EPSON DFX-8500 Service Manual

Service Manual
Epson America, Inc.
EPSON DFX-8500
Service Manual
TM-DFX8500
FCC COMPLIANCE STATEMENT

FOR AMERICAN USERS
This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of
the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential
installation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in
accordance with the instructions, may cause harmful interference to radio and television reception. However, there is
no guarantee that interference will not occur in a particular installation. If this equipment does cause interference to
radio and television reception, which can be determined by turning the equipment off and on, the user is encouraged to
try to correct the interference by one or more of the following measures:
Reorient or relocate the receiving antenna.

Increase the separation between the equipment and receiver.
Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.
Consult the dealer or an experienced radio/TV technician for help.
WARNING
The connection of a non-shielded equipment interface cable to this equipment will invalidate the FCC Certification of
this device and may cause interference levels that exceed the limits established by the FCC for this equipment. It is the
responsibility of the user to obtain and use a shielded equipment interface cable with this device. If this equipment has
more than one interface connector, do not leave cables connected to unused interfaces.
Changes or modifications not expressly approved by the manufacturer could void the user's authority to operate the
printer.
FOR CANADIAN USERS
This Class B digital apparatus meets all requirements of the Canadian Interference-Causing Equipment Regulations.
Cet appareil numrique de la classe B respecte toutes les exigences du Rglement sur le materiel brouilleur du
Canada.
COPYRIGHT NOTICE
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any
form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the written permission of
Epson America, Inc. No patent liability is assumed with respect to use of the information contained herein. Neither is
any liability assumed for damages resulting from the use of the information contained herein. While every precaution
has been taken in the preparation of this book, 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.
Epson America, Inc., shall not be liable against any damages or problems arising from the use of any options or any
consumable products other than those designated as Original EPSON Products or EPSON-Approved Products by
Seiko Epson Corporation.
ii
EPSON DFX-8500 Service Manual
TRADEMARKS
EPSON and ESC/P are registered trademarks and ESC/P 2 and EPSON Stylus are trademarks of Seiko Epson
Corporation. MicroDot and Super MicroDot are trademarks of Epson America, Inc.
General Notice: Other product names used herein are for identification purposes only and may be trademarks of their
respective companies. EPSON disclaims any and all rights in those marks.
Copyright 1998 Epson America, Inc.
20770 Madrona Avenue
Torrance, CA 90503
iii
PRECAUTIONS
There are cautionary notes throughout the text to help you avoid personal injury or equipment damage.
WARNING
Signals a precaution which, if ignored, could result in serious or fatal personal injury. Great caution should
be exercised in performing procedures preceded by a WARNING heading.
CAUTION
Signals a precaution which, if ignored, could result in damage to equipment.
Always observe the measures listed below when performing repair or maintenance procedures.
WARNING
1. Always disconnect the product from both the power source and host computer before performing any
maintenance or repair procedure.
2. No work should be performed on the unit by persons unfamiliar with basic safety measures dictated for
all electronics technicians in their line of work.
3. In performing testing described in 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 the
power supply and other electronic components.
CAUTION
1. Repairs on EPSON products should be performed only by an EPSON-certified repair technician.
2. Make certain that the source voltage is the same as the rated voltage listed on the serial number/rating
plate. If the EPSON product has a primary AC rating different from the 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. 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 recommended by the manufacturer;
introduction of second-source ICs or other nonapproved components may damage the product and void
any applicable EPSON warranty.
iv
CHAPTER 1
PRODUCT DESCRIPTION
1.1
FEATURES __________________________________________________________________ 1-1
1.2
SPECIFICATIONS____________________________________________________________ 1-3
Printing Specifications _____________________________________________________________________ 1-3

Paper Feeding Specifications ________________________________________________________________ 1-6
Electrical Specifications ____________________________________________________________________ 1-6
Environmental Specifications ________________________________________________________________ 1-6
Reliability _______________________________________________________________________________ 1-6
Safety Approvals __________________________________________________________________________ 1-7
CE Marking _____________________________________________________________________________ 1-7
Acoustic Noise ___________________________________________________________________________ 1-7
Ribbon Cartridge__________________________________________________________________________ 1-7
Physical Specifications _____________________________________________________________________ 1-7
Printable Area ____________________________________________________________________________ 1-8
Paper and Media _________________________________________________________________________ 1-12
Continuous Paper (Single-sheet and Multi-sheet Forms)________________________________________ 1-12
Labels _______________________________________________________________________________ 1-14
Continuous Forms with Labels ____________________________________________________________ 1-15
Overlapping Multi-sheet Forms ___________________________________________________________ 1-16
Perforations ___________________________________________________________________________ 1-16
Notes ________________________________________________________________________________ 1-16
1.3
INTERFACES _______________________________________________________________ 1-19
Parallel Interface (Forward Channel) _________________________________________________________

Parallel Interface (Reverse Channel) _________________________________________________________
Serial Interface __________________________________________________________________________
Optional Interface ________________________________________________________________________
Interface Selection________________________________________________________________________
Preventing Timeouts ______________________________________________________________________
1.4
OPERATING INSTRUCTIONS ________________________________________________ 1-25
Control Panel ___________________________________________________________________________

Buttons ______________________________________________________________________________
Indicators_____________________________________________________________________________
Errors and Buzzers _______________________________________________________________________
DIP Switch Settings ______________________________________________________________________
Control Panel Functions ___________________________________________________________________
Normal Operation ______________________________________________________________________
Advanced Control Panel Functions ________________________________________________________
Automatic Detection Functions ___________________________________________________________
Paper Memory Functions __________________________________________________________________
Initializations ___________________________________________________________________________
Hardware Initialization __________________________________________________________________
Software Initialization___________________________________________________________________
Panel Initialization _____________________________________________________________________
1.5
1-19
1-21
1-23
1-23
1-24
1-24
1-25
1-26
1-27
1-28
1-30
1-34
1-34
1-36
1-37
1-38
1-39
1-39
1-39
1-39
MAIN COMPONENTS _______________________________________________________ 1-40
M-3I60 Printer Mechanism ________________________________________________________________ 1-41
C204 Main Board_________________________________________________________________________ 1-42

C204 DRV Board _________________________________________________________________________ 1-43
C204 DRV-B Board _______________________________________________________________________ 1-44
C204 SUB Board _________________________________________________________________________ 1-44
C204 PSB/PSE Board _____________________________________________________________________ 1-45
Control Panel ____________________________________________________________________________ 1-46
Housing ________________________________________________________________________________ 1-46
PRODUCT DESCRIPTION
1.1 FEATURES
The EPSON DFX-8500 is an 18-pin, serial impact dot matrix printer designed for business use. This printer
provides high-speed, high-volume printing with continuous-sheet handling. Main features include:

Advanced paper handling:

Paper jam detection
Paper width detection
Front and rear two-way push tractors
Optional pull tractor
Automatic paper back-out and loading from another paper path
Automatic platen gap adjustment
Automatic tear-off positioning
Paper memory function
Automatic paper path switching
Auto-cut mode enables the optional perforation cutter to cut continuous paper at the perforation.
Bi-directional parallel interface (IEEE-1284 nibble) and RS-232C serial interface standard
EPSON ESC/P (upward-compatible with DFX-8000) and IBM/Lexmark 2381 Plus emulation
35 character tables in the NLSP (National Language Support) version
11 character tables in the standard version
One draft and two NLQ bitmap typefaces and 8 barcode fonts are supported.
Optional paper cutter and perforation cutter
Upgraded data handling
128KB input buffer
Automatic interface selection
Type-B optional interface cards

Figure 1-1. DFX-8500 (Exterior View)
1-1
DFX-8500
The following table shows options.
Table 1-1. Options
Code
#8766
#8767
#8309
#8502
C815001
C815071
C823051
C823071
C823121
C823141
C823151
C823452
C823572
1-2
Name
Ribbon cartridge
Ribbon pack
Pull tractor
Printer stand
Paper cutter
Perforation cutter
Serial interface card
32KB serial I/F card
Local Talk I/F card
Coax I/F card
Twinax I/F card
Bi-directional parallel I/F card
Multi-protocol Ethernet I/F card
PRODUCT DESCRIPTION
1.2 SPECIFICATIONS
This section contains the specifications for the DFX-8500.
PRINTING SPECIFICATIONS

Print method:
Number of pins:
Pin arrangement:
Pin diameter:
Color:
Print direction:
Printable columns:
Impact dot matrix

18-pin (See Figure 1-2.)
9x2
0.0114 inches (0.29 mm)
Black
Bi-directional with logic seeking
See Table 1-2.
0.0138 in. (0.35 mm)
0.111 in. (2.82 mm)
0.0665 in. (1.69 mm)
Figure 1-2. Printhead Pin Configuration
Table 1-2. Printable Columns

Print Mode
High speed draft
Draft
Draft condensed
Draft
NLQ
NLQ condensed
Character Pitch
Printable Columns
10 cpi
10 cpi
12 cpi
15 cpi
17 cpi
20 cpi
10 cpi
10 cpi
12 cpi
15 cpi
17 cpi
20 cpi
136
136
163
204
233
272
136
136
163
204
233
272
1-3
DFX-8500
Resolution:
See Table 1-3.

Table 1-3. Resolution
Print Mode
High speed draft
Draft
Draft condensed
Draft
NLQ
Bit image
1-4
Control code:
Horizontal Resolution
90 dpi
120 dpi
240 dpi
120 dpi
240 dpi
60, 72, 80, 90, 120 or 144
dpi
120 or 240 dpi
Vertical Resolution
72 dpi
72 dpi
72 dpi
72 dpi
144 dpi
72 dpi
Adjacent Dot Print

No
No
No
Yes
No
Yes
72 dpi
No
ESC/P and IBM 2381 Plus emulation
PRODUCT DESCRIPTION
Character tables and typefaces:
Standard version
NLSP version
International
Character Sets
(both versions)
Bar Codes
(both versions)
See Table 1-4.
Table 1-4. Character tables and typefaces

Character Table
Italic Table
PC437 (US, Standard Europe)
PC850 (Multilingual)
PC860 (Portuguese)
PC861 (Icelandic)
PC863 (Canadian French)
PC865 (Nordic)
Abicomp
BRASCII
Roman 8
ISO Latin 1
Italic Table
PC437 (US, Standard Europe)
PC437 Greek
PC852 (East Europe)
PC853 (Turkish)
PC855 (Cyrillic)
PC857 (Turkish)
PC866 (Russian)
PC869 (Greek)
MAZOWIA (Poland)
Code MJK (CSFR)
ISO 8859-7 (Latin/Greek)
ISO Latin 1T (Turkish)
Bulgaria
Estonia
PC 774 (LST 1283:1993)
ISO 8859-2 (ISO Latin 2)
PC 866 LAT. ( Latvian)
PC 866 UKR
PC 860
PC 861
PC 865
PC APTEC
PC 708
PC 720
PC AR864
PC 863*
Abicomp*
BRASCII*
Roman 8*
ISO Latin 1
Hebrew 7*
Hebrew 8*
PC 862*
USA
France
Germany
U.K.
Denmark 1
Sweden
Italy
Spain 1
Japan
Norway
Denmark 2
Spain 2
Latin America
Bitmap Font
EPSON Draft
EPSON Roman
EPSON Sans Serif
EPSON Draft
EPSON Roman
EPSON Sans Serif
EAN-13
EAN-8
Interleaved 2 of 5
UPC-A
UPC-E
Code 39
Code 128
POSTNET
* These tables cannot be selected using DIP switches.

Notes: The ESC R command works on all the character tables.
The international and legal characters are: 23h, 24h, 40h, 5Bh, 5Ch, 5Dh, 5Eh, 60h, 7Bh, 7Ch, 7Dh,
and 7Eh.
Input data buffer:
0KB or 128KB (depends on DIP switch settings)
1-5
DFX-8500
PAPER FEEDING SPECIFICATIONS

Feeding method:
Feeder:
Paper insertion side alignment:
Paper path:
Line spacing:
Push tractor feed (front and rear)

Push and pull tractor feed (front and rear)
Front push tractor, rear push tractor, pull tractor (option)
Left
Tractors (front in, rear in, top out)
1/6-inch, or programmable in 1/216-inch increments.
ELECTRICAL SPECIFICATIONS
120 V version:
Rated voltage:
Input voltage range:
Rated frequency range:
Input frequency range:
Rated current:
Power consumption:
Insulation resistance:
Dielectric strength:
220 - 240 V version:

Rated voltage:
Input voltage range:
Rated frequency range:
Input frequency range:
Rated current:
Power consumption:
Insulation resistance:
Dielectric strength:
120 VAC
99 to 132 VAC
50 to 60 Hz
49.5 to 60.5 Hz
3.5 A (maximum 7.5 A)
Approximately 160 W (ISO/IEC 10561 Letter pattern)
ENERGY STAR compliant
10 M minimum (between AC line and chassis, 500 VDC)
1000 AC Vrms. 1 minute or
1200 AC Vrms. 1 second (between AC line and chassis)
220 to 240 VAC
198 to 264 VAC
50 to 60 Hz
49.5 to 60.5 Hz
1.4 A (maximum 3.5 A)
Approximately 160 W (ISO/IEC 10561 Letter pattern)
ENERGY STAR compliant
10 M minimum (between AC line and chassis, 500 VDC)
1500 AC Vrms. 1 minute (between AC line and chassis)
ENVIRONMENTAL SPECIFICATIONS

Temperature :
41 to 95 F (5 to 35 C) (operating)
o
o
-22 to 140 F (-30 to 60 C) (non-operating)
Printing stops when the printhead temperature rises above the upper limit. The printer resumes printing
when the print head temperature falls below the upper limit.
Humidity :
10 to 80 % RH (operating) *
5 to 85 % RH (non-operating) *
Resistance to shock :
1 G, within 1 ms (operating)
2 G, within 2 ms (non-operating)
Resistance to vibration : 0.25 G, 10 to 55 Hz (operating)
0.50 G, 10 to 55 Hz (non-operating)
* Without condensation
With shipment container
RELIABILITY

1-6
Total print volume:

MTBF:
Printhead life:
Ribbon life:
26 million lines (excepting the printhead)

9,000 Power On Hours (POH) (at 25% duty)
400 million characters at 14 dots/character
15 million characters at 14 dots/character
PRODUCT DESCRIPTION
SAFETY APPROVALS
120 V version:
Safety standards :
UL1950 with D3
CSA C22.2 No.950 with D3
FCC part 15 subpart B class B
CSA C108.8 class B
EMI :
230 V version:
Safety standards :
EMI:
EN60950 (VDE, NEMKO)

EN55022 (CISPR pub. 22) class B
AS / NZS 3548 class B
CE MARKING
230-240 V version:
Low Voltage Directive 73/23/EEC :
EMC Directive 89/336/EEC :
EN60950
EN55022 class B
EN61000-3-2
EN61000-3-3
EN50082-1
IEC801-2
IEC801-3
IEC801-4
ACOUSTIC NOISE
Level:
58 dB(A) (ISO 7779 pattern)
RIBBON CARTRIDGE

Type:
Color:
Ribbon life:
Dimensions:
Fabric
Black
15 million characters (draft 10 cpi, 14 dots/character)
19.9 (W) 4.86 (D) 0.91 (H) in.
[506.0 (W) 123.5 (D) 23.0 (H) mm]
PHYSICAL SPECIFICATIONS

Dimensions:
Weight:
27.6 (W) 15.0 (D) 14.5 (H) in.

[700 (W) 382 (D) 369 (H) mm]
Approximately 64 lb. (29 kg)
1-7
DFX-8500
PRINTABLE AREA
Continuous paper:
See Figure 1-3.
LM
RM
PW
TM
ABCD
WXYZ
ABCD
WXYZ
ABCD
WXYZ
PL
BM
Figure 1-3. Continuous Paper Printable Area

Measurement
Paper Width (PW)
Paper Length (PL)
Left Margin (LM)
Right Margin (RM)
Top Margin (TM)
Bottom Margin (BM)
Length
See Paper and Media on page 1-12.
0.51 to 1.22 inches (13 to 31 mm)
0.51 inch (13 mm) or more
0.10 inch (2.6 mm) or more
Notes:
Paper feeding may be irregular for the top 3 inches (75 mm) of a new stack of paper.
If the optional pull tractor is used, the top 4.72 inches (120 mm) of a new stack should not be used.
Paper feeding pitch is not guaranteed.
The printable area ends 0.35 to 0.59 inch (9 to 15 mm) above the bottom edge of the paper.

1-8
PRODUCT DESCRIPTION
Labels:
See Figure 1-4.
RM
LM
PW
TM
Label
Label
Label
Label
PL
BM
Figure 1-4. Label Printable Area

Measurement
Paper Width (PW)
Paper Length (PL)
Left Margin (LM)
Right Margin (RM)
Top Margin (TM)
Bottom Margin (BM)
Length
0.51 to 1.22 inches (13 to 31 mm)
Notes:
Do not feed paper backwards or change the paper path.
Paper feeding pitch may be irregular in the top 2.95 inches (75 mm) of a new stack of paper.

1-9
DFX-8500
Continuous forms with labels:
See Figure 1-5.

LM
RM
PW
TM
TFL
Label
BFL
PL
LFL
RFL
Non Printable Area
BM
ABCD
WXYZ
TOL
Printable Area
BOL
LOL
Label
ROL
Figure 1-5. Continuous Forms with Labels Printable Area

Measurement
Paper Width (PW)
Paper Length (PL)
Left Margin (LM)
Right Margin (RM)
Top Margin (TM)
Bottom Margin (BM)
Left Margin from Label (LFL)
Right Margin from Label (RFL)
Top Margin from Label (TFL)
Bottom Margin from Label (BFL)
Left Margin on Label (LOL)
Right Margin on Label (ROL)
Top Margin on Label (TOL)
Bottom Margin on Label (BOL)
Length
0.51 to 1.22 inches (13 to 31 mm)
2.6 inches (65 mm) or more
2.6 inches (65 mm) or more
Notes:

1-10
PRODUCT DESCRIPTION
Overlapping multi-sheet forms:
See Figure 1-6.
LM
RM
PW
Perforations
Carrier
PL
BM
NA
OL
TM
Figure 1-6. Overlapping Multi-sheet Form Printable Area

Measurement
Paper Width (PW)
Paper Length (PL)
Left Margin (LM)
Right Margin (RM)
Top Margin (TM)
Bottom Margin (BM)
Overlapping Length (OL)
Non-printable Area (NA)
Length
0.51 to 1.22 inches (13 to 31 mm)
Less than 0.39 inch (10 mm)
1 inch (25.4 mm) or more
Notes:
The printable area ends 0.35 to 0.59 inches (9 to 15 mm) above the bottom edge of the paper.

1-11
DFX-8500
PAPER AND MEDIA

Continuous Paper (Single-sheet and Multi-sheet Forms)
Table 1-5. Continuous Paper
Measurement
Width
Length
Copies
Total Thickness
Weight
(single sheet)
Weight
(multiple sheet)
Quality
Multi-sheet binding
Perforations
Notes
Units
Front Path
Rear Path
Minimum
Maximum
Minimum
Maximum
inches 4.0
16.0
4.0
16.0
mm
101
406
101
406
inches 4.0
17.0
4.0
17.0
mm
101
431
101
431
1 original + 6 copies
1 original + 5 copies
inches 0.0025
0.021
0.0025
0.018
mm
0.065
0.53
0.065
0.46
lbs
14
22
14
22
2
g/m
52.6
82.7
52.6
82.7
lbs
11
15
11
15
2
g/m
41.4
56.4
41.4
56.4
Plain paper, recycled paper, and carbonless multi-sheet forms
Roughly bound multi-sheet forms can cause paper jams.
Multi-sheet forms should be held together by spot gluing, paper-stapling,
or tape stitching. Spot gluing is recommended for the best printing quality.
Spot glue must be applied on both sides of the paper. (See Figure 1-7.)
Spot glued parts must be pressed flat. There must be no creases in the
paper.
Paper staples must be applied from the front; the paper must be flat. (See
Figure 1-8.)
Paper staples must be able to feed through the printer in both directions.
(See Figure 1-9.)
Paper staples must be flat. (See Figure 1-10.)
Never use metal staples.
The bindings must be outside the printable area.
Multi-sheet forms should be bound firmly to each other; the binding must
not be too wide or thick.
See Perforations on page 1-16.
See Notes on page 1-16.

Figure 1-7. Spot Glue Positioning
1-12
PRODUCT DESCRIPTION
Figure 1-8. Paper Stapling Height
Figure 1-9. Paper Stapling, Method 1
Figure 1-10. Paper Stapling, Method 2
1-13
DFX-8500
Labels
Table 1-6. Labels
Measurements
Units
Label Size
Backing Sheet Width
Backing Sheet Length
Label Thickness
Total Thickness
Quality
Perforations
Notes
inches
mm
inches
mm
inches
mm
inches
mm
Front Path
Rear Path
Minimum
Maximum
Minimum
Maximum
See Figure 1-11.
4.0
16.0
101
406
3.5
17.0
89
431
0.0
0.0047
0.0
0.12
0.0025
0.0075
0.065
0.19
Avery continuous form labels, Avery
mini-line labels, or labels of equal

quality
Easy-peel labels should not be used.
Labels must have rounded corners.
Do not use folded or creased label sheets.
The entire printable area must be covered with the label material,
including the gutters between the labels.
The backing sheet must be continuous.
Do not use labels in the rear paper path.
Also, see Notes on page 1-16.

Figure 1-11. Label Size
Table 1-7. Allowed Label Sizes

Width
inches
2.5
4.0
4.0
1-14
mm
63.5
101
101
Height
inches
15/16
15/16
17/16
mm
23.8
23.8
27.0
PRODUCT DESCRIPTION
Continuous Forms with Labels

Table 1-8. Continuous Forms with Labels
Measurements
Units
Front Path
Rear Path
Minimum
Maximum
Minimum
Maximum
Label Size
See Labels on page 1-14.
Width
inches 4.0
16.0
mm
101
406
Length
inches 4.0
17.0
mm
101
431
Weight
lbs
14
22
2
(single sheet)
g/m
52.6
82.7
Weight
lbs
11
15
2
(multiple sheet)
g/m
41.4
56.4
Label Thickness
inches 0.0
0.0047
mm
0.0
0.12
Total Thickness
inches 0.0025
0.021
mm
0.065
0.53
Quality (Multi-sheet forms)
Plain paper, recycled paper, and
carbonless multi-sheet forms

Quality (Label)
Avery continuous form labels, Avery
mini-line labels, or labels of equal

quality
Multi-sheet binding
Roughly bound multi-sheet forms can cause paper jams.
Multi-sheet forms should be held together by spot gluing, paper-stapling,
or tape stitching. Spot gluing is recommended for the best printing quality.
Spot glue must be applied on both sides of the paper. (See Figure 1-7.)
Spot glued parts must be pressed flat. There must be no creases in the
paper.
Paper staples must be applied from the front; the paper must be flat. (See
Figure 1-8.)
Paper staples must be able to feed through the printer in both directions.
(See Figure 1-9.)
Paper staples must be flat. (See Figure 1-10.)
Never use metal staples.
The bindings must be outside the printable area.
Multi-sheet forms should be bound firmly to each other; the binding must
not be too wide or thick.
Perforations
Notes
Easy-peel labels should not be used.
Labels must have rounded corners.
Do not use folded or creased label sheets.
The entire printable area must be covered with the label material,
including the gutters between the labels.
The backing sheet must be continuous.
Do not use labels with the rear paper path.
Also, see Notes on page 1-16.

1-15
DFX-8500
Overlapping Multi-sheet Forms

Table 1-9. Overlapping Multi-sheet Forms
Measurement
Units
Front Entry
Rear Entry
Minimum
Maximum
Minimum
Maximum
Width
inches
4.0
16.0
mm
101
406
Length
inches
4.0
17.0
mm
101
431
Weight
lbs
14
22
2
(single sheet)
g/m
52.6
82.7
Weight
lbs
11
15
2
(multiple sheet)
g/m
41.4
56.4
Copies
1 original + 5 copies + 1 backing
sheet
Total Thickness
inches
0.0025
0.021
(print area)
mm
0.065
0.53
Total Thickness
inches
0.005
0.028
(overlap area)
mm
0.13
0.70
Overlapping Length
inches
more than 0
0.39
mm
more than 0
10
Quality (multi-sheet forms)
Plain paper, recycled paper, and
carbonless multi-sheet forms
Multi-sheet binding
Multi-sheet paper must be bound at the top with spot gluing. (See Figure 1-12.)
The binding must be outside the printable area.
Multi-sheet forms should be bound firmly to each other; the binding must not be
too wide or thick.
Perforation
See Perforations below.
Notes
Overlapping multi-sheet forms must be inserted into the front entrance.
Also see Notes below.

Perforations

Weak horizontal and vertical perforations may cause paper jams.

The ratio of the perforation length to the distance between perforations must be between 3 and 5. (See
Figure 1-13.)
Sheet edges must be uncut. (See Figure 1-14.)
Horizontal and vertical perforations must not cross. (See Figure 1-15.)
The perforation must be raised no more than 0.04 inch (1 mm) from the surrounding sheet surface. (See
Figure 1-16.)
Notes

Use clean paper with no folds, creases, or tears. (See Figure 1-17.)
The sprocket holes must be round. The holes may have teeth. (See Figure 1-18.)
The sprocket holes must be in the same location on each sheet. (See Figure 1-19.)
Punched out bits of paper must be removed before printing.
Paper should be fan-folded at horizontal perforations. Never use paper that is not fan-folded properly.
(See Figure 1-20.)
The printable area must be free of holes.
1-16
PRODUCT DESCRIPTION
19 or more
19 - 31
13 + 3
21.2 or more
13 + 3
Multi-part cut sheet
Page Length
Base sheet
Spot-glued part
4.2 or more
21.2 or more
Perforation of base sheet
Spot-glued psrt
Lower edge
Page Width
Spot-glued part
Unit : mm
Figure 1-12. A Spot Glued Multi-sheet Form
Figure 1-13. Perforations (1)
1-17
DFX-8500
Figure 1-16. Raised Perforation

a)
b)
c)
Figure 1-18. Sprocket Holes (1)
Figure 1-19. Sprocket Holes (2)
Figure 1-17. Examples of Unsuitable Paper
Figure 1-20. Incorrectly Folded Paper
1-18
PRODUCT DESCRIPTION
1.3 INTERFACES
The DFX-8500 has a parallel interface, a serial interface, and a slot for an optional Type-B interface card.
This section presents the specifications for each interface type.
PARALLEL INTERFACE (FORWARD CHANNEL)

Data transmission mode:

8-bit parallel, IEEE-1284 compatible mode
Synchronization:
/STROBE pulse
Connector type:
57-30360 (AMPHENOL) 36-pin plug or equivalent
Handshaking:
BUSY and /ACK handshaking
Note: The BUSY signal is set HIGH before setting either /ERROR low or PE high. The BUSY signal is held
HIGH until all these signals return to their inactive state. The BUSY signal is HIGH in the following cases:
During data entry (see data transmission timing below)
When the input data buffer is full
When the /INIT signal is at a low level
During hardware initialization
During printer errors (see /ERROR signal)
While printing a self-test or DIP switch settings
When the parallel interface is not selected
Note: The /ERROR signal is set LOW when the printer is in one of the following states:
Printer hardware error (fatal error)
Paper out error
Paper jam error
The cover is open
Paper change incomplete error
Paper size error
Ribbon jam error
Note: The PE signal is set HIGH during paper out errors.

Data transmission timing:
See Figure 1-21 below.

DATA (n+1)
DATA (n)
DATA
thold
STROBE
tsetup
tnex t
tstb
BUSY
tready
ACKNLG
tbus y
treply
tack
tnbusy
Figure 1-21. Data Transmission Timing
1-19
DFX-8500
Table 1-10. Data Transmission Timing
Parameter
tsetup
thold
tstb
tready
tbusy
treply
Minimum
500 ns
500 ns
500 ns
0
Maximum
500 ns
Parameter
tack
tnbusy
tnext
tt-out*
tt-in**
Minimum
500 ns
0
0
Maximum
10 us
120 ns
200 ns
* Rise and fall time of output signals.

