Brother BAS-361 Service Manual

SERVICE

MANUAL

FOR

BAS-361

PROGRAMMABLE ELECTRONIC

PATTERN SEWER

Profile

L

CONTENTS

DISASSEMBLY
MACHINE

OJ

Feed Guide Mechani sm and

Cover Removal . . . . . . . . . . . . . . . . . . . . . . 2

[I]

Rail-Y Cover

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

[]] Machine Head Removal . . . . . . . . . . . . . . 6

STITCH

LENGTH

MACHINE
LOWER

AND

THREAD

BOBBIN

FOR

TRANSPORTATION

and

DO

Motor

AND

SPEED

CAPACITY

REPLACEMENT

FREQUENCY

~

MECHANICAL

OJ

Needle Bar. Thread Take-up lever,
Lower Shaft
Mechanism

[I]

Work

Clamp

Feed Mechani sm . . . . . . . . . . . . . . . . . . . . . 12

[]]

Feed Guide Mechanism

m

[[]

Thread Trimming Mechanism
Thread Catcher Mechanism

lil

Bottom Plunger Mechanism .

m

[]]

Bobbin Winder Mechani sm

ecdle Bar Descent

!Il

Needle Cooler

MACHINE
BLY

PROCEDURES

OJ

Bottom Plung

[I]

Thread

[]]

Thr

IT]

Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . .

[[]

Rotary

[I]

Stepping Foo t

[I]

Needle Bar. Thread

[I]

Needle Bar Descent Guard Assembly .

ead

Trimmer
Catcher

Hook .

DESCRIPTIONS

and Rotar

.......

Mechani sm . . . . . . . . . . . . . II

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

HEAD

er

......

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

y Hook

..

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

.........

...........

...........

Guard

and

DISASSEM-

Assembly

.......

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

Take-up

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

..

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

..

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

...........

.

.......

..........

.....

. . . .

.

. . 14

...

..

9

9

~

10

. 10

13

16
IS
IS

19

20
20

20
21
21
22
22
23
23

MACHINE

[

PROCEDURES

OJ

Needle Bar.

[I]

Stepp ing

OJ

Rotary Hook

IT]

Thread Catcher Mechanism

[}]

Thread Trimming Mechanism .

[I]

Bottom Plunger Assembly . .

[I]

Cylinders

[I]

Needle Bar Descent Guard Assembly

~

STANDARD

OJ

Adjustment

[I]

Adjustment

[]] Adjustment

the Needle

IT]

Adjustment

[[] Air Pressure Adjustment

[I]

Work Clamp Adju stment .

[I]

Work Clamp Position Adjustment

[]]

Mo

vable Knife Adjustment

!Il

Thread Trimming Slider Adjustment

[I£]

Thread Catcher S

(DJ

Bottom Plun

@]

Thr

ead Trimming Cylinder Speed

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . .

[ill Thread Catcher Cylinder Adjustment

[ill Bottom Cylinder Speed Adjustment . . . .

[ill Work Clamp Cylind er Speed

Adju stment

[ill Presser Foot Lift

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . .

[ill Movable Knife Timing Adjus tment

[ill Origin Position Adjustment . . . . . . . . . . . 42

[ill Ovcrlimit Switch Adjustment

~

Pulse

[ill Belt Tension Adjustment

0]

Encoder (Position Detector)

Adjustment . .

[Til

Direct Drive
Inspection

[E)

Bobbin Win

Foot

...

and

Motor

......

HEAD

Thr

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

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

ASSEMBLY

ead

Take

-up

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

.........

.

....

...........

........

...........

ADJUSTMENTS

of

the

Rotar

y Hook

of

the

1'\ccd

lc

Bar Height ...

of

the Clearance between

the Ro

tar

y Hook

of

the Presser

lid

ger

Adju stment

........

er

Backlash Adjustment . . .

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

Motor

..

der

Adjustment

Foot

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

er Adjustment

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

Cylinder Speed

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

Maintenance

........

.......

......

........

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

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

...........

..........

.

..........

...........

J

_ .

. .

.. ..

l ·

.....

...

.....

...

..... 39

. 25

.

..
..

~

24

25
27
2S
29
29
31

32

32
.12

32
33
34
34
.14

35

35
36
.16

37
37
.IX

3X

39

43
44
45

46

4S
4S

BEARING REPLACEMENT

AND ADJUSTMENT

[JJ

Slider Bearing Replacement
Adjustment

[I]

Guide Rail Hold

Replacement and Adju stment

[]] Raii-Y Bearing Replacement

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . .

1IJ

Gear Replacement. Adjustment

Mai ntenan

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

er

Front

ce

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

and

Bearing

..........

and

and

49

49

50

51

. . 52

TROUBLE SHOOTING

FLOW

lEXPLANATION ON

MARKINGS]

[JJ

[I]

CHART

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

Troubleshooting Flow

for Machine
Troub
for Pr

ogramm

Control

leshooting Flow Chart

ing De vice

Device ........... !l

Chart

........

....

......

......

80

80

l

90

WORK
CONSTRUCTION

CLAMP

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

PROPER USE OF SPECIAL
ACCESSORIES

~

AUTO

[JJ

[I]

[]] /\tHo-eject Assembly

1IJ

~

ADJUSTMENT

~

ELE[TRICAL ADJUSTMENT

E.J

ECT

(optional parts)) . . . .

Auto-eject
Auto-eject Disassembly

Auto-eject Adjustment

Fun

ction

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

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

@IDE

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

...

..........

~

-

.........

53

60
60

61
63

...

67

68

~

-.

72

~ACTION

COUNTERMEASURE~

91

[JJ

Fu

se

Replacement . . . . . . . . . . . . . . . . . . . .

[I]

Circuit Boards
Re

pl

acemen t . . . . . . . . . . . . . . . . . . . . . . . .

[]] Dip Swit

!Il

Con

nectors . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTROL CIRCUIT

ch

and

Dip Switch

Usc

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

BLOCK

DIAGRAM .

..

72

73
76
77

79

~DISASSEMBLY

FOR

MACHIN~

TRANSPORTATIO~

* This machine

Wh

en the entrance or e:w is narrow. fir

and then

di

i

~

14

sas~em

bl c

00 (W) X

in the following order until the machine

1390

(L) X

1200 (H) mm.

l!t

mca~ure

the entrance

- - transportatio n

~itc.:

a

nd

compa re

11

ill

pas~

through the entrance.

St

ep A (machine

Perfo

rm

steps I
and Cover
illustration at right

R

ei

nstallation

step 9

Removal." The dimension shown

"'

I.

of

11ith

size: 1390

"'9

in''ITJ Feed

of

these

is

performed

rem ova

the

machine·~

mm)

Guid

will

become 1180

parb

in the

I.

dimcnsiom

~.:

Mechanism

in the

mm
after machine
opposite orde

.

r.

Step 8 (machine

Perform
Removal"
Removal"

at righ t will become 960 mm . Rein!.taii<Hion aft

machine transportation

o

rder

St

Perform "
Remol'al"

Remo1al" and "

regular order.
become 860 mm. Rcinl!
t

ra

"ITJ

.

ep C (machine

ITJ

nsportation

size:

1180

mm)

Feed Guid e

and "!II Raii-Y Cover and

in

regular order.

size: 960

Feed Guide Mechani,m and Co1cr

and

"!II Raii-Y C01er and

ITJ

The

dimension

i~

the rc1er

Mcchani~m

The

i

~

the re1ersc

mm)

Machine Head Rcm01al"

l!l1011

tallation aft..:r machine

sc

of

rcmo1al.

and Cover

DD

dim ension shown

of

DD

n at right 11i

Mot or

rem01a l

Motor

er

in

ll

- I -

OJ

FEED GUIDE

MECHANISM

AND

COVER

REMOVAL

I.

(I)

(2) Loosen the nut 8
(3) Remove the set screws 0 for each

Feed Guide
tion

Remove the 4

f)

slightly back by

holder

arrow.

and

-~on

(front) 8 out

disconnect the

clamps

Mechanism

boltsO,

hand.

at

air

8.

and

remove the nylon clamps

Removal

and

in

the direction

each

tubes

and

after

pushing rail-Y

pull the guide rail

of

the four elbows,

8.

Installa-

of

the three

of

the

(4) After moving the feed guide mechanism

or

either the left
forward

(5) Installation

and

right side, pull the mechanism

remove.

is

the reverse

of

removal order.

* When inserting the feed guide mechanism

0 into the slider

guide

CD

on

and

insert while firmly pressing

top

of

the guide

*

Connect
the correspondingly

2. Needle
(I)

Remove the twelve

while raising needle plate L slightly, pull it

forward

(2) Installation

the

Plate L Removal

and

is

f),

the

top

bar

air

tubes 8

mounting

remove.

the reverse

rest the side

of

the slider spacer

down

48.

and

elbows 8 in

numbered

and

of

locations.

Installation

screws

removal order.

of

the feed

0.

0 to

4B,

on

the

and

-2-

3. Programmer Drawer Removal and Installation

(I)

Disconnect the connector 8 for the pro-

grammer.

(2) Pull

(3) Remove the programmer

(4) Installation

4. Panel Setting Plate Cover Removal and

(I)

(2) Holding both sides

out

the programmer drawer 8 and

remove the programmer

it

up

and

down.

is

the reverse

Installation

Remove the four screws 8 on the bottom and

the one screws
setting plate cover

cover

8.

8 on the side

pull it forward firmly and remove.

8.

drawer8

of

by shifting

removal order.

of

8.

of

the panel setting plate

the panel

Be

sure

to

*

8 after installing front cover R

5. Rotary Hook Cover Removal and Installation

(I)

Remove the four screws 8 in the rotary hook

cover R

8 and rotary hook cover front 8

R
When doing this step,
cover front

8 with your hand so they

(2) Installation

install the panel setting plate cover

8.

8,

and

remove the rotary hook cover

as

bottom

not fall.

8

and

is

the reverse

support

rotary hook cover

the rotary hook

do

of

removal order.

a set.

-3-

6. Front ('over Upper

(I)

Insert a screwdriver
front

cover

upper

screws

8.

(2)

Remove
the

(3) Slightly lift the

forward
Installation

(4)

*

When
first place the

cover 0 and

front

installing

the

fourscrews8

cover

and

remove.

is

the reverse

bottom

the legs.

0.

front

I.

Removal

from

L 0

cover

the

front

edge between

and

and

Installation

the

bottom

and

loosen the

on

the

upper

of

removal

cover

then finish installing.

upper

L

0.

upper

the

of

four

part

pull it

order.

L

front

the

of

0.

7. Front Cover Upper R Remm·al

(I)

Insert a
front
screws

(2)

Remove
the

(3)

Slightly
forward

Installation

(4)

When

*

first place
coverO

screwdriver

cover

upper

8.

the

three

front

cover

lift the front

and

is the reverse

installing the

the

and

R 0

screws8

0.

remove.

bottom

the legs.

from

cover

front

edge between

and

and

Installation

the

bottom

and

loosen the

in the

upper

of

removal

cover

then finish installing.

upper

R

0.

upper

the

of

two

part

pull it

order.

R O.

front

the

8. Panel Setting Plate Removal and Installation

(I)

Remove
legs.

(2) While

hand.
the

(3)

Gradually
side
it.

the

supporting

remove

cover.

cover

8.

two

bolts 0

the

screw 0 in the

reducing

slide the

side

the

on

cover

strength

cover

the

bottom

R 8 with

top

supporting

down

and

of

one

center

remO\·e

the

the

of

of

To

*

install

in the

-4-

the

cover

side

stops

cover.

and

first insert its

then

finish installing.

four

tabs

(4) Disconnect floppy

harne

!>~

B 0 from the floppy

the two
plate

(5)

Di!>eon

0.

{6)

Loosen the four screw:-

setting plate

(7)

l

mtallation

harnessc~

f)

.

nect the barne

and

pull it inside the panel setting plate

f)

forward and remove.

is

the reverse

harne!>s

out from the panel

A 0

and flop

dri,

·e 0 . and pull

s:-

0 to the switch panel

~.

pull the panel

of

removal order.

py

~etting

f)

.

When installing.

*

connectors firml

9. Needle Pl

Installation

(I) While holding need

remove th e eight bolts to needle plate support

guide brackets A

needle plate

To

(2)

~upport

e. I ex

p. 2). firmly tighten the eight bolts

in

stalling the
ate

pl

ate

install. temporarily install needle plate

guide bracket A e with the eight

t.

after installing needle plate

L.

be

~urc

to plug in all

y.

Support Guide Remo\'al and

le

plate support guidc A 0 .

e.

and

then remo

suppor

t guide

support

as

a single unit.

guides. remove needle

ve

bolt~

L(refer

e.

Af

the

to

ter

ITJ

RAlL-Y COVER AND DO MOTOR REMOVAL

(I) Loo!>e

(2) Remove the four screws e. and rcmO\C the

{3)

(4) Installation

*

n the two right a nd left set

remove

arm

Remo

motor

cord

as~embly

When
assembly. take note
shaft

prope

180° out

theY

rear cover 0 .

ve

the five

bracket assembly

is

pulled up slight. t

can

rcmo'

and

rl

y installed. the mot

of

-5-

-axis rail cover e.

serew!>

O . and

0.

he

be placed on the tabl

is

the

rC\Cr~e

ing the

DD motor

phase.

()()

or

make a mark

coupling posi ti on. If not

sen:wsO.and

remo\e

At this time. if the

DD

of

removal order.

motor

or

and shaft will

the

motor bracket

e.

brad.et

of

the arm

DO

be

II

arm

bed

*

foliO\\

(I)

Refer

a:-.is rail

Disconnect

(2)

DO motor
clamps
from the hole in the back
Disco

(3)

(4)

R

emo\e

DO

motor

ln::.tallati

(5)

remm

ing

\tep~

to

the

pre\iou'

co\cr

the encoder

circuit

0

(three strap

nnect th e DO m

the three

bracket

on

i'

a I "

neee,,a

Ill

order

.

page

and

arm

rear

assembly

board

L 0 , remove the cord

s), and pull the cord

of

oto

r power

'ere"'

0 .

a"embh

the

re\er'c

ot

r~.

and

rernme

co\er.

cord

the arm.

connector(@.

and

()

.

rcmmal

pert

orm

0 from

remme

order.

1 he

theY-

out

the

\\'hen

•

a!>~embl~.

-,haft

proper!~

J8Q

IIJ

MACHINE

I. Table

(

I)

Remo\c

(2)

Remo\e

(3) RemO\ e

0

Co

(4)

with the t

1

0te:

(5) I

rcmO\ tng

and

C

OUt

Remo,·al and ln!>

in

place.

mp

ress the bellows 0

Wh

en rern

in

side

then

nstallation

take

note

DD

motor

in\talled.

of

pha\C .

HEAD

the

four

the

four

the

t\\0

able

left 0

o\

edge

of the table

remove.

is

the r

the

I)

I)

motor

ur

m.tke a mark

coupling

the

nwtor

po,tlton. If

and

REMOVAL

tallation

bolt' 8 at

bolt-. 0

sere\\\ e holding

and

ing

table

c,crsc

the

at

the

table

and

remove together

table right 0 .

right 0 . ra ise

approx

of

rcmoHtl

uf

'halt

table

the

.

.10

brJckct
the

arm

not

"'II

be

left 0 .

right 0 .

bellO\\!>

th

e

em

and

order.

-6-

2.

Slider

and

Slider

tion

(I ) Remove the

remove the belt

••

(2) Hold slider

e by

hand.

left. lift

(3)

Remove the

slider

••

Note:

(4)

Installation

and

guideO

There

arc
in the slider guide
middle bolt

Guide

Remm·al

two

bolts 0 right

support

upper

and

while moving the slider right to

remove.

four

from the rail guide base brackets

four

plate e from the slider

left G

and

bolts

8.

places with three bolts each

0:

in

each

of

is

the reverse

of

and

Installa-

and

left.

slider

upper

and

remove the

remove only the

the four places.

removal

order.

and

right

3. Raii-Y

(I)

(2) Pull rail-Y 8 forward

(3)

4.

Arm

(I)

(2) Disconnect the six

(3) Remove the air hoses

Removal

Remove the

dog

f).

Installation

Bed
Remove
machine positioning brackets

trimmer

thread
with the

lated

to

air.

and

two

is

the reverse

Removal

the

four

assembly.

air

tubes.

Installation

boltsO.and

and

bolts

coupling

remove

and

remove.

of

removal

Installation

f)

in

each

theY

of

0.

nuts 8

and

remove together

on

the machine head re-

-ES

order.

the four

to

the

-7-

(4) With two

arm

(5) Installation

*

Be
the correspondingly numbered connection.

or

more people. raise

bed.

is

the reverse

sure to connect thread trimmer

and

of

removal order.

remove the

air

tubes to

-8-

~STITCH

*

On

the HAS-360. machine

selector switches

LENGTH

sreed will be automatically

ur

10

four set

AND

~reeds

can

MACHINE

adju~ted

be

selected.

SPEED~

according to stitch length. or by using the

sreed

s

~

0.1 ~ 2.4

2.5 ~ 4.4

4.5

LOWER

mrn
mm

~I'

d

mm

THREAD

REPLACEMENT

I.

With t

he

thread wou nd

be

low.

~

.

Col! on

Srun

rayon

to

appr

2.000

1.400
800

CAPACIT

FRE

ox.

90

UENCY

~[

of

the

#8

20

I

bobbin\

m

2

1.750

1.300
700

AND

outer diameter. thread length will

BOBBIN

#20

29

111

32

m

3

1.500

1.200
600

11

30

44 m

4

1.250

1.

100

500

be

as in the table

#50

81

m

87

m

Yinylon

Polyester

2.

When the lower thread

bobbin

~

will need

e
Col!on #8
Couon
Couon
Couon

Sru
Srun rayo n #50 0

Yinylon

#20
#30 0
#50 0 0 0

n rayon #20

#8

rer

lacing the

23m

-----------

30

111

is

wound to the caracities ind icated

number

of

tim

e~

shown in the following table.

