SATO CL412E - Manuals

PN 9001078Rev. B Page 1-3 Section 1. Overview and Specifications SATO CL408e/CL412e Service Manual 1.3 Printer Features INTERFACE SLOT POWER SWITCH PCMCIA MEMORY EXPANSION SLOT AC POWER INPUT CONNECTOR AC FUSE EXT CONNECTOR COVER PLATE-REMOVE FOR ACCESS TO DISPENSER AND FAN-FOLD SLOTS INTERFACE SLOT...

PN 9001078 Rev. B Page 1-4 SATO CL408e/CL412e Service Manual Section 1. Overview and Specifications FRONT ACCESS DOORINTERLOCK : This switch prevents printer operation when the Front Access Door is open. The Top Access Door must be open before the Front Access Door can be opened or closed. FRONT ACC...

PN 9001078 Rev. B Page 1-6 SATO CL408e/CL412e Service Manual Section 1. Overview and Specifications RIBBON MOTION SENSOR: This sensor is a motion detector that signals the printer when the ribbon supply is turning. This sensor is used for both the ribbon end and ribbon near end sensing. LABEL SENSOR...

PN 9001078 Rev. B Page 1-8 SATO CL408e/CL412e Service Manual Section 1. Overview and Specifications Operation Panel LCD DISPLAY PANEL 2 Line x 16 Character LCD display. Used for setting operational parameters of the printer. STATUS LED Two-color (Red, Green) LED that indicates the following status c...

PN 9001078Rev. B Page 1-9 Section 1. Overview and Specifications SATO CL408e/CL412e Service Manual 1.6 Installation Considerations Printer 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 res...

PN 9001078 Rev. B Page 1-10 SATO CL408e/CL412e Service Manual Section 1. Overview and Specifications 1.8 Environment & Approvals 1.9 General Printer Specifications n o i t a c i f i c e p S e 8 0 4 L C e 2 1 4 L C a i d e M h t d i W m u m i n i M ) m m 2 2 ( . n i 7 8 . h t g n e L m u m i n i ...

PN 9001078Rev. B Page 1-11 Section 1. Overview and Specifications SATO CL408e/CL412e Service Manual General Printer Specifications n o i t a c i f i c e p S e 8 0 4 L C e 2 1 4 L C g n i s n e S u r h t - e e S e v i s s i m s n a r T e l b a v o M k r a M - e y E e v i t c e l f e R e l b a v o M m...

PN 9001078Rev. B Page 1-13 Section 1. Overview and Specifications SATO CL408e/CL412e Service Manual 1.10 Character Fonts n o i t a c i f i c e p S e 8 0 4 L C e 2 1 4 L C s t n o F x i r t a M t n o F U ) H s t o d 9 x W s t o d 5 ( t n o F S ) H s t o d 5 1 x W s t o d 8 ( t n o F M ) H s t o d 0 2...

PN 9001078 Rev. B Page 1-14 SATO CL408e/CL412e Service Manual Section 1. Overview and Specifications 1.11 Bar Codes n o i t a c i f i c e p S e 8 0 4 L C e 2 1 4 L C s e i g o l o b m y S ) l a t n e m e l p p u S N A E / C P U ( d n a l k o o B 3 1 - N A E , 8 - N A E R A B A D O C 9 3 e d o C 3 9 ...

Page 2-1 SATO CL408e/CL412e Service Manual PN 9001078Rev. B Configuration 2.1 Dip Switch Settings 2 Section Two DIP switches (DSW2 & DSW3) are located inside the Front Access Door. These switches can be used to set: • Thermal transfer or direct thermal mode • Head Check Mode • Hex Dump Mode • La...

Page 2-2 Section 2. Configuration SATO CL408e/CL412e Service Manual PN 9001078 Rev. B DSW1 ON OFF 1 2 3 4 5 6 7 8 DSW1 ON OFF 1 2 3 4 5 6 7 8 DSW1 ON OFF 1 2 3 4 5 6 7 8 DSW1 ON OFF 1 2 3 4 5 6 7 8 DSW1 ON OFF 1 2 3 4 5 6 7 8 DSW1-4 SETTING Off 1 Stop Bit On 2 Stop Bits Parity Selection (DSW1-2, DSW...

Page 2-3 Section 2. Configuration SATO CL408e/CL412e Service Manual PN 9001078Rev. B Dip Switch Settings For more information about the cause of troubleshooting printer errors, see Section 8, Troubleshooting. DSW2 ON OFF 1 2 3 4 5 6 7 8 DSW2 ON OFF 1 2 3 4 5 6 7 8 DSW2 ON OFF 1 2 3 4 5 6 7 8 DSW2 ON...

Page 2-7 Section 2. Configuration SATO CL408e/CL412e Service Manual PN 9001078Rev. B 2.2 Default Settings Dip Switch Selections All switches are placed in the Off position (default) except Receive Buffer for shipping. This will result in the following operating configuration: Communications: (1) 8 d...

Page 2-8 Section 2. Configuration SATO CL408e/CL412e Service Manual PN 9001078 Rev. B 2.3 LCD Panel Configuration The LCD Panel on the CL408e/CL412e is used in conjunction with the LINE and FEED switches by the operator to manually enter printer configuration settings. Many of the settings can also ...

Page 2-9 Section 2. Configuration SATO CL408e/CL412e Service Manual PN 9001078Rev. B LCD Panel — Normal Mode When the printer is first powered on it displays the current ROM version of the printer then immediately displays the ONLINE mode. The LCD Panel will display the ONLINE status on the top line...

Page 2-10 Section 2. Configuration SATO CL408e/CL412e Service Manual PN 9001078 Rev. B There are five Speed settings on the printer. The setting is listed on the bottom line of the display. The current setting is indicated by an underline under one of the speed settings. To change the setting: STEP ...

Page 2-11 Section 2. Configuration SATO CL408e/CL412e Service Manual PN 9001078Rev. B STEP PROCEDURE 4. Press the FEED key to accept the setting and advance the cursor to the second digit. Again use the LINE key to step to the desired setting. Once it is correct, press the FEED key to advance to the...

Page 2-12 Section 2. Configuration SATO CL408e/CL412e Service Manual PN 9001078 Rev. B If the printer has a print job(s) loaded in memory, selecting YES will cause the job(s) to be cleared. The default selection is NO. Make sure that you want to cancel the print job before selecting YES as the job c...