** Rise and fall time of input signals.
Signal Level:
TTL-level compatible, IEEE-1284 level 1 device

See Table 1-11 below.
Table 1-11. Signal Level

Parameter
Minimum
Maximum
Condition
VOH*
5.5 V
VOL*
0.5 V
IOH*
0.32 mA
VOH = 2.4 V
IOL*
12 mA
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
* A low logic level is 2.0 V or less; a high logic level is 3.0 V or more. The receiver shall provide an
impedance equivalent to 7.5 k to ground.
1-20
PRODUCT DESCRIPTION
Connector pin assignments and signals:
Table 1-12. Signal and Connector Pin Assignment (Forward channel)

1
Pin No.
Signal Name
/STROBE
Return GND pin

19
I/O*
I
2-9
DATA 0-7
20-27
10
/ACKNLG
28
11
BUSY
29
12
13
PE
SLCT
28
28
O
O
14
31
/AFXT
/INIT
30
30
I
I
32
36
18
35
17
16,33,19,30
15,34
/ERROR
/SLIN
Logic H
+5 V
Chassis GND
GND
NC
29
30
-
O
I
O
O
-
Description
The strobe pulse. Reads in data at the falling
edge of this pulse.
The DATA 0 through DATA 7 signals represent
data bits 0 to 7, respectively. Each signal is
HIGH when data is 1 and LOW when data is 0.
This signal is a negative pulse indicating that
the printer can again accept data.
A high signal indicates that the printer cannot
receive data.
A high signal indicates a paper-out error.
Always at high level when the printer is
powered on.
Not used.
The falling edge of a negative pulse or a low
signal on this line causes the printer to
initialize. A minimum 50-s pulse is necessary.
A low signal indicates a printer error.
Not used.
Pulled up to +5 V via a 3.9 k resistor.
Chassis GND.
Signal GND.
Not connected.
* From the printers point of view.
PARALLEL INTERFACE (REVERSE CHANNEL)

Data transmission mode:

Connector type:
Synchronization:
Handshaking:
Data transmission timing:
Signal level:
Extensibility request:
Device ID:
IEEE-1284 nibble mode

57-30360 (AMPHENOL) 36-pin plug or equivalent
See the IEEE-1284 specification.
TTL-level compatible, IEEE-1284 level 1 device
When the printer receives the hexadecimal signals 00h or 04h, it
responds in the following manner:
00h: The printer enters reverse channel mode, allowing data to be sent to
the host.
04h: The printer sends the device ID to the host.
[00h][3Ah]
MPG: EPSON;
CMD: ESCP9, PRPII9, BDC;
MDL: DFX-8500;
CLS: PRINTER
1-21
DFX-8500
Connector pin assignments:
Table 1-13. Signal and Connector Pin Assignment (Reverse channel)

Pin No.
1
Signal Name
HostClk
I/O*
I
2-9
DATA 1-8
10
11
12
13
14
PtrClk
PtrBusy
AckDataReq
Xflag
HostBusy
O
O
O
O
I
15
16
17
NC
GND
CHASSISGND
18
19-30
31
32
33
34
35
36
NC
GND
Ninit
NdataAvail
GND
NC
+5 V
/SLCT IN
I
O
I
1-22
Description
This signal is a strobe pulse used to read extension request values
from the host computer during negotiation.
The signals are data bits of extension request values. This printer
supports the following values:
0000 0100: Request Device ID (by nibble mode sending)
0000 0000: Request nibble mode
Printer sending clock data.
Printer sending data bits 3 and 7 to the host computer.
This signal informs the printer of the host computer state. When
this signal is HIGH, the host computer cannot accept data.
Not used.
Logic ground level.
Connected to the printer chassis. The printer chassis GND and the
signal GND are connected to each other.
Not connected.
Ground level for the twisted pair return signal.
This signal is always HIGH.
Same as pins 19 to 30.
Not used.
Pulled up to +5V through a 1.0 k resistor.
1284 Active: If this signal is set to HIGH, P1284 (reverse mode) is
active.
PRODUCT DESCRIPTION
SERIAL INTERFACE

Synchronization:
Asynchronous
Signal level (ELA-232D):
MARK (logical 1):
3 V to 25 V
SPACE (logical 0):
+3 V to +25 V
Word length:
Start bit:
1 bit
Data bit:
8 bit
Parity bit:
Odd, Even, None, or Ignore
Stop bit:
1 bit or more
Baud rate:
2400, 4800, 9600 or 19200 bps
Handshaking:
DTR signal or X-ON / X-OFF
DTR=MARK, X-OFF:
Indicates that the printer cannot receive data.
DTR=SPACE, X-ON:
Indicates that the printer is ready to receive data.
Note: The DTR signal MARK, X-OFF (DC3, 13h) is transmitted when the input buffer reaches 256 bytes.
The DTR signal SPACE, X-ON (DC1, 11h) is transmitted when the input buffer falls below 256 bytes.
Error handling:
When a parity error is detected, the received byte is changed to the "*"
character code and a string of asterisks is printed. Overrun and framing
errors are ignored.
Connector:
25-pin sub-miniature D-shell connector (female)
Connector pin assignment and signals: See Table 1-14.

Table 1-14. Signal and Connector Pin Assignment (EIA-232D)

Pin No.
2
20
11
4
3
7
1
Other
Signal
Name
TXD
DTR
REV
RTS
I/O*
O
O
O
O
RXD
Signal GND
Chassis
GND
NC
Description
I
-
Transmits data.
Indicates whether the printer is ready to receive data.
Connected directly to the DTR signal.
Request to Send: always set to SPACE when the printer is on.
Receive data.
Signal GND.
Chassis GND.
Not used. Not connected.
OPTIONAL INTERFACE
Type-B and Type-B (level 2) optional interfaces are available. (See Table 1-1.)
1-23
DFX-8500
INTERFACE SELECTION
The printer has three interfaces: parallel, serial, and optional Type-B. These interfaces are selected
automatically or manually using DIP switches.

Manual selection:
One of three interfaces can be selected using DIP switches.
Automatic selection:
If the automatic interface is selected using DIP switch settings, the printer is initialized to an idle
state, scanning all interfaces to see which receives data first. The interface that receives data first
becomes active. When the host stops data transfer, and the printer is in stand-by state for the time
specified by the DIP switch settings, the printer returns to the idle state. As long as the host keeps
sending data or the printer interface is in a busy state, the selected interface remains selected.
Interface state and interface selection:
When the parallel interface is not selected, the interface enters a busy state.
When the serial interface is not selected, the interface sends the DTR signal MARK, X-OFF.
When the optional interface is not selected, the printer sends disable commands to the optional
interface.
When the printer is initialized or returned to the idle state, the parallel interface enters a ready state,
the serial interface sends DTR signal SPACE, X-ON, and the printer sends enable commands to the
optional interface.
Note: Interrupt signals (such as an /INIT signal for the parallel interface) are not effective while the
target interface is not selected.
PREVENTING TIMEOUTS
Hosts abandon data transfer to peripherals when a peripheral is in a busy state for some time. To prevent
hosts from timing out, the printer receives data very slowly, at a rate of several bytes per minute, even if the
printer is in a busy state. This slowdown begins when the input buffer grows to several hundred bytes.
Eventually, if the input buffer fills completely, the printer enters a continuously busy state.
1-24
PRODUCT DESCRIPTION
1.4 OPERATING INSTRUCTIONS

This section describes the functions performed through the control panel, such as test printing, hexadecimal
dumps, and paper memory functions.
CONTROL PANEL
The printer control panel gives you easy control over most common printer operations. The panel consists of
the indicator lights and buttons shown in Figure 1-22.
Power
Paper
Out
Ribbon
Font
Sper Draft
Dfaft
Roman
Sans serif
Pitch
Copy
Top of
Form
LF/FF
Load
Pause
Micro
Feed
Tractor Select
PAPER SELECT
10 cpi
12 cpi
15 cpi
17 cpi
20 cpi
PS
Reset
Tear Off
3sec
Paper Select
LED Off
Front / Rear
LED On
Figure 1-22. Control Panel
1-25
DFX-8500
Buttons
The control panel contains eleven buttons.
Button Functions during Normal Operation:

During normal operation, control panel buttons perform the following functions. (See Table 1-15.)
Table 1-15. Button Functions during Normal Operation
Button
Front/Rear
Pause

Micro Feed
Micro Feed
LF/FF Load
TOF (top of form)
Tear Off
Copy
Pitch
Font
Paper Select
Function
Toggles between the front and rear paper paths.
Toggles between printing and paused status.
Holding this button down for three seconds resets the printer.
Feeds paper forward 1/216 inch.
Feeds paper backward 1/216 inch.
Loads the paper when the printer is empty.
Pressing this button feeds paper forward one line.
Holding this button down for a few seconds feeds paper forward one
page.
Allows top of form position adjustment.
Allows loading position adjustment when pressed just after loading
paper.
Advances continuous paper to the tear-off position.
Toggles between multi-form copy and normal printing.
Selects pitch.
Selects font.
Selects memorized paper setting.

Operation with the Power Button:

Control panel buttons perform the functions shown in Table 1-16 when pressed at the same time as the
Power button.
Table 1-16. Button Function when Combined with the Power Button
Button
LF/FF Load
Tear Off
Tear Off and LF/FF
Pause
LF/FF Load, Micro Feed and Pause*
Pause and Front/Rear

Copy
Paper Select
Tear Off, Micro Feed , and Front/Rear
Tear Off, Micro Feed , and Front/Rear
Micro Feed and Micro Feed
Function
Draft self test
NLQ self test
Hex dump
DIP switch setting printout
Clear EEPROM area 2
Clear EEPROM area 1
Clear ribbon counter
This button is used for paper memory storage and
recall. See Paper Memory Functions on page 138.
Flight time adjustment (See Chapter 4.)
Platen gap adjustment (See Chapter 4.)
Sets printable area.
Note: For details, see Advanced Control Panel Functions on page 1-36.
* All mechanism adjustment values are cleared. The printer mechanism adjustment must be performed after
this. (See Chapter 4.)
All user setting values are replaced with the factory setting values.
1-26
PRODUCT DESCRIPTION
Indicators
The control panel contains fifteen LEDs.

Rear (2) (Green / Red):

Green: The rear paper path is selected and has paper in it.
Red: The rear paper path is selected has no paper in it.
Off: The front paper path is selected.
Front (2) (Green / Red):
Green: The front paper path is selected and has paper in it.
Red: The front paper path is selected and has no paper in it.
Off: The rear paper path is selected.
Pause (Orange):
On: The printer is paused.
Off: The printer is not paused.
Blinking: The printhead is too hot.
Top of Form (Green):
On: The top of form and tear-off positions are adjustable.
Tear Off (Green):
On: The paper is at the tear-off position.
Off: The paper is not at the tear-off position.
Copy (Green):
On: Copy mode.
Off: Normal mode.
Pitch (Green):
The current pitch selection is displayed on three LEDs:
: 10 cpi
: 12 cpi
: 15 cpi
: 17 cpi
: 20 cpi
: PS
(: LED off, : LED on.)
Font (Green):
The current font selection is displayed on two LEDs:
: Super draft
: Draft
: Roman
: Sans Serif
(: LED off, : LED on.)
Power (Green):
On: The printer is on.
Off: The printer is off.
Paper Out (Red):
On: The printer is out of paper.
Blinking: There is a paper jam.
Ribbon (Red):
Blinking: There is a ribbon jam.
Paper Select (7-segment, Green):
This LED indicates the selected paper size number and displays error codes.
1-27
DFX-8500
ERRORS AND BUZZERS

Errors fall into 2 types: normal errors/warnings and fatal errors. See the tables below for detailed
information. See Chapter 5 for more information about errors and troubleshooting.
Table 1-17. Error/Warning Beeper Information
Error/Warning
Printhead hot
Printhead fan hot
Paper out
Pause
LED
Blinking
Blinking
On
Paper Out
LED
Off
Off
On
Ribbon
LED
Off
Off
Off
...
Cover open
ON
Off
Off
...
Paper change
incomplete
Paper backfeed
incomplete
Paper size error
On
Off
Off
...
On
Blinking
Off
...
ON
Off
Off
...
Paper jam
ON
Blinking
Off
-----
Ribbon jam
On
Off
Blinking
-----
Carriage motor
error
On
Blinking
Blinking
-----
Illegal panel
operation
1-28
Beeper
Description
This error occurs when the

printer fails to load a sheet.
(Three 100-ms beeps with a
100-ms interval.)
printers cover is open.
printer fails to change the paper.
This error occurs when the set

paper width and the current
paper size are different.
printer fails to eject a sheet.
(Five 500-ms beeps with a
100-ms interval.)
ribbon jams or when no ribbon is
installed.
carriage deceleration time is
abnormal.
PRODUCT DESCRIPTION
Table 1-18. Fatal Error Information
Fatal Error
Carriage motor circuit
shortage error
Cutter error
Platen gap error
Carriage lock error
Carriage load measurement
error
Printhead fan error
Head circuit shortage error
RAM check error
Paper memory setting error
EEPROM data comparison
error
Tractor change error
Internal CPU error
7-segment
LED Display *
1
Beeper
Description
Auto power off after 12 seconds
2
3
4
6
------------
7
8
9
a
b
-----------------------------------------
Printhead shuts off immediately

Printhead shuts off immediately
c
d
------------

Auto power off

Auto power off
Auto power off
Auto power off
after 12 seconds
after 12 seconds
after 12 seconds
after 12 seconds
* The 7-segment LED flashes E and the error number.

500-ms beeps with 100-ms intervals.
Turn the printer power off after a fatal error occurs or the printer will shut down automatically; if this
happens, you must wait 5 minutes before turning on the printer again.
1-29
DFX-8500
DIP SWITCH SETTINGS

There are 5 banks of 8 DIP switches located at the front paper entrance of the printer. The printer default
settings are set using these DIP switches. When the printer is turned on or reset, the DIP switch selections
are treated as the default setup. If the setup is changed, the printer should be reset or turned off and on.
Table 1-19 shows the DIP switch selections for this printer.
Table 1-19. DIP Switch Settings
Switch No.
1-1 to 1-6
1-7
1-8
2-1 to 2-4
2-5 to 2-8
3-1
3-2
3-3
3-4
3-5
3-6
3-7
3-8
4-1
4-2
4-3 to 4-4
4-5 to 4-6
4-7 to 4-8
5-1
5-2
5-3
5-4
5-5 to 5-8
1-30
Function
Character table
Skip over perforation
Print direction
Page length for front tractor
Page length for rear tractor
Auto tear-off
Zero slash
Auto line feed
Buzzer
Auto carriage return
(IBM 2381 Plus)
IBM character table
Auto cut mode
Software
Input buffer
Auto I/F wait time
I/F mode
Serial I/F parity
Serial I/F baud rate
Overlapping multi-sheet forms
Continuous forms with labels
Skip over binding
Paper memory
(reserved)
Off
On
See Tables 1-18 or 1-19.
Inactive
Active
Bi-d.
Uni-d.
See Table 1-20.
See Table 1-21.
Inactive
Active
Inactive
Active
Inactive
Active
Active
Inactive
Inactive
Active
Factory Setting
All Off
Off
Off
All Off
All Off
Off
Off
Off
Off
Off
Table 2
Inactive
ESC/P
Active
10 sec.
See Table 1-22.
See Table 1-23.
See Table 1-24.
Inactive
Inactive
Inactive
Memory a
-
Off
Off
Off
Off
Off
All Off
All Off
All Off
Off
Off
Off
Off
Off
Table 1
Active
IBM 2381 Plus
Inactive
30 sec.
Active
Active
Active
Memory b
-
PRODUCT DESCRIPTION
Table 1-20. Character Table Setting (Standard)
SW1-1
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
SW1-2
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
On
On
SW1-3
Off
Off
Off
Off
Off
Off
Off
Off
On
On
On
On
On
On
On
On
Off
Off
SW1-4
Off
Off
Off
Off
On
On
On
On
Off
Off
Off
Off
On
On
On
On
Off
Off
SW1-5
Off
Off
On
On
Off
Off
On
On
Off
Off
On
On
Off
Off
On
On
Off
Off
SW1-6
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Others
Character table
PC437 (US, standard Europe)
PC860 (Portuguese)
PC861 (Icelandic)
PC863 (Canadian-French)
PC865 (Nordic)
Abicomp
BRASCII
Roman 8
ISO Latin 1
Italic USA
Italic France
Italic German
Italic U.K
Italic Denmark
Italic Sweden
Italic Italy
Italic Spain
PC437
1-31
DFX-8500
Table 1-21. Character Table Setting (NLSP)
SW1-1
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
On
On
1-32
SW1-2
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
On
On
On
On
On
On
On
On
On
On
On
On
On
On
On
On
Off
Off
SW1-3
Off
Off
Off
Off
Off
Off
Off
Off
On
On
On
On
On
On
On
On
Off
Off
Off
Off
Off
Off
Off
Off
On
On
On
On
On
On
On
On
Off
Off
SW1-4
Off
Off
Off
Off
On
On
On
On
Off
Off
Off
Off
On
On
On
On
Off
Off
Off
Off
On
On
On
On
Off
Off
Off
Off
On
On
On
On
Off
Off
SW1-5
Off
Off
On
On
Off
Off
On
On
Off
Off
On
On
Off
Off
On
On
Off
Off
On
On
Off
Off
On
On
Off
Off
On
On
Off
Off
On
On
Off
Off
SW1-6
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Others
Character table
PC437 (US, standard Europe)
PC437 Greek
PC852 East Europe
PC853
PC855 (Cyrillic)
PC857 (Turkish)
PC866 (Russian)
PC869 (Greek)
MAZOWIA (Poland)
Code MJK (CSFR)
ISO 8859-7 (Latin/Greek)
ISO Latin 1T (Turkish)
Bulgaria (Bulgarian)
Estonia (Estonia)
PC774 (LST 1283:1993)
ISO8859-2
PC866LAT (Latvian)
PC866 UKR
PCAPTEC
PC708
PC720
PC AR864
PC860(Portuguese)
PC861(Icelandic)
PC865(Nordic)
Italic USA
Italic France
Italic German
Italic U.K
Italic Denmark
Italic Sweden
Italic Italy
Italic Spain
PC437
PRODUCT DESCRIPTION
Table 1-22. Front Tractor Page Length
SW2-1
Off
Off
Off
Off
Off
Off
Off
Off
On
On
On
On
On
On
SW2-2
Off
Off
Off
Off
On
On
On
On
Off
Off
Off
Off
On
On
SW2-3
Off
Off
On
On
Off
Off
On
On
Off
Off
On
On
Off
Off
SW2-4
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Others
Page length for front tractor

11 inches
3 inches
3.5 inches
4 inches
5.5 inches
6 inches
7 inches
8 inches
8.5 inches
70/6 inches
12 inches
14 inches
17 inches
Others
11 inches
Table 1-23. Rear Tractor Page Length

SW2-1
Off
Off
Off
Off
Off
Off
Off
Off
On
On
On
On
On
On
SW2-2
Off
Off
Off
Off
On
On
On
On
Off
Off
Off
Off
On
On
SW2-3
Off
Off
On
On
Off
Off
On
On
Off
Off
On
On
Off
Off
SW2-4
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Others
Page length for rear tractor

11 inches
3 inches
3.5 inches
4 inches
5.5 inches
6 inches
7 inches
8 inches
8.5 inches
70/6 inches
12 inches
14 inches
17 inches
Others
11 inches
Table 1-24. I/F Selection
SW4-3
Off
Off
On
On
SW4-4
Off
On
Off
On
I/F Mode
Auto
Parallel I/F
Serial I/F
Optional I/F
Table 1-25. Serial I/F Parity Setting

SW4-5
Off
Off
On
On
SW4-6
Off
On
Off
On
Serial parity
None
Odd
Even
Ignore
1-33
DFX-8500
Table 1-26. Serial I/F Baud Rate Setting
SW4-7
Off
Off
On
On
SW4-8
Off
On
Off
On
Baud rate
19200
9600
4800
2400
CONTROL PANEL FUNCTIONS

Normal Operation
Front / Rear:
Toggles between the front and rear paper paths.
If the printer is set to use normal paper and the pull tractor is not used:
The printer feeds the paper to the tear off position, cuts the paper using the cutter, and feeds the paper
backward to the paper park position. A paper change incomplete error occurs if the cutter is not used. If
you arent using the cutter, cut the paper above the platen, then press the Pause or Front/Rear button.
The printer feeds the paper backward. After the paper is out, the printer loads paper from the other paths
tractor.
If the printer is set to use overlapping multi-sheet forms or continuous forms with labels (DIP
switches 5-1 or 5-2 are on) or the pull tractor is used:
A paper change incomplete error occurs immediately. Cut the paper below the platen, then press the
Pause or Front/Rear button. The printer feeds the paper forward. After the paper is out, the printer loads
paper from the other paths tractor.
Pause:
This button causes the printer to pause.
Hold this button down for 3 seconds to reset all printer data.
Press this button to clear a paper change incomplete error.
Micro feed:
Adjusts the paper position, the top of form position, and the tear off position. The button advances the
paper 1/216 inch, and the button retracts the paper 1/216 inch.
LF/FF Load:
Pressing this button advances the paper one line.
Holding this button down for a few seconds advances the paper one page.
When the printer is out of paper, pressing this button will load continuous paper.
Top of Form:
Pressing this button starts the top of form adjustment mode, turns on the top of form LED, and advances the
paper until the character base line lies directly beneath the red mark on the ribbon mask holder. You can
adjust the top of form position using the Micro Feed buttons while in this mode. Press the Top of Form
button again to exit the top of form adjustment mode. The adjusted position is stored as the new top of form
position, and the paper is retracted to its normal printing position.
If you adjust the top of form position just after loading, the adjusted position will be treated as the loading
position. This button is inactive if the printer cover is closed.
Tear Off:
Pressing this button starts the tear off adjustment mode, turns on the tear off LED, and advances the paper
until the perforation lies directly beneath the cutting edge of the printer cover. You can adjust the tear off
position using the Micro Feed buttons while in this mode. Press the Tear Off button again to cut the paper
(optional cutter required) and exit the tear off adjustment mode. The adjusted position is stored as the new
tear off position, and the paper is retracted to its normal printing position. The printer will also exit this mode
1-34
PRODUCT DESCRIPTION
if it receives data from the host computer.
Copy:
This button toggles the printer between copy mode or normal mode.
Pitch:
Press this button to select among the following pitches:
10 cpi, 12 cpi, 15 cpi, 17 cpi, 20 cpi and PS (proportional spacing)
Font:
Press this button to select among the following fonts:
Super Draft, Draft, Roman, Sans Serif
Paper Select:
Paper sizes can be preset. Pressing this button selects one of the following preset paper sizes:
1, 2, 3, 4, 5, 6, 7, and 8: Paper sizes must be created within the printer driver. See the Users Guide
for details.
0:
Default; use when no driver settings have been made.
a, b:
Hardware settings used for sheets with labels. See the Users Guide for
details.
If the printer is set to use normal paper and the pull tractor is not used:
Pressing this button retracts the paper to the paper park position. If a print job was just performed, the
printer will advance the paper to the tear off position and cut the paper (if the optional cutter is installed).
If the cutter is not installed, a paper change incomplete error occurs. Manually cut the paper above the
platen, then press the Pause button. The printer will retract the paper. After the new paper has been
placed into position, the printer will load the new paper. If a paper change incomplete error occurred,
insert the new paper and press the Pause button to load it.
If the printer is set to use overlapping multi-sheet forms or continuous forms with labels (DIP
switches 5-1 or 5-2 are on) or the pull tractor is used:
Pressing this button will cause an immediate paper change incomplete error. Manually cut the paper
below the platen, then push the Pause button. The printer will advance the paper until it is out, then load
the selected paper. If you get another paper change incomplete error, insert the new paper and press the
Pause button to load it.
If the paper setting is currently setting a or b:
The printer advances the paper. If a paper path change incomplete error occurs, cut the paper below
the platen and press the Pause button. The printer ejects the paper.
If the printer is not currently using the a and b settings:
The printer advances the paper to the tear-off position and cuts the paper if the cutter is installed.
The printer then retracts the paper to the paper park position. If the cutter is not installed, or the
printer fails to advance the paper to the paper park position, a paper path change incomplete error
will occur. If this happens, cut the paper above the platen, then press the Pause button. The printer
retracts the paper.
1-35
DFX-8500
Advanced Control Panel Functions

See Table 1-16 on page 1-26 for instructions on how to access these functions.
Self test:
Prints the self test pattern. To cancel the self test, press the Pause button and turn off the printer.
DIP switch setting print:

Prints the settings of all DIP switches.
Hex dump:
Starts a hex dump; all input data is printed as a list of hexadecimal numbers beside the corresponding
characters.
Clear EEPROM Area 1:

Resets all user settings.
Clear EEPROM Area 2:

Resets the printer mechanism adjustment data to the standard factory setting.
Clear ribbon counter:

Resets the ribbon counter.
Paper memory setting:

Accesses settings that improve printing on label sheets and overlapping forms.
Mechanism adjustment:
Starts mechanism adjustment mode. You can adjust the beta value, flight time value, and Bi-D setting using
this mode.
Platen gap adjustment:

Starts platen gap parameter adjustment mode. You can adjust the alpha and beta values using this mode.
Set printable area:

Starts automatic measurement seeking. The carriage deceleration time is measured and saved in the
EEPROM.
1-36
PRODUCT DESCRIPTION
Automatic Detection Functions
Cover open detection:

When the cover is opened, the printer stops printing and pauses after several beeps. The printer stays
paused until the cover is closed and the Pause button is pressed.
Paper width detection:

The printer detects the right paper edge and determines the right edge of the printable area. Print jobs that
extend beyond that edge won't be printed.
Automatic platen gap adjustment:

This printer measures the thickness of each new paper stack. The distance between the printhead and the
platen is then automatically adjusted.
Skip over binding:

If the paper is a multi-sheet form with thick bindings that could scratch the printhead during paper feeding,
this feature allows the printhead to lift up and over these bindings to avoid paper jams. This feature can be
activated using DIP switches. (See Dip Switch Settings on page 1-30.) Use of this feature will reduce print
speed.
Auto cut mode:

The printer automatically cuts the paper at each perforation during printing. This function is valid when the
perforation cutter is used, DIP switch 3-7 is on, and the paper is over 4 inches long. The printer driver
setting has priority over the DIP switch setting. Do not use this mode for labels, continuous forms with
labels, or overlapping multi-sheet forms.
Automatic Top of Form (TOF) position adjustment:

When the TOF position is different from the loading position, the printer automatically feeds the paper to the
next TOF position.
1-37
DFX-8500
PAPER MEMORY FUNCTIONS

Use the paper memory function to get better quality printouts on overlapping multi-sheet forms or
continuous forms with labels. Before using paper memory, you must use the control panel and DIP switches
to set the paper length. This function is available only when using the front paper path.
How to recall paper memories:

Paper settings stored in memory can be used by setting the appropriate DIP switches.
Notes:

A 1-inch perforation area is automatically included for overlapping multi-sheet forms.

The commands ESC C, ESC (C, and ESC (c can be used with stored paper settings.
The ESC N command can be used with stored paper settings, but if the perforation length is set to
less than 1 inch, the setting is ignored when using overlapping multi-sheet forms.
ESC 0 cannot be used with stored paper settings for overlapping multi-sheet forms.
You must adjust the loading position for overlapping multi-sheet forms each time they are used.
If the paper is not at the top of form position when the printer is turned on, the printer automatically
advances the paper to the top of the next page.
How to save settings for all paper except continuous forms with labels (settings a & b only):
1) Make sure the printer is turned off.
2) Select a memory location. (See DIP Switch Settings on page 1-30.)
3) Select the page length. (See DIP Switch Settings on page 1-30.)
4) Select the paper type. (See DIP Switch Settings on page 1-30.)
5) Turn the printer on while pressing the Paper Select button.
6) The printer writes the information in the memory you selected, and beeps.
How to save settings for continuous forms with labels (settings a & b only):
1) Make sure the printer is turned off.
2) Select a memory location. (See DIP Switch Settings on page 1-30.)
3) Select the page length. (See DIP Switch Settings on page 1-30.)
4) Select the paper type. (See DIP Switch Settings on page 1-30.)
5) Turn the printer on while pressing the Paper Select button.
6) Set the label size.
a) Open the printer cover.
b) Move the pointer (see Figure 1-23) to the labels upper left corner:
To move the carriage up or down, use the Micro Feed buttons
To move the carriage right or left, slide the printhead manually.
c) Press the Top of Form button.
d) Move the pointer to the lower right corner of the label.
e) Press the Top of Form button.
f) Close the printer cover.
7) Listen for confirmation.
1 or 2 beeps: The settings were saved correctly.
3 beeps: the settings were not saved correctly. Try again.
1-38
PRODUCT DESCRIPTION
INITIALIZATIONS
Hardware Initialization
Initialization occurs when the printer is turned on or when the printer receives an /INIT signal (negative
pulse) or cold-reset command (remote RS command). Initialization does the following:
initializes the printer mechanism
clears all data buffers
cancels downloaded character translation
places the printer in a stand-by state
performs a software initialization (see below)
Software Initialization
The control codes ESC @ (for ESC/P) or ESC [K (for IBM/Lexmark 2381 Plus) will also initialize the printer.
Software initialization sets all printer settings to their default values.
Panel Initialization
You can initialize the printer from the control panel by pressing the Reset button for 3 seconds. This
initialization:
clears all data in the buffer
performs a software initialization
1-39
DFX-8500
1.5 MAIN COMPONENTS

The main components of the DFX-8500 are:

Printer mechanism:
Main control board:
Mechanism driver board:
Printhead driver board:
DIP switch board:
Power supply board:
Control Panel
Housing
M-3I60
C204 Main board
C204 DRV board
C204 DRV-B board
C204 SUB board
C204 PSB/PSE board
Carriage Connector Junction Board

(PPL Name: CR Intermit Board)
Printhead Junction Board
(PPL Name: Intermit Board)
Panel Unit
C204 PSB/PSE Board

Connector
Junction Board
C204 Main Board, C204 DRV Board,

C204 DRV-B Board, and C204 SUB Board
Figure 1-23. Main Components
1-40
PRODUCT DESCRIPTION
M-3I60 PRINTER MECHANISM

The M-3I60 printer mechanism is an 18-pin (in two rows of 9 pins), serial impact dot matrix printer
mechanism developed for the DFX-8500. It is designed to provide high-speed, high-volume printing, and is
especially heavy and durable. The paper feeding mechanism accepts several kinds of fan-fold paper. An
automatic mechanism is included to provide enhanced paper handling.
The structural differences between the DFX-8500 and the DFX-8000 are:

The DFX-8500 includes a carriage motor isolation resistance sensor.

