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SATO M-8400RV Thermal Label Printer

1. Label Sensor Selection DSW3 3 Enables or disables the Label Sensor If the Sensor is enabled it will detect the edge of the label and position it automatically If it is disabled the positioning must be under software control using Line Feed commands DSW3 3 SETTING 0508 on Back Feed Selection DSW3 4 When Back Feed is enabled the printer will position the label for dispensing cutting and retract it to the correct print position before printing the next label DSW3 4 SETTING ON Disabled Enabled OFF 1 2 3 4 5 6 7 8 External Signal Interface The EXT connector on the printer rear panel is intended for use with the external printer accessories such as label rewinders or applicators The 14 pin Centronics type connector provides a choice of four different output signals along with various error conditions DSW3 Print Start Signal Selection DSW3 5 DSW3 wes NOTE This switch must be in the ON position if a VeriScan is used to control the printer via the EXT connector 25 Rev C M 8400RV Service Manual SECTION 2 Configuration External Signal Type Selection DSW3 6 DSW3 7 Selects the type of output signal Refer to Section 3 6 for a description of the available external signal types Repeat Print via External Signal DSW3 8 Allows an external device to control the reprint of the label in the print buffer DSW3 DSW3 8 SETTING ON Disabled
2. 4 HIGH LEVEL ADJUSTMENT If you are using adhesive labels position the complete label face stock attached to the backing in the sensors field of view If using a tag position the tag so the notch is not in the sensors field of view Check the voltage reading If the voltage shown on your meter is 3 0 volts or more no further adjustment is required Go to Step 6 5 If the HIGH LEVEL ADJUSTMENT voltage indicated in Step 4 is less than 3 0 volts you must repeat Step 3 and adjust VR2 to a lower voltage value The target value should be 2 0 volts less than the high level voltage obtained in Step 4 6 Test your adjustment by properly installing a roll of label or tags and a roll of ribbon Power on the printer With the printer OFF LINE press the FEED key One label or tag should feed and no error should be indicated on the display VR2 PIN 1 amp 8 ROTATE CLOCKWISE 66 Rev C SATO M 8400RV Service Manual Section 4 Electrical Checks and Adjustments 4 6 Ribbon Sensor Adjustment Required Equipment Number 2 Phillips Screwdriver DC Voltmeter Small flathead screwdriver for potentiometer adjustment Refer to Section 4 2 for steps prior to adjustment 1 Connect the printer AC power cord to a grounded AC outlet Place the power switch in the ON position 2 On the main circuit board turn VR4 clockwise to the maximum position Refer to Fig 4 9 3 Attach the DC voltmeter negative lead
3. LABEL TEAR OFF COVER 1 SCREW 144 Rev C SATO M 8400RV SERVICE MANUAL SECTION 9 5 9 5 Label Cutter Unit REMOVE 2 SCREWS REMOVE 4 SCREWS HOLDING PRINT MECHANISM 1 SCREW SPACER PANEL LABEL CUTTER ATTACH TWO Fig 9 19 HINGE HALVES WITH 4 SCREWS 145 Rev C SATO M 8400RV SERVICE MANUAL SECTION 9 5 9 5 Label Cutter Unit 00008000 Lem CONNECTOR END VIEW AT CUTTER PCB END OF CABLE T SF hd E Fig 9 21 GRAY PLUGGED HOLE AND MISSING PIN ON CUTTER PCB DETERMINE REQUIRED ORIENTATION PLASTIC KEYS ON CABLE CONNECTOR HOUSING DO NOT PREVENT INCORRECT CONNECTION HOWEVER THE KEYS ARE ALSO PROVIDED AS AN ORIENTATION DEVICE AND MUST FACE DOWN WHEN CONNECTING CABLE TO CUTTER PCB CONNECTOR FROM PRINT MECHANISM CONNECTOR FROM PRINT MECHANISM 146 Rev C SATO M 8400RV SERVICE MANUAL SECTION 9 5 9 5 Label Cutter Unit SECURE WITH SCREW TO PRINT MECHANISM LOOSEN 2 SCREWS ON LABEL CUTTER 9 6 Calendar The Calendar Option allows the date and time to be maintained in the local printer rather than using the system clock It consists of a special clock chip that replaces the EEPROM on the main PCB A qualified technician should perform the upgrade as it requires modifications to the main PCB FOR THIS OPTION CONTACT FACTORY SATO
4. pins 1 3 4 and 6 each have open collector output These pins normally measure 07 maximum when a true condition exists If a false condition occurs the voltage will drop to To achieve a signal level of 5V you must add a 1K ohm W pull up resistor between the open collector output pin and Vcc pin 13 as illustrated This will provide a signal level of 5V for a true condition and when a false condition exists The maximum voltage that can be applied to these pins is 50V and the maximum current they can sink is 500 milliamps 57 Rev C SATO M 8400RV Service Manual SECTION 3 Interface Specifications 3 6 Accessory EXT Connector Cont External Output Signal Types Pin 13 Vcc 5V na 1 K ohm 14W Signal Out Pin 1 34 0r 6 45V TYPE 1 OV 20 milliseconds 45V TYPE 2 OV 5V TYPE 3 0v 5V 52 7 7 4 Start Print End Print Label Feed Label Feed Stop Stop 58 Rev C SATO M 8400RV Service Manual Section Electrical Checks and Adjustments 4 1 Overview This chapter describes how to check M 8400RV voltage levels and adjust threshold sensor voltages The M 8400RV power supply converts 125 VAC into regulated DC voltages The printer uses 5V 12V 12V and 24V These DC voltages are not adjustable however you can measure these DC voltages at test points located on the If a voltage is out
5. 84 Hv M 8400RV Service Manual Section Replacement Procedures 6 1 Overview The SATO M 8400RV printer contains replaceable components and sub assemblies This chapter contains step by step instructions for removing and replacing the following components and sub assemblies e Fuses e Print Head e Main Circuit Board e Power Supply e Label Sensor e Ribbon Motion Sensor e Ribbon Clutch Washers e Timing Belts e Platen e Display Panel Stepper Motor 85 Rev C SATO M 8400RV Service Manual SECTION 6 Replacement Procedures 6 2 Replacing Fuses Fuse replacement is described in the following section 6 2 1 Removing and Replacing the Main Power Fuse e 6 2 2 Removing and Replacing the 5V Fuse e 6 2 2 Removing and Replacing the 24VDC External Fuse NOTE Before replacing a fuse determine the cause of the overload condition 6 2 1 Removing and Replacing the Main Power Fuse Required Equipment T3 15 Amp 250 V Fuse STEP PROCEDURE 1 Switch the printer OFF and disconnect the power cable 2 On the back of the printer locate the fuse cap Unscrew the remove the defective fuse 3 Replace the fuse with one of equal rating 13 15 Amp 250 V Do not use a fuse with a higher rating Fig 6 1 4 Screw the fuse cap back and connect the power cable BACK OF PRINTER FUSE UNDER COVER 86 Rev C M 8400RV Service Manual SECTION 6 Repla
6. Remove 2 screws holding the label cover to the printer Rotate the cover down then remove it by lifting up Refer to Fig 9 5 Move the print head lock lever to the open position Refer to Fig 9 6 Insert the Dispenser in place of the cover removed in Step 4 carefully mating the Dispenser s drive gears with those of the print mechanism while routing the cable through the slot in the printer side wall Refer to Fig 9 7 NOTE Remove and dispose of extra screw from the side of the Dispenser side wall Replace the 2 screws removed in Step 4 Mate the cable from the Dispenser to the socket on the free end of the 3 wire cable carefully observing the keying of the connectors Refer to Fig 9 8 Carefully route all cables and close the door and lid and secure cover with screws removed in Step 3 Connect the AC power cord to the printer and place the power switch in the ON position The installation of the Dispenser is now complete 137 Rev C SATO M 8400RV SERVICE MANUAL SECTION 9 5 9 3 Label Dispenser Unit Installation LOCK LEVER SHOWN IN OPEN POSITION Fig 9 5 LABEL COVER MOTOR MOUNTING SCREWS 2 SCREWS MATE DISPENSER GEARS TO PRINTER GEARS ROUTE CABLE THROUGH SLOT MATE CABLE FROM DISPENSER TO THE SOCKET OBSERVE Fig 9 8 OF CONNECTORS 138 Rev C SATO M 8400RV SERVICE
7. 1 0V or less 2 0V to 3 5V If the measured values are outside this range you may have trouble finding a value that will work properly under all conditions If this is the case a higher quality label may be needed to get adequate performance or adjust VR2 See Section 4 5 Calculate the starting point voltage using the formula above Use the LINE key to step the counter to the desired setting The display will increment one step for each time the LINE key is pressed If the LINE key is held down for more than two seconds it will automatically go into the fast scroll mode The reading will advance to a setting of 4 9 the maximum voltage after which it will automatically wrap and start at 0 0 again If a value of 0 0 is set the printer will automatically set the level between the two measured voltages each time the printer is powered on with labels loaded 5 Repeat this procedure using values slightly higher or lower until the optimum performance is obtained If you cannot find a setting between the high and low readings that gives adequate performance then the label stock has too much variation in its opacity and a better quality stock should be used 6 Once the setting is correct press the FEED key to accept the setting 38 Rev C SATO M 8400RV Service Manual SECTION 2 Configuration Sensor Threshold Level Continued Eye I Mark Reflective Sensor When setting the Eye I Mark th
8. OFFSET 8492 Horizontal Offset is the distance that the label image is shifted either to the right or left on the label The image is shifted to the left towards the inside edge of the label for a positive setting and is shifted to the right towards the outside edge of the label for a negative setting This setting changes the base reference point for all subsequent label jobs It s effect is identical to the ESC A3 Base Reference point command Since the printer can only print in discrete steps equal to the size of the print dot the units of measure for the Horizontal Offset distance is dots Note This setting can be overridden by the Base Reference Point Command It is recommended that you relocate printing in your software as adjustments made here will affect all of your label formats To access this setting perform the following steps STEP PROCEDURE 1 Use the LINE key to step the underline to either the positive or negative selection A positive selection increases moves the horizontal reference point for the label to the right edge of the label towards the outside while a negative selection moves the horizontal reference point for the label to the left towards the inside of the printer 2 Once the setting is underlined press the FEED key to accept the setting and advance the display to the Horizontal Offset adjustment 3 Use the LINE key to step the counter to the desired setting The display
9. 5232 Serial Interface Cont Pin Assignments Cont RS232C Interface Signals PIN DIRECTION SIGNAL DESCRIPTION 4 To Host RTS Request to Send Used with Ready Busy flow control to indicate an error condition RTS is high and remains high unless the print head is open in this case RTS would return to the high state after the print head is closed and the printer is placed back on line or an error condition occurs during printing e g ribbon out label out 5 To Printer CTS Clear to Send When this line is high the printer assumes that data is ready to be transmitted The printer will not receive data when this line is low If this line is not being used it should be tied high to pin 4 To Printer DSR Data Set Ready When this line is high the printer will be ready to receive data This line must be high before data is transmitted If this line is not being used it should be tied high to pin 20 To Host DTR Data Terminal This signal applies to Ready Busy flow control The printer is ready to receive data when this pin is high It goes low when the printer is off line either manually or due to an error condition and while printing in the Single Job Buffer mode It will also go low when the data in the buffer reaches the Buffer Near Full level Ready Busy Flow Control Ready Busy is the hardware flow control for the serial interface on the M8400RV printer By raising lowering the vol
10. EM T M LL Aa i Fig 4 4 1 5 5 MAIN CIRCUIT BOARD Fig 4 6 62 Rev C SATO M 8400RV Service Manual Section 4 Electrical Checks and Adjustments 4 4 Reflective I Mark Label Pitch Sensor Adjustment Required Equipment Number 2 Phillips Screwdriver DC Voltmeter Digital preferred w small alligator clip voltage probes Small flathead screwdriver for potentiometer adjustment NOTE Dip Switch setting for DSW2 2 Select I Mark must be in the ON position for using this procedure To adjust the Reflective Label Pitch Sensor voltage perform the following steps STEP PROCEDURE Refer to Section 4 2 for steps prior to adjustment 1 Load a roll of label stock with a black ink into the printer Leave the print head lock lever in the OPEN up position 2 On the main circuit board turn 1 clockwise to the maximum position Refer to Fig 4 7 3 Attach the DC voltmeter negative lead small alligator clip recommended to pin 1 ground of the test point pin array labeled CH on the main circuit board Attach the DC voltmeter positive lead to pin 7 of the CH test point pin array 4 LOW LEVEL ADJUSTMENT I Mark Position the label tag in the sensors field of view Refer to Section 1 7 for sensor location Be sure that the printed I Mark is not in the sensors field of vie
11. Rev C M 8400RV Service Manual SECTION 6 Replacement Procedures 6 5 Replacing the Power Supply REMOVE 2 SCREWS OPPOSITE SIDE CABLE CONNECTIONS Fig 6 8b FUSE WIRING POWER UNIT 9 SHOWN DETACHED PCB SHOWN one DETACHED 93 Rev C SATO M 8400RV Service Manual SECTION 6 Replacement Procedures 6 6 Replacing the Label Pitch Sensor Assembly The Label Sensor Assembly can be removed from the printer to clear label fragments and for service No critical alignment is required when replacing the sensors Required Equipment 2 Phillips Screw Driver To remove and replace the Label Sensor perform the following steps and refer to the illustrations STEP PROCEDURE 10 Switch the printer OFF and disconnect the power cable Open the top and side access doors on the mechanical side of the printer Loosen 2 inside screws holding the LH cover to the inside top of the printer and remove 2 screws holding the cover to the frame Lift off the cover for access to the sensor module Refer to Fig 4 1 4 2 amp 4 3 in Section 4 Remove 1 screw securing label tear off cover Rotate forward and lift to remove Refer to Fig 6 9 Remove 2 screws from the bracket that holds the module to the side frame Fig 6 10 6 11 Carefully glide the sensor back out through the access opening Fig 6 10 amp 6 12 Detach 2 top connectors from the PCB to free the sensor from the pr
12. e SECTION 8 TROUBLESHOOTING e SECTION 9 OPTIONS Rev C M 8400RV Service Manual SECTION 1 Overview amp Specifications 1 2 Physical Characteristics TOP ACCESS DOOR LEFT SIDE SIDE ACCESS DOOR DIMENSIONS 10 4 in 265 17 in 430 13 341 40 Ibs 18 Kg POWER REQUIREMENTS Voltage 100 115 V 10 96 220 V 10 96 50 60 Hz 1 Power Consumption 50 Watts ldle 130 Watts Operating Rev C M 8400RV Service Manual SECTION 1 Overview amp Specifications 1 3 Components DIP SWITCH CONFIGURATION TABLE MEDIA LOADING PROGRAM TOP ACCESS DOOR RIBBON SUPPLY SPINDLE MEDIA HOLDER RIBBON REWIND SPINDLE SIDE ACCESS DOOR LABEL ROLL RETAINER SENSORS AND SWITCHES LCD DISPLAY Refer to Section 1 7 HEAD LATCH PRINT HEA ASSEMBLY OPERATOR PANEL PLATEN ROLLE POWER ON OFF LABEL SENSOR SWITCH POSITIONING ADJUSTMENT Rev C M 8400RV Service Manual SECTION 1 Overview amp Specifications 1 3 Components POWER SUPPLY UNIT MAIN PC BOARD OF PANEL LCD BOARD _ LED BOARD BACKSIDE 2a TEAR OFF LABEL COVER STEPPER MOTOR SHAFT TIMING BELTS Rev C SATO M 8400RV Service Manual SECTION 1 Overview amp Specifications 1 4 Ribbon Use only SATO thermal transfer ribbons which were formulate
13. Enabled 1 2 3 4 5 6 7 Note Switch functions listed incorporate the latest firmware revisions at the time of printing 26 Rev C SATO M 8400RV Service Manual SECTION 2 Configuration 2 2 Default Settings Switch Selections All switches are placed in the Off position default for shipping This will result in the following operating configuration Communications 8 data bits no parity 1 Stop bit 9600 Baud Protocol Ready Busy Sensor Gap Sensor Receive Buffer Single Job Mode Batch continuous Label Sensor Sensor Used Back feed Disabled External Signals Disabled Software Default Settings The M8400RV stores the software settings upon receipt and uses them until they are again changed by receipt of a command containing a new setting These settings are stored in non volatile RAM and are not affected by powering the printer off The printer may be reset to use the default software settings by depressing the LINE and FEED keys simultaneously while powering the printer on This will result in the following default configuration User Mode Default Settings Print Darkness 3 Speed 3 6 inches per second Pitch Offset 00mm Advanced Mode Default Settings Zero Slash YES Auto Online YES b us DEFRULT SETTING Horiz 0000 E Input 1 5 COMPLETED Calendar Enabled NO Ignore CR LF NO Print Darkness 1 Once the default o
14. LCD panel Note If the printer firmware version you are using is 1E2040 or higher the advanced mode is split into two sections Setup and Counters The LINE key is used to toggle between these two sections Press the FEED key to enter the selected section For the Setup section see next page For the counters section refer to page 42 For other firmware versions the counters information can only be accessed by performing a large test print as shown on page 43 To reset the counters refer to Section 7 Factory Resets Counter Clear on page 114 From the advanced mode display the advanced settings are accessed in sequence by pressing the FEED key or the YES NO keys 32 Rev C SATO M 8400RV Service Manual SECTION 2 Configuration Advanced Mode Flow Refer to the following pages for a full description of each setting ADVANCED MODE CALENDAR ENABLED SETUP VES FEED KEY CBLEHDHE 25 245 ae a a IGNORE YES Ho PRINT CHRRKNESS 1 EXIT MODE YES HDURHCED MODE OFFLIHE SETUP Hanan Press FEED KEY to recycle back through the ADVANCED MODE SETUP section or press the LINE key to select the counters section For the counters section refer to page 42 ZERO SLASH YES HO AUTO HO YES FEED _ Rev M 8400RV Service Manual SECTION 2 Configuration 2 4 Advanced Mode Settings and Ad
