P-touch SERVICE MANUAL MODEL: PT-300 (For U.S.A.) LS-7 (Panduit ) REVISED
PREFACE This publication is a service manual covering the specifications, theory of operation, disassembly/reassembly procedure, and troubleshooting of the Brother PT-300 (For U.S.A.) and LS-7 (Panduit). It is intended for service personnel and other concerned persons to accurately and quickly provide after-sale service for our PT-300 (For U.S.A.) and LS-7 (Panduit). 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 appendix. CHAPTER I CHAPTER II CHAPTER III CHAPTER IV APPENDIX SPECIFICATIONS THEORY OF OPERATION DISASSEMBLY & REASSEMBLY TROUBLESHOOTING MAIN PCB CIRCUIT DIAGRAM SUB PCB CIRCUIT DIAGRAM 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.
CONTENTS CHAPTER I SPECIFICATIONS... I-. MECHANICAL SPECIFICATIONS... I-.. External Appearance... I-..2 Keyboard... I-..3 Display... I-2..4 Printing Mechanism... I-2..5 Tape Cassette... I-3..6 Tape Cutter... I-3.2 ELECTRONICS SPECIFICATIONS... I-5.2. Character Generator... I-5.2.2 Power Supply... I-5.3 SPECIAL KEY... I-6.3. Format... I-6.3.2 Demonstration Print... I-6.3.3 Switching the LCD Display... I-6 CHAPTER II THEORY OF OPERATION... II- 2. OUTLINE OF MECHANISMS... II- 2.. Print Mechanism... II- 2..2 Platen Roller, (Tape Feed )Sub Roller Setting & Retracting Mechanism... II-2 2..3 Tape & Ribbon Feed Mechanism... II-3 2..4 Tape Cutter Mechanism... II-5 2..5 Interlock Mechanism of the Roller Holder ASSY and Cassette Cover... II-6 2.2 OUTLINE OF ELECTRONICS... II-7 2.2. Configuration... II-7 [ ] Main PCB... II-7 [ 2 ] Sub PCB... II-7 [ 3 ] Motor... II-7 [ 4 ] Thermal Head... II-7 i
2.2.2 Main PCB... II-8 [ ] Block Diagram... II-8 [ 2 ] CPU... II-9 [ 3 ] Keyboard and Solder Points... II-9 2.2.3 Power Supply Circuit... II-0 2.2.4 Cassette Sensor Circuit... II- CHAPTER III DISASSEMBLY & REASSEMBLY... III- 3. DISASSEMBLY PROCEDURE... III- [ ] Removing the Cassette Cover, the Tape Cassette and the Batteries... III- [ 2 ] Removing the Cassette Spring... III-2 [ 3 ] Removing the Bottom Cover... III-2 [ 4 ] Removing the Frame ASSY... III-4 [ 5 ] Removing the Battery Terminal Support and Releasing the Battery Terminals... III-7 [ 6 ] Removing the Sub PCB ASSY... III-9 [ 7 ] Removing the Main PCB ASSY and the Rubber 52 Key... III-0 3.2 REASSEMBLY PROCEDURE... III- [ ] Installing the Rubber 52 Key and Main PCB ASSY... III- [ 2 ] Installing the Sub PCB ASSY... III-2 [ 3 ] Installing the Battery Terminals and Battery Terminal Support... III-3 [ 4 ] Mounting on the Bottom Cover of the Frame ASSY... III-5 [ 5 ] Installing the Bottom Cover... III-9 [ 6 ] Mounting the Cassette Spring... III-20 [ 7 ] Installing the Tape Cassette, the Batteries, and the Cassette Cover... III-2 [ 8 ] Final Check... III-22 CHAPTER IV TROUBLESHOOTING... IV- 4. PRECAUTIONS... IV- 4.2 AFTER REPAIRING... IV- 4.3 TROUBLESHOOTING FLOWS... IV-2 [ ] Tape Feeding Failure... IV-2 ii
[ 2 ] Printing Failure... IV-4 [ 3 ] Powering Failure (Nothing Appears on the LCD.)... IV-6 [ 4 ] Abnormal LCD indication... IV-8 [ 5 ] No Key Entry Possible... IV-8 [ 6 ] Tape Cassette Type not Identified... IV-9 Appendix. CIRCUIT DIAGRAMS Appendix. A Appendix. B Appendix. C Main PCB CIRCUIT DIAGRAM Sub PCB CIRCUIT DIAGRAM (PT-300) Sub PCB CIRCUIT DIAGRAM (LS-7) iii
CHAPTER I SPECIFICATIONS. MECHANICAL SPECIFICATIONS.. External Appearance Fig..- External Appearance () Dimensions (W x D x H) 2 x 90 x 7 mm (2) Weight Machine proper only In package Approx. 520 g.9 kg or less (including the mahine, packing materials and packaged standard components)..2 Keyboard () Entry system Rubber 52 key (2) Number of alphanumeric 40 and symbol keys (3) Number of function keys (including ON/OFF key) (4) Key arrangement See Fig..-2. I-
..3 Display () Display type Liquid crystal display (LCD) (2) Number of columns 2 columns x 2 row (See Fig..-2.) (3) Number of indicators 7 (See Fig..-2.) (4) Character size 5 dots wide by 7 dots high (5) Field-of-view angle Fixed by a resistor adjustment..4 Printing Mechanism () Print method Thermal transfer onto plastic tapes (laminate tape and non-laminated tape) (Fixed print head and tape feeding mechanism) (2) Print speed 0 mm/second (Typical) (3) Print head Type Heat generator Size of heating element Thermal print head Consists of 28 heating elements vertically aligned 0.95 mm wide by 0.4 mm high (4) Character size Size Height x Width 9 4 dots x 0 dots 2 20 dots x 5 dots 8 32 dots x 24 dots 24 42 dots x 3 dots 2 mm, big size 54 dots x 40 dots 36 64 dots x 48 dots 8 mm, big size 06 dots x 82 dots * When there is no indication of frame, underline and style. * The dimensions indicated are for the letter H. * The figures in the Size column indicate the point size. The dot size for the character H is used as an example in the table above, because the character size varies depending on the width of the tape and the character. I-2
