D508/D512 PRINTER SERVICE MANUAL PN: 9001178
SATO America, Inc. 10350A Nations Ford Road Charlotte, NC 28273 Main Phone: (704) 644.1650 Technical Support: (704) 644.1660 Technical Support Fax: (704) 644.1661 E-Mail: satosales@satoamerica.com techsupport@satoamerica.com www.satoamerica.
Table of Contents Overview Introduction ........................................................................................................................................... 1-3 Unpacking ............................................................................................................................................. 1-4 Printer Part Names ...............................................................................................................................
Problem: Print Start Position Is Incorrect Vertically ............................................................................ 3-13 Problem: Print Start Position Is Incorrect Horizontally ........................................................................ 3-14 Problem: White Lines Appear In Printed Labels ................................................................................ 3-14 Problem: Labels are Not Being Dispensed Properly By The Optional Dispenser Unit ......................
Unit 1: Overview OVERVIEW SATO D508/D512 Service Manual Page 1-1
OVERVIEW Thank you for your investment in this SATO printer product. This Service Manual contains information about the specifications, replacement procedures, checking/calibration procedures, and troubleshooting of common problems associate with the D508/D512.
Unit 1: Overview INTRODUCTION The SATO D508/D512 Printer Service Manual provides information for installing and maintaining D508/D512 Direct Thermal printers. Step-by-step maintenance instructions are included in this manual with typical problems and solutions. It is recommended that you become familiar with each section in this manual before installing and maintaining the printer. The major difference in the D508 and the D512 printers is the resolution of the print head.
Unit 1: Overview UNPACKING When unpacking the printer, take note of the following: 1 The box should stay right-side up. Lift the printer out of the box carefully. 4 If the printer has been stored in the cold, allow it to reach room temperature before turning it on. 2 Remove the plastic covering from the printer. 5 Set the printer on a solid, flat surface. Inspect the shipping container and printer for any sign of damage that may have occurred during shipping.
PRINTER PART NAMES Clear window and fanfold-label Loading Top Cover Label Outlet Release latch for Top Cover LINE/FEED/ Power buttons and LEDs 7-segment Error Status LED Front cover (allows access to optional cutter unit, DIP switches and potentiometers) Thermal Print Head assembly Label Holders Label Sensor Mini Screwdriver Label Holder Release Knob Platen Assembly Optional Cutter Page 1-5 SATO D508/D512 Service Manual
Unit 1: Overview SETTING UP THE PRINTER Consider the following when setting up the printer: Locate a solid flat surface with adequate room to set the printer. Make sure the AC adaptor can be located so that the AC power cable can be attached to the printer and an AC power outlet. The location should be near the host or computer terminal. The maximum distance recommended is: - 10 feet for a Parallel interface cable.
LOADING MEDIA The SATO D508/D512 printer can print to direct thermal die-cut labels, tags or continuous media. The media supply can be either in Roll or Fanfold format. Roll Media Roll media should be between 0.98" (25 mm) and 4.3" (110 mm) in width and wound face-out on a core with a minimum internal diameter of 1.6" (40 mm). 1. Make sure the printer is turned OFF. 2. Open the Top Cover by pressing on cover release points located on the right-hand side of the printer.
Unit 1: Overview 6. Route the label material through the Paper Sensor Assembly and over the Platen. Note that the Sensor is part of the left Label Roll Guide so that the Paper Sensor is always positioned in the same location relative to the left edge of the label. Platen 7. Close the Top Cover. 8. Press the LINE button so that the printer is in the OFF LINE mode and then press the FEED button. The label should advance to the next index (label gap) position. Paper Sensor Paper Guide Fanfold media 1.
6. Close the Top Cover. 7. After loading the label media, it is recommended that you run a Test Print to make sure the labels are correctly loaded and printed. LABEL SENSING Roll-label path Fanfold-label path Overview of the fanfold-paper loading path The SATO D508/D512 uses label Gap (see-through) or Eye-Mark (reflective) sensing. The Sensor Assembly is located on the left edge of the media and is automatically positioned by the Paper Guides.
