SATO CL608 User manual

CL608/CL612
Thermal Transfer Printers
Service Manual
PN 9001024
Rev. B January 2000
SATO America, Inc.
545 Weddell Drive
Sunnyvale, CA 94089
Industrial Bar Code Printers

SATO America, Inc.
545 Weddell Drive
Sunnyvale, CA 94089
Main Phone: [phone]
Tech Support Hotline: [phone]
Fax: [phone]
http:\\www.satoamerica.com
Copyright 2000
SATO America, Inc.
Warning: This equipment complies with the requirements in Part 15 of FCC
rules for a Class A computing device. peration of this equipment in a
residential area may cause unacceptable interference to radio and TV
reception requiring the operator to take whatever steps are necessary to
correct the interference.
All rights reserved. No part of this document may be reproduced or issued to
third parties in any form whatever without the express written permission of
SAT America, Inc. The materials in this document are provided for general
information and are subject to change without notice. SAT America, Inc.
assumes no responsibility for any errors that may appear.
PN 9001024
Rev. B Jan. 2000 SATO CL608 & CL612 SERVICE MANUAL
SATO America, Inc .

i
PN 9001024
Rev. B Jan. 2000 SATO CL608 & CL612 SERVICE MANUAL
Contents Page
Section 1. OVERVIEW & SPECIFICATIONS
Overview ...................................................................................................... 1-1
Physical Characteristics.............................................................................. 1-2
Components ................................................................................................ 1-4
Ribbon.......................................................................................................... 1-7
Installation Considerations ........................................................................ 1-7
Switches and Sensors ................................................................................ 1-8
Operator Panel/Displays ............................................................................. 1-10
Optional Accessories .................................................................................. 1-12
Environment & Approvals .......................................................................... 1-12
Print .............................................................................................................. 1-13
Media, Sensing and Ribbon........................................................................ 1-13
Controls and Signals, Adjustments ........................................................... 1-14
Interface Connections................................................................................. 1-15
Processing ................................................................................................... 1-15
Character Fonts........................................................................................... 1-16
Bar Codes and Other Features ................................................................... 1-17
Section 2. CONFIGURATION
Dip Switch Settings ..................................................................................... 2-1
Default Settings ........................................................................................... 2-9
Printer Adjustments .................................................................................... 2-10
Advanced Mode Settings and Adjustments............................................... 2-16
Printing Test Labels .................................................................................... 2-25
Section 3. INTERFACE SPECIFICATIONS
Overview ...................................................................................................... 3-1
Interface Types ............................................................................................ 3-1
Receive Buffer ............................................................................................. 3-2
RS232C Serial Interface .............................................................................. 3-3
Dip Switch Settings for RS232C Serial Interface....................................... 3-11
Centronics Parallel Interface ...................................................................... 3-13
Accessory (EXT) Connector....................................................................... 3-15
Section 4. ELECTRICAL CHECKS AND ADJUSTMENTS
Overview ...................................................................................................... 4-1
Steps Prior to Some Procedures ................................................................ 4-2
Power Supply Checks ................................................................................. 4-3
Potentiometer Assignments....................................................................... 4-6
Pitch Potentiomter (User adjustment)........................................................ 4-7
Offset Adjustment (User adjustment)......................................................... 4-8
Label Gap Adjustment................................................................................. 4-9
Eye-Mark Adjustment.................................................................................. 4-11
Ribbon Senser Adjustment ........................................................................ 4-13
LCD Display Adjustment............................................................................. 4-15
Print Darkness Adjustment ........................................................................ 4-16

