Brother PE-180D, Service Manual

Page 1: ... 8 2001 ...

Page 2: ...ch are current at the time of printing of this manual However specifications are subject to change for improvement without notice so contract the manufacturer or your local sales agent for information regarding such changes Brother Industries Ltd Nagoya Japan I PRINCIPAL MECHANISMS 2 II DISASSEMBLY AND REASSEMBLY PROCEDURES 8 III ADJUSTMENT STANDARDS AND ADJUSTMENT PROCEDURES FOR MECHANICAL PARTS ...

Page 3: ...he service and maintenance of this product Please be sure to observe the following 1 Always wear rubber gloves when handling the circuit boards Never touch metal components with your bare hands 2 Ground your body to prevent static charge build up 3 When storing and shipping circuit boards always wrap the circuit board in the specified aluminum foil wrapper or equivalent static prevention bag and p...

Page 4: ...SSEMBLY VERTICAL NEEDLE BAR MOVEMENT THREAD TAKE UP MOVEMENT AND ROTARY HOOK MOVEMENT 4 3 ELECTRONIC PARTS LAYOUT CHART 5 4 CONTROL SYSTEM BLOCK DIAGRAM 5 5 MAIN MOTOR CONTROL SYSTEM 6 6 PATTERN GENERATOR 6 7 OTHER ELECTRONIC COMPONENT FUNCTIONS 7 ...

Page 5: ... 3 1 MECHANICAL CHART ...

Page 6: ...OK MOVEMENT Main motor T pulley Hand wheel Upper shaft gear Main shaft Thread take up Counter weight Timing belt Rotary hook shaft pulley Rotary hook Needle Needle bar Needle bar clamp Needle bar crank rod Needle bar crank Thread take up lever Vertical shaft pulley Vertical shaft Vertical shaft gear ...

Page 7: ... 5 3 ELECTRONIC PARTS LAYOUT CHART 4 CONTROL SYSTEM BLOCK DIAGRAM ...

Page 8: ...e X and Y pulse motors to produce the patterns It is therefore possible to increase the number of stored patterns and the total number of stitches by simply increasing the storage capacity of the embroidery machine Good positioning and response speed are also required of the pulse motors used in this machine because the embroidery frame must be moved and stopped in a precise position while the nee...

Page 9: ...timing of the embroidery frame drive pulse motor and the tension release solenoid and detects the vertical position of the needle Also detects the turning angle of the upper shaft by means of a photointerruptor and shutter installed on the upper shaft Speed sensor Detects the operating speed of the main motor by means of a photointerruptor and shutter installed on the upper shaft Bobbin winder swi...

Page 10: ... 8 1 DISASSEMBLY AND REASSEMBLY PROCEDURES FOR EXTERNAL PARTS AND MAJOR COMPONENTS 9 2 SECURING THE LEADS 12 ...

Page 11: ... X carriage cover 4 Remove the four screws of the bottom plate and the two screws of the cover and then remove the bottom plate 5 Remove the four screws of the rear cover and then remove the rear cover 6 Remove the main cover to the left side 7 Remove the four screws of the front cover Then remove the front cover from the lower section of the thread path cover and the part around the tension contr...

Page 12: ...and then remove the main motor cover 220 to 240 V models only 14 Remove the two screws of the motor holder disconnect the electrical connectors and then remove the motor holder assembly 15 Remove the screws and then remove the shutter cover 16 Remove the screw of the back cover 17 Remove the three screws of the fixation unit 18 Remove the two screws of the upper shaft bushing fixation and then rem...

Page 13: ...ook unit 24 Remove the screw and then remove the circuit board mounting plate 25 Remove the three screws and then remove the power supply unit cover 26 Remove the screw and then remove the switch holder 27 Remove the three screws and then remove the power supply unit 28 Remove the four screws and then remove the main frame 29 Remove the two screws and then remove the inlet assembly ...

Page 14: ...s from the power supply PC board extend to the front from the right side of the main PC board amount of the bobbin winder holder 3 The leads coming from the power supply PC board pass under the cord holder of the power supply unit and out to the front 4 For 220 240 V specifications only Pass the cord for the main motor under the main motor cover so that it will not directly touch the main motor ...

Page 15: ...NG ADJUSTMENT OF BOBBIN WINDER SWITCH 21 9 POSITION OF INNER ROTARY HOOK BRACKET 22 10 ADJUSTMENT OF INNER ROTARY HOOK TENSION 23 11 ADJUSTMENT OF TREAD TENSION DIAL 24 12 POSITION OF TENSION RELEASE SOLENOID 25 13 NEEDLE THREADER 26 14 NEEDLE THREADER ADJUSTMENT OF NEEDLE THREADER 27 15 NEEDLE THREADER REPLACEMENT OF HOOK 28 16 X Y CARRIAGE X TIMING BELT TENSION 29 17 X Y CARRIAGE Y TIMING BELT T...

