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

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EPSON TERM NAL PR

DFX-5000+

NTER

SERVICE MANUAL

EPSON

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

Page 1: ...EPSON TERM NAL PR DFX 5000 NTER SERVICE MANUAL EPSON ...

Page 2: ...acy 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 Centronics is a registered trademark of Centronics Data Computer Corporation Epson and Epson ESC P are registered trademark of Seiko Epson Corp...

Page 3: ...S MANUAL 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 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 PL...

Page 4: ... 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 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 te...

Page 5: ...ue Rev B April 20 1994 Page 4 10 Addition the notes Page 4 1 1 Addition the notes Rev C November 22 1994 Page 4 4 to 4 7 Change the explanation 1 I Rev D i December 15 1994 I Whole Revise of the Chap 4 Rev E March 7 1995 Page 4 12 Change the explanation Page 4 12 Addition the notes ...

Page 6: ... OF CONTENTS CHAPTER 1 CHAPTER 2 CHAPTER 3 CHAPTER 4 CHAPTER 5 CHAPTER 6 APPENDIX GENERAL DESCRIPTION OPERATING PRINCIPLES DISASSEMBLY AND ASSEMBLY ADJUSTMENTS TROUBLESHOOTING MAINTENANCE AND LUBRICATION vi ...

Page 7: ...4 1 4 15 Control Panel 1 17 Self test 1 18 Hexadecimal Dump Function 1 18 Paper Out Detection Function 1 18 Cover Open Detection 1 18 Paper Width Detection 1 19 Automatic PaperThickness Adjustment 1 19 Paper Memory Function 1 19 1 4 8 1 Using the Paper Memory Function 1 20 1 4 8 2 Saving Paper Format and Thickness Information 1 20 Automatic Tear Off Function 1 21 PaperJam Detection 1 21 Automatic ...

Page 8: ...mission Timing 1 14 Figure 1 23 Control Panel 1 17 Figure 1 24 Multi part Forms with a Label 1 19 Figure 1 25 overlapping Multi part Forms 1 19 Figure 1 26 Main Components 1 26 Figure 1 27 M 3C11 Printer Mechanism 1 27 Figure 1 28 C117 MAIN Board Assembly 1 28 Figure 1 29 C117 PSB PSE Board Assembly 1 28 Figure 1 30 C117 PNL Board Assembly 1 29 Figure 1 31 Housing 1 29 List of Tables Table 1 1 Opt...

Page 9: ... paper back out and loading from another paper path and paper park Automatic platen gap adjustment for paper thickness Automatic tear off 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: ... card SSI mm screw 1 I C82307 I 32KB intelligent serial l F card inch screw C82308 32KB intelligent serial I F card mm screw C8231O 32KB intelligent parallel l F card C82312 LocalTalk l F card C82313 32KB IEEE 488 I F card C82314 Coax l F card i I C82315 I Twinax I F card I C82324 I Ethernet I Fcard The digit indicated by an asterisk vanes by country A simple serial interface card has no CPU the p...

Page 11: ...de Printing direction Text mode Bit image mode Built in fonts Bidirectional with logic seeking Unidirectional mode can be selected using the ESC U command Unidirectional Draft NLQ Roman NLQ Saris Serif Table 1 2 Character Size and Pitch Type of Letters Width in mm Height in mm Pitch in mm printable Columns inches inches inches Pica 1 O cpi 2 12 0 08 3 1 0 12 2 54 0 10 136 Elite 12 cpi 1 69 0 07 3 ...

Page 12: ...4 Character Tables Character Tables standard Version NLSP Version IBM Mode Italic o 0 x PC437 U S Standard Europe o 0 0 PC850 Multilingual o 0 x PC860 Portuguese o 0 x PC863 Canadian French o 0 x PC865 Norwegian o 0 0 PC861 Iceland o 0 x BRASCII o 0 x Abicornp o 0 x PC853 Turkish x o x PC857 Turkish x o x ISO Latin IT Turkish x o x PC437 Greak x o x PC869 Greek x o x ISO 8859 7 Greek x o x PC855 C...

Page 13: ...nd Intermittent 26 ins line Note The feeding speed 10 ips is reduced to 6 ips when the optional pull tractor is installed 1 2 3 Paper Specifications Fanfold Paper Quality Plain paper Width 101 406 mm 4 16inches Copy capability Front 6 sheets 1 original 5 carbonless copies Rear 4 sheets 1 original 3 carbonless copies Total thickness Front Up to 0 46 mm 0 018 inches Rear Up to 0 30 mm 0 012 inches W...

Page 14: ...e 4 5 6 creases Figure 1 4 Unsuitable Paper Form override printing is available for 20 lines after the paper end The paper feeding pitch is not guaranteed The end of the printable area is 15 mm 0 60 inches above the bottom edge of the paper A A p6D o lo 0 o 0 0 I s o 10 o 10 L D E il o 1 E w wJ END OF PAPER V In If Figure 1 5 Form override Area Weak horizontal and vertical perforations cause paper...

Page 15: ...hows examples of correct perforation intersections I I II I I I I I I Figure 1 8 Perforation Intersections The raised portion at a perforation fold must be less than 1 mm 0 04 inches from the flat part and the bottom layer must be kept flat by force Perforations Figure 1 9 Raised Portion 10 Sprocket holes must be circular and may have teeth at a Perforation OC3 Figure 1 10 Sprocket Holes 11 The sp...

Page 16: ...n Overlapping Mutti part Forms Paper path Front only Quality Plain paper Width 101 406 mm 4 16 inches Copy capability 5 sheets 1 original 4 carbonless copies excluding the bottom carrier Overlap length 10 mm 0 394 inches maximum Total thickness Print area 0 46 mm 0 018 inches maximum Overlap area 0 70 mm 0 028 inches maximum including the bottom carrier Weight Multi part 35 48 kg 11 15 lb up to th...

Page 17: ...y 3 For multi part forms joined with dotted paste the form sheets can be joined on either a single side or both sides Figure 1 14 shows the recommended paste positions Surface o o a m o 0 0 0 Ea m 0 0 0 0 m m 0 0 0 0 mB W 0 0 0 0 m 0 0 Figure 1 14 Dotted Paste Positions 4 The pasted areas must be pressed flat There must be no creases in the paper 5 Paper stapling must be applied from the front and...

Page 18: ...nd there should be no spilled giue Figure 1 18 shows the correct multi part form binding method Multi part firm sheets should be securely bound to each other and the binding area must not be too large Paate Figure 1 18 Correct Muiti part Form Binding Fanfold Paper with a Labal Paper path Front only Quality Plain paper Width 101 406 mm 4 16 inches Total thickness 0 46 mm 0 018 inches rruximum Weigh...

Page 19: ... oflfinction to avoid a paper jam it is important not to feed label forms backward Notes 1 2 3 4 5 6 7 8 Load label forms only onto the front tractor The paper select function must not be used Feed label forms only in the forward direction using the forward feeding MICRO FEED button A Do not feed label forms in the reverse direction Feeding label forms backward may cause a paper jam or the labels ...

Page 20: ... H X 140 D mm 20 24X 0 92 x5 60 inches Ribbon 13 mm x 70 m 0 52 inches x 231 0 tit endless Life 15 million characters 14 dots character 1 2 5 Environmental Conditions Table 1 5 Acceptable Environmental Conditions Condition Operating storage Temperature 5 35 C 41 95 F 30 80 C 22 140 F Humidity 10 WY RH q 5 85 RH v Shock resistance 1 G within 1 msec 2 G within 2 maec Vibration resistance 0 25 G 55 H...

Page 21: ...imum applying 500 VDC between AC line applying 500 VDC between AC IHw and chassis and chassis 1000 VAC rms 1 minute or 1200 VAC rrns 1 second 1500 VAC rrns 1 minute between AC line and chassis between AC line and chassis 1 2 8 Safety Approvals Safety standards Radio frequency interference RFI 1 2 9 Physical Specifications Size W x D x H Weight 8000 power on hours POH at a duty cycle of zs o 24 mil...

Page 22: ...d fall time of each input signal must be less than 0 2 ILS The BUSY signal is active HIGH under the following conditions During data reception See Figure 1 22 When the t buffer is full When the INIT input signal is active During initialization When the ERROR or PE signal is active During the self test II I paper memory setting mode IrI pause mode When a fatal error occurs 6 The ERROR signal is act...

Page 23: ...e next data 12 PE 30 0 HIGH indicates paper out This signal is effective only when the ERROR signal is LOW 13 SLCT o Always HIGH output Pulled up to 5 V through a 3 3 KQ resistor If the signal is LOW when the printer is 14 AFXT I initialized a line feed is automatically performed when a CR code is input auto LF 15 34 NC No connection not used 16 Ov Signal ground level 17 FG Chassis ground In the p...

