Z-8550A Z-8560A SERVICE MANUAL Please read this manual before making any adjustments.
This service manual is intended for Z-8550A, Z-8560A; be sure to read the Z-8550A, Z-8560A instruction manual before this manual. Carefully read the “SAFETY INSTRUCTIONS” and the whole of this manual to understand this product before you start maintenance. As a result of research and improvements regarding this product, some details of this manual may not be the same as those for the product you purchased. If you have any questions regarding this product, please contact a Brother dealer.
SAFETY INSTRUCTIONS [1] Safety indications and their meanings This service manual and the indications and symbols that are used on the machine itself are provided in order to ensure safe operation of this machine and to prevent accidents and injury to yourself or other people. The meanings of these indications and symbols are given below.
[2] Notes on safety DANGER Wait at least 5 minutes after turning off the power switch and disconnecting the power cord from the wall outlet before opening the face plate of the control box. Touching areas where high voltages are present can result in severe injury. CAUTION Environmental requirements Use the sewing machine in an area which is free from sources of strong electrical noise such as high-frequency welders. Sources of strong electrical noise may cause problems with correct operation.
CAUTION Sewing This sewing machine should only be used by operators who have received the necessary training in safe use beforehand. Attach all safety devices before using the sewing machine. If the machine is used without these devices attached, injury may result. The sewing machine should not be used for any applications other than sewing. Never touch the knife on the face plate when opening the thread takeup guard cover at times such as when taking up slack in the thread, otherwise injury may result.
CAUTION Maintenance and inspection Maintenance and inspection of the sewing machine should only be carried out by a qualified technician. Ask your Brother dealer or a qualified electrician to carry out any maintenance and inspection of the electrical system. Turn off the power switch and disconnect the power cord from the wall outlet at the following times, otherwise the machine may operate if the treadle is depressed by mistake, which could result in injury.
4 Direction of operation 5 6 Do not touch the thread takeup or the knife, otherwise injury may result. If the actuator is pressed by mistake when using the correction sewing function, the needle will move in a zigzag motion while the machine is operating, and injury may result.
CONTENTS 1. MACHINE SPECIFICATIONS............... 1 5. MECHANICAL DESCRIPTIONS .......... 32 5-1. Needle bar and thread take-up mechanisms....32 2. SEWING PATTERN.............................. 2 3. FUNCTION SETTINGS......................... 3 3-1. Setting memory switches.................................. 3 3-2. List of memory switch settings ......................... 4 3-3. Data initialization .............................................. 14 3-3-1. Resetting the settings to their defaults .. 14 3-3-2.
. ADJUSTMENTS ................................... 67 10-2. Applying grease ..............................................86 9-1. Actuator position............................................... 67 10-3. Resetting the cumulative operating time.........87 9-2. Adjusting the safety switch position.................. 68 9-3. Thread tension spring....................................... 69 9-4. Presser foot height ........................................... 70 9-5. Feed dog height.............................
1. MACHINE SPECIFICATIONS 1. MACHINE SPECIFICATIONS 8550A Thread trimmer Upper thread feeding device Back tack/condense device *1 SPECIFICATIONS Use Max. stitch length Max. sewing speed Sewing pattern Max. zigzag width Thread take-up lever Needle bar stroke Feed dog height Presser foot Lifting lever height Knee lifter Presser foot pressure Needle Motor Control box power supply voltage Control circuit 0 - A - 8560A 3 c c c c 8550A 8560A -031, -A31 -331 For light-weight to medium-weight materials 2.
2. SEWING PATTERN 2. SEWING PATTERN • This sewing machine is equipped with the following built-in sewing patterns. Select the pattern number from the operation panel to use a pattern.(Refer to “6-2-2. Setting the sewing pattern” of the instruction manual.) • Different zigzag widths and zigzag lengths can be set for each sewing pattern. (Refer to “5-6. Adjusting the stitch length”, “6-2-3. Setting the zigzag width” of the instruction manual.) Pattern no.
3. FUNCTION SETTINGS 3. FUNCTION SETTINGS 3-1. Setting memory switches • If the icon (1) on the LOCK key is on, release the lock before carrying out the following operations. • If the icon (2) on the MAX key is on, press the MAX key to return the main display to the stitch number display (orange). 2238M 1 Memory switch No. setting value • The main display will change to green and memory switch setting mode will be enabled.
3. FUNCTION SETTINGS 3-2. List of memory switch settings Memory switch No. 0 - 15 No.
3. FUNCTION SETTINGS Memory switch No. 16 - 30 No. Initial value Setting range 16 3 (minutes) 0 - 30 (minutes) 17 1 0-3 18 50 (ms) 10 - 200 (ms) Setting details Overtime function 0: None 1-30: After continuous operation for the set length of time, operation stops and [Err 190] is displayed.
3. FUNCTION SETTINGS Memory switch No. 31 - 46 No.
3. FUNCTION SETTINGS Memory switch No. 47 - 60 No. Initial value Setting range 47 0 0-1 48 0 0-1 49 0 0-1 51* 0 0-1 52 2 (stitches) 1 – 99 (stitches) 53* 10 (stitches) 0 - 100 (stitches) 54* 1 0-2 55 0 0-1 56 0 0-1 57 0 0-1 58 0 0-1 59 0 (ms) 0 - 150 (ms) Setting details Operation during standing operation when AUTO function is on 0: When high-speed pedal turns on, sewing is momentarily stopped, and it is resumed when pedal turns off.
3. FUNCTION SETTINGS Memory switch No. 68 - 69 No. Initial value 68 69 Setting range 0 0-1 1 0-3 Setting details Seam matching function during automatic backtacking (Used when you would like seams to be accurately matched when using automatic backtacking; No. 78 sets the stop position and No. 79 can be used to change the time until restart.
3. FUNCTION SETTINGS Memory switch No. 80 - 88 No.
3. FUNCTION SETTINGS Memory switch No. 90 - 110 No. Initial value Setting range 160 150 - INCH 90 (rpm) (rpm) 220 150 - 300 91 (rpm) (rpm) 1400 500 - 2500 92 (rpm) (rpm) 300 INCH - 1000 93 (rpm) (rpm) 3000 INCH - 3000 94 (rpm) (rpm) 1200 INCH - 3000 96 (rpm) (rpm) HIL INCH - HIL 98 (rpm) (rpm) INCH - 5000 99 (*1) (rpm) 8.0 3.0 - 10.
