Page 3: Table Of Contents
1. Outline of Mechanism ................1 - 1 Main Mechanisms ................1 - 2 Driveline ..................1 - 3 Positions of electronic components ..........1 - 5 Control system block diagram ............1 - 7 Operation of other electronic components ........1 - 8 2. Disassembly ..................2 - 1 Main parts ......................2 - 2 Motor cover and carriage cover removal ...................2 - 3 Bed cover removal ..........................2 - 4...
Page 4: Table Of Contents
Needle thread unit ...................2 - 26 Needle thread assembly removal .....................2 - 27 Hook holder assembly removal .......................2 - 27 Rack and hook holder link removal ....................2 - 28 TH motor assembly and LED light assembly removal ..............2 - 28 Needle bar change unit ..................2 - 29 Change box removal ........................2 - 30 Change box disassembly (Step 1) ....................2 - 30...
Page 5: Table Of Contents
Power PCB assembly removal ......................2 - 57 Power PCB disassembly ........................2 - 58 Adjust-bolt removal .........................2 - 59 Thread cut unit ....................2 - 60 Picker disassembly ...........................2 - 61 Cutter unit disassembly (Step 1) ......................2 - 62 Cutter unit disassembly (Step 2) ......................2 - 63 Thread tension unit ..................2 - 64 Loosen the tension nut removal .......................2 - 65 Tension base bracket removal ......................2 - 65...
Page 6: Table Of Contents
Thread tension unit ..................3 - 10 Thread take-up bracket assembly ....................3 - 11 Thread take-up lever cover assembly (Step 1) .................3 - 12 Thread take-up lever cover assembly (Step 2) .................3 - 13 Spool stand frame assembly (Step 1) ....................3 - 14 Spool stand frame assembly (Step 2) ....................3 - 14 Antenna assembly (Step 1) ......................3 - 15 Antenna assembly (Step 2) ......................3 - 15...
Page 7: Table Of Contents
Case positioning plate assembly attachment ...................3 - 53 Needle bar case final assembly .......................3 - 53 Needle bar attachment ........................3 - 54 Thread take-up lever assembly ......................3 - 55 Thread take-up lever assembly attachment ..................3 - 56 Case guide D attachment .........................3 - 57 Change roller base assembly attachment ..................3 - 57 Needle bar case final assembly attachment ..................3 - 58 Thread wiper unit .....................3 - 59...
Page 8: Table Of Contents
Thread take-up lever cover attachment ....................3 - 96 Operation panel assembly attachment .....................3 - 96 Spool stand frame final assembly attachment ..................3 - 97 Main PCB assembly attachment ......................3 - 98 LED PCB plate attachment ......................3 - 99 LED drive PCB assembly attachment .....................3 - 99 Base cover L attachment ........................3 - 100 Base cover R attachment ........................3 - 101 Arm cover L attachment ........................3 - 102...
Page 9: Table Of Contents
4. Adjustment (for PR620/BMP8) ............4 - 1 Adjustment flow ....................4 - 2 Bent needle ......................4 - 3 Blunt needle .......................4 - 4 Starting test mode / Selecting adjustment test mode ........4 - 5 Main board test mode ..................4 - 6 Panel board test mode ..................4 - 12 Reference needle bar data for adjustment after main PCB replacement ..4 - 17 Motor belt tension adjustment ................4 - 19...
Page 10: Table Of Contents
The needle bar does not move normally............5 - 8 Thread breakage detection does not function normally........5 - 9 The hoop does not move normally..............5 - 10 The main shaft does not rotate normally............5 - 12 Thread is not cut normally................5 - 13 The wiper does not function normally.
Page 11: Outline Of Mechanism
Outline of Mechanism Main Mechanisms ............ 1 - 2 Driveline ..............1 - 3 Positions of electronic components......1 - 5 Control system block diagram........1 - 7 Operation of other electronic components ....1 - 8 1 - 1...
Page 12: Main Mechanisms
Outline of Mechanism Main Mechanisms Needle bar change box mechanism Upper shaft mechanism Needle bar mechanism Thread cutting mechanism Lower shaft mechanism Feed mechanism Needle threader mechanism 1 - 2...
Page 13: Driveline
Outline of Mechanism Driveline A) Up and down movement of needle bar, movement of presser foot thread take-up mechanism Thread take-up Thread take-up Thread take-up lever driving lever assy differential lever assy Thread take-up cam Presser foot cam Upper shaft Pulley Needle bar crank rod Presser foot driving...
Page 14 Outline of Mechanism Driveline B) Movement of rotary hook Idle pulley Timing belt Timing pulley Upper shaft Pulley Lower shaft gear Lower shaft Rotary hook Pulley Timing pulley Upper shaft Timing belt Lower shaft gear Idle pulley Lower shaft Rotary hook 1 - 4...
Page 15: Positions Of Electronic Components
Outline of Mechanism Positions of electronic components ASSY: TH sensor ASSY: Head PCB ASSY: Inverter PCB ASSY: SW PCB Touch panel LCD module ASSY: Panel PCB ASSY: LED Drive PCB ASSY: Main PCB ASSY: Main shaft sensor ASSY: LED Light 1 - 5...
Page 16 Outline of Mechanism Positions of electronic components ASSY: Picker motor ASSY: Picker sensor ASSY: Y area sensor ASSY: USB PCB ASSY: X motor ASSY: TH cutter motor ASSY: Connect PCB ASSY: TH cutter sensor ASSY: Y motor ASSY: Power SW ASSY: Power PCB 100 (ASSY: Power PCB 200) ASSY: Color change sensor...
Page 17: Control System Block Diagram
Outline of Mechanism Control system block diagram LED light Index sensor Thread amount sensor x6 Wiper sensor Color change sensor AC Power ASSY : supply LED DRIVE PCB Color change ASSY : MAIN Main motor Wiper motor ASSY : HEAD PCB SHAFT SENSOR motor Inlet...
Page 18: Operation Of Other Electronic Components
Outline of Mechanism Operation of other electronic components Start/stop switch ..... . This switch is used to start and stop the sewing machine. Thread cut switch .
Page 19: Disassembly
Disassembly Main unit Main parts........2 - 2 Feed unit.........2 - 15 Needle thread unit ......2 - 26 Needle bar change unit ....2 - 29 Thread wiper unit......2 - 32 Needle bar unit .......2 - 36 Upper shaft unit ......2 - 42 Lower shaft unit ......2 - 52 Power unit........2 - 55 Thread cut unit........2 - 60...
Page 20 Main unit Main parts 2 - 2...
Page 21 Main unit Main parts Motor cover and carriage cover removal 1. Remove the screw cover 1. 2. Remove the screw 1, and then remove the carriage cover 2. 3. Remove the 2 screw 2, and then remove the motor cover 3. Start movie clip (CD-ROM version only) 2 - 3...
Page 22 Main unit Main parts Bed cover removal 1. Remove the 2 screws 1, and then remove the bed cover bottom assembly 2. Remove the 2 screws 2, and then remove the bed cover lid 2 from the bed cover bottom assembly. 3.
Page 23: Main Parts
Main unit Main parts Arm cover R removal 1. Remove the 5 screw covers 1. 2. Remove the 2 screws 1, and then remove the arm cover R lid 2. *Key point • Remove the thumb bolt (M4S) from the operation panel assembly before removing arm cover R.
Page 24 Main unit Main parts Arm cover L removal 1. Remove the 3 screw covers 1. 2. Remove the screw inside the cover 1 and the 2 screws outside the cover 2, and then remove arm cover L 2. Start movie clip (CD-ROM version only) Outside Inside 2 - 6...
Page 25 Main unit Main parts Base cover R removal 1. Remove the 2 screw covers 1. 2. Remove the 2 screws 1 and then remove the base cover R lid 2. 3. Removes the 3 screws 2 and then remove the base cover R 3. *Key point •...
Page 26 Main unit Main parts Base cover L removal 1. Remove the 2 screw covers 1. 2. Remove the 2 screws 1, and then remove the base cover L lid 2. 3. Remove the 3 screws 2, and then remove the base cover L 3. *Key point •...
Page 27 Main unit Main parts LED PCB plate removal 1. Remove the 2 screws 1, and then remove the LED PCB plate 1. Main PCB assembly removal 1. Disconnect all connectors from the main PCB. 2. Remove the 4 screws 1, and then remove the main PCB assembly 1. 3.
Page 28 Main unit Main parts Operation panel assembly removal 1. Remove the 6 screws 1, and then remove the operation panel assembly Thread take-up cover removal 1. Remove the 2 screws 1, and then remove the thread take-up cover 1. *Key point •...
Page 29 Main unit Main parts Tension base removal 1. Remove the screw 1, and then remove the cord clamp NK-4N from the arm bed. 2. Remove the 4 screws 2, and then remove the tension base assembly. Start movie clip (CD-ROM version only) Needle plate removal 1.
Page 30 Main unit Main parts Needle plate base assembly removal 1. Remove the 2 screws 1 to disconnect the cutter link assembly 1. 2. Remove the 2 screws 2, and then remove the needle plate base assembly. Needle plate base disassembly 1.
Page 31 Main unit Main parts Picker bracket disassembly 1. Remove the retaining ring E2, and then remove the picker assembly and the spring 2. Remove the screw 1, and then remove the picker holder 1 from the picker bracket. Retaining ring E2 Rotary hook removal 1.
Page 32 Main unit Main parts Cutter unit final assembly and picker final assembly removal 1. Remove the screw 1, and then remove the cord clamp NK-5N and the lead wire from the arm bed. 2. Remove the 2 screws 2, and then remove the picker final assembly. *Key point •...
Page 33 Main unit Feed unit 2 - 15...
Page 34 Main unit Feed unit T-belt (Y-guide) removal 1. Remove the 2 screws 1, and then remove the Y-belt presser 1 (one each on left and right). 2. Remove the 2 screws 2, and then remove the Y-tension plate assembly 2 and T-belt (one each on left and right).
Page 35 Main unit Feed unit Feed final assembly removal 1. Draw the feed final assembly toward you. 2. Unlock the connector of the Y-area sensor assembly, and then remove the FFC SML2CD-Y 1 from the Y-area sensor assembly. 3. Remove the screw 1, and then remove the sheet and sheet B. 4.
Page 36 Main unit Feed unit Y-motor final assembly removal 1. Remove the screw 1, and then remove the cord clamp NK-4N and the Y- motor assembly's lead wire from the base frame. 2. Remove the 2 screws 2, and then remove the Y-motor final assembly. Y-motor disassembly 1.
Page 37 Main unit Feed unit Y-driving shaft assembly removal 1. Remove the 2 screws 1, and then remove the 2 bushing pressers A. 2. Remove the Y-driving shaft assembly 1. 3. Remove the 2 felts 2. Cord grip removal 1. Remove the screw 1, and then remove the cord grip. 2.
Page 38 Main unit Feed unit FFC and X-area sensor assembly removal 1. Remove the screw 1, and then remove the sheet. 2. Remove the 2 screws 2, and then remove the sheet. 3. Remove the screw 3, and then remove the X-area sensor assembly and the X-frame spacer.
Page 39 Main unit Feed unit X-carriage A assembly and X-carriage B assembly removal 1. Remove the 4 screws 1, and then remove the hoop sensor assembly's lead wire connector 1 from the hoop PCB assembly while removing the X- carriage A assembly. 2.
Page 40 Main unit Feed unit Hoop sensor removal 1. Remove the screw 1. 2. Remove the screw 2, and then remove the hoop lever. 3. Remove the nut 1 and the plain washer S6, and then remove the hoop sensor assembly and the spring Start movie clip (CD-ROM version only) X-guide shaft removal 1.
Page 41 Main unit Feed unit T-belt (Y-drive) removal 1. Remove the 2 screws 1, and then remove the tension pulley plate assembly and the T-belt. Feed frame disassembly 1. Remove the 4 screws (1 2, 2 each), and then remove the Y-carriage RB. 2.
Page 42 Main unit Feed unit Y-carriage L disassembly 1. Remove the 2 screws 1, and then remove the connect PCB final assembly. 2. Remove the 2 screws 2, and then remove the Y-sensor dog. 3. Remove the 2 screws 3, and then remove the X-motor assembly. 4.
