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Brother PR-600II, Service Manual, Page: 120 / 333

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Brother PR-600II Service Manual Download Page 120

3 - 22

Main unit

Thread cut unit

2 

Cutter unit assembly (Step 2)

1. Attach the cutter bracket assembly and the 2 collars 

1

 to the CT motor

bracket assembly with the 2 screws 

1

. 

2. Attach the thread cutter sensor assembly (white) 

2

 to the CT motor

bracket assembly with the screw 

2

. 

3. Apply MOLYKOTE EM-30L  to the level link assembly's shaft 

3

.

4. Attach the lever link assembly 

4

 to the lever gear, and then attach the

retaining ring E2.

 Start movie clip (CD-ROM version only)

Apply MOLYKOTE EM-30L to the lever link assembly's 
shaft.

Size of a grain of 

rice

1

Torque

1.18 – 1.57 N-m

2

Torque

0.57 – 0.78 N-m

1

1

3

4

2

2

Retaining ring E2

Screw, Bind

M

4X16

Screw, Pan (S/P washer)

M3X6

Summary of Contents for PR-600II

Page 1: ......

Page 2: ......

Page 3: ... Needle plate base assembly removal 2 12 Needle plate base disassembly 2 12 Picker bracket removal 2 12 Picker bracket disassembly 2 13 Rotary hook removal 2 13 Cutter unit final assembly and picker final assembly removal 2 14 Feed unit 2 15 T belt Y guide removal 2 16 Feed final assembly removal 2 17 Y motor final assembly removal 2 18 Y motor disassembly 2 18 Y driving shaft assembly removal 2 1...

Page 4: ...ning plate assembly removal 2 39 Case positioning plate disassembly 2 40 Case bracket assembly removal 2 40 Case bracket disassembly 2 41 Case guide UL disassembly 2 41 Upper shaft unit 2 42 Main motor final assembly removal 2 43 Main motor disassembly 2 43 Driving jump assembly removal 2 44 Driving jump disassembly 2 45 Base needle bar removal 2 46 J clamp disassembly 2 46 Presser foot vertical b...

Page 5: ...2 73 Operation panel lever assembly removal 2 74 Operation panel lever ASSY disassembly 1 2 74 Operation panel lever ASSY disassembly 2 2 75 Panel B support removal 2 75 USB cord holder removal 2 75 Operation panel B assembly removal 2 76 Operation panel B ASSY disassembly 2 76 Board case removal 2 77 Panel PCB assembly removal 2 77 Inverter D6 removal 2 77 PCB attachment plate removal 2 78 LCD re...

Page 6: ...assembly attachment 3 28 Power switch assembly and inlet attachment 3 29 Lower shaft unit 3 30 Lower shaft attachment 3 31 Idle pulley assembly 3 32 Idle pulley assembly attachment 3 32 Connection of arm bed and base frame 3 33 Upper shaft unit 3 34 Upper shaft assembly attachment 3 35 Presser foot driving shaft assembly 3 36 Presser foot driving shaft assembly attachment 3 37 Crank rod assembly a...

Page 7: ...le thread assembly attachment 3 71 Feed unit 3 72 Connect PCB final assembly 3 73 Y carriage R assembly 3 74 Y carriage L assembly 3 75 Feed frame assembly attachment 3 76 T belt X drive attachment 3 77 X guide shaft attachment 3 78 Hoop sensor attachment 3 79 X sensor dog attachment 3 80 X carriage A assembly and X carriage B assembly attachment 3 81 X feed frame B attachment 3 82 Y frame spacer ...

Page 8: ... after main PCB replacement 4 16 Motor belt tension adjustment 4 18 Timing belt tension adjustment 4 19 Needle position adjustment front back 4 20 Needle position adjustment right left 4 21 Needle bar rising length and needle space adjustment 4 22 Needle bar height adjustment 4 23 Rotary hook stopper clearance adjustment 4 24 Presser foot height adjustment 4 25 Needle bar top dead center adjustmen...

Page 9: ...ustment 4 25 Presser foot height adjustment 4 26 Needle bar top dead center adjustment 4 27 Needle threader adjustment up down 4 28 Needle threader adjustment right left 4 29 Needle threading check 4 30 Y belt tension adjustment 4 31 X belt tension adjustment 4 32 Picker activation adjustment 4 33 Movable knife origin adjustment 4 34 Thread presser base up down position adjustment 4 35 Hoop sensor...

Page 10: ... picker does not function normally 5 16 LED light does not turn ON 5 17 Embroidery card cannot be used normally 5 18 Universal serial bus USB function cannot be used normally 5 19 Universal serial bus USB cannot be used normally 5 20 The hoop sensor does not function normally 5 21 Error message 5 24 6 Maintenance 6 1 7 Special Instructions of Wiring 7 1 Head wiring 7 2 Arm wiring 7 3 Base wiring 7...

Page 11: ...1 1 1 Outline of Mechanism Main Mechanisms 1 2 Driveline 1 3 Positions of electronic components 1 5 Control system block diagram 1 7 Operation of other electronic components 1 8 ...

Page 12: ... 2 Outline of Mechanism Main Mechanisms Needle bar mechanism Thread cutting mechanism Lower shaft mechanism Needle threader mechanism Feed mechanism Upper shaft mechanism Needle bar change box mechanism ...

Page 13: ...t Presser foot Pulley Junp bracket Thread take up driving lever assy Needle bar clamp Needle bar Thread guide needle bar Thread take up differential lever Thread take up lever assy Needle Pulley Upper shaft Presser foot cam Thread take up cam Needle bar crank rod assy Thread take up driving lever assy Jump bracket Presser foot vertical base assy Presser foot Presser foot clamp Presser foot spring ...

Page 14: ...iveline B Movement of rotary hook Lower shaft gear Timing belt Timing pulley Rotary hook Lower shaft Upper shaft Pulley Idle pulley Pulley Timing pulley Upper shaft Timing belt Idle pulley Lower shaft gear Lower shaft Rotary hook ...

Page 15: ...m Outline of Mechanism Positions of electronic components ASSY TH sensor ASSY Head PCB ASSY Inverter PCB ASSY SW PCB Touch panel LCD module ASSY Panel PCB ASSY Main PCB ASSY LED Drive PCB ASSY Main shaft sensor ASSY LED Light ...

Page 16: ...H cutter motor ASSY TH cutter sensor ASSY Y area sensor ASSY Picker motor ASSY Picker sensor ASSY X motor ASSY Connect PCB ASSY Y motor ASSY Hoop sensor ASSY Hoop PCB ASSY X area sensor ASSY TH motor ASSY Needle TH sensor ASSY Wiper sensor ASSY Wiper motor ASSY Index sensor ASSY Color change sensor ASSY Index motor ASSY Main motor ...

Page 17: ...Thread amount sensor x6 ASSY HEAD PCB Main motor driver Stepping motor driver x7 CPLD Thread guide sensor Thread guide motor Thread cutter sensor Thread cutter motor Picker sensor Picker motor Y motor Y sensor ASSY CONNECT PCB X motor Hoop sensor ASSY HOOP PCB X sensor OPERATION PANEL ASSY PANEL PCB Power supply 5V 3 3V 1 9V ROM FLASH ROM SDRAM EEPROM I F Communication USB controller LCD controlle...

Page 18: ...the arm when attaching the hoop in order to identify the hoop Stop position sensor A B phase sensor These sensors detect the angle of the main shaft and the rotational speed Index sensor color change sensor These sensors detect the color change position Thread quantity sensor This sensor detects the consumption of upper thread It also detects upper lower thread breakage indicated by the consumptio...

Page 19: ...2 2 Feed unit 2 15 Needle thread unit 2 26 Needle bar change unit 2 29 Thread wiper unit 2 32 Needle bar unit 2 36 Upper shaft unit 2 42 Lower shaft unit 2 52 Power unit 2 55 Thread cut unit 2 60 Thread tension unit 2 64 Operation panel 2 73 ...

Page 20: ...2 2 Main parts Main unit ...

Page 21: ...mbly 1 Motor cover and carriage cover removal 1 Remove the screw cover 1 2 Remove the screw 1 and then remove the carriage cover 2 3 Remove the 2 screw 2 and then remove the motor cover 3 Start movie clip CD ROM version only 1 1 2 3 2 ...

Page 22: ...ly 1 2 Remove the 2 screws 2 and then remove the bed cover lid 2 from the bed cover bottom assembly 3 Remove the hinged door 3 and the spring 4 from the bed cover bottom assembly 4 Remove the 4 screws 3 and then remove the bed cover top 5 and the bed cover 6 Start movie clip CD ROM version only 2 1 1 2 3 3 4 6 5 ...

Page 23: ...rew covers 1 2 Remove the 2 screws 1 and then remove the arm cover R lid 2 Key point Remove the thumb bolt M4S from the operation panel assembly before removing arm cover R 3 Remove the 3 screws 2 and then remove the arm cover R 3 Start movie clip CD ROM version only 1 1 2 3 2 ...

Page 24: ...arts 4 Arm cover L removal 1 Remove the 3 screw covers 1 2 Remove the screw inside the cover 1 and the 2 screws outside the cover 2 and then remove arm cover L 2 Start movie clip CD ROM version only 2 1 1 Inside Outside 2 ...

Page 25: ...2 screw covers 1 2 Remove the 2 screws 1 and then remove the base cover R lid 2 3 Removes the 3 screws 2 and then remove the base cover R 3 Key point Fully draw the feed final assembly toward you before removing the base cover R Start movie clip CD ROM version only 1 2 3 1 2 ...

Page 26: ... 2 and then remove the base cover L 3 Key point Fully draw the feed final assembly toward you before removing the base cover L Start movie clip CD ROM version only 1 1 2 3 2 7 LED drive PCB removal 1 Disconnect the lead wire connector 2 on the LED drive PCB assembly 1 from the Main PCB 2 2 Remove the 2 screws 1 and then remove the LED drive PCB assembly 1 1 1 2 ...

Page 27: ... 1 Disconnect all connectors from the main PCB 2 Remove the 4 screws 1 and then remove the main PCB assembly 1 3 Remove the 4 screws 2 and then remove board holder U 2 and board holder D 3 1 2 2 3 1 2 1 10 Spool stand frame final assembly removal 1 Remove the 3 screws 1 and then remove the spool stand frame final assembly 1 2 Remove the 3 studs 2 1 1 2 ...

Page 28: ...the operation panel assembly 1 1 1 1 1 12 Thread take up cover removal 1 Remove the 2 screws 1 and then remove the thread take up cover 1 Key point The pin protruding from the needle bar case final assembly rests on the inner left side of the thread take up cover Start movie clip CD ROM version only 1 1 ...

Page 29: ...emove the screw 1 and then remove the cord clamp NK 4N from the arm bed 2 Remove the 4 screws 2 and then remove the tension base assembly Start movie clip CD ROM version only 1 2 2 14 Needle plate removal 1 Remove the 2 screws 1 and then remove the needle plate 1 1 1 ...

Page 30: ...r 2 Remove the screw 3 and then remove the movable knife and the movable knife collar Caution If there s a spacer under the movable knife collar remove it too 3 Remove the screw 4 and then remove the fixed knife 4 Remove the screw 5 and then remove the thread holding plate 3 1 2 5 4 17 Picker bracket removal 1 Remove the retaining ring E2 and then remove the picker link 2 Remove the 2 screws 1 and...

Page 31: ...etaining ring E2 and then remove the picker assembly and the spring 2 Remove the screw 1 and then remove the picker holder 1 from the picker bracket Retaining ring E2 S54 1 1 S54 19 Rotary hook removal 1 Remove the 3 screws 1 and then remove the rotary hook 1 from the lower shaft 1 1 ...

Page 32: ...re from the arm bed 2 Remove the 2 screws 2 and then remove the picker final assembly Key point Fully draw the feed final assembly toward you before removing the cutter unit final assembly and the picker final assembly Be careful not to bend the picker link 3 Remove the 2 screws 3 and then remove the cutter unit assembly Start movie clip CD ROM version only 1 2 3 ...

Page 33: ...2 15 Disassembly Feed unit Main unit ...

Page 34: ...each on left and right 2 Remove the 2 screws 2 and then remove the Y tension plate assembly 2 and T belt one each on left and right 3 Remove the retaining ring E4 and then remove the Y tension pulley and the washer 7 X 2 from the Y tension plate assembly Start movie clip CD ROM version only 1 1 2 2 Retaining ring E4 ...

Page 35: ...ea sensor assembly and then remove the FFC SML2CD Y 1 from the Y area sensor assembly 3 Remove the screw 1 and then remove the sheet and sheet B 4 Remove the 4 screws 2 and then remove the 2 fixed Y shaft plates one each on left and right 5 Remove the feed final assembly and the 2 Y guide shafts 2 Start movie clip CD ROM version only 1 1 2 2 2 ...

Page 36: ...ew 1 and then remove the cord clamp NK 4N and the Y motor assembly s lead wire from the base frame 2 Remove the 2 screws 2 and then remove the Y motor final assembly 1 2 4 Y motor disassembly 1 Remove the 2 screws 1 and then remove the Y motor assembly from the Y motor stay 1 ...

Page 37: ...ing pressers A 2 Remove the Y driving shaft assembly 1 3 Remove the 2 felts 2 1 1 1 2 6 Cord grip removal 1 Remove the screw 1 and then remove the cord grip 2 Disconnect the X feed motor s lead wire from the connect PCB 1 3 Unlock the connect PCB s connector 2 and then disconnect the FFC SML2CD C from the connect PCB 1 1 2 ...

Page 38: ...pacer 4 Unlock the X area sensor assembly s 2 connectors 1 and then disconnect the 2 FFCs SML2CD C and SML2CD X from the X area sensor assembly 3 1 2 1 8 Y frame spacer and X belt presser removal 1 Remove the screw 1 and then remove the X belt presser 2 Remove the 4 screws 2 and then remove the 2 Y frame spacers 1 2 2 9 X feed frame B removal 1 Remove the 4 screws 12 2 each and then remove the X f...

Page 39: ...assembly s FFC SML2CD X connector 2 3 Disconnect the FFC SML2CD X from the hoop PCB assembly and then remove the screw 2 and the sheet 4 Remove the screw 3 and then remove the hoop PCB assembly 5 Remove the 4 screws 4 and then remove the X carriage B assembly Start movie clip CD ROM version only 1 1 1 2 2 3 4 4 11 X sensor dog removal 1 Remove the screw 1 and then remove the sheet and disconnect t...

