable Removal left side Step 5 Open the rear cover Remove the four CBB M3x12 screws and two CB M3x12 screws securing the interface cover and remove the cover Step 6...

Page 110: ...r to protect it from scratches tilt back the printer and lay it on its back Step 8 Remove the eight CBB M4x16 screws securing the bottom panel assembly and slowly remove the bottom panel unit assembly C B B M 4 X 1 6 Figure 3 26 Bottom Panel Assembly Removal ...

Page 111: ...N5 and remove the four CCN M3x30 screws securing it and remove the fan Step 3 Disconnect connectors CN2 CN3 and CN4 Step 4 Remove the six CBB M3x12 screws and CPN O M3x8 screw securing the C204 power supply board unit and remove the board C B B M 3 X 1 2 C N 3 C N 5 C 2 0 4 P S B P S E B o a r d C N 4 C 2 0 4 M A I N B o a r d C N 1 A C I n l e t S e t C C N M 3 X 3 0 C P N O M 3 X 8 C N 2 Figure ...

Page 112: ...sconnect connectors CN15 and CN16 on the C204 MAIN board Step 3 Remove the CBB M3x8 screw and the CBB M3x12 screw securing the C204 SUB board assembly and remove the board C B B M 3 X 1 2 C B B M 3 X 8 C N 1 6 C N 1 5 C N 1 5 C N 1 6 C 2 0 4 M A I N B o a r d C 2 0 4 S U B B o a r d U n i t Figure 3 28 C204 SUB Board Unit Removal ...

Page 113: ...V B board C 2 0 4 D R V B o a r d C N 3 C N 1 4 C 2 0 4 D R V B B o a r d C N 2 C N 1 C a b l e f r o m C 2 0 4 M A I N b o a r d C 2 0 4 M A I N b o a r d Figure 3 29 C204 DRV DRV B Boards Removal Step 4 Remove the eight CBS M3x8 screws securing the C204 DRV B board and C204 DRV board via shielding plate respectively S h i e l d i n g P l a t e S h i e l d i n g P l a t e C 2 0 4 D R V B o a r d ...

Page 114: ...rd units Refer to Section 3 2 4 4 Step 4 Disconnect connectors CN6 CN7 CN8 and CN10 H a r n e s s C N 3 t o C N 6 7 p i n t o C N 7 6 p i n C N 2 C 2 0 4 M A I N B o a r d Figure 3 31 C204 MAIN Board Removal 1 4 C N 4 H a r n e s s C N 1 0 8 p i n C 2 0 4 M A I N B o a r d t o C N 1 0 8 p i n t o C N 4 Figure 3 32 C204 MAIN Board Removal 2 4 H a r n e s s C N 8 8 p i n C 2 0 4 M A I N B o a r d Fi...

Page 115: ... 3 X 8 X 2 C 2 0 4 M A I N B o a r d U n i t H o o k s f o r C 2 0 4 M A I N B o a r d I n s t a l l a t i o n Figure 3 34 C204 MAIN Board Removal 4 4 When you install the C204 MAIN board assembly perform the following adjustments z Platen gap motor value platen gap adjustment described in Section 4 1 7 z Bidirectional printing adjustment described in Section 4 1 8 ADJUSTMENT REQUIRED ...

Page 116: ...6 screw securing the grounding plate to the bottom panel assembly and remove the grounding plate C B B M 3 X 8 B o t t o m P a n e l A s s e m b l y G r o u n d i n g P l a t e C B O M 4 X 6 A C I n l e t S e t Figure 3 35 Grounding Plate Removal Step 4 Remove the two CFS M3x10 screws securing the AC inlet to the grounding plate and remove the AC inlet A C I n l e t S e t G r o u n d i n g P l a t...

Page 117: ... Refer to Section 3 2 3 3 Step 2 Disconnect connectors CN1 and CN2 on the C204 PNL board Step 3 Remove the CBB M4x10 screw securing the C204 PNL board to the front panel unit and remove the board C B B M 4 X 1 0 F r o n t P a n e l C 2 0 4 P N L B o a r d C N 2 C N 1 Figure 3 37 C204 PNL Board Removal ...

Page 118: ...a r d W h i t e 2 p i n R e d 3 p i n C o v e r O p e n S e n s o r C o n n e c t o r Figure 3 38 Interlock Switch Assembly Removal Step 3 Remove the CBB M4x10 screw securing the interlock switch assembly to the lower case and remove it Step 4 Remove the CBB M3x10 screw securing the cover open sensor to the upper case and remove it I n t e r l o c k S W A s s e m b l y C B B M 4 X 1 0 L o w e r C ...

Page 119: ...e the interlock switch assembly Refer to Section 3 2 5 Step 3 Remove the two CBS O M4x8 screws securing the green and yellow earth cables to the grounding plate Then disconnect connectors 1 through 4 as shown in Figure 3 41 Ensure all connectors 1 through 7 indicated in the figure are disconnected Step 4 Remove the CBS O M4x8 screw securing the earth cable as shown in Figure 3 42 E a r t h C a b l...

Page 120: ...remove it from the lower case L i f t H a n d l e E 6 5 6 P r i n t e r M e c h a n i s m L o w e r H o u s i n g A s s e m b l y Figure 3 44 Printer Mechanism Removal 2 2 ASSEMBLING POINT When you install the printer mechanism route the cables as shown in Figures 3 41 and 3 42 Make sure the cables do not get caught between the printer mechanism and lower case ADJUSTMENT REQUIRED When you install ...

Page 121: ...r to Section 3 2 3 2 Step 3 Disconnect the connector for the fan from the relay connector Step 4 Remove the CP O 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 Then remove the fan along with the fan duct C P O 4 x 5 C C 3 x 3 0 L e f t F r a m e Figure 3 45 Fan Removal ...

Page 122: ... t R i b b o n F e e d G e a r C o v e r R i b b o n F e e d G e a r R i b b o n F e e d M o t o r R i b b o n F e e d M o t o r F r a m e R i b b o n F e e d C h a n g e L e v e r U n i t Figure 3 46 Ribbon Feed Change Lever Unit Removal 1 2 Step 5 Remove the two CBS M3x6 screw securing the ribbon feed change lever unit to the left side frame then remove the ribbon feed change lever unit C o n n ...

