Brother BL6200 Service Manual
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Brother BL6200 Service Manual

Brother BL6200 Service Manual

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4. 1998.

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  • Page 1 4. 1998.
  • Page 2 • This service manual is complied for repairing service of DOMESTIC SEWING MACHINE. BL6200, 6700 PS1000, 1250, 1800, 1950, 2000, 2100 STAR 10, 15, 20, 20E, 30E, 40E MYSTAR 15 • Use this manual with Parts Catalogue for fault findings when you make a repair.

  • Page 3: Table Of Contents

    MECHANICAL CHART (B338, B346, B347, B348) ......2 MECHANICAL CHART (B341, B349, B351, B352) ......3 POWER TRANSMISSION CHART ............4 DISPLAY SYSTEM BY MICRO-COMPUTER ........8 DISPLAY SYSTEM BY MICRO-COMPUTER ........9 MAIN MOTOR CONTROLLED BY MICRO-COMPUTER ....10 - 1 -...

  • Page 4: Mechanical Chart (B338, B346, B347, B348)

    1. MECHANICAL CHART (B338 ⋅ B346 ⋅ B347 ⋅ B348) * This part is not installed on the B346 since it is a 4-step BH model. - 2 -...

  • Page 5: Mechanical Chart (B341, B349, B351, B352)

    1. MECHANICAL CHART (B341 ⋅ B349 ⋅ B351 ⋅ B352) * These parts are not installed on the B341, B351 and B352 since they are LCD models. - 3 -...

  • Page 6: Power Transmission Chart

    2. POWER TRANSMISSION CHART (A) Generating mechanism of needle bar, thread take-up lever and zigzag movements (B338 ⋅ B346 ⋅ B347 ⋅ B348) Thread take-up Eccentric Upper shaft Worm gear Pulley lever counter weight Needle bar crank rod Pattern cam Needle bar clamp Needle bar...
  • Page 7 (A) Generating mechanism of needle bar, thread take-up lever and zigzag movements (B341 ⋅ B349 ⋅ B351 ⋅ B352) Thread take- Eccentric Upper shaft Worm gear Pulley up lever counter weight Needle bar crank rod Pattern cam Needle bar clamp Needle bar Zigzag connecting Needle bar...
  • Page 8 (B) Mechanism of feed dog and oscillating hook movement Feed pattern Feed finger Horizontal feed cam Worm gear Pulley Forked Feed dog Feed regulator Motor belt connecting rod Timing belt Outer rotary hook Horizontal Horizontal Horizontal Feed bar Motor assembly feed plate feed shaft feed arm...
  • Page 9 (C) Automatic 1-step BH mechanism (B338 ⋅ B341 ⋅ B347 ⋅ B348 ⋅ B349 ⋅ B351 ⋅ B352) Feed control BHF finger 2-(B) cam (BH) assembly BH change BH change BHF finger BH stopper BH cam shaft assembly BH Iever 2-(A) BH foot - 7 -...

  • Page 10: Display System By Micro-Computer

    3. DISPLAY SYSTEM BY MICRO-COMPUTER (B341 ⋅ B351) An 8 bit micro-computer in models installed with an LCD (liquid crystal display) regulates the LCD controller driver which controls the information shown on the display. < > 1 LINE DISPLAY SYSTEM BLOCK CHART LCD panel LCD unit Power supply...

  • Page 11: Display System By Micro-Computer

    3. DISPLAY SYSTEM BY MICRO-COMPUTER (B352) An 8 bit micro-computer in models installed with an LCD (liquid crystal display) regulates the LCD controller driver which controls the information shown on the display. < > 4 LINE DISPLAY SYSTEM BLOCK CHART LCD panel segment controller...

