Epson DFX-8500 manual

EPSON IMPACT SERIAL DOT MATRIX PRINTER DFX-8500 SERVICE MANUAL SEIKO EPSON CORPORATION 4009310[...]

ii NOTICE  All rights reser ved. Reproduction of any part of t his manual in any for m whatsoever without SEIKO EPSON’s express written permission is forbidden.  The contents of this manual are subjects to change without notice.  All eff ort s have been made to ensure the accuracy of the content s of t his manual. However, shoul[...]

iii PRECAUTIONS Precautionary notations throughout the text are categorized relative to 1) personal injur y and 2) damage to equipment. WARNING Signals a precaution whic h, if ignored, c ould res ult in serious or f atal per sonal inj ury. Great caution s hould be exercis ed in perf orm ing pr ocedures preceded by WARNING Headings. CAUTION Signals [...]

iv PREFACE This m anual desc ribes func tions, theory of electrical and m echanical oper ations, maintenanc e, and repair of DFX-8500. The inst ructions and pr ocedures inc luded herein are intended for the exper ience r epair tec hnician, and attention should be given to die precautions on the preceding page. T he Chapters ar e organized as follow[...]

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.[...]

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[...]

CHA PTER 1 GENERA L DESCRIPTION 1.1 FEA TURES............................................................................................................. 1-1 1.2 SPECIFICA TIONS .................................................................................................. 1-3 1.2.1 Printing Specification .......................................[...]

1.5.4 C204 DRV-B Board ................................................................................................................ 1-41 1.5.5 C204 SUB Board.................................................................................................................... 1-41 1.5.6 C204 PSB/PSE Board...........................................[...]

GENERAL DESCRIPTION Rev . B 1- 1 1.1 FEA TURES The DFX -8500 is a 18-pin, s er ial, dot m atrix printer with a m axim um speed of 1 120 characters per s ec ond (cps) . It is designed for bus iness us e and provides high- speed, high- volum e printing and c ontinuous -s heet handling. The m ain f eatures of the printer are:  Maxim um printing [...]

DFX-8500 Rev . B 1-2 The f ollowing table shows options. T able 1-1. Option Code Name #8766 Ribbon cartridge #8767 Ribbon pack #8309 Pull tractor unit C81500X Paper cutter C81507X Perforation c utter C82305* Serial interfac e card (inc h screw) C82306* Serial interfac e card (m m s crew) C82307* 32-KB intelligent serial I/F c ard (inch s crew) C823[...]

GENERAL DESCRIPTION Rev . B 1- 3 1.2 SPECIFICA TIONS This s ection desc ribes the s pecific ations for DFX-8500. 1.2.1 Printing Specification  Print method : Impac t dot m atrix  Number of pins : 18-pin (Ref er to Figure 1-2.)  Print pin arrangem ent : 9 x 2  Print pin diam eter : 0.01 14 inches (0.29 m m )  Color : Bl[...]

DFX-8500 Rev . B 1-4  Resolution: Refer to T able 1-3. T able 1-3. Resolution Print M ode Horizontal Density V ertical Density A djacent Dot Print High speed draf t 90 dpi 72 dpi No Draft 120 dpi 72 dpi No Draft c ondensed 240 dpi 72 dpi No Draft em phasized 120 dpi 72 dpi Y es NLQ 240 dpi 144 dpi No Bit image 60, 72, 80, 90, 120 or 144 dpi 7[...]

GENERAL DESCRIPTION Rev . B 1- 5  Character tables and ty pe faces : Refer to T able 1-4. T able 1-4. Character tables and type faces Character T able Bitmap Font Standard version Italic T able EPSO N Draft PC437 (US, Standard Europe) EPSON Rom an PC850 (Multilingual) EPSON Sans Serif PC860 (Portuguese) PC861 (Icelandic) PC863 (Canadian Frenc[...]

DFX-8500 Rev . B 1-6 1.2.2 Paper Feeding  Feeding method: Push tractor feed (f ront / rear) Push and pull tractor feed (f ront / rear)  Feeder: Front push trac tor , rear pus h tractor , pull trac tor (option)  Paper insertion s ide alignment :  Left  Paper path: Tractor (f ront in, rear in, top out)  Line s pacing:[...]

GENERAL DESCRIPTION Rev . B 1- 7 1.2.6 Safety A pprovals  120 V version:  Safety standards : UL1950 with D3 CSA C22.2 No.950 with D3  EMI : FCC part 15 subpar t B class B CSA C108.8 class B  230 V version:  Safety standards : EN60950 (VDE, NEMKO)  EMI : EN55022 (CISPR pub.22) clas s B AS / NZS 3548 class B 1.2.7 [...]

DFX-8500 Rev . B 1-8 1.2.11 Printable area  Continuous paper : Refer to Figure 1-3. WX Y Z ABC D ABC D W XYZ ABC D W XYZ LM RM BM TM PL PW . Continuous Paper PW (width) Refer to Sec tion 1.2.12. PL (length) Refer to Sec tion 1.2.12. LM (left m argin) 13 mm to 31m m RM (right m argin) 13 mm or mor e TM (to p ma rg in ) 2. 6 mm o r mo re B M (b[...]

GENERAL DESCRIPTION Rev . B 1- 9  Labels : Refer to Figur e 1-4. LM RM BM TM PL PW Label Label Label Label . Continuous Paper PW (width) Refer to Sec tion 1.2.12. PL (length) Refer to Sec tion 1.2.12. LM (left m argin) 13 mm to 31m m RM (right m argin) 13 mm or mor e TM (to p ma rg in ) 2. 6 mm o r mo re B M (b ot to m marg in ) 4. 2 mm o r m[...]

DFX-8500 Rev . B 1-10  Continuous for ms with labels : Refer to Figur e 1-5. ABC D W XYZ LM RM BM TM PL PW P r i nt abl e A r ea LO L R O L Label BO L TO L LF L R F L Label BF L TFL Label N on P r i nt abl e A r ea Continuous Paper PW (width) Refer to Sec tion 1.2.12. PL (length) Refer to Sec tion 1.2.12. LM (left m argin) 13 m m to 31m m RM [...]

GENERAL DESCRIPTION Rev . B 1- 11  Overlapping m ulti-part f orm s : Refer to Figur e 1-6. LM P er f or at i ons C a rri e r PW PL NA OL BM TM RM Continuous Paper PW (width) Refer to Sec tion 1.2.12. PL (length) Refer to Sec tion 1.2.12. LM (left m argin) 19 mm to 31m m RM (right m argin) 19 mm or mor e TM (top m ar gin) 21.2 mm or mor e B M [...]

DFX-8500 Rev . B 1-12 1.2.12 Paper and M edia 1.2.12.1 Continuous paper (Single sheet and multi-part) T able 1-5. Continuous Paper Front Entry Rear Entry Minimum M aximum M inimum Maximum Wi d t h ( i n c h ) (mm) 4.0 101 16.0 406 4.0 101 16.0 406 Length (inch) (mm) 4.0 101 17.0 431 4.0 101 17.0 431 Copies 1 original + 6 copies 1 original + 5 copie[...]

GENERAL DESCRIPTION Rev . B 1- 1 3 Figure 1-8. Paper-stapling Height Fi g ure 1-9. Pa p er-sta p lin g Method 1 Figure 1-10. Paper -stapling Method 2[...]

DFX-8500 Rev . B 1-14 1.2.12.2 Labels T able 1-6. Labels Front Entry Rear Entry Minimum Maximum Minimum M aximum Label Size Refer to Figure 1-1 1. - Back ing Sheet W idth (inch) (mm) 4.0 101 16.0 406 -- Back ing Sheet Length (inch) (mm) 3.5 89 17.0 431 -- Label Thic knes s (inch) (mm) 0.0 0.0 0.0047 0.12 -- T otal Thick nes s (inch) (mm) 0.0025 0.0[...]

GENERAL DESCRIPTION Rev . B 1- 1 5 1.2.12.3 Continuous Forms with Labels T able 1-7. Continuous Forms w ith Labels Front Entry Rear Entry Minimum Maximum Minimum M aximum Label Size Refer to Sec tion 1.2.12.2. - Wi d t h ( i n c h ) (mm) 4.0 101 16.0 406 -- Length (inch) (mm) 4.0 101 17.0 431 -- W eight (not m ulti-part) (g/m 2 ) (lb) 52.6 14 82.7 [...]

DFX-8500 Rev . B 1-16 1.2.12.4 Overlapping Multi-part Form T able 1-8. Ov erlapping Multi-part Form Front Entry Rear Entry Minimum Maximum M inimum Maximum Wi d t h ( i n c h ) (mm) 4.0 101 16.0 406 -- Length (inch) (mm) 4.0 101 17.0 431 -- W eight (not m ulti-part) (g/m 2 ) (lb) 52.6 14 82.7 22 -- W eight (one sheet of multi- part) (g/m 2 ) (lb) 4[...]

GENERAL DESCRIPTION Rev . B 1- 1 7 19 - 31 13 + 3 P age Lengt h P age W i dt h S pot - gl ued par t Low er edge S pot - gl ued ps r t P er f or at i on of bas e sheet 4. 2 or m or e 21. 2 or m or e S pot - gl ued par t B ase s heet M u lti- p a r t c u t s h e e t 21. 2 or m or e 13 + 3 19 or m or e U n i t : m m Figure 1-12. Paper Width Overlappin[...]

DFX-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[...]

GENERAL DESCRIPTION Rev . B 1- 1 9 1.3 INTERF A CES The DFX -8500 is equipped with parallel interf ace, serial inter face, and optional Ty pe-B interf ace card. This s ection pres ents the spec ifications for eac h interfac e type. 1.3.1 Parallel Interface (Forw ard channel)  Data transm ission m ode: 8-bit parallel, IEEE-1284 com patibility [...]

DFX-8500 Rev . B 1-20  Signal Level: TT L-level co mpatible, IEEE- 1284 level 1 device Refer to T able 1-9. T able 1-9. Signal Level Parameter Minimum Maximum Condition VOH* - 5.5 V VOL* -0.5 V - IOH* - 0.32 mA VOH = 2.4 V IOL* - 12 m A VOL = 0.4 V CO - 50 pF VIH - 2.0 V VIL 0.8 V - IIH - 0.32 mA VIH = 2.4 V IIL - 12 mA VIL = 0.8 V CI - 50 pF[...]

GENERAL DESCRIPTION Rev . B 1- 21 1.3.2 Parallel Interface (Reverse channel)  Data transm ission m ode: IEEE-1284 nibble mode  Connector type: 57-30360 (AMPHENOL) 36-pin plug or equivalent  Sy nc hronization: No Inf o.  Handshak ing: No info.  Data transm ission tim ing: No info.  Signal Level: TT L-level co mpat[...]

DFX-8500 Rev . B 1-22 1.3.3 Serial Interface  Sy nc hronization : Asynchronous  Signal level (ELA-232D) :  MARK (logical 1) : -3Vto-25V  SP ACE (logical 0) : +3Vto+25V  W or d length :  Start bit : 1 bit  Data bit : 8 bit  Parity bit : Odd, Even, Non, of Ignor e  Stop bit : 1 bit or m ore [...]