Unit 1: Overview CONFIGURATION Before using the printer, it is best to read this manual thoroughly first. Otherwise, you may disturb default settings around which the instructional procedures in this manual are based upon. 3.1 OPERATING PANEL The Operator Panel consists of three LED indicators and three switches. POWER The green LED lights up when the printer is ON. ERROR The red LED lights up when there is a system fault such as an unlatched print head.
CONFIGURATION: THE REAR PANEL All of the printer cable connectors are located on the Rear Panel, as follows.
Unit 1: Overview THE CONFIGURATION PANEL The Configuration Panel is accessible when you lift up the top cover. The panel consists of an eight-position DIP switch, four adjustment potentiometers and a sevensegment LED Error Status display. Receptacles for connecting the optional Cutter (factory installed) are also located on this panel.
DIP SWITCH SETTINGS (CONT’D) Switches 1–3: Font/Graphic loading settings Enables the loading of fonts and/or graphics into printer memory for faster retrieval. DSW1 DSW2 DSW3 Off On Mode On Load Font Configuration Switch ON OFF 1 Switch 4: Unused 2 3 DSW4 This switch is reserved for future use. 4 5 6 7 8 7 8 7 8 7 8 Mode Off DT On Reserved Configuration Switch ON OFF 1 Switch 5: Head Check Enables or Disables the printer function that checks the print head automatically.
Unit 1: Overview DIP SWITCH SETTINGS (CONT’D) Switch 7: DATA Dump When ON, the printer will print out the hex value for each character received. When OFF, the printer will accept and process the data stream in a normal fashion. DSW7 Mode Off Disabled On Enabled Configuration Switch ON OFF 1 Switch 8: Unused This switch is reserved for future use.
OFFSETS There are two offset settings stored in the printer; one for the Cut mode and one for the Tear-Off mode. These two offsets can be set independently and will remain in the printer until a new command is received changing the setting or until power is turned off. The default settings can be determined by printing a User Test Label.
Unit 1: Overview POTENTIOMETER ADJUSTMENTS PITCH OFFSET This can be done using the VR4 potentiometer on the Configuration Panel. This potentiometer is set at the factory so that it has a range of +/-3.75 mm. The midpoint setting should have no effect on the label pitch. Turning the potentiometer all the way clockwise should move the print position 3.75 mm upwards towards the leading edge of the label. Turning the it all the way counterclockwise should move the print position down 3.
Print Darkness A fine adjustment for PRINT DARKNESS can be made using potentiometer VR1 on the Front Operator Panel. It provides a continuous range of adjustment, allowing you to make precise changes. Turning VR1 clockwise will make the print darker, and counterclockwise will make it lighter. 1. Place DSW6 on the Configuration Switch in the ON position. 2. Turn the Power Switch OFF. 3. While pressing the FEED button on the Operator Panel, turn the Power Switch ON. 4.
Unit 1: Overview DATA DUMP DIAGNOSTIC LABEL The contents of the printer buffer can be examined using the DATA Dump mode. This printout labels each line of the received data in the left hand column, the data in the middle column followed by the same data in ASCII format in the right-hand column. 1. Turn the printer OFF. 2. Place DSW7 on the configuration Switch in the ON position. 3. Turn the printer ON. 4. Transmit data to the printer. 5. The data received is printed on the label. 6.
PRINTING TEST LABELS 1. The User Test Label prints the current default settings of the printer. 2. Press the FEED button while turning the power ON. 3. When the printer beeps, release the FEED button. 4. To print a large (4" wide) test label, press the LINE button. To print a small (2" wide) test label, press the FEED button. 5. The printer will continuously print the USER TEST LABEL until the FEED button is pressed. If the FEED button is pressed another time, printing will resume. 6.
