CL608e/CL612e Printers Service Manual PN 9001079 Rev. B SATO America, Inc. 10350-A Nations Ford Rd. Charlotte, NC 28273 Main Phone: (704) 644-1650 Technical Support Hotline: (704) 644-1660 Fax: (704) 644-1661 http:\\www.satoamerica.com ã Copyright 2002 SATO America, Inc. 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 qc@satoamerica.com Warning: This equipment complies with the requirements in Part 15 of .CC rules for a Class B computing device. Operation 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 SATO America, Inc. The materials in this document are provided for general information and are subject to change without notice. SATO America, Inc. assumes no responsibility for any errors that may appear. PN 9001079 Rev. B SATO CL608e/CL612e Service Manual Table of Contents Section 1. Overview and Specifications 1 2 3 4 5 6 7 8 9 10 11 12 13 Page Overview ........................................................................................................... 1-1 Physical Characteristics .................................................................................. 1-2 Printer Features ................................................................................................ 1-3 Operation PanelDisplays ................................................................................. 1-5 Components ..................................................................................................... 1-7 Switches and Sensors ..................................................................................... 1-8 Ribbon ............................................................................................................. 1-10 Installation Considerations ........................................................................... 1-10 Optional Accessories .................................................................................... 1-10 Environment & Approvals ............................................................................. 1-11 General Printer Specifications ...................................................................... 1-11 Character Fonts ............................................................................................. 1-14 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 2 3 4 5 6 7 8 9 1 2 3 4 5a PN 9001079 Rev. B Overview ........................................................................................................... 3-1 Interface Types ................................................................................................. 3-1 Receive Buffer .................................................................................................. 3-3 IEEE 1284 Parallel Interface ............................................................................ 3-4 Optional RS232C Serial Interface ................................................................... 3-6 Universal Serial Bus (USB) Interface ............................................................. 3-9 Local Area Network (LAN) Interface .............................................................. 3-10 Bi-Directional Communications ..................................................................... 3-10 Accessory (EXT) Connector ........................................................................... 3-19 Overview ........................................................................................................... Steps Prior to Some Procedures .................................................................... DC Power Voltage Checks ............................................................................... Potentiometer Assignments & Adjustments ................................................. Pitch Offset Adjustment .................................................................................. SATO CL608e/CL612e Service Manual Section 4. Electrical Checks and Adjustments 4-1 4-2 4-3 4-6 4-8 i 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 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 10 11 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 Feed Roller Adjustment (Label Tracking) ...................................................... 5-9 Timing Belt Tension Adjustment ................................................................... 5-11 Head Latch Adjustment ................................................................................. 5-12 Notch/Gap Sensor Adjustment .................................................................... 5-13 Section 6. Replacement Procedures Overview .......................................................................................................... 6-1 Replacing the Main Circuit Board .................................................................. 6-2 Replacing the Fuses........................................................................................ 6-7 Replacing the Power Supply ........................................................................... 6-9 Replacing the Stepper Motor ........................................................................ 6-12 Replacing the Timing Belts ........................................................................... 6-13 Replacing the Print Head ............................................................................... 6-16 Replacing the Platen ...................................................................................... 6-19 Replacing the Ribbon Drive Clutch Washers .............................................. 6-23 Replacing the Ribbon Motion Sensor .......................................................... 6-27 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 2 3 4 5 6 7 1 2 3 Overview ........................................................................................................... Factory/Service Test Print ............................................................................... Clear Head Counters ........................................................................................ Clear Dispenser Counter ................................................................................. Clear Cutter Counter ........................................................................................ Clear EEPROM .................................................................................................. Sample Test Prints ........................................................................................... 7-1 7-2 7-3 7-4 7-5 7-6 7-7 Section 8. Troubleshooting Overview .......................................................................................................... 8-1 Initial Checklist ................................................................................................ 8-2 The IEEE 1284 Parallel Interface .................................................................... 8-2 ii SATO CL608e/CL612e Service Manual PN 9001079 Rev. B Table of Contents Section 8. Troubleshooting 4 5 6 7 8 9 10 1 2 3 4 5 6 The RS232C Serial Interface ........................................................................... 8-4 The Universal Serial BUS (USB) .................................................................... 8-4 The LAN Ethernet Interface ............................................................................ 8-5 Error Signals .................................................................................................. 8-10 Troubleshooting Tables ................................................................................. 8-11 Head Pattern Examples ................................................................................ 8-15 Hex Dump Diagnostic Labels ....................................................................... 8-17 Overview .......................................................................................................... 9-1 Label Cutter Kit Installation ............................................................................ 9-2 Label Dispenser Kit Installation ..................................................................... 9-6 PCMCIA Memory Expansion Installation .................................................... 9-15 Flash Memory Expansion Installation ......................................................... 9-20 Real Time Clock Installation ......................................................................... 9-22 Section 9. Optional Accessories Section 10. Parts List 1 2 3 4 5 6 7 8 9 10 11 Overview ........................................................................ ...