3. FUNCTION SETTINGS Memory switch No. 111 - 123 No. Initial value Setting range 111 1000 (rpm) 500 - 2000 112 1 0-1 113 0 0-1 114 0 0-1 115 1.0 (1.0 ms) 0.1 - 4.9 (0.1 - 4.9 ms) Setting details Limit speed for sewing patterns with changed sewing pitch (T stitches) Needle lifting and needle lowering are carried out at low speed when No. 110 is set to “1”.
3. FUNCTION SETTINGS Memory switch No. 125 - 148 No. Initial value Setting range 125 0 0-1 126 1 (seconds) 0 - 120 (seconds) 127 100 (hours) 0 - 500 (hours) 128 0 0-3 129 130 0 0 131 700 (hours) 137 20 (degrees) 138 40 (degrees) -3 - 2 -3 - 2 0 - 1200 (hours) 0 - 40 (degrees) 0 - 120 (degrees) 139 40 (ms) 0 - 40 (ms) 140 40 (ms) 0 - 100 (ms) 141 142 30 (ms) 30 (ms) 5 - 60 (ms) 5 - 60 (ms) 143 30 (ms) 0 - 60 (ms) 144 1.0 (1.0 ms) 0.1 - 4.9 (0.1 - 4.
3. FUNCTION SETTINGS Memory switch No. 132 - 135 The following memory switch numbers are used for displaying maintenance information. No. Explanation of display details 132 Cumulative power on time (Actual time = Displayed time x 10 hours) 133 Cumulative running time (Actual time = Display xxxx x 10 hours) 135 ROM version (x.
3. FUNCTION SETTINGS 3-3. Data initialization Initialization of memory data refers to returning all operation panel setting data (including data that has been set using memory switches) to the factory default settings. 3-3-1. Resetting the settings to their defaults 1 While holding down the RESET key on the operation panel, turn on the power switch (1). Orange display 3457M 2 Green display The operation panel settings will be returned to their factory defaults.
3. FUNCTION SETTINGS 1 While holding down the FUNC key on the operation panel, turn on the power switch (1). Orange display 0172B 2 Green display The memory switch setting data will be initialized. After this, operation panel and treadle operation will be possible. 0173B 1 While holding down the CF key on the operation panel, turn on the power switch (1).
3. FUNCTION SETTINGS 3-3-2. When data is initialized automatically All setting data will be initialized automatically at the following times.
3. FUNCTION SETTINGS 3-4. Error history checking method 3-4-1. Error history checking method The past error history can be checked by the following procedure. 1 While holding down the TEST key on the operation panel, turn on the power switch (1). * After the following display appears, keep the TEST key pressed down until the buzzer makes a short beep. 0176B 2 The error history order number (1) and the error code (2) will appear in the main display. (Refer to “3-4-2.
3. FUNCTION SETTINGS 3-4-2. Error history display examples Setting items If there is no error history Error [E110] is displayed first. Main display (1) [000] [001] Main display (2) [E---] [E110] 3-5. Software version checking method 3-5-1. Version update checking method 1 While pressing the [Speed ] key on the operation panel, turn on the power switch (1). ] key pressed down until the buzzer makes a short beep.
3. FUNCTION SETTINGS 3-6. Checking input and output Use this to check for any malfunctions of the operation panel keys, circuit boards or sensors, and for checking for broken cords and for adjusting sensor positions. You can check whether the CPU is correctly reading the signals from keys and sensors. 3-6-1. Input and output checking method 1 While holding down the TEST key on the operation panel, turn on the power switch (1).
3. FUNCTION SETTINGS Treadle unit and standing operation pedal operation Operation panel Operation block indicator block Forward depression - ON Treadle unit Standing operation pedal Forward depression - ON (1st step - ON is when DIP switch No. 2 is ON) Backward depression to 1st step - ON Backward depression - ON High-speed switch - ON Low-speed switch - ON Plain zigzag LED Forward depression ON signal position Depress the treadle unit forward.
3. FUNCTION SETTINGS 3-7. DIP switch setting method DANGER Wait at least 5 minutes after turning off the power switch and disconnecting the power cord from the wall outlet before opening the cover of the control box. Touching areas where high voltages are present can result in severe injury.
3. FUNCTION SETTINGS 3-8. Needle zigzag home position adjustment procedure OPERATION PROCEDURE 1 While pressing the [zigzag width/zigzag reference line position] key on the operation panel, turn on the power switch (1). The offset value will be displayed. (Initial setting is “0”) 0185B 2 Move the needle bar to the needle up stop position, and then press and hold the RESET key for 2 seconds or more.
4. USING CF CARDS 4. USING CF CARDS 4-1. Precautions when handling CF cards (commercially available) • • • • • • • • • • • Use CF cards with a capacity of 32, 64, 128 or 256 MB. Do not attempt to disassemble or modify the CF cards. Do not forcibly bend, drop or scratch CF cards or place heavy objects on top of them. Do not allow them to come into contact with liquids such as water, oil, solvents or drinks.
4. USING CF CARDS 4-3. Preparation for reading/writing data 1 With the power turned off, insert the CF card into the CF slot. NOTE: • Make sure the CF card is facing the correct way. • Always be sure to keep the cover closed except when inserting and removing the CF card. If this is not done, dust may get inside and cause problems with operation. 4453Q 2 Turn on the power switch (1). MEMO icon illuminates. * If no valid data can be found on the CF card, the MEMO icon will not illuminate.
4. USING CF CARDS 4-4. Reading additional sewing data into the sewing machine 0197B 1 2 Carry out steps 1 to 3 in “4-3. Preparation for reading/writing data”. Select [r 1] in CF data read/write mode. 0191B 3 0192B 4 Select the program numbers to be read (ALL, 1-99). * If [ALL] is displayed, all additional sewing data will be read at once. 0193B 5 The buzzer will sound and the selected sewing data will be read from the CF card and copied into the sewing machine's internal memory.
