Brother BAS-411 User manual

SERVICE MANUAL
FOR
BAS -4 11
BAS-415
SINGLE HEAD ELECTRONIC EMBROIDERY
MACHINE
I
· · . ~ -
From the library of: Superior Sewing Machine & Supply LLC

CONTENTS
( PART NAMES ) ·. · · · · · · · · · · · · · · · · · · ·· · · · · · · · · · ·· · · · · · · ·· · ·· · · · · · · · ·· · · · ·· · · · · · · · · · · · · · · · 1
( MECHANICALDESCRIPTIONS ) · · · · · · ·· · · · · · · ·· · · · · · · ·· · · · · · ·· · · ·· · · · · · · · · · · ·· · · · · · · · 3
[I] .upper shaft mechanism . .. . . •. . . . . .. . . . . . . . . . . ••. . . . . .. . •. . . . . . . . . .•. . •• . . •. .. . . . . . . . . . 3
00 Lower shaft and rotary hook mechanism . . . . . . •••••. . . . . .. . . . . . . . . •. .. ••. . ••. . . . . . . •. . . . 4
00 Thread trimmer mechanism . •. . . . . . . . . . •. . . . . .. . . . . . . .. . . . . . . . . . . .. . . . . .•. . . . . . ••••••. • 5
[j] Thread wiper mechanism . •. . •. . . . . . . . . . . . . .•. •. . . . . . . . . . . . . . . . . . .•••••. ••. •.. . . . . . •. . . 6
[§] Needle bar flip-up mechanism . . ••. . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . .. . . •.. . . . . . . . . •••. ••. 7
[§] Pickermechanism •. . . . . . . . . . . . . . . . . . . . . . . . . . .•. ••. . . . . . .•. . . . . . . •. •. . ••. •. . . . . . •. . . . . . 8
[1] Drive, (X) feed mechanism . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . •••. . . . •. . . •. . . . . . . . . . . . . . . •. 9
[I] Drive, (Y) feed mechanism . . . . . . . . . . . . . . . . . . . .•. •. . . . . . . . . . .. . . . . •. •. . •. . . .. . . . . . . . ••. 10
( STANDARDADJUSTMENT ) · · · · · ·· · · · · · · · · · · ·· · · ·. · · · · ·· · · · · · ·· · · · · ·· · · · · · · ·· · · · · · · · · 11
[I] Adjusting needle bar height ...•..............••...... ~ . . . . .. . . . ••. . . . . . . . •. .••••••••• 11
~ Adjusting timing of needleand rotary hook . . •. . . ••. . . . . .. . . . . . . . . . .. . . . . . . . . . . •. ••••. • 13
00 Adjusting cloth presser height . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . . . .•. •. . . . . . . . .. . . . . . . •. 13
[j] Adjusting knife and fixed knife . •. . . . . . . . . . . . . ••. . . . . . .. . . . . . . . .. •.. . . . . . . . . . . . . . . . . . . . 14
[§] Adjusting picker . . . . . . . . . . . . . . . . . . . . . . . •. .. . . . . . . . . .. . . . . . . •. . . . .. . . . . . . . . . . . . . ••• •. . 15
[§] Adjusting the thread wiper . . . . . . . . . . . . . . . . . . . .. . . . . . . . .. •. . . . . . . .•. . . . . . . . .•. . . . . . . •• 16
[1] Adjusting wire tension .....•.................•........................••...•.•...•••• 17
1. X- feed wire . . . . . . . . . . . . . . . . . . . . . . . . . . . .. •. . . . . . .. . . •.. . . . . •.. . . . . . . . . . . . •. •••••. 17
2. Y -feed wire . . . . . . . . . . . . . . •. . . . . . . . •. . . . . . . . . . . . . . .. . . . . . . . . . . . . •. . . . . .. . . . . •. . . . 18
00 Adjusting thread breakage detect stud ..........................•.•.....•.•............ 19
00 Adjusting bobbin winder ...................•......................................... 20
lim BAS-411·415 test mode . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. . . . . . . . . . .••••••. . . . •. . . . . . . . . 21
In] Adjusting synchronizer . . . . . . . •. •. . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . . . •. . . . . 23
1m Adjusting home position using home position plate . . . . . .. . . . . . . . . . •. . . •. . . . . . . . . •. . . . . . 26
lj} Positioning over limit sensor ...................................•..••..•............... 28
IB1 How to adjust thread sensor(thread breakage detector) . . . . . . . . . . . . . .. . . . . . . . . . . . •. . . . . . 35
( LUBRICATION ) ·· · · · · · · · · · · · · · · · · · · · · · · · · · · · ·· · · · · · · · · · · · · · · ·· · · ·· · · · · · · · · ·· · · · · · · · · · · 36
[I] Machine head . . . . . . . . . . . . . . . . . . . . . . . . •. . . •. . . . . . . . .. . . . . . . . . . . . .•••••. . •. . . . . . . . . . . . 36