Unit 1: Overview PRINTING FACTORY/SERVICE TEST PRINTS The Factory/Service Test Label prints the internal operating parameters of the printer. 1. Open the top cover to open print head. 2. Press the LINE and FEED buttons while turning the printer ON. 3. When the printer beeps, release the LINE and FEED buttons. The printer will then beep 3 times, indicating that the print head/cover is open. 4. Close top cover to latch print head in closed position 5.
Unit 2: Interface Specifications BASIC AND INTERFACE SPECIFICATIONS • • D508/D512 Service Manual Basic Printer Specs Interface Specs Page 2-1
1.1 BASIC PRINTER SPECIFICATIONS Attribute PRINT Print Method CPU Printer Command Language Resident Fonts Font Memory Print Head Resolution Print Speed Max. Print Area MEDIA Label Thickness (Label + backing paper) Label Form Label Size (adhesive labels) Direct Thermal 32-bit RISC processor SBPL U S M XU XS SM WB WL XB XL CG Times CG Triumvirate OCR-A OCR-B 4 MB 8 dots per mm for 203 dpi | 12 dots per mm for 305 dpi 6 ips 104 mm (width) by 400 mm (pitch) 0.06 mm* ~ 0.
Unit 2: Interface Specifications 1.
1.
Unit 2: Interface Specifications 1.1 GENERAL SPECIFICATIONS (CONT’D Optional Accessories Internal Cutter IEEE1284 Interface Serial Interface LAN Interface USB Interface RFID Wireless LAN Interface User or factory installed Internal option allowing labels to be cut at specified intervals. Parallel interface. Factory or User installable High Speed RS232 Interface option, 9600 bps to 57.6 Kbps. Factory or User installable. TCP/IP Protocol Interface option. Factory or User installable.
INTERFACE SPECIFICATIONS INTERFACE TYPES The SATO D508/D512 printer can be ordered with any of the interfaces described in this section. The user can specify the desired interface at the time of placing an order. Thereafter, if the user needs to change the interface, it is a simple matter of purchasing a suitable interface card from a SATO dealer.
Unit 2: Interface Specifications THE RECEIVE BUFFER This printer has the ability to receive a data stream from the host in one of two ways. The receive buffer may be configured to accept one print job at a time or multiple print jobs. The single job print buffer is generally used by software programs that wish to maintain control of the job print queue so that it can move a high priority job in front of ones of lesser importance.
THE RECEIVE BUFFER (CONT’D) Multi Job Buffer The printer is able to continuously receive print jobs, compiling and printing other jobs at the same time. It acts much like a "print buffer" to maximize the performance of the host and the printer. When you are using the RS232 Serial interface, the Multi Job Buffer uses either the Ready/Busy with DTR (pin 20) or X-On/X-Off flow control protocols.
Unit 2: Interface Specifications IEEE1284 PARALLEL INTERFACE The parallel interface for this printer conforms to the IEEE1284 specification. It will automatically detect the IEEE1284 signals and operate in the high speed mode. If it does not detect the IEEE1284 signals, it will operate in the standard Centronics mode, which is significantly slower. For this reason, an interface cable and host interface conforming to the IEEE1284 specification must be present to fully utilize the speed capabilities.
RS-232C INTERFACE The High Speed Serial Interface is an factory installed option that must be installed in the printer at the time of order. The D500 recognizes the RS-232 interface automatically.
Unit 2: Interface Specifications Pin Assignments Pin 13 Pin 1 Pin 25 Pin 14 RS-232C INTERFACE SIGNALS Pin Direction Signal Definition 1 Reference FG (Frame Ground) 2 To Host TD (Transmit Data) -Data from the printer to the host computer. Sends X-On/X-Off characters or status data (Bi-Directional protocols). 3 To Printer 4 To Host RTS (Request to Send) -Used with Ready/Busy flow control to indicate an error condition.
DB9 DB2 5 HOST INTERCONNECTION PRINTER 1 1 FG 1 FG (Frame Ground) 2 3 RD 2 TD (Transmit Data) 3 2 TD 3 RD (Receive Data) 8 5 CTS 4 RTS (Request to Send) 7 4 RTS 5 CTS (Clear to Send) 4 20 DTR 6 DSR (Data Set Ready) 6 6 DSR* 20 DTR (Data Terminal Ready) 5 7 SG 7 SG (Signal Ground) * 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.