Page 40: ...emoval 1 Remove the 2 nuts 2 M6 1 on both ends of the X guide shaft 2 plain washers 6 2 and 2 spring washers 2 6 3 Then remove the X guide shaft and the 2 bearing case X assemblies from the feed frame assembly 2 Remove the retaining ring E4 and then remove the X roller from the bearing case X assembly 2 sets 3 Remove the 2 external retaining rings C21 and then remove the linear bearing 12 from the...

Page 41: ...crews 1 2 2 each and then remove the Y carriage RB 2 Remove the retaining ring E4 plain washer M6 washer Y driving gear pulley A spring for gear and Y driving gear pulley B 3 Remove the 4 screws 3 and then remove the Y carriage R assembly and the Y carriage L assembly 4 Remove the 4 screws 4 and then remove the 2 cap connections Start movie clip CD ROM version only 2 1 3 3 4 4 Retaining rings E4 ...

Page 42: ...crews 2 and then remove the Y sensor dog 3 Remove the 2 screws 3 and then remove the X motor assembly 4 Remove the 4 screws 4 and then remove the bearing case Y assembly 2 sets 5 Remove the 2 external retaining rings C19 and then remove the linear bearing 10 from the bearing case Y assembly 2 sets 2 1 3 4 4 4 4 External retaining rings C19 ...

Page 43: ...19 and then remove the linear bearing 10 from the bearing case Y assembly 2 sets 1 External retaining rings C19 1 1 1 18 Connect PCB disassembly 1 Unlock the connect PCB assembly s connector and then disconnect the FFC SML2CD Y 1 2 Remove the screw 1 and then remove the connect PCB from the PCB holder 3 Remove the screw 2 and then remove the FFC SML2CD Y and the sheet from the PCB holder 1 1 2 ...

Page 44: ...2 26 Needle thread unit Main unit ...

Page 45: ...y removal 1 Remove the cap 1 2 Remove the hook holder assembly 2 and then remove the spring and the hook holder axis B assembly Key point The hook holder assembly s tab is engaged in the groove on the hook holder axis B 3 Remove the set collar assembly 4 Remove the screw 1 from the hook holder axis B and then remove the bush Start movie clip CD ROM version only 2 1 1 S56 S56 ...

Page 46: ... assembly 1 Retaining ring E4 Retaining ring E3 4 TH motor assembly and LED light assembly removal 1 Remove the screw 1 and then remove the LED light assembly 1 Key point Remove the lead wire of the LED light assembly 1 from the lead wire guide 2 2 Remove the 2 screws 2 and then remove the lead wire guide 2 3 Remove the 2 screws 3 and then remove the TH motor assembly 3 and 2 spacers 4 Remove the ...

Page 47: ...2 29 Disassembly Needle bar change unit Main unit ...

Page 48: ...C sensor bracket assembly and the C sensor bracket assy lower 2 Remove the 2 screws 2 and then remove the color change sensor assembly and the index sensor assembly from the C sensor bracket assembly and the C sensor bracket assy lower 3 Remove the 2 screws 3 and then remove the change motor base assembly 4 Remove the 2 screws 4 and then remove the index sensor assembly from the change motor base ...

Page 49: ...4 and then remove the plain washer M6 C differential gear and second plain washer M6 from the differential gear shaft 3 Remove the 2 screws 2 and then remove the change gear 4 Remove the 2 screws 3 and then remove the change camshaft assembly thrust washer and change cam 5 Remove the 2 screws 4 and then remove the C stop position dog from the change camshaft 2 1 3 4 Retaining rings E4 ...

Page 50: ...2 32 Thread wiper unit Main unit ...

Page 51: ...e bar case final assembly 1 1 1 2 Thread presser base disassembly 1 Remove the 2 screws 1 and then remove the thread presser cover assembly and the 2 thread presser spacers from the thread presser base assembly 1 3 Wiper set assembly removal 1 Remove the screw 1 and then remove the cord clamp NK 5N 2 Remove the 2 screws 2 and then remove the wiper set assembly 1 2 ...

Page 52: ... 4 Wiper guide and wiper sensor removal 1 Remove the screw 1 and then remove the wiper sensor assembly 2 Remove the 6 screws 2 and then remove the wiper guide assembly 3 Remove the wiper cushion 1 from the wiper guide assembly 1 1 2 2 ...

Page 53: ...the wiper hook 1 2 Remove the retaining ring E4 plain washer M6 and washer and then remove the wiper lever assembly 3 Remove the retaining ring E4 and plain washer M5 and then remove the wiper link assembly from the wiper lever 4 Remove the 2 screws 1 and then remove the wiper motor assembly Start movie clip CD ROM version only 1 1 Retaining rings E4 ...

Page 54: ...2 36 Needle bar unit Main unit ...

Page 55: ... the 4 screws 1 and then remove the needle bar case assembly Start movie clip CD ROM version only 1 2 Change roller base assembly removal 1 Remove the 2 screws 1 and then remove the change roller base assembly 1 3 Case guide D removal 1 Remove the 2 screws 1 and then remove the case guide D 1 ...

Page 56: ...e 2 screws 1 and then remove the thread take up shaft 1 and the 6 thread take up lever assemblies 2 2 Remove the 2 thread take up bushes 3 1 1 2 3 5 Thread take up lever disassembly 1 Remove the 2 screws 1 and then remove the thread take up boss from the thread take up lever 6 sets 1 ...

Page 57: ...ng collar 8 needle bar clamp 9 cushion rubber washer A and spring while pulling the needle bar upward 6 locations 5 Remove the screw 4 from the needle bar 6 sets Start movie clip CD ROM version only 3 1 2 4 9 8 7 6 3 4 2 1 S47 S48 A 5 S48 S47 7 Needle bar case disassembly 1 Remove the 2 screws 1 and then remove the top dead center plate 6 locations 2 Remove the 4 screws 2 and then remove the needl...

Page 58: ...aft from the case positioning plate 1 10 Case bracket assembly removal 1 Remove the screw 1 and then remove the case guide cover UL 2 locations 2 Remove the screw 2 and then remove the slide roller stopper 2 locations 3 Remove the case bracket assembly 1 and the slide roller 2 4 Remove the 2 screws 3 and then remove the case guide UL assembly 3 Start movie clip CD ROM version only 1 1 2 2 3 3 ...

Page 59: ...guide US and the case bracket assembly 2 Remove the 2 retaining rings E3 and then remove the 2 ball bearings 694 from the case bracket assembly Start movie clip CD ROM version only 1 Retaining ring E3 12 Case guide UL disassembly 1 Remove the 2 screws 1 and then remove the case guide UL 1 and the thread take up guide 1 1 ...

Page 60: ...2 42 Upper shaft unit Main unit ...

Page 61: ...crews 2 and then remove the tension pulley final assembly 4 Remove the screw 3 and then remove the tension pulley assembly 1 2 3 2 Main motor disassembly 1 Remove the 2 screws 1 and then remove the main motor assembly motor holder spacer and motor spacer presser from the motor holder 2 Remove the fender rubber 1 from the motor holder 3 Remove the 2 spacers 4 x 7 2 from the fender rubber 4 Remove t...

Page 62: ...2 44 Main unit Upper shaft unit 3 Driving jump assembly removal 1 Remove the 2 screws 1 and then remove the driving jump assembly 1 ...

Page 63: ...g E4 and then remove the J slide lever shaft 3 from the J slide lever 3 Remove the retaining ring E4 and then remove the J differential lever 4 from the J link assembly 4 Remove the J driving lever 5 and the spring from the J base assembly 5 Remove the screws 2 and then remove the J cushion pin and the J cushion Start movie clip CD ROM version only 1 1 2 3 Retaining ring E4 Retaining ring E4 4 5 2...

Page 64: ...t movie clip CD ROM version only 1 1 2 3 6 J clamp disassembly 1 Remove the 2 screws 1 and then remove the J clamp 2 Remove the J spring collar and the spring 3 Remove the thrust washer jump bracket 1 and thrust washer 4 Remove the screw 2 and then remove the J vertical bush 2 from the J bracket assembly 5 Remove the 2 screws 3 and then remove the J cushion base Start movie clip CD ROM version onl...

Page 65: ...he presser foot vertical pin 1 2 Remove the screw 2 and then remove the presser foot vertical bush 2 3 Remove the screw 3 and then remove the presser foot cushion base 3 1 1 3 3 2 2 8 Thread take up driving lever final assembly removal 1 Remove the 2 screws 1 and then remove the thread take up driving lever final assembly 1 ...

Page 66: ... spacer 2 Remove the thread take up roller pin 2 from the thread take up differential lever assembly and then remove the roller 3 Remove the thread take up driving lever assembly 3 from the thread take up bearing 4 Remove the nut 1 M5 4 and the spring washer 2 5 and then remove the roller shaft assembly from the thread take up driving lever assembly 2 1 3 4 1 ...

Page 67: ...val 1 Remove the screw 1 and then remove the main shaft sensor final assembly 2 Remove the screw 2 and then remove the main shaft sensor assembly from the sensor holder 2 1 11 Crank rod removal 1 Remove the 2 screws 1 and then remove the crank rod assembly from the thread take up cam 1 ...

Page 68: ...ing pressers 2 Remove the pressure foot driving shaft assembly 1 3 Remove the 2 felts 2 from the metal collar on the arm bed 1 1 2 13 Presser foot driving shaft disassembly 1 Remove the screw 1 and then remove the presser foot lever shaft presser foot connecting rod 1 and thrust washer from the presser foot differential lever 1 1 ...

Page 69: ...crews 1 and then remove the 2 metal pressers 2 Remove the upper shaft final assembly 1 Key point Be careful not to damage the encoder 3 Remove the 2 felts 2 from the metal collar on the arm bed 4 Remove the pulley from the upper shaft final assembly Start movie clip CD ROM version only 1 1 1 2 ...

Page 70: ...2 52 Lower shaft unit Main unit ...

Page 71: ... and the 4 plain washers M8 and then remove the arm bed from the base frame Start movie clip CD ROM version only 1 1 2 Idle pulley assembly removal 1 Remove the 4 screws 1 and then remove the 2 bushing pressers 2 Remove the idle pulley assembly 1 1 1 1 3 Idle pulley disassembly 1 Remove the 2 screws 1 and then remove the set screw collar thrust washer idle pulley and second thrust washer 2 Remove ...

Page 72: ...llar screws 2 and then remove the lower shaft 1 lower shaft metal F set collar thrust wafer 7 24 lower shaft metal R and second thrust wafer 7 24 3 Remove the 3 screws 3 and then remove the lower shaft gear from the lower shaft 4 Remove the 2 felts 2 from the metal collar on the arm bed Start movie clip CD ROM version only 1 3 1 1 2 2 ...

Page 73: ...2 55 Disassembly Power unit Main unit ...

Page 74: ...bly s lead wire and power unit lead wire assembly from the base frame 2 Remove the 2 screws 2 and remove the inlet cover lid and then remove the rocker switch on the power switch assembly from the inlet cover 3 Remove the 2 screws 3 and then remove the inlet cover 4 Remove the 2 screws 4 and then remove the power switch assembly 5 Remove the 2 power lead wire assemblies 1 from the power switch ass...

Page 75: ...se frame 2 Remove the 2 screws 2 and then remove the Y area sensor assembly 3 Remove the 2 screws 3 and then remove the USB PCB holder assembly 4 Remove the 2 screws 4 and then remove the USB PCB cover from the USB PCB holder assembly 5 Remove the 2 screws 5 and then remove the USB PCB assembly from the USB PCB holder 1 2 3 4 5 3 Power PCB assembly removal 1 Remove the 3 screws 1 and then remove t...

Page 76: ...ire assembly 1 from the power PCB assembly 100 or 200 2 Remove the 4 screws 1 and then remove the power unit cover assembly from the power unit stay 3 Remove the 4 screws 2 and then remove the insulation sheet and the power PCB assembly from the power unit cover assembly 1 1 1 2 2 ...

Page 77: ...l 1 Remove the 4 adjust bolt assemblies 1 from the base frame 2 Remove the 4 nuts 2 M8 from the 4 adjust bolt assemblies 3 Remove the 2 screws 1 and then remove the handle 2 4 locations 4 Remove the 2 bushes 3 from the handle 2 4 locations 1 1 1 1 1 1 2 2 3 2 ...

Page 78: ...2 60 Thread cut unit Main unit ...

Page 79: ...er and the picker link 1 2 Remove the screw 1 and then remove the picker sensor assembly 3 Remove the 2 retaining rings E2 2 plain washers S3 rack assembly and 2 plain washers S3 4 Remove the 2 retaining rings E2 5 Remove the 2 screws 2 and then remove the picker motor assembly 1 Retaining ring E2 Retaining ring E2 2 1 ...

Page 80: ...taining ring E2 and then remove the lever link assembly 2 Remove the screw 1 and then remove the thread cutter sensor assembly white 3 Remove the 2 screws 2 separate the cutter bracket 1 from the CT motor bracket assembly 2 and then remove the 2 collars 1 Retaining ring E2 1 2 2 2 ...

Page 81: ...t Disassembly 3 Cutter unit disassembly Step 2 1 Remove the lever gear 1 2 Remove the retaining ring E2 and then remove the initial gear 3 Remove the 2 screws 1 and then remove the thread cutter motor assembly 1 1 Retaining ring E2 ...

Page 82: ...2 64 Thread tension unit Main unit ...

Page 83: ... the spring only for thread tension A A 1 6 2 3 4 5 4 S51 S51 S51 2 Tension base bracket removal 1 Remove the cord bush KR51 1 from the tension base bracket and then remove the tension base lead wire assembly 2 from the head PCB assembly on the tension base 2 Remove the screw 1 and then remove the head grounding wire 3 Remove the 4 screws 2 and then remove the tension base bracket 4 Remove the 2 s...

Page 84: ...sensor PCB assembly and head PCB assembly removal 1 Disconnect the FFC SML2CD H from the head PCB assembly 1 6 locations 2 Remove the 4 screws 1 and then remove the head PCB assembly 3 Remove the 2 screws 2 and then remove the thread tension bracket thread quantity sensor cover and head grounding wire assembly 6 locations 4 Remove the 2 retaining rings CS2 and then remove the 2 rubber washers and ...

Page 85: ...p 1 6 locations 2 Loosen the thread guide tension screw 2 and remove the nut 2 M3 Then remove the thread guide tension plate spring and upper thread eyelet base 6 locations 1 2 S53 S53 6 Antenna assembly removal 1 Remove the 4 screws 1 and then remove the antenna assembly from the thread stand base assembly 1 1 ...

