SATO PV4 User manual

Service Manual
PV4
BARCODE PRINTER
Ver. 1.00

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Table of Contents
1. Precaution Segment......................................................................................................4
1-1 Safety Precautions......................................................................................................4
1-2 Servicing Precaution...................................................................................................5
1-3 Precaution for Electrostatically Sensitive Devices (ESDs)..........................................6
1-4 Operational Precautions.............................................................................................6
1-5 Battery Safety Warning...............................................................................................7
2. Installation & Usage.......................................................................................................9
2-1 Battery Installation......................................................................................................9
2-2 Battery Charging.........................................................................................................9
2-2-1 Using AC/DC Adaptor...........................................................................................9
2-2-2 Using 1CH Battery Charger (Optional)...............................................................10
2-2-3 Using 4CH Battery Charger (Optional)...............................................................10
2-3 Paper Installation......................................................................................................12
2-4 Using Peeler.............................................................................................................13
2-5 Using Belt Strap........................................................................................................14
2-6 Using Fan-Fold Paper...............................................................................................15
2-7 Using Control Panel..................................................................................................16
2-9 Recommended Papers.............................................................................................17
2-10 Self Test..................................................................................................................18
2-11 LCD Menu...............................................................................................................20
2-12 Peripherals Connection ..........................................................................................23
2-12-1 Bluetooth, Wireless LAN Connection................................................................23
2-12-2 Interface Cable Connection..............................................................................24
2-12-3 Fixed Interface Cable Connection ....................................................................25
3. Product Specifications................................................................................................26
3-1 General Specifications..............................................................................................26
3-2 Printer Specifications................................................................................................27
3-2-1 SET Identification number..................................................................................27
3-2-2 Printer Classification...........................................................................................27
3-2-3 Printer Appearance.............................................................................................28
3-2-4 Other Component Specifications........................................................................30
3-3 Accessories Specifications .......................................................................................31
3-3-1 Accessories Classification ..................................................................................31
3-3-2 Accessories Appearance ....................................................................................32
3-3-3 WWPV45010 Lithium ion Battery for PV4 Smart................................................33
3-3-4 WWPV95950 PV AC/DC AdaptorS W/O PC ......................................................33
3-3-5 WWPV99310 PV 1CH Battery Cradle ASSY......................................................33
3-3-6 WWPV95360 PV 1CH BC AdaptorAW/O Power cord .......................................33
3-3-7 WWPV99340 PV 4CH Battery Cradle ASSY......................................................33
3-3-8 WWPV95380 PV 4CH BC AdaptorS W/O Power cord.......................................33
3-3-9 WWPV93700, WWPV93750 Interface cable for PC...........................................34
3-3-10 TYPE-C USB Interface cable for PC ................................................................36
4. Hardware ......................................................................................................................37
4-1 Wiring diagram..........................................................................................................37
4-1-1 Main board TOP wiring diagram.........................................................................37
4-1-2 Main board BOTTOM wiring diagram.................................................................37

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5. Disassembly and Exploded view................................................................................38
5-1 Disassembly .............................................................................................................38
5-1-1 ASSY-TOTAL Disassembly.................................................................................38
5-1-2 ASSY-COVER-LOWER disassembly..................................................................40
5-1-3 ASSY-COVER-PAPER disassembly...................................................................41
5-1-4 ASSY-HOLDER-PLATEN disassembly...............................................................42
5-1-5 ASSY-PEELER disassembly ..............................................................................43
5-1-6 ASSY-SUB-COVER-LOWER disassembly.........................................................44
5-1-7 ASSY-TERMINAL disassembly...........................................................................45
5-1-8 ASSY-COVER-UPPER disassembly ..................................................................46
5-1-9 ASSY-FRAME-MAIN-NR disassembly................................................................48
5-1-10 ASSY-SUB-FRAME MAIN disassembly............................................................50
5-1-11 ASSY-ARM-LOCKING-L disassembly...............................................................51
5-1-12 ASSY-ARM-LOCKING-R disassembly..............................................................52
5-1-13 ASSY-TPH-R disassembly................................................................................53
5-1-14 ASSY-SENSOR-PEELER disassembly............................................................54
5-1-15 ASSY-FRAME-PAPER disassembly.................................................................55
5-1-16 ASSY-PAPER-HOLDER-L-19 disassembly......................................................57
5-1-17 ASSY-PAPER-HOLDER-R-19 disassembly......................................................58
6. Printer Cleaning...........................................................................................................59
7. Troubleshooting...........................................................................................................60
7-1 Troubleshooting Flow Chart......................................................................................60
7-2 Troubleshooting Table...............................................................................................61

