Brother RH-9820 Service Manual Download

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6. ASSEMBLY

RH-9820

Lower shaft provisional installation position

This position is the provisional position for the lower shaft until the procedure in “7-5. Adjusting the looper
stroke” is carried out

Turn the upper shaft pulley (d) to the needle up

stop position.
(Align the pulley groove (E) with the arm
reference line (D).)

2) Align the index mark (I) of the lower shaft cam

(28) with the hole (H) in the bed.

Push the lower shaft cam (28) against the end
of the bearing collar (2), and then provisionally
tighten the two set screws (29).

Should be no clearance.

0941B
0942B
0943B

Summary of Contents for RH-9820

Page 1: ...RH 9820 Please read this manual before making any adjustments ELECTRONIC EYELET BUTTON HOLER SERVICE MANUAL ...

Page 2: ... SAFETY INSTRUCTIONS and the whole of this manual to understand this product before you start maintenance As a result of research and improvements regarding this product some details of this manual may not be the same as those for the product you purchased If you have any questions regarding this product please contact a Brother dealer ...

Page 3: ...h or serious injury CAUTION The instructions which follow this term indicate situations where failure to follow the instructions could cause injury when using the machine or physical damage to equipment and surroundings Symbols This symbol indicates something that you should be careful of The picture inside the triangle indicates the nature of the caution that must be taken For example the symbol ...

Page 4: ...ll outlet Lightning may cause problems with correct operation Installation Machine installation should only be carried out by a qualified technician Contact your Brother dealer or a qualified electrician for any electrical work that may need to be done The sewing machine weighs approximately 120 kg Installation of the sewing machine and adjustment of the table height should be carried out by four ...

Page 5: ...Maintenance and inspection Disassembly assembly maintenance and inspection of the sewing machine should only be carried out by a qualified technician Ask your Brother dealer or a qualified electrician to carry out any maintenance and inspection of the electrical system Turn off the power switch and disconnect the power cord at the following times If this is not done the sewing machine may operate ...

Page 6: ...ty devices Devices such as eye guard finger guard needle bar guard needle guide cover and belt cover 4 Be careful not to get your hands caught when returning the machine head to its original position after it has been tilted 5 Be careful not to get your hands caught when moving the feed base backward 6 Be sure to connect the ground If the ground connection is not secure you run a high risk of rece...

Page 7: ...RH 9820 v Belt cover Rear 0331B 0332B 0334B 0486B 0485B 0333B ...

Page 8: ...sm 34 4 13 Lower thread release and lower thread take up mechanisms 35 4 14 Gimp thread take up mechanism 01 specifications only 35 4 15 Lower thread trimmer mechanism 36 5 DISASSEMBLY 38 5 1 Covers and presser foot mechanism 39 5 2 Upper shaft motor unit mechanism 40 5 3 Feed mechanism 41 5 3 1 Feed base unit 41 5 3 2 X feed unit 42 5 3 3 Y feed unit 42 5 4 Lower thread tension mechanism 43 5 5 S...

Page 9: ... 7 24 3 Adjusting the position of the thread trimmer lever bracket 168 7 25 Replacing and adjusting the movable knife and fixed knife for the lower thread and gimp 01 specifications 169 7 25 1 Replacing the movable knife and fixed knife 169 7 25 2 Adjusting the cutting pressure 170 7 25 3 Adjusting the meshing amount 170 7 25 4 Adjusting the thread nipper assembly and opener 171 7 25 5 Adjusting t...

Page 10: ...ngth Eyelet buttonholes 8 50mm Straight buttonholes 5 50mm Eyelet buttonholes 8 42mm Straight buttonholes 5 42mm L1422 14 22 mm 2 L1826 18 26 mm L2230 22 30 mm L2634 26 34 mm 2 L3442 34 42 mm 2 Stitch pitch 0 5 2 0 mm Zigzag width 1 5 5 0 mm Max 4 0 mm with mechanism Max 1 0 mm with software Taper bartack length 0 20 mm Work clamp height Standard 12 mm up to 16 mm possible 16 mm Starting method Fo...

Page 11: ...to 2 3 Memory switch setting method Advanced 7 Software version display function Refer to 2 8 Software version checking method 3 Data initialization function Refer to the Instruction manual 8 Data read write mode Refer to 3 3 Data read write mode 4 Error log display function Refer to 2 5 Error history checking method 9 Home position adjustment mode Referto 7 33 Adjusting the looper base home posit...

Page 12: ...section contains a list of advanced functions and the key operations which are used to call the setting mode for the functions 1 Production counter setting mode Refer to the Instruction manual 2 Data read write mode Refer to 3 3 Data read write mode 4550Q 0708B 0709B ...

Page 13: ...t this time only the memory switches whose current setting values are different from the default values will appear 3 Change the memory switch setting B If you would like to return the setting which is currently being displayed to the default value press the RESET key If the memory switch setting is different from the original setting the display will flash 4 Apply the changed setting The setting ...

Page 14: ...y is being pressed 300 1 40 Operates as a 7th shortcut key The numerals indicate the parameter numbers OFF Parameter checking column 1 in automatic mode 1 Shows the sewing length 301 2 Shows the sewing pitch 1 Parameter checking column 2 in automatic mode 3 Shows the sewing speed 302 4 Shows the number of stitches 3 Display screen contrast 303 0 30 The higher the value the greater the contrast 15 ...

Page 15: ...ed to the neutral position 055 ON After the work clamp has been lowered the work clamp is held in the lowered position even when the treadle is moved to the neutral position and the work clamp is raised when the treadle is depressed backward OFF Work clamp down operation when feed base is forward OFF When the feed base moves to the forward setting position after sewing is finished the work clamp m...

Page 16: ...ly before stopping rpm 153 250 450 The speed immediately before stopping can be set Setting can be carried out in units of 10 rpm 350 Current limit value during upper shaft acceleration 154 1 8 When a larger value is set a larger amount of current flows during acceleration 8 Current limit value during upper shaft deceleration 155 1 8 When a larger value is set a larger amount of current flows duri...

Page 17: ... the Y axis direction becomes slower Setting can be carried out in units of 50 Hz 0 θ axis test feeding speed correction Hz 255 500 0 When a smaller value is set the test feeding speed in the θ axis direction becomes slower Setting can be carried out in units of 50 Hz 0 Number of home position start cycles OFF After sewing is finished home position detection is not carried out 256 1 9 Home positio...

Page 18: ...change automatically to no cutting OFF User program settings No Setting range Setting items Default value Maximum sewing speed rpm 450 1000 2500 A limit to the maximum sewing speed can be set Setting can be carried out in units of 100 rpm 2500 Maximum number of cycle programs 451 0 9 The number of effective cycle programs can be set If cycle programs are never used it can be useful to set this to ...

Page 19: ... out in units of 100 ms This is used when there is a problem with the hammer position sensor OFF Upper thread remaining amount increase mm OFF Normal 555 1 3 By delaying the upper thread trimming timing by the amount set it is possible to increase the amount of upper thread remaining from normal Setting can be carried out in units of 1 mm OFF Upper thread tension release off timing ms This is only...

Page 20: ...10 10 When a larger value is set the upper thread nipping timing is delayed by more Setting can be carried out in units of 1 mm 0 Lapel device option This is not overwritten by CF card data OFF Lapel device is disabled 566 ON Lapel device is enabled When a straight buttonhole program is selected the sub hammer is lowered The material setting position is automatically set to the forward position OF...

Page 21: ... Setting range Setting items Default value Time before buzzer stops sounding seconds OFF When an error occurs the buzzer keeps sounding until the error is cleared 650 5 15 When an error occurs the buzzer sounds for the set time and then stops It can be set in units of 5 sconds OFF Pulse motor energization status when a non resettable error occurs OFF When a non resettable error occurs pulse motor ...

Page 22: ...e 26 34 mm 851 L3442 Sets to L3442 specifications The setting range for the sewing length will be 34 42 mm Circular stitch work clamp This is only displayed for 00 and 01 specifications This is not overwritten by CF card data NOTE Always be sure to set this to match the work clamp specifications OFF When using a normal not circular stitch work clamp 852 ON When using a circular stitch work clamp P...

Page 23: ... displayed The display starting from the left side will be history number error code and production counter 2 When the or key is pressed the history numbers will change Up to 64 history events can be recorded starting from the latest to be recorded No 1 will be the latest error that has occurred 3 To exit error history checking mode The sewing machine will change to home position detection standby...

Page 24: ...ding signals from the key and the sensor correctly 1 Release the air 2 While holding down the key push the POWER switch at the ON side 1 The mode will switch to input checking mode 3 Select the check number A to be checked 4 Refer to the input check list for key and sensor responses 5 To return to normal operation Press the POWER switch at the OFF side to turn off the power turn on the air and the...

Page 25: ...When depressed backward About 48 When at neutral position About 100 When depressed forward About 190 9 Work clamp switch Press the work clamp switch ON When pressed OFF When not pressed 10 Start switch Press the start switch ON When pressed OFF When not pressed 11 STOP switch connection signal ON Connected OFF Not connected 12 STOP switch Press the STOP switch ON When pressed OFF When not pressed ...

Page 26: ...et buttonhole position sensor Move the sub hammer up and down by hand ON When sub hammer is raised OFF When sub hammer is lowered 44 Straight buttonhole sensor Place material underneath the straight buttonhole sensor ON No material underneath sensor OFF Material underneath sensor 45 Feed plate home position sensor Install the feed plate ON Installed OFF Not installed 46 Feed plate drive cylinder l...

Page 27: ...cking output 1 While holding down the key push the POWER switch at the ON side 1 The sewing machine will switch to starting standby mode 2 Press the start switch 2 The feed base will move to the home position 3 Select the check number A to be checked Refer to the output check list for the details of signals being checked 4 Press the start switch 2 The operation corresponding to the signal being ch...

Page 28: ...te in the θ axis direction within a range of 49 5 to 364 5 It will stop when the start switch is released 9 Upper shaft motor The buzzer will sound for 0 7 second and then the work clamp will be lowered and the upper shaft motor will start It will stop when the start switch is released The upper shaft encoder value stop position will be displayed immediately after the upper shaft stops Normally a ...

Page 29: ...rt switch is released Encoder offset is measured and displayed during operation 19 Upper thread nipper device vertical movement The upper thread nipper device will be lowered while the start switch is being pressed Only with the upper thread nipper device 20 Upper thread nipper device forward back movement The upper thread nipper device will move forward while the start switch is being pressed Onl...

Page 30: ...e control program versions A will be displayed MN Main control program MT Motor control program PL Panel control program When the F key is pressed the IPL versions B will be displayed MN Main IPL PL Panel IPL 2 To exit version checking mode The sewing machine will change to home position detection standby A 0721B 0710B 0452B 0448B B 0983B ...