Page 123: ... e l e c t S e n s o r T o R F M o t o r C o n n e c t o r J u n c t i o n B o a r d Figure 3 48 Removing Connectors ASSEMBLING POINT When you install the ribbon feed change lever unit join the tip of the tractor select lever and the tractor select gear holder correctly Refer to Figure 2 12 ...

Page 124: ...and securing the ribbon feed motor and tractor select sensor cables to the ribbon feed motor frame E r i n g 3 W a s h e r L e a f S p r i n g T r a c t o r S e l e c t T r a n s m i s s i o n G e a r E r i n g 3 T r a c t o r S e l e c t T r a n s m i s s i o n G e a r R i b b o n F e e d M o t o r F r a m e R i b b o n F e e d M o t o r C P S P 1 M 3 X 6 T r a c t o r S e l e c t L e v e r l o w...

Page 125: ...tion 3 2 3 2 Step 2 Disconnect the connector for the sensor from the connector junction board Step 3 Remove the CP S P1 M3x6 screw securing the sensor to the bracket and remove the sensor C P S P 1 M 3 x 6 F r o n t R e a r T r a c t o r S e l e c t L e v e r A s s e m b l y Figure 3 51 Ribbon Jam Sensor Removal ...

Page 126: ...ver assembly Refer to Section 3 2 6 2 Step 4 Disconnect the connector for the CR sensor encoder from the FPC board assembly Step 5 Remove the 2 CBS M3x8 screws securing the FPC cover and remove the cover Refer to Figure 3 10 Then remove the CPS P 1 M3x6 screw securing the FPC board assembly to the printer mechanism and remove the FPC board assembly C o n n e c t o r J u n c t i o n B o a r d F P C...

Page 127: ... P1 M3x6 screws securing the PG motor and remove the motor E n c o d e r P l a t e P G M o t o r P i n i o n G e a r P l a t e n G a p S e n s o r C P S P M 3 X 6 P G M o t o r C P S P 1 M 3 x 6 Figure 3 53 PG Sensor and PG Motor Removal ASSEMBLING POINT When you install the PG motor make sure the backlash between the PG motor and PG motor transmission gear is between 0 05 and 0 15 mm almost no ba...

Page 128: ...er connector from the connector junction board assembly and remove the plunger cable from the connector junction board assembly Step 2 Remove the two CP S P1 M3x6 screws securing the plunger to the left side frame and remove the plunger Step 3 Remove the iron core of the plunger from the paper bail shaft P l u n g e r I r o n C o r e C P S P 1 M 3 X 6 2 p i n B l a c k Figure 3 54 Plunger Removal ...

Page 129: ... duct Then remove the CR fan duct along with the CR fan Refer to Section 3 2 6 1 Step 7 Remove the right tension roller lever spring Step 8 Remove 2 E rings to release the release tension lever at the inner side of the left frame Step 9 Remove the E ring 6 at the right end of the paper bail shaft Then remove the paper bail lever leaf spring and shaft holder Step 10 Slide the shaft left to release ...

Page 130: ...a r d T o p P E S e n s o r C o n n e c t o r L e f t S i d e F r a m e Figure 3 57 Top PE Sensor Connector Removal Step 3 Remove the two CBS M4x6 screws securing the upper paper guide to both frames and remove the paper guide Step 4 Remove the two CPS SP M3x8 screws securing the top PE sensor to the upper paper guide and remove the sensor T o p P E S e n s o r U p p e r P a p e r G u i d e C B S ...

Page 131: ...e the paper bail assembly Refer to Section 3 2 6 7 Step 3 While pushing the tension pulley to the front remove the CR timing belt Step 4 Remove the upper paper guide Refer to Section 3 2 6 8 Step 5 Using tweezers unlock the locking tab of the tension roller gear at the left end of the tension roller shaft and remove the gear Step 6 Remove the E ring 6 on the left end of the tension roller shaft an...

Page 132: ...f spring and the washer Step 9 Remove the tension roller shaft by taking it out from the right frame T e n s i o n R o l l e r S h a f t A s s e m b l y T e n s i o n R o l l e r S h a f t H o l d e r L e a f S p r i n g E r i n g C a r r i a g e M o t o r W a s h e r Figure 3 60 Shaft Holder Removal T e n s i o n R o l l e r S h a f t A s s e m b l y F r o n t L e f t Figure 3 61 Tension Roller S...

Page 133: ...e a r Figure 3 62 Platen Removal P l a t e n P l a t e n H o l d e r P o s i t i o n n i n g T a b 0 0 3 m m T h i c k n e s s G a u g e F r o n t R e a r N o t h r o u g h Figure 3 63 Platen Positioning ASSEMBLING POINT When you attach the 3 parts of the lower paper guide to the platen start with the one at the right end and work toward the left When you mount the platen to the platen holders spa...

Page 134: ...e platen L o w e r P a p e r G u i d e C P N S P M 4 X 8 P l a t e n R i g h t L e f t Figure 3 64 Lower Paper Guide Left Part Removal Step 4 Unhook the paper jam sensor magnetic transistor cover to remove it Step 5 Remove the paper jam sensor P a p e r J a m S e n s o r P a p e r J a m S e n s o r C o v e r L o w e r P a p e r G u i d e L e f t Figure 3 65 Paper Jam Sensor Removal ASSEMBLING POIN...

Page 135: ...pull tractor sensor connector from the connector junction board 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 C P S M 2 X 1 4 W a s h e r P u l l T r a c t o r S e n s o r P l a t e n H o l d e r R i g h t H e x a g o n N u t Figure 3 66 Pull Tractor Sensor removal ...

Page 136: ... 1 Disconnect the connector for the PW sensor Step 2 Remove the CP S P1 M2 5x6 screw securing the PW sensor to the ribbon mask holder C P S P 1 M 2 5 x 6 P a p e r W i d t h S e n s o r P a p e r W i d t h S e n s o r C o n n e c t o r Figure 3 67 PW Sensor Removal ...

Page 137: ...carriage guide shaft C a r r i a g e G u i d e S h a f t R e a r E r i n g C a r r i a g e G u i d e S h a f t G e a r Figure 3 68 Carriage Guide Shaft Gear Removal Step 3 Disconnect the white 2 pin PG home sensor connector from the connector junction board assembly Step 4 Detach the hook securing the PG home sensor and remove the sensor P G H o m e S e n s o r P l a t e n G a p P G M o t o r Figu...

