Brother BAS-320 Service Manual

Electronically Programmable lockstitch Machine

with

Cylinder Arm Profile Sll

Service manual

CONTENTS

1.

MECHANISM

4.

STANDARD

ADJUSTMENTS

Needle bar, thread take-up, lower shaft,

D

m

11

m

m m

fJ

m m

2. DISASSEMBLY PROCEDURES

shu~tle

and Work clamp mechanism (1) Work clamp mechanism (2) Work clamp mechanism (3)

Feed

mecha.nism

Feed

mechanism Intermittent-presser Intermittent-presser

Thread trimming mechanism Thread Thread wiper mechanism Thread winding mechanism

Lubrication

hook mechanism

(X (Y

release

mechanism

.......................

axis)

..............

axis)

..............

foot

mechanism (1)

foot

mechanism (2)

..............

..........

............

....

............

.............

............

D Covers . . . . . . . . . . . . . . . . . . . . . . . . . . 8

PJ-1

Work clamps (solenoid type) . . . . . . . . . . . 10

PJ-2

Work clamps (pneumatic type) . . . . . . . . .

11

Lower shaft . . . . . . . . . . . . . . . . . . . . . . .

EJ

Longitudinal feed

D)

Traverse

GJ

Thread wiper . . . . . . . . . . . . . . . . . . . . . . 15

fJ

I nterm

[;]

Needle bar

D)

Work clamp

ml

Thread trimming . . . . . . . . . . . . . . . . . . . 19

feed

itti

nt-presser

m Intermittent-presser

1m

Upper shaft . . . . . . . . . . . . . . . . . . . . . . .

3. ASSEMBLY PROCEDURES

(Y

axis) . . . . . . . . . . . . . 13

(X axis) . . . . . . . . . . . . . . . . 14

foot

. . . . . . . . . . . . . . 16

........................

lifter

and

thread

release

. . . . . . . 18

foot

lifter.

. . . . . . . . . . 20

AND

ADJUSTMENT

11 12

17

21

D Upper shaft . . . . . . . . . . . . . . . . . . . . . . . 22

PJ

Intermittent-presser

11

Needle bar . . . . . . . . . . . . . . . . . . . . . . . . 24

E)

Intermittent-presser

1!1

Work clamp

G)

Thread

fJ

Traverse feed (X axis) . . . . . . . . . . . . . . . .

[;]

Longitudinal feed (Y axis) . . . . . . . . . . . . . 32

DJ

Lower shaft

1m

Work clamp arm

lifter

trimming

and

m Thread wiper

1m

Intermittent-presser

foot

lifter.

. . . . . . . . . . 23

foot

. . . . . . . . . . . . . . 25

and

thread

release

. . . . . . .

. . . . . . . . . . . . . . . . . . . 29

relevant . . . . . . . . . . . . . . 33

and

relevant . . . . . . . . . . . 34

......................

foot

. . . . . . . . . . . . . . 38

27

30

36

Ill Covers and relevant . . . . . . . . . . . . . . . . . . 39

D Adjustment

of

needle-bar height . . . . . . . . . 42

D

6 Matching the needle

with

the

tip

of

1

11

2 2 3

3

4 4

5 5

6 6

7

Adjustment

needle and the

EJ

Adjustment

the driver . . . . . . . . . . . . . . . . . . . . . . 43

DJ

Adjustment

thread guide

G)

Adjustment

fJ

Adjustment

[;]

Adjustment

D) Adjustment

foot

lift

ml

Adjustment

m Adjustment

and

feed timing . . . . . . . . . . . . . . . . . . 49

16

Adjustment

Ill Adjustment

release

timing . . . . . . . . . . . . . . . . . . . .

Ill Adjustment

mJ

Adjustment

1m

Adjustment

position . . . . . . . . . . . . . . . . . . . . . . . 53

5.

HOW TO

D How

fJ

How

to

make up the clamping type

to

make up the

the shuttle hook . . . . . . . . 42

of

clearance between the

tip

of

the shuttle hook . . . 43

of

the needle receiver

of

the shuttle hook

.....................

of

the

work

clamp

of

the moving blade . . . . . . . . . 45

of

the

presser

of

the intermittent-presser

.......................

of

the thread

of

the needle-stop position

of

the original

of

the upper thread

of

the backlash . . . . . . . . . . . . 52

of

the thread trimming

of

the

work

MAKE

foot

wiper.

clamp

UP

cassette

of

lift

. . . . . . . . 45

. . . . . . . . . . 47

. . . . . . . . . 48

point

. . . . . . . . . 50

cam

lifter

base

THE PRESSER

presser

type

presser

. . . . 53

. . . 56

44

47

51

. . 54

fl

II

I I I

II

6.

ADJUSTMENT

APPLIANCES

Description on fuse

D

Voltage measurement

PJ

LEOs

on

PCB

11

How

m

m m

to Description Description

7.

TROUBLESHOOTING LIST

......................

use

the DIP switch . . . . . . . . . . . . .

of

each

on

OF ELECTRIC

........•.........

................

connector

control box

..........•

.............

.....

58 59

60 61 63

65

66

I

I I

8. SPARE PARTS LIST

9.

CONTROL

DIAGRAM

10. TROUBLESHOOTING FLOW

11. COUNTERMEASURES

CIRCUIT

..................

CHART

...........

BLOCK

..............

..........

69

70

71

78

MECHANISM

D Needle bar, thread take-up, lower shaft,

a

W

(j) Needle

bar

and

shuttle hook mechanism

!

Up

and

down

lo

wer

sha

ft

gear

Swing

O Swing gear

motion

Direction

of

Pulley

rotation

fl

Work

•

clamp mechanism ( 1 )

®Sol

enoid

lever shaft

@

Work

clamp

cam lever

Needle Lower

bar/Thread

shaft/shuttle

take-up

hook

machanism

mechanism

@ Sol

enoid

CD

Main

(acting

1 2 3 4 5 6 7 ®

(j)-->®--->

lever

work

clamp solenoid

on

the final needle

~-0-0-0

when

turned

ON)

--+8--+

(l)

I ®

t

Up

and

down motion

Work

clamp

lifter

plate

Work

clamp mechanism (2)

Work

clamp mechanism (3)

~--@

Work clamp arm lever plate

@Work

foot

clamp

@Work

• While

the

sewing machine

to

comes work clamp lifter pedal solenoid

a rest in "Work clamp mechanism (2)

@works,

2

clamp

lifter

solenoid-ON

is

kept

stopped,

is

pressed,

raising the work clamp @ .

the

work clamp lifter

the

mechanism

."

When

the

RJ

Feed mechanism

@ T imi

ng

pulley

__

_

(X

®

__.,

axis)

Idle

gear--

--,

MECHANISM

T

belt

shaft

X retai

ner

•

Support

the

ed and guid

feed

base

X fixed

Feed mechanism

ed

®

Timing

by

the X reta

on

the

timing belt traverses.

(Y

axis)

belt

--

iner

----'

(j)

and

X feed guid

Feed base X

e,

CD

Pulse

motor

Y assembly·ON

@v

rack

~

F

orwa

backward

rd and

motion

® Feed

pla

te

3

El

Intermittent-presser foot mechanism {1)

®Intermittent

arm L

(j) Link L

@ Feed-lever roller

feed

-----@Intermittent

Direction of rotation

::)~

~-"'----@Intermittent

lever

feed arm R

~CD

Upper shaft

®Presser

foot lifter cam

Intermittent-presser foot mechanism {2)

•

Mechanism

for raising the presser foot.

@ Intermittent

presser lever

\.

4

Gt

Thread trimming mechanism

MECHANISM

n

"

Stopper -

Gl

Thread release mechanism

~

Moving blade connecting

@ Thread

•

The thread

lever ®

stopper and

is

trimming

~@

0

trimming released

connecting lever

falls

cam

from

down.

rod

the

@Thread

.tJIIII"""

Forward and backward

trimming

rod

assembly B Swing

® Thred

lever \

motion

trimming

Swing

motion

~

Up

® Thread

and

down

@Thread

(f) Thread

trimming

motion

trimming

rod assembly A

shaft

lever

5

CD

Main

work

clamp solenoid-ON

(j)

Work

Upper-thread release

@

lever

clamp I

ifter

lever

6 Thread wiper mechanism

® Solenoid

CD

@ Thread wiper crank

CJ

Thread winding mechanism

lever----..

Wiper solenoid-ON

assembly

@Wiper

CD

Bobbin holder

® Thread-winding cam

shaft

@ Leaf spring

6

(!] Lubrication

MECHANISM

7

DISASSEMBLY PROCEDURES

D Covers(1)

® Upper cover

0 Disassemble

the

illustrated parts in

the

order of

the

encircled figures.

(jJ)

Side cover LU

® Side cover LD

@ Large shuttle

---...

(4.

76X

~~

14)

hook

cover

@Bellow

holder

Cl)Bellow

-----'

8

:Cave~(~)

:-·

- -- -

...

-

(3.57X6)

@ Belt cover U

~~'--

(4.76X6)

~~----

@Original

point

cover

@ Remove this belt.

®

Return

the

the original pos1t1on.

hea~

!o

9

11-1

Work

clamp

(solenoid

type)

Work clamp

lifter

plate

CD

Turn hand work plate.

the

pully

to

lower

clamp

by

the

lifter

@Stop

(M5X

ring

16)

~®

(Az,®

~@

Work

clamp arm

®Stop

'---__,.....-®

lifter

ring

Work clamp

solenoid

@

Lift

the

auxiliary

plate and remove

it.

10

6-2 Workclamp(pneumatictype)

®Stud

screw--""'"'

DISASSEMBL V PROCEDURES

(f) Cylinder

support------J

®Air

tube

CD

Air

,.-----@

Pull

tube

~·

tube

Stud screw

out

the air

while pushing

11

Lower

shaft

Extract

the

(j) Driver

shaft.

®Lower

®Loosen

shaft

12

the

set collar.

DISASSEMBLY PROCEDURES

,---@

Y feed guide L

®Pulse

motor

Yassembly

13

'---

(J)

Y rack assembly

Iii

Traverse

feed (X

®X

retainer----

axis)

(1)

.......

® X feed guide

(DBelt

holder U

CD

Belt holder D

----..

----

------"

(3X8)

'*Steps@

~

d'

d"

through

(5X22)

I

(l)

Pully

base

@ Bearing cover

@)

indicate the removal procedure of the timing belt.

