Monarch 9460 User manual

TC9460SM Rev AB 05/00 ©2000 Monarch Marking Systems, Inc. All rights reserved.
Monarch
9460Printer

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. All rights reserved. No part of this publication
may be reproduced, transmitted, stored in a retrieval system, or translated into any
language in any form by any means, without the prior written permission of Monarch
Marking Systems, Inc.
WARNING
This equipment has been tested and found to comply with the limits for a Class A digital device,
pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection
against harmful interference when the equipment is operated in a commercial environment. This
equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in
accordance with the instruction manual, may cause harmful interference to radio communications.
Operation of this equipment in a residential area is likely to cause harmful interference in which case
the user will be required to correct the interference at his own expense.
CANADIAN D.O.C. WARNING
This digital apparatus does not exceed the Class A limits for radio noise emissions from digital
apparatus set out in the Radio Interference Regulations of the Canadian Department of
Communications.
Le présent appareil numérique n’émet pas de bruits radioélectriques dépassant les limites
applicables aux appareils numériques de la classe A prescrites dans le Réglement sur le brouillage
radioélectrique édicte par le ministère des Communications du Canada.
Trademarks
Monarch is a registered trademark of Monarch Marking Systems, Inc.
Monarch, 917, 9403, 9800, 9805, 9820, 9830, 9835, 9840, and 9856 are trademarks of Monarch Marking Systems,
Inc.
Paxar is a trademark of Paxar Corporation.
Microsoft and MS-DOS are registered trademarks of Microsoft in the U.S. and other countries.
Windows is a registered trademark of Microsoft in the U.S. and other countries.
TrueType is a trademark of Apple Computer, Inc.
Hewlett-Packard is a registered trademark of Hewlett-Packard Company.
CG Triumvirate and CG Triumvirate Bold are trademarks of AGFA Corporation.
Adobe and Acrobat are trademarks of Adobe Systems Incorporated which may be registered in certain jurisdictions.
Centronics is a registered trademark of Centronics Data Computer Corporation.
Monarch Marking Systems
P.O. Box 608
Dayton, Ohio 45401

Confidential
January 2001 Page i
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
Calls attention to improper practices that could
result in a potentially serious, even lethal injury.
CAUTION
Calls attention to practices that could cause minor
injury or damage to equipment.
Familiarize yourself with proper procedures before operating or repairing the equipment. Follow these precautions for
your own safety and to protect the equipment.
Equipment Safety
Your body is a giant capacitor. It can store several
thousand volts of electricity. Digital equipment is easily
damaged or destroyed by this static electricity. You do
not have to see a spark to ruin an IC; 50 volts is
enough. To protect the equipment from static damage,
follow these guidelines:
Ground yourself before reaching into the equipment or
touching any circuit board or other electrical
component. The Monarch Static Ground Kit contains
everything you need.
Re-ground yourself whenever you walk away and return
to the equipment. Be especially careful around carpet.
Carpet is a major source of static buildup in the body.
Even a few steps can recharge you.
The smaller the object, the greater the precautions
must be. A board in the machine is better protected
than one that is not plugged in. A chip on a board is
better protected than one in your hand.
Avoid touching pins coming out of a chip or the
connector edge of circuit boards. These metal parts
have signal and data lines that are connected directly to
fragile circuits.