Page 138: ...G adjustment transmission gear as shown in the figure below then rotate the CR guide shaft gear 10 mm in CCW F r a m e L e f t C R G u i d e S h a f t G e a r P G T r a n s m i s s i o n G e a r F l a t P a r t o f C R G u i d e S h a f t R e a r A d v a n c e 1 0 m m S t o p p e r Figure 3 70 CR Guide Shaft Gear Phase Alignment ...

Page 139: ...tor 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 C P S P 1 M 4 X 8 P a p e r F e e d M o t o r Figure 3 71 PG Home Sensor Removal ...

Page 140: ...ect lever assembly Refer to Section 3 2 6 2 Step 2 Remove the connector junction board assembly Refer to Section 3 2 6 5 Step 3 Remove the PG motor Refer to Section 3 2 6 6 Step 4 Remove the series of gears in the order indicated by the numbers in Figure 3 72 Figure 3 72 Left Side Frame Gear Removal ...

Page 141: ... Remove the E ring 6 securing the rear shaft of the front tractor assembly to the left side frame and remove the shaft holder Step 8 Move the assembly to left to release the right end of the shaft then release the left side of the shaft from the left side frame and remove the assembly C B S M 4 X 8 T r a c t o r W i r e H o l d e r L C a r r i a g e M o t o r F l a n g e N u t T r a c t o r W i r ...

Page 142: ...e the holder Step 6 Remove the rear tractor gear Step 7 Remove the E ring and release the shaft holder from the left side frame Step 8 To remove the rear tractor assembly first move it to the left to release the right end of the shaft from the right side frame Then release the left end of the shaft and remove the assembly S h a f t H o l d e r E r i n g 6 T r a c t o r A s s e m b l y R e a r W a ...

Page 143: ...9 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 F a n F i x i n g S c r e w s R i g h t F r a m e C R M o t o r F a n Figure 3 76 CR Motor Fan Removal ...

Page 144: ... 3 Remove the three CP S M4x10 screws securing the CR motor to the right side frame and remove the motor C P S M 4 X 1 0 C R M o t o r Figure 3 77 CR Motor Removal ADJUSTMENT REQUIRED When you install the CR motor perform the carriage timing belt tension adjustment as described in Section 4 1 2 When you install the printhead perform the platen gap motor value platen gap adjustment as described in ...

Page 145: ... junction board Step 3 Remove the two CP S P1 M2 6 x 5 screws securing the CR sensor to the carriage and remove the sensor C a r r i a g e 4 p i n C o n n e c t o r C a r r i a g e E n c o d e r S e n s o r C a r r i a g e C o n n e c t o r J u n c t i o n B o a r d Figure 3 78 CR Sensor Removal 1 2 C a r r i a g e C a r r i a g e E n c o d e r S e n s o r C P S P 1 M 2 6 X 5 Figure 3 79 CR Sensor...

Page 146: ... the belt pulley from the belt pulley holder S i d e F r a m e L B e l t P u l l e y B e l t P u l l e y H o l d e r Figure 3 80 Belt Pulley Removal Step 3 Unhook the spring securing the encoder belt to the right side frame Refer to Figure 2 5 Step 4 Loosen the two flange nuts securing the front carriage guide shaft to the left and right side frames F l a n g e N u t F l a n g e N u t F r o n t C ...

Page 147: ...2 Rear Carriage Guide Shaft Removal Step 8 Remove the PG motor Refer to Section 3 2 6 6 Step 9 Remove the carriage damper solid rubber from the inner side of the right side frame and remove the three CBS M4x8 screws securing the carriage motor holder to the right side frame Step 10 Remove the guide shaft holding spring and the E ring then remove the right guide shaft holder lever Step 11 Remove th...

Page 148: ...D When you assemble the carriage mechanism perform the following adjustments Carriage timing belt tension adjustment described in Section 4 1 2 Carriage guide shaft parallelism adjustment described in Section 4 1 5 and Section 4 1 6 Platen gap motor value platen gap adjustment described in Section 4 1 7 Bidirectional printing adjustment described in Section 4 1 8 ...

Page 149: ...in the Appendix remove the paper support assembly ADJUSTMENT REQUIRED When you install the paper support assembly perform the following adjustments Carriage timing belt tension adjustment described in Section 4 1 2 Carriage guide shaft parallelism adjustment described in Section 4 1 5 and Section 4 1 6 Platen gap motor value platen gap adjustment described in Section 4 1 7 Bidirectional printing a...

Page 150: ... the exploded diagram in the Appendix remove the PF driver roller ADJUSTMENT REQUIRED When you install the PF drive roller perform the following adjustments Carriage timing belt tension adjustment described in Section 4 1 2 Carriage guide shaft parallelism adjustment described in Section 4 1 5 and Section 4 1 6 Platen gap motor value platen gap adjustment described in Section 4 1 7 Bidirectional p...

Page 151: ... Tension Adjustment 4 2 4 1 3 Tractor Wire Spring Tension Adjustment 4 3 4 1 4 Pull Tractor Sensor Position Adjustment 4 4 4 1 5 Carriage Guide Shaft Parallelism Adjustment 4 5 4 1 6 Platen Angle Adjustment 4 9 4 1 7 Platen Gap Motor Value Adjustment 4 12 4 1 8 Measurement Seeking and Bi directional Printing Adjustment 4 15 ...

Page 152: ......

Page 153: ...y aligned or the pinion gear and cog are too tight printer operation is noisy or the character density is incorrect If the PG motor backlash is too tight PG motor doesn t rotate smoothly and the panel indicates E3 Step 1 Loosen the two screws securing the PG motor to the left side frame Refer to Section 3 2 6 4 Step 2 Make sure the PG motor pinion gear is properly aligned with the PG transmission ...

Page 154: ...oosen the three tension adjustment screws on the CR motor Confirm that the carriage timing belt is attached properly and that no load is applied to it Step 2 Insert the tension gauge hook through the hole in the tension lever Step 3 Pull the tension gauge horizontally to apply a 7 kg 15 4 lb force Step 4 Move the belt left and right while pulling the tension gauge and move the motor pulley slightl...