2 mm

I

o

~

I

o

~

I I I

I

3 mrn

t~3

t~2

o

~

0

~2

I

~

---------

~

65

---------

in

the

abo

\C

table and make 10.000

4 mm 5

2 ~ 3

~2

I

I I

~2

0

2

"'

3

m

111111

3~4

2

~

3

1

~2

o~

t

~3

o~t

2"-' 4

----------

=----------

s

titchc

~.

the

6

111111

3~6

2~4

t

~2

t

o~t

2 ~ 3

o~t

3

"'

5

Polyest

er

#8

Polyester #30

0"'1

0 0

I 1 "-'2 1 "-'3

"-'

1

0

- 9 -

0"-'

2 ~ 4

1

I

~MECHANICAL

OJ

NEEDLE

BAR.

THREAD

DE§CRIPTIONS

TAKE-UP

LEVER. LOWER

))

SHAFT.

AND

ROTARY

HOOK

MECHANISM

I Needle

(I ) When the

(2)

(3)

II

(4)
(5)

(6)

{7)

*

(8)

Bar

and

Thread Take-up

DO

motor

shaft e.

The nee
vertically by mea ns
The needle

bw.hing [) 0 and the needle

Lower

When the
The lower shaft
The sp iral gear

rotary hook
twice.
A rot

with

Hand

Pushing
the a rm
Pushing

dle.:

bar

bar

Shaft

DD

ary

hook

the shaft

Rotation

on

the pulley

~ha

ft

on the

cr

ank 0

f)

sup

and

Hotary

motor

4B

(0

connected to the end

shaft~-

4D

~

-

8

can

stoppe

I.e'

cr .\lechanism

0 rotates in t

is

of

the needle

ported by the needle

Hook

0 rotates

is co nnected to timin

When the lower shaft

is connected to the end of the rotar) hook shaft

G)

will engage the

then be turned by hand.

r~

again

he

direction

connected to the take

bar

connecting rod e.

bar

guide

~lcchanism

in

the

arrow

of

stopper~

"ill

release the

of

bar

clamp 0

block~-

direction . timing pulley U

g pul

ley

the lower shaft

4B

rotates one full revolution . the

the

arro\\.

-up

and

D (I) and

causing the pulley shaft

stopper

the take-up len:r

le\er

crank

0.

is

guided by needle

~hould

move

smoothly

is

driven by the timing be

4B

meshes with the pinion gea r

to

it!.

original position.

and

4D

4D.

gear

crank

0

i~

rotated by the

mo\e~

the need

bar

bushing U 0 . needle

up and dO\\n.

rotates.

lt

a.

4D

rotar

y hook

and

rotates simultaneously

f)

to me!>h \\ith

arm

le

bar

clamp 0

bar

.

connected to the

s

haft~

ro tates

gearfl)

and

-10-

[I]

WORK CLAMP

MECHANISM

(I)

When

air

pressure

connected

(2) Lever A 8

stud

(3)

When
maximum

(4) When pressure in the pressure cylinder 8

to

is

e.

presser

and

is

increased

the pressure cylinder 8

connected

arm 0 drops

the

to

work

to

the pressure cylinders 8 by the

lever B 8 by the lever

and

the

clamp

holds the material firmly.

is

collar G is

pushed

is

increased by

forward

stud

in

and

lever A 8

f).

and

the presser

line with lever stud

air

tube

air

tubes

0.

is

rocked via the

arm 0 is

f).

work

O. the presser

the

cylinder setting plate 8

collar

G.

lowered. pivoting

clamp

pressure reaches a

arm

0 rises.

on

hinge

-11-

IIJ

FEED

[X-aixs]

1.

When the pulse

the timing belt e

2.

The
slider

3.

The

MECHANISM

timing belt 8

8.

slider 8

(DRIVE SIDE)

motor

0 rotat..:s. the timing pulley H 0

arc

driven

is

connected to the belt

is

guided by the slider guide G.

in

turn.

support

and

is

panel

0.

relays pulse

turned

and

motor

via

g..:ar X 8

the belt

support

0 revolutions

and

the

gear

assemhly 8

panel 0

to

is

connected to the

the feed guide assembly.

and

[Y-axis]

motor

4. When the pulse
moves rail-Y $ in a straight line.

5.

Rail-Y

the rail guide holder front 6' which

4D

is guided by raii-Y guide front

0 rotates. the pulse

motor

gear

4»

and

rail-Y guide

is

connected the end

G)

meshes with the rack 8 installed

readD.

of

rail- Y

$.

-12-

and

relays pulse

motor

on

rail- Y

f)

revolutions

$.and

to

[I]

FEED

GUIDE

MECHANISM

[X-axis]

I. When the

upper

2.

The
to the

[Y-axis]

3. When the guide rail holder front

4.

The
The

5.
to the

sliderO

left

8.

feed guide plate front 0

clamp

feed guide 0

feed guide plate front 0

clamp

slider

f)

f)

and

and

moves a full

upper

feed plate 0 which

is

connected

feed plate 0 which

center 0 and

and

and

trip

on

the X-a.xis.

slider

clamp

mechanism

arc

mm·es a full trip

to

feed guide X

clamp

mechanism

arc

connected

motion

upper

f)

arcconneetcd

connected

on

theY

41>:

it

f)

arc

is

relayed

right

0.

to

these.

-a

.xis.

is

guided by the slider 0

connected

to

the guide plate front 0

to

to

action

to

the feed

the feed

is

relayed

the feed

guideO

guide8.and

guideO.

to

matching

and

and

that

mo,·es

clamp

is

guided by slider

motion

feed guide X
on

the Y -axis.

and

motion

mechanism

is

relayed

is

relayed

41).

0.

-13-

IT]

THREAD

TRIMMING

MECHANISM

(I)

Thread

I.

When
arrow

The

2.
arm

3.

The
movable knife

4. When the solenoid valve 0 becomes off. the

and

Trimming

the thread
direction.

knife lever 8 connected

shaft

G.

forked-part

the movable knife 8 returns

Mechanism

trimming

of

knife rock

8 connected

signal

to

the

arm

to

the movable knife base assembly

turns

the solenoid valve 0

thread

trimming

A 8 fits the movable knife base assembly

to

its original position.

thread

on.

the

thread

trimming

cylinder 8 activates knife rock

8.

trimming

cylinder8

moves opposite

cylinder 8 moves in

arm

A 8 via the knife rock

8.

and

thereby moves the

to

the

arrow

the

direction

-14-

(II)

Upper

and

(I)

When the needle

lowest position. the
upper
trimmer
knife

thread

is

stationary

Lower

signal has been sent.

Thread

is

moved 2.2

loop. At this time. the

because

rotary

Trimming

mm

hook

the

above

point

but

signal

the needle

catches the

thread

the

movable

is

delayed.

(2)

The
point
The

The

(3)

been opened by
spreading

upper

thread

loop

and

passes

around

movable knife begins

needle rises
lifts the
passes

upper

through

and

thread.

the

the

occurs.

is

pulled by the

the

inner

to

the

thread

The

upper

thread

rotary

hook

move.

movable

loop

point

rotary

hook

..

take-up

knife tip

which has

and

hook

lever

loop

Movable
knife

•

Lower

Movable

If this timing

appear
and

m1sses.

thread

knife

in

may be the cause

is

the

operation

either

too

fast

of

of

or

the

thread

too

slow. it will

movable knife

trimming

(4)

The

*

needle rises.

The

upper
When
stress

The

thread

after

the

is

made

thread

and

stops

at

the needle up position; the

or

lower thread

movable

on

the

length set by the movable knife becomes

trimming.

hooked

knife pulls

upper

This effects the stitch

the

thread

by

thread

and

the

it pulls

movable

and

retracts.

at

knife

out

smoothly.

both

the

start

thread

is

cut by

the

thread

the

needle

of

new sewing.

take-up

the

fixed knife as the

tension release activates

thread

length

-15-

lever

approaches

movable

and

the

bobbin

its highest

knife retracts.

so

that

no

thread length

point.

excess

I

[II

THREAD

CATCHER

MECHANISM

STANDARD SPECIFICATION

(I)

Thread Catcher Mechanism

L.

When the solenoid valve 0 becomes

ON

before the start

arrow direction.

2.

The

thread catcher

rock arm shaft B

3.

The forked-part
catcher spring

4.

When the synchronization signal at the first stitch at the start
catcher cylinder

lever@

connected to the thread catcher cylind

0.

of

knife rock arm B 0

8

co

nnected to movable knife base bracket B 0 .

f)

moves opposite

fits th

e movable knife base brack

to

arrow direction and the thread catcher spring

tion.

of

sewing,

of

the thread catcher cylinder

er

f}

activates the knife rock arm B 0 via knife

et

B 0 and th ereby activates the thread

sewing turns the solenoid valve 0

f)

f}

moves

in the

OFF

, the thread

returns to its original posi-

SPECIFICATIONS

(I)

Thread Catc

1.

When the solenoid valve 0 becomes

FOR

her

Mechanism

BAG ASSEMBLY AND NECKTIE

ON

before the start

of

sewin

g,

the thread catcher cylinder
arrow direction.
The

2.

thread catcher lever ~ connected to the thread catcher cylinder

rock arm shaft B

3.

The

forked-part of knife rock arm B 0 fits the mo vab le knife base bracket B 0 and thereby activates the thread

catcher spring

0.

8 connected to movable knife base bracket B

0.

f)

activates the knife rock arm B 0 via knife

4. When the synchronization signal at the first stitch at the start of sewing turns the solenoid valv
catcher

cylinder

f}

moves

oppo

site to arrow direction and the thread catcher spring

f)

returns to its original posi-

tion.

d1

e start

of

5. After several stitches has been sewn at

cy

linder

(j)

mo

the

ves in the direction

of

the arro

sewing, the signal from the machine turns on the solenoid valve,

w,

the thread catcher spring

f)

rotates and the needle thread is re-

leased.

f)

moves

in

the

e 0 OFF, the thread

-16-

(II) Thread Catcher Operation

Thread catcher

I. Before sewing starts. the thread catcher spring

advances.

2.

At the first stitch. the rotary hook point catches the
upper thread.
pulled below the needle plate.

and

the end

of

the upper thread

is

The

3.
catcher
thread
spring

synchronization signal causes the thread

spring

to

retract.

is

held lightly between the thread catcher

and

the

bottom

and

the tip

of

the needle plate.

of

the upper

-17-

4.

As

sewing continues. the upper thread

from the thread catcher spring.

is

released

[!]

BOTTOM PLUNGER

MECHANISM

;?f8if'

(Up) (Down)

I. When the solenoid valve 0 becomes

direction.

2.

The

bottom

bottom

3. When sewing ends
direction

lever plate 8 connected

plunger 8 via the

and

the solenoid valve 0 becomes off. the

and

the

bottom

plunger 8 returns to its original position.

bottom

shaft

to

on

the

at

bottom

8.

the

start

of

cylinder8

sewing. the

[I)

I. When the bobbin

bottom

is fixed to the

bottom

BOBBIN

winder spindle

8

is

swung towards the bobbin winder spindle

cylinder 8 moves in the

bottom

cylinder 8 moves opposite

WINDER

0.

and

leverG.and

is

O. the bobbin winder

mounted on the bobbin winder
pin

8 presses the leaf spring

2.

The leaf spring 8

winder lever
winder screw

limit switch 0 turns

motor
bobbin as long as the bobbin winder
rotating.

3.

When the specified

onto

the bobbin. the bobbin winder
hinge pin
lever

8 moves away from the limit switch

the

motor

spindle

8

8.

0 begins to

0 swings back. the bobbin winder

0 stops.

0 stops.

is

and

revolves

When the bobbin winder

turn.

amount

activates the

MECHANISM

mounted

bobbin

stop

on

winder

latch

trippingarmG

stop

8.

mounted

on.

winding thread

and

on

around

the bobbin winder

of

thread

the bobbin winder

arrow

to

arrow

the bobbin

stop

latch

latch hinge

the bobbin

the bobbin

motor

onto

the

spindleO

is

wound

stop

latch

0.

is

-18-

IT]

NEEDLE BAR

DESCENT

GUARD

AND

NEEDLE COOLER

I. When the feed mechanism functions. the solenoid 0 is on. thin material cylinder

of

the

arrow,

0 will

2.

When material feed
the

arrow.

3. At the beginning
direction
arrow.

4.

During

will move

*

The

needle cooler 8 will only function while solenoid 0

* Tension release will only function when the machine

times

it

and

presser foot lifter cylinder 0 will

then

turn

off.

and

the thin material cylinder

is

completed. the presser foot lifter cylinder 0 will move back. opposite

assuming

of

the

During sewing solenoid 0 will remain on.

thread cutting after sewing

in

the direction

holds the needle thread tight.

the

stand-by

of

sewing when the solenoid 0

arrow.

and

the presser foot lifter cylinder 0 will move naturally

of

condition illustrated above.

is

completed. solenoid 0 will

the

arrow.

operate

58

turns

and

vertically

will move back. opposite

on,

the thin material cylinder

the

needle cooler 8 will continue

is

is

in

the stand-by mode

on.

turn

in

off. and

the direction

the

and

-19-

58

will move in the direction

of

the

arrow.

The

to

the direction

58

in

the

opposite direction

presser foot

during

thread cutting;

of

to

the direction

will move in the

to

function.

liftercylinderO

solenoid

the arrow.

of

of

the

at

other

~MACHINE

(;)

HEAD

0
0

DISASSEMBLY

PROCEDURES)

•

To

S

tar

t

Perform these steps aft
Feed Guide Mechanism a
machine tran sportation.

OJ

BOTTOM PLUNGER

I. Remove the two flat screws

needle

2.

Remo

plates

ve

sto

p ring E 8

e.

er

performing the steps

nd

ASSEMBLY

and

e.

3. Loo

se

n the screw 8 from

0

4. Remove the stop ring
the bottom lever shaft
bott om lever

IT]

THREAD

I.

Remove the st

e.

pin

2. Remo

3. Loosen

ve
movable
connected parts still attached.

C).

TRIMMER

op

the t

wo

knife

th

e screw 8 and remove the knife lever

and

0.

ring 0 and pull out the link

screws

base bracket G with all

8.

o.

4.

Loosen the set

remove knife rock

sha

ft

A~-

5.

Remo

ve

the two screws

movable knife base assem bly

6. Remove screws
movable knife

7. Remove the two screws

thread presser spring

s

pnn

g.

sc

rew 8 and screw

arm

A 0

4D.

fD

and

4D

G).

4D

4D

and then thr

"OJ

Cover Removal" for

0.

and

remove

pull out the link pin

be

low the bed.

washer

an

8;

remove

and remove the

and remove the

0.

and

d knife rock

and

remo

ve

arm

the

f».

and remove the

an

d remove the

ead catch

er

-20

-

[l]

THREAD CATCHER

I. Remove the two screws O.

thread catcher spring

2.

Remove the

pinG.

3.

Remove the four screws
thread
connected.

4.

Loosen screw

G.

lever

5.

Loosen the two screws 0

rock

arm

6.

Loosen screw 8 from below the bed. pull

slide shaft 8

8

•.

stop

catcher

0.

8 0

48.

8.

ring

8.

base 8 with all parts still

and

remove the thread catcher

and

knife rock

and

remove movable knife base

and

8.

and

and

pull

out

and

remove knife

arm

remove the

the link

remove the

shaft 8

4D.

out

11]

CYLINDERS

I. Remove the nuts 0 for each

connected to the elbows.
tubes.

2.

Remove the

the knife cylinder base

8

and

3. Remove the
the

bottom

screws

4. Remove the bolt 0

thread catcher cylinder base
screws
cylinder

two

screws

the knife cylinder

two

screws 8

cylinder base

0

and

remove the

8

and

remove the threa'd

48.

and

8.

8.

remove the two screws

8.

and

of

the six

air

tubes

disconnect the

and

after removing

and

after removing

0.

remove the two

bottom

after removing the

cylinder

49.

remove the two

0.

catcher

air

-21-

rn

ROTARY

HOOK

I. Remove the screw

case holder position bracket

2.

Loosen the three screws

rotary

!I]

I.

Remove the three screws

plate

2.

Remove the screws O.

foot drive

3.

Remove the presser foot adjusting

remove the presser spring guide G. presser

spring

4.

Loosen the set screw

foot

5.

Loosen the set screw
down
presser

hook

STEPPING FOOT

8.

cam

8.

O.

and

out.

bar

clamp

0.

0.

and

remove the bobliin

8.

8.

and

0.

and remove the face

and

remove the stepping

8.

screwO.

0.

and

remove the presser

41!).

pull the presser

and

remove the stepping foot

f).

remove the

and

badD

-~----~

48

:

I

I

I
I

I

I

I

I

1

...

-~

----

----

--

-22-

12]

NEEDLE BAR, THREAD TAKE-UP

I.

Remove the set screw

needle

8.

remove the thread guide

2.

Remove the oil

3.

Loosen screws 0

up

and

out

from the

stepping foot presser

4.

Remove the flat screw 0 (left-hand thread), and

remove the needle
to the needle
When doing this. be careful not
needle bearing

block$.

bar

0.

capO.

and

0.

bar

bar

clamp

crank rod

4D

or

and

after removing the

pull the needle

arm.

and

remove the

clamp

O.

G)

still connected

Gi).

to

the needle

8.

drop

bar

bar

the

guide

8

5.

Remove oil caps

6.

Loosen screws
bar

crank

f,D.

drop

the needle bearing

7.

Loosen screw @). pull

stud

0 and remove the thread take-up lever

[!]

NEEDLE BAR
ASSEMBLY

I.

Disconnect the

nipple

O.

2.

Remove the

0.

and

single Allen bolt
thin material cylinder
and

the cylinder support

3.

Remove the E-shaped

pin

Gi),

and

4.

Remove the two screws fl),

bracket

5.

Loosen the Allen bolt

cylinder bracket

41).

fD

fl

and

When doing this, be careful

DESCENT

air

hose 8 from the nylon hose

four

Allen bolts

then

remove the piston rod

$.

and

8,

5

snap

6}.

and

remove the needle

G)

and

washer

out

the rotary take-up

GUARD

8.

two Allen bolts

0.

and

then remove

e.

coupling

0.

ring

0.

and

remove the

fl.

and

remove the

not

fJ).

f).

hook

••

and

link

joint@).

hook

to

-23-

~MACHINE

HEAD

ASSEMBLY

PROCEDURES)

[!]

