CL Series e Thermal Transfer Printers
Operator Manual for CL408e, CL412e, CL608e & CL612e
CL408e and CL412e Printer Users Please Refer To Supplemental Operator Manual PN: 9001159

PN 9001074 Rev. B

SATO America, Inc. 10350A Nations Ford Road Charlotte, NC 28273 Main Phone: (704) 644-1650 Fax: (704) 644-1662 Tech Support Hotline: (704) 644-1660 Tech Support Fax: (704) 644-1661 Email: satosupport@satoamerica.com www.satoamerica.com
Copyright 2003 SATO America, Inc.
Warning: This equipment complies with the requirements in Part 15 of FCC rules for a Class A 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 whatsoever without the express permission of SATO America, Inc. The materials in this document is provided for general information and is subject to change without notice. SATO America, Inc. assumes no responibilities for any errors that may appear.
SATO CL Series e Printers

08/31/03

WARNING
CL408e AND CL412e PRINTERS ARE SHIPPED WITH EITHER A110-VOLT OR 220-VOLT POWER SUPPLY AS A CUSTOMER SPECIFIED OPTION. BEFORE CONNECTING A PRINTER TO ANY POWER SOURCE, ENSURE IT WAS FACTORY CONFIGURED FOR THE APPROPRIATE VOLTAGE. THE VOLTAGE FOR THE PRINTER DELIVERED MAY BE FOUND ON THE SHIPPING CONTAINER. CONTACT SATO AMERICA, INC. OR OUR AUTHORIZED RESELLER SHOULD A DISCREPANCY EXIST.

PREFACE

CL SERIES e PRINTER OPERATORS MANUAL
The CL Series e Printer Operators Manual contains basic information about the printer such as setup, installation, cleaning and maintenance. It also contains complete instructions on how to use the operator panel to configure the printer. The following is a brief description of each section in this manual. SECTION 1. PRINTER OVERVIEW This section contains a discussion of the printer specifications and optional features. SECTION 2. INSTALLATION This section contains instructions on how to unpack and set up the printer, AND load the labels and ribbon. SECTION 3. CONFIGURATION This section contains instructions on how to use the operator panel to configure the printer. SECTION 4. CLEANING AND MAINTENANCE This section contains instructions on how to clean and maintain the printer. SECTION 5. PROGRAMMING This section has been replaced by the e and PRO Printer Programming Reference, PN 9001096 on the Printer Utilities CD-ROM. It introduces the SATO printer programming language. It contains the commands that are used with the printer to produce labels with bar codes, alphanumeric data and graphics. SECTION 6. INTERFACE SPECIFICATIONS This section contains the printers interface specifications, which include detailed information on how to properly interface your printer to the host system. SECTION 7. TROUBLESHOOTING This section contains troubleshooting procedures to follow in the event you have printer problems.

SATO CL e Series Printers

Page - i

Preface
APPENDICES APPENDIX A: Optional Features

Page - ii

TABLE OF CONTENTS
SECTION 1. PRINTER OVERVIEW
Introduction. General Printer Specifications Character Fonts. Bar Codes. Physical. Optional Accessories.

1-1 1-2 1-4 1-5 1-6 1-7

SECTION 2. INSTALLATION AND CONFIGURATION
Introduction. 2-1 Unpacking and Parts Identification. 2-2 Setting Up the Printer. 2-3 Loading Labels, Tags and Ribbon in the CL608 and CL612e. 2-4 Loading Labels, Tags and Ribbon in the CL408 and CL412e. 2-8 Label Sensor Adjustments, CL608e and CL612e. 2-11 Label Sensor Adjustments, CL408e and CL412e. 2-11 Operator Panel, CL608e and CL612e. 2-12 Operator Panel,CL408e and CL412e. 2-14 Rear Panel, CL608e and CL612e. 2-16 Rear Panel, CL408e and CL412e. 2-17 Switches and Sensors, CL608e and CL612e. 2-18 Switches and Sensors, CL408e and CL412e. 2-19

SECTION 3. CONFIGURATION

Printer DIP Switch Configuration. 3-1 Default Settings. 3-6 Potentiometer Adjustments. 3-7 LCD Panel Printer Configuration. 3-9 Normal Mode. 3-10 Advanced Mode. 3-12 Card Mode. 3-15 Service Mode. 3-18 Counter Mode. 3-22 Test Print Mode. 3-22 Default Setting mode. 3-23 Clear Non-Standard Protocol Codes. 3-24
SATO CL e Series Printers PN 9001074 Rev. B Page - iii
Preface Download User Defined Protocol Codes. 3-24 Hex Dump Mode. 3-25
SECTION 4. CLEANING AND MAINTENANCE
Introduction. Procedures. Adjusting the Print Quality. Darkness. Print Speed. Cleaning the Print Head, Platen and Rollers, CL608e and CL612e. Replacing the Print Head, CL608e and CL612e. Cleaning the Sensors, CL608e and CL612e. Replacing the Fuse, CL608e and CL612e. Cleaning the Print Head and Platen, CL408e and CL412e. Replacing the Print Head, CL408e and CL412e. Cleaning the Sensors, CL408e and CL412e. Replacing the Fuse, CL408e and CL412e.
4-1 4-1 4-1 4-1 4-2 4-2 4-4 4-5 4-6 4-7 4-8 4-9 4-9
Procedures, CL408e and CL412e. 4-7

