Brother B-500 Service Manual Download Page 198

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Special Instructions of Wiring Wiring of needle bar module

1. Wiring on left side of needle-presser module

Secure the lead wires a clip. (bend
the tip of a clip in the inside of the
arm bed.)

Secure the lead wires so
that the head part of the
band becomes it inward.

The BHL lead wires should
be loose.

The lead wires should be positioned
above the rib.

Hang over the
three hooks.

Summary of Contents for B-500

Page 1: ...SERVICE MANUALFOR COMPUTERIZED SEWING MACHINE NV 10 NV 10A ML 600 B 500 NS 10 CAMPUS300 NV15 NV15P NS15 NV15WT NV10A 7 2007 7 2016 ...

Page 2: ......

Page 3: ...LIST of UPDATE RECORD 6 2012 Date Added Models Contents NV15 8 2013 NV15P 9 2013 NS15 7 2014 7 2016 NV15WT NV10A ...

Page 4: ...ng panel H assy Removal of Buttons 2 10 Disassembly of Selecting panel H assy Removal of Selecting dial 2 11 Disassembly of Selecting panel H assy Removal of Single light guide assy 2 11 Removal of Rear cover assy 2 12 Disassembly of Rear cover assy Removal of Bobbin presser 2 12 Disassembly of Rear cover assy Removal of Spool pin 2 13 Disassembly of Rear cover assy Removal of Thread guide support...

Page 5: ...31 Removal of Plate spring 2 31 Base plate and handle 2 32 Removal of Base plate 2 33 Removal of Inlet assy 2 33 Removal of Adjusting screw assy Base rubber A 2 33 Removal of Handle 2 34 Needle presser module 2 35 Removal of Presser feed holder assy 2 36 Removal of BH switch assy 2 36 Removal of Thread take up lever link 2 36 Removal of Needle bar crank rod assy 2 37 Removal of Needle bar assy 2 3...

Page 6: ...sm 3 5 Attachment of Plate spring 3 6 Attachment of Needle presser module 3 7 Attachment of Coaching clip 3 8 Attachment of Upper shaft assy 3 9 Attachment of Bushing presser For upper shaft 3 9 Feed mechanism 3 10 Attachment of Feed module 3 11 Attachment of Inner rotary hook assy 3 12 Attachment of Lower shaft bushing 3 12 Attachment of Tension pulley assy 3 12 Bobbin winder mechanism 3 13 Attac...

Page 7: ...hment of Front cover assy 3 36 Assembly of Front cover assy Attachment of SV key top 3 37 Assembly of Front cover assy Attachment of Buttons 3 37 Assembly of Front cover assy Attachment of SSVR PCB assy 3 38 Assembly of Front cover assy Attachment of LED lamp R 3 38 Attachment of Base plate cover 3 38 Attachment of Free arm plate 3 39 Attachment of Free arm cover 3 39 Attachment of Needle plate B ...

Page 8: ...r sub assy 3 63 Attachment of F gear teeth alignment 3 64 Attachment of Spring 3 64 Attachment of Outer rotary hook assy 3 65 Attachment of Inner rotary hook bracket assy 3 65 Attachment of Feed dog 3 65 Attachment of Needle plate A assy 3 66 Assembly of Needle plate A assy 3 66 4 Adjustment 4 1 Needle curvature Tip damage to needle 4 2 Starting test mode 4 3 Test mode list 4 4 Adjustment of Timin...

Page 9: ... does not turn 5 6 Main motor rotation abnormal 5 8 Cannot sew pattern well 5 9 Cannot sew button holes well 5 10 Stitch length and zigzag width cannot be done by manual adjustment 5 11 Problems with vertical needle movement and reverse stitching 5 12 Does not operate when the foot controller is used 5 13 LCD display is not normal 5 14 LCD light does not come on 5 15 Bobbin winding cannot be done ...

Page 10: ...1 1 1 Outline of Mechanism Main Mechanisms 1 2 Driveline 1 3 Positions of electronic components 1 4 Control system block diagram 1 5 Operation of other electronic components 1 6 Using the threader 1 7 ...

Page 11: ...echanism Main Mechanisms Main body Needle bar Presser mechanism Thread guide mechanism Bobbin winder mechanism Upper shaft mechanism Rotary hook drive mechanism Feed Rotary hook mechanism Needle thread block mechanism ...

Page 12: ... counter weight Needle bar crank Needle bar crank rod Needle bar block Needle bar hook stand Needle bar Needle Unit shaft Joint Upper shaft Pulley Needle bar supporter assy Z zigzag lever Needle bar release lever Z zigzag cam Z pulse motor Lower shaft gear Lower shaft assy Timing pulley D Timing belt Upper shaft Feed bar Feed arm A Feed bar Vertical adjusting screw Feed arm b assy F pulse motor Up...

Page 13: ...components Main body Power supply assy Power switch Foot controller jack Inlet assy PCB assy SS VR SW assy PF F LCD PCB assy SW assy BW Main PCB NP sensor Operation PCB assy Z pulse motor BH change switch BH switch lever F pulse motor LED lamp R assy ...

Page 14: ...PCB ASSY POWER PCB ASSY ZPM Drive circuit NP Sensor 2 NP Sensor 1 NP Sensor FPM Drive circuit Switching power supply 30V 5V circuit Pattern selection sensor Photo interrupter x 4 LED PCB ASSY White LED Backlight LCD LED PCB ASSY White LED Lamp Needle area Main motor Drive circuit EEPROM 1kb CPU Foot controller jack Z pulse motor F pulse motor KEY x 5 SS VR PCB ASSY SS SW BK SW NP SW Speed VR ...

Page 15: ... ends of the button hole according to the BH presser and lever BH button hole lever switch This switch detects whether the BH lever is up or down NP sensor This sensor detects the drive timing for the pulse motor for zigzagging and feed the vertical stop position for the needle It detects the upper shaft angle of rotation using a shutter attached to the upper shaft and an optical sensor Speed sens...

Page 16: ...Cautions 1 The threader cannot be used with sewing machine thread and needle combinations that are not in the table or those marked with an x 2 Since combinations marked with an asterisk have a greater possibility of damaging the threader or not working properly do your best to encourage users to avoid them 3 When using the threader lower the presser 4 Do not turn the pulley while using the thread...

Page 17: ...1 8 ...

Page 18: ...al parts and main motor 2 15 Thread tension mechanism 2 19 Bobbin winder mechanism 2 22 Feed mechanism 2 26 Needle bar presser mechanism Upper shaft mechanism 2 29 Base plate and handle 2 32 Modules Needle presser module 2 35 Feed and bobbin module 2 44 ...

Page 19: ...2 2 Main parts Main parts location diagram Main unit ...

Page 20: ... accessory table door 2 from the accessory table 1 2 1 2 Removal of Face plate assy 1 Remove the screw 1 and then remove the face plate assy 1 1 1 2 1 Disassembly of Face plate assy 1 Remove the screw 1 and then remove the face plate cutter holder 2 from the face plate assy 1 2 Remove the NT lower thread cutter 3 from the face plate assy 2 1 1 3 ...

Page 21: ...Remove the cutter cover 2 from the needle plate B assy 1 2 Remove the spring plate 3 from the cutter cover 2 and then remove the NT lower thread cutter 4 3 Remove the slide button 5 from the needle plate B assy 1 Key point Remove the hooks 6 2 locations from the backside of the needle plate B assy 1 2 1 5 5 4 6 2 3 4 Removal of Free arm cover 1 Remove the screw 1 and then remove the free arm cover...

Page 22: ...t Disassembly 5 Removal of Free arm plate 1 Remove the 2 screws 1 and then remove the free arm plate 1 1 1 6 Removal of Base plate cover 1 Remove the 2 screws 1 and then remove the base plate cover 1 from the base plate 1 1 1 ...

Page 23: ...d then remove the hooks 2 and 3 while pushing the parts of 4 and 5 Rear cover side Key point Be careful not to damage the hooks 3 Remove the 2 hooks 7 from the base plate 8 while sliding the front cover assy to the right 4 Remove the 2 connectors 0 from the main PCB assy 9 and then remove the front cover assy 1 2 1 2 7 8 3 9 4 5 ...

Page 24: ...then remove the LED lamp R 1 2 1 3 1 7 2 Disassembly of Front cover assy Removal of SSVR PCB assy 1 Cut the band 1 2 Remove the 3 screws 1 and then remove the board presser 2 the insulator sheet 3 and the SSVR PCB assy 4 1 1 4 1 3 2 7 3 Disassembly of Front cover assy Removal of Buttons 1 Remove the SS button 1 the reverse button 2 and the NP button 3 from the front cover assy 2 1 3 3 1 2 ...

Page 25: ...nit Main parts 7 4 Disassembly of Front cover assy Removal of SV key top 1 Remove the SV key top 1 from the front cover assy Key point Undo the hooks 2 2 locations from the backside of the front cover assy 1 1 2 ...

Page 26: ...ide of the front cover assy and then remove the selecting panel H assy 2 1 1 1 1 1 1 2 8 1 Disassembly of Selecting panel H assy Removal of Operation PCB assy 1 Remove the connector 1 and the flat cable 2 from the operation PCB assy M1H 3 2 Remove the 5 screws 1 and then remove the operation PCB assy M1H 3 from the selecting panel H assy 3 1 2 1 ...

