SATO CL608 Service Manual
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SATO CL608 Service Manual

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

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Summary of Contents for SATO CL608

  • Page 1 Industrial Bar Code Printers CL608/CL612 Thermal Transfer Printers Service Manual SATO America, Inc. 545 Weddell Drive PN 9001024 Sunnyvale, CA 94089 Rev. B January 2000...
  • Page 2 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 SATO America, Inc. The materials in this document are provided for general information and are subject to change without notice. SATO America, Inc.

  • Page 3: Table Of Contents

    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 PN 9001024 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 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 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 5 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 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 6 • Section 5 - Mechanical Adjustments • Section 6 - Replacement Procedures • Section 7 - Factory Resets • Section 8 - Troubleshooting • Section 9 - Addendum Page 1-1 PN 9001024 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...

  • Page 7: Section 1. Overview & Specifications

    SECTION 1 – Overview & Specifications 1-2 Physical Characteristics Depth Height FRONT ACCESS DOOR Width . n i . n i . n i a t l Page 1-2 PN 9001024 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 8 7 inches, using the wrong setting can void the print head warranty due to excessive pressure. PRINT HEAD MEDIA HOLD ASSEMBLY DOWN PLATEN ROLLER HEAD LATCH Page 1-3 PN 9001024 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...

  • Page 9: Components

    To protect the machine from abnormal power input. Type 3A/250V AC INPUT CONNECTOR: Connect to 115V 50/60 Hz.with cable provided EXT. PORT CONNECTOR: External signal connector Page 1-4 PN 9001024 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 10 ROLLERS MOVEABLE PORTION "EYE - MARK" SENSOR STATIONARY PORTION LABEL MEDIA GUIDE HOLDER PAPER OUT SWITCH MOVEABLE NOTCH/GAP SENSOR & "EYE-MARK" SENSOR PRINT HEAD WITH SWITCH Page 1-5 PN 9001024 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 11 SECTION 1 – Overview & Specifications 1-3 Components PRINT HEAD RIBBON GUIDE PLATEN PLATE LCD BOARD AND KB BOARD ON BACKSIDE OF PANEL TIMING BELTS STEPPER MOTOR PLATENS Page 1-6 PN 9001024 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...

  • Page 12: Ribbon

    SECTION 1 – Overview & Specifications 1-3 Components POWER SUPPLY UNIT OPTIONAL MEMORY CARD ADAPTER MAIN PC BOARD WITH PLUG-IN INTERFACE CARD - CENTRONICS I/O SHOWN 1-4 Ribbon 1-5 Installation Considerations Page 1-7 PN 9001024 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...

  • Page 13: Switches And Sensors

    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. Page 1-8 PN 9001024 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 14 Media Hold Down is in the up position. All printer operations stop, and an error message is displayed on the LCD. Page 1-9 PN 9001024 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...

  • Page 15: Operator Panel/Displays

    When the printer is on- line. line, another copy of the last label will be printed. Page 1-10 PN 9001024 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 16 Refer to Section 2 for settings. NOTE: DSW 1 is reserved. To set DSW1 on the interface board, see Section 3. COVER Page 1-11 PN 9001024 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...

  • Page 17: Optional Accessories

    . s t all RISC based t n i SATO Printers. 1-9 Environment & Approvals y t i y t i c i t Page 1-12 PN 9001024 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...

  • Page 18: Print

    . n i . n i , s l , d l p i l l l o . n i . n i Page 1-13 PN 9001024 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...

  • Page 19: Controls And Signals, Adjustments

    . t f 1-12 Controls and Signals, Adjustments c t i c t i c t i t n i c t i s f f Page 1-14 PN 9001024 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...

  • Page 20: Interface Connections

    ) f f y l l t n i y l l t i l i 1-14 Processing ) t i Page 1-15 PN 9001024 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...

  • Page 21: Character Fonts

    . t i Page 1-16 PN 9001024 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...

  • Page 22: Bar Codes And Other Features

    SECTION 1 – Overview & Specifications 1-16 Bar Codes and Other Features t n I , s t l a i Page 1-17 PN 9001024 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 23 SECTION 1 – Overview & Specifications ® Page 1-18 PN 9001024 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...

  • Page 24: Section 2. Configuration

    RECEIVE BUFFER SIZE FOR THESE • SETTINGS, SEE OPERATION MODE SECTION 3 DIP SWITCHES FLIP-DOWN COVER DIP SWITCH TABLE IS LOCATED ON THE UNDERSIDE OF FRONT ACCESS DOOR Page 2-1 PN 9001024 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 25 Sensor Type Selection (DSW2-2) DSW2 DSW2-2 SETTING “I - Mark” Head Check Selection (DSW2-3) DSW2 DSW2-3 SETTING Disabled Enabled Hex Dump Selection (DSW2-4) DSW2 DSW2-4 SETTING Disabled Enabled Page 2-2 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 26 DSW2 DSW2-5 SETTING Single Job Multi Job Protocol Control Code Selection (DSW2-6 & DSW2-7) DSW2 DSW2-6* DSW2-7 SETTING Reserved Standard Reserved Non-Std. Selecting Protocol Control Codes PN 9001024 Page 2-3 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 27 SECTION 2 – Configuration Selecting Protocol Control Codes (Cont.) Download Command Structure s a l STEP PROCEDURE DSW2-7 FEED LINE Page 2-4 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 28 SECTION 2 – Configuration Selecting Protocol Control Codes (Cont.) Download Procedure STEP PROCEDURE DSW2-7 LINE DSW2-7 DSW2-7 DSW2-7 LINE ON-LINE FEED FEED PN 9001024 Page 2-5 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 29 - f f M84XX Compatibility (DS2-8) DSW2 DSW2-8 SETTING OFF (Normal Operation) M-8400 Compatibility Mode Selection (DSW3-1 and DSW3-2) DSW3 DSW3-1 DSW3-2 SETTING Batch/Continuous Tear Off Cutter Dispenser Page 2-6 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 30 Sensor Used Not Used Back Feed Selection (DSW3-4 ) DSW3 DSW3-4 SETTING Disabled Enabled External Signal Interface Print Start Signal Selection (DSW3-5) DSW3 DSW3-5 SETTING Disabled Enabled PN 9001024 Page 2-7 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 31 Repeat Print via External Signal (DSW3-8) DSW3 DSW3-8 SETTING Disabled Enabled Note: The DIP Switch functions listed incorporate the latest firmware revisions at the time of printing. Page 2-8 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...

