The information supplied in this manual was current at time of
publication. If you come across procedures that need clarification or
find errors or have suggestions contact us at qc@satoamerica.com
PN 9001079
Rev. B
Warning: This equipment complies with the requirements in Part 15 of FCC
rules for a Class B computing device. Operation of this equipment in a
residential area may cause unacceptable interference to radio and TV
reception requiring the operator to take whatever steps are necessary to
correct the interference.
All rights reserved. No part of this document may be reproduced or issued to
third parties in any form whatever without the express permission of SATO
America, Inc. The materials in this document are provided for general
information and are subject to change without notice. SATO America, Inc.
assumes no responsibility for any errors that may appear.
Index .............................................................................................................................. Index -1
PN 9001079
Rev. B
SA T O CL608e/CL612e Service Manual
iii
iv
SA TO CL608e/CL612e Service Manual
PN 9001079
Rev. B
Section
Overview and Specifications
1.1 Overview
The SATO CL608e/CL612e Printers Service Manual provides information for
installing and maintaining CL608e/CL612e Thermal Transfer printers. Step-bystep maintenance instructions are included in this manual with typical problems
and solutions. It is recommended that you become familiar with each section in
this manual before installing and maintaining the printer.
The major differences between the CL608e and the CL612 printers is the
resolution of the head and label width. The CL608e with its 203 dpi head
provides an economical labeling solution for most applications. It can print
labels up to six inches wide. The CL612e provides a higher print resolution, 305
dpi to give laser-quality printing. It is useful when higher resolution is needed
for detailed graphic images. It can print labels up to 6.5 inches wide.
The CL Series "e" printers use a subset of the standard SATO Command
Language. The CL608e/CL612e share the same command set, the only
differences are the allowable values representing the print positions on the label.
These values are specified in "dots" and will vary depending upon the resolution
of the printer and the amount of memory available for imaging the label. The
allowable range for each printer is specified in a table for those command codes.
The sections in this manual cover the following:
·Section 1. Overview and Specifications
·Section 2. Configuration
·Section 3. Interface Specifications
·Section 4. Electrical Checks and Adjustments
·Section 5. Mechanical Adjustments
·Section 6. Replacement Procedures
·Section 7. Factory Resets
·Section 8. Troubleshooting
·Section 9. Optional Accessories
·Section 10. Parts list
PN 9001079
Rev. B
SATO CL608e/CL612e Service Manual
Page 1-1
Section 1. Overview and Specifications
1.2 Physical Characteristics
Depth
FRONT
Height
ACCESS DOOR
Width
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Page 1-2
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SA T O CL608e/CL612e Service Manual
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PN 9001079
Rev. B
1.3 Printer Features
POWER SWITCH
Section 1. Overview and Specifications
INTERF ACE SLOT (SHOWN
WITH CENTRONICS P ARALLEL
INTERF ACE INST ALLED)
EXTERNAL
ACCESSORY
CONNECTOR
PCMCIA MEMORY
EXP ANSION SLOT
AC FUSE
AC POWER INPUT
CONNECTOR
COVER PLATE-REMOVE FOR
ACCESS TO FAN-FOLD SLOTS
Rear Panel
INTERF ACE SLOTSlot 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-25P.
IEEE1284 Parallel I/F Module, AMP 57-40360
Universal Serial Bus I/F Module
Ethernet 10/100 BaseT I/F Module
MEMORY CARD SLOTOne slot for optional PCMCIA Memory Cards.
EXT CONNECTORExternal signal connector for Accessories, AMP 57-60140
POWER SWITCHTurns power On/Off
PN 9001079
Rev. B
AC FUSEInput power protection. Type 3A/250V.
AC POWER INPUTInput 115V 50/60 Hz connector. Use the cable provided.
SA T O CL608e/CL612e Service Manual
Page 1-3
Section 1. Overview and Specifications
Printer Features
RIBBON UNWIND
SPINDLE
ACCESS DOOR
RIBBON REWIND
SPINDLE
LABEL TEAR
OFF PLA TE
SWITCHES AND SENSORS
Adjust the Media Knob based on the
media you have loaded. For media up to
2.3 inches wide, use the "1" position. For
media between 2.3 and 4.6 inches wide,
use the "2" position. For media wider than
4.6 inches wide, use the "3" position. If
you use media narrower than 7 inches,
using the wrong setting can void the print
head warranty due to excessive pressure.