Page 31: ...o turn off the power for the sewing machine before inserting and removing CF cards CF cards are already formatted at the time of purchase so do not reformat them The recommended CF cards are commercially available ones from SanDisk or HAGIWARA SYS COM CF cards from other manufacturers can be used but different formatting methods may mean that reading from or writing to such cards may not be possib...

Page 32: ...ode will switch to data read write mode You can switch to data read write mode by pressing the TEST key and the F key together even when in test mode 3 Select the desired read write code A Refer to Read write code list given below 4 To exit data read write mode Read write code list Code Setting items R1 Parameter data is read from the CF card W2 Parameter data is written to the CF card R3 Memory s...

Page 33: ...EST key Data read write mode will end 3 6 Reading memory switch data from the CF card 1 Select R3 in data read write mode 2 Press the ENTER key The memory switch data will be read from the CF card except for some memory switch data Memory switch data relating to specifications and devices 050 561 564 566 572 752 850 851 852 and 853 will not be read Once writing is complete a COMPLETED message and ...

Page 34: ... you press the RESET key the operation will be canceled Firmware updating will start It should take about one minute Once writing is complete an UPDATED SUCCESSFULLY message and the power off symbol will be displayed 4 Push the POWER switch to the OFF side to turn off the power and then turn the power back on again 3 10 Updating the panel control program 1 Select R7 in data read write mode 2 Press...

Page 35: ...the numbers shown in the illustration number indicate the flow of operations that occur separately from each other 4 1 Upper shaft and Needle bar mechanisms 1 Motor assembly 2 Lower shaft 3 Upper shaft 4 Upper shaft crank 5 Needle bar crank 6 Crank rod unit 7 Needle bar clamp 8 Spacer 9 Needle bar 0658B ...

Page 36: ... Hypoid gear 3 Orthogonal shaft 4 Zigzag cam 4 Roller take up cam 5 Zigzag fork 5 Thread take up roller 6 Zigzag connecting rod 6 Thread take up 7 Zigzag crank 8 Zigzag driving lever 9 Zigzag lever 10 Zigzag horizon link 11 Needle bar block bracket 12 Needle bar block 13 Needle bar guide 0659B ...

Page 37: ...ar rocking mechanism 1 Pulse motor R 2 Theta M pulley assembly 3 Timing belt D 4 Looper pulley assembly 4 Driving looper shaft assembly 5 Looper base assembly 5 Vertical shaft timing pulley U assembly 6 Timing belt U 7 Needle bar gear block unit 0660B ...

Page 38: ...ar 4 X rack 5 X feed shaft holder N 6 X feed guide shaft A B 7 X feed shaft holder S 8 Y feed guide shaft 9 Feed base Y direction 1 Pulse motor Y 2 Driving gear 20 3 Idler gear 4 Timing pulley 5 Y Timing belt 6 Y driving shaft holder Belt holder 7 Y shaft 8 Y bearing 9 Y guide shaft 10 Feed base 0661B 0662B ...

Page 39: ...er shaft 6 Clamp lever B 7 Clamp lever 8 Clamp arm 9 Work clamp When work clamp is raised Because the air is bled from the clamp cylinder the force from the spring 1 has the opposite effect from when lowered 1 Spring 2 Clamp cylinder 16X10 3 Clamp cylinder rod 4 Clamp cylinder rod pin 5 Clamp driving lever 6 Clamp lever shaft 7 Clamp lever B 8 Clamp lever 9 Clamp arm 10 Work clamp 0663B 0783B ...

Page 40: ...r operation 1 Opening cylinder assembly 16X15 2 Opening cylinder rod 3 Opening cylinder rod pin 4 Opening driving lever 5 Opening connecting rod 6 Slide block 7 Fulcrum lever plate 8 Rocker lever 9 Work clamp plate a Bolt b Extension spring c Opening stopper plate 0664B ...

Page 41: ...k 7 Driving shaft presser 8 Cutter driving shaft 9 Hammer bracket assembly 10 Hammer a Knife bracket unit b Knife c Spring extension 4 8 Looper mechanism 1 Lower shaft 2 Lower shaft cam 3 Lower shaft cam collar 4 Looper lever assembly 5 Looper driving plate 6 Looper driving shaft 7 Looper link clamp 8 Looper link unit 9 LS holder base assembly 10 Looper 0665B 0666B ...

Page 42: ... 3 Spreader lever A 4 Spreader lever B 5 Slide block 6 Spreader link shaft 7 Spreader link base 8 Spreader cam link 9 Spreader driving cam 10 Spreader 4 10 Upper thread trimmer mechanism 1 Upper thread trimmer cylinder 2 Hammer 3 Thread trimmer lever bracket 4 Upper movable knife 0667B 0668B ...

Page 43: ...ension release solenoid 2 Bolt 3 Tension release pin 4 12 Upper thread take up mechanism 1 Cylinder assembly 10 30 2 Cylinder joint A 3 Collar B 3 Rubber cushion 4 Thread take up lever driving plate 4 Impact support shaft 5 Thread take up lever plate 5 Spring compression A 0669B 0670B ...

Page 44: ...d take up 4 Tension release pin tension release 00 02 Lower thread release only 1 Lower tension release solenoid 2 Lower solenoid shaft 3 Lower thread release plate 4 Tension release pin tension release 4 14 Gimp thread take up mechanism 01 specifications only 1 Feed bar Y direction operation 2 Gimp thread take up guide collar 3 Gimp thread take up G E plate 4 Gimp thread take up guide plate 0671B...

Page 45: ...immer arm 02 1 Cylinder 16X30 assembly B 2 Thread trimmer lever J assembly 3 Thread trimmer lever arm B 4 Movable knife driving plate 5 Thread trimmer link A assembly 5 Thread trimmer link B assembly 6 Movable knife L 6 Movable knife R 0673B 0674B Refer to Principle of the thread handler in 7 25 5 Adjusting the thread handler for details about the thread handler A ...

Page 46: ...4 MECHANICAL DESCRIPTIONS RH 9820 37 ...

Page 47: ... the pressure gauge to drop to 0 before carrying out inspection adjustment and repair of any parts which use the pneumatic equipment Be sure to wear protective goggles and gloves when handling the lubricating oil and grease so that they do not get into your eyes or onto your skin otherwise inflammation can result Furthermore do not drink the oil or eat the grease under any circumstances as they ca...

Page 48: ...Top cover 5 Screws with washers 4 pcs 6 Belt cover 7 Screws 2 pcs 8 Plain washers 2 pcs 9 Eye guard 10 Screws 4 pcs 11 Main plate 12 Socket bolts 2 pcs 13 Needle bar guard 14 Screws 4 pcs 15 Needle guide cover 16 Screws 5 pcs 17 Rear cover 18 Shoulder screw 19 Wave washer 20 Zigzag window cover 21 Work clamp plate R assembly 22 Work clamp plate L assembly Tilt back the machine head 23 Screws 3 pcs...

Page 49: ...er shaft motor unit mechanism Start with the machine head in its upright position 1 Screws 2 pcs 2 Belt guide 3 Socket bolts with washers 2 pcs Tilt back the machine head 4 Socket bolt with washer 1 pcs 5 Upper shaft motor unit 1080B ...

Page 50: ...2 Hammer 3 Socket bolt Loosen 4 Knife 5 Truss screws 2 pcs 6 Feed base cover U 7 Shoulder screws 2 pcs 8 Bending washers 2 pcs 9 Plate pressers 2 pcs 10 Flat screws 12 pcs 11 Feed base cover R 12 Feed base cover L 13 Socket bolts with washers 2 pcs 14 Set screws 4 pcs Loosen 15 X feed guide shafts 2 pcs Pull forward to remove 16 Feed base unit 1081B ...

Page 51: ... Upper shaft motor unit mechanism before disassembling the 5 3 3 Y feed unit Start with the machine head in its upright position 19 Socket bolt Loosen 20 Y shaft holder Tilt back the machine head 21 Socket bolt Loosen Return the machine head to its upright position 22 Y shaft Pull backward to remove Tilt back the machine head 23 Socket bolts 3 pcs 24 Y feed assembly 1082B 1083B ...

Page 52: ...5 DISASSEMBLY RH 9820 43 5 4 Lower thread tension mechanism Carry out the following with the machine head tilted back 1 Socket bolts 3 pcs 2 Lower thread guide adjust assembly 1084B ...

Page 53: ...echanism before the disassembly procedure in 5 5 Spreader mechanism Carry out the following with the machine head tilted back 1 Screw 2 Tube support B 3 Screw Loosen 4 Set screws 2 pcs Loosen 5 Spreader lever shaft 6 Screws 2 pcs 7 Spreader lever B assembly 8 Spreader lever shaft 9 Spreader lever A assembly 1085B ...

Page 54: ...der mechanism before the disassembly procedure in 5 6 Looper mechanism Carry out the following with the machine head tilted back 1 Screw Loosen 2 Socket bolt Loosen 3 Looper driving shaft 4 Looper driving shaft bracket 5 Set screws 2 pcs Loosen 6 Looper lever shaft 7 Looper lever assembly 1086B ...

Page 55: ...ts with washers 2 pcs 2 Tension pulley D assembly 3 Socket bolts 2 pcs 4 Motor stopper 5 Socket bolts with washers 4 pcs 6 Pulse motor assembly R 7 Timing belt D Return the machine head to its upright position 8 Socket bolts with washers 2 pcs 9 Tension pulley U assembly 10 Socket bolt Loosen 11 Set screws 2 pcs Loosen Tilt back the machine head once more 12 Driving looper shaft assembly 13 Vertic...

Page 56: ...cedure in 5 5 Spreader mechanism and the 5 6 Looper mechanism before the disassembly procedure in 5 8 Looper base mechanism Carry out the following with the machine head tilted back 1 Socket bolts 2 pcs 2 Partition 3 Screw Loosen 4 Looper pulley screw type 5 Looper base unit 1078B ...

Page 57: ... 6 Needle bar guides 2 pcs 7 Plain washers 2 pcs 8 Set screws 2 pcs Loosen 9 Needle bar guide collars 2 pcs 10 Set screw 11 Shoulder screw 12 Tension spring Needle thread holder plate Needle guide A 13 Screws 2 pcs Loosen 14 Needle bar assembly Pull out from the top 15 Needle bar clamp 2 pcs 16 Washers 2 pcs 17 Rubber cap 18 Set screws 3 pcs Loosen 19 Needle bar crank Crank rod unit 20 Slide block...

Page 58: ...5 DISASSEMBLY RH 9820 49 5 10 Lubrication 1089B ...

Page 59: ... Screws 3 pcs 19 Cord holders 10 3 pcs 20 Lower shaft cover assembly 21 Felt 22 Oil gauge window 23 Screw 24 Cord holder 5 25 Screws 4 pcs 26 Oil plate assembly 27 Screw 28 Cord holder NK 3N 29 Screw 30 Cord holder 4N 31 Screw 32 Cord holder 33 Screw 34 Cord holder NK 3N 35 Socket bolts 2 pcs 36 Tube support assembly From this point on disassemble after the disassembly in 5 13 Cutter mechanism has...