Page 2-9

LOADING THE RIBBON 1. Open the Top and Front Access Doors. 2. Open the Print Head Assembly by rotating the green the Head Latch counter clockwise. The print head is spring loaded and will raise to the open position as soon as the latch is released. 3. Locate the Extra Ribbon Core supplied with the printer. Place the core on the Ribbon Rewind Spindle, pushing it all the way to the inside of the spindle. Note that the new empty core of each subsequent roll becomes the next rewind core. 4. Load the ribbon onto the Ribbon Supply Spindle, pushing it all the way to the inside of the spindle. The dull side of the ribbon should be facing down as it travels through the Print Head Assembly. 5. Feed the leader portion of the ribbon through the Print Head Assembly and up to the Ribbon Rewind Spindle following the routing shown in the diagram. 6. Load the ribbon behind and over the top of the Ribbon Rewind Spindle and tape it to the Extra Ribbon Core. Make sure it matches the ribbon path shown in the diagram. 7. Manually turn the Ribbon Rewind Spindle to wrap the ribbon onto the core one to two turns to secure it. 8. If the labels or tags are already loaded, close the Print Head Assembly by rotating the green Head Latch clockwise until it latches closed and close the Front and Top Access Doors. NOTE: Run a test print to ensure that the labels and ribbons were loaded correctly. See the Test Print section on page 3-22 for instructions on how to run test prints.

Ribbon Supply Roll

Empty Core

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Ribbon Supply Spindle

Ribbon Roll

Ribbon Path Label Supply Spindle
Ribbon Rewind Spindle Print Head Assembly

Label Path

LABEL SENSOR ADJUSTMENTS
The Gap (transmissive) sensor on the CL608e and CL612e can be adjusted over a limited range. It is located in the Label Hold-Down Assembly and can be adjusted by loosening the Sensor Adjust Cap Screw on the front of the Label Hold-Down and sliding the Sensor Adjust Tab to the desired position. The Gap sensor can be adjusted from a minimum of 1.0 in. (25mm) to a maximum of 3.5 in. (90mm). The Eye Mark sensor is fixed at 0.33 in. (9mm).
Both the Eye-Mark (refelective)and Gap (transmissive) sensors on the CL408e and CL412e can be adjusted over a limited range. They are both located in the Label Sensor Unit. The assembly can be adjusted by loosening the green Sensor Adjust knob located underneath the Label Transport Assembly and sliding the Label Sensor Unit to the desired position. The Gap sensor can be adjusted from a

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minimum of 0.67 in. (17mm) to a maximum of 2.5 in. (64 mm), and the Eye-Mark from a minimum of 0.25 in. (6mm) to a maximum of 2.1 in. (53mm).

LABEL TAKEN THRESHOLD:

OPTION CONNECTOR:

LABEL TAKEN:

Page 2-15
Section 2. Installation REAR PANEL
Power On/Off Switch: AC Input: Turns power On or Off. Input 115V 50/60 Hz connector. Use the cable provided. Input power protection. Type 3A/250V. 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, DB-25P. IEEE1284 Parallel I/F Module, AMP 57-40360 Universal Serial Bus I/F Module Ethernet 10/100BaseT I/F Module Two connectors for optional PCMCIA Memory Cards. External signal connector, AMP 57-60140.

AC Fuse: Interface Slot:

Memory Card Slot: EXT:
Cover Plate Remove for access to Dispenser and Fan-Fold Slots
PCMCIA Memory Expansion slot
I/F Module Parallel Shown

Power Switch

AC Fuse
External Accesory Connector AC Power Input Connector

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Power: AC Input: Switch to turn power On or Off. Input 115V 50/60 Hz connector. Use the cable provided. Input power protection. Type 3A/250V. 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, DB-25P. IEEE1284 Parallel I/F Module, AMP 57-40360 Universal Serial Bus I/F Module Ethernet 10/100BaseT I/F Module Two slots for optional PCMCIA Memory Cards. External signal connector for Accessories, AMP 57-60140.
Cover Plate Remove for access to Fan-Fold Slots
External Accesory Connector
PCMCIA Memory Expansion slot Power Switch

AC Power Input Connector

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Section 2. Installation SWITCHES AND SENSORS

Ribbon End Sensor:

This sensor is a motion detector that signals the printer when the ribbon supply is turning. When the print head is opened, this switch is activated and the printer will stop printing. This sensor unit contains two types of sensors, one for label gap and one for Eye-Mark sensing.

Head Open Switch:

Label Sensor Unit:

Ribbon Motion Sensor

Label Sensor Unit
Miminum Eye-Mark Size.12 in (3 mm) W x.24 in. (6 mm) L Label Feed Direction Min. Inter-Label Gap 0.12" (3 mm) 1.0" (25 mm) to 3.5" (90 mm) Label Gap Sensor
0.33" (9 mm) Eye-Mark Sensor
Backing Paper Inside Edge Label Inside Edge
CL608 and CL612 Label Sensor Positioning
Page 2-18 PN 9001074 Rev. B SATO CL Series e Printers
This sensor is a motion detector that signals the printer when the ribbon supply is turning. When the print head is opened, this switch is activated and the printer will stop printing. This sensor unit contains two types of sensors, one for label gap and one for Eye-Mark sensing. The sensors are adjustable over a limited range. This switch prevents printer operation when the Front Access Door is open. The Top Access Door must be open before the Front Access Door can be opened or closed.
Front Access Door Interlock:
Front Access Door Interlock Switch
Miminum Eye-Mark Size.12 in (3 mm) W x.24 in. (6 mm) L Label Feed Direction Minimum Inter-Label Gap 0.12" (3 mm) 0.67" to 2.5" (17mm to 64mm) Label Gap Sensor Note: These positions are different from the M84XX printers. Label Inside Edge

Inside Label Guide

0.25" to 2.1" (6 mm to 53mm) Eye-Mark Sensor
Backing Paper Inside Edge
CL408 and CL412 Label Sensor Positioning
SATO CL Series e Printers PN 9001074 Rev. B Page 2-19

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PRINTER DIP SWITCH CONFIGURATION
DIP Switch Panels There are two DIP switches (DSW2 and DSW3) located inside the cover. These switches can be used to set: Thermal transfer or direct thermal mode Label sensor enable/disable Head check mode Hex dump mode Single Job or Multi-Job Receive buffer Operation mode In addition, a third DIP switch is located on the RS232 Serial Adapter module and is used to set the RS232C transmit/receive parameters 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 effective until the power is cycled. 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 bit data bits for each byte transmitted.

