Brother BAS-411, BAS-415 Service Manual

SERVICE

FOR

MANUAL

BAS

-4

11

BAS -415

SINGLE HEAD ELECT RONIC EMBROIDERY MACHINE

I

· ·.~

-

(

PART

NAMES )

CONTENTS

·.

· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1

( MECHANICAL

[I] .upper

00

Lower

00

Thread

[j]

Thread [§] Needle

[§] Picker mechanism • . . . . . . . . . . . . . . . . . . . . . . . . . . . • . • • . . . . . . . • . . . . . . . • . • . . • • . • . . . . . . • . . . . . . 8

[1]

Drive, (X)

[I]

Drive, (Y)

( STANDARD ADJUSTMENT ) · · · · · · · · · · · · · · · · · · · · ·

[I]

Adjusting

~

Adjusting

00

Adjusting

[j]

Adjusting [§]

Adjusting

DESCRIPTIONS ) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 3

shaft

mechanism . . . . . • . . . . . . . . . . . . . . . . . • • . . . . . . . . • . . . . . . . . . . • . . • • . . • . . . . . . . . . . . . 3

shaft

and

rotary trimmer wiper

bar

feed feed

mechanism . • . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . • • • • • • . • 5

mechanism . • . . • . . . . . . . . . . . . . . • . • . . . . . . . . . . . . . . . . . . . • • • • • . • • . • . . . . . . . • . . . 6

flip-up

mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • • • . . . . • . . . • . . . . . . . . . . . . . . . • . 9

mechanism . . . . . . . . . . . . . . . . . . . . • . • . . . . . . . . . . . . . . . . • . • . . • . . . . . . . . . . . . • • . 10

needle timing cloth

presser

knife

and

picker . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . • • • • . . 15

hook

mechanism . . . . . . • • • • • . . . . . . . . . . . . . . . • . . . • • . . • • . . . . . . . • . . . . 4

mechanism . . • • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . • • • . • • . 7

·.

· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·

bar

height

of

needle and

height

fixed

...•..............••......

rotary

hook

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . • . . . . . . . . . . . . . . . . • . 13

knife

. • . . . . . . . . . . . . . • • . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . 14

. . • . . . • • . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . • • • • . • 13

~

. . . . . . . . . • • . . . . . . . . • . . • • • • • • • • •

11

[§]

Adjusting

[1]

Adjusting

00

Adjusting

00

Adjusting

lim

BAS-411·415

In]

Adjusting

1m

Adjusting

lj}

Positioning

IB1

How

1. X-feed

2. Y -feed

the

thread

wire

wire thread bobbin

test

synchronizer . . . . . . . • . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . 23

home

over

to

adjust

thread

wiper

tension

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . • . . . . . . • . . . . . . . . . . . . . • . • • • • • . 17

. . . . . . . . . . . . . . • . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . • . . . . 18

breakage

winder

mode

position

limit

sensor

sensor (thread breakage detector) . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . 35

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . • . . . . . . . . . • . . . . . . . • • 16

.....•.................•........................••...•.•...••••

detect

...................•.........................................

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • • • • • • . . . . • . . . . . . . . .

using

stud

..........................•.•.....•.•............

home

position

...................................•..••..•...............

plate

. . . . . . . . . . . . . . . . • . . . • . . . . . . . . . • . . . . . . 26

17

19 20 21

28

( LUBRICATION ) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 36

[I]

~

Machine Feed

head . . . . . . . . . . . . . . . . . . . . . . . . • . . . • . . . . . . . . . . . . . . . . . . . . . . • • • • • . . • . . . . . . . . . . . . 36

guide

mechanism

.......................................•........•..............

38

(

REPLACINGANDADJUSTINGPARTS)

[I]

Removing and

~

Removing and

lm

Removing needle

1!1

Replacing

~

Replacing

[§]

Attaching X wire

[1]

Attaching Y wire

(

ELECTRIC

[!)

Circuit

~

Replacing

00

Fuses

(!]

P-ROMS

~

DIP switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

[§]

Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

board

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

up

and

jump

adjusting adjusting

bar

down

solenoid

machine head (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

machine head (2) .

case

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

motion

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

parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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

COMPONENTS ) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 46

locations

circuit

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

board

...•............................................................

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

· · · ·

..

··

. . . . .

· · · · · · · · · · · · ·

.. . ..

..

. . . . . . .

··

· · · ·

..

··

· · · · · · · ·

. . . . .

.. ..

··

..

.. .. ..

· · · · · · ·

. . . . 40

··

39

41

43 44 45

46 47 58

[1]

troubleshooting

BAS-411 BAS-415

00

Harness connections and connectors

(

EXPLANATIONOFOPTIONALPARTSINSTALLATION)

[]]

ML

6511amp set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

~

Light

marker

00

Connecting

1!1

Bobbin

(

TROUBLESHOOTING)·····························································

winder

[!) Mechanical

~ Electrical

00

List

BAS-411 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

of

problem

error

flowchart

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

optional

problem

messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

parts

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

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

number

with

machine . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

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

..

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

70 70 81 92

· · · · · · · · · · · · · · · · · · · · · · · · · · · 106

.. ..

. . . .

..

. .

..

. . . . .

..

. 112

118

BAS-415 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

BAS-411 KEYBOARD BAS-415 KEYBOARD UNIT CONTROL BAS-411 CONTROL BAS-41

5 CONTROL

UN

IT CONTROL

BLOCK BLOCK

DIAGRAM DIAGRAM

BLOCK BLOCK

DIAGRAM DIAGRAM

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

(

Part

(

BAS-411

names

)

0 Thread 0 Embroidery

@)Spool

@ Speed dial

guide

shaft

bar

hoop

(B)

@ Thread tension dial

<9

Table plate 6 Operation panel

(!) Keyboard assembly

4D

Disk drive

@)

Thread take-up

CD

Guard bar

-1-

0 Thread take-up cover

@)

48

Power switch Contrast dial

of

liquid

crystal display

( ·

BAS-415

)

0 Thread

@ Embroidery

@)

Spool

Q) Speed dial

guide

shaft

bar 8 Thread tension dial

hoop

(B)

(!) Table

tD)

4D

plate Keyboard assembly Disk drive

@)

Thread take-up

8 Operation panel

4D

Guard bar

8 Thread take-up cover

~

C8

-2-

Power switch Contrast dial

of

liquid

crystal display

(MECHANICAL

DESCRIPTIONS )

lii Upper shaft

mechanism

1)

When

the

pulley 0 rotates

The upper.shaft 8 then rotates

2)

The thread take-up driving

3)

The

up

and

down

motion

down.