Unit 2: Interface Specifications The Universal Serial Bus (USB) interface is a factory installed option that must be specified at the time of order. It requires a driver (shipped with each printer that has the interface installed) that must be loaded on your PC and the PC must be configured to support USB peripherals using Microsoft Windows. Details for loading the USB driver are contained in the USB Interface Manual that is shipped with each printer with a USB Optional interface installed.
Unit 2: Interface Specifications This page is left blank intentionally D508/D512 Service Manual Page 2-14
Unit 3: Troubleshooting TROUBLESHOOTING • • • • SATO D508/D512 Service Manual Error Signals Troubleshooting Table Interface Troubleshooting Test Print Troubleshooting Page 3-1
TROUBLESHOOTING ERROR SIGNALS DISPLAY LINE LED 0 Off 1 ERROR BUZZER LED ERROR CONDITION CORRECTIVE ACTION On 1 Beep Flash Memory error Consult SATO dealer Not Assigned 2 Off On 1 Beep Machine error Consult SATO dealer 3 Off On 1 Beep EEPROM error Replace EEPROM 4 Off On 1 Beep Head error Replace Print Head 5 Off Blink 3 Beeps Top Cover Open Close and latch cover 6 Off Blink 3 Beeps Out of Paper 1) Replenish media supply 2) Properly route media 7 Off Blink 3 Beep
Unit 3: Troubleshooting TROUBLESHOOTING TABLE IMAGE VOIDS Damaged print head Replace print head Damaged electronics Replace circuit board Damaged or worn platen roller Replace platen roller Vertical line in printed image Dirty or defective print head LIGHT PRINT IMAGES Low print head energy/darkness Adjust darkness control Low print head pressure Ensure top cover is securely closed.
NO PRINTED IMAGE Data input error Ensure correct data stream MEANDERING MEDIA Incorrectly loaded media Ensure correct loading Improperly adjusted media guides Adjust as required Worn or improperly adjusted platen roller Adjust.
Unit 3: Troubleshooting INTERFACE TROUBLESHOOTING This unit provides a checklist for the various interface types. Locate the checklist relative to the interface used and perform each of the troubleshooting tasks until the problem has been isolated. PARALLEL INTERFACE CHK TROUBLESHOOTING STEP Ensure the interface card is correctly installed. Run self-test to verify. Ensure the printer cable is connected to the appropriate LPT port on the host computer.
LAN ETHERNET INTERFACE CHK TROUBLESHOOTING STEP Ensure the interface has been correctly configured. Wait two minutes and run self-test to verify. If a test label does not print, there may be a hardware problem. Ensure the serial cable meets specifications and is correctly connected at each end. Ensure the cable and its ports are not defective. Ensure that a faulty print server or other protocol related scenarios are not creating a queue setup issue.
