Sewing Machine User Manual

ManualsBrandsBrother ManualsSewing MachineS-7200C

S-7200C

Please read this manual before making any adjustments.

SINGLE NEEDLE DIRECT DRIVE STRAIGHT LOCK STITCHER

WITH THREAD TRIMMER

SERVICE MANUAL

Summary of content (172 pages)

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S-7200C SERVICE MANUAL Please read this manual before making any adjustments.
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This service manual is intended for S-7200C; be sure to read the S-7200C 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.
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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. Indications DANGER The instructions which follow this term indicate situations where failure to follow the instructions will result in death or serious injury.
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[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 cover 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 electrical line noise or static electric noise.
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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. Do not touch any of the moving parts or press any objects against the machine while sewing, as this may result in personal injury or damage to the machine.
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[3] Warning labels The following warning labels appear on the sewing machine. Please follow the instructions on the labels at all times when using the machine. If the labels have been removed or are difficult to read, please contact your nearest Brother dealer. 1 2 Touching areas where high voltages are present can result in severe injury. Turn off the power before opening the cover.
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S-7200C
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CONTENTS 7-6-1. Thread trimming mechanism operation sequence .................................................... 63 1. MACHINE SPECIFICATIONS.............. 1 2. NOTES ON HANDLING........................ 2 7-6-2. Upper and lower thread trimming sequence ... 65 3 7-7. Tension release mechanism................................ 66 7-8. Thread wiper mechanism (option device) ............ 67 3. COMPARISON OF FUNCTIONS (G50 AND G10 OPERATION PANELS)... 4. FUNCTION SETTINGS (G50 OPERATION PANEL) ...........
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-10. Knee lifter lever mechanism .............................. 98 9-11. Needle bar and thread take-up mechanism ....... 99 9-12. Presser foot mechanism .................................. 100 9-13. Feed rock shaft ................................................ 101 9-14. Feed mechanism (1)........................................ 101 9-15. Feed mechanism (2)........................................ 102 9-16. Feed bar mechanism ....................................... 102 9-17.
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1. MACHINE SPECIFICATIONS １. MACHINE SPECIFICATIONS 3 O - Quick reverse Thread wiper Lubrication type Use Max. sewing speed Start backtacking and continuous backtacking speed End backtacking speed Max.
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2. NOTES ON HANDLING ２. NOTES ON HANDLING About the machine set-up location ・ Do not set up this sewing machine near other equipment such as televisions, radios or cordless telephones, otherwise such equipment may be affected by electronic interference from the sewing machine. ・ The sewing machine should be plugged directly into an AC wall outlet. Operation problems may result if extension cords are used.
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3. COMPARISON OF FUNCTIONS (G50 AND G10 OPERATION PANELS) ３.
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4. FUNCTION SETTINGS (G50 OPERATION PANEL) ４. FUNCTION SETTINGS (G50 OPERATION PANEL) ４-１. List of advanced functions This section contains a list of advanced functions and the key operations which are used to call the setting mode for the functions. 1988B 1 Maximum sewing speed and start backtack sewing speed setting Release the lock 2 ＋ Refer to “4-3. Maximum sewing speed and start backtack sewing speed setting methods”.
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4. FUNCTION SETTINGS (G50 OPERATION PANEL) ４-２. List of special functions when power is turned on This section contains a list of functions for the G50 operation panel and the key operations which are used to call the setting mode for the functions. 1992B 1991B 1 Memory switch setting mode (Advanced) 2 Refer to “4-6. Memory switch setting method (Advanced)”. Data initialization function 3 Refer to “4-7. Data initialization function”.
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4. FUNCTION SETTINGS (G50 OPERATION PANEL) ４-３. Maximum sewing speed and start backtack sewing speed setting methods If the LOCK key icon (1) is on, release the lock before carrying out the following operations. 2001B 1 Maximum sewing speed Start backtack sewing speed The main display (2) will change from an orange display to a green display.
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4. FUNCTION SETTINGS (G50 OPERATION PANEL) ４-４. Using the LOCK key Control box 2006B 4221M When the power switch is turned on, the LOCK key (1) turns on. (The icon (2) is illuminated.) This causes all key operations which have been set using the protect settings feature to become disabled, and you can use this feature to prevent setting values from being changed by accident. * For details on the protect settings feature, refer to “4-11. Protecting settings”.
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4. FUNCTION SETTINGS (G50 OPERATION PANEL) ４-５. Memory switch setting method (Standard) 2007B 1 NOTE: ・ This cannot be set if DIP switch 1 has been set to ON, so set it to OFF. ・ If the LOCK key icon (1) is on, release the lock before carrying out the following operations. ・ If the MAX key icon (2) is on, press the MAX key to return the main display to stitch number display (orange).
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4. FUNCTION SETTINGS (G50 OPERATION PANEL) Presser foot lifter operation and pedal operation settings (001-) No.
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4. FUNCTION SETTINGS (G50 OPERATION PANEL) Sewing machine motor settings (100-) No.
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4. FUNCTION SETTINGS (G50 OPERATION PANEL) Sewing program settings (400-) No. Setting range Initial value Setting units 400 2-6 2 1 401 2-6 2 1 402 1-2 1 1 403 ON/OFF OFF - 404 ON/OFF OFF - 405 1-2 1 1 11 Setting details Start backtack sewing pattern * If A=0, there is no A operation, and if B=0, there is no B operation. 2: A-B 3: B-A-B 4: A-B-A-B 5: B-A-B-A-B 6: A-B-A-B-A-B End backtack sewing pattern * If C=0, there is no C operation, and if D=0, there is no D operation.
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4. FUNCTION SETTINGS (G50 OPERATION PANEL) Standard device settings (500-) No.
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4. FUNCTION SETTINGS (G50 OPERATION PANEL) ４-６. Memory switch setting method (Advanced) 1 Change to memory switch mode (While holding down the MAX key and the FUNC (function) key, press the power ON switch.) The memory switch number (A) and the setting details (B) for that number will be displayed in green in the main display (1).
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4. FUNCTION SETTINGS (G50 OPERATION PANEL) Presser foot lifter and presser foot lifter pedal settings (050-) No. Setting range Initial value Setting units 050 ON/OFF ON - 051 ON/OFF (*1) - 055 ON/OFF OFF - 057 ON/OFF (*1) - Setting details Forward treadle operation interlock during thread trimming ON: Depressing treadle forward during thread trimming is disabled (After the treadle is returned to the neutral position, depressing it forward is enabled.
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4. FUNCTION SETTINGS (G50 OPERATION PANEL) 080 081 082 083 084 085 Setting range -7-7 -5-5 -5-5 -5-5 -5-7 -7-7 Initial value 0 0 0 0 0 0 Setting units 1 1 1 1 1 1 086 -2-2 0 1 087 -2-2 0 1 088 0-3 (*2) 1 No.
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4. FUNCTION SETTINGS (G50 OPERATION PANEL) Sewing machine motor settings (150-) No.
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4. FUNCTION SETTINGS (G50 OPERATION PANEL) No.
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4. FUNCTION SETTINGS (G50 OPERATION PANEL) Panel operation settings (350-) No. Setting range Initial value Setting units 350 ON/OFF ON - 351 0-10 (seconds) 0 (seconds) 1 352 ON/OFF ON - 353 ON/OFF ON - 354 0-2 1 1 Setting details Buzzer (electronic sound) during panel operation ON: Used OFF: Not used * The buzzer will always be ON when a warning or error is displayed.
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4. FUNCTION SETTINGS (G50 OPERATION PANEL) Sewing program settings (450-) No.
