SATO M84PRO Service Manual
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SATO M84PRO Service Manual

Thermal transfer printer
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See also: Operator's Manual , Operating Manual
M84PRO
Thermal Transfer Printer

SERVICE MANUAL

PN 9001111A

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Summary of Contents for SATO M84PRO

  • Page 1: Service Manual

    M84PRO Thermal Transfer Printer SERVICE MANUAL PN 9001111A...
  • Page 2 All rights reserved. No part of this document may be reproduced or issued to third parties in any form whatsoever without the express permission of SATO America, Inc. The materials in this document is provided for general information and is subject to change without notice. SATO America, Inc.

  • Page 3: Table Of Contents

    Flash Memory PCMCIA Memory Expansion Real-time Clock Interface Module Upgrade CONFIGURATION Dip Switch Panels RS232 Transmit/receive Setting Printer Setup Default Settings Software Default Settings Potentiometer Adjustments LCD Panel Printer Configuration TROUBLESHOOTING Error Signals Troubleshooting Table Troubleshooting Procedures PN 9001111A 4-10 4-12...
  • Page 4 REPLACEMENT PROCEDURES Main Circuit Board Interface Board (Module) Daughter Board Memory Board (Card) Power Board Panel Board LCD Board Fuse Motor Platen Roller Feed Roller Timing Belt Print Head Label-out Sensor Switch Label Position Sensor Ribbon Sensor Cutter Belt Cutter Circuit Board ADJUSTMENT PROCEDURES Print Head Position Alignment Print Head Balance...

  • Page 5: Introduction

    INTRODUCTION This manual is laid out consistent with the product discussed and provides all of the information required for general printer configuration, troubleshooting, and maintenance. For specialized programming, refer to the Programming Manual also provided with the product. Step-by-step maintenance instructions are provided with typical problems and solutions. It is recommended that you become familiar with each section before installing and maintaining the printer.

  • Page 6: General Description

    These values are specified in “dots” and will vary depending upon the printer resolution and the amount of memory available for label imaging. The M84Pro was designed to be compatible with preceding M-8400 series printers. The main difference is how it receives the command sequence and how it responds to certain commands.
  • Page 7 INTERFACE BOARD RIBBON SUPPLY SPINDLE RIBBON REWIND SPINDLE LCD PANEL OPERATOR PANEL PLATEN ROLLER STEPPER MOTOR M84Pro Service Manual DAUGHTER BOARD MAIN CIRCUIT BOARD POWER BOARD Figure 1-2, Primary Components PRINT ASSEMBLY LABEL HOLD DOWN LOWER FEED ROLLER Figure 1-3, Primary Components...

  • Page 8: Switches And Indicators

    Section 1: Introduction SWITCHES AND INDICATORS The table below identifies and defines printer switches and indicators for operator interface. The accompanying graphics display their locations and appearance. Power Switch Two position on/off switch that controls power flow to the system.
  • Page 9 OFFSET ERROR PITCH ON LINE DISPLAY DSW1 DSW2 DSW3 PANEL COVER Figure 1-4, Switches, Indicators, and Connection Ports M84Pro Service Manual FEED KEY POTENTIOMETERS DIP SWITCHES MEMORY CARD SLOT POWER SWITCH REAR COVER PN: 9001111A INTERFACE PORT EXT PORT EXT.

  • Page 10: Technical Data

    30 to 80% RH Non-Condensing Direct or Thermal Transfer M84PRO-2: 2 to 10 Inches Per Second (50 - 250 mm/s) M84PRO-3: 2 to 8 Inches Per Second (50 - 200 mm/s) M84PRO-6: 2 to 6 inches Per Second (50 - 150 mm/s) M84PRO-2: .0049 Inches (.125 mm)

  • Page 11: Media

    Ethernet Data Transmission PROCESSING FLash ROM SDRAM Receive Buffer Memory Expansion M84Pro Service Manual .87 Inches (22 mm) 0.24 Inches (6 mm) 0.63 Inches (16 mm) 1.18 Inches (30 mm) 1.18 Inches (30 mm) 5.0 Inches (125 mm) Die Cut Labels, Fan-Fold, Tag Stock or Continuous .008 Inches (.21 mm)

  • Page 12: Character Font Capabilities

    A Font B Font DOWNLAODABLE FONTS CHARACTER CONTROL M84Pro Service Manual 5 dots W x 9 dots H 8 dots W x 15 dots H 13 dots W x 20 dots H 5 dots W x 9 dots H (Helvetica)

  • Page 13: Regulatory Approvals

    0, 90, 180, and 270 Degrees Sequential numbering of both numerics and bar codes RAM storage for special characters Full dot addressable graphics, SATO Hex/Binary, .BMP or .PCX formats Form overlay for high-speed editing of complex formats VCCI (Class B), UL, CUL, CE, FCC (Class B)

  • Page 14: Interface Specifications

    The multiple job buffer, on the other hand prints all jobs in the order they are received by the printer, and the order of printing cannot be changed.
  • Page 15 With an empty receiving buffer, the status of DTR is “high” (in X-On status if using X-On/X-Off) meaning the printer is ready to receive data. When the receive buffer is holding 2.0 MB of data (1 MB from being full), DTR will go “low” (an X-Off is sent) indicating the printer can no longer receive data.