The DFX-8500 includes a paper jam sensor.
The DFX-8500 includes a ribbon sensor.
The DFX-8500 includes a tractor wire at the front and rear tractors to prevent paper jams.
The detection method of the carriage encoder sensor differs from previous printers. In the
DFX-8000, the encoder plate was attached to the rotor of the carriage motor, while the DFX-8500
uses a belt-type encoder.
The DFX-8500 does not include a carriage home position sensor.
Figure 1-24. M-3I60 Printer Mechanism
1-41
DFX-8500
C204 MAIN BOARD

The C204 main board contains the following ICs:

16-bit CPU:
Gate array:
PROM (including C.G.):
RAM:
ADM232L:
Reset IC:
EEPROM:
TMP95C051A; 24.57 MHz (IC2)

E05B36 (IC1)
2M-bit (IC5)
4M-bit (IC14)
RS-232C level converter (IC9)
PST391D (IC13)
93C66 (IC11)
There are two types of C204 main board, distinguished by the hex screw used to attach the serial interface.
The screw for the USA and Pacific Rim board is imperial; the screw for the European board is metric.
Figure 1-25. C204 Main Board
1-42
PRODUCT DESCRIPTION
C204 DRV BOARD

The C204 DRV board drives the printer mechanism. The printhead fan, plunger, paper feed (PF) motor,
carriage (CR) motor, carriage fan, platen gap (PG) motor, and ribbon feed (RF) motor driver circuits are
located on this board. This board contains half of the printhead driver circuits; the other half are on the C204
DRV-B board. Sensor signals from the printer mechanism are connected to the main board via this board.
The major ICs on the DRV board are:

carriage motor drive IC:

paper feed motor drive IC:
comparator IC:
STK561 (IC1)
STK5713B (IC2)
uPC393C (IC3)
Figure 1-26. C204 DRV Board
1-43
DFX-8500
C204 DRV-B BOARD

The C204 DRV-B board contains half of the printhead driver circuits; the other half are on the C204 DRV
board. Most of this board is devoted to discrete bipolar FETs.
Figure 1-27. C204 DRV-B Board
C204 SUB BOARD

The C204 SUB board consists of five banks of DIP switches. It is located behind the front paper cover.
Figure 1-28. C204 SUB Board Unit
1-44
PRODUCT DESCRIPTION
C204 PSB/PSE BOARD

The C204 PSB/PSE board is a power supply circuit board that generates power for the main and driver
boards. There is a cooling fan on the top of this board. The PSB board takes 100-120 VAC, and the PSE
board takes 220-240 VAC.
Figure 1-29. C204 PSB/PSE Board
1-45
DFX-8500
CONTROL PANEL
The control panel for this printer consists of buttons, LEDs, and beepers (See Figure 1-22 on page 1-25.).
HOUSING
The housing for this printer consists of the upper housing, lower housing, printer cover, ink cartridge cover,
rear sheet guide, tractor unit, knob, adjust lever and release lever.
The DFX-8500 housing has many more components than previous DFX housings. The lower case holds the
mechanism and circuits, covered by the upper case, bottom plate and side cover. The housing has large
openings in both the front and rear for paper entry and exit. It also has a lid on the bottom plate to enable
the PROM on the main board to be easily replaced.
Figure 1-30. Housing
1-46
CHAPTER 2
OPERATING PRINCIPLES
2.1
PRINTER MECHANISM OPERATION__________________________________________ 2-1
Printhead Mechanism ______________________________________________________________________ 2-4

Carriage Mechanism_______________________________________________________________________ 2-5
Platen Gap Adjustment Mechanism ___________________________________________________________ 2-6
Paper Feed Mechanism _____________________________________________________________________ 2-7
Tractor Wire Operation___________________________________________________________________ 2-9
Ribbon Feed and Tractor Select Mechanisms___________________________________________________ 2-10
Plunger Mechanism ______________________________________________________________________ 2-12
2.2
POWER SUPPLY OPERATION _______________________________________________ 2-13
Power Supply Overview ___________________________________________________________________ 2-14
2.3
CONTROL CIRCUITS _______________________________________________________ 2-17
Control Circuit Operation Overview _________________________________________________________

Reset Circuit ____________________________________________________________________________
Sensor Circuits __________________________________________________________________________
Carriage Motor Drive Circuit _______________________________________________________________
Paper Feed Motor Drive Circuit _____________________________________________________________
Ribbon Feed Motor Drive Circuit ____________________________________________________________
Platen Gap Motor Drive Circuit _____________________________________________________________
Plunger Drive Circuit _____________________________________________________________________
Printhead Drive Circuit____________________________________________________________________
2-17
2-21
2-22
2-26
2-32
2-34
2-35
2-37
2-38
2.1 PRINTER MECHANISM OPERATION

This section describes the Model 3I60 printer mechanism and explains how the printer works. The printer
mechanism features an 18-pin, impact dot printhead for serial printing. The printer mechanism is the main
component of the printer and is supported by the power supply and control circuits. Figure 2-1 shows the
printer mechanism.
Printhead
Paper Bail
Plunger
Paper Feed
Timing Belt
Connector
Junction
Board
Front Tractor
Ribbon Feed Motor
Platen Gap Motor
Figure 2-1. Model 3I60 Printer Mechanism
The printer mechanism consists of the following main components:
Printhead:
The printhead is the component that actually prints characters (dot matrix patterns). The pins are arranged
in 2 vertical lines. To print, the pins strike against the ribbon and the paper surface. As the printhead moves
horizontally, this operation is repeated to print an entire character. The printhead includes a fan and
thermistor. When the printhead or fan is too hot, the printer stops printing until it cools. (See Printhead
Drive Circuit on page 2-38.)
Plunger mechanism:
During printing, the paper bail holds the paper under tension so that it is fed smoothly. When paper is loaded
or ejected or when the tear off button is pressed, the paper bail needs to move up to prevent a paper jam.
The bail is spring-loaded and held down by the plunger. When current is withheld from the plunger, the
paper bail is lifted by the spring.
2-1
DFX-8500
Carriage mechanism:
The carriage mechanism moves the printhead along the platen. The carriage motor drives the carriage. The
printhead is attached to the carriage. The carriage encoder sensor detects the carriage motor speed and
carriage position. The carriage motor is closed-loop controlled. Because the carriage motor is driven at a
very high speed, it has an isolation resistance sensor to detect abnormal resistance. The sensor detects an
error if the resistance is less than 2.2 k. (See Carriage Motor Drive Circuit on page 2-26.)
Interlock switch:
When the top cover is opened, the interlock switch cuts the drive voltage to the carriage motor to slow down
the carriage speed and prevent accidents. This is necessary because the carriage ordinarily moves at
dangerous speed. A control circuit decelerates the carriage motor. (See Carriage Motor Drive Circuit on
page 2-26.) Printing resumes when the top cover is closed.
Auto platen gap adjustment mechanism:
The printer mechanism has an automatic platen gap adjustment function that measures paper thickness and
adjusts the gap between the platen and printhead accordingly. The printer mechanism adjusts the platen gap
by moving the carriage (and printhead) either forward or backward. The front and rear carriage guide shafts
that hold the carriage are eccentrically mounted; the carriage moves as the platen gap motor rotates the
shafts. The platen gap sensor transmits the amount of movement to the control circuit.
Ribbon feed mechanism:
The printer's ribbon cartridge contains an endless ribbon. The ribbon feed mechanism moves the ribbon so
that there is always fresh ribbon in front of the pins. The ribbon feed motor drives the ribbon feed
mechanism.
Rear Carriage Guide Shaft
Platen Gap Motor
Interlock Switch
Printhead
Carriage Timing Belt

Platen Gap Home
Position Sensor
Ribbon Feed
Motor
Carriage Encoder Belt

Carriage Sensor
Figure 2-2. Printer Mechanism Operation (1)
2-2
Carriage
Motor
Paper feed mechanism:
The paper feed motor drives the paper feed mechanism, which controls both line and form feeding.
The front, rear, and top paper end sensors detect paper in the paper path, and stop printing when there is no
paper. The printer is equipped with three paper end sensors: the front paper end sensor at the front tractor,
the rear paper end sensor at the rear tractor, and the top paper end sensor at the paper bail. The pull tractor
sensor detects whether the optional pull tractor unit is installed.
The printer is also equipped with a paper jam sensor. The control circuit reads the signals from the sensors
and indicates when an error occurs.
Tractor select mechanism:
The printer mechanism has two paper entrances: one at the front tractor and one at the rear tractor. By
controlling the ribbon feed motor, the tractor select mechanism chooses which tractor to use, and power
from the paper feed motor is conveyed to that tractor via a series of gears. The tractor select sensor detects
the selected tractor and signals that information to the control circuit. (See Ribbon Feed and Tractor Select
Mechanisms on page 2-10.)
Paper
Pull Tractor
Paper Bail
Pull Tractor Sensor

Plunger
Printhead
Top Paper End Sensor

Paper Jam Sensor
Tractor Select Sensor
Rear Paper End Sensor
Front Paper End

Sensor
Front Tractor
Sprocket
Rear Tractor Sprocket

Paper Feed Motor
Ribbon Feed Motor
Figure 2-3. Printer Mechanism Operation (2)
2-3
DFX-8500
PRINTHEAD MECHANISM
The printhead is a charge-type, impact dot printhead. Figure 2-4 contains a diagram of printhead operation.
The dot wire is attached to the actuating spring at point A. The actuating spring is pulled back (left in the
figure) by magnetic force when the printer is on and not printing. When current flows through the coil, a
counter-magnetic field is induced in the coil. Then, the actuating spring ejects the dot wire forward against
the ink ribbon, printing a dot on the paper.
Actuating Spring
+35 VDC
GND
Mask Holder
Dot Wire
Iron Core
Printhead Drive Coil
Ribbon
Figure 2-4. Printhead
2-4
Platen
CARRIAGE MECHANISM
Figure 2-5 shows the carriage mechanism. The front and rear carriage guide shafts support the carriage.
The carriage motor rotates, turning the carriage belt pulleys and the carriage timing belt. The printhead is
mounted on the carriage, which is attached to the carriage timing belt.
The printer does not have a carriage home position sensor; the home position is detected using the carriage
encoder sensor and belt. A bumper is attached to the left side of the frame. When the carriage hits the
bumper, the sensor detects an interruption in regular pulses. The control circuits interpret this interruption as
the carriage home position.
The encoder belt has equally spaced line markings and is mounted under the timing belt. A photo interrupter
(carriage encoder) surrounds the encoder belt and converts the carriage movement into a series of pulses.
Printhead Bumper
Paper Width Sensor
Printhead
Ribbon Mask Holder
Carriage Motor
Carriage Belt Pulley

Carriage Encoder Sensor
Front Carriage Guide Shaft
Carriage Encoder Belt
Carriage Timing Belt
Figure 2-5. Carriage Mechanism
2-5
DFX-8500
PLATEN GAP ADJUSTMENT MECHANISM

Figure 2-6 shows the platen gap adjustment mechanism. The front and rear carriage guide shafts supporting
the carriage are eccentrically mounted. The rotation of the platen gap motor is transmitted to the rear
carriage guide shaft through the gear train. Counterclockwise rotation of the motor expands the platen gap,
and clockwise rotation reduces it.
The encoder plate has equally spaced slits and turns on the motor axis. When the motor rotates, the platen
gap sensor detects these slits and sends out pulses. Each pulse corresponds to a platen gap change of
0.0025 mm. The platen gap can range from 0.35 to 0.84 mm.
Platen
Printhead
Ribbon Mask Holder

Platen Roller Gear
Platen Roller Transmission Gear
Platen Gap Sensor

Platen Gap Encoder Plate
Platen Gap
Motor
CW
CCW
Figure 2-6. Platen Gap Adjustment Mechanism
2-6
PAPER FEED MECHANISM

Figures 2-7, 2-8, and 2-9 show the paper feed mechanism. After the printer loads the paper, it is fed by the
tension roller, platen roller, and front or rear tractor assembly.
The paper feed motor rotates the tension roller (Figure 2-7) and tractor select gear (Figures 2-8 and 2-9) and
moves either the front or rear tractor assembly. The paper feed transmission gear rotates the tractor select
gear, which can engage either tractor train. The tractor select mechanism alternates the engagement of the
rear tractor assembly gear train and front tractor assembly gear train. (See Ribbon Feed and Tractor Select
Mechanisms on page 2-10.)
The front and rear paper end sensors are on the tractor sprockets. When paper is loaded, the paper pushes
a leaf spring and blocks the photo interrupter. When no paper is loaded, the photo interrupter is not blocked.
The top paper end sensor is attached to the upper paper guide and is used with a reflection plate on the
paper bail assembly. When paper is loaded, the paper surface absorbs the beam; when there is no paper,
the beam is reflected. The pull tractor sensor monitors whether the pull tractor is installed.
Pull Tractor Sensor

Top Paper
End Sensor
Tension Roller
Paper Bail Lever
Paper Feed Timing Belt

Platen Gear
Tension Pulley
Tractor Select Gear
Paper Feed
Transmission Gear
Paper Feed Motor
Pinion Gear
Figure 2-7. Tension Roller and Paper Feed Roller Operation
2-7
DFX-8500
Paper
Paper Bail
Tension Roller
Tractor Select Gear
Front Paper End Sensor

Paper Feed
Motor Pinion
Gear
Front Tractor
Paper Feed Transmission Gear
Figure 2-8. Front Tractor Assembly Operation
Paper
Paper Bail
Tension Roller
Rear Paper
End Sensor
Tractor Select Gear
Paper Feed
Transmission Gear
Rear Tractor
Paper Feed
Motor Pinion
Figure 2-9. Rear Tractor Assembly Operation
2-8
Tractor Wire Operation

The printer is equipped with a tractor wire to straighten and maintain the proper horizontal tension in the
paper and prevent paper jams. The tractor wire tension spring on the right frame pulls the wire. Figure 2-10
shows how the tractor wire operates.
The front left tractor sprocket or rear right tractor sprocket is held in place on the tractor shaft by a small
clamp, while the other sprocket (the front right sprocket or rear left sprocket) can move freely along the
tractor shafts. When the tractor release lever is released, the sprocket can move smoothly along the tractor
shafts. When the tractor release lever is engaged, the sprocket can still move along the tractor shafts, but
the tractor wire applies some tension.
In Figure 2-10, range A shows the movement range of the left tractor sprocket when the tractor release lever
is released. Range B shows the movement range of the right tractor sprocket.
If the paper in the printer begins to rise up or doesnt lie flat, you can pull the tractor wire to the right to
stabilize the paper tension between the left and right tractor sprockets.
Tension
Tractor Wire
Tractor Wire
Tension Spring
Figure 2-10. Tractor Wire Operation
2-9
DFX-8500
RIBBON FEED AND TRACTOR SELECT MECHANISMS

The ribbon feed motor supplies power to both the ribbon feed and tractor select mechanisms. The rotation of
the ribbon feed motor pinion swings the ribbon feed select gear like a pendulum, using the lever axis as a
fulcrum. The rotation of the ribbon feed motor is transmitted after the gears are engaged. When the ribbon
feed motor pinion gear rotates counterclockwise, the motor drives the ribbon feed mechanism; when it
rotates clockwise, the motor drives the tractor select mechanism.
Ribbon feed mechanism:
Figure 2-11 shows the ribbon feed mechanism. The ribbon is fed in only one direction. Counterclockwise
rotation of the ribbon feed motor is transmitted to the ribbon feed gear through the ribbon feed select gear
and ribbon feed transmission gear. The ribbon feed drive gear engages the winding roller on the ribbon
cartridge and feeds the ribbon.
Winding Roller
Ribbon Cartridge
Ribbon Feed
Select Gear
Ribbon Feed Drive Gear
Ribbon Feed Transmission Gear

Ribbon Feed Motor
Figure 2-11. Ribbon Feed Mechanism
2-10
Tractor select mechanism :
Figure 2-12 shows the operation of the tractor select mechanism. When the ribbon feed motor turns
clockwise, it rotates the ribbon feed select gear, which turns the tractor select transmission gear. These
gears rotate the tractor select cam clockwise. A spring holds the tractor select lever against the cam; when
the cam rotates, the tractor select lever moves horizontally.
When the tractor select lever moves to the left, the tractor select gear engages the rear tractor gear train,
and the paper feed motor rotates the rear tractor. When the tractor select lever moves to the right, the
tractor select gear engages the front tractor. The tractor select sensor is a relay that contacts the cam and
closes when it reaches the convex portion. (See Figure 2-12.)
The ribbon jam sensor is used to detect ribbon jams and count the length of ribbon used.
Tractor Drive Gear
Tractor Select
Transmission Gear
Tractor Select Gear
Holder
Tractor Select
Lever Lower
Tractor Select Sensor
Tractor Select
Lever Upper
Convex portion of cam

Tractor Select Cam
Tractor Select
Transmission Gear
Ribbon Feed
Select Gear
Ribbon Feed
Motor
Ribbon Jam Sensor
Ribbon Feed Gear
Figure 2-12. Tractor Select Mechanism
2-11
DFX-8500
PLUNGER MECHANISM
Figure 2-13 shows the plunger mechanism. The paper bail lever is attached to the end of the plunger's iron
core. The paper bail shaft is connected to the frame. When current to the plunger coil is interrupted, the
force of the paper bail spring returns the paper bail to its original position.
Paper Bail Lever
Plunger
Iron Core
Coil
Tension Spring
Figure 2-13. Plunger Mechanism
2-12
2.2 POWER SUPPLY OPERATION

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 operation of these two boards is the voltage supplied to the
mechanism. They supply power to the printer in the same way. The power supply board outputs the DC
current required to drive the control circuits and printer mechanism. Table 2-1 shows the input voltages and
fuse ratings of the boards and Table 2-2 shows the PSB/PSE board output specifications.
Table 2-1. Power Supply Boards Input
Board
Input Voltage
Fuse Ratings
C204 PSB board
120 VAC
12 A /125 VAC
C204 PSE board
220-240 VAC
6.3 A / 250 VAC
Table 2-2. Power Supply Board Output Specifications

+37 VDC Line
+5 VDC Line
Item
VP1
VP2
VP3
Rated Output Voltage
+37.0 VDC
+5.0 VDC
Available Output
Voltage Fluctuation
35.5 - 37.5 VDC
4.75 - 5.25 VDC
Rating Output Current
1.5 A
2.0 A
Available Output
Current Fluctuation
0.0 - 4.5 A*
Over Current Protection
Yes
Yes
Over Current Protection

Reset Method
Turn the power switch off, then turn it on again.
Automatically recovers.
Short Circuit Current
Less than 1.0 A
Less than 1.0 A
Over Voltage Protection
Yes
Yes
Over Voltage Protection

Reset Method
Turn the power switch off, then turn it on again.
Automatically recovers.
Over Voltage Limit

Value
+42 VDC
+7 VDC
0.0 - 5.0 A*
0.0 - 2.0 A
Controlled by C204 main board with /PD signal.
* +37 V DC line maximum total current is 13.0 A.
2-13
DFX-8500
POWER SUPPLY OVERVIEW

Figure 2-14 shows a block diagram of the C204 PSB/PSE board.
Surge Cut
(at Power On)
CN1
L
Power
Switch.
Fuse
Input Filter
Circuit
AC Inlet
Smoothing
Circuit
Rectifier
Circuit
T1
+37 V
Switching
Line #1
+37 V
(VP1/VP2)
Smoothing
Circuit
Over Current
Protection
GP
AC Source
PC101
Power Down
Control
GP1
GP1
GP2
GP2
Current Limit
Monitoring
CN3
CL
PD
PC102
DRERR
Constant
Voltage
Control
SD
CN4
VP3 Down
Monitoring
PC1
Over Voltage
Protection
+5 V Regulator
Circuit
+5 V
Overcurrent
Protection
T2
GL
+5 V Regulator
+37 V
Switching
Line #2
+37 V
(VP3)
Smoothing
Circuit
CN2
GP3
GL
PC201
Constant
Voltage
Control
Current Limit
Monitoring
Abnormal
Current
(VP1/VP2)
Monitoring
GP3
Fan Driver
CN5
FANDR
GP
Figure 2-14. Power Supply Board Block Diagram

General:
The power supply board converts AC input voltage to the DC voltages required to operate the printer. The
AC voltage is input to the AC inlet, and sent to the C204 PSB/PSE board via the power switch and a fuse.
The two main switching regulator circuits consist of two blocks, +37 V switching lines #1 and #2. Switching
line #1 converts AC voltage to the +37 VDC required for the printhead drive coils. Switching line #2 converts
AC voltage to the +37 VDC required to drive the printer mechanism (motors, solenoid, etc.) and the +5 VDC
required for the regulator circuit (See Table 2-3).
37 V line #1:
+37 VDC is sent to two separate pin groups; printhead pins 1, 2, 7, 9, 10, 11, 12, 15, and 17 form one group;
the other group consists of printhead pins 3, 4, 5, 6, 8, 13, 14, 16 and 18.
37 V line #2:
+37 VDC is supplied to the motors and plunger, and to the +5 VDC regulator circuit and its output.
+5 VDC is supplied to the main logic circuit.
2-14
Cooling fan:
The C204 PSB/PSE board includes a cooling fan that is driven by +37 VDC. The fan lowers the temperature
of the PSB/PSE board circuit components and the carriage motor.
Table 2-3. PSB/PSE Board Output DC Voltages
Voltage
Board
Application
+37 V (Voltage Point 1 - Ground

Point 1)
C204 DRV-B
+37 V (VP2-GP2)
C204 Main
+37 V (VP3-GP3)
C204 DRV
C204 PSB/PSE
+5 V GL
C204 Main
C204 DRV
C204 DRV-B
C204 PNL
VX - GL
C204 Main
C204 DRV

Printhead driver circuit #1

Printhead driver circuit #2
Carriage motor
Paper feed motor
Platen gap motor
Ribbon feed motor
Head fan
Carriage fan
Plunger
Optional cutter motor
Cooling fan on the PSB/PSE unit
All logic systems operating voltage
Paper feed motor hold voltage
Plunger hold voltage
Platen gap motor hold voltage
Power for all the sensors
Voltage for power system pull-up. It is
switched by VXCNT signal of the CPU (IC2).
C204 DRV-B
Protection circuits:
These +37 VDC line blocks perform voltage control. They limit current, and prevent voltage from becoming
too high.
Control and status signals:
The PSB/PSE board receives two control signals from the C204 main board and outputs two status signals
to the main board. See Table 2-4 for the meaning of each signal.
Fatal error recovery:
When the printer detects a fatal error, the PSB/PSE board is shut down for approximately 10 minutes by the
DRERR signal. You must wait 10 minutes before turning the power on again.
2-15
DFX-8500
Table 2-4. PSB/PSE Board Control Signals

Signal
Input/
Output*
Signal Level
Logic
Signal
Function
/PD
In
TTL
(Power Down)
DRERR
In
TTL
(Printhead coil/driver
error)
/SD
Out
TTL
(Source Down)
CL
Out
(Current Limit )
* From the view of the PSB/PSE board.
VP1-GP1 and VP2-GP2.
VP3-GP3 and +5V-GL.
Due to high duty printing.
2-16
Block 2
High
37 VDC
37 VDC, 5 VDC
Low
0 VDC
37 VDC, 5 VDC
High
0 VDC
0 VDC, 0 VDC
Low
37 VDC
37 VDC, 5 VDC
High
Undefined
> 30 VDC, 5 VDC

< 30 VDC, 5 VDC
Low
TTL
Block 1
High
37 VDC
37 VDC, 5 VDC
Low
< 35 VDC
< 35 VDC, 5 VDC
2.3 CONTROL CIRCUITS

Figure 2-15 shows a block diagram of the control circuits, with the C204 main board at the center.
CONTROL CIRCUIT OPERATION OVERVIEW

The core of the control circuit is the TMP95C061AF CPU (IC2). This CPU is driven using a 24.57 MHz
external clock (CRU1). The CPU executes programs stored in the PROM (IC5). The CPU starts executing a
program upon receiving the reset signal from an external device via the gate array E05B36 (IC1). The CPU
accesses the internal and external RAM (IC14). The CPU also controls the EEPROM (IC11), used to store
parameters, such as the tear-off position, while the printer is turned off.
The CPU controls all printer operations via the peripheral IC E05B36 (IC1). The main functions of the
E05B36 (IC1) are:

/CS (Chip Select) signal creation

Address decoding and latching
Clock pulse creation
Printhead driver control
Carriage driver control
Encoder pulse circuit control
Platen gap and HF phase signal creation
Interface control
Monitoring of the carriage and paper feed motor drivers for abnormal current.
Reset signal creation
PSB/PSE board control
LED control
Reading the DIP switch settings on the C204 SUB board
Signals such as DRERR (driver error) and PD (power down), are sent to the C204 PSB/PSE board to
provide back-up control of the EEPROM (when the printer is turned off) and control of the power supply
voltage. When the CPU receives a POFF or CL signal, the CPU turns off the power supply voltage of the
C204 PSB/PSE board by outputting a /PD signal.
The reset circuit outputs the reset signal when the printer is turned on or off, the voltage level drops, or a
reset signal is input from an external device. It resets the control circuit for a certain period, directly or via
the gate array (E05B36).
2-17
DFX-8500
Main Board
Mechanism
CPU
TMP95C061
(IC2)
EEPROM
(IC11)
HTMP
Printhead
Temperature
PWIDTH
Paper Width
Head Fan
Temperature
HFTMP
Serial I/F
24.57MHz
(CRU1)
Level Converter
(IC9)
Cover Open
Sensor`
DRV Board
TXD/RXD
CR Motor
Insulation
CRINS
RF
RF Motor
Drive Circuit
RF Motor
PF
PF Motor
Drive Circuit (IC2)
PF Motor
POFF
AB
DB
RAM
(IC14)
HPSENS,
Control HNSENS
DRV-B Board
Printhead
Drive Circuit 1/2
Printhead 1/2
Printhead
Drive Circuit 2/2
Printhead 2/2
CR Motor
Control & Drive
Circuit (IC1, IC3)
Interlock SW.
P-ROM
(IC5)
PFA
HD
DTR/CTS
Optional
Type-B I/F
Card
Current Monitoring
CRCLM
G/A
E05B36
(IC1)
CR
ENCA,
ENCB
PG
PG Motor
Drive Circuit
CR Motor
CR Encoder
PG Motor
PG Home
PGENCA,
PGENCB
PG Encoder
AB
DB
PE Signals
(Front, Rear, Top)
Paper Jam
Control
Ribbon Jam
PSB/PSE
Board
Control &
Monitoring
CL,
PD,
DRERR
+37 VDC,
+5 VDC
Pull Tractor
Tractor Select
PLG
Option
Cutter
FAN
19.55MHz
(CRU2)
Plunger Drive
Circuit
Fan Drive
Circuit
Fan
Head Fan
Drive Circuit
Head Fan
LED,
SW
Panel Unit
Reset IC
(IC13)
IEEE1284 I/F
RESET,
RSTOUT,
ERRCRPFX
PDATA1-8,
/STB,
SWCNT
/ACK, BUSY
SWITCH
Figure 2-15. Control Circuit Block Diagram
2-18
Plunger
SUB Board
(DIP SWs)
Table 2-5 describes the functions of the main components of the C204 main and C204 DRV boards.
Table 2-5. Main IC Functions
Board
IC Name
Location
Functions
C204 Main
TMP95C061
IC2
Receives data from the host computer via the gate array,
loads the data to the input buffer in the RAM, and converts
the image data to print data.
(CPU)
E05B36
IC1
(Gate Array)
C204 DRV

/CS (Chip Select) signal creation

Address decoding
Address latching
Clock pulse creation
Printhead driver control
Carriage motor driver control
Encoder pulse I/O
Platen gap and head fan motor phase signal creation
Interface control
Abnormal current detection for the carriage and paper
feed motors
/RESET signal creation
PSB/PSE board control
LED control
DIP switch reading
PROM
IC5
Contains the program that runs the CPU.
RAM
IC14
Holds the CPU working area and buffers (input, line, and
image buffers).
EEPROM
IC11
Remembers printer settings while the power is off.
ADM232
IC9
EIA to logic level voltage level converter
PST591D
IC13
System reset IC
STK681-050
IC1
Drives the carriage motor.
STK67138MK4
IC2
Drives the paper feed motor.
uPC393C
IC3
Detects current in the carriage motor driver and feeds it back

to the gate array on the main board.
2-19
DFX-8500
Figure 2-16 shows the data flow through the parallel interface. Although various circuits perform data
processing, the control core is the CPU, where all operations are executed. In this circuit, the E05B36 IC
(IC1) provides the interface between the external host computer and the CPU, and all data processing is
performed by read/write operations to MMIO (Memory Mapped Input/Output).
Data from the host computer is accepted and stored (latched) by repeating steps 1 through 3 below.
1. Upon receiving the /STROBE pulse, IC1 latches the data into ports PDATA 1 - 8 and sets the BUSY
signal to HIGH.
2. The CPU reads the latched data from the MMIO port, checks whether the data is a print command (CR
code), and stores it in the input data buffer if it is not.
3. After checking the data, the CPU makes IC1 clear the BUSY signal and output the /ACKNLG signal, via
the MMIO accesses. When either a CR code is received or the input data buffer becomes full, the CPU
sets the BUSY signal to HIGH and executes printing.
4. The CPU reads the data from the input data buffer, analyzes each byte to determine whether it is a
character or a command, and converts it to print data. The print data consists of 1-byte character codes
and 2-byte attributes. Character data is stored as character codes and commands or character types are
stored as attributes.
5. The print data is stored in the line buffer in units of one line of data.
6. The CPU reads the print data stored in the line buffer byte by byte, accesses the CG (Character
Generator), and turns the ASCII data into dots in the image buffer (or in the case of downloaded
characters, in the download CG). A row of dots is output to the printhead control circuit as printhead data.
Note: The data flow from the Type-B I/F card is the same as the data flow from the parallel interface,
described above, except the signal names and data access method differ.
E05B36 (IC1)
RAM (IC3)
CPU (IC2)
/STROBE
1
Input Data Buffer
STBINT
No
DATA
DATA
CR command ?
Buffer full ?
DATA
Yes
Yes
BUSY, /ACK
3
MMIO
CPU (IC2)
4
Command
Analyzer
Line Buffer
Attribute
Character Generator
Controls
printer mechanism.
8
6
E05B36
Figure 2-16. Parallel Interface Data Flow
2-20
Image Buffer
Download
RESET CIRCUIT
This section describes the hardware reset circuit. When the hardware reset signal is input, all ICs in the
control circuit are reset, and the CPU executes the firmware program from the starting address. Figure 2-17
shows the reset circuit block diagram.
The circuit is equipped with a reset IC: PTS591 (IC13) is used for resetting the +5 VDC line. The reset
operation is described below.
Power On/Off Reset:
Reset IC PTS591 (IC13) monitors the +5 VDC line on the main board. If it drops to 4.2 VDC or smaller, the
reset IC outputs a LOW signal to the CPU (IC2) and E05B36 (IC1) gate array.
Forced Reset:
The gate array outputs the RSTOUTX or ERRCRPFX signals to the XRESET on the CPU, and also to the
gate array itself.
/INIT Signal Reset:
When the gate array receives the /INIT signal from the host computer, the signal is transferred to INT4 on
the CPU, then the CPU performs the /INIT reset operation.
+5
R215
3
VCC
VOUT
PST591
(IC13)
R218
Type-B,
Parallel I/F
/INIT signal
113
/RESETX
C52
112
111
/RSTOUTX
E05B36
(IC1)
100
INITRQ
/ERRCRPFX
30
36
XRESET
C56
INT4
CPU
TMP95C061
(IC2)
Figure 2-17. Reset Circuit Block Diagram
2-21
DFX-8500
SENSOR CIRCUITS
Figure 2-18 shows the sensor circuits in block diagram form. The printer has the following sensors:
1. Front and rear paper end sensors (photo interrupter)
2. Top paper end sensor (photo interrupter detects the TOF position)
3. Paper jam sensor (magnetic transistor)
4. Tractor select sensor (micro mechanical switch)
5. Pull tractor sensor (micro mechanical switch)
6. Carriage encoder sensor (photo interrupter)
7. Platen gap encoder sensor (photo interrupter)
8. Platen gap home sensor (micro mechanical switch)
9. Ribbon jam sensor (photo interrupter)
10. Cover open sensor (micro mechanical switch)
11. Printhead temperature sensor (thermistor)
12. Head fan temperature sensor (thermistor)
13. Paper width sensor (photo reflector)
14. Carriage motor isolation resistance sensor (monitored by the analog port of the CPU)
15. PSB/PSE board power off sensor (signal interface)
16. Top cover sensor (Hall effect sensor)
2-22
CPU
TMP95C061 (IC2)
21
20
29
19
22
Printhead Temperature
ENCB
Head Fan Temperature
Paper Width
CN3
ENCA
CN1
148
149
28
35
25
34
PG Home
18
36
TRSEL
19
28
PTRCT
20
29
21
30
22
31
23
32
24
33
29
37
PGENCA
PGENCB
E05B36 (IC1)
23
Cover Open
CR Motor Insulation
POFF (SD)
CN10 CN14
AN0
18
AN1
35
AN3
22
INT5
AN2
XNMI
10
PJAM
FPE
RPE
TPE
RBJAM
ENCA
CN4
ENCB
CR Encoder
PGENCA
PGENCB
PG Home
Tractor Select
Pull Tractor
Paper Jam
Front PE
CN14
Rear PE
Top PE
Ribbon Jam
Figure 2-18. Sensor Circuit Block Diagram
2-23
DFX-8500
Each sensor is described below.

