Brother PC8200 SUPER GALAXIE 2000, Service Manual

Page 1: ...SERVICE MANUAL FOR COMPUTERIZED SEWING MACHINE PC8200 SUPER GALAXIE 2000 9 1997 ...

Page 2: ...HANISMS 1 II DISASSEMBLING AND REASSEMBLING THE SEWING MACHINE 8 III HOW TO ADJUST MECHANICAL ELEMENTS 22 IV HOW TO ADJUST ELECTRONIC ELEMENTS 46 CAUTION 1 Always use rubber gloves when handling printed circuit boards and never touch the metal portion of a printed circuit board with bare hands 2 Keep your body earthed in order to avoid generating static electricity 3 Pack printed circuit boards in...

Page 3: ...CHANICAL CHART 2 2 POWER TRANSMISSION CHART 3 3 ELECTRONIC PARTS ARRANGEMENT CHART 4 4 CONTROL SYSTEM BLOCK DIAGRAM 4 5 MAIN MOTOR CONTROL 5 6 PATTERN GENERATOR 5 7 AUTOMATIC THREAD TENSION 6 8 OTHER ELECTRONIC COMPONENT FUNCTIONS 7 ...

Page 4: ... 2 1 MECHANICAL CHART EMBROIDERY UNIT MECHANISM ...

Page 5: ... 3 2 POWER TRANSMISSION CHART A Generating mechanism of needle bar thread take up lever and zigzag movements B Mechanism of feed dog and rotary hook movement ...

Page 6: ... 4 3 ELECTRONIC PARTS ARRANGEMENT CHART PC 8200 Model 985 4 CONTROL SYSTEM BLOCK DIAGRAM ...

Page 7: ...pulse motor to directly rock the needle bar and the feed regulator to generate the pattern As a result of this it is possible to increase the number of patterns and the number of stitches simply by adding extra memory capacity so that about 3 800 patterns comprising a total of approximately 20 000 stitches can be stored In addition the pulse motors must move the position of the needle while the ne...

Page 8: ...ension disks On this model however the thread tension is calculated based on the horizontal and vertical movements of the embroidery frame and the appropriate needle thread amount is fed by the thread tension pulse motor This always gives you correct the thread tension regardless of thread kinds of fabric or sewing speed Automatic thread tension block diagram ...

Page 9: ...on for selecting the desired pattern and number Buttonhole stitch switch used to detect the edges of the buttonhole stitch by means of the buttonhole stitch presser foot and lever Buttonhole stitch lever switch used to detect whether the buttonhole stitch lever is raised or lowered Rotation sensor detects the drive timing of the embroidery frame drive pulse motor and the tension release solenoid a...

Page 10: ... 8 II DISASSEMBLING AND REASSEMBLING THE SEWING MACHINE 1 DISASSEMBLING AND REASSEMBLING THE OUTER PARTS AND MAIN PARTS 9 2 LEAD WIRE ARRANGEMENT 21 ...

Page 11: ... first When the front cover has been removed always adjust the touch panel after assembling the front cover 7 Remove the two screws securing the needle plate and the needle plate 8 Remove the three screws securing the rear cover and the rear cover from the rear side Disassembly Points 3 To remove the belt cover unhook the bottom catch A slide the belt cover to the right then unhook the top catches...

Page 12: ... assembly Disassembly Points 10 To disconnect the connectors grab the base of the connector and pull it straight out In order to reduce the risk of static electric damage to the main PC board after it is removed from the sewing machine do not touch the board s front surface and only carry it by its edges in the same way that you hold a compact disk 16 To remove the thread guard cover from the tens...

Page 13: ...presser bar spring 24 Remove the presser spring screw and the presser bar clamp 25 Remove the presser lifting shaft by lifting it from above and the presser lifter 26 Pull the tension releaser plate out forward 27 Remove the screw and the thread take up shaft Disassembly Point 20 Before removing the thread cutting assembly move the thread cutter cam so that its notch faces the front of the sewing ...

Page 14: ...embly 34 Remove the screw and the outer rotary hook assembly 35 Remove the two metal presser screws and remove the lower shaft assembly and timing belt 36 Remove the connector the two screws and the power supply unit assembly 37 Remove the three screws and base plate assembly Disassembly Points 28 To remove the upper shaft assembly more easily remove the two feed rod tension springs A and the tens...