  • Page 32: Default Settings

    Print Speed: Pitch Offset: Advanced Mode Default Settings Zero Slash: Auto Online Vert. Offset: DEFAULT SETTING Horiz: Input: COMPLETED Calendar Enabled: = Ignore CR/LF: Print Darkness: PN 9001024 Page 2-9 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...

  • Page 33: Printer Adjustments

    Default Protocol POWER+LINE+FEED+ Refer to Codes DSW2-7 = ON Page 2-4 Print Hex RECEIVE BUFFER Dump Label Hex Dump Label POWER+DSW2-4 = ON Refer to Page 2-2 Page 2-10 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 34 PROCEDURE LINE FEED Note: The setting can be overridden by software. Finer adjustments can also be made using the PRINT potentiometer setting on the adjustment panel. PN 9001024 Page 2-11 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 35 Note: This setting can be overridden by software. Pitch Offset and Direction MOVED WITH MINUS (-) OFFSET ORIGINAL PRINT LINE MOVED WITH POSITIVE (+) OFFSET LINE FEED DIRECTION Page 2-12 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 36 SECTION 2 – Configuration Pitch Offset and Direction STEP PROCEDURE LINE FEED LINE FEED FEED PN 9001024 Page 2-13 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...

  • Page 37: Advanced Mode Settings And Adjustments

    SECTION 2 – Configuration Cancel Print Job STEP PROCEDURE LINE FEED FEED LINE 2-4 Advanced Mode Settings and Adjustments LINE FEED Page 2-14 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 38 ADVANCED MODE SETUP FEED KEY section or press the LINE key to select the counters section. For the counters section refer to page 42. 2-24. PN 9001024 Page 2-15 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 39 SECTION 2 – Configuration 2-4 Advanced Mode Settings and Adjustments Zero Slash Setting STEP PROCEDURE LINE FEED Auto Online Setting ONLINE OFFLINE LINE STEP PROCEDURE LINE FEED Page 2-16 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 40 STEP PROCEDURE LINE LINE FEED FEED ORIGINAL PRINT LINE LOCATION PRINT LINE VERTICALLY RELOCATED USING THE LINE KEY IN STEP 1 LINE FEED DIRECTION PN 9001024 Page 2-17 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 41 STEP PROCEDURE LINE FEED LINE LINE FEED FEED LINE FEED PRINT LINE DIRECTION HORIZONTALLY RELOCATED USING THE ORIGINAL PRINT LINE KEY IN STEP 3 LINE LOCATION Page 2-18 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 42 SECTION 2 – Configuration Sensor Threshold Level DSW2-2 DSW2-2 GAP SENSOR: STEP PROCEDURE PN 9001024 Page 2-19 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 43 SECTION 2 – Configuration Sensor Threshold Level Gap Sensor (Continued) STEP PROCEDURE Backing with Label Label Backing Only 2.0V to 3.5V 1.0V or less LINE LINE LINE FEED Page 2-20 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 44 SECTION 2 – Configuration Sensor Threshold Level (Continued) "Eye-Mark" (Reflective) Sensor: STEP PROCEDURE Label Only Eye Mark 1.0V or less 2.5V to 3.5V LINE LINE LINE FEED PN 9001024 Page 2-21 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 45 If the Calendar Option <ESC>WT YY/MM/DD hh:mm STEP PROCEDURE Year: LINE LINE Month: FEED LINE LINE Day: FEED LINE LINE Hour: FEED LINE LINE Minute: FEED LINE LINE FEED Page 2-22 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 46 SECTION 2 – Configuration Ignore Carriage Return/Line Feed Print Darkness Setting STEP PROCEDURE LINE FEED Exit Mode STEP PROCEDURE LINE YES. FEED PN 9001024 Page 2-23 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 47 SECTION 2 – Configuration Advance Mode Counters LIFE COUNTERS HD DSP CUT LIFE STEP PROCEDURE LINE FEED FEED LINE FEED LINE Page 2-24 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...

  • Page 48: Printing Test Labels

    SECTION 2 – Configuration 2-5 Printing Test Labels FEED FEED Print Size To access this setting, perform the following steps: STEP PROCEDURE LINE FEED PN 9001024 Page 2-25 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 49 SECTION 2 – Configuration Print Size (Cont.) STEP PROCEDURE SMALL FEED LINE FEED FEED FEED SMALL LABEL LARGE LABEL Page 2-26 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...

  • Page 50: Section 3. Interface Specifications

    WARNING: Never connect or disconnect interface cables or use a switch box with power applied to either the host or the printer. This may cause damage to the interface circuitry in the printer/host and is not covered by warranty. PN 9001024 Page 3-1 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 51 3-3 The Receive Buffer Single Job Buffer Multi Job Buffer Ready/Busy X-On/X-Off X-On X-On/X-Off X-Off DTR High or X-On DTR Low or X-Off Buffer Near Full Fig. 3-1 Page 3-2 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 52 7 or 8 data bits (selectable) s t i Odd, Even or No Parity (selectable) y t i 1 or 2 Stop bits (selectable) s t i PN 9001024 Page 3-3 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 53 PIN 1 PIN 14 PIN 25 . t f : h t RS232C Interface Signals Pin Assignments t n i . ) l t n i Page 3-4 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 54 . l e Ready/Busy Flow Control PN 9001024 Page 3-5 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 55 SECTION 3 – Interface Specifications 3-4 RS232C Serial Interface (Cont.) Cable Requirements Data Streams <STX><ESC>A..Job#1..<ESC>Z<ETX><STX><ESC>A..Job#n..<ESC>Z<ETX> NOTE: All characters, including STX, ESC and ETX are in ASCII. Page 3-6 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 56 SECTION 3 – Interface Specifications 3-4 RS232C Serial Interface (Cont.) X-On/X-Off Flow Control X-On/X-Off X-On/X-Off X-On X-Off X-On X-Off X-On X-Off X-On X-On X-Off X-On X-On Cable Requirements PN 9001024 Page 3-7 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 57 SECTION 3 – Interface Specifications 3-4 RS232C Serial Interface (Cont.) X-On/X-Off Flow Control (Cont.) Data Streams X-On/X-Off STX, ESC <STX><ESC>A..Job#1..<ESC>Z<ESC>A..Job#n..<ESC>Z<ETX Example: <STX>A..Job#1..<ESC>Z<ETX>XXXX Bi-Directional Communications DTR) Cable Requirements Page 3-8 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 58 SECTION 3 – Interface Specifications 3-4 RS232C Serial Interface (Cont.) Bi-Directional Communications (Cont.) Status Response STX/ETX <STX>{2 Byte ID}{1 Status Byte}{6 Byte Label Remaining}<ETX> <ESC>ID Status Label Remaining (<ESC>A…<ESC>Z) PN 9001024 Page 3-9 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 59 Page 3-10 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 60 3-4 RS232C Serial Interface (Cont.) Status Byte Definition, Bi-Directional Protocol f f u l l u t t u 3-5 Dip Switch Settings for RS232 Serial Interface DSW1 PN 9001024 Page 3-11 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 61 Parity Selection (DSW1-2 and DSW1-3): DSW1 DSW1-2 DSW1-3 SETTING No Parity Even Not Used RS232 Transmit/Receive Setting Stop Bit Selection (DSW1-4): DSW1 DSW1-4 SETTING 1 Stop Bit 2 Stop Bits Page 3-12 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...