Page 60: ... cam Slide to remove from zigzag fork 5 Set screws 2 pcs Loosen 6 Zigzag coaxial rock shaft Pull out 7 Spacer 8 Set screw Loosen 9 Zigzag fork support shaft Pull out 10 Zigzag unit Remove the whole unit from the side of the arm main plate 11 Needle bar block collar Thread take up mechanism 12 Set screw Loosen 13 Thread take up L support shaft Pull out 14 Thread take up lever unit Remove the roller...

Page 61: ...n 7 Upper shaft unit Pull out from the back 8 Pinion 9 Screws 3 pcs 10 Plain washers 3 pcs 11 Pulley 12 Set screws 2 pcs Loosen 13 Set screws 2 pcs Loosen 14 Set screws 2 pcs Loosen 15 Set screws 2 pcs Loosen 16 Orthogonal shaft unit Pull out from the rear cover 17 Pulley base 18 Take up cam roller 19 Gear 20 Zigzag cam NOTE The bearing unit 16 and the bearing inner rings A and B are joined with a...

Page 62: ...Cutter lever assembly 10 Set screws 2 pcs Loosen 11 Set screws 2 pcs Loosen 12 Cutter arm shaft Pull out 13 Cutter arm assembly Tilt back the machine head 14 Set screws 2 pcs Loosen 15 Cylinder support shaft Pull out Return the machine head to the upright position once more 16 Cylinder assembly Lift up to remove 17 Socket bolts 4 pcs 18 Hammer bracket assembly 19 Socket bolts 3 pcs 20 Cutter drivi...

Page 63: ...the air hoses from the air supply and wait for the needle on the pressure gauge to drop to 0 before carrying out inspection adjustment and repair of any parts which use the pneumatic equipment Be sure to wear protective goggles and gloves when handling the lubricating oil and grease so that they do not get into your eyes or onto your skin otherwise inflammation can result Furthermore do not drink ...

Page 64: ...ecified by Brother MOLYKOTE LONGTERM W2 manufactured by Dow Corning Corporation in the places indicated by 0785B Refer to 7 16 2 Making fine adjustments to the knife position Refer to 7 14 Adjusting the axial play of the hammer Adjust so that the cutter driving shaft 2 turns smoothly with no play and then fully tighten the two socket bolts 4 Install so that it is not twisted Insert so that the gro...

Page 65: ...s 38 Hammer bracket assembly 39 Socket bolts 4 pcs 40 Knob screw Temporarily tighten 41 Cutter sensor assembly 42 Screws 2 pcs 43 Eccentric pin 44 Knife garbage joint 45 Block stopper plate 46 Screw Temporarily tighten 47 Knife block holder 48 Socket bolt Temporarily tighten 49 Knife bracket 50 Knife trash tube 51 Socket bolts 3 pcs Temporarily tighten 02 L1422 L1826 L2230 specifications only 52 H...

Page 66: ...gear block 6 Needle bar gear nut 7 Screw 8 Gear nut cover Push the needle bar gear block 5 in as far as it will go If it is not properly inserted oil leaks will occur Apply sealant Threebond 1212 to the outer circumference of the bearing Apply a small amount of sealant evenly over the outer circumference If the sealant is not applied evenly over the whole surface oil leaks will occur 0790B ...

Page 67: ... gear nut 6 and then while pushing the needle bar gear block 5 with a force of 78 4 N tighten the screw 7 NOTE If pressure is not applied it will not be possible to adjust the turning center for the needle bar and looper base and this will cause problems with sewing such as skipped stitches 0791B ...

Page 68: ...stration Adjust so that there is no play Refer to 7 3 Adjusting the zigzag base line position when fully tightening 0849B Adjust so that there is no play Align the end of the shaft with the edge of the arm B A Adjust so that there is no play Refer to 7 2 Adjusting the zigzag width stitch width Check the direction of installation ...

Page 69: ...haft 23 Set screw 24 Wick 25 Felts 6 pcs 26 Cap4 27 Zigzag coaxial rock shaft 28 Zigzag crank 29 Spacer 30 Set screws 2 pcs 31 Needle bar block bracket 32 Screw A Install the two wicks 10 and the wick 11 as shown in the illustration Push in the felt 13 so that the wick will not pull out and then push in the four felts 12 so that they do not protrude from the end of the shaft After this install the...

Page 70: ...t in the turning direction is at the screw stop position Apply the grease specified by Brother MOLYKOTE LONGTERM W2 manufactured by Dow Corning Corporation in the places indicated by 0821B Place the zigzag cam 24 against the gear 25 and then tighten Refer to 7 29 Adjustment of the phase for the take up roller cam when assembling Place against the bearing collar 15 and then tighten A A B B C A C B ...

Page 71: ...hem apply adhesive Threebond 1373B to the outer circumferences of the bearings and apply adhesive Threebond 1401 to the inside of the bearing on the orthogonal shaft 23 Be sure to wipe away any excess adhesive from the bearings at this time to avoid letting the adhesive get inside the mechanism B Upper shaft and orthogonal shaft pressure adjustment Adjusting the pressure of the upper shaft 1 While...

Page 72: ...ign the marks on the pinion 11 and the gear 25 as shown in the illustration Next align the set screw 30 at the front of the pinion 11 in the turning direction with the screw stop on the upper shaft 7 and then provisionally tighten the two set screws 30 so that the pinion 11 can still move in the axial direction The arrow shows the direction of rotation 3 Push the pinion 11 against the gear 25 and ...

Page 73: ...tion in the places indicated by 1 Wick 2 Oil tube 3 Fastening band 4 Roller 5 Roller shaft 6 Set screw 7 Thread guide 8 Thread take up L support shaft 9 Set screw 10 Felt Apply adhesive 3M DP 125 clear and then install Be sure to wipe away any excess adhesive Application location 0829B 0828B 0830B Insert the wick 1 into the groove wind it around and then tie it Tie Push in the felt 10 so that the ...

Page 74: ...ONGTERM W2 manufactured by Dow Corning Corporation in the places indicated by Refer to 7 30 Adjusting the needle bar and looper base turning center when fully tightening Refer to 7 6 Adjusting the height of the needle bar when fully tightening Install so that the needle bar moves up and down smoothly and the amount of play when the needle bar turns is as small as possible 0832B B A F F E D C ...

Page 75: ...pcs 24 Needle bar guide washers 2 pcs 25 Needle bar guides 2 pcs 26 Needle bar guide springs 2 pcs 27 Needle bar guide support plates 2 pcs 28 Screws 2 pcs 29 Needle bar bracket screws 2 pcs Temporarily tighten 30 Needle guide A 31 Needle thread holder plate A 32 Tension spring 33 Shoulder screw 34 Needle 35 Set screw SM 36 Slide block guide F 37 Socket bolts 4 pcs 38 Needle bar guard 39 Socket bo...

Page 76: ...bolts 10 f from the side of the arm 3 Fully tighten the four socket bolts 10 Face plate side Right side E Slide block guide F installation 1 Provisionally tighten the three socket bolts 37 so that the slide block guide F 36 can still move 2 While pushing the slide block guide F 36 gently from the face plate side toward the arm installation surface tighten the fourth socket bolts 37 g from the side...

Page 77: ...crank rod unit 14 slightly 3 Push the place indicated by to gently push the Slide block 13 against slide block guide D 9 so that the upper shaft crank h can still turn easily then tighten the set screw 12 j through the hole in the side of the arm and then tighten the other set screw 12 i After this turn the upper shaft crank h and provisionally tighten the third set screw 12 on the opposite side A...

Page 78: ...ed by Dow Corning Corporation in the places indicated by NOTE After carrying out this procedure be sure to adjust the Y home position while referring to 7 35 Adjusting the needle up signal home position for the upper shaft and upper shaft motor Assemble so that the flanges are on the inside Install so that the motor connectors are facing as indicated by the arrow Install the timing belt 0839B C A ...

Page 79: ...ly tighten 28 Driving gear 20 29 Set screws 2 pcs 30 Pulse motor Y assembly 31 Washers 4 pcs 32 Socket bolts 4 pcs 33 Y feed base 34 Socket bolts 3 pcs 35 Y shaft 36 Y shaft holder 37 Socket bolt 38 Socket bolt A 1 Push the Y pulley shaft F 8 and the Y timing pulley assembly 9 in the direction of the arrow so that there is no play in the parts and then tighten the two set screws 12 2 Align the idl...

Page 80: ...f the Y pulley support assembly a 2 Use the adjustment screw c to adjust the belt tension 3 Tighten the two screws b of the Y pulley support assembly a Be sure to use a belt tension gauge to measure the belt tension and measure at the position shown in the illustration The belt tension gauge should be set to measure a unit weight of 0 04 kg m a belt width of 10 mm and a span length of 120 mm 0844B...

Page 81: ...d A of the Y shaft holder 36 and the reference line B on the Y shaft 35 and then tighten the socket bolt 37 Y shaft and Y driving shaft holder installation positions Align the end C of the Y driving shaft holder 24 and the reference line D on the Y shaft 35 and then tighten the socket bolt 38 0846B 0847B 0848B 0847B Front ...

Page 82: ...sting the upper movable knife C D E F Refer to 7 24 2 Adjusting the upper movable knife J K Refer to 7 28 Adjusting the position of the lower thread presser 02 specifications only Refer to 7 24 3 Adjusting the position of the thread trimmer lever bracket Refer to 7 11 Adjusting the height of the throat plate Refer to 7 8 Adjusting the needle guard Refer to 7 1 Adjusting the heights of the spreader...

Page 83: ... 50 Collar 51 L thread take up spring support 52 Screw Temporarily tighten 53 Thread take up spring 54 L thread take up spring support 55 Screw Temporarily tighten 56 L thread take up spring support 57 Screw with washer 58 Vertical pin 59 Set screw Temporarily tighten 60 Throat plate 61 Screw Temporarily tighten 00 and 01 specifications only 62 Upper movable knife A 63 Screw Temporarily tighten 64...

Page 84: ...b in the LS holder base 34 Push in so that the knot does not protrude from the hole b 2 Tie the other end of the wick 8 to one end of the wick 9 and then wind them around the LS holder base 34 as shown in the illustration Tie the wicks twice to form the knot Wind so that the knot is directly below the hole c and so that it does not protrude to the outside Wind the wick 8 and the wick 9 so that the...

Page 85: ...and then cut off the excess length so that the ends are 2 3 mm in length E Hook the thread take up spring 53 onto the hook d of the L thread take up spring support 54 as shown in the illustration F 1 Hook the wick onto the hook e of the L thread take up spring support 56 as shown in the illustration 2 Raise the end of the hook e of the L thread take up spring support 56 so that it touches the supp...

Page 86: ...the felt 76 to the wick release plate 78 with the two cable ties 77 Cut the ends of the two cable ties 77 so that a length of 0 to 2 mm remains Viewed from the front Viewed from the right H Pass the wick 9 and the wick 75 through the oil tube 79 as shown in the illustration and then pass them through the hole f I Push the five wicks g into the hole h as shown in the illustration and then install t...