Page 15: ...tric metal Moving the hole downward decreases the play Although the ideal position is facing forward if there is an unusually large play adjust the position in order to prevent the rotary hook from generating an irregular noise 42 The screw E used to install the top of the FPM holder should have a screw of 14 mm 42 Install a spacer poly washer on the right side of the feed adjusting assembly 42 Pr...

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Page 17: ...adjust the position where rotation is prevented Refer to A If there is a small rotation prevention amount the inner rotary hook may slip and start rotating causing damage to the inner rotary hook or breaking the needle 55 Before installing the thread cutting assembly move the thread cutter cam so that its notch faces the front B of the sewing machine 55 Thread cutting assembly installation procedu...

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Page 19: ...annot operate and the thread tension cannot be adjusted 57 Before installing the needle bar supporter assembly insert it into the needle bar crank rod insert the needle bar supporter stud holder then install a spring Hook the longer end of the other spring F to the main unit 58 Install the needle bar supporter stud holder from the needle bar supporter pin side then attaching it using a 14 mm screw...

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Page 21: ...over 71 Insert the base cover into the base plate and attach using the two screws 72 Attach the belt cover using the screw and fit the blind cap on 73 Attach the free arm cover using the screw 74 Attach the face plate using the screw Assembly Points 67 When installing the rear cover lower the presser foot lifter slightly lift the back of the unit then install the rear cover 69 When installing the ...

Page 22: ...ove the side cover from the lower side 3 Remove the two screws and pull the main cover to the right 4 Remove the three screws and the base cover Assembly Point 3 Securely fit the bottom rear part of the side cover into the base cover If these parts do not securely fit together the side cover may become loose and raisep up ...

Page 23: ... 21 2 LEAD WIRE ARRANGEMENT PC 8200 Model 985 ...

Page 24: ...w main PC board is installed this adjustment must be performed 33 12 POSITION OF BUTTONHOLE SWITCH LEVER 34 13 BOBBIN WINDER 35 14 BOBBIN THREAD DETECTOR 36 15 INNER ROTARY HOOK BRACKET POSITION 37 16 LARGE ONE POINT PATTERN SHAPE SOFT ADJUSTMENT 38 17 FEED ADJUSTMENT VERTICAL FEED 39 18 INNER ROTARY HOOK TENSION 40 19 NEEDLE THREADER 40 20 NEEDLE THREADER CHECKING THE HOOK POSITION IN HORIZONTAL ...

Page 25: ...unds once when cross number 5 is touched the adjustment has been made correctly If the buzzer sounds twice when cross number 5 is touched an error has occurred In this case touch the crosses on the touch panel again in order from 1 to 5 Never press the thread cutter button during this time Doing so may cause a malfunction 3 Turn the power off then on again and check that the screen display and the...

Page 26: ...ary hook 27 6 Left right position of feed dog 30 10 Bobbin thread detector 36 The other test modes are used for factory adjustments Making initial adjustments with the test modes After the operations listed below are performed the test modes should be used to make initial adjustments to the sewing machine 1 When new main PC board assembly is installed Make adjustments using test modes 2 and 3 2 Wh...

Page 27: ...r 2 Adjust the belt tension by moving the motor holder 3 Tighten the two screws Adjustment Points 1 If the timing belt tension is too loose the belt may jump while sewing on denim and other thicker fabrics or overlapping fabric or the feed timing or the closeness of the needle and rotary hook may prevent sewing 2 If the motor belt tension is too tight the torque becomes too much causing the motor ...

Page 28: ...ce wheel to move the needle to the needle down position 3 Loosen the screw securing the zigzag connecting rod assembly 4 Turn the balance wheel to move the needle to the left and right and then turn the zigzag adjusting nut by using the box wrench to set the needle in the center of the needle hole 5 Tighten the screw securing the zigzag connecting rod assembly 6 Turn the balance wheel and check th...

Page 29: ...point should be positioned at the right side of the needle 4 Tighten the three screws of the lower shaft gear 5 Turn the eccentric screw and set the clearance between the needle and the rotary hook point to 0 1 mm or less Make sure that the needle does not make contact with the rotary hook point Adjustment Points 1 When adjusting the timing the needle should be at its lowest and leftmost position ...

