Brother P-touch PRO DX PT-9200DX User manual

SERVICE MANUAL
MODEL: PT-9200DX

SERVICE MANUAL
MODEL: PT-9200DX

Copyright Brother 2000
All rights reserved.
No part of this publication may be reproduced in any
form or by any means without permission in writing from
the publisher.
Specifications are subject to change without notice.

PREFACE
This publication is a service manual covering the specifications, theory of operation,disassembly/
reassembly procedure, and troubleshooting of the Brother label printer PT-9200DX. It is intended
for service personnel and other concerned persons to accurately and quickly provide after-sale
service for our PT-9200DX.
To perform appropriate maintenance so that the machine is always in best condition for the
customer, the service personnel must adequately understand and apply this manual.
This manual is made up of four chapters and an appendix.
CHAPTER I SPECIFICATIONS
CHAPTER II MECHANISMS
CHAPTER III ELECTRONICS
CHAPTER IV TROUBLESHOOTING
APPENDIX CIRCUIT DIAGRAM

CHAPTER I
SPECIFICATIONS

CONTENTS
CHAPTER I SPECIFICATIONS
1.1 MECHANICAL SPECIFICATIONS ................................................................................................I-1
1.1.1 External View..................................................................................................................I-1
1.1.2 Input Specifications.........................................................................................................I-2
1.1.3 Display Specifications......................................................................................................I-2
1.1.4 Printing Specifications.....................................................................................................I-2
1.1.5 Tape Cassette Specifications ..........................................................................................I-3
1.1.6 Tape Cutter Specifications...............................................................................................I-3
1.1.7 PC Interface Specifications .............................................................................................I-3
1.2 ELECTRONIC SPECIFICATIONS.................................................................................................I-4
1.2.1 Power Supply Specifications............................................................................................I-4

I - 1
1.1 MECHANICAL SPECIFICATIONS
1.1.1 External View
(1) Dimensions (W ×D ×H) 115 mm ×245 mm ×145 mm
(2) Weight
Machine proper Approx. 1.5 kg (only the machine)
Machine and package Approx. 3.0 kg
Fig. 1.1-1 External View

I - 2
1.1.2 Input Specifications
(1) Number of keys 2 (ON/OFF ( ) and FEED/CUT ( ) keys)
(2) Key layout See Fig. 1.1-2.
Fig. 1.1-2 Key Layout
1.1.3 Display Specifications
(1) Display method LED (green/red)
1.1.4 Printing Specifications
(1) Printing method Thermal transfer or heat sensitizing method
by thermal head
Printing on plastic tapes (laminated and non-
laminated tapes) or special tapes (instant
lettering tape, non-laminated thermal film
tape, and fabric printing tape)
(Fixed print head and tape feed mechanism)
(2) Printing speed 20 mm/sec
(3) Print head
Type Thin film thermal head
384 dots ×1 dot
Dimensions of a heating
element 0.08 mm wide by 0.0545 mm high
ON/OFF key
FEED/CUT key

I - 3
1.1.5 Tape Cassette Specifications
(1) Cassette Cartridge type
(2) Types of cassettes
Laminated tape cassette Laminated tape, ink ribbon, and adhesive
base tape
Non-laminated tape
cassette Non-laminated tape and ink ribbon
Instant lettering tape
cassette Instant lettering tape and ink ribbon
Fabric printing tape
cassette Fabric printing tape and ink ribbon
Stamp tape cassette Porous-stamp tape and mount
(3) Tape size
Width Length
Laminated tape 6,9,12,18,24,36 mm 8 m
(5 m for fluorescent
coating tapes)
Non-laminated tape 6,9,12,18,24 mm 8 m
Instant lettering tape 18 mm 8 m
Fabric printing tape 18 mm 8 m
Stamp tape 18 mm 8 m
1.1.6 Tape Cutter Specifications
(1) Tape cutting method Automatic full cutting method
(not user-replaceable)
Automatic half cutting method
(not user-replaceable)
1.1.7 PC Interface Specifications
(1) Method
* Serial (RS-232C)
Baud rate Max. 115.2 Kbps
** USB
Standard USB standard Ver.1.1 Full speed
(2) Attachments
Serial I/F cable Dedicated cable
Editor Dedicated editor
USB I/F cable USB standard cable

I - 4
1.2 ELECTRONIC SPECIFICATIONS
1.2.1 Power Supply Specifications
(1) Power supply method
Commercially available power (100V-120V AC, 60 Hz and 220V-240V AC, 50
Hz) is input and stabilized to generate DC voltage by the switching regulator in
the machine.
The power supply cord is inserted into an inlet.

