Brother Innov-is NV4000D Service Manual Download Page 46

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Thread tension unit location diagram

Main unit

Summary of Contents for Innov-is NV4000D

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Page 3: ...B assembly removal 2 8 Front cover disassembly thread PCB assembly removal 2 9 Front cover disassembly SS PCB assembly removal 2 9 Front cover disassembly button removal 2 9 Front cover disassembly plate D removal 2 9 Front cover disassembly inverter D6 assembly removal 2 10 Front cover disassembly board case assembly removal 2 11 Front cover disassembly card PCB cover assembly removal 2 12 Front ...

Page 4: ...Presser SW holder ASSY removal and disassembly 2 30 Spring removal 2 30 Presser SW link removal 2 30 Tension presser plate removal 2 31 Tension plate removal 2 31 Thread release link removal 2 32 Thread tension gear assembly removal 2 33 Thread take up spring assembly removal 2 34 Thread take up spring ASSY disassembly 2 34 Thread guide wire removal 2 34 Spring tape removal 2 34 Bobbin winder 2 35...

Page 5: ...oval 2 53 Needle holder assembly removal 2 54 Hook release plate removal 2 55 Release adjuster removal 2 55 Release guide plate removal 2 55 Release lever spring removal 2 55 Release lever assembly removal 2 56 Release lever ASSY disassembly 2 56 Needle holder ASSY disassembly 2 56 Needle bar ASSY disassembly 2 57 Lever AB assembly removal 2 58 Lever AB ASSY disassembly 2 58 Shaft bushing A remova...

Page 6: ...2 76 Outer rotary hook removal 2 77 Spring removal 2 78 Feed bar assembly removal 2 78 Feed dog base assembly removal 2 78 Feed dog correction plate removal 2 79 Vertical adjusting screw removal 2 79 Vertical rod removal 2 79 Vertical feed bush removal 2 80 Spring removal 2 80 F gear stopper plate removal 2 80 F pulse motor holder assembly removal 2 81 F pulse motor holder ASSY disassembly 2 81 Sp...

Page 7: ...sassembly 2 100 EMB relay PCB assembly removal 2 101 E cord supporter cord removal 2 101 E cord supporter removal 2 101 X sensor PCB assembly cord removal 2 102 X sensor PCB assembly removal 2 102 X belt presser removal 2 102 XY carriage unit removal 2 103 X guide plate removal 2 103 X pulse motor removal 2 104 X tension pulley assembly removal 2 104 X driving gear pulley assembly removal 2 104 X ...

Page 8: ...er attachment 3 17 Bobbin winder assembly attachment 3 17 Spool pin attachment 3 18 Sub spool stand pin attachment 3 19 Thread guard plate attachment 3 20 Thread guide plate attachment 3 20 Bobbin base assembly attachment 3 21 Tension guide assembly attachment 3 21 Thread tension unit 3 22 Spring tape attachment 3 23 Thread guide wire attachment 3 23 Thread take up spring ASSY assembly 3 24 Thread...

Page 9: ...ent 3 47 Front cover assembly foot controller jack assembly attachment 3 48 Front cover assembly connector cover attachment 3 48 Front cover assembly card PCB cover assembly attachment 3 48 Front cover assembly board case attachment 3 49 Front cover assembly inverter D6 assembly attachment 3 50 Front cover assembly plate D attachment 3 50 Front cover assembly button attachment 3 50 Front cover ass...

Page 10: ...ock attachment 3 74 Lower shaft B ASSY assembly 3 75 Lower shaft B assembly attachment 3 76 Drop assembly adjustment 3 77 Grease application 3 77 Feed arm ASSY assembly 3 78 Feed arm assembly attachment 3 79 Set screw collar attachment 3 79 Shaft stopper plate attachment 3 80 Spring attachment 3 80 F pulse motor holder ASSY assembly 3 80 F pulse motor holder assembly attachment 3 81 F gear adjustm...

Page 11: ...ase lever assembly attachment 3 111 Z zigzag lever assembly attachment 3 112 Thread take up counter weight attachment 3 113 Thread take up lever assembly attachment 3 114 Tension release rod attachment 3 115 Press foot lifter attachment 3 116 Release plate assembly attachment 3 117 Adjusting plate ASSY assembly 3 118 Adjusting plate assembly attachment 3 118 Adjust plate attachment 3 119 Shaft bus...

Page 12: ...ttachment 3 145 Cord grip attachment 3 146 X slider attachment 3 147 X guide shaft presser attachment 3 147 X driving gear pulley assembly attachment 3 148 X tension pulley assembly attachment 3 148 X pulse motor attachment 3 149 X guide plate attachment 3 149 XY carriage unit attachment 3 150 X belt presser attachment 3 151 X sensor PCB assembly attachment 3 151 X sensor PCB assembly cord arrange...

Page 13: ...9 Inner rotary hook tension adjustment 4 20 Cloth pressure setting adjustment 4 21 Feed dog height and squareness adjustment 4 22 Front back and left right position of feed dog adjustment 4 23 Side feed straight stitch adjustment 4 24 One point adjustment 4 25 Feed forward backward adjustment 4 26 Knee lifter position adjustment 4 27 BH lever switch position adjustment 4 28 X belt tension adjustme...

Page 14: ...mally 5 19 Bobbin winding cannot be done 5 20 The lamp at hand does not have light 5 21 Bobbin thread detection does not work normally 5 23 Upper thread sensor does not work normally 5 24 Automatic needle threader does not work correctly 5 25 The presser foot lifter does not work correctly 5 27 Card cannot be used normally 5 30 Universal serial bus USB cannot be used normally 5 31 The hoop sensor ...

Page 15: ...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 8 ...

Page 16: ...ary hook drive mechanism Feed Rotary hook mechanism Thread cutting mechanism Bobbin winder mechanism Thread guide mechanism Needle bar Presser mechanism Y belt Y pulse motor Y driving gear Y sensor PC board Y guide shaft X guide shaft X sensor PC board X pulse motor X belt X driving gear ...

Page 17: ...take up lever Needle bar crank rod Needle bar block Needle bar release lever Z zigzag Z zigzag cam Z pulse motor Needle bar supporter assy Needle bar Needle Lower shaft gear Lower shaft b assy Joint Lower shaft A S pulse motor Side feed bar Timing pulley D Timing belt Side feed plate Upper shaft Feed arm A Outer rotary hook Feed bar Vertical adjusting screw Feed dog Feed arm b assy F pulse motor U...

Page 18: ...OTOR ASSY PFSW D6 ASSY TGSW D6 SS PCB D6 PCB UNIT LED LAMP D6R GT PULSE MOTOR ASSY AT INIT SWITCH ASSEMBIY PCB UNIT LED LAMP 3 ASSY ATPF INIT PCB ASSY ATTHD INT PCB PCB UNIT LED RAMP D6L ASSY UPTHREAD SENSOR ASSY BWSW D6 POWER SUPPLY UNIT MAIN PCB NP PCB ASSY MAIN MOTOR KNEE LIFTER SENSOR S PULSE MOTOR EMBROIDERY CONNECTOR ASSY PHOTO DIODE ASSY PHOTO TRANSISTOR C PURLSE MOTOR ASSY PLSW D6 TH PULSE...

Page 19: ...1 5 Outline of Mechanism Outline of Mechanism Control system block diagram ...

Page 20: ...le bar to its original position Raise Presser Switch This switch toggles the presser foot between the up and down positions Touch Panel Used to select pattern and input test mode number required for sewing by simply touching the display on the panel This simplifies the oparation for selecting the desired pattern and number Speed Control Lever This lever detects for the speed of sewing BH buttonhol...

Page 21: ... detecting needle plate for straight line or not Foot control jack This is the jack for plugging in the foot controller when it is used FR assembly and FL assembly LED lamps White LED lamps for illuminating the work space Up thread PCB assy Detects the presence or absence of the upper thread and whether it is cut or not Initial Sensor PCB Assembly Detects the original position of pulse motor for t...

Page 22: ...d 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 When transparent nylon thread is used use a 14 16 sewing machine needle regardless of what is in the table below ...

Page 23: ...eed rotary hook unit thread cutter unit side feed unit 2 41 Needle presser unit needle threader unit upper shaft unit 2 44 Modules Needle presser module 2 49 Needle thread module 2 67 Feed rotary hook module 2 73 Side feed module 2 87 Thread cutter module 2 90 Embroidery Main parts 2 95 With the CD ROM version click to start the movie clip ...

Page 24: ...2 2 Main parts location diagram Main unit ...

Page 25: ... the left and remove it 1 2 Top cover removal 1 Turn the handle 1 and open the top cover 2 2 Remove the top cover 2 from the hinge 3 of the main unit Start movie clip CD ROM version only 2 3 1 3 Needle plate B assembly removal 1 Slide the needle plate B assembly 1 toward you and then remove it 1 ...

Page 26: ...ger and then remove the cutter cover 5 3 Remove the spring plate 6 on the rear of the cutter cover and then remove the NT lower thread cutter 7 4 Remove the slide button 1 Key point Remove the hooks 2 locations on the rear of the slide button Start movie clip CD ROM version only 1 2 3 4 5 6 7 1 5 Face plate assembly removal 1 Remove the screw 1 on the rear of the face plate assembly and then remov...

Page 27: ...ing CS5 7 Front thread guide cover removal 1 Remove the screw 1 and then remove the front thread guide cover 1 1 1 8 Thread guide cover A removal 1 Remove the screw 1 and then remove thread guide cover A 1 1 1 9 Lower thread cutter removal 1 Remove the screw 1 and then remove the cutter holder 1 2 Remove the lower thread cutter 2 from the cutter holder 1 2 1 1 ...

Page 28: ...cover removal 1 Remove the 2 screws 1 and then remove the base plate cover 1 Key point Slide the base plate cover to the left and then remove the hooks 4 locations from the base plate 1 1 12 Bobbin winder removal 1 Remove the 5 screws 1 and screw 2 and then remove the bobbin winder module 1 2 Disconnect the 2 lead wire connectors 2 from the main PCB of the bobbin winder module Start movie clip CD ...

Page 29: ...e the screw 12 and then remove the front cover Key point Remove the hooks 1 2 locations from the base plate and the hook 2 from the rear cover 2 Disconnect the 2 lead wire connectors 3 from the main PCB of the front cover Start movie clip CD ROM version only 1 1 2 2 3 ...

Page 30: ...LED lamp R removal 1 Remove the retaining ring CS4 and then remove LED lamp R 1 Retaining ring CS4 1 16 Front cover disassembly LED lamp 3 removal 1 Remove the 2 screws 1 and then remove LED lamp 3 1 adjusting plate B 2 and insulation sheet 3 3 2 1 1 17 Front cover disassembly VR PCB assembly removal 1 Remove the 2 screws 1 and then remove the VR PCB assembly 1 1 1 ...

Page 31: ...cover disassembly SS PCB assembly removal 1 Remove the 2 screws 1 and then remove the S holder 1 2 Remove the 2 screws 2 and then remove the SS PCB assembly 2 2 1 2 1 20 Front cover disassembly button removal 1 Remove the thread button 1 operation button 2 and SS button 3 1 2 3 21 Front cover disassembly plate D removal 1 Remove the screw 1 and then remove plate D 1 1 1 ...

Page 32: ...s 1 and then remove the inverter D6 assembly 1 2 Remove the clip inserted into the ferrite core 2 of the foot controller jack assembly 3 Disconnect the LCDKCG089 lead wire connector 3 and the inverter lead wire assembly connector 4 4 Remove the 2 screws 2 and then remove the inverter D6 5 1 3 5 4 2 2 1 ...

Page 33: ... assembly 2 3 Remove the 5 screws 2 and then remove the 5 board pressers 4 Disconnect the LCD holder assembly lead wire connector 3 and FFC cord connector 4 and then remove the panel PCB 5 and the lower board case assembly 6 5 Remove the screw 3 and then remove the upper ground plate 7 from the upper board case 8 6 Remove the screw 3 and then remove the lower ground plate 9 from the lower board ca...

Page 34: ...the hooks 2 locations from the inside of the front cover 1 25 Front cover disassembly connector cover removal 1 Remove the retaining ring CS4 and then remove the connector cover 1 1 Retaining ring CS4 26 Front cover disassembly foot controller jack assembly removal 1 Use a jack screwdriver to remove the foot controller jack assembly ...

Page 35: ...oval 1 Remove the 4 screws 1 2 Remove the hooks 2 locations on the left side of the LCD holder assembly 1 and then remove the LCD holder assembly 1 1 1 1 28 Front cover disassembly SV keytop removal 1 Pull out the SV keytop 1 2 Remove the SV joint plate 2 on the rear of the front cover 1 2 ...

Page 36: ...ove LCD presser B 1 4 locations 2 Remove the 2 screws 2 and then remove LCD presser A 2 3 Remove LCDKCG089 3 and then disconnect the LCD cable FFC SML2CD 4 4 Reverse LCDKCG089 3 and then remove front cover spacers B 5 2 locations 5 Remove the touch panel 6 Start movie clip CD ROM version only 1 3 2 2 4 6 5 3 1 ...

Page 37: ... presser foot lifter 2 Remove the 3 screws 1 and then remove the rear cover 1 Key point Remove the hooks 2 2 locations from the base plate Start movie clip CD ROM version only 1 1 2 1 1 31 Rear cover disassembly plate B removal 1 Remove the screw 1 and then remove plate B 1 1 1 ...

Page 38: ...ate A removal 1 Remove the 2 screws 1 and then remove plate A 1 2 locations 1 1 33 Drop cover removal 1 Pull out the drop cover 1 from the rear of the main unit 1 34 Handle assembly removal 1 Remove the 4 screws 1 and then remove the handle assembly 1 1 1 ...

Page 39: ...rts Main unit Disassembly 35 Handle ASSY disassembly 1 Remove the 2 retaining rings E4 and then remove the handle holder R assembly 1 and handle holder L assembly 2 from the handle 3 1 3 2 1 3 Retaining ring E4 2 1 ...

Page 40: ...2 18 Power unit motor unit location diagram Main unit ...

Page 41: ...onnectors from the power PCB assembly D6US 2 2 Remove the 3 screws 1 and then remove the power PCB assembly D6US 2 1 1 2 2 Power PCB ASSY disassembly 1 Remove the 4 screws 1 and then remove the insulator sheet 1 and the power PCB assembly D6US 2 2 Remove the power switch assembly D6 3 from the power unit cover 4 3 12 1 4 ...

Page 42: ...val 1 Remove the 3 screws 1 and then remove the base plate assembly 1 1 1 4 Inlet assembly removal 1 Remove the screw 1 and then remove the inlet assembly 1 1 1 5 Knee lifter assembly removal 1 Remove the 2 screws 1 and then remove the knee lifter assembly 1 1 1 1 ...

Page 43: ...crew and screw 2 and then remove the main PCB assembly 1 1 1 2 8 NP PCB assembly D6 removal 1 Remove the 3 screws 1 and then remove the NP PCB assembly D6 1 NOTE Remove the NP PCB assembly D6 carefully to avoid damaging the sensor on the rear of the assembly 1 1 9 NP PCB assembly D6 disassembly 1 Remove the lead wire of the NP PCB assembly D6 1 from the guide 2 of the PCB holder 2 Remove the 2 scr...

Page 44: ...ove the motor fan NOTE Be careful removing the motor fan because the wings of the fan are very fragile 11 Main motor assembly removal 1 Remove the 2 screws 1 and then remove the main motor assembly 1 and PCB holder R 2 2 Remove the timing belt motor belt 3 3 1 1 2 ...

Page 45: ... Main motor assembly disassembly 1 Remove the screws 1 two and remove the main motor assembly 1 and the motor spacer presser 2 2 Remove the fender rubber 3 from the motor holder 4 3 Remove the spacer 4x7 two from the fender rubber 3 1 3 4 2 1 1 2 4 3 1 ...

Page 46: ...2 24 Thread tension unit location diagram Main unit ...

Page 47: ...de assembly 1 Start movie clip CD ROM version only 1 1 2 Thread guide removal 1 Remove the screw 1 and then remove the thread guide 1 1 1 3 Upper thread PCB assembly removal 1 Remove the screw 1 and then remove the upper thread PCB assembly 1 1 1 4 Upper thread PCB ASSY disassembly 1 Remove the screw 1 and then remove the upper thread PCB assembly 1 from the thread sensor holder 2 1 2 1 ...

Page 48: ...T PCB ASSY disassembly 1 Remove the screw 1 and then remove the AT INIT PCB assembly 1 from the AT pulse motor sensor holder 2 1 2 1 7 Thread guide base removal 1 Remove the 3 screws 1 and then remove the thread guide base 1 Start movie clip CD ROM version only 1 1 8 Thread hook removal 1 Remove the thread hook slider 1 and thread hook 2 1 2 ...

Page 49: ...ng pulley 2 and the 2 rollers 3 Start movie clip CD ROM version only 3 1 2 10 Belt guide removal 1 Remove the belt guide 1 Key point The lower part of the belt guide 2 contacts the frame of the thread guide assembly so remove the belt guide as shown in the drawing on the right Start movie clip CD ROM version only 1 2 ...

Page 50: ...sembly 1 2 Remove the TG pulse motor cover 2 and the idle gear 3 2 1 1 3 12 TG pulse motor ASSY disassembly 1 Remove the 2 screws 1 and then remove the TG pulse motor assembly 1 from the TG pulse motor holder assembly 2 2 Remove the retaining ring E2 and then remove the spring and the brake plate 3 3 1 1 2 Retaining ring E2 S02 S02 ...