Page 87: ...ntil their surfaces j are fully touching Wipe away any excess adhesive at this time 3 Insert the looper base assembly k K Looper base pressure adjustment 1 Gently screw the looper pulley assembly 93 onto the threaded section l of the looper base 2 Secure the looper pulley assembly 93 so that it will not turn and then push the back of the looper base 92 at a point 20 mm to the left of center with a...

Page 88: ...6 ASSEMBLY RH 9820 79 6 9 Needle bar rocking mechanism Refer to the detailed descriptions on pages 80 to 84 for details on A to G in the illustration 0922B A B C D G E F ...

Page 89: ... ring 26 Bearing 27 Internal retaining ring 28 Tension pulley 29 Retaining ring C 30 Timing pulley holder assembly 31 Socket bolts with washers 2 pcs A Push the driving looper shaft assembly 9 from the lowered to the raised position then push the set screw collar 3 down to clamp the bearing 4 and then tighten the two set screws 2 B Place the timing belt 8 onto the needle bar gear block a and the v...

Page 90: ... it is within the ranges given below When using a new belt 80 90 N When reusing an old belt 60 70 N Be sure to use a belt tension gauge to measure the belt tension and measure at the position shown in the illustration The belt tension gauge should be set to measure a unit weight of 0 04 kg m a belt width of 10 mm and a span length of 219 mm NOTE If you do not have a belt tension gauge adjust so th...

Page 91: ...ull the tension pulley 28 in the direction of the arrow to adjust the belt tension so that it is within the ranges given below When using a new belt 80 90 N When reusing an old belt 60 70 N 3 Check that the mechanism is at the Standard installation when belt is tensioned position given above at this time If the reference lines are more than 5 mm apart readjust the mechanism Be sure to use a belt t...

Page 92: ...e line B on the bed is aligned with reference line C 0 left side on the looper base 4 Install the positioning gauge f to the end of the needle bar gear block a with the screw g The thread guide e on the needle bar should be all the way in on the right side in the illustration Install the positioning gauge f so that it is pushed up to the top left 5 Turn the needle bar gear block a in the direction...

Page 93: ...6 ASSEMBLY RH 9820 84 6 Push the vertical shaft timing pulley U assembly 7 up gently until it touches the bearing 1 and then tighten the socket bolt 6 0932B ...

Page 94: ...0 85 6 10 Lower shaft mechanism Refer to the detailed descriptions on pages 86 to 89 for details on A to C in the illustration 0933B B A C Press fit into the arm after assembling Press fit into the arm after assembling ...

Page 95: ... shaft upper shaft motor Temporarily tighten 25 Timing belt For upper shaft lower shaft 26 Lower shaft cover assembly 27 Screws 2 pcs 28 Lower shaft cam 29 Set screws 2 pcs Temporarily tighten A Lower shaft pressure adjustment 1 Set so that the amount of protrusion is 24 8 mm and then tighten the two set screws 10 of the bearing collar 2 against the lower shaft 9 This is to prevent the shaft from ...

Page 96: ...e hexagonal part c of the eccentric shaft of the tension pulley assembly a in the direction of the arrow to adjust the belt tension to within the ranges given below and then tighten the socket bolt 23 When using a new belt 170 190 N When reusing an old belt 140 170 N Be sure to use a belt tension gauge to measure the belt tension and measure at the position shown in the illustration The belt tensi...

Page 97: ...e illustration and then place the timing belt 25 for upper shaft lower shaft onto the upper shaft timing pulley b idler pulley 16 lower shaft tension pulley B 7 and tension pulley assembly a 4 Use a spanner to turn the hexagonal part c of the eccentric shaft of the tension pulley assembly a in the direction of the arrow to adjust the belt tension to within the ranges given below and then tighten t...

Page 98: ...stroke is carried out 1 Turn the upper shaft pulley d to the needle up stop position Align the pulley groove E with the arm reference line D 2 Align the index mark I of the lower shaft cam 28 with the hole H in the bed 3 Push the lower shaft cam 28 against the end of the bearing collar 2 and then provisionally tighten the two set screws 29 Should be no clearance 0941B 0942B 0943B ...

Page 99: ...r shaft 4 Set screw 5 Wick 6 Wick 7 Oil tube 8 Wick 9 Oil tube 10 Looper tube clamp B 11 Screw 12 Looper tube clamp A 13 Screw 14 Looper driving plate 15 Shafts 2 pcs 16 Set screws 2 pcs 17 Looper lever 18 Looper lever shaft 19 Set screws 2 pcs 20 Looper driving shaft bracket 21 Looper driving shaft 22 Socket bolt 23 Screw Temporarily tighten A Check that the looper driving plate 14 turns smoothly...

Page 100: ...eft Viewed from the front 1104B 1103B 1102B Tie in two knots Cut the ends at a length 2 mm from the knots Fold twice and pass through the hole Tie in two knots Cut the ends at a length 2 mm from the knots Tie once Pass the knot through the tube Tie once Pass the knot through the tube Clearance Viewed from underneath ...

Page 101: ... 3 Screw 4 Wick 5 Oil tube 6 Fastening bands 2 pcs 7 Wick 8 Retaining ring C 9 Shaft 10 Retaining ring C 11 Shaft 12 Set screws 2 pcs 13 Slide blocks 2 pcs 14 Spreader lever A 15 Spreader link shaft 16 Spreader lever B 17 Spreader lever shaft 18 Set screws 2 pcs 19 Eccentric pin 20 Screw Temporarily tighten 21 Plain washers 2 pcs 22 Screws 2 pcs Temporarily tighten 23 Screw Fully tighten A The lar...

Page 102: ...top of the spreader link base b with the reference line a on the spreader link shaft 15 and then tighten the screw 23 1027B 1028B Tie Tie Cut at 0 2 mm Tighten so that the two fastening bands 6 are not lifted up 1 1 1 Set to 1 mm or less 1 Cut the ends at a length 4 mm from the knots ...

Page 103: ...mmer mechanism Install in the positions shown in the illustration 1 Cylinder assembly 2 Socket bolts 2 pcs 3 Hammer 4 Hammer guide plate 5 Socket bolts 2 pcs 6 Cylinder setting plate 7 Socket bolts 2 pcs 0985B When at maximum extension Clearance ...

Page 104: ...manufactured by Dow Corning Corporation in the places indicated by Tighten the shoulder screw 11 followed by the nut 12 so that the gimp thread take up driving plate 9 and the gimp thread tale up plate 10 move smoothly with no play 0944B Make sure the direction is correct Make sure the direction is correct ...

Page 105: ... 12 Nut 13 Springs 2 pcs 14 Gimp thread guide 15 Screw 16 Gimp thread take up G holder 17 Socket bolts 2 pcs 00 and 02 specifications only 18 Gimp thread guide J 19 Socket bolts 2 pcs 02 specifications only 20 O Ring 2 pcs 21 Retaining ring E 22 Solenoid 23 Screws 2 pcs 24 Gimp thread shaft 25 Set screws 2 pcs 26 Tension disc 27 Gimp thread clamp 28 Screws 2 pcs 29 Gimp thread clamp plate 30 Socke...

Page 106: ...led descriptions on pages 102 and 103 for details on A to K in the illustration Apply the grease specified by Brother MOLYKOTE LONGTERM W2 manufactured by Dow Corning Corporation in the places indicated by 6 15 1 Feed base 0986B 2 1 1 3 2 3 I J G G C H E H F A B K D ...

Page 107: ... lever R assembly 75 Retaining ring E 76 Cylinder rod pin B 77 Retaining ring E 78 Fulcrum lever plate 79 Slide block 80 Rocker lever 81 Washer 82 Retaining ring E 83 Cylinder 84 Retaining ring E 85 Shoulder screw 3 pcs 86 Speed nut 87 Screw Temporarily tighten 88 Stopper plate 89 Opening stopper plate 90 Washer 91 Screw Temporarily tighten 92 Speed nut 93 Screw Temporarily tighten 94 Stopper plat...

Page 108: ...air tubes and harnesses 00 specifications The air tubes and harnesses are numbered as shown in the illustration Check the number of each air tube and harness to make sure that they are routed correctly as shown in the illustration 0987B ...

Page 109: ...air tubes and harnesses 01 specifications The air tubes and harnesses are numbered as shown in the illustration Check the number of each air tube and harness to make sure that they are routed correctly as shown in the illustration 0988B ...

Page 110: ...air tubes and harnesses 02 specifications The air tubes and harnesses are numbered as shown in the illustration Check the number of each air tube and harness to make sure that they are routed correctly as shown in the illustration 0989B ...

Page 111: ...C 4 onto one side of the ball bearing 5 then apply adhesive Threebond 1373B to the ball bearing 5 and then insert it into the Y bearing 7 Wipe away any excess adhesive at this time Install so that the layout of the balls d is in an X pattern on the installation surface as shown in the illustration C Assemble as shown in the illustration D Assemble as shown in the illustration E Assemble as shown i...

Page 112: ...ht side H Assemble while referring to the finished assembly diagram shown below Left side Right side I For 02 specifications only Install to the feed base a as shown in the illustration below J For 02 specifications only Install so that the centers of the pin holes e and f are at the distance shown in the illustration K For 01 and 02 specifications only Install at the distance shown in the illustr...

Page 113: ...dicated by 1 Ball bearings 4 pcs 2 Ball bearing stoppers 4 pcs 3 Screws 4 pcs 4 X feed guide shaft B 5 X feed guide shaft A 6 Gears 2 pcs 7 Socket bolts 4 pcs 8 Set screw Temporarily tighten 9 X feed shaft holder N 10 Washers 2 pcs 11 Socket bolts 2 pcs Temporarily tighten 12 Set screw Temporarily tighten 13 X feed shaft holder S 14 Washers 2 pcs 15 Socket bolts 2 pcs Install the feed base to the ...

Page 114: ...hten the four screws 3 At this time insert the projections b of the four ball bearing stoppers 2 into the grooves c and check that the ball bearing stoppers 2 are flush with the bed surface B Install the two gears 6 to X feed shaft holder N 9 so that the gear 6 with the shorter distance between the thread hole and the edge is on the right While pushing the two gears 6 in the direction of the arrow...

Page 115: ... Align the screw stop on the Y feed guide shaft 16 with the screw hole in X feed shaft holder N 9 4 Align the end of the Y feed guide shaft 16 with the end of X feed shaft holder N 9 and then tighten the two set screws 17 5 Install the Y feed guide shaft 16 on the right side also by following steps 2 to 4 above D For 01 specifications only Install the Cylinder screw 20 in the position shown in the...