Page 27: ...t Main parts 8 2 Disassembly of Selecting panel H assy Removal of Buttons 1 Remove the feed adjusting button 1 the adjusting button 2 and the reinforcement stitch button 3 from the selecting panel H assy 1 2 3 1 3 2 ...

Page 28: ... Remove the pattern selecting shaft 4 the pattern selecting roller 5 and the dial spring 6 from the selecting panel H assy 2 4 Remove the selecting dial 7 from the selecting panel H assy 2 5 Reomve the dial roller guide 8 from the selecting panel H assy 2 2 8 2 7 1 2 1 3 6 5 2 4 8 4 Disassembly of Selecting panel H assy Removal of Single light guide assy 1 Remove the 2 screws 1 and then remove the...

Page 29: ...ve the rear cover assy 2 from the arm bed Key point Check that the section 3 get over the presser lever 4 Be careful not to break the wing of the motor fan 2 1 4 1 3 1 2 9 1 Disassembly of Rear cover assy Removal of Bobbin presser 1 Remove the screw 1 and then remove the bobbin presser 1 and the nut 1 M3 2 1 2 1 ...

Page 30: ...holder assy 1 from the rear cover assy 2 Remove the spool pin 2 from the shaft of the spool pin holder assy 1 3 Remove the spool presser 3 from the spool pin 2 1 1 3 2 9 3 Disassembly of Rear cover assy Removal of Thread guide supporting plate 1 Remove the screw 1 and then remove the thread guide supporting plate 1 from the rear cover assy 1 1 1 ...

Page 31: ...2 14 Main unit Main parts 9 4 Disassembly of Rear cover assy Removal of Thread guide plate assy 1 Remove the screw 1 and then remove the thread guide plate assy 1 from the rear cover assy 1 1 ...

Page 32: ...2 15 Disassembly Electrical parts and main motor Electrical parts and main motor location diagram Main unit ...

Page 33: ...remove the insulator sheet 3 3 Remove the 2 screws 1 and then remove the shutter cover 4 from the arm bed 4 1 3 1 2 1 1 1 Disassembly of Shutter cover Removal of Main PCB assy 1 Remove the screw 1 and then remove the main PCB plate spring 1 from the shutter cover 2 2 Remove the main PCB assy from the shutter cover while pushing the hook 3 to the left 1 1 3 2 ...

Page 34: ...ng clip 2 3 Disconnect the connectors 3 and 4 4 Remove the 2 screws 3 and then remove the power supply assy 6 from the insulation cover 5 5 Disconnect the connector 7 of the PWSW assy and the connector 8 of the power lead wire assy from the power supply assy 6 3 4 5 2 2 3 6 1 1 6 3 7 3 Removal of Insulation cover 1 Remove the 3 screws 1 and then remove the insulation cover 1 from the arm bed 1 1 ...

Page 35: ...te core 4 from the lead wire of the pin jack assy 2 4 3 2 1 6 Removal of Main motor sub assy 1 Cut the band 1 2 Remove the 2 screws 1 and then remove main motor sub assy 2 from the arm bed 3 Remove the T belt 3 2 3 1 1 6 1 Disassembly of Main motor sub assy 1 Remove the motor fan 2 from the main motor sub assy 1 2 Remove the 2 screws 1 and then remove the main motor sub assy 1 from the motor holde...

Page 36: ...2 19 Disassembly Thread tension mechanism Thread tension mechanism location diagram Main unit ...

Page 37: ...moval of Thread guard cover 1 Remove the thread guard cover 1 from the thread unit L 2 Key point Remove it while lifting the section 4 of the thread guard cover 1 to get over the boss 3 of the thread unit L 2 1 2 1 3 2 4 1 2 Disassembly of Thread unit L Removal of Bobbin winder guide assy 1 Remove the screw 1 and then remove the bobbin winder guide assy 1 from the thread unit L 1 1 ...

Page 38: ...e thread tension plate 4 4 Remove the spring the washer 7 the tension disc washer 8 the thread release plate 9 the washer 0 the tension disc B A and the tension disc A B from the shaft of the thread unit L 6 4 S03 5 7 9 B 6 A 8 3 2 1 1 S03 1 4 Disassembly of Thread unit L Removal of Thread guide wire 1 Remove the screw 1 and then remove the washer 1 and the thread guide wire 2 from the thread unit...

Page 39: ...2 22 Bobbin winder mechanism Bobbin winder mechanism location diagram Main unit ...

Page 40: ...obbin base assy 1 from the bobbin winder assy 2 1 2 1 1 Disassembly of Bobbin base assy 1 Remove the bobbin thread cutter holder 2 from the bobbin base assy 1 Key point Be careful not to damage the hooks 3 4 locations 2 Remove the NT lower thread cutter 4 from the bobbin base assy 1 1 2 2 1 3 3 4 ...

Page 41: ...2 locations and then remove SW assy BW F 2 from the bobbin winder assy 3 1 2 3 2 2 Disassembly of Bobbin winder assy Removal of BW shaft holder assy 1 Open the bobbin winder assy 2 Remove the spring 3 Remove the BW shaft holder assy 1 from the bobbin winder assy holder 2 4 Remove the bobbin winder shaft spring 3 from the BW shaft holder assy 1 5 Remove the rubber ring 4 from the BW shaft holder as...

Page 42: ...winder shaft stopper 1 Remove the screw 1 and then remove the bobbin winder shaft stopper 1 from the bobbin winder assy holder 2 1 2 1 2 4 Disassembly of Bobbin winder assy Removal of SW adjust plate 1 Remove the screw 1 and then remove the SW adjust plate removal 1 from the bobbin winder assy holder 2 1 2 1 ...

Page 43: ...2 26 Feed mechanism Feed mechanism location diagram Main unit ...

Page 44: ...ley assy 1 Remove the screw 1 and then remove the tension pulley assy 1 from the arm bed 1 1 2 Removal of Lower shaft bushing 1 Remove the screw 1 and then remove the lower shaft bushing 1 1 1 3 Removal of Inner rotary hook assy 1 Remove the inner rotary hook assy 1 1 ...

Page 45: ...m 4 Removal of Feed module 1 Remove the screw 1 and the 2 screws 2 and then remove the feed module 1 from the arm bed Key point Move up and remove the feed module 1 and then remove the timing puley D 2 from the T belt 3 1 1 2 3 2 ...

Page 46: ...2 29 Disassembly Needle bar presser mechanism Upper shaft mechanism Needle bar presser mechanism Upper shaft mechanism location diagram Main unit ...

Page 47: ... 1 Remove the screw 1 2 Remove the upper shaft assy 1 Key point Remove the thread take up counter weight 2 from the needle bar crank rod assy 3 while drawing out the upper shaft assy 1 3 Remove the T belt 4 from the upper shaft assy 1 4 Remove the pulley 5 from the upper shaft assy 1 3 1 2 1 5 4 3 Removal of Coaching clip 1 Cut the band 1 2 Remove the screw 1 and then remove the coaching clip 2 an...

Page 48: ... Needle presser module 1 Remove the screw 1 2 Remove the 2 screws 2 and then remove the 2 presser plates 1 3 Remove the needle presser module 2 from the arm bed 1 2 2 1 1 5 Removal of Plate spring 1 Remove the adjusting screw 1 2 Remove the 2 screws 1 and then remove the plate spring 2 1 2 1 ...

Page 49: ...2 32 Base plate and handle Base plate and handle location diagram Main unit ...

Page 50: ...rews 1 and then remove the base plate 1 1 1 2 Removal of Inlet assy 1 Remove the screw 1 and then remove the inlet assy 1 1 1 3 Removal of Adjusting screw assy Base rubber A 1 Remove the adjusting screw assy 1 from the base plate 2 2 Remove the 4 base rubbers A 3 from the base plate 2 3 2 1 ...

Page 51: ...e the 2 screws 1 and then remove the handle holder 1 from the arm bed 2 Remove the 2 retaining rings E4 and then remove the 2 polyester sliders 2 3 Remove the 2 handle shafts 3 and then remove the handle 4 from the handle holder 1 1 1 4 1 Retaining ring E4 4 1 2 3 3 ...

Page 52: ...2 35 Disassembly Needle presser module Needle presser module breakout diagram Modules ...

Page 53: ...1 Remove the screw 1 and then remove the BH switch assy 1 1 1 3 Removal of Thread take up lever link 1 Remove the 2 screws 1 and then pull the take up support shaft 1 and then remove the washer spring 2 and the thread take up lever link 3 Key point Pull the thread take up lever link 3 from the shaft of the thread take up lever 4 2 Remove the retaining ring E5 from the take up support shaft 1 1 1 2...

Page 54: ...oval of Needle bar crank rod assy 1 Remove the needle bar crank rod assy 1 from the needle bar block 2 2 Remove the screw 1 and then remove the thread take up lever 3 from the needle bar crank rod assy 1 Key point The screw is reverse threaded 1 2 1 3 1 ...

Page 55: ...f Needle bar assy 1 Remove the screw 1 and then remove the needle bar thread guide 1 from the needle bar 2 2 Remove the screw 2 and then remove the needle block 3 from the needle bar 2 3 Remove the needle thread plate 4 from the needle block 3 2 1 2 1 3 3 4 6 Removal of Shaft assy 1 Remove the screw 1 and then remove the shaft assy 1 from the base holder assy 2 Remove the needle holder block 2 fro...

