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Brother Z-8550A manual

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Table of contents for the manual

  • Page 1

    Z-8550A Z-8560A Please read this manual before making any adjustments. ELECTRONIC DIRECT DRIVE ZIGZAG LOCK STITCHER ELECTRONIC DIRECT DRIVE ZIGZAG LOCK STITCHER WITH THREAD TRIMMER SER VICE MANUAL[...]

  • Page 2

    Z-8550A, 8560A 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 who le of this manual to underst and this p roduct before you start maintenance. As a result of resear ch and improvement s regarding this pro duct, som[...]

  • Page 3

    Z-8550A, 8560A i SAFETY INSTRUCTIONS [1] Safety indications and their meanings This service manual and the indications and symbols that are used on the machine itself ar e provided in order to ensure safe operation of this machine and to prevent acci dents and injury to y ourself or other people. The meanings of these indications and symbols are gi[...]

  • Page 4

    Z-8550A, 8560A ii [2] Notes on safety DANGER Wait at least 5 minutes after turning off the pow er swit ch 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 [...]

  • Page 5

    Z-8550A, 8560A iii CAUTION Sewing This sewing machine should only be used by operators who have received the necessary training in safe use beforehand. The sewing machine should not be used for any applications other than sewing. Be sure to wear protective goggles when using the machine. If goggles are not worn, ther e is the danger that if a needl[...]

  • Page 6

    Z-8550A, 8560A iv CAUTION Maintenance and inspection Maintenance and inspection of the sew ing 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 pow er cord from the wall o[...]

  • Page 7

    Z-8550A, 8560A v 4 Direction of operation 5 If the actuator is press ed 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. 6 Do not touch the thread takeup or the knife, otherwise injury may result. 3316M Oil pan 3317M (For Europe)[...]

  • Page 8

    Z-8550A, 8560A CONTENTS 1. MACHINE SPEC IFICATIONS............... 1 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 init ializatio n ..........................[...]

  • Page 9

    Z-8550A, 8560A 9. ADJUS TMENTS ................................... 67 9-1. Actuator position ............................................... 67 9-2. Adjusting the safe ty switch position .................. 68 9-3. Thread tens ion spri ng ....................................... 69 9-4. Presser foot hei ght ...........................................[...]

  • Page 10

    Z-8550A, 8560A 1. MA CHINE SPECIFICATIONS 1 1. MACHINE SPECIFICA TIONS 8550A 8560A 0 A 3 Thread trimmer - - c Upper thread feeding device - - c Back tack/condense device *1 - c c 8550A 8560A SPECIFICATIONS -031, -A31 -331 Use For light-weight to medium-w eight materials Max. stitch length 2.0mm *2 Max. sewing speed 5,000rpm *3 Sewing pattern 14 pat[...]

  • Page 11

    Z-8550A, 8560A 2. SEWING PA TTERN 2 2. SEWING P A TTERN • This sewing machine is equipped with the following built-in se wing patterns. Select the p a ttern number from the operation panel to use a pattern.(Refer to “6-2-2. Setting the sew ing pattern” of the instruction manual.) • Different zigzag widths and zigzag lengths can be set for e[...]

  • Page 12

    Z-8550A, 8560A 3. FUNCTION SETTINGS 3 3. FUNCTION SETTINGS 3-1. Setting memory switches • If the icon (1) on the LOCK key is on, release the lock before carry ing out the following operations. • If the icon (2) on the MAX key is on, pre ss the MAX key to return the main display to the stitch number display (orange). 1 • The main display will [...]

  • Page 13

    Z-8550A, 8560A 3. FUNCTION SETTINGS 4 3-2. List of memory switch settings Memory switch No . 0 - 15 No. Initial value Setting range Setting details 0 0 (degrees) -10 - 10 (degrees) Needle up stop position setting Higher Lower 1 0 (degrees) -10 - 10 (degrees) Needle down stop position setting Higher Lower 2 0 0 - 1 Depressing treadle forward w hen t[...]

  • Page 14

    Z-8550A, 8560A 3. FUNCTION SETTINGS 5 Memory switch No . 16 - 30 No. Initial value Setting range Setting details 16 3 (minutes) 0 - 30 (minutes) Overtime function 0: None 1-30: After continuous operation for t he set length of time, operation stops and [Err 190] is displayed. 17 1 0 - 3 Correction stitch function (corre ction stitch icon [when off/[...]

  • Page 15

    Z-8550A, 8560A 3. FUNCTION SETTINGS 6 Memory switch No . 31 - 46 No. Initial value Setting range Setting details 31 0 0 - 1 Stopping while start backtacking is in progress, and speed during start backtacking 0: When the treadle is returned to the neutral position, start backtacking ends, sewing stops and the sew ing s peed becomes the start backtac[...]

