Brother P-touch PT-9600 User manual

SERVICE MANUAL
MODEL: PT-9600/3600

SERVICE MANUAL
MODEL: PT-9600/3600

PREFACE
This publication is a service manual covering the specifications, theory of operation,
disassembly/reassembly procedure, and troubleshooting and error message of the Brother PT-
9600/3600. It is intended for service personnel and other concerned persons to accurately and
quickly provide after-sale service for our PT-9600/3600.
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 appendices.
CHAPTER I SPECIFICATIONS
CHAPTER II THEORY OF OPERATION
CHAPTER III DISASSEMBLY AND REASSEMBLY
CHAPTER IV TROUBLESHOOTING AND ERROR MESSAGE
APPENDICES 1. MAIN PCB CIRCUIT DIAGRAMS
2. LCD PCB CIRCUIT DIAGRAMS
© Copyright Brother 2002
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.

i
CONTENTS
CHAPTER I SPECIFICATIONS......................................................................... I-1
1.1 MECHANICAL SPECIFICATIONS ........................................................................ I-1
1.1.1 External Appearance...................................................................................... I-1
1.1.2 Keyboard........................................................................................................ I-2
1.1.3 Display........................................................................................................... I-2
1.1.4 Printing Mechanism........................................................................................ I-3
1.1.5 Tape Cassette................................................................................................ I-3
1.1.6 Tape Cutter.................................................................................................... I-4
1.1.7 PC Interface................................................................................................... I-4
1.2 ELECTRONICS SPECIFICATIONS ...................................................................... I-10
1.2.1 Character Generator....................................................................................... I-10
1.2.2 Power Supply................................................................................................. I-10
1.3 KEY COMMANDS FOR SPECIAL FUNCTIONS................................................... I-10
1.3.1 Initializing....................................................................................................... I-10
1.3.2 Demonstration Print........................................................................................ I-10
CHAPTER II THEORY OF OPERATION........................................................... II-1
2.1 OUTLINE OF MECHANISMS................................................................................ II-1
2.1.1 Print Mechanism ............................................................................................ II-1
2.1.2 Roller Holder ASSY Setting & Retracting Mechanism..................................... II-3
2.1.3 Tape & 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 Tape Eject Mechanism (Full Cut Only)........................................................... II-8
2.1.7 Release Button............................................................................................... II-9
2.1.8 Roller Holder ASSY & Cassette Cover Interlocking Mechanism...................... II-9
2.1.9 AV Label Print Start Position Detector Mechanism......................................... II-11
2.2 OUTLINE OF ELECTRONICS .............................................................................. II-12
2.2.1 Configuration.................................................................................................. II-12
2.2.2 Main PCB....................................................................................................... II-14

ii
[ 1 ] Block Diagram............................................................................................. II-14
[ 2 ] Solder Ponits............................................................................................... II-16
[ 3 ] Cassette Sensor & AV Cassette Sensor Circuit............................................ II-16
2.2.3 LCD PCB ....................................................................................................... II-18
CHAPTER III DISASSEMBLY AND REASSEMBLY ......................................... III-1
3.1 DISASSEMBLY PROCEDURE ............................................................................. III-2
[ 1 ] Removing the Tape Cassette ...................................................................... III-2
[ 2 ] Disassembling the Cassette Cover ASSY.................................................... III-3
[ 3 ] Removing the Screw from Bottom Cover .................................................... III-4
[ 4 ] Removing the KB Unit/Rubber Key Unit ...................................................... III-5
[ 5 ] Disassembling the KB Unit/Rubber Key Unit................................................ III-6
[ 6 ] Removing the Body Cover .......................................................................... III-10
[ 7 ] Removing the Chassis Unit ......................................................................... III-11
[ 8 ] Disassembling the Chassis Unit................................................................... III-12
[ 9 ] Removing the Main PCB............................................................................. III-23
[ 10 ] Removing the LCD Module Unit.................................................................. III-24
[ 11 ] Removing the Release Button, Tape End Sensor PCB and
Cassette Sensor PCB.................................................................................. III-26
3.2 REASSEMBLY PROCEDURE .............................................................................. III-29
[ 1 ] Reassembling the Cassette Sensor PCB, Tape End Sensor PCB and
Release Button............................................................................................ III-29
[ 2 ] Reassembling the LCD Module Unit............................................................ III-32
[ 3 ] Reassembling the Main PCB....................................................................... III-35
[ 4 ] Reassembling the Components of the Chassis Unit..................................... III-36
[ 5 ] Installing the Chassis Unit ........................................................................... III-47
[ 6 ] Reassembling the Body Cover .................................................................... III-49
[ 7 ] Reassembling the KB Unit/Rubber Key Unit................................................ III-50
[ 8 ] Installing the KB Unit/Rubber Key Unit ........................................................ III-54
[ 9 ] Reassembling the Bottom Cover................................................................. III-55
[ 10 ] Reassembling the Cassette Cover ASSY .................................................... III-56
[ 11 ] Reassembling the Tape Cassette................................................................ III-58
[ 12 ] Final Check................................................................................................. III-59