  • Page 16: Ieee1284 Parallel Interface

    17 FG Frame Gnd 18 +5V (z=24k ohm) To Host 1 Signals required for ieee 1284 mode. M84Pro Service Manual SPECIFICATIONS AMP 57-40360 DDK (or equivalent) AMP 57-30360 DDK (or equivalent) IEEE1284 Parallel, 10 ft. (3 m) or less High = +2.4V to +5.0V, Low = 0V to -0.4V <ESC>A .

  • Page 17: Rs232 Serial Interface

    Section 3: Interface Specifications RS232 SERIAL INTERFACE The High Speed Serial Interface is a Plug-In Interface Module that can be installed in the printer by the user. Asynchronous ASCII Data Transmission Rate Character Format Connector Cable Signal Levels NOTE: Pin assignments begin with one (1) in the upper right corner and descend to thirteen (13) in the upper left corner.
  • Page 18 Readyî (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 in a manner similar to the function of pin 20 (DTR) as previously explained.

  • Page 19: Universal Serial Bus (Usb) Adapter

    /ACK/NAK NQUIRE In the Bi-Com 4 mode, the host transmits an ENQ (05 hexadecimal) 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 with an RS232C...
  • Page 20 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.
  • Page 21 Section 3: Interface Specifications (DLE) RINT If a DLE (10 hexadecimal) is received by the printer, the print process is stopped and an ACK (06 hexadecimal) is returned if there are no errors and a NAK (16 hexadecimal) if a printer error exists.

  • Page 22: Accessories Installation

    Remove the ribbon and label stock if applicable and leave the print head open. Remove screw (1, Figure 4-1a) securing front cover (2) to the printer frame. Lift away front cover (2).
  • Page 23 Reapply two screws (7) to side frame bracket (8) and four screws (5) to back panel (6) to secure print mechanism. Attach two hinge halves (9, Figure 4-1b) to the front base of the printer using two screws (10) for each.
  • Page 24 Section 4: Accessories Installation Route the single connector end of cutter wiring harness (11, Figure 4-1c) through the printer side wall from the electric side to the mechanical side. CAUTION: WHEN ROUTING THE WIRING HARNESS, ENSURE THAT IS IS ROUTED IN A MANNER SO AS TO PREVENT PINCHING OR INTANGLEMENTS.

  • Page 25: Dispenser

    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 automatically backfeed the label stock for correct alignment of the next print cycle.
  • Page 26 Remove the ribbon and label stock if applicable and leave the print head open. Remove screw (1, Figure 4-2a) securing front cover (2) to the printer frame. Lift away front cover (2).
  • Page 27 Encase cutter wiring harness (3) along with the power cable, in cable shield (7) and secure using two screws (6). Place the DSW3-1 and the DSW3-2 dip switches in the up position. Load the printer with ribbon and media stock and close/install all housing covers. M84Pro Service Manual Figure 4-2b, Dispenser Installation...

  • Page 28: Flash Memory

    Restore power and test cycle. FLASH MEMORY INSTALLATION Switch off the printer and disconnect the power supply cord. Open/remove the top, right, and left housing covers. NOTE: Figure 10-1 in the Diagrams & Schematics section provides guidance on housing cover removal.

  • Page 29: Pcmcia Memory Expansion

    Open/remove the top, right, and left housing covers. NOTE: Figure 10-1 in the Diagrams & Schematics section provides guidance on housing cover removal. Remove two screws (1, Figure 4-4a) securing interface board (2) to the rear printer hous- ing. Withdraw interface board (2) from printer.
  • Page 30 NOTE: It is advised that all wiring harnesses remain connected during expansion board instalation to prevent the possibility of incorrect connections. Insert two long screws (6, Figure 4-4b) into main circuit board (4) from the front. M84Pro Service Manual Figure 4-4a, Memory Expansion Figure 4-4b, Memory Expansion...

  • Page 31: Real-Time Clock

    REAL-TIME CLOCK INSTALLATION The real time clock chip 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 chip on the main cicuit board.
  • Page 32 FEED key to move the cursor laterally for each date entry. Verify proper operation and replace housing covers. NOTE: Figure 10-1 in the Diagrams & Schematics section provides guidance on housing cover installation. M84Pro Service Manual SET CALENDER CALENDER 00/00/00 00:00...

  • Page 33: Interface Module Upgrade

    All of the interface cards are installed within the same slot located in the rear of the printer with little or no difference in installation methodology. Refer to the Interface Board procedure of the Replacement Procedures section for specific directions for this upgrade.