  • Page 16

    Z-8550A, 8560A 3. FUNCTION SETTINGS 7 Memory switch No . 47 - 60 No. Initial value Setting range Setting details 47 0 0 - 1 Operation during st anding operation when AUTO function is on 0: When high-speed pedal turns on, se wi ng is momentarily stopped, and it is resumed when pedal turns off. 1: Above function is disabled This function is disabled [...]

  • Page 17

    Z-8550A, 8560A 3. FUNCTION SETTINGS 8 Memory switch No . 68 - 69 No. Initial value Setting range Setting details 68 0 0 - 1 Seam matching function during automatic backtacking (Used when y ou 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 rest[...]

  • Page 18

    Z-8550A, 8560A 3. FUNCTION SETTINGS 9 Memory switch No . 80 - 88 No. Initial value Setting range Setting details 80* 0 -7 - 7 Backward depression on (thread trimming) point for treadle 81* 0 -5 - 5 Backward depression 1 st step on (presser foot lifting) point for treadle 82* 0 -5 - 5 Forward depression 1 st step on (presser foot lowering) point for[...]

  • Page 19

    Z-8550A, 8560A 3. FUNCTION SETTINGS 10 Memory switch No . 90 - 110 No. Initial value Setting range Setting details 90 160 (rpm) 150 - INCH (rpm) Thread trimming speed (TRIM) 91 220 (rpm) 150 - 300 (rpm) Low speed (INCH) 92 1400 (rpm) 500 - 2500 (rpm) Stop improvement position (POS) [Do not change this setting.] 93 300 (rpm) INCH - 1000 (rpm) Slow s[...]

  • Page 20

    Z-8550A, 8560A 3. FUNCTION SETTINGS 11 Memory switch No . 111 - 123 No. Initial value Setting range Setting details 111 1000 (rpm) 500 - 2000 Limit speed for sewing patterns w ith changed sew ing pitch (T stitches) Needle lifting and needle lowering are carried out at low speed w hen No. 110 is set to “1”. 112 1 0 - 1 Low speed limit w hen sew [...]

  • Page 21

    Z-8550A, 8560A 3. FUNCTION SETTINGS 12 Memory switch No . 125 - 148 No. Initial value Setting range Setting details 125 0 0 - 1 Servo lock operation 0: None 1: When stopped 2: When presser foot lifting signal is on 126 1 (seconds) 0 - 120 (seconds) Servo lock timer setting 0: No timer operation 1-120: Timer operation (1-120 seconds) 127 100 (hours)[...]

  • Page 22

    Z-8550A, 8560A 3. FUNCTION SETTINGS 13 Memory switch No . 132 - 135 The following memory sw itch numbers are used for displaying maintenance information. No. Explanation of display details 132 Cumulative pow er on time (Actual time = Displayed time x 10 hours) 133 Cumulative running time (Actual time = Display xxxx x 10 hours) 135 ROM version (x.xx[...]

  • Page 23

    Z-8550A, 8560A 3. FUNCTION SETTINGS 14 3-3. Data initialization Initialization of memory data refers to returning all oper ation panel setting data (inclu di ng data that has been set using memory sw itches) to the factory default settings. 3-3-1. Resetting the settings to their defaults <Initialization of all setting da ta> 1 While holding d[...]

  • Page 24

    Z-8550A, 8560A 3. FUNCTION SETTINGS 15 <Initialization of memory s w itch setting data only > 1 While holding down the FUNC key on the operat ion panel, turn on the power sw itch (1). 2 The memory switch setting data w ill be initialized. After this, operation panel and treadle operation will be possible. <Initialization of custom patte rn[...]

  • Page 25

    Z-8550A, 8560A 3. FUNCTION SETTINGS 16 3-3-2. When data is initialized automatically All setting data will be initialized autom atically at the follow ing times. • When the power sw itch is turned on for the first time • When the power sw itch is turned on for the firs t time after the control box has been replaced • When the power switch is [...]

  • Page 26

    Z-8550A, 8560A 3. FUNCTION SETTINGS 17 3-4. Error history checking method 3-4-1. Error history checking method The past error history can be che cked by the follow ing procedure. 1 While holding down the TEST key on the operat ion panel, turn on the power sw itch (1). * After the following display appears, keep the TEST key pressed down until the b[...]

  • Page 27

    Z-8550A, 8560A 3. FUNCTION SETTINGS 18 3-4-2. Error history display examples Setting items Main display (1) Main display (2) If there is no error history [000] [E---] Error [E110] is displayed first. [001] [E110] 3-5. Software version checking method 3-5-1. Version update checking method 1 While pressing the [Speed ] key on the operation panel, tur[...]

  • Page 28

    Z-8550A, 8560A 3. FUNCTION SETTINGS 19 3-6. Checking input and output Use this to check for any malfunctions of the operation panel keys, circuit boards or sensors, and fo r 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 chec[...]

  • Page 29

    Z-8550A, 8560A 3. FUNCTION SETTINGS 20 Treadle unit and standing ope ration pedal operation Operation block Operation panel indicator block Forward depression - ON Plain zigzag LED Forward depression ON signal position Depress the treadle unit forward. Forward depression - ON (1 st step - ON is when DIP switch No. 2 is ON) 3-step zigzag LED Presser[...]