GENERAL DESCRIPTION Rev . B 1- 2 3 1.3.5 Interface Selection The printer has thr ee interfac es; the parallel interf ace, s erial interfac e, and optional T ype-B interface. These inter fac es are selec ted m anually by DIP SW or selected autom atic ally .  Manual selection:  One of thr ee interfac es can be selec ted by DIP SW setting. ?[...]

DFX-8500 Rev . B 1-24 1.4 OPERA TING INSTRUCTIONS This sec tion des cribes the functions perform ed through the control panel, s uch as test print, hexadec imal dump, and paper m emor y function. 1.4.1 Control Panel The printer c ontrol panel gives you easy c ontr ol over m os t com m on pr inter oper ations. T he panel c onsis ts of indicator ligh[...]

GENERAL DESCRIPTION Rev . B 1- 2 5 1.4.1.1 Switches The c ontrol panel contains eleven switches.  Operation in normal mode: In norm al m ode, pressing panel s witches executes following func tion. Refer to T able 1-13. T able 1-13. Sw itch Function in Normal Mode Switch Function Front / Rear Change the front and rear paper path alternately . [...]

DFX-8500 Rev . B 1-26 1.4.1.2 Indicators The contr ol panel contains f ifteen LEDs .  Rear ( 2) (Green / Red) :  Gr een LED on when the rear paper path is s elected with paper .  Red LED on when the rear paper path is selected without paper .  Off when the front paper path is selected.  Front ( 2) (Green / Red) : ?[...]

GENERAL DESCRIPTION Rev . B 1- 2 7 1.4.2 Errors and B uzzers Errors fall into 2 types; normal er ror/warning and fatal er ror . See the tables below for detailed inform ation. T able 1-15. Error/Warning Buzzer In formation Error/Warning P A U SE LED Paper O ut LED Ribbon LED Beeper *1) Description On Lin e Off Off Off Pause On Off O ff Head hot Bli[...]

DFX-8500 Rev . B 1-28 1.4.3 DIP Sw itch Settings There ar e f ive DIP switches that ar e located at the f ront paper entr anc e of the pr inter . T hes e DIP s witches can set the printer defaults. W hen power is applied or the printer is reset, the DIP s witch selections are treated as the default setup. If the setup is changed, the power s hould [...]

GENERAL DESCRIPTION Rev . B 1- 2 9 T able 1-17. Character T able Setting (Standard) SW 1-1 SW 1-2 SW1-3 SW1-4 SW1-5 SW1-6 Character table Off Off Off Off Off Off PC437 (US, s tandard Europe) Off Off Off Off Off On PC850 (Multilingual) Off Off Off Off On Off PC860 (Portugues e) Off Off Off Off On On PC861 (Ic elandic) Off Off Off On Off Off PC863 (C[...]

DFX-8500 Rev . B 1-30 T able 1-19. Front T ractor Page Length SW2-1 SW2-2 SW2-3 SW2-4 Page length for front tractor Off Off Off Off 1 1 inches Off Off Off On 3 inch es Off Off On Off 3.5 i nches Off Off On On 4 inch e s Off On Off Off 5.5 inches Off On Off On 6 inches Off On On Off 7 inches O f f O nO nO n8 i n c h e s On Of f Of f Off 8.5 in ches [...]

GENERAL DESCRIPTION Rev . B 1- 31 1.4.4 Functions 1.4.4.1 Usual operation  Front / Rear: Changes the fr ont and rear paper path alternately .  Normal paper is set and the pull tractor is not used: The printer feeds the paper to the tear off position and cut the paper by the cutter , and feeds backward to paper park position. If the c ut[...]

DFX-8500 Rev . B 1-32  Pap er Select: Pressing it s elects one of the following paper Num bers. 1,2,3,4,5,6,7,8 : W hen the pr inter has the paper inf orm ation. 0 : Always a, b : W hen the printer has the paper mem or y data.  Normal paper is set and the pull tractor is not used: The printer feeds the paper to the tear off position and[...]

GENERAL DESCRIPTION Rev . B 1- 3 3 1.4.4.2 Operation at Power On  Self test: Prints the self test pattern. T o canc el it, m ake pr inter pause and turn off the power .  DIP switch sett ing print: Starts the setting pr inting m ode.  Data dump: Starts the data dump mode, in which all the input data are printed as hexadecim al num [...]

DFX-8500 Rev . B 1-34 1.4.4.3 Built-in Detection  Cover open detection: W hen the cover is opened, the printer stops printing and enter s the pause m ode autom atically after several beeps. T he printer s tays at the state until the cover is c losed and the “Pause” s witch is press ed. Several printer s ettings loaded at each power-on c a[...]

GENERAL DESCRIPTION Rev . B 1- 3 5 1.4.5 Paper M emory Function Y ou can get better printing quality w hen you print on overlapping m ulti-part f orm s or on c ontinuous for m s with labels by us ing the paper m em ory function. W hen y ou us e this f unction, you have to w r ite the inform ation of paper thick ness to the pr inter using DIP switch[...]

DFX-8500 Rev . B 1-36 1.4.6 Initialization s 1.4.6.1 Power-on Initialization The initialization of this level is activated by power-on or /INIT signal (negative puls e) or cold- reset com m and (rem ote RS c om m and). T his initialization is: • to initialize the printer mec hanism . • to clear the all buffers of data. • to cancel the downloa[...]

GENERAL DESCRIPTION Rev . B 1- 3 7 1.5 MA IN COMPONENT The m ain com ponents of the DFX- 8500 are as f ollows:  Printer m echanis m : M-3I60  Main control board: C204 MAIN boar d  Mechanism driver board: C204 DRV board  ½ Printhead driver board: C204 DRV-B board  DIP SW. board: C204 SUB board  Power supply board[...]

DFX-8500 Rev . B 1-38 1.5.1 M-3I60 Printer M echanism The M-3I60 printer mec hanism is a 18-pin (9-pin two lows), s erial im pact dot m atrix pr inter m echanism developed for the DFX -8500. It is designed to provide high-speed, high- volume printing, and is es pecially heavy and dur able when com pared with existing term inal printer mec hanism s,[...]

GENERAL DESCRIPTION Rev . B 1- 3 9 1.5.2 M ain Contr ol Boar d (C204 M A IN Board) The C204 MAIN board is a m ain controller boar d. The board c ontains f ollowing ICs:  16-bit CPU: TMP95C051A; 24.57 MHz (IC2)  Gate array: E05B36 (I C1)  PROM (including C.G. ) : 2M-bit (IC5)  RAM 4M-bit (IC14)  ADM232L RS-232C level co[...]

DFX-8500 Rev . B 1-40 1.5.3 C204 DRV Board The C204 DRV board is the dr iver board spec ially for the printer m echanism . T he ½ printhead, printhead fan, plunger , PF (paper f eed) m otor , CR (carriage) motor , CR f an, PG (platen gap) m otor , and RF (ribbon feed) m otor dr ive circuits are located on the driver boards. Sensor signals from the[...]

GENERAL DESCRIPTION Rev . B 1- 41 1.5.4 C204 DRV-B Board The C204 DRV-B board is the ½ printhead driver boar d. The drive par t is m ainly consists of the dis crete bipolar FET s. 1.5.5 C204 SUB Board The C204 SUB board c onsists of f ive DIP switch units. It is loc ated behind the front paper cover . Figure 1-28. C204 DRV-B Board Figure 1-29. C20[...]

DFX-8500 Rev . B 1-42 1.5.6 C204 PSB/PSE Board C204 PSB/PSE board is a pow er supply circuit board which generates the power f or the control c ircuit (m ain control board) and printer m echanis m drive circuit ( driver board). It c ontains cooling f an on the top. The PSB board is a 100-120 V AC version, and the PSE boar d is for 220-240 V AC. Fig[...]

GENERAL DESCRIPTION Rev . B 1- 4 3 1.5.7 Control Panel The control panel for this printer cons ists of switches, LEDs, and buzzers (Ref er to Figure 1-22 on page 1-23.). 1.5.8 Housing The housing us ed in the DFX-8500 c onsists of m any more com ponents than previous designs . The lower cas e is used as the main f ram e which holds the m ec hanism [...]

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CHA PTER 2 OPERA TING PRINCIPLES 2.1 PRINTER MECHA NISM OPERA TION ..................................................................2-1 2.1.1 Printhead Mechanism ........................................................................................................... 2-4 2.1.2 Carriage Mechanism ..................................................[...]

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OPERA TING PRINCIPLES Rev . B 2-1 2.1 PRINTER MECHA NISM OPERA TION This sec tion describes the Model 3I60 printer mec hanism and explains how the printer works . The Model 3I60 printer mec hanism f eatures a 18-pin, im pact dot printhead for ser ial printing. The printer m echanism is the main com ponent of the printer and is s upported by the oth[...]

DFX-8500 Rev . B 2- 2  Carriage mechanism : The carriage m echanism m oves the printhead in the horizontal direction. The CR m otor drives the c arriage, with the printhead on it. The CR encoder sens or detec ts the CR m otor s peed and c arr iage position. T he CR motor is clos ed-loop c ontrolled. Bec aus e the CR m otor is driven at a very[...]

OPERA TING PRINCIPLES Rev . B 2- 3  Paper feed mechanism : The CR motor controls printing in the horizontal direction, and the paper feed m ec hanism controls m ovem ent in the vertical dire ction (line f eeding and for m feeding). T he paper f eed m echanism f eeds paper ver tically . The PF m otor dr ives the paper f eed mec hanism . The fr[...]

DFX-8500 Rev . B 2- 4 2.1.1 Printhead M echanism The printhead is a charge-t y pe, impact dot printhead. Figur e 2-4 shows its oper ation. T he dot wire is attac hed to the actuating spring at point A. It is pulled back (lef t in the f igur e) by magnetic f orc e when power is applied and during standby . The m agnetic forc e holds back the actuati[...]

OPERA TING PRINCIPLES Rev . B 2- 5 2.1.2 Carriage Mechanism Figure 2-5 shows the c arriage m echanism . T he fr ont and rear car riage guide shaf ts support the c arriage. T he rotation of the CR m otor is tr ansm itted to the car r iage tim ing belt thr ough the car r iage belt pulleys at the right and left sides. The printhead is mounted on the c[...]

DFX-8500 Rev . B 2- 6 2.1.3 Platen Gap A djustment M echanism Figure 2-6 shows the platen gap adj ustm ent m echanism . T he f ront and rear carr iage guide s hafts supporting the carriage have a vertical section. T he rotation of the PG m otor is trans m itted to the rear carr iage guide shaft thr ough the gears. Counterc lock wise rotation of the[...]