4. USING CF CARDS 4-5. Writing additional sewing data to CF cards 0211B 1 2 Carry out steps 1 to 3 in “4-3. Preparation for reading/writing data”. Select [w 2] in CF data read/write mode. 0198B 3 0199B 4 Select the program numbers to be written (ALL, 1 - 99). * If [ALL] is displayed, all additional sewing data will be read at once. 0200B 5 The buzzer will sound and the selected sewing data will be copied from the internal memory onto the CF card. When [End] is displayed, the process is complete.
4. USING CF CARDS 4-6. Reading memory switch data into the sewing machine 0197B 1 2 Carry out steps 1 to 3 in “4-3. Preparation for reading/writing data”. Select [r 3] in CF data read/write mode. 0202B 3 The buzzer will sound and the memory switch data will be loaded from the CF card and copied into the sewing machine's internal memory. Reading Finished when [End] is displayed. 0203B 4 Set the power switch (1) to OFF and remove the CF card.
4. USING CF CARDS 4-7. Writing memory switch data to a CF card 1 2 0211B Carry out steps 1 to 3 in “4-3. Preparation for reading/writing data”. Select [w 4] in CF data read/write mode. 0204B 3 The buzzer will sound and the memory switch data will be copied from the internal memory onto the CF card. Writing 4 Writing complete 0205B Press the TEST key to exit read/write mode. 0195B 5 Set the power switch (1) to OFF and remove the CF card.
4. USING CF CARDS 4-8. Updating the control program version 0197B 4-8-1. Control program version updating procedure 1 2 Carry out steps 1 to 3 in “4-3. Preparation for reading/writing data”. Select [r 7] in CF data read/write mode. 0206B 3 Version number for control program saved on CF card 0207B 4 Version updating in progress Complete when [End] is displayed NOTE: * Version updating takes a maximum of 60 seconds.
4. USING CF CARDS 4-8-2. Restoring the control program if an error occurs during version updating If the version updating did not complete normally, such as because of a power outage, the sewing machine will not operate correctly. If this happens, restore the control program by the following procedure. 1 Insert the CF card containing the control program data into the CF card slot. 4453Q 2 Set the power switch (1) to ON. The operation panel will switch off and the version updating will be carried out.
4. USING CF CARDS 4-9. Writing error log data to CF cards 1 2 0211B Carry out steps 1 to 3 in “4-3. Preparation for reading/writing data”. Select [w 8] in CF data read/write mode. 0209B 3 The buzzer will sound and the error log data will be copied from the internal memory onto the CF card. Writing Writing complete 0210B 4 Press the TEST key to exit read/write mode. 0195B 5 Set the power switch (1) to OFF and remove the CF card.
5. MECHANICAL DESCRIPTIONS 5. MECHANICAL DESCRIPTIONS Each mechanism operates in the order of the numbers shown in the illustration. * and [number] indicate the flow of operations that occur separately from each other. * (number) indicates only the names of parts. (They are not part of the indication of operation flow.) 5-1. Needle bar and thread take-up mechanisms 1109B 1. Motor 2. Upper shaft <2> Pulley 3. Thread take-up crank 4. Needle bar connecting rod shaft 5.
5. MECHANICAL DESCRIPTIONS 5-2. Lower shaft and shuttle race mechanisms 0074B 1. プーリ 2. モータ 1. Motor 2. Upper shaft 3. Timing pulley U 4. Timing belt 5. Timing pulley D 6. Lower shaft 7. Bevel gear 8. Bevel gear 9. Rotary hook driving shaft 10. Timing pulley 39 11. Timing belt 12. Timing pulley 26 13. Rotary hook shaft 14.
5. MECHANICAL DESCRIPTIONS 5-3. Zigzag mechanism 1. Pulse motor 2. Motor lever 3. Zigzag connecting rod 4. Zigzag joint 5. Needle bar base 1110B 6.
5. MECHANICAL DESCRIPTIONS 5-4. Presser foot mechanism 1. Presser adjusting screw 2. Presser bar spring 3. Presser bar 4. Presser foot 1111B 1. Knee lifter 2. Knee lifter shaft 3. Knee lifter complying bar assembly 4. Knee lifter bar 5. Knee lifter lever 6. Knee lifter connecting rod 7. Presser bar lifter lever 8. Presser bar bracket 9. Presser bar 10.
5. MECHANICAL DESCRIPTIONS 1. Lifting lever 2. Presser bar lifter lever 3. Presser bar bracket 4. Presser bar 5. Presser foot 1113B 1. Presser foot lifter solenoid set 2. Knee lifter shaft L 3.
5. MECHANICAL DESCRIPTIONS 5-5. Feed mechanism [Forward/back movement] 1114B 1. Lower shaft 7. Feed rocker bracket arm 2. Level feed eccentric wheel 8. Feed bar 3. Feed driving connecting rod 9. Feed dog (forward/back movement) 4. Side connecting rod 5. Feed rocker arm 6. Feed rocker shaft (1) Feed regulator [Up/down movement] 1115B 1. Lower shaft 2. Lower shaft tip (eccentricity) 3. Feed lifting link 4. Feed bar 5.
5. MECHANICAL DESCRIPTIONS 1. Stitch length dial 5 2. Feed regulator 3. Connecting rod U 4. Feed adjusting lever U 5. Connecting rod D 6. Feed adjusting lever D 7. Feed regulator shaft 8. Feed connecting lever 9. Feed regulator connecting rod 10. Feed regulator lever 11. Feed regulator 12 Feed regulator spring 1116B Adjusting the stitch length dial changes the angle of the feed regulator.
5. MECHANICAL DESCRIPTIONS Adjusting the condense dial changes the angle of the feed regulator when the reverse stitching lever is pushed down. When the condense dial is aligned with the - side scale, the angle of the feed regulator increases and feed is reversed. 1117B 1. Reverse stitching lever 2. Lever guide 3. Reverse lever shaft 4. Feed adjusting lever U 5. Connecting rod D 6.
5. MECHANICAL DESCRIPTIONS 5-6. Lubrication mechanism ： Flow of oil 1176B 1. Oil feeding 2. Oil tank 3. Plunger pump <3> Oil gauge window 4. Rotary hook shaft bush 5. Rotary hook shaft [5] Adjusting screw 6.