Page 43 Main unit Feed unit Y-carriage R disassembly 1. Remove the 4 screws 1, and then remove bearing case Y from the Y- carriage R (2 locations). 2. Remove the 2 external retaining rings C19, and then remove the linear bearing (10) from the bearing case Y assembly (2 sets). External retaining rings C19 Connect PCB disassembly 1.
Page 44: Needle Thread Unit
Main unit Needle thread unit 2 - 26...
Page 45: Needle Thread Assembly Removal
Main unit Needle thread unit Needle thread assembly removal 1. Remove the 6 screws 1, and then remove the needle thread assembly 1. Hook holder assembly removal 1. Remove the cap 1. 2. Remove the hook holder assembly 2, and then remove the spring and the hook holder axis B assembly.
Page 46: Rack And Hook Holder Link Removal
Main unit Needle thread unit Rack and hook holder link removal 1. Remove the 2 screws 1, and then remove the needle thread sensor assembly. 2. Remove the 2 retaining rings E4, and then remove the rack assembly. 3. Remove the retaining ring E3, and then remove the hook holder link from the rack assembly.
Page 47: Needle Bar Change Unit
Main unit Needle bar change unit 2 - 29...
Page 48: Change Box Removal
Main unit Needle bar change unit Change box removal 1. Remove the 2 screws 1, and then remove the change box assembly 1. Change box disassembly (Step 1) 1. Remove the 2 screws 1, and then remove the C sensor bracket assembly and the C sensor bracket assy lower.
Page 49: Change Box Disassembly (step 2)
Main unit Needle bar change unit Change box disassembly (Step 2) 1. Remove the screw 1, and then remove the differential gear shaft assembly. 2. Remove the retaining ring E4, and then remove the plain washer (M6), C differential gear, and second plain washer (M6) from the differential gear shaft.
Page 50: Thread Wiper Unit
Main unit Thread wiper unit 2 - 32...
Page 51: Thread Presser Base Removal
Main unit Thread wiper unit Thread presser base removal 1. Remove the 4 screws 1, and then remove the thread presser base assembly 1 from the needle bar case final assembly. Thread presser base disassembly 1. Remove the 2 screws 1, and then remove the thread presser cover assembly and the 2 thread presser spacers from the thread presser base assembly.
Page 52: Wiper Guide And Wiper Sensor Removal
Main unit Thread wiper unit Wiper guide and wiper sensor removal 1. Remove the screw 1, and then remove the wiper sensor assembly. 2. Remove the 6 screws 2, and then remove the wiper guide assembly. 3. Remove the wiper cushion 1 from the wiper guide assembly. 2 - 34...
Page 53: Wiper Set Disassembly
Main unit Thread wiper unit Retaining rings E4 Wiper set disassembly 1. Remove the nut (3, M4), spring washer (2-4), and wiper shoulder screw, and then remove the wiper hook 1. 2. Remove the retaining ring E4, plain washer (M6), and washer, and then remove the wiper lever assembly.
Page 54: Needle Bar Unit
Main unit Needle bar unit 2 - 36...
Page 55: Needle Bar Case Final Assembly Removal
Main unit Needle bar unit Needle bar case final assembly removal 1. Remove the 4 screws 1, and then remove the needle bar case assembly. Start movie clip (CD-ROM version only) Change roller base assembly removal 1. Remove the 2 screws 1, and then remove the change roller base assembly. Case guide D removal 1.
Page 56: Thread Take-up Lever Assembly Removal
Main unit Needle bar unit Thread take-up lever assembly removal 1. Remove the 2 screws 1, and then remove the thread take-up shaft 1 and the 6 thread take-up lever assemblies 2. 2. Remove the 2 thread take-up bushes 3. Thread take-up lever disassembly 1.
Page 57: Needle Bar Removal
Main unit Needle bar unit Needle bar removal 1. Remove the screw 1 and the washer. (6 locations) 2. Remove the screw 2. (6 locations) 3. Remove the screw 3, and then remove the thread guide 1, needle bar thread guide 2, presser foot cushion 3, presser foot assembly 4, and felt 4.
Page 58: Case Positioning Plate Disassembly
Main unit Needle bar unit Case positioning plate disassembly 1. Remove the nut (2, M4) 1, spring washer (2-4), and plain washer (M4), and then remove the ball bearing (694) and the case positioning shaft from the case positioning plate. Case bracket assembly removal 1.
Page 59: Case Bracket Disassembly
Main unit Needle bar unit Case bracket disassembly 1. Remove the 4 screws 1, and then remove the case guide US and the case bracket assembly. 2. Remove the 2 retaining rings E3, and then remove the 2 ball bearings (694) from the case bracket assembly.
Page 60: Upper Shaft Unit
Main unit Upper shaft unit 2 - 42...
Page 61: Main Motor Final Assembly Removal
Main unit Upper shaft unit Main motor final assembly removal 1. Remove the 2 screws 1, and then remove the main motor final assembly and the T-belt (XA9644-050). 2. Remove the motor fan from the main motor final assembly. 3. Remove the 2 screws 2, and then remove the tension pulley final assembly.
Page 62: Driving Jump Assembly Removal
Main unit Upper shaft unit Driving jump assembly removal 1. Remove the 2 screws 1, and then remove the driving jump assembly. 2 - 44...
Page 63: Driving Jump Disassembly
Main unit Upper shaft unit Driving jump disassembly 1. Remove the 2 screws 1, and then remove the J differential lever 1, thrust washer, and J slide lever assembly 2. 2. Remove the retaining ring E4, and then remove the J slide lever shaft 3 from the J slide lever.
Page 64: Base Needle Bar Removal
Main unit Upper shaft unit Base needle bar removal 1. Remove the screw 1, and then remove the J-clamp final assembly 2 and the presser foot vertical base assembly 3 while pulling the base needle bar 1 upward. Start movie clip (CD-ROM version only) J-clamp disassembly 1.
Page 65: Presser Foot Vertical Base Disassembly
Main unit Upper shaft unit Presser foot vertical base disassembly 1. Remove the screw 1, and then remove the presser foot vertical pin 1. 2. Remove the screw 2, and then remove the presser foot vertical bush 2. 3. Remove the screw 3, and then remove the presser foot cushion base 3. Thread take-up driving lever final assembly removal 1.
Page 66: Thread Take-up Driving Lever Disassembly
Main unit Upper shaft unit Thread take-up driving lever disassembly 1. Remove the screw 1, and then remove the thread take-up differential lever 1 and the spacer. 2. Remove the thread take-up roller pin 2 from the thread take-up differential lever assembly, and then remove the roller. 3.
Page 67: Main Shaft Sensor Final Assembly Removal
Main unit Upper shaft unit Main shaft sensor final assembly removal 1. Remove the screw 1, and then remove the main shaft sensor final assembly. 2. Remove the screw 2, and then remove the main shaft sensor assembly from the sensor holder. Crank rod removal 1.
Page 68: Pressure Foot Driving Shaft Assembly Removal
Main unit Upper shaft unit Pressure foot driving shaft assembly removal 1. Remove the 2 screws 1, and then remove the 2 bushing pressers. 2. Remove the pressure foot driving shaft assembly 1. 3. Remove the 2 felts 2 from the metal collar on the arm bed. Presser foot driving shaft disassembly 1.
Page 69: Upper Shaft Assembly Removal
Main unit Upper shaft unit Upper shaft assembly removal 1. Remove the 4 screws 1, and then remove the 2 metal pressers. 2. Remove the upper shaft final assembly 1. *Key point • Be careful not to damage the encoder. 3.
Page 70: Lower Shaft Unit
Main unit Lower shaft unit 2 - 52...
Page 71: Arm Bed And Base Frame Disconnection
Main unit Lower shaft unit Arm bed and base frame disconnection 1. Mark the position where the arm bed is attached to the base frame. Mark the position on the base frame. *Key point • Marking prevents miss-location during re-assembly. 2.
Page 72: Lower Shaft Removal
Main unit Lower shaft unit Lower shaft removal 1. Remove the 4 screws 1, and then remove the 2 bushing pressers. 2. Remove the 2 collar screws 2, and then remove the lower shaft 1, lower shaft metal F, set collar, thrust wafer 7.24, lower shaft metal R, and second thrust wafer 7.24.
Page 73: Power Unit
Main unit Power unit 2 - 55...
Page 74: Power Switch Assembly And Inlet Removal
Main unit Power unit Power switch assembly and inlet removal 1. Remove the 3 screws 1 and the 3 cord clamps (NK-6N), and then remove the power PCB assembly's lead wire, USB lead wire assembly, Y-area sensor assembly's lead wire, and power unit lead wire assembly from the base frame.
Page 75: Usb Pcb Assembly And Y-area Sensor Assembly Removal
Main unit Power unit USB PCB assembly and Y-area sensor assembly removal 1. Remove the 2 screws 1 and the 2 cord clamps (NK-6N), and then remove the USB PCB's lead wire and the Y-area sensor's lead wire from the base frame.
Page 76: Power Pcb Disassembly
Main unit Power unit Power PCB disassembly 1. Disconnect the power lead wire assembly 1 from the power PCB assembly 100 (or 200). 2. Remove the 4 screws 1, and then remove the power unit cover assembly from the power unit stay. 3.
Page 77: Adjust-bolt Removal
Main unit Power unit Adjust-bolt removal 1. Remove the 4 adjust-bolt assemblies 1 from the base frame. 2. Remove the 4 nuts (2, M8) from the 4 adjust-bolt assemblies. 3. Remove the 2 screws 1, and then remove the handle 2. (4 locations) 4.
Page 78: Thread Cut Unit
Main unit Thread cut unit 2 - 60...
Page 79: Picker Disassembly
Main unit Thread cut unit Picker disassembly 1. Remove the retaining ring E2, and then remove the washer and the picker link 1. 2. Remove the screw 1, and then remove the picker sensor assembly. 3. Remove the 2 retaining rings E2, 2 plain washers S3, rack assembly, and 2 plain washers S3.
Page 80: Cutter Unit Disassembly (step 1)
Main unit Thread cut unit Cutter unit disassembly (Step 1) 1. Remove the retaining ring E2, and then remove the lever link assembly. 2. Remove the screw 1, and then remove the thread cutter sensor assembly (white). 3. Remove the 2 screws 2, separate the cutter bracket 1 from the CT motor bracket assembly 2, and then remove the 2 collars.
Page 81: Cutter Unit Disassembly (step 2)
Main unit Thread cut unit Cutter unit disassembly (Step 2) Retaining ring E2 1. Remove the lever gear 1. 2. Remove the retaining ring E2, and then remove the initial gear. 3. Remove the 2 screws 1, and then remove the thread cutter motor assembly.
Page 82: Thread Tension Unit
Main unit Thread tension unit 2 - 64...
Page 83: Loosen The Tension Nut Removal
Main unit Thread tension unit Loosen the tension nut removal 1. Loosen the tension nut 1, and then remove the washer 2, spring tension disc presser 3, tension disc felt 4, rotary disc assembly 5, and second tension disc felt 4. (6 locations) NOTE •...
Page 84: Inner Thread Eyelet Base Removal
Main unit Thread tension unit Inner thread eyelet base removal 1. Remove the 2 screws 1, and then remove the inner thread eyelet base assembly from the tension base assembly. 2. Remove the tension axis cap 1. (6 locations) 3. Loosen the thread guide tension axis 2, and then remove the spring and the thread guide tension plate 3.
Page 85: Upper Thread Eyelet Base Removal
Main unit Thread tension unit Upper thread eyelet base removal 1. Remove the tension axis cap 1. (6 locations) 2. Loosen the thread guide tension screw 2, and remove the nut (2, M3). Then remove the thread guide tension plate, spring , and upper thread eyelet base.
Page 86: Antenna Disassembly
Main unit Thread tension unit Antenna disassembly 1. Remove the 4 screws 1, and then remove the 2 antennas A, 2 antennas B, and antenna E assembly from the antenna C assembly. 2. Remove the screws 23 from the antenna C assembly. 3.