  • Page 34: Dip Switch Panels

    Switch settings are read by the printer electronics during the power up sequence and will not become effective until the power is cycled. RS232 TRANSMIT/RECEIVE SETTING Data Bit Selection (DSW1-1): Sets the printer to receive either 7 or 8 data bits for each byte transmitted. DSW1-1...
  • Page 35 Refer to the Interface Specifications section in this manual for more information. (* Will select the Status 2 protocol if DSW2-8 is ON). DSW1-7 DSW1-8 SETTING Rdy/Bsy Xon/Xoff Bi-Com 3 Bi-Com 4 M84Pro Service Manual DSW1 DSW1 DSW1 9001111A Page 5-2...

  • Page 36: Printer Setup

    Sensor Type Selection (DSW2-2): Selects between the use of a transmissive label gap or a reflective eye-mark sensor. DSW2-2 SETTING Eye-Mark Head Check Selection (DSW2-3): When selected, the printer will check for head elements that are electrically malfunctioning. DSW2-3 SETTING Disabled Enabled Hex Dump Selection (DSW2-4): Selects Hex Dump mode.
  • Page 37 If a 10/100BaseT LAN card is installed, DS2-5 has the following definitions: DSW2-5 SETTING ENQ Response Periodic Response Firmware Download (DSW2-6): Places the printer in the Firmware Download mode for downloading new firmware into flash ROM. DSW2-6 SETTING Disabled Enabled Protocol Code Selection (DSW2-7): Selects the command codes used for protocol control.
  • Page 38 If it is disabled, the positioning must be under software control using Line Feed commands. DSW3-3 SETTING Sensor Used Not Used M84Pro Service Manual DSW2 SETTING DSW3 Continuous Tear-Off...
  • Page 39 Section 5: Printer Configuration Back-Feed Selection (DSW3-4): When Back-Feed is enabled, the printer will position the last printed label for dispensing and retract it before printing the next label. The amount of backfeed offset is adjustable. DSW3-4 SETTING Enabled Disabled External Signal Interface: Refer to the Interface Specifications section for information on External Signals.

  • Page 40: Default Settings

    These settings are stored in non-volatile memory 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.

  • Page 41: Potentiometer Adjustments

    Once the default operation is complete, a DEFAULT COMPLETED message will be displayed on the LCD panel. The printer should be powered off while this message is being displayed (or after the beep is heard. This saves the default settings in the non-volatile memory where they will be automatically loaded the next time the printer is powered on.

  • Page 42: Lcd Panel Printer Configuration

    The LCD Panel allows the printer to communicate with the operator. The operator communicates with the printer largely through the use of the LINE and FEED keys. Many settings may also be controlled via software commands. Where software commands and control panel settings conflict, the printer will always use the last valid setting.
  • Page 43 Clear Non-Standard Protocol DSW2-7 ON + LINE + FEED + POWER Protocol Code Download Hex Dump The printer initially powers on in the ONLINE mode. The user can access the User Settings using the following procedures. LCD DISPLAY V 05.00.03.00 Displays the firmware during the initialization.
  • Page 44 An Advanced Mode is provided to make adjustments that require only occasional changes. Since they affect the basic operation of the printer, the procedure for entering this mode is designed to prevent someone from accidently changing the settings.
  • Page 45 This setting determines the mode in which the printer powers up. If YES is selected, the printer powers up in the ON-LINE mode and is ready to print. If NO is selected, the printer powers up in the OFF-LINE mode and must be manually placed in the ON-LINE mode by pressing the LINE key before it is ready to print.
  • Page 46 (CR/LF ) from the data stream, including graphics and 2D bar codes. It is used primrily to maintain compatibility with earlier models of SATO printers. 1. Use the LINE key to step the cursor to either the YES or NO option.
  • Page 47 R/W Error No Card Error Mem Full Error Indicates that there is insufficient memory This selection allows SATO fonts to be copied from the PCMCIA Memory card CARD->MEMORYCOPY SATOFONT installed in the Memory Card slot.
  • Page 48 1. Use the LINE key to step the cursor to desired option. If Yes is selected, the printer will enter the Card Copy mode. If No is selected, the display will advance to the Card to Memory Copy All mode.
  • Page 49 PCMCIA Memory Card. 1. Use the LINE key to step the cursor to desired option. If Yes is selected, the printer will enter the Card Copy mode. If No is selected, the display will advance to the mode display.
  • Page 50 “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...
  • Page 51 The reading will advance to a setting of 4.9 (the maximum voltage). If a value of “0.0” is set, the printer will automatically set the level each time the printer is powered on with labels loaded and the head is closed.
  • Page 52 AUTO ONLINE FEED This selection specifies whether or not the printer will feed a label when it is placed in the On-Line mode. 1. Use the LINE key to step the cursor to desired option. If Yes is selected, the printer will feed a blank label anytime it enters the Online mode.
  • Page 53 If Mode1 is selected, pin 9 will be true when the printer is ready to print, i.e. it is on-line and has a print job loaded (a quantity of labels to be printed on the display). If Mode 2 is selected, pin 9 will be true if the printer is on-line.
  • Page 54 NO. If wanting to read the counter and reset it to 0.0, select YES. 5. Press the FEED key to return to the Counters Mode display. COUNTERS MODE 6. To exit the Counters Mode, turn power to the printer off and then back on. M84Pro Service Manual DEFINITION COUNTERS MODE...
  • Page 55 5. To exit the Test Print Mode, power the printer off and then back on. Occassionally it is desirable to reset all printer configuration settings to their original default conditions. This allows the operator to start reconfiguration of the printer starting from a know set of conditions. LCD DISPLAY V 05.00.03.00...
  • Page 56 Default Setting Mode, power the printer off and then back on. This function is used to clear counters and reset the printer’s firmware. It is also used after upgrading the flash firmware or installing a new memory module.
  • Page 57 The standard protocol codes used by the printer can be modified to accomodate the requirements of different host systems. However, if the printer is to be used with a system that does not use the custom protocol codes, they can be cleared and the default protocol codes reactivated. The default values are: STX = 7BH, ETX = 7DH, ESC = 5EH, ENQ = 40H, NULL = 7EH, CAN = 21H and OFFLINE = 5DH.
  • Page 58 Section 5: Printer Configuration In addition to the Test Print Labels, the printer can print the contents of the receive buffer in a hexadecimal format to allow the data stream to be examined for errors and troubleshooting. LCD DISPLAY V 05.00.03.00 Displays the firmware during the initialization.