Page 24: ... 27 V Connector EIA standard 25 pin cmnector Table 1 8 shows the signal functions and connector pin assignments for the serial interface Table 1 8 Serial Interface Signals and Connector Pin Assignments Pin No I Signal Name I I o I Description I 1 FG I Chassis ground r I I 2 I TXD I O I TmllSmt tafOrx Ow OFF hndShake I 3 RXD I Receive data 7 SG Signal ground Indicates whether the printer is ready t...

Page 25: ...ton functions only when the printer is in pause mode The tear off position can be adjusted using the MICRO FEED buttons The adjusted value is stored in the EEPROM on the main board when the printer is turned off Adjusts the paper position including the top of form TOF and tear off positions The forward MICRO FEED button A advances the paper in 1 216 inch increments and the backward MICRO FEED butt...

Page 26: ... the printer The self test prints the following Program ROM version number Built in characters To print the current DIP switch settings hold down the PAUSE button and turn on the printer The printer does not print the self test in draft mode if NLQ mode is selected using DIP switch 1 3 1 4 3 Hexadecimal Dump Function The hexadecimal dump function prints the data the printer receives in hexadecimal...

Page 27: ...e the paper memory function It allows you to save paper format and thickness information using the DIP switches and the control panel buttons The paper memory function is available only for forms loaded on the front tractor Cl Forms with a label Multi part forms that vary in thickness include forms with a label the label area is thicker than the rest of the form 0 0 Figure 1 24 Multi part Forms wi...

Page 28: ... when using the paper memory function however if the skip length is less than 1 inch the setting is ignored when using overlapping forms Q ESC O reset skip over perforation is valid when using the paper memory function with overlapping forms Q When using overlapping forms the loading position must be adjusted each time you load paper 1 4 8 2 Saving Paper Format and Thickness Information To save pa...

Page 29: ...r until its perforation reaches the tear off position of the printer cover under these conditions Cl The paper is advanced to the TOFposition after a print job Q The printer receives an FFcode and then no other codes or characters for at least3 seconds The printer has finished a print job Ll The pull tractor is not being used D The paper memory function is not being used Then if the printer receiv...

Page 30: ...following Printer initializ ation Li ESC P software reset command ESC Page length command ESCC 2 IBM top of form setting command ESC4 1 4 15 Buzzer Operation The buzzer sounds for approximately 0 1 second when a BEL code 07H is input Buzzer beeps indicate printer status as shown below Each asterisk represents one 0 1 second beep The ESC BEL command 07H is input 1 beep A carnage error is detected d...

Page 31: ... E See Table 1 15 See Table 1 16 2 2 Input buffer 2 3 Automatic LF bv CR 2 4 2 5 2 6 Interface 2 7 2 8 3 1 3 2 Serial bit rate Page length See Table 1 17 Valid 1 Invalid 2 1 Valid Invalid Valid Invalid Valid Invalid Skip over perforation Paper memory area 3 3 3 4 3 5 Overlapping forms Forms with a label Skip binding 3 6 3 7 3 8 Automatic tear off Valid I Invalid OFF IBM mode indicates IBM ProPrint...

Page 32: ... OFF ON ON ON PC437 PC437 OFF ON OFF OFF OFF PC850 PC850 OFF ON OFF OFF ON PC860 PC860 OFF ON OFF ON OFF PC863 PC863 OFF ON OFF ON ON PC865 PC865 OFF ON ON OFF OFF PC861 PC861 OFF ON ON OFF ON BRASCII BRASCII OFF ON ON ON OFF Abicomp Abicomp OFF ON ON ON ON PC437 Greek ON OFF OFF OFF OFF PC869 ON OFF OFF OFF ON 1s0 8859 7 ON OFF OFF ON OFF PC853 ON OFF OFF ON ON PC857 ON OFF ON OFF OFF ISO Latin I...

Page 33: ...lection serial interface no parity 10 seconds OFF ON ON Parallel interface ON OFF OFF Serial interface odd parity ON OFF ON Serial interface even parity ON ON OFF Serial interface no parity ON ON ON This is the standby time See Section 1 4 11 Automatic Interface Selection Table 1 16 Baud Rate Selection Bit Rate bps SW 2 7 Sw 2 8 19 200 OFF OFF 9 600 OFF ON 1 200 ON OFF 300 ON ON Table 1 17 Page Le...

Page 34: ...e designed fix easy removal and replacement These e 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 Y c Figure 1 26 Main Components 1 26 Rev A ...

Page 35: ...5000 includes a CR motor isolation resistance sensor Ll The DFX 5000 includes a paper jam sensor Cl To prevent paper jams the DFX 5000 includes a tractor wire at the front and rear tractors U The DFX 5000 does not include a carriage home position sensor LI The detection method of the carriage encoder sensor has been changed In the DFX 5000 the encoder plate was attached to the rotor of the CR moto...

Page 36: ...3 II í ÿ üà œ pE Œ õ Ô I i I zlJGJca Db witches W S 22 10 13 16 i4 16 20 21 dnv r for PRINTHEAD LQ28 031 dnvor for MOTOR RF figure 1 28 C117 MAIN Board Assembly 1 6 3 Power Supply Circuit C117 PSB PSE Board Assembly The C117 PSB PSE tmrd assembly power supply circuit supplies the control circuit and printer mechanism drive circuit with power The fan motor on this board keeps the temperature in the...

Page 37: ...6 5 Housing The housing consists of many parts The lower case is the main frame which holds the printer mechanism and circuits These components are covered by the upper case bottom plate and two side covers each of which has various covers The housing has large openings in the front and rear for the paper entrances and exits It also has a cover on the bottom plate to provide easy access to the PRO...

Page 38: ...sm 2 11 2 2 POWER SUPPLY OPERATION 2 12 2 2 1 PowerSupplyOverview 2 12 2 2 2 5 VDCLine RegulatorCircuk 2 14 2 2 3 35 VDCLine RegulatorCircuti 2 15 2 2 4 12 VDC Half wave Rectifier Smoothing Circuit 2 16 2 3 CONTROL CIRCUIT 2 17 2 3 1 2 3 2 2 3 3 2 3 4 2 3 5 2 3 6 2 3 7 2 3 8 2 3 9 Control Circuit Operation Overview 2 17 Reset Circuit 2 21 Sensor Circuits 2 Z CR Motor Driver Cimufi 2 25 PF Motor Dr...

Page 39: ...igure 2 18 Control Circuit Block Diagram 2 18 Figure2 19 Data Flow from the Parallel Interface 2 19 Figure2 20 Reset Circuit Block Diagram 2 21 Figure 2 21 SensorCircuit Block Diagram 2 22 Figure 2 22 CRMotor Internal Circuit 2 25 Figure 2 23 CR Motor Driver Block Diagram 2 25 Figure 2 24 Acceleration Control Cutve 2 27 Figure 2 25 Deceleration Control Curve 2 28 Figure 2 26 Measurement Sequence 2...

Page 40: ...iage mechanism moves the printhead in the horizontal direction The CR motor drives the carriage with the printhead on it The CR sensor detects the CR motor speed and carriage position The CR motor is closed loop controlled Because the CR motor is driven at a very high speed it includes an isolation resistance sensor to detect abnormal resistance The sensor detects an error if the resistance is les...

Page 41: ...d stop the printer from printing when there is no paper The printer is equipped with three PE sensors the front PE sensor at the front tractor the rear PE sensor at the rear tractor and the top PE sensor at the paper bail The pull tractor sensor detects whether the optional pull tractor is installed The printer is also equipped with a paper jam sensor The control circuit reads the signals from the...

Page 42: ... type impact dot pnnthead 13gure 24 shows its operation The dot wire is attached to the actuating spring at point A It is pulled back left in the figure by magnetic form when power is applied and during standby The magnetic force holds back the actuating spring When current flows through the coil a countermagnetic field is rnduced in the coil Then the actuating spring ejects the dot wire fix ward ...

Page 43: ...ing disordered pulses of the CR motor and CR sensor linear belt type A gum pad is attached to the left side of the frame When the carriage hits the pad the CR motor pulse is disordered by this obstacle The control circuit monitors the CR motor s pulse when it is disordered the control circuit recognizes the carriage home position The CR motor is equipped with an encoder unit which generates pulses...

Page 44: ...ation of the motor expands the platen gap and clockwise rotation reduces it The encoder plate with equally pitched slits is attached coaxially to the motor axis When the motor rotates the PG sensor detects it and outputs the pulses Each pulse corresponds to detection of a 0 015 mm resolution horizontal distance The system range is O to 0 7 mm ENASSEMBL 23P Mask less Holder PLATEN SHAFT CR ON GEAR ...

Page 45: ...ection 2 1 5 Ribbon Feed and Tractor Select Mechanisms for more information 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...