Page 2-13 Section 2. Configuration SATO CL408e/CL412e Service Manual PN 9001078Rev. B STEP PROCEDURE 1. Use the LINE key to step the underlined cursor to either Yes or No. 2. Once the correct setting is underlined, press the FEED key to accept the setting and advance to the Auto Online display. STEP...

Page 2-14 Section 2. Configuration SATO CL408e/CL412e Service Manual PN 9001078 Rev. B Since the printer moves the label in discrete steps equal to the size of the print dot, the units of measure for Vertical and Horizontal Offset distance is dots. Vertical Offset is the distance down from the leadi...

Page 2-15 Section 2. Configuration SATO CL408e/CL412e Service Manual PN 9001078Rev. B STEP PROCEDURE 1. Year - The first display shown will have the two digit year selection underlined. You can scroll through the dates by pressing the LINE key. The year number will increase by one each time the LINE...

Page 2-16 Section 2. Configuration SATO CL408e/CL412e Service Manual PN 9001078 Rev. B character pitch prop fixed STEP PROCEDURE 1. Use the LINE key to step the underlined cursor to the desired setting. 2. Once the desired setting is underlined, press the FEED key to accept the setting and advance t...

Page 2-17 Section 2. Configuration SATO CL408e/CL412e Service Manual PN 9001078Rev. B STEP PROCEDURE 1. Use the LINE key to step the cursor to the desired setting (Card or Memory). 2. Once the desired setting is underlined, press the FEED key to accept the setting and advance the display. The Card M...

Page 2-18 Section 2. Configuration SATO CL408e/CL412e Service Manual PN 9001078 Rev. B STEP PROCEDURE 1. Use the LINE key to step the underlined cursor to the desired setting. IF Yes is selected, the printer will enter the Card Copy mode. If No is selected, the display will advance to Card to Memory...

Page 2-24 Section 2. Configuration SATO CL408e/CL412e Service Manual PN 9001078 Rev. B STEP PROCEDURE 1. Use the LINE key to step the underlined cursor to the desired setting. IF Yes is selected, the printer will enter the Memory Format mode. If No is selected, the display will advance to the mode d...

Page 2-25 Section 2. Configuration SATO CL408e/CL412e Service Manual PN 9001078Rev. B STEP PROCEDURE 1. Press the LINE key while simultaneously turning the power on. When the printer emits one long beep, release the LINE key to display the first screen. 2. Press the LINE key twice to enter the Servi...

Page 2-26 Section 2. Configuration SATO CL408e/CL412e Service Manual PN 9001078 Rev. B LCD Panel — Service Mode GAP - When setting the "GAP" threshold, the voltage shown on the top line of the display must be measured with nothing but the backing in the sensor and then again with a label sti...

Page 2-27 Section 2. Configuration SATO CL408e/CL412e Service Manual PN 9001078Rev. B EYE - When setting the "EYE" threshold, the voltage must be measured with nothing but the label under the sensor and then again with the printed "eye" mark under the sensor. The formula to be used f...

Page 2-28 Section 2. Configuration SATO CL408e/CL412e Service Manual PN 9001078 Rev. B This selection specifies whether or not the printer will automatically feed a blank label when it is placed in the Online mode. Auto online feed yes no LCD Panel — Service Mode STEP PROCEDURE 1. Use the LINE key t...

Page 2-29 Section 2. Configuration SATO CL408e/CL412e Service Manual PN 9001078Rev. B This display will only appear when Backfeed is enabled (DSW3-4 = OFF). The maximum backfeed distance is 255mm. Forward/BackfeedDistance Default STEP PROCEDURE 1. Press the FEED key to use the default distance. This...

Page 2-30 Section 2. Configuration SATO CL408e/CL412e Service Manual PN 9001078 Rev. B This selection allows the user to select the language used in the LCD menu and error messages. The selections are English, French, German, Spanish, Italian and Portuguese. Select LCD DisplayLanguage STEP PROCEDURE...

Page 2-31 Section 2. Configuration SATO CL408e/CL412e Service Manual PN 9001078Rev. B LCD Panel — Service Mode This selection allows the user to assign a priority for Print Darkness, Print Speed and Print Offset. Priority SettingLCD Command STEP PROCEDURE 1. Use the LINE key to step to the desired p...

Page 2-32 Section 2. Configuration SATO CL408e/CL412e Service Manual PN 9001078 Rev. B STEP PROCEDURE 1. Use the LINE key to step the underlined cursor to the desired counter, the Head (HD) counter or the LIFE counter. The default position is the Head Counter. 2. Press the FEED key to display the cu...

Page 2-33 Section 2. Configuration SATO CL408e/CL412e Service Manual PN 9001078Rev. B STEP PROCEDURE 4. Use the FEED key to select the desired setting. If you only want to read the counter value, select NO. If you want to read the counter and reset it to 0.0, place the underline cursor under YES. On...

Page 2-34 Section 2. Configuration SATO CL408e/CL412e Service Manual PN 9001078 Rev. A LCD Panel — Test Print Mode Once you have selected the type of test label to be printed, use the FEED key to accept the selection and the display advances to the Test Print Size display. This display allows you to...

Page 2-35 Section 2. Configuration SATO CL408e/CL412e Service Manual PN 9001078Rev. B LCD Panel — Maintenance Mode — Factory Mode STEP PROCEDURE 1. Record all current dip switch positions, then place all switches in the OFF position. 2. Place the DSW2-4 in the ON or up position. 3. Press the LINE an...

Page 2-36 Section 2. Configuration SATO CL408e/CL412e Service Manual PN 9001078 Rev. B STEP PROCEDURE 1. Record all current dip switch positions, then place all switches in the OFF position. 2. Place the DSW2-4 in the ON or up position. 3. Press the LINE and FEED key while simultaneously turning ON ...

Page 2-37 Section 2. Configuration SATO CL408e/CL412e Service Manual PN 9001078Rev. B LCD Panel — Clear Non-Standard Protocol To Clear Non-Standard protocol codes, place DSW2-7 in the ON position and power on the printer while simultaneously pressing the LINE and FEED keys. Alt. ProtocolDefault Comp...