iii
CHAPTER IV TROUBLESHOOTING AND ERROR MESSAGE....................... IV-1
4.1 OVERVIEW .......................................................................................................... IV-1
4.2 TROUBLESHOOTING GUIDE.............................................................................. IV-1
4.3 ERROR MESSAGE .............................................................................................. IV-2
4.4 TROUBLESHOOTING FLOWS ............................................................................ IV-40
[ 1 ] Printing is performed with specific dots omitted........................................... IV-40
[ 2 ] The tape cassette type is not detected correctly .......................................... IV-41
[ 3 ] No printing is performed.............................................................................. IV-42
[ 4 ] The interface malfunctions (RS-232C)......................................................... IV-42
[ 5 ] The Interface malfunctions (USB)................................................................ IV-43
[ 6 ] The tape is not fed correctly ........................................................................ IV-44
[ 7 ] The tape is not cut....................................................................................... IV-46
[ 8 ] Half cut failure............................................................................................. IV-47
[ 9 ] Forced tape eject failure.............................................................................. IV-48
Appendix 1. MAIN PCB CIRCUIT DIAGRAM
Appendix 2. LCD PCB CIRCUIT DIAGRAM

I-1
CHAPTER ISPECIFICATIONS
1.1 MECHANICAL SPECIFICATIONS
1.1.1 External Appearance
Fig. 1.1-1 External Appearance (1)
PT-9600 (Europe)
PT-9600/3600 (U.S.A./CANADA)

I-2
Fig. 1.1-1 External Appearance (2)
[ 1 ] Dimensions(W x D x H) 237 mm x 302 mm x 104 mm
[ 2 ] Weight Machine proper Approx. 1.9kg
Approx. 2.0kg (including a tape cassette)
In package Approx. 4.0kg
1.1.2 Keyboard
[ 1 ] Entry system Rubber key pad (PT-3600 Europe)
Full keyboard (PT-9600/PT-3600 U.S.A.)
[ 2 ] Number of alphanumeric and symbol keys 39
[ 3 ] Number of function keys 27 (PT-9600)
21 (PT-3600 U.S.A.)
19 (PT-3600 Europe)
(excluding “ON/OFF” key, “PRINT” key)
[ 4 ] Key arrangement See Fig. 1.1-2.
1.1.3 Display
[ 1 ] Display type Liquid crystal display (LCD)
(PT-9600 having Back-light)
[ 2 ] Configuration (See Fig.1.1-2.) 119 dots wide by 24 dots high and
guidance
[ 3 ] Number of indicators (See Fig.1.1-2.) : 32
[ 4 ] Field-of-view angle adjustment : Fixed by a resistor.
PT-3600 (Europe)