15. SATO M 8400RV SERVICE MANUAL SECTION 9 5 9 2 CLEARANCE HOLE IN BACK PANEL BRACKET A WITH SCREW BRACKET B WITH 2 SCREWS Fig 9 1 BRACKET WITH x c 2 SCREWS a Fig 9 2 INSTALL END TO MAIN 4 MOUNTING MEMORY PCB PCB CONNECTOR SCREWS SEE FIG 9 3 134 Rev C SATO M 8400RV SERVICE MANUAL SECTION 9 5 9 2 a CARD Fig 9 3 PCB CONNECTOR F CONNECTOR FROM MEMORY CARD Wy KEY ALIGNMENT MEMORY SLOT a MEMORY MODULE m SHOWN INSTALLED m IN MEMORY SLOT i CARD 1 A 11 a E 44 EL Fig 9 4 135 Rev C SATO M 8400RV SERVICE MANUAL SECTION 9 5 9 2 Error Handling ERROR DESCRIPTION INDICATION REMEDY Low Battery Low battery condition is ERROR LED Blinking Replace Memory Card battery detected when printer is powered on Audible Beep 1 long Note that all data will be lost Display Card Low Battery when the battery is removed Depress LINE key to print Card Status Card R W Error ERRORLED On 1 Insert card into selected slot 1 Nocardis inserted Audible Beep 1 long 2 Remove write protect tab Card is write protected Display Card R W Error 3 Correct program 2 3 Invalid store recall number 4 Initialize card
16. To avoid damage from static electricity do not unpack new circuit boards from anti static bags until instructed to do so STEP PROCEDURE 1 Switch the printer OFF but keep the power cable plugged in to discharge any possible static charges 2 Open the top and side access doors on the mechanical side of the printer 3 Loosen 2 inside screws holding the LH cover to the inside top of the printer and remove 2 screws holding the cover to the frame Lift off the cover for access to the electrical section Refer to Fig 4 1 4 2 amp 4 3 in Section 4 4 Refer to Fig 9 1 and install the brackets a Insert 1 self tapping screw through clearance hole in printer back panel and thread into Bracket b Insert 2 self tapping screws through clearance holes in Bracket and thread into printer base Insert 2 self tapping screws through clearance holes in Bracket and thread into printer base Tighten all screws firmly 5 Fasten memory PCB to brackets with 4 screws Refer to Fig 9 2 6 Route the cable from the memory card and attach to the connector which is located on the back side of the main PCB Note proper key alignment Refer to Fig 9 3 75 Install memory module s Refer to Fig 9 4 8 Upon completion of memory installation replace and secure the LH cover to the printer base with 2 screws previously removed Tighten 2 inside screws and reconnect the power 133 Rev C
17. the ribbon feed roller and the ribbon rewind spindle via a series of toothed pulleys and timing belts STEP PROCEDURE 10 11 Required Equipment 2 Phillips Screw Driver Switch the printer OFF and disconnect the power cable Open the top and side access doors on the mechanical side of the printer Loosen 2 inside screws holding the LH cover to the inside top of the printer and remove 2 screws holding the cover to the frame Lift off the cover for access to the timing belts Refer to Fig 4 1 4 2 amp 4 3 in Section 4 Remove the ribbon and label stock if installed Remove 1 screw holding the label tear off cover Fig 6 34 Remove 2 mounting screws attaching the stepper motor to the frame Access the body of the motor from the opening previously covered by the label cover Detach the motor from the belts Fig 6 35 Unfasten and remove the pulley from the motor shaft Detach 2 screws holding wires to the Label Out Sensor Micro Switch Remove and replace the motor Fig 6 36 Reattach the wires to the Label Out Sensor Remount the motor to the frame and secure the pulley to the motor shaft Adjust belt tension as outlined in Section 5 9 Replace the label tear off cover and replace the LH cover Reconnect the power 109 Rev C M 8400RV Service Manual SECTION 6 Replacement Procedures 6 12 Replacing the Stepper Motor LABEL TEAR OFF COVER STEPPER SENSOR AND SCRE
18. 6 7 8 Head Check Selection DSW2 3 When selected the printer will check for head elements that are electrically malfunctioning DSW2 DSW2 3 SETTING ON Disabled Enabled WS a Hex Dump Selection DSW2 4 Selects Hex Dump mode DSW2 4 SETTING ON DSW2 Disabled OFF Enabled 1 2 3 4 5 6 7 8 Receive Buffer Selection DSW2 5 20 Rev C SATO M 8400RV Service Manual SECTION 2 Configuration Selects the operating mode of the receive buffer Note The Centronics interface operates only in the multi job buffer mode regardless of the switch setting DSW2 serm Protocol Control Code Selection DSW2 6 amp DSW2 7 Selects the command codes used for protocol control Reserved for Future Use DSW2 6 NOTE The Centronics Parallel communications port on the M8400RV is always enabled regardless of the settings for the RS232 port There are no settings for Centronics Both the Centronics and the RS232 ports are active at all times Care should be taken to ensure that data is not transmitted to both ports simultaneously as the received message will be corrupted Selecting Protocol Control Codes Protocol control codes are used to tell the printer that a specific type of information is being transmitted to the printer As an example the Standard Protocol Command Code specifies the use of an lt ESC gt character to tell the printer that the
19. Centronics Parallel Interface Pin Assignments sw Pe 2 _ Pe reemer 2s Tem _ s reemer 2 Tem _ o pep mg owe Drs pene 56 Rev C SATO M 8400RV Service Manual SECTION 3 Interface Specifications 3 6 Accessory EXT Connector The Accessory or EXT connector on the M8400RV printer is intended for use with the external printer accessories such as label rewinders or applicators The 14 pin Centronics type connector provides a choice of four different output signals along with various error conditions PIN Assignments Pm DRECTION SONADESCRPRON Label Out This pin goes low 0V when a label out error exists such as head open or receiving buffer full 5 To Printer Print Start The printer will print one label when this pin is pulled to ground This signal must be enabled by placing switch DSW3 5 on the Control Panel in the ON position End Print It is used to drive an applicator or other external device requiring synchronization with the print cycle You may choose between four types of output signals using control panel DSW3 6 and DSW3 7 selections To Printer Print Repeat The printer repeatedly prints the current label in the print buffer immediately after receiving this signal DSW3 8 must be ON 2 NOTE The signals
20. Electrical Checks and Adjustments 4 8 Pitch Offset Adjustment Service Use Pitch VR to adjust print position and Offset VR to adjust stop position Required Equipment Small flathead screwdriver for potentiometer adjustment STEP PROCEDURE Tolerance of VR5 on main PCB 3 75 mm Turn the Pitch VR to the center position on the front panel and VR5 on the main PCB to the center position Refer to Fig 4 11 amp 4 12 Place the print head in the open position and the DSW2 5 on the front panel in the ON position Turn on the power while pressing the LINE amp FEED keys Release when an audible tone is heard Place the print head back in the closed position and DSW2 5 in the OFF position Verify display Factory Mode Press the FEED key once and verify display COUNTER CLEAR HERD Press the FEED key Press the LINE key to initiate test Printing Press FEED key again to stop Printing Adjust VR5 on main while confirming with scale test print Repeat Step 6 if necessary Press FEED key to stop test print then turn the power off gt mr 6 4 Fig 4 11 69 SATO M 8400RV Service Manual Rev SECTION 4 Electrical Checks and Adjustments 4 9 Feed Backfeed Adjustment Tear Off Mode Use Offset to adjust label stop position Required Equipment Small flathead screwdriver for potentiometer adjustment STEP PROC
21. LINE key is pressed 2 Month After you have set the correct year press the FEED key to advance the underline cursor to the two digit Month position Press the LINE key to scroll through the numbers corresponding to the month The month number will increase by one value each time the LINE key is pressed 3 Day After you have set the correct month press the FEED key to advance the underline cursor to the two digit Day position Press the LINE key to scroll through the numbers corresponding to the date The date number will increase by one value each time the LINE key is pressed 4 Hour After you have set the correct date press the FEED key to advance the underline cursor to the two digit Hour position Press the LINE key to scroll through the numbers corresponding to the hour using a 24 hour clock The hour number will increase by one value each time the LINE key is pressed 5 Minute After you have set the correct hour press the FEED key to advance the underline cursor to the two digit minute position Press the LINE key to scroll through the numbers corresponding to the minute The minute number will increase by one value each time the LINE key is pressed 6 After you have set the calendar press the FEED key to accept the setting and advance to the next display 40 Rev C SATO M 8400RV Service Manual SECTION 2 Configuration Ignore Carriage Return Line Feed IGNORE CRLF YES This setting is
22. M 8400RV SERVICE MANUAL 147 Rev C
23. MANUAL SECTION 9 5 9 3 Label Dispenser Unit Setup STEP PROCEDURE Install the label dispenser as directed Power on the printer The printer must be configured to use the label dispenser option Remove one or two lead labels from the backing paper Open the label dispenser by lifting up its front panel and swinging open the unit such that the knurled roller is easily seen 6 Open the print head assembly and feed the lead of the backing paper through the print area in the normal manner 7 At the label exit area feed the backing paper down and behind the knurled roller then out the lower exit of the label dispenser 8 Close the front panel of the label dispenser until it locks into place and again is flush with the front of the printer 9 Close the print head assembly and place the printer on line 10 The label dispenser is ready for use General Operation Send your data stream in the normal manner to the printer Labels should print one at a time even if your print quantity command requests more than one label As labels are printed and presented for the operator to remove the backing paper will continue to feed out the dispenser s lower exit path If the dispenser s backfeed option has been set to TRIGGER in the printer configuration the next label will print only after removing the current label from the label exit path You may also control th
24. Section Overview and Specifications 1 1 Overview The SATO M 8400RV Printer Service Manual provides information for installing and maintaining the M 8400RV printer Step by step maintenance instructions are included in this manual with typical problems and solutions It is recommended that you become familiar with each section in this manual before installing and maintaining the printer The M 8400RV printer has a resolution of 203 dpi and can print labels up to four inches wide It uses the standard SATO RISC printer command codes and the only difference between it and other RISC printers are the allowable values representing the print positions on the label These values are specified in dots and will vary depending upon the resolution of the printer and the amount of memory available for imaging the label The allowable range for the M 8400RV is specified in a table for those command codes The M 8400RV is compatible with the standard M 8400 The main difference is how it receives the command sequence and how it responds to certain commands Refer to the Operator and Technical Reference Manual for other information This manual is divided into the following nine sections e SECTION 1 OVERVIEW AND SPECIFICATIONS e SECTION 2 CONFIGURATION SECTION 3 INTERFACE SPECIFICATIONS SECTION 4 ELECTRICAL CHECKS AND ADJUSTMENTS e SECTION 5 MECHANICAL ADJUSTMENTS SECTION 6 REPLACEMENT PROCEDURES e SECTION 7 FACTORY RESETS
25. all jobs in the order they are received by the printer and the order of printing cannot be changed Single Job Buffer The printer receives and prints one job at a time Each job must not exceed 64 K bytes Multi Job Buffer The printer is able to continuously receive print jobs compiling and printing other jobs at the same time It acts much like a print buffer to maximize the performance of the host and the printer When using the RS232 Serial interface the Multi Job Buffer uses either the Ready Busy with DTR pin 20 or X On X Off flow control protocols See these sections for more details With an empty receiving buffer the status of DTR is high or an X On status if using X On X Off meaning the printer is ready to receive data When the receive buffer is holding 62K bytes of data 2K bytes from being full DTR will go low or an X Off is sent indicating the printer can no longer receive data This condition is called Buffer Near Full See Figure 3 1 46 Rev C SATO M 8400RV Service Manual SECTION 3 Interface Specifications Multi Job Buffer Cont 0 62K 64K DTR High or X On DTR Low or X Off Buffer Near Full Fig 3 1 The receiving buffer will not be able to receive more data again until a Buffer Available condition occurs This takes place when the receiving buffer has emptied so that only 56K bytes of data are being held 8K bytes from being full At this t
26. all the heating elements on the print head and therefore should be used for testing purposes only to avoid damaging the print head especially when performed with labels less than the full width of the print head Place the printers power switch to the OFF position and return all switches to their original positions Refer to Page 118 for test print sample 116 Rev SATO M 8400RV Service Manual SECTION 7 Factory Resets 7 5 Clear Cutter Counter STEP PROCEDURE Record all current dip switch positions then place all switches in the off position Place the print head in the open position and the DSW2 5 in the ON position Turn on the power while pressing the LINE amp FEED keys Release when an audible tone is heard Place the print head back in the closed position and DSW2 5 in the off position Verify display Factory Mode Press the FEED key once Verify display Press the LINE key three times to change the display to CUT Press the FEED key The cut counter will be reset to 0 zero COUNTER CLEAR CUT Press the LINE key once After a slight pause 1 blank label will feed out followed by a factory test print Warning This test activates all the heating elements on the print head and therefore should be used for testing purposes only to avoid damaging the print head especially when performed with labels less than the full width of the print head Verify that cutter co
27. capital letters e Your protocol codes are set for Standard or Non Standard and your data stream is consistent with these 5 If you ve checked all of the above and the printer still isn t printing you may want to try a Receive Buffer Hex Dump to determine what if anything the printer is receiving from your computer See Hex Dump Diagnostic Labels The Centronics port is now listening for incoming data Send your print job The printer will now print only once a Hexadecimal Hex Dump of everything it received from the host computer Each 2 digit hexadecimal character represents a character the printer received It may be tedious but now you can analyze and troubleshoot the data stream 6 While checking the Hex Dump printout if you notice OD Carriage Return and Line Feed characters throughout The command string should be continuous CR or characters are not allowed between the Start Command lt gt and the Stop Command lt 5 gt 2 If you are using BASIC it may be adding these characters automatically as the line wraps Adding width statement to your program can help to suppress these extra OD OA characters by expanding the line length up to 255 characters If you re not programming in BASIC check to see if you have an equivalent statement in the language you re using to suppress extra carriage returns and line feeds from your data being sent out to the printer We want the data stream to be one com
28. darker settings The current setting is indicated by a line under one of the range settings To change the setting perform the following steps STEP PROCEDURE 1 Use the LINE key to step underlined cursor to the desired setting 2 Once the correct setting is underlined press the FEED key to accept the setting and advance to the next adjustment Note The setting can be overridden by software Finer adjustments can also be made using the PRINT potentiometer setting on the adjustment panel 29 Rev C M 8400RV Service Manual SECTION 2 Configuration Print Speed Adjustment There are five SPEED settings on the M8400RV Each setting is listed on the bottom line of the display The current setting is indicated by a line under one of the speed settings DSW2 8 OFF DSW2 8 ON Print Speed 1 2 ips 1 2 ips FRIHT SPEED Setting 2 4 ips 2 3 ips 3 c 3 6ips 3 4 ips 4 8 ips 4 5 ips 5 10 ips 5 6 ips To change the setting perform the following steps STEP PROCEDURE 1 Use the LINE key to step the underlined cursor to the desired setting 2 Once the correct setting is underlined press the FEED key to accept the setting and advance to the next adjustment Pitch Offset Note This setting can be overridden by software Pitch Offset and Direction The label pitch is the distance from the leading edge the edge that comes out of the printer first of a label and
