Brother PT-2420PC, Service Manual

Page 1: ...SERVICE MANUAL MODEL PT 2420PC ...

Page 2: ...t condition for the customer the service personnel must adequately understand and apply this manual This manual is made up of four chapters and appendixes CHAPTER I SPECIFICATIONS CHAPTER II GENERAL MECHANISM CHAPTER III DISASSEMBLY REASSEMBLY PROCEDURE CHAPTER IV ERROR INDICATION AND TROUBLESHOOTING APPENDIX 1 MAINTENANCE SOFTWARE APPENDIX 2 CIRCUIT DIAGRAM Copyright Brother 2002 All rights reser...

Page 3: ...older ASSY Setting Retracting Mechanism II 3 2 1 3 Roller Holder ASSY Cassette Cover Interlocking Mechanism II 4 2 1 4 Tape Ribbon Feed Mechanism II 5 2 1 5 Tape Cutter Mechanism II 7 2 2 OUTLINE OF ELECTRONIC CONTROL II 8 2 2 1 Configuration II 8 2 2 2 Main PCB II 9 CHAPTER III DISASSEMBLY REASSEMBLY PROCEDURE III 1 3 1 DISASSEMBLY PROCEDURE III 2 1 Removing the Tape Cassette III 2 2 Removing the...

Page 4: ...tom Cover Cassette Cover and Tape Cassette III 24 9 Self Print Test III 26 CHAPTER IV ERROR INDICATION AND TROUBLESHOOTING IV 1 4 1 OVERVIEW IV 1 4 2 TROUBLESHOOTING GUIDE IV 1 4 3 IF THE INDICATOR LED ON THE PT 2420PC LIGHTS OR FLASHES IV 2 4 4 IF ANY ERROR MESSAGE IS DISPLAYED ON THE COMPUTER SCREEN IV 3 4 5 IF ANY OF THE FOLLOWING PROBLEMS OCCURS IV 5 1 Tape Feeding Failure IV 5 2 Printing Fail...

Page 5: ...1 CHAPTER I SPECIFICATIONS 1 1 MECHANICAL SPECIFICATIONS 1 1 1 External View 1 Dimensions W x D x H 66 x 145 x 123 mm 2 Weight Machine proper Approx 0 4 kg In package Approx 1 5 kg Fig 1 1 1 External View ...

Page 6: ... tape and non laminate tape or special tapes instant lettering tape non laminate thermal film tape and iron on transfer tape Fixed thermal print head and tape feed mechanism 2 Printing speed 10 2 mm sec 3 Print head Type Thermal print head Heat generator Consisting of 128 heating elements vertically aligned Size of a heating element 0 195 mm wide by 0 141 mm high ON OFF and FEED button LED Cover C...

Page 7: ...Iron on transfer tape cassette Iron on transfer tape and ink ribbon 3 Tape size Width Length Laminate tape 6 9 12 18 24 mm 8 m 5 m for the fluorescent coating tape Non laminate tape 6 9 12 18 24 mm 8 m Instant lettering tape 18 mm 8 m Non laminate thermal film tape 12 18 mm 8 m Iron on transfer tape 18 mm 6 m 1 1 5 Tape Cutter 1 Tape cutting method Manual cutter Not user replaceable 1 1 6 PC Inter...

Page 8: ...I 4 1 2 ELECTRICAL SPECIFICATIONS 1 2 1 Power Supply 1 Power supply Dedicated AC adapter 9 5 VDC 1 3A provided as attachment ...

Page 9: ...ttes 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 When using non laminated thermal film tape cassettes no ink ribbon is sandwiched For tape cassettes except non laminated thermal film tape cassettes If the selected heating element s generates heat the in...

Page 10: ... of the tape 3 Character Formation While the tape feed motor DC motor feeds the tape and ink ribbon tape only when using non laminated thermal film tape cassettes by 0 141 mm for 13 8 ms the thermal head generates heat once The feed amount of 0 141 mm is smaller than the width 0 195 mm of the heating elements so that the heat generated at one heating cycle will overlap with the next heating cycle ...

Page 11: ...a uniform load by the roller holder springs At the same time the platen gear becomes engaged with the P 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 sandwiched inbetween under a uniform load by the roller holder springs At the same time the sub roller gear ...

