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