Page 116: ... 2 pcs 6 Idler gear 7 Set screws 2 pcs Temporarily tighten 8 Feed gear 9 Set screws 2 pcs 10 Pulse motor X assembly 11 Plain washers 4 pcs 12 Socket bolts 4 pcs 13 X motor support 14 Socket bolts 3 pcs Install so that the motor connectors are facing as indicated by the arrow Apply adhesive to the outer circumferences of the two bearings 2 and then install 0963B Apply adhesive to the outer circumfe...

Page 117: ...ler gear 6 while the X rack d and the idler gear 4 are engaged in the standard position 3 Set so that the screw stop A of the pulse motor X assembly 10 and the two set screws 9 of the feed gear 8 are in the positions shown in the illustration 4 While pushing the idler gear 4 and idler gear 6 to engage them with the X racks d and e at opposite sides install the motor unit f 5 Tighten the two set sc...

Page 118: ...ge for details on A in the illustration Apply the grease specified by Brother MOLYKOTE LONGTERM W2 manufactured by Dow Corning Corporation in the places indicated by Refer to 7 32 Adjusting the lower thread loosening amount Refer to 7 23 Adjusting the lower thread feeding amount 01 specifications only 0969B A ...

Page 119: ...n 2 Stopper 3 Lower thread take up guide lever 4 Spring 5 Retaining ring C 6 Lower thread guide B 7 Screws 2 pcs 8 Lower thread guide A 9 Screws 2 pcs 10 Tension discs 2 pcs 11 Tension disc presser 12 Spring 13 Washer 14 Tension nut 15 Tension stud 16 Tension release pin 17 Nut Temporarily tighten 18 Solenoid cushion 19 Washer 20 Solenoid shaft 21 Solenoid 22 Plain washers 2 pcs 23 Spring washers ...

Page 120: ...talled install them first After carrying out the procedure in C Standard installation of upper shaft motor unit and belt tension adjustment be sure to carry out the adjustments in 7 35 Adjusting the needle up signal home position for the upper shaft and upper shaft motor and 7 36 Adjusting the upper shaft stop position 1 Motor assembly 2 Socket bolts 5 pcs 3 Timing pulley 4 Set screws 2 pcs 5 Moto...

Page 121: ...position 4 Provisionally screw in the two remaining socket bolts with washers g at the back of the machine head until they are almost fully tightened and then place the motor on the lower shaft side 5 Place the belt h onto the lower shaft timing pulley i and the motor pulley j 6 Insert a screwdriver into the gap between the motor holder d and the bed k and move the upper shaft motor unit c to the ...

Page 122: ...s installed to the upper shaft motor unit c 3 With the machine head tilted back hold the upper shaft motor unit c at the front and then place the belt h onto the motor pulley j so that the D cut section D of the encoder is facing directly to the right 4 Place the positioning pin e at the rear of the machine head into the slot A in the motor holder d 5 Provisionally screw in the socket bolt with wa...

Page 123: ...ion gauge should be set to measure a unit weight of 0 04 kg m a belt width of 15 mm and a span length of 92 mm 9 Tighten the two socket bolts with washer g 10 Tilt back the machine head and fully tighten the socket bolt with washer f at the front 11 Check that the D cut section D of the encoder is facing directly to the right 10 at this time If it is not in this position repeat steps 3 to 10 If it...

Page 124: ...6 ASSEMBLY RH 9820 115 6 19 Covers 1064B ...

Page 125: ...s 7 Eye guard assembly 8 Plain washers 2 pcs 9 Screws 2 pcs 10 Zigzag window cover 11 Wave washer 12 Shoulder screw 13 Rear cover 14 Screws 5 pcs 15 Belt cover 16 Screws with washers 4 pcs 17 Top cover assembly 18 Screws 9 pcs 19 Needle bar guard 20 Socket bolts 2 pcs 21 Switch cover 22 Screws with washers 3 pcs ...

Page 126: ...riptions on pages 119 and 120 for details on A to D in the illustration Apply the grease specified by Brother MOLYKOTE LONGTERM W2 manufactured by Dow Corning Corporation in the places indicated by Refer to 7 26 4 Adjusting the position of the sub clamp 1008B B A D C A B D C A B D C ...

Page 127: ...23 Thread trimmer B 24 Thread trimmer A 25 Screw 26 Opening slide block 27 Slide block support plate 28 Screws 2 pcs 29 Needle plate R 30 Flat screws 2 pcs 31 Clamp shaft holder 32 Screws 2 pcs 33 Cloth guide R 34 Screw 35 Bending washer 36 Cloth work clamp R 37 Clamp support pin 38 Work clamp plate R 01 specifications only 39 Nut 40 Clamp arm R 41 Socket bolt Temporarily tighten 42 Clamp lever R ...

Page 128: ...llustration 2 After adjusting tighten the two set screws 20 B Cloth work clamp L forward back adjustment 1 Loosen the socket bolt 16 and then adjust the forward back position of clamp arm L 15 2 Next adjust cloth work clamp L 11 so that its side is flush with the side of needle plate L 4 3 Once adjustment is complete tighten the socket bolt 16 Viewed from directly to the left 1009B 1010B ...

Page 129: ...tion 2 After adjusting tighten the two set screws 45 D Cloth work clamp R forward back adjustment 1 Loosen the socket bolt 41 and then adjust the forward back position of clamp arm R 40 2 Next adjust the cloth work clamp R 36 so that its side is flush with the side of needle plate R 29 3 Once adjustment is complete tighten the socket bolt 41 Viewed from directly to the right 1012B 1011B ...

Page 130: ...ply the grease specified by Brother MOLYKOTE LONGTERM W2 manufactured by Dow Corning Corporation in the places indicated by 1013B A C B D Refer to 7 25 Replacing and adjusting the movable knife and fixed knife for the lower thread and gimp 01 specifications Refer to 7 25 Replacing and adjusting the movable knife and fixed knife for the lower thread and gimp 01 specifications E ...

Page 131: ...ead handler 22 Flat screw Temporarily tighten 23 Screw Temporarily tighten 24 Movable knife 25 Flat screws 3 pcs 26 Movable knife collar 27 Thread nipper opener 28 Shoulder screw 29 Opener spring 30 Screws 2 pcs 31 Fixed knife 32 Fixed knife plate spring 33 Fixed knife plate spring U 34 Thread guide plate 35 Socket bolts 2 pcs 36 Fixed knife setting bracket 37 Screws 2 pcs Temporarily tighten 38 O...

Page 132: ...ntil the end of the spring hook 4 is flush with the top surface of the cloth work clamp plate a Install the spring hook 4 so that the hole b is facing in the direction shown in the illustration B Install the pin 14 so that it projects by the distance shown in the illustration C Install the spring hook 15 so that it faces in the direction shown in the illustration 1014B 1015B 1016B Top Bottom Shoul...

Page 133: ...LY RH 9820 124 D Insert the end of the opener spring 29 into the notch c of the thread nipper opener 27 E Install all parts so that the edges are aligned as shown in the illustration 1017B 1018B Align the edges ...

Page 134: ...ecified by Brother MOLYKOTE LONGTERM W2 manufactured by Dow Corning Corporation in the places indicated by 1019B F G Refer to 7 26 Replacing and adjusting the movable knife and fixed knife for the lower thread and gimp 02 specifications Refer to 7 26 Replacing and adjusting the movable knife and fixed knife for the lower thread and gimp 02 specifications ...

Page 135: ... Nut 23 Pin 24 Spring hook 25 Screw 26 Thread cutter lever arm 27 Socket bolt Temporarily tighten 28 Spring 29 Work clamp plate JU 30 Screws 2 pcs F Spring hook installation 1 Provisionally tighten the nut 5 about halfway onto the spring hook 6 2 Install the spring hook 6 to the cloth work clamp plate a and then tighten the nut 5 to the position shown in the illustration Check that the end of the ...

Page 136: ...scriptions on the next page for details on A to C in the illustration Apply the grease specified by Brother MOLYKOTE LONGTERM W2 manufactured by Dow Corning Corporation in the places indicated by Refer to 7 31 Adjusting the upper thread loosening amount After installing the Socket bolt 16 tighten the two screws 4 so that the cylinder moves smoothly 0857B A C B ...

Page 137: ...stud U 31 Set screw 32 Tension release pin 33 Solenoid cushion 34 Washer 35 Nut 36 Bolt 37 Upper thread tension release solenoid 38 Plain washers 2 pcs 39 Spring washers 2 pcs 40 Bolts 2 pcs 41 Solenoid setting plate 42 Screws 2 pcs 43 Upper thread guide A 44 Screw 45 Thread guide discs 2 pcs 46 Pre tension spring B 47 Tension nut 48 Tension stud 49 Thread guide rod A 50 Sewing thread retainer gui...

Page 138: ...r 11 Cord holder 12 Cord holder 13 Cord holder 14 Cord holder A G Indicates holes H Indicates a gap Routing order Part name 1 2 3 4 5 6 7 8 9 Stop switch 1 2 3 4 5 A 8 Cutter sensor 6 7 A 8 Upper tension release solenoid A 8 Main valve harness 8 9 B E 12 F 13 14 G Relay harness 9 B E 12 F 13 14 G Upper thread solenoid harness 9 B E 12 F 13 14 G 1106B Stop switch Upper tension release solenoid Cutt...

Page 139: ... F 13 14 G Y sensor 10 D 11 13 14 G Lower tension release solenoid E 12 F 13 14 G Safety switch 11 13 14 G X motor 13 14 G Y motor G θmotor G Upper shaft motor H Fan G 1107B Y sensor Gimp thread solenoid Safety switch Lower tension release solenoid X motor θ motor Fan Y motor Upper shaft motor ...

Page 140: ... the air tubes No 13 and No 14 of the upper thread cutter cylinder c through the hole in the bed and out through the bottom 2 Secure the air tubes with the cord holder d 3 Pass the air tubes No 13 and No 14 through the hole in the bed as shown in the illustration below 4 Pass the air tubes No 13 and No 14 out through the bottom of the bed into the side of the arm and then pass them out through the...

Page 141: ...s the air tube No 1 through the hole in the bed and out from the rear of the bed Cutting scraps 1 Secure the air tube f for cutting scraps with the cord holder g 2 Pass the air tube f for cutting scraps through the hole and out from the rear of the bed 3 Secure the air tube No 1 for the valve unit e and the air tube f for cutting scraps with the tube presser h 1069B 1070B 1071B 1072B ...

Page 142: ...ked on each air tube Insert the air tubes onto nipples with corresponding numbers Solenoid valve tubes and functions Label No Solenoid valve type 1 For upper thread take up 2 For upper thread trimming 3 For cloth spreading for auxiliary clamp arm 1 4 For cloth work clamp 5 For lower thread trimming 2 1 Auxiliary clamp arm is for 02 specifications only 2 The solenoid valve for label No 5 is not pre...

Page 143: ...6 ASSEMBLY RH 9820 134 Securing the air tubes Secure the air tubes and the harnesses with the cord holders k 2 places Tubes and harnesses from the feed base 1075B ...