Page 30: ... 3 Loosen the screw of the needle bar block assembly 4 Move the needle bar vertically to adjust the clearance to between 1 0 1 4 mm 5 Tighten the screw of the needle bar block assembly NOTE The needle bar clamp should be parallel to the side of the needle plate If the needle bar is loose when you adjust the needle bar height it may result in sewing troubles Adjustment Points 1 If the needle bar he...

Page 31: ...ily so as the center of lower shaft is positioned higher by 1 mm against the center of eccentric metal 2 Install the outer rotary hook 3 Tighten the screw on the bushing presser L by turning the eccentric metal Make sure that there is no backlash on the gears ...

Page 32: ...mode 6 2 Loosen the screw securing the horizontal feed plate 3 Align the feed dog s left right position 4 In the test mode align the feed dog s left right position 5 Tighten the screw securing the horizontal feed plate 6 Move to the feed start position in the test mode 7 Loosen the screw securing the horizontal feed arm 8 Set the clearance between the feed dog and needle plate to 0 5 to 1 0 9 Tigh...

Page 33: ...he vertical feed roller shaft to adjust the feed dog height to within 0 9 1 1 mm 4 Tighten the screw securing the vertical feed roller shaft Adjustment Points 1 If the feed dog is too high the feed dog may contact the back of the needle plate a noise may be generated an incorrect forward and backward motion of the feed bar may be produced an incorrect feed may be produced or the fabric may not fee...

Page 34: ...t should be positioned in the center of the needle hole of the needle plate Adjustment Points 1 Install presser foot J 2 When adjusting the presser bar height the presser foot should be parallel with the feed dog hole in the needle plate Refer to A A hexagonal pencil can be used to check the height 3 If the presser foot is not parallel with the feed dog hole the needle may contact the presser foot...

Page 35: ...uzzer should sound twice 4 Insert a spacer with a thickness of 3 mm beneath the J presser foot 5 Press 3 mm on the display The buzzer should sound twice NOTE If the values read in steps 3 and 5 are normal the buzzer will sound twice each time If they are not normal the buzzer will sound four times each time If there is an abnormality perform the procedure again starting from 2 Adjustment Points 1 ...

Page 36: ...d lower the presser foot lever 3 Adjust the position of buttonhole lever so that BH0 touches BH1 when the buttonhole eccentric shaft is rotated NOTE In case that the legs are shorter than the standard bend the BH 1 to be far from BH 0 In case that the legs are longer than the standard bend the BH 2 to be close to BH 0 Adjustment Point If the buttonhole eccentric shaft C is rotated clockwise the cl...

Page 37: ...g the thread guide holder vertically C 4 Tighten the thread guide holder screw 5 Loosen the screw securing the bobbin presser slightly 6 Turn the bobbin presser to adjust the bobbin thread amount 7 Tighten the screw of the bobbin presser 8 Set the bobbin winder assembly to the left 9 Loosen the screw of the bobbin winder switch 10 Adjust the clearance between the bobbin winder switch and the bobbi...

Page 38: ... 11 8 mm and set the bobbin in the inner rotary hook 4 Loosen the screw holding the photo transistor slightly turn the photo transistor to the left until appears on the display Then turn it to the right until 0 0 appears on the display and tighten the screw NOTE Keep the area around the photo transistor and the photo diode clean Remove the lamp during the adjustments Adjustment Points 1 Remove the...

Page 39: ...w securing the inner rotary hook bracket 2 Adjust the position of the inner rotary hook bracket by moving it vertically and or horizontally NOTE Surface A of the inner rotary hook bracket should be perpendicular to the feeding direction 3 Tighten the screw of the inner rotary hook bracket Adjustment Point 1 If the inner rotary hook bracket position is moved by a large amount be sure to check and a...

Page 40: ...before sewing 3 Adjust the pattern Adjustment Points 1 If the pattern is compressed in the direction press the vertical button A If the pattern is stretched in the direction press the vertical button B If the pattern is compressed in the direction press the horizontal button C If the pattern is stretched in the direction press the horizontal button D 2 The should be adjusted using the four setting...

Page 41: ...t N before the adjustment 3 Tighten the screw securing the pulse motor Adjustment Points If the pulse motor position is to be adjusted when the screw is to be turned or the motor is to be moved turn off the power to the sewing machine in order to reduce the risk of a short circuit or damage to the main PC board with the screwdriver 1 If the pattern is open as shown by E move the pulse motor slight...

