Chapter 12 Troubleshooting. Brother BES-961BC, BES-962BC

Chapter 12 Troubleshooting

Chapter 12 Troubleshooting

If there is any indication of trouble with the machine, check and correct as described in the table. If the trouble cannot be corrected, turn off the power and contact your distributor for corrective actions.

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Chapter 12 Troubleshooting

Mechanical Section

252

Problem

Thread breakage

Check Point

• Is the machine properly threaded?

• Is thread tension too high?

• Is the rotary hook assembly clogged?

• Is there thread in the bobbin?

• Is the needle bent?

• Is there a rough edge or flaw on the needle plate, rotary hook, or bobbin case that might cut the thread?

• Is the needle installed correctly (direction, angle, etc.)

• Is the presser foot in contact with the material?

• Are the thread thickness and needle size correct?

• Is a thread with right-hand twist being used? (If such a thread is used, replace with a thread with left-hand twist.)

• Is there any adhesive on the needle?

• Is the material tension too weak?

• Is there too much play between the outer rotary hook and inner rotary hook?

• Does the outer rotary hook turn smoothly?

• Is the clearance between the rotary hook stopper and the rotary hook adjusted correctly?

• Does the thread come out from the bobbin case smoothly?

Needle (presser foot) interference with embroidery hoop

• Is the embroidery hoop too small?

• Check the size and needle start position in the sewing data.

Needle breakage • Is the needle attached correctly (direction, height, etc.)?

• Is the needle bent?

• Is the rotary hook attached correctly?

• Is the timing set correctly?

• Is there any backlash with the needle bar case (back/forth and right/left)?

• Is the rotary hook stopper correctly attached to stop the rotary hook?

• Is the needle size correct and the tip sharp?

• Does the thread pass through the hole center of the presser foot?

Not embroidered properly

Machine operation abnormal

• Is the material edge caught in the machine?

(Are embroidery hoop and other related parts operating correctly?)

• Is the material stretched properly?

• Is thread tension proper?

Does the lower thread come out smoothly?

• Is any set screw of the rotary encoder loosened?

• Is any set screw of the machine pulley loosened?

• Is any set screw of the machine motor pulley loosened?

• Is embroidery data normal?

• Is the XY carriage belt loosened?

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Chapter 12 Troubleshooting

Problem

Machine operation abnormal

Check Point

• Is the XY carriage belt damaged?

• Are any set screws for the XY pulley loosened?

• Are any set screws for the coupling of the XY pulse motor loosened?

Upper shaft locks at a certain point in one cycle

• Is the thread take-up stopped due to interference with the upper case cover?

[Adjustment]

Thread take-up

Upper case cover Bolt

Needle case

Thread take-up operating lever

Loosen the hexagon socket head cap screw of the thread takeup operating lever and adjust the take-up movable range.

Tighten it securely afterwards.

• Are the needle bar clamp and the top dead center stopper positioned correctly?

Error display • Check the rotary hook of a machine head whose MENDING lamp

(green) is blinking to see if the thread is caught.

[Adjustment]

1.Take out the thread tangled in the rotary hook race so that the rotary hook can be rotated forcibly by manual operation.

2.Check that the machine pulley is set to 100˚ of the scale, and press the END switch.

[Measures]

1.If the thread end is left too long or stitching is left loosened before starting embroidering, the thread is caught in the machine and operation stops.

2.When starting embroidering, hook the thread end on the spring or hold it with a hand.

3.Leave thread of about 60 ~ 70 mm from the needle hole when starting embroidering.

• Is thread tangled in the rotary hook?

Clean the rotary hook.

• Conduct BC sensor test of the PC test mode.

If there is any failure, replace the lower shaft with a new one.

(Refer to "Replacing the Lower Shaft Module".)

Upper shaft pulley does not turn.

• Is the presser foot lifted at a retract position when the power is turned on?

Lower the presser foot for the six machine heads using the lever.

Stitches cannot be made.

• Is the needle attached properly?

• Is the timing of the needle and rotary hook correct?

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Electrical Section

Cautions

• Be sure to turn off the power of the machine and unplug the power cord before checking cable connections.

• When you check connection of the cables as instructed in this manual, also check connection and continuity between connectors.