14

DISASSEMBL V PROCEDURES

@Stop

ring

(4.

76 X 14)

~

___

,,,

(6X20)l)

..

'

1.......---@Pulse

motor

(5X22)

base

@Remove

link.

the

wiper

@Wiper

~--(])Wiper

solenoid~

15

@Solenoid

(3.57X10)

lever

6

lntennittent-presser

foot

@Loosen the

set screw.

(5.95)

CD

Presser foot

@Intermittent

~~

L@Roller

fii\

'--

Intermittent support f )

1.!!.1

(Intermittent sup

lever

®stopring

• port sha t

® Loosen the screw

(4.76X16)

@Intermittent

stopper L

@ Intermittent

feed arm R

"(4.37 X 12)

\___@Loosen

the screw.

16

DISASSEMBLy

@Loosen the

(4.37

X8)

screw.

PROCEDURES

@Loosen

the screws.

@Loosen

(5.

) e screw.

95

th

~

®Needle

bar clamp

17

(g

Work

clamp

lifter

and

thread

release

(DWork

@Work

base

clamp

assembly

clamp

lifter

lever

® Upper thread-release lever

®Remove

spring.

18

the

1Dl

Thread·

trimming

(DLay

the sewing machine

DISASSEMBL V PROCEDURES

down.

®Needle

®

Turn

down.

plate assembly

the sewing machine

@Nut__}

(5.95)

r-----@

'f/

Lubrication support assembly

1

\__®Stud

screw

@Thread

@ Return the sewing machine

19

trimming

to

its original position.

shaft

"'

base

'-

"-

"

m

lntennittent-presser

foot lifter

~---

®Presser

foot solenoid

-~~

~.:.:~~

(4.

76 X 12)

,..---@Intermittent

®Intermittent

foot shaft

pre~

@Loosen the

screw.

(4.37)

"------(])Intermittent

20

-{1~·---

@Stop

presser foot lever

presser foot leverspring

ring

DISASSEMBLY PROCEDURES

@Loosen the

(6.35)

screw.----'

(6X16)

'----@Pully

'------@Bearing

.-----(j)

-----

Presser foot I ifter

------(j)

case

cam

(j) Feed connecting rod

Cam

washer

21

ASSEMBLY

AND

D

Upper

ADJUSTMENT

shaft

PROCEDURES

( 1)

Pass

the upper shaft

lifter

cam

@,

washer@

(2} Attach the bearing

in

that

CD

feed connecting rod

order.

case@

through the

to

the frame.

presser

@,

and

foot

cam

Push

the

(3)

screw

lightly,

(4)

Allow lightly,

(5) Align the matching mark on the crank rod upper

cover

presser

recess

and

then tighten.

the pulley and

attach

@with

@. Attach the crank rod @

upper cover

foot

lifter

cam

(g)

against the

so

that

the

cam

washer @ sti

®to

to

the matching mark on the crank rod

@ .

touch the

the upper shaft

to

CD.

the crank rod

set

II

collar

turns

(J)

22

@

(6)

(1)

Fit

the

hole

crank

Insert rod arm.

screw hole

of

the

to

the

upper shaft.

the

intermittent presser lever

®,and

presser foot lifter

of

upper shaft

the

balance crank @ with

CD.

Attach

RS

the

CD,

connecting

lever@

balance

into

the

(j)l--

Insert

........

'------®

'-----CD

@

(2) Fit

shaft

presser

(3)

Insert into stop lightly shaft toward

(4) Set

the

presser

of

the presser

foot

the

intermittent presser lever

ring®.

pressing

the

spring@,

foot

lifter

foot

solenoid @

intermittent presser foot lifter

Tighten

the

intermittent presser foot lifter

the

arm.

and

RS

lever @

solenoid

to

the

frame.

the

stop screw (j) while

the

right-side stop

@.

CD

onto

Attach

shaft®

and fit

ring@.

the the

the

23

Bl

Needle

bar

(5)

Lift pushing

solenoid@

®.

(1)

Assemble up support support shaft

recess with

the

presser

it

forward. Turn

clockwise, and then tighten

the

foot

lifter

thread take-up

shaft®.

lightly, and attach it

screw.

Push

RS

lever@

the

rotary plate

CD

and thread take-

the

thread take-up

onto

the

while

of

the

bolt

screw

Insert

(2)

take-up

Remove

of

part with

the

crank.

(3) Turn

(4)

the

through

Insert

® with

(5)

Insert

connecting rod

the

needle bar

CD

and balance crank

the

screw@

the

needle bar

screw recess. Tighten

pulley so

the

side hole. Then, tighten

the

slide block (j) into

the

hole

the

needle bar

®and

and make sure

crank@

that

of

the

clamp®

slide block (j).

crank@

the

screw ® can be fixed

slide block facing upward.

into

the

assembly@.

that

comes into

the

needle bar

the

screw ®.

the

needle bar guide

into

the

needfe bar

thread

the

shaft

contact

24

ASSEMBL V AND ADJUSTMENT PROCEDURE

DPX5

OPX17

--®

Cutting

part

(6) Insert

(with

toward

(7) Turn

the the

17). Tighten (In case of the needle

ence line.)

(8) Fit

bar@.

the

needle

the

oblique

the

operator).

the

pulley so

lowest position. Match

needle bar with

the

needle-bar thread guide @

Attach

@.

(9) Mount

the

oil caps

the

bar@

cut

that

screw

the

@and

from

the

part

of

the

needle bar comes

the

reference line

the

second lowest line

of

the

needle bar clamp.

DP

x 5, use

screw@

@on

to

the

top

of

needle

the

on

the

needle bar

frame.

the

top

the

arm

bar@

(DP

refer-

needle

to of

x

lEI

Intermittent-presser

foot

@

(1) Fit

(2) Insert

(3) Lightly hold

(4) Fit

the

intermittent feed shaft

the

insert

the

@.

Tighten

tent

feed arm R

feed shaft tighten

the from

®

(Position bar@

the

guide

groove

the

at

the

toward you.)

intermittent feed arm

CD

screw®.

of

top

same time.

the

(Dto

the

R®.

roller@

the

and intermittent feed arm R

part

the

of

screw hole plane part

into

the feed lever ®at

frame between

of

frame. Insert

the

shaft@

the

center

the

presser bar clamp (j) with

arm, and insert

feed connecting rod

to

of

the

presser bar @

the

of

frame and

the

intermit-

oval hole.

intermittent

®and

stopper L

the

presser

®

Threaded plane

the presser bar @.

of

25

,..----®

(5)

Fit

the

intermittent lever ®

presser bar clamp (j), and tighten

@.

in

the

shaft

of

roller shaft

the

r----

Roller

shaft

(6) Attach

(7) Fit

lever guide

(8) Attach

(9) Try

find a Tighten

(10)

Fit

(11) Fit

the

feed lever

@.

<[4)

the

to

move

point

the

roller®

the

intermittent

link@.

roller@

Temporarily secure

to

the

frame.

adjusting

the where

intermittent

presser

in

the

screw@

there

guide®

roller shaft.

support

.

bar®

is

in

the

intermittent

the

intermittent

up and down and

the

least resistance.

at

this point.

shaft@

in

@ , and fit with the screw recess. Lightly push

the

intermittent

support

shaft

@ and tighten.

the

roller

"'--T-i--@

frJ.JJ~~ef---....;.-i---

(J)

®

(12) Fit

( 13) Remove

the

stop

ring@

the

adjusting screw

presser bar spring

in

@.

again and fix it with

(14) Turn

the

pulley until lowest position. Loosen L@.

(15)

Try

to

move

the

link

and find a

tween clamp (j) and

®

at

ing it

place where

the

bottom

the

stopper L

this point. (Move

at

the

point

indicated by

link L becomes easily movable.)

the

roller shaft. ·

Tighten

the

nut

@.

the

presser bar comes

the

intermittent feed arm

L@

leftward and rightward,

there

surface

of

®.

the

link

@and

the

is

no clearance be-

Tighten L@

the

insert

adjusting screw

the

presser bar

the

while push-

arrow, and

to

the

link

the

26

lit

·WGrk

clamp

lifter

aod

thread

ASSEMBLY AND ADJUSTMENT PROCEDURE

release

(1) Assemble the

thread

rod@.

Insert the

(2)

until shaft@.

(3)

Fit

release

Put the assembly in the arm.

end

it

comes

the lever spring

work lever®,

clamp

and

of

the upper thread

contact

with

@with

lifter

lever

upper thread

release

the thread

the

boss

of

CD,

upper

release

rod® release

the frame.

Push lightly.

(4)

Insert the work clamp lower surface

(5)

Fit

the slide block (j) in the shaft

clamp

(6) Insert the work clamp

with pushing the

27

lifter

the

plate®.

screw

work

of

the frame.

recess.

clamp

lifter

plate®

lifter

lever shaft @

Tighten the

lifter

lever shaft lightly.

from the

of

the

screw®

work

and

while

fit

®

<D

{7)

Raise

the work clamp

lever spring@

(8)

Place

the roller

clamp lifter levereD,

lifter

base@.

0.5 mm between the and

the

end

of

lifter

plate ®

with

the work clamp lever

of

the

cam

lever®

and

mount the work clamp

Ensure that there

end

of

feed

the work clamp lifter

and

fit

CD.

under the

is

a clearance

roller shaft @

cam

work

@ .

the

of

0.5mm

(9) Turn the pulley until the thread take-up

the lowest position, while pushing the main clamp solenoid on the work clamp I ifter

( 1

0)

Push

the thread upper thread upper thread tension disk

@so

release

loosens.

that the feed roller @

cam

@ .

shaft

rod@,

lever®

®with

and adjust

part ®

until the thread

comes

work

rests

of

using

to

the the

28

ASSEMBLY AND ADJUSTMENT PROCEDURE

(8X20)

~

~®:

®;;:::::::---~-~----CD

0.5mm

®~/])

@~

@

®

(1) Attach

Ensure the thread trimming cam @ .

(2) Attach

to

(3)

Lay

(4) Attach

frame.

the

thread trimming base

that

there

end

of

the

roller

the

upper shaft lubrication

the

thread trimming base

the

sewing machine down.

the

thread trimming shaft

is

a clearance

shaft®

of

and

CD.

CD

to

the

0.5

mm between

the

end

support

base@

frame.

of

the

plate@

to

the

(5) Attach

trimming

(6) Attach

trimming cam

@).

the

thread trimming rod B

lever(]).

the

thread trimming rod

lever®,

and tighten with

®to

A®

to

the

thread

the

nut

29

Return

to

the original

position.