NEEDLE BAR,

I. Connect the thread take-up lever 0 to the

by

the thread take-up lever stud

sc

rew e.

2. Put the need le bearing 0

up lever

one

tighten screw s

In

the needle

3. Insert o

0:

hand.

in

stall so that screw

bar

il

caps 0 and

THREAD

wh

il

e holding the washer 0

sert the needle bar crank e.

f)

and

0 to ho

f)

crank e.

~

TAKE-UP

f).

onto

the thread take-

ld

aligns with the screw

-

and

tighten

wi

it in place.

arm

th

an

in

d

4. Put need le be_
rod

4D

the nat scre\\

5.

Put t

he

bar

guide.

clamp

6. Insert

7. Insert o

8. Install the needle

the needle

pass

it

cl

amr

temporarily tighten screws

of

the needle ba

aringf)

and connect to the needle

~(l

needle bar gu

and

insert the tip

6)

.

bar~

through the stepping foot needle

4D

a

nd

the needle

il

cap

fJ)

.

bar

r.

and tight

onto t

he

needle ba r crank

bar

crank with

eft-hand

id

thread guide 0 on the end

thread).

e block e into the needle

of

the needle

from the t

bar

fP)

and

en scr

or

of

clamp

~

ew

fl).

the

«)

-

bar

arm.

bar

and

- 24 -

[!]

STEPPING FOOT

I.

Pass the presser
the

arm,

and

clamp

8.

Install so
top

are

2.

Install the presser foot 8 on the

the presser

3.

Install the needle 8 in the needle bar.

4.

After pressing pulley
clockwise
the presser

that

end

of

in

close alignment.

8 aligns with the center

presser foot
fix the position.

5.

Set the presser
spring
tighten the presser spring adjustment screw
appropriately.

o.

bar 0 through

install the stepping foot presser

the end

the stepping foot presser

bar

of

the presser

0 with screw

8.

and

lower the needle bar; now, move

bar 0 and

8.

barO

and

adjust

of

and

then tighten set screw

in

place, insert the presser

presser spring guide

8.

turn

so

that

the

needle hole

the

bar

bottom

the pulley 8

bottom

bar

the needle

and

clamp

end

e.

in

f)

of

bar

the

of

the

to

and

Ci)

[I]

ROTARY HOOK

I. Temporarily

rotary

hook

2.

Install the

8

to

the

bottom

r---

:?7

--

-25-

connect

shaft

bobbin

the

rotary

8 by the three set screws

case

holder

of

the bed with screw

hook 0 to

the

8.

position bracket

8.

3.

Turn

the pulley

from the needle lowest position;
loosen the three set screws
rotary

hook

point 8 aligns with the center

After adjusting, the
point

and

0.08 mm.

and

raise the needle 2.2 mm

0.

adjusting

the needle should

so

gap

between the rotary

8

and

that

the

of

be

between 0.0 I

at

this time,

rotate the

rotary

hook

the needle.

hook

"'

~:

Center

f+-l

\/

of

-----.-

needle

2.2

mm

4.

When the pulley
point

e.

is

aligned with the needle center. loosen
screws
position

point 0 to needle hole

0

and

of

the needle

is

turned and the rotary hook

0'.

and adjust the vertical

bar

so

that

the rotary

top

gap

is

1.5"'

2.0 mm.

hook

Center

of

needle

-26-

0

5.

After mounting the U-part
drive cam
stepping foot needle
screw

6. Rest the stepping foot needle
the

top

place with screw

7.

Attach the face plate4D with the three

[!]

THREAD CATCHER

I. Pass slide shaft B 0 through the bed

slider B

2.

Align the edge

side

3.

Connect knife rock

shaft B 8 with the two screws

one

of

4.

Pass knife rock
thread catcher base bracket
catcher

temporarily tighten screw 0

vertical play (along the shaft).

5.

Mount
the roller
attach
bottom

6. Temporarily install the thread catcher spring
with two screws

0

onto

4D.

of

the needle

41.

f).

of

slide shaft B 0 even with the

of

the bed,

the screws meets the screw stop.

lever 0

the U-part

the thread catcher base bracket 8 to the

of

and

tighten screw

arm

arm

at

the

of

on

the

bottom

the bed with two screws G).

48.

of

the stepping foot

the stud screw

bar

clamp. secure

bar

clamp

bar

clamp.

and

MECHANISM

8.

B 8 to knifer rock

0.

Install

shaft B 8

f);

install the thread

bottom

knife rock

of

so

of

slider B

shaft B

that

arm

G)

of

it

48

tighten

screws&.

and

install

so

through

0.

there

B 8

f);

next,

the

with

on

in

arm
that

the

and

is

no

onto

4D

-27-

[[]

THREAD

0

TRIMMING

«o

I I

l....

---

-........

--.J

r----

I

I I
I

I •

I

I

I

I

MECHANISM

e\

~

--~~r

I. Install the slider assembly 0

trimming

2.

Install knife rock

arm

set screw 8

alignment

Pass knife rock

3.
thread
thread
A

8.

there

Mount

4.
the roller
temporarily
bracket

base bracket 8 with two screws

arm

A 0

shaft

A 8 with set screws 8

is

aligned with the position

hole when tightening

arm

shaft

trimming

trimming

and

temporarily

is

no vertical play (along the shaft).

the U-part

at

the

bottom

install

base

bracket

lever 8

on

tighten screw 0 so

of

knife rock

of

the

the

thread

8 with the two bolts

onto

the

thread

onto

knife rock

and

8.

Be

the

screws.

A 8

through

f):

install the

the

bottom

arm

slider assembly

trimming

of

A 0

0.

8.

sure

the

shaft

that

onto

0:

base

5.

Install the movable knife

CD

and

screw
tighten screw
so

that

the movable knife

or

thread

the pulley

arrow,

8

the

movable

after

screw

left.

knifeCii)

right

6.

Set the

the movable

two screws

horizontally.

7.

Turn

8. While pressing with
movable
the
bracket

of
center:
and

48.

4B

in the middle

catcher

knife41!)

C.

so

and

and

move

both

and

movable

knife

adjusting. tighten the

4B.

41!)

with flat head screw

At this time.

41!>

spring

and

temporarily tighten

that

the spring does not slide

lower the needle bar.

your

finger

sliding

it

the

thread

knife

41!)

aligns with the needle

temporarily

of

the screw hole

can be adjusted

G)

directly below

on

the

in

the direction

trimming

Cli)

so

that

two

top

of

the tip

bolts 0

the

the

of

base

-28-

I!]

BOTTOM PLUNGER ASSEMBLY

0

•

f)

•

•

_bv3-rm

I.

Pass the

and

2.

Put the washer 8 on the

and

3. Align the end
the side

[1]

CYLINDERS

(I)

Thread Catcher Cylinder

I.

Connect
thread catcher cylinder base
cylinder mounting screws

2.

Temporarily install the
base
both

3.

Connect

and

and
connecting, check
cylinder moves smoothly,
tighten bolt

4.

Connect
tubes to the elbows.

5.

Move the thread catcher cylinder by
when the thread catcher spring
retracted, loosen screw
catcher lever
spring

0.5 mm.

6. Move the thread catcher cylinder by
fully advance the thread catcher spring
turn

adjust

left
oval hole.

bottom

install the

attach

of

the thread catcher cylinder 8

lever shaft 8

bottom

the

stop

of

the

the bed

lever

bottom

ring

8.

bottom

and

tighten screw

through

8.

lever shaft

lever shaft 8 with

8 with the two

8.

thread

8 with bolt 8

the bed

the thread catcher lever 0 with link pin

secure the link pin with

and

the

thread

8

the correspondingly numbered

0

4D

and

movable knife

the pulley, loosen the two screws

the needle so

and

right sides

and

thread catcher base

catcher cylinder rod

that

and

the two screws

G)

so

that

that

of

the needle when it is in the

catcher

the two screws 8 to

stop

ring G). After

the thread

and

then firmly

and

move the thread

the

gap

between the

f)

is

between 0.3

the spaces are even

8.

8.

8.

hand

4D

hand,

CD;

the bed,

8.

to

the

cylinder

joint

8

8.

catcher

air

and

is

fully

"'

and

next,

41.

and

on

Thread catcher
spring retract

Thread catcher

spring advance

-29-

0.3-0.5

mm

-

(2) Thread Trimming Cylinder

I. Install the

thread
cylinder

2.

Temporarily
base
the two set screws

3.

Connect

8

and

0

and
these.
moves
screws

4.

Connect
tubes to the elbows.

5. While lightly pressing the
knife

trimming
and
adjusting

base
movable knife

thread

trimming

mounting

0

on

the cylinder

the thread

the

thread

attach

confirm

smoothly.

8.

the correspondingly numbered

CD

with

cylinder by

move the thread

the

4B

to

trimming

cylinder base 0 with the two

screws

install the thread

e.

connecting

8.

trimming

trimming

stop

that

the

and

your

gap

between the slider4D

within 0.3

is

moved

leverO

ring

f).

thread

then tighten the two set

finger. move

hand;

trimming

"'

both

cylinder 8

trimming

cylinder rod

After connecting

trimming

top

of

loosen set screw

0.5

mm

forward

on

cylinder

plate 8 with

with link pin

cylinder

the movable

the

thread

lever

and
when

and

the

joint

air

G)

0.

slider

the

back.

---0

(3) Bottom Cylinder

I. Install the

cylinder base 0 with the two cylinder

screws

2.

Temporarily
onto

2 set screws

3.

Connect
bottom

stop
that
then tighten the two set screws

4. Connect the correspondingly numbered
tubes to the elbows.

bottom

cylinder 8

e.

install the

the

thread

catcher

8.

the

bottom

lever plate 0 with link pin 0

ri.ng

f).

After connecting these.

the

bottom

bottom

cylinder base 8 with the

cylinder rod

cylinder moves

on

the

bottom

mounting

cylinder base 0

joint 8 and

and

attach

confirm

smoothly.

8.

the

and

air

-30-

5.

Install needle plate S ~ with two flat head

screws

6.
the
the
needle plate; next, raise the
fully,

plunger~

then firmly tighten the two set screws 8 in this

position.

49.

Moving the

bottom

bottom

and

bottom

plunger~

plunger~

adjust

is I mm

cylinder by

and

with the

so

that

above

the needle plate,

hand.

align the

top

surface

bottom

the

top

first lower

top

plunger~

end

end

of

of

of

the

the

and

(Up)

About 1 mm

(Down)

* If the up

is

gap

Likewise, if the

decrease the gap.

[!]

I.

Mount
foot lifter cylinder
bolt

2.

Mount
lifter cylinder

secure it with the E-shaped

3.

Mount
support
material cylinder 5 ~ with two Allen bolts

4.

Mount

G)

screw

5.

Mount
bracket
connect the

6.

Finally. push the
screwdriverto
does not. loosen screw

49.

and

and

down

stroke

less

than I mm,

between the

NEEDLE BAR
ASSEMBLY

the cylinder bracket 0

loosen nut G),

stopper

stroke

DESCENT

f),

and

8.

the piston rod

the

hook

joint 8 on

f),

insert the link pin

bracket 0

0 with the two screws

the

coupling

on

the thin material cylinder 5

in

the nylon hose nipple

the cylinder

0 with

air

adjust

the

then retighten the screw

hook~

support 0 on

four

Allen bolts

hose

4D

coupling

confirm

0

hook

so

of

the

bottom

and

increase the

CD

and

rod

is

greater

secure with the Allen

than I mm,

GUARD

on

the presser

the presser foot

snap

ring O.

on

the cylinder

0.

and

with the Allen bolt

~.and

e.

the cylinder

49.

to

the

nipple

hook

41

that

it moves freely. If it

and

Allen bolts

that

it does move freely.

and

bolts.

plunger

joint

8.

the

and

CD.

with a

CD

&.

and

thin

CD.

then

then

and

-31-

~

STANDARD

ITJ

ADJUSTMENT

ADJUSTMENTS

OF

THE

ROTARY

0

~

HOOK

~

Center of

:

?-r---l ----.

I I

11

the

nee

* T urn the pulley and rai

the rotary hook

aligned with the

[I]

ADJUSTMENT

e to make an adjustment in such a

ce

nter of the needl

OF

2.2

mm

dle

se

the needle b

THE

NEEDLE BAR HEI

0

ar

2.2 mm from the lowest
wa

e.

GHT

y that

p o~itio n.

th

Then.l

e hoo k point 0 of

oosc n the set screws

the rotar

y hook becomes

f)

a

nd

turn

Center of the needle

Turn the pull

8 . a

nd

face p

ey

la

0 to needle hole top g

OJ

ADJUSTMENT

and align the rotary hook point with the needle center. Remove the

te e . loosen screws 0 a

ap

is 1

.5

OF

THE

CLEARANCE

nd

"' 2.0 m

o.

and vertically adjust the needle

m.

BETWEEN THE

NEEDLE

*

Turn
rotary hoo k w
loos

en

moving the rotary hook 8 so that

cl

eara

nd the hoo k point of the rotary hook.

a

bar

AND

the pulley a

it

the scr

ew

nce ofO.

OI "'0.08 mm betw

so that the ro tary hook point

THE

ROTARY

nd

align the hook point of th e

h the center

s 0

and

make an adjustment

0

thr

ee sc rews

HOOK

of

the needle. T hen.

there

een the needle

by

i a

- 32 -

[I]

ADJUSTMENT

+

OF THE PRESSER FOOT

* Lower the presser foot

and

make

following

To

lower the presser foot:

adjustments

procedure.

to

the lowest position,

according

© Before sewing

Turn

the test

and

then press the step back switch

presser foot.

© When emergency

sewing

First release the emergency
step back switch.
down

to lower the presser foot

©

During

First release the test/intermediate sewing switch.
and

then press the
presser foot
mechanism will again function when the
tcst/intcrmcd iatc sewing switch is pressed again.

(I)

Turn
need

lc
presser foot
adjustment
cap

0.

adjustment
After
the presser
screw
Note:
being used,
misaligned
On

the
sufficiently, it
occur.

(2) Loosen the set screw

the position
presser foot
surface

and

intermediate sewing switch

to

lower the

stop

switch is pressed

stop

switch. press the

and

set the presser foot

position. Now press the read/write switch

to

the lowest position.

test feed

read/

write switch

to

the lowest position.

the pulley.

enters the center

loosen the set screw

making the necessary

and

check

of

the needle hole

f).

If not. loosen the presser

screw 0 sufficiently. remove

by moving the presser foot.

adjustment.

adjustment

screw 0

to

confirm

0.

to

and

and

lower the

The

that

make

0.

that

when

the

stepping presser foot is

the

sewing material can become

if

the

presser foot

other

hand,

can

cause stitch-skipping

0.

at

which the lower surface

f)

lightly

of

the sewing material.

is

if

it is

and

contacts

lowered

not

then

tighten it at

lowered

the

to

the

on.

during

to

the

feed

the

of

the

the

an

tighten

the set

not

too

far.

to

of

the

upper

Ill If the stepping presser foot

If the stepping presser foot

can be removed in the following procedure.

(I)

Remove the face plate.

Turn

(2)

(J)

the pulley.

highest position.

Remove the

stepping presser

-33-

stud

is

not

is

not to be used.

and

raise the needle bar

screwO.

cam

and

f).

to

be

used.

it

to

the

then remove the

[!]

WORK

CLAMP

ADJUSTMENT

[[]

AIR PRESSURE

• Use an air pressure at 5 kgf/cm
Pull

up

the cap
adjust the pressure. After adjustment, push the
cap down

• When water has gathered in the bottle

the air cock 8 and push the drain cock 0
remove the water.

to

lock it.

ADJUSTMENT

at

the

top

of

2

•

the air unit 0 and

8,

close

to

To

adjust the work

clamp

to

the

top

nut

0 and slide nut

opening increases. Adjust the nut left

* Increasing the work

opening

increases work

clamp

install a

of

the needle plate should be within 45

f)

in

or

clamp

clamp

standard

out

and

opening makes

pressure.

work

clamp.

adjust

as needed. When adjusting. if

or

right

as

needed.

it

harder

The distance from the

~55

to hold material securely. Decreasing the work clamp

-34-

mm when the work

nut

[2]

WORK CLAMP POSITION

bottom

clamp

f)

of

the back

is

raised: if

is

turned right. the work clamp

ADJUSTMENT

The

work clamp should be positioned so

work

clamp

adjust. loosen the four Allen screws 0

the clamp guide
necessary. When using a unit work
to adjust the
right

and

pressure evenly over the material.

f)

in

the

arrow

clamp

guide angle the same on

left.

of

it

is

not.

direction

clamp.

the work

loosen

as

to

apply

and

move

be sure

both

To

as

III MOVABLE KNIFE

ADJUSTMENT

0

* Adjust after releasing the

I.

Remove the screws 0

••

2.

Turn

the pulley

3.

While pressing

8 with your finger
8 in the

and
tip aligns with the needle center.

arrow

screw 8 to adjust

and

and

lower the ·needle.

on

the

top

and

sliding the movable knife

direction. loosen set screw 8

so

that

air

pressure.

remove needle

of

the movable knife

the movable knife

plateS

Movable knife

* When

[!]

thread

illustration. Note

THREAD

~-

If

this part is not shaprened
smoothly, that causes the
upper thread to snap.

trimming leaves the tip

that

the movable knife

TRIMMING

SLIDER

-

0.3-0.5

mm

::e>

of

the. thread rough

cannot

ADJUSTMENT

be sharpened: replace

Fixed knife

or

ragged. sharpen the fixed knife as shown in the

it

with a new movable knife.

0

•

* Adjust

While pressing lightly
loosen set screw
between 0.3

after

"'

0.5 mm.

releasing the

on

the

8

and

move knife rock

air

pressure.

top

of

the movable knife 0

arm

and

moving the slider 8 by hand in the

A

8.

adjusting the gap between the

* Install the lower thread catcher spring 8 directly below the movable knife

-35-

slider&

0.

arrow

and

the slider base 8

direction,

to

1!2]

THREAD CATCHER SLIDER

6)

ADJUSTMENT

0.3-0.5

I

_==iiJ?> l

0

I

Thread catcher spring retract Thread

* Adjust

(I)

(2) Move slider B

[ill BOTTOM PLUNGER

after

releasing the

Move slider B 0 by

rock

arm

B

8.

adjusting

catcher

spring 8 is

0 by

needle is lowered
that

the spaces

into

on

hand

within 0.3

hand

the oval hole, loosen set screw G

the left

ADJUSTMENT

mm

air

pressure.

and

fully retract the

both

front

"'

and

with the

and

right sides

catcher

and

0.5 mm.