..5 Tape Cassette () Cassette Cartridge type (TZ-cassette) (2) Types of tape cassettes Laminated tape cassette Non-laminated tape cassette Instant lettering tape cassette Non-laminated thermal film tape cassette Iron-on transfer tape cassette Stamp tape cassette Cloth tape cassette Laminate tape, ink ribbon, and adhesive base tape Non-laminate tape and ink ribbon Instant lettering tape and ink ribbon Non-laminated thermal film tape Iron-on transfer tape and ink ribbon Porous-stamp tape and base paper Cloth tape and ink ribbon (3) Tape size Width Length Laminate tape 6, 9, 2, 8 mm 8 m (5 m for the fluorescent coating tape) Non-laminate tape 6, 9, 2, 8 mm 8 m Instant lettering tape 8 mm 8 m Iron-on transfer tape 8 mm 5 m Porous stamp tape 8 mm 3 m Cloth tape 2 mm 4 m Cleaning tape 8 mm 2.5 mm Non-laminate thermal film tape 2, 8 mm 8 m (4) Tape cassette packed with the machine..6 Tape Cutter LS-7 : Laminated tape cassette containing a 8-mm-wide black ink ribbon, laminate tape, and adhesive base tape. PT-300 : Laminated tape cassette containing a 2-mm-wide black ink ribbon, laminate tape, and adhesive base tape. () Tape cutting Manual cutting with the cutter lever (2) Cutter unit Not user-replaceable I-3
PT-300 (For U.S.A.) LS-7 (Panduit) Fig..-2 Key Arrangement I-4
.2 ELECTRONICS SPECIFICATIONS.2. Character Generator PT-300 LS-7 Internal characters U.S.A. 76 U.S.A. 46 Internal font HELSINKI HELSINKI Print buffer capacity 99 characters 99 characters Phrase memory capacity 300 characters 300 characters.2.2 Power Supply () Power supply Driven by 6 batteries Optional AC adapter (9.5VDC,.3A) available (2) Battery type 6 alkaline batteries (LR6) (3) Service life of batteries Will last through one tape cassette, and then some. (at room temperature and normal humidity) (4) Automatic power off Yes (5) Battery indication ) Battery weak detection (If the machine remains unused for approx. 5 minutes, it automatically powers itself off.) When using dry cell batteries, if the battery voltage is detected to be 6. V or less at the A/D terminals of the CPU twice in succession during printing, the status comes into effect. 2) Battery empty detection When using dry cell batteries, if the battery voltage is detected to be 5.9 V or less at the A/D terminals of the CPU twice in succession during printing, the status comes into effect. 3) System OFF When using dry cell batteries, if the battery voltage is detected to be 5.7 V or less at the A/D terminals of the CPU twice in succession during printing, the system is forcibly turned OFF. Other than during printing, the system is forcibly turned OFF when the battery voltage is detected to be 6.9 V or less at the CPU A/D terminals. 4) Use of high voltage AC adapters Adapters with an output of 5.4 V or greater are designated as and cannot be used. adapters I-5
.3 SPECIAL KEY.3. Format Push the Code + BS + (ON / OFF) key, when the power is off..3.2 Demonstration Print Push Code + D key. (Effective when there is no data in the text.).3.3 Switching the LCD Display The LCD display can be switched between English (U.S.A.) and French (Canada) by the key operation as follows; () Press down the Code + F key. (2) Display the values currently established. Press down the F key with Code key being pressed down. (3) The set value is switched. Release the Code key. (4) Message is established. I-6
CHAPTER II THEORY OF OPERATION 2. OUTLINE OF MECHANISMS 2.. Print Mechanism () Structure of Thermal Head This machine uses thermal transfer printing. The thermal print head has a heat generator consisting of 28 heating elements which are vertically aligned as shown in Fig. 2.-. Each heating element is 0.95 mm wide by 0.4 mm high. (2) Printing Process Fig. 2.- Heat Generator of Thermal Head When the cylindrical rubber platen roller is pressed against the thermal print head with the tape* and ink ribbon pinched between, the CPU applies electric power to the selected elements of the 28 heating elements. * Laminate tape when using laminated tape cassettes. Non-laminated tape when using non-laminated tape cassettes. When the selected heating element(s) generate(s) heat, the ink on the pinched ribbon is melted and transferred to the tape, producing a (dots) on the tape. The ink ribbon and the tape are advanced and then the heating cycle is repeated, thus forming characters on the tape. (3) Character Formation While the drive motor (DC motor) feeds the tape and ink ribbon by 0.4 mm in 3.6 ms, the thermal head generates heat once. The feed amount of 0.4 mm is smaller than the width (0.95 mm) of the heating elements so that the heat generated in one heating cycle will overlap with that of the next heating cycle. This forms a character having no gap between adjacent printed dots. II-
