SATO CL608e/CL612e - Manuals

PN 9001079Rev. B Page 1-3 Section 1. Overview and Specifications SATO CL608e/CL612e Service Manual 1.3 Printer Features INTERFACE SLOT Slot to plug in an interface adapter. An adapter must be connected before the printer is operational. The adapter types available are: RS232C Serial I/F Module, DP-2...

PN 9001079 Rev. B Page 1-4 SATO CL608e/CL612e Service Manual Section 1. Overview and Specifications Printer Features RIBBON UNWIND SPINDLE ACCESS DOOR RIBBON REWIND SPINDLE MEDIA HOLDER PLATENROLLER MEDIA KNOB LABEL SUPPLY GUIDE HEAD LATCH PRINT HEAD ASSEMBLY SWITCHES AND SENSORS Refer to Section 1....

PN 9001079 Rev. B Page 1-6 SATO CL608e/CL612e Service Manual Section 1. Overview and Specifications Operation Panel/Displays POTENTIOMETERS VR1 (Print) To adjust print darkness (fine adjustment). VR2 (Offset) To adjust amount of back/forward feed for dispenser/cutter/tear-offbar position (+/- 3.75)....

PN 9001079 Rev. B Page 1-8 SATO CL608e/CL612e Service Manual Section 1. Overview and Specifications 1.6 Sensors and Switches Components POWER SUPPLY UNIT PLUG-IN INTERFACECARD - CENTRONICSI/O SHOWN RIBBON SENSOR: This sensor is a motion detector that signals the printerwhen the ribbon supply is turn...

PN 9001079Rev. B Page 1-9 Section 1. Overview and Specifications SATO CL608e/CL612e Service Manual Switches and Sensors MEDIA HOLD DOWN: Open bylifting up on the release tabunderneath the green tab marked"PUSH". The Media Hold Down isspring loaded and will remain in theup position. Close by ...

PN 9001079 Rev. B Page 1-10 SATO CL608e/CL612e Service Manual Section 1. Overview and Specifications 1.9 Optional Accessories Y R O S S E C C A e 2 1 6 L C / e 8 0 6 L C n o i s n a p x E y r o m e M 4 r o h s a l F B M 6 1 o t p u ( s d r a C y r o m e M A I C M C P r o f t o l s e n O r o f d e s ...

PN 9001079Rev. B Page 1-11 Section 1. Overview and Specifications SATO CL608e/CL612e Service Manual 1.10 Environment & Approvals 1.11 General Printer Specifications l a t n e m n o r i v n E e 2 1 6 L C / e 8 0 6 L C e r u t a r e p m e T g n i t a r e p O 1 4 0 4 0 1 o t 0 5 ( F 0 0 4 o t 0 ) C...

PN 9001079 Rev. B Page 1-12 SATO CL608e/CL612e Service Manual Section 1. Overview and Specifications General Printer Specifications n o i t a c i f i c e p S e 8 0 6 L C e 2 1 6 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 d e x i F m r ...

PN 9001079Rev. B Page 1-15 Section 1. Overview and Specifications SATO CL608e/CL612e Service Manual 1.13 Bar Codes n o i t a c i f i c e p S e 8 0 6 L C e 2 1 6 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 e...

Page 2-1 SATO CL608e/CL612e Service Manual PN 9001079Rev. 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 CL608e/CL612e Service Manual PN 9001079 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 CL608e/CL612e Service Manual PN 9001079Rev. 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 CL608e/CL612e Service Manual PN 9001079Rev.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 da...

Page 2-8 Section 2. Configuration SATO CL608e/CL612e Service Manual PN 9001079 Rev. B 2.3 LCD Panel Configuration The LCD Panel on the CL608e/CL612e 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 CL608e/CL612e Service Manual PN 9001079Rev. 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 CL608e/CL612e Service Manual PN 9001079 Rev. B There are three 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 CL608e/CL612e Service Manual PN 9001079Rev.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 CL608e/CL612e Service Manual PN 9001079 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 CL608e/CL612e Service Manual PN 9001079Rev. 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 CL608e/CL612e Service Manual PN 9001079 Rev. B Vertical Offset is the distance down from the leading edge in dots (the edge of the label that comes out of the printer first) to the first vertical print position. A positive setting moves the first print positio...