SATO CL Series e Printers PN 9001074 Rev. B Page 3-7
3. Press the FEED key to feed out a blank label. 4. Adjust the position using the OFFSET potentiometer on the front control panel and feed another label by depressing the FEED key. Repeat this procedure until the label is fully released from the liner. DISPLAY This potentiometer is used to adjust the contrast of the LCD display for optimum viewing under various lighting conditions. PRINT The PRINT potentiometer is used to adjust the amount of heat (i.e., power) applied to the head for printing. It provides a continuous range of adjustment. Maximum print darkness is obtained by turning the potentiometer all the way clockwise and a maximum counterclockwise setting will give the lightest print. NOTE: The PRINT potentiometer adjustment will affect the darkness in all of the command code speed and darkness ranges.

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Section 3. Configuration LCD PANEL PRINTER CONFIGURATION
The LCD Panel is used by the operator in conjunction with the LINE and FEED switches to manually enter printer configuration settings. Many of these 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 nine modes of operation. 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.
MODE Normal Advanced Test Print Default Setting Clear Non-Standard Protocol Protocol Code Download Hex Dump
KEY SEQUENCE POWER LINE + POWER FEED + POWER LINE + FEED + POWER DSW2-7 ON + LINE + FEED + POWER DSW2-7 ON + POWER DSW2-4 ON + POWER
INITIAL DISPLAY ONLINE QTY:000000 ADVANCED MODE TEST PRINT MODE CONFIGURATION DEFAULT SETTING YES NO ALT. PROTOCOL USER DOWNLOAD ONLINE QTY:000000
PAGE 3-10 3-12 3-22 3-23 3-24 3-24 3-25

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NORMAL MODE The printer initially powers on in the ONLINE mode. The user can access the User Settings using the following procedures.
ONLINE QTY:000000 The LCD will display the ONLINE status on the top line and the bottom line will contain the label quantity (QTY) status. The messsge will be changed to OFFLINE whenever the printer is switched offline by pressing the LINE key. As soon a print job is received, the quantily line will indicate the number of labels to be printed. As soon as the label job begins to print, the display will indicate the number of labels in the print job that remains to be printed. Press the LINE key once. When the display changes to OFFLINE, press the FEED and LINE keys simultaneously for more than one second. The LCD now displays the Print Darkness selections. The current setting is indicated by a cursor over one of the range settings. 1. Press the LINE key to step the cursor to the desired setting. 2. Once the correct setting is highlighted, press the FEED key to accept the selection and step the display to the next adjustment. PRINT SPEED 8 The print speed selections are dependent upon the printer model. The current setting is indicated by the underline cursor. 1. Use the LINE key to step the cursor to the desired setting. 2. Once the correct setting is highlighted, press the FEED key to accept the selection and step the display to the next adjustment.

OFFLINE 000000 PRINT DARKNESS 5
CL408e/CL412e 2 ips 3 ips 4 ips 5 ips 6 ips
CL608e/CL612e 4 ips 6 ips 8 ips

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The label Pitch is the distance from the leading edge (the edge that comes out of the printer first) of a label and the leading edge of the next label. The leading edge position of the label can be adjusted relative to the print head +/- 49mm in increments of 1mm. Once the position is set, it can be fine adjusted +/- 3.75mm using the PITCH potentometer on the Adjustment Panel. 1. The cursor will initially be positioned over the Pitch Direction setting. Pressing the LINE key will step the setting to the positive (+) or negative (-) selection. A positive selection moves the leading edge of the label forward (away from the print head) while a negative selection moves the leading edge of the label back into the mechanism. 2. Once the correct direction is selected, pressing the FEED key will accept the setting and advance the cursor to the Offset selection. 3. Use the LINE key to step the first digit of the counter to the desired setting. The display will increment one step each time the LINE key is pressed. The reading will advance to a setting of 4 after which it will automatically wrap and start at 0 again. 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, pressing the FEED key will step to the next adjustment. You may wish to print a test label after completing the adjustments to ensure they are correct.

PITCH OFFSET + 00mm

ABCDEFG ABCDEFG
Moved with negative (-) offset to print on leading edge of the label Leading edge of the label as detected by Original (0 offset) first line print position

ABCDEFG

Sensor Position
Moved with positive (+) offset to print on trailing edge of label

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If the printer has a print job(s) in memory, selecting YES will cause the job(s) to be cleared. The default selection is NO. Be sure you want to cancel the print job(s) before selecting yes as the job(s) cannot be recovered and will have to be retransmitted tyo the printer. 1. Use the LINE key to step the cursor to either the YES or NO selection. 2. Once the correct setting is highlighted, pressing the FEED key will accept the setting. CANCEL PRINT JOB COMPLETED 3. After the print job(s) have been cleared from memory, the printer will display a COMPLETED message for 3 seconds and then return to the initial ONLINE Normal Mode. 4. If you wish to change any of the settings, you must enter the User Settings mode again by taking the printer OFFLINE and pressing the LINE and FEED keys.

