Brother Z-8550A Service Manual Download

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15. ERROR CODES

Z-8550A, 8560A

115

<Communication and memory-related errors>

Code

Cause and remedy

Err 401

Communication error with motor CPU was detected when the power was turned on. Turn off the power switch
and then turn the power back on again.

Err 403

Connection error with needle zigzag PMD P.C. board detected when power was turned on. Turn off the power
switch, and then check that connector P1 on the PMD P.C. board and connector P31 on the main P.C. board
are properly connected.

Err 411

Communication error with motor CPU detected. Turn off the power switch and then turn the power back on
again.

Err 413

Communication error with needle zigzag PMD P.C. board detected. Turn off the power switch and then turn the
power back on again.

Err 420

No CF card is inserted.

Err 421

Program number on CF is invalid, or no data exists.
Change program No.

Err 422

Error occurred while reading CF card.
Check the data on the CF card.

Err 424

Insufficient free space on CF card. Use a different CF card.

Err 425

Error occurred while writing to CF card.
Use the specified type of CF card.

Err 427

R/W key unneeded error

Err 430

Problem with flash ROM data on main P.C. board.
Turn off the power switch and then turn the power back on again.

Err 440

Data cannot be backed up to EEPROM.
Turn off the power switch and then turn the power back on again.

Err 441

Data cannot be read from EEPROM.
Turn off the power switch and then turn the power back on again.

Err 442

Incorrect data initialized into EEPROM.
Turn off the power switch and then turn the power back on again.

Err 450

Problem with data in machine head memory. (Model selection cannot be read.)
Turn off the power switch and then turn the power back on again.

Err 452

Machine head memory is not connected.
Turn off the power switch and then turn the power back on again.

Err 474

Internal memory is full and copying is not possible.

<Data editing-related errors>

Code

Cause and remedy

Err 510

Problem with sewing data. (Invalid code in sewing data.)
For additional data, re-read the data from the CF card.

Err 512

Number of stitches exceeds allowed maximum.

Summary of Contents for Z-8550A

Page 1: ...Z 8550A Z 8560A Please read this manual before making any adjustments ELECTRONIC DIRECT DRIVE ZIGZAG LOCK STITCHER ELECTRONIC DIRECT DRIVE ZIGZAG LOCK STITCHER WITH THREAD TRIMMER SERVICE MANUAL ...

Page 2: ...ly read the 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: ...sult in death or severe 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 ...

Page 4: ...ause 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 more than 50 kg The installation should be carried out by two or more people Do not connent the power cord until installation is complete The mach...

Page 5: ...ld the machine head when tilting it back or returning it to its original position If only one hand is used the weight of the machine head may cause your hand to slip and your hand may get caught If an error occurs in machine or if abnormal noises or smells are noticed immediately turn off the power switch Then contact your nearest Brother dealer or a qualified technician If the machine develops a ...

Page 6: ... Never touch the knife on the face plate when opening the thread takeup guard cover otherwise injury may result 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 When removing the needle plate auxiliary needle plate and knife unit use a screwdriver that matches the size of the scr...

Page 7: ...is pressed by mistake when using the correction sewing function the needle will move in a zigzag motion while the machine is operating and injury may result 6 Do not touch the thread takeup or the knife otherwise injury may result 3316M Oil pan 3317M For Europe ...

Page 8: ...CF card 28 4 8 Updating the control program version 29 4 8 1 Control program version updating procedure 29 4 8 2 Restoring the control program if an error occurs during version updating 30 4 9 Writing error log data to CF cards 31 5 MECHANICAL DESCRIPTIONS 32 5 1 Needle bar and thread take up mechanisms 32 5 2 Lower shaft and shuttle race mechanisms 33 5 3 Zigzag mechanism 34 5 4 Presser foot mech...

Page 9: ...22 Adjusting the tension of the plate spring 8560A only 83 9 23 Adjusting the thread trailing length after thread trimming 8560A only 83 9 24 Adjusting the thread wiper 8560A only optional device 84 10 APPLYING GREASE When GrEASEUP appears 85 10 1 To continue sewing temporarily without applying grease 85 10 2 Applying grease 86 10 3 Resetting the cumulative operating time 87 11 ELECTRICAL MECHANIS...

Page 10: ...er consumption 400 VA Control circuit Microprocessor 1 Used for sewing condensed stitches and backtack stitches 2 If replacing gauge parts and then changing the maximum feed amount setting the maximum setting is 5 mm Refer to 8 CHANGING THE FEED AMOUNT TO LONG STITCH SPECIFICATIONS 3 At the time of shipment from the factory the maximum sewing speed is set to 4 000 rpm If using a sewing speed highe...

Page 11: ...the column marked with a reflection pattern can be sewn by stopping the sewing machine and then pressing the actuator Refer to 6 2 2 Setting the sewing pattern of the instruction manual Standard scallop 24 stitches Scallop left Even scallop 24 stitches Reflection pattern Crescent scallop 24 stitches Even scallop 12 stitches Standard scallop 24 stitches Scallop right Even scallop 24 stitches Blind ...

Page 12: ...st of memory switch settings 4 The buzzer will sound for approximately 1 second and the setting value will be accepted The main display will return to the stitch number display orange Press for 2 seconds or more NOTE If the treadle is depressed before the ENTER key is pressed the main display will return to an orange display and the setting value will not be changed If the memory switch number is ...

Page 13: ...s 1 None 7 0 0 1 End backtacking speed 0 Limited by speed bar key setting 1 Not limited by speed bar key setting 9 0 0 1 End backtacking sewing speed 0 Speed can be set independently from start backtacking speed 1 Speed is set to start backtacking speed 12 0 0 1 Presser foot condition when treadle is returned to neutral position after thread trimming 0 Presser foot is lowered it is not lowered whe...