4)

The needle bar 8

is

guided by

in

cam@)

parts

the

direction

the

thread take-up driving

transmits

<9,

attached

the

needle bar

of

the

to

case

the

arrow,

motion

the

@).

it

cam

to

the

main needle bar

transmits

@). connecting rod

the

0,

rotation

9.

move

the

to

the

upper shaft

needle bar 8 up and

8.

-3-

~

Lower shaft and rotary hook mechanism

1)

When

the

The upper

2)

Upper shaft gear

3)

The

lower

attached

NOTE:

In BAS-

pulley 0 rotates shaft@

shaft gear 0 transmits

to

the 411

then rotates upper shaft gear (A)@).

(A)@)

lower

and 415,

in

transmits

shaft@), rotates in

the

rotary hook makes

the

direction

the

of

the

movement

rotation

the

direction

to

the

two

arrow,

the

it

transmits

lower

shaft gear 0 via the vertical shaft

attached lower shaft

of

the arrow.

revolutions

the

rotation

@).

for

each revolution made by

to

Then

the

upper shaft @.

the

rotary hook

the

e.

6,

pulley.

-4-

~

Thread trimmer

mechanism

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

~

After moves.

the

final stitch, roller shaft (A) 0

Then the knife 0 engages

moves

with

the fixed knife

into

the

groove

0,

of

trimming the thread.

the

cam

@,and connecting plate

(B)

@)

-5-

II]

Thread

wiper

mechanism

~--------

After

sewing

and

the

presser.

is

completed, upper thread guide hook The thread presser

the

thread guide solenoid 0

secures

@)

attached

the trimmed thread.

to

the plate @ brings the trimmed thread

moves

the

plate

@in

the direction

of

to

the

arrow, thread

-6-

[§]

Needle

bar

flip-up

mechanism

~~------

After are

activated.

receiving

the

set needle bar

The needle bar

flip-up

signal,

is

performed

cam

gears (A) 8 and

by

the

change cam

(B)

9.

@)

attached

to

the

pulse

motor

0

-7-

[§]

Picker

mechanism

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

The

picker solenoid 0 functions

attached under

During thread trimming,

to

connecting plate

the

material.

at

the

(A)@

the

picker@) operates

moves in the direction

beginning

to

keep the needle thread length constant.

of

sewing and after thread trimming.

of

the bobbin

case

e, then pulls the upper thread

The

picker

@)

-8-

[1]

Drive, (X) feed mechanism

1)

Pinion gear @).

2)

When idle gear (A)@) rotates, the (X) wire direction

of

(B)

@ attached

the

X-axis

(left

e right) via

to

the X-pulse motor 0 rotates, then transmits the rotation

the

CD

reeled in the wire drum

pulley

<9.

(X)

e moves

to

the

carriage & in

idle gear (A)

the

-9-

[II.

Drive, (Y) feed

mechanism

1)

Pinion gear (B)@

2) When idle gear (A) @)rotates, the

right

and the

pulley8.

of

theY-pulse motor 0 rotates, then transmits the rotation

left

move the carriage

(Y)

wires @)(left) and (right) reeled in

fi

in the direction

of

theY-axis (backwards e forwards) via the

to

idle gear

the

wire drums

(A)@).

(Y)

8 on

the

-10-

c

STANDARD

lii

Adjusting

ADJUSTMENT

needle

bar

height

)

Tighten the screw

0so

that

the

is

kept equal.

gap

~

1)

Lower rotary hook shaft,

the

-30°.

2)

Raise

the

Then

tighten

NOTE:

Make sure

needle bar

tighten

needle bar

the

screw 0

that

the

to

its lowest position. When

the

screw

of

the

needle bar clamp @

to

its highest position. Lightly

so

that

it

is

positioned in

stopper does

not

strike

the

needle

press

the

stopper

the

front.

the

needle bar guide rail.

tip

is

raised 9 mm above

so

that

the

screw 0 leans

@)

to

the

center

to

the

cushion rubber 9 side.

of

right

the

25°

-11-

When using

the

gauge (optional)

Gauge

1)

Loosen

2)

Insert the gauge (option)

3)

Loosen

gauge NOTE:

4)

Tighten

the screw 0 and remove the

screw e

at

its lowest position.

Do

not

use

the

screw 9

of

the

of

the

into

the lower shaft.

the

needle bar clamp

flat

part

of

the

needle bar

rotary

gauge

clamp@)

hook@

@).

Turn

at

this time.

firmly.

from the lower shaft.

the

pulley until the needle

tip

lightly contacts

the

-12-

~ Adjusting timing

of

needle and rotary hook

I I

1/

I

I I

: I

1)

Selectthefirstneedlebar

2)

Remove

3)

When rotary hook the At

4)

As the

the

two

the

needle bar

@),

two

stop screws.

this time,

for

3 screws

the

other needle bars,

of

the

I

\

I I

Aprrox.1 mm

2.5mm

0.

screws and

and adjust

needle bar height should be about 1 mm. {Figure A) .

rotary hook.

is

raised

the

needle plate@.

2.5

mm

so

that

if

the

gap between

(201°)

the

needle meets

above its lowest position (180°), loosen

the

rotary hook point. Then, temporarily

the

needle and rotary hook

point

is

0.01 -0.2

the

screw 0

mm,

of

tighten

the

~

Adjusting cloth presser height

Adjust

mmthick.)

1.5

the

cloth presser 0

mm

from

the

needle plate @

height

with

at

the

Cut and insert.

the

cushion rubber

cloth presser's lowest position. {A sheet

@).

The cloth presser 0 height should be raised 1

of

the

cushion rubber

is

0.5

~13-

(j] Adjusting knife

1.

Attaching fixed knife

1)

Attach broadens

the

fixed knife

at

part®.

Make sure

and

fixed knife

so

that

the

attached part parallels

fixed knife doesn't contact

the

rotary hook

it

at

this part.

base.

~-

The movable knife

2.

Knife timing

1)

While pushing When

the

of

the

24 J gear e I

blade should be in

2)

Tighten shaft. While pushing

begins

3.