  • Page 30

    Z-8550A, 8560A 3. FUNCTION SETTINGS 21 3-7. DIP switch setting method DANGER Wait at least 5 minutes after turning off the power sw itch and disconnecting the power cord from the w all outlet before opening the cover of the control box. Touching areas where high voltages are present can result in severe injury. ON Presser foot low ers (models for E[...]

  • Page 31

    Z-8550A, 8560A 3. FUNCTION SETTINGS 22 3-8. Needle zigzag home position adjustment procedure OPERA TION PROCEDURE 1 While pressing the [zigzag width/zigzag reference line posit ion] key on th e operation panel, turn on the pow er switch (1). 2 Move the needle bar to the needle up st op position, and then press and hold the RESET key for 2 seconds o[...]

  • Page 32

    Z-8550A, 8560A 4. USING CF CA RDS 23 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 t[...]

  • Page 33

    Z-8550A, 8560A 4. USING CF CARDS 24 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 w hen inserting and removing the CF card. If this is not done, dust may get inside and cause pr[...]

  • Page 34

    Z-8550A, 8560A 4. USING CF CA RDS 25 4-4. Reading additional sewing data into the sewing machine 1 Carry out steps 1 to 3 in “4-3. Preparation for reading/writing data”. 2 Select [r 1] in CF data read/write mode. 3 4 Select the program number s to be read (ALL, 1-99). * If [ALL] is displayed, all additional se wing data will be read at once. 5 [...]

  • Page 35

    Z-8550A, 8560A 4. USING CF CARDS 26 4-5. Writing additional sewing data to CF cards 1 Carry out steps 1 to 3 in “4-3. Preparation for reading/writing data”. 2 Select [w 2] in CF data read/w rite mode. 3 4 Select the program numbers to be w ritten (ALL, 1 - 99). * If [ALL] is displayed, all additional se wing data will be read at once. 5 The buz[...]

  • Page 36

    Z-8550A, 8560A 4. USING CF CA RDS 27 4-6. Reading memory switch data into the sewing machine 1 Carry out steps 1 to 3 in “4-3. Preparation for reading/writing data”. 2 Select [r 3] in CF data read/write mode. 3 The buzzer will sound and the memory switch data w ill be loaded from the CF card and copied into the sewing machine's internal me[...]

  • Page 37

    Z-8550A, 8560A 4. USING CF CARDS 28 4- 7 . Writing memory switch data to a CF card 1 Carry out steps 1 to 3 in “4-3. Preparation for reading/writing data”. 2 Select [w 4] in CF data read/w rite mode. 3 The buzzer will sound and the memory sw itch data will be copied from the internal memory onto the CF card. W r i t i n g W r i t i n g c o m p [...]

  • Page 38

    Z-8550A, 8560A 4. USING CF CA RDS 29 4-8. Updating the control program version 4-8-1. Control program version updating procedure 1 Carry out steps 1 to 3 in “4-3. Preparation for reading/writing data”. 2 Select [r 7] in CF data read/write mode. 3 Version number for control program saved on CF card 4 Version updating in progress Complete when [E[...]

  • Page 39

    Z-8550A, 8560A 4. USING CF CARDS 30 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 pow er outage, the se wing machine will not operate correctly. If this happens, restore the control pr ogram by the follow ing procedure. 1 Insert the CF card con[...]

  • Page 40

    Z-8550A, 8560A 4. USING CF CA RDS 31 4-9. Writing error log data to CF cards 1 Carry out steps 1 to 3 in “4-3. Preparation for reading/writing data”. 2 Select [w 8] in CF data read/w rite mode. 3 The buzzer will sound and the error log data will be copied from the internal memory onto the CF card. W r i t i n g W r i t i n g c o m p l e t e 4 P[...]

  • Page 41

    5. MECHA NICAL DESCRIPTIONS Z-8550A, 8560A 32 5. MECHANICAL DESCRIPTIONS Each mechanism operates in the order of the numbers show n in the illustration. * <number> and [number] indicate the flow of oper ations that occur separ ately from each other. * (number) indicates only the names of parts. (They are not part of the indica tion of operati[...]

  • Page 42

    5. MECHA NICAL DESCRIPTIONS Z-8550A, 8560A 33 5-2. Lower shaft and shuttle race mechanisms 1. プーリ 2. モータ 1. Motor 2. Upper shaft 3. T iming pulley U 4. Timing belt 5. T iming 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[...]

  • Page 43

    5. MECHA NICAL DESCRIPTIONS Z-8550A, 8560A 34 5-3. Zigzag mechanism 1. Pulse motor 2. Motor lever 3. Zigzag connecting rod 4. Zigzag joint 5. Needle bar base 6. Needle bar 1110B[...]