Page 46: ...RONT PAPER FEED MOTOR Tractor Sprocket Front Pinion Gear Figure 2 8 Front Tractor Assembly Operation Paper PAPER BAIL LEVER TENSION ROLLER SENSOR ASSY PE FRONT TRACTOR SELECT GEAR I k i l U xtw 1 Tractor Sprocket Rear y t j E FEED MOTOR Figure 2 9 Rear Tractor Assembiy Operation Rev A 2 7 ...

Page 47: ... move along 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 ...

Page 48: ...re engaged When the RF motor pinion gear rotates counterclockwise the motor rotates the ribbon feed mechanism when it rotates clockwise the motor rotates the tractor select mechanism Figure 2 11 shows the ribbon feed mechanism 7he ribbon is fed in only one direction Counterclockwise rotatkm of the RF motor is transmitted to the ribbon feed gear through the ribbon d select gear and ribbon feed tran...

Page 49: ...lly along the curve When the tractor select lever is set to the left the tractor select gear engages the rear tractor assembly train and the PF motor rotates the 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 TRACTOR DRIVE GEAR...

Page 50: ...e 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 PAPER BAIL LEVER I I Figure 2 13 Plunger Mechanism Rev A 2 11 ...

Page 51: ...e 2 1 shows the input voltages and fuse ratings of the boards Table 2 1 Power Supply Boards Board Input Voltage Fuse Ratings Cl 17 PSB board assembly 100 120 VAC 6 3 A1250 VAC Cl 17 PSE board assembly 220 240 VAC 12 A 125 VAC 2 2 1 Power Supply Overview Figure 2 14 shows a block diagram of the power supply board a Surga cut Recfifiar Smoothing Circuil circuit circuit o 1 t a r Main swhching Smooth...

Page 52: ...f the circuit components and is located under the carnage motor so that it also lowers the carriage motor temperature To prevent a surge in the current the power supply board cannot recover for approximately thee minutes after the power is turned off Therefore after the printer is turned off wait three minutes before you turn it back on m The specifications for the C117 power supply board assembly...

Page 53: ...it is a common circuit with the DRERR signal feedback circuit on the C117 MAIN board assembly D 5 VDC line over voltage control over current control circuit IC151 TL494 includes this control circuit IC151 contains two internal comparators One comparator is used for over voltage control Pin 16 12 monitors the 5 VDC line If this voltage exceeds 5 V pin 15 internal comparator 1 outputs a HIGH signal ...

Page 54: ...156 D151 and D251 on the secondary side of T1 and T2 prevent current flow in the secondary side When QIOl is turned on the primary side of transformer coil T2 3 receives an rnput voltage which induces voltage in windings W 4 and 12 3 When Q101 is turned off the currmt flows to the wamdary side of the transformer coil o Filter Clrcuk Surge cul R9ctifbr smoothing Circuit arcuit C wit o H H H h I p a...

Page 55: ...GH CLIMIT signal to the base of transistor Q187 IC152 monitors the two 35 VDC line creation circuits Cl 13 VDC creation circuit When the printer is turned on the C117 power supply board assembly creates 13 VDC to check the printhead drivers on the C117 MAIN board assembly After 140 ms the C117 MAIN board assembly sends the DRERR driver error or the VPC 35 VDC permission signal to the C117 power su...

Page 56: ... main functions of the E05A87 gate array are Chip Select signal creation address decodina printhead driver control carriage driver control encoder pulse arcuit control PG and fan motor phase signal creation interface control CR and PF motor driver abnormal sensor arcuit control reset signal creation control signal creation for the power supply board control of the LEDs on the Cl 17 PNL board assem...

Page 57: ... PG Home position 6 PuII Tractor 7 Tractor Select 8 Cover Open 9 Paper Wide 10 Fan Temperature 11 MOTOR CR isolation 12 Head Temperature 13 MOTOR PF Watch Dog Timer 14 Drop Error Signal Detection from BOARD ASSEMBLY C117PS I 1 FAN 1 SDC03 QM2 P MOTOR PG Q17 Q18 PLUNGER ZICR A L Interlock itch Q26 22 10 13 16 14 18 20 21 PRINTHEAD I 1 I Each Sensors Circuit I 11 PG encorder sensor 2 CR encorder sen...

Page 58: ... in the input data buffer if it is not 3 After checking the data the CPU makes IC7 clear the BUSY signal and output the ACKNLG signal via the MMIO accesses When either a CR code is received or the input data buffer becomes full the CPU sets the BUSY signal to HIGH and executes printing E05A87 IC7 STROBE 40 1 CPU ICI PS RAM IC3 o 2 Input Data Buffer e o 0 DATA DATA CR command DATA Buffer Full Yes Y...

Page 59: ...fetched Table 2 3 describes the functions of the main printer components Note The data flow from the serial interface is the same as the data flow from the parallel interface described above except the signal names and data access method differ Table 2 3 Main IC Functions IC Name Location Functions TMP96C141 Receives data from the host computer via the gate array CPU Icl loads the data to the inpu...

Page 60: ...U gate array and optional interface board l he gate array outputs the RESET signal to the reset port of the CPU and also to the gate array itself via the delay control arcuit CR circuit The delay cxmtrol circuit cmsists of R26 and C72 and controis the reset timing for the CPU and Type B interface card Cl 35 VDC reset circuit Reset IC M51955 monitors the 35 VDC line Normally the dividing resistors ...

Page 61: ...h Pull tractor sensor uses a micro mechanical switch Cover open sensor uses a micro mechanical switch CR encoder sensor uses an LED and photo diode PG sensor uses a photo interrupter PG home sensor uses a micro mechanical switch 35 VDC voltage drop sensor signal interface Head temperature sensor uses a thermistor Fan temperature sensor uses a thermistor PW sensor uses a photo reflector Carriage mo...

Page 62: ... transistor Rectangle wave 1 channel TTL level Resistance for latch up prevention 10 KQ Paper feed Level changes continuously Paper jam Level remains the same The magnetic transistor is attached to the tension roller on the paper tension unit Micro mechanical switch Resistance for latch up prevention 10 Kf2 Pulled up to 390 f2 resistance Front tractor LOW closed Rear tractor HIGH open Micro mechan...

Page 63: ...ircuit Pulled up to 3 32 KCl resistance CR filter circuit 1 KKt and 0 1 pF 12 Fan temperature sensor uses a thermistor Cl Input circuit Pulled up to 3 32 Kf2 resistance CR filter circuit 1 K i2 and 0 1 p F 13 Paper width sensor Cl Detection form Photo reflector D Output form Emitter follower Cl Input circuit CR filter circuit 10 KLt and 0 01 pF D Judgement No paper present Standard voltage level P...

Page 64: ...f the printer cover is open at power on the CR motor driver power is cut The ENC A pulse that the carriage encoder outputs is input to general purpose port ENCA of the gate array and the ENC B pulse that the carriage enmder outputs is input to general purpose port ENCB of the gate array The gate array munts these pulses using the internal munter and determines the amount and direction of motor rot...

Page 65: ...ation mode 3 controls deceleration NLQ HD 600 Note 1 Bit image 4 525 Bit image 4 HD 500 Home position Carriage seek 315 moves without Pa er width printing de ction seek m Note 3 Logical seek 1 630 Logical seek 2 1260 Note 1 Table 2 5 describes Deceleration mode 3 Note 2 This division applies to all printing modes PI control oversees theconstant speed Refer to page 2 32 for more information on PI c...

Page 66: ...he carriage motor speed to the PWM port of the gate array and determines the duty of the carriage drive timing 4 CR ports A B and C output the drive signal for the CR motor Q Acceleration control Until the carriage speed reaches the constant speed set by PI control acceleration control determines the speed of the carriage The printer can print while the carriage is accelerating The carriage speed ...

Page 67: ...SP1 the printer uses the acceleration driving mode based on the duty data and the rest of the time it uses Deceleration driving mode 2 Refer to Table 2 5 During this time the control circuit measures time periods using the encoder signal and controls the following Cl When duty data becomes Duty ti before the carriage speed reaches SP2 Then when the carnage speed reaches SP2 the next sequence SP2 t...

Page 68: ... temperature detection sequence which consists of the tbllowing steps 1 A unit of one section is 72 5 ms Every 72 5 ms the sotlware monitors the number of carriage movements and saves this number 2 The printer calculates the total number of movements for the eight most recent sections 3 When the printer is in the normal drive sequence and tie total number of carriage movements is more than 3250 th...

Page 69: ...motor is controlled using open loop phase switching based on the specified time data and the phase driving method is 1 2 phase excitation When the PF motor is held the phase driving method is 2 phase excitation The CPU selects the most suitable driving mode from the modes below according to conditions such as the paper feed step number and the pull tractor condition D Micro feed adjust mode LI Nor...