Page 56: ...e base holder assy 1 S09 S08 1 S09 S08 8 Removal of Threader hook assy 1 Remove the threader hook assy 2 from the needle bar holder assy 1 Key point Remove the hook part 3 of the threader hook assy 2 and then pull it to the lower side 2 3 1 9 Removal of Zigzag adjusting nut 1 Remove the screw 1 and then remove the zigzag adjusting nut 1 from the needle bar supporter assy 1 1 ...

Page 57: ...ft 2 and then remove the needle holder shaft A 3 from the needle bar supporter assy 1 1 3 S07 2 2 S07 11 Removal of PF switch assy 1 Remove the screw 1 and then remove the presser switch holder 1 from the base holder assy 2 Remove the PF switch assy 2 from the presser switch holder 1 1 1 2 1 12 Removal of Presser foot lifter 1 Remove the retaining ring E4 and then remove the presser foot lifter 1 ...

Page 58: ...then pull the presser bar 1 from the base holder assy and then remove the spring 2 and the presser bar clamp 3 1 1 2 3 1 14 Removal of Thread release lever 1 Remove the retaining ring CS4 and then remove the thread release lever 1 and the spring from the base holder assy 1 S06 Retaining ring CS4 S06 ...

Page 59: ...e Z zigzag lever assy 1 2 Remove the retaining ring E4 and then remove the Z zigzag lever assy 1 and the polyester slider 3 1 Retaining ring E4 2 3 16 Removal of Z zigzag cam 1 Remove the retaining ring E3 and then remove the Z zigzag cam 1 Retaining ring E3 1 17 Removal of Rubber 1 Remove the rubber 1 1 ...

Page 60: ... pulse motor 1 from the base holder assy 2 Remove the lead wire sub assy 2 from the Z pulse motor 1 1 1 2 19 Removal of Lock nut 1 Remove the lock nut 1 from the base holder assy 2 Remove the screw 1 1 1 20 Removal of Shaft bushing 1 Remove the 2 screws 1 and then remove the shaft bushing 1 from the base holder assy 1 1 ...

Page 61: ...2 44 Feed and bobbin module Feed and bobbin module breakout diagram Modules ...

Page 62: ...emove the F gear stopper plate 1 from the needle plate A 2 2 Remove the 2 screws 2 and then remove the needle plate B support plate 3 and the stopper plate 4 from the needle plate A 2 2 2 1 1 4 3 2 Removal of Feed dog 1 Remove the 2 screws 1 and then remove the feed dog 1 1 1 3 Removal of Inner rotary hook bracket assy 1 Remove the screw 1 and then remove the inner rotary hook bracket assy 1 from ...

Page 63: ...tary hook assy 1 Remove the screw 1 and then pull the outer rotary hook shaft 1 and then remove the spacer 2 the outer rotary hook assy 3 the washer 6 4 and the spacer 5 from the shaft supporter 6 6 5 1 4 3 2 1 5 Removal of Spring 1 Remove the spring S15 S15 ...

Page 64: ...etaining ring CRS 10 and then remove the FPM holder sub assy 1 from the base plate assy 4 Remove the rubber 2 from the FPM holder sub assy 1 1 2 S14 2 1 Retaining ring CRS 10 S14 7 Removal of F pulse motor 1 Remove the 2 screws 1 and then remove the F pulse motor 1 from the FPM holder sub assy 2 2 Remove the lead wire assy FPM LE 3 from the F pulse motor 1 1 3 2 1 ...

Page 65: ...taining rind CS4 and then remove the polyester slider 1 the feed bar 2 and the polyester slider 3 from the feed arm A assy 2 1 Retaining ring CS4 3 10 Removal of Vertical adjuster screw assy 1 Remove the vertical adjuster screw assy 1 from the feed bar 2 2 Remove the M5 nut 3 from the vertical adjuster screw assy 1 2 3 1 ...

Page 66: ... remove the washer plain 2 the spring and the vertical lever 3 3 Remove the retaining ring E3 from the vertical feed shaft 1 4 Remove the drop knob 4 from the base plate assy Key point Remove it while lifting the section 6 of the drop knob 4 to get over the boss part 5 of the base plate assy Retaining ring E3 3 2 S12 1 Retaining ring E3 5 6 4 S12 ...

Page 67: ...4 from the base plate assy 4 Remove the feed arm supporter 1 from the needle plate supporter shaft B 4 3 2 4 1 13 Removal of Shaft supporter 1 Remove the 2 screws 1 and then remove the shaft supporter 1 from the base plate assy 1 1 14 Removal of Feed supporting plate 1 Remove the screw 1 and then remove the feed supporting plate B 1 and the feed supporting plate 2 from the feed arm assy 3 2 1 1 3 ...

Page 68: ...ing ring E6 and then lower shaft bushing 1 from the lower shaft assy 2 2 Retaining ring E6 1 17 Removal of Bushing presser B 1 Remove the retaining ring E6 and then remove the washer thrust 2 from the lower shaft assy 1 2 Remove the 3 screws 1 and then remove the bushing presser B 3 from the base plate assy 3 Remove the lower shaft bushing 4 and the washer thrust 5 from the lower shaft assy 1 2 1 ...

Page 69: ...ve the set collar 2 1 1 2 19 Removal of Feed arm A assy 1 Remove the screw 1 and then remove the set collar 1 2 Remove the screws 2 and then pull the horizontal feed shaft 2 and then remove the washer thrust 3 the feed arm A assy 4 and the washer thrust 5 Key point Remove the feed regulator slide shaft of the feed arm B assy from the feed adjuster 1 1 2 2 3 5 4 ...

Page 70: ...e polyester slider 2 from the feed arm A assy 3 1 CS Retaining ring CSTW 3 5 3 2 21 Removal of Feed adjuster assy 1 Pull the feed adjuster 1 from the base plate assy and then remove the spring and the polyester slider 2 1 S10 2 S10 21 1 Disassembly of Feed adjuster assy 1 Remove the spring and then remove the F gear 2 from the feed adjuster 1 S11 2 1 1 2 S11 ...

Page 71: ...2 54 ...

Page 72: ...justments Main unit Base plate and handle 3 2 Needle bar presser mechanism upper shaft mechanism 3 5 Feed mechanism 3 10 Bobbin winder mechanism 3 13 Thread tension mechanism 3 17 Electrical parts and main motor 3 22 Main parts 3 30 Modules Needle presser module 3 42 Feed and bobbin module 3 54 ...

Page 73: ...3 2 Base plate and handle Base plate and handle location diagram Main unit ...

Page 74: ...sliders 4 into the handle shaft 3 and then attach the retaining ring E4 3 Attach the handle holder 2 to the arm bed with the 2 screws 1 1 Torque 1 47 1 96 N m 2 1 4 3 4 3 Retaining ring E4 2 1 2 Taptite Bind S M4X10 2 Attachment of Adjusting screw assy Base rubber A 1 Attach the 4 base rubbers A 1 to the base plate 2 Attach the adjusting screw assy 2 to the base plate 2 1 ...

Page 75: ...with the screw 1 Key point Check that the boss part of the inlet assy 1 engaged with the positioning hole of base plate 1 Torque 0 78 1 18 N m 1 1 Screw Pan S P washer M4X8 4 Attachment of Base plate 1 Attach the base plate 1 to the arm bed with the 3 screws 1 1 Torque 1 47 1 96 N m 1 1 Taptite Bind S M4X10 ...

Page 76: ...3 5 Assembly Needle bar presser mechanism upper shaft mechanism Needle bar presser mechanism upper shaft mechanism location diagram Main unit ...

Page 77: ...Plate spring 1 Attach the plate spring 1 from the front of the arm bed with the 2 screws 1 2 Attach the adjusting screw 2 from the back of the arm bed Key point Tighten the adjusting screw 2 so that the screw threads are completely hidden 1 Torque 1 18 1 57 N m 1 1 2 Screw Bind M4X8 ...

Page 78: ... Key point Set in the take up support shaft 2 to the groove 3 2 locations of the arm bed 2 Attach the 2 presser plates 4 with the 2 screws 1 3 Tighten the screw 2 temporarily Key point Fully tighten the screw after performing 4 10 Adjustment of Clearance between 1 Torque 1 47 1 96 N m 2 Torque 0 59 0 78 N m 3 2 1 1 4 2 Taptite Bind S M4X10 Screw Pan Washer M3X18 ...

Page 79: ...d wire sub assy with the band 1 2 Attach the insulator sheet 2 and the coaching clip 3 to the arm bed with the screw 1 3 Bind up the lead wires with the band 4 Key point Refer to Special Instructions of Wiring Secure the lead wire of the BH switch assy and the lead wire sub assy with the coaching clip 3 1 Torque 1 18 1 57 N m 1 4 2 1 3 Screw Bind M4X6 ...

Page 80: ...n attach the upper shaft assy 2 to the arm bed Key point Check that the 2 lower shaft bushings 7 engaged with the attaching part 8 of the arm bed 4 Attach the scrrew 1 Key point Check that the screw 1 with the D cut surface of the needle bar crank rod assy 5 1 Torque 1 18 1 57 N m 2 3 4 1 7 2 8 8 6 5 1 Set Screw Socket FT M5X5 5 Attachment of Bushing presser For upper shaft 1 Attach the 2 bushing ...

Page 81: ...3 10 Feed mechanism Feed mechanism location diagram Main unit ...