PRINT OFFSET V:+000 H:+000

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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 key is pressed until it reaches its maximum legal value (i.e., 99 for the year digits) at which point it will wrap around to the 00 setting. 2. Month - After you have set the correct year, pressing the FEED key will advance the cursor to the two digit Month position. You can scroll through the numbers corresponding to the month by pressing the LINE key. The month number will increase by one each time the LINE key is pressed until it reaches a value of 12 at which point it will wrap around to the 01 setting. 3. Day - After you have set the correct month, pressing the FEED key will advance the cursor to the two digit Day position. You can scroll through the numbers corresponding to the month date by pressing the LINE key. The date number will increase by one each time the LINE key is pressed until it reaches a value of 31 at which point it will wrap around to the 01 setting. 4. Hour - After you have set the correct date, pressing the FEED key will advance the cursor to the two digit Hour position. You can scroll through the numbers corresponding to the hour (using a 24 hour clock) by pressing the LINE key. The hour number will increase by one each time the LINE key is pressed until it reaches a value of 24 at which point it will wrap around to the 01 setting. 5. Minute- After you have set the correct hour, pressing the FEED key will advance the cursor to the two digit Minute position. You can scroll through the numbers corresponding to the hour by pressing the LINE key. The minute number will increase by one each time the line key is pressed until it reaches a value of 60 at which point it will wrap around to the 01 setting. 6. After you have set the minutes, pressing the FEED key will accept the setting and advance to the Ignore CR/LF selection. IGNORE CR/LF YES NO This selection tells the printer to strip out all carriage return/line feed pairs (CRLF ) from the data stream, including graphics and 2D bar codes. It is used primrily to maintain compatibility with earlier models of SATO printers. 1. Use the LINE key to step the cusor to either the YES or NO selection. 2. Once the correct setting is highlighted, pressing the FEED key will accept the setting and advance the display to the Character Pitch display.

MEMORY->CARDCOPY ALL <XMB> Y/N
4. Once the copy process is completed, press the FEED key to step the display.
5. If an error is encountered in the copy process, one of the following messages will be displayed on the second line: R/W Error No Card Error Mem Full Error Indicates a Read/Write error occured Indicates no card was regognized Indicates that there is insufficient memory available.
CARD->MEMORYCOPY PROGRAM Y/N
This selection allows the user to copy printer firmware from the PCMCIA Memory Card to the printer. 1. Use the LINE key to step the cursor to desired setting. If Yes is selected, the printer will enter the Card Copy mode. If No is selected, the display will advance to the mode display.
COPY START YES NO CARD->MEMORY COPY COPYING CARD->MEMORYCOPY COMPLETED CARD COPY/FORMAT XXXXXXX ERROR
2. Confirm your selection by stepping the underline cursor to the Yes selection. If you select No, the display will return to the previous selection. 3. Press the FEED key to accept the selection. If Yes was selected the copy process will start
4. Once the copy process is completed, press the FEED key to step the display. 5. If an error is encountered in the copy process, one of the following messages will be displayed on the second line: R/W Error No Card Error Mem Full Error Indicates a Read/Write error occured Indicates no card was regognized Indicates that there is insufficient memory available.
MEMORY->CARDCOPY PROGRAM Y/N
This selection allows the user to copy the current firmware installed in the printer to a PCMCIA Memory Card. 1. Use the LINE key to step the cursor to desired setting. If Yes is selected, the printer will enter the Card Copy mode. If No is selected, the display will advance to the mode display.

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2. Press the FEED key to accept the selection. If Yes was selected the copy process will start. If you select No, the display will return to the previous selection. 3. Once the copy process is completed, press the FEED key to step the display. 4. If an error is encountered in the copy process, one of the following messages will be displayed on the second line: R/W Error No Card Error Mem Full Error CARD FORMAT YES NO Indicates a Read/Write error occured Indicates no card was regognized Indicates that there is insufficient memory available.

GAP INPUT

[X.XV] [X.XV]
EYE - When setting the eye threshold, the voltage must be measured with nothing but the label under the sensor and then again withthe printed eye mark under the sensor. The formula for this is: (High Voltage Level + Low Voltage Level) x 0.5 = Start Value 1. Insert a label into the sensor and close the Label Hold-Down. Make sure the printed eye mark is not under the sensor. Record the voltage shown on the top line of the LCD panel. This line should have the message EYE on the top line (DIP switch DSW2-2 = ON). 2. Now pull the label forward until the eye mark is positioned under the sensor (the voltage reading should be at its highest point). Record the voltage shown on the top line of the LCD panel. The voltage ranges measured should be within the following ranges: Label Only = 0.3 to 0.7V Eye-Mark 1.2V above low value If the measured values are outside this range, you may have trouble in finding a value that will work properly under all conditions. If this is the case, a higher quality label may be needed to get adequate performance. 3. Calculate the starting point voltage using the formula. 4. Use the LINE key to step the counter to the desired setting. The display will increment one step for each time the LINE key is pressed. If the LINE key is held pressed for more than two seconds, it will automatically go into the fast scroll mode. The reading will advance to a setting of 3.3 (the maximum voltage) after which it will automatically wrap and start at 0.0 again. If a value of 0.0 is set, the printer will automatically set the level each time the printer is powered on with labels loaded or the head is closed. 5. Once the setting is correct, pressing the FEED key will accept the setting and advance to the Online Feed display. ONLINE FEED YES NO This selection specifies whether or not the printer will automatically feed a blank label when it is placed in the Online mode. 1. Use the LINE key to step the cursor to desired setting. If Yes is selected, the printer will feed a blank label anytime it enters the Online mode. If No is selected, the display will advance to the mode display. FEED ON ERROR YES NO This selection specifies whether or not the printer will feed a blank label automatically when an error condition is cleared. 1. Use the LINE key to step the cursor to desired setting. If Yes is selected, the printer will feed a blank label anytime an error condition is cleared. If No is selected, the display will advance to the mode display.

