Monarch 9460 Printer TC9460SM Rev AB 05/00 ©2000 Monarch Marking Systems, Inc. All rights reserved.
Each product and program carries a respective written warranty, the only warranty on which the customer can rely. Monarch reserves the right to make changes in the product, the programs, and their availability at any time and without notice. Although Monarch has made every effort to provide complete and accurate information in this manual, Monarch shall not be liable for any omissions or inaccuracies. Any update will be incorporated in a later edition of this manual. ©2000 Monarch Marking Systems, Inc.
Confidential SAFETY SUMMARY Warning and caution messages appear throughout this manual. They alert you to potential safety hazards or potential damage to equipment. The messages and their meanings are shown below. WARNING CAUTION Calls attention to improper practices that could result in a potentially serious, even lethal injury. Calls attention to practices that could cause minor injury or damage to equipment. Familiarize yourself with proper procedures before operating or repairing the equipment.
9460 Service Manual Confidential Preface Table of Contents Safety Summary i Chapter 1.
Preface Chapter 4.
9460 Service Manual Confidential Preface List of Figures Figure 1-1. Figure 1-2. Figure 1-3. Figure 2-1. Figure 2-2. Figure 2-3. Figure 2-4. Figure C-1. Figure C-2. Figure C-3. Figure C-4. Figure C-5. 9460 printer. ....................................................................................................................................... 2 Connecting Communications Cable. .....................................................................................................
Confidential CHAPTER 1. PRINTER OVERVIEW & INSTALLATION PURPOSE PUBLICATIONS This manual contains information service technicians need to service, troubleshoot and repair the Monarch Sierra Sport2™ 9460™ printer. Field service technicians should be familiar with the documentation shown in the following table. • Chapter 1 contains general information and installation procedures. • Chapter 2 contains physical and functional descriptions of major components.
9460 Service Manual Confidential In continuous (non-peel) mode, the entire batch job is printed and fed in one continuous operation. The supply and liner (if used) are fed out together. Linerless models are also available but must use the special linerless platen roller. In on-demand (peel) mode, the on-demand sensor detects the removal of a label, and the printer prints and feeds the next label. In on-demand mode, the label is separated (peeled) from the supply liner.
Printer Overview & Installation Confidential 9460 Service Manual INSTALLATION AND CHECKOUT PROCEDURES Communications Interface 1. Clear a work area approximately two feet wide. 2. Carefully open shipping carton. The following parameters are software selectable. The defaults are listed in bold. 3. Remove documentation. 4. Remove large cardboard insert. 5. The printer’s asynchronous RS-232 port is a DB9 connector located on the inside of the back outer case.
9460 Service Manual Confidential Printer Overview & Installation The following cables are available to connect the 9460 printer to other devices.
Confidential CHAPTER 2. PHYSICAL/FUNCTIONAL DESCRIPTION This chapter contains a physical and functional description of the 9460 printer modules shown below.
9460 Service Manual Confidential Physical/Functional Description Peel Door Roller Compression Spring Front Flex Assembly RF PCB Supply Holder Assembly Platen Roller Figure 2-2. Front Case Assembly. FRONT CASE ASSEMBLY 11998901/03 The Front Case Assembly will be stocked for service replacement.
Confidential Supply Holder Side Idler Gear Extension Spring Supply Holder Side Supply Hubs Figure 2-3. Supply Holder Assembly. Supply Holder Assembly 119991 Peel Roller Assembly The Supply Holder Assembly is made up of a molded part that has a gear rack and provisions for a single spring on the underside. The design is such that two of these parts interlock and slide so that any supply roll width between 12.7 (.50”) and 50.8(2.00”) can be accommodated.
9460 Service Manual Confidential Front Flex Assembly 119995 The Front Flex Assembly contains the black mark sensor and RF connector. When black mark sensing is selected, the start-of-label position synchronization for each label is accomplished through the use of the reflective optical sensor (black mark sensor). The black-mark sensor detects a black mark pre-printed on the back of the supply and the die cut sensor detects the change in the amount of light passed through the label liner.