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4. FUNCTION SETTINGS (G50 OPERATION PANEL) Standard device settings (550-) Setting range Initial value 0-1 0 (*1) 0-500 (ms) -345-345 (degrees) -345-345 (degrees) -345-345 (degrees) -345-345 (degrees) 150 (ms) 0 (degrees) 0 (degrees) 0 (degrees) 0 (degrees) 10 (ms) 560 10-200 (ms) 20 (ms) 10 (ms) Motor 561 10-200 (ms) 50 (ms) 10 (ms) Thread wiping 562 10-200 (ms) 50 (ms) 10 (ms) No.
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4. FUNCTION SETTINGS (G50 OPERATION PANEL) Error processing settings (650-) No. 650 651 652 Setting range OFF/ 5-30 (seconds) Initial value Setting units OFF 1 OFF/ 3 1-30 (minutes) （minutes） ON/OFF ON 1 - Setting details Time until buzzer stops (seconds) OFF: Buzzer does not stop 5-30: Buzzer stops after the specified time Overtime error display * If the thread wiper key is OFF, error displays do not appear.
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4. FUNCTION SETTINGS (G50 OPERATION PANEL) ４-７. Data initialization function NOTE: When DIP switch 1 is set to ON, set it to OFF and then carry out the following operations. 1 Change to initialization mode “init ALL” will appear in orange in the main display (1). (While pressing the RESET key, press the power ON switch.) 2 4195M Select the item to be initialized Item No.
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4. FUNCTION SETTINGS (G50 OPERATION PANEL) ４-８. Error history checking method The past error history can be checked by the following procedure. 1 Change to error history display mode The history number (A) and the error code (B) will appear in the main display (1) in orange. (While pressing the MAX key, press the power ON switch.) NOTE: The following error codes do not remain in the history, and so they will not be displayed.
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4. FUNCTION SETTINGS (G50 OPERATION PANEL) ４-９. Input checking method This is used at the following times. ・ When there is a problem with an operation panel key, PCB or sensor ・ When you would like to check for broken cords ・ When you would like to adjust a sensor position This lets you check if the CPU is reading signals from the keys and the sensors correctly.
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4. FUNCTION SETTINGS (G50 OPERATION PANEL) The four characters on the left side of the main display on the operation panel show the item number/item name, and the four characters on the right side show the input status. Item No. Item name Input status [ 1] [ PDL] [0.000]-[5.
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4. FUNCTION SETTINGS (G50 OPERATION PANEL) Item No. Item name Input status [ 17] [ IN1] [ ON]-[ OFF] [ 18] [ IN2] [ ON]-[ OFF] [ 19] [ IN3] [ ON]-[ OFF] [ 20] [DIP1] [ ON]-[ OFF] [ 21] [DIP2] [ ON]-[ OFF] [ 22] [DIP4] [ ON]-[ OFF] [ 23] [EDGK] [ ON]-[ OFF] Check item and checking method Option input 1 “ON” when the input signal is LOW, and “OFF” when it is HIGH. Option input 2 “ON” when the input signal is LOW, and “OFF” when it is HIGH.
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4. FUNCTION SETTINGS (G50 OPERATION PANEL) 1 Select the test number Test number Test number [ ALL] [TES1] [TES2] [TES3] [TES4] [TES5] [TES6] [TES7] Test name All tests (Test 1-Test 7) Test 1 (Individual) Test 2 (Individual) Test 3 (Individual) Test 4 (Individual) Test 5 (Individual) Test 6 (Individual) Test 7 (Individual) 2020B 2 Start the test A. For all tests ([ ALL]) Test result (OK / NG) Test number All tests from Test 1 to Test 7 are carried out.
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4.
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4. FUNCTION SETTINGS (G50 OPERATION PANEL) ４-１０. Output checking method This is used at the following times. ・ When there is a problem with the operation panel PCB ・ When there is a problem with the drive mechanism ・ When you would like to check for broken codes. You can check whether the signals being output by the CPU are driving the mechanisms correctly.
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4. FUNCTION SETTINGS (G50 OPERATION PANEL) The four characters on the left side of the main display on the operation panel show the item number/item name, and the four characters on the right side show the output status. Item No.
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4. FUNCTION SETTINGS (G50 OPERATION PANEL) Item No. 31 Item name Output status [ 14] [BUZZ] OFF [ 15] [ PNL] [****] [ 16] [MOVE] OFF [ 17] [OUT1] OFF [ 18] [OUT2] OFF Check item and checking method Buzzer When the treadle is depressed, the buzzer sounds for 1 second. Panel display When the treadle is depressed, checking of the operation panel indicators, main display, speed display and lower thread counter display starts.
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4. FUNCTION SETTINGS (G50 OPERATION PANEL) ４-１１. Protection settings 1 2 Set the power switch to OFF, and then set DIP switch 1 to OFF. Change to protect setting mode (Protection level) (While pressing the key and the start backtack key, press the power ON switch.) [PLV] and the protection level will appear in the main display (1) in orange. (At the time of shipment from the factory, the protection level is set to “1”.
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4. FUNCTION SETTINGS (G50 OPERATION PANEL) [If set to level 3] To make individual settings, select level 3. 4 Confirm the protection level Individual setting number Protection setting value (ON/OFF) * When the key is pressed, the display will return to the protection level setting display [PLV 3]. 2035B 4161M 5 Select an individual setting number (1 – 6) 2036B NOTE: The range for disabling operation varies depending on the setting for DIP switch 1.
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4. FUNCTION SETTINGS (G50 OPERATION PANEL) ○: Enabled □: Immediately after the power is turned on, the LOCK key icon will show the previous status. After this, the LOCK key can be used to change the enabled/disabled status. △: Immediately after the power is turned on, the function is disabled (the LOCK icon illuminates). After this, the LOCK key can be used to change the enabled/disabled status.
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4. FUNCTION SETTINGS (G50 OPERATION PANEL) ４-１２. Software version checking method 1 Change to version display mode The software type (A) and the software version (B) will be displayed in the main display (1) in orange. (While pressing the speed key (+), press the power ON switch.) 2 2037B Select the software type (A) Software type (A) Software Version (B) [1. MN] Main CPU [1.0|00] [2. PL] Panel CPU [1.000] [3.IPL] Main IPL [1.000] * Initially the main CPU version will be displayed.
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4. FUNCTION SETTINGS (G50 OPERATION PANEL) ４-１３. Viewing maintenance information This allows you to check the information which is stored in the head detector unit. 1 Change to maintenance display mode The item name (A) and the details for that item (B) will be displayed in the main display (1) in orange. (While pressing the keys, press the power ON switch.) 2039B 2138M 2139M 2 Select the item name No.
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4. FUNCTION SETTINGS (G50 OPERATION PANEL) ４-１４. Adjusting the sewing machine reference position 1 Change to sewing machine reference position adjustment mode (While pressing the 2 2041B 2138M The adjustment item name (A) and the adjustment value for that item (B) will be displayed in the main display (1) in orange. key, press the power ON switch.
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5. FUNCTION SETTINGS (G10 OPERATION PANEL) ５. FUNCTION SETTINGS (G10 OPERATION PANEL) ５-１. List of special functions when power is turned on This section contains a list of functions for the G10 operation panel and the key operations which are used to call the setting mode for the functions. 1991B 1 2045B Memory switch setting mode (Standard) 7 (This setting is not possible with the G10 operation panel.
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5. FUNCTION SETTINGS (G10 OPERATION PANEL) ５-２. Function setting method 1 Change to function setting mode (Setting item) (While pressing the end backtack key, press the power ON switch.) 2 4203M Select the setting item (Refer to (P.40)) (Setting item) 2050B 3 Change to the setting value display (Setting value) 2051B 4 Change the setting value. * If the setting value is different from the original details, the setting value will flash.
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5.
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5. FUNCTION SETTINGS (G10 OPERATION PANEL) ５-３. Data initialization function NOTE: When DIP switch 1 is set to ON, set it to OFF and then carry out the following operations. 1 Change to initialization mode [in.AL] will appear in the display (1). (While pressing the continuous backtack key, press the power ON switch.) Display 1 [in.AL] Initialization item Clear all (Sewing programs (panel display), memory switch settings, speed settings and function settings [Refer to (P.