Needle

spring advance

thread

back so that the

thread

of

the needle

catcher

catcher

spring

8:

gap

between the movable knife 8

spring 8 fully

and

move the

are

equal.

loosen set screw G

advanced.

thread

turn

catcher

spring

and

move knife

and

thread

the pulley: when the

8.

adjusting so

* Adjust

(I)

(2) Move the rod

* Adjustment

(3) With the

after

releasing the

Move the rod

bottom

stopper 8 and

8

plunger

and

lever

is

bottom

move the

8.

~A-

'

(Bottom

(Bottom up)

air

pressure.

joint

0 by hand

e.

adjusting

joint

0 by

rod

joint 0 so

easier if the cylinder has been disconnected.

lever G raised manually.

bottom

and

so

that

hand.

and

that

plunger.

lower the

the

top

lift the

the

top

adjusting

of

bottom

of

turn

so

down)

bottom

the

bottom

the

bottom

the pulley

that

~

plunger

plunger

the needle

8.

Loosen

plunger

8:

plunger 8 is

and

and

loosen nut e

lower the needle bar: loosen the

is

in the

the

two

top

of

the needle plate

and

I mm above the

center

of

the needle hole in the

screws 8

adjust

top

and

move the

are

even.

the

gap

between

of

the needle plate.

two

set screws

Needle

the

bottom

-36-

[ill

THREAD

(third

TRIMMING

valve

from

bottom

Thread catcher speed

CYLINDER

in

eight

SPEED

valve series)

ADJUSTMENT

About

20.5

mm

8

0

Insertion speed

8

0

• Movable Knife Speed
If the movable knife speed
loop will be late

possible by loosening nut 0

• Movable Knife Returning Speed
If the movable knife returning speed

the needle thread may be
continues.
trimming finishes before the feed mechanism advances to the next sewing position. Adjust by loosening nut
and

turning speed control

* Values

in

and

and

will result in thread trimming misses

the above illustration may vary slightly. Use them as a guide.

is

slower

may result in thread trimming misses. Adjust the movable knife to insert as quickly

too

than

necessary. the timing

and

turning the speed

is

faster

short.

Furthermore.

control

than

necessary. the

if it

of

the movable knife entering the

upper

f).

thread

will be

cut

by only the fixed knife,

is

too slow. the thread will not be

and

defects in sewing. Therefore. adjust so that thread

cut

until sewing

e.

thread

as

and

8.

[IT]

THREAD

Insertion speed

CATCHER

CYLINDER

ADJUSTMENT

About

(fourth

20.5

valve

mm

from

...

Thread catcher

speed

•

Thread

If the thread catcher speed

knife's thread trimming operation
necessary, the thread catcher will strike the needle before the thread trimming
Therefore. loosen nut
trimming.

• Thread Catcher Returning Speed
If the thread catcher speed

and

the

thread will not be caught. Therefore.loosen nut 8

the upper thread as consistently

* Values in the above illustration may vary slightly. Use them as a guide.

Catcher Speed

a longer

thread

upper

catcher will retract

is

faster than necessary. the

and

0

and

turn

the speed

is

faster

than

thread will be left

after

the thread has pulled

short

result in lower

control

is

necessary, a

on

the

back

as possible.

thread

catcher

thread

trimming misses.

f).

adjusting to a speed which

upper

thread will be caught by the thread

of

the sewn article. Furthermore, if it

out

of

the oval hole in the thread catcher

and

turn

speed control G. adjusting

spring will advance

top

in

eight

Furthermore.

operation

does

not interfere with thread

is

slower than necessary,

to

a speed

valve series)

during

the movable

if it

is

slower

ends.

catcher.longer,

and
that

than

the

upper

will leave

is

-37-

~

BOTTOM CYLINDER SPEED

L;lt;ng,.,.edt

ADJUSTMENT

(fourth

About21 mm

valve

from

bottom

in

eight

valve series)

""'"'"'

•

Bottom
A synchronization signal
too
of
bottom

•

Bottom
If
Therefore. loosen nut

mechanism proceeds to the next sewing step.

* Values

[ffi WORK CLAMP CYLINDER

Plunger Lifting Speed

slow. sewing will continue for several stitches with the

the

bottom

the descent speed

plunger will be lost. Therefore. loosen nut 0

plunger operates

Plunger Descent Speed

is

in

the above illustration may vary.

.,

...

~

at

the first stitch causes the

as

too

8

quickly

slow. the

and

as

possible.

bottom

turn speed control

SPEED

ADJUSTMENT (second valve

bottom

plunger may strike the feed plate when material

8.

Use

them as a guide.

plunger to rise. Consequently. if the lifting speed

bottom

adjusting so

and

plunger

turn

speed

that

from

in

the lowered position.

control8.

the plunger

bottom

adjusting

drops

in

eight

is

and

the effect

so

that

the

is

being fed.

·before the feed

valve series)

~

o...,.,

•

Work

Clamp

If

the work

and

•

Work

the work

If
striking the feed plate. Loosen nuts
banging. .

Note: Adjust speed controls

* Values in the above illustration may vary.

clamp

turn

speed controls 8

Clamp Descent Speed

clamp

operate

'""

Lifting Speed

lifting speed

descent speed

at

the

same

is

faster

and

8.

is

8 and G.

speed.

than

necessary. the entire work clamp will vibrate. Loosen nuts 0

adjusting

faster

than

8 and 8

and 8 and 0 in

Use

to

a speed where the work clamp does not vibrate.

necessary. a banging
and

turn

speed controls 8

pairs so that both right

them as a guide.

-38-

sound

and

8

may be heard from the work clamp

and

0.

adjusting so

and

left work clamp cylinders

that

there

is

no

1m

PRESSER FOOT LIFTER CYLINDER SPEED

(third

valve

from

bottom

in

eight

valve series)

ADJUSTMENT

t Uft;"l! opood

~

o

...

ont

., ..

,

• Presser Foot Lifting Speed

If the presser foot lifting speed in slower

or

cassette. Therefore. loosen nut 0

as possible.

• Presser Foot Descent Speed

Note

that

presser foot descent speed

nut

8.

and

turn speed control valve 0

* Values in the above figure will vary slightly with different machines: use these us a guide.

than

and

turn

is

constant.

to

necessary. the presser foot may strike

speed

control8.

and

speed control valve 0 will not vary it. However. loosen

adjust as shown

adjusting

in

the above picture.

so

that

and

damage the work clamp

the presser foot rises as quickly

ill]

MOVABLE

KNIFE

TIMING

ADJUSTMENT

The thread trimming signal

bar's down position. However. if the solenoid valve
turns

on

with the transmission
lowest signal. the movable knife will operate before
the

upper

thread loop
thread will not be cut.
movable knife timing

circuit

board.

to

turn
transmitted,
trimming misses.

Delay time can be adjusted
each. Refer to the table on the next page for dip
switch positions.

* Switches

dip

switches

OFF.

Note:

set a delay time for the solenoid valve

on

after the needle

and

adjust to a timing for no thread

No.5"' 8 of

are

not used. They should be set to

The

movable knife timing

because the needle lowest signal

electrical signal) causes the thread trim-

ming mechanism to switch the solenoid

valve,

air

pressure causes the cylinders to
operate.
the precision

and

is

adjusted

is

formed

To

prevent this. switch. the

dip

switch

bar

in

the movable knife timing

signal positions may vary due

of

mechanical parts.

to

the needle

of

the needle

and

the upper

on

the control

lowest signal

16

steps

of

is

adjustable

10

bar

ms

(an

is

• It stands for

70

ms.

-39-

0 This table shows the

Dip switch

I

CQTI

[QEEJ

OEJ

2

0~

I

I

0 1-

I

0:\

1:

OK]

I

I

02TI

c::QD

I

[JK]

o

c::QTIJ

CQKJ

[QED

I

I

I

t-F

01'\

o~

I
I

[QED

I

[QITJ

CQS::J

I
I

[QIT]

[illiJ

I 01- 1- I

I oFF

I Ot-1-

de

lav time

3

re~ulting

4

02TI

D2D

DB:]

02TI

L:.QBJ

DB]

ors:J

CQD

from dip switch positioning.

Delay time

0 ms

10

ms

20

ms

30

ms

40

ms

50

ms

60

m

~

70 m

~

I 2 J 4

OK]

[QEEJ

[Qs::J

[Qill

OITI

CQEO

[Qs::J

CQEO

Dip switch

CQKJ

OK]

[QEE]

[QEtJ

DID

OK]

CQIEJ

OIITJ I

I O'i I

DID

CQSJ

c:::Qs:::J

I

OFI-

I [QEEJ

I 01-1- I

01-1-

I

I

OH

·

I

[QED

[QEEJ

OillJ

[illiJ

[QITJ

[QIT]

I 0

1-1-

Delay time

I

80

m

~

90 ms

100

ms

I

10 rns

1

20

ms

130m~

140m~

150

ms

(D

elay time

I).:Lu 11mc 0 ( (

I

hn:•~

1111\'ll."'-

and thr

tru11n11n~

fj

ead trimming misses]

50

nh

f'ol)

()

(

2

XII

nl'

70

rn'

