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Brother XR9000 Service Manual

Computerized sewing machine with low-end computer 3 series
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Summary of Contents for Brother XR9000

  • Page 4: Table Of Contents

    1. Outline of Mechanism ............... 1 - 1 Main Mechanisms ..................... 1 - 2 Driveline ......................1 - 3 Positions of electronic components ..............1 - 4 Control system block diagram ................1 - 5 Operation of other electronic components ............1 - 6 2.
  • Page 5 Feed unit ......................2 - 22 Needle plate A assy. removal ......................2 - 23 Needle plate A assy. disassembly .................... 2 - 23 Spring removal ..........................2 - 23 Inner rotary hook bracket assy. removal ..................2 - 23 Feed dog removal ..........................
  • Page 6 Needle-presser unit attachment ......................3 - 7 Upper shaft assy. attachment ......................3 - 8 Feed unit assy. attachment ........................ 3 - 9 Spring attachment ..........................3 - 9 Upper shaft and lower shaft phase matching .................. 3 - 10 Tension pulley assy.
  • Page 7 Spring attachment ........................... 3 - 35 Needle plate A assy. attachment ..................... 3 - 36 Needle plate A ASSY assembly ....................3 - 36 Needle-presser unit ..................3 - 37 Presser switch assy. attachment ...................... 3 - 38 Z pulse motor attachment ....................... 3 - 38 Lock nut attachment ........................
  • Page 8 Inner rotary hook bracket position ..............4 - 20 Inner rotary hook assy. (lower thread) tension ..........4 - 21 Pattern ......................4 - 22 5. Failure Investigation for Electronic Parts ........5 - 1 Error message list ..................... 5 - 2 Power does not come on ..................

  • Page 10: Outline Of Mechanism

    Outline of Mechanism Main Mechanisms ............ 1 - 2 Driveline ..............1 - 3 Positions of electronic components ......1 - 4 Control system block diagram ........1 - 5 Operation of other electronic components ....1 - 6 1 - 1...
  • Page 11 Outline of Mechanism Main Mechanisms Bobbin winder mechanism Thread tension mechanism Needle bar / Presser foot mechanism Upper shaft mechanism Lower shaft mechanism Feed / Rotary hook mechanism 1 - 2...
  • Page 12 Outline of Mechanism Driveline A) Up and down movement of needle bar, movement of thread take-up lever and zigzag mechanism Thread take-up Upper shaft Pulley counter weight Needle bar crank Thread take-up lever Needle bar crank rod Needle bar block Needle bar supporter Z zigzag cam Z zigzag lever...
  • Page 13 Outline of Mechanism Positions of electronic components Front cover side LCD module Mode selection PCB Operation PCB SS-VR PCB LED lamp Machine (rear cover) side BW switch PF switch Z pulse motor Main PCB BH change switch NP sensor BH lever switch Power supply PCB Main motor Power switch/Inlet...
  • Page 14 Outline of Mechanism Control system block diagram MACHINE (REAR COVER) PF SW BH SW BW SW MAIN PCB SENSOR 1 SENSOR 2 SENSOR FOOT CONTROLLER Z PULSE Z PULSE JACK MOTOR MOTOR DRIVER BUZZER F PULSE EEPROM F PULSE MOTOR MOTOR DRIVER RESET IC...
  • Page 15 Outline of Mechanism Operation of other electronic components Start/Stop (SS) button....Button for starting and stopping the sewing machine. The machine operates at a slow speed while the button is being held down.
  • Page 16 Disassembly Main parts........2 - 2 Feed unit........2 - 22 Needle-presser unit ....... 2 - 30 2 - 1...
  • Page 17 Main unit Main parts Main parts location diagram 2 - 2...
  • Page 18 Main unit Main parts Accessory table removal 1. Remove the accessory table 1. Base cover removal 1. Remove the screw 1, and then remove the base cover 1. 2. Remove the screw 2, and then remove base cover A 2. 2 - 3...

  • Page 19: Needle Plate B Assy. Removal

    Main unit Main parts Needle plate B assy. removal 1. Remove the needle plate cover 1. 2. Remove the needle plate B assy. 2. Needle plate B assy. disassembly 1. Remove the cutter cover 2 from the needle plate B assy. 1. 2.
  • Page 20 Main unit Main parts Face plate assy. removal 1. Remove the screw 1, and then remove the face plate assy. 1. Face plate A assy. disassembly 1. Remove the screw 1, and then remove the cutter cover assy. 1. 2. Remove the CS retaining ring 2, and then remove the NT lower thread cutter 3.

  • Page 21: Front Cover Assy. Removal

    Main unit Main parts Front cover assy. removal 1. Remove screws 1 (front, 1 pc.), 2 (rear, 1 pc.), and 3 (rear, 5 pcs.), and then remove the front cover assy.. *Key point • Disconnect the SSVR PCB lead wire connector 1 and the operation PCB lead wire connector 2 from the main PCB assy.

  • Page 22: Thread Guide Assy. A Removal

    Main unit Main parts Thread guide assy. A removal 1. Remove the two screws 1. 2. Remove the thread guide A assy. 1. Thread guide assy. A disassembly 1. Remove the screw 1, and then remove the notch spring 2 from the thread tension holder assy.

  • Page 23: Thread Guide Assy. B Removal

    Main unit Main parts Thread guide assy. B removal 1. Remove the screw 1. 2. Remove the thread guide assy. B 1. Thread guide assy. B disassembly 1. Remove the screw 1. 2. Remove the thread catching spring case 2 from thread take-up holder B 3.

  • Page 24: Ssvr Pcb Assy. Removal

    Main unit Main parts SSVR PCB assy. removal 1. Cut the 2 bands 1. 2. Remove the 3 screws 1, and then remove the SSVR PCB assy. 2. Buttons removal 1. Remove the SS button 1, the backstitching button 2 and the NP button LED lamp removal 1.