ii
PN 9001024
Rev. B Jan. 2000
SATO CL608 & CL612 SERVICE MANUAL
Contents
Section 8. TROUBLESHOOTING
Overview ...................................................................................................... 8-1
Initial Checklist ............................................................................................ 8-2
Troubleshooting the Centronics (Parallel) Interface................................. 8-2
Troubleshooting the RS232C (Serial) Interface ........................................ 8-4
Error Signals ................................................................................................ 8-5
Troubleshooting Tables.............................................................................. 8-6
Head Pattern Examples............................................................................... 8-9
Section 9. ADDENDUM
Overview ...................................................................................................... 9-1
Notable Differences..................................................................................... 9-2
Replacing the Main PCB.............................................................................. 9-4
Page
Section 5. MECHANICAL ADJUSTMENTS
Overview ...................................................................................................... 5-1
Ribbon Clutch Adjustments ....................................................................... 5-2
Print Head Position Adjustment ................................................................. 5-5
Print Head Balance Adjustment.................................................................. 5-7
Ribbon Roller Adjustment .......................................................................... 5-8
Ribbon Tension Balance Adjustment ........................................................ 5-9
Feed Roller Adjustment (Label Tracking) .................................................. 5-11
Timing Belt Tension Adjustment ................................................................ 5-13
Head Latch Adjustment............................................................................... 5-14
Notch/Gap Sensor Adjustment................................................................... 5-15
Section 6. REPLACEMENT PROCEDURES
Overview ...................................................................................................... 6-1
Replacing the Main Circuit Board ............................................................... 6-2
Replacing the Fuses.................................................................................... 6-5
Replacing the Power Supply....................................................................... 6-7
Replacing the Stepper Motor ...................................................................... 6-10
Replacing the Timing Belts.......................................................................... 6-11
Replacing the Print Head............................................................................. 6-15
Replacing the Platen.................................................................................... 6-18
Replacing the Ribbon Drive Clutch Washers ............................................ 6-22
Replacing the Ribbon Motion Sensor........................................................ 6-26
Replacing the Paper End Switch and bottom
1/2 of the Notch/Gap and Eye-Mark Sensors............................................. 6-29
Replacing the Top 1/2 of the Notch/Gap Sensor ........................................ 6-34
Replacing the Display Panel or Keyboard ................................................. 6-37
Section 7. FACTORY RESETS
Overview ...................................................................................................... 7-1
Factory Test Print without Resetting Printer ............................................. 7-2
EEPROM Clear All ....................................................................................... 7-3
Clear Counter Heads................................................................................... 7-4
Clear Cutter Counter ................................................................................... 7-5

iii
PN 9001024
Rev. B Jan. 2000 SATO CL608 & CL612 SERVICE MANUAL
Contents Page
Section 9. ADDENDUM
Replacing the Fuses.................................................................................... 9-6
Replacing the Power Supply....................................................................... 9-8
Installing the Memory Board....................................................................... 9-10
Replacing the Print Head............................................................................. 9-12
Replacing the Top Half of the Notch/Gap Sensor ...................................... 9-15
Replacing the Paper End Switch and the
Bottom Half of the Notch/Gap and Eye-Mark Sensors.............................. 9-18
Power Supply Checks ................................................................................. 9-22
Potentiometer Assignments....................................................................... 9-24
Gap/See-Through Sensor ........................................................................... 9-25
Pitch Sensor Adjustment (Eye-Mark Tag/Label) ....................................... 9-27
Ribbon Sensor Adjustment ........................................................................ 9-29

PN 9001024
Rev. B Jan. 2000 Page 1-1
SATO CL608 & CL612 SERVICE MANUAL
Overview and Specifications
1-1 Overview

Section
The SATO CL608/612 Printer Service Manual provides infor ation for installing and
aintaining CL608/612 Direct Ther al/Ther al Transfer printers. Step-by-step
aintenance instructions are included in this anual with typical proble s and
solutions. It is reco ended that you beco e fa iliar with each section in this anual
before installing and aintaining the printer.
The CL608 printer has a resolution of 203 dpi and can print labels up to six inches wide.
The CL612 printer has a resolution of 305 dpi and can print labels up to 6.5 inches wide.
These printers use the standard SATO RISC printer co and codes, the only difference
between the and other RISC printers are the allowable values representing the print
positions on the label. These values are specified in dots and will vary depending upon
the resolution of the printer and the a ount of e ory available for i aging the label.
The allowable range for CL608/612 is specified in a table for those co and codes.
The sections in this anual cover the following:
• Section 1 - Overview and Specifications
• Section 2 - Configuration
• Section 3 - Interface Specifications
• Section 4 - Electrical Checks and Adjustments
• Section 5 - Mechanical Adjustments
• Section 6 - Replacement Procedures
• Section 7 - Factory Resets
• Section 8 - Troubleshooting
• Section 9 - Addendum