  • Page 12: Main Motor Controlled By Micro-Computer

    4. MAIN MOTOR CONTROLLED BY MICRO-COMPUTER (B341 ⋅ B349 ⋅ B351 ⋅ B352) The sewing machine’s main motor requires a constant rotation at all speeds regardless of the changes in the load, power supply or temperature. In addition, to make the machine easy to use, it should take into account that the machine should run slowly when it starts and the needle should be in the up position when it stops.
  • Page 13 1. Machine skips stitches................. 13 2. Fabric does not feed................13 3. Fabric does not feed straight............... 13 4. Upper thread breaks at start..............13 5. Upper thread breaks during sewing............. 13 6. Upper thread breaks during reverse sewing........13 7.
  • Page 14 28. The motor does not run............... 18 29. The motor does not run smoothly or it does not run at a high speed..................18 30. Even after the machine is started, it stops suddenly......18 31. The speed at which the machine operates cannot be adjusted... 19 32.

  • Page 15: Machine Skips Stitches

    PROBLEM CAUSE CORRECTION Machine skips Improper setting of the needle. Set the needle correctly. stitches. Bent or blunt needle. Change the needle. Improper threading. Reset threading correctly. Improper combination of needle/ Select correct combination of needle/ thread/fabric. thread/fabric. Stretch fabric is used. Use stretch fabric needle, optional stretch presser foot.

  • Page 16: Needle Breaks

    PROBLEM CAUSE CORRECTION Needle breaks. Touch pattern dial while needle is in Operate machine correctly. the fabric. Needle hits inner rotary hook. Adjust the position of inner rotary hook stopper. * Refer to P.30. Needle hits needle plate. Make sure the correct needle is used. * Refer to P.27, P.37.

  • Page 17: No Characters Appear On The Lcd

    PROBLEM CAUSE CORRECTION 1 line LCD 1 line LCD 17. No characters appear on the Improper setting of LCD contrast key. Adjust LCD contrast key. LCD. Disconnection of connector CN 1. Connect CN1 on LCD unit. Voltage between terminal 2-1 of LW1 Replace the motor control unit.

  • Page 18: The "Bobbin Winding" Message Continues To Appear On The Lcd

    PROBLEM CAUSE CORRECTION 1 line LCD 1 line LCD 21. The "Bobbin Winding" message BW switch does not work. Adjust the BW stitch. continues to appear *Refer to P.51. on the LCD. Inferior BW switch. Replace the BW switch. *Refer to P.51. Inferior LCD unit.

  • Page 19: Message "Lower Bh Lever" Appears When Buttonhole Lever Is Lowered

    PROBLEM CAUSE CORRECTION 1 line LCD 1 line LCD 26. Message "Lower BH Lever" appears BH lever switch does not work. Adjust the BH lever switch. when button-hole *Refer to P.49. lever is lowered. Inferior BH lever switch Replace the BH lever switch. *Refer to P.49.

  • Page 20: The Motor Does Not Run

    PROBLEM CAUSE CORRECTION 28. The motor does not The pulley is turned too tightly. Adjust the mechanism so that the pulley run. rotates easily. The resistance between the two ends of Replace the motor. motor connector CN2 is not between 25 and 35 Ω.* Inferior SS switch.

  • Page 21: The Speed At Which The Machine Operates Cannot Be Adjusted

    PROBLEM CAUSE CORRECTION The output from the transformer is Replace the motor control unit 31. The speed at which incorrect. The voltage between pins 5 the machine and 6 of the transformer should be operates cannot be approximately 8V AC. adjusted.

  • Page 22: The Machine Stops Immediately After Bobbin Winding Is Started

    PROBLEM CAUSE CORRECTION 34. The machine stops If the machine stops approx. 1 second Replace the BW switch. immediately after after bob-bin winding starts, the BW *Refer to P.51. bobbin winding is switch is not operating correctly.* started. The resistance between pins 1 and 2 of connector CN5 (black) should be less than 1 Ω...
  • Page 23 III. 1. ADJUSTMENT OF EACH CONTROL UNIT (4-STEP BH MODEL) ....22 ADJUSTMENT OF EACH CONTROL UNIT (1-STEP BH MODEL) ....2. ADJUSTMENT OF THE TIMING BETWEEN THE UPPER AND LOWER SHAFTS ..24 3. TENSION ON MOTOR BELT AND TIMING BELT ......... 25 4.