Page 70: ...e RF motor specifications The RF motor is a stepping motor The control circuit perlbrms open loop phase switching control according to the timing data for acceleration mnstant speed and deceleration CPU ports PG1O to PG13 output the motor phase switching signals The control method is not equipped with a hold circuit for changing the motor phase The RF motor rotates when the carriage moves w TMP96C...

Page 71: ...gate array and the phase B output pulse from the platen gap encoder ENCB is input to general purpose port ENCB of the gate array The gate array counts these pulses using the internal counter and determines the amount and direction of motor rotation VP or 5 E05A67 SDC03 QM2 Q1 Q15 IC7 PGI T PGA PGB PGAN Z z c l Cu PGBN Plsten gap encoder on the CARRIAGE 15 16 B1 13 14 B2 11 12 B3 9 10 B4 v v v w MO...

Page 72: ... when they are LOW but the invertor ICS IC6 and IC7 convert these signals to HIGH When ports HD1 to HD8 of IC7 go LOW the FET gates are biased and the FETs are turned on so that current flows through the printhead coil When the HD port of IC7 goes HIGH the FETs are turned off and the printhead coil current is cut The trigger power of these FETs is 12 VDC If extra curnmt charges into the head mil m...

Page 73: ...rinciple DEHOOO Service Manual m 0 0 l g FANA r m 0 n z 1 FANAN J 1 x w 0 x 0 Zz 00 N 1 1 z x 00 u lo T 0 a I 1 L z co HEAD FAN thermistor data HEAD thermistor data Figure 2 31 Printhead Driver Circuit 2 34 Rev A ...

Page 74: ... Disassembly 3 24 3 2 7 1 3 2 7 2 3 2 7 3 3 2 7 4 3 2 7 5 3 2 7 6 3 2 7 7 3 2 7 8 3 2 7 9 Removing the Front Rear Tractor Select Lever Assembly 3 24 Disassembling the Front Rear Tractor Select Lever Assembly 3 25 Removing the Connector Junction Board Assembly and FPC Board Assembly 3 27 Removing the PG Sensor and PG Motor 3 28 Removing the Plunger and Paper Bail Assembly 3 29 Removing the Upper Pa...

Page 75: ...igure 3 25 Removing the AC Inlet 3 19 Figure 3 26 Removing the C117 PNL Board Assembly 3 20 Figure 3 27 Removing the Interlock Switch Assembly 3 21 Figure 3 28 Removing the Printer Mechanism 3 22 Figure 3 29 Lifting the Printer Mechanism 3 23 Figure 3 30 Connecting the Cables 3 23 Figure 3 31 Removing the Tractor Select Lever 1 3 24 Figure 3 32 Removing the Tractor Select Lever2 3 24 Figure 3 33 D...

Page 76: ...g the Timing Belt Holder 3 41 Figure 3 55 Removing the CR Motor 3 41 Figure 3 56 Removing the CR Sensor 3 42 Figure 3 57 Removing the Belt Pulley 3 43 Figure 3 58 Removing the Front Carriage Guide Shaft 3 43 Figure 3 59 Removing the Right Side Frame 3 44 List of Tables Table 3 1 Tools 3 3 Table 3 2 Abbreviations for Small Parts 3 5 Table 3 3 Screw Names and Illustrations 3 6 ...

Page 77: ... it Whenever it needs to be moved two or more persons must carry it supporting itfrom the botiom Never lifi the printer by holding the front cover because it may come o Before transporting the printer remove the paper and ribbon cartridge Then attach the following packing materials as shown in Figure 3 1 LI Transport locking bracket Cl Carriage guide shaft support bar Ll Printhead protector LI Foa...

Page 78: ... power cord from the printer and the wall outlet Discomect the printer from the computer and then remove the paper and ribbon cartridge Because you may need to turn the printer while you disassemble or assemble it place it on a clean thick cloth such as a blanket before starting Before assembling the printer lubricate it as described Chapter 6 Mainfenunce and Lubrication A substantial amount of oi...

Page 79: ...s across o A B741700200 E ring holder No 3 I o I A I B740800500 E ring holder No 6 I o I A I B740800800 Round nose pliers I o I A I B7404OO1OO Diagonal wire cutters I o I A I B7405OO1OO Tweezers o A B641OOO1OO I I I Electric soldering imn o A B7402OO1OO Tension gauge 4000 g o A B747700300 Tension gauge 2000 g o A B7477OO1OO Tension gauge 200 g o A 6765114601 Lift habctles E656 E A B7651 11001 Dial...

Page 80: ...er Catalog number Part number Catalog number Part number Catalog number B1019466OO Dial gauges F610 v Figure 3 3 Dial Gauges B1019467OO Dial gauge base F611 1 Figure 34 Dial Gauge Base B1019468OO Dial gauge master F612 0 Figure 3 5 Dial Gauge Master 3 4 Rev A ...

Page 81: ...Cross Pan head with Spring lock washer Plane washer CP Ps C Pan head with Plane washer Spring lock washer CPB Cross Pan head B tight screw CPB 0 Cms Pan head B tight screw with Outside toothed lock washer CPS Crose Pan head S tight screw CPS P Cress Pan head S tight screw with Plain washer CPS SP Cross Pan head S tight screw with Spring lock washer Plain washer CPN Cress Pan head screw CPN 0 Cross...

Page 82: ...3 3 Screw Names and Illustrations Head Body Washer Top Side 1 Cross recessed 1 Bind 1 Normal 1 Plain washer head Ul P 2 S tight with fjotch mo I i 2 Outside toothed lock washer 2 Pan 3 B tight 0 I Ii m Q 3 Flat b 4 Tapping 3 Spring washer 0 Ob ma 3 s Rev A ...

Page 83: ...instructions in these notes 3 2 1 Replacing the Printhead You can replace the printhead without disassembling the printer Q When you remove theconnectorcover becarefil not to break the tabs Ct When you remove theprinthead cable hohier becarejid not to break thepn ntheadcabi holder latch Use a slotted screwdriver ifnecessay 1 Remove the top cover 2 Pry up the 2 hooks for the head cable cover and re...

Page 84: ...screws securing the pnnthead to the carriage Disengage the printhead with the PW sensor and the masldess holder Ribbon Fee BOARD TRACTOR ASSEMBLY REAR Figure 3 8 Removing the Printhead Q When you install the printhead torque the screws to 8 kglcm 44 lblinch Cl Tighten the screws while pulling the printhead backward to secure the printheadjirmly When you install the printhead perform the platen gap...

Page 85: ...over or any other ptinter components Spread a thick sofl cloth under theprz nter before you follow the steps below Remove the ROMcarejidly to avoid damagn ng the board Before you install a new ROM check the ZNDEXmark on the socket to be sure the ROMis oriented correctly Insert the ROM care filly to avoid damafl ng the ROMp ns and the board 1 Tilt back the printer and lay it on its back Hold the to...

Page 86: ...e person must hold 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 1 Open the top cover 2 While someone supports the top cover remove the4 screws 2 on therightand 2 on the left securing the top cover to the hinges and remove the cover I Figure 3 10 Removing the Top Cover 3 ...

Page 87: ... main switch on the right side cover Figure 3 11 Removing the Left and Right Side Covers When you attach the right side cover connect the cablej om connector CNI on the Cl17power supply board assembly and the cable from the AC inlet to the main sun tch on the right side cover as shown below F Wrse sided the side cover R c c 1 AC rnlet set 1 L ight browI able Light browr cebie I 1 I Cl 17 pxer wppl...

Page 88: ...ure the new fuse meets the printer s AC power specifications CARRIAGE MOTOR 1 Grounding Harries RIGHT Side Figure 3 13 Removing the Fuse 4 Remove the 3 CBB M4 x 10 screws securing the left side of the front cover to the lower cover Then remove the screws on the right side and remove the front cover with the 2 hinges CB Figure 3 14 Removing the Front Cover 3 12 Rev A ...

Page 89: ...Cl17 PNL board assembly and its cable 3 2 3 4 0 0 1111111111111 WI 4 CBB M4x16 Figure 3 15 Removing the Front Panel Removing the Upper Case 1 Remove the front panel Refer to Section 3 2 3 3 2 Disconnect connector CN7 the cover open sensor connector from the C117 MAIN board assembly 3 Remove the 6 CBB M4 x 16 screws and 2 CPS M3 x 8 screws from the upper case and then remove the upper case with the...

Page 90: ...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 x 8 screws from the case op sensor and remove the sensor UPPER CASE reverse CASE OPEN SENSOR Figure 3 17 Removing the Cover Open Sensor side 3 14 Rev A ...

Page 91: ... on the top cover or any other printer components 2 Spreada thick soft cloth under theprinterbefore youjbllow the steps below When you attach the bottompanel make sure theparallel interface cable latch is not caught between the lower case and bottom panel 1 Remove theleftand right side covers Refer to Section 3 232 2 Open the rear cover Remove the4CPB M3 x 12 screws and 2 CPT 0 IWI x 12 screws sec...