5. MECHANICAL DESCRIPTIONS ： Flow of oil 1119B 0090B 1. Plunger pump 2. Rotary hook shaft bush 3. Rotary hook shaft 4. Felt 5. Screw <3> Adjusting screw (Adjusts the size of the outlet.) <4> Bed 6. Lubricating felt 7.
5. MECHANICAL DESCRIPTIONS 5-7. Thread trimmer mechanism (8560A only) 0091B 1. Thread trimmer solenoid 2. Solenoid joint 3. Solenoid lever 4. Driving rod 5. Thread trimmer driving rod plate 6. Main lever assembly 7. Roller 8. Thread trimmer cam 9. Knife driving rod 10. Thread trimmer driving lever 11.
5. MECHANICAL DESCRIPTIONS 5-8. Tension release mechanism 1120B 1. Lifting lever <1> Knee lifter connecting rod (Press the knee switch.) 2. Presser bar lifter lever 3. Tension release plate 4. Tension release stud 5. Tension release pin (Press the tension disc presser.) 6. Tension disc presser 7.
5. MECHANICAL DESCRIPTIONS 1. Solenoid 2. Link 3. Lever B 4. Lever A 5. Tension release connecting rod 6. Tension release plate 7. Tension release stud 8. Tension release pin 1121B 1. Solenoid 2. Link 3. Lever B (Tension release is delayed by the length of the slot) 4. Base 5.
5. MECHANICAL DESCRIPTIONS 5-9. Thread wiper mechanism (8560A only, optional device) 1. Thread wiper solenoid 2. Thread wiper rod 3. Thread wiper lever 4. Thread wiper crank shaft 5. Thread wiper 6.
6. DISASSEMBLY 6. DISASSEMBLY DANGER Wait at least 5 minutes after turning off the power switch and disconnecting the power cord from the wall outlet before opening the face plate of the control box. Touching areas where high voltages are present can result in severe injury. CAUTION Disassembly should only be carried out by a qualified technician. Turn off the power switch before carrying out disassembly.
6. DISASSEMBLY Disassemble the parts in the order shown in the illustration. * (number) indicates only the names of parts. (It does not indicate the disassembly order.) 6-1. Covers 1124B 1. Screw (Loosen) 10. Flat screws [7 pcs] 2. Needle 11. Face plate 3. Screws [2 pcs] 12. Face plate packing 4. Thread take-up guard assembly 13. Screws [6 pcs] 5. Flat screws [3 pcs] 14. Rear cover 6. Rotary thread take-up lever 15. Panel 7. Rotary take-up mounting plate 16. Screws [3 pcs] 8.
6. DISASSEMBLY 6-2. Presser foot mechanism 1. Screw 2. Presser foot 3. Adjusting screw nut (Loosen) 4. Presser adjusting screw 5. Spring guide 6. Spring 7. Spring guide collar 8. Screw (Loosen) 9. Presser bar bracket 10. Presser bar 1125B 6-3. Needle bar mechanism 1. Rubber cap 2. Screw 3. Thread guide 4. Screw (Loosen) 5. Needle bar 6. Needle bar clamp 7. Set screws [2 pcs] (Loosen) 8. Needle bar connecting rod shaft 9.
6. DISASSEMBLY 6-4. Zigzag mechanism Remove the solenoid before doing this. (1) Screws [3 pcs] (2) Shoulder screw 1127B 1. Shoulder screw 2.
6. DISASSEMBLY 0103B 3. Screw 10. Set screw (Loosen) 4. Screw 11. Needle bar base guide R 5. Bolt (Loosen) 12. Set screw (Loosen) 6. Zigzag joint (Pull out in the direction of the arrow.) 13. Needle bar base guide pin (Loosen) 14. Needle bar base 7. Wick (Remove from needle bar base.) (1) Needle bar base shaft 8. Bolts [3 pcs] (2) Oil tank 9.
6. DISASSEMBLY 6-5. Rotary hook mechanism 0105B 0104B 0106B 1. Slide plate (8550A) <1> Knife unit (8560A) 2. Flat screws [2 pcs] 3. Needle plate 4. Flat screws [2 pcs] 5. Auxiliary needle plate 6. Screws [2 pcs] 7. Feed dog 8. Scew 9. Bobbin case holder position bracket 10. Set screws [2 pcs] (Loosen) 11.
6. DISASSEMBLY 6-6. Lubrication mechanism 1. Screw (Drain the oil from inside the gearbox.) 2. Screws [9 pcs] 3. Bed bottom cover assembly 4. Bottom cover packing 0107B 6-7. Feed mechanism 0108B 1. Screw (Loosen) (1) Set screw collar 2. Set screws [2 pcs] (Loosen) (2) Feed rocker arm 3. Screws [2 pcs] (Loosen) 4. Feed rocker shaft (Pull out to the left.) 5.
6. DISASSEMBLY 6-8. Thread trimmer mechanism (8560A only) 1. Shoulder screw [2 pcs] 2. Knife driving rod 3. Washer 4. Screws [3 pcs] 5. Thread trimmer solenoid assembly 1128B 1. Screws [4 pcs] 2. Knife holder 3. Movable knife 4. Fixed knife 5.
6. DISASSEMBLY 6-9. Thread wiper mechanism (8560A only, optional device) 1130B 1. Screw 2. Presser foot 3. Screw 4. Solenoid cover 5. Retaining ring 1129B 6. Washer 7. Screws [2 pcs] 8. Screw 9. Bolt 10. Wiper bracket 11. Screws [2 pcs] 12. Thread wiper base 13. Screws [6 pcs] 14. 14-pin machine connector (1) Black (2) White A special tool is needed to pull out the pin.
7. ASSEMBLY 7. ASSEMBLY Assemble each part in the order shown in the illustration. * (number) indicates only the names of parts. (It does not indicate the assembly order.) IMPORTANT: Be sure to apply grease in the required locations when reassembling, and also once every two years. 7-1. Thread wiper mechanism (8560A only) 1. 2. 3. 4. 5.