Page 12: ...er ASSY is pressed towards the thermal head side Fig 2 1 3 Roller Release Lever and Roller Release Rod Fig 2 1 4 Roller Holder ASSY Cassette Cover Interlocking Mechanism If you open the cassette cover the roller release lever will pop up shifting the roller release rod so that the roller holder ASSY will be retracted from the thermal head side Tape cassette Roller holder ASSY Roller release lever ...

Page 13: ...1 2 As the DC motor rotates the rotation is transmitted via the gear train to the P idle gear which rotates the platen gear and the tape idle gear which rotates the tape feed roller and 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 laminate tape adhesive base tape and ink ribb...

Page 14: ...ed 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 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 tape feed speeds at the platen and at the ribbon drive cam is absorbed by the clutch...

Page 15: ...e printed tape will come through those blades Pressing the cutter lever will drive the cutter drive gear whose pin will move the movable blade cutting the printed tape just like a scissors Fig 2 1 7 Tape Cutter Mechanism Stationary blade Tape cassette Pin of the cutter drive gear Cutter lever Movable blade ...

Page 16: ...rmal print head ASSY and USB interface 2 Sub PCB This holds the ON OFF switch ON OFF and FEED and an indicator LED green 3 DC Motor The DC motor is a power source to advance tape and ink ribbon 4 Thermal Print Head This is a thick film thermal print head which integrates a heat generator consisting of 128 heating elements vertically aligned in 180 dpi and driver circuitry 5 Switch ASSY cassette se...

Page 17: ...ROM 1 kilobit 4 USB interface circuit 5 LED ON OFF circuit thermal head control circuit and motor driver circuit 6 Reset circuit 7 Oscillator circuit 8 Cassette sensor circuit and cutter sensor circuit 9 Head property detector circuit 10 Voltage detector circuit and ambient temperature detector circuit 11 ON OFF switch circuit Fig 2 2 2 Block Diagram of Main PCB ...

Page 18: ... 4 Be careful not to lose screws washers or other parts removed for parts replacement 5 Tighten screws to the torque values listed below Tightening Torque List Location Screw type Q ty Tightening torque Middle cover Taptite bind B M2 6 x 8 5 0 39 0 10 N m 4 1 kgf cm Chassis sub ASSY Taptite bind B M2 6 x 6 2 0 39 0 10 N m 4 1 kgf cm DC motor Screw pan M1 7x2 5 2 0 15 0 05 N m 1 5 0 5 kgf cm Cutter...

Page 19: ...ening the cassette cover the platen is released from the thermal head so that there is a gap between them to make possible to replace the tape cassette Fig 3 1 1 Removing the Tape Cassette 2 Removing the Cassette Cover and Bottom Cover 1 Pull the arms of the cassette cover outwards to remove the cassette cover from the middle cover Fig 3 1 2 Removing the Cassette Cover A Tape cassette Cassette cov...

Page 20: ...rews securing the bottom cover Fig 3 1 3 Removing the Bottom Cover 1 3 Turn the machine upside down so that the bottom cover is at the top Remove the bottom cover Fig 3 1 4 Removing the Bottom Cover 2 Screws Screws Bottom cover ...

Page 21: ...s six for the cassette sensor three for the sub PCB ASSY two for the DC motor soldered onto the main PCB ASSY 4 Remove the one screw securing the FG harness from the chassis ASSY Fig 3 1 6 Removing the Main PCB ASSY 2 Screw Middle cover Thermal head flat cable Main PCB ASSY Screw For cassette sensor For DC motor FG harness For sub PCB ASSY Fixing tape Middle cover Chassis ASSY Middle cover FG harn...

Page 22: ...ng the Top Cover 2 Remove the one screw securing the sub PCB ASSY to remove the sub PCB ASSY CAUTION When pulling the sub PCB out of the top cover ensure not to break the two positioning pins on the top cover 3 Remove the power supply actuator and LED cover from the top cover Fig 3 1 8 Removing the Sub PCB ASSY Power Supply Actuator and LED Cover A Top cover Top cover Cutter lever Chassis ASSY Top...

Page 23: ...lease lever as shown in the figure below 3 Pull the chassis ASSY out of the middle cover Warning When removing the chassis ASSY take care not to get injured in your fingers with the cutter blade Fig 3 1 9 Removing the Chassis ASSY Roller release lever Middle cover Cutter ASSY cutter blade Chassis ASSY Screws ...

