Cl6xxe Service A

CL608e/CL612e Printers

Service Manual

PN 9001079Rev. A

SATO America, Inc.545 Weddell Drive

Sunnyvale, CA 94089 Main Phone: (408) 745-1300

Tech Support Hotline: (408) 745-1379Fax: (408) 745-1309

http:\\www.satoamerica.com

Copyright 2002SATO America, Inc.

PN 9001079Rev. A

SATO CL608e/CL612e Service Manual

The information supplied in this manual was current at time ofpublication. If you come across procedures that need clarification orfind errors or have suggestions contact us at [email protected]

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iPN 9001079Rev. A


Section 1. Overview and Specifications Page1 Overview ........................................................................................................... 1-12 Physical Characteristics .................................................................................. 1-23 Printer Features ................................................................................................ 1-34 Operation PanelDisplays ................................................................................. 1-55 Components ..................................................................................................... 1-76 Switches and Sensors ..................................................................................... 1-87 Ribbon ............................................................................................................. 1-108 Installation Considerations ........................................................................... 1-109 Optional Accessories .................................................................................... 1-1010 Environment & Approvals .............................................................................1-1111 General Printer Specifications ...................................................................... 1-1112 Character Fonts ............................................................................................. 1-1413 Bar Codes ...................................................................................................... 1-15

Section 2. Configuration1 Dip Switch Settings .......................................................................................... 2-12 Default Settings ................................................................................................ 2-73 LCD Panel Printer Configuration .................................................................... 2-8

Normal Mode ................................................................................................. 2-9M8400 Compatible Mode ........................................................................... 2-12Advanced Mode .......................................................................................... 2-13Card Mode ................................................................................................... 2-17Service Mode .............................................................................................. 2-25Counters Mode ........................................................................................... 2-31Test Print Mode ........................................................................................... 2-32Default Setting Mode .................................................................................. 2-33Maintenance Mode ..................................................................................... 2-34Clear Non-Standard Protocol .................................................................... 2-36Download User Defined Protocol Codes ................................................. 2-36Hex Dump Mode ......................................................................................... 2-37Download Mode .......................................................................................... 2-38User Download Mode ................................................................................. 2-39

4 Sample Test Labels ........................................................................................ 2-40

Section 3. Interface Specifications1 Overview ........................................................................................................... 3-12 Interface Types ................................................................................................. 3-13 Receive Buffer .................................................................................................. 3-34 IEEE 1284 Parallel Interface ............................................................................ 3-45 Optional RS232C Serial Interface ................................................................... 3-66 Universal Serial Bus (USB) Interface ............................................................. 3-97 Local Area Network (LAN) Interface .............................................................. 3-108 Bi-Directional Communications ..................................................................... 3-109 Accessory (EXT) Connector ........................................................................... 3-19

Section 4. Electrical Checks and Adjustments1 Overview ........................................................................................................... 4-12 Steps Prior to Some Procedures .................................................................... 4-23 DC Power Voltage Checks............................................................................... 4-34 Potentiometer Assignments & Adjustments ................................................. 4-65a Pitch Offset Adjustment .................................................................................. 4-8

Table of Contents

ii SATO CL608e/CL612e Service Manual PN 9001079Rev. A

Table of ContentsSection 4. Electrical Checks and Adjustments

5b Pitch Offset Adjustment .................................................................................. 4-96 Label Gap Adjustment ................................................................................... 4-107 Eye-Mark Adjustment .................................................................................... 4-118 Feed/Backfeed Adjustment (Tear-Off) .......................................................... 4-129 Feed/Backfeed Adjustment (Cutter) ............................................................. 4-1310 Feed/Backfeed Adjustment (Dispenser) ...................................................... 4-1411 Ribbon Sensor Verification ........................................................................... 4-1512 Ribbon Sensor Adjustment (Near End) ........................................................ 4-1613 LCD Display Adjustment ............................................................................... 4-1714 Print Darkness Adjustment ........................................................................... 4-18

Section 5. Mechanical Adjustments1 Overview ........................................................................................................... 5-12 Ribbon Clutch Adjustments ............................................................................ 5-23 Print Head Position Adjustment ..................................................................... 5-54 Print Head Balance Adjustment...................................................................... 5-75 Ribbon Roller Adjustment ............................................................................... 5-86 Feed Roller Adjustment (Label Tracking) ...................................................... 5-97 Timing Belt Tension Adjustment ................................................................... 5-118 Head Latch Adjustment ................................................................................. 5-129 Notch/Gap Sensor Adjustment .................................................................... 5-13

Section 6. Replacement Procedures1 Overview .......................................................................................................... 6-12 Replacing the Main Circuit Board .................................................................. 6-23 Replacing the Fuses........................................................................................ 6-74 Replacing the Power Supply ........................................................................... 6-95 Replacing the Stepper Motor ........................................................................ 6-126 Replacing the Timing Belts ........................................................................... 6-137 Replacing the Print Head ............................................................................... 6-168 Replacing the Platen ...................................................................................... 6-199 Replacing the Ribbon Drive Clutch Washers .............................................. 6-2310 Replacing the Ribbon Motion Sensor .......................................................... 6-2711 Replacing the Paper End Switch (Micro-Switch) and the

Bottom Half of the Notch/Gap and Eye-Mark Sensors ............................... 6-3012 Replacing the Top Half of the Notch/Gap Sensor ....................................... 6-3413 Replacing the Display Panel or Keyboard ................................................... 6-37

Section 7. Factory Resets1 Overview ........................................................................................................... 7-12 Factory/Service Test Print ............................................................................... 7-23 Clear Head Counters ........................................................................................ 7-34 Clear Dispenser Counter ................................................................................. 7-45 Clear Cutter Counter ........................................................................................ 7-56 Clear EEPROM.................................................................................................. 7-67 Sample Test Prints ........................................................................................... 7-7

Section 8. Troubleshooting1 Overview .......................................................................................................... 8-12 Initial Checklist ................................................................................................ 8-23 The IEEE 1284 Parallel Interface .................................................................... 8-2

iiiPN 9001079Rev. A


Section 8. Troubleshooting4 The RS232C Serial Interface ........................................................................... 8-45 The Universal Serial BUS (USB) .................................................................... 8-46 The LAN Ethernet Interface ............................................................................ 8-57 Error Signals .................................................................................................. 8-108 Troubleshooting Tables ................................................................................. 8-119 Head Pattern Examples ................................................................................ 8-1510 Hex Dump Diagnostic Labels ....................................................................... 8-17

Section 9. Optional Accessories1 Overview .......................................................................................................... 9-12 Label Cutter Kit Installation............................................................................ 9-23 Label Dispenser Kit Installation ..................................................................... 9-64 PCMCIA Memory Expansion Installation .................................................... 9-155 Flash Memory Expansion Installation ......................................................... 9-206 Real Time Clock Installation ......................................................................... 9-22

Section 10. Parts List1 Overview ........................................................................................................ 10-12 Base Cover Assembly ................................................................................... 10-23 Frame Assembly ........................................................................................... 10-114 Print Head Assembly .................................................................................. 10-185 Ribbon Assembly ........................................................................................ 10-226 Feed Roller Assembly ................................................................................. 10-277 Main PCB Assembly .................................................................................... 10-308 Interface Option ........................................................................................... 10-319 Dispenser Assembly Option ...................................................................... 10-3210 Cutter Assembly Option ............................................................................. 10-3911 PCMCIA Memory Option .............................................................................10-43

Index .............................................................................................................................. Index -1

Table of Contents

iv SATO CL608e/CL612e Service Manual PN 9001079Rev. A

1PN 9001079Rev. A


Overview and Specifications

1.1 Overview

Section

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

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PN 9001079Rev. A

Page 1-2 SATO CL608e/CL612e Service Manual


1.2 Physical Characteristics

Width

Height

Depth

FRONT

ACCESS DOOR

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PN 9001079Rev. A

Page 1-3



1.3 Printer Features

INTERFACE SLOT "#"$#"&""$#"'"&

0*(1!#,2 %- $(3334 (1!#,! -5%4*67(1!#37(1!#

MEMORY CARD SLOT " !(!'#$

EXT CONNECTOR 3+,! -5%4

POWER SWITCH "

AC FUSE ("""$'"*-8$

AC POWER INPUT ("-8-9:$6&"##$

Rear Panel

INTERFACE SLOT (SHOWNWITH CENTRONICS PARALLELINTERFACE INSTALLED)

POWER SWITCH

PCMCIA MEMORYEXPANSION SLOT

AC POWER INPUTCONNECTOR

AC FUSE

EXTERNALACCESSORYCONNECTOR

COVER PLATE-REMOVE FORACCESS TO FAN-FOLD SLOTS

PN 9001079Rev. A



Printer FeaturesRIBBON UNWIND

SPINDLE

ACCESS DOOR

RIBBON REWINDSPINDLE

MEDIA HOLDER

PLATENROLLER

MEDIA KNOB

LABEL SUPPLYGUIDE

HEAD LATCH

PRINT HEADASSEMBLY

SWITCHES AND SENSORSRefer to Section 1.6

LABEL TEAROFF PLATE

Adjust the Media Knob based on themedia you have loaded. For media up to2.3 inches wide, use the "1" position. Formedia between 2.3 and 4.6 inches wide,use the "2" position. For media wider than4.6 inches wide, use the "3" position. Ifyou use media narrower than 7 inches,using the wrong setting can void the printhead warranty due to excessive pressure.