LABEL SUPPLY
GUIDE
MEDIA HOLDER
Refer to Section 1.6
MEDIA KNOB
Page 1-4
PRINT HEAD
ASSEMBLY
PLATEN
ROLLER
SA T O CL608e/CL612e Service Manual
MEDIA HOLD
DOWN
HEAD LA TCH
PN 9001079
Rev. B
1.4 Operation Panel/Displays
LCD DISPLAY
Section 1. Overview and Specifications
ADVISORY LED'S
LINE KEY
FEED KEY
COVER
ADVISORY LED'S
POWERIlluminated when power is on.
ONLINEIlluminated when printer is ready to receive data. Turn ON/OFF by
toggling the LINE key.
PN 9001079
Rev. B
LABELIlluminated when label supply is out.
RIBBONIlluminated when ribbon motion sensor does not detect any ribbon
motion.
ERRORIlluminated when there is a system fault such as an open print head.
LCD SCREEN2 LINE x 16 Character LCD display . Used for setting operational
parameters of the printer and displaying error conditions
LINE KEYMomentary switch. Pressing this key toggles the printer between
the on-line and off-line mode. When the printer is on-line, it is
ready to receive data from the host. This key acts as a pause
during a print job by taking the printer off-line.
FEED KEYMomentary switch. Pressing this key feeds one blank label
through the printer when it is off-line. When the printer is on-line, there is a
user selectable option in the Service Mode (see page 2-28) to either print
a copy of the previously printed label or feed a blank label. The default is
to feed a blank label.
SA T O CL608e/CL612e Service Manual
Page 1-5
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-off
bar position (+/- 3.75).
VR3 (Pitch)To adjust home print position of the label (+/- 3.75 mm).
VR4 (Display)To adjust the contrast of the LCD display.
*NOTE: Optional RS232 Communication Card contains DSW1 switches which
Page 1-6
*DSW2 & DSW3Dip Switches used to set operational
parameters of printer. Refer to Section
2 for settings.
are configured when supplied with the printer.
SA T O CL608e/CL612e Service Manual
PN 9001079
Rev. B
1.5 Components
PLATEN
Section 1. Overview and Specifications
PRINT HEAD
RIBBON GUIDE
PLATE
TIMING
BELTS
PLATENS
LCD BOARD AND
KB BOARD ON
BACKSIDE OF P ANEL
STEPPER
MOTOR
PN 9001079
Rev. B
SA T O CL608e/CL612e Service Manual
Page 1-7
Section 1. Overview and Specifications
Components
POWER SUPPLY UNIT
PLUG-IN INTERFACE
CARD - CENTRONICS
I/O SHOWN
1.6 Sensors and Switches
RIBBON SENSOR: Thissensor 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.
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
SA T O CL608e/CL612e Service Manual
PN 9001079
Rev. B
Switches and Sensors
Section 1. Overview and Specifications
MEDIA HOLD DOWN: Open by
lifting up on the release tab
underneath the green tab marked
"PUSH". The Media Hold Down is
spring loaded and will remain in the
up position. Close by pushing down
on the same green tab.
NOTCH/GAP SENSOR
(Top Half is adjustable)
( Refer to Section 5-10)
MEDIA HOLD DOWN
(Underside)
"EYE-MARK" SENSOR
(Fixed: Non adjustable)
NOTCH/GAP SENSOR
LED ARRA Y (Bottom
Half is Non-adjustable)
LABEL OUT SENSOR: This micro
switch is activated when media
stock is out or when the Media Hold
Down is in the up position. All
printer operations stop, and an
error message is displayed on the
LCD.
PN 9001079
Rev. B
SA T O CL608e/CL612e Service Manual
Page 1-9
Section 1. Overview and Specifications
1.7 Ribbon
Use only SATO thermal transfer ribbons which were formulated expressly for use in all
SATO printers. Use of other than approved ribbons may result in unsatisfactory print
quality and/or damage to the print head and may void your warranty.
1.8 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
results from the printer, avoid locations influenced by:
Direct or bright sunlight, since bright light will make the label sensor less responsive
and may cause the label to be sensed incorrectly.
Warm temperatures which can cause electrical problems within the printer. (See
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
• Label sensor enable/disable
• Single Job or Multi-Job Receive Buffer
• Operation Mode
DIP SWITCHES
In addition, a third DIP switch (DSW1) is located on the optional RS232 Serial
Adapter card and is used to set the RS232C transmit/receive parameters.
DSW1
Each switch is an eight section toggle switch. The On position is always to the
top. To set the switches, first power the unit Off, then position the DIP switches.
Finally after placing the switches in the desired positions, power the printer back
on. The switch settings are read by the printer electronics during the power-up
sequence. They will not become effect until the power is cycled.
