Brother PE-180D Service Manual
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Brother PE-180D Service Manual

Home embroidery machine
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8. 2001.

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  • Page 1 8. 2001.
  • Page 2 • This service manual has been compiled for explaining the repair procedures for the PE-180D HOME EMBROIDERY MACHINES. • Use this service manual in conjunction with the Part List when you make a repair. • This machine is manufactured based on product specifications which are current at the time of printing of this manual.
  • Page 3 Most processes in the manufacturer of LSI devices such as microprocessors involve MOS (metal oxide semiconductor) technology. It is thus necessary to take extreme care to prevent erasure or other damage caused by static electricity during the use and manufacture of products using such LSI devices. This embroidery machine is manufactured and assembled under a strictly controlled system preventing such damage.

  • Page 4: Table Of Contents

    1. MECHANICAL CHART ..................3 2. POWER TRANSMISSION ASSEMBLY (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.

  • Page 5: Mechanical Chart

    MECHANICAL CHART - 3 -...

  • Page 6: Power Transmission Assembly (Vertical Needle Bar Movement,Thread Take-Up Movement And Rotary Hook Movement)

    POWER TRANSMISSION ASSEMBLY (VERTICAL NEEDLE BAR MOVEMENT, THREAD TAKE-UP MOVEMENT AND ROTARY HOOK MOVEMENT) Thread take-up lever Thread take-up Main shaft Upper shaft gear Hand wheel Counter weight Needle bar crank T pulley Vertical shaft gear Needle bar crank Main motor Vertical shaft Needle bar clamp Vertical shaft pulley...

  • Page 7: Electronic Parts Layout Chart

    ELECTRONIC PARTS LAYOUT CHART CONTROL SYSTEM BLOCK DIAGRAM - 5 -...

  • Page 8: Main Motor Control System

    MAIN MOTOR CONTROL SYSTEM The main motor must operate at a constant speed regardless of load fluctuations, temperature fluctuations, or other changes in operating conditions. The main motor is therefore driven by means of PWM (Pulse Width Modulation) control. PATTERN GENERATOR This embroidery machine stores the pattern data to memory, and drives the embroidery frame using the X and Y pulse motors to produce the patterns.

  • Page 9: Other Electronic Component Functions

    OTHER ELECTRONIC COMPONENT FUNCTIONS Start/stop switch ....... Used to start and stop machine operation. When starting, the embroidery machine operates at low speed as long as the switch is pressed. The need will stop in the up position if pressed immediately after the "Raise needle" error message is displayed.
  • Page 10 1. DISASSEMBLY AND REASSEMBLY PROCEDURES FOR EXTERNAL PARTS AND MAJOR COMPONENTS ............9 2. SECURING THE LEADS................12 - 8 -...

  • Page 11: Disassembly And Reassembly Procedures For External

    DISASSEMBLY AND REASSEMBLY PROCEDURES FOR EXTERNAL PARTS AND MAJOR COMPONENTS Raise the presser foot lever, remove the screw, and then remove the face plate from the left side. Remove the two screws of the needle plate and then lift out the needle plate. Loosen the screw of the X carriage cover and then remove the X carriage cover.
  • Page 12 Disconnect the 13 electrical connectors, remove the two screws, and then remove the main PC board. 10. Remove the screws and then remove the embroidery presser foot and needle. 11. Remove the two screws of the thread path assembly, remove the tension spring, and then remove the thread path assembly.
  • Page 13 22. Remove the two screws of the bushing fixation and then remove the vertical shaft. 23. Remove the three screws of the rotary hook shaft frame assembly and then remove the rotary hook unit. 24. Remove the screw and then remove the circuit board mounting plate. 25.

  • Page 14: Securing The Leads

    SECURING THE LEADS Please note the following. Be sure the LCD module leads are not pinched by the handle when passed through the shutter cover and the handle is lifted. The sew light leads 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.
  • Page 15 1. TEST MODE SETTING METHOD..............14 2. TENSION OF MOTOR DRIVE BELT AND ROTARY HOOK SHAFT BELT. 15 3. POSITION OF SENSOR SHUTTER .............. 16 4. ADJUSTMENT OF NEEDLE DROP POINT ..........17 5. CLEARANCE BETWEEN NEEDLE AND ROTARY HOOK POINT AND LOOP LIFT ....................

  • Page 16: Test Mode Setting Method

    TEST MODE SETTING METHOD STANDARD To enter the test mode, press and hold down both the left and right sides of the CHARACTER PATTERNS button 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.