2..2 Platen Roller, (Tape Feed) Sub Roller Setting & Retracting Mechanism This mechanism consists of the roller release lever, the roller release rod, and the roller holder ASSY. The roller holder ASSY supports the platen roller and the sub roller so that : the platen roller can move perpendicularly to the thermal head and rotate freely, and the sub roller can move perpendicularly to the tape feed roller and rotate freely. Install the cassette cover. When the cassette cover is closed, the roller release lever is pushed by the cassette cover, which moves the roller release rod to the left. This pivots the roller holder ASSY around the shaft provided on the frame so as to press the roller holder ASSY towards the thermal head side. The platen roller is pressed perpendicularly against the thermal head with the tape and ink ribbon (only the tape when using non-laminated thermal film tape cassettes) pinched between under a uniform load applied by the roller holder springs (upper and lower). Also, the (tape feed) sub roller is pressed perpendicularly against the tape feed roller built into the tape cassette with the tape (the laminate tape and adhesive base tape when using laminated tape cassettes) pinched between by the roller holder springs (upper and lower) and at the same time the (tape feed) sub roller gear becomes engaged with the tape feed gear. Removing the cassette cover, (at this time, the roller release lever is released by the cover), retracts the roller holder ASSY from the thermal head, providing you with enough space to replace the tape cassette. Adhesive base tape Tape cassette Laminate tape Tape feed roller Ink ribbon (Tape feed) sub roller Thermal head Roller release lever Roller holder ASSY Platen roller Shaft Roller release rod Roller holder release spring Platen roller Platen spring (Tape feed) sub roller gear (Tape feed) sub roller Sub roller springs Sub roller holder Fig. 2.-2 Platen and (Tape Feed) Sub Roller Setting & Retracting Mechanism II-2
2..3 Tape & Ribbon Feed Mechanism This mechanism consists of a DC motor, gear train, and roller holder ASSY. () Tape Feeding As the drive motor rotates, the rotation is transmitted via the gear train to the tape idle gear which rotates both the tape feed roller and the (tape feed) sub roller (whose gear is engaged with the tape idle gear) at the same rotation speed. Accordingly, the pinched tape is advanced. (When a laminated tape cassette is installed, the pinched laminate tape and adhesive base tape are advanced together.) Adhesive base tape Laminate tape Tape feed roller (Tape feed) sub roller Platen roller Thermal Head ASSY Roller holder ASSY DC motor Frame Tape idle gear Fig. 2.-3 Tape Feeding Mechanism II-3
(2) Adhesive Base Tape Feeding (only for laminated tape cassettes) A laminated tape cassette contains both a transparent laminate tape roll and a separate adhesive base tape roll. When the transparent laminate 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 laminate tape is, therefore, sealed up with the adhesive base tape. (3) Ink Ribbon Feeding As the DC 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 idle gear. The difference between the tape 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. In this way, the ink ribbon is kept tense, which enables the ribbon to clearly separate from the tape at the stabilized angle after printing. Tape feed roller Ink ribbon (Tape feed) sub roller Platen roller Roller holder ASSY Thermal Head ASSY Frame DC motor Ribbon drive cam Tape idle gear Fig. 2.-4 Ribbon Feeding Mechanism II-4
2..4 Tape Cutter Mechanism The cutter unit is composed of the fixed cutter edge and the moving cutter edge. The tape after printing is sent from the tape cassette, and it stops after passing between the moving cutter edge and the fixed cutter edge. You can cut the tape by pushing the cutter lever, since this rotates the moving cutter edge via its gear part of it. Tape cassette Fixed cutter edge Cutter lever Cutter moving gear Tape Moving cutter edge Fig. 2.-5 Tape Cutter Mechanism II-5
2..5 Interlock Mechanism of the Roller Holder ASSY and Cassette Cover When the cassette cover is closed, the roller release lever is pressed downward and its tip engages with the hook on the inside of the cassette cover. As explained in section 2..2, the roller release lever moves the roller release rod, causing the roller holder ASSY to be pressed against the thermal head. Tape cassette Thermal head Platen roller (Tape feed) sub roller Shaft Frame ASSY Roller holder ASSY Roller release rod Roller release lever Roller release lever Roller release rod Roller holder release spring Frame ASSY Fig. 2.-6 Roller Release Lever and Roller Release Rod Hook Fig. 2.-7 Interlock Mechanism of the Roller Holder ASSY and Cassette Cover When the cassette cover is opened, the roller release lever is pulled upward by the hook of the cassette cover, and the roller holder ASSY is pulled away from the thermal head by the roller holder spring. II-6