  • Page 44

    5. MECHA NICAL DESCRIPTIONS Z-8550A, 8560A 35 5-4. Presser foot mechanism 1. Presser adjusting screw 2. Presser bar spring 3. Presser bar 4. Presser foot 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[...]

  • Page 45

    5. MECHA NICAL DESCRIPTIONS Z-8550A, 8560A 36 1. Lifting lever 2. Presser bar lifter lever 3. Presser bar bracket 4. Presser bar 5. Presser foot <For options> 1. Presser foot lifter solenoid set 2. Knee lifter shaft L 3. Knee lifter complying bar assembly 1113B 0079B[...]

  • Page 46

    5. MECHA NICAL DESCRIPTIONS Z-8550A, 8560A 37 5-5. Feed mechanism [Forw ard/back movement] 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/dow n movement] 1. Low[...]

  • Page 47

    5. MECHA NICAL DESCRIPTIONS Z-8550A, 8560A 38 <Dial feed mechanism> 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 regulato[...]

  • Page 48

    5. MECHA NICAL DESCRIPTIONS Z-8550A, 8560A 39 <Backtacking mechanism> 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. 1. Reverse stitching lever 2. Lever [...]

  • Page 49

    5. MECHA NICAL DESCRIPTIONS Z-8550A, 8560A 40 5-6. Lubrication mechanism ： F low of oil 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. Rotary hook (Continued on next page) 1176B[...]

  • Page 50

    5. MECHA NICAL DESCRIPTIONS Z-8550A, 8560A 41 ： F low of oil 1. Plunger pump 2. Rotary hook shaft bush 3. Rotary hook shaft <3> Adjusting screw 4. Felt (Adjusts the size of the outlet.) 5. Screw <4> Bed 6. Lubricating felt 7. Wick felt 1119B 0090B[...]

  • Page 51

    5. MECHA NICAL DESCRIPTIONS Z-8550A, 8560A 42 5-7. Thread trimmer mechanism (8560A only) 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. Movable knife (1) Fixed knife clut[...]

  • Page 52

    5. MECHA NICAL DESCRIPTIONS Z-8550A, 8560A 43 5-8. Tension release mechanism 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. Rotary disc (1) Tension release p[...]

  • Page 53

    5. MECHA NICAL DESCRIPTIONS Z-8550A, 8560A 44 <During thread trimming (8560A only)> 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 <Upper thread feeding mechanism (8560A only)> 1. Solenoid 2. Link 3. Lever B (Tension release is delayed b[...]

  • Page 54

    5. MECHA NICAL DESCRIPTIONS Z-8550A, 8560A 45 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. Thread wiper spring 1123B[...]

  • Page 55

    6. DISA SSEMBL Y Z-8550A, 8560A 46 6. DISASSEMBL Y DANGER Wait at least 5 minutes after turning off the power sw itch and disconnecting the power cord from the wall outlet before opening the face plate of the control box. Touching areas where high voltages ar e present can result in severe injury. CAUTION Disassembly should only be carried out by a[...]

  • Page 56

    6. DISA SSEMBL Y Z-8550A, 8560A 47 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 1. Screw (Loosen) 10. F lat screws [7 pcs] 2. Needle 11. Face plate 3. Screws [2 pcs] 12. Face plate packing 4. Thread take-up guard assembly 13. Sc[...]

  • Page 57

    6. DISA SSEMBL Y Z-8550A, 8560A 48 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 6-3. Needle bar mechanism 1. Rubber cap 2. Screw 3. Thread guide 4. Screw (Loosen) 5. Needle bar [...]

  • Page 58

    6. DISA SSEMBL Y Z-8550A, 8560A 49 6-4. Zigzag mechanism <For the 8560A> Remove the solenoid before doing this. (1) Screws [3 pcs] (2) Shoulder screw 1. Shoulder screw 2. Knee lifter bar 1127B 0102B[...]

  • Page 59

    6. DISA SSEMBL Y Z-8550A, 8560A 50 3. Screw 10. Set screw (Loosen) 4. Screw 11. Needle bar base guide R 5. Bolt (Loosen) 12. Set screw (Loosen) 6. Zigzag joint 13. Needle bar base guide pin (Loosen) (Pull out in the direction of the arrow.) 14. Needle bar base 7. Wick (Remove from needle bar base.) (1) Needle bar base shaft 8. Bolts [3 pcs] (2) Oil[...]

  • Page 60

    6. DISA SSEMBL Y Z-8550A, 8560A 51 6-5. Rotary hook mechanism 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. Rotary hook (1) Needle plate spacer[...]

  • Page 61

    6. DISA SSEMBL Y Z-8550A, 8560A 52 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 6-7. Feed mechanism 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[...]

  • Page 62

    6. DISA SSEMBL Y Z-8550A, 8560A 53 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 <Knife unit> 1. Screws [4 pcs] 2. Knife holder 3. Movable knife 4. Fixed knife 5. Knife bracket 1128B 0110B[...]