Page 2-15 Section 2. Configuration SATO CL608e/CL612e Service Manual PN 9001079Rev. 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 CL608e/CL612e Service Manual PN 9001079 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 return to...

Page 2-17 Section 2. Configuration SATO CL608e/CL612e Service Manual PN 9001079Rev. 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 CL608e/CL612e Service Manual PN 9001079 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 CL608e/CL612e Service Manual PN 9001079 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 CL608e/CL612e Service Manual PN 9001079Rev. 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 CL608e/CL612e Service Manual PN 9001079 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 CL608e/CL612e Service Manual PN 9001079Rev. 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 CL608e/CL612e Service Manual PN 9001079 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 CL608e/CL612e Service Manual PN 9001079Rev. 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 CL608e/CL612e Service Manual PN 9001079 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 CL608e/CL612e Service Manual PN 9001079Rev. 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 CL608e/CL612e Service Manual PN 9001079 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 CL608e/CL612e Service Manual PN 9001079Rev. B LCD Panel — Counters Mode 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 unde...

Page 2-34 Section 2. Configuration SATO CL608e/CL612e Service Manual PN 9001079 Rev. B 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 CL608e/CL612e Service Manual PN 9001079Rev. 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 CL608e/CL612e Service Manual PN 9001079 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 CL608e/CL612e Service Manual PN 9001079Rev. 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 CL608e/CL612e Service Manual PN 9001079 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 CL608e/CL612e Service Manual PN 9001079Rev. 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 CL608e/CL612e Service Manual PN 9001079 Rev. B 2.4 Sample Test Labels CONFIGURATION BAR CODE MEMORY HEAD CHECK FACTORY

Page 3-1 SATO CL608e/CL612e Service Manual PN 9001079Rev. B Interface Specifications 3.1 Overview ! Section The parallel interface for CL608e/CL612e 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 CL608e/CL612e Service Manual PN 9001079 Rev. B Interface Types In order to provide flexibility in communicating with a variety of host computer systems, CL608e/612e printers use a Plug-In Interface Module. The IEEE1284 Interface module is shipped wit...

Page 3-3 Section 3. Interface Specifications SATO CL608e/CL612e Service Manual PN 9001079Rev. B 3.3 The Receive Buffer The CL608e/CL612e 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 CL608e/CL612e Service Manual PN 9001079 Rev.B 3.4 IEEE 1284 Parallel Interface The parallel interface for the CL608e/CL612e 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 CL608e/CL612e Service Manual PN 9001079Rev. 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 CL608e/CL612e Service Manual PN 9001079 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 CL608e/CL612e Service Manual PN 9001079Rev. B RS232C Serial Interface Cable Requirements * This connection at the host side of the interface would depend upon the pin that is being used as theReady/Busy signal by the driving software. Typically on a ...

Page 3-8 Section 3. Interface Specifications SATO CL608e/CL612e Service Manual PN 9001079 Rev. B RS232C Interface Signals Ready/Busy Flow Control Ready/Busy is the hardware flow control for the serial interface on the CL608e/CL612e printers. By raising/lowering the voltage level on Pin 20 of the RS2...

Page 3-9 Section 3. Interface Specifications SATO CL608e/CL612e Service Manual PN 9001079Rev. 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 CL608e/CL612e Service Manual PN 9001079 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 drive...

Page 3-11 Section 3. Interface Specifications SATO CL608e/CL612e Service Manual PN 9001079Rev. 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 CL608e/CL612e Service Manual PN 9001079 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 CL608e/CL612e Service Manual PN 9001079Rev.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 +5...

Page 4-1 SATO CL608e/CL612e Service Manual PN 9001079Rev. B " Section Electrical Checks and Adjustments 4.1 Overview This chapter describes how to check CL608e/CL612e 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 CL608e/CL612e Service Manual PN 9001079 Rev. B STEP PROCEDURE 1.Switch the printer OFF and disconnect the AC power cord. 2.Remove (3) screws holding the left side cover to the printer. Raise the access door and loosen the (2) screws on the ins...

