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SERVICE MANUAL MO200
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MODEL : MO200, 5200QDC
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MO200
5200QDC

CONTENTS
SERVICE ACCESS (1) TOP COVER, FACE COVER .................................................... 2
SERVICE ACCESS (2) BASE, BED COVER .................................................................. 3
SERVICE ACCESS (3) BELT COVER ............................................................................ 4
SERVICE ACCESS (4) FRONT COVER ........................................................................ 5
SERVICE ACCESS (5) REAR COVER ........................................................................... 6
PRESSER BAR HEIGHT AND ALIGNMENT .................................................................. 7
NEEDLE DROP POSITION ............................................................................................ 8
NEEDLE TO HOOK TIMING ........................................................................................... 9
NEEDLE BAR HEIGHT ................................................................................................. 10
NEEDLE CLEARANCE TO SHUTTLE........................................................................... 11
BACKLASH (BETWEEN LOWER SHAFT GEAR AND HOOK DRIVE GEAR) ............ 12
FEED DOG HEIGHT ..................................................................................................... 13
ZIGZAG SYNCHRONIZATION ..................................................................................... 14
NEEDLE THREAD TENSION ....................................................................................... 15
STRETCH STITCH FEED BALANCE ........................................................................... 16
REPLACEMENT AND ADJUSTMENT OF THE NEEDLE THREADER PLATE............ 17
ADJUSTING BUTTONHOLE LEVER POSITION ......................................................... 18
CONNECTOR DIAGRAM ............................................................................................. 19
SELF DIAGNOSTIC TESTS .................................................................................. 20 - 23
REPLACING PRINTED CIRCUIT BOARD A AND FUSES ........................................... 24
REPLACING PRINTED CIRCUIT BOARD K AND SLIDE VOLUME ............................ 25
REPLACING PRINTED CIRCUIT BOARD F AND PRINTED CIRCUIT BOARD L ....... 26
REPLACING DC MOTOR AND ADJUSTING MOTOR BELT TENSION ..................... 27
REPLACING MACHINE SOCKET (UNIT) .................................................................... 28
REPLACING THE TRANSFORMER............................................................................. 29
REPLACING THE ZIGZAG WIDTH MOTOR ................................................................ 30
REPLACING THE FEED STITCH MOTOR .................................................................. 31
REPLACING THE NEEDLE PLATE MOTOR ............................................................... 32
PARTS LIST ........................................................................................................... 33 - 55

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MO200
5200QDC
SERVICE ACCESS (1)

TOP COVER

TO REMOVE:
1. Remove the 2 setscrews (A) and setscrew (B), and remove the top cover.
TO INSTALL:
2. Follow the above procedure in reverse.

FACE COVER

TO REMOVE:
1. Remove the 2 setscrews (C) and remove the face cover.
TO INSTALL:
2. Follow the above procedure in reverse.

Setscrew (A)

Top cover

Setscrew (B)

Face cover

Setscrew (C)

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MO200
5200QDC
SERVICE ACCESS (2)

BASE

TO REMOVE:
1. Remove the 4 setscrew (A) and the 2 setscrew (B), remove the base.
TO INSTALL:
2. Place the part C (concave part in the illustration) between the base and the arm boss.
Install the base with the 4 setscrews (A) and the 2 setscrews (B).

BED COVER

TO REMOVE:
1. Set the drop lever to the left and remove the 2 setscrews (D), remove the bed cover.
TO INSTALL:
2. Set the drop lever to the left and install the bed cover.
Secure the bed cover with the 2 setscrews (D).

C part

Base

Setscrew (A)

Setscrew (D) Setscrew (B)

Bed cover

Drop lever

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MO200
5200QDC
SERVICE ACCESS (3)

BELT COVER

TO REMOVE:
1. Remove the setscrew (A), (B), and remove the belt cover.

TO INSTALL:
2. Install the belt cover with the setscrew (A) and (B).

Setscrew (A)

Belt cover

Setscrew (B)

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MO200
5200QDC
SERVICE ACCESS (4)

FRONT COVER

TO REMOVE:
1. Remove the top cover and belt cover (see pages 2 and 6).
2. Loosen the setscrew (A), (B), (C), (D) and (E), remove the setscrew (F).
(Remove setscrews for the lump fixing plate when the setscrew (A) is hard to access.)
3. Disconnect the connector and flexible cable from the board "A", then remove the front cover (disengage

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part G).