Page 92: ...B 0 M4 x 8 screws securing the green and yellow earth cable between the bottom plate of the printer mechanism and the earth plate on the bottom panel assembly 7 Disconnect connectors CN1O CN6 CN7 and CN8 8 Since comector CN9 is fixed to the C117 MAIN board assembly remove the junction connector not labeled with a CN number between the interlock switch and connector CN9 on the C117 MAIN board assem...

Page 93: ...er 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 CBS O Earth Cable M4X8 BO P o I Figure 3 21 Removing the Bottom Psnel Assembly 2 ...

Page 94: ...y 1 1 LC r _L SET v CCN M3x30 CPN 0 M3x8 Removing the Cl 17 Power Supply Cl 17 MAIN Board Assembly 3 2 4 3 Removing the C117 MAIN Board Assembly 1 Remove the bottom panel assembly Refer to Section 3 2 4 1 2 Disconnect connectors CN1 and CN3 3 Remove the 5 CPB M3 x 11 screws and 2 CPN 0 M3 x8 screws securing the Cl17MAIN board assembly and remove the board CN3 CPN 0 M3x8 BOARD ASSY C POWER SUPPLY A...

Page 95: ...toSection3 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 CPB M4x AC INLET SET Figure 3 24 Removing the Earth Plate 4 Remove the 2 CFS M3 x 12 screws securing the AC inlet to the earth plate and remove the AC inlet AC INLET SET Eafih C3 CFS M3x12 Figure 3 25 Removing the AC Inlet Plate Rev A 3 19 ...

Page 96: ...move the front panel Refer to Section 3 2 3 3 2 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 FRONT c117 PNL PANEL Figure 3 26 Removing the C117 PNL Board Assembly 3 20 Rev A ...

Page 97: ...efer to Section 3 23 4 2 Di SCQMeCt the interlock assembly cable from junction comector CN9 on the C117 MAIN 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 3 _ Figure 3 27 Removing the Interlock Switch Assembly c Rev A 3 21 ...

Page 98: ...when you remove or install it U To avoid straining your waist hands or feet place the printer on a low table before following the steps below 1 Remove the interlock switch assembly Refer to Section 3 2 5 2 I move the 3 CBS 0 M4 x 8 screws securing the green and yellow earth cables to the earth plate There are two screws on the left and one on the right 3 Disconnect the cables from connectors CN1O ...

Page 99: ...all the printer mechanism route the cables as shown in Figure 3 30 Make sure the cables do not get caught between the ptinter mechanism and lowercase Inte R 1 11 I I q I I I I I I I PRINTER MECHANISM I I I U 2 J HEAD I I 1 I I I I t J y _J c SM CN9 Fixed SHILD PLATE SHILD PLATE LEFT Side RIGHT Side Figure 3 30 Connecting the Cables When you install the printer mechanism perjorm the follom ng adjus...

Page 100: ... 2 q MOTOR RIBBON FEED MOTOR FRAME CPN M3x6 2 ŒÌ Ž ˆ Œ z Figure 3 31 Removing the Tractor Select Lever 1 4 On the connector junction board assembly disconnect the white 6 pin connector for RF motor control and the yellow 2 pin connector for the tractor select sensor 5 Remove the CPN M3 x 6 screw securing the front rear tractor select lever assembly to the left side frame 6 Remove the RF motor driv...

Page 101: ...e black comector on the RF motor 3 Remove the E ring 3 securing the front rear tractor select lever and remove the lever Remove the E ring 3 securing the tractor select cam and remove the mm 4 Remove the CPS IW2 x 10 screw securing the tractor select sensor and remove the wnsor r c T W S E L E C T o L A A 1 HAG I UH StLtb I LEVER LOWER 1 RIBBON FEED MOTOR FRAME m RIBBON FEED MOTOR i a I CP PS M3x6...

Page 102: ...Assembly DFX 5000 Service Manual T a RIBBON FEED MOTOR FRAME TRACTOR SELECT CAM TRACTOR SELECT GEAR HOLDER El I 1 J TRACTOR SELECT LEVER UPPER and LOWER Figure 3 34 Tractor Select Lever Mounting Position Ill 3 26 Rev A ...

Page 103: ...ard assembly 3 Remove the front rear tractor select lever assembly Refer to Section 3 2 7 1 4 Disconnect the connector for the CR sensor encoder from the FPCboard assembly 5 Remove the 2 CPN M3 x 8 screws securing the FPC cover and remove the cover Then remove the CPB M3 x 6 screw securing the FPC board assembly to the printer mechanism and remove the FPC board assembly 62 J f Connector Board C I ...

Page 104: ...g the PG motor and remove the motor CP PS M3x6 Plate GAP ADJUSTMENT Pinion Gear I GAP SENSOR 1 CPS P M3x6 Figure 3 36 Removing the PG Sensor and PG Motor UWhen 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 backlash LWhen you install the PG sensor join portion A in Figure 3 36 correctly and match the screw a...

Page 105: ...rom the connector junction board assembly and remove the plunger cable from the connector junction board assembly Refer to the Appendix for more intimation on the connector junction board able connections 2 Remove the 2 CPS SP M3 x 6 screws securing the plunger to the left side frame and remove the plunger 3 Remove the iron core of the plunger from the paper bail shaft Iron core 1A CPS SP M3x6 Fig...

Page 106: ...with its washer 7 While lifting the paper bail assembly on the right side remove the paper bail gear you can remove it easily by gently lifting the clip with tweezers 8 Remove the E ring at the right side of the paper bail shaft Then remove the paper bail lever paper bail balance lever leaf spring and shaft holder 9 Remove the paperbail assembly PLATEN ROL ER SHAFT HOLDER 9 PAPER BAIL LEVER 9 TENS...

Page 107: ... GUIDE CPS M4x6 Figure 3 39 Removing the Top PE Sensor 3 2 7 7 Removing the Tension Roller Shaft This section describes how to remove the tension roller shaft It is easiest to remove the tension roller shaft when the paper bail assembly is removed however removing it is not required Refer to Section 3 2 7 5 for instructions on how to remove the paper bail assembly c 1 Remove the comector junction ...

Page 108: ...pull out the platen roller shaft holder with its leaf spring and washer R 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 Figure 3 42 Removing the Tension Roller Shaft 3 32 Rev A ...

Page 109: ... right and remove the paper guide from the platen l e lower paper guide consists of three parts PLATEN HOLDER LEFT PLATEN HOLDER RIGHT Figure 3 43 Removing the Platen Wen you attach the lower paper guide to the platen start with the ieft most part of the paper guide and work toward the right Wwn you install the platen perform the follom ng adjustments Carriageguide shajlparallelism adjustvnent des...

Page 110: ...e the CPN SP M4 x 7 screw securing the left part of the lower paper guide to the platen Figure 3 44 Removing the Left Part of Lower Paper Guide 3 Unhook the paper jam sensor magnetic transistor cover and remove the cover 4 Remove the paper jam sensor OR PAP COVER LOWER P PER GUIDE LEFT Figure 3 45 Removing the Paper Jam Sensor When you attach the paper jam sensor to the right part of the lower pap...

Page 111: ...emove 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 CPN SP M2x14 SENSOR ASSY PULL TRACTOR PLATEN HOLDER RIGHT Hexagon Nut Figure 3 46 Removing the Pull Tractor Sensor 3 2 7 11 Removing the Paper MMth PW Sensor 1 Remove theprinthead Refer to S ion3 2 1 2 Remove the CPN SP M2 x 6 screw securing the PW sensor to the m...

Page 112: ... ring securing the carriage guide shaft gear to the rear carnage guide shaft IDE IDE Figure 3 48 Removing the Carriage Guide Shaft Gear 3 Discomect the white 2 pin PG home sensor comector from the comector junction board assembly 4 Detach the hook securing the PG home sensor and remove the sensor ACTOR SELECT NSOR 2 pin white l J AT MtiTOR Figure 3 49 Removing the PG Home Sensor ...

Page 113: ... PF Motor 1 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 Remove the PF motor from the inside of the left side frame P j i Figure 3 50 Removing the PF Motor Rev A 3 37 ...

Page 114: ...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 Remove the series of gears in the order indicated by the numbers in Figure 3 51 lo 12 Figure 3 51 Removing the Left Side Frame Gears 3 38 Rev A ...

Page 115: ... remove the right tractor wire spring holder set 4 To release the tractor wire remove the CPN M4 x 8 screw securing the left tractor wire spring holder set to the left side frame 5 Remove the E ring Securing thestmftat the back of the front tractor assembly to the left side frame 6 To remove the front tractor assembly first move it to the left Remove the right side of the shaft by pulling it forwa...