Page 155: ...he CBS M4 X 8 screws securing the wire holding plate L Step 4 Pull the tractor wire left to make correct tension to the tractor wire wire holding plate R and the tip of the gold seal are 5 mm 0 2 inches apart Step 5 Fix the CBS M4 X 8 screws on the wire holding plate L Step 6 As the same manner adjust the tractor spring tension for the rear tractor T r a c t o r W i r e T e n s i o n S p r i n g T...

Page 156: ...djustment Figure 4 4 illustrates the pull tractor sensor position adjustment When you assemble the pull tractor sensor or rear paper guide check the following items Verify that the pull tractor sensor lever is touching the rear paper guide frame but the sensor is off Make sure the distance between the sensor lever and sensor switch is approximately 2 mm 08 inches 0 8 L e f t S i d e F r a m e S e ...

Page 157: ...s than 0 015 mm Since this value is extremely small you must use the two dial gauges dial gauge base and dial gauge master supplied by EPSON Do not adjust the parallelism using any other method Dial gauges x 2 F610 Part No B1019466 Dial gauge base F611 Part No B1019467 Dial gauge master F612 Part No B1019468 Before performing the carriage guide shaft parallelism adjustment you must assemble the tw...

Page 158: ...nd to the another gauge measure and tighten the hexagonal screw Step 5 Set the black marker to the 0 position 2 Attach the gauge needle to the master surface then correspond to the another gauge measure 3 Tighten the hexagonal screw Figure 4 7 Dial Gauge set Up 2 Figure 4 8 Black Marker to 0 Position Setting ...

Page 159: ...1 Using the carriage guide shaft gear adjust the gauge mounting position so that the tips of the gauges portions A and B in the Figure 4 10 are securely attached to the platen C P P S M 3 X 6 T i m i n g B e l t H o l d e r C a r r i a g e C a r r i a g e G u i d e S h a f t R e a r Figure 4 9 Carriage Plate Removal 0 1 0 1 0 2 0 2 0 3 0 3 0 0 1 0 1 0 2 0 2 0 3 0 3 0 P l a t e n D i a l G a u g e ...

Page 160: ... shown in Figure 4 8 When the parallelism adjust lever is moved in the direction of the black arrow the distance between the right side of the platen and print head nose narrows a little bit Step 14 Repeat steps 11 and 12 until the distance between the distance measured at the two positions is less than 0 015 mm The F610 dial gauge matches the 15 notches Step 15 When the distance is within the spe...

Page 161: ...aft to the platen measured at the two positions shown in Figure 4 7 is less than 0 015 mm Since this value is extremely small you must use the two dial gauges dial gauge base and dial gauge master supplied by EPSON Do not adjust the parallelism using any other method Dial gauge F610 Part No B1019466 Dial gauge base F611 Part No B1019467 Dial gauge master F612 Part No B1019468 Step 1 Perform the ca...

Page 162: ...age with the dial gauge toward the right side See Figure 4 11 C a r r i a g e g u i d e S h a f t G e a r S i d e F r a m e L C a r r i a g e G u i d e S h a f t P l a t e n A t t a c h b o t h n e e d l e s R e f e r t o F i g u r e 4 1 0 a Figure 4 14 Attaching Two Needles to Platen Surface 0 10 10 20 20 30 30 0 10 10 20 20 30 30 Platen 0 10 10 20 20 30 30 0 10 10 20 20 30 30 0 10 10 20 20 30 30...

Page 163: ...nd manually Step 7 Tighten two hexagonal screws securing the platen stay to both side frames After perform the adjustment confirm the value of platen parallelism again When this value is out of order readjust the platen parallelism and the platen angle adjustment until the value to be correct P l a t e n B i t A B i t B A n g l e A d j u s t m e n t M e t h o d U p D o w n Figure 4 16 Measuring An...

Page 164: ... because it determines the platen gap so be sure to use the exclusive thickness gauge set and tension gauge Thickness gauge 0 43 mm Thickness gauge 0 80 mm Tension gauge 200 g F545 EPSON Part No B765114601 Do not turn the printer off during adjustment When adjusting the platen gap to narrower or wider using the Micro Feed and Micro Feed v switches be sure to adjust the gap by 1 step at a time Afte...

Page 165: ... Step 10 Set the BETA3 value when the tension gauge indicates the 150 135 165 gf the tension gauge can move to right in a degree Step 11 After complete BETA3 adjustment press Pause SW to enter next step Step 12 Close the print head nose to the platen by pressing the below switch Press the Micro Feed v switch to increment value by 1 Press the Micro Feed switch to decrement the value by 1 The panel ...

Page 166: ...alue Default Value 1 BETA 3 0 43 mm with 150gf pull BETA 2 0 00 mm 367 419 408 BETA 3 0 43 mm 405 437 435 BETA 4 0 80 mm 418 475 461 1 When EEPROM is reset P l a t e n T e n s i o n G a u g e T h i c k n e s s G a u g e B E T A 3 0 4 3 m m 1 3 5 1 6 5 g f Figure 4 19 Thickness Gauge Setting Method ...

Page 167: ...t 4 1 6 Platen Angle Adjustment 4 1 7 Platen Gap Motor Value Adjustment The parameters to be written to the EEPROM on the C204 Main board in this adjustment are as follows 1 Measurement seeking 2 Print head flight time adjustment value 3 Bi directional printing alignment value for each speed mode Super Draft Draft and NLQ If the DIP SW 3 5 is set to the IBM mode On it can not perform the Bi D adju...

Page 168: ... e d v S W s T h e p r i n t e r p e r f o r m s c a r r i a g e m e a s u r e m e n t s e e k i n g a u t o m a t i c a l l y I t g o e s t o O N L I N E s t a t u s a f t e r t h i s o p e r a t i o n T u r n t h e p r i n t e r p o w e r o f f M o u n t t h e r i b b o n c a r t r i d g e Figure 4 20 Carriage Measurement Seeking ...

Page 169: ... i g h t t i m e s e t t i n g v a l u e R e f e r t o F i g u r e 4 2 2 D o e s t h e o d d 1 s t a n d 3 r d a n d e v e n 2 n d a n d 4 t h l i n e s v e r t i c a l a l i g n m e n t i s O K C h a n g e t h e f l i g h t t i m e a d j u s t m e n t v a l u e D e c l e m e n t 1 0 s t e p s T o p o f F o r m S W o n c e D e c l e m e n t 1 s t e p P u s h M i c r o F e e d S W o n c e I n c l e...