OPERA TING PRINCIPLES Rev . B 2- 7 2.1.4 Paper Feed M echanism Figures 2-7, 2- 8, and 2-9 show the paper feed m echanism. Af ter the printer loads the paper , it is f ed by the tension roller , platen roller , and front or rear trac tor ass embly . The PF m otor r otates the tension roller and tractor s elect gear (F igures 2-8 and 2- 9) and m oves[...]

DFX-8500 Rev . B 2- 8 Paper Tension Roller Paper Bail Front PE Sensor Tractor Sprocket (Front) PF Motor Pinion Gear Tractor Select Gear PF Transmission Gear Figure 2-8. Front T ractor Assembly Op eration Paper Tension Roller Paper Bail Tractor Select Gear PF Motor Pinion Tractor Sprocket (Rear) Rear PE Sensor PF Transmission Gear Figure 2-9. Rear T[...]

OPERA TING PRINCIPLES Rev . B 2- 9 2.1.4.1 Tractor Wire Operation The printer is equipped with a tractor wire (white line) to prevent paper jam s when continuous paper is loaded from the front or rear entrance. The trac tor tens ion s pring on the r ight side f r am e pulls the wire and releases the s tress on the continuous paper being f ed. Figur[...]

DFX-8500 Rev . B 2-1 0 2.1.5 Ri bbon Feed and T ractor Select M echanisms The RF motor s upplies power to both the ribbon f eed and tractor s elect m echanism s. The rotation of the RF motor pinion swings the ribbon f eed select gear lik e a pendulum , using the lever axis as a s upport point. The rotation of the RF m otor is transm itted af ter th[...]

OPERA TING PRINCIPLES Rev . B 2-1 1  Tr actor select mechanism : Figure 2-12 shows the operation of the tractor s elect m echanis m. Cloc kwise r otation of the RF m otor is transm itted to the tr actor select cam through the r ibbon feed selec t gear and tractor select trans m ission gear , and rotates the trac tor s elec t cam c lock wise. [...]

DFX-8500 Rev . B 2-1 2 2.1.6 Plunger M echanism Figure 2-13 shows the plunger m echanism . The paper bail ass embly is attached to the end of the plunger's iron core. The paper bail assem bly axis is c onnected to the fr am e. W hen the plunger coil is energized, the forc e of the paper bail s pring returns the paper bail assem bly to its orig[...]

OPERA TING PRINCIPLES Rev . B 2-1 3 2.2 POWER SUPPL Y OPERA TION The printer can be powered by either of two power supply boards : the 120 V C204 PSB board or the 220/240 V C204 PSE board. The only difference in the oper ation of these two boards is in the prim ary circuitr y . They supply pow er to the printer in the sam e way . T he power supply [...]

DFX-8500 Rev . B 2-1 4 2.2.1 Pow er Suppl y Overview Figure 2-14 shows a bloc k diagr am of the C204 PSB/PSE board. Fuse Power SW. AC Inlet AC Source Input Filter Circuit Rectifier Circuit Surge Cut (at Power On) Smoothing Circuit +37V Line Switching 1/2 +37V Line Switching 2/2 Smoothing Circuit PC101 Power Down Control +37V (VP1/VP2) PC102 Constan[...]

OPERA TING PRINCIPLES Rev . B 2-1 5  General : The power supply board converts the AC input voltage to the DC voltages required to operate the printer . The AC voltage is input to the AC inlet, and is supplied to the C204 PSB/PSE boar d via the power switch and a fuse. T wo main switching regulator circuits cons ist of two blocks, +37 V Lines[...]

DFX-8500 Rev . B 2-1 6  Protection circuits : Thes e +37VDC line block s perf orm voltage contr ol, and they have over-current lim iting and over voltage protection circ uits f or each.  Control and status signals : The PSB//PSE board receives two control signal from the C204 MAIN board and outputs two status signals to the MAIN board. [...]

OPERA TING PRINCIPLES Rev . B 2-1 7 2.3 CONTROL CIRCUIT Figure 2-15 shows a bloc k diagr am of the control c ircuit with the C204 MAIN board at the center . 2.3.1 Contr ol Cir c ui t Oper ation Overvi ew The cor e of the c ontrol circuit is the TMP95C061AF CPU ( IC2). T his CPU is driven us ing a 24.57 MHz external clock (CRU1). T he CPU executes p[...]

DFX-8500 Rev . B 2-1 8 Printhead Drive Circuit 2 /2 Printhead Drive Circuit 1/2 Control & Monitoring +37 VDC, +5 VDC Printhead Temperature Paper Width PG Encoder PE Signals (Front, Rear, Top) Paper Jam Pull Tractor Tractor Select Head Fan Temperature Current Monitori ng CR Motor Insulation PSB/PSE Board Option Cutter Panel Unit Reset IC (IC13) [...]

OPERA TING PRINCIPLES Rev . B 2-1 9 T able 2-5 describes the functions of the m ain com ponents on the C204 MAIN and C204 DRV board. T able 2-5. M ain IC Functions Board IC Nam e Location Functions C204 MAIN T MP95C061 (CPU) IC2 Receives data f rom the hos t computer via the gate array , loads the data to the input buffer in the RAM, and c onverts [...]

DFX-8500 Rev . B 2-2 0 Figure 2-16 shows the data f low for data input via the parallel inter face. Although var ious circ uits perf orm data processing, the control cor e is the CPU and all operations are ex ecuted via the CPU. In this circ uit, the E05B36 IC (IC1) provides the interfac e between the external host com puter and the CPU, and all da[...]

OPERA TING PRINCIPLES Rev . B 2-21 2.3.2 Reset Circuit This s ection desc ribes the hardware r eset circ uit. W hen the hardware reset s ignal is input, all ICs in the control circ uit are res et, and the CPU executes the pr ogram f rom the starting address . Figure 2-17 s hows the reset circ uit block diagram . The cir cuit is equipped with a rese[...]

DFX-8500 Rev . B 2-2 2 2.3.3 Sensor Circuits Figure 2-18 shows the s ensor cir cuits in block diagram f orm . T he printer is equipped with the following sensors : 1. Front and rear PE s ensors ( use a photo interrupter ) 2. T op PE sensor (to detec t the TOF position, us es a photo interrupter ) 3. Paper jam sens or (uses a m agnetic transis tor) [...]

OPERA TING PRINCIPLES Rev . B 2-2 3 Each sensor is desc ribed below . 1. Front and rear paper end sensors  Detec tion form : Photo interrupter  Output f orm : Open collector (pulled up to 10 K ohm s r esistor)  Logic al: Paper pres ent: LOW Paper out: HIGH 2. T op paper end sensor ( to detect the TOF position)  Detec tion fo[...]

DFX-8500 Rev . B 2-2 4 13. Paper width sensor  Detec tion form : Photo reflector  Output f orm : Emitter follower  J udgemwnt : N o paper present: Standard voltage level. Paper present: T he voltage level is double the s tandard voltage level. 14. CR motor isolation res istance sens or (m onitored by port AN2 of the CPU) T o provi[...]

OPERA TING PRINCIPLES Rev . B 2-2 5 2.3.4 CR M otor Drive Circuit Figure 2-19 shows the internal c ircuit f or the CR m otor ,T able 2-6 provides the CR m otor spec ific ation, and Figure 2-20 shows a bloc k diagr am f or the CR m otor dr ive circuit. An STK681-050 (IC1) bipolar driver IC drives the CR m otor . It has built- in bipolar switching tr[...]

DFX-8500 Rev . B 2-2 6 T able 2-7 lists the CR m otor drive m odes . T able 2-7. CR Mo tor Drive M odes Division Drive M ode CR Motor Speed (rpm) A cceleration / Deceleration Control Curve Note1) Constant Speed Control Carriage m oves Super Draft 2800 Acceleration and PI control with printing. Super Draf t HD 2666 Deceleration 1 Note 2) Dr aft 2100[...]

OPERA TING PRINCIPLES Rev . B 2-2 7  PI Con trol : PI control k eeps the CR m otor s peed constant using the enc oder pulses ENCA and ENCB with the gate array E05B36. T he E05B36 generates the PW M ( pulse wi dth modulation) signal according to the CR m otor speed to the PW M port of the gate arr ay and determines the duty of the carriage dri[...]

DFX-8500 Rev . B 2-2 8  Deceleration control: Deceleration contr ol provides sm ooth dec eleration and prevents r apid vibration. The duty data for deceleration c ontrol is determ ined for each printing m ode. Pulse width modulation (PW M) determ ines each printing m ode. Current speed - SP3 1. The printer uses Dec eleration driving m ode 2, [...]

OPERA TING PRINCIPLES Rev . B 2-2 9 2.3.5 PF Motor Drive Circuit Stepping motor driver ST K6713BMK4 (IC2) dr ives the PF m otor . Figure 2-22 s hows the PF motor drive circuit bloc k diagr am, and T able 2-9 pr ovides the PF m otor spec ifications . T able 2-9. PF Mo tor Specifications Specification Description Form 4-phase, 200-pole, HB* puls e m [...]

DFX-8500 Rev . B 2-3 0 2.3.6 RF M otor Drive Circuit Figure 2-24 shows a bloc k diagr am of the RF m otor drive c ircuit, and T able 2-10 pr ovides the RF m otor specif ications. The RF motor is a stepping motor . T he control c ircuit perf orm s open- loop phase switching control according to the timing data for acceler ation, constant speed, and [...]

OPERA TING PRINCIPLES Rev . B 2-31 2.3.7 PG Motor Drive Circuit Figure 2-25 shows a bloc k diagr am of the PG m otor dr ive circuit, and T able 2- 1 1 provides PG m otor specif ications. The PG motor is a stepping motor . T he m otor phase s witching signals are output f rom the E05B36 ports PGA to PGD. T he m otor com m on voltage (PGCO M) alterna[...]

DFX-8500 Rev . B 2-3 2 2.3.8 Pl unger Dri ve Circuit Figure 2-26 shows a bloc k diagr am of the plunger drive c irc uit, T able 2-12 provides the plunger s pecif ic ation, and T able 2-13 provides the plunger s witching pattern. The plunger is driven using three s witching patterns. G ate array E05B26 ports PLP and PLN output the plunger coil drive[...]

OPERA TING PRINCIPLES Rev . B 2-3 3 2.3.9 Printhead Drive Circuit Figure 2-27 shows a printhead dr ive circuit bloc k diagr am .  General : The print data lines from IC1 are active when they are HIGH . W hen ports HDR1 (HDL1) to HDR9 (HDL9) of IC1 go HIGH, the FET gates ar e biased, and the FET s are turned on to apply the current to the prin[...]

DFX-8500 Rev . B 2-3 4  Printhead high temperat ure feedback operation : The printer supports the pr inthead tem perature detection s equence, which cons ists of the following steps: 1. W hen the printhead tem perature is less than 1 10 o C, the printer perf orm s norm al printing. 2. W hen the printhead tem perature ex ceeds equal or m or e [...]

CHA PTER 3 DISA SSEMBL Y A ND A SSEMBL Y 3.1 OVER VIEW ............................................................................................................3-1 3.1.1 Precautions for Disassembly and A ssembly ....................................................................... 3-1 3.1.2 T ools ..............................................[...]

