Brother BES-1216AC Service Manual

BES-116AC, 916AC, 1216ACPlease read this manual before making any adjustments.SINGLE HEAD ELECTRONIC EMBROIDERY MACHINESERVICE MANUAL

BES-116AC, 916AC, 1216AC2BES-916AC, 1216AC(1) Thread guidespool shaft(2) Thread tension dial (3) Thread take up (4) Embroidery hoop(5) Table (6) Power

BES-116AC, 916AC, 1216AC928-4. About P-ROM (BES-116AC, 916AC, 1216AC)H0231(NOTE) Be sure to turn off the power before replacement.(NOTE) Use care when

BES-116AC, 916AC, 1216AC938-5. Connectors8-5-1. Min circuit board connectorsH0234P1 P2 P3 P4 P5 P6 P7P8P9P10P11P12P13P14P18P17 P16 P15P24P23P22P21P19P

BES-116AC, 916AC, 1216AC94ConnectorNo.Connecting point Drive signalsSymptoms resulting from badconnectionP2 Main circuit board- Rotary encoder- Stop p

BES-116AC, 916AC, 1216AC95ConnectorNo.Connecting point Drive signalsSymptoms resulting from badconnectionP19 Main circuit board- Power supply circuitb

BES-116AC, 916AC, 1216AC96Optional connectorP5 Main circuit board- Emergency stop SW-Emergency stopsignal- Machine does not stoppedwhen emergency stop

BES-116AC, 916AC, 1216AC978-5-2. Power supply circuit board connectorsH0235ConnectorNo.Connecting point Drive signalsSymptoms resulting from improperC

BES-116AC, 916AC, 1216AC988-5-3. Head PCB connectorsH0236Set the rotary switch to 1.Rotary switch

BES-116AC, 916AC, 1216AC99ConnectorNo.Connecting point Drive signalSymptoms resulting fromImproper connection orbreakageP1 Unused - Power LED Head LED

BES-116AC, 916AC, 1216AC1008-5-4. Panel PCB connectorsConnectorNo.Connecting point Main signalsSymptoms resulting fromImproper connection or breakageP

BES-116AC, 916AC, 1216AC101ConnectorNo.Connecting point Main signalsSymptoms resulting fromImproper connection or breakageP9 Not used (This is notused

BES-116AC, 916AC, 1216AC32. Mechanical descriptions2-1. Upper shaft mechanism (BES-116AC, 916AC, 1216AC)1. When the upper shaft pulley (1) is turned i

BES-116AC, 916AC, 1216AC1029. Error code listBES-116ACCode Error Messages Error MeasuresE-00 ERROR 00 NO error occurs.E-01 ERROR 01Either motor of mai

BES-116AC, 916AC, 1216AC103Code Error Messages Error MeasuresE-1C Restart perimeterThe machine stops duringmask tracing.Tracing is cancelled if the ST

BES-116AC, 916AC, 1216AC104Code Error Messages Error MeasuresE-38Area over Needle overhang(-Y)E-39Area over Needle overhang(+X, -Y)E-3CArea over Needl

BES-116AC, 916AC, 1216AC105Code Error Messages Error MeasuresE-CD ERROR CDSpeed command can not bereceived.Turn the power off and on once. If thesame

BES-116AC, 916AC, 1216AC106Code Error Messages Error MeasuresE-FA ERROR FAInterface receive data sumcheck errorE-FB ERROR FB Send time up errorE-FF ER

BES-116AC, 916AC, 1216AC107BES-916AC, 1216ACCode Error messages Error MeasuresE-00 ERROR 00 No error occurs.E-01 ERROR 01Either motor of main shaft,X-

BES-116AC, 916AC, 1216AC108Code Error messages Error MeasuresE-17 ERROR 17Speed Vol. No. is out ofrange.E-1A ERROR 1ADestination coordinateserrorThis

BES-116AC, 916AC, 1216AC109Code Error messages Error MeasuresE-31Area over Needle overhang(+X)E-32Area over Needle overhang(+Y)E-33Area over Needle ov

BES-116AC, 916AC, 1216AC110Code Error messages Error MeasuresE-C3 ERROR C3Embroidering data bufferemptyE-C9Embroidering starterrorEmbroidering start e

