Page 4 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 Layout for P.C.B. connectors ................1 - 8 Operation of other electronic components ............1 - 10 2.
Page 5 Needle thread unit ...................2 - 28 Needle thread assembly removal .....................2 - 29 LED pointer removal ........................2 - 29 Hook holder assembly removal .......................2 - 30 Rack and hook holder link removal ....................2 - 30 TH motor assembly removal ......................2 - 31 Needle bar change unit ..................2 - 32 Change box center cover removal ....................2 - 33 Change box removal ........................2 - 33...
Page 6 Idle pulley assembly removal ......................2 - 59 Idle pulley disassembly ........................2 - 59 Lower shaft removal ........................2 - 60 Power unit ......................2 - 61 Power switch assembly and inlet removal ..................2 - 62 EX connector holder removal ......................2 - 62 Power supply unit removal ......................2 - 62 Adjust-bolt removal .........................2 - 63 Thread cut unit ....................2 - 64...
Page 7 USB cover attachment ........................3 - 5 Panel PCB assy attachment ........................3 - 5 Panel PCB case attachment ........................3 - 6 Back light drive PCB attachment .......................3 - 6 Pen holder attachment ........................3 - 7 Card cover attachment ........................3 - 7 Lead wire assy panel attachment .......................3 - 7 Panel rear cover attachment .......................3 - 8 USB cord holder attachment ......................3 - 8...
Page 8 Base needle bar attachment ......................3 - 44 Driving jump assembly (1) ......................3 - 45 Driving jump assembly (2) ......................3 - 46 Driving jump assembly attachment ....................3 - 47 Tension pulley assembly attachment ....................3 - 47 Main motor final assembly ......................3 - 48 Main motor final assembly attachment ....................3 - 48 Needle bar unit ....................3 - 49 Case guide UL assembly .........................3 - 50...
Page 9 X-carriage A assembly and X-carriage B assembly attachment ............3 - 83 X-feed frame B attachment ......................3 - 84 Y-frame spacer and X-belt presser attachment ................3 - 85 FFC and X-area sensor assembly attachment ..................3 - 85 Cord grip attachment ........................3 - 86 Y driving shaft assembly attachment ....................3 - 87 Y-motor final assembly ........................3 - 87 Y motor final assembly attachment ....................3 - 88...
Page 10 Needle threader (left/right) ................4 - 29 Y belt tension ....................4 - 30 X belt tension ....................4 - 31 Picker activation ....................4 - 32 Movable knife initial position ................4 - 33 Thread presser base up/down position ............4 - 34 Hoop sensor (A/D value) .................4 - 35 Upper shaft encoder phase ................4 - 37 X, Y carriage initial position ................4 - 38 Movable knife and Fixed knife engagement load ..........4 - 39...
Page 11 6. Maintenance & Replacement .............6 - 1 How to reset the counter of the maintenance ............6 - 2 Necessary grease & oil ..................6 - 3 Maintenance point (Every 1,500 hours) .............6 - 4 Maintenance point (Every 500 hours) ..............6 - 10 Maintenance point (Every day) ................6 - 11 Replacement parts location ................6 - 12 Main PCB assy ....................6 - 13...
Page 12 Outline of Mechanism Main mechanisms ............ 1 - 2 Driveline ..............1 - 3 Positions of electronic components......1 - 5 Control system block diagram........1 - 7 Layout for P.C.B. connectors ........1 - 8 Operation of other electronic components ....1 - 10 1 - 1...
Page 13: 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 14: 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 15 Outline of Mechanism Driveline B) Movement of rotary hook Idle pulley Timing belt Timing pulley Upper shaft Pulley Motor belt Main motor Lower shaft gear Lower shaft Rotary hook Pulley Timing pulley Upper shaft Motor belt Timing belt Main motor Idle pulley Lower shaft gear Lower shaft...
Page 16: Positions Of Electronic Components
Outline of Mechanism Positions of electronic components Head PCB TH sensor (Thread quantity sensor) X motor Connect PCB LED light X area sensor Hoop sensor PCB Hoop sensor Pi ck er sensor Pi cker motor Y area sensor TH cutter motor (Thread cutter motor) Extension IF PCB TH cutter sensor...
Page 17 Outline of Mechanism Positions of electronic components Index motor Color change sensor Main shaft sensor Index sensor Wiper motor Main PCB Wiper sensor Needle TH sensor (Needle thread sensor) Main motor LED pointer Panel PCB TH motor (Needle thread motor) LCD module Back light drive PCB Touch panel...
Page 18: Control System Block Diagram
Outline of Mechanism Control system block diagram LED light PCB Thread quantity Main shaft sensor AC power sensor x6 supply Stop phase position Index Wiper sensor sensor sensor sensor Color change Index Wiper Head Inlet LED pointer sensor motor motor Power supply Main PCB LED driver x2...
Page 19: Layout For P.c.b. Connectors
Outline of Mechanism Layout for P.C.B. connectors The illustration below shows layout for Printed Board connectors. Main P.C.B. CN11 SPOOL_L HEAD * Not used (Head PCB) CN13 TORG CN12 CN10 (Thread cutter PANEL SPOOL_R THRD sensor) (Panel PCB) * Not used (Needle thread motor) CN14 IORG...
Page 20 Outline of Mechanism Layout for P.C.B. connectors Panel P.C.B. LCDM CAMERA (Touch panel) (LCD module) *Not used CN16 *Not used CN10 *Not used (Start/Stop switch PCB) CN12 USB_H_H (USB2.0 HOST) *Not used CN13 USB_H_F (USB2.0 Function) *Not used CN11 USB_F MAIN (USB1.1 HOST) (Main PCB)
Page 21: 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 cutter switch .
Page 22: Disassembly
Disassembly Main unit Main parts........2 - 2 Feed unit.........2 - 16 Needle thread unit ......2 - 28 Needle bar change unit ....2 - 32 Thread wiper unit......2 - 36 Needle bar unit .......2 - 40 Upper shaft unit ......2 - 48 Lower shaft unit ......2 - 58 Power unit........2 - 61 Thread cut unit........2 - 64...
Page 23 Main unit Main parts Main parts 2 - 2...
Page 24 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 screws 2, and then remove the motor cover 3. 2 - 3...
Page 25 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 1. 3.
Page 26 Main unit Main parts Arm cover R removal 1. Remove the 5 screw covers 1. 2. Remove the 2 thumb bolts (M4L) 2, the 2 washer springs (2-4) and the 2 washer plains (M4) from the operation panel assembly. *Key point •...
Page 27: Main Parts
Main unit Main parts Arm cover L removal 1. Remove the 2 screw covers 1. 2. Remove the screw 1 inside the cover and the 2 screws 2 outside the cover, and then remove arm cover L 2. Outside Inside 2 - 6...
Page 28 Main unit Main parts Base cover R removal 1. Remove the 2 screws 1, and then remove the base cover R lid 1. 2. Remove the 2 screw covers 2. 3. Removes the 3 screws 2, and then remove the base cover R 3. *Key point •...
Page 29 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 30 Main unit Main parts Main PCB assembly removal 1. Disconnect the all connectors from the main PCB assembly. 2. Disconnect the motor harness from the main PCB assembly. 3. Release the 2 hooks to remove the PCB supporter 1 (2 locations). 4.
Page 31 Main unit Main parts Board holder U/D removal 1. Remove the 4 screws 1, and then remove the board holder U 1. 2. Remove the 2 screws 2, and then remove the board holder D 2 and the cord clamp 3. 3.
Page 32 Main unit Main parts Operation panel assembly removal 1. Remove the screw 1, and then remove the cord clamp 1. 2. Remove the 6 screws 2, and then remove the operation panel assembly Thread take-up lever cover removal 1. Remove the 2 screws 1, and then remove the thread take-up lever cover *Key point •...
Page 33 Main unit Main parts Tension base removal 1. Remove the lead wires from the spiral tube. 2. Remove the screw 1, and then remove the cord clamp from the arm bed. 3. Remove the 4 screws 2, and then remove the tension base assembly. Needle plate removal 1.
Page 34 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 35 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 36 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 37 Main unit Feed unit Feed unit 2 - 16...
Page 38 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 set 2 and T- belt (one each on left and right).
Page 39 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 FFC SML2CD-Y and Y cable protection sheet A.