Knife position

Loosen

knife's tip.

If

the

revolution. In

4.

Knife and fixed knife

1)

With the

2)

If

the

lower

NOTE: NOTE:

the

to

the

knife does

a marker, color

colored portion

engagement

set screw

The inclination

bottom set screw

This

the

knife

@)

screw

move,

screw & and adjust

After

that

CD).

is

fine adjustment. Adjust carefully.

cam

lever 0 up

begins

the

of

the

thread trimming, not

case,

is

to

move,

fix

the

cam

center

the

blade in

stop

the

is

shaved equally.

wrong, loosen

of

24 J gear e

cam

lever 0 up

the

at

the

move

the

back

of

the

fixed knife @)should

CD).

with

a finger, rotate

the

pulley

CD

by hand

the rotary hook supporter@).

rotary hook should be in

the

knife

the

knife should be in this position.

stop position,

knife

the

knife

This

the

will

become harder

so

it

does

so

there

is

no backlash

with

a finger, rotate

@)

position

the

upper shaft

to

the

stop position by hand.

@)

and engage

shows proper knife engagement.

screw

@)

of

the

not

rotate, and

the

so

that

it

fixed knife

be

adjusted

pulley @ in

to

turn.

of

the

cam

the

pulley @again. When

center

with

of

the

its end projects 1 mm beyond

will

be locked and

the fixed knife

@)

and adjust

with

the

direction

At

this time, tighten

turn

the

pulley.

in

the

direction

rotary hook supporter

it

cannot make one

@)

manually.

the

two

top

of

the

The

rotary hook

of the

Check

inclination

screws

@)

the

knife

@).

the

with

and

arrow.

screw

lower

@)

fixed

full

that

the the

-14-

1§1

Adjusting

picker

1)

Insert

2)

Leave screw0.

3)

Adjust bracket(!)

4)

Adjust pushed

5)

Adjust

the

bobbin

the

solenoid arm

the

picker @

with

the

gap between

to

the

pulley side (the solenoid operation position), then tighten

the

picker position

case

the

so

screw

0 containing

@)

pushed

that

there

is

8.

the

point

of

so

that

it

the

bobbin

to

the

needle bar side, then

no

looseness and

the

picker and

is

bisected by

into

the

rotary hook and set

tighten

so

that

it

functions lightly. Then

the

bobbin

to 1 -1.5

case

spring

Figure A

the

picker@ position.

connecting plate (A) e

tighten

mm.

Leave

the

solenoid arm

the

screw@).

(see

figure A).

with

the

picker

@)

-15-

[§]

Adjusting

the

thread wiper

1)

2)

With

a finger, move

adjust

the

Adjust

the

solenoid arm 0 in

upper thread guide

upper thread guide hook @

hook@

so

the

that

direction

it

moves slightly.

its cut part

of

the

is

located

arrow.

at

the

Loosen

center

the

of

two

screws @ then

the

needle hole.

-16-

111

Adjusting

1.

X-feed wire

wire

tension

Using a 1.5 kg

is

a deflection

torque of

wrench

approximately

or

a similar

14

mm.

tool,

0

push

at

1.5 kg

the

location marked by

the

arrow

and adjust

so

there

How

to

adjust

1)

Remove

2)

Loosen

3)

There are tension and

4) When

5)

After

the

seven screws 0 and

the

two

stoppers (U)

turning

the

tension

tightening

the

screws 0

is

screw

of

both

(S)

on them counterclockwise proper,

0,

tighten

firmly

two

covers

hook

(LX)

the

right

screw

retighten stoppers

@)

and hook

and

will

0.

(LR,

the

decrease

-17-

LL)@.

(RX)

left

(U)

(S)

0.

sides.

the

so

Turning them clockwise

tension.

there

is

no

looseness.

will

increase

the

2.

Y-feed wire

At

points marked points similar

on

tool.

the

right

and

in

diagram), adjust

left

wires where a line extended from

the

deflection

to

approximately 8

the

carriage intersects

mm,

using a 1.5 kg torque wrench

(see

the

arrow-

or

a

How

to

adjust

1)

Remove

2)

Loosen

3)

There are tension and

4)

When

5)

After

the

seven

the

two

stoppers

turning

the

tension

tightening

screws 0 and

screws

CD

of

(U)

them counterclockwise

is

proper,

screw@,

the

both hook

(S)

on

tighten

firmly

retighten stopper

two

covers

(L

Y)

the

right

screw@.

(LR,

@)

and hook

and

the

will

decrease

-18-

LL)

left

(U)

@.

(RY)

(S)

8.

sides.

the

tension.

so

there

Turning them clockwise

is

no

looseness.

will

increase

the

[!] Adjusting thread breakage detect

stud

3/4

When stud the {Adjust

the

needle thread

Ois

slowly returned,

tension by moving shaft no.1@

so

that

the

spring moves

NOTE:

When #120 thread

is

the

pulled near

thread breakage detect stud 0 should return

within

is

used,

the

needle and

right

or

left. _

3/4

of

the

needle thread tension should be from

hole@)

the

thread which moves

of

the

2-stage thread guide)

the

thread breakage detect

to

its position smoothly. Adjust

60-

120 g ..

-19-

[j] Adjusting bobbin winder

1.

Positioning bobbin

winder

claw stud screw

1)

Remove Remove

2)

Move position where thread-winding ends.

3)

Tighten

the

three screws 0 and

the

two

screws 8 and

the

bobbin presser @)toward

the

two

screws

@)

so

@).

2.

Positioning

button

presser

the

that

bobbin

the

bobbin

the

plate spring

winder

cover@.

equipment assembly

winder

fi

shaft

<9.

is

at

the stepped section

9.

Stop moving just before

of

the

bobbin

it

reaches

winder

the

claw

Loosen

the

bobbin.

screw

41!)

and adjust

the

bobbin presser

tD

-20-

so

that

the

proper

amount

of

thread

can

be

wound

on

rml

BAS-411·415 test mode

The

BAS-411 displayed, pressing test mode operation.

1.