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DISASSEM BL Y AND ASSEM BL Y Rev . B 3-1 3.1 OVER VIEW This chapter des cribes the dis ass em bly /assem bly procedures to be us ed f or r eplacing the m ain assem blies of the DFX-8500. 3.1.1 Precautions for Disassembly and A ssembly Read this section bef ore you disassem ble, ass emble, or transport the pr inter . ; Because the DFX-8500 weighs[...]

DFX-8500 Rev . B 3- 2 Before trans porting the printer , rem ove the paper and ribbon cartridge. T hen attac h the following pack ing mater ials, as s hown in Figure 3-1:  Transport loc king br ack et  Carr iage guide shaft s upport bar  Printhead pr otector  Foam pack ing f or paper bail Figure 3-1. Packing M aterial A t ta[...]

DISASSEM BL Y AND ASSEM BL Y Rev . B 3- 3 3.1.2 T ools This s ection desc ribes the tools required f or assem bling, dis assem bling, or adj usting the printer . Note : Refer to CHAPTER 4 for adjustment tools, CHAPTE R 5 for troubleshooting tools, and CHAPTER 6 for tools for maintenance, lubrication, and adhesives. T able 3-1. Recommended T ools T [...]

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 G auge Figure 3-6. Dial Gauge M aster[...]

DISASSEM BL Y AND ASSEM BL Y Rev . B 3- 5 3.1.3 Specification for Screw s In the following sections , abbreviations are us ed for s m all parts suc h as sc rews and washers . T able 3- 2 lists these abbr eviations. T able 3-3 lists screw and washer types. T able 3-2. Screw Abbreviations A bbreviation Part Name CBB Cross- Bind head,, B-tight sc rew [...]

DFX-8500 Rev . B 3- 6 3.1.4 Service Checks A fter Repair Before returning the printer after ser vice, use the check list in T able 3-4, which provides a record to m ake servicing and s hipping m ore eff icient. T able 3-4. Inspection Check List for th e Repaired Printer Cate gory Item to che ck Is Che ck requi red? Maintenance Are all necessary adj[...]

DISASSEM BL Y AND ASSEM BL Y Rev . B 3- 7 3.2 DISA SSEMBL Y A ND A SSEMBL Y ; Before you disas semble or as semble the printer , be sur e to read and follow the instruc tions in Section 3.1, "OVERVIEW." ; Before you disas semble the printer , be sure to turn the printer power off and disc onnect AC cable. This sec tion descr ibes ho[...]

DFX-8500 Rev . B 3- 8 3.2.1 ROM Replacement ; It is best to remov e the top cover before you tilt back the printer as descr ibed in the steps below . Refer to Section 3.2.3.1 for ins tructions on removing the top cov er . ; If you tilt back the pr inter with the top cov er attached, be car eful not to put too muc h weight on the top cover or [...]

DISASSEM BL Y AND ASSEM BL Y Rev . B 3- 9 3.2.2 Pr inthead and Ribbon M ask Assembly Removal The printhead c an be changed without disassem bling the entir e unit. Use the exclus ive printhead k it for printhead ex change on the DFX- 8500. W hen you receive the kit, check that all of the f ollowing are included. P r i nt head U ni t Oi l ( O- 2 ) H[...]

DFX-8500 Rev . B 3-1 0 CAUTION ; When y ou remove the c onnector cov er , be careful not to break the tabs. ; When you remove the printhead cable holder , be careful not to break the printhead holder latc h. Use a slotted scr ewdriver if nec essar y . Step 1: Open the t o p co v e r and remove the ribbon c artridge. Ste p 2: Remove the two CB[...]

DISASSEM BL Y AND ASSEM BL Y Rev . B 3-1 1 Step 5: Disconnect the nar row FPC cable fr om white connec tor (lock -type). Step 6: Move the car riage to around 90 th column, rem ove the two CP(S-P1)(M4X7) screws s ecuring the printhead and remove the CP(S-P1)(M3X6) s crew sec uring the ground FPC, then rem ove the printhead. Na r r o w F P C Ca b l e[...]

DFX-8500 Rev . B 3-1 2 A S S E M B L IN G P O IN T z Confirm that the cables ar e connected c orrectly . (Refer to Figur es 3-12 and 5-3..) z Tighten the screws while pulling the pr inthead as shown below to sec ure the printhead firmly . Figure 3-14. Printhead Installation Step 12: Install the cable cover and the FPC c over . Step 13: W ipe [...]

DISASSEM BL Y AND ASSEM BL Y Rev . B 3-1 3 3.2.3 Housi ng Removal This s ection desc ribes how to rem ove the housing. 3.2.3.1 Top Cover Removal CAUTION ; T wo people are r equired to remove the top c over; one per son must hold the top cov er while the other person removes the screws . If the top cover is not suppor ted while the screws are rem[...]

DFX-8500 Rev . B 3-1 4 3.2.3.2 Left, Right, and Front Covers Removal and Fuse Replacement Step 1: Remove the f our CBB (M4x 16) scr ews securing the lef t side cover and rem ove the cover . Step 2: Rem ove the right side c over in the same way as y ou rem oved the lef t s ide c over . Also r em ove the four c ables fr om the m ain s witch on the ri[...]

DISASSEM BL Y AND ASSEM BL Y Rev . B 3-1 5 Step 3: After you remove the r ight side cover , you can replace the input fus e for the C204 power supply board unit. WARNING ; Make sure the new fuse meets the printer's AC power specific ations. C a r r i a g e M o to r CN1 C 2 0 4 PSB/ PSE Bo a r d G r oundi ng H ar nes s (R i g h t S i d e ) F[...]

DFX-8500 Rev . B 3-1 6 3.2.3.3 Front Panel Unit Removal Step 1: Remove the lef t and right side cover s. (Ref er to Section 3.2.3.2) Step 2: Open the top cover and disc onnect connec tor CN5 (the panel unit connec tor). Step 3: Remove the two CBB (M4x 16) scr ews from the front panel unit and rem ove the panel unit along with the panel connector ca[...]

DISASSEM BL Y AND ASSEM BL Y Rev . B 3-1 7 3.2.3.4 Upper Case Removal Step 1: Remove the f ront panel unit. (Ref er to Section 3.2.3.3) Step 2: Remove the s ix CBB (M4x16) scr ews, and two CBB (M3x10) sc rews from the upper case. Then rem ove the upper cas e. C BB( M 4 X1 6 ) C BB( M 3 X1 0 ) Up p e r Ca s e Figure 3-22. Upper Case Removal[...]

DFX-8500 Rev . B 3-1 8 3.2.4 Circuit Boards Removal This s ection desc ribes how to rem ove the circ uit boards. 3.2.4.1 Bottom Panel Assembly Removal CAUTION ; It is best to remov e the top cover before you tilt back the printer as descr ibed in the steps below . Refer to Section 3.2.3.1 for ins tructions on removing the top cov er . ; If yo[...]

DISASSEM BL Y AND ASSEM BL Y Rev . B 3-1 9 Step 3: From the left side, rem ove the two CPB(O )(M4X8) screws s ecuring the green and yellow earth cables between the bottom plate of the pr inter m echanism and the earth on the bottom panel assembly . Ste p 4: Disc onnect the 6 connec tors, (1) thr ough (6) as s hown in Figure 3-24. E ar t h C abl e E[...]

DFX-8500 Rev . B 3-2 0 Step 7: W hile supporting the top cover to protect it f rom scr atches, tilt back the printer and lay it on its back. Ste p 8: Rem ove the eight CBB (M4x16) screws s ecuring the bottom panel ass em bly , and s lowly remove the bottom panel unit as sem bly . C BB( M 4 X1 6 ) Figure 3-26. Bottom Panel Assembly Remov al[...]

DISASSEM BL Y AND ASSEM BL Y Rev . B 3-21 3.2.4.2 Cooling Fan and C204 Power Supply Board Unit Removal Ste p 1: Rem ove the bottom panel assem bly . (Refer to Section 3.2.4.1) Ste p 2: If y ou need to remove the cooling fan, disc onnect connector CN5 and rem ove the f our CCN (M3x30) screws s ecuring it, and rem ove the f an. Ste p 3: Disconnect co[...]

DFX-8500 Rev . B 3-2 2 3.2.4.3 C204 SUB Board Unit Removal Ste p 1: Rem ove the bottom panel assem bly . (Refer to Section 3.2.4.1) Ste p 2: Disc onnect connec tors CN15 and CN16 on the C204 MAIN board. Ste p 3 : Rem ove the CBB ( M3x8) sc rew and the CBB (M3x12) s crew secur ing the C204 SUB board assem bly and remove the board. C BB( M 3 X1 2 ) C[...]

DISASSEM BL Y AND ASSEM BL Y Rev . B 3-2 3 3.2.4.4 C204 DRV-B and C204 DRV Board Units Removal Ste p 1: Rem ove the bottom panel assem bly . (Refer to Section 3.2.4.1) Ste p 2: Disc onnect connec tor CN3 and cable connec tor CN14 for the C204 DRV board. Ste p 3: Disc onnect connec tors CN1 and CN2 on the C204 DRV-B board. C 204 D R V B oar d CN3 CN[...]

DFX-8500 Rev . B 3-2 4 3.2.4.5 C204 MAIN Board Unit Removal Step 1: Remove the bottom panel as sem bly . (Refer to Sec tion 3.2.4.1) Step 2: Remove the C204 SUB boar d unit (Ref er to Section 3.2.4.3.) Step 3: Remove the C204 DRV-B boar d and C204 DRV board units (Ref er to Section 3.2.4.4.) Step 4: Disconnect c onnectors CN6, CN7, CN8, and CN10. H[...]

DISASSEM BL Y AND ASSEM BL Y Rev . B 3-2 5 Ste p 5 : Rem ove the f our CBB (M3x 12) sc rews and two CBS (O) (M3x8) s crews secur ing the C204 MAIN board unit and rem ove the board. : C BB( M 3 X1 2 ) X 4 : C BS( O ) ( M 3 X8 ) X 2 C 204 M A I N B oar d U ni t H ook s f or C 204 M A I N B oar d I ns t al l at i on Figure 3-34 . C204 M A IN Board Rem[...]

DFX-8500 Rev . B 3-2 6 3.2.4 .6 AC Inlet Removal Step 1: Remove the C204 power supply board assem bly . (Refer to Section 3.2.4.2) Step 2: Remove the C204 MAIN boar d assem bly . (Refer to Sec tion 3.2.4.5) Step 3: Remove the thr ee CBB (M3x8) s crews and one CB (O ) (M4x6) screw sec uring the grounding plate to the bottom panel as sem bly and remo[...]

DISASSEM BL Y AND ASSEM BL Y Rev . B 3-2 7 3.2.4.7 C204 PNL Board Removal Step 1: Remove the f ront panel unit. (Ref er to Section 3.2.3.3) Step 2: Disconnect c onnectors CN1 and CN2 on the C204 PNL boar d. Step 3: Remove the CBB ( M4x10) sc rew securing the C204 PNL board to the f ront panel unit and rem ove the board. C BB( M 4 X1 0 ) F r ont P a[...]