Page 40 Main unit Feed unit Y area PCB assembly removal 1. Remove the screw 1, and then remove the cord clamp 1. 2. Remove the screw 2, and then remove the cord clamp 2. 3. Remove the screw 3, and then remove the cord clamp 3. 4.
Page 41 Main unit Feed unit Y motor assembly removal 1. Remove the screw 1, and then remove the cord clamp 1. 2. Remove the 2 screws 2, and then remove the Y motor assembly 2. Y-motor disassembly 1. Remove the 2 screws 1, and then remove the Y-motor assembly from the Y-motor stay.
Page 42 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 43 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, X- frame spacer and the insulation sheet.
Page 44 Main unit Feed unit X-carriage A assembly and X-carriage B assembly removal 1. Remove the 3 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 45 Main unit Feed unit Hoop sensor removal 1. Remove the screw 1, and then remove the X carriage CX 1. 2. Remove the screw 2, and then remove the hoop lever 2. 3. Remove the nut 3 and screw 3, and then remove the hoop sensor assembly 4, PT meter plate 5 and spring X-guide shaft removal Bearing case X...
Page 46 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 47 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 48 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 49: Needle Thread Unit
Main unit Needle thread unit Needle thread unit 2 - 28...
Page 50: Needle Thread Assembly Removal
Main unit Needle thread unit Needle thread assembly removal 1. Unlock the lock of the connector 1, and then disconnect the LED wire assy LED. 2. Remove the 6 screws 1, and then remove the needle thread assembly. LED pointer removal 1.
Page 51: Hook Holder Assembly Removal
Main unit Needle thread unit 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. *Key point • The hook holder assembly's tab is engaged in the groove on the hook holder axis B.
Page 52: Th Motor Assembly Removal
Main unit Needle thread unit TH motor assembly removal 1. Remove the 2 screws 1, and then remove the lead wire guide 1. 2. Remove the 2 screws 2, and then remove the TH motor assembly 2 and 2 spacers. 3.
Page 53: Needle Bar Change Unit
Main unit Needle bar change unit Needle bar change unit 2 - 32...
Page 54: Change Box Center Cover Removal
Main unit Needle bar change unit Change box center cover removal 1. Remove the spiral tube from the lead wires. 2. Cut the band 1, and then remove the lead wires from the guide parts. 3. Remove the 2 screws 1, and then remove the change box center cover 2. 4.
Page 55: Change Box Disassembly (Step 1)
Main unit Needle bar change unit 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. 2. Remove the 2 screws 2, and then remove the color change sensor assembly and the index sensor assembly from the C sensor bracket assembly and the C sensor bracket assy lower.
Page 56: 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 57: Thread Wiper Unit
Main unit Thread wiper unit Thread wiper unit 2 - 36...
Page 58: Led Unit Left Assy Removal
Main unit Thread wiper unit LED unit left assy removal 1. Remove the 2 screws 1, and then remove the 2 cord clamps 1. 2. Remove the lead wire from the guide parts. 3. Remove the 2 screws 2, and then remove the LED unit left assy 2. LED unit right assy removal 1.
Page 59: Wiper Set Assembly Removal
Main unit Thread wiper unit Wiper set assembly removal 1. Remove the screw 1, and then remove the cord clamp NK-5N. 2. Remove the 2 screws 2, and then remove the wiper set assembly. Wiper guide and wiper sensor removal 1.
Page 60: Wiper Set Disassembly
Main unit Thread wiper unit Wiper set disassembly Retaining rings E4 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 61: Needle Bar Unit
Main unit Needle bar unit Needle bar unit 2 - 40...
Page 62: Led Unit Left Assy Disassembly
Main unit Needle bar unit LED unit left assy disassembly 1. Remove the screw 1, and then remove the LED lower cover left 1 from the LED upper cover 2. 2. Disconnect the connector of the LED wire assy LED 3 from the LED PCB supply assy 4.
Page 63: Led Cord Guide Removal
Main unit Needle bar unit LED cord guide removal 1. Remove the 4 screws 1, and then remove the 2 LED cord guides 1. Needle bar case final assembly removal 1. Remove the 4 screws 1, and then remove the needle bar case assembly. Change roller base assembly removal 1.
Page 64: 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 65: 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 5.
Page 66: Case Positioning Plate Assembly Removal
Main unit Needle bar unit Case positioning plate assembly removal 1. Remove the screw 1 and spring washer (2-5), and then remove the case positioning plate assembly. 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.
Page 67: Case Bracket Assembly Removal
Main unit Needle bar unit Case bracket assembly removal 1. Remove the screw 1, and then remove the case guide cover UL. (2 locations) 2. Remove the screw 2, and then remove the slide roller stopper. (2 locations) 3. Remove the case bracket assembly 1 and the slide roller 2. 4.
Page 68: 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 69: Upper Shaft Unit
Main unit Upper shaft unit Upper shaft unit 2 - 48...
Page 70: 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 71: Main Motor Disassembly
Main unit Upper shaft unit Main motor disassembly 1. Remove the 2 screws 1, and then remove the main motor assembly, motor holder spacer, and motor spacer presser from the motor holder. 2. Remove the fender rubber 1 from the motor holder. 3.
Page 72: 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 73: 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. J-clamp disassembly 1.
Page 74: 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 75: 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 76: 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 77: 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 78: 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 79: Lower Shaft Unit
Main unit Lower shaft unit Lower shaft unit 2 - 58...
Page 80: 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 81: 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 82: Power Unit
Main unit Power unit Power unit 2 - 61...
Page 83: Power Switch Assembly And Inlet Removal
Main unit Power unit Power switch assembly and inlet removal 1. Remove the screw 1, and then remove the cord clamp (NK-6N). 2. Remove the 2 screws 2 and remove the inlet cover lid, and then remove the rocker switch on the power switch assembly from the inlet cover. 3.
Page 84: 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 85: Thread Cut Unit
Main unit Thread cut unit Thread cut unit 2 - 64...
Page 86: 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 87: 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 88: 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 89: Thread Tension Unit
Main unit Thread tension unit Thread tension unit 2 - 68...
Page 90: 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 91: 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 92: 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 93: 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 94: 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 stand frame R and spool stand frame L. 2. Remove the thumb bolt (M4L) 3 and the 2 washers, and then disconnect the spool stand link R from the spool stand link L.
Page 95: 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 96: 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 97: 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 98: Operation Panel
Main unit Operation panel Operation panel 2 - 77...
Page 99: Operation Panel Lever Assembly Removal
Main unit Operation panel Operation panel lever assembly removal 1. Remove the 2 screws 1, and then remove the 2 cord clamps 1 from the operation panel lever assembly 2. 2. Remove the 4 screws 2, and then remove the operation panel lever assembly 2 from the panel rear cover 3.
Page 100: Panel Holder Removal
Main unit Operation panel Panel holder removal 1. Remove the 2 thumb bolts (M4L) 1, the 2 washer springs (2-4) 2 and the Retaining ring E6 2 washer plains (M4) 3. (2 locations) 2. Remove the 2 retaining rings E6, and then remove the operation panel holder shaft 4 and the panel holder 5 from the operation panel lever A Retaining ring E6 Operation panel lever A removal...
Page 101: Panel Rear Cover Removal
Main unit Operation panel Panel rear cover removal 1. Remove the 4 screws 1. 2. Remove the panel rear cover 1, and then disconnect the connector 2. Lead wire assy panel removal 1. Remove the screw 1, and then remove the ground wire 1 of the lead wire assy panel 2 and the ground spring 3 from the panel rear cover.
Page 102: Card Cover Removal
Main unit Operation panel Card cover removal 1. Release the 2 hooks 1, and then remove the card cover 2 from the panel rear cover. Pen holder removal 1. Remove the 2 screws 1, and then remove the 2 pen holders 1 from the panel rear cover.
Page 103: Panel Pcb Case Removal
Main unit Operation panel Panel PCB case removal 1. Remove the 5 screws 1, and then remove the panel PCB case 1. 2. Remove the 2 scerws 2, and then remove the ground plate USB 2 from the panel PCB case 1. Panel PCB assy removal 1.
Page 104: Board Supporter Removal
Main unit Operation panel Board supporter removal 1. Push up the board supporter 1, and remove it from the PCB base plate. 2 - 83...
