Epson DFX-8500 service manual

EPSON

IMPACT SERIAL DOT MATRIX PRINTER

DFX-8500

SERVICE MANUAL

SEIKO EPSON CORPORATION

4009310

Contents

Main NOTICE Copyright 1998 by SEIKO EPSON CORPORATION Nagano, Japan PRECAUTIONS WARNING CAUTION WARNING CAUTION PREFACE Page Page CHAPTER 1 GENERAL DESCRIPTION Page 1.1 FEATURES 1-2 1.2 SPECIFICATIONS 1.2.1 Printing Specification 0.35 mm (1/72") 2.82 mm (8/72") 1.69 mm (1/15") 1-4 Note: These tables can not be selected by DIP switch. Page 1-6 1.2.2 Paper Feeding Note : The feeding speed will be reduced to 0.152 mps (6.0 ips) when the pull tractor is mounted. 1.2.3 Electrical Specification 1.2.4 Environmental Condition *1: Without condensation *2: With shipment container 1.2.6 Safety Approvals 1.2.7 CE Marking 1.2.8 Acoustic Noise 1.2.9 Ribbon Cartridge 1.2.10 Physical Specifications 1.2.11 Printable area Page Page Page 1-12 1.2.12 Paper and Media 1.2.12.1 Continuous paper (Single sheet and multi-part) Page 1-14 1.2.12.2 Labels W H 1.2.12.3 Continuous Forms with Labels 1-16 1.2.12.4 Overlapping Multi-part Form 1.2.12.5 Perforation 1.2.12.6 Notes Figure 1-12. Paper Width Overlapping Area Figure 1-13. Perforations 1 Figure 1-14. Perforations 2 Page 1.3 INTERFACES 1.3.1 Parallel Interface (Forward channel) 1-20 Note: * In/Out refers to the direction of signal flow from the printers point of view. 1.3.2 Parallel Interface (Reverse channel) Note: * In/Out refers to the direction of signal flow from the printers point of view. 1.3.3 Serial Interface 1.3.4 Optional Interface 1.3.5 Interface Selection 1.3.6 Prevention Hosts from Data Transfer Time-out 1-24 1.4 OPERATING INSTRUCTIONS Figure 1-22. Control Panel 1.4.1 Control Panel LED Off LED On 1.4.1.1 Switches 1-26 1.4.1.2 Indicators 1.4.2 Errors and Buzzers Note 1: The descriptions .and - show how the beeper sounds. 1-28 1.4.3 DIP Switch Settings Page 1-30 1.4.4 Functions 1.4.4.1 Usual operation 1-32 1.4.4.2 Operation at Power On 1-34 1.4.4.3 Built-in Detection 1.4.5 Paper Memory Function 1-36 1.4.6 Initializations 1.4.6.1 Power-on Initialization 1.4.6.2 Software Initialization 1.4.6.3 Panel Initialization 1.5 MAIN COMPONENT 1.5.1 M-3I60 Printer Mechanism 1.5.2 Main Control Board (C204 MAIN Board) 1.5.3 C204 DRV Board Page Page Page Page CHAPTER 2 OPERATING PRINCIPLES Page 2.1 PRINTER MECHANISM OPERATION Page Page 2.1.1 Printhead Mechanism 2.1.2 Carriage Mechanism 2- 2.1.3 Platen Gap Adjustment Mechanism 2.1.4 Paper Feed Mechanism Page 2.1.4.1 Tractor Wire Operation Page Rev. B 2-11 2.1.6 Plunger Mechanism 2.2 POWER SUPPLY OPERATION 2.2.1 Power Supply Overview Figure 2-14 shows a block diagram of the C204 PSB/PSE board. Figure 2-14. Power Supply Board Block Diagram CN3 CN4 CN2 CN5 Page Page 2.3 CONTROL CIRCUIT 2.3.1 Control Circuit Operation Overview Figure 2-15. Control Circuit Block Diagram Page Page 2.3.2 Reset Circuit 2.3.3 Sensor Circuits Figure 2-18. Sensor Circuit Block Diagram POFF (SD) CN10 CN1 Page Page 2.3.4 CR Motor Drive Circuit Page Acceleration Cu rve Note: 1, 2, and 3 indicate the PWM control section number. 2.3.5 PF Motor Drive Circuit 2.3.6 RF Motor Drive Circuit TMP95C061A (IC2) E05B36 (IC1) Rev. B 2-31 2.3.7 PG Motor Drive Circuit 2.3.8 Plunger Drive Circuit PLN Plunger Coil Rev. B 2-3 2.3.9 Printhead Drive Circuit Printhead Coils 1/2 Printhead Thermistor Printhead Coils 2/2 MAIN Board 2-3 CHAPTER 3 DISASSEMBLY AND ASSEMBLY Page 3.1 OVERVIEW 3.1.1 Precautions for Disassembly and Assembly Page 3.1.2 Tools Page 3.1.3 Specification for Screws 3.1.4 Service Checks After Repair 3.2 DISASSEMBLY AND ASSEMBLY 3.2.1 ROM Replacement 3.2.2 Printhead and Ribbon Mask Assembly Removal Page 3-11 Page 3.2.3 Housing Removal 3.2.3.1 Top Cover Removal 3.2.3.2 Left, Right, and Front Covers Removal and Fuse Replacement Make sure the new fuse meets the printer's AC power specifications. 