  • Page 25: Selecting And Manual Buttons Removal

    Main unit Main parts Operation PCB assy. removal 1. Disconnect the connector 2 from the operation PCB assy. 1. 2. Disconnect the connector 3 from the mode select PCB assy. 4. 3. Remove the 3 screws 1, and then remove insulator sheet 5 and the operation PCB assy.
  • Page 26 Main unit Main parts SV keytop removal 1. Remove the SV keytop 1. *Key point • Press the SV keytop hooks 2 (2 locations) from the inside of the front cover assy. 3 to remove the SV keytop. 2 - 11...

  • Page 27: Panel Cover Assy. Removal

    Main unit Main parts Panel cover assy. removal 1. Remove the 4 screws 1, and then remove the panel cover assy. 1 from the front cover assy.. 16-1 Panel cover assy. disassembly 1. Remove the panel plate assy. 1 from the panel cover assy. 2. 2.

  • Page 28: Base Plate Rubber Removal

    Main unit Main parts Base plate rubber removal 1. Remove the 2 base plate rubbers 1. Upper cover thread guide removal 1. Remove the upper cover thread guide 1. Main PCB assy. removal 1. Reconnect the all connectors from the main PCB assy. 1. 2.

  • Page 29: Power Pcb Assy. Removal

    Main unit Main parts Power PCB assy. removal 1. Remove the ZPM lead wire assy. 1 from the guide parts 2 of the insulation cover. 2. Remove screws 1 and 2 (1pc. /2 pcs.), and then remove the power PCB assy.

  • Page 30: Fc Jack Removal

    Main unit Main parts FC jack removal 1. Remove the jack nut 1, and then remove the FC jack assy. 2. Main motor assy. removal 1. Remove the 2 screws 1, and then remove the main motor assy. 1 fron the rear cover assy..

  • Page 31: Tension Pulley Assy. Removal

    Main unit Main parts Tension pulley assy. removal 1. Remove the 2 screws 1, and then remove the tension pulley assy. 1 from the rear cover assy.. 24-1 Tension pulley assy. disassembly 1. Remove the screw 1, and then remove the tension pulley holder 2 from the tension pulley assy.

  • Page 32: Feed Unit Assy. Removal

    Main unit Main parts Feed unit assy. removal 1. Remove the 2 screws 1, and then remove the upper shaft bearing presser 2. Remove the 2 screws 2, and then remove the feed unit assy. 2 from the rear cover assy.. Upper shaft assy.

  • Page 33: Needle-Presser Unit Removal

    Main unit Main parts Needle-presser unit removal 1. Peel the label, and then remove the screw 1. 2. Remove the 2 screws 2, and then remove the needle-presser unit 1. Plate spring removal 1. Remove the adjusting screw 1. 2. Remove the 2 screws 1, and then remove the adjusting plate 2 and the plate spring 3.

  • Page 34: Bobbin Base Assy. Removal

    Main unit Main parts Bobbin base assy. removal 1. Remove the bobbin base assy. 2 from the bobbin winder shaft 1. 30-1 Bobbin base assy. disassembly 1. Remove the bobbin thread cutter holder 2 from the bobbin base assy. 1, and then remove the NT lower thread cutter 3.

  • Page 35: Spool Pin Removal

    Main unit Main parts Spool pin removal 1. Remove the spool pin spring 1 and pull out the spool pin 2. 2. Peel the spool pin stand 3. Bobbin presser removal 1. Remove the screw 1, and then remove the bobbin presser 1. Thread guide assy.
  • Page 36 Main unit Main parts Base plate rubber removal 1. Remove the screw 1, and then remove the plain washer (M 3.5) 1 and rubber cushion A 2. 2 - 21...
  • Page 37 Main unit Feed unit location diagram 2 - 22...

  • Page 38: Needle Plate A Assy. Removal

    Main unit Feed unit Needle plate A assy. removal 1. Remove the 2 screws 1, and then remove the needle plate A assy. 1. Needle plate A assy. disassembly 1. Remove the screw 1, and then remove the F gear stopper plate 1. 2.

  • Page 39: Feed Dog Removal

    Main unit Feed unit Feed dog removal 1. Remove the 2 screws 1, and then remove the feed dog 1. Vertical adjuster screw assy. removal 1. Remove spring 2. Remove the M5 nut 1 3. Remove the vertical adjuster screw assy. 2. Outer rotary hook removal 1.

  • Page 40: Feed Bar Removal

    Main unit Feed unit Feed bar removal 1. Remove the retaining ring (CS4). 2. Remove the polyester slider 1, feed bar 2, and polyester slider 1 in this order. Retaining ring CS4 Needle plate supporter shaft B removal 1. Remove nut 1 (M3) 1. 2.

  • Page 41: Feed Arm A Assy. Removal

    Main unit Feed unit Feed arm A assy. removal 1. Remove the screw 1, and then remove the set collar 1 and the thrust wafer 2 in this order. 2. Remove the screw 2, and then remove the horizontal feed shaft 3. 3.

  • Page 42: Feed Adjuster Assy. Removal

    Main unit Feed unit Feed adjuster assy. removal 1. Remove the feed adjuster assy. 1, polyester slider 2, and spring this order. 11-1 Feed adjuster disassembly 1. Remove spring , and then remove the F gear 2 from the feed adjuster Vertical lever removal 1.

  • Page 43: Fpm Holder Assy. Removal

    Main unit Feed unit FPM holder assy. removal 1. Remove the screw 1, and then remove spring 2. Remove the screw 2, and then remove the FPM holder assy. 1. 13-1 FPM disassembly 1. Remove the lead wire assy. (FPM-LE) 1. 2.