Explanation

(

BAS-411

/

(i)SYNCH P.ROM

P.ROM

and 415 main menu contain test mode functions. Although

the

number

of

test mode display

)

®Ov-

J Ver. M

K Ver. *

TRVL

*•

S *

( BAS-415 )

<0>

key

(BAS-411)

l--------J~~oo-

1------~_..~

1--------J~~oo-

or

the<*>

test options

P-ROM P-ROM

the

test

options

key on

version on version on the keyboard circuit board

the

keyboard

the

main circuit board

(BAS-415)

will

not

will

be

start

~

[SYNC]

J Ver

*,

'------------------J~~oo-

2.

Explanation

CD

P-ROM[]J]-Ver.

®

P-ROM

[TRVEL]~

* K Ver *

I

IL...------------J~~oo-

of

P-ROM

version

M[*r.j_S~.....__r]

- - •: version No.(1-Z)

[K[}Ver.[r.__]

_______

- : version

\--------"'JIIoo-

___

test options

P-ROM P-ROM

....,.

- J stands

E stands

_....,..

version on version on

for

P-ROM

for

P-ROM

No.(1-Z)

the

main circuit board

the

keyboard circuit board

for

domestic

for

overseas (English)

use

(Japanese)

'---------------~-

*

Howtostartthetestmode

BAS-411

BAS-41

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

5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Select

K stands

(common

Selectthe<O>keyinthemainmenu.

-21-

for

the

< * > key in

P-ROM

on the keyboard

both domestic and

the

main menu.

ov~rseas)

3.

Explanation

1)

of

test menu

( ____

The

2)

(

____ ® ___

The

Pressing

After

adjustment,

~

___ s __ v __ N

menu

for

adjusting

r

___

r

menu

for

adjusting

alphanumeric

press

__

c ___ H

the

needle

__ a __ v ___ e __

the

position

keys < 1 >

the

<END>

_____

position

l

____

_,)

of

or

< 2 > will set

key

)

detecting

the

overtravel sensor.

the

to

return

to

synchronizer

machine

the

main

on

the

machine

into

one

of

the

test

modes.

menu. (BAS-411·415)

upper

shaft.

-22-

IDJ

Adjusting synchronizer

The

synchronizer detects

base. When thread trimming, the

1.

the

emergency stop operates

the

same position

as

Adjusting machine stop position (stop signal)

the

needle bar

the

other

needle position and synchronizes

after

the

power switch

will

be released in

8 needle bars.

the

is

turned on,

jump

condition, and

the

motion

or

of

the

needle and

when

the

thread take-up

the

machine stops

will

stop

holder

after

at

(

BAS-411

<DSYNCH

ROM ROM

(

BAS-415

+-

[SYNC]

J-Ver * K-Ver *

(

BAS-411

(

®Ov-

J-Ver.

M*,

K-Ver. *

SYNCH

S*

[TRVEL]-+

check

)

TRVL

)

TDU

)

1) Turn on

2)

(BAS-411)

Press

the

menu.

(BAS-415)

Press

the<*>

3)

(BAS-411)

Press

the

4)

The

green panel shown in

the

machine power.

alphanumeric key

key

in

< 1 > key

LED

will

display

the

to

located on

the

figure on

<0>

key

the main menu.

select

<DSYNCH.

the

upper

numbers from

the

left.

in

the

right

<D

to ® as

main

of

the

(

BAS-415

(_SY_N_C_H·

__

)

T_=_·_D_=_•_U_=_O

__

(BAS-415)

By

pressing

The

]

-23-

circles next

black.

the < <l>

to

"T"

key, select

and

"D"

[SYNC].

in

the

display are

Timing pulse ® Needle do

Curved mark

si

gnal@

wn Nee

si

gnal @

dl e up

Stop

mar

The

synchronizer will

display

the

signals

as

follows:

bl

in

<D

timing ® needle @needle

pulse

CD .........

down

signal ©

up

signal @

..

.

goes

.

goes between

ks every 7.5°

off

at -21

off

when

-92.5

oo

°

and 112.5°

92

.5° . . . . . . When t he needle bar

mm

112S

210

° . . . . . . .

below

When the

mm b

When

its highest position.

needle bar is lowered

elow

its highest

the needle bar

is

lowered 20

positio

is

n.

raised

29

20

mm above its lowest position.

k

5)

Turn

the

machine pulley in i

To adjust

sc

rew 0 so that

when

pos NOTE:

the ne ed

ition

At

the

.

this time, the curved mark on

should

synchronizer

the

needle s

le

is

20 mm bel

be aligned wi

ts

normal direct

assembly@

top signal goes

ow its

th th

e st

op

ion

, loosen the

off

highe

st

the

pulley

mark.

.

-24

-

2.

Adjusting needle down signal

When position,

NOTE

the

1:

2: How

machine pulley 0

the

lit

needle

When procedure 1 "Adjusting machine stop position" the

same adjusted. When only to

be adjusted.

to Rotate stop

the

of

down

angle.

attach

the

the sewing machine upper shaft and attach

is

turned

signal should

Be

sure

to

the

needle

sewing machine pulley

adjust

in

the

in

its normal direction and

go

off.

the

down

normal rotation direction. Align

the

pulley. Then,

Loosen

needle down signal when machine stop position

signal

the

two

is

adjusted,

tighten

screws@

is

done,

the

needle

to

the

needle

machine stop position does

the

screw.

is

adjust.

down

the

first screw

5 mm above its lowest

signal

with

will

move has not

the

to been need

screw

-25-

Ill

Adjusting

home

position using home position plate

NOTE1: NOTE2:

Use

the

Before making this adjustment,

< X-direction >

XY-~xis

home position plate assembly

turn

the power switch

(521078-001

1)

Remove

0,

plate

2)

Remove

3)

Loosen

drum X

4)

Temporarily tighten the screw limit

5)

Attach

(180 degrees) from home position

6)

While holding down the the power.

optional).

off.

the holder

and then attach the

assembly@).

the

seven

set screw &

<9

can

dog~

is

the

X-limit dog

base

screws

of

turn

idly.

centered in its hole.

the

dog([!) interrupts

8 from

XY

-axis home position

0 and table R

wire drum X

@)

~

so

that

sensor

CD

sensor

EMERGENCY

the

<9

so

it

when

key,

X-carriage

0.

that

wire

that

the

is

opposite

the

X-axis

4D

light.

turn

X-

on

7)

The

machine detects

XY-axis home position plate@)

8)

Turn XY-home manually and adjust that

it

is

in

the home position plate firmly

so

that

there

the

position

center

is

X-home position and

stops.

plate

the

needle

of

the

@).