EYE INPUT

Page 3-20
This selection specifies whether or not the printer will print the last printed label stored in memory when the FEED key is pressed in the Normal Online mode. 1. Use the LINE key to step the cursor to desired setting. If Yes is selected, the printer will reprint the last label when the FEED key is pressed when the printer is Online. If the printer is Offline, pressing the FEED key will feed a blank label. If No is selected, the display will advance to the mode display. FORWARD/BACKFEED DISTANCE DEFAULT This dsiplay will only appear when Backfeed is enabled (DSW3-4 = OFF). The maximum backfeed distance is 255 mm. 1. Use the LINE key to select either the Default or the Distance selection. If Default is selected, the display steps to the Web acceleration selection. FORWARD/BACKFEED DISTANCE XXXmm 2. If Manual setting is selected, use the LINE key to advance the distance to the desired setting. Each time the LINE key is pressed, the Distance will advance 1 mm. The maximum distance is 255 mm. 3. Once the desired distance is set, press the FEED key to accept the setting and step to the next display. EURO CODE D5 This selection allows the user to specify the dexadecimal code for the character which is replaced with the Euro Character. The default is D5H. 1. The cursor should be positioned over the first digit selection. Use the LINE key to step to the desired setting. 2. Press the FEED key to advance the cursor to the second digit of the desired hexacecimal code. 3. Press the LINE key to step to the desired setting. 4. When the setting is correct, press the FEED key to accept the setting and step to the next display. SELECT LANGUAGE ENGLISH This selection allows the user to select the character set used by the printer. The selections are English, French, German, Spanish, Italian and Portuguese. 1. Press the LINE key to advance to the desired languarge setting. 2. When the setting is correct, press the FEED key to accept the setting and step to the next display. PRIORITY SETTING LCD COMMAND This selection allows the user to assign a priority for Print Darkenss, Print Speed and Print Offset. 1. Use the LINE key to step to the desired priority. If LCD is selected, the setting established via the LCD display/menu system will be used for an incoming label job, regardless of any different command settings. If Command is selected, any commands in the label job will take precedence and be used for printing the job and the LCD Display will reflect the new setting. 2. Once the desired setting is selected, press the FEED key to accept the setting and step to the next display.

REPLACING THE PRINT HEAD

The print head on the CL6XXe printers is a user-replaceable item. If it becomes damaged for any reason, it can be easily removed and replaced. Contact your local SATO representative for information on obtaining a new print head. Supplies needed: No. 2 Phillips screwdriver (a magnetic tip is helpful)
1. Turn the printer off and remove the power cable. 2. Open the Label Access door. 3. Open the Print Head Assembly by pushing the Head Latch toward the rear of the printer. The Print Head Assembly is spring-loaded and will automatically open as soon as the Head Latch is disengaged. 4. Remove the ribbon from the Ribbon Rewind Spindle if necessary. 5. View the Print Head Assembly from the front of the printer. Locate the two mounting screws on the top of the assembly. They are accessible through the two holes in the Top Assembly Plate. Unscrew these two screws and set them aside. 6. The Print Head should now be loosened from the top of the assembly by grasping either side and carefully pulling it forward.

Mounting Screws

Signal Connector Print Head

Power Connector

Page 4-4
7. Disconnect the signal and power cables from the print head connectors and set the Print Head aside. 8. Carefully attach the new print head to the connectors, using caution to make sure the connector keys are correctly positioned. NOTE: Be careful not to scratch the printing surface of the print head while installing it. Scratching the surface will cause permanent and irreparable damage and is not covered by the warranty! 9. Locate the two mounting screws in the top plate assembly and align them with the tapped holes in the new print head. 10. Re-secure the print head by tightening the screws.

CLEANING THE SENSORS

There are two sensors that are used to control the positioning of the label. One is a transmissive see-thru sensor that detects the edge of the label by looking through the backing paper which is translucent and detecting the presence of the opaque label. The other is a reflective sensor that detects the light reflected from the bottom of the label liner. When a printed black Eye-Mark passes through the beam, the light is no longer reflected back to the sensor detector, indicating to the printer that it should use this position as the start of a new label. When dust, dirt or other foreign matter interferes with the light path of either of these sensors, the results is erratic label positioning. These sensors should be cleaned regularly, at least every two rolls of labels. Supplies Needed: 1. Turn the printer off and remove the power cable. 2. Open the Label Access Door. 3. Open the Label Hold-Down by disengaging the latch. The Label Hold-Down is spring loaded and will stay in the up position. Two rectangular holes will be visible underneath the Label Hold-Down when it is raised. These are located approximately 1 and 2 inches in from the printer side plate. 4. Apply SATO Thermal Print Head Cleaner to one of the cotton swabs.

To Printer To Host

To Printer

Reference To Host

Cable Requirements
DB5 DB7 HOST FG RD TD CTS RTS DTR DSR* SG INTERCONNECTION PRINTER FG (Frame Ground) RD (Receive Data) RTS (Request to Send) CTS (Clear to Send) DSR (Data Set Ready) SG (Signal Ground) 2. TD (Transmit Data)
20 DTR (Data Terminal Ready)
* This connection at the host side of the interface would depend upon the pin that is being used as the Ready/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.
READY/BUSY FLOW CONTROL Ready/Busy is the hardware flow control method for the serial interface on the Se printers. By raising/lowering the voltage level on Pin 20 of the RS232 port, the printer notifies the host when it is ready to receive data. Pin 4 (RTS) and pin 20 (DTR) are the important signals on the printer for this method of flow control. The