  • Page 62: Centronics Parallel Interface

    Single Job Buffer: The Single Job Buffer mode is not available when using the Centronics interface Multi Job Buffer: <STX><ESC>A..Job#1..<ESC>Z<ETX> <STX><ESC>A..Job#n..<ESC>Z<ETX> Note that for parallel communications, the 56: and -6: characters are not required. PN 9001024 Page 3-13 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 63 Page 3-14 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...

  • Page 64: Accessory (Ext) Connector

    The maximum voltage that can be applied to these pins is +50V and the maximum current they can sink is 500 milliamps. PN 9001024 Page 3-15 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 65 Pin 1, 3 4 or 6 TYPE 1 20 milliseconds TYPE 2 TYPE 3 TYPE 4 Start Print End Print (Label Feed (Label Feed Stop) Stop) Page 3-16 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...

  • Page 66: Section 4. Electrical Checks And Adjustments

    Label Sensors • Ribbon Sensor • Pitch Offset • Label Positions Checks and adjustments in this section require standard metric tools. Other equipment is listed where needed. PN 9001024 Page 4-1 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...

  • Page 67: Steps Prior To Some Procedures

    Fig. 4-1 & 4-2 RAISE THE ACCESS DOOR AND LOOSEN (2) SCREWS ON THE INSIDE TOP OF THE PRINTER Fig 4-1 REMOVE (3) SCREWS ELECTRONICS COMPARTMENT Fig 4-2 Page 4-2 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...

  • Page 68: Power Supply Checks

    Fig. 4-3 & 4-4 Fig. 4-5 & 4-6 Fig. 4-5 & 4-6 Fig. 4-5, 4-6 & 4-7. TEST POINT CONNECTOR MAIN PCB VR1-VR7 Ref. Section 4-4 HEAT SINK PN 9001024 Page 4-3 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 69 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 CORRECT POSITION OF NIBS ON Fig 4-3 CONNECTOR MAIN PCB TP TEST MODULE TO PCB TEST POINT DIGITAL TP TEST MULTIMETER MODULE Fig 4-4 Page 4-4 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 70 DC VOLT MUST BE SELECTED DIAL VOLT GROUND SIG PIN Fig 4-5 Fig 4-6 DIGITAL TP TEST MODULE MULTIMETER " " & Fig 4-7 TEST POINT CHART PN 9001024 Page 4-5 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...

  • Page 71: Potentiometer Assignments

    POTENTIOMETERS ARE LOCATED ON MAIN PCB s f f c t i POTENTIOMETERS ARE LOCATED UNDERNEATH A FLIP - DOWN COVER ON THE FRONT PANEL Page 4-6 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...

  • Page 72: Pitch Potentiomter (User Adjustment)

    4-8 (Generated Test Print) Fig. 4-9 FEED STEP 4 Fig 4-9 POTENTIOMETERS ARE LOCATED UNDERNEATH A FLIP-DOWN COVER ON THE FRONT PANEL Fig 4-8 TEST PRINT PN 9001024 Page 4-7 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...

  • Page 73: Offset Adjustment (User Adjustment)

    SECTION 4 – Electrical Checks and Adjustments 4-6 Offset Adjustment (User Adjustment) POTENTIOMETERS ARE LOCATED UNDERNEATH A FLIP - DOWN COVER ON THE FRONT PANEL Page 4-8 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...

  • Page 74: Label Gap Adjustment

    SECTION 4 – Electrical Checks and Adjustments 4-7 Label Gap Adjustment STEP PROCEDURE Refer to Section 4-2 for access to main PCB Fig. 4-10 Fig. 4-11 & 4-12. PN 9001024 Page 4-9 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 75 ADJUSTMENT FOR STEP 1 VR 2 IS LOCATED ON MAIN PCB INSIDE PRINTER Fig 4-11 CONNECT + PROBE CONNECT - PROBE OF MULTIMETER OF MULTIMETER TP TEST MODULE Page 4-10 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...

  • Page 76: Eye-Mark Adjustment

    SECTION 4 – Electrical Checks and Adjustments 4-8 "Eye-Mark" Adjustment STEPPROCEDURE Refer to Section 4-2 for access to main PCB Fig. 4-13 Fig. 4-14 & 4-15. PN 9001024 Page 4-11 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 77 VR 1 Fig 4-14 IS LOCATED ON MAIN PCB INSIDE PRINTER Fig 4-13 CONNECT + PROBE CONNECT - PROBE OF MULTIMETER OF MULTIMETER TP TEST MODULE Page 4-12 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...

  • Page 78: Ribbon Senser Adjustment

    SECTION 4 – Electrical Checks and Adjustments 4-9 Ribbon Sensor Adjustment STEP PROCEDURE Refer to Section 4-2 for access to main PCB Fig. 4-16 Fig. 4-17 & 4-18. PN 9001024 Page 4-13 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 79 ADJUSTMENT FOR STEP 1 Fig 4-17 IS LOCATED ON MAIN PCB INSIDE PRINTER CONNECT + PROBE CONNECT - PROBE OF MULTIMETER OF MULTIMETER TP TEST MODULE Page 4-14 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...

  • Page 80: Lcd Display Adjustment

    SECTION 4 – Electrical Checks and Adjustments 4-10 LCD Display Adjustment STEP PROCEDURE Fig. 4-19 VR 4 Fig 4-19 POTENTIOMETERS ARE LOCATED UNDERNEATH A FLIP - DOWN COVER OF THE FRONT PANEL PN 9001024 Page 4-15 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...

  • Page 81: Print Darkness Adjustment

    Fig. 4-20 LINE LINE FEED print darkness 1 2 3 LINE FEED Fig 4-20 POTENTIOMETERS ARE LOCATED UNDERNEATH A FLIP - DOWN COVER ON THE FRONT PANEL Page 4-16 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...

