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Epson DFX-5000+ Service Manual

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  • Page 1 ® EPSON Service Manual Epson America, Inc.
  • Page 2 Service Manual Revision Level Revision Date 1st printing ® EPSON Printed on Recycled Paper.
  • Page 3 If this equipment has more than one interface connector, do not leave the cables connected to unused interfaces. Changes or modifications not expressly approved by the manufacturer could void the user’s authority to operate the equipment. EPSON DFX-5000+ Service Manual...
  • Page 4 Epson America, Inc., assumes no responsibility for errors and omissions. Neither Epson America, Inc., nor its affiliates shall be liable to the purchaser of this product or third parties for damages, losses, costs, or expenses incurred by purchaser or third parties as a result of accident, misuse, or abuse of this product or unauthorized modifications, repairs, or alterations to this product.
  • Page 5 Caution 1. Repairs on EPSONproducts should beperformed only by an EPSON-certified repair technician. 2. Make certain that the source voltage is the same us the rated voltage listed on the serial from the availablepower source, do not connect it to thepower source.
  • Page 6 Buenos Aires, Argentina San Jose, Costa Rica Phone: (541) 394-2439 Phone: (506) 34-6666 Fax: (54 1) 322-4637 Fax: (506) 25-5709 Epson Mexico S.A. De C.V. Epson Venezuela S.A. Mexico, D.F. Caracas, Venezuela Phone: (525) 395-9897 Phone: (582) 241-0433 Fax: (525) 395-9499...

  • Page 7: Table Of Contents

    Figure 1-2. Pin Configuration........1-3 Figure 1-3. Printable Area for Fanfold Paper ..... . . 1-6 EPSON DFX-5000+ Service Manual...
  • Page 8 Table 1-15. Interface Selection ....... . EPSON DFX-5000+ Service Manual...
  • Page 9 Figure 2-12. Tractor Select Mechanism... 2-12 Figure 2-13. Plunger Mechanism ....EPSON DFX-5000+ Service Manual...
  • Page 10 Removing the Housing ....3-17 Removing the Circuit Boards ..3-25 Removing the Interlock Switch Assembly EPSON DFX-5000+ Service Manual...
  • Page 11 Figure 3-41. Removing the Shaft Holder ....3 - 3 8 Figure 3-42. Removing the Tension Roller Shaft ... . . EPSON DFX-5000+ Service Manual...
  • Page 12 Figure 4-2. Carriage Timing Belt Tension Adjustment..Figure 4-3. Tractor Wire Tension Adjustment......Figure 4-4. Pull Tractor Sensor Position Adjustment..... Figure 4-5. Parallelism Adjust Lever........... Figure 4-6. Dial Gauges and Dial Gauge Base Attachment Figure 4-7. Carriage Guide Shaft Parallelism Adjustment..EPSON DFX-5000+ Service Manual...
  • Page 13 Preventive Maintenance ......Lubrication and Adhesive Application ....EPSON DFX-5000+ Service Manual XIII...
  • Page 14 Table A-12. CN1, C117 PSB Power Supply Board A-10 Table A-13. CN2, C117 PSB Power Supply Board Assembly A-11 Assembly Table A-14. CN3, C117 PSB Power Supply Board A-11 Assembly Table A-15. CN4, C117 PSB Power Supply Board EPSON DFX-5000+ Service Manual...

  • Page 15: Product Description

    Automatic platen gap adjustment for paper thickness Automatic tear off Paper memory function Eight-bit parallel interface and RS-232C serial interface standard Epson ESC/P-83 (ESC/P version 83) printer driver (compatible with the 9 character tables in the standard version 20KB input buffer Automatic interface selection Type B optional interface cards The figure on the next page shows the DFX-5000+.
  • Page 16 Interface Cover for Optional Interface Rear Cover \w Figure l-l. Exterior View of the DFX-5000+ Table l-l. Options and Consumables Description A simple serial interface card has no CPU; the printer processes the data from the card. EPSON DFX-5000+ Service Manual...

  • Page 17: Specifications

    9 x 9 (draft mode) 18 x 23 (NLQ mode) Printing direction: Text mode Bidirectional with logic seeking (Unidirectional mode can be selected using the ESC U command.) Unidirectional Bit image mode Built-in fonts: Draft NLQ Roman NLQ Sans Serif EPSON DFX-5000+ Service Manual...
  • Page 18 Elite (12 cpi) 0.07 (1.69) 0.12 (3.1) 0.08 (2.12) 15 cpi 0.06 (1.41) 0.12 (3.1) 0.07 (1.69) Condensed (17.1 cpi) 0.04 (1.06) 0.12 (3.1) 0.06 (1.48) Condensed elite (20 cpi) 0.03 (0.85) 0.12 (3.1) 0.05 (1.27) EPSON DFX-5000+ Service Manual...

  • Page 19: Paper Handling Specifications

    Rear Up to 0.012 inches (0.30 mm) Weight: 14 - 22 Single lb (45 - 70 kg) Multi-part 11 - 15 lb (35 - 48 kg) x yil (n I S), up to the total thickness EPSON DFX-5000+ Service Manual...
  • Page 20 When using the optional pull tractor, the top 4.8 inches (120 mm) of the firs page are unprintable. 3. Use clean paper with no folds, creases, or tears (especially for multi-par paper). Figure l-4 shows paper you should not use. EPSON DFX-5000+ Service Manual...
  • Page 21 The end of the printable area is 0.60 inches (15 mm) above the bottom edge ofthe paper. Form Override Area END OF PAPER Figure l-5. Form Override Area Weak horizontal and vertical perforations cause paper jams. EPSON DFX-5000+ Service Manual...
  • Page 22 At the intersection of a horizontal and vertical perforation, the perforation cuts must not cross each other. Figure 1-8 shows examples of correct perforation intersections. - - - - - - - - Figure l-8. Perforation Intersections EPSON DFX-5000+ Service Manual...
  • Page 23 Figure l-11. Aligned Sprocket Holes 12. Any pieces ofpaper remaining in the sprocket holes must be removed. 13. The paper should be fanfolded at the horizontal perforations. Never use incorrectly folded paper, such as the paper shown below. EPSON DFX-5000+ Service Manual...
  • Page 24 Total thickness: Print area 0.018 inches (0.46 mm) maximum Overlap area 0.028 inches (0.70 mm) maximum, including the bottom carrier Weight: Multi-part 11 - 15 lb (35 - 48 kg), up to the total thickness Carrier 1-10 EPSON DFX-5000+ Service Manual...
  • Page 25 Figure 1-13. Printable Area, Overlapping Multi-part Forms CAUTION When using overlapping multi-part forms, do not use thepuper select (change tractors) or tear offfunction; to avoid a paper jam, it is important not to feed overlapping multi-part forms buckw urd. EPSON DFX-5000+ Service Manual 1-11...
  • Page 26 The pasted areas must be pressed flat. There must be no creases in the paper. 5. Paper stapling must be applied from the front, and the paper must be flat Figure 1-15 shows a cross section of the stapled area. Printable surface Figure 1-15. Stapled Area 1 1-12 EPSON DFX-5000+ Service Manual...
  • Page 27 11. Multi-part form sheets should be securely bound to each other, and the binding area must not be too large. Carrier Carrier Figure 1-18. Correct Multi-part Form Binding Figure 1-18. Correct Multi-part Form Binding 1-13 EPSON DFX-5000+ Service Manual...
  • Page 28 35 - 48 kg (11 - 15 lb) x yil (n I S), up to the total thickness NO PRINTING AREA Figure 1-19. Printable Area for Fanfold Paper with a Label Labels Paper path: Front only Label size (W x H) : 4 x 15/16 inches 4 x 17/16 inches 1-14 EPSON DFX-5000+ Service Manual...
  • Page 29 ). Do not feed label forms in the reverse direction. (Feeding label forms backward may cause a paper jam, or the labels may come When using label forms, do not use the TOF (top of form) function Do not use easy-peel labels 1-15 EPSON DFX-5000+ Service Manual...
  • Page 30 7. Labels must be on carrier paper, and there should be carrier paper between the labels. (The labels should not touch each other.) The label surface must be flat. 4-16” Figure 1-21. Label and Carrier EPSON DFX-5000+ Service Manual 1-16...

