Page 2 - WARNING
SATO America, Inc. 10350A Nations Ford Road Charlotte, NC 28273 Main Phone: (704) 644.1650 Technical Support Hotline: (704) 644.1660 Technical Support Fax: (707) 644.1661 E-Mail: [email protected] technical [email protected] www.satoamerica.com WARNING THE EQUIPMENT REFERENCED IN THIS ...
Page 3 - TABLE OF CONTENTS; INTRODUCTION
PN 9001138B TABLE OF CONTENTS INTRODUCTION About This Manual 1-2 General Description 1-3 Control Features 1-4 TECHNICAL DATA Physical Characteristics 2-2 Power 2-2 Enviromental 2-2 Processing 2-2 Command 2-2 Interface Modules 2-2 Print 2-3 Media 2-3 Ribbon 2-3 Sensing 2-3 Character Font Capabilities...
Page 6 - ABOUT THIS MANUAL; PROVIDES INFORMATION THAT, IF UNHEEDED, MAY
Unit 1: Introduction SATO GT4xxe Series Operator Manual PN 9001138B Page 1-2 ABOUT THIS MANUAL This manual is laid out consistent with the product discussed and provides all of the informationrequired for printer maintenance and repair by SATO approved personnel. For the repairtechnician, this manua...
Page 7 - GENERAL DESCRIPTION
Unit 1: Introduction SATO GT4xxe Series Operator Manual PN 9001138B Page 1-3 GENERAL DESCRIPTION The GT4xxe series printer is a high-performance printer capable of printing all popular bar codesand twelve human-readable fonts; providing an inventory of thouasnds of styles and sizes. Itsheavy metal c...
Page 8 - CONTROL FEATURES; LINE
Unit 1: Introduction SATO GT4xxe Series Operator Manual PN 9001138B Page 1-4 CONTROL FEATURES This chapter identifies the interactive control features of the printer. These functions aregenerally defined here. More specific explainations will be found throughout this manual on howto use them. Figure...
Page 9 - TECHNICAL DATA
SATO GT4xxe Series Operator Manual PN 9001138B Page 2-1 TECHNICAL DATA • Physical Characteristics • Power • Enviromental • Processing • Print • Media • Ribbon • Sensing • Interface Modules • Character Font Capabilities • Barcode Capabilities • Regulatory Approvals
Page 12 - CHARACTER FONT CAPABILITIES
Unit 2: Technical Data SATO GTxxe Series Operator Manual PN 9001138B Page 2-4 CHARACTER FONT CAPABILITIES MATRIX FONTS U 5 dots W x 9 dots H S 8 dots W x 15 dots H M 13 dots W x 20 dots H XU 5 dots W x 9 dots H (Helvetica) XS 17 dots W x 17 dots H (Univers Condensed Bold) XM 24 dots W x 24 dots H (U...
Page 14 - INSTALLATION
SATO GT4xxe Series Operator Manual PN 9001138B Page 3-1 INSTALLATION • Unpacking • Parts Identification• Printer Installation• Interface Selection• Accessories Installation
Page 15 - UNPACKING & PARTS IDENTIFICATION; Unpack the printer as directed in the following procedure.
Unit 3: Installation SATO GT4xxe Series Operator Manual PN 9001138B Page 3-2 UNPACKING & PARTS IDENTIFICATION Unpack the printer as directed in the following procedure. 1 Place the shipping container (box) upright on a soid, flat surface. 2 Open the box, remove any loose items and the first laye...
Page 16 - PRINTER INSTALLATION; SITE LOCATION; Stationed on a solid flat surface.; CABLE CONNECTION
Unit 3: Installation SATO GT4xxe Series Operator Manual PN 9001138B Page 3-3 PRINTER INSTALLATION This chapter provides guidance on how to station, connect, and load the printer once unpacked.Following printer setup, procede to the next chapter for information on interface selection. SITE LOCATION •...
Page 17 - MEDIA SELECTION
Unit 3: Installation SATO GT4xxe Series Operator Manual PN 9001138B Page 3-4 MEDIA SELECTION The size and type of the labels or tags to be printed should have been taken into considerationbefore printer purchase. Ideally, the media width will be equal to, or just narrower than, the printhead. Using ...
Page 19 - INTERFACE SELECTION; RS232C Asynchronous Serial; RS232C SERIAL INTERFACE; RS232C SPECIFICATIONS
Unit 3: Installation SATO GT4xxe Series Operator Manual PN 9001138B Page 3-6 INTERFACE SELECTION This chapter presents the printer interface types and their specifications. These specificationsinclude detailed information to assist in the selection of the most appropriate method for theprinter to in...