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1. Precaution Segment
1-1 Safety Precautions
1. Make sure that there are no cabinet openings through which people – particularly children – might insert
fingers and contact dangerous voltages. Such openings include excessively wide cabinet ventilation slots
and improperly fitted covers and drawers.
2. Leakage Current Hot Check:
Use a leakage-current tester or a metering system that complies with American National Standards
Institute (ANSI C101.1, Leakage Current for Applications), and Underwriters Laboratories (UL Publications
UL1410, 59.7). With the unit completely reassembled, plug the AC line cord directly into a 100VAC or
240VAC outlet of the Adaptor.
With the unit’s AC switch first in the ON position and then OFF, measure the current between a known
Earth ground (metal water pipe, conduit, etc.) and all exposed metal part, including: metal cabinet, frame,
and screw-heads and printer. The current measure should not exceed 0.1 milliamp. Reverse the power-
plug prong in the AC outlet and repeat the test.
3. Design Alteration Warning:
Never alter or add to the mechanical or electrical design of the printer. Unauthorized alterations might
create a safety hazard. Also any design changes or additions will void the manufacture’s warranty.
4. Components, parts and wiring that appear to have overhead or that are otherwise damaged should be
replaced with parts that meet the original specifications. Always determine the cause of damaged or
overheating and correct any potential hazards.
5. Observe the original lead dress, especially near the following areas: sharp edges, and especially the AC
and high voltage supplies. Always inspect for pinched, out-of-place, or frayed wiring.
Do not change the spacing between components and the printed circuit board. Check the AC power cord
for damage. Make sure that leads and components do not touch thermally hot parts.
6. Product Safety Notice:
Some electrical and mechanical parts have special safety-related characteristics, which might not be
obvious from visual inspection. These safety features and the protection they give might be lost if the
replacement component differs from the original-even if the replacement is rated for higher voltage,
wattage, etc.
Use replacement components that have the same ratings, especially for flame resistance and dielectric
strength specifications. A replacement part that does not have the same safety characteristics as the
original might create shock, fire or other hazards.

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1-2 Servicing Precaution
WARNING 1: First read the Safety Precaution section of this manual. If some unforeseen
circumstance creates a conflict between the servicing and safety precautions,
always follow the safety precaution.
WARNING 2: An electrolytic capacitor installed with the wrong polarity might explode.
1. Always unplug the unit’s AC power cord from the AC power source or the power switch off before
attempting to:
(a) Remove or reinstall any component or assembly,
(b) Disconnect an electrical plug or connector,
2. An insulation tube or tape is sometime used. The internal wiring is sometimes clamped to prevent contact
with thermally hot components. Reinstall all such elements to their original position.
3. After servicing, always check that the screws, components and wiring have been correctly reinstalled.
Make sure that the portion around the serviced part has not been damaged.
4. Check the insulation between the blades of the AC plug and accessible conductive parts
5. Insulation Checking Procedure: Disconnect the power cord from the AC source and turn the power switch
on. Connect an insulation resistance meter (500V) to the blades of the AC plug.
The insulation resistance between each blade of the AC plug and accessible conductive parts should be
greater than 1 mega-ohm.
6. Always connect an instrument’s ground lead to the instrument chassis ground before connecting the
positive lead; always remove the instrument’s ground lead last.