7. ASSEMBLY 7-2. Feed mechanism 1. Feed lifting link 2. Feed bar set 3. Feed rocker shaft (Insert from the left all the way to the right.) (1) Spacer (2) Bush L (3) Feed rocker shaft (4) Retaining ring 0118B Push all the way to the left until it touches, then tighten the set screw. 0119B 0120B 4. Set screw collar 5. Set screws [2 pcs] 6. Screws [2 pcs] (Temporarily tighten) (5) Bush M (6) Feed bar set (7) Feed rocker shaft (8) Feed rocker arm Tighten after adjusting the feed dog. Refer to “9-7.
7. ASSEMBLY 7-3. Lubrication mechanism 0121B 1. 2. 3. 4. 5. Bottom cover packing Bed bottom cover assembly Screws [9 pcs] Screw (Add lubricating oil [approx. 120 ml].
7. ASSEMBLY 7-4. Zigzag mechanism 1. Needle bar base (With needle bar base guide pin inserted) 2. Needle bar base guide R 3. Set screw 4. Needle bar base guide pin 5. Set screw 6. Pulse motor assembly 7. Bolts [3 pcs] 8. Wick (Pull in oil tank.) 9. Wick (ring) (Pass the shaft through the ring.) 10. Zigzag joint (Pass the shaft through.) 11. Bolt (Temporarily tighten) 12. Screw 13. Screw Pass the harness of the pulse motor encoder detection unit through. After carrying out the assembly operations in “7-5.
7. ASSEMBLY 7-5. Needle bar mechanism 1. 2. 3. 4. Needle bar connecting rod Needle bar connecting rod shaft Screws [2 pcs] Needle bar clamp Push in. (1) Thread take-up crank (2) Felt 0124B 5. 6. 7. 8. 9. Needle bar Screw (Temporarily tighten) Thread guide Screw Rubber cap 1135B Face the needle check hole toward the front. Tighten the screws after carrying out the adjustment in “9-10. Needle bar height”.
7. ASSEMBLY 7-6. Rotary hook mechanism Tighten after carrying out the adjustments in “9-7. Feed dog forward/back and sideways position”. Install after carrying out the adjustments in “9-14. Needle and rotary hook timing”. Tighten after carrying out the adjustments in “9-14. Needle and rotary hook timing”. Tighten after carrying out the adjustments in “9-15. Bobbin case holder bracket position”. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
7. ASSEMBLY 7-7. Presser foot mechanism 1. Presser bar 2. Presser bar bracket 3. Screw (Temporarily tighten) 4. Spring guide collar 5. Presser bar spring 6. Spring guide 7. Presser adjusting screw 8. Adjusting screw nut 0130B Loosen once, and then tighten after adjusting 12 and 13. 1137B 9. 10. 11. 12. 13. 14. 15. 16.
7. ASSEMBLY 7-8. Covers Be careful of the knives. 1. 2. 3. 4. 5. 6. 7. 8. 9. Window plate (8550A) Pulse motor cover Screws [3 pcs] Panel Rear cover Screws [6 pcs] Face plate packing Face plate Flat screws [7 pcs] 10. Thread guide 11. Flat screw 12. Rotary take-up mounting plate 13. Rotary thread take-up lever 14. Flat screws [3 pcs] 15. Thread take-up guard assembly 16.
7. ASSEMBLY 7-9. Thread wiper mechanism (8560A only, optional device) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. After assembling, carry out the adjustments in “9-24. Adjusting the thread wiper”. Thread wiper base Screws [2 pcs] Solenoid setting plate Screws [2 pcs] Wiper bracket Bolt Washer Retaining ring Presser foot Screw Solenoid cover Screw Screw (Secure the harness.) Align the bottom of the presser bar bushing with the bottom of the wiper bracket.
8. CHANGING THE FEED AMOUNT TO LONG STITCH SPECIFICATIONS (from 2.0mm to 5.0mm) 8. CHANGING THE FEED AMOUNT TO LONG STITCH SPECIFICATIONS (from 2.0mm to 5.0mm) CAUTION Replacement of parts should only be carried out by a qualified technician. Turn off the power switch and disconnect the power cord before carrying out this operation. The machine may operate if the treadle is depressed by mistake, which could result in injury.
8. CHANGING THE FEED AMOUNT TO LONG STITCH SPECIFICATIONS (from 2.0mm to 5.0mm) 5. Turn the stitch length dial (7) and the condense dial (8) to the maximum feed amount for the feed dog being used. (Set the condense dial (8) to a negative number.) 3501M 3501M 6. Check that the feed dog does not touch the needle plate both when the reverse stitching lever (9) is not lowered and when it is lowered. If it touches, adjust the forward/back installation position (centering) of the feed dog. 3502M 7.
8. CHANGING THE FEED AMOUNT TO LONG STITCH SPECIFICATIONS (from 2.0mm to 5.0mm) 9. For sewing machine models and specifications other than 8550A-031, push the reverse stitching lever (9) down all the way (so that the plunger (11) of the quick reverse solenoid has moved to its highest position), and then tighten the two screws (1) at the position where the quick reverse solenoid (2) is touching to top of section (A) of the plunger (11). 3505M Turning the stitch length dial (1) to a setting greater than 2.
9. ADJUSTMENTS 9. ADJUSTMENTS CAUTION Use both hands to hold the machine head when tilting it back or returning it to its original position. If only one hand is used, the weight of the machine head may cause your hand to slip, and your hand may get caught. Maintenance and inspection of the sewing machine should only be carried out by a qualified technician. Ask your Brother dealer or a qualified electrician to carry out any maintenance and inspection of the electrical system.
9. ADJUSTMENTS 9-2. Adjusting the safety switch position The safety switch (1) is normally installed as shown in figure [A]. However, if the processing method used for the table leaves too much space between the machine bed and the table hole, it may adversely affect the operation of the safety switch (1). 3801M The standard amount of clearance between the machine bed and the table hole is 1.5 mm. If the clearance is 3.
9. ADJUSTMENTS 9-3. Thread tension spring 3802M The standard position of the thread tension spring (1) is 5-8 mm above the surface of the thread guide (3) when the presser foot (2) is lowered. 1. Lower the presser foot (2). 2. Loosen the set screw (4). 3. Turn the thread tension bracket (5) to adjust the spring position. 4. Securely tighten the set screw (4). 3512M The standard tension of the thread tension spring (1) is 0.25 to 0.30 N. 1.