Page 21 - IEEE1284 PARALLEL INTERFACE
Unit 3: Installation SATO GT4xxe Series Operator Manual PN 9001138B Page 3-8 IEEE1284 PARALLEL INTERFACE The parallel interface is a plug-in module that can be installed by the user and conforms toIEEE1284 specifications. It automatically detects the IEEE1284 signals and operates in the highspeed mo...
Page 23 - RECEIVE BUFFER
Unit 3: Installation SATO GT4xxe Series Operator Manual PN 9001138B Page 3-10 RECEIVE BUFFER The data stream is received from the host to the printer one job at a time. This allows thesoftware program to maintain control of the job print queue so that it can move a high priority jobin front of ones ...
Page 24 - ACCESSORIES INSTALLATION; EXTERNAL SIGNAL CONNECTOR
Unit 3: Installation SATO GT4xxe Series Operator Manual PN 9001138B Page 3-11 ACCESSORIES INSTALLATION EXTERNAL SIGNAL CONNECTOR This connector permits the interface of an external source with the printer for the purpose ofregulating print actiivity to coincide with those external requirements (i.e....
Page 25 - MEMORY EXPANSION; Disconnect power supply cord.
Unit 3: Installation SATO GT4xxe Series Operator Manual PN 9001138B Page 3-12 MEMORY EXPANSION The memory cartridge provides additional storage of user data and graphics. Access to thememory cartridge port, and its installation, is very simple. The instructions below provideguidance. 1 Disconnect po...
Page 26 - INTERFACE UPGRADE; USB Interface
Unit 3: Installation SATO GT4xxe Series Operator Manual PN 9001138B Page 3-13 INTERFACE UPGRADE The printer is typically ordered with a high-speed parallel interface board installed. However,interface requirements sometimes change and an upgrade is desired. All of the interface boardsare installed w...
Page 27 - LABEL CUTTER INSTALLATION
Unit 3: Installation SATO GT4xxe Series Operator Manual PN 9001138B Page 3-14 LABEL CUTTER INSTALLATION The label cutter, when installed, replaces the printer’s lower front housing cover. Its internalsensor monitors media feed and activates the cut sequence based on user established values. The cutt...
Page 28 - PRINTER
SATO GT4xxe Series Operator Manual PN 9001138B Page 4-1 PRINTER OPERATION • Configuration Modes• Operational Adjustments
Page 29 - CONFIGURATION MODES; NORMAL MODE
Unit 4: Operation SATO GT4xxe Series Operator Manual PN 9001138B Page 4-2 CONFIGURATION MODES This chapter provides an overview of the various configuration modes of the operation menu. Allof the following configuration activities are performed via the use of the operator panel located onthe printer...
Page 30 - USER MODE
Unit 4: Operation SATO GT4xxe Series Operator Manual PN 9001138B Page 4-3 USER MODE This mode allows cofiguration of printing features that are prone to change from job to job. Theseare some of the most basic and common adjustments of all of the configuration modes. Figure 4-2, User Mode OFFSET VOLU...
Page 31 - ADVANCED MODE
Unit 4: Operation SATO GT4xxe Series Operator Manual PN 9001138B Page 4-4 ADVANCED MODE The Advanced Mode is provided to make basic printer operational adjustments. Typically, oncethese adjustments or settings have been made, they will not require additional address unless anew job is downloaded. Th...
Page 32 - IEEE1284 INTERFACE SETUP MODE
Unit 4: Operation SATO GT4xxe Series Operator Manual PN 9001138B Page 4-5 IEEE1284 INTERFACE SETUP MODE This chapter provides the programming sequences required for IEEE1284 interface setup. Usethe keys of the printer’s operator panel to select and enter the required options. Figure 4-4, IEEE1284 In...
Page 33 - RS232C INTERFACE SETUP MODE
Unit 4: Operation SATO GT4xxe Series Operator Manual PN 9001138B Page 4-6 RS232C INTERFACE SETUP MODE This chapter provides the programming sequences required for RS232C interface setup. Use thekeys of the printer’s operator panel to select and enter the required options. Figure 4-5, RS232C Interfac...
Page 34 - CENTRONICS INTERFACE SETUP MODE
Unit 4: Operation SATO GT4xxe Series Operator Manual PN 9001138B Page 4-7 CENTRONICS INTERFACE SETUP MODE This chapter provides the programming sequences required for Centronics interface setup. Usethe keys of the printer’s operator panel to select and enter the required options. Figure 4-6, Centron...