Physical/Functional Description Confidential 9460 Service Manual PRINT MODULE ASSEMBLY Stepper Motor 119980 The M09460 supply feed is accomplished by means of 11997501/02 a stepper motor driving an elastomeric drive roller The Print Module contains: • Sensor Flex Assembly • Printhead Assembly • Stepper Motor • IrDA Processor Assembly (if ordered as an option-11997502) Sensor Flex Assembly 119988 The Sensor Flex Assembly contains the on-demand sensor, die Cut sensor, DB9 and IrDA port connectors.
9460 Service Manual Confidential MAIN PCB ASSEMBLY 119810 The Main PCB Assembly contains the micro controller, RAM, flash memory, reset circuitry, and the associated electrical components. The system is designed with minimum connections in the signal lines between these basic parts, which form the heart of the system. The micro controller used in the M09460 is a Motorola MC68336GCFT20 micro controller operating at 18.35 MHz.
Confidential CHAPTER 3. TROUBLESHOOTING Troubleshooting the 9460 printer is accomplished through messages displayed by the printer, built-in test diagnostics, and manual troubleshooting. Certain errors are identified by error codes. Error codes and hardware failure messages are listed in Appendix A. Before troubleshooting, always fully charge the battery. Using a discharged battery pack can give false failure indications.
9460 Service Manual Confidential PRINT IMAGE MISSING DOTS, CREATING A WHITE LINE THROUGH IMAGE AREA Troubleshooting NO DISPLAY AT POWER UP 1. Check battery pack. Charge/replace as necessary. 2. Replace the following items one at a time and retest: • Display/Keyboard PCB Assembly • Print Module Assembly • Front Case Assembly. 1. Inspect and clean printhead and platen. 2. Use diagnostics to check printhead. 3. 3. Use diagnostics to print test pattern.
Troubleshooting Confidential 9460 Service Manual BATTERY CONDITION CHECK PRINTER SHUTS 1. A fully charged battery pack should show as close COMPLETELY OFF WHILE to the full designator on the display as possible PRINTING upon power up of the printer. 2. To verify exact voltage reading, go to Diagnostics, Printer, then Battery. Readings greater than 8.2 indicate a fully charged battery pack. Readings less than 7.3 will indicate that the printer is close to indicating a low battery condition.
Confidential CHAPTER 4. DIAGNOSTICS OVERVIEW Battery Check The 9460 printer has a diagnostics utility in flash memory when it is shipped from the factory. It tests the capabilities, features, and functions (hardware and software) of the printer. Customers can use it before calling Service to obtain diagnostics data that gives an indication of the problem. Service personnel can also use it for other tests. If the battery voltage is less than 7.
Diagnostics Setup Confidential Stock Energy Backlight LCD Contrast Printer Diagnostics Standard Special High Energy Exit Disable Enable Exit Contrast Supply Pos Print Pos Margin Adj Demand Sensor Displays the Main Diagnostics menu. Printer Displays the Printer Diagnostics menu. Test Label Displays the Test Label menu. Disable Enable Exit Stock Sensor Exit Serial Comm. Power Mgmt.
9460 Service Manual Confidential Display Displays the Display Diagnostics menu. • • • Backlight Turns the backlight on and off (even if the backlight is disabled). Pixel Turns all display pixels on and off. Exit Returns to the Main Diagnostics menu. Keyboard Runs the keyboard test. Setup Displays the Setup Main menu. Stock Energy Sets the type of supply being used. • Standard Standard supplies are being used. • High Energy Synthetic or linerless supplies are being used.
Diagnostics Confidential Serial Comm. Displays the Serial Communications Setup menu. • Baud Rate Selects the baud rate. • Parity Selects the parity. • Data Bits Selects the number of data bits. • Stop Bits Selects the number of stop bits. • Flow Control Selects the flow control. • Exit Returns to the Setup Main menu. Power Mgmt. 9460 Service Manual Sensor Cal Allows the service technician to select a sensor to perform a sensor calibration with installed supplies.
9460 Service Manual Confidential MONARCH INITIALIZATION FILES (.MIF) .MIF files specify parameters for the printer. They provide a quick and easy way to alter certain aspects of the printer’s activity from the system defaults. To load a .MIF file, use the Monarch Flash Utility, and then reboot the printer. To change the parameters, reflash the printer with a new .MIF file. To return the printer to the system defaults, do a virgin reset. To create a .