Page 14: ... B N backtacks 1 Stitch Nos A B A B N backtacks doubled 22 0 0 1 End backtacking operation 0 Stitch Nos C D 1 Stitch Nos C D C D N backtacks doubled 26 0 0 1 Speed when changing to end backtacking 0 Speed decelerates to low speed then end backtacking starts 1 Speed decelerates to end backtacking speed then end backtacking starts allows shortening of cycle time 27 0 0 1 Continuous backtacking opera...

Page 15: ...set to 0 39 12 10 12 Sensing voltage constant from presser foot lowering command until presser foot lifter solenoid momentarily turns on only enabled when No 35 is set to 0 If it is set to 10 the response will be fastest and the operating noise will be loudest 40 0 0 1 Operation when presser foot is lifted and lowered using knee switch This setting is only enabled when DIP switch No 1 is set to OF...

Page 16: ...itches Counting units for stitch counter display 0 No counting operation 1 100 Display counts down by the set number of stitches 54 1 0 2 Stitch counter warning operation when icon is displayed 0 Starting using treadle is always enabled 1 Starting using treadle prevented thread trimming is possible when treadle is depressed backward 2 Operation using treadle fully prevented when treadle is returne...

Page 17: ... degrees 345 345 degrees Quick reverse solenoid on timing during start backtacking continuous backtacking 75 30 degrees 345 345 degrees Quick reverse solenoid off timing during start backtacking continuous backtacking 76 30 degrees 345 345 degrees Quick reverse solenoid off timing during end backtacking 77 15 degrees 345 345 degrees Quick reverse solenoid on timing during end backtacking Enabled w...

Page 18: ...oint for standing operation variable speed pedal 88 0 0 2 Treadle speed curve 0 Constant 1 Curves downward 2 Curves upward Settings indicated with are enabled after the power is turned off and then back on again When the neutral position for the treadle is taken as 0 depressing the treadle forward results in values and depressing the treadle backward results in values and these are added to or sub...

Page 19: ...erns 5 to 9 are selected 2 Returns to start of patterns when plain 2 step or 3 step zigzag is selected patterns 2 to 9 Plain 2 step and 3 step zigzag will be sewn at the position set by No 105 105 0 0 1 Sewing start position when plain 2 step or 3 step zigzag is selected When stopped at left Free When stopped at right 0 Left edge Left edge Right edge 1 Right edge Right edge Left edge This setting ...

Page 20: ...ame label sewing is complete 115 1 0 1 0 ms 0 1 4 9 0 1 4 9 ms On time for solenoid type presser lifter solenoid during chopping Enabled when No 37 is set to 0 116 2 5 2 5 ms 0 1 4 9 0 1 4 9 ms On time for pneumatic type presser lifter solenoid during chopping Enabled when No 37 is set to 1 117 1 1 1 1 ms 0 1 4 9 0 1 4 9 ms On time for quick reverse solenoid during chopping 118 85 85 ms 40 100 40 ...

Page 21: ... on timing Angle from needle drop signal 138 40 degrees 0 120 degrees Upper thread feeding on timing Angle from needle drop signal 139 40 ms 0 40 ms Thread trimmer off timing Time from needle up stop 140 40 ms 0 100 ms Upper thread feeding off timing Time from needle up stop 141 30 ms 5 60 ms Quick reverse solenoid on response time for T stitches 142 30 ms 5 60 ms Quick reverse solenoid off respon...

Page 22: ... following memory switch numbers are used for displaying maintenance information No Explanation of display details 132 Cumulative power on time Actual time Displayed time x 10 hours 133 Cumulative running time Actual time Display xxxx x 10 hours 135 ROM version x xxx ...

Page 23: ...T key on the operation panel turn on the power switch 1 2 The operation panel settings will be returned to their factory defaults After this operation panel and treadle operation will be possible Initialization of speed data only 1 While holding down the MAX key on the operation panel turn on the power switch 1 2 The speed data will be set to the speed data for the machine head detection unit Afte...

Page 24: ...sible Initialization of custom patterns only 1 While holding down the CF key on the operation panel turn on the power switch 1 2 The custom pattern data in the internal memory will be displayed If there is no custom pattern data in the internal memory the buzzer will sound twice Deleting all custom pattern data Press and hold the RESET key After this press the ENTER key The initial display will ap...

Page 25: ...ferent speed specifications The operation panel and treadle cannot be used for approximately 4 seconds in all these cases After approximately 4 seconds iniT rPM will appear in green in the main display This indicates that the sewing machine s speed settings have been initialized NOTE If any of the settings relating to the sewing machine s sewing speed are different from the setting data in the mac...

Page 26: ...ber 1 and the error code 2 will appear in the main display Refer to 3 4 2 Error history display examples for details on reading the display 3 To switch the error history display in order of errors The error history will switch in order of the errors 4 To display the time stamp for the error history that is currently being displayed The time stamp will be displayed The last seven digits 3 show the ...

Page 27: ...wer switch 1 After the following display appears keep the Speed key pressed down until the buzzer makes a short beep 2 Select the program that you would like to check the version for The display switches between a symbol 2 to indicate the program and the current version 3 each time the key is pressed The programs indicated by the symbols 2 are as follows Symbol 2 Program 1MN Main program 2 MT Moto...

Page 28: ...p signal ON OFF position for upper shaft motor Turn the pulley by hand Needle position signal Needle down signal ON Needle down icon Needle down signal ON OFF position for upper shaft motor Turn the pulley by hand Z phase signal ON Zigzag width reference line LED Home position signal ON OFF position for needle zigzag motor Signal should turn ON OFF near the needle bar center position when the need...

