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Brother ULT2003D Service Manual
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Brother ULT2003D Service Manual

Computerized sewing machine
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Summary of Contents for Brother ULT2003D

  • Page 2 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

    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................5 6. PATTERN GENERATOR ................. 6 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...

  • Page 7: Control System Block Diagram

    CONTROL SYSTEM BLOCK DIAGRAM 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 this machine adopts Pulse width modulation (PWM) control using Field Effect Transistor (FET).

  • Page 8: Pattern Generator

    PATTERN GENERATOR For conventional sewing machines, the pattern was generated by rocking the needle bar and the feed regulator by means of a pattern cam onto which the pattern data had been mechanically engraved. In contrast to this, this model stores the data electronically in memory and uses a feed pulse motor, horizontal pulse motor and a zigzag pulse motor to directly rock the needle bar and the feed regulator to generate the pattern.

  • 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 1. DISASSEMBLING AND REASSEMBLING THE OUTER PARTS AND MAIN PARTS............9 2. LEAD WIRE ARRANGEMENT............... 23...
  • 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 notch on the right side of the upper cover, and while holding it to the right remove the upper cover.
  • Page 12 10. Remove the presser holder and needle. 11. Remove the 17 connectors, the four screws, and the main PC board. 12. Remove the screw and thread winding assembly. 13. Remove the three screws and NP base assembly. 14. Remove the two washers. Remove the 2 screws and the wire support plates. Remove the wire assembly . 15.
  • Page 13 -11-...
  • Page 14 23. Remove the connector, then remove the two screws and the thread cutter unit. 24. Remove the screw and the inner rotary hook rotation prevention bracket. 25. Remove the presser bar clamp screw. 26. Remove the presser bar by lifting it from above, and the presser bar clamp and presser spring. 27.
  • Page 15 30. Remove the 4 screws from the horizontal feed shaft supporter and the feed adjustment unit shaft supporter. Remove the horizontal feed assembly. 31. Pull out the motor connector. Remove the 3 screws and the power supply unit. 32. Remove the motor belt and the 2 screws and the main motor. (When removing the motor from the motor holder, remove the motor fan then remove the 2 screws.) 33.
  • Page 16 38. Use the presser plate and the screw to attach the lower shaft assembly. 39. Position the outer rotary hook assembly and the three washers to the lower shaft assembly (see diagram below) and attach with the screw. 40. Run the upper shaft through the timing belt and attach with the two presser plates and the screws. 41.
  • Page 17 -15-...
  • Page 18 46. Attach the thread take-up shaft using the screw and presser plate. 47. Attach the lifter and the presser foot lifter with the presser foot shaft. 48. Attach the presser frame assembly using the two screws. 49. Insert and attach the presser bar with spring into the presser bar clamp. 50.
  • Page 19 -17-...
  • Page 20 53. Attach the ZPM holder assembly using the three screws. 54. Wrap the lead wire cord, then tighten the 2 screws on the 2 cord holders. 55. Attach the needle bar supporter assembly using the two springs. (Insert into the needle bar clamp and needle bar crank rod) 56.
  • Page 21 63. When installing the bobbin winder assembly, align the tab (C) in the bobbin winder assembly holder with the positioning hole in the sewing machine. 64. Insert the connectors correctly and pass the lead wires under the guides (E). -19-...
  • Page 22 66. Put the thread winder cover on the thread winder assembly. 67. Attach the rear cover using the three screws. 68. Attach the needle plate assembly using the two screws. 69. Connect the three connectors, and attach the front cover using the three screws. (When inserting the flat cable, confirm that the lock on the main board connector is open.
  • Page 23 DISASSEMBLING AND REASSEMBLING THE EMBROIDERY UNIT Remove the screw and X carriage cover. Remove the screw, and remove the YPM cover. Remove the four screws and pull the main cover to the right. Remove the four screws and the base cover. Attach in the opposite order from when disassembling the unit.
  • Page 24 Embroidery unit - Quiet parts assembly method In the case of X: Insert on end of the spring (c) into the small hole (dia. 1mm) of the X driving gear pulley B (e). Insert the other end of the spring into the small hole of the X driving gear pulley A (c), put the 3 parts (d), (c) and (e) together, rotate (c) and hold so that (e) and the dia.
  • Page 25 LEAD WIRE ARRANGEMENT -23-...
  • Page 26 III. 1. POSITION OF TOUCH PANEL (Be sure to adjust the touch panel after reconnecting the touch panel connector.) ..................25 2. SETTING THE TEST MODE ................26 3. TENSION OF MOTOR BELT AND TIMING BELT ........31 4. NEEDLE DOWN POSITION ADJUSTMENT ..........32 5.