MEDIA HOLDDOWN

PN 9001079Rev. A

Page 1-5



1.4 Operation Panel/Displays

LCD DISPLAY

FEED KEY

COVER

ADVISORY LED'S

LINE KEY

ADVISORY LED'S

POWER Illuminated when power is on.

ONLINE Illuminated when printer is ready to receive data. Turn ON/OFF bytoggling the LINE key.

LABEL Illuminated when label supply is out.

RIBBON Illuminated when ribbon motion sensor does not detect any ribbonmotion.

ERROR Illuminated when there is a system fault such as an open print head.

LCD SCREEN 2 LINE x 16 Character LCD display. Used for setting operationalparameters of the printer and displaying error conditions

LINE KEY Momentary switch. Pressing this key toggles the printer betweenthe on-line and off-line mode. When the printer is on-line, it isready to receive data from the host. This key acts as a pauseduring a print job by taking the printer off-line.

FEED KEY Momentary switch. Pressing this key feeds one blank labelthrough the printer when it is off-line. When the printer is on-line, there is auser selectable option in the Service Mode (see page 2-28) to either printa copy of the previously printed label or feed a blank label. The default isto feed a blank label.

PN 9001079Rev. A



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).

VR3 (Pitch) To adjust home print position of the label (+/- 3.75 mm).

VR4 (Display) To adjust the contrast of the LCD display.

*DSW2 & DSW3 Dip Switches used to set operationalparameters of printer. Refer to Section2 for settings.

*NOTE: Optional RS232 Communication Card contains DSW1 switches whichare configured when supplied with the printer.

PN 9001079Rev. A

Page 1-7



1.5 Components

RIBBON GUIDEPLATE

STEPPERMOTOR

TIMINGBELTS

LCD BOARD ANDKB BOARD ON

BACKSIDE OF PANEL

PRINT HEAD

PLATEN

PLATENS

PN 9001079Rev. A



1.6 Sensors and Switches

Components

POWER SUPPLY UNIT

PLUG-IN INTERFACECARD - CENTRONICSI/O SHOWN

RIBBON SENSOR: This sensor is amotion detector that signals the printerwhen the ribbon supply is turning. Thissensor is used for both the ribbon end andribbon near end sensing.

HEAD LATCH LEVER: When theprint head is opened, a microswitch is activated and the printerwill stop printing. Error messagewill be displayed on the LCDoperator panel.

PN 9001079Rev. A

Page 1-9



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 pushing downon the same green tab.

LABEL OUT SENSOR: This microswitch is activated when mediastock is out or when the Media HoldDown is in the up position. Allprinter operations stop, and anerror message is displayed on theLCD.

MEDIA HOLD DOWN(Underside)

"EYE-MARK" SENSOR(Fixed: Non adjustable)

NOTCH/GAP SENSORLED ARRAY (BottomHalf is Non-adjustable)

NOTCH/GAP SENSOR(Top Half is adjustable)( Refer to Section 5-10)

PN 9001079Rev. A



1.9 Optional Accessories

YROSSECCA e216LC/e806LC

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*.stnofepyTeurTdedaolnwod

radnelaCotdesuebnactahtpihcemiT/etaDdetnuomyllanretninA

*.gnitnirpfoemitehttaslebalpmatsemit/etad

rettuClebaLtatucebotslebalgniwollatnemhcattadetnuomyllanretninA

*.gnimmargorphguorhtdellortnoC.slanretnideificeps

resnepsiDlebaLrofgnikcabmorfdeleepotslebalgniwollatnemhcattalanretnI

detnuompu-ekatgnikcaB.noitacilppa)dnamedno(etaidemmi.retnirpforaerotyllanretxe

redniweRlebaLerayehtretfalloraotnoslebalsdniwertahtnoitpolanretxE

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ecafretnIlaireS eludoMecafretnI232SRlaireSdeepShgiH

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1.7 Ribbon6'&+"'"$6""#&&''".'##"##'#''$

1.8 Installation Considerations "&'"$"#,#'###&$&"",##&'

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$3$

PN 9001079Rev. A

Page 1-11



1.10 Environment & Approvals

1.11 General Printer Specifications

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PN 9001079Rev. A



General Printer SpecificationsnoitacificepS e806LC e216LC

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PN 9001079Rev. A

Page 1-13



General Printer Specifications


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PN 9001079Rev. A



1.12 Character Fonts


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tnoFMX dloBdesnednoCsrevinU)Hstod42xWstod42(

tnoFAO A-RCO)Hstod22xWstod51( A-RCO)Hstod33xWstod22(

tnoFBO B-RCO)Hstod42xWstod02( B-RCO)Hstod63xWstod03(

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PN 9001079Rev. A

Page 1-15



1.13 Bar CodesnoitacificepS e806LC e216LC

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yalrrevOmroF stamrofxelpmocfognitidedeeps-hgihrofyalrevomroF

PN 9001079Rev. A



1SATO CL608e/CL612e Service ManualPN 9001079Rev. A

Configuration

2.1 Dip Switch Settings

2Section

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

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DIP SWITCHES

DSW1

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2


SATO CL608e/CL612e Service Manual PN 9001079Rev. A

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, DSW1-3):+","+,

Stop Bit Selection (DSW1-4): %,"+%

Baud Rate Selection (DSW1-5, DSW1-6):",#"

Dip Switch Settings

Data Bit Selection (DSW1-1):"'01,+%

RS232 Transmit/Receive Setting (located on RS232 I/F Module)

DSW1-1 SETTING

Off 8 data bits

On 7 data bits

Protocol Selection (DSW1-7, DSW1-8):,")"2"3.$%,4.1566,.1*7

DSW1-2 DSW1-3 SETTING

Off Off NoneOff On EvenOn Off OddOn On Not Used


Off Off 9600Off On 19200On Off 38400On On 57600


Off Off Rdy/BsyOff On Xon/XoffOn Off Bi-Com 3On On Bi-Com 4*

3


SATO CL608e/CL612e Service ManualPN 9001079Rev. A

Dip Switch Settings

%,%,)" 1 )

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

OFF

1 2 3 4 5 6 7 8

DSW2

ON

OFF

1 2 3 4 5 6 7 8

DSW2-2 SETTING

Off Gap

On Eye-Mark

DSW2-3 SETTING

Off Disable

On Enable

DSW2-4 SETTING

Off Disable

On Enable

DSW2-5 SETTING

Off 1 Item

On Multi-Job

Printer Set up

Sensor Type Selection (DSW2-2):,)",'(+.4-

Head Check Selection (DSW2-3): "-,%+%,)

Hex Dump Selection (DSW2-4):89%"%

Receive Buffer Selection (DSW2-5):")%,',,,",,%,%

DSW2-1 SETTING

Off Transfer

On Direct Therm

Print Mode Selection (DSW2-1):%")%+'""%,"))

4



Protocol Code Selection (DSW2-7):%%,"

DSW2

ON

OFF

1 2 3 4 5 6 7 8

DSW2

ON

OFF

1 2 3 4 5 6 7 8

DSW2-7 SETTING

Off Standard

On Non-Std.

Dip Switch Settings

DSW2-6 SETTING

Off Disabled

On Enabled

Firmware Download (DSW2-6):"%%,),%,#*4

DSW2

ON

OFF

1 2 3 4 5 6 7 8

M8400 Emulation Mode (DSW2-8):%),%%+,"%)9),,,)+!.0!.1

DSW3

ON

OFF

1 2 3 4 5 6 7 8


Off Off Batch/Continuous

Off On Tear Off

On Off Cutter

On On Dispenser

Backfeed Sequence Selection (DSW3-1 and DSW3-2):")%,"3&$-""

DSW2-8 SETTING

Off Disabled

On Enabled

5



DSW3

ON

OFF

1 2 3 4 5 6 7 8

DSW3

ON

OFF

1 2 3 4 5 6 7 8

DSW3

ON

OFF

1 2 3 4 5 6 7 8

DSW3-3 SETTING

Off Sensor Used

On Sensor NotUsed

DSW3-4 SETTING

Off Enabled

On Disabled

DSW3-5 SETTING

Off Disabled

On Enabled

Label Sensor Selection (DSW3-3): (:, ),"%+, ")%,):%%

Back-Feed Selection (DSW3-4): 3-. "",")&),")9%,-,;

External Signal Interface(* $"% 3-,(9))

Dip Switch Settings

6



Dip Switch Settings

DSW3

ON

OFF

1 2 3 4 5 6 7 8


Off Off Type 4

Off On Type 3

On Off Type 2

On On Type 1

DSW3

ON

OFF

1 2 3 4 5 6 7 8

DSW3-8 SETTING

Off Disabled

On Enabled

External Signal Type Selection (DSW3-6, DSW3-7): 3"+)+"'",9"+=)),,,)+"