  • Page 59: Troubleshooting

    Error blinks Ribbon End Ribbon on Error blinks, Media Error Label blinks Ribbon blinks Line blinks M84Pro Service Manual BEEP ERROR CONDITION 1 long Machine Error 1 long EEPROM read/write error 1 long Print Head is damaged 3 short Sensor...

  • Page 60: Troubleshooting Table

    Ribbon not matched to label stock. Low ribbon and drive torque or no ribbon movement. Foreign material on print head. Poor head alignment. Excessive print speed. M84Pro Service Manual No Ribbon Movement No Label Movement No Printed Image Display Problem Use thermal transfer compatible stock.
  • Page 61 Ribbon sensor cable disconnected. Incorrectly positioned display potentiom- eter. POWER LED NOT ILLUMINATED AC power cable disconnected. M84Pro Service Manual Use high quality label stock. Use genuine SATO ribbons. Clean print head and platen roller. Use high quality label stock.

  • Page 62: Troubleshooting Procedures

    ERIAL NTERFACE • Ensure the serial cable is thoroughly connected to the PC and the printer. CAUTION: 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 INTER- FACE CIRCUITRY AND IS NOT COVERED BY WARRANTY.
  • Page 63 3. Click on the Device Manager tab. 4. Ensure that the View Device By Type is checked. 5. Scroll down to SATO-USB Device and ensure that errors do not exist. Reinstall as required. 6. Reboot the PC and the printer.
  • Page 64 NTERFACE • If the printer does not come up ready: Ensure the printer is powered on, all cables are con- nected, and the printer is on-line. If possible, connect a terminal to the serial port and observe for a boot prompt indicating the print server firmware has not been loaded properly. If reload- ing does not correct the problem, try pressing switch 1 for more than 10 seconds.
  • Page 65 ODULE SAGE The SATO TP Test Module is a purchase option specially designed and sold by SATO America to assist in troubleshooting SATO Printers. The use of this device will facilitate the identification and isolation of problem circuitry and for voltage adjustment.
  • Page 66 Used for testing and adjustment of the VR2 potentiometer when printing with dispencer. The potentiometer should be turned fully clock-wise for this operation. Used for testing and adjustment of the VR3 potentiometer for ribbon end sensing. M84Pro Service Manual Figure 6-1, TP Test Module Usage APPLICATION DESCRIPTION...
  • Page 67 1 Access the dip switches located on the Operator Panel. 2 Record all dip switch positions. 3 Place DSW2-1 dip switch in the off position, then switch off the printer. 4 Remove ribbon from the printer as applicable and latch down print head.
  • Page 68 Section 6: Troubleshooting M84Pro Service Manual PN 9001111A Page 6-10...