(7) Hook up

(8) Return

the

thread trimming

sewing machine

spring@

to

the

.

original position.

16

Traverse

feed

(X

axis)

(9) Attach

thread trimming trimming connecting the

(1)

Attach

pulse

the

needle

flat head screw.

the

timing.belt®and

motor

o@.

base

plate@

lever@

CD

by fitting

into hole

rod@ . Start

and

then

the

in

tightening with

timing

attach

pully@to

the

belt

on

the

th.read

the

shaft

(2)

Set

the

bearing

at

the

top

of

recess by

them, and then fix with

(3)

Ensure

timing pulley @ are equal. Secure

pulley recess.

30

that

@with

collarS@

the

belt shaft

lightly holding

the

clearances on both sides

the

screws while adjusting

and idle

D@.

the

screws.

gear®

Adjust

belt shaft against

in place

the

screw

of

the

timing

screw

ASSEMBL V AND ADJUSTMENT PROCEDURE

(6X20)

II

~~

I

l.

(6X20)

I

'(5X22)

G9

!

'----CD

(4) Securely attach the pulse-motor

base.

(5)

Attach the timing belt the pulley the

reverse

(6) Mount the stop

attach the bearing cover @ .

base

(j). Attach the belt shaft U

side.

ring®

CV

and

on the belt shaft U

base

timing

CD

to

the

pulley®

bed

to

®on

®and

(7)

Ensure

timing

screws pulley ®

recess.

(8) Temporarily tighten the pulley

base. bolt tion

CV

applied at the center base

(9) Fix the adjusting

that the

pulley ®

Adjust the timing belt

@

of

4 mm under a

with

the

so

that

3 bolts.

clearances

are

screws

the timing belt produces a deflec-

bolt@

on both

equal. Tighten the timing

while adjusting the screw

CV

load

of

approximately 400 g

of

the belt. Fix the

with

the

base

using

nut@

(j) on the

sides

of

the

bed

the adjusting

pu

I ley

.

Apply

a load

(of

approx.

400

g).

31

(1

0) Push

the

X feed

bed base, and tighten.

guide@

against

the

end

of

the

C)

Longitudinal

feed

(V

axis)

,.----@

Attach

(11)

the

( 12) Temporarily tighten

guide Try ward while pushing

point

tering and moves smoothly. Fix

this

(13)

Fit

the

and tighten while moving

the X retainer@

X feed guide @ .

the

@

to

the

feed table X ® using

to

move

the

feed table X rightward and left-

the

where

point

the

belt holder D @ . Load 2 belt holders U ®

using

teeth

the

feed table X @ causes no chat-

the

bolts.

of

the

timing belt into

and feed table

X retainer

X feed

the

feed table

@and

guide@.

the

X@

X feed

the

bolts.

Find a

feed table

groove

X@.

to

at

of

CD

32

(

1)

(2)

Put

the

original

Attach

raising it

Y rack point

the

CD

into

dog ® with it parallel

pulse-motor Y @

lightly so

that

the

frame. Insert

to

the

its backlash becomes 0.

the

to

the

axis.

frame while

Y

ASSEMBL V AND ADJUSTMENT PROCEDURE

Push lightly for

adjustment.

®

(3) Push

(4) Attach

(5) Attach

(6) Tighten

the

Y feed guide L @ against

feed table X ®, and tighten.

theY

retainer®

the

Y retainer @ and Y feed guide R @

and move

push

where

and moves smoothly, using

the

feed table X ®

theY

feed

guideR®,

the

feed table Y (f) causes no chattering

the

Y rack

@.

and feed table

the

Q)to

the

end

of

the

v(f).

to

the

left. Lightly

and tighten

bolts.

X feed shaft support

at

a point

BJ,

Lower

@------..

shaft

and

relevant

(1) Lay

(2) Put

(3) Engage

(4) Mount

(5) Fit

(6) Return

the

sewing machine down.

the

lower shaft rear side, and fit it collar®

and tighten does

rarily tighten it through

not

the

facing

the

lower shaft

the

chatter.

stop

driver@

the

sewing machine

CD

to

the

bushing side.

set

collar®

ring@

with

in

the

machine from

ground surface

gear®

on

the

with

so

that

the

lower shaft

stop

ring@.

to

its original position.

of

the

swing gear,

the

lower shaft

CD.

the

CD

Tempo-

the

set

33

1Dl

Work clamp arm and

~levant

Tightening screws

• For electromagnetic types (For pneumatic types,

(1) Attach

tighten while matching auxiliary plate with

plate®.

(2) Tighten

(3) Attach

@.

start

from item (10).)

(4) Attach

®

to

the

auxiliary plate

the

feed plate @

the

feed table

the

work clamp lifter solenoids R

the

frame.

CD

the

upper surface

to

the

cover@

to

the

frame, and

upper surface

of

the

feed table

to

the

feed table Y

CD

of needle

Y@.

and L

the

,---@

r---(1)

@--

(J)

(5) Remove the presser

® (6) Fit

(7)

@

(8) Put

--

the

work clamp

feed table

Attach the presser

clamp lifter

Y@

the

plunger pin (j)

wire®,

®.

springs@

arm@

and secure.

springs@

and hold it with

at

.

into

again.

the

top

groove

of

the

stop ring

in

the

work

34

ASSEMBLY AND ADJUSTMENT PROCEDURE

• For pneumatic types

(9) Hold the

®

with

(10)

Fit

the work clamp

feed

table

tip

of

the wire

Y@,

the work clamp

presser

and

V ® ,

arm@

secure.

into the groove in the

and

lifter

tighten.

wire fitting

(11) Attach the cylinder

®.

(12) Attach the cylinder

arm lever C

( 13) Connect the air tube

the left.

@ .

support@

joint

as

illustrated in the Figure to

to the

@to

the work clamp

feed

table Y

Viewed

from

the lower rear side

of

the

machine table

35

m

Thread

wiper

Face

plate-----r-1..._11_

r-----<D

<D

(1) Attach the wiper solenoid

CD

to

®.

(2) Temporarily tighten the solenoid

wiper

solenoid

(3)

Attach the thread wiper spring@,

and

CD.

set

collar

CD

as

crank@,

illustrated.

the solenoid

lever®

to

washer@,

base

the

(4) Lightly

screw the thread wiper crank.

(5) Hook the

(6)

Fit

wiper

(7) Temporarily tighten the thread wiper

thread wiper

(8) Attach the

push

is

aligned

spring®

the wiper

crank@,

face

the thread wiper

with

the

screw

on

the

screw.

link®

and

crank@.

plate

with

mount the stop

(jJ)

.

crank@

recess,

the pin

on

ring®.

until the

and

tighten

the thread

®to

the

~-®

36

ASSEMBLY AND ADJUSTMENT PROCEDURE

(9) Attach the

(10) Adjust

thread wiper where

(

11)

Turn the pulley 19

mm away from the upper surface

plate.

(

12)

Adjust by putting the thread wiper @ in until there needle

needle@.

using

it

stops.

and

threed

the solenoid

@

becomes

so

that

is

clearance

wiper®.

lever

horizontal at the point

needle

of 2 mm

®

so

tip

is

positioned

of

the

between the

that the

needle

and

out

Tip

of

the

shuttle

~@

~

hook

DPX17

(13) Turn the pulley by

lowest position. Align the reference line needle

(In the

highest reference line.)

Insert the shuttle

(14)

the at the center

bar

case

driver®

with

of

until the

of

hand

until the

the lowest reference line

the

needle

hook@

needle.

tip

DP x 5,

into

of

the shuttle hook

needle

use

the arm. Adjust

(DP

the

is

at the

of

x 17).

second

rests

the

(15) Attach the shuttle

set

the claw. Put the bobbin case@ in the shuttle

hook@.

37

race

ring@

to

the arm,

and

1m

Intermittent-presser

foot

(1)

Remove

the

oil cap

CD

on

the

face plate.

(2) Turn

(3) Loosen

(4)

(5) Fit

the

position.

Turn

the

position.

the align with porarily tighten

pulley until

the

screw on

pulley until

presser

the

top

the

foot@

end

the

presser foot.

the

needle

presser bar

the

needle

in

the presser

of

the

screw

is

at

the lowest

clamp®.

is

at

the

bar@

head@.

highest

and

Tem-

(6)

Turn

the

pulley until lowest position the center of

(7) Press lightly

the needle hole plate, and tighten presser bar

(8) Attach the oil cap (D.

(9) Attach

foot®.

at

while ensuring the needle rests

the

clamp®.

the center of the groove of

hole

top

in

of

the

needle bar rests

presser foot.

presser

foot@

the

screw on the

the

at

the

at

against

presser

38

ASSEMBLY AND ADJUSTMENT PROCEDURE

CD-----...

~·

4.37X8

( 1 ) Attach the upper cover

(2)

Attach the bellows R ®

table rightward to

the

feed

(3)

Attach the bellow holder R

and

table@.

leftward while tightening them

CD.

and

®and

L@.

Move

L@.

the

feed

(4) Attach the

(5)

Attach the

side

cover R (j).

side

cover

LU@.

39

(6) Attach the

side

cover

LD@.

(7) Attach the

(8) Mount the emergency stop

(9) Attach the intermittent

(10) Attach the

using the

bed

large

wave

cover®.

shuttle hook

washer @

switch@.

cover@

and

stud screw ® .

.

to

the

arm

(11) Lay the

return the sewing machine

(12) Attach the belt cover M

40

sewing

machine down.

to

its original position.

®.

Fit

the V-belt

and

ASSEMBLY AND ADJUSTMENT PROCEDURE

{3.57X6)

fi,(j,

®,-----,.

(13) Attach the belt cover

( 14) Attach

.the

belt cover D @ with two

U@.

washers.

(15) Attach the original point

cover@.

screws

and

41

STANDARD ADJUSTMENTS

g,

Adjustmen~

of

n•le~bar

heigflt

(1)

Remove

the oil

cap

CD.

DPX5

Lowest position

11

Matching the needle with the tip

~---

~--

Needle bar Needle bar bushing

Needle bar bushing

of

(2) Turn the pully until the

lowest position.