Page 16: ...utton while simultaneously turning on the power switch Fig 1 The test mode numbers will be displayed in the touch panel Fig 2 Select the desired test mode by pressing the corresponding number Adjustment item Test mode No Thread take up spring adjustment 26 All other test mode numbers are reserved and are not used for adjustment Fig 1 Fig 2 ...

Page 17: ...e in by 6 8 mm when a force of approximately 2 N 200 g is applied midway between the rotary hook shaft pulley and vertical shaft pulley ADJUSTMENT 1 Loosen the two screws of the motor holder 2 Move the motor holder to adjust the belt deflection to 5 7 mm 3 Tighten the two screws of the motor holder 4 Slightly loosen the screw of the eccentric shaft 5 Turn the eccentric shaft right or left to adjus...

Page 18: ...the front of the machine ADJUSTMENT 1 Turn the hand wheel to raise the needle bar to its highest position 2 Loosen the screw of the rotary shutter 3 Turn the screw of the rotary shutter toward the front 4 Tighten the screw of the rotary shutter NOTE Make sure the side of the rotary shutter does not contact the photointerrupter Turn the hand wheel by hand to check ...

Page 19: ...Turn the hand wheel by hand and observe the position of the needle in the needle hole 2 Loosen the screw and the set screw of the presser unit 3 Move the presser unit right or left so that the needle point locates 0 9 mm inward from the left end of the needle hole 4 Tighten the screw and the set screw of the presser unit 5 Turn the hand wheel by hand and recheck the needle drop point ...

Page 20: ...tact between the rotary hook point and the needle ADJUSTMENT Remove the inner rotary hook before adjusting 1 Loosen the two set screws of the rotary hook pulley 2 Adjust so that the rotary hook should be at the side of the needle when the needle is raised 2 2 2 6 mm from its lowest position 3 Tighten the two set screws of the rotary hook pulley 4 Loosen the screw 5 Turn the set screw in or out so ...

Page 21: ...1 Turn the hand wheel so that the rotary hook point is at the closest point to the needle 2 Loosen the set screw of the needle bar clamp 3 Move the needle bar up or down to adjust the gap to 1 6 2 0 mm 4 Tighten the set screw of the needle bar clamp NOTE The needle bar can turn easily when adjusting the needle bar height possibly resulting in sewing problems Make sure the needle clamp is properly ...

Page 22: ...mode 26 2 Loosen the screw of the thread take up spring cover 3 Turn the thread take up spring cover to adjust the thread take up spring stroke to 8 9 mm 4 Tighten the screw of the thread take up spring cover 5 Loosen the screw of the thread breakage sensor PC board 6 Lift the thread take up spring and adjust the sensor PC board so that the buzzer sounds when the thread take up spring is raised 4 ...

Page 23: ...3 Adjust the bobbin winding by moving the bobbin winder guide 4 Tighten the screw of the bobbin winder guide 5 Slightly loosen the screw of the bobbin presser 6 Turn the bobbin presser to adjust the bobbin winding amount 7 Tighten the screw of the bobbin presser 8 Remove the rear cover Refer to page 9 9 Set the bobbin winder spindle to the left and turn the bobbin winder switch off 10 Loosen the s...

Page 24: ...ary hook should overlap each other by 1 9 2 1 mm ADJUSTMENT 1 Loosen the screw of the inner rotary hook bracket 2 Adjust the forward backward and sideways positions of the inner rotary hook bracket NOTE Surface A of the inner rotary hook should be parallel to the front of the embroidery machine parallel to the upper shaft 3 Tighten the screw of the inner rotary hook bracket ...

Page 25: ... a 90 polyester thread is pulled gently using a tension gauge ADJUSTMENT 1 Thread a 90 polyester thread normally to the inner rotary hook and then pull the thread gently using a tension gauge 2 Turn the spring adjustment screw with a screwdriver to adjust the thread tension NOTE Lock the screw with paint after adjusting ...

Page 26: ...the tension dial to 5 2 Raise the presser foot lever pass a 60 polyester thread through the open tension disc and then lower the presser foot lever to hold the 60 polyester thread in the tension disc 3 Using a tension gauge pull gently down on the 60 polyester thread held in the tension disc 4 Turn the thread tension adjustment screw to adjust the dial tension NOTE After completing the adjustment ...

Page 27: ...ld be 0 0 5 mm and the gap between tension release plate A and the tension release solenoid shaft should be 0 mm ADJUSTMENT 1 Lower the presser foot lever 2 Loosen the two screws of the solenoid holder 3 Shift the solenoid holder right or left to adjust the gap between tension release plate A and B 4 Tighten the two screws of the solenoid holder ...

Page 28: ...PRECAUTIONS 1 Be sure the embroidery presser foot is down when operating the needle threader 2 Do not turn the hand wheel when using the needle threader 3 Do not lower the needle threader lever when using the machine This could break the needle threader making it unusable and possibly causing needle breakage or harm to the operator 4 If the needle is not at least 7 mm above the top of the needle p...