TO INSTALL:
2. Follow the above procedure in reverse.

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Setscrew (F)

Setscrew (E)
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Flexible cable
Setscrew (A)
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Part G
Setscrew (D)

Printed circuit board "F"

connector

Setscrew (C)

Setscrew (B)

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MO200
5200QDC
SERVICE ACCESS (5)

REAR COVER

TO REMOVE:
1. Remove the top cover and belt cover (see pages 2 and 6).
2. Loosen the setscrews (A), (B), (C), and (D), then remove the setscrew (E).
* To remove the cover, detach the presser foot lifter section first, with the presser foot lifter in the down
position.

TO INSTALL:
3. Follow the above procedure in reverse.

Setscrew (A)

Setscrew (E)

Setscrew (B)

Rear cover

Setscrew (D)

Setscrew (C)

Presser foot lifter

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MO200
5200QDC
MECHANICAL ADJUSTMENT

PRESSER BAR HEIGHT AND ALIGNMENT

When the presser foot is raised, the clearance between the presser foot and the needle plate should be 5.7-
6.3 mm.
When the presser foot is lowered, the edge of the foot and the feed dog window on the needle plate should
be parallel.

1. Remove the face cover and raise the presser foot.

Loosen the setscrew to adjust the presser foot height (6.0 mm) and the presser foot alignment.
2. Tighten the setscrew firmly.
3. Install the face cover.

Setscrew
Presser bar lifter

[Height of presser foot]

Presser foot
[Presser foot alignment]

Needle plate

6.0 mm
Should be parallel

Feed dog

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MO200
5200QDC
MECHANICAL ADJUSTMENT

NEEDLE DROP POSITION

Set the stitch pattern at " "; the standard needle drop position should be at the center of the needle
plate hole.
When the needle swings in maximum zigzag width " ", the distance between both ends of the needle
hole in the needle plate and the needle should be 0.2 mm or more. If not, adjust as follows.

ADJUSTMENT PROCEDURE:
1. Turn on the power switch, check the needle drop position by setting the stitch pattern at straight " " and
the zigzag width at maximum " ".
2. If the needle drop position is not in the center of the needle plate hole when the straight stitch is selected,
or if the clearance between the needle and edge of the needle plate hole on both side is less than 0.2 mm
when the stitch pattern is set to maximum zigzag width, open the face cover and loosen the setscrew (A),
then adjust the needle drop position by turning the eccentric pin.

NOTE:
Make sure the eccentric pin is positioned with its off-center head facing downward.
3. When you have finished adjusting the needle drop position, tighten the setscrew.

Setscrew (A)
Eccentric pin

Needle plate hole

Eccentric pin position

(Off -center head)

0.2 mm or more 0.2 mm or more

Adjust the needle drop position by turning the
eccentric pin as shown
A=B

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MO200
5200QDC
MECHANICAL ADJUSTMENT

NEEDLE TO HOOK TIMING

When the machine is set the straight stitch pattern " " (left needle position), the amount of ascending
travel of the needle bar from its lowest position to the position where the tip of the hook meets the right side
of the needle should be 3.5 - 3.75 mm.

1. Remove the needle plate and bobbin holder.

2. Turn on the power switch, set the straight stitch pattern " " (left needle position).
3. Remove the bed cover (see page 3).
4. Turn the handwheel toward you, and set the needle bar at the lowest position.
5. Loosen the 2 setscrews on the lower shaft gear.
6. Raise the needle bar 3.6 mm from the lowest position of the needle bar.
7. Turn the lower shaft timing gear until the tip of hook meets with the right side of needle.
8. Tighten the 2 setscrews on the lower shaft gear.
9. Attach the bed cover, bobbin holder and needle plate.

Needle plate

2 setscrews
Bobbin holder

Lower shaft gear

Match the tip of hook at

the right side of needle

Needle #14

3.5-3.75 mm

Lower needle position

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MO200
5200QDC
MECHANICAL ADJUSTMENT

NEEDLE BAR HEIGHT

The distance between the upper edge of needle eye and the tip of the hook should be in the range of 1.4-
1.75 mm when the tip of hook meets the right side of the needle in ascending travel of needle from its left
and lowest position.

1. Remove the needle plate and bobbin holder.

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2. Turn on the power switch.
3. Select the pattern " " (left needle position).
4. Turn the handwheel toward you until the tip of hook meets the right side of the needle.
5. Loosen the setscrew (A).