Page 29: ... LED High speed switch ON signal position Turn on high speed switch for standing operation pedal Low speed switch ON CF LED Low speed switch ON signal position Turn on low speed switch for standing operation pedal Thread trimming switch ON Scallop right LED Thread trimming switch ON signal position Turn on thread trimming switch for standing operation pedal Standing operation pedal Presser foot Sw...

Page 30: ...OFF Disabled models for other than Europe ON Key lock function available 3 Operation panel key lock OFF Key lock function not available 4 Always set to OFF 3 1 If the knee switch is used to momentarily lower the presser foot the presser foot cannot be raised by operating the treadle when the sewing machine has stopped In such cases the presser foot can only be lifted and lowered using the knee swi...

Page 31: ... 50 50 so that the needle is at the home position The needle bar will move in accordance with the setting value When the setting has been changed the orG display will change from illuminated to flashing 4 Move the needle bar to the needle up stop position and then press the RESET key Home position detection will be carried out After detection is complete the orG display will stop flashing and illu...

Page 32: ...ps of important data Be sure to 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 loading from or writing t...

Page 33: ...e list 4 Select the mode The mode changes each time the key is pressed Read write mode list Mode No Symbol name Setting items r 1 SEd Additional sewing data is read from the CF card into the sewing machine w 2 SEd Additional sewing data is written from the sewing machine to the CF card r 3 MEM Memory switch settings are read from the CF card to the sewing machine w 4 MEM Memory switch settings are...

Page 34: ...rs to be read ALL 1 99 If ALL is displayed all additional sewing data will be read at once 5 The buzzer will sound and the selected sewing data will be read from the CF card and copied into the sewing machine s internal memory When End is displayed the process is complete Reading complete 6 Press the TEST key to exit read write mode 7 Set the power switch 1 to OFF and remove the CF card 0195B 0191...

Page 35: ... numbers to be written ALL 1 99 If ALL is displayed all additional sewing data will be read at once 5 The buzzer will sound and the selected sewing data will be copied from the internal memory onto the CF card When End is displayed the process is complete Writing complete 6 Press the TEST key to exit read write mode 7 Set the power switch 1 to OFF and remove the CF card 0200B 0198B 0199B 0211B 019...

Page 36: ...aration for reading writing data 2 Select r 3 in CF data read write mode 3 The buzzer will sound and the memory switch data will be loaded from the CF card and copied into the sewing machine s internal memory Reading Finished when End is displayed 4 Set the power switch 1 to OFF and remove the CF card 0202B 0203B 0197B 0196B ...

Page 37: ...r reading writing data 2 Select w 4 in CF data read write mode 3 The buzzer will sound and the memory switch data will be copied from the internal memory onto the CF card Writing Writing complete 4 Press the TEST key to exit read write mode 5 Set the power switch 1 to OFF and remove the CF card 0204B 0205B 0211B 0195B 0196B ...

Page 38: ...ion updating in progress Complete when End is displayed NOTE Version updating takes a maximum of 60 seconds The time taken will vary depending on the manufacturer and storage capacity of the CF card being used Never remove the CF card or turn off the power switch while reading of the CF card is in progress If the filename and folder name for the control program are incorrect error Err 421 will be ...

Page 39: ... will not operate correctly If this happens restore the control program by the following procedure 1 Insert the CF card containing the control program data into the CF card slot 2 Set the power switch 1 to ON The operation panel will switch off and the version updating will be carried out When the power turns back on the updating is complete 3 Set the power switch 1 to OFF and remove the CF card 4...

Page 40: ...r reading writing data 2 Select w 8 in CF data read write mode 3 The buzzer will sound and the error log data will be copied from the internal memory onto the CF card Writing Writing complete 4 Press the TEST key to exit read write mode 5 Set the power switch 1 to OFF and remove the CF card 0209B 0210B 0211B 0195B 0196B ...

Page 41: ...flow of operations that occur separately from each other number indicates only the names of parts They are not part of the indication of operation flow 5 1 Needle bar and thread take up mechanisms 1 Motor 2 Upper shaft 2 Pulley 3 Thread take up crank 4 Needle bar connecting rod shaft 5 Needle bar connecting rod 5 Rotary thread take up lever 6 Needle bar clamp 7 Needle bar 1109B ...

Page 42: ...tle race mechanisms 1 プーリ 2 モータ 1 Motor 2 Upper shaft 3 Timing pulley U 4 Timing belt 5 Timing pulley D 6 Lower shaft 7 Bevel gear 8 Bevel gear 9 Rotary hook driving shaft 10 Timing pulley 39 11 Timing belt 12 Timing pulley 26 13 Rotary hook shaft 14 Rotary hook 0074B ...

Page 43: ...5 MECHANICAL DESCRIPTIONS Z 8550A 8560A 34 5 3 Zigzag mechanism 1 Pulse motor 2 Motor lever 3 Zigzag connecting rod 4 Zigzag joint 5 Needle bar base 6 Needle bar 1110B ...

Page 44: ...ing screw 2 Presser bar spring 3 Presser bar 4 Presser foot 1 Knee lifter 2 Knee lifter shaft 3 Knee lifter complying bar assembly 4 Knee lifter bar 5 Knee lifter lever 6 Knee lifter connecting rod 7 Presser bar lifter lever 8 Presser bar bracket 9 Presser bar 10 Presser foot 1111B 1112B ...

Page 45: ...Z 8550A 8560A 36 1 Lifting lever 2 Presser bar lifter lever 3 Presser bar bracket 4 Presser bar 5 Presser foot For options 1 Presser foot lifter solenoid set 2 Knee lifter shaft L 3 Knee lifter complying bar assembly 1113B 0079B ...

Page 46: ...et arm 2 Level feed eccentric wheel 8 Feed bar 3 Feed driving connecting rod 9 Feed dog forward back movement 4 Side connecting rod 5 Feed rocker arm 6 Feed rocker shaft 1 Feed regulator Up down movement 1 Lower shaft 2 Lower shaft tip eccentricity 3 Feed lifting link 4 Feed bar 5 Feed dog up down movement 1114B 1115B ...