  • Page 82: Section 5. Mechanical Adjustments

    • Ribbon Roller Adjustment • Ribbon Tension Balance Adjustment • Feed Roller Adjustment • Timing Belt Tension Adjustment • Head Latch Adjustment • Notch/Gap Sensor Adjustment Page 5-1 PN 9001024 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...

  • Page 83: Ribbon Clutch Adjustments

    5-2 Ribbon Clutch Adjustments 5-2.1 Ribbon Unwind Clutch Adjustment STEP PROCEDURE Fig. 5-1 Fig. 5-2 & 5-3 Fig. 5-2 & 5-3 RAISE THE MAIN COVER Fig. 5-1 Page 5-2 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 84 Fig. 5-2 RIBBON REWIND SPINDLE TENSION GAUGE TENSION GAUGE STRING 500-700g REWIND 600-800g STRING UNWIND EMPTY RIBBON CORES Fig. 5-4 Fig. 5-3 REWIND CLUTCH UNWIND CLUTCH PN 9001024 Page 5-3 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 85 SECTION 5 – Mechanical Adjustments 5-2 Ribbon Clutch Adjustments 5-2.2 Ribbon Rewind Clutch Adjustment STEP PROCEDURE Fig. 5-1 Fig. 5-2 & 5-4 Fig. 5-2 & 5-4 Page 5-4 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...

  • Page 86: Print Head Position Adjustment

    PROCEDURE Fig. 5-1 FEED USER TEST PRINT Small large LINE Large FEED FEED Fig. 5-5 (Generated Test Print) Fig. 5-6 & 5-7 NOTE: Fig. 5-5 NOTE: PN 9001024 Page 5-5 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 87 BOTTOM OF BARCODE TO BOTTOM OF LABEL TO BOTTOM OF LABEL Fig. 5-5 TEST PRINT STAY Fig. 5-6 STAY TURN SCREWS Fig. 5-7 CW/CCW ADJUST SCREWS ALLEN WRENCH Page 5-6 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...

  • Page 88: Print Head Balance Adjustment

    SECTION 5 – Mechanical Adjustments 5-4 Print Head Balance Adjustment STEP PROCEDURE Fig. 5-1 NOTE: Fig. 5-8 NOTE: ADJUST PLATE LOCKING SCREWS ECCENTRIC Fig. 5-8 PN 9001024 Page 5-7 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...

  • Page 89: Ribbon Roller Adjustment

    SECTION 5 – Mechanical Adjustments 5-5 Ribbon Roller Adjustment NOTE: STEP PROCEDURE Fig. 5-1 Fig. 5-9 TURN ECCENTRIC LOOSEN LOCKING SCREWS Fig. 5-9 Page 5-8 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...

  • Page 90: Ribbon Tension Balance Adjustment

    5-6 Ribbon Tension Balance Adjustment NOTE: Fig. 5-10 NOTE: STEP PROCEDURE Fig. 5-1 Fig. 5-11. Fig. 5-12 RIBBON UNWIND RIBBON REWIND SPINDLE SPINDLE STAY RIBBON SHOWN WITH WRINKLES Fig. 5-10 PN 9001024 Page 5-9 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 91 "A" MUST BE PARALLEL WITH "B" RIBBON ROLLER "C" MUST BE PARALLEL WITH "D" Fig. 5-11 ADJUST PLATES LOCKING SCREWS Fig. 5-12 MOVE THE ADJUST PLATES UP/DOWN Page 5-10 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...

  • Page 92: Feed Roller Adjustment (Label Tracking)

    SECTION 5 – Mechanical Adjustments 5-7 Feed Roller Adjustment (Label Tracking) STEP PROCEDURE Fig. 5-1 Fig. 5-13 & 5-14 Fig. 5-15 Fig. 5-16 PN 9001024 Page 5-11 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 93 MEDIA PULL ADJUST SCREW & FIXING NUT ON BOTH ENDS OF MEDIA COVER Fig. 5-15 MOVE WITH FLAT BLADE SCREWDRIVER ADJUST PLATE Fig. 5-16 LOCKING SCREW Page 5-12 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...

  • Page 94: Timing Belt Tension Adjustment

    Fig. 5-17 TENSION GAUGE TIMING BELT "A" NOT ADJUSTABLE TIMING BELT "B" TENSION RANGE 100-500g TIMING BELT "B" LOCKING Fig. 5-17 TENSION TENSION SCREWS IDLER IDLER MOTOR PN 9001024 Page 5-13 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...

  • Page 95: Head Latch Adjustment

    LATCHED POSITION UNLATCHED POSITION Page 5-14 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...

  • Page 96: Notch/Gap Sensor Adjustment

    Sensor Location (shown for ref. only) NOTCH/GAP SENSOR ADJUSTMENT RANGE NOTCH/GAP LOCATIONS (MAXIMUM & MINIMUM) 1" (25 mm) LABEL FEED Minimum DIRECTION 3.5" (90 mm) Maximum PN 9001024 Page 5-15 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 97 SECTION 5 – Mechanical Adjustments ® Page 5-16 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...

  • Page 98: Section 6. Replacement Procedures

    • Timing Belts • Print Head • Platen • Ribbon Clutch Washers • Ribbon Motion Sensor • Label Sensor • Top Notch/Gap and "Eye-Mark Sensors • Display Panel Page 6-1 PN 9001024 SATO CL608 & CL612 SERVICE MANUAL Rev. B Sept. 1999...

  • Page 99: Replacing The Main Circuit Board

    SECTION 6 – Replacement Procedures 6-2 Replacing the Main Circuit Board STEP PROCEDURE Figs. 6-1 & 6-2 Figs. 6-3 & 6-4 Fig. 6-5 Fig. 6-5 Fig. 6-5 Page 6-2 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 100 REMOVE (4) SCREWS TO DETACH THE OPTIONAL MEMORY CARD Fig. 6-3 PULL AWAY THE OPTIONAL MEMORY CARD TO DISCONNECT CONNECTOR FROM MAIN CIRCUIT BOARD Fig. 6-4 PN 9001024 Page 6-3 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 101 6- 2 Replacing the Main Circuit Board REMOVE EPROMS AFTER BOARD REMOVAL REMOVE (3) SCREWS AND (1) STUD TO DETACH BOARD DETACH ALL CONNECTORS FROM MAIN CIRCUIT BOARD Fig. 6-5 Page 6-4 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...