(3)

Loosen

(4)

Align the lower DP

x 17). (For a

reference line).

the shuttle hook

(1)

Turn the pulley

lowest position

with the lower

a

DP x 17

second

the

screw®.

second

end

of

needle). (For a

highest reference I i

lowest reference line with the

the

needle

DP

to

raise

and

align the lowest reference line

end

of

needle

bar bushing (the

x 5

needle,

the

needle

DP

ne.)

bar

use

needle

bar bushing (for

x 5

needle,

rests

at the

needle

the highest

bar from the

use

of

the

Tip

of

the

shuttle

hook

DPX17

Center

of

needle

(2)

Loosen

®so

the center

the

set

that the

of

the

screw

tip

of

needle.

CD

and

adjust

the shuttle hook

using

the driver

aligns

with

42

Tip

of

the shuttle

hook

Center

of

needle

(1) Turn the pulley

hook

to

align

with

to

allow the

the center

tip

of

the needle.

of

the shuttle

E1

Adjustment

Tip

of

the shuttle

of

Center

the

of

needle

I

i

hook

needle

Tip

of

receiver

the shuttle

hook

of

the

(2) Adjust by loosening the

eccentric shaft the needle

0.01 mm

to

®so

and

the

0.08 mm.

driver

(1) Align the

the

needle

tip

of

the shuttle hook

by

turning the pulley.

screw

CD

and

turning the

that the clearance between

tip

of

the shuttle hook

with

is

the center

from

of

(2) Lay the

(3)

Loosen the

tric

needle

43

sewing

shaft @

receiver

machine down.

screw®.

so

that the

of

the driver

Adjust by turning the

needle

lightly contacts the

CD

.

eccen-

(1)

(2)

(3)

Remove

Loosen

Raise

it

the

the auxiliary

toward the operator.

feed

plate

screws®

<D.

.

plate@

and

remove

by

sliding

(4)

Remove

(5) Drive the

guide@

Allow tighten.

the

needle

into both

needle

plate®.

groove

to

of

the shuttle hook thread

sides

of

the

needle

lightly touch the bottom

center.

and

44

DJ

A,~jJJ$tm,ent

of

tb!3

_wort<

c.laRJp

STANDARD ADJUSTMENTS

lift

(1) Loosen the

@until work clamp the arm, when the work clamp lifter plate

<To

set the work clamp

( 1 ) Loosen the

that there clamp lifter plate

left) when the holder

nut®

there

lifter

screws

is

a clearance

and

adjust the adjusting screw

is

a clearance

plate

CD

and

lift

to

a maximum

@ (right and left)

of

1 mm between the

CD

and

lever

is

lowered.

of

2 mm between the

the lower surface

plate®

is

of

20

and

adjust

(right and

of

raised.

mm:>

so

work

fJ

Adj~stment

of the moving blade

5-6mm

@

(2)

If

the clearance

(3) Loosen the

solenoid part

(1) Set the

(2) Loosen the screw

trimming connecting lever groove

CD

side

becomes 5 to

sewing_machine

edge

is

even

is

screws@

until the wire

®

with

the

greater, the

and

6 mm.

in the stop position.

®

and

of

the shuttle hook thread guide

tip

of

lift

is

reduced.

pull the wire tube on the

of

the

presser

adjust using the thread

@

so

the moving

that

the needle

blade®.

arm

lever

45

• Replacement

of

the

moving and fixed blades

( 1 ) Remove

the

feed plate

CD

.

(2) Loosen

(3) Raise

(4) Remove

(5) Remove

the

it toward

the

new one.

the

screws®.

auxiliary the

the

needle

the

plate®

operator.

plate@.

moving

and remove by sliding

blade@

and replace it with

~@

®

~

Do

notpro!QJ@

leftward

from

here.

(6) Remove

new one. Ensure between

fixed blade

the

leftward from

(7)

Reassemble

ing

46

the

tip

of

the

disassembly steps.

fixed

blade®

that

needle hole plate (j) and

®after

the

fixed blade ® does

the

end

the

moving and fixed blades

and replace it with the·

there

is

a clearance

replacement. Make sure

of

the

needle-hole plate (j).

not

of

1

mm

the

new that

protrude

by

revers-

STANDARD ADJUSTMENTS

(1)

Turn the pulley until the presser foot

lowest position.

(2)

Loosen the screw

the

where

lightly contacts the material

(3)

Turn the pulley and make sure enters

(4)

If

the presser foot, remove screw@,

lower surface

the

center of the presser foot.

needle does not enter the center of

and turn

<D.

Retighten it

the

presser

of

the presser

to

be sewn:

oil

cap@,

bar@

at

that

to

is

at the

a position

foot®

the

needle

the loosen adjust.

the

I]

Adjustment

of

the intermittent-presser foQt

Standard lilt 3.5mm

L~~:ta

®

CD

lift

o The standard I ift

~

t

<To

change the standard lift:>

1)

Loosen the nut

(

the

feed connecting

\lncrea~

S Decrease

lowering the set position decreases

(2)

Remove the face

of

the presser foot

<D.

Raising the set position

rod®

plate@.

is

increases the lift;

the

3.5 mm.

of

lift.

47

(3) Turn

the

position. Loosen

pulley until

the

presser bar

intermittent feed arm L

is

at

its lowest

@.

1m

Adjustment

--,~~------.'-#---@

'------®

of

the

tbread

wiper

(j)

(4) Ensure that there

bar clamp bar kept touching

Tighten

(

1)

Adjust

® so

stop position.

(j) I intermittent

bushing@,

the

intermittent feed arm L

the

thread wiper

that

the

is

no clearance among

stopper®

with

the

intermittent

intermittent stopper

CD

with

the

wiper becomes horizontal

the

I and presser

support@

support@.

@.

solenoid lever

presser

at

the

e.:-_;:::-·

\

.\

·~

@____)'-

<D

2mm

®

(2) Actuate

wiper with

of

CD

thread wiper does

At the

approximately 2 mm from

48

the

approximately 2

and the tip

the

same time, ensure

front the tip

thread wiper

screw@

mm

of

the needle. Make sure

not

of

the

CD.

so

that

between

strike

the

that

thread wiper

the

center

Adjust there

presser

when viewed from

the

is

a clearance

the

thread wiper

foot@.

CD

protrudes

of

the

thread

that

the

needle.

m

Adjustment

of the

needle-$top

position

an_~:-~

tifTiing:

STANDARD ADJUSTMENTS

. i

Needle

19mm

top

position

Material

Needle stop

position raises.

Direction

of

rotation

(1) Remove

(2) Adjust

®so mm plate.

stop position; counterclockwise,

the

cover

the

needle-stop position with

that

the

away from

Turning

CD

of

needle tip comes

the

upper surface

the

element®

the

synchronizer.

lowers it.

the

element

to

a stop 19 of

clockwise raises

the

......

20

needle

Needle

_[I

top

position

LBF

Direction

of

rotation

..

...

stop position

lowers.

eeong

d.

No

feed

(3)

Adjust element @ so

needle has come and stops before

Note: For thicker material, increasing timing speed reduces sewing performance.

the

timing

that

of

the needle and feed with

feed starts working after

out

of

the

material being sewn

the

needle touches

needle flow and improves

the

the the

material.

the

feed

~atch

The element ® coincides with

the

magnet@

take-up

thread tion.

top

at

posi·

the

49

J$

Adjustment

of

the original point

(1) Remove the feed plate

(2)

Attach

original

the original -

point

is

in

the center on the operator side.

point

CD

.

reference plate

®.

The

Q)-------

Orig

inal point

(X-O·Y.Q

)

<

Adjustment

(1) Remove (2) Remove the bellow L ® . (3) Switch (4)

Press

(5) Move the

reference plate

(6) Loosen

aligned

by

moving the X original

and

<

Adjustment

(1) Remove the (2) Switch the sewing machine ON. (3)

Press

(4) Move

reference plate

(5) Loosen

point

needle

of

X axis>

the bellow

the

sewing machine

the

[E] key on the programmer.

needle

th

e screws ®

with

the original point.

leftward.

of

Y axis>

original-

the [E) key on the programmer.

the

needle

the hexagonal

dog ® forward and backward

tip

aligns

holder LG).

tip

by

turning

point

tip

by

turning

with

the

ON.

toward

the

so

that

point

cover

toward

the

bolt

® . Move

original

the

pulley.

the needle

Adjust dog @ rightward

eD.

the

pulley.

point

original-point

tip

is

the X axis

original-

the

.

point

original-

until

the

50

Tension gauge

Approx.

~mm

e:-

420g

±11

r----®

(3)

Loosen

with

(4)

Ensure imately 4 mm imately

STANDARD ADJUSTMENTS

the

nut @ and

the adjusting screw @ .

that the timing belt

at

420

g.

screw@.

the center under a load

Make adjustment

is

deflected

by

of

approxapprox-

Ill

.

Adjustment

<D---

of

the

upper

thread

release

timing

(

1)

Remove

(2) Turn the pulley while pushing the main

clamp solenoid the take-up@

with

upper thread

the upper cover

®.

work

clamp

the upper thread

lifter

at the lowest position. Then, adjust

loosens.

Place

cam@

~

CD.

the

feed

release

cam

and

keep the thread

lever®

roller

until the

work

@on

51

lEI

Adjustment

of

.the

,backlash

<Lower

(1)

(2) Loosen

shaft>

Lay

the

®

to

0.07 mm

sewing machine down.

the

screw

CD

and turn

adjust

at

the

backlash. Provide a play of

the

top

of

the

driver®.

swing gear shaft

0.04-

l.

(5X10) fiP

<Longitudinal

(1)

Loosen the bolts motor between the drive gear and theY-rack shaft.

..

~.~:""'llii.,_

Lift

it

up

slightly.

---®

(

1)

Loosen the bolts motor between

52

feed>

CD

and slightly raise

® . Adjust so

X®.

Adjust so

the

drive gear ® and the idle gear

that

no backlash remains

CD

and slightly raise the pulse-

that

there

the

is

no backlash

@.

pulse-

STANDARD ADJUSTMENTS

lm.~

Adjqstmeqt

Qf

0.5mm

1he

(])~

®---¥

ml

~djt~.~ent

of

the.

thread

work

c_lamp·

..

trirnming,t:aro

CD

lifter

ba~

(

1)

Adjust with the thread trimming there shaft

CD

is a clearance

and

the thread trimming

of

0.5

P9'ition

(1) Attach the work clamp lifter

ing

that there

work clamp lifter

@.

is a clearance

cam

®and

cam

mm

between the roller

cam®.

base

CD

while

of

0.5

mm

between the

feed

cam

roller shaft

11

®until

ensur-

53

HOW

TO MAKE UP THE PRESSER

e The presser

The

maximum

• Clamping

Type

~

How

to

is

available in

sewing

Work

clamp

two

range

types; clamping

is

100 ( L) x 120

Work (Single

clamp

type)

type

and cassette type.