Page 47: ... 8 Feed connecting lever 9 Feed regulator connecting rod 10 Feed regulator lever 11 Feed regulator 12 Feed regulator spring Adjusting the stitch length dial changes the angle of the feed regulator 1 Feed regulator 2 Side connecting rod 3 Feed driving connecting rod 4 Feed rocker arm Changing the angle of the feed regulator causes the amount of horizontal feed movement to change Continued on next p...

Page 48: ...e of the feed regulator increases and feed is reversed 1 Reverse stitching lever 2 Lever guide 3 Reverse lever shaft 4 Feed adjusting lever U 4 Condense regulator 5 Connecting rod D Touching tip of screw 6 Feed adjusting lever D 5 Feed regulating stud tip 7 Feed regulator shaft 8 Feed connecting lever 1 Condense dial 5 9 Feed regulator connecting rod 10 Feed regulator lever 11 Feed regulator 1 Fee...

Page 49: ...ONS Z 8550A 8560A 40 5 6 Lubrication mechanism Flow of oil 1 Oil feeding 2 Oil tank 3 Plunger pump 3 Oil gauge window 4 Rotary hook shaft bush 5 Rotary hook shaft 5 Adjusting screw 6 Rotary hook Continued on next page 1176B ...

Page 50: ...DESCRIPTIONS Z 8550A 8560A 41 Flow of oil 1 Plunger pump 2 Rotary hook shaft bush 3 Rotary hook shaft 3 Adjusting screw 4 Felt Adjusts the size of the outlet 5 Screw 4 Bed 6 Lubricating felt 7 Wick felt 1119B 0090B ...

Page 51: ...immer solenoid 2 Solenoid joint 3 Solenoid lever 4 Driving rod 5 Thread trimmer driving rod plate 6 Main lever assembly 7 Roller 8 Thread trimmer cam 9 Knife driving rod 10 Thread trimmer driving lever 11 Movable knife 1 Fixed knife clutch 2 Fixed knife 3 Plate spring 4 Movable knife 0091B 0092B ...

Page 52: ...chanism 1 Lifting lever 1 Knee lifter connecting rod Press the knee switch 2 Presser bar lifter lever 3 Tension release plate 4 Tension release stud 5 Tension release pin Press the tension disc presser 6 Tension disc presser 7 Rotary disc 1 Tension release pin 1120B ...

Page 53: ...enoid 2 Link 3 Lever B 4 Lever A 5 Tension release connecting rod 6 Tension release plate 7 Tension release stud 8 Tension release pin Upper thread feeding mechanism 8560A only 1 Solenoid 2 Link 3 Lever B Tension release is delayed by the length of the slot 4 Base 5 Wire 1121B 1122B ...

Page 54: ...ESCRIPTIONS Z 8550A 8560A 45 5 9 Thread wiper mechanism 8560A only optional device 1 Thread wiper solenoid 2 Thread wiper rod 3 Thread wiper lever 4 Thread wiper crank shaft 5 Thread wiper 6 Thread wiper spring 1123B ...

Page 55: ...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 If the oil and grease get into your eyes or onto your skin inflammation can result Furthermore do not drink or eat the lubricating oil or grease They may cause diarrhea or vomiting Keep the oil out of the reach of children Use only the proper replacement ...

Page 56: ...sembly order 6 1 Covers 1 Screw Loosen 10 Flat screws 7 pcs 2 Needle 11 Face plate 3 Screws 2 pcs 12 Face plate packing 4 Thread take up guard assembly 13 Screws 6 pcs 5 Flat screws 3 pcs 14 Rear cover 6 Rotary thread take up lever 15 Panel 7 Rotary take up mounting plate 16 Screws 3 pcs 8 Flat screw 17 Pulse motor cover 9 Thread guide 18 Window plate 8550A 1124B ...

Page 57: ...usting screw 5 Spring guide 6 Spring 7 Spring guide collar 8 Screw Loosen 9 Presser bar bracket 10 Presser bar 6 3 Needle bar mechanism 1 Rubber cap 2 Screw 3 Thread guide 4 Screw Loosen 5 Needle bar 6 Needle bar clamp 7 Set screws 2 pcs Loosen 8 Needle bar connecting rod shaft 9 Needle bar connecting rod 1125B 1126B 0100B ...

Page 58: ...6 DISASSEMBLY Z 8550A 8560A 49 6 4 Zigzag mechanism For the 8560A Remove the solenoid before doing this 1 Screws 3 pcs 2 Shoulder screw 1 Shoulder screw 2 Knee lifter bar 1127B 0102B ...

Page 59: ...bar base guide R 5 Bolt Loosen 12 Set screw Loosen 6 Zigzag joint 13 Needle bar base guide pin Loosen Pull out in the direction of the arrow 14 Needle bar base 7 Wick Remove from needle bar base 1 Needle bar base shaft 8 Bolts 3 pcs 2 Oil tank 9 Pulse motor assembly 3 Wick 0103B ...

Page 60: ...50A 1 Knife unit 8560A 2 Flat screws 2 pcs 3 Needle plate 4 Flat screws 2 pcs 5 Auxiliary needle plate 6 Screws 2 pcs 7 Feed dog 8 Scew 9 Bobbin case holder position bracket 10 Set screws 2 pcs Loosen 11 Rotary hook 1 Needle plate spacer 8560A 0106B 0104B 0105B For the 8560A ...