Page 82: ...arm bed 3 Attach the feed module 5 to the arm bed with the 2 screws 1 and 2 Key point Check that there is the gullet 7 of the upper shaft pulley and the reference point 8 of the outer rotary hook assy in the front side when the needle bar 6 and the feed dog 9 are the highest point 1 Torque 1 18 1 57 N m 2 Torque 0 78 1 18 N m 3 2 4 1 5 1 2 7 8 6 9 Stud screw M4 Screw Bind M3X12 ...

Page 83: ...1 Attach the lower shaft bushing 1 to the arm bed with the screw 1 1 Torque 1 47 1 96 N m 1 1 Taptite Bind S M4X10 4 Attachment of Tension pulley assy 1 Set the tension pulley assy 1 to the arm bed and then tighten the scerw 1 temporarily Key point Fully tighten the screw after performing 4 5 Adjustment of Timing belt tension 1 Torque 1 18 1 57 N m 1 1 Screw Pan S P washer M4X10 ...

Page 84: ...3 13 Assembly Bobbin winder mechanism Bobbin winder mechanism location diagram Main unit ...

Page 85: ...ate 1 with the positioning hole of the bobbin winder assy holder 2 and then tighten the screw 1 temporarily Key point Fully tighten the screw after performing 4 19 Adjustment of BW switch position 1 Torque 0 59 0 78 N m 1 1 2 Screw Bind M3X6 1 2 Assembly of Bobbin winder assy Attachment of Bobbin winder shaft stopper 1 Align the boss part of the bobbin winder shaft stopper 1 with the positioning h...

Page 86: ...BW shaft holder assy 1 engaged with the 2 positioning holes of the bobbin winder assy holder 4 4 Attach the spring to the BW shaft holder assy 1 and the bobbin winder assy holder 4 Key point Attach the side where the hook part of the spring is twisted in the right angle to the BW shaft holder assy 1 S01 1 2 3 4 1 S01 S01 BOBBIN WINDER SPRING XZ0070 7 1 2 5 4 4 2 8 1 4 Assembly of Bobbin winder ass...

Page 87: ...eck that the 2 gullets 3 of the bobbin base assy 1 engage with the 2 protrusions 4 of the bobbin winder 2 3 1 4 2 1 Assembly of Bobbin base assy 1 Attach the NT lower thread cutter 2 to the bobbin base assy 1 2 Attach the bobbin thread cutter holder 3 to the bobbin base assy 1 Key point Be careful not to damage the hooks 4 4 locations 1 2 3 4 4 ...

Page 88: ...3 17 Assembly Thread tension mechanism Thread tension mechanism location diagram Main unit ...

Page 89: ... Thread unit L 1 to the arm bed with the 2 screws 1 Key point Check that the thread release plate 2 is on the left side of the thread release lever 3 Refer to 4 7 Adjustment of Upper thread tension 2 Bind up the lead wire with the band 4 1 Torque 1 18 1 57N m 1 1 4 3 2 Stud screw M4 ...

Page 90: ...ith the screw 1 Key point Check that the protrusions 5 2 locations of the thread catching spring case 3 engaged with the positioning hole 6 of the Thread unit L 1 Check that from the lower side of the notch part of the Thread unit L 1 to the bent section of the spring is 9 to 10 mm 1 Torque 0 59 0 78 N m S02 4 5 3 S02 2 1 1 3 1 5 6 9 10mm S02 Screw Pan Washer M3X18 15 6 7 4 SPRING XE2029 1 2 Assem...

Page 91: ... tension adjusting screw A into the shaft of the Thread unit L 1 and then attach the thread tension dial B to the Thread unit L 1 with the tension dial shaft E 3 Attach the notched spring F to the Thread unit L 1 with the screw 1 Key point Insert the tip of notched spring F into the bottom of the thread tension dial B Check that the boss part of the Thread unit L 1 engaged with the positioning hol...

Page 92: ... the thread guard cover 1 to the Thread unit L 2 Key point Attach it while lifting the section 4 of the thread guard cover 1 to get over the boss 3 of the Thread unit L 2 Check that the protrusions 5 2 locations of the Thread unit L 2 engaged with the gullets 6 2 locations of the thread guard cover 1 1 2 1 2 6 6 4 5 5 3 ...

Page 93: ...3 22 Electrical parts and main motor Electrical parts and main motor location diagram Main unit ...

Page 94: ...wire with the band 4 4 Secure the lead wire with the coaching clip 5 Key point Refer tp Special Instruction of Wiring 1 Torque 1 18 1 57 N m 3 5 4 1 1 2 Upset 4X12DB 1 1 Assembly of Main motor sub assy 1 Attach the coaching clip 1 to the motor holder 2 with the screw 1 2 Attach the main motor sub assy 3 to the motor holder 2 with the 2 screws 2 3 Attach the motor fan 4 to the gear for main motor s...

Page 95: ...y point See the figure to the right for positioning Refer to Special instruction of Wiring 1 2 3 3 Attachment of PWSW assy 1 Attach the PWSW assy 1 to the insulation cover 2 Key point Check that the hook of the PWSW assy 1 hang on the insulation cover 2 Check that the match mark 3 of the PWSW assy 1 engaged with the match mark 4 of the insulation cover 2 4 1 3 2 ...

Page 96: ... to the power supply assy 2 2 Attach the power supply assy 2 to the insulation cover 3 with the 2 screws 1 3 Attach the connector 4 and the connector 5 to the power supply assy 2 4 Attach the coaching clip 6 to the insulation cover 3 with the screw 2 Key point Attach the ferrite core 7 with the coaching clip 6 5 Attach the insulator sheet 8 to the insulation cover 3 with the screw 3 1 2 3 Torque 0...

Page 97: ...own in the photo on the right and then attach it with the band 6 Key point Refer to Special Instructions of Wiring 1 Torque 1 18 1 57 N m 1 2 6 3 5 1 4 Stud screw M4 6 1 Assembly of Main PCB assy to the shutter cover 1 Insert the main PCB assy 1 from the lower side in the hooks 2 2 locations of the shutter cover 3 2 Set the main PCB assy 1 in the shutter cover 3 while pushing the hook 4 to the lef...

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Page 101: ...3 30 Assembly Main parts Main parts location diagram Main unit ...

Page 102: ... the 2 positioning holes of the arm bed Be careful not to break the wing of the motor fan 3 Attach the rear cover assy 2 with the 2 screws 1 1 Torque 1 18 1 57 N m 1 3 2 2 1 4 1 1 Screw Bind M4X8 1 1 Assembly of Rear cover assy Attachment of Thread guide plate assy 1 Attach the thread guide plate assy 1 to the rear cover assy with the screw 1 Key point Check that the boss of the rear cover assy en...

Page 103: ...12 1 3 Assembly of Rear cover assy Attachment of Spool pin 1 Attach the spool pin 2 to the shaft of the spool pin holder assy 1 2 Attach the spool presser 3 to the spool pin 2 3 Set the spool pin holder assy 1 to the rear cover and then attach it with the screw 1 Key point Check that the 2 bosses 5 of the rear cover engaged with the 2 positioning holes 4 of the spool pin holder assy 1 1 Torque 0 3...

Page 104: ... assy 1 Attach the selecting panel H assy 1 to the front cover assy and then attach it with the 4 screws 1 Key point First hang the hooks 2 2 locations on the front cover and then hang the hooks 3 2 locations on the front cover 1 Torque 0 39 0 78 N m 2 3 1 1 1 Taptite Bind B M3X10 2 1 Assembly of Selecting panel H assy Attachment of Single light guide assy 1 Attach the single light guide assy 1 to...

Page 105: ...pring 5 5 Attach the indication sheet to the selecting shutter 9 Key point Check that the boss part A of the selecting shutter 9 engaged with the positioning hole B of the indication sheet 0 6 Attach the selecting shutter 9 to the selecting panel H assy 2 Key point Check that the protrusion C of the selecting dial 4 engaged with the groove D of the selecting shutter 9 7 Attach the selecting shutte...

Page 106: ... point Check that the protrusion of the selecting panel H assy 4 engaged with the notch of the each button 2 3 1 4 4 3 2 1 2 4 Assembly of Selecting panel H assy Attachment of Operation PCB assy M1H 1 Attach the operation PCB assy M1H 1 to the selecting panel H assy 2 with the 5 screws 1 2 Attach the connector 3 and the flat cable 4 to the operation PCB assy M1H 1 1 Torque 0 39 0 78 N m 1 2 1 3 4 ...

Page 107: ...ont cover assy 3 Key point Check that the hooks 4 2 locations hang on the base plate 5 and the hooks 6 3 locations hang on the hook attaching part 7 3 Fix the front cover assy 3 to the rear cover assy 8 with the screw 1 and 2 1 Torque 0 39 0 78 N m 2 Torque 0 78 1 18 N m 2 1 6 7 3 6 7 4 2 1 8 5 Taptite Bind P M3X16 Taptite Cup B M4X14 ...

Page 108: ...e hooks 2 2 locations of the SV key top 1 is the upper side and it hang on the front cover assy 1 2 1 3 2 Assembly of Front cover assy Attachment of Buttons 1 Attach the SS button 1 the reverse button 2 and the NP button 3 to the font cover assy Key point Check that the protrusion of the front cover assy engaged with the notch of the each button 1 3 2 1 2 3 ...

Page 109: ...y 1 contact the each buttons 3 locations 3 Bind up the SSVR PCB assy lead wire and the operation PCB assy lead wire with the band 7 1 Torque 0 39 0 78 N m 2 Torque 0 39 0 78 N m 5 4 1 6 7 2 3 2 1 1 Taptite Bind B M3X10 Taptite Bind B M3X12 3 4 Assembly of Front cover assy Attachment of LED lamp R 1 Attach the LED lamp R 1 to the front cover assy with the screw 1 2 Attach the connector 2 of the LED...