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6. Adjust the height of the needle bar by moving the needle bar upward or downward without turning it.
(Make sure that the needle setting groove of the needle bar is in the front).
7. Tighten the setscrew (A).
8. Insert the bobbin holder, then attach the needle plate.
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Needle plate
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Setscrew (A)

Bobbin holder
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Needle setting groove

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Tip of hook meets right side of needle

Needle #14 Hook race

1.4-1.75 mm

Hook race unit Upper edge of needle eye

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MO200
5200QDC
MECHANICAL ADJUSTMENT

NEEDLE CLEARANCE TO SHUTTLE

The clearance between the needle and the tip of hook should be -0.1 to +0.05 mm.

PREPARATION:
1. Remove the needle plate, bobbin holder, and bed cover (see page 3), and replace the needle with the test pin.
2. Turn the power switch on, and select pattern " " (simple zigzag). (Maximum zigzag width)

ADJUSTMENT PROCEDURE:
1. Loosen the screws (A), (B), (C), then slightly tighten the hinge screw (C).
2. Turn the handwheel toward you, and adjust the clearance between test pin and the point of the hook in
the left and right needle position to –0.1 to +0.05 mm by moving the hook set plate up or down.
3. Tighten the setscrews (A), (B), (C).
4. Check the backlash of the hook drive gear and lower shaft gear. If the backlash is too great or not enough,
adjust the backlash in accordance with "to adjust the backlash of hook drive gear and lower shaft gear".
5. Attach the bed cover, needle plate and bobbin holder, and remove the master needle.

Needle plate

Bobbin holder

Test pin

Point of hook
–0.1 to +0.05 mm

Hinge screw (C)

Hook set plate

Setscrew (B)
Setscrew (A)

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MO200
5200QDC
MECHANICAL ADJUSTMENT

BACKLASH (BETWEEN LOWER SHAFT GEAR AND HOOK DRIVE GEAR)

Jog the hook race back and forth to check rotary play.
The standard play should be 0.8 mm (0.03") or less when the hook point is within the feed dog width. If play
exceeds 0.8 mm, adjust as follows.

ADJUSTMENT:
1. Remove the bed cover (see page 3).
2. Loosen the setscrew.
3. Turn the lower shaft bushing (eccentric bushing) clockwise (B) if there is too much play in the hook.
Turn the lower shaft bushing (eccentric bushing) counterclockwise (A) if there is too little play in the
hook.
4. Tighten the setscrew securely after adjustment and install the bed cover.
NOTE:
After adjusting the backlash, be sure to check the needle to hook timing and the feed dog height.

Backlash allowance

Point of shuttle hook

Check the backlash

Groove

Setscrew

Shuttle hook gear

Lower shaft gear Groove on the lower shaft bushing

B A

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MO200
5200QDC
MECHANICAL ADJUSTMENT

FEED DOG HEIGHT

The highest position of the feed dog should be between 0.8 to 0.9 mm from the surface of the needle plate
when the pressure foot pressure adjusting lever is set at "3" and the presser foot is raised.

1. Set the pressure foot pressure adjusting lever at "3" and lower the presser foot.
2. Turn on the power switch.
3. Remove the bed cover (see page 3).
4. Turn the handwheel toward you to set the feed dog at the highest position.
5. Loosen the setscrew (A) and nut (B).
6. Adjust the feed dog height by turning the adjusting screw (C).
7. Tighten the nut (B) and setscrew (A).

Presser foot
0.80-0.90 mm

Presser foot pressure

adjusting lever
Feed dog Surface of the
needle plate

E (to raise)

Setscrew (A) D (to lower)

Nut (B)
Adjusting screw (C)

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MO200
5200QDC
MECHANICAL ADJUSTMENT

ZIGZAG SYNCHRONIZATION

The needle should start swing 8.2 mm above the surface of the needle plate when the machine is set for
zigzag stitching.

1. Remove the front cover (refer to page 7).

2. Turn on the power switch, select the pattern no. 2 and set the machine at the maximum zigzag width.
3. Turn the handwheel toward you slowly with your hand until the needle start to sewing. Loosen the
setscrew and turn the upper shaft shield plate in the direction of;
* A. If the swing point is higher than 8.2 mm.
* B. If the swing point is lower than 8.2 mm.
4. Position the upper shaft shield plate as close as possible to the left.
(It should not touch the upper shaft sensor).
5. Check the swing point by turning the handwheel, then tighten the setscrew.
6. Attach the front cover.