Page 170: ...ibbon Bi d adjustment PG adjustment positive 300 negative 400 Pause 10 Top of Form 20 Tear Off 30 Copy 40 Pitch 50 60 70 Font 80 90 7 Segment 3 0 to 9 1 off On 2 Indicates 2 nd column 3 Indicates 1 st column 4 0 C O L 4 0 C O L 5 6 C O L F l i g h t T i m e X X X Figure 4 22 Test Print Pattern ...

Page 171: ...e c l e m e n t 1 0 s t e p s T o p o f F o r m S W o n c e D e c l e m e n t 1 s t e p P u s h M i c r o F e e d S W o n c e I n c l e m e n t 1 0 s t e p s T e a r O f f S W o n c e I n c l e m e n t 1 s t e p P u s h M i c r o F e e d v S W o n c e P a n e l d i p l a y s t h e c u r r e n t B i D a d j u s t m e n t v a l u e A d j u s t m e n t R e t u r n A d j u s t m e n t D r a f t P r i ...

Page 172: ......

Page 173: ...CHAPTER 5 TROUBLESHOOTING 5 1 PROBLEM ISOLATION 5 1 5 2 SELF DIAGNOSTIC FUNCTION 5 2 5 3 TROUBLESHOOTING 5 3 ...

Page 174: ......

Page 175: ...sn t close exactly The parallelism adjustment is incorrect PG adjustment values are incorrect Auto power off after 12 seconds Carriage load measurement error 6 PW sensor is defective The CR motor is defective The CR encoder sensor is defective Auto power off after 12 seconds Head fan error 7 The head fan driver IC is shorted The head fan of the print head is defective Head power off immediately He...

Page 176: ... side cover 2 make the short circuit connectors for the interlock switch and cover open sensor connectors 3 insert the short circuit connectors for the interlock switch and cover open sensor connectors C o v e r O p e n S e n s o r I n t e r l o c k S W C N 3 C o n n e c t o r J u n c t i o n B o a r d C 2 0 4 M A I N B o a r d W h i t e 2 p i n R e d 3 p i n Figure 5 1 Interlock Switch Assembly L...

Page 177: ...tance Part Coil Resistance CR motor 1 66 ohms 10 PF motor 2 80 ohms 10 at 25 o C RF motor 150 ohms 10 at 25 o C PG motor 250 ohms 18 ohms at 25 o C Head fan 61 ohms 4 3 ohms at 25 o C Plunger 9 ohms 5 at 25 o C Printhead 2 93 ohms 0 2 ohms at 25 o C Head Cable Board Head Cable Protection Sheet Head FPC Double sided Adhesive Tape Shield Cable 1 2 3 4 5 C B A Figure 5 3 Disconnect Printhead FPC ...

Page 178: ...Head coil P S side Head thermistor MA Fan motor phase A MB Fan motor phase B MC Fan motor common MT Fan motor thermistor PWD Paper width sensor 5V 5 VDC ENCA Encoder A GND GND HT Head thermistor P S Power supply 37 VDC ENCB Encoder B Figure 5 4 Printhead Coil Resistance ...

Page 179: ... power supply board Is the output voltage normal Yes No Yes Is the fault corrected See Section 5 3 to repair the printer mechanism Check all motors solenoid printhead and drivers using a multimeter Are they within normal range Yes No Replace bad motor solenoid or printhead If driver also is bad replace at the same time END Yes Is the fault corrected Retest Is the problem fixed No END Yes No Does t...

Page 180: ...sm Perform repair necessary No Yes Is the fault corrected END Smooth END Check the CR motor and CR motor drivers using a multimeter OK No If the motor is bad replace If drivers are bad replace at the same time Yes Is the fault corrected No Yes NOTE 1 Check the following connectors Junction board connector to interlock switch Junction board connector to CR motor Head junction board connectors to pr...

Page 181: ...form the bidirectional printing adjustment No Yes Check printhead cable continuity Visually check printhead pins Replace any bad part Is the fault corrected Yes No A Does the printer perform self test Is there any dot missing or dragging NOTE 1 Check the following connectors Three head junction board connectors to printhead CN1 of C204 MAIN board to head junction board CN2 of C204 MAIN board to C2...

Page 182: ... Is the printhead resistance correct No Yes Are the drivers OK A Yes No Yes B Is the print OK No If the printhead drivers are OK replace the printhead Check the printhead drivers No Are the drivers OK Yes END Refer to Section 5 3 Repair of the Printer Mechanism B Yes Check the print head coil resistance Replace the C204 MAIN and or C204 DRV B board Replace the C204 MAIN and or C204 DRV B board Rep...

Page 183: ...on is normal but the self test is printed incorrectly 3 3 B Yes Perform bidirectional adjustment END No Is the print correct Go back to Section 5 3 Repair of the Printer Mechanism and check for other problems Perform bidirectional adjustment END ...

Page 184: ...or resistance OK and are the drivers OK No Refer to Section 5 5 Repair of the Printer Mechanism Are the drivers shorted or open Yes Perform final printing of self test END No Is the print OK Yes Refer to Chapter 4 and perform the PG motor backlash adjustment END No Is the print OK Refer to Chapter 4 and perform the PG motor backlash adjustment END END Yes When you move the PF motor manually does i...

Page 185: ...es work correctly Reinsert connector CN correctly START Do the buttons work END END Replace the C MAIN board Is the fault corrected Yes No No Yes No END Replace the C PNL board No No Yes Yes Yes END END Using a multimeter check the switches on the C PNL board 5 204 204 204 204 204 Is CN5 between the C204 MAIN and C204 PNL board connected correctly ...

Page 186: ...u using Built in Parallel Serial or Optional Yes Replace cable No END END Yes If you are using a serial I F is your cable a null modem cable No Yes Replace C MAIN board END If you are using a Type B optional I F for a network is the network configured correctly Not using serial Yes Replace Type B interface END Reconfigure network END No Set switches correctly END No Are the DIP switches set correc...