29. following character s will represent a specific command Sometimes the host computer is unable to generate the character or it uses the lt ESC gt character to control another function In this case an Alternate Protocol Command Code set can be selected for use by placing DIP switch 2 7 in the ON position When the Alternate set is selected The lt ESC gt character is not used and is instead replaced with a carrot character A command stream would then start with an A instead of an lt 5 gt These two sets of Protocol Command Codes are adequate for the majority of all applications but occasionally situations occur where conflicts exist when using the Alternate set In these cases the user can define and download a custom set of Protocol Command Codes that are stored in EEPROM memory in the printer After these are downloaded they replace the Alternate Command Code set when DIP switch DSW2 7 is in the ON position When DIP switch DSW2 7 is in the OFF position the Standard Protocol Command Codes are used 21 Rev C M 8400RV Service Manual SECTION 2 Configuration Selecting Protocol Control Codes Cont Download Command Structure The command for downloading a new set of Protocol Command Codes takes the form of lt ESC gt LD a b c d e f g h i The parameters specified for a through i can be transmitted in either ASCII characters or hex notation allowing a complete 128 charac
30. host requests printer status it transmits an ENQ to the printer and the printer will respond with its status within five milliseconds If printing it will respond upon finishing the current label then resume printing In order for this protocol to work properly pin 6 DTR and pin 5 CTS must be held high by the host One way to ensure these pins are always in the correct state is to tie pin 20 DTR to pin 6 DSR and pin 4 RTS to pin 5 CTS at the printer end of the cable Cable Requirements 2 TD Transmit Data 3 RD Receive Data 4RI eqestoSen LLL p i oons __ E m om Temara If a CAN 18 hexadecimal is received by the printer it will cancel the current print job and clear all data from the receive buffer 52 Rev C SATO M 8400RV Service Manual SECTION 3 Interface Specifications 3 4 5232 Serial Interface Cont Bi Directional Communications Cont Status Response The Bi Directional protocol is an advanced version of bi directional communications where the printer can also report the number of labels remaining to be printed for the current print job Upon receipt of an ENQ command the printer responds with nine bytes of status information bounded by an STX ETX pair The Bi Directional protocol works only in the Multi Job Buffer mode The status information is defined as follows lt STX gt 2 Byte ID 1 Status Byte 6 Byte Label Remaini
31. pin 20 control characters representing Printer Ready X On 11 hexadecimal or Printer Busy X Off 13 hexadecimal are transmitted by the printer on pin 2 Transmit Data to the host In order for this method of flow control to function correctly the host must be capable of supporting it X On X Off operates a manner similar to the function of pin 20 as previously explained When the printer is first powered on and goes on line an X On is sent out In the Single Job Buffer mode when the printer receives a viable job it transmits an X Off and begins printing When it is done printing it transmits an X On In the Multi Job Buffer mode the printer sends an X Off when the Buffer Near Full level is reached and a X On when the data level of the buffer drops below the Buffer Available mark When the printer is taken off line manually it transmits an X Off indicating it cannot accept data When it is placed back on line manually it sends an X On indicating it is again available for receipt of data If an error occurs during printing paper out ribbon out the printer sends nothing in the Single Job Buffer mode since the last character transmitted was an X Off When the error is cleared and the printer resumes printing no X On is sent until the current job is completed and the printer is once again read to receive the next job If it is in the Multi Job Buffer mode it sends an X Off as soon as an error condition is detected Whe
32. stop the test label print pause the printer and then turn power off without placing it On Line 44 Rev C SATO M 8400RV Service Manual Section Interface Specifications 3 1 Overview This section explains the interface specifications for the M8400RV printer These specifications include detailed information on how to properly interface your printer with your host system and includes data about the following e INTERFACE TYPES e USING THE RECEIVE BUFFER RS232C SERIAL INTERFACE CENTRONICS PARALLEL INTERFACE ACCESSORY EXT CONNECTOR 3 2 Interface Types In order to provide flexibility in communicating with a variety of host computer systems all M8400RV printers can be configured for operation with either parallel or serial data transfers Both a parallel Centronics and a serial RS232 interface are supplied with the standard printer The Centronics Parallel interface will probably be the most useful in communicating with IBM PCs and compatibles The RS232C Serial interface allows connectivity to a number of other hosts For instructions on how to properly configure the M8400RV printer for either of these interface types see the printer configuration instructions in Section 2 of this manual NOTE Both the Centronics and RS232C interfaces are active at the same time i e data can be received on either one however no provision is made for port contention If data is transmitted to both ports simultaneously
33. the cables 8 Close the door and lid and secure cover with screws removed in Step 3 9 Return the printer to service by reconnecting the power cable 10 Reset printer to factory defaults by following the Factory Default Procedure 90 Rev C M 8400RV Service Manual SECTION 6 Replacement Procedures 6 4 Replacing the Main Circuit Board REMOVE 4 SCREWS TO DETACH PCB DISCONNECT CABLES DISCONNECT CABLES REMOVE EPROMS SATO M 8400RV Service Manual 91 Rev C SECTION 6 Replacement Procedures 6 5 Replacing the Power Supply The M 8400RV Power Supply is a non repairable component with no service parts and is replaced as a complete assembly Required Equipment 2 Phillips Screw Driver To remove and replace the Power Supply perform the following steps STEP PROCEDURE 1 Refer to Section 6 4 and detach the main circuit board for access to the power supply 2 Remove 2 screws from the mechanical side of the printer which fastens the power supply to the wall Fig 6 8 3 Detach 3 cable connections and remove the defective unit Fig 6 8b 4 Install the new power supply using screws previously removed Reattach cable connections 5 Reattach PCB referring to Section 6 4 6 Close the door and lid and secure cover with screws removed in Step 2 REMOVE 2 SCREWS HOLDING POWER SUPPLY TO OPPOSITE SIDE OF WALL Fig 6 8 92
34. the leading edge of the next label The leading edge position of the label can be adjusted relative to the print head 49 mm in increments of 1 mm using the following procedure Once the position is set it can be adjusted 3 75 mm using the PITCH potentiometer on the adjustment panel MOVED WITH MINUS OFFSET ORIGINAL PRINT LINE MOVED WITH POSITIVE OFFSET LINE FEED DIRECTION 30 Rev C SATO M 8400RV Service Manual SECTION 2 Configuration Pitch Offset and Direction Cont PITCH OFFSET To change the setting perform the following steps STEP PROCEDURE 1 Use the LINE key to step the underlined cursor to either the positive or the negative selection A positive selection increases the pitch offset direction while a negative selection decreases the pitch offset direction 2 Once the desired setting is underlined press the FEED key to accept the setting and advance to the first numerical position Press the LINE key to set a value in the first position 0 4 only Each time the line key is pressed it will increment one step Press the FEED key to advance to the second position to set a value Press the line key repeatedly to advance to the desired value 0 9 Once the setting is correct press the FEED key to accept the setting and advance to the Cancel Print job display 3 You may wish to check your settings by printing a test label after you have completed the a
35. the rewinder then set the power switch to ON The printer must be powered on for the rewinder to function 140 Rev C SATO M 8400RV SERVICE MANUAL SECTION 9 5 9 4 Label Rewinder CABLE FROM PRINTER REWINDER TO EXT CONNECTOR ON PRINTER REWINDER gus REWINDER 2 MOUNTING SCREWS MOUNTING PLATE AT BOTTOM OF PRINTER Removing and Unwinding the Roll As labels are printed tension from the rewinder should keep the label stock taut as it wraps onto the rewind spindle To remove the roll from the spindle first set the power switch OFF Remove the metal clamp then remove the rewound roll of labels To unwind for using with an applicator first set the power switch OFF Attach the lead edge of the labels from the rewind spindle to the applicator entry point Select the WIND option on the rewinder and when ready to begin set the power switch to ON 141 Rev C SATO M 8400RV SERVICE MANUAL SECTION 9 5 9 5 Label Cutter Unit The M 8402 label cutter automatically cuts each label after completion of the print operation using a motorized rotary knife As soon as the completed label has been cut the label stock is backfed to the print position for proper alignment of the printed data on the succeeding label Installation Required Equipment 2 Phillips Screw Driver STEP PROCEDURE 10 11 12 13 Switch the printer OFF but keep the power cab
36. the tension gauge 4 Gradually lift the tension gauge pulling the string to unwind it from core Once the spindle begins to move the gauge should indicate 300 to 400 grams of tension Excessive or insufficient tension must be corrected by adjusting the ribbon unwind clutch Refer to Fig 5 1 5 2 To adjust the clutch loosen the set screw and move the adjust nut CW for more tension and CCW for less tension Tighten the set screw and repeat Steps 3 and 4 until the correct tension is achieved 74 HN SATO M 8400RV Service Manual SECTION 5 Mechanical Adjustments 5 2 Ribbon Clutch Adjustments RIBBON UNWIND SPINDLE ADJUST NUT SET SCREW IS INSIDE ADJUST NUT Fig 5 1 RIBBON REWIND SPINDLE 600 800g 300 400g REWIND UNWIND TENSION GAUGE Fig 5 2 EMPTY RIBBON CORES M 8400RV Service Manual 75 Rev C SECTION 5 Mechanical Adjustments 5 2 2 Ribbon Rewind Clutch Adjustment To adjust the Ribbon Wind Clutch perform the following steps and refer to the illustrations on previous page STEP PROCEDURE 1 Connect the power cable to the printer and AC outlet Place the printer s power switch to the ON position 2 Place an empty ribbon core on the ribbon wind spindle Attach the free end of the string to the tension gauge Refer to Fig 5 1 3 Wind the string tightly around the ribbon core in a single layer and in a counter clockwise direction Att
37. to the frame Lift off the cover for access to the sensor module Refer to Fig 4 1 4 2 amp 4 3 in Section 4 4 Remove the following parts from two spindle shafts in order Refer to Fig 6 21 ITEM NO DESCRIPTION QTY EA ASSY 1 Screw 1 2 Adjustment Nut 1 3 Stopper Collar 1 4 Spring 1 5 Disc 1 6 Oil less Dry Metal Washer 1 y Collar 2 8 Ribbon Boss 1 9A amp 9B Disc Plate Different 1 10 Friction Washer 1 11 Hold Plate 1 NOTE Disassemble one spindle at a time so that the other can be used for reference 101 Rev C M 8400RV Service Manual SECTION 6 Replacement Procedures 6 9 Replacing the Ribbon Drive Clutch Washers UNWIND SPINDLE TEETH MUST FACE ITEM 10 COMPONENTS SHOWN ASSEMBLED 102 Rev C SATO M 8400RV Service Manual SECTION 6 Replacement Procedures 6 9 Replacing the Ribbon Drive Clutch Washers To replace the parts to each spindle perform the following steps Refer to Fig 6 21 6 22 STEP PROCEDURE NOTE Do not over tighten the adjustment nut since this screw is used to adjust the clutch tension Adjust the clutch tension as outlined in Section 5 2 To each spindle install Item 11 Plate with teeth facing outward and align the plate with the peg on the Ribbon Shaft Flange Install Item 10 Felt Friction Washer onto the Ribbon Shaft and slide it against Item 11 Plate Install 1 ea Item 9A amp 9B Wind and Unw
38. 2 Phillips Screwdriver Small Flat Blade Screwdriver STEP PROCEDURE 1 Load the ribbon and label stock into the printer 25 Loosen 2 screws Insert flat blade screwdriver in slot and rotate CW or CCW Rotating CW moves the Feed Roller Assembly backward and labels will track to the outside Rotating CCW moves the Feed Roller Assembly forward and labels will track towards the inside Refer to Fig 5 10 Tighten the 2 screws after adjusting 3 Eventually fine tuning may be required To increase pressure between the upper and lower rollers adjust the two screws on the media lid Refer to Fig 5 11 81 Rev C M 8400RV Service Manual SECTION 5 Mechanical Adjustments 5 7 Feed Roller Adjustment Label Tracking Adjustment MEDIA LID COVER Fig 5 10 ADJUSTMENT MARKS LOOSEN TIGHTEN 2 SCREWS PLACE FLAT BLADE SCREWDRIVER IN SLOT AND ROTATE CW OR CCW MEDIA LID COVER ADJUST SCREWS BOTH ENDS FOR FINE TUNING ADJUSTS PRESSURE BETWEEN UPPER AND LOWER ROLLERS 82 Hex M 8400RV Service Manual SECTION 5 Mechanical Adjustments 5 8 Pitch Sensor Modification for Sensing Corner Notch Tags Required Equipment e Snap Ring Remover Tool e 2 Phillips Screwdriver STEP PROCEDURE 1 Remove 2 screws holding the label tear off cover to the printer Rotate the cover down then remove it by lifting up Refer to Fig 5 12 2 Remo
39. 87 7 Industrial Bar Code Printers SATO M 8400RV Service Manual SATO America Inc 10350 A Nations Ford Rd P N 9001042 Charlotte NC 28273 Rev C Rev SATO America Inc 10350 A Nations Ford Rd Charlotte NC 28273 Main Phone 704 644 1650 Technical Support Hotline 704 644 1660 Fax 704 644 1661 Copyright 1997 SATO America Inc Warning This equipment complies with the requirements in Part 15 of FCC rules for a Class A computing device Operation of this equipment in a residential area may cause unacceptable interference to radio and TV reception requiring the operator to take whatever steps are necessary to correct the interference rights reserved No part of this document may be reproduced or issued to third parties in any form whatever without the express permission of SATO America Inc The materials in this document are provided for general information and are subject to change without notice SATO America Inc assumes no responsibility for any errors that may appear SATO M 8400RV SERVICE MANUAL Table Of Contents SECTION 1 OVERVIEW amp SPECIFICATIONS Page OVER VIC W PD Ee 1 1 1 Physical Ghatacletlstlos rerit tr 1 2 2 COIMMPONGING 1 3 3 zi o ao 1 4 5 Installation Considerations 1 5 5 Interface 5 iere eo
40. Bookland UPC EAN Supplemental EAN 8 EAN 13 UPC A and UPC E CODABAR Code 39 Code 93 Code 128 Interleaved 2 of 5 Industrial 2 of 5 Matrix 2 of 5 MSI POSTNET UCC EAN 128 Data Matrix Maxicode PDF417 Graphics Full dot addressable graphics SATO Hex Binary or PCX formats Form Overlay Form overlay for high speed editing of complex formats 15 Rev SATO M 8400RV Service Manual SECTION 1 Overview amp Specifications 16 Rev SATO M 8400RV Service Manual Section Configuration 2 1 Dip Switch Settings Three DIP switches DSW1 DSW2 and DSW3 are located underneath a snap on cover on the operation panel These switches can be used to set e RS232C TRANSMIT RECEIVE PARAMETERS e THERMAL TRANSFER OR DIRECT THERMAL MODE e LABEL SENSOR ENABLE DISABLE e HEAD CHECK MODE e HEX DUMP MODE SNAP ON COVER RECEIVE BUFFER SIZE SHOWN REMOVED e OPERATION MODE De Switch TABLE WC DIP Switch Panel FE e Eric Lu ies rp WARNING Remove labels and carbon rinben before sh nping DIP SWITCH TABLE IS LOCATED ON BACK SIDE OF TOP ACCESS DOOR 17 Rev C SATO M 8400RV Service Manual SECTION 2 Configuration 2 1 Dip Switch Settings Cont Each switch is an eight position toggle switch The ON position is always to the top To set the switches first power the unit Off then position the DIP switches After placing the switches in th
41. CB Refer to Fig 4 1 4 2 amp 4 3 Refer to the appropriate sub section to begin adjustments TOP AND SIDE ACCESS DOORS LEFT SIDE COVER Fig 4 3 2 SCREWS Fig 4 2 60 Rev C SATO M 8400RV Service Manual Section 4 Electrical Checks and Adjustments 4 3 Power Supply Checks Required Equipment Number 2 Phillips Screwdriver e DC Voltmeter To check voltage levels first check the Main fuses 6 1 and replace if necessary then perform the following steps STEP PROCEDURE Refer to Section 4 2 for steps prior to adjustment 1 On the main circuit board attach the DC voltmeter negative lead to the test point labeled CH1 Ground on the main circuit board Attach the DC voltmeter positive lead to the corresponding voltage test point and place the power switch in the ON position Refer to table below and Fig 4 4 4 5 Test Points Nominal Voltage CH1 amp CH3 4 8 to 5 2V 5V NOTE The power supply voltages are not adjustable All voltages must read within 10 of the nominal value for correct operation of the printer 2 After performing tests replace and secure the Left Side Cover to the printer base with 2 screws previously removed Tighten 2 inside screws and close the doors 61 SATO M 8400RV Service Manual Rev SECTION 4 Electrical Checks and Adjustments 4 3 Power Supply Checks TEST PINS 1 10
42. Codes DSW27 0N 22 DEFAULT COMPLETE Print Hex Dump Label POWER then DSW2 4 ON Print Buffer Hex Dump Label Refer to Page 20 OML THE Print Hex j Receive Buffer Dump Label Hex Dump Label POWER DSW2 4 ON peter Dade 21 28 Rev C SATO M 8400RV Service Manual SECTION 2 Configuration ONL IHE Normal Mode When the printer is powered on the LCD Panel will display the ONLINE status on the top line of the display and the bottom line will contain the label quantity QTY status The ONLINE message will be changed to OFFLINE whenever the printer is switched offline by depressing the LINE key As soon as a print job is received the QTY message will indicate the number of labels to be printed As soon as the label job begins to print the display will indicate the number of labels remaining in the print job that remain to be printed User Mode OFFLIHE To enter the USER mode perform the following steps STEP PROCEDURE 1 The printer is first taken offline by pressing the LINE key once The display will change to OFFLINE 2 Press the FEED and LINE keys simultaneously for more than one second The printer now displays the first USER mode adjustment Print Darkness NOTE Refer also to page 41 for print darkness setting Type 1 and Type 2 that work in conjunction with these fine adjustment settings There are five Darkness or heat range settings on the M8400RV The higher numbers represent