  • Page 63

    6. DISA SSEMBL Y Z-8550A, 8560A 54 6-9. Thread wiper mechanism (8560A only, optional device) 1. Screw 2. Presser foot 3. Screw 4. Solenoid cover 5. Retaining ring 6. Washer 7. Screws [2 pcs] 8. Screw 9. Bolt 10. Wiper bracket 11. Screw s [2 pcs] 12. Thread wiper base 13. Screw s [6 pcs] 14. 14-pin machine connector (1) Black (2) White A special too[...]

  • Page 64

    7. A SSEMBL Y Z-8550A, 8560A 55 7. ASSEMBL Y 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 location s w hen reassembling, and also o nce every two years. 7-1. Thread wiper mechanism (8560A only) 1.[...]

  • Page 65

    7. A SSEMBL Y Z-8550A, 8560A 56 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 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 sh[...]

  • Page 66

    7. A SSEMBL Y Z-8550A, 8560A 57 7-3. Lubrication mechanism 1. Bottom cover packing 2. Bed bottom cover assembly 3. Screws [9 pcs] 4. Screw 5. (Add lubricating oil [approx. 120 ml].) (1) Bed (2) Wick (3) Felt (4) Bed bottom cover 0121B 1134B[...]

  • Page 67

    7. A SSEMBL Y Z-8550A, 8560A 58 7-4. Zigzag mechanism 1. Needle bar base 8. Wick (With needle bar base guide pin inserted) (Pull in oil tank.) 2. Needle bar base guide R 9. Wick (ring) 3. Set screw (Pass the shaft through the ring.) 4. Needle bar base guide pin 10. Zi gzag joint (Pass the shaft through.) 5. Set screw 11. Bolt (Temporarily tighten) [...]

  • Page 68

    7. A SSEMBL Y Z-8550A, 8560A 59 7-5. Needle bar mechanism 1. Needle bar connecting rod 2. Needle bar connecting rod shaft 3. Screws [2 pcs] 4. Needle bar clamp (1) Thread take-up crank (2) Felt 5. Needle bar 6. Screw (Temporarily tighten) 7. Thread guide 8. Screw 9. Rubber cap 0124B Push in. Face the needle check hole toward the front. Tighten the [...]

  • Page 69

    7. A SSEMBL Y Z-8550A, 8560A 60 7-6. Rotary hook mechanism 1. Needle 2. Screw 3. Rotary hook 4. Set screws [2 pcs] (Temporarily tighten) 5. Bobbin case holder position bracket 6. Screw (Temporarily tighten) 7. Feed dog 8. Screws [2 pcs] (Temporarily tighten) 9. Needle plate 10. Flat screws [2 pcs] 11. Auxiliary needle plate 12. Flat screws [2 pcs] [...]

  • Page 70

    7. A SSEMBL Y Z-8550A, 8560A 61 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 9. Lifting lever (Lift up) 10. Presser foot 11. Screw 12. (Adjust the height) 13. (Align the hole positions) 1[...]

  • Page 71

    7. A SSEMBL Y Z-8550A, 8560A 62 7-8. Covers 1. Window plate (8550A) 10. Thread guide 2. Pulse motor cover 11. Flat screw 3. Screws [3 pcs] 12. Rotary take-up mounting plate 4. Panel 13. Rotary thread take-up lever 5. Rear cover 14. Flat screws [3 pcs] 6. Screws [6 pcs] 15. T hread take-up guard assembly 7. Face plate packing 16. Screws [2 pcs] 8. F[...]

  • Page 72

    7. A SSEMBL Y Z-8550A, 8560A 63 7-9. Thread wiper mechanism (8560A only, optional device) 1. Thread wiper base 2. Screws [2 pcs] 3. Solenoid setting plate 4. Screws [2 pcs] 5. Wiper bracket 6. Bolt 7. Washer 8. Retaining ring 9. Presser foot 10. Screw 11. Solenoid cover 12. Screw 13. Screw (Secure the harness.) 14. 14-pin machine connector 15. (Sec[...]

  • Page 73

    8. CHA NGING THE FEED AMOUNT TO LONG ST ITCH SPECIFICA TIONS (from 2.0mm to 5.0mm) Z-8550A, 8560A 64 8. CHANGING THE FEED AMOUNT TO LONG STITCH SPECIFICA TIONS (from 2.0mm to 5.0mm) CAUTION Replacement of parts should only be ca rried out by a qualified technician. Turn off the power sw itch and disconnect the pow er cord before carrying out this o[...]

  • Page 74

    8. CHA NGING THE FEED AMOUNT TO LONG STITCH SPECIFICA TIONS (from 2.0mm to 5.0mm) Z-8550A, 8560A 65 5. Turn the stitch length dial (7) and the condense dial (8) to the maximum feed amount fo r the feed dog being used. (Set the condense dial (8 ) to a negative number.) 6. Check that the feed dog do es not touch the needle plate both when the reverse[...]