Page 29: ...screws of the needle threader base 3 Operate the needle threader and move the needle threader base to the right and left so that the hook passes exactly through the center of the needle hole and then tighten the two screws 4 Loosen the screw of the positioning support 5 Operate the needle threader and move the needle threader positioning guide up and down so that the clearance between the top of t...

Page 30: ...lace the hook with a new one and then tighten the two hook mounting screws Caution Do not over tighten the hook mounting screws as this could strip the screw threads which will make tightening impossible 3 If the hook doesn t pass correctly through the needle hole after the hook has been replaced adjust the needle threader position Refer to ADJUSTMENT in 14 NEEDLE THREADER ADJUSTING THE NEEDLE THR...

Page 31: ...eft the timing belt should give 2 4 mm when pressed with a 1N 100 g load midway of the belt ADJUSTMENT 1 Move the X carriage all the way to the left 2 Loosen the screw of the X tension pulley 3 Adjust the position of the X tension pulley with the adjustment screw 4 Tighten the screw of the X tension pulley ...

Page 32: ...the front the timing belt should give 2 4 mm when pressed with a 1 N 100 g load from the X carriage body measurement hole ADJUSTMENT 1 Move the Y carriage all the way to the front 2 Loosen the screw of the Y tension pulley and adjust the timing belt tension 3 Tighten the screw of the Y tension pulley ...

Page 33: ...NT 1 Remove the stop ring holding the middle gear for X carriage drive 2 Remove middle gears A and B and the gear spring from the main frame 3 Align the reference holes in middle gears A and B reassemble the gears to the main frame and then secure with the stop ring 4 Loosen the two mounting screws of the X carriage drive motor 5 Press the X carriage drive motor gear to the middle gears to reduce ...

Page 34: ...anywhere ADJUSTMENT 1 Loosen the three mounting screws of the X carriage 2 Move the X carriage right or left so that the X carriage is perpendicular to the upper shaft 3 Tighten the three mounting screws of the X carriage 4 Stretch a piece of felt in the embroidery frame and then set the frame in the embroidery machine 5 Select the preprogrammed frame pattern square border enlarge the size to maxi...

Page 35: ...the mounting screw of the fixed blade holder The lower thread guide plate should be 29 4 mm above the rotary hook shaft frame In addition the gap between the lower thread guide plate and inner rotary hook should be 1 5 mm 4 Loosen the mounting screw of the lower thread guide plate 5 Move the lower thread guide plate so that it is 29 4 mm above the rotary hook shaft frame 6 Move the lower thread gu...

Page 36: ...S TURNED ON AND THE NEEDLE IS IN THE UP POSITION 35 3 PATTERN SELECTION IS NOT POSSIBLE 36 4 MAIN MOTOR DOES NOT OPERATE 36 5 MAIN MOTOR OPERATES UNEVENLY 36 6 EMBROIDERY FRAME OPERATION IS NOT NORMAL 37 7 LCD DOES NOT OPERATE NORMALLY 37 8 LCD BACKLIGHT DOES NOT WORK 37 9 BOBBIN WINDING IS NOT POSSIBLE 37 10 NEEDLE THREAD DETECTION DOES NOT OPERATE NORMALLY 37 ...

Page 37: ... the blown fuse 4 Replace the main PC board assembly 2 Pulse motors do not correctly detect the home position after the power is turned on and the needle is in the up position 1 Is there the normal resistance between the following pins of the connector of the pulse motor that does not detect the home position X CN16 Between 1 2 3 4 Approx Ω Y CN17 Between 1 2 3 4 Approx Ω 2 The pulse motor only de...

Page 38: ...ss than 1 Ω When switch is released infinite 5 Is the presser foot lever down Is the presser switch normal Resistance between both sides of CN8 Presser foot is up less than 1 Ω Presser foot is down infinite 6 Other 1 Correct installation so hand wheel turns easily 2 Confirm connection 3 Replace the main motor assembly 4 Replace the SS PC board assembly 5 Confirm the presser switch installation if ...

Page 39: ...om the power supply PC board is the voltage between 3 4 normal Between 3 4 13 to 18 V DC 2 Is the voltage between 9 10 of the LCD module connector CN5 9V DC 3 Other 1 Replace the power supply unit assembly 2 Replace the main PC board assembly 3 Replace the LCD module assembly 9 Bobbin winding is not possible 1 Is the resistance between both sides of the bobbin winder switch connector CN4 less than...

Page 40: ... 38 Main PC board LCD module ...

Page 41: ... 39 Power supply PC board For 120V AC models For 230 V AC models ...

Page 42: ... 40 Main motor assembly For 120 V AC models without insulation For 230 V AC models with insulation ...

Page 43: ...s SS PC board assembly NP PC board assembly Y sensor PC board assembly X sensor PC board assembly Thread breakage sensor PC board assembly Inlet For 120 V AC models without insulation For 230 V AC models with insulation ...

Page 44: ...PE 180D H1060205 ...