(W)

mm.

v~l

Feed plate

make up the clamping type presser

• Cassette

Cl

amp

1.

How

Type

spring~

~

to

make up

the

:7

~""

work

-

Cassette clamp

·

~

Cassette cl

clamp blank

<OpPOrt

amp

assembly

Presser

Feed

foot

plate

-----

D/2 +

1-1

.5

D/2

mm

~-

+ 1-1.5

Work

,--

Feed plate

Work

Sewing

clamp

(One-piece

(The

threads along.)

clamp

position

needle

mm

type)

2.

Cut

out the

si

ze

is

presser

D:

How

wor

wider

than a sewing

foot

diameter + 1-1.5 mm

Diameter

to

make up

k clamp blank

of

the

top

end

the

feed plate blank

posit

of

so

that

the

ion

by

(half

). the presser

cutout

of

the

foot

Cut

out

the feed plate blank 1-1.5

ng

the

case

I

I I I

I

L

l...

_-_-_-_-_-_-_-l

~

1-1.5

Sewing

position

mm

the sewi

In required on

54

position.

of

the

both sid

mm

left

figure, 1-1.5 mm margin

es

of

the

sewing position.

apart

from

is

Work

clamp

(Standard) \

OT

clamp

asse mbly

3. How (

1)

(2) Bond a

to

make

Cut

out

contour

around material

up

the

of

a material

paper

the

cut-out

to

be

plastic presser

plastic pla

to

cushion

part

sewn.

te

according

be

sewn.

material

to

secure ly press a

or

to

the

like

fl

How

Feed plate blan k

to

make up the cassette type presser

~

Hin

g e

s

Cassette pl

ate

U

(3) Make

*

Th

e cassette plate in

the left

(1)

item

U,

Cut

up

"2.

cassette

figure.

out

the

ting dimensions, refer

make

up

the

* Making up

nately

w

the

feed

plate

How

to

make

type

presser

plate

D,

cassette plates U

clamping

two

cassettes

blank

upthefeedplateblank."

is

composed

and

to

type

by

hinges as illustrated

and

section

presser."

to

use them al

ill increase work efficiency.

referring

of

a cassette

D.

For

"1.

How

to

cut-

to

ter

-

Cassette

\_

clamp

assembly

Cassette

Casse

Lower cassette plate (Plastic plat

tte

plat

plate

e D-A

D-B

(I

ron)

(2) Bond a

aro material

*

The

cassette

und

paper

the

to

be

plate

cushion

cut-out

part

sewn.

D is available

material

to

or

secure ly press a

in

two

the

like

types; D-A

and D-B.

* Use

the

cassette

the

D-A,

except

must

be

bonded

mounting

a

counters

eter

hinges

countersunk

plastic plate.

unk

plate

that on on

screw

hole

D-B

a plastic

the

back

the

cassette

M3 into

prior

with

of

the

plate

the D-B.

plate

the

4.6

to

Co

unt

same

way as

or

the

D-B, insert

mm

bonding

ersunk

screw M3

like

When

diam

the

-

I

~

e)

Lower cassette plate

Bond

55

I

Work

clamp

Work clamp blank B·1R Work chimp blank 8·1 L Work clamp blank B·3R Work clamp blank

blank

BolL

I

t3.2

t4

153448-000 153449-000

153470-000

153471-000

DDI·

50+--1

Work clamp blank 1·3R Work clump blank 1-3L Work clamp blank 1-4R Work clamp blank 1-4L

Work clamp blank 1-5R Work damp blank 1·5L 502826-000

t3.2

t4

t5

502821-000 502822-000 502823-000 502824-000 502825-000

Work clamp blank 2·3R

Work chimp blank Work clamp blank 2-4R Work clamp blank

~ork

clamp blank 2·5R

Work clamp blank

2·3L

2-4L

2·5L

t3.2

t4

t5

502827-000 502828-000 502829-000 502830-000 502831-000 502832-000

Work clamp blank 3·3 Work clamp blank 3-4 Work clamp blank 3·5

Back

T

11

....__

___

1--150~

I

Feed

plate

___,

1

blank

Feed

plate blank 1

Work clamp blank 5·3

W~rk

Work clamp blank 5-5

clamp blank 5-4

Work clomp blank 4·3 Work clamp blank 4-4

Work

clamp blank 4·5

r~

l 1

1--170--j

Feed

plate blank 2

Feed

plate blank 3

T

156

I

Feed

plate blank 4

56

I

Feed

plate blank 5

Cassette clamp j

Cassette clamp 1 A Cassette clamp 1 L

[ni

106

Cassette clamp Cassette

I Clamp spring I

clamp

2R

2L

70-11

82--1

crr·~

10

10-t

1

82~

Cassette clamp

Cassette

clamp

3R

3 L

Cassette clamp

Cassette support

assembly(t3.2)

502963-001

Lower cassette plate

A(t1)

502969-000

B (

t2)

502970-000

4R 4L

236~

~\&,

~

t0.4

I Clamp spring 1 I 502853-00 I I I Clamp spring

OTclamp assembly A

(t0.5)

t2)

503902-001 503904-001

8 ( t 1 ) 503903-001

c (

~~

Cassette plate U-A ( t

-152632-001

1)

B(t2)

