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EPSON TERM NAL PR NTER
DFX-5000+
SERVICE MANUAL
EPSON
NOTICE
All rights reserved. Reproduction of any part of this manual in any form whatsoever without
SEIKO EPSON's express written permission is forbidden.
The contents of this manual are subjects to change without notice.
All efforts have been made to ensure the accuracy of the contents of this manual. However, should
any errors be detected, SEIKO EPSON would greatly appreciate being informed of them.
The above notwithstanding SEIKO EPSON can assume no responsibility for any errors in this
manual or the consequence thereof.
Centronics is a registered trademark of Centronics Data Computer Corporation.
Epson and Epson ESC/P are registered trademark of Seiko Epson Corporation.
@Copyright 1994 by SEIKO EPSON CORPORATION Nagano, Japan
-iv-
PRECAUTIONS
Precautionary notations throughout the text are categorized relative to 1) personal injury and 2)
damage to equipment.
DANGER Signals a precaution which, if ignored, could result in serious or fatal personal injury.
Great caution should be exercised in performing procedures preceded by DANGER
Headings.
WARNING Signals a precaution which, if ignored, could result in damage to equipment.
The precautionary measures itemized below should always be observed when performing repair/
maintenance procedures.
1. ALWAYS DISCONNECT THE PRODUCT FROM BOTH THE POWER SOURCE AND
PERIPHERAL DEVICES PERFORMING ANY MAINTENANCE OR REPAIR PROCE-
DURE.
2. NO WORK SHOULD BE PERFORMED ON THE UNIT BY PERSONS UNFAMILIAR WITH
BASIC SAFETY MEASURES AS DICTATED FOR ALL ELECTRONICS TECHNICIANS IN
THEIR LINE OF WORK.
3. WHEN PERFORMING TESTING AS DICTATED WITHIN THIS 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.
1. REPAIRS ON EPSON PRODUCT SHOULD BE PERFORMED ONLY BY AN EPSON
CERTIFIED REPAIR TECHNICIAN.
2. MAKE CERTAIN THAT THE SOURCE VOLTAGE IS THE SAME AS THE RATED VOLT-
AGE, LISTED ON THE SERIAL NUMBER/RATING PLATE. IF THE EPSON PRODUCT
HAS A PRIMARY AC RATING DIFFERENT FROM AVAILABLE POWER SOURCE, DO
NOT CONNECT IT TO THE POWER SOURCE.
3. ALWAYS VERIFY THAT THE EPSON PRODUCT HAS BEEN DISCONNECTED FROM
THE POWER SOURCE BEFORE REMOVING OR REPLACING PRINTED CIRCUIT
BOARDS AND/OR INDIVIDUAL CHIPS.
4. IN ORDER TO PROTECT SENSITIVE MICROPROCESSORS AND CIRCUITRY, USE
STATIC DISCHARGE EQUIPMENT, SUCH AS ANTI-STATIC WRIST STRAPS, WHEN
ACCESSING INTERNAL COMPONENTS.
5. REPLACE MALFUNCTIONING COMPONENTS ONLY WITH THOSE COMPONENTS
BY THE MANUFACTURE; INTRODUCTION OF SECOND-SOURCE ICS OR OTHER
NON APPROVED COMPONENTS MAY DAMAGE THE PRODUCT AND VOID ANY
APPLICABLE EPSON WARRANTY.
- ii -.
PREFACE
This manual describes functions, theory of electrical and mechanical operations, maintenance, and repair
of DFX-5000+.
The instructions and procedures included herein are intended for the experience repair technician, and
attention should be given to the precautions on the preceding page. The chapters are organized as
follows:
CHAPTER 1. GENERAL DESCRIPTION
Provides a general product overview, lists specifications, and illustrates the main components of the printer.
CHAPTER 2. OPERATING PRINCIPLES
Describes the theory of printer operation.
CHAPTER 3. DISASSEMBLY AND ASSEMBLY
Includes a step-by-step guide for product disassembly and assembly.
CHAPTER 4. ADJUSTMENTS
Includes a step-by-step guide for adjustment.
CHAPTER 5. TROUBLESHOOTING
Provides Epson-approved techniques for adjustment.
CHAPTER 6. MAINTENANCE AND LUBRICATION
Describes preventive maintenance techniques and lists Lubricants and adhesives required to service the equipment.
APPENDIX
Describes connector pin assignments, circuit diagrams, circuit board component layout and exploded diagram.
The contents of this, manual are subject to change without notice.