Page 35 - LAN INTERFACE SETUP MODE
Unit 4: Operation SATO GT4xxe Series Operator Manual PN 9001138B Page 4-8 LAN INTERFACE SETUP MODE This chapter provides the programming sequences required for LAN and mini-LAN interfacesetup. Use the keys of the printer’s operator panel to select and enter the required options. Figure 4-7, LAN Inte...
Page 36 - USB INTERFACE SETUP MODE
Unit 4: Operation SATO GT4xxe Series Operator Manual PN 9001138B Page 4-9 USB INTERFACE SETUP MODE This chapter provides the programming sequences required for USB interface setup. Use thekeys of the printer’s operator panel to select and enter the required options. Figure 4-8, USB Interface Setup M...
Page 37 - CARTRIDGE MODE
Unit 4: Operation SATO GT4xxe Series Operator Manual PN 9001138B Page 4-10 CARTRIDGE MODE This mode permits the configuration of an optional memory cartridge. This cartridge, whenloaded, provides increased storage capacity for text and graphics. Use the keys of the printer’soperator panel to select ...
Page 38 - SEMBL MODE
Unit 4: Operation SATO GT4xxe Series Operator Manual PN 9001138B Page 4-11 SEMBL MODE SEMBL (SATO Embedded Basic Language) allows software programs written in standard Basiclanguage to be loaded into the printer and executed without additional computer connections. Use the keys of the printer’s oper...
Page 39 - TEST PRINT MODE
Unit 4: Operation SATO GT4xxe Series Operator Manual PN 9001138B Page 4-12 TEST PRINT MODE Figure 4-11 provides the specific sequence of events required by the operator, the printer, andthe printer’s software for a test label to be printed. Test labels are designed to identify failures inconfigurati...
Page 40 - DOWNLOAD MODE
Unit 4: Operation SATO GT4xxe Series Operator Manual PN 9001138B Page 4-13 DOWNLOAD MODE This download feature allows the operator to download print jobs to the printer. Whendownloading is complete, the LCD screen will return to the original display. If an error occurs, aDOWNLOAD ERROR will display....
Page 41 - HEX DUMP MODE
Unit 4: Operation SATO GT4xxe Series Operator Manual PN 9001138B Page 4-14 HEX DUMP MODE The contents of the print buffer and the data received before it is placed into the print buffer maybe examined through the use of the Hex Dump Mode. Each line of the printed data is inumeratedin the first colum...
Page 42 - BOOT DOWNLOAD MODE
Unit 4: Operation SATO GT4xxe Series Operator Manual PN 9001138B Page 4-15 BOOT DOWNLOAD MODE Figure 4-14 provides the specific sequence of events required by the operator, the printer, andthe printer’s software Use the keys of the printer’s operator panel to select and enter therequired options. Fi...
Page 43 - DATA SAVE MODE
Unit 4: Operation SATO GT4xxe Series Operator Manual PN 9001138B Page 4-16 DATA SAVE MODE Figure 4-15 provides the specific sequence of events required by the operator, the printer, andthe printer’s software to store the printer’s history.Use the keys of the printer’s operator panel to select and en...
Page 44 - DEFAULT SETTINGS MODE
Unit 4: Operation SATO GT4xxe Series Operator Manual PN 9001138B Page 4-17 DEFAULT SETTINGS MODE Figure 4-16 provides the specific sequence of events required by the operator, the printer, andthe printer’s software to return the printer to the configuration state as recieved from the factory. Use th...
Page 45 - PRINT CANCEL MODE
Unit 4: Operation SATO GT4xxe Series Operator Manual PN 9001138B Page 4-18 PRINT CANCEL MODE Figure 4-17 provides the specific sequence of events required by the operator, the printer, andthe printer’s software to cancel a print job once initiated. Use the keys of the printer’s operatorpanel to sele...
Page 46 - PRINT DARKNESS DEFAULT MODE
Unit 4: Operation SATO GT4xxe Series Operator Manual PN 9001138B Page 4-19 PRINT DARKNESS DEFAULT MODE Figure 4-18 provides the specific sequence of events required by the operator, the printer, andthe printer’s software to return to the print darkness (density) setting as received from the factory....