  • Page 17: Tension Of Motor Drive Belt And Rotary Hook Shaft Belt

    TENSION OF MOTOR DRIVE BELT AND ROTARY HOOK SHAFT BELT STANDARD Motor belt tension: The belt should move in by 5 - 7 mm when a force of approximately 2 N (200 g) is applied midway between the drive pulley and motor shaft. Rotary hook shaft belt tension: The belt should move 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.

  • Page 18: Position Of Sensor Shutter

    POSITION OF SENSOR SHUTTER STANDARD When the needle bar is at its highest position, the rotary shutter should be positioned so that the screw is facing toward the front of the machine. ADJUSTMENT Turn the hand wheel to raise the needle bar to its highest position. Loosen the screw of the rotary shutter.

  • Page 19: Adjustment Of Needle Drop Point

    ADJUSTMENT OF NEEDLE DROP POINT STANDARD The needle should enter 0.9 mm inward from the left end of the needle hole in the needle plate when the hand wheel is turned. ADJUSTMENT Turn the hand wheel by hand and observe the position of the needle in the needle hole. Loosen the screw and the set screw of the presser unit.

  • Page 20: Clearance Between Needle And Rotary Hook Point And Loop Lift

    CLEARANCE BETWEEN NEEDLE AND ROTARY HOOK POINT AND LOOP LIFT STANDARD When the needle is raised 2.2 - 2.6 mm from its lowest position, the rotary hook point should be at the side of the needle. The gap between the needle (75/11) and rotary hook point at this time should be less than 0.1 mm with no contact between the rotary hook point and the needle.

  • Page 21: Height Of Needle Bar

    HEIGHT OF NEEDLE BAR STANDARD The distance from the top edge of the needle eye to the bottom of the rotary hook point should be 1.6 - 2.0 mm when the rotary hook point is at the side of the needle by turning the hand wheel. ADJUSTMENT Turn the hand wheel so that the rotary hook point is at the closest point to the needle.

  • Page 22: Adjustment Of Thread Take-Up Spring (Adjustment Of Thread Breakage Shutter)

    ADJUSTMENT OF THREAD TAKE-UP SPRING (ADJUSTMENT OF THREAD BREAKAGE SHUTTER) STANDARD When the thread take-up spring stroke is 8 - 9 mm and test mode 26 is selected, the buzzer should sound when the thread take-up spring is raised 4 - 5 mm from the down position. ADJUSTMENT Select test mode 26.

  • Page 23: Adjustment Of Bobbin Winding (Adjustment Of Bobbin Winder Switch)

    ADJUSTMENT OF BOBBIN WINDING (ADJUSTMENT OF BOBBIN WINDER SWITCH) STANDARD The thread should be wound parallel to the bobbin core to 85% - 90% of the outside diameter of the bobbin. The gap between the bobbin winder switch and the bobbin winder spindle base should be 0.5 - 1.0 mm. ADJUSTMENT Remove the face plate.

  • Page 24: Position Of Inner Rotary Hook Bracket

    POSITION OF INNER ROTARY HOOK BRACKET 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 of the inner rotary hook bracket.

  • Page 25: Adjustment Of Inner Rotary Hook Tension

    ADJUSTMENT OF INNER ROTARY HOOK TENSION STANDARD The inner rotary hook tension should be 0.12 - 0.14 N (12 - 14 g) when a #90 polyester thread is pulled gently using a tension gauge. ADJUSTMENT Thread a #90 polyester thread normally to the inner rotary hook and then pull the thread gently using a tension gauge.

  • Page 26: Adjustment Of Tread Tension Dial

    ADJUSTMENT OF THREAD TENSION DIAL STANDARD When the tension dial is set to [5] and a #60 polyester thread held in the tension disc is pulled gently using a tension gauge, the thread tension should be 0.23 - 0.26 N (23 - 26 g). ADJUSTMENT Set the tension dial to [5].

  • Page 27: Position Of Tension Release Solenoid

    POSITION OF TENSION RELEASE SOLENOID STANDARD When the tension release solenoid is off, the gap between tension release plates A and B should be 0 - 0.5 mm, and the gap between tension release plate A and the tension release solenoid shaft should be 0 mm. ADJUSTMENT Lower the presser foot lever.

  • Page 28: Needle Threader

    NEEDLE THREADER USING THE NEEDLE THREADER The provided needle threader can be used with sewing machine needle sizes 75/11 to 100/16. A 75/11 needle is standard when embroidering, but a 90/14 needle is recommended when working with thick material. OTHER PRECAUTIONS Be sure the embroidery presser foot is down when operating the needle threader.