Page 86: ...assembly 3 Remove the retaining ring E5 separate the antenna C assembly from the antenna D and then remove the antenna shaft 4 Remove the retaining ring E5 from the antenna shaft 5 Remove the 6 O rings P5 from the tip of the 6 pipe bushes A 1 attached to the antenna E assembly and then remove the 6 pipe bushes from the antenna E assembly Key point Turn the pipe bush 90 degrees to remove it 1 1 1 2...

Page 87: ...shers S10 and then remove the spool stand frame L and spool stand frame R from the spool stand base 2 1 4 3 9 Spool stand frame disassembly Step 2 1 Remove the retaining ring E8 and then remove the spool stand link spring washer plain washer S10 and spool stand stud from the spool stand frame L assembly 2 Remove the retaining ring E8 and then remove the spool stand link spring washer plain washer ...

Page 88: ...move the screw 3 and then remove the cutter cover assembly from the thread holder base assembly 6 locations 3 Remove the retaining ring CS5 from the cutter cover assembly and then remove the 6 NT lower thread cutters 4 Remove the 6 retaining rings E1 5 and then remove the 6 needle thread presser plates and the 6 springs from the thread holder base 1 2 3 Retaining ring CS5 Retaining ring E1 5 S50 S...

Page 89: ...crews 1 and then remove the thread tension bracket base 2 Remove the 6 screws 2 and then remove the thread tension bracket base 3 Remove the 6 thread guide cover assemblies 2 from the thread take up lever cover 1 4 Remove the thread take up bracket assembly 3 from the thread guide cover assembly 6 sets 1 3 2 1 2 ...

Page 90: ...t Disassemble the six thread take up bracket assemblies 1 Remove the screw 1 and then remove the thread guide wire and the thread guard 2 Remove the screw 2 and then remove the thread catching spring case assembly 3 Remove the spring from the thread catching spring case 1 2 S49 S49 ...

Page 91: ...2 73 Disassembly Operation panel Main unit ...

Page 92: ...ASSY disassembly 1 1 Remove the 2 thumb bolts M4L 1 2 spring washers 2 4 2 and 2 plain washers M4 3 2 Remove the retaining ring E6 inside the operation panel lever A 4 and then remove the operation panel holder shaft 5 3 Remove the retaining ring E6 from the operation panel holder shaft 5 4 Remove the operation panel holder 6 from operation panel lever A 4 3 2 1 3 2 1 Retaining ring E6 Retaining r...

Page 93: ...ing E6 and then remove the 2 operation panel lever shafts 4 3 Remove operation panel lever A 6 and operation panel lever C 7 from operation panel lever B 5 4 1 2 3 7 5 4 1 1 2 3 6 2 3 Retaining ring E6 4 Panel B support removal 1 Remove the 2 screws 1 and then remove the panel B support 1 1 1 5 USB cord holder removal 1 Remove the 3 screws 1 and then remove the three USB cord holders 1 1 1 ...

Page 94: ... 3 on the operation panel B assembly 1 from the panel PCB 1 1 2 2 3 7 Operation panel B ASSY disassembly 1 Remove USB lead wire assembly A 1 and the panel lead wire assembly 2 from operation panel B 3 Key point Remove these parts while pushing the lock holding the cord bushing 4 from the inside of operation panel B 2 Remove the cord bushing 4 from USB lead wire assembly A 1 and the panel lead wire...

Page 95: ...e FFC 1 Key point Unlock the connector and pull out the FFC 1 2 Remove the FFC 2 and then remove the ferrite core 3 Key point Unlock the connector and pull out the FFC 2 3 Remove the 2 lead wires 4 Remove the 7 screws 1 and then remove the panel PCB assembly 4 4 1 1 3 2 1 10 Inverter D6 removal 1 Remove the lead wire 1 2 Remove the 2 screws 1 and then remove inverter D6 2 and the 2 inverter PCB co...

Page 96: ... and then remove the PCB attachment plate 1 1 1 12 LCD removal 1 Remove the LCD 1 from operation panel A 2 Remove the FFC 2 from the LCD 1 Key point Unlock the connector and pull out the FFC 2 1 2 13 Touch panel removal 1 Remove the touch panel EMU601A2B040 1 from the operation panel A 1 ...

Page 97: ... Disassembly 14 Button removal 1 Remove the 3 screws 1 and then remove the switch PCB assembly from the operation panel A 2 Remove the SS button 1 operation button 2 and thread cut button 3 from the operation panel A 1 1 3 2 1 3 1 2 ...

Page 98: ...2 80 ...

Page 99: ...nel 3 2 Thread tension unit 3 10 Thread cut unit 3 20 Power unit 3 24 Lower shaft unit 3 30 Upper shaft unit 3 34 Needle bar unit 3 49 Thread wiper unit 3 59 Needle bar change unit 3 64 Needle thread unit 3 68 Feed unit 3 72 Main unit 3 90 ...

Page 100: ...3 2 Operation panel Main unit ...

Page 101: ... 3 to operation panel A 2 Attach the switch PCB assembly 4 with the 3 screws 1 1 Torque 0 39 0 79 N m 1 1 3 2 1 3 1 2 Taptite Bind B M3X8 2 Touch panel attachment 1 Attach the touch panel EMU601A2B040 1 to operation panel A Key point Attach the touch panel so that the face with the flat cable connected is on the front side 1 ...

Page 102: ...FFC 1 and then lock the connector 2 Attach the LCD 2 to operation panel A 2 1 2 4 PCB attachment plate attachment 1 Position the LCD lead wire 1 and the SW PCB assembly lead wire 2 as shown in the photo on the right 2 Attach the PCB attachment plate 3 with the 6 screws 1 1 Torque 0 39 0 79 N m 1 3 2 1 Taptite Bind B M3X10 ...

Page 103: ...chment 1 Attach the panel PCB assembly 1 with the 7 screws 1 2 Connect the inverter lead wire 2 and the SW PCB assembly lead wire 3 to the panel PCB assembly 1 3 Insert the FFC 4 through the ferrite core 5 4 Attach the FFC 4 to the connector on the panel PCB assembly 1 Key point Unlock the connector insert the FFC and then lock the connector 5 Attach the FFC 6 to the connector on the panel PCB ass...

Page 104: ... B assembly 1 Attach the cord bushing 3 to USB lead wire assembly A 1 and the panel lead wire assembly 2 Key point Open the lid of the cord bushing 3 attach the cord bushing to the lead wires and then close the lid The distance from the cord bushing 3 to the tip of each lead wire should be 80 5 mm 2 Insert USB lead wire assembly A 1 and the panel lead wire assembly 2 from the back of operation pan...

Page 105: ...se parts with the four screws 2 1 Torque 0 49 0 69 N m 2 Torque 0 39 0 78 N m 1 2 1 3 2 Screw Bind M3X4 Taptite Bind B M3X10 10 USB cord holder attachment 1 Attach the three USB cord holders 1 with the 3 screws 1 Key point Insert the lug on the USB cord holder 1 into the positioning hole on the operation panel 1 Torque 0 39 0 78 N m 1 1 Taptite Bind B M3X10 11 Panel B support attachment 1 Attach t...

Page 106: ...6 3 Tighten the thumb bolt M4 L 5 spring washer 2 4 6 and plain washer M4 7 3 locations 3 5 6 7 1 2 3 5 5 6 7 4 6 7 Retaining ring E6 13 Operation panel lever assembly Step 2 1 Attach the retaining ring E6 to the operation panel holder shaft 2 Align the operation panel holder 2 with operation panel lever A 1 thread the operation panel holder shaft 3 through them and then attach the retaining ring ...

Page 107: ...nit Assembly 14 Operation panel lever assembly attachment 1 Insert the operation panel holder 2 into the groove 1 on the panel B support and secure these parts with the 2 screws 1 1 Torque 0 78 1 18 N m 2 1 1 Taptite Cup B M4X14 ...

Page 108: ...3 10 Thread tension unit Main unit ...

Page 109: ... to the thread take up bracket with the screw 1 Key point Align the protrusion on the thread catching spring case assembly with the hole on the thread take up bracket and turn them counterclockwise until they stop Then tighten the screw 1 3 Attach the thread guide wire 2 and the thread guard 3 to the thread take up bracket with the screw 2 Key point Check that the spring does not extend beyond lin...

Page 110: ... 3 to the thread tension bracket base 4 with the 6 screws 1 3 Secure the thread tension bracket base assembly to the thread take up lever cover 5 with the 2 screws 2 Key point Attach the thread tension bracket base assembly so that the clearance in each slot is equal when viewed from the front of the assembly 1 Torque 0 59 0 78 N m 2 Torque 0 38 0 78 N m 2 1 1 2 4 3 5 Screw Bind M3X4 Taptite Bind ...

Page 111: ...CS5 3 Attach the cutter cover assembly to the needle thread presser plates with the screw 1 6 locations 4 Temporarily secure the thread holder base to the thread take up lever cover with the 2 screws 2 5 Attach the rear cover 4 with the 4 screws 3 4 2 each Key point Lift the rear cover 4 and secure it 1 Torque 1 47 1 96 N m 2 3 Torque 0 39 0 78 N m 4 Torque 0 39 0 78 N m S50 Retaining rings E1 5 2...

Page 112: ...her S10 3 spring washer 4 and spool stand link 5 to the tip of the spool stand stud and then attach the retaining ring E8 6 2 1 3 4 5 5 Spool stand frame assembly Step 2 1 Attach spool stand frames L and R to the spool stand base with the 2 stud screws 1 2 spring washers 2 and 2 plain washers S10 3 2 Put spool stand link R 4 the washer 5 spool stand link L 6 and the other washer 5 together and the...

Page 113: ...ue 1 18 1 57 N m Retaining rings CS5 1 1 2 3 2 Screw Pan S P washer M4X8DB Screw Bind M4X6 7 Antenna assembly Step 2 1 Attach pipe bush A 2 to antenna E 1 and then attach the O ring P5 3 to the tip of pipe bush A 6 locations Key point Turn pipe bush A 90 degrees after it has been attached to antenna E 2 Attach the 2 antennas A 4 2 antennas B 5 and the antenna E assembly to the antenna C assembly w...

Page 114: ...h the upper thread eyelet base 1 and the thread guide tension plate 2 to the tension base assembly 6 locations 2 Thread the thread guide tension screw 3 through the spring attach the nut 2 M3 4 from the rear side of the tension base assembly and then tighten the thread guide tension screw 6 locations 3 Attach the tension axis cap 5 to the thread guide tension screw 6 locations S53 5 3 2 1 4 S53 S5...

Page 115: ...cket assembly 4 thread quantity sensor cover assembly 5 and head grounding wire assembly 6 to the tension base assembly with the 2 screws 1 6 locations Key point ighten the head grounding wire assembly together with the thread tension bracket assembly 6 locations 4 Attach the head PCB assembly 7 to the tension base assembly with the 4 screws 2 and then connect the 6 FFCs SML2CD H to the head PCB a...

Page 116: ...bly from the tension base assembly with the 2 screws 1 Tightening torque of thread guide tension axis 0 59 0 78 N m 1 Torque 0 39 0 78 N m S52 4 3 2 1 S52 1 S52 Taptite Bind B M3X8 BOBBIN WINDER GUIDE COMPRESSION X56456 5 4 3 12 Tension base bracket attachment 1 Attach the tension base bracket to the tension base assembly with the 4 screws 1 2 Attach the bracket cover 1 to the tension base bracket...

Page 117: ...tachment 1 Attach the tension disc felt 1 rotary disc assembly 2 tension disc felt 1 tension disc presser 3 spring washer 4 and tension nut 5 6 locations NOTE Insert the thread tension washer 6 between the spring and the washer 4 only for thread tension A Key point Attach the rotary disc assembly 2 so that the magnetic surface is facing down Attach the spring so that the larger diameter end is at ...

Page 118: ...3 20 Thread cut unit Main unit ...

Page 119: ...s shaft and then attach the retaining ring E2 4 Attach the lever gear 4 to the motor bracket assembly s shaft and then apply MOLYKOTE EM 30L to the gear Key point Align the marking 5 on the lever gear with the marking on the initial gear Start movie clip CD ROM version only Apply MOLYKOTE EM 30L to the CT motor bracket assembly s shaft Size of a grain of rice Apply MOLYKOTE EM 30L to the lever gea...

Page 120: ...CT motor bracket assembly with the screw 2 3 Apply MOLYKOTE EM 30L to the level link assembly s shaft 3 4 Attach the lever link assembly 4 to the lever gear and then attach the retaining ring E2 Start movie clip CD ROM version only Apply MOLYKOTE EM 30L to the lever link assembly s shaft Size of a grain of rice 1 Torque 1 18 1 57 N m 2 Torque 0 57 0 78 N m 1 1 3 4 2 2 Retaining ring E2 Screw Bind ...

Page 121: ... the PK motor bracket assembly s shaft 2 locations and then attach the 2 retaining rings E2 5 Attach the picker sensor assembly to the PK motor bracket assembly with the screw 2 6 Place the washer and the picker link s slot 6 on the rack assembly s shaft and then attach the retaining ring E2 7 Paint the picker motor assembly s connector black Apply MOLYKOTE EM 30L to the rack assembly s moving sur...

Page 122: ...3 24 Power unit Main unit ...

Page 123: ... screws 1 4 locations 3 Attach the 4 nuts 2 M8 4 to the 4 adjust bolts M8 3 Key point Lightly tighten the nut 2 M8 against the head of the adjust bolt M8 4 Attach the 4 adjust bolt assemblies 5 to the base frame Key point Lightly tighten the adjust bolt assembly 5 against the base frame 1 Torque 0 00 0 00 N m 4 3 2 1 5 5 1 1 1 1 1 1 Screw Pan S P washer M3X10 ...

Page 124: ...t 2 to the power unit cover 1 with the 4 screws 1 2 Attach the power unit cover assembly to the power unit stay 3 with the 4 screws 2 3 Connect the power lead wire assembly 4 to the power PCB assembly 1 Torque 0 39 0 78 N m 2 Torque 0 78 1 18 N m 1 3 4 2 2 1 Taptite Bind B M3X8 Screw Pan S P washer M4X8 ...

Page 125: ...ame 2 Run the PCB holder final assembly s lead wire and the power supply s lead wire through the 2 cord holes 1 on the base frame and route them along the upper section of the base frame so that the PCB holder final assembly is aligned with the 3 screws 1 and attach it to the base frame 3 Firmly tighten the 3 screws 1 1 Torque 1 18 1 57 N m 1 1 1 Screw Pan S P washer M4X8DB ...