Page 144: ...greasing and routing the oil tubes 1 to 8 should be done before carrying out the assembly procedure in 6 1 Cutter mechanism Refer to the detailed descriptions on pages 136 to 140 for details on A to J in the illustration 1029B A E C B J D H F I G ...

Page 145: ... plate assembly 27 Screws 4 pcs 28 Cord holder 5 29 Screw 30 Oil gauge window 31 Felt 32 Lower shaft cover assembly 33 Screws 2 pcs 34 Cord holders 5 35 Screw 36 Cord holders 10 2 pcs 37 Screws 2 pcs 38 Cord holder NK 3N 39 Screw 40 Sub tank assembly 41 Socket bolts 2 pcs 42 Tube clip spring 43 Oil tube 6 Push into sub tank 44 Cord holders 7N 4 pcs 45 Screws 4 pcs 46 Wick 47 Wick 48 Felts 2 pcs 49...

Page 146: ...Tapping in the oil pot window 1 Insert the oil tube 6 and the oil tube b coming from the oil plate assembly 26 into the oil tank 2 Check that the wick c is attached to the base of the oil tank and then tap in the oil gauge window 30 E Inserting the wicks 1 Insert the four wicks d into the arm relay hole e Insert the four wicks d securely into the holes as far as they will go A list of the four wic...

Page 147: ...m through the felts G 1 Secure the oil tube 43 with the cord holder 5 34 2 Install the two cord holders 10 36 as guides for routing the oil tube 43 3 Connect the oil tube 43 to the sub tank assembly 40 Make sure that the wick 5 does not cover the hole H Secure the oil tube g coming from the sub tank assembly 40 with the four cord holders 44 1035B 1036B 1037B Maintain a clearance ...

Page 148: ...the positions shown in the illustration 3 Insert the four wicks mentioned below into the bed hole h Thin wick i coming from sub tank assembly 40 Wick 6 and wick 8 j of 6 11 Looper mechanism Wick 4 k of 6 12 Spreader mechanism 4 Push the felt 49 into the bed hole h 5 Secure the oil tubes with the tube support B 50 1038B 1039B 1040B ...

Page 149: ...ough the underside of the bed 2 Pass the oil tube l through the hole m n in the bed and out from the looper base side 3 Push the felt 52 in through the hole o in the bed so that it is touching the wick 4 Secure the oil tube l with cord holder 5 53 1041B 1042B ...

Page 150: ... carrying out some adjustment be extremely careful to observe all safety precautions If any safety devices have been removed be absolutely sure to re install them to their original positions and check that they operate correctly before using the machine 7 1 Adjusting the heights of the spreaders and loopers Spreader height When viewed from directly above When viewed from the front 1 Remove the wor...

Page 151: ...t 1 Turn the cover 1 to open it 2 Use the accessory socket wrench to loosen the zigzag width adjustment nut 2 3 Move the adjustment screw 3 up or down along the slot to adjust The zigzag width becomes smaller as the adjustment screw 3 is moved upward The zigzag width becomes larger as the adjustment screw 3 is moved downward There are index marks at the 2 mm and 3 mm zigzag width positions Align t...

Page 152: ... of the needle is 15 mm 2 Sharpen the tip of the needle NOTE Sharpen the needle so that the tip of the needle is in the middle 3 Place a piece of paper 1 underneath the work clamps 4 Turn the upper shaft pulley 2 to set the needle to its lowest position 5 Move the needle up or down to adjust the installation position of the needle so that the tip of the needle makes a hole with a width of about 0 ...

Page 153: ...n the previous page 3 Move the feed base 4 forward to near the sewing start position by hand 4 Place a piece of paper 5 underneath the work clamps Secure the piece of paper so that it will not move 5 Turn the upper shaft pulley 6 to lower the needle so that it makes a small hole in the paper 5 6 Turn the upper shaft pulley 6 in reverse to return the needle to its original position needle up positi...

Page 154: ...ve the cap 11 11 Insert a flat tipped screwdriver into the hole and turn the zigzag eccentric pin 12 to adjust the zigzag base line position 12 Tighten the socket bolt 9 13 Repeat steps 4 12 until the inner zigzag base line is aligned correctly 14 Once adjustment is complete return the cap 11 cover 10 and face plate 8 to their original positions 0476B 0434B ...

Page 155: ...e bar to its lowest position at the inside sewing position 3 Use calipers to measure the length from the edge of the needle bar 4 to the top of the needle bar bush holder base 5 4 Next turn the upper shaft pulley 3 until the tip of the eye looper 6 is aligned with the needle center 7 5 In the same was as in step 3 use calipers to measure the length from the edge of the needle bar 4 to the top of t...

Page 156: ... 2 7 mm to the value obtained in step 2 above and set the width of the calipers to the resulting value 4 Turn the upper shaft pulley 1 until the edge of the needle bar 2 touches the edge of the calipers and stop turning the upper shaft pulley 1 at that point A Push against Should be no gap 5 Tilt back the machine head 6 Loosen the two set screws 5 of the lower shaft cam 4 7 With the upper shaft pu...

Page 157: ...s at the inside sewing position 3 Loosen the two screws 4 of the top and bottom needle bar clamps 3 4 Lower the needle bar 5 2 5 mm from the position where the tip of the eye looper 1 is aligned with the top edge of the needle hole 5 In order to make the needle bar turn smoothly adjust so that there is no play in the needle bar but so that there is enough of a gap between the needle bar clamps 3 a...

Page 158: ...otation is already adjusted at the time of shipment from the factory After making this adjustment carry out the adjustment procedures given in 7 9 Adjusting the spreader installation positions 7 8 Adjusting the needle guard If the needle count has been changed always be sure to check the position of the needle guard and adjust the position if necessary This adjustment should be made for both the i...

Page 159: ...s shown in the illustration below 2 Once adjustment is complete tighten the set screw 4 3 Loosen the set screw 8 and adjust the spreader stopper R 9 so that the top edge of the tip of spreader R 6 is aligned with the top edge of the tip of looper R 7 4 Once adjustment is complete tighten the set screw 8 NOTE Spreader L 1 and spreader R 6 should not protrude above the eye looper 2 or looper R 7 res...

Page 160: ... before the needle bar reaches its lowest position Adjustment can be carried out more easily if it is done in manual mode 1 Tilt back the machine head 2 Loosen the two screws 5 and then loose the set screw 6 3 Turn the eccentric pin 7 to adjust 4 After adjusting tighten the set screw 6 and the two screws 5 in that order NOTE Make sure that spreader R 1 and spreader L 2 do not obstruct the needle a...

Page 161: ...ht of the throat plate 8 as follows For 00 and 01 specifications Adjust so that the top of the throat plate 8 and the top of the needle plate 9 are at the same height For 02 specifications Adjust so that the top of the throat plate 8 is 0 4 0 6 mm lower than the top of the needle plate 9 NOTE If the position of the throat plate 8 is too high it may obstruct the movable knife and damage it Press do...

Page 162: ...er to Figure A Use a grinder to grind section b of the hammer so that cutting length 1 5 mm a 3 If installing a new hammer Push the hammer against the positioning pin 3 or the hammer spacer 4 and then tighten the knob screw 1 NOTE If the knife that was being used previously is replaced by a knife with a different number replace the hammer also If the same hammer is used for two or more different t...

Page 163: ...d hammer after the knife has been replaced If the same hammer is used it may damage the tip of the knife 7 13 1 Filing the cutting surface of the hammer The cutting pressure over the whole of the hammer should be uniform so that the material will be cut cleanly File the cutting surface of the hammer so that the knife incision will be uniform over the whole of the hammer The hammer can be filed unt...

Page 164: ...four screws 1 Push the hammer bracket 2 in the direction of arrow C and firmly upward in the direction of D shown in the illustration so that there is no gap between the hammer bracket 2 and the cutter driving shaft 3 and then tighten the screws This operation will position the hammer bracket 2 accurately by pushing the pin 4 of the hammer bracket 2 against the hole side of the cutter driving shaf...

Page 165: ... to move together as a single unit 1 Turn the cock 5 in the direction of the arrow to close it and stop the supply of air 2 Press the button 6 to release the air NOTE When the air is released the hammer may lower by its own weight 3 Remove the upper cover 7 and the face plate 8 4 Lower the cylinder rod 9 to align the screw A of the cutter driving shaft 2 with B inside the face plate 5 Use a commer...

Page 166: ... and the knife 2 and then loosen the socket bolt 3 and remove the knife 2 2 Place the new knife to be installed against the block stopper plate 1 and then tighten the socket bolt 3 NOTE When replacing the knife use the parameter settings to change the eyelet pattern to the pattern that corresponds to the knife number 4 that is given on one side of the knife Refer to 5 3 1 Parameter list in the ins...

Page 167: ...ing pressure This is so that the knife will not make several overlapping incisions in the hammer and so that the paper for checking the needle drop does not become pierced while adjusting the knife position 3 Press the AFTER key 2 on the operation panel to set the cutting method to cutting after sewing 4 Place a piece of paper 3 underneath the work clamps 5 Start the sewing machine and trace the n...

Page 168: ...ck stopper plate 6 against the knife and then tighten the screw 5 The block stopper plate 6 is a guide for showing the current position of the knife so be sure to move the block stopper plate 6 so that it is touching against the knife Tilt adjustment 11 Loosen the socket bolts 7 8 and 9 12 Turn the eccentric pin 10 to adjust Fine adjustments can also be made by turning centering on the pivot 11 13...

Page 169: ...x 3 8 4 2 x 4 9 Cutting before sewing Cutting after sewing 7 17 Adjusting the cutting pressure Set the cutting pressure to the minimum pressure that still allows the material to be cut Set to between 0 1 0 6 MPa It is set to 0 4 MPa at the time of shipment from the factory Adjustment method Turn the knob 1 of the hammer pressure adjustment regulator on the underside of the table to adjust the air ...

Page 170: ...ws 5 and the shoulder screw 6 and then remove feed base cover R 7 at the right side Viewed from directly to the right 3 Insert a block with a thickness of 12 mm or 16 mm or a gauge 10 in between the support point of work clamp R 8 and the needle plate 9 4 Loosen the screw 12 of the clamp driving lever 11 5 Push section B of crank lever B 1 upward so that the tip 13 is pressed against the end of cl...

Page 171: ...de work clamp Viewed from directly to the right Forward back adjustment 1 Loosen the socket bolt 1 and then move the position of the clamp arm 2 forward or back to adjust 2 Next adjust so that the side of work clamp R 3 is parallel to the side of the needle plate 4 3 Once adjustment is complete tighten the socket bolt 1 Sideways adjustment 1 Loosen the two set screws 5 and then adjust the sideways...

Page 172: ...nge the value simply by pressing the keys 5 2 Press the TEST key 6 to turn on test mode and then start test operation Refer to 5 4 Checking the sewing pattern in test mode in the instruction manual 3 Press and hold the start switch 7 until the feed base moves to the position where the straight section of the sewing shape is sewn and then release the start switch 7 Straight section when using a 2 p...