DFX-8500 Rev . B 3-2 8 3.2.5 Interlock Sw itch and Cover Open Sensor A ssembly Removal Step 1: Remove the upper case. (Ref er to Sect ion 3.2.3.4) Step 2: Disconnec t the interlock switch cable and the cover open sensor cable fr om the j unction board respec tively . C ov er O pen S ens or In te r l o c k S W . CN3 C onnec t or J unc t i on B oar d[...]

DISASSEM BL Y AND ASSEM BL Y Rev . B 3-2 9 3.2 .6 Printer M echanism Removal This s ect ion desc r ibes how to rem ove and dis ass em ble the pr inter m ec hanism . Bef ore f ollowing the st eps in this section, r em ove the printer m echanis m f rom the printer as descr ibed in Section 3.2.6. Because the printer mechanism is large and heavy , you [...]

DFX-8500 Rev . B 3-3 0 Step 5: Remove the f our sc rews secur ing the printer m echanism to the lower c ase. Sc r e w s Sc r e w s Figure 3-43. Printer M echanism Removal 1/2 Step 6: Install the lift handles from the ins ide of the printer m ec hanism . Insert each handle through the two holes in the side fram es of the printer m ec hanism . Then s[...]

DISASSEM BL Y AND ASSEM BL Y Rev . B 3-31 3.2.6.1 Fan Removal Step 1: Remove the upper case unit. (Ref er to Sect ion 3.2.3.4.) Step 2: Remove the r ight cover . (Ref er to Section 3.2.3.2.) Step 3: Disconnect the c onnector f or the fan f rom the relay connector . Step 4: Remove the CP( O) sc rew securing the f an duct to the left fram e and the C[...]

DFX-8500 Rev . B 3-3 2 3.2.6.2 Ribbon Feed Change Lever Unit Removal Step 1: Release the three hook s sec uring the ribbon feed gear c over to the ribbon f eed m otor fram e and rem ove the cover and the ribbon f eed gear . Step 2: Disconnect the thr ee connectors for the r ibbon feed m otor , tractor select s ensor , and the ribbon jam sensor from[...]

DISASSEM BL Y AND ASSEM BL Y Rev . B 3-3 3 T o R i bbon J am S ens or T o T r ac t or S el ec t S ens or T o R F M o to r C onnec t or J unc t i on B oar d Figure 3-48. Removing Connectors A S S E M B L IN G P O IN T When y ou install the ribbon feed change lev er unit, join the tip of the trac tor select lev er and the trac tor select gear holder [...]

DFX-8500 Rev . B 3-3 4 3.2.6.3 Tractor Select Lever (Upper and Lower) Assembly Disassembly This section describes how to disas sem ble the tractor s elect lever as sem bly , including how to rem ove the ribbon feed m otor and tr actor selec t sensor . Step 1: Remove the ribbon f eed change lever unit. ( Refer to Sec tion 3.2.6.2.) Step 2: Rem ove t[...]

DISASSEM BL Y AND ASSEM BL Y Rev . B 3-3 5 3.2.6.4 Ribbon Jam Sensor Removal Step 1: Remove the right c over . (Refer to Section 3.2.3.2) Step 2: Disconnect the c onnector f or the sensor from the c onnector junc tion board. Step 3: Remove the CP( S-P1) (M3x6) screw sec uring the sensor to the brack et, and rem ove the sens or . C P ( S - P 1) ( M [...]

DFX-8500 Rev . B 3-3 6 3.2.6.5 Connector Junction Board Assembly and FPC Board Assembly Removal This s ection desc ribes how to rem ove the connec tor junc tion board assem bly and FPC board assem bly . Step 1: Remove the lef t side cover . ( Refer to Sec tion 3.2.3.2) Step 2: Disconnect all the c ables f rom the connector junction board as sem bly[...]

DISASSEM BL Y AND ASSEM BL Y Rev . B 3-3 7 3.2.6.6 PG Sensor and PG Motor Removal CAUTION When y ou remove or ins tall the PG sens or , be careful not to bend the PG motor encoder plate. Step 1: Remove the c onnector junc tion board ass embly . (Ref er to Section 3.2.6.5) Step 2: Rem ove the CBS sc rew (3X6) s ecuring the PG s ensor unit to the lef[...]

DFX-8500 Rev . B 3-3 8 3.2.6.7 Plunger and Paper Bail Assembly Removal This s ection desc ribes how to rem ove the plunger ( loading solenoid) and paper bail ass em bly . Step 1: Disc onnect the black, 2-pin plunger connector f rom the connec tor junc tion board assem bly , and rem ove the plunger cable f rom the connector junction boar d assem bly[...]

DISASSEM BL Y AND ASSEM BL Y Rev . B 3-3 9 Ste p 4: Rem ove the lef t tension roller lever spr ing. Ste p 5: Rem ove the E-ring (6) sec uring the paper bail shaf t to the left f ram e and rem ove the platen roller shaft holder and paper bail lever . E -ri n g s S h a ft H o l d e r P aper B ai l S haf t P aper B ai l Lev er E -ri n g T ens i on R o[...]

DFX-8500 Rev . B 3-4 0 3.2.6.8 Upper Paper Guide and Top PE Sensor Removal Step 1: Remove the paper bail as sem bly . (Refer to Sec tion 3.2.6.7) Step 2: Disconnect the r ed, 3-pin, top PE sensor connector f rom the connec tor junction boar d assem bly . C onnec t or J unc t i on B oar d T op P E S ens or C onnec t or Lef t S i de Fr a m e Figure 3[...]

DISASSEM BL Y AND ASSEM BL Y Rev . B 3-41 3.2.6.9 Tension Roller Shaft Removal This sec tion describes how to remove the tension roller shaft. It is better to rem ove the tension r oller shaf t with the paper bail assem bly removed; however , rem oving it is not required. ( Refer to Sec tion 3.2.6.7.) f or instructions on how to rem ove the paper b[...]

DFX-8500 Rev . B 3-4 2 Step 7: Remove the CR m otor fan. (Ref er to Section 3.2.6.19.) Ste p 8 : Rem ove the E-r ing (6) at the right end of the tension roller s haft and rem ove the tens ion roller shaf t holder along with the leaf spring and the washer . Ste p 9: Rem ove the tension r oller shaf t by taking it out from the r ight fram e. T ens i [...]

DISASSEM BL Y AND ASSEM BL Y Rev . B 3-4 3 3.2. 6.10 Platen Removal Step 1: Remove the paper bail as sem bly . (Refer to Sec tion 3.2.6.7.) Step 2: Remove the upper paper guide. (Ref er to Section 3.2.6.8.) Step 3: Rem ove the four hexagon soc ket screws s ecuring the platen to the platen holders. Then r emove the platen with the lower paper guide [...]

DFX-8500 Rev . B 3-4 4 3.2 .6.11 Paper Jam Sensor Removal Step 1: Remove the platen along with the lower paper guide com posed of 3 parts. ( Refer to Section 3.2.6.10.) Step 2: Remove the CPN( SP)(M4x8) s crew sec uring the left part of the lower paper guide to the platen. Step 3: Remove the par t from the platen. L o w e r P a p e r G u i d e CP N[...]

DISASSEM BL Y AND ASSEM BL Y Rev . B 3-4 5 3.2. 6.12 Pull Tractor Sensor Removal Step 1: Remove the upper paper guide. (Ref er to Section 3.2.6.8) Step 2: Disconnec t the red 2-pin pull tractor s ensor c onnector f rom the connector junction board assembly . Step 3: Rem ove the CP(S) ( M2x14) s cr ew sec uring the pull trac tor sens or (a m icr o-s[...]

DFX-8500 Rev . B 3-4 6 3.2.6.13 Paper Width (PW) Sensor Removal Step 1: Disconnect the c onnector f or the PW sens or . Step 2: Remove the CP( S-P1) (M2.5x6) screw sec uring the PW sensor to the ribbon m ask holder . C P ( S - P 1) ( M 2. 5x 6) P aper W i dt h S ens or P aper W i dt h S ens or C onnec t or Figure 3-67. PW Sensor Removal[...]

DISASSEM BL Y AND ASSEM BL Y Rev . B 3-4 7 3.2.6.14 PG Home Sen so r Removal Step 1: Remove the f ront/rear tr actor selec t lever ass em bly . ( Refer to Section 3.2.6.2.) Step 2: Remove the E- ring securing the c arriage guide shaf t gear to the rear c arriage guide shaf t. C ar r i age G u i de S haf t (R e a r) E -ri n g C ar r i age G u i de S[...]

DFX-8500 Rev . B 3-4 8 A S S E M B L IN G P O IN T When y ou install the CR guide shaft gear , align the rib in the CR guide s haft gear with the PG adjustment transmiss ion gear as shown in the figur e below , then rotate the CR guide shaft gear 10 mm in CCW. F r am e Lef t CR G u i d e S haf t G ear PG T r ans m i s s i on G ear F l at P ar t of [...]

DISASSEM BL Y AND ASSEM BL Y Rev . B 3-4 9 3.2.6.15 PF Motor Removal Step 1: Remove the c onnector junc tion board ass embly . (Ref er to Section 3.2.6.5.) Step 2: Remove the thr ee CP (SP-1) (M4x 8) sc rews secur ing the PF motor to the left side f ram e. Step 3: Remove the PF m otor f rom the inside of the left s ide fram e. C P (S -P 1 )(M 4 X 8[...]

DFX-8500 Rev . B 3-5 0 3.2.6.16 Left Side Frame Gear Removal Step 1: Remove the f ront/rear tr actor selec t lever ass em bly . ( Refer to Section 3.2.6.2.) Step 2: Remove the c onnector junc tion board ass embly . (Ref er to Section 3.2.6.5.) Step 3: Remove the PG motor . ( Refer to Sec tion 3.2.6.6.) Step 4: Remove the s eries of gear s in the or[...]

DISASSEM BL Y AND ASSEM BL Y Rev . B 3-51 3.2.6.17 Front T ract o r A ssembly Removal This s ection desc ribes how to rem ove the f ront tractor assem bly . Step 1: Disconnect the c onnector white 3-pin fr ont PE sensor from the connec tor junc tion board. Step 2: Remove the c onnector junc tion board ass embly . (Ref er to Section 3.2.6.5.) Step 3[...]

DFX-8500 Rev . B 3-5 2 3.2.6.18 Rear Tractor Assembly Removal This s ection desc ribes how to rem ove the rear tractor as sem bly . Step 1: Disconnect the c onnector white 3-pin rear PE s ensor f rom the connec tor junction boar d. Step 2: Remove the c onnector junc tion board ass embly . (Ref er to Section 3.2.6.5.) Step 3: Rem ove the flange nut [...]