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5. FUNCTION SETTINGS (G10 OPERATION PANEL) ５-４. Error history checking method The past error history can be checked by the following procedure. 1 Change to error history display mode (Error history number) (While pressing the MAX key, press the power ON switch.) 2 2054B Change the error history number Up to 99 histories (01-99) are stored in order starting from the newest. (No. 01 represents the newest error.
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5. FUNCTION SETTINGS (G10 OPERATION PANEL) ５-５. Input checking method This is used at the following times. ・ When there is a problem with an operation panel key, PCB or sensor ・ When you would like to check for broken cords ・ When you would like to adjust a sensor position This lets you check if the CPU is reading signals from the keys and the sensors correctly. 1 Change to input check mode (While pressing the (Item number) key, press the power ON switch.
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5. FUNCTION SETTINGS (G10 OPERATION PANEL) The display on the operation panel shows the item number/item name, or the input status. Item No. Item name Input status [ 1] [ PDL] [0.000]-[5.
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5. FUNCTION SETTINGS (G10 OPERATION PANEL) Item No. Item name Input status [ 17] [ IN1] [ ON]～[ OFF] [ 18] [ IN2] [ ON]～[ OFF] [ 19] [ IN3] [ ON]～[ OFF] [ 20] [DIP1] [ ON]～[ OFF] [ 21] [DIP2] [ ON]～[ OFF] [ 22] [DIP4] [ ON]～[ OFF] 45 Checking item and checking method Option input 1 “ON” when the input signal is LOW, and “OFF” when it is HIGH. Option input 2 “ON” when the input signal is LOW, and “OFF” when it is HIGH.
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5. FUNCTION SETTINGS (G10 OPERATION PANEL) 1 Change to test number display 2 Select the test number 3 Start the test 2065B 2066B When the thread wiper key is pressed, the test starts. A. For all tests [ ALL] All tests from Test 1 to Test 7 are carried out. ・ If all tests are completed and the results are all OK, [7 OK] will be displayed. ・ If an NG result occurs during the test, [* NG] will be displayed as the right four characters in the display.
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5.
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5. FUNCTION SETTINGS (G10 OPERATION PANEL) ５-６. Output checking method This is used at the following times. ・ When there is a problem with the operation panel PCB ・ When there is a problem with the drive mechanism ・ When you would like to check for broken cords You can check whether the signals being output by the CPU are driving the mechanisms correctly. 1 Change to output check mode (While pressing the 2 (Item number) key, press the power ON switch.
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5. FUNCTION SETTINGS (G10 OPERATION PANEL) The display on the operation panel shows the item number/item name, or the output status. Item No.
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5. FUNCTION SETTINGS (G10 OPERATION PANEL) Item No. Item name Output status [ 14] [BUZZ] OFF [ 15] [ PNL] [****] [ 16] [MOVE] OFF [ 17] [OUT1] OFF [ 18] [OUT2] OFF Checking item and checking method Buzzer When the treadle is depressed, the buzzer sounds for 1 second. Panel display When the treadle is depressed, checking of the operation panel indicators and display will start.
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5. FUNCTION SETTINGS (G10 OPERATION PANEL) ５-７. Protection settings 1 2 Set the power switch to OFF, and then set DIP switch 1 to OFF. Change to protect setting mode 2074B 2138M (Protection level) (While pressing the key and the start backtack key, press the power ON switch.) 3 [PLV] and the protection level will be displayed in the display. (* is the protection level. At the time of shipment from the factory, the protection level is set to “1”.
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5. FUNCTION SETTINGS (G10 OPERATION PANEL) [If set to level 3] To make individual settings, select level 3. 4 Confirm the protection level Individual setting Individual protection setting value ([-]:OFF、[□]:ON) number NOTE: * When the key is pressed, the display will return to the protection level setting display [PLV 3]. 2076B 4161M 5 Select an individual setting number (1-6) NOTE: The range for disabling operation varies depending on the setting for DIP switch 1.
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5.
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5. FUNCTION SETTINGS (G10 OPERATION PANEL) ５-８. Software version checking method 1 Change to version display mode (Version display) (While pressing the start backtack key, press the power ON switch.) 2 2079B Check the versions of each software If you press the buttons as shown in the table, you can check the various software versions. Indicator Software Version display Main CPU [1.0.00] Panel CPU [1.000] Main IPL [1.
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5. FUNCTION SETTINGS (G10 OPERATION PANEL) ５-９. Viewing maintenance information This allows you to check the information which is stored in the head detector unit. 1 Change to maintenance display mode (Item name) (While pressing the 2 and keys, press the power ON switch.) 2083B 2138M 2139M Select the maintenance item No.
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5. FUNCTION SETTINGS (G10 OPERATION PANEL) ５-１０. Adjusting the sewing machine reference position 1 Change to sewing machine reference position adjustment mode (Adjustment item name) (While pressing the 2 2088B 2138M key, press the power ON switch.
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6. SETTING THE DIP SWITCHES (G50 AND G10 OPERATION PANELS) ６. SETTING THE DIP SWITCHES (G50 AND G10 OPERATION PANELS) 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. 1 2 3 4 Key protect settings ON/OFF Disables operation panel key operations. (*1) Should always be set to OFF. Should always be set to OFF.
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7. MECHANICAL DESCRIPTIONS ７. MECHANICAL DESCRIPTIONS The mechanisms operate in the order of the numbers given in the illustrations. * and [number] indicates the flow of each operations given. * (number) indicates part names only. (They do not represent the flow of operations.) ７-１. Upper shaft and needle bar mechanism 4338M 1. Pulley 2. Motor shaft 3. Upper shaft 4. Thread take-up crank 5. Needle bar crank 6. Needle bar crank rod assembly 7. Needle bar clamp 8.
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7. MECHANICAL DESCRIPTIONS ７-２. Lower shaft and rotary hook mechanism 4339M 1. Pulley 2. Motor shaft 3. Joint assembly 4. Timing pulley U 5. Timing belt 6. Timing pulley D 7. Lower shaft 8. Lower shaft gear 9. Rotary hook shaft gear 10. Rotary hook shaft 11.
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7. MECHANICAL DESCRIPTIONS ７-３. Feed mechanism Feed dog up/down movement 4340M Feed dog forward/back movement 4341M 1. 2. 3. Pulley Upper shaft Lower shaft (Feed dog up/down movement) <4> Feed lifting eccentric wheel assembly <5> Feed lifting feed shaft assembly <6> Feed bar 11. Feed dog (Feed dog forward/back movement) 4. Level feed eccentric wheel assembly 5. Level feed connecting rod 6. Feed regulator assembly 7. Feed rock shaft 8. Feed rock bracket arm 9. Feed bar shaft assembly 10.
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7. MECHANICAL DESCRIPTIONS ７-４. Quick reverse mechanism (quick back mechanism) Normal feed Reverse feed 4342M 1. Actuator <1> Reverse lever 2. Quick reverse solenoid <2> Reverse sewing shaft 3. Solenoid lever <3> Handle shaft arm assembly <4> Feed regulator connecting rod 4. Eccentric pin 5. Feed regulator shaft arm 6. Feed regulator shaft 7. Feed regulator shaft joint 8. Feed regulator connecting rod S 9.
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7. MECHANICAL DESCRIPTIONS ７-５. Lubrication mechanism (thread take-up and rotary hook) This sewing machine’s lubrication mechanism is a dry head type using tank lubrication. The oil level can be checked in the oil gauge window without needing to tilt back the machine head or operate the sewing machine. Thread take-up minimum lubrication To upper shaft, thread take-up and needle bar, etc. (-[]0[] specifications) 1. Oil feeding pocket 2. Oil tank 3. To upper shaft, thread take-up and needle bar, etc.