2.2 OUTLINE OF ELECTRONICS 2.2. Configuration Fig. 2.2- Shows a block diagram of the control electronics of the PT-300 (For U.S.A.) and LS-7 (Panduit). The control electronics consists of a printed circuit board (main PCB + sub PCB), a motor, and a thermal head assembly. [ ] Main PCB This manages all the PT-300 (For U.S.A.) and LS-7 (Panduit) components including the LCD, motor, keyboard, and thermal head. [ 2 ] Sub PCB The sub PCB consists of the sensor switches which identify the tape cassette type, the governor circuit which controls the rotation of the DC motor, the AC adapter jack and the battery terminal. [ 3 ] Motor DC motor which feeds tape. [ 4 ] Thermal Head This is a thick film thermal print head which integrates a heat generator (consisting of 28 heating elements vertically aligned) and drive circuit. Fig. 2.2- Configuration of the Electronic Part II-7
2.2.2 Main PCB [ ] Block Diagram Fig 2.2-2 shows a block diagram of the main PCB. The main PCB consists of the following: () CPU (2) CG ROM (3) LCD driver (4) Key contacts matrix and solder points (destination switching circuit) (5) Power ON/OFF circuit and power saving circuit (6) Motor control circuit (7) Cassette sensor circuit (8) Thermal print head driver (9) Voltage detector circuit and termperature sensor circuit (0) Oscillator circuit () Reset circuit (2) +5BV power source Fig. 2.2-2 Block Diagram of Main PCB II-8
[ 2 ] CPU The CPU (#2) is an 8bit microprocessor produced by the CMOS silicon gate process, which integrates a 64 kilobyte (LS-7 : 97kilobyte) ROM and a 2048 byte (LS-7 : 0 kilobyte) RAM. [ 3 ] Keyboard and Solder Points Fig. 2.2-3 shows a circuit diagram relating to the keyboard and solder points. Solder points through 5 are connected to satisfy the specification of PT-300 and LS-7. * No solder points are used with American specifications. Solder points A through E are reserved for future use for the thermal head ranking. The CPU reads the solder point status once during powering-on to confirm the specification. Fig. 2.2-3 Keyboard and Solder Points II-9
2.2.3 Power Supply Circuit A 3-terminal regulator S8250PG stabilizes the battery output or the AC line adapter output, producing the +5BV power source within the variation of ±0.5V. Capacitor C (Main PCB) is for the logic circuit; capacitor C (Sub PCB) is for the thermal head and DC motor drive sources. Connecting the AC adapter plug with the AC jack P cuts off the power fed from the batteries and feeds power from the AC adapter. When the AC adapter plug is connected to AC jack P, input terminal the CPU is L level and the CPU detects that power is supplied from the AC adapter. Fig. 2.2-4 shows the polarity of the AC adapter plug. Fig. 2.2-4 AC Adapter Plug II-0
2.2.4 Cassette Sensor Circuit This circuit detects each of the five sensor switches (LS-7 : four sensor switches) which are depressed or not depending upon the ID holes proveded on the tape cassette currently mounted. By perceiving the states of these sensor switches, the CPU identifies the tape cassette type (the variety and the width). If an ID hole is open, the sensor switch is not depressed. Table 2.2-5 lists the coded values for identifying the tape cassette type. (LS-7) 0: Switch ON (ID hole closed) : Switch OFF (ID hole opened) SW3 SW4 SW5 SW6 Cassette type Tape width 0 0 0 0 No Cassette loaded 0 0 Wild Card (*) 0 0 0 Laminated tape cassette (Panduit) 6 mm 0 Laminated tape cassette (Panduit) 9 mm 0 0 Non-Laminated tape cassette (Panduit) 8 mm Position of Sensor Switches (LS-7) SW6 SW5 SW4 SW3 (*) The Wild Card is as follows; 2 mm Laminated tape cassette (Panduit) Label code () 8 mm Laminated tape cassette (Panduit) Label code (2) 2 mm Non-Laminated tape cassette (Panduit) Label code (3) 9 mm Non-Laminated tape cassette (Panduit) Label code (4) 6 mm Non-Laminated tape cassette (Panduit) Label code (5) * The user inputs the label code (tape cassette type) from the software of the machine to use the tape cassette described above after installing it into the machine. (PT-300) 0: Switch ON (ID hole closed) : Switch OFF (ID hole opened) SW SW2 SW3 SW4 SW5 Cassette type Tape width 0 0 0 0 0 No Cassette loaded 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Laminated tape cassette Laminated tape cassette Non-Laminated tape cassette Non-Laminated tape cassette Non-Laminated thermal film tape cassette Iron-on transfer tape cassette & Instant lettering tape cassette Laminated tape cassette Non-Laminated tape cassette 8 mm 2 mm Position of Sensor Switches (PT-300) SW5 SW4 SW3 SW2 SW 0 0 0 0 0 Laminated tape cassette Non-Laminated tape cassette 9 mm 0 0 0 0 0 0 0 Laminated tape cassette Non-Laminated tape cassette 6 mm Other settings Same processing as for no cassette loaded Table. 2.2-5 Coded Values for Identifying Tape Cassette Type II-
CHAPTER III DISASSEMBLY & REASSEMBLY 3. DISASSEMBLY PROCEDURE [ ] Removing the Cassette Cover, the Tape Cassette and the Batteries () Turn the machine upside down. (2) Remove the cassette cover by pushing section A. The roller release lever is released automatically by the hooked section of the cassette cover. (3) Remove the tape cassette. (4) Remove the batteries. Cassette cover A Fig. 3.- Removing the Cassette Cover Tape cassette Batteries Fig. 3.-2 Removing the Tape Cassette and the Batteries III-