• Carry out items described in the "Measures" section in order of appearance.

• Some checks and replacement works can be conducted only by repair people. In such cases, contact your dealer.

Symptom

The machine does not operate even if the power is turned on.

Measures

• Is the power cord of the machine plugged in?

Plug in the power cord.

• Is the connector at the rear of the control box connected?

Connect it after checking the connector number and the harness number.

• Is the connector in the control box or the power supply base connected?

Connect it after checking the types and colors of the connectors.

• Is fuse F1 or F2 on the power PCB in the power supply base blown?

Replace the fuse with a new one. If the fuse is blown again, something is faulty. Check to see if the wiring is correct. Replace the control box with a new one.

The machine does not operate even if the power is turned on.

The message, "Release stop SW to operate!", is displayed on the panel.

• Is the stop switch turned on?

Reset the stop switch.

• The message, "Is the presser foot removed?", is displayed on the machine controller when the power is turned on.

• The red LED of head 2 or 4 or 6 does not light and the presser foot remains lowered.

An overtravel error occurs.

The needle stop position error occurs.

• Is the retract bed sensor adjusted properly?

Adjust the retract bed sensor of the faulty head. (Refer to "Replacing the retract bed sensor PCB".)

• Refer to the block diagram showing cable connection and check connection from the retreat bed sensor to the main PCB.

• Check to see if the frame type is set to every other head with the machine controller.

• Is the frame within the cap frame area?

Move the frame within the cap frame area and turn on the power.

• Check to see if the signal of the X area sensor turns ON and OFF in

PORT test mode.

When the signal does not change, refer to the block diagram showing the cable connections and check to see if connection from the X area sensor to the main PCB is proper. Replace the X area sensor with a new one.

• Is the pulley manually turned and out of the stop angle?

Turn the pulley, adjust the needle at the stop position, and reset the error.

• Check the signal of the stop position sensor in the encoder test mode.

Refer to the adjustment or cable connection block diagram and check connection from the needle position detention sensor to the main

PCB. Replace the needle position detection sensor with a new one.

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Symptom

The needle stop position error occurs.

Measures

• Is the main shaft brake solenoid operating?

If not, refer to the block diagram showing the cable connections and check to see if the connections from the brake solenoid to the power

PCB and from connector P27 of the power PCB to connector P1 of the main PCB are proper.

• Check the resistance value of the main shaft brake solenoid at the connector section of the solenoid. The normal resistance value is approximately 50 Ω .

If it is not normal, replace the solenoid with a new one. In this case, the power PCB in the control box may also be faulty. Replace it with a new one if it does not operate properly even after a new solenoid is installed.

• Are there any problems with the main shaft mechanism? (i.e., The screw of the main shaft pulley is loose.)

The needle bar case lock error occurs.

• Is the INDEX motor rotating?

If not, refer to the block diagram showing the cable connections and check to see if connection from the INDEX motor to the main PCB is proper.

Check the resistance values of pins 1 and 2 and pins 3 and 4 at the connector section of the INDEX motor. The normal resistance value is approximately 4.4

Ω

.

If it is not normal, replace the INDEX motor with a new one. Also replace the main PCB with a new one.

• Manually turn the color change pulley.

If it is abnormally heavy, adjust the color change mechanism and the needle cap case.

• Start the machine after invalidating its initial setting and operate the head solenoid in solenoid test mode.

If a certain head and the heads following it do not operate, refer to the block diagram showing the cable connections and check to see if connection of the head communication sign is proper.

• Only head 1 does not operate.

Check the communication line to head 1 and connection of the power harness for head 1.

• Do the rotary switch settings of each head PCB correspond with the numbers of each head?

If not, set them according to the head numbers.

• Start the machine after invalidating its initial setting and enter the CASE test mode. Do figures on the panel change when the color change pulley is manually turned?

If not, check to see if connection from the needle bar position sensor to connector P7 of the head PCB (1) is proper.

• Replace the needle bar position sensor (potentiometer) with a new one.

• Replace the head PCB 1 with a new one.

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Symptom

X-axis or Y-axis home position detection error occurs.

Measures

• Was the XY carriage moving?