Page 105: Lcd Supply Assy Disassembly
Main unit Operation panel LCD supply assy disassembly 1. Pull out the FFC 1 from the ferrite core 2. 2. Remove the 5 screws 1, and then remove the PCB base plate 3, the LCD space 4, the LCD supply assy 5, the electric static preventer 6 and the touch panel 7 from the panel front cover badge assy 8.
Page 106: Ss Pcb Assy Removal
Main unit Operation panel SS PCB assy removal 1. Remove the 3 screws 1, and then remove the SS PCB assy 1 from the panel front cover. Buttons removal 1. Remove the SS button 1 and the operation button 2 from the panel front cover.
Page 107: Assembly
Assembly Main unit Operation panel ........3 - 2 Thread tension unit......3 - 11 Thread cut unit........3 - 22 Power unit........3 - 26 Lower shaft unit ......3 - 30 Upper shaft unit ......3 - 34 Needle bar unit .......3 - 49 Thread wiper unit......3 - 61 Needle bar change unit ....3 - 66 Needle thread unit ......3 - 71...
Page 108: Operation Panel
Main unit Operation panel Operation panel 3 - 2...
Page 109: Speaker Set Attachment
Main unit Operation panel Speaker set attachment 1. Attach the speaker set 1 to the panel front cover with the 2 screws 1. Taptite, Bind B M3X8 Buttons attachment 1. Attach the SS button guide 1 to the panel front cover. 2.
Page 110: Attachment Of Lcd Supply Assy
Main unit Operation panel Attachment of LCD supply assy 1. Attach the ferrite core 1 to the ferrite holder 2. 2. Attach the ferrite core 1 and the ferrite holder 2 to the PCB base plate 3. *Note • Check that hang the 2 hooks 4 of the ferrite holder 2 on the PCB base plate 3.
Page 111: Board Supporter Attachment
Main unit Operation panel Board supporter attachment 1. Attach the board supporter 1 to the positioning part of the PCB base plate. USB cover attachment 1. Attach the USB cover 1 to the positioning part of the PCB base plate, and then hang the 2 hooks 2.
Page 112: Panel Pcb Case Attachment
Main unit Operation panel Panel PCB case attachment 1. Attach the ground plate USB 1 to the panel PCB case 2 with the 2 screws 2. Attach the panel PCB case 2 to the PCB base plate with the 5 screws 2. Screw, Bind M3X5 Back light drive PCB attachment...
Page 113: Pen Holder Attachment
Main unit Operation panel Pen holder attachment 1. Attach the 2 pen holders 1 to the panel rear cover with the 2 screws 1. Torque Taptite, Bind B 0.59 — 0.78 N-m M3X8 Card cover attachment 1. Attach the card cover 1 to the panel rear cover. *Key point •...
Page 114: Panel Rear Cover Attachment
Main unit Operation panel Panel rear cover attachment 1. Connect the connector of the lead wire assy com-panel 1 to the panel PCB supply assy. 2. Attach the panel rear cover 2 to the panel front cover with the 4 screws Torque Taptite, Bind B 0.59 —...
Page 115: Operation Panel Lever A Attachment
Main unit Operation panel Operation panel lever A attachment 1. Set the operation panel lever A 1 to the operation panel lever B 2, and then insert the operation panel lever shaft 3 into the operation panel lever A 1 and the operation panel lever B 2, and then secure them with the retaining ring E6.
Page 116: Operation Panel Lever Assembly Attachment
Main unit Operation panel Operation panel lever assembly attachment 1. Attach the operation panel lever assembly 1 to the panel rear cover with the 4 screws 1. 2. Set the 2 cord clamp 2 to the cord, and then attach the 2 cord clamp 2 to the operation panel lever assembly 1 with the 2 screws 2.
Page 117: Thread Tension Unit
Main unit Thread tension unit Thread tension unit 3 - 11...
Page 118: 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 119: 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 120: 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 121: 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 1 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 1, and then attach the retaining ring E8.
Page 122: 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 123: 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 124: Thread Sensor Assembly And Head Pcb Assembly Attachment
Main unit Thread tension unit Thread sensor 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 125: 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 thread guide tension axis 3 to the inner thread eyelet base 1 with the screw.
Page 126: 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 1, and then push it into the groove 3 on the tension base bracket.
Page 127: Tension Nut Attachment
Main unit Thread tension unit Tension nut attachment 1. Attach the tension disc felt 1, rotary disc assembly 2, tension disc felt 1, tension disc presser 3, spring , washer 4, and tension nut 5. (6 locations) NOTE • Insert the thread tension washer 6 between the spring the washer 4 only for thread tension A.
Page 128: Thread Cut Unit
Main unit Thread cut unit Thread cut unit 3 - 22...
Page 129: 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 130: 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 131: 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 132: Power Unit
Main unit Power unit Power unit 3 - 26...
Page 133: 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 1 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 134: Power Supply Unit Attachment
Main unit Power unit Power supply unit attachment 1. Tighten the 3 screws 1 temporarily. 2. Insert the lead wire 1 of the power supply unit 2 into the hole of the arm bed. 3. Connect the connector of the power switch assy 3 to the power supply PCB assy.
Page 135: Ex Connector Holder Attachment
Main unit Power unit EX connector holder attachment 1. Attach the EX connector holder cover 1 to the EX connector holder 2 with the 2 screws 1. 2. Attach the EX connector holder 2 to the base frame with the 2 screws 2. Torque Screw, Pan (S/P washer) 0.78 —...
Page 136: Lower Shaft Unit
Main unit Lower shaft unit Lower shaft unit 3 - 30...
Page 137: 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 1 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 138: 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 2 ball bearings 6 to the idle pulley. 3. Attach the retaining ring E7 to the idle pulley shaft 2. 4.
Page 139: 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 1 with the marking on the base frame, and firmly tighten the 4 screws 1.
Page 140: Upper Shaft Unit
Main unit Upper shaft unit Upper shaft unit 3 - 34...
Page 141: Upper Shaft Assembly
Main unit Upper shaft unit Upper shaft assembly 1. Set the presser foot cam 1 to the presser foot cam collar 2. *Key point • Check that the center of the positioning hole 3 of the presser foot cam 1 is the same as the center of the positioning hole 4 of the presser foot cam collar 2.
Page 142: 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 felt 1 to the lower shaft metal collar 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 143: 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 144: 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 felt 1 to the lower shaft metal collar on the arm bed. (2 locations) 3. Align the presser foot driving shaft assembly's 2 lower shaft metals 2 with the lower shaft metal collars on the arm bed, and then attach the presser foot driving shaft assembly to the arm bed.
Page 145: 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 146: 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 147: 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 1, and temporarily tighten the screw 1.
Page 148: 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 149: 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 150: 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 151: 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 152: 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 153: 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 1 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 154: 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 3. 4.
Page 155: Needle Bar Unit
Main unit Needle bar unit Needle bar unit 3 - 49...
Page 156: 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 157: Case Bracket Assembly
Main unit Needle bar unit Case bracket assembly 1. Attach the 2 ball bearings 694 to the case bracket assembly, and attach the 2 retaining rings E3. 2. Place the 4 washers (plain S, 4) in the case bracket assembly, and then attach the case guide US 1 with the 4 screws 1.
Page 158: 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 159: Case Positioning Plate Assembly
Main unit Needle bar unit Case positioning plate assembly 1. Attach the ball case positioning shaft assy 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 160: 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 161: 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 162: 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 163: 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 stud bolt (M4) 2. Tightening torque of stud bolt M4 1.18 - 1.57 N·m Change roller base assembly attachment 1.
Page 164: 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 165: Led Cord Guide Attachment
Main unit Needle bar unit LED cord guide attachment 1. Attach the 2 LED cord guides 1 with the 4 screws 1. Torque Screw, Bind 0.78 — 1.18 N-m M4X8 LED unit right assy assembly 1. Set the LED base plate right 1, the LED light base 2 and the LED PCB supply assy 3 to the LED upper cover 4, and then secure them with the 2 screws 1.
Page 166: Led Unit Left Assy Assembly
Main unit Needle bar unit LED unit left assy assembly 1. Set the LED base plate left 1, the LED light base 2 and the LED PCB supply assy 3 to the LED upper cover 4, and then secure them with the 2 screws 1.
Page 167: Thread Wiper Unit
Main unit Thread wiper unit Thread wiper unit 3 - 61...
Page 168: 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, washer 8, and the plain washer (M5) 9 to the wiper lever 3, and then attach the retaining ring E4.