)i(J

zn,

~,

f

',\

·:ln8~

~~~

rn

..

HXlnh

flO

100

[Time between thread trimming operations and

thread trimming misses]

~

~

I

Hn~

li

me:

3~

c.

--

~

l..ih

nn

il

tunc

,£

nh

(

~

Ill Selection

mi

sses
Thread trimming timing will
vario us co nditio n

normally

of

a delay time for no thread trimming

va

ry with each

s.

However. became th ere

around

4 ~ 5 speed

~c

ttin

gs

of

arc

with no
trimming misses. adjust to the timing speed that
be

st matches the sewing conditions .

( I) Feed programs

th

read trimming
compared with
long

(30 seconds

• Fast timing results in many
mi

sses.

in

which t

operatiom

pro

grams

or

more).

he

time between

is short

in

\\hich this time is

thr

ead trimming

a!>

• Likewise. slow timing results in fewer thread
trimm

ing misses.

-40-

Delay

Accclcra-

2.

;;i

ted

~

[

hook

;'1-

Standard

§·

hook

21---+--J

oil

Delayed

hook

time

>trOk<

timin~

timin~

timin~

(2) Needle

When the

•

Slow

bar

stroke

and

thread trimming misses

hook

timing

is

accelerated

timing increases thread trimming misses.

• Likewise. fast timing decreases thread trim­ming misses.

When the

timing

is

delayed

hook

• Fast timing increases thread trimming misses.

• Slow timing decreases thread trimming misses.

(3)

Sewing thick
trimming

and

misses

thin materials

and

thread

• With thick materials. the delay time has a
tendency

to

increase.

• Likewise, with thin materials. the delay time
has a tendency
nearly the same when timing

to

tends

to

decrease. (T!Je delay time

change more.)

is

fast; slow timing

is

Do:lay

H

-~

.::.1;,

9

3

s·

..

Movable

time

Thick

material

Medium·

thick

material

Thin

material

.

kmfe\

--:;::.1

Hook_____,./

(

(

)

(

(

\~

~(sewing

.'

_,...,-Upper thread

_,a,

(m~edle

"----

s1de)

Lower

Upperthread

edge)

thread

thread

(4) Special threads

With

andalia

time has a tendency

and

thread

and

similar threads. the delay

trimming misses

to

decrease the same as

with thin fabrics.

(5)

Short
As

shown

needle thread

in

the right figure. before a normal

after

thread trimming

loop has formed. the movable knife may

advance, catch the needle

hook

and

trim the thread with the knife. When
this happens the needle
short.

and

thread come-off will

thread

thread

side with

will become

occur

sewing starts.

If the needle thread
for normal
increasing

the

* When timing must be between 60

thread
account

temperature

trimming

for timing variations resulting

and

is

extremely

thread

trimming

delay time.

misses. select a 70

humidity .

short.

by slightly

"'90

ms

the

when

adjust

ms for no
setting

to

from

-41-

Point

of

Origina

l

(X-O

•Y -0)

[ill

ORIGIN

(I)

Origin Posit i

I. Remove the four installation scre

remo ve the clamp

2.

Remove the four screws E). and remove the feed
plate

3.

Remove the three screws

slider

4. Install the program referen

5. Mo ve the feed guide to t
Turn

6.

7.

Depress the work clamp lifter switch. and after
setting the c lamp
depr

ess the st

8.

The feed mechanism wil move to the origin

pos ition and the emergency
ill

uminate.

Turn

9.
that the needle tip aligns with the origin position
on

the program reference plat e

*

To

program the machin e, press key
mechanism wi
way. the
the origin position.

POSITION ADJUSTMENT

on

Check

f).

e.

0.

cover

0.

ce

he

the power switch on.

in

the cl

art

switch.

the pulley. lower t

ll

mo ve to the origin position. This

programmer

he

can a lso be used to check

ws

0 and

and remove t

plate

f).

center.

amp

ing position.

stop

lamp will

needle and confirm

f).

IIJ:

the feed

he

(2)

Origin

[X-a x

I. After pushing the

f).

2. Remove the two screws e and after

remove table right

3. Install needle pla

4. Adjust by loosening the four set screws

5. After adjustmen t. check the origin position.

6. After removing needle plate L

Pos

is

Adjustment]

iti

on

Adjustment

fee

d guide assembly to the le

compre

0.

te L f)

.

f)

and insta

ft

rear. remo

ssing the bellows assembly G. remove the four Allen bolt s 0 : next.

f)

and

mo\

lli

ng table right

-42-

ve

the twelve screws O. and remove needle plate L

·ing the X-position

0.

reinstall need le plate L

dog

0 .

f).

[m

OVERLIMIT

SWITCH

ADJUSTMENT

[Y -axis

7. Push the feed

8.

9.

Adjustment)

Loo

sen the

Y-po

sition

After

two

dog~.

adjustment.

guide

scr

check

assembly

ews

f):

to the rear.

adjust

the o rigin position.

by moving the

@)

$ ®

~I

f-

-

6

00

3~4mm

(30 ~ 40

[

X-axis

I.

Refer to

2. Push the feed g uide asse

3. Remove the twelve screws. and remove needle

4. Remove the eight Allen

5. In sta

6. Ins

7.

Turn the

8. Using
pul

O.

9. In the same way. move the f

pulses) f

ove

PLS)

Adjustm

steps I

ll needle

tall the prog

power sw

the prog

ses) f

urth

er

adjusting

urth

er

rlimit

switch 0

ent)

"'3

in

plate

L.

ram

reference

itch

ramm

er, move

to the ri

so that the

to

ght fro m t

the lef

turns on.

"Or

igin

Position Chec

mbly to

bolt

on.

overl

t; n

the rear.

s.

and

plate.

the feed mecha nism

he

orig

imit

switch 0

eeder to the left side by using the p

ow, loo

sen the t

remove

in position

1 ~ 3

(10

both

wo

l

l_j

I

mm

~

30

PLS)

k" and remove the

plate

L.

right a

nd left tabl

to the

origin

pos

; n

ow.loosen the tw

turn

s o

n.

rogrammer.

Allen

bo

lts 0 and m

work clamp

es.

iti

on.

and move

o Allen bolts

and

ove the

. feed plat

the feede

f)

then move

X-ES dog

and

0.

e. and

r

3"'

move the

it I

"'

a

djustin

slider

cover.

4

mm

(30 "'40

X-ES

dog

3 mm ( 10"'

g so

that the

30

*

Co

nfirm that

doe

s.

origi

n limit

sw

itch 0 always

turns on before

-43

-

over

limit swi

tch 0 on

the

initia l

pos

ition limit side

I

@)

®

@)

tl

[Y

-axis Adjustm ent)

10.

Using the

pulses): loosen

II. In the same way. using the program mer mo

mm

4D

* Check that o

doe

12. After removing needle plate

pro

(I

0 ~ 30 pulses

turn

s on.

s.

gram me

ri

gin limit switch

r.

move the feeder

th

e four Allen bolts 0

):

loosen the two Allen bolts

to

and

G)

always turns on before overlimit sw

1.

. install table right

(/)

_J

Ea.

E~

I J

'<~"

/

LJ

l o

M£2

0

l!l

N

the origin position.
move Y-ES

ve the feeder

4D

dog4D.

to

the opposite side. and then move

and move

and

table left. a nd then reinstall needle plate

and

move the feed

er

forw a rd 3 ~ 4 mm

adjusting so that overlimit

the Y-ES dog. adjusting so

it

ch 0 on the in itial pos

sw

itch 0

it a further I

that

ovcrlimit switch

it

ion limit side

(JO~

turn

L..

40

s on.

"'J

~

r---

PULSE

----

MOTOR

--------

BACKLASH

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

[Y-axis Adjustment)

I. Remove the four screws

2.

Loosen the six A
is within
Also.

0

co

nfirm th

ll

en bolts 0

"'

0.03 mm when th e

at

the Iced gu ide assemb ly mo\'es smoothly when

ADJUSTMENT

0.

and remove the
and

move the rack

power

switch

arm

rear cover 0 .

0.

adjusting so th at t

is

on

and

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

he

the

fee

d guide assembly

it

is

gear

assembly

i

~

moved back

pushed forwa

----

--------

f)

and rack 0 backlash

and

forth by hand.

rd

and back by hand.

-,

-44-

[X-a.xi~

I. R

2. T

.1.

4. Remme

Adjustmen

emo\'e

th

en

reinsta

urn

the

f)

a nd shi

onlyO~

when

the
left by
Make

smoothly

then

rein

needle

pom.:r on. l

ft

O.O.I

feed
hand
sure

both right
needle
sta

t]

plate

1..

ll needle

the

mmofpla~

guide

.

the

ll

needle

pulse

feed

plate

plate

oosen

motor

assembly

and

L.

plat e L.

remO\e

L.

the

mount 0 so

inth

egearassernbly

is

guide

lef

t.

reinstall

table

rig

four

/\lien

moved

assembly

tab

le

right.

ht.

there

righ t

1110\

and

holts

is

O

and

'es

and

[ill BELT

I. After

asse

2.

Remove the t

3. Rem

4. Rem

5.

Move the feed guide

TENSION

turning

mbl

y

e.

ove screw
ove

the

ADJUSTMENT

the

air

wo

Allen

8.

a

nd

two screw

assembly unt

off.

disconnect the

bolts 0 on

remove the left side

s

f).

and compr

il

the

it

air

tub

back

of

cove

ess the

meets the

e O.

Remove

the

support

r

0.

bellows

right-side X-ES dog.

assem

the two

.

bly 0

Allen

to

the lef

bolt

t side.

s

f).

and

remove

the

air

uni t

6.

Align

and

set

accessory

7. H

ook the belt

8. Loosen nut
adju

st

so that

top of the belt aligns with the b

9.

After

adjustment, first tighten

4D

screw

on

an

tension

d a ft

er loose

49

tensio

n p late C 0

pla

te A

nin

m

eets tension

ottom

bolt

4D

a

nd

g Allen

plate

of tension

4D

, t

align

bolt

A

hen

at the

rig

ht edge of table

it

wit

h t

he ext

49.

loosen

left

4D

when tension plateD

plate C

tighten

f)

bolts

.

49

ended part

and

rig

ht All

f)

Turning bol

and

set

left~-

of

en

is

t

4D

with nu

- 45 -

tension

bolts

raised

to

the

ts

plat

e C

4D

and turn

with the

4D

index

right increases

.

f)

.

Allen

fin

ger

belt

bolt

4D

, a nd

tension.

to

the

[m

ENCODER

8

0

(POSITION

DETECTOR}

ADJUSTMENT

(I)

Encoder

Opening

I. Re move

encoder

2. L

oosen the
and
cover.

turned

(2)

Synchronization
Turn the pull ey by h

bar
the
needle
the machine motor

loosening

synchron
Thi

*

the machine
length 4.5
is less

needle

signa

Cover Removal

the

cover

two

open the r

the rear

several

above

needle tip is 0

plate;

th

izati

s synchronization signa l is o nl y used when

mm

than

bar

l.

thr

ee

f).

rear

ear

cover
times and

the

needle

now.

e t

wo

on

sig

speed

or

4.5

mm.

down

screws

cover

cove

r

0.

mounting

used as

Signal

"'

Position Adjustment

and and

bar

0.5

mm

adj

ust

so

circuit board

screws 0

nal

slit O.

is 500

"' 800

more);

when the stitch leng

this si

posi tio n syn

and

Rear

O. a nd

mounting

When

down pos

above

that LED

gnal is used as

remove

screws 8

open

screws e can

stops

raise

the
ition until

the top

goes out by

and move the

rpm{with stitch

chronint

Cov

er

the

ing the

be

support.

needle

of the

No . 2 on

th

the

ion

LED

4

(Needle up)

LED

3

(

Thr

ead trimmi

LED

2

(Synchronization)

LE

D 1

(Needle down)

0 0

ng)

T

hread

(3)

tion Adjustment

Turn

bar

LED

goes out by l

mo

This

*

when

thr
also

adjust

p. 40).

the

incr

Need

(4)

Turn the pulley by

bar from

is

Now.

moto r ci

two

s

Trimming

the

to

its

No.3

ving

the

signal a l

the

ead

trimmin

functioning

the m

If

movable knife inserti o n t

eased.

le

Up

II

"'

14 mmabove

adj

rcuit boa

sc r

ews 0 and moving the needle

lit~

.

Sig

pulley by h

down position.

on

oose

thread

stitch le

ovab

the dow

Signal

its highest pos

ust

so

and and

the machine

nin

g the

trimmer

so functions as

ngth

g signal is

as the sy nc s igna l. be s

le knife insertion

n s

igna

Posit

hand

thetopofth

that

LED

rd

goes

nal

(down signal)

lower

l\ow.

adjust

motor

two

screws

signa l slit

the

is

4.4

mm

or less. If this

adjusted

l position

iming

ion

Adjustment

and l

ower the needle

ition

until the need le tip

eneed

No. 4

on the machine

out

by l

Posi-

the ne

edle

so

circuit

board

f)

0.

sync signal

when it is

ure

timing

is

delayed.

sho

uld be

le pl

oose

ning

up

signal

that

a

nd

to

(see

ate.

the

(5)

0 ~ 0.5

mm

Thread
signal

I

trimming

Synchro
n

ization

signa

l

-

Need le
Loosen the two

down

I on the
be twee n the time
the

needle

the

down position when the pull

han

d.

- 46 -

Down

signa l slit4D.

Position

machine

up

pos

screws

th

Adjustment

4D

and move the needle

adjusting

moto r circuit board

e needle

ition and the

so that

bar

desce nds
tim
ey

e it reaches

is t

LED

No.

goes out

from

urn

ed by

Rl

Synchronization signal

R2

Thread trimming signal

R3

Needle up signal

R4

Needle

down

signal

(6) Needle Position Detector Sensitivity Adjust-

ment

The

sensitivity

needle position detector may
the machine
Therefore, periodically check the sensitivity
this phototransistor.

I. Apply the negative

negative side

encoder

positive
terminals.

circuit

(+)

of

the

phototransistor

drop

motor

of

side

To

test, set the testers range to

from operating normally.

(-)

side

of

a tester to the

the

10

).1F(25

V)capacitoron

board,

to

each

and

then apply the

of

the signal's resistor

and

for the

prevent

of

the

10-V

DC.

2.

Turn

the power switch on

hand; check if the

and

R4

is
synchronization, thread trimming, needle up,
and

needle
confirm
circuit board are

3.

As
output
machine

Also check

revolution, signals
locations.

that

performed

voltage

is

output

over 4.5 V in each

down

positions. At this same time

LEOs I

not

in

step 2 above, confirm

of

R I

in

any

position not specified above.

that

are

and

turn

the pulley by

voltage

"'4

on

illuminated.

"'

R4

in

motor

not transmitted from two

of

R I, R2. R3.

of

the machine

is

below 2 V when the

one machine

motor

that

the

the

0

(7) Speed Detector Sensitivity Adjustment

If the

photo

interlapper
detector
detected
speed. stop

will illuminate. Accordingly. if the machine
suddenly stops during sewing
cy stop lamp illuminates. it
adjust the interlapper sensitivity for the speed
detector.

L

Turn

speed by

machine

2.

Turn

circuit board
position where the machine suddenly stopped.

3.

If the emergency

machine will again begin to operate; this time.
turn
the position where the machine suddenly
stopped.

4. Adjust to between the two positions recorded in
steps 2

machine operates normally.

completed.

varies, machine speed will not be
and

the machine will run

and

then the emergency

the: power

motor

the adjustment control 0 on the encoder

the control to the left,

and

on

using

the
boar.d.(Refer to

to

the right

3 above,

stop

output

and

run

the

.dip switch.

and

switch

and

and

run

the machine. If the

for the speed

at

high

stop

lamp

and

the emergen-

is

necessary to

macili_n,~

on

the

~~.h~gh

lf>p,

Pflthe

p.r16);

store the

is

depressed, the

as

adjustment

control

above record

is

* This adjustment

operates normally.

-47-

is

not necessary if the machine

lllJ

DIRECT

DRIVE

MOTOR

MAINTENANCE

INSPECTION

(I)

I. Remove screw

2.

Remove washer 8 and brush O.

3.

After brush inspection a

semble in the original order

o.

* When not replacing the brushes.

re

the

*

Maintenance

I.

Do

shock to the motor.

2.

When replacing the brushes.
preve

3.

If the brushes ha

replace them with
are replaced. run the machine at high speed for
approx. one

Brush

install

top

and

not strike,

nt

Inspection

and

Replacement

O.

in

the original pos ition;

bottom positions.

Inspection Notes

drop

or

otherwise cause any big

any

dust

or

dirt from entering the motor.

ve

worn down to the mark.

ne

w brushes. When bru sh

hour

for trial.

nd

replacement. reas-

and

tighten screw

be

do

not mistake

be

care

sure to

ful

to

es

~

BOBBIN

(I)

Bobbin
clamping

I.

Remove the

bobbin winder base

2.

Move the bobbin winder stop latch 0 towards

th

e bobbin winder spindle 0 to

imm

ediat

tio

n.

3.

Tighten the two set screws

pring

s

WINDER

winder

screw

four set screws

ADJUSTMENT

stop

latch

0.

and remove the

tripping

8.

th

e point

ely prior to bobbin winding comple-

f)

so

that

the leaf

0 comes to the should

er

of

the clamping

G.

(2)

Bobbin

I.

Loosen the set screw
winder stop
thread wou

winder

stop

latch

nd

on the bobbin.

latch

position

0.

and move

the bobbin

0 to adjust the amount

arm

of

- 48 -

~BEARING

OJ

SUDER

A type B type

BEARINGS

[Symmetric

REPLACEMENT AND

REPLACEMENT

roller

shaft]

[Eccentric

roller

shaft]

c type

~r--

A type (2 pieces) C type

ADJUSTMENT~

AND

ADJUSTMENT

I. After pushing the feed g

rear. remove the twelve screws and remo

needle pIa te

2.

Move the

remove the four Allen

right.

3.

Remove the six screws O.

guide cover fro

4.

Loosen t

replaced. a

5. Remove the stop ring
removed ro

with a n

position.

• * There

6.

* When adjusting the eccentric roller shaft for the

3

mm

* When replacing symmetric roller shafts only.

* When replacing eccentri c ro
* When replacing both

D type

* When adjusting with out replacing the bearings.

-

0

* Adjus

~3mm

7.

(1

0 pieces)

are

use

in

the s
type.
Turn the eccentric roller shaft
th

e bearings move smooth
over th e feed guide
s

urf

aces.

sl

ider

0.

it

does not fall

adjustment

the eccentric roller shaft and adjust.

roller shafts. first
sha

ft

. and then

roller shaft.

loosen Allen bolt
eccentric ro

tm

ro

ll

er shaft oppo

and then adjust the remaining eccentric roller

s.

shaft

Move the feed guide assemb ly

a

ll

of

the bearings rotate even if depressed by
your finger. If a bearing slips. read
eccentric roller shaft.

ui

de assembly to the

L.

feed guid

he

nd

e assembl y to t

bolts.

and

and

remove the feed

nt

f).

Allen bolt 0

remove the bearing assembly

at

the place

0 from the previously

ll

er

shaft. replace the old bearing 0

ew

one. a

nd rei

nstall in the orig inal

four types

lid

er; be sure to install the correct

support the roller shaft

is

not necessary.

ll

er shaft.

ent order:

of bear

out.

in

sta

turn

0

and

fir

site the symmetric roller sha

ing assemblies for

and

ly

with no r

f)

and slider gu

by

ll

er shaf

sy

mmetric and eccentric

ll

the symmetric roller

and

adj ust the eccentric

then

turn

st

adjust the eccentric

and cunfirm that

he left

fron

remove ta ble

to

e.

adj ust so

hand so that

ts on ly.

and

that

att

ling

id

e 0

turn

adjust the