Page 110: ... Attach the free arm plate 1 to the arm bed with the 2 screws 1 1 Torque 1 18 1 57 N m 1 1 Screw Bind M4X6 6 Attachment of Free arm cover 1 Attach the free arm cover 1 to the free arm plate with the screw 1 1 Torque 0 78 1 18 N m 1 1 Screw Pan S P washer M4X8 ...

Page 111: ... of Needle plate B assy 1 Attach the slide button 1 to the needle plate B assy 2 Key point Check that the hooks 3 2 locations hang on the needle plate B assy 2 2 Attach the NT lower thread cutter 5 and the spring plate 6 to the cutter cover 4 3 Attach the cutter cover 4 to the needle plate B assy 2 Key point Check that the hook 7 hang on the needle plate B assy 2 3 1 6 4 5 2 1 4 2 2 7 ...

Page 112: ...of Face plate assy 1 Attach the NT lower thread cutter 1 to the face plate assy 2 2 Attach the face plate cutter holder 3 to the face plate assy 2 with the screw 1 1 Torque 0 39 0 78 N m 3 2 1 1 Taptite Pan B M3X6 9 Attachment of Accessory table 1 Attach the accessory table 1 1 9 1 Assembly of Accessory table 1 Attach the accessory table door 2 to the accessory table 1 2 1 ...

Page 113: ...3 42 Assembly Needle presser module Needle presser module breakout diagram Modules ...

Page 114: ...k nut 1 to about half of the screw 1 2 Attach the screw 1 to the base holder assy Key point Tighten it until the lock nut 1 hit the base holder assy Refer to 4 9 Forward and back adjustment of needle and presser 1 Torque 0 78 1 18 N m 1 1 1 1 Set Screw Socket CP M4X12 3 Attachment of Z pulse motor 1 Attach the Z pulse motor 1 to the base holder assy with the 2 screws 1 2 Attach the lead wire sub a...

Page 115: ...sy Key point Check that the match mark 3 on the Z zigzag cam 1 Align the match mark 5 on the Z pulse motor gear 4 2 Attach the retaining ring E3 to the shaft 2 of the base holder assy Apply EPNOC AP N 0 to all of the sliding part of the Z zigzag cam pin Bead XC8387 Apply EPNOC AP N 0 to all of the Z zigzag cam Bead XC8387 Apply EPNOC AP N 0 to the teeth around the Z zigzag cam gear Bead XC8387 Ret...

Page 116: ...er assy and then attach the retaining ring E4 Key point Check that the shaft 4 of the Z zigzag lever assy 3 is at the left of the Z zigzag cam 5 2 Attach the Z lever cap 6 to the Z zigzag lever assy 3 Apply EPNOC AP N 0 to the shaft of the base holder assy Bead XC8387 Apply EPNOC AP N 0 to the shaft of the Z zigzag lever Bead XC8387 1 2 Retaining ring E4 3 4 6 5 3 ...

Page 117: ...0 to the shaft of the base holder assy Small amount XC8387 S06 2 S06 Retaining ring CS4 1 S06 SPRING XC2460 5 0 8 Attachment of Presser bar 1 Insert the base holder assy the presser bar clamp 2 the spring 3 and the base holder assy from the bottom of the presser bar 1 and then tighten the screw 1 temporarily Key point Fully tighten the screw after performing 4 15 Adjustment of Presser bar height a...

Page 118: ...ount XC8387 Apply EPNOC AP N 0 to the operating surface of the presser bar lifter presser bar clamp Small amount XC8387 3 2 1 4 Retaining ring E4 10 Attachment of PF switch assy 1 Attach the PF switch assy 1 to the presser switch holder 2 Key point Check that the boss part of the PF switch assy 1 align the positioning hole of the presser switch holder 2 2 Attach the presser switch holder 2 to the ...

Page 119: ...der shaft A 1 4 Attach the spring to the plate 4 and the needle bar supporter assy Key point Attach the hook side of the spring to the plate 4 Apply FBK OIL RO 100 to the needle holder shaft A 1 2 drops XC8388 1 Torque 0 78 1 18 N m 2 Torque 0 59 0 78 N m S07 2 1 3 1 2 5 4 4 S07 S07 Screw Bind M3X5 Set Screw Socket CP M3X5 SPRING X50476 23 4 12 Attachment of Z zigzag adjusting nut 1 Set the Z zigz...

Page 120: ...le holder shaft A 2 of the needle bar supporter assy 1 into the shaft bushing 3 of the base holder assy and then attach the needle bar supporter assy 1 to the base holder assy 2 Attach the spring to the needle bar supporter assy 1 and the base holder assy Key point Attach the long side of the hook of the spring to the shaft bushing 3 Attach the spring to the needle bar supporter assy 1 and the bas...

Page 121: ... M3X10 16 Attachment of Needle bar assy 1 Insert the needle bar supporter assy the needle bar block 2 the needle thread block 3 and the needle bar supporter assy from the lower side of the needle bar assy 1 and then tighten the 2 screws 1 temporarily Key point When the needle thread block 3 is viewed from the front it is secured in a position turned slightly counterclockwise Fully tighten the scre...

Page 122: ...eck that the screw 1 is on the right side 3 Attach the needle bar thread guide 4 to the needle bar 3 with the screw 2 Key point Check that there should no gap 5 between the needle bar thread guide 4 and the right side of the needle bar 2 Check that there should be a 0 2 mm 0 5 mm gap between the needle bar thread guide 4 and the left side of the needle bar 2 1 2 Torque 0 39 0 78 N m 1 2 3 2 1 2 4 ...

Page 123: ...w attachment face of the needle bar crank Small amount XC8387 1 Torque 1 18 1 57 N m 2 1 1 3 2 Screw Flat SM3 57 40X7L 18 Attachment of Thread take up lever link 1 Attach the retaining ring E5 to the take up support shaft 1 2 Set the base holder assy as shown in the right figure and then insert the take up support shaft 1 into the washer spring 2 the thread take up lever link 3 and the base holder...

Page 124: ...witch holder assy engaged with the positioning hole 2 of the BH switch assy 1 Refer to 4 20 Adjustment of BH lever switch position 1 Torque 0 78 1 18 N m 2 1 3 1 Screw Pan S P washer M4X8 20 Attachment of Presser feed holder assy 1 Attach the presser feed holder assy 1 to the presser bar 2 2 Attach the Z foot 3 to the presser feed holder assy 1 1 Torque 0 78 1 18 N m 2 1 1 3 Screw 3 57 ...

Page 125: ...3 54 Assembly Feed and bobbin module Feed and bobbin module breakout diagram Modules ...

Page 126: ...BK OIL RO 100 1 2 drops XC8388 Apply EPNOC AP N 0 to the entire operating part of the feed adjuster feed regulator slide block Small amount XC8387 S10 2 1 S10 1 S10 SPRING XC2531 8 8 9 9 5 5 1 1 Assembly of Feed adjuster assy 1 Attach the F gear 2 to the feed adjuster 1 Key point When set it as shown in the right figure check that the protrusion 3 of the F gear 2 is the upper side 2 Attach the spr...

Page 127: ... feed adjuster 4 2 Insert the horizontal feed shaft 5 into the feed arm A assy 1 the washer thrust 6 and the base plate assy from the right side and then align the positioning hole on the feed arm supporter shaft and then attach it with the screw 1 3 Insert the washer thrust 7 and the set collar 8 into the horizontal feed shaft 5 and then attach it with the screw 2 Key point Attach the feed arm A ...

Page 128: ... assy 1 and then tighten the 2 screws 1 temporarily Key point Check that the cut surface 3 of the set collar 2 is the out side Fully tighten the screw after performing 3 58 Attachment of Bushing presser B 2 Set the lower shaft assy 1 to the base plate assy 1 Torque 0 78 1 18 N m 1 2 3 1 1 Set Screw Socket CP M4X4 ...

Page 129: ...en tighten the screw 2 Key point Check that the lower shaft assy 1 is not a wobble and it moves smoothly Lubricate the lower shaft bushing round surface with FBK OIL RO 100 1 2 drops XC8388 Apply MOLYKOTE EM30L to all of the teeth around the lower shaft gear Small amount XC8385 1 Torque 0 39 0 78 N m 2 Torque 0 78 1 18 N m 2 1 3 2 1 1 4 Retaining ring E6 3 5 2 2 Taptite Bind B M3X6 Set Screw Socke...

Page 130: ...otrusion 3 of the feed supporting plate 1 engaged with the groove 4 of the feed arm B assy 2 2 Set the feed supporting plate B 5 to the feed supporting plate 1 attach the feed arm B assy 2 with the screw 1 Key point Check that the boss of the feed supporting plate B 5 engaged with the positioning hole of the feed supporting plate 1 Check that sandwich the feed cam 6 with the feed supporting plate ...

Page 131: ... needle plate supporter shaft B 1 Key point Check that the hook part 3 of the feed arm supporter 2 is the lower side 2 Attach the needle plate supporter shaft B 1 to the base plate assy 3 Attach the nut 1 M3 4 to the needle plate supporter shaft B 1 4 Hang the hook part 3 of the feed arm supporter 2 on the base plate assy 2 3 1 4 3 1 ...