Page 2-38 Section 2. Configuration SATO CL408e/CL412e Service Manual PN 9001078 Rev. B (Countinued) STEP PROCEDURE 3. Transmit the download data command stream to the printer. 4. After the data has been received, the printer will beep and print a status label. If it does not beep and print a status ...

Page 2-39 Section 2. Configuration SATO CL408e/CL412e Service Manual PN 9001078Rev. B LCD Panel —Firmware Download Mode STEP PROCEDURE 1. Record all current dip switch positions, then place all switches in the OFF position. 2. Place the DSW2-6 in the ON or up position. 3. Turn ON the power switch. T...

Page 2-40 Section 2. Configuration SATO CL408e/CL412e Service Manual PN 9001078 Rev. B 2.4 Sample Test Labels CONFIGURATION BAR CODE MEMORY HEAD CHECK FACTORY

Page 3-1 SATO CL408e/CL412e Service Manual PN 9001078Rev. B Interface Specifications 3.1 Overview ! Section The parallel interface for CL408e/CL412e printers is a high speed, bi-directional parallel interface that conforms to the IEEE 1284 specification. (ECP mode on some computers). The interface i...

Page 3-2 Section 3. Interface Specifications SATO CL408e/CL412e Service Manual PN 9001078 Rev. B Interface Types In order to provide flexibility in communicating with a variety of host computer systems, CL408e/412e printers use a Plug-In Interface Module. The IEEE1284 Interface module is shipped wit...

Page 3-3 Section 3. Interface Specifications SATO CL408e/CL412e Service Manual PN 9001078Rev. B 3.3 The Receive Buffer The CL408e/CL412e printers have the ability to receive a data stream from the host in one of two ways. The receive buffer may be configured to accept one print job at a time or mult...

Page 3-4 Section 3. Interface Specifications SATO CL408e/CL412e Service Manual PN 9001078 Rev. B 3.4 IEEE 1284 Parallel Interface The parallel interface for the CL408e/CL412e printers is a Plug-In Interface Module that can be installed by the user. It conforms to the IEEE 1284 specification. It will...

Page 3-5 Section 3. Interface Specifications SATO CL408e/CL412e Service Manual PN 9001078Rev. B IEEE 1284 Parallel Interface PIN ASSIGNMENTS - IEEE 1284 CABLE END 18 1 36 19 N I P L A N G I S N O I T C E R I D N I P L A N G I S N O I T C E R I D 1 E B O R T S r e t n i r P o T 9 1 E B O R T S n r u ...

Page 3-6 Section 3. Interface Specifications SATO CL408e/CL412e Service Manual PN 9001078 Rev. B 3.5 RS232C Serial Interface The High Speed Serial Interface is a Plug-In Interface Module that can be installed in the printer by the user. General Specifications: Asynchronous ASCII Half-duplex communic...

Page 3-7 Section 3. Interface Specifications SATO CL408e/CL412e Service Manual PN 9001078Rev. B 9 B D 5 2 B D T S O H N O I T C E N N O C R E T N I 5 2 B D R E T N I R P 1 1 G F 1 ) d n u o r G e m a r F ( G F 2 3 D R 2 ) a t a D t i m s n a r T ( D T 3 2 D T 3 ) a t a D e v i e c e R ( D R 8 5 S T ...

Page 3-8 Section 3. Interface Specifications SATO CL408e/CL412e Service Manual PN 9001078 Rev. B RS232C Interface Signals Ready/Busy Flow Control Ready/Busy is the hardware flow control for the serial interface on the CL408e/CL412e printers. By raising/lowering the voltage level on Pin 20 of the RS2...

Page 3-9 Section 3. Interface Specifications SATO CL408e/CL412e Service Manual PN 9001078Rev. B X-On/X-Off Flow Control X-On/X-Off flow control must be used whenever hardware (Ready/Busy) flow control is not available or desirable. Instead of a voltage going high/low at pin 20, control characters re...

Page 3-10 Section 3. Interface Specifications SATO CL408e/CL412e Service Manual PN 9001078 Rev. B 3.7 Ethernet Interface The Ethernet interface is a Plug-In Interface Module that can be installed by the user. It requires a driver (shipped with each printer) that has the interface installed. The driv...

Page 3-11 Section 3. Interface Specifications SATO CL408e/CL412e Service Manual PN 9001078Rev. B The EXT connector on the rear panel of the CL408e/CL412e printers is intended for use with external printer accessories such as label rewinders or applicators. The 14 pin Centronics type connector provid...

Page 3-12 Section 3. Interface Specifications SATO CL408e/CL412e Service Manual PN 9001078 Rev. B NOTE: The signals on pins 1, 3, 4, 6, 9 and 10 each have an open collector output. These pins normally measure +.07V maximum when a true condition exists. If a false condition occurs, the voltage will d...

Page 3-13 Section 3. Interface Specifications SATO CL408e/CL412e Service Manual PN 9001078Rev. B Repeat Print Print End Type 3 Print End Type 4 Start of Print Cycle End of Print Cycle Print Start Input Print Repeat Input +5V 0V +5V 0V Print End Type 1 Print End Type 2 +5V 0V +5V 0V 20 Milliseconds +...

Page 4-1 SATO CL408e/CL412e Service Manual PN 9001078Rev. B " Section Electrical Checks and Adjustments 4.1 Overview This chapter describes how to check CL408e/CL412e Printers voltage levels and adjust threshold sensor voltages. The power supply converts 125 VAC into regulated DC voltages. The p...

Page 4-2 Section 4. Electric Checks and Adjustments SATO CL408e/CL412e Service Manual PN 9001078 Rev. B 4.2 Steps Prior to Some Procedures Some adjustments in this section require access to potentiometers and the test point connector located on the main PCB. Raise the door and remove the LH cover fo...

Page 4-3 Section 4. Electric Checks and Adjustments SATO CL408e/CL412e Service Manual PN 9001078Rev. B 4.3 DC Power Voltage Checks To check voltage levels, first check the fuses (Section 6.3) and replace if necessary. Then remove the LH cover, (Section 4.2) and perform the following steps. Addtional...

Page 4-4 Section 4. Electric Checks and Adjustments SATO CL408e/CL412e Service Manual PN 9001078 Rev. B DC Power Voltage Checks TP TEST MODULE MAIN PCB TP TEST MODULE TO PCB TEST POINT @ CN13 TP TEST MODULE CONNECTOR CONNECTOR RECEPTACLE ON PCB @ CN13 CORRECT POSITION OF NIBS ON CONNECTOR 1234567890...