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7. MECHANICAL DESCRIPTIONS ７-６. Thread trimming mechanism ７-６-１. Thread trimming mechanism operation sequence The illustration below shows the mechanism with the high-speed rotary hook removed. 1） When thread rimming signal is input 1. Solenoid plunger 2. Solenoid lever 3. Thread trimmer cam lever shaft 4. Roller (Moves to above (1)) (1) Thread trimmer cam 4345M 2） Rocking of movable knife holder 1. Thread trimmer cam 2. Roller 3. Slide block 4. Forked shaft 5. Thread trimmer lever 6.
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7. MECHANICAL DESCRIPTIONS 3） Thread trimming complete and operation stopped 4347M 1. Extension spring <1> Thread trimmer lever [1] Thread trimmer lever 2. Thread trimmer cam lever <2> Thread trimmer connecting rod [2] Forked shaft 3. Solenoid lever <3> Thread trimmer holder [3] Slide block 4.
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7. MECHANICAL DESCRIPTIONS ７-６-２. Upper and lower thread trimming sequence Movable knife 1643M 1. The needle rises 1.8 mm from its lowest position and the rotary hook tip catches the loop made by the needle. (For heavy-weight materials, it rises 2.2 mm.) Movable knife 1644M 2. The thread trimming signal turns on and the thread trimming cam moves the movable knife. The upper thread is held by the rotary hook, and it passes underneath the inner rotary hook.
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7. MECHANICAL DESCRIPTIONS ７-７. Tension release mechanism 4349M When the thread trimming signal turns off, parts such as the solenoid lever [2] and the tension release wire [3] return to their original positions. When the presser foot is lowered, the presser bar lifter lever spring (2) causes the tension release plate 9 to return. (Presser foot is raised using the knee lifter plate (1)) 1.
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7. MECHANICAL DESCRIPTIONS ７-８. Thread wiper mechanism (option device) 4350M (Thread wiper signal is input) 1. Thread wiper solenoid 2. Thread wiper rod 3. Thread wiper crank assembly 4.
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8. DISASSEMBLY ８. 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 cover 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. If the treadle is depressed by mistake, the sewing machine might start operating and injury could result.
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8. DISASSEMBLY ８-２. Cable tie 1. Cable tie (Cut) 4374M 2. Cable tie (Cut) 3. Cable tie (Cut) 4. Cable tie (Cut) ８-３. Connector 4375M When pulling out the pin from the connector, use a pin puller manufactured by Molex (model no. 570316000). 1. Head detector unit connector 2. Operation panel connector 3. Resolver connector 4. Connector 5. Motor connector 6.
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8. DISASSEMBLY ８-４. Operation panel and head detector unit 4376M 1. Screw [2 pcs] 2. Operation panel 3. Screw [6 pcs] 4. Side plate 5. Screw [3 pcs] (Loosen) 6. Screw [2 pcs] 7. Head detector unit 8.
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8. DISASSEMBLY ８-５. Covers and bobbin winder unit 1. Screw [3 pcs] 2. Face plate assembly 3. Screw [5 pcs] 4. Motor cover 5. Screw 6. Cord holder 7. Bobbin winder fixed screw [3 pcs] 8.
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8. DISASSEMBLY ８-６. Tension release wire and thread trimmer solenoid 4378M 1. Screw 2. Tension release wire 3. Screw 4. Wire holder D 5. Screw 6. Cord holder plate 7. Screw [3 pcs] 8. Thread trimmer solenoid 9. Tension release wire (Remove from tension release plate) 10. Screw 11. Wire holder U 12.
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8. DISASSEMBLY ８-７. Wick holder and oil tube (-[]0[] specifications) 4379M 1. Wick (Unite the knot) 2. Screw 3. Wick holder 4. Screw 5. Cord holder 6. Vinyl tube (Remove from wire code holder) 7.
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8. DISASSEMBLY ８-８. Oil tank, bed bottom cover and sub tank -[]0[]、[]3[] specifications only 1) Hold a dish under the lubricating oil drain hole, and then remove the screw to drain out the lubricating oil (1). 2) Install the screw to the lubricating oil drain hole. -[]0[], []3[] specifications only 1. Screw 2. Screw 4380M 3. Sub tank assembly (Pull out) 4. Vinyl tube (Pull out) 5. Vinyl tube (Pull out) 6. Screw [2 pcs] 7. Oil tank 8. Screw [9 pcs] 9.
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8. DISASSEMBLY ８-９. Stand 4381M 1. Stand L [2 pcs] 2. Stand R [2 pcs] ８-１０. Safety switch and quick reverse solenoid 4382M 1. Screw 2. Tube holder 3. Vinyl tube (Pull out) 4. Screw 5. Washer 6. Safety switch 7. Screw [2 pcs] 8.
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8. DISASSEMBLY ８-１１. Needle, presser foot and R-actuator Integrated finger guard type 4383M 1. Set screw 5. Presser foot 2. Needle 6. Screw [2 pcs] 3. Screw 7. R-actuator 4. Finger guard ８-１２. Thread tension mechanism 4384M 1. Pre-tension assembly 8. Tension release stud 2. Thread guide 9. Screw 3. Screw 10. Needle bar thread guide 4. Arm thread guide R 11. Thread guide D 5. Set screw 12. Set screw 6. Thread tension bracket assembly 13. Bobbin winder tension assembly 7.
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8. DISASSEMBLY ８-１３. Needle plate, feed dog, etc. 4385M 1. Flat screw [2 pcs] 2. Needle plate 3. Slide plate 4. Screw [2 pcs] 5. Feed dog 6. Screw 7.
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8. DISASSEMBLY ８-１４. Bobbin case, rotary hook and thread trimmer mechanism 4386M 1. Screw 11. Thread trimmer lever spring (Remove) 2. Hook stopper 12. Set screw (Loosen) 3. Bobbin case 13. Retaining ring E 4. Set screw [3 pcs] 14. Thread trimmer cam lever shaft (Pull out) 5. Rotary hook 15. Cushion 6. Flat screw [3 pcs] 16. Washer 7. Knife holder presser plate 17. Thread trimmer lever assembly 8. Thread trimmer lever spring (Remove from hole) 18. Extension spring 9. Screw (Loosen) 19.
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8. DISASSEMBLY ８-１５. Feed bar mechanism 4387M 1. Set screw (Loosen) 2. Feed lifting rock bar shaft 3. Screw [2 pcs] (Loosen) 4. Feed bar assembly (Open) 5. Set screw [2 pcs] (Loosen) 6. Feed lifting eccentric wheel assembly ８-１６. Feed rock shaft 1. Rubber cap 4388M 2. Screw (Loosen) 3. Feed rock arm (Open) 4. Set screw [2 pcs] (Loosen) 5. Feed rock shaft (Pull out) 6.
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8. DISASSEMBLY ８-１７. Presser foot mechanism 4389M 1. Presser adjusting screw 2. Spring guide 3. Presser bar spring 4. Washer 5. Screw 6. Thread guide presser bar bracket 7. Screw 8. Presser bar guide bracket 9. Presser bar (Pull upward) 10. Retaining ring E 11. Presser bar lifter lever spring 12. Set screw 13. Presser bar lifter lever shaft (Slide to the right) 14. Retaining ring E 15. Presser bar lifter lever shaft (Pull out) 16. Washer 17.
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8. DISASSEMBLY ８-１８. Knee lifter lever mechanism 4390M 1. Shoulder screw 2. Knee lifter bar (Pull out) 3. Shoulder screw 4. Presser bar lifter lever assembly (Remove in the direction of the allow) 5. Shoulder screw 6. Knee lifter lever ８-１９. Tension pulley 4391M 1. Bolt [2 pcs] 2.