BES-116AC, 916AC, 1216AC111Code Error messages Error MeasuresE-F3 ERROR F3Request-to-receive time uperrorE-F4 ERROR F4 Receive command errorE-F5 ERROR

BES-116AC, 916AC, 1216AC42-2. Lower shaft and rotary hook mechanism (BES-116AC, 916AC, 1216AC)1. When the upper shaft pulley (1) rotates in the direct

BES-116AC, 916AC, 1216AC11210. Troubleshooting flowchart10-1. Troubleshooting flowchart when the power is on

BES-116AC, 916AC, 1216AC113Connector check Energized harness Board check Other partsMain board:P12(RS232C)Control panel board:P11RS232C)Floppy harness

BES-116AC, 916AC, 1216AC11410-2. Troubleshooting flowchart in thread trimming operation

BES-116AC, 916AC, 1216AC115Connector check Energized harness Check board Other partsWiper sensor board attached on theinternal wiperHead board:P5(WSEN

BES-116AC, 916AC, 1216AC11610-3. Troubleshooting flowchart in sewing operation (1)

BES-116AC, 916AC, 1216AC117Connector check Energized harness Check board Other partsMain boardX-axis pulse motor connectorMain board:P18(X-MOTOR)X-axi

BES-116AC, 916AC, 1216AC11810-4. Troubleshooting flowchart in sewing operation (2)

BES-116AC, 916AC, 1216AC119Connector check Energized harness Check board Other partsRotary encoder of the spindle pullyMain board:P2(TIMING)Timing har

BES-116AC, 916AC, 1216AC12010-5. Troubleshooting flowchart in data entry operation

BES-116AC, 916AC, 1216AC121Tblhifl hid iConnector check Energized harness Check board Other partsControl panel board:P4(FDD-P)Floppy drive 34-pinPanel

BES-116AC, 916AC, 1216AC52-3. Thread trimmer mechanism (BES-116AC, 916AC, 1216AC)1. Upon making the final stitch, the roller of the thread trimmer div

BES-116AC, 916AC, 1216AC12210-6. Troubleshooting flowchart of control panel display

BES-116AC, 916AC, 1216AC123Connector check Energized harness Check board Other partsMain board:P12(RS232C)Control panel board:P11(RS232C)Panel harness

BES-116AC, 916AC, 1216AC12411. Voltage checkVerify each connector voltage on the power board11-1. Input voltage from transformerInsert the connector i

BES-116AC, 916AC, 1216AC12511-2. Output voltage to each boardRemove the connector from the board and then carry out voltage measurements between speci

BES-116AC, 916AC, 1216AC12611-3. Tap voltages on the transformer11-3-1. Tap voltage layout on the terminal block11-3-2. Voltage valuesPower on the mac

BES-116AC, 916AC, 1216AC12712. Trouble shootingMechanical SectionBES-116ACProblem Check Point- Thread breakage- Is the machine properly threaded?- Is

BES-116AC, 916AC, 1216AC128Problem Check Point- Machine operationabnormal- Is any set screw of the rotary encoder loosened?- Is any set screw of the m

BES-116AC, 916AC, 1216AC129BES-916AC, 1216ACProblem Check Point- Thread breakage- Is the machine properly threaded?- Is thread tension too high?- Is t

BES-116AC, 916AC, 1216AC130Problem Check Point- Upper shaft locks at acertain point in one cycle- Is the thread take-up stopped due to interference w

BES-116AC, 916AC, 1216AC131Electrical SectionBES-116AC(NOTE) Be sure to turn off the power of the machine and unplug the power cord before checkingcab

BES-116AC, 916AC, 1216AC62-4. Thread wiper mechanism (BES-916AC, 1216AC)1. After sewing is finished, the wiper solenoid (1) moves the plate (2) in the

BES-116AC, 916AC, 1216AC132Symptom MeasuresX-axis or Y-axis homeposition detection erroroccurs.- Was the XY carriage moving?-> If so, refer to the

BES-116AC, 916AC, 1216AC133Symptom MeasuresERROR E5 to ERROR FFfrequently occur.- Replace the main PCB with a new one.All solenoids of head do notoper

BES-116AC, 916AC, 1216AC134BES-916AC, 1216AC(NOTE) Be sure to turn off the power of the machine and unplug the power cord before checkingcable connect

