SATO CL612e User manual

CL608e/CL612e Printers
Service Manual
PN 9001079
Rev.B

SATO America, Inc.
10350-A Nations Ford Rd.
Charlotte, NC 28273
Main Phone: [phone]
Technical Support Hotline: [phone]
Fax: [phone]
http:\\www.satoamerica.com
ãCopyright 2002
SATO America, Inc.
PN 9001079
Rev. B SATO CL608e/CL612e Service Manual
The information supplied in this manual was current at time of
publication. If you come across procedures that need clarification or
find errors or have suggestions contact us at [email protected]
Warning: This equipment complies with the requirements in Part 15 of FCC
rules for a Class B 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 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.

i
PN 9001079
Rev. B SATO CL608e/CL612e Service Manual
Section 1. Overview and Specifications Page
1 Overview ........................................................................................................... 1-1
2 Physical Characteristics.................................................................................. 1-2
3 Printer Features................................................................................................ 1-3
4 Operation PanelDisplays................................................................................. 1-5
5 Components ..................................................................................................... 1-7
6 Switches and Sensors ..................................................................................... 1-8
7 Ribbon ............................................................................................................. 1-10
8 Installation Considerations ........................................................................... 1-10
9 Optional Accessories .................................................................................... 1-10
10 Environment & Approvals .............................................................................1-11
11 General Printer Specifications ......................................................................1-11
12 Character Fonts............................................................................................. 1-14
13 Bar Codes ...................................................................................................... 1-15
Section 2. Configuration
1 Dip Switch Settings.......................................................................................... 2-1
2 Default Settings ................................................................................................ 2-7
3 LCD Panel Printer Configuration .................................................................... 2-8
Normal Mode................................................................................................. 2-9
M8400 Compatible Mode ........................................................................... 2-12
Advanced Mode .......................................................................................... 2-13
Card Mode ................................................................................................... 2-17
Service Mode .............................................................................................. 2-25
Counters Mode ........................................................................................... 2-31
Test Print Mode........................................................................................... 2-32
Default Setting Mode.................................................................................. 2-33
Maintenance Mode ..................................................................................... 2-34
Clear Non-Standard Protocol .................................................................... 2-36
Download User Defined Protocol Codes ................................................. 2-36
Hex Dump Mode ......................................................................................... 2-37
Download Mode .......................................................................................... 2-38
User Download Mode ................................................................................. 2-39
4 Sample Test Labels ........................................................................................ 2-40
Section 3. Interface Specifications
1 Overview...........................................................................................................3-1
2 Interface Types.................................................................................................3-1
3 Receive Buffer..................................................................................................3-3
4 IEEE 1284 Parallel Interface............................................................................3-4
5 Optional RS232C Serial Interface...................................................................3-6
6 Universal Serial Bus (USB) Interface .............................................................3-9
7 Local Area Network (LAN) Interface ..............................................................3-10
8 Bi-Directional Communications .....................................................................3-10
9 Accessory (EXT) Connector ...........................................................................3-19
Section 4. Electrical Checks and Adjustments
1 Overview ........................................................................................................... 4-1
2 Steps Prior to Some Procedures .................................................................... 4-2
3 DC Power Voltage Checks............................................................................... 4-3
4 Potentiometer Assignments & Adjustments................................................. 4-6
5a Pitch Offset Adjustment .................................................................................. 4-8
Table of Contents

ii
SATO CL608e/CL612e Service Manual
PN 9001079
Rev. B
Table of Contents
Section 4. Electrical Checks and Adjustments
5b Pitch Offset Adjustment .................................................................................. 4-9
6 Label Gap Adjustment ................................................................................... 4-10
7 Eye-Mark Adjustment ....................................................................................4-11
8 Feed/Backfeed Adjustment (Tear-Off).......................................................... 4-12
9 Feed/Backfeed Adjustment (Cutter) ............................................................. 4-13
10 Feed/Backfeed Adjustment (Dispenser) ...................................................... 4-14
11 Ribbon Sensor Verification ........................................................................... 4-15
12 Ribbon Sensor Adjustment (Near End)........................................................ 4-16
13 LCD Display Adjustment ............................................................................... 4-17
14 Print Darkness Adjustment ........................................................................... 4-18
Section 5. Mechanical Adjustments
1 Overview ........................................................................................................... 5-1
2 Ribbon Clutch Adjustments............................................................................ 5-2
3 Print Head Position Adjustment ..................................................................... 5-5
4 Print Head Balance Adjustment...................................................................... 5-7
5 Ribbon Roller Adjustment............................................................................... 5-8
6 Feed Roller Adjustment (Label Tracking)...................................................... 5-9
7 Timing Belt Tension Adjustment...................................................................5-11
8 Head Latch Adjustment................................................................................. 5-12
9 Notch/Gap Sensor Adjustment .................................................................... 5-13
Section 6. Replacement Procedures
1 Overview .......................................................................................................... 6-1
2 Replacing the Main Circuit Board.................................................................. 6-2
3 Replacing the Fuses........................................................................................ 6-7
4 Replacing the Power Supply........................................................................... 6-9
5 Replacing the Stepper Motor ........................................................................ 6-12
6 Replacing the Timing Belts ........................................................................... 6-13
7 Replacing the Print Head............................................................................... 6-16
8 Replacing the Platen...................................................................................... 6-19
9 Replacing the Ribbon Drive Clutch Washers .............................................. 6-23
10 Replacing the Ribbon Motion Sensor .......................................................... 6-27
11 Replacing the Paper End Switch (Micro-Switch) and the
Bottom Half of the Notch/Gap and Eye-Mark Sensors ............................... 6-30
12 Replacing the Top Half of the Notch/Gap Sensor ....................................... 6-34
13 Replacing the Display Panel or Keyboard ................................................... 6-37
Section 7. Factory Resets
1 Overview ........................................................................................................... 7-1
2 Factory/Service Test Print............................................................................... 7-2
3 Clear Head Counters........................................................................................ 7-3
4 Clear Dispenser Counter ................................................................................. 7-4
5 Clear Cutter Counter........................................................................................ 7-5
6 Clear EEPROM.................................................................................................. 7-6
7 Sample Test Prints........................................................................................... 7-7
Section 8. Troubleshooting
1 Overview .......................................................................................................... 8-1
2 Initial Checklist ................................................................................................ 8-2
3 The IEEE 1284 Parallel Interface .................................................................... 8-2