DISASSEM BL Y AND ASSEM BL Y Rev . B 3-5 3 3.2.6.19 CR Motor Fan R emov al Step 1: Disconnect the c able for the m otor f rom the relay connector . Step 2: Remove 2 f an fixing s crews and rem ove the f an. F an F i x i ng S c r ew s R i ght F r am e CR M o t o r F a n Figure 3-76. CR Motor Fan Removal[...]

DFX-8500 Rev . B 3-5 4 3.2.6.20 CR Moto r Removal Step 1: Remove the right c over . (Refer to Section 3.2.3.2.) Ste p 2 : Disconnect the r ed and black cables f rom the term inals on the CR m otor . (t wo cables for each term inal) Ste p 3 : Rem ove the three CP(S) (M4x10) s crews sec uring the CR m otor to the right s ide f ram e and rem ove the m[...]

DISASSEM BL Y AND ASSEM BL Y Rev . B 3-5 5 3.2.6.21 CR (Carriage Encoder) Sensor Removal Step 1: Remove the printhead. ( Refer to Section 3.2.2.) Step 2: Disconnect the r ed 4-pin CR sensor connector f rom the car riage connector j unction board. Step 3: Rem ove the two CP( S-P1) (M2.6 x 5) sc rews secur ing the CR sensor to the carriage and r em o[...]

DFX-8500 Rev . B 3-5 6 3.2.6.22 Carriage Mechanism Disassembly This s ection desc ribes how to disas sem ble the carriage m ec hanism , inc luding rem oving the carr iage, CR timing belt, and f ront and rear carriage guide shaf ts. Step 1: Remove the CR m otor . (Ref er to Sect ion 3.2.6.20.) Step 2: Remove the belt pulley from the belt pulley hold[...]

DISASSEM BL Y AND ASSEM BL Y Rev . B 3-5 7 Ste p 5: Remove the front carriage guide shaft by pulling it through the hole in the right side fram e. (W hen y ou remove the f ront carr iage guide shaft, m ove the car riage to the left s ide.) Ste p 6 : O n the left s ide fram e, rem ove the E-r ing (6) sec uring the carriage guide shaf t gear to the r[...]

DFX-8500 Rev . B 3-5 8 A S S E M B L IN G P O IN T When y ou install the front carriage guide s haft, tighten the scr ews while pus hing the shaft toward the platen. ADJUSTMENT REQU IRED When y ou assemble the c arriage mechanis m, perform the following adjustments : • Carriage timing belt tension adjus tment (desc ribed in Section 4.1.2) • Car[...]

DISASSEM BL Y AND ASSEM BL Y Rev . B 3-5 9 3.2 .6 .23 Paper Support A ssembly Removal Step 1: Disass emble the c arriage m echanis m and r em ove all the parts related to the car riage. (R efer to Section 3.2.6.22.) Step 2: Referring to the ex ploded diagram in the Appendix, rem ove the paper s upport assem bly . ADJUSTMENT REQU IRED When y ou inst[...]

DFX-8500 Rev . B 3-6 0 3.2.6.24 3.2.6.21 PF Dr iv e R olle r Removal Ste p 1: Rem ove the platen. (Ref er to 3.2.6.10) Ste p 2: Rem ove the CR m otor . (Ref er to Section 3.2.6.20) Ste p 3: Rem ove the left s ide fram e gears . (Ref er to Section 3.2.6.16) Ste p 4: Refer ring to the exploded diagram in the Appendix , rem ove the PF driver roller . [...]

CHA PTER 4 A DJUSTMENT 4.1 PRINTER MECHA NISM A DJUSTMENTS ............................................................ 4-1 4.1.1 PG M otor Backlash Adjustment ........................................................................................... 4 -1 4.1.2 Carriage Timing Belt T ension A djustment .............................................[...]

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ADJUSTM ENT Rev . B 4-1 4.1 PRINTER MEC H A NISM A DJUSTME N T S This sec tion descr ibes the printer m echanis m adjustm ents for the DFX -8500. W henever the printer is disassem bled and the printer par ts m entioned in this sec tion are replaced or repaired, perf orm the appropriate adjus tm ents to ensure pr oper printer oper ation. Perform adj[...]

DFX-8500 Rev . B 4- 2 4.1.2 Carriage T iming Belt T ens ion A djustment The car riage tim ing belt tension m ust be adj usted when any carriage mec hanism part (s uch as the CR m otor , belt pulley , or carriage tim ing belt) is disass embled. Rem ove the pr inter m echanis m bef ore perf orm ing this adjustm ent. (Ref er to Section 3.2.6) ; Bef[...]

ADJUSTM ENT Rev . B 4- 3 4.1.3 T ractor Wire Spring T ension A djustment This s ec tion des cr ibes the trac tor wire spring tens ion adj ustm ent. If the s pr ing is not adj us ted proper ly , paper jam s m ay oc cur , becaus e the continuous paper tens ion (in the horizontal direction) is incorrec t. W hen you rem ove the front or rear trac tor a[...]

DFX-8500 Rev . B 4- 4 4.1.4 Pull T ractor Sensor Position Ad justment This s ection desc ribes the pull trac tor sens or position adjus tm ent. If the sens or position is incorrec t, the sensor is alway s on. W hen you replace or disass emble the platen, r ear paper guide, platen roller shaft, tension roller s haft, or pull tr actor sens or , perfo[...]

ADJUSTM ENT Rev . B 4- 5 4.1.5 Carriage Guide Sh aft Parallelism Ad justment The rear carriage guide s haft m ust be par allel to the platen. If it is not, pr inting m ay be abnorm al bec ause paper is not f ed evenly at the lef t and right sides of the platen. A paper jam may occur . T his adjus tment is required when the r ear carriage guide shaf[...]

DFX-8500 Rev . B 4- 6 Step 3: Attach the another needle to the mas ter sur face, APPRO X. 2.00 m m depth, then corr espond to the another gauge m easure, and tighten the hex agonal screw . Step 5: Set the black m ark er to the "0" position. 2. Attach the gauge needle to the master surface, then correspond to the another gauge measure. 3. [...]

ADJUSTM ENT Rev . B 4- 7 Step 6: Remove a CP(PS)( M3X6) sc rew secur ing the timing belt holder to the tim ing belt, then rem ove the timing belt holder . Step 7: Remove the paper bail ass em bly . (Refer to Section 3.2.6.5.) Step 8: Remove the tension roller shaft. ( Refer to Section 3.2.6.7.) Step 9: Remove the printhead with the m ask -less hold[...]

DFX-8500 Rev . B 4- 8 Step 12: Measure the distance between the platen and the carr iage guide shaft on the lef t side. T hen meas ure the distanc e between the platen and the rear carriage guide s haft on the right s ide, and com pare these values .(Figure4-1 1 shows the m easurem ent position and the par allelism adjust lever operation.) Note: Wh[...]

ADJUSTM ENT Rev . B 4- 9 4.1.6 Platen A ngle Ad justment This s ection desc ribes the platen angle adj ustm ent. The platen m us t be at a right angle to the carr iage assem bly . This adjustm ent is requir ed when the platen is rem oved or replac ed or when the two hexagonal screws s ecuring the platen to both side f ram es are loos ened. Do not r[...]

DFX-8500 Rev . B 4-1 0 Step 4: Using the carriage guide shaf t gear , attach the both dial gauge needles to the platen s urfac e.(The needle doesn’t reach the end of the strok e). Step 5: Measure the angle differenc e about three position suc h as f igure below .(Us ing the CR m otor pulley to move the carr iage with the dial gauge toward the rig[...]

ADJUSTM ENT Rev . B 4-1 1 Step 6: If the angle differenc e of two values are m ore than + 0.015 m m , loosen ( but do not rem ove) the two hexagonal scr ews secur ing the platen stay to both side fram es, then change the platen angle slowlly and manually .) Step 7: T ighten tw o hexagonal screws sec uring the platen stay to both side fram es. After[...]

DFX-8500 Rev . B 4-1 2 4.1.7 Platen Gap M otor V alue Adjustment This section des cribes how to meas ure the param eter ( ALPHA and BET A values ) for the PG m echanis m unit. Since the ALPHA and BET A values are unique to eac h m echanism unit, it is written on the label as shown in Figures 4-17 and 4-18, so that it c an be c onf irm ed at glanc e[...]

ADJUSTM ENT Rev . B 4-1 3 Step 1: Remove the paper , ribbon car tridge, and ribbon m ask holder f rom the printer . T hen confir m the ALPHA value written on the print head nose. Step 2: Close the top c over . A LPHA V alu e Write M ode : Step 3: Turn the printer on while pressing the T ear Off, Mic ro Feed (v), and Front/Rear switches. At this tim[...]

DFX-8500 Rev . B 4-1 4 T able 4-1. BET A V alues A d justment Beta No. Reference Thickness G auge A llow ed V alue Def ault V alue*1) BET A 3' 0.43 m m with 150gf pull - - BET A 2 0.00 mm 367 - 419 408 BET A 3 0.43 mm 405 - 437 435 BET A 4 0.80 mm 418 - 475 461 *1: W hen EEPROM is res et. P l at en T ens i on G auge T hi c k nes s G auge ( BET[...]

ADJUSTM ENT Rev . B 4-1 5 4.1.8 M easurement Seeking and Bi-directional Printing Ad justment The purpos e of this adjustm ent is to c orrect the printer m echanism param eters which contr ol bi-dir ectional printing. Be sure to per form this adjustm ent when required. If this adjustm ent is not perform ed correc tly , bi- directional printing may b[...]

DFX-8500 Rev . B 4-1 6 E ND ST A R T T ur n t he pow er S W on w hi l e pr es s i ng M i c r o F eed ^ and M i c r o F eed v S W s . T he pr i nt er per f or m s c ar r i age m eas ur em ent s eek i ng aut om at i c al l y . ( It g o e s to O N L IN E s ta tu s a fte r th i s o p e r a ti o n .) T ur n t he pr i nt e r pow er of f . M ount t he r i[...]

ADJUSTM ENT Rev . B 4-1 7 Ye s S T ART T ur n t he pow er S W on w hi l e pr es s i ng T ear O f f , M i c r o F eed^ , and F r ont / R ear S W s . S et t he 15" f anf ol d paper at F r ont or R ear t r act or and l oad t he paper by pr es s i ng LF / F F Load S W or F r ont / R ear S W . " P G A l pha= A A A " i s pr i nt ed. 1 . &q[...]

DFX-8500 Rev . B 4-1 8 T able 4-2. LED indication and Adjustment V alue Comparison LED*1) Off On*2) Ribbon (Bi-d. adjus tm ent) (PG adjustm ent) + (positive) 300 ( negative) 400 Pause 10 T op of Form 20 T ear Off 30 Copy 40 Pitch    50 60 70 Font   80 90 7 Segment*3) 0 to 9 *1)  : off ,  : On *2) Indica [...]