BES-116AC, 916AC, 1216AC135Symptom MeasuresThe needle bar case lockerror occurs.- Is the INDEX motor rotating?-> If not, refer to the block diagram

BES-116AC, 916AC, 1216AC136Symptom MeasuresThe main shaft motor lockerror occurs.- Enter the encoder signal mode and manually turn the main shaftpulle

BES-116AC, 916AC, 1216AC137Symptom MeasuresJump solenoid does notoperate.- Check to see if connection from the jump solenoid to connectorP10 of the he

BES-116AC, 916AC, 1216AC138

BES-116AC, 916AC, 1216AC139H0239

SERVICE MANUALBROTHER INDUSTRIES, LTD.15-1, Naeshiro-cho, Mizuho-ku, Nagoya 467-8561, Japan. Phone: 81-52-824-2177155-116, 916, C16I1050809F2001.08.F

BES-116AC, 916AC, 1216AC72-5. Needle bar case driving mechanism (BES-916AC, 1216AC)1. Stepping motor (1) drive the change cam (4) through cam gears A

BES-116AC, 916AC, 1216AC82-6. Picker mechanism (BES-116AC, 916AC, 1216AC)1. Rotary solenoid (1) pull the wire (2) so that the fork of picker lever (3

BES-116AC, 916AC, 1216AC92-7. Drive, (X) feed mechanism (BES-116AC, 916AC, 1216AC)1. Pinion gear B (2) attached to the X-pulse motor (1) rotates, then

BES-116AC, 916AC, 1216AC102-8. Drive, (Y) feed mechanism (BES-116AC, 916AC, 1216AC)1. Pinion gear B (2) of the Y-pulse motor (1) rotates, then transmi

BES-116AC, 916AC, 1216AC112-9. Presser foot mechanism (BES-116AC, 916AC, 1216AC)1. When the power is turned on, the presser retracting solenoid (1) ro

BES-116AC, 916AC, 1216ACiThank you very much for buying a BROTHER sewing machine. Before using your new machine,please read the safety instructions be

BES-116AC, 916AC, 1216AC122-10. Cap frame device (optional)1. The wire (2) fixed on X-carriage (1) drive the cap frame driver in rotation direction.2.

BES-116AC, 916AC, 1216AC133. Parts replacement and adjustment CAUTIONThis sewing machine should only beused by operators who have receivedthe necessar

BES-116AC, 916AC, 1216AC141. Remove screws and belt cover B (1) and A (2).2. Remove screws and the motor cover (3) attached to the bottom of the table

BES-116AC, 916AC, 1216AC153-2. Attaching X wire (BES-116AC, 916AC, 1216AC)(NOTE) Be careful not to scratch the wire as it is coated with resin and a s

BES-116AC, 916AC, 1216AC165. Put the ball on the wire into the hole of wire drum X (10).Fit the wire completely into the groove, then wind the wire se

BES-116AC, 916AC, 1216AC173-3. Attaching Y wire (BES-116AC, 916AC, 1216AC)Remove Y wire L1. Push the carriage (1) all the way to the back, and secure

BES-116AC, 916AC, 1216AC18Remove Y wire R1. Pull the carriage (1) forward and secure it.2. Remove the bolt (12) from hook RY (11). Remove Y wire R (13

BES-116AC, 916AC, 1216AC193-4. Adjusting the needle bar case position3-4-1. BES-116ACH0030H00311. Remove two bolts (2), and the needle bar case (1).2.

BES-116AC, 916AC, 1216AC203-4-2. BES-916AC, 1216AC1. Remove the four bolts (2), and the needle bar case (1).2. When setting the needle bar case, make

BES-116AC, 916AC, 1216AC213-5. Replacing the thread take-up lever3-5-1. BES-116ACH0033H00341. Remove the two bolts (2) and the needle bar case (1).2.