Page 61: ...l from inside the gearbox 2 Screws 9 pcs 3 Bed bottom cover assembly 4 Bottom cover packing 6 7 Feed mechanism 1 Screw Loosen 1 Set screw collar 2 Set screws 2 pcs Loosen 2 Feed rocker arm 3 Screws 2 pcs Loosen 4 Feed rocker shaft Pull out to the left 5 Feed bar set 0108B 0107B ...

Page 62: ...Thread trimmer mechanism 8560A only 1 Shoulder screw 2 pcs 2 Knife driving rod 3 Washer 4 Screws 3 pcs 5 Thread trimmer solenoid assembly Knife unit 1 Screws 4 pcs 2 Knife holder 3 Movable knife 4 Fixed knife 5 Knife bracket 1128B 0110B ...

Page 63: ...1 Screw 2 Presser foot 3 Screw 4 Solenoid cover 5 Retaining ring 6 Washer 7 Screws 2 pcs 8 Screw 9 Bolt 10 Wiper bracket 11 Screws 2 pcs 12 Thread wiper base 13 Screws 6 pcs 14 14 pin machine connector 1 Black 2 White A special tool is needed to pull out the pin 0114B 1129B 1130B 1131B ...

Page 64: ...A only 1 Thread trimmer solenoid assembly 2 Screws 3 pcs 3 Washer 4 Knife driving rod 5 Shoulder screws 2 pcs Knife unit 1 Fixed knife 1 Knife driving rod 2 Movable knife 2 Thread trimmer cam 3 Knife holder 3 Roller 4 Screws 4 pcs 4 Knife bracket 0117B Adjust the length of the knife driving rod so that the roller moves smoothly in and out of the straight section A in the groove of the thread trimm...

Page 65: ...ush L 3 Feed rocker shaft 4 Retaining ring 4 Set screw collar 5 Set screws 2 pcs 6 Screws 2 pcs Temporarily tighten 5 Bush M 6 Feed bar set 7 Feed rocker shaft 8 Feed rocker arm 0118B 0119B Tighten after adjusting the feed dog Refer to 9 7 Feed dog forward back and sideways position 0120B Push all the way to the left until it touches then tighten the set screw ...

Page 66: ...MBLY Z 8550A 8560A 57 7 3 Lubrication mechanism 1 Bottom cover packing 2 Bed bottom cover assembly 3 Screws 9 pcs 4 Screw 5 Add lubricating oil approx 120 ml 1 Bed 2 Wick 3 Felt 4 Bed bottom cover 0121B 1134B ...

Page 67: ...he pulse motor encoder detection unit through After carrying out the assembly operations in 7 5 Needle bar mechanism tighten while carrying out the adjustments in 9 12 Needle zigzag sideways position Then carry out the adjustments in 9 11 Needle zigzag forward back position If there is a lot of looseness in the wick ring after installing pull only the wick shown in the illustration through the oil...

Page 68: ...ing rod shaft 3 Screws 2 pcs 4 Needle bar clamp 1 Thread take up crank 2 Felt 5 Needle bar 6 Screw Temporarily tighten 7 Thread guide 8 Screw 9 Rubber cap 0124B Push in Face the needle check hole toward the front Tighten the screws after carrying out the adjustment in 9 10 Needle bar height 1135B 0126B ...

Page 69: ...iary needle plate 12 Flat screws 2 pcs 13 Slide plate 8550A 13 Knife unit 8560A 1 Needle plate spacer 8560A 1136B Tighten after carrying out the adjustments in 9 14 Needle and rotary hook timing Install after carrying out the adjustments in 9 14 Needle and rotary hook timing Tighten after carrying out the adjustments in 9 7 Feed dog forward back and sideways position Tighten after carrying out the...

Page 70: ...e collar 5 Presser bar spring 6 Spring guide 7 Presser adjusting screw 8 Adjusting screw nut 9 Lifting lever Lift up 10 Presser foot 11 Screw 12 Adjust the height 13 Align the hole positions 14 Screw 15 Presser adjusting screw 16 Adjusting screw nut 0130B Loosen once and then tighten after adjusting 12 and 13 1138B 1139B 1137B 0133B ...

Page 71: ... cover 11 Flat screw 3 Screws 3 pcs 12 Rotary take up mounting plate 4 Panel 13 Rotary thread take up lever 5 Rear cover 14 Flat screws 3 pcs 6 Screws 6 pcs 15 Thread take up guard assembly 7 Face plate packing 16 Screws 2 pcs 8 Face plate 9 Flat screws 7 pcs 1140B Be careful of the knives ...

Page 72: ...olenoid cover 12 Screw 13 Screw Secure the harness 14 14 pin machine connector 15 Secure with the 6 screws 1 Black 2 White 1141B Align the bottom of the presser bar bushing with the bottom of the wiper bracket Check that the thread wiper connecting rod assembly moves smoothly and the wiper bracket is horizontal to the arm and then tighten 0137B After assembling carry out the adjustments in 9 24 Ad...

Page 73: ...e the feed dog 1 and needle plate 2 with the ones for long stitches 2 After this change the maximum feed amount as described below Changing the maximum feed amount If the feed dog has been replaced by one that does not match the feed amount that is currently being used the feed dog may touch the needle plate if the stitch length dial or condense dial are mistakenly set to settings that are larger ...

Page 74: ... when the reverse stitching lever 9 is not lowered and when it is lowered If it touches adjust the forward back installation position centering of the feed dog 7 Without lowering the reverse stitching lever 9 move the stopper 5 up until it touches F regulator connecting rod 10 and then tighten the screw 3 Fig A 8 With the reverse stitching lever 9 lowered all the way move the stopper 6 down until ...

Page 75: ...se replace gauge parts such as the feed dog with parts for using with a feed amount of more than 2 0 mm In addition change the maximum feed amount setting while referring to page 64 and then adjust the stitch length dial 1 as described below 1 Turn the stitch length dial 1 all the way to 2 5 2 After this push the left lever 2 while turning the stitch length dial 1 so that it can be turned a second...

