Singer 5400 Series User manual

Service Manual
Sewing Machine
5400 Series5400 Series
THE SINGER COMPANY
2000 SINGER DO BRASIL
ALL RIGHTS RESERVED
Registered Trademark “THE SINGER COMPANY LTD.” Printed In Brazil
357773-002 MAY/00

5400 Series - REVISION RECORD
Rev. Description Approval
and date
MAY/00
Rev. n .
o
Service Manual
P/N 357773-00201

Service Manual
02
This manual is designed for use by trained and qualified service
persons.
THE SINGER COMPANY will not be responsible for any parts
requiring replacement owing to natural wear or to abuse or negligence
of the use or in the event the machine is serviced by other than a
trained and qualified service person, or if parts are substituted which
do not meet applicable specifications.
P/N 357773-002
MAY/00
Rev. n .
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Scope
Machine Description
Tool requirements
"Duratec" Casting
This service manual describes all of the servicing procedures,including all adjustments and parts removal
and replacement for the series 5400 machines. Supplementary information covering any production
changes, improvements or changes to parts will be made by issuing Singer service/parts bulletins.
Tubular bed
Lightweight "Duratec" casting.
Apollo sewing system.
Electronic triac foot speed controller.
New "FT" fabric feed system.
Vertical needle profile.
Motor concealed in arm.
Horizontal spool pin.
Touch and wind declutching hand wheel.
Bobbin capacity of 4 meters (45 yds) minimum.
Universal presser bar pressure control.
Maximum stitch lenght 5 mm (5 s.p.i.).
Self-threading take-up lever.
Push button instant reverse.
One-way needle insertion.
Direct pattern selection.
Bed length 378 mm. ( 4.88 inches) without cloth plate.
Bed width 85 mm. (7.28 inches).
Bed height 83 mm. (3.2 inches).
Clearance under free arm 25,4 mm. ( .0 inch).
Free arm circunference 264 mm. ( 0.39 inches).
Overall height 300 mm. ( .8 inches).
Weight 9 kg. ( 9 lbs).
For servicing the series 5400, the following tools are required:
/8" screwdriver
3/ 6" screwdriver
" screwdriver
Sharp nose screwdriver
Philips screwdriver
8 mm. open end wrench
0 mm. open end wrench
Pliers
Wire-cutter pliers
Feeler gauge GM8092
Feeler gauge set.
With the introduction of "Duratec", selfthreading screws have been used to mount many of the parts and
assemblies to the structure. If is important that when replacing these screws, they be threaded into the
original screw threads. The proper procedure for doing this is to insert the screw into the hole and turn the
screw counterclockwise until the screw can be felt to "drop" in place. An audible "click" may also be heard.
Once the screw is properly in place, it may then be tightened.
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General Information
P/N 357773-002
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Service Manual

lParts removals and replacements....................................................................................
Face plate.......................................................
Light bulb replacement................................. .........
Bottom bed cover................................................ .
Rear cover..................................................... ..
Front cover................................................. .....
Needle bar................................................ .......
Head end assembly................................. .........
Take-up lever assembly and needle bar connecting link.................................................
Hand wheel..................................................... ..
Hand wheel disassembly..................................................................................................
Camstack.........................................................................................................................
Arm shaft and horizontal bevel gear................................................................................
Tension assembly....................................... ...
Needle bar driving arm - needle bar driving arm tension spring...................................
Cam controlled feed mechanism....................... .......
Motor and motor belt..................................... ........
Hook....................................................... ......
Feed lifting lever assembly..................................... .
Feed rock shaft assembly........................................ .
Feed forked connection......................................... ..
Vertical shaft bevel gear................................... .....
Vertical shaft...................................................
Pattern selector mechanism............................. .............
Needle position lever..........................................
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Stitch lenght and buttonhole control assembly ............................................................
Table of contents
Section I
04
06
07-08
07-08
09-10
11-12
13-14
15-16
17-18
19-20
21-22
21-22
23-24
25-26
27-28
29-30
31-32
33-34
35-36
37-38
39-40
41-42
43-44
45-46
47-48
49-50
51-52
P/N 357773-002
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Service Manual

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Bobbin case position finger..............................................................................................
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Notes.............................................................................................................................
Sequential order of adjustment procedures....................... .
Vertical shaft end play..........................................
Bevel gear mesh and arm shaft end play.......
Disc and disc follower end play..................................
Camstack radial play.............................................
Take-up lever and needle bar connecting link lost motion.. .......
Needle bar bearings........................................... ...
Needle bar height.............................................. ..
Needle bar pendulum timing (timing the camstack).................
Zig-zag centralizing procedure............................. ......
Centralizing left-center-right needle position...................
Needle location in the needle place slot.....
Needle to hook relationship......................................
Zig-zag bight stop in the straight stitch position......... ......
Maximum width zig-zag bight stop............... ...............
Needle bar safety bight stop ..........................................
Alignment of knobs with panel graphics..........................................................................
Presser bar height and alignment.................................
Hook drive belt tension and hook brive belt retainer bracket....
Hook timing (hook and needle synchronism).............................
Bobbin case position bracket and plate...........................
Bobbin case clearance..........................................
Needle Thread tension.............................................
Bobbin winder....................................................
Feed rock shaft end play.........................................
Feed dog centralization...................... ....................
Feed dog height..............................................
Feed dog throw............................................. ..........
Stitch lenght regulator spring tension................ ...........
Motor belt tension......................................... ......
Lubrication.......................................... ...................
Flexi feed zeroing......................................... ......
Zero feed...................................................... ..
Buttonhole cutting space................................... ......
05
Section II
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54-55
56-57
58-59
58-59
60-61
62-63
64-65
66-67
68-69
70-71
72-73
74-75
76-77
78-79
80-81
82-83
84-85
86-87
88-89
90-91
90-91
92-93
94-95
96-97
98-99
100-101
100-101
102-103
104-105
106-107
108 to111
112-113
114-115
116-117
118 to 120
Service Manual