43. EAD 130 Rev C M 8400RV Service Manual Section tions 9 1 Overview The following options are available for the M 8400RV printer Memory Card Label Cutter Label Dispenser Calendar Label Rewinder Memory Card Label Rewinder Label Dispenser Label Cutter SATO M 8400RV SERVICE MANUAL SECTION 9 5 9 2 Description The Memory Card Option provides the connectors and interface board for two PCMCIA memory card slots The two Memory Card slots labeled Card 1 and Card 2 are on the memory option board mounted inside the printer Access to these cards is by removing the PC board compartment cover The printer memory can be expanded up to 4MB SRAM PCMCIA Version 2 1 JEIDA Version 4 1 Type Applicable Specifications Size 128KB 256 512KM 1 or 2MB Connector Pins 68 Battery Approximately two years manufacturer dependent Write Protect Yes Low Battery Detect M 8400RV PRINTER UNIT INSTALL END TO MAIN SELF TAPPING MEMORY CONNECTOR SCREWS 132 Rev C SATO M 8400RV SERVICE MANUAL SECTION 9 5 9 2 Installation Required Equipment 2 Phillips Screwdriver NOTE Many of the components on these boards are extremely susceptible to damage by static electricity
44. ED key and a single audible signal will be heard Release the FEED key and the printer to display the following message on the LCD panel Print Size USER TEST PRINT Small Large To access this setting perform the following steps STEP PROCEDURE 1 Use the LINE key to step the underline cursor to either the Large or Small selection If Large is underlined a label will be printed for a maximum width label 2 Press the FEED key to print the label which will contain a head check pattern and current printer setting information The default position is Large 43 Rev C M 8400RV Service Manual SECTION 2 Configuration Print Size Cont PRIHT SIZE 1 Cont Bam If SMALL is underlined the Print Size message will be displayed You must enter the size of the label The minimum label size that can be selected is 4 cm 1 6 and the maximum size is 10 cm 3 9 Press the LINE key to increment the setting by 1 cm each time the key is pressed Once the maximum size is reached the display will wrap around and start incrementing at 04 cm again Once the correct label width is selected press the FEED key to initiate the print The SMALL label only contains a head check pattern If you wish to pause the printer after it starts to print a test label press the LINE key to place it Off Line Press the LINE key again to place the printer back On Line and to resume the test label printing To
45. EDURE 1 Turn the OFFSET VR on the front panel to the center position Refer to Fig 4 13 2 Turn the power on while pressing the FEED key 3 Press the LINE key to set the cursor on Small USER TEST FRIHT Small Large 4 Press the FEED key once Verify display PRINT SIZE _ aE m 5 Press the LINE key to adjust the print width 6 Press the FEED key to initiate test printing Press FEED key again to stop printing 7 Turn OFFSET VR to adjust label stop position 8 Press FEED key to stop test print then turn the power off Tolerance of OFFSET VR 3 75 mm A 3 a e 3 Fig 4 13 70 Rev 5 M 8400RV Service Manual Section 4 Electrical Checks and Adjustments 4 10 Feed Backfeed Adjustment Cutter Mode Use Offset to adjust label stop position Required Equipment Small flathead screwdriver for potentiometer adjustment STEP PROCEDURE 1 Turn the OFFSET VR on the front panel to the center position Refer to Fig 4 14 2 Turn the power on while pressing the FEED key 3 Press the LINE key to set the cursor on Small USER TEST PRINT Small Large 4 Press the FEED key once Verify display PRINT SIZE _ H4cm 5 Press the LINE key to adjust the print width 6 Press the FEED key to initiate test printing Press FEED key again to stop printing 7 Adjust label cut position with OFFSET VR in the right position 8 Press FEED key to sto
46. EXTRUSION Fig 6 15 96 Rev C SATO M 8400RV Service Manual SECTION 6 Replacement Procedures 6 7 Replacing the Label Out Sensor Assembly Micro Switch The Label Sensor Assembly can be removed from the printer to clear label fragments and for service No critical alignment is required when replacing the sensors Required Equipment 2 Phillips Screw Driver To remove and replace the Label Sensor perform the following steps and refer to the illustrations STEP PROCEDURE 1 Switch the printer OFF and disconnect the power cable 2 Open the top and side access doors the mechanical side of the printer 3 Loosen 2 inside screws holding the LH cover to the inside top of the printer and remove 2 screws holding the cover to the frame Lift off the cover for access to the sensor module Refer to Fig 4 1 4 2 amp 4 3 in Section 4 4 Lift label lid to expose label out sensor switch Refer to Fig Group 6 16A and perform the following procedures 5 Remove screws indicated 6 Remove the door latch and angle supports Carefully detach the side plate from the rest of the unit and set aside 7 Access the sensor under the Ramp Assembly and detach 2 screws from the motor 8 Install the new sensor module using screws previously removed 9 Carefully maneuver the side plate into position and replace screws removed in Step 5 Replace angle supports and door latch 10 Upon completion of sensor installation re
47. L TEAR OFF COVER PRINT HEAD HEAD HOLDER ALIGNMENT PINS PRINT HEAD P H DATA CABLE Fig 6 5 6 6 89 Rev C SATO M 8400RV Service Manual SECTION 6 Replacement Procedures 6 4 Replacing the Main Circuit Board The Main Circuit Board contains the control electronics for the M 8400RV and is located behind the LH cover of the printer NOTE Many of the components on these boards are extremely susceptible to damage by static electricity To avoid damage from static electricity do not unpack new circuit boards from anti static bags until instructed to do so Required Equipment 2 Phillips Screw Driver STEP PROCEDURE 1 Switch the printer OFF and disconnect the power cable 2 Open the top and side access doors on the mechanical side of the printer 3 Loosen 2 inside screws holding the LH cover to the inside top of the printer and remove 2 screws holding the cover to the frame Lift off the cover to expose the PCB Refer to Fig 4 1 4 2 amp 4 3 in Section 4 4 Note cable connections locations then disconnect all cables from the PCB board Fig 6 7 5 Remove 4 screws to detach the PCB from the printer Fig 6 7 6 Carefully remove the EPROM s from the defective and install in the same location s on the new PCB Fig 6 7 Note Make sure the marks on the EPROM s are aligned correctly with the socket 7 Reinstall the using screws previously removed Reattach
48. N 2 SCREWS EE RIBBON PLATE Fig 5 4 77 Rev M 8400RV Service Manual SECTION 5 Mechanical Adjustments 5 4 Print Head Position Alignment Required Equipment 2 Phillips Screwdriver To adjust the print head alignment and make print quality consistent across label perform the following steps STEP PROCEDURE 1 Loosen the 1 center and 2 side screws attaching the head adjustment plate to the head 2 Slide head adjustment plate forward and backward aligning the center index scale as a guide to adjust Tighten the screws NOTE Use the printed head pattern as a guide to even print position Refer to Section 8 7 ALIGNMENT Fig 5 5 HEAD AJUSTMENT PLATE REFER TO SECTION 8 7 FOR HEAD PATTERN EXAMPLES 78 Ho SATO M 8400RV Service Manual SECTION 5 Mechanical Adjustments 5 5 Print Head Balance Adjustment Required Equipment 2 Phillips Screwdriver To further optimize print quality especially when using thick label stock additional adjustments are possible Perform the following steps using head pattern as a guide STEP PROCEDURE 1 Load the ribbon label stock into the Printer 2 Loosen screw near the bottom of the plate 3 Rotate adjusting screw to achieve optimum print quality along the length of the print head NOTE Rotating screw CW places pressure on the inside end left side of the print head creating a darker impression o
49. P PROCEDURE 1 Switch the printer OFF and disconnect the power cable 2 Open the top and side access doors on the mechanical side of the printer 3 Remove 2 screws securing Label Tear Off Cover Rotate forward and lift to remove Fig 6 3 4 Remove the ribbon and label stock if installed 5 Remove the center screw Fig 6 4 6 Carefully open the print head so that it will drop down 7 Carefully disconnect the cables and remove the print head 8 Install the new print head by reconnecting the print head data cable and the print head power cable to the print head Fig 6 5 6 6 9 Position the print head so the center screw is aligned with the mechanism and the alignment pins are aligned with the head Replace center screw and 1 side screw Tighten securely 10 Replace label tear off cover and close doors Before you return the printer to normal service you should perform the following procedures Clear Counter Heads Refer to Section 7 4 e Confirm that the head cables are connected and that it does not touch the head opening spring Also confirm that you can open and close the head without restriction and that the ribbon guide plate adjustment is correct e Print test pattern 88 Rev C M 8400RV Service Manual SECTION 6 Replacement Procedures 6 3 Replacing the Print Head LABEL TEAR OFF COVER Fig 6 3 1 SCREW BACK SIDE OF LABE
50. SPENSED OR HOU MANY LABELS have been cut The correct counter values can be viewed by printing out a test label The Counters are identified in the display as LIFE Life HD Head Counter COUNTERS _ DSP Dispense Counter HD DSP LUT LIFE CUT Cutter Counter To access this setting perform the following steps STEP PROCEDURE 1 Use the LINE key to step the underline cursor to the counter to be reset displayed the Head counter HD Dispenser DSP counter CUT Cutter counter or the LIFE counter 2 Once the correct setting is underlined press the FEED key display selected counter value in meters 3 Press the FEED key to advance to the Counter Clear display CNTR CLEAR Use the LINE key to underline YES if you want to reset the counter to O0 Underline NO to keep the current values Press FEED to continue the desired operation and advance to the EXIT ADV Mode display 4 Using the LINE key underline YES or NO to exit advanced mode YES NO to return to the Advanced Mode Setup display 42 Rev C SATO M 8400RV Service Manual SECTION 2 Configuration 2 5 Printing Test Labels This option allows you to print a test label It is recommended that you print a test label after you have changed any of the settings in the Advanced Mode The test label allows you to verify that you indeed did make the desired changes To enter the User Test Print Mode power up the printer while pressing the FE
51. Specifications 1 8 rator Panel Displays Cont DSW1 2 amp 3 DIP Switches used to set operational parameters of printer Refer to Section 2 for settings LED S STATUS INDICATORS POWER LED illuminated when the power is on LABEL LED illuminated when label supply is out RIBBON LED illuminated when ribbon motion sensor does not detect any ribbon motion ribbon out ERROR LED illuminated when there is a system fault such as an open print head ON LINE LED illuminated when printer is ready to receive data Turn ON OFF by toggling the LINE key Rev C M 8400RV Service Manual SECTION 1 Overview 4 Specifications 1 9 Optional Accessories ACCESSORIES Refer to Section 9 for installation instructions Memory Expansion Two slots for PCMCIA Memory Cards up to 2MB each that can be used for Graphic File storage print buffer expansion format storage and downloaded TrueType font storage Label Dispenser Internal attachment allowing labels to be peeled from backing for immediate on demand application Backing is not rewound Label Rewinder External option rewinds labels onto a roll after they are printed Label Cutter Internal attachment allowing labels to be cut at specified internals Controlled through programming Real Time Clock amp An internally mounted Date Time clock that can be used to Calendar date time stamp labels at the time of printing Coax Triax Adapter Coa
52. Timing Belts LABEL TEAR STEPPER FF COVER a ds MOTOR SCREW TO CARBON REWIND SHAFT 1 SCREW Fig 6 23 TO FRAME BELT 105 Rev C M 8400RV Service Manual SECTION 6 Replacement Procedures 6 11 Replacing the Platen Before replacing the platen tension must be released from the timing belts Required Equipment 2 Phillips Screw Driver e Flat head Screw Driver STEP PROCEDURE 10 11 12 Switch the printer OFF and disconnect the power cable Open the top and side access doors on the mechanical side of the printer Loosen 2 inside screws holding the LH cover to the inside top of the printer and remove 1 screw holding the cover to the frame Lift off the cover for access to the timing belts Refer to Fig 4 1 4 2 amp 4 3 in Section 4 Remove the ribbon and label stock if installed Remove 1 screw holding the label tear off cover Fig 6 26 Loosen the screw holding the clamp which supports the platen to the side frame Fig 6 27 Loosen 2 mounting screws attaching the stepper motor to the frame Access the motor from the opening previously covered by the label cover Move the motor in the motor mounting slots to release pressure from the belts Fig 6 28 Remove the E snap ring from the end of platen shaft and slide off the belts from the toothed gears Fig 6 29 Remove the screw holding the clamp and platen component
53. WS MOTOR E 1 SCREW COVER Fig 6 94 TO FRAME MOTOR SHAFT AND PULLEY 2 SCREWS Fig 6 35 MOTOR TO FRAME 110 M 8400RV Service Manual SECTION 6 Replacement Procedures 6 13 Replacing the LC Display and Keyboard PCB Display Access to the display panels is from the left side of the printer Required Equipment 2 Phillips Screw Driver STEP PROCEDURE 1 Switch the printer OFF and disconnect the power cable 2 Open the top and side access doors on the mechanical side of the printer 3 Loosen 2 inside screws holding the LH cover to the inside top of the printer and remove 2 screws holding the cover to the frame Lift off the cover for access to the display PCBs Refer to Fig 4 1 4 2 amp 4 3 in Section 4 4 Refer to Fig 6 37 To remove LC Display remove 2 screws and detach cables To remove Keyboard PCB Display remove 2 screws and detach cables Replace either panel as required After replacing either panel perform the following procedures Refer to Section 2 1 Dip Switch Settings to readjust Refer to Section 4 7 Pitch Offset Adjustment to readjust Refer to Section 4 9 4 10 4 11 Feed Backfeed Adjustment to readjust gia cae ipao qs Refer to Section 2 3 Printer Adjustment to adjust print darkness 111 Rev SATO M 8400RV Service Manual SECTION 6 Replacement Procedures 6 13 Replacing the LC Display a
54. ach the free end of the string to the tension gauge 4 Gradually lift the tension gauge pulling the string to unwind it from the core Once the spindle begins to move the gauge should indicate from 600 to 800 grams of tension Excessive or insufficient tension must be corrected by adjusting the ribbon unwind clutch Refer to Fig 5 1 5 2 To adjust the clutch loosen the set screw and move the adjust nut CW for more tension and CCW for less tension Tighten the set screw and repeat Steps 3 and 4 until the correct tension is achieved 76 Hove SATO M 8400RV Service Manual SECTION 5 Mechanical Adjustments 5 3 Ribbon Guide Plate Adjustment Required Equipment 2 Phillips Screw Driver e Flat blade Screw Driver If the ribbon is not smooth across the guide plate ribbon wrinkle and adjustment is required perform the following steps STEP PROCEDURE 1 Check for even ribbon tension by watching the ribbon movement under the guide plate as it moves upward toward the ribbon rewind spindle If it appears uneven wrinkles proceed to Step 2 Refer to Fig 5 3 2 Reposition and adjust the ribbon guide plate by loosening two screws moving the plate with a flat blade screw driver Refer to Fig 5 4 HEAD ADJUSTMENT PLATE PRINT HEAD BRACKET RIBBON GUIDE MOVE UP OR DOWN WITH PLATE FLATBLADE SCREW DRIVER TO ELIMINATE RIBBON WRINKLE ES ER EN Fig 5 3 LOOSE
55. an entry provided to ignore a Carriage Return or Line Feed command in the data stream Print Darkness Setting PRINT DARKNESS TYPE 1 There are two Darkness or heat range settings The higher number represents darker settings The current setting is indicated by an line under one of the range settings Refer to page 29 for user mode darkness settings that work in conjunction with these two broad range settings STEP PROCEDURE 1 Use the LINE key to step the underlined cursor to the desired setting 2 Once the desired setting is underlined press the FEED key to accept the setting and advance to the next adjustment OFFLIHE To access this setting perform the following steps STEP PROCEDURE 1 Use the LINE key to step the underlined cursor to either or YES 2 Once the desired setting is underlined press the FEED key to advance the display to the offline mode if YES is selected or to recycle back through the advanced mode if NO is selected 41 Rev C M 8400RV Service Manual SECTION 2 Configuration Advance Mode Counters For firmware versions 1E2040 or higher For all other firmware versions refer to Section 7 for Counter Clear instructions The Counter Clear display is used to reset the internal printer counters to zero The counters allow the user to keep track of the number of centimeters of label material that HAS PASSED THROUGH THE PRINTER HOW MANY LABELS HAVE BEEN DI
56. ause Press the LINE key to initialize reset After a slight pause 2 blank labels will feed out followed by a test print Warning This test activates all the heating elements on the print head and therefore should be used for testing purposes only to avoid damaging the print head especially when performed with labels less than the full width of the print head Press the FEED key to stop printing Verify that the counters on test print have reset to 0 0 km Place the power switch to the OFF position and return all switches to the original positions Refer to Page 118 for test print sample 115 Rev SATO M 8400RV Service Manual SECTION 7 Factory Resets 7 4 Clear Counter Heads STEP PROCEDURE Record all current dip switch positions then place all switches in the off position Place the print head in the open position and the DSW2 5 in the ON position Turn on the power while pressing the LINE amp FEED keys Release when an audible sound is heard Place the print head back in the closed position and DSW2 5 in the OFF position Verify display Factory Mode Press the FEED key once Verify display Press the LINE key twice to change the display to HEAD COUNTER CLEAR Press the FEED key The head counter HEAD will be reset to 0 zero Press the LINE key once After a slight pause 1 blank label will feed out followed by a test print Warning This test activates