Page 132: ... side Key point Insert it until the retaining ring hit the base plate assy 4 Attach the 3 retaining rings E3 to the grooves 3 locations of the vertical feed shaft 4 Apply EPNOC AP N 0 to the sliding parts of the drop knob and the base plate assy Bead XC8387 Lubricate the vertical feed shaft with OILER 1 2 drops XZ0206 Apply EPNOC AP N 0 to the vertical feed cam surface A Small amount XC8387 S12 2 ...

Page 133: ...e feed shaft hole in the feed bar Bead XC8387 Apply EPNOC AP N 0 to the feed arm A assy Bead XC8387 Apply EPNOC AP N 0 to the groove of the vertical lever Small amount XC8387 3 1 Retaining ring CS4 2 4 6 5 14 Attachment of Spring 1 Attach the spring to the feed bar 1 and the base plate assy 2 S13 S13 2 1 S13 SPRING XE1940 21 1 3 8 15 Attachment of F pulse motor 1 Attach the F pulse motor 1 to the ...

Page 134: ... 3 Sandwich the spring between the FPM holder sub assy 1 and the base plate assy and then attach the screw 1 Key point Tighten the screw 1 until the screw hole 6 in the base plate assy comes approximately to the center of the positioning hole 7 in the FPM holder sub assy 1 4 Tighten the screw 2 temporarily Key point Fully tighten the screw after performing 4 17 Adjustment of Feed 1 Torque 0 78 1 1...

Page 135: ...h the teeth of the F gear 5 and then mesh it and the F pulse motor gear 1 Key point Check that the match mark 6 of the F gear 5 and the match mark 7 of the F pulse motor gear 1 are together Apply EPNOC AP N 0 to the all of the teeth on the feed adjusting assy F gear Bead XC8387 3 2 1 4 5 1 5 6 1 7 18 Attachment of Spring 1 Attach the spring to the FPM holder assy 1 and the feed bar 2 S15 1 S15 1 S...

Page 136: ...shaft with the OILER Apply liberally XZ0206 1 Torque 0 78 1 18 N m 6 5 1 4 3 2 1 Set Screw Socket CP M4X6 20 Attachment of Inner rotary hook bracket assy 1 Attach the inner rotary hook bracket assy 1 to the base plate assy with the screw 1 Key point Check that the positioning hole 2 to the inner rotary hook bracket assy 1 engaged with the boss 3 of the base plate assy Refer to 4 23 Adjustment of I...

Page 137: ... the needle plate A 2 with the screw 1 Key point Check that the boss part of the F gear stopper plate 1 engaged with the positioning hole of the needle plate A 2 2 Attach the stopper plate 3 and the needle plate B support plate 4 to the needle plate A assy 2 with the 2 screws 2 Key point Check that the boss part of the stopper plate 3 engaged with the positioning hole of the needle plate A 2 1 2 T...

Page 138: ...3 67 ...

Page 139: ...nd the rotary hook point 4 10 Adjustment of Needle bar rise 4 11 Adjustment of Needle bar height 4 12 Adjustment of Needle interference left right 4 13 Adjustment of Needle thread block 4 14 Adjustment of Presser bar height and parallel 4 15 Adjustment of Inner rotary hook lower thread tension 4 16 Adjustment of Feed 4 17 Adjustment of Bobbin winder 4 18 Adjustment of BW switch position 4 19 Adjus...

Page 140: ...ip damage to needle 1 Check to be sure that there is no curvature in the needle on a level block horizontal block 2 Touch the tip of the needle to your finger and check to be sure it does not catch The gap with the block should be even ...

Page 141: ...top button and the Reverse stitch button while turning the power on the buzzer will sound four times and test mode will start How to get start in each test mode Turn the pattern selection dial and select the test mode number Pattern display window Pattern selection dial Test mode No Stitch pattern No ...

Page 142: ... Sewing speed controller Three point needle drop adjustment 4 8 Clearance between the needle and the rotary hook point adjustment 4 10 Needle bar rise adjustment 4 11 Needle bar height adjustment 4 12 Needle interference left right adjustment 4 13 Forward and reverse feed 6 100 stitches forward on the left base line 100 stitches reverse on the right base line It is freely changed with the Sewing s...

Page 143: ... 10 on the tension pulley assembly 3 With a force of 1 96 N 200 g pushing on the center of the belt adjust the tension pulley assembly position for a deflection of 4 5 mm 4 Tighten the pan head screw S P washer M4 x 10 on the tension pulley assembly torque 1 18 1 57N m XC2277001 Push pull gauge 3 N 1 96N 200g Pan head screw S P washer M4 x 10 ...

Page 144: ...w M4 x 12 DB in the motor holder 3 With a force of 0 98 N 100 g pushing on the center of the belt adjust the motor pulley position for a deflection of 4 5 mm 4 Tighten the 2 upset screw M4 x 12 DB in the motor holder torque 0 78 1 18N m XC2277001 Push pull gauge 3 N 0 98N 100g Upset screw M4 x 12 DB ...

Page 145: ...foot lifter 6 Pull the thread with a tension gauge and adjust the thread tension adjusting screw depth for 0 41 0 46N 42 47g 7 Apply a small amount of screw locking compound to the thread tension adjusting screw Screw locking compound for thread tension adjusting screw Small amount XA9154001 Tension gauge 50 0 5 N Thread tension dial Tension disk Thread tension adjuting screw 0 41 0 46N 42 47g Sch...

Page 146: ...ey by hand and insert the tip of the needle into the needle hole 5 Loosen the socket bolt M3 x 10 of the zigzag adjusting nut 6 Adjust the zigzag adjusting nut so that the left base line center base line right base line needle drop is uniform to the left and right of the needle plate A needle hole 7 Tighten the socket bolt M3 x 10 torque 0 78 1 18N m 8 Turn off the power XE2395001 Box screw driver...

Page 147: ...n the pulley by hand and insert the tip of the needle into the needle hole 3 Loosen the lock nut 4 Adjust the needle tip to the front back center position of the needle hole using the socket set screw CP M4 x 12 5 Tighten the lock nut Lock nut Needle hole Needle tip position Socket set screw CP M4 x 12 Rear of main unit ...

Page 148: ... washer M3 x 18 7 Turn the pulley by hand until the right edge of the needle and the outer rotary hook tip meet 8 Adjust the gap between the needle and the outer rotary hook tip front and back to left base line 0 25mm or less and right base line 0 15mm or less using the tightening depth of the adjusting screw 9 Tighten the screw pan head screw washer M3 x 18 torque 0 59 0 78N m 10 Turn off the pow...

Page 149: ...he needle bar at its lowest point 7 Loosen the 2 socket set screws CP M5 x 5 on lower shaft pulley D 8 With the needle bar raised 2 9 3 3 mm from the needle bar low point reference line adjust by moving the lower shaft pulley D and lower shaft assembly so that the right edge of the needle and the outer rotary hook tip come together 9 Secure the 2 socket set screws CP M5 x 5 on lower shaft pulley D...

Page 150: ... the outer rotary hook tip meet 7 Loosen the socket set screw FT M4 x 4 of the needle bar block 8 Adjust the height of the needle bar for 1 0 1 4 mm between the top of the needle hole and lower edge of the outer rotary hook tip NOTE Make sure the needle block is not positioned at a slant 9 Tighten the socket set screw FT M4 x 4 of the needle bar block torque 0 78 1 18N m 10 Perform Adjustment of N...

Page 151: ...the pulley by hand and insert the tip of the needle into the needle hole 6 Loosen the screw M3 x 10 7 Adjust the needle holder block to the left or right so that the left base line right base line needle drop is uniform left and right gaps between the needle and the tip of the outer rotary to be approximately the same 8 Tighten the screw M3 x 10 torque 1 18 1 57N m 9 Turn off the power 10 Attach t...

Page 152: ...hat the position of the needle thread block set screw is seen to be slight to the left when viewed from the front Adjust so that the upper edge of the threading hook and the upper edge of the needle hole are at the same height NOTE If the needle thread block set screw position is too far to the left the hook will not operate and treading cannot be done Fig 1 If the needle thread block set screw po...

Page 153: ...clamp assy 5 Adjust the height of the presser bar so that there is 6 0 6 5 mm between the top of needle plate A and the bottom of the presser 6 Tighten the stud screw M5 in the presser bar clamp assy torque 1 18 1 57N m NOTE Use the J presser Adjust the presser bar so that the needle plate feed dog hole and the presser are parallel to prevent slanting during serging and damage to the needle Stud s...

Page 154: ...ound with Schappe Spun Sewing Thread thread 60 in the inner rotary hook 2 Pull the thread with a tension gauge and adjust the spring adjusting screw so that it is 0 1 0 12 N 10 12 g 3 Apply a small amout of screw lock agent to the spring adjusting screw XA9153001 Tension gauge 30 0 3 N ...

Page 155: ... using the screw M4 x 25 Key point Confirm that when a material of two layers of broadcloth with paper in between is given 100 stitches forward and reverse Feed forward and reverse mode the forward side is plus or minus 5 mm longer than the reverse side Tightening the screw M4 x 25 shortens the reverse side Loosening the screw M4 x 25 lengthens the reverse side 7 Apply a small amount of screw lock...