Page 51: ...y 2 1 2 1 14 Tension release holder assembly removal 1 Remove the 2 screws 1 and then remove the tension release holder assembly 1 NOTE Be careful not to bend tension release plate A 2 Start movie clip CD ROM version only 1 2 1 15 Initial SW holder ASSY removal and disassembly 1 Remove the screw 1 and then remove the initial SW holder assembly 1 2 Remove the initial SW assembly 2 from the initial ...

Page 52: ...ve the screw 1 and then remove the presser SW holder assembly 1 2 Remove the presser SW assembly 2 from the presser SW holder 3 1 1 3 2 17 Spring removal 1 Remove spring S65 S65 18 Presser SW link removal 1 Remove the retaining ring E3 and then remove the presser SW link 1 1 Retaining ring E3 ...

Page 53: ...ser assembly 1 in the direction of the arrow 2 Remove the tension release cam 2 and spring Start movie clip CD ROM version only 2 1 1 S03 S03 20 Tension plate removal 1 Remove the retaining ring E2 and then remove the spring and the tension plate 1 2 Remove the spacer 2 Start movie clip CD ROM version only 1 Retaining ring E2 S03 2 S03 ...

Page 54: ...2 32 Main unit Thread tension unit 21 Thread release link removal 1 Remove the retaining ring E3 and then remove the thread release link 1 1 Retaining ring E3 ...

Page 55: ...crew 2 spring washer 5 tension disk washer 6 tension release plate assembly 7 and washer 5 from the thread tension disk shaft 4 of the thread guard 4 Remove the retaining ring E2 and then remove spring and the plain washer S3 9 from the calking pin 8 of the thread guard 5 Remove tension disk B and tension disk A A from the tension thread disk shaft 4 of the thread guard Start movie clip CD ROM ver...

Page 56: ...1 1 1 24 Thread take up spring ASSY disassembly 1 Remove spring 2 Remove the thread cutting shutter 1 from the thread catching spring case 2 2 1 S11 S11 25 Thread guide wire removal 1 Remove the screw 1 and then remove the thread guide wire 1 and the plain washer 2 1 1 2 26 Spring tape removal 1 Remove the spring tape 1 from the thread guard frame 1 ...

Page 57: ...2 35 Disassembly Bobbin winder location diagram Main unit ...

Page 58: ...obbin base assembly removal 1 Pull up the bobbin base assembly 1 to remove it NOTE Do not reuse the bobbin base assembly once it has been removed 1 3 Thread guide plate removal 1 Remove the screw 1 and then remove the thread guide plate 1 1 1 4 Thread guard plate removal 1 Remove the screw 1 and then remove the thread guard plate 1 1 1 ...

Page 59: ...embly 5 Sub spool stand pin removal 1 Remove the 2 screws 1 and then remove the sub spool pin holder assembly 1 2 Remove the screw 2 and then remove the spring 2 3 Remove the shaft 3 and then remove the sub spool stand pin 4 1 2 2 1 4 3 ...

Page 60: ...pool pin removal 1 Remove the screw 1 and then remove the spool pin holder B assembly 1 2 Remove the spool pin 2 2 1 1 7 Bobbin winder assembly 1 Cut the band 2 Remove the 3 screws 1 and then remove the bobbin winder assembly 1 1 1 1 ...

Page 61: ... removal 1 Remove the screw 1 Reverse the bobbin winder assembly 1 and then remove the bobbin presser cover 2 1 1 2 9 BWSW assembly D6 removal 1 Remove the screw 1 and then remove the BWSW assembly D6 1 2 Remove the BWSW assembly 1 from the BW switch holder 2 1 1 2 ...

Page 62: ...etaining ring E3 and then remove the bobbin presser guide assembly 1 and the polyester slider 2 2 1 Retaining ring E3 12 Bobbin presser removal 1 Remove the retaining ring E3 and then remove the bobbin presser 1 1 Retaining ring E3 13 BW motor assembly removal 1 Remove the 2 screws 1 and then remove the BW motor assembly 1 1 1 ...

Page 63: ...2 41 Disassembly Rotary hook driving unit feed rotary hook unit thread cutter unit side feed unit location diagram Main unit ...

Page 64: ...crews 12 2 each and then remove the side feed module 1 Key point Refer to Side feed module on page 2 87 for the disassembly procedure Start movie clip CD ROM version only 2 1 1 3 Thread cutter module removal 1 Remove the screws 1 and 2 on the bottom of the thread cutter module 1 and then remove the thread cutter module 1 from the feed rotary hook module Key point Refer to Thread cutter module on p...

Page 65: ...ove the 2 screws 1 and then remove the feed rotary hook module 1 3 Remove the disk 2 from the lower shaft Key point Refer to Feed rotary hook module on page 2 73 for the disassembly procedure Start movie clip CD ROM version only 2 1 1 5 Sheet removal 1 Remove the sheet 1 2 locations 1 6 Lower shaft A assembly removal 1 Remove the 2 screws 1 and then remove the bushing pressers 1 2 locations 2 Remo...

Page 66: ...2 44 Needle presser unit needle threader unit upper shaft unit location diagram Main unit ...

Page 67: ... unit upper shaft unit Main unit Disassembly 1 Upper shaft cover removal 1 Remove the screw 1 and then remove the upper shaft cover 1 1 1 2 Tension pulley assembly removal 1 Remove the screw 1 and then remove the tension pulley assembly 1 1 1 ...

Page 68: ...ate the upper shaft half a turn and remove the 2 screws 2 2 Remove the screw 3 and then remove the bushing presser 1 3 Move the fixed joint 2 to the right and then remove the upper shaft assembly 3 4 Remove the timing belt 4 and then pull the fixed joint 2 to the left to remove it Start movie clip CD ROM version only 1 2 1 3 2 4 3 ...

Page 69: ...le 2 Remove the 2 screws 2 and then remove presser plate B 1 adjust plate A 2 3 Remove the 2 screws 3 and then remove presser plate A 3 4 Remove the needle presser module 4 5 Remove the shaft 5 from the needle presser module 4 Key point Refer to Needle presser module on page 2 49 for the disassembly procedure Start movie clip CD ROM version only 4 1 2 2 3 5 3 1 ...

Page 70: ...en remove the plate spring 1 1 1 6 Needle thread module removal 1 Remove the screw 1 and then remove the LED lamp PCB assembly D6L 1 2 Remove the 3 screws 2 and then remove the needle thread module 2 Key point Refer to Needle thread module on page 2 67 for the disassembly procedure Start movie clip CD ROM version only 2 1 1 2 ...

Page 71: ...2 49 Disassembly Needle presser module location diagram Modules ...

Page 72: ...ward to remove it from needle threader shaft A 2 Start movie clip CD ROM version only 1 2 3 Presser pulse motor holder assembly removal 1 Remove the 3 screws 1x2 and 2 and then remove the presser pulse motor holder assembly 1 1 1 2 4 Presser pulse motor holder ASSY disassembly 1 Remove the screw 1 and then remove the ATPF INIT PCB assembly 1 2 Remove the 2 screws 2 and then remove the presser puls...

Page 73: ...HSW D6 SW assembly 1 1 1 7 PT holder assembly removal 1 Remove the screws 1 2 and the remove the PT holder assembly 1 Start movie clip CD ROM version only 1 2 1 8 PT holder ASSY disassembly 1 Remove the screw 1 and then remove the PT lever 1 and spring 2 2 Remove the nut 3 and then remove the plain washer M6 4 3 Remove the cloth thickness sensor assembly 5 from the PT holder 6 Start movie clip CD ...

Page 74: ...he screw 1 with the lock nut 1 attached 2 Remove the lock nut 1 from the screw 1 1 1 10 Zigzag adjusting nut removal 1 Remove the screw 1 and then remove the zigzag adjusting nut 1 11 Spring removal 1 Remove spring S10 S10 12 Spring Z removal 1 Remove spring S20 S20 ...

Page 75: ...ock removal 1 Remove the screw 1 at the lower section of the unit holder and then remove the needle holder shaft block 1 and needle holder block 2 1 1 2 14 Spring removal 1 Remove spring S62 S62 15 Spring removal 1 Remove spring Start movie clip CD ROM version only S42 S42 ...

Page 76: ...he plate 1 2 Remove the screw 2 and then press the left end of the shaft 2 to remove the shaft from the right end 3 Pull out the shaft 3 4 Remove the needle bar block shaft 4 from the crank rod 5 5 Remove the needle holder assembly 6 from the unit holder Start movie clip CD ROM version only 1 1 2 2 2 3 6 4 5 ...

Page 77: ...move the 2 screws 1 and then remove the release adjuster 1 1 1 19 Release guide plate removal 1 Remove the 2 screws 1 and then remove the release guide plate 1 1 1 20 Release lever spring removal 1 Remove spring Key point Release the straight section of spring from the groove on the needle holder assembly 1 Disengage the hook of spring from the release lever 2 Start movie clip CD ROM version only ...

Page 78: ...fer 3 and the retaining ring E2 5 from the release lever shaft 1 1 3 Retaining ring E2 5 2 23 Needle holder ASSY disassembly 1 Remove the screw 1 from the needle holder block 1 and the screw 1 from the needle bar hook stand assembly 2 2 Pull the needle bar assembly 3 downward and then remove the needle bar block 4 needle holder block 1 needle bar hook stand assembly 2 spring and thrust washer 5 St...

Page 79: ... bar thread guide 2 plate spring 3 and needle block 4 from the needle bar Key point The plate spring 3 is inserted to the needle bar thread guide 2 3 Remove the plate spring 3 from the needle bar thread guide 2 4 Remove the needle thread plate 5 from the needle block 4 Key point Press both ends of the needle thread plate hanging over the needle block to remove the plate 1 1 1 2 4 2 2 3 5 4 ...

Page 80: ...shaft 1 from the unit holder 4 Remove the lever AB assembly 3 from the lever guide shaft 1 5 Remove the retaining ring E2 from the lever guide shaft 1 Start movie clip CD ROM version only 1 Retaining ring E2 Retaining ring E2 1 2 1 3 26 Lever AB ASSY disassembly 1 Remove the 2 screws 1 and then remove the needle threader driving plate 1 1 1 27 Shaft bushing A removal 1 Remove the screw 1 and then ...

Page 81: ...d then remove the adjust plate 1 1 1 29 Adjusting plate assembly removal 1 Remove the 2 screws 1 and then remove the adjusting plate assembly 1 and spring 1 1 S58 S58 30 Adjusting plate ASSY disassembly 1 Remove the retaining ring E3 and then remove tension release plate C 1 1 Retaining ring E3 ...

Page 82: ...2 60 Modules Needle presser module 31 Release plate assembly removal 1 Remove the retaining ring E2 and then remove the release plate assembly 1 Start movie clip CD ROM version only Retaining ring E2 1 ...

Page 83: ...r 1 and 2 washers 2 2 Pull out the presser lift shaft 3 from the rear of the adjusting plate assembly and then remove the retaining ring E4 Start movie clip CD ROM version only Retaining ring E4 1 1 2 Retaining ring E4 1 3 33 Tension release rod removal 1 Remove the retaining ring E3 and then remove the tension release rod 1 Retaining ring E3 1 ...

Page 84: ...rod 3 Start movie clip CD ROM version only 3 2 1 1 2 35 Thread take up counter weight removal 1 Remove the 2 screws 1 Key point Remove the 2 face to face screws 1 tightened at the center of the thread take up counter weight 2 Remove the thread take up counter weight 2 and the thrust wafer 3 from the unit shaft 1 3 Pull out the unit shaft 1 in the direction of the arrow and then remove the thrust w...

Page 85: ...2 Remove the Z lever cap 2 from the Z zigzag lever 1 Key point Remove the retaining ring E3 attached to the T cam Start movie clip CD ROM version only Retaining ring E3 2 1 37 Thread release lever assembly removal 1 Remove the retaining ring E3 on the rear of the thread release lever assembly 1 and then remove the thread release lever assembly 1 Start movie clip CD ROM version only Retaining ring ...

Page 86: ...assembly 1 Key point Rotate pulse motor Z counterclockwise to remove it 2 Peel the insulation tape from the PCB of the Z pulse motor assembly Start movie clip CD ROM version only 1 1 40 Shaft removal 1 Press the top of the shaft 1 and remove it from the bottom Start movie clip CD ROM version only 1 41 T cam removal 1 Lift the right end of the T cam 1 and then remove the T cam from the unit holder ...

Page 87: ...amp assembly 1 and then pull the presser bar upward 2 Remove the presser bar clamp assembly 1 and spring 3 Remove the retaining ring E5 from the presser bar 4 Remove the screw 2 and then remove the plate spring 2 and the presser bar bushing 3 Start movie clip CD ROM version only Retaining ring E5 S60 1 1 3 2 2 S60 ...

Page 88: ...the shaft 1 and then remove spring and the thread take up lever link 2 Start movie clip CD ROM version only 1 1 2 S06 Retaining ring E4 S06 S06 44 Shaft bushing assembly removal 1 Remove the 2 screws 1 and then remove the shaft bushing assembly 1 1 1 1 45 Presser dial gear removal 1 Pull out the presser dial shaft assembly 1 2 Remove the presser dial gear 2 and the presser foot rack 3 2 3 1 ...

Page 89: ...2 67 Disassembly Needle thread module location diagram Modules ...

Page 90: ...odules 1 Pile holder assembly removal 1 Remove the screw 1 and then remove the pile holder assembly 1 1 1 2 Thread guide base plate assembly removal 1 Remove the screw 1 and then remove the thread guide base plate assembly 1 1 1 ...

Page 91: ... link plate A assembly 2 3 Remove the retaining ring E2 on the rear of the base plate and then remove the link plate B assembly 3 4 Remove the retaining ring E2 and then remove the thread guide plate assembly 4 and the polyester slider 5 Start movie clip CD ROM version only 1 1 2 3 4 5 Retaining ring E3 Retaining ring E2 S66 Retaining ring E2 S66 4 Thread guide base assembly removal 1 Remove the 3...

Page 92: ...disassembly 1 Remove the screw 1 and then remove the ATTHD INIT PCB assembly 1 from the sensor holder 2 1 1 2 7 TH pulse motor assembly removal 1 Remove the 2 screws 1 and the CS1 clip attached to the lower right screw and then remove the TH pulse motor assembly 1 2 Remove the TH pulse motor lead wire assembly 2 from the PCB of the TH pulse motor assembly 2 1 1 ...

Page 93: ...shaft 1 to the right 2 Remove the retaining ring E3 from the outside of the guide shaft 1 3 Remove the trigger 2 4 Slide the rack assembly 3 to the right and then lift the right end of the rack assembly to remove it 1 1 2 3 Retaining ring E3 Retaining ring E3 9 Rack ASSY disassembly 1 Remove the 3 screws 1x2 and 2 and then remove the slider 1 and the rack 2 1 2 2 1 ...

Page 94: ...2 72 Needle thread module Modules 10 Idle gear A removal 1 Remove the retaining ring E2 5 and then remove idle gear A 1 1 Retaining ring 2 5 1 11 Drive gear A removal 1 Remove drive gear A 1 1 ...

Page 95: ...2 73 Disassembly Feed rotary hook module location diagram Modules ...

Page 96: ...g E3 2 Drop lever removal 1 Remove the retaining ring E2 on 2 slide shafts A 1 from the rear of the drop lever 2 2 Remove 2 slide shafts A 1 from the front of the drop lever 2 and then remove the other retaining ring E2 on 2 slide shafts A 1 3 Remove the drop lever 2 Retaining ring E2 1 2 1 2 Retaining ring E2 3 Needle plate A removal 1 Remove the 2 screws 1 and then remove needle plate A 1 1 1 ...

Page 97: ... hook bracket assembly removal 1 Remove the screw 1 and then remove the inner rotary hook bracket assembly 1 1 1 6 Cord holder removal 1 Remove the screw 1 and then remove the cord holder 1 1 1 7 Needle plate switch ASSY removal 1 Remove the PLT SW assembly D6 1 from the needle plate switch holder 2 Key point Disengage the hook on the needle plate switch holder 1 2 ...

Page 98: ...oto diode holder assembly 1 1 1 9 Photo diode holder ASSY disassembly 1 Remove the photo diode holder assembly 1 from the photodiode holder 2 Key point Disengage the 2 hooks on the photo diode holder 2 1 10 Feed dog removal 1 Remove the 2 screws 1 and then remove the feed dog 1 Start movie clip CD ROM version only 1 1 ...

Page 99: ...oint Press the bottom of the outer rotary hook shaft 1 and then pull the outer rotary hook shaft 1 out from the outer rotary hook assembly 2 Remove the spacer 2 outer rotary hook assembly 3 washer 4 and spacer 5 Key point Rotate the outer rotary hook assembly 3 counterclockwise to remove it Start movie clip CD ROM version only 1 1 2 3 4 5 1 1 2 3 4 5 ...

Page 100: ...shafts A 1 2 Remove the feed bar assembly 2 Start movie clip CD ROM version only 1 2 1 14 Feed dog base assembly removal 1 Remove the screw 1 and then pull out feed dog base shaft B 1 2 Remove the screw 1 pull out feed dog base shaft A 2 and then remove the polyester slider 3 3 Remove the feed dog base assembly 4 Start movie clip CD ROM version only 1 1 4 2 4 3 ...