  • Page 75

    8. CHA NGING THE FEED AMOUNT TO LONG ST ITCH SPECIFICA TIONS (from 2.0mm to 5.0mm) Z-8550A, 8560A 66 9. For sewing machine models a nd specificatio ns other than 8550A-031, push the reverse stit ching 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 screw[...]

  • Page 76

    Z-8550A, 8560A 9. A DJUSTMENTS 67 9 . ADJUSTMENTS CAUTION 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 sw itch and disconnect the power cord at the foll[...]

  • Page 77

    Z-8550A, 8560A 9. A DJUSTMENTS 68 9-2. Adjusting the safety switch position The safety switch (1) is normally installed as shown in figure [A]. However, if the processing me thod used for the table leaves too much space between the machine bed and the table ho le, it may adversely affect the operat ion of the safety sw itch (1). <A djustment met[...]

  • Page 78

    Z-8550A, 8560A 9. A DJUSTMENTS 69 9-3. Thread tension spring <Thread tension spring position> The standard position of the thr ead 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 ad[...]

  • Page 79

    Z-8550A, 8560A 9. A DJUSTMENTS 70 9-4. Presser foot height The standard height of the presser foot (1) is 6 mm w hen the presser foot (1) is raised by means of the lifting lever (2). 1. Loosen the t wo screws (3) and then remove the thread take-up guard (4). 2. Loosen the nut (5) of the pr esser adjusting screw (6), and then turn the presser adjust[...]

  • Page 80

    Z-8550A, 8560A 9. A DJUSTMENTS 71 0141B 0140B 9-6. Feed dog angle 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 t he feed dog (1) is raised to its highest position above the needle [...]

  • Page 81

    Z-8550A, 8560A 9. A DJUSTMENTS 72 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 fini shed stitches diff ers greatly fro m the scale, carry out the following adjustment. (The scale is intended as a guide.) [...]

  • Page 82

    Z-8550A, 8560A 9. A DJUSTMENTS 73 9-10. Needle bar height 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 low est position. 1. Remove the needle (4) and the presser foot (5). For the 8560A (Ref[...]

  • Page 83

    Z-8550A, 8560A 9. A DJUSTMENTS 74 9-11. Needle zigzag forward/back position Adjust so that the following are obtained. • The needle is in the center of the needle hole in the forward/back direction. • T here 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 [...]

  • Page 84

    Z-8550A, 8560A 9. A DJUSTMENTS 75 9-12. Needle zigzag sideways position Adjust the position of the needle so that it is in about th e 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 [...]

  • Page 85

    Z-8550A, 8560A 9. A DJUSTMENTS 76 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 l oad is 12-15 N.m when the needle bar (3) moves sideway s. 4. Securely tighten the nut (1). * Be ca[...]

  • Page 86

    Z-8550A, 8560A 9. A DJUSTMENTS 77 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,[...]

  • Page 87

    Z-8550A, 8560A 9. A DJUSTMENTS 78 9-16. Adjusting the rotary hook lubrication amount CAUTION Be careful not to touch y our fingers or the lubrication amount check sheet against moving parts such as the rotary hook or the feed mechanism w hen checki ng the amount of oil supplied to the ro tary hook.If they are touched, injury may result. Use the fol[...]

  • Page 88

    Z-8550A, 8560A 9. A DJUSTMENTS 79 9-17. Adjusting the presser foot floating amount (minute lifting amount) When sewing stretch materials and materials with long pile, you can make minute adjustment s 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) be[...]

  • Page 89

    Z-8550A, 8560A 9. A DJUSTMENTS 80 9-19. Adjusting the quick reverse device (8550A-A31, 8560A) 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 low est position w hile the feed amount is at the maximum setting. 1. Turn the condense dial (5) counter clock[...]

  • Page 90

    Z-8550A, 8560A 9. A DJUSTMENTS 81 9-20. Adjusting the tension release during thread trimming (8560A only) <a> : 6-7mm <b> : 0.2-1.0mm The tension release mechanism operates during thread trimming. When the lifting lever (1) is lowered and the distance <a> for the plunger (3) of the sol enoid (2) becomes 6 to 7 mm, the tension disc[...]

  • Page 91

    Z-8550A, 8560A 9. A DJUSTMENTS 82 9-21. Adjusting the position of the thread trimming cam (8560A only) The knife unit (1) should already be installed in the correct way when the follow ing adjustments are carried out. <Horizontal position adjustment> 1. Tilt back the machine head. 2. Loosen the two screws (2). 3. Move the stopper (4) to adj u[...]

  • Page 92

    Z-8550A, 8560A 9. A DJUSTMENTS 83 9-22. Adjusting the tension of the plate spring (8560A only) 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). (R efer to “11-1. Fixed knife and [...]

  • Page 93

    Z-8550A, 8560A 9. A DJUSTMENTS 84 <Adjusting the upper thread trailing amount> The standard trailing length fo r the upper thread is 50-60 mm. If adjustment is necessary, adjust the positi on of the wire e as described below. 1. Loosen the set screw (1). 2. Turn the base (2) to adjust the vertical position of the end of the wire (3). • To i[...]