If so, refer to the block diagram showing the cable connections and check to see if connection from the X and Y area sensor to the main

PCB is proper.

• Was the XY motor rotating?

If so, check the XY carriage mechanism.

• If the XY motor is not rotating, refer to the cable connection block diagram and check to see if connection from the XY motor to the main

PCB is proper.

The thread breakage error frequently occurs although thread is not broken.

The X-axis motor connector connection error occurs.

The main shaft motor lock error occurs.

ERROR A7 occurs.

ERROR A8 frequently occurs.

• Enter the CASE test mode and turn the thread breakage sensor pulley corresponding to each needle bar of the head with which this error occurs while switching the needle bar from number 1 in ascending order and check to see that the red LED on the head blinks.

If there is no problem, lower the thread breakage sensitivity value of the machine controller. (The standard value is 0.)

• Check connection from the thread breakage sensor PCB to the head

PCB if it does not blink.

• Replace the thread breakage sensor PCB with a new one.

• Refer to the block diagram showing the cable connections and check the connection from the two X motors on the left and right to the main

PCB.

• Enter the encoder signal mode and manually turn the main shaft pulley.

If it is abnormally heavy, the main shaft mechanism is faulty.

• Does the main shaft motor rotate at all when the error occurs?

If it does not rotate at all, check fuse F5 on the power supply PCB in the control box. Refer to the block diagram showing the cable connections and check to see if connection from the main shaft motor to the main PCB is proper. Also check connection of connectors P6 and P4 of the main PCB and connectors P19 and P12 on the power

PCB in the box, and connection from connector P11 of the power supply

PCB to the 14v terminal of the power transformer.

• Manually turn the main shaft pulley in the encoder signal test mode and check to see if the stop position signal and encoder signal are proper.

If either of the signals does not change, refer to the block diagram showing the cable connections and check to see if connection from the encoder and stop position sensor to the main PCB is proper.

• Check the CPU ROM version for the upper shaft.

If it is version A, replace it with the latest ROM of version B or later.

(PROM#4 on the main PCB)

• In the encoder signal test mode, manually turn the main shaft pulley and check to see that the stop position signal is correct.

If the signal does not change, refer to the cable connection block diagram and check to see if connection from the stop position sensor to the main PCB is proper.

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Symptom

Thread is frequently tangled in the rotary hook.

Measures

• Is thread tangled in the rotary hook?

Clean the rotary hook.

• Conduct BC sensor test of the test mode.

If there is any failure, replace the lower shaft module with a new one.

• Conduct automatic out-of-step limit measurement of BC automatic test in the test mode.

Replace the lower shaft module with a new one if there is any fault.

• Check to see if the lower shaft fan of the head with which the error frequently occurs is correctly rotating.

If the fan is at standstill, check to see if connection from the lower shaft fan to the BC PCB is proper. Replace the lower shaft fan with a new one.

• If all the lower shaft fans are at standstill, check fuse F4 on the power supply PCB in the control box.

• Is the hole next to the bed with which the error frequently occurs clogged with dust?

If so, clean it.

The lower shaft motor zero point error occurs.

• Is thread tangled in the rotary hook?

Clean the rotary hook.

• Is the lower shaft with which the error occurs rotating?

If so, check to see if connection from the lower shaft sensor PCB to the BC PCB is proper. Adjust the lower shaft sensor. Replace the lower shaft sensor PCB with a new one.

• If the lower shaft with which the error occurs is not rotating, check to see if connection from the lower shaft motor to the BC PCB is proper.

Replace the lower shaft module with a new one. Replace the BC PCB with a new one.

The lower shaft motor standby position error occurs.

• Is the rotary hook rotated manually?

This is not a fault.

• Check to see if connection from the lower shaft sensor PCB to the BC

PCB is proper. Replace the lower shaft module with a new one.

The lower shaft overheat error occurs.

• Check to see if the lower shaft fan is normally rotating. If the fan is at standstill, check to see if connection from the lower shaft fan to the BC

PCB is proper. Replace the lower shaft fan with a new one.

• If all the lower shaft fans are at standstill, check fuse F4 on the power supply PCB in the control box.

• Is the hole next to the bed with which the error frequently occurs clogged with dust?

If so, clean it.