I-3
1.1.4 Printing Mechanism
[ 1 ] Print method Thermal transfer onto plastic tapes (laminate tape
and non-laminated tape) or special tapes (instant
lettering tape, non-laminated thermal film tape,
iron-on transfer tape, and porous-stamp tape, and
*AV labels tape)
(Fixed print head and tape feeding mechanism)
* AV labels tape : PT-9600/PT-3600 U.S.A. only
[ 2 ] Print speed (max.) 285 dots (20.1 mm) per second
[ 3 ] Print head
Type Thermal print head
Heat generator Consists of 384 heating elements vertically aligned
Size of heating element 0.08 mm wide by 0.0705 mm high
[ 4 ] Character size (dots)
Character size
(Point size) dots Height x Width (mm) Character size (Point size) dots Height x Width (mm)
622 x 17 (1.54 x 1.19) 22 80 x 61 (5.6 x 4.27)
726 x 20 (1.82 x 1.4) 24 88 x 67 (6.16 x 4.69)
829 x 22 (2.03 x 1.54) 28 102 x 79 (7.14 x 5.53)
933 x 25 (2.31 x 1.75) 32 117 x 89 (8.19 x 6.23)
10 37 x 28 (2.59 x 1.96) 36 131 x 101 (9.17 x 7.07)
11 40 x 31 (2.8 x 2.17) 40 146 x 112 (10.22 x 7.84)
12 44 x 34 (3.08 x 2.38) 48 175 x 135 (12.25 x 9.45)
14 51 x 39 (3.57 x 2.73) 56 204 x 157 (14.28 x 10.99)
16 58 x 45 (4.06 x 3.15) 64 234 x 179 (16.38 x 12.53)
18 66 x 50 (4.62 x 3.5) 72 263 x 201 (18.41 x 14.07)
20 73 x 56 (5.11 x 3.92) 76 277 x 213 (19.39 x 14.91)
* Scaling with width settings
WIDE 2
NARROW 2/3
NARROWEST 1/2
1.1.5 Tape Cassette
[ 1 ] Cassette Cartridge type
[ 2 ] Types of tape cassettes
•Laminated tape cassette Laminate 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
•Iron-on transfer tape cassette Iron-on transfer tape and ink ribbon
•Stamp tape cassette Porous-stamp tape and base paper
•Cloth tape cassette Cloth tape and ink ribbon
•AV (Avery) labels cassette AV labels and base paper
Note: The tape cassette for Head cleaning is provided.
* The height and width of printed characters will
differ depending on characters. The values in the
above list apply to character “H” of HELSINKI.
* The character size refers to the point size.

I-4
[ 3 ] Tape size
Type of tape Width Length
Laminate tape 6, 9, 12, 18, 24, 36
mm 8 m (5 m for the fluorescent coating tape)
Non-laminated tape 6, 9, 12, 18, 24 mm 8 m
Instant lettering tape 12, 18, 24 mm 8 m
Iron-on transfer tape 18 mm 6m
Porous-stamp tape 18, 24 mm 3m
Cloth tape 12, 18 mm 4m
AV address labels tape 24 mm 7m
AV return address labels tape 24 mm 7m
AV file folder labels tape 24 mm 7m
Head cleaning tape 36 mm 2.5 m (Approx. 100 times)
[ 4 ] Tape cassette packed with the machine
PT-9600/PT-3600 (Europe) version Laminated tape cassette (containing a 24-mm-wide
black ink ribbon, laminate tape, and adhesive base
tape)
PT-3600 U.S.A. version Laminated tape cassette (containing a 24-mm-wide
black ink ribbon, laminated tape, and adhesive
base tape) and AV address labels cassette
(containing a24-mm-wide AV labels tape and base
tape)
1.1.6 Tape Cutter
[ 1 ] Tape cutting (1) Automatic full cutter
(2) Automatic half cutter
Not user-replaceable (1) and (2)
1.1.7 PC Interface
[ 1 ] Comunication Interface USB, Serial interface (RS-232C)(PT-9600 only)
[ 2 ] Applicable OSs Microsoft Windows 95
(for the RS-232C I/F of PT-9600 only)
Microsoft Windows 95/98 SE
Microsoft Windows ME
Microsoft Windows NT 4.0
(for the RS-232C I/F of PT-9600 only)
Microsoft Windows 2000 Professional
Microsoft Windows XP
Macintosh Mac OS 8.6 ~ 9.x
Macintosh Mac OS X 10.1/10.2
[ 3 ] Printer emulation Serial I/F (PT-9600 only)
[ 4 ] ASCII, ESC/P N/A (PT-3600 only)

I-5
PT-9600 U.S.A./CANADA
PT-9600 U.K.
Fig. 1.1-2 Key Arrangement (1)

I-6
PT-9600 German
PT-9600 French
Fig. 1.1-2 Key Arrangement (2)

I-7
PT-9600 Belgium
PT-3600 U.S.A.
Fig. 1.1-2 Key Arrangement (3)

I-8
PT-3600 U.K.
PT-3600 German
Fig. 1.1-2 Key Arrangement (4)

I-9
PT-3600 French
PT-3600 Belgium
Fig. 1.1-2 Key Arrangement (5)