  • Page 44: Lower Shaft Assy. Removal

    Main unit Feed unit Lower shaft assy. removal 1. Remove the retaining ring (E6), and then remove the thrust washer 1. 2. Remove the lower shaft assy. 2. *Key point • Push down the lower shaft assy. 2 to remove it. •...
  • Page 45 Main unit Needle-presser unit location diagram 2 - 30...
  • Page 46 Main unit Needle-presser unit Thread slider guide removal 1. Remove the screw 1, and then reomve thread slider guide 1. Bands removal 1. Cut the 5 bands 1. Threader hook assy. removal 1. Pull the needle thread slider 1 toward you, and then remove the threader hook assy.

  • Page 47: Bh Switch Assy. Removal

    Main unit Needle-presser unit BH switch assy. removal 1. Remove the screw 1, and then remove the BH switch assy. 1. Thread take-up lever and needle bar crank removal 1. Remove the needle bar crank rod 1. 2. Remove the screw 1, and then remove the needle bar crank 3 from the thread take-up lever 2.
  • Page 48 Main unit Needle-presser unit Needle bar assy. removal 1. Loosen the screws 1 and 2, and then pull the needle bar 1 down and remove the needle thread block 2 and the needle bar block 3. Needle bar assy. disassembly 1.

  • Page 49: Needle Holder Assy. Removal

    Main unit Needle-presser unit Needle holder assy. removal 1. Remove springs 2. Remove the screw 1, and then remove the shaft 1, needle holder block 2, and needle holder assy. 3. *Key point • Pull out the needle holder assy. from the top. 2 - 34...
  • Page 50 Main unit Needle-presser unit Needle holder assy. disassembly 1. Remove spring 2. Remove the screw 1, and then remove the plate 1. 3. Remove the screw 2. Pull out the shaft 2, and then remove needle holder shaft A 3. 4.

  • Page 51: Presser Bar Removal

    Main unit Needle-presser unit Presser bar removal 1. Remove the screw 1. Pull out the presser bar 1, and then remove the spring 2 and the presser bar clamp 3. *Key point • Remove the presser bar 1 and the presser feed holder assy. 2.
  • Page 52 Main unit Needle-presser unit 11-1 Z zigzag lever disassembly 1. Pull out the Z zigzag cap 2 from the Z zigzag lever 1. Z zigzag cam removal Retaining ring E3 1. Remove the retaining ring (E3), and then remove the Z zigzag cam 1. 2.

  • Page 53: Thread Release Lever Removal

    Main unit Needle-presser unit Thread release lever removal 1. Remove the retaining ring (CS4), and then remove the thread release lever 1 and the spring 2. Retaining ring CS4 Lock nut removal 1. Remove the lock nut 1, and then remove the screw 1. Z pulse motor removal 1.
  • Page 54 Assembly In this chapter, explains the disassembly and assembly of the each module. When fix and replace the each module, use this chapter. Main parts........3 - 2 Feed unit........3 - 25 Needle-presser unit ....... 3 - 37 3 - 1...
  • Page 55 Main unit Main parts Main parts location diagram 3 - 2...
  • Page 56 Main unit Main parts Base plate rubber attachment 1. Attach the base plate rubber 1 to the front cover assy.. • Attach rubber cushion A 2 and the plain washer (M3.5) 3 to the front cover assy. with the screw 1. Torque Taptite, Pan B ·...

  • Page 57: Spool Pin Attachment

    Main unit Main parts Spool pin attachment 1. Attach the spool pin stand 1 so that it does not protrude from the attachment section. 2. Insert the spool pin 2 into the rear cover assy.. Insert the pin from the grooved end.

  • Page 58: Bobbin Winder Assy. Attachment

    Main unit Main parts Bobbin winder assy. attachment 1. Attach the rubber ring 1 to the bobbin winder pulley. 2. Insert the bobbin winder shaft 2 into the groove on the rear cover assy., and secure the shaft with the 2 screws 1. 3.

  • Page 59: Bobbin Base Assy. Attachment

    Main unit Main parts Bobbin base assy. attachment 1. Attach the bobbin base assy. 1. Bobbin base assy. assembly 1. Attach the 2 NT lower thread cutters 2 and the bobbin thread cutter holder 3 to the bobbin base assy. 1. Plate spring attachment 1.

  • Page 60: Needle-Presser Unit Attachment

    Main unit Main parts Needle-presser unit attachment 1. Attach the needle-presser unit 1 to the rear cover assy. with screws 1 and 2 (1 pc. and 2 pcs. respectively). *Key point • Lift the presser foot lifter 2 and insert it into the hole on the rear cover assy.

  • Page 61: Upper Shaft Assy. Attachment

    Main unit Main parts Upper shaft assy. attachment 1. Pass timing belt 420-5GT-6 (timing belt) 2 and timing belt 372-2GT-6 (motor belt) 3 to the upper shaft assy. 1. 2. Attach the needle bar crank 5 to the thread take-up counter weight 4. 3.

  • Page 62: Feed Unit Assy. Attachment

    Main unit Main parts Feed unit assy. attachment 1. Fit the feed unit 1 to the rear cover assy. attachment position, and secure them with the 2 screws 1. 2. Fit the lower shaft bushing 2 to the rear cover assy. attachment position, set the lower shaft bearing presser 3, and secure them with the 2 screws *Key point •...

  • Page 63: Upper Shaft And Lower Shaft Phase Matching

    Main unit Main parts Upper shaft and lower shaft phase matching 1. Rotate the upper shaft 1 until the trench on the upper shaft pulley 2 is at the front. 2. Turn the lower shaft 3 to the point where the mark on the outer rotary hook 4 is at the front, the larger feed cam 5 is at the rear, and the hole on the lower shaft 6 is at the top.

  • Page 64: Main Motor Assy. Attachment

    Main unit Main parts Main motor assy. attachment 1. Hang the motor belt 2 over the main motor assy. 1. 2. Attach the main motor assy. 1 to the rear cover assy. with the 2 screws 1. *Key point • Perform "4 - 4 Motor belt tension. Torque Giza Tite ·...

  • Page 65: Power Pcb Assy. Attachment

    Main unit Main parts Power PCB assy. attachment 1. Attach the power unit assy. 1 with screws 1 and 2 (1 pc. and 2 pcs. respectively). *Key point • Attach the power plate spring 3 to the upper screw 2. 2.