~ Feed guide mechanism .......................................•........•.............. 38
From the library of: Superior Sewing Machine & Supply LLC

( REPLACINGANDADJUSTINGPARTS) · · · · ·· · · · · · · · · ·· · · · ·· · · · · ·· · · · · · · · · ·· · · · · · · · ·· 39
[I] Removing and adjusting machine head (1) . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
~ Removing and adjusting machine head (2) . .. . . . . . .. . .. .. . . . . . . . .. .. . . . .... .. ...... . . . . 40
lm Removing needle bar case ............................................................ 41
1!1 Replacing up and down motion parts . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . 42
~ Replacing jump solenoid .............................................................. 43
[§] Attaching X wire ..................................................................... 44
[1] Attaching Y wire ..................................................................... 45
( ELECTRIC COMPONENTS ) · · · · · ·· · · · · · · · · ·· · · · · · · · · ·· · · · · · · · · · · · ·· · · · · · · ·· · · · · · · · · · 46
[!) Circuit board locations ...•............................................................ 46
~ Replacing circuit board ............................................................... 47
00 Fuses ............................................................................... 58
(!] P-ROMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
~ DIP switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
[§] Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
[1] troubleshooting flowchart ........................................................... 70
BAS-411 .......................................................................... 70
BAS-415
.......................................................................... 81
00 Harness connectionsand connectors number ........................................... 92
( EXPLANATIONOFOPTIONALPARTSINSTALLATION) ·· · · · · · · · ·· · · · · · · · · · · · · · · · · 106
[]] ML 6511ampset . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 106
~ Light marker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
00 Connecting optional parts with machine . . . . . . .. .. . . . . . . .. . . . . . .... . . . . .. . . .. . . . . . .. . 112
1!1 Bobbin winder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
( TROUBLESHOOTING)····························································· 118
[!) Mechanical problem . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
~ Electrical problem . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
00 List of error messages . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
BAS-411 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . 122
BAS-415 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
BAS-411 KEYBOARD UN IT CONTROL BLOCK DIAGRAM
BAS-415 KEYBOARD UNITCONTROL
BLOCK DIAGRAM
BAS-411 CONTROL
BLOCK DIAGRAM
BAS-41 5 CONTROL BLOCK DIAGRAM
.........................................................
.........................................................
From the library of: Superior Sewing Machine & Supply LLC

( Part names )
( BAS-411 )
0 Thread guide bar @ Thread tension dial @) Thread take-up
0 Embroidery hoop <9 Table plate 6 Operation panel
@)Spool shaft (B) (!) Keyboard assembly CD Guard bar
@ Speed dial 4D Disk drive
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0 Thread take-upcover
@) Powerswitch
48 Contrastdial of liquid crystal display
From the library of: Superior Sewing Machine & Supply LLC

( · BAS-415 )
0 Thread guide bar 8 Thread tension dial @) Thread take-up
@ Embroidery hoop (!) Table plate 8 Operation panel
@) Spool shaft (B) tD) Keyboard assembly 4D Guard bar
Q) Speed dial 4D Disk drive
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8 Thread take-upcover
~ Powerswitch
C8 Contrastdial of liquid crystal display
From the library of: Superior Sewing Machine & Supply LLC

(MECHANICAL DESCRIPTIONS )
lii Upper shaft mechanism
1) When the pulley 0 rotates in the direction of the arrow, it transmits the rotation to the uppershaft 8.