  • Page 31: Ribbon Specifications

    Product Description Ribbon Specifications Ribbon cartridge: Ribbon pack: Ribbon pack exchanges: 4 times per cartridge maximum Ribbon color: Black Dimensions: Cartridge 20.24 x 0.92 x 5.60 inches (506 (W) x 23 (H) x 140 (D) mm) Ribbon 0.52 inches x 231.0 feet (13 m m x 70 mm), endless Life: 15 million characters (14 dots/character) Environmental Conditions...

  • Page 32: Electrical Specifications

    P h y s i c a l S p e c i f i c a t i o n s 27.6 x 15.0 x 14.5 inches Size (W x D x H): (700 x 382 x 369 mm) 63.8 lb (29 kg) Weight: EPSON DFX-5000+ Service Manual 1-18...

  • Page 33: Interface Specifications

    The ERROR signal is active (LOW) under the following conditions: -When a paper out error occurs -When a paper jam error occurs -When a fatal error occurs The PE signal is active (HIGH) when a paper out error occurs 1-19 EPSON DFX-5000+ Service Manual...

  • Page 34: Parallel Interface

    Signal ground. S L C T I N If the signal is LOW when the printer is initialized, DCl/DC3 control is disabled. *The I/O column indicates the direction ofthe signal as viewed from the printer. 1-20 EPSON DFX-5000+ Service Manual...

  • Page 35: Rs-232C Serial Interface

    +27 V Connector: EIA standard 25-pin connector Table 1-8 shows the signal functions and connector pin assignments for the serial interface. * The I/O column indicates the data flow as viewed from the printer. EPSON DFX-5000+ Service Manual 1-21...

  • Page 36: Printer Operation

    MICRO FEED buttons. This button functions only when paper is loaded into the printer using the LF/ FF LOAD button and the printer is in pause mode. In TOF setting mode, the PAUSE LED is lit and the TOF LED blinks. 1-22 EPSON DFX-5000+ Service Manual...

  • Page 37: Self-Test

    To run the self-test in NLQ mode, hold down the TEAR OFF button and turn on the printer. The self-test can be interrupted by pressing the PAUSE button. To end the self-test, press the PAUSE button and then turn offthe printer. 1-23 EPSON DFX-5000+ Service Manual...

  • Page 38: Hexadecimal Dump Function

    Automatic Paper Thickness Adjustment The printer measures the paper thickness each time paper is loaded. The distance between the printhead and the platen is automatically adjusted to match the paper’s thickness and obtain the best print quality. EPSON DFX-5000+ Service Manual 1-24...

  • Page 39: Paper Memory Function

    Figure l-25. Overlapping Multi-part Forms Set the information about the label and overlap areas before printing. The printer works according to this information. 1-25 EPSON DFX-5000+ Service Manual...
  • Page 40 DIP switch 3-4 is off. This is the printer’s default setting. To select memory area 2, turn on the switch. Table l-9. Selecting the Paper Memory Area DIP SW 3-4 Paper Memory Area Use DIP switches 3-l and 3-2 or software commands to set the page length. 1-26 EPSON DFX-5000+ Service Manual...
  • Page 41 Table l-10. Setting the Page Length DIP SW DIP SW Page Length (inches) Use DIP switches 3-5 and 3-6 to set the paper type Table l-11. Setting the Paper Type Paper Type Hold down both MICRO FEED buttons and turn on the printer. If you are using forms with a label, indicate the label’s position by following these steps: (1) Open the printer cover.

  • Page 42: Automatic Tear Off Function

    When this function is used, the head parks away from the binding during paper feeding to avoid paper jams. Use DIP switch 3-7 to enable or disable the skip binding function; when it is enabled, throughput is reduced. 1-28 EPSON DFX-5000+ Service Manual...

  • Page 43: Printer Initialization

    (The printer runs out ofpaper or a paper jam occurs during paper feeding or printing.) *** (3 beeps) Another paper error is detected: (The previous print job is not torn off.) (The paper is out at power on.) 1-29 EPSON DFX-5000+ Service Manual...
  • Page 44 A short circuited printhead fan is detected. (8 sets of 2 beeps) An illegal paper memory setting is detected. ********** (10 beeps) A micro adjust limit is detected. A platen gap adjust error is detected. ** 0.1 second interval Note : EPSON DFX-5000+ Service Manual 1-30...

  • Page 45: Dip Switch Settings

    Product Description DIP Switch Settings This section describes the tinctions ofthe DIP switches. After setting one or more DIP switches, turn on the printer to put your settings into effect. Table 1-12. DIP Switch Settings Factory Function Settina * IBM mode indicates IBM ProPrinter emulation mode. **These DIP switches are used for paper memory function settings.
  • Page 46 Product Description Table 1-13. IBM Mode Selection Factory Function Setting Table 1-14. ESC/P Mode Selection 1-32 EPSON DFX-5000+ Service Manual...
  • Page 47 Product Description Table 1-15. Interface Selection Interface Automatic hterface Selection. Table 1-16. Baud Rate Selection Bit Rate (bps) Table 1-17. Page Length Selection Page Length 1-33...

  • Page 48: Main Components

    Power supply board ( Cl 17 PSB board assembly) Control panel (Cl 17 PNL board assembly) Printhead Connector Junction Board Head Cable Board Cl 17 Power Supply Board Assembly Connector Junction Board Cl 17 MAIN Board Assembly Figure l-26. Main Components EPSON DFX-5000+ Service Manual 1-34...

  • Page 49: M-3C11 Printer Mechanism

    In the DFX-5000+, the angle between the printhead and the surface of the platen has been changed to reduce noise. In the DFX-5000+, the ribbon guide is not attached to the ribbon mask; the ribbon mask is attached to the printhead carriage. Figure 1-27. M-3C11 Printer Mechanism EPSON DFX-5000+ Service Manual 1-35...

  • Page 50: Main Control Board (C117 Main Board Assembly)

    PROM (2 megabit including the CG ROM), a PS-RAM (256K), an EEPROM, an SLA7026M for the paper feed motor, an SLA5007 for the CR motor, each driver’s IC, and the parallel and serial interface control circuits. Figure 1-28. Cl17 MAIN Board Assembly EPSON DFX-5000+ Service Manual 1-36...

  • Page 51: Power Supply Circuit (C117 Psb Board Assembly)

    Figure l-29. Cl17 PSB Board Assembly Control Panel Board (C117 PNL Board Assembly) The Cl 17 PNL board assembly is the operator control panel. It contains the buttons, indicator LEDs, and buzzer. Figure l-30. Cl17 PNL Board Assembly EPSON DFX-5000+ Service Manual 1-37...
  • Page 52 It also has a cover on the bottom plate to provide easy access to the PROM on the main board. Figure 1-31. Housing EPSON DFX-5000+ Service Manual 1-38...