1. Front and rear paper end sensors

Detection form:
Photo interrupter
Output form:
Open collector (pulled up to 10 k resistor)
Logical states:
Paper present: LOW

Paper out: HIGH
2. Top paper end sensor (detects the TOF position)

Detection form:
Photo reflector
Output form:
Open collector
Logical states:
Paper present: LOW

Paper out: HIGH
3. Paper jam sensor

Detection form:
Magnetic transistor
Output form:
Rectangle wave (1 channel, TTL level)
Logical states:
Paper feed: Signal level changes continuously.

Paper jam: Signal level remains the same.
Note:
The magnetic transistor is attached to the tension roller on the paper

tension unit.
4. Tractor select sensor

Detection form:
Micro mechanical switch
Logical states:
Front tractor: LOW (closed)

Rear tractor: HIGH (open)
5. Pull tractor sensor

Detection form:
Logical states:
Pull tractor installed: LOW (closed)

Pull tractor not installed: HIGH (open)
6. Carriage encoder sensor

Detection form:
Photo reflector
Transaction:
Rectangle wave, A and B phases.
7. Platen gap encoder sensor

2-24
Detection form:
Photo interrupter
Output form:
Rectangle wave, 2 channel
PG response:
T = 0.015 mm / pulse
Available range:
0 < T < 0.7 mm
8. Platen Gap home position sensor

Detection form:
Logical states:

Home: LOW (closed)
Out of home: HIGH (open)
9. Ribbon jam sensor

Detection form:
Photo interrupter
Function:
The main board monitors signal changes during ribbon feed.
10. Cover open sensor

Detection form:
Logical:
Cover closed: LOW

Cover open: HIGH
11. Printhead temperature sensor (thermistor)

This thermistor is on the printhead.
12. Head fan temperature sensor (thermistor)
This thermistor is on the printhead fan.
13. Paper width sensor

Detection form:
Photo reflector
Output form:
Emitter follower
Logical states:
No paper present: Standard voltage level.

Paper present: The voltage level is double the standard voltage level.
14. Carriage motor isolation resistance sensor (monitored by port AN2 of the CPU)
To provide information about the carriage motor life, the analog port (AN2) of the CPU checks the
isolation resistance every time the printer is turned on. If the isolation resistance is equal or less than
2.2 k, a carriage error is detected and the printer beeps.
15. PSB/PSE Board power off sensor (signal interface)
When the +37 VDC line voltage drops, the PSB/PSE board sends a HIGH POFF signal to the main
board.
16. Top Cover Sensor (Hall effect sensor)
When the cover is open, the printer emits a 3 beep code and the +35 V line voltage drops.
2-25
DFX-8500
CARRIAGE MOTOR DRIVE CIRCUIT

Figure 2-19 shows the internal circuit of the carriage motor. Table 2-6 provides the carriage motor
specification. Figure 2-20 shows a block diagram of the carriage motor drive circuit.
An STK681-050 (IC1) bipolar driver IC drives the carriage motor. It has built-in bipolar switching transistors
and a current limiter. A uPC393C comparator (IC3) monitors the current in the carriage motor driver IC
(IC1). If the current exceeds the set value, it is fed back to the gate array (E05B36). The gate array then
outputs the signal for the current setting transistors (Q5, Q6, and Q7).
When the printer is turned on, CPU analog port AN2 measures the isolation resistance in the carriage motor.
If the isolation resistance is equal or less than 2.2 k, the printer displays a carriage error.
If the printer cover is open during power on, the interlock switch cuts the carriage motor driver power.
The ENCA pulse that the carriage encoder outputs is input to the general purpose port CRENCA of the gate
array, and the ENCB pulse that the carriage encoder outputs is input to general purpose port CRENCB of
the gate array. The gate array counts these pulses using the internal counter and determines the amount
and direction of motor rotation.
VP3 (+37 VDC)
Table 2-6. Carriage Motor Specifications

Specification
Description
Form
DC servo motor
Supply Voltage
+37 VDC
Internal Coil
Resistance
1.66 (+10%)
Current
Consumption*
Acceleration / Deceleration:
4.6 A (average)
Q1
Q3
Motor
Q4
R1
Q2
Constant Speed:
2.5 A (average)
* during Super draft printing, +10%
GP3 (GND)
Figure 2-19. Carriage Motor Internal Circuit
2-26
ENCA
Main
Board
VX
VX
DRV
Board
ENCB
Interlock Switch
VP3
STK681-050(IC1)
E05B36
CRENCB
CRENCA

CRAX
CRBX
CRCX
CRDX
Q16,
Q17,
Q18,
Q19
IN_A
IN_B
Q34,
Q35,
ZD2
VCC1
VCC1
IN_C
CRI2
CRI0
CRI1
CRCLM
IN_D
CRCLK
CLK
OUT2
GP
GP
Vref
Q5,
Q6,
Q7
CR A
OUT1
Carriage
Motor
CR B
GP3
Vx
AIN+
+5V
AINVref
A OUT
uPC393C(IC3)
ZD1
4.3 V
CRCLM
CPU
TMP85C061
(IC2)
AN2
GP3
CRINS
Partial Pressure
Circuit
D3
Figure 2-20. Carriage Motor Drive Circuit Block Diagram
2-27
DFX-8500
Table 2-7 lists the carriage motor drive modes.

Table 2-7. Carriage Motor Drive Modes
Action
Drive Mode
Carriage Motor
Speed (rpm)
Acceleration /
Deceleration Control
Curve*
Constant
Speed
Control
Carriage moves
Super Draft
2800
Acceleration and
Carriage
motor pulse
control
Super Draft HD
2666
Deceleration 1
Draft
2100
Draft HD
2000
Bit image 1
1050
Acceleration and
Bit image 2
1050
Deceleration 3
Bit image 3
1050
NLQ
1050
NLQ HD
1000
Super Draft 1/3
888
Bit image 4
933
Draft 1/3
666
Bit image 1 1/3
555
Bit image 2 1/3
500
Bit image 3 1/3
444
NLQ 1/3
333
Draft 1/6
333
Bit image 4 1/3
277
Bit image 3 1/6
222
Home position
seek
500
Paper width
detection seek
500
Logical seek 0
2100
Logical seek 1
1050
Logical seek 2
333
and prints.
Carriage moves
without printing.
Measurement seek
* See Table 2-8.

This action includes all printing modes. Carriage motor pulse control adjusts the carriage speed. (See
below for more information on carriage motor pulse control.) For increased throughput, printing is allowed
when accelerating or decelerating between the Super Draft and Draft HD drive modes.
2-28
The printer has three deceleration control modes. The degree of deceleration is determined by which
carriage motor transistors are on. Table 2-8 describes how the transistors determine the mode.
Table 2-8. Carriage Motor Drive Sequence
Carriage Transfer Direction
Driving Mode
Motor Transistors
(See Figure 2-19.)
Q1
Q2
Acceleration
Left -> Right
Deceleration 1
Q3
Q4
ON
ON
ON
ON
Deceleration 2
Right -> Left
Deceleration 3
ON
ON
Acceleration
ON
ON
Deceleration 1
ON
ON
Deceleration 2
Deceleration 3
ON
ON
Carriage Motor Pulse Control:
Carriage motor pulse control keeps the carriage motor speed constant using the encoder pulses ENCA and
ENCB with the gate array. The gate array generates the PWM (pulse width modulation) signal according to
the carriage motor speed, then sends the signal to the PWM port of the gate array and determines the duty
of the carriage drive timing. Carriage ports I0, I1, and I2 output the drive signal for the carriage motor.
Acceleration control :
Until the carriage speed reaches a constant speed (set by carriage motor pulse control), acceleration control
determines the speed of the carriage. The printer can print during acceleration. The carriage accelerates
smoothly to prevent the carriage motor from exceeding the constant control speed. The gate array controls
the motor driver (STK681-050), which performs current chopping. Figure 2-21 shows the acceleration
control curve.
Speed 0 - SP1
1. Control circuits cause the carriage to accelerate.
2. The control circuit measures time periods with the encoder signal; when the carriage speed reaches SP1,
the next sequence (SP1 - SP2) begins.
2-29
DFX-8500
SP1 - SP2
1. When the carriage speed reaches SP1, the printer uses the acceleration driving mode, based on the duty
data, and the rest of the time, it uses deceleration driving mode 2.
2. During deceleration driving mode 2, the control circuit measures time periods using the encoder signal,
and controls the following:

If duty data reaches Dutymin before the carriage speed reaches SP2, the next sequence (SP2-SPref)
begins when the carriage speed reaches SP2.
If the carriage speed reaches SP2 before duty data reaches Dutymin, the next sequence (SP2-SPref)
begins.
SP2 - SPref
Acceleration Curve
When the carriage speed reaches SP2, carriage motor pulse control oversees the carriage speed.
SPref
SP2
SP1
Control Signal
0
Acceleration
Deceleration 2
2-30
Constant
Speed
Control
Deceleration control:
Deceleration control provides smooth deceleration and prevents rapid vibration.

The duty data for deceleration control is determined for each printing mode. Pulse width modulation (PWM)
determines each printing mode.
Current speed - SP3
1. The printer uses Deceleration driving mode 2, based on the duty data, and the rest of the time, it uses
Deceleration driving mode 1.
2. During deceleration driving mode 1, the control circuit measures time periods using the encoder signal,
and controls the following:

When duty data reaches Dutymin1 before the carriage speed reaches SP3, the next sequence (SP3 Speed 0) begins.
When the carriage speed reaches SP3 before duty data reaches Dutymin1, the next sequence (SP3 Speed 0) begins.
SP3 - Speed 0
1. When the carriage speed reaches SP3, Deceleration driving mode 3 begins. This control method is the
inverse-continuity break method.
2. During deceleration driving mode 3, the control circuit measures time periods using the encoder signal.
When the rising edge of next pulse is not detected after 1.5 seconds, Deceleration driving mode 1 begins
and the control circuit controls short-break.
Deceleration Curve
SPref
SP3
0
Control Signal
Deceleration 2
or
Deceleration 1
Deceleration 3
PWM Perodic Time
2-31
DFX-8500
PAPER FEED MOTOR DRIVE CIRCUIT

Stepping motor driver STK6713BMK4 (IC2) drives the paper feed motor. Figure 2-22 shows the paper feed
motor drive circuit block diagram, and Table 2-9 contains motor specifications.
Table 2-9. Paper Feed Motor Specifications
Specification
Description
Form
4-phase, 200-pole, hybrid pulse motor
Supply Voltage
+37 VDC (applied to the drive circuit)
Internal Coil Resistance
2.8 +10% per phase at 25 C
Frequency
Normal mode, constant driving:

4274 pulses per second (pps), 9.9 inches per second (ips)
Middle speed mode, constant driving:

2610 pps, 6 ips
Current Consumption
Driving: 1.75 A, + 0.20 A per phase (average)

Holding: 0.26 A, + 0.20 A per phase (average)
The motor pulse switching signals are transmitted from CPU ports PG00 to PG03. The paper feed motor is
controlled using open-loop phase switching based on the specified time data. The phase driving method is
1-2 phase excitation. (When the paper feed motor is held, the phase driving method is 1-phase excitation.)
The CPU determines the paper length and whether the pull tractor is installed, then selects the most suitable
driving mode from the modes below.

Micro feed (adjust) mode: < 20 / 432 inches

Middle speed mode:
> 20 / 432 inches and < 60 / 432 inches, or with optional pull tractor
Normal speed mode:
> 60 / 432 inches
Each phase switching FET in driver IC2 is an open collector. When the phase switching data is HIGH, the
motor is turned on. The PFA port of the gate array monitors the phase A signal of the paper feed motor and
checks whether it is operating normally. The PFA port is used as the WDT (watch dog timer).
If paper feed motor operation is abnormal, the gate array outputs the /RSTOUT (reset request) signal to the
system reset IC (IC13). See Reset Circuit on page 2-21.
2-32
Main
Board
Gate Array
E05B36 (IC1)
DRV
Board
+5V
PFH/R
Ref. Voltage
Setting Circuit (Q9)
Vref
4.3 VDC
PFA
PG00
IN_A
PG01
INXA
PG02
IN_B
PG03
VREF
VREF
CPU TMP95C061A
(IC2)
GP3
VP3
STK6713B
(IC2)
INXB
PF COM
GP
SG
OUT_A
PF A
OUTXA
PF B
OUT_B
PF C
OUTXB
PF D
GP3
Figure 2-23. Paper Feed Motor Drive Circuit Block Diagram
2-33
DFX-8500
RIBBON FEED MOTOR DRIVE CIRCUIT

Figure 2-24 shows a block diagram of the ribbon feed motor drive circuit, and Table 2-10 provides the ribbon
feed motor specifications. The ribbon feed motor is a stepping motor. The control circuit performs open-loop
phase switching control according to the timing data for acceleration, constant speed, and deceleration.
CPU ports PG10 to PG13 output the motor phase switching signals. The control method is not equipped with
a hold circuit for changing the motor phase. The ribbon feed motor rotates when the carriage moves.
Table 2-10. Ribbon Feed Motor Specifications
Specification
Description
Form
4-phase, 48-pole, PM pulse motor
Supply Voltage
37 VDC (applied to the drive circuit)
150 ohms + 10 % per phase at 25 C
Frequency
720 pps
Current Consumption
Driving: 0.10 A (average)
Driving Method
Constant voltage driving, 2-2 phase drive
VP 3
Main
Board
E05B36
(IC1)
RFCOM
DRV
Board
F1
Q20,Q21
Q22
TMP95C061A
(IC2)
RF COM
RF A
PG10
PG11
Q23
PG12
Q24
RF C
PG13
Q25
RF D
RF B
PNP Transistor x4
Figure 2-24. Ribbon Feed Motor Drive Circuit Block Diagram
2-34
RF Motor
PLATEN GAP MOTOR DRIVE CIRCUIT

Figure 2-25 shows a block diagram of the platen gap motor drive circuit, and Table 2-11 provides platen gap
motor specifications.
The platen gap motor is a stepping motor. The motor phase switching signals are output from the gate array
ports PGA to PGD. The motor common voltage (PGCOM) alternates between drive mode (+37 VDC) and
hold mode (+5 VDC), according to the PG H/R signal of the gate array. The phase driver circuit is made of
discrete transistors Q12 to Q15.
The phase A output pulse from the platen gap encoder (ENCA) is input to port ENCA on the gate array and
the phase B output pulse from the platen gap encoder (ENCB) is input to port ENCB on the gate array. The
gate array counts these pulses using an internal counter and determines the amount and direction of motor
rotation.
Table 2-11. Platen Gap Motor Specifications
Specification
Description
Form
4-phase, 48-pole, PM pulse motor
Supply Voltage
250 + 18 per phase at 25 C
Current Consumption
Driving: 0.20 A (average)
Holding: 0.02 A + 5 mA
Frequency
285 pps
Driving Method
Constant voltage driving, 2-2 phase drive
2-35
DFX-8500
Main Board
DRV Board
+5V
VP 3
D10
F2
Gate Array
E05B36 (IC1)
PGENCB
PGENCA
PG H/R
Q10,
Q11
PG A
PG B
PG C
Q12,
Q13,
Q14.
Q15
PG D
Platen Gap
Motor
Figure 2-25. Platen Gap Motor Drive Circuit Block Diagram
2-36
PGCOM
PG A
PG B
PG C
PG D
Plsten Gap
Encoder
PLUNGER DRIVE CIRCUIT

Figure 2-26 shows a block diagram of the plunger drive circuit. Table 2-12 provides the plunger
specification, and Table 2-13 provides the plunger switching pattern.
Three switching patterns drive the plunger. Gate array ports PLP and PLN output the plunger coil drive
signals. When the PNP port of the gate array turns on, switching transistors Q30 and Q31 are turned on and
the supply voltage (VP3) flows into the plunger coil. When switching transistor Q30 is turned off, Q31 is also
turned off, and the hold voltage (+5 V) flows into the plunger coil via Q32, using the gate array PLN port.
Table 2-12. Plunger Specifications
Specification
Description
Form
DC solenoid
Supply Voltage
9 + 5 % at 25 C
Current Consumption
Driving: 3.7 A (maximum)
Holding: 0.4 A
Table 2-13. Plunger Switching Pattern
Suspension Roller Status
Q30 and Q31
Q32
Closed
Off
Off
Closed -> Opened
On
Off
Closed with holding voltage
Off
On
VP 3
F3
NPN
Q31
Q30
Gate Array
E05B36 (IC1)
PLP
PNP
PLN
+5V
PLGP
Plunger Coil
B
Q32
C
GP3
Figure 2-26. Plunger Drive Circuit Block Diagram
2-37
DFX-8500
PRINTHEAD DRIVE CIRCUIT

Figure 2-27 shows the printhead drive circuit block diagram.
General:
The print data lines from IC1 are active when they are HIGH. When ports HDR1 (HDL1) to HDR9 (HDL9) of
IC1 go HIGH, the FET gates are biased, and the FETs are turned on to send current to the printhead coil. At
the same time, ports HDRS1 (HDLS1) to HDRS9 (HDLS9) of IC1 go HIGH, the FET gates are biased, and
the FETs are turned on. Each printhead coil is driven through the bipolar drive method. When the HD port of
IC1 goes LOW, the FET is turned off and the printhead coil current is cut.
Two +37 VDC lines (VP1-GP1 on the C204 DRV-B board and VP2-GP2 on the main board) supply the
common voltage for the printhead coil. The VP2-GP2 line (CN1 on the main board) supplies pins 1, 2, 7, 9,
10, 11, 12, 16, and 17. The VP1-GP1 line (CN1 on the C204 DRV-B board) supplies pins 3, 4, 5, 6, 8, 13,
14, 15, and 18.
The CPU monitors the printhead temperature and head fan (HF) temperature. When the temperature rises
above 120 F, printing stops at once until the temperature cools.
The CPU also monitors the printhead driver status, P-channel and N-channel FET respectively. If the
printhead driver FET shorts, CPU (IC2) port PDRERR (P-channel) / NDRERR (N-channel) detects a HIGH
level and the E05B36 (IC1) sends the DRERR (Driver Error) signal to the C204 PSB/PSE board. When the
C204 PSB/PSE board receives this signal, it stops the output voltage and the printer beeps.
2-38
Main Board
FTMP
HF Motor Thermistor
Q10
FTMP
HFANA
FANA
HF Motor
E05B36 (IC1)
HDR1-HDR9
HDL1-HDL9
HDRS1-HDRS9
HDLS1-HDLS9
NDRERR
PDRERR
HTMP
VX VP1 GP1
VX VP2 GP2
DRV-B Board
Printhead Driver
Circuit 2/2
R100
Printhead Coils 1/2

Printhead Coils 2/2
HTMP
Printhead Thermistor
Monitoring NPNs
Short Circuit
Monitoring PNPs
Short Circuit
R101
ZD4
5.1V
Printhead Driver Circuit

1/2
HPSENS
HNSENS
VP2
Q11
FANAX
TMP95C061A
(IC2)
HFANB
ZD1
24V
GP2
R98
R99
GP2
Figure 2-27. Printhead Drive Circuit Block Diagram
2-39
DFX-8500
Printhead high temperature feedback operation:
The printer supports the printhead temperature detection sequence, which consists of the following steps:
o
1. When the printhead temperature is less than 110 C, the printer performs normal printing.
o
2. When the printhead temperature exceeds 110 C, the printer performs interval printing (carriage rest time
at the sides is a little bit longer than normal).
o
3. When the printhead temperature exceeds 120 C, the printer stops printing until the temperature goes
o
down to 100 C or less.
o
4. When the printhead temperature returns to less than 100 C, the printer prints normally again.
HF temperature feedback operation:
The printer supports the head fan (HF) temperature detection sequence, which consists of the following
steps:
o
1. When the printhead fan temperature rises to 65 C or above, the HF starts rotating.
o
2. When the printhead temperature falls to 50 C or less, the HF stops.
2-40
CHAPTER 3
DISASSEMBLY AND ASSEMBLY
3.1
OVERVIEW _________________________________________________________________ 3-1
3.1.1
3.1.2
3.1.3
3.1.4
3.2
Precautions ______________________________________________________________________
Tools ___________________________________________________________________________
Screw Specifications _______________________________________________________________
Service Checks After Repair _________________________________________________________
3-1
3-3
3-5
3-6
DISASSEMBLY AND ASSEMBLY ______________________________________________ 3-7
3.2.1
ROM Replacement ________________________________________________________________ 3-8
3.2.2
Printhead and Ribbon Mask Assembly Removal _________________________________________ 3-9
3.2.3
Housing Removal ________________________________________________________________ 3-13
3.2.3.1 Top Cover Removal_____________________________________________________________ 3-13
3.2.3.2 Left, Right, and Front Covers Removal and Fuse Replacement___________________________ 3-14
3.2.3.3 Front Panel Removal____________________________________________________________ 3-16
3.2.3.4 Upper Case Removal____________________________________________________________ 3-17
3.2.4
Circuit Board Removal ____________________________________________________________ 3-18
3.2.4.1 Bottom Panel Removal __________________________________________________________ 3-18
3.2.4.2 Fan and C204 Power Supply Board Removal_________________________________________ 3-21
3.2.4.3 C204 SUB Board Removal _______________________________________________________ 3-22
3.2.4.4 C204 DRV-B and C204 DRV Board Removal ________________________________________ 3-23
3.2.4.5 C204 Main Board Removal ______________________________________________________ 3-24
3.2.4.6 AC Inlet Removal ______________________________________________________________ 3-26
3.2.4.7 C204 PNL Board Removal _______________________________________________________ 3-27
3.2.5
Interlock Switch and Cover Open Sensor Removal ______________________________________ 3-28
3.2.6
Printer Mechanism Removal________________________________________________________ 3-29
3.2.6.1 Fan Removal __________________________________________________________________ 3-31
3.2.6.2 Ribbon Feed Change Lever Unit Removal ___________________________________________ 3-32
3.2.6.3 Tractor Select Lever Disassembly__________________________________________________ 3-34
3.2.6.4 Ribbon Jam Sensor Removal______________________________________________________ 3-35
3.2.6.5 Connector Junction Board and FPC Board Removal ___________________________________ 3-36
3.2.6.6 Platen Gap (PG) Sensor and PG Motor Removal ______________________________________ 3-37
3.2.6.7 Plunger and Paper Bail Removal __________________________________________________ 3-38
3.2.6.8 Upper Paper Guide and Top PE Sensor Removal ______________________________________ 3-40
3.2.6.9 Tension Roller Shaft Removal ____________________________________________________ 3-41
3.2.6.10
Platen Removal ______________________________________________________________ 3-43
3.2.6.11
Paper Jam Sensor Removal _____________________________________________________ 3-44
3.2.6.12
Pull Tractor Sensor Removal ___________________________________________________ 3-45
3.2.6.13
Paper Width Sensor Removal ___________________________________________________ 3-46
3.2.6.14
Platen Gap Home Sensor Removal _______________________________________________ 3-47
3.2.6.15
Paper Feed Motor Removal_____________________________________________________ 3-49
3.2.6.16
Left Gear Train Removal ______________________________________________________ 3-50
3.2.6.17
Front Tractor Removal ________________________________________________________ 3-51
3.2.6.18
Rear Tractor Removal _________________________________________________________ 3-52
3.2.6.19
Carriage Motor Fan Removal ___________________________________________________ 3-53
3.2.6.20
Carriage Motor Removal_______________________________________________________ 3-54
3.2.6.21
Carriage Encoder Sensor Removal _______________________________________________ 3-55
3.2.6.22
Carriage Mechanism Disassembly _______________________________________________ 3-56
3.2.6.23
Paper Guide Support Plate Removal ______________________________________________ 3-59
3.2.6.24
Platen Roller Removal_________________________________________________________ 3-59
3.1 OVERVIEW
This section describes procedures for disassembling main components of the EPSON DFX-8500. Unless
otherwise specified, you can assemble units or components by reversing disassembly. Therefore, no
assembly procedures are included. Precautions for disassembly or assembly are described under the
heading CAUTION. Adjustments required after assembling the unit are described under REQUIRED
ADJUSTMENTS.
3.1.1 Precautions
Read this section before you disassemble, assemble, or transport the printer.
WARNING

Two or more people must carry this printer. Support the printer from the bottom. Never lift the printer
by the front cover; it may break off.
Disconnect the power cable before disassembling or assembling the printer.
Disconnect the interface cable before disassembling or assembling the printer.
Make sure the printhead is cool before handling it. The printhead can be very hot and could burn
your hands.
Wear gloves to protect your hands when handling the printer.
Handle the sharp metal frame edges with care.
CAUTION

To prevent static electrical damage to microchip circuitry, do not touch the integrated circuits or other
terminals without first grounding yourself.
Use only the recommended tools to ensure safe and efficient maintenance work. Inappropriate tools
may damage the printer.
Properly pack the printer in the correct container before transportation, as described on page 3-3-2.
Remove the ribbon cartridge and any paper from the printer before transportation or disassembly.
Place the printer on a clean, thick cloth, such as a blanket, before starting work. This will help if you
need to turn the printer during disassembly.
Lubricate and clean the printer after assembly, following the instructions in Chapter 6. A considerable
amount of oil may be removed during maintenance or repair work.
3-1
DFX-8500
Remove the ribbon cartridge and any paper before transporting the printer. 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
Printhead Protector
Transportation
Locking Brackets
Foam Packing
Carriage Guide
Support Bar
Figure 3-1. Attaching the Packing Material

After attaching the packing materials, pack the printer in its container, as shown in Figure 3-2.
Figure 3-2. Packing the DFX-8500
3-2
3.1.2 Tools
This section describes the tools required for assembling, disassembling, and adjusting the printer.
Note: See Chapter 4 for adjustment tools, Chapter 5 for troubleshooting tools, and Chapter 6 for
maintenance, lubrication, and adhesion tools.
Table 3-1. Recommended Tools
Tool
Phillips screwdriver No. 2;
0.79 in (20 mm) or longer magnetic shaft
recommended.
Phillips screwdriver No. 1
Box screwdriver; 0.28 inches (7 mm)
across
E-ring holder No. 3
E-ring holder No. 6
Round nose pliers
Diagonal wire cutters
Tweezers
Electric soldering iron
Tension gauge, 15.4 lb (7000 g)
Tension gauge, 0.44 lb (200 g)
Lift handles #E656
Dial gauges #F610
Dial gauge base #F611
Dial gauge master #F612
Thickness gauge (t=0.43 mm)
Thickness gauge (t=0.80 mm)
Motor screwdriver
(Phillips head, torque adjustable)
Chip Puller
o: Commercially available
E: EPSON exclusive
A: Mandatory
B: Recommended
Type
o
Class
A
Code
B743800200
Reference
o
o
A
A
B743800400
B741700200
o
o
o
o
o
o
o
o
E
E
E
E
o
o
o
A
A
A
A
A
A
A
A
B
A
A
A
A
A
B
B740800500
B740800800
B740400100
B740500100
B741000100
B740200100
B777200301
B765114601
B765111001
B101946600
B101946700
B101946800
Figure 3-3
Figure 3-4
Figure 3-5
Figure 3-6
3-3
DFX-8500
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 3-6. Thickness Gauge Set

Figure 3-5. Dial Gauge Master
3-4
3.1.3 Screw Specifications

In the following sections, abbreviations are used for small parts such as screws and washers. Table 3-2 lists
these abbreviations and their meanings. Table 3-3 shows screw and washer types.
Table 3-2. Screw Abbreviations
Abbreviation
CBB
CBS (O)
CBS (SP)
CFS
CP (SP)
CP (PS)
CPB
CPB (O)
CPS
CPS (P)
CPS (SP)
CPN
CPN (O)
CPN (SP)
CPT (O)
Part Name
Cross-Bind head, B-tight screw
Cross-Bind head, S-tight screw with outside-toothed lock washer
Cross-Bind head, S-tight screw with spring lock washer + plane washer
Cross-Flat head, S-tight screw
Cross-Pan head with spring lock washer + plane washer
Cross-Pan head with plane washer + spring lock washer
Cross-Pan head B-tight screw
Cross-Pan head B-tight screw with outside toothed lock washer
Cross-Pan head S-tight screw
Cross-Pan head S-tight screw with plain washer
Cross-Pan head S-tight screw with spring lock washer + plain washer
Cross-Pan head screw
Cross-Pan head screw with outside toothed lock washer
Cross-Pan head screw with spring lock washer + plain washer
Cross-Pan head tapping screw with outside toothed lock washer
Table 3-3. Screw and Washer Illustrations
3-5
DFX-8500
3.1.4 Service Checks After Repair

Before returning the printer to the customer, use the check list in Table 3-4. This checklist helps make
servicing and shipping more efficient.
Table 3-4. Inspection Check List for the Repaired Printer
Category
Checkpoint
Maintenance Are all necessary adjustments completed? Are
the results within specified tolerances? (See
Chapter 4.)
Passed?
[ ] Yes [ ] No
Have all lubricants and adhesives been properly [ ] Yes [ ] No

applied? (See Chapter 6.)
Operation
ROM
Upgrade
Cleaning
Return to
customer
Packing
3-6
Does the printer perform initialization correctly

when turned on?
Does the printer work correctly with the
associated utility program?
Is the ROM version up to date?
Has all dust been removed from the inside of
the printer?
Is the exterior housing clean?
Is the power off?
Has the ribbon cartridge been removed?
Have you included all necessary attachments
(power cord, optional units, etc.)?
[ ] Yes [ ] No
[ ] Yes [ ] No
[ ] Yes [ ] No
[ ] Yes [ ] No
[
[
[
[
] Yes [
] Yes [
] Yes [
] Yes [
] No
] No
] No
] No
3.2 DISASSEMBLY AND ASSEMBLY

WARNING

Be sure to read and follow the instructions in Section 3.1, "Overview," before disassembling the
printer.
Be sure to turn the printer power off and unplug the AC cable before disassembling the printer.
This section describes how to disassemble the printer. See the Appendix for an exploded diagram of the
printer. Use this diagram for simple disassembly procedures not described here. To assemble the printer,
follow the disassembly instructions in this chapter in reverse. Any extra information you need to assemble
printer components is provided in notes labeled CAUTION or REMINDER. Adjustments required before
assembly are described in notes labeled REQUIRED ADJUSTMENT.
3-7
DFX-8500
3.2.1 ROM Replacement
CAUTION

1.
2.
3.
4.
Remove the ROM carefully to avoid damaging the board.