57. bon Continuous Form Sensor not used Software Controlled 1 13 Controls and Signals Adjustments 12 Rev SATO M 8400RV Service Manual SECTION 1 Overview amp Specifications 1 14 Interface Connections INTERFACE CONNECTIONS Parallel Amp 36 pin Centronics Compatible Standard Serial DB25S RS232C 2400 to 19 2 bps Standard Hardware Flow Control Ready Busy Serial Protocol Software Flow Control X On X Off Bi directional ENQ Response 1 15 Processing 1 16 Character Fonts 13 Rev C SATO M 8400RV Service Manual SECTION 1 Overview amp Specifications 1 16 Character Fonts AUTO SMOOTHING FONTS WB WB Font 18 dots W x 30 dots H Univers Condensed Bold WL WL Font 28 dots W x 52 dots H Sans Serif XB XB Font 48 dots W x 48 dots H Univers Condensed Bold XL XL Font 48 dots W x 48 dots H Sans Serif VECTOR FONT Helvetica Bold Proportional or Fixed Spacing Font Size 50 x 50 dots to 999 x 999 dots 10 Font Variations DOWNLOADABLE FONTS TrueType Fonts Storage requires Optional Memory Expansion CHARACTER CONTROL Expansion up to 12x in either the X or Y coordinates Character Pitch Control O to 99 dots Line Space Control 0 to 99 dots Journal Print facility 0 90 180 and 270 Rotation 14 Rev SATO M 8400RV Service Manual SECTION 1 Overview amp Specifications 1 17 Bar Codes and Other Features SYMBOLOGIES
58. cement Procedures 6 2 2 Removing and Replacing the 5V Or 24V FUSE s Required Equipment e Amp 250 V Fuse 5V Or e 3 Amp 250 V Fuse 24VDC e 2 Phillips Screwdriver To remove and replace the Main Power Fuse perform the following steps STEP PROCEDURE 1 Switch the printer OFF and disconnect the power cable 2 Open the top and side access doors on the mechanical side of the printer 3 Loosen 2 inside screws holding the LH cover to the inside top of the printer Remove 2 screws holding the LH cover to the printer base at the outside of the printer and remove the cover to expose the main PCB Refer to Fig 4 1 4 2 amp 4 3 in Section 4 4 Refer to Fig 6 2 and locate the 5 Fuse F2 or 24 Fuse F1 5 Remove and replace the Fuse s with one of equal rating Do not usea fuse with a higher rating 6 Close the door and lid and secure cover with screws removed in Step 3 Z Return the printer to service by reconnecting the power cable MAIN PC BOARD F2 5V FUSE F1 24V FUSE I Fig 6 2 87 Rev SATO M 8400RV Service Manual SECTION 6 Replacement Procedures 6 3 Replacing the Print Head If the M 8400RV print head becomes damaged for any reason it can be easily removed and replaced No critical adjustments are required Before you replace the print head check the head counter values by printing a test pattern Required Equipment 2 Phillips screwdriver STE
59. cnenersnarsscanaencssscaesencnnenenanans 3 4 47 Centronics Parallel 3 5 55 Accessory EXT 3 6 57 SECTION 4 ELECTRICAL CHECKS AND ADJUSTMENTS OVEN VICW 4 1 59 Steps Prior to Adjustments 4 2 60 Power Supply Checks teer ertet iere ene 4 3 61 Reflective Label Pitch Sensor Adjustment 4 4 63 See Thru Gap Pitch Sensor Adjustment 4 5 65 Ribbon Sensor 4 6 67 Pitch Offset Adjustment User 4 7 68 Pitch Offset Adjustment Service 4 8 69 Feed Backfeed Adjustment Tear Off Mode 4 9 70 Feed Backfeed Adjustment Cutter Mode 4 10 71 Feed Backfeed Adjustment Dispenser Mode 4 11 72 i Rev C M 8400RV Service Manual Table Of Contents SECTION 5 MECHANICAL ADJUSTMENTS SECTION 9 OPTIONS 81 14 71 1 D E 5 1 Ribbon Clutch Adjustments eere rere rennen nnn nnn 5 2 Ribbon Guide Plate Adjustmen
60. crewdriver DC Voltmeter Digital preferred w small alligator clip voltage probes Small flathead screwdriver for potentiometer adjustment NOTE 1 It is important to use pressure sensitive label stock that is rated for use with thermal transfer printers using see through transmissive sensing NOTE 2 Dip Switch setting for DSW2 2 must be in the OFF position for using this procedure To adjust the See Thru Pitch Sensor voltage perform the following steps STEP PROCEDURE Refer to Section 4 2 for steps prior to adjustment 1 On the main circuit board turn VR2 clockwise to the maximum position Refer to Fig 4 8 2 Attach DC voltmeter negative lead Small alligator clip recommended to pin 1 ground of the test point pin array labeled CH on the main circuit board Attach the DC voltmeter positive lead to 8 of the CH test point of the main circuit board 3 LOW LEVEL ADJUSTMENT GAP If you are using adhesive labels remove the label face stock from its backing paper Position the backing paper in the sensors field of view Refer to Section 1 7 for sensor location If you are using a notched tag position the tag so the notch is located in the sensor s field of view Adjust VR2 to set the voltage at approximately 1 0 volts or less 65 SATO M 8400RV Service Manual Rev SECTION 4 Electrical Checks and Adjustments 4 5 See Thru GAP Pitch Sensor Adjustment Cont STEP PROCEDURE
61. d expressly for use in all SATO printers Use of other than approved ribbons may result in unsatisfactory print quality and or damage to the print head and may void your warranty 1 5 Installation Considerations Printer operation can be affected by the printer environment The location of the printer should be free from dust humidity and sudden vibrations To obtain optimum results from the printer avoid locations influenced by Direct or bright sunlight since bright light will make the label sensor less responsive and may cause the label to be sensed incorrectly e Warm temperatures which can cause electrical problems within the printer See Section 3 Specifications 1 6 Interface Connections Rear Panel EXT PORT CONNECTOR External signal connector CENTRONICS CONNECTOR Printer using parallel communication connection RS232 CONNECTOR Printer using serial communication connection AC FUSE To protect the machine from abnormal power Li input Type 3A 250V AC INPUT CONNECTOR Connect to 115V 50 60 Hz with cable provided Rev C SATO M 8400RV Service Manual SECTION 1 Overview amp Specifications 1 7 Switches and Sensors HEAD LATCH LEVER When the print head is opened a micro switch is activated and the printer will stop printing Error message will be displayed on the LED operator panel RIBBON SENSOR The sensor will react to the ribbon unwind when approx
62. decimal if a printer error exists SATO M 8400RV Service Manual 53 Rev C SECTION 3 Interface Specifications 3 4 5232 Serial Interface Cont Status Byte Definition Bi Directional Protocol OFF LINE im Buffer Near Full s s Feson near Erdara euternear f ON LINE WAITING FOR DATA Ds freme 0000000 L 54 Rev 5 M 8400RV Service Manual SECTION 3 Interface Specifications 3 4 5232 Serial Interface Cont Status Byte Definition Bi Directional Protocol s Ca e e we i i s or i i ww X 3 5 Centronics Parallel Interface Electrical Specifications Printer Connector AMP 57 40360 DDK or equivalent Cable Connector AMP 57 30360 DDK or equivalent Cable Length 10 ft or less Signal Level High 2 4V to 5 0V Low OV to 0 4V Data Streams Single Job Buffer The Single Job Buffer mode is not available when using the Centronics interface Multi Job Buffer lt STX gt lt ESC gt A Job 1 lt ESC gt Z lt ETX gt lt STX gt lt ESC gt A Job n lt ESC gt Z lt ETX gt Note that for parallel communications the STX and ETX characters are not required 55 Rev C SATO M 8400RV Service Manual SECTION 3 Interface Specifications 3 5 Centronics Parallel Interface Cont
63. djustments to ensure that they are correct See page 43 for instructions on how to print a test label 31 Rev SATO M 8400RV Service Manual SECTION 2 Configuration Cancel Print Job CHMCEL PRINT TES If the printer has a print job s loaded in memory selecting YES will cause the job s to be cleared The default selection is NO Make sure that you want to cancel the print job before selecting YES as the job cannot be recovered and will have to be retransmitted to the printer To cancel the print perform the following steps STEP PROCEDURE 1 Use the LINE key to step the underlined cursor to either YES or NO 2 Once the correct setting is underlined press the FEED key to accept the setting and terminate the user mode of operation and return to the normal mode OFFLINE display If you wish to change any of the settings you must enter the user mode again by simultaneously pressing FEED and LINE keys for more than one second 2 4 Advanced Mode Settings and Adjustments Advanced mode is provided to make adjustments that require only occasional adjustments Since they affect the basic operation of the printer the procedure for entering this mode is designed to prevent someone from accidentally changing the settings To enter advanced mode the printer is powered on while pressing the LINE key The printer will emit a single audible signal and display the first configuration selection on the
64. e SATO ribbons Low print head energy darkness Adjust darkness control See Operator Manual Head balance uneven Correct head balance Low ribbon drive torque Adjust ribbon drive clutch 5 2 No ribbon movement Foreign material on head Clean head and platen Poor head alignment Align Print Head 5 4 Excessive print speed Reduce print speed setting Use Premier II ribbon with a 1C Ribbon not matched to label stock thermal transfer ribbon stock or equivalent for optimum results 125 Rev C SATO M 8400RV Service Manual SECTION 8 Troubleshooting Symptom Probable Cause Suggested Corrective Action Use Premier II ribbon with 1 Smearing Poor quality labels thermal transfer ribbon stock or equivalent for optimum results EN Poor quality ribbons Use genuine SATO ribbons Num Foreign material on head platen Clean head and platen Foreign material on labels Use high quality label stock Excessive head Adjust darkness control Excessive speed Adjust Print speed NENNEN Excessive head pressure Use correct head balance Movement RENE Loose drive clutch Adjust clutch tension 5 2 Loose 1 drive belt Adjust replace belt 6 10 Test power supply and replace if No 24 volt t 2 4 pulley Damaged electronics Replace circuit board 6 4 Loose broken platen drive belt Adjust replace belt 6 10 Movement Incorrect label pitch sensor Select correct label sensor
65. e desired positions power the printer back on The switch settings are read by the printer electronics during the power up sequence They will not become effective until the power is cycled RS232 Transmit Receive Setting Data Bit Selection DSW1 1 This switch sets the printer to receive either 7 or 8 bit data bits for each byte transmitted DSW1 sers 8 Data Bits ON 7 Data Bits OFF 1 2 3 4 5 6 7 8 Parity Selection DSW1 2 DSW1 3 These switches select the type of parity used for error detection oswia serno on 18 Rev C SATO M 8400RV Service Manual SECTION 2 Configuration Stop Bit Selection DSW1 4 Selects the number of stop bits to end each byte DSW1 swa sera ON 1 Stop Bi 2 Stop Bits OFF 1 2 3 4 5 6 7 8 Baud Rate Selection DSW1 5 DSW1 6 Selects the data rate bps for the RS232 port Communication Protocol Selection DSW1 7 DSW1 8 Selects the flow control and status reporting oswie sermo ii 19 Rev C M 8400RV Service Manual SECTION 2 Configuration Print Mode Selection DSW2 1 Selects between direct thermal printing on thermally sensitive paper and thermal transfer printing using a ribbon DSW2 pswai SETTING ON Therm Xfr 4 Sensor Selection DSW2 2 Selects between the use of a label gap or a reflective I Mark detector DSW2 DSW2 2 SETTING 1 2 3 4 5
66. e is displayed on the LED 1 8 Operator Panel Displays 7 Rev C M 8400RV Service Manual SECTION 1 Overview amp Specifications POWER LABEL RIBBON ERROR ON LINE LINE FEED PRINT OFFSET PITCH DISPLAY LINE Key Momentary switch Pressing this key toggles the printer between the on line and off line mode When the printer is on line it is ready to receive data from the host This key acts as a pause during a print job by taking the printer off line It can also be used as a pause function key toNtop the printer during the printing process LCD SCREEN 2 Line x 16 Character LCD display Used for setting operational parameters of the printer and displaying error conditions FEED Key Momentary switch Pressing this key feeds one blank label through the printer when it is off line When the printer is on line another copy of the last label will be printed DIP SWITCH COVER p a FINE TUNING USE SOFTWARE FIRST PRINT POTENTIOMETER To adjust print darkness fine adjustment OFFSET POTENTIOMETER To adjust back forward feed for dispenser cutter tear bar position 3 75mm PITCH POTENTIOMETER Adjusts home position of the label 3 75mm Affects stop position of label feed print position and dispense position DISPLAY POTENTIOMETER Used to adjust the lighting intensity contrast of the LED S Rev C SATO M 8400RV Service Manual SECTION 1 Overview 4
67. e printing of the next label with an external device attached to printer s EXT connector Contact a SATO representative for more information on this method SATO M 8400RV SERVICE MANUAL 139 Rev C SECTION 9 5 9 4 Label Rewinder The Label Rewinder is an external unit that allows for labels or tags to be rewound in rolls up to 8 5 inches It derives its power directly from the printer s EXT connector using a built in cable The rewinder provides the ability to rewind labels tags from the printer and subsequently be unwound for later use with applicators Installation Required Equipment 2 Phillips Screw Driver STEP PROCEDURE 1 Fasten the rewinder mounting plate to the bottom of the printer with 2 screws provided 2 Position the rewinder in the slots the mounting plate at the front of the printer and align it with the label slot The rewind wheel spindle should be positioned away from the printer Refer to Fig 9 9 3 Connect the built in cable from the rewinder to the EXT connector at the rear of the printer Refer to Fig 9 10 4 On the rewinder remove the metal clamp from the rewind spindle Feed the lead end of the label stock under the first spindle and onto the rewind spindle Feed the label stock around the spindle once then replace the metal clamp over the label stock Wind another revolution to ensure the labels are secure on the spindle 6 Select the REWIND option on
68. e teet a petentes 1 6 5 Switches and Sensors rc Eire E D essere ies 1 7 6 Operator Panel DIsplays ee iore ior sepa rMiquE 1 8 8 1 9 10 Environment amp Approvals eerie 1 10 10 lili c EE 1 11 11 Media Sensing and Ribbon e eeeee sees ee ense enne nena nnn 1 12 11 Controls and Signals Adjustments ceres 1 13 12 ee eiie uentris eres 1 14 13 PIOCBSSIID iom Ie tii Eam Iii 1 15 13 Character FONTS neronen PARERES E AMER EOK 1 16 13 Bar Codes Other Features eese 1 17 15 SECTION 2 CONFIGURATION Dib Switch Setlings oer ERE 2 1 17 pri me 2 2 27 Printer Adjustmenls eer aniraa datara ariarian 2 3 28 Advanced Mode Settings and Adjustments 2 4 32 Printing Test Eabels 2 5 43 SECTION 3 INTERFACE SPECIFICATIONS EDD i 3 1 45 Interfac RAUM 3 2 45 E 3 3 46 RS232C Serial Interface 1 10ssscssssccsnsss
69. ear Full Slow down transmission rate 123 Rev C SATO M 8400RV Service Manual SECTION 8 Troubleshooting 6 6 Troubleshooting Tables The troubleshooting tables below include the following general symptom descriptions e Image Voids No Label Movement LABEL LED on e Ribbon Wrinkle No printed Image e RIBBON LED on e Light Images e Display Problem e ON LINE LED not on e Smearing POWER LED not on No Label Drive e No Ribbon Movement ERROR LED on Print Quality Problems Symptom Probable Cause Suggested Corrective Action Illegal printer memory state Cycle POWER switch off and back on LED not on on No Label Timing Belt bad loose Replace tighten timing belts 6 10 Drive Poor quality ribbons Use genuine SATO ribbons Ribbon not matched to label Check with media suppliers stock Damaged electronics Replace circuit board 6 4 Damaged Platen Replace Platen Image Voids Poor quality labels Use thermal transfer compatible stock 124 Rev C M 8400RV Service Manual SECTION 8 Troubleshooting Print Quality Problems Symptom Probable Cause Suggested Corrective Action Ribbon Poor Head Alignment ies iis ae 5 5 Wrinkle Head Balance A JOSEN ODON TOTEI Adjust head alignment Ribbon Tension Adjust ribbon tension Foreign material on head or Clean head and platen platen Light Images Poor quality labels Use thermal transfer compatible stock Poor quality ribbons Use genuin
70. edge of the label that comes out of the printer first to the first vertical print position It is always a positive setting since making it negative would move it up and off the printable label This setting changes the base reference point for all subsequent label jobs It s effect is identical to the ESC Base Reference point command Since the printer moves the label in discrete steps equal to the size of the print dot the units of measure for Vertical Offset distance is dots The maximum value that can be set is 1424 2848 in Expanded mode Each dot is 0049 inches 125mm Note This setting can be overridden by the Base Reference Point Command It is recommended that you relocate printing in your software as adjustments made here will affect all of you label formats To access this setting perform the following steps STEP PROCEDURE 1 Use the LINE to step to desired setting display will increment one step each time the LINE key is pressed Press the FEED key to advance to each subsequent digit 2 Once the setting is correct press the FEED key to accept the setting advance the display to the Horizontal Direction display ORIGINAL PRINT m LINE LOCATION PRINT LINE SU VERTICALLY RELOCATED USING THE LINE KEY STEP 1 LINE FEED DIRECTION 35 Rev C M 8400RV Service Manual SECTION 2 Configuration Horizontal Offset and Direction
