Brother Industries E-100 Installation and maintenance instructions

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3. 2002.

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This service manual has been compiled for explaining repair procedures of this model.
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
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I . PRINCIPAL MECHANISMS............................................................................... 1-0
II . DISASSEMBLY/REASSEMBLY AND INSPECTION PROCEDURES.............. 2-0
III . HOW TO ADJUST ELECTRONIC ELEMENTS ................................................ 3-0
IV. PARTS CATALOGUE........................................................................................ 4-0
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1. Always use rubber gloves when handling printed circuit boards and never touch the metal portion of a printed
circuit board with bare hands.
2. Keep your body earthed in order to avoid generating static electricity.
3. Pack printed circuit boards in aluminum foil and avoid subjecting them to any form of impact during storage
or transportation.
4. Do not touch or damage the metal portion of a printed circuit board with a screwdriver or any other tool while
making repairs or the like.

1-0
I. 
1. TECHNICAL DIAGRAMS.............................................................................. 1-1
2. POWER TRANSMISSION CHART...............................................................1-2
3. WIRING DIAGRAM OF ELECTRONIC COMPONENTS..............................1-2
4. CONTROL SYSTEM BLOCK DIAGRAM ..................................................... 1-3
5. FUNCTIONS OF ELECTRONIC COMPONENTS......................................... 1-4

1-1
1. TECHNICAL DIAGRAMS

1-2
2. POWER TRANSMISSION CHART
(A) Generating mechanism for the needle (thread cartridge)
(B) Thread cartridge installation/removal and thread-cutting mechanism
3. WIRING DIAGRAM OF ELECTRONIC COMPONENTS

1-3
4. CONTROL SYSTEM BLOCK DIAGRAM

1-4
5. FUNCTIONS OF ELECTRONIC COMPONENTS
AC adaptor...........................................Used to supply power to the unit.
Be sure to use the specially designed AC adaptor
(Power) key.....................................Used to turn the unit on and off.
When the power supplied to the unit is cut, unplug the AC adaptor from
the electrical outlet.
(Removetheembroideryframe)key.....Moves the embroidery frame to a position from where it can be removed.
(Start/Stop) key...............................Used to start and stop embroidering.
, , & (Cursor) keys ...............Press these keys to make a choice (for example, to find the pattern or
letter that you want).
(OK) key .........................................Press this key to confirm the choice (for example, to select the chosen
pattern or letter).
(Return) key....................................Press this key to return to the previous screen.
Thread cutting switch ...........................Detects if a thread cartridge is installed, since there is a mechanism that
cuts the thread when the thread cartridge is removed.
NP sensor.............................................Detects the timing for moving the embroidery frame and the stop position
of the needle in the thread cartridge.
Speed sensor.......................................Detects the rotational speed of the main motor.
Main motor ...........................................Drives the thread cartridge and forms the stitches.
Determines the sewing speed according to the stitch length.
X,Y pulse motor....................................Drives the embroidery frame.
REG PC board .....................................Produces circuit power from power supplied by the AC adaptor.
LCD (Liquid crystal display)..................Displays the machine status, operating procedures and the embroidery
pattern.

2-0
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1. DISASSEMBLING THE OUTER PARTS AND MAIN PARTS...................... 2-1
2. ASSEMBLING THE OUTER PARTS AND MAIN PARTS............................ 2-8
3. LEAD WIRE ARRNGEMENT
(For details, refer to the instructions of wiring.)..................................... 2-15
4. POST-REPAIRS INSPECTION PROCEDURES......................................... 2-16

2-1
1. DISASSEMBLING THE OUTER PARTS AND MAIN PARTS
1. With test mode 2, move the carriage to its removal position.
Selecting test mode 2
(1) Enter the test mode by holding down and while pressing , then releasing and .
(2) Press (to initialize) . appears.
(3) Press . appears.
(4) Press . appears.
(5) Press to move the carriage to its removal position (innermost position).
(6) Press to turn off the unit.
2. Remove the three screws securing the under cover assy (refer to the bottom-view diagram below), and then
lift off the upper cover assy.
3. Disconnect the six connectors, and then remove the upper cover assy.
Note
1. If the carriage is not moved to its removal position, the upper cover assy cannot be removed
T-1
MESH PTN
T-2
DECOMPOSE POSS
DECOMPOSE POSS