  • Page 53: Overview Of Printer Mechanism Operation

    The CR motor is closed-loop controlled. Because the CR motor is driven at a very high speed, it includes an isolation resistance sensor to detect abnormal resistance. The sensor detects an error ifthe resistance is less than 1K R. EPSON DFX-5000+ Service Manual...
  • Page 54 The CR motor controls printing in the horizontal direction, and the paper feed mechanism controls movement in the vertical direction (line feeding and form feeding). The paper feed mechanism feeds paper vertically. The PF motor drives the paper feed mechanism. EPSON DFX-5000+ Service Manual...
  • Page 55 Figure 2-3 shows this operation. Paper Pull Tractor Assembly Paper Bail Upper PE Sensor Paper Jam Sensor Tractor Select Sensor Rear PE Sensor Rear Tractor Paper Feed (PF) Front Tractor Ribbon Feed (RF) Figure 2-3. Printer Mechanism Operation 2 EPSON DFX-5000+ Service Manual...

  • Page 56: Printhead Mechanism

    A gum pad is attached to the left side ofthe frame. When the carriage hits the pad, the CR motor pulse is disordered by this obstacle. The control circuit monitors the CR motor’s pulse; when it is disordered, the control circuit recognizes the carriage home position. EPSON DFX-5000+ Service Manual...

  • Page 57: Platen Gap Adjustment Mechanism

    The encoder plate with equally pitched slits is attached coaxially to the motor axis. When the motor rotates, the PG sensor detects it and outputs the pulses. Each pulse corresponds to detection of a 0.015 mm resolution (horizontal distance). The system range is 0 to 0.7 mm. EPSON DFX-5000+ Service Manual...

  • Page 58: Paper Feed Mechanism

    When paper is loaded, the paper surface reflects the beam; when there is no paper, the beam is absorbed (not reflected). The pull tractor sensor monitors whether the pull tractor is installed. EPSON DFX-5000+ Service Manual...
  • Page 59 Operating Principles Pull Trwta Seraor - Upper PE Seraor - Tractor Sdect Piri u7 Gear Figure 2-7. Tension Roller and PF Roller Operation Paper Feed Mdor Figure 2-8. Front Tractor Assembly Operation EPSON DFX-5000+ Service Manual...
  • Page 60 In the Figure 2-10, point A shows the movement range of the left tractor sprocket when the tractor release lever is released. Point B shows the movement range of the right tractor sprocket when the release lever is engaged or released. EPSON DFX-5000+ Service Manual...

  • Page 61: Ribbon Feed And Tractor Select Mechanisms

    The rotation of the RF motor is transmitted after the gears are engaged. When the RF motor pinion gear rotates counterclockwise, the motor rotates the ribbon feed mechanism; when it rotates clockwise, the motor rotates the tractor select mechanism. EPSON DFX-5000+ Service Manual...
  • Page 62 The tractor select lever contacts the inside curve of the cam due to the spring force; when the cam rotates, the tractor select lever moves horizontally along the curve. EPSON DFX-5000+ Service Manual 2-10...
  • Page 63 The tractor select sensor contacts the cam and closes when it reaches the convex portion. Transmission G ear Upper Tmctw Sel& Leer Ribbon Feed Select G w Figure 2-12. Tractor Select Me chanism 2-11 EPSON DFX-5000+ Service Manual...

  • Page 64: Plunger Mechanism

    The paper bail assembly axis is connected to the frame. When the plunger coil is energized, the force of the paper bail spring returns the paper bail assembly to its original position. Figure 2-13. Plunger Mechanism EPSON DFX-5000+ Service Manual 2-12...

  • Page 65: Power Supply Operation

    Table 2-l shows the input voltages and tise ratings ofthe board. Table 2-l. Power Supply Board Fuse Ratings Board Input Voltage Power Supply Overview Figure 2-14 shows a block diagram ofthe power supply board. Figure 2-14. Power Supply Board Block Diagram 2-13 EPSON DFX-5000+ Service Manual...
  • Page 66 Therefore, after the printer is turned off, wait three minutes before you turn it back on. Before replacing the power supply, be sure to replace the fuse and power cord 2-14 EPSON DFX-5000+ Service Manual...
  • Page 67 Type B optional interface voltage supply) Note : Before the power supply board outputs +35 VDC, it outputs +13 VDC to the printhead drivers on the Cl17 MAIN board assembly. This procedure is a driver check to prevent printhead damage. 2-15 EPSON DFX-5000+ Service Manual...

  • Page 68: Vdc Line Regulator Circuit

    Ifthe printhead drivers are normal, the control board outputs the VPC signal to the power supply board. When the power supply board receives this signal, the line rises to +35 VDC after 140 ms. 2-16 EPSON DFX-5000+ Service Manual...

  • Page 69: +35 Vdc Line Regulator Circuit

    +35 VDC line rises from +13 V to +35 V. The +35 VDC line circuit uses a ringing choke convertor (RCC) AC input switching power circuit. This system uses few parts and a small transformer, and is often used when a small power supply is required. EPSON DFX-5000+ Service Manual 2-17...
  • Page 70 When the over-current flows to the input voltage line, the shunt regulator is turned on, Q103 (Q203) and Q102 (Q202) are turned on, and QlOl (Q20 1) is turned off. EPSON DFX-5000+ Service Manual 2-18...
  • Page 71 VPC signal is HIGH, Q182 is turned on, and motor driver check, the VPC signal is LOW. When this signal is LOW, Q182 stays off, the base of Q182 stays HIGH, and then two Zener diodes (ZD15 1 and ZD181) output +13 VDC. EPSON DFX-5000+ Service Manual 2-19...

  • Page 72: F12 Vdc Half-Wave Rectifier Smoothing Circuit

    RS-232C interface on the standard or optional board and uses the printhead fire trigger. Both the +12 VDC and --12 VDC lines have a half-wave rectifier circuit. This smoothing circuit consists ofcapacitors Cl82 and C181. TwoZener diodes stabilize the f12 VDC line. Figure 2-17. Half-wave Rectifier Circuit EPSON DFX-5000+ Service Manual 2-20...

  • Page 73: Control Circuits

    When the CLIMIT signal informs the CPU that the power has been turned off (or that the power supply voltage has dropped), the CPU turns offthe power supply voltage from the Cl 17 power supply board assembly by outputting the CLIMIT signal. EPSON DFX-5000+ Service Manual 2-21...
  • Page 74 CPU. In this circuit, the gate array IC (IC7) provides the interface between the external host computer and the CPU, and all data processing is performed by read/write operations to MM10 (Memory Mapped Input/Output). EPSON DFX-5000+ Service Manual 2-22...
  • Page 75 The print data consists of l-byte character codes and 2-byte attributes. Character data is stored as character codes and commands or character types are stored as attributes. EPSON DFX-5000+ Service Manual 2-23...
  • Page 76 2-3 describes the functions ofthe main printer components. The data flow from the serial interface is the same as the data flow from the Note : parallel interface, described above, except the signal names and data access method differ. EPSON DFX-5000+ Service Manual 2-24...

  • Page 77: Reset Circuit

    The printer is equipped with two reset ICs: PTS591D is used for resetting the + 5 VDC line and M5 1955 is used for resetting the +35 VDC line. These reset ICs are described on the following page. EPSON DFX-5000+ Service Manual 2-25...
  • Page 78 1.7 VDC, the +35 VDC line drops into the 22.9 V to 30.0 V range. to the CPU’s NM1 port. When the printer is turned off, this circuit operates and manages writing to the EEPROM. Figure 2-20. Reset Circuit Block Diagram EPSON DFX-5000+ Service Manual 2-26...