Page 173: ...ess the start switch 3 Check that the feed base moves and that the work clamp plates 1 at left and right both open This opening amount is a Cloth opening amount b a 3 Use calipers to measure a at both left and right 4 Turn off the power for the sewing machine The gap a will become wider This opening amount is b 5 Lower the work clamps and then use calipers to measure b at both left and right Cloth...

Page 174: ...ad feeding amount It is necessary for enough of an upper thread feeding amount to be maintained so that the amount of upper thread is sufficient for stitches to be formed accurately at the sewing start NOTE The thread take up lever 1 operates at the same time as sewing ends and it stops operating at the same time as the feed base starts moving when the start switch is pressed More thread Less thre...

Page 175: ...n the upper shaft pulley and check the condition of the lower thread If adjustment is necessary 3 Turn off the power and then tilt back the machine head 4 Loosen the two screws 1 and then move lower thread guide C 2 in the direction of the arrow to adjust If it is moved to the right the lower thread feeding amount will increase and if it is moved to the left the amount will decrease 5 Once adjustm...

Page 176: ...he needle to 0 1 0 4 mm 3 Turn the upper shaft pulley to set the needle to its highest position needle up stop position at the outside sewing position 4 Loosen the screw 4 and then adjust the position of the upper movable knife 1 so that it is in between the throat plate 5 and spreader L 6 without touching either of them 5 Move the upper movable knife 1 sideways by hand and check that it does not ...

Page 177: ...n it is at the maximum zigzag width for the outside sewing position 1 Loosen the nut 1 2 Turn the screw 2 to adjust a in the illustration to 12 mm 3 Turn the looper base 3 and check that the thread trimmer lever bracket 4 moves underneath the thread trimmer hammer 5 without obstructing any other parts 4 Once adjustment is complete securely tighten the nut 1 Viewed from the front 0545B 0546B ...

Page 178: ... 4 3 Install the new movable knife and then tighten the three screws 3 Fixed knife replacement 4 Remove the two screws 5 and then remove the fixed knife 6 5 Install the new fixed knife 6 fixed knife plate spring 7 fixed knife plate spring U 8 and thread guide plate 9 on top of each other in that order and then tighten the two screws 5 After replacing the knives carry out the adjustments from 7 25 ...

Page 179: ... movable knife 4 first start touching is immediately above the mark 5 4 Once adjustment is complete securely tighten the two screws 2 7 25 3 Adjusting the meshing amount 1 Turn the thread trimmer link lever 1 in the direction of the arrow until it touches the screw 2 2 Loosen the socket bolt 3 3 Adjust the position of the thread trimmer arm 7 so that the tip of the fixed knife 6 is directly above ...

Page 180: ... screws 5 and then move the thread nipper assembly 3 along the dotted line A in the illustration in the direction of the arrow B to adjust Adjust so that the gap a between the thread nipper assembly 3 and the thread handler 7 is as narrow as possible without the two parts touching when the thread trimmer arm 6 is turned in the direction of the arrow C NOTE If the gap a is too wide problems with th...

Page 181: ...pen by 0 3 mm or more when the thread nipper opener 4 pushes down on the opener pin 10 b Thread nipper D 1 should close immediately before the thread is trimmed 0 3 mm or more c Thread nipper D 1 should not open when the thread trimmer arm 6 returns after thread trimming so that the thread nipper opener 4 returns without going over the opener pin 10 3 Once adjustment is complete securely tighten t...

Page 182: ...out in manual mode the lower thread trimming operation can be checked step by step which will make adjustment easier 1 Use the parameter settings to set the stitch pitch to 2 0 mm and reduce the total number of stitches Refer to 5 3 1 Parameter list in the instruction manual 2 In manual mode depress the start switch and then turn the upper shaft pulley to sew manually as far as the final stitch Re...

Page 183: ...the shoulder screw 4 5 Adjust the cutting pressure see below and then tighten the nut 3 6 Install work clamp plate U 2 7 26 2 Adjusting the cutting pressure Adjust the cutting pressure to the minimum pressure at which thread trimming can be carried out cleanly 1 Loosen the nut 1 2 Turn the shoulder screw 2 to adjust the cutting pressure NOTE If the shoulder screw 2 is tightened as far as it will g...

Page 184: ... the movable knife driving plate 4 so that the tip A of movable knife R 3 and the corner C of the needle plate 2 are aligned 4 Turn thread trimmer lever arm B 7 until the thread trimmer link lever J assembly 5 touches against the screw 6 and then tighten the screw 1 5 Once adjustment is complete install work clamp plate U NOTE Check that the movable knife driving plate 4 and thread trimmer lever a...

Page 185: ...res that the material does not move during thread trimming in order to maintain a stable thread length after trimming 1 Loosen the socket bolt 1 2 Adjust the installation position of the sub clamp wrist 4 with respect to the article being sewn so that the button clamp 2 moves above the needle plate 3 3 Once adjustment is complete securely tighten the socket bolt 1 0530B ...

Page 186: ...et back varies depending on the size Advantage The feed base position when the material is set back s the same for all sizes L specifications changed replacement parts Needle plate L and R Work clamp L and R Total 4 points Needle plate L and R Movable knife L and R Specification harness Work clamp L and R Total 7 points Other settings Settings for memory switch No 851 changed 00 01 02 L2634 L3442 ...

Page 187: ...the material is set back and when the knife is lowered the position of the feed base varies depending on L specifications size Knife position shifted Feed base shifted Feed base shifted L1826 Cutting range Cutting range Cutting range Cutting range Cutting range ...

Page 188: ...rns back from 180 degrees to 0 degrees after the gimp has been trimmed gimp thread guide C J 2 pulls the gimp to make it come out Adjustment of the gimp trailing length is necessary in the following cases When the sewing length has been changed the gimp is trimmed at the feed base home position so the length of b will change As a result the gimp trailing length a will also change When the type of ...

Page 189: ...oove 3 in the throat plate 2 2 Check that the lower thread presser 1 does not cover the groove at the front of the throat plate 2 If the groove is covered loosen the nut 5 and then turn the screw 6 to adjust 3 Check that the front of the throat plate 2 and the lower thread presser 1 are overlapping by 0 5 1 0 mm after thread trimmer lever bracket B 7 has operated If adjustment is required remove t...

Page 190: ...ve A in the upper shaft crank at this time so that the upper shaft is secured and cannot be turned 6 Remove the upper shaft pulley 7 7 Remove the rubber cap 8 and then insert the accessory pin 9 into the hole in the take up roller cam 2 8 Push the take up roller cam 2 against the edge of the bearing B and then tighten one of the set screws 3 9 Pull out the pins 6 and 9 and then tighten the other s...

Page 191: ... the needle 3 Turn the looper base 5 by hand and check that the distance A between the tip of eye looper 1 and the needle when the looper base 5 is turned to 0 is the same as the distance B when the looper base is turned to 180 4 If there is a large difference between distance A and distance B loosen the three bolts 6 and move the needle bar 7 gently forward or back to adjust the position of needl...

Page 192: ...the nut 5 and turn the bolt 3 to adjust so that the clearance between the end of the bolt 3 and the solenoid setting plate 4 is 13 8 mm 2 With the upper thread tension release solenoid 1 installed to the upper cover 6 check that the opening amount for the tension discs 7 is 0 5 1 mm when the plunger 2 is pushed all the way in Section A should be sealed at this time 0754B ...

Page 193: ...e 2 by hand or push the plunger 3 of the tension release solenoid from the back to turn the lower thread release plate 2 until the tension release pin 4 is sitting on stepped part A 3 Turn the tension stud D 6 to adjust the height so that the opening amount for the tension discs 5 is 1 0 3 mm at this time 4 Tighten the nut 1 0781B ...

Page 194: ... right work clamp plates Z 2 While holding down the and keys 1 push the POWER switch at the ON side 2 3 Press the start switch 3 The motors will carry out home position detection and then the sewing machine will switch to home position adjustment mode At this time X will appear in the display A 4 Press the or key 4 to change the display A to θ When θ is displayed the X and Y feed motors will be tu...

Page 195: ...home position detection operation will be carried out and the offset value B will be saved NOTE If you continue to the next step without pressing the ENTER key 6 the offset value will not be changed 7 Check that the bed reference line a and the looper base reference line 0 b are aligned If they are not aligned repeat steps 5 and 6 until they are aligned 8 Press the TEST key 7 Home position adjustm...

Page 196: ...e POWER switch at the ON side 2 3 Press the start switch 3 The motors will carry out home position detection and then the sewing machine will switch to home position adjustment mode At this time X will appear in the display A 4 Press the or key 4 as necessary to change the display A so that Y appears X or Y should be displayed while this adjustment is carried out When X is displayed The motor θ fo...

Page 197: ... by hand and measure the distances a and b 5 2 When you press the or key 1 to change the offset value B the feed base 7 will move as the keys are pressed Repeat this step until distances a and b are equal The setting range is 2 00 2 00 mm in units of 0 05 mm Adjusting the Y home position Carry out the following adjustments so that the distance c between the rear of the feed base 7 and the hollow i...

Page 198: ...justing the needle up signal home position for the upper shaft and upper shaft motor NOTE Before carrying out this adjustment check that the adjustments in 6 18 Upper shaft motor mechanism Standard installation of upper shaft motor unit and belt tension adjustment and 6 10 Lower shaft mechanism Belt upper shaft lower shaft installation and belt tension adjustment have been carried out correctly Af...

Page 199: ...over 11 from the upper shaft motor 10 7 Loosen the bolt 12 for the needle up magnet of the motor by 90 only NOTE Do not loosen the screw by more than 90 If it is loosened too much the parts may touch the P C board and damage may result 8 Move the position of the slot 13 to the point where the panel display B switches from ON to OFF and tighten the bolt 12 at that point 9 Press the POWER switch at ...

Page 200: ...et value A is displayed 3 Press the start switch 3 again until the upper shaft begins to move 4 After the upper shaft stops check that the arm reference line a and the upper shaft pulley reference line b are aligned If they are not aligned Press the or key 4 to change the offset value A and then repeat step 3 The setting range is 5 10 in units of 1 If they are aligned Continue to the next step 5 P...

Page 201: ...ion parts ready Ref No Code Qty Part name 34 SA7152001 1 Sub clamp wrist L 9 10 SA5683001 2 Air hose outer dia 4 mm inner dia 2 5 mm length 750 mm Be sure to remove the stickers A before using the air hoses 9 and 10 Top 1 Stop the air and then bleed the air Refer to 3 16 Adjusting the air pressure in the instruction manual 2 Remove the feed base unit 1 from the bed Refer to 5 3 Feed mechanism 3 Di...

Page 202: ...and pull out the shaft 12 8 Insert the shaft 12 into the sub clamp S holder 13 in the direction shown in the illustration and then install retaining ring C 11 9 Set the joint 14 and the cylinder rod 15 so that they are facing as shown in the illustration Top Bottom 10 Insert the shaft 16 of the sub clamp connecting rod into the hole in the feed base and then install retaining ring C 6 11 Tighten t...