Check the INDEX mark on the chip socket to be sure the new ROM is oriented correctly before
inserting it. Insert the ROM chip carefully to avoid damaging the chip pins and the board.
Remove the top cover of the printer. (See section 3.2.3.1.)
Lay the printer on its back.
Remove 1 screw (CBB, M310) securing the ROM cover, then remove the cover.
Remove the ROM using a chip puller.
Screw (CBB, M310)
Figure 3-7. ROM Replacement
3-8
3.2.2 Printhead and Ribbon Mask Assembly Removal

The printhead can be changed without disassembling the entire unit.
Use the printhead kit (Part # 1043489-00) to change the DFX-8500 printhead. When you receive the kit,
make sure it includes the following components.
Printhead
(Part # F004010-0200)
Oil (O-2)
Printhead Cable Protection Sheet
Instruction Manual
Ribbon Mask
Figure 3-8. Printhead Kit Contents
3-9
DFX-8500
CAUTION

When you remove the connector cover, be careful not to break the tabs.
When you remove the printhead cable holder, be careful not to break the printhead holder latch. Use
a slotted screwdriver if necessary.
1. Open the top cover and remove the ribbon cartridge.

2. Remove the 2 screws (CBS, M38) securing the FPC cover to the bottom plate of the printer
mechanism.
3. Disconnect the three printhead cables and a ground cable from the connector junction board on the
bottom plate.
Notes:
Grip the cables close to the connector when removing them.
Hold the connector so it wont detach from the board.
Pull the cables horizontally; do not pull up.
Screws (CBS, M38)
FPC Cover
Printhead Cables
FPC Board
Figure 3-9. Ribbon Cartridge Removal
Figure 3-10. Printhead Cable Removal
4. Unlock the two latches on the printhead cable cover by pressing them toward each other, then remove
the cover by sliding it to the right. (See Figure 3-11.)
5. Remove the cable protection sheet.
Figure 3-11. Printhead Cable Cover Removal
3-10
6. Disconnect the narrow FPC cable from the white connector. (See Figure 3-12.)
th
7. Move the carriage to the 90 column (on the scale above the platen). Remove 2 screws (CP (S-P1),
M47) securing the printhead, then remove 1 screw (CP (S-P1), M36) securing the ground FPC. (See
Figure 3-12.)
8. Remove the printhead.
S c re w s (C P (S -P 1 ), M 4 7 )
P a p e r W id th S e n s o r
F P C C a b le
S c re w (C P (S -P 1 ), M 3 6 )
P r in th e a d
C a r r ia g e
Figure 3-12. Printhead Removal
9. Disconnect the paper width sensor cable from the white connector on the ribbon mask. (See Figure 313.)
10. Remove the 2 shafts securing the ribbon mask to the carriage using an Allen wrench, then remove the
ribbon mask. (See Figure 3-13.)
S h a fts
R ib b o n
M a s k
P a p e r W id th
S e n s o r C o n n e c to r
C a r r ia g e E n c o d e r
Figure 3-13. Ribbon Mask Removal
3-11
DFX-8500
11. Install the new printhead, ribbon mask, and cable protection sheet by following Steps 1 to 10 in reverse.
Torque the printhead screws to 12 + 1 kg cm.
12. Make sure the ribbon mask is a little loose.
REMINDER
Tighten the printhead screws while pulling the printhead as shown in Figure 3-14 to secure the
printhead firmly.
Figure 3-14. Printhead Installation

13. Wipe off any stains from the carriage guide shaft, lubricate both ends of the carriage guide shaft with
the included oil (0-2), and spread the oil over the shaft by moving the carriage manually. (See Chapter 6
for the proper amount of oil to use.)
Figure 3-15. Lubricating the Carriage Guide Shafts
REQUIRED ADJUSTMENT
3-12
After installing the printhead, perform the platen gap adjustment as described in Chapter 4.
3.2.3 Housing Removal

This section describes how to remove the housing.
3.2.3.1 Top Cover Removal
CAUTION
Two people are required to remove the top cover; one person must hold the top cover while the other
removes the screws. If the top cover is not supported while the screws are removed, the weight of
the top cover may damage the rear hinges.
1. Open the top cover.

2. While someone supports the top cover, remove the four screws (two on the right and two on the left)
securing the top cover. Then remove the cover.
Top Cover
Figure 3-16. Top Cover Removal
3-13
DFX-8500
3.2.3.2 Left, Right, and Front Covers Removal and Fuse Replacement
1. Remove 4 screws (CBB, M416) securing the left cover, then remove the left cover.
2. Remove the right cover the same way.
3. Disconnect 4 cables from the main power switch in the right cover. (See Figure 3-18.)
Screws (CBB, M416)
Screws (CBB, M416)
Screws (CBB, M416)
Screws (CBB, M416)
Right and Left Covers
Figure 3-17. Left and Right Cover Removal
ASSEMBLING POINT
When you attach the right side cover, connect the cable from connector CN1 on the C204 power supply
board unit and the cable from the AC inlet to the main switch in the right cover, as shown below.
Inside Right Cover
Main Switch
AC Inlet Set
Brown cable
C204 Power
Supply Board
CN1
Brown cable
11 12
Blue cable
24 25
Blue cable
Figure 3-18. Cables to the Main Switch
3-14
4. After you remove the right side cover, you may replace the C204 power supply boards input fuse.
WARNING
Make sure the new fuse meets the printer's AC power specifications.
Carriage Motor
Ground Cable
Fuse
CN1
C204 PSB/PSE Board
(Right Side)
Figure 3-19. Fuse Removal

5. Remove 3 screws (CBB, M416) securing the left side of the front cover to the lower cover. Then
remove the front cover along the left hinge.
Screw (CBB, M416)
Front Cover
Figure 3-20. Front Cover Removal
3-15
DFX-8500
3.2.3.3 Front Panel Removal

1. Remove the left and right covers. (See Section 3.2.3.2)
2. Open the top cover and disconnect control panel connector CN5.
3. Remove 2 screws (CBB, M416) from the control panel, then remove the control panel and control
panel connector cable.
Screws (CBB, M416)
Front Panel Unit
Figure 3-21. Front Panel Removal
3-16
3.2.3.4 Upper Case Removal

1. Remove the left and right covers. (See Section 3.2.3.2.)
2. Remove the front panel unit. (See Section 3.2.3.3.)
3. Remove 8 screws (6 CBB, M416 and 2 CBB, M310) from the upper case, then remove the upper
case. (See Figure 3-21.)
Screws (CBB, M416)
Upper Case
Screws (CBB, M310)
Figure 3-22. Upper Case Removal
3-17
DFX-8500
3.2.4 Circuit Board Removal

This section describes how to remove the circuit boards.
3.2.4.1 Bottom Panel Removal
CAUTION

Spread a thick, soft cloth under the printer before you follow the steps below.
Make sure the parallel interface cable latch is not caught between the lower case and bottom panel
when you attach the bottom panel..
1. Remove the left and right covers. (See Section 3.2.3.2)

2. On the right side of the printer mechanism, remove 1 screw (CBS (O), M48) securing the green and
yellow ground cable to the ground plate.
Ground Cable
Screw (CBS (O), M48)

C204 PSB/PSE
Board
Bottom Panel
Assembly
(Right side)
Figure 3-23. Connector and Ground Cable Removal (right side)
3-18
3. On the left side of the printer mechanism, remove 2 screws (CPB (O), M48) securing the green and
yellow ground cables to the bottom plate of the printer mechanism and the bottom panel.
4. Disconnect connectors 1 through 6 as shown in Figure 3-24.
4
1
Ground Cable
5 2
3
Ground Cable
1
2
3
4
5
6
Flat Cable Connector (50-pin): Mechanism

CN4 (4-pin):
Carriage
CN9 (7-pin):
Optional Cutter
Flat Cable Connector (50-pin): Printhead
CN3 (2-pin):
Cover Open Sensor
CN5 (14-pin):
Control Panel
Figure 3-24. Connector and Earth Cable Removal (left side)

5. Open the rear cover. Remove 6 screws (4 CBB, M312, and 2 CB, M312) securing the interface cover,
then remove the rear cover. (See Figure 3-25.)
6. Remove 2 screws (CB, M312) securing the optional interface cover, then remove the optional interface
cover. (See Figure 3-26.)
Screws (CB, M312)
Optional
Interface Cover
Interface Cover
Screws (CBB, M312)
Rear Cover
Figure 3-25. Interface Cover Removal
3-19
DFX-8500
7. Lay the printer on its back.

8. Remove 8 screws (CBB, M416) securing the bottom panel, then carefully remove the bottom panel.
(See Figure 3-26.)
Screws (CBB, M416)
Figure 3-26. Bottom Panel Removal
3-20
3.2.4.2 Fan and C204 Power Supply Board Removal

1. Remove the left and right covers. (See Section 3.2.3.2.)
2. Remove the bottom panel. (See Section 3.2.4.1.)
3. To remove the fan, disconnect CN5 on the power supply board. Remove 4 screws (CCN, M3x30)
securing the fan, then remove the fan.
4. Disconnect CN2, CN3, and CN4 on the power supply board.
5. Remove 7 screws (6 CBB, M312 and 1 CPN (O), M38) securing the C204 power supply board, then
remove the board.
Screws (CBB, M312)
CN5
CN3
CN2
CN1
C204 PSB/PSE
Board
C204 MAIN
Board
CN4
AC Power Cable
Screws (CCN, M330)
Screws (CPN (O), M38)
Figure 3-27. Fan and C204 PSE/PSB Board Removal
3-21
DFX-8500
3.2.4.3 C204 SUB Board Removal

1.
2.
3.
4.
Remove the left and right covers. (See Section 3.2.3.2.)

Remove the bottom panel. (See Section 3.2.4.1.)
Disconnect CN15 and CN16 on the C204 main board.
Remove 2 screws (1 CBB, M38 and 1 CBB, M312) securing the C204 SUB board, then remove the
board.
Screw (CBB, M38)
C204 SUB Board Unit
Screw (CBB, M312)

CN16
CN15
CN15
CN16
C204 Main Board
Figure 3-28. C204 SUB Board Removal
3-22
3.2.4.4 C204 DRV-B and C204 DRV Board Removal

1.
2.
3.
4.

Disconnect CN3 and CN14 on the C204 DRV board.
Disconnect CN1 and CN2 on the C204 DRV-B board.
C204 DRV Board
C204 DRV-B Board
CN3
CN14
CN1
CN2
C204 Main Board

Cable (from C204 Main Board)
Figure 3-29. C204 DRV/DRV-B Boards Removal (1)

5. Remove 8 screws (CBS, M38) securing the C204 DRV-B and C204 DRV boards and two shielding
plates. (See Figure 3-30.)
6. Remove the boards.
: Screw (CBS, M38) 8

Shielding Plate
Shielding Plate
C204 DRV Board
C204 DRV-B Board
Figure 3-30. C204 DRV/DRV-B Boards Removal (2)
3-23
DFX-8500
3.2.4.5 C204 Main Board Removal

1.
2.
3.
4.
5.

Remove the C204 SUB board. (See Section 3.2.4.3.)
Remove the C204 DRV-B and C204 DRV boards. (See Section 3.2.4.4.)
Disconnect CN6, CN7, CN8, and CN10 on the main board. (See Figures 3-31 through 3-33.)
Harness
to CN7(6-pin)
to CN6(7-pin)
CN2
CN3
C204 Main Board
Figure 3-31. C204 Main Board Removal (1)
Cable
to CN4
to CN10
(8-pin)
CN4
CN10
(8-pin)
C204 Main Board
3-24
Cable
C204 Main Board

CN8(8-pin)

6. Remove 6 screws (4 CBB, M312 and 2 CBS (O), M38) securing the main board, then remove the
main board.
: Screw (CBS (O), M38) 2
: Screw (CBB, M312) 4
C204 Main Board Unit
Hooks for C204 Main Board Installation
REQUIRED ADJUSTMENTS
When you install the main board, perform the following adjustments, described in Chapter 4:

Platen gap adjustment.

Bidirectional printing adjustment.
3-25
DFX-8500
3.2.4.6 AC Inlet Removal

1.
2.
3.
4.
5.

Remove the bottom panel (See Section 3.2.4.1.)
Remove the C204 power supply board. (See Section 3.2.4.2.)
Remove the C204 main board. (See Section 3.2.4.5.)
Remove 4 screws (3 CBB, M38 and 1 CB (O), M46) securing the grounding plate to the bottom panel,
then remove the grounding plate. (See Figure 3-35.)
Screws (CBB, M38)
Bottom Panel
Grounding Plate
Screw
(CB (O), M46)
AC Cable
Figure 3-35. Grounding Plate Removal

6. Remove 2 screws (CFS, M310) securing the AC inlet to the grounding plate, then remove the AC inlet.
(See Figure 3-36.)
AC Inlet
Grounding
Plate
Screw (CFS, M310)
Figure 3-36. AC Inlet Removal
3-26
3.2.4.7 C204 PNL Board Removal

1.
2.
3.
4.

Remove the front panel. (See Section 3.2.3.3.)
Disconnect CN1 and CN2 on the C204 PNL board.
Remove 1 screw (CBB, M410) securing the C204 PNL board to the front panel unit, then remove the
C204 PNL board.
Screw (CBB, M410)
Front Panel
C204 PNL Board
CN2
CN1
Figure 3-37. C204 PNL Board Removal
3-27
DFX-8500
3.2.5 Interlock Switch and Cover Open Sensor Removal

1.
2.
3.
4.
5.

Remove the front panel (See Section 3.2.3.3.)
Remove the upper case. (See Section 3.2.3.4.)
Disconnect the interlock switch cable from the connector junction board. (See Figure 3-41.)
Disconnect the cover open sensor cable from the main board. (See Figure 3-41.)
Interlock Switch.
Connector
Junction Board
Cover Open
Sensor
C204 Main Board

CN3
Figure 3-38. Disconnecting the Interlock Switch and Cover Open Sensor Cables
6. Remove 1 screw (CBB, M410) securing the interlock switch and cover open sensor to the lower case,
then remove the switch and sensor. (See Figure 3-39.)
Interlock Switch and

Cover Open Sensor
Screw (CBB, M410)
Lower Housing
Figure 3-39. Interlock Switch and Cover Open Sensor Removal

Cover Open Sensor
To CN3 on C204 Main Board

Screw (CPS, M2.318)
To Connector Junction Board
Interlock Switch
Figure 3-40. Interlock Switch and Cover Open Sensor
3-28
3.2.6 Printer Mechanism Removal

This section describes how to disassemble the printer mechanism. Before following the steps in this section,
remove the printer mechanism as described in Section 3.2.6.
WARNING
Because the printer mechanism is large and heavy, you must be careful when you remove it. When you
lift or lower the printer mechanism, follow these precautions:

Two people are required to remove or install the printer mechanism.

Use the lift handles (#E656, part number B765111001) to lift the printer mechanism.
Place the printer on a low table to avoid straining your waist, back, hands, or feet.
1.
2.
3.
4.
5.
6.

Remove the interlock switch and cover open sensor. (See Section 3.2.5.)
Remove 2 screws (CBS (O), M48) securing the green and yellow ground cables to the grounding plate.
Disconnect connectors (1) through (4) in Figure 3-41. Make sure connectors (5) through (7) in Figure
3-41 have been disconnected.
7. Remove 1 screw (CBS (O), M48) securing the ground cable. (See Figure 3-42.)
5
4
1
2
3
4
5
6
7
Ground Cable
6 2
Flat Cable Connector (50-pin): Mechanism

CN4 (4-pin): Carriage
CN9 (7-pin): Optional Cutter
Flat Cable Connector (50-pin): Printhead
Interlock Switch Cable (2-pin)
CN3 (2-pin): Cover Open Sensor
CN5 (14-pin): Control Panel
Ground Cable
Figure 3-41. Connector Removal (left side)
Ground Cable
Screw (CBS (O), M48)

C204 PSB/PSE
Board
Bottom Panel
(Right side)
Figure 3-42. Connector Removal (right side)
3-29
DFX-8500
8. Remove the four screws securing the printer mechanism to the lower case. (See Figure 3-43.)
Screws
Screws
Figure 3-43. Screw Removal

9. Insert the lift handles through the two holes in each side of the printer mechanism. Slowly lift up the
printer mechanism using the handles and remove the mechanism from the lower case. (See Figure
3-44.)
Lift Handle #E656
Printer Mechanism
Lower Housing
Figure 3-44. Printer Mechanism Removal
REMINDER
When you reinstall the printer mechanism, arrange the cables as shown in Figures 3-41 and 3-42. Make
sure the cables dont get caught between the printer mechanism and the lower case.
REQUIRED ADJUSTMENT
When you install the printer mechanism, perform the following adjustments, described in Chapter 4:

3-30
Platen gap adjustment

Bidirectional printing adjustment
3.2.6.1 Fan Removal

1.
2.
3.
4.
5.
6.

Remove the printer mechanism. (See Section 3.2.6.)
Disconnect the fan connector from the relay connector.
Remove 1 screw (CP(O), 45) securing the fan duct to the left frame and 2 screws (CC, 330) securing
the fan and the fan duct to the left frame.
7. Remove the fan along with the fan duct.
Screw (CP (O), 45)
Left Frame
Screws (CC, 330)
Figure 3-45. Fan Removal
3-31
DFX-8500
3.2.6.2 Ribbon Feed Change Lever Unit Removal

1.
2.
3.
4.
5.
6.

Remove the fan. (See Section 3.2.6.1.)
Release the 3 hooks securing the ribbon feed gear cover to the ribbon feed motor frame, then remove
the cover and the ribbon feed gear. (See Figure 3-46.)
7. Disconnect the connectors for the ribbon feed motor, tractor select sensor, and the ribbon jam sensor
from the connector junction board. (See Figures 3-47 and 3-48.)
8. Remove the head damper from the left frame. (See Figure 3-46.)
9. Remove the fan from the left frame. (See Section 3.2.6.1.)
Ribbon Feed Gear Cover
Left Printhead Damper
Ribbon Feed
Gear
Ribbon Feed
Change Lever Unit
Ribbon Feed
Motor
Ribbon Feed
Motor Frame
Figure 3-46. Ribbon Feed Change Lever Unit Removal (1)

10. Remove 2 screws (CBS, M36) securing the ribbon feed change lever to the left frame, then remove
the ribbon feed change lever unit.
3-32
Screw (CBB, M410)
Front Panel
C204 PNL Board
CN2
CN1
Figure 3-47. Ribbon Feed Change Lever Unit Removal (2)

To Ribbon Feed Motor
To Tractor Select Sensor
To Ribbon Jam Sensor
Connector Junction Board
Figure 3-48. Removing Connectors
REMINDER
When you install the ribbon feed change lever unit, make sure you correctly join the tip of the tractor
select lever and the tractor select gear holder. (See Figure 2-12.)
3-33
DFX-8500
3.2.6.3 Tractor Select Lever Disassembly

This section describes how to disassemble the tractor select lever and how to remove the ribbon feed motor
and tractor select sensor.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Remove the ribbon feed change lever unit. (See Section 3.2.6.2.)
Remove 2 screws (CP (S-P1), M36), 2 leaf springs, and 2 washers securing the ribbon feed motor to
the ribbon feed motor frame, then remove the motor. (See Figure 3-49.)
Remove 1 e-ring (# 3) securing the upper and lower tractor select levers, then remove the levers. (See
Figure 3-49.)
Remove 1 e-ring (# 3) securing the tractor select cam, then remove the cam. (See Figure 3-49.)
Remove 1 screw (CPS (P1), M210) securing the tractor select sensor, then remove the sensor. (See
Figure 3-49.)
Use wire cutters to cut the wire band securing the ribbon feed motor and tractor select sensor cables to
the ribbon feed motor frame.
T r a c to r S e le c t C a m
E - r in g ( 3 )
W a s h e r
L e a f S p r in g
T r a c to r S e le c t T r a n s m is s io n G e a r
T r a c to r S e le c t L e v e r
U p p e r
T r a c to r S e le c t
L e v e r S p r in g
E - r in g ( 3 )
T r a n s m is s io n G e a r
C P S (P 1 )(M 2 X 1 0 )
S e n s o r
L e v e r lo w e r
R ib b o n F e e d M o to r
F ra m e
R ib b o n F e e d M o to r
C P (S -P 1 )(M 3 X 6 )
Figure 3-49. Tractor Select Lever Disassembly
3-34
REMINDER
During assembly, attach the tractor select levers to the tractor select cam as shown in Figure 3-50.
Ribbon Feed Motor Frame
Tractor Select Cam
Tarctor Select Gear Holder
Ribbon Feed Change Lever

(Upper and Lower)
Figure 3-50. Tractor Select Lever Installation
3.2.6.4 Ribbon Jam Sensor Removal

1. Remove the left cover. (See Section 3.2.3.2.)
2. Disconnect the ribbon jam sensor connector from the connector junction board.
3. Remove 1 screw (CP (S-P1), M36) securing the sensor to the bracket, then remove the sensor. (See
Figure 3-51.)
Screw (CP (S-P1), M36)
Ribbon Jam Sensor
Front/Rear Tractor Select Lever
Figure 3-51. Ribbon Jam Sensor Removal
3-35
DFX-8500
3.2.6.5 Connector Junction Board and FPC Board Removal

This section describes how to remove the connector junction board and FPC board.
2. Disconnect all the cables from the connector junction board. Remove 2 screws (CP (S-P1), M36)
securing the connector junction board to the printer mechanism, then remove the connector junction
board. (See Figure 3-52.)
3. Remove the tractor select lever. (See Section 3.2.6.3.)
4. Disconnect the carriage encoder sensor connector from the FPC board.
5. Remove 2 screws (CBS, M38) securing the FPC cover, then remove the cover. (See Figure 3-10.)
6. Remove 1 screw (CPS (P-1), M36) securing the FPC board to the printer mechanism, then remove the
FPC board. (See Figure 3-52.)
F P C
B o a rd
C a r r ia g e E n c o d e r
C o n n e c to r J u n c tio n B o a r d
S c re w (C P S (P 1 ), M 3 6 )
S c re w s (C P S (S P -1 ), M 3 6 )
Figure 3-52. Connector Junction Board and FPC Board Removal
REMINDER
When you reconnect cables to the connector junction board, make sure the connectors have the same
color and number of pins as the corresponding cable.
3-36
3.2.6.6 Platen Gap (PG) Sensor and PG Motor Removal
CAUTION
Be careful not to bend the PG motor encoder plate when removing or installing the PG sensor.
2. Remove the connector junction board. (See Section 3.2.6.5.)
3. Remove 1 screw (CBS, 36) securing the PG sensor and the surrounding unit to the left frame, then
remove the sensor toward the front. (See Figure 3-53.)
4. Remove 1 screw securing the PG sensor to the surrounding unit, then remove the sensor.
5. Remove 2 screws (CP (S-P1), M36) securing the PG motor, then remove the motor.
Encoder Plate
Platen Gap Motor
Platen Gap Motor

Pinion Gear
Screws
(CP (S-P1), M36)
Platen Gap Sensor
Screw (CPS (P), M36)
Figure 3-53. PG Sensor and PG Motor Removal
REMINDER

When you install the PG motor, make sure the distance between the PG motor and PG motor
transmission gear is between 0.002 and 0.006 inch (0.05 and 0.15 mm).
When you install the PG sensor unit, align the c-shaped cutout on the unit with the lower shaft
securing the PG motor to the frame.
REQUIRED ADJUSTMENT
When you install the PG sensor or PG motor, perform the platen gap adjustment, as described in
Chapter 4.
3-37
DFX-8500
3.2.6.7 Plunger and Paper Bail Removal

This section describes how to remove the plunger (loading solenoid) and paper bail.
1.
2.
3.
4.
5.

Disconnect the black, 2-pin plunger connector on the connector junction board, then remove the plunger
cable from the connector junction board.
6. Remove 2 screws (CP (S-P1), M36) securing the plunger to the left frame, then remove the plunger.
7. Remove the iron core of the plunger from the paper bail shaft. (See Figure 3-54.)
Iron Core
Screws (CP (S-P1), M36)
Plunger
Black Connector,
2 pins
Figure 3-54. Plunger Removal
3-38
8. Remove the left tension roller lever spring. (See Figure 3-55.)
9. Remove 1 e-ring securing the paper bail shaft to the left frame, then remove the platen roller shaft
holder and paper bail lever. (See Figure 3-55.)
E - r in g s
S h a ft H o ld e r
P a p e r B a il S h a ft
P a p e r B a il L e v e r
E - r in g
T e n s io n R o lle r
L e v e r S p r in g
Figure 3-55. Paper Bail Lever Removal

10.
11.
12.
13.
14.
Disconnect 2 fan harnesses and remove 2 screws (CPS-P1) securing the carriage fan duct.
Remove the carriage fan duct and carriage fan. (See Section 3.2.6.1.)
Remove the right tension roller lever spring.
Remove 2 e-rings to release the tension release lever at the inner side of the left frame.
Remove 1 e-ring at the right end of the paper bail shaft. Then remove the paper bail lever, leaf spring
and shaft holder.
15. Slide the shaft left, releasing the right end of the shaft from the frame. Then lift the right end of the shaft
and remove it and the tension release lever. (See Figure 3-56.)
E-ring (#6)
Paper Bail Assembly
Shaft Holder
Leaf Spring
Paper Bail Lever
Figure 3-56. Paper Bail Assembly Removal
3-39
DFX-8500
3.2.6.8 Upper Paper Guide and Top PE Sensor Removal

1.
2.
3.
4.
5.
6.

Remove the plunger and paper bail. (See Section 3.2.6.7)
Disconnect the top PE sensor connector (red, 3 pins) from the connector junction board. (See Figure
3-57.)
Left Side
Frame
Top Paper End
Sensor Connector
Connector Junction
Board
Figure 3-57. Top PE Sensor Connector Removal

7. Remove 2 screws (CBS, M46) securing the upper paper guide to both frames, then remove the upper
paper guide. (See Figure 3-58.)
8. Remove 2 screws (CPS (SP), M38) securing the top PE sensor to the upper paper guide, then remove
the sensor. (See Figure 3-58.)
Top Paper End Sensor
Screw (CBS, M46)
Screw (CPS (SP), M48)
Upper Paper Guide
Screw (CBS, M46)
Figure 3-58. Upper Paper Guide and Top PE Sensor Removal
3-40
3.2.6.9 Tension Roller Shaft Removal

1.
2.
3.
4.
5.
6.
7.
8.
9.

Remove the connector junction board. (See Section 3.2.6.5.)
Remove the plunger and paper bail. (See Section 3.2.6.7.)
Push the tension pulley to the front, then remove the carriage timing belt.
Remove the upper paper guide. (See Section 3.2.6.8.)
Using tweezers, unlock the locking tab of the tension roller gear at the left end of the tension roller shaft,
then remove the tension roller gear.
10. Remove 1 e-ring (6) on the left end of the tension roller shaft and remove the shaft holder. (See Figure
3-59.)
Right
Left
E-ring (#6)
Tension Roller Gear

Tension Roller Shaft
Tension Roller Shaft Holder
Figure 3-59. Tension Roller Gear Removal
3-41
DFX-8500
11. Remove the carriage motor fan. (See Section 3.2.6.19.)

12. Remove 1 e-ring (6) from the right end of the tension roller shaft, then remove the tension roller shaft
holder, 1 leaf spring and 1 washer. (See Figure 3-60.)
13. Pull the tension roller shaft out of the right frame and remove it. (See Figure 3-61.)
Tension Roller Shaft Holder
Leaf Spring
Washer
E-ring
Carriage Motor
Figure 3-60. Shaft Holder Removal
Front
Left
Figure 3-61. Tension Roller Shaft Removal
3-42
3.2.6.10 Platen Removal

1.
2.
3.
4.
5.
6.
7.
8.
9.

Remove the four hex screws securing the platen to the platen holders. (See Figure 3-62.)
Remove the platen and the lower paper guide. (See Figure 3-62.)
Slide the 3 parts of the lower paper guide slide out of the corresponding notches in the platen, then
remove them from the platen.
Hex Screws
Platen
Rear
Platen Holder (Right)
Platen Holder (Left)
Lower Paper Guide
Figure 3-62. Platen Removal

Thickness gauge should not fit here
Rear
Platen
0.03 mm
Thickness Gauge
Front
Platen Holder
Positioning Tab
Figure 3-63. Platen Positioning
REMINDER

Attach the 3 parts of the lower paper guide to the platen from right to left.
There must be less than 0.0012 in. (0.03 mm) between the platen and the positioning tabs. (See
Figure 3-63.)
REQUIRED ADJUSTMENT
After installing the platen, perform the following adjustments, described in Chapter 4:

Carriage guide shaft parallelism adjustment

Platen angle (right angle) adjustment
3-43
DFX-8500
3.2.6.11 Paper Jam Sensor Removal

1.
2.
3.
4.
5.
6.
7.
8.