CHAPTER II
MECHANISMS

CONTENTS
CHAPTER II MECHANISMS
2.1 THEORY OF MECHANISM OPERATION....................................................................................II-1
2.1.1 Printing Mechanism........................................................................................................II-1
2.1.2 Roller Holder Assy Setting and Retracting Mechanism ...................................................II-3
2.1.3 Regular Tape and Ribbon Feed Mechanism...................................................................II-4
2.1.4 Tape Automatic Full Cutter Mechanism..........................................................................II-6
2.1.5 Tape Automatic Half Cutter Mechanism .........................................................................II-7
2.1.6 Forced Tape Eject Mechanism.......................................................................................II-8
2.1.7 Cover Open Button (Cover Lock Button) ........................................................................II-9
2.1.8 Cover Open (Cover Lock) Sensor...................................................................................II-9
2.2 DISASSEMBLY AND REASSEMBLY.........................................................................................II-10
2.2.1 Disassembly Procedures ..............................................................................................II-11
[1] Removing the Tape Cassette.................................................................................II-11
[2] Removing the Cassette Cover................................................................................II-11
[3] Disassembly of the Cassette Cover Components...................................................II-12
[4] Removing the Lower Cover.................................................................................... II-13
[5] Removing the Bottom Cover and the Front Cover.................................................. II-14
[6] Removing the Power Supply PCB Assy..................................................................II-16
[7] Removing the Main PCB Assy and the Mechanical Printing Unit............................ II-18
[8] Disassembly of the Body Cover .............................................................................II-20
[9] Removing the Eject Unit Assy, the Half Cutter Assy, the Half Spacer,
and the Cutter Assy................................................................................................ II-23
[10] Removing the Half Frame Assy.............................................................................. II-24
[11] Disassembly of the Mechanical Unit.......................................................................II-26
[12] Disassembly of the Head/Roller Holder Unit...........................................................II-28

2.2.2 Reassembly Procedures...............................................................................................II-29
[1] Reassembly of the Head/Roller Holder Unit ...........................................................II-29
[2] Reassembly of the Mechanical Unit .......................................................................II-30
[3] Reassembly of the Half Frame Assy ......................................................................II-32
[4] Reassembly of the Cutter Assy, the Half Spacer, the Half Cutter Assy,
and the Eject Unit Assy.......................................................................................... II-34
[5] Reassembly of the Body Cover..............................................................................II-35
[6] Reassembly of the Mechanical Printing Unit and the Main PCB assy..................... II-38
[7] Reassembly of the Power Supply PCB Assy ..........................................................II-41
[8] Reassembly of the Covers .....................................................................................II-44
[9] Reassembly of the Cassette Cover Components....................................................II-47
[10] Reassembly of the Cassette Cover ........................................................................II-48
[11] Reassembly of the Tape Cassette..........................................................................II-48
[12] Test Printing and Operation Check.........................................................................II-49
[13] Error Code .............................................................................................................II-50
[14] Error Message........................................................................................................ II-51

II - 1
2.1 THEORY OF MECHANISM OPERATION
2.1.1 Printing Mechanism
(1) Construction of thermal head
This machine uses thermal transfer printing. The thermal head contains 384
heating elements vertically arranged. The size of one heating element is
0.08 mm wide by 0.0545 mm high, as shown in Fig. 2.1-1.
Fig. 2.1-1 Heating Elements of the Thermal Head
(2) Theory of printing
During printing operation, the cylindrical rubber platen crimps the tape* and the
ink ribbon** on the thermal head. At this time, the CPU selects the required
heating elements out of the 384 heating elements to energize them. The
theory of printing depends on the use of non-laminated thermal film tape
cassettes or other tape cassettes:
(*) Laminated tape when using laminated tape cassettes.
Non-laminated tape when using non-laminated tape cassettes.
Instant lettering tape when using instant lettering tape cassettes.
Fabric printing tape when using fabric printing tape cassettes.
Stamp tape when using stamp tape cassettes.
(**) When using non-laminated thermal film tape cassettes, no ink ribbon is
present.