  • Page 79: Sensor Circuits

    PG home sensor (uses a micro mechanical switch) Head temperature sensor (uses a thermistor) Fan temperature sensor (uses a thermistor) PW sensor (uses a photo reflector) Carriage motor isolation resistance sensor (monitored by the analog port of the CPU) EPSON DFX-5000+ Service Manual 2-27...
  • Page 80 CR filter circuit (10 KR and 39 pF) Paper present: LOW Paper out: HIGH 2. Top paper end sensor (to detect the TOF position) Open collector CR filter circuit (10 KR and 39 pF) Paper present: LOW Paper out: HIGH EPSON DFX-5000+ Service Manual 2-28...
  • Page 81 Pulled up to 390 R resistance 10. +35 VDC voltage drop sensor (signal interface) When the +35 VDC line voltages drop, the Cl 17 power supply board assembly sends a HIGH CLIMIT signal to the Cl 17 MAIN board assembly. 2-29 EPSON DFX-5000+ Service Manual...

  • Page 82: Cr Motor Driver Circuit

    Table 2-4 lists the CR motor drive modes. The printer has three deceleration control modes. The degree of deceleration is determined by how the carriage motor transistors are driven. Table 2-5 describes how the transistors are driven for each mode. EPSON DFX-5000+ Service Manual 2-30...
  • Page 83 Operating Principles Figure 2-22. CR Motor Internal Circuit Figure 2-23. CR Motor Driver Block Diagram EPSON DFX-5000+ Service Manual 2-31...
  • Page 84 Operating Principles Table 2-4. CR Motor Drive Modes Acceleration/ Constant Drive Motor Division Deceleration Speed Mode Speed Control Curve Control 2-32 EPSON DFX-5000+ Service Manual...
  • Page 85 The CPU outputs the PWM (pulse width modulation) signal according to the carriage motor speed to the PWM port ofthe gate array and determines the duty of the carriage drive timing. CR ports A, B, and C output the drive signal for the CR motor. EPSON DFX-5000+ Service Manual 2-33...
  • Page 86 Duty min represents the minimum duty data for acceleration control. Pulse width modulation (PWM) determines each section number. For each section, the carriage motor driver is turned on part of the time and off part ofthe time. EPSON DFX-5000+ Service Manual 2-34...
  • Page 87 Deceleration control provides smooth deceleration and prevents rapid vibration. Figure 2-25. Deceleration Control Curve Note : In Figure 2-25, the deceleration curve is labeled A and the driving modes are labeled B. 1,2, and 3 indicate the PWM control section number. 2-35 EPSON DFX-5000+ Service Manual...
  • Page 88 2000, the printer changes back to the normal drive sequence. Because printer mechanisms differ, the acceleration and deceleration curves also differ. The measurement sequence control adjusts for these variations so that the carriage accelerates and decelerates smoothly. EPSON DFX-5000+ Service Manual 2-36...
  • Page 89 This procedure compensates for individual variations in the printer mechanism. Therefore, carriage operation control for column n is determined by the data in column n-l. Figure 2-26 illustrates the measurement sequence Figure 2-26. Measurement Sequence EPSON DFX-5000+ Service Manual 2-37...

  • Page 90: Pf Motor Driver Circuit

    The PFA port is used as the WDT (watch dog timer). If PF motor operation is abnormal, the gate array outputs the RSTOUT (reset request) signal to the CPU and the +5 V system reset IC (IC9). EPSON DFX-5000+ Service Manual 2-38...

  • Page 91: Rf Motor Driver Circuit

    The control method is not equipped with a hold circuit for changing the motor phase. The RF motor rotates when the carriage moves. Figure 2-28. RF Motor Driver Circuit EPSON DFX-5000+ Service Manual 2-39...

  • Page 92: Pg Motor Driver Circuit

    ENCA ofthe gate array and the phase B output pulse from the platen gap encoder (ENCB) is input to general purpose port ENCB ofthe gate array. The gate array counts these pulses using the internal counter and determines the amount and direction ofmotor rotation. EPSON DFX-5000+ Service Manual 2-40...
  • Page 93 I l . 1 2 9, IO Figure 2-29. PG Motor Driver Circuit Table 2-9. PG Motor Sr>ecifications Specification Description 2-41...

  • Page 94: Plunger Driver Circuit

    Operating Principles Plunger Driver Circuit Figure 2-30 shows a block diagram ofthe plunger driver circuit, and Table 2-9 provides the plunger switching pattern. The plunger is driven using three switching patterns. Gate array general purpose ports PLP and PLN output the plunger coil drive signals.

  • Page 95: Printhead Driver Circuit

    P34 detects a LOW level and the CPU sends the DRERR (Driver Error) signal to the Cl 17 power supply board assembly. When the Cl 17 power supply board assembly receives this signal, it stops the output voltage and the printer beeps. EPSON DFX-5000+ Service Manual 2-43...
  • Page 96 Operating Principles H E A D t h e r m ,stor d a t a Figure 2-31. Printhead Driver Circuit EPSON DFX-5000+ Service Manual 2-44...

  • Page 97: D I S A S S E M B L Y A N D A S S E M B L Y 3

    Before transporting the printer, remove the paper and ribbon cartridge. Then attach the following packing materials, as shown in Figure 3-1. Transport locking bracket Carriage guide shaft support bar Printhead protector Foam packing for paper bail Figure 3-1. Attaching the Packing Materials EPSON DFX-5000+ Service Manual...
  • Page 98 Before assembling the printer, lubricate it as described in Chapter 6, during maintenance or repair work.) Also, be sure to clean the printer as described in Chapter 6. EPSON DFX-5000+ Service Manual...

  • Page 99: Tools

    Refer to Chapter 4 for adjustment tools, Chapter 5 for troubleshooting tools, and Chapter 6 for tools for maintenance, lubrication, and adhesives Table 3-l. Tools Box driver T w e e z e r s A: Mandatory 0: Commercially available B: Recommended E: EPSON exclusive EPSON DFX-5000+ Service Manual...
  • Page 100 Catalog number: Dial gauges #F610 Figure 3-3. Dial Gauges 1019467 Part number: Catalog number: Dial gauge base #F611 Figure 3-4. Dial Gauge Base 1019468 Part number: Catalog number: Dial gauge master #F612 Figure 3-5. Dial Gauge Master EPSON DFX-5000+ Service Manual...

  • Page 101: Small Parts

    Disassembly and Assembly 1020471 Part number: Catalog number: Thickness gauge #F616 Figure 3-6. Thickness Gauge Small Parts Table 3-2. Abbreviations for Small Parts Abbreviation Part Name EPSON DFX-5000+ Service Manual...
  • Page 102 Disassembly and Assembly Table 3-3. Screw Names and Illustrations Washer Body Head (assembled) Side 1 .ljormal 2. S-tight (with Notch) lock washer 3. B-tight EPSON DFX-5000+ Service Manual...

  • Page 103: Disassembly And Assembly

    Pry up the 2 hooks for the head cable cover and remove it from the carriage. Disconnect the white FPC cable, 4-pin white harness connector, and 4-pin red harness connector from the connector junction board on the carriage. EPSON DFX-5000+ Service Manual...
  • Page 104 [for Fan Drive Signal and Thermistor [for Carriage Encoder Signal) CP[SP [M3X6] Figure 3-7. Removing the FPC Cover and the Connectors Remove the 2 CPN (M3 x 8) screws securing the FPC cover to the bottom plate of the printer mechanism. EPSON DFX-5000+ Service Manual...
  • Page 105 2 CP (PS) (M4 x 7) screws securing the printhead to the carriage. Disengage the printhead with the PW sensor and the Right HmdDamper Figure 3-8. Removing the Printhead Assembly Notes EPSON DFX-5000+ Service Manual...