Page 126: ...h the Y area sensor assembly 4 to the base frame with the 2 screws 4 5 Attach the Y area sensor s lead wire to the base frame with the screw 5 and the cord clamp NK 6N 6 Attach the USB PCB assembly s lead wire and the Y area sensor assembly s lead wire to the base frame with the screw 6 and the cord clamp NK 6N 1 2 Torque 0 78 1 18 N m 3 Torque 1 47 1 96 N m 4 Torque 1 18 1 96 N m 5 6 Torque 0 78 ...

Page 127: ...ws 2 4 Place the power switch assembly s rocker switch 4 in the inlet cover pay attention to the direction and then attach the inlet cover lid with the 2 screws 3 5 Attach the power lead wire assembly to the base frame with the screw 4 and the cord clamp NK 6N 6 Attach the USB lead wire assembly and the Y area sensor assembly s lead wire to the base frame with the screw 5 and the cord clamp NK 6N ...

Page 128: ...3 30 Lower shaft unit Main unit ...

Page 129: ...ower shaft assembly thrust washer 7 24 lower shaft metal R 3 thrust washer 7 24 collar 4 and lower shaft metal F 5 Secure the 2 lower shaft metal pressers with the 4 screws 2 6 Move the lower shaft to the front and the collar to the rear and then secure the collar with the 2 screws 3 Start movie clip CD ROM version only Apply FBK OIL RO100 to the 2 felts Soak the felts in FBK OIL RO100 Apply oiler...

Page 130: ...the T belt S5M 525 2 over the idle pulley assembly 1 and attach the idle pulley assembly s 2 lower shaft metals so that they are aligned with the lower shaft metal collars of the arm bed 2 Attach the 2 bushing pressers and temporarily tighten them with 4 screws 1 3 Insert a flat screwdriver from the rear rotate the idle pulley shaft and adjust the backlash between the lower shaft gear and the idle...

Page 131: ... base frame and temporarily tighten the 4 screws 1 and 4 plain washers M8 2 Align the arm bed with the marking on the base frame and firmly tighten the 4 screws 1 Key point Attach the arm bed so that it is parallel to the base frame Start movie clip CD ROM version only 1 Torque 5 88 N m 1 1 1 Bolt Socket M5X12 ...

Page 132: ...3 34 Upper shaft unit Main unit ...

Page 133: ...ch the upper shaft to the arm bed Key point Be careful not to damage the encoder 4 Secure the 2 metal pressers 3 with the 4 screws 1 5 Apply MOLYKOTE EM 30L to the groove on the presser foot cam and thread take up cam 6 Apply oiler to the upper shaft metal 4 7 Align the notch on the encoder base with the pulley s base line and attach the pulley to the upper shaft assembly Start movie clip CD ROM v...

Page 134: ...ever shaft to the presser foot connecting rod 1 2 Align the screw hole on the presser foot driving shaft assembly with the presser foot lever shaft s D cut face 2 and secure the presser foot driving shaft assembly with the screw 1 Start movie clip CD ROM version only 1 Torque 0 78 1 18 N m 1 2 1 Set Screw Socket CP M3X4 ...

Page 135: ...haft metal collar on the arm bed and then attach the presser foot driving shaft assembly to the arm bed Key point Place the presser foot driving shaft assembly s roller 3 into the groove on the presser foot cam 4 Secure the 2 bushing pressers with the 2 screws 1 5 Apply oiler to the presser foot driving shaft assembly s metal 4 Start movie clip CD ROM version only Apply oiler to the presser foot d...

Page 136: ...p cam 1 and secure them with the 2 screws 1 Key point Align the crank rod assembly s D cut face 3 with screw hole 4 2 Firmly tighten the screw 2 Key point Screw 2 is a left hand thread Start movie clip CD ROM version only 1 Torque 1 57 1 96 N m 2 Torque 1 18 1 57 N m 2 4 3 2 1 1 Set Screw CP SM6 35 Screw SM3 57 40X6 L ...

Page 137: ...2 with the screw 1 2 Attach the main shaft sensor final assembly 3 to the arm bed with the screw 2 Key point Rotate the pulley 360 degrees and check that the photo diode does not contact the 150DPI encoder transparent disk on the upper shaft final assembly 1 Torque 0 59 0 78 N m 2 Torque 1 47 1 96 N m 2 2 1 1 3 Taptite Pan B M3X6 Taptite Bind S M4X10 ...

Page 138: ... bearing attach the thread take up differential lever assembly to the tip of the thread take up driving lever assembly s shaft and temporarily tighten the screw 1 Key point Temporarily tighten the screw 1 first Firmly tighten it after completing thread take up differential lever height adjustment in 3 58 Needle bar case final assembly attachment 6 Apply MOLYKOTE EM 30L to the thread take up differ...

Page 139: ...r final assembly 1 to the arm bed with the 2 screws 1 Key point Align the roller 2 with the groove 3 on the thread take up cam Press the bottom of the thread take up driving lever final assembly against the arm bed and then secure them with the 2 screws 1 Start movie clip CD ROM version only 1 Torque 1 57 1 96 N m 1 3 2 1 Screw Bind M5X12 ...

Page 140: ...ertical base assembly and then tighten the screw 2 3 Attach the presser foot vertical pin 4 to the presser foot vertical base assembly and tighten the screw 3 Key point Align the presser foot vertical pin with the end face 5 of the presser foot vertical base Start movie clip CD ROM version only 1 Torque 0 78 1 18 N m 2 Torque 0 59 0 78 N m 3 Torque 1 57 1 96 N m 1 1 2 2 3 3 4 5 Screw Pan M3X4 Scre...

Page 141: ...ch on the J spring collar 6 Attach the J spring collar assembly to the J vertical bush assembly and insert the longer J spring hook into the hole 6 on the jump bracket 7 Insert the shorter J spring hook into the hole 7 on the J clamp while aligning the spring hook with the notch on the J spring collar and then tighten the 2 screws 3 Key point Check that there is no axial backlash in the J bracket ...

Page 142: ...Insert the shaft 1 of the J vertical set assembly to the crank rod 6 Insert the shaft 1 of the presser foot vertical base assembly to the presser foot connecting rod 7 3 Tighten the screw 1 Key point Align the needle bar with the top face of the arm bed Start movie clip CD ROM version only Apply MOLYKOTE EM 30L to the shaft and the hole of the J vertical set assembly and the presser foot vertical ...

Page 143: ...he shaft of the J driving level assembly 5 and insert the J driving lever assembly to the J base assembly Key point Hang the U shaped hook 6 of the spring over the J driving lever assembly and then the other hook 7 over the J cushion Start movie clip CD ROM version only Apply MOLYKOTE EM 30L to the shaft hole on the J base assembly Size of a grain of rice 1 Torque 0 59 0 78 N m S46 3 6 7 1 2 4 5 S...

Page 144: ...bly to the 2 shafts of the J base assembly 5 Thread the thrust washer onto the shaft 5 of the J driving lever and attach the J differential lever assembly while aligning it with the shaft of the J driving lever and the hole on the J slide lever 6 Thread the positioning pin 8 through the positioning hole 6 of the J base assembly and the positioning groove 7 of the J link assembly and then tighten t...

Page 145: ...ump bracket is 0 to 0 2 mm Start movie clip CD ROM version only 1 Torque 1 18 1 57 N m 1 2 1 Screw Pan S P washer M4X8DB 14 Tension pulley assembly attachment 1 Attach the tension pulley assembly 2 to the motor holder base 1 with the screw 1 Key point Temporarily tighten the screw 1 first Firmly tighten it after completing 4 19 Timing belt tension adjustment 2 Attach the tension pulley final assem...

Page 146: ...th the main motor moved in the direction of the arrow 1 Torque 1 18 1 57 N m 5 3 4 1 6 2 1 Screw Pan S P washer M4X16DB 16 Main motor final assembly attachment 1 Hang the T belt XA9644 050 1 over the pulley on the main motor assembly and the pulley on the upper shaft assembly and then attach the main motor final assembly to the arm bed with the 2 screws 1 Key point Temporarily tighten the screw 1 ...

Page 147: ...3 49 Assembly Needle bar unit Main unit ...

Page 148: ...unit 1 Case guide UL assembly 1 Attach the thread take up guide 1 to the case guide UL 2 with the 2 screws 1 Key point Check that these are attached in the direction shown in the photo 1 Torque 1 18 1 57 N m 1 1 2 Screw Pan M4X8 ...

Page 149: ...ining rings E3 2 Place the 4 washers plain S 4 in the case bracket assembly 1 and then attach the case guide US 2 with the 4 screws 1 Key point Temporarily tighten the screw 1 first Firmly tighten it after completing 3 52 Case bracket assembly attachment Start movie clip CD ROM version only 1 Torque Hand start 2 1 Retaining ring E3 Bolt Socket M4X8 ...

Page 150: ...cket assembly Key point Adjust the attachment position of the case bracket assembly vertically so that the clearance between the 2 ball bearings 694 of the case bracket assembly and the case guide UL assembly is zero 4 Attach the 2 slide roller stoppers 3 to both ends of case guide US with the 2 screws 3 5 Attach the 2 case guide UL lids 4 to both ends of the case guide UL assembly with the 2 scre...

Page 151: ...tioning plate assembly 1 to the arm bed with the screw 1 and the spring washer 2 5 Key point Temporarily tighten the screw 1 first Firmly tighten it after completing 4 20 Needle position adjustment front back 1 Torque 1 18 1 57 N m 1 1 Bolt Socket M5X10 6 Needle bar case final assembly 1 Attach the needle bar guide rail 1 to the needle bar case assembly with the 4 screws 1 2 Attach the top dead ce...

Page 152: ...ide A and then secure the thread guide B with the screw 2 6 needle bars 6 Secure the presser foot assembly to the presser foot clamp with the screw 3 6 locations Key point Temporarily tighten the screw 3 first Firmly tighten it after completing 4 25 Presser foot height adjustment 7 Place the washer C on the screw hole on the needle bar clamp and tighten the screw 4 6 locations Key point Temporaril...

Page 153: ...ever assembly 1 Attach the thread take up boss 1 to the thread take up lever 2 with the 2 screws 1 6 sets Key point Apply ThreeBond 1401 to the screw 1 and then tighten it Apply ThreeBond 1401 Size of a grain of rice 1 Torque 0 59 0 78 N m 2 1 1 Screw Pan M3X6 ...

Page 154: ... and then attach the 6 thread take up lever assemblies 4 Adjust the clearance between the right thread take up bush and the needle bar case to 1 6 mm and then secure the thread take up bush with the screw 1 5 Move the left thread take up bush to the right and then secure the bush with the screw 1 Start movie clip CD ROM version only Apply MOLYKOTE EM 30L to the shaft holes on the thread take up le...

Page 155: ...guide D 1 to the needle bar case assembly with the 2 screws 1 1 Torque 1 18 1 57 N m 1 1 Bolt Socket M4X16 11 Change roller base assembly attachment 1 Attach the change roller base assembly 1 to the needle bar case assembly with the 2 screws 1 1 Torque 0 78 1 18 N m 1 1 Screw Flat M4X10 ...

Page 156: ...roller on the thread take up differential lever Align the case guide D a with the case positioning plate assembly 4 Move the ball bearing 694 assembly 2 on the case positioning plate assembly toward you and firmly tighten the nut 2 M4 5 Adjust the vertical position of the thread take up differential lever so that the needle bar case final assembly lightly moves right and left Firmly tighten the sc...

Page 157: ...3 59 Assembly Thread wiper unit Main unit ...

Page 158: ...r and plain washer M6 to the wiper base assembly s shaft and then attach the retaining ring E4 Key point Align the mark 5 on the wiper lever assembly s gear with the mark on the wiper lever assembly 4 Attach the wiper hook 8 to the wiper link with the wiper shoulder screw 6 spring washer 2 4 and the nut 3 M4 7 5 Paint the wiper motor assembly s connector blue Start movie clip CD ROM version only T...

Page 159: ...e assembly to the wiper base assembly with the 6 screws 1 3 Attach the wiper sensor assembly 3 to the wiper base assembly with the screw 2 4 Apply MOLYKOTE EM 30L to the wiper lever gear 4 Apply MOLYKOTE EM 30L to the wiper lever gear Size of a grain of rice 1 Torque 0 59 0 78 N m 2 Torque 0 59 0 78 N m 3 1 2 2 4 1 1 Screw Pan M3X6 Screw Pan S P washer M3X6 ...

Page 160: ... J slide lever and the J base 3 Thread the wiper sensor assembly s lead wire and the wiper motor assembly s lead wire through the spiral tube B 3 and then attach them to the wiper base assembly with the screw 2 and the cord clamp NK 5N 4 Thread the wiper sensor assembly s lead wire and the wiper motor assembly s lead wire through the hole 4 on the arm bed until they come out from the right side of...

Page 161: ...2 screws 1 1 Torque 0 78 1 18 N m 1 3 1 1 2 2 Screw Pan M3X7 5 Thread presser base attachment 1 Attach the thread presser base assembly 1 to the needle bar case 2 with the 4 screws 1 Key point Temporarily tighten the screws 1 first Firmly tighten them after completing 4 34 Thread presser base up down position adjustment Start movie clip CD ROM version only 1 Torque Hand start 2 1 1 1 Screw Bind M4...

Page 162: ...3 64 Needle bar change unit Main unit ...

Page 163: ...p position dog is at the top 2 Apply MOLYKOTE EM 30L to the 2 shaft holes 4 on the change box assembly 3 Attach the change camshaft assembly thrust washer 5 and change cam 6 to the change box assembly and then secure the change cam with the 2 screws 2 Key point Align the C stop position dog with the mark 7 on the change cam Start movie clip CD ROM version only Apply MOLYKOTE EM 30L to the shaft ho...

Page 164: ... M6 to the differential gear shaft 2 and then attach the retaining ring E4 4 Attach the differential gear shaft assembly to the change gear box and then tighten the screw 2 Key point Turn the differential gear shaft to adjust the backlash of the C differential gear 5 Apply MOLYKOTE EM 30L to the groove 4 on the change cam Start movie clip CD ROM version only Apply MOLYKOTE EM 30L to the groove on ...

Page 165: ...e sensor assembly 5 to the C sensor bracket lower 6 with the screw 5 7 Attach the C sensor bracket assy lower to the change box with the screw 6 8 Paint the index motor assembly s connector green Start movie clip CD ROM version only Apply MOLYKOTE EM 30L to the index motor gear and the C differential gear Size of grain of rice 1 Torque 0 59 0 78 N m 2 4 6 Torque 1 18 1 57 N m 3 5 Torque 0 59 0 78 ...

Page 166: ...3 68 Needle thread unit Main unit ...