  • Page 66: Main Pcb Assy. Attachment

    Main unit Main parts Main PCB assy. attachment 1. Attach the main PCB assy. 1 to the shutter cover 2. *Key point • Check that the 3 hooks hang on the main PCB assy. 1. 2. Hang the hook 4 of the bobbin winder shaft stopper 3 on the positioning part 5 of the shutter cover 2, and then align the boss of the rear cover assy.

  • Page 67: Panel Cover Assy. Attachment

    Main unit Main parts Panel cover assy. attachment 1. Attach the panel cover assy. 1 to the front cover assy. with the 4 screws *Key point • Align the protrusion of the panel cover assy. 1 to the positioning hole of the front cover assy. Torque Taptite, Bind B ·...

  • Page 68: Sv Keytop Attachment

    Main unit Main parts SV keytop attachment 1. Attach the SV keytop 1. *Key point • Check that the 2 hook parts 2 of the SV keytop 1 align the front cover assy.. Mode select PCB assy. attachment 1. Attach the mode select PCB assy. 1 with the 2 screws 1. Torque Taptite, Bind B ·...

  • Page 69: Selecting And Manual Buttons Attachment

    Main unit Main parts Selecting and manual buttons attachment 1. Attach the manual button A 1, manual button B 2, and 2 selecting buttons 3. Operation PCB assy. attachment 1. Connect the LCD cable 1 to the operation PCB assy. 2. 2.
  • Page 70 Main unit Main parts Buttons attachment 1. Attach the SS button 1, the backstitching button 2 and the NP button 3. 3 - 17...

  • Page 71: Ssvr Pcb Assy. Attachment

    Main unit Main parts SSVR PCB assy. attachment 1. Attach the SSVR PCB assy. 1 with 3 screws 1. *Key point • Insert the speed dial 2 of the SSVR PCB assy. 1 into the slot 3 on the SV key top. 2.

  • Page 72: Thread Guide Assy. B Assembly

    Main unit Main parts 30-1 Thread guide assy. B assembly 1. Attach the wire 2 to thread guide assy. B assy. 1. 2. Insert the tip of the thread take-up spring 3 into the second hole from the bottom on the thread catching spring case 4, secure 9.7 to 10.7 mm from the top of the groove on thread guide assy.

  • Page 73: Thread Guide Assy. A Attachment

    Main unit Main parts Thread guide assy. A attachment 1. Attach the thread guide A assy. 1 with the 2 screws 1. *Key point • Insert the wire of the thread tension holder assy. B 1 into the groove on the front cover assy., and then insert the boss into the hole on the front cover assy..

  • Page 74: Front Cover Assy. Attachment

    Main unit Main parts Front cover assy. attachment 1. Connect the SSVR PCB connector 1 and the operation PCB connector 2 to the main PCB 3. *Key point • Pass the lead wires to the hook section of the shutter cover 4 while preventing them from lifting or disconnecting.

  • Page 75: Face Plate A Assy. Attachment

    Main unit Main parts Face plate A assy. attachment 1. Attach the face plate A assy. 1 with the screw 1. Torque Taptite, Cup P · M4X20 0.78 — 1.18 N 33-1 Face plate A assy. assembly 1. Attach the NT lower thread cutter 2 to the cutter cover 1, and then attach the CS retaining ring 3.

  • Page 76: Needle Plate B Assy. Attachment

    Main unit Main parts Needle plate B assy. attachment 1. Attach the needle plate B assy. 1. 2. Attach the needle plate cover 2 to the needle plate B assy. 1. 34-1 Needle plate B assy. assembly 1. Attach the slide button 1 to needle plate B 2. 2.
  • Page 77 Main unit Main parts Accessory table attachment 1. Attach the accessory table 1. 3 - 24...
  • Page 78 Main unit Feed unit Feed unit location diagram 3 - 25...

  • Page 79: Lower Shaft Bushing Attachment

    Main unit Feed unit Lower shaft bushing attachment 1. Attach the lower shaft bushing 2 and bushing presser B 3 to the base plate assy. 1 with the 3 screws 1. Torque Taptite, Bind B · M3X6 0.39 — 0.78 N Lower shaft assy.

  • Page 80: Fpm Holder Assy. Attachment

    Main unit Feed unit FPM holder assy. attachment 1. Insert the FPM holder assy. 1 into the feed adjuster shaft 3 of the base plate assy. 2. 2. Insert spring between the base plate assy. 2 and the FPM holder assy.

  • Page 81: Vertical Lever Attachment

    Main unit Feed unit Vertical lever attachment 1. Insert the vertical feed shaft 1 into the inside of the drop knob 2, and Retaining ring E3 then insert the plain washer (L4) 3, spring , vertical lever 4, and drop knob 5 in this order. Retaining ring E3 *Key point •...

  • Page 82: Feed Adjuster Assy. Attachment

    Main unit Feed unit Feed adjuster assy. attachment 1. Insert the polyester slider 2 into the shaft of the feed adjuster assy. 1, and then attach spring *Key point • Insert the spring from the smaller end. 2. Apply 1 or 2 drops of OILER to the shaft of the feed adjuster assy. 1. 3.

  • Page 83: Feed Arm A Assy. Attachment

    Main unit Feed unit Feed arm A assy. attachment 1. Insert the feed arm A assy. 1 from the rear of the base plate assy. 2, and then insert the square shaft 4 of the feed arm B assy. 3 into the feed adjuster 5.

  • Page 84: Feed Arm B Assy. Assembly

    Main unit Feed unit Feed arm B assy. assembly 1. Insert the polyester slider2 into the shaft of the feed arm A assy. 1. 2. Apply a bead of MOLYKOTE EM-30L to the shaft of the feed arm A assy. 3.