06
Section I
Parts removal and
replacement
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Service Manual
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B
A
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08
Removal:
Replacement:
Removal:
Replacement:
1
1
1
1
- Raise presser foot.
2- Remove face plate screw (A).
3- Remove face plate (B) by grasping it around the bottom edge and pulling toward the left, then down
and away from the machine.
Replacement is the same as removal in reverse order. Be sure the presser foot is in the raised
position.
Turn the machine off and remove plug from outlet
Remove face plate.
2- Push bulb (C) up into the socket and turn it in a clockwise direction to unlock bulb pins.
3- Pull bulb (C) down out of socket.
Push bulb (C) up into socket and turn in a counterclockwise direction until bulb pins lock into
position.
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-
-.
Face Plate
Light Bulb Replacement
Service Manual
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09
Service Manual
B
A
C
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10
Removal:
Replacement:
1
1
-
-
-
-
Remove three bottom bed cover screws (A).
2 Remove 8 mm hex nut (B).
3 Remove bottom bed cover (C).
Replacement is the same as removal in reverse order.
Service Manual
Bottom Bed Cover
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Service Manual
B
B
A
C
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12
Removal:
Replacement:
1
1
-
-
Raise carrying handle and remove the free-arm extension table.
2- Remove the bottom bed cover located under the machine.
3- Loose screws (A) and screw ( C ) by turning them twice.
4- Remove the 6 screws (B)
5- Turn on the machine
6- Remove the cover from needle plate area first, for there are tips in this area connecting the front
cover.
7- Remove the cover by pulling it straigh upwards.
Replacement is the same as removal in reverse Order.
Make sure the covers (rear and front) are correctly connected, specially in the needle plate area
tips.
Note:
Rear Cover
Service Manual
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Service Manual
0•
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•
•
•
•
1
2
3
4
5
1
2
3
4
A
B
D
E
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14
Removal:
Replacement
1
1
-
-
Remove the free-arm extension table, face plate, bottom bed cover and rear cover.
2- Position the tension assembly dial (A) to "0" and remove it by pulling straight frontwards. Use same
procedure to remove the two seletor knobs (B).
3- Loose the two screws (C ) and screw (D). (Turn them 3 times)
4- Turn the machine down placing the front cover upwards.
5- Loose the two screws (E). Turn them twice.
6- Remove the front cover by pulling it up. In the tension assembly area there is a pression tip. Pull the
cover first in this area. This will make disconnection easier.
Replacement is the same as removal in reverse order.
Replace the cover by compelling it enough to make the screw groove end (E), (D) and (C ) lean against
the screw diameter. Make sure the cover is completely joined and leaned, specially in the tension
assembly area.
Note:
Service Manual
Front Cover
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Service Manual
A
C
B
D
E
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Removal:
Replacement:
1
1
-
-
Remove tension assembly dial, the knobs of the zig-zag and needle position levers and all covers
(face plate, rear, bottom bed and front)
2- Remove needle by loosing the screw (B) with thread guide, and needle bar gib (C).
3- Loosen needle bar clamping screw (D).
4- Draw needle bar (E) up and out of the machine.
Replacement is the same as removal in reverse order.
2- Then, adjust needle bar height.
Needle Bar
Service Manual
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17
Service Manual
A
J
I
K
G
F
E
D
C
H
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Service Manual
18
Removal:
Replacement:
1
1
- Remove the free arm extension table, tension assembly dial, the knobs of the zig-zag and
needle position levers, all covers (face plate, rear, bottom bed and front) and needle.
6- Remove three screws and washers (C), (F) and ( J ) .
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2- Loosen screw (A).
3- Remove presser foot (D) and presser foot screw (E).
4- Remove screw (H), light socket (G) and light shield(I).
5- Raise presser bar.
7- Remove head end assembly.
Replacement is the same as removal in reverse order. Make sure that light harness is located in
wire guard as illustrated in (K) or interference may occur bettween the harness and the needle
bar drive lever.
2- Adjust needle location in the needle plate slot and needle to hook relationship. (See pages 72 to 75)
3- Check hook timing needle bar height and presser bar height and adjust if necessary. (See pages 64-
65 and 88-89)
4- Adjust presser bar alignment and height. (See pages 84-85)
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Head End Assembly
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Service Manual
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C
B
D
A
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