Needle #14

Surface of needle plate

8.2 mm

Upper shaft shield plate

Setscrew

Upper shaft sensor

A

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MO200
5200QDC
MECHANICAL ADJUSTMENT

NEEDLE THREAD TENSION

The standard tension should be 80 to 95 grams when the tension dial is set at "A" (auto), measured with
a #50 white polyester thread being pulled at approximately 110 mm/sec.
If the tension is outside the standard range, adjust as follows:

ADJUSTMENT:

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1. Set the thread tension dial to "A" and check the thread tension.
2. Remove the face cover (see page 4).
3. If the tension is outside the standard range, turn the dial to find a position where the correct tension is
obtained.

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4. Insert a screwdriver into the slit on the shaft and push it until the tension dial is disengaged from the shaft.
5. While holding the shaft in place with the screwdriver, turn the dial back to position "A" and engage it
with the shaft.
6. Remove the screwdriver.
7. Check the thread tension to confirm that it is correct, then install the face cover.
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Shaft
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Pull the thread at a speed of approx. 110 mm/sec.

In the direction of arrow.
Set the thread tension dial at "A"
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Thread (polyester sewing

thread (#50 white))
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MO200
5200QDC
MECHANICAL ADJUSTMENT

STRETCH STITCH FEED BALANCE

When the number 8 is sewn 5 times with the feed balancing dial at the standard setting mark, the measurement
should be between 35.7 and 36.3 mm as shown.

ADJUSTMENT PROCEDURE:
1. Turn the power switch on while pressing the reverse button & auto-lock button.
Press the 8 button. (The standard mode shows up if you do not press the 8 button within 3 seconds.)

▲
2. Set the feed balancing dial at standard setting mark .
3. Sew 8 of number 8 and check if the measurement of five of them is between 37.7 and 36.3 mm.
4. Remove the cap and setscrew (A).
5. When the pattern is expanded, turn the adjusting screw counterclockwise "C".
When the pattern is blocked, turn the adjusting screw clockwise "D".
6. Attach the cap.

1. Turn the power switch on 2. Press the 8 button.

while pressing the reverse (The standard mode shows up if you do
button & auto-lock button. not press the 8 button within 3 seconds.)

Standard setting
mark

Feed balancing dial

35mm Setscrew Cap

C D Setscrew (A)

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MO200
5200QDC
MECHANICAL ADJUSTMENT

REPLACEMENT AND ADJUSTMENT OF THE NEEDLE THREADER PLATE

If the hook of the threader plate is damaged, change and adjust the part as follows:

TO CHANGE THE THREADER PLATE:

TO REMOVE:
1. Push down the needle threader knob and pull the threader plate supporter (A) down to remove it (see
FIG 1).
2. To install the needle threader plate, line the groove up with the pin (B) and push it up to snap fit.

TO ADJUST THE THREADER PLATE POSITION:

1. If the hook on the threader plate touches the left or right side of the needle hole, loosen setscrew (C) and
adjust the hook position (FIG 2).
2. If the hook on the threader plate touches the top or bottom side of the needle hole, loosen setscrew (D)
and adjust the hook position (FIG.3)

Replacing the needle threader cover

(with the threader plate attached
FIG. 1

Pin (B) Vertical adjustment

FIG. 3
Threader plate
supporter (A)

Setscrew (D)
Adjustment of left or right direction
FIG. 2

Threader plate View from "X"

Setscrew (C)
Nut

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MO200
5200QDC
ADJUSTING BUTTONHOLE LEVER POSITION

TO ADJUST THE BUTTONHOLE LEVER GUIDE:

1. Enter adjusting mode, by turning the power switch on while pressing the "Reverse" and "Auto-lock"
buttons. Press the #4 key within 3 seconds. The LCD screen shows "BH sensor [H] or [L]".
2. Open the face cover and loosen setscrew (A).
3. Lower the buttonhole lever. Position the buttonhole lever guide so the screen displays "L".
Tighten setscrew (A).