9460 Service Manual Confidential Preface
Page ii January 2001
Table of Contents
Safety Summary i
Chapter 1. Printer Overview & Installation 1
PURPOSE --------------------------------------------------------------------------------------------------------------------------------------------- 1
ELECTROSTATIC DISCHARGE --------------------------------------------------------------------------------------------------------------- 1
PUBLICATIONS -------------------------------------------------------------------------------------------------------------------------------------- 1
EQUIPMENT DESCRIPTION-------------------------------------------------------------------------------------------------------------------- 1
EQUIPMENT SPECIFICATIONS--------------------------------------------------------------------------------------------------------------- 2
Bar Codes------------------------------------------------------------------------------------------------------------------------------------------- 2
Additional Specifications ---------------------------------------------------------------------------------------------------------------------- 2
INSTALLATION AND CHECKOUT PROCEDURES------------------------------------------------------------------------------------- 3
Printer Checkout---------------------------------------------------------------------------------------------------------------------------------- 3
Communications Interface-------------------------------------------------------------------------------------------------------------------- 3
Chapter 2. Physical/Functional Description 5
FRONT CASE ASSEMBLY 11998901/03-------------------------------------------------------------------------------------------------- 6
Platen Roller Assembly------------------------------------------------------------------------------------------------------------------------ 6
Supply Holder Assembly 119991----------------------------------------------------------------------------------------------------------- 7
Latch Springs-------------------------------------------------------------------------------------------------------------------------------------- 7
Peel Roller Assembly--------------------------------------------------------------------------------------------------------------------------- 7
Front Flex Assembly 119995---------------------------------------------------------------------------------------------------------------- 8
RF PCB Assembly 118752------------------------------------------------------------------------------------------------------------------- 8
BATTERY PACK 120095------------------------------------------------------------------------------------------------------------------------- 8
PRINT MODULE ASSEMBLY 11997501/02----------------------------------------------------------------------------------------------- 9
Sensor Flex Assembly 119988 ------------------------------------------------------------------------------------------------------------- 9
Printhead Assembly 119990----------------------------------------------------------------------------------------------------------------- 9
Stepper Motor 119980-------------------------------------------------------------------------------------------------------------------------- 9
IrDA Processor Assembly -------------------------------------------------------------------------------------------------------------------- 9
BACK INNER CASE ASSEMBLY 119961S----------------------------------------------------------------------------------------------- 9
MAIN PCB ASSEMBLY 119810--------------------------------------------------------------------------------------------------------------10
KEYBOARD/DISPLAY ASSEMBLY --------------------------------------------------------------------------------------------------------10
BACK OUTER CASE ASSEMBLY 119960S---------------------------------------------------------------------------------------------10
Chapter 3. Troubleshooting 11
GENERAL PRINT QUALITY COMPLAINTS ----------------------------------------------------------------------------------------------11
PRINTS LIGHT IMAGE ACROSS ENTIRE SUPPLY ----------------------------------------------------------------------------------11
PRINTS LIGHT IMAGE ON ONE SIDE OF SUPPLY ONLY------------------------------------------------------------------------11
PRINTS VOIDS ACROSS PRINT AREA---------------------------------------------------------------------------------------------------11
PRINT IMAGE MISSING DOTS, CREATING A WHITE LINE THROUGH IMAGE AREA --------------------------------12
PRINTS COMPRESSED IMAGE-------------------------------------------------------------------------------------------------------------12
PRINTER DOES NOT FEED-------------------------------------------------------------------------------------------------------------------12
PRINTER SKIPS LABELS ----------------------------------------------------------------------------------------------------------------------12
NO DISPLAY AT POWER UP-----------------------------------------------------------------------------------------------------------------12
INCORRECT OR NO RESPONSE WHEN KEY IS PRESSED--------------------------------------------------------------------12
NO COMMUNICATIONS BETWEEN PRINTER AND HOST------------------------------------------------------------------------12
BATTERY CONDITION CHECK ---------------------------------------------------------------------------------------------------------------13
PRINTER SHUTS COMPLETELY OFF WHILE PRINTING--------------------------------------------------------------------------13