Then, tighten screw &

no end play

assembly

tip

cross

of

position

of

the

XV

shaft.

the

@)

so

-axis

-26-

< Y·diredion >

[ENTER] [START(sewing)]

[EDIT]

[COMMUNICATE]

Remove

(

1)

screw 0 and cover LV@ on the left.

BAS-411

Turn on the power. Press

the

<0>

)

key in the main menu.

<DSYNCH ROM

J-Ver.

ROM

K-Ver. *

<D+X

File

No.

01

*

~

[SYNC]

J-Ver 1 I 1

®Ov-

M*,

®-X

[TRVEL]-+

S*

1

TRVL

®+Y

K-Ver 1

@-Y

2)

Press

the

< 2 > key

3)

Loosen and bracket (forward and backward).

(

BAS-415

1)

Turn on

Press

2)

Press

the

bolt

<END>

e by moving

the

power.

the<*> the<-+>

key alternately, adjust

)

to

select

@).

While pressing

key

in

the main menu.

key

to

select

Ov-

TRVL.

the

it

in

the y direction

..

TRVEL.

..

<2>

the

key

sensor

3)

+

-X=

0,

- Y =

0,

+ Y = 0

Loosen and bracket (forward and backward).

NOTE:

-27-

the bolt@). While pressing

<END>

e by moving

Move the sensor bracket toward the

needle

the<-+>

key alternatly, adjust

it

j n

the y direction

is

not

in

the center

of

the

sensor

center

cross.

key

if

!nl

Positioning over

limit

sensor

<Over

(

<X-direction

limit

BAS-411

[ENTER] [ST

sensor

location>

)

>

[EDIT] [COMMUNICATE]

ART(sewi ng)]

1)

Press

the

numeric key

<0>

in

the

main menu.

CD

SYNCH ®Ov-

P-

ROM

J-Ver.

P-ROM

1---C_OD_E

CD

+X

CD

+X

SPEED

K-Ver. *

®

N_o

TRV

M*,

S*

-X

@

-X

@

.

~'21

'21

l!;_][g

L

+Y

ffilljl

L!JQJ

@

-Y

rpm.

2)

Press

the

3)

Press

the move 227 displayed on under

4) Loosen so

that figure 227 .5 pressed.

<2

> key to select ® Ov -

< 1 > key. The

.3

mm

to

the

panel and

the

number CD.

two

screws

the

thread sensor

on

the

display

mm

when

left

of

the

between

<E-->

hoop

and

. The

the

X-limit

indicator

and

TRVL.

the

holder

figure

cursor appears

dog

lights

227.0

<~>

base

"227

.3"

and adjust

with

mm and

keys

is

the

are

5)

Pressthe <END

-

28-

> key.

I

<D+X

(j)

+X

®-X

¢

®-X

$$

®+Y

@-Y

~

6)

Press

the

move 227.3

displayed on

under the number

·

7)

Loosen

so

that

the

on

when

<2>

key.

The

mm

the

to

the

right.

panel and

hoop and

the

The

figure 11227.3

the

cursor appears

holder

0.

two

screws

the

centering indicator lights

display between 227.0 mm - 227.5 mm

jog

keys<~>

of

the

and

X-limit

<~>are

dog and adjust

pressed.

with

figure

base

..

is

CODE

SPEED

(j)

+X

'

<.DSYNCH P-ROM P-ROM

[ENTER] [ST

J-Ver. MO, K-Ver. 4

ART(sewi

No.

I

®-X

I

®Ov-TRVL

I

[EDIT]

ng)]

[2][2]~[31~

rpm.~

8)

Press

END

I

®+Y

END

SO

END

[COMMUNICATE]

®-Y

I

~

9)

the

11

CAUTION

and the holder

Press

the

menu.

<END>

MOVING!

base

<END>

Screws

key

twice.

II

is

displayed and

move

to

key again

the

to

The message

the

center.

return

to

the

hoop

main

-29-

<Y·diredion>

[ENTER] [START(sewi

<DSYNCH

ROM ROM

t--~-~ED_E~_No_.

J-Ver. MO, K-Ver.4

<D+X

[EDIT]

(COMMUNICATE]

ng)]

®Ov-

®-X

TRVL

SO

®+Y

~+Y

----~[]~

@-Y

8][5]

rpm.

1)

Press

the

numeric key

2)

Press

the < 2 > key

3)

Press

the

<3>

move 143.5 mm toward

"143.5"

appears under

4)

Loosen position

with

-

144.0 mm when < f >

(143.5

is

displayed on

two

so

that

the

figure on the display between 143.0 mm

mm

desireble)

<0>

in

the

main menu.

to

select

®Ov-

key.

The

hoop and the

the

number®.

bolts.

Adjust

the thread sensor indicator lights

TRVL.

the

holder

operator. The figure

panel and

sensor

or

<

J,

>

the

cursor

bracket

is

pressed.

base

A

<D+X

®-X

®+Y

@-Y

5)

Press

the

<END>

key.

-30-

<D+X

®-X

I

®+Y

®-Y

6)

Press

the

<4>

key.

The

hoop and move figure cursor appears under the number@.

143.5

11

143.5"

mm

away

from

is

displayed on the panel and

the

holder

the

operator. The

base

the

r

t--c_oo_E

SPEED

N_o.

<D+X

--~OJ~

I

END

®-X

I

END

8][5]

I

®+Y

I

_

rpm.~

®-Y

""'

7)

Adjust sensor centering indicator lights display between 143.0 mm • 144.0 mm

< f >

desireble)

8)

Press main menu.

or

the

bracket B position

<

.L

>

is

pressed. (143.5 mm

<END>

key three times

with

the

so

that

figure on

to

return

the

when

most

to

the

(j)SYNCH P-ROM

ROM

[ENTER] [START(sewi

\..

J-Ver * MO,

K-Ver. *

[EDIT]

®Ov • TRVL

SO

*

I

END

I

[COMMUNICATE]

ng)]

-31-

( BAS-415 )

<Y-diredion>

File No.

01

*

+--

[SYNC]

J-Ver

+

-X=O, -Y=O,

+

-X=O,

length

+

-X=O,

length

[TRVEL]-+

1, 1,

-Y=O,

K-Ver 1

+Y=O

= 143.5 mm

+Y=•

= 143.5 mm

1)

Press

the

< * > key in

2)

Press

the<

I>> keytoselectTRAVEL.