Page 169: 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 170: 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 171: 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 172: Needle Bar Change Unit
Main unit Needle bar change unit Needle bar change unit 3 - 66...
Page 173: 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 174: 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 175: 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 176: Change Box Center Cover Attachment
Main unit Needle bar change unit Change box center cover attachment 1. Attach the LED cord holder 1 with the screw 1. 2. Attach the change box center cover 2 with the 2 screws 2. 3. Secure the lead wires to the LED cord holder 1 with the band 3. 4.
Page 177: Needle Thread Unit
Main unit Needle thread unit Needle thread unit 3 - 71...
Page 178: Th Motor Assembly Attachment
Main unit Needle thread unit TH 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 1 after completing 4 - 27 "Needle threader (up/down)."...
Page 179: Hook Assembly
Main unit Needle thread unit Hook assembly 1. Attach the bush 2 to the hook holder axis B 1 with the screw 1. *Key point • Temporarily tighten the screw 1 first. Firmly tighten it after completing 4 - 29 "Needle threader (left/right)". 2.
Page 180: 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 1.47 — 1.96 N-m M4X10 3 - 74...
Page 181: Feed Unit
Main unit Feed unit Feed unit 3 - 75...
Page 182: Connect Pcb Final Assembly
Main unit Feed unit Connect PCB final assembly 1. Attach the sheet 2 and the FFC (SML2CD-Y) 3 to the PCB holder 1 with the screw 1. 2. Attach the connect PCB assembly 4 to the PCB holder assembly with the screw 2.
Page 183: Y-Carriage L Assembly
Main unit Feed unit Y-carriage L assembly External retaining ring 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 184: Feed Frame Assembly
Main unit Feed unit Feed frame assembly 1. Attach the cylinder connection L/R 1 to the feed frame with the 4 screws 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 185: T-Belt (Y-Drive) Attachment
Main unit Feed unit T-belt (Y-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 186: 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 and XB 1, and then attach the 2 external retaining rings C21. (2 sets) 2. Attach the X-roller 3 to the bearing case X and XB assembly, and then attach the retaining ring E4.
Page 187: Hoop Sensor Attachment
Main unit Feed unit Hoop sensor attachment 1. Attach the hoop sensor assembly 1 to the X carriage CX 2, and then tighten the nut 3 temporarily. 2. Attach the PT meter plate 4, and then fully tighten the nut 3 and screw 3.
Page 188: X-Sensor Dog Attachment
Main unit Feed unit X-sensor dog attachment 1. Attach the X-sensor dog 1 to the X-carriage B 2 with the 2 screws 1. 2. Attach the FFC (SML2CD-X) and the sheet 3 to X-carriage B with the screw 2. Torque Bolt, Socket 0.59 —...
Page 189: 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 X carriage DX 3 to the X-carriage B assembly 1 with the 2 screws 2.
Page 190: 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 191: 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 2 to X-carriage B.
Page 192: 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) 1 with the cord grip 2, and then tighten the screw 1.
Page 193: 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 felt 1 to the metal collar on the base frame. (2 locations) 3. Attach the Y driving shaft assembly 2 to the base frame. 4.
Page 194: 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 195: 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 5, and then attach the feed final assembly 5 to the base frame. 2. Secure the 2 fixed Y-shaft plates 6 with the 4 screws 1 (one each on left and right).
Page 196: 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 set of retaining rings E4. 2.
Page 197: Main Unit
Main unit Main unit Main unit 3 - 91...
Page 198: 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 199: 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. *Key point • Temporarily tighten the 3 screws 1 first. Firmly tighten them after completing 4 - 20 "Needle bar rising and Needle clearance".
Page 200: Needle Plate Base Assembly
Main unit Main unit Needle plate base assembly *Key point • We recommend to replace the fixed knife 2 and movable knife 4 at once. • Adjust the following procedure after attaching the needle plate assy to the arm bed when replacing the fixed knife 2 and movable knife 4: 4 - 39 "Movable knife and Fixed knife engagement load"...
Page 201: 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 202: 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 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 203: 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 1 over the 2 holes 3 on the operator's side of the tension base assembly 2, and then align the pin on the left side of the needle bar case final assembly with the groove 4...
Page 204: Operation Panel Assembly Attachment
Main unit Main unit Operation panel assembly attachment 1. Attach the operation panel assembly 1 with the 6 screws 1. 2. Set the cord clamp 2 to the lead wires, and then attach the cord clamp 2 with the screw 2. Torque Screw, Pan (S/P washer) 1.18 —...
Page 205: Board Holder U/D Attachment
Main unit Main unit Board holder U/D attachment 1. Attach the board holder U 1 to the arm bed with the 4 screws 1. 2. Set the cord clamp 2 to the spiral tube. 3. Attach the board holder D 3 and the cord clamp 2 to the arm bed with the 2 screws 2.
Page 206: Main Pcb Assembly Attachment
Main unit Main unit Main PCB assembly attachment 1. Attach the main PCB assembly 1 to the board holder U and the board holder D with the 4 screws 1. 2. Attach the 2 PCB supporters 2 to the main PCB assembly 1 and the board holder U.
Page 207: 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 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.
Page 208: Base Cover R Attachment
Main unit Main unit Base cover R attachment 1. Attach the base cover R 1 with the 3 screws 1. *Key point • Fully draw the X-guide toward you before attachment. 2. Attach the 2 screw covers 2. 3. Attach the base cover R lib 3 with the 2 screws 2. Torque Screw, Pan (S/P washer) 0.78 —...
Page 209: 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 2. Inside Torque Taptite, Cup B 0.78 — 1.18 N-m M4X14 Torque Screw, Pan (S/P washer) 0.78 —...
Page 210: Arm Cover R Attachment
Main unit Main unit Arm cover R attachment 1. Attach the arm cover R 1 witht the 3 screws 1. 2. Attach the arm cover R lib 2 with the 2 screws 2. 3. Tighten the thumb bolt (M4L), spring washer (2-4), and plain washer (M4) 3.
Page 211: 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 rotary hook cover 5 to the bed cover bottom assembly 3.
Page 212: 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. Torque Taptite, Cup B 0.78 —...
Page 213: Adjustment
Adjustment Inspection Needle point damage .......4 - 2 Test mode Starting test mode ......4 - 3 Selecting test mode ......4 - 4 Input needle bar data for adjustment...4 - 13 Adjustment Motor belt tension ......4 - 15 Timing belt tension ......4 - 16 Needle drop (front/back)....4 - 17 Needle position (left/right)....4 - 19 Needle bar rising and Needle clearance ..4 - 20...
Page 214: Needle Point Damage
Inspection Needle point damage 1. Put needle on a level block, and check a needle is not bent. *Key point • Check all needles. The gap with the block should be even. Level block 2. Slide a needle on your finger and check if moves smoothly (no damage on needle point). *Key point •...
Page 215: Starting Test Mode
Test mode Starting test mode 1. Starting test mode Turn on the power while pressing the [Start/Stop] button, [Thread trimming] button and the [Automatic needle-threading] button. 2. Selecting test mode 1) Press the button on the screen, and select the test mode. MAIN BOARD TEST MODE SELECTION SCREEN MAIN / PANEL BOARD TEST MODE...
Page 216 Test mode Selecting test mode After replacing the main PCB, you must set the picker motor over-pulses (Test mode #05) and adjust the frame sensor (Test mode #08). 2) Press the number on the screen, and select the test mode. MAIN BOARD TEST MODE SELECTION SCREEN [01].
Page 217 Test mode Selecting test mode 3) Test mode Manual This section primarily explains only the test modes used for checking the state of the sewing machine. For more detailed descriptions of the test modes used for each adjustment, refer to the pages containing instructions for each specific adjustment.
Page 218 Test mode Selecting test mode #09. Needle bar case motor test When the needle bar data has been read to the sewing machine, the needle bar data is displayed below “Read needle date”. (13 characters) The status of the thread breakage sensor is indicated using “H” or “L” at the right side of the “Thread breakage”.
Page 219 The type of each component is displayed at the middle of the screen. 1 : PR650e/PR655 0 : PR650 #22. Switch checking Check whether the [Start/Stop] button, [Thread trimming] button and the [Automatic needle-threading] button are operating correctly.