Page 76: ...your hand may get caught Do not touch the face plate knives when opening the thread take up guard cover If they are touched injury may result 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 When removing the needle plate auxiliary needle plate and knife unit use a screwdriver th...

Page 77: ...een the machine bed and the table hole is 1 5 mm If the clearance is 3 5 mm or more install the safety switch 1 so that the washer 2 is on the machine bed side as shown in Figure B If the position cannot be satisfactorily adjusted in this way add more washers of the same thickness Safety switch operation 3691M 3692M By changing the position of the safety switch the required spring stroke can be ma...

Page 78: ...thread tension spring 1 is 0 25 to 0 30 N 1 Press the upper thread slightly above the thread tension bracket 5 with a finger to stop the thread spooling out 2 Pull the upper thread down until the thread tension spring 1 starts to move down and measure the tension of the thread tension spring 1 at this point 3 Insert the tip of a screwdriver into the groove in the thread tension stud 6 and turn it ...

Page 79: ...t of the presser foot 1 to 6 mm 5 Tighten the screw 7 6 Adjust the presser foot pressure using the presser adjusting screw 6 and then tighten the nut 5 7 Install the thread take up guard 4 with the two screws 3 9 5 Feed dog height The standard height of the feed dog 1 when it is raised as far as possible above the surface of the needle plate is as given below 8550A 1 mm 8560A At the front 1 1 mm A...

Page 80: ...eed dog 1 Fig B 5 Securely tighten the set screw 4 When the angle of the feed dog 1 is adjusted the height and forward back position of the feed dog 1 will also change and will need to be readjusted 9 7 Feed dog forward back and sideways position Adjust the sideways clearances X between the feed dog 1 and the needle plate so that that are approximately equal Adjust so that the clearances Y between...

Page 81: ...s zero loosen the screw 3 turn only the dial of the condense dial 1 to align it with the 0 position on the scale and then secure it by tightening the screw 3 9 9 Needle and feed timing Adjust so that the mark on the level feed eccentric wheel 2 is aligned with the mark on the feed driving connecting rod 3 when the reference line on the thread take up lever 1 is aligned with the mark B for the 8550...

Page 82: ...e needle plate 3 onto the needle plate installation surface 2 Install the accessory needle bar height gauge 2 to the needle bar 1 and then tighten it with the set screw 8 3 Loosen the screw 9 4 Move the needle bar up or down to adjust so that the needle bar height gauge 2 is touching the top of the needle plate 3 when the machine pulley is turned so that the needle bar 1 is at its lowest position ...

Page 83: ...bar base presser pin 3 is further in than needle bar base guide R 4 as shown in the illustration With the bolt 7 loosened 1 Remove the presser foot Keep it removed while adjustment is being carried out 2 Loosen the two set screws hexagonal hole 2 5 mm width across flats 8 and then push needle bar base guide R 4 to adjust the position Turn the machine pulley and check that the needle drops into the...

Page 84: ...tion In addition set the motor lever 5 so that the longer part is vertical 4 Turn on the power switch If UP is displayed turn the machine pulley until the display disappears 5 Press the TEST key 6 on the operation panel and check that the TEST icon 7 illuminates For safety purposes be sure to carry out this step It prevents the motor from operating even if the treadle is depressed 6 Press the stra...

Page 85: ... screw 2 at this time After adjusting check the needle zigzag load again 9 14 Needle and rotary hook timing 1 Turn on the power switch 2 Press the TEST key 1 and check that the TEST icon 2 illuminates For safety purposes be sure to carry out this step it prevents the motor from operating even if the treadle is depressed 3 Set both the zigzag width and the zigzag base line position to 0 Refer to 6 ...

Page 86: ...eedle and check that the distance from the upper edge of the needle hole to the tip of the rotary hook 10 is 0 2 to 0 5 mm at this time If the distance is not correct carry out the adjustment in 9 10 Needle bar height 9 If needle deflection occurs when sewing material with joints bend the needle guard 13 as shown in the illustration A so that it touches the needle After this check that the clearan...

Page 87: ...hold it there Then run the sewing machine at the normal sewing speed for 10 seconds Any type of paper can be used as the lubrication amount check sheet 1 5 Check the amount of oil which has spattered onto the sheet Be sure to repeat this operation three to four times to check average lubrication amounts If adjustment is necessary carry out the following operations in Adjusting the lubrication amou...

Page 88: ...ing the treadle Forward depression sensitivity adjustment If the machine starts running at low speed when your foot is simply resting on the treadle or if the treadle pressure is felt to be too weak adjust the position a to c at which the treadle spring 1 is hooked onto the treadle lever 2 a is the weakest position and it becomes gradually stronger at b and c respectively Backward depression sensi...

Page 89: ...f the quick reverse solenoid 2 when the reverse stitching lever 1 is lowered to its lowest position while the feed amount is at the maximum setting 1 Turn the condense dial 5 counterclockwise to its maximum setting 2 Loosen the two screws 4 3 Move the quick reverse solenoid 2 up or down to adjust 4 Securely tighten the two screws 4 0153B 0154B ...

Page 90: ...ing carried out 2 Lower the lifting lever 1 3 Adjust the tension release connecting rod 4 and the crimping pin of the tension release plate 5 so that the distance b is 0 2 to 1 0 mm Loosen the two set screws 6 and move the lever 7 to adjust distance b It is easier to adjust if you touch the tension release connecting rod 4 against the crimping pin and then adjust to the distance shown in the illus...

Page 91: ...straight section A of the groove in the thread trimming cam 10 7 Provisionally tighten the two set screws 5 8 Place the set screw collar 11 firmly against the thread trimming cam 10 and then securely tighten the two set screws 6 Rotating direction adjustment 1 While still pushing thread trimming driving rod 7 by hand turn the machine pulley slowly by hand toward you until the reference line on the...