Page 187: ... for the C204 PSB PSE board and Table 5 4 shows the C204 PSB PSE board component level troubleshooting Table 5 4 C204 PSB PSE Board Main Parts List Location Description DB1 Diode bridge TY1 TRIAC QF101 Switching FET for VP1 and VP2 QF201 Switching FET for VP3 and 5 VDC IC101 PWM switching controller IC204 5 V regulator IC Table 5 5 C204 PSB PSE Board Component Repair 1 3 Symptom Cause Checkpoint S...

Page 188: ...is defective Pin 5 FB must be HIGH then observe the voltage waveform between pin 2 VOUT and pin 12 GND of IC101 Replace IC101 The 37 VDC VP3 line is dead The main switching FETs QF201 is defective Observe the voltage waveform between the drain side and GND Replace QF201 Q201 is defective Observe the voltage waveform between the collector side and GND Replace Q201 Q202 is defective Observe the volt...

Page 189: ...ormal IC102 is defective If this IC is defective it cannot monitor the 37 VDC lines and printing operation becomes abnormal When the input voltage of the minus port pin 6 for VP1 and pin2 for VP2 is less than 1 3 VDC the comparator outputs a HIGH signal Replace IC203 37 VDC line VP3 is abnormal IC203 is defective If this IC is defective it cannot monitor the 37 VDC lines and motor operations becom...

Page 190: ... board VP1 or C204 DRV B board VP2 The PD signal was sent to the C204 power supply board HIGH level turns off the power supply Check the logic level of the PD signal during power on and verify the voltage waveform for the head driver Refer to the head driver waveform figure above Replace the head driver or gate array The reset circuit is not operational for logic Check the logic level at pin1 VOUT...

Page 191: ...Confirm that the PROM is inserted the socket correctly Replace IC5 The gate array IC1 is defective Check pin 86 D0 of IC1 for a change in the signal HIGH or LOW Replace IC1 The CPU IC2 is defective Look at the oscillator at either pin 27 x1 or pin 28 of the CPU Replace CRU1 or IC1 The DRAM IC14 is defective Observe pin 2 D0 of IC14 for a change in the signal HIGH or LOW Replace IC14 ...

Page 192: ...age motor phases at collectors Q16 CRA Q17 CRB Q18 CRC and Q19 CRD Replace Q16 Q17 Q18 or Q19 IC1 is doesn t work Check the voltage level between Anode and Kathode of ZD2 is APPROX 6 2 V Replace ZD2 Q34 or Q35 IC1 on the C204 DRV board is defective Check the signals for the carriage motor phases at pins 14 IN_A and 10 OUT1 of IC1 Replace IC1 Measure the voltage level at pins 10 OUT1 and 5 GP of IC...

Page 193: ...ates abnormally The carriage encoder sensor is defective Observe the carriage encoder sensor output signal at pins 4 ENCA and 3 ENCB of CN4 on the C204 MAIN board Replace the carriage encoder sensor Carriage operation is unstable due to a lack of motor torque Check the switching waveform for Q5 Q6 and Q7 Replace the abnormal transistor ...

Page 194: ... IC2 Ribbon feeding is abnormal The CPU IC2 on the C204 MAIN board is defective Check the RF motor phase drive signals at pins 6 9 of IC2 Replace IC2 The common switching transistor on the C204 DRV board is defective Check the collector voltage of Q21 Replace Q20 or Q21 The phase switching transistor on the C204 DRV board is defective For transistors Q22 Q25 observe the input signal from the CPU b...

Page 195: ...0 or Q11 The phase switching transistor on the C204 DRV board is defective For transistors Q12 Q15 observe the output signal collector if there is no output signal replace the abnormal transistor Fuse F2 on the C204 DRV board is defective Check if fuse F2 is defective Replace F2 The PG sensor is defective Observe the PG sensor output signal at pins 35 PGENCA and 34 PGENCB of CN14 Replace the PG se...

Page 196: ... MAIN board is defective Observe the output signal at pins 136 181 of IC1 Replace IC1 The head driver FETs on the C204 MAIN and or C204 DRV B boards are defective Observe the voltage waveform at the each FET drain side Replace the abnormal FET The CPU IC2 on the C204 MAIN board is defective Observe the signals at pins 38 PTS1 and 42 PTS2 of the IC2 Replace the IC2 ...

Page 197: ...any foreign objects The CR motor is defective Measure the coil resistance of the CR motor It should be approximately 1 66 ohms 10 Replace the CR motor The carriage timing belt is defective Manually check the carriage timing belt tension Perform the carriage timing belt tension adjustment as described in Section 4 1 2 The carriage guide shaft parallelism value is incorrect Check whether the carriag...

Page 198: ...oes not feed paper or does not feed it correctly Foreign objects are lodged in the paper path Visually check the paper path Remove any foreign substances The PF motor is not driving the gear properly Check whether the PF motor pinion gear rotates smoothly when rotated manually Check backlash between PF motor pinion gear and paper feed reduction gear The PF motor is defective Measure coil resistanc...

Page 199: ...ft gear as described in Chapter 4 Adjustments The PG encoder sensor is defective Check the output signal of the PG encoder sensor Refer to Table 5 6 Replace the PG encoder sensor The encoder plate is defective Check whether the encoder plate is broken or stained Replace the PG motor or clean the encoder plate The PG home sensor is defective Check the continuity of the sensor Check the status of th...

Page 200: ...assembly The tension value of the tractor wire spring is incorrect The distance between the frame and the seal securing the white line should be about 3 mm 0 12 inches Perform the tractor wire spring tension adjustment as described in Section 4 1 3 The tractor select front or rear function is not working The tractor select sensor is defective Check the continuity of the tractor select sensor Repla...

Page 201: ...CHAPTER 6 MAINTENENCE 6 1 PREVENTIVE MAINTENENCE 6 1 6 2 LUBRICATION AND ADHESIVE APPLICATION 6 1 ...

Page 202: ......

Page 203: ...bricated at the points illustrated in Figures 6 2 6 3 and 6 4 using EPSON lubricants O2 and G26 These lubricants have been extensively tested and found to comply with needs of the printer Refer to Table 6 1 for information on lubricants O2 and G26 Table 6 2 lists the appropriate lubricant for each point Make sure the parts to be lubricated are clean before applying lubricant Also avoid applying to...