Page 220 Test mode Selecting test mode #23. Sewing light, Speaker and S/S LED checking Select this mode to check whether the Sewing light, Speaker and the Start/ Stop LED are operated correctly. [LED Check]: Turn the LED lamp off to press [ON] button. : Turn the LED lamp on to press [OFF] button.
Page 221 Test mode Selecting test mode #26. USB HOST checking Select this mode to check the USB HOST function. [USB HOST 1]: USB port of the upper side of the side surface of the panel [USB HOST 2]: USB port of the lower side of the side surface of the panel Insert the USB media into the USB port, and then press the [START] button.
Page 222 Test mode Selecting test mode #31. Touch panel adjustment checking Select this mode to check that there is no gap in the touch panel and LCD. Touch the center of the [+] symbol with a touch pen. The gap (dots) of X or Y is displayed. When the gap is within an allowance, “OK”...
Page 223 Test mode Selecting test mode #32. Parameter default checking When the all displayed parameters are default, “OK” is displayed. When there is parameter that is not default, “NG” is displayed. *Key point • The parameter that is not default is reversed display (Refer to 1). [CLEAR] : The all displayed parameters is default value.
Page 224 Test mode Selecting test mode #36. Error list display The maximum of 30 error messages displayed while in use in the sewing machine are saved. When press the [+] button, the error message that one old is displayed. When press the [-] button, the error message that one new is displayed. *Key point •...
Page 225: Input Needle Bar Data For Adjustment
Test mode Input needle bar data for adjustment When replacing the needle bar case assy perform the following steps to save the “needle bar data” to the sewing machine's flash memory. *Key point • If the needle bar data is not saved to the sewing machine “NO DATA”...
Page 226 Test mode Input needle bar data for adjustment Reference: How to read the barcode data You can also select the standard needle bar and perform any necessary adjustments from the barcode data (13-digit) found on the needle bar case assy. Needle bar data on Bar code 5 Needle threader adjustment (front/back) 4 Needle threader adjustment (right/left)
Page 227: Motor Belt Tension
Adjustment Motor belt tension [Standard] The belt slack should be 1.5 to 3.5 mm when pushing the center of the motor belt with a force of 0.98N (100g). [Adjustment] 1. Remove the 4 screws of the main PCB and the 2 PCB supporters to remove the main PCB. 2.
Page 228: Timing Belt Tension
Adjustment Timing belt tension [Standard] The belt slack should be 3.5 to 4.0 mm when pushing the center of the timing belt with a force of 1.96N (200g). [Adjustment] 1. Remove the 4 screws of the main PCB and the 2 PCB supporters to remove the main PCB. 2.
Page 229: Needle Drop (Front/Back)
Adjustment Needle drop (front/back) [Standard] The clearance between the needle and the needle plate hole in the front/back direction should be more than 0.3 mm. [Adjustment] 1. Remove the 4 screws 1 of the LED unit right assy and the LED unit left assy to remove the LED unit right assy and the LED unit left assy.
Page 230 Adjustment Needle drop (front/back) 6. Loosen the screw 3 of the case positioning plate on the lower section of the needle bar case unit. 7. Move the case positioning plate to either the front or back to adjust the needle front/back position. 8.
Page 231: Needle Position (Left/Right)
Adjustment Needle position (left/right) [Standard] The clearance between the needle and the needle plate hole in the front/back direction should be more than 0.3 mm. And the needle bar case unit should move smoothly when the change box gear is rotated. [Adjustment] 1.
Page 232: Needle Bar Rising And Needle Clearance
Adjustment Needle bar rising and Needle clearance [Standard] The right edge of the needle matches up with the outer rotary hook point when the needle bar is raised 1.8 to 2.2 mm from its lowest point. And the clearance between the scarf of the needle and the outer rotary hook point in the front/back direction should be 0 to 0.4 mm.
Page 233 Adjustment Needle bar rising and Needle clearance 7. Loosen the 3 screws 3 at the base of the rotary and turn the outer rotary by hand until the right edge of the needle matches up with the rotary hook point of the outer rotary. Then move the outer rotary to the front or back to adjust the needle clearance and tighten the 3 screws 3 to secure the rotary when done.
Page 234: Needle Bar Height
Adjustment Needle bar height [Standard] The gap between the top of needle eye and the outer rotary hook point in the up/down direction should be 1.8 to 2.2 mm when the right edge of the needle matches up with the outer rotary hook point. The thread guide of the needle bar should be facing directly frontward.
Page 235 Adjustment Needle bar height 6. Hold the inner rotary and turn the pulley by hand to lower the needle bar to its lowest point. *CAUTION • When rotating the pulley by hand be careful not to pierce your finger with either the outer rotary hook point or the needle tip.
Page 236: Rotary Hook Stopper Clearance
Adjustment Rotary hook stopper clearance [Standard] The clearance between the rotary hook stopper and the rotary hook is 0.65 should be 0.95 mm. [Adjustment] 1. Remove the 2 screws of the needle plate to remove the needle plate. 2. Remove the screw 1 and screw 2 of the rotary hook stopper to remove the rotary hook stopper. 3.
Page 237: Presser Foot Height
Adjustment Presser foot height [Standard] The clearance between the section surrounding the needle plate hole and the bottom face of the presser foot should be 0.8 to 1.4 mm. [Adjustment] 1. Attach the needle plate and turn the pulley by hand to move the needle bar to its lowest position. 2.
Page 238: Needle Bar Top Dead Center
Adjustment Needle bar top dead center [Standard] When the needle bar is in highest position, there should not be clearance between the top dead center plate and the cushion rubber. And the cushion rubber should be compressed slightly (approx. 0.3 mm). [Adjustment] 1.
Page 239: Needle Threader (Up/Down)
Adjustment Needle threader (up/down) [Standard] The clearance between the top end of the hook and the top end of the needle eye is 0.1 to 0.2 mm. * The top end of the hook and the top end of the needle eye should contact a little. [Checking] 1.
Page 240 Adjustment Needle threader (up/down) [Adjustment] 1. Press [<] or [>] to select smallest needle bar of the clearance between the top end of the hook and the top end of the needle eye. 2. Press [Manual move] and move the hook to the front of needle eye. 3.
Page 241: Needle Threader (Left/Right)
Adjustment Needle threader (left/right) [Standard] The hook should be passed through the needle eye. [Adjustment] 1. Start the test mode and select [#12: Needle threader] under [MAIN BOARD TEST MODE]. 2. Press the [L-R position] and the standard needle bar for adjustment will be selected automatically.
Page 242: Y Belt Tension
Adjustment Y belt tension [Standard] The belt slack should be 3.9 mm when pushing the center of the Y belt with a force of 2.4 to 2.5N (245 to 255g). [Adjustment] 1. Move the XY carriage to the innermost position. 2.
Page 243: X Belt Tension
Adjustment X belt tension [Standard] The belt slack should be 5.7 mm when pushing the center of the X belt with a force of 1.75 to 1.85N (178 to 189g). [Adjustment] 1. Move the frame-mounting plate of the X carriage to the rightmost position. 2.
Page 244: Picker Activation
Adjustment Picker activation [Standard] The clearance between the bobbin and the picker should be 0.5 to 1.5 mm. [Adjustment] 1. Remove the bobbin case from the rotary hook. 2. Start the test mode and select [#05: Picker test] under [MAIN BOARD TEST MODE].
Page 245: Movable Knife Initial Position
Adjustment Movable knife initial position [Standard] The point of the movable knife should be out 0 to 1.0 mm from the fixed knife. [Adjustment] 1. Remove the 2 screws of the needle plate and remove the needle plate. 2. Start the test mode and select [#03: Trim test] under [MAIN BOARD TEST MODE].
Page 246: Thread Presser Base Up/Down Position
Adjustment Thread presser base up/down position [Standard] The clearance between the thread presser base upper assy and the wiper hook should be more than 0.2 mm for all needle positions. [Adjustment] 1. Loosen the 4 screws 1 of the thread presser base assembly. 2.
Page 247: Hoop Sensor (A/D Value)
Adjustment Hoop sensor (A/D value) After replace the hoop lever (potentiometer) and the hoop PCB assy, need to adjust. [Standard] The attached frame type and the displayed frame type on the screen are the same types. [Adjustment] 1. Attach the tubular round arm set A to the carriage. 2.
Page 248 Adjustment Hoop sensor (A/D value) 6. Attach the tubular round arm set B to the carriage. Thumb screw Fig.3 7. Press the [BORDER Save] after attaching the left arm of the Thumb screw tubular round arm set B to the position 1 (refer to Fig.3) and tightening the 2 thumb screws certainty.