TO ADJUST THE BUTTONHOLE SENSOR POSITION:

4. Attach the buttonhole foot (R).
5. Lower the buttonhole lever to its lowest position, and insert a 1.6 mm thickness gauge into the button-
hole foot.
6. Turn the adjusting screw to the left until the screen display changes from "L" to "H".
7. Then, turn the adjusting screw to the right until the screen display changes from "H" to "L".
8. Check if the LCD screen shows "H" when the 1.4 mm thickness gauge is inserted and "L" when the
1.8 mm thickness gauge is inserted.
9. Turn off the power switch.

NOTE
If there is any lint in the buttonhole sensor slit, remove the setscrew (B), clean out with a swab.

LCD screen shows

1. Turn the power switch on while 2. Press the 4 button. (The standard mode
pressing the reverse button & shows up if you do not press the 4
auto-lock button. button within 3 seconds.)

Setscrew (B)
Buttonhole
lever guide
Buttonhole sensor

Setscrew (A) Adjusting screw

BH lever

Clearance
1.6 mm

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MO200
5200QDC

CONNECTOR DIAGRAM
REFER TO THE DIAGRAM FOR LOCATING THE CONNECTOR POST ON THE CIRCUIT
BOARD
A : Buttonhole sensor (BLK) J : Bobbin winder switch (BLU)
B : Sewing light (WHT) K : Presser foot lifter switch (BLK)
C : Upper shaft sensor (BLK) L : Thread tension switch (BLU)
D : Feed motor (BLK) M: Arm lamp (RED)
E : Zigzag width motor (WHT) N: Needle plate switch (RED)
F : DC motor (WHT) O: Needle plate motor (WHT)
G: Power transformer (primary circuit) (BLK) P: Machine plug (secondary circuit) (WHT)
H : Power transformer (secondary circuit) (RED) Q: Printed circuit board “G2” (RED)
I : Printed circuit board “F” (BLK) R: Receptacle (primary) (WHT)

K
J

L M

A Q
C
G
H
O
N

B F
E
J C I R
D
M
K P
Q Flexible cable
B
A N
L P
Flexible cable E
O Printed circuit board "F"
D
H F

G R

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MO200
5200QDC

SELF DIAGNOSTIC TESTS

PREPARATION:
• Turn off the power switch.
• Shift the bobbin winder spindle to the left.
• Raise the feed dog.
• Shift the speed control lever to the left.
• Remove the presser foot and raise the presser foot lifter.
• Turn the handwheel toward you to raise the needle to its highest position.

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• Plug the foot control to the machine.

NOTE:
• Be careful: The sewing machine may start running by its own while in test mode.

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• Turn off the power switch before replacing any parts.
• Repeat the diagnostic test until the problems has been resolved.

Turn on the power switch. If any of following problems occur, take the recommended actions in the order
they are shown.
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• THE MACHINE DOES NOT RESPOND WHEN THE POWER SWITCH IS TURNED ON.
1. Check each connector connection.
2. Replace the machine socket.
3. Replace the printed circuit board "A".
4. Replace the power supply cord.
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5. Replace the power transformer.

• THE SEWING MACHINE LIGHT DOES NOT LIGHT UP.

1. Replace the lamp.
2. Replace the circuit board "A".
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• THE LCD SCREEN DOES NOT DISPLAY.

1. Replace the printed circuit board "A".
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SPECIAL MODE LIST DISPLAY

1. Turn the power switch on 2. Press the 1 button.
while pressing the reverse (The standard mode shows
button & auto-lock button. up if you do not press the 1
button within 3 seconds.)

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MO200
5200QDC

SELF DIAGNOSTIC TESTS

DEFECTIVE RESULTS /
TESTS CORRECT RESULTS REPLACEMENT AND
ADJUSTMENT
1) Turn the power switch on while • The display shows "Self check start". DEFECTIVE RESULTS:
LCD & LED pressing the reverse button & LCD and led blinks. • Does not enter the self-
auto-lock button. Then press the • Beeps when enter the LCD & LED diagnostic mode.
01 button within 3 seconds to check mode.
enter the self-diagnostic mode. REPLACE:
• Replace the touch panel.
• Replace the board A.

Press CLR button to proceed to the next

step.

