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Brother PC8200 SUPER GALAXIE 2000 Service Manual

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

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Summary of Contents for Brother PC8200 SUPER GALAXIE 2000

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

  • Page 2: Principal Mechanisms

    This was produced based on up-to-date product specifications at the time of issue, but there may have been changes of specifications for the purpose of improvements. Contact manufacturer or local sales company for information concerning such changes. Brother Industries, Ltd. Nagoya, Japan I . PRINCIPAL MECHANISMS ..................1 II .

  • Page 3: Table Of Contents

    PRINCIPAL MECHANISMS 1. MECHANICAL 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: Mechanical Chart

    MECHANICAL CHART EMBROIDERY UNIT MECHANISM...

  • Page 5: Power Transmission Chart

    POWER TRANSMISSION CHART Generating mechanism of needle bar, thread take-up lever and zigzag movements Mechanism of feed dog and rotary hook movement...

  • Page 6: Electronic Parts Arrangement Chart

    ELECTRONIC PARTS ARRANGEMENT CHART (PC-8200, Model 985) CONTROL SYSTEM BLOCK DIAGRAM...

  • Page 7: Main Motor Control

    MAIN MOTOR CONTROL The main motor for the sewing machine is required to smoothly change from low speed to high speed without any fluctuations due to load or temperature changes. To fully comply with this requirement, the Super Galaxie adopts PWM control using FET.

  • Page 8: Automatic Thread Tension

    AUTOMATIC THREAD TENSION On former models, the operator adjusted the thread tension of the needle and bobbin threads by changing the pressure between the tension 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.

  • Page 9: Other Electronic Component Functions

    OTHER ELECTRONIC COMPONENT FUNCTIONS Start/stop switch........used to start and stop (SS) the machine. If you want to start sewing at low speed, keep this switch depressed and start sewing. Backstitch switch ........ used for backstitching and lockstitching. Backstitching is performed at low speed in the reverse direction while the switch is pressed.
  • Page 10 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 DISASSEMBLING AND REASSEMBLING THE OUTER PARTS AND MAIN PARTS Remove the screw securing the face plate, and the face plate by sliding it to the left. Remove the screw securing the free arm cover, and the free arm cover by sliding it to the left. Remove the blind cap on the belt cover, the screw securing the belt cover, and the belt cover from below by sliding it to the right.
  • Page 12 9. Remove the presser holder and needle. 10. Remove the 15 connectors, the two screws, and the main PC board. 11. Remove the two screws and handle holder assembly. 12. Remove the screw and thread winding assembly. 13. Remove the motor belt and pull out the motor connector. Remove the two screws and the main motor. 14.
  • Page 13 20. Remove the two screws and the thread cutter unit. 21. Remove the screw and the inner rotary hook bracket. 22. Remove the presser bar clamp screw. 23. Remove the presser bar by lifting it from above, and the presser bar spring. 24.
  • Page 14 28. Remove the two screws securing the upper shaft metal, and the upper shaft assembly. 29. Remove the screw and the N.P. board assembly. 30. Remove the screw and the tension pulley holder. 31. Remove the two feed rod tension springs. 32.
  • Page 15 38. Attach the base plate using the three screws. 39. Attach the power supply unit assembly using the two screws, and insert the inlet connector. 40. While attaching the timing belt, assembly the lower shaft assembly using the metal presser and screw. 41.
  • Page 16 -14-...
  • Page 17 48. Attach the thread take-up shaft using the screw. 49. Insert the tension plate. 50. Attach the presser spring using the collar and screw. 51. Insert and attach the presser foot lifter using the presser lifter shaft. 52. Insert and attach the presser bar into the presser bar clamp. 53.
  • Page 18 -16-...
  • Page 19 56. Attach the ZPM holder assembly using the two screws. 57. Attach the needle bar supporter assembly using the two springs. (Insert into the needle bar clamp and needle bar crank rod) 58. Attach the needle bar supporter stud holder using the screw. (Insert the needle bar supporter arm into the pin on the needle bar supporter.) 59.
  • Page 20 -18-...
  • Page 21 67. Attach the rear cover using the three screws. 68. Attach the needle plate assembly using the two screws. 69. Connect the five connectors, and attach the front cover using the three screws. (When inserting the touch panel connector, confirm that the lock on the main board connector is open.) When the front cover has been removed, always adjust the touch panel after assembling the front cover.
  • Page 22 DISASSEMBLING AND REASSEMBLING THE EMBROIDERY UNIT Remove the screw and Y carriage cover. Remove the screw, and remove the side cover from the lower side. Remove the two screws and pull the main cover to the right. Remove the three screws and the base cover. Assembly Point Securely fit the bottom rear part of the side cover into the base cover.
  • Page 23 LEAD WIRE ARRANGEMENT (PC-8200, Model 985) -21-...
  • Page 24 III. HOW TO ADJUST MECHANICAL ELEMENTS 1. POSITION OF TOUCH PANEL (Be sure to adjust the touch panel after reconnecting the touch panel connector.) ......................23 2. SETTING THE TEST MODE..................24 3. TENSION OF MOTOR BELT AND TIMING BELT..........25 4. NEEDLE DOWN POSITION ADJUSTMENT............26 5.

