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Brother PE-300S Service Manual

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2. 1999.

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Summary of Contents for Brother PE-300S

  • Page 1     2. 1999.
  • Page 2 This service manual has been compiled for explaining repair procedures of the model PE-300S. 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.

  • Page 3: Table Of Contents

     1. MECHANICAL CHART ..................2 2. POWER TRANSMISSION CHART ..............3 3. ELECTRONIC PARTS ARRANGEMENT CHART........... 4 4. CONTROL SYSTEM BLOCK DIAGRAM ............5 5. MAIN MOTOR CONTROL................6 6. PATTERN GENERATOR ................. 6 7. OTHER ELECTRONIC COMPONENT FUNCTIONS ........6 - 1 -...

  • Page 4: Mechanical Chart

    MECHANICAL CHART EMBROIDERY UNIT MECHANISM - 2 -...

  • 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 - 3 -...

  • Page 6: Electronic Parts Arrangement Chart

    ELECTRONIC PARTS ARRANGEMENT CHART - 4 -...

  • Page 7: Control System Block Diagram

    CONTROL SYSTEM BLOCK DIAGRAM - 5 -...

  • Page 8: Main Motor Control

    In contrast to this, the PE-300S stores the data electronically in memory and uses a zigzag pulse motor to directly rock the needle bar and the feed gear to generate the pattern. In addition, the pulse motors must move the position of the...
  • Page 9      1. DISASSEMBLY AND REASSEMBLY OF THE OUTER PARTS AND MAIN PARTS (SEWING MACHINE) ............8 2. ASSEMBLY AND DISASSEMBLY OF THE EMBROIDERY UNIT ....24 3. LEAD WIRE ARRANGEMENT............... 26 * Note On this machine, the arm bed cannot be setup when the outer components are disassembled. Likewise, damage can result when items are attached to the rear side of arm bed and the machine is carelessly laid on its side or knocked over.
  • Page 10 DISASSEMBLY AND REASSEMBLY OF THE OUTER PARTS AND MAIN PARTS (SEWING MACHINE) Disassembly Remove both screws from needle plate, remove needle plate, remove inner rotary hook. Remove screw from face plate, remove face plate to the left side. Remove all 3 screws from front cover, remove front cover. Remove SS (start/stop) VR board connectors from main PC board.
  • Page 11 - 9 -...
  • Page 12 10. Remove both screws, remove main motor. 11. Remove both screws, remove idle pulley assembly and motor belt. 12. Remove both screws, and remove thread tension unit holder and handle together. 13. Remove screw and remove set plate A. 14. Remove screw and remove set plate B. 15.
  • Page 13 - 11 -...
  • Page 14 22. Remove both screws from bushing presser and remove bushing presser. 23. Remove screws from presser plate, remove thread take-up lever and thread take-up lever shaft. 24. Remove both screws and remove ZPM assembly. -1. Remove screw, remove set plate. -2.
  • Page 15 25-1 25-2 - 13 -...
  • Page 16 38. Remove both screws and remove drop holder assembly. 39. Remove both screws and remove power supply unit. Disassembly Points 39. First disconnect electrical connector lead wire of NP (needle position) board in front of machine from guide of power unit cover. - 14 -...
  • Page 17 - 15 -...
  • Page 18 Assembly 40. Align hole of presser foot lift with hole in the arm bed, attach presser foot lift shaft so that it catches onto guide of presser foot lift. 41. Attach thread tension plate B to arm bed and attach spring. 42.
  • Page 19 45-2 45-1 Diagram A - 17 -...
  • Page 20 54. Attach tension pulley assembly with Allen screw. 55. Set feed link assembly into arm. Attach horizontal feed shaft and fasten with screw. (Be sure to attach one poly washer each to both top and bottom of feed gear.) 56. Insert guide pin holder assembly pin into groove of vertical feed stand. Attach guide pin holder assembly with screw.
  • Page 21 Diagram A - 19 -...
  • Page 22 67. Screw B and C power unit covers to power supply. 68. Screw on BH switch baseboard (with BH switch assembly and sewing light assembly attached) and attach sewing light connectors. 69. Attach rear cover to machine with 4 screws. 70.
  • Page 23 diagram A - 21 -...
  • Page 24 77. Attach connector set plate assembly to rear cover using 2 screws. Run lead wire through grooves in rear cover and set plate guide. 78. Use 3 screws to attach main PC board assembly. Attach connectors in all 10 places. 79.
  • Page 25 - 23 -...
  • Page 26 ASSEMBLY AND DISASSEMBLY OF THE EMBROIDERY UNIT Disassembly Remove screw, and remove X carriage cover. Move X carriage towards the left edge, remove all 4 screws, and remove top cover to the right side. * When doing this, gently slide frontal upper surface of top cover with finger. Remove both screws.
  • Page 27 - 25 -...
  • Page 28 LEAD WIRE ARRANGEMENT - 26 -...
  • Page 29      1. POSITION OF TOUCH PANEL (BE SURE TO ADJUST THE TOUCH PANEL AFTER RECONNECTING THE TOUCH PANELCONNECTOR.) ..............28 2. SETTING THE TEST MODE ................29 3. TENSION OF MOTOR BELT AND TIMING BELT ........30 4.