Page 42: ...tanding of how to use it otherwise the needle threader may be damaged or needle threading may not be possible Be sure to read and understand the following so that you can handle customer complaints NOTE 1 Needle threader accepts only circled needle and thread combinations 2 Combinations marked with a are not recommended since they might lead to the breakage of needle threader imperfect performance...

Page 43: ...es not go through are defective Example for checking When you check five brand new sewing needles HA X1 9 on condition that it achieves above first case if the hook does not go through eyelet of all of these needle all five needles are defective and you judge the hook position is not defective ADJUSTMENT In case the hook is defective after above checking adjust the hook by bending with pliers Do n...

Page 44: ...low Adjust needle threader position setter slightly up and check the clearance between the top of hook and top of needle eye is 0 mm In case part a and part b is not parallel or the hook does not work readjust needle threader by loosening the screw If a and b are not parallel the needle threader will not be held by the needle threader position setter refer to Fig 1 the hook will not enter the eyel...

Page 45: ... after the X carriage unit is moved all the way to the right ADJUSTMENT 1 Move the X carriage unit all the way to the right 2 Loosen the screw of the X tension pulley screws A and B 3 Adjust the position of the X tension pulley 4 Tighten the screw of the X tension pulley screws A and B Adjustment Point If the tension in the belt is too weak or too tight the embroidery may not be aligned correctly ...

Page 46: ... the Y carriage is moved all the way forward ADJUSTMENT 1 Move the Y carriage all the way forward 2 Loosen the screw of the Y tension pulley screw C 3 Adjust the position of the Y tension pulley 4 Tighten the screw of the Y tension pulley screw C Adjustment Point If the tension in the belt is too weak or too tight the embroidery may not be aligned correctly the inside of the pattern may not align ...

Page 47: ... carriage is moved to the left be sure that the X pulse motor gear does not contact the initial rubber 27 ADJUSTING THE Y BELT PRESSER Move the Y pulse motor gear in the direction shown in the illustration then move the Y carriage and tighten the Y belt presser screw at the point where the initial rubber contacts the Y pulse motor gear After the Y carriage is moved to the left be sure that the Y p...

Page 48: ...ted 48 6 Correct patterns are not created 48 7 Buttonholes are not stitched correctly 48 8 Manual operation of feed and zigzag pulse motors is not possible 48 9 Vertical movement of needle bar and backstitch operation are abnormal 48 10 Foot controller does not operate normally when depressed 48 11 Thread tension is not correct 49 12 Needle bar release mechanism does not operate correctly 49 13 Th...

Page 49: ...tion for the same pulse motors irrespective of needle position 3 Is a fuse blown 4 Is the voltage between pins 4 5 normal when the output connector CN7 is disconnected from the main power board Between 4 5 22 26 VDC 5 Others 1 Replace the pulse motor which shows an abnormality 2 Replace NP board assembly 3 Replace fuse after correcting defect that caused fuse to blow 4 Replace power supply unit as...

Page 50: ...al Between 1 2 Between 2 3 Buttonhole lever is pulled forward 1 W or less Buttonhole lever is pushed back 1 W or less 4 Others 1 Check stitch foot 2 Adjust button hole lever or replace BH switch assembly 3 Adjust button hole lever or replace BH switch assembly 4 Replace main PC board assembly 8 Manual operation of feed and zigzag pulse motors is not possible 1 Do manual keys of feed and zigzag pul...

Page 51: ... lead wire assembly 3 Replace main PC board assembly 14 Display does not appear clearly 1 Are voltages between the following pins of connector CN5 for LCD module correct 2 Others Between 12 11 16 22 VDC Between 13 11 16 22 VDC 1 Replace main PC board assembly 2 Replace LCD module or main PC board assembly 15 The LCD light does not light 1 Is the voltage between pins 4 5 24 to 30 VDC when the outpu...

Page 52: ...ween pins 1 3 and 2 4 of connectors on X and Y pulse motors where embroidery unit is installed 8 10 W 4 When ebmbroidery unit is installed are resistances between pins 1 3 and 2 4 of connectors CN21 and CN22 on X and Y pulse motors 8 10 W 5 Are resistances between pins 5 6 of connector CN21 on the X pulse motor correct in the following states When embroidery unit is installed 1 W orless When embro...

Page 53: ... 51 Main PC board Power supply unit ...

Page 54: ... 52 LCD unit Other PC boards 985 ...

Page 55: ... 53 PC8200 SG2000 H7070093 ...