SATO CL-408 User manual

P/N 9001040
Rev C
SATO CL-408/412
Service Manual
Industrial Bar Code Printers

SATO CL408/412 Service Manual
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SATO America, Inc.
10350A Nations Ford Road
Charlotte, NC 28273
MainPhone: 704.644.1650
Technical Support Hotline: [phone]
Technical Support Fax: [phone]
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Copyright 1997
SATO America, Inc.
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SATO CL408/412 Service Manual
i
Table Of Contents
SECTION 1. INTRODUCTION Page
Installation Considerations............................................ 1-1 1
Ribbon.............................................................................. 1-2 2
Dimensions...................................................................... 1-3 2
Component Designations............................................... 1-4 3
Interface Connections, Input Output Panel .................. 1-5 4
Switches and Sensors.................................................... 1-6 5
SECTION 2. PRINTER CONFIGURATION
Dip Switch Settings ........................................................ 2-1 9
Default Settings.............................................................. 2-2 19
Printer Adjustments........................................................ 2-3 20
Printing Test Labels........................................................ 2-4 33
SECTION 3. SPECIFICATIONS
Print.................................................................................. 3-1 35
Media, Sensing and Ribbon........................................... 3-2 36
Printer Controls and Signals, Adjustments and
Interface Connections ................................................... 3-3 37
Processing ...................................................................... 3-4 38
Character Fonts .............................................................. 3-5 38
Bar Codes and Other Features...................................... 3-6 39
Physical ........................................................................... 3-7 40
Optional Accessories..................................................... 3-8 41
SECTION 4. TROUBLESHOOTING
Troubleshooting Tables ................................................. 4-1 43
Head Pattern Examples.................................................. 4-2 47
SECTION 5. ELECTRICAL CHECKS AND ADJUSTMENTS
Power Supply Checks .................................................... 5-1 52
Reflective Label Pitch Sensor Adjustment................... 5-2 54
See Through Label Pitch Sensor Adjustment.............. 5-3 55

SATO CL408/412 Service Manual
ii
Table Of Contents
SECTION 6. MECHANICAL ADJUSTMENTS Page
Ribbon Clutch Adjustments ...........................................6-1 58
Ribbon Guide Plate Adjustment.....................................6-2 61
Print Head Position Alignment (Minor).........................6-3 62
Print Head Balance Adjustment.....................................6-4 63
Print Head Alignment Adjustment (Major)....................6-5 64
Timing Belt Tension Adjustment ...................................6-6 65
Tear Plate Adjustment.....................................................6-7 66
SECTION 7. REPLACEMENT PROCEDURES
Replacing Fuses..............................................................7-1 68
Replacing the Print Head................................................7-2 70
Replacing the Main Circuit Board ..................................7-3 72
Replacing the Power Supply ..........................................7-4 74
Replacing the Label Sensor Assembly..........................7-5 76
Replacing the Label Sensor Module..............................7-6 78
Replacing the Ribbon Motion Sensor............................7-7 79
Replacing the Ribbon Drive Clutch Washers................7-8 81
Replacing the Timing Belts.............................................7-9 84
Replacing the Platen .......................................................7-10 88
Replacing the Display Panel PCB..................................7-11 91
Replacing the Stepper Motor..........................................7-12 92
SECTION 8. FACTORY RESETS
Resetting the Printer .......................................................8-1 96
EE Prom Clear All............................................................8-2 97
Clear Counter Heads.......................................................8-3 98
Clear Cutter Counter .......................................................8-4 99

SATO CL408/412 Service Manual
1
Introduction
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1.1 INSTALLATION CONSIDERATIONS
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Section
1

Section 1 Introduction
SATO CL408/412 Service Manual
2
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1.2 RIBBON
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1.3 DIMENSIONS
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Width
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epth
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Section 1 Introduction
SATO CL408/412 Service Manual
3
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1.4 COMPONENT DESIGNATIONS
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OPERATION PANEL
DISPLAY RIBBON UNWIND
SHAFT
RIBBON REWIND
SHAFT
PRINT HEAD
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LATEN ROLLER
OPTIONAL
CUTTER
ASSEMBLY
DIP SWITCH
CONFIGURATION
TABLE
KB PC BOARD
MAIN PC BOARD
POWER
SUPPLY UNIT
STEPPER MOTOR
TIMING
BELTS