Page 249: Upper Shaft Encoder Phase
Adjustment Upper shaft encoder phase [Standard] When the jump bracket is lowered 19.5 to 20.0 mm from the top dead center position, [Needle up] signal display should be changed from [H] to [L]. [Adjustment] 1. Start the test mode and select [#07: Sensor test] under [MAIN BOARD TEST MODE].
Page 250: X, Y Carriage Initial Position
Adjustment X, Y carriage initial position After replace the X area PCB assy and the Y area PCB assy, need to adjust. [Standard] The needle plate hole should be aligned with the embroidery sheet (Size: LL) center hole. [Adjustment] 1. Attach the tubular round arm set A to the carriage. 2.
Page 251: Movable Knife And Fixed Knife Engagement Load
Adjustment Movable knife and Fixed knife engagement load [Standard] The engagement load of the movable and the fixed knife should be 4.9 to 9.8N (500 to 1000g). [Adjustment] 1. Remove the 2 screws of the needle plate to remove the needle plate. 2.
Page 252: Movable Knife And Fixed Knife Pre-Conditioning
Adjustment Movable knife and Fixed knife pre-conditioning Be sure to operate this adjustment when the movable knife and/or fixed knife has been replaced. [Preparation] Adjust items below before operating this adjustment: (1) "4-39 Movable knife and Fixed knife engagement load" (2) "4-33 Movable knife initial position"...
Page 253: Led Pointer Position
Adjustment LED pointer position [Standard] The needle drop point is within a radius of the LED pointer beam. Needle position [Adjustment] detection sticker 1. Turn OFF the power switch. 2. Attach the needle position detection sticker so that the needle hole on the needle plate will be completely covered.
Page 254 Adjustment LED pointer position When the needle drop point is not matched with the pointer beam, adjust the LED pointer position by following procedures below. [Adjustment] 1. Remove the arm cover R lid and arm cover R. Arm cover R lid Arm cover R 2.
Page 255 Adjustment LED pointer position When the LED pointer deviates to the left or right of the needle drop point [Adjustment] 1. Remove the arm cover R lid and arm cover R. Arm cover R lid Arm cover R 2. Loosen the screw of the LED PT base plate. LED PT base plate Screw Hex wrench 2.5 mm...
Page 256: 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 257: Error Message List
Failure Investigation for Electronic Parts Error message list Error message list See page Error message list See page The pattern is too large for the extra large Main motor rotate error. 5 - 21 5 - 12 embroidery frame. Change to a larger embroidery frame. Main motor encoder signal error.
Page 258: The Power Is Not Turned On
Failure Investigation for Electronic Parts The power is not turned on. • The power is not turned on • Nothing is displayed on the display. Is the power cord properly connected Connect it properly. to both the inlet and the plug outlet? Is the resistance between the two terminals at both ends 1 or below when the power cord...
Page 259 Failure Investigation for Electronic Parts The power is not turned on. From the previous page From the previous page Change the power switch and the lead wire assy:power. Does the machine function normally when the power Change the power supply PCB supply PCB unit is replaced with a reliable one? unit.
Page 260 Failure Investigation for Electronic Parts The power is not turned on. From the previous page Is the backlight lead properly connected to connector CN8 on the panel PCB and Connect it properly. connector CN1 on the backlight drive PCB? Is the resistance between each pin at both ends Change the lead wire assy: 1 or below when the backlight lead is removed X2 PR-E LED BL.
Page 261: The Touch Panel Does Not Work
Failure Investigation for Electronic Parts The touch panel does not work. The touch panel does not work. Is the touch panel adjusted correctly? Adjust it correctly. Is the touch panel's FPC properly connected to connector CN7 on the Connect it properly. panel PCB? Is the resistance between pins 2 and 4, Change the touch panel and...
Page 262: The Panel Switch Does Not Work
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 SS PCB's lead properly connected to connector CN2 on the Connect it properly. panel PCB? Does the machine function normally when Change the panel PCB.
Page 263: 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 CN15 on the main PCB? Is the index sensor's lead properly connected Connect it properly.
Page 264: 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 265: 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-CX) properly connected to CN1 on the X area sensor PCB and CN3 Connect it properly. on the connect PCB? Is the orientation of the FFC (SML2CD-C) correct? Is the FFC (SML2CD-YC) properly connected to CN1 on the Y area sensor PCB and CN1...
Page 266 Failure Investigation for Electronic Parts The hoop does not move normally. From the previous page Does the machine function normally when the Y Change the Y area sensor PCB. area sensor PCB is replaced with a reliable one? Does the machine function normally when the Change the connect PCB.
Page 267: 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 the main shaft encoder. bent, or damaged due to contact? Is the main shaft sensor's lead properly Connect it properly.
Page 268 Failure Investigation for Electronic Parts The main shaft does not rotate normally. From the previous page Change the main motor. Change the lead wire assy: power motor. Change the lead wire assy: power signal. Does the machine function normally Change the power supply when the power supply PCB unit is PCB unit.
Page 269: Thread Is Not Cut Normally
Failure Investigation for Electronic Parts Thread is not cut normally. Thread is not cut normally. Is the TH cutter sensor's lead properly connected to CN13 on the Connect it properly. main PCB? Is the TH cutter motor's lead properly connected to CN4 on the Connect it properly.
Page 270: 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 CN16 on the main Connect it properly. PCB? Is the wiper motor's lead properly connected to CN7 on the main Connect it properly.
Page 271: 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 TH sensor's lead properly connected to CN17 on the Connect it properly. main PCB? Is the TH motor's lead properly connected to CN8 on the main Connect it properly.
Page 272: 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 CN18 on the main Connect it properly. PCB? Is the picker motor's lead properly connected to CN5 on the main Connect it properly.
Page 273: Led Light Does Not Turn On
Failure Investigation for Electronic Parts LED light does not turn ON. Is the LED lead properly connected to the left side of the LED PCB? Is the lamp set to "ON"? Set the lamp to "ON". Is the LED lead properly connected Connect it properly.
Page 274: Usb Function And Usb Media Cannot Be Used Normally
Failure Investigation for Electronic Parts USB function and USB media cannot be used normally. USB function cannot be used normally. Is the USB cable properly connected to both the personal computer and Connect it properly. the sewing machine? Does the machine function normally when the USB cable is replaced with Change the USB cable.
Page 275: 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 properly connected Connect it properly. to CN1 on the hoop sensor PCB? Is the FFC (SML2CD-XH) connected to CN2 on the hoop sensor PCB and CN1 on the X Connect it properly.
Page 276 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 FFC Change the FFC (SML2CD-CX). (SML2CD-CX) are removed from the PCB? Is the resistance between each terminal at both ends 1Ω...
Page 277 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 the Y area sensor PCB. area sensor PCB is replaced with a reliable one? Does the machine function normally when the Change the main PCB.
Page 278: Sound Does Not Work
Failure Investigation for Electronic Parts Sound does not work Sound does not work. Is the variable setting of value to Cancel the mute setting of sound? the variable setting of value. Is the speaker free from damage Connect the speaker correctly and correctly connected to the or replace it.
Page 279: Led Pointer Does Not Light
Failure Investigation for Electronic Parts LED pointer does not light LED pointer does not light. Is the attached frame usable for the Attach a frame usable for the LED pointer? LED pointer. Turn the LED pointer setting Is the LED pointer setting turned ON? Is the lead wires of the light source assy correctly connected to the lead Connect it properly.
Page 280: Cannot Upgrade Software
Failure Investigation for Electronic Parts Cannot upgrade software If you cannot upgrade the software installed in the machine, refer to the instructions below. 1. Upgrading thorough USB media Step Instruction Check if there are multiple upgrade files in the USB media. If there are, leave only one file and try upgrading again.
Page 281 Failure Investigation for Electronic Parts Cannot upgrade software <From previous page> If upgrading stops, check the percent complete shown on the screen to take appropriate measure according to the estimated error cause shown in the table below. Percent complete Cause Remedy Update error in display data or panel Replace the upgrade program* or panel...
Page 282: 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 CN23 on the main Connect it properly. PCB? Does the machine function normally when the Y area sensor PCB is Change the Y area sensor PCB.