  • Page 24: Adjustment Of Each Control Unit (4-Step Bh Model)

    1. ADJUSTMENT OF EACH CONTROL UNIT (4-STEP BH MODEL) (B346) - 22 -...

  • Page 25: Adjustment Of Each Control Unit (1-Step Bh Model)

    1. ADJUSTMENT OF EACH CONTROL UNIT (1-STEP BH MODEL) (B338 ⋅ B341 ⋅ B347 ⋅ B348 ⋅ B349 ⋅ B351 ⋅ B352) - 23 -...

  • Page 26: Adjustment Of The Timing Between The Upper And Lower Shafts

    2. ADJUSTMENT OF THE TIMING BETWEEN THE UPPER AND LOWER SHAFTS STANDARD When the mark on the horizontal feed cam of the upper shaft is at its topmost position, the mark on timing pulley D of the lower shaft should be at its bottommost position. (Turn pulley counterclockwise.) ADJUSTMENT 1.

  • Page 27: Tension On Motor Belt And Timing Belt

    3. TENSION ON MOTOR BELT AND TIMING BELT STANDARD There should be 4 ~ 6 mm of slack on the motor belt, 3 ~ 4 mm of slack on timing belt, when the center of each belt is just pushed with about 200g pressure. ADJUSTMENT 1.

  • Page 28: Timing Of Needle Bar And Feed

    4. TIMING OF NEEDLE BAR AND FEED (B341 ⋅ B349 ⋅ B351 ⋅ B352) STANDARD When the needle bar is at its highest position, the mark on the horizontal feed cam should be at its topmost position. (Horizontal feed should start when needle bar reaches at the position of -7 ~ -17° from its highest position.) (Turn the pulley counterclockwise.) ADJUSTMENT 1.

  • Page 29: Position Of Zigzag Needle Swing

    5. POSITION OF ZIGZAG NEEDLE SWING STANDARD Set pattern dial to zigzag stitch. The needle should drop in the needle hole balanced. When the zigzag width dial is turned from "0" to "5" while the needle is in the right position, horizontal movement of the needle should be less than 0.1 mm.

  • Page 30: Position Of Rotary Hook

    6. POSITION OF ROTARY HOOK STANDARD When pattern dial is set to zigzag stitch, zigzag width dial is set to "5" (the needle is at the left side) and needle raises from its lowest position by 2.75 ~ 3.15 mm, the pointed end of rotary hook should meet with right side of needle.

  • Page 31: Height Of Needle Bar

    7. HEIGHT OF NEEDLE BAR STANDARD When pattern dial is set to the zigzag stitch, the zigzag width dial is set to "5" (the needle is at the left side) and the pointed end of the rotary hook contacts the right side of the needle, the clearance between the top of the needle eye and the hook point should be 0.8 ~ 1.2 mm.

  • Page 32: Position Of Inner Rotary Hook Stopper

    8. POSITION OF INNER ROTARY HOOK STOPPER STANDARD Inner rotary hook stopper should hold inner rotary hook by 1.9 ~ 2.1 mm as shown in drawing. ADJUSTMENT 1. Loosen the screw on inner rotary hook stopper. 2. Adjust the position of inner rotary hook stopper. (Face A on inner rotary hook and feed direction should be at right angles.) 3.

  • Page 33: Position Of Feed Dog

    9. POSITION OF FEED DOG STANDARD When the upper shaft is rotated once with the maximum feed, the feed dog should not contact the needle plate on the left and right. When the feed dog is in its initial feed position (as far forward as possible), the clearances between the feed dog and the needle plate should be 0.3 ~ 0.8 mm.

  • Page 34: Height Of Feed Dog

    10. HEIGHT OF FEED DOG STANDARD Feed dog should be higher than the needle plate by 0.9 ~ 1.1 mm when the feed dog is raised to its highest position. ADJUSTMENT 1. Raise the feed dog using the drop lever, then raise the feed dog to its highest position by turning the pulley.