ADJUSTM ENT Rev . B 4-1 9 B i- D . A d ju s t m e n t M o d e S uper D r af t P r i nt M ode: No Ye s 1. P anel di pl ay s t he c ur r ent B i - D . adj us t m ent v al ue. 2. P r i nt er pr i nt s " S peed = A A A B i d adj us t = B B B " . B B B * 1) i s t he c ur r ent adj us t m ent v al ue. D o e s th e odd ( 1s t and , 3r d) and ev [...]

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CHA PTER 5 TROUBLESHOOTING 5.1 PROBLEM ISOLA TION..........................................................................................5-1 5.2 SELF DIA GNOSTIC FUNCTION ............................................................................ 5-2 5.3 TROUBLESHOOTING ............................................................................[...]

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TROUBLESHOOTING Rev . B 5-1 5.1 TROUBLESHOOTING INFORMA TION The inform ation in this c hapter mak es troubles hooting easier to perf orm by listing various problem s that c an occur and providing possible s olutions. Note: For this printer , no special tools are necessary for troubleshooting to the unit level, with the exception of a digital multi[...]

DFX-8500 Rev . B 5- 2 5. 1. 2 By passing Interlock Switch and Cover Open Sensor T o print with the top cover open or rem oved, you need to by pass the interlock switch and c over open s ensor because these s ensors automatic ally disable printing when the top cover is open. The interlock switch and cover open sens or consists of an assem bly . T o [...]

TROUBLESHOOTING Rev . B 5- 3 5. 1. 3 Coil Resistance The f ollowing table provides the coil res istance f or the m otor , head fan, plunger , and printhead. T able 5-2. Motor , Fan, Plunger , and Printhead Coil Resistance Part Coil Resist ance CR motor 1.66 ohms + 10 % PF motor 2.80 ohms + 10 % at 25 o C RF motor 150 ohm s + 10 % at 25 o C PG m oto[...]

DFX-8500 Rev . B 5- 4 FPC A FPC B FPC C Load Pattern : Head coil GND side : 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. P[...]

TROUBLESHOOTING Rev . B 5- 5 1. The printer does not operate when pow er is turned on. E ND Replace the C204 MAIN board, C204 DRV board, and/or C204 DRV-B board. I s the A C i nput v o l tage n o r m a l ? N o Y e s Us e the c o rr e c t A C v o l tage. H a s fu s e F1 on the C 204 po w e r s upp l y boa r d b l o w n? Y e s N o W hen y ou tu r n o[...]

DFX-8500 Rev . B 5- 6 2. Carriage operation is abnormal. END S T AR T N o Y es A r e t he connec t o r s li s t ed i n N OT E 1 i nse r t ed secu r e l y? R e i nse r t t he connec t o r s . I s t he f au l t co rr ec t ed? N o Y es M anua ll y m ove t he ca rr i age t o see i f m ove m en t i s s m oo t h o r no t. N o t s m oo t h R e f e r t o S[...]

TROUBLESHOOTING Rev . B 5- 7 3. Carriage operation is normal, but the self-test is printed incorrectly (1/3). R e i n se rt co rr e ctly. Y e s S T A R T N o Y e s N o I s the fau l t c o rr e c ted? E ND E ND P e r fo r m the s e l f - te s t. A r e the c onn e c to r s li s te d i n N O T E 1 i n s e r te d s e c u r e l y ? N o Y e s P e r fo r [...]

DFX-8500 Rev . B 5- 8 3. Carriage operation is normal, but the self-test is printed incorrectly (2/3). R e f e r t o S e c ti on 5 . 3 , R epa i r o f t he P r i n t e r M e c han i s m . P r i n t O K ? . If t he p r i n t head d r i v e r s a r e O K, r ep l a c e t he p r i n t head . C he ck t he p r i n t head d r i v e r s . N o I s t he p r [...]

TROUBLESHOOTING Rev . B 5- 9 3. Carriage operation is normal, but the self-test is printed incorrectly (3/3). B Y e s P e r fo r m b i d i r e c t i ona l ad j u s t m ent. E ND N o I s the p r i nt c o rr e c t? G o ba ck to S e c t i on 5.3 R epa i r of the P r i nte r M e c han i s m , an d c he ck fo r othe r p r ob l e m s . P e r fo r m b i d[...]

DFX-8500 Rev . B 5-1 0 4. Printing is normal, but paper feeding is abnor mal. A r e t he d r i v e r s s ho r te d o r open? Load the pape r c o rr e c t l y . S T A R T Y e s I s the pape r l oaded c o rr e c t l y ? Y e s I s P F m ot o r c o il r e s i s ta n c e c o rr e c t? Y e s N o Y e s E ND N o I s the p r i nt O K ? R efe r to S e c t i [...]

TROUBLESHOOTING Rev . B 5-1 1 5. Panel unit operation is abnormal. R ep l a c e th e C P N L boa r d. I s the fau l t c o rr e c ted? R ep l a c e the C MA I N boa r d. D o the sw i t c he s w o r k c o rr e c t l y ? R e i n s e r t c onne c to r CN c o rr e c t l y . S T A R T D o the button s w o r k ? E ND E ND R ep l a c e the C MA I N boa r d[...]

DFX-8500 Rev . B 5-1 2 6. Data sent by the host computer is printed incorrectly . Note : The flowchart below assumes th e host computer is operating normally . R ep l a c e C M A I N boa r d . C he ck t he c ab l e c onne c t i on f r o m t he ho s t c o m pu t e r . Tr oub l e s hoo t p r i n t e r u s i ng t he p r e v i ou s f l o w c ha r t s .[...]

TROUBLESHOOTING Rev . B 5-1 3 5.2 CIRCUIT BOA RD REP A IR This s ection provides detailed tr oubleshooting methods to isolate com ponents in the power supply or on the main boar d. This inform ation is for us e by service personnel who repair to the c om ponent level. The table below provides c aus es, c hec k points, and s olutions f or diff er en[...]

DFX-8500 Rev . B 5-1 4 T able 5-5. C204 PSB/PSE Board Component Repair 2/3 Symptom Cause Checkpoint Solution The +37 VDC (VP1 / VP2) line is dead. The m ain switching FET s QF101 is def ective. Observe the voltage waveform between the drain side and GND. Replace QF101. IC101 is defec tive. Pin 5 (FB) m ust be HIG H then observe the voltage waveform[...]

TROUBLESHOOTING Rev . B 5-1 5 T able 5-5. C204 PSB/PSE Board Component Repair 3/3 Symptom Cause Checkpoint Solution The 5 VDC line is defective. IC204 is defec tive. Chec k the voltage level at pin 10 ( V1) and pin5 (GP). Replace IC204. Observe the drive wavef orm at pin 8 (VO) and pin 5 (G P). Replace IC204 or ZD21 1. 37 VDC line (VP1/VP2) is abno[...]

DFX-8500 Rev . B 5-1 6 5.2.2 C204 M AIN/DR V/DR V-B Boards Repair T able 5-6 indicates m ajor com ponents which is used f or the C204 MAIN/DRV/DRV-B boards and T able 5-7 shows the C204 MAIN/DRV/DRV-B boards com ponent level troubleshooting. T able 5-6. C204 MAIN/DR V/DR V-B boards Component Repair 1/7 Symptom Cause Checkpoint Solution The printer [...]

TROUBLESHOOTING Rev . B 5-1 7 T able 5-6. C204 MAIN/DR V/DR V-B boards Component Repair 2/7 Symptom Cause Checkpoint Solution The printer does not operate at all. The c ontrol ROM is defective. Conf irm that the PROM is inserted the socket correct ly . Replace IC5. The gate arr ay (IC1) is defec tive. Check pin 86 (D0) of IC1 f or a change in the s[...]

DFX-8500 Rev . B 5-1 8 T able 5-6. C204 MAIN/DR V/DR V-B boards Component Repair 3/7 Symptom Cause Checkpoint Solution The car riage operates abnorm ally . IC1 on the C204 MAIN board is defective. Check the signals f or the carr iage motor phases at pins 204 (CRA), 205 (CRB), 206 (CRC), and 5 (CRD) of IC1 Replace IC1. Q16, Q17, Q18, or Q19 on the C[...]

TROUBLESHOOTING Rev . B 5-1 9 T able 5-6. C204 MAIN/DR V/DR V-B boards Component Repair 4/7 Symptom Cause Checkpoint Solution The car riage operates abnorm ally . The car riage encoder sensor is defec tive. Obs erve the carriage enc oder sensor output signal at pins 4 (ENCA) and 3 (ENCB) of CN4 on the C204 MAIN board. Replace the carriage encoder s[...]

DFX-8500 Rev . B 5-2 0 T able 5-6. C204 MAIN/DR V/DR V-B boards Component Repair 5/7 Symptom Cause Checkpoint Solution Paper feeding is abnorm al. The CPU IC2) on the C204 MAIN board is defective. Check the PF m otor phase drive signals at pins 2 - 5 of IC2. Replace IC2. IC2 on the C204 DRV board is def ective. At IC2, check the output signals for [...]

TROUBLESHOOTING Rev . B 5-21 T able 5-6. C204 MAIN/DR V/DR V-B boards Component Repair 6/7 Symptom Cause Checkpoint Solution The head f an operation is abnorm al. IC1 on the C204 MAIN board is defective. Observe the PG m otor phase signal at pins 163 (F ANA) and 164 (F ANAX) of IC1. Replace IC1. Q10 or Q1 1 on the C204 MAIN board is defective. Obse[...]

DFX-8500 Rev . B 5-2 2 T able 5-6. C204 MAIN/DR V/DR V-B boards Component Repair 7/7 Symptom Cause Checkpoint Solution The s elf-tes t is printed incorr ectly IC1 on the C204 MAIN board is defective. Observe the output signal at pins 136- 181 of IC1. Replace IC1. The head driver FET s on the C204 MAIN and/or C204 DRV-B boards are def ective. Observ[...]

TROUBLESHOOTING Rev . B 5-2 3 5.2.3 Printer Mechanism Repair The table below des cribes how to isolate problem s with the printer mechanis m. T o replace or adj ust printer mec hanism parts, r efer to Chapter 3, Disass embly and Ass embly , and Chapter 4, Adjustments . If a symptom recurs following a repair attem pt, look for other possible c auses[...]

DFX-8500 Rev . B 5-2 4 T able 5-7. Printer M echanism Repair 2/4 Symptom Cause Checkpoint Solution A particular dot does not print. The pr inthead is defective. Meas ure the printhead coil r esistanc e. (Refer to Figure 5-4 f or details.) Replace the printhead. Check whether a dot wire is worn. Replace the printhead. The print is too light or print[...]

TROUBLESHOOTING Rev . B 5-2 5 T able 5-7. Printer M echanism Repair 3/4 Symptom Cause Checkpoint Solution The RF m otor does not operate. The par allelism value is incor rect . Check whether the car riage m oves sm oothly w hen moved m anually . (Check that for eign objects are not lodged in the printer m echanis m.) Perform the parallelism adjustm[...]

DFX-8500 Rev . B 5-2 6 T able 5-7. Printer M echanism Repair 4/4 Symptom Cause Checkpoint Solution Printing occu rs outside the paper width. The PW s ensor is defective. Chec k the PW sensor . Replace the PW sensor . The paper bail assem bly does not work. The plunger is defective. Chec k the c oil resist ance of the plunger . (It should be about 9[...]