Page 101: ... removal 1 Remove the screw 1 and then remove the feed dog correction plate 1 1 1 16 Vertical adjusting screw removal 1 Remove the screw 1 and then remove the M5 nut 1 2 Remove the cap 2 from the bottom of the screw 1 1 1 2 17 Vertical rod removal 1 Pull out the vertical rod 1 1 ...

Page 102: ...ical feed bush 1 1 1 19 Spring removal 1 Remove spring S16 S16 20 F gear stopper plate removal 1 Remove the screw 1 and then remove the F gear stopper plate 1 Key point Remove the screw 1 from the bottom of the F gear stopper plate and then lift the plate upward to remove it Start movie clip CD ROM version only 1 1 ...

Page 103: ...1 1 1 2 S15 S15 22 F pulse motor holder ASSY disassembly 1 Disconnect the F pulse motor lead wire assembly 2 from the pulse motor M35SP 8N 1 2 Remove the 2 screws 1 and then remove the pulse motor M35SP 8N 1 from the F pulse motor holder 3 3 Remove the rubber 4 from the shaft of the F pulse motor holder 3 1 2 3 4 1 23 Spring removal 1 Remove spring from the bottom S37 S37 ...

Page 104: ...ssembly removal 1 Remove the retaining ring E5 of the horizontal feed shaft 1 2 Pull the horizontal feed shaft 1 to the left to remove it and then remove the 2 thrust washers 2 3 Remove the feed arm assembly from the bottom of the feed rotary hook module Key point Remove the rectangular feed slide shaft of feed arm B 3 on the top of the feed arm assembly from the feed adjuster 4 Start movie clip C...

Page 105: ... supporting plate 5 from feed arm B 4 Start movie clip CD ROM version only 1 Retaining ring E3 2 3 5 4 Retaining ring E2 28 Lower shaft B assembly removal 1 Remove the 2 screw 1 and then remove the joint 1 2 Remove the 2 screws 2 and then remove bushing presser A 2 3 Lift the left end of the lower shaft B assembly 3 slightly and then pull it to the left to remove it 4 Remove bushing supporter A 4 ...

Page 106: ...ve the thrust washer 3 lower shaft bushing 4 thrust washer 3 and set screw collar 1 from the lower shaft B assembly 2 4 1 3 1 2 2 1 3 4 1 Retaining ring E6 30 Stopper plate block removal 1 Remove the screw 1 from the bottom of the stopper plate block 1 and then remove the stopper plate block 1 Key point Rotate the stopper plate block 1 clockwise to remove it 1 1 ...

Page 107: ...en the vertical supporting plate 2 and the set screw collar Key point Slide the set screw collar to the left to remove the retaining ring E3 3 Pull the vertical feed shaft 3 to the right to remove it and then remove the polyester slider 4 and the retaining ring E3 4 Remove spring the feed dog correction lever 5 polyester slider 6 vertical lever 7 and set screw collar 1 Start movie clip CD ROM vers...

Page 108: ... and spring Start movie clip CD ROM version only S14 1 2 1 1 S14 34 Feed adjuster ASSY disassembly 1 Remove the polyester slider 2 from the adjusting shaft 1 2 Remove spring and then remove the F gear 4 from the feed adjuster 3 4 3 2 1 S13 S13 35 Bushing presser B removal 1 Remove the 3 screws 1 and then remove bushing presser B 1 and the lower shaft bushing 2 1 1 2 1 ...

Page 109: ...2 87 Disassembly Side feed module location diagram Modules ...

Page 110: ... assembly removal 1 Remove the screw 1 and then remove plate spring A 1 and the side feed arm assembly 2 1 1 2 2 Side feed adjust plate removal 1 Remove the screw 1 and then remove plate spring B 1 the washer 2 and side feed adjust plate 3 1 1 3 2 ...

Page 111: ...it from the S pulse motor gear 4 4 Remove the spring from the S gear 3 then pull out the S gear 3 from the side feed plate 5 5 Pull out the S gear 4 from the side feed plate 3 Start movie clip CD ROM version only 2 1 3 1 3 4 6 5 S41 Retaining ring E3 S41 4 S pulse motor removal 1 Remove the 2 screws 1 and then remove the S pulse motor 1 from the S pulse motor holder 2 1 1 1 2 ...

Page 112: ...2 90 Thread cutter module location diagram Modules ...

Page 113: ...e 2 screws 1 then remove the thread cutter frame assembly 1 from the motor holder assembly 2 and then remove the collar 1 1 1 2 2 Presser plate assembly removal 1 Remove the screw 1 and then remove the presser plate 1 and the plate spring 2 2 1 1 3 Pile 4X8 removal 1 Peel the pile 4X8 from the presser plate 1 1 ...

Page 114: ...washer 1 and the polyester slider 2 2 Reverse the thread cutter frame 3 and then remove the thread hook assembly 4 and the spacer 5 3 Remove the lower thread cutter 6 from the spacer 5 3 2 1 Retaining ring E4 3 4 5 5 5 6 5 Rubber removal 1 Remove the retaining ring E3 and then remove the rubber 1 Retaining ring E3 1 ...

Page 115: ... from the idle gear 2 and then remove it from the thread cutter lever shaft 3 2 3 1 7 Thread cutter lever ASSY disassembly 1 Remove the screw 1 and then remove the thread cutter lever gear 1 from the thread cutter lever 2 1 3 2 1 1 8 Photo transistor assembly removal 1 Remove the screw 1 and then remove the photo transistor assembly 1 1 1 1 ...

Page 116: ...g ring E2 and then remove idle gear A 1 spring 2 and idle gear B 3 1 2 3 Retaining ring E2 10 Z pulse motor assembly removal 1 Disconnect the lead wire connector 2 from the PCB of the Z pulse motor assembly 1 2 Remove the 2 screws 1 and then remove the Z pulse motor assembly 1 2 1 1 1 ...

Page 117: ...2 95 Disassembly Main parts location diagram Embroidery ...

Page 118: ...emove the screw 1 and then remove the YPM cover 2 Key point Remove the screw 1 from the lower section 3 of the YPM cover Slide the YPM cover toward you and disengage the 2 hooks 4 inside the indicated section 3 of the YPM cover Disengage the 2 hooks 6 on the side face 5 of the X carriage cover Start movie clip CD ROM version only 4 1 1 2 3 5 6 ...

Page 119: ...nt section 1 on the left 2 Remove the screw 1 and then remove the X carriage cover 2 Key point Remove the screw 1 from the front of the indicated section 3 of the X carriage cover Slide the X carriage cover backward to remove it 1 1 2 3 3 E hoop stay cover removal 1 Remove the screws 1 2 and then remove the E hoop stay cover 1 1 1 2 ...

Page 120: ...ent section on the right 3 Slide the X carriage assembly 3 to the left as far as possible 4 Slide the EX main cover assembly 1 to the right to remove it 3 1 2 2 1 5 EMB relay PCB assembly lead wire removal 1 Cut the band 2 Disconnect the lead wire connector 1 of the drop SW assembly white lead wire connector 2 and black lead wire connector 3 of the EMB unit lead wire assembly from the EMB relay PC...

Page 121: ...k release lever assembly removal 1 Remove spring from the lock finger 2 of the lock release lever assembly 1 2 Remove the lock release lever assembly 1 3 Remove spring from the ES base cover 1 2 S64 S64 S64 9 Lock release lever ASSY disassembly 1 Remove the lock finger 2 from the lock release lever 1 1 2 10 Drop lever assembly removal 1 Remove the screw 1 and then remove the drop lever assembly 1 ...

Page 122: ...cam 3 3 Remove the screw 2 and then remove the drop switch holder assembly 4 4 Remove the drop switch assembly 5 from the drop switch holder 6 Start movie clip CD ROM version only 6 3 2 1 4 1 2 5 12 Drop lever calking ASSY disassembly 1 Remove the screw 1 and then remove the drop knob 1 from the drop lever calking assembly 2 2 Remove the screw 2 and then remove the notched cam 3 from the drop leve...

Page 123: ... then remove the EMB relay PCB assembly 1 2 Disconnect the 5 connectors from the EMB relay PCB assembly 1 1 1 14 E cord supporter cord removal 1 Disconnect the bundle of three cords from the E cord supporter 1 1 15 E cord supporter removal 1 Remove the screw 1 and then remove the E cord supporter 1 1 1 ...

Page 124: ... carriage assembly 1 of the main frame assembly to the left as far as possible 4 Disconnect the lead wire of the X sensor PCB assembly 3 from the right hook 4 on the bottom of the main frame Start movie clip CD ROM version only 1 2 3 1 4 3 17 X sensor PCB assembly removal 1 Slide the X carriage assembly of the main frame assembly to the right limit 2 Remove the screw 1 and then remove the X sensor...

Page 125: ...d rotate it toward you 3 Lift the right end of the X guide shaft 1 upward at an angle to remove it and then remove the XY carriage unit 2 from the main frame assembly 3 4 Pull out the X guide shaft 1 from the Y carriage assembly 4 Start movie clip CD ROM version only 1 1 1 2 4 3 1 3 20 X guide plate removal 1 Remove the 3 screws 1 and then remove the X guide plate 1 1 1 ...

Page 126: ...ulse motor 2 1 1 22 X tension pulley assembly removal 1 Remove the 2 screws 1 and then remove the tension pulley assembly 1 2 Remove the timing belt X belt 2 1 2 1 23 X driving gear pulley assembly removal 1 Remove the driving gear pulley assembly 1 Key point Disengage the hook at the upper section of the driving gear pulley assembly Start movie clip CD ROM version only 1 ...

Page 127: ...X guide shaft presser plate 2 1 2 1 25 X slider removal 1 Disconnect the 3 cords hanging over the guide on the X slider 1 2 Remove the 2 screws 1 and then remove the X slider 1 3 Remove the 3 cords fro the groove on the X slider 1 1 1 26 Cord grip removal 1 Remove the screw 1 and then remove the cord grip 1 2 Remove the 3 cords from the cord grip 1 1 1 1 ...

Page 128: ...e the 2 screws 1 from the Y carriage assembly 1 Key point Do not remove the Y carriage assembly 1 at this point 2 Remove the stop ring 10 69 from the inside of the Y guide shaft 2 3 Pull the Y guide shaft 2 to the left to remove it 4 Slide the Y carriage assembly 1 to the left to remove it from the Y slider 3 5 Remove the stop ring 10 69 from the outside of the Y guide shaft 2 and then remove the ...

Page 129: ...1 FFC support ASSY disassembly 1 Remove the FFC cord 2 from the FFC support 1 2 1 32 E hoop presser plate assembly removal 1 Remove the 2 screws 1 and then remove the E hoop presser plate assembly 1 Key point Remove the E hoop presser plate assembly from the bottom Start movie clip CD ROM version only 1 1 33 E hoop stay plate assembly removal 1 Remove the 2 screws 1 and then remove the E hoop stay...

Page 130: ...1 and then remove the E hoop lock lever spring 1 2 Remove the retaining ring E4 and then remove the E hoop lock lever 2 3 Remove the 2 screws 2 and then remove the frame PCB assembly 3 and the insulation sheet 4 Start movie clip CD ROM version only 1 1 2 2 3 4 Retaining ring E4 36 XC sub cover removal 1 Remove the screw 1 and then remove the XC sub cover 1 1 1 37 Y pulse motor removal 1 Remove the...

Page 131: ... timing belt Y belt 2 from the Y slider 3 3 1 2 1 40 Y driving gear pulley assembly removal 1 Remove the driving gear pulley assembly 1 Key point Disengage the hook at the upper section of the driving gear pulley assembly Start movie clip CD ROM version only 1 41 FFC cord guide removal 1 Remove the 3 screws 1 and then remove the FFC cord guide 1 and the FFC cord supporter 2 Key point The FFC cord ...

Page 132: ...2 110 Embroidery Main parts 42 Y sensor PCB assembly removal 1 Remove the screw 1 and then remove the Y sensor PCB assembly 1 1 1 ...

Page 133: ...cutter unit side feed unit 3 8 Bobbin winder unit 3 14 Thread tension unit 3 22 Power unit motor unit 3 37 Main parts 3 43 Module Thread cutter module 3 59 Side feed module 3 66 Feed rotary hook module 3 70 Needle thread module 3 95 Needle presser module 3 104 Embroidery Main parts 3 134 With the CD ROM version click to start the movie clip ...

Page 134: ...3 2 Needle presser unit needle threader unit upper shaft unit location diagram Main unit ...

Page 135: ...e with the shaft 6 below the needle holder block of the needle presser module 2 Attach the LED PCB assembly D6L with the screw 2 Key point Engage the positioning tab on the LED PCB assembly D6L with the positioning hole on the needle thread module Refer to Needle thread module on page 3 95 for the assembly procedure Start movie clip CD ROM version only 1 Torque 1 18 1 57 N m 2 Torque 0 78 1 18 N m...

Page 136: ...rew 1 to the rear of unit and adjust clearance between needle and rotary hook point Then fully tighten the screw 1 Key point Refer to Clearance between needle and rotary hook point adjustment on page 4 11 for the adjustment procedure 6 Attach shaft support plate B and adjust plate A 5 to the shaft bushing 3 of the arm bed with the 2 screws 2 7 Attach shaft support plate A to the shaft 6 of the arm...

Page 137: ... 3 Attach the upper shaft assembly 5 to the arm bed Key point Place the encoder 7 of the upper shaft assembly on the left side of the arm rib 8 Place the upper shaft bushing 2 of the upper shaft assembly on the upper shaft bushing attachment section of the arm bed 4 Attach bushing presser A 9 to the upper shaft bushing attachment section of the arm bed with the screw 1 Start movie clip CD ROM vers...

Page 138: ...ews 1 on the fixed joint 3 6 Rotate the upper shaft half a turn and tighten the 2 screws 2 in the 2 screw holes on the fixed joint 3 Key point Tighten the screws 2 in the following order 2 2 and then 2 1 Be sure to tighten the 4 screws 2 after fully tightening the 2 screws 1 on the fixed joint If the needle presser module and the upper shaft assembly are assembly properly the base line 6 of the pu...

Page 139: ...ser unit needle threader unit upper shaft unit Main unit Assembly 6 Upper shaft cover attachment 1 Attach the upper shaft cover 1 to the arm bed with the screw 1 1 Torque 0 79 1 18 N m 1 1 Screw Bind M4X6 Color Silver ...

Page 140: ...3 8 Rotary hook driving unit feed rotary hook unit thread cutter unit side feed unit location diagram Main unit ...

Page 141: ... the bushing pressers 7 on the lower shaft bushings 4 one each at 2 locations 6 Secure the bushing pressers 7 with the screw 1 2 locations Key point Before tightening the screw 1 check that the slit on the joint 8 is vertical and the screw hole 9 faces the front NOTE Check the lower shaft rotation torque If the rotation torque is heavy perform the following adjustment Drop a brass bar of approx 1 ...

Page 142: ...fer to Timing belt tension adjustment on page 4 3 for the adjustment procedure 1 Torque 1 18 1 57 N m 1 1 Screw Pan S P washer M4X10DA Color Gold 3 Sheet attachment 1 Wipe the sheet attachment face 1 of the arm bed with a cloth dampened with alcohol 2 Attach the sheet to the sheet attachment face 1 Key point Check that the alcohol on the sheet attachment face 1has dried before attaching the sheet ...

Page 143: ... shaft B is at the top slit on the joint is horizontal Lightly press the feed rotary hook module from above and tighten the 2 screws 2 5 Loosen the 2 screws 1 securing lower shaft A Move the joint 6 to the left and then retighten the 2 screws 1 NOTE After attaching the feed rotary hook module check that the following conditions are met while the base line of the pulley upper shaft is at the top Th...

Page 144: ...M4X5 Color Silver 6 Side feed module removal attachment 1 Attach the side feed module 1 to the arm bed with the 2 screws 1 CS 6 clip is secured to both screws Key point Tighten the screws 1 in the following order 1 1 temporarily tighten 1 2 fully tighten and 1 1 fully tighten 2 Attach the side feed adjust plate 2 of the side feed module to the feed bar of the feed rotary hook module with the 2 cre...

Page 145: ... holder attachment 1 Attach the lead wire guide holder 1 to the feed rotary hook module with the screw 1 Key point Engage the positioning tab on the lead wire guide holder with the positioning hole on the feed rotary hook module Start movie clip CD ROM version only 1 Torque 0 79 1 18 N m 1 1 1 Screw Bind M3X4 Color Silver ...

Page 146: ...3 14 Bobbin winder unit location diagram Main unit ...

Page 147: ...olor Silver 2 Bobbin presser attachment 1 Position the bobbin winder cam 1 of the BW motor assembly laterally 2 Place the bobbin presser 2 onto the shaft of the bobbin winder holder assembly longer shaft at the center and attach the retaining ring E3 1 2 Retaining ring E3 3 Bobbin presser guide assembly attachment 1 Place the polyester slider 1 and then the bobbin presser guide 2 onto the shaft of...

Page 148: ...winder holder assembly S59 1 3 2 S59 S59 S59 29 SPRING XA9545 5 BWSW assembly D6 attachment 1 Attach the BWSW assembly 1 D6 and BWSW holder 2 Key point Engage the positioning tab on the BWSW assembly with the positioning hole on the BWSW holder 2 Attach the BWSW assembly D6 to the bobbin winder holder assembly 3 using the screw 1 with coating clip Key point Engage the positioning tab on the bobbin...