  • Page 29: Needle Threader (Adjustment Of Needle Threader)

    NEEDLE THREADER (ADJUSTING THE NEEDLE THREADER) STANDARD • When the hook has passed through the hole of the needle (75/11 or 80/12), the hook should be in the middle of the hole with the same clearances between it and the left and right sides of the hole. •...

  • Page 30: Needle Threader (Replacement Of Hook)

    NEEDLE THREADER (REPLACING THE HOOK) • If the point of the hook becomes bent or broken, the hook must be replaced. STANDARD HOOK DIMENSIONS REPLACING THE HOOK Remove the two hook mounting screws. Replace the hook with a new one, and then tighten the two hook mounting screws. Caution •...

  • Page 31: X-Y Carriage (X Timing Belt Tension)

    X - Y CARRIAGE (X TIMING BELT TENSION) STANDARD When the X carriage is positioned all the way to the left, the timing belt should give 2 - 4 mm when pressed with a 1N (100 g) load midway of the belt. ADJUSTMENT Move the X carriage all the way to the left.

  • Page 32: X-Y Carriage (Y Timing Belt Tension)

    X - Y CARRIAGE (Y TIMING BELT TENSION) STANDARD When the Y carriage is positioned all the way to 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 Move the Y carriage all the way to the front.

  • Page 33: X-Y Carriage (Drive Gear Adjustment)

    X - Y CARRIAGE (DRIVE GEAR ADJUSTMENT) STANDARD The drive gears of the X carriage and Y carriage must be assembled with the reference holes in middle gears A and B aligned. The gears must also be assembled to minimize the backlash between the drive motor gear and middle gears and enable the gears to operate silently.

  • Page 34: X-Y Carriage (X Carriage Position)

    X - Y CARRIAGE (X CARRIAGE POSITION) STANDARD The X carriage must be installed perpendicularly to the embroidery machine arm (upper shaft). Select the pre-programmed "frame pattern (square border)", enlarge the size to maximum, and then touch the "TRIAL" to move the embroidery frame: the embroidery presser foot should not contact the inside of the embroidery frame at anywhere.

  • Page 35: Adjustment Of Inner Rotary Hook Holder And Lower Thread Guide Plate

    ADJUSTMENT OF INNER ROTARY HOOK HOLDER AND LOWER THREAD GUIDE PLATE STANDARD • The inner rotary hook holder should be 27.3±0.2 mm above the rotary hook shaft frame. ADJUSTMENT Loosen the mounting screw of the fixed blade holder. Move the inner rotary hook holder so that it is 27.3±0.2 mm above the rotary hook shaft frame. Tighten the mounting screw of the fixed blade holder.
  • Page 36 1. POWER IS ON BUT THE BUZZER DOES NOT SOUND AND NOTHING IS DISPLAYED ON THE LCD................ 35 2. PULSE MOTORS DO NOT CORRECTLY DETECT THE HOME POSITION AFTER THE POWER IS TURNED ON AND THE NEEDLE IS IN THE UP POSITION................35 3.
  • Page 37 ELECTRICAL SYSTEMS TROUBLESHOOTING * When measuring resistance, always turn the power off and disconnect the connector to be measured from the circuit board before taking the measurement. * Refer to the figures for where to check. CONDITION PROBLEM SYMPTOMS COUNTERMEASURES 1.
  • Page 38 CONDITION PROBLEM SYMPTOMS COUNTERMEASURES 3. Pattern 1) Is the start/stop switch stuck? 1) Correct, or replace the SS PC board selection is not assembly. possible. 2) Other 2) Replace the LCD module assembly. 4. Main motor 1) Does the hand wheel turn easily? 1) Correct installation so hand wheel turns does not easily.
  • Page 39 CONDITION PROBLEM SYMPTOMS COUNTERMEASURES 6. Embroidery 1) Is the rotary shutter correctly positioned? 1) Adjust (see page 16.) frame operation 2) Is the resistance between the following 2) Replace the defective pulse motor. is not normal. pulse motor connector pins normal? X (CN16)..
  • Page 40 Main PC board LCD module - 38 -...
  • Page 41 Power supply PC board For 120V AC models For 230 V AC models - 39 -...
  • Page 42 Main motor assembly For 120 V AC models without insulation For 230 V AC models with insulation - 40 -...
  • Page 43 Other PC boards 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 - 41 -...
  • Page 44 PE-180D H1060205...

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