Page 283 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 the main shaft encoder. bent, or damaged due to contact? Is the main shaft sensor's lead properly connected to CN19 on the Connect it properly.
Page 284 Failure Investigation for Electronic Parts Error message Main motor current error (Dialog message) Is the main motor's lead properly connecte d to the power supply Connect it properly. PCB's lead? Is the power motor's lead properly connecte d to CN4 on the power Connect it properly.
Page 285 Failure Investigation for Electronic Parts Error message • Panel communication error. • Communication timeout error. • Data receiving command error. • Communication error. (Dialog message) Is the panel lead properly connected to connector CN5 on the panel PCB and Connect them properly. connector CN10 on the main PCB? Is the resistance between each pin at both ends Change the lead wire assy:...
Page 286 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 287: Replacement Of Main Pcb Assy Or Panel Pcb Assy
Failure Investigation for Electronic Parts Replacement of main PCB assy or panel PCB assy Do not replace the main PCB assy and panel PCB assy simultaneously. The setting data required to run the sewing machine correctly is stored in both the main PCB assy and the panel PCB assy.
Page 288: Correspondence Table Of "Model" And "Printed-Circuit Board"
Failure Investigation for Electronic Parts Correspondence table of “Model” and “Printed-circuit board” Panel PCB Marking character Model Specifications Parts code on (A) PR655 for all country XF2215*** XF2215*** ********* VER*.** Main PCB Marking character Model Specifications Parts code on (B)
Page 289: Maintenance & Replacement
Maintenance & Replacement Maintenance How to reset the counter of the maintenance ....6 - 2 Necessary grease & oil..........6 - 3 Maintenance point (Every 1,500 hours)......6 - 4 Maintenance point (Every 500 hours)......6 - 10 Maintenance point (Every day) ........6 - 11 Replacement Replacement parts location .........6 - 12 Main PCB assy ............6 - 13...
Page 290: How To Reset The Counter Of The Maintenance
Maintenance How to reset the counter of the maintenance When the operating time of the machine reaches 1500 hours, the maintenance message (MSG) will be displayed on the LCD. And then do the maintenance according to the instructions of 6-4 to 6-9, and finally reset the hour counter according to the following instructions.
Page 291: Necessary Grease & Oil
Maintenance Necessary grease & oil Grease Name: MOLYKOTE EM30L Name: MOLYKOTE M DISPERSION Part #: XC8385001 Part #: XC8386001 Note This MOLYKOTE M DISPERSION needs to be diluted by OILER (Part #: XZ0206051). Need to mix MOLYKOTE M DISPERSION : OILER = 1 : 10.
Page 292: Maintenance Point (Every 1,500 Hours)
Maintenance Maintenance point (Every 1,500 hours) 1. Maintenance point by dealer (Every 1,500 hours) (a) Thread take-up lever and Presser foot driving cam (b) Needle bar case Name of grease/oil Quantity Check point MOLYKOTE EM-30L 0.3cm MOLYKOTE EM-30L 0.3cm FBK OIL RO 100 three drops FBK OIL RO 100 one drop...
Page 293 Maintenance Maintenance point (Every 1,500 hours) (c) Change cam (d) Thread take-up driving lever Name of grease/oil Quantity Check point 14 MOLYKOTE EM-30L 0.3cm 15 MOLYKOTE EM-30L 0.3cm 16 MOLYKOTE EM-30L 0.3cm Check presser foot height 17 MOLYKOTE EM-30L 0.3cm 18 MOLYKOTE EM-30L 0.3cm 6 - 5...
Page 294 Maintenance Maintenance point (Every 1,500 hours) (e) Upper shaft bushing (R) Timing belt Motor belt Name of grease/oil Quantity Check point Check motor belt tension 19 FBK OIL RO 100 three drops Check timing belt tension 6 - 6...
Page 295 Maintenance Maintenance point (Every 1,500 hours) (f) X carriage X driving gear X sensor Clean up Clean up Name of grease/oil Quantity Check point 20 MOLYKOTE EM-30L 0.3cm Check X belt tension Check X belt presser 21 MOLYKOTE EM-30L 0.3cm 6 - 7...
Page 296 Maintenance Maintenance point (Every 1,500 hours) (g) Y carriage (R) (h) Y carriage (L) Y sensor Clean up Name of grease/oil Quantity Check point 22 MOLYKOTE EM-30L 0.3cm Check Y belt tension Check Y belt presser 23 MOLYKOTE EM-30L 0.3cm 6 - 8...
Page 297 Maintenance Maintenance point (Every 1,500 hours) (i) Y driving shaft (R) (j) Y driving shaft (L) Clean gear part Name of grease/oil Quantity Check point 24 FBK OIL RO 100 one drop 25 FBK OIL RO 100 one drop Rotary hook and lower shaft bushing Lower shaft bushing and lower shaft gear Oil here through the hole at the side of arm...
Page 298: Maintenance Point (Every 500 Hours)
Maintenance Maintenance point (Every 500 hours) 2. Maintenance point by dealer (Every 500 hours) Maintenance needs to be carried out on a machine at 500 hours use, if the machine is used for industrial purpose. (a) Needle bar case Name of grease/oil Quantity Check point OILER...
Page 299: Maintenance Point (Every Day)
Maintenance Maintenance point (Every day) 3. Maintenance point by end user (Every day) Cleaning of knives and rotary hook Maintenance Remove the needle plate. Use the included cleaning brush to remove any lint and dust from knives and Clean up rotary hook.
Page 300: Replacement Parts Location
Replacement Replacement parts location Click the parts names, and follow the each procedure. Main motor assy Main PCB assy LCD module Power supply PCB unit Panel PCB assy 6 - 12...
Page 301: Main Pcb Assy
Replacement Main PCB assy XY carriage Bed bottom cover - Check that the power supply cord is disconnected. - Slide the XY carriage to the direction of the arrow. - Remove the 2 screws, and then remove the bed bottom cover. Bed cover Bed cover top - Remove the 4 screws, and then remove the bed cover...
Page 302 Replacement Main PCB assy Base cover R lid Arm cover R XY carriage - Remove the thumb bolt, the spring washer and the - Slide the XY carriage to the direction of the arrow. plain washer."A" - Remove the 2 screws, and then remove the base - Remove the 3 screws, and then remove the arm cover R.
Page 303 Replacement Main PCB assy Main PCB assy Main PCB assy - Disconnect the all connectors on the main PCB assy. - Remove the 4 screws, and then remove the main PCB assy. 6 - 15...
Page 304: Power Supply Pcb Unit
Replacement Power supply PCB unit Power supply PCB unit Power supply PCB unit - Remove the 3 screws, and then remove the power supply PCB unit. - Disconnect the 4 connectors from the power supply PCB unit."A" 6 - 16...
Page 305: Main Motor Assy
Replacement Main motor assy XY carriage Bed bottom cover - Check that the power supply cord is disconnected. - Slide the XY carriage to the direction of the arrow. - Remove the 2 screws, and then remove the bed bottom cover. Bed cover Bed cover top - Remove the 4 screws, and then remove the bed cover...
Page 306 Replacement Main motor assy Base cover R lid Arm cover R XY carriage - Remove the thumb bolt, the spring washer and the - Slide the XY carriage to the direction of the arrow. plain washer."A" - Remove the 2 screws, and then remove the base - Remove the 3 screws, and then remove the arm cover R.
Page 307 Replacement Main motor assy PCB supporters Main PCB assy Main PCB assy - Disconnect the all connectors on the main PCB assy. - Remove the 2 PCB supporters. - Remove the 4 screws, and then remove the main PCB assy. Board holder U - Remove the 4 screws, and then remove the board holder U.
Page 308: Panel Pcb And Lcd Module
Replacement Panel PCB and LCD module Panel rear cover - Remove the 4 screws, and then remove the panel rear - Disconnect the connector of the lead wire assy. "A" cover. Panel PCB Back light drive PCB Panel PCB case - Disconnect the connector of the back light drive PCB - Remove the 5 screws, and then remove the panel PCB case.
Page 309 Replacement Panel PCB and LCD module PCB base plate USB cover Panel front cover badge assy Touch panel - Remove the USB cover from the PCB base plate. - Disassembly the PCB base plate 1, the LCD spacer 2, the LCD supply assy 3, the electric static preventer 4, the touch panel 5 and the panel front cover badge assy 6.