  • Page 69: Main Circuit Board

    REPLACEMENT PROCEDURES The M84PRO Printer contains replaceable components and sub-assemblies. This section contains step-by-step instructions for the removal and replacement of those primary components and sub-assemblies that are subject to wear or damage. MAIN CIRCUIT BOARD REPLACEMENT The main circuit board contains the control electronics for the printer and is located behind the left side cover.
  • Page 70 Withdraw main circuit board (1) from within the printer. Prepare to replace main circuit board (1). Install main circuit board (1) into mounting position and secure to the printer frame using three screws (8). Secure the exterior of main circuit board (1) using two screws (7).
  • Page 71 Insert replacement interface board (2) through the housing slot to connect with main circuit board (3). Secure interface board (2) to printer housing using two screws (1). Reconnect power supply cord, test cycle, and reattach left side cover. NOTE: Figure 10-1 of the Daigrams & Schematics section provides guidance on housing cover installation.

  • Page 72: Daughter Board

    Section 7: Replacement Procedures DAUGHTER BOARD REPLACEMENT Switch off the printer and disconnect the power supply cord. Open/remove thetop, right, and left housing covers. NOTE: Figure 10-1 of the Daigrams & Schematics section provides guidance on housing cover removal. Disconnect the print head wiring harness (1, Figure 7-4) from daughter board (2).

  • Page 73: Power Board

    Lift away cable guard (3) and disconnect power supply harness (C). Remove two screws (4) from the exterior back side of printer. Remove one screw (5) from the interior securing power board (1) to the printer housing. Manipulate power board (1) from within the printer.

  • Page 74: Panel Board

    Locate panel board (1, Figure 7-6) mounted to the interior of the front cover. Disconnect wiring harnesses (A), (B), and (C). Remove two screws (2) securing panel board (1) to the printer. Manipulate panel board (1) laterally from within the printer.

  • Page 75: Lcd Board

    Locate LCD board (1, Figure 7-7) mounted to the interior of the front cover. Disconnect wiring harnesses (A) and (B) from panel board (2). Remove two screws (3) and one plastic washer (4) securing LCD board (1) to the printer. Manipulate LCD board (1) laterally from within the printer.

  • Page 76: Fuse

    Section 7: Replacement Procedures FUSE REPLACEMENT The M84Pro Printer has three fuses; one is externally accessible and is wired to the power supply while the other two are located internally and directly connected to the main circuit board. There is an additional fuse integrated into the optional cutter assembly which is easily accessible by opening the cutter attachment.

  • Page 77: Motor

    NOTE: Figure 10-1 of the Daigrams & Schematics section provides guidance on housing cover removal. Locate motor (1, Figure 7-9) position from the left side of the printer. NOTE: The left side of the printer contains the circuit board, power board, and gear configuration.
  • Page 78 Section 7: Replacement Procedures Remove belt from the motor shaft and withdraw motor (1) to the media side of the printer. Disconnect wiring harness (3) from motor (1). Remove two screws (4) securing damper (5) and heat plate (6) to motor (1).

  • Page 79: Platen Roller

    Loosen screw and clamp (not shown) on the left end of roller spindle. Withdraw platen roller (1) along with left and right bushings (6) and gear (7) from the printer. Assemble replacement roller as required with gear (7) and bushings (6).

  • Page 80: Feed Roller

    This treading contact will eventually wear grooves into the rubber material and negatively effect print output. Switch off the printer and disconnect the power supply cord. Open or remove the top, right, and left housing covers. NOTE: Figures 10-1, 10-2, and 10-3 of the Daigrams & Schematics section provide guidance on housing cover, media, and ribbon removal.
  • Page 81 Withdraw pulley (6) from left drive roller spindle and inner belt (not shown). Loosen screw (7) and clamp (8) on the left end of drive roller (1). Withdraw drive roller (1) along with left and right bushings (9) from the printer. Assemble replacement roller as required with bushings (9).

  • Page 82: Timing Belt

    TIMING BELT REPLACEMENT The M84pro Printer utilizes four timing belts coupled with dual action toothed pulleys to provide drive distribution throughout the assembly. Two belts are configured to transfer torque from the motor to the label feed roller.
  • Page 83 Figure 7-12a, Motor and Feed Belt Replacement Figure 7-12b, Motor and Feed Belt Replacement Remove e-clip (7, Figure 7-12b), pin (8), and bushing (9) from pulley bracket (2) to free transition pulley (10), and belts 3, 4. M84Pro Service Manual 9001111A Page 7-15...
  • Page 84 Prepare to replace timing belts (3), (4), (14), and (15). Apply replacement belt (15) to pulley (22) and allow to suspend. Apply ribbon frame (21) to the printer frame and secure using four screws (20) and two screws (19). M84Pro Service Manual...
  • Page 85 Apply the free ends of belts (4, Figure 7-12a) and (3) to feed roller pulley (6) and motor spindle (5) respectively. Secure pulley bracket (2) to printer frame using two screws (1). Adjust belt tension in accordance with its relative procedure in the Adjustment Procedures section of this manual.