Page 4-6 Section 4. Electric Checks and Adjustments SATO CL408e/CL412e Service Manual PN 9001078 Rev. B 4.4 Potentiometer Assignments & Adjustments t s u j d A o t R V M E T I L A I D N O I T I S O P V 5 0 V 4 2 3 1 R V T E S F F O H C T I P 4 R V P A G 5 5 R V K R A M - E Y E 4 2 R V d e s U t ...

Page 4-7 Section 4. Electric Checks and Adjustments SATO CL408e/CL412e Service Manual PN 9001078Rev. B MAIN PCB VR1 OFS INTERFACE BOARD POWER SUPPLY VR4 GAP VR5 IM CN13 TEST POINTCONNECTOR VR2 DEM VR3 CE Potentiometer Assignments & Adjustments

Page 4-8 Section 4. Electric Checks and Adjustments SATO CL408e/CL412e Service Manual PN 9001078 Rev. B 4.5a Print Position Adjustment Print Position is adjusted with the Pitch potentiometer on the Front Panel or VR1 potentiometer on the main PCB board to change print position. The following instruc...

Page 4-9 Section 4. Electric Checks and Adjustments SATO CL408e/CL412e Service Manual PN 9001078Rev. B 4.5b Print Position Adjustment Using the VR1 potentiometer on the main PCB board. STEP PROCEDURE Refer to Section 4.2 for access to main PCB 1.Record all current dip switch positions, then place al...

Page 4-10 Section 4. Electric Checks and Adjustments SATO CL408e/CL412e Service Manual PN 9001078 Rev. B 4.6 Label Gap Adjustment Additional equipment required: TP Test Module Digital Multimeter STEP PROCEDURE Refer to Section 4.2 for access to main PCB 1.Turn VR4 (GAP) potentiometer on the main PCB...

Page 4-12 Section 4. Electric Checks and Adjustments SATO CL408e/CL412e Service Manual PN 9001078 Rev. B 4.8 Offset Label Stop Position Adjustment The Label Stop Position is adjusted with the Offset potentiometer on the Front Panel. STEP PROCEDURE 1.Open the Front Door for access to Offset-VR.2.Turn...

Page 4-13 Section 4. Electric Checks and Adjustments SATO CL408e/CL412e Service Manual PN 9001078Rev. B 4.9a Ribbon Sensor Operation Verification 1.Open the Front Door for access to DIP Switches.2.Record all dip switch positions, then place DSW2-1 in the OFF position and the power switch OFF . 3.Rem...

Page 4-14 Section 4. Electric Checks and Adjustments SATO CL408e/CL412e Service Manual PN 9001078 Rev. B 4.9b Ribbon Sensor Voltage Checking There is no adjustment POT for the ribbon sensor on the CL408e/412e. The CE POT on the main logic board has no effect on the voltage values. The voltage values...

Page 4-15 Section 4. Electric Checks and Adjustments SATO CL408e/CL412e Service Manual PN 9001078Rev. B Ribbon Sensor Voltage Checking ATTACH THE GROUND (BLACK) PROBE FROM THE MULTIMETER TO PIN 4 (GROUND) AND THE SIGNAL (WHITE) PROBE TO PIN 3 TO CHECK VOLTAGE RANGE FORRIBBON SENSOR, ROTATE CARBONUNW...

Page 4-16 Section 4. Electric Checks and Adjustments SATO CL408e/CL412e Service Manual PN 9001078 Rev. B 4.10 Print Darkness Adjustment 1.Open the Front Door for access to Pitch Potentiometer.2.Turn the power switch ON . 3.Send print data from your PC and confirm the result.4.Adjust the Pitch Potent...

Page 5-1 SATO CL408e/CL412e Service Manual PN 9001078Rev. B # Section Mechanical Adjustments 5.1 Overview The SATO CL408e/CL412e contain adjustable sub-assemblies. This means that during your regular maintenance, your service technicians are able to make adjustments to reset the printer to factory s...

Page 5-2 Section 5. Mechanical Adjustments SATO CL408e/CL412e Service Manual PN 9001078 Rev. B 5.2 Ribbon Clutch Adjustments Excessive ribbon and rewind tension will result in variable ribbon motion and could be the cause of print quality problems.Follow the procedures 5.2.1 and 5.2.2 to verify that...

Page 5-3 Section 5. Mechanical Adjustments SATO CL408e/CL412e Service Manual PN 9001078Rev. A RIBBON UNWIND SPINDLE ADJUST NUT LOCKING SCREW IS INSIDE ADJUST NUT 950-1050gREWIND EMPTY RIBBON CORE UNWIND CLUTCH Fig. 5-3 Fig. 5-2 450-550gUNWIND TENSION GAUGE TENSION GAUGE STRING Ribbon Clutch Adjustme...

Page 5-5 Section 5. Mechanical Adjustments SATO CL408e/CL412e Service Manual PN 9001078Rev. B 5.3 Ribbon Guide Plate Adjustment If the ribbon is not smooth across the guide plate (ribbon wrinkle) adjustment is required. To remedy the problem perform the Print Head Balance Adjustment (Section 5.6) be...

Page 5-6 Section 5. Mechanical Adjustments SATO CL408e/CL412e Service Manual PN 9001078 Rev. B 5.4 Tear Plate Adjustment STEP PROCEDURE 1. Loosen the Tear Plate mounting screws and position plate so that the lip is parallel to the bottom of the printer assembly. Figs. 5-5 2. Tighten the mounting scr...

Page 5-7 Section 5. Mechanical Adjustments SATO CL408e/CL412e Service Manual PN 9001078Rev. B 5.5 Print Head Position Alignment STEP PROCEDURE 1. Loosen the center and right screw on the ribbon adjustment plate. Print a user test pattern (Section 8.9). Realign the right side of print head by prying ...

Page 5-8 Section 5. Mechanical Adjustments SATO CL408e/CL412e Service Manual PN 9001078 Rev. B 5.6 Print Head Balance Adjustment STEP PROCEDURE 1. Load the ribbon and label stock into the printer. 2. Hold eccentric nut along flats with 10mm box wrench and loosen holding screw. Fig. 5-7 3. Adjust ecc...