Repeat Print via External Signal (DSW3-8): ""'",";,",,",)/%

7



2.2 Default Settings

Dip Switch Selections"*,,",9"#'3,,,""),)"),)

Communications: (1) 8 data bits, no parity, 1 Stop bit, 9600 Baud (1)

Protocol: (1) Ready/BusySensor: Gap SensorReceive Buffer: Multi-JobMode: Batch ContinuousLabel Sensor: Sensor UsedBackfeed: EnabledExternal Signals: Disabled

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edoMgnitteStluafeD)locotorPdtS(

REWOP+DEEF+ENILGNITTESTLUAFED

ONSEY43-2

edoMecnanetniaM+ENIL+NO4-2WSD

REWOP+DEEFEDOMECNANETNIAM

FFO>-NO4-2WSPID53-2

edoMpmuDxeH REWOP+NO4-2WSDENILNO

000000:YTQ83-2

erawmriFedoMdaolnwoD

REWOP+NO6-2WSDDAOLNWODHSALF

YDAER93-2

9



LCD Panel Normal Mode",""+#*4',"%%+"+*7:7(%

:$"+*7:7(","+%/+C?%))*:7('",,+"):7(-+";' C?%)%,";)" "+%,%)";%"

D)),)"

STEP PROCEDURE

! ",-,,+")-+"+)*:7(

-+%+,%""+,D(#%;%-

))")%"-))+,))

))",%,)"

STEP PROCEDURE

! D-+")

*) "-+")'9;%

Print Darkness Setting

!E:)E4%E-

!"

#$%&'''

User Settings

10



)")%,"+)+,")))

STEP PROCEDURE

! D-+"")

5E5&!66%%&AEA&!>6%%&1E1&66%%&

*) "-+")'9;%

Print Speed Adjustment

()**+

, - .

",%)))%,",,)),9))",;'"F&.5G%%%,!%%*" ,;F&.0>%%)$8"%;%"

Pitch Offset Adjustment

)/0$11(*

2%%

STEP PROCEDURE

! +")D-+""'F)'."%')),,+,%")'%')),-%%

*) "-+")'*,,;%

DB+",),)"+%"%-+")'),5,%+"6)

LCD Panel Normal Mode

11



STEP PROCEDURE

5 -+")'))-+")* "-+'9;%,%");%

Pitch Offset Adjustment

A B C D E F G

A B C D E F G

A B C D E F GS

enso

r P

ositi

on

Line

Fee

d D

irect

ion

Leading Edge of LabelMoved with negative (-)offset to print on leadingedge of the label

Original (0 offset) firstline position

Moved with positive (+)offset to print on trailingedge of the label


12



,"";%%+ )?(;,7*4-+";,)?(;''%"

" ",%,)"

Cancel Print Job

STEP PROCEDURE

! -+"

*) "-+")

,";',%%%+ ""+$*4:((%),*7:7(7%4

,+)+,) +%D%)+-)"*:7(%+")-+

//* )#3$4

5*( $

//* )#3$4


13



STEP PROCEDURE

! D-+"

*) "-+")'*"+

STEP PROCEDURE

! D-+"

*) "-+")'"+*,,"+

67

)%,=")',%%?( ",'),=

8$$ *

)%%""",?("""*7:7(%+",7* """*:7(%%%+"*7:7(%+"):7(-+,+"

Zero Slash

AutoOnline

LCD Panel Advanced Mode'%"'%-;%/+;%+,,"," ",)%)"'%,%+)))

('4

STEP PROCEDURE

! -+%+)""%)" -+"+,

-+"+H"+

+&/*+%$+* !"

#$%&'''

14



I*,,,%))),%,",,'"""')%',""),%-))'%'"),%9%%'1

8=*,,%),),"')%),,),)')%)%),)),)),",/;,,J($K3#,"%%%9%%'!55

(*/ *+#

Print Offset

STEP PROCEDURE

! D-+",),)"+%"%-+"

-+")'))-+")* "-+'9;%

*) "-+")'9"+

,%");%

%)+"+,$*""

$",$:A61&$:A!")%%+):$"+'J($K$%%) %+',%% '+"',%,"+??&44&%%?&4&+&%,%,9)

$,, "-+?(,$, "-+7*) -+

#$11(*

&2 72

Set Calendar

LCD Panel Advanced Mode

"%'"/=," ,%,I8=*,,

15



STEP PROCEDURE

! .,"+')+?)+")-++%+%-+"%9%%)' @GG@,+)""@66@)

.,+'+ ")-+')4"?)%")%+")-+%%+%-+"',@!@""@6!@)

.,+'% ")-+')+"?)%")%+")-+%+%-+"',@!@""@6!@)

5 .,+' ")-+')8"?)%"))5-+")-+%+%-+"',@5@""@6!@)

> ! .,+' ")-+')4"?)%")+")-+%%+%-+"',@A6@""@6!@)

A ,+'% ")-+")')$#&:

Set Calendar(Continued)


/ *+#

99

Calendar00/00/00 00:00

16



/0#/*#)/0

)#$) 1:*+

STEP PROCEDURE

! D-+")

*) "-+")'4

9'% ",,"-

)+,",9")""")

Character Pitch


"$#*/#9 1

STEP PROCEDURE

! D-+"?(7*

*) "-+")'$"+

)"")&,"$#:,%% ))""%+%%"+%,*"

Ignore CR/LF

+&/*+$+*Exit Advanced Mode

17



STEP PROCEDURE

! D-+")$4%+

*) "-+")'"+

$4"%)(9"4%+$4$$(9"#*4$4,%'4"++")-+

+&/*+$+* /#+$+*

$4"+"$4'4%$$! "-+

%*%(* */

#+ *%$#5

%+","9"%%+@$$!@%%%$#","$4$$$!"(9"#*4$$4%+","(9"#*4$$!"$4$$$

Mem Select (CC1)

LCD Panel Card Mode

18



STEP PROCEDURE

! D-+")? "$$"+%

,7 "+'!"#$%%-+"'"+

$,%++"")?,+7 "+"'

-+",? "+"

5 *"+"%" "-+'"+

> ,"+" ,,)%)"+

#&(#&7$( )=4%( ,,

%%+'

/#+;MemoryCopyTrueTypeFont Y/N

/$)5(#

5*( $

#8*5)*1$/$)5

/$)5"

#8*5)*1$/$)5

/$%) **+

9

=======

LCD Panel Card Mode

19



STEP PROCEDURE

! D-+")? "$$"+%

,7 "+'$.K4%+$"+%-+"'"+

$,%++"")?,+7 "+"'

-+",? "+"

5 *"+"%" "-+'"+

> ,"+" ,,)%)"+

#&(#&7$( )=4%( ,,

%%+'

/#+;

20



/#+;MemoryCopyAll Y/N

STEP PROCEDURE

! D-+")? "$$"+%

,7 "+'$.K4%+$"+%

$,%++"")?,+7 "+"'

-+",? "+"

5 *"+"%" "-+'"+

> ,"+" ,,)%)"+

#&(#&7$( )=4%( ,,

%%+'

/$)5(#

5*( $

/#+;

21



*%$#5;:%4Card CopyAll Y/N

STEP PROCEDURE

! D-+")? "$$"+%

,7 "+'$.K4%+$"+%

$,%++"")?,+7 "+"'

-+",? "+"

5 *"+"%" "-+'"+

> ,"+" ,,)%)"+

#&(#&7$( )=4%( ,,

%%+'

/$)5(#

5*( $

%*%$#5;

22



/#+;Memory CopyProgram Y/N

STEP PROCEDURE

! D-+")? "$$"+%

,7 "+'%"+

$,%++"")?,+7 "+"'

-+",? "+"

5 *"+"%" "-+'"+

> ,"+" ,,)%)"+

#&(#&7$( )=4%( ,,

%%+'

/$)5(#

5*( $

/#+;

23



%*%$#5;

24



STEP PROCEDURE

! D-+")? "4%+%%

,7 "+'%"+

9$4 ",," -

3,$4$ %,%7%)++$

Card Format Yes No

STEP PROCEDURE

! D-+")? "$%%

,7 "+'%"+

#+1$#%

5*( $

/#+%$+*

3,(9"4%+ %,%7%)%%+++

Memory Format Yes No

%*%$#51$#%

5*( $

LCD Panel Card Mode

25



STEP PROCEDURE

! -+%+)""%)" :7(-+"+,

-+'4

'4"+"'4', "-+

LCD Panel Service Mode

'4""""%,",%'4

?

To Enter Advanced Mode:

(*#&/*%$+*

$:A61&$:A!"%,)),+%),,)')"-@(?(@%-;%+%+')'%9%%%%%)'.+",.*" ),.L":$"+@L@")),.*7" :$"+@(?(@"),',%)@66I@ "%+),,,""%%+'%;,) -)"+,,@(?(@%-'),+,'),)"

Gap [X.XV]Input [X.XV}

") @:':&A

)8 @:':&A

26




GAP.)@L@ ')","+%%)-))-),%,)

8)I):'F:I):'96>EI

STEP PROCEDURE

! -):8.#')",:$"'%)@L@".E*4-+

",%-)-)"::#')",:$"'))%,))

3-)E6>I3-)E!6IK&.'