  • Page 106: Replacing The Rom

    Tilt back the printer and lay it on its back. Hold the top cover closed if it is not removed. Remove the CBB (M3 x 10) screw securing the ROM cover, remove the cover, and replace the ROM using the ROM holder. Figure 3-9. Replacing the ROM 3-10 EPSON DFX-5000+ Service Manual...

  • Page 107: Removing The Housing

    While someone supports the top cover, remove the 4 screws (2 on the right and 2 on the left) securing the top cover to the hinges and remove the cover. Figure 3-10. Removing the Top Cover 3-11 EPSON DFX-5000+ Service Manual...
  • Page 108 When you attach the right side cover, connect the cablefrom connector CNl on the Cl1 7 power supply board assembly and the cablefrom theAC inlet to the main switch on the right side cover, us shown on the next page. EPSON DFX-5000+ Service Manual 3-12...
  • Page 109 Figure 3-12. Connecting the Cables to the Main Switch After you remove the right side cover, you can replace the input tise for the Cl 17 power supply board assembly. Warning Make sure the new fuse meets the printer’s ACpower specifications (12 A). EPSON DFX-5000+ Service Manual 3-13...
  • Page 110 Remove the 3 CBB (M4 x 10) screws securing the left side ofthe front cover to the lower cover. Then remove the 3 screws on the right side and remove the front cover with the 2 hinges. Figure 3-14. Removing the Front Cover 3-14 EPSON DFX-5000+ Service Manual...
  • Page 111 Open the top cover and disconnect connector CN8 (the control panel connector). Remove the 2 CBB (M4 x 16) screws from the front panel and remove the panel with the C117 PNL board assembly and its cable. Figure 3-15. Removing the Front Panel 3-15 EPSON DFX-5000+ Service Manual...
  • Page 112 Remove the 6 CBB (M4 x 16) screws, and 2 CPS (M3 x 8) screws from the upper case, and then remove the upper case with the cover open sensor. Figure 3-16. Removing the Upper Case EPSON DFX-5000+ Service Manual 3-16...

  • Page 113: Removing The Circuit Boards

    Front Covers and Replacing the Fuse on page 3-12.) Open the rear cover. Remove the 4 CPB (M3 x 12) screws and 2 CPT (0) (M3 x 12) screws securing the interface cover and remove the cover. 3-17 EPSON DFX-5000+ Service Manual...
  • Page 114 Remove the 8 CPB (M4 x 16) screws securing the bottom panel assembly. Slowly return the printer to its upright position before you remove the screws for the bottom panel assembly. Then remove the rear cover. 3-18 EPSON DFX-5000+ Service Manual...
  • Page 115 (not labeled with a CN number) between the interlock switch and connector CN9 on the Cl 17 MAIN board assembly. CN 6 [M ec hsnism Drive] C 117MPIN Ecardtis~mbly Panel] Open SWISW] [LEFT Side] Figure 3-20. Removing e the Connector and Earth Cable 3-19 EPSON DFX-5000+ Service Manual...
  • Page 116 Then slowly lift up the bottom panel assembly. Remove the CBS (0) (M4 8) screw securing earth plate [RIGHT Side] Figure 3-21. Removing the Bottom Panel Assembly 2 EPSON DFX-5000+ Service Manual 3-20...
  • Page 117 Remove the 6 CPB (M3 x 11) screws and CPN (0) (M3 x 8) screw securing the Cl 17 power supply board assembly and remove the board. CPN [O] [M 3x81 Figure 3-22. Removing the Cl17 Power Supply Board Assembly 3-21 EPSON DFX-5000+ Service Manual...
  • Page 118 Remove the C117 MAIN board assembly, as described in the section above. Remove the 3 CPS (M3 x 8) screws and 1 CPB (0) (M4 x 5) screw securing the earth plate to the bottom panel assembly and remove the earth plate. EPSON DFX-5000+ Service Manual 3-22...
  • Page 119 Bottom Panel Assembly Figure 3-24. Removing the Earth Plate Remove the 2 CFS (M3 x 12) screws securing the AC inlet to the earth plate and remove the AC inlet. Figure 3-25. Removing the AC Inlet 3-23 EPSON DFX-5000+ Service Manual...
  • Page 120 Disconnect connectors CNl and CN2 on the Cl17 PNL board assembly. Remove the CPB (M4 x 9) screw securing the Cl 17 PNL board assembly to the front cover and remove the board. Cl 17 FNL Ewdhsernbly Figure 3-26. Removing the Cl17 PNL Board Assembly EPSON DFX-5000+ Service Manual 3-24...