  • Page 85: Needle Plate Supporter Shaft B Attachment

    Main unit Feed unit Needle plate supporter shaft B attachment 1. Insert the feed arm supporter 1 into the needle plate supporter shaft B 2, and attach them to the base plate assy. 3. 2. Tighten nut 1 (M3) 4. 3.

  • Page 86: Fpm Gear Engagement

    Main unit Feed unit FPM gear engagement 1. Rotate the FPM gear 1 clockwise until the stopper 2 of the FPM gear 1 contacts the shaft 3 of the bushing B assy.. 2. Rotate the feed adjuster assy. 4 to the point 5 it contacts the FPM gear *Key point •...

  • Page 87: Feed Bar Attachment

    Main unit Feed unit Feed bar attachment 1. Insert the polyester slider 2 to the left shaft of the feed arm A assy. 1. 2. Apply a bead of MOLYKOTE EM-30L to the shaft of the feed arm A assy. 3.

  • Page 88: Vertical Adjuster Screw Assy. Attachment

    Main unit Feed unit Vertical adjuster screw assy. attachment 1. Attach the vertical adjuster screw assy. 1. 2. Attach the M5 nut 2 to the vertical adjuster screw assy. 1. 3. Attach spring 18.8 SPRING XC4935*** Feed dog attachment 1. Temporarily tighten the 2 screws 1 to attach the feed dog 2 to the feed bar 1.

  • Page 89: Feed Unit

    Main unit Feed unit Needle plate A assy. attachment 1. Attach the needle plate A assy. 1 with the 2 screws 1. Torque Screw · 0.78 — 1.18 N 17-1 Needle plate A ASSY assembly 1. Attach the F gear stopper plate 1 with the screw 1. 2.
  • Page 90 Main unit Needle-presser unit Needle-presser unit location diagram 3 - 37...

  • Page 91: Presser Switch Assy. Attachment

    Main unit Needle-presser unit Presser switch assy. attachment 1. Attach the presser switch assy. 1 to the base holder assy. with the screw NOTE • Engage the ridge of the presser switch 1 with the trench of the base holder assy. 2. Torque Screw, Bind ·...

  • Page 92: Lock Nut Attachment

    Main unit Needle-presser unit Lock nut attachment 1. Attach the screw 1 to the lock nut 1. *Key point • Screw 1 the screw in half way. 2. Attach the screw 1 to the base holder assy.. *Key point • Tighten the screw until the lock nut 1 contacts the base holder assy..

  • Page 93: Presser Foot Lifter Attachment

    Main unit Needle-presser unit Presser foot lifter attachment 1. Apply a bead of EPNOC AP (N) 0 to the presser foot lifter shaft 1 of the base holder assy.. 2. Attach the presser foot lifter 2 to the shaft 1. 3.

  • Page 94: Z Zigzag Cam Attachment

    Main unit Needle-presser unit Z zigzag cam attachment 1. Attach the rubber 2 to the shaft 1 of the base holder assy.. 2. Apply a bead of EPNOC AP (N) 0 to the Z zigzag cam shaft 3 of the base holder assy..

  • Page 95: Z Zigzag Lever Assy. Attachment

    Main unit Needle-presser unit Z zigzag lever assy. attachment 1. Attach the polyester slider 2 to the Z zigzag lever shaft 1 of the base holder assy.. 2. Apply a bead of EPNOC AP (N) 0 to the Z zigzag lever shaft 1 of the base holder assy..

  • Page 96: Presser Bar Attachment

    Main unit Needle-presser unit Presser bar attachment 1. Attach the presser feed holder assy. 2 to the presser bar 1 with the screw 2. Attach the J foot 3. 3. Apply a light covering of OILER to the circumference of the presser bar 1 (upper 20 mm).

  • Page 97: Needle Holder Assy. Attachment

    Main unit Needle-presser unit Needle holder assy. attachment 1. Apply 1 or 2 drops of FBK OIL RO 100 to the circumference of needle holder shaft A 1 of the needle holder assy.. 2. Apply 1 or 2 drops of MOLYKOTE M DISPERSIOIN to the circumference of the needle holder assy.

  • Page 98: Needle Holder Assy. Assembly

    Main unit Needle-presser unit 10-1 Needle holder assy. assembly 1. Attach the zigzag adjusting nut 1 with the screw 1. 2. Apply OILER to the circumference at the top of the needle holder 2. 3. Pass the needle holder shaft A 3 from the end with the hole through the rear of the needle holder assy.

  • Page 99: Needle Bar Assy. Attachment

    Main unit Needle-presser unit Needle bar assy. attachment 1. Insert the needle bar assy. 1 from the bottom of the needle holder assy., and then insert the needle bar block 2 and the needle thread block 3 through the needle bar assy. and then through to the upper hole. *Key point •...

  • Page 100: Thread Take-Up Lever And Needle Bar Crank Attachment

    Main unit Needle-presser unit Thread take-up lever and needle bar crank attachment 1. Apply a light covering of MOLYKOTE EM-30L to the thread take-up lever attachment section of the needle bar crank 1. 2. Attach the thread take-up lever 2 to the needle bar crank 1 with the screw 1.

  • Page 101: Lead Wire Assy. Assembly

    Main unit Needle-presser unit Lead wire assy. assembly 1. Attach the lead wire assy. 1 with the screw 1. Torque Screw, Pan (S/P washer) · M4X8 1.18 — 1.57 N Threader hook assy. attachment 1. Pull the needle thread slider 1 toward you, and then align the D-cut of the threader hook assy.
  • Page 102 Adjustment Test Mode Starting test mode/Starting and stopping operation ... 4 - 2 Adjustment Timing belt tension........4 - 3 Motor belt tension ........4 - 4 Upper thread tension ......4 - 5 Left base line needle drop....... 4 - 6 Rotary hook unit position ......

  • Page 103: Test Mode

    Test Mode Starting test mode/Starting and stopping operation 1. How to start test mode • Turn on the power while pressing the (Stitch selection key) and the (Reverse stitch button), then test mode starts. 2. Mode selection • Press the (Stitch selection keys) and select pattern number (mode).