,%') +%+',)'-""+, )/+%+)/",%

$)"')),%

5 D-+")"+%",%-+",-+,% %+),%)'),%9%%'),%+"@66@),',@66@ "%+'%""

> *) ")-+")'*"+

") @:':&A

)8 @:':&A

Gap [X.XV]Input [X.XV}

27



EYE.)@(?(@ ')%%))"@+@%-,%,

8)I):'F:I):'96>EI

STEP PROCEDURE

! :8.4-"@+@%-#')",:$"'%)@(?(@".E*7

7",@+@%-"')))"#')",:$"'))%,))

:*+E6.6>I(+.%-E(/)!I''

,%') +%+',)'-""+, )/+%+)/",%

$)"')),%

5 D-+")"+%",%-+",-+,% %+),%)'),%9%%'),%+"@66@),',@66@ "%+'%""

> *) ")-+")'*"+

*5* @:':&A

)8 @:':&A


Eye [X.XV]Input [X.XV}

28



","%+,-"*%

8$$ *1**+

5*( $


STEP PROCEDURE

! D-+")? ",-+%

,7 "+'%"+

STEP PROCEDURE

! D-+")? ",-+%*%

,7 "+'%"+

",",-%+

Feed on Error Yes No

1**+$*##$#

5*( $

Auto Online Feed Yes No

STEP PROCEDURE

! D-+")? ""((-+""*,"*,, ")-+,-

,7 "+'%"+

","""%%+((-+"7%*%

Reprint W/Feed Yes No

#*)#B91**+

5*( $

29



"++""3-,.5E*%9%%-,>>%%

Forward/BackfeedDistance Default

STEP PROCEDURE

! -+,)""",!&1@)"%)-""

-++-,">>%%(%+":7(-+ '!%%

$D*7-,'56%%%+-/;%

-+"-,

1$#B#+94/C1**+

+(/* +*18


1$#B#+94/C1**+

+(/* ===%%

,MG,!5"(

30



)):$%%)() L% " )

Select LCD DisplayLanguage

STEP PROCEDURE

! -+')))

) "-+")'9"+

(* */ "8"*

*" (0

",+9%,"($,>89

Euro CodeD5

STEP PROCEDURE

! ",)D-+")

-+'),9%

-+")

5 ) "-+")'9"+

*8#$/$+*

+E


31




)"+,- "*,,

Priority SettingLCD Command

STEP PROCEDURE

! D-+""+,:$ )':$"+&%+%,%); ),+,,%%),$%% +%%;-",");:$"+,)

*) "-+")'9"+

)#$#5(*"

/+ /$%%+

"$#* /9+ *

5*( $

,

J:(K89!6""%%

J$7K89!1%%

D,%"+%"+,+"+,#.$8,,),53."

9'4"",, -

Service Mode(*#&/*%$+*

#44$*#*+

*4 * +(4 *

,+"+#8,,),3.",,%"+@@'" "D-+("'9

32



STEP PROCEDURE

! D-+" 88:(,"8$

-+"+'%

-+'9

LCD Panel Counters Mode

STEP PROCEDURE

! -+%+)""%)" :7(-+"+,

-+

33



LCD Panel Counters Mode

STEP PROCEDURE

5 D-+),++' 7*,+66 "?(*) "-+$4"+

9$4"",, -

/$8*#(%$+*

Test Print Mode4,,,,,",),.>*7 +%%%

"+"%%+",+')+,)'4+',++%-)

D4

Test Print ModeConfiguration

STEP PROCEDURE

! "")-+#-+""+4%):$"

D-+"+",+"

$,)3$8$-4%++

*()#%$+*

/$1"8#$

See last pages in this section fortest label sample print-outs

*+'+"," ((-+"'="+"++

34



LCD Panel Test Print Mode

*+'+"," -+""+'="+"++

Test Print Size10 CM

STEP PROCEDURE

! D-+(%-+" ='!%%9%%,!6%""%=,5%

-+"

-+")+

5 -+""

94 "",, -

*()#!*

/%

)#*((1**+C*5$

($))#"

Default Setting Mode*+",))),",),"),%-,

,)4"-+%+")""%)"-+

Default Setting Mode

STEP PROCEDURE

! D-+?(7*

*) "-+""),

"%"" ,)$%""+""",,)

9,)4 "",, -

+*18 (*"

5*( $

+*18 (*"

/$%) **+

7*("+""4%+*+%4%+"

35



LCD Panel Maintenance Mode Factory Mode

STEP PROCEDURE

! #"" ""

"#$%""

-+%+)"

"" -+,)""

5 "#$%",)""

> -+"+9

A -+)%)"","+8 8$+"" "$.%,-"$D $$.%,+:( :,$%,-)":: $,%",+,))")),%

0 -+,," 9

""

1 "=+")-+,:#L(

G -+,"-+)"")

,"N,%

",")),,%)%%+%

/$8*#/ *#

*()#

)#*((1**+C*5

)#(!*

(% #"*

/$8*#/ *#

$*

1/$#5%$+*

!"

#$%&'''

%*/*%$+*

+B;,$;

36



STEP PROCEDURE

! #"" "

"

"#$%""

-+%+)""" -+,)

""

5 "$%*",)""

> -+"+9

A -+"+9

0 -+$*D7(#((#*4$((#*4&,%,+,)

1 -+"+9

G -+,"-++

!6 ""%))%","

!! ,,"944

LCD Panel Maintenance Mode

/ *#%$+*

1/$#5%$+*

!"

#$%&'''

%*/*%$+*

+)(B;,$;

37



LCD Panel Clear Non-Standard Protocol

$7." ""#$&"""%+")-+

Alt. ProtocolDefault Complete

STEP PROCEDURE

! "%)"-+

-+ """,'

,,)%" "%")"%"

9% "",, -

"+"%,%/%,,,+%8' ,"+%%" +,"','

8

Download User Defined Protocol Codes,,%"%")J($K:%%

D% ".0"""%+")-+"%)"-+

User DownloadPress the Line Key

STEP PROCEDURE

! "#$&"""","

-+"),

8(*#+$B $+

B"

)#$$/$

+*18 /$%) **

!"

#$%&'''

!"

#$%&'''

8(*#+$B $+

)#*((0* *C*5

38



(Countinued)

STEP PROCEDURE

%%%%"

5 ,' ""","" ""

> ,""" ",,-+%,"'

A ,% "-+"%%",+ ",,")-+)")

LCD Panel Download User Defined Protocol CodesUser DownloadPress the Line Key

Hex Dump ModeD: "",',,9%,%%9%,)

89%"% ""#$%"""

Online

STEP PROCEDURE

! "+'

%"

'"9%,%

5 "%" ""#$%"""-*7

$ *

F5

!"

#$%&'''

Refer to the Operator and Technical Reference Manual for the data stream commandstructure required.

39



LCD Panel Firmware Download Mode

STEP PROCEDURE

! #"" "

"

"#$'""

",)""

!"

#$%&'''

1 (0+$B $+

#*+5

Refer to the specific instructions provided with the flash firmwarefiles provided by SATO America Technical Support ordownloaded from the SATO America Web Site.

www.satoamerica.com

40



2.4 Sample Test Labels

CONFIGURATION BAR CODE

MEMORY

HEAD CHECK

FACTORY


Interface Specifications

3.1 Overview

Section

!"#$%!&! &$'&$&!$ $'($) && !&)'!

3.2 Interface Types

!

$*#$+$,$$,'!

&!

- '

- .)/$

- #

- .010

- /2$$.010

- 3)0/30"30/%

- 45&6"45%

- ,

2



Interface Types),'$&)'$'$#$+$! $&$'!)"78!9%3)0/$"30/%!

#&'$$$&/+#!.010&)'$!30/&$$30/$!

! "!

#!

Available Interfaces

CENTRONICS PARALLEL INTERFACE

USB INTERFACERS232C SERIALINTERFACE

ETHERNETINTERFACE

3



3.3 The Receive Buffer)')&&'!)$'$:$:!:$'$'&&:($$)':!$:$:')'!

Single Job Buffer

):!:$,!;7+/!

Multi Job Buffer$$')::!$6

4



3.4 IEEE 1284 Parallel Interface#$+$'$! !&$' ! &&'&!$% "&&&'()* !+

'$6!