71. emblies are e Ribbon Unwind Rewind Assembly e Ribbon Guide Roller Assembly e Print Head Assembly Drive Belt Assembly In this section you will find procedures for e Ribbon Unwind and Rewind Clutch Adjustment e Ribbon Guide Plate Adjustment Print Head Position Alignment e Print Head Balance Adjustment e Print Head Pressure Check e Feed Roller Adjustment e Pitch Sensor Modification e Timing Belt Tension Adjustment 73 Rev C SATO M 8400RV Service Manual SECTION 5 Mechanical Adjustments 5 2 Ribbon Clutch Adjustments Excessive ribbon unwind and rewind tension will result in variable ribbon motion and could be the cause of print quality problems Follow the procedures 5 2 1 and 5 2 2 to verify that the ribbon unwind and rewind tensions are within specification or if adjustment of either clutch is necessary 1 Kg Tension Gauge Ribbon Core empty String 12 mm Wrench 2 Phillips Screw Driver Required Equipment FOR 5 2 1 amp 5 2 2 5 2 1 Ribbon Unwind Clutch Adjustment To adjust the Ribbon Unwind Clutch perform the following steps and refer to the illustrations STEP PROCEDURE 1 Remove the ribbon if installed 2 Place an empty ribbon core on the ribbon unwind spindle Attach the free end of the string to the tension gauge Refer to Fig 5 1 5 2 3 Wind the string tightly around the ribbon core in a single layer and in a counter clockwise direction Attach the free end of the string to
72. es in this section This table list symptoms probable causes and suggested corrective actions Many of the suggested corrective actions include references to a section or paragraph found elsewhere in this manual where more complete descriptions and procedures may be found Both print quality and general operational problems are listed in the troubleshooting table Make sure the basics have been checked before deciding you are unable to proceed any further To help you this section has been divided into the following parts Initial Checklist e Centronics Parallel Interface RS232C Serial Interface e Error Signals Troubleshooting Tables Head Pattern Examples 119 Rev C SATO M 8400RV Service Manual SECTION 8 Troubleshooting 8 2 Initial Checklist If you are unable to produce output on the M 8400RV check the following before deciding you are unable to proceed any further l Is the printer powered up and ON LINE 2 Doany of the Front Panel LEDs indicate an error condition If this light is ON it may indicate the print head assembly is open 3 Is the Print Head and the Label Hold Down in the down and latched position Other areas that may need looking at include 8 3 Troubleshooting the Centronics Parallel Interface 1 Is the parallel printer cable connected securely to your parallel port DB 25S Female on the PC and to the Centronics connector on the printer Warning Never connect o
73. g bracket Feed sensor connector back through the frame hole and reattach to SEN4 on the PCB Attach the sensor bracket to the frame Replace the unwind spindle shaft referring to Section 6 9 Replace and secure the LH cover to the printer base with 2 screws previously removed Tighten 2 inside screws Reconnect the power 99 Rev C SATO M 8400RV Service Manual SECTION 6 Replacement Procedures 6 8 Replacing the Ribbon Motion Sensor UNWIND SPINDLE ASSEMBLY Fig 6 17 SENSOR AND MOUNTING SCREW SENSOR CONNECTOR Fig 6 18 2 SCREWS ATTACHING SENSOR TO BRACKET Fig 6 19 100 Rev C M 8400RV Service Manual SECTION 6 Replacement Procedures 6 9 Replacing the Ribbon Drive Clutch Washers Both the ribbon unwind and the rewind drive spindles incorporate a friction clutch assembly to control tension The friction washers within these clutch assemblies are replaceable The procedure is identical for both the off wind and the on wind clutch assemblies Required Equipment 2 Phillips Screw Driver 12mm Open End Wrench STEP PROCEDURE 1 Switch the printer OFF and disconnect the power cable 2 Open the top and side access doors the mechanical side of the printer 3 Loosen 2 inside screws holding the LH cover to the inside top of the printer and remove 2 screws holding the cover
74. he electrical side Insert the connector into the socket identified as CUT on the circuit board of the cutter Refer to Fig 9 21 WARNING INCORRECT ORIENTATION OF THESE CONNECTORS WILL RESULT IN SEVERE DAMAGE TO THE PRINTER CUTTER 15 Route and attach the connectors from the split cable to the sockets on the PCB Refer to Fig 9 22 9 23 amp 9 24 WARNING INCORRECT ORIENTATION OF THIS CONNECTOR WILL RESULT IN SEVERE DAMAGE TO THE PRINTER CUTTER 16 Mate the hinges on the cutter to those installed in Step 10 Carefully slide the cutter to the inside of the printer The cutters drive pulley s and belts extend into the opening in the inside of the printer Refer to Fig 9 19 17 Loosen 2 screws holding bracket on the cutter frame Attach the bracket to the print mechanism using screw provided but do not tighten Refer to Fig 9 25 18 Be sure all cables are properly routed Close the door and lid and secure cover with screws removed in Step 3 19 Connect the AC power cord to the printer and place the power switch in the ON position The installation of the Dispenser is now complete 143 Rev C SATO M 8400RV SERVICE MANUAL SECTION 9 5 9 5 Label Cutter Unit TOP AND SIDE ACCESS DOORS LH COVER LOOSEN 2 Fig 9 11 SCREWS Fig 9 13 2 SCREWS Fig 9 12 LOCK LEVER SHOWN IN OPEN POSITION Fig 9 14
75. imately 45 feet of ribbon remains This sensor is a motion detector that signals the printer when the ribbon supply is turning This sensor is used for both the ribbon end and ribbon rear end sensing When error is displayed Ribbon out not turning Rev C M 8400RV Service Manual SECTION 1 Overview amp Specifications 1 7 Switches and Sensors Cont MICRO SWITCH LABEL SENSOR UNIT Both the Mark reflective and Gap transmissive sensors can be adjusted over a limited range They are both located in the label sensor unit The assembly can be adjusted by loosening the green sensor adjust knob located underneath the label transport assembly and sliding the label sensor unit to the desired position The gap sensor can be adjusted from a minimum of 0 67 in 17mm to a maximum of 2 5 in 64 mm and the Mark from a minimum of 0 25 in 7 mm to a maximum of 2 1 in 54 mm from the fixed position inside label guide The range of sensor adjustment can be increased to allow the Gap sensor to be positioned as close as 3mm from the inside label edge Refer to Section 5 8 MEDIA HOLD DOWN Open by lifting up on the release tab underneath the green tab LABEL OUT SENSOR Micro switch is marked PUSH activated when media stock is out or when the Close by pushing down on the same Media Hold Down is in the up position green tab printer operations stop and an error messag
76. ime DTR will go high or an X On is sent to tell the host that it can again receive data See Figure 3 2 0 56K 64K DTR High or DTR Low or X On a Buffer Available Fig 3 2 3 4 RS232C Serial Interface General Specifications Asynchronous ASCII Half duplex communication Ready Busy Hardware Flow Control Pin 20 DTR Control Pin 4 RTS Error Condition X On X Off Software Flow Control Bi Directional communication ENQ Response Data Transmission Rate 2400 4800 9600 and 19200 bps Character Format 1 Start Bit fixed 7 or 8 data bits selectable Odd Even or No Parity selectable 1 or 2 Stop bits selectable 47 Rev C SATO M 8400RV Service Manual SECTION 3 Interface Specifications 3 4 RS232C Serial Interface Cont Electrical Specifications 13 DB 25P Male 50 ft maximum length For cable configuration refer to Cable Requirements appropriate to the RS232C protocol chosen Signal Levels High 5V to 12V Low 5V to 12V Pin Assignments RS232C Interface Signals DIRECTION SIGNAL DESCRIPTION FG Frame Ground 2 To Host TD Transmit Data Data from the printer to the host computer Sends X On X Off characters or status data Bi Directional protocol RD Receive Data Data to the printer from the host computer 48 Rev C SATO M 8400RV Service Manual SECTION 3 Interface Specifications 3 4
77. ind Disc Plates onto Item 8 Ribbon Bosses Align the hole in the Disc Plates over the pegs on Item 8 The teeth slots on the unwind disc plate must be facing away from the Ribbon Boss Install this assembly onto the Ribbon Shaft and slide it against the felt friction washer Install Item 6 Oil less Dry Metal Washer onto the ribbon shaft with the copper side facing inward the black carbon side will face outward Align Item 6 Washer with the peg on 8 Ribbon Boss Install Item 5 Disc onto the ribbon shaft with the smooth side facing Item 6 Washer one side of the disc is smooth and the other side has sharp edges Install Item 4 Spring onto the ribbon shaft Install Item 3 Stopper Collar onto the ribbon shaft Screw the Item 2 Adjustment Nut clockwise into the end of the ribbon shaft Replace 1 Screw and tighten 103 Rev C SATO M 8400RV Service Manual SECTION 6 Replacement Procedures 6 10 Replacing the Timing Belts There are three timing belts in the M 8400RV Printer Belt Label Feed Roller Timing Belt is used to feed torque from the stepper motor to a set of toothed pulleys which is connected to the label feed mechanism Belt Platen Pulley Timing Belt is used to transmit torque from the stepper motor to the platen pulley via a set of toothed pulleys Belt Carbon Pulley Rewind Timing Pulley is used to transmit torque from the platen pulley to the ribbon roller via another set of to
78. inter Fig 6 13 Remove 2 screws holding the spring plate to the shaft and sensor Fig 6 14 Replace sensor module Reattach spring plate to the shaft and sensor Carefully slide the unit into the access hole of the back plate The extrusion of the module must fit into T slot of the side frame assembly Fig 6 15 amp 6 16 Replace the bracket that holds the module to the side frame with 2 screws previously removed Reattach cable connections Upon completion of sensor installation replace label tear off cover and the LH cover Reconnect the power 94 Rev C Nov 1998 M 8400RV Service Manual SECTION 6 Replacement Procedures 6 6 Replacing the Label Pitch Sensor Assembly SIDE FRAME LABEL COVER Fig 6 10 sipe FRAME BRACKET SCREWS TEAR OFF COVER 1 SCREW FE BACK SIDE OF Eum LABEL TEAR OFF Fig 6 11 COVER LABEL PITCH SENSOR MODULE IN POSITION SENSOR MODULE SHOWN REMOVED Fig 6 12 95 Rev SATO M 8400RV Service Manual SECTION 6 Replacement Procedures 6 6 Replacing the Label Pitch Sensor Assembly DETACH 2 TOP CONNECTORS Fig 6 13 PLATE Fig 6 14 SPRING PLATE SHAFT amp SENSOR ACCESS OPENING EXTRUSION OF BACK PLATE MODULE Kz THIS END FORWARD SLOT FOR MODULE
79. it will cause the data in the receive buffer to be corrupted 45 Rev C SATO M 8400RV Service Manual SECTION 3 Interface Specifications 3 2 Interface Types Cont WARNING Never connect or disconnect interface cables or use a switch box with power applied to either the host or the printer This may cause damage to the interface circuitry in the printer host and is not covered by warranty The receiving buffer will not be able to receive more data again until a Buffer Available condition occurs This takes place when the receiving buffer has emptied so that only 56K bytes of data are being held 8K bytes from being full At this time DTR will go high or an X On is sent to tell the host that it can again receive data printer error conditions i e label out ribbon out will cause the printer to go busy DTR low or X Off until the problem is corrected and the printer is placed on line The printer will also be busy if taken off line from the front panel 3 3 The Receive Buffer The M8400RV printer has the ability to receive a data stream from the host in one of two ways The receive buffer may be configured to accept one print job at a time or multiple print jobs The single job print buffer is generally used by software programs that wish to maintain control of the job print queue so that it can move a high priority job in front of ones of lesser importance The multiple job buffer on the other hand prints
80. justments Zero Slash Setting ZERO SLASH This setting determines if a zero is printed with a slash or without a slash This setting can also be controlled via software commands When YES is selected the U S M WB WL XU XS XM XB XL and vector fonts will have a slash through the center of the zero character To access this setting perform the following steps STEP PROCEDURE 1 Use the LINE to step underlined cursor to either 2 Once the correct setting is underlined press the FEED key to accept the setting and advance to the Auto Online display Auto Online Setting AUTO OHLIHE YES This setting determines the mode in which the printer powers up If the YES selection is made the printer powers up in the ONLINE mode and is ready to print If NO is selected the printer powers up in the OFFLINE mode and must be manually placed in the ONLINE mode by pressing the LINE key before it is ready to print To access this setting perform the following steps STEP PROCEDURE Use the LINE key to step the underlined cursor to either YES or NO 2 Once the correct setting is underlined press the FEED key to accept the setting and advance to the Vertical Offset display 34 Rev C SATO M 8400RV Service Manual SECTION 2 Configuration Vertical Offset Setting WERT OFFSET Ut 1951 Vertical Offset is the distance down from the leading edge the
81. le plugged in to discharge any possible static charges Open the top and side access doors on the mechanical side of the printer Loosen 2 inside screws holding the LH cover to the inside top of the printer and remove 2 screws holding the cover to the frame Lift off the cover for access to the electrical section Refer to Fig 9 11 9 12 amp 9 13 Remove the screw from the front hinge of the top cover for Step 9 below Remove 1 screw holding the label tear off cover to the printer Rotate the cover down then remove it by lifting up Refer to Fig 9 14 Move the print head lock lever to the open position Refer to Fig 9 15 Remove 2 screws to detach spacer panel Refer to Fig 9 16 Remove 4 screws holding the print mechanism to the back panel and 2 screws attached to the hinges Refer to Fig 9 16 9 17 amp 9 18 Slide the print mechanism as far forward as it will go It will cover the space left by the removal of the spacer panel Step 7 Replace 6 screws removed in Step 8 Attach two hinge halves to the front base of the printer Refer to Fig 9 19 Install spacer panel Refer to Fig 9 20 Reattach hinge removed in Step 4 142 Rev C SATO M 8400RV SERVICE MANUAL SECTION 9 5 9 5 Label Cutter Unit Installation cont STEP PROCEDURE 14 Pass the cable with the single grey connector attaches to the cutter through the access hole in the print mechanism wall from t
82. ll advance to a setting of 4 9 the maximum voltage after which it will automatically wrap and start at 0 0 again Ifa value of 0 0 is set the printer will automatically set the level each time the printer is powered on with labels loaded or the head is closed 5 Repeat this procedure using values slightly higher or lower until the optimum performance is obtained If you cannot find a setting that will give you adequate performance then the label stock or printed I Mark has too much variation in its reflectance and a better quality stock should be used 6 Once the setting is correct press the FEED key to accept the setting 39 Rev C M 8400RV Service Manual SECTION 2 Configuration Calendar Set CALENDAR CALEMDAR 257725775 o If the Calendar Option is installed in the printer the date and time can be set manually using the LCD display or via the lt ESC gt wT Calendar Set command last setting set either manually or via software command received by the printer will be the value used The format of the display is YY MM DD hh mm Year Month Day hours minutes The date format is fixed and cannot be changed To access this setting perform the following steps STEP PROCEDURE 1 Year The first display shown will have the two digit year selection underlined Press the LINE key to scroll through the dates The year number will increase by one value each time the
83. n that surface Rotating screw CCW places pressure on the outside end right side of the print head creating a darker impression on that surface ROTATE ADJUSTING SCREW INDEXING POINTER SHOWS HOW MUCH SHAFT END HAS MOVED UP OR DOWN CHANGING HEAD BALANCE LOOSEN SCREW 79 Rev C M 8400RV Service Manual SECTION 5 Mechanical Adjustments 5 6 Print Head Pressure Check Required Equipment 2 Phillips Screwdriver 5Kg Tension Gage STEP PROCEDURE 1 Remove the ribbon if installed 2 Load label stock into Printer 3i Remove 2 screws to detach ribbon guide plate from print head bracket Fig 5 8 4 Fasten a length of cord to both ends of the head bracket and attach to the tension gage Gradually pull upward on gage while gently pulling forward on the label stock Fig 5 9 Note tension reading when label stock just begins to move forward as a result of the pulling force If the tension reading is not within the specified range of 3 3 5Kg the print head spring plates must be replaced THERE IS NO ADJUSTMENT OF THE PRINT HEAD TENSION TENSION GAGE HEAD ADJUSTMENT PLATE PRINT HEAD BRACKET RIBBON GUIDE E PLATE o Sa a 7 i NS G Fig 5 9 Fig 5 8 REMOVE 2 SCREWS 80 Heute M 8400RV Service Manual SECTION 5 Mechanical Adjustments 5 7 Feed Roller Adjustment Label Tracking Adjustment Required Equipment
84. n the error is cleared and the printer is placed back on line it transmits an X On indicating it is again ready to accept data Upon power up if no error conditions are present the printer will continually send X On characters at five millisecond intervals until it receives a transmission from the host Cable Requirements 2 TD Transmit Data 3 RD Receive Data 4 RTS Request to Send ae 5 CTS Clear to Send 6 DSR Data Set Ready 20 Data Terminal Ready 7 SG Signal Ground 51 Rev C SATO M 8400RV Service Manual SECTION 3 Interface Specifications 3 4 5232 Serial Interface Cont X On X Off Flow Control Cont Data Streams The Data streams for X On X Off are constructed in the same way as they are for Ready Busy flow control The STX and ETX control characters must frame the data stream NOTE All characters including STX ESC and are in ASCII lt STX gt lt ESC gt A Job 1 lt ESC gt Z lt ESC gt A Job n lt ESC gt Z lt ETX Example lt STX gt A Job 1 lt ESC gt Z lt ETX gt XXXX Bi Directional Communications This is a two way communications protocol between the host computer and the printer thus enabling the host to check printer status When this protocol is selected there is no busy signal from the printer pin 20 DTR is always high The host must request the complete status from the printer including ready busy Whenever the