Section 1 Introduction
SATO CL408/412 Service Manual
4
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1.5 INTERFACE CONNECTIONS, INPUT AND OUTPUT PANEL
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REAR OF UNIT
F
RONT OF UNIT
OPERATION
PANEL
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oards are supplied with the following connectors:
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ENTRONICS CONNECTOR:)RUSULQWHUXVLQJSDUDOOHO
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WINAX/COAX CONNECTOR:)RUSULQWHURSHUDWLQJLQD
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XT. CONNECTOR: 7KLVLVDQH[WHUQDOVLJQDO
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CONTAINS RIBBON,
MEDIA, SENSORS
DISPLAY
PANEL

Section 1 Introduction
SATO CL408/412 Service Manual
5
C
OVER OPEN SENSORS: :KHQWKLVVHQVRU
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1.6 SWITCHES AND SENSORS
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Section 1 Introduction
SATO CL408/412 Service Manual
6
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1.6 SWITCHES AND SENSORS (CONT.)
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RIBBON SENSOR: 7KHVHQVRUZLOOUHDFWWRWKHULEERQ
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LABEL SENSOR: 
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Section 1 Introduction
SATO CL408/412 Service Manual
7
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1.6 SWITCHES AND SENSORS (CONT.)
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POWER LED: ,OOXPLQDWHGZKHQWKH
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OFFSET Potentiometer: 7RDGMXVWEDFNIRUZDUG
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Section 1 Introduction
SATO CL408/412 Service Manual
8
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SATO CL408/412 Service Manual
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PrinterConfiguration
2.1 DIP SWITCH SETTINGS
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DIP Switch Panel Layout for DSW1
Located on RS232 Interface Board
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Section
2

Section 2 Printer Configuration
SATO CL408/412 Service Manual
10

2.1 DIP SWITCH SETTINGS
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RS232 Transmit/Receive Setting
Data Bit Selection (DSW1-1)
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Parity Selection (DS1-2, DS1-3)
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Factory Default
1 2 3 4 5 6 7 8
ON
OFF
DSW1
DSW1-2 SETTING SETTING
*OFF *OFF No Parity
OFF ON Even
ON OFF Odd
ON ON Not Used
DSW1-1 SETTING
*OFF 8 Data Bits
ON 7 Data Bits
1 2 3 4 5 6 7 8
ON
OFF
DSW1

Section 2 Printer Configuration
SATO CL408/412 Service Manual
1
1
Stop Bit Selection (DS1-4)
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Baud Rate Selection (DS1-5, DS1-6)
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Communication Protocol Selection (DS1-7, DS1-8)
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*Factory Default
DSW1-5 DSW1-6 SETTING
*OFF *OFF 9600
OFF ON 19200
ON OFF 4800
ON ON 2400
DSW1-7 DSW1-8 SETTING
*OFF *OFF Rdy/Bsy
OFF ON Xon/XOff
ON OFF Bi-Com
ON ON Not Used
1 2 3 4 5 6 7 8
ON
OFF
DSW1
DSW1
DSW1-4 SETTING
*OFF 1 Stop Bit
ON 2 Stop Bits
1 2 3 4 5 6 7 8
ON
OFF
DSW1
ON
OFF
1 2 3 4 5 6 7 8

Section 2 Printer Configuration
SATO CL408/412 Service Manual
12

Print Mode Selection (DS2-1)
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SULQWLQJXVLQJDULEERQ
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Sensor Type Selection (DS2-2)
6HOHFWVW\SHRIVHQVLQJ
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Head Check Selection (DS2-3)
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Hex Dump Selection (DS2-4)
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*Factory Default
DSW2-2 SETTING
*OFF Gap
ON “I” Mark
1 2 3 4 5 6 7 8
ON
OFF
DSW2
DSW2-1 SETTING
*OFF Therm Xfr
ON Direct Therm
1 2 3 4 5 6 7 8
ON
OFF
DSW2
DSW2-3 SETTING
*OFF Disabled
ON Enabled
ON
OFF
DSW2
1 2 3 4 5 6 7 8
DSW2
DSW2-4 SETTING
*OFF Disabled
ON Enabled
ON
OFF
1 2 3 4 5 6 7 8