  • Page 30: Position Of Touch Panel (Be Sure To Adjust The Touch Panel After Reconnecting The Touch Panelconnector.)

    POSITION OF TOUCH PANEL (BE SURE TO ADJUST THE TOUCH PANEL AFTER RECONNECTING THE TOUCH PANEL CONNECT.) 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 positions buttons, turn on the power to display the screen for the touch panel adjustment mode.

  • Page 31: Setting The Test Mode

    SETTING THE TEST MODE BASIC TEST MODE 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 32: Tension Of Motor Belt And Timing Belt

    TENSION OF MOTOR BELT AND TIMING BELT STANDARD When gently pressing the center of the driving belt with a finger tip, there should be about 4-4.5mm of slack. (Press using approximately 0.6N(60g) of force.) When gently pressing the center of the timing belt with a fingertip, there should be 4-4.6mm of slack. (Press using approximately 2N(200g) of force.) ADJUSTMENT •...

  • Page 33: Timing Of Rotation Shutter And Up-Down Feed Cam

    TIMING OF ROTATION SHUTTER AND UP-DOWN FEED CAM STANDARD When needle bar is in highest position, foundation hole of vertical shaft pulley should be facing front of sewing machine. At this time, base line of outer rotary hook pulley should also be facing front of sewing machine. Phases of base line of rotation shutter even with screw hole and foundation hole of vertical shaft pulley should be the same.

  • Page 34: Needle Down Position Adjust Timing Belt

    NEEDLE DOWN POSITION ADJUSTMENT STANDARD Set machine to test mode and select (3) 3-point needle drop. The needle should straight come down through the middle of the left, right and center needle plate holes. ADJUSTMENT Set machine to test mode and select (3) 3-point needle drop. Press the •...

  • Page 35: 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 While in test mode (3) 3-point needle drop, select left needle drop. When the needle is raised 2.75-3.15mm from its lowest position, the rotary hook point should clear the outer side of the needle. When using a #11 needle, the clearance between the needle and outer rotary hook point should be under 0.1mm.

  • Page 36: Needle Bar Height

    NEEDLE BAR HEIGHT STANDARD While in test mode (3) 3-point needle drop, select left needle drop, turn balance wheel with your hand so needle (#11 needle) meets that outer rotary hook point. At this time, the distance between the top of the needle eye and the bottom of the rotary hook point should be 1.0-1.4mm.

  • Page 37: Front/Back, Left/Right Position Of Feed Dog

    FRONT/BACK, LEFT/RIGHT POSITION OF FEED DOGS STANDARD Select test mode (5) feed dog position. When feed dog moves back and forth, they should not come into contact with needle plate. Regarding feed dog position, when feed dog is in the forward position, there should be 0.5- 1.1mm of clearance between center feed dog and grooves in needle plate.

  • Page 38: Feed Dog Height

    FEED DOG HEIGHT STANDARD Feed dog should come 0.9-1.1mm above top of needle plate when feed dog is in their highest position. ADJUSTMENT Turn balance wheel until feed dog is in the highest position. Loosen eccentric collar screw of up-down feed arm. Turn groove of eccentric collar with the tip of a standard screwdriver, adjust height of feed dog so it comes between 0.9-1.1mm.

  • Page 39: Presser Bar Height

    PRESSER BAR HEIGHT STANDARD If presser bar is set to appropriate height and presser foot lifter is raised (up one step), the distance between top surface of needle plate and bottom of presser bar should be between 6.0-6.5mm. ADJUSTMENT Remove BH switch base board. Raise presser foot lifter up one step.

  • Page 40: Button Holer (Position Of Buttonholer Lever)

    BUTTON HOLER (POSITION OF BUTTONHOLE LEVER) STANDARD When the BH (buttonhole) lever is lowered, the clearance of the front part of the buttonholer foot (A) should be 1.5mm, and when the presser foot lifter is lowered, BH0 should touch BH1. ADJUSTMENT Flip on power switch, select button holing stitch (bar tack).

  • Page 41: Bobbin Winder (Adjust Bobbin Winder Switch)

    BOBBIN WINDER (ADJUST BOBBIN WINDER SWITCH) STANDARD Thread should be wind parallel to the bobbin and around about 75-95% of the circumference of the bobbin. During bobbin winding, loosen bobbin winder switch 1-1.2mm and switch on. ADJUSTMENT Loosen screw on bobbin winder switch and adjust the overlap of bobbin winder switch. Tighten screw on bobbin winder switch.

  • Page 42: Inner Rotary Hook Bracket Position

    INNER ROTARY HOOK BRACKET POSITION STANDARD There should be 1.9-2.1mm overlap between inner rotary hook bracket spring and convex part of inner rotary hook. ADJUSTMENT Loosen screw on inner rotary hook bracket. Adjust the overlap so that it is 1.9-2.1mm between inner rotary hook bracket spring and convex part of inner rotary hook.