  • Page 86: Print Head

    Before replacing the print head, check the head counter values by printing a test pattern. Switch off the printer and disconnect the power supply cord. Open/remove the top, right, and front housing covers. NOTE: Figures 10-1, 10-2, and 10-3 of the Daigrams & Schematics section provides guidance on housing cover, media, and ribbon removal.
  • Page 87 Reconnect power supply cord, test cycle, and reattach/close all covers. NOTE: Figures 10-1, 10-2, and 10-3 of the Daigrams & Schematics section provides guidance on housing cover, media, and ribbon installation. M84Pro Service Manual Figure 7-14, Print Head Replacement 9001111A...

  • Page 88: Label-Out Sensor Switch

    Switch off the printer and disconnect the power supply cord. Open or remove the top, left, right, and front housing covers.
  • Page 89 Feed the wiring harness of replacement switch (1) through the slot adjacent to the motor. Apply switch (1) against the printer frame and secure using two screws (8). NOTE: A properly oriented sensor switch will permit its mounting orifices to align with those of the frame while its contact arm protrudes through the paper ramp.

  • Page 90: Label Position Sensor

    Section 7: Replacement Procedures LABEL POSITION SENSOR REPLACEMENT Switch off the printer and disconnect the power supply cord. Open or remove the top, left, right, and front housing covers. NOTE: Figures 10-1, 10-2, and 10-3 of the Daigrams & Schematics section provides guidance on housing cover, media, and ribbon removal.

  • Page 91: Ribbon Sensor

    (9) consecutively. Disconnect the wiring harness of ribbon sensor (1) from the main circuit board. Remove screw (10) securing ribbon sensor (1) to printer frame. Lift away sensor (1). Route replacement sensor (1) through printer frame.
  • Page 92 Install ribbon, restore power, test cycle, and install/close housing covers. NOTE: Figures 10-1 and 10-3 of the Daigrams & Schematics section pro- vides guidance on housing cover and ribbon installation. Figure 7-21, Ribbon Sensor Replacement M84Pro Service Manual Figure 7-22, Wiring Harness Connection PN 9001111A Page 7-24...

  • Page 93: Cutter Belt

    The cutter assembly is an accessory to the printer. As a purchase option, the cutter assembly may not apply to the printer in question. The cutter assembly mounts to the face of the printer in place of the standard front cover.
  • Page 94 Section 7: Replacement Procedures M84Pro Service Manual Figure 7-23a, Cutter Belt Replacement Figure 7-23b, Cutter Belt Replacement PN 9001111A Page 7-26...

  • Page 95: Cutter Circuit Board

    Section 7: Replacement Procedures CUTTER CIRCUIT BOARD REPLACEMENT Switch off the printer and disconnect the power supply cord. Remove cutter assembly (1, Figure 7-24) from the printer. NOTE: If unsure how to remove the cutter assembly, refer to the Label Cutter Installation procedure in the Accessories Installation section for guidance.
  • Page 96 Connect wiring harnesses to replacement circuit board. Re-install the cutter assembly, connect power supply cord, and test cycle. NOTE: Refer to the Label Cutter Installation procedure in the Accessories Installation section of this manual for installation guidance. M84Pro Service Manual PN 9001111A Page 7-28...

  • Page 97: Adjustment Procedures

    ADJUSTMENT PROCEDURES The SATO M84pro Printer incorporates a series of sub-assemblies that, in conjunction, comprise the total printer assembly. Many of these sub-assemblies are designed to be adjustable to maintain optimum performance of the printer throughout its life. This service manual section addresses the proper technique for their adjustment.

  • Page 98: Print Head Position Alignment

    Print head position has a direct impact on print quality. An improperly aligned print head will cause the print to be inconsistent across the label. The following procedure will provide guidance on print head alignment. M84Pro Service Manual Print Head Balance Adjustment Print Head Position Alignment...

  • Page 99: Print Head Balance

    Loosen thumbscrew (2) and two set screws (3). Load printer with media and ribbon as applicable and latch (4) print head (1) closed. NOTE: Figures 10-2 and 10-3 of the Diagrams & Schematics section provides guidance on media and ribbon installation.
  • Page 100 Manipulate screw (4) to adjust print head (3) while observing scale (5) under latch (6). NOTE: Clockwise screw rotation raises the print head on the right side. Counter-clockwise rotation conversely lowers the print head. Retighten set screw (3). M84Pro Service Manual PN 9001111A Page 8-4...

  • Page 101: Ribbon Guide Plate

    Connect the power supply cord, restore power, and test cycle. Manually manipulate print head latch (1, Figure 8-4) to open print head (2). NOTE: The printer will go into a standby mode when the print head is opened. It is not necessary to turn the printer off.

  • Page 102: Feed Roller

    Feed roller adjustment is used for fine tuning label tracking. By adjusting the pressure between the upper and lower rollers, the media may be directed through the printer as desired. If mal- adjusted, the label media will have a tendency to want to track to the left or to right depending on which side has the greatest pressure.
  • Page 103 NOTE: Each side of the upper roller may be adjusted independently. Only loosen the lock nut and adjust the set screw on the end of the roller deemed necessary to adjust. 10 Test cycle and readjust as necessary. M84Pro Service Manual Figure 8-5, Feed Roller Adjustment PN: 9001111A Page 8-7...