  • Page 25: Position Of Touch Panel

    POSITION OF TOUCH PANEL (Be sure to adjust the touch panel after reconnecting the touch panel connector.) STANDARD The deviation between the liquid crystal display and touch panel should be within 1 mm when the touch panel is pressed. ADJUSTMENT While pressing the start/stop, reverse stitch and needle position buttons, turn on the power to display the screen for the touch panel adjustment mode.

  • Page 26: Setting The Test Mode

    SETTING THE TEST MODE BASIC TEST MODES To set the test mode, turn on the power switch while holding down the start/stop button and backtack button simultaneously. Numerals will appear on the touch panel. The respective test mode will be entered when the numeral is pressed.

  • Page 27: Tension Of Motor Belt And Timing Belt

    TENSION OF MOTOR BELT AND TIMING BELT STANDARD There should be a 4-6 mm slack in the motor belt when the center of the motor belt is pressed with a force of 200g. There should be a 3-4 mm slack in the timing belt when it is pressed with a force of 200g. ADJUSTMENT Timing belt Loosen the screw of the belt adjusting pulley.

  • Page 28: Needle Down Position Adjustment

    NEEDLE DOWN POSITION ADJUSTMENT STANDARD When test mode "4" is selected, the needle should be exactly at the middle of the needle plate hole in the needle down position. ADJUSTMENT Select test mode "4". Turn the balance wheel to move the needle to the needle down position. Loosen the screw securing the zigzag connecting rod assembly.

  • Page 29: Timing Of Needle And Rotary Hook (Clearance Between The Needle And The Rotary Hook Point)

    TIMING OF NEEDLE AND ROTARY HOOK (CLEARANCE BETWEEN THE NEEDLE AND THE ROTARY HOOK POINT) STANDARD When test mode "5" is selected and the needle is raised 2.9-3.3 mm from its lowest position, the rotary hook point should be positioned at the right side of the needle. The clearance between the needle and the rotary hook point should be 0.1 mm or less, and they should never touch each other.

  • Page 30: Needle Bar Height

    NEEDLE BAR HEIGHT STANDARD When test mode "5" is selected, turn the balance wheel so that the needle meets the rotary hook point. At this time, the clearance between the upper end of the needle eye and the bottom of the rotary hook point should be 1.0-1.4 ADJUSTMENT Select test mode "5".

  • Page 31: Lower Shaft

    LOWER SHAFT Attach the bushing presser L temporarily so as the center of lower shaft is positioned higher by 1 mm against the center of eccentric metal. Install the outer rotary hook. 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: Front/Back, Left/Right Position Of Feed Dog

    FRONT/BACK, LEFT/RIGHT POSITION OF FEED DOG STANDARD When test mode "6" is selected, move the feed dog front/back and left/right. At this time, the feed dog should not contact the needle plate. When the front/back position is the maximum feed amount, the clearance between the feed dog and needle plate at the feed start position (when feed dog is at very front) should be 0.5 to 1.0.