3)

Press

the

<V

> key. The hoop and

base

move 143.5 mm

figure 11143.5

4)

Press

the adjust circle

of

between 143.0 mm and 143.7 mm.

11

is

<V

> key again. Loosen

the

sensor bracket A position

the

..

+ Y

the

toward

displayed on

=0"

turns black

main menu.

the

operator and

the

display.

two

when

the

holder

bolts and

so

that length is

the

5)

After

adjustment,

+

-X=O,

+

-X=O, -Y=O,

length

-Y=O,

= 143.5 mm

+Y=•

+Y=O

-32-

6)

Press

the

<6

base

move 143.5 mm away

the

figure 11143.5"

7)

Press

the

<6 adjust circle between 143.3 mm and 143.7 mm.

the

sensor bracket B position

of

the

press

the<

END> key.

> key.

The

from

is

displayed on

hoop and

> key again. Loosen

11

-Y=O

..

turns black

the

operator and

the

display.

two

bolts and

so

when

holder

that

the

length

is

+

-X=O,

+

-X=O,

length

-Y=e,

= 143.9mm

I

END

I

-Y=e,

I

+Y=O

8)

After

returns pressing main menu.

adjustment, pressing the

the

machine

it

three times returns

to

its home position and

<END>

the

machine

key twice

to

the

"

CAUTION

"

+-

[SYNC]

J-Ver

r

File

No.

*

"

<X-diredion

MOVING

1,

01

>

I

END

I

[TRVEL]-+

1,

K-Ver 1

I

END

I

""'I

.I

File

No.

01

*

+-

[SYNC]

J-Ver

-X=O,

+

-X=O, length =227.3mm

1,

[TRVEL]-+

1,

-Y=O,

K-Ver 1

+Y=O

1)

2)

3)

Press

the

< * > key in the main menu.

Press

the<

Press

the < <l > key.

base

move

11

227.3

11

is

Screws

I>> keytoselectTRAVEL.

The

hoop and

227.3

mm

to

the

left

displayed on the display.

and

the the

holder figure

-33-

+

-x=e,

length =227.3mm

+

-x=e,

+

-X=O, length

+

-X=•, length

-Y=O,

-Y=O, =227.3mm

-Y=O, =227.3

+Y=O

mm

4)

Press

the <

<l

> key again.

the X-limit dog and adjust

II+

-X=

Oil

turns black when length

227.0

mm

and

227.5

5)

After adjustment,

Press

6)

7)

the <

base

move

11

227.3

Press

the<[>> the X-limit dog II+

-X=0

227.0

mm

I>

>

227.3

11

is

displayed on the display.

and

11

turns black when length

and

227.5

mm.

press

the

key.

The

mm

to

the right and the figure

key again.

adjust

mm.

Loosen

so

that

<END>

hoop

Loosen

so

that

two

screws

the circle

is

between

key.

and

the holder

two

screws

the circle

is

between

of

the

~

of

the

+

-X=•,

CAUTION

+-[SYNC]

J-Ver

1,

File

No.

01

*

-Y=O,

MOVING

[TRVEL]-+

1,

I

END

I

+Y=O

K-Ver 1

I

8)

After adjustment, returns the machine pressing main menu.

.)

it

three times returns the machine

pressing

to

the

<END>

its home position and

key twice

to

the

-34-

rHI

How

If

the

thread sensor does

to adjust thread sensor (thread breakage detector)

not

function

:

1)

Make sure on.

2)

Remove that bar position.

the

that

the

adjustment

swit

ch

the

thread sensor

@ indicator lights

base

indicator

~

and make sure

at

each needle

0 is

I

0 X

Stud

0 X

3)

If

the

indicator most needle bar positions, adjust the switch @ position.

4)

If

the

indicator specific detect stud

NOTE

needle bar, adjust its

: Do

of

the

switch @ does

of

the

switch @ does

0

by

gently

not

overbend. The stud 0 may break.

bending it

not

thread

with

not

a plier.

light

at

light

at

a

breakage

-

35-

c

LUBRICATION)

II1

Machine

head

Lubrication Everyday before using

NOTE:

1)

Lubricate these six places:

is

necessary

<DBe

sure

to

use

®Overlubrication may

for

keeping

the

machine, add

Brother-specified sewing machine oil

cause

the

machine in good condition.

1-2

oil

to

drop(s)

drip

on

to

of

oil

the

at

each location in

for

lubrication.

material.

the

figure marked by an arrow.

2)

Add a

drop

of

oil

at

the

reel

of

the

NOTE:

3)

Do

not

lubricate aside from

Lubricate needle bar. (18 places should be lubricated

two

places

on

the

each

rotary hook.

needle

on

in

the

all.)

-36-

4) Move

apply one When

the

needle bar or

the

machine

two

case

drop(s)

is

used

all

the

way

to

the

right

or

the

left

side. From

of

grease

every day, lubricate daily before using. ·

to

the

base

needle bar and

the

base

the

side

of

needle bar felt.

the

machine head,

-37-

~

Feed

guide

mechanism

linear

guide rail: X· axis

Linear guide

rail: Y· axis

NOTE NOTE

1: For

2: 3:

4: Before

lubrication,

Be

sure

After

applying

use

Brother-specified grease

to

lubricate every 6 months.

grease

applying

to

the

grease, remove covers

X·Y

guide

tank

rail, move

to

make

-38-

30.

the

work

X carriage

easier.

right

and

left

2-3 times.

c

REPLACING

lii

Removing

AND

and

adjusting

ADJUSTING

machine

head

PARTS

(1)

)

1)

Remove

2)

Remove

3)

Remove

4) Loosen to

the

X-carriage cover

the

belt & from

the

wires

from

the

four

nuts @)securing

the

machine head, remove

0,

table (R)@,

the

pulley (i).

the

curcuit board,

the

table

the

synchronizer, and

sewing machine

machine head.

(L)@),

-39-

base

and

@.

belt

covers (A) e and (B)@ in

the

With

ground.

the

sewing machine

that

base

@ attached

order.

~

Removing

and

adjusting

machine

head

(2)

1)

2)

3)

Use

the

four

nuts@

Be

sure

to

have

The

distance from table

Use

the

two

rear

After

adjustment, tighten

and@)

an

approximately 2 mm

nuts@)

on the

(C)~

to

adjust.

the

four

base 0 to

space

the

end

of

the

nuts@ and@).

adjust.

between

cyrindrical

nut

9 and

bed®,

nut

0 when adjusting.

and distance® should

be

the

same.