iii
PN 9001079
Rev. B SATO CL608e/CL612e Service Manual
Section 8. Troubleshooting
4 The RS232C Serial Interface........................................................................... 8-4
5 The Universal Serial BUS (USB) .................................................................... 8-4
6 The LAN Ethernet Interface ............................................................................ 8-5
7 Error Signals.................................................................................................. 8-10
8 Troubleshooting Tables .................................................................................8-11
9 Head Pattern Examples ................................................................................ 8-15
10 Hex Dump Diagnostic Labels ....................................................................... 8-17
Section 9. Optional Accessories
1 Overview .......................................................................................................... 9-1
2 Label Cutter Kit Installation............................................................................ 9-2
3 Label Dispenser Kit Installation..................................................................... 9-6
4 PCMCIA Memory Expansion Installation .................................................... 9-15
5 Flash Memory Expansion Installation ......................................................... 9-20
6 Real Time Clock Installation......................................................................... 9-22
Section 10. Parts List
1 Overview ........................................................................................................ 10-1
2 Base Cover Assembly................................................................................... 10-2
3 Frame Assembly...........................................................................................10-11
4 Print Head Assembly .................................................................................. 10-18
5 Ribbon Assembly ........................................................................................ 10-22
6 Feed Roller Assembly................................................................................. 10-27
7 Main PCB Assembly.................................................................................... 10-30
8 Interface Option........................................................................................... 10-31
9 Dispenser Assembly Option ...................................................................... 10-32
10 Cutter Assembly Option ............................................................................. 10-39
11 PCMCIA Memory Option .............................................................................10-43
Index .............................................................................................................................. Index -1
Table of Contents

iv SATO CL608e/CL612e Service Manual PN 9001079
Rev. B

Page 1-1
PN 9001079
Rev. B
SATO CL608e/CL612e Service Manual
Overview and Specifications
1.1 Overview

Section
The sections in this manual 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. Optional Accessories
·Section 10. Parts list
The SATO CL608e/CL612e rinters Service Manual provides information for
installing and maintaining CL608e/CL612e Thermal Transfer printers. Step-by-
step maintenance instructions are included in this manual with typical problems
and solutions. It is recommended that you become familiar with each section in
this manual before installing and maintaining the printer.
The major differences between the CL608e and the CL612 printers is the
resolution of the head and label width. The CL608e with its 203 dpi head
provides an economical labeling solution for most applications. It can print
labels up to six inches wide. The CL612e provides a higher print resolution, 305
dpi to give laser-quality printing. It is useful when higher resolution is needed
for detailed graphic images. It can print labels up to 6.5 inches wide.
The CL Series "e" printers use a subset of the standard SATO Command
Language. The CL608e/CL612e share the same command set, the only
differences 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 amount of memory available for imaging the label. The
allowable range for each printer is specified in a table for those command codes.

PN 9001079
Rev. B
Page 1-2 SATO CL608e/CL612e Service Manual
Section 1. Overview and Specifications
1.2 Physical Characteristics
Width
Height
Depth
FRONT
ACCESS DOOR
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PN 9001079
Rev. B Page 1-3
Section 1. Overview and Specifications
SATO CL608e/CL612e Service Manual
1.3 Printer Features
INTERFACE SLOT Slot to plug in an interface adapter. An adapter must be
connected before the printer is operational. The adapter types
available are:
RS232C Serial I/F Module, D -25 .
IEEE1284 arallel I/F Module, AM 57-40360
Universal Serial Bus I/F Module
Ethernet 10/100 BaseT I/F Module
MEMORY CARD SLOT One slot for optional CMCIA Memory Cards.
EXT CONNECTOR External signal connector for Accessories, AM 57-60140
POWER SWITCH Turns power On/Off
AC FUSE Input power protection. Type 3A/250V.
AC POWER INPUT Input 115V 50/60 Hz connector. Use the cable provided.
Rear Panel
INTERFACE SLOT (SHOWN
WITH CENTRONICS PARALLEL
INTERFACE INSTALLED)
POWER SWITCH
PCMCIA MEMORY
EXPANSION SLOT
AC POWER INPUT
CONNECTOR
AC FUSE
EXTERNAL
ACCESSORY
CONNECTOR
COVER PLATE-REMOVE FOR
ACCESS TO FAN-FOLD SLOTS