  • Page 33: Height Of Feed Dog

    HEIGHT OF FEED DOG STANDARD When the balance wheel is turned to raise the feed dog to its highest position, the standard height of the feed dog above the needle plate should be 0.9-1.1 mm. ADJUSTMENT Turn the balance wheel to raise the feed dog to its highest position. Loosen the screw securing the vertical feed roller shaft.

  • Page 34: Presser Bar Height

    PRESSER BAR HEIGHT STANDARD The clearance from the needle plate top to the bottom of the presser bar should be 7.0-7.5 mm. ADJUSTMENT Raise the presser foot lifter. Loosen the screw of the presser bar guide bracket. Adjust the height of the presser bar by moving it vertically. Tighten the screw of the presser bar guide bracket.

  • Page 35: Checking Detection Of Fabric Thickness (If A New Main Pc Board Is Installed, This Adjustment Must Be Performed.)

    CHECKING DETECTION OF FABRIC THICKNESS (If a new main PC board is installed, this adjustment must be performed.) STANDARD When the fabric thickness is set to 0 mm and 3 mm in test mode "2", the buzzer should sound twice if operation is normal.

  • Page 36: Position Of Buttonhole Switch Lever

    POSITION OF BUTTONHOLE SWITCH LEVER STANDARD When the buttonhole lever is lowered, the clearance of front part of buttonhole foot is 1.5 mm and the presser foot lever is lowered BH 0 should touch BH 1. ADJUSTMENT Turn on power switch and select pattern Fit the buttonhole foot (A).

  • Page 37: Bobbin Winder

    BOBBIN WINDER STANDARD The thread should be wound parallel to the bobbin and around about 85-90% of the bobbin at low speed.(A) The clearance between the bobbin winder switch and the bobbin winder assembly should be 0.5-1.0 mm.(B) ADJUSTMENT 1. Remove thread guide cover by lifting it from above. 2.

  • Page 38: Bobbin Thread Detector

    BOBBIN THREAD DETECTOR STANDARD When the amount of the bobbin thread has decreased until the bobbin diameter is 11.4-11.8 mm, the message "Bobbin thread is running out." should appear on the display. ADJUSTMENT Select test mode No.10 on the touch panel. Turn the balance wheel in its normal rotation direction, align the opening of the outer rotary hook with the photo diode, and make sure that "0.0"...

  • Page 39: Inner Rotary Hook Bracket Position

    INNER ROTARY HOOK BRACKET POSITION STANDARD When the inner rotary hook bracket and the rotary hook meet, the spring of the inner rotary hook bracket and the inner rotary hook should overlap each other by 1.9-2.1 mm. ADJUSTMENT Loosen the screw securing the inner rotary hook bracket. Adjust the position of the inner rotary hook bracket by moving it vertically and/or horizontally.

  • Page 40: Large One-Point Pattern Shape (Soft Adjustment)

    LARGE ONE-POINT PATTERN SHAPE (SOFT ADJUSTMENT) STANDARD When pattern adjustment "3" is selected in test mode and the start/stop button is pressed, the vertical and horizontal separation of the test pattern outline should be 1 mm or less. ADJUSTMENT Select "3" pattern adjustment in the test mode. Press the start/stop button and sew the test pattern outline.

  • Page 41: Feed Adjustment (Vertical Feed)

    FEED ADJUSTMENT (VERTICAL FEED) STANDARD Adjustment of the pattern should be possible in test mode "3". ADJUSTMENT Loosen the screw securing the pulse motor. Rotate the pulse motor and adjust the pattern. * Make sure not to contact the main PC board during the adjustment. * Install presser foot N before the adjustment.