  • Page 104: Timing Belt Tension

    Adjustment Timing belt tension 1. Loosen the pan head screw (S/P washer, M4 x 8) on the tension pulley assy.. 2. Adjust the tension pulley assy. forward and back so that there should be 4 to 5mm slack in the timing belt when the center of the belt is pressed with a force of 1.96N (200g).

  • Page 105: Motor Belt Tension

    Adjustment Motor belt tension 1. Loosen the 2 screws (giza tite 5 x 16) in the motor holder. 2. Adjust the motor holder up and down so that there should be 3 to 4mm slack in the timing belt when the center of the belt is pressed with a force of 0.98N (100g).

  • Page 106: Upper Thread Tension

    Adjustment Upper thread tension 1. Raise the presser foot lever. 2. Set the thread tension dial to [4]. 3. Pass the Schappe Spun Thread #60 through the thread tension disc. 4. Lower the presser foot lever. 5. Pull the thread by a tension gauge, and turn the thread tension adjusting screw, and adjust the tension to 0.37 to 0.42N (38 to 43g).

  • Page 107: Left Base Line Needle Drop

    Adjustment Left base line needle drop 1. Attach the front cover assy.. 2. Start the test mode. 3. Select the pattern number "02" (3-point needle drop mode). 4. Move the needle to the left with the (Reverse stitch button), and then turn the power off. 5.

  • Page 108: Rotary Hook Unit Position

    Adjustment Rotary hook unit position 1. Attach the front cover temporarily. 2. Start the test mode. 3. Select the pattern number "02" (3-point needle drop mode). 4. Move the needle to the left with the (Reverse stitch button), and then turn the power off. 5.

  • Page 109: Needle Clearance Left/Right

    Adjustment Needle clearance left/right 1. Attach the front cover assy.. 2. Remove the presser foot, the needle plate B and the needle plate A, and then remove the inner rotary hook. 3. Start the test mode. 4. Select the pattern number "02" (3-point needle drop mode). 5.

  • Page 110: Needle Bar Rising

    Adjustment Needle bar rising 1. Attach the front cover assy.. 2. Remove the presser foot, the needle plate B and the needle plate A, and then remove the inner rotary hook. 3. Start the test mode. 4. Select the pattern number "02" (3-point needle drop mode). 5.

  • Page 111: Needle Bar Height

    Adjustment Needle bar height 1. Attach the front cover assy.. 2. Remove the presser foot, the needle plate B and the needle plate A, and then remove the inner rotary hook. 3. Start the test mode. 4. Select the pattern number "02" (3-point needle drop mode). 5.

  • Page 112: Clearance Between Needle And Rotary Hook Point

    Adjustment Clearance between needle and rotary hook point 1. Attach the front cover assy.. 2. Remove the presser foot, the needle plate B and the needle plate A, and then remove the inner rotary hook. 3. Remove the label. 4. Start the test mode. 5.

  • Page 113: Needle Threader

    Adjustment Needle threader 1. Attach the size 75/11 needle. 2. Turn the pulley by hand and move the needle to its highest point. 3. Loosen the socket set screw (FT, M4 x 4) of the needle thread block. 4. Loosen the socket screw (FT, M4 x 4), then move needle thread block up and down and adjust the clearance between the upper edge of hook and the upper edge of needle eye is 0mm.

  • Page 114: Presser Bar Height And Parallelism

    Adjustment Presser bar height and parallelism 1. Attach the J presser foot. 2. Raise the presser foot lever. 3. Turn the pulley by hand and down the feed dog lower than the needle plate A. 4. Loosen the socket set screw (CP, M5 x 10) of the presser bar clamp assy.. 5.

  • Page 115: Forward/Backward Feed

    Adjustment Forward/backward feed 1. Attach the front cover assy.. 2. Start the test mode. 3. Select the pattern number “05” (Forward and reverse feed mode). 4. Insert a paper between folded broadcloth, and press the (Start/Stop button) to run the machine in "Forward and reverse feed mode", checking the forward and backward feed length.

  • Page 116: Bobbin Winder

    Adjustment Bobbin winder 1. Move the thread guide assy. up and down to adjust uneven bobbin winding. Thread guide assy. 2. Turn the bobbin presser left and right, and adjust the winding quantity *Key point • The target for the bobbin winding quantity is filling 80 to 90% of the diameter.. Bobbin presser 4 - 15...

  • Page 117: Bh Lever Switch Position

    Adjustment BH lever switch position 1. Raise the presser foot lever. 2. Extend the BH presser foot maximum, back it 2 clicks. (Fig. 1) 3. Attach the BH presser foot. 4. Turn the pulley by hand, and down the feed dog lower than the needle plate. 5.

  • Page 118: Needle And Presser Foot Front/Back Position

    Adjustment Needle and presser foot front/back position 1. Lower the presser foot lever. 2. Turn the pulley by hand, and drop the needle top into the presser foot hole. 3. Loosen the lock nut. 4. Adjust the needle top to the front/back center position of the presser foot hole using the socket set screw (CP, M4 x 12).

  • Page 119: Front/Back And Left/Right Position Of Feed Dog

    Adjustment Front/back and left/right position of feed dog 1. Remove the needle plate B, the presser foot, the presser foot holder and the needle. 2. Start the test mode. 3. Select the pattern number “07” (Feed dog position mode). 4. Remove the 2 flat screws (M4) of the needle plate A, and then remove the needle plate A. 5.

  • Page 120: Feed Dog Height

    Adjustment Feed dog height 1. Remove the needle plate B, the presser foot, the presser foot holder and the needle. 2. Turn the pulley by hand to raise the feed dog to its highest position. 3. Remove the 2 flat screws (M4) of the needle plate A, and then remove the needle plate A. 4.