Page 156: ...nding 4 Tighten the screw M3 x 10 torque 0 59 0 78N m 5 Loosen the pan head screw S P washer M3 x 20 6 Turn the bobbin presser left and right and adjust the winding quantity Key point The target for the bobbin winding quantity is filling 80 90 of the diameter 7 Tighten the pan head screw S P washer M3 x 20 torque 0 59 0 78N m Bobbin winder guide assy Screw M3 x 10 Bobbin presser Pan head screw S P...

Page 157: ...justing plate 3 The position in the figure to the lower and move the SW adjusting plate and adjust it so that the gap is 0 0 5mm between the SW switch assy and the BW shaft holder assy 4 Tighten the bind screw M3 x 6 of the SW adjusting plate torque 0 58 0 78N m SW switch assy BW shaft holder assy 0 0 5mm SW adjusting plate Bobbin winder shaft stopper Bind screw M3 x 6 Bobbin winder cam ...

Page 158: ...nd set to the BH presser 6 Rotate the BH eccentric shaft so that BH0 comes into contact with BH1 Key point With the presser foot lifter raised pull the BH presser forward as much as possible and check that BH0 comes into contact with BH2 and that BH2 has some deflection With the presser foot lifter raised push the BH presser back as much as possible and check that BH0 comes into contact with BH1 a...

Page 159: ...ulse motor gear match marks feed in 0 mm position 6 Loosen the 2 bind screw M3 x 8 temporarily install the needle plate A and adjust the forward reverse and left right positions of the feed dog Key point Adjust the gap between the forward edge of the feed dog middle tooth and feed plate A front to back to 3 2 3 8 mm Adjust the left and right gaps between the feed dog and needle plate A to be appro...

Page 160: ...ter screw assembly does not turn 5 With the feed dog in the lowest position check that the feed dog is 0 3 mm or more below the upper surface of the needle plate A NOTE When the feed dog is too high problems such as abnormal noise bad feed quantities and the cloth not being fed arise When the feed dog is too low problems such as bad feed quantities and the cloth not being fed arise XC2278001 Feed ...

Page 161: ...ok 2 Loosen the pan head screw S P washer M3 x 6 securing the inner rotary hook bracket assy 3 Adjust the inner rotary hook bracket assy attachment position so that contact between the inner rotary bracket assy and inner rotary hook is 1 9 2 1 mm and secure with the pan head screw S P washer M3 x 6 1 9 2 1mm Pan head screw S P washer M3 x 6 ...

Page 162: ...4 24 ...

Page 163: ...ted 5 5 Main motor does not turn 5 6 Main motor rotation abnormal 5 8 Cannot sew pattern well 5 9 Cannot sew button holes well 5 10 Stitch length and zigzag width cannot be done by manual adjustment 5 11 Problems with vertical needle movement and reverse stitching 5 12 Does not operate when the foot controller is used 5 13 LCD display is not normal 5 14 LCD light does not come on 5 15 Bobbin windi...

Page 164: ...n main motor F2 5 19 Key pressed continually with power ON operation system SW F3 5 20 Key pressed continually with power ON operation panel SW F4 5 21 FC disconnect F5 5 22 Dirty speed sensor F6 5 22 NP sensor disconnect F7 5 23 Speed VR disconnect F8 5 24 Electronic power supply abnormal F9 5 24 EEPROM abnormal ...

Page 165: ... Does the buzzer sound when the power is turned ON with the SS VR PCB assy connector disconnected from the main PCB assy Y Reconnect the connector of the PW SW assy to CN101 of the power supply PCB assy or Replace the PW SW assy Reconnect the connector of the power lead wire to CN201 of the power supply PCB assy and to CN5 of the main PCB aasy or Replace the power supply PCB assy N N Replace the o...

Page 166: ... the correct position of the shutter cover Is the resistance between the 1 2 pins and 3 4 pins on the pulse motor connectors 6 7 7 7 Ω Regardless of needle position this pulse motor returns to the starting point Is the voltage between pins 3 4 of CN5 on the main PCB assy 30 V DC N N Replace the power supply PCB assy N Y Y Y Reconnect it correctly Is the connector of the Z pulse motor correctly con...

Page 167: ... correctly Is the connector of the operation PCB assy correctly connected to CN4 of the main PCB assy Is the shutter of the selecting shutter in the concave portion of the photo interrupter of the operation PCB assy N Attach the operation PCB assy to the correct position or Replace the main PCB assy N Y Y Replace the main PCB assy ...

Page 168: ...o CN401 of the power supply PCB assy Y Reconnect it correctly N Is the connector of the SS VR PCB assy correctly connected to CN1 of the main PCB assy Y Replace the main motor Is the main motor resistance 2 5 Ω at any rotation position Y N Reconnect it correctly Is the power lead wire assy correctly connected to CN201 of the power PCB assy and to CN5 of the main PCB assy Y To next page Main motor ...

Page 169: ...main PCB assy attached to the correct position of the shutter cover N N Y Y Replace the PF switch assy From previous page Replace the operation PCB assy or Replace the main PCB assy or Replace the power supply PCB assy Are the resistance values for the Stop Start switch reverse switch raise needle switch and the thread cut switch normal Switch resistance values Switch pressed 1 Ω or less Switch re...

Page 170: ...is moved with the power ON does the voltage between pins 4 5 of CN1 on the SS VR PCB assy vary 0 7 4 3 V DC N Reconnect it correctly Replace the main PCB assy or Replace the power supply PCB assy Is the connector of the main motor correctly connected to CN401 of the power PCB assy N Reconnect it correctly Is the power lead wire assy correctly connected to CN201 of the power PCB assy and to CN5 of ...

Page 171: ... can you lightly move the needle bar left and right by hand Replace the pulse motor N Y Is the resistance between pins 1 2 and pins 3 4 on the Z pulse motor and the F pulse motor connectors 6 7 7 7 Ω Reconnect it correctly Is the connector of the Z pulse motor correctly connected to CN8 of the main PCB assy N Reconnect it correctly Is the connector of the F pulse motor correctly connected to CN10 ...

Page 172: ...al BH lever pulled forward Pins 1 2 1 Ω or less pins 2 3 BH lever pushed back Pins 1 2 pins 2 3 1 Ω or less Is the resistance between the BH lever switch connector pins 4 5 normal BH lever down 1Ω or less BH lever up Change to correct presser N Replace the main PCB assy Y Y Is the correct presser being used N N Y Adjust the BH lever or Replace the BH switch assy Adjust the BH lever or Replace the ...

Page 173: ...th eatch switch And is there a click feeling of each switch Is the resistance between pins 1 2 and pins 3 4 on the Z pulse motor and the F pulse motor connectors 6 7 7 7 Ω Replace the pulse motor N Set the switch correctly or Replace the operation PCB assy Reconnect it correctly Is the connector of the Z pulse motor correctly connected to CN8 of the main PCB assy N Reconnect it correctly Is the co...

Page 174: ...PCB assy Reconnect it correctly Is the BW switch assy OFF Is the connector of the SS VR PCB assy correctly connected to CN1 of the main PCB assy Are the resistance values for the Stop start switch reverse switch and raise needle switch normal Switch resistance values Switch pressed 1 Ω or less Switch released N N N Adjust the assembly of the BW switch assy Y Y Y Replace the main PCB assy ...

Page 175: ... the pedal is stepped in the maximum 8 kΩ 13 8 kΩ When the pedal is not stepped 1 Ω or less Foot controller model T S When the pedal is stepped in the maximum 0 9 kΩ 1 2 kΩ When the pedal is not stepped 33 kΩ 73 kΩ Is the resistance between the FC jack assy connector pins 2 3 normal Foot controller disconnected 1 Ω or less Foot controller connected N N Y Replace the main PCB assy Reconnect it corr...

Page 176: ...ht guide assy correctly connected to CN3 of the operation PCB assy N Y Is the connector of operation PCB assy correctly connected to CN4 of the main PCB assy N Y Replace the single light guide assy or Replace the main PCB assy Reconnect it correctly Reconnect it correctly Reconnect it correctly Y Is the voltage between pins 2 3 of CN1 on the operatrion PCB assy connector approximately 5 V AC N Rep...

Page 177: ... the single light guide assy correctly connected to CN3 of the operation PCB assy N Replace the operation PCB assy Is the voltage between pins 1 2 of CN3 on the operation PCB assy connector 3 8 4 6 V DC N Y Reconnect it correctly Is the connector of the operation PCB assy correctly connected to CN4 of the main PCB assy N Y Y Replace the single light guide assy ...

Page 178: ...in winder mechanism assembled and attached correctly Is the resistance between the BW F SW assy connector pins 1 2 normal Bobbin winder shaft in bobbin wind position 1 Ω or less Bobbin winder shaft not in bobbin wind position N N Replace BW switch assy Y Y Replace the main PCB assy Reconnect it correctly Is the connector of the BW F SW assy correctly connected to CN1 of the main PCB assy N ...

Page 179: ...e SS VR PCB assy correctly connected to CN5 of the main PCB assy N Y Reconnect it correctly Is the connector of the LED lamp R correctly connected to CN3 of the SS VR PCB assy N Y Reconnect it correctly Replace the SS VR PCB assy Is the voltages between pins 1 2 of CN3 on the SS VR PCB assy connector 3 8 4 6 V DC LED Lamp disconnected N Y Replace the LED lamp R ...

Page 180: ... After replaceing the power supply PCB assy start test mode and select test mode 11 Next press the BK key F1 error mode is canceled When the power is once turned off and is switched on again is it displayed as F1 Y N OK F1 is displayed Replace the main PCB assy Does the motor rotate correctly N Y ...