PN 9001079
Rev. B
Page 1-4 SATO CL608e/CL612e Service Manual
Section 1. Overview and Specifications
Printer Features RIBBON UNWIND
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 9001079
Rev. B Page 1-5
Section 1. Overview and Specifications
SATO CL608e/CL612e Service Manual
1.4 Operation Panel/Displays
LCD DISPLAY
FEED KEY
COVER
ADVISORY LED'S
LINE KEY
ADVISORY LED'S
POWER Illuminated when power is on.
ONLINE Illuminated when printer is ready to receive data. Turn ON/OFF by
toggling the LINE key.
LABEL Illuminated when label supply is out.
RIBBON Illuminated when ribbon motion sensor does not detect any ribbon
motion.
ERROR Illuminated when there is a system fault such as an open print head.
LCD SCREEN 2 LINE x 16 Character LCD display. Used for setting operational
parameters of the printer and displaying error conditions
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.
FEED KEY Momentary switch. Pressing this key feeds one blank label
throughtheprinterwhenit is off-line.When the printeris on-line, thereis a
user selectable option in the Service Mode (see page 2-28) to either print
acopyof the previouslyprintedlabelor feed ablanklabel. Thedefault is
tofeedablank label.

PN 9001079
Rev. B
Page 1-6 SATO CL608e/CL612e Service Manual
Section 1. Overview and Specifications
Operation Panel/Displays
POTENTIOMETERS
VR1 (Print) To adjust print darkness (fine adjustment).
VR2 (Offset) To adjust amount of back/forward feed for dispenser/cutter/tear-off
bar position (+/- 3.75).
VR3 (Pitch) To adjust home print position of the label (+/- 3.75 mm).
VR4 (Display) To adjust the contrast of the LCD display.
*DSW2 & DSW3 Dip Switches used to set operational
parametersofprinter. Referto Section
2forsettings.
*NOTE: OptionalRS232Communication CardcontainsDSW1 switches which
areconfigured whensuppliedwith theprinter.

PN 9001079
Rev. B Page 1-7
Section 1. Overview and Specifications
SATO CL608e/CL612e Service Manual
1.5 Components
RIBBON GUIDE
PLATE
STEPPER
MOTOR
TIMING
BELTS
LCD BOARD AND
KB BOARD ON
BACKSIDE OF PANEL
PRINT HEAD
PLATEN
PLATENS

PN 9001079
Rev. B
Page 1-8 SATO CL608e/CL612e Service Manual
Section 1. Overview and Specifications
1.6 Sensors and Switches
Components
POWER SUPPLY UNIT
PLUG-IN INTERFACE
CARD - CENTRONICS
I/O SHOWN
RIBBON SENSOR: This sensor is a
motiondetectorthat signalstheprinter
whenthe ribbonsupply isturning. This
sensorisused for both theribbonendand
ribbonnearend 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 9001079
Rev. B Page 1-9
Section 1. Overview and Specifications
SATO CL608e/CL612e Service Manual
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 9001079
Rev. B
Page 1-10 SATO CL608e/CL612e Service Manual
Section 1. Overview and Specifications
1.9 Optional Accessories
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1.7 Ribbon
Use only SATO thermal transfer ribbons which were formulated expressly for use in all
SATO printers. Use of other than approved ribbons may result in unsatisfactory print
quality and/or damage to the print head and may void your warranty.
1.8 Installation Considerations
rinter operation can be affected by the printer environment. The location of the
printer should be free from dust, humidity and sudden vibrations. To obtain optimum
results from the printer, avoid locations influenced by:
 Direct or bright sunlight, since bright light will make the label sensor less responsive
and may cause the label to be sensed incorrectly.
 Warm temperatures which can cause electrical problems within the printer. (See
Section 1.10 Environment.
* Check with your software vendor to make sure these functions are supported.

PN 9001079
Rev. B Page 1-11
Section 1. Overview and Specifications
SATO CL608e/CL612e Service Manual
1.10 Environment & Approvals
1.11 General Printer Specifications
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PN 9001079
Rev. B
Page 1-12 SATO CL608e/CL612e Service Manual
Section 1. Overview and Specifications
General Printer Specifications
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PN 9001079
Rev. B Page 1-13
Section 1. Overview and Specifications
SATO CL608e/CL612e Service Manual
General Printer Specifications
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PN 9001079
Rev. B
Page 1-14 SATO CL608e/CL612e Service Manual
Section 1. Overview and Specifications
1.12 Character Fonts
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