2-2
4. Remove the two screws securing the needle plate cover, and then remove the needle plate cover.
5. Remove the two screws securing the carriage guide, and then remove the carriage guide.
6. Remove the screw securing the REG board assy, and then remove the REG board assy.
7. Remove the screw securing the sensor board assy, and then remove the sensor board assy.
8. Remove the needle plate.
Disassembly Points
6. Since the carriage can freely be moved as soon as the carriage guide is removed, moving the carriage so
the screw for the REG board assy can be seen allows the REG board assy to be removed easily.

2-3
9. Pull the cassette button forward, and when it is partially removed, turn it counterclockwise to remove it
from the cassette button spring.
10. Remove the cassette button spring.
11. Remove the cassette release lever spring.
12. Remove the retaining ring, and then remove the cassette release lever assy and the washer.
13. Remove the retaining ring, and then remove the cassette lever.
14. Remove the retaining ring, and then remove the cassette lever spring.

2-4
15. Remove the three E2 retaining rings and the E3 retaining ring, and then remove the thread cutter leverassy,
and the two thread cutter links.
16. Remove the E3 retaining ring.
17. Remove the screw, and then remove the thread cutter assy.
18. Remove the screw, and then remove the thread cutter switch assy.
19. Remove the three screws from the bottom of the under cover assy, and then remove the under cover assy.
Disassembly Points
16. Since the E3 retaining ring is only used to position the thread cutter lever assy, not removing
the retaining ring does not prevent other parts from being removed.

2-5
20. Remove the retaining ring, and then remove the driving cam.
21. Pull the pin from the shaft.
22. Remove the retaining ring, and then remove the idle gear.
23. Remove the two retaining rings, and then remove the driving lever assy, the two collars, and
the polyester slider.
24. Remove the two retaining rings, and then remove the driving cam shaft assy and the shutter.
25. Remove the two retaining rings, and then remove the Y guide shaft and the carriage.
26. Remove (cut) the band, remove the two screws, and then remove the main motor assy.
27. Remove the two screws, and then remove the Y pulse motor assy.

2-6
28. Remove the screw, and then remove the spring and the pin (for the Y pulse motor assy).
29. Remove the screw, and then remove the spring and the pin (for the X pulse motor assy).
30. Remove the two screws, and then remove the X pulse motor assy.
31. Remove the four retaining rings, and then remove the X guide shaft L and the X guide shaft S.
32. Remove the spring from the X carriage.
Note
32. The spring fits onto the tab on the X carriage. Be careful not to deform the spring while removing it.

2-7
33. Remove the four screws and the main PC board assy screw, and then remove the middle cover.
34. Remove the three screws, and then while pressing on the composite spring section of the upper cover assy,
remove the liquid crystal display. Next, remove the main PC board assy.
35. Remove the operation keys.
36. Remove the cassette guide from the upper cover assy.
Disassembly Points
36. Since the cassette guide is snapped into place, release the hooks on the guide to remove it.

2-8
2. ASSEMBLING THE OUTER PARTS AND MAIN PARTS
1. Attach the cassette guide to the upper cover assy.
2. Install the operation keys.
3. While pressing on the composite spring section of the upper cover assy, attach the liquid crystal display,
and then secure the main PC board assy with the three screws.
4. Secure the middle cover with the four screws and the main PC board assy screw.
Note
2. Make sure that each button correctly fits into its hole in the upper cover assy Make sure that the keys are
not inserted into bosses for the screws of the main PC board assy and be sure not to push too strongly.
2. Since the black parts of the operation keys are the contact points, make sure that it is not covered with
dust or grease.
3. Since the flexible cable breaks easily, be extremely careful when handling it.
3.4. The main PC board assy screw and the middle cover screws have different lengths, so be sure to install
them in their correct locations.
4. After installation, check that each switch clicks.