BES-116AC, 916AC, 1216ACii2. Notes on safety DANGERWait at least 5 minutes after turning off the power switch and disconnecting the power cord from th

BES-116AC, 916AC, 1216AC223-5-2. BES-916AC, 1216AC1. Loosen the set screw (2) on the right of the needle bar case (1) viewed from the front, and the s

BES-116AC, 916AC, 1216AC23(NOTE) Notes on assembly.- When attaching the thread take-up lever (6) and the thread take-up holding (7), set aclearance of

BES-116AC, 916AC, 1216AC243-6. Replacing the needle bar (BES-116AC, 916AC, 1216AC)1. Remove the set screw (1), and the needle (2).2. Remove the needle

BES-116AC, 916AC, 1216AC253-7. Replacing the jump bracket (BES-116AC, 916AC, 1216AC)1. Loosen the screw (1) on the left of the machine head.2. Pull ou

BES-116AC, 916AC, 1216AC263-8. Replacing and adjusting the jump solenoid (BES-116AC/96AC/1216AC)H0043H0042H0044H00451. Remove the two screws (1) and t

BES-116AC, 916AC, 1216AC2710. Attach the cam plate (2) to the side of the machine head using the shoulder screw. Attach the jumpsolenoid to the side o

BES-116AC, 916AC, 1216AC283-9. Replacing the synchronizer and the sensor circuit board(BES-116AC, 916AC, 1216AC)H0047H0046H0048 H0049Replacing the syn

BES-116AC, 916AC, 1216AC29Replacing the sensor circuit board1. Remove the connector (10) of the sensor circuit board (9).2. Remove the two screws, and

BES-116AC, 916AC, 1216AC303-10. Replacing and adjusting the parts related to the presser foot(BES-116AC, 916AC,1216AC)3-10-1. Replacing the presser fo

BES-116AC, 916AC, 1216AC315. Remove the three screws (8), and thepresser guide plate (9).6. Remove the three screws, and the solenoidcover (10). Remov

BES-116AC, 916AC, 1216ACiii CAUTIONSewingThis sewing machine should only be used byoperators who have receives the necessary trainingin safe use befor

BES-116AC, 916AC, 1216AC323-10-3. Adjusting the presser shaft when the needle bar case is attached1. Turn the pulley to set the presser foot to itslow

BES-116AC, 916AC, 1216AC333-10-5. Replacing the retracting solenoid lever1. Remove the three screw, and the solenoidcover (1).2. Remove the two screws

BES-116AC, 916AC, 1216AC343-10-7. Replacing the presser retracting solenoid1. Remove the three screws, and the solenoidcover (2) from the presser sole

BES-116AC, 916AC, 1216AC353-11. Replacing and adjusting the parts related to the needle bar flip-up mechanism (BES-916AC)3-11-1. Replacing the cam gea

BES-116AC, 916AC, 1216AC363-11-2. Assembly1. Temporarily attach cam gear A (1) to theshaft of the pulse motor (2).2. Insert the cam shaft (6) into cam

BES-116AC, 916AC, 1216AC376. Attach the circuit board base (9) using thefour screws.7. Attach the change collar (7) to thepotentiometer (10) with the

BES-116AC, 916AC, 1216AC38Replacing and adjusting the parts related to the needle bar flip-up mechanism (BES-1216AC)Replacing the cam gear1. Remove th

BES-116AC, 916AC, 1216AC397. Loosen each set screws of cam gears A (13) and B (12), and reduction gear A (11) and the changecam (14) remove the cam sh

BES-116AC, 916AC, 1216AC40Assembly1. Temporarily attach cam gear A (1) to theshaft of the pulse motor (2).2. Insert the cam shaft (6) into cam gear B

BES-116AC, 916AC, 1216AC416. Loop the reduction gear A (8) around thereduction gear B (10) with the set screw.(NOTE) Make sure that cam gear B (3) isn

BES-116AC, 916AC, 1216ACiv3. Warning labelsThe following warning labels appear on the sewing machine.Please follow the instructions on the labels at a

BES-116AC, 916AC, 1216AC4210. Attach the adjustment base (18) using thefour screws (19) and insert connector (20)into the rear of the adjustment base

BES-116AC, 916AC, 1216AC434. Adjustment CAUTIONIf the power switch needs to be left onwhen carrying out some adjustment, beextremely careful to observ

BES-116AC, 916AC, 1216AC443. Loosen the screw of the needle bar clamp (3) when the needle tip is positioned 10.8 mm abovethe center of the rotary shaf

BES-116AC, 916AC, 1216AC454-1-1. When using the bottom dead center gaugeH0098 H0099H0097H0100H0101 H01021. Turn the pulley (1) to set the needle bar t