Unit 3: Troubleshooting TROUBLESHOOTING FLOWCHARTS PROBLEM: PRINTER DOES NOT POWER UP See Pg 5-10 See Pg 4-5 SATO D508/D512 Service Manual Page 3-7
PROBLEM: LABEL DOES NOT FEED OUTWARD IN A STRAIGHT PATH See Pg 4-3 PROBLEM: PRINTER DOES NOT PRINT Page 3-8 SATO D508/D512 Service Manual
Unit 3: Troubleshooting PROBLEM: PRINTER DOES NOT PRINT See Pg 4-2 See Pg 4-5 SATO D508/D512 Service Manual Page 3-9
PROBLEM: PRINTER DOES NOT FEED LABELS See Pg 1-13 to 1-15 See Pg 4-3 See Pg 4-13 See Pg 4-5 Page 3-10 SATO D508/D512 Service Manual
Unit 3: Troubleshooting PROBLEM: PRINTER DOES NOT STOP AT THE CORRECT POSITION See Pg 1-13 to 1-15 See Pg 5-8 - 5-9 See Pg 4-5 PROBLEM: WIRELESS LAN PRINTER IS NOT PRINTING SATO D508/D512 Service Manual Page 3-11
PROBLEM: PRINTING IS TOO DARK See Pg 5-4 See Pg 5-4 See Pg 4-2 See Pg 4-5 PROBLEM: PRINTING IS TOO LIGHT ON ONE SIDE See Pg 4-3 See Pg 4-2 Page 3-12 SATO D508/D512 Service Manual
Unit 3: Troubleshooting PROBLEM: PRINT START POSITION IS INCORRECT VERTICALLY See Pg 5-8 - 5-9 See Pg 5-2 SATO D508/D512 Service Manual Page 3-13
PROBLEM: PRINT START POSITION IS INCORRECT HORIZONTALLY See Pg 4-3 PROBLEM: WHITE LINES APPEAR IN PRINTED LABELS See Pg 4-2 Page 3-14 SATO D508/D512 Service Manual
Unit 3: Troubleshooting PROBLEM: LABELS ARE NOT BEING DISPENSED PROPERLY BY THE OPTIONAL DISPENSER UNIT SATO D508/D512 Service Manual Page 3-15
PROBLEM: THE CUTTER IS NOT WORKING See Pg 1-13 to 1-15 See Pg 4-17 PROBLEM: THE CUTTER IS NOT WORKING See Pg 4-17 Page 3-16 SATO D508/D512 Service Manual
Unit 3: Troubleshooting TEST PRINT TROUBLESHOOTING Chapter provides instruction on special printing to identify and resolve specific print problems. TEST LABELS The test label is designed to assist in the identification of print problems. FEED + POWER Printer Beeps Release FEED Press LINE Large Label / Small Label Prints large labels. Press FEED Prints small labels. Press FEED Printing is paused. Press FEED Printing commences.
NOTE: The only print problem that the following sample test label does not display is fading of print image from one side of the label to the other. This is the result of improper print head balance.
Unit 3: Troubleshooting DATA DUMP DIAGNOSTIC LABEL The contents of the print buffer can be examined using the Data Dump Mode. In the left column, each line of data received is numbered. The center column provides the data in hexadecimal format. And in the right column, same data is provided in the ASCll format. Follow the flow chart provided below to perform this activity. POWER = OFF DSW7 = ON Power = ON Printer receives data and prints.
PRINTING FACTORY/SERVICE TEST LABELS The Factory/Service Test Labels prints the internal operating parameters of the printer. Open top housing cover LINE + FEED + POWER Printer Beeps Release LINE + FEED Printer beeps 3 times. Close top housing cover Press LINE Large Label / Small Label Prints large labels. Press FEED Prints small labels. Press FEED Printing is paused. Press FEED Printing commences.
Unit 3: Troubleshooting This page is left blank intentionally SATO D508/D512 Service Manual Page 3-21
Unit 3: Troubleshooting SATO D508/D512 Service Manual Page 3-22
Unit 4: Replacement Procedures REPLACEMENT PROCEDURES • • • • • • • • • • • SATO D508/D512 Service Manual Print Head Platen Roller Fuse Main Circuit Board Panel Board Label Sensor Board Label Sensor Cover Open Sensor Drive Motor Drive Gear Cutter Replacement Page 4-1
REPLACEMENT PROCEDURES This unit contains step-by-step instructions for the removal and replacement of all primary components and sub-assemblies. PRINT HEAD REPLACEMENT If the print head becomes damaged or worn, it can be easily removed and replaced without having to make critical adjustments. 1 Turn the printer OFF and disconnect the power supply cord. 2 Lift up the top housing cover (1) (See Figure 4-1) to access the print head assembly.
Unit 4: Replacement Procedures PLATEN ROLLER REPLACEMENT The platen roller is a high wear component due to its treading against the print media. This treading will eventually wear grooves into the rubber material and negatively affect print output. 1 Turn the printer OFF and disconnect the power supply cord. 2 Lift up the top housing cover (1) (See Figure 4-2) to access the platen roller (2). 3 Detach the platen gear cover (3) from the printer housing (4).