Page 116: ...ning the hexagonal nut on the right side remove the right tractor wire holder 5 To release the tractor wire remove the CPN M4 x 8 screw securing the left tractor wire spring wire set to the left side frame Refer to Section 3 2 7 15 6 Remove the 2 E rings securing the shaft at the back of the rear tractor assembly to the both sides frame 7 To remove the rear tractor assembly first move it to the le...

Page 117: ...rom the white 2 pin connector on the connector junction board assembly and unhook the CR motor cables at the base frame of the printer mechanism 5 Remove the 3 CBS SP M4 x 10 screws securing the CR motor to the right side frame and remove the motor CBS c Figure 3 55 Removing the CR Motor Nomuwnukwc g 1 When you install the CR motor perform the cam age timing belt tension adjustment as described in...

Page 118: ...ove the printhead Refer to Section 3 2 1 2 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 Figure 3 56 Removing the CR Sensor 3 42 Rev A ...

Page 119: ...g the encoder belt to the right side frame Loosen the hexagonal nuts securing the front carriage guide shaft to the left and right side frames Remove the front carriage guide shaft by pulling it through the hole in the right side frame When you remove the front carriage guide shaft move the carriage to the left side On the left side frame remove the E ring securing the carriage guide shaft gear to...

Page 120: ... Right Side Frame 10 Remove the rear carriage guide shaft with the carriage base from the right side frame When you install the front carriage guide shafl tighten the screws while pushing the shaft toward the platen When you assemble the cam age mechanism perform the following adjustments Q Carriage timing belt tension adjustment described in Section 4 1 2 D Carriage guide shaft parallelistn adjus...

Page 121: ...or value platen gap adjustment described in Section 4 1 7 Q Bidirectional printing adjustment described in Section 4 1 8 3 2 7 21 Removing the Platen Roller 1 Remove the platen Refer to Section 3 2 7 8 2 Remove the CRmotor Refer to Section 3 2 7 17 3 Remove the left side frame gears Refer to Section 3 2 7 14 4 Referring to the exploded diagram in the Appendix remove the platen roller When you inst...

Page 122: ...4 8 4 1 8 Bi Directional Printing Adjustment 4 10 Figure 4 1 Figure 4 2 Figure 4 3 Figure 4 4 Figure 4 5 Figure 4 6 Figure 4 7 Figure 4 8 Figure 4 9 List of Figures Platen Gap Motor Backlash Adjustment 4 1 Carriage Timing Belt Tension Adjustment 4 2 Tractor Wire Tension Adjustment 4 3 Pull Tractor Sensor Position Adjustment 4 3 Parallelism Adjust Lever 4 4 Dial Gauges and Dial Gauge Base Attachmen...

Page 123: ...stment the PG motor pinion gear must mesh smoothly with the carriage guide shaft gear cog If the pinion gear is poorly aligned or the pinion gear and cog are too tight printer operation is noisy or the character density is incorrect 1 Loosen the 2 screws securing the PG motor to the left side frame Refer to Section 3 2 7 4 2 Make sure the PG motor pinion gear is properly aligned with the carriage ...

Page 124: ...al direction 1 2 3 4 5 6 7 Refer to Figure 42 and loosen the 3 tension adjustment screws on the CR motor Loosen the screws but do not remove them Confirm that the carriage timing belt is attached properly and that no load is applied to it Insert the tension gauge hook through the hole in the tension lever Refer to Figure 42 Pull the tension gauge horizontdy to apply a 4 kg 8 8 lb force Move the be...

Page 125: ...s apart Refer to Figure 4 3 Ala IL S I x 04 Gdd Sesl C mm Tractor Wire Tension Spring Tractor Wire Tension Spring Figure 4 3 Tractor Wire tension Adjustment 4 1 4 Pull Tractor Sensor Position Adjustment This section desaibes the pull tractor sensor position adjustment If the sensor position is incorrect the sensor is always on When you replace or disassemble the platen rear paper guide platen roll...

Page 126: ...usted so that the difference between the distances from the rear carriage guide shaft to the platen measured at the two positions shown in Figure 4 7 is less than 0 01 mm 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 ...

Page 127: ... so that the tips of the gauges portions A and B in the Figure 47 are securely attached to the platen 8 Measure the distance between the platen and the carriage guide shaft on the Ie side Then measure the distance between the platen and the carriage guide shaft on the right side and compare these values Figure47 shows the measurement position and the parallelism adjust lever operation L 4 Pull Fig...

Page 128: ...HOLDER LEVER RIGHT 0 GUIDE SHAFT HOLDING SPRING v Q Jw b CP PS M4x6 CARRIAGE MOTOR HOLDER CBS 0 Screw M4x8 Figure 4 9 Parallelism Adjust Lever Operation Note The carnage guide shaft moves as shown in Figure 4 8 When the parallelism adjust lever 10 11 12 is moved i e direction of the black arrow the distance between the right side of the platen and print head nose narrows a little bit Repeat step 7...

Page 129: ...ances from the rear carriage guide shafi to the platen measured at the two positions shown in Figure 4 7 is less than 0 01 mm 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 B1019467 L1 Dial gauge master ...

Page 130: ...gauge needle to the master surface Figure 4 12 Attaching the Another Dial Gauge 4 To eliminate any play between the dial gauge base and the dial gauge master pull the tie band to secure the dial gauge base and the dial gauge master before you securing the thumb screws Do procedure with two men 5 Then set the black marker to the O position v v Figure 4 13 Setting the Black Marker to O Position 4 8 ...

Page 131: ...es 11 12 Figure 4 14 Loosen the 2 Hexagonal Screws Remove the print headwith the maskless holder as described in section 3 2 1 Then attach the dial gauge base with two dial gauges in the same way as you attach the print head When you attach the dial gauge base to the carriage secure two thumbscrews while you pulling the tie band forward you to hold the tool securely Using the platen gap drive gear...

Page 132: ...ing the Angle Difference If the angle difference of two values are more than 0 015 mm loosen but do not remove the two hexagonal screws securing the platen stay to both side frames then change the platen angle manually Tighten two hexagonal screws securing the pIaten stay to both side frames After perform the adjustment confi rm the value of platen parallelism again When this value is out of order...

Page 133: ...nged this parameter that there is just reason for it 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 B765114601 Do not tum the printer oflduringadjustment When adjusting the platen gap to narrower or wider using ...

Page 134: ... ALPHA value written to the memory by pressing the LF FF switch The buzzer beeps each time the MICRO FEED switch is pressed and if the value incorrect return to Step 5 After writing the ALPHA value in the memory press the PAUSE switch At this time the adjustment state shifts to the BETA value adjustment Remove the ribbon cartridge Reset the BETA value pressing the TEAR OFF and MICRO FEED v switche...

Page 135: ... e purpose of this adjustment is to correct the printer mechanism parameters which control bidirectional printing Be sure to perform this adjustment when required If this adjustment is not performed correctly bidirectional printing may be misaligned or in the worst case the carriage might operate incorrectly Before performing this adjustment be sure to that the following adjustment are completed c...

Page 136: ...press the LF FF switch to print the current flying value automatically by NLQ mode The nple pattern H that is stkctured by 4 rows is printed automatically 8 Write the flying time value into the memory Press the MICRO FEED A switch to shift an even number toward left Press the MICRO FEED v switch to shift an even number toward right 9 Press the PAUSE switch and then press the LF FF switch to print ...

Page 137: ... MECHANISM 5 24 List of Figures Figure 5 1 Bypassing the Interlock Switch 5 2 Figure 5 2 Bypassing the Cover Open Sensor 5 2 Figure 5 3 Printhead Coil Resistance 5 3 List of Tables Table 5 1 Error Codes 5 1 Table 5 2 Motor Fan Plunger and Printhead Coil Resistance 5 3 Table 5 3 Symptoms and Reference Pages 5 4 Table 5 4 Cl 17 PSB PSE Board Assembly Main Parts List 5 13 Table 5 5 C117 PSBIPSE Board...

Page 138: ...sets of 4 beeps Cl The printer detects a paper jam jam QThe front rear or top PE sensor is broken QThe paper is out at power on 3 beeps Other paper error Q The printer backs out paper but the previous print job is not tom off 5 beeps with a pause Abnormal voltage t3 The voltage of the Cl 17 power suppl between each beep board assembly is too low 5 sets of 2 beeps Incorrect RAM Q Incorrect RAM is d...

Page 139: ...ve the top cover and close the left cover hinge Inter Lock Switch CASE OPEN SENSOR j h r I I I I I I I I I n I I I UI k I iARDhW Connector I Junction I B o a r d CN8 c 47 CNIO P R I N T E R M E C H A N I S M CN9 Fixed SHILD PLATE Figure 5 1 Bypassin9 the Interlock Switch 1 HEAD To bypass the cover open sensor remove the left side cover disco the cable from CN7 on the C117 MAIN board assembly and j...