-40-

[II

Removing needle bar

case

Before replacing parts related

1)

2)

3)

Loosen Remove Adjust

the

four

the

four

the

needle bar

screws@

screws e

case

to

the

needle bar mechanism, be sure

of

the

thread presser base

of

the

needle bar

@)so

that

it

moves

case@)

right

0.

and

the

left

to

case.

slightly

remove

when

the

needle bar

attached

with

case.

four

screws.

-41-

[j] Replacing up and

down

motion parts

1)

Loosen

2)

Move or

3)

Loosen Remove

above.

4)

Remove

5)

When assembling, reverse

NOTE1: NOTE2: NOTE3:

the

four

screws@ on

the

thread take-up shaft

2 thread take-up lever(s) 0 and thread take-up stopper(s)

the

screw & on

theE

ring @)attached

the

up

and

down

When attaching which When attaching there

that

wi

II

is a 0.5

Make sure

it

is

in

be

that the

the

right

and

the

@)

and

the

thread take-up supporter shaft 0

the

bottom

motion parts

the

attached

the

mm

space

the

thread take-up stopper

thread take-up support

of

the

right

to

the

main needle bar

([i)

from

above procedure.

main needle

to

the

thread take-up lever(s) 0 and

between

bar@,

main needle bar@).

@)

and

left

sides

side

of

the

connecting rod

secure

tD

or@)

CD

@.

(Fig.A)

of

the

<9.

arm.

@,then

the

and

does

bottom

of

the

thread take-up

30-

pull

out

the

4D.

bearing

the

@.

not

@by

pressing

thread take-up stopper

contact

the

thread take-up lever 0 and

base

40 mm, and remove 1

main needle bar

it

with

theE

<9,

fix

0.

@from

ring

them

@)

so

-42-

[§]

Replacing

jump

solenoid

0.2mm

..

1,

..

I

7.2mm

1)

Loosen

2)

Remove

3) Remove

4) When assembling, reverse

NOTE1:

NOTE2:

the

set screw@

the

two

set screws e from

the

nut~

The end distance between them Adjustment references: When

mm.

When

mm. To base@).

the the

avoid mispositioning

of

the

of

the

solenoid

solenoid rod

front

cover

(L)

0 and move cover

the

solenoid

solenoid @. Then, remove

the

above procedure.

@should

to

approximately 0.2 mm by moving

is

pushed,

is

returned,

of

the

solenoid,

cover@)

not

contact

the

distance between

the

distance between the end

do

the

not

(L) 0 to

and

the

solenoid

the

up and

remove

the

bottom left.

cover.

while

turning

down

nut~.

the

end

the

solenoid bracket

it.

motion parts

of

the

rod and

of

the

rod and

4.0mm

fi.

@)

the

or

Adjust

nut

the

bracket

is is

the

7.2

4.0

-43-

(§]

Attaching X

wire

Carriage

1)

Position the carriage in the back, toward the

2)

Attach the wire end (the end closer

3)

Feed

the wire around pulley from the wind

4)

After Then, put the

Fit the wire completely

5)

Feed

6)

Wind the wire

7)

Wind the wire over pulley (I) from above, then around pulley Attach the wire

NOTE:

left

side,

and

over pulley

it

around pulley@ from the right.

winding the wire around pulley@, feed

ball on the wire into the hole

into

the groove, then wind the wire eight times around the wire drum.

the wire around the back

onto

pulley~

to

hook

(LX) @ with

Be

careful

durability.

not

to

scratch the wire.

to

the ball)

@)

from the

@).

of

pulley

from below, then around pulley

bolt

left

of

the machine, making

to

hook

left

side,

then under pulley

Then,

feed the wire around pulley & from the left, and finally

some

of

wire drum

tiD

I then around pulley m from the left.

4D.

The

wire

(RX) 0 with

slack

into the wire. (X)@).

is

coated

bolt@.

@from

with

resin

sure

0.

Then

the left.

and a

it

does

feed

scratch

not

move.

it

behind pulley @

may

decrease

r-"'

its

-44-

[Z]

Attaching Y wire

Ywire(L)

1)

Push

2)

Use

the

3)

Put

the

Wind

Ywire(R)

1)

Pull

the

2)

Use

the

3)

Put

the

Wind

the

carriage 0

bolt 0 to

wire

onto

the

wire

carriage 0 forward and secure it.

bolt@)

wire

on

the

wire

to

the

back and secure it.

attach

pulleys 0 and(!). Then,

four

to

attach (Y)

to

four

times,

pulley

times,

(Y)

put

4).

put

wire

L@ end (the end furthest from the ball)

it

around

wireR

Then,

it

around pulleys@ and

put

the

wire

pulley~,

ID

end (the end closest

put

the

wire

then attach

ball

into

CD,

ball

the

into

the hole

it

to

stand

to

the

ball)

hole

of

wire

then, attach

to

of

(RL)@)

to

stand

drum (Y)

it

to

hook

wire

drum

with

(RR)

hook

(RY) @ with

(L

Y)@.

the

0.

@.

(Y)

6.

bolt(!).

the

bolt

@.

-45-

c

ELECTRIC

IIJ

Circuit board locations

(

BAS-411

COMPONENTS

)

0 Main circuit board

@ PMD circuit board @

Sew

ing machine

0 Synchronizer circuit board

0 Keyboard circuit board

motor

circuit board

( BAS-415 )

-

46-

~

Replacing

circuit

boards

Main circuit board

Be

sure

to

turn

off

1)

Disconnect

2)

Press Replace

3)

Place

support clamps

4)

Connect Be

sure

15

the

six

circuit board support clamps inward and remove

the

main circuit board.

new

main circuit board on the supports. Secure the circuit board by pushing

the

connectors

not

to

Suppo:---n

the

power

connectors.

until

treat

and open

it

snaps

into

position.

while

supporting

the

circuit board forcefully.

the

cover before replacement.

the

circuit board from

the

main circuit board from

the

back side.

P13

down

the

supports.

near each

of

the

NOTE1: NOTE2: NOTE3: NOTE4:

NOTES: NOTE6:

When replacing connectors,

connectors. Note

that

the

flat

cable

P13 direction. Treat

the

circuit boards carefully.