Preface Confidential 9460 Service Manual
January 2001 Page iii
Chapter 4. Diagnostics 14
OVERVIEW-------------------------------------------------------------------------------------------------------------------------------------------14
POWER-UP DIAGNOSTICS--------------------------------------------------------------------------------------------------------------------14
RAM Test ------------------------------------------------------------------------------------------------------------------------------------------14
Printhead Test------------------------------------------------------------------------------------------------------------------------------------14
Battery Check------------------------------------------------------------------------------------------------------------------------------------14
USER DIAGNOSTICS-----------------------------------------------------------------------------------------------------------------------------14
Password Entry----------------------------------------------------------------------------------------------------------------------------------15
Diagnostics----------------------------------------------------------------------------------------------------------------------------------------15
Online Diagnostics------------------------------------------------------------------------------------------------------------------------------16
Setup ------------------------------------------------------------------------------------------------------------------------------------------------16
Service Diagnostics ----------------------------------------------------------------------------------------------------------------------------17
Exit---------------------------------------------------------------------------------------------------------------------------------------------------17
MONARCH INITIALIZATION FILES (.MIF)-------------------------------------------------------------------------------------------------18
PC DIAGNOSTICS ---------------------------------------------------------------------------------------------------------------------------------19
IMMEDIATE COMMANDS ----------------------------------------------------------------------------------------------------------------------19
Chapter 5. Tests and Adjustments 20
MAIN PCB ASSEMBLY--------------------------------------------------------------------------------------------------------------------------20
BATTERY TEST-------------------------------------------------------------------------------------------------------------------------------------20
SENSOR CALIBRATION-------------------------------------------------------------------------------------------------------------------------20
PRINTHEAD VERIFICATION-------------------------------------------------------------------------------------------------------------------20
Chapter 6. Disassembly Procedures 21
TOOLS REQUIRED--------------------------------------------------------------------------------------------------------------------------------21
REMOVING THE BOOT, 11997203/06/08-------------------------------------------------------------------------------------------------21
REMOVING THE BACK OUTER CASE, 119960S-------------------------------------------------------------------------------------21
Assembly Note-----------------------------------------------------------------------------------------------------------------------------------21
REMOVING THE DB9 DOOR------------------------------------------------------------------------------------------------------------------21
REMOVING THE CASE TOP------------------------------------------------------------------------------------------------------------------21
REMOVING THE KEYBOARD/DISPLAY ASSEMBLY-------------------------------------------------------------------------------21
REMOVING THE CPU BOARD ASSEMBLY --------------------------------------------------------------------------------------------22
REMOVING THE PRINT MODULE-----------------------------------------------------------------------------------------------------------22
REMOVING THE FRONT CASE ASSEMBLY-------------------------------------------------------------------------------------------22
Assembly Note-----------------------------------------------------------------------------------------------------------------------------------22
RETROFITTING TO IrDA -------------------------------------------------------------------------------------------------------------------------22
Chapter 7. PC Diagnostics 23
ENABLING ONLINE DIAGNOSTICS---------------------------------------------------------------------------------------------------------23
DETECTING THE PRINTER--------------------------------------------------------------------------------------------------------------------24
DOWNLOADING FILES TO THE PRINTER-----------------------------------------------------------------------------------------------24
DISPLAYING MUX VALUES-------------------------------------------------------------------------------------------------------------------25
TESTING THE PRINTHEAD--------------------------------------------------------------------------------------------------------------------25
DISPLAYING SERVICE TOTALS-------------------------------------------------------------------------------------------------------------25
DISPLAYING STOCK HISTORY --------------------------------------------------------------------------------------------------------------26
UPLOADING IMAGES----------------------------------------------------------------------------------------------------------------------------26
Appendix A. Error Codes 28
Appendix B. Care & Maintainence 34
CLEANING--------------------------------------------------------------------------------------------------------------------------------------------34
CLEARING LABEL JAMS-----------------------------------------------------------------------------------------------------------------------35
Appendix C. Circuit Card Assembly Layouts 36

9460 Service Manual Confidential Preface
Page iv January 2001
List of Figures
Figure 1-1. 9460 printer. .......................................................................................................................................2
Figure 1-2. Connecting Communications Cable. .....................................................................................................3
Figure 1-3. RS-232 Serial Port Connector Pinouts. .................................................................................................3
Figure 2-1. Printer Main Assembly........................................................................................................................5
Figure 2-2. Front Case Assembly..........................................................................................................................6
Figure 2-3. Supply Holder Assembly. ....................................................................................................................7
Figure 2-4. Print Module Assembly. ......................................................................................................................8
Figure C-1. Main PCB (Primary Side). .................................................................................................................36
Figure C-2. Main PCB (Secondary Side)..............................................................................................................37
Figure C-3. RF PCB...........................................................................................................................................38
Figure C-4. IrDA Processor Board. ......................................................................................................................38
Figure C-5. IrDA Transceiver. ..............................................................................................................................39
List of Tables
Table 1-1. Related Publications.............................................................................................................................1
Table 1-2. Specifications ......................................................................................................................................2
Table 4-1. 9460 Printer Menu Structure................................................................................................................14