Page 167: ... 3 with the 2 screws 2 3 Paint the thread motor s connector red 4 Attach the lead wire guide 5 to the thread guide base 1 with the 2 screws 3 5 Attach the LED light assembly 6 to the thread guide base 1 with the screw 4 Key point Thread the lead wire of the LED light assembly 6 through the lead wire guide 5 Start movie clip CD ROM version only 1 Torque Hand start 2 Torque 0 59 0 78 N m 3 Torque 0 ...

Page 168: ...59 0 78 N m 2 1 Retaining rings E4 1 3 4 Screw Pan S P washer M3X6 3 Hook assembly 1 Attach the bush 2 to the hook holder axis B 1 with the screw 1 Key point Temporarily tighten the screw 1 first Firmly tighten it after completing 4 28 Needle threader adjustment right left 2 Attach the set collar assembly 3 to the base plate assembly Key point Thread the set collar assembly through the slot on the...

Page 169: ...3 71 Needle thread unit Main unit Assembly 4 Needle thread assembly attachment 1 Attach the needle thread assembly 1 with the 6 screws 1 1 Torque Hand start 1 1 1 Taptite Bind S M4X10 ...

Page 170: ...3 72 Feed unit Main unit ...

Page 171: ...heet 2 and the FFC SML2CD Y 3 to the PCB holder 1 with the screw 1 3 Attach the connect PCB assembly 4 to the PCB holder assembly with the screw 2 4 Connect the FFC SML2CD Y to the connect PCB assembly and then lock the connector 1 Torque 0 59 0 78 N m 2 Torque 0 59 0 78 N m 4mm 50mm 55mm 1 2 4 2 1 3 Screw Bind M3X4 Screw Pan S P washer M3X6 ...

Page 172: ...linear bearing 10 2 to bearing case Y 1 and then attach the 2 external retaining rings C19 2 Attach the 2 bearing case Y assemblies to Y carriage R 3 with the 8 screws 1 1 Torque 0 78 1 18 N m External retaining rings C19 1 1 3 1 2 1 1 Screw Pan S P washer M3X10DA ...

Page 173: ...ttach the X motor assembly 4 to Y carriage L with the 2 screws 2 4 Attach the caution easy to bend Y carriage L with the 2 screws 3 NOTE The Y sensor dog bends easily Handle it carefully 5 Attach the connect PCB finial assembly 5 to Y carriage L with the 2 screws 4 1 2 Torque 0 78 1 18 N m 3 Torque 0 59 0 78 N m 4 Torque 0 59 0 78 N m 2 1 1 3 1 2 External retaining rings C19 1 1 4 4 5 3 4 Screw Pa...

Page 174: ... spring to the small hole 7 on Y driving gear pulleys B and A Turn Y driving gear pulley A clockwise until the large hole 8 on Y driving gear pulley A is aligned with the large hole on Y driving gear pulley B Engage the pulleys with the X motor gear and attach them to the shaft 4 Temporarily attach Y carriage RB 9 to the feed frame and Y carriage R with the 2 screws 3 4 2 each 5 Adjust the positio...

Page 175: ...bly 1 and the tension pulley plate final assembly 2 and then secure the tension pulley plate final assembly to the feed frame assembly with the 2 screws 1 Key point Temporarily tighten the screws 1 first Firmly tighten them after completing 4 31 X belt tension adjustment 1 Torque Hand start 3 1 1 2 Screw Pan S P washer M4X8DB ...

Page 176: ...ssemblies through the X guide shaft 5 attach the X guide shaft to the feed frame assembly and then tighten the 2 nuts 2 M6 6 2 plain washers 7 and 2 spring washers 2 6 8 to both ends of the X guide shaft Key point Attach the X guide shaft so that the end with a cut to prevent turning together is on the right side Y carriage R assembly side Start movie clip CD ROM version only Apply MOLYKOTE EM 30L...

Page 177: ...r 3 and then tighten the screw 1 4 Tighten the screw 2 from the rear side of the X carriage A assembly hoop sensor assembly side while pushing down the hoop lever Key point Tighten the screw with the hoop lever pushed down so that it contacts the screw 2 from the beneath after the screw has been tightened Check operation after attachment Start movie clip CD ROM version only Tightening torque of nu...

Page 178: ...he 2 screws 1 NOTE The X sensor dog bends easily Handle it carefully 2 Bend the FFC SML2CD X 3 90 degrees at a point 60 mm from the tip 3 Attach the FFC SML2CD X and the sheet 4 to X carriage B with the screw 2 1 Torque 0 59 0 78 N m 2 Torque 0 59 0 78 N m 2 1 1 4 2 3 Bolt Socket M3X5 Screw Bind M3X4 ...

Page 179: ...tighten the screw 3 Key point After the FFC SML2CD X has been connected to the hoop PCB assembly lock the connector 4 Attach the X carriage A assembly 5 to the bearing case X final assembly 2 locations with the 4 screws 4 5 Connect the hoop sensor assembly s lead wire to the hoop PCB assembly 6 Adjust the X guide shaft 6 back and forth so that the X carriage A assembly s sheet 7 contacts the feed ...

Page 180: ...ith the 4 screws 1 2 2 each Key point No clearance is allowed between X carriage A and the feed frame No clearance is allowed between the X roller and X feed frame B Start movie clip CD ROM version only Apply MOLYKOTE EM 30L to the surface where the X feed frame contacts the X roller Size of a bean 1 Torque 1 18 1 57 N m 2 Torque 1 18 1 57 N m 1 2 1 2 2 Screw Bind M4X4 Screw Pan S P washer M4X8DB ...

Page 181: ...frame spacers 1 to X carriage B with the 4 screws 1 2 Align the X belt presser 2 with the highest point of the T belt and then attach the X belt presser to X carriage B Secure them with the screw 2 1 Torque 0 39 0 78 N m 2 Torque 0 78 1 18 N m 2 2 1 1 1 Taptite Bind B M3X8 Screw Pan S P washer M4X8DA ...

Page 182: ...ch the X area sensor assembly and the X frame spacer 3 to the feed frame assembly with the screw 1 4 Hold the FFC SML2CD X with sheet B 4 and secure the FFC to the feed frame assembly with the 2 screws 2 5 Thread the FFC SML2CD C through the slot 5 on the feed frame assembly 6 Hold the FFC SML2CD C with sheet C 6 and secure the FFC to the feed frame assembly with the screw 3 Start movie clip CD RO...

Page 183: ... 2 Connect the X feed motor s lead wire to the connect PCB 3 Bind the X feed motor s lead wire and the FFC SML2CD C with the cord grip 2 and then tighten the screw 1 Key point Insert the X feed motor s lead wire into the groove 3 on Y carriage L Start movie clip CD ROM version only 1 Torque 0 59 0 78 N m 1 3 1 2 Screw Bind M3X4 ...

Page 184: ...cklash in the shaft direction and then secure the collar with the 2 screws 2 6 Apply oiler to the Y driving shaft s 2 metals Start movie clip CD ROM version only Apply FBK OIL RO100 to the felts Soak the felts in FBK OIL RO100 Apply oiler to the Y driving shaft s metals 1 to 2 drops 1 Torque 1 47 1 96 N m 2 Torque 0 78 1 18 N m 1 1 2 4 2 3 2 Taptite Bind S M4X10 Set Screw Socket CP M3X4 15 Y motor...

Page 185: ...aft gear to zero Make sure the Y motor gear and the Y guide shaft gear are parallel 2 Apply MOLYKOTE EM 30L to the Y motor gear 2 3 Secure the Y motor final assembly s lead wire and the cord clamp NK 4N to the base frame with the screw 2 0 Apply MOLYKOTE EM 30L to the Y motor gear Size of a grain of rice 1 Torque 1 18 1 67 N m 2 Torque 1 18 1 57 N m 1 2 1 2 Screw Pan S P washer M4X10DB Screw Pan S...

Page 186: ...crews 1 one each on left and right 3 Pull the feed final assembly toward you 4 Connect the FFC SML2CD Y connected to the feed final assembly s connect PCB to the Y area sensor assembly 2 and lock the connector 5 Attach the sheet 3 FFC SML2CD Y and sheet B 4 to the base frame with the screw 2 Start movie clip CD ROM version only 1 Torque 1 47 1 96 N m 2 Torque 1 18 1 57 N m 2 1 2 1 1 4 3 Taptite Bi...

Page 187: ...ate assembly to the base frame with the 2 screws 1 one each on left and right Key point Temporarily tighten the screws 1 first Firmly tighten them after completing 4 30 Y belt tension adjustment 4 Align the Y belt presser 4 with the T belt s highest point attach the Y belt presser to the Y carriage and then secure them with the 2 screws 2 5 Firmly tighten the 2 screws to secure the Y driving shaft...

Page 188: ...3 90 Main unit Main unit ...

Page 189: ...ing the cutter unit final assembly and the picker final assembly Be careful not to bend the picker link 3 when threading it through the hole on the arm bed to the needle plate side 3 Thread the cutter unit final assembly s lead wire and the picker final assembly s lead wire through the spiral tube D 4 and then attach them to the arm bed with the screw 3 and cord clamp NK 5N Start movie clip CD ROM...

Page 190: ...ker bracket 3 and then attach the retaining ring E2 Start movie clip CD ROM version only Apply MOLYKOTE EM 30L to the picker assembly s shaft Size of a grain of rice S54 1 Retaining ring E2 S54 1 2 3 S54 PICKER SPRING XC5853 13 5 2 12 4 Picker bracket final assembly attachment 1 Attach the picker bracket final assembly 1 to the arm bed with the 2 screws 1 2 Attach the picker link 2 to the picker a...

Page 191: ... the fixed knife against the pin 3 on the needle plate base assembly 3 Attach the movable knife 4 and the movable knife collar 5 to the needle plate base assembly with the screw 3 4 Attach the rotary hook stopper 6 to the needle plate base assembly with the screws 4 5 Key point Temporarily tighten the screws 4 and 5 first Firmly tighten them after completing 4 24 Rotary hook stopper clearance adju...

Page 192: ...le on the movable knife 3 Connect the cutter unit s lever link assembly 3 to the cutter link assembly with the 2 screws 2 Key point Temporarily tighten the screws 2 first Firmly tighten them after completing 4 33 Movable knife origin adjustment Start movie clip CD ROM version only 1 Torque 1 18 1 57 N m 2 Torque Hand start 2 2 1 1 3 Screw Pan M4X8 Screw Bind M3X4 7 Needle plate attachment 1 Attach...

Page 193: ...1 to the needle bar case final assembly with the 4 screws 1 2 Attach the cord clamp NK 4N to the tension base cord at a point 125 mm from the tension base and secure it to the arm bed with the screw 2 1 Torque 1 18 1 57 N m 2 Torque 0 78 1 18 N m 2 1 1 Screw Bind M4X6 Screw Pan S P washer M4X10DB ...

Page 194: ...n the operator s side of the tension base assembly and then align the pin on the left side of the needle bar case final assembly with the groove 4 on the inner left side of the thread take up lever cover Start movie clip CD ROM version only 1 Torque 1 18 1 57 N m 4 3 2 1 1 Screw Pan S P washer M4X10DB 10 Operation panel assembly attachment 1 Attach the operation panel assembly 1 with the 6 screws ...

Page 195: ...rame final assembly attachment 1 Attach the 3 studs 1 to the top face of the arm bed 2 Attach the spool stand frame final assembly 2 to the 3 studs with the 3 screws 1 Tightening torque of stud 1 18 1 57 N m 1 Torque 1 18 1 57 N m 1 2 1 Screw Bind M4X8 ...

Page 196: ...holder U 1 and the board holder D 2 with the 4 screws 1 2 Attach the main PCB assembly 3 with the 4 screws 2 3 Connect the lead wires Start movie clip CD ROM version only 1 Torque 1 47 1 96 N m 2 Torque 0 59 0 78 N m 2 1 2 3 2 1 1 Taptite Bind S M4X10 Screw Pan S P washer M3X6 ...

Page 197: ... the 2 screws 1 1 Torque 1 47 1 96 N m 1 1 Taptite Bind S M4X10 14 LED drive PCB assembly attachment 1 Attach the LED drive PCB assembly 2 to the LED PCB plate 1 with the 2 screws 1 2 Attach the connector 3 on the LED drive PCB assembly 1 to the main PCB 1 Torque 1 47 1 96 N m 1 2 3 1 Screw Pan S P washer M3X6 ...

Page 198: ...ve cover C 5 to the rear of the base cover L lid 4 3 Attach the base cover L with the 3 screws 1 Key point Fully draw the X guide toward you before attachment 4 Attach the base cover L lid to the base cover L with the 2 screws 2 5 Attach the 2 screw covers Start movie clip CD ROM version only 1 2 Torque 0 78 1 18 N m 2 1 4 2 3 1 5 Screw Pan S P washer M4X10DB ...

Page 199: ...groove cover C 5 to the rear of the base cover R lid 4 3 Attach the base cover R with the 3 screws 1 Key point Fully draw the X guide toward you before attachment 4 Attach the base cover R lid to the base cover R with the 2 screws 2 5 Attach the 2 screw covers Start movie clip CD ROM version only 1 2 Torque 0 78 1 18 N m 2 1 1 2 3 4 5 Screw Pan S P washer M4X10DB ...

Page 200: ...utside Inside 2 1 Screw Pan S P washer M4X10DB Taptite Cup B M4X14 18 Arm cover R attachment 1 Attach the arm cover R 1 with the 3 screws 1 2 Attach the arm cover R lid 2 with the 2 screws 2 Key point Remove the operation panel assembly s thumb bolt M4S 3 before attaching the arm cover R lid 3 Attach the 5 screw covers Start movie clip CD ROM version only 1 2 Torque 0 78 1 18 N m 2 3 1 1 2 Screw P...

Page 201: ...g 4 and the hinged door 5 to the bed cover bottom 3 3 Attach the bed cover lid 7 to the bed cover bottom assembly 6 with the 2 screws 2 4 Attach the bed cover bottom assembly to the arm bed with the 2 screws 3 Start movie clip CD ROM version only 1 3 Torque 0 78 1 18 N m 2 Torque 0 39 0 78 N m 2 4 1 1 3 5 7 3 2 6 Screw Pan S P washer M4X10DB Taptite Bind B M3X8 ...

Page 202: ...Attach the motor cover 1 with the 2 screws 1 2 Attach the carriage cover 2 to the X guide with the screw 2 3 Attach the screw cover Start movie clip CD ROM version only 1 Torque 0 78 1 18 N m 2 Torque 0 78 1 18 N m 2 1 2 1 Taptite Cup B M4X14 Screw Pan S P washer M4X10DB ...