Page 47 - SERVICE MODE
Unit 4: Operation SATO GT4xxe Series Operator Manual PN 9001138B Page 4-20 SERVICE MODE Allows the programming of various dimensional settings, sensor thresholds, and languageoptions. Use the keys of the printer’s operator panel to select and enter the required options. Figure 4-19, Service Mode COP...
Page 48 - FACTORY MODE
Unit 4: Operation SATO GT4xxe Series Operator Manual PN 9001138B Page 4-21 FACTORY MODE The Factory Mode permits counter reset of various printer components. Use the keys of theprinter’s operator panel to select and reset those features. Figure 4-20, Factory Mode MAIN PCBREVISION REV 0. 0 HEAD OPEN ...
Page 49 - MENU
Unit 4: Operation SATO GT4xxe Series Operator Manual PN 9001138B Page 4-22 NORMAL MODE (4-1) MENU DESCRIPTION Displays the operational status of the printer. The ONLINEstatus is displayed on the top line and the label quantity statuson the bottom. The message will be changed to OFFLINEwhenever the p...
Page 76 - OPERATIONAL ADJUSTMENTS; POTENTIOMETER
Unit 4: Operation SATO GT4xxe Series Operator Manual PN 9001138B Page 4-49 OPERATIONAL ADJUSTMENTS These operational adjustments are for fine tuning the printer as necessary following theconfiguration process and are largely confined to the four potentiometers located on the operatorpanel. Refer to ...
Page 77 - DI
Unit 4: Operation SATO GT4xxe Series Operator Manual PN 9001138B Page 4-50 Figure 4-21, Sensor & Accessory Positioning Print Head Cutter Tear-Off Dispenser Invalid Area for Print 0.69" 0.25" 0.45 " 0. 63" 0.79" 0.64" 2.05" Print Width: 4.09"/4.20" L A B E L PR...
Page 78 - Figure 4-22, Print Base Reference Position
Unit 4: Operation SATO GT4xxe Series Operator Manual PN 9001138B Page 4-51 Figure 4-22, Print Base Reference Position L A B E L PRIN T DIRECTIO N REFLECTIVE SENSOR TRANSMISSION SENSOR Base Print Position CONTINUOUS MODE REFLECTIVE SENSOR TRANSMISSION SENSOR Base Print & Tear- Off Position TEAR-O...
Page 79 - TROUBLESHOOTING; Error Signals
SATO GT4xxe Series Operator Manual PN 9001138B Page 5-1 TROUBLESHOOTING • Error Signals • Troubleshooting Table • Interface Troubleshooting • Test Print Troubleshooting • Sensor Locations
Page 85 - TROUBLESHOOTING TABLE
Unit 5: Troubleshooting SATO GT4xxe Series Operator Manual PN 9001138B Page 5-7 TROUBLESHOOTING TABLE IMAGE VOIDS Damaged print head. Replace print head. Damaged electronics. Replace circuit board. Damaged or worn platen roller. Replace platen roller. Vertical line in printed image. Dirty or defecti...
Page 87 - INTERFACE TROUBLESHOOTING; PARALLEL INTERFACE; RS232 SERIAL INTERFACE; CHK
Unit 5: Troubleshooting SATO GT4xxe Series Operator Manual PN 9001138B Page 5-9 INTERFACE TROUBLESHOOTING This unit provides a checklist for the various interface types. Locate the checklist relative to theinterface used and perform each of the troubleshooting tasks until the problem has been isolat...
Page 88 - LAN EHTERNET INTERFACE
Unit 5: Troubleshooting SATO GT4xxe Series Operator Manual PN 9001138B Page 5-10 LAN EHTERNET INTERFACE CHK TROUBLESHOOTING STEP Ensure the interface has been correctly configured. Wait two minutes and run self-test to verify. If atest label does not print, there ma y be a hardware problem. Ensure t...
Page 89 - TEST PRINT TROUBLESHOOTING; HEX DUMP
Unit 5: Troubleshooting SATO GT4xxe Series Operator Manual PN 9001138B Page 5-11 TEST PRINT TROUBLESHOOTING Chapter provides instruction on special printing to identify and resolve specific print problems. HEX DUMP Allows the operator to determine if there wereproblems in the downloading of data. TE...
Page 90 - TEST LABEL PRINTING
Unit 5: Troubleshooting SATO GT4xxe Series Operator Manual PN 9001138B Page 5-12 TEST LABEL PRINTING The test label is designed to assist in the identification of print problems. Follow the flow chartprovided below to perform this activity. Figure 5-2, Test Print Mode FEED + POWER Printer beeps TEST...