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host must be capable of supporting this flow control method for it to function properly. X-On/X-Off FLOW CONTROL X-On/X-Off flow control is used whenever hardware (Ready/Busy) flow control is not available or desirable. Instead of a voltage going high/low at pin 20, control characters representing Printer Ready (X-On =11 hexadecimal) or Printer Busy (X-Off = 13 hexadecimal) are transmitted by the printer on pin 2 (Transmit Data) to the host. In order for this method of flow control to function correctly, the host must be capable of supporting it. X-On/X-Off operates in a manner similar to the function of pin 20 (DTR) as previously explained. When the printer is first powered on it sends an X-Off when the Buffer Near Full level is reached and a X-On when the data level of the buffer drops below the Buffer Available mark. When the printer is taken off-line manually, it transmits an X-Off indicating it cannot accept data. When it is placed back on line manually, it sends an X-On, indicating it is again available for receipt of data. If an error occurs during printing (paper out, ribbon out), the printer sends an X-Off as soon as an error condition is detected. When the error is cleared and the printer is placed back on-line, it transmits an X-On indicating it is again ready to accept data. Upon power up if no error conditions are present, the printer will continually send X-On characters at five millisecond intervals until it receives a transmission from the host. Data Streams The data streams for X-On/X-Off and Ready/Busy flow control are constructed in the same way as they are for Ready/Busy flow control.

Page 7-2 PN 9001074 Rev. B SATO CL Series e Printers
carriage returns and line feeds from your data being sent out to the printer. We want the data stream to be one complete line going to the printer.
USING THE RS232C SERIAL INTERFACE
1. Is the RS232C Serial cable connected securely to your serial port on the PC (DB- 25S or DB-9S Male) and to the RS232C connector on the printer? WARNING: Never connect or disconnect interface cables (or use a switch box) with power applied to either the printer or the host. This may cause damage to the interface circuitry and is not covered by warranty. 2. Is the cable defective? At the very least, you should be using a Null Modem Cable, which crosses pins in a specific manner. This should enable your printer to print. But we recommend that you eventually use a cable built to specifications as described in Section 6: Interface Specifications. 3. Is the RS232 Interface Module installed in the printer? 4. Check for obvious errors in the data stream. Is the data properly framed with the <ESC>A and <ESC>Z commands? See Section 5 if necessary. 5. If after sending your job to the printer, it only beeps and displays an error message on the LCD display, you may have a configuration problem. There may be some inconsistencies with the Baud Rate, Parity, Data Bits, or Stop Bits in relation to your host computer. If you are confused as to what the printers current RS232 settings are, print a Configuration Test label(see Section 3). It will list all of the current printer configuration settings. 6. If you still are unable to get printer output, try the Hex Dump as described in Step 5 under the Parallel Interface troubleshooting. In this case, the printer monitors the RS232C interface for incoming data. 7. From the Hex Dump, if you are seeing extra 0DH 0AH (CR and LF) characters, and are using BASIC, refer to the beginning of the Command Code section. It provides hints for writing a SATO program in BASIC.

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Section 7. Troubleshooting ERROR SIGNALS
The LCD Display, Front Panel LED Indicators and Buzzer provide a visual/audio indication of the type of error encountered.
LED Error On Error On Error On Error On Error Blinks Error Blinks Error Blinks Error Blinks Error On Line Blinks Error On Line Blinks Error On Line Blinks Error On Line Blinks Error Blinks Label On Error Blinks Ribbon On Error Blinks Label Blinks Ribbon Blinks Line Blinks LCD MESSAGE Machine Error EEPROM Error Head Error Sensor Error Card R/W Error Card Low Battery Head Open Cutter Error PARITY ERROR Overrun Error Framing Error Buffer Over Paper End AUDIBLE BEEP 1 Long 1 Long 1 Long 3 Short 1 Long 1 Long 3 Short 3 Short 3 Short 3 Short 3 Short 3 Short 3 Short ERROR CONDITION Machine Error EEPROM Read/Write Head Sensor Memory Card Read/Write Memory Card Battery Low Head Open Cutter RS232 Parity Error RS232 Overrun Error RS232 Framing Error Buffer Overflow Label End TO CLEAR Cycle power on/off Cycle power on/off Cycle power on/off Cycle power on/off Cycle power on/off Cycle power on/off Close head lever Cycle Power On/Off Cycle power on/off Cycle power on/off Cycle power on/off Cycle power on/off Open/close Head Lever Open/close Label Holddown Open/close Head Lever Open/close Label Holddown Open/close Head Lever Replace ribbon with full roll Slow down transmission rate

Industrial Bar Code Printers

CL408e/CL412e Printer

Parts List

Page 1-1 P/N 9001077

Rev. A
SATO Industrial Bar Code Printers

Table of Contents

CL408e/CL412e Parts List Page
Frame Assembly.... 3 Print Head Assembly... 6 Ribbon Assembly.... 10 Base Cover Assembly... 14 Main PCB Assembly... 21 Interface Options.... 22 PCMCIA Memory Option.... 23 Cutter Assembly Option.... 24 Dispenser Assembly Options... 26

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SATO CL408e/CL412e Printer Parts List

Frame Assembly

Page 3
ITEM NO. 23 CODE PA1772700 MD4300621 MD3401021 PA1772800 MD4300621 MD4401021 P D 1770100 MD4401021 PA1773100 P B 2770200 P C 1770100 MD4301422 P E 5680000 MH0301221 P E 1770300 MH0300821 PR7770100 P E 2770500 P C 1770100 P E 2770400 MH0300821 P B 0770500 MT1400722 DESCRIPTION ENGINE FRAME PAN HEAD SCREW PAN HEAD SCREW SIDE FRAME PAN HEAD SCREW PAN HEAD SCREW STAY PAN HEAD SCREW GUIDE PLATE COLLAR SPRING (GUIDE) PAN HEAD SCREW GUIDE SHAFT P-TIGHT SCREW GUIDE BLOCK P-TIGHT SCREW PITCH SENSOR SUB COLLAR SPRING (GUIDE) COLLAR P-TIGHT SCREW POST HEX NUT QTY 1