[ 2 ] Removing the Cassette Spring () Press the bent part of the cassette spring with a flat-blade screwdriver or similar tool and remove the cassette spring from the cassette cover. (2) Turn the cassette pin through 90 and remove it from the cassette spring. Cassette spring Fig. 3.-3 Removing the Cassette Spring Cassette pin [ 3 ] Removing the Bottom Cover () Place the machine upside down. (2) Remove the three screws. (3) Disengage the four hooks, then the bottom cover and the upper cover can be separated. Screw Screw Screw Hook Hook Bottom cover Hook Upper cover Hook Fig. 3.-4 Removing the Bottom Cover () III-2
(4) Open the bottom cover to the left as shown below. (5) Discharge the condensers on the sub PCB ASSY with tool like a screwdriver or similar tool. (6) Disconnect the relay harness connector and thermal head flat cable from the main PCB ASSY. Sub PCB ASSY Bottom cover Thermal head flat cable Relay harness connector Main PCB ASSY Upper cover Fig. 3.-5 Removing the Bottom Cover (2) III-3
[ 4 ] Removing the Frame ASSY () Remove the strap belt. (2) Remove the two motor harnesses from the sub PCB ASSY by melting the solder. (3) Remove the three screws. (4) Confirm that the roller release lever is extended, and remove the frame ASSY and antistatic spring from the bottom cover. Screws Anti-static spring Frame ASSY Motor harnesses Roller release lever Bottom cover Melting solder Strap belt Sub PCB Fig. 3.-6 Removing the Frame ASSY III-4
Disassembling the Frame ASSY Removing the motor ASSY and the cutter sub ASSY () Remove the two screws from the frame ASSY and take out the motor ASSY. (2) Remove a screw and take out the cutter sub ASSY from the frame ASSY. (3) Take off the retaining ring and remove the cutter lever and cutter return spring. (4) Take off the retaining ring, and remove the cutter rack gear, the cutter moving gear ASSY from the frame ASSY. Motor ASSY Screw Retaining ring Cutter sub ASSY Cutter lever Cutter return spring Frame ASSY Cutter moving gear ASSY Cutter rack gear Retaining ring Screws Fig. 3.-7 Removing the Motor ASSY and the Cutter Sub ASSY III-5
Removing the roller holder ASSY and thermal head ASSY When handling the thermal head ASSY, do not touch the thermal head by hand. Otherwise, it may be damaged due to the electricity charged in your body. () Remove the retaining ring from the roller holder. (2) As shown in the figure below, pull the roller release lever upward, and lift up the roller holder ASSY together with the roller release lever and rod. While doing this, take care to ensure that the roller holder spring does not fly out. (3) Remove the screw and remove the thermal head ASSY. Roller holder ASSY Screw Retaining ring Roller release rod Roller release lever Thermal head ASSY Roller holder spring Frame ASSY Fig. 3.-8 Disassembly of the Frame ASSY III-6
[ 5 ] Removing the Battery Terminal Support and Releasing the Battery Terminals () Release the two latches provided on the bottom cover by prising them outwards and pull up the battery terminal support. (2) Remove the negative ( ) terminal of the battery power wire from the battery terminal support by moving the terminal in the direction of arrow x. Battery terminal support Negative ( ) terminal Latches To the sub PCB Bottom cover Groove Fig. 3.-9 Pulling up the Battery Terminal Support and Releasing the Negative ( ) Terminal (3) Lift up the two battery terminal plates from the bottom cover. (4) Release the locking pawl of the positive (+) terminal of the battery power wire form the bottom with a flat bladed screwdriver, and the push out the positive (+) terminal. Battery terminal plates Battery power wire Bottom cover Flat screwdriver Positive (+) terminal Viewed from the bottom Locking pawl of the positive (+) terminal Fig. 3.-0 Removing the Battery Terminal Plates and Positive (+) Terminal III-7
(5) As shown below, release the locking pawl of each of the three battery terminal plates with a small flat bladed screwdriver and push out the terminal plates from the bottom cover. Battery terminal plates Bottom cover Flat screwdriver Locking pawls Fig. 3.- Removing the Battery Terminal Plates III-8
[ 6 ] Removing the Sub PCB ASSY After removing the relay harness connector, the battery terminal (+), and ( ), remove the two screws and remove the sub PCB ASSY. Screws Relay harness connector Sub PCB ASSY Battery terminal ( ) Battery terminal (+) Bottom cover Fig. 3.-2 Removing the Sub PCB ASSY III-9
[ 7 ] Removing the Main PCB ASSY and the Rubber 52 Key Remove the two screws, then take off the main PCB ASSY and the rubber 52 key. Note: Before handling the main PCB, touch a metal portion of the machine to discharge static electricity, otherwise the LSI and other electronic devices may be damaged due to the electricity charged in your body. Screws Main PCB ASSY Upper cover Fig. 3.-3 Removing the Main PCB ASSY Main PCB ASSY Rubber 52 key Upper cover Fig. 3.-4 Removing the Rubber 52 Key III-0