Page 87: Spool Stand Frame Disassembly (step 1)
Main unit Thread tension unit Spool stand frame disassembly (Step 1) 1. Remove the 6 spool pins 1 and the 2 sponges 2 from the spool frame stand R and spool frame stand L. 2. Remove the thumb bolt (M4L) 3 and the 2 washers, and then disconnect the spool stand link R from the spool link L.
Page 88: Thread Take-up Lever Cover Disassembly (step 1)
Main unit Thread tension unit Thread take-up lever cover disassembly (Step 1) 1. Remove the 4 screws (1 2, 2 each), and then remove the thread holder base assembly and the thread guide back cover. 2. Remove the screw 3, and then remove the cutter cover assembly from the thread holder base assembly.
Page 89: Thread Take-up Lever Cover Disassembly (step 2)
Main unit Thread tension unit Thread take-up lever cover disassembly (Step 2) 1. Remove the 2 screws 1, and then remove the thread tension bracket base. 2. Remove the 6 screws 2, and then remove the thread tension bracket base. 3.
Page 90: Thread Take-up Bracket Disassembly
Main unit Thread tension unit Thread take-up bracket disassembly *Key point • Disassemble the six thread take-up bracket assemblies. 1. Remove the screw 1, and then remove the thread guide wire and the thread guard. 2. Remove the screw 2, and then remove the thread catching spring case assembly.
Page 91: Operation Panel
Main unit Operation panel 2 - 73...
Page 92: Operation Panel Lever Assembly Removal
Main unit Operation panel Operation panel lever assembly removal 1. Remove the 2 screws 1, and then remove the operation panel lever assembly 1 from the operation panel assembly. Operation panel lever ASSY disassembly (1) 1. Remove the 2 thumb bolts (M4L) 1, 2 spring washers (2-4) 2, and 2 plain washers (M4) 3.
Page 93: Operation Panel Lever Assy Disassembly (2)
Main unit Operation panel Operation panel lever ASSY disassembly (2) 1. Remove the 3 thumb bolts (M4L) 1, 3 spring washers (2-4) 2, and 3 plain washers (M4) 3. 2. Remove the retaining ring (E6), and then remove the 2 operation panel lever shafts 4.
Page 94: Operation Panel B Assembly Removal
Main unit Operation panel Operation panel B assembly removal 1. Remove the 4 screws 1, and then remove the operation panel B assembly 2. Remove the screw 2, and then remove the grounding wire 2 on the panel lead wire assembly from the PCB attachment plate. 3.
Page 95: Board Case Removal
Main unit Operation panel Board case removal 1. Remove the 2 screws 1, and then remove the board case 1. 2. Remove the screw 2, and then remove the clip 2. Panel PCB assembly removal 1. Remove FFC 1. *Key point •...
Page 96: Pcb Attachment Plate Removal
Main unit Operation panel PCB attachment plate removal 1. Remove the 6 screws 1, and then remove the PCB attachment plate 1. LCD removal 1. Remove the LCD 1 from operation panel A. 2. Remove the FFC 2 from the LCD 1. *Key point •...
Page 97: Button Removal
Main unit Operation panel Button removal 1. Remove the 3 screws 1, and then remove the switch PCB assembly from the operation panel A. 2. Remove the SS button 1, operation button 2, and thread cut button 3 from the operation panel A. 2 - 79...
Page 98 2 - 80...
Page 99: Assembly
Assembly Main unit Operation panel ........3 - 2 Thread tension unit......3 - 10 Thread cut unit........3 - 20 Power unit........3 - 24 Lower shaft unit ......3 - 30 Upper shaft unit ......3 - 34 Needle bar unit .......3 - 49 Thread wiper unit......3 - 59 Needle bar change unit ....3 - 64 Needle thread unit ......3 - 68...
Page 100 Main unit Operation panel 3 - 2...
Page 101 Main unit Operation panel Button attachment 1. Attach the SS button 1, operation button 2, and thread cut button 3 to operation panel A. 2. Attach the switch PCB assembly 4 with the 3 screws 1. Torque Taptite, Bind B 0.39 –...
Page 102 Main unit Operation panel LCD attachment 1. Attach the FFC 1 to the LCD 2. *Key point • Unlock the connector, insert the FFC 1, and then lock the connector. 2. Attach the LCD 2 to operation panel A. PCB attachment plate attachment 1.
Page 103 Main unit Operation panel Inverter D6 attachment 1. Position the inverter PCB collars 1 on the PCB attachment plate, set inverter D6 2, and then secure them with 2 screws 1. 2. Attach the inverter lead wire 3 and the LCD lead wire 4 to inverter D6 Torque Screw, Pan (S/P washer) 0.49 –...
Page 104 Main unit Operation panel Board case attachment 1. Attach the board case 1 with the 2 screws 1. *Key point • Insert the hook on the board case into the positioning hole on the PCB attachment plate, and then slide the hook into position.
Page 105 Main unit Operation panel Operation panel B attachment 1. Attach the lead wire 2 on operation panel B 1 to the connector on the panel PCD. 2. Attach the grounding wire 3 to the PCB attachment plate with the screw *Key point •...
Page 106 Main unit Operation panel Operation panel lever assembly (Step 1) 1. Align operation panel lever B 2 with operation panel lever C 1, thread the operation panel level shaft 3 through them, and then attach the retaining ring E6. 2. Align operation panel lever B 2 with operation panel lever A 4, thread the operation panel level shaft 3 through them, and then attach the retaining ring E6.
Page 107 Main unit Operation panel Operation panel lever assembly attachment 1. Insert the operation panel holder 2 into the groove 1 on the panel B support, and secure these parts with the 2 screws 1. Torque Taptite, Cup B 0.78 – 1.18 N-m M4X14 3 - 9...
Page 108 Main unit Thread tension unit 3 - 10...
Page 109: Thread Take-up Bracket Assembly
Main unit Thread tension unit Thread take-up bracket assembly *Key point • Make 6 thread take-up bracket assemblies. 1. Attach the spring to the thread catching spring case 1. *Key point • There are 4 holes on the spring case. Insert the tip of the spring into the hole indicated by the arrow in the figure.
Page 110: Thread Take-up Lever Cover Assembly (step 1)
Main unit Thread tension unit Thread take-up lever cover assembly (Step 1) 1. Attach the thread take-up bracket assembly 2 to the thread guide cover 1. (6 sets) 2. Attach the 6 thread guide cover assemblies 3 to the thread tension bracket base 4 with the 6 screws 1.
Page 111: Thread Take-up Lever Cover Assembly (step 2)
Main unit Thread tension unit Thread take-up lever cover assembly (Step 2) Retaining rings E1.5 1. Attach the 6 needle thread presser plates 2 and the 6 springs to the thread holder base 1, and then attach the 6 retaining rings E1.5. 2.
Page 112: Spool Stand Frame Assembly (step 1)
Main unit Thread tension unit Spool stand frame assembly (Step 1) 1. Attach the retaining ring E8 to the spool stand stud 1. (2 sets) 2. Attach the spool stand stud to spool stand frame R 2, attach the plain washer (S10) 3, spring washer 4, and spool stand link 5 to the tip of the spool stand stud, and then attach the retaining ring E8.
Page 113: Antenna Assembly (step 1)
Main unit Thread tension unit Antenna assembly (Step 1) 1. Attach the retaining ring E5 to the antenna shaft 1. 2. Attach the antenna C assembly 3 to antenna D 2, thread the antenna shaft assembly through them, and then attach the retaining ring E5. 3.
Page 114: Antenna Assembly Attachment
Main unit Thread tension unit Antenna assembly attachment 1. Attach the antenna assembly to the thread stand base assembly with the 4 screws 1. Torque Screw, Bind 1.18 – 1.57 N-m M4X6 Upper thread eyelet base attachment 1. Attach the upper thread eyelet base 1 and the thread guide tension plate 2 to the tension base assembly.
Page 115: Thread Sensor Pcb Assembly And Head Pcb Assembly Attachment
Main unit Thread tension unit Thread sensor PCB assembly and head PCB assembly attachment 1. Connect the FFC (SML2CD-H) 2 to the thread sensor assembly 1. (6 locations) *Key point • Connect the FFC (SML2CD-H) so that the blue surface is facing the thicker portion of the thread sensor assembly's connector.
Page 116: Inner Thread Eyelet Base Attachment
Main unit Thread tension unit Inner thread eyelet base attachment 1. Attach the thread guide tension plate 2 to the inner thread eyelet base 1. (6 locations) 2. Thread the thread guide tension axis 3 through the spring , and then secure the guide tension axis to the inner thread eyelet base with the screw.
Page 117: Tension Base Lead Wire Assembly Attachment
Main unit Thread tension unit Tension base lead wire assembly attachment 1. Connect the tension base lead wire assembly 1 to the head PCB assembly. 2. Attach the cord bush (KR51) 2 to the tension base lead wire assembly, and then push it into the groove 3 on the tension base bracket. Start movie clip (CD-ROM version only) Tension nut attachment 1.
Page 118 Main unit Thread cut unit 3 - 20...
Page 119: Cutter Unit Assembly (step 1)
Main unit Thread cut unit Cutter unit assembly (Step 1) 1. Apply MOLYKOTE EM-30L to the CT motor bracket assembly's shaft 1. 2. Attach the thread cutter motor assembly 2 to the CT motor bracket assembly with the 2 screws 1. 3.
Page 120: Cutter Unit Assembly (step 2)
Main unit Thread cut unit Cutter unit assembly (Step 2) 1. Attach the cutter bracket assembly and the 2 collars 1 to the CT motor bracket assembly with the 2 screws 1. 2. Attach the thread cutter sensor assembly (white) 2 to the CT motor bracket assembly with the screw 2.
Page 121: Picker Assembly
Main unit Thread cut unit Picker assembly 1. Attach the picker motor assembly 1 to the PK motor bracket assembly with the 2 screws 1. 2. Attach the 2 retaining rings E2 to the PK motor bracket's shaft 2 (2 locations).
Page 122 Main unit Power unit 3 - 24...
Page 123: Adjust Bolt Attachment
Main unit Power unit Adjust bolt attachment 1. Attach the 2 bushes 2 to the handle 1. (4 locations) 2. Attach the handle to the base frame with the 2 screws 1. (4 locations) 3. Attach the 4 nuts (2, M8) 4 to the 4 adjust bolts (M8) 3. *Key point •...
Page 124: Power Pcb Assembly
Main unit Power unit Power PCB assembly 1. Attach the power PCB assembly and the insulation sheet 2 to the power unit cover 1 with the 4 screws 1. 2. Attach the power unit cover assembly to the power unit stay 3 with the 4 screws 2.
Page 125: Power Pcb Assembly Attachment
Main unit Power unit Power PCB assembly attachment 1. Temporarily tighten the 3 screws 1 in the attachment holes on the PCB holder at the bottom of the base frame. 2. Run the PCB holder final assembly's lead wire and the power supply's lead wire through the 2 cord holes 1 on the base frame, and route them along the upper section of the base frame so that the PCB holder final assembly is aligned with the 3 screws 1, and attach it to the base frame.
Page 126: Usb Pcb Assembly And Y-area Sensor Assembly Attachment
Main unit Power unit USB PCB assembly and Y-area sensor assembly attachment 1. Attach the USB PCB assembly 2 to the USB PCB holder 1 with the 2 screws 1. 2. Attach the USB PCB cover 3 to the USB PCB holder assembly with the 2 screws 2.
Page 127: Power Switch Assembly And Inlet Attachment
Main unit Power unit Power switch assembly and inlet attachment 1. Connect the free end of the 2 power lead wire assemblies 1 (one end is connected to the power PCB assembly) to the power switch assembly 2. *Key point •...
Page 128 Main unit Lower shaft unit 3 - 30...
Page 129: Lower Shaft Attachment
Main unit Lower shaft unit Lower shaft attachment 1. Apply FBK OIL RO100 to the 2 felts 1. 2. Attach the felt to the lower shaft metal collars on the arm bed. (2 locations) 3. Thread the lower shaft gear 2 through the lower shaft, align the lower shaft end face with the lower shaft gear end face, and tighten the 3 screws 1.