Page 149: ... 79 1 18 N m 1 2 1 Taptite Bind B M3X8 Color Gold 7 Bobbin winder assembly attachment 1 Attach the bobbin winder assembly 1 to the rear of the upper cover with the 3 screws 1 Key point Tighten the screws 1 in the following order 1 1 1 2 and 1 3 2 Tie the BW motor lead wire and the BWSW lead wire with a band Key point Pass the BW motor lead wire over the motor Place the band in the groove on the bo...

Page 150: ... the shaft hole on the spool pin 1 on the rear of the upper cover 2 Insert the shaft of spool pin holder assembly B 2 into the hole on the spool pin 1 3 Attach spool pin holder assembly B 2 with the screw 1 1 Torque 0 59 0 79 N m 1 1 2 Taptite Cup B M3X8 Color Gold ...

Page 151: ...e sub spool pin holder 3 on the rear of the upper cover 3 Insert the shaft 4 into the hole on the sub spool pin holder 3 from the rear of the upper cover and attach these to the bushing 4 Attach the sub spool pin holder assembly 2 with the 2 screws Key point Tighten the screws 2 in the following order 2 1 temporarily tighten 2 2 fully tighten and 2 1 fully tighten 1 Torque 0 79 1 18 N m 2 Torque 0...

Page 152: ... point Tighten the screw 1 from the rear of the upper cover 1 Torque 0 59 0 79 N m 1 1 Taptite Cup B M3X8 Color Silver 11 Thread guide plate attachment 1 Insert the thread guide plate 1 into the groove on the top face of the upper cover 2 Attach the thread guide plate 1 with the screw 1 Key point Tighten the screw 1 from the rear of the upper cover 1 Torque 0 59 0 79 N m 1 1 Taptite Bind B M3X8 Co...

Page 153: ...ear a click Key point Engage the tab on the bobbin winder shaft assembly with the notch on the bobbin base assembly 1 2 13 Tension guide assembly attachment 1 Insert the tension guide assembly 1 into the groove on the top face of the upper cover 2 Attach the tension guide assembly 1 with the screw 1 1 Torque 0 59 0 79 N m 1 1 Screw Pan S P washer M3X8DA Color Silver ...

Page 154: ...3 22 Thread tension unit location diagram Main unit ...

Page 155: ...hread guide wire attachment 1 Insert the hook of the thread guide wire 1 into the hole on the thread guard 2 Insert the plain washer 2 between the thread guide wire 1 and the thread guard 3 Attach the thread guide wire 1 to the thread guard with the screw 1 Key point Move the thread guide wire upward and then attach it Start movie clip CD ROM version only 1 Torque 0 78 1 18 N m 1 2 1 Screw Bind M3...

Page 156: ...spring to the spring groove of the thread cutting shutter 2 Key point Position the thread cutter shutter spring groove between two tabs on the bottom of the thread catching spring case Start movie clip CD ROM version only Apply silicon grease to the outer and inner peripheries of spring Light covering S11 2 1 S11 S11 S11 S11 S11 S11 15 6 7 4 THREAD TAKE UP SPRING XZ0145 4 Thread take up spring ass...

Page 157: ...the thread plate assembly Key point Compress spring to place the thread plate assembly 5 Apply a light covering of EPCON AP N 0 to the entire surface of the calking pin A of the thread guard 6 Apply a light covering of EPCON AP N 0 to the entire rear surface of the thread tension gear assembly B 7 Place the thread tension gear assembly B onto the calking pin A of the thread guard and then attach t...

Page 158: ...ent 1 Place the spacer 1 on the tension release holder assembly 2 Key point Engage the positioning tab on the tension release holder assembly with the square positioning hole on the spacer 2 Place the tension plate 3 and the spring onto the calking shaft of the tension release holder assembly 2 and attach the retaining ring E2 Start movie clip CD ROM version only S03 2 1 3 2 S03 Retaining ring E2 ...

Page 159: ...threading the tension presser plate assembly through to the bottom insert the positioning tab on the tension release holder assembly into the square positioning hole on the tension plate 6 Set the screw 1 of the tension presser plate 1 as shown in the illustration on the right and fully tighten the screw 2 of the tension release cam 2 Start movie clip CD ROM version only Apply EPCON AP N 0 to the ...

Page 160: ...er ASSY assembly and attachment 1 Attach the presser switch assembly 1 to the presser switch holder 2 Key point Engage the positioning tab on the presser switch assembly with the positioning hole on the presser switch holder 2 Pass the presser switch assembly lead wire 1 through the guide of the presser switch holder 2 3 Attach the presser switch holder assembly 3 to the tension release holder ass...

Page 161: ...itial SW holder assembly with the positioning slot on the tension release holder assembly Start movie clip CD ROM version only 1 Torque 0 78 1 18 N m 1 2 3 1 Screw Bind M3X4 Color Silver 13 Tension release holder assembly attachment 1 Attach the tension release holder assembly 1 to the thread guard assembly 2 with the 2 screws 1 Key point The tension release plate A 3 and the presser SW link 4 sho...

Page 162: ...r 15 TG pulse motor ASSY assembly 1 Place the brake plate 3 and then the spring onto the shorter calking shaft 2 of the TG pulse motor holder 1 Attach the retaining ring E2 2 Apply 1 or 2 drops of Turbine oil 100 to the shaft of the TG pulse motor assembly 4 3 Attach the TG pulse motor assembly 4 to the TG pulse motor holder assembly 1 with the 2 screws 1 Key point Attach the TG pulse motor assemb...

Page 163: ... to the TG pulse motor holder Key point Engage the 2 positioning tabs on the TG pulse motor cover with the corresponding positioning holes on the TG pulse motor holder 3 Attach the TG pulse motor assembly 3 to the thread guard with the 2 screws 1 Key point Engage the tab of the TG pulse motor assembly s idle gear with the hole on the thread guard Start movie clip CD ROM version only 1 Torque 0 78 ...

Page 164: ...g pulley attachment 1 Place the 2 rollers 1 onto the corresponding shafts of the belt guide Key point Position the roller tab face up 2 Place the driving pulley 2 onto the shaft of the TG pulse motor assembly Key point Position the driving pulley gear face up 3 Hang the belt 3 over the roller driving pulley and roller in this order with the gear of the belt 3 facing out Start movie clip CD ROM ver...

Page 165: ...movie clip CD ROM version only 1 Torque 0 78 1 18 N m 1 1 Screw Bind M3X5 Color Silver 21 AT INIT PCB ASSY assembly 1 Attach the AT INIT PCB assembly 1 to the AT pulse motor sensor holder 2 with the screw 1 Key point Engage the positioning tab on the AT pulse motor sensor holder center tab of 3 tabs with the positioning notch U shape on the AT INIT PCB assembly Move the AT INIT PCB assembly to the...

Page 166: ...that the shutter of the thread tension gear assembly is almost at the center relative to the sensor of the AT INIT PCB assembly Start movie clip CD ROM version only 1 Torque 0 78 1 18 N m 1 1 Screw Bind M3X4 Color Silver 23 Upper thread PCB ASSY assembly 1 Attach the upper thread PCB assembly 1 to the thread sensor holder 2 with the screw 1 Key point Engage the positioning tab on the thread sensor...

Page 167: ...OTE Check that the shutter of the thread cutting shutter is almost at the center relative to the sensor of the upper thread PCB assembly 1 Torque 0 78 1 18 N m 1 1 Screw Bind M3X4 Color Silver 25 Thread guide attachment 1 Attach the thread guide 1 to the thread guard assembly with the screw 1 Key point Engage the tab on the thread guard assembly rear of AT pulse motor attachment screw with the pos...

Page 168: ...with the 2 screws 1 Key point Engage the positioning tab on the needle presser module with the positioning hole on the thread guide assembly Place the tip of tension release plate A 1 on the L shaped section of tension release plate C 2 Start movie clip CD ROM version only 1 Torque 1 18 1 57 N m 1 2 1 Taptite Bind B M4X10 Color Silver ...

Page 169: ...3 37 Assembly Power unit motor unit location diagram Main unit ...

Page 170: ...ly tighten the 2 screws 1 Key point Refer to Motor belt tension adjustment on page 4 4 for the adjustment procedure 1 Torque 1 18 1 57 N m 1 2 1 3 4 Upset 4X12DB Color Gold 2 Motor fan attachment 1 Insert the motor fan 1 to the motor pulley NOTE Be careful removing the motor fan because the wings of the fan are very fragile 1 3 NP PCB ASSY D6 assembly 1 Place the insulation sheet 2 on the NP PCB a...

Page 171: ...oint Refer to Upper shaft rotation shutter angle adjustment on page 4 5 for shutter angle adjustment 1 Torque 0 78 1 18 N m 1 1 Screw Bind M4X8 Color Silver 5 Main PCB assembly attachment 1 Attach the main PCB assembly 1 to the PCB holder and PCB holder R with the 3 screws 1 CS1 clip is attached to the right upper screw and screw 2 Key point Attach the clip CS1 at an angle of 45 lower left as show...

Page 172: ...nee lifter assembly attachment 1 Attach the knee lifter assembly 1 to the base plate 2with the 2 screws 1 1 Torque 0 79 1 18 N m 2 1 1 Screw Bind M4X6 Color Silver 8 Inlet assembly attachment 1 Attach the inlet assembly 1 to the base plate 2 with the screw 1 Key point Engage the 2 positioning tabs on the inlet assembly with the corresponding positioning holes on the base plate 1 Torque 0 79 1 18 N...

Page 173: ... S M4X10 Color Gold 10 Power PCB ASSY D6US assembly 1 Attach the power switch assembly D6 1 to the power cover 2 Key point Attach the power switch assembly D6 so that the ON mark is on the right side 2 Place the insulation sheet 4 on the power PCB assembly D6US 3 and secure them to the power unit cover2 with the 4 screws 1 1 Torque 0 57 0 78 N m 2 1 4 3 1 1 1 Taptite Bind B M3X8 Color Gold ...

Page 174: ...with the 3 screws 1 NOTE Be careful not to pinch the inlet cord and motor cord 2 Connect the motor cord 2 inlet cord 3 and power switch assembly D6 lead wire connector 4 to the power PCB assembly D6US Key point Refer to Wiring procedure for wiring details 1 Torque 0 78 1 18 N m 1 1 3 4 2 1 Screw Pan S P washer M4X14 Color Silver ...

Page 175: ...3 43 Assembly Main parts location diagram Main unit ...

Page 176: ... the handle assembly 1 to the rear of the arm bed with the 4 screws 1 1 Torque 1 47 1 98 N m 1 1 Taptite Bind S M4X10 Color Gold 3 Drop cover attachment 1 Place the drop cover 1 onto the tab on the drop knob as shown in the illustration on the right 1 4 Rear cover assembly Plate A attachment 1 Attach plate A 1 2 locations to the inside of the rear cover with the screw 1 Key point Engage the positi...

Page 177: ... on plate B 1 Torque 0 59 0 98 N m 1 1 Taptite Cup B M4X10 Color Silver 6 Rear cover attachment 1 Attach the rear cover 1 to the arm bed with the 3 screws 1 Key point Attach the 2 hooks 2 on the rear cover to the base plate Engage the positioning tab 3 on the rear cover with the positioning hole on the rear of the arm bed Start movie clip CD ROM version only 1 Torque 1 18 1 57 N m 1 1 3 2 1 Taptit...

Page 178: ... left side of the LCD holder with the 2 screws 1 Key point Tighten the screws 1 in the following order 1 1 temporarily tighten 1 2 fully tighten 5 Attach LCD presser B 7 4 locations to the center and right side of the LCD holder with the screws 2 Key point Tighten the screws 2 in the following order 2 1 2 2 2 3 and 2 4 6 Insert the LCD cable FFC SML2CD 8 into the connector of LCDKCG089 PCB 9 Key p...

Page 179: ... holes 3 locations on the LCD holder assembly section of the front cover 2 Attach the LCD holder assembly 1 to the LCD holder assembly attachment section on the front cover Key point Set the right hooks 3 locations of the LC holder assembly 1 into the LCD holder assembly attachment section and then attach the left hooks 2 locations 3 Tighten the 4 screws 1 from the inside of the front cover Key po...

Page 180: ...1 Front cover assembly connector cover attachment 1 Attach the connector cover 1 to the shaft inside the front cover and attach the retaining ring CS4 1 Retaining ring CS4 1 12 Front cover assembly card PCB cover assembly attachment 1 Press the pen holder 1 into the groove 2 on the card PCB cover to attach it 2 Attach the card PCB cover assembly 3 to the side face of the front cover Key point Set ...

Page 181: ...case assembly 2 to the 5 screws 2 and 5 board pressers Key point Tighten the screws 2 in the following order 2 1 2 2 2 3 2 4 and 2 5 5 Insert the LCD holder assembly s lead wire 6 and FFC cord 7 into the panel PCB assembly s connector 5 6 Attach the upper board case assembly 4 to the lower PCB case assembly 2 with the 4 screws 3 Start movie clip CD ROM version only 1 Torque 0 39 0 79 N m 2 Torque ...

Page 182: ...ough the notch on the inverter D6 assembly Tighten the screws 2 in the following order 2 1 temporarily tighten 2 2 fully tighten and 2 1 fully tighten 5 Insert the clip on the right screw 2 through the ferrite core of the foot controller jack assembly Start movie clip CD ROM version only 1 Torque 0 39 0 79 N m 2 Torque 0 39 0 79 N m 1 2 1 2 2 1 2 2 1 1 5 4 3 7 6 Taptite Bind B M3X8 Color Gold Tapt...

Page 183: ...the following order 2 1 temporarily tighten 2 2 fully tighten and 2 1 fully tighten 1 Torque 0 39 0 79 N m 2 Torque 0 39 0 79 N m 1 2 1 2 1 1 2 2 2 1 Taptite Bind B M3X8 Color Gold Taptite Bind B M3X14 Color Gold 18 Front cover assembly thread PCB assembly attachment 1 Attach the thread PCB assembly 1 to the thread button inside the front cover with the 2 screws 1 Key point Insert the switch secti...

Page 184: ...1 Torque 0 39 0 79 N m 1 1 1 1 2 2 Taptite Bind B M3X8 Color Gold 20 Front cover assembly LED lamp 3 attachment 1 Attach the LED lamp 3 1 adjusting plate B 2 and insulation sheet 3 to the inside of the front cover Key point Engage LED lamp 3 1 with the notch on the front cover and then align adjusting plate B 2 and the insulation sheet 3 with the screw hole Tighten the screws 1 in the following or...

Page 185: ...in unit Assembly 22 Front cover assembly panel PCB connector attachment 1 Connect the connectors to the corresponding positions on the panel PCB 1 Key point Refer to Wiring procedures 2 Tie the lead wires with a band 1 1 ...

Page 186: ... over the base plate Hang the center hook 4 of the front cover over the rear cover Insert the screw 1 to the screw hole on the thread cutter module via the U shaped section at the left end of the front cover Tighten the screw 2 into the screw hole of the adjust plate A Start movie clip CD ROM version only 1 Torque 0 57 0 78 N m 2 Torque 0 78 1 18 N m 2 1 3 4 1 2 Screw Pan T washer M3X6 Color Silve...

Page 187: ...Color Silver Screw Bind M4X6 Color Silver 25 Base plate cover attachment 1 Attach the base plate cover 1 to the base plate with the 2 screws 1 Key point Hang the 4 hooks of the base plate cover over the base plate and then slide the base plate cover to the right 1 Torque 0 79 1 18 N m 1 1 Screw Bind M4X6 Color Silver 26 Free arm cover attachment 1 Attach the free arm cover 1 to the arm bed with th...

Page 188: ... groove in the upper section inside the thread guide cover A assembly with the frame of the thread module Start movie clip CD ROM version only 1 Torque 0 58 0 78 N m 1 1 Screw Bind M3X6 Color Silver 29 Front thread guide cover attachment 1 Attach the front thread guide cover 1 to the thread guard with the screw 1 Key point Engage the thread guide of the thread guard with the groove on the right si...

Page 189: ...ate B ASSY assembly 1 Attach the slide button 1 to needle plate B 2 2 Attach the NT lower thread cutter 3 to the cutter cover 4 3 Insert the plate spring 5 and secure the NT lower thread cutter 3 4 Attach the cutter cover 4 to needle plate B 2 Key point Insert the lower section of the cutter cover to needle plate B to attach the cutter cover 5 Attach the needle plate cover 6 to needle plate B 2 Ke...

Page 190: ...t 1 Engage the tab 2 on the left of the top cover 1 with the top cover attachment hole 2 Press the top cover 1 to the hinge 3 of the main unit to attach it 1 2 3 35 Accessory table attachment 1 Slide the accessory table 1 to the right to attach it 1 ...

Page 191: ...3 59 Assembly Thread cutter module location diagram Module ...

Page 192: ...Z pulse motor assembly so that the PCB is at the lower right section 2 Connect the lead wire connector to the PCB of the Z pulse motor assembly 3 Apply 1 or 2 drops of Turbine Oil 100 to the bushing of the Z pulse motor Start movie clip CD ROM version only Apply Turbine Oil 100 to the bushing of the Z pulse motor 1 2 drops 1 Torque 0 78 1 18 N m 1 2 1 Screw Bind M3X4 Color Silver ...