CHA PTER 6 MA INTENENCE 6.1 PREVENTIVE MA INTENENCE .............................................................................. 6-1 6.2 LUBRICA TION A ND A DHESIVE A PPLICA TION ................................................... 6-1[...]

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M AINTENANCE Rev . B 6-1 6.1 PREVENTIVE MA INTENA NCE T o keep the printer in good c ondition, regularly clean the case exterior (using denatured alc ohol) and vac uum the mechanis m 's interior to remove dus t and paper debris. Af ter cleaning the pr inter , check that it is adequately lubr icated, as des cribed in Section 6.2, below . Befor [...]

DFX-8500 Rev . B 6- 2 T able 6-2. Lubrication Points Ref. No. Ref. Figure Lubrication Point Lubricant (1 ) 6- 3 Carriage oil pad ring (on both lef t and right sides of car riage) O2 (2 ) 6- 3 Carriage oil pad (under the carriage head cable holder ), O 2 (3 ) 6- 3 Hole holding the tip of the rear carriage guide s haft (in both lef t and right side f[...]

M AINTENANCE Rev . B 6- 3 Figure 6-2. Lubrication and A dhesive Diagram 1[...]

DFX-8500 Rev . B 6- 4 Fi g ure 6-3. Lubrication and A dhesive Dia g ram 2[...]

M AINTENANCE Rev . B 6- 5 Figure 6-4. Lubrication and A dhesive Diagram 3[...]

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A PPENDIX A .1 CONNECTOR PIN A SSIGNMENTS ..................................................................... A -1 A .2 CIRCUIT DIA GRAMS ........................................................................................... A-9 A .3 COMPONENT LA YOUT...................................................................................... A -21[...]

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APPENDIX Rev . B A-1 A .1 CONNECTOR PIN A SSIGNMENTS Figure A-1 illustr ates the interc onnec tion of the prim ar y components . T able A- 1 s um m arize the des c ription and sizes of the connec tors. CN1(3) CN5(2) CN3(12) CN2(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) CN[...]

DFX-8500 Rev . B A- 2 T able A -1. Board Connector Summary Connector Connection Pin Number T able to Refer C204 MAIN Board CN1 => Mechanism (Print head) 30 pins T able A-2 CN2 => C204 DRV-B board 20 pins T able A-3 CN3 => Cover Open 2 pins T able A-4 CN4 => Mechanism (Car riage encoder) 4 pins T able A-5 CN5 => Panel unit 14 pins T a[...]

APPENDIX Rev . B A- 3 T able A -2. C204 M AIN Board Connector CN1 Pin Signal Name I/O Function 1 P+10 O Printhead pin #10 2P - 1 0 O G N D 3 P+12 O Printhead pin #12 4P - 1 2 O G N D 5 P+16 O Printhead pin #16 6P - 1 6 O G N D 7P - 1 7 O G N D 8P - 9 O G N D 9 P+17 O Printhead pin #17 10 P-1 1 O GND 1 1 P+1 1 O Printhead pin #1 1 12 P-7 O GND 13 P+[...]

DFX-8500 Rev . B A- 4 T able A -5. C204 M AIN Board Connector CN4 Pin Signal Name I/O Function 1G N D - 2+ 5 V - 3 ENCB I CR encoder B phase pulse 4 ENCA I CR encoder A phase pulse T able A -6. C204 M AIN Board Connector CN5 Pin Signal Name I/O Function 1 LED_DA T A O LED data 2 LED_XLE O LED data latc h 3 LED_CLK O LED data cloc k 5 LED_XOE O LED [...]

APPENDIX Rev . B A- 5 T able A -12. C204 M AIN Board Connector CN1 1 Pin Signal Name I/O Function 1, 2, 3, 4, 5, 6 +5 - 7 BTX D O Transm it data 8 XREADY O Ready 9 BRXD I Receive data 10 NC - 1 1 BXRST O Reset signal 12 INH O Inhibit signal output 13 XCMDREQ I Comm and reques t signal 14 XW RRDY I W rite ready s ignal 15 XRDREQ I Read request s ign[...]

DFX-8500 Rev . B A- 6 T able A -13. C204 M AIN Board Connector CN14 Pin Signal Name I/O Function 1 VP3 - +37 VDC 2, 3, 4 GND - 5, 6, 7, 8 +5 - 9, 10 VX - +5 VDC switched by reset status 1 1 F AN O HF control signal 12 PLN O Plunger N channel 13 RFH/R O RF motor com m on 14 RFC O RF m otor C phase puls e 15 RF A O RF m otor A phas e pulse 16 PGD O P[...]

APPENDIX Rev . B A- 7 T able A -15. C204 M AIN Board Connector CN16 Pin Signal Name I/O Function 1 DIPCNT2 O DIP SW select port 2 2 DIPCNT3 O DIP SW select port 3 3 DIPCNT4 O DIP SW select port 4 4 DIPCNT5 O DIP SW select port 5 5 DIPCNT6 O DIP SW select port 6 6 DIPCNT7 O DIP SW select port 7 7 DIPCNT8 O DIP SW select port 8 T able A -16. C204 DRV[...]

DFX-8500 Rev . B A- 8 T able A -17. C204 DRV Board Connector CN3 Pin Signal Name4 I/O Function 1, 2, 3 VP3 - +37 VDC 4, 5, 6 GP3 I GND for VP3 T able A -18. C204 DRV-B Board Connector CN1 Pin Signal Name4 I/O Function 1 P+6 O Printhead pin #6 2 P+4 O Printhead pin #4 3P - 1 8 O G N D 4P - 4 O G N D 5 P+14 O Printhead pin #14 6P - 1 4 O G N D 7 P+18[...]

APPENDIX Rev . B A- 9 A .2 CIRCUIT DIA GRA MS See the following pages for the figures below: Figure A -2. C204 M AIN Board Exploded Diagram C204 MA IN 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 C2 04 PS B Figure A-6. C204 PSE Board Exp[...]

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APPENDIX Rev . B A-21 A .3 Component Lay out Figure A - 7. C204 M AIN Board Component Lay out (1)[...]

DFX-8500 Rev . B A-2 2 Figure A - 8. C204 M AIN Board Component Lay out (2)[...]

APPENDIX Rev . B A-2 3 Figure A - 9. C204 DRV Board Component Layout (1) Figure A - 10. C204 DRV Board Component Layout (2)[...]

DFX-8500 Rev . B A-2 4 Figure A - 1 1. C204 DRV-B Board Component Layout (1) Figure A - 12. C204 DRV-B Board Component Layout (2)[...]

APPENDIX Rev . B A-2 5 Figure A - 13. C204 PSB Board Component Layout[...]

DFX-8500 Rev . B A-2 6 Figure A - 14. C204 PSE Board Component Layout[...]

APPENDIX Rev . B A-2 7 A .4 Connectors on the Connector Junction Board See the figure bellow for the connector ar rangem ent on the connector junction board. R B W G Y B B W W W W W R R W R B W B t o P l unger t o O pt i on P ul l T r ac t or S ens or t o R ear P E S ens or to T o p P E S e n s o r to P G E n c o d e r to P G M o to r to T S /R F M[...]

DFX-8500 Rev . B A-2 8 A .5 Part List T able A -20. Part List (1/3) No. Part Names No. Part Nam es 100 HOUSING ASSY .,LO W ER 163 SP ACER,PS UNIT 101 FRAME ASSY .,BO TTO M 164 LEAF SPRING,BASE F RAME 102 COVER ASSY .,FRONT 165 COVER, DIP SW IT CH 103 HOUSING ASSY .,UPPER 166 COVER,CONNECTO R,UPPER ECW 104 HOUSING ASSY .,T OP 167 C.B.(O )SCREW M3X8 [...]

APPENDIX Rev . B A-2 9 T able A -20. Part List (2/3) NO. Part Nam es NO. Part Names 529 BOARD ASSY .,INT ERMIT ,HEAD 587 PLA TEN ROLLER T RANSMISSION GEAR 530 BOARD ASSY .,INT ERMIT ,CARRIAGE 588 PLA TEN ROLLER MIDDLE GEAR 531 BOARD ASSY .,DET ECTOR,PT S 589 T ENSION ROLLER GEAR 532 P APER ASSY .,SUPPO RT 590 P APER BAIL GEAR 533 ROLLER ASSY .,LOAD[...]

DFX-8500 Rev . B A-3 0 T able A -20. Part List (3/3) NO. Part Nam es NO. Part Names 647 SPUR,GEAR,40 669 F AN,CR 648 EXTENSION SPRING, 320 671 RIBON MASK SUB ASSY . 649 MOUNT PLA TE W IRE,RIGHT 672 SPUR,GEAR,24 650 MOUNT PLA TE,W IRE,LEFT 673 MOUNT PLA T E,DET ECTOR,RJ 651 EXTENSION SPRING, 40 674 DETECTOR ASSY .,RJ 0V ,0A, 652 SPUR GEAR,32 675 HAR[...]

APPENDIX Rev . B A-31 A .6 EXPLODED DIA GRA M S See the following pages for the exploded diagrams below . Note that the last page s hows the pack ing mater ial for DFX- 8500. Figure A-16. EXPLODED DIA GRAMS FOR DFX-8500 ( 1) EXPLODED DIAG RAM (1) Figure A-17. EXPLODED DIA GRAMS FOR DFX-8500 ( 2) EXPLODED DIAG RAM (2) Figure A-18. EXPLODED DIA GRAMS[...]

DFX-8500 Rev . B A-3 2 Figure A -16. Exploded Diagrams (1)[...]

APPENDIX Rev . B A-3 3 Figure A -17. Exploded Diagrams (2)[...]

DFX-8500 Rev . B A-3 4 Figure A -18. Exploded Diagrams (3)[...]

APPENDIX Rev . B A-3 5 Figure A -19. Exploded Diagrams (4)[...]

DFX-8500 Rev . B A-3 6 Figure A -20. Exploded Diagrams (5)[...]

APPENDIX Rev . B A-3 7 Figure A -21. Exploded Diagrams (6)[...]

DFX-8500 Rev . B A-3 8 Figure A -22. Exploded Diagrams (7)[...]

APPENDIX Rev . B A-3 9 Figure A -23. Packing M aterial[...]

EPSON OVERSEAS MARKETING LOCATIONS EPSON AMERICA, Inc. 20770 Madrona Avenue, P.O. Box 2842 Torrance, CA 90509-2842 Phone: (800)922-8911 Fax: (310)782-5220 EPSON DEUTCHLAND GmBH Zülpicher Straße 6, 4549 Düsseldorf Germany Phone: (0211)56030 Telex: 8584786 EPSON UK LTD. Campus 100, Maylands Avenue, Hemel Hempstead, Herts, HP2 7TJ U.K. Phone: (+44)[...]

EPSON SEIKO EPSON CORPORATION[...]