Page 203: ...r bead bands 17 as shown in the illustration 14 Loosen the socket bolt 18 and then remove the sub clamp wrist 19 15 Remove the spring 20 16 Remove retaining ring C 21 and then remove the sub clamp arm 22 17 Remove retaining ring C 23 loosen the two set screws 24 and then remove clamp support shaft J 25 in the direction of the arrow Continued on next page 1171B 1172B Viewed from the underside Work ...

Page 204: ...tween the clamp shaft holder 29 and clamp lever L 30 is 2 5 0 5 mm Check that the sides of work clamp L 31 and needle plate L 32 are aligned at this time If they are not aligned loosen the socket bolt 33 and adjust 22 Install the button clamp 35 to the optional sub clamp wrist L 34 23 Install sub clamp wrist L 34 to the sub clamp arm 22 and then secure it by tightening the socket bolt 36 Refer to ...

Page 205: ...install retaining ring C 23 26 Tighten the two set screws 24 so that the clearance between the clamp shaft holder 37 and clamp lever R 38 is 2 5 0 5 mm Check that the sides of work clamp R 39 and needle plate R 40 are aligned at this time If they are not aligned loosen the socket bolt 41 and adjust 1175B Viewed from the underside ...

Page 206: ... the following operations Opening and closing the control box Replacing fuses Inserting and disconnecting connectors Measuring resistance values Any other tasks that may involve touching components inside the control box Some inspection items require the control box to be open when the power is turned on and voltages are measured At such times be extremely careful never to touch anywhere other tha...

Page 207: ...e air intake slots in the cover and control box 2 places should be cleaned about once a month Conversion transformer Two types are used depending on the power supply voltage specifications This breaks down the power supply voltage into the voltages that are required for control operations NF P C board This eliminates the electrical interference that is generated by the power supply line Panel P C ...

Page 208: ...ed θ pulse motor does not operate and E220 is displayed F3 Fuse 6AFB Glass tube fuse 6A 250V SA3759 001 Thread trimming solenoid or digital tension tension release solenoid does not operate and thread trimming or thread tightening problems occur F4 Fuse 3AFB Glass tube fuse 3A 250V 616167 001 Communication problem with PMD P C board and E403 is displayed F5 Fuse 3AFB Glass tube fuse 3A 250V 616167...

Page 209: ... connectors that are not inserted correctly or which are contacting poorly As a result check that all connectors are inserted correctly and that the pins and wires are crimped properly before carrying out problem diagnosis 8 4 1 Connector positions Main P C board 1 This is a spare signal for special orders 1200B ...

Page 210: ...8 ELECTRICAL MECHANISM 201 RH 9820 PMD P C board Power supply motor P C board 0693B 4593Q ...

Page 211: ...8 ELECTRICAL MECHANISM 202 RH 9820 Panel P C board 0694B ...

Page 212: ...briefly but does not detect the home position correctly E200 or E210 is displayed Problems with feed mechanism moving forward and back E210 or E211 is displayed Problems with feed mechanism moving to the left and right E200 or E201 is displayed Feed motor does not operate E200 is displayed θ pulse motor mechanism Trouble symptom Connector No and position The θ pulse motor operates but the home pos...

Page 213: ...d and lower thread solenoid do not operate No error displayed Sewing operations Trouble symptom Connector No and position Power indicator does not illuminate and sewing machine does not operate Operation is unstable E403 is displayed when the power is turned on and the sewing machine does not start 5244Q 4717Q 0757B ...

Page 214: ...light does not illuminate Sewing machine does not start when foot switch is depressed Treadle Work clamp drops when depressed to the 1st step Sewing machine starts when depressed to the 2nd step 2 pedal Work clamp drops when work clamp switch left is depressed Sewing machine starts when start switch right is depressed After the power is turned on E055 is displayed After the power is turned on E450...

Page 215: ...ing to 8 4 Description of connectors 2 Diagnosis flowchart Carry out diagnosis while following the steps in 8 5 2 Diagnosis flowchart on the next page and if a problem is reached continue to the next procedure 3 Remedy Refer to 8 5 3 Remedy for the item that corresponds to the problem Carry out the inspections for the problems in the order of the numbers in the Cause column NOTE When replacing the...

Page 216: ...MECHANISM 207 RH 9820 8 5 2 Diagnosis flowchart Description of symbols Setting and status Switch operation Continued on previous next page Judgment OFF Power switch OFF Problem symbol in the 8 5 3 Remedy lists 0760B ...

Page 217: ...8 ELECTRICAL MECHANISM 208 RH 9820 0761B ...

Page 218: ...8 ELECTRICAL MECHANISM 209 RH 9820 0762B ...

Page 219: ...ations 1 OK if there is continuity between pins 1 8 2 8 3 8 4 8 5 8 and 6 8 of the 8 pin connector coming out from the transformer Fig A 2 OK if there is continuity between pins 1 2 3 4 and 5 6 of the 6 pin connector coming out from the transformer Fig C 3 OK if there is continuity between pins 1 2 and 4 5 of the 5 pin connector coming out from the transformer Fig D For 380V 400V specifications 1 ...

Page 220: ...ct connector P17 M MOTOR of the main P C board turn on the power and then measure the voltages between the pins at the cord side connector OK if the voltages are as shown in the table below After measuring turn off the power wait 5 minutes or more and then insert P14 Power supply motor P C board 6 Malfunction of main P C board With connector P17 M MOTOR inserted into the main P C board turn on the...

Page 221: ...sensor and needle up signal input while referring to 2 6 Input checking method 5 If E403 is displayed there is a poor connection between the main P C board and the PMD P C board 1 Check that connector P1 MAIN is inserted into the PMD P C board 2 Check if there is a harness short circuit Main P C board PMD P C board 6 If E401 is displayed there is a poor connection between the main P C board and th...

Page 222: ...rd side connector OK if normally Ω and 0 Ω when the foot switch is depressed Foot switch Foot switch cord assembly Hand start switch Problem 4 Feed base home position is shifted Cause Inspection Remedy Adjustment Replacement if a malfunction Incorrect home position adjustment Switch to home position adjustment mode and adjust the position of the feed base while referring to 7 34 Adjusting the feed...

Page 223: ...e between pins 1 2 of the cord side connector OK if approx 100 V After measuring turn off the power wait 5 minutes or more and then insert P9 4 Disconnect connector P2 POWER2 from the PMD P C board and then measure the voltage between pins 1 2 of the cord side connector OK if approx 16 V After measuring turn off the power wait 5 minutes or more and then insert P2 5 Check that connector P1 MAIN is ...

Page 224: ...3 If a metallic object is brought close to the Y axis home position sensor and the LED inside the sensor does not illuminate there is a malfunction of the sensor Y axis home position sensor Problem 7 When the start switch is depressed an error code E220 is displayed Cause Inspection Remedy Adjustment Replacement if a malfunction 1 If the θ pulse motor does not move and E220 is displayed there is a...

Page 225: ...ement if a malfunction 1 Malfunction of sewing machine motor cord Check connector P4 UVW of the power supply motor P C board and the sewing machine motor connector Motor cable 2 If the fuse F1 on the power supply motor P C board is blown there is a malfunction of the main P C board 1 If the fuse F1 is blown check the resistance values between all pins of the connector P4 UVW and the pins of the fu...

Page 226: ...nerating strong electrical interference Motor assembly CCD 9820 2 If E150 is displayed after the sewing machine operates the motor is abnormally overheating 1 Turn off the power and let the sewing machine stand for 30 minutes or more 2 Turn the power back on OK if operation is normal Problem 12 Upper thread trimming does not operate Cause Inspection Remedy Adjustment Replacement if a malfunction M...

Page 227: ...ion of valve or valve harness Check that connector P12 AIR1 is inserted into the main P C board Valve harness Problem 15 Hammer does not operate when set to cutting after sewing Cause Inspection Remedy Adjustment Replacement if a malfunction Malfunction of valve or valve harness Check that connector P25 AIR2 is inserted into the main P C board Valve harness ...

Page 228: ... after the power was turned on or connection of start switch is defective Turn off the power and check if the start switch is pressed If the start switch is not being pressed check the switch connector P6 at the main P C board 200 E034 Work clamp switch is being pressed Release the work clamp switch so that it turns off 1 E035 Work clamp switch was depressed or connection of work clamp switch is d...

Page 229: ...e synchronizer connector P5 at the power supply motor P C board 201 217 E132 Problem detected with sewing machine motor operation Turn off the power and then turn the upper shaft pulley and check if the sewing machine has locked up Check that the upper shaft motor connector P4 and synchronizer connector P5 are connected at the power supply motor P C board 201 E133 Sewing machine motor stopping pos...

Page 230: ...position sensor connection Turn off the power and then check that the Y feed motor connector P8 is connected at the PMD P C board and that the Y pulse motor encoder connector P4 and sensor connector P8 are connected at the main P C board 200 201 215 E211 Y feed motor stopped due to a problem Turn off the power and then check if there are any problems in the Y feed direction E220 θ feed motor home ...

Page 231: ... then check that connector P17 on the main P C board and connector P6 on the power supply motor P C board are properly connected 200 201 E420 No CF card is inserted No messages are displayed Turn off the power and then insert a CF card into the CF card slot of the control box E422 Error occurred while reading CF card Check the data on the CF card E424 Insufficient free space on CF card Use a diffe...

Page 232: ... trimmer does not operate or lower thread trimming sensor is faulty Turn off the power and then check that the valve harness connector P12 and sensor connector P10 are inserted at the main P C board 200 E650 Hammer is lowered or hammer position sensor is faulty Turn off the power and then check that the hammer valve harness connector P25 and hammer position sensor connector P3 are inserted at the ...

Page 233: ... trying to sew a straight buttonhole while there is material under the straight buttonhole sensor Press the RESET key 5 E950 No response from feed plate home position sensor while feed plate is being driven Turn off the power and then check that connector P23 and connector P25 on the main P C board are properly connected 5 E951 No response from feed plate left sensor while feed plate is being driv...

Page 234: ...ion manual Needle and looper adjustment is incorrect Adjust the clearance between the needle and looper the needle bar height or the looper and spreader height 141 148 149 Needle looper spreader throat plate or thread path is damaged Repair or replace the respective part s Thread breaks Thread is not threaded correctly Thread the thread correctly Instruction manual Upper thread tension is too stro...

Page 235: ... full stroke because air pressure is too weak Adjust the air pressure Instruction manual Movable knife position is incorrect Adjust the position of the movable knife or the thread handler 170 173 175 Lower thread is not cut Cutting pressure for lower thread trimming is too weak Adjust to an appropriate cutting pressure 170 174 Lower thread is not being held Adjust the lower thread nipper 01 specif...

Page 236: ...SERVICE MANUAL RH 9820 I6100920B 2007 03 B 1 Printed in Japan ...

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