II - 2
[For non-laminated thermal film tape cassettes]
If the selected heating element(s) generates heat, the thermal film tape
develops itself to produce a dot on the tape. The tape is advanced and the
next printing cycle is repeated, thus forming a character and graphics on the
tape.
When using laminated tape cassettes, instant lettering tape cassettes, or fabric
printing tape cassettes, print data is processed so that a character and
graphics read correctly when viewed from the opposite side of the printing
surface of the tape. (In other words, the mirror image of the character and
graphics is printed.)
[For stamp tape cassettes]
If the selected heating element(s) generates heat, the porous-stamp tape will
be melted so that a pore(s) will be formed in the tape. The tape is advanced
and the next heating cycle is repeated, thus forming a character of pores in the
tape. The printed stamp tape can be used as the face of a stamp. When the
stamp is pressed against the ink-pad, it will absorb ink through the pores.
(3) Character Formation
While the main motor (stepping motor) feeds the tape and ink ribbon (tape only
when using non-laminated thermal film tape cassettes or stamp tape
cassettes) by 0.0705 mm for 3.5 ms, the thermal head generates heat once.
The feed amount of 0.0705 mm is smaller than the width (0.08 mm) of the
heating elements so that the heat generated at one heating cycle will overlap
with the next heating cycle. This forms a character having no gap between
adjacent printed dots.

II - 3
2.1.2 Roller Holder Assy Setting and Retracting Mechanism
This mechanism consists of the release cam, roller release rod, and roller
holder/head assy.
The roller holder assy incorporates the platen holder and the sub roller holder.
These holders support the platen and the tape feed sub roller so that they can
move perpendicularly to the thermal head and the tape feed roller, respectively.
The platen is pressed perpendicularly against the thermal head under a uniform
load regardless of the thickness of the tape, so that the tape is fed.
Closing the cassette cover pushes down the release cam which moves the roller
release rod to the left (when viewed from the front of the machine). This pivots the
roller holder assy around the shaft secured on the thermal head assy so as to press
the roller holder assy against the thermal head.
The platen is pressed perpendicularly against the thermal head with the tape and
ink ribbon (only the tape when using non-laminated thermal film tape cassettes or
stamp tape cassettes) sandwiched inbetween under a uniform load by the platen
spring.
At the same time, the platen gear becomes engaged with the platen idle gear.
Also, the tape feed sub roller is pressed perpendicularly against the tape feed roller
built in the tape cassette with the tape (and base paper when using laminated tape
cassettes or stamp tape cassettes) sandwiched inbetween under a uniform load by
the sub roller holder springs. At the same time, the sub roller gear becomes
engaged with the tape feed gear.
Opening the cassette cover causes the release lever spring to slide the roller
release rod in the direction of the arrow. This retracts the roller holder assy from the
thermal head, providing you with enough space to replace the tape cassette.
Fig. 2.1-2 Roller Holder Assy Setting and Retracting Mechanism
Tape cassette
Platen idle gear
Tape feed roller
Adhesive base tape
Platen roller
Tape feed sub roller
Roller holder assy
Roller release rod Thermal head assy
Roller holder shaft
Release cam
Ink ribbon
Laminated tape
Platen gear Platen roller
Platen spring
Sub roller spring
Roller holder
Sub roller gear
Sub roller

II - 4
2.1.3 Regular Tape and Ribbon Feed Mechanism
This mechanism consists of the tape feed motor, the gear train, and the roller holder
assy.
(1) Regular Tape Feeding
When you load a tape cassette and close the cassette cover, the platen and
the thermal head sandwich the tape and ink ribbon (only the tape when using
non-laminated thermal film tape cassettes or stamp tape cassettes) inbetween.
Also, the tape feed sub roller in the roller holder assy and the tape feed roller
inside the tape cassette sandwich the tape (and base paper when using
laminated tape cassettes or stamp tape cassettes) inbetween, as described in
Subsection 2.1.2.
As the tape feed motor (stepping motor) rotates, the rotation is transmitted via
the gear train to the platen idle gear (which rotates the platen gear) and the
tape feed gear (which rotates the tape feed roller and the tape feed sub roller
at the same rotation speed).
Accordingly, the sandwiched tape and ink ribbon will be advanced. (When a
laminated tape cassette is mounted, the sandwiched laminated tape, adhesive
base tape, and ink ribbon will be advanced together.)
The feeding amount of the tape feed sub roller is slightly greater than that of
the platen roller.
Fig. 2.1-3 Tape Feed Mechanism
Adhesive base tape
Tape feed roller
Platen idle gear
Tape feed sub roller
Platen roller
Roller holder assy
Thermal head assy
Transparent laminated tape
Tape feed gear
Sub roller gear
Platen gear Platen idle gear
Tape feed motor
Main frame