- iv -
REVISION SHEET
Revision Issue Data Revision Page
/ Rev.-A 1 February 9, 1994 / 1 st issue
Page 4-10: Addition the notes
Rev.-B April 20, 1994
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
Page 4-12: Change the explanation
Rev.-E March 7, 1995
Page 4-12: Addition the notes
TABLE OF CONTENTS
CHAPTER 1. GENERAL DESCRIPTION
CHAPTER 2. OPERATING PRINCIPLES
CHAPTER 3. DISASSEMBLY AND ASSEMBLY
CHAPTER 4. ADJUSTMENTS
CHAPTER 5. TROUBLESHOOTING
CHAPTER 6. MAINTENANCE AND LUBRICATION
APPENDIX
- vi -
CHAPTER 1 Product Description
Table of Contents
1.1 GENERAL FEATURES 1-1
1.2 SPECIFICATIONS 1-3
1.2.1 Printer Capabilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-3
1.2.2 Paper Handling Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-3
1.2.3 Paper Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.2.4 Ribbon Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.2.5 Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.2.6 Electrical Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.2.7 Reliability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.2.8 Safety Approvals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.2.9 Physical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1.3 INTERFACE SPECIFICATIONS 1-14
1.3.1 Parallel Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
1.3.2 RS-232C Serial interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
1.4 PRINTER OPERATION 1-17
.-
1.4.1 Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
1.4.2 Self-test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1.4.3 Hexadecimal Dump Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1.4.4 Paper Out Detection Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1.4.5 Cover Open Detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1.4.6 Paper Width Detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
1.4.7 Automatic PaperThickness Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 1-19
1.4.8 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
1.4.9 Automatic Tear Off Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
1.4.10 PaperJam Detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..... 1-21
1.4.11 Automatic Interface Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
1.4.12 Thermal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
1.4.13 Skip Binding Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
1.4.14 Printer Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
1.4.15 Buzzer Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......... 1-22
1.5 DIP SWITCH SETTINGS 1-23
1.6 MAIN COMPONENTS 1-26
1.6.1 M-3C11 Printer Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
1.6.2 Main Control Board (Cl 17 MAIN Board Assembly). . . . . . . . . . . . . . . . 1-28
1.6.3 Power Supply Circuit (C117 PSB/PSE Board Assembly) . . . . . . . . . . . 1-28
1.6.4 Control Panel Board (C117 PNL Board Assembly). . . . . . . . . . . . . . . . 1-29
1.6.5 Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-29
List of Figures ..
Figure 1-1. Exterior View of the DFX-5000+. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Figure 1-2. Pin Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Figure 1-3. Printable Area for Fanfold Paper. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Figure 1-4. Unsuitable Paper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Figure 1-5. Form Override Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Figure 1-6. Perforation Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Figure l-7. Paper Edge at a Horizontal Perforation . . . . . . . . . . . . . . . . . . . . . . 1-7
Figure l-8. Perforation Intersections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Figure l-9. Raised Portion at aPerforation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Figure 1-10. Sprocket Holes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Figure 1-11. Aligned Sprocket Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Figure 1-12. Incorrectly Folded Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Figure 1-13. Printable Area, Overlapping Multi-part Forms. . . . . . . . . . . . . . . . 1-8
Figure 1-14. Dotted Paste Positions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Figure 1-15. Stapled Area 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Figure 1-16. Stapled Area 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Figure 1-17. Stapled Area 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Figure 1-18. Correct Multi-part Form Binding. . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Figure 1-19. Printable Area for Fanfold Paper with a Label. . . . . . . . . . . . . . . 1-10
Figure 1-20. Printable Area for Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Figure 1-21. Label and Carrier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Figure 1-22. Data Transmission 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. Options and Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Table 1-2. Character Size and Pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Table 1-3. Printing Speeds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Table 1-4. Character Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Table 1-5. Acceptable Environmental Conditions. . . . . . . . . . . . . . . . . . . . . . . 1-12
Table 1-6. Rated Electrical Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Table 1-7. Parallel lnterface Signals and Connector Pin Assignments. . . . . . . 1-15
Table 1-8. Serial Interface Signals and Connector Pin Assignments . . . . . . . 1-16
Table 1-9. Selecting the Paper Memory Area . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Table 1-10. Setting the Page Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Table 1-11. Setting the Paper Type.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Table 1-12. DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Table 1-13. IBM Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Table 1-14. ESC/P Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Table 1-15. Interface Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Table 1-16. Baud Rate Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Table 1-17. Page Length Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
DFX-5000+ Service Manual Product Description
1.1 GENERAL FEATURES
The DFX-5000+ is a 9-pin, serial, dot matrix printer with a maximum speed of 560 characters per
second (cps). It is designed for business use and provides high-speed, high-volume printing and
continuous-sheet handling. The main features of the printer are:
Cl Maximum printing speeds:
560 cps (high-speed draft mode)
504 cps (draft elite mode)
420 cps (draft pica mode)
Cl Advanced paper handling:
-10 inches per second (ips) paper feeding
- Paper jam detection
- Paper width detection
- Front and rear two-way push tractors
- Automatic 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
21 character tables in the NLSP (National Language Support) version
Cl Upgraded data handling:
- 20KB input buffer
- Automatic interface selection
- Type B optional I/F cards
The figure below shows the DFX-5000+.