  • Page 102: Replacing The Fuses

    6-3.1 Removing and Replacing the Main Power Fuse STEP PROCEDURE Do not use a fuse with a higher rating. Fig. 6-6 BACK OF PRINTER FUSE (UNDER COVER) Fig. 6-6 PN 9001024 Page 6-5 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 103 6-3.2 Removing and Replacing the 1A, 250V or 3.15A, 250V Fuse(s) STEP PROCEDURE Fig. 4-1 & 4-2 Fig. 6-7 Do not use a fuse with a higher rating. MAIN PC BOARD FUSES Fig. 6-7 Page 6-6 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...

  • Page 104: Replacing The Power Supply

    6-4 Replacing the Power Supply STEP PROCEDURE Figs. 6-8 & 6-9 NOTE: Fig. 6-12 Figs. 6-10 & 6-11 Fig. 6-12 NOTE: Figs. 6-13 & 6-14 Fig.6-15 POWER SUPPLY INSTALLED PN 9001024 Page 6-7 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 105 REMOVE (4) SCREWS TO DETACH THE OPTIONAL MEMORY CARD Fig. 6-10 PULL AWAY THE OPTIONAL MEMORY CARD TO DISCONNECT CONNECTOR FROM MAIN CIRCUIT BOARD Fig. 6-11 Page 6-8 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 106 BOARD MOUNTING LOWER THE PLATE MEDIA HOLDER REMOVE BOTTOM AND TOP SCREWS Figs. 6-14 REMOVE TOP AND BOTTOM SCREWS FROM BACK END OF PRINTER Fig. 6-15 PN 9001024 Page 6-9 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...

  • Page 107: Replacing The Stepper Motor

    Fig. 6-16 REMOVE (3) MOUNTING SCREWS DETACH CONNECTOR FROM CIRCUIT BOARD Fig. 6-18 REMOVE PULLEY FROM OLD Fig. 6-17 UNIT AND TRANSFER OR REPLACE IF NECESSARY Page 6-10 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...

  • Page 108: Replacing The Timing Belts

    Fig. 6-20 & 6-21 Do not disturb two adjacent screws. Fig. 6-22 Fig. 6-23 Fig. 6-24. Fig. 6-25 Fig. 6-26. REMOVE THE RIBBON AND LABEL STOCK Fig. 6-19 PN 9001024 Page 6-11 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 109 Fig. 6-20 BELT "A" GEAR TO ENGAGE FEED ROLLER SPRING LOADED IDLER FRONT PLATEN BELT "B" ROLLER REAR TENSION PLATEN ADJUSTMENT ROLLER MOTOR IDLER Fig. 6-21 Page 6-12 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 110 Fig. 6-22 REMOVE SCREW (ATTACHES TO REWIND SPINDLE) Fig. 6-23 BEARING PULL REWIND SPINDLE FORWARD TO DISLODGE BELT "A" REMOVE & REPLACE BELT "A" Fig. 6-24 PN 9001024 Page 6-13 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 111 6-6 Replacing the Timing Belts For Belt "B" Fig. 6-26 LOOSEN ADJUSTMENT IDLER SCREWS DISLODGE BELT "B" FROM MOTOR SHAFT AND GEARS Fig. 6-25 ADJUSTMENT IDLER Page 6-14 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...

  • Page 112: Replacing The Print Head

    6-7 Replacing the Print Head STEP PROCEDURE Fig. 6-27 Fig. 6-27 & 6-28 Fig. 6-29 Fig. 6-29 Fig. 6-30 Fig. 6-31 Fig. 6-32 & 6-29 Fig. 6-32 & 6-29 PN 9001024 Page 6-15 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 113 REMOVE (2) STUD SCREWS Fig. 6-27 HEAD LATCH LEVER Fig. 6-28 DISLODGE AND REMOVE RIBBON GUIDE PLATE Fig. 6-29 PRINT HEAD DISCONNECT CABLES Fig. 6-30 PRINT HEAD Page 6-16 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 114 SECTION 6 – Replacement Procedures 6-7 Replacing the Print Head SET SWITCH TO RIGHT SIDE POSITION Fig. 6-31 ALIGNMENT PINS RECONNECT CABLES PRINT HEAD Fig. 6-32 PN 9001024 Page 6-17 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...

  • Page 115: Replacing The Platen

    6-8 Replacing the Platen STEP PROCEDURE Fig. 6-33 Fig. 6-34 Fig. 6-34 Fig. 6-35 & 6-36 Fig. 6-37, 6-38 Fig. 6-39 Figs. 6-40 & 6-41 Fig. 6-42, 6-43 Page 6-18 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 116 PLATEN TO FRAME LABEL STOCK PLATEN Fig. 6-33 SLIGHTLY LOOSEN ECCENTRIC SCREW Fig. 6-34 LOOSEN (2) IDLER SCREWS TO RELEASE BELT TENSION Fig. 6-36 REMOVE BELT Fig. 6-35 PN 9001024 Page 6-19 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 117 CL608 PLATEN CL612 PLATEN Fig. 6-37 CL612 PLATEN Fig. 6-38 REMOVE (2) SCREWS HOLDING RETAINER TO THE FRAME (SCREW IS PARTIALLY HIDDEN BY GEAR) Fig. 6-39 Page 6-20 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 118 SPRING IN CORRECT HOLDING CLAMP BUSHING PLATE POSITION WITH HEAD RELEASE LEVER IN PLACE SPRING END MUST NOT BE UNDER BUSHING PLATE Fig. 6-42 Fig. 6-43 PN 9001024 Page 6-21 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...

  • Page 119: Replacing The Ribbon Drive Clutch Washers

    List 6A and Figs. 6-45 through 6-48 l l o REMOVE RIBBON - l i AND LABEL STOCK l a t l l o & t c i List 6-A Fig. 6-44 Page 6-22 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 120 AND ADJUSTMENT NUT ORDER (SEE ITEM LIST 6A) 4 5 6 1 2 3 REWIND DRIVE SPINDLE Fig. 6-47 Fig. 6-48 UNWIND DRIVE CONTINUED SPINDLE FROM FIG. 6-46 PN 9001024 Page 6-23 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 121 Fig. 6-47 and Fig. 6-51 List 6-A, Fig. 6-47 and Fig. 6-52 List 6-A and Fig. 6-46 List 6-A and Fig. 6-46 Fig. 6-45 & 6-46 NOTE: Page 6-24 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 122 FELT WASHER ITEM 8 RIBBON BOSS ALIGN HOLE WITH PEG Fig. 6-51 INSERT PEGS INTO ITEM 8 RIBBON LOCATION HOLES BOSS Fig. 6-52 ITEM 6 OIL-LESS WASHER PN 9001024 Page 6-25 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...