  • Page 121: Inner Rotary Hook Bracket Position

    Adjustment Inner rotary hook bracket position 1. Set the inner rotary hook assy. in the outer rotary hook. 2. Loosen the pan head screw (S/P washer, M3 x 6) of the inner rotary hook bracket assy.. 3. Move the inner rotary hook bracket assy. forward and back, and adjust the clearance (overlap) between the inner rotary hook point and the bracket spring to 2.3 to 2.5mm.

  • Page 122: Inner Rotary Hook Assy. (Lower Thread) Tension

    Adjustment Inner rotary hook assy. (lower thread) tension 1. Set the bobbin (the schappe spun thread #60) in the inner rotary hook assy.. 2. Pull the thread by a tension gauge, and turn the spring adjusting screw, adjust the tension to 0.1 to 0.12N (10 to 12g).

  • Page 123: Pattern

    Adjustment Pattern 1. Turn on the power. 2. Press the Character stitch key. Character stitch key 3. Select the pattern number "59" (Stitch adjustment Stitch length adjustment key mode). 4. Set the "0" by pressing the Stitch length adjustment key. 5.
  • Page 124 Failure Investigation for Electronic Parts * Perform resistance measurements after turning off the power, and detaching the connectors to be measured from the PCB. Error message list ............5 - 2 Power does not come on..........5 - 3 Pulse motors do not return to starting position....5 - 4 Pattern cannot be selected..........

  • Page 125: Error Message List

    Failure Investigation Error message list for Electronic Parts Error display Cause (5 - 17) Abnormal rotation in main motor Key pressed continually with power ON. (5 - 17) (performance system SW) (5 - 18) Key pressed continually with power ON. (operation system SW) (5 - 18) FC disconnect...

  • Page 126: Power Does Not Come On

    Failure Investigation Power does not come on for Electronic Parts When the power is turned on, nothing appears on the LCD. Is the power supply cord free from Connect the power supply damage and connected correctly? cord correctly or replace it. When the inlet assy.

  • Page 127: Pulse Motors Do Not Return To Starting Position

    Failure Investigation Pulse motors do not return to starting position for Electronic Parts When the power is turned ON, the pulse motors do not return to the starting position. • When needle is up : Z pulse motor returns to it's starting position. •...

  • Page 128: Pattern Cannot Be Selected

    Failure Investigation Pattern cannot be selected for Electronic Parts Pattern cannot be selected. Replace the operation PCB assy. Replace the main PCB assy. 5 - 5...

  • Page 129: Main Motor Does Not Turn

    Failure Investigation Main motor does not turn for Electronic Parts Main motor does not turn. Reassemble the upper shaft Does the pulley turn smoothly? assy. Is the main motor connector correctly Connect it properly. connected to the power PCB assy. (CN401)? Is the main motor resistance 2-5Ω...
  • Page 130 Failure Investigation Main motor does not turn for Electronic Parts From previous page Is the presser foot lever down? Lower the presser foot lever. Are the resistance values for the PF switch assy. normal? • PF switch assy. resistance values Replace the PF switch assy.

  • Page 131: Main Motor Rotation Abnormal

    Failure Investigation Main motor rotation abnormal for Electronic Parts • The rotation of the main motor is unstable. • The rotation speed does not reach maximum. • The rotation speed can not be adjusted. Is the main motor connector correctly connected to the power supply PCB assy.

  • Page 132: Cannot Sew Pattern Correctly

    Failure Investigation Cannot sew pattern correctly for Electronic Parts The pattern is not sewn correctly. With the power OFF, can you lightly more Adjust the attachment of the the needle bar left and right by hard? needle-presser module. Is the resistance between pins 1 & 2 and 3 &...

  • Page 133: Cannot Sew Button Hole Correctly

    Failure Investigation Cannot sew button hole correctly for Electronic Parts Cannot sew button hole correctly. Is the appropriate presser foot Attach the appropriate being used? presser foot. Is the resistance between pins 4 & • Adjust the BH lever. 5 on the BH switch connector normal? •...

  • Page 134: Problems With Vertical Needle Movement And Reverse Stitching

    Failure Investigation Problems with vertical needle movement and reverse stitching for Electronic Parts Problems with vertical needle movement and reverse stitching. Is the resistance for the start / stop switch, reverse stitch switch and needle position button normal? Replace the SSVR PCB assy. •...

  • Page 135: Does Not Operate When The Foot Controller Is Used

    Failure Investigation Does not operate when the foot controller is used for Electronic Parts Does not operate when the foot controller is used. Is the resistance between pins 2 & 3 on the Replace the foot controller foot controller jack assy. connector normal? jack assy.

  • Page 136: Bobbin Winding Cannot Be Done

    Failure Investigation Bobbin winding cannot be done for Electronic Parts Bobbin winding cannot be done. Adjust the bobbin winder Is the bobbin winder assy. attached assy. for correct attachment. correctly? Is the resistance between the BW-F SW assy. connector pins 1 & 2 normal? •...

  • Page 137: Led Lamp Does Not Come On

    Failure Investigation LED lamp does not come on for Electronic Parts The LED lamp does not light. Are the operation PCB assy. and LED Connect it properly. lamp assy. correctly connected? Is the LCD (back light PCB assy.) lead wire correctly connected to the Connect it properly.

  • Page 138: Lcd Display Is Not Normal

    Failure Investigation LCD display is not normal for Electronic Parts LCD display is not normal. Is the FFC of the LCD correctly connected Connect it properly. to the operation PCB assy. (CN3)? Are the main PCB assy. and the operation Connect it properly.

  • Page 139: Buzzer Does Not Sound

    Failure Investigation Buzzer does not sound for Electronic Parts When the power is turned on or the pattern is selected, the buzzer does not sound. When the power supply PCB assy. connector (CN201) is disconnected, Replace the power supply are the voltages between pins 2 & 3 and 4 &...