PN 9001079
Rev. B
SA T O CL608e/CL612e Service Manual
Page 2-1
Section 2. Configuration
Dip Switch Settings
RS232 Transmit/Receive Setting (located on RS232 I/F Module)
Data Bit Selection (DSW1-1): This switch sets the printer to receive either 7 or 8
data bits for each byte transmitted.
DSW1-1SETTING
ON
DSW1
Off8 data bits
OFF
On7 data bits
1 2 3 4
5 6 7 8
Parity Selection (DSW1-2, DSW1-3): These switches select the type of parity used
for error detection.
DSW1-2DSW1-3SETTING
OffOffNone
ON
DSW1
OffOnEven
OnOffOdd
OFF
OnOnNot Used
1 2 3 4
5 6 7 8
Stop Bit Selection (DSW1-4): Selects the number of stop bits to end each byte
transmission.
DSW1
DSW1-4SETTING
Off1 Stop Bit
ON
OFF
On2 Stop Bits
1 2 3 4
5 6 7 8
Baud Rate Selection (DSW1-5, DSW1-6): Selects the data rate (bps) for the RS232
port.
DSW1
DSW1-5DSW1-6SETTING
ON
OffOff9600
OffOn19200
OnOff38400
OnOn57600
OFF
1 2 3 4
5 6 7 8
Protocol Selection (DSW1-7, DSW1-8): Selects the flow control and status
reporting protocols.
(* Will select protocol Bi-Com 2 for M-8400 if DSW2-8 is ON)
DSW1-7DSW1-8SETTING
OffOffRdy/Bsy
OffOnXon/Xoff
ON
OFF
DSW1
OnOffBi-Com 3
OnOnBi-Com 4*
1 2 3 4
5 6 7 8
Page 2-2
SA T O CL608e/CL612e Service Manual
PN 9001079
Rev. B
Section 2. Configuration
Dip Switch Settings
Printer Set up
Print Mode Selection (DSW2-1): Selects between direct thermal printing on
thermally sensitive paper and thermal transfer printing using a ribbon.
DSW2
DSW2-1SETTING
OffTransfer
O nDirect Therm
ON
OFF
1 2 3 4
5 6 7 8
Sensor Type Selection (DSW2-2): Selects between the use of a label gap or a
reflective Eye-Mark.
DSW2
DSW2-2SETTING
OffGap
ON
OFF
OnEye-Mark
1 2 3 4
5 6 7 8
Head Check Selection (DSW2-3): When selected, the printer will check for head
Receive Buffer Selection (DSW2-5): Selects the operating mode of the receive
buffer. See Section 3: Interface Specifications for more information.
DSW2
DSW2-5SETTING
Of f1 Item
ON
OFF
OnMulti-Job
1 2 3 4
5 6 7 8
For more information about the cause of troubleshooting printer errors, see
Section 8, Troubleshooting.
PN 9001079
Rev. B
SA TO CL608e/CL612e Service Manual
Page 2-3
Section 2. Configuration
Dip Switch Settings
Firmware Download (DSW2-6): Places the printer in the Firmware Download mode
for downloading new firmware into flash ROM.
DSW2
DSW2-6SETTING
OffDisabled
OnEnabled
ON
OFF
1 2 3 4
5 6 7 8
Protocol Code Selection (DSW2-7): Selects the command codes used for protocol
control.
DSW2
DSW2-7SETTING
OffStandard
ON
OFF
OnNon-Std.
1 2 3 4
5 6 7 8
M8400 Emulation Mode (DSW2-8): For emulating earlier series software commands.
Should be used only if problems are encountered when using existing software. This
switch will also affect the setttings selected by DSW1-7 and DSW1-8.
DSW2
DSW2-8SETTING
ON
OffDisabled
OnEnabled
OFF
1 2 3 4
5 6 7 8
Backfeed Sequence Selection (DSW3-1 and DSW3-2): Selects the operating mode
of the printer. Batch/Continuous disables the label taken (dispense option) sensor.
DSW3
DSW3-1DSW3-2SETTING
ON
Of fOffBatch/Continuous
OFF
Of fO nT ear Off
1 2 3 4
5 6 7 8
O nOffCutter
OnOnDispenser
Page 2-4
SA T O CL608e/CL612e Service Manual
PN 9001079
Rev. B
Section 2. Configuration
Dip Switch Settings
Label Sensor Selection (DSW3-3): Enables or disables the Label Pitch sensor. If the
sensor is enabled, it will detect the edge of the label and position it automatically. If
it is disabled, the positioning must be under software control using Line Feed
commands.