Page 24: ...ove the one screw to remove the cutter ASSY from the chassis sub ASSY Warning When removing the cutter ASSY take care not to get injured in your fingers with the cutter blade 5 Remove the one retaining ring to remove the cutter rack gear and cutter drive gear ASSY from the chassis sub ASSY Fig 3 1 10 Removing the DC Motor ASSY and Cutter ASSY Cutter rack gear Retaining ring Chassis sub ASSY Cutter...

Page 25: ...rod in the direction of the arrow to remove its boss from the roller release lever Fig 3 1 11 Removing the Roller Release Rod 4 Turn the roller release lever in the direction of the arrow to align its boss with the hole on the chassis sub ASSY Then remove the roller release lever 5 Remove the retaining ring to remove the roller holder ASSY and roller release rod from the chassis sub ASSY Fig 3 1 1...

Page 26: ...heir shafts Then remove the double gear 2 idle gear tape idle gear and P idle gear 2 Remove the one retaining ring to remove the ribbon drive cam ribbon clutch spring and ribbon drive gear in this order Fig 3 1 14 Removing the Gears Chassis sub ASSY Screw Thermal head flat cable Tape Thermal head ASSY Retaining ring Chassis sub ASSY Ribbon drive cam Ribbon clutch spring Ribbon drive gear Double ge...

Page 27: ...witch ASSY 1 Pull the three hooks on the middle cover outwards slightly to remove the switch ASSY Caution Make sure not to break the hooks on the middle cover Fig 3 1 15 Removing the Switch ASSY Middle cover Hooks Switch ASSY ...

Page 28: ...Assembling the Switch ASSY 1 Pull the three hooks on the middle cover outwards slightly to assemble the switch ASSY Caution Make sure not to break and deform the hooks Fig 3 1 16 Assembling the Switch ASSY Hooks Middle cover Switch ASSY ...

Page 29: ... ribbon drive gear 3 Assemble the ribbon clutch spring onto the ribbon drive cam Set the ribbon drive cam onto the shaft on the chassis sub ASSY and assemble the one retaining ring Note When assembling the ribbon clutch spring ensure that the straight end is at thebottom and install it into the slit on the ribbon drive gear Fig 3 1 17 Assembling the Gears Chassis sub ASSY Retaining ring Ribbon dri...

Page 30: ...sembling the Thermal Head ASSY 4 Apply half of a rice grain size of the grease onto the slideway at the rear of the roller holder ASSY where the roller release rod slides Grease Shinetsu Silicon silicon grease G501 5 Assemble the roller release rod onto the pin on the roller holder ASSY Assemble the roller holder ASSY onto the shaft on the chassis sub ASSY and fix it with the retaining ring Fig 3 ...

Page 31: ...it into the hole on the roller release lever Refer to Fig 3 1 21 8 Fix the end A of the release spring into the hole on the roller release lever and hook the end B of the release spring onto the position C on the chassis to assemble the release spring Refer to Fig 3 1 20 Fig 3 1 20 Assembling the Roller Release Lever and Release Spring Fig 3 1 21 Assembling the Roller Release Rod B A C Release spr...

Page 32: ...n assembling the cutter lever ensure to fix the boss B of the cutter lever into the frame C on the cutter rack gear 4 Insert the pin of the cutter drive gear ASSY into the oblong hole on the cutter ASSY and install the cutter ASSY into the positioning bosses on the chassis sub ASSY to secure it with the one screw Warning When assembling the cutter ASSY take care not to get injured in your fingers ...

Page 33: ...ure to fix the motor harness as shown in the figure below 8 Assemble the double gear 3 onto the chassis sub ASSY and fix it with the washer 2 6 Fig 3 1 24 Assembling the DC Motor ASSY Cutter rack gear Note Assemble the cutter rack gear while turning the cutter drive gear ASSY in the direction of the arrow to attach it onto the chassis sub ASSY Cutter drive gear ASSY Double gear 3 Screws DC motor A...

Page 34: ...o get injured in your fingers with the cutter blade Note When assembling the chassis ASSY onto the middle cover make sure that there is no gap between them 2 Secure the chassis ASSY with the two screws Caution When securing the chassis ASSY make sure not to catch the harnesses of the switch ASSY and DC motor Fig 3 1 25 Assembling the Chassis ASSY Screws Chassis ASSY Slit Boss Ribs Middle cover Rol...