Electrical Specifications:

Printer Connection AMP 57-40360 (DDK) or equivalent

Cable Connection AMP 57-30360 (DDK) or equivalent

Cable IEEE1284 Parallel, 10 ft. (3 m) or less

Signal Level High = +2.4V to +5.0VLow = 0V to -0.4V

Data Streams:A .. Job#1 .. ZA .. Job#n .. Z

4"!!$$%&$$'"

5



IEEE 1284 Parallel Interface

PIN ASSIGNMENTS - IEEE 1284 CABLE END18 1

36 19

NIP LANGIS NOITCERID NIP LANGIS NOITCERID

1 EBORTS retnirPoT 91EBORTS

nruteRecnerefeR

2 1ATAD retnirPoT 02 nruteR1ATAD ecnerefeR








01 KCA tsoHoT 82 nruteRKCA ecnerefeR

11 ysuB tsoHoT 92 nruteRYSUB ecnerefeR

21retnirP

rorrEtsoHoT 03 nruteREP ecnerefeR

31 TCELES tsoHoT 13 TINI tsoHmorF

41 DFOTUA )1( tsoHoT 23 TLUAF tsoHoT

51 desUtoN 33 desUtoN

61 dnGcigoL 43 desUtoN

71 GF dnuorGemarF 53 desUtoN

81K42=Z(V5+

)mhotsoHoT 63 NOITCELES )1( tsoHmorF

6



3.5 RS232C Serial InterfaceB00#$+$'$!

General Specifications:Asynchronous ASCII Half-duplex communication

Ready/Busy Hardware Flow ControlPin 20, DTR ControlPin 4, RTS Error Condition

X-On/X-Off Software Flow Control

Bi-Directional Communication

Data Transmission Rate 9600, 19200, 38400, 57600 bps

Character Format 1 Start Bit (fixed)

7 or 8 data bits (selectable)

Odd, Even or No Parity (selectable)

1 or 2 Stop bits (selectable)

Electrical Specifications:Connector DB-25S (Female)

Cable DB-25P (Male), 50 ft. maximum length. For cable configuration,refer to Cable Requirements appropriate to the RS232C protocolchosen.

Signal Level High = +5V to +12VLow = -5V to -12V

13 1

25 14

PIN ASSIGNMENTS - RS232C PRINTER END

7



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 PC, it would be either CTS (pin 5) or DSR (pin 6)on a DB-25 connector.

9BD 52BD TSOH NOITCENNOCRETNI 52BD RETNIRP

1 1 GF 1 )dnuorGemarF(GF

2 3 DR 2 )ataDtimsnarT(DT

3 2 DT 3 )ataDevieceR(DR

8 5 STC 4 )dnesottseuqeR(STR

7 4 STR 5 )dneSotraelC(STC

4 02 TRD 6 )ydaeRteSataD(RSD

6 6 *RSD 02 )ydaeRlanimreTataD(RTD

5 7 GS 7 )dnuorGemarF(GS

Please Note:SATO does not recommend the use of mechanical data switches commonly called A/Bswitches, as they are known to damage both the computer and printer serial ports.

8



RS232C Interface Signals

Ready/Busy Flow Control.'/$'&&!/'&))#.01&')!# "%"%&!$$&$'!

NIP NOITCERID NOITPIRCSEDLANGIS

1 ecnerefeR )dnuorGemarF(GF

2 tsoHoT.retupmoctsohehtotretnirpehtmorfataD-)ataDtimsnarT(DT

.)locotorplanoitceriD-iB(atadsutatsrosretcarahcffO-X/nO-XsdneS

3 retnirPoT .retupmoctsohehtmorfretnirpehtotataD-)ataDevieceR(DR

4 tsoHoT

otlortnocwolfysuB/ydaeRhtiwdesU-)dneSottseuqeR(STRehtsselnuhgihsniamerdnahgihsiSTR.noitidnocrorrenaetacidni

etatshgihehtotnruterdluowSTR,esacsihtni(neposidaehtnirp)enil-nokcabdecalpsiretnirpehtdnadesolcsidaehtnirpehtretfa

.)tuolebal.g.e(gnitnirpgnirudsrucconoitidnocrorrenaro

5 retnirPoT

semussaretnirpeht,hgihsienilsihtnehW-)dneSotraelC(STCatadeviecertonlliwretnirpehT.dettimsnartebotydaersiatadtaht

deitebdluohsti,desugniebtonsienilsihtfI.wolsienilsihtnehw.)4nipot(hgih

6 retnirPoT

eblliwretnirpeht,hgihsienilsihtnehW-)ydaeRteSataD(RSDsiataderofebhgihebtsumenilsihT.atadeviecerotydaer

ot(hgihdeitebdluohsti,desugniebtonsienilsihtfI.dettimsnart.)02nip

7 ecnerefeR )dnuorGlangiS(GS

02 tsoHoT

wolfysuB/ydaeRotseilppalangissihT-)ydaeRlanimreTataD(RTDtI.hgihsinipsihtnehwatadeviecerotydaersiretnirpehT.lortnoc

naoteudroyllaunamrehtieenil-ffosiretnirpehtnehwwolseogtI.edomreffuBboJelgniSehtnignitnirpelihwdna,noitidnocrorreraeNreffuBehtsehcaerreffubehtniatadehtnehwwologoslalliw

.levellluF

9



X-On/X-Off Flow Control&$$&)&".'/$'%&)!)&/$&&

10



3.7 Ethernet Interface#$+$'$!($)"&%!)$'$##$$$$&6$/45!2)+$&&!

General Specifications:Type: 10/100BaseT

Connector: RJ-45 Receptical

Cable: Category 5

Electrical Specifications:Power Supply: Powered from printer

Refer to the manual & CD supplied with the interface card.

3.8 Bi-Directional Communications&&'$&$$6$!=/ /1/$$'!$($$$'$'!

Refer to the Operator's and Technical Manual for complete information.

General Specifications:Connector: USB Type B Plug

Cable: 10ft (3 m) max.Host: Windows 98

USB Port

Electrical Specifications:Power Supply: Bus Power through cable

Power Consumption:: +5V@80ma

Universal Serial Bus (USB) Interface (Cont)

11



@ $&,$&! ')$$$&)$!42/; )'!

3.9 Accessory (EXT) Connector

Pin AssignmentsOld

DB-9 14 PinCentronics

NIP NIP NOITCERID NOITPIRCSEDLANGIS

1 31 tsoHoT V5+/-ccV

2 01 tsoHoTnobbirfotnuomaehtnehwhgihseognipsihT-dnEraeNnobbiR

lliwtuptuoehT.)m41(teef64yletamixorppasitfahsdniwnuehtno.tuoyletelpmocsinobbirehtnehwwoleb

3 4 tsoHoTnoitidnocrorrenastcetedretnirpehtnehwwolseognipsihT-rorrE

.llufsireffubgniviecerronepodaehsahcus

4 7 retnirPoTdetnirpereblliwbojtnirpanilebaltsalehtfoetacilpudA-tnirpeR

.deviecersilangissihtnehw

5 5 retnirPoTotdellupsinipsihtnehwlebalenotnirplliwretnirpehT-tratStnirPno5-3WSDhctiwsgnicalpybdelbaneebtsumlangissihT.dnuorg

.noitisopFFOehtnilenaPlortnoCeht

6 6 tsoHoT

ecivedlanretxerehtororotacilppanaevirdotdesusitI-tnirPdnEesoohcyamuoY.elcyctnirpehthtiwnoitazinorhcnysgniriuqer

6-3WSDlenaplortnocgnisuslangistuptuofosepytruofneewteb.egaptxennostrahcgnimiteeS.snoitceles7-3WSDdna

7 1 tsoHoT .stsixerorrelebalanehw)V0(wolseognipsihT-tuOlebaL

8 3 tsoHoT .tuosinobbirnehw)V0(wolseognipsihT-tuOnobbiR

9 2 ecnerefeR dnuorGlangiS

8 retnirPoT .tupnilangisrofecruoSrewoPdetalosI

9 tsoHoT

boJtnirPeniL-nO=egatloVhgiHdetcelesDCLni1edoMnehW.gnitiaw

seogsihT.eniL-nO=egatloVhgiHdetcelesDCLni2edoMnehW.eniL-ffOretnirpnehw)V0(wol

11 devreseR

21 tsoHoT secivedlanretxerofrewoP-A2@%01-/+V42+

41 dnuorGemarF

12



,&"'%-%*%.%/'0 !

1023 %"

03"143%! --0 %56

3'-"143

03 "

1403 !7400

Pin 13Vcc= +5V

330 ohm, 1/4W

Pin 1, 3, 4, 6, 9 or 10

Signal Out

Standard OperationStart of Print Cycle End of Print Cycle

Print StartInput

+5V

0V

Print RepeatInput

+5V

0V

+5V

0V

+5V

0V

Print EndType 1

Print EndType 2

+5V

0V

Print EndType 3

Print EndType 4

+5V

0V

20 Milliseconds

13



Repeat Print

Print EndType 3

Print EndType 4

Start of Print Cycle End of Print Cycle

Print StartInput

Print RepeatInput

+5V

0V

+5V

0V

Print EndType 1

Print EndType 2

+5V

0V

+5V

0V

20 Milliseconds

+5V

0V

+5V

0V

Error Signals

Print EndType 3

Print EndType 4

Paper or Ribbon End Paper/RibbonReplenished

Print Motion

Paper End

+5V

0V

+5V

0V

Print EndType 1

Print EndType 2

+5V

0V

+5V

0V

+5V

0V

+5V

0VRibbon End

Machine Error

+5V0V

Head Open Head ClosedMotionStopped

14




Section

Electrical Checks and Adjustments

4.1 Overview

!"#$% &'"#'(# %)!*%+ ,(-.*%

/. **.. 0.!.)!!.* $.**).**

/&

Power Supply

Label Sensors

Ribbon Sensor

Pitch Offset

Label Positions

Checks and adjustments in this section require standard metric tools.Also required:

Digital Multimeter required for use with SATO TP Test Module (VoltageChecker) Part # RH1773100 and is required for most electricaladjustments.