  • Page 27: 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 28: 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 29 NO07 Feed dog height Feed dog height Refer to 41 NO08 Whip stitch Whip stitch pattern NO09 Sample fabric straight line Sample fabric straight line NO010 Bobbin thread detector Refer to 46 condition display mode NO011 Upper thread breakage sensor Upper thread breakage sensor display mode display mode...
  • Page 30 NO014 Rotation count mode Rotation count mode Check maximum rotation count When the maximum rotation count (850 RPM) is measured, the buzzer will sound intermittently NO015 Electricity measurement pattern Electricity measurement pattern NO016 All type SW monitor mode All type SW monitor mode Presser foot SW, BHSW, BW front/back SW (2SW)
  • Page 31 NO022 NP sensor condition check NP sensor condition check Check the angle of the top shaft by the buzzer: 5° -- 50°: no buzzer 50° -- 75°: buzzer sounds 75° -- 125°: no buzzer 125° -- 169°: buzzer sounds 169° -- 273°: no buzzer 273°...
  • Page 32 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. When new main PC board assembly is installed: ∗ Make adjustments using test modes "2" and "3" and "25". When the main PC board is replaced, upgrade the software to the newest version.

  • Page 33: Tension Of Motor Belt And Timing Belt

    TENSION OF MOTOR BELT AND TIMING BELT STANDARD There should be a 1.5-3.5 mm slack in the motor belt when the center of the motor belt is pressed with a force of 1N (100g). There should be a 3-4 mm slack in the timing belt when it is pressed with a force of 2N (200g). ADJUSTMENT Timing belt Loosen the screw of the belt adjusting pulley.

  • Page 34: 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 35 Test mode for main PC board only (3-point needle drop, alarm check) Turn on the power with the front cover removed. Press the SW5 switch. The main seam position will change each time it is pressed: left seam position middle seam position right seam position.

  • Page 36: Timing Of Needle And Rotary Hook

    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 37: 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 mm.

  • Page 38: 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 39: 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 0.3 to 1.2 mm.
  • Page 40 Test mode for main PC board only Feed dog position, thread cutting check Turn on the power with the front cover removed. (Disregard whether the needle is up or down and run Z, F, S, AT initialization.) Press the SW4 switch. Feed dogs = change between the left position and right position each time the switch is pressed.

  • Page 41: 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 42: 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 once if operation is normal.

  • Page 43: 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 44: Adjusting The Upper Thread Tension

    ADJUSTING THE UPPER THREAD TENSION [Adjustment standard] While displaying the test mode screen (Fig. 1), the tension is to be 52 to 62 cN (53 to 63 gf) when a schappe (#60) thread is gently pulled with a tension gauge. [Adjustment procedure] Enter the test mode.
  • Page 45 Adjusting the upper thread tension (Initial adjusting system - Adjustment method for when the thread tension plate assembly parts have been replaced) [Adjustment procedure] Perform steps 1 to 5 of the adjustment procedure on the previous page. Rotate the thread tension cam counterclockwise by hand so that it is almost as shown by arrow (a). (At this time, the thread tension cam moves in steps of 7.5°.) Check (gap (b)) that the initial adjust plate can move to the right side, and tighten the screw when the rubber is touching the tab of the thread tension cam.

  • Page 46: 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 47: Bobbin Winder

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

  • Page 48: 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 49: 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 1.7 ± 0.1 mm. ADJUSTMENT Loosen the screw securing the inner rotary hook bracket.

  • Page 50: 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 51: 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. ∗...