The upper.shaft8 then rotates the threadtake-updriving cam @).
2) The threadtake-updriving cam@) transmits the motion to the connecting rod 9.
3) The up and down motion parts <9, attached to the main needle bar 0, move the needle bar 8 upand
down.
4) The needle bar8 is guided by the needle bar case @).
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~ Lower shaft and rotary hook mechanism
1) When the pulley 0 rotates in the direction of the arrow, it transmits the rotation to the uppershaft @.
The upper shaft@ then rotates uppershaftgear(A)@).
2) Uppershaftgear (A)@) transmits the movement to the lower shaftgear0 via the vertical shaft e.
3) The lower shaftgear 0 transmits the rotation to the attached lowershaft @). Then the rotary hook 6,
attached to the lower shaft@), rotates in the direction of thearrow.
NOTE: In BAS- 411 and 415, the rotary hookmakes two revolutions for each revolution made by the pulley.
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~ Thread trimmer mechanism
-------------------
After the final stitch, roller shaft (A) 0 moves into the groove of the cam @,and connecting plate (B) @)
~ moves. Then the knife 0 engages with thefixed knife 0, trimmingthe thread.
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II] Thread wiper mechanism
~--------
After sewing is completed, the thread guide solenoid 0 moves the plate @in the direction of the arrow,
and
the upper thread guide hook @) attached to the plate @ brings the trimmed thread to the thread
presser. The thread presser secures thetrimmedthread.
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[§] Needle bar flip-up mechanism
~~------
After receiving the set needle bar flip-up signal, cam gears (A) 8 and (B) @) attached to the pulse motor 0
are activated. The needlebar flip-up is performed by the changecam 9.
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[§] Picker mechanism
------------
The picker solenoid 0 functions at the beginning of sewing and after thread trimming. The picker @)
attached to connecting plate (A)@ moves inthe direction of the bobbin case e,then pullsthe upperthread
under
the material.
Duringthread trimming,
the picker@) operates to keep the needle thread length constant.
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[1] Drive, (X) feed mechanism
1) Pinion gear (B) @ attached to the X-pulse motor 0 rotates, then transmits the rotation to idle gear (A)
@).
2) When idlegear(A)@) rotates, the (X) wire CD reeled inthewire drum (X) e moves the carriage & in the
direction of the X-axis (left e right) via the pulley <9.
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[II. Drive, (Y) feed mechanism
1) Pinion gear(B)@ of theY-pulse motor0 rotates, thentransmitsthe rotation to idlegear (A)@).
2) When idlegear (A) @)rotates, the (Y) wires @)(left) and (right) reeled in the wire drums (Y) 8 on the
right and the left move the carriage fi in the direction of theY-axis (backwards e forwards) via the
pulley8.
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c STANDARD ADJUSTMENT )
lii Adjusting needle bar height
Tightenthescrew
0so that the gap
is kept equal.
1) Lower the needle bar to its lowest position. When the needle tip is raised 9 mm above the center of the
~ rotaryhookshaft, tighten the screw of the needle barclamp @ so that the screw 0 leans to the right 25°
-30°.
2) Raise the needle bar to its highest position. Lightly press the stopper @) to the cushion rubber 9 side.
Then
tighten the screw0 so that it is positioned in the front.
NOTE: Make sure that the stopperdoes not strike the needle bar guide rail.
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When using the gauge (optional)
Gauge
1) Loosen thescrew 0 and remove the rotary hook@ from the lowershaft.
2) Insertthe gauge (option) into the lowershaft.
3) Loosen the screw e of the needle bar clamp @). Turn the pulley until the needle tip lightlycontacts the
gauge at its lowestposition.
NOTE: Do not use the flat part of the gauge at thistime.
4) Tighten the screw 9 of the needle bar clamp@) firmly.
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~ Adjusting timing of needle and rotary hook
1/
I I
I
I I
I I
I I
: I
1) Selectthefirstneedlebar 0.
\
I
I
I
I
I I
I I
I I
2) Remove the two screws and the needle plate@.