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1-3 Precaution for Electrostatically Sensitive Devices (ESDs)
1. Some semiconductor (solid state) devices are easily damaged by static electricity. Such components are
called electrostatically sensitive devices (ESDs); examples include integrated circuits and some field-effect
transistors. The following techniques will reduce the occurrence of component damaged caused by static
electricity.
2. Impapertely before handling any semiconductor components or assemblies, drain the electrostatic charge
from your body by touching a known earth ground. Alternatively, wear a discharging wrist-strap device.
(Be sure to remove it prior to applying power-this is an electric shock precaution.)
3. After removing an ESD-equipped assembly, place it on a conductive surface such as aluminum foil to
prevent accumulation of electrostatic charge.
4. Do not use freon-propelled chemical. These can generate electrical charges that damage ESDs.
5. Use only a grounded-tip soldering iron when soldering or unsoldering ESDs.
6. Use only an anti-static solder removal device. Many solder removal devices are not rated as anti-static;
these can accumulate sufficient electrical charge to damage ESDs.
7. Do not remove a replacement ESD from its protective package until you are ready to install it.
Most replacement ESDs are packaged with leads that are electrically shorted together by conductive foam,
aluminum foil or other conductive materials.
8. Minimize body motions when handling unpacked replacement ESDs. Motions such as brushing clothes
together, or lifting a foot from a carpeted floor can generate enough static electricity to damaged an ESD.
1-4 Operational Precautions
1. The heating element of the printer mechanism’s thermal head and the driver IC are easily damaged.
Never allow these components to come into contact with metal or other hard objects.
2. Never touch the printer mechanism’s heating element with your hand. Doing so can damage the heating
element and affect proper operation.
3. The head and motor areas are very hot during and impapertely after printing. Do not touch components in
these areas directly with your hand.
4. Do not use any paper other than these specified in this manual otherwise print head reliability and print
quality are affected adversely.
5. Thermal paper starts to color at around 70ºC. Take care to protect unused and printed thermal paper
against the affects of heat, light and characters on the paper to feed.
6. Take the roll paper out of the printer when you will not use the printer for a long time in a high temperature
and humidity environment.

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1-5 Battery Safety Warning
Please be sure to read this guide prior to use.
Warning
1. If the battery is not charged after the charging time, stop charging and contact the seller.
2. Store and use the battery where it will not come into contact with liquid (water, salt water, etc.). There
may be a risk of overheating, rupturing or igniting.
3. Avoid exposing the battery to high temperatures over 50 ℃and do not store or use it in a place with high
temperature and humidity. There may be a risk of overheating, rupturing or igniting. In addition, it may
reduce the performance and life of the battery. There is a risk of explosion, especially when the battery is
placed by a fire or stored near a heating device (e.g., heater, etc.).
4. Do not put the battery in a microwave oven or high-pressure cooker (pressure cooker, etc.). There may
be a risk of overheating, rupturing or igniting.
5. Do not use or leave the battery exposed to direct sunlight or high temperatures such as in a car. It may
reduce battery performance and life, or there may be a risk of overheating, rupturing or igniting.
6. The usage temperature range of the battery is as follows. If used outside of this range, battery
performance and life may be reduced, or there may be a risk of overheating, rupturing or igniting.
- Charging: 0 to 50 °C (32 to 122 °F)
- Using: -15 to 50 °C (5 to 122 °F)
- Long-term storage (over 30 days): -15 to 40 °C (5 to 104 °F)
7. Be sure to only use an adaptor or charger approved by us to charge the battery. Use of any other adaptor
or charger may reduce battery performance and life, or cause a risk of overheating, rupturing or igniting.
8. Do not use the (+) and (-) terminals of the battery reversely. Failure to use the equipment may result in an
abnormal chemical reaction inside the battery, which may cause overheating, rupturing or igniting.
9. Do not touch the (+) and (-) terminals of the battery with metal. Also, do not carry or store it with metallic
goods (necklaces, hair pins, coins, etc.). There may be a risk of overheating, rupturing or igniting.
10. Do not use the battery in a place where static electricity can be generated. It may damage the protective
device, resulting in reduction of battery performance and life, or there may be a risk of overheating,
rupturing or igniting.
11. Avoid causing any strong impact to the battery or throwing it. The protective device inside the battery
may be damaged, which may reduce the battery performance and life, or there may be a risk of
overheating, rupturing or igniting.
12. Do not disassemble or modify the battery. The battery contains safety and protection devices to prevent
danger. It may reduce battery performance and life due to damage, or there may be a risk of overheating,
rupturing or igniting.
13. If any leakage of the battery comes into contact with the eyes or skin, impapertely rinse with clean water
such as tap water and consult a doctor impapertely.
14. Keep the battery out of the reach of children and infants. If it is swallowed, consult a doctor impapertely.