PN 9001024
Rev. B Jan. 2000
Page 1-2 SATO CL608 & CL612 SERVICE MANUAL
SECTION 1 – Overview & Specifications
Width
Height
Depth
FRONT
1-2 Physical Characteristics
ACCESS DOOR
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PN 9001024
Rev. B Jan. 2000 Page 1-3
SATO CL608 & CL612 SERVICE MANUAL
SECTION 1 –Overview & Specifications
1-2 Physical Characteristics
RIBBON SUPPLY
SPINDLE
ACCESS DOOR
RIBBON REWIND
SPINDLE
MEDIA HOLDER
PLATEN
ROLLER
MEDIA KNOB
LABEL SUPPLY
GUIDE
HEAD LATCH
PRINT HEAD
ASSEMBLY
SWITCHES AND SENSORS
Refer to Section 1.6
LABEL TEAR
OFF PLATE
Adjust the Media Knob based on the
media you have loaded. For media up to
2.3 inches wide, use the "1" position. For
media between 2.3 and 4.6 inches wide,
use the "2" position. For media wider than
4.6 inches wide, use the "3" position. If
you use media narrower than 7 inches,
using the wrong setting can void the print
head warranty due to excessive pressure.
MEDIA HOLD
DOWN

PN 9001024
Rev. B Jan. 2000
Page 1-4 SATO CL608 & CL612 SERVICE MANUAL
SECTION 1 –Overview & Specifications
FRONT PANEL
DIP SWITCH AND
VARIABLE RESISTOR (VR)
ADJUSTMENTS
LCD DISPLAY
1-3 Components
MEMORY CARD
OPTION SLOTS
PLUG-IN INTERFACE
CARD (CENTRONICS
PARALLEL SHOWN)
FUSE AC INPUT
CONNECTOR
OFF/ON
SWITCH
REAR PANEL
EXTERNAL
CONNECTOR
MEMORY CARD OPTION SLOTS:
PLUG-IN INTERFACE CARDS:
POWER ON/OFF SWITCH:
AC FUSE:
AC INPUT CONNECTOR:
EXT. PORT CONNECTOR:
Two slots for PCMCIA Memory
Cards (up to 2MB each)
Ethernet, RS232C, RS422/485,
Coax/Twinax or Centronics Parallel
To turn the printer on or off
To protect the machine from
abnormal power input. Type 3A/250V
Connect to 115V 50/60 Hz.with cable
provided
External signal connector

PN 9001024
Rev. B Jan. 2000 Page 1-5
SATO CL608 & CL612 SERVICE MANUAL
SECTION 1 –Overview & Specifications
1-3 Components
MOVEABLE NOTCH/GAP
SENSOR & "EYE-MARK"
SENSOR
MOVEABLE
PORTION
STATIONARY
PORTION
"EYE - MARK"
SENSOR
PAPER OUT
SWITCH
LABEL UNWIND
ROLLERS
LABEL
GUIDE MEDIA
HOLDER
PRINT HEAD
WITH SWITCH

PN 9001024
Rev. B Jan. 2000
Page 1-6 SATO CL608 & CL612 SERVICE MANUAL
SECTION 1 –Overview & Specifications
RIBBON GUIDE
PLATE
1-3 Components
STEPPER
MOTOR
TIMING
BELTS
LCD BOARD AND
KB BOARD ON
BACKSIDE OF PANEL
PRINT HEAD
PLATEN
PLATENS

PN 9001024
Rev. B Jan. 2000 Page 1-7
SATO CL608 & CL612 SERVICE MANUAL
SECTION 1 –Overview & Specifications
MAIN PC BOARD WITH PLUG-IN
INTERFACE CARD - CENTRONICS
I/O SHOWN
POWER
SUPPLY UNIT
1-3 Components
1-4 Ribbon
Use only SATO ther al transfer ribbons which were for ulated expressly for use in all
SATO printers. Use of other than approved ribbons ay result in unsatisfactory print
quality and/or da age to the print head and ay void your warranty.
1-5 Installation Considerations
Printer operation can be affected by the printer environ ent. The location of the
printer should be free fro dust, hu idity and sudden vibrations. To obtain opti u
results fro the printer, avoid locations influenced by:
 Direct or bright sunlight, since bright light will ake the label sensor less responsive
and ay cause the label to be sensed incorrectly.
 War te peratures which can cause electrical proble s within the printer. (See
Section 1-9, Environ ent.
OPTIONAL
MEMORY CARD
ADAPTER

PN 9001024
Rev. B Jan. 2000
Page 1-8 SATO CL608 & CL612 SERVICE MANUAL
SECTION 1 –Overview & Specifications
1-6 Switches and Sensors
RIBBON SENSOR: The sensor will
react to the ribbon unwind when
approximately 45 feet of ribbon remains.
This sensor is a motion detector that
signals the printer when the ribbon
supply is turning. This sensor is used for
both the ribbon end and ribbon near end
sensing.
HEAD LATCH LEVER: When the
print head is opened, a micro
switch is activated and the printer
will stop printing. Error message
will be displayed on the LCD
operator panel.