3.2 REASSEMBLY PROCEDURE [ ] Installing the Rubber 52 Key and Main PCB ASSY () Turn the upper cover upside down and place the rubber 52 key so that it is fitted onto the 3 pins provided on the upper cover. (2) Check that there is no foreign material or dust on the key contacts of the main PCB ASSY, then install the PCB. (Refer to Fig. 3.2-) (3) Tighten the two screws for securing the PCB, confirming that the main PCB ASSY is fitted onto the two pins. Tightening torque: 29.4N cm Screws Main PCB ASSY Rubber 52 key Pin Fig. 3.2- Installing the Rubber 52 Key and Main PCB ASSY III-
[ 2 ] Installing the Sub PCB ASSY () Set the sub PCB ASSY onto the locating pin and AC jack groove, and tighten the two screws, confirming that each of the sensor switch actuators is securely fitted into the hole in the bottom cover and moves up and down freely. Note: The five sensor switch actuators are provided for PT-300 while the four are provided for LS-7. Check the positions of the sensor switch actuators referring to the Fig 3.2-2. Tightening torque: 29.4N cm LS-7 PT-300 Screws Sub PCB ASSY Sensor switch actuators Bottom cover AC jack groove Fig. 3.2-2 Installing the Sub PCB ASSY III-2
[ 3 ] Installing the Battery Terminals and Battery Terminal Support () Place the bottom cover upside down. (2) Set the three battery terminal plates into the bottom cover as shown below, making sure that they snap into place. Battery terminal plates Bottom cover Fig. 3.2-3 Setting the Battery Terminal Plates (3) Turn the bottom cover rightside up. (4) Set the positive (+) terminal of the battery power wire on the bottom cover. (5) Set the two battery terminals plates on the bottom cover. Negative ( ) terminal Battery terminals Battery power wires Positive (+) terminal Bottom cover Fig. 3.2-4 Installing the Positive (+) Terminal and Battery Terminal Plates III-3
(6) As illustrated below, set the negative ( ) terminal of the battery power wire on the battery terminal support, and then push the battery terminal support down the grooves into place. Check that the two latches catch on the battery terminal support. Negative ( ) terminal Battery terminal support Latch Groove Bottom cover Fig. 3.2-5 Installing the Negative ( ) Terminal and Battery Terminal Support III-4
[ 4 ] Mounting on the Bottom Cover of the Frame ASSY () If the frame ASSY has been disassembled, assemble the components by referring to the next page. (2) With the roller release lever extended, pass the roller release lever, and projections of the frame ASSY through the holes in the bottom cover, set the frame ASSY on the 3 locating bosses and secure it with screws. (3) Put the anti-static spring onto the pin on the bottom cover, and tighten screw with the frame ASSY. (4) Solder the motor harness to the sub PCB ASSY. Note: Pay attention to the polarity of the motor harness (+) and ( ) wires and make sure they do not project from the designated place when soldering. (5) Pass the hole of the strap belt over the boss on the bottom cover and set the strap belt in the notch. Tightening torque: 39.2N cm Screws Anti-static spring Tape idle gear Motor harness ( ) black Motor harness (+) red Boss Ribbon drive cam Boss Bottom cover Boss Soldering Strap belt Sub PCB Fig. 3.2-6 Installing the Frame ASSY III-5
Assembling the Frame ASSY () Mount the thermal head ASSY with a single screw. (For details on aligning the thermal head and platen, refer to chapter IV TROUBLESHOOTING. (2) Mount the roller holder spring and combination of the roller release lever and rod to the roller holder ASSY. The roller release lever and rod can be easily mounted to the frame ASSY by joining them at the angle indicated below. Roller release lever Roller holder ASSY Screw Roller release rod Thermal head ASSY Frame ASSY Roller holder spring Fig. 3.2-7 Assembling the Frame ASSY III-6
Installing the cutter unit and the motor ASSY () Mount the cutter moving gear ASSY to the shaft of the frame ASSY. Apply 2mm 3 of grease to the bottom D and window E of the cutter rack gear. (Grease: Silicon grease G50) (2) Insert the cutter rack gear while it is rotated as shown in A. Apply 2mm 3 of grease to the pin B and gear C of the cutter moving gear ASSY. (Grease: Silicon grease G50) (3) Set the retaining ring. (4) Mount the cutter sub ASSY to the frame ASSY, and tighten the screw. Tightening torque: 58.8N cm (5) Confirm that the cutter unit operates correctly. (6) Mount the cutter return spring and cutter lever and fit the retaining ring. III-7
(7) Secure the motor to the frame ASSY with the two screws. Pay attention to the polarity of the motor harness. Tightening torque: 9.8~9.6N cm Cutter sub ASSY Retaining ring Cutter lever Screw A Cutter moving gear ASSY Cutter return spring Frame ASSY Cutter lever C Frame ASSY B Cutter moving gear ASSY Cutter return spring D Cutter rack gear E Retaining ring Frame ASSY Motor ASSY Frame ASSY Motor harnesses Screws Fig. 3.2-8 Installing the Cutter Unit and the Motor ASSY III-8