Hinge, right

502968-000 502971-000

t 0.6

21

502854-00 I I I Clamp spring 3 I 502855-00 I l

~~~~~~amp

Cossette plate U·A

Hinge, left Hinge, right

Cassette plate D·A

t 0.8

A

502959-001 502968-000

152633-001 152632-001

502966-001

Cassette plate D-A(t1)

502966-001

I Presser

foot

I

Presser foot L

502469-001

Presser foot R

502441-001

57

~::'~~,,!=lamp

Cassette plate U·B Hinge, left Hinge, rigtlt cassette

B

plate D·A

Presser foot

505667-001

502960-001 502971-000

152633-001 152632-001

502966-001

MM

D

Description

ADJUSTMENT

OF

ELECTRIC APPLIANCES

on

fuse

1. Position Open

the front.

the control box cover.

of

fuse

Control

box

At

the upper left

---f---

is

the

fuse

holder

having

three

fuses,

when viewed from

2. Fuse capacity

No.

1

2

3

I

i

. ®

I®~®

~®~&

&A

~

(4X10)

Type and capacity

Cylindrical fuse:

Glass

tube fuse:

Glass

tube fuse:

of

fuses

5A-500V

15A-125V

For AC

For pulse

For and brake

input

pulse

Remarks

motor

motor, solenoid,

of

sewing machine

and

motor

clutch

58

3. Countermeasures when a fuse blows

For

your

reference, the following table shows phenomena when a fuse blows.

the

same

capacity

as

that

of

the blown

one.

Be

sure

to

use

a fuse

with

Fuse No.

0

No power lamp lights

o The low o

The

o No presser opens o

The of

presser

low

motor.

torque

measurement

6

1

2

3

Voltage

The following figures show where

1. Check

Measure

for

control voltage +5V, + 12V and

voltage

with

a tester· between check pins on the PCB;

CH4

CH3

CH2

0 0 0 0

-12V

+12V ±OV

Trouble encountered when a fuse blows

or

works.

of

pulse

motor

causes the distorted

is

easily moved by hand even when

or

closes.

of

pulse

motor

causes feed malfunction only with noisy sound

to

measure

voltage on the

-12V

CH

1

+5V

the

PCB

or

dislocated patterns.

motor

is

energized.

and

connectors.

CH

1-CH2,

CH2-CH4

Reference page

and

CH2-CH3.

78 (#2)

80 (#7)

79 (#5)

Check list 1

SV

DC±

C H I

C

H4EB-

C H

ffi-

2EB-

C H

28 28

38

12V

59

0.25V, acceptable

DC±

O.SV,

acceptable

2. Check

( 1 )

for

drive voltages

Remove

VL

and

the connector P 1 .

VH

I]·

On

(2)

Note:

lffi-38

2®-38

...

LEOs.

the

Measure wire

side

Use

on

:PCB

PCB

are

drive voltages

of

the connector

a tester probe

Check list 2

Approximately

Approximately 1

eight LED lamps by which the operator

VL

on

and

P1

using a tester.

the

side

44 V DC,

OV

DC, acceptable

VH

on the

of

the lead.

acceptable

lead

can

D

monitor

(Viewed

control

7 6

8 9

from

signals.

3 2 1

5 4

13

In

11

12

10

-

the lead wire side)

1.

Monitoring solenoid The

LE

Ds

noid

is

turned ON.

LED 1: LED 2:

LED3: LED4: LED 5: Left

output

1 through 6 light when

Right

side

of

presser Presser Thread wiper

Main

foot

presser

side

of

presser

o

o o

oD

each

iU

·oooo

sole-

0

CJ

2.

000000

Monitoring

LED 7

LED 8 for brake:

LED7

LEOS

output

for

clutch:

Lights while the

rotating.

Lights momentarily when the sewing machine panied by a braking sound.

of

brakes and clutches

sewing

comes

to

a stop, accom-

machine

is

LED6:

Thread trimming

60

El

How

1.

Changing movement

to

use

the

DIP sWitch

selectors 1 through 3

of

the

presser.

of

DIP switch

CD

located on the lower

Turn

the power

then open the

off

and

control

ADJUSTMENT

left

box.

OF

of

the control

ELECTRIC APPLIANCES

PCB

varies

the

The presser

OFF

ON

:~

is

automatically raised after sewing.

····································

OFF

:1

Raise

the presser by pressing the work clamp lifter pedal

after sewing.

Pressing the work presser@,

ously.

To lower them, turn the switches

low. (The work clamp lifter

stage switch.)

1st stage switch 2nd stage switch 0

1st stage switch

2nd stage switch

clamp lifter pedal ® raises the right

left

presser@,

ON

-the

N-

the right presser @ and presser foot

ON

-the

ON-

the left presser @ and presser foot

ON

n

and presser

pedal®

left

presser@

@ lower.

right

@ lower.

foot@

is

presser@

ON

designed

lowers.

simultane-

as

shown

lowers.

be-

as a 2-

1st stage switch

2nd stage switch

61

ON

-the

right presser @ and left pres-

ser@

lower.

presser foot @lowers.

2. Selector 4

of

DIP switch

CD

is

used for selecting

the

electromagnetic

type

or

pneumatic type.

3.

Selectors 5 through 8

The

sewing machine

(the thread trimming speed).

The sewing machine turns within a speed range 1500

spm.

OFF

~~

For electromagnetic

of

DIP

OFF

;

7

8

OFF

;

7

8

ON

~;i~i~i~i~i~i

=~=~=~=~=~=~

~=~=~=~=~=~=

turns

at

ON

~==~=~=~{:

·~=r=~=~=~=

=~=~=~=~=~==

:::::~:~::::

type

switch

CD

approximately

serve

as

230

of

the

spm

550-

test

switch for

The sewing machine turns within a speed range of

1200

volume

The

2000

For pneumatic type

the

sewing machine motor.

OFF

:

~;i~i~i~i~i~~

7

8

spm. The speed may be changed

on

the

panel.

OFF

5

6

7

·1

8

sewing machine turns within a speed range

spm.

ON

~=~=~=~:::::

=~=~=~=~::::

with

the

ON

t=~=~=~=i

:f~=~=~=~

r~

:i:~:i:i:i:

of

400--

speed

850-

Selectors 5 through 8 are provided solely for testing OFF when

the

sewing machine

is

in

normal use.

the

sewing machine controls.

Be

sure

to

set

all

of

them

62

II

Deseriptian

Most

of

the sewing machine failures

faulty contact. Check

contact

with

of

,each

each

wire before troubleshooting. For

connector

to

make

resulting from connector failures.

*For

the connector No., refer

to

are

due

to

connector problems

sure

that

each

connector

your

is

properly inserted

reference, the following table

the control circuit block diagram

ADJUSTMENT

such

as

on

page

OF

ELECTRIC APPLIANCES

improperly inserted connectors

and

each

comes

shows

in proper

the symptoms

70.

and

Connector No.

p 1

J 1

P2

J 2

I

J

27

P27

P3

J 3

I

J

28

P28

P4

J 4

I

J

29

P29

Connection

Power

supply

t

PCB

t

Each

solenoid

PCB

t

X pulse

motor

PCB

t

Y pulse

motor

signal

Main

+ 5

V, + 12V,

Drive voltage

Solenoid drive power supply

Pulse-motor

supply

Pulse-motor supply

+44

+

-12V

V

y

10

drive power

Phenomenon resulting

Abnormal motion

o o No motion

o

Malfunction wiper parts, main

ming parts.

o Disorder in X direction.

Abnormal sound

o

o Disorder in Y direction. o

Abnormal noise

from

of

presser,

from

from Y pulse

improper contact

presser

X pulse-motor.

and

foot,

thread

motor

thread

trim-

P5

J 5

I

J

30

P30

P6

J 6

I

J

21

P21

P7

J 7

P8

J 8

I

J

25

P25

PCB

t

Brakes and clutches

PCB

t

Synchronizer

PCB

t

Switch panel

PCB

t

Programmer

Sewing and

machine starting

stopping currents

+5V

Needle

top

position,

synchronizing, and rotation signals

+5V

Speed

volume signal

Key switch signal Display signal

o Abnormal rotation o Poor stop

o The sewing machine turns at high

stops. (The emergency stop lamp lights.)

o The mechanism does

needle

o The sewing machine turns

mechanism

o The power

o

Even the sewing machine stant

o Malfunction

of

top

position.

does

lamp

though the

speed

of

sewing machine

not

work.

does

not

light.

speed

volume

keeps

2000

spm.

of

programmer

speed

stop

above

but

turning at a con-

and

the

the feed

is

turned,

63

Connector No.

Connection Main

signal

Phenomenon resulting from improper

contact

P9

J 9

I

J

26

P26

P10

J

10

I

J

24

P24

Pll

Jll

I

J

23

P23

p

12

J

12

I

J

22

P22

PCB

FMC device

PCB

Original

PCB

Emergency

PCB

Pedal switch

...

I

..

t

point

t

stop

t

PCB

switch

Read and write signals. microdisk

X and Y original-point

signals

o Emergency

signal

o LED

o

Start

o Work

stop

switch

signal

clamp lifter signal

of

o

The

microdisk will

o Switches for data, step-back, and tests will

not

function.

o

The

original

o An emergency o

The

emergency

is

not

released.

o

The

work

clamp I ifter and

not

work

when their pedals are pressed.

point

stop

not

is

read.

not

lamp

detected.

initiated.

is

turned

start

switches will

ON

but

64

1.

Connection of connectors

ADJUSTMENT

OF

ELECTRIC APPLIANCES

The rear face

of

the control box:

2. Fan motor

The fan tronic clogged.

motor

parts may

J21 J22: J23: J24: J25: J26: J27: J28: J29:

cools the inside

be

damaged. Regularly clean the fan equipment

of

Synchronizer connector

:

Foot-switch connector Emergency stop connector Original Programmer connector

FMC device connector

Solenoid connector

X pulse Y pulse

Clutch

J30:

point

signal connector

motor

connector

motor

connector

and

brake connector

the control box. Make

sure

that the fan

so

that

the air inlet

is

working:

if

does

not, the

not

become

elec-

65

TROUBLESHOOTING LIST

Trouble

Inadequate work Improperly posi-

clamp lift

Malfunction

thread wiper

Improper quantity

of

wound lower

thread

of

1--r--

tioned lever plate

Improperly posi-

'--

tioned work clamp lifter plate

Interference between

the thread wiper and

--

the

Improperly posi-

'--

tioned thread wiper

Improperly posi-

I--

tioned bobbin holder

Cause

needle

Check

Distance between the upper surface

1-

needle plate and the work

Clearance between Adjust clearance

1-

the

work clamp lifter

plate and arm

Clearance between

f--.--

the

thread wiper and

needle

Sewing machine

-

position

,-

Thread wiper position

Quantity

f---

thread

clamp

tip

of

the

stop

wound

Adjust

1-

clamp height.

1-

2 mm with ing screw.

Adjust height

1-

thread wiper.

Adjust

(19-20

1-

needle and the upper face of

the needle plate)

Adjust

r---

where starts working.

Adjust

-

the

Remedy

the

work

to

the

adjust- 45

of

the

the stop position.

mm

above the

the

position

the

thread wiper

the

position

bobbin holder.

I

I I

L

of

v

.............

45

48

49

48

J

Thread escape

Upper thread break

in

the

hook,

cut

needle

is

too

needle.

of

the

needle

Variations

~

thread length

Excess upper thread

.--

tension

Improperly mounted

f--

needle

The

f--

'--

f--

-

thread

thick for

Improper strength and height thread take-up spring spring

Flaws and burrs on the shuttle

hole plate, needle, etc.

Thermal

1---

Sub-tension

I-

Upper thread tension.

Direction

I--

needle

~

Thread and needle

Strength and height

~

of

the

thread take-up

~

Flaws and burrs

I--

Thread end

of

the

Adjust sub-tension.

r--

Adjust upper thread

~

tension.

Mount

1-

~

1-

I--

~

the

longitudinal

groove toward operator.