Page 310: Head Unit
Replacement Head unit Bracket cover - Put the tension base as shown in the figure. - Remove the 2 screws, and the remove the bracket cover. - Remove the 4 screws. Head unit Cord bush - Remove the cord bush. - Disconnect the connector of the tension base lead wire assy, and then remove the head unit.
Page 311: Hook Holder
Replacement Hook holder 1. Start the test mode and select [#06: Threader test] under [MAIN BOARD TEST MODE]. 2. Press [<] or [>] to select the number 6 needle bar. (The needle bar case unit moves to left or right.) 3.
Page 312: Sub Tension Assy
Replacement Sub tension assy To replace the “thread guide tension screw” to the upper thread adjustable “sub tension assy” on the machine with “thread guide tension screw”, follow the instructions below. 1. Remove the tension base from the machine. 2. Remove the cap from the thread guide tension screw. 3.
Page 313: Special Instructions Of Wiring
Special Instructions of Wiring Base frame..........7 - 2 Y-feed cable..........7 - 3 X-feed cable..........7 - 5 Head unit..........7 - 8 Panel unit ..........7 - 9 LED pointer ..........7 - 14 Left side of arm bed .......7 - 16 LED unit ..........7 - 17 Arm ............7 - 24 Right side of arm bed......7 - 25 Main PCB..........7 - 27...
Page 314 Special Instructions of Wiring Base frame 1. Wiring on left side of base frame Secure the lead wires to the base frame with the cord clamps. Extention IF PCB lead wire Y area PCB lead wire 2. Wiring on right side of base frame Y area PCB lead wire Extention IF PCB lead wire Y motor lead wire...
Page 315 Special Instructions of Wiring Y-feed cable 1. Wiring of Y feed cable (1) Align the center of the Y-cable protection sheet with the center of the FFC, and paste them together. 55mm Y-cable protection sheet FFC: SML2CD-YC Y-cable protection sheet is not bent here. 2.
Page 316 Special Instructions of Wiring Y-feed cable 3. Wiring of Y feed cable (3) Unlock the connector lock, and connect the FFC, and lock again. FFC: SML2CD-CX Y area PCB ASSY PCB set plate Y-cable protection sheet X-motor lead wire Screw FFC: SML2CD-YC 4.
Page 317 Special Instructions of Wiring X-feed cable 1. Wiring of X-feed cable (1) X-cable fixing sheet A FFC (SML2CD-X) X-cable fixing sheet B Bottom edge clearance: 1mm / mountain fold 2. Wiring of X-feed cable (2) X-carriage FFC: SML2CD-X Hoop sensor lead wire Assy: hoop sensor 7 - 5...
Page 318 Special Instructions of Wiring X-feed cable 3. Wiring of X-feed cable (3) X-carriage Screw X-cable fixing sheet E FFC: SML2CD-X Assy: hoop sensor 4. Wiring of X-feed cable (4) X area sensor X-cable fixing sheet B FFC: SML2CD-X 7 - 6...
Page 319 Special Instructions of Wiring X-feed cable 5. Wiring of X-feed cable (5) X-carriage Check that the FFC is parallel to the X belt. Assy: hoop sensor FFC: SML2CD-X X belt 7 - 7...
Page 320 Special Instructions of Wiring Head unit 1. Wiring on inside of tension base Connect the head quantity sensor Head PCB Do not allow the cable to the connector correctly. head earth wire to protrude from the case. Head earth wire attachment position (seven locations)
Page 321 Special Instructions of Wiring Panel unit 1. Wiring of FFC Back side of LCD spacer LCD spacer Back light FPC Pass the back light FPC through the hole of the LCD spacer. FFC: SML2CD-50 Bend the FFC at the reinforcing tape. Reinforcing tape Back side of LCD module Be careful not to...
Page 322 Special Instructions of Wiring Panel unit 2. Wiring of LCD module and touch panel Unlock the Unlock the connector lock. connector lock. Panel PCB Pass the FFC through the Connect the FFC ferrite core, and of the touch panel then connect to the connector the FFC to the correctly.
Page 323 Special Instructions of Wiring Panel unit 3. Wiring of SS PCB Hang the SS lead wires on the hooks. (2 locations) SS lead wires Panel PCB SS PCB 4. Wiring of speaker Hang the lead wire on the hook. Speaker lead wire Speaker holder Pass the lead wire through inside of...
Page 324 Special Instructions of Wiring Panel unit 5. Wiring of back light drive PCB Back light lead wires Connect the FPC to the connector. Panel PCB Back light FPC Unlock the connector lock. Back light drive PCB Lock the connector lock. 7 - 12...
Page 325 Special Instructions of Wiring Panel unit 6. Wiring of panel PCB assy Screw Lead wire assy: main-panel Panel PCB assy 7 - 13...
Page 326 Special Instructions of Wiring LED pointer 1. Wiring of LED pointer (1) Adjustment hole LED pointer 2. Wiring of LED pointer (2) LED pointer's lead wire Check that the lead wire can be seen from the front side. 7 - 14...
Page 327 Special Instructions of Wiring LED pointer 3. Wiring of LED pointer (3) LED pointer's lead wire Guide parts Lead wire guide Guide parts Motor lead wire 7 - 15...
Page 328 Special Instructions of Wiring Left side of arm bed 1. Wiring on upper side of arm bed Pass the lead wire through between the PCB and the sensor Spiral tube bracket hook. Assy: color change sensor Assy: index sensor Pass the lead wire through between the PCB and the sensor bracket hook.
Page 329 Special Instructions of Wiring LED unit 1. LED PCB (Left) Pass the LED lead wire through Hang the LED lead wire on the hook. between the boss and the outside wall. 2. LED PCB (Right) Pass the LED lead wire through Hang the LED lead wire on the hook.
Page 330 Special Instructions of Wiring LED unit 3. Left side of needle bar case Pass the LED lead wire through the guide. Secure the LED lead wire with the LED cord clamp. (2 locations) * No slack allowed. 7 - 18...
Page 331 Special Instructions of Wiring LED unit 4. Right side of needle bar case Pass the LED lead wire through the guide. Secure the LED lead wire with the LED cord clamp. (2 locations) * No slack allowed. 7 - 19...
Page 332 Special Instructions of Wiring LED unit 5. Upper side of arm (1) : Marking of LED lead wire 161 mm Mark on the Measure from left/right LED the end of the lead wire. LED cord guide. Marking 7 - 20...
Page 333 Special Instructions of Wiring LED unit 6. Upper side of arm (2) : Securing of LED lead wire (Left side) Cross the left/right LED lead wire. Align the marking with the upper surface of the LED cord holder. 7 - 21...
Page 334 Special Instructions of Wiring LED unit 7. Upper side of arm (3) : Securing of LED lead wire (Right side) Align the marking with Hang the LED lead the upper surface of wire on the hook. the LED cord holder. 7 - 22...
Page 335 Special Instructions of Wiring LED unit 8. Upper side of arm (4) Secure the left/right LED lead wire to the hook of the LED cord holder with the band. 7 - 23...
Page 336 Special Instructions of Wiring Arm 1. Wiring of panel lead wire Panel holder Panel lead wire Secure the panel lead wire to the panel holder with the cord clamp. Secure the panel lead wire to the operation panel Lever B with the cord clamp.
Page 337 Special Instructions of Wiring Right side of arm bed 1. Wiring on right side of arm bed (1) Cord bushing (back) Head lead wire Distance from cord bushing to cord clamp: 125 mm Secure the left/right LED lead wire to the hook of the LED cord Secure the head lead wire holder with the band.
Page 338 Special Instructions of Wiring Right side of arm bed 3. Wiring on right side of arm bed (3) Needle TH sensor lead wire Spiral tube B Secure the needle TH sensor lead wire and TH motor lead wire with the spiral tube B, and TH motor lead wire secure them to the thread guide base with the cord clamp.
Page 339 Special Instructions of Wiring Main PCB 1. Wiring on upper side of main PCB Main shaft sensor lead wire Spiral tube A Hang the main shaft sensor lead wire on the hook B. Hook B Cross the lead wires. Distance from the hook B to the spiral tube A: more than 15 mm.
Page 340 Special Instructions of Wiring Arm bed 1. Wiring of arm bed Picker motor lead wire Hang the picker motor lead wire and the picker sensor lead wire Picker sensor on the hooks. (3 locations) lead wire 7 - 28...

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Brother PR655 Service Manual

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