[ 5 ] Installing the Bottom Cover () Hold the bottom cover as shown below, then connect the thermal head flat cable to the main PCB and connect the power supply harness connector. (2) Fit the upper cover and the bottom cover together by engaging the four hooks. Note: Take care not to pinch the cords between the covers or put the cords on the condenser. Upper cover Power supply harness connector Thermal head flat cable Bottom cover Fig. 3.2-9 Installing the Bottom Cover () (3) Place the upper and bottom cover upside down. Secure the bottom cover with the three screws. Tightening torque: 39.2N cm Screws Bottom cover Upper cover Fig. 3.2-0 Installing the Bottom Cover (2) III-9
[ 6 ] Mounting the Cassette Spring () Insert the cassette pin into the cassette spring and turn it through 90. (2) Insert the cassette spring into the cassette cover; it must click into place. Cassette spring Cassette pin Fig. 3.2- Mounting the Cassette Spring III-20
[ 7 ] Installing the Tape Cassette, the Batteries, and the Cassette Cover () Load the tape cassette. (2) Put the batteries in the bottom cover. Tape cassette Batteries Fig. 3.2-2 Installing the Tape Cassette and the Batteries (3) Align the bottom end of the cassette cover with that of the bottom cover and push down the top end of the cassette cover by pushing on section A. Note: Confirm that the roller release lever is released. Cassette cover Section A Roller release lever Bottom cover Fig. 3.2-3 Installing the Cassette Cover III-2
[ 8 ] Final Check () Check that the rubber key is moved smoothly and correctly. (2) Check that the cutter lever is moved smoothly. (3) Press the (ON/OFF) key. (4) While holding down the Code key, press the BS key to cancel data previously entered. (5) Install the tape cassette whose width is 8mm into the machine and close the cassette cover. (6) Enter the inspection mode following the procedure below to implement the final check. The inspection mode includes the following five sub modes; Information Sub Mode, Cassette Sensor / Temperature Check Sub Mode, Key Inspection Sub Mode, Cut Sub Mode, Print Sub Mode. Reference: The inspection mode supports the ten sub modes for the factory inspection. Namely, the inspection mode includes other five modes than the five described above. Since it is not necessary to implement the inspections in the other five modes, their details are omitted in this section. If one of other modes than the five described in this section is displayed, press the, 2, 3, 4 or 5 key to select the one from the Information Sub Mode, Cassette Sensor / Temperature Sub Mode, Key Inspection Sub Mode, Cut Sub Mode and Print Sub Mode, and proceed to the mode you want to implement. Press the Code, K and (ON/OFF) keys together while the power is being OFF. When releasing the keys, always make sure to release the (ON/OFF) key first, then release the Code and K keys. The machine goes into the inspection mode, and the Fig. display is indicated. PT-300 LS-7 Fig. Note : When the Fig.2 display is indicated, the CGROM is defective. Replace the main PCB. Fig. 2 Note 2: When the Fig.3 display is indicated, check the solder point. Two or more solder points may be soldered, or the solder point may not be correct. Fig. 3 III-22
(6.) Information Sub Mode ([ ] key *) (* Shifts to the Information Sub Mode from other modes by pressing the [ ] key while the Key Inspection Sub Mode is not being implemented.) When the machine goes into the inspection mode, the Fig. display is indicated, and the machine goes into the Information Sub Mode. (6..) The Information Sub Mode allows you to check the model, destination (excluding LS-7), head rank, power supply voltage and LCD performance. The Fig.4 shows the details. Model display Fig. 4 For PT-300, [ 300 ] is displayed. For LS-7, [ LS7 ] is displayed. Power supply voltage Head rank Destination Model Destination display For PT-300, [ USA ] is displayed. Head rank display The solder points A to E are used for setting the head rank. When there is no solder point, (blank) is displayed. Power supply voltage display If the power supply voltage is in the range of the specified input voltage (7.2V ~ 8.2V), the mark is displayed. If it is not in the range, the [ ] mark is displayed. When using a brandnew battery, the voltage is approximately 9V. It is out of the range, and the [ ] is displayed. (6..2) Press the key. The LCD check display is indicated as shown in Fig.5. Fig. 5 All guidance ON. All cursors OFF. Press the key. The LCD check display 2 is indicated as shown in Fig.6. Fig. 6 All guidance OFF. All cursors ON. III-23