too cover
"'"'"'"" `NV'
control panel
poper separator
----, .-n".fltnr
~"p=, >Gpu,.. a"$ f-flue,
----
rial interface
e cover for
I interface
-,
~orallel interface
Figure 1-1. Exterior View of the DFX-5000+
Rev. A 1-1
Product Description DFX-5000+ Service Manual
Table 1-1. Options and Consumables
I I
Model Description
#8309 Pull tractor unit
#8766 Ribbon cartridge
#8767 Ribbon pack
t ,
I C82305* I Serial I/Fcard, simple serial interface** (SSi), inch screw
I C82306*
1
Serial I/F card, SSI, mm screw
I C82307'
C82308*
I 32KB intelligent serial l/F card (inch screw)
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.
q *A simple serial interface card has no CPU; the printer processes the data from
the card.
1-2 Rev. A
DFX-5000+ Service Manual Product Description
1.2 SPECIFICATIONS
This section provides detailed information about the DFX-5000+.
1.2.1 Printer Capabilities
Printing method: Serial impact dot matrix
Pin configuration: 9 wires
Pin diameter: 0.29 mm (0.01 inches)
mm (1/72")
I o
8/72" o
0
0
0
L3-
Figure 1-2. Pin Configuration
Dot matrix:
9 x 7 (high-speed draft mode)
9 x 9 (draft mode)
18x 23 (NLQ mode)
Printing direction:
Text mode Bidirectional with logic seeking
(Unidirectional mode can be selected using the ESC U command.)
Bit image mode Unidirectional
Built-in fonts: Draft
NLQ Roman
NLQ Saris Serif
Table 1-2. Character Size and Pitch
Width in mm Height in mm Pitch in mm printable Columns
Type of Letters (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) 3.1 (0.12) 2.12 (0.08) 163
15 cpi 1.41 (0.06) 3.1 (0.12) 1.69 (0.07) 204
Condensed (17.1 cpi) 1.06 (0.04) 3.1 (0.12) 1.48 (0.06)
1.27 (0.05)
233
272
I
Condensed elite (20 cpi) 0.85 (0.03) 3.1 (0.12)
Rev. A 1-3
Product Description DFX5000+ Service Manuai
Table 1-3. Printing Speeds
Type of Letters Print Speed (cps) High Duty (cps)
High-speed draft 533
Draft pica 10@ 420 400
Draft elite 12 cpi
Draft 15 cpi 420 400
Draft condensed pica 17 Cpi
Draft emphasized pica 20cpi 210 200
NLQ pica 84 80
NLQ elite 101 96
Input data buffer: 20KB or O bytes (selectable by DIP switch 2-2)
control codes: ESC/P-83 mode
Table 1-4. Character Tables
standard
Character Tables NLSP* Version IBM Mode
Version
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 (Cyrillic) x o x
PC866 (Russian) x o x
PC852 (East Europe) x o x
MAZOWIA (Polish) x o x
Code MJK (Czecho, Slovak) x o x
Bulgaria (Bulgaria) x o x
0: supported
x: Not supported
*: Nationa/Language Support
1-4 Rev. A
DFX-5000+ Service Manual Product Description
1.2.2 Paper Handling Specifications
Feeding methods: Push tractor feed (front and rear)
Push-pull feed with the optional pull tractor (front or rear)
Paper size:
Fanfold paper 101 -406 mm (4 - 16 inches) wide
Single sheet paper Not available
Roll paper Not available
Line spacing: 1/6- or l/8-inch feed or programmable with a l/216-inch
minimum increment
Feeding speed
(1/6-inch per line):
Continuous 17 ins/line (10 inches per second)
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)
Weight:
Single 45-70 kg(14- 22 lb)
Multi-part 35-48 kg (11 - 15 lb) x n (n < 8), up to the total thickness
13-31 mm More than 13mm
~
o .-------- o
o rABCD wxY~ ~
I
Io
0
I I
o
I
0
0
0
I0 0
H
m
E O~BCD WXYZJ
---------
`o
0-- - -- --- -- ----- ---------
0
>
- -- - --w--- :
g ~~BcD
s I
01 A A
/0
Figure 1-3. Printable Area for Fanfold Paper
Rev. A 1-5
Product Description DFX-5000+ Service Manual
Notes:
1. Horizontal alignment maybe irregular in the top 75 mm (3 inches) of the first page.
2. When using the optional pull tractor, the top 120 mm (4.8 inches) of the first page are
unprintable.
3. Use clean paper with no folds, creases, or tears (especially for multi-part paper). Figure 1-4
shows paper you should not use.
creases
Figure 1-4. Unsuitable Paper
4. 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
o
:p6D-- --- ~lo -
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