Section 2 Printer Configuration
SATO CL408/412 Service Manual
1
3
Receive Buffer Selection (DS2-5)
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Protocol Control Code Selection (DS2-6 & DS2-7)
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SELECTING PROTOCOL CONTROL CODES 
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*Factory Default
DSW2-5 SETTING
OFF Single Job
ON Multi Job-
1 2 3 4 5 6 7 8
ON
OFF
DSW2
DSW2-6- DSW2-7 SETTING
Reserved *OFF Standard
Reserved ON Non - Std.
1 2 3 4 5 6 7 8
ON
OFF
DSW2

Section 2 Printer Configuration
SATO CL408/412 Service Manual
14
SELECTING PROTOCOL CONTROL CODES (CONT.)
CONTROL
CHARACTER STANDARD DSW2-7 OFF
NON-STANDARD
DSW2-7 ON DESCRIPTION
STX02 Hex 7B Hex = { Start of Data
ETX 03 Hex 7D Hex = } End of Data
ESC 1B Hex 5E Hex = ^ Command code to follow
Null 00 Hex 7E Hex = ~ Cutter command
ENQ 05 Hex 40 Hex = @ Get printer status, Bi-Com
mode
Can 18 Hex 21 Hex = ! Cancel print job, Bi Com mode
Off-Line 40 Hex 5D Hex = ] Take printer Off-Line
M-8400 Compatibility (DS2-8)
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Mode Selection (DS3-1 and DS3-2)
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*Factory Default
DSW2-8 SETTING
*OFF OFF
ON M-8400
Compatibility
1 2 3 4 5 6 7 8
ON
OFF
DSW2
DSW3-1 DSW3-2 SETTING
OFF OFF Batch/Continuous
OFF ON Tear Off
ON OFF Cutter
ON ON Dispenser
1 2 3 4 5 6 7 8
ON
OFF
DSW3

Section 2 Printer Configuration
SATO CL408/412 Service Manual
1
5
Label Sensor Selection (DS3-3)
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FRQWUROXVLQJ/LQH)HHGFR DQGV
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Back Feed Selection (DS3-4)
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UHWUDFWLWWRWKHFRUUHFWSULQWSRVLWLRQEHIRUHSULQWLQJWKHQH[WODEHO
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External Signal Interface
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SURYLGHVDFKRLFHRIIRXUGLIIHUHQWRXWSXWVLJQDOVDORQJZLWKYDULRXVHUURUFRQGLWLRQV
Print Start Signal Selection (DS3-5)
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*Factory Default

DSW3-3 SETTING
*OFF Sensor Used
ON Enables Continuous
Operation
1 2 3 4 5 6 7 8
ON
OFF
DSW3
DSW3-4 SETTING
*OFF Enabled
ON Disabled
1 2 3 4 5 6 7 8
ON
OFF
DSW3
DSW3-5 SETTING
*OFF Disabled
ON Enabled
1 2 3 4 5 6 7 8
ON
OFF
DSW3

Section 2 Printer Configuration
SATO CL408/412 Service Manual
16
External Signal Interface(Cont.)
Refer to Page 18
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Repeat Print via External Signal (DSW3-8)
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*Factory Default, is reserved for future use, and should remain in the OFF position
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DSW3-8 SETTING
*OFF Disabled
ON Enabled
1 2 3 4 5 6 7 8
ON
OFF
DSW3
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ILUPZDUHUHYLVLRQVDWWKHWLPHRISULQWLQJ
1 2 3 4 5 6 7 8
ON
OFF
DSW3-6 DSW3-7 SETTING
*Off Off Type 4
Off On Type 3
On Off Type 2
On On Type 1
(Output on Pin 6)
DSW3