Page 92: ...pring 1 to 0 03 to 0 11 N NOTE If using a tension gauge sold separately to measure the tension take the reading from the scale on the side of the red line 9 23 Adjusting the thread trailing length after thread trimming 8560A only Standard position for upper thread feeding device The standard position for the upper thread feeding device is as shown in the illustration 1 Loosen the set screw 1 2 Tur...

Page 93: ...g the rotary disc 7 to rotate smoothly The thread tension will change at this time so be sure to re adjust the upper thread tension Refer to 9 1 Adjusting the thread tension of the Instruction Manual 9 24 Adjusting the thread wiper 8560A only optional device Horizontal position adjustment The front corner of the thread wiper 2 should be positioned 9 mm away from the left edge of the needle hole of...

Page 94: ...he treadle is depressed The power indicator 3 will flash NOTE The GrEASEUP notification will continue to appear and the power indicator 3 will flash each time the power switch is turned on until you apply grease and reset the cumulative operating time refer to pages 86 87 If you continue to use the sewing machine after the GrEASEUP notification appears without applying grease or without carrying o...

Page 95: ...to each of the holes until the grease overflows slightly 3 Tighten the screws in order to push the grease in 4 Turn the machine pulley by hand to move the needle bar up and down several times in order to disperse the grease 5 Use a cloth to wipe away any excess grease from around the screws NOTE For screws 1 and 2 remove the screws once more and then wipe around the seats with the rag After doing ...

Page 96: ...ear in green in the main display 1 xxx represents the time between grease applications 5 Press the rightmost key 7 The will change to 0 6 Press and hold the ENTER key 8 for two seconds or more A long beep will sound and the main display 1 will switch to zigzag width zigzag base line position display mode 7 Depress the treadle to run the sewing machine for 1 second or more 8 Turn the power switch t...

Page 97: ...ntrol 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 than the specified locations In addition note that high...

Page 98: ... main shaft motor There are 3 fuses on this P C board Cooling fan This fan cools the inside of the control box The filters at the air intake slots in the cover and base plate should be cleaned about once a month Transformer Two types are available depending on the power supply voltage specifications This breaks down the power supply voltage into the voltages that are required for control operation...

Page 99: ...d LED 1 on power supply P C board does not illuminate F3 Fuse 5A Glass tube fuse 5A 250V J 04418 001 Needle zigzag motor does not operate and Err 200 is displayed R70 Fuse resistor 1 2W 0 47Ω J 04415 001 Needle zigzag motor does not operate and Err 200 is displayed R73 Fuse resistor 1 2W 0 22Ω J 02754 001 Needle zigzag motor does not operate and Err 200 is displayed R1 R2 R3 Fuse resistor 1 4W 0 4...

Page 100: ... and fuse resistors No Part name Parts code Symptom when fuse blows F Fuse 8A Glass tube fuse 8A 250V J04502 001 Err 790 is displayed when the sewing machine starts R25 Fuse resistor 1 2W 0 22Ω J02754 001 Power does not turn on and green LED 1 does not illuminate 0162B ...

Page 101: ...often caused by 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 11 4 1 Connector positions Main P C board PMD P C board 0163B 0164B ...

Page 102: ...11 ELECTRICAL MECHANISM Z 8550A 8560A 93 Power supply P C board 0165B ...

Page 103: ...ectors 2 Diagnosis flowchart Carry out diagnosis while following the steps in 11 5 2 Diagnosis flowchart on the next page and if a problem No is reached continue to the next procedure 3 Remedy Refer to 11 5 3 Remedy for the item that corresponds to the problem No After identifying the cause in the Cause column carry out the necessary inspections repairs or adjustments and replace any parts if a pr...

Page 104: ...ECHANISM Z 8550A 8560A 95 11 5 2 Diagnosis flowchart Description of symbols Switch operation Setting and status Judgment OFF Power switch OFF Refer to the corresponding Problem No in 11 5 3 Remedy Problem No xx 0303B ...

Page 105: ...11 ELECTRICAL MECHANISM Z 8550A 8560A 96 0304B ...

Page 106: ...5 on the main P C board is blown Main P C board 2 If the red LED on the power supply P C board is illuminated Malfunction of transformer main P C board or panel assembly If the power indicator green on the main P C board is illuminated 3 Replace the part s indicated at right Main P C board or panel assembly Problem No 2 An error code is displayed when the power switch is turned on Cause Inspection...

Page 107: ...on again Main P C board 10 When Err 700 is displayed Abnormal rise in power supply voltage Check that the power supply voltage at the wall outlet is within the range of the specification voltage 10 11 When Err 705 is displayed Abnormal drop in power supply voltage Check that the power supply voltage at the wall outlet is within the range of the specification voltage 10 12 When Err 101 is displayed...

Page 108: ...motor Check the home position adjustment 4 When Err 711 is displayed Abnormal current detected in needle zigzag motor Replace the part s indicated at right PMD P C board Problem No 8 9 Sewing machine motor does not operate and an error code is displayed when treadle is depressed forward Cause Inspection Remedy Adjustment Replacement if a malfunction 1 When Err 50 is displayed Sewing machine safety...

Page 109: ...e the part s indicated at right Power supply P C board Problem No 12 Sewing machine does not stop correctly needle down stop or needle up stop Cause Inspection Remedy Adjustment Replacement if a malfunction 1 Needle stop position for sewing machine motor cannot be verified Try carrying out the procedures in 3 6 Checking input and output 2 Stop position for needle zigzag motor cannot be verified If...

Page 110: ...11 ELECTRICAL MECHANISM Z 8550A 8560A 101 11 6 Wiring diagrams 0124B ...