  • Page 94

    Z-8550A, 8560A 10. A PPLYING GREA SE (When “G r EA SEUP” appears ) 85 1 0 . APPL YING 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 w ill not operate at this time, even if the treadle is [...]

  • Page 95

    Z-8550A, 8560A 10. A PPLYING GREASE (When “G r EA SEUP” appears) 86 10-2 . Applying grease Use Brother-specified <GREASE (SA2355-001)>. 1. Using the tube 2. Applying grease 1. Turn the power switch to “OFF”. 2. Apply grease in the places indicated by arrow s [A] to [G] below. 2216M 1. Remove the screws. 2. Apply grease to each of the [...]

  • Page 96

    Z-8550A, 8560A 10. A PPLYING GREA SE (When “G r EA SEUP” appears ) 87 After applying grease in the places indicated by arrow s [A ] to [G] above, carry out the reset operation described below. 10-3. Resetting the cumulative operating time After the grease has been applied, carry out the following procedure to reset the cumulative time between g[...]

  • Page 97

    1 1. ELECTRICAL MECHA NISM Z-8550A, 8560A 88 11. ELECTRICAL MECHANISM DANGER Wait at least 5 minutes after turning off the power sw itch and disconnecting the power cord from the w all 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 [...]

  • Page 98

    1 1. ELECTRICAL MECHA NISM Z-8550A, 8560A 89 11-2 . Control box internal configuration Main P .C. board Secured to the side. This is the P .C. boar d that controls sewi ng 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 . Pow er supp[...]

  • Page 99

    1 1. ELECTRICAL MECHA NISM Z-8550A, 8560A 90 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 ar e damaged, the fuses may blow again s oon even after they have been replaced. No. Part n[...]

  • Page 100

    1 1. ELECTRICAL MECHA NISM Z-8550A, 8560A 91 11-3-2 . Main P .C. board (fuses and fuse resistors) No. Part name Parts code Symptom w hen fuse blows F Fuse 8A (Glass tube fuse 8A-250V) J04502-001 [Err 790] is displayed when the sew ing machine starts. R25 Fuse resistor 1/2W 0.22 Ω J02754-001 Power does not turn on and green LED (1) does not illumin[...]

  • Page 101

    1 1. ELECTRICAL MECHA NISM Z-8550A, 8560A 92 11-4. Description of connectors A large number of problems are often caused by connectors that are not inserted corre ctly or w hich 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[...]

  • Page 102

    1 1. ELECTRICAL MECHA NISM Z-8550A, 8560A 93 Pow er supply P.C. board 0165B[...]

  • Page 103

    1 1. ELECTRICAL MECHA NISM Z-8550A, 8560A 94 11-5. T roubleshooting 11-5-1. T roubleshooting procedure Carry out troubleshooting by follo wing the procedure given below . 1 Checking connectors With the power turned of f, check that a ll connectors are securely inserted w hile referring to “1 1-4. Description of connectors”. 2 Diagnosis flow cha[...]

  • Page 104

    1 1. ELECTRICAL MECHA NISM Z-8550A, 8560A 95 11-5-2. Diagnosis flowchart Description of symbols Switch operation Setting and status Judgment OFF Powe r switch OFF Refer to the corresponding “Problem No.” in “11-5-3. Remedy”. Problem No. xx 0303B[...]

  • Page 105

    1 1. ELECTRICAL MECHA NISM Z-8550A, 8560A 96 0304B[...]

  • Page 106

    1 1. ELECTRICAL MECHA NISM Z-8550A, 8560A 97 11-5-3. Remedy If a problem No. is reached while carrying out the diagnosis steps in “11-5-2. Diagnosis flow chart”, refer to the table for the corresponding number.After identifying the cause in the “C ause” column, carry out the steps in the “Inspection/Remedy/Adjustment” column, and if a m[...]

  • Page 107

    1 1. ELECTRICAL MECHA NISM Z-8550A, 8560A 98 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 machi[...]

  • Page 108

    1 1. ELECTRICAL MECHA NISM Z-8550A, 8560A 99 Problem No. 4, 5, 6, 7 Needle bar does not move to the home position and an error code is displayed when the power sw itch 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[...]

  • Page 109

    1 1. ELECTRICAL MECHA NISM Z-8550A, 8560A 100 Problem No. 11 Error code is displayed w hile sewing machine is operating. Cause Inspection/Remedy/Adjustment Replacement if a malfunction When [Err 710] is displayed w hile sewing machine is operating: Abnormal current detected in sewing machine motor (Replace the part(s) indicated at right.) Power sup[...]

  • Page 110

    1 1. ELECTRICAL MECHA NISM Z-8550A, 8560A 101 11-6. Wiring diagrams 0124B[...]

  • Page 111

    1 1. ELECTRICAL MECHA NISM Z-8550A, 8560A 102 0125B[...]