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8. DISASSEMBLY ８-２０. Needle bar and thread take-up mechanism 4392M 1. Rubber cap 2. Rubber cap [2 pcs] 3. Rubber cap 4. Rubber cap [2 pcs] 5. Rubber cap 6. Screw (Loosen) 7. Needle bar 8. Needle bar clamp 9. Needle bar guide slide block 10. Set screw (Loosen) 11. Needle bar bush U 12. Set screw [3 pcs] (Loosen) 13. Needle bar crank 14. Set screw [2 pcs] (Loosen) 15. Thread take-up lever assembly 16.
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8. DISASSEMBLY ８-２１. Pulley and motor If the motor will not pull out … 1) Insert the two screws (1) which were removed from the end of the motor into the screw holes (a) and tighten them. The motor (2) will lift up and be easier to remove. NOTE: Tighten the left and right screws little by little and evenly. 2) Once the motor (2) can be removed, remove the screws (1). 4393M 1. Screw [3 pcs] 2. Pulley washer [3 pcs] 3. Pulley 4. Screw [3 pcs] 5. Screw 6. Ground wire 7.
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8. DISASSEMBLY ８-２２. Timing belt 4394M 1. Timing belt (Remove from timing pulley D) 2. Screw [3 pcs] 3. Fan 4. Flange 5. Timing belt (Remove from arm) ８-２３. Feed mechanism (1) 4403M 1. Spring assembly 2. Retaining ring C 3. Washer 4. Pin 5.
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8. DISASSEMBLY ８-２４. Feed mechanism (2) 1. Set screw (Loosen) 2. Eccentric pin 3. Set screw (Loosen) 4. Set screw (Loosen) 5. Solenoid lever assembly 6. Dial lock lever (Raise) 7. Stitch length dial (Turn to the left and remove) 8. Positioning pin 9. Notch spring 10. Set screw [2 pcs] (Loosen) 11. Feed regulator shaft 12. Washer 13.
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8. DISASSEMBLY ８-２５. Feed mechanism (3) 4396M 1. Set screw [2 pcs] (Loosen) 6. Rubber cap 2. Set screw [2 pcs] (Loosen) 7. Set screw [3 pcs] (Loosen) 3. Feed regulator shaft (Pull out) 8. Feed regulator support shaft 4. Spring hook arm assembly 5. Rubber cap 9. Feed regulator shaft L 10.
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8. DISASSEMBLY ８-２６. Lower shaft, lower shaft gear and feed regulator unit 4397M 1. Set screw [2pcs] (Loosen) 2. Set screw [2pcs] (Loosen) 3. Set screw [2pcs] (Loosen) 4. Lower shaft assembly 5. Feed regulator assembly 6.
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8. DISASSEMBLY ８-２７. Plunger, rotary hook shaft, rotary hook shaft gear and thread trimmer cam 4398M 1. Rubber cap 6. Set screw [2pcs] (Loosen) 2. Cap screw pump 7. Set screw [2pcs] 3. Spring 8. Spacer [2pcs] 4. Plunger 5. Set screw [2 pcs] (Loosen) 9. Rotary hook shaft 10. Rotary hook shaft gear ８-２８. Reverse lever 4399M 1. Socket bolt (Loosen) 3. Reverse lever assembly 2. Screw [2pcs] 4.
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9. ASSEMBLY ９. ASSEMBLY 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. CAUTION Assembly should only be carried out by a qualified technician. Turn off the power switch before carrying out assembly. If the treadle is depressed by mistake, the sewing machine might start operating and injury could result.
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9. ASSEMBLY Assemble each part in the order shown in the illustration. ■ Apply grease to the places marked with white arrows in the illustrations. Use the “Grease kit (SA8837-001)” specified by Brother for the grease. Using the tube 4087M ９-１. Stitch length dial and feed regulator mechanism With the positioning pin (a) set into the groove of the dial lock lever (b), screw in the stitch length dial (7). 1. Feed regulator assembly 2. Washer 3. Feed regulator shaft 4. Set screw [2 pcs] (Tighten) 5.
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9. ASSEMBLY ９-２. Reverse lever 4406M 1. Handle shaft support 2. Reverse lever assembly 3. Screw [2 pcs] 4. Socket bolt (Tighten) 5.
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9. ASSEMBLY ９-３. Plunger, rotary hook shaft, rotary hook shaft gear and thread trimmer cam 4407M 1. Rotary hook shaft (Insert) 11. Plunger 2. Thread trimmer cam 12. Spring 3. Rotary hook shaft gear 13. Pump cap screw 4. Set screw (Align with screw stop) 14. Rubber cap 5. Set screw (Tighten) 6. Set screw (Align with screw stop) 7. Set screw (Tighten) 8. Rotary hook shaft (Check that it rotates smoothly with no play) 9. Spacer [2 pcs] 10.
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9. ASSEMBLY ９-４. Lower shaft, lower shaft gear and feed regulator unit Align Turn the rotary hook shaft gear (a) so that the upper set screw (b) is facing toward the front, and also turn the lower shaft gear (c) so that the lower set screw (d) is facing toward the front, and then align the blade of the rotary hook gear (a) with the blade of the lower shaft gear (c). In this position, align with the screw stop on the lower shaft (e), and then tighten the lower set screw (d). 4408M 1.
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9. ASSEMBLY ９-５. Feed mechanism (1) Turn the feed regulator support shaft (3) so that the screw stop is facing toward the front and so that the feed regulator assembly (1) is in a position where it can turn smoothly with no play, and then tighten. 4409M Lastly, check that the feed regulator assembly (1) moves smoothly. 1. Feed regulator assembly 2. Feed regulator shaft L 3. Feed regulator support shaft 4. Set screw (Sharp tip .. align with hole in feed regulator shaft L and tighten) 5.
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9. ASSEMBLY ９-６. Feed mechanism (2) Lastly, check that the feed regulator assembly (a) moves smoothly. 4410M 1. Feed regulator shaft (Insert) 2. Spring hook arm assembly 3. Set screw (Align with screw stop) 4. Set screw (Tighten) 5. Set screw (Align with screw stop) 6.
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9. ASSEMBLY ９-７. Upper shaft mechanism 4414M 1. Upper shaft assembly (Insert) 2. Set screw [One at upper shaft side] (Align with screw stop) 3.
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9. ASSEMBLY ９-８. Timing belt 4411M 1. Timing belt 2. Flange 3. Fan 4. Screw [3 pcs] ９-９. Pulley, motor and ground wire ■Refer to “11-3. Motor and timing belt” when carrying out assembly. 4412M 1. Motor (Insert) 6. Ground wire 2. Screw [3 pcs] 7. Screw 3. Pulley 8. Set screw [One at motor side] (Align with screw stop) 4. Pulley washer [3 pcs] 9. Set screw [One at motor side] (Tighten) 5.
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9. ASSEMBLY ９-１０. Knee lifter lever mechanism 4413M 1. Knee lifter lever 2. Shoulder screw 3. Presser bar lifter lever assembly (Insert) 4. Shoulder screw 5. Knee lifter bar (Insert) 6.
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9. ASSEMBLY ９-１１. Needle bar and thread take-up mechanism Turn the machine pulley back and forth 2 or 3 times by approximately 90° each time to move the thread take-up lever assembly (2) to the proper position. In this position, tighten the set screws (12). ■ Refer to “10-14. Adjusting the thread take-up amount (-[][]3 specifications)” when carrying out assembly. 4415M ■Refer to “10-10. Adjusting the needle bar height” when carrying out assembly. 1. Washer 11. Screw (Tighten) 2.
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9. ASSEMBLY ９-１２. Presser foot mechanism 4416M 1. Presser bar lifter lever shaft (Insert) 11. Screw (Provisionally tighten) 2. Tension release plate 12. Washer 3. Washer 13. Presser bar spring 4. Presser bar lifter lever assembly 14. Spring guide 5. Retaining ring E 15. Presser adjusting screw 6. Presser bar lifter lever spring 16. Thread guide presser bar bracket 7. Retaining ring E 17. Screw (Provisionally tighten) 8. Set screw 9. Presser bar (Insert) 10.