Page 111: ...11 ELECTRICAL MECHANISM Z 8550A 8560A 102 0125B ...

Page 112: ...for treadle depression stroke Set the Neutral position Maximum forward depression position and Maximum backward depression position The modulation position for the depression force at the first step is set automatically D Depression force When depressing forward or depressing backward The depression force hardly changes at all from the start of depression until the maximum depression When depressi...

Page 113: ...ed change starting point 6 7 85 S4 Maximum speed arrival point S5 1 S5 1 S5 Maximum forward depression point 14 5 12 14 5 32 81 S6 Backward automatic presser foot lifting point 2 2 14 80 S7 Thread trimming operation point 5 22 5 35 S8 Maximum backward depression point 8 28 8 43 1 Enabled when DIP switch No 1 is set to ON and memory switch No 13 is set to 1 2 Enabled when memory switch No 12 is set...

Page 114: ...anged or if the treadle unit or main P C board has been replaced The following procedure sets the operating positions for the treadle depression strokes to the standard values 1 Entering signal settings 1 Set the power switch 1 to OFF 2 Set DIP switch No 4 to ON 3 While pressing the straight stitch key 2 turn on the power switch 1 PdFF x xxx will appear in the main display 3 x xxx indicates the de...

Page 115: ...epression amount Press the straight stitch key 2 while the treadle is at the point of maximum backward depression Pd x xxx will appear in the main display 3 5 Ending the settings 1 Press the ENTER key 4 The buzzer will sound and the main display 3 will switch off NOTE If you do not press the ENTER key 4 the settings will not be stored 2 Set the power switch 1 to OFF 3 Set DIP switch No 4 to OFF 35...

Page 116: ...g operation pedal 3 with 2 step speed 3 pedals J80630 001 CDD foot plug assembly J04099 101 13 1 Installing the foot plug DANGER Wait at least 5 minutes after turning off the power switch and disconnecting the power cord from the wall outlet before opening the cover of the control box Touching areas where high voltages are present can result in severe injury 1 Insert the foot plug 1 into connector...

Page 117: ... connector 1 DC 8V 2 High speed switch 3 Thread trimming switch 4 SOV 5 Spare 6 Low speed switch 7 Presser foot switch 8 Variable speed input 9 Ground NOTE Connector types Name of manufacturer Connector No Connector pins MOLEX 1292P 1380TL 0220B 1868M 1867M High speed Thread trimming Low speed Presser foot High speed Thread trimming Low speed Presser foot ...

Page 118: ...ult in injury Problem Possible cause Page 1 Upper thread is not tight Is the upper thread tension too weak or is the lower thread tension too strong Adjust the upper thread tension or lower thread tension Was the thread threaded through the thread guide of the bobbin case in accordance with the type and thickness of the sewing article s material Use thread guide A or B in accordance with the mater...

Page 119: ... Adjust the force required to depress the treadle backward so that it is a bit heavier 79 5 Skipped stitches at sewing start Thread unravelling at sewing start Is the thread take up spring tension too strong Reduce the tension of the thread take up spring Is the thread take up spring operating range too large Lower the position of the thread take up spring Is the needle too thick Try using a needl...

Page 120: ...Is the rotary hook bobbin case thread take up lever or some other part in the thread path damaged Repair the damage or replace the part with a new one Instruction manual 84 69 69 73 76 77 8 Large degree of puckering excess tension Is the upper thread tension too strong Make the upper thread tension as weak as possible Is the lower thread tension too strong Make the lower thread tension as weak as ...

Page 121: ... strong Adjust the upper thread or lower thread tension Is the upper thread may be loose because the thread take up spring operating range is too small Adjust the position of the thread take up spring Is the needle and rotary hook timing incorrect Adjust the height of the needle bar Adjust the clearance between the needle and the rotary hook Is the thread too thick for the needle Use the correct n...

Page 122: ...hread feeding device 84 15 Oil gauge 1 is not visible in oil gauge window Is the oil tank empty Fill the oil tank with oil Instruction manual 16 Machine does not operate at high speed Is the sewing speed setting or backtack speed setting incorrect Use the sewing speed control keys to set the high speed Instruction manual 17 Machine stops during sewing Is the fixed stitch key turned on 8560A Press ...

Page 123: ... operate Check the needle bar position Err 130 Sewing machine motor does not operate Motor 4P connector is not connected correctly sewing machine is locked or malfunction of control devices Turn off the power switch and check the motor 4P connector or turn the pulley and check if it turns stiffly Err 131 Encoder connector P13 of sewing machine motor is not connected correctly or malfunction of enc...

Page 124: ...nt free space on CF card Use a different CF card Err 425 Error occurred while writing to CF card Use the specified type of CF card Err 427 R W key unneeded error Err 430 Problem with flash ROM data on main P C board Turn off the power switch and then turn the power back on again Err 440 Data cannot be backed up to EEPROM Turn off the power switch and then turn the power back on again Err 441 Data ...

Page 125: ...it to rise above 450 V Err 2 Err 710 Overcurrent Alarm signal detected in ARM IPM Err 3 Err 131 Sewing machine motor encoder If UVW pole pattern in encoder is an unrecognized pattern Err 4 Err 130 Lock detected If either needle up or needle down signal is not input for 3 seconds Err 5 Err 50 Machine head tilt detection if the machine head detection switch does not turn on when the treadle is depre...

Page 126: ...16 SEGMENT DISPLAY DEFINITION TABLE Z 8550A 8560A 117 16 SEGMENT DISPLAY DEFINITION TABLE LCD display character list Additional special symbols 0169B ...

Page 127: ...Z 8550A 8560A MEMO 118 ...

Page 128: ...SERVICE MANUAL Z 8550A 8560A I5120896B 2006 12 B 1 Printed in Japan ...

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