Page 35: ...e two positioning pins on the top cover and secure the one screw to assemble the sub PCB ASSY onto the top cover Note When assembling the sub PCB ASSY onto the top cover ensure not to break the two positioning pins on the top cover 3 Fix the three harnesses of the sub PCB ASSY into the slits A on the top cover Fig 3 1 27 Assembling the Sub PCB ASSY Power supply actuator LED cover Top cover Sub PCB...

Page 36: ...ncave on the top cover with the convex on the middle cover to assemble the top cover onto the middle cover Note Make sure not to catch the harness of the sub PCB ASSY between the covers Fig 3 1 28 Assembling the Top Cover Top cover Convex Concave B Top cover Cutter lever Chassis ASSY ...

Page 37: ...er Fig 3 1 29 Assembling the Main PCB ASSY 1 3 Solder the harnesses of the switch ASSY onto the six soldered points on the main PCB ASSY Fig 3 1 30 Assembling the Main PCB ASSY 2 Sub PCB ASSY harnesses DC motor harnesses Slits where the DC motor harnesses are fixed Top cover Slits where the sub PCB harnesses is fixed Switch ASSY harnesses Orange Blue Yellow Red Green Black Middle cover FG harness ...

Page 38: ...in PCB ASSY Fig 3 1 31 Assembling the Main PCB ASSY 3 5 Solder the harnesses of the DC motor ASSY onto the two soldered points on the main PCB ASSY Fig 3 1 32 Assembling the Main PCB ASSY 4 Middle cover Yellow Green Black Sub PCB ASSY harnesses Middle cover Red Black DC motor ASSY harnesses ...

Page 39: ...ve been already bound with the tape check that they are bound correctly If not bind the harnesses again with a new tape Fig 3 1 33 Assembling the Main PCB ASSY 5 7 Secure the FG harness onto the chassis ASSY with the one screw Fig 3 1 34 Assembling the Main PCB ASSY 6 Middle cover Main PCB ASSY Fixing tape The stepped side should be at the top Screw Chassis ASSY Middle cover FG harness Main PCB AS...

Page 40: ... pin on the middle cover and secure the one screw to assemble the main PCB ASSY Caution When replacing the main PCB with a new one always write the serial number into the new PCB following the flow described in Appendix 1 Maintenance Software Fig 3 1 35 Assembling the Main PCB ASSY 7 Screw Main PCB ASSY Pin Middle cover Boss Termal head flat cable ...

Page 41: ...the middle cover and top cover to assemble the bottom cover Fig 3 1 36 Assembling the Bottom Cover 1 2 Turn the machine upside down so that the bottom cover is at the bottom Secure the bottom cover with the five screws Fig 3 1 37 Assembling the Bottom Cover 2 Ribs Hole Ribs Top cover Middle cover Ribs Bottom cover Hole Screws Screws ...

Page 42: ...ds to assemble the cassette cover onto the middle cover Fig 3 1 38 Assembling the Cassette Cover 4 Open the cassette cover and install the tape cassette Fig 3 1 39 Installing the Tape Cassette Cassette cover Middle cover Arm Arm Tape cassette Cassette cover ...

Page 43: ...e The indicator LED starts flashing slowly and then quickly 5 If the indicator LED flashes quickly release the cutter lever and ON OFF switch The self print test will start 6 Check the print quality and tape length Fig 3 1 40 Print Sample Note If the printout horizontally shows non print sections just like horizontal white leaks then lightly wipe off the heat generator of the thermal head with a c...

Page 44: ...occurs unplug the thermal head flat cable and check the thermal head and related circuits Until they come to operate normally do not plug the thermal head flat cable 3 To supply power to the machine use the dedicated AC adapter If you need to use a regulated DC power supply its specifications should be 11 VDC with minimum 5A supply After repairing After repairing the defective section be sure to c...

Page 45: ...ta reception and printing During printing no check is made Remove the error factor and press the ON OFF button The machine will switch to the standby mode for data reception The tape has run out Tape replacement is required The controller checks the tape state at the start of printing Communications error Cutter sensor error The controller checks the sensor state at the start of data reception and...

Page 46: ...e and print again Take extra care not to get injured in your fingers with the cutter blades Cannot change cassette while printing Turn the P touch off and then on Click the Resume button in the P touch monitor screen Appropriate cassette not installed Load a tape cassette specified in the P touch monitor screen and click the Resume button P touch may have invalid data in memory Turn the P touch of...