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ITEM NO. CODE NA1040022 NB0040022 P E 1770400 P C 2770100 P B 2770100 MD4401421 MD4300821 PR7770200 PA1770800 MD4300621 PT8127064 PA1773200 P E 1770800 MD4300821 RH1770800 MD3201221 P E 6770900 NA1030022 PR7771000 PT8130064 DESCRIPTION PLAIN WASHER SPRING WASHER LATCH HANDLE SPRING (LATCH HANDLE) COLLAR PAN HEAD SCREW PAN HEAD SCREW PLATEN (CL408E) CLAMP (B) PAN HEAD SCREW TIMING BELT (CL408E) TEAR-OFF CUTTER CUTTER PROTECTOR PAN HEAD SCREW HEAD OPEN SW PAN HEAD SCREW PAPER GUIDE PLAIN WASHER PLATEN ROLLER SUB (CL412e) TIMING BELT (CL412e) QTY 1 1

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Print Head Assembly

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ITEM NO. 23 CODE PA1772000 MD4401021 PA1772500 PA1771900 MD4300621 PA1772300 MD4300621 PA1771800 MD4300621 PA1770600 P B 2770300 MA0401021 P B 0770700 ND0020030 P B 2770100 MD4401421 PA1771500 P L2720100 MD4300821 NA1040022 MD4300821 P C 0770100 P B 0770600 DESCRIPTION HEAD FRAME PAN HEAD SCREW HEAD BRACKET PLATE (RIBBON ADJUST) PAN HEAD SCREW ADJUST PLATE (A) PAN HEAD SCREW HEAD SUB BRACKET PAN HEAD SCREW ADJUST PLATE (B) COLLAR PAN HEAD SCREW SHAFT (HEAD ADJUST) E-SNAP RING COLLAR PAN HEAD SCREW ADJUST PLATE ADJUST COLLAR PAN HEAD SCREW PLAIN WASHER PAN HEAD SCREW SPRING SHAFT (HEAD PRESSURE) QTY 1

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ITEM NO. 41 43
CODE P E 1740100 P E 1740200 P C 1770200 PA0740100 ND0060030 P E 2770300 P B 3770100 P B 0770300 MD4300621 PR7770600 NG2201230 PR7770700 GH000531A MD4300621 RH1775100 RH1775201 P V 9740300 GH000771A
DESCRIPTION HEAD PRESSURE BRACKET HEAD TENSION PIN SPRING (HEAD) PRESSURE PLATE E-SNAP RING COLLAR ROLLER SHAFT (SUPPORT) PAN HEAD SCREW LATCH HANDLE PIN HEAD PRESSURE SET PRINT HEAD (CL408e) PAN HEAD SCREW CABLE ASSY PRINTHEAD , CABLE ASSY PRINTHEAD , BUSHING PRINT HEAD (CL412e)

QTY 1 1

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Ribbon Assembly

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ITEM NO. 23 CODE P E 4730100 P E 2720100 PA4690900 MH0300521 PT2301020 PA0680400 P C 1730100 P E 2730100 P B 5730100 MA0303022 MA1300822 MT1300522 MD4300621 PB0771101 P E 4720200 MA0301821 MA0302522 MT1300522 MH1250621 PA0680300 P C 0740200 PA0730100 PA0730200 DESCRIPTION RIBBON BOSS COLLAR SPRING P-TIGHT SCREW OILLESS DRY METAL DISC SPRING STOPPER COLLAR ADJUST SCREW PAN HEAD SCREW FLAT HEAD SCREW HEX NUT PAN HEAD SCREW RIBBON (SHAFT) PLATE HOLDER BOSS PAN HEAD SCREW PAN HEAD SCREW HEX NUT P-TIGHT SCREW LINING SPRING GUIDE PLATE HOLD PLATE QTY 2

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ITEM NO. CODE PE1681100 P E 7720100 P E 6720100 MD4300621 PA1770500 MD4300621 MA0300621 RH1740400 PA1772600 MD4300621 PA1771700 MD4300621 MD4401021 PT1112080 PR1720400 ND0060030 JG100501A PT8170064 PR1730900 PR1770100 P C 0740200 MH0300821 PA2771300 MD4300621 DESCRIPTION GUIDE PLATE (B) DISC PLATE (A) DISC PLATE COVER PAN HEAD SCREW SENSOR BRACKET PAN HEAD SCREW PAN HEAD SCREW RIBBON SENSOR (SEN4) RIBBON FRAME PAN HEAD SCREW ADJUST PLATE PAN HEAD SCREW PAN HEAD SCREW BALL SUPPORTER PULLEY (50) E-SNAP RING PUSH BUTTON WIRE TIE TIMING BELT RIBBON BOSS PULLEY SPRING (BACK) P-TIGHT SCREW SPRING BRACKET PAN HEAD SCREW QTY 1 2