Also,

do

not

touch

IC

pins.

Do

not

bend circuit boards. The circuit pattern large size Check When while

of

the

that

new

turning

holding

circuit board.

main circuit board

the

power

down

on

the

emergency stop switch. This clears

treat

them

c~refully.

is

directional {refer

for

MOS-IC

has a CPU

the

first

in

time

Do

to

the arrow).

the

circuit boards

or

IC

may

{HD64180) and

after

replacing

not

pull on

be

two

the

-47-

the

wires when detaching

It

can

not

be inserted in

is

easily damaged by static electricity.

broken by external force due

EP-ROMs{27512).

the

main circuit board, be sure

internal memory.

the

opposite

to

the

do

it

PMD

pulse

motor

circuit board

1)

Disconnect the

2)

Push

the inside and remove the pulse Replace the pulse

3)

Place supports. Secure down will

new

near each

snap

four

five circuit board supports towards

motor

pulse

of

into

position, securing the circuit board.

connectors.

motor

circuit board.

motor

the

circuit

supports. The support tips

board

board by pushing

on

the

Machine

motor

circuit board

1) Disconnect

2)

Push

the

four inside and remove board.

Replace

3)

Place supports. Secure down will

the

new machine

near each

snap

into

the

three connectors.

circuit board supports towards

the

machine

position, securing the circuit board.

of

motor motor

the

circuit board.

circuit

supports. The support tips

motor

board on

board by pushing

the

circuit

the

-48-

Synchronizer circuit board

1)

Disconnect

2)

Remove

3)

Remove the

Memory expansion circuit board (option)

the

connector

the

three screws@ and four

screws 0 and the synchronizer circuit board

0.

the

circuit board attachment

base@).

0.

1)

Remove board@.

NOTE:

four

screws 0 and then remove the memory expansion circuit board

When circuit board will

turning

be cleared.

on

@,

power

be

sure

of

BAS-411·415

to

do

it

while

holding down

for

the

first

time

after replacing

the

EMERGENCY

-49-

@from

the

switch. The inside memory

the

main circuit

memory expansion

(

BAS-411

Keyboard circuit board {1)

)

1)

Manually loosen

2)

Loosen

At

3)

Disconnect

this

the

time,

the

two

screws@. Pull

do

not

pull strongly on

the

EMERGENCY

two

screws@

in

the

upper

the

EMERGENCY

switch 0 connector

keyboard cable 0 and remove it. part

of

the

panel 0

stop switch@ cable.

C9

from

-50-

toward

the

keyboard circuit board

yourself and detach

fi.

it.

Keyboard circuit board (2}

Pull

the

hatched part

the

flat

cable shown in

the

lock and pull

4) Disconnect

5)

Disconnect

6)

Loosen the

panel

the

connector 0

the

flat

four

base

~.

cables@)

screws(!) on

from and 0

the

keyboard circuit

from

the

right

and

left

board@.

keyboard circuit board @.

sides

of

the

supporter

-51-

0.

of

the

flat

Remove

the

black connector attached

the

figure on

cable

the

toward

key sheet

the

left.

yourself.

Release

fi

from

to

Keyboard circuit board (3)

the

7) Loosen

8)

Remove

9)

When

screw@

the

four

assembling, reverse

so

screws@ and

that

the

knob 0

the

above procedure. For assembling, note

can

be removed easily. Then, remove

keyboard circuit board

0.

the

followin

knob

0.

g points.

NOTE

1:

NOTE2:

Attach Align

Insert

the

Pull If

and insert

the

hatched

the

flat

cable

flat

contrast

white

point

connectors

part

ofthe

cables 0

is

loose,

into

the

slots correctly.

knob 0 as

of

connector

and@

the

follows:

the

knob 0 with

White

point

the

flat

cab

to

lightly

cables may have been improperl y inserted

~Jjt

SPEED

les

0 and @

lock

to

che

the

position line. Tighten

.

while

it

in pl

ace.

ck

if

they

are locked properly.

ffv

the

screw@.

Position line

the

black connector lock

into

the

slots.

is

released. Insert

Release

the

lock

~

0

__.__..-

~~

~ " -

"

-----v

\ 0

-52

-

Keyboard

unit

When rep I acing

1)

Manually loosen

2)

Remove stand Atthis

3)

When assembling, reverse

LCD

module

the

whole

the

four

screws 0 on

0.

time, be careful

assembmly

keyboard

two

screws@ in

not

to

the

\ _

unit,

follow

the

back side

drop

the

above procedure.

the

board cable 0 and remove it.

of

keyboard unit@).

_.

procedures below.

the

keyboard unit@). Then remove

it

from

the

keyboard

1)

2)

3)

4)

5)

6)

Loosen Remove Remove Remove Remove Remove

two

screws@

two

screws@)

the

flat

four

screws@)

the

LCD

four

screws~

of

and

cables@)

and

module

and

the

keyboard cable 0 and remove

the

411

panel

0.

and

(S)

from

the

keyboard circuit board

the

support@).

assembly«!>

the

connector

LCD

module assembly

4D

-53-

from

«!>.

the

cable from the keyboard unit.

fj.

the

keyboard circuit board

fj.

(

BAS-415

)

Keyboard circuit board (1)

1)

Manually

2) Loosen At

this

3) Disconnect

loosen

the

time,

the

four

screws@). Pull

do

not

the

EMERGENCY

two

pull

screws@

strongly

in

the

upper

on

the

switch@) connector

keyboard cable 0 and remove

part

of

the

EMERGENCY

<9

panel 0

stop switch@) cable.

from

toward

the

keyboard circuit

-54-

it.

yourself and detach

board&.

it.

Keyboard circuit board (2)

Pull

the

hatched part

the

flat

cable shown in

the

lock and pull

4) Disconnect

5)

Disconnect

6)

Lift

the

connector@)

the

flat

cable@)

from

the

keyboard circuit board

the

keyboard circuit board

key sheet support (!) and remove

it

from

the

panel

6.

base

m.

-55-

the

ofthe

black connector attached

the

figure on

flat

cable

toward

the

left.

yourself.

to

Release

Keyboard circuit board (3)

7)

Loosen

8)

Remove

9)

When assembling, reverse

the

screw@

four

screws@)

so

that