  • Page 35: Height Of Presser Bar

    11. HEIGHT OF PRESSER BAR STANDARD The clearance between presser foot and needle plate should be 6.0 ~ 6.5 mm. ADJUSTMENT 1. Raise presser foot. 2. Loosen the screw on presser bar guide bracket. 3. Adjust height of presser bar. (Presser foot should be parallel to feed dog.) 4.

  • Page 36: Adjustment Of Thread Tension Dial

    12. ADJUSTMENT OF THREAD TENSION DIAL (B341 ⋅ B349 ⋅ B351 ⋅ B352) STANDARD When thread tension dial is set to "AUTO" and presser foot is lowered, upper thread tension should be 10 ~ 13g using polyester thread #60. ADJUSTMENT 1.

  • Page 37: Adjustment Of Auto Tension

    13. ADJUSTMENT OF AUTO TENSION (B341 ⋅ B349 ⋅ B351 ⋅ B352) (ADJUSTMENT OF ROLLER FOR THREAD TENSION CONTROL) STANDARD Thread polyester thread #60 between roller and thread holder. Turn the pully counterclockwise. The thread should be locked when the top of the needle eye comes down 0 ~ 1.5 mm down from the surface of needle plate.

  • Page 38: Position Of Pattern Indication Plate

    14. POSITION OF PATTERN INDICATION PLATE (B338 ⋅ B346 ⋅ B347 ⋅ B348 ⋅ B349) STANDARD Each pattern on indication plate should be indicated at the center of the indication window. ADJUSTMENT 1. Set pattern dial to zigzag stitch and check baseline on selecting cam which should meet with upper end of release lever.

  • Page 39: Clearance Between Cam And Cam Finger

    15. CLEARANCE BETWEEN CAM AND CAM FINGER STANDARD When pattern dial is set to rick-rack stitch and cam finger is released, clearance between cam finger and pattern cam & feed cam should be 0.3 ~ 0.5 mm. ADJUSTMENT 1. Set pattern dial to rick-rack stitch and release cam finger from pattern and feed cam. 2.

  • Page 40: Position Of Cam Finger For Feed Cam And Pattern Cam

    16. POSITION OF CAM FINGER FOR FEED CAM AND PATTERN CAM STANDARD Feed cam finger and zigzag cam finger should be center position of each cam. ADJUSTMENT 1. Check the position of feed cam finger and zigzag cam finger by turning pattern dial. 2.

  • Page 41: Setting Of Feed Bracket

    17. SETTING OF FEED BRACKET STANDARD When stitch length dial is set to "0", each mark on feed dial gear, feed gear, feed cam and feed finger should meet in line. ADJUSTMENT 1. Set stitch length dial to "0". 2. Set the mark on the feed cam to feed finger. 3.

  • Page 42: Forward And Reverse Sewing For Rick-Rack Stitch

    18. FORWARD AND REVERSE SEWING FOR RICK-RACK STITCH STANDARD When pattern dial is set to rick-rack stitch, there should be no difference between forward and reverse feed. ADJUSTMENT 1. Set pattern dial to rick-rack stitch. 2. Loosen the nut for adjustment screw. 3.

  • Page 43: Adjustment Of Feed

    19. ADJUSTMENT OF FEED STANDARD When stitch length dial is set to "0", stitch length should be 0 mm. ADJUSTMENT 1. Set the pattern dial to the zigzag stitch, the zigzag width dial to "5" and the stitch length dial to "0". 2.

  • Page 44: Buttonhole Adjustment (Forward And Reverse Feeding)

    20. BUTTONHOLE ADJUSTMENT (FORWARD AND REVERSE FEEDING) 1 STEP BH MODEL (B338 ⋅ B341 ⋅ B347 ⋅ B348 ⋅ B349 ⋅ B351 ⋅ B352) STANDARD When pattern dial is set to "1" (Buttonhole), there should be no feeding difference between left and right legs. ADJUST 1.

  • Page 45: Buttonhole Adjustment (Bar Tack Feeding)

    21. BUTTONHOLE ADJUSTMENT (BAR TACK FEEDING) 1 STEP BH MODEL (B338 ⋅ B341 ⋅ B347 ⋅ B348 ⋅ B349 ⋅ B351 ⋅ B352) STANDARD The feeding of bar tack should be less than 1 mm/10 feedings. ADJUSTMENT 1. Set pattern dial to "1" (Buttonhole). 2.