Page 203: ...g length and needle space adjustment 4 22 Needle bar height adjustment 4 23 Rotary hook stopper clearance adjustment 4 24 Presser foot height adjustment 4 25 Needle bar top dead center adjustment 4 26 Needle threader adjustment up down 4 27 Needle threader adjustment right left 4 28 Check Needle threading check 4 29 Adjustment Y belt tension adjustment 4 30 X belt tension adjustment 4 31 Picker ac...

Page 204: ...stment front back 4 20 2 Needle position adjustment right left 4 21 3 Needle bar rising length and needle space adjustment 4 22 4 Needle bar height adjustment 4 23 5 Rotary hook stopper adjustment 4 24 6 Presser foot height adjustment 4 25 7 Needle bar top dead center adjustment 4 26 8 Needle threader adjustment up down 4 27 9 Needle threader adjustment right left 4 28 When only Rotary hook stoppe...

Page 205: ...ion and Adjustment Inspection Bent needle 1 Place the needle on the surface plate level block to check that the needle is not bent Key point Check all six needles The gap with the block should be even Level block ...

Page 206: ...4 4 Inspection Blunt needle 1 Touch the needle tip with your finger to check that the needle tip is not blunt ...

Page 207: ...mode 1 Turn the POWER switch on with the START STOP button THREAD CUT button THREAD GUIDE button simultaneously held down Selecting adjustment test mode 1 Select the desired adjustment mode by pressing the corresponding mode key displayed on the screen TEST MODE MAIN BOARD TEST MODE PANEL BOARD TEST MODE ...

Page 208: ...he screen shown below appears MAIN MOTOR TEST Opens the main shaft motor test mode screen XY MOTOR TEST Opens the X Y carriage motor test mode screen TRIM MOTOR TEST Opens the trim thread cut motor test mode screen WIPER JUMP MOTOR TEST Opens the wiper and jump bracket motor test mode screen PICKER MOTOR TEST Opens the picker motor test mode screen THREAD SET MOTOR TEST Opens the thread motor test...

Page 209: ...ng on the settings for SPEED and PITCH MOVE ORIGIN POSITION After returns the X and Y carriages to their origins moves the center of S hoop Changes the X and Y carriage origins 10 10 SAVE Saves changes to the X and Y carriage origins in the EEPROM SPEED Sets the motor speed 100 1200 PITCH Sets the pitch 0 0 20 0 REPEAT Sets the number of repeats 1 10 SELECT X Moves the X carriage at the preset spe...

Page 210: ...TEST MOVE ORIGIN POSITION Returns the wiper and jump bracket motor to their origins MOVE WIPER Moves the wiper WIPER ON OFF Turns the wiper on and off MOVE JUMP Moves the jump bracket JUMP ON OFF Turns the jump bracket on and off CLOSE Closes the WIPER JUMP MOTOR TEST screen 8 PICKER MOTOR TEST MOVE PICKER Moves the picker motor PICKER ON OFF Turns the picker on and off Sets the picker drive over ...

Page 211: ...CODER B Although the current angle of the main shaft is displayed at the last line is displayed until the status of the NEEDLE UP sensor changes after power has been turned on INITIALIZE Moves the angle of the main shaft to the initial adjustment position approx 350 deg CLOSE Closes the SENSOR TEST screen 11 A D TEST 24V power supply voltage 40V power supply voltage frame sensor A D value and calc...

Page 212: ...ad via USB needle bar numbers for front back adjustment and left right adjustment are displayed and the read needle bar data is displayed to the right of these 13 characters FRONT BACK POSITION Moves the needle bar to the position for front back adjustment RIGHT LEFT POSITION Moves the needle bar to the position for right left adjustment Selects the needle bar The needle bar number is displayed at...

Page 213: ...t adjustment are displayed and the read needle bar data is displayed to the right of these 13 characters FRONT BACK POSITION Moves the needle bar to the position for front back adjustment RIGHT LEFT POSITION Moves the needle bar to the position for right left adjustment Selects the needle bar The needle bar number is displayed at CLOSE Closes the NEEDLE POSITION screen ...

Page 214: ... displayed Menu descriptions 1 Switch test Select this mode to check whether the three push buttons are operating correctly The button on the screen turns red while the actual button is held down 2 LED test Select this mode to check whether the LED lights correctly Pressing On red LED lights the LED red The LED remains lit until Off LED is pressed Pressing On green LED lights the LED green The LED...

Page 215: ...ilable on the 5th page of Setting Menu 4 LCD Contrast Select this mode to adjust the contrast on the LCD screen 5 Emb Card Select this mode to check whether the embroidery card slot is operating correctly Insert an embroidery card in the slot and select this mode When the card is recognized correctly Copyright by Brother Industries Ltd is displayed If the card is not recognized correctly No Embroi...

Page 216: ...htness Adjustment screen Touch the center of the symbols with a stylus pen in the following order top left corner bottom left corner bottom right corner top right corner and center When the touch panel is adjusted correctly a black square appears in the top left corner of the screen If adjustment fails a red square appears If a red square appears repeat the operation from step 1 9 PANEL EEPROM Sel...

Page 217: ...Pressing the Clear trip button resets Trip Stitches and Trip Time to zero Parameters Default Thread spool All color information set for spools is cleared resulting in no spool set Reserved thread All spools are released Sewing area display LL frame area is displayed Grid display Only the center is displayed Cursor display A small cross cursor is displayed Sewing order display Name of Color Display...

Page 218: ...ve data in text format type the 13 digit figure on the barcode attached to the needle bar case and save the file as NEEDLE txt 2 Connect the sewing machine and the PC with a USB cable and start test mode 3 Transfer the NEEDLE txt file from the PC to the sewing machine 4 Execute READ NEEDLE DATA in CASE MOTOR TEST 5 Check that the figure displayed on the screen matches the figure on the needle bar ...

Page 219: ... on screen How to select a needle bar number 1 Start up Test mode 2 Select MAIN BOARD TEST MODE 3 Select CASE MOTOR TEST 4 Select a needle bar number used for an adjustment by pressing or key NEEDLE BAR DATA ON BAR CODE Production NO Not used for any adjustment Needle threader adjustment right left Needle bar rising length and Needle space adjustment Needle position adjustment right left Needle po...

Page 220: ... Move the motor holder up and down to adjust the motor belt tension 3 Tighten the 2 screws 1 Motor belt deflection when a load of approx 0 98 N 100 g is applied to the center of the motor belt 2 0 3 5 mm 1 Torque 1 18 1 57 N m Upset 4X14DB Color Gold 0 98N 100g 2 0 3 5mm 1 ...

Page 221: ...rew 1 2 Move the tension pulley right and left to adjust the timing belt tension 3 Tighten the screw 1 Timing belt deflection when a load of approx 1 96 N 200 g is applied to the center of the timing belt 3 0 4 0 mm 1 Torque 1 18 1 57 N m Screw Pan S P washer M4X10DB 1 96N 200g 3 0 4 0mm 1 ...

Page 222: ...until the needle tip enters the needle hole 4 Loosen the screw 1 at the lower section of the needle bar case final assembly 5 Move the case positioning plate assembly back and forth to adjust the needle front back position 6 Tighten the screw 1 7 Check the position for the other 5 needle bars Key point Pressing and selects the other needle bars 1 Torque 1 18 1 57 N m Bolt Socket M5X10 Color Black ...

Page 223: ...he needle bar until the needle tip enters the needle hole 4 Loosen the 2 screws 1 5 Move the change box right and left to adjust the needle right left position 6 Tighten the 2 screws 1 7 Check the position for the other 5 needle bars Key point Pressing and selects the other needle bars 1 Torque 588N 60kg BOLT S P WASHER M5X16 Color Black The change box should be parallel to the needle bar case fin...

Page 224: ...g length and the needle space and tighten the 3 screws 1 5 Check the needle bar rising length and the needle space for the other 5 needle bars Key point Pressing and selects the other needle bars 1 Torque 0 59 0 78 N m Foot set screw 4 46 The right end of the needle matches the rotating hook s tip when the value of MAIN MOTOR ANGLE is 199 approx 2 mm Technical standard The right end of the needle ...

Page 225: ...le bar height for the other 5 needle bars Key point Pressing and selects the other needle bars Clearance between top edge of rotating hook s tip and top edge of needle hole 1 8 2 2 mm Alignment of needle bar and needle guard relative to upper shaft Tilt to the right when viewed from the front 0 to 2 1 Torque 0 78 1 18 N m Set Screw Socket CP SM4 37 40X4 The clearance between the top edge of rotati...

Page 226: ...t the clearance between the rotary hook stopper and the rotary hook 3 Tighten the screws 1 and 2 Clearance between rotary hook stopper end face and rotary hook 0 65 0 95 mm 1 Torque 0 59 0 78 N m 2 Torque 0 59 0 78 N m Bolt Socket M3X6 Screw P F 0 65 0 95mm Rotary hook stopper Rotary hook 1 2 ...

Page 227: ...rs Key point Pressing and selects the other needle bars Clearance between section surrounding eye of needle and bottom face of presser foot 0 5 1 1 mm 1 Torque 0 78 1 18 N m Screw 0 5 1 1 mm The clearance between the section surrounding the eye of the needle and the bottom face of the presser foot should be 0 5 1 1 mm The bottom face of presser foot is slightly lower than the top face of the needl...

Page 228: ... connect the needle bar clamp and the J vertical set assembly surely 4 Loosen the screw 1 5 Push the top dead center plate towards the needle bar downward so that the cushion rubber is compressed slightly approx 0 3 mm and tighten the screw 1 6 Adjust the needle thread unit to the height of the selected needle bar 7 For the top dead center plate of the other 5 needle bars secure the plate at the p...

Page 229: ... height of the needle hole s top edge Raise the rack to its original position 4 Repeat the same steps to check the height for the other needle bars numbers 2 to 6 Key point Pressing and selects the other needle bars 5 Loosen the screw 1 6 Adjust the up down position of the base plate assembly hook to the highest needle bar position checked through steps 2 to 4 above 7 Tighten the 2 screws 1 1 Torq...

Page 230: ... moves 3 Loosen the screw 1 4 Manually lower the needle thread assembly s rack to the bottom and move the hook to the position immediately before the needle hole 5 Manually hold the bush and rotate the hook holder assembly using a screwdriver to adjust the right and left positions of the hook assembly 6 Tighten the screw 1 7 Check that the hook passes through the needle hole for the other 5 needle...

Page 231: ... 2 Press MOVE ORIGIN POSITION to move the hook to its origin 3 Press MOVE THREAD SET MOTOR to check that the hook passes through the needle hole 4 Check that the hook passes through the needle hole for the other 5 needle bars Key point Press CLOSE MAIN BOARD TEST MODE and then NEEDLE THREADER and then pressing or selects the other needle bars ...

Page 232: ...e Y belt tension 4 Tighten the 2 screws 2 5 Repeat the same steps to adjust the Y belt tension on the right side 6 Tighten the 2 screws 1 Load when the center of the Y belt is deflected 4 3 mm 2 35 2 55 N 240 260g 1 Torque 0 78 1 18 N m 2 Torque 1 18 1 57 N m Set Screw Socket CP M3X3 Color Black Screw Pan S P washer M4X10DB 3 9mm 2 35 2 55N 240 260g 2 1 ...

Page 233: ...oosen 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 the center of the X belt is deflected 5 7 mm 1 27 1 47 N 130 150g 1 Torque 1 18 1 57 N m Screw Bind M4X6 5 7mm 1 27 1 47N 130 150g 1 ...

Page 234: ... the rotary hook 4 Press MOVE PICKER MOTOR to turn the picker on 5 Press or OVER PULSE to adjust the clearance should be 0 45 mm 1 05 mm between the bobbin and the picker tip 6 If the clearance cannot be adjusted by following the above procedure move the picker holder attachment screw 1 back and forth to adjust the clearance Clearance between bobbin and picker tip 0 95 1 05 mm 1 Torque 0 59 0 78 N...

Page 235: ...E and then TRIM MOTOR TEST 2 Press MOVE ORIGIN POSITION to move the needle plate base assembly s movable knife to its origin 3 Loosen the 2 screws 1 4 Adjust the position the movable knife stops 5 Tighten the 2 screws 1 Distance between edges of movable knife and fixed knife 1 mm 1 Torque 0 78 1 18 N m Screw Bind M3X4 1 1 mm ...

Page 236: ...oosen the 4 screws 1 2 Adjust the vertical position of the thread presser base 3 Tighten the 4 screws 1 Clearance between wiper hook top face and thread presser cover 0 0 2 mm 1 Torque 1 18 1 57 N m Screw Bind M4X6 clearance 0 0 2mm 1 Wiper hook Thread presser cover 1 ...

Page 237: ... and press MAIN BOARD TEST MODE and then A D TEST 3 After the hoop stay assembly s LL hoop has been attached press LL to save the A D value 4 Replace the LL hoop with the S hoop and then press S to save the A D value 5 After adjustment move the tubular round arm L and check that the hoop size matches the display on the test mode screen ...

Page 238: ...en the screw NOTE In adjustment the encoder base move counterclockwise and make sure that the encoders do not contact when tightening the screw NOTE After adjustment check the following points and then check the index operation of the needle bar case Check points Position of the needle bar clamp and jump bracket when the sewing machine stops operation Position of the thread take up differential le...

Page 239: ... hoop stay assembly 3 Attach the embroidery sheet to the LL hoop 4 Enter the test mode and press MAIN BOARD TEST MODE and then XY MOTOR TEST 5 Press SAVE to move the feed unit to its origin 6 Use the and keys to adjust the position of the embroidery hoop so that the needle bar presser is aligned with the hole on the embroidery hoop 7 Press SAVE ...

Page 240: ...tment steps 1 Measure the engagement load of the movable and fixed knives 2 When the engagement load is not within the specifications insert a spacer below the collar of the movable knife as shown in Figure 2 3 Measure the engagement load of the movable and fixed knives 4 Repeat steps 2 and 3 until the engagement load is within the specifications Engagement load of movable and fixed knives 4 9 N 9...

Page 241: ...le space adjustment4 23 Needle bar height adjustment 4 24 Rotary hook stopper clearance adjustment 4 25 Presser foot height adjustment 4 26 Needle bar top dead center adjustment 4 27 Needle threader adjustment up down 4 28 Needle threader adjustment right left 4 29 Check Needle threading check 4 30 Adjustment Y belt tension adjustment 4 31 X belt tension adjustment 4 32 Picker activation adjustmen...

Page 242: ...ont back 4 21 2 Needle position adjustment right left 4 22 3 Needle bar rising length and needle space adjustment 4 23 4 Needle bar height adjustment 4 24 5 Rotary hook stopper adjustment 4 25 6 Presser foot height adjustment 4 26 7 Needle bar top dead center adjustment 4 27 8 Needle threader adjustment up down 4 28 9 Needle threader adjustment right left 4 29 When only Rotary hook stopper adjustm...