• Check to see if connection from the thermister of the lower shaft module to the BC PCB is proper.

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Symptom

Lower shaft motor overcurrent error occurs.

Measures

• Is the red LED for the BC PCB off?

If not, refer to the block diagram showing the cable connections and check to see if the connection from the BC PCB to the main PCB is proper.

• Check to see if connection from the lower shaft motor to the BC PCB of the bed on BC PCB whose red LED is off is proper.

Replace the harness or the lower shaft module if a short circuit occurs due to line insertion.

• Measure the resistance values of pin 1 and pin 2, pin 2 and pin 3, pin 3 and pin 4, pin 4 and pin 5, and pin 5 and pin 1 at the connector of the lower shaft motor with the tester and check to see if they are approximately 2.6

Ω .

Replace the faulty lower shaft module with a new one.

• Replace the BC PCB with a new one.

Thread trimming motor zero point error occurs.

• Is lint clogged between the travelling blades?

Remove it.

• Is the thread trimming motor operating?

If so, refer to the block diagram showing the cable connections and check to see if connection from the thread breakage sensor to the main

PCB is proper. Also adjust the thread breakage sensor PCB. (Refer to

"Replacing thread breakage sensor PCB.)

• If it is not operating, refer to the block diagram showing the cable connections and check to see if connection from the thread trimming motor to the main PCB is proper.

• Check to see if connection from connector P3 of the main PCB to connector P9 of the power supply PCB in the control box is proper.

• Check fuse F6 on the power supply PCB in the control box.

If it is blown, replace it with a new one. If it is blown again, replace the power supply PCB.

Power frequency error occurs.

Wiper out error occurs.

• Check to see if connection from connector P16 of the main PCB to connector P10 of the power supply PCB in the control box is proper.

• Refer to the block diagram showing the cable connection and check to see if connection from connector P26 of the power PCB in the control box to connector P7 of the power supply PCB in the power supply base is proper.

• Check fuse F3 on the power supply PCB in the power supply base.

If it is blown, replace it with a new one. If it is blown again, there is a fault somewhere in the 24v system circuit.

• Does the wiper on the error head remain projected?

If the wiper is tangled with a thread, remove it. If the wiper does not return smoothly, adjust it.

• Enter the solenoid test mode and operate the wiper solenoid. Check the icon on the panel.

If a sensor signal is not given, check to see if connection from the wiper sensor to the head PCB is proper. Replace the wiper sensor with a new one. Replace the head PCB with a new one.

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Symptom

Presser foot down error occurs.

ERROR C7 occurs.

Main shaft rotation speed error occurs.

Cylinder bed position error occurs.

Power PCB error occurs.

Cooling fan motor stops.

Exhaust fan motor stops.

When all three fans in the control box stop

Measures

• Is the presser foot attached?

If not, attach it.

• Does it rise and drop immediately?

If so, adjust the presser foot sensor.

• Does the presser foot rise and make some noise for a while?

If so, check to see if connection from the presser foot sensor to the head PCB is proper. Replace the presser foot sensor with a new one.

Replace the head PCB with a new one.

• Does the presser foot move? If it does not move at all, check to see if connection from the presser foot motor to the head PCB is proper.

Replace the presser foot motor with a new one. Replace the head

PCB with a new one.

• Is the lower shaft being tested in the test mode?

If so, refer to the operation method of the test mode and exit the test mode or turn the power off once and on again.

• Turn the power off once and on again. If the same error occurs again, replace the main PCB with a new one.

• Enter the encoder signal test mode and manually turn the main shaft pulley.

If it is abnormally heavy, the main shaft mechanism is faulty.

• Refer to the block diagram showing the cable connections and check to see if connection from the main shaft motor to the main PCB is proper. Also check the connection from connectors P6 and P4 of the main PCB to connectors P19 and P12 of the power supply PCB in the box and the connection from connector P11 of the power PCB to the

14v terminal of the power transformer.

• The bed retract sensor is not adjusted properly. Adjust it properly.

• Check to see if connection from connector P16 of the main PCB to connector P10 of the power supply PCB in the control box is proper.