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Recommendations
1. Do not charge for longer than the charging time described in this guide, as it may reduce battery
performance and duration.
2. If the battery is not expected to be used for a long time, remove it from the equipment and keep in a place
with low humidity.
3. Be sure to turn off the power of the equipment after use. Failure to do so may reduce the performance and
life of the battery.
4. Batteries that have not been used for a long time may fail to charge properly. Even if you do not use the
battery for a long time, charge it at least once every 6 months before storing it.
5. If the (+) and (-) terminals of the battery are contaminated, wipe them with a dry cloth and use in a clean
condition. The contamination of battery may result in unstable contact with the equipment and the power
may be cut off or the battery may not be charged.
Disposal
1. When using, storing or charging the battery, if you detect any abnormality such as an odor, overheating,
discoloration, deformation, leakage, etc., please remove the battery from the equipment or charger and
dispose of it impapertely.
2. When disposing of the battery, completely discharge it, tape the terminals with insulation, and dispose of it
at a designated location according to relevant laws and regulations set by the government.

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2. Installation & Usage
2-1 Battery Installation
1) Insert the battery in the bottom of the
printer, and ensure that you align the
battery hook properly.
2) Push the battery into the slot until you
hear it “click” in place.
NOTE
As the battery is partially changed at the time of
purchase, charge the battery prior to product
use. (Use the AC/DC adaptor or the optional
1CH/4CH battery charger.)
2-2 Battery Charging
2-2-1 Using AC/DC Adaptor
1) Turn off the printer power.
2) Connect the power cord ②
to the
AC/DC adaptor ①
and then connect AC
power.
3) Open the external interface cap in the
direction of ③.
4) Connect the AC/DC adaptor to the power
connector.
NOTE
Battery charging status descriptions are as follows.
LED
Charge Status
Charge Time
Red LED On
Charging
Within 6 hours
Green LED On
Fully Charged
Red LED Blinking
Error Replace
or Reinstall Battery
Caution
The printer may incur serious damage if the AC/DC adaptor provided by
SATO is not used. SATO is not legally liable for any such damages.
(The voltage and electrical current specifications of the printer and battery
charger must match.)
Warning Turn off the power before charging the battery for the printer.

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2-2-2 Using 1CH Battery Charger (Optional)
1) Connect the power cord ②to the
battery charger ①.
2) Connect the battery charger ①to the
power connector of the cradle ③.
3) Plug the power cord ②into an electrical
outlet.
4) Insert the battery ④into the cradle ③
a snapping sound is heard.
Caution
- The printer may incur serious damage if you do not use the battery charger
provided by SATO when using a single battery charger.
SATO is not legally liable for any such damages.
- You must use the battery charger power supply provided by SATO to use
the single battery charger. (AC/DC adaptor is not available)
2-2-3 Using 4CH Battery Charger (Optional)
2-2-3-1 Connecting the cables
1) Connect the power cord to the Adaptor,
and Connect the Adaptor to the power
connector of the quad battery charger.
2) Plug the power cord into a power Outlet.
Input power is 100 ~ 240VAC, 50/60Hz,
1.0A.
3) When the power is applied, the yellow,
green and red LEDs are on for three
seconds and do the self-test.
Warning Use only designated AC/DC Adaptor. (12VDC, 3A)