2) Press the keys in order as The display shows "Key" and the DEFECTIVE RESULTS:
KEYS described below. machine beeps. • Does not display the name of button
1 Reverse stitch button or does not beep when buttons are
2 Auto-lock button • Beeps when enter the key check mode. pressed.
3 Up/down needle position button • Beeps when buttons or keys are
4 Mode key pressed. REPLACE:
5 Stitch width key "+" • The display shows the name of pressed • Replace the touch panel.
6 Stitch width key "–" button or key. • Replace the board A, board F and
7 Stitch length key "+" board K.
8 Stitch length key "–"
Press the rest of keys in order from
left to right, starting from the
highest column to the lowest
column.

Press CLR button to proceed to the next

step.

3) The display shows "Switch" and the DEFECTIVE RESULTS:

BOBBIN Move the bobbin winder to the machine beeps. • The value does not change.
WINDER right. • The value does not match with the
SPINDLE Move the bobbin winder to the left. • When bobbin winder is move to the correct results.
right, the display shows [SP:ON].
• When bobbin winder is move to the left, REPLACE:
the display shows [SP:OFF].
• Adjust the sensing switch.
• Replace the sensing switch.
• Replace the board A.
PRESSER FOOT Raise the presser foot lifter. • When presser foot lifter is raised the
LIFTER Lower the presser foot lifter. display shows [FL:UP].
• When presser foot lifter is lowered the
display shows [FL:DOWN].

NEEDLE Turn the needle thread tension • When needle thread tension dial is set
THREAD dial. at "A" (auto), the display shows
TENSION DIAL [TD:ON].
• When needle thread tension dial is rest
of set at "A" (auto), the display shows
[TD:OFF].

Press CLR button to proceed to the next

step.

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MO200
5200QDC

SELF DIAGNOSTIC TESTS

DEFECTIVE RESULTS /
TESTS CORRECT RESULTS REPLACEMENT AND
ADJUSTMENT
4) The display shows "Sensor" and the DEFECTIVE RESULTS:
BUTTONHOLE Lower the buttonhole lever. machine beeps. • The display does not change or
SENSOR Pull, and push the buttonhole lever, show the correct results.
then check the display. • When the buttonhole lever is pulled, the
screen displays "BH:H". REPLACE OR ADJUST:
• When the buttonhole lever is positioned • Adjust the position of the shield
in center, the screen displays "BH:L". plate.
• When the buttonhole lever is pushed, • Adjust the position of the
the screen displays "BH:H". photosensor.
• Replace the photosensor.
NEEDLE PLATE "Twin needle button" is pushed, Each time the twin needle button is • Replace the board A.
SENSOR then check the display. presses, the screen displays
NP1:ON NP2:ON or OFF NP1:ON
NP3:OFF NP4:OFF NP1:ON
in order.
UPPER-SHAFT Turn the handwhell toward you to • When needle is in the highest position,
SENSOR move the needle from highest to the screen displays "Bsen:H, Fsen:L".
the lowest position. • When needle is in the lowest position,
Check the screen. the screen displays "Bsen:L, Fsen:H".

Each time the stock call button is

pressed, the screen displays
M:ON MR:OFF ML:OFF M:ON
in order.

Press CLR button to proceed to the next

step.

5) Turn the handwheel clockwise one The display shows "Velocity Seneor" and DEFECTIVE RESULTS:
VELOCITY complete turn. the machine beeps. • The value does not change.
SENSOR • The value should be 370 to 376 when
(DC MOTOR) the handwheel is rotated once. REPLACE:
• Cleaning of velocity sensor slit.
• Adjust the velocity sensor.
• Replace the DC motor.
• Replace the board A.

Press CLR button to proceed to the next

step.

6) Set the speed control to the The display shows "Volume" and the DEFECTIVE RESULTS:
SLIDE VOLUME leftmost position. machine beeps. • The value does not change.
Then slide the speed control lever • When the speed control lever is at left, • The value does not match with
from left to right, then return to left. the screen displays "000" to "010". the correct results.
• When the speed control lever is at right,
the screen displays "255" to "250". REPLACE:
• Adjust the slide volume.
• Replace the DC motor.
• Replace the board A and board K.

Press CLR button to proceed to the next

step.

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MO200
5200QDC

SELF DIAGNOSTIC TESTS

DEFECTIVE RESULTS /
TESTS CORRECT RESULTS REPLACEMENT AND
ADJUSTMENT
7) Depress the foot control fully, then The display shows "Foot Controller" and DEFECTIVE RESULTS:
FOOT CONTROL release the foot control. the machine beeps. • The value does not change.
• When the foot control is not depressed, • The value decreases when the foot
the screen should display "000" to "016". control is de pressed.
• When the foot control is depressed fully,
the screen should display "208" to "250". REPLACE:
• When the plug is removed, the screen • Replace the foot control.
should display "251" to "255". • Replace the machine socket.
• Replace the board A.