2

Section 4. Electric Checks and Adjustments


STEP PROCEDURE

,566$

7*123. 713. ....8*+

7.-*

REMOVE (3) SCREWS

RAISE THE ACCESSDOOR AND LOOSEN(2) SCREWS ON THEINSIDE TOP OF THE

PRINTER

4.2 Steps Prior to Some Procedures

,**9**+ 7*4.*+

3



4.3 DC Power Voltage Checks)..1, 23.! *4)1,( 3.*.

$9*9& :%:*

STEP PROCEDURE

7.(-2(-" $.*:

*+ ;. ;+.

$.**:

4



DC Power Voltage Checks

TP TESTMODULE

MAIN PCB

TP TEST MODULETO PCB TEST

POINT @ CN13

TP TESTMODULE

CONNECTOR

CONNECTORRECEPTACLE ON

PCB @ CN13

CORRECT POSITIONOF NIBS ON

CONNECTOR

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123123123123

123123123123

12341234123412341234

12341234123412341234

CONNECT TP TESTMODULE TO PCB

TEST POINT @CN13

5



DIGITALMULTIMETER

LCD DISPLAY

VOLT

COM

CABLE TO PCB

DIAL

GROUNDPIN

TP TEST MODULE

SIG PIN

PROBES

TEST POINT CHART

;5=&! $*'->.*..

DC Power Voltage Checks

SOPlaiD CSID EGNAREGATLOV ELUDOMTSETPT

GS

CN

0 V5+ V2.5+ot8.4+ )DNG(1AHC-)V5+(3AHC

1 V0.2+ V1.2+ot09.1+ )DNG(1AHC-)V0.2+(4AHC

2 V3.3+ V5.3+otV1.3+ )DNG(1AHC-)V3.3+(5AHC

3 V42+ V5.42+otV5.32+ )DNG(1AHC-)V42+(6AHC

B1

B6

A1

A6

GND

+5V

+2.0V

+3.3V

+24V

6



4.4 Potentiometer Assignments & Adjustments

POTENTIOMETERS ARELOCATED ON MAIN PCB

TSUJDAOTRV METI

1RV ssenkraD

2RV tesffO

3RV hctiP

4RV yalpsiD

POTENTIOMETERS ARE LOCATEDUNDERNEATH A FLIP - DOWN COVER

ON THE FRONT PANEL

tsujdAotRV METI LAIDNOITISOP

V5 0

V2 1

V3.3 2

V42 3

1RV tesffOhctiP

4RV PAG 5

5RV kraM-eyE 4

2RV MED *6

3RV EC 7

* USED WITH DISPENSER OPTIONTURN VR2 FULL CW FOR DISPENSER

7



Potentiometer Assignments & Adjustments

POWER SUPPLY

TEST POINTCONNECTOR

MAIN PCB

VR1 OFS

INTERFACEBOARD VR4 GAP

VR5 IM

CN13VR2 DEM

VR3 CE

8



4.5a Print Position Adjustment#721043*6#7**+

..*6 7.,( ".***+

STEP PROCEDURE

6..*

#72

2 !*!

( ?)! .

" !!8

@A!. !**! $..B)*!:

C !. !

$*. ?*).. 0.DA!+ 7.,

Note: The VR3 (PITCH) is for changingthe print position but not for the printstop position. The stop position can bechanged with the VR2 (OFFSET).

VR3 adjustment range is +/- 3.75mm.POTENTIOMETERS ARE LOCATED

UNDERNEATH A FLIP - DOWN COVEROF THE FRONT PANEL

VR 3

9



4.5b Print Position Adjustment

STEP PROCEDURE

Refer to Section 4.2 for access to main PCB

7)

*+

2 %,?-(13

( !*!

" ?)! .

%,?-(13!8

C !!8

.*E;E!!8

.

B !. !

$#7*. ?*).. 0.D#7):+ 7.,

VR1 adjustment range is+/- 3.75mm.

@#7**+

10



4.6 Label Gap Adjustment

$9*9& :%:*

STEP PROCEDURE


**+!.

7.,( 2 ,**%*** $.*:*+ ;. ;+. ,"

2 1'3.**,'1-3

11



4.7 Eye-Mark Adjustment

$9*9& :%:*

STEP PROCEDURE


**+!.

7.,( 2 ,**%*** $.*:*+ ;. ;+. ,(

2 1'3.**,'1-3

12



4.8 Offset Label Stop Position Adjustment@..*..5..)%:

,5..*6

STEP PROCEDURE

6..*

#71566,=3

2 !*!

( ?)! .

" !!8

@A!. !**0;=! $..B)*!:

C !. !

$#7. ?*).. 0.DA!+ 7.,

Note: The stop position only ischanged with the VR2 (OFFSET).The print position is changed withthe VR3(PITCH).

The VR2(OFFSET) adjustment rangeis +/- 3.75mm.POTENTIOMETERS ARE LOCATED

UNDERNEATH A FLIP - DOWN COVEROF THE FRONT PANEL

VR 2

13



4.9 Ribbon Sensor Operation Verification

6..

7)%,?-

2 7*.*45

( G .!

" !..-

! .!.*.*.

C ..

G,( +.. !.*

!

"##

PLACE DSW2-1 INTHE OFF POSITION

STEP PROCEDURE

SEE PAGE 1-8 FORSENSOR LOCATION

No adjustment is providedfor this sensor

14



4.10 Ribbon Sensor Adjustment

$9*9& :%:*

STEP PROCEDURE


**+!

7.,( 2 ,**%*** $.*:*+ ;. ,C

2 1'3.**,'1-3

15



4.11 LCD Display Adjustment

STEP PROCEDURE

.*%*!

2 $!*1.-..3!

VR 4


OF THE FRONT PANEL

16



4.12 Print Darkness Adjustment

STEP PROCEDURE

*1.-.3

!..- !*!.*!

2 !)!

(

"

$%&$'&($)&


ON THE FRONT PANEL

VR1


Section

Mechanical Adjustments

5-1 Overview !"!#"$ % &"& "!&&"

'

Ribbon Unwind/Rewind Assembly's

Ribbon Guide Roller Assembly

Print Head Assembly

Drive Belt Assembly's

( ")&&'

Ribbon Clutch Adjustment

Print Head Position Adjustment

Print Head Balance Adjustment

Ribbon Roller Adjustment

Feed Roller Adjustment

Timing Belt Tension Adjustment

Head Latch Adjustment

Notch/Gap Sensor Adjustment

2



*+$)))$ &,"

-) ..$&" ))) &&& "

5.2.1 Ribbon Unwind Clutch Adjustment

/,*,' 0 1!2!0 /#"0 !0 3 0 456$)$

STEP PROCEDURE

)

/ $ %&

7 !" /8)3 !! " !"%) && ! !!

9 2"& !!#! !)& !$# !! 9...!&*+$&&"! /8)

. # %!)$ 3&3&! %!)79 $

Fig. 5-1

REMOVE THERIBBON ANDLABEL STOCK

5.2 Ribbon Clutch Adjustments

3



Ribbon Clutch Adjustments

Fig. 5-3

RIBBON UNWINDSPINDLE

ADJUST NUT

LOCKING SCREW ISINSIDE ADJUST NUT

950-1050gREWIND

STRING

EMPTY RIBBONCORES

RIBBON REWINDSPINDLE

Fig. 5-4

Fig. 5-2

450-550gUNWIND

TENSION GAUGETENSION GAUGE

STRING

REWIND CLUTCH UNWIND CLUTCH

4



STEP PROCEDURE

)

/ $ %&

7 !" //)3 !! " !"%) && ! !!

9 2"& !!#! !)& !$ !! :..!&*+$&&"! )

. # %!)$ 3&3&! %!)79 $

5.2.2 Ribbon Rewind Clutch Adjustment

Ribbon Clutch Adjustments

5



STEP PROCEDURE

/&;

5@" $ & "$ $,"!

/,*,' 0 3 .0 /

5.3 Print Head Position Adjustment

6



Print Head Position Adjustment

ALLEN WRENCH ADJUST SCREWS

Fig. 5-7

STAY

STAYFig. 5-6

NELLAFONOITATORHCNERW

DAEHTNIRPFOTNEMEVOM

ESIWKCOLC TNORFEHTOT

ESIWKCOLC-RETNUOC DRAWKCAB

TURN SCREWSCW/CCW

TEST PRINT Fig. 5-5

MEASURE FROMBOTTOM OF BARCODETO BOTTOM OF LABEL

MEASURE FROMBOTTOM OF BARCODETO BOTTOM OF LABEL

7



5.4 Print Head Balance Adjustment

/,*,' 0 456$)$0 )

STEP PROCEDURE

)

/ %($ %)!

