Brother Industries SUPER ACE+e Service Manual Download

Page: 1 / 56

2.2001.

www.promelectroavtomat.ru

Summary of Contents for SUPER ACE+e

Page 1: ... 2 2001 www promelectroavtomat ru ...

Page 2: ...ASSEMBLING THE SEWING MACHINE 8 III HOW TO ADJUST MECHANICAL ELEMENTS 23 IV HOW TO ADJUST ELECTRONIC ELEMENTS 47 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 aluminum foil and avoid subjecting them ...

Page 3: ... 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 www promelectroavtomat ru ...

Page 4: ... 2 1 MECHANICAL CHART EMBROIDERY UNIT MECHANISM OPTION www promelectroavtomat ru ...

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 www promelectroavtomat ru ...

Page 6: ... 4 3 ELECTRONIC PARTS ARRANGEMENT CHART 4 CONTROL SYSTEM BLOCK DIAGRAM www promelectroavtomat ru ...

Page 7: ...st to this this model stores the data electronically in memory and uses a feed pulse motor and a zigzag pulse motor to directly rock the needle bar and the feed regulator to generate the pattern In addition the pulse motors must move the position of the needle while the needle is raised and stop it in the correct position and similarly they must move the position of the feed regulator while the ne...

Page 8: ...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 www promelectroavtomat ru ...

Page 9: ...lecting 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 zigzag feed and thread feed pules motor and detects the...

Page 10: ... 8 II 1 DISASSEMBLING AND REASSEMBLING THE OUTER PARTS AND MAIN PARTS 9 2 LEAD WIRE ARRANGEMENT 22 www promelectroavtomat ru ...

Page 11: ... below free arm Open the front cover toward the front remove the four connectors and then the front cover 6 Remove the two screws securing the needle plate and the needle plate 7 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 B...

Page 12: ... Points 9 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 15 To remove the thread guard cover from the tension link more easily c...

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Page 14: ...23 Remove the presser spring screw and the presser bar spring 24 Remove the presser lifter by pulling the presser lifting shaft straight out from the front 25 Pull the tension releaser plate out forward 26 Remove the screw and the thread take up shaft Disassembly Point 19 Before removing the thread cutting assembly move the thread cutter cam so that its notch faces the front of the sewing machine ...

Page 15: ...older assembly 34 Remove the screw and the outer rotary hook assembly 35 Remove the two metal presser screws and remove the lower shaft assembly and the 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 27 To remove the upper shaft assembly more easily remove the two feed rod tension springs A...

Page 16: ...ook shaft washer is in on top 41 Adjust position of notch of eccentric metal to adjust play of the outer rotary hook assembly and the lower shaft rotation direction slack of the outer rotary hook assembly Positioning the notch at the bottom will reduce play Under normal conditions the ideal position is towards the front However when play is excessive adjust to prevent the rotary hook noise 42 For ...

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Page 18: ...t 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 56 Before installing the thread cutting assembly move the thread cutter cam so that its notch faces the front B of the sewing machine 56 Thread cutting assembly installation procedure 1 ...

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Page 20: ...nd the thread tension cannot be adjusted 58 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 59 Install the needle bar supporter stud holder from the needle bar supporter pin side then attaching it using a 14 mm screw 60 Before inst...

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Page 22: ...blind cap on 73 Attach the free arm cover using the screw 74 Attach the face plate using the screw Assembly Points 68 When installing the rear cover lower the presser foot lifter slightly lift the back of the unit then install the rear cover 70 When installing the front cover do not pinch the lead wires on the left side of the main PC board between the cover and the sewing machine 71 Check that th...

Page 23: ...e parts do not securely fit together the side cover may become loose and raised up Check to make sure that there is space between sensors on X and Y shutters Set X sensor lead wire and X pulse motor lead wire in section A Attach main frame taking care not to pinch cord Using a clip fix Y sensor lead wire firmly in place so that there is no slack between in and section B Move X carriage side to sid...

Page 24: ... 22 2 LEAD WIRE ARRANGEMENT www promelectroavtomat ru ...

Page 25: ...OIDERY UPPER THREAD ADJUSTMENT OPTION 34 12 POSITION OF BUTTONHOLE SWITCH LEVER 35 13 BOBBIN WINDER 36 14 BOBBIN THREAD DETECTOR 37 15 INNER ROTARY HOOK BRACKET POSITION 38 16 LARGE ONE POINT PATTERN SHAPE SOFT ADJUSTMENT 39 17 FEED ADJUSTMENT VERTICAL FEED 40 18 INNER ROTARY HOOK TENSION 41 19 NEEDLE THREADER 42 20 NEEDLE THREADER CHECKING THE HOOK POSITION IN HORIZONTAL DIRECTION 43 21 NEEDLE TH...

Page 26: ... panel The respective test mode will be entered when the numeral is pressed Test Mode No Adjustment Item Page 2 Checking detection of fabric thickness 33 3 Pattern 39 4 Needle down position 26 5 Timing of needle and rotary hook 27 6 Position of feed dog 30 21 Bobbin thread detector 37 22 Embroidery Upper thread OPTION 34 The other test modes are used for factory adjustments www promelectroavtomat ...

Page 27: ... 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 to rotate ...

Page 28: ...wheel to move the needle to the needle down position 3 Loosen the screw securing the zigzag adjusting nut 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 adjusting nut 6 Turn the balance wheel and check the needle down position ...