Page 181: ...vestigation for Electronic Parts Error is displayed Replace the SS VR PCB assy or Replace the main PCB assy Is one of the SS key NP key and BK key stuck in a pressed down condition N Y Release the switch that is stuck F2 is displayed ...

Page 182: ...ronic Parts Error is displayed Replace the operation PCB assy or Replace the main PCB assy Is one of the operation panel keys Pattern selection key etc stuck in a pressed down condition N Y Release the switch that is stuck F3 is displayed ...

Page 183: ...oller jack assy lead wires broken Y N F4 is displayed When the foot controller is replaced with a new one does it work correctly N Y Correctly connect the foot controller jack assy to the main PCB assy CN3 Replace the main PCB assy Is the foot controller jack assy correctly connected to the main PCB assy CN3 N Y Replace the foot controller ...

Page 184: ...utter of the upper shaft assy dirty or broken N Y Attach the main PCB assy to the correct position of the shutter cover Is the main PCB assy assembled to the correct position of the shutter cover N Y Replace the upper shaft assy or Clean the timing shutter The error message F5 or F6 is displayed on the screen ...

Page 185: ...t the SS VR PCB assy to CN1 on the main PCB assy correctly Is the SS VR PCB assy correctly connected to the main PCB assy CN1 N Y F7 is displayed Replace the main PCB assy Is F7 still displayed even when another SS VR PCB assy is connected to the main PCB assy Replace the SS VR PCB assy N Y ...

Page 186: ... for Electronic Parts Error is displayed F9 is displayed Replace the main PCB assy Y F8 is displayed Replace the power supply assy Is the voltage between pins 3 4 of CN5 on the main PCB assy 30 V DC N Y Replace the main PCB assy ...

Page 187: ...6 1 6 Repair Manual ...

Page 188: ...nnected Plug connector in 3 36 Power supply enter but safety timer does not operate Foot controller connector disconnected or broken it Plug connector in Replace foot controller Bad pin jack assy Replace pin jack 2 18 3 24 Bad main PCB assy Replace main PCB assy 2 16 3 26 Sewing machine lamp LED lamp does not light machine operation normal Bad PCB unit LED lamp R Broken lead wire of PCB unit LED l...

Page 189: ...stment screws Adjust needle bar height 4 12 6 Does not turn Electronic sounds and operating display lamps normal at startup Bad main motor Replace main motor 2 18 3 23 Sewing machine runs when S S button is pushed Check that the sewing machine starts and stops when the S S button is pushed when green Main motor connector disconnection Plug connector in 3 26 Bad power supply PCB assy Replace power ...

Page 190: ... adjuster assy Reattach feed adjuster assy 2 53 3 55 Horizontal rattle in feed dog Loose feed dog attachment screw Adjust feed dog attachment screw 4 21 Left right rattle in feed dog With the feed dog up check that there is no rattle when the feed dog is lightly moved left and right Horizontal rattle in feed bar Reattach feed bar 2 48 3 62 Bad feed dog height adjustment Adjust feed dog height 4 22...

Page 191: ...8 3 23 Lower shaft noise Lower shaft axial rattle Reassemble lower shaft assy 2 52 3 57 Vertical feed cam noise Vertical feed cam out of grease Lubricate lower shaft assy 3 58 Horizontal feed arm noise Bad horizontal feed arm Replace feed arm A 2 52 3 56 Noise from contact between needle plate A and feed dog Back front and left right rattle in feed dog Reattach feed dog 2 45 3 65 Bad feed dog fron...

Page 192: ...supporter assy 2 39 3 49 Bad thread guide shape Replace hook assy 2 39 3 49 Needle thread shaft and top gap too small Replace needle bar supporter assy 2 39 3 49 Needle thread lever operation catches part way through Bad needle stop position NP sensor damage Replace main PCB assy 2 16 3 26 Grease or dirt adhering to NP sensor Remove grease and dirt Rotation shutter damage Replace upper shaft assy ...

Page 193: ...ad bobbin thread falls down to the right of thread bobbin because the spool pressure is insufficient Rethread Thread catches on spool presser scratches on spool presser Replace spool presser Needle catches and bends before or after sewing Replace needle Thread breakage stitch skipping Thread breakage Actual sewing straight line zigzag Check that the thread does not break during actual sewing Threa...

Page 194: ...al sewing straight line zigzag Check that it does not stop during actual sewing No gap for bobbin winder switch Adjust BW switch assy position 4 19 No gap for BH lever switch Adjust BH lever switch position 4 20 No play in S S button reverse button or vertical stop button Reassemble SSVR PCB assy 2 7 3 38 14 Cannot sew BH BH is blocked BH cannot switch BH switches part way through BH sewing imposs...

Page 195: ... 3 33 Bobbin winder winds unevenly Bad bobbin winder guide assembly height adjustment Loose bobbin winder guide assembly screw Adjust bobbin winder guide assembly height 4 18 Abnormal sound when the bobbin winder rotates Bobbin is coming into contact with bobbin presser Remove front cover and adjust position using bobbin winder holder attachment screw 2 24 3 14 Timing pulley scratches Repair scrat...

Page 196: ...6 10 ...

Page 197: ...ecial Instructions of Wiring Wiring of needle bar module 7 2 Wiring of feed rotary module 7 4 Wiring of power module 7 5 Wiring of bobbin winder assy 7 10 Wiring of main PCB assy 7 11 Wiring of front cover 7 12 ...

Page 198: ... needle presser module Secure the lead wires a clip bend the tip of a clip in the inside of the arm bed Secure the lead wires so that the head part of the band becomes it inward The BHL lead wires should be loose The lead wires should be positioned above the rib Hang over the three hooks ...

Page 199: ...right side of needle presser module The PF lead wires should not be loose Secure the lead wires with a band Pass the lead wires to the gullet of the arm bed The lead wires should be positioned above the rib Pass the lead wires to the notch part of the thread tension holder Secure the lead wires at with a band right lower side hole of the thread tension holder ...

Page 200: ...dule 1 Wiring on front side of main body 2 Wiring FP motor lead wire and main motor lead wire Main motor FP motor Secure the lead wires with a band FP motor lead wire Ferrite core Main motor lead wire Less than 25 mm 45 degrees Secure the lead wires with a clip ...

Page 201: ... lead wires on the hook Pass the FC lead wires between the ribs 2 locations Ferrite cover Cross the FC lead wires and hang it on the hook The ferrite core should not go out of the broken line outside Insulation cover FC lead wire Hang the FC lead wire on the hook of the insulation cover and send it backward and insert it into the cylinder inside and pull it to the front side Insulation cover ...

Page 202: ... lead wires assy Surely insert the VH connector into the connector of the power supply assy VH connector Insulation cover PW SW lead wire B PW SW lead wire A I side of the PW SW Power supply assy O side of the PW SW Surely insert the connector of the power lead wire into the connector of the power supply assy Power supply assy Power lead wire ...

Page 203: ...e power supply assy to the insulation cover with the screw Insulation cover Power lead wire Power supply assy The PW SW lead wire should pass between the boss of the insulation cover and the outer wall Insulation cover Attach with the screw The power lead wire should not sandwitch between the power supply assy and the boss of the insulation cover PW SW lead wire Boss of the insulation cover Boss o...

Page 204: ...on back side of main body upper side of power module Inlet assy Secure the inlet assy with a clip Power module Main motor lead wire Insert the main motor lead wire into the cylinder of the insulation cover from the back side of main body and insulation it into the connector of power supply assy Power supply assy ...

Page 205: ...module 9 Wiring on front side of main body lower side of main PCB Hang the FP motor lead wire on the hook of the shutter cover FP motor lead wire Power lead wire Connector Pass the FC lead wire to the lower side of the FP motor lead wire and then insert it the connector FC lead wire ...

Page 206: ...CB assy Sutter cover BW lead wire Pull the BW lead wire from the gap on the side of shutter cover to the sront side of main body Pass the BW lead wire to the lower side of the FC lead wire and then insert it into the connector of the main PCB assy BW lead wire FC lead wire Notch part of the shutter cover Push the BW lead wire to all the way of notch part Main PCB assy ...

Page 207: ...de of main PCB assy 15 mm ZP motor lead wire Secure the lead wire with a band FP motor lead wire Power lead wire Pass the ZP motor lead wire to the lower side of the power lead wire and insert it into the connector Insulator sheet Insert the insulator sheet into between the main PCB assy and the gap of lead wire ...

Page 208: ...t cover 1 Wiring on back side of selecting panel assy Pass the backlight lead wire between the boss A and the boss B Single light guide assy Boss A Backlight lead wire Boss B Operation PCB assy LCD lead wire Backlight lead wire CN3 Selecting panel CN1 ...

Page 209: ...iring of SS VR lead wire and operation lead wire Insert the connector of the LED lead wire into the connector of the SS VR PCB assy LED lead wire Pass the LED lead wire to front of the SS VR PCB assy SS VR PCB assy 40mm SS VR lead wire Operation PCB assy Operation lead wire Secure the lead wires with a band SS VR PCB assy 40mm ...

Page 210: ...7 14 Special Instructions of Wiring Wiring of front cover 4 Assembly of front cover Operation lead wire Main PCB assy SS VR lead wire CN4 Operation lead wire Main PCB assy SS VR lead wire CN1 ...

Page 211: ...09F07HF885V11 ...

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Brother B-500, Service Manual

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