Page 204: ...ge guide shaft G26 7 6 3 Carriage guide shaft on the both front and rear shafts G26 8 6 4 Platen roller shaft holder contact point with the platen roller G26 9 6 4 Paper bail gear G26 10 6 2 Shafts of paper feed gears shafts on the left frame G26 O2 11 6 2 Paper feed gears gears on the left frame G26 12 6 2 Tension pulley pulley shaft and hook for the tension pulley spring G26 13 6 3 Fulcrum point...

Page 205: ...MAINTENANCE Rev B 6 3 Figure 6 2 Lubrication and Adhesive Diagram 1 ...

Page 206: ...DFX 8500 Rev B 6 4 Figure 6 3 Lubrication and Adhesive Diagram 2 ...

Page 207: ...MAINTENANCE Rev B 6 5 Figure 6 4 Lubrication and Adhesive Diagram 3 ...

Page 208: ......

Page 209: ...APPENDIX A 1 CONNECTOR PIN ASSIGNMENTS A 1 A 2 CIRCUIT DIAGRAMS A 9 A 3 COMPONENT LAYOUT A 21 A 4 CONNECTOR JUNCTION BOARD CONNECTORS A 27 A 5 PART LIST A 28 A 6 EXPLODED DIAGRAMS A 31 ...

Page 210: ......

Page 211: ...2 6 CN4 8 Fan C204 PSB PSE CN3 2 CN4 4 CN5 14 CN9 7 CN1 30 CN2 20 C204 DRV B CN1 30 CN3 20 CN2 8 CN8 8 CN6 6 CN12 36 CN13 7 IEEE1284 EIA 232D CN11 36 TYPE B CN10 8 CN7 12 CN14 50x2 CN16 7 CN15 6 CN2 7 CN1 6 C204 SUB C204 MAIN C204 DRV CN2 50 CN3 6 CN1 50x2 Printer Mechanism C204 PNL CN1 7 CN2 7 Cover Open Sensor CR Encoder Junction Board Printhead Paper Cutter Unit AC Input Figure A 1 Cable Connec...

Page 212: ...I F card 36 pins Table A 12 CN12 IEEE 1284 I F 36 pins Tables 1 10 an 1 11 CN13 EIA 232D I F 7 pins Table 1 12 CN14 C204 DRV board 50 pins X 2 Table A 13 CN15 C204 SUB board 6 pins Table A 14 CN16 C204 SUB board 7 pins Table A 15 C204 DRV Board CN1 C204 MAIN board 50 pins X 2 Table A 13 CN2 Printer mechanism 50 pins Table A 16 CN3 C204 PSB PSE board 6 pins Table A 17 C204 DRV B Board CN1 Mechanism...

Page 213: ... coil 6 drive signal 2 HR2P O Print head coil 4 drive signal 3 HR9N O Print head coil 18 drive signal 4 HR2N O Print head coil 4 drive signal 5 HR7P O Print head coil 14 drive signal 6 HR7N O Print head coil 14 drive signal 7 HR9P O Print head coil 18 drive signal 8 HR3N O Print head coil 6 drive signal 9 HL8P O Print head coil 15 drive signal 10 HL3N O Print head coil 5 drive signal 11 HL8P O Pri...

Page 214: ... CN6 Pin Signal Name I O Function 1 2 3 VP1 37 VDC 4 5 6 GP1 GND for VP1 Table A 8 C204 MAIN Board Connector CN7 Pin Signal Name I O Function 1 2 3 VP2 37 VDC 4 5 6 GP2 GND for VP2 Table A 9 C204 MAIN Board Connector CN8 Pin Signal Name I O Function 8 7 6 VP1 37 VDC 5 4 3 GP1 GND for VP1 1 VX 5 VDC switched by reset status 2 GND Table A 10 C204 MAIN Board Connector CN9 Pin Signal Name I O Function...

Page 215: ...Q I Command request signal 14 XWRRDY I Write ready signal 15 XRDREQ I Read request signal 16 XWR O Write signal 17 XRD O Read signal 18 XCS O Chip select signal 19 20 21 22 23 24 GND 25 A3 O Address bus 3 26 A2 O Address bus 2 27 A1 O Address bus 1 28 A0 O Address bus 0 29 D7 I O Data bus 7 30 D6 I O Data bus 6 31 D5 I O Data bus 5 32 D4 I O Data bus 4 33 D3 I O Data bus 3 34 D2 I O Data bus 2 35 ...

Page 216: ... Pull tractor mount dismount 30 P_JAM I Paper jam detection 31 F_PE I Front paper end 32 R_PE I Rear paper end 33 T_PE I Top paper end 34 PGENCB I PG encoder B signal 35 PGENCA I PG encoder A signal 36 PGHOME I PG home position 37 RBJAM I Ribbon jam 38 PLP O Plunger P channel 39 RFD O RF motor bridge D signal 40 RFB O RF motor bridge B signal 41 PGH R O PG motor common 42 PGC O PG motor C phase pu...

Page 217: ...nal 16 PGHOME PG home position 17 RFD RF motor phase D 18 RFCOM RF motor common 19 RFB 20 RFA RF motor phase A 21 PGCOM PG motor common 22 RFC RF motor phase C 23 PGA PG motor phase A 24 PGD PG motor phase D 25 PGC PG motor phase C 26 PGB PG motor phase B 27 PENCB PG encoder phase B 28 PENCA PG encoder phase A 29 R_PE Rear PE sensor 30 T_PE Top PE sensor 31 5V 32 F_PE PE sensor front 33 P_TRCT Pul...

Page 218: ...rinthead pin 14 6 P 14 O GND 7 P 18 O Printhead pin 18 8 P 6 O GMD 9 P 15 O Printhead pin 15 10 P 5 O GND 11 P 13 O Printhead pin 13 12 P 3 O GND 13 P 15 O GND 14 P 13 O GND 15 P 5 O Printhead pin 5 16 P 3 O Printhead pin 3 17 P 8 O Printhead pin 8 18 P 8 O GND 19 20 NC Table A 19 C204 PSB PSE Board Connector CN1 Pin Signal Name4 I O Function 1 L I AC input 2 NC 3 N I AC input Table A 20 C204 PSB ...