II - 5
(2) Adhesive Base Tape Feeding (only for laminated tape cassettes)
A laminated tape cassette contains both a transparent laminated tape roll and
a separate adhesive base tape roll.
When a transparent laminated tape and an adhesive base tape pass through
the contact point (between the tape feed roller and tape feed sub roller), they
are then bonded together into a single, printed tape. The ink printed on the
laminated tape is, therefore, sealed up with the adhesive base tape.
(3) Ink Ribbon Feeding (except for non-laminated thermal film tape cassettes and
stamp tape cassettes)
As the main motor rotates, the ribbon drive cam located at the middle of the
gear train rotates counterclockwise. When fitted on the ribbon drive cam, the
ribbon take-up roll in the tape cassette also rotates to take up the ink ribbon.
To apply proper tension to the ink ribbon between the platen roller and the
ribbon drive cam, the feed amount of the ribbon drive cam is slightly greater
than that of the tape feed gear. The difference between the feed speeds at
the platen roller and at the ribbon drive cam is absorbed by the clutch spring
which is integrated in the ribbon drive cam and allows the cam to slip.
This way, the ink ribbon is kept tense, which enables the ribbon to clearly
separate from the tape at the stabilized angle after printing.
Fig. 2.1-4 Ribbon Feed Mechanism
Tape feed roller
Tape feed sub roller
Platen roller
Roller holder assy
Thermal head assyInk ribbon
Ribbon take-up roll
Main frame Tape feed motor
Ribbon drive cam

II - 6
2.1.4 Tape Automatic Full Cutter Mechanism
The tape automatic full cutter mechanism consists of a stationary blade and a
movable blade driven by the full cutter motor.
Upon completion of printing and tape feeding, the CPU activates the full cutter
motor (DC motor) whose clockwise rotation is transmitted to the cutter helical gear.
As the cutter helical gear rotates counterclockwise, its boss “A” (which is fitted in the
opening of the movable blade) actuates the movable blade to pivot it around shaft
“B”. Consequently, the cutter cuts the printed tape routing through the movable and
stationary blades, just like a pair of scissors.
Subsequently, the CPU keeps the full cutter motor on. When the movable blade
returns to the home position, part “C” of the cutter helical gear presses the full cutter
sensor switch secured on the half frame. The moment the CPU receives the sensor
signal, it stops the full cutter motor.
Fig. 2.1-5 Tape Automatic Full Cutter Mechanism
Full cutter sensor
Cutter helical gear
“C”
Stationary blade
“B”
“A” Cutter helical gear
Full cutter motor assy
Movable blade

II - 7
2.1.5 Tape Automatic Half Cutter Mechanism
The tape automatic half cutter mechanism consists of a stationary plate and a half
cutter holder (equipped with a cutter blade) which is operated by the half cutter
motor.
Half cutting is performed only for laminated tapes.
Upon completion of printing and tape feeding, the CPU activates the half cutter
motor (DC motor) whose counterclockwise rotation is transmitted to the half rock
gear by the clutch gear and the three idle gears.
As the half rock gear rotates counterclockwise, its groove “D” (into which the
projection on the half cutter holder is inserted) operates the half cutter holder to
pivot it around shaft “E”. The stationary plate is provided with space as wide as the
separator of a laminated tape. A laminated tape is pressed against the stationary
plate by the half cutter holder for half cutting.
Half cutting refers to cutting a tape except its separator.
Subsequently, the CPU rotates the half cutter motor counterclockwise to return the
half cutter holder to the home position. Part “F” of the half rock gear presses the
half cutter sensor switch provided on the half frame. The moment the CPU receives
the sensor signal, it stops the half cutter motor.
Fig. 2.1-6 Tape Automatic Half Cutter Mechanism
Half cutter sensor
Half rock gear
Half cutter holder
“F” “D”
Half cutter motor assy
“E”
Stationary blade
Tape
Separator
Cut line