Page 130: Idle Pulley Assembly
Main unit Lower shaft unit Idle pulley assembly 1. Apply FBK OIL RO100 to the shaft hole 1 on the idle pulley. 2. Attach the retaining ring E7 to the idle pulley shaft 2. 3. Attach the thrust washer 3, idle pulley 4, thrust washer 3, and set collar 5 to the idle pulley shaft.
Page 131: Connection Of Arm Bed And Base Frame
Main unit Lower shaft unit Connection of arm bed and base frame 1. Attach the arm bed 1 to the base frame, and temporarily tighten the 4 screws 1 and 4 plain washers M8. 2. Align the arm bed with the marking on the base frame, and firmly tighten the 4 screws 1.
Page 132 Main unit Upper shaft unit 3 - 34...
Page 133: Upper Shaft Assembly Attachment
Main unit Upper shaft unit Upper shaft assembly attachment 1. Apply FBK OIL RO100 to the 2 felts 1. 2. Attach the felts to the lower shaft metal collars on the arm bed. (2 locations) 3. Hang the T-belt (S5M-525) currently on the lower shaft over the timing pulley of the upper shaft final assembly 2.
Page 134: Presser Foot Driving Shaft Assembly
Main unit Upper shaft unit Presser foot driving shaft assembly 1. Attach the thrust washer and the presser foot lever shaft to the presser foot connecting rod 1. 2. Align the screw hole on the presser foot driving shaft assembly with the presser foot lever shaft's D-cut face 2, and secure the presser foot driving shaft assembly with the screw 1.
Page 135: Presser Foot Driving Shaft Assembly Attachment
Main unit Upper shaft unit Presser foot driving shaft assembly attachment 1. Apply FBK OIL RO100 to the 2 felts 1. 2. Attach the felts to the lower shaft metal collars on the arm bed. (2 locations) 3. Align the presser foot driving shaft assembly's 2 2 lower shaft metals with the lower shaft metal collar on the arm bed, and then attach the presser foot driving shaft assembly to the arm bed.
Page 136: Crank Rod Assembly Attachment
Main unit Upper shaft unit Crank rod assembly attachment 1. Attach the crank rod assembly 2 to the thread take-up cam 1, and secure them with the 2 screws 1. *Key point • Align the crank rod assembly's D cut face 3 with screw hole 2.
Page 137: Main Shaft Sensor Final Assembly Attachment
Main unit Upper shaft unit Main shaft sensor final assembly attachment 1. Attach the main shaft sensor assembly 1 to the sensor holder 2 with the screw 1. 2. Attach the main shaft sensor final assembly 3 to the arm bed with the screw 2.
Page 138: Thread Take-up Driving Lever Final Assembly
Main unit Upper shaft unit Thread take-up driving lever final assembly 1. Attach the roller 2 to the thread take-up differential lever 1, and tighten the thread take-up roller pin 3. 2. Attach the spacer 4 to the thread take-up differential lever, and temporarily tighten the screw 1.
Page 139: Thread Take-up Driving Lever Final Assembly Attachment
Main unit Upper shaft unit Thread take-up driving lever final assembly attachment 1. Attach the thread take-up driving lever final assembly 1 to the arm bed with the 2 screws 1. *Key point • Align the roller 2 with the groove 3 on the thread take-up cam.
Page 140: Presser Foot Vertical Base Final Assembly
Main unit Upper shaft unit Presser foot vertical base final assembly 1. Attach the presser foot cushion base 2 to the presser foot vertical base 1 with the screw 1. 2. Thread the presser foot vertical bush 3 through the presser foot vertical base assembly, and then tighten the screw 2.
Page 141: Vertical Set Assembly
Main unit Upper shaft unit Vertical set assembly 1. Attach the J cushion base 2 to the J bracket 1 with the 2 screws 1. 2. Thread the J vertical bush 3 through the J bracket assembly, and then tighten the screw 2. 3.
Page 142: Base Needle Bar Attachment
Main unit Upper shaft unit Base needle bar attachment 1. Apply MOLYKOTE EM-30L to the shaft 1 and the hole 2 of the J- clamp final assembly and the presser foot vertical base assembly. 2. Attach the base needle bar 3, J vertical set assembly 4, and presser foot vertical base assembly 5.
Page 143: Driving Jump Assembly (1)
Main unit Upper shaft unit Driving jump assembly (1) 1. Attach the J cushion pin 2 and the J cushion 3 to the J base assembly 1, and then tighten the screw 1. 2. Apply MOLYKOTE EM-30L to the shaft hole 4 on the J base assembly. 3.
Page 144: Driving Jump Assembly (2)
Main unit Upper shaft unit Driving jump assembly (2) Retaining ring E4 *Key point • Use a positioning pin (one of adjustment jigs). 1. Thread the plain washer M5 through the differential lever, attach the differential lever to the J link assembly 1, and then attach the retaining ring E4.
Page 145: Driving Jump Assembly Attachment
Main unit Upper shaft unit Driving jump assembly attachment 1. Attach the driving jump assembly 1 to the arm bed with the 2 screws 1. *Key point • Adjust the attachment position of the driving jump assembly so that the clearance 2 between the driving jump assembly's J driving lever bearing and the J-clamp final assembly's jump bracket is 0 to 0.2 mm.
Page 146: Main Motor Final Assembly
Main unit Upper shaft unit Main motor final assembly 1. Attach the motor cap 1 to the main motor assembly. 2. Attach the fender rubber 3 to the motor holder 2. 3. Attach the 2 spacers (4 x 7) 4 to the fender rubber. 4.
Page 147 Main unit Needle bar unit 3 - 49...
Page 148: Case Guide Ul Assembly
Main unit Needle bar unit Case guide UL assembly 1. Attach the thread take-up guide 1 to the case guide UL 2 with the 2 screws 1. *Key point • Check that these are attached in the direction shown in the photo.
Page 149: Case Bracket Assembly
Main unit Needle bar unit Case bracket assembly 1. Attach the 2 ball bearings 694 to the case bracket assembly 1, and attach the 2 retaining rings E3. 2. Place the 4 washers (plain S, 4) in the case bracket assembly 1, and then attach the case guide US 2 with the 4 screws 1.
Page 150: Case Bracket Assembly Attachment
Main unit Needle bar unit Case bracket assembly attachment 1. Attach the case guide UL assembly 1 to the arm bed with the 2 screws 1. 2. Apply MOLYKOTE EM - 30L to the slide roller 2 (4 locations). 3. Place the slide roller 2 in the V groove on the case bracket assembly, slide the case bracket assembly horizontally to attach it to the case guide UL assembly 1, and then firmly tighten the 2 screws 2 of the case bracket assembly.
Page 151: Case Positioning Plate Assembly
Main unit Needle bar unit Case positioning plate assembly 1. Attach the ball bearing 694 assembly 2 to the case positioning plate 3 with the nut 2, M4 1, spring washers 2-4, and plain washers M4. *Key point • Temporarily tighten the nut 2, M4 1 first. Firmly tighten them after completing 3 - 58 "Needle bar case final assembly attachment."...
Page 152: Needle Bar Attachment
Main unit Needle bar unit Needle bar attachment 1. Attach a screw 1 to each of the 6 needle bars 1. 2. Apply MOLYKOTE EM-30L to the 12 insertion holes 2 on the needle bar case. 3. Attach the spring and the washer to the needle bar, and then thread the needle bar through the upper hole on the needle bar case assembly.
Page 153: Thread Take-up Lever Assembly
Main unit Needle bar unit Thread take-up lever assembly 1. Attach the thread take-up boss 1 to the thread take-up lever 2 with the 2 screws 1. (6 sets) *Key point • Apply ThreeBond 1401 to the screw 1 and then tighten it. Size of a grain of Apply ThreeBond 1401.
Page 154: Thread Take-up Lever Assembly Attachment
Main unit Needle bar unit Thread take-up lever assembly attachment 1. Attach the 2 thread take-up bushes 1 to the needle bar case assembly. 2. Apply MOLYKOTE EM-30L to the 6 shaft holes 2 on the thread take-up lever assembly. 3.
Page 155: Case Guide D Attachment
Main unit Needle bar unit Case guide D attachment 1. Attach the case guide D 1 to the needle bar case assembly with the 2 screws 1. Torque Bolt, Socket 1.18 – 1.57 N-m M4X16 Change roller base assembly attachment 1.
Page 156: Needle Bar Case Final Assembly Attachment
Main unit Needle bar unit Needle bar case final assembly attachment 1. Rotate the pulley until the base line on the pulley is at the top. 2. Apply MOLYKOTE EM-30L to the roller 1 of the thread take-up differential lever. 3.
Page 157 Main unit Thread wiper unit 3 - 59...
Page 158: Wiper Set Assembly
Main unit Thread wiper unit Wiper set assembly 1. Attach the wiper motor assembly 2 to the wiper base assembly 1 with the 2 screws 1. 2. Attach the wiper link assembly 4 and the plain washer (M5) to the wiper lever 3, and then attach the retaining ring E4.
Page 159: Wiper Guide And Wiper Sensor Attachment
Main unit Thread wiper unit Wiper guide and wiper sensor attachment 1. Attach the wiper cushion 2 to the wiper guide 1. 2. Attach the wiper guide assembly to the wiper base assembly with the 6 screws 1. 3. Attach the wiper sensor assembly 3 to the wiper base assembly with the screw 2.
Page 160: Wiper Set Assembly Attachment
Main unit Thread wiper unit Wiper set assembly attachment 1. Slightly rotate the wiper lever counterclockwise to create a clearance between the wiper lever dog and the wiper sensor assembly 1. 2. Attach the wiper set assembly to the arm bed with the 2 screws 1. *Key point] •...
Page 161: Thread Presser Base Assembly
Main unit Thread wiper unit Thread presser base assembly 1. Attach the 2 thread presser spacers 2 and the thread presser cover assembly 3 to the thread presser base assembly 1 with the 2 screws 1. Torque Screw, Pan 0.78 – 1.18 N-m M3X7 Thread presser base attachment 1.
Page 162 Main unit Needle bar change unit 3 - 64...
Page 163: Change Box Assembly (step 1)
Main unit Needle bar change unit Change box assembly (Step 1) 1. Attach the C stop position dog 1 to the change camshaft 2 with the 2 screws 1. *Key point • Align the change camshaft's end face (grooved) with the C stop position dog's end face.
Page 164: Change Box Assembly (step 2)
Main unit Needle bar change unit Change box assembly (Step 2) 1. Attach the change gear 1 to the change camshaft. 2. Move the change gear toward the change cam, and secure it with the 2 screws 1. *Key point •...
Page 165: Change Box Assembly (step 3)
Main unit Needle bar change unit Change box assembly (Step 3) 1. Attach the index motor assembly 1 to the change motor base 2 with the 2 screws 1. 2. Attach the change motor base assembly to the change box assembly with the 2 screws 2.
Page 166 Main unit Needle thread unit 3 - 68...
Page 167: Thread Motor Assembly Attachment
Main unit Needle thread unit Thread motor assembly attachment 1. Attach the base plate assembly 2 to the thread guide base 1 with the 2 screws 1. *Key point • Firmly tighten the 2 screws 2 after completing 4 - 27 "Needle threader adjustment (up/down)."...
Page 168: Rack Assembly And Hook Holder Link Attachment
Main unit Needle thread unit Rack assembly and hook holder link attachment 1. Attach the hook holder link 1 to the rack assembly's shaft, and then attach the retaining ring E3. 2. Apply MOLYKOTE EM-30L to the gear face 2 and the connecting face on the rack assembly, and the hook holder shaft attachment hole 3 on the hook holder link.
Page 169: Needle Thread Assembly Attachment
Main unit Needle thread unit Needle thread assembly attachment 1. Attach the needle thread assembly 1 with the 6 screws 1. Torque Taptite, Bind S Hand start M4X10 3 - 71...
Page 170: Feed Unit
Main unit Feed unit 3 - 72...