ju

st the

ve

t.

be

ft.

B

type

(2 pieces)

- 49 -

11]

GUIDE RAIL HOLDER FRONT BEARING REPLACEMENT

AND

ADJUSTMENT

I. Move the feed guide

2.

Loosen the Allen bolt 0

replaced,
from the guide rail holder front

3. Replace the bearing in the same way slider
bearings
eccentric roller shaft so
smoothly with no rattling over the side
guide X

4. Move the feed guide assembly left
confirm
even if depressed by
slips, readjust the eccentric roller shaft.

and

are

G.

that

all

to

the left front.

at

the bearing to be

remove the bearing assembly 8

e.

replaced.

of

Turn

and

adjust the

that

the bearing moves

of

feed

and

right,

and

the bearings roll smoothly

your

finger. If a bearing

* If a rattle develops in the roller shaft holder 8

and

feed

support
Allen bolts
mount
feed

0 until the

support

guide 0

8

and

bearingO

guide 0 fairly strongly.

action,loosen

move the roller shaft holder

presses against the

the two

* When replacing the bearing assembly

roller shaft holder
replace in the same way the slider bearing
replaced.

8.

loosen Allen bolt $

G)

on the

and

is

-SO-

[I]

RAll-Y

BEARING REPLACEMENT

AND

ADJUSTMENT

I. Remove the

cover

2.

Remove the
motor

• When removing the
coupling position. If

motor

3.

Remove the eight left
remove

4. Loosen the Allen bolt 0

replaced,

from

inside the rail-Y guide.

*

To

replace the

the

other

replace shafts

and

adjust

replace shafts 8 following

bearings

8

make

5.

To

replace the

remove

8.

pull rail-Y

6. As in slider bearing replacement,

8.

8

over rail-Y

7. Install rail-Y
two Allen bolts

8. Check the origin position alignment.
p.42.)

four

set screws

rear.

three

set screws, remove

bracket assembly

will be 180°

the

arm

and

two eccentric roller shafts

out

cover

remove the bearing assembly 8

two

eccentric roller shafts 8

and

and

put

motor,

not

properly installed,

of

phase.

and

right set screws,

side.

for

the bearing

8 while shafts 8

the bearing position. After

the

of

eccentric roller bearing shafts 8

the X-axis perpendicular

four

symmetric roller shafts

the

two Allen bolts

out

and 8 so

forward

that

G.

remove Y-ES

and

the bearings roll

0.

0,

and

secure Y-ES

G.

remove the

it on the table.

mark

are

still secured,

same steps.

to

replace it.
turn

dog

the

down

to

8.

that.

theY

-axis.

and

adjust

smoothly

8 with

(Refer

arm

DD

the
the

and

be

and
first

The
and

8.

dog

to

-51-

(I]

GEAR REPLACEMENT, ADJUSTMENT

0

AND

MAINTENANCE

I. Remove the f

rear.

2. Remove the four screws. and remove the left­arm

hand

3.

Remove the three screws, and remove the
motor bracket assembly

* When removing the motor, mark

coupling position. If not properly installed. the

motor

4. Remo

5. Loo

6.

7. Insta

ve the

dog

8 a

se

n the two Allen bolts O.

gear assemb ly
easi ly removed

lifting

Mount the new
motor
Allen bolts
the top

e.

rake

ll

* If there is excessi

assembly

bolts

Likewise. if the gear assembl y
teeth meet too strongly. adjust
(Refer to p.43.)

8. Install Y-ES dog 8 with t

9.

C

h ~ck

p.42.)

our

screws. and remove

cover sid

will

be

nd

up

on both sides.

shaft and adjust

e.

180° out

two Allen bolts

pull rail-Y forward

0.

The

by

using two screwdrivers

gear

and

put

of

phase.

0.

gear assembly

assembly 0 on the pulse

so

that

arm

it

on the table.

down

remove Y-ES

and

out.

and

remove the

one

of

0 meets the screw guide: now align

of

the gear assembly with the top

and

firmly tighten the Allen bolts

raii-Y

f).

ve

backlash between the gear

0 and rack e. loosen the six Allen

0.

and

shi

ft

the rack e to adjust.

0 and rack e

in

the same way.

wo

Allen bolts 0 .

the origin position

alignm~nt.

(Refer to

cover

DO

the

can

be

and

the two

of

the

0.

* Maintenance

I.

Regular!~

grca~c

grca!>c

whcnc\cr

the rack e gear teeth. Apply

nccc!>~ary

.

-52-

~WORK

*

There
which

[Bar

tack type)

are

work

two

CLAMP

ways

to

clamps

CONSTRUCTION~

use

the

work

are

interchangeable.

clamp:

I)

the

clamp

uses th e

cassette

(Cassette type]

as a ba

rtack.

and

2)

the

ca~!>cttc

type in

Work

Bar

tack type

Cassette

(I)

I.

The right
th

2. P
dim

clamp

typ

Wor

e s

tand

oss

ible

ensions

type

Sewi

e

k Cl

Sewing
Simultaneous sew

amp

Cons

illustration shows

ard work

ewing

are show

Sewing condition

ng on a O

piec

es

truction

clamp.

area

and

n in

compariso

at

sur

face

onto

background

ing

of

more

dimensions for

wo

rk

clamp

n a

lri

s

than

ght.

material.

two

spo

!::

Set

time

It

ems

which

are

set

eas

Items

which

take

time

ts.

____!£_·

-r

H""-

60.=,-

.-

~24~0

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

9

120

to set

-

637

300

I

Sewing

ily Relatively sh

Relativclj

TI

.

_ 9

a.

I

a.

~

"'

~M

"'

N

"'

h

time

ort

long

50

15

~

N

,._

27

"'

·,

-53-

;=<-::

"'

'

600

10

3. On the reference work clamp there are

16

However. if installation in a position other
Next. install the standard plate spring according
not interfere with sewing.

57

80

80

110 110

80 80

1--

M4

screw holes for the installation

than

these

is

desirable, drill and

to

the illustration below. being sure that the spring will

M4

tap

new holes

of

the work clamp spring.

as

is

appropriate.

(2) Cassette Construction

I. Cassette assembly dimensions

are

shown in

the right illustration.

2.

The below table shows the various cassette tops and

article

to

be sewn.

[Cassette top]

630

[Cassette bottom]

640

c:o

......

N

15

35

-

00

f

~

5

bottoms

Cassette top I
Cassette top 2
Cassette top 3
Cassette bottom

710
680

610

0 0

670

available. Select parts

Parts Name

0 0

00

~

: I

appropriate

Parts No.

158586000
157763000 2 mm
157727000
157764000

to the

Thickness

(mm)

I mm

3 mm

I mm

...

..

~:;!

8N""

0

en

N

-54-

"'

0

N

3.

Decide
Cassette
usa

*

Cut

40

L

Ia

Ia

where

assembly

ble

interchangeabl

out

both

"

to

place

and

cassette

600

Sewing

and

sew the

the

y,

cut

bottoms and tops

·,·

fi

f_.X<

area

...

garment

sewing

area should

the casse ttes

and

cut

out

the

meet

the

out

to

the same

only "A" greate

r­I I

I I

I I

I

I I

L

~

_____________

cassette

dimensions shown

dimensions.)

r t

--

appropriate

han the sewing

---

--------,

to

below.

area.

the

sew

(If

cassette~

-I--

ing

dimensions.

arc

-measurement

!---......._

Sewi

1

"measu

_

A

Inner

to

ng

be

remen

t

4. Four mountin
installation

I

I

93

5 8

Jl

in a ny

0 0

~

.

5. I

nstal

l the hinge

,....

c

"'

-5

~

0

~

~

E

,-~:,I

g holes

are

other position.

477

as foll

ows.

pro

vided in the

LO

,....

Scr

i

open

8

li

0 0

ew

Washer

cassette

mounting

-

~

.

(3

mm)

Pr

esser

ho ld

ho les in the

er

for i

cassette

Spring

D:

Diameter

B: Clearance b

foot

nstallation

Nut

(3

of

one

ho l

der

as sh

Cassette hole measurement

mm)

Screw

washe

r

A = D/ 2

of

the

etween the

and

the

presser

casse

tte top.

own

below.

~

hol

e

+ B

press

er

foot

presser

For

Hinge (right

(1

52632

001 )

)

Upper casse

Lower

cassette

tt

e

-55-

Screw

(3

mm)

~

Hinge (left )

(152633001)

Screw

hole

6. When hinges

below.

and

two cassettes

top

are installed

to

cassette the predirilled holes. the assembly

appears

as

G:~

~@~~@..If!>

0

0

7. Apply a

paper

__

~

cushion type-material

L~~~®JI~~l

around

the cut

out

area

in

order

l<!il_~®

to

firmly

~

L®®.IELq>]

clamp

the material.

Upper cassette

Lower cassette

~

0

0

J"

-56-

~PROPER

USE

OF

0

Needle plate Need le

S assembly A plate s asse

Thread cat
spring

cher

hole

Needle plate Needle

Thread cat

surface Thread catcher

cher

SPECIAL

X

mbly

spring

B plate

hole

ACCf:SSORIES~

(I)

Needle Plate S Assembly

The needle plate S
nee

dle pl

ateS

pl

ate), and

bottom

• Use

•

of

When
needle plate S assembly
us

ed.
align with
and when the
wi

ll

str

in tr

ou

Using
Wh

en

need le

a

pai
used bec
installed

needle plat

plunger).

the

needle hole

using

the

the upper

the

thread

ike

the

ble.

the

bott

usin g

the

pl

ateS

r.

Needle

ause

it

on

the be

assembly

assembly A

eS

plate

nee

dle hole

thread catch

bottom

needle ho le pl

om

assemb

of

catc

plunger

bo tt

om plunger, always

ly

plate S assembly A ca

will strike the

d.

cons

(fo

r the needle hole

assemb

plate,

A.

If

assembly B is

er

surfa

the

needle

her

spring

ate

and may result

Band

the

bottom plung

ists

of

ly B

(for

always

ce

will not

hole

plat

advances it

bottom

lid in

nnot be

the

the

use

e.

use

er if

0

Nee

dle

plate

Bottom

cover

S

""mbly

~"'""m

Bo

ttom

B

·'

plunge r

k

¢5

Bott

om

X

It

plunger

gets

tou

ched

(2)

Bottom

Whe
pa

Plate

n using the bottom plunge

ir with needle plate S assembly B.

r, always u

se

in

a

Bottom

plate A

157538001

-

57-

(3)

Bottom Plungers

There are two bottom plungers: bottom

plunger A for medium thick garments
bottom plunger 8 for thick garments. Select the
plunger appropriate to the sewing job.

and

Bottom plunger A

157795001

Thread catcher spring A

157790000

Needle plate
S assembly A Needle hole

) plate

I -

2mm

.J

~

Bottom plunger B

157796001

Thread catcher spring B

157791000

Needle plate

S assembly B Bottom cover

llqsnnL

3mm

Bottom plunger

(4) Thread Catcher Spring

There are two thread catcher springs: A, for the

needle hole plate; and
plunger.

• Using the needle hole plate
When using the needle hole plate, use thread

catcher spring

used, catcher pressure

surface will weaken
cannot be held.

• Using the bottom plunger
When using the

catcher spring

used, thread catcher pressure will be too great

and

the garment will be pulled.

A.

If thread catcher spring 8

bottom

B.

If thread catcher spring A

8,

for the

at

the thread catcher

and

the upper thread

plunger, use thread

bottom

is

is

-58-

II!

Standard Combinations

Parts

Name

Needle plate

S assembly

Bottom plate

Bottom plunger

Thread presser spring

Use

Use

with needle hole plate

Needle plate

S assembly A

157534001

Use

with

bottom

Needle plate

S assembly B

157536001

Bottom plate A

157538001

Bottom plunger A

157795001

*Bottom plunger B

157796001

plunger

for medium thick garments

148593000

Thread catcher spring

Thread catcher spring A

157790000

Note: Items with a * mark are optionally available. Please order separately.

II!

Movable and Fixed Knife Shape

The movable knife on this machines
shown below. use it as

Movable knife Fixed knife

is.

is

the same shape

Type

360: long blade. large arc

as

tyep 832.·However. because it differs

Thread catcher spring B

157791000

in

the points

Fixed knife

Movable knife

Type 832: short blade,

small arc

-59-

Fixed knife

Movable knife

~AUTO

OJ

AUTO-EJECTOR

EJECT (optional parts) J

FUNCTION

I. When the

arrow
when

2.

This

3. B

ecause

to hori

4.

Tab

5. If the
wi

ll move opposite the

from the feed

cassette

when

the

pre

motion

slide

zontal

f)

pulls position

pres

ser fo

When cassett e install

holde r 0

the

so

leno id 0

sser foot lift

is transferred

block

0 is

and

vert

ical
detector

ot lifter swit

arrow.

assembly.

is mounted

is

turned

er

switch is

to

the

gu

ided by

motion.

ch

is
tab

ed

on

off

both

depre

slide

blo

the two rollers

and

relayed

A

f)

,

and

depressed

f)

will press

the

feed

when the

sse

d.

ck 0

to

holds the

when

sew

position

assembly. the

two

and

tab

f)

0.

the straight-line

tab

f)

.

cassette

ing is complet

detecto

cy

position

connec

ho

lder 0

ed.

r B

0.

When

casse

lind e r 15 0 will m

detectors

ted

motion

the solen o

a nd the

1\

f)

turn

to

cylinde

to the feed asse

r 15

of

the

id

0 wil l

cassette

tte

removed

ove

in the

limit switch e o

0.

cylind e r

holderO will

150

mbl

y.

turn on.

direction

is conve

cylinder

be

rel

of

the

n.

and

rted

15

eased

0

- 60 -

[I]

AUTO-EJECTOR

DISASSEMBLY

0
0

Remove th e fou r set scr

I.

Remove th e two set screws

1.

3.

Remo

ve

the t

wo

Di

sconnect the air hoses from the two nylon nipples

4.

Loosen nut

5.

6.

Remo
pos itions.

7.

Repeat steps I.

Remove

H.

~-

Remove th e four Allen

9.

front
Attach

1

0.

Mount the

*

0.

remove slide block

ve

the two set screws

to

the four set screws

plate~-

th

Next. remove the eight Allen bolts $ . and remove position detectors C

l.!

front

fro

nt~

ew:.

O. and remove the cylind

0.

a

nd remove the s

set screws

6. for the other side.

plate~

so th

0.

49.

bolts~

to the

at

and remove the roller 0 a

6)

. cylinder mo unt R

an

d then remove mieroswitch assembl y A E

.

remo

feed

the bevel

fl!).

ve

guider inner plate fl)

is

er

supp

ort

0 .

lid

e block guide

0.

nd

two cylinder collars

f)

.

0.

and remove the two Allen bolts $ and ta b f!) .

fD

.

an

d then replace the set screws

4D

from

feed

guide inner front A E

feed guide inner fro

on the front bottom.

nt

AE

by

~

.four

four Allen

All

en

bolts

bolts~-

~.

f1)

6)

in their origina l

and then remove t

an

d D@). two each.

hl.!

-61

-

II.

Use

the program reference plate e

Refer to p. 43 for origin adjustment.

*

12.

Remove the

13.

Disconnect the six

14.

Disconnect the spiral tubing

15.

Cap

the solenoid e with the auxiliary stops in place

16.

Disconnect the

17.

Disconnect the connector

four

Allen bolts

air

tubes from union

air

tube from elbow G. and disconnect the elbow

to

and

mount the feed guider inner plate

8.

Allen bolt

f).

G.

T -connector

microswitch AE

f».

fD,

48.

L-bracket

nipple G.

of

the T -connector

i},

f)

and

then replace Allen bolt

and

the three

air

fD

G)

from pressure switch

with the three set screws

f».

tubes.

and nipple G.

G.

f.D.

-62-

[I]

AUTO-EJECTOR ASSEMBLY

1.

When eight valve groups are connected as shown
in the figure at right, mount T -connector
nipple 8 at the second from bottom group.

0 and

2.

Mount

on the power unit with two Allen bolts

then connect the elbow 8

with

the pressure switch 0 on the fan

and

air

tube

e (300 mm).

plateG

0.

T-connctor

and

0

-63-

3.

Temporarily mount the two position detectors C 8 and D 0 (two each) on the feed guide inner

with the eight Allen bolts

* Install the

4. Remove the feed guide inner front presently in place,

three Allen bolts

D

0,

the needle plate

right
the inside) with the four screws

5.

Install the microswitch AE 0 with

pass between cylinder plates R

6.

Mount
back.

7.

Pass roller

cylinder

nut f». Next,

elbow
cylinder
front surface position detector C
position. Next, install one

* Adjust screw

bottom

front 8 so

8.

and mount them with eight Allen bolts

at

this time. Next, tighten the three Allen bolts

of

the feed guide inner cover front

the

four

universal elbows

4&

through cylinder

plateR

e and the

15

mount

CD.

The

tD

0 and

tap

so

G.

Next, install the two

that

the bevel

Use the program reference plate

0.

bottom

is

on the front bottom.

and

Position detectors C

fronts 8 with the four screws

temporarily install feed guide inner front AE 0 with

to

determine the positions

8.

0.

and then install cylinder

f).

four

screws

CD

and L

CD

and

four nylon hose nipples

15

CD.

place the two cylinder collars

LCD

with

twoscrewstD.

the elbow e

hole

slide block 8 should be mounted so that when

that

slide block guide

on

the slide block

of

the slide block •

8

and

the inner face

of

the slide block guides

fl.

Be

careful the switch

CD.

fD

Install

rollerguidefi

f)

with the two Allen bolts

are

perpendicular, and then mount the slide block • on the

of

the slide block are nearly aligned. Secure the nut

fi.

fi

is positioned between cylinder plate R 0 and L

of

position detector C 8 and

f)

and

D 0 should be perpendicular

Remove the four screws

plateR

CD

and

LCD

(with the larger flank on

is

properly installed; the cord should

on the two cylinders

CD

on

both sides

on

plateR

0 and

t)

it

is

pushed back with the cylinder

15

of

the roller, and install

LCD

so

that

the inner side

so that they face the

fron~

AE 0

0.

f)

on the left and

with screwfD

of

15

CD.

at

CD.

to

and

the

the

this

-64-

H.

Connect

the six air tubes

to

* There are three tube lengths.

mm tube
tube
325-mm
retightening the union
union as shown in the figure.

9.

Remove
rear
union

connectors

back G.

bolts

10.

Secure the

on

II.

Mount
panels R

to

the center union

to

the rear right

tube

to

the

three Allen bolts fJ)

of

the pressure foot

mount

f)

between

and

secure them with the

G.

four

right

and

left cylinder

the cylinder

fD

and

and

left sides;

the front right

f)

support

front

G>.

enclose the two

the

air

tubes to the nylon nipples

15

support

LCD

with the four set screws

e.

12.

Remove needle plate

13.

Secure the

center

G.

and

nipples

air

of

the T

the tubes from

G.

tubes coming from

L.

and

-connector
the

f)

the two unions

Connect

f);

nut

the 2260-

the 265-mm

connect

and

left. After

fi,

adjust

at

the center

fl. install the

mount

front

G)

four

e.

G)

on

cylinder

remove table left.

the

rear

to

the service T

front

center

to

f).

the

the

T-

and

Allen

4D

and

the

AE

harness

14.

Cut

the section

indicated by the

solder the

to the normal open terminal
switch
common

15. Disconnect the spiral tubing
six air tubes. Wire the
along with the spiral tube and bind them with
the band
Use the cord clamps (previously used) to secure

16.
the microswitch assembly cord $ and pressure

B

switch 0 cord to the leg, and connect them to