Select a thread

proper size so match

the

Adjust

the and height thread take-up spring.

Polish faulty parts or

replace.

Use

liquid (silicone)

cooling equipment.

needle with

of

the

it

will

needle.

strength of

the

I/

v v v

66

Trouble

Lower thread break

Excess lower-thread

,..--

tension

1-

Flaws

'--

the

needle hole plate

and bobbin case

Cause

on

the

edge

of

1---

Lower-thread tension

1--

Flaws

Check

Adjust

1---

tension.

Polish faulty parts

t---

replace.

Remedy

lower thread

v

or

IV

Lower thread cut.

skip

Stitch

Improper

t---

when

sioner

Excessive clearance between the needle and the

Improper the shuttle

Driver overloaded

~-L

by the

f--

Bent needle

Improperly

...._

needle

timing

the

main ten-

is

released released

shuttle

hook

contact

needle with

hook

needle

tip

of

the

mounted

Timing when

-

upper thread

Clearance between the needle and shuttle

Lift

of

Contact

Clearance

1---

the

driver and the

needle

1----

Bent needle

Direction

1--

needle

the

is

hook

tip

needle bar

between

of

the

Adjust timing when

t---

the

upper thread

released.

Adjust between and

shuttle

Adjust height.

Adjust

(position

shuttle driver).

Adjust the

1---

contact

1---

Replace the needle.

Mount

,___

the

longitudinal groove

toward operator.

the

clearance

the

needle

hook

the

needle bar

contact

of

the

needle

on

the

needle with

is

tip.

driver.

51

43

42

43

v v

Needle break

The needle interferes

.----

with

the

hook.

f--

The needle

-

The needle moves

-

sidewise.

The

-

needle strikes

the

moving blade.

shuttle

is

bent.

Clearance between

~

the

needle and

shuttle

1-

Lift

'---

f...--

-

of

bar

Bent needle

Timing between

needle and feed

Position

moving blade

hook

the

of

tip

needle

the

t---

1---

- Replace

the

1---

~

clearance

Adjust tween

the

shuttle

Adjust needle bar height.

Adjust of

synchronizer feed

detecting part.

Adjust of

the

needle and

hook

tip.

the

needle.

the

position

the

position

moving blade.

be-

43

42

IV

49

45

67

Trouble

Cause

Check

Remedy

The

is

not

upper

cut.

thread

Dull fixed blade

-

Insufficient

blade

-

..._

motion weak thread spring pressure

The moving blade

will

not

thread.

-

The moving blade not

catch upper thread

f--

because skips.

Improperly posi-

f--

tioned moving blade

Improper timing

..._

when

the

tensioner

moving-

due

to

trimming

catch upper

will

the

final stitch

main

is

released

-

Fixed-blade edge

Thread trimming

-

spring pressure

Position

r-

shuttle thread guide

of

hook

the

- blade

-

f---

-

Direction

'--

of

Skipping

f--- f---

final stitch

Position

f---

moving blade

Timing for releasing

-

the

of

the

upper thread

seams

final stitch

of

the

of

the

f---

Sharpen a new one.

Replace

trimming spring with

a stranger one,

Adjust the

thread guide.

Adjust so stitch ends proper seam direction.

Refer "stitch

Adjust the

Adjust timing for

upper thread.

the

fixed

or

replace with

the

thread

B.

the

position

shuttle

hook

that

the

in

the

to

the

item,

skip."

the

position

moving blade.

the

release

the

of

/

44

/

67

45

51

·Poorly thread

tightened

Excessively weak

r--

upper-thread tension

Excessively weak

-

lower-thread tension

Improper strength

'--

and height thread take-up spring

of

the

Upper

-

f---

thread

Lower-thread tension

Strength and height . of

the

thread

spring

tension

take-up

Adjust upper-thread

r---

tension.

Adjust lower-thread

f---

tension.

Adjust strength and

f---

height take-up spring.

of

the

/

thread

/

68

SPARE PARTS LIST

Item

Needle

Needle hole plate

Shuttle

hook

race

ring

Thin

ol!!

Ci)

Needle

Needle Needle Needle Needle Needle Needle

Needle hole plate (C/>1.6

for

Needle hole plate ((/}2.2

for

material)

Shuttle

~

Shuttle

and medium-thick material

16

19

107415-009 107415-011

107415-016 107415-018 107415-019 107415-021

S02371-001

S02373-001

152685-001

152682-001

DPX5 DPX5 DPX5 DPX5 DPX5 DPX5 DPX5

thin

medium-thick

hook

race

# 9 #11 #14 107415-014 # #18 # #21

A

material)

F

A

ring A

Thicker Needle Needle

Needle D P X17 Needle

Needle Needle Needle

Needle hole plate E

(C/>2.6

material)

D P X17 # D P X17

D P X17 D P X17 D P X17 D P X17

for

extremely

~

Shuttle

hook

race

material

14

#

16 #18 #19 #21 #24 #25

thick

145646-014 145646-016 145646-018 145646-019

145646-021 145646-024 145646-025

S02372-001

v

B

ring B 152686-001

152687-001

0

Thread take-up spring

Thread tension spring

Caution: Needle and needle-hole plate must

•

Thread tension spring

~

be

properly selected

145519-001

104525-001

to

match the thread and material

Thread take-up spring B

Thread tension spring

to

be

144588-001

107606-001

sewn.

69

..

------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

1

, I I I

1

!Ground

Power

source

-

;~g~

>

<>-

"'

uo

....

..J>

><>

J21

P21

Synchronizer

•

••

•

--~--~.........

"(

p~~~~l

;:~=::~

'•

Control

PCB

::~

~

•

....

--

os~ooa

bUbbUU

CUWCUCIUI)

:S

oo:S:S:S

uuuuuu

~88008

------r

I

:::::!:~~:5::;;E~i~~~~

H3

I ,

lll=tw'!"•&::....:J:

0

:

ff!dj

.....

..,i

Clamp

0

f'-

.c:.--

''l

eader

Card

..

I

JJ

PHil

[o

"'I

Ln

~

•

..!l

...A.lJ

~

;;

'--~--

.

''IJ .

L

__

{FIVI

r

C)

est tap

ata

ast ata

ower

am~

bac

lamp:

lamp

j

1

I

P'2

1

P(O

Y

pulse

motor

•

I

I""""'

IIOXO)II

·~

··~

I

P&~

--

•

c=c:::::.

Brake

crl

~-

I

--~oil

main

motor

Sewing

·®0:::::.

~

machine

X

pulse

motor

0.

E

.,

u

""

i

~~TROUBLESHOOTING

FLOW CHART

Description

Symbols

of

1 .

2.

3 .

4.

0

means "manual operation."

means "switch operation."

means "decision."

means in Chapter

"refer

the

first column

11

to

Abnormal Item No."

of

the

list,

COUNTERMEASURES.

5.

6 .

7.

0

means "set-up

means

means "switch-off

"continue

of

conditions

to

next page."

of

power supply."

or

situation."

71

When

power

switch

turned

is

NO

ON

Micro-

disk

input

NO

YES

72

Presser

operation

TROUBLESHOOTING FLOW CHART

NO

Movement to

sewing

start point

L

NO

YES

Input

sewing

data.

NO

73

Input sewing data

and move presser to

sewing-start point.

Test

NO

74

NO

Input

sewing data and move sewing-start

to

point.

TROUBLESHOOTING FLOW CHART

Sewing

YES

NO

75

Emergency

stoP,

during

sewmg

NO

Input sewing

and

start

sewing.

data

NO

76

Programming

device

TROUBLESHOOTING FLOW CHART

77

Ill

COUNTERMEASURES

Caution on Diagnosis:

1.

Be

sure

to

turn

the power switch OFF before plugging and unplugging the power cord.

·2. Turn the power switch OFF before opening the cover.

3.

4.

When When

When

symbols in a box

(a,

(0

b,

),

turn

replacing a fuse,

c,

etc.) appear in a circle

the power switch

be

sure

to

use

a new one

ON

(0 and

of

),

turn

measure

the

one.

• Before Adjustment:

1.

Check

2.

Check

3.

Refer

Type trouble

Machine's main will when power switch turned

#1

motor

not

is

ON

for

blown

to

see

to

the Flow Chart

of

1. Power

turn

2. Faulty power switch

fuses.

if

each

and cord

plug

Cause

is

not

is

properly inserted.

to

identify

ON.

the status (#1

a.

Check

b.

Check connected.

because bad connection results

operation.

® With

out,

between

white, black and green) using a tester. The power switch and tinuity

"'

Check/Repair/

the

3-phase power supply.

the

3-phase plug

Check the grounding wire connections

the

power plug and reverse J41 plugs pulled

turn

power switch ON. Check for

the

power plug and

cord

are acceptable if

check.

the power switch OFF

and

measure

the voltage.

same

quality

and

with

the

same

25) from which a problem occurs.

Adjustment

to.

make sure it

the

is

properly

in

single-phase

continuity

J41 plugs (red,

they

pass

the

con-

the resistance.

capacity

Parts

to

be

replac~d

Power switch

and cord

as

the old

Page

70

#2

Power lamp will

not light when. power switch is

turned

ON

1.

Faulty power

;

2.

Blown fuse

3. Faulty power supply unit

171615141312111 Is

I91Johllll12l131

~e-

4. Faulty control

5.

Faulty lamp (LED)

or

cord

~~=:~~::::,

PCB

00

With

the

power

control box,

the

voltage. An acceptable voltage

® Remove

is

acceptable if

00

Remove

power ON and measure

box

is

Note:

liD

Use a tester

If

the

3,

plug

power ON and measure

(+) and CH2

the

voltage

® Remove

the

voltage. pointer moves tion.

turn

the

fuse No. 1 and check for continuity. It

there

connector

acceptable if

power supply unit was found normal

the

connector

(-).

is

+5

connector

The

to

connector

the

probe on

The

V.

panel assembly the

P43 unplugged from

power switch

is

continuity.

J1 from

the

value

the

J1

into

the

control

J7

from

maximum range

ON

and measure

is

200 V AC.

the

PCB.

Turn

voltage. The control

is

+5

V.

side

of

the

lead wire.

in

Item

the

PCB.

Turn

voltage between

PCB

is

acceptable

the

PCB

and measure

is

acceptable if a

of

CH

magnifica-

the

1

if

Power cord

Tube fuse

Control

Panel assem-

bly

box

PCB

SA

70

58

59

70

78

Type

of

trouble

Cause

Check/Repair/

Adjustment

Parts

to

replaced

be

Page

#3

The

data lamp will neither light nor read when

the

data

switch

is

depressed depressed.

1. Faulty

2.

connector

contact

Faulty power supply unit

CH3

o

Ctf2o

-12V ±OV

CHI

+5V

I

C~4

+12V

f9~+12V

E~

I 1 Is I s I ISI9110inl11l12]13]

-12V

(Viewed

wire

3. Faulty control

4. Faulty

41

s I 2

11

!5~

from

the

side.)

foot

lead

PCB

switch

Check connectors P9 ·

a.

connection, disconnection, and faulty pins.

Turn

riJ

[61

I

a.

b.

a.

b.

the tween check pins voltages are +5V (1-2). +12V (2-3) and Remove sure voltage. The acceptable voltages are

No. 9 ~ - No. No. 7 ~ - No. 5 9 No. 8 9 - No. 5 ®

Turn

the switch. The control gency

stop

pressed and goes

Press

the

works

normally,

When

the

automatically

is

switch Remove

the

press normally,

trouble.

J9,

and P26 ·

power ON and measure

1,

2, 3 and 4.

connector

power ON and press

lamp lights

work clamp lifter pedal.

power

faulty.

connector

data switch. If

the

10

out

the

is

work,

foot

turned on,

J1.

Turn

9

12 V 12 V

PCB

is

acceptable if

the

first time

the

P22 from

PCB

which means

the

data switch functions

switch

is

power ON and mea-

5V

the

J26

for

the

voltages

The

acceptable

-12V

as

follows:

DC DC DC

the

emergency

the

switch