Throughout the rest of this Service Manual, reference will be made to the main board of the printer. To access the main board, follow the instructions below. 1 Turn the printer OFF and disconnect the power supply cord. 2 Place the printer with its underside facing upward. 3 Remove the bottom housing cover (See Figure below) by removing four screws. 4 Put the screws in a safe place so that they can be used to re-secure the bottom housing cover when servicing is complete.
Unit 4: Replacement Procedures FUSE REPLACEMENT 1 Turn the printer OFF and disconnect the power supply cord. 2 Remove the base cover from the housing cover to access the fuse. 3 Locate fuse (1), (See Figure 4-4) on the main circuit board (2). 4 Detach the defective fuse (1) from the metal holders (3). 5 Attach a replacement fuse (1) to the metal holders (3) on the main circuit board (2). 6 Attach base cover to the housing cover. 7 Load some media, and run some tests to confirm proper function.
MAIN CIRCUIT BOARD REPLACEMENT 1 Turn the printer OFF and disconnect the power supply cord. 2 Remove the base cover from the housing cover to access the main circuit board. 3 Remove the five screws (1) (See Figure 4-5) that secure the main circuit board (2) to the printer (3). 4 Disconnect all wiring harnesses from the defective main circuit board (2). 5 Remove the defective main circuit board (2), along with the interface cover (4), from the printer (3).
Unit 4: Replacement Procedures PANEL BOARD REPLACEMENT 1 Turn the printer OFF and disconnect the power supply cord. 2 Remove the base cover from the housing cover to access the panel board. 3 Remove the two screws (1) (See Figure 4-6) that secure the panel board bracket (2) to the printer (3). 4 Disconnect the wiring harness for the defective panel board (4) from the main circuit board (5). 5 Detach the lens unit (6), button unit (7), and panel board (4), from the bracket, in this order (2).
RELAY BOARD (LABEL SENSOR BOARD) REPLACEMENT 1 Turn off the printer and disconnect the power supply cord. 2 Remove all media from the printer. 3 Remove one screw (1) (See Figure 4-7a) that secures the bar (2) to the printer (3). 4 Remove one screw (4) and gear (5) from the printer (3). 5 Lift away the left-side media holder (6) from the printer (3).
Unit 4: Replacement Procedures 6 9 8 7 Figure 4-7b, Relay Board Replacement 8 Remove the base cover from the housing cover to access the main board (10) (Figure 4-7c). 9 Remove the five screws (11) securing the main circuit board (10) to the printer (3). 10 11 3 Figure 4-7c, Detachment of Relay Board signal cable from Main Board 10 Lift the main board (10) and disconnect the wiring harness of the relay board. 11 Now replace the relay board and reconnect the main signal wire to the main board.
LABEL SENSOR REPLACEMENT 1 Turn the printer OFF and disconnect the power supply cord. 2 Remove all media from the printer. 3 Remove one screw (1) (See Figure 4-8a) that secures the bar (2) to the printer (3). 4 Remove one screw (4) and gear (5) from the printer (3). 5 Lift away the left-side media holder (6) from the printer (3). 6 Remove one screw (7) that secures the sensor cover (8) to the left-side media holder (6).
Unit 4: Replacement Procedures 8 Remove three screws (11) (See Figure 4-8b) securing the cover (12) to the left-side media holder (6). 9 Disconnect the wiring harnesses of the defective sensors (10&13) from the sensor board (14). 10 Insert replacement sensors (13&10) into the left-side media holder (6) and connect their relative wiring harnesses to the sensor board (14). NOTE: Each wiring harness connector is different from the others. To reconnect the wiring harnesses, simply match mating halves.