• Refer to the block diagram showing the cable connections and check to see if connection from connector P4 of the BC PCB to the power supply PCB in the control box, and connection from connector P9 of the main PCB to connector P3 of the power supply PCB in the control box are proper.

• Replace the power supply PCB with a new one.

• Replace the main PCB with a new one.

• Refer to the block diagram showing the cable connections and check to see if connection from connector P5 of the power PCB in the control box to connector P1 of the power supply PCB in the power supply base, and connection from connector P4 of the power supply PCB in the power supply base to the 18v terminal of the power transformer are proper.

• Check fuse F3 on the power supply PCB in the power supply base.

If it is blown, replace it with a new one. If it becomes blown again, the 24v system circuit is faulty.

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Symptom

Only cooling fan motor stops.

Measures

• Check to see if the cooling fans on the left of the main PCB and inward of the power supply PCB are rotating.

If either of them is at standstill, check to see if connection from the cooling fan which is at standstill to P20 or P25 of the power supply

PCB in the control box is proper. If they are connected properly, replace the cooling fan which is at standstill.

• Both cooling fans are rotating.

Check to see if connection from connector P16 of the main PCB to connector P10 of the power supply PCB in the control box is proper.

Replace the main PCB with a new one.

• Check to see if the cooling fan on the right side of the main PCB is rotating.

If it is at standstill, check to see if connection from the cooling fan to

P12 of the main PCB is proper. If they are connected properly, replace the faulty cooling fan.

• The cooling fan is rotating.

Replace the main PCB with a new one.

Power voltage upper or lower limit error occurs.

X-axis motor overcurrent stop occurs.

• Is the voltage set on the panel?

If not, set it according to the power supply voltage of the area where the machine is used.

• Is the tap voltage of the power transformer (terminal connection of mark tube

T) adjusted to the power voltage of the area where the machine is used?

If not, switch the tap connection.

• Check the input voltage values in the power/voltage check test mode.

Measure the power supply voltage with the tester and compare them.

If the voltage value is significantly out of the normal range ( ± 5v or more), calibrate it with the voltage calibration in the test mode.

• When you cannot enter the test mode because this error frequently occurs, set the voltage to a relatively high value with the machine controller if it is E-D2 and to a relatively low value if it is E-D3 to avoid errors. Check and calibrate the voltage in the test mode.

• Check to see if connection from connector P16 of the main PCB to connector P10 of the power supply PCB in the control box is proper.

• Is the power supply abnormally low because a machine with a large capacity (compressor and the like) is used?

Change the power to the other system. Use a stabilizer.

• Replace the power PCB with a new one. Replace the main PCB with a new one.

• Measure the resistance values of pin 1 and pin 2, pin 2 and pin 3, pin 3 and pin 4, pin 4 and pin 5, and pin 5 and pin1 at each connector section of two X-axis motors with the tester and check to see if they are approximately 2.1

Ω

.

Replace the faulty motor with a new one.

• Refer to the block diagram showing the cable connection and check to see if connection from the X-axis motor to the main PCB is proper.

• Replace the main PCB with a new one.

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Symptom

Y-axis motor overcurrent stop occurs.

The following errors frequently occur.

• Lower shaft memory error

• ERROR E5 to ERROR FF

Measures

• Measure the resistance values of pin 1 and pin 2, pin 2 and pin 3, pin 3 and pin 4, pin 4 and pin 5, and pin 5 and pin 1 at each connector section of the Y-axis motor with the tester and check to see if they are approximately 2.4

Ω .

Replace the faulty motor with a new one.

• Refer to the block diagram showing the cable connection and check to see if connection from the Y-axis motor to the main PCB is proper.

• Replace the main PCB with a new one.

• Replace the main PCB with a new one.

Only a certain head does not operate.

Jump solenoids and wiper solenoids of all heads do not operate.

Jump solenoid does not operate.

• Is the head out of action with either the head switch or the machine controller?

• Refer to the block diagram showing cable connections and check to see that other cables are connected to the head switch PCB and the head PCB and the head PCB properly.

• Refer to the block diagram showing cable connections and check to see if connection from connector P4 of the power supply PCB in the control box to connector P6 of the power supply PCB in the power supply base, and connection from connector P5 of the power supply

PCB in the power supply base to the 39 terminal of the power transformer are proper.