BES-116AC, 916AC, 1216AC464-2. Adjusting the timing between the needle and the rotary hook[when the needle bar is raised 2mm] (BES-116AC, 916AC, 1216A

BES-116AC, 916AC, 1216AC474-3. Adjusting the presser foot height(BES-116AC, 916AC, 1216AC)H0108BES-116ACH0109BES-916AC, 1216ACH0110Adjust the presser

BES-116AC, 916AC, 1216AC484-4. Adjusting the springBES-116ACH0113H0114(MEMO) The standard operation range of the thread take-up spring is about 6-8 mm

BES-116AC, 916AC, 1216AC494-5. Adjusting the picker (BES-116AC, 916AC, 1216AC)H0117H0118H01191. Insert the bobbin case (1) containing the bobbin into

BES-116AC, 916AC, 1216AC504-6. Adjusting the clearance between the rotary hook and the inner rotary hook stopper(BES-116AC, 916AC, 1216AC)1. The clear

BES-116AC, 916AC, 1216AC514-8. Adjusting the thread wiper (BES-916AC, 1216AC)1. Move the solenoid arm (1) in the direction of the arrow with your fing

BES-116AC, 916AC, 1216ACv[BES-1216AC]H0623Finger guard43[BES-916AC]4351Belt coverFinger guard2Guard cover

BES-116AC, 916AC, 1216AC524-9. Adjusting wire tension (BES-116AC, 916AC, 1216AC)4-9-1. X-feed wirePushing by 4.9N torque wrench or similar tool at the

BES-116AC, 916AC, 1216AC534-9-2. Y-feed wirePushing by 4.9N torque wrench or similar tool at the center point of wires, adjust so there is adeflection

BES-116AC, 916AC, 1216AC544-10. Adjusting the thread trimmer cam (BES-116AC, 916AC, 1216AC)1. The clearance between the edge of thethread trimmer cam

BES-116AC, 916AC, 1216AC554-11. Adjusting the thread sensor (BES-116AC)- Select the needle bar moving test mode.- To turn the thread trimmer detect pu

BES-116AC, 916AC, 1216AC564-12. Adjusting the wire of the cap frame device (BES-116AC, 916AC, 1216AC)1. Loosen the screw (3), and adjust the wiretensi

BES-116AC, 916AC, 1216AC57BES-916AC2. Turn on the power of the machine.3. The machine starts the needle bar movingtest in the test mode. Refer to “Tes

BES-116AC, 916AC, 1216AC58BES-1216AC2. Turn on the power of the machine.3. The machine starts the needle bar movingtest in the test mode. Refer to “Te

BES-116AC, 916AC, 1216AC594-14. Adjusting the bobbin winder (BES-116AC, 916AC, 1216AC)4-14-1. Positioning the bobbin winder clawH0149 H01501. Remove t

BES-116AC, 916AC, 1216AC604-14-2. Positioning the bobbin presserLoosen the screw (1), and adjust the bobbin presser (2) by moving it so that the prope

BES-116AC, 916AC, 1216AC615. Test Mode5-1. Entering into the test mode1. Press the key twice on the embroidery initial screen.2. Select the icon wi

BES-116AC, 916AC, 1216ACContents1. Part descriptions ...1BES-116AC...

BES-116AC, 916AC, 1216AC625-3. Function of the test mode5-3-1. Needle bar moving testH0153- If you press the left needle bar switch key, the number of

BES-116AC, 916AC, 1216AC63- When the thread trimmer pulley of the needle bar selected is turned, the icon of needlebar number blinks.- When the or

BES-116AC, 916AC, 1216AC645-3-2. Carriage sensor test, stopper adjustmentSelect the flat hoop or cap hoop icons with thejog keys ( and ).When the ke

BES-116AC, 916AC, 1216AC65Adjust the right and left stopper in the back ofthe machine to make contact with thecarriage at the point where Y302.0 isdis

BES-116AC, 916AC, 1216AC665-3-3. Encoder signal testH0167H0168When the pulley is turned at the needle upper stop position (at 92.5 to 112.5 degrees of

BES-116AC, 916AC, 1216AC675-3-4. Presser foot testH0171When the jog switch ( )is pressed, the presser foot rises, is displayed, and the buzzer sound