COVER SENSOR REPLACEMENT 1 Turn the printer OFF and disconnect the power supply cord. 2 Lift up the top housing cover (1) (See Figure 4-9a) to access the sensor area. 3 Remove the two screws (2) securing the cable cover (3) to the top housing cover (1). 4 Remove the screw (4) that secures the cover sensor (5) to the top housing cover (1). 5 4 3 2 1 Figure 4-9a, Cover Sensor Replacement 5 Remove the base cover from the printer to access the main board (6) (See Figure 4-9b).
Unit 4: Replacement Procedures 10 Secure the base cover to the printer (8). 11 Secure the sensor (5) (See Figure 4-9a) to the top housing cover (1) using screw (4). 12 Return the cable cover (3) to the top housing cover (1) and secure it using two screws (2). 13 Load some media, and run some tests to confirm proper function.
DRIVE MOTOR REPLACEMENT 1 Turn the printer OFF and disconnect the power supply cord. 2 Remove the base cover from the housing cover to access the drive motor. 3 Remove the five screws (1) (See Figure 4-10a) that secure the main circuit board (2) to the printer (3). 4 Disconnect all wiring harnesses from the defective main circuit board (2). 5 Remove the circuit board (2), along with the interface cover (4), from the printer (3), and set it aside.
Unit 4: Replacement Procedures Drive Motor Replacement (cont’d) 8 Remove the three screws (7) (See Figure 4-10b) that secure the gear cover (8) to the motor bracket (9). 9 Remove the screw (10) that secures the defective motor (11) to the motor bracket (9). 10 Install the replacement motor (11) to the motor bracket (9) using one screw (10). 11 Attach the gear cover (8) to the motor bracket (9) using three screws (7).
DRIVE GEAR REPLACEMENT 1 Turn the printer OFF and disconnect the power supply cord. 2 Remove the base cover from the housing cover to access the drive motor. 3 Remove the five screws (1, Figure 4-11a) that secure the main circuit board (2) to the printer (3). 4 Disconnect all wiring harnesses from the defective main circuit board (2). 5 Remove the circuit board (2), along with the interface cover (4), from the printer (3), and set it aside.
Unit 4: Replacement Procedures Drive Gear Replacement (cont’d) 8 Remove the three screws (7) (See Figure 4-11b) that secure the gear cover (8) to the motor bracket (9). 9 Detach the two snap rings (10) securing the worn gears (11 &12) and remove. 10 Insert replacement gears (12 & 11) onto their relative spindles using the snap rings (10). 11 Attach the gear cover (8) to the motor bracket (9) using three screws (7).
CUTTER ASSEMBLY The cutter assembly is an optional unit typically preinstalled at the factory. To retrofit a X700 printer that was not originally delivered with a cutter, follow the procedures here but make sure to order the complete set of components that also includes the cutter alignment assembly that mounts near the print head. 1 Turn off the printer and disconnect the power supply cord. 2 Open top housing cover (1) and remove front cover (2) from printer base (3).
Unit 4: Replacement Procedures NOTE: If the cutter assembly was pre-existing on this particular printer and this is a replacement operation, the cutter blade may not require installation nor replacement. Perform step 6 only if deemed necessary. 8 Press latch (7, Figure 4-12b) to release print head (8) from mounting bracket (9). Lift away print head (8). NOTE: Press on the latch while manually lowering the print head to remove.
Unit 4: Replacement Procedures This page is left blank intentionally SATO D508/D512 Service Manual Page 4-20
1CHECKS/ADJUSTMENT PROCEDURES • • • • • • • • • • • SATO D508/D512 Service Manual Top of Form Position Factory Clear Print Darkness Printer Counter Clear Cutter Counter Clear Test Print Counter Clear Cut Position Paper Sensor Sensitivity Gap Sensor Sensitivity Eye-Mark Sensor Adjustment Power Supply Checks Page 5-1
Unit 5: Adjustment Procedures ADJUSTMENT PROCEDURES This unit covers all of the printer adjustment procedures that may occur following the initial configuration. TOP OF FORMS OFFSET This can be done using the VR4 potentiometer on the Configuration Panel. This potentiometer is set at the factory so that it has a range of +/-3.75 mm. The midpoint setting should have no effect on the label top of form. Turning the potentiometer all the way clockwise should move the print position 3.