Remove the upper paper guide and top PE sensor. (See Section 3.2.6.8.)
Remove the platen. (See Section 3.2.6.10.)
Remove 1 screw (CPN (SP), M48) securing the left part of the lower paper guide to the platen. (See
Figure 3-64.)
9. Remove the left part of the lower paper guide from the platen. (See Figure 3-64.)
Platen
Right
Left
Lower Paper Guide
Screw (CPN (SP), M48)
Figure 3-64. Lower Paper Guide Left Part Removal

10. Unhook the paper jam sensor cover, then remove it. (See Figure 3-65.)
11. Remove the paper jam sensor. (See Figure 3-65.)
Paper Jam Sensor
Paper Jam Sensor

Cover
Lower Paper Guide (Left)
Figure 3-65. Paper Jam Sensor Removal
REMINDER
Make sure the paper jam sensor is oriented correctly when you reattach it.
3-44
3.2.6.12 Pull Tractor Sensor Removal

1.
2.
3.
4.
5.
6.
7.
8.

Remove the upper paper guide. (See Section 3.2.6.8)
Disconnect the pull tractor sensor connector (red, 2 pins) from the connector junction board.
Remove 1 screw (CP (S), M214) securing the pull tractor sensor to the left side frame, then remove
the sensor. (See Figure 3-66.)
Screw (CP (S), M214)
Washer
Pull Tractor Sensor

Right Platen Holder
Hexagon Nut
Figure 3-66. Pull Tractor Sensor Removal
3-45
DFX-8500
3.2.6.13 Paper Width Sensor Removal

1. Open the top cover.
2. Disconnect the paper width sensor connector. (See Figure 3-67.)
3. Remove 1 screw (CP (S-P1), M2.56) securing the paper width sensor to the ribbon mask holder, then
remove the sensor. (See Figure 3-67.)
Paper Width Sensor

Screw
(CP (S-P1), M2.56)
Paper Width Sensor Connector
Figure 3-67. Paper Width Sensor Removal
3-46
3.2.6.14 Platen Gap Home Sensor Removal

1.
2.
3.
4.
5.
6.
7.
8.
9.

Remove the printer mechanism (See Section 3.2.6.)
Remove the ribbon feed change lever. (See Section 3.2.6.2.)
Remove the tractor select lever. (See Section 3.2.6.3.)
Remove 1 e-ring securing the carriage guide shaft gear to the rear carriage guide shaft. (See Figure
3-68.)
Carriage Guide Shaft

Gear
E-ring
Figure 3-68. Carriage Guide Shaft Gear Removal

10. Disconnect the platen gap home sensor connector (white, 2 pins) from the connector junction board.
11. Detach the hook securing the platen gap home sensor, then remove the sensor. (See Figure 3-69.)
Platen Gap Home Sensor
Platen Gap Motor
Figure 3-69. PG Home Sensor Removal
3-47
DFX-8500
REMINDER
When installing the carriage guide shaft gear, align the rib on the gear with the platen gap adjustment
transmission gear, then rotate the carriage guide shaft gear counterclockwise for 10 mm. (See
Figure 3-70.)
Flat Part of Rear Carriage Guide Shaft
Frame Left
Advance 10 mm
Stopper
Carriage Guide
Shaft Gear
Platen Gap
Transmission Gear
Figure 3-70. Carriage Guide Shaft Gear Alignment
3-48
3.2.6.15 Paper Feed Motor Removal

1.
2.
3.
4.
5.
6.
7.

Remove 3 screws (CP (SP-1), M48) securing the paper feed motor to the left frame. (See Figure
3-71.)
8. Remove the print feed motor from the left frame. (See Figure 3-71.)
Paper Feed Motor
Figure 3-71. Paper Feed Motor Removal
3-49
DFX-8500
3.2.6.16 Left Gear Train Removal

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Remove the ribbon feed change lever unit. (See Section 3.2.6.2.)
Remove the tractor select lever. (See Section 3.2.6.3.)
Remove the platen gap motor. (See Section 3.2.6.6.)
Remove the gears pictured in Figure 3-72 in numerical order.
Figure 3-72. Left Gear Train Removal
3-50
3.2.6.17 Front Tractor Removal

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Lay the printer mechanism on its back.
Remove 1 screw securing the tractor wire holder to the left side frame, then remove the left tractor wire
holder. (See Figure 3-73.)
Loosen the flange nut securing the front tractor to the left frame, then remove the tractor transmission
gear. (See Figure 3-74.)
Remove the flange nut on the right side of the front tractor, then remove the right tractor wire holder.
(See Figure 3-73.)
Remove 1 e-ring (6) securing the rear shaft of the front tractor to the left frame, then remove the shaft
holder, leaf spring, and washer. (See Figure 3-74.)
Pull the front tractor to the left to release the right end of the shaft from the frame, then remove the front
tractor. (See Figure 3-74.)
Nut
Carriage
Motor
Screw (CBS, M48)

Tractor Wire Holder (L)
Tractor Wire
Holder (R)
Tractor
Wire Spring
<Left>
<Right>
Figure 3-73. Tractor Wire Removal
Flange Nut
Tractor Transmission
Gear
E-ring (#6)
Flange Nut
Shaft Holder
Leaf Spring
Washer
Shaft Holder
E-ring (#6)
Front Tractor
Figure 3-74. Front Tractor Removal
REMINDER
When you install the front tractor, perform the tractor wire spring adjustment described in Chapter 4..
3-51
DFX-8500
3.2.6.18 Rear Tractor Removal

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Remove the flange nut securing the wire holder spring set to the right frame, then remove the spring
set.
Loosen the flange nut securing the rear tractor to the left frame.
Remove 1 screw (CBS, M48) securing the tractor wire holder, then remove the holder.
Remove the tractor gear. (See Figure 3-75.)
Remove 1 e-ring securing the shaft holder, then remove the shaft holder. (See Figure 3-75.)
Pull the rear tractor to the left to release the right end of the shaft from the right frame, then remove the
rear tractor.
Right
Left
Flange Nut
Shaft Holder
Tractor Wire Holder
Leaf Spring
Washer
E-ring (#6)
Tractor Gear
Flange Nut
Rear Tractor
E-ring (#6)
Screw (CPN, M48)
Shaft Holder
Figure 3-75. Rear Tractor Removal
REQUIRED ADJUSTMENT
When you install the rear tractor, perform the tractor wire spring adjustment described in Chapter 4.
3-52
3.2.6.19 Carriage Motor Fan Removal

1.
2.
3.
4.
5.
6.

Disconnect the motor cable from the relay connector. (See Figure 3-76.)
Remove 2 screws securing the fan, then remove the fan. (See Figure 3-76.)
Screws
Carriage Motor Fan
Right Frame
Figure 3-76. Carriage Motor Fan Removal
3-53
DFX-8500
3.2.6.20 Carriage Motor Removal

1.
2.
3.
4.
5.
6.

Remove the carriage motor fan. (See Section 3.2.6.19.)
Disconnect the red and black cables from the terminals on the carriage motor. There are two cables for
each terminal.
7. Remove 3 screws (CP (S), M410) securing the carriage motor to the right frame, then remove the
motor. (See Figure 3-77.)
Screw (CP (S), M410)
Carriage Motor
Figure 3-77. Carriage Motor Removal
REQUIRED ADJUSTMENT
When you install the CR motor, perform the carriage timing belt tension and platen gap adjustments, as
described in Chapter 4.
3-54
3.2.6.21 Carriage Encoder Sensor Removal

1. Remove the printhead. (See Section 3.2.2.)
2. Disconnect the carriage encoder sensor connector (red, 4 pins) from the carriage connector junction
board. (See Figure 3-78.)
3. Remove 2 screws (CP (S-P1), M2.65) securing the carriage encoder sensor to the carriage, then
remove the sensor. (See Figure 3-79.)

Carriage
Red Connector, 4 pins
Carriage Connector
Junction Board
Figure 3-78. Disconnecting the Carriage Encoder Sensor
Screw (CP (S-P1), M2.65)
Carriage Encoder
Sensor
Carriage
Figure 3-79. Carriage Encoder Sensor Removal
3-55
DFX-8500
3.2.6.22 Carriage Mechanism Disassembly

This section describes how to disassemble the carriage mechanism, including the carriage, carriage timing
belt, and front and rear carriage guide shafts.
1.
2.
3.
4.
5.
6.
7.

Remove the carriage motor. (See Section 3.2.6.20.)
Remove the belt pulley from the belt pulley holder. (See Figure 3-80.)
Left Frame
Belt Pulley
Belt Pulley
Holder
Figure 3-80. Belt Pulley Removal

8. Unhook the spring securing the encoder belt to the right frame. (See Figure 2-5.)
9. Loosen the two flange nuts securing the front carriage guide shaft to the frame. (See Figure 3-81.)
Flange Nut
Flange Nut
Front Carriage Guide Shaft
Figure 3-81. Front Carriage Guide Shaft Removal
3-56
10. Slide the carriage to the left side. Pull the front carriage guide shaft through the hole in the right frame
and remove it. (See Figure 3-81.)
11. On the left frame, remove 1 e-ring (6) securing the carriage guide shaft gear to the rear carriage guide
shaft.
12. Remove the carriage guide shaft gear and paper thickness sensor holder. (See Figure 3-82.)
13. Unhook the spring securing the paper thickness sensor, then remove the sensor. (See Figure 3-82.)
Paper Thickness
Sensor
Carriage Guide
Shaft Gear
E-ring (#6)
Screws (CP (P), M36)

Platen Gap Motor
Figure 3-82. Rear Carriage Guide Shaft Removal

14. Remove the platen gap motor. (See Section 3.2.6.6.)
15. Remove the rubber carriage damper from inside the right frame, then remove 3 screws (CBS, M48)
securing the carriage motor holder to the right side frame. (See Figure 3-83.)
16. Remove the guide shaft holding spring and 1 e-ring securing the right guide shaft holder lever, then
remove the right guide shaft holder lever. (See Figure 3-83.)
17. Remove 2 screws (CP (S-P1), M46) securing the parallelism adjustment lever, then remove the lever.
(See Figure 3-83.)
18. Remove the rear carriage guide shaft and the carriage base from the right frame. (See Figure 3-83.)
3-57
DFX-8500

Parallelism Adjustment Lever
Right Guide Shaft

Holder Lever
Guide Shaft Holding Spring

Screw (CBS, M48)
Carriage Motor Holder
Figure 3-83. Right Side Frame Removal
REMINDER
When you install the front carriage guide shaft, push the shaft toward the platen while you tighten the
screws.
REQUIRED ADJUSTMENT
When you assemble the carriage mechanism, perform the following adjustments described in Chapter 4:

3-58
Carriage timing belt tension adjustment

3.2.6.23 Paper Guide Support Plate Removal

1.
2.
3.
4.
5.
6.
7.
8.

Disassemble the carriage mechanism. (See Section 3.2.6.22.)
Remove the paper guide support plate. (See the exploded diagram in the Appendix.)
ADJUSTMENT REQUIRED
When you install the paper guide support plate, perform the following adjustments described in
Chapter 4:


3.2.6.24 Platen Roller Removal

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Remove the platen. (See 3.2.6.10)
Remove the left gear train. (See Section 3.2.6.16.)
Remove the platen roller (See the exploded diagram in the Appendix.)
ADJUSTMENT REQUIRED
When you install the platen roller, perform the following adjustments described in Chapter 4:


3-59
DFX-8500
3-60
CHAPTER 4
ADJUSTMENT
4.1
OVERVIEW ___________________________________________________________________1
4.2
Platen Gap Motor Placement Adjustment ____________________________________________1
4.3
Carriage Timing Belt Tension Adjustment ___________________________________________2
4.4
Tractor Wire Spring Tension Adjustment ____________________________________________3
4.5
Pull Tractor Sensor Position Adjustment_____________________________________________4
4.6
Carriage Guide Shaft Parallelism Adjustment ________________________________________5
4.7
Platen Angle Adjustment__________________________________________________________9
4.8
Platen Gap Adjustment __________________________________________________________ 11
Resetting the Platen Gap Values _______________________________________________________________ 12

Measuring the Platen Gap Values______________________________________________________________ 13
4.9
Bi-directional Printing Adjustment ________________________________________________15
ADJUSTMENT
4.1 OVERVIEW
This chapter describes the printer mechanism adjustments required after any part is replaced or repaired.
Perform the appropriate adjustments before assembling the printer.
4.2 PLATEN GAP MOTOR PLACEMENT ADJUSTMENT

In this adjustment, the platen gap motor pinion gear must mesh smoothly with the platen gap transmission
gear. If the pinion gear is poorly aligned or the two gears are too tight, the printer operation will be noisy or
the character density will be incorrect.
CAUTION
If the platen gap motor placement is too tight, the platen gap motor wont rotate smoothly and the panel will
flash E3.
1. Loosen 2 screws securing the platen gap motor to the left frame. (See Figure 4-1.)
2. Make sure the platen gap motor pinion gear is properly aligned with the platen gap transmission gear.
The space between them should be 0.002 to 0.01 inches (0.05 to 0.15 mm). (See Figure 4-1.)
3. Tighten the 2 screws securing the platen gap motor to the left frame. (See Figure 4-1.)
Platen Gap Transmission Gear
0.002-0.01 inch
(0.05 - 0.15 mm)
Platen Gap Motor
Pinion Gear
Screws
Platen Gap Motor
Figure 4-1. Platen Gap Motor Mounting Position Adjustment
4-1
DFX-8500
4.3 CARRIAGE TIMING BELT TENSION ADJUSTMENT

Adjust the carriage timing belt tension when you disassemble any carriage mechanism part (such as the
carriage motor, belt pulley, or carriage timing belt). Remove the printer mechanism before performing this
adjustment. (See Section 3.2.6.)
CAUTION
Before performing this adjustment, carefully secure the printer mechanism; pulling the tension lever applies
a 15.4 lb. (7 kg) force to it.
1. Loosen the three tension adjustment screws on the carriage motor. Confirm that the carriage timing belt
is attached properly and that no load is applied to it.
2. Insert the tension gauge hook through the hole in the tension lever.
3. Pull the tension gauge horizontally to apply 15.4 lbs (7 kg) force.
4. Move the belt left and right while pulling the tension gauge, and move the motor pulley slightly.
5. Tighten the 3 tension adjustment screws (CPS, M410) while you pull the tension gauge.
6. Finish tightening the three tension adjustment screws with 12 kg-cm torque.
Screws (CPS, M410)
15.4 lbf. 0.44 lbf.

(7000 gf 200 gf)
Figure 4-2. Carriage Timing Belt Tension Adjustment
4-2
ADJUSTMENT
4.4 TRACTOR WIRE SPRING TENSION ADJUSTMENT

Perform this adjustment when you remove the front or rear tractor assembly. If the spring is not adjusted
properly, incorrect paper tension may cause paper jams.
1.
2.
3.
4.

Release the front tractor sprockets.
On the left frame, loosen the screws (CBS, M48) securing the left wire holding plate. (See Figure 4-3.)
Pull the tractor wire to the left until the right wire holding plate and the tip of the gold seal are 0.2 inches
(5 mm) apart. (See Figure 4-3.)
5. Tighten the screws (CBS, M48) on the left wire holding plate.
6. Follow the same steps to adjust the spring tension for the rear tractor.
Right Wire Holding Plate
Tractor Wire
Gold Seal
0.2 inch
(5 mm)
Tractor Wire
Tractor Wire
Tension Spring
Tension Spring
Screw (CBS, M48)
Left Wire Holding Plate
Pull,adjust, fix,
or cut wire here.
Tractor Release Lever
0.39-0.59 inch
(10 - 15 mm)
Figure 4-3 Tractor Wire Tension Adjustment (Front View)
4-3
DFX-8500
4.5 PULL TRACTOR SENSOR POSITION ADJUSTMENT

Perform this adjustment when you replace or disassemble the platen, rear paper guide, platen roller shaft,
tension roller shaft, or pull tractor sensor. If the sensor position is incorrect, the sensor is always on. Figure
4-4 illustrates the pull tractor sensor position adjustment.
When you assemble the pull tractor sensor or rear paper guide, make sure:

The pull tractor sensor lever is touching the rear paper guide frame, but the sensor is off.
The distance between the sensor lever and sensor switch is approximately .08 inch (2 mm).
Sensor Switch
Left Frame
0.8 inch
(2 mm)
Sensor Lever
Pull Tractor Sensor

Figure 4-4. Pull Tractor Sensor Position Adjustment
4-4
ADJUSTMENT
4.6 CARRIAGE GUIDE SHAFT PARALLELISM ADJUSTMENT

The rear carriage guide shaft must be parallel to the platen to prevent uneven paper feeding and paper
jams. Perform this adjustment when you remove the rear carriage guide shaft or platen, or move the
parallelism adjustment lever. Do not remove the printer mechanism or the adjustment will be undone when
you install it. Remove the tension roller shaft before performing this adjustment. (See Section 3.2.6.7.)
CAUTION
The difference between the distances from the rear carriage guide shaft to the platen measured at the
two ends of the shaft must be less than + 0.015 mm. Since this value is extremely small, you must use
the two dial gauges, a dial gauge base, and a dial gauge master supplied by EPSON to measure it. Do
not adjust the parallelism using any other method.

Dial gauges (x 2) #F610 (Part No. B1019466)

Dial gauge base #F611 (Part No. B1019467)
Dial gauge master #F612 (Part No. B1019468).
Before performing the parallelism adjustment, you must assemble the two dial gauges, dial gauge base, and
dial gauge master. Follow these steps:
1. Attach the two thumbscrews for the dial gauge base to the dial gauge master. To eliminate any play, pull
the tie band between the two dial gauges to secure the dial gauge base and the dial gauge master
before you tighten the thumb screws.
Master
Base
Figure 4-5. Attaching the Dial Gauge Base to the Dial Gauge Master
2. Put a dial gauge through the dial gauge base, depressing the needle against the master to a depth of
approximately 0.04 inch (1 mm). (See Figure 4-6.)
4-5
DFX-8500
Hex screw
Gauge needle
Figure 4-6. Dial Gauge Setup

3. Tighten the hexagonal screw securing the dial gauge to the base.
4. Install the second gauge the same way. Set both gauges to exactly the same reading, then tighten the
hexagonal screw. (See Figure 4-7.)
Hex screw
Gauge needle
Figure 4-7. Installing the Second Dial Gauge

5. Set the black marker to the "0" position. (See Figure 4-8.)
Figure 4-8. Setting the Gauges to Zero
4-6
ADJUSTMENT
6. Remove 1 screw (CP (PS), M36) securing the timing belt holder to the timing belt, then remove the
timing belt holder. (See Figure 4-9.)

Screw (CP (PS), M36)
Timing Belt Holder
Carriage
Figure 4-9. Timing Belt Holder Removal
7.
8.
9.
10.
Remove the paper bail. (See Section 3.2.6.5.)

Remove the tension roller shaft. (See Section 3.2.6.7.)
Remove the printhead and ribbon mask. (See Section 3.2.1.)
Attach the dial gauge base and dial gauges to the carriage in the same way you would attach the
printhead. Tighten the two thumbscrews while pulling the dial gauge base toward you. (See Figure 4-10.)
11. Using the carriage guide shaft gear, adjust the gauge mounting position so that the tips of the gauges
(A and B in Figure 4-10) are touching the platen.
Dial Gauge Master
B
Platen
Carriage
See Figure
4-10a.
Dial Gauge Base
Carriage Guide Shaft Gear
Right Carriage Guide Shaft
Dial Gauge
Tie band
Figure 4-10. Attaching the Dial Gauges to the Carriage
4-7
DFX-8500

Stopper
Platen Gap Transmission Gear
Figure 10a. Carriage Guide Shaft Gear Positioning

12. Measure the distance between the platen and the carriage guide shaft on the left end of the platen. Then
measure the distance between the platen and the carriage guide shaft on the right end of the platen, and
compare the two values. (Figure 4-11 shows the measurement position and the parallelism adjust lever
operation.)
Note: Rotate the carriage motor pulley to move the carriage. Do not touch the dial gauges.
2.8 inches
(70 mm)
2.8 inches
(70 mm)
Right Side Frame

Carriage Parallelism
Adjust Lever
30
20
10
30
0
20
10
Carriage Motor
Motor Pulley
Figure 4-11. Carriage Guide Shaft Parallelism Adjustment

13. If the left measurement is greater than the right, move the carriage parallelism adjust lever in the
direction shown by the white arrow in Figure 4-11. If the right measurement is greater than the left,
move the lever in the direction shown by the black arrow.
14. Repeat steps 11 and 12 until the difference between the distance measured at the two positions is less
than + 0.015 mm.
15. When the difference is within the specified range, tighten the 2 screws (CP (PS), M46) securing the
parallelism adjustment lever. Then measure the distances again as described in step 11.
16. If the difference is within the specified range, apply a screw-locking compound to the two screws. (See
Section 6.2 for lubrication and adhesive application instructions.)
17. Perform the platen angle adjustment (See Section 4.7.)
4-8
ADJUSTMENT
4.7 PLATEN ANGLE ADJUSTMENT

The platen must make a right angle with the carriage. Perform this adjustment after you remove or replace
the platen or loosen the two hexagonal screws securing the platen to the frame. Do not remove the printer
mechanism, or the adjustment will be undone when you install it. Remove the tension roller shaft before
performing this adjustment. (See Section 3.2.6.7.)
1. Perform the carriage guide shaft parallelism adjustment. (See Section 4.1.5.) After the adjustment is
finished, leave the dial gauge unit on the carriage.
2. Remove the pull tractor sensor. (See Section 3.2.6.10.)
3. Loosen (but do not remove) the two hexagonal screws securing the platen stay to both side frames.
(See Figure 4-12.)
Hexagonal Screws (M48)
Positioning Tab
Platen Stay (L)
Platen Stay (R)
Positioning Tab
Left Frame
Right Frame
Figure 4-12. Loosening the Hexagonal Screws

4. Using the carriage guide shaft gear, touch both dial gauge needles to the platen surface. Dont push the
needles all the way in.
Left Side Frame
Attach both needles.
Platen
See Figure
4-10a.
Carriage Guide Shaft
Figure 4-13. Touching the Needles to the Platen Surface

5. Measure the gauge reading differences in three positions, as shown below. Use the carriage motor
pulley to move the carriage with the dial gauge toward the right side. Do not touch the dial gauge unit
itself. (See Figure 4-15.)
4-9
DFX-8500
2.8 inches
(70 mm)
2.8 inches
(70 mm)
Center Position
Platen
30
30
20
10
10
0
20
10
30
20
30
30
0
20
30
10
20
10
10
0
20
10
30
30
20
30
0
20
10
30
20
10
10
0
20
30
20
10
30
0
20
10
Figure 4-14. Measuring the Platen Angle (not to scale)
Up
A
Platen
B
Down
(Angle Adjustment Method)
Figure 4-15. Adjusting the Platen Angle
6. If the difference between the two gauge values is more than 0.015 mm at any point, loosen (but do not
remove) the 2 hexagonal screws securing the platen stay to the frame, then slowly adjust the platen
angle.
7. Tighten the 2 hexagonal screws to secure the platen stay to the frame.
CAUTION
After you perform this adjustment, confirm the carriage guide shaft parallelism value again. If this value is
too large, readjust the carriage guide shaft parallelism and the platen angle until both are correct.
4-10
ADJUSTMENT
4.8 PLATEN GAP ADJUSTMENT

This section describes how to measure and adjust the Alpha and Beta values for the platen gap mechanism.
The Alpha and Beta values are unique to each mechanism, the preset factory values have been printed on
labels as shown in Figures 4-17 and 4-18. Use these values when resetting the platen gap values after
replacing the main board, the printhead, or the ROM. After replacing the platen, carriage shafts, or carriage,
measure the new Beta values before resetting them.
CAUTION
This measurement is important because it determines the platen gap, so be sure to use the
EPSON exclusive thickness gauge set and tension gauge.
Thickness gauge (0.43 mm) : #F616 (EPSON Part No. B102047100)
Thickness gauge (0.80 mm)

Tension gauge (200 g) : #F545 (EPSON Part No. B765114601)

The printer must be on during adjustment.
When adjusting the platen gap using the Micro Feed buttons, adjust only 1 step at a time.
After you perform this adjustment, perform the bi-directional adjustment on page 4-14.
P r in th e a d
A L P H A V a lu e L a b e l
Figure 4-16. Alpha Value Location
L e ft F ra m e
B E T A V a lu e L a b e l
F ro n t F ra m e
P r o d u c tio n N o .
Figure 4-17. Beta Values Location
4-11
DFX-8500
RESETTING THE PLATEN GAP VALUES

To reset the Alpha and Beta values:
1. Remove the paper, ribbon cartridge, and ribbon mask holder from the printer.
2. Write down the Alpha value written on the side of the printhead.
3. Write down the Beta values written on the label on the inside bottom right corner of the printer
mechanism, under the ribbon cartridge.
4. Close the top cover.
Alpha value:
5. Turn the printer on while holding down the Tear Off, Micro Feed , and Front/Rear buttons. Hold the
buttons down until the printer beeps once.
6. The control panel will display the current Alpha value within 10 seconds. (See Table 4-2.)
7. Adjust the Alpha value:
Press the Micro Feed button to increase the value by 1.
Press the Micro Feed button to decrease the value by 1.
8. Press the LF/FF Load button to save the new Alpha value to the EEPROM and exit adjustment mode.
9. Press the Pause/Reset button to write the new Alpha value to the EEPROM and enter Beta adjustment
mode.
Beta values:
10. The control panel will display the current Beta 3 value. (Default = 450)
11. Adjust the Beta 3 value until it is equal to Beta 3 (listed on the mechanism) + 10:
Press the Tear Off button to increase the value by 10.
Press the Top of Form button to decrease the value by 10.
12. Press the Pause/Reset button to save the Beta 3 value to the EEPROM.
13. The 7-segment LED will flash a 2. This shows the next Beta value to be adjusted, Beta 2. Press the
Micro Feed button. The control panel will display the current Beta 2 value.
14. Adjust the Beta 2 value in the same way you adjusted the Beta 3 value.
22. Turn off the printer and reinstall the ribbon mask holder and ribbon cartridge
4-12
ADJUSTMENT
MEASURING THE PLATEN GAP VALUES

To measure and enter new Beta values:
1. Remove the paper, ribbon cartridge, and ribbon mask holder from the printer.
2. Write down the Alpha value written on the side of the printhead.
3. Write down the Beta values written on the label on the inside bottom right corner of the printer
mechanism, under the ribbon cartridge.
4. Close the top cover.
To reset the Alpha value:
1. Turn the printer on while pressing the Tear Off, Micro Feed , and Front/Rear buttons. Hold the buttons
down until the printer beeps once. The printer performs a platen gap home position seek, and the
carriage moves to column 15.
2. The control panel indicates the current Alpha adjustment value (See Tables 4-1 and 4-2.)
3. Enter the Alpha value on the printhead into memory, using the Micro Feed buttons:
4. If you are finished and do not wish to adjust the Beta values, press the LF/FF Load button. The Alpha
value is written to the EEPROM and the adjustment is complete. Turn the power off and install the
ribbon mask holder and the ribbon cartridge.
5. If you wish to continue on to Beta value adjustment, press the Pause/Reset button. The Alpha value is
written to the EEPROM, and the printer enters the Beta values write mode.
To measure the Beta values:
6. Open the top cover and insert the 0.43 mm thickness gauge into the space between the platen and the
printhead nose. (At this time, do not shift the print head. If you do, return to Step 4.)
7. Hook the tension gauge through the hole of the thickness gauge and pull it straight to the right.
8. Gradually bring the printhead to the surface of the thickness gauge using the Micro Feed buttons:
The panel indicates the current Beta 3 adjustment value. (See Table 4-1.)
9. Adjust the Beta 3 value until the tension gauge shows about 150 (135 - 165) gf, and the thickness
gauge can still move to the right very slowly.
10. Press the Pause/Reset button.
11. Remove the thickness gauge, and gradually bring the printhead nose to the platen using the Micro Feed
buttons:
13. Insert the 0.43 mm thickness gauge into the space between the platen and the printhead nose.
16. Insert the 0.80 mm thickness gauge into the space between the platen and the printhead nose.
4-13
DFX-8500
18. Press the Pause/Reset button. All of the measured Beta values are written to the EEPROM.
Note:
If the measured Beta values are outside the allowed range (See Table 4-1), the printer sounds six
beeps and doesnt write the values to the EEPROM.
19. Turn the printer power off, then reinstall the ribbon mask holder and the ribbon cartridge.
Platen
Tension Gauge
135 - 165 gf
Thickness Gauge
(for BETA3' = 0.43 mm)
Figure 4-18. Using the Thickness Gauge

Table 4-1. Beta Values Adjustment
Beta No.
Reference Thickness Gauge
Allowed Value Default Value*
Beta 3'
0.43 mm with 150 gf tension
Beta 2
0.00 mm
367 419
408
Beta 3
0.43 mm
405 437
435
Beta 4
0.80 mm
418 475
461
*1: After the EEPROM is reset.
Table 4-2. LED Value Display
LED*
Ribbon
Pause
Top of Form
Tear Off
Copy
Pitch
Font
7 Segment
4-14
Off
(Bi-d. adjustment)
(platen gap adjustment)
On
+ (positive) (negative)
300
400
Each LED
equals +10.
0 to 9
ADJUSTMENT
4.9 BI-DIRECTIONAL PRINTING ADJUSTMENT

The purpose of this adjustment is to correct the printer mechanism parameters that control bi-directional
printing. If the adjustment is not performed correctly, bi-directional printing may be misaligned, or the
carriage might operate incorrectly. Before performing this procedure, be sure that the following adjustments
have been completed correctly:

Carriage Timing Belt Tension Adjustment

Carriage Guide Shaft Parallelism Adjustment
Platen Angle Adjustment
Platen Gap Motor Value Adjustment
The parameters to be written to the EEPROM in this adjustment are:

1. Printhead flying time adjustment value (Flight Time)
2. Bi-directional printing alignment value for each print speed: Super Draft, Draft, and NLQ
CAUTION

Before you perform the Bi-D adjustment, turn DIP switch 1-6 off. Otherwise, the adjustment wont
work.
If you replace the main board, you must perform the platen gap adjustment before performing the bidirectional printing adjustment.
4-15
DFX-8500
START
Mount the ribbon cartridge.
Turn the power on while pressing the Tear Off,

Micro Feed , and Front/Rear buttons.
Put 15-inch fanfold paper in the Front or Rear

tractor, then load the paper by pressing LF/FF
Load or Front/Rear.
The printer prints "PG Alpha=AAA, PG Beta1=BBB,

PG Beta2=CCC, PG Beta3=DDD, and PG Beta4=EEE ".
The control panel diplays the current flight time value

(See Table 4-2.).
The printer then prints "Flight Time = FFF".
The printer prints the test print pattern using

the current flight time value. See Figure 4-20.
Are the
odd (1st and 3rd) and
even (2nd and 4th) lines
vertically aligned?
Ye s
No
Change the flight time value:
Decrease by 10: Press Top of Form once.
Decrease by 1: Press MicroFeed once.
Increase by 10: Press Tear Off once.
Increase by 1: Press MicroFeed once.
Press the Pause button

.
The current flight time adjust value

is stored in the EEPROM.
Panel diplays the current flight time adjustment value.
Press the Copy button.
Perform the Bi-D Adjustment.