  • Page 112

    Z-8550A, 8560A 12. TREA DLE UNIT 103 12. TREADLE UNIT 12-1 . Types • T wo 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 <A> Changing the hooking position of the spring (1) inside the treadle uni[...]

  • Page 113

    Z-8550A, 8560A 12. TREA DLE UNIT 104 12-2. Standard setting values SPECIFICATIONS Treadle unit -G Treadle unit -H Operation Automatic presser foot lifting does not occur Automatic pre sser foot lifting occurs Spring position setting No modulation at 1 st step forward or backward (Figure [a] on previous page) Modulation at 1 st step forward and back[...]

  • Page 114

    Z-8550A, 8560A 12. TREA DLE UNIT 105 12-3. Standard settings for treadle depression stroke DANGER Wait at least 5 minutes after turning off the power sw itch and disconnecting the power cord from the w all outlet before opening the cover of the control box. Touching areas where high voltages are present can result in severe injury. Carry out the fo[...]

  • Page 115

    Z-8550A, 8560A 12. TREA DLE UNIT 106 3) Storing the neutral position Press the straight stitch key (2 ) w hile your foot is released from the treadle. “Pdrr x.xxx” will appear in the main display (3). 4) Storing the maximum backw ard depression amount Press the straight stitch key (2) w hile the treadle is at the point of maximum backward depre[...]

  • Page 116

    Z-8550A, 8560A 13. STA NDING OPERATION PEDA L 107 13. ST ANDING OPERA TION PEDAL The CDD foot plug assembly (J04099-001, sold separately) is required. <Related table parts> 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 Sta[...]

  • Page 117

    Z-8550A, 8560A 13. STA NDING OPERATION PEDA L 108 13-2. Connectors <At foot plug> <At pedals> <A> Two-step pedal <B> Variable speed pedal Standing operation pedal No. 9P connector 1 DC+8V 2 High-speed switch 3 Thread trimming switch 4 SOV 5 Spare 6 Low-speed sw itch 7 Presser foot switch 8 Variable speed input 9 Ground NOTE:[...]

  • Page 118

    Z-8550A, 8560A 14. TROUBLESHOOTING 109 14. TROUBLESHOOTING • Please check the following points befor e calling for repairs or service. • If the following remedies do not fix the problem, turn off the power sw itch and consult a qualif ied technician or the place of purchase. DANGER Wait at least 5 minutes after turning off the power sw itch and[...]

  • Page 119

    Z-8550A, 8560A 14. TROUBLESHOOTING 110 Problem Possible cause Page 3 Skipped stitches occur whi l e s ewi n g. • 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. • Is the machine properly threaded? If [...]

  • Page 120

    Z-8550A, 8560A 14. TROUBLESHOOTING 111 Problem Possible cause Page 6 Uneven seam • 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. Instruction manual 70 7 Horizo[...]

  • Page 121

    Z-8550A, 8560A 14. TROUBLESHOOTING 112 Problem Possible cause Page 9 Lower thread is tangled at the sewing start. Spinning of bobbin during thread trimming • Is the bobbin spinning direction correct when the lower thread is being pulled? Set the bobbin so that it turn s in the opposite direction to the rotary hook. • Is there too much thread wo[...]

  • Page 122

    Z-8550A, 8560A 14. TROUBLESHOOTING 113 Problem Possible cause Page 12 Incorrect thread trimming (8560A) (Upper and lower threads are both not being trimmed) • Is the fixed knife or mo vable knife damaged or worn? Replace the fixed knife or the movable knife. • Is the thread trimming timing incorrect? Adjust the rotating direction of the thread [...]

  • Page 123

    Z-8550A, 8560A 15. ERROR CODES 114 15. ERROR CODES DANGER Wait at least 5 minutes after turning off the power sw itch and disconnecting the power cord from the w all 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[...]

  • Page 124

    15. ERROR CODES Z-8550A, 8560A 115 <Communication and memory-related errors> Code Cause and remedy Err 401 Communication error w ith motor CPU was detected w hen t he power w as turned on. Turn off the power sw itch and then turn the power back on again. Err 403 Connection error w ith needle zigzag PMD P.C. board detec ted when pow er was tur[...]

  • Page 125

    Z-8550A, 8560A 15. ERROR CODES 116 <P.C. board-related errors> Code Cause and remedy Err 700 Abnormal rise in pow er supply voltage. Turn o ff the pow er switch and che ck the power supply voltage. Err 701 Abnormal rise in sew ing machine motor power supply vo ltage. Turn off the power, and then check the voltage. Problem with pow er supply P[...]

  • Page 126

    16. SEGMENT DISPLA Y DEFINITION T ABLE Z-8550A, 8560A 117 16. SEGMENT DISPLA Y DEFINITION T ABLE LCD display character list <Additional special symbols> 0169B[...]

  • Page 127

    Z-8550A, 8560A MEMO 118[...]

  • Page 128

    SERVICE MANUAL Z-8550A, 8560 A I5120896B 2006. 12. B (1) Printed in Ja p an[...]