9. ADJUSTMENTS 9-4. Presser foot height The standard height of the presser foot (1) is 6 mm when the presser foot (1) is raised by means of the lifting lever (2). 1. Loosen the two screws (3) and then remove the thread take-up guard (4). 2. Loosen the nut (5) of the presser adjusting screw (6), and then turn the presser adjusting screw (6) so that there is no pressure applied to the presser foot. 3. Raise the presser foot (1) by using the lifting lever (2). 4.
9. ADJUSTMENTS 9-6. Feed dog angle 3517M The standard angle for the feed dog (1) is for the top of the needle plate to be parallel with the top of the feed dog (1) (for the 8550A) or raised slightly at the side closest to the operator (for the 8560A) when the feed dog (1) is raised to its highest position above the needle plate. (With the mark on the feed bracket shaft (2) aligned with the mark on the feed rocker bracket arm (3)). 1.
9. ADJUSTMENTS 9-8. Feed amounts for reverse stitching and condense stitching The feed amounts for reverse stitching and condense stitching are set using the condense dial (1). If the stitch length for the finished stitches differs greatly from the scale, carry out the following adjustment. (The scale is intended as a guide.) 1. Set the condense dial (1) to “0”. 2. With the reverse stitching lever (2) pushed down, turn the machine pulley about 10 times and check that the material feed amount is zero.
9. ADJUSTMENTS 9-10. Needle bar height 3805M With the accessory needle bar height gauge (2) installed to the needle bar (1), adjust so that the needle bar height gauge (2) is touching the top of the needle plate (3) when the needle bar (1) is at its lowest position. 1. Remove the needle (4) and the presser foot (5). For the 8560A (Refer to Fig. A) 1) Remove the needle plate (3) and then the auxiliary needle plate (6). 2) Remove the needle plate spacer (7).
9. ADJUSTMENTS 9-11. Needle zigzag forward/back position 1147B Adjust so that the following are obtained. • The needle is in the center of the needle hole in the forward/back direction. • There is no play in the needle bar in the forward/back direction. • When the power switch is turned off, the needle bar can be moved smoothly sideways by hand. * Carry out adjustment with the sewing machine set to the following conditions. • With the needle bar base assembly (1) and the zigzag joint (2) not secured.
9. ADJUSTMENTS 9-12. Needle zigzag sideways position Adjust the position of the needle so that it is in about the center of the slot in the needle hole when the power is turned on and the zigzag width and zigzag base line position have both been set to 0 mm at the operation panel. * When the straight stitch key on the operation panel is pressed, the zigzag width will be set to 0.0 mm. 0149B 1. Turn off the power switch. 2.
9. ADJUSTMENTS 9-13. Needle zigzag load This adjusts the resistance load for needle zigzagging. 1. Turn off the power switch. 2. Loosen the nut (1). 3. Tighten the screw (2) to increase the needle zigzag load. * Adjust so that the load is 12-15 N.m when the needle bar (3) moves sideways. 4. Securely tighten the nut (1). * Be careful not to turn the screw (2) at this time. * After adjusting, check the needle zigzag load again. 1150B 9-14. Needle and rotary hook timing 1. Turn on the power switch. 2.
9. ADJUSTMENTS 1151B 4. Remove the presser foot (3), needle plate (4), auxiliary needle plate (5), feed dog (6) and needle plate spacer (7) (8560A only). 5. Turn the machine pulley to raise the needle bar (8) from its lowest position until the reference line on the thread take-up lever (9) is aligned with the Ø mark on the face plate, and then check the following. • The tip of the rotary hook (10) should be aligned with the center of the needle.
9. ADJUSTMENTS 9-16. Adjusting the rotary hook lubrication amount CAUTION Be careful not to touch your fingers or the lubrication amount check sheet against moving parts such as the rotary hook or the feed mechanism when checking the amount of oil supplied to the rotary hook.If they are touched, injury may result. Use the following procedure to check the amount of oil being supplied to the rotary hook after replacing the rotary hook or when changing the sewing speed. 3529M Approx. 25 mm Approx.
9. ADJUSTMENTS 9-17. Adjusting the presser foot floating amount (minute lifting amount) 3807M Floating amount When sewing stretch materials and materials with long pile, you can make minute adjustments to the floating amount for the presser foot (1) in accordance with the material. 1. Turn the sewing machine pulley by hand to move the feed dog (2) below the needle plate (3). 2. Use the lifting lever to lower the presser foot (1). 3. Loosen the nut (4). 4.
9. ADJUSTMENTS 9-19. Adjusting the quick reverse device (8550A-A31, 8560A) 0154B 0153B Adjust so that the plunger rubber (3) touches the bottom of the quick reverse solenoid (2) when the reverse stitching lever (1) is lowered to its lowest position while the feed amount is at the maximum setting. 1. 2. 3. 4. Turn the condense dial (5) counterclockwise to its maximum setting. Loosen the two screws (4). Move the quick reverse solenoid (2) up or down to adjust. Securely tighten the two screws (4).
9. ADJUSTMENTS 9-20. Adjusting the tension release during thread trimming (8560A only) A Be careful of the knives. 0155B 1165B : 6-7mm : 0.2-1.0mm 0158B The tension release mechanism operates during thread trimming. When the lifting lever (1) is lowered and the distance for the plunger (3) of the solenoid (2) becomes 6 to 7 mm, the tension discs begin to loosen. Carry out adjustment by the following procedure. 1. Remove all of the parts shown in Figure A.
9. ADJUSTMENTS 9-21. Adjusting the position of the thread trimming cam (8560A only) 3809M The knife unit (1) should already be installed in the correct way when the following adjustments are carried out. 1. Tilt back the machine head. 2. Loosen the two screws (2). 3. Move the stopper (4) to adjust so that the edge of the movable knife (3) is aligned with the edge of the knife unit (1). 4. Securely tighten the two screws (2). 5.