  • Page 52: Inner Rotary Hook Tension

    INNER ROTARY HOOK TENSION STANDARD While slowly pulling polyester thread #60/3 plies using a tension gauge, inner rotary hook tension should be 0.11-0.13N (11-13g). The difference between this and the tension for silk thread (#80) should be 0.02-0.03N (2-3g). ADJUSTMENT Pass polyester thread #60 through the inner rotary hook correctly, and pull it using the tension gauge.

  • Page 53: 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 54: (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 55: Needle Threader (Exchange)

    NEEDLE THREADER (EXCHANGE) HOW TO REPLACE NEEDLE THREADER Remove the needle and lower the presser foot lifter. Lower the needle threader lever as far as possible. With the hook rotated, push down on the needle threader device to remove it. (Push down on the portion of the thread guide assembly shaded in the illustration.) Place the new device so that groove S and groove T of the hook assembly and thread guide assembly are aligned with pin A, as shown in the illustration.

  • Page 56: 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 57: Timing Belt Tension For The X Direction

    EMBROIDERY UNIT ADJUSTMENTS TIMING BELT TENSION FOR THE X DIRECTION STANDARD There should be 4 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 1.2 ± 0.12N (120 ± 10g) after the X carriage unit is moved all the way to the right.

  • Page 58: Timing Belt Tension For The Y Direction

    TIMING BELT TENSION FOR THE Y DIRECTION STANDARD The distance between the backs of both sides of the timing belt should be 4.2 mm (about 8 mm of slack) as shown in the diagram and there should be a load of 1.5±0.2 N (150±20 gf) after the Y carriage is moved all the way forward and a 5 N (500 g) push/pull gauge is applied to the center of the timing belt between the Y drive shaft and the Y tension pulley.

  • Page 59: Fd Upgrade Procedure

    FD UPGRADE PROCEDURE Operations on the Sewing Machine Hold down the bobbin winding button while turning on the machine. After 5 seconds, release the bobbin winding button. The following message will appear on the LCD, and the machine will be in UPGRADE mode. Display: UPGRADES AND UPDATES INSERT FLOPPY DISK NO1 AND PRESS THE BOBBIN WINDING START/STOP BUTTON.
  • Page 60 1. When power is turned on, buzzer does not sound and nothing appears on display ..................59 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.).....
  • Page 61 ∗ You must turn off the power and remove connectors from printed circuit boards before measuring resistance. PROBLEM CHECK REMEDY 1. When power is 1) Has the display contrast been adjusted? 1) Adjust the contrast. turned on, buzzer 2) Is the voltage between the AC inlet connectors (CN2 on 2) Replace the inlet assembly.
  • Page 62 6. Operation of 1) When moving the speed slide, does the voltage between 1) Replace the VR PC board main motor is not pins 4-2 on the VR PC board connector (CN 8 on the card assembly. stable, maximum PC board) change between DC 0V and DC 3.3V? speed operation 2) Does the voltage between pins 1-6, 4-6, 5-6 on the NP PC 2) Replace the NP PC board...
  • Page 63 12. Thread tension is 1) Is thread route correct? 1) Check. not correct. 2) Were adjustments made for fabric thickness? 2) Check the fabric thickness adjustment. 3) Replace the AT pulse motor. 3) Is the resistance for the pins on the thread tension pulse Ω...
  • Page 64 19. Embroidery unit 1) Is your card a embroidery card? Is the embroidery unit 1) Check. does not work connected to sewing machine correctly? correctly. 2) Is embroidery unit installed in sewing machine correctly? 2) Adjust the torque of the Are timing belt tension, gear meshing, and wiring correct? embroidery frame’s movement.
  • Page 65 Main PC board Feed pulse motor Bobbin thread detector Thread cutter solenoid Zigzag pulse motor Tread tension pulse motor Horizontal feed pulse motor Needle thread detector BH switch Embroidery unit connector Potention meter Needle position sensor board Lamp Power supply board Bobbin switch Bobbin motor Floppy disk drive...
  • Page 66 Card PC board Touch panel VR PC board SS PC board LCD module Memory card Main PC board Inverter Foot controller Other PC boards Switch Main PC board Card PC board Switch Speed volume SS PC board Card PC board VR PC board Needle position sensor Speed sensor...
  • Page 67 ULT2003D S.G.3100D ULT2001N ULT2001C M3000N M3000C 11C03HF114200...