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Base Cover Assembly

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ITEM NO. 35 36

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CODE PR3770500 PT6680100 PZ0771500 MD4401021 PA1771000 MD4300621 P E 1770200 P E 3770100 P B 0770100 P E 8770100 ND0040030 MD4401021 P B 0770400 PA3741800 P B 0740900 P C 0740100 P E 3720100 MD4300621 MD4301422 MT1300522 ND0040030 PA1775400 MD4300621 PZ0771000 MD4300621 P E 6771001 P B 5A 20001 PH3683802 PT9520100 PA1772100 MD4300621 PA1773500 PA4520300 P E 1720300 MH0300821 NA1030022
DESCRIPTION BASE FRAME RUBBER FOOT CENTER FRAME PAN HEAD SCREW LID PAN HEAD SCREW ROLLER BRACKET ROLLER POST GEAR E-SNAP RING PAN HEAD SCREW POST TENSION BRACKET SHAFT (TENSION ROLLER) SPRING (TENSION) TENSION ROLLER PAN HEAD SCREW PAN HEAD SCREW HEX NUT E-SNAP RING PCB BRACKET PAN HEAD SCREW REAR COVER PAN HEAD SCREW MEMORY CARD COVER PAN HEAD SCREW LID NYLON RIVET GUIDE PLATE PAN HEAD SCREW UNWIND BRACKET STOPPER SPRING LABEL STOPPER P-TIGHT SCREW PLAIN WASHER
ITEM NO. 77 CODE MD4300621 PA2770200 MD4401021 P L1770100 MJ1400524 RH1770300 MD3401221 PA1771400 P E 6770200 MD4300621 PZ0770400 PT3770100 MH1300821 MA1300622 P E 6770400 P E 6770300 MH0300821 PZ0771300 PR1340500 PA1773000 MH0300821 PR3770100 PH2720100 MT1300522 NA1030022 MD4300621 PH1770100 MD4300621 K A 500631A MD4300821 RH1771700 RH1770600 RJ1771501 RH1770500 P E 6770600 DESCRIPTION PAN HEAD SCREW MOTOR BRACKET PAN HEAD SCREW MOTOR PULLEY (CL408e) W-POINT SCREW STEPPING MOTOR PAN HEAD SCREW PLATE NUT CONNECTOR COVER PAN HEAD SCREW FRONT COVER HINGE P-TIGHT SCREW FLAT HEAD SCREW LENS SWITCH BUTTON P-TIGHT SCREW LOGO PLATE (CL408e) ANTI-STATIC BRUSH LATCH BRACKET P-TIGHT SCREW COVER RH WINDOW HEX NUT PLAIN WASHER PAN HEAD SCREW COVER LH PAN HEAD SCREW POWER SUPPLY UNIT (115V) PAN HEAD SCREW POW 1 CABLE POW 2 CABLE DISPLAY PCB K B C A B LE S E T KB PROTECTOR QTY 1

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ITEM NO. 98 CODE MD4300621 P E 6770700 PR7770300 PR7770400 MD3201221 PA1772900 MH0300821 HD100321A MD4300621 NA1030022 P L1770200 PR7771100 PZ0771400 PR7773500 PR7773600 P E 6A 21900 JG100551A DESCRIPTION PAN HEAD SCREW CABLE PROTECTOR MOTOR PULLEY SET (CL408e) GUIDE ROLLER PAN HEAD SCREW SENSOR SLIT P-TIGHT SCREW FUSE (250V 3.15A) PAN HEAD SCREW PLAIN WASHER MOTOR PULLEY (CL412e) MOTOR PULLEY SET (CL412e) LOGO PLATE (CL412e) COVER FRONT SUB (CL408e) COVER FRONT SUB (CL412e) MICRO DRIVER CK CLAMP QTY 1

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Main PCB Assembly

ITEM NO. 6 9

CODE RJ1771200 RJ7770200 P C 9730100 P C 9680000 MD4300621 RJ7770300
DESCRIPTION MAIN PCBA MEMORY PCB SPRING SPRING PAN HEAD SCREW MEMORY PCB (4MB UPGRADE OPTION)

QTY 5 1

Page 21

Interface Options

ITEM NO. 5 6
CODE MD3300622 WCL404070 WCL404051 WCL404060 11S000158 11S000136
DESCRIPTION SCREW IEEE-1284 PARALLEL INTERFACE SERIAL INTERFACE USB INTERFACE ETHERNET INTERFACE CX/TX INTERFACE

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PCMCIA Memory Option

ITEM NO. 1

CODE RJ4770100
DESCRIPTION PCMCIA MEMORY OPTION
NOTE: PCMCIA Memory Card not included with the option.

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Cutter Assembly Option

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ITEM NO. 18 CODE PR7772000 MD4300621 PA2770700 MH0300821 P B 0771000 MD4300621 RJ1773600 MD4300621 RH1772000 P E 1771000 MD4300821 PA2770500 MH0300821 P V 9770600 PG0770000 DESCRIPTION CUTTER SET PAN HEAD SCREW CUTTER BRACKET P-TIGHT SCREW POST PAN HEAD SCREW CUTTER PCB SET PAN HEAD SCREW CUTTER CABLE COLLAR PAN HEAD SCREW CABLE COVER P-TIGHT SCREW EMI GASKET FG PLATE QTY 1

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Dispenser Assembly Option

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ITEM NO. 36 CODE PA1774100 PA1770700 MD4300621 PR0770100 PT1112060 P E 1770900 PR1770200 ND0040030 MH0300821 PR1520200 P B 0770200 ND0040030 P B 0770900 ND0020030 P E 1570300 MH0250821 RH1772100 PA1774200 MH0300821 MD4300821 PT9689000 MH1300621 MH4300821 NA1003022 P B 0770800 P E 4770100 P E 4770200 MD4301221 ND0060030 P E 1520700 PA1774000 MD4300621 PA1773900 MD4300621 P E 8770400 DESCRIPTION DISPENSE FRAME ROLLER BRACKET PAN HEAD SCREW DISPENSE ROLLER BALL SUPPORTER DISPENSE BRACKET GEAR E-SNAP RING P-TIGHT SCREW PRESSURE ROLLER SHAFT (PRESSURE) E-SNAP RING SHAFT (DISPENSE) E-SNAP RING DISPENSE SENSOR BRACKET P-TIGHT SCREW DISPENSE CABLE LATCH BRACKET P-TIGHT SCREW PAN HEAD SCREW MAGNET P-TIGHT SCREW S-TIGHT SCREW PLAIN WASHER SHAFT (REWIND) REWIND CORE REWIND BOSS PAN HEAD SCREW E-SNAP RING HANDLE REWIND FRAME PAN HEAD SCREW REWIND PLATE PAN HEAD SCREW PULLEY QTY 1