7 %!)

9 3 !# ) ) %) "A%B& & !%) "A%B& & !

. > ) ) ! %!)7$

$&" %!"

; (&"! !,"#.75>5& ? 5>

8



/,*,' 0 456$)$0 )

STEP PROCEDURE

)

/ %

7 %!)

9 ) )

. 3 $$") )%!#! %!)

LOOSENLOCKINGSCREWS

TURN ECCENTRIC

Fig. 5-9

" &!))..

5.5 Ribbon Roller Adjustment

9



5.6 Feed Roller Adjustment (Label Tracking)

/,*,' 0 456$)$0 ..) 0 1!2!

STEP PROCEDURE

) )

/ $ %&

7 &C)%! & !!8 $# ) ) "2" !! &/ &

9 &&) & ! !

. ) # )&+!) ..) )

!& # %!)$ ) )$ ,&

; ! %!)

8&&!))

10



ADJUST SCREW & FIXINGNUT ON BOTH ENDS OF

MEDIA COVER

Fig. 5-10

ADJUSTPLATE

Fig. 5-11

Fig. 5-12

Fig. 5-13

TENSIONGAUGE

BACKING PAPERLEFT SIDE

MEDIALIDPULL

BACKING PAPERRIGHT SIDE

PULL

MOVE WITHFLAT BLADE

SCREWDRIVER

LOCKING SCREW

Feed Roller Adjustment (Label Tracking)

11



STEP PROCEDURE

/$A7B) ! &$ / AB) & &&& &$

%!))&! #$! )

7 / &$

ADJUSTMENTSPRING

LOCKINGSCREWS

TIMING BELT "B"

Fig. 5-15

5.7 Timing Belt Tension Adjustment

Fig. 5-14REMOVE (3)SCREWS

RAISE THE ACCESS DOOR ANDLOOSEN (2) SCREWS ON THE INSIDE

TOP OF THE PRINTER

12



LATCHEDPOSITION

UNLATCHEDPOSITION

Pairs of set-screws oneach end of shaft mustbe tightened to avoidslippage of media andlight printing on the left

side of the labels

' "&"!! ! AB)

5.8 Head Latch Adjustment

13



! !A$B*"D%A&$B "E3A!7B !$!

LOOSEN ADJUSTMENTSCREW AND REPOSITIONIN SLOT. TIGHTEN SCREW

LABEL FEEDDIRECTION

INSIDE EDGEOF PRINTER

1" (25 mm)Minimum

12345678901234567890123456123456789012345678901234561234567890123456789012345612345678901234567890123456123456789012345678901234561234567890123456789012345612345678901234567890123456

NOTCH/GAP SENSORADJUSTMENT RANGE

NOTCH/GAP LOCATIONS(MAXIMUM & MINIMUM)

3.5" (90 mm) Maximum

.33" (9 mm) Eye-MarkSensor Location (shown for ref. only)

EYE - MARK Minimum Size.12" (3 mm) W x .24" (6 mm) L

LABEL

MINIMUM INTER-LABELGAP .012" (3 mm)

5.9 Notch/Gap Sensor Adjustment

14




Replacement Procedures

6.1 Overview

Section

!"#$$ "%$

Main Circuit Board

Fuse(s)

Power Supply

Stepper Motor

Timing Belts

Print Head

Platen

Ribbon Drive Clutch Washers

Ribbon Motion Sensor

Paper End Switch

Notch/Gap & Eye-Mark Switch

Display Panel & Keyboard

2



6.2 Replacing the Main Circuit Board

&'()!" $!!#$"!*+%"$%$$

), " -#" .,"!"*% "#

STEP PROCEDURE

% %

/#012% $ "# / 02% " """ "#3 ,

REMOVE (3) SCREWS

Fig. 6-1

RAISE THE ACCESSDOOR AND LOOSEN(2) SCREWS ON THEINSIDE TOP OF THE

PRINTER

3



Replacing the Main Circuit Board

STEP PROCEDURE

1 /#02% $ .,."" +" %! ""

4 /#02%

5 &* "! "

/#012% $ , "/# "

6 7 )!) ),"!% " ),)!7 )!), "!"% /# " "& 3$ )!),"$ ),

. )!) ),& 3$ . ),)!73!45%!" ),,8! %

9 / ,#$ $ 5

7!/

REMOVE (2) SCREWS AND PULLAWAY TO DETACH IF INTERFACECARD IS INSTALLED

Figs. 6-2

REMOVE (2)SCREWS TO

DETACH MAINCIRCUITBOARD

4




REMOVE (2) SCREWS

REMOVE SCREW

DISCONNECT CABLES

DISCONNECT CABLES

Figs. 6-3

5




MEMORY MODULE PCB IN THEMAIN PCB MEMORY FRAME

* CAREFULLY PRESS OUTWARDON TABS ON BOTH ENDS OF THE

FRAME TO RELEASE THE MEMORYPCB.

INDEXING NOTCHES

*

*

PRESS OUTWARD

PRESS OUTWARD

Figs. 6-4

6



INDEXING NOTCH

NO NOTCH ON THIS SIDE

FLASH MEMORY MODULE

INSERT THE FLASH MEMORYMODULE INTO THE MAIN PCB

MEMORY FRAME ATAPPROXIMATELY 450. NOTE THE

INDEXING NOTCH ON THEMODULE. GENTLY PUSH DOWN TO

SNAP INTO POSITION

INDEXING NOTCHES

APPROXIMATELY450 ANGLE

Figs. 6-5


7



6.3 Replacing the Fuses

7 "%$

6.3.1 Removing and Replacing the Main Power Fuse

6.3.2 Removing and Replacing the Internal Fuse

6.3.1 Removing and Replacing the Main Power Fuse

&'(,"$"* " #

/:( 71*5;77

STEP PROCEDURE

% %

" +"

8



Replacing the Fuses

/:( 15*5;75;7

# "02 "%$(

STEP PROCEDURE

% %

/#012% $ "# / 02% " """ "#3 ,

1 /" " ,

4 /# "02% ":$

5 / # %

/ #!$ %

MAIN PC BOARD

FUSES

Figs. 6-7

9



%!% #!

STEP PROCEDURE

% %

/#012% $ "# / 02% " """ "#3 ,

1 /#02% $ .,."" +" %! "" ,

4 /#02%

5 /#02%% $ +"

/#02% ,)$"!#" %!" %!!

6 /#02%% %! +"

% )- " "02% $ %!/# %

9 = 02# "#%!

.%!#$ $ 9

+ =%#$/"41

6.4 Replacing the Power Supply

10



Replacing the Power Supply

REMOVE (2) SCREWSTO DETACH MAINCIRCUIT BOARD

REMOVE (2) SCREWS

Fig. 6-9

REMOVE (2) SCREWS AND PULLAWAY TO DETACH IF INTERFACECARD IS INSTALLED

Figs. 6-8

REMOVE (2) SCREWSFig. 6-10

11



Replacing the Power Supply

REMOVE MOUNTING PLATE(WITH PCB ATTACHED) AND

MOVE AWAY FROM THEPOWER SUPPLY

Fig. 6-11

REMOVE (2) SCREWS(POWER SUPPLY)

LOWER THEMEDIA HOLDER

Fig. 6-13

REMOVE BOTTOMAND TOP SCREWS

Fig. 6-14

Fig. 6-12

POWER SUPPLY

DETACH CABLE

LIFT OUT POWERSUPPLY

Fig. 6-15

12



) "$ : "* * "* %#" $$

REMOVE (3)MOUNTING SCREWS

Fig. 6-16

Fig. 6-17

DETACH CONNECTORFROM CIRCUIT BOARD

STEP PROCEDURE

% %

/#012% $ "# / 02% " """ "#3 ,

1 /#012$% $ "= "

4 = "

5 /#!""%/"!"$

.,%">/"5

6 / "# %

Fig. 6-18

6.5 Replacing the Stepper Motor

REMOVE PULLEY FROM OLDUNIT AND TRANSFER ORREPLACE IF NECESSARY

13



STEP PROCEDURE

% %

/#012% $ "# / 02% " """ "#

1 /# +"

4 /",???,?

5 #,??*#% % "">!

. *$! %$,??

6 .$"%!