Page 243: ...ion and Adjustment Inspection Bent needle 1 Place the needle on the surface plate level block to check that the needle is not bent Key point Check all six needles The gap with the block should be even Level block ...

Page 244: ...4 4 Inspection Blunt needle 1 Touch the needle tip with your finger to check that the needle tip is not blunt ...

Page 245: ...mode 1 Turn the POWER switch on with the START STOP button THREAD CUT button THREAD GUIDE button simultaneously held down Selecting adjustment test mode 1 Select the desired adjustment mode by pressing the corresponding mode key displayed on the screen TEST MODE MAIN BOARD TEST MODE PANEL BOARD TEST MODE ...

Page 246: ...he screen shown below appears MAIN MOTOR TEST Opens the main shaft motor test mode screen XY MOTOR TEST Opens the X Y carriage motor test mode screen TRIM MOTOR TEST Opens the trim thread cut motor test mode screen WIPER JUMP MOTOR TEST Opens the wiper and jump bracket motor test mode screen PICKER MOTOR TEST Opens the picker motor test mode screen THREAD SET MOTOR TEST Opens the thread motor test...

Page 247: ...ng on the settings for SPEED and PITCH MOVE ORIGIN POSITION After returns the X and Y carriages to their origins moves the center of S hoop Changes the X and Y carriage origins 10 10 SAVE Saves changes to the X and Y carriage origins in the EEPROM SPEED Sets the motor speed 100 1200 PITCH Sets the pitch 0 0 20 0 REPEAT Sets the number of repeats 1 10 SELECT X Moves the X carriage at the preset spe...

Page 248: ...TEST MOVE ORIGIN POSITION Returns the wiper and jump bracket motor to their origins MOVE WIPER Moves the wiper WIPER ON OFF Turns the wiper on and off MOVE JUMP Moves the jump bracket JUMP ON OFF Turns the jump bracket on and off CLOSE Closes the WIPER JUMP MOTOR TEST screen 8 PICKER MOTOR TEST MOVE PICKER Moves the picker motor PICKER ON OFF Turns the picker on and off Sets the picker drive over ...

Page 249: ...ITIALIZE Moves the angle of the main shaft to the initial adjustment position approx 350 deg CLOSE Closes the SENSOR TEST screen 11 A D TEST 24V power supply voltage 40V power supply voltage frame sensor A D value and calculated results are displayed The main PCB mask program version and the check sum are also displayed When turn on the power while pressing the START STOP and NEEDLE THREAD button ...

Page 250: ...ad via USB needle bar numbers for front back adjustment and left right adjustment are displayed and the read needle bar data is displayed to the right of these 13 characters FRONT BACK POSITION Moves the needle bar to the position for front back adjustment RIGHT LEFT POSITION Moves the needle bar to the position for right left adjustment Selects the needle bar The needle bar number is displayed at...

Page 251: ...t adjustment are displayed and the read needle bar data is displayed to the right of these 13 characters FRONT BACK POSITION Moves the needle bar to the position for front back adjustment RIGHT LEFT POSITION Moves the needle bar to the position for right left adjustment Selects the needle bar The needle bar number is displayed at CLOSE Closes the NEEDLE POSITION screen ...

Page 252: ... displayed Menu descriptions 1 Switch test Select this mode to check whether the three push buttons are operating correctly The button on the screen turns red while the actual button is held down 2 LED test Select this mode to check whether the LED lights correctly Pressing On red LED lights the LED red The LED remains lit until Off LED is pressed Pressing On green LED lights the LED green The LED...

Page 253: ...ilable on the 5th page of Setting Menu 4 LCD Contrast Select this mode to adjust the contrast on the LCD screen 5 Emb Card Select this mode to check whether the embroidery card slot is operating correctly Insert an embroidery card in the slot and select this mode When the card is recognized correctly Copyright by Brother Industries Ltd is displayed If the card is not recognized correctly No Embroi...

Page 254: ... Brightness Adjustment screen Touch the center of the symbols with a stylus pen in the following order top left corner bottom left corner bottom right corner top right corner and center When the touch panel is adjusted correctly a black square appears in the top left corner of the screen If adjustment fails a red square appears If a red square appears repeat the operation from step 1 9 PANEL EEPRO...

Page 255: ...es the pocket data Parameters Default Thread spool All color information set for spools is cleared resulting in no spool set Reserved thread All spools are released Sewing area display LL frame area is displayed Grid display Only the center is displayed Cursor display A small cross cursor is displayed Sewing order display Name of Color Display expanded thread color OFF Thread selection Brother s o...

Page 256: ...nter and sewing time counter Total and Trip are displayed on the left side and the Clear trip button is displayed on the right side of the screen Pressing the Clear trip button resets Trip Stitches and Trip Time to zero And the Trip Stitches and Trip Time are saved at the Maintenance of the lower step ...

Page 257: ...ows you to save data in text format type the 13 digit figure on the barcode attached to the needle bar case and save the file as NEEDLE txt 2 Connect the sewing machine and the PC with a USB cable and start test mode 3 Transfer the NEEDLE txt file from the PC to the sewing machine 4 Execute READ NEEDLE DATA in CASE MOTOR TEST 5 Check that the figure displayed on the screen matches the figure on th...

Page 258: ...w to select a needle bar number 1 Start up Test mode 2 Select MAIN BOARD TEST MODE 3 Select CASE MOTOR TEST 4 Select a needle bar number used for an adjustment by pressing or key NEEDLE BAR DATA ON BAR CODE Production NO Not used for any adjustment Needle threader adjustment right left Needle bar rising length and Needle space adjustment Needle position adjustment right left Needle position adjust...

Page 259: ... 2 screws 1 2 Move the motor holder up and down to adjust the motor belt tension 3 Tighten the 2 screws 1 Motor belt deflection when a load of approx 0 98 N 100 g is applied to the center of the motor belt 2 0 3 5 mm 1 Torque 1 18 1 57 N m Upset 4X14DB Color Gold 0 98N 100g 2 0 3 5mm 1 ...

Page 260: ...the tension pulley right and left to adjust the timing belt tension 3 Tighten the screw 1 Timing belt deflection when a load of approx 1 96 N 200 g is applied to the center of the timing belt 3 0 4 0 mm 1 Torque 1 18 1 57 N m Screw Pan S P washer M4X10DB 1 96N 200g 3 0 4 0mm 1 ...

Page 261: ...e needle bar until the needle tip enters the needle hole 4 Loosen the screw 1 at the lower section of the needle bar case final assembly 5 Move the case positioning plate assembly back and forth to adjust the needle front back position 6 Tighten the screw 1 7 Check the position for the other 5 needle bars Key point Pressing and selects the other needle bars 1 Torque 1 18 1 57 N m Bolt Socket M5X10...

Page 262: ... until the needle tip enters the needle hole 4 Loosen the 2 screws 1 5 Move the change box right and left to adjust the needle right left position 6 Tighten the 2 screws 1 7 Check the position for the other 5 needle bars Key point Pressing and selects the other needle bars 1 Torque 588N 60kg BOLT S P WASHER M5X16 Color Black The change box should be parallel to the needle bar case final assembly C...

Page 263: ...dle bar rising length and the needle space and tighten the 3 screws 1 5 Check the needle bar rising length and the needle space for the other 5 needle bars Key point Pressing and selects the other needle bars 1 Torque 0 59 0 78 N m Foot set screw 4 46 The right end of the needle matches the rotating hook s tip when the value of MAIN MOTOR ANGLE is 199 approx 2 mm Technical standard The right end o...

Page 264: ... for the other 5 needle bars Key point Pressing and selects the other needle bars Clearance between top edge of rotating hook s tip and top edge of needle hole 1 8 2 2 mm Alignment of needle bar and needle guard relative to upper shaft Tilt to the right when viewed from the front 0 to 2 1 Torque 0 78 1 18 N m Set Screw Socket CP SM4 37 40X4 The clearance between the top edge of rotating hook s tip...

Page 265: ...and 2 2 Adjust the clearance between the rotary hook stopper and the rotary hook 3 Tighten the screws 1 and 2 Clearance between rotary hook stopper end face and rotary hook 0 65 0 95 mm 1 Torque 0 59 0 78 N m 2 Torque 0 59 0 78 N m Bolt Socket M3X6 Screw P F 0 65 0 95mm Rotary hook stopper Rotary hook 1 2 ...

Page 266: ...Pressing and selects the other needle bars Clearance between section surrounding eye of needle and bottom face of presser foot 0 5 1 1 mm 1 Torque 0 78 1 18 N m Screw 0 5 1 1 mm The clearance between the section surrounding the eye of the needle and the bottom face of the presser foot should be 0 5 1 1 mm The bottom face of presser foot is slightly lower than the top face of the needle plate 0 5 1...

Page 267: ...60 degrees to connect the needle bar clamp and the J vertical set assembly surely 4 Loosen the screw 1 5 Push the top dead center plate towards the needle bar downward so that the cushion rubber is compressed slightly approx 0 3 mm and tighten the screw 1 6 Adjust the needle thread unit to the height of the selected needle bar 7 For the top dead center plate of the other 5 needle bars secure the p...

Page 268: ...e needle hole s top edge Raise the rack to its original position 4 Repeat the same steps to check the height for the other needle bars numbers 2 to 6 Key point Pressing and selects the other needle bars 5 Loosen the screw 1 6 Adjust the up down position of the base plate assembly hook to the highest needle bar position checked through steps 2 to 4 above 7 Tighten the 2 screws 1 1 Torque 1 18 1 57 ...

Page 269: ...inal assembly moves 3 Loosen the screw 1 4 Manually lower the needle thread assembly s rack to the bottom and move the hook to the position immediately before the needle hole 5 Manually hold the bush and rotate the hook holder assembly using a screwdriver to adjust the right and left positions of the hook assembly 6 Tighten the screw 1 7 Check that the hook passes through the needle hole for the o...

Page 270: ... ORIGIN POSITION to move the hook to its origin 3 Press MOVE THREAD SET MOTOR to check that the hook passes through the needle hole 4 Check that the hook passes through the needle hole for the other 5 needle bars Key point Press CLOSE MAIN BOARD TEST MODE and then NEEDLE THREADER and then pressing or selects the other needle bars ...

Page 271: ... to adjust the Y belt tension 4 Tighten the 2 screws 2 5 Repeat the same steps to adjust the Y belt tension on the right side 6 Tighten the 2 screws 1 Load when the center of the Y belt is deflected 4 3 mm 2 35 2 55 N 240 260g 1 Torque 0 78 1 18 N m 2 Torque 1 18 1 57 N m Set Screw Socket CP M3X3 Color Black Screw Pan S P washer M4X10DB 3 9mm 2 35 2 55N 240 260g 2 1 ...

Page 272: ...crews 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 the center of the X belt is deflected 5 7 mm 1 27 1 47 N 130 150g 1 Torque 1 18 1 57 N m Screw Bind M4X6 5 7mm 1 27 1 47N 130 150g 1 ...

Page 273: ...n inserted to the rotary hook 4 Press MOVE PICKER MOTOR to turn the picker on 5 Press or OVER PULSE to adjust the clearance should be 0 45 mm 1 05 mm between the bobbin and the picker tip 6 If the clearance cannot be adjusted by following the above procedure move the picker holder attachment screw 1 back and forth to adjust the clearance Clearance between bobbin and picker tip 0 95 1 05 mm 1 Torqu...

Page 274: ...IM MOTOR TEST 2 Press MOVE ORIGIN POSITION to move the needle plate base assembly s movable knife to its origin 3 Loosen the 2 screws 1 4 Adjust the position the movable knife stops 5 Tighten the 2 screws 1 Distance between edges of movable knife and fixed knife 1 mm 1 Torque 0 78 1 18 N m Screw Bind M3X4 1 1 mm ...

Page 275: ...djustment 1 Loosen the 4 screws 1 2 Adjust the vertical position of the thread presser base 3 Tighten the 4 screws 1 Clearance between wiper hook top face and thread presser cover 0 0 2 mm 1 Torque 1 18 1 57 N m Screw Bind M4X6 clearance 0 0 2mm 1 Wiper hook Thread presser cover 1 ...

Page 276: ...IN BOARD TEST MODE and then A D TEST 3 After the hoop stay assembly s LL hoop has been attached press LL to save the A D value 4 Replace the LL hoop with the S hoop and then press S to save the A D value 5 After adjustment move the tubular round arm L and check that the hoop size matches the display on the test mode screen ...

Page 277: ...nd then tighten the screw NOTE In adjustment the encoder base move counterclockwise and make sure that the encoders do not contact when tightening the screw NOTE After adjustment check the following points and then check the index operation of the needle bar case Check points Position of the needle bar clamp and jump bracket when the sewing machine stops operation Position of the thread take up di...

Page 278: ...sembly 3 Attach the embroidery sheet to the LL hoop 4 Enter the test mode and press MAIN BOARD TEST MODE and then XY MOTOR TEST 5 Press SAVE to move the feed unit to its origin 6 Use the and keys to adjust the position of the embroidery hoop so that the needle bar presser is aligned with the hole on the embroidery hoop 7 Press SAVE ...

Page 279: ...s below Adjustment steps 1 Measure the engagement load of the movable and fixed knives 2 When the engagement load is not within the specifications insert a spacer below the collar of the movable knife as shown in Figure 2 3 Measure the engagement load of the movable and fixed knives 4 Repeat steps 2 and 3 until the engagement load is within the specifications Engagement load of movable and fixed k...

Page 280: ...pears up to 3 times and will not come up when the machine is turned on for the 4th time If an hour counter is still not reset any maintenance has not been done after the MSG the MSG will come up again at 1600 hours and 1700 hours also up to 3 times each When an hour counter reaches 2000 hours Preventative maintenance is recommended 2000 hours exceeded MSG will appear on the LCD every time the mach...

Page 281: ...ustment 1 Turn the POWER switch on with the START STOP button THREAD CUT button THREAD GUIDE button simultaneously held down 2 Select the PANEL BOARD TEST MODE 3 Select the Clear trip 4 Select the Clear trip 5 The state that was cleared ...

Page 282: ...4 42 ...

Page 283: ...age detection does not function normally 5 9 The hoop does not move normally 5 10 The main shaft does not rotate normally 5 12 Thread is not cut normally 5 13 The wiper does not function normally 5 14 A needle is not threaded normally 5 15 The picker does not function normally 5 16 LED light does not turn ON 5 17 Embroidery card cannot be used normally 5 18 Universal serial bus USB function cannot...