  • Page 123: Replacing The Ribbon Motion Sensor

    6-10 Replacing the Ribbon Motion Sensor STEP PROCEDURE Fig. 6-53 Figs. 6-54 & 6-55 Figs. 6-56 & 6-57 Figs. 6-58 & 6-59 Fig. 6-54 RAISE THE MAIN COVER Fig. 6-53 Page 6-26 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 124 ALIGNMENT PIN REMOVE SCREW Fig. 6-54 Fig. 6-55 Fig. 6-57 PULL THE SENSOR CABLE AND CONNECTOR Fig. 6-56 THROUGH THE FRAME HOLE UNPLUG SEN4 FROM THE PCB PN 9001024 Page 6-27 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 125 SECTION 6 – Replacement Procedures 6-10 Replacing the Ribbon Motion Sensor REMOVE (2) SCREWS HOLDING SENSOR TO THE BRACKET Fig. 6-58 DISASSEMBLED RIBBON MOTION SENSOR AND MOUNTING BRACKET Fig. 6-59 Page 6-28 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 126 THE NOTCH/GAP SENSOR NOTCH/GAP SENSOR (TOP HALF) EYE-MARK SENSOR PAPER END SWITCH (MICRO-SWITCH) NOTCH/GAP SENSOR Fig. 6-61 (BOTTOM HALF) SENSOR LOCATIONS RAISE THE MAIN COVER Fig. 6-60 PN 9001024 Page 6-29 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 127 IDLER AND GEAR MUST BE REMOVED FOR ACCESS TO THE 3RD SCREW WHICH IS UNDER THE GEAR. REFER TO FIG. 6-64, 6-65 & 6-66 Fig. 6-67 Fig. 6-68 Fig. 6-69 Fig. 6-70 Fig. 6-71 NOTE: Page 6-30 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 128 OPTION INSTALLED, THIS IDLER AND GEAR MUST BE REMOVED FOR ACCESS TO THE 3RD SCREW (SCREW IS UNDER GEAR) WHICH SECURES THE RAMP TO THE FRAME Fig. 6-64 PN 9001024 Page 6-31 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 129 REMOVE 3RD SCREW TO DETACH RAMP FROM FRAME Fig. 6-66 DETACH CONNECTORS FROM SEN1 & SEN7 Fig. 6-68 WIGGLE THE RAMP Fig. 6-67 PLATE FREE FROM THE PRINTER Page 6-32 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 130 BOTTOM HALF NOTCH/GAP AND EYE-MARK SENSORS PAPER END-SWITCH (MICRO-SWITCH) Fig. 6-69 NOTCH/GAP SENSOR (BOTTOM Fig. 6-70 HALF) PAPER END SWITCH REMOVE (2) REMOVE (2) SCREWS SCREWS Fig. 6-71 PN 9001024 Page 6-33 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 131 Fig. 6-72 Fig. 6-73 Fig. 6-74 Fig. 6-75, 6-76 & 6-77 Fig. 6-78, 6-79 & 6-81 NOTE: Fig. 6-80 Fig. 6-82 RAISE THE MAIN COVER Fig. 6-72 Page 6-34 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 132 FROM THE FRAME Fig. 6-73 Fig. 6-74 REMOVE (2) SCREWS TO OPEN COVER AND ACCESS THE NOTCH/GAP SENSOR Fig. 6-75 NOTCH/GAP SENSOR Fig. 6-76 Fig. 6-77 PN 9001024 Page 6-35 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 133 Fig. 6-78 Fig. 6-79 ALLEN HEAD SCREW WITH COLLAR Fig. 6-80 Fig. 6-81 Fig. 6-82 DISLODGE BRACKET WITH SENSOR REMOVE (2) SCREWS TO DETACH SENSOR FROM BRACKET Page 6-36 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 134 STEP PROCEDURE Fig. 6-83 & 6-84 Fig. 6-85 Fig. 6-86 Fig. 6-87 Fig. 6-88 Fig. 6-89 Fig. 6-90 MECHANICAL SECTION LID DISPLAY PANEL COVER Fig. 6-83 PN 9001024 Page 6-37 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 135 PLATEN REMOVE (1) SCREW REMOVE (2) SCREWS BRACKET ATTACHED Fig. 6-85 TO FRAME REMOVE (2) SCREWS Fig. 6-87 ROTATE AND LIFT TO DETACH Fig. 6-86 COVER Page 6-38 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 136 DISPLAY PANEL ASSEMBLY REMOVE (1) SCREW DISPLAY PANEL ASSEMBLY Fig. 6-88 MECHANICAL SECTION SIDE REMOVE DISPLAY PANEL OR KEYPAD Fig. 6-89 REMOVE (2) SCREWS Fig. 6-90 PN 9001024 Page 6-39 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 137 SECTION 6 – Replacement Procedures ® Page 6-40 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...

  • Page 138: Section 7. Factory Resets

    The Factory Reset Mode allows you to: • Factory Test Print Without Resetting Printer • EEProm Clear All • Clear Head Counters • Clear Cutter Counter PN 9001024 Page 7-1 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...

  • Page 139: Factory Test Print Without Resetting Printer

    Press the FEED key to stop printing. Place the printers power switch to the OFF position and return all switches to their original positions. PN 9001024 Page 7-2 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...

  • Page 140: Eeprom Clear All

    Press the FEED key to stop printing. Verify that the counters on test print have reset to 0.0 km. Place the printers power switch to the OFF position and return all switches to their original positions. PN 9001024 Page 7-3 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...

  • Page 141: Clear Counter Heads

    Place the printers power switch to the OFF position and return all switches to their original positions. PN 9001024 Page 7-4 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...

  • Page 142: Clear Cutter Counter

    Verify that the cutter counter has been reset to (0). Place the printers power switch to the OFF position and return all switches to their original positions. PN 9001024 Page 7-5 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...

  • Page 143: Section 8. Troubleshooting

    Section Troubleshooting 8-1 Overview • Initial Checklist • Centronics Parallel Interface • RS232C Serial Interface • Error Signals • Troubleshooting Tables • Head Pattern Examples PN 9001024 Page 8-1 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...