Press CLR button to proceed to the next

step.

8) The display shows "Stepping Motor" and DEFECTIVE RESULTS:

STEPPING 1. When the memory key is the machine beeps. 1. The display shows [E1 error]
MOTOR pressed with the needle bar at 2. The display shows [E3 error]
“UP” position, the needle bar 3. The display shows [E2 error]
vibrates and the needle drop is
set at center position. REPLACE:
• Check the stepping motors if they
rotate smoothly.
• Replace the stepping motor.
• Replace the board A.

2. When the memory key is

pressed with the needle bar at
“middle” position, the needle
plate is set at straight stitch
position.

3. When the memory key is

pressed with the needle bar at
“down” position, the feed dog
vibrates and the feed dog is in
the middle of its travel.

Press CLR button to proceed to the next

step.

9) The display shows "Sewing Motor" and DEFECTIVE RESULTS:

DC MOTOR Depress the foot control to check the machine beeps and runs. The display shows "error".
the sewing speed. • When slide volume is move to the left,
the machine runs at the lowest speed REPLACE:
(70 to 90spm). • Check the motor belt tension.
• When slide volume is move to the right, • Replace the motor.
the machine runs at the highest speed • Replace the board A.
(800 to 840spm).

* Press the CLR button to return to "step 1". End the self diagnostic tests.

23
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MO200
5200QDC
REPLACING PRINTED CIRCUIT BOARD A AND FUSES

REPLACING PRINTED CIRCUIT BOARD "A"

TO REMOVE:
1. Remove the front cover (see page 5).
2. Unplug the connectors from the printed circuit board "A".
3. Remove the 3 setscrews and remove printed circuit board "A".
TO INSTALL:
4. To install, follow the above procedure in reverse.

REPLACING THE FUSES

TO REMOVE:
5. Remove the printed circuit board "A".
6. Remove the 4 setscrews and remove the printed circuit board "A" case and case lid.
7. Remove the fuse (pry it out with a screwdriver).
TO INSTALL:
8. Follow the above procedure in reverse.

F1:
AC125V 3.15A
Setscrews (B)

F2:
AC125V 2.5A

Setscrews (A)

Printed circuit
Printed circuit
board "A" case lid
F3: board "A" case
Printed circuit AC125V 2.5A
board "A"

Fuse

Fuse holder

Setscrews (A)

24
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MO200
5200QDC
REPLACING PRINTED CIRCUIT BOARD K
AND SLIDE VOLUME
REPLACING PRINTED CIRCUIT BOARD "K"
TO REMOVE:
1. Remove the front cover unit (see page 5).
2. Unplug the printed circuit board "L" connector and slide volume connector.
3. Remove the 9 setscrews and remove the printed circuit board "K".
TO INSTALL:
4. To install the printed circuit board "K", follow the above procedure in reverse.

m
REPLACING THE SLIDE VOLUME
TO REMOVE:
5. Unplug the slide volume connector from printed circuit board "K".

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6. Remove the 2 CS-3 rings and remove the side volume.
TO INSTALL:
7. To install the slide volume, follow the above procedure in reverse.
es
Printed circuit board "K" Printed circuit board "L" connector
Setscrews (A)
uid

Setscrews (A)
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Setscrews (A)
all

Slide volume connector

CS-3 rings (2) Slide volume control

25
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MO200
5200QDC
REPLACING PRINTED CIRCUIT BOARD F
AND PRINTED CIRCUIT BOARD L
REPLACING PRINTED CIRCUIT BOARD "F"
TO REMOVE:
1. Remove the front cover unit (see page 5).
2. Unplug the printed circuit board "F" connector and remove the cs ring.
3. Remove the two setscrews (A) and remove the printed circuit board "F".
TO INSTALL:
4. To install the printed circuit board "F". Follow the above procedure in reverse.
* Each button (needle up/down button, start/stop button, reverse button) should "Click" when pressed.

REPLACING PRINTED CIRCUIT BOARD "L"

TO REMOVE:
5. Unplug the printed circuit board "L" connector from printed circuit board "F".
6. Remove the setscrew (B) and remove the printed circuit board "L".
TO INSTALL:
7. To install the printed circuit board "L". Follow the above procedure in reverse.