Page 5-9 Section 5. Mechanical Adjustments SATO CL408e/CL412e Service Manual PN 9001078Rev. B 5.7 Print Head Alignment Adjustment STEP PROCEDURE 1. Load the ribbon and label stock into the printer. 2. Loosen and adjust screw along slot to move indexing pointer for maximum print quality. Fig. 5-8 To ...

Page 5-10 Section 5. Mechanical Adjustments SATO CL408e/CL412e Service Manual PN 9001078 Rev. B 5.8 Timing Belt Tension Adjustment STEP PROCEDURE 1. Press in the center of each timing belt with the tension gauge and note the tension reading when the belt is moved 1 to 2mm. 2. If the tension reading ...

Page 6-1 SATO CL408e/CL412e Service Manual PN 9001078Rev. B Replacement Procedures 6.1 Overview $ Section SATO CL408e/CL412e Printers contain replaceable components and sub- assemblies. This section contains step-by-step instructions for removing and replacing the following components and sub-assemb...

Page 6-2 Section 6. Replacement Procedures SATO CL408e/CL412e Service Manual PN 9001078 Rev. B The Main Circuit Board contains the control electronics for the printers and is located behind L.H. cover of the printer. The I/O PCB interface and optional memory card unit if installed, which are attache...

Page 6-3 Section 6. Replacement Procedures SATO CL408e/CL412e Service Manual PN 9001078Rev. B STEP PROCEDURE 4. If an interface card is installed remove (2) screws holding the card to the rear cover and pull away to detach the card from the PCB Board. Figs. 6-2 5. Remove (2) screws holding EXT Conne...

Page 6-4 Section 6. Replacement Procedures SATO CL408e/CL412e Service Manual PN 9001078 Rev. B Replacing the Main Circuit Board REMOVE (2) SCREWS AND PULLAWAY TO DETACH IF INTERFACECARD IS INSTALLED REMOVE (2) SCREWSHOLDING EXT CONNECTORTO CABINET DISCONNECT CABLE DISCONNECT CABLES DISCONNECTCABLES ...

Page 6-7 Section 6. Replacement Procedures SATO CL408e/CL412e Service Manual PN 9001078Rev. B 6.3 Replacing the Fuses Fuse replacement is described in the following section. · 6.3.1 Removing and Replacing the Main Power Fuse · 6.3.2 Removing and Replacing the Internal Fuse 6.3.1 Removing and Replaci...

Page 6-8 Section 6. Replacement Procedures SATO CL408e/CL412e Service Manual PN 9001078 Rev. B Replacing the Fuses 6.3.2 Removing and Replacing the Internal Fuse(s) Required: T3.15A, 250V Fuse or T1 Amp 250V Fuse To remove and replace these fuse(s) do the following: STEP PROCEDURE 1. Switch the prin...

Page 6-9 Section 6. Replacement Procedures SATO CL408e/CL412e Service Manual PN 9001078Rev. B 6.4 Replacing the Power Supply The Power Supply is a non-repairable component with no service parts and is replaced as a complete assembly. STEP PROCEDURE 1. Switch the printer OFF and disconnect the power ...

Page 6-10 Section 6. Replacement Procedures SATO CL408e/CL412e Service Manual PN 9001078 Rev. B Replacing the Power Supply REMOVE (2) SCREWS POWERSUPPLY Figs. 6-9 REMOVESCREW POWERSUPPLY DETACH CONNECTORS

Page 6-11 Section 6. Replacement Procedures SATO CL408e/CL412e Service Manual PN 9001078Rev. B 6.5 Replacing the Stepper Motor The stepper motor is used to transmit motion to the print mechanism for precise print positioning. The stepper motor transmits torque to the label feed roller, the platen ro...

Page 6-12 Section 6. Replacement Procedures SATO CL408e/CL412e Service Manual PN 9001078 Rev. B 6-6 Replacing the Timing Belts Timing Belt "A" is used to transmit torque from the stepper motor to the platen pulley via a set of toothed pulleys.Timing Belt "B" is used to transmit torqu...

Page 6-13 Section 6. Replacement Procedures SATO CL408e/CL412e Service Manual PN 9001078Rev. B Replacing the Timing Belts CENTER SCREW REWIND SPINDLE SPRING LOADED IDLER BELT "A" BELT "B" MOTOR TO FRONT PLATEN GEAR BELT "B" BELT "A" SLIDE BELT FROM PULLEY WHILE PULLIN...

Page 6-14 Section 6. Replacement Procedures SATO CL408e/CL412e Service Manual PN 9001078 Rev. B 6.7 Replacing the Print Head If the print head becomes damaged, it can be easily removed and replaced. No critical adjustments are required. Before you replace the print head, check the head counter value...

Page 6-15 Section 6. Replacement Procedures SATO CL408e/CL412e Service Manual PN 9001078Rev. B Replacing the Print Head Fig. 6-14 RAISE THE TOP ACCESS DOOR CLOSE THE HEAD LATCH LEVER OPEN THE FRONT ACCESS DOOR REMOVE (2) SCREWS TO DETACH RIBBON GUIDE PLATE Fig. 6-15 REMOVE CENTER SCREW Fig. 6-16

Page 6-17 Section 6. Replacement Procedures SATO CL408e/CL412e Service Manual PN 9001078Rev. B 6.8 Replacing the Platen Before removing and replacing the platen, timing belts A & B must first be removed from pulleys, but do not need to be fully removed from the carbon rewind shaft gear. STEP PRO...

Page 6-18 Section 6. Replacement Procedures SATO CL408e/CL412e Service Manual PN 9001078 Rev. B Replacing the Platen Fig. 6-19 TIMING BELTS Fig. 6-20 MOTOR MOUNTING SCREWS REMOVE "E" RING PLATEN CLAMP PLATEN & COMPONENTS PLATEN SHAFT SCREW BUSHING FLATS SIDE FRAME Fig. 6-21 Fig. 6-22 (CL...

Page 6-19 Section 6. Replacement Procedures SATO CL408e/CL412e Service Manual PN 9001078Rev. B 6.9 Replacing the Ribbon Drive Clutch Washers Both the ribbon unwind and the rewind drive spindles incorporate a friction clutch assembly to control tension. The friction washers within these clutch assemb...