• Check fuse F4 on the power supply PCB in the power supply base.

If it is blown, replace it with a new one. The 50v circuit is faulty if the fuse is blown immediately after turning on the power even after replacing the fuse.

• Check to see if connection from the jump solenoid to connector P10 of the head PCB is proper.

• Check the resistance value of the jump solenoid which does not operate with the connector section. The normal resistance value is approximately 56 Ω .

If it is faulty, replace the solenoid with a new one. In this case, the head PCB may also be faulty. Also replace the head PCB with a new one if it does not operate properly even after replacing the solenoid.

• Refer to the block diagram showing the cable connections and check to see if connection from connector P12 of the head PCB to connectors

P7, 8, 13, 14, 15, and 16 on the power supply PCB in the control box is proper.

• Replace the head PCB with a new one.

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Symptom

Wiper solenoid does not operate.

The lower shaft PCB is faulty.

The lower shaft module is faulty.

Measures

• Check to see if connection from the wiper solenoid to connector P11 of the head PCB is proper.

• Check the resistance value of the wiper solenoid which does not operate with the connector section. The normal resistance value is approximately 28 Ω .

If it is faulty, replace the solenoid with a new one. In this case, the head PCB may also be faulty. Also replace the head PCB with a new one if it does not operate properly even after replacing the solenoid.

• Refer to the block diagram showing the cable connections and check to see if connection from connector P12 of the head PCB to connectors

P7, 8, 13, 14, 15, and 16 on the power supply PCB in the control box is proper.

• Replace the head PCB with a new one.

1. Turn off the power of the machine.

2. Disconnect P4 and P10 of the lower shaft PCB.

If the lower shaft PCB is removed from the machine or P8 or P9 is disconnected, the lower shaft connected to other lower shaft PCB will not operate, either.

3. Turn on the power of the machine.

The E-B2 error occurs and the green LED blinks with the head corresponding to the faulty lower shaft. Turn off the pause switch of the head (flip it down) and keep flipping up the mending switch until the green LED stops blinking.

4. If there is just one lower shaft PCB, reset the LEDs of the two heads and reset the error with the STOP key on the panel or the step back key of the head.

1. Turn off the power of the machine.

2. Disconnect P1, P3, and P5 (for a fixed bed) or P2, P4, and P6 (for a retract bed) connected to the lower shaft PCB from the faulty lower shaft module.

3. Turn on the power of the machine.

The E-B2 error occurs and the green LED blinks for the bed corresponding to the faulty lower shaft. Turn off the pause switch of the head (flip it down) and keep flipping up the mending switch until the green LED stops blinking.

4. When the LED of the corresponding head stops blinking, reset the error with the STOP key on the panel or the step back key of the head.

Note:

The above operation will prohibit operation of the lower shaft connected to the faulty lower shaft PCB or the faulty lower shaft module and cause the corresponding heads to pause. This is reset when the power of the machine is turned on again. Start from the step 3 to prohibit the operation again.

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Personal Computer Section

Trouble Check Point

The power lamp does not light up when the computer power switch is turned on.

• Is the cable correctly plugged in the computer?

• Is the AC line live?

The display does not light up when the computer power switch is turned on.

• Is the display power lamp on?

• Is the display's cable correctly connected?

• Is the display's contrast correctly adjusted?

"Windows" cannot be started.

• Is a floppy disk inserted?

"Windows" can be started but the embroidery software cannot.

• Is the selection of other icons possible?

• Is the selected icon correct?

• Can you double-click more quickly?

The window does not open though the machine power is turned on?

• Is the cable to the machine and the interface board correctly connected?

• Is the interface board attached properly? (Refer to Page 39.)

• Is the correct COM port selected? (Refer to Page 131.)

The screen changes when the mouse is not operated for a while.

• The screen saver is preset. Invalidate this function on the control panel screen. Do not validate the power-saving function.

The screen of the editor, the explorer or the production report disappears during operation.

• The machine controller screen was clicked so that the current screen is hidden behind it. Move the mouse to the bottom of the screen and select the program (editor, explorer, or production report).

Colors set for a design and threads are not available.

• The number of colors is set to 256. Increase the number to

65000 or more on the control panel screen.

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