Page 219: ...ures below Figure A 2 C204 MAIN Board Exploded Diagram C204 MAIN Figure A 3 C204 DRV Board Exploded Diagram C204 DRV Figure A 4 C204 DRV B Board Exploded Diagram C204 DRV B Figure A 5 C204 PSB Board Exploded Diagram C204 PSB Figure A 6 C204 PSE Board Exploded Diagram C204 PSE ...

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Page 225: ...APPENDIX Rev B A 21 A 3 Component Layout Figure A 7 C204 MAIN Board Component Layout 1 ...

Page 226: ...DFX 8500 Rev B A 22 Figure A 8 C204 MAIN Board Component Layout 2 ...

Page 227: ...APPENDIX Rev B A 23 Figure A 9 C204 DRV Board Component Layout 1 Figure A 10 C204 DRV Board Component Layout 2 ...

Page 228: ...DFX 8500 Rev B A 24 Figure A 11 C204 DRV B Board Component Layout 1 Figure A 12 C204 DRV B Board Component Layout 2 ...

Page 229: ...APPENDIX Rev B A 25 Figure A 13 C204 PSB Board Component Layout ...

Page 230: ...DFX 8500 Rev B A 26 Figure A 14 C204 PSE Board Component Layout ...

Page 231: ...S e n s o r t o P G H P S e n s o r t o P a p e r J a m S e n s o r t o F r o n t P E S e n s o r t o C R M o t o r t o P a p e r F e e d M o t o r t o C R M o t o r F a n t o O p t i o n C u t t e r P o w e r t o F a n t o R i b b o n J a m S e n s o r t o I n t e r l o c k S w i t c h R R e d W W h i t e G G r a y Y Y e l l o w B B l a c k C o n n e c t o r C o l o r s 2 p i n s 4 p i n s 2 p i ...

Page 232: ... PRINTER MECHANISM M 3I60 125 C P SCREW WITH S WM3X16 501 FRAME ASSY LEFT 126 C F S SCREW M3X10 502 FRAME ASSY RIGHT 127 C B B SCREW M3X8 503 SOLENOID ASSY LD 128 C B S SCREW M3X8 504 MOTOR ASSY PG 129 C B SCREW M3X12 505 MOTOR ASSY CR 131 C B B SCREW M3X10 506 FRAME LOWER 132 C B B SCREW M3X12 507 FRAME FRONT 133 C B B SCREW M4X10 508 MOTOR ASSY PF DC4 34 134 C B B SCREW M4X16 509 PULLY ASSY BELT...

Page 233: ...FT REAR 612 C B S O SCREW M4X8 554 TRACTOR RIGHT REAR 613 PLANE WASHER 4 1X0 2X7 8 555 SPACER PF ROLLER 614 RETAINING RING TYPE E 556 ROLLER PF DRIVE 615 LEAF SPRING4 1X0 13X8 3 557 SPUR GEAR 18 4 616 H N F M4 558 SHAFT CR GUIDE REAR 617 FLANGE NUT 559 SHAFT CR GUIDE FRONT 618 C P S P S SCREW M3X8 561 LEVER SHAFT LEFT 619 RETAINING RING TYPE E 562 LEVER SHAFT RIGHT 620 C B S SCREW 4X8 563 GUIDE SH...

Page 234: ...01 INDIVIDUAL CARTON FOR AMERICA 655 HEXAGON NUT B 901 INDIVIDUAL CARTON BOX FOR EUROPE 656 LEVER TENSION CANCEL 1001 INDIVIDUAL CARTON BOX FOR PACIFIC 657 BUSH 8 1102 OUTER CARTON BOX 658 BUSH 12 1203 PAD PRINTER UPPER 660 RESISTOR 0OHM 1304 SHEET PRINTER 661 C B S O SCREW M4X8 1405 PAD PRINTER UNDER 662 MOUNTING PLATE FAN CR 1506 SHEET A 663 DOUBLE SIDE TAPE 20X10 1607 SHEET B 664 SHAFT FASTEN D...

Page 235: ... Figure A 17 EXPLODED DIAGRAMS FOR DFX 8500 2 EXPLODED DIAGRAM 2 Figure A 18 EXPLODED DIAGRAMS FOR DFX 8500 3 EXPLODED DIAGRAM 3 Figure A 19 EXPLODED DIAGRAMS FOR DFX 8500 4 EXPLODED DIAGRAM 4 Figure A 20 EXPLODED DIAGRAMS FOR DFX 8500 5 EXPLODED DIAGRAM 5 Figure A 21 EXPLODED DIAGRAMS FOR DFX 8500 6 EXPLODED DIAGRAM 6 Figure A 22 EXPLODED DIAGRAMS FOR DFX 8500 7 EXPLODED DIAGRAM 7 Figure A 23 PAC...

Page 236: ...DFX 8500 Rev B A 32 Figure A 16 Exploded Diagrams 1 ...

Page 237: ...APPENDIX Rev B A 33 Figure A 17 Exploded Diagrams 2 ...

Page 238: ...DFX 8500 Rev B A 34 Figure A 18 Exploded Diagrams 3 ...

Page 239: ...APPENDIX Rev B A 35 Figure A 19 Exploded Diagrams 4 ...

Page 240: ...DFX 8500 Rev B A 36 Figure A 20 Exploded Diagrams 5 ...

Page 241: ...APPENDIX Rev B A 37 Figure A 21 Exploded Diagrams 6 ...

Page 242: ...DFX 8500 Rev B A 38 Figure A 22 Exploded Diagrams 7 ...

Page 243: ...APPENDIX Rev B A 39 Figure A 23 Packing Material ...

Page 244: ...9 Sesto S Giovanni MI Italy Phone 2 262331 Fax 2 2440750 EPSON AUSTRALIA PTY LIMITED 1 70 Gibbes Street Chatswood 2067 NSW Australia Phone 2 9903 9000 Fax 2 9903 9177 EPSON SINGAPORE PTE LTD No 1 Temasek Avenue 36 00 Millenia Tower Singapore 039192 Phone 065 3377911 Fax 065 3341185 EPSON HONG KONG LTD Rooms 4706 10 47 F China Resource Bldg 26 Harbour Road Wanchai Hong Kong Phone 2585 4300 Fax 2827...

Page 245: ...EPSON SEIKO EPSON CORPORATION ...

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