Page 193: ...overlap 7 With the large holes 6 aligned 7 align the match mark 8 on the idle gear assy and the match mark 9 on the C pulse motor gear and attach the idle gear assy to 1 Start movie clip CD ROM version only Apply Epnoc Grease AP to the lever guide shaft Small amount 2 8 6 3 4 5 7 1 9 Retaining ring E2 3 Photo transistor ASSY assembly 1 Engage the 2 hooks of the sensor holder 2 with the photo trans...

Page 194: ...thread cutter lever gear with the notch on the thread cutter lever Start movie clip CD ROM version only 1 Torque 0 78 1 18 N m 2 1 1 Screw Pan S P washer M3X6DA Color Gold 6 Thread cutter lever assembly attachment 1 Apply a small bead of EPNOC AP N 0 to the thread cutter lever shaft 1 2 Place the thread cutter lever assembly 2 onto the thread cutter lever shaft 1 Key point Position the thread cutt...

Page 195: ...sert the lower thread cutter 3 into the groove on the spacer 1 Key point Insert the blade 4 of the lower thread cutter in the direction shown in the illustration on the right 3 Attach the thread hook assembly 5 to the spacer 1 Key point Insert the pin 6 on the rear of the thread hook assembly into the groove on the spacer Cover the lower thread cutter with the thread hook of the thread hook assemb...

Page 196: ...screw 1 Key point Engage the positioning tab on the thread cutter frame with the positioning hole on the presser plate and plate spring Start movie clip CD ROM version only 1 Torque 0 78 1 18 N m 2 3 1 1 Screw Bind M3X4 Color Silver 11 Grease application 1 Apply a small bead of EPNOC AP N 0 to idle gears A and B 1 and the Z pulse motor gear 2 2 Apply a small bead of EPNOC AP N 0 to the engaged fac...

Page 197: ...d wire between the thread cutter lever shaft 4 and the collar 3 Thread the 2 screws 1 through the collar 3 and then tighten them Engage the positioning hole on the thread cutter lever shaft 4 with that on the thread cutter frame assembly 5 Insert the pin of the thread hook assembly 6 on the rear of the thread cutter frame assembly into the slot on the thread cutter lever 7 3 Tie the lead wires wit...

Page 198: ...3 66 Side feed module location diagram Module ...

Page 199: ...Key point Position the S pulse motor assembly so that the PCB is at the upper right section 2 Connect the lead wire connector to the PCB of the S pulse motor assembly 3 Apply 1 or 2 drops of Turbine Oil 100 to the S pulse motor bushing Apply Turbine Oil 100 to the S pulse motor bushing 1 2 drops 1 Torque 0 78 1 18 N m 1 2 1 Screw Bind M3X4 Color Silver ...

Page 200: ... Key point Attach the spring end on the side feed plate side to the round hole and the end on the S feed gear side to the spring hook 5 Engage the side feed gear 5 with the S pulse motor gear 6 Key point Align the mark 8 on the side feed gear with the mark 7 on the S pulse motor gear 6 Attach the S stopper 9 to the S pulse motor holder assembly with the screw 1 Key point Engage the positioning tab...

Page 201: ...otch on plate spring B Apply MOLYKOTE EM 30L to the shaft hole on the edge of the side feed adjust plate Bead 1 Torque 0 79 1 18 N m 1 1 4 5 2 3 Screw Bind M3X5 Color Silver 4 Side feed arm assembly attachment 1 Apply a bead of MOLYKOTE EM 30L to the shaft hole on the side feed plate 1 2 Attach plate spring A 2 to the screw 1 3 Insert the shaft of the side feed arm assembly 3 into the shaft hole o...

Page 202: ...3 70 Feed rotary hook module location diagram Module ...

Page 203: ...18 N m 2 1 1 Screw Bind M3X5 Color Silver 2 Feed adjuster ASSY assembly 1 Apply a small bead of EPNOC AP N 0 to the face that contacts the F gear of the feed adjuster 2 Place the F gear 2 onto the shaft of the feed adjuster1 Key point Position the plane of the F gear facing the feed adjuster 3 Align the gears of the F gear 2 in the feed adjuster 1 and then attach spring 4 Place the polyester slide...

Page 204: ...side of the base plate with the 3 screws 1 Key point Engage the positioning tab on the feed adjuster assembly with the positioning hole on the base plate 5 Apply a small bead of EPNOC AP N 0 to the operating section of the rectangular slide 4 of the feed adjuster assembly 3 Start movie clip CD ROM version only Apply EPNOC AP N 0 to the shaft of the feed adjuster Small bead Apply EPNOC AP N 0 to th...

Page 205: ... reaches the left shaft hole on the vertical supporting plate 3 5 Temporarily attach the screw 1 to the set screw collar 4 Key point Perform Drop assembly adjustment on page 3 77 and then fully tighten the screw 1 6 Attach the retaining ring E3 between the vertical supporting plate 3 and the set screw collar 4 Key point Slide the set screw collar 4 to the left to attach the retaining ring E3 7 App...

Page 206: ... only 1 Torque 1 18 1 57 N m 1 1 Screw Bind M4X5 Color Silver 6 Stopper plate block attachment 1 Attach the stopper plate block 1 to the base plate with the screw 1 Key point Engage the positioning tab on the stopper plate block with the positioning hole on the base plate and then rotate the stopper plate block counterclockwise Shift the stopper plate block in the direction of the arrow shown in t...

Page 207: ... Key point Attach the set screw collar with the polished surface facing the left 2 Secure the set screw collar 2 with the 2 screws 1 Key point Move the set screw collar to the lower shaft bushing and then secure it 3 Apply 1 or 2 drops of Turbine oil 100 to the lower shaft bushing 4 Start movie clip CD ROM version only Apply Turbine oil 100 to the lower shaft bushing 1 2 drops 1 Torque 0 78 1 18 N...

Page 208: ...nserting the shaft 4 Place the lower shaft bushing 5 of the lower shaft B assembly 2 onto bushing supporter A 1 5 Attach bushing presser A 6 to the lower shaft bushing 5 with the 2 screws 1 6 Attach the joint 7 to lower shaft B 3 with the 2 screws 2 Key point Align the screw hole on the joint with the D cut face on lower shaft B NOTE Rotate the joint to check the rotation torque If the rotation to...

Page 209: ... version only 1 Torque 1 18 1 57 N m 3 1 1 2 4 Set Screw Socket CP M4X4 Color Black 10 Grease application 1 Apply a bead of EPNOC AP N 0 to the horizontal feed cam 1 of the lower shaft B assembly 2 Apply a bead of EPNOC AP N 0 to the vertical feed cam 2 of the lower shaft B assembly 3 Apply a bead of EPNOC AP N 0 to the circumference of the lower shaft gear 3 of the lower shaft B assembly Apply EP...

Page 210: ...rops of Turbine oil 100 to the shaft 4 of the feed arm B assembly 3 4 Insert the shaft 4 of the feed arm B assembly 3 into the shaft hole on feed arm A 5 5 Place the polyester slider 6 onto the shaft 4 of the feed arm B assembly 3 from the outside of feed arm A 5 and then attach the retaining ring E3 Apply Turbine oil 100 to the shaft of the feed supporting plate assembly 1 2 drops Apply Turbine o...

Page 211: ...ring E5 between right feed arm A and the base plate Key point Move the retaining ring E5 to feed arm A so that it can secure the thrust washer 5 8 Apply 1 or 2 drops of sewing lubricant to the 2 sections 6 where the horizontal feed shaft is inserted in feed arm A Start movie clip CD ROM version only Apply sewing lubricant to the 2 sections where the horizontal feed shaft is inserted in feed arm A ...

Page 212: ... feed supporting plate 1 and feed arm B 2 S37 1 2 S37 S37 SPRING XZ0174 4 18 8 16 F pulse motor holder ASSY assembly 1 Place the rubber 3 onto the shaft 2 of the F pulse motor holder 1 2 Attach the pulse motor M35SP 8N 4 with the 2 screws 1 3 Place the F pulse motor lead wire assembly 5 in the pulse motor M35SP 8N 4 4 Apply 1 or 2 drops of Turbine oil 100 to the bushing 6 of the pulse motor M35SP ...

Page 213: ...1 Key point Move the screw hole to the center of the slot 6 on the F pulse motor holder before tightening the screw 1 4 Temporarily tighten the screw 2 in the screw hole visible in the slot Key point Adjust forward backward feed and then fully tighten the screw 2 Refer to Feed forward backward adjustment on page 4 26 for the adjustment procedure Start movie clip CD ROM version only 1 2 Torque 0 29...

Page 214: ...e motor with your finger to prevent the gear from rotating Align the mark on the feed adjuster gear 6 with the mark on the F gear 7 Start movie clip CD ROM version only Apply EPNOC AP N 0 to the gear surface of the feed adjuster Small bead 1 2 5 3 4 4 7 6 19 F gear stopper plate attachment 1 Attach the F gear stopper plate 1 to the base plate with the screw 1 Key point Insert the F gear stopper pl...

Page 215: ... Key point Face the cut face of the vertical feed bush inside Start movie clip CD ROM version only 1 Torque 0 78 1 18 N m 1 1 Screw Bind M3X8 Color Silver 22 Vertical rod attachment 1 Apply 1 or 2 drops of sewing lubricant to the shaft of the vertical rod 1 2 Insert the vertical rod 1 into the vertical feed bush 2 3 Apply a bead of MOLYKOTE EM 30L to the top face of the vertical rod 1 Apply sewing...

Page 216: ...ut until it is approximately 1 5 mm from the top end of the vertical adjusting screw 1 2 Attach the vertical adjusting screw 1 to the feed bar 3 Key point Tighten the vertical adjusting screw until the bottom of the M5 nut reaches the feed bar 3 Attach the cap 4 to the bottom of the vertical adjusting screw 1 Start movie clip CD ROM version only 3 2 1 1 4 ...

Page 217: ...tion plate attachment 1 Attach the feed dog correction plate 1 to the feed dog base assembly 2 with the screw 1 Key point Move the feed dog correction plate upward to attach it Start movie clip CD ROM version only 1 Torque Hand tighten 1 2 1 Screw M3X8 Color Black ...

Page 218: ...Insert feed bar shaft B 5 from the right side of the feed bar 1 and then pass the shaft through the shaft hole on the feed bar and the shaft hole on the feed dog base assembly 5 Secure feed bar shaft A on the left side with the screw 1 Key point Move the feed dog base assembly 2 to the left and then tighten the screw 1 6 Secure feed bar shaft B on the right side with the screw 1 Key point Tighten ...

Page 219: ...feed bar shaft A 4 both right and left through the hole on the feed shaft 2 and the hole on the feed arm 5 and then secure it with the screw 1 Key point Align the end face of feed bar shaft A with the end face of the feed arm both right and left Start movie clip CD ROM version only Apply MOLYKOTE EM 30L to the hole on the feed shaft of the feed bar Small bead Apply MOLYKOTE EM 30L to feed bar shaf...

Page 220: ...3 88 Module Feed rotary hook module 27 Spring attachment 1 Attach spring to the feed bar 1 and the vertical feed shaft 2 Start movie clip CD ROM version only S63 2 1 S63 S63 SPRING XZ0385 23 4 3 4 ...

Page 221: ... hook assembly 3 clockwise with the D cut 6 face of lower shaft B facing the top the slit on the joint is horizontal to insert the outer rotary hook assembly 3 into the shaft supporter 1 Key point Hold lower shaft B with the D cut 6 face facing the top while inserting the outer rotary hook assembly Turn the outer rotary hook assembly counterclockwise 45 degrees and insert it so that the reference ...

Page 222: ...e positioning hole on needle plate A 2 Attach the stopper plate 3 to the rear of needle plate A with the screw 1 Key point Engage the positioning tab on the stopper plate with the positioning hole on needle plate A Start movie clip CD ROM version only 1 Torque 0 59 0 78 N m 3 1 2 1 Screw Bind M2 6X3 Color Silver 31 Needle plate A attachment 1 Attach needle plate A 1 to the needle plate supporter s...

Page 223: ... rotary hook bracket 1 Torque 0 29 0 49 N m 1 1 2 Screw Bind M2 6X3 Color Gold 34 Needle plate switch ASSY attachment 1 Insert the PLT SW D6 assembly 1 into the needle plate switch holder 2 Key point Align the pin of the needle plate switch holder with the hole on the PLT SW D assembly and then insert the assembly until it catches the hook on the needle plate switch holder 1 2 35 Cord holder attac...

Page 224: ...the stopper plate block 2 with the screw 1 Key point Engage the positioning tab on the inner rotary hook bracket with the positioning slot on the stopper plate block Refer to Inner rotary hook bracket position adjustment on page 4 32 for the adjustment procedure 1 Torque 0 78 1 18 N m 2 1 1 Screw Bind M3X8 Color Silver ...

Page 225: ... to one end of the 2 slide shafts A 4 4 Insert 2 slide shafts A 4 from the outside of the base plate and attach the retaining ring E2 from the inside of the base plate 5 Apply a small bead of MOLYKOTE EM 30L to the 2 oscillating sections 5 of the drop lever and slide shaft A Start movie clip CD ROM version only Apply MOLYKOTE EM 30L to the 2 oscillating sections of the drop lever and slide shaft A...

Page 226: ...sembly and then attach the retaining ring E3 2 Attach the plate spring 2 with the screw 1 Key point Hang the lower hook of the plate spring over the base plate Move the drop knob vertically to check that it operates a click can be heard 1 Torque 0 78 1 18 N m Retaining ring E3 1 1 2 Screw Bind M3X4 Color Silver ...

Page 227: ...3 95 Assembly Needle thread module location diagram Module ...

Page 228: ...the upper side Apply MOLYKOTE EM 30L to the 2 calking shafts of the unit assembly Small bead Apply MOLYKOTE EM 30L to the circumference of drive gear A Light covering 1 2 Idle gear A attachment 1 Apply a light covering of MOLYKOTE EM 30L to the circumference of idle gear A 1 2 Place idle gear A 1 onto the shorter calking shaft of the unit assembly and then attach the retaining ring E2 5 Key point ...

Page 229: ...he rack with the gear on the upper side Position the slider with the trigger plate 3 on the upper side 2 Tighten the screw 2 in the right screw hole 3 Tighten the screw 1 in the left screw hole and then fully tighten the screw 1 in the center screw hole 1 Torque 0 58 0 78 N m 2 Torque 0 58 0 78 N m 1 3 1 2 2 Screw Pan S P washer M3X8 Color Silver Screw Pan S P washer M3X10 Color Silver ...

Page 230: ...ab 8 over the screw 9 that extends to the rear of the rack assembly longest among the three screws 3 Attach the retaining ring E3 to the outer groove on the guide shaft 4 Apply a light covering of MOLYKOTE EM 30L to the surface of the guide shaft 5 Insert the guide shaft from the right shaft hole on the unit assembly Key point Insert the guide shaft into the right shaft hole passing through the ra...

Page 231: ... with the 2 screws 1 CS 1 clip is attached to the lower right screw Apply Turbine oil 100 to the shaft of the TH pulse motor assembly 1 2 drops Apply MOLYKOTE EM 30L to the circumference of the TH pulse motor assembly s gear Light covering 1 Torque 0 78 1 18 N m 1 1 Screw Bind M3X4 Color Silver 6 ATTHD INIT PCB ASSY assembly 1 Attach the ATTHD INIT PCB assembly 1 to the sensor holder 2 with the sc...

Page 232: ...version only 1 Torque Hand tighten 1 2 1 Screw Pan S P washer M3X5 Color Silver 8 Pile B attachment 1 Wipe the pile B attachment surface of thread guide cover B 1with a cloth dampened with alcohol 2 Attach Pile B 2 to thread guide cover B 1 Key point Attach Pile B approximately 10 mm from the top face of thread guide cover B and 1 mm from the side face 1 2 9 Thread guide cover B assembly attachmen...

Page 233: ...ghten the 3 screws 1 Adjust the shuttle and then fully tighten the 3 screws 1 Key point Refer to Shuttle adjustment on page 4 16 for the adjustment procedure Place the tab 2 on the thread guide base assembly between the 2 tabs 3 on the trigger of the unit assembly Start movie clip CD ROM version only 1 Torque 0 98 N m 2 1 1 3 Screw Pan S P washer M3X5 Color Silver ...

Page 234: ...h the narrower hook out 6 Apply a light covering of EPNOC AP N 0 to the surface of the calking shaft of the link A base assembly 5 7 Insert the calking shaft of the link A base assembly 5 into from the rear of the link plate A assembly 4 and then attach the retaining ring E3 from the front of the link plate A assembly 8 Attach the link A base assembly 5 to the side face of the thread guide base pl...

Page 235: ...ew 1 Key point Engage the positioning tab on the thread unit assembly with the positioning hole on the thread guide base plate assembly 1 Torque 0 78 1 18 N m 2 1 1 Screw Bind M3X4 Color Silver 13 Pile holder assembly attachment 1 Attach the pile holder assembly 1 to the thread guide base plate assembly 2 with the screw 1 1 Torque 0 58 0 78 N m 1 1 2 Screw Truss M3X4 Color Silver ...

Page 236: ...3 104 Needle presser module location diagram Module ...