PN 9001024
Rev. B Jan. 2000 Page 1-9
SATO CL608 & CL612 SERVICE MANUAL
SECTION 1 –Overview & Specifications
1-6 Switches and Sensors
MEDIA HOLD DOWN: Open by
lifting up on the release tab
underneath the green tab marked
"PUSH". The Media Hold Down is
spring loaded and will remain in the
up position. Close by pushing down
on the same green tab.
LABEL OUT SENSOR: This micro
switch is activated when media
stock is out or when the Media Hold
Down is in the up position. All
printer operations stop, and an
error message is displayed on the
LCD.
MEDIA HOLD DOWN
(Underside)
"EYE-MARK" SENSOR
(Fixed: Non adjustable)
NOTCH/GAP SENSOR
LED ARRAY (Bottom
Half is Non-adjustable)
NOTCH/GAP SENSOR
(Top Half is adjustable)
( Refer to Section 5-10)

PN 9001024
Rev. B Jan. 2000
Page 1-10 SATO CL608 & CL612 SERVICE MANUAL
SECTION 1 –Overview & Specifications
1-7 Operator Panel/Displays
LCD SCREEN: 2 LINE x 16 Character LCD
display. Used for setting operational
parameters of the printer and displaying error
conditions.
FEED KEY: Momentary switch.
Pressing this key feeds one blank
label through the printer when it is
off-line. When the printer is on-
line, another copy of the last label
will be printed.
LINE KEY: Momentary switch. Pressing
this key toggles the printer between the
on-line and off-line mode. When the
printer is on-line, it is ready to receive data
from the host. This key acts as a pause
during a print job by taking the printer off-
line.
LED's: STATUS INDICATORS
POWER LED, illuminated when power is on.
ONLINE LED, illuminated when printer is
ready to receive data. Turn ON/
OFF by toggling the LINE key.
LABEL LED, illuminated when label supply
is out.
RIBBON LED, illuminated when ribbon
motion sensor does not detect any
ribbon motion.
ERROR LED, illuminated when there is a
system fault such as an open print
head.

PN 9001024
Rev. B Jan. 2000 Page 1-11
SATO CL608 & CL612 SERVICE MANUAL
SECTION 1 –Overview & Specifications
1-7 Operator Panel/Displays
VR1-PRINT POTENTIOMETER:
To adjust print darkness (fine
adjustment).
VR3-PITCH POTENTIOMETER:
To adjust home print position of
the label (+/- 3.75 mm).
VR4-DISPLAY POTENTIOMETER:
To adjust the contrast of the LCD
display.
VR2-OFFSET POTENTIOMETER:
To adjust amount of back/forward
feed for dispenser/cutter/tear-off
bar position (+/- 3.75).
DSW 1, 2 & 3: Dip switches used
to set operational parameters of
printer. Refer to Section 2 for
settings. NOTE: DSW 1 is
reserved. To set DSW1 on the
interface board, see Section 3.
COVER

PN 9001024
Rev. B Jan. 2000
Page 1-12 SATO CL608 & CL612 SERVICE MANUAL
SECTION 1 –Overview & Specifications
1-9 Environment & Approvals
1-8 Optional Accessories
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PN 9001024
Rev. B Jan. 2000 Page 1-13
SATO CL608 & CL612 SERVICE MANUAL
SECTION 1 –Overview & Specifications
1-10 Print
1-11 Media, Sensing and Ribbon
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PN 9001024
Rev. B Jan. 2000
Page 1-14 SATO CL608 & CL612 SERVICE MANUAL
SECTION 1 –Overview & Specifications
1-12 Controls and Signals, Adjustments
1-11 Media, Sensing and Ribbon
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PN 9001024
Rev. B Jan. 2000 Page 1-15
SATO CL608 & CL612 SERVICE MANUAL
SECTION 1 –Overview & Specifications
1-13 Interface Connections
1-14 Processing
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