  • Page 104: Timing Belt

    Section 8: Adjustment Procedures TIMING BELT ADJUSTMENT The following procedure covers the adjustment of all timing belts within the printer. Not included, is the adjustment procedure for the optional cutter assembly. However, the adjustment technique is exactly the same as here. Remove the cutter assembly to gain access to its belts.
  • Page 105 The following procedure applies to labels with notches along the left perimeter of the label stock. Ignore this procedure otherwise. Switch off the printer and disconnect the power supply cord. Remove the front housing cover. NOTE: Figure 10-1 in the Diagrams & Schematics section provides guidance on housing cover removal.

  • Page 106: Print Position

    There are three methods of print position adjustment. Two of the methods allow for coarse adjustment, and the third permits fine adjustment. Although there are three methods, only two are recommended for non-SATO personnel. For this reason, the VR1 potentiometer located on the main circuit board will only be identified here and not explained.

  • Page 107: Label Gap Sensor

    Section 8: Adjustment Procedures Coarse print position adjustment should be through the software provided with the printer and fine adjustment should be performed by manually adjusting the PITCH potentiometer located on the printer front panel cover. Turn OFFSET potentiometer (1, Figure 8-9) located on the front panel to the center position.
  • Page 108 14 Disconnect test module (1) from main circuit board (2) and replace housing covers. NOTE: Figure 10-1 in the Diagrams & Schematics section provides guidance on housing cover installation. M84Pro Service Manual Figure 8-9, Label Sensor Adjustment PN 9001111A Page 8-12...

  • Page 109: Eye-Mark Sensor

    13 Test print labels to ensure proper function. 14 Disconnect test module (1) from main circuit board (2) and replace housing covers. NOTE: Figure 10-1 in the Diagrams & Schematics section provides guidance on housing cover installation. M84Pro Service Manual PN: 9001111A Page 8-13...

  • Page 110: Offset Label Stop Position

    1 Turn the OFFSET potentiometer to the center position. NOTE: The Offset potentiometer is located on the Operator Panel of the front housing cover. Press and hold the FEED key while switching on the printer. When the printer beeps, release the FEED key. LCD DISPLAY: LCD DISPLAY: Press the FEED key to advance to the next screen.

  • Page 111: Print Darkness

    Begin printing test labels antedates the PRINT potentiometer as necessary to achieve the desired results. NOTE: It may be necessary to repeat the procedure and selecting a different print darkness setting from the operator panel. M84Pro Service Manual PRINT DARKNESS PN: 9001111A Page 8-15...
  • Page 112 Section 8: Adjustment Procedures M84Pro Service Manual PN 9001111A Page 8-16...

  • Page 113: Factory Settings/Test Print

    FACTORY RESETS This section of the service manual covers instructions on how to return the printer to its factory settings. The instructions are separated into differing categories of interest. FACTORY SETTINGS / TEST PRINT CAUTION: RESETTING THE PRINTER WILL CLEAR ALL REGISTERS.

  • Page 114: Clear Head Counters

    PRINT HEAD DAMAGE. Verify that the counters on the test print have reset to 0.0 km. Power Off the printer and confirm that all switches are in the Off or down position. CLEAR HEAD COUNTERS CAUTION: RESETTING THE PRINTER WILL CLEAR ALL REGISTERS.

  • Page 115: Clear Dispenser Counter

    PRINT HEAD DAMAGE. Verify that the counters on the test print have reset to 0.0 km. Power Off the printer and confirm that all switches are in the Off or down position. CLEAR DISPENSER COUNTER CAUTION: RESETTING THE PRINTER WILL CLEAR ALL REGISTERS.

  • Page 116: Clear Cutter Counter

    PRINT HEAD DAMAGE. Verify that the counters on the test print have reset to 0.0 km. Power Off the printer and confirm that all switches are in the Off or down position. CLEAR CUTTER COUNTER CAUTION: RESETTING THE PRINTER WILL CLEAR ALL REGISTERS.

  • Page 117: Clear Eeprom

    PRINT HEAD DAMAGE. Verify that the counters on the test print have reset to 0.0 km. Power Off the printer and confirm that all switches are in the Off or down position. CLEAR EEPROM CAUTION: RESETTING THE PRINTER WILL CLEAR ALL REGISTERS.

  • Page 118: Housing Cover Removal & Installation

    DIAGRAMS & SCHEMATICS HOUSING COVER REMOVAL & INSTALLATION Screws x2 Screws x2 Screws x4 Screws x2 Screws x1 Figure, 10-1, Housing Cover Removal & Installation M84Pro Service Manual 9001111A Page 10-1...