Page 237: ...h the mark ridge 5 on the presser dial gear 4 Insert the presser dial shaft assembly 6 into the presser dial gear 3 through the shaft hole on the unit holder Key point Align the D cut face of the presser dial shaft assembly with the D cut face of the presser dial gear Insert the presser dial shaft assembly until the hook of the presser dial gear is caught in the groove on the presser dial shaft as...

Page 238: ...ttachment 1 Attach the shaft bushing 1 to the unit holder with the 2 screws 1 Key point Insert the shaft bushing from the inside of the unit holder Start movie clip CD ROM version only 1 Torque 1 18 1 57 N m 1 1 1 Screw Pan S P washer M4X14 Color Silver ...

Page 239: ...with the larger cylindrical section 4 Attach the retaining ring E4 to the shaft bushing 2 of the shaft 1 Key point Move spring to the thread take up lever link Do not allow any clearance between the retaining ring E4 and the shaft bushing 5 Tighten the screw 1 in the shaft and then apply 1 or 2 drops of THREEBOND 1401 to the screw 1 to secure it Start movie clip CD ROM version only Apply MOLYKOTE ...

Page 240: ...w 2 Key point Refer to Presser bar height and parallelism adjustment on page 4 12 for the adjustment procedure 8 Apply a bead of MOLYKOTE EM 30L to the groove on the stopper pin of the unit holder 9 Insert spring and the presser bar clamp 5 into the presser bar 3 Key point Engage the stopper pin 6 of the presser bar clamp 5 with the groove on the stopper pin of the unit holder 10 Pass the presser ...

Page 241: ... the T cam 3 5 Place the T cam 3 onto the T cam attachment shaft 2 Key point Position the T cam with the cam groove down Press the cut face of the T cam against the wall of the unit holder 4 to insert the T cam Start movie clip CD ROM version only Apply MOLYKOTE EM 30L to the T cam attachment shaft Small bead Apply MOLYKOTE EM 30L to the cam groove on the T cam Light covering Apply MOLYKOTE EM 30L...

Page 242: ...o the shaft of the Z pulse motor assembly 1 2 drops 1 Torque 0 78 1 18 N m 1 1 Taptite Bind B M3X10 Color Gold 8 Z zigzag cam attachment 1 Apply a small bead of MOLYKOTE EM 30L to the Z zigzag cam shaft 1 2 Attach the Z zigzag cam 2 to the Z zigzag cam shaft 1 Key point Align the mark 3 ridge on the Z zigzag cam with the mark 4 trough on the Z pulse motor assembly 3 Attach the retaining ring E2 to...

Page 243: ...the shaft hole on the unit holder and then attach the retaining ring E3 Key point Position the thread release lever with the hole down 3 Apply a bead of MOLYKOTE EM 30L to the calking shaft lower 3 of the thread release lever 1 Start movie clip CD ROM version only Apply MOLYKOTE EM 30L to the calking shaft center of the thread release lever Small bead Apply MOLYKOTE EM 30L to the calking shaft low...

Page 244: ...ing shaft center of the Z zigzag lever assembly 2 3 Insert the calking shaft center of the Z zigzag lever assembly into the shaft hole on the unit holder and then attach the retaining ring E3 from the rear of the unit holder Key point Attach the retaining ring E3 to the T cam Start movie clip CD ROM version only Apply MOLYKOTE EM 30L to the calking shaft center of the Z zigzag lever assembly Small...

Page 245: ...and the thread take up counter weight 1 from the D cut face of the unit shaft 2 6 Fully tighten the 2 screws 1 of the thread take up counter weight 1 with the D cut face next to the unit shaft 2 retaining ring E8 and the screw hole face 5 of the thread take up counter weight facing the front See the illustration on the right Key point Tighten the 2 face to face screws 1 temporarily attached to the...

Page 246: ...he thread take up counter weight 6 Fully tighten the 2 screws 1 temporarily attached to the thread take up counter weight 4 7 Insert the calking shaft of the thread take up lever assembly 2 into the shaft hole on the thread take up lever link 5 8 Insert the calking shaft shorter of the needle bar crank 1 into the shaft hole on the thread take up lever assembly 2 and then tighten the screw 2 Key po...

Page 247: ...ad release lever assembly 3 into the slot on the tension release rod 2 and then insert the calking shaft of the tension release rod 1 into the shaft hole on the unit holder 3 Attach the retaining ring E3 to the calking shaft of the thread release lever assembly 3 Start movie clip CD ROM version only Apply MOLYKOTE EM 30L to the calking shaft of the tension release rod Small bead 3 2 1 2 Retaining ...

Page 248: ...holder Key point Lift the presser bar clamp slightly when inserting washers 5 Apply a bead of MOLYKOTE EM 30L to the section where the presser foot lever 3 contacts the presser bar clamp 6 Insert the presser foot lever 3 into the presser lift shaft 1 from the rear of the unit holder and then attach the retaining ring E4 Start movie clip CD ROM version only Apply MOLYKOTE EM 30L to the surface of t...

Page 249: ...release plate assembly 1 into the shaft hole on the unit holder Key point Move the Z zigzag cam 2 to the position of the photo 3 Attach the retaining ring E2 to the calking shaft of the release plate assembly 1 from the rear of the unit holder Start movie clip CD ROM version only Apply MOLYKOTE EM 30L to the calking shaft at the end of the release plate assembly Small bead 1 1 Retaining ring E2 2 ...

Page 250: ...plate assembly attachment 1 Place spring onto the presser lift shaft 1 2 Attach the L shaped section of spring to the groove on the presser foot lifter 2 3 Attach the adjusting plate assembly 3 to the unit holder with the 2 screws 1 Key point Attach the hook 4 of spring to the adjusting plate assembly Press the indicated section 5 of the adjusting plate assembly to the indicated section 6 of the u...

Page 251: ... face of the needle holder assembly Start movie clip CD ROM version only 1 Torque 0 20 0 49 N m 1 1 Screw Bind M2 6X5 Color Silver 19 Shaft bushing A attachment 1 Attach shaft bushing A 1 to the unit holder with the screw 1 Key point Insert shaft bushing A into the unit holder 1 Torque 0 58 0 78 N m 1 1 Taptite Bind B M3X8 Color Silver 20 Lever AB ASSY assembly 1 Attach the needle threader driving...

Page 252: ...uide shaft 1 into the shaft hole on the unit holder and then insert the slider 4 of the lever AB assembly 2 into the slide groove 3 of the unit holder 6 Place the lever supporter plate 5 beneath the lever guide shaft 1 and then attach the lever supporter plate 5 to the unit holder with the screw 1 7 Attach the retaining ring E2 to the lever guide shaft 1 from the rear of the unit holder Start movi...

Page 253: ... needle bar 4 Tighten the screw 1 temporarily Key point Align the tab on the shaft hole 5 of the needle bar thread guide with the groove 6 on the D cut face of the needle bar Move the needle block upward and then tighten the screw 1 temporarily 5 Attach the needle block supporter 7 to the needle bar thread guide 2 with the screw 2 from the rear of the needle bar 4 Key point Engage the positioning ...

Page 254: ...rew 1 temporarily 7 Adjust the needle bar height and then fully tighten the screw 1 Key point Refer to Needle bar height adjustment on page 4 9 for the adjustment procedure 8 Attach spring and the thrust washer 6 to the needle bar assembly 3 and then pass the needle bar assembly completely through the shaft hole on the needle holder assembly Key point Position spring with the end with the smaller ...

Page 255: ... 0 to the tab on the rear of the oscillating section of the release lever s needle bar hook stand assembly Small bead 1 2 Retaining ring E2 5 3 25 Release lever assembly attachment 1 Attach the release lever assembly 1 to the needle holder assembly the position shown in the illustration on the right with the screw 1 Key point Tighten the screw 1 while lightly pressing the release lever shaft of th...

Page 256: ...lip CD ROM version only 1 Torque 0 79 1 18 N m 1 2 1 1 1 Screw Bind M3X5 Color Silver 28 Release adjuster attachment 1 Attach the release adjuster 1 to the needle holder assembly the position shown in the illustration on the right and then tighten the 2 screws 1 temporarily 2 Adjust the needle bar hook height and then fully tighten the 2 screws 1 Start movie clip CD ROM version only 1 Torque 0 19 ...

Page 257: ...t from the end without a shaft hole 6 Insert shaft C 6 into the shaft hole on the top of the needle holder assembly and pass it through the shaft hole on shaft A 4 Key point Insert shaft C from the end with a groove Cross shaft A and shaft C 7 Attach the plate 7 to the needle holder assembly with the screw 1 Key point Attach the U shaped section of the plate to the groove on shaft C 8 Attach the s...

Page 258: ... Attach spring in the following direction Plate From the left side Needle bar hook stand assembly From the front side S42 1 S42 2 S42 S42 SPRING XC6252 A decided hook form is the same 29 4 32 Spring attachment 1 Attach spring to the plate 1 and the lever AB assembly 2 S62 1 S62 2 S62 A decided hook form is the same SPRING XC7816 27 7 3 2 ...

Page 259: ...mporarily tighten the screw 1 to the needle holder shaft block from the bottom of the unit holder 6 Adjust the clearance between the needle and the rotary hook point and then fully tighten the screw 1 Key point Refer to Clearance between needle and rotary hook point adjustment on page 4 11 for the adjustment procedure Start movie clip CD ROM version only 1 Torque 0 98 N m 2 1 3 2 1 Screw 3X10 Colo...

Page 260: ...C AP N 0 to the cylindrical section 1 of the zigzag adjusting nut 2 Attach the zigzag adjusting nut 1 to the rear of the needle holder and then tighten the screw 1 temporarily Key point Position the zigzag adjusting nut with the larger eccentric section 2 section shifted from the center on the top 3 Adjust the 3 needle drop points and then fully tighten the screw 1 Key point Refer to Three point n...

Page 261: ... Key point Thread the lock nut to the mid point of the screw 1 2 Attach the screw 1 to the upper rear section of the unit holder Key point Tighten the screw 1 until the lock nut contacts the unit holder Start movie clip CD ROM version only 1 Torque 0 39 0 49 N m 1 1 1 Set Screw Socket CP M4X12 Color Black ...

Page 262: ...h the end that has an obtuse hook on the bottom 4 Attach the lower hook of spring to the spring hole 5 on the PT holder 2 5 Attach the upper hook of spring to the PT lever 6 and then insert the PT lever into the shaft of the cloth thickness sensor assembly 1 6 Secure the PT lever 6 with the screw 1 Key point Align the shaft end of the cloth thickness sensor assembly with the top face of the PT lev...

Page 263: ...e Bind B M3X8 Color Gold 40 BHSW D6 SW assembly attachment 1 Attach the BHSW D6 SW assembly 1 with the screw 1 Key point Engage the positioning tab on the side face of the unit holder with the positioning hole on the BHSW D6 SW assembly 1 1 Torque 1 18 1 57 N m 1 1 Taptite Pan B M4X12 Color Gold 41 Presser dial attachment 1 Raise the presser foot 1 2 Insert the presser dial 1 into the presser dial...

Page 264: ...PCB assembly Tighten the screw 2 at the center of the slot on the ATPF INIT PCB assembly Apply Turbine oil 100 to the shaft of the presser pulse motor 1 2 drops 1 Torque 0 58 0 78 N m 2 Torque 0 58 0 78 N m 2 1 1 4 2 3 Screw Bind M3X4 Color Silver Screw Pan S P washer M3X5 Color Silver 43 Presser pulse motor holder assembly attachment 1 Attach the presser pulse motor holder 1 to the unit holder wi...

Page 265: ...edle threader shaft A 2 until you hear a click 2 1 45 Presser feed holder attachment 1 Temporarily attach the screw 1 to the presser feed holder assembly 1 2 Move the presser feed holder assembly 1 upward and then tighten the screw 1 3 Attach the Z foot 2 1 Torque 1 18 1 57 N m 1 2 1 Screw 3 57 Color Silver ...

Page 266: ...3 134 Main parts location diagram Embroidery ...

Page 267: ... support to the screw on the left Tighten the screws 1 in the following order 1 1 temporarily tighten 1 2 fully tighten 1 3 fully tighten and 1 1 fully tighten 1 Torque 0 59 0 79 N m 1 2 1 1 1 3 2 1 Screw Bind M3X6 Color Silver 3 Y driving gear pulley assembly attachment 1 Apply a bead of EPNOC AP N 0 to the shaft of the X carriage assembly 2 Place the driving gear pulley assembly 1 onto the shaft...

Page 268: ...ssembly attachment 1 Hang one end of the timing belt Y belt 1 over the driving gear pulley assembly 2 2 Place the Y slider 3 over the Y sensor PCB assembly 4 and then insert the guide 6 on the X carriage assembly into the groove 5 on the Y slider 3 3 Hang the other end of the timing belt 1 over the tension pulley assembly 7 and then attach the tension pulley assembly 7 to the left side of the X ca...

Page 269: ...Insert the Y pulse motor assembly from the bottom of the X carriage assembly Apply of Turbine oil 100 to the bushing of the Y pulse motor 1 2 drops 1 Torque 0 79 1 18 N m 1 1 1 2 Screw Pan S P washer M3X7 Color Silver 7 XC sub cover attachment 1 Attach the XC sub cover 1 to the end of the X carriage assembly with the screw 1 Key point Hang the hook 2 of the XC sub cover over the groove of the X ca...

Page 270: ...Engage the positioning pin on the E hoop stay plate sub assembly with the positioning hole on the E hoop lock lever spring Align the E hoop lock lever spring with the bottom of the slot on the E hoop stay plate sub assembly Start movie clip CD ROM version only 1 Torque 0 59 0 79 N m 2 Torque 0 98 1 18 N m 4 2 1 Retaining ring E4 3 5 2 1 1 1 2 Screw Pan S P washer M3X7 Color Silver Screw Bind M3X4 ...

Page 271: ...0 98 1 18 N m 1 2 1 1 1 Screw Bind M4X6 Color Silver 11 E hoop presser plate assembly attachment 1 Attach the E hoop presser plate assembly 1 to the E hoop stay plate assembly 2 with the 2 screws 1 Key point Attach the E hoop presser plate assembly to the lower section of the E hoop stay plate assembly Engage the positioning tab on the E hoop presser plate assembly with the positioning hole on the...

Page 272: ... black line between the guide 3 and the guide 4 4 Insert the other end of the FFC cord 1 into the guide 6 and then pull the tip of the FFC cord 1 until a fold 7 is created immediately before the guide 6 Key point Insert the other end of the FFC cord into the guide 6 with the rear of the cord surface without the blue tag facing you so that a fold is created as shown in the illustration on the right...

Page 273: ...ly 1 into the connector of the frame PCB assembly 2 2 Attach the FFC support assembly 1 to the Y carriage assembly 3 with the 2 screws 1 Key point Tighten the screws 1 in the following order 1 1 temporarily tighten 1 2 fully tighten and 1 1 fully tighten 1 Torque 0 59 0 79 N m 1 2 1 3 2 1 1 Screw Bind M3X6 Color Silver ...

Page 274: ...guide shaft 1 the end without the retaining ring into the shaft hole on the left end of the X carriage assembly until it reaches the shaft hole at the right end 5 Press the left end of the Y guide shaft 1 to the right and then attach the stop ring 10 69 to the inner groove 6 Secure the Y carriage assembly 6 with the 2 screws 1 Key point Tighten the screws 1 in the following order 1 1 temporarily t...

Page 275: ...carriage assembly 1 to the left as far as possible 2 Thread the tip of the FFC cord 2 from the left end of the X carriage assembly 3 into the Y slider 3 Pull the tip of the FFC cord 2 until the FFC cord 2 is inside the screw 4 on the left end of the X carriage assembly 1 2 3 4 ...

Page 276: ...h the cord clip to the hole 4 on the right side the XY carriage assembly Key point Insert the tab on the rear of the cord clip into the hole on the XY carriage assembly larger hole and then slide the cord clip to the left to secure it 2 Cord clip 1 to be attached to the left Hold the FFC cord 2 with the guide on the cord clip 1 and attach the cord clip to the hole on the left side the XY carriage ...

Page 277: ...3 145 Main parts Embroidery Assembly 17 YPM lead wire assembly attachment 1 Insert the YPM lead wire assembly 1 into the connector of the Y pulse motor 2 2 1 ...

Page 278: ... inward and pass it under the Y sensor PCB 2 3 Bundle the FFC cord 1 Y sensor PCB lead wire 3 wire cord and YPM lead wire 3 4 wire cord in this order and thread them through the cord grip 4 4 Attach the cord grip 4 to the lower right of the X carriage assembly with the screw 1 1 Torque 0 59 0 78 N m 2 4 3 2 1 4 1 1 Screw Bind M3X6 Color Silver ...

Page 279: ... 4 wire cord so that it contacts the X carriage 4 Place the lead wires over the FFC cord with the Y sensor PCB lead wires on the left and the YPM lead wires on the right 5 Pass the 3 cords through the lower guide and then the upper guide of the X slider 4 Key point Pull the 3 lead wires from the top of the X slider to make them taut Start movie clip CD ROM version only 1 Torque 0 19 0 39 N m 1 18 ...

Page 280: ... Apply EPNOC AP N 0 to the shaft of the main frame sub assembly Bead 1 22 X tension pulley assembly attachment 1 Hang the timing belt X belt 1 over the driving gear pulley assembly 2 2 Hang the other end of the timing belt 1 over the tension pulley assembly 3 and then attach the tension pulley assembly 3 to the left side of the main frame assembly with the 2 screws 1 Key point Move the tension pul...