Confidential
January 2001 Page 1
CHAPTER 1. PRINTER OVERVIEW & INSTALLATION
PURPOSE
This manual contains information service technicians
need to service, troubleshoot and repair the Monarch
Sierra Sport2™ 9460™ printer.
•Chapter 1 contains general information and
installation procedures.
•Chapter 2 contains physical and functional
descriptions of major components.
•Chapter 3 contains procedures to perform
troubleshooting beyond the capabilities of built-
in diagnostics.
•Chapter 4 contains procedures to run built-in
diagnostics for initial fault detection.
•Chapter 5 describes printer tests and
adjustments.
•Chapter 6 contains step-by-step procedures to
remove and replace failed assemblies and
modules.
•Chapter 7 describes diagnostics available with
the MonarchMPCL™ Toolbox software.
Additional maintenance assistance is available in
Appendix A, Error Codes; Appendix B, Care &
Maintenance; Appendix C, Circuit Card Assembly
Layouts.
The 9460 Illustrated Parts Breakdown contains
additional information for replacing individual parts.
ELECTROSTATIC
DISCHARGE
The 9460 printer contains devices that are sensitive to
electrostatic discharge (ESD). It is essential that you
follow proper ESD procedures. Use the Monarch-
approved ESD Field Service Kit. Failure to provide
proper static grounding can damage the printer
components.
PUBLICATIONS
Field service technicians should be familiar with the
documentation shown in the following table.
Table 1-1. Related Publications.
Title Publication
Number
Operator’s Handbook TC9460OH
1-Station Battery Charger
Operating Instructions TC9461OI
AC Adapter Instructions TC9463OI
4-Station Battery Charger
Operating Instructions TC9464OI
Installing a Linerless Platen
Roller TC9460ACPROI
Carrying Your 9460 PrinterTC9460ACHPOI
Programmer's Manual
(placed on Web site) TC9460PM
RCL Programmer’s Manual
(placed on Web site) TC9460RCL
EQUIPMENT DESCRIPTION
The 9460 printer is portable, and can print an image
that is 1.89 inches wide on supplies up to 2.05 inches
wide. Options include RF and IrDA communications,
1-and 4-station battery chargers, on-demand printing,
an AC adapter, linerless printing, shoulder strap, hand
strap, hip strap, and a belt clip that comes individually
or with the hip strap.
The display is graphical. The keyboard has 5 keys-
power, feed, and three that are context-sensitive (They
have different functions according to the selected menu
option.)
The standard memory configuration consists of 1 MB of
Flash and 512K of static Random Access Memory
(RAM).
The printer uses thermal direct printing to print on
supplies listed in Table 1-2.
The printer operates in continuous or optionally, on-
demand modes.