(See Figure 4-21.)
Turn the printer power off.
END
Figure 4-19. Flight Time Adjustment
4-16
ADJUSTMENT
Decrease flight time
Increase flight time

TTTTTTTTTTTTTTTTTTTTT
40 COLUMNS
56 COLUMNS
40 COLUMNS
Figure 4-20. Flight Time Pattern
4-17
DFX-8500
Bi-D. Adjustment Mode
Adjustment
Super Draft Print Mode
The control panel diplays the current Bi-D value.

Adjustment
The printer prints "Speed = AAA Bid adjust = BBB".

BBB* is the current Bi-D value.
Draft Print Mode

The printer prints the test print pattern using the
current value.
Adjustment
Yes
o
NLQ Print Mode
Are the
odd (1st and 3rd) and
even (2nd and 4th) lines
vertically aligned?
No
Adjustment
No
Are all
adjustments complete
and correct?
Yes
Change the Bi-D value.

Decrease by 10: Press Top of Form once.
Decrease by 1: Press MicroFeed once.
Increase by 10: Press Tear Off once.
Increase by 1: Press MicroFeed once.
The control panel diplays the current Bi-D value.
Press the Copy button.
Turn the printer off.
END
Press the Pause button.

The current adjustment value
is stored in the EEPROM.
Return
*BBB Settings
Speed
Super Draft
Draft
NLQ
Figure 4-22. Bi-D Adjustment
4-18
BBB
SdrSpd
DrfSpd
NLQSpd
CHAPTER 5
TROUBLESHOOTING
5.1
TROUBLESHOOTING INFORMATION ___________________________________________ 1
Error Messages _____________________________________________________________________________

Bypassing the Interlock Switch and Cover Open Sensor _____________________________________________
Coil Resistance and Printhead Cable Signals ______________________________________________________
Unit Replacement ___________________________________________________________________________
5.2
1
3
4
6
CIRCUIT BOARD REPAIR _____________________________________________________ 14
C204 PSB/PSE Board Repair _________________________________________________________________ 14

C204 Main/DRV/DRV-B Boards Repair_________________________________________________________ 16
Printer Mechanism Repair____________________________________________________________________ 19
TROUBLESHOOTING
5.1 TROUBLESHOOTING INFORMATION

This chapter lists various problems that can occur with the DFX-8500 and provides possible solutions. No
special tools, other than a digital multi-meter, are necessary to troubleshoot at the unit level. Some
component-level troubleshooting may require an oscilloscope.
ERROR MESSAGES
The DFX-8500 indicates errors using beeps. Tables 5-1 and 5-2 list standard errors.
Table 5-1. Error/Warning Beeper Information
Error/Warning
Printhead hot
Printhead fan hot
Paper out
Pause
LED
Blinking
Blinking
On
Paper Out
LED
Off
Off
On
Ribbon
LED
Off
Off
Off
...
Cover open
ON
Off
Off
...
Paper change
incomplete
Paper backfeed
incomplete
Paper size error
On
Off
Off
...
On
Blinking
Off
...
ON
Off
Off
...
Paper jam
ON
Blinking
Off
-----
Ribbon jam
On
Off
Blinking
-----
Carriage motor
error
On
Blinking
Blinking
-----
Illegal panel
operation
Beeper
Description

printer fails to load a sheet.
(Three 100-ms beeps with a
100-ms interval.)
printers cover is open.
printer fails to change the paper.
This error occurs when the set

paper width and the current
paper size are different.
printer fails to eject a sheet.
(Five 500-ms beeps with a
100-ms interval.)
ribbon jams or when no ribbon is
installed.
carriage deceleration time is
abnormal.
5-1
DFX-8500
Table 5-2. Fatal Error Information

Fatal Error
Beeper
7-segment
LED *
1
--
Platen gap
error
---
Carriage lock
error
Encoder error
Carriage load
measurement
error
Head fan error
Carriage motor
circuit short
Cutter error
Description
Note
Auto power off

after 12 seconds
Auto power off
after 12 seconds
----
The isolation resistance in the carriage

motor is too low.
The optional cutter cable is not
connected securely.
The optional cutter is defective.
The PG home sensor is broken.
The PG motor is broken.
The parallelism adjustment is
incorrect.
PG adjustment values are incorrect.
PG motor pinion is too tight against
the PG transmission gear.
The carriage is locked.
----
The encoder sensor is defective.
------
PW sensor is defective.
-------
The head fan driver IC is shorted.

The head fan is defective.
The printhead driver IC is shorted.
The printhead coil is defective.
The DRAM on the main board is
defective.
-
Auto power off

after 12 seconds
Auto power off

after 12 seconds
Auto power off
after 12 seconds
Auto power off
after 12 seconds
Printhead power
off immediately
Printhead power
off immediately
Auto power off
after 12 seconds
-
Printhead
8
-------circuit short
RAM check
9
--------error
Paper memory a
---------setting error
EEPROM data b
----------The EEPROM is defective.
compare error
Tractor change c
- - - - - - - - - - - - The tractor select mechanism or ribbon Auto power off
error
feed motor is defective.
after 12 seconds
Internal CPU
d
The main board is defective.
Auto power off
error
after 12 seconds
*: During a fatal error, the 7 segment LED alternately flashes an E and the error number.
: 500 ms beeps with 100 ms intervals.
: Turn the printer power off while the 7 segment LED is on, or the printer will shut down. The printer will not
turn back on for 5 minutes after the printer shuts down automatically.
5-2
TROUBLESHOOTING
BYPASSING THE INTERLOCK SWITCH AND COVER OPEN SENSOR

To print with the top cover open or removed, you need to bypass the interlock switch and cover open sensor.
These sensors automatically disable printing when the top cover is open.
Interlock Switch
Connector
Junction Board
Cover Open
Sensor
C204 Main Board

CN3
Figure 5-1. Interlock Switch and Cover Open Sensor

The interlock switch and cover open sensor are attached. To bypass the interlock switch and the cover open
sensor, follow these steps:
1. Remove the left side cover.
2. Remove the interlock switch and cover open sensor from the housing.
3. Insert a half-inch spacer (for example, an eraser) as shown in Figure 5-2.
Cover Open
Sensor
Spa
To CN3 on the Main Board
cer
0.51
( 1 3 inch
mm
)
To Connector Junction Board
Interlock Switch
Figure 5-2. Bypassing the Interlock Switch and Cover Open Sensor
5-3
DFX-8500
COIL RESISTANCE AND PRINTHEAD CABLE SIGNALS

The following table provides the coil resistance for the motor, head fan, plunger, and printhead.
Table 5-3. Motor, Fan, Plunger, and Printhead Coil Resistance
Part
Coil Resistance
Carriage (CR) motor
1.66 + 10 %
o
Print Feed (PF) motor
2.80 + 10 % at 25 C
o
Ribbon Feed (RF) motor
150 + 10 % at 25 C
o
Platen Gap (PG) motor
250 + 18 at 25 C
o
Head fan
61 + 4.3 at 25 C
o
Plunger
9 + 5 % at 25 C
o
Printhead
2.93 + 0.2 at 25 C
Shield Cable
Double-sided Adhesive Tape
C
Printhead FPC
B
A
1
3
5
4
Printhead Cable
Protection Sheet
Printhead Cable Board
Figure 5-3. Printhead FPC
5-4
TROUBLESHOOTING
FPC A
FPC B
FPC C
Load Pattern
: Printhead coil GND side

: Printhead coil P/S side
: Printhead thermistor
PWD : Paper width sensor
+5V : +5 VDC
ENCA: Encoder A
GND : Ground
HT : Printhead thermistor
MA : Fan motor phase A

MB : Fan motor phase B
MC : Fan motor common
MT : Fan motor thermistor
P/S : Power supply (+37 VDC)
ENCB: Encoder B
Figure 5-4. Printhead Cable Signals
5-5
DFX-8500
UNIT REPLACEMENT
1. The printer does not operate when power is turned on.
START
Does the
printer beep
before it dies?
Yes
Check Table 5-1, Error

Codes.
No
Is the
AC input voltage
normal?
No
Use the correct AC voltage.
Yes
Has fuse F1
on the C204 power
supply board blown?
Yes
No
No
Disconnect the PSB from the

main board and measure the
output voltage from the PSB.
Replace the fuse F1 and

disconnect CN2, CN3, and
CN4 on the C204 power
supply Board.
Is the
problem
fixed?
Reconnect CN2,
CN3, and CN4
and turn on the
printer.
When you
turn on power
again, does the
new fuse also
blow?
No
Yes
END
Yes
Is the
output voltage
normal?
No
Replace the C204 power supply

board.
Yes
Connect only the main board to the
PSB, disconnect all other connectors
from the main board, and check the
voltage again.
Is the
output voltage
normal?
Retest
No
Replace the main

board.
Yes
Check all motors, solenoid, printhead,
and drivers using a multimeter.
Are they
within normal
range?
No
Replace the bad motor, solenoid,

printhead, or DRV boards.
Yes
No
Replace the C204 MAIN board,
C204 DRV board, and/or
C204 DRV-B board.
Is the
fault corrected?
Yes
END
Is the
fault corrected?
Yes
No
See Section 5.3 to

repair the printer
mechanism.
Note: The printer has a 5 minute shut down safety

built into the main board. If an error occurs and
the printer shuts down after 12 seconds or less,
please do not assume it is a PSB problem.
In order to prevent the printer from shutting down
for 5 minutes, do the following:
END
5-6
1. Turn off the printer within 12 seconds.

2. Open the top cover within 12 seconds.
(this will cause a cover open error, which
takes precedence over the shut down.)
TROUBLESHOOTING
2. Carriage operation is abnormal.

START
Are the
connectors listed in
the note below
inserted securely?
No
Reinsert the connectors.
Yes
No
Is the problem
fixed?
Yes
END
Manually move the
carriage to see if
movement is smooth
or not.
Not smooth
Check the
CR encoder belt and
encoder sensor.
Are they clean?
Smooth
Yes
Check the
CR motor and CR motor
drivers using a multimeter.
Are they OK?
Yes
Refer to Section 5.3, Repair

of the Printer Mechanism.
No
No
No
Replace or clean the
defective component
Yes
Is the problem
fixed?
Is the problem
fixed?
Yes
END
No
Replace the C204 main board and/or

C204 DRV board.
END
NOTE: Make sure these connectors are secure:

Interlock switch connector on connector junction board
Carriage motor connector on connector junction board
Printhead connector on printhead junction board
CN4 on the main board
5-7
DFX-8500
3. Carriage operation is normal, but the self-test is printed incorrectly (1/3).
START
Perform the self-test.
Does the
printer perform the
self-test?
No
Yes
Are any
dots missing or
delayed?
Are the connectors

listed in the note below
inserted securely?
Yes
No
R e in s e rt c o rrectly .
Yes
No
No
Is the problem
fixed?
Yes
Check the printhead cable
and terminal pins.
Replace any bad parts.
Yes
Is the problem
fixed?
No
Perform the bidirectional
printing adjustment.
A
END
NOTE: Check the following connectors:

Three printhead junction board connectors to the printhead
CN1 on the C204 DRV-B board
5-8
END
TROUBLESHOOTING
Check the printhead

coil resistance.
Is the
printhead resistance
correct?
No
Yes
Check the printhead drivers.
Check the printhead drivers.

Are the
drivers OK?
Are the
drivers OK?
No
Replace the DRV

board.
Yes
No
Replace the DRV

board and the
printhead.
Yes
Replace the printhead .
If the ribbon mask is not seated

.
properly, reseat or replace it.
Is the problem
fixed?
Yes
No
Refer to Section 5.3, Repair of the
Printer Mechanism.
Is the problem
fixed?
No
Yes
END

Printer Mechanism.
5-9
DFX-8500
Is the print
correct?
Yes
No
Perform bidirectional
adjustment.
Go back to Section 5.3, Repair

of the Printer Mechanism, and
check for other problems.
END
Perform bidirectional
adjustment.
END
5-10
TROUBLESHOOTING
5. Printing is normal, but paper feeding is abnormal.

START
Is the
paper loaded
correctly?
No
Load the paper correctly.
Yes
Is there
anything stuck in the
path of the paper?
Clear the paper path.
No
Is PF
motor coil
resistance
correct?
Check the resistance of the PF motor

coils and check the PF motor drivers.
Yes
Are the
drivers shorted or
open?
No
Is the
motor resistance OK
and are the drivers
OK?
No
Are the
drivers shorted or
open?
No
Yes
No
Yes
Yes
Replace the
C204 DRV board
and the PF motor.

Printer Mechanism.
Replace the
PF motor.
Replace the
C204 MAIN board and/or
C204 DRV board.
Perform final printing of self-test.

Perform final printing of self-test.
Is the problem
fixed?
No
Is the problem
fixed?
Yes
END
No
END
Perform the platen gap

motor placement
adjustment.
(See Chapter 4.)
See Section 5.3, Repair

of the Printer Mechanism.
Is the problem
fixed?
END
END
No
Perform the platen gap motor

placement adjustment. (See
Chapter 4.)
END
5-11
DFX-8500
7. Control panel operation is abnormal.

START
Is CN5
between the C204 Main
and C204 PNL board
connected correctly?
No
Reinsert connector CN5

correctly.
Yes
No
Yes
Is the problem
fixed?
Using a multimeter, check

the switches on the
C204 PNL board.
Do the
switches work
correctly?
END
Yes
Replace the C204 Ma in board.

No
Yes
Replace the C 204 PNL board.
Is the problem
fixed?
END
Do the
buttons work?
No
No
Replace the C 204 PNL board.
Yes
END
END
Replace the C204
END
5-12
Main board.
TROUBLESHOOTING
8. Data sent by the host computer is printed incorrectly.

Note : The flowchart below assumes the host computer is operating normally.
START
Run the self-test.
Is the self-test
printed correctly?
Yes
Can you print

from DOS?
No
Troubleshoot printer using the
previous flowcharts.
Yes
Check the software

application setup
No
END
Built-in Parallel
Which I/F are

you using?
Serial or
Optional
Are the DIP
switches set correctly?
(See Tables 1-16,1-21,
1-22,and 1-23.)
Check the cable connection

from the host computer.
No
Set switches
correctly.
Yes
No
END
If you
are using a
serial I/F, is your
cable a null modem
cable?
Is
your parallel cable a
shielded, twisted-pair cable
shorter than 6 feet, and does it
work with another
printer?
No
Yes
Replace C204 MAIN board.
Replace cable.
Yes
Replace C204 MAIN board.
END
END
END
Not using serial.
If you are
using a Type B
optional I/F for a network, is
the network configured
correctly?
No
Reconfigure network.
Yes
Replace Type B interface.
END
END
5-13
DFX-8500
5.2 CIRCUIT BOARD REPAIR

This section describes troubleshooting and repair procedures for the DFX-8500 circuit boards. By referring
to the checkpoints below, you can determine which component is defective and perform the proper repair
procedure. The tables have four columns:

Symptom:
Cause:
Checkpoint:
Solution:
Common printer problems

Possible causes of each symptom
Troubleshooting checks to help isolate your problem
Repair instructions
C204 PSB/PSE BOARD REPAIR

Table 5-4 describes the major components of the C204 PSB/PSE board. Table 5-5 contains troubleshooting
instructions.
Location
DB1
TY1
QF101
QF201
IC101
IC204
5-14
Table 5-4. C204 PSB/PSE Board Main Parts List

Description
Diode bridge
TRIAC
Switching FET for VP1 and VP2
Switching FET for VP3 and +5 VDC
PWM switching controller
+5 V regulator IC
TROUBLESHOOTING
Table 5-5. C204 PSB/PSE Board Component Repair

Cause
Checkpoint
Solution
Wait until the printer
PD signal is HIGH
Measure the PD signal
prints again.
(signal from the main
level at CN4.
board).
Replace E05B36 on the
main board.
Measure the DRERR
Replace the printhead
The DRERR signal is
HIGH.
signal level at CN4.
driver on the main
board and/or C204
DRV-B board.
CL signal is HIGH.
Measure the CL signal
Wait until the printer
at CN4.
prints again.
Replace the E05B36 on
the C204 MAIN board.
Fuse F1 blows
The line filter circuit is
Check if pins C1
Replace the defective
immediately after
defective.
through C5 or R1 are
element.
replacement.
shorting the AC line.
The +37 VDC (VP1The main switching FET Observe the voltage
Replace QF101.
VP2) line is dead.
QF101 is defective.
waveform between the
FET drain and GND.
IC101 is defective.
While pin 5 (FB) is
Replace IC101.
HIGH, observe the
voltage waveform
between pin 2 (VOUT)
and pin 12 (GND) of
IC101.
The +37 VDC (VP3) line The main switching FET Observe the voltage
Replace QF201.
is dead.
QF201 is defective.
FET drain and GND.
Q201 is defective.
Observe the voltage
Replace Q201.
FET collector and GND.
Q202 is defective.
Observe the voltage
Replace Q202.
FET collector and GND.
The 5 VDC line is
IC204 is defective.
Check the voltage level Replace IC204.
defective.
at pin 10 (V1) and pin 5
(GP).
Observe the drive
Replace IC204 or
waveform at pin 8 (VO) ZD211.
and pin 5 (GP).
The 37 VDC line (VP1- IC102 is defective. (If
When the input voltage
Replace IC203.
VP2) is abnormal.
this IC is defective, it
of the minus port (pin 6
cannot monitor the 37
for VP1 and pin 2 for
VDC lines, and printing
VP2) is less than 1.3
becomes abnormal.),
VDC, the comparator
outputs a HIGH signal.
Symptom
No DC voltage at the
output. (The fan on the
power supply board
doesnt rotate.)
5-15
DFX-8500
C204 MAIN/DRV/DRV-B BOARDS REPAIR

Table 5-6 includes troubleshooting procedures.
Symptom
The printer does
not operate at all.
The driver
circuits dont
operate at all.
The serial
interface is dead.
The printer does
not operate at all.
The carriage
operates
abnormally.
5-16
Table 5-6. C204 Main/DRV/DRV-B Boards Component Repair

Cause
Checkpoint
Solution
The DRERR signal
Check the level of the DRERR signal
Replace the
was sent to the C204 at CN10, or check the VP1 and VP2
printhead driver on
power supply board
voltage.
the main board
(HIGH level turns off
(VP1) or C204
the power supply).
DRV-B board
(VP2).
The PD signal was
Check the level of the PD signal
Replace the
sent to the C204
during power on and verify the
printhead driver or
power supply board.
voltage waveform for the printhead
gate array.
(A HIGH signal turns driver.
off the power supply)
The reset circuit is
Check the logic level at pin 1 (VOUT) Replace IC13.
not working.
of IC13.
The pull up voltage
When the collector of Q15 is high,
Replace Q15.
VX is not being
check the logic level at the collector
generated.
of Q14 (VX). When the collector of
Q15 is high, VX is HIGH.
The level converter
Check the signal level change
Replace IC9.
IC is defective.
between the in and out ports of IC9.
The control ROM is
Confirm that the PROM is inserted in
Replace IC5.
defective.
the socket correctly.
The gate array (IC1)
Check pin 86 (D0) of IC1 for a change Replace IC1.
is defective.
in the signal (HIGH or LOW).
The CPU (IC2) is
Check the waveform at pin 27 (x1) or
Replace CRU1 or
defective.
pin 28 of the CPU.
IC1.
The DRAM (IC14) is
Check pin 2 (D0) of IC14 for a change Replace IC14.
defective.
in the signal (HIGH or LOW).
IC1 on the main
Check the signals for the carriage
Replace IC1.
board is defective.
motor phases at pins 204 (CRA), 205
(CRB), 206 (CRC), and 5 (CRD) of
IC1.
Q16, Q17, Q18, or
Replace Q16, Q17,
Q19 on the main
motor phases at collectors Q16
Q18, or Q19.
board is defective.
(CRA), Q17 (CRB), Q18 (CRC), and
Q19 (CRD).
IC1 doesnt work.
The voltage level between the anode
Replace ZD2, Q34,
and cathode of ZD2 is about 6.2 V.
or Q35.
IC1 on the C204
Replace IC1.
DRV board is
motor phases at pins 14 (IN_A) and
defective.
10 (OUT1) of IC1.
.
Measure the voltage level at pins 10
Replace IC1.
(OUT1) and 5 (GP) of IC1 when the
carriage is operating. (The normal
voltage level is approximately 37
VDC.)
IC3 on the C204
Observe the waveform at pin 1 of
Replace IC3.
DRV board is
IC3.
defective.
TROUBLESHOOTING
Table 5-6. C204 Main/DRV/DRV-B Boards Component Repair (continued)

Symptom
Cause
Checkpoint
Solution
The carriage
The carriage encoder Observe the carriage encoder sensor
Replace the
operates
sensor is defective.
output signal at pins 4 (ENCA) and 3
carriage encoder
abnormally.
(ENCB) of CN4 on the main board.
sensor.
Carriage operation is Check the switching waveform for Q5, Replace the
unstable (due to a
Q6, and Q7.
abnormal transistor.
lack of motor torque).
Paper feeding is
The CPU (IC2) on
Check the PF motor phase drive
Replace IC2.
abnormal.
the main board is
signals at pins 2 through 5 of IC2.
defective.
IC2 on the C204
At IC2, check the output signals for
Replace IC2.
DRV board is
pins 2 (OUT_A), 3 (OUTXA), 6
defective.
(OUT_B), and 7 (OUTXB).
Ribbon feeding is The CPU (IC2) on
Check the RF motor phase drive
Replace IC2.
abnormal.
the main board is
signals at pins 6 through 9 of IC2.
defective.
The common
Check the collector voltage of Q21.
Replace Q20 or
switching transistor
Q21.
on the C204 DRV
board is defective.
The phase switching
For transistors Q22 through Q25,
If there is no output
transistor on the
observe the input signal from the
signal, replace the
C204 DRV board is
CPU (base) and the output signal
defective.
(collector).
Fuse F1 on the C204 Check if fuse F1 is defective.
Replace F1.
DRV board is
defective.
The head fan
IC1 on the main
Observe the PG motor phase signal
Replace IC1.
operation is
board is defective.
at pins 163 (FANA) and 164 (FANAX)
abnormal.
of IC1.
Q10 or Q11 on the
Observe the head fan phase drive
Replace Q10 or
main board is
voltage level for pins 25 (HFANA) and Q11.
defective.
17 (HFANB) of CN1. (The normal
voltage is approximately 37 VDC.)
The PG motor
IC1 on the main
Observe the PG motor phase signal
Replace IC1.
operates
board is defective.
at pins 10 (PGA), 12 (PGB), 14
abnormally.
(PGAX), and 13 (PGBX) of IC1.
The common
Check the collector voltage of Q11.
Replace Q10 or
switching transistor
Q11.
on the C204 DRV
board is defective.
The phase switching
For transistors Q12 through Q15,
If there is no output
transistor on the
observe the output signal (collector).
signal, replace the
C204 DRV board is
defective.
Fuse F2 on the C204 Check fuse F2.
Replace F2.
DRV board is
defective.
The PG sensor is
Observe the PG sensor output signal
Replace the PG
defective.
at pins 35 (PGENCA) and 34
sensor.
(PGENCB) of CN14.
5-17
DFX-8500
Table 5-6. C204 Main/DRV/DRV-B Boards Component Repair (continued)

Symptom
Cause
Checkpoint
Solution
The PG home
Check the PG HP sensor signal level
Replace the PG
position sensor is
at pin 36 (PGHOME) of CN14. (PG
home position
defective.
home = LOW; other = HIGH)
sensor.
The plunger is
Fuse F3 is defective
Check fuse F3.
Replace F3.
defective.
IC1 on the main
When paper is loaded into the printer, Replace IC1.
board is defective.
look at the switching signal at pins 16
(PLP) and 17 (PLN)of IC1.
Plunger drive
Observe the Q31 collector voltage at
Replace Q31, Q30,
transistor on the
paper loading.
or Q32.
C204 DRV board is
defective.
The self-test
IC1 on the main
Observe the output signal at pins
Replace IC1.
prints incorrectly. board is defective.
136-181 of IC1.
The head driver
Observe the voltage waveform at
Replace the
FETs on the main
each FET drain side.
abnormal FET.
and/or C204 DRV-B
boards are defective.
The CPU (IC2) on
Observe the signals at pins 38 (PTS1) Replace IC2.
the main board is
and 42 (PTS2) of IC2.
defective.
5-18
TROUBLESHOOTING
PRINTER MECHANISM REPAIR

The table below describes how to isolate problems with the printer mechanism. To replace or adjust printer
mechanism parts, see Chapters 3 and 4. If a symptom recurs following a repair, look for other possible
causes and solutions in the table below.
Symptom
The carriage
(CR) motor does
not operate.
The carriage
moves, but no
printing is
performed.
A particular dot
does not print.
Print jobs are too

light or print
density is not
uniform.
Table 5-7. Printer Mechanism Repair

Cause
Checkpoint
The transport-locking Verify that the transport-locking
bracket (used to hold bracket has been removed.
the carriage in place
when the printer is
moved) has not been
removed.
Foreign objects are
Manually move the carriage to see if
lodged in the gears
the motor rotates.
or elsewhere (e.g.
paper dust on the
carriage encoder
belt) in the
mechanism.
The CR motor is
Measure the coil resistance of the CR
defective.
motor. It should be approximately
1.66 + 10 %. Check the CR motor
drivers.
The carriage-timing
Manually check the carriage-timing
belt is defective.
belt tension.
The carriage guide

shaft parallelism
value is incorrect.
Check whether the carriage moves

smoothly when moved manually.
Check that foreign objects are not
lodged in the printer mechanism.
The CR encoder
The carriage encoder
belt is damaged or
covered with dust.
The printhead FPC
wires are broken.
Check the waveform for the carriage

encoder signal.
Check the encoder belt (below the
carriage timing belt).
The printhead is
defective.
Measure the printhead coil resistance.

(Refer to Figure 5-4 for details.)
Check whether an impact dot wire has
been worn down.
Check whether an impact dot wire has
been worn down.
The printhead is
defective.
Check the wires in the printhead FPC.