Page 281: ...mbly Bend the XPM lead wire assembly of the X pulse motor assembly toward you Apply Turbine oil 100 to the bushing of the X pulse motor 1 2 drops 1 Torque 0 79 1 18 N m 2 3 3 1 1 1 Screw Pan S P washer M3X7 Color Silver 24 X guide plate attachment 1 Attach the X guide plate 1 to the main frame and temporarily tighten the 3 screws 1 Adjust the X carriage height and then fully tighten the 3 screws 1...

Page 282: ...ame assembly 3 Position the tab on the right end of the X guide shaft 3 at an angle and then insert the tab downward at an angle relative to the right bushing 5 4 Hold both ends of the X guide shaft 3 and then rotate the shaft away from the operator to secure it 5 Tighten the screws 1 at both ends of the X guide shaft 3 Start movie clip CD ROM version only 1 Torque 1 18 1 57 N m 4 1 2 3 5 1 Screw ...

Page 283: ...X belt presser and then fully tighten the screw 1 Start movie clip CD ROM version only 1 Torque 1 18 1 57 N m 1 1 Screw Pan S P washer M4X8 Color Silver 27 X sensor PCB assembly attachment 1 Slide the X carriage assembly of the main frame assembly to the right as far as possible 2 Attach the X sensor PCB assembly to the X guide plate 1 with the screw 1 Key point Engage the positioning tab at the l...

Page 284: ...then tie it with a band 3 Slide the X carriage assembly 1 of the main frame assembly to the left as far as possible 4 Hang the lead wire of the X sensor PCB assembly 2 over the right hook 4 on the bottom of the main frame 1 4 2 1 3 2 29 E cord supporter attachment 1 Attach the E cord support 1 to the X guide plate with the screw 1 Key point Attach the screw 1 to the hole at the left side of the sc...

Page 285: ...so they are taut Key point Bend the 3 cords to thread them through the E cord supporter guide 1 4 2 3 5 31 EMB relay PCB assembly attachment 1 Connect the X sensor PCB assembly connector 1 Y sensor PCB assembly connector 2 FFC cord connector 3 XPM connector 4 and YPM connector 5 to the EMB relay PCB assembly 6 2 Attach the EMB relay PCB assembly 6 to the X guide plate with the 3 screws 1 Key point...

Page 286: ...ng tabs on the notched cam with the corresponding positioning holes on the drop lever calking assembly Tighten the screw 1 from the rear of the drop lever calking assembly 2 Attach the drop knob 3 to the drop lever calking assembly 2 with the screw 2 1 Torque 0 59 0 79 N m 2 Torque 0 49 0 69 N m 2 1 1 3 2 Taptite Bind P M3X10 Color Black Screw Pan S P washer M3X7 Color Silver ...

Page 287: ... notched cam 7 with the hole on the drop lever support assembly 8 Insert the assembly until the hook at the upper section of the notched cam 9 is caught in the groove on the lock lever support assembly a click can be heard 4 Attach the drop notched plate to the drop lever support assembly with the screw 2 Key point Engage the positioning tab on the drop lever support assembly with the positioning ...

Page 288: ... to the ES base cover assembly 2 with the screw 1 Key point Engage the 2 positioning tab on the EX base cover assembly with the corresponding positioning holes on the drop lever assembly Insert the shaft of the drop lever calking assembly 6 into the hole on the drop connection rod before tightening the screw 1 1 Torque 0 59 0 79 N m 1 4 2 3 1 5 2 6 Taptite Bind P M3X10 Color Black 35 Lock release ...

Page 289: ...nto the spring hole 2 on the ES base cover 1 2 Insert the lock finger 4 and the lock release lever 5 of the lock release lever assembly 3 into the corresponding holes on the EX base cover 1 3 Hook the other end of spring onto the hole on the lock finger4 S64 2 3 5 4 4 S64 S64 1 S64 S64 SPRING XC8096 19 8 5 ...

Page 290: ...ng positioning holes on the main frame assembly Pass the FFC cord Y sensor PCB assembly lead wire and YPM lead wire under the main frame assembly 1 Torque 0 79 1 18 N m 1 2 1 Taptite Cup B M4X14 Color Silver 38 EMB unit lead wire assembly attachment 1 Attach the EMB unit lead wire assembly 1 to the ES base cover 2 with the 2 screws 1 Key point Insert the black connector of the EMB unit lead wire a...

Page 291: ...ith a band 2 1 5 3 4 40 ES main cover assembly attachment 1 Position the embroidery unit assembly with the main unit attachment section on the right and then slide the X carriage assembly 2 to the left as far as possible 2 Attach the ES main cover assembly 3 to the ES base cover assembly 1 with the 10 screws 1x5 and 2x5 Key point Push the X carriage assembly to the felt of the ES main cover assemb...

Page 292: ...mbly with the screws 1 and 2 Key point Engage the positioning tab on the E hoop stay cover with the positioning hole on the Y carriage assembly Slide the E hoop stay cover to the right Tighten the screws 1 in the following order 1 temporarily tighten 2 fully tighten and 1 fully tighten 1 Torque 0 59 0 79 N m 2 Torque 0 59 0 79 N m 2 1 1 Screw Pan S P washer M3X7 Color Silver Screw Bind M3X4 Color ...

Page 293: ...e cover 2 to the X carriage assembly 3 with the screw 1 Key point Insert the 2 tabs 5 on the X carriage assembly 4 into the corresponding grooves 6 inside the X carriage cover Press the indicated section of the X carriage cover from the top and then tighten the screw 1 Start movie clip CD ROM version only 1 Torque 0 79 1 18 N m 2 1 4 6 5 3 1 7 Screw Pan S P washer M4X8 Color Silver ...

Page 294: ...f the X carriage cover 3 with the screw 1 Key point Hang the 2 hooks 5 on the side face of the X carriage cover over the YPM cover Hang the 2 hooks 6 inside the YPM cover over the X carriage cover Press the YPM cover until you hear a click Tighten the screw 1 from the bottom of the YPM cover Start movie clip CD ROM version only 1 Torque 0 59 0 78 N m 1 3 4 2 1 5 6 Taptite Bind P M3X10 Color Black ...

Page 295: ...ustment 4 13 Fine tension adjustment 4 14 Upper thread tension adjustment 4 15 Shuttle adjustment 4 16 Shuttle origin position adjustment 4 18 Thread scratch link adjustment 4 19 Inner rotary hook tension adjustment 4 20 Cloth pressure setting adjustment 4 21 Feed dog height and squareness adjustment 4 22 Front back and left right position of feed dog adjustment 4 23 Side feed straight stitch adju...

Page 296: ...h the positions marked with crosses on the touch panel in order from 1 to 5 NOTE Setting is successful if a single beep sounds when 5 is pressed An error has occurred if two beeps sound when 5 is pressed Repeat from position 1 again 3 Turn the power off and then on again Check that the screen display matches the positions on the touch panel ...

Page 297: ... pulley assembly 2 Adjust the position of the tension pulley so that the belt deflects 2 95 to 3 05 mm when a force of 1 96N 200g is applied to the center of the belt 3 Tighten the pan head screw S P washer M4X10 to secure the tension pulley assembly 2 95 3 05mm 1 96N 200g Tension pulley assembly Screw pan S P washer M4x10 ...

Page 298: ...securing the motor holder 2 Adjust the position of the motor holder so that the belt deflects 1 5 to 3 5 mm when a force of 0 98N 100g is applied to the center of the belt 3 Tighten the screw to secure the motor holder Motor holder 1 5 3 5mm Upset 4x12DB 0 98N 100g ...

Page 299: ...raise the needle bar to the limit 4 Loosen the screws securing the upper shaft rotation shutter 5 Turn the pulley to lower the needle bar 1 3mm 0 1mm 6 Rotate the upper shaft rotation shutter in the shaft rotation direction and secure the rotation shutter at the position the buzzer stops position the shutter at the far right enters the sensor 1 2 1 4mm ...

Page 300: ...front cover is attached 3 Turn the pulley by hand until the tip of the needle enters the needle hole 4 Loosen the socket bolt M3X10 of the zigzag adjusting nut 5 Adjust the zigzag adjusting nut so that the needle drop is centered over the needle hole on needle plate A at the left base line center base line and right base line 6 Tighten the socket bolt M3X10 Zigzag adjusting nut Screw 3x10 ...

Page 301: ... by hand until the tip of the needle enters the needle hole 2 Loosen the screw 3X10 3 Move the needle holder shaft block to the left or right so that the needle drop is centered over the needle hole on needle plate A at the left base line and right base line 4 Tighten the screw 3X10 ...

Page 302: ... limit 6 Loosen the 3 socket set screws FT M5X5 securing the lower shaft pulley D 7 Move the lower shaft pulley D and the lower shaft A assembly so that the right edge of the needle is aligned with the tip of the outer rotary hook when the needle bar is raised 2 9 to 3 3 mm from the reference line of the lowest point Set a ruler on the left side and measure the distance 8 Tighten the 3 socket set ...

Page 303: ...ve needle plate A from the feed base 5 Turn the pulley by hand until the right edge of the needle is aligned with the tip of the outer rotary hook 6 Loosen the socket set screw CP M4X4 securing the needle bar block 7 Adjust the height of the needle bar so that the clearance between the top of the needle hole and the lower edge of the outer rotary hook tip is 1 0 to 1 4 mm NOTE Make sure the needle...

Page 304: ...int Secure the socket set screw FT M4X4 at a position slightly to the left when viewed from the front of the machine Adjust the height so that the upper edge of the threading hook is level with the upper edge of the needle hole NOTE If the position of the needle thread block socket set screw is too far to the left the hook will not operate and treading is not possible If the position of the needle...

Page 305: ...the needle bar to the left base line 3 Turn the power off 4 Remove the 2 flat screws M4 and then remove needle plate A from the feed base 5 Loosen the screw M3X20 6 Turn the pulley by hand until the right edge of the needle is aligned with the tip of the outer rotary hook 7 Adjust the clearance between the needle and the outer rotary hook front and back to 0 1 mm or less using the adjusting screw ...

Page 306: ...Loosen the set screw CP M5X10 securing the presser bar clamp assembly 5 Adjust the height of the presser bar so that the clearance between the top of needle plate A and the bottom of the presser is 7 0 7 5 mm NOTE Use the J foot Adjust the presser bar so that the needle plate feed dog hole is parallel to the presser Set screw socket CP M5x10 Upper surface of needle plate 7 0 7 5mm ...

Page 307: ...the pulley by hand until the tip of the needle enters the needle hole 3 Loosen the lock nut 4 Move the needle tip to the center position front back of the needle hole using the socket set screw CP M4X12 5 Tighten the lock nut Set screw socket CP M4x12 Lock nut Rear of main unit Needle hole Needle tip position ...

Page 308: ...ter 2 Pass the Schappe Spun Sewing Thread 60 through the thread guide and then the tension plate 3 Lower the presser foot lifter 4 Pull the thread with a tension gauge and adjust the tension to 0 08 to 0 11N 8 to 11g using the power lock 2x3 Power lock 2x3 Tension plate ...

Page 309: ...ad 60 through the thread guide tension plate tension disk and brake plate assembly in this order 5 Lower the presser foot lifter 6 Pull the thread with a tension gauge and adjust the tension to 0 51 to 0 62N 52 to 63g using the thread tension adjusting screw 7 Apply a small amount of screw lock agent to the thread tension adjusting screw Tension disk Tension plate Thread guide Brake plate assembly...

Page 310: ...se line comes to the top 4 Select test mode 22 NP sensor mode 5 Turn the pulley by hand until it reaches the position the buzzer stops upper shaft rotation angle 32 6 Press Close 7 Select test mode 28 8 As shown in the attached photo1 9 Select THPM and then lower the shuttle to the limit 10 Turn the power off continued on the next page 1 ...

Page 311: ...d guide hook NOTE As a result of the above adjustment both ends of the thread are positioned behind the needle resulting in the thread curving at the needle as shown in the attached photo4 correct state When positioned too far in front curvature too small the thread will be chipped or threading failure will occur When positioned too bar behind the thread guide plate assembly contacts the needle th...

Page 312: ...t is FF press 1 3 Press 2 THPM OFF 4 Turn the THPM by hand until it reaches the position the shuttle begin a movement 5 Loosen the screw of the TH sensor holder 6 Raise and lower the TH sensor holder fit the TH sensor the position just before the buzzer stops and tighten the screw of the TH sensor holder 2 1 ...

Page 313: ...n tighten the screw Reference 1 3 Select THPM and then lower the shuttle to the limit 4 Loosen the screw of thread scratch link again 5 Adjust the height of the thread scratch linkso that the clearance between the rack and the thread scratch link is 0 2 0 3 mm Reference 2 6 Tighten the screw of thread scratch link 1Before adjustment 2After adjustment Screw Thread scratch link ...

Page 314: ...o the inner rotary hook and thread the needle 2 Pull the thread with a tension gauge and adjust the tension to 0 10 to 0 12N 10 to 12g using the spring adjusting screw 3 Apply a small amount of screw lock agent to the spring adjusting screw 0 10 0 12N 10 12g Schappe spun sewing thread 60 Spring adjusting screw ...

Page 315: ...he pulley by hand until the feed dog is lower than the needle plate 4 Lower the presser lever and then press 0 on the screen 5 Raise the presser lever and insert a 3 mm gauge 6 Lower the presser lever and press 3 on the screen 7 Remove the 3mm gauge lower the press lever 8 Press OK of PF AM Adjust 9 Press CLOSE 3mm ...

Page 316: ...of the feed dog is 0 9 to 1 1 mm from the top face of needle plate A Reference 1 3 Loosen the bolt next to the feed adjuster and then tighten it again Reference 2 4 Adjust the bolt on the operator s side so that the feed dog is at the parallel Reference 3 After adjustment check that the front tooth is level with the far back tooth of the feed dog Feed dog uppermost position Needle plate surface 0 ...

Page 317: ...and left right right positions of the feed dog Key point Adjust the clearance between the forward edge of the feed dog middle tooth and needle plate A to 3 2 to 3 8 mm Adjust the clearance left right between the feed dog and needle plate A to be equal Do not allow the feed dog to engage needle plate A at an angle 4 Secure the feed dog with 2 screws bind M3x8 5 Fully tighten the M4 screws to secure...

Page 318: ...g height and alignment so that the U shape is almost on the right and the sewing length at the upper section is 26 0 to 31 0 mm 2Adjust the skew feed correction value so that the vertical clearance on the right is 4 0 to 6 0 mm 3Adjust the left right length correction value so that the difference between the upper and lower length is 1 0 mm or less Positive correction Negative correction Less than...

Page 319: ... prevent pattern overlapping opening and or shift Key point If the pattern is compressed in the direction press the vertical button A If the pattern is stretched in the direction press the vertical button B If the pattern is compressed in the direction press the horizontal button C If the pattern is stretched in the direction press the horizontal button D ...

Page 320: ...d backward feed length using the FPM holder assembly screw 4X25 Key point After feeding the two layers of broadcloth with a sheet of paper inserted between them forward and backward for 100 stitches check that the forward feed length is 0 5 0mm longer than the backward feed length Tightening the screw 4X25 increases the backward feed length Loosening the screw 4X25 decreases the backward feed leng...

Page 321: ...ent 1 Select test mode 02 2 Turn the pulley by hand until the feed dog is lower than the needle plate top face 3 Lower the presser lever and press MIN 4 Insert the lever and press MAX with the lever fully turned to the right 5 Press CLOSE Knee lifter lever ...

Page 322: ...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 and that BH1 has some deflection Extend fully and return two piches Two piches Contact BH eccentric sh...

Page 323: ...ustment 1 Loosen the 2 screws 1 2 Move the tension pulley plate assembly right and left to adjust the X belt tension 3 Tighten the 2 screws 1 Load when center of X belt is deflected 6 0 mm 2 254 to 2 646N 230 to 270g 1 6 0mm 2 254 2 646N 230 270g ...

Page 324: ...ment 1 Loosen the 2 screws 1 2 Move the tension pulley plate assembly right and left to adjust the Y belt tension 3 Tighten the 2 screws 2 Load when center of Y belt is deflected 6 0 mm 1 28 to 1 67N 130 to 170g 1 6 0mm 1 28 1 67N 130 170g ...

Page 325: ...the power off 3 Remove the embroidery hoop 4 Loosen the screws securing the embroidery hoop stay plate 5 Adjust the clearance between the cover and the embroidery hoop stay plate to 3 3 to 3 7 mm at a position 5 mm from the right edge of the embroidery hoop stay plate 6 Tighten the screws to secure the embroidery hoop stay plate ...

Page 326: ...en the screw bind M3X8 securing the inner rotary hook bracket assembly 3 Adjust the position of the inner rotary hook bracket assembly so that the inner rotary bracket assembly contacts the inner rotary hook along 1 6 to 1 8 mm and secure the inner rotary hook bracket assembly with the screw bind M3X8 Bind M3x8 1 6 1 8mm ...

Page 327: ... reverse stitching 5 14 Does not operate when the foot controller is used 5 15 Needle bar cutting and separating does not occur normally 5 16 Thread tensioning does not go well 5 17 Thread cutter does not work normally 5 19 Bobbin winding cannot be done 5 20 The lamp at hand does not have light 5 21 Bobbin thread detection does not work normally 5 23 Upper thread sensor does not work normally 5 24...