the treadle connector

ED.

at

of

the limit switch assembly

arrow

long cord from

and

the cord

terminal

of

the microswitch

7-8 places.

0>.

0)

in the right picture. Now

the

left microswitch

of

the pressure

that

was

cut

to

the

f).

e,

and rewrap the

AE

harness separately

-65-

1

7. lhc

a pin extract

the 112

connector~.

and

t/3

Be

or

to

disconnect the

con

n ector~

!lu

re to note for subsequent

from the treadle

rcconncction the colors and numbers
respective connectors and cords: the machine
will

not function normally if

cord~

connectors arc improperly co nnected.
cut

off

the cord

th

e microswitch

~how

n

in

connector~

l

l<.

rurn

dipswitch

19.

Replace table right. needle plate L. and the left

pins~.

4D

insert the cords from

and

pressure sw itch

the picture. and then reconnect

in

its original position.

:"Jo.

6 (D on.

front co\'cr.

cord~

or

of

and

:"Jex

Ga

t.

s

-66

-

0 AUTO-EJECTOR

1 . Auto-ejector speed adjustment

Removal speed

• Speed adjustment for ejector insertion
If the

tab

0 moves slower than

before the auto-ejector
increase the speed as required.

• Speed adjustment for ejector removal
If the

tab

0 moves slower

forward. Loosen nut

ADJUSTMENT

Insertion speed

is

properly inserted. Should this happen. loosen nut

than

8

and

is

necessary for ejector insertion. the feed mechanism will start

is

necessary for ejector removal. the cassette assembly 8 will not be brought

turn speed control 0 to increase the speed as required.

f),

and turn speed

to

function

controiO

to

2.

Auto-ejector feed adjustment

Make the following adjustments so
cassette
and left sides moving parallel.

(I)

To

• Mount the lower feed block guide 0 as far as

possible

• Loosen nut
and retighten.

•

The
position detector A

(2)

To

• Mount the lower feed block guide 0 as far as

possible

• Loosen nut
retighten.

• When the auto-ejector

of
face

positioned forward
project. the cassette will not be held firmly
place.

is

moved back

increase the cassette feed stroke

in

the direction

f).

tab

0 should

move

and

forth with the right

of

the arrow.

it

opposite to the arrow.

be

at

least I mm above

8 during ejector removal.

decrease the cassette feed stroke

in

the direction opposite

f).

move it toward the

is

inserted, the inner side

the

tabO

should

of

position detector C

be

roughly aligned with the

8.

It

of

this face; if it does

that

to

the arrow.

arrow

should not

the

and

be

in

--u--

o~

1

mm

-67-

~

ADJUSTMENT

GUIDE

~

L__T_r_ou_b_l_e

:'\cedle breakage

r

__

~l

Ll

______

Needle

r-

Needle

f-

spri

~

Needle

~

Needle hits the press

~

or

presser

Correct

-

posit

ng

ion

c_au_s_e

hits

hit s

hits

needle

____

movable

thread

bo11om

up

~l

knife

I--

catcher

I--

plunger

sto

er

I--

foot

I--

p

I--

Ll

______

Scar

Scar
spring

Scar

Scar
or

Needle

c_h_

on

movable

on

on

bo11om

on the presser foot

presser

up

stop position

ec

_k----~~

knife

catcher

thread

plunger

LI

______

Adjust

r-

sl

ider

f-

Adjust thread trimming

'----

signal

Adjust

1---

strike

thread

Adjust

1---

strike bo11om

so

Adjust
strike
presser

Adjust
pos

iti

the

on

1--

1--

R_e_m_e_d)_

thread

·

--

trimming

--~~-R-e~-~

35

46

so

needle

does

catch

so

needle

the needle

presser foot

the

needle

er

does

plunger

does

up

not

spring

not

not

stop

or

37

36

33

46

-~-~-ce~~

Skip

stitches

Imp

'--

timing

I

mproper

r-

hook

Excessive needle

-

hook

Presser foot

I-f-

high

~

Im

Presser

~

low

Bo11om

f-

when

roper

tim ing

gap

proper

it rises

needle

needle

clamping

foot

pressure

plunger

and

and

and

position

is

too

feed

rotary

rotary

100

is

too

low

1---

I--

r--

I--

I--

I--

r--

doesn"t move thoug

Feed

needle is in

Ho

ok timing

Needle

gap

Pre

sser

material

presser

down

plunger

foot

during

gap

b

ed?

Does

and

Bo11om

material

and

properly

foot

vibrate
sewing?

height

garment

clamp-

up

h

r--

1--

-

1---

1---

1--

r--

Adjust feed
chronitation

Adjust

the h

Adjust needle
hook

gap

Adjust the
position

Change

the

clamp

Adjust

presser

su

re

Adjust

plunger

signal)

ook

timing

timing

and

prc,,cr

type

foot pres-

height

(syn-

rotar

foo l

46

32

y

32

33

53

33

36

r-

.__

Needle
short

thread

lcngt h

Is needle

is

too

f-

Is

L_

ti

on

the

-68

needle

too

thread

high?

-

length

up stop

OK'!

posi-

1---

-

Adjust

the pretension

Adjust the

position

needle

up

stop

I/

46

L---T_r_o_ub_I_e

__

~ll

~------c_a_u_s_e

______

~l

Ll

______

c

__

h_ec_k

______

__JII

L------R_e_m

__

ed_Y

____

~I_R_e_~-~-~-nc~e~

Thread
come-offs
at sewing start

Thread breaks
and frays

Thread take-up spring

r-

weak

Thread catcher spring does

t-

I-

not catch upper thread

Needle thread length

L-

shon

Needle center not aligned

r-

with presser foot needle hole

in

I-

Scratch
die hole

presser foot nee-

,_

Needle center not aligned

r--

with bottom plunger needle
hole

is

too

is

too

Does thread take-up spring
work during thread trim-

1---

ming'!

thread

Is

r-

speed too

t-

Does thread catcher spring

L-

meet the needle plate?

Is

r-

OK?

t-

Is

L-

tion

f--

Is

Scratch

-

needle hole

Bottom plunger position

r---

slow'?

needle thread length

the needle up stop posi-

too

high?

presser foot position OK'!

in

catcher

presser

spring

is

foot

Strength the thread take-up

f...--

spring

Adjust thread catcher spring

~

speed

Replace with thread catcher

spring that meets needle

f...--

plate

Adjust the pretension

f...--

Adjust the needle up stop

f...--

position

Adjust presser foot position

~

Remove the scratch

f...--

presser foot needle hole with

sandpaper

Adjust bottom plunger posi-

f...--

tion

v

37

59

17

46

33

in

17

36

Upper thread
breakage

Scratch

in

r--

needle hole

Scratch in needle hole

I-

needle hole plate

yscratch

surface

Upper thread

...-

great

Improper needle installation

I-

I-

Improper

I-

spring strength. height

Scratches

I-

hook,
needle. etc.

Improper
timing

bottom

Mar

thread take-up

or

bottom

needle and feed

plunger

on

rotary hook

tension

marred rotary

plunger.

m

too

Scratch in bottom plunger

1---

needle hole

1---

Needle hole scratch

Scratch on rotary
surface

Upper thread tension

~

Needle facing

~

Thread take-up spring

1---

strength. height

1---

Scratch. marring

Feed does not operate

though needle

is

in

material

hook

Remove scratch with sand-

f...--

paper

Remove scratch with sand-

~

paper

Remove scratch with sand­paper

Adjust upper thread tension

~

Install

1---

f...--

spring strength. height

f...--

so

faces forward

Adjust thread take-up

Correct

or

part

Adjust

chronization signal)

replace damaged

feed

needle

ummg

groove

(syn-

[7

[7

~

[7

I/

[7

I/

46

-69-

~--T-ro_u_b_J_e

Lower thread
breakage

__

~ll

~------C--au_s_e

thread

Lower

r-

great

-

Scratch

'--

bottom plunger

on bobbin case.

______

tension

~l

lL

______

too

Lower thread tension

f--

Scratch

f--

c_h_e_c_k------~~~

L

______

Adjust lower thread tension

-

Correct

-

R_e_m_e_d_Y

or

replace

____

~I_R_e_~_~_e:_c~e~

/
/

Thread
misses

(upper.

lower

threads

aren't cut)

trimming

Movable knife

r-

knife

do

Damaged knife tip

1-

r-

Movable knife tip not

1-

aligned with needle center

Thread trimming speed too

f-

slow

not meet

and

Y Movable knife doesn't move

Improper needle installation

....--

fixed

Movable knife operating

-

position

Fixed knife tip

-

-

'---

Movable knife tip

Movable knife position

-

Has next sewing procedure

f--

before thread cut-

started

ting'!

Is

thread

sent?

Needle position

trimming signal

Adjust

-

slider

Sharpen

-

Replace

-

Adjust movable knife posi-

r-

lion

Adjust

1--

speed

Inspect electrical circuits

1--

Install properly

thread trimming

or

thread

replace

trimming

35

35

/

35

37

/

/

Thread

trimming

misses

(upper

thread isn'

cut)

H Needle skips

Stitch quality

-

at

final stitch stroke

at

last stitch

is

not good

-

doesn't

Movable

-

catch loop sit ion

~

Movable knife and

knife

Dull knife tip

-

knife

don't

meet position

fixed

Thread

f--

Movable

-

timing

Thread trimming signal po-

1--

-

Movable

-

too slow

Movable

1--

r-

Fixed knife tip

take-up

knife

knife

-

'--

Movable knife tip

-70-

spring

knife insertion

timing

operating

"Skip

or

Stitches"

replace

take-up

position

68

/

39

46

39

35

35

Refer to

Adjust thread

f--

spring stroke

Adjust

1--

Adjust the down

f--

signal

is

Adjust movable knife speed

1--

Adjust the thread trimming

t--

slider

f--

Sharpen

t---

Replace

/

L_

__

T_ro_u_b_l_e

Thread trimming

misses (lower

thread

isn)

__

~l

Ll

r-

I-f--

cut)

______

Movable knife and lixed

knife

Damaged knife tip

c_a_u_s_e

____

~l

do

not meet position position

Ll

______ c __

t--

Movable knife operating

....-

Fixed knife tip

I-

.__

Movable knife tip

h_ec_k------~~

LI

______

R_e_m_e_d_Y

,_____

Adjust trimming slider 35

,_____

Sharpen

or

,_____

Replace

____

replace

~I_R_epa_re_~_e~-c~e~

35

[7

Pattern

distortion

I

'--

Thread
advances

Gap

r-

and bearing

Excessive

f--

backlash

Improper belt tension

f--

r-

Material position is

f--

changed

catcher spring

too

quickly trimming

between

guide plate

gear

and

rack

Thread catcher spring

1---

advances before thread

L---~----------~

bearing

the

Does

t--

properly?

Gear

and

-

Belt tension

-

Material properly clamped'!

r--

Work

f-

weak

rack backlash

clamp

pressure

-

Needle

and

1-

feed timing OK'!

roll

too

,_____

Adjust thread catcher speed

1---

Adjust

or

replace bearing

Adjust gear

1---

lash

Adjust belt tension

-

~

Adjust work clamp

1---

Adjust work

Adjust needle and

1---

timing (synchronization sig­nal)

and

rack back-

clamp

pressure

feed

37

49

44

45

34

33

46

L-

t--

Origin position

'---

Work clamp

Presser foot descends

Origin position

is

off

is

too

heavy

1---

1---

Work clamp

too

far

t--

1--

1---

-71-

Adjust presser foot height

Adjust origin position

material

Use

possible

as light as

33

42

53

~ELECTRICAL

*

Wh

en replacing any

[JJ

FUSE REPLACEMENT

(l)

Fuse Positions

Open

the

rear

cove

e

quipm

ent fuse box.

ADJUSTMENT~

part

s. a lways

r. Fuses No. I ~ 12

turn

the

and

power

fuse n

switch of

umb

er

f.

13

for the pulse

motor ar

e inside

the

electrical

1 2 3 4

u~~:

(2)

Fuse Capacity

No. Fuse types and capacity Remarks

1

2 Slow blow fuse
3 Fuse 10A- 125V For D.D-rnotor

4 Slow blow fuse 0.5A-250V For bobbin winder motor

6 Fuse

7 Fu se 1A- 125V For floppy motor

9 Fuse

10

11

12
13 Slow blow fuse 1A-250V For pulse motor logic

56 7 89101112

~

~:

~

m

Slow blow fuse 5A-250V

5A

- 250V For pulse motor

5A

- 125V For air solenoid

5A-125V For pulse motor

Fuse 5A-125V For control + 5V
Fuse 1A-125V For control + 12V
Fuse 1A-125V For control -

For pulse motor

SV

(h

igh voltage)

-72

-

(3)

Fuse Replacement

The chart

Ca

ution

: Be sure to

bel

ow shows that happ

alw

ays

repl

ace a fu

ens whe n

se with one of the same capacit

eac

h fuse bl

ows.

Refer

to

y.

it

when re

pla

cing fuses .

Fu

se

No.

I. 2. 9 •

3

4 • When

6

7

I

I.

12

13

moto r torq

Pul

se

operati
Unusual

•

to program.

•

m

• T hou gh
th
op

• When programmi

sou

• Ab

• When the
abnormall

• T he feed

ng prop

sounds

Ma

chin

e will not opera te: e mergency lamp

the

power sw

oves slightly.

air

rea

d tri

mme

era

te.

however. the

nd h

eard.

solu

tely

no

power

y high spee

mec

boa

rd

LED will

erly

pressure

r. bott

emergency

mach

hani sm will n

Result of blown fuse

ue

d r

but feed

heard:

itch

is

normal, the

om plu

ng the memory disc.

ine

move

swit ch is

d.

not

illumin

moto r sounds as

ops:

mechanism

feed d

oes

is

turn

ed on o r of

nger and thr

lamp

illumin

ment.

turne

d o n, the machine run

ot

operate.

ate.

doc

s not work.

no t

opera

illuminate

f. the m

work

clamp. presser foot.

ead cat

the lamp

ates

with

and

pulse mot

if

it were

te

cco

a

s.

ach

cher \Viii

illum

ina

no clicking

s at

or

circui

rding

ine

not

tes:

an

t

Referen

p. 97

# 14, I

p.I

O I #24, 1.

p.96

#9.

4

#5,

p.94

p.9 1 # I, 3
p.92 #2, I

p.97 #14, I

4

ce pag

e

I}]

CIRCUIT BOARDS

(I) Circuit Boa

Ope

n the

back

rd

Pos

cover and

ition s

AND

the

DIP

D.D

SWITCH

mot

or, con

REPLACEMENT

tro

l. and pulse mot

or

circuit

boards

a re ar

ranged

as

shown

below.

-73

-

(2)

Circuit Board Functions

Circuit board functions are listed below. Refer
to

these lists when replacing circuit boards.

D.D

I.

2.

Motor

•

D.D

•

D.D

• Relay
signals to the control board.

Control Circuit Board

• Transmits command signals
motor

• Transmits command signals to the puis
circuit board.

• Memory disc control

• Air solenoid drive (clamp. thread trimmer.

bottom

• Discrimination

• Programming control

Circuit Board

motor

rotation control

motor

needle up stop position

of

synchronization

circuit board.

plunger. thread catcher)

of

input to each switch

and

thread trimmer

to

the

D.D

motor

3.

Pulse

• Pulse

-74-

Motor

motor

Circuit Board

drive

(3)

* Always

back cov

[I]

I. Disconnect

©.

2.

Disconnect

3.

Remove

repl

*

Be sure

proper

[2]

I.

Disconnect

2.

Disconnect flat

3.

Loosen the two set screws

cir

4.

~

I

Remove the

replace the

Circuit Board Replacement

turn

the

power

switch off. then

er

and

D.D

ace

Contro

cu

it

perform

Motor

board

Circuit

connectors®

tab

terminal

the six installation

the

D. D motor

to recon

orde

l Circuit Board

nect the

r.

connectors@.®.®.@.

cab

mounting

four

control

the following steps.

Board

and@

s

0.

circuit

tab

Replacement

les

CD.

Q).

plate

installation

circuit

board

open

Replacement

and

flat cable

f).

0

and

screw

s 0

boa

rd .

terminals

a

®.and

0.

and

(0.

shift the

0.

screws

0.

0.

the

0.

and

in the

nd@.

and

[3] Pulse

I.

Disconnect

2.

Remove the
replace the pulse

-

75-

Motor

connectors@.®.®

Circuit

four

Board

installation screws

motor

circuit

Replacement

an

d@

0.

board

0.

.

a nd

[I] DIP SWITCH USE

1.

D.D

Motor Circuit Board Dip Switches

These switches are the
test switches. They should normally be

D.D

motor

circuit self-

OFF.

Note

I:

High speeds are selectable by the speed selector switches

and

turned

Note
Note

Note

the machine, change speeds

2:

The

thread

3:

If only No. I switch
emergency lamp may illuminate. However. this

4:

Do

not use switches 5 ~ 8.

trimmer

will not work until the machine has been run

is

2. Control Circuit Board Dip Switches

There are two sets
specification selection.

of

control

circuit

© Specification Selection Dip Switches

Switch

No.

I

2

3

4

Work clamp still down when
sewing completed.

Simultaneous clamp rise; de­scent

is

Clamp
simultaneous descent.

Operate without air pressure

ON

left clamp, then right.

rise is left, then right;

proceed sewing.

on

and

off. the machine will stop suddenly after high speed

board

dip switches, one for thread trimmer timing

Clamp

end.

Left
descend simultaneously.

Machine stops if pressure

not over 4 kg/

No.

* Switch priority runs from switch

on

is

not a malfunction

OFF

automatically rises

and

right clamps rise.

em~.

D. D motor

I
2
3

4

·

Machine high speed
Machine low speed (
Machine superlow speed

Thread

the control panel.

and

or

at

operation when switch

150

trimming

To

change speeds, first stop

then stopped.

operation

unusual.

and

the

Remarks

No. 3 has priority.

Normally off

rpm)

(100 rpm)

number

other

on

I ~ 4.

and

for

5

6

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

Ejector specification

500 ~ 800 rpm regardless

7

stitch length.

888IT]

is

8

thread.

split for lower

of

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

Bar tack specification

Sewing speed changes accord­ing to stitch length.

888IT]
feed.

Thread trimmer

dip

switch

is

no thread-trimming

Note: There may be later additions for improve-

* Refer to "Movable Knife Timing

(p.39) concerning the

-76-

ment

This function not in

1-1.

2-1. 3-1. 4- I. 5-1. 6-1.

thread

PROM

trimmer

All prior to
2-3, 3-3, 4-1, 5-1, 6-4 are
lower thread split.

of

product performance.

PROM

1-5.

Adjustment"

dip

switch.

[!) CONNECTORS

Improper connector connections and contacts may be the cause
performing the troubleshooting checks. check whether the connectors are properly connected,
pins

and

wires have proper contact. The below table lists the results

necessary.

of

various malfunctions. Consequently, before

of

improper connections. Refer to

* Refer to the block diagrams for connector numbers. (Refer to p. 70.)

and

whether the

it

as

Connector No. Connected portion

Control Circuit board • Speed command from

t

D. D

motor

t

motor

circuit

circuit

Cfl)

lli)(ill)

CID

(P28)

board

Control circuit board

Pulse

board
Control circuit board

t

(P29)

CID

Programming circuit

board

Micro switch

l

Extension circuit board
Power supply

(ill

t

Control circuit board

Extension circuit board External switch signals

@)(P30)

t

Control circuit board
Power supply

ceu~

t

(ill)

Pulse

Pulse

motor

t

motor

circuit board

Main signal

control circuit board

• Synchronization and needle
down position signals from
encoder

• Power supply to machine

motor

circuit board

(+5V;

command operate

display signals. operate

+12V;

motor

Pulse

Key switch signals and