Diagnostics Confidential PC DIAGNOSTICS The Monarch MPCL Toolbox software includes more service diagnostics. See Chapter 7 for more information. IMMEDIATE COMMANDS There are two 9460 MPCL immediate commands for service use only, as follows. Command ^MF January 2001 Description Uploads the .MIF file from the printer to the host. Command ^MS 9460 Service Manual Description Uploads information about the flash file system contents from the printer to the host.
Confidential CHAPTER 5. TESTS AND ADJUSTMENTS Because of the complex test fixtures required to build the sub-assemblies in the printer, Service will replace by sub-assembly instead of by component. There are no mechanical or electrical adjustments that can be done in the field apart from what is available through the configuration packets in MPCL. These adjustments are available through the keyboard (refer to Chapter 4 for details) and through the MPCL Toolbox.
Confidential CHAPTER 6. DISASSEMBLY PROCEDURES TOOLS REQUIRED REMOVING THE DB9 DOOR • 3/32 Allen wrench 1. Remove the boot. • #1 Phillips screwdriver 2. Remove the back outer case. • small straight slot screwdriver 3. REMOVING THE BOOT, 11997203/06/08 Carefully spread the pins on the DB9 door, and remove them from the slots in the Back Inner Case Assembly. 4. Reassemble in reverse order. 1. Remove the optional strap assembly, if present. 2.
9460 Service Manual Confidential Disassembly Procedures REMOVING THE CPU BOARD REMOVING THE FRONT ASSEMBLY CASE ASSEMBLY 1. Remove the boot. 1. Remove the boot. 2. Remove the back outer case. 2. Remove the back outer case. 3. Remove the DB9 door. 3. 4. Remove the case top. 5. Remove the Keypad/Display Assembly. Disconnect the RF link/black bark sensor flex from ZIF connector CN9, and remove the tape holding the flex to the back inner case. 6.
Confidential CHAPTER 7. PC DIAGNOSTICS The Printer Diagnostics utility is one of the components of the MONARCH MPCL Toolbox software. The Printer Diagnostics utility mimics the functionality available in the Manufacturing Sendfile program. 2. Press the A button under the p icon. You will Using the Printer Diagnostics utility you can: • download files to the printer. • display MUX values. • test the printhead. • display service totals. • display stock history. • upload images.
9460 Service Manual Confidential PC Diagnostics DETECTING THE PRINTER Click Detect Printer to sense which printer is connected and start using the utility. The model DOWNLOADING FILES TO THE PRINTER You can download format and batch (*.FAB) files and others to the connected printer. 1. From the File menu, select Download... You will see Page 24 being tested and the software version number displays. 2. Highlight the file to download and click Open. You see the message "Downloading...
PC Diagnostics Confidential 9460 Service Manual DISPLAYING MUX VALUES 1. Click Display MUX Values to show the current values for each sensor, contrast setting, printhead temperature, battery voltage, and more. The current voltages for the sensors are constantly monitored and updated. The displays correspond to the channels of the A/D converter on the CPU board. The high, low, and Delta readings are also displayed. 2. Click f when you finished looking at the MUX values. You return to the main screen.
9460 Service Manual 2. Confidential Click Edit Totals to modify the totals. You will be prompted to enter a password. After entering the password, click f. (The password for modifying the service/machine totals is the common password [jmartin] for Monarch Marking service personnel.) If you enter the wrong password, you can still view the Service and Machine totals, but you cannot change them. If you entered the correct password, you will see 3.
PC Diagnostics 2. Confidential Information about the image is displayed, such as the length and width of the image in dots (scan lines and scan columns), if batch separators are enabled, and the margin/print adjustments. Click Upload Image. You will see January 2001 9460 Service Manual 3. Click Upload. The message "Receiving data" appears while the image is sent from the printer's image buffer to the PC and converted to a .BMP file. The .BMP file is a true black and white Windows DIB BitMap file.