Page 4-3 Section 4. Electric Checks and Adjustments SATO CL608e/CL612e Service Manual PN 9001079Rev. 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 CL608e/CL612e Service Manual PN 9001079 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 CL608e/CL612e Service Manual PN 9001079 Rev. B 4.4 Potentiometer Assignments & Adjustments POTENTIOMETERS ARE LOCATED ON MAIN PCB T S U J D A O T R V M E T I 1 R V s s e n k r a D 2 R V t e s f f O 3 R V h c t i P 4 R V y a l p s i D POTEN...

Page 4-7 Section 4. Electric Checks and Adjustments SATO CL608e/CL612e Service Manual PN 9001079Rev. B Potentiometer Assignments & Adjustments POWER SUPPLY TEST POINTCONNECTOR MAIN PCB VR1 OFS INTERFACE BOARD VR4 GAP VR5 IM CN13 VR2 DEM VR3 CE

Page 4-8 Section 4. Electric Checks and Adjustments SATO CL608e/CL612e Service Manual PN 9001079 Rev. B 4.5a Print Position Adjustment Print Postition is adjusted with the VR3(PITCH) potentiometer on the Front Panel and/or VR1 potentiometer on the main PCB board.The following instructions are for ad...

Page 4-9 Section 4. Electric Checks and Adjustments SATO CL608e/CL612e Service Manual PN 9001079Rev. B 4.5b Print Position Adjustment STEP PROCEDURE Refer to Section 4.2 for access to main PCB 1.Record all current dip switch positions, then place all switches in the OFF position and the power switch...

Page 4-10 Section 4. Electric Checks and Adjustments SATO CL608e/CL612e Service Manual PN 9001079 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 CL608e/CL612e Service Manual PN 9001079 Rev. B 4.8 Offset Label Stop Position Adjustment Used for fine adjustment of label stop position for Tear Off, Cutter and Dispense Modes. The Label Stop Position is adjusted with the Offset potentiomete...

Page 4-13 Section 4. Electric Checks and Adjustments SATO CL608e/CL612e Service Manual PN 9001079Rev. B 4.9 Ribbon Sensor Operation Verification 1.Flip down the cover on the front panel for access to the dip switches.2.Record all dip switch positions, then place DSW2-1 in the OFF position and the po...

Page 4-14 Section 4. Electric Checks and Adjustments SATO CL608e/CL612e Service Manual PN 9001079 Rev. B 4.10 Ribbon Sensor Adjustment Additional equipment required: TP Test Module Digital Multimeter STEP PROCEDURE Refer to Section 4.2 for access to main PCB 1.Turn VR4 potentiometer on the main PCB ...

Page 4-15 Section 4. Electric Checks and Adjustments SATO CL608e/CL612e Service Manual PN 9001079Rev.B 4.11 LCD Display Adjustment STEP PROCEDURE 1.Turn ON the power. 2.Confirm the backlight on the LCD is lit and message is displayed. 3.Adjust the display darkness with VR4 potentiometer (located und...

Page 4-16 Section 4. Electric Checks and Adjustments SATO CL608e/CL612e Service Manual PN 9001079 Rev. B 4.12 Print Darkness Adjustment STEP PROCEDURE 1.Turn VR1 potentiometer (located underneath a flip-down cover ot the front panel) to the center postion. 2.Turn ON the power. Press the LINE key to ...

Page 5-1 SATO CL608e/CL612e Service Manual PN 9001079Rev. B # Section Mechanical Adjustments 5-1 Overview SATO CL608e/CL612e printers contain adjustable sub-assemblies. This means that during your regular maintenance, your service technicians are able to make adjustments to reset the printer to fact...

Page 5-2 Section 5. Mechanical Adjustments SATO CL608e/CL612e Service Manual PN 9001079 Rev. B Excessive ribbon unwind 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 the ribbon unwind and...

Page 5-3 Section 5. Mechanical Adjustments SATO CL608e/CL612e Service Manual PN 9001079Rev. B Ribbon Clutch Adjustments Fig. 5-3 RIBBON UNWIND SPINDLE ADJUST NUT LOCKING SCREW IS INSIDE ADJUST NUT 950-1050gREWIND STRING EMPTY RIBBON CORES RIBBON REWIND SPINDLE Fig. 5-4 Fig. 5-2 450-550gUNWIND TENSIO...