Printed circuit board "L"

Printed circuit board "K" connector Setscrew (B)

Printed circuit
board "L"

Setscrews (A)

Printed circuit board "F"

26
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MO200
5200QDC
REPLACING DC MOTOR AND ADJUSTING
MOTOR BELT TENSION
TO REMOVE:
1. Remove the belt cover (see page 4).
2. Unplug the DC motor connector.
3. Remove the two setscrews, then remove the DC motor and belt.

TO INSTALL:
4. Lightly tighten the two screws.
5. Put the motor belt on the pulley and adjust the belt deflection to about 7 to 9 mm by pressing the middle
of the motor belt with your finger (with approximately 300 grams of pressure). Then, tighten the screws
firmly.
6. Install the belt cover.

Belt
DC motor connector

Pressure 300g

Belt deflection:
7~9 mm

DC motor

Setscrews (2)

27
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MO200
5200QDC
REPLACING MACHINE SOCKET (UNIT)

REPLACING THE MACHINE SOCKET

TO REMOVE:
1. Remove the front and rear cover (see page 5 and 6).
2. Remove the two screws and remove the machine socket.

TO INSTALL:
3. To install the machine socket, follow the above procedure in reverse.

NOTE
Pull out the cord in front of the arm to prevent it from contacting with the lower shaft or other moving parts,
and secure it to the feed motor cord with a binder.

Setscrew

Setscrew
Machine socket (unit)

28
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MO200
5200QDC
REPLACING THE TRANSFORMER

REPLACING THE TRANSFORMER

TO REMOVE:
1. Remove the board "A" (see page 24).
2. Remove the two setscrews and remove the transformer.

TO INSTALL:
3. To install the transformer, follow the above procedure in reverse.

NOTE
Place the rear end of the transformer on the transformer support.
Slide the two transformer wire tubes to the side of transformer and secure them to the zigzag stepping
motor wire so they will not come in contact with any moving parts.

Transformer

Transformer support

Transformer

Setscrew

Setscrew

29
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MO200
5200QDC
REPLACING THE ZIGZAG WIDTH MOTOR

REPLACING THE ZIGZAG WIDTH MOTOR

TO REMOVE:
1. Remove the board "A" (see page 24).
2. Remove the two zigzag rod setscrews (A). Disconnect the connector from the board "A".
3. Remove the two setscrews (B) and remove the zigzag width motor.

m
TO INSTALL:
4. To install the zigzag width motor, follow the above procedure in reverse.

NOTE

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1. The setscrew of zigzag rod should be tightened to 5~7 kg of torque.
2. Check to ensure that the upper shaft sensor mounted on the zigzag width motor does not interfere
with the upper shaft shield plate.
3. Adjust the needle drop position (see page 8).
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uid

Setscrew (B)
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Setscrew (B)
all

Zigzag rod setscrew (A)

Setscrew (B)

Zigzag width motor

Setscrew (B)

30
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MO200
5200QDC
REPLACING THE FEED STITCH MOTOR

REPLACING THE FEED MOTOR

TO REMOVE:
1. Remove the base cover (see page 3).
2. Remove the front cover (see page 5).
3. Disconnect the connector from the board "A".
4. Remove the snap ring (E-3).
5. Remove the two setscrews (A), (B) and remove the feed motor.

TO INSTALL:
6. To install the feed motor, follow the above procedure in reverse.

NOTE
Adjust the stretch stitch pattern feed balance (see page 16).

Setscrew (A) Setscrew (B)

Feed motor (unit)

Snap ring (E-3)

31
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MO200
5200QDC
REPLACING THE NEEDLE PLATE MOTOR

REPLACING THE NEEDLE PLATE MOTOR

TO REMOVE:
1. Remove the base cover (see page 3).
2. Remove the front cover (see page 5).
3. Disconnect the connector from the board "A".
4. Remove the two setscrews (A) and remove the needle plate motor.

TO INSTALL:
5. To install the needle plate motor, follow the above procedure in reverse.

NOTE
Check if the sub needle plate is closed when pattern #1 is selected, and the sub needle plate is open
when pattern #4 is selected.

Setscrew (A)

Micro switch

Switch set plate

Setscrew (A) Setscrew (B)

Needle plate motor

32