2-9
5. Install the X pulse motor assy and secure it with the two screws.
6. Attach the spring to the X carriage.
7. Install the spring and the pin, and then secure them with the screw (for the X pulse motor assy).
8. Install the spring and the pin, and then secure them with the screw (for the Y pulse motor assy).
9. Pass the X guide shaft L and the X guide shaft S through the holes in the X carriage, and then secure
the guide shafts with the four retaining rings.
Note
6. The spring fits onto the tab on the X carriage. Be careful not to deform the spring while installing it.

2-10
10. Secure the Y pulse motor assy with the two screws.
11. Secure the idle gear with the retaining ring.
12. Secure the main motor assy with the two screws. (Position the main motor assy so that the red lead wire is
almost at the top.)
13. Secure the lead wires for the main motor assy and the Y pulse motor assy with the band. (LEAD WIRE
ARRANGEMENT (page 2-15); For details, refer to the instructions of wiring.)
14. Pass the Y guide shaft through the hole in the Y carriage, and then secure the guide shaft with the two
retaining rings.
15. Secure the shutter to the driving cam shaft assy with the retaining ring, and then secure the driving cam
shaft assy to the base plate assy with the retaining ring.
16. Secure the driving lever assy, the two collars, and the polyester slider to the base plateassy with the two
retaining rings. (The driving lever assy should be moved carefully.)
17. Insert the pin into the driving cam shaft.
18. Secure the driving cam to the driving cam shaft with the retaining ring.
Assembly Points
11. If the driving cam that is installed next does not fit because of the position of the retaining ring, move the
opening of the retaining ring toward the driving cam.
12. Using the screws, move the position of the main motor assy to adjust the backlash between the motor
gear and the idle gear. (backlash of 0.1 to 0.2 mm)
18. When installing the driving cam, position the shutter at the right, and then align the φ2 projection on the
driving cam at the top as shown in the illustration.

2-11
19. From the bottom of the under cover assy, secure the base plate assy with the three screws.
20. Secure the thread cutter assy to the base plate assy with the screw.
21. Attach the E3 retaining ring to the thread cutter lever shaft of the base plateassy.
22. Secure the two thread cutter links to the thread cutter assy with the two E2 retaining rings.
23. Secure the thread cutter lever assy to the thread cutter links with the E2 retaining ring, and then secure it to
the thread cutter lever shaft with the E3 retaining ring.
24. Secure the thread cutter switch assy to the base plate assy with the screw.
Assembly Points
24. It is necessary to adjust the installation angle of the thread cutter switch assy. Adjust it so that the switch is
off when the thread cutter lever is lowered, and the switch is on when the lever is slowly brought back up.
(The amount that it is pressed after the switch is turned on is 1 to 2 mm.)

2-12
25. Pass the cassette lever spring over the lever shaft, and then attach it with the retaining ring.
26. Pass the cassette lever over the lever shaft, hook the cassette lever spring onto the cassette lever (as
shown in the illustration below), and then attach it with the retaining ring.
27. Secure the washer and the cassette release lever assy to the driving lever assy with the retaining ring.
28. Install the cassette release lever spring.
29. Fit the cassette button spring into the notch in the cassette button. (Refer to the illustration below).
30. Turn the wheel of the shutter to move the driving lever assy and cassette release lever assy to their lowest
points. Attach the cassette button (with cassette button spring attached). (Refer to the illustration below.)
Assembly Points
28. When the cassette release lever is lowered and released, it should return to its previous position under
the force of the spring. At that time, check that the thread cutter operates smoothly.
30. Check that the cassette lever assy operates smoothly when the wheel of the shutter is turned and
the cassette button is pressed when the driving lever assy and cassette release lever assy are raised.