(6.2) Cassette Sensor / Temperature Check Sub Mode ([ 2 ] key *) (* Shifts to the Cassette Sensor / Temperature Check Sub Mode from other modes by pressing the [ 2 ] key.) When pressing the key while the LCD check display 2 Fig.6 is being indicated, it is changed to the display of the Cassette Sensor / Temperature Sub Mode as shown in Fig.7. Cassette sensor check display Fig. 7 Temperature check display Cassette sensor check display The [ 000 ] display indicates the status of each of the five cassette sensor switches. (0: OFF, : ON) The Table shows the position of the cassette sensor switch number indicated on the LCD. Display position on LCD Left 2 nd from the left Center 2 nd from the right Right PT-300 SW SW2 SW3 SW4 SW5 LS-7 SW5 SW3 SW4 SW6 Table Reference: The only four sensor switches are provided for the LS-7 model. For SW0 indicating no sensor switch (2 nd from the left), therefore, [ 0 ] is always displayed. Temperature check display The [ 8A ] display indicates the input value of the thermistor in hexadecimal. (6.3) Key Inspection Sub Mode ([ 3 ] key *) (* Shifts to the Key Inspection Sub Mode from other modes by pressing the [ 3 ] key.) When pressing the key while the display of the cassette sensor / temperature check Fig.7 is being indicated, it is changed to the display of the Key Inspection Sub Mode as shown in Fig.8. Fig. 8 The machine goes into the Key Inspection Mode by pressing the key as shown in Fig.9. Fig. 9 III-24
Press the keys in the st row from the left to the right, in the 2 nd row from the right to the left, in the 3 rd row from the left to the right, in the 4 th row from the right to the left and in the 5 th row from the left to the right in this order. If the correct key is pressed, the key to be pressed next is displayed. If not, the key to be pressed and the [ XX ] mark are displayed as shown in Fig.0. (In the Fig.0 example, the N key is incorrect.) Fig. 0 When completing to check all keys and there is no error, the Fig. display is indicated, and [ OK ] is printed. Fig. (6.4) Cut Sub Mode ([ 4 ] key *) (* Shifts to the Cut Sub Mode from other modes by pressing the [ 4 ] key.) When pressing the key while the display of the key inspection Fig. is being indicated, it is changed to the display of the Cut Sub Mode as shown in Fig.2. Fig. 2 When pressing the key, the Fig.3 display is indicated. The tape is cut, and the Fig.2 display is indicated by pressing the key. Fig. 3 When pressing the key, the Fig.4 display is indicated. The tape is cut, and the Fig.2 display is indicated by pressing the key. Fig. 4 III-25
When pressing the key, the Fig.5 display is indicated. The tape is cut, and the Fig.2 display is indicated by pressing the key. Fig. 5 When pressing the key, the Fig.6 display is indicated. The tape is cut. Fig. 6 (6.5) Print Sub Mode ([ 5 ] key *) (* Shifts to the Print Sub Mode from other modes by pressing the [ 5 ] key.) When pressing the key while the display of the cut check Fig.6 is being indicated, it is changed to the display of the Print Sub Mode as shown in Fig.7. Fig. 7 When pressing the key, the Fig.8 display is indicated and the machine starts printing. Fig. 8 The print sample is as follows; (632 dots, length: 89 ± 4.5mm) Print Sample After printing, all memory is initialized, and the machine is turned off. Cut the tape to be printed and check the length of the printed text. If it is longer or shorter than the length indicated on the print sample, follow the flow described in Chapter IV TROUBLESHOOTING. The inspection mode is finished. III-26
CHAPTER IV TROUBLESHOOTING This section gives the service personnel some of the troubleshooting procedures to be followed if an error or malfunction occurs with the PT-300 (U.S.A.) and LS-7 (Panduit). It is impossible to anticipate all of the possible trouble which may occur in the future and determine the troubleshooting procedures for them, so this chapter covers some example types of trouble. However, these examples will help service personnel pinpoint and repair other defective elements if they analyze and examine them well. 4. PRECAUTIONS Be sure to observe the following precautions to prevent the secondary problems from happening during troubleshooting: () Get a good idea of what the trouble is. Whenever more than one trouble source is found, plan the most reasonable repairing procedure after reviewing the relationship between them. (2) When supplying power to a machine which has problems with either a set of batteries or the AC adapter, make sure that its output voltage level is 8 to 0V under no load. (3) When supplying power from a stabilized power unit, use a power unit with approx. 3A capacity and choose the output level of 7 to 9V. When connecting it to the machine, be careful about the polarity. (4) When using a circuit tester for testing conductivity, remove all of the batteries and the AC adapter from the machine. (5) To repair an error which occurred in the thermal head or its related sections, disconnect the thermal head cable until repairs are finished. 4.2 AFTER REPAIRING After troubleshooting, be sure to check that the failure has been completely remedied. Keep details of the troubleshooting procedure actually followed for later troubleshooting. IV -
4.3 TROUBLESHOOTING FLOWS [ ] Tape Feeding Failure IV - 2
IV - 3
[ 2 ] Printing Failure IV - 4
IV - 5
[ 3 ] Powering Failure (Nothing Appears on the LCD.) IV - 6
IV - 7
[ 4 ] Abnormal LCD Indication [ 5 ] No Key Entry Possible IV - 8
[ 6 ] Tape Cassette Type not Identified IV - 9
Apr., 2002 5V2098BE Printed in Japan