Page 5-5 Section 5. Mechanical Adjustments SATO CL608e/CL612e Service Manual PN 9001079Rev. B STEP PROCEDURE 1. Refer to Section 7.2 and run a test print. Fig. 5-5 2. By adjusting the Allen head screws on the rear of the Stay, you can move the print head forward or backward. This allows you to posit...

Page 5-6 Section 5. Mechanical Adjustments SATO CL608e/CL612e Service Manual PN 9001079 Rev. B Print Head Position Adjustment ALLEN WRENCH ADJUST SCREWS Fig. 5-7 STAY STAY Fig. 5-6 N E L L A F O N O I T A T O R H C N E R W D A E H T N I R P F O T N E M E V O M E S I W K C O L C T N O R F E H T O T E...

Page 5-7 Section 5. Mechanical Adjustments SATO CL608e/CL612e Service Manual PN 9001079Rev. B 5.4 Print Head Balance Adjustment Required Equipment: • #2 Pozidrv Screwdriver • 10mm wrench STEP PROCEDURE 1. Connect the power cable to the printer and AC outlet. Turn the printer ON . 2. Raise the access...

Page 5-8 Section 5. Mechanical Adjustments SATO CL608e/CL612e Service Manual PN 9001079 Rev. B Required Equipment: • #2 Pozidrv Screwdriver • 10mm wrench STEP PROCEDURE 1. Connect the power cable to the printer and AC outlet. Turn the printer ON . 2. Raise the access door and load the ribbon and lab...

Page 5-10 Section 5. Mechanical Adjustments SATO CL608e/CL612e Service Manual PN 9001079 Rev. B ADJUST SCREW & FIXING NUT ON BOTH ENDS OF MEDIA COVER Fig. 5-10 ADJUST PLATE Fig. 5-11 Fig. 5-12 Fig. 5-13 TENSION GAUGE BACKING PAPER LEFT SIDE MEDIA LID PULL BACKING PAPER RIGHT SIDE PULL MOVE WITH ...

Page 5-11 Section 5. Mechanical Adjustments SATO CL608e/CL612e Service Manual PN 9001079Rev. B STEP PROCEDURE 1. Remove (3) screws holding the left side cover to the printer. Raise the access door and loosen the (2) screws on the inside top of the printer. Lift off the left side cover. Fig. 5-14 2. ...

Page 5-12 Section 5. Mechanical Adjustments SATO CL608e/CL612e Service Manual PN 9001079 Rev. B LATCHED POSITION UNLATCHED POSITION Pairs of set-screws on each end of shaft must be tightened to avoid slippage of media and light printing on the left side of the labels The set-screws which attach the ...

Page 5-13 Section 5. Mechanical Adjustments SATO CL608e/CL612e Service Manual PN 9001079Rev. B The CL-608e/612e printers can position labels using either a label gap (transmissive) or a Eye-Mark (reflective) sensor. The sensor used is selected by DSW2-2. (page 2-3) The gap sensor position can be adj...

Page 6-1 SATO CL608e/CL612e Service Manual PN 9001079Rev. B Replacement Procedures 6.1 Overview $ Section SATO CL608e/CL612e 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 CL608e/CL612e Service Manual PN 9001079 Rev. B 6.2 Replacing the Main Circuit Board NOTE: Many of the components on this board are susceptible to damage by static electricity. To avoid damage from static electricity, do not unpack new circuit boards fr...

Page 6-3 Section 6. Replacement Procedures SATO CL608e/CL612e Service Manual PN 9001079Rev. B Replacing the Main Circuit Board STEP PROCEDURE 3. Remove (2) screws holding the I/O PCB Interface from the back side of the unit. Pull away to detach the connector on the interface from the main circuit bo...

Page 6-4 Section 6. Replacement Procedures SATO CL608e/CL612e Service Manual PN 9001079 Rev. B Replacing the Main Circuit Board REMOVE (2) SCREWS REMOVE SCREW DISCONNECT CABLES DISCONNECT CABLES Figs. 6-3

Page 6-7 Section 6. Replacement Procedures SATO CL608e/CL612e Service Manual PN 9001079Rev. 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 CL608e/CL612e Service Manual PN 9001079 Rev. B Replacing the Fuses 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 printer OFF and disconnect the power cable. 2. Remove ...