. # " $./"5>

9 #,?,?*>=$,?,?" "$./"5>

/ "# %


Fig. 6-19

6.6 Replacing the Timing Belts

14



Fig. 6-20

BELT "B"

BELT "A"

Fig. 6-21

MOTOR

TENSIONADJUSTMENT

IDLER

IDLER

BELT "B"

BELT "A"

FRONTPLATENROLLER

REWINDSPINDLE

REARPLATENROLLER

GEAR TOENGAGE FEED

ROLLER

Replacing the Timing Belts

15



Replacing the Timing Belts

Figs. 6-22

Figs. 6-23

REMOVE SCREW(ATTACHES TO

REWIND SPINDLE)

PULL REWIND SPINDLEFORWARD TO

DISLODGE BELT "A"

REMOVE &REPLACEBELT "A"

DO NOT DISTURBTHESE TWO

SCREWS

BEARING

BEARING

DISLODGE BELT "B"FROM MOTOR

SHAFT AND GEARS

LOOSENADJUSTMENT

IDLER SCREWS

16



6.7 Replacing the Print Head." $*!#&>:,"! * + #!$0/"$12

STEP PROCEDURE

% %

/ # +"

1 - #"#" -/#02%

4 "! - # -%%

5 =$# /8" -

"! # -

6 % $ %- $

. -!$ -=-% - /8

9 -$!% $/8

- # %%

,"! #*! " "%$

@ -0/"612

@ " ! $$" ! %

@ 0/"$12

17



Replacing the Print Head

REMOVE THERIBBON AND

LABEL STOCK

Fig. 6-24

Fig. 6-25

REMOVE (2)STUD SCREWS

PRINT HEAD

DISLODGE ANDREMOVE RIBBON

GUIDE PLATE

DISCONNECTCABLES

Fig. 6-26

Fig. 6-27

HEAD LATCHLEVER

RIBBON GUIDEPLATE

PRINT HEAD

PLATEN

18



Fig. 6-28

RECONNECTCABLES

PRINT HEAD

ALIGNMENTPINS

Fig. 6-29

FOR THIS MODELPRINTER SET SWITCH

TO THE RIGHT

Replacing the Print Head

19



STEP PROCEDURE

% %

/#012% $ "# / 02% " """ "#

1 /# +"

4 # % $ "

5 $ !% $>

. 02%$""$

6 ."*#!""!$%%$"" "

/#02% $ "

9 =!$%!" $ "% $ "

/# $% $"%

.%!#$##

&'(.#"! $ # $ $!$

/!""$"%$"!

1 /

4 /"5>

5 "-,>54

/ "# %

6.8 Replacing the Platen

20



Fig. 6-30


Fig. 6-31

Fig. 6-32

Replacing the PlatenPLATEN

LOOSEN CLAMPAND SCREW

HOLDING PLATENTO FRAME

SLIGHTLY LOOSENECCENTRIC SCREW

REMOVE BELT

LOOSEN IDLER SCREWSTO RELEASE BELT

TENSION

21



Replacing the Platen

Fig. 6-35

REMOVE (2) SCREWSHOLDING RETAINER

TO THE FRAME

CL612 PLATEN

CL612 PLATEN

LOOSEN (2) SET SCREWSAND REMOVE PULLEYFROM END OF SHAFT

Fig. 6-34

Fig. 6-33

CL608 PLATEN

MECHANICALCOMPARTMENT

SIDE

ELECTRONICCOMPARTMENT

SIDE

(SCREW ISPARTIALLYHIDDEN BYGEAR)

22



Replacing the Platen

Fig. 6-39

Fig. 6-37

PULL PLATENTHROUGH HOLE IN

FRAME AND OUT THEELECTRONICS

COMPARTMENT

Fig. 6-36

DISPLACE PLATEN BYPULLING UP AND

AWAY FROM HOLDINGCLAMP

Fig. 6-38

HOLDING CLAMPWITH HEAD RELEASE

LEVER IN PLACE

HOLDING CLAMPWITH HEAD RELEASE

LEVER REMOVEDFOR CLARITY AND

SHOWING THESPRING IN CORRECT

POSITIONBUSHING PLATE

SPRING END MUSTNOT BE UNDERBUSHING PLATE

23



, % %#" ! "% % " ""% %

STEP PROCEDURE

% %

/ ## +"

1 /# "%$" % "02

&'(= ""

Fig. 6-40

REMOVE RIBBONAND LABEL STOCK

DISASSEMBLE

.ONMETI NOITPIRCSED YSSAHCAE.YTQ

1 wercSgnikcoL )1(

2 tuNtnemtsujdA )1(

3 ralloCreppotS )1(

4 gnirpS )1(

5 csiD )1(

6yrDssel-liO

rehsaWlateM)1(

7 ralloC )3(

8 ssoBnobbiR )1(

B9&A9etalPcsiD

)tnereffidyssahcae()1(

01 rehsaWnoitcirF )1(

11 etalPdloH )1(

List 6-A

6.9 Replacing the Ribbon Drive Clutch Washers

24



Replacing the Ribbon Drive Clutch Washers

1

2

3

4

5

6

7

7

9a

10

11

9b

USE 12mm OPEN END WRENCHAND PHILLIPS SCREW DRIVER TO

REMOVE THE LOCKING SCREWAND ADJUSTMENT NUT

REMOVE & INSTALLPARTS IN THIS

ORDER (SEE ITEMLIST 6A)

REWIND DRIVESPINDLE

UNWIND DRIVESPINDLE

Fig. 6-41Fig. 6-42

Fig. 6-43Fig. 6-44

9b

9a

CONTINUEDFROM FIG. 6-42

8

1 2 3 4 5 6

25




STEP PROCEDURE

7 *".*% "$%% 02%'3".9* " %%*

..77A / "$. >$$ .%?$? "% 02.99A&+% " "> =#$ > %> > 5

9 .+$%->% % % $ $%# $$ >

/ %

ASSEMBLE

26




Fig. 6-45

Fig. 6-46

Fig. 6-47

FASTEN ITEM 11WITH (2) SCREWS

TEETH/SLOTS ONITEM 9a DISC PLATEFACING TOWARDS

FELT WASHER

ITEM 6 OIL-LESSWASHER

ITEM 9a/9b DISK PLATE

ITEM 11 TEETH FACINGOUTWARD TO ENGAGEITEM 10 FELT WASHER

ITEM 8 RIBBONBOSS

LOCATIONHOLES

INSERT PEGS INTOLOCATION HOLES

ITEM 8 RIBBONBOSS

ALIGN HOLEWITH PEG

Fig. 6-48

27



6.10 Replacing the Ribbon Motion Sensor

STEP PROCEDURE

% %

/#012% $ "# / 02% " """ "#3 ,/"4

1 /# +"

4 /# $%

5

28



Replacing the Ribbon Motion Sensor

Fig. 6-50

Fig. 6-51

REMOVE SCREW

PULL THE SENSOR CABLEAND CONNECTOR

THROUGH THE FRAME HOLEUNPLUG SEN4FROM THE PCB

HARNESS

Fig. 6-52

Fig. 6-53

ALIGNMENT PIN

29



Replacing the Ribbon Motion Sensor

Fig. 6-54

Fig. 6-55

REMOVE (2) SCREWSHOLDING SENSOR TO

THE BRACKET

DISASSEMBLED RIBBONMOTION SENSOR ANDMOUNTING BRACKET

30



6.11 Replacing the Paper End Switch (Micro-Switch) and theBottom 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

NOTCH/GAP SENSOR(TOP HALF)

NOTCH/GAP SENSOR(BOTTOM HALF)

PAPER END SWITCH(MICRO-SWITCH)

EYE-MARKSENSOR

SENSOR LOCATIONSFig. 6-57

Fig. 6-56


31



Replacing the Paper End Switch (Micro-Switch) and theBottom Half of the Notch/Gap and Eye-Mark Sensors

STEP PROCEDURE

% %

/#012% $ "# / 02% " """ "#3 ,

1 /# +"

4 / %# /#012% " "0 2

5 %"$"%/#012% " "+02

= " ,

6 "!%$$ "" "

#3

9 '% *#02% % +.%

"" & 8'!)+*#02% .."%% %$* !

/ " " , $ *0'% 2* " " $! $

/ "# %

& 8'!)+#" "$"#&$:% $

32




Fig. 6-59

REMOVE (3) SCREWSTO DETACH THE RAMP

PLATE FROM THERAMP FRAME

Fig. 6-58 RAMP FRAME

RAMP PLATE

REMOVE (3) SCREWS TODETACH THE RAMP PLATE

FROM THE BACK PLATE

WIGGLE THE RAMPPLATE FREE FROM

THE PRINTERFig. 6-60

LOOSEN SCREWS FROMIDLER GEAR PLATE FOR

ACCESS TO SCREW

33




Fig. 6-62

BOTTOM HALF NOTCH/GAPAND EYE-MARK SENSORS

Fig. 6-61

PAPER END SWITCHREMOVE (2)

SCREWS

NOTCH/GAPSENSOR(BOTTOM

HALF)REMOVE (2)

SCREWS

Fig. 6-63

PAPER END-SWITCH(MICRO-SWITCH)

34



6.12 Replacing the Top Half of the Notch/Gap Sensor

STEP PROCEDURE

% %

/#012% $ "# / 02% " """ "#3 ,

1 /# +"

4 /". # % $ %0$ "" & 82 "= " ,% % $ " /# %

5 /#02% %# & 8

/# % % +=$ +" % $$"

%

6 /#02% & 8" +

.%+

9 .+% %*$ %

/ %#/ % "

%# "" & 8>%.

REMOVE THE RIBBONAND LABEL ST

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