Confidential APPENDIX A. ERROR CODES This appendix provides a listing of error codes that may be generated by the 9460 printer. 001 002 003 004 005 006 007 010 011 012 013 014 015 016 017 018 020 021 022 023 024 025 030 031 033 040 041 042 Format ID number must be 1 to 99. Name must be a printer-assigned name or be 1 to 8 characters inside quotes. Action must be A (add) or C (clear). Supply length is invalid (maximum is 4"). Supply width is invalid (maximum is 2"). Storage device must be R (volatile RAM).
Error Codes 043 044 045 046 051 101 102 104 105 106 107 108 109 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 251 252 253 Confidential 9460 Service Manual End column is invalid. Line segment or box end column is defined outside of printable area. Dot pattern for line or box must be "" (literally just two double quotes). Line length is defined beyond the maximum length of 3.72". Line type must be S (segment) or V (vector).
9460 Service Manual 254 255 256 257 258 259 260 261 262 263 264 265 266 267 268 269 270 271 272 273 282 283 284 285 286 287 288 289 290 291 292 310 311 314 325 327 328 340 350 351 Page 30 Confidential Error Codes Slash zero selection must be 0 (standard zero). Supply type must be 0 (black mark) or 1 (die cut). Ribbon selection must be 0 (direct) or 1 (transfer). Feed mode must be 0 (continuous) or 1 (on-demand). Supply position is outside the range. Contrast adjustment must be -390 to 156 dots.
Error Codes 352 380 400 401 402 403 404 405 409 410 411 412 413 414 415 420 421 422 424 425 426 427 428 429 430 433 497 499 571 572 573 574 575 601 603 611 612 Confidential 9460 Service Manual Insufficient memory is available for the downloaded font. Job request is invalid. Must be 0 to 4. The character immediately following { is invalid. Internal software failure. Field separator is not in the expected location. Record separator was not found. Bad token, number, or string is too long.
9460 Service Manual 613 614 615 616 618 619 703 704 750 751 752 753 754 755 756 757 758 759 760 761 763 764 765 766 768 790 800 801 802 803 810 811 Page 32 Confidential Error Codes Reference point off tag. Portion of field off tag. There may be an invalid character in the packet. Make sure you did not enter the letter O for the number 0. Internal overfull error. Dot shifting failed. A bad dot falls on a bar code that cannot be shifted. Magnification must be 1 to 7. Bad JIS code for Kanji.
Error Codes 812 813 820 821 822 900 904 906 907 909 910 911 930 931 932 933 934 935 936 937 938 939 940 950-999 Confidential 9460 Service Manual The file in flash memory is full. You cannot access flash memory. An error occurred in the flash program. An error occurred while erasing flash memory. There is a flash ID error. RAM test failure. No configuration memory for native layer. Power failure. No configuration memory for application layer. RAM is corrupted. Warm start. Virgin restart.
Confidential APPENDIX B. CARE & MAINTAINENCE This chapter explains how to 3. Lay the printer on its back. • clean the printhead, platen roller, and the supply sensors. 4. Caution: Ground yourself by using your field service static kit. • clear label jams. 5. Clean the printhead with a clean soft cloth moistened with isopropyl alcohol, a cleaning pen, or a small brush. Caution: Do not use sharp objects to clean the printhead. This may damage the printer and require a service charge.
Care & Maintenance 8. Confidential Clean the on-demand and black mark sensors with a cleaning pen or a clean soft cloth moistened with isopropyl alcohol. On-Demand Sensor Black Mark Sensor 9. 9460 Service Manual Reload the supply. 10. Close the supply door until the release buttons click into place. 11. Turn on the printer by pressing and holding the P button until the display turns on. CLEARING LABEL JAMS When you are printing and jam occurs, you see a supply error message.
Confidential APPENDIX C. CIRCUIT CARD ASSEMBLY LAYOUTS Figure C-1. Main PCB (Primary Side).
Circuit Card Assembly Layouts Confidential 9460 Service Manual Figure C-2. Main PCB (Secondary Side).
9460 Service Manual Confidential Circuit Card Assembly Layouts Figure C-3. RF PCB. Figure C-4. IrDA Processor Board.
Circuit Card Assembly Layouts Confidential 9460 Service Manual Figure C-5. IrDA Transceiver.