Page 6-9 Section 6. Replacement Procedures SATO CL608e/CL612e Service Manual PN 9001079Rev. B The Power Supply is a non-repairable component with no servicable parts and is to be replaced as a complete assembly. STEP PROCEDURE 1. Switch the printer OFF and disconnect the power cable. 2. Remove (3) s...

Page 6-10 Section 6. Replacement Procedures SATO CL608e/CL612e Service Manual PN 9001079 Rev. B Replacing the Power Supply REMOVE (2) SCREWS TO DETACH MAIN CIRCUIT BOARD REMOVE (2) SCREWS Fig. 6-9 REMOVE (2) SCREWS AND PULLAWAY TO DETACH IF INTERFACECARD IS INSTALLED Figs. 6-8 REMOVE (2) SCREWS Fig....

Page 6-12 Section 6. Replacement Procedures SATO CL608e/CL612e Service Manual PN 9001079 Rev. B 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 roller, the ribbon feed roller, a...

Page 6-13 Section 6. Replacement Procedures SATO CL608e/CL612e Service Manual PN 9001079Rev. B STEP PROCEDURE 1. Switch the printer OFF and disconnect the power cable. 2. Remove (3) screws holding the left side cover to the printer. Raise the access door and loosen the (2) screws on the inside top o...

Page 6-14 Section 6. Replacement Procedures SATO CL608e/CL612e Service Manual PN 9001079 Rev. B Fig. 6-20 BELT "B" BELT "A" Fig. 6-21 MOTOR TENSION ADJUSTMENT IDLER IDLER BELT "B" BELT "A" FRONT PLATEN ROLLER REWIND SPINDLE REAR PLATEN ROLLER GEAR TO ENGAGE FEED ROLLE...

Page 6-16 Section 6. Replacement Procedures SATO CL608e/CL612e Service Manual PN 9001079 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 6-17 Section 6. Replacement Procedures SATO CL608e/CL612e Service Manual PN 9001079Rev. B Replacing the Print Head REMOVE THE RIBBON AND LABEL STOCK Fig. 6-24 Fig. 6-25 REMOVE (2) STUD SCREWS PRINT HEAD DISLODGE AND REMOVE RIBBON GUIDE PLATE DISCONNECT CABLES Fig. 6-26 Fig. 6-27 HEAD LATCH LEVE...

Page 6-19 Section 6. Replacement Procedures SATO CL608e/CL612e Service Manual PN 9001079Rev. B STEP PROCEDURE 1. Switch the printer OFF and disconnect the power cable. 2. Remove (3) screws holding the left side cover to the printer. Raise the access door and loosen the (2) screws on the inside top o...

Page 6-20 Section 6. Replacement Procedures SATO CL608e/CL612e Service Manual PN 9001079 Rev. B Fig. 6-30 REMOVE THERIBBON ANDLABEL STOCK Fig. 6-31 Fig. 6-32 Replacing the Platen PLATEN LOOSEN CLAMP AND SCREW HOLDING PLATEN TO FRAME SLIGHTLY LOOSEN ECCENTRIC SCREW REMOVE BELT LOOSEN IDLER SCREWS TO ...

Page 6-23 Section 6. Replacement Procedures SATO CL608e/CL612e Service Manual PN 9001079Rev. B Both the ribbon unwind and the rewind drive spindles incorporate a friction clutch assembly to control tension. The friction washers within these clutch assemblies are replaceable. The procedure is identic...

Page 6-24 Section 6. Replacement Procedures SATO CL608e/CL612e Service Manual PN 9001079 Rev. B Replacing the Ribbon Drive Clutch Washers 1 2 3 4 5 6 7 7 9a 10 11 9b USE 12mm OPEN END WRENCH AND PHILLIPS SCREW DRIVER TO REMOVE THE LOCKING SCREW AND ADJUSTMENT NUT REMOVE & INSTALL PARTS IN THIS O...