Page 29: ...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 If the cleara...

Page 30: ... 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 height is too l...

Page 31: ... 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 www promelectroavtomat ru ...

Page 32: ...front should be 0 5 to 1 0 mm Refer to illustration ADJUSTMENT 1 Select test mode 6 2 Loosen the screw securing the horizontal feed plate 3 Align the feed dog s left right position 4 Tighten the screw securing the horizontal feed plate 5 Move to the feed start position in the test mode 6 Loosen the screw securing the horizontal feed arm 7 In the test mode set the clearance between the feed dog and...

Page 33: ...eed 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 feed 2 If the fe...

Page 34: ...ositioned 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 or the fabri...

Page 35: ...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 Be sure to in...

Page 36: ...idery thread tension is too low press the setting with a higher value than current setting to tighten thread tension 4 If embroidery thread tension is high press the setting with a lower value than current setting to loosen thread tension NOTE If thread tension is not set correctly on your sewing machine problems such as needle breakage and fabric puckering may result 2 2 3 4 www promelectroavtoma...

Page 37: ...resser 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 clearance D bet...

Page 38: ...3 Tighten the bobbin winding guide screw 4 Loosen the screw securing the bobbin presser slightly 5 Turn the bobbin presser to adjust the bobbin thread amount 6 Tighten the screw of the bobbin presser 7 Set the bobbin winder assembly to the left 8 Loosen the screw of the bobbin winder switch 9 Adjust the clearance between the bobbin winder switch and the bobbin winder assembly to 0 5 1 0 mm B 10 Ti...

Page 39: ...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 needle plate...

Page 40: ...e 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 adjust the bob...

Page 41: ... test pattern outline Install presser foot N before sewing 3 A trial pattern for adjustment purposes can then be embroidered Adjust shapes of stitch using the and stitch length keys From 9 to 9 Adjustment Point 1 The pattern should be adjusted using the three settings for each direction 3 to 3 If the pattern cannot be adjusted using the three settings for each direction refer to 17 FEED ADJUSTMENT...

Page 42: ...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 B move the pulse motor slightly backward 2 I...

Page 43: ...rence between this and the tension for silk thread 80 should be 0 02 0 03N 2 3g ADJUSTMENT 1 Pass polyester thread 60 through the inner rotary hook correctly and pull it using the tension gauge 2 Adjust the tension by turning the screw to either the right or left using a screwdriver NOTE After adjusting the tension lock the screw with paint www promelectroavtomat ru ...

Page 44: ...ead combinations 2 Combinations marked with a are not recommended since they might lead to the breakage of needle threader imperfect performance 3 Lower the presser foot when you use needle threader 4 Nylon transparent thread is applicable in needle 14 16 5 Do not turn the balance wheel when using needle threader 6 Do not lower the needle threader lever while the machine is running If it is lowere...

Page 45: ...ough 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 not bend the h...

Page 46: ...edle 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 eyelet of the nee...

Page 47: ...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 the ins...

Page 48: ...iage 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 with the ou...

Page 49: ... Manual operation of feed and zigzag pulse motors is not possible 50 9 Vertical movement of needle bar and backstitch operation are abnormal 50 10 Foot controller does not operate normally when depressed 50 11 Thread tension is not correct 50 12 Needle bar release mechanism does not operate correctly 50 13 Thread cutter does not operate correctly 50 14 Display does not appear clearly 50 15 The LCD...

Page 50: ...n pulse motors do not return to their home positions with respect to the needle position Zigzag pulse motor when needle bar is raised and feed pulse motor when needle bar is lowered 1 Are the resistances between the connector pins given below normal for the pulse motors which do not return to the home position Zigzag CN14 1 3 2 4 8 10 Ω Feed CN15 1 3 2 4 8 10 Ω 2 Set the home position for the same...

Page 51: ...en pins 2 1 pins 4 1 pins 5 1 and 6 1 of connector CN13 for NP board change to either 0 or 5 VDC 3 Others 1 Replace VR board assembly 2 Replace NP board assembly 3 Replace main PC board 6 Correct patterns are not created 1 If the power is turned off and the needle bar is moved horizontally by hand does it move easily 2 Are the resistances between the connector pins for the zigzag and feed pulse mo...

Page 52: ...er or jack assembly 3 Replace main PC board assembly 11 Thread tension is not correct 1 Is thread route correct 2 Are the 0 mm and 3 mm fabric thickness adjustments correct 3 Turn off power and lower presser foot When turning AT pulse motor gear manually does it turn easily and together with roller 4 Are resistances between pins 1 3 and pins 2 4 of connector CN16 for AT pulse motor 8 to 10 Ω 5 Is ...

Page 53: ...between pins 2 1 of connector CN17 for bobbin thread detecting photo transistor correct Bobbin without thread 0 1 to 0 2 VDC Bobbin with thread 2 to 5 VDC 4 Others 1 Correct directions of bobbin thread detector ends 2 Replace photo diode assembly 3 Replace photo transistor assembly 4 Replace main PC board 19 Embroidery unit does not work correctly OPTION 1 Is your card a embroidery card Is embroid...

Page 54: ... 52 Main PC board Power supply unit www promelectroavtomat ru ...

Page 55: ... 53 LCD unit Other PC boards www promelectroavtomat ru ...

Page 56: ...SUPER ACE e T1030146 www promelectroavtomat ru ...

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