Page 171: Connect Pcb Final Assembly
Main unit Feed unit Connect PCB final assembly 1. Bend the FFC (SML2CD-Y) 90 degrees at a point 55 mm from the tip. 2. Attach the sheet 2 and the FFC (SML2CD-Y) 3 to the PCB holder 1 55mm with the screw 1. 3.
Page 172: Y-carriage R Assembly
Main unit Feed unit Y-carriage R assembly External retaining rings C19 1. Attach the linear bearing 10 2 to bearing case Y 1, and then attach the 2 external retaining rings C19. 2. Attach the 2 bearing case Y assemblies to Y-carriage R 3 with the 8 screws 1.
Page 173: Y-carriage L Assembly
Main unit Feed unit Y-carriage L assembly External retaining rings C19 1. Attach the linear bearing 10 2 to bearing case Y 1, and then attach the 2 external retaining rings C19. (2 sets) 2. Attach the 2 bearing case Y assemblies to Y-carriage L 3 with the 8 screws 1.
Page 174: Feed Frame Assembly Attachment
Main unit Feed unit Feed frame assembly attachment 1. Attach the 2 cap connections 1 to the feed frame with the 4 screws 1. (2 locations) 2. Temporarily attach the Y-carriage R assembly 2 and the Y-carriage L assembly 3 to the feed frame assembly with the 4 screws 2. 3.
Page 175: T-belt (x-drive) Attachment
Main unit Feed unit T-belt (X-drive) attachment 1. Hang the T-belt B60S796 3 over the Y driving gear pulley assembly 1 and the tension pulley plate final assembly 2, and then secure the tension pulley plate final assembly to the feed frame assembly with the 2 screws *Key point •...
Page 176: X-guide Shaft Attachment
Main unit Feed unit X-guide shaft attachment External retaining rings C21 1. Attach the linear bearing (12) 2 to bearing case X 1, and then attach the 2 external retaining rings C21. (2 sets) 2. Attach the X-roller 3 to the bearing case X assembly, and then attach the retaining ring E4.
Page 177: Hoop Sensor Attachment
Main unit Feed unit Hoop sensor attachment 1. Attach the spring to the X-carriage A assembly. 2. Attach the hoop sensor assembly 2 to the X-carriage A assembly with the nut 1 and plain washer (S6), and then thread the hoop sensor assembly's shaft through the spring 3.
Page 178: X-sensor Dog Attachment
Main unit Feed unit X-sensor dog attachment 1. Attach the caution 1 to the X-carriage 2 with the 2 screws 1. NOTE • The X sensor dog bends easily. Handle it carefully. 2. Bend the FFC (SML2CD-X) 3 90 degrees at a point 60 mm from the tip. 3.
Page 179: X-carriage A Assembly And X-carriage B Assembly Attachment
Main unit Feed unit X-carriage A assembly and X-carriage B assembly attachment 1. Attach the X-carriage B assembly 1 to the 2 bearing case X final assemblies 2 attached to the X-shaft with the 4 screws 1. 2. Attach the hoop PCB assembly 3 to the X-carriage B assembly with the screw 2.
Page 180: X-feed Frame B Attachment
Main unit Feed unit X-feed frame B attachment 1. Apply MOLYKOTE EM-30L to the surface 1 where the X-feed frame contacts the X-roller. 2. Attach the X-feed frame B 2 to the feed frame assembly with the 4 screws (1 2, 2 each). *Key point •...
Page 181: Y-frame Spacer And X-belt Presser Attachment
Main unit Feed unit Y-frame spacer and X-belt presser attachment 1. Attach the 2 Y-frame spacers 1 to X-carriage B with the 4 screws 1. 2. Align the X-belt presser 2 with the highest point of the T-belt, and then attach the X-belt presser to X-carriage B.
Page 182: Ffc And X-area Sensor Assembly Attachment
Main unit Feed unit FFC and X-area sensor assembly attachment 1. Bend the free end of the FFC (SML2CD-X) connected to the hoop PCB assembly 90 degrees at two points, connect it to the X-area sensor assembly 1, and lock the connector. 2.
Page 183: Cord Grip Attachment
Main unit Feed unit Cord grip attachment 1. Connect the FFC (SML2CD-C) 1 to the connect PCB, and lock the connector. 2. Connect the X-feed motor's lead wire to the connect PCB. 3. Bind the X-feed motor's lead wire and the FFC (SML2CD-C) with the cord grip 2, and then tighten the screw 1.
Page 184: Y Driving Shaft Assembly Attachment
Main unit Feed unit Y driving shaft assembly attachment 1. Apply FBK OIL RO100 to the 2 felts 1. 2. Attach the felts 1 to the metal collars on the base frame. (2 locations) 3. Attach the Y driving shaft assembly 2 to the base frame. 4.
Page 185: Y Motor Final Assembly Attachment
Main unit Feed unit Y motor final assembly attachment 1. Attach the Y motor final assembly 1 to the base frame with the 2 screws *Key point • Adjust the backlash of the Y motor gear and the Y-guide shaft gear to zero.
Page 186: Feed Final Assembly Attachment
Main unit Feed unit Feed final assembly attachment 1. Attach the 2 Y-guide shafts 1 to the feed final assembly, and then attach the feed final assembly to the base frame. 2. Secure the 2 fixed Y-shaft plates with the 4 screws 1 (one each on left and right).
Page 187: T-belt (y-guide) Attachment
Main unit Feed unit T-belt (Y-guide) attachment Retaining rings E4 1. Attach the Y tension pulley 1 and the plain washer 7 X 2 to the Y tension plate assembly, and then attach the 2 sets of retaining rings E4. 2.
Page 188: Main Unit
Main unit Main unit 3 - 90...
Page 189: Cutter Unit Final Assembly And Picker Final Assembly Attachment
Main unit Main unit Cutter unit final assembly and picker final assembly attachment 1. Attach the cutter unit final assembly 1 to the arm bed with the 2 screws 2. Attach the picker final assembly 2 to the arm bed with the 2 screws 2. *Key point •...
Page 190: Rotary Hook Attachment
Main unit Main unit Rotary hook attachment 1. Attach the rotary hook 1 to the lower shaft with the 3 screws 1. Torque Foot set screw 0.78 – 1.18 N-m 4.46 Picker bracket final assembly 1. Apply MOLYKOTE EM-30L to the picker assembly's shaft 1. 2.
Page 191: Needle Plate Base Assembly
Main unit Main unit Needle plate base assembly *Key point • After assembling the needle plate base, be sure to do 4 - 38 "Cutter knife engagement adjustment". 1. Attach the thread holding plate 1 to the needle plate base assembly with the screw 1.
Page 192: Needle Plate Base Assembly Attachment
Main unit Main unit Needle plate base assembly attachment 1. Attach the needle plate base assembly 1 to the arm bed with the 2 screws *Key point • Attach the needle plate base assembly 1 so that it is parallel to the arm bed.
Page 193: Tension Base Attachment
Main unit Main unit Tension base attachment 1. Attach the tension base assembly 1 to the needle bar case final assembly with the 4 screws 1. 2. Attach the cord clamp (NK-4N) to the tension base cord at a point 125 mm from the tension base, and secure it to the arm bed with the screw 2.
Page 194: Thread Take-up Lever Cover Attachment
Main unit Main unit Thread take-up lever cover attachment 1. Attach the thread take-up lever cover 1 to the tension base assembly 2 with the 2 screws 1. *Key point • Place the 2 tabs on the upper section of the thread take-up lever cover over the 2 holes 3 on the operator's side of the tension base assembly, and then align the pin on the left side of the needle bar case final assembly with the groove 4 on...
Page 195: Spool Stand Frame Final Assembly Attachment
Main unit Main unit Spool stand frame final assembly attachment 1. Attach the 3 studs 1 to the top face of the arm bed. 2. Attach the spool stand frame final assembly 2 to the 3 studs with the 3 screws 1.
Page 196: Main Pcb Assembly Attachment
Main unit Main unit Main PCB assembly attachment 1. Attach the board holder U 1 and the board holder D 2 with the 4 screws 2. Attach the main PCB assembly 3 with the 4 screws 2. 3. Connect the lead wires. Start movie clip (CD-ROM version only) Torque Taptite, Bind S...
Page 197: Led Pcb Plate Attachment
Main unit Main unit LED PCB plate attachment 1. Attach the LED PCB plate 1 to the arm bed with the 2 screws 1. Torque Taptite, Bind S 1.47 – 1.96 N-m M4X10 LED drive PCB assembly attachment 1. Attach the LED drive PCB assembly 2 to the LED PCB plate 1 with the 2 screws 1.
Page 198: Base Cover L Attachment
Main unit Main unit Base cover L attachment 1. Attach the groove cover A 2 and the groove cover B 3 to the rear of the base cover L 1. 2. Attach the groove cover C 5 to the rear of the base cover L lid 4. 3.
Page 199: Base Cover R Attachment
Main unit Main unit Base cover R attachment 1. Attach the groove cover A 2 and the groove cover B 3 to the rear of the base cover R 1. 2. Attach the groove cover C 5 to the rear of the base cover R lid 4. 3.
Page 200: Arm Cover L Attachment
Main unit Main unit Arm cover L attachment Outside 1. Attach the arm cover L 1 with the 3 screws 1 and 2. 2. Attach the 3 screw covers. Start movie clip (CD-ROM version only) Inside Torque Screw, Pan (S/P washer) 0.78 –...
Page 201: Bed Cover Attachment
Main unit Main unit Bed cover attachment 1. Attach the bed cover 1 and the bed cover top 2 to the arm bed with the 4 screws 1. 2. Attach the spring 4 and the hinged door 5 to the bed cover bottom 3. 3.
Page 202: Motor Cover / Carriage Cover Attachment
Main unit Main unit Motor cover / carriage cover attachment 1. Attach the motor cover 1 with the 2 screws 1. 2. Attach the carriage cover 2 to the X-guide with the screw 2. 3. Attach the screw cover. Start movie clip (CD-ROM version only) Torque Taptite, Cup B 0.78 –...
Page 203: Adjustment
Adjustment Precaution Adjustment flow ........4 - 2 Inspection Bent needle ........4 - 3 Blunt needle........4 - 4 Test mode Starting test mode / Selecting adjustment test mode 4 - 5 Main board test mode.......4 - 6 Panel board test mode ....4 - 12 Reference needle bar data for adjustment after main PCB replacement4 - 16 Adjustment Motor belt tension adjustment ..4 - 18...
Page 204: Adjustment Flow
Precaution Adjustment flow The following adjustment items are inter-related. This means that adjusting one of them will affect the adjusted values of the subsequent items. Be sure to adjustment these items according to the flow below. 1. Needle position adjustment (front/back) .
Page 205: Bent Needle
Inspection Bent needle 1. Place the needle on the surface plate (level block) to check that the needle is not bent. *Key point • Check all six needles. The gap with the block should be even. Level block 4 - 3...
Page 206: Blunt Needle
Inspection Blunt needle 1. Touch the needle tip with your finger to check that the needle tip is not blunt. 4 - 4...
Page 207: Starting Test Mode / Selecting Adjustment Test Mode
Test mode Starting test mode / Selecting adjustment test mode Starting test mode 1. Turn the [POWER] switch on with the [START/STOP] button, [THREAD CUT] button, [THREAD GUIDE] button simultaneously held down. Selecting adjustment test mode 1. Select the desired adjustment mode by pressing the corresponding mode key displayed on the screen. TEST MODE MAIN BOARD TEST MODE PANEL BOARD TEST MODE...
Page 208: Main Board Test Mode
Test mode Main board test mode Test Mode Operation Manual NOTE • After replacing the main board, you must set the picker motor over-pulses (See 8. in this chapter) and adjust the frame sensor (See 11. in this chapter). 1. Hold down the three mechanical switches on the operation panel ([START/STOP], [THREAD CUT], [THREAD GUIDE]) and turn the [POWER] switch on.
Page 209: Test Mode
Test mode 4. [MAIN MOTOR TEST] [MOVE ORIGIN POSITION] : Adjusts the angle of the main shaft to the needle top stop position. [ROTATE MAIN MOTOR] : Rotates the main shaft at the preset speed. [STOP MAIN MOTOR] : Stops the main shaft. [<] [>] : Sets the motor speed.