Page 6-27 Section 6. Replacement Procedures SATO CL608e/CL612e Service Manual PN 9001079Rev. B 6.10 Replacing the Ribbon Motion Sensor STEP PROCEDURE 1. Switch the printer OFF and disconnect the power cable. 2. Remove (3) screws holding the left side cover to the printer. Raise the access door and l...

Page 6-28 Section 6. Replacement Procedures SATO CL608e/CL612e Service Manual PN 9001079 Rev. B Replacing the Ribbon Motion Sensor Fig. 6-50 Fig. 6-51 REMOVE SCREW PULL THE SENSOR CABLE AND CONNECTOR THROUGH THE FRAME HOLE UNPLUG SEN4 FROM THE PCB HARNESS Fig. 6-52 Fig. 6-53 ALIGNMENT PIN

Page 6-29 Section 6. Replacement Procedures SATO CL608e/CL612e Service Manual PN 9001079Rev. B Replacing the Ribbon Motion Sensor Fig. 6-54 Fig. 6-55 REMOVE (2) SCREWSHOLDING SENSOR TO THE BRACKET DISASSEMBLED RIBBON MOTION SENSOR AND MOUNTING BRACKET

Page 6-30 Section 6. Replacement Procedures SATO CL608e/CL612e Service Manual PN 9001079 Rev. B 6.11 Replacing the Paper End Switch (Micro-Switch) and the Bottom Half of the Notch/Gap and Eye-Mark Sensors MEDIA HOLD DOWN COVER (SHOWN IN RAISED POSITION) CONTAINS THE TOP HALF OF THE NOTCH/GAP SENSOR ...

Page 6-33 Section 6. Replacement Procedures SATO CL608e/CL612e Service Manual PN 9001079Rev. B Replacing the Paper End Switch (Micro-Switch) and the Bottom Half of the Notch/Gap and Eye-Mark Sensors Fig. 6-62 BOTTOM HALF NOTCH/GAP AND EYE-MARK SENSORS Fig. 6-61 PAPER END SWITCH REMOVE (2) SCREWS NOT...

Page 6-34 Section 6. Replacement Procedures SATO CL608e/CL612e Service Manual PN 9001079 Rev. B 6.12 Replacing the Top Half of the Notch/Gap Sensor STEP PROCEDURE 1. Switch the printer OFF and disconnect the power cable. 2. Remove (3) screws holding the left side cover to the printer. Raise the acce...

Page 6-35 Section 6. Replacement Procedures SATO CL608e/CL612e Service Manual PN 9001079Rev. B Replacing the Top Half of the Notch/Gap Sensor REMOVE SCREW TO DETACH MEDIA HOLD DOWN UNIT Fig. 6-65 Fig. 6-66 REMOVE MEDIA HOLD DOWN UNIT FROM THE FRAME REMOVE (2) SCREWS TO OPEN COVER AND ACCESS THE NOTC...

Page 6-37 Section 6. Replacement Procedures SATO CL608e/CL612e Service Manual PN 9001079Rev. B STEP PROCEDURE 1. Switch the printer OFF and disconnect the power cable. 2. Remove (3) screws holding the left side cover to the printer. Raise the access door and loosen the (2) screws on the inside top o...

Page 6-38 Section 6. Replacement Procedures SATO CL608e/CL612e Service Manual PN 9001079 Rev. B Replacing the Display Panel or Keyboard COVER REMOVE (1) SCREW REMOVE (2) SCREWS DISPENSER COVER REMOVE (2) SCREWS ROTATE AND LIFT TO DETACH COVER Fig. 6-76 Fig. 6-77 Fig. 6-78 Fig. 6-79 DISPLAY PANEL ASS...

Page 7-1 SATO CL608e/CL612e Service Manual PN 9001079Rev. 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 CL608e/CL612e Service Manual PN 9001079Rev.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 simul...

Page 7-4 Section 7. Factory Resets SATO CL608e/CL612e Service Manual PN 9001079 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 CL608e/CL612e Service Manual PN 9001079Rev. 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 CL608e/CL612e Service Manual PN 9001079Rev. 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 CL608e/CL612e Service Manual PN 9001079Rev. B Troubleshooting 8.1 Overview This section has been devised to help you if you are unable to produce output on the CL608e/CL612e 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 CL608e/CL612e Service Manual PN 9001079 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 CL608e/CL612e Service Manual PN 9001079Rev. 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 CL608e/CL612e Service Manual PN 9001079 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 poin...