Page 6-20 Section 6. Replacement Procedures SATO CL408e/CL412e Service Manual PN 9001078 Rev. B Replacing the Ribbon Drive Clutch Washers 2 1 3 4 5 7 8 9 6 10 11 A 9 A 9 B 10 11 USE 12mm OPEN END WRENCH AND PHILLIPS SCREW DRIVER TO REMOVE LOCKING SCREW AND ADJUSTMENT NUT REMOVE & INSTALL PARTS I...

Page 6-23 Section 6. Replacement Procedures SATO CL408e/CL412e Service Manual PN 9001078Rev. B 6.10 Replacing the Ribbon Motion Sensor The Ribbon Motion Sensor is easily replaced for service. STEP PROCEDURE 1. Switch the printer OFF and disconnect the power cable. 2. Raise the access door and remove...

Page 6-24 Section 6. Replacement Procedures SATO CL408e/CL412e Service Manual PN 9001078 Rev. B 6.11 Replacing the Label Sensor The Label Sensor can be removed from the printer to clear label fragments and for service. No critial alignment is required when replacing the sensor. STEP PROCEDURE 1. Swi...

Page 6-25 Section 6. Replacement Procedures SATO CL408e/CL412e Service Manual PN 9001078Rev. B Replacing the Label Sensor CUT TIE WRAP Fig. 6-31 SLIDE CABLE THROUGH HOLE IN CENTER FRAME LABEL SENSOR ASSEMBLY Fig. 6-32 LABEL SENSOR WITH PAPER GUIDE SHOWN INSTALLED IN PRINTER PAPER GUIDE

Page 6-26 Section 6. Replacement Procedures SATO CL408e/CL412e Service Manual PN 9001078 Rev. B 6.12 Replacing the Label Sensor Module After removing the Label Sensor Assembly from the printer, if the sensor module needs to be replaced, do the following: STEP PROCEDURE 1. Detach the paper guide from...

Page 6-27 Section 6. Replacement Procedures SATO CL408e/CL412e Service Manual PN 9001078Rev. B 6.13 Replacing the Head Open Switch The Head Open Switch is easily replaced for service. STEP PROCEDURE 1. Switch the printer OFF and disconnect the power cable. 2. Raise the access door and remove (2) scr...

Page 6-28 Section 6. Replacement Procedures SATO CL408e/CL412e Service Manual PN 9001078 Rev. B 6.14 Replacing the Display Panel PCB The Display Panel PCB is mounted inside the printer. STEP PROCEDURE 1. Switch the printer OFF and disconnect the power cable. 2. Raise the access door and remove (2) s...

Page 7-1 SATO CL408e/CL412e Service Manual PN 9001078Rev. B % Section Factory Resets 7.1 Overview The Factory Reset Mode allows you to: • Factory Settings/Test Print • Clear Head Counters • Clear Dispenser Counter • Clear Cutter Counter • Clear EEPROM

Page 7-3 Section 7. Factory Resets SATO CL408e/CL412e Service Manual PN 9001078Rev. B 7.3 Clear Head Counters STEP PROCEDURE 1. Record all current dip switch positions, then place all switches in the OFF position. 2. Place the DSW2-4 in the ON or up postion. 3. Press the LINE and FEED key while simu...

Page 7-4 Section 7. Factory Resets SATO CL408e/CL412e Service Manual PN 9001078 Rev. B 7.4 Clear Dispenser Counter STEP PROCEDURE 1. Record all current dip switch positions, then place all switches in the OFF position. 2. Place the DSW2-4 in the ON or up postion. 3. Press the LINE and FEED key while...

Page 7-5 Section 7. Factory Resets SATO CL408e/CL412e Service Manual PN 9001078Rev. B 7.5 Clear Cutter Counter STEP PROCEDURE 1. Record all current dip switch positions, then place all switches in the OFF position. 2. Place the DSW2-4 in the ON or up postion. 3. Press the LINE and FEED key while sim...

Page 7-7 Section 7. Factory Resets SATO CL408e/CL412e Service Manual PN 9001078Rev. B 7.7 Sample Test Prints LARGE TEST PRINT SMALL TEST PRINT ILLUSTRATIONS SHOWN ARE EXAMPLES ONLYAND MAY NOT EXACTLY MATCH YOUR OUTPUT

Page 8-1 SATO CL408e/CL412e Service Manual PN 9001078Rev. B Troubleshooting 8.1 Overview This section has been devised to help you if you are unable to produce output on the CL408e/CL412e printers. Use this section to make sure the basics have been checked before deciding you are unable to proceed f...

Page 8-2 Section 8. Troubleshooting SATO CL408e/CL412e Service Manual PN 9001078 Rev. B 8.2 Initial Check List If you are unable to produce output on your printer, check the following before deciding you're unable to proceed any further.1. Is the printer powered up and ON-LINE?2. Is the ERROR light ...

Page 8-5 Section 8. Troubleshooting SATO CL408e/CL412e Service Manual PN 9001078Rev. B 8.6 Lan Ethernet Interface Installation Problems (Printer Does Not Come Up Ready) If you cannot print to the SATO enhanced ethernet adapter after you install it, check the following: 1. Make sure that the printer ...

Page 8-6 Section 8. Troubleshooting SATO CL408e/CL412e Service Manual PN 9001078 Rev. B 4. If the job exits the queue but does not print, make sure that you have the correct driver installed. If you do, turn DSW2-4 on and cycle power. Try resending your print job. If something prints out at this poi...

Page 8-7 Section 8. Troubleshooting SATO CL408e/CL412e Service Manual PN 9001078Rev. B 5. Also verify that the host computer and the print server are either on the same subnet (for example, if the print server has a subnet mask of 255.255.255.0, the host must have the same subnet mask) or that the r...

Page 8-8 Section 8. Troubleshooting SATO CL408e/CL412e Service Manual PN 9001078 Rev. B 1. If you cannot create a print queue, make sure that you have sufficient NetWare privileges. With NetWare 3.12 and earlier, you MUST be logged in as SUPERVISOR (not someone with Supervisor privileges). If you ar...

Page 8-9 Section 8. Troubleshooting SATO CL408e/CL412e Service Manual PN 9001078Rev. B W indows NT/LAN Server Troubleshooting 2. Make sure that TCP/IP and lpr printing are installed and running on the Windows NT system or the LAN Server file server. 3. If you are having problems printing to the SATO...