  • Page 121: Removing The Interlock Switch Assembly

    Disconnect the interlock assembly cable from junction connector CN9 on the Cl 17 MAIN board assembly. Remove the CBB (M4 x 10) screw securing the interlock switch assembly to the lower case and remove the interlock switch assembly. Figure 3-27. Removing the Interlock Switch Assembly EPSON DFX-5000+ Service Manual 3-25...
  • Page 122 Disconnect the cables from connectors CNlO, CN7, and CN6 on the left side of the Cl 17 MAIN board assembly. Remove the 4 screws securing the printer mechanism to the lower case. Screw Figure 3-28. Removing the Printer Mechanism EPSON DFX-5000+ Service Manual 3-26...
  • Page 123 Figure 3-29. Lifting the Printer Mechanism Assembly Note When you install theprinter mechanism, route the cables us shown in Figure 3-30. Make sure the cables do not get caught between theprinter mechanism and lower case. EPSON DFX-5000+ Service Manual 3-27...
  • Page 124 Removing the Front/Rear Tractor Select Lever Assembly Remove the head damper from the left side frame. Remove the CPN (M3 x 6) screw securing the front/rear tractor select lever assembly to the left side frame. EPSON DFX-5000+ Service Manual 3-28...
  • Page 125 Remove the CPN (M3 x 6) screw securing the front/rear tractor select lever assembly to the left side frame. Remove the RF motor drive gear from the front/rear tractor select lever assembly. Then remove the lever assembly from the left side frame. EPSON DFX-5000+ Service Manual 3-29...
  • Page 126 Remove the E ring (# 3) securing the front/rear tractor select lever and remove the lever. Remove the E ring (# 3) securing the tractor select cam and remove the cam. Remove the CPS (M2 x 10) screw securing the tractor select sensor and remove the sensor. 3-30 EPSON DFX-5000+ Service Manual...
  • Page 127 Using wire cutters, cut the wire band securing the RF motor and tractor select sensor cables to the front/rear tractor select lever assembly. Assembly Note Attach thefront/reur tractor select lever to the tractor select cum us shown in figure 3-34. Figure 3-34. Tractor Select Lever Mounting Position 3-31 EPSON DFX-5000+ Service Manual...
  • Page 128 When you connect the cables to the connector junction board assembly, note that the matching connectors have the same color and number of pins. (The Appendix provides the connector pin assignments the connector junction board assembly.) EPSON DFX-5000+ Service Manual 3-32...
  • Page 129 0.05 and 0.15 mm (almost no backlash). screw at portion B to thefrume hole, so that the PG sensor is secure. Adjustment Required When you install the PG sensor or PG motor, perform theplaten gap motor value (platen 3-33 EPSON DFX-5000+ Service Manual...
  • Page 130 Remove the 2 CPS (SP) (M3 x 6) screws securing the plunger to the left side frame and remove the plunger. Remove the iron core ofthe plunger from the paper bail shaft. Iron Core connector Figure 3-37. Removing the Plunger EPSON DFX-5000+ Service Manual 3-34...
  • Page 131 Remove the E-ring at the right side of the paper bail shaft. Then remove the paper bail lever, paper bail balance lever, leaf spring, and shaft holder. Remove the paper bail assembly. Parser Bail Lever - I Figure 3-38. Removing the Paper Bail Assembly EPSON DFX-5000+ Service Manual 3-35...
  • Page 132 Remove the connector junction board assembly, as described previously in this chapter. While pushing on the tension pulley, remove the CR timing belt, described later in this chapter. Remove the upper paper guide. (See the description at the top ofthe page.) EPSON DFX-5000+ Service Manual 3-36...
  • Page 133 Figure 3-40. Removing the Tension Roller Gear Remove the E-ring on the right side ofthe tension roller shaft and pull out the platen roller shaft holder with its leaf spring and washer. Figure 3-41. Removing the Shaft Holder EPSON DFX-5000+ Service Manual 3-37...
  • Page 134 Remove the upper paper guide. (Refer to Removing the Upper Paper Guide and Top PE Sensor, on page 3-36.) Using a 3 mm hex driver, remove the 4 hexagon screws securing the platen to both holders. Then remove the platen with the lower paper guide. EPSON DFX-5000+ Service Manual 3-38...
  • Page 135 When you attach the lowerpuperguide to theplaten, start with the left-most part of the paper guide and w ark toward the right. Adjustment Required When you install theplaten, perform thefollowing adjustments, us described in Chapter 4: 3-39 EPSON DFX-5000+ Service Manual...
  • Page 136 Remove the CPN (SP) (M4 x 7) screw securing the left part ofthe lower paper guide to the platen. Figure 3-44. Removing the Left Part of Lower Paper Guide Unhook the paper jam sensor (magnetic transistor) cover and remove the cover. EPSON DFX-5000+ Service Manual 3-40...
  • Page 137 Disconnect the red, 2-pin, pull tractor sensor connector from the connector junction board assembly. Remove the CPN (SP) (M2 x 14) screw securing the pull tractor sensor (a micro-switch type sensor) to the left side frame and remove the sensor. 3-41 EPSON DFX-5000+ Service Manual...
  • Page 138 Removing the Paper Width (PW) Sensor Remove the printhead. (Refer to Replacing the Printhead, on page 3-7.) Remove the CPN (SP) (M2 x 6) screw securing the PW sensor to the maskless holder. Figure 3-47. Removing the PW Sensor EPSON DFX-5000+ Service Manual 3-42...
  • Page 139 Remove the E-ring securing the carriage guide shaft gear to the rear carriage guide shaft. E ting Figure 3-48. Removing the Carriage Guide Shaft Gear Disconnect the white, 2-pin, PG home sensor connector from the connector junction board assembly. EPSON DFX-5000+ Service Manual 3-43...
  • Page 140 Figure 3-49. Removing the PG Home Sensor Removing the PF Motor Remove the connector junction board assembly. (See page 3-32.) Remove the 3 CP (PS) (M4 x 8) screws securing the PF motor to the left side frame. EPSON DFX-5000+ Service Manual 3-44...
  • Page 141 Remove the connector junction board assembly. (See Removing Connector Junction Board Assembly and FPC Board Assembly on page 3-32.) Remove the PG motor. (See Removing the PG Sensor and PG Motor on page 3-33 .) EPSON DFX-5000+ Service Manual 3-45...
  • Page 142 Loosen the hexagonal nuts securing the shaft at the front of the front tractor assembly to the left and right side frames. After loosening the hexagonal nut on the right side, remove the right tractor wire spring holder set. EPSON DFX-5000+ Service Manual 3-46...
  • Page 143 Caniage Washer Front Tractor Assembly Figure 3-52. Removing the Front Tractor Assembly Adjustment Required When you install thefront tractor assembly, perform the tractor wire spring adjustment, us described in Chapter 4. EPSON DFX-5000+ Service Manual 3-47...
  • Page 144 E tin g [ Washer Figure 3-53. Removing the Rear Tractor Assembly Adjustment Required When you install the rear tractor assembly, perform the tractor wire spring adjustment, us described in Chapter 4. EPSON DFX-5000+ Service Manual 3-48...
  • Page 145 Figure 3-54. Removing the Timing Belt Holder Disconnect the CR motor cable from the white, 2-pin connector on the connector junction board assembly and unhook the CR motor cables at the base frame ofthe printer mechanism. 3-49 EPSON DFX-5000+ Service Manual...
  • Page 146 When you install theprintheud, perform theplaten gap motor value (platen gap) adjustment, us described in Chapter 4. Removing the CR (Carriage Encoder) Sensor 1. Remove the printhead. (See page 3-7.) Disconnect the red, 4-pin, CR sensor connector from the connector junction board assembly. EPSON DFX-5000+ Service Manual 3-50...
  • Page 147 This section describes how to disassemble the carriage mechanism, including removing the carriage, CR timing belt, and front and rear carriage guide shafts. Remove the CR motor. (See Removing the CR hfotor, on page 3-49.) EPSON DFX-5000+ Service Manual 3-51...
  • Page 148 On the left side frame, remove the E-ring securing the carriage guide shaft gear to the rear carriage guide shaft, then remove the carriage guide shaft gear and paper thickness sensor holder. EPSON DFX-5000+ Service Manual 3-52...
  • Page 149 (0) (M4 x 8) screws securing the carriage motor holder to the right side frame. Remove the right guide shaft holder lever. Remove the 2 CP (PS) (M4 x 6) screws securing the rear carriage guide parallelism adjustment lever and remove the lever. EPSON DFX-5000+ Service Manual 3-53...
  • Page 150 10. Remove the rear carriage guide shaft with the carriage base from the right side frame. Assembly Note When you install thefront carriage&de shaft, tighten the screws whilepushing the shaft toward theplaten. Adjustment Required When you assemble the carriage mechanism, perform thefollowing adjustments, described in Chapter I: EPSON DFX-5000+ Service Manual 3-54...
  • Page 151 Remove the CR motor. (See Removing the CR hfotor, on page 3-49.) Remove the left side frame gears. Referring to the exploded diagram in the Appendix, remove the platen roller. Adjustment Required When you install theplaten roller, perform thefollowing adjustments, us described in Chapter 4: EPSON DFX-5000+ Service Manual 3-55...
  • Page 152 Move the PG motor until there is 0.05 to 0.15 mm (0.002 to 0.01 inches) between the PG motor pinion gear and carriage guide shaft gear cog. Then tighten the 2 screws. Figure 4-l. Platen Gap Motor Backlash Adjustment EPSON DFX-5000+ Service Manual...
  • Page 153 Move the belt left and right while pulling the tension gauge, and move the motor pulley slightly. Tighten the 3 tension adjustment screws and secure them while the 8.8 lb (4 kg) force is applied. Finish tightening the 3 tension adjustment screws. EPSON DFX-5000+ Service Manual...
  • Page 155 Pull the tractor wire right. When the tractor wire spring tension is correct, the shaft holder frame and the tip of the gold seal are 0.2 inches (5 mm) apart. (See Figure 4-3.) Figure 4-3. Tractor Wire Tension Adjustment EPSON DFX-5000+ Service Manual...
  • Page 156 When you assemble the pull tractor sensor or rear paper guide, check the following items: Verify that the pull tractor sensor lever is touching the rear paper guide frame, but the sensor is off. approximately .08 inches (2 mm). Figure 4-4. Pull Tractor Sensor Position Adjustment EPSON DFX-5000+ Service Manual...
  • Page 157 0.01 mm. Since this value is extremely small, you must use the 2 dial gauges, dial gauge base, and dial gauge muster supplied by EPSON. Do not adjust theparallelism using any other method. # F611 Before performing the carriage guide shaft parallelism adjustment, you must assemble the 2 dial gauges, dial gauge base, and dial gauge master to form one tool.
  • Page 158 (portions A and B in the Figure 4-6) are both touching the platen. (To eliminate any play between the dial gauge base and the carriage, pull the tie band to secure the dial gauge base before securing the thumb screws.) EPSON DFX-5000+ Service Manual...
  • Page 159 (Figure 4-7 shows the measurement position and the parallelism adjust lever operation .) Note : When you shift the carriage manually, do not touch either dial gauge. Rotate the carriage motor pulley. Figure 4-7. Carriage Guide Shaft Parallelism Adjustment EPSON DFX-5000+ Service Manual...
  • Page 160 Then measure the distances again, as described in step 5. 11. If the difference between the measured distances is within the specified range, apply screw lock to the 2 screws. (See Chapter 6 for lubrication and adhesive application instructions.) EPSON DFX-5000+ Service Manual...
  • Page 161 0.02 mm. (The #F610 dial gauge matches the “20” notches.) Caution Afterperforming the adjustment, confirm the value ofplaten parallelism again. If this value is incorrect, readjust the platen parallelism and theplaten angle until the value becomes correct. EPSON DFX-5000+ Service Manual 4-10...
  • Page 162 Adjustments Approx.40 mm (Measurement Pmition) Figure 4-8. Platen Angle Adjustment EPSON DFX-5000+ Service Manual 4-11...
  • Page 163 1, but you may change this, if necessary. Caution the exclusive thickness gauge set and tension gauge supplied by EPSON. Thickness gauge set (0.39 mm): #F616 (Part No. 1020471) Tension gauge (200 g): #F54.5 (Part No. B76.5114601) during the adjustment.
  • Page 164 ) buttons simultaneously. (The buzzer sounds 2 beeps to confirm the reset.) Open the top cover and insert the #F616 EPSON-exclusive thickness gauge into the space between the maskless holder and the printhead nose. (Never move the printhead during this procedure. If you have moved the printhead by accident, return to step 3 .)
  • Page 165 Caution When you remove the thickness gaugeforcibly without using the PG drivegear, the perform step 13 before turning off theprinter. Figure 4-11. Pulling the Thickness Gauge EPSON DFX-5000+ Service Manual 4-14...
  • Page 166 (A value of “0” is written to every board.) For this reason, (since the PG will be too large) theprinter cannot print the current values, and you must perform theplaten gap value adjustment beforeperforming this adjustment. 4-15 EPSON DFX-5000+ Service Manual...
  • Page 167 12, repeat the adjustment 4 times (steps 11 to 12) to adjust the rest of the speed modes. 13. After adjusting all speed modes, press the TOP OF FORM button. (The printer ejects the paper and the control panel prohibits all button operations.) 14. Turn the printer power off. EPSON DFX-5000+ Service Manual 4-16...