  • Page 42: Inner Rotary Hook Tension

    9. Needle threader does not work when you use the side-cutter. Thread the needle before attaching the side cutter. 10. When doing embroidery, use a #11 needle. Use special Brother #50 embroidery thread and #50-#80 silk thread for the embroidery thread.

  • Page 43: (Checking The Hook Position In Horizontal Direction)

    NEEDLE THREADER (CHECKING THE HOOK POSITION IN HORIZONTAL DIRECTION) STANDARD The measure from inside of the hook guard to the center point of hook is 0.42 mm. CHECK As sewing needle HA X1 (#14) is standard, so prepare five brand-new sewing needles HA X1 (#14) and check by changing all of these.

  • Page 44: Needle Threader (Checking The Hook In Standard Position)

    NEEDLE THREADER (CHECKING THE HOOK IN STANDARD POSITION) STANDARD The clearance between the top of hook and the top of needle eye is 0 mm. Threading is possible when needle is located higher than 8 mm from the needle plate. CHECK (refer to illustration) Case A Hook position is too high.

  • Page 45: Timing Belt Tension For The X Direction

    EMBROIDERY UNIT ADJUSTMENTS TIMING BELT TENSION FOR THE X DIRECTION STANDARD There should be 4 ± 1 mm slack in the timing belt looped around the X driving shaft and the X tension pulley shaft, when the center of the belt is pressed by a force of 120g after the X carriage unit is moved all the way to the right. ADJUSTMENT Move the X carriage unit all the way to the right.

  • Page 46: Timing Belt Tension For The Y Direction

    TIMING BELT TENSION FOR THE Y DIRECTION STANDARD There should be 4 ± 1 mm slack in the timing belt when the center of timing belt at the Y drive shaft and Y tension pulley is pressed with a force of 120g after the Y carriage is moved all the way forward. ADJUSTMENT Move the Y carriage all the way forward.

  • Page 47: Adjusting The X Belt Presser

    ADJUSTING THE X BELT PRESSER Move the X pulse motor gear in the direction shown in the illustration, then move the X carriage and tighten the X belt presser screw at the point where the initial rubber contacts the X pulse motor gear. After the X carriage is moved to the left, be sure that the X pulse motor gear does not contact the initial rubber.
  • Page 48 IV. HOW TO ADJUST ELECTRONIC ELEMENTS 1. When power is turned on, buzzer does not sound and nothing appears on display ....................47 2. After the power is turned on, 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 and horizontal feed pulse motors when needle bar is lowered.) ......47 3.
  • Page 49 * You must turn off the power and remove connectors from printed circuit boards before measuring resistance. PROBLEM CHECK REMEDY 1. When power is turned 1) Has the display contrast been adjusted? 1) Adjust the contrast. on, buzzer does not 2) If the voltage between both inlet terminals is 2) Replace the power cord.
  • Page 50 5. Operation of main 1) When turning on power and moving speed slide, does 1) Replace (SS) VR board assembly. motor is not stable, voltage between pins 3 and 1 of connector CN9 (for maximum speed speed slide) change from 0 to 5 VDC? operation is not 2) When turning balance wheel opposite its normal 2) Replace NP board assembly.
  • Page 51 11. Thread tension is not 1) Is thread route correct? 1) Check thread route. correct. 2) Are the 0 mm and 3 mm fabric thickness adjustments 2) Check. correct? 3) Turn off power and lower presser foot. When turning 3) Adjust or replace ATPM holder AT pulse motor gear manually, does it turn easily, and complete.
  • Page 52 18. Bobbin thread detector 1) Are both ends of bobbin thread detector correctly 1) Correct directions of bobbin thread does not operate positioned? detector ends. correctly. 2) Is voltage between pins 1-2 of connector CN20 (for 2) Replace photo-diode assembly. bobbin thread detecting LED) approx.
  • Page 53 Main PC board Power supply unit -51-...
  • Page 54 LCD unit Other PC boards (985) -52-...
  • Page 55 PC8200 SG2000 H7070093 -53-...

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