9. ADJUSTMENTS 9-22. Adjusting the tension of the plate spring (8560A only) 3539M 3540M Adjust the tension of the plate spring (1) so that the tension is 0.03 to 0.11 N when the plate spring (1) is pulling the lower thread (nylon thread: 100D 1 X 3 (Z)) after thread trimming. 1. Remove the knife unit (2). (Refer to “11-1. Fixed knife and movable knife (8560A only)” of the Instruction Manual.) 2. Move the knob (3) to slide out the movable knife (4), and then hook the thread as shown in the illustration.
9. ADJUSTMENTS 3811M Stronger The standard trailing length for the upper thread is 50-60 mm. If adjustment is necessary, adjust the position of the wire e as described below. Weaker 1. Loosen the set screw (1). 2. Turn the base (2) to adjust the vertical position of the end of the wire (3). • To increase the upper thread trailing amount, raise the position of the wire (3) without letting it touch the upper thread (4).
10. APPLYING GREASE (When “GrEASEUP” appears) 10. APPLYING GREASE (When “GrEASEUP” appears) If “GrEASEUP” flashes on the main display (1) and a buzzer sounds when the power switch is turned on, it means that grease needs to be applied. (The sewing machine will not operate at this time, even if the treadle is depressed.) Apply grease while referring to the following page. 3481M 10-1. To continue sewing temporarily without applying grease 1. Press the RESET key (2). 2.
10. APPLYING GREASE (When “GrEASEUP” appears) 10-2. Applying grease Use Brother-specified . 1. Using the tube 2216M 2. Applying grease 1. Turn the power switch to “OFF”. 2. Apply grease in the places indicated by arrows [A] to [G] below. 1159B Grease 3484M 1. Remove the screws. 2. Apply grease to each of the holes until the grease overflows slightly. 3. Tighten the screws in order to push the grease in. 4.
10. APPLYING GREASE (When “GrEASEUP” appears) Use the tip of a long brush or similar to apply approx 1g of grease to the places indicated by arrows [E] to [G]. 2. Apply approx 1g of grease. 1. Pull the needle bar (3) forward with your finger. 3. Turn the machine pulley to gently apply the grease onto the felt. Felt 4. Move the needle bar (3) back and forth with your finger to spread the grease.
11. ELECTRICAL MECHANISM 11. ELECTRICAL MECHANISM DANGER Wait at least 5 minutes after turning off the power switch and disconnecting the power cord from the wall outlet before opening the cover of the control box. Touching areas where high voltages are present can result in severe injury. 11-1. Precautions while carrying out adjustments Be sure to note the following cautions when opening the control box to carry out inspections and adjustments.
11. ELECTRICAL MECHANISM 11-2. Control box internal configuration Main P.C. board Secured to the side. This is the P.C. board that controls sewing machine operation. There is 1 fuse on this P.C. board. PMD P.C. board Secured to the base plate. This is the P.C. board that drives the needle zigzag pulse motor. Power supply P.C. board Secured to the rear. This P.C. board generates the voltages that are required for control, and drives the main shaft motor. There are 3 fuses on this P.C. board.
11. ELECTRICAL MECHANISM 11-3. Description of fuses 11-3-1. Power supply P.C. board (fuses and fuse resistors) When replacing the fuses and fuse resistors, be sure to use the parts specified below. If the components on the P.C. boards are damaged, the fuses may blow again soon even after they have been replaced. No.
11. ELECTRICAL MECHANISM 11-3-2. Main P.C. board (fuses and fuse resistors) No. F R25 Part name Fuse 8A (Glass tube fuse 8A-250V) Fuse resistor 1/2W 0.22Ω Parts code J04502-001 J02754-001 Symptom when fuse blows [Err 790] is displayed when the sewing machine starts. Power does not turn on and green LED (1) does not illuminate.
11. ELECTRICAL MECHANISM 11-4. Description of connectors A large number of problems are often caused by connectors that are not inserted correctly or which are contacting poorly. As a result, check that all connectors are inserted correctly and that the pins and wires are crimped properly before carrying out problem diagnosis. 11-4-1. Connector positions Main P.C. board 0163B PMD P.C.
11. ELECTRICAL MECHANISM Power supply P.C.
11. ELECTRICAL MECHANISM 11-5. Troubleshooting 11-5-1. Troubleshooting procedure Carry out troubleshooting by following the procedure given below. 1 Checking connectors With the power turned off, check that all connectors are securely inserted while referring to “11-4. Description of connectors”. 2 Diagnosis flowchart Carry out diagnosis while following the steps in “11-5-2. Diagnosis flowchart” on the next page, and if a problem No. is reached, continue to the next procedure.
11. ELECTRICAL MECHANISM 11-5-2. Diagnosis flowchart Description of symbols Switch operation Judgment Problem No. xx Setting and status OFF Power switch OFF Refer to the corresponding “Problem No.” in “11-5-3. Remedy”.
11.
11. ELECTRICAL MECHANISM 11-5-3. Remedy If a problem No. is reached while carrying out the diagnosis steps in “11-5-2. Diagnosis flowchart”, refer to the table for the corresponding number.After identifying the cause in the “Cause” column, carry out the steps in the “Inspection/Remedy/Adjustment” column, and if a malfunction is found, replace the parts specified in “Replacement if a malfunction”. Problem No. 1 The power indicator (red) on the power supply P.C.
11. ELECTRICAL MECHANISM Cause Inspection/Remedy/Adjustment Replacement if a malfunction 5. When [Err 91] is displayed: Problem with treadle unit settings Repeat the standard settings for the treadle unit. (Refer to “12-3. Standard settings for treadle depression stroke”.) - 6. When [Err 450] is displayed: Problem with machine head memory data; Model selection cannot be loaded (Replace the part(s) indicated at right.) Machine head memory unit 7.
11. ELECTRICAL MECHANISM Problem No. 4, 5, 6, 7 Needle bar does not move to the home position and an error code is displayed when the power switch is turned on. Cause Inspection/Remedy/Adjustment Replacement if a malfunction 1. When [Err 200] is displayed: • Needle zigzag motor cannot move to home position • Encoder cord of needle zigzag motor is not connected. Check that connector P3 (ENC) is inserted into the main P.C. board. Encoder P.C. board in needle zigzag motor 2.