  • Page 140: Error Is Displayed

    Failure Investigation Error is displayed for Electronic Parts "F1" is displayed. After the power supply PCB assy. is replaced, start the test mode and Replace the main PCB assy. select the test mode "10" and press the reverse stitch button. Replace the power supply Does the motor correctly rotate PCB assy.
  • Page 141 Failure Investigation Error is displayed for Electronic Parts "F3" is displayed. Is one of the stitch selection key, Replace the operation PCB assy. stitch length adjustment key and stitch width adjustment key stuck in Replace the main PCB assy. a pressed down condition? Release the key that is stuck.
  • Page 142 Failure Investigation Error is displayed for Electronic Parts "F5" is displayed. Is the main PCB assy. attached Reassemble the main PCB assy. correctly? Is the timing shutter of the upper Clean the dirty of the timing shaft dirty? shutter. Replace the main PCB assy. 5 - 19...
  • Page 143 Failure Investigation Error is displayed for Electronic Parts "F7" is displayed. Replace the SSVR PCB assy. Replace the main PCB assy. "F8" is displayed. When the power lead wire assy. is disconnected from the power supply PCB assy. connector (CN201), are Replace the power supply the voltages between pins 2 &...
  • Page 144 Repair Manual In this chapter, projects the cause from contents of the malfunction of the products, and explains the method of the fix and the maintenance. When do not understand the cause of the malfunction and the method of the fix and the maintenance, use this chapter.
  • Page 145 Repair Manual Problem Primary factors and causes Repair method Items for Inspection method Inspection and standards Stitch skipping Needle tip damaged while Needle replacement Tip damage to Touch the needle tip Thread abrasion sewing needle with your finger, be Thread breakage Needle catches and bends sure that it is not Seam unevenness...
  • Page 146 Repair Manual Problem Primary factors and causes Repair method Items for Inspection method Inspection and standards Stitch skipping Bad needle interference Adjust needle interference Needle and tip Refer to Clearance Thread abrasion adjustment (4-11) between needle and Thread breakage Loose needle interference rotary hook point.
  • Page 147 Repair Manual Problem Primary factors and causes Repair method Items for Inspection method Inspection and standards Bad pattern shape Vertical rattle in feed dog Back/front rattle With the feed dog up, • Blocked by in feed dog check that there is no •...
  • Page 148 Repair Manual Problem Primary factors and causes Repair method Items for Inspection method Inspection and standards Sewing sounds Operating noise Check that there is no Inappropriate abnormal noise in 3- sounds point drop (test mode • Thread take- Shaft noise up noise •...
  • Page 149 Repair Manual Problem Primary factors and causes Repair method Items for Inspection method Inspection and standards 10 Threading not Thread pushed out at the hook Threading Check that when possible function threading is carried out with Schappe Spun • Vertical slippage in needle Adjust needle thread (4-12) Sewing Thread #60 /...
  • Page 150 Repair Manual Problem Primary factors and causes Repair method Items for Inspection method Inspection and standards 12 Utility sewing Utility sewing Check that the needle (straight line / does not break during • Needle Needle contacts outer rotary Adjust clearance between zigzag) actual sewing and that breakage...
  • Page 151 Repair Manual Problem Primary factors and causes Repair method Items for Inspection method Inspection and standards 13 Cannot sew BH button hole Check that there is no stitch skipping or • BH is blocked Bad BH switch lever connecting Adjust BH switch lever position clogging with BH •...

  • Page 152: Special Instructions Of Wiring

    Special Instructions of Wiring Needle bar / Presser module wiring..7 - 2 Power supply unit wiring ......7 - 6 Front cover wiring ........7 - 9 7 - 1...
  • Page 153 Special Instructions of Wiring Needle bar / Presser module wiring 1. Wiring of BH switch assy. Hang the lead wires on the hooks. Pass a band through the hole of base holder and secure the lead wires with the band. Hang the ground lead wire on the hooks.
  • Page 154 Special Instructions of Wiring Needle bar / Presser module wiring 2. Wiring on upper side of needle bar / presser module Pass a band through the hole of base holder and secure the lead wires with the band. Cut end should Secure the lead wires face front.
  • Page 155 Special Instructions of Wiring Needle bar / Presser module wiring 3. Wiring on front side of needle bar / presser module 4. Wiring on left upper side of main PCB assy. Lead wires should pass under the ribs. Hang the lead wires on the hook. 7 - 4...
  • Page 156 Special Instructions of Wiring Needle bar / Presser module wiring 5. Wiring on right upper side of main PCB assy. Hang the ground lead wire on the hooks. Hang the BW lead wires on the hooks. 7 - 5...
  • Page 157 Special Instructions of Wiring Power supply unit wiring 1. Wiring of foot controller jack assy. Pass the lead wires of foot controller jack assy. between the main motor and cover. 2. Wiring on lower side of power supply unit Surely insert the connector. 7 - 6...
  • Page 158 Special Instructions of Wiring Power supply unit wiring 3. Wiring on upper side of power supply unit 4. Wiring on left side of power supply unit Hang the lead wires on the hooks. 7 - 7...
  • Page 159 Special Instructions of Wiring Power supply unit wiring 5. Wiring of power supply unit and main PCB assy. Wind the lead wires around the rib once. Hang the ferrite core that is passed the lead wires on the hook. Hang the lead wires on the hooks.
  • Page 160 Special Instructions of Wiring Front cover wiring 1. Wiring of LED lamp assy. Pass the lead wires between the PCB and cover. Hang the lead wires on the hook. Pass the lead wires between 2 bosses. Pass the lead wires between the boss and rib.
  • Page 161 Special Instructions of Wiring Front cover wiring 2. Wiring of LED assy. Connector of LED lamp Connector of LCD module 3. Wiring of operation PCB assy. Secure the lead wires with a bands. 7 - 10...
  • Page 162 Special Instructions of Wiring Front cover wiring 4. Wiring of front cover and main PCB Rear cover Hang the front cover lead Front cover wires on the 3 hooks. 7 - 11...
  • Page 163 7 - 12...

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