I-10
1.2 ELECTRONICS SPECIFICATIONS
1.2.1 Character Generator
[ 1 ] Internal characters U.S.A./CANADA : 574 characters
(including symbols)
U.K. : 584 characters
(including symbols)
German : 606 characters
(including symbols)
French/Belgium : 585 characters
(including symbols)
[ 2 ] Internal fonts U.S.A./CANADA versions : 10
European versions : 10
[ 3 ] Internal memory Text buffer : 1000 characters
File memory : 10000 characters
1.2.2 Power Supply
[ 1 ] AC adapter Dedicated switching system AC adapter (AD9000)
Power supply Commercially available power (120V AC, 60Hz for North America
and Canada, and 230V AC, 50Hz for Europe) is input and stabilized
to generate DC voltage by the switching regulator in the machine.
The power supply cord is inserted into an inlet.
The protect circuit for the opposite polarity AC adapter is provided.
[ 2 ] Storage battery Dedicated Ni-MH storage battery (BA9600)
(PT-9600 only)
[ 3 ] Automatic powering-off Yes
Normal mode : 5 min ±30sec.
IF mode : 30 min ±30sec.
1.3 KEY COMMANDS FOR SPECIAL FUNCTIONS
1.3.1 Initializing
No powering on the machine with both the “Code” + “R” + “ON/OFF” keys held down will initialize
the machine. (Release the ON/OFF key earlier than other keys.)
1.3.2 Demonstration Print
When the machine is turned on, pressing the “D” key with the “Code” key held down will display
“SELF PRINT” on the LCD and start demonstration print.
(This key command takes effect only when no data is etered.)
Given below is a demonstration printout that is reduced in size.

II-1
CHAPTER II THEORY OF OPERATION
2.1 OUTLINE OF MECHANISMS
2.1.1 Print Mechanism
Structure of Thermal Head
The machine uses thermal transfer printing. The thermal print head has a heat generator
consisting of 384 heating elements which are vertically aligned as shown in Fig. 2.1-1.
Each heating element is 0.08 mm wide by 0.0705 mm high.
Fig. 2.1-1 Heat Generator of the Thermal Head
Printing Process
When the cylindrical rubber platen is pressed against the thermal print head with the tape* and
ink ribbon** sandwiched inbetween, the CPU applies electric power to the selected heating
elements out of 384.
*Laminate tape when using laminated tape cassettes.
Non-laminated tape when using non-laminated tape cassettes.
Instant lettering tape when using instant lettering tape cassettes.
Iron-on transfer tape when using iron-on transfer tape cassettes.
Cloth tape when using cloth tape cassettes.
Thermal tape when using AV (Avery) labels cassettes.
** When using AV labels cassettes or stamp tape cassettes, no ink ribbon is sandwiched.
[For tape cassettes except stamp tape cassettes and AV labels cassettes]
If the selected heating element(s) generates heat, the ink on the sandwiched ribbon will be
melted and transferred to the tape, producing a dot(s) on the tape. The ink ribbon and the tape
are advanced and then the next heating cycle is repeated, thus forming a character on the
tape.
[For AV labels cassettes]
If the selected heating element(s) generates heat, the thermal tape develops itself to produce a
dot on the tape. The tape is advanced and the next heating cycle is repeated, thus forming a
character on the tape.

II-2
[For stamp tape cassettes]
If the selected heating element(s) generates heat, the porous-stamp tape will be melted so that
a pore (pores) will be formed in the tape. The tape is advanced and the next heating cycle is
repeated, thus forming a character of pores on 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.
For laminated tape cassettes, instant lettering tape cassettes, and iron-on transfer tape
cassettes, the CPU processes the print data to generate a mirror image so that the printed
character can be seen normally when viewed from the other side of the printed face of the
tape.
Character Formation
While the tape feed motor feeds the tape and ink ribbon (only the tape when using AV labels
cassettes or stamp tape cassettes) by 0.0705 mm, the thermal head generates heat once. The
feed amount is determined by sending five pulses of the signal per dot (0.0705 mm) when a
pair of photointerrupters detect the encode gear fitted over the motor shaft. 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 & Retracting Mechanism
This mechanism consists of the release lever, 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 lever 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 AV labels 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 roller.
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 & Retracting Mechanism
Adhesive base tape
Platen idle gear
Tape feed roller
Platen
Tape feed sub roller
Roller holder ASSY
Roller release rod Thermal head
Release lever
Roller holder shaft
Tape cassette
Ink ribbon
Laminated tape
Sub roller gear
Roller holder
Platen spring
Sub roller spring
Sub roller Platen gear
Platen roller

II-4
2.1.3 Tape & Ribbon Feed Mechanism
This mechanism consists of the tape feed motor, the gear train, and the roller holder ASSY.
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 adhesive base laminated tape) 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
Transparent laminated tape
Main frame
Tape feed motor
Platen idle gear
Sub roller
Tape feed roller
Platen roller