  • Page 46: Buttonhole Adjustment (The Length Of The Buttonhole And The Pressure Of The Bh Lever)

    22. BUTTONHOLE ADJUSTMENT (THE LENGTH OF THE BUTTONHOLE AND THE PRESSURE OF THE BH LEVER) (1 STEP BH MODEL) (B338 ⋅ B341 ⋅ B347 ⋅ B348 ⋅ B349 ⋅ B351 ⋅ B352) STANDARD The length of buttonhole should be 21 ~ 23 mm, when the button is 20.0 mm in diameter. The pressure needed to pull the BH Lever forward should be 50 ~ 110 g.

  • Page 47: Maximum Stitch Width When Set At Straight (Left) And Zigzag Stitch

    23. MAXIMUM STITCH WIDTH WHEN SET AT STRAIGHT (LEFT) AND ZIGZAG STITCH STANDARD Left end of straight stitch should be same position as left end of zigzag stitch. ADJUSTMENT 1. Lower the feed dog using the drop lever, then place a piece of paper on the needle plate and lower the presser foot.

  • Page 48: Forward And Reverse Feeding For Straight Stitch

    24. FORWARD AND REVERSE FEEDING FOR STRAIGHT STITCH STANDARD When stitch length dial is set to "2", there should be no difference between forward and reverse feed. ADJUSTMENT 1. Set pattern dial to straight stitch. 2. Set stitch length dial to "2". 3.

  • Page 49: Adjustment Of Bobbin Winding

    25. ADJUSTMENT OF BOBBIN WINDING STANDARD Thread should be wound parallel to the bobbin and be wound 75 ~ 85% of the outer-diameter of bobbin. ADJUSTMFNT 1. In case bobbin thread is wound unbalanced, loosen the screw for bobbin winder thread guide slightly. 2.

  • Page 50: Position Of N.p. (Needle Position) Shutter

    26. POSITION OF N.P. (NEEDLDE POSITION) SHUTTER (B341 ⋅ B349 ⋅ B351 ⋅ B352) STANDARD Needle position shutter works when the needle reaches at the position of 0.4 mm lower than its highest position. ADJUSTMENT 1. Turn the pulley counterclockwise and set the needle at the position of 0.4 mm lower than its highest position.

  • Page 51: Adjustment Of Bh Lever Switch

    27. ADJUSTMENT OF BH LEVER SWITCH (B341 ⋅ B351 ⋅ B352) STANDARD When the BH lever reaches its lowest position, it should have enough distance from BH lever switch. When BH lever is raised, BH lever switch should be clearly ON. ADJUSTMENT 1.

  • Page 52: Adjustment Of Reverse Sewing Switch

    28. ADJUSTMENT OF REVERSE SEWING SWITCH (B341 ⋅ B349 ⋅ B351 ⋅ B352) STANDARD The clearance between the BT switch and the reverse sewing lever B should be 1.0 ~ 1.5 mm. ADJUSTMENT 1. Loosen the screw for BT switch holder slightly. 2.

  • Page 53: Adjustment Of Bobbin Winding Switch

    29. ADJUSTMENT OF BOBBIN WINDING SWITCH (B341 ⋅ B349 ⋅ B351 ⋅ B352) STANDARD When bobbin winder is moved to bobbin presser, bobbin winding switch should be on. When bobbin winder is returned, the clearance between bobbin winder and switch should be 1.0 ~ 1.5 mm. ADJUSTMENT 1.

  • Page 54: Adjustment Of Inner Rotary Hook Tension

    30. ADJUSTMENT OF INNER ROTARY HOOK TENSION (B338 ⋅ B341 ⋅ B346 ⋅ B347 ⋅ B348 ⋅ B349 ⋅ B351 ⋅ B352) STANDARD When pulling polyester thread #60 through slowly, inner rotary hook tension should be 10 ~ 12g. ADJUSTMENT 1.