  • Page 144: Initial Checklist

    WARNING: Never connect or disconnect interface cables (or use a switch box) with power applied to either the printer or the host. This may cause damage to the interface circuitry and is not covered by warranty. <ESC>A—DATA—<ESC>Z Page 8-2 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 145 SECTION 8 – Troubleshooting 8-3 Troubleshooting the Centronics (Parallel) Interface (Cont) <ESC> WARNING: A small label may produce a large amount of data when printed in Hex Dump. PN 9001024 Page 8-3 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...

  • Page 146: Troubleshooting The Rs232C (Serial) Interface

    Warning: Never connect or disconnect interface cables (or use a switch box) with power applied to either the printer or the host. This may cause damage to the interface circuitry and is not covered by warranty. Page 8-4 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...

  • Page 147: Error Signals

    PN 9001024 Page 8-5 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...

  • Page 148: Troubleshooting Tables

    Image Voids Image Voids y t i t n i t n i Image Voids y t i y t i Page 8-6 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...
  • Page 149 / t s t l e t l o t i u t l e / t s t l e PN 9001024 Page 8-7 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 150 / s t l Page 8-8 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...

  • Page 151: Head Pattern Examples

    SECTION 8 – Troubleshooting 8-7 Head Pattern Examples Fig. 8-1 FACTORY DEFAULT Fig. 8-2 GOOD ADJUSTMENT, CLEAR, DARK, EVEN TEXT PN 9001024 Page 8-9 SATO CL608 & CL612 SERVICE MANUAL Rev. B Jan. 2000...
  • Page 152 DIAGONAL VOIDS (WHITE STREAKS) THAT "WALK" ACROSS LABEL CAUSE: POOR HEAD ALIGNMENT, POOR RIBBON TENSION, WORN PLATEN, FOREIGN MATERIAL, DAMAGED PRINT HEAD, PRINT HEAD BALANCE Fig. 8-5 Page 8-10 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Rev. B Jan. 2000...

  • Page 153: Overview

    Potentiometer Assignments • Section 9-12 Gap/See Through Sensor • Section 9-13 Pitch Sensor Adjustment (Eye-Mark Tag/Label) • Section 9-14 Ribbon Sensor Adjustment SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Page 9-1 Serial No. 81199999 and below Rev. B Jan. 2000...
  • Page 154 NOTCH/GAP SENSOR EXT. PORT CONNECTOR MEMORY CARD OPTION SLOTS SERIAL & CENTRONICS OFF/ON INTERFACES RESIDENT AC INPUT FUSE CONNECTOR REAR PANEL SATO CL608 & CL612 SERVICE MANUAL Page 9-2 PN 9001024 Serial No. 81199999 and below Rev. B Jan. 2000...
  • Page 155 WITHOUT SWITCH LABEL GUIDE RIBBON ADJUST PLATE DIFFERENT (ADJUSTABLE IF INSTALLED) SYTLE POWER SUPPLY UNIT MAIN PC BOARD WITH INTEGRATED INTERFACES SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Page 9-3 Serial No. 81199999 and below Rev. B Jan. 2000...
  • Page 156 9-3 Replacing the Main Circuit Board CL608 & CL612 Serial #8199999 and below STEP PROCEDURE Fig. 9-1 Fig. 9-1 Fig. 9-1 SATO CL608 & CL612 SERVICE MANUAL Page 9-4 PN 9001024 Serial No. 81199999 and below Rev. B Jan. 2000...
  • Page 157 REMOVE (4) SCREWS TO DETACH BOARD REMOVE EPROMS AFTER BOARD REMOVAL Fig. 9-1 PCB BOARD IS SHOWN WITH OPTIONAL DALLAS TIMECHIP INSTALLED SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Page 9-5 Serial No. 81199999 and below Rev. B Jan. 2000...

  • Page 158: Section 9. Addendum

    PROCEDURE Do not use a fuse with a higher rating. Fig. 9-2 BACK OF PRINTER FUSE (UNDER FUSE CAP) Fig. 9-2 SATO CL608 & CL612 SERVICE MANUAL Page 9-6 PN 9001024 Serial No. 81199999 and below Rev. B Jan. 2000...
  • Page 159 9-3.2 Removing and Replacing the 1A, 250V or 3.15A, 250V Fuse(s) STEP PROCEDURE Fig. 9-3 Do not use a fuse with a higher rating. FUSES Fig. 9-3 MAIN PC BOARD SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Page 9-7 Serial No. 81199999 and below Rev. B Jan. 2000...

  • Page 160: Replacing The Power Supply

    9-5 Replacing the Power Supply CL608 & CL612 Serial #8199999 and below STEP PROCEDURE Figs. 9-4 & 9-5 Fig.9-6 Fig. 9-4 LOWER THE MEDIA HOLDER SATO CL608 & CL612 SERVICE MANUAL Page 9-8 PN 9001024 Serial No. 81199999 and below Rev. B Jan. 2000...
  • Page 161 Serial #8199999 and below REMOVE TOP AND BOTTOM SCREWS Figs. 9-5 REMOVE TOP AND BOTTOM SCREWS FROM BACK END OF PRINTER Fig. 9-6 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Page 9-9 Serial No. 81199999 and below Rev. B Jan. 2000...

  • Page 162: Installing The Memory Board

    Serial #8199999 and below STEP PROCEDURE Fig. 9-7 Fig. 9-8 Fig. 9-8 Fig. 9-9 MAIN CIRCUIT BOARD ATTACH (4) Fig. 9-7 STANDOFFS SATO CL608 & CL612 SERVICE MANUAL Page 9-10 PN 9001024 Serial No. 81199999 and below Rev. B Jan. 2000...
  • Page 163 Fig. 9-8 Fig. 9-9 ATTACH (4) STANDOFFS CONNECTOR ON MEMORY BOARD MAIN CIRCUIT BOARD SHOWN INSTALLED Error Handling: Error Description Indication Remedy SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Page 9-11 Serial No. 81199999 and below Rev. B Jan. 2000...

  • Page 164: Replacing The Print Head

    Fig. 9-10 Fig. 9-10 & 9-11 Fig. 9-12 Fig. 9-12 Fig. 9-13 Fig. 9-14 Fig. 9-15 & 9-12 Fig. 9-15 & 9-12 SATO CL608 & CL612 SERVICE MANUAL Page 9-12 PN 9001024 Serial No. 81199999 and below Rev. B Jan. 2000...
  • Page 165 HEAD LATCH LEVER Fig. 9-11 DISLODGE AND REMOVE RIBBON GUIDE PLATE DISCONNECT CABLES PRINT HEAD Fig. 9-12 Fig. 9-13 PRINT HEAD SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Page 9-13 Serial No. 81199999 and below Rev. B Jan. 2000...
  • Page 166 CL608 & CL612 Serial #8199999 and below SET SWITCH TO LEFT SIDE POSITION Fig. 9-14 ALIGNMENT PINS RECONNECT CABLES PRINT HEAD Fig. 9-15 SATO CL608 & CL612 SERVICE MANUAL Page 9-14 PN 9001024 Serial No. 81199999 and below Rev. B Jan. 2000...