Page 8-11 Section 8. Troubleshooting SATO CL408e/CL412e Service Manual PN 9001078Rev. B 8.8 Troubleshooting Tables The troubleshooting table below includes the following general symptoms descriptions: Print Quality Problems • Image Voids • No Ribbon Movement • POWER LED not on • Ribbon Wrinkle • No ...

Page 8-15 Section 8. Troubleshooting SATO CL408e/CL412e Service Manual PN 9001078Rev. B 8.9 Head Pattern Examples FEED DIRECTION FACTORY DEFAULT GOOD ADJUSTMENT CLEAR, DARK, EVEN TEXT IRREGULAR UNEVEN TEXT POOR HEAD ALIGNMENT, BALANCE OUT OF ADJUSTMENT POOR HEAD ALIGNMENT, BALANCE OUT OF ADJUSTMENT ...

Page 8-16 Section 8. Troubleshooting SATO CL408e/CL412e Service Manual PN 9001078 Rev. B Head Pattern Examples DIAGONAL VOIDS (WHITE STREAKS) THAT “WALK” ACROSS LABEL RIBBON WRINKLE POOR HEAD ALIGNMENT, POOR RIBBON TENSION, WORN PLATEN, FOREIGN MATERIAL, DAMAGED PRINT HEAD IMPROPER ALIGNMENT BOTTOM ...

Page 8-17 Section 8. Troubleshooting SATO CL408e/CL412e Service Manual PN 9001078Rev. B 8.10 Hex Dump Diagnostic Labels STEP PROCEDURE 1. Turn on the printer. 2. Send and print a label. 3. Place the printer in the Off-Line mode by pressing the LINE key. The LINE LED should go out. 4. Place DSW2-4 in...

Page 9-1 SATO CL408e/CL412e Service Manual PN 9001078Rev. B Optional Accessories 9.1 Overview ' Section This section contains instructions for installing the following optional accessories: · Label Cutter Kit · Label Dispenser Kit · PCMCIA Memory Expansion · Flash Memory Expansion · Real Time Clock

Page 9-2 Section 9. Optional Accessories SATO CL408e/CL412e Service Manual PN 9001078 Rev. B 9.2 Label Cutter Kit Installation - Guillotine Type LABEL CUTTER KIT MOUNTING BRACKET (2) SELF TAPPING SCREWS LABEL CUTTER ASSEMBLY (2) PAN HEAD SCREWS STEP PROCEDURE 1. Switch the printer OFF but keep the p...

Page 9-3 Section 9. Optional Accessories SATO CL408e/CL412e Service Manual PN 9001078Rev. B REMOVE FRONT DOOR FROM CL-408/412e PRINTER Label Cutter Kit Installation - Guillotine Type STEP PROCEDURE 7. Remove the connector cover (located under the DSW2 and DSW3 switches) and install the interface cab...

Page 9-6 Section 9. Optional Accessories SATO CL408e/CL412e Service Manual PN 9001078 Rev. B 9.3 Label Dispenser Installation LABEL DISPENSER KIT Installation of the optional Label dispenser into the printer adds the convenience of automatic label dispensing. Each label is printed, then peeled from ...

Page 9-7 Section 9. Optional Accessories SATO CL408e/CL412e Service Manual PN 9001078Rev. B RH COVER LH COVER FRONT DOOR STEP PROCEDURE 1. Switch the printer OFF but keep the power cable plugged in to discharge any possible static charges. 2. Raise the RH cover uncovering the mechanical section. Loo...

Page 9-12 Section 9. Optional Accessories SATO CL408e/CL412e Service Manual PN 9001078 Rev. B STEP PROCEDURE 10. Detach the existing Tension Plate by removing (2) screws. Discard the screws. Fig. 9-21 11. Position the Tension Plate over the Peel Bar as shown in Fig. 9-20 & 9-22. 12. Attach these...

Page 9-16 Section 9. Optional Accessories SATO CL408e/CL412e Service Manual PN 9001078 Rev. B 9.4 PCMCIA Memory Expansion Installation The Memory PCB Board provides the interface board for (1) PCMCIA memory card slot. MEMORY PCB BOARD STANDOFFS SHOWN AS RECEIVED. STANDOFFS WILL BE REMOVED AND USED T...

Page 9-17 Section 9. Optional Accessories SATO CL408e/CL412e Service Manual PN 9001078Rev. B PCMCIA Memory Expansion Installation RAISE THE TOP ACCESS DOOR AND REMOVE (2) SCREWS HOLDING THE SIDE COVER TO THE FRAME REMOVE (2) SCREWS HOLDING THE SIDE COVER TO THE OUTSIDE FRAME STEP PROCEDURE 1. Turn t...

Page 9-18 Section 9. Optional Accessories SATO CL408e/CL412e Service Manual PN 9001078 Rev. B PCMCIA Memory Expansion Installation STEP PROCEDURE 4. If an interface card is installed remove (2) screws holding the card to the rear cover and pull away to detach the card from the PCB Board. Figs. 9-32 ...

Page 9-21 Section 9. Optional Accessories SATO CL408e/CL412e Service Manual PN 9001078Rev. B PCMCIA Memory Expansion Installation REMOVE (2) SCREWS AND WASHERS FROM THIS END OF STANDOFFS (STEP 2) REMOVE (2) SCREWS, NUTS AND STANDOFFS. THIS HARDWARE WILL BE MOUNTED ON THE MAIN PCB BOARD (STEP 1) HOLE...

Page 9-23 Section 9. Optional Accessories SATO CL408e/CL412e Service Manual PN 9001078Rev. B 9.5 Flash Memory Expansion Installation RAISE THE TOP ACCESS DOOR AND REMOVE (2) SCREWS HOLDING THE SIDE COVER TO THE FRAME REMOVE (2) SCREWS HOLDING THE SIDE COVER TO THE OUTSIDE FRAME STEP PROCEDURE 1. Tur...

Page 9-24 Section 9. Optional Accessories SATO CL408e/CL412e Service Manual PN 9001078 Rev. B Flash Memory Expansion Installation STEP PROCEDURE 4. Carefully press outward on the tabs on both ends of the Main PCB Board Memory Frame to release the Standard Memory PCB. The Standard Memory PCB should l...