  • Page 119: Media Loading

    Section 10: Diagrams & Schematics MEDIA LOADING Figure 10-2, Media Loading RIBBON LOADING Figure 10-3, Ribbon Loading M84Pro Service Manual 9001111A Page 10-2...

  • Page 120: Paper Specifications

    Section 10: Diagrams & Schematics PAPER SPECIFICATIONS La b el Tick et 14mm 14mm 14mm 1.5mm 1.5mm Figure 10-4, Paper Specifications M84Pro Service Manual PN 9001111A Page 10-3...

  • Page 121: Accessories & Sensors Location

    97.0 mm 49.5 mm Unprintable Area (3.2 mm) Printable Width (104 mm) Head Width (112 mm) Thermal Head 11.5 mm 16.0 mm Dispenser 19.5 mm Tear-Off Cutter Figure 10-5, Accessories & Sensors Location Diagram M84Pro Service Manual 9001111A Page 10-4...

  • Page 122: Print Position Reference

    LABEL EYE-MARK LABEL LABEL EYE-MARK LABEL LABEL EYE-MARK LABEL LABEL Figure 10-6, Print Position Reference Diagram M84Pro Service Manual CONTINUOUS PRINTING Base Reference Print Position Base Reference Print Position TEAR-OFF MODE Tear-Off Position Tear-Off Position Base Reference Print Position Base Reference...

  • Page 123: Print Operation Sequence

    Print 1 page Print 2 page Print 3 page (Note) Above is the base reference position when the gap sensor is used. M84Pro Service Manual NABLED HECK ISABLED Head Figure 10-7, Operation Sequence Chart 9001111A Pitch sensor (gap) Page 10-6...
  • Page 124 Print 2 page +head check Print 3 page +head check (Note) Above is the base reference position when the gap sensor is used. M84Pro Service Manual ISABLED HECK ISABLED Head Figure 10-8, Operation Sequence Chart PN 9001111A Pitch sensor (gap)
  • Page 125 Before print operation After print operation Paper is transported actual print size portion in vertical direction. However, if the <EP> command is specified, the paper is transported at the specified vertical paper size portion. M84Pro Service Manual ISABLED HECK NABLED...
  • Page 126 After printing, if there is no following print data after 500 msec passes, feeds to manual cut position Above is the base reference position when the gap sensor is used. Figure 10-10, Operation Sequence Chart M84Pro Service Manual HECK ISABLED...
  • Page 127 (Note) After printing, if there is no following print data after 500 msec passes, feeds to manual cut position Above is the base reference position when the gap sensor is used. M84Pro Service Manual HECK NABLED Manual cut Head...
  • Page 128 * 1: Because back feed operation is not performed, an unprintable area occurs at the front. (Note) Above is the base reference print position when the gap sensor is used. Figure 10-12, Operation Sequence Chart M84Pro Service Manual Head Note 1: Unprintable area PN 9001111A...
  • Page 129 Section 10: Diagrams & Schematics UTTER PERATION Standby Print 1 page Cutter operation Back feed (Note) Above is the base reference position when the gap sensor is used. Figure 10-13, Operation Sequence Chart M84Pro Service Manual Head Pitch sensor (gap) 9001111A Page 10-12...
  • Page 130 Note 1: Because backfeed operation is not performed, an unprintable area occurs at the front. (Note) Above is the base reference print position when the gap sensor is used. Figure 10-14, Operation Sequence Chart M84Pro Service Manual ULSE NPUT Head...
  • Page 131 Standby Print signal input Print 1 page Cutter operation Backfeed (Note) Above is the base reference position when the gap sensor is used. Figure 10-15, Operation Sequence Chart M84Pro Service Manual ULSE NPUT Head 9001111A Pitch sensor (gap) Page 10-14...
  • Page 132 Note 2: Because backfeed operation is not performed, an unprintable area occurs at the front. (Note) Above is the base reference position when the gap sensor is used. Figure 10-16, Operation Sequence Chart M84Pro Service Manual ACKFEED Head Pitch sensor (gap)
  • Page 133 Note 1: The peel-off sensor checks the peel-off status of the label, and does not move to the next operation until the label is peeled. (Note) Above is the base reference position when the gap sensor is used. Figure 10-17, Operation Sequence Chart M84Pro Service Manual PERATION Pitch sensor (gap) Peel-off Head...
  • Page 134 Note 1: Because backfeed operation is not performed, an unprintable area occurs at the front. (Note) Above is the base reference position when the gap sensor is used. Figure 10-18, Operation Sequence Chart M84Pro Service Manual ACKFEED Peel-off Head Pitch sensor (gap)
  • Page 135 ULSE NPUT Standby Print signal input Print 1 page Backfeed (Note) Above is the base reference position when the gap sensor is used. Figure 10-19, Operation Sequence Chart M84Pro Service Manual PERATION Peel-off Head Pitch sensor (gap) 9001111A Page 10-18...

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