  • Page 167: Replacing The Top Half Of The Notch/Gap Sensor

    Fig. 9-16 Fig. 9-17 Fig. 9-18 & 9-19 Fig. 9-20 & 9-21 Fig. 9-22 & 9-23 RAISE THE ACCESS DOOR Fig. 9-16 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Page 9-15 Serial No. 81199999 and below Rev. B Jan. 2000...
  • Page 168 DETACH SEN2 CONNECTOR FROM THE PCB BOARD REMOVE (2) SCREWS TO REMOVE COVER AND ACCESS THE NOTCH/GAP SENSOR Fig. 9-19 Fig. 9-20 SATO CL608 & CL612 SERVICE MANUAL Page 9-16 PN 9001024 Serial No. 81199999 and below Rev. B Jan. 2000...
  • Page 169 DOWN COVER (SHOWN REMOVED) MEDIA HOLD DOWN UNIT (OPPOSITE SIDE) Fig. 9-21 NOTCH GAP SENSOR REMOVE (2) SCREWS Fig. 9-23 Fig. 9-22 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Page 9-17 Serial No. 81199999 and below Rev. B Jan. 2000...

  • Page 170: Bottom Half Of The Notch/Gap And Eye-Mark Sensors

    3RD SCREW WHICH IS UNDER THE GEAR. REFER TO FIG. 9-27, 9-28 & 9-29. Fig. 9-30 Fig. 9-31 Fig. 9-32 Fig. 9-33 Fig. 9-34 NOTE: SATO CL608 & CL612 SERVICE MANUAL Page 9-18 PN 9001024 Serial No. 81199999 and below Rev. B Jan. 2000...
  • Page 171 AND GEAR MUST BE REMOVED FOR ACCESS TO THE 3RD SCREW (SCREW IS UNDER GEAR) WHICH SECURES THE RAMP TO THE FRAME Fig. 9-27 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Page 9-19 Serial No. 81199999 and below Rev. B Jan. 2000...
  • Page 172 FROM FRAME Fig. 9-29 DETACH CONNECTORS FROM SEN1 & SEN7 Fig. 9-31 WIGGLE THE RAMP PLATE FREE FROM THE PRINTER Fig. 9-30 SATO CL608 & CL612 SERVICE MANUAL Page 9-20 PN 9001024 Serial No. 81199999 and below Rev. B Jan. 2000...
  • Page 173 CL608 & CL612 Serial #8199999 and below Fig. 9-33 REMOVE (2) SCREWS TO DETACH FROM BRACKET Fig. 9-32 REMOVE (2) SCREWS Fig. 9-34 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Page 9-21 Serial No. 81199999 and below Rev. B Jan. 2000...

  • Page 174: Power Supply Checks

    CL608 & CL612 Serial #8199999 and below NOTE: STEP PROCEDURE Fig.9-35 , 9-36, 9-37 & 9-38. & & & & NOTE: WARNING: SATO CL608 & CL612 SERVICE MANUAL Page 9-22 PN 9001024 Serial No. 81199999 and below Rev. B Jan. 2000...
  • Page 175 MAIN PCB Fig. 9-35 Fig. 9-37 LCD DISPLAY DC VOLT MUST BE SELECTED Fig. 9-36 TEST PINS VOLT Fig. 9-38 DIGITAL MULTIMETER SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Page 9-23 Serial No. 81199999 and below Rev. B Jan. 2000...

  • Page 176: Potentiometer Assignments

    Fig. 9-39 POTENTIOMETERS ON FRONT PANEL NEXT TO DIP SWITCHES Fig. 9-40 POTENTIOMETERS ON MAIN PCB BOARD SATO CL608 & CL612 SERVICE MANUAL Page 9-24 PN 9001024 Serial No. 81199999 and below Rev. B Jan. 2000...

  • Page 177: Gap/See-Through Sensor

    STEP PROCEDURE Refer to Section 4-2 for access to main PCB Fig. 9-41 Fig. 9-42 & 9-43 Fig. 9-44 & 9-45 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Page 9-25 Serial No. 81199999 and below Rev. B Jan. 2000...
  • Page 178 Fig. 9-45 CONNECT (+) CONNECT (-) PROBE OF PROBE OF Fig. 9-43 MULTIMETER MULTIMETER TO TP CH8 TO TP CH1 POTENTIOMETERS (VR) SATO CL608 & CL612 SERVICE MANUAL Page 9-26 PN 9001024 Serial No. 81199999 and below Rev. B Jan. 2000...

  • Page 179: Pitch Sensor Adjustment (Eye-Mark Tag/Label)

    STEP PROCEDURE Refer to Section 4-2 for access to main PCB Fig. 9-46 Fig. 9-47 & 9-48 Fig. 9-49 & 9-50 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Page 9-27 Serial No. 81199999 and below Rev. B Jan. 2000...
  • Page 180 Fig. 9-50 CONNECT (+) CONNECT (-) PROBE OF PROBE OF Fig. 9-48 MULTIMETER MULTIMETER TO TP CH7 TO TP CH1 POTENTIOMETERS (VR) SATO CL608 & CL612 SERVICE MANUAL Page 9-28 PN 9001024 Serial No. 81199999 and below Rev. B Jan. 2000...

  • Page 181: Ribbon Sensor Adjustment

    Serial #8199999 and below STEP PROCEDURE Refer to Section 4-2 for access to main PCB Fig. 9-51 & 9-52 CH10 Fig. 9-53 & 9-54 SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Page 9-29 Serial No. 81199999 and below Rev. B Jan. 2000...
  • Page 182 Fig. 9-54 CONNECT (-) CONNECT (+) PROBE OF PROBE OF MULTIMETER MULTIMETER TO TP CH1 TO TP CH10 Fig. 9-52 POTENTIOMETERS (VR) SATO CL608 & CL612 SERVICE MANUAL Page 9-30 PN 9001024 Serial No. 81199999 and below Rev. B Jan. 2000...
  • Page 183 SECTION 9 – Addendum ® SATO CL608 & CL612 SERVICE MANUAL PN 9001024 Page 9-31 Serial No. 81199999 and below Rev. B Jan. 2000...

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