85. nd Keyboard PCB Display 2 MOUNTING LC DISPLAY SCREWS FRONT LEFT SIDE COVER SHOWN DETACHED FROM PRINTER KEYBOARD PCB DISPLAY PANEL 112 Eee SATO M 8400RV Service Manual Section Factory Resets 7 1 Overview The Factory Reset Mode allows you to e Reset the printer e Clear Counter Heads e EEProm Clear all e Clear Cutter Counter LINE FEED POWER LABEL RIBBON ERROR PRINT OFFSET PITCH ON LINE DISPLAY pew DSWE Dee 113 Rev C M 8400RV Service Manual SECTION 7 Factory Resets 7 2 Resetting the Printer Test Print This procedure allows the user to run a self test to verify e Head Counters s li Refer to Page 118 for test print sample e Printer Setups To run the test perform the following steps STEP PROCEDURE iW Record all current dip switch positions then place all switches in the off position 2 Place the DSW2 5 in the ON position 3 Place the print head in the OPEN position keeping both the LINE amp FEED keys depressed power on the printer 4 Upon hearing the audible tone release the LINE amp FEED keys Place the print head back in the CLOSED position and DSW2 5 in the OFF position 5 Verify display Factory Mode 6 Press the FEED key once Verify display COUNTER CLEAR HOH 7 Press the LINE key to initialize reset After a slight pause 1 blank will feed out foll
86. ng lt ETX gt ID This is a two byte number identifying the current print job ID The print job ID is defined using the lt ESC gt ID Job ID command transmitted with the print job see Job ID Store in the command listing for more information on how to use this command The range is from 00 to 99 Status A single byte defining the current status of the printer see the Status Byte Definition table Label Remaining Six bytes defining the number of labels remaining in the current print job The range is from 000000 to 999999 labels If an ENQ is received after the print job specified in the ID bytes has been completed or there is no data in the buffer the printer will respond with two space characters 20 hexadecimal for the ID number and six zero characters 30 hexadecimal in the Remaining Labels bytes If a CAN 18 hexadecimal command is received it will stop the print job and clear all data from the receive and print buffers A delay of five milleseconds or more is required before any new data can be downloaded The CAN command is effective immediately upon receipt even if the printer is off line or in an error condition The printer will return an ACK 06 hexadecimal if there is no printer error condition and a NAK 15 hexadecimal if an error condition exists Upon receipt of a valid print job lt ESC gt A lt ESC gt Z and ACK 06 hexadecimal will be returned by the printer if there are no errors and a NAK 16 hexa
87. oard PCB Display 6 13 SECTION 7 FACTORY RESETS Qu e 7 1 Resetting the Printer Test Print eeeeeeeeeeeeeeeeeee 7 2 Prom Clear All coiere tru ineo 7 3 Clear Counter Heads ertet oe ueni 7 4 Clear Cutter Countef csi ccccsccscssscaicssesssecsanatevsetcccesactcveserstsvcecevesecctisezsess 7 5 SECTION 8 TROUBLESHOOTING OVAA EA cess EE 8 1 8 2 Troubleshooting the Centronics Parallel Interface 8 3 Troubleshooting the RS232C Serial Interface 8 4 A 8 5 Troubleshooting 8 6 Head Pattern Examples eiecit 8 7 9 1 Memory Gard oer eben 9 2 Label Dispenser Uhilt ierit bci edet 9 3 Label Hewinder exces mur 9 4 B Neu giu NRE NP AN 9 5 p EE 9 6 Rev C SATO M 8400RV SERVICE MANUAL Page 111 113 114 115 116 117 119 120 120 122 123 124 128 131 132 137 140 142 147
88. of specification the power supply must be replaced Section 4 1 contains procedures for measuring DC voltage levels Power supply removal and replacement procedures are located in Section 6 5 You can adjust threshold voltage levels for label sensors These adjustments are made to allow for variations in the characteristics of the labels used with the printer If you cannot calibrate the label sensor voltage level within the specified voltage range you should reposition the label sensor by following the adjustment procedures included in this section After completing the label sensor adjustment procedures perform the label sensor voltage level adjustment procedure You can check or adjust e Power Supply e Label Sensor e Ribbon Sensor e Pitch Offset e Label Positions 59 SATO M 8400RV Service Manual Rev SECTION 4 Electrical Checks and Adjustments 4 2 Steps Prior to Adjustments All the adjustments in this section begin by removing the covers to the mechanical section and removing the LH cover to gain access to the main Required Equipment Number 2 Phillips Screwdriver STEP PROCEDURE 1 Open the top and side access doors the mechanical side of the printer 2 Loosen 2 inside screws holding the Left Side Cover to the inside top of the printer Remove 2 screws holding the Left Side Cover to the printer base at the outside of the printer and remove the cover to expose the main P
89. othed pulleys Required Equipment 2 Phillips Screw Driver e Flat head Screw Driver STEP PROCEDURE 1 Switch the printer OFF and disconnect the power cable 2 Open the top and side access doors the mechanical side of the printer 3 Loosen 2 inside screws holding the LH cover to the inside top of the printer and remove 2 screws holding the cover to the frame Lift off the cover for access to the timing belts Refer to Fig 4 1 4 2 amp 4 3 in Section 4 4 Remove the ribbon and label stock if installed Remove 1 screw holding the label tear off cover Fig 6 23 6 Remove the center screw holding the carbon rewind shaft to the shaft supporting bracket Pull rewind shaft forward to dislodge from the bracket and release pressure from belt C Fig 6 24 7 Loosen 2 mounting screws attaching the stepper motor to the frame Access the motor from the opening previously covered by the label cover Move the motor in the motor mounting slots to release pressure from the belts Remove and replace belts as required Fig 6 25 Replace center screw to carbon rewind shaft Adjust the belt tension as outlined in Section 5 9 10 Replace the cover removed in Step 5 Replace and secure the LH cover to the printer base with 2 screws previously removed in Step 3 Tighten 2 inside screws Reconnect the power 104 Hoy SATO M 8400RV Service Manual SECTION 6 Replacement Procedures 6 10 Replacing the
90. owed by a factory test print Warning This test activates all the heating elements on the print head and therefore should be used for testing purposes only to avoid damaging the print head especially when performed with labels less than the full width of the print head 8 Press the FEED key to stop printing 9 Place the printers power switch to the off position and return all switches to their original positions 7 3 EEProm Clear All 114 SATO M 8400RV Service Manual This setting clears all counters resets printer to factory defaults STEP PROCEDURE IMPORTANT NOTE To clear EEPROM ERROR this procedure may need to be performed twice SECTION 7 Factory Resets Record all current dip switch positions then place all switches in the OFF position Place the print head in the open position Turn on DSW1 7 amp 8 DSW2 5 Turn on the power while pressing the LINE amp FEED keys Release when an audible sound is heard Verify display Head Open Place the print head back in the closed position Turn off DSW1 7 amp 8 and DSW2 5 in that order Verify display Factory Mode Press the FEED key once Verify display COUNTER CLEAR NON Press the LINE key once to change the display from NON to ALL Verify display COUNTER CLEAR Press the FEED key Version1E2040 ALL display reads FACTORY TEST PRINT and printer starts printing test prints Press Feed key to p
91. p test print then turn the power off Tolerance of OFFSET VR 3 75 mm A e 3 Fig 4 14 71 SATO M 8400RV Service Manual Rev SECTION 4 Electrical Checks and Adjustments 4 11 Feed Backfeed Adjustment Dispenser Mode Use Offset to adjust label stop position Required Equipment Small flathead screwdriver for potentiometer adjustment STEP PROCEDURE 1 Turn the OFFSET VR on the front panel to the center position Refer to Fig 4 15 2 Turn the power on while pressing the FEED key 3 Press the LINE key to set the cursor on Small USER TEST PRINT Small Large 4 Press the FEED key once Verify display SIZE 5 Press the LINE key to adjust the print width 6 Press the FEED key to initiate test printing Press FEED key again to stop printing 7 Adjust dispensed label edge position with OFFSET VR in the right position 8 Press FEED key to stop test print then turn the power off Tolerance of OFFSET VR 3 75 mm Fig 4 15 CEEA Eo 72 Rev C SATO M 8400RV Service Manual Section Mechanical Adjustments 5 1 Overview The M 8400RV printer contains adjustable mechanical sub assemblies This means that during your regular maintenance your service technicians are able to make adjustments to reset the printer to factory specifications thereby ensuring optimum performance of your printer The main mechanical sub ass
92. peration is completed a SATO DEFAULT COMPLETED message will be displayed on the LCD panel and a single audible signal will be heard The printer should be powered off while this message is being displayed This saves the default settings in the EEPROM where they will be automatically loaded the next time the printer is powered on SATO M 8400RV Service Manual 27 Rev C SECTION 2 Configuration 2 3 Printer Adjustments The LCD Panel on the M 8400RV printer is used in conjunction with the LINE and FEED switches by the operator to manually enter printer configuration settings Many of the settings can also be controlled via software commands and in the case of conflict between software and control panel settings the printer will always use the last valid setting If you load a label job that includes software settings and then enter a new setting via the operation panel the manually set values will be used by the printer If you set the values manually and then download a job with software settings the software settings will be used mue Normal User Mode Refer to Print Test Labels POWER FEED Page 43 Advanced Mode MNT Settings and efer to Ale nente POWER LINE 33 eee Load SATO M Ref Default Settings as aire DEFRULT SETTING COMPLETED Download User Refer to Page21 USER BOWUNLORC odes f Reset to SATO Default Protocol POWER LINE FEED Referto PROTOCOL
93. place and secure the LH cover to the printer base with 2 screws previously removed Tighten 2 inside screws Reconnect the power 97 Rev C SATO M 8400RV Service Manual SECTION 6 Replacement Procedures 6 7 Replacing the Label Out Sensor Assembly Micro Switch LOOSEN SCREW SENSOR CONTACT DOOR LATCH AND ANGLE SUPPORTS SIDE PLATE SENSOR AND SCREWS UNDERSIDE OF RAMP ASSEMBLY GROUP Fig 6 16A 98 Rev C M 8400RV Service Manual SECTION 6 Replacement Procedures 6 8 Replacing the Ribbon Motion Sensor The Ribbon Motion Sensor is easily replaced for service Required Equipment 2 Phillips Screw Driver STEP PROCEDURE Switch the printer OFF and disconnect the power cable Open the top and side access doors on the mechanical side of the printer Loosen 2 inside screws holding the LH cover to the inside top of the printer and remove 2 screws holding the cover to the frame Lift off the cover for access to the sensor module Refer to Fig 4 1 4 2 amp 4 3 in Section 4 Remove the unwind spindle shaft using procedure in Section 6 9 Fig 6 17 Remove sensor mounting screw Fig 6 17 Unplug the SENA connector from the PCB and pull the sensor unit through the frame hole Fig 6 18 Remove 2 screws holding sensor to the mounting bracket Fig 6 19 Replace sensor and reattach to the mountin
94. plete line going to the printer SATO M 8400RV Service Manual 121 Rev C SECTION 8 Troubleshooting 8 4 Troubleshooting the RS232C Serial Interface 1 Is the RS232C Serial cable connected securely to your serial port the DB 25S Male and to the RS232C connector on the printer Warning Never connect or disconnect interface cables or use a switch box with power applied to either the printer or the host This may cause damage to the interface circuitry and is not covered by warranty Is the cable defective At the very least you should be using Null Modem Cable which crosses pins in a specific manner This should enable your printer to print We recommend that you use a cable built to specifications described in Section 3 Interface Specifications Check for obvious errors in the data stream Remember that all print jobs for serial data must be framed by an STX and ETX If after sending your job to the printer it only or displays a Framing Error message on the LCD panel you may have a configuration problem There may be some inconsistencies with the Baud Rate Parity Data Bits or Stop Bits in relation to your host computer If you are confused as to what the printer s current RS232 settings are you may choose the SATO defaults all DIP switches in the OFF position to achieve 9600 baud no parity 8 databits and 1 stop bit If you still are unable to get printer out
95. put try the Hex Dump as described in Step 5 under the Centronics Interface troubleshooting In this case the printer monitors its RS232C interface for incoming data From the Hex Dump if you are seeing extra OD CR and characters and are using BASIC refer to the beginning of the Command Code section in the Operator and Technical Reference Manual 122 Rev C M 8400RV Service Manual SECTION 8 Troubleshooting 8 5 Error Signals LCD AUDIBLE ERROR MESSAGE BEEP CONDITION TO CLEAR EEPROM 1 Long EEPROM Error On 3 Short Cycle power ON OFF Error Blinks Card R W 1 Long Memory Card Cycle power ON OFF Error Read Write Error Blinks Card Low 1 Long Memory Card Cycle power ON OFF Battery Battery Low Error Blinks Head Open Head Open Close head lever Error On PARITY 3 Short RS232 Parity Error On Overrun Error 3 Short RS232 Overrun Cycle power ON OFF Line Blinks Error Error On Framing Error 3 Short RS232 Framing Cycle power ON OFF Line Blinks Error Error On Buffer Over 3 Short Buffer Overflow Cycle power ON OFF Line Blinks Error Blinks Paper End 3 Short Label End Open close Head Lever Label On Open close Label Hold down Error Blinks Ribbon End 3 Short Ribbon End Open close Head Lever Ribbon On Open close Label Hold down Error Blinks Media Error 3 Short Media Error Open Close Head Lever Label Blinks Ribbon Blinks Replace ribbon with roll End Line Blinks o Buffer N
96. r disconnect interface cables or use a switch box with power applied to either the printer or the host This may cause damage to the interface circuitry and is not covered by warranty 2 Is there more than one parallel interface port on your PC LPT1 LPT2 etc If so make sure you are sending data out the correct port 3 When you send the print job to the printer and it does not respond do you get an error message on your PC that says Device Fault or something similar This may mean that the computer doesn t know the printer is there Verify that a Both ends of the cable are securely inserted into their respective connectors b The printer is ON LINE The cable is not defective There are other things that can cause this error message on your computer but at this stage a defective cable may be one of the reasons 120 Rev C M 8400RV Service Manual SECTION 8 Troubleshooting 4 When you send the print job to the printer and it does not respond and there is no error message on the PC a Check your data stream for some of the basics Is your job framed as follows lt ESC gt A DATA lt ESC gt Z b Verify that you ve included all required parameters in the data stream c Verify the following e You have not typed a 0 zero for an letter or vice versa e You have not missed any lt ESC gt characters where they re needed sure all printer command codes are
97. reshold the voltage must be measured with nothing but the label under the sensor and then again with the printed I Mark under the sensor The formula for this is High Voltage Level Low Voltage Level x 0 5 Start Value To access this setting perform the following steps STEP PROCEDURE 1 Insert a label into the sensor and close the Label Hold Down Make sure the printed Eye is not under the sensor Record the voltage shown on the top line of the LCD panel This line should have the message Eye on the top line DIP switch DSW2 2 ON 2 Now pull the label forward until the mark is positioned under the sensor the voltage reading should be at its highest point Record the voltage shown on the top line of the LCD panel The voltage ranges measured should be within the following ranges Label Only Eye Mark 1 0V or less 2 5V to 3 5V If the measured values are outside this range you may have trouble finding a value that will work properly under all conditions If this is the case a higher quality label may be needed to get adequate performance or adjust See Section 4 4 3 Calculate the starting point voltage using the formula Use the LINE key to step the counter to the desired setting The display will increment one step for each time the LINE key is pressed If the LINE key is held down for more than two seconds it will automatically go into the fast scroll mode The reading wi
98. s to the back plate Fig 6 29 Displace platen by tilting up and forward from the hole in the back plate and releasing from ball supporter on opposite end of shaft Separate the platen and components for replacing Fig 6 30 amp 6 31 Install new platen component s Refer to Section 5 9 to adjust belts Replace the label tear off cover and the LH cover Reconnect the power 106 Rev C M 8400RV Service Manual SECTION 6 Replacement Procedures 6 11 Replacing the Platen LABEL TEAR OFF COVER STEPPER PLATEN 1 SCREW COVER TO FRAME PLATEN SHAFT PULLEY SNAP T RING REMOVE SNAP RING 2 SCREWS Fig 6 28 MOTOR TO FRAME SCREW amp CLAMP 107 Rev C M 8400RV Service Manual SECTION 6 Replacement Procedures 6 11 Replacing the Platen TILT PLATEN UP AND FORWARD TO PLATEN amp DISPLACE COMPONENTS BACK PLATE BALL BEARING SUPPORT LOCATED AT BOTH ENDS OF SHAFT BALL BEARING SUPPORT MUST BE SEATED IN RECESS SUPPORTER CLAMP 108 Hoy SATO M 8400RV Service Manual SECTION 6 Replacement Procedures 6 12 Replacing the Stepper Motor The stepper motor is used to transmit motion to the print mechanism for precise print positioning The stepper motor transmits torque to the label feed roller the platen roller