Page 47: ...ory to print document Wait until any other application s is finished and then try to print again Not enough disk space to spool document Ensure sufficient disk space Invalid port was specified Choose a valid printer port and try to print again Port being used for another application Wait until any other application s is finished and then try to print again If this error persists A communication ap...

Page 48: ...IF ANY OF THE FOLLOWING PROBLEMS OCCURS Tape feeding failure Printing failure The indicator LED will not come on Interface malfunctions Follow the related troubleshooting flows given below 1 Tape Feeding Failure ...

Page 49: ...IV 6 2 Printing Failure ...

Page 50: ...IV 7 3 The Indicator LED will not come on ...

Page 51: ...IV 8 4 Interface Malfunctions ...

Page 52: ... stored in the EEPROM by using the EEPROM initialization program and then run the test program Appendix 1 2 SETTING UP THE TEST ENVIRONMENT Installing the maintenance software to your computer Make sure that the OS of your computer is Windows98 or Windows98SE Make sure that the PT 2420PC printer driver has been installed to your computer Test program Install the PT15TESTSE EXE and patern01 prn to ...

Page 53: ... Note If the dialog The Port Monitor not loaded displays install the PT 2420PC printer driver restart your computer and go back to step 2 above 4 Open the Port list select the PTUSB PT 2420PC 000000001 and then click the OK button The following window will appear 5 Type the lower nine digits of the serial number printed on the nameplate of the PT 2420PC in the Serial No box If E52827 D0A322331 is ...

Page 54: ...supply and connection between your computer and PT 2420PC Go to the recovery procedure given in Appendix 1 5 6 Click the Cassette sensor check button The display will change to the following Note If the Results area shows any error message click the Stop the cassette sensor check button and the Finish checking and exit button in this order to abort the test program Go to the recovery procedure giv...

Page 55: ...or check will complete and the display will automatically change to the following Note If the cassette sensor check will not finish even after you press all of those five sensor switches then the cassette sensor may be defective Click the Stop the cassette sensor check button to quit the check and then click the Finish checking and exit button to abort the test program 8 Open the cassette cover an...

Page 56: ... given in Appendix 1 5 10 Push down the cutter lever to cut the tape The PT 2420PC will feed the tape again Note If the tape will not feed click the Stop the feed cut test button to stop the test Then check the tape cassette If the tape has run out remove the cassette and go back to step 8 If not so the cutter sensor may be defective Click the Finish checking and exit button to abort the test prog...

Page 57: ...feed and the display will change to the following Note If any error message appears in the Results area click the Stop printing test 1 button and the Finish checking and exit button in this order to abort the test program Then check the tape cassette If no tape cassette is loaded or the tape has run out replace the tape cassette with a new one and go back to step 12 If not so go to the recovery pr...

Page 58: ...e General setting button to call up the Setting dialog In the Setting dialog if the right hand Printing test 1 area does not show patern01 prn then select it click the OK button to close the Setting dialog and go back to step 12 If the patern01 prn is shown but the patern01 prn is not located in the same directory where the PT15TESTSE EXE exists then copy the patern01 prn to the same directory and...

Page 59: ...ing Note If any error message appears in the Results area go to the recovery procedure given in Appendix 1 5 16 Check that the serial number you entered is displayed in the Results area then click the Finish checking and exit button The test program will terminate 17 Turn the PT 2420PC off and unplug the USB interface cable ...

Page 60: ... 2 above 4 Open the Port list select the port that includes the current serial number and character string PT 2420PC and then click the OK button Lower nine digits of the serial number printed on the nameplate of the PT 2420PC if the serial number has been written or 0000000001 if no serial number has been written The following window will appear 5 Click the Reset button Note If NG appears click t...

Page 61: ...cess 5 If an error persists at the same testing process abort the program turn the PT 2420PC and your computer off and unplug the USB interface cable from the PT 2420PC 6 Restart your computer 7 Carry out steps 2 through 5 8 From the Printers Folder on the computer screen remove the PT 2420PC Printer to uninstall the PT 2420PC printer driver and then restart your computer 9 Install the PT 2420PC p...

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Page 63: ...Jan 2002 8V2029BE0 Printed in Japan ...