11. ELECTRICAL MECHANISM Problem No. 11 Error code is displayed while sewing machine is operating. Cause Inspection/Remedy/Adjustment When [Err 710] is displayed while sewing machine is operating: Abnormal current detected in sewing machine motor Problem No. 12 (Replace the part(s) indicated at right.) Replacement if a malfunction Power supply P.C. board Sewing machine does not stop correctly (needle down stop or needle up stop).
11. ELECTRICAL MECHANISM 11-6.
11.
12. TREADLE UNIT 12. TREADLE UNIT 12-1. Types • Two types of treadle unit are available: a type which controls the automatic presser foot lifter and a type which does not control it. • It is possible to switch between the two specifications by Changing the hooking position of the spring (1) inside the treadle unit; setting DIP switch No. 2; and setting the treadle depression stroke.
12. TREADLE UNIT 12-2. Standard setting values SPECIFICATIONS Operation Function No.
12. TREADLE UNIT 12-3. Standard settings for treadle depression stroke DANGER Wait at least 5 minutes after turning off the power switch and disconnecting the power cord from the wall outlet before opening the cover of the control box. Touching areas where high voltages are present can result in severe injury. Carry out the following reset procedure if the specifications for the treadle unit have been changed or if the treadle unit or main P.C. board has been replaced.
12. TREADLE UNIT 3) Storing the neutral position Press the straight stitch key (2) while your foot is released from the treadle. “Pdrr x.xxx” will appear in the main display (3). 3575M 4) Storing the maximum backward depression amount Press the straight stitch key (2) while the treadle is at the point of maximum backward depression. “Pd-- x.xxx” will appear in the main display (3). 3576M 5) Ending the settings 1. Press the ENTER key (4). The buzzer will sound and the main display (3) will switch off.
13. STANDING OPERATION PEDAL 13. STANDING OPERATION PEDAL The CDD foot plug assembly (J04099-001, sold separately) is required. Part name Code No. Variable-speed standing operation pedal 40 #6 (2 pedals + kick pedal) J80081-040 Variable-speed standing operation pedal 3 #40 (3 pedals) J80380-040 Standing operation pedal 3 with 2-step speed (3 pedals) J80630-001 CDD foot plug assembly J04099-101 0772M 0773M 1144M 13-1.
13. STANDING OPERATION PEDAL 13-2. Connectors No. 1 2 3 4 5 6 7 8 9 Standing operation pedal 9P connector DC+8V High-speed switch Thread trimming switch SOV Spare Low-speed switch Presser foot switch Variable speed input Ground 0220B NOTE: Connector types Name of manufacturer MOLEX Connector No.
14. TROUBLESHOOTING 14. TROUBLESHOOTING • Please check the following points before calling for repairs or service. • If the following remedies do not fix the problem, turn off the power switch and consult a qualified technician or the place of purchase. DANGER Wait at least 5 minutes after turning off the power switch and disconnecting the power cord from the wall outlet before opening the face plate of the control box. Touching areas where high voltages are present can result in severe injury.
14. TROUBLESHOOTING 3 Problem Skipped stitches occur while sewing. 0621M 4 Flattened zigzags appear in the stitch during intermittent sewing. (8550A) 1406M 5 Skipped stitches at sewing start Thread unravelling at sewing start 0622M Upper thread Possible cause • Is the needle tip bent? Is the needle tip blunt? If the needle tip is bent or broken, replace the needle. • Is the needle properly installed? If it is incorrect, install the needle correctly.
14. TROUBLESHOOTING 6 Problem Uneven seam 0625M 7 Horizontal thread tightening not balanced Upper thread Lower thread Possible cause • Is the presser foot pressure too weak? Adjust the presser foot pressure. • Is the feed dog too low? Adjust the feed dog height. • Is the bobbin scratched? If the bobbin is damaged, smooth it with an oiled grindstone or replace it. • Is the upper thread tension or lower thread tension too strong or too weak? Adjust the upper thread tension or lower thread tension.
14. TROUBLESHOOTING 9 Problem Lower thread is tangled at the sewing start. Spinning of bobbin during thread trimming Lower thread 0628M 10 Upper and lower threads are breaking. Possible cause • Is the bobbin spinning direction correct when the lower thread is being pulled? Set the bobbin so that it turns in the opposite direction to the rotary hook. • Is there too much thread wound onto the bobbin? The bobbin winding amount should not be more than 80 %.
14. TROUBLESHOOTING 12 13 14 15 Problem Incorrect thread trimming (8560A) (Upper and lower threads are both not being trimmed) Incorrect thread trimming (8560A) (Upper thread or lower thread is not being trimmed) The thread wiper does not wipe the thread. (8560A) Oil gauge (1) is not visible in oil gauge window. Possible cause • Is the fixed knife or movable knife damaged or worn? Replace the fixed knife or the movable knife.
15. ERROR CODES 15. ERROR CODES DANGER Wait at least 5 minutes after turning off the power switch and disconnecting the power cord from the wall outlet before opening the cover of the control box. Touching areas where high voltages are present can result in severe injury. If a malfunction should occur with the sewing machine, a buzzer will sound and an error code will appear in the display window. Follow the remedy procedure to eliminate the cause of the problem.
15. ERROR CODES Code Err 401 Err 403 Err 411 Err 413 Err 420 Err 421 Err 422 Err 424 Err 425 Err 427 Err 430 Err 440 Err 441 Err 442 Err 450 Err 452 Err 474 Cause and remedy Communication error with motor CPU was detected when the power was turned on. Turn off the power switch and then turn the power back on again. Connection error with needle zigzag PMD P.C. board detected when power was turned on.
15. ERROR CODES Code Err 700 Err 701 Err 705 Err 710 Err 711 Err 740 Err 790 Err 791 Cause and remedy Abnormal rise in power supply voltage. Turn off the power switch and check the power supply voltage. Abnormal rise in sewing machine motor power supply voltage. Turn off the power, and then check the voltage. Problem with power supply P.C. board. Abnormal drop in power supply voltage. Turn off the power switch and check the power supply voltage.
16. SEGMENT DISPLAY DEFINITION TABLE 16.
MEMO Z-8550A, 8560A 118
SERVICE MANUAL Printed in Japan Z-8550A, 8560A I5120896B 2006. 12.