  • Page 55: Needle Threader

    31. NEEDLE THREADER CAUTION 1. Needle threader accepts only circle marked needle and thread combinations. 2. * marked combinations is not recommended since it might lead to the breakage of needle threader or imperfect performance. 3. Lower the presser foot when you use needle threader. 4.

  • Page 56: Needle Threader (Checking The Hook Position In Horizontal Direction)

    32. NEEDLE THREADER (CHECKING THE HOOK POSITION IN HORIZONTAL DIRECTION) STANDARD The measure from inside of the hook guard to the center point of hook is 0.42 mm. CHECK Prepare 5 pcs. of brand-new sewing HA × 1 (#14) and check by changing all of these. After Checking A.

  • Page 57: Needle Threader (Exchange)

    33. NEEDLE THREADER (EXCHANGE) HOW TO EXCHANGE NEEDLE THREADER 1. Remove needle and lower the presser foot. 2. Push down needle threader to take out. 3. Place new one so that guide is immediately under the guide pin as shown Figure A. 4.

  • Page 58: Needle Threader (Checking The Hook Position In Vertical Direction)

    34. NEEDLE THREADER (CHECKING THE HOOK POSITION IN VERTICAL DIRECTION) STANDARD 1. The clearance between the top of hook and the top of needle eye is zero. 2. Threading is capable when needle is located higher than 8.0 mm from the needle plate. CHECK (Refer to illustration) Case A Hook position is too high.

  • Page 59: Needle Threader (Adjustment The Hook Position In Vertical Direction)

    35. NEEDLE THREADER (ADJUSTMENT THE HOOK POSITION IN VERTICAL DIRECTIOIN) CASE A (Hook point is too high) 1. Set the needle position at right and loosen the screw. 2. Adjust needle threader slightly down and check the clearance between the top of hook and top of needle eye is zero.
  • Page 60 REMOVING THE COVERS ..............59 LAMP REPLACEMENT ............... 60 LEAD WIRES ARRANGEMENT ............61 ..................... 62 < > LCD UNIT ................63 < > DISPLAY SYSTEM ..............64 < > MOTOR CONTROL UNIT ....65 < > TEST MODE (Language/Machine Specifications Settings) - 58 -...

  • Page 61: Removing The Covers

    1. REMOVING THE COVERS 1. Remove the base plate by loosening four screws. 2. Remove the face plate by loosening the screw. 3. Remove the rear cover by loosening six screws. 4. Remove the front cover by loosening the screw. NOTE INSTALLING THE FRONT COVER (B338 ⋅...

  • Page 62: Lamp Replacement

    2. LAMP REPLACEMENT 1. Loosen the screw of face plate. 2. Remove face plate. 3. Attach new sew-light bulb to lamp socket. (B338 ⋅ B346 ⋅ B347 ⋅ B348) (B341 ⋅ B349 ⋅ B351 ⋅ B352) - 60 -...

  • Page 63: Lead Wires Arrangement

    3. LEAD WIRES ARRANGEMENT (B338 ⋅ B346 ⋅ B347 ⋅ B348) (B341 ⋅ B349 ⋅ B351 ⋅ B352) - 61 -...

  • Page 64: Lcd Unit

    < > LCD UNIT 1 LINE LCD TYPE - 62 -...

  • Page 65: Display System

    < > DISPLAY SYSTEM LCD control PCB LCD module 4 LINE LCD TYPE - 63 -...

  • Page 66: Motor Control Unit

    < > MOTOR CONTROL UNIT 230V 120V MODE SWITCH UNIT 1 LINE LCD TYPE 4 LINE LCD TYPE - 64 -...

  • Page 67: Test Mode (Language/Machine Specifications Settings)

    < > TEST MODE (Language/Machine Specifications Settings) This Test Mode is used to switch the language in which LCD displays appear, and to switch the machine specifications. Setting the Test Mode 1. Turn off the power supply. 2. Lower the BH lever. 3.
  • Page 68 BL6200 (B338) BL6700 (B341) H7110109 - 66 -...

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