  • Page 168: T R O U B L E S H O O T I N G 5

    (10 beeps, with a pause between each Head fan driver IC shot-ted. -lead fan driver shot-l (8 sets of 2 beeps) Illegal paper Incorrect paper is loaded in printer. ooooooooo (10 beeps) EPSON DFX-5000+ Service Manual...
  • Page 169 (3 sets of 3 beeps) Note: indicates a 0.1 second interval. indicates a 0.3 second interval. Figure 5-1. Layout of Connector Junction Board Pin 1 is on the right side of each connector above, except for the PF connector EPSON DFX-5000+ Service Manual...

  • Page 170: Bypassing The Interlock Switch And Cover Open Sensor

    To bypass the cover open sensor, remove the left side cover, disconnect the cable from connector CN7 on the Cl 17 MAIN board assembly, and jumper pins 1 and 2 of connector CN7. Figure 5-3. Bypassing the Cover Open Sensor EPSON DFX-5000+ Service Manual...

  • Page 171: Coil Resistance

    Below are resistances for the motor, head fan, plunger, and printhead. Table 5-2. Motor, Fan, Plunger, and Printhead Coil Resistances Part to Test Method (Use Figure 5-4 for PH and Coil Resistance Figure 5-1 for Motors) Check Figure 5-4. Printhead Coil Resistance EPSON DFX-5000+ Service Manual...
  • Page 172 Table 5-3. Checking the Power Supply Connectors Test Method Solution on PS Table 5-4. Checking the Sensors Junction Board Sensor Test Method Meter Reading Connector MAIN Board Connector...
  • Page 173 Troubleshooting Figure 5-5. Checking the Drivers Test Method Measurement Driver (Set Meter to Diodes) EPSON DFX-5000+ Service Manual...

  • Page 174: Repair By Unit Replacement

    2. When you replace or disassemble the PG motor or PG sensor, perform these adjustments: 3. When you replace or disassemble the CR motor, perform the carriage timing belt tension adjustment. 4. When you disassemble the printer mechanism, perform these adjustments: EPSON DFX-5000+ Service Manual...
  • Page 175 Troubleshooting 1. The printer does not operate when power is turned on. ths TM and turn EPSON DFX-5000+ Service Manual...
  • Page 176 Troubleshooting 2. Carriage operation is abnormal. NOTE I: Check thr Toll~~&~g oannisotors: EPSON DFX-5000+ Service Manual...
  • Page 177 Troubleshooting 3. Carriage operation is normal, but the self-test is printed incorrectly. START check 5-10 EPSON DFX-5000+ Service Manual...
  • Page 178 Troubleshooting 3. Carriage operation is normal, but the self-test is printed incorrectly (continued). Check the prlnthsad dtlusts. Check th4 printhead drivera. are OK, replac:s thg MAIN board. 1. GN6 EPSON DFX-5000+ Service Manual 5-11...
  • Page 179 Troubleshooting 3. Carriage operation is normal, but the self-test is printed incorrectly (continued). 5-12 EPSON DFX-5000+ Service Manual...
  • Page 180 4. Printing is normal, but paper feeding is abnormal. ths PF motor drlusrs Replace the See Priillsr Mscirani3m Repdr b PF mmr. flx fh6 printer mechanism. and Lhn PF molar. Perform final printing of self-teat. and perform the PG 5-13 EPSON DFX-5000+ Service Manual...
  • Page 181 Troubleshooting 5. Control panel operation is abnormal. S T A R T Da fh6 EPSON DFX-5000+ Service Manual 5-14...
  • Page 182 Troubleshooting 6. Data sent by the host computer is printed incorrectly. Note : The flowchart below assumes the host computer is operating normally self-test. Troubleshoot prmtsr usmg the EPSON DFX-5000+ Service Manual 5-15...

  • Page 183: Printer Mechanism Repair

    Check the carriage Replace the CR defective. encoder signal. sensor. The carriage encoder Check the encoder Replace or clean the belt is damaged or belt (below the carriage encoder belt. covered with dust. carriage timing belt). EPSON DFX-5000+ Service Manual 5-16...
  • Page 184 PF motor drivers. The ribbon feed (RF) The ribbon cartridge Remove the ribbon Replace the ribbon motor does not is defective. cartridge, rotate it, cartridge. operate. and check whether it feeds the ribbon normally. EPSON DFX-5000+ Service Manual 5-17...
  • Page 185 Replace the PG defective. signal of the PG sensor. sensor. (Refer to Table 5-6.) The encoder plate is Check whether the Replace the PG defective. encoder plate is motor or clean the broken or stained. encoder plate. 5-18 EPSON DFX-5000+ Service Manual...
  • Page 186 The tractor select Visually check the Join the tip of the gear is disconnected tractor select gear tractor select lever to from the tractor holder. the tractor select select cam. gear holder. EPSON DFX-5000+ Service Manual 5-19...