Aprrox.1 mm
2.5mm
3) When the needle bar is raised 2.5 mm (201°) above its lowest position (180°), loosen the screw 0 of the
rotary hook @), and adjust so that the needle meets the rotary hook point. Then, temporarily tighten
the two stopscrews.
At thistime, the needle barheightshould be about 1mm. {Figure A) .
4) As for other needle bars, if the gap between the needle and rotary hook point is 0.01 - 0.2 mm, tighten
the 3screws of the rotary hook.
~ Adjusting cloth presser height
Cutand insert.
Adjust the cloth presser 0 height with the cushion rubber @). The cloth presser 0 heightshould be raised 1
-
1.5 mm from the needle plate @ at the cloth presser's lowest position. {Asheet of the cushion rubber is 0.5
mmthick.)
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(j] Adjusting knife and fixed knife
1. Attaching fixed knife
1) Attach the fixed knife so that the attached part parallels the rotary hook base. The movable knife
broadens
at part®. Makesure the fixed knife doesn'tcontact it at thispart.
2. Knife timing
1) While pushing the cam lever 0 up with a finger, rotate the pulley @ in the direction of the arrow.
When
the knife @) begins to move, the pulley will become harder to turn. At thistime,tighten the screw
of the 24 Jgear eI fix the cam CD by hand so it does not rotate, and turn the pulley. The rotary hook
bladeshould be in the center of the rotaryhooksupporter@).
2) Tighten the screw of the 24 J gear e so there is no backlash of the cam in the direction of the lower
shaft. While pushing the cam lever 0 up with a finger, rotate the pulley @again. When the knife @)
begins to move, the blade in the rotary hookshould be in the center of the rotaryhooksupporter @).
3. Knife position
Loosen the screw & and adjust the knife @) position so that its end projects 1 mm beyond the fixed
knife'stip.
After threadtrimming, the knifeshould be in this position.
If the knife does not stop at the stop position, the uppershaft will be locked and it cannot make one full
revolution. In that case, move the knife to the stop position byhand.
4. Knife and fixed knife
1) With a marker, color the back of the knife @) and engage it with thefixed knife @) manually. Check that
the colored portion is shaved equally. This shows properknifeengagement.
2) If the engagement is wrong, loosen the screw @) of the fixed knife @) and adjust the inclination with the
lower set screw CD).
NOTE: The inclination of the fixed knife @)should be adjusted with the two top screws @) and the
bottomsetscrew CD).
NOTE: This is fineadjustment. Adjust carefully.
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~-
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1§1 Adjusting picker
FigureA
1) Insert the bobbin case 0 containing the bobbin into the rotaryhookand set the picker@ position.
2) Leave the solenoid arm @) pushed to the needle bar side, then tighten connecting plate (A) e with the
screw0.
3) Adjust the picker @ so that there is no looseness and so that it functions lightly. Then tighten the picker
bracket(!) with the screw 8.
4) Adjust the gap between the point of the pickerand the bobbin to 1 -1.5 mm. Leave the solenoid arm @)
pushed to the pulleyside (thesolenoid operation position), thentighten the screw@).
5) Adjust the picker position so that it is bisected by the bobbin case spring (see figureA).
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[§] Adjusting the thread wiper
1) With a finger, move the solenoid arm 0 in the direction of the arrow. Loosen the two screws @ then
adjust
the upperthread guide hook@ so that it movesslightly.
2) Adjust the upperthread guide hook @ so that itscut part is located at the center of the needle hole.
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111 Adjusting wire tension
1. X-feed wire
0 1.5 kg
Using a 1.5 kg torque wrench or a similar tool, push at the location marked by the arrow and adjust so there
is a deflection of approximately 14 mm.
How to adjust
1) Remove the seven screws 0 and the two covers (LR, LL)@.
2) Loosen the two screws 0 of both hook (LX) @) and hook (RX) 0.
3) There are two stoppers (U) (S) on the right and the left sides. Turning them clockwise will increase the
tension and turning them counterclockwise will decrease the tension.
4) When the tension is proper, tighten screw 0.
5) After tightening screw 0, firmly retighten stoppers (U) (S) so there is no looseness.
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