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9. ASSEMBLY ９-１３. Feed rock shaft 4417M 1. Feed rock shaft (Insert) 5. Set screw (Align with screw stop) 2. Washer 6. Set screw (Tighten) 3. Set screw collar 7. Screw (Tighten) 4. Feed rock arm ９-１４. Feed mechanism (1) 4418M 1. Solenoid lever assembly 4. Set screw (Tighten) 2. Eccentric pin 5. Set screw (Align with screw stop) 3. Retaining ring C 6.
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9. ASSEMBLY ９-１５. Feed mechanism (2) 4419M 1. Quick reverse solenoid plunger 4. Retaining ring C 2. Pin 5. Spring assembly 3. Washer ９-１６. Feed bar mechanism 4420M ■Refer to “10-8. Adjusting the feed dog height”, “10-9. Adjusting the feed dog angle” and “10-11. Adjusting the needle and feed mechanism timing” when carrying out assembly. 1. Feed dog 6. Feed bar assembly 2. Feed bar 7. Screw [2 pcs] (Tighten) 3. Screw (Tighten) 8. Feed lifting rock bar shaft 4.
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9. ASSEMBLY ９-１７. Tube holder, safety switch and quick reverse solenoid 4421M 1. Quick reverse solenoid 2. Screw [2 pcs] 3. Tube holder ■Refer to “10-6. Quick reverse device” when carrying out assembly. 4. Screw 5. Safety switch 6. Washer 7.
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9. ASSEMBLY ９-１８. Thread trimmer mechanism 4422M 1. Forked shaft (Insert) 11. Thread trimmer lever spring 2. Thread trimmer cam lever shaft (Insert) 12. Thread trimmer lever assembly 3. Rubber cushion 13. Knife holder presser plate 4. Collar 14. Flat screw [3 pcs] 5. Extension spring 15. Thread trimmer lever spring (Insert into hole) 6. Thread trimmer lever assembly 16. Fixed knife 7. Retaining ring E 17. Flat screw (Tighten) 8. Washer 18. Lower thread finger 9. Cushion 19. Washer 10.
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9. ASSEMBLY ９-１９. Oil tank, bed bottom cover and sub tank ■ Refer to “11-1. Daily cleaning procedures [2. Lubrication]” in the Instruction Manual when carrying out assembly. ■ Refer to “3-3. Lubrication (-[]0[], []3[] specifications)” in the Instruction Manual when carrying out assembly. 1. Bed bottom cover 4423M 2. Screw [9 pcs] 3. Screw 4. Oil tank 5. Screw [2 pcs] 6. Vinyl tube (Insert) 7. Sub tank assembly (Insert) 8. Screw 9. Vinyl tube (Insert) 10.
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9. ASSEMBLY ９-２０. Needle, presser foot and R-actuator ■ Adjusting the presser foot height ■ Adjusting the height of the presser bar The standard lifting amount is 6 mm when the presser foot (a) has been lifted by the lifting lever (b). 1. Use the lifting lever (b) to lift the presser foot (a). 2. Move the presser bar (c) up or down to adjust the height of the presser foot (a) so that it is 6 mm above the top of the needle plate.
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9. ASSEMBLY ９-２１. Thread tension mechanism ■Refer to “10-4. Adjusting arm thread guide R” when carrying out assembly. 4424M <-3[]S・-3[]3> 6～8 ㎜ <-3[]5> 4～6 ㎜ 4428M 4429M ■ Adjusting the vertical position of the ■ Adjusting the thread tension bracket thread take-up spring The standard vertical position for the thread take-up spring (a) is 6 to 8 mm (4 to 6 mm for -3[]5 specifications) above the top of the presser bar bracket thread guide (b) when the presser foot is lowered. 1.
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9. ASSEMBLY ９-２２. Tension release wire and thread trimmer solenoid ■Refer to “10-13. Adjusting the thread trimming timing” when carrying out assembly. ■Refer to “10-18. Adjusting the tension release wire” when carrying out assembly. 4426M 8. Screw 1. Tension release wire (Insert into tension release plate) 9. Tension release wire 2. Wire holder U 3. Screw 10. Screw 4. Tension release wire (Insert) 11. Cord holder plate 5. Thread trimmer solenoid 12. Screw 6. Screw [3 pcs] 13.
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9. ASSEMBLY ９-２３. Wick holder and oil tube (-[]0[] specifications) 4427M 1. Vinyl tube (Insert) 5. Wick holder 2. Vinyl tube (Insert into wire cord holder) 6. Screw 3. Cord holder 7. Wick (Clamp) 4. Screw ９-２４. Tension pulley 4432M 1. Tension pulley unit 2.
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9. ASSEMBLY ９-２５. Rotary hook ■Refer to “10-12. Adjusting the needle and rotary hook timing” when carrying out assembly. 4439M 1. Rotary hook 2. Set screw [3 pcs] (Tighten) 3. Bobbin case 4. Hook stopper 5.
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9. ASSEMBLY ９-２６. Stand 4381M 1. Stand L [2 pcs] 2. Stand R [2 pcs] ９-２７. Needle plate, feed dog, etc. 4433M 1. Needle plate 2. Flat screw [2 pcs] 3. Slide plate 4. Ruler plate 5.
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9. ASSEMBLY ９-２８. Covers and operation panel (1) 1. Face plate assembly 2. Screw [3 pcs] 3. Cord holder 4. Screw 5. Motor cover 6. Screw [5 pcs] 7. Bobbin winder unit 8.
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9. ASSEMBLY ９-２９. Covers and operation panel (2) 4435M 1. Head detector unit 5. Side plate 2. Screw [2 pcs] 6. Screw [6 pcs] 3. Cord [2 pcs] 7. Operation panel 4. Screw [3 pcs] (Tighten) 8. Screw [2 pcs] ９-３０. Cable tie 4436M 1. Cable tie 3. Cable tie 2. Cable tie 4.
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9. ASSEMBLY ９-３１. Connector 4437M 1. Head detector unit connector 2. Operation panel connector 3. Resolver connector 4. Connector 5. Motor connector 6. Pins 14P 1 2 3 4 5 6 7 Cord (Ground) － Thread trimmer solenoid Thread wiper Quick reverse solenoid R-actuator Safety switch 14P 8 9 10 11 12 13 14 Cord －－ Thread trimmer solenoid Thread wiper Quick reverse solenoid R-actuator Safety switch ９-３２. Knee lifter lever 1. Knee lifter bracket 4438M 2.
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10. ADJUSTMENTS １０. ADJUSTMENTS CAUTION Maintenance and inspection of the sewing machine should only be carried out by a qualified technician. 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. Ask your Brother dealer or a qualified electrician to carry out any maintenance and inspection of the electrical system.
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10. ADJUSTMENTS １０-２. 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 head and the table hole, it may adversely affect the operation of the safety switch (1). 4249M The standard amount of clearance between the machine head and the table hole is 1.5 mm. If the clearance is 3.
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10. ADJUSTMENTS １０-３. Adjusting the thread take-up spring The standard position of the thread take-up spring (1) is 6-8 mm [4-6 mm for -[][]5 specifications] 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).
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10. ADJUSTMENTS １０-４. Adjusting arm thread guide R Becomes greater The standard position of arm thread guide R (1) is the position where the screw (2) is in the center of the adjustable range for arm thread guide R (1). Becomes less * To adjust the position, loosen the screw (2) and then move arm thread guide R (1). ・ When sewing thick material, move arm thread guide R (1) to the left. (The thread take-up amount will become greater.) ・ When sewing thin material, move arm thread guide R (1) to the right.