  • Page 43: Thread Tension (Uper Thread Tension)

    THREAD TENSION (UPER THREAD TENSION) STANDARD Set upper thread tension dial to the right of "5". Using #60 spun polyester thread, slowly pull thread down with tension gauge using a force of 0.33-0.38N(33-38g). ADJUSTMENT Set thread tension dial so that the space to the right of "5" is in the uppermost position as shown in diagram below.

  • Page 44: Setting Z Gear

    SETTING Z GEAR STANDARD Line up indicator marks on release cam and ZPM gear evenly with mark on shaft. Line up indicator marks on ZPM and Z gears, and set gears. ADJUSTMENT (release cam) Loosen screw on release cam. Align indicator marks on release cam and ZPM gear to mark on shaft. Tighten screw on release cam.

  • Page 45: Feed Adjustment (Gear Backlash)

    FEED ADJUESTMENT (GEAR BACKLASH) STANDARD When test mode (6) initial feed position is selected, clearance between FPM gear and rubber stop of initial plate should be 1.0-2.0mm. F gear and FPM gear should be set so that F gear moves freely with no clearance. ADJUSTMENT Remove both screws from set plate C.

  • Page 46: Needle Threader

    NEEDLE THREADER USING THE NEEDLE THREADER There are a wide variety of different needles and sewing machine threads available. The right ones should be selected in accordance with the sewing conditions. The accessory needle threader is designed to make threading of needles easier, but it cannot handle every single circumstance of use (combinations of needle and thread) that may occur.

  • Page 47: Needle Threader (Exchange)

    In case that, hook does not go through eyelet of some needles..Needles through which the hook does not go through are defective. (Example for checking) When you check five brand-new sewing needles HA130 (#9) on condition that it achieves 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.

  • Page 48: Needle Threader

    NEEDLE THREADER (CHECKING THE HOOK POSITION IN VERTICAL DIRECTION) ADJUSTMENT Loosen positioning supporter screw. Raise and lower the positioning supporter very slightly and check that there is 0mm clearance between top of hook and top of needle eye. (a) When hook point is too high Lower positioning supporter a tiny bit.

  • Page 49: Timing Belt Tension For The X Direction

    TIMING BELT TENSION FOR THE X DIRECTION (EMBROIDERY UNIT) STANDARD There should be 2-4mm slack in the belt when looped around the X driving pulley shaft and the X tension pulley shaft when center of the belt is pressed with a force of 100g after the X carriage unit is moved all the way to the right.

  • Page 50: Timing Belt Tension For The Y Direction

    TIMING BELT TENSION FOR THE Y DIRECTION (EMBROIDERY UNIT) STANDARD There should be 2-4mm slack in the belt when belt is looped around Y driving pulley and Y tension pulley shaft and depressed in the center with a force of 100g after the Y carriage is moved all the way forward. ADJUSTMENT Move Y carriage assembly all the way forward.
  • Page 51      1. When power is turned on, buzzer does not sound and nothing appears on display ..................50 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 is raised.

  • Page 52: When Power Is Turned On, Buzzer Does Not Sound And Nothing Appears On Display

    * Turn off the power and remove connectors from printed circuit boards before measuring resistance. * Refer to diagrams for location of check points. PROBLEM CHECK REMEDY 1. When power is 1. Has the display contrast been adjusted? 1. Adjust the contrast. turned on, 2.

  • Page 53: Operation Of Main Motor Is Not Stable, Maximum Speed Operation Is Not Possible, Or Speed Cannot Be Adjusted

    PROBLEM CHECK REMEDY 5. Operation of main 1. When turning on power and moving speed 1. Exchange SS (VR) PC board assembly. motor is not slide, does voltage between pins 3 and 7 stable, maximum connector CN4 (for speed slide) change from 0 speed operation to 5 VDC? is not possible, or...

  • Page 54: Foot Controller Does Not Operate Normally When Depressed

    PROBLEM CHECK REMEDY 10. Foot controller 1. Is resistance between pins 2-3 of foot controller 1. Replace pin jack assembly connector (CN1 of NP board) 1 Ω or less when does not operate there is no pin jack and ∞ with a pin jack? normally when depressed.
  • Page 55 Main PC board Presser switch SSVR Touch panel BHSW Bobbin winder switch Speed sensor Main motor control NP sensor Zigzag pulse motor Feed pulse motor Card Embroidery unit connector Power source 2 Power supply unit NP board (CN2) Main PC board Lamp (CN6) Transformer...
  • Page 56 Other PC boards Needle thread breakage detector NP board Speed VR Main PC board (CN13) Main PC board (CN9) NP sensor Main PC board Power source 1 Foot controller Needle thread breakage detector board Needle thread breakage detector X initial sensor board Y initial sensor board SSVR Board - 54 -...
  • Page 57 PE-300S H8080132...

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