Page 284: ... 5 19 XY moving error 5 12 EEPROM read write error 3 98 EEPROM read error 3 5 Main motor rotate error 5 12 Main motor lock 5 12 Main motor encoder signal error 5 25 Main motor encoder connect error 5 25 Main motor current error 5 26 Trimming sensor error 5 13 Wiper error 5 14 Sewing data error 5 27 Needle threadder error 5 15 Picker error 5 16 Main motor speed error 5 12 Power supply voltage error...

Page 285: ... inlet N Y Is the power cord properly connected to both the inlet and the plug outlet Connect it properly Is connector CN21 on the main PCB properly connected N Y Is lead on the panel properly connected to connector CN10 on the main PCB Y Connect it properly N To the next page Connect it properly N Is the voltage between pins 1 and 2 and 3 and 4 of connector CN21 on the main PCB 38 0 42 0V 22 8 26...

Page 286: ...s replaced with a reliable one N Change main PCB Y Does the machine function normally when the main PCB is replaced with a reliable one N Change panel PCB Y Does the machine function normally when the panel PCB is replaced with a reliable one N Change inverter PCB Y Does the machine function normally when the inverter PCB is replaced with a reliable one N To the next page From the previous page Ch...

Page 287: ... PCB and the inverter PCB Y Change inverter PCB Y Does the machine function normally when the inverter PCB is replaced with a reliable one N Connect it properly N Is the LCD s lead properly connected to connector on the inverter PCB Y Connect it properly N Is the FFC for the LCD properly connected to connector CN2 on the panel PCB and the LCD s connector Y Change FFC for the LCD Y Does the machine...

Page 288: ... Y Connect it properly Is the touch panel s FFC properly connected to connector CN1 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 90 650Ω 500 2000Ω respectively N Y Is the touch panel tuned correctly Change panel PCB and tune the touch panel again ...

Page 289: ... does not work The panel switch does not work or The panel s LED does not light Connect it properly N Y Change panel PCB Does the machine function normally when the switch PCB is replaced with a reliable one N Y Is the switch PCB s lead properly connected to connector CN7 on the panel PCB Change switch PCB ...

Page 290: ...e main PCB Change color change sensor N Y Does the voltage between pins 1 and 3 of connector CN12 on the main PCB vary from 0 to 3V at each needle bar position when the index motor s gear is rotated by hand Change index sensor N Y Does the voltage between pins 1 and 3 of connector CN22 on the main PCB vary from 0V at the position of the 1st needle bar to 3V at the position of the 2nd needle bar wh...

Page 291: ...ed to connector CN7 on the head PCB and connector CN8 on the main PCB Change thread quantity sensor s FFC N Y Is the resistance between each terminal at both ends 1Ω or below when the thread quantity sensor s FFC is removed from the PCB Change head leads N Y Is the resistance between each pin at both ends 1Ω or below when connectors at both ends of the head leads are removed from the PCB Change th...

Page 292: ...N19 on the main PCB N Is the FFC SML2CD C properly connected to CN1 on the X area sensor PCB and CN4 on the connect PCB Is the orientation of the FFC SML2CD C correct Y Change FFC SML2CD C Is the resistance between each terminal at both ends 1Ω or below when the FFC SML2CD C is removed from the PCB N Y Change FFC SML2CD Y Is the resistance between each terminal at both ends 1Ω or below when the FF...

Page 293: ...oes the machine function normally when the connect PCB is replaced with a reliable one Y N Change X motor Is the resistance between pins 1 and 2 and 3 and 4 of the X motor 5 4 6 8Ω respectively when the motor s connector CN3 is removed from the connect PCB N Y Change Y motor Is the resistance between pins 1 and 2 and 3 and 4 of the Y motor 5 2 6 4Ω respectively when the motor s connector CN20 is r...

Page 294: ...main PCB Connect it properly N N Is the main shaft motor s lead properly connected to CN1 on the main PCB Y Change main shaft sensor PCB Y Does the machine function normally when the main shaft sensor PCB is replaced with a reliable one Change main shaft motor N Y Is the resistance between pins 1 and 2 of the main shaft motor 1 0 2 0Ω when the motor s connector CN2 is removed from the main PCB Cha...

Page 295: ... PCB Connect it properly N Y Is the thread cutter motor s lead properly connected to CN6 on the main PCB Change thread cutter sensor PCB Y Does the machine function normally when the thread cutter sensor PCB is replaced with a reliable one N Change thread cutter motor N Is the resistance between pins 1 and 2 and 3 and 4 of the thread cutter motor 5 6 6 4Ω respectively when the motor s connector CN...

Page 296: ...main PCB Connect it properly N Y Is the wiper motor s lead properly connected to CN5 on the main PCB Change wiper sensor PCB Y Does the machine function normally when the wiper sensor PCB is replaced with a reliable one N Change wiper motor N Is the resistance between pins 1 and 2 and 3 and 4 of the wiper motor 4 7 5 7Ω respectively when the motor s connector CN5 is removed from the main PCB Chang...

Page 297: ... CN14 on the main PCB Connect it properly N Y Is the thread motor s lead properly connected to CN6 on the main PCB Change needle thread sensor PCB Y Does the machine function normally when the needle thread sensor PCB is replaced with a reliable one N Change thread motor N Is the resistance between pins 1 and 2 and 3 and 4 of the thread motor 4 7 5 7Ω respectively when the motor s connector CN6 is...

Page 298: ...ain PCB Connect it properly N Y Is the picker motor s lead properly connected to CN3 on the main PCB Change picker sensor PCB Y Does the machine function normally when the picker sensor PCB is replaced with a reliable one N Change picker motor N Is the resistance between pins 1 and 2 and 3 and 4 of the picker motor 4 7 5 7Ω respectively when the motor s connector CN3 is removed from the main PCB C...

Page 299: ...ED drive PCB Connect main PCB and LED drive PCB properly N Connect LED drive PCB and LED light assembly properly N Y Is the LED drive PCB properly connected to CN9 on the main PCB Change LED drive PCB Y N Change LED light assembly N Change main PCB Does the LED light turn ON when the LED light assembly is replaced with another one Does the LED light turn ON when the LED drive PCB is replaced with ...

Page 300: ... Investigation for Electronic Parts Embroidery card cannot be used normally Embroidery card cannot be used normally Change panel PCB N Y Does the machine function normally when another card is used Use another card ...

Page 301: ... cable Y N Does the machine function normally when the USB cable is replaced with a reliable one Connect them properly N Are relay connectors for the lead on the USB PCB and USB lead A properly connected to each other Y Change USB PCB Y Does the machine function normally when the USB PCB is replaced with a reliable one N Connect it properly N Is USB lead A properly connected to connector CN6 on th...

Page 302: ...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 dose it work correctly Change panel PCB ...

Page 303: ...rrect Connect it properly N Is the FFC SML2CD C properly connected to CN1 on the X area sensor PCB and CN4 on the connect PCB Is the orientation of the FFC SML2CD C correct Y Connect it properly N Is the FFC SML2CD Y properly connected to CN1 on the Y area sensor PCB and CN2 on the connect PCB Is the orientation of the FFC SML2CD Y correct Y Connect it properly N Is the Y area sensor s lead proper...

Page 304: ... sensor PCB is replaced with a reliable one Change hoop sensor and tune it again N Does the hoop sensor s lever rotate smoothly and return to the stopper by the force of its spring when pressed with fingers Y Change hoop sensor and tune it again N Does the resistance between pins 1 and 2 and 2 and 3 of the connector vary from approximately 0 to 1 2kΩ respectively as the lever rotates when the hoop...

Page 305: ...nsor does not function normally Y Change Y area sensor PCB Y Does the machine function normally when the Y area sensor PCB is replaced with a reliable one N Change main PCB N Does the machine function normally when the connect PCB is replaced with a reliable one Change connect PCB From the previous page ...

Page 306: ... Does the machine function normally when the Y area sensor PCB is replaced with a reliable one Y N Change Y motor Is the resistance between pins 1 and 2 and 3 and 4 of the Y motor 5 2 6 4Ω respectively when the motor s connector CN20 is removed from the main PCB N Y Is the Y area sensor s lead properly connected to CN19 on the main PCB Change main PCB ...

Page 307: ...rror Dialog message Change main shaft encoder N Y Change Y area sensor PCB Is the main shaft sensor s lead properly connected to CN17 on the main PCB N Y Change main PCB Does the machine function normally when the main shaft sensor PCB is replaced with a reliable one N Y Is the main shaft encoder deformed bent or damaged due to contact Change main shaft sensor PCB ...

Page 308: ...aft motor Is the resistance between pins 1 and 2 of the main shaft motor 1 0 2 0Ω when the motor s connector CN2 is removed from the main PCB N Y Change main PCB Does the machine function normally when the power PCB is replaced with a reliable one N Y Is the main shaft motor s lead properly connected to CN1 on the main PCB Change power PCB ...

Page 309: ...d B on the panel are removed from the main PCB and the panel PCB N Y Change main PCB Does the machine function normally when the panel PCB is replaced with a reliable one N Y Are relay connectors for leads A and B on the panel properly connected to each other Change encoder N Y TEST MODE Does the ENCODER A B within the SENSOR TEST change from H to L to H Change encoder or wipe off the dirt Y N Doe...

Page 310: ...upply voltage error 40V high Power supply voltage error 40V low Dialog message Connect it properly N Y Change power PCB Is the voltage between pins 1 and 2 and 3 and 4 of connector CN21 on the main PCB 38 0 42 0V and 22 8 26 4V respectively when the power is ON N Y Is the power lead properly connected to CN21 on the main PCB Change main PCB ...

Page 311: ...6 1 6Maintenance ...

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Page 317: ...7 1 7Special Instructions of Wiring Head wiring 7 2 Arm wiring 7 3 Base wiring 7 6 Main PCB wiring 7 7 Bed wiring 7 8 Y feed cable wiring 7 9 X feed cable wiring 7 11 Panel wiring 7 14 ...

Page 318: ...sor cable correctly Grounding wire at tachment position seven locations Head grounding wire Head PCB Do not allow the grounding wire to pro trude from the case Make sure that the tab on the lock faces up Lock the head PCB con nector correctly Do not allow the lead wire to protrude from the iron plate Position of lock Ap prox 30 mm from end of insulator Head grounding wire Cord bushing KR51 Head le...

Page 319: ...lead wire Color change sensor Sensor bracket hook Needle position sensor Sensor shutter Spiral A Color change sensor lead wire Sensor bracket hook Distance from cord bushing to cord clamp 125 mm Cord bushing back Route spiral A under the lug on the motor base Head lead wire Cord clamp Spiral A Color change motor Change motor base ...

Page 320: ...cure the tube Make sure that the bulge on the clamp is inside when securing the tube Semicir cular sag Spiral B Cord clamp Motor bracket Wiper motor Hook Wiper lead wire Wiper sensor Sensor shutter Needle thread base LED lead wire guide LED lead wire Thread the lead wire through the hole on the thread guide base ...

Page 321: ...allowed USB lead wire A Spiral A Pull out the relay connector from the middle point of spiral C and po sition it between spirals A and C Cord clamp Position of relay connector At least 15 mm Motor lead wire LED lead wire Panel lead wire Spiral C Wind the lead wires once around the cord clamp and then cover them with a spiral tube ...

Page 322: ...B Cord clamp A Y sensor lead wire Cord clamp B USB lead wire Y feed driving gear Y feed driving belt Round hole Square hole Remove any slack in the Y motor lead wire to prevent it contacting the Y feed driving shaft and then secure the lead wire with the cord clamp Y feed driving shaft Power lead wire Power switch Switch holder Inlet holder Y sensor lead wire USB lead wire B Power PCB lead wire ...

Page 323: ... 2 Lower section of main PCB Main shaft shutter Hook B Spiral B Hook A LED lead wire Main shaft sensor lead wire At least 15 mm Panel lead wire Spiral A Spiral C Power lead wire Core E04SR200935A Thread cut motor lead wire Picker motor lead wire Spiral D 20 40 mm Within 30 mm Approx 50 mm ...

Page 324: ...7 8 Wiring instructions Bed wiring 1 Bed PK motor bracket hook CT motor bracket hook Picker sensor lead wire Picker motor lead wire Protection sheet Lower shaft Screw ...

Page 325: ...center of the protection sheet Position the FFC at the center of the protection sheet Bending dimen sion 55 mm Valley fold di mension 5 mm Bending dimen sion 18 mm Feed relay cable medium PCB holder Screw Secure the PCB holder cable and protection sheet in parallel Do not allow the FFC to become taut when bent in a U shape FFC protection sheet FFC SML2CD Y ...

Page 326: ...ctor C Connector D X motor lead wire Make sure that the slack is above the cord clip FFC SML2CD C Cord clip Y cable protection sheet B Y cable protection sheet Screw FFC SML2CD Y Connector A Make sure that the PCB holder cable and protection sheet are parallel ...

Page 327: ... dimen sion 45 mm Bottom edge clearance 1 mm Bending dimension 10 mm X cable fixing sheet B Bottom edge clearance 1 mm Mountain fold Bottom edge clearance 1 mm FFC SML2CD X Bending dimen sion 60 mm X carriage B Screw Check that these parts are parallel FFC SML2CD X X cable fixing sheet A Move the fixing sheet in the direction of the ar row to remove a clear ance before tightening the screw ...

Page 328: ...d cable 3 4 X feed cable 4 Hoop sensor lead wire X carriage A X cable fixing sheet C Screw X carriage B FFC SML2CD X Connector A Connector B Connector FFC SML2CD X X cable fixing sheet B Screw X carriage Allowance for lift Up to 10 mm ...

Page 329: ...7 13 Wiring instructions Wiring instructions 5 X feed cable 5 X carriage Check that the FFC is parallel to the X belt Screw adjustment window for X cable fixing sheet X sensor shutter FFC SML2CD X ...

Page 330: ...ule 2 Inside of panel 1 LCD module Front cover spacer B Approx 1 mm from edge of display Grounding plate SW lead wire Thread the SW lead wire through the notch on the PCB Safaia II identification mark Attach the tape at the lower section of the grounding plate ...

Page 331: ...ide of panel 3 Back light lead wire Inverter lead wire SW lead wire PCB bracket PCB case Route the lead wires under the PCB case being careful to prevent them being crushed by the case Touch panel lead wire LCD lead wire Clip Panel lead wire USB lead wire Folding position ...

Page 332: ...6 Wiring instructions 5 Back of panel USB lead wire A Cord bushing Panel lead wire Almost the same length Make sure that the tab is facing down Align right end of bushing with right end of contraction tube ...

Page 333: ......

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