Page 140: ...85 ohms f 0 3 ohms at 25 C 77 F I RF motor 150 ohms 10 ohms at 25 C 77 F 1 I PG motor 250 ohms 18 ohms at 25 C 770F I I Head fan 61 ohms f4 30hmsat25 C 77 F I Plunger I 90hms 0 450hmsat25 c 77oF I Printhead 8 1 ohms f 0 8 ohms at 25 C 77 F I FPC1 I FPC1 I Q NC T1 T 2 A c B l c1 C2 8 C3 C4 C5 C6 9 5 Fan motor Driver Head Q n Machaniam and aanaor Haad Note 1 9 Head coil Cl C2 Common 2 4 6 C3 C6 Comm...

Page 141: ...es 4 Control panel operation is QWhen the LF button is pressed no paper is fed abnormal I 5 Data sent by the host QThe carriage operates normatly at power on and the computer is printed self test is printed correctly but print data from the 6 incorrectly host computer is not printed cofrectly Note Be sure to perform the appropriate adjustments below 1 When you replace the C117 MAIN board assembly ...

Page 142: ... L Measure the output voltage from the Cl 17 power supply board Replace the Cl 17 power supply board Yes Check all motors solenoid printhead and drwers using a multlmeter Retest No Replace bad motor solenoid or b printhead If driver also is bad replace at the same time Replace the Cl 17 MAIN board Yes See Section 5 5 to repair the printer mechanism END 5 5 Rev A ...

Page 143: ...If drivers are bad replace at the same time Yes Replace the Cl 17 MAIN board I L__ Refer to Section 5 5 Repair of the Printer Mechanism Perform repair necessary No END NOTE 1 Check the following connectors CN9 Cl 17 MAIN board to interlock switch CN6 Cl 17 MAIN board to FPC to junction board CN1O Cl 17 MAIN board to CR encoder Junction board connector to CR motor r 5 6 Rev A ...

Page 144: ...st Yes Are the connectors inserted securely 4 No v Check printhead cable continuity Visually check printhead pins Replace any bad part 4 fault corrected I Perform the bidirectional I I 17 E N D NOTE 1 Check the followin connectors i 1 CN6 Cl 17 MAI board 2 Four connectors on the connector junction board in the printer mechanism Rev A s 7 ...

Page 145: ... drivers are OK replace the N If the printhead drivers printhead are OK replace the Yes Replace the printhead and Cl 17 MAIN board v Replace the Cl 17 MAIN board L I I Yes the p t OK No Refer to Section 5 5 Repair of the Printer Mechanism Refer to Section 5 5 Repair of the Printer Mechanism NOTE1 Check the followin connectors 1 CN6 Cl 17 MAI board 2 Four connectors on the connector junction board ...

Page 146: ...roubleshooting 3 Camiage operation is normal but the self testis printed incorrectly continued Perform bidirectional adjustment Go back to Section 5 5 Repair of the Printer Mechanism and check for other problems e END Rev A 5 9 ...

Page 147: ...e resistance of the PF motor coils and check the PF motor drivers drivers shorted or Perform final printing of self test Perform final printing of self test I o Is the No print OK 7 END J Refer to Chapter 4 and perform the PG I motor backlash x I adjustment END Yes K7 END Refer to Section 5 5 Repair of the Printer Mechanism e Is the No print OK Refer to Chapter 4 and perform the PG motor backlash ...

Page 148: ...between the C 117 MAIN Reinsert connector CN8 Yes correctly I 1 I 4 No Yes v Using a m ultim eter check v the switches on the Cl 17 PNL board Yes Replace the Cl 17 MAIN board No Replace the Cl 17 PN L board Yes v Replace the Cl 17 PNL board I Yes Replace the Cl 17 MAIN board Rev A 5 11 ...

Page 149: ...est I No Troubleshoot printer using the previous flowcharts Built in Parallel Check the cable connection from the host computer No Set switches correctly No cable under 6 and does it work with another No b v Replace Cl 17 MAIN board Replace cable Replace Cl 17 MAIN board optional IF for a network is No the network confgure Reconfigure network Replace Type B interface c J i h j 5 12 Rev A ...

Page 150: ...pair the printer using the instructions in this column Table 5 4 C117 PSB PSE Board Assembly Main Parts List Location Name Description IC151 TL494 PWM switching controller IC152 A B NJM2903 Comparator IC voltage drop monitor for the two 35 VDC lines Q101 K1 531 Main switching FET Q201 K1531 Main switching FET Table 5 5 C117 PSB PSE Board Assembly Component Repair Symptom Cause Checkpoint Solution ...

Page 151: ...103 or Q203 is defective Checkpoint Check the voltage waveform between the drain side and GND r I i I 1 L I I I I 1 I 1 1 1 1 I 1 1 Observe the voltage waveform between the collector side and GND I I 1 I I I I LIV14YW w 1 1 1 L w A Check the voltage waveform between the collector side and GND I I I I I MV14W I I I I WY 2LS I ATI O OU I Solution Replace Q101 or Q201 Replace Q101 or Q201 aca 2103 or...

Page 152: ...DFX 5000 Service Manual Troubleshooting Table 5 5 C117 PSB PSE Board Assembly Component Repair continued Rev A 5 15 ...

Page 153: ...Ttvublestmting mx 60 Serv ce Ahmu8J Table 5 5 C117 PSBIPSE Board Assembly Component Repair continued 6 16 Rev A ...

Page 154: ...AIN Board Assembly Component Repair Symptom Cause Checkpoint Solution The printer The DRERR signal Measure the voltage level of the Replace the does not was sent to the Cl 17 DRERR signal at CN1 or check the head driver operate at all pwer SUPPIY board head driver IC S voltage waveform a HIGH level turns off the power supply The VPC signal Check the voltage waveform for the Replace the HIGH level ...

Page 155: ...Troubleshooting DlW50 Service Wnual Table 5 6 C117 MAIN Board Assembly Component Repair continued u 5 18 Rev A ...

Page 156: ...als for the carriage motor phases at pins 108 109 110 and 111 of IC7 Check the signals for the carriage motor phases at pins 9 and 11 of QM1 I dw 1 5 W LI r 741 e 1 SAv E i 20V Measure the voltage level at pins 9 anc 11 of IC QM1 when the carriage is perating The normal voltage level is mxxoximatelv 35 VDC observe the switching waveform oetween the base side and the mllector side of Q3 or Q6 Solut...

Page 157: ...k of motor torque Checkpoint Observe the carriage encoder sensor output signal at pins 3 and 4 of CN1 O Check the switching waveform for Q4 Q7 and Q8 Obsme the feedback signal at pin 101 IC1 O that detects the current in the carriage motor asure the voltage level at pin 3 of C1O The normal wltage is ipproximateiy 4 7 VDC Solution Replace the carriage encoder sensor Replace the abnormal transistor ...

Page 158: ...DFX 5000 Service Manual Troubleshooting Table 5 6 C117 MAIN Board Assembly Component Repair continued Rev A S 21 ...

Page 159: ...Troubleshooting DF 50tM Service Manual Table 5 6 C117 MAIN Board Assembly Component Repair continued k f L J s 22 Rev A ...

Page 160: ...ly Cause IC7 is defective The head driver FETs are defective The CPU is defective Checkpoint Observe the output signal at pins 129 137 of IC7 Observe the voltage waveform at the drain side B VI Uv Observe the PTS signal at pin 15 of the CPU LIVH j2QV AT l 92ms SAVE F 5V 1 Solution Replace IC7 Replace the abnormal FET Replace the CPU Rev A S 23 ...

Page 161: ...e encoder beft in the mechanism The CR motor is Measure the coil Replace the CR motor defective resistance of the CR motor It should be approximately 6 2 ohms The carriage timing Manualiy check the Perform the carriage belt is defective carriage timing Mt timing belt tension tension adjustment as described in Section 4 1 2 The carriage guide Check whether the Perform the carriage shaft parallelism...

Page 162: ...lodged in the paper paper path substances not feed paper or path does not feed it The PF motor is not Check whether the Check backlash correctly driving the gear PF motor pinion gear between PF motor properly rotates smoothly pinion gear and paper when rotated feed reduction gear manually The PF motor is Measure coil Replace the PF defective resistance for the PF motor and if motor The correct dri...

Page 163: ...adjust manually the backlash between the PG motor pinion gear and the carriage guide shaft gear as described in Chapter 4 A strnenfs The PG sensor is Check the output Replace the PG defective signal of the PG sensor sensor Refer to Table 5 6 The encoder plate is Check whether the Replace the PG motor defective encoder plate is or clean the encoder broken or stained plate The PG home sensor Check t...

Page 164: ...m the tractor becomes crumpled at the tractor wire spring between the frame wire spring tension the front or rear is incorrect and the seal securing adjustment as tractor assembly the white line should described in Section be about 3 mm 4 1 3 12 inches The tractor select The tractor select Check the continuity Replace the tractor front or rear function sensor is defective of the tractor select sel...