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10. ADJUSTMENTS １０-６. Quick reverse device 1. 2. 3. 4. 5. 6. Turn the stitch length dial to the maximum setting. Remove the side plate. Tilt back the machine head. Turn the stitch length dial to the maximum setting. Loosen the two screws (1). With the reverse lever (3) lowered as far as it will go, push quick reverse solenoid (4) until the clearance between the surface of the quick reverse solenoid (4) and the groove in the plunger (5) is 3 mm. 7. Tighten the screws (1).
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10. ADJUSTMENTS １０-８. Adjusting the feed dog height The standard height of the feed dog (1) when it is at its maximum height above the top of the needle plate is 0.8 mm for -[][]S / [][]3 specifications, and 1.2 mm for -[][]5 specifications. <-[][]S / [][]3> 0.8mm <-[][]5> 1.2mm 2279M 1. Turn the pulley until the feed dog (1) rises to the highest position. 2. Tilt back the machine head. 3. Loosen the screw (2). 4.
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10. ADJUSTMENTS １０-９. Adjusting the feed dog angle The standard angle for the feed dog (1) when it is at its highest position above the needle plate is when the “ ” mark (or V groove) on the shaft (2) is aligned with the feed rocker bracket arm (3). 1. Turn the machine pulley to move the feed dog (1) to its highest position above the needle plate. 2. Tilt back the machine head. 3. Loosen the two set screws (4). 4.
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10. ADJUSTMENTS １０-１０. Adjusting the needle bar height 2286M Reference line (a), which is the second line from the bottom of the needle bar (1) (fourth line from the bottom when using a DA x 1 needle) should be aligned with the lower edge of the needle bar bush D (2) as shown in the illustration when the needle bar (1) is at its lowest position. 1. Turn the machine pulley to set the needle bar (1) to its lowest position. 2. Remove the oil cap (3). 3.
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10. ADJUSTMENTS １０-１２. Adjusting the needle and rotary hook timing 2290M 2291M 0.5 - 0.7mm <-[][]S / [][]3> 1.8mm <-[][]5> 2.
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10. ADJUSTMENTS １０-１３. Adjusting the thread trimming timing Remove the presser foot, needle plate and feed dog. Lowest position of needle bar Reference line (a) Raised 5 mm < Thread trimming cam position adjustment > 1. Turn the machine pulley to raise the needle bar 5 mm from its lowest position (reference line (a) position) so that reference line (b) is aligned with the bottom edge of the needle bar bush. Reference line (b) 1204B 2.
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10. ADJUSTMENTS １０-１４. Adjusting the thread take-up amount (-[][]3 specifications) CAUTION Turn off the power switch before carrying out this operation. The machine may operate if the treadle is depressed by mistake, which could result in injury. NOTE: Do not use this function with models that are not –[][]3 specifications. When sewing heavy materials, the thread tension can be adjusted more easily if the thread take-up amount is set to a larger amount. 1. Remove the face plate.
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10. ADJUSTMENTS １０-１５. Adjusting the needle up stop position 1 2128B 2138M (While pressing the 2 key (1), press the power ON switch.) Selecting “UpoS xxx” “MorG xxx” will appear in orange in the main display (2). (xxx is the value at the time of shipment from the factory, and varies depending on the sewing machine.) “xxx” is the setting value for the needle up stop position, and “0” is the default setting.
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10. ADJUSTMENTS 1 4217M 2138M (While pressing the 2 key (1), press the power ON switch.) “MorG” will appear in the display (2). Selecting “UPoS” (Setting item) (Press once) 3 4218M Needle up stop position setting Example: (Setting value) ・ If you press the key, the setting value increase and the needle up stop position become lower. ・ If you press the key, the setting value decrease and the needle up stop position become higher. ・ The setting range is from –10 to 10.
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10. ADJUSTMENTS １０-１６. Adjusting the treadle 4259M If the machine starts running at low speed when your foot is simply resting on the treadle, or if the treadle pressure is felt to be too weak, adjust the position (a to c) at which the treadle spring (1) is hooked onto the treadle lever (2). * a is the weakest position, and it becomes gradually stronger at b, c and d respectively. 1.
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10. ADJUSTMENTS １０-１８. Adjusting the tension release wire 4369M If the tension discs remain open or if the upper thread pulls out from the needle hole after thread trimming, carry out the following adjustment. * Lower the presser foot before carrying out the adjustment. Opened Start of opening A. If the upper thread pulls out of the needle hole (The tension release wire is not operating enough during thread trimming.
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10. ADJUSTMENTS １０-１９. Adjusting the rotary hook lubrication amount (-[]0[], []3[] specifications) 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, otherwise injury may result. Use the following procedure to check the amount of oil being supplied to the rotary hook when replacing the rotary hook or when changing the sewing speed.
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11. REPLACING PARTS １１. REPLACING PARTS 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. Replacement of parts should only be carried out by a qualified technician. Use only the proper replacement parts as specified by Brother. Turn off the power switch and disconnect the power cord before replacing any parts.
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11. REPLACING PARTS １１-３. Motor and timing belt < Timing belt removal > 1. Remove the side plate (1). 2. Remove the five screws (2), and then remove the motor cover (3). 3. Tilt back the machine head. 4. While pushing the timing belt (4) in the direction of the arrow, turn the machine pulley (5) forward to remove the timing belt (4) from timing pulley D (6). 5. Return the machine head to its original position. 4356M 6.
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11. REPLACING PARTS < Timing belt installation > 1. Place the timing belt (4) onto timing pulley U (14). 2. Secure the motor (12) with the three screws (11). * Insert the motor (12) so that the upper set screws (8) on the joint (7) are facing toward the front and also so that the notch (b) on the motor shaft (15) is facing toward the front. 3. Tighten the two set screws (8) at the left side of the joint (7) starting from the one at the top.
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11. REPLACING PARTS <-[][]S・[][]3> <-[][]5> Approx. 1mm Approx. 3mm 4360M < Timing belt installation check > 1. Check that the needle and rotary hook timing is correct. (Refer to “10-12. Adjusting the needle and rotary hook timing”.) * If they are correct, continue from step 5, otherwise continue from step 2. 2. Check that the needle and feed mechanism timing is correct.
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11. REPLACING PARTS １１-４. Rotary hook RP If replacing the standard rotary hook with a rotary hook RP (lubrication-free rotary hook) on sub-class -40[] or -43[] machines, use the following parts. S52936-001 (ROTARY HOOK, W/BOX) SB0414001 (SCREW, CAP) NOTE: When using the rotary hook RP (lubrication-free rotary hook), set the sewing speed to 4,000 sti/min or less. 1. Remove the needle and the presser foot. 2. Remove the needle plate (1) and the feed dog (2). 3. Remove the rotary hook. 4.
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11. REPLACING PARTS １１-５. Feed bar shaft, lifting feed shaft When changing over these parts, apply grease as described below and then install the parts to the sewing machine. * Use Brother-specified grease (SA8837-001). 2316M Feed bar shaft unit Grease 1. Apply grease to the holes of each part as shown in the arrow until a small amount of grease overflows. 2. Tighten the screws to force the grease in. 3. Wipe away any excess grease from around the screws. 4.
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12. APPLYING GREASE (-[]3[], []5[] SPECIFICATIONS) １２. APPLYING GREASE (-[]3[], []5[] SPECIFICATIONS) １２-１. When “GrEASEUP” appears…When using the G50 operation panel 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 as required, while referring to the following for details.
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12. APPLYING GREASE (-[]3[], []5[] SPECIFICATIONS) <-[]5[] specifications> <-[]3[], []5[] specifications> Turn the machine pulley to lower the needle bar until the hole is visible. 4242M 4241M 4243M 1. Turn the power switch to “OFF”. 2. Remove the screws and the set screws. 3. Apply grease to each of the holes until the grease overflows slightly. 4. Tighten the screws and the set screws in order to push the grease in. 5.