Origin position and overlimit
switch signals

+5V,

+l2V,

For

solenoid drive (+50V)

For

floppy

+120V,

Motor

-5V)

operation

-5V

motor

(+12V)

+7V,

15V

drive current

AC

Improper

operation

Pulse motor does not

• Programmer switch does not

• Faulty programmer display

• Origin position not detected

• Emergency stop illuminates,
cannot

Improper control functions

Refer

• Abnormal operation

• Abnormal sounds from the

pulse

• During programming, one pulse

is

Result of improper connection

D.D

motor

be

cancelled.

to®.@,@,

motor

skipped

by

the feed key.

@

-77-

Connector

(ill)

(ill)

CE0

Clli)(P38)

®l)(P22)

No.

Connected

Power supply

:

D. D morot circuit

board

t

Machine motor
Encoder

1

D.D

motor circit

board

EM

switch assembly • Emergency stop switch

!

EM

harness

Extension circuit board
Foot switch assembly

Foot connector

*

l

portion

Main

signal

+SOY

Machine motor drive

current

+

12V,

encoder signal

signal

• LED signal

Start signal, work
clamp lifter signal

Result

of

improper

Machine motor will not
operate (emergency stop lamp
illuminates).

• Machine runs
momentarily and then stops.

(Emergency stop lamp

illuminates.)

• Synchronization, needle
down, needle up, down
position signals are not output.

• Emergency stop does not
function

• Emergency stop lamp
illuminates, will not cancel

Will not operate even
though work clamp lifter
and start switches are
depressed. (Emergency stop
lamp does not illuminate.)

connection

at

high speed

@j)(P34)

®2)(P20)

®I)(P32)

(P26)

(P25)

Extension circuit board

Air solenoid

+

• Solenoid drive current

• Pressure switch signal

l

Air connections

t

Control circuit board

Control circuit board +12V, +5V, floppy

control signal

I

Floppy drive
Programming circuit board Drive current for display

Display circuit board
Programming circuit

board

Key

!

f

switch circuit board

Key

switch signals

Improper work clamp,
presser foot, movable knife,
thread catcher, bottom
plunger operation

Emergency stop lamp
soon illuminates during
data storage and
read-in on the memory
disc

lmporper programmer display

Programmer key switches

do

not function.

-78-

~

CONTROL

P

ower

supply Breaker SW

CIRCUIT

Ob

t-----,

BLOCK·

DIAGRAM~

Encoder

Machine

Floppy drive

I~

~:--·f

1 4

Readtn~

memory '-1>1-+--l

Wr1t

LEO

memo

~wer

I

Lower

Test

Stepback

I

Read/Wrlle cC:

SW

Bottom

1~ead

spht sw

1

Pauern

SW

motor

I

,,

r-:-

~

1rlQ

~

ry

~

r,

~

thread

wa

rnmg

"Z

SW

SW

.4.._

..c

, ...

'i

..

/ _ f 18

~

~-

--4818

SW

,........-~

catche

r

~o-

~

-

~

o---c_

~

oL-,_

select

~

FI

:~

10

eiO

'"'

.,.

Al

ii---

811

r-":.:'-•...:'..:.";_ _ _,

A

l2

""

,,

..

..

A5

>019

87

>0

AB

A7~

Al l

""

>012

~~-~~~--1

as

r

'9;_

..,

f-0-""-

6

A9 r

":.:'-•=-"::

M

~··~'-•

~".:.'-•

8

17

A

17

~10-3--

OY + 16Y

IL

Exte

nston

@)

""

...

I

16

(

11

3

20

'"

L

f

29

-l~'::":_--;

1

1

-•

.:..

'=-

'

'---

-l

':_--;

.:..

1~22'--~~

.:.1:..2':..._~H

2

1

1

.:.

;:.

--

:H

12

§)

""

)Ot8

-•"-"-'---i

..

,r-

"='- • ='--

>o

='-•=;_

r ' '

:..:'

-•=;_

"''

5

~

)0

-•=

,..

''"..;:._

-iiiF----'

".:.:•

;_·=--_,

'"

~

~

t----

"'"

witch

..

18

1

-

_

_

§)

-_,

_,
_,

_,

_j

L

ower threa

counter

Split

SW

1

----

l

~

....-c

....-c

~

d

[?or!--

O"'"'(~A1

o'C

O"""i

'-

---

ro=='Cf-

nu

mber

O'"""'t!-

o--<f!-

r"">~.,

'-

---

1

eur-"-'

fL.-

•

.,

t!-

·~;r''

rL-

Al•

014~

~

a 'sr"""'

e .,sr-

-i•l•r-

A2

82~

.,~

..,.•___,

83

-t

••

I __ _

Panel s

ov

+80\1

L

0.0 mot

or

cucu

•t

boa

rd

!PC11

1)

ctrcu•l board (PCB4) I

-

---

14

"

13

'

3

I

.

5

6

••

'"

17

10

9

•

II

7

'

•

'

5

3

I

'

3

I

8

B

~

a

·

~

:

~

""

.

.::; X-d,ecto

,

...

""

.,...

~

..

~

c

ow

H0

~

, ..

..

~

~

COM

~

,

...

.o

'*'

, ...

I

-

----,

-~

X-d"ewon

X-darecuon l

9

Y-d.,ectoon

Y-d1r

Y ·d

irection

9

Emer9ency

E

mergen

St

anSW

Wo

rk cla

eci

Power supply

'

on

orogon

SW

roght s•de SW

eft

stde

SW

orogon

SW

100 forward

back

stop

cy

stop la

mp lift

ward

SW

er

SW

mp

SW

SW

equ

ipment

-t5

0Y

UL

OV

+ 12VOY+12V-t5

Control

ClfCUII

board
IPCB21

-·

I

Fu

se

A

V - $V

0V+l20V-t7V

C15V

OY

0~

Pulse

mot

C"CUit

{PCB3i

X·direct ion
p

ulse

mot

or

83

82

3

.,

l PIB

L:J:%VM

~,

~

.--

r"4

..

...

"-'.-

••

.l

--4'

:r

_!--t4:h]

~

••

••

812

Al l
Al2

1-=

:~:

-

----.lj

,.

AB

~

Ill

LY

s

Prog

~

ClfCUil boa rd

Programmin

~~gt~

lPCBSI I

~)@

Ke

CIICUI\

g device

Soleno

.,_J,b:!J:

r I

~

rr

. .

co

..

@!)

=

==~~

PC&el

Ly.sw;;

ch

board

I

,.

or

board

Y -direction

ulse motor

p

1d

valve

Cla

Cla
Presser l

Thread

Bonom
Movab

..J)

: Pressure

~

Auto e,ect

Needle

bar

and Needle cooler

mp

Ill

mp

IAI

le kntfe

SW

descen

oot

catcher

plunger

t Guard

-79-

~TROUBLE

SHOOTING

FLOW

CHART~

[EXPLANATION

I.

d

2.

0

3.

4.

[]

ON

MARKINGS]

means "ma nual operation"

means "switch ope ration

means "dicision"

means "refer to Item Numb er"

..

5.

6.

7.

means "set-up

means "continue to next page"

means "switch-off

of

conditions

of

power supply"

or

situation"

- 80 -

[I] TROUBLESHOOTING FLOW

c

0

.!!l

.c

(.)

-

-~

"'

...

~

~

0

Q..

CHART

YES

FOR

NO

MACHINE

CONTROL

DEVICE

#I

112

:::J

-

c.

c

(.)

"'

~

»

...

0

e

~

~

YES

113

NO

114

YES

115

-81-

;

c..

c

u

-~

-o

>.

....

0

E

0

~

NO

#6

YES

#7

.b

..r::;,

E

0

"'

~

"'

c..

E

~

0

Open the floppy
lid; remove the
floppy disc; close

the lid.

• Can be performed with memory disc still inserted.

YES

#8

NO

#9

NO

YES

-82-

#10

.....

::c

e

~

<tl

"'

0.

e

<tl

0

NO

NO

#II

-83-

c

.!2

·;;;

-

0

0.

...

-

s

"'

Ql)

c

-~

4.1

"'

4.1

-5

£

4.1

>

0

2

YES

NO

NO

YES

Input sewing

data

#12

#13

#14

#IS

NO

NO

#16

#17

-84-

NO

NO

Input sewing data
and move work
clamp to sewing
start position.

#IS

c

0

e

C1J

0.

0

...

"'

~

#19

NO

#20

NO

#21

-85-

c

0

....

e

CJ

0.
0

NO

#22

bO

c

·~

CJ

Cll

YES

NO

NO

NO

Input sewing data

and shift

the work

clamp to the

sewing start

position.

#23

#24

NO

-86-

#25

c.o

c

·~

~

ell

NO

#26

YES

#27

NO

#28

NO

#29

NO

#30

NO

NO

#31

-87-

Input sewing data

with intermediate
split.

YES

YES

NO

NO

Input sewing

data

and

sew.

#32

#33

NO

Input sewing

data

and sew.

-88-

#34

#35

#36

#37

-89-

#38

[I) TROUBLESHOOTING FLOW CHART

NO

FOR

PROGRAMMING

DEVICE

#39

NO

NO

NO

-90-

~

ACTION COUNTERMEASURE »

WARNIN

I. Mak e sure to remo

2.

Switch

3.

When replacing fuse. always make sure to use exactly the sa

4.

0 .....

0 .....

~

BEFORE

GS

WHEN

off

the power supply when taking

Turn

the switch on. and check the voltag

Turn

the switch off.

MAKING

CARRYING

ve

or

replace th e plug after switching off the power supply.

and

check the resistance.

ADJUSTMENTS

CUT

TROUBLESHOOTING:

off

the covers

e.

~

I. Check whether fuse is not blown.

2.

Conf

irm whether a

3.

Find out with now chart under what condit ion it's symptom

No.

#I I. Power

supplied.

II

plugs are properly connected.

Cause

1s

not being 0 Measure the voltage of 3ph power.

Check,

Repair,

or

tables from the machine.

me

quality and capac ity of fuse.

s occurs .

Adjustment

Replacement

parts

Page

-o

-o

c

0

....

E

::>

E

::>

0

c

....

"'

0

0.

E

....

....

;;:

0

0..

2.

Fault on powe

sw

itch cord plug and turn power switch on: using

3.

Blown fuse 0 Remo

4. Fault on

or

cord

A I

1111

1111

8'

5. Defective electrical

equ ipment

----v----v--

0 I Q 2

o• o s o b

o'

?1

~e

()('

r supply 0 Open the rear cover. Disconnect power Power swit

la

mp

(LED)

10

~~1

111

Q.l

ox

09

0 9" Q

SV

12

a tester. check between
elect

ri

cal equipment terminal pane

the power plug.

If continuity exists. th e cord

ve fuse

nuity.

If continuity exists. the fuse

0

Di

sconnect plug

circuit board and measure t

If the

A20

11111

820

magnification range. the lamps
OK.

0 Disconnect plug P7 on the control circu

boa rd. and measure the voltage.

If

Check whether the connect

contacts

ing a faulty connection.

ne

5V DC. equipme

o.

10

or

No. 10 and test for conti- Fuse No.

edle moves

ffi - 'o. II 8

the connect

R.

S.

is

P21

on the intermediate

In

the rmtxrmum

nt

is

OK.

or

or

pins are caus-

T.

E on the Power supp ly cord

l.

and

is

OK.

OK.

Switch panel

he

resistance.

or

cords arc

pin-to-cord Connector pin

assembly (LED)

Power

it

supp
equi pment
(Power supply circu
board)

10

ch

(5/\)

73

79

ly

it

79

-91-

No.

#2

13

c

0

c

....

:I

-

Cause

I. Blown fuse

2.

Fault

on

equipment

DC I

SV

<&

T

power

supply

Check. Repair, Adjustment

0

Remove
continuity.
OK.

fuse No. II

If

0 Test fuse No.

continuity

exists. the fuse

* If a fuse blows.

abnormally

0 Disconnect

board.
matches

No.6

No.2

Check

for

pins

and

fast (4000 ~ 5000 rpm).

plug

and

measure

the

below values.

(l) -

8 -

faulty

cords.

(+

12V).

and

continuity

12(-5V)inthesameway.lf

machine

P7

connection

exists.

is

motor

on

the

the

voltage. If voltage

parts

No.

II

8

No.

II

ffi

between

the

OK.

rpms will be

control

are

DC
DC

connector

test

fuse

circuit

OK.

12V

SV

Replacement parts

for

Fuse

No. II (I A)

is

Fuse

No.

Power
equipment
(Power

board)

Connector

12(1A)

supply

supply

pin

Page

73

circuit

79

..c

..c

f-

#3

-.:;

-

·~

"

.E

..:2

UJ

~

c

u

OS

E

~

u

c

u

"'

0

c

c

o:l

~

"'

:;

c

:I

c.

E

c.

0

"'

;;.,

u

c

~

01)

....

~

E

3.

Fault

on

DD

I.

board
circuit

Fault

stop

switch

circuit

or

control

board

on

emergency

or

cord

5 I

If
motor
5000 rpm). replace

If
(under
board.

0 Disconnect plug P38

:+:

~JI~

'--

~

the

above

runs

the

machine

2000

circuit

~

CD-0
0-0

®e-

checks

at

unusually

the

motor

rpm).

replace the

board.

and

Emergency

switch

If

continuity exists.

OK.
If

continuity

not

exist.

OK.

CDffi

are

OK

and

the

high speeds

DD

motor

circuit

runs

at

an

even speed

control

on

the

intermediate

check

for

continuity.

stop

off

does

Emergency

switch

If

continuitv

not

exist.

If

continuity exists.

OK.

If needle waves m

the

maximum
fication
sistance.

range

OK .

machine

(4000~

board.

circuit

stop

on

does

OK.

magni-

for

re-

DD

circuit

Control

EM assembly

EM harness

assembly

circuit

board

board

75

79

-92-

No.

Cause

Check, Repair, Adjustment

Replacement parts

Page

#3

2.

Fault

on

overlimit

or

circuit switch

3. Fault

4.

on

equipment

Fault on
board circuit

control

cord

power supply

circuit If the above cases are OK. change

0 Disconnect plug P6

board.

and check for continuity.

a.

If continuity exists between 0

<D

and

®.

®and

b. If

continuity

® and

* Confirm

on.

0 If the voltage between the

terminals
5V

DC. OK.

0 Acceptable value for the above voltage

is

+SV.

adjust

power circuit board.

board.

by exists between

®.

® and @. 0 and

that

on

the

±0.25V: if outside this range.

to

+SV with the controls on the

on

the intermediate

@).

®and

@. OK.

<D

@,

the overlimit switch

OV

-

control

circuit board

and

and

OK.

is

+5V

control

CD.
CD.

not

Micro-switch

assembly

Power supply

is

equipment
(Power

board)

Control

79

supply circuit

79

circuit board

75

I.

#4

Fault

switch

AI

lllllllllltllllll]

81

2.

Fault on
lamp

AI A20

111111111!1111111111

81

3.

Fault

board

on

data

or

cord

data

(LED)

or

e

on

control circuit

input

~

input

cord

0 Disconnect plug P6

circuit

board.

and check for continuity.

Al8-

0 Disconnect plug P6 on the intermediate

circuit

820

If

circuit

818

board.

and check for continuity.

89

8 -

B@)

the above cases are

board.

on

the intermediate

When

data

is

off. continuity does not

exist.

data

When
1s

on. continuity should

exist.

If needle waves
maximum magnification
range for resistance.

OK.

change control

input switch

input switch

in

the

OK.

Switch panel assembly

(LED)

Switch panel assembly

(LED)

Control

circuit

board

79

79

75

-93-

No.

Cause

Check, Repair, Adjustment

Replacement parts

Page

#5

0.

E

..!

0.

£

"'

c

c

~

0

E

0

0

.c

-

I.

Forgot to insert
memory disc

2.

Fault on memory disc

3.

Incorrect inserting
memory disc

4. Blown fuse

5.

Fault on power supply 0 Disconnect plug P7 on control circuit Power suppply

equipment board

Insert a memory disc.

If a standard memory disc

data

can be input normally, the first disc

is

defective.

Insert memory disc

0 Disconnect fuse

motor)

and check for continuity.

If continuity exists, OK.

Check for faulty connector pin contact.

No.

and

I

Ef)

on

in

P7

the control circuit board

measure the voltage. equipment

- No. 8 If

is

inserted

correct direction.

(for floppy drive Fuse No. 7 (I

12V

DC, OK.

and

Memory disc

Connector pin

/

I

/

A)

73

79

tll)

c

·;;;

6. Fault on cord

"'

~

0.

u

"0

...

u

.:::

cG

"'

"0

c

0

::l

"'

~

0

>

II>

Vl

7.

8.

DC

12VL...----....1

Fault on floppy drive

Fault

on control circuit

board

0 Disconnect plug

supply) on control circuit board
for continuity.

No. 3

Ef)

-

No.2

Ef)

- No. I 8 in the maximum

Check for defect in flat cable connected
to

plug P32

Change floppy drive.

other

In
board.

cases. fault

P31

(for

floppy power

and

No.4

8

If

needle waves

magnification range
for resistance.

of

the control circuit board.

on

control circuit

check

OK.

Floppy harness B

Floppy harness A

Floppy drive

Control circuit board

79

v

75

-94-

No.

Cause

Check,

Refer to #5-2. -6. -7. -8.

Repair,

Adjustment

Replacement

parts

Page

111

118

c

"'

.

..C-o

~

"'

"'

"'

"'

... ...

"'

"'

"'

0.

c "'

·-

"0

e

"'

:s

·-

=..c

·-

(j

o..:::

e

~

"'

"'

-

...

o,<U

oC:::

u;:.:

>.0.

...

e

c "'

oou

"'-

i;~

e o

"'

~

..C..c

"'

"'

1--

Refer to #5-2. -6. -7. -8.

I.

Short

of

air

pressure

2. F auh

on

pressure switch

or

cord

AI

11111111111~111

81

AI~

81~

air

pressure

If
it

is

OK.

0 With

0 Reset

air

pressure

plug

P34

of

check for continuity.

AI2-

Al3 -812

812 If continuity does not exist.

connector

is

appropriate

at

5 kg/ cm

the control circuit board and

OK.

If continuity exists.

P34.

(5 kg/ cm2),

2

. disconnect

OK.

33

Pressure switch

Parts connected with

solenoid valve

79

I.

Fault

on

lifter switch

work clamp

or

cord

0 Disconnect plug P22

board and check for continuity.

®-CD

0 Reset connector P30

board.

When depressing work clamp
Jifter at
is

OK.

of

JeaSt

on

extension circuit

OQ

USUally

control circuit

IXI{l)

-95-

Foot switch assembly

Foot switch harness

assembly

Foot

connector

79

No.

Cause

Check, Repair, Adjustment

Replacement parts

Page

#9

2.

Fault on working of

air

cylinder

3.

Fault on solenoid valve
or

cord

[I

111111111111

I 815

0..

E

"'

;:;

.><'

4. Blown fuse

...

0

:t

11)

-5

..c:

t>l)

::s

0

5.

-5

c::

11)

;;.

11)

11)

"'

·.:::

0

c::

11)

"'

0

"0

0

.;:

...

11)

"'

"'

~

~

Fault on power supply 0 Disconnect plug P7

equipment board and measure the voltage. equipment

6. Fault on control circuit

board

+ AIS

Adjust so the cylinder shaft moves lightly.

Work clamp lifter

cylinder assembly

0 Disconnect connector P34

of

control circuit

Air solenoid valve.

board and measure resistance.

83-

A3

If

approx 400!1. OK.

0 Reset connector.

0 Disconnect fuse No. 6 and check for Fuse No. 6 (5A)

continuity.

No.7

If continuity exists. OK.

of

E!J-

No.9

8

control circuit Power supply

If approx. 50V DC. OK.

0 Check whether the contact of connector Connector pin

is

bad

or

not.

Control circuit board

In

pin

other

case. change control circuit board.

38

79

73

79

75

#10

.><'

...

0

;!:

11)

-5

..c:

g:>

0

-5

c::

11)"0

> 11)

11)

c::

11) 11)

0.. 0..

0 11)

_"C

0

c::

"'..c:

~

"0

o.."'

E

o:s.:::

u=

.><'0..

....

0

~

I. Fault on working of Adjust so the cylinder shaft moves lightly.

air

cylinder

2.

Fault on solenoid valve 0 Disconnect connector P34

board and measure resistance. solenoid valve

•

~

~

"'

·-

-~

:t

~

E

o:s

..

lr.il

1m

''llrh

''lr11'1'1'1'1'1'1'1'1

ltltLL I I I I I I

~

3.

Fault on control circuit

board.

LL

AI-

81

If

approx 400!1. OK.

A2-

82

Reset connector.

In

other cases. change control circuit board

-96-

Work clamp lifter

cylinder

of

control circuit Parts connected with

Control circuit board

38

79

75

No.

Cause

Check,

Repair,

Adjustment

Replacement

parts

Page

#II

-"'

...

0

3:

0

.c

-

.c

co

:I

0

.c

-

I:

o-o

;> 0

"'

0
0

"'

~

e

-

D.

<.I

0

_-o

0

"'

s:·-

.,.c

0

<.I

.g

-~

c."'

e t

cu.:::

u:.=

-"'D.

....

e

0

"'

~0

I.

2.

Fault on control circuit

board

Refer to #9-1.

Change control circuit board.

Refer to

#8.

Control circuit board

75

I. Fault on start switch

or

cord

(*In this case. presser

foot does not move to
original point.)

I. Fuse failure

0 Disconnect plug P22

board and check for continuity.

Switch OFF....

ON ......

Reset connector P30 connecting extension

circuit board with control circuit board.

0 Remove fuse No. I. No. 9 and No.

check for continuity.

If continuity exists. OK.

If No. I. No. 2 and No. 9 are disconnected.
presser foot does not lift though motor

sounds.

If No.
PMD

13.

is

disconneted. LED lamp on

cercuit board does not illuminate.

of

extension circuit

(D-(D

coQ

(D-(D

0 Q

13.

and

Foot switch assembly
Foot switch harness

assembly

Foot connector

Fuse

No.

I.

No.2

(Slow blow SA)

No.9

(SA)

No. 13(1A)

79

73

-97-