Unit 5: Adjustment Procedures FACTORY CLEAR This procedure clears all data from the EEPROM. Once initialized and completed, the process cannot be reversed. 1 Open the Top Cover and remove the front cover. 2 Switch ON the DSW5 and DSW6 dip switches. NOTE: Refer to Figure 5-1 for visual assistance in performing this procedure. 3 Press and hold the LINE and FEED buttons while switching on the printer. 4 Release the LINE and FEED buttons when a beep sounds.
Unit 5: Adjustment Procedures PRINT DARKNESS A fine adjustment for PRINT DARKNESS can be made using potentiometer VR1 on the Front Operator Panel. It provides a continuous range of adjustment, allowing you to make precise changes. Turning VR1 clockwise will make the print darker, and counterclockwise will make it lighter. 1 Place DSW6 on the Configuration Switch in the ON position. 2 Turn the Power Switch OFF. 3 While pressing the FEED button on the Operator Panel, turn the Power Switch ON.
Unit 5: Adjustment Procedures Label Pitch Offset Eye Offset or Darkness VR1 VR2 VR3 Identification VR4 Gap Printer Test Panel Dip Switch Complex 8 Test Connector Potentiometers 1A 2A 3A Set the dial to the correct pin number 8 0 4A 1 5A 7 2 Test Module Dial 1B 6 3 5 4 2B 3B 4B Connect ground probe here Connect positive probe here 6A GND SIG 5B 6B Figure 5-2, Test Module Usage SATO D508/D512 Service Manual Page 5-5
Unit 5: Adjustment Procedures PRINTER COUNTER CLEAR This procedure clears the internal cycle counters of various components and returns their values to zero. 1 Open the Top Cover and remove the front cover. 2 Set the DSW5 dip switch to the ON position. NOTE: Refer to Figure 5-1 for visual assistance in performing this procedure. 3 Press and hold the LINE and FEED buttons while switching ON the printer. 4 Release the LINE and FEED buttons when a beep sounds.
Unit 5: Adjustment Procedures TEST PRINT COUNTER CLEAR 1 Open the Top Cover. 2 Press and hold the LINE and FEED buttons while switching ON the printer. 3 Release the LINE and FEED buttons when a beep sounds. 4 Latch the Top Cover closed. NOTE: When the Top Cover is closed, the clear process will automatically be initialized. During the clear process, the printer will be in an offline state. Press the LINE button to test print a large label and the FEED button to test print a small label.
Unit 5: Adjustment Procedures EYE MARK / PAPER END SENSOR SENSITIVITY 1 Open the Top Cover and remove the front cover. 2 Turn the VR2 potentiometer fully counter-clockwise. 3 Connect the Test Module to the test connector on the printer’s test panel. NOTE: Refer to Figure 5-2 for visual assistance in performing this procedure. NOTE: Use of the Test Module on this printer also requires the use of a connector adapter cable that should also be purchased with the module.
Unit 5: Adjustment Procedures GAP SENSOR SENSITIVITY 1 Open the Top Cover and remove the front cover. 2 Turn the VR3 potentiometer fully counter-clockwise. NOTE: Refer to Figure 5-2 for visual assistance in performing this procedure. 3 Connect the Test Module to the test connector on the printer’s test panel. NOTE: Use of the Test Module on this printer also requires the use of a connector adapter cable that should also be purchased with the module.
Unit 5: Adjustment Procedures POWER SUPPLY CHECKS Obtain a DC Multimeter and Number 2 Phillips screwdriver for this check. To check voltage levels, first check the Main PCB fuse (see next page) and replace it if necessary. Then follow the steps below: 1 Turn the printer OFF. 2 Set the multimeter to DC mode. 3 Attach the negative (-) lead from the multimeter to Pin 3 (GND) of CN3 on the configuration panel. 4 Attach the positive (+) lead from the multimeter to Pin 4 of CN3 on the configuration panel.