Page 8-7 Section 8. Troubleshooting SATO CL608e/CL612e Service Manual PN 9001079Rev. 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 CL608e/CL612e Service Manual PN 9001079 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 CL608e/CL612e Service Manual PN 9001079Rev. 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 CL608e/CL612e Service Manual PN 9001079Rev. 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 CL608e/CL612e Service Manual PN 9001079Rev. 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 CL608e/CL612e Service Manual PN 9001079 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 CL608e/CL612e Service Manual PN 9001079Rev. 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 CL608e/CL612e Service Manual PN 9001079Rev. B Optional Accessories 9.1 Overview ' Section This section contains instructions for installing the following optional accessories: · Label Cutter Kit Installation · Label Dispenser Kit Installation · PCMCIA Memory Expansion · Flash ROM Memor...

Page 9-2 Section 9. Optional Accessories SATO CL608e/CL612e Service Manual PN 9001079 Rev. B 9.2 Label Cutter Kit Installation STEP PROCEDURE 1. Turn the printer OFF and disconnect the AC power cord. 2. Remove (3) screws holding the left side cover to the printer. Raise the access door and loosen th...

Page 9-5 Section 9. Optional Accessories SATO CL608e/CL612e Service Manual PN 9001079Rev. B Label Cutter Kit Installation DETACH SEN3 CONNECTORFROM PCB BOARD AND REPLACEWITH CABLE CONNECTORMARKED “CUTS” FROM CUTTER ATTACH CABLE CONNECTOR ENDMARKED “CUTP” FROM CUTTERTO CN2 ON POWER SUPPLY Figs. 9-6 S...

Page 9-6 Section 9. Optional Accessories SATO CL608e/CL612e Service Manual PN 9001079 Rev. B 9-3 Label Dispenser Installation DISPENSERFEED ROLLER DISPENSER UNIT WITH ROLLER AND SPRINGS PULLEY ANDGEAR WITHHARDWARE REWIND PULLEY ASSEMBLY AND BELT Installation of the optional Label dispenser into the ...

Page 9-7 Section 9. Optional Accessories SATO CL608e/CL612e Service Manual PN 9001079Rev. B PULLEY COVER Label Dispenser Installation Components asSupplied in Kit REWINDERASSEMBLY SCREWS SUPPLIED IN KIT CABLE STAY Fig. 9-8f Fig. 9-8e Fig. 9-8g Fig. 9-8h

Page 9-15 Section 9. Optional Accessories SATO CL608e/CL612e Service Manual PN 9001079Rev. 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 TO...

Page 9-16 Section 9. Optional Accessories SATO CL608e/CL612e Service Manual PN 9001079 Rev. B PCMCIA Memory Expansion Installation STEP PROCEDURE 1. Switch the printer OFF. 2. Refer to Section 6.2 and remove the main circuit board. 3. Remove (2) screws, nuts and standoffs from the Memory PCB Board f...

Page 9-17 Section 9. Optional Accessories SATO CL608e/CL612e Service Manual PN 9001079Rev. B PCMCIA Memory Expansion Installation REMOVE (2) SCREWS AND WASHERS FROM THIS END OF STANDOFFS (STEP 4) REMOVE (2) SCREWS, NUTS AND STANDOFFS. THIS HARDWARE WILL BE MOUNTED ON THE MAIN PCB BOARD (STEP 3) HOLE...

Page 9-19 Section 9. Optional Accessories SATO CL608e/CL612e Service Manual PN 9001079Rev. B 9.5 Flash Memory Expansion Installation STEP PROCEDURE 1. Switch the printer OFF and disconnect the power cable. 2. Remove (3) screws holding the left side cover to the printer. Raise the access door and loo...

Page 9-20 Section 9. Optional Accessories SATO CL608e/CL612e Service Manual PN 9001079 Rev. B Flash Memory Expansion Installation Figs. 9-25 INDEXING NOTCH NO NOTCH ON THIS SIDE FLASH MEMORY MODULE INSERT THE FLASH MEMORY MODULE INTO THE MAIN PCB MEMORY FRAME AT APPROXIMATELY 45 0 . NOTE THE INDEXIN...