(See Figure 5-4.)
Solution
Remove bracket.
(See Section 3.1.)
Remove any
foreign objects.
Replace the CR
motor and/or
drivers.
Perform the
carriage timing belt
tension adjustment,
as described in
Section 4.3.
Perform the
carriage guide shaft
parallelism
adjustment, as
described in
Section 4.6.
Replace the CR
encoder sensor.
Replace or clean
the carriage
encoder belt.
Replace the FPC.
Replace the
printhead.
Replace the
printhead.
Replace the
printhead.
5-19
DFX-8500
Symptom
The printer does

not feed paper
correctly.
The RF motor
does not operate.
The PG motor
does not operate.
Table 5-7. Printer Mechanism Repair (continued)

Cause
Checkpoint
The parallelism
Print density differs at the right and
value is incorrect.
left sides of the page (darker on one
side).
The platen gap value

is incorrect.
Print density is too light even when a

new ribbon cartridge is mounted.
Foreign objects are

lodged in the paper
path.
The PF motor is not
driving the gear
properly.
Visually check the paper path.
The PF motor is
defective.
Measure the coil resistance of the PF

motor. (The correct resistance is
approximately 2.8 + 10%.) Also
check the PF motor drivers.
The ribbon cartridge

is defective.
Foreign objects are
caught in the gears.
Remove the ribbon cartridge and

make sure the spool freely rotates.
Check whether the ribbon driving gear
rotates when the cartridge is moved
manually.
The parallelism
value is incorrect.
Check whether the carriage moves

smoothly when moved manually.
(Check that foreign objects are not
lodged in the printer mechanism.)
The RF motor is
defective.
Check the coil resistance of the RF

motor. (It should be about 150
+ 10 %.) Check the DRV board.
Check whether the carriage guide
shaft rotates smoothly when rotated
manually.
The motor is not

positioned properly.
The PG encoder
The encoder plate is
defective.
5-20
Check whether the PF motor pinion

gear rotates smoothly when rotated
manually.
Check the output signal of the PG

encoder sensor.
Check whether the encoder plate is
broken or stained.
Solution
Perform the
parallelism
adjustment, as
described in
Section 4.6.
Perform the
parallelism
adjustment, as
described in
Section 4.6.
Remove any
foreign substances.
Check distance
between PF motor
pinion gear and PF
reduction gear.
(See Section 4.2.)
Replace the PF
motor, and if the
drivers are bad,
replace the DRV
board at the same
time.
Replace the ribbon
cartridge.
Remove any
foreign objects and
replace any
damaged ribbon
feed mechanism
parts
Perform the
parallelism
adjustment, as
described in
Section 4.6.
Replace the RF
motor and/or the
DRV board.
Perform the platen
gap motor
placement
adjustment as
described in
Section 4.2.
Replace the PG
encoder sensor.
Replace the PG
motor or clean the
encoder plate.
TROUBLESHOOTING
Symptom
Printing
continues past
the end of the
paper.
When paper
jams, the printer
does not beep.
The ribbon jam
error occurs even
when the ribbon
feeds correctly.
Printing occurs
outside the paper
width.
The paper bail
assembly does
not work.
Continuous paper
becomes
crumpled at the
front or rear
tractor assembly.
The tractor select

(front or rear)
function is not
working.
Table 5-7. Printer Mechanism Repair (continued)

Cause
Checkpoint
The PG home sensor Check the continuity of the sensor.
is defective.
(Check the status of the two micro
switches.)
The PG motor is
Check the coil resistance of the PG
defective.
motor. (It should be about 250
+ 18 .)
The front, rear, or top Check the PE sensors.
PE sensor is
defective.
Paper size has been
Check the software and DIP switch
set incorrectly.
settings.
The paper jam
Check the paper jam sensor.
Solution
Replace the PG
home sensor (micro
switch type).
Replace the PG
motor.
Replace the PE
sensors.
Correct the paper
size setting.
Replace the paper
jam sensor.
The ribbon jam

Check the ribbon jam sensor.
Replace the ribbon

jam sensor.
The PW sensor is
defective.
Check the PW sensor.
Replace the PW
sensor.
The plunger is
defective.
Check the coil resistance of the

plunger. (It should be about 9 ohms.)
Replace the
plunger.
The tension value of

the tractor wire
spring is incorrect.
The distance between the frame and

the seal securing the white line should
be about 3 mm (0.12 inches).
The paper guide

assembly is
defective.
The tractor select
Check the paper guide assembly.
Perform the tractor

wire spring tension
adjustment, as
described in
Section 4.1.3.
Replace the paper
guide assembly.
Check the continuity of the tractor

select sensor.
Replace the tractor

select sensor.
The tractor select

gear is disconnected
from the tractor
select cam.
Visually check the tractor select gear

holder.
Join the tip of the

tractor select lever
to the tractor select
gear holder.
5-21
DFX-8500
5-22
CHAPTER 6
MAINTENENCE
6.1
PREVENTIVE MAINTENANCE ___________________________________________________1
6.2
LUBRICATION AND ADHESIVE APPLICATION ____________________________________1
MAINTENANCE
6.1 PREVENTIVE MAINTENANCE

To keep the printer in good condition, regularly clean the case exterior with a soft cloth and some alcohol
and vacuum the mechanism's interior to remove dust and paper debris. After servicing the printer, make
sure it is adequately lubricated, as described in Section 6.2. Before returning the printer to the customer,
make sure the springs and paper feed rollers operate properly.
CAUTION
Unplug the printer before performing maintenance. Do not use thinner, trichloroethylene, or ketonebased solvents on the plastic components of the printer.
Note: The carriage encoder belt should be cleaned periodically. Clean it when the printer is returned for
service.
6.2 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 O2 and G26. These lubricants have been extensively tested and found to comply with the
needs of the printer. See Table 6-1 for information on lubricants O2 and G26. Table 6-2 lists the appropriate
lubricant for each lubrication point. Make sure the parts are clean before applying lubricant. Avoid applying
too much lubricant, this may damage surrounding parts.
Adhesive application is necessary at the points indicated in Table 6-3 when parts are disassembled or
replaced. EPSON recommends Neji Lock #2 (G) adhesive be applied to the points illustrated in Figures 6-2,
6-3, and 6-4. Avoid adhesive overflow onto related parts.
Table 6-1. Recommended Lubricants
Type
Name
Quantity
Part No.
Grease
G26
40 g
B702600001
Oil
O2
40 cc
B710200001
Adhesive
Neji Lock #2 (G)
1000 g
B730200200
Note: E = EPSON exclusive product (not commercially available)
Availability
E
E
E
6-1
DFX-8500
Table 6-2. Lubrication Points

Lubrication
Point
1
2
3
See Figure:
Description
6-3
6-3
6-3
4
5
6-3
6-3
6-4
7
8
9
10
11
12
6-3
6-4
6-4
6-2
6-2
6-2
13
14
15
16
17
6-3
6-4
6-3
6-3
6-3
Carriage oil pad ring (on both left and right sides of carriage)
Carriage oil pad (under the carriage head cable holder),
Hole holding the tip of the rear carriage guide shaft (in both
left and right frames)
Both edges of the rear carriage guide shaft
Parallelism adjustment lever (where it contacts the rear
carriage guide shaft)
Rear carriage shaft holding lever (where it contacts the rear
carriage guide shaft)
Carriage guide shaft (on the front and rear shafts)
Platen roller shaft holder (where it contacts the platen roller)
Paper bail gear
Shafts of paper feed gears (shafts on the left frame)
Paper feed gears (gears on the left frame)
Tension pulley (pulley shaft and hook for the tension pulley
spring)
Fulcrum point for the paper bail shaft and plunger
Platen gap motor pinion
Carriage guide shaft gear
Ribbon feed gears
Tractor select cam
Lubricant
O2
O2
G26
G26
G26
G26
G26
G26
G26
G26,O2
G26
G26
G26
G26
G26
G26
G26
Table 6-3. Adhesive Application Points

Adhesion
Point
(25)
See Figure:
Description
Adhesive
6-3
Tractor tension wire
Neji Lock #2 (G)
Figure 6-1. Correct Adhesive Application
6-2
MAINTENANCE
Figure 6-2. Lubrication and Adhesion Points (1/3)
6-3
DFX-8500
6-4
MAINTENANCE
6-5
DFX-8500
6-6
APPENDIX
A.1
CONNECTOR PIN ASSIGNMENTS ____________________________________________A-1
A.2
COMPONENT LAYOUT DIAGRAMS __________________________________________A-10
A.3
CONNECTORS ON THE CONNECTOR JUNCTION BOARD _____________________A-16
A.4
PARTS LIST ________________________________________________________________A-17
A.5
EXPLODED DIAGRAMS _____________________________________________________A-20
A.6
CIRCUIT DIAGRAMS _______________________________________________________A-28
APPENDIX
A.1 CONNECTOR PIN ASSIGNMENTS

Figure A-1 illustrates the connections between the primary components. Table A-1 lists the connectors and
pin assignments.
Fan
CN3(20)
C204 DRV-B
CN3(12)
CN1(30)
CN5(2)
CN4(8)
CN1(3)
CN2(6)
C204 PSB/PSE
CN2(8)
EIA-232D
AC Input
IEEE1284
CN3(2)
CN2(20)
Printer Mechanism
CN13(7)
TYPE-B
CN10(8)
CN12(36)
Cover Open Sensor
CN5(14)
Printhead
CN9(7)
Junction Board
Paper Cutter
Unit
CN1(30)
CN4(4)
CN11(36)
CR Encoder
CN8(8)
C204 Main
CN15(6)
CN1(6)
CN16(7)
CN2(7)
C204 SUB
CN6(6)
CN7(12)
CN14(50x2)
CN3(6)
CN2(50)
C204 DRV
CN1(50x2)
CN1(7)
CN2(7)
C204 PNL
Figure A-1. Cable Connections
A-1
DFX-8500
Table A-1. Board Connector Summary

Connector
Connected to:
C204 Main Board
CN1
Mechanism (Printhead)
CN2
C204 DRV-B board
CN3
Cover Open
CN4
Mechanism (Carriage encoder)
CN5
Panel unit
CN6
C204 PSB/PSE board
CN7
C204 PSB/PSE board
CN8
C204 DRV-B board
CN9
Optional paper cutter
CN10
C204 PSB/PSE board
CN11
Optional Type-B I/F card
CN12
IEEE-1284 I/F
CN13
EIA 232D I/F
CN14
C204 DRV board
CN15
C204 SUB board
CN16
C204 SUB board
C204 DRV Board
CN1
C204 Main board
CN2
Printer mechanism
CN3
C204 PSB/PSE board
C204 DRV-B Board
CN1
Mechanism (Printhead)
CN2
C204 Main board
CN3
C204 Main board
C204 PSB/PSE board
CN1
AC inlet
CN2
C204 Main board
CN3
C204 Main (CN7) and C204 DRV
(CN3) boards
CN4
C204 Main board
CN5
Cooling fan motor
A-2
No. of Pins
Details
30 pins
20 pins
2 pins
4 pins
14 pins
6 pins
12 pins
8 pins
7 pins
8 pins
36 pins
36 pins
7 pins
50 pins 2
6 pins
7 pins
Table A-2
Table A-3
Table A-4
Table A-5
Table A-6
Table A-7
Table A-8
Table A-9
Table A-10
Table A-11
Table A-12
Tables 1-10 and 1-11
Table 1-12
Table A-13
Table A-14
Table A-15
50 pins 2
50 pins
6 pins
Table A-13
Table A-16
Table A-17
30 pins
6 pins
20 pins
Table A-18
Table A-9
Table A-3
3 pins
6 pins
12 pins
Table A-19
Table A-7
Tables A-8 and A-17
8 pins
2 pins
Table A-11
Table A-20
APPENDIX
Table A-2. C204 Main Board Connector CN1

Pin
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
25
29
30
23, 24, 26, 27, 28
Signal Name
P+10
P-10
P+12
P-12
P+16
P-16
P-17
P-9
P+17
P-11
P+11
P-7
P+9
P-7
P+2
P+1
HFANB
P-1
FTMP
P-2
FANCOM
HTMP
HFANA
PWIDTH
+5
GND
I/O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
I
O
O
I
O
I
Function
Printhead pin #10
GND
Printhead pin #12
GND
Printhead pin #16
GND
GND
GND
Printhead pin #17
GND
Printhead pin #11
GND
Printhead pin #9
GND
Printhead pin #2
Printhead pin #1
HF motor phase B
GND
HF motor temperature
GND
HF motor common
Printhead temperature
HF motor phase A
Paper width signal

Pin
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
167
18
19
20
Signal Name
HR3P
HR2P
HR9N
HR2N
HR7P
HR7N
HR9P
HR3N
HL8P
HL3N
HL8P
HL2N
HL8N
HL7N
HL3P
HL2P
HR4P
HR4N
HRSENS
HNSENS
I/O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
I
I
Printhead coil
Printhead coil
Printhead coil
Printhead coil
Printhead coil
Printhead coil
Printhead coil
Printhead coil
Printhead coil
Printhead coil
Printhead coil
Printhead coil
Printhead coil
Printhead coil
Printhead coil
Printhead coil
Printhead coil
Printhead coil
Printhead coil
Printhead coil
Function
#6 drive signal
#4 drive signal
#18 drive signal
#4 drive signal
#14 drive signal
#14 drive signal
#18 drive signal
#6 drive signal
#15 drive signal
#5 drive signal
#13 drive signal
#3 drive signal
#15 drive signal
#13 drive signal
#5 drive signal
#3 drive signal
#8 drive signal
#8 drive signal
shortage monitoring
shortage monitoring
A-3
DFX-8500

Pin
1
2
Signal Name
COPEN
GND
I/O
I
Function
Cover open status

Pin
1
2
3
4
Signal Name
GND
+5V
ENCB
ENCA
I/O
I
I
Function
CR encoder B phase pulse

CR encoder A phase pulse

Pin
1
2
3
5
6
7
9
9
11
13
4, 10, 12, 14
Signal Name
LED_DATA
LED_XLE
LED_CLK
LED_XOE
BUZZER
VCC
SW_INH
SW_S/XL
SW_DATA
SW_CLK
GND
I/O
O
O
O
O
O
O
O
I
O
Function
LED data
LED data latch
LED data clock
LED light enable
Buzzer
+5 VDC
Switch data transfer inhibit
Switch data shift/load select
Switch data
Switch data clock

Pin
1, 2, 3
4, 5, 6
Signal Name
VP1
GP1
I/O
Function
+37 VDC
GND for VP1

Pin
1, 2, 3
4, 5, 6
Signal Name
VP2
GP2
I/O
Function
+37 VDC
GND for VP2

Pin
8, 7, 6
5, 4, 3
1
2
Signal Name
VP1
GP1
VX
GND
I/O
Function
+37 VDC
GND for VP1
+5 VDC switched by reset status

Pin
1
2
3
A-4
Signal Name
CUTON
CUTDIR
CUTTER
I/O
O
I
I
Function
Cut signal
Cut direction
Paper cutter mount/dismount
APPENDIX
4
5
6
7
CUTHPI
+5V
GND
RF
Cutter home position
Reverse point signal

Pin
1, 2
3, 4
5
6
7
8
Signal Name
+5V
GND
DRERR
/PD
CL
SD
I/O
I
O
O
O
I
I
Function
Printhead driver error signal

Power down signal
Current limit signal
Power shutdown signal

Pin
1, 2, 3, 4, 5, 6
7
8
9
10
11
12
13
14
15
16
17
18
19, 20, 21, 22, 23, 24
25
26
27
28
29
30
31
32
33
34
35
36
Signal Name
+5
BTXD
XREADY
BRXD
NC
BXRST
INH
XCMDREQ
XWRRDY
XRDREQ
XWR
XRD
XCS
GND
A3
A2
A1
A0
D7
D6
D5
D4
D3
D2
D1
D0
I/O
O
O
I
O
O
I
I
I
O
O
O
O
O
O
O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
Function
Transmit data
Ready
Receive data
Reset signal
Inhibit signal output
Command request signal
Write ready signal
Read request signal
Write signal
Read signal
Chip select signal
Address bus 3
Address bus 2
Address bus 1
Address bus 0
Data bus 7
Data bus 6
Data bus 5
Data bus 4
Data bus 3
Data bus 2
Data bus 1
Data bus 0
A-5
DFX-8500

Pin
1
2, 3, 4
5, 6, 7, 8
9, 10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26, 27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
A-6
Signal Name
VP3
GND
+5
VX
FAN
PLN
RFH/R
RFC
RFA
PGD
PGB
CRINS
I/O
O
O
O
O
O
O
O
I
CRI1
CRCLM
CRD
CRB
PFH/R
PFC
PFA
GND
TR_SEL
P_TRCT
P_JAM
F_PE
R_PE
T_PE
PGENCB
PGENCA
PGHOME
RBJAM
PLP
RFD
RFB
PGH/R
PGC
PGA
CRI2
CRI0
CRCLK
CRC
CRA
PFD
PFB
O
I
O
O
O
O
O
I
I
I
I
I
I
I
I
I
I
O
O
O
O
O
O
O
O
O
O
O
O
O
Function
+37 VDC
+5 VDC switched by reset status

HF control signal
Plunger negative channel
RF motor common
RF motor C phase pulse
RF motor A phase pulse
PG motor D phase pulse
PG motor B phase pulse
CR motor isolation resistance
monitoring
CR motor current limit signal 1
CR motor current limit signal
CR motor bridge D signal
CR motor bridge B signal
PF motor common
PF motor C phase pulse
PF motor A phase pulse
Tractor select signal
Pull tractor mount/dismount
Paper jam detection
Front paper end
Rear paper end
Top paper end
PG encoder B signal
PG encoder A signal
PG home position
Ribbon jam
Plunger P channel
RF motor bridge D signal
RF motor bridge B signal
PG motor common
PG motor C phase pulse
PG motor A phase pulse
Clock pulse for CR motor driver
CR motor bridge C signal
CR motor bridge A signal
PF motor bridge D signal
PF motor bridge B signal
APPENDIX

Pin
1
2
3
4
5
6
Signal Name
DIP1
DIP2
DIP3
DIP4
DIP5
DIPCNT1
I/O
I
I
I
I
I
O
Function
DIP switch bank 1 status
DIP switch bank3 status
DIP switch select port 1

Pin
1
2
3
4
5
6
7
Signal Name
DIPCNT2
DIPCNT3
DIPCNT4
DIPCNT5
DIPCNT6
DIPCNT7
DIPCNT8
I/O
O
O
O
O
O
O
O
Function
A-7
DFX-8500
Table A-16. C204 DRV Board Connector CN2

Pin
1, 3, 5, 8
2
4
6
7
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48, 49, 50
A-8
Signal Name
VP3
+5V
K
RBJAM
NC
INTLOC
FANDRV
INTLOC
INTLOC
GND
GP3
TR_SEL
PGHOME
RFD
RFCOM
RFB
RFA
PGCOM
RFC
PGA
PGD
PGC
PGB
PENCB
PENCA
R_PE
T_PE
+5V
F_PE
P_TRCT
P_JAM
PLGP
GND
CRB
PLGN
CRB
PFA
CRB
PFB
CRA
PFC
CRA
PFD
CRA
PFCOM
I/O
Function
+37 VDC
GND
Ribbon jam
GND
CR fan drive
GND
GND
GND for VP3
Tractor select signal
PG home position
RF motor phase D
RF motor common
RF motor phase A
PG motor common
RF motor phase C
PG motor phase A
PG motor phase D
PG motor phase C
PG motor phase B
PG encoder phase B
PG encoder phase A
Rear PE sensor
Top PE sensor
PE sensor front
Pull tractor
Paper jam sensor
Plunger
O
O
O
O
O
O
O
O
O
O
CR motor phase B
Plunger
CR motor phase B
PF motor phase A
CR motor phase B
PF motor phase B
CR motor phase A
PF motor phase C
CR motor phase A
PF motor phase D
CR motor phase A
PF motor common
APPENDIX
Table A-17. C204 DRV Board Connector CN3

Pin
1, 2, 3
4, 5, 6
Signal Name
VP3
GP3
I/O
Function
+37 VDC
GND for VP3
Table A-18. C204 DRV-B Board Connector CN1

Pin
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19, 20
Signal Name
P+6
P+4
P-18
P-4
P+14
P-14
P+18
P-6
P+15
P-5
P+13
P-3
P-15
P-13
P+5
P+3
P+8
P-8
NC
I/O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
Function
Printhead pin #6
Printhead pin #4
GND
GND
Printhead pin #14
GND
Printhead pin #18
GND
Printhead pin #15
GND
Printhead pin #13
GND
GND
GND
Printhead pin #5
Printhead pin #3
Printhead pin #8
GND
Table A-19. C204 PSB/PSE Board Connector CN1

Pin
1
2
3
Signal Name
L
NC
N
I/O
I
Function
AC input
AC input
Table A-20. C204 PSB/PSE Board Connector CN5

Pin
1
2
Signal Name
VP3
/FANDR
I/O
O
O
Function
Fan motor drive
A-9
DFX-8500
A.2 COMPONENT LAYOUT DIAGRAMS
Figure A-2. C204 Main Board Component Layout (1)
A-10
APPENDIX
Figure A-3. C204 Main Board Component Layout (2)
A-11
DFX-8500
Figure A-4. C204 DRV Board Component Layout (1)
Figure A-5. C204 DRV Board Component Layout (2)
A-12
APPENDIX
Figure A-6. C204 DRV-B Board Component Layout (1)
Figure A-7. C204 DRV-B Board Component Layout (2)
A-13
DFX-8500
Figure A-8. C204 PSB Board Component Layout
A-14
APPENDIX
Figure A-9. C204 PSE Board Component Layout
A-15
DFX-8500
A.3 CONNECTORS ON THE CONNECTOR JUNCTION BOARD
to C R M o to r
H P S e n s o r
to P G
to F /R T r a c to r S e le c t S e n s o r
M o to r
to P G
to T S /R F M o to r
E n c o d e r
to P G
to T o p P E S e n s o r
to R e a r P E S e n s o r
to P a p e r J a m
to F ro n t P E S e n s o r
to O p tio n P u ll T r a c to r S e n s o r
S e n s o r
to P lu n g e r
The figure below illustrates the arrangement of connectors on the connector junction board.
r C o lo r s
la c k
e d
h ite
ra y
e llo w
to R ib b o n J a m
S e n s o r
to In te r lo c k S w itc h
to F a n
B
B
e c to
: B
: R
: W
: G
: Y
W
W
C o n n
B
R
W
G
Y
W
to O p tio n C u tte r P o w e r
to P a p e r F e e d M o to r
to C R M o to r F a n
Figure A-10. Connectors on the Connector Junction Board
A-16
APPENDIX
A.4 PARTS LIST

Table A-20. Parts List
No.
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
Part Names
HOUSING ASSY.,LOWER
FRAME ASSY.,BOTTOM
COVER ASSY.,FRONT
HOUSING ASSY.,UPPER
HOUSING ASSY.,TOP
LOGO PLATE
COVER,PAPER SUPPORT
CAP,LOWER
COVER,REAR
CAP,MAGNET
HOUSING SUB ASSY.,TOP
COVER,I/F
MAGNET SUB ASSY.,TOP
MECHANISM MOUNTING SCREW
TOP COVER HINGE SCREW
HOLDER,CONTROL PANEL
HOUSING,LEFT
HOUSING,RIGHT
COVER,TOP,SUB ASSY.
COVER,PUSH TRACTOR SUB ASSY.
PAPER SUPPORT SUB ASSY.
MOUNT,INTERLOCK
SHIELD PLATE
C.B.S.(O) SCREW M3X8
C.B.(O) SCREW M4X6
C.P. SCREW WITH S/WM3X16
C.F.S.SCREW M3X10
C.B.B. SCREW M3X8
C.B.S. SCREW M3X8
C.B.SCREW M3X12
C.B.B. SCREW M3X10
C.B.B. SCREW M3X12
C.B.B.SCREW M4X10
C.B.B. SCREW M4X16
C.P.(PS) SCREW M4X8
C.B.S.SCREW, 4X14 F/ZN
C.B.S. SCREW M3X6
C.B.B. SCREW M3X10
C.F.B. SCREW M3X10
C.B.S. SCREW M3X4
METAL,TRANSPORT,FIX,LEFT
TRANSPORT LOCKING BRACKET
FERRITE CORE RISC-4
FERRITE CORE
FERRITE CORE RISC-8
No.
163
164
165
166
167
168
170
171
172
173
174
175
176
200
201
201
202
203
204
205
206
212
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
Part Names
SPACER,PS UNIT
LEAF SPRING,BASE FRAME
COVER, DIP SWITCH
COVER,CONNECTOR,UPPER ECW
C.B.(O)SCREW M3X8 F/ZN
CONNECTOR LOCK NUT for USA
CONNECTOR LOCK NUT for others
DETECTOR,INTER LOCK 2.5,30
BOARD ASSY.,SUB
GROUNDING PLATE,MECHANISM
PLATE
SHIELD PALTE,DRV-B
SHIELD PLATE,DRV
GRONDING PLATE,BLACKET
MOUNT,DIP SWITCH
BOARD ASSY.,MAIN
SCREW for USA
SCREW for EUR, S.E.ASIA, ACEANIA
GUIDE,I/F BOARD
BRACKET,I/F
SHIELD PLATE,MAIN
EARTH SPRING;B
HARNESS
C.B.S. SCREW M3X6
PRINTER MECHANISM,M-3I60
FRAME ASSY.,LEFT
FRAME ASSY.,RIGHT
SOLENOID ASSY.,LD
MOTOR ASSY.,PG
MOTOR ASSY.,CR
FRAME,LOWER
FRAME,FRONT
MOTOR ASSY.,PF DC4.34
PULLY ASSY.,BELT
TENSION PULLEY ASSEMBLY
FRAME ASSY.,MOTOR RF
TRACTOR SELECT DETECTOR
MOTOR ASSY.,RF
RIBBON FEED SELECT GEAR
TRACTOR SELECT LEVER UPPER
TRACTOR SELECT LEVER LOWER
TRACTOR SELECT LEVER SPRING
TRACTOR SELECT CAM
TRACTOR SELECT TRANSMISSION
GEAR
RIBBON FEED TRANSMISSION GEAR
A-17
DFX-8500
Table A-20. Parts List (continued)

No.
147
148
152
153
159
160
161
162
529
Part Names
+.ONEWAY PLA- LOCK,3X12,F/ZN
DAMPER SHEET
DAMPER SHEET;B
SHAFT,FRONT,LOWER,RIGHT ECW
SHAFT,FRONT,LOWER,LEFT
LEVER ASSY.,LOCK,LEFT
LEVER ASSY.,LOCK RIGHT
BOARD ASSY.,INTERMIT,HEAD
No.
521
522
523
524
525
526
527
528
587
530
531
532
533
534
535
536
537
538
539
540
541
543
544
545
546
547
548
549
550
551
552
553
554
555
556
557
558
559
561
562
563
564
565
BOARD ASSY.,INTERMIT,CARRIAGE
BOARD ASSY.,DETECTOR,PTS
PAPER ASSY.,SUPPORT
ROLLER ASSY.,LOAD
BLUSH,ELIMINATION ELECTLIC
DETECTOR ASSY.,PE,UPPER
DETECTOR ASSY.,PW
HARNES,CUTTER
HODLER,CR MOTOR
MOUNT PLATE,CR MOTOR
CABLE,BOARD,INTERMIT,HEAD
FAN
WIRE,TRACTOR
DETECTOR PLATE,PTS
WIRE BAND
RESISTOR
TRACTOR SUB ASSY.,LEFT,FRONT
TRACTOR,RIGHT,FRONT
PAPER SUPPORT
SHAFT,TRACTOR
TRACTOR GUIDE SHAFT
FRAME ASSY.,PF
TRACTOR SUB ASSY.,LEFT,REAR
TRACTOR,RIGHT,REAR
SPACER,PF ROLLER
ROLLER,PF,DRIVE
SPUR GEAR 18.4
SHAFT,CR,GUIDE,REAR
SHAFT,CR,GUIDE,FRONT
LEVER,SHAFT,LEFT
LEVER,SHAFT,RIGHT
GUIDE SHAFT HOLDING SPRING
LEVER,GAP,ADJUST
PAPER GAP ADJUSTMENT MIDDLE
GEAR
DUCT,FAN
COVER,CONNECTOR
DAMPER,LEFT
DAMPER,RIGHT
DAMPER,LOWER
588
589
590
591
592
593
595
596
597
598
599
600
601
602
603
604
605
606
607
608
610
611
612
613
614
615
616
617
618
619
620
621
622
623
Part Names
PAPER THICKNESS DETECTOR
DETECTOR ASSY.,PGHP
DETECTOR ASSY.,PULL TRACTOR
PAPER GUIDE,UPPER
CARRIAGE ASSY.
LEAD WIRE
BELT PULLEY HOLDER
PLATEN ASSY.
PLATEN ROLLER TRANSMISSION
GEAR
PLATEN ROLLER MIDDLE GEAR
TENSION ROLLER GEAR
PAPER BAIL GEAR
PAPER BAIL LEVER
CUP SCREW M3X30
TIMING BELT,PF
PAPER FEED REDUCTION GEAR
PAPER FEED MIDDLE GEAR
TRACTOR SELECT GEAR HOLDER
TENSION PULLEY SPRING
RIBBON FEED TRANSMISSION GEAR
PLAIN WASHER 3X0.2X9
C.P.S.P.SCREW M3X6 F/ZN
C.P.(C).(S) SCREW M4X10
C.P.S.(P) SCREW M3X6
C.P.(PS) SCREW M4X6
C.P.(S) SCREW M2.6X5 F/ZN
MINI CLAMPYMC-05-H-0
C.P.(PS) SCREW M4X8
C.P.S.P.SCREW M2.5X6
PLANE WASHER 4.1X0.2X7.8
RETAINING RING TYPE-E
LEAF SPRING4.1X0.13X8.3
H.N.F. M4
FLANGE NUT
C.P.S.(P.S) SCREW M3X8
RETAINING RING TYPE-E
C.B.S SCREW 4X8
LEAF SPRING 8.2X0.15X15
WIRE HOLDER
624
625
626
627
628
HEXAGON NUT M2
RIBBON FEED DRIVE GEAR
RIBBON FEED GEAR COVER
CABLE CLIP
ROCKING WIRE SADDLE
566
567
568
569
570
A-18
APPENDIX
Table A-20. Parts List (continued)

No.
571
572
573
574
575
576
577
579
580
581
582
584
585
586
647
648
649
650
651
652
653
654
655
Part Names
OIL PAD COVER
OIL PAD RING
FLAME,CABLE,HEAD
COVER,HEAD CABLE
SHAFT,FASTEN,HOLDER
TIMING BELT,CR
HOLDER,BELT FASTEN
FRAME,PAPER GUIDE MOUNT
EXTENSION SPRING,1000
PAPER GUIDE,LOWER
SHEET,HEAD CABLE,PROTECT
PLATEN ROLLER GEAR
PLATEN ROLLER SHAFT HOLDER
PLATEN ROLLER REDUCTION GEAR
SPUR,GEAR,40
EXTENSION SPRING,320
MOUNT PLATE WIRE,RIGHT
MOUNT PLATE,WIRE,LEFT
EXTENSION SPRING,40
SPUR GEAR,32
C.P.S SCREW,2X14,F/ZN
HEXAGON NUT A
HEXAGON NUT,B
No.
629
630
632
633
634
635
637
638
639
640
641
644
645
646
669
671
672
673
674
675
676
801
901
656
LEVER,TENSION,CANCEL
1001
657
658
660
661
662
663
664
665
666
667
668
BUSH,8
BUSH,12
RESISTOR 0OHM,
MOUNTING PLATE,FAN,CR
DOUBLE SIDE TAPE,20X10
SHAFT,FASTEN,DAMPER,LEFT
CABLE,SHIELD
BOARD ASSY.,INTERMIT,MECHANISM
SHEET,PROTECT,CABLE
COMPOSITION SCREW,FAN
1102
1203
1304
1405
1506
1607
1708
1809
1910
2011
2118
Part Names
C.P.(PS).SCREW M4X8
C.P.S.SCREW M2X10
C.P.S.(O) SCREW M3X6
C.P.S(P.S) SCREW,3X10,F/ZN
METAL FITTINGS,FASTEN,SHAFT
C.P.O SCREW M4X5
PLAIN WASHER 2.5X0.5X7.5
SHEET,DUST PROOF
C.B.S. SCREW M3X6
C.B.S. SCREW M3X8
C.B.S.SCREW M4X6
PLASTI RIVET
HOLDER,PLATEN,RIGHT
HOLDER,PLATEN,LEFT
FAN,CR
RIBON MASK SUB ASSY.
SPUR,GEAR,24
MOUNT PLATE,DETECTOR,RJ
DETECTOR ASSY.,RJ0V,0A,
HARNESS,FAN
PAPER GUIDE ASSY.,PJ DETECTOR
INDIVIDUAL CARTON FOR AMERICA
INDIVIDUAL CARTON BOX FOR
EUROPE
INDIVIDUAL CARTON BOX FOR
PACIFIC RIM
OUTER CARTON BOX
PAD,PRINTER,UPPER
SHEET,PRINTER
PAD,PRINTER,UNDER
SHEET A
SHEET B
JOINT
JOINTHP-601
CARRIAGE FIXING PLATE
PAD,PAPER GUIDE
PLASTIC BAG50X70X
A-19
DFX-8500
A.5 EXPLODED DIAGRAMS

See the following pages for exploded diagrams.
Figure A-11. Exploded Diagrams (1)
A-20
APPENDIX
A-21
DFX-8500
A-22
APPENDIX
A-23
DFX-8500
A-24
APPENDIX
A-25
DFX-8500
A-26
APPENDIX
A-27
DFX-8500
A.6 CIRCUIT DIAGRAMS

See the following pages for these circuit diagrams:

C204 Main Board

C204 DRV Board
C204 DRV-B Board
C204 PSB Board
C204 PSE Board
A-28

EPSON DFX-8500 Service Manual

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

EPSON DFX-8500 Service Manual

Uploaded by

Copyright:

Available Formats

Service Manual

Epson America, Inc.

FCC COMPLIANCE STATEMENT

Reorient or relocate the receiving antenna.