99. t eee 5 3 Print Head Position Alignment eere 5 4 Print Head Balance Adjustment eere nnn 5 5 Print Head Pressure 5 6 Feed Roller Adjustment Label Tracking 5 7 Pitch Sensor Modification for Sensing R Corner Notch Tags 5 8 Timing Belt Tension eene 5 9 SECTION 6 REPLACEMENT PROCEDURES OVOFVIOW A 6 1 6 2 Replacing the Print 6 3 Replacing the Circuit 4 12 04 111116 6 6 4 Replacing the Power Supply 6 5 Replacing the Label Pitch Sensor Assembly 6 6 Replacing the Label Out Sensor Assembly 6 7 Replacing the Ribbon Motion Sensor oos 6 8 Replacing the Ribbon Drive Clutch Washers 6 9 Replacing the Timing 6 10 Replacing the aue ke 6 11 Replacing the Stepper Motor eere eere 6 12 Replacing the LC Display and Keyb
100. tage level on Pin 20 of the RS232 port the printer notifies the host when it is ready to receive data Pin 4 RTS and Pin 20 DTR are the important signals on the printer for this method of flow control The host must be capable of supporting this flow control method for it to function properly 49 Rev C SATO M 8400RV Service Manual SECTION 3 Interface Specifications 3 4 5232 Serial Interface Cont Cable Requirements 1 FG Frame Ground 3 RD Receive Data 4 RTS Request to Send This connection at the host side of the interface would depend upon the pin that is being used as the Ready Busy signal by the driving software Typically on a PC it would be either CTS pin 5 or DSR pin 6 on a DB 25 connector Data Streams Once the flow control method has been chosen for the RS232C interface the data stream must be sent in a specific manner The STX aznd ETX Control characters must frame the data stream lt STX gt lt ESC gt A Job 1 lt ESC gt Z lt ETX gt lt STX gt lt ESC gt A Job n lt ESC gt Z lt ETX gt NOTE All characters including STX ESC and ETX are in ASCII 50 Rev C SATO M 8400RV Service Manual SECTION 3 Interface Specifications 3 4 5232 Serial Interface Cont X On X Off Flow Control X On X Off flow control must be used whenever hardware Ready Busy flow control is not available or desirable Instead of a voltage going high low at
101. ted value must be adjusted to ensure reliable label feeding such as when the backing opacity or the reflectance of the I Mark varies significantly within a roll of labels or between label rolls In these instances the value should be set using the following procedures GAP SENSOR When setting the gap threshold the voltage shown on the top line of the display must be measured with nothing but the backing paper in the sensor and then again with a label still attached to the backing The formula to be used for setting the threshold is High Voltage Level Low Voltage Level x 0 5 Start Value To access this setting perform the steps STEP PROCEDURE 1 Insert label still attached to the backing into the sensor close the Label Hold Down Record the voltage shown on the top line of the LCD panel This line should have the message GAP on the top line DIP switch DSW2 2 OFF Make sure the label is all the way under the sensor and See Through Sensor is aligned over your label 37 Rev C M 8400RV Service Manual SECTION 2 Configuration Sensor Threshold Level Gap Sensor Continued STEP PROCEDURE 2 Strip label from backing insert strip under sensor and close the label lid Record the voltage shown on the top line of the LCD panel The voltage ranges measured should be within the following ranges Backing with Label Label Backing Only
102. ter except for the set to be used for selecting the custom code ALTERNATE PARAMETER STANDARD SETTING SETTING DEFAULT a STX x b ETX 5 d ENQ f z g OFFLINE h Auto ONLINE No n 12 i Zero Slash No 12 Reset ALT PROTOCOL DEFAULT COMPLETE If the custom Protocol Command codes are incorrect or if the printer does not respond to commands using the custom set the Alternate Protocol Control Codes can be restored by the following procedure STEP PROCEDURE 1 Turn the printer off 2 Place switch DSW2 7 the ON position 3 Turn power on while simultaneously pressing the FEED and LINE switches 22 Rev C SATO M 8400RV Service Manual SECTION 2 Configuration Selecting Protocol Control Codes Cont Download Procedure USER DOWNLOAD The procedure for downloading a custom Protocol Command Code set is STEP PROCEDURE 1 Reset the printer to the default settings using the Reset procedure 2 Place DIP switch DSW2 7 in the ON position 3 Turn power ON while simultaneously pressing the LINE switch This places the printer in the USER DOWNLOAD mode as signified by USER DOWNLOAD displayed on the LCD panel For printers that do not have an LCD panel you will hear a single signifying the printer is in the USER DOWNLOAD mode 4 Set DIP switch DSW2 7 in the position to accept the Protocol Control codes to be used for do
103. tion correctly Label sensor blocked Clean label sensor Incorrect label sense threshold Adjust label sense threshold 4 3 4 4 setting Platen drive malfunction See Section 5 Mechanical Adjustments RIBBON Ribbon supply roll empty Replenish ribbon supply DS Ribbon sensor out of alignment Realign ribbon sensor 4 6 WEE Ribbon sensor blocked Clean ribbon sensor No cardboard core on ribbon Use cardboard core on ribbon rewind rewind 127 Rev C SATO M 8400RV Service Manual SECTION 8 Troubleshooting 8 7 Head Pattern Examples Fig 8 1 FEED DIRECTION FACTORY DEFAULT GOOD ADJUSTMENT CLEAR DARK EVEN TEXT 128 Rev C M 8400RV Service Manual SECTION 8 Troubleshooting 8 7 Head Examples DISPLAY IRREGULAR UNEVEN TEXT ECCENTRIC NUT TURNED TOO FAR COUNTER CLOCKWISE CAUSE POOR HEAD ALIGNMENT BALANCE OUT OF ADJUSTMENT FEED DIRECTION 27772 Fig 8 3 DISPLAY IRREGULAR UNEVEN TEXT ECCENTRIC NUT TURNED TOO FAR CLOCKWISE FEED DIRECTION CAUSE POOR HEAD ALIGNMENT BALANCE OUT OF ADJUSTMENT Fig 8 5 129 Rev C M 8400RV Service Manual SECTION 8 Troubleshooting 8 7 Head Examples DISPLAY RIBBON WRINKLE DIAGONAL VOIDS WHITE STREAKS THAT WALK ACROSS LABEL CAUSE POOR HEAD ALIGNMENT POOR RIBBON TENSION WORN PLATEN FOREIGN MATERIAL DAMAGED PRINT H
104. to pin 1 of the test point labeled CH Ground on the main circuit board Attach the DC voltmeter positive lead to pin 10 of the CH test point of the main circuit board 4 Turn the ribbon unwind boss spindle slowly until the lowest possible voltage reading is displayed on the voltmeter If the voltage reading is not equal to or less than 0 5 VDC adjust 4 to obtain that reading VR4 PIN 1 amp 10 ROTATE CLOCKWISE 67 SATO M 8400RV Service Manual Rev SECTION 4 Electrical Checks and Adjustments 4 7 Pitch Offset Adjustment User Use Pitch to adjust print position and Offset to adjust stop position Required Equipment Small flathead screwdriver for potentiometer adjustment STEP PROCEDURE 1 On the front panel turn the Pitch VR to the center position Refer to Fig 4 10 2 Turn the power on while pressing the FEED key 3 Press the LINE key to set the cursor on Small USER TEST PRINT Small Large 4 Press the FEED key once Verify display PRINT SIZE 5 Press the LINE key to adjust the print width 6 Press the FEED key to initiate test printing Press FEED key again to stop printing ys Adjust Pitch VR while confirming with scale on test print Repeat Step 6 if necessary 8 After adjusting turn the power off Tolerance of Pitch VR 3 75 mm 2 E e 3 Fig 4 10 68 Rev C SATO M 8400RV Service Manual Section 4
105. type selected DSW2 2 Replace fuse on main PCB 6 2 No 24 volt output Test power supply and replace if required 4 3 Loose set screw on platen Tighten set screws pulley stepper motor No Printed vut hesdxtconmsaed Verify print head connector fully Image seated at head and main PCB 6 3 Ribbon upside down Use genuine SATO ribbons No 24 volt output Test power supply and replace if required 4 3 126 Rev C M 8400RV Service Manual SECTION 8 Troubleshooting Symptom Probable Cause Suggested Corrective Action No Printed Damaged print head Replace print head 6 3 Image WEE Damaged electronics Replace circuit board 6 4 Back light but no words on display or no display Most common failure of printer is Verify that the cable and connector DOA situation The most likely are properly seated cause is the ribbon cable has fallen out or not seated fully into connector Adjust display potentiometer on display panel POWERLED Ac power cable not connected Verify that the cable is connected to not on the printer and the AC outlet Fuse defective Replace fuse 6 2 Test power supply and replace if Defect EN efective power supply defective 4 3 6 5 ERROR LED Head not locked Close and latch head release on LABEL LED Label supply roll empty Replenish label supply on Label stock not routed through Reload labels sensor Label sensor not positioned Adjust sensor posi
106. unter has been reset to 0 Place the printers power switch to the off position and return all switches to Refer to Page 118 for test print sample their original positions 117 Rev C SATO M 8400RV Service Manual SECTION 7 Factory Resets BERE Factory Service Mode M nese TTT LOTT Ul it lj 1 Life Counter 6 8 Km Head Counter 1 5 0 Km Fead Counter 2 6 8 Km Head Counter 3 9 8 Km Cutter Counter 8 H Horiauctal Offset 886 DOT V Vertical Offset a BOT Print Soged mn Print Darkregs ROM 1 Version E ROM 2 Version xi Oba DATE 88987101 Head Check All Check OK Reflective Sensor Low WRI 85 1 8 amp 8 NONE Reflective Sensor Hih 5 lt NOKE Reflective Serscr Level 1 3 TransmssiW Sersor Low WRZ 4 1 0 8 Trammssws Sensor Hgh 2 11 5 lt Hi Lo 3 Bv Transmissiya Sensor Sire Level 1 1 Pitch Offset VRS 71 5 41 5 1 25nm Pont Front 34 66 Offset VR Front 1 8 1 5 48 A AS Front 1 41 5 8 EEL CEEEEEEDI WHAT Test Print Sample 118 Rev C M 8400RV Service Manual Section Troubleshooting 8 1 Overview The design of the SATO M 8400RV printer is based upon proven technology and reliable components When a problem occurs the solution can be easily traced using the troubleshooting tabl
107. ve the E Snap Ring from rod to allow sensor the full range of adjustment Refer to Fig 5 13 3 Replace label tear off cover MOTOR MOUNTING SCREWS ACCESS FROM OPPOSITE SIDE REMOVE E SNAP RING PITCH SENSOR FROM ROD LABEL TEAR Fig 5 12 OFF COVER 2 SCREWS BACK SIDE OF LABEL TEAR OFF COVER 83 Rev C M 8400RV Service Manual SECTION 5 Mechanical Adjustments 5 9 Timing Belt Tension Adjustment Required Equipment 1Kg Tension Gauge e 2 Phillips Screwdriver STEP PROCEDURE 1 Pull the center of each timing belt with the tension gauge and note the tension reading when the belt is moved 1 to 2mm If the tension reading of each belt is not within range of 100 300g the stepper motor mounting screws must be loosened to adjust the motor pulley 2 To gain access to the motor remove 2 screws holding the label tear off cover to the printer Rotate the cover down then remove it by lifting up Fig 5 14 3 Loosen the 2 stepper motor mounting screws and move motor to achieve the required range Tighten but do not over tighten screws Belts should have some movement Replace label tear off cover Fig 5 15 MOTOR MOUNTING SCREWS ACCESS FROM OPPOSITE SIDE TIMING BELTS Fig 5 14 LABEL TEAR OFF COVER 2 SCREWS Fig 5 15 MOTOR MOUNTING BACK SIDE OF LABEL SCREWS ACCESS TEAR OFF COVER THIS SIDE
108. w Adjust 1 to set the voltage at approximately 0 8 volts or less 5 HIGH LEVEL ADJUSTMENT I Mark Reposition the label tag so the black printed I Mark on the backside down is in the sensors field of view Check the voltage reading If the voltage shown on your meter is 2 8 volts or more no further adjustment is required Go to Step 7 63 SATO M 8400RV Service Manual Rev SECTION 4 Electrical Checks and Adjustments 4 4 Reflective I Mark Label Pitch Sensor Adjustment Cont STEP PROCEDURE 6 If the HIGH LEVEL ADJUSTMENT voltage indicated in Step 5 is less than 2 8 volts you must repeat Step 4 and adjust VR1 to a lower voltage value The target value should be 2 0 Volts less than the high level voltage obtained in Step 5 If the difference between the values obtained in Steps 4 amp 5 is less than 2 0 volts your label stock may be out of spec for proper operation of this printer Contact your Sato Distributor for assistance 7 Test your adjustment by properly installing a roll of label or tags and a roll of ribbon Power on the printer With the printer OFF LINE press the FEED key One label or tag should feed and no error should be indicated on the display VR1 PIN 1 amp 7 ROTATE CLOCKWISE 64 Rev C SATO M 8400RV Service Manual Section 4 Electrical Checks and Adjustments 4 5 See Thru GAP Pitch Sensor Adjustment Required Equipment Number 2 Phillips S
109. will increment one step each time the LINE key is pressed Press the FEED key to advance to each subsequent digit The horizontal direction set in the previous step will be displayed in front of the Offset setting 4 Once the setting is correct press the FEED key to accept the setting and advance to the Sensor Threshold display LINE FEED DIRECTION 49 PRINT LINE HORIZONTALLY RELOCATED USING THE ORIGINAL PRINT LINE KEY IN STEP 3 LINE LOCATION 36 Rev C SATO M 8400RV Service Manual SECTION 2 Configuration Sensor Threshold Level GAP INFUT The M8400RV printer determines the location of the leading edge of the label by measuring the difference between light levels when it sees either a label edge or a black I Mark This adjustment allows you to manually set the threshold voltage level between the maximum and minimum light levels DIP switch DSW2 2 selects the sensor type If DSW2 2 is in the OFF position the setting will be for a See Thru or Gap sensor and the LCD will display on the top line along with the current setting If DSW2 2 is in the ON position the LCD will display I Mark on the top line with its current setting If the value entered for the bottom line setting is 0 0V then the printer will automatically calculate the setting when the first label is fed after the printer is powered on or the head is closed There are some instances where the automatically calcula
110. with BUF 4 Card has not been initialized Printer must be powered off to command reset Warning Audible Beep 1 1 Correct program 1 Duplicate number Display None 2 Correct program 2 Data notin print area 3 Correct program 3 Data overflows card memory Printer will ignore invalid commands 136 Rev C SATO M 8400RV SERVICE MANUAL SECTION 9 5 9 3 Label Dispenser Unit Installation of the optional M 8403 Label Dispenser into the printer adds the convenience of automatic label dispensing Each label is printed then peeled from the backing paper and presented at the front of the printer for removal by the operator A photo electric sensor detects the presence of a completed label and signals the printer to await removal Once the completed label is removed this sensor signals the printer to automatically backfeed the label stock for correct alignment of the printing on the next label Installation s Required Equipment 2 Phillips Screw Driver STEP PROCEDURE 10 Switch the printer OFF but keep the power cable plugged in to discharge any possible static charges Open the top and side access doors on the mechanical side of the printer Loosen 2 inside screws holding the LH cover to the inside top of the printer and remove 2 screws holding the cover to the frame Lift off the cover for access to the sensor module Refer to Fig 4 1 4 2 amp 4 3 in Section 4
111. wnloading i e DSW2 7 OFF for Standard codes and DSW2 7 ON to use the Alternate set 5 Press the LINE key to place the printer in the ON LINE mode The printer is ready to receive the download command data stream 6 After the command has been sent the unit will beep and print a status label If it does not beep and print the label the printer did not accept the data 7 If the printer does not beep print a setting label turn the printer off check your download command stream for errors and start the download process over at step 1 8 If custom codes are correct press the FEED key to accept them and terminate the download process If they are incorrect turn the unit off without pressing the FEED key and begin the download process again at step 1 23 Rev C M 8400RV Service Manual SECTION 2 Configuration Selecting Protocol Control Codes Cont CONTROL STANDARD NON STANDARD CHARACTER DSW2 7 OFF DSW2 7 ON DESCRIPTION 05 Hex 40 Hex Get printer status Bi Com mode Off Line 5D Hex Take printer Off Line M84XX Compatibility DS2 8 For emulating M8400 software Should be used only if problems are encountered when using existing M8400 software un SETTING ae OFF Normal oN 8400 Compatibility Mode Selection DSW3 1 DSW3 2 Selects the operating mode of the printer 24 Rev C SATO M 8400RV Service Manual SECTION 2 Configuration
112. x emulates an 3287 2 printer Coax Twinax Interface with a standard Type A connector Twinax emulates IBM 5224 5225 5226 or 4214 printer with auto terminate cable through capabilities 1 10 Environment amp Approvals ENVIRONMENTAL Operating Temperature 41 to 104 F 5 to 40 Storage Temperature 0 to 104 F 20 to 40 Operating Humidity 15 85 RH non condensing Storage Humidity Max 9096 RH non condensing Electrostatic Discharge 10 Rev C SATO M 8400RV Service Manual SECTION 1 Overview amp Specifications 1 11 Print PRINT Method Direct or Thermal Transfer Speed User Selectable 2 to 10 ips 50 to 250 mm s Print Module Dot Size 0049 in 125 mm Resolution 203 dpi 8 dpmm Maximum Print Width 4 1 in 104 mm Maximum Print Length 14 in Expanded Print Length 356 mm Maximum Print Length 49 5 in with 2MB Memory Card 1249 mm 1 12 Media Sensing and Ribbon Minimum Maximum Width 87 in to 5 0 in 22 mm to 128 mm Minimum Maximum Length 5 in to 19 7 in 12 7 mm to 500 mm Type Die Cut Labels Fan Fold Tag Stock or Continuous Caliper thickness Maximum 010 in 25 mm including backing paper Roll OD max 8 6 in 218 mm Face In Wind Core ID min 1 5 in 38 mm Core ID Recommended 3 in 76 mm 11 SATO M 8400RV Service Manual SECTION 1 Overview amp Specifications 1 12 Media Sensing and Rib

SATO M-8400RV Thermal Label Printer

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