BES-116AC, 916AC, 1216AC685-3-5. Port/voltage checkDisplays the current status of ports A, B,and C.Details of what are displayed are as follows:BIT7 B

BES-116AC, 916AC, 1216AC695-3-6. Solenoid testThe presser foot lowers and the screen shownto the left is displayed.H0175When the 1. key is pressed, th

BES-116AC, 916AC, 1216AC705-3-7. Main shaft motor rotation test- steps up the set value of thespeed.- steps down the set value of thespeed.- When is

BES-116AC, 916AC, 1216AC715-4. Adjusting the rotary encoder and sensor PCB- The rotary encoder and sensor PCB is used to detect the needle stop positi

BES-116AC, 916AC, 1216AC4-13. Replacing an adjusting the potentiometerassembly ... 564-14. Adju

BES-116AC, 916AC, 1216AC725-4-2. Adjusting the synchronizing signal1. Turn on the power, and the machine startsthe encoder signal test in the test mod

BES-116AC, 916AC, 1216AC735-5. Adjusting home position using home position plate(NOTE) Use the XY-axis home position plate assembly (S36461-001 option

BES-116AC, 916AC, 1216AC74<Y-direction>1. While pushing DEL key, turn on the power.2. The machine detects the X-home positionand the XY-axis hom

BES-116AC, 916AC, 1216AC755-6. Adjusting the overtravel sensor and flat hoop stopper using the home position plateThe sensor and stoppers are used for

BES-116AC, 916AC, 1216AC766. Upgrading version of machine programThis chapter explains how to upgrade the version of programs using the upgrade file w

BES-116AC, 916AC, 1216AC776-3. Using the installation disk (upgrading the program)1. Press the key twice during standby.H01962. Press the jog keys (

BES-116AC, 916AC, 1216AC78Go to step 8 if the following screen is displayed.H02027. Installation from “SETUP***-***.BUP” starts.8. The following scree

BES-116AC, 916AC, 1216AC797. Lubrication CAUTIONTurn off the power switch at the following times, otherwise the machine may operate if thestart switch

BES-116AC, 916AC, 1216AC80Refill with new oil from the holes indicated with arrows if necessary.(NOTE) Replenish oil in the machine front oil tank onc

BES-116AC, 916AC, 1216AC817-2. Feed guide mechanism (BES-116AC, 916AC, 1216AC)(NOTE) For lubrication, use Brother-specified grease tank 30.(NOTE) Be s

BES-116AC, 916AC, 1216AC11. Part descriptionsBES-116AC(1) Thread guidespool shaft(2) Thread tensiondial(3) Thread take up (4) Embroidery hoop(5) Table

BES-116AC, 916AC, 1216AC827-3. CleaningKeep the machine clean and unclogged to prevent machine trouble.Keep the machine clean:Remove dirt with a soft,

BES-116AC, 916AC, 1216AC838. Electric components DANGERWait at least 5 minutes after turning off the power switch and disconnecting the power cordfrom

BES-116AC, 916AC, 1216AC848-2. Replacing circuit boards8-2-1. Main circuit board(NOTE) Be sure to turn off the power and open the cover before replace

BES-116AC, 916AC, 1216AC858-2-2. Machine motor circuit board1. Disconnect the eight connectors. Disconnect the terminating resistance connector.2. Pus

BES-116AC, 916AC, 1216AC868-2-3. Replacing the power supply circuit board1. Remove all connectors of the power supply circuit board.2. Remove the powe

BES-116AC, 916AC, 1216AC878-2-4. Replacing the panel PCB1. Loosen the four screws (1) securing the panel at the top and bottom, and lift the panel cap

BES-116AC, 916AC, 1216AC888-2-5. Replacing the control panelWhen replacing the whole control panel, follow the procedures below. Loosen the four screw

BES-116AC, 916AC, 1216AC898-2-6. Replacing the TR breakage sensor PCB1. Remove the adjustment base cover (1).2. Remove the four screws (3) securing th

BES-116AC, 916AC, 1216AC908-3. Fuses8-3-1. Position of fuses1. Remove cover (1).2. There is a fuse holder in front of the transformer in the power sup

BES-116AC, 916AC, 1216AC918-3-3. Replacing fuse(NOTE) The problems are listed below for your reference to replace a fuse.(NOTE) Use the same type and