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12. APPLYING GREASE (-[]3[], []5[] SPECIFICATIONS) １２-２. When “GrUP” appears ... When using the G10 operation panel If “GrUP” flashes in the display (1) and the buzzer sounds when the power ON switch is pressed, it means that it is time to add grease. (The sewing machine will not operate at this time, even if the treadle is depressed.) Apply grease as required, while referring to the following for details.
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12. APPLYING GREASE (-[]3[], []5[] SPECIFICATIONS) <-[]3[], []5[] specifications > <-[]5[] specifications > Turn the machine pulley to lower the needle bar until the hole is visible. 4241M 4242M 4243M 1. Turn the power switch to “OFF”. 2. Remove the screws and the set screws. 3. Apply grease to each of the holes until the grease overflows slightly. 4. Tighten the screws and the set screws in order to push the grease in. 5.
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13. SETTING METHOD FOR STANDARD DEPRESSION STROKES １３. SETTING METHOD FOR STANDARD DEPRESSION STROKES 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. Use the following procedure to set the operating positions for the depression stroke. １３-１.
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13. SETTING METHOD FOR STANDARD DEPRESSION STROKES 5 Memorizing the maximum backward position “Pd-” will appear in the main display (1). (With the treadle depressed backward to the maximum backward position, press the thread trimming key.) 6 2108B Completion of setting 2109B The buzzer will sound and “ End” will appear in the main display (1). NOTE: ・ If you do not press the ENTER key (2), the settings will not be memorized. ・ If the treadle is not operated correctly, “E091” may be displayed.
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13. SETTING METHOD FOR STANDARD DEPRESSION STROKES １３-２. When using the G10 operation panel 1 Signal setting entry Control box (Press the power OFF switch, and then set DIP switch No. 4 to ON.) 2104B 2 “FF x.x” will appear in the display (1). (x.x indicates the depression voltage.) (While pressing the 3 key at C, press the power ON switch.) 2111B 2138M Memorizing the maximum forward position “nn x.x” will appear in the display (1).
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13. SETTING METHOD FOR STANDARD DEPRESSION STROKES 6 Completion of setting 2115B The buzzer will sound and “ End” will appear in the display (1). NOTE: ・ If you do not press the thread wiper key (2), the settings will not be memorized. ・ If the treadle is not operated correctly, “E091” may be displayed. If this happens, after “FF x.x” appears in the display (1), repeat the operation from step 3. 7 Control box (Press the power OFF switch, and then return DIP switch No. 4 to OFF.
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14. CONTROL BOX AND MOTOR １４. CONTROL BOX AND MOTOR １４-１. Checking the motor and power supply CAUTION Turn off the power switch and disconnect the power cord from the wall outlet before carrying out these operations. The machine may operate if the treadle is depressed by mistake, which could result in injury. If the power switch needs to be left on when carrying out some adjustment, be extremely careful to observe all safety precautions. 1.
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14. CONTROL BOX AND MOTOR １４-２. Checking the solenoids 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. 2118B 1. Disconnect the 14P sewing machine connector (1) from the main PCB. 2. Measure the resistance of the sewing machine connector 14P (1) using an ohmmeter in the x 1 range.
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15. STANDING OPERATION PEDAL １５. STANDING OPERATION PEDAL The foot plug assembly CDD (J04099-101) that is sold separately is required. １５-１. Installing the foot plug 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. 2119B 1. 2. 3. Insert the foot plug (1) into connector on the main PCB.
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15. STANDING OPERATION PEDAL １５-２. Connectors No. 1 2 3 4 5 6 7 8 9 Standing operation pedal 9P connector DC+8 V High-speed switch Thread trimmer switch SOV Spare Low-speed switch Presser foot switch Variable speed input Ground 2120B 1867M NOTE: Connector types Manufacturer MOLEX Connector No.
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16. WIRING DIAGRAMS (X-7200C) １６.
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17. CONNECTOR LAYOUT DIAGRAM (MAIN PCB) １７. CONNECTOR LAYOUT DIAGRAM (MAIN PCB) 2123B (Continued on next page.
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17. CONNECTOR LAYOUT DIAGRAM (MAIN PCB) Connector No. Name Description P8 Head detector unit connector P12 Solenoid-type pressure lifter connector P13 Sewing machine connector Connects to connector from machine head. P6 Resolver connector P7 Operation panel connector P3 Relay connector P4 Coupler connector P1 DC power connector Supplies power from switching power supply PCB. P14 Treadle connector Connects to connector from treadle unit.
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18. COMBINATION OF TRANSFORMER SPECIFICATIONS AND CONTROL DEVICE SPECIFICATIONS １８. COMBINATION OF TRANSFORMER SPECIFICATIONS AND CONTROL DEVICE SPECIFICATIONS “X” indicates accessory parts which are not used.
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19. TROUBLESHOOTING １９. 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.
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19. TROUBLESHOOTING Problem 5 Possible cause Skipped stitches at sewing start Thread unravelling at sewing start Page ・ Is the thread take-up spring tension too strong? Reduce the tension of the thread take-up spring. 117 ・ Is the thread take-up spring operating range too large? Lower the position of the thread take-up spring. 117 ・ Are the trailing lengths of the upper threads too short after thread trimming? Adjust the pretension.
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19. TROUBLESHOOTING Problem 8 Possible cause Material slippage Page ・ Is the presser foot pressure too strong? Adjust the presser foot pressure. Instruction manual ・ 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. Instruction manual 0750M 9 Lower thread is tangled at the sewing start.
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19. TROUBLESHOOTING Problem 13 Possible cause Broken needles Page ・ Is the material being pushed or pulled with excessive force during sewing? Instruction manual ・ Is the needle properly installed? If it is incorrect, install the needle correctly. ・ Is the needle bent, is the needle tip broken, or is the needle hole blocked? Replace the needle. ・ Is the needle and rotary hook timing correct? Adjust the height of the needle bar. Adjust the clearance between the needle and the tip of the rotary hook.
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19. TROUBLESHOOTING 18 Problem Nothing appears on the operation panel display Possible cause ・ Is the power supply connector disconnected from the control box? Insert the connector securely. Page 4263M Instruction manual ・ Is the operation panel connector P7 inside the control box disconnected? Insert the connector securely. ・ Are the relay connector of the drive PCB and P3 on the main PCB inside the control box disconnected? Insert the connector securely.
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19. TROUBLESHOOTING １９-２. Error code displays If an error code appears on the operation panel display 1. Make a note of the error code and then turn off the power. 2. After the operation panel display has turned off, eliminate the cause of the error and then turn the power back on. ・ For items with “ * ” appearing in the “Page” column, ask the place of purchase for advice.
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19. TROUBLESHOOTING Error code E090 Treadle connector is not connected. E091 Possible cause ・ Is the 4-pin treadle connector inside the control box disconnected? Press the power OFF switch, and then check that the 4-pin treadle connector is connected to connector P14 on the main PCB. If there is a broken wire in the cord of the treadle connector, replace the treadle unit. ・ The settings in “Setting method for standard depression stroke” may be incorrect.
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19. TROUBLESHOOTING Error code E150 Motor is overheating. E151 Problem with motor overheating sensor. Possible cause ・ This is displayed when the motor becomes abnormally hot and the temperature protection has activated. After the temperature has dropped, press the power ON switch and operate the sewing machine as normal. Page ・ Is the connector inside the motor disconnected? Press the power OFF switch, and then check that the connector is securely inserted.
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19. TROUBLESHOOTING Error code E452 Head detector unit connection error E701 Abnormally high power supply voltage E705 Abnormally low power supply voltage E710 Motor overcurrent E791 Possible cause ・ Is the 6-pin head detector unit connector inside the control box disconnected? Press the power OFF switch, and then check that the 6-pin head detector unit connector is connected to connector P8 on the main PCB.
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20. 7-SEGMENT DISPLAY ２０.
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SERVICE MANUAL Printed in Japan S-7200C I8120941B 2009. 05.