Page 165: ...st of Figures Figure 6 1 Correct Adhesive Application 6 3 Figure 6 2 Lubrication and Adhesive Diagram 1 6 3 Figure 6 3 Lubrication and Adhesive Diagram 2 6 4 Figure 6 4 Lubrication and Adhesive Diagram 3 6 5 List of Tables Table 6 1 Lubricants and Adhesive 6 1 Table 6 2 Lubrication Points 6 2 Table 6 3 Adhesive Application Points 6 2 ...

Page 166: ...ON AND ADHESIVE APPLICATION EPSON recommends that the printer be lubricated at the points illustrated in Figures 6 2 6 3 and 6 4 using EPSON lubricants 02 and G26 These lubricants have been extensively tested and found to comply with needs of the printer Refer to Table 6 1 for information on lubricants 02 and G26 Table 6 2 lists the appropriate lubricant for each point Make sure the parts to be lu...

Page 167: ...6 2 Shafts of paper feed gears shafts on the left frame G26 02 11 6 2 Paper feed gears gears on the left frame G26 12 6 2 Ter on pulley pulley shaft and hook for the tension pulley spring G26 13 6 3 Fulcrum point for the paper bail shaft and plunger G26 14 6 4 Platen gap motor pinion 15 6 3 Carriage guide shaft gear G26 16 6 3 Ribbon feed gears G26 17 6 3 Tractor select cam Tabie 6 3 Adhesive Appl...

Page 168: ...DFX 5000 Sewice Manual Maintenance and Lubrication i Figure 6 1 Correct Adhesive Application 11 T 12 Figure 6 2 Lubrication and Adhesive Diagram 1 Rev A 6 3 ...

Page 169: ...6 4 Rev A ...

Page 170: ...DFX 5000 Sewice Manual Maintenance and Lubrication In Figure 6 4 Lubrication and Adhesive Diagram 3 Rev A S 5 ...

Page 171: ...oded Diagram 2 A 16 Figure A 8 DFX 5000 Exploded Diagram 3 A 17 Figure A 9 DFX 5000 Case Outline Drawing A 18 List of Tables Table A 1 Connector Summary A 2 Table A 2 CN1 Cl 17 MAIN Board Assembly A 3 Table A 3 CN2 Cl 17 MAIN Board Assembly A 3 Table A 4 CN3 Cl 17 MAIN Board Assembly A 3 Table A 5 CN4 Cl 17 MAIN Board Assembly A 4 Table A 6 CN5 Cl 17 MAIN Board Assembly A 4 Table A 7 CN6 Cl 17 MAI...

Page 172: ... 3 5V 0 0 0 0 0 To CR motor A 1 1 GND 2 PGA 3 PGB 4 5V 1 PG COMMON 2 PG COMMON 3 PG phase D 4 PG phase C 5 PG phase B 6 PG phase A L 1 RF COMMON 2 RF COMMON 3 RF phase D 4 RF phase C 5 RF phase B 6 RF phase A r I I ml 2 lhL 1 Tractor select signal 2 GND h PGHP I 2 GND L 64 pin cable L_ 1 _ Connector unc ion oard Cl 17 Main Board ...

Page 173: ...r I I Interlock Switch CR Motor 35 VDC ON OFF 1 v CR Sensor Cooling Fan Carriage Encoder Ac nlet in Lower Case Standard Centronics Parallel Interface la Gil gpifls CN3 2 pins 2 pins 8 pins CN2 4pins n CNl 2 pins 2 pins 22 pins Cl 17 MAIN Board Assembly n n CN1 9 pins n m g CN3 8 pins Serial Interface u Type B Optional Interface CN6 J Printer Mechanism Control Control for the motors printhead and s...

Page 174: ... fan tenprature Cl PG sensor Q PW sensor CN6 Q Front rear or top PE sensor 64 A 7 Cl Paper jam sensor Cl PG home sensor Q Tractor select sensor Q Pull tractor sensor Q Printhead temperature sensor Cl Printhead coil driver signal CN7 Connector for the signals from the cover open 2 sensor A 8 Connector for the signals from the Cl 17 PNL CN8 d A 9 CN9 Connector for the interlock switch 2 A 10 CN1O Co...

Page 175: ...ce 1 I I 6 7 1 i GND I Ground for logic 8 9 I I I 5 I Power source for logic Table A 3 CN2 C117 MAIN Board Assembly Pin No 1 0 Name Description 1 0 REV Reverse same function as DTR 2 0 DTR Data terminal ready 1 3 I RXD Receive data 1 1 4 0 I TXD Transmit data 5 NC Not connected 6 SG Signal ground 1 I I 7 FG Frame ground Table A 4 CN3 C117 MAIN Board Assembly Pin No 1 0 Name Description 1 2 I 35A F...

Page 176: ...t 16 0 m Wriie signal input 17 0 m Read signal input 18 0 Chip select signal input I 19 24 GND Ground 25 28 0 A3 AO Address output 29 36 1 0 D7 DO Data bus a 1 I 2 9 1 0 10 0 11 0 12 0 I 13 0 I 14 I I 15 34 t 16 1 30 17 31 I 32 0 18 35 I Table A 6 CN5 Cl 17 MAIN Board Assembly Name Description STRBX I Strobe signal input DATA1 8 I Data input output ACK Acknowledge signal output I BUSY I Busy Signa...

Page 177: ...C signal output 44 45 I PENCA PENCB PG sensor data input 1 4 0 FANA FANB Head fan motor driver signal output I I I 2 I O I FANCOM I Head fan motor common 63 64 I O I PFCOM I PF motorcommon 56 60 o I PFA PFD I PF motor phase signal output 34 0 RFCOM RF motor common 36 38 35 0 RFA RFD RF motor phase signal output 3 I HMP Head fan motor temperature detection data input 26 I PWID Paper width detection...

Page 178: ...loaded output green 8 0 10CPIL 10 cpi PITCH LED output 9 0 FRRLP FRONT LED paper out output red 10 0 POUTLP PAPER OUT LED Ol Ut 11 0 TOFLP TOP OF FORM LED Output 12 0 PAUSEL PAUSE LED OUtpUt 13 I LFFFSW LF FF button input 14 i MFBSW Backward MICRO FEED button input 15 I PSELSW PAPER SELECT button input 16 I MFFSW Forward MICRO FEED button input 17 I PITCH PITCH button input 18 I TEARSW TEAR OFF bu...

Page 179: ...35 VDC 7 8 I o I I 35 VDC for the main board for three of the nine 35V 2A printhead pins 2 4 and 6 and the motors I Table A 14 CN3 Cl 17 PSB PSE Power Supply Board Assembly Pin No 1 0 Name Description 1 I VPC OK for 35 VDC voltage output used in conjunction with DRERR 2 I DRERR Driver error signal to prohibit 35 VDC voltage head driver broken 3 0 CLIMIT Voltage drop detection signal sent to main b...

Page 180: ...DFX 5000 Service Manual Appendix O I 1 T I I J I Figure A 3 C117 PSB Board Assembly Circuit Diagram Rev A A 1 1 ...

Page 181: ...Appendix DFX OOO Service Manual I P I I 1 1 I I 1 1 1 I I i I Figure A 4 C117 PSE Board Assembly Circuit Diagram A 1 2 Rev A ...

Page 182: ...DFX 5000 Service Manual Appendix A 3 CIRCUIT BOARD COMPONENT LAYOUT CI06 HMZ7CIO AG 12 2 I 41 8 Figure A 5 C117 MAIN Board Assembly Component Layout Rev A A 13 ...

Page 183: ...Appendix DFX 5000 Service Manual MODEL EPS 1 S u mTN 15 54 n w C w C I i 7 PSE _ CflK C2X A D N4 C eo Figure A 6 C117 PSB PSE Board Assembly Component Layout A 14 Rev A ...

Page 184: ...Appendix Dl 5000 Service Manual A 5 CASE OUTLINE DRAWING i L J Figure A 10 rim L J DFX 5000 Case Outline Drawing A 1a Rev A ...

Page 185: ...Cerdanyola del Vanes 20099 Sesto S Giovanni Ml Italy Barcelona Spain Phone 02 262331 Phone 582 15 00 Fax 02 2440750 Fax 582 15 55 EPSON AUSTRALIA PTY LTD EPSON SINGAPORE PTE LTD 1 70 Gibbes Street No 1 Raffles Place 26 00 Chatswood 2067 NSW Australia OUB Centre Singapore 0104 Phone 02 415 9000 Phone 5330477 Fax 02 417 0077 Fax 5338119 EPSON HONG KONG LTD EPSON ELECTRONICS TRADING LTD 20 F Harbour ...

Page 186: ...EPSON ...

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