3.2.3.3 Front Panel Unit Removal 3.2.3.4 Upper Case Removal 3.2.4 Circuit Boards Removal 3.2.4.1 Bottom Panel Assembly Removal CB(M3X12) CBB(M 3X12) Rear Cover Optional In te rfa c e C o v e r In te rfa c e C o v e r Page 3-21 3.2.4.2 Cooling Fan and C204 Power Supply Board Unit Removal 3.2.4.3 C204 SUB Board Unit Removal 3.2.4.4 C204 DRV-B and C204 DRV Board Units Removal 3.2.4.5 C204 MAIN Board Unit Removal Page 3.2.4.6 AC Inlet Removal 3.2.4.7 C204 PNL Board Removal 3.2.5 Interlock Switch and Cover Open Sensor Assembly Removal In te rlo ck S W Assembly Upper Case CBB(M4X10) Lower Case CBB(M3X10) Cover Open Sensor 3.2.6 Printer Mechanism Removal Two people are required to remove or install the printer mechanism. Earth Cable CBS(O) Screw(M4x8) C204 PSB/PSE Board (R ig h t s id e ) Bottom P anel Assembly Page 3-31 3.2.6.1 Fan Removal 3.2.6.2 Ribbon Feed Change Lever Unit Removal Page 3.2.6.3 Tractor Select Lever (Upper and Lower) Assembly Disassembly Attach the tractor select levers to the tractor select cam as shown in Figure 3-50. 3.2.6.4 Ribbon Jam Sensor Removal 3.2.6.5 Connector Junction Board Assembly and FPC Board Assembly Removal 3.2.6.6 PG Sensor and PG Motor Removal 3.2.6.7 Plunger and Paper Bail Assembly Removal Page 3.2.6.8 Upper Paper Guide and Top PE Sensor Removal 3-41 3.2.6.9 Tension Roller Shaft Removal Page 3.2.6.10 Platen Removal 3.2.6.11 Paper Jam Sensor Removal When you attach the paper jam sensor, make sure it is oriented correctly (front to back). 3.2.6.12 Pull Tractor Sensor Removal 3.2.6.13 Paper Width (PW) Sensor Removal 3.2.6.14 PG Home Sensor Removal Page 3.2.6.15 PF Motor Removal 3.2.6.16 Left Side Frame Gear Removal 3-51 3.2.6.17 Front Tractor Assembly Removal <Left> <Right> 3.2.6.18 Rear Tractor Assembly Removal 3.2.6.19 CR Motor Fan Removal 3.2.6.20 CR Motor Removal 3.2.6.21 CR (Carriage Encoder) Sensor Removal 3.2.6.22 Carriage Mechanism Disassembly Side Fram e (L) Belt Pulley Belt Pulley Holder Flange N ut Front Carriage G uide Shaft Page Page 3.2.6.23 Paper Support Assembly Removal 3-6 3.2.6.24 3.2.6.21 PF Drive Roller Removal Page Page 4.1 PRINTER MECHANISM ADJUSTMENTS 4.1.1 PG Motor Backlash Adjustment 4.1.2 Carriage Timing Belt Tension Adjustment 7000 gf + 200 gf CPS(M4X10) Rev. B 4- 4.1.3 Tractor Wire Spring Tension Adjustment 4.1.4 Pull Tractor Sensor Position Adjustment 4.1.5 Carriage Guide Shaft Parallelism Adjustment Page Rev. B 4- CP(PS)M3X6) Tim ing Belt Holder Carriage Carriage G uide Shaft (Rear) A B Page 4.1.6 Platen Angle Adjustment Hexagonal Screws (M 4X8) Platen Stay (R ) Platen Stay (L) Positioning Tab Positioning Tab Side Frame R SideSide Frame L S ide Platen Center Position 70 mm 70 mm Page 4.1.7 Platen Gap Motor Value Adjustment A L P H A V a l u e P r i n t P r in t h e a d Page Page 4.1.8 Measurement Seeking and Bi-directional Printing Adjustment Page START G o to B i-D . A d ju s t m e n t M o d e . Figure 4-21. Flight Time Adjustment END 40 CO L. 40 CO L.56 CO L. Flight Time + XX X B i-D . A d ju s t m en t M o de Figure 4-23. Bi-d. Adjustment *1) No Return Page Page Page 5.1 TROUBLESHOOTING INFORMATION 5.1.1 Error Messages 5.1.2 Bypassing Interlock Switch and Cover Open Sensor Short Circuit Connector Rev. B 5- 5.1.3 Coil Resistance Head FPC C B A FPC A FPC B FPC C Rev. B 5- 1. The printer does not operate when power is turned on. 5- 2. Carriage operation is abnormal. A 5- A B Check the print head coil resistance. Replace the C204 MAIN and./or B 4. Printing is normal, but paper feeding is abnormal. No No Page 6. Data sent by the host computer is printed incorrectly. Note : The flowchart below assumes the host computer is operating normally. 5.2 CIRCUIT BOARD REPAIR 5.2.1 C204 PSB/PSE Board Repair Page Page 5.2.2 C204 MAIN/DRV/DRV-B Boards Repair Page Page Page Page Rev. B 5-21 Page Rev. B 5-2 5.2.3 Printer Mechanism Repair Adjustments Page Rev. B 5-2 Adjustments Page Page Page 6.1 PREVENTIVE MAINTENANCE 6.2 LUBRICATION AND ADHESIVE APPLICATION 6- Page Page Page Page Page Page Rev. B A-1 A.1 CONNECTOR PIN ASSIGNMENTS Figure A-1. Cable Connection Page Page Page Page Page Page Page A.2 CIRCUIT DIAGRAMS Page Page Page Page Page Page Page Page Page Page Page Rev. B A-2 A.4 Connectors on the Connector Junction Board Figure A- 15. Connectors on the Connector Junction Board See the figure bellow for the connector arrangement on the connector junction board. A-2 A.5 Part List Rev. B A-2 A-3 Rev. B A-31 A.6 EXPLODED DIAGRAMS Page Page Page Page Page Page Page Page EPSON OVERSEAS MARKETING LOCATIONS As of September, 1996