time

the

switch

If

the

is

good.

the

work clamp will

that

the

control box and

responsible for

poor

be-

(3-4).

stop

emer-

is is

presser

foot

the

Control box

Control PCB

Start

switch (adjustment of

2-stage

switch)

59

70

#4 Emergency stop

lamp lights several seconds data is

after

switch

depressed

#5

Work clamp will

not

rise

when

the work clamp lifter pedal is depressed

Faulty

FMC

device

PCB

jE><f>j

5.

Faulty micro-disk

1.

2. Faulty

Faulty control

3.

1 . Blown fuse

2. Faulty power supply unit

Plsi5I4131211J I a I 9

110

lnl11

1121131

(Viewed

3. Faulty switch

wire

cord

8

from

side.l

the lead

and

1

Replace

a.

If

other

is

responsible for

Replace

the

FMC.

micro-disks are read normally,

the

faulty FMC device. FMC device

the

faulty

® Remove fuse No. 3 and

acceptable subject Turn

the

rm

into voltage

® Remove

continuity.

Acceptable if resistance ON:

power ON with

the

PCB.

is

approximately

connector J 12

ooQ

when pedal switch

~ill

the

trouble.

control

to

Measure

PCB.

~heck

for

continuity.

the

connector

the

voltage. An acceptable

44V

DC.

from

the

PCB

is

on

when

is

OFF.

FMC device

the

micro-disk Micro-disk

Control

is

Fuse (15A)

Control box

I ifter switch or

It

plugged

J1

to

check for Work clamp

pedal switch

No.3

cord

PCB

58

70

79

Type

trouble

of

Cause

Check/Repair I Adjustment

Parts

replaced

to

be

Page

#5

Work clamp

not

will when work clamp

lifter pedal

depressed

rise

the

4. Faulty

is

(J27 viewed

5. Faulty solenoid

•IQJ©©9 © ©

© ©

4

[Q)

PCB

from

the

(QJI?,

CQ]~

© ©

a.

Refer

to

#3-3,

b.

The

control

when

the

@]

Turn

the power ON with

Press

the

voltage applied

No. 1

No. 2 9 - No. 8

o Solenoid type: Acceptable if approximately 15V

DC

is

measured.

o Pneumatic type: Acceptable if approximately

44V

DC

o No. 4 8

side)

mately

® Measure resistance with

Acceptable value

No.

1 - No. 7 : Approximately 15 n

No.

2 - No. 8 : Approximately

No.4-

12

a.

part

is

good if LED's 1, 2 and 5 light

pedal

is

depressed.

connector

pedal

to

turn

ON LED's 1, 5, 6. Measure

to

J27

using a tester.

9 - No. 7

Ef>

is

measured.

-No.

15V

No. 10: Approximately

DC

for

10

<±)

is

measured.

connector

the

resistance is:

: Acceptable

P27 unplugged.

if

approxi-

J27

unplugged.

15

n

15

n

Control

Solenoid

PCB

70

65

70

65

#6

Work clamp

will

not lower when work

clamp lifter pedal pressed

#7

The presser will

notre·

turn

to

the original when start depressed

point

the

pedal

(J27 viewed

1. Faulty pedal switch (Faulty 2-stage

switch)

is

1.

Faulty start switch and cord

8

111111111

2. Erroneous original point

is

from

signal

the

side)

a.

Make sure the work clamp lowers when turned work a work raises again when switch

b.

a.

tors

OFF. If

clamp rises

faulty pedal switch should be suspected.

clamp lowers when

is

responsible for

See #5-5.a.

If

the

presser will

J12-P12

and

@ Check for continuity with

1

acceptable resistance

An The resistance should be turned ON.

a.

If

the

presser moves

rasps

noisily, an erroneous signal may be responsible.

b.

Plug

in

connectors

and

J32-P32

c. Remove

from

the

Manually

The

LED

d. Check

original

once again.

the

pulse-motor connectors P28 and P29

control box and

move

on

the

to

see if light

point

PCB

the

power

without

J22-P22

being manually operated,

the

pedal

the

trouble.

not

move

once again.

connector

is

oon

on

in

the

J10-P10,

the

feed near

original point

is

striking

(the Y original

the

power

is

turned ON and

If

pedal

is

pressed,

is

released,

at

all, plug

between (j) and

when

reverse direction and

J24-P24,

turn

the

PCB

the

point

the

pedal

in

connec-

J 12 removed.

the

start

pedal

J31-P31

the

power ON.

original point.

should blink.

sensor

on

in

particular).

the

but

@.

the

is

Foot

switch

(adjustment

of

2-stage

switch)

Foot

switch

70

3. Blown fuse

® Check for continuity with fuses No. 2 and No. 3

removed.

80

Fuse

15

A

58

Type

of

trouble

Cause

Check/Repair/ Adjustment

COUNTERMEASURES

Parts

to

be

replaced

Page

#7

The

work

clamp

will

not

return

to

the

origi-

nal

point

when

the

start

pedal

is

depressed

#8

Emergency

stop

lamp

after

lights presser moves to

the

original

point

4. Faulty power supply unit

171615

I a I 9

(Viewed

side.)

5. Faulty pulse-motor and

11

o

from

cord

-

I

IQJ©

4 3

lnl••

........

the lead

2l1J

121131

wire

4

©Qltg

3

[Q)

© 5

-

6. Faulty control

1.

Faulty micro-disk

PCB

to

#5-2, the

1

OV

a. voltage DC

at

connector J 1.

between 2 ~ and

An acceptable

3

9.

a. Refer

lli] Measure

value

is

® Remove connectors P28 and P29 from

box

and measure

resistance value

- 2, 1 -

Replace

Insert a good micro-disk.

3,

4 - 5, and 4 - 6.

the

control

the

resistance. An acceptable

is

approximately

PCB.

o.sn

the

control

between 1

Control box

Pulse-motor

assembly

Control

PCB

70

#9

The

work clamp move ing

start

#10

Test

lamp

not

I ight when

test

switch

pressed

#11

The

feed not

effected during test

will

to

the

not

sew-

point

will

is

1. Faulty micro-disk

2. Faulty control

1. Faulty

AI

test

and faulty

PCB

switch

cord

II II I II II I

81

2. Faulty and

cord

:~:

~

3.

Faulty

I IIIII

-

test

lamp

control

..

PCB

A13

813

Use

other

micro-disks.

micro-disk

Replace

® Remove

for continuity. Acceptable if resistance between A

ON.

® Remove

continuity. of

Replace

Refer

is

responsible for

the

control

the

connector

10 - B8

maximum magnification.

B12®-

to

connector

the

control

#7-1,

is

oon

The

B98

3,

4, 5 and 6. (See pages

PCB.

or

Oil when

J9

pointer

PCB.

If

they

work

the

problem.

J9

from

test

from

the

should move

normally,

the

PCB

switch

PCB

and check for

to

80

and

is

the

and 81.)

the

check

turned

range

Micro-disk

Control

FMC device

Control

PCB

70

Refer

to

#5-3.

#12

Rapid feed

not

can used during the

be

test

1. Faulty work clamp lifter pedal switch

(See page 79.)

81

Type

trouble

of

Cause

Check/Repair/ Adjustment

Parts

replaced

to

be

Page

#13

The feed does

not

move as

programmed

the

during

test

#14

Machine stops turning during sewing

#15

During opera-

tion

the chine starts turning

high speed and then makes an emergency stop.

ma-

at

1. Feed mechanism improperly adjusted.

2.

1. Faulty cord

2. Faulty control

3. Faulty machine

motor

main

is

PCB

1~

1. Faulty synchronizer and cord

Adjust so

Refer

Check connectors tinuity.

a.

[]iJ

that

the

feed moves smoothly by hand.

to

#7-1,

3"'

6.

J5 -J30,

Turn power switch

Remove P30 from

as

a. (above), measure

ceptable voltage

on

the

ON

PCB.

(See pages

and

turn

LED

the

control box and

the

is

approximately 44V

18-20.

a.

Check

to

see if

the

main

motor

@ Remove connector

tinuity. An acceptable resistance 7il

between 1 - 2.

a.

Check connectors

b. Replace

the

synchronizer.

J40

P6-J6

80

and 81.)

and P30 -

ON

7 should light.

voltage

is

and check P40 for con-

and

J21-P21.

J40

for con-

selector 8 on DIP

do

the same

at

J30.

An ac-

DC

between

turning.

is

approximately

ECM

harness

Control

Synchronizer assembly

PCB

61 60 62

70

#16 Machine in reverse

direction

#

17

Machine but

presser

will

not

18

#

Thread

not

be

trimmed

turns

move

will

1.

Connector plugged in reverse

1. Faulty synchronizer Refer and cord *When this failure occurs, tests are normally performed

1. Faulty synchronizer Refer and cord

2. Faulty

.....--+===.---{~

~

l

3. Faulty thread

PCB

91©

~

[Q)

© ©

-©

©

@-

12

© ©

trimming solenoid,

work clamp

solenoid and cord

L~J~~

4

[Q

r-----

Q

Ql

(Q]

lifter

12

Correctly plug in power connector J41, which leads the

machine motor.

to

#15.

to

#15.

[!J Perform the thread trimming with

P27 plugged into

-

nector cover and measure the voltage by using a

1

4

(J27 viewed from

probe on the lead wire side.

9

(±)

The voltage should momentarily register mately

- 3 e and

30V

the

lead wire side)

the

control box. Remove the con-

11

(±)

DC

during thread trimming.

- 5 e

the

® Remove connector P27 from the box and measure

the

resistance.

mately

7il

An

acceptable resistance

between 3 - 9;

14il

between 5 - 11.

connector

approxi-

is

approxi-

to

Control

Thread trim-

ming solenoid assembly

Work clamp

lifter solenoid assembly

PCB

70

82

Type

of

trouble

Cause

Check/Repair/ Adjustment

COUNTERMEASURES

Parts

to

be

replaced

Page

#19

Mechanism will

not

stop above the needle after thread

trim-

ming

#20

Pattern formed as programmed

Machine will not emergency stop pressed

Thread trimmed when emergency stop switch lease

is

not

#21

stop when

switch

#22

is

not

is

re-

1. Improperly adjusted synchronizer

2. Faulty

1. Faulty emergency stop

switch and cord

5

is

PCB

I I

If

the

machine stops

random, adjust the position from which raised.

The

LED

8

on

the

motor

stops.

Refer

brake should click after thread trimming

to

#13.

(See page 82.)

® Remove connector J

continuity. Between 3-5: Between 4-5: Between 1

to

Refer

An acceptable resistance

8-2 0:

#18

and

the

on, oon,

#19.

but

the needle

PCB

should light momentarily and

11

from

oon

if

switch

on

if

switch The probe moves range magnification.

(See pages

is

the

PCB

ON ON

of

the maximum

82

and 83.)

positioned

the

signal

and check for

is:

to

at

is

the

Control

Emergency stop assembly

PCB

switch

49

70

#23

Step-back

will

switch

not

function

#24

The machine

stops during sewing

#25

Program can not

be ex-

ecuted

1. F au tty step back

and

switch

A1

II II

II

81

1. Faulty and

2. Faulty programmer

3. Faulty control

_

ll

connector

cord

J

IIIII

J

ltlll

PCB

A13

813

J

@Remove

continuity. An acceptable resistance is:

Refer

Plug

Replace

connector J11 from

Between Between 4-5 :

Between 18 - 2

to

in

connectors

3-5:

#13

and

the

programmer.

the

control

#14.

J8

PCB.

the

on,

oon

if switch

oon,

on

if switch

(±):

The probe moves

range magnification.

(See page 82.)

and P25 correctly.

PCB

and check for

ON ON

of

the

to

the

maxi mum

FMC

device

Progammer

Control

PCB

70

83

BROTHER

HEAD

OFFICE: HORITA-DORI, CABLE:

BROTHER

TELEX:

BROTHER

INDUSTRIES,

No.

35,

9-CHOME.

MIZUHO-KU,

NAGOYA,

4473696J & J59743

NAGOYA,

LTD.

JAPAN

Printed

I

5100214

in

467

Japan

F@