9460 Service Manual Confidential Printer Overview & Installation
Page 2January 2001
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.
9460 printers have seven major elements:
•Front Case Assembly
•Battery Pack
•Print Module Assembly
•Back Inner Case Assembly
•Main PCB Assembly
•Keyboard/Display Assembly
•Back Outer Case Assembly
Figure 1-1. 9460 printer.
Chapter 2 contains a physical and functional
description of each element.
EQUIPMENT
SPECIFICATIONS
Bar Codes
The printer prints the following bar codes:
Linear Bar Codes
UPCA UPCA+2
UPCE UPCA+5
EAN8 UPCA+Price CD
EAN13 UPCE+2
POSTNET UPCE+5
I 2 of 5 EAN8+2
I 2 of 5 with Barrier Bar EAN8+5
Extended Code 39 EAN13+2
Codabar (NW7) EAN13+5
Code 128 EAN13+Price CD
Code 93 MSI
2-D Stacked Bar Codes
Code 16K PDF 417
Maxicode Data Matrix
Additional Specifications
Specifications for the 9460 printer and its supplies are
shown below.
Table 1-2. Specifications
Feature Specification
Shipping Weight 3.1 lbs. (1.4 kg)
Battery Pack 7.4V Lithium Ion
Chargers 15 VDC at 5 A (1-Station) or
24 VDC at 4.5 A
8 VDC at 5 A (4-Station)
Operating Limits 40°F to 104°F (4°C to 40°C)
Relative Humidity 5% to 90 % Non-condensing
Display Multi-line, graphical LCD with
backlight and adjustable
contrast
Keyboard 5 keys (power, feed, and three
context-sensitive)
Printhead 1.89 inches/48 mm/384 dots
wide; (203 dots per inch; 8
dots per mm)
Printing Method Thermal Direct
Print Speed Up to 3 inches (76 mm) per
second
Maximum Print Area 22.68 square inches (146 sq
cm)
Maximum Print
Image Width 1.89 inches (48 mm)
Maximum Print
Image Length 12 inches (305 mm)
Stock:
Supply Types Tags, labels, and receipt
paper (paper and synthetic).
Width .5" (13 mm) to 2.05" (52
mm)
Length Min. 0.5 inch (13 mm)
Max. 12 inches (305 mm)
Supply Thickness .0024 inches to .007 inches
Roll Diameter Maximum roll OD: 2.5” (64
mm)
Minimum core ID: 1.02” (26
mm)

Printer Overview & Installation Confidential 9460 Service Manual
January 2001 Page 3
INSTALLATION AND
CHECKOUT PROCEDURES
1. Clear a work area approximately two feet wide.
2. Carefully open shipping carton.
3. Remove documentation.
4. Remove large cardboard insert.
5. Remove smaller cardboard insert.
6. Remove battery pack.
7. Place packing materials back in the carton and
store carton.
8. Inspect printer for damage. Report damage using
established procedures.
9. Insert the battery pack into the printer if charging
through the printer charger adapter. Otherwise,
remove the battery pack from the printer and insert
into the battery charger adapter.
10. Charge the battery (approximately 2 hours for full
charge).
Printer Checkout
1. Turn printer on by pressing the power button.
2. Check printer display for error indications.
3. Push down on the locking tabs to install supplies.
4. Print a test label. Use instructions in Chapter 4.
5. Review setup instructions with operator. Refer to
9460 Operator’s Handbook (TC9460OH).
6. Connect communications cable as shown. Ensure
the cable is pushed inward as the door is tightened
down to provide strain relief.
Figure 1-2. Connecting Communications Cable.
Communications Interface
The printer’s asynchronous RS-232 port is a DB9
connector located on the inside of the back outer case.
The following parameters are software selectable. The
defaults are listed in bold.
•Baud rate: 1200, 2400, 4800, 9600, 19200, or
38400, 57600, 115.2K
•Parity: Odd, Even, or None
•Stop Bits: 1or 2
•Data Bits: 7 or 8-bit
•Flow Control: XON/XOFF, RTS, or DTR
Following are the pinouts and signals of the DB9
connector.
Figure 1-3. RS-232 Serial Port Connector Pinouts.
ANSI/EIA-232-D
Contact # Circuit Description
8CTS Clear to Send
7RTS Request to Send
3TXD Transmitted Data
5GND Signal Ground
2RXD Received Data
4DTR Data Terminal Ready
6DSR Data Set Ready
1--- Reserved –Do not connect
9--- N/C

9460 Service Manual Confidential Printer Overview & Installation
Page 4January 2001
The following cables are available to connect the 9460
printer to other devices.
Cable Number Type
12029306 Symbol 3800 LRT/LDT
12029309 Telxon 960
12029314 DB9 to DB9 female serial port
12029315 DB9 to DB25 female serial
port
12029316 Symbol PDT 3100
12029323 Unterminated locking
12029343 Telxon 960SL
12029344 Symbol PDT 6100
12029345 Symbol SPT 1500
12029346 Symbol SPT 1700
12029347 Symbol SPT 2700