Page 91 - SAMPLE TEST LABEL
Unit 5: Troubleshooting SATO GT4xxe Series Operator Manual PN 9001138B Page 5-13 Figure 5-3, Sample Test Label NOTE: The only print problem that the following sample test label does notdisplay is fading of print image from one side of the label to the other. This isthe result of improper print head ...
Page 92 - SENSOR LOCATIONS; IN
Unit 5: Troubleshooting SATO GT4xxe Series Operator Manual PN 9001138B Page 5-14 SENSOR LOCATIONS This chapter provides a diagram identifying the locations of the printer’s various sensors. Refer tothe diagram provided below. Figure 5-4, Sensor Locations Print Head Cutter Tear-Off Dispenser Invalid ...
Page 93 - MAINTENANCE
SATO GT4xxe Series Operator Manual PN 9001138B Page 6-1 MAINTENANCE • Cleaning Procedures• Replacement Procedures• Adjustment Procedures
Page 94 - CLEANING PROCEDURES
Unit 6: Maintenance SATO GT4xxe Series Operator Manual PN 9001138B Page 6-2 CLEANING PROCEDURES Cleaning of the printer is a necessary maintenance activity to ensure print quality and long printerlife. There are two basic types of cleaning involved; the removal of loose debris and the removalof resi...
Page 95 - REPLACEMENT PROCEDURES; PRINT HEAD REPLACEMENT; Switch off the printer and disconnect the power supply cord.
Unit 6: Maintenance SATO GT4xxe Series Operator Manual PN 9001138B Page 6-3 REPLACEMENT PROCEDURES This unit contains step-by-step instructions for the removal and replacement of all primarycomponents and sub-assemblies. PRINT HEAD REPLACEMENT If the print head becomes damaged or worn, it can be eas...
Page 96 - PLATEN ROLLER REPLACEMENT
Unit 6: Maintenance SATO GT4xxe Series Operator Manual PN 9001138B Page 6-4 Figure 6-1b, Print Head Replacement PLATEN ROLLER REPLACEMENT The platen roller is considered to be a high wear component due to its treading against the printmedia. This treading contact will eventually wear grooves into th...
Page 98 - ADJUSTMENT PROCEDURES; PRINT HEAD ALIGNMENT
Unit 6: Maintenance SATO GT4xxe Series Operator Manual PN 9001138B Page 6-6 ADJUSTMENT PROCEDURES This unit covers all of the printer and printer accessory adjustments. These adjustments includemechanical adjustments required following the replacement of components and assemblies, inaddition to, the...
Page 99 - PRINT HEAD PRESSURE ADJUSTMENT; Figure 6-4, Print Head Pressure Adjustment
Unit 6: Maintenance SATO GT4xxe Series Operator Manual PN 9001138B Page 6-7 PRINT HEAD PRESSURE ADJUSTMENT Print head pressure adjustment allows for the print head to be adjusted to accommidate differentmedia types (thicknesses). The pressure setting switch is two position (normal, high). The tablet...
Page 100 - PRINT HEAD BALANCE ADJUSTMENT; Figure 6-5, Print Head Balance Adjustment
Unit 6: Maintenance SATO GT4xxe Series Operator Manual PN 9001138B Page 6-8 PRINT HEAD BALANCE ADJUSTMENT Print head balance is the equalization of pressure against the platen roller from one end to theopposite. If the print head balance is out of adjustment, the printed image will be darker on side...
Page 101 - RIBBON GUIDE ADJUSTMENT
Unit 6: Maintenance SATO GT4xxe Series Operator Manual PN 9001138B Page 6-9 RIBBON GUIDE ADJUSTMENT If the print ribbon is not spread smoothly over the print head when it makes contact with themedia, print voids will occur at the point of the ribbon fold. Typically, this is the result of the axis of...
Page 102 - LABEL SENSOR POSITIONING
Unit 6: Maintenance SATO GT4xxe Series Operator Manual PN 9001138B Page 6-10 LABEL SENSOR POSITIONING The label sensor assembly provides a mounting apparatus for the eye-mark, gap, and paper-endsensors. Position adjustment of the label sensor is not required when using standard labelmedia. When non-...
Page 103 - POTENTIOMETER ADJUSTMENTS
Unit 6: Maintenance SATO GT4xxe Series Operator Manual PN 9001138B Page 6-11 POTENTIOMETER ADJUSTMENTS These operational adjustments are for fine tuning the printer as necessary following theconfiguration process and are largely confined to the four potentiometers located on the operatorpanel. Refer...