Page 9-26 Section 9. Optional Accessories SATO CL408e/CL412e Service Manual PN 9001078 Rev. B The Real Time Clock Chip allows the date and time to be maintained in the local printer rather than using the system clock. It consists of a special clock chip that replaces the EEPROM chip on the main PCB....

Page 9-27 Section 9. Optional Accessories SATO CL408e/CL412e Service Manual PN 9001078Rev.B Real Time Clock Installation STEP PROCEDURE 1. Refer to Figs. 9-42 Remove the EEPROM chip. CAUTION: Using a screwdriver to remove EEPROM may cause damage to the PCB. Be sure to have Prom remover under EEPROM ...

Page 9-28 Section 9. Optional Accessories SATO CL408e/CL412e Service Manual PN 9001078 Rev. B Real Time Clock Installation MAIN PCB BOARD REMOVE THE EEPROM CHIP MARK ON CHIP IDENTIFIESPIN 1. BE SURE TO ALIGNCHIP CORRECTLY IN CHIPBLOCK SOCKET USING THE“U” SHAPED NOTCH ASREFERENCE INSTALL THE TIMEKEEP...

Page 9-29 Section 9. Optional Accessories SATO CL408e/CL412e Service Manual PN 9001078Rev. B Factory Reset Procedure STEP PROCEDURE 1. Record all current dip switch positions, then place all switches in the OFF position. 2. Place the DSW2-4 in the ON or up postion. 3. Press the LINE and FEED key whi...

Page 9-30 Section 9. Optional Accessories SATO CL408e/CL412e Service Manual PN 9001078 Rev. B STEP PROCEDURE Press the LINE key while simultaneously turning the power on. When the printer emits one long beep, release the LINE key to display the first screen. Press the FEED key 11 times to display th...

Page 10-1 SATO CL408e/CL412e Service Manual PN 9001078Rev. B Spare Parts List 10.1 Overview Section The following parts lists are included for the CL408e/CL412e Printers: · Frame Assembly · Print Head Assembly · Ribbon Assembly · Base Cover Assembly · Main PCB Assembly · Interface Options · PCMCIA M...

Page 10-2 Section 10. Parts List SATO CL408e/CL412e Service Manual PN 9001078 Rev. B 10.2 Frame Assembly

Page 10-3 Section 10. Parts List SATO CL408e/CL412e Service Manual PN 9001078Rev. B Frame Assembly . O N M E T I E D O C N O I T P I R C S E D Y T Q 1 0 0 7 2 7 7 1 A P E M A R F E N I G N E 1 2 1 2 6 0 0 3 4 D M W E R C S D A E H N A P 3 3 1 2 0 1 0 4 3 D M W E R C S D A E H N A P 2 4 0 0 8 2 7 7 1...

Page 10-5 Section 10. Parts List SATO CL408e/CL412e Service Manual PN 9001078Rev. B 10.3 Print Head Assembly

Page 10-6 Section 10. Parts List SATO CL408e/CL412e Service Manual PN 9001078 Rev. B Print Head Assembly

Page 10-9 Section 10. Parts List SATO CL408e/CL412e Service Manual PN 9001078Rev. B 10.4 Ribbon Assembly

Page 10-10 Section 10. Parts List SATO CL408e/CL412e Service Manual PN 9001078 Rev. B Ribbon Assembly

Page 10-13 Section 10. Parts List SATO CL408e/CL412e Service Manual PN 9001078Rev. B 10.5 Base Cover Assembly

Page 10-14 Section 10. Parts List SATO CL408e/CL412e Service Manual PN 9001078 Rev. B Base Cover Assembly

Page 10-20 Section 10. Parts List SATO CL408e/CL412e Service Manual PN 9001078 Rev. B 10.6 Main PCB Assembly . O N M E T I E D O C N O I T P I R C S E D Y T Q 1 0 0 2 1 7 7 1 J R A B C P N I A M 1 3 0 0 2 0 7 7 7 J R B C P Y R O M E M 1 4 0 0 1 0 3 7 9 C P G N I R P S 1 5 0 0 0 0 8 6 9 C P G N I R P...

Page 10-21 Section 10. Parts List SATO CL408e/CL412e Service Manual PN 9001078Rev. B 10.7 Interface Options . O N M E T I E D O C N O I T P I R C S E D Y T Q 1 2 2 6 0 0 3 3 D M W E R C S 2 2 0 7 0 4 0 4 L C W E C A F R E T N I L E L L A R A P 4 8 2 1 - E E E I 1 3 1 5 0 4 0 4 L C W E C A F R E T N ...

Page 10-22 Section 10. Parts List SATO CL408e/CL412e Service Manual PN 9001078 Rev. B 10.8 PCMCIA Memory Option . O N M E T I E D O C N O I T P I R C S E D Y T Q 1 0 0 1 0 7 7 4 J R Y R O M E M B M 6 1 A I C M C P T I K N O I T P O 1

Page 10-23 Section 10. Parts List SATO CL408e/CL412e Service Manual PN 9001078Rev. B 10.9 Cutter Assembly Option

Page 10-24 Section 10. Parts List SATO CL408e/CL412e Service Manual PN 9001078 Rev. B Cutter Assembly Option . O N M E T I E D O C N O I T P I R C S E D Y T Q 1 0 0 0 2 7 7 7 R P T E S R E T T U C 1 2 1 2 6 0 0 3 4 D M W E R C S D A E H N A P 2 3 0 0 7 0 7 7 2 A P T E K C A R B R E T T U C 1 5 1 2 8...

Page 10-25 Section 10. Parts List SATO CL408e/CL412e Service Manual PN 9001078Rev. B 10.10 Dispenser Assembly Option

Page 10-26 Section 10. Parts List SATO CL408e/CL412e Service Manual PN 9001078 Rev. B Dispenser Assembly Option

PN 9001078Rev. B Index-1 Index SATO CL408e/CL412e Service Manual Index A AC Fuse 1-3AC Power Input Connector 1-3Access Plate 1-5, 9-9Accessories 1-9Accessory (EXT) Connector 3-11Alignment Pins 6-16All Clear Mode 2-36Auto Online Feed 2-28Auto Online 2-13 B Back-Feed Selection 2-5Bar Codes 1-14Base Co...