DSW3
DSW3-3SETTING
ON
Of fSensor Used
O nSensor Not
OFF
1 2 3 4
5 6 7 8
Used
Back-Feed Selection (DSW3-4): When Back-Feed is enabled, the printer will
position the label for dispensing/cutting and retract it before printing the next label.
The amount of backfeed is adjustable.
DSW3
DSW3-4SETTING
OffEnabled
ON
OFF
OnDisabled
1 2 3 4
5 6 7 8
External Signal Interface
The EXT connector on the printer rear panel is intended for use with the external
printer accessories such as label rewinders or applicators. The 14-pin Centronics
type connector provides a choice of four different output signals along with various
error conditions.
PN 9001079
Rev. B
EXT Print Start Signal Selection (DSW3-5): Allows an external device to initiate
a label print for synchronization with the applicator. See Section 3: Interface
Specifications for a description of the signal level and requirements. When DSW35 is On, the unit is in the Continuous print mode, Backfeed is disabled an External
Signals are ignored.
DSW3
DSW3-5SETTING
OffDisabled
ON
OFF
OnEnabled
1 2 3 4
SA TO CL608e/CL612e Service Manual
5 6 7 8
Page 2-5
Section 2. Configuration
Dip Switch Settings
External Signal Type Selection (DSW3-6, DSW3-7): Both the polarity and signal
type (level or pulse) of the external print synchronizing signal can be selected. See
Section 3 for a definition of signal types.
DSW3-6DSW3-7SETTING
DSW3
ON
OffOffType 4
OFF
OffOnType 3
OnOffType 2
1 2 3 4
5 6 7 8
OnOnType 1
Repeat Print via External Signal (DSW3-8): Allows an applicator or other device to
reprint the last label of the print job. See Section 3: Interface Specifications for a
description of the signal requirements.
DSW3
DSW3-8SETTING
OffDisabled
ON
OFF
OnEnabled
1 2 3 4
5 6 7 8
Page 2-6
SA T O CL608e/CL612e Service Manual
PN 9001079
Rev.B
Section 2. Configuration
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:
(1) Applicable only if an RS232 Interface Card is installed in the printer.
Software Default Settings - The printer stores any software settings upon receipt from
the host and uses them until they are again changed by receipt of a command
containing a new setting. These settings are stored in non-volatile memory and are
not affected by powering the printer off. The printer may be reset to use the default
software settings by depressing the LINE and FEED keys simultaneously while
powering the printer on. You will be asked to confirm that you want the printer
default settings by selecting either YES or NO by using the LINE key to step the
underline cursor to the desired setting. If you select YES and press the FEED key, the
following default configuration will be stored:
(1)
(1)
8 data bits, no parity, 1 Stop bit, 9600 Baud
Ready/Busy
(1)
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Once the default operation is completed, a DEFAULT SETTING COMPLETED
message will be displayed on the LCD panel and a single "beep" will be heard. The
printer should be powered off while this message is being displayed. This saves the
default settings in the EEPROM where they will be automatically loaded the next time
the printer is powered on.
DEFAULT SETTING
COMPLETED
PN 9001079
Rev.B
SA TO CL608e/CL612e Service Manual
Page 2-7
Section 2. Configuration
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 be controlled via software commands and in the case of conflict between
software and control panel settings, the printer will always use the last valid setting. If you
load a label job that includes software settings and then enter a new setting via the LCD
Panel, the manually set values will be used by the printer. If you set the values manually
and then download a job with software settings, the software settings will be used.
There are 7 configuration and operation modesyou can aaccess from the LCD panel. To
enter the desired mode, the KEY SEQUENCE combination listed in the table below must be
performed. The initial LCD display message is shown for each mode.
EDOMECNEUQESYEKYALPSIDLAITINIEGAP
edoMlamroNrewoP
ENILNO
000000:YTQ
edoMdecnavdAREWOP+ENILEDOMDECNAVDA31-2
edoMtnirPtseTREWOP+DEEF
edoMgnitteStluafeD
)locotorPdtS(
edoMecnanetniaM
edoMpmuDxeHREWOP+NO4-2WSD
erawmriF
edoMdaolnwoD
REWOP+DEEF+ENIL
+ENIL+NO4-2WSD
REWOP+DEEF
ENILNO
REWOP+NO6-2WSD
YDAER
EDOMTNIRPTSET
NOITARUGIFNOC
GNITTESTLUAFED
ONSEY
EDOMECNANETNIAM
FFO>-NO4-2WSPID
000000:YTQ
DAOLNWODHSALF
9-2
33-2
43-2
53-2
83-2
93-2
Page 2-8
SA T O CL608e/CL612e Service Manual
PN 9001079
Rev. B
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