Page 328: ...th power ON operation system SW F04 5 40 FC disconnect F05 5 41 Dirty speed sensor F06 5 41 NP sensor disconnect F07 5 42 Speed VR disconnect The safety device has been activated Is the turned tougled Is the needle bent No rotation in main motor A malfunction occurred Turn the machine off the on again PM Each pulse motor has not returned to its original position ...

Page 329: ...12 and panel PCB CN3 N N Y When lead wires A and B on the main panel are removed from the main PCB and power is turned on in the no front cover test mode does the buzzer sound N Y Replace the power supply unit D6 Y Connect lead wire B on the main panel correctly or replace it Replace the power PCB Y Replace the power supply unit D6 When the power is turned on does the buzzer sound after a while Is...

Page 330: ...onnect the FFC for the LCD correctly or replace it N Y Y Is FFC Flexible flat cable for the LCD free from damage and correctly connected to the panel PCB CN10 and LCD module Replace the inverter D6 Replace the LCD module Y Is the backlight turned on Is the inverter lead wire free from damage and correctly connected From previous page ...

Page 331: ...f the TG switch assembly normal When switch is pressed 1Ω or less When switch is released Are the main PCB and TH PF and AT initial sensor PCB assemblies correctly connected N N Replace the main motor N Are the main PCB and TG switch assembly correctly connected Replace the main motor N Y Y Y Y To next page When the power is turned ON the pulse motors do not return to the starting point When needl...

Page 332: ...PCB assembly CN12 between 24 7 and 27 3 V DC N Y Y Y N Replace the pulse motor lead wire Is the resistance between the pins at the ends of each pulse motor lead wire 1 Ω or less AT TH Z C and S pulse motor lead wires Between pins 1 1 2 2 3 4 and 4 3 F pulse motor lead wire Between pins 1 1 2 2 3 3 and 4 4 PF pulse motor lead wire Between pin 1 yellow housing pin 3 white housing Between pin 2 yello...

Page 333: ...operly N Y Connect it properly Is the touch panel s FFC properly connected to connector CN16 on the panel PCB N Y Change touch panel and tune it again Is the resistance between pins 2 and 4 and 1 and 3 of the touch panel 85 350W 500 2050Ω respectively N Y Is the touch panel tuned correctly Change panel PCB and tune the touch panel again ...

Page 334: ...read switch normal Switch resistance values When switch is pressed 1Ω or less When switch is not pressed N N Reconnect it correctly N N N Y Is the main motor connector correctly connected to the power PCB assembly CN301 Y Y Replace the main motor Replace the SS PCB assembly D6 or thread switch PCB assembly Is the main motor resistance 0 5 2 5Ω Y Y To next page Main motor does not turn Is the harne...

Page 335: ... N Reconnect it correctly Is the NP PCB assembly D6 connector correctly connected to the main PCB assembly CN15 N N Y Y Y Replace the power supply unit Are the parts on the power PCB assembly Q603 Q608 Q611 Q612 PTC601 PTC602 J117 and J118 free from discoloration or flaws Y Select test mode 14 Is an F01 error message displayed on the LCD and was test mode 14 selected after servicing N N Replace PF...

Page 336: ...ved with the power on does the voltage between pins 3 and 1 on the panel PCB assembly CN6 change between 0 3 and 2 9 V DC N Replace NP PCB D6 assy Replace main PCB assy When the upper shaft pulley is slowly turned by hand does the voltage between pins 2 and 1 on the main PCB assembly CN15 change between 0 and 5 V DC N Y Replace the power supply unit D6 Are the parts on the power PCB assembly Q603 ...

Page 337: ...eedle presser module N Replace main PCB assy Y Y With the power OFF can you lightly move the needle bar left and right by hand Replace pulse motor N Y Is the resistance between pins 1 2 and 3 4 on the Z F and S pulse motor connectors normal Replace the pulse motor lead wire Is the resistance between the pins at the ends of each pulse motor lead wire 1 Ω or less Z and S pulse motor lead wires Betwe...

Page 338: ...N21 normal 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 pins 4 and 5 on the BH switch connector CN21 normal BH lever down 1Ω or less BH lever up Change to correct presser N Replace main PCB assy Y Y Is the correct presser being used N N Y Adjust BH lever or Replace BH switch assy Adjust BH lever or Replace BH swi...

Page 339: ...h and the manual key for zigzag width are turned ON and OFF normally Is the resistance between pins 1 2 and 3 4 on the Z and F pulse motor connectors normal Replace pulse motor N Y Replace the pulse motor lead wire Is the resistance between the pins at the ends of each pulse motor lead wire 1 Ω or less Z pulse motor lead wire Between pins 1 1 2 2 3 4 and 4 3 F pulse motor lead wire Between pins 1 ...

Page 340: ... Replace NP D6 PCB assy When the upper shaft pulley is slowly turned by hand does the voltage between pins 2 1 4 1 5 1 and 6 1 on the main PCB assembly CN15 change between 0 and 3 V DC Is the resistance for the start stop switch reverse switch raise needle switch thread cut switch presser foot lifter switch and thread switch normal Switch resistance values Switch depressed 1 Ω or less Switch out N...

Page 341: ...bly N Replace the foot controller Y Is the foot controller jack assembly correctly connected to the panel PCB assembly CN9 Replace the main motor N Y When the foot controller is replaced with a new one does it work correctly Replace the panel PCB assembly N Y Does not operate when the foot controller is used Is the resistance between pins 2 and 3 on the foot controller jack assembly connector norm...

Page 342: ...le presser module assembly Is the needle bar cutting and separating operation easy and smooth N Replace the Z pulse motor Is the resistance across pins 1 2 and pins 3 4 for the Z pulse motor connector 5 7 Ω N Y Y Replace main PCB assy Replace the Z pulse motor lead wire Is the resistance between pins 1 1 2 2 3 4 and 4 3 at the ends of the Z pulse motor lead wire 1 Ω or less N Y ...

Page 343: ... N Y Use the correct combination Is the material thread and needle combination correct N Y Y Y Replace the main motor Are the main PCB and AT initial sensor PCB assembly correctly connected N Replace the AT initial PCB assembly N Y When the slit section of the AT initial sensor PCB assembly is switched to the open closed position with the power on does the voltage between pins 2 and 3 on the main ...

Page 344: ...nector CN8 between 5 and 7 Ω N Y Y Replace the AT pulse motor lead wire N Is the resistance between pins 1 1 2 2 3 4 and 4 3 at the ends of the AT pulse motor lead wire 1 Ω or less Adjust inner rotary hook tension Is the inner rotary hook tension right N Adjust upper thread tension disk Is the thread tension adjuster gap correct N Y Replace main PCB assy Y From previous page ...

Page 345: ...the thread cutter module Do the thread hook assy and lever gear move easily Is the resistance between the 1 2 pins and 3 4 pins on the C pulse motor connectors CN11 5 7Ω N N Replace C pulse motor Y Y Replace main PCB assy Is the resistance between pins 1 1 2 2 3 4 and 4 3 at the ends of the C pulse motor lead wire 1Ω or less N Replace the C pulse motor lead wire Y ...

Page 346: ...ctly N Y Y Replace main PCB assy The bobbin winder motor does not rotate Is the resistance between pins 1 and 2 on the BW switch assembly D6 connector normal When bobbin presser is in bobbin winding position 1 Ω or less When bobbin presser is not in bobbin winding position 8 N Replace the BW switch assembly D6 Replace the BW motor assembly Is the resistance of the bobbin winder motor between 72 an...

Page 347: ... Reconnect the panel PCB assembly and LED lamp R assembly Are the panel PCB assembly and LED lamp R assembly correctly connected N Reconnect the panel PCB assembly and LED lamp work area assembly N Y Are the panel PCB assembly and LED lamp work area assembly correctly connected Y Y Reconnect lead wire A on the main panel or replace it N Set the lamp to ON Is lead wire A on the main panel free from...

Page 348: ...ssembly or Replace the LED lamp R assembly or Replace the LED lamp work area assembly or Replace the panel PCB assembly or Replace the main PCB assembly Replace the power supply unit D6 When the power PCB connector main PCB CN13 is removed is the voltage between pins 5 6 and 8 6 26 V DC N Y From previous page ...

Page 349: ...photo transistor PCB assembly Are the main PCB assembly and photo transistor PCB assembly correctly connected N N When another photodiode PCB assy is connected to CN20 of the motor PCB assy and brought into the proximity of the phototransistor PCB assy does it operate normally Replace the phototransistor PCB assy Replace the photodiode PCB assy When another phototransistor PCB assy is connected to...

Page 350: ... upper thread PCB assembly Are the main PCB assembly and upper thread PCB assembly correctly connected N Y Replace the up thread PCB assy When the slit section of the upper thread PCB assembly is switched to the open closed position with the power on does the voltage between pins 2 and 3 on the main PCB assembly CN24 change between 0 3 3 V DC N Y Replace main PCB assy ...

Page 351: ...n the slit section of the TH initial sensor PCB assembly is switched to the open closed position with the power on does the voltage between pins 2 and 3 on the main PCB assembly CN2 change between 0 3 3 V DC Replace the TH initial sensor PCB assembly N Are the main PCB assembly and TG switch assembly correctly connected Replace the main motor N Are the main PCB assembly CN2 and TH initial sensor P...

Page 352: ...eplace the TH pulse motor lead wire N Replace the pulse motor N Y Is the resistance between pins 1 1 2 2 3 4 and 4 3 at the ends of the TH pulse motor lead wire 1 Ω or less Is the resistance between pins 1 2 and 3 4 on the TH and TG pulse motor connectors normal TH pulse motor 5 7 Ω TG pulse motor 11 13 Ω From previous page ...

Page 353: ...ead PCB N Replace the main motor N When the slit section of the PF initial sensor PCB assembly is switched to the open closed position with the power on does the voltage between pins 2 and 3 on the main PCB assembly CN3 change between 0 3 3 V DC Replace the PF initial sensor PCB assembly N Is the presser correctly adjusted Is the knee lifter correctly adjusted Replace the main motor N Are the main...

Page 354: ... between pins 2 and 3 on the main PCB assembly CN26 change between 0 and 5 V DC Is the knee lifter sensor PCB assembly correctly connected Y Y Replace the ATPF INIT PCB assembly N When the presser is moved up and down with the power on does the voltage between pins 2 and 3 on the main PCB assembly CN18 change between 0 and 5 V DC Replace the main motor N Is the ATPF INIT PCB assembly correctly con...

Page 355: ...eplace the PF pulse motor N Y Is the resistance between pins 1 2 and 3 4 on the PF pulse motor connector between 5 and 7 Ω Is the resistance between pin 1 yellow housing pin 3 white housing pin 2 yellow housing pin 4 white housing pin 3 yellow housing pin 2 white housing and pin 4 yellow housing pin 1 white housing on the PF pulse motor lead wire 1 Ω or less From previous page ...

Page 356: ...ilure Investigation for Electronic Parts Card cannot be used normally Change panel PCB N Y Does the machine function normally when another card is used Use another card Embroidery card cannot be used normally ...

Page 357: ...iversal serial bus USB cannot be used normally Universal serial bus USB cannot be used normally Connect it properly N Y Is the USB device firmly connected Replace the USB device Y N When the USB device is replaced with a new one does it work correctly Change panel PCB ...

Page 358: ...lly Universal serial bus USB cannot be used normally Connect it properly N Y Is the USB cable properly connected to both the personal computer and the sewing machine Change USB cable Y N Does the machine function normally when the USB cable is replaced with a reliable one Change panel PCB ...

Page 359: ...ector correctly Are the motor and sensor connectors inside the embroidery unit correctly connected N Reconnect the main body lead wire assy to the main PCB assy correctly Is the main body lead wire assy correctly connected to the main PCB assy N Y Y To next page Y Is the resistance between pin 1 CN3 pin 8 CN1 pin 2 CN3 pin 7 CN1 pin 3 CN3 pin 6 CN1 pin 4 CN3 pin 5 CN1 pin 1 CN4 pin 4 CN1 pin 2 CN4...

Page 360: ... 2 white housing pin 2 black housing pin 3 white housing pin 4 black housing and pin 4 white housing pin 3 black housing on the YPM lead wire assembly 1 Ω or less Replace the XPM lead wire assembly N Replace the YPM lead wire assembly N Y Y Replace the Y sensor PCB assy When operation is initially started with the X sensor s slit section closed does the embroidery hoop move in the right direction ...

Page 361: ...pin 7 8 way housing pin 18 pin 8 8 way housing pin 19 pin 10 11 way housing and pin 20 pin 11 11 way housing 1 Ω or less Where the first pin in each of the combinations above is on the main body lead wire assembly Y Is the resistance between pin 1 pin 1 white housing pin 2 pin 2 white housing pin 3 pin 3 white housing pin 4 pin 4 white housing pin 11 pin 1 black housing pin 12 pin 2 black housing ...

Page 362: ...ire assembly connector correctly connected to the main PCB assembly Is the resistance of the frame switch normal Frame switch assembly resistance When switch is pressed 1 Ω or less When switch is released When the frame PCB assembly and embroidery relay PCB assembly are connected with the FFC is the resistance between pins 1 1 pins 2 2 pins 3 3 pins 4 4 pins 5 5 and pins 6 6 on the frame PCB CN1 a...

Page 363: ...e resistance between pin 5 pin 5 white housing pin 6 pin 6 white housing pin 7 pin 7 white housing pin 8 pin 8 white housing and pin 9 pin 9 white housing 1 Ω or less Where the first pin in each of the combinations above is on the embroidery unit lead wire assembly Replace the main body lead wire assembly N Y Is the resistance between pin 5 pin 5 11 way housing pin 6 pin 6 11 way housing pin 7 pin...

Page 364: ... 38 Failure Investigation for Electronic Parts Error is displayed Replace main PCB assy After the power supply unit D6 is replaced does the motor correctly rotate in test mode 14 N Y OK F01 is displayed ...

Page 365: ...rts Failure Investigation for Electronic Parts Error is displayed Replace SS PCB assy Is one of the SS key NP key BK key and CUT key stuck in a pressed down condition N Y Release the switch that is stuck F02 is displayed ...

Page 366: ... wires broken Y N F04 is displayed When the foot controller is replaced with a new one does it work correctly N Y Correctly connect the foot controller jack assembly to the panel PCB assembly CN9 Is the foot controller jack assembly correctly connected to the panel PCB assembly CN9 N Y Replace the panel PCB assembly Replace the foot controller ...

Page 367: ... the NP PCB assembly D6 is replaced with a new one does it work correctly N Y Correctly connect the NP PCB assembly D6 to the main PCB assembly CN15 Is the NP PCB assembly D6 correctly connected to the main PCB assembly CN15 N Y Replace the NP PCB assembly The error message F05 or F06 is displayed on the screen ...

Page 368: ...gation for Electronic Parts Error is displayed Connect the VR PCB assy to CN6 on the main PCB assy correctly Is the VR PCB assembly correctly connected to the panel PCB assembly CN6 N Y Replace VR PCB assy F07 is displayed ...

Page 369: ...6 1 6Special Instructions of Wiring ...

Page 370: ... wire the THPM lead wire and the TH sensor lead wire under a coating clip Tie lead wires with a band The lead wires should be tied below the shaft This holder is not used for holding the LED lamp L lead wire Band stopper should be positioned below the top edge of steel plate No slack Shaft 6 2 ...

Page 371: ...3 Upper side of AT pulse motor 4 Thread guide mechanism TG sensor lead wire should be passed under the adjust plate A as shown No slack Adjust plate A 6 3 Special Instructions of Wiring ...

Page 372: ...5 Upper shaft cover 6 Lead wire guide of PCB holder 1 2 3 6 4 ...

Page 373: ...7 Upper back side of machine 8 NP sensor lead wire The end of spiral tube should be aligned with the edge of arm Fasten with a coating clip 6 5 Special Instructions of Wiring ...

Page 374: ...n PCB 2 Upper right of the main PCB Lead wires of all connectors to be connected to the right side of main PCB should be bound by the NP lead wire Attach the coating clip as shown Tie with a band NP lead wire Coating clip 6 6 ...

Page 375: ...3 Right side of main PCB Make sure connectors are connected properly 6 7 Special Instructions of Wiring ...

Page 376: ...of main PCB Tie with a band The BH lead wire should be passed under the upper thread sensor lead wire the AT INIT sensor lead wire and the TGPM lead wire BH lead wire Upper thread sensor lead wire AT INIT sensor lead wire TGPM lead wire 6 8 ...

Page 377: ...6 Left side of main PCB Make sure connectors are connected properly 6 9 Special Instructions of Wiring ...

Page 378: ...1 Front cover 2 Front cover Tie with a band 6 10 ...

Page 379: ...3 Inverter cover Enlarged picture 6 11 Special Instructions of Wiring ...

Page 380: ...otor lead wire and the BWSW lead wire over a coating clip as shown in left picture 2 Bend the coating clip toward left 3 Bend the coating clip toward right 4 There should be some slack in the BW motor lead wire Make sure the lead wire touches the BW motor when the lead wire is pushed Push around here 6 12 ...

Page 381: ......

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Brother Innov-is NV4000D, Service Manual

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