Page 9-21 Section 9. Optional Accessories SATO CL608e/CL612e Service Manual PN 9001079Rev. 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 9-22 Section 9. Optional Accessories SATO CL608e/CL612e Service Manual PN 9001079 Rev. B Real Time Clock Chip 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 TIM...

Page 9-23 Section 9. Optional Accessories SATO CL608e/CL612e Service Manual PN 9001079Rev. 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 9-24 Section 9. Optional Accessories SATO CL608e/CL612e Service Manual PN 9001079 Rev. 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 FEED key 11 times to disp...

Page 10-1 SATO CL608e/CL612e Service Manual PN 9001079Rev. B Spare Parts List 10.1 Overview Section The following parts lists are included for the CL608e/CL612e Printers: · Base Cover Assembly · Frame Assembly · Print Head Assembly · Ribbon Assembly · Feed Roller Assembly · Main PCB Assembly · Inter...

Page 10-2 Section 10. Parts List SATO CL608e/CL612e Service Manual PN 9001079 Rev. B 10.2 Base Cover Assembly

Page 10-3 Section 10. Parts List SATO CL608e/CL612e Service Manual PN 9001079Rev. B Base Cover Assembly

Page 10-12 Section 10. Parts List SATO CL608e/CL612e Service Manual PN 9001079 Rev. B Frame Assembly

Page 10-18 Section 10. Parts List SATO CL608e/CL612e Service Manual PN 9001079 Rev. B 10.4 Print Head Assembly

Page 10-19 Section 10. Parts List SATO CL608e/CL612e Service Manual PN 9001079Rev. B Print Head Assembly

Page 10-22 Section 10. Parts List SATO CL608e/CL612e Service Manual PN 9001079 Rev. B 10.5 Ribbon Assembly

Page 10-23 Section 10. Parts List SATO CL608e/CL612e Service Manual PN 9001079Rev. B Ribbon Assembly

Page 10-27 Section 10. Parts List SATO CL608e/CL612e Service Manual PN 9001079Rev. B 10.6 Feed Roller Assembly

Page 10-28 Section 10. Parts List SATO CL608e/CL612e Service Manual PN 9001079 Rev. B Feed Roller Assembly

Page 10-30 Section 10. Parts List SATO CL608e/CL612e Service Manual PN 9001079 Rev. B 10.7 Main PCB Assembly 1 RJ1771200 Main PCBA 1 2 PC9730100 Spring (Lock) 1 3 PA3739900 Connector lock 1 4 MD4300621 Pan head screw 5 5 RJ7770200 Memory PCB Assy-B 1 8 RJ7770300 Memory PCB (4 MB Memory Option) 1 NO....

Page 10-31 Section 10. Parts List SATO CL608e/CL612e Service Manual PN 9001079Rev. B 10.8 Interface Option 1 MD3300622 Screw 2 2 WCL404070 IEEE-1284 Parallel Interface 1 3 WCL404051 Serial Interface 1 4 WCL404060 USB Interface 1 5 11S000158 Ethernet Interface 1 6 11S000136 CX/TX Interface 1 1 2 3 4 ...

Page 10-32 Section 10. Parts List SATO CL608e/CL612e Service Manual PN 9001079 Rev. B 10.9 Dispenser Assembly Option

Page 10-33 Section 10. Parts List SATO CL608e/CL612e Service Manual PN 9001079Rev. B Dispenser Assembly Option

Page 10-39 Section 10. Parts List SATO CL608e/CL612e Service Manual PN 9001079Rev. B 10.10 Cutter Assembly Option

Page 10-40 Section 10. Parts List SATO CL608e/CL612e Service Manual PN 9001079 Rev. B Cutter Assembly Option

PN 9001079Rev. B Index-1 Index SATO CL608e/CL612e Service Manual Index A AC Fuse 1-3AC Power Input Connector 1-3Access Door 1-2, 1-4, 4-2Accessory (EXT) Connector 3-11Adjust Plate 5-7, 5-10Adjustment Spring 5-11Advisory LED'S 1-5All Clear Mode 2-36AutoOnline 2-13 B Back-Feed Selection 2-5Backfeed Se...