  • Page 187: Repair To The Component Level

    Measure the voltage level of the Replace HIGH. DRERR signal at CN3. head driver on the main board. CLIMIT signal is Measure the voltage level of the Wait until the HIGH. CLIMIT signal at CN3. printer prints again. 5-20 EPSON DFX-5000+ Service Manual...
  • Page 188 GND. VDC line is dead. are defective. Q201. Replace Observe voltage waveform defective. between the collector side and GND. Q201. Replace Check the voltage waveform defective. between the collector side and Q203. 5-21 EPSON DFX-5000+ Service Manual...
  • Page 189 Look at the PWM control waveform Replace for IC151 (at pin 8 or 11) and Q152 IC151 or Q152. Q151 is defective. Check the voltage waveform Replace between the collector side and Q151. GND. EPSON DFX-5000+ Service Manual 5-22...
  • Page 190 Verify that approximately fl2 V is line is dead. defective. abnormal output at the terminal of Cl 60 and element. Cl 61, and verify that Q183 and Q184 (or Q185 and Q188) are not defective. EPSON DFX-5000+ Service Manual 5-23...

  • Page 191: C117 Main Board Assembly Repair

    Replace IC9. The reset circuit is Look at the voltage waveform for not operational (for the +5 V line (pin 3 of IC9) and the reset signal (pin 1 of IC9). logic). EPSON DFX-5000+ Service Manual 5-24...
  • Page 192 (HIGH or LOW). Refer to the figure above. The CPU is defective. Look at the oscillator at either pin If this signal 26 or pin 27 of the CPU. is detected, replace ICl Otherwise, replace EPSON DFX-5000+ Service Manual 5-25...
  • Page 193 11 of IC QMl when the carriage is operating. (The normal voltage is approximately 35 VDC.) Measure voltage level at pins 9 and 11 of IC QMl when the carriage is operating. (The normal voltage is approximately 35 VDC.) EPSON DFX-5000+ Service Manual 5-26...
  • Page 194 3 and carriage of CNl 0. encoder sensor. Carriage operation is Check the switching waveform for Replace the unstable (due to a Q4, Q7, and Q8. abnormal lack of motor torque). transistor. EPSON DFX-5000+ Service Manual 5-27...
  • Page 195 Measure the voltage level at pin 3 Replace of ICl 0. (The normal voltage is D52. approximately 4.7 VDC.) Replace Paper The CPU is defective. Check the paper feed motor phase feeding is drive signals at pins l-4 of ICl abnormal. EPSON DFX-5000+ Service Manual 5-28...
  • Page 196 CPU input signal, abnormal. (base) and the output signal replace ICl ; (collector). if there is no output signal, replace the abnormal transistor. Fuse F3 is defective. Check if fuse F3 is defective. Replace F3. EPSON DFX-5000+ Service Manual 5-29...
  • Page 197 The PG home sensor Measure voltage at pin 32 of CN6 Replace the is defective. during the printers platen gap micro switch measurement sequence. for the PG (PG home = LOW; other = HIGH.) home sensor. EPSON DFX-5000+ Service Manual 5-30...
  • Page 198 The head driver FETs Observe the voltage waveform at Replace the are defective. the drain side. abnormal F E T . The CPU is defective. Observe the PTS signal at pin 15 Replace the of the CPU. CPU. EPSON DFX-5000+ Service Manual 5-31...

  • Page 199: Preventive Maintenance

    Lubrication and Adhesive Application EPSON recommends that the printer be lubricated at the points illustrated in Figures 6-2, 6-3, and 6-4 using EPSON lubricants 02 and G26. These lubricants have been extensively tested and found to comply with needs ofthe printer. Refer to Table 6-l for information on lubricants 02 and G26.
  • Page 200 Platen roller holder (contact point with the platen roller) Paper bail gear Fulcrum point for the paper bail shaft and plunger Platen gap motor pinion Carriage guide shaft gear Ribbon feed gears Tractor select cam Tension unit drive gear EPSON DFX-5000+ Service Manual...
  • Page 201 Lower paper guide assembly fixing screws (3 screws) 6 - 4 Connector junction board fixing screws (2 screws) 6 - 4 Platen gap motor fixing screws (2 screws) 6 - 4 Tractor tension wire 6 - 3 EPSON DFX-5000+ Service Manual...
  • Page 202 Maintenance and Lubrication Figure 6-l. Correct Adhesive Application Figure 6-2. Lubrication and Adhesive Diagram 1 EPSON DFX-5000+ Service Manual...
  • Page 205 A p p e n d i x Connector Summary Figure A-l illustrates the interconnection of the primary components, and Table A-l summarizes the tinctions and sizes ofthe connectors. 2 plh3 and sen&u~~S; Figure A-l. DFX-5000+ Cable Connections EPSON DFX-5000+ Service Manual...
  • Page 206 RF, PF, CR, and PG motor and fan driver signals Front, rear, or top PE sensor Connector for the signals from the cover open sensor. Connector for the signals from the Cl 17 PNL board. Connector for the interlock switch. A-10 EPSON DFX-5000+ Service Manual...
  • Page 207 Receives the control signal (DRERR) from the C1 17 MAIN board assembly. A-15 Supplies the DC voltage (+35 V) to the C1 17 MAIN board assembly for the fan drivers. Table A-2. CN1, C117 MAIN Board Assembly EPSON DFX-5000+ Service Manual...
  • Page 208 Appendix Table A-3. CN2, C117 MAIN Board Assembly Table A-4. CN3, C117 MAIN Board Assembly EPSON DFX-5000+ Service Manual...
  • Page 209 Appendix Table A-5. CN4, C117 MAIN Board Assembly ower source Not connected Data bus 29-36 EPSON DFX-5000+ Service Manual...
  • Page 210 Appendix Table A-6. CN5, Cl17 MAIN Board Assembly Data 1- Data 8 Not connected VDC pull up Printer select signal input EPSON DFX-5000+ Service Manual...
  • Page 211 Appendix Table A-7. CN6, Cl17 MAIN Board Assembly Head fan motor driver tor phase B signal Pull tractor sensor status EPSON DFX-5000+ Service Manual...
  • Page 212 Appendix Table A-S. CN7, C117 MAIN Board Assembly EPSON DFX-5000+ Service Manual...
  • Page 213 PITCH button input TEAR OFF button input T E A R S W T O F S W TOP OF FORM button input P A U S E PAUSE button input Ground Power source for control panel EPSON DFX-5000+ Service Manual...
  • Page 214 (1, 3, 5, 7, 8, and 9) of the nine printhead pins (1, 3, 5, 7, 8, and 9) Ground for +35 VDC Ground for +35 VDC Ground for +35 VDC Ground for +35 VDC EPSON DFX-5000+ Service Manual A-10...
  • Page 215 Appendix Table A-13. CN2, C117 PSB Power Supply Board Assembly (continued) Table A-15. CN4, C117 PSB Power Supply Board Assembly A-11 EPSON DFX-5000+ Service Manual...
  • Page 222 Appendix A-18 EPSON DFX-5000+ Service Manual...
  • Page 223 Appendix Figure A-7. C117 MAIN Board Circuit Diagram A-19 EPSON DFX-5000+ Service Manual...

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