Page 210 Test mode 6. [TRIM MOTOR TEST] [MOVE ORIGIN POSITION] : Returns the trim (thread cut) motor to its origin. [MOVE TRIM MOTOR] : Moves the trim (thread cut) motor. [TRIM ON OFF] : Turns the trim (thread cut) motor on and off. [TRIM MANUAL] : Cuts the thread.
Page 211 Test mode 9. [THREAD SET MOTOR TEST] [MOVE ORIGIN POSITION] : Returns the thread motor to its origin. [MOVE THREAD SET MOTOR] : Performs needle threading. [MANUAL MOVE] : Moves the TH motor to stand by at the needle thread hook change position. [CLOSE] : Closes the <THREAD SET MOTOR TEST>...
Page 212 Test mode 12. [CASE MOTOR TEST] In addition to conduct the needle bar case motor test, the status of the thread breakage sensor is indicated using "H" or "L". (A buzzer goes off when the status of the thread breakage sensor changes.) Needle bar data that has already been read via USB is displayed below [THREAD BREAKAGE].
Page 213 Test mode 15. [NEEDLE THREADER] When the needle bar data has been read via USB, the needle bar numbers for front/back adjustment and left/right adjustment are displayed, and the read needle bar data is displayed to the right of these. (13 characters) [[FRONT - BACK] POSITION] : Moves the needle bar to the position for front/back adjustment.
Page 214: Panel Board Test Mode
Test mode Panel board test mode Starting test mode Hold down the [START/STOP], [THREAD CUT], and [THREAD GUIDE] buttons and turn the [POWER] switch on. The screen shown below appears. Select [PANEL BOARD TEST MODE]. When [PANEL BOARD TEST MODE] is selected, the menus shown below are displayed. Menu descriptions 1.
Page 215 Select this mode to check whether the embroidery card slot is operating correctly. Insert an embroidery card in the slot, and select this mode. When the card is recognized correctly, [Copyright by Brother Industries Ltd.] is displayed. If the card is not recognized correctly, [No Embroidery Card.] is displayed.
Page 216 Test mode 7. USB-F file list Select this mode to display a list of the files transferred from the PC to check that the USB function is operating correctly. 8. Touch Panel adj Select this mode to adjust the touch panel. This mode can also be started as follows: 1) Press the [POWER] switch with one hand while touching the screen with your other hand.
Page 217 A small cross cursor is displayed. Sewing order display Name of Color Display expanded thread color OFF Thread selection Brother's original pallet DST thread trimming feed +3 when thread trimming is turned on Deleting short stitches 0.3 mm or less...
Page 218: Reference Needle Bar Data For Adjustment After Main Pcb Replacement
Test mode Reference needle bar data for adjustment after main PCB replacement When the main PCB has been replaced, [NO DATA] is displayed next to the reference needle bar selections in test mode. Follow the steps below to store the reference needle bar data. [NO DATA] is displayed.
Page 219 Test mode • HOW TO READ NEEDLE BAR NUMBERS ON BAR CODE <e.g.> It is also possible to adjust by selecting the numbers printed on bar code which is stuck on needle bar case. (But it is displayed as "NO DATA" on screen.) How to select a needle bar number: 1.
Page 220: Motor Belt Tension Adjustment
Adjustment Motor belt tension adjustment 1. Loosen the 2 screws 1. 2. Move the motor holder up and down to adjust the motor belt tension. Motor belt deflection when a load of approx. 0.98 2.0 - 3.5 mm N (100 g) is applied to the center of the motor belt 3.
Page 221: Timing Belt Tension Adjustment
Adjustment Timing belt tension adjustment 1. Loosen the screw 1. 2. Move the tension pulley right and left to adjust the timing belt tension. Timing belt deflection when a load of approx. 3.0 - 4.0 mm 1.96 N (200 g) is applied to the center of the timing belt 3.
Page 222: Needle Position Adjustment (front/back)
Adjustment Needle position adjustment (front/back) Front/back position adjustment 1. Enter the test mode, and press [MAIN BOARD TEST MODE] and then [NEEDLE POSITION]. 2. Press [[FRONT - BACK] POSITION]]. The reference needle bar is selected and the needle bar case final assembly moves.
Page 223: Needle Position Adjustment (right/left)
Adjustment Needle position adjustment (right/left) Right/left position adjustment 1. Enter the test mode, and press [MAIN BOARD TEST MODE] and then [NEEDLE POSITION]. 2. Press [[RIGHT - LEFT] POSITION]]. The reference needle bar is selected and the needle bar case final assembly moves.
Page 224: Needle Bar Rising Length And Needle Space Adjustment
Adjustment Needle bar rising length and needle space adjustment 1. Enter the test mode, and press [MAIN BOARD TEST MODE] and then [NEEDLE SPACING]. 2. Press [[SPACING] POSITION]]. The reference needle bar for rising length adjustment is selected and the needle bar case final assembly moves.
Page 225: Needle Bar Height Adjustment
Adjustment Needle bar height adjustment 1. Rotate the pulley manually to move the needle bar until the needle's right edge matches the rotating hook's tip. 2. Loosen the screw 1. 3. Adjust the needle bar height and alignment. 4. Tighten the screw 1. 5.
Page 226: Rotary Hook Stopper Clearance Adjustment
Adjustment Rotary hook stopper clearance adjustment 1. Loosen the screw 1 and 2. 2. Adjust the clearance between the rotary hook stopper and the rotary hook. 3. Tighten the screws 1 and 2. Clearance between rotary hook stopper end face 0.65 - 0.95 mm and rotary hook Torque...
Page 227: Presser Foot Height Adjustment
Adjustment Presser foot height adjustment 1. Rotate the pulley manually to move the needle bar to the bottom point. 2. Loosen the screw 1. 3. Adjust the presser hoot height. 4. Tighten the screw 1. 5. Repeat the same steps to adjust the presser hoot height for the other 5 needle bars. *Key point •...
Page 228: Needle Bar Top Dead Center Adjustment
Adjustment Needle bar top dead center adjustment 1. Enter the test mode, and press [MAIN BOARD TEST MODE] and then [NEEDLE THREADER]. 2. Press [[RIGHT - LEFT] POSITION]]. The reference needle bar for needle threader right/left position adjustment is selected and the needle bar case final assembly moves. 3.
Page 229: Needle Threader Adjustment (up/down)
Adjustment Needle threader adjustment (up/down) Up/down position adjustment 1. Enter the test mode, and press [MAIN BOARD TEST MODE] and then [NEEDLE THREADER]. 2. Press [←] or [→] to select the number 1 needle bar, and the needle bar case final assembly moves. 3.
Page 230: Needle Threader Adjustment (right/left)
Adjustment Needle threader adjustment (right/left) Right/left position adjustment 1. Enter the test mode, and press [MAIN BOARD TEST MODE] and then [NEEDLE THREADER]. 2. Press [RIGHT - LEFT] POSITION]. The reference needle bar for needle threader right/left position adjustment is selected and the needle bar case final assembly moves.
Page 231: Needle Threading Check
Check Needle threading check 1. Enter the test mode, and press [MAIN BOARD TEST MODE] and then [THREAD SET MOTOR TEST]. 2. Press [MOVE ORIGIN POSITION] to move the hook to its origin. 3. Press [MOVE THREAD SET MOTOR] to check that the hook passes through the needle hole. 4.
Page 232: Y-belt Tension Adjustment
Adjustment Y-belt tension adjustment 1. Loosen the 2 screws 1. 2. Loosen the 2 screws 2. 3. Move the Y tension plate assembly back and forth to adjust the Y-belt tension. 4. Tighten the 2 screws 2. 5. Repeat the same steps to adjust the Y-belt tension on the right side. 6.
Page 233: X-belt Tension Adjustment
Adjustment X-belt tension adjustment 1. Loosen the 2 screws 1. 2. Move the tension pulley plate assembly right and left to adjust the X-belt tension. 3. Tighten the 2 screws 1. Load when the center of the X-belt is deflected 1.27 - 1.47 N (130 - 150g) 5.7 mm Torque...
Page 234: Picker Activation Adjustment
Adjustment Picker activation adjustment 1. Remove the bobbin case. 2. Enter test mode and press [MAIN BOARD TEST MODE] and then [PICKER MOTOR TEST]. 3. Press [MOVE PICKER MOTOR] to release the picker, and then attach the bobbin case with a bobbin inserted to the rotary hook.
Page 235: Movable Knife Origin Adjustment
Adjustment Movable knife origin adjustment 1. Enter the test mode, and press [MAIN BOARD TEST MODE] and then [TRIM MOTOR TEST]. 2. Press [MOVE ORIGIN POSITION] to move the needle plate base assembly's movable knife to its origin. 3. Loosen the 2 screws 1. 4.
Page 236: Thread Presser Base Up/down Position Adjustment
Adjustment Thread presser base up/down position adjustment 1. Loosen the 4 screws 1. 2. Adjust the vertical position of the thread presser base. 3. Tighten the 4 screws 1. Clearance between wiper hook top face and 0 - 0.2 mm thread presser cover Torque Screw, Bind...
Page 237: Hoop Sensor Adjustment
Adjustment Hoop sensor adjustment 1. Attach the hoop stay assembly to the feed unit. 2. Enter the test mode, and press [MAIN BOARD TEST MODE] and then [A/D TEST]. 3. After the hoop stay assembly's LL-hoop has been attached, press [LL] to save the A/D value. 4.
Page 238: Upper Shaft Encoder Phase Adjustment
Adjustment Upper Shaft Encoder Phase Adjustment 1. Enter the test mode, and press [MAIN BOARD TEST] and then press [SENSOR TEST]. Select MAIN BOARD TEST Select MAIN BOARD TEST Select SENSOR TEST 2. Rotate the upper shaft counterclockwise until the J-clamp final assembly is lowered19.5 - 20.0 mm from the top dead center position ( = the needle bar crank rod is in a vertical position).
Page 239: Xy-guide Origin Adjustment
Adjustment XY-guide origin adjustment 1. Attach the hoop stay assembly to the feed unit. 2. Attach the LL-hoop to the hoop stay assembly. 3. Attach the embroidery sheet to the LL-hoop. 4. Enter the test mode, and press [MAIN BOARD TEST MODE] and then [XY MOTOR TEST]. 5.
Page 240: Cutter Knife Engagement Adjustment
Adjustment Cutter knife engagement adjustment Check that the engagement load of the movable and fixed knives when the movable knife is pulled in the direction shown in Figure 1 is within the specifications. If it is not within the specifications, adjust the load according to the steps below. Adjustment steps 1.
Page 241 Adjustment (for PR620/BMP8) Precaution Adjustment flow ........4 - 2 Inspection Bent needle ........4 - 4 Blunt needle........4 - 4 Test mode Starting test mode / Selecting adjustment test mode 4 - 5 Main board test mode.......4 - 6 Panel board test mode ....4 - 12 Reference needle bar data for adjustment after main PCB replacement4 - 17 Adjustment Motor belt tension adjustment ..4 - 19...
Page 242 Precaution Adjustment flow The following adjustment items are inter-related. This means that adjusting one of them will affect the adjusted values of the subsequent items. Be sure to adjustment these items according to the flow below. 1. Needle position adjustment (front/back) .
Page 243 Inspection Bent needle 1. Place the needle on the surface plate (level block) to check that the needle is not bent. *Key point • Check all six needles. The gap with the block should be even. Level block 4 - 3...
Page 244 Inspection Blunt needle 1. Touch the needle tip with your finger to check that the needle tip is not blunt. 4 - 4...
Page 245 Test mode Starting test mode / Selecting adjustment test mode Starting test mode 1. Turn the [POWER] switch on with the [START/STOP] button, [THREAD CUT] button, [THREAD GUIDE] button simultaneously held down. Selecting adjustment test mode 1. Select the desired adjustment mode by pressing the corresponding mode key displayed on the screen. TEST MODE MAIN BOARD TEST MODE PANEL BOARD TEST MODE...
Page 246 Test mode Main board test mode Test Mode Operation Manual NOTE • After replacing the main board, you must set the picker motor over-pulses (See 8. in this chapter) and adjust the frame sensor (See 11. in this chapter). 1. Hold down the three mechanical switches on the operation panel ([START/STOP], [THREAD CUT], [THREAD GUIDE]) and turn the [POWER] switch on.
Page 247 Test mode 4. [MAIN MOTOR TEST] [MOVE ORIGIN POSITION] : Adjusts the angle of the main shaft to the needle top stop position. [ROTATE MAIN MOTOR] : Rotates the main shaft at the preset speed. [STOP MAIN MOTOR] : Stops the main shaft. [<] [>] : Sets the motor speed.
Page 248 Test mode 6. [TRIM MOTOR TEST] [MOVE ORIGIN POSITION] : Returns the trim (thread cut) motor to its origin. [MOVE TRIM MOTOR] : Moves the trim (thread cut) motor. [TRIM ON OFF] : Turns the trim (thread cut) motor on and off. [TRIM MANUAL] : Cuts the thread.
Page 249 Test mode 9. [THREAD SET MOTOR TEST] [MOVE ORIGIN POSITION] : Returns the thread motor to its origin. [MOVE THREAD SET MOTOR] : Performs needle threading. [MANUAL MOVE] : Moves the TH motor to stand by at the needle thread hook change position. [CLOSE] : Closes the <THREAD SET MOTOR TEST>...
Page 250 Test mode 12. [CASE MOTOR TEST] In addition to conduct the needle bar case motor test, the status of the thread breakage sensor is indicated using "H" or "L". (A buzzer goes off when the status of the thread breakage sensor changes.) Needle bar data that has already been read via USB is displayed below [THREAD BREAKAGE].
Page 251 Test mode 15. [NEEDLE THREADER] When the needle bar data has been read via USB, the needle bar numbers for front/back adjustment and left/right adjustment are displayed, and the read needle bar data is displayed to the right of these. (13 characters) [[FRONT - BACK] POSITION] : Moves the needle bar to the position for front/back adjustment.
Page 252 Test mode Panel board test mode Starting test mode Hold down the [START/STOP], [THREAD CUT], and [THREAD GUIDE] buttons and turn the [POWER] switch on. The screen shown below appears. Select [PANEL BOARD TEST MODE]. When [PANEL BOARD TEST MODE] is selected, the menus shown below are displayed. Menu descriptions 1.
Page 253 Select this mode to check whether the embroidery card slot is operating correctly. Insert an embroidery card in the slot, and select this mode. When the card is recognized correctly, [Copyright by Brother Industries Ltd.] is displayed. If the card is not recognized correctly, [No Embroidery Card.] is displayed.
Page 254 Test mode 7. USB-F file list Select this mode to display a list of the files transferred from the PC to check that the USB function is operating correctly. 8. Touch Panel adj Select this mode to adjust the touch panel. This mode can also be started as follows: 1) Press the [POWER] switch with one hand while touching the screen with your other hand.
Page 255 A small cross cursor is displayed. Sewing order display Name of Color Display expanded thread color OFF Thread selection Brother's original pallet DST thread trimming feed +3 when thread trimming is turned on Deleting short stitches 0.3 mm or less...
Page 256 Test mode 13. Clear trip When this mode button is selected, the current values for the stitch counter and sewing time counter (Total and Trip) are displayed on the left side, and the [Clear trip] button is displayed on the right side of the screen. Pressing the [Clear trip] button resets [Trip Stitches] and [Trip Time] to zero.
Page 257 Test mode Reference needle bar data for adjustment after main PCB replacement When the main PCB has been replaced, [NO DATA] is displayed next to the reference needle bar selections in test mode. Follow the steps below to store the reference needle bar data. [NO DATA] is displayed.
Page 258 Test mode • HOW TO READ NEEDLE BAR NUMBERS ON BAR CODE <e.g.> It is also possible to adjust by selecting the numbers printed on bar code which is stuck on needle bar case. (But it is displayed as "NO DATA" on screen.) How to select a needle bar number: 1.
Page 259 Adjustment Motor belt tension adjustment 1. Loosen the 2 screws 1. 2. Move the motor holder up and down to adjust the motor belt tension. Motor belt deflection when a load of approx. 0.98 2.0 - 3.5 mm N (100 g) is applied to the center of the motor belt 3.
Page 260 Adjustment Timing belt tension adjustment 1. Loosen the screw 1. 2. Move the tension pulley right and left to adjust the timing belt tension. Timing belt deflection when a load of approx. 3.0 - 4.0 mm 1.96 N (200 g) is applied to the center of the timing belt 3.
Page 261 Adjustment Needle position adjustment (front/back) Front/back position adjustment 1. Enter the test mode, and press [MAIN BOARD TEST MODE] and then [NEEDLE POSITION]. 2. Press [[FRONT - BACK] POSITION]]. The reference needle bar is selected and the needle bar case final assembly moves.
Page 262 Adjustment Needle position adjustment (right/left) Right/left position adjustment 1. Enter the test mode, and press [MAIN BOARD TEST MODE] and then [NEEDLE POSITION]. 2. Press [[RIGHT - LEFT] POSITION]]. The reference needle bar is selected and the needle bar case final assembly moves.
Page 263 Adjustment Needle bar rising length and needle space adjustment 1. Enter the test mode, and press [MAIN BOARD TEST MODE] and then [NEEDLE SPACING]. 2. Press [[SPACING] POSITION]]. The reference needle bar for rising length adjustment is selected and the needle bar case final assembly moves.
Page 264 Adjustment Needle bar height adjustment 1. Rotate the pulley manually to move the needle bar until the needle's right edge matches the rotating hook's tip. 2. Loosen the screw 1. 3. Adjust the needle bar height and alignment. 4. Tighten the screw 1. 5.
Page 265 Adjustment Rotary hook stopper clearance adjustment 1. Loosen the screw 1 and 2. 2. Adjust the clearance between the rotary hook stopper and the rotary hook. 3. Tighten the screws 1 and 2. Clearance between rotary hook stopper end face 0.65 - 0.95 mm and rotary hook Torque...
Page 266 Adjustment Presser foot height adjustment 1. Rotate the pulley manually to move the needle bar to the bottom point. 2. Loosen the screw 1. 3. Adjust the presser hoot height. 4. Tighten the screw 1. 5. Repeat the same steps to adjust the presser hoot height for the other 5 needle bars. *Key point •...
Page 267 Adjustment Needle bar top dead center adjustment 1. Enter the test mode, and press [MAIN BOARD TEST MODE] and then [NEEDLE THREADER]. 2. Press [[RIGHT - LEFT] POSITION]]. The reference needle bar for needle threader right/left position adjustment is selected and the needle bar case final assembly moves. 3.
Page 268 Adjustment Needle threader adjustment (up/down) Up/down position adjustment 1. Enter the test mode, and press [MAIN BOARD TEST MODE] and then [NEEDLE THREADER]. 2. Press [←] or [→] to select the number 1 needle bar, and the needle bar case final assembly moves. 3.
Page 269 Adjustment Needle threader adjustment (right/left) Right/left position adjustment 1. Enter the test mode, and press [MAIN BOARD TEST MODE] and then [NEEDLE THREADER]. 2. Press [RIGHT - LEFT] POSITION]. The reference needle bar for needle threader right/left position adjustment is selected and the needle bar case final assembly moves.
Page 270 Check Needle threading check 1. Enter the test mode, and press [MAIN BOARD TEST MODE] and then [THREAD SET MOTOR TEST]. 2. Press [MOVE ORIGIN POSITION] to move the hook to its origin. 3. Press [MOVE THREAD SET MOTOR] to check that the hook passes through the needle hole. 4.
Page 271 Adjustment Y-belt tension adjustment 1. Loosen the 2 screws 1. 2. Loosen the 2 screws 2. 3. Move the Y tension plate assembly back and forth to adjust the Y-belt tension. 4. Tighten the 2 screws 2. 5. Repeat the same steps to adjust the Y-belt tension on the right side. 6.
Page 272 Adjustment X-belt tension adjustment 1. Loosen the 2 screws 1. 2. Move the tension pulley plate assembly right and left to adjust the X-belt tension. 3. Tighten the 2 screws 1. Load when the center of the X-belt is deflected 1.27 - 1.47 N (130 - 150g) 5.7 mm Torque...
Page 273 Adjustment Picker activation adjustment 1. Remove the bobbin case. 2. Enter test mode and press [MAIN BOARD TEST MODE] and then [PICKER MOTOR TEST]. 3. Press [MOVE PICKER MOTOR] to release the picker, and then attach the bobbin case with a bobbin inserted to the rotary hook.
Page 274 Adjustment Movable knife origin adjustment 1. Enter the test mode, and press [MAIN BOARD TEST MODE] and then [TRIM MOTOR TEST]. 2. Press [MOVE ORIGIN POSITION] to move the needle plate base assembly's movable knife to its origin. 3. Loosen the 2 screws 1. 4.
Page 275 Adjustment Thread presser base up/down position adjustment 1. Loosen the 4 screws 1. 2. Adjust the vertical position of the thread presser base. 3. Tighten the 4 screws 1. Clearance between wiper hook top face and 0 - 0.2 mm thread presser cover Torque Screw, Bind...
Page 276 Adjustment Hoop sensor adjustment 1. Attach the hoop stay assembly to the feed unit. 2. Enter the test mode, and press [MAIN BOARD TEST MODE] and then [A/D TEST]. 3. After the hoop stay assembly's LL-hoop has been attached, press [LL] to save the A/D value. 4.
Page 277 Adjustment Upper Shaft Encoder Phase Adjustment 1. Enter the test mode, and press [MAIN BOARD TEST] and then press [SENSOR TEST]. Select MAIN BOARD TEST Select MAIN BOARD TEST Select SENSOR TEST 2. Rotate the upper shaft counterclockwise until the J-clamp final assembly is lowered19.5 - 20.0 mm from the top dead center position ( = the needle bar crank rod is in a vertical position).
Page 278 Adjustment XY-guide origin adjustment 1. Attach the hoop stay assembly to the feed unit. 2. Attach the LL-hoop to the hoop stay assembly. 3. Attach the embroidery sheet to the LL-hoop. 4. Enter the test mode, and press [MAIN BOARD TEST MODE] and then [XY MOTOR TEST]. 5.
Page 279 Adjustment Cutter knife engagement adjustment Check that the engagement load of the movable and fixed knives when the movable knife is pulled in the direction shown in Figure 1 is within the specifications. If it is not within the specifications, adjust the load according to the steps below. Adjustment steps 1.
Page 280 Adjustment How to reset the counter of the maintenance. When the operating time of the machine becomes 1500h, because following the MSG is displayed, and follow the following instructions. And then maintain the maintenance following by 6-2, 6-3, 6-4, and finally reset the counter.
Page 281 Adjustment 1. Turn the [POWER] switch on with the [START/STOP] button, [THREAD CUT] button, [THREAD GUIDE] button simultaneously held down. 2. Select the [PANEL BOARD TEST MODE]. 3. Select the [Clear trip]. 4. Select the [Clear trip] 5. The state that was cleared. 4 - 41...
Page 282 4 - 42...
Page 283: Failure Investigation For Electronic Parts
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 The power is not turned on....5 - 3 The touch panel does not work..5 - 6 The panel switch does not work.
Page 284 Failure Investigation for Electronic Parts Error message list Error message list See page Error message list See page Inappropriate needle stop position. 5 - 12 This card cannot be used. 5 - 18 Needle bar case position error. 5 - 8 Frame area over.
Page 285 Failure Investigation for Electronic Parts The power is not turned on. • The power is not turned on • Nothing is displayed on the liquid crystal display (LCD). power cord properly connected to both the inlet and the Connect it properly. plug outlet? Is the resistance between the two terminals at both ends 1 Ω...
Page 286 Failure Investigation for Electronic Parts The power is not turned on. From the previous page From the previous page When the power cord is removed from the inlet and the power lead is removed from the power PCB, is Change power switch the resistance between the inlet and the power lead assemblies and power leads.
Page 287 Failure Investigation for Electronic Parts The power is not turned on. From the previous page Is the inverter lead properly connected to connector CN5 on the panel PCB and Connect it properly. connector on the inverter PCB? Is the resistance between each pin at both ends 1 Ω...
Page 288 Failure Investigation for Electronic Parts The touch panel does not work. The touch panel does not work. Is the touch panel tuned correctly? Connect it properly. Is the touch panel's FFC properly connected to connector CN1 on the Connect it properly. panel PCB? Is the resistance between pins 2 and Change touch panel and...
Page 289 Failure Investigation for Electronic Parts The panel switch does not work. • The panel switch does not work, • The panel's LED does not light. Is the switch PCB's lead properly connected to connector CN7 on the Connect it properly. panel PCB? Does the machine function normally when the Change panel PCB.
Page 290: The Needle Bar Does Not Move Normally
Failure Investigation for Electronic Parts The needle bar does not move normally. The needle bar does not move normally. Is the color change sensor's lead properly Connect it properly. connected to connecter CN12 on the main PCB? Is the index sensor's lead properly connected Connect it properly.
Page 291: Thread Breakage Detection Does Not Function Normally
Failure Investigation for Electronic Parts Thread breakage detection does not function normally. Thread breakage detection does not function normally. Is the FFC for the thread quantity sensors properly connected to each thread quantity Connect it properly. sensor and connectors (CN1 - CN6) on the head PCB? Is the orientation of the FFC correct? Is the head lead properly connected to connector CN7 on the head PCB and...
Page 292: The Hoop Does Not Move Normally
Failure Investigation for Electronic Parts The hoop does not move normally. The hoop does not move normally. Is the FFC (SML2CD-C) properly connected to CN1 on the X area sensor PCB and CN4 Connect it properly. on the connect PCB? Is the orientation of the FFC (SML2CD-C) correct? Is the FFC (SML2CD-Y) properly connected to CN1 on the Y area sensor PCB and CN2...
Page 293 Failure Investigation for Electronic Parts The hoop does not move normally. From the previous page Does the machine function normally when the Y Change Y area sensor PCB. area sensor PCB is replaced with a reliable one? Does the machine function normally when the Change connect PCB.
Page 294: The Main Shaft Does Not Rotate Normally
Failure Investigation for Electronic Parts The main shaft does not rotate normally. The main shaft does not rotate normally. Is the main shaft encoder deformed, Change main shaft encoder. bent, or damaged due to contact? Is the main shaft sensor's lead properly connected to CN17 on the Connect it properly.
Page 295: Thread Is Not Cut Normally
Failure Investigation for Electronic Parts Thread is not cut normally. Thread is not cut normally. Is the thread cutter sensor's lead properly connected to CN11 on the Connect it properly. main PCB? Is the thread cutter motor's lead properly connected to CN6 on the Connect it properly.
Page 296: The Wiper Does Not Function Normally
Failure Investigation for Electronic Parts The wiper does not function normally. The wiper does not function normally. Is the wiper sensor's lead properly connected to CN13 on the main Connect it properly. PCB? Is the wiper motor's lead properly connected to CN5 on the main Connect it properly.
Page 297: A Needle Is Not Threaded Normally
Failure Investigation for Electronic Parts A needle is not threaded normally. A needle is not threaded normally. Is the needle thread sensor's lead properly connected to CN14 on the Connect it properly. main PCB? Is the thread motor's lead properly connected to CN6 on the main Connect it properly.
Page 298: The Picker Does Not Function Normally
Failure Investigation for Electronic Parts The picker does not function normally. The picker does not function normally. Is the picker sensor's lead properly connected to CN15 on the main Connect it properly. PCB? Is the picker motor's lead properly connected to CN3 on the main Connect it properly.
Page 299: Led Light Does Not Turn On
Failure Investigation for Electronic Parts LED light does not turn ON. LED light does not turn ON. Is the LED light assembly properly Connect LED drive PCB and connected to CN1 on the LED drive LED light assembly properly. PCB? Is the LED drive PCB properly Connect main PCB and LED connected to CN9 on the main...
Page 300: Embroidery Card Cannot Be Used Normally
Failure Investigation for Electronic Parts Embroidery card cannot be used normally. Embroidery card cannot be used normally. Does the machine function normally Change panel PCB. when another card is used? Use another card. 5 - 18...
Page 301: Universal Serial Bus (usb Function) Cannot Be Used Normally
Failure Investigation for Electronic Parts Universal serial bus (USB function) cannot be used normally. Universal serial bus (USB function) cannot be used normally. Is the USB cable properly connected to both the Connect it properly. personal computer and the sewing machine? Does the machine function normally when the Change USB cable.
Page 302: Universal Serial Bus (usb) Cannot Be Used Normally
Failure Investigation for Electronic Parts Universal serial bus (USB) cannot be used normally. Universal serial bus (USB) cannot be used normally. Connect it properly. Is the USB device firmly connected? When the USB device is replaced with Replace the USB device. a new one, dose it work correctly? Change panel PCB.
Page 303: The Hoop Sensor Does Not Function Normally
Failure Investigation for Electronic Parts The hoop sensor does not function normally. The hoop sensor does not function normally. Is the hoop sensor tuned correctly? Connect it properly. Is the FFC (SML2CD-X) properly connected to CN1 on the hoop sensor PCB and CN2 Connect it properly.
Page 304 Failure Investigation for Electronic Parts The hoop sensor does not function normally. From the previous page Is the resistance between each terminal at both ends 1Ω or below when both ends of the Change FFC (SML2CD-C). FFC (SML2CD-C) are removed from the PCB? Is the resistance between each terminal at both ends 1Ω...
Page 305 Failure Investigation for Electronic Parts The hoop sensor does not function normally. From the previous page Does the machine function normally when the Y Change Y area sensor PCB. area sensor PCB is replaced with a reliable one? Does the machine function normally when the Change main PCB.
Page 306: Error Message
Failure Investigation for Electronic Parts Error message Y-axis home position error (Dialog message) Is the Y area sensor's lead properly connected to CN19 on the main Connect it properly. PCB? Does the machine function normally when the Y Change Y area sensor PCB. area sensor PCB is replaced with a reliable one? Is the resistance between pins 1 and 2, and 3 and 4 of the Y motor 5.2 - 6.4Ω,...
Page 307 Failure Investigation for Electronic Parts Error message • Main motor encoder signal error • Main motor encoder connect error (Dialog message) Is the main shaft encoder deformed, Change main shaft encoder. bent, or damaged due to contact? Is the main shaft sensor's lead properly connected to CN17 on the Change Y area sensor PCB.
Page 308 Failure Investigation for Electronic Parts Error message Main motor current error (Dialog message) Is the main shaft motor's lead properly connected to CN1 on the Connect it properly. main PCB? Is the resistance between pins 1 and 2 of the main shaft motor 1.0 - 2.0Ω...
Page 309 Failure Investigation for Electronic Parts Error message • Sewing data error • Panel communication error • Communication timeout error • Data receiving command error • Communication error (Dialog message) Does not the encoder have the dirt, Change encoder or or damaged due to contact. wipe off the dirt.
Page 310 Failure Investigation for Electronic Parts Error message • Power supply voltage error (24V high) • Power supply voltage error (24V low) • Power supply voltage error (40V high) • Power supply voltage error (40V low) (Dialog message) Is the power lead properly connected Connect it properly.
Page 311 Maintenance 6 - 1...
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Page 317: Special Instructions Of Wiring
Special Instructions of Wiring Head wiring........7 - 2 Arm wiring.........7 - 3 Base wiring ........7 - 6 Main PCB wiring .......7 - 7 Bed wiring.........7 - 8 Y-feed cable wiring ......7 - 9 X-feed cable wiring ......7 - 11 Panel wiring ........7 - 14 7- 1...
Page 318 Wiring instructions Head wiring 1. Inside of case Insert the thread quantity Head PCB sensor cable correctly. Do not allow the grounding wire to pro- Grounding wire at- trude from the case. tachment position (seven locations) Head grounding Do not allow the wire grounding wire to touch the lug.
Page 319 Wiring instructions Arm wiring 1. Section above the arm (1) Needle position sensor Sensor bracket hook Needle position lead wire sensor Sensor shutter Color change sensor Spiral A Color change sensor Sensor bracket hook lead wire 2. Section above the arm (2) Cord bushing (back) Route spiral A under the lug on the motor base.
Page 320 Wiring instructions Left side of arm. Cover all lead wires with a spiral Wiper motor Wiper lead wire tube and secure the tube Make sure that the bulge Hook on the clamp is inside when securing the tube. Semicir- cular sag Motor bracket Cord clamp Wiper sensor...
Page 321 Wiring instructions 5. Right side of arm (2) Thread guide base No slack allowed. LED lead wire 6. Right side of arm (3) USB lead wire A Panel lead wire Spiral A Pull out the relay connector from Motor lead wire the middle point of spiral C and po- sition it between spirals A and C.
Page 322 Wiring instructions Base wiring 1. Left side of base USB lead wire Cord clamp B Y-feed driving gear Y-feed driving belt Y-sensor lead wire Cord clamp A Make sure that the lead Hang the lead wire over the U- wire is in the trench on shaped notch on the Y-sensor the base.
Page 323 Wiring instructions Main PCB wiring 1. Upper section of main PCB Main shaft LED lead wire shutter Hook A Hook B Panel lead wire Spiral A Spiral C Spiral B At least 15 mm Main shaft sensor lead wire 2. Lower section of main PCB Power lead wire Thread cut motor lead wire Picker motor lead wire...
Page 324 Wiring instructions Bed wiring PK motor bracket hook CT motor bracket hook Screw Picker sensor lead wire Picker motor Lower shaft Protection sheet lead wire 7 - 8...
Page 325 Wiring instructions Y-feed cable wiring 1. Y-feed cable (1) Bending dimen- sion: 55 mm Position the FFC at Feed relay cable the center of the (medium) Valley fold di- protection sheet. mension: 5 mm Bending dimen- sion: 18 mm Position the FFC at the center of the FFC protection sheet FFC (SML2CD-Y)
Page 326 Wiring instructions 3. Y-feed cable (3) Make sure that the Connector B Connector D X-motor lead wire slack is above the cord clip. FFC (SML2CD-C) Connector C Cord clip Make sure that the PCB holder, cable and protection sheet are parallel.
Page 327 Wiring instructions X-feed cable wiring 1. X-feed cable (1) Bending dimen- Bottom edge Align the left end sion: 60 mm with the slit. clearance: 1 mm X-cable fixing FFC (SML2CD-X) sheet A Bottom edge clearance: 1 mm Protrusion dimen- / Mountain fold sion: 40 mm X-cable fixing sheet B...
Page 328 Wiring instructions 3. X-feed cable (3) Hoop sensor lead wire X-cable fixing sheet C Screw X-carriage A X-carriage B FFC (SML2CD-X) Connector B Connector A 4. X-feed cable (4) Allowance for lift: X-carriage Up to 10 mm Connector FFC (SML2CD-X) X-cable fixing sheet B Screw 7 - 12...
Page 329 Wiring instructions 5. X-feed cable (5) Check that the FFC is Screw adjustment window X-carriage parallel to the X belt. for X-cable fixing sheet X-sensor shutter FFC (SML2CD-X) 7 - 13...
Page 330 Wiring instructions Panel wiring Surface of LCD module Front cover spacer B LCD module Approx. 1 mm from edge of display 2. Inside of panel (1) Grounding plate Safaia II identification mark Attach the tape at the lower section of the grounding plate.
Page 331 Wiring instructions 3. Inside of panel (2) Inverter lead wire Back light lead wire Route the lead wires under the PCB case, being careful to prevent them being crushed by the case. SW lead wire PCB bracket PCB case 4. Inside of panel (3) Touch panel lead wire LCD lead wire Clip...
Page 332 Wiring instructions Back of panel USB lead wire A Align right end of bushing with right end Cord bushing of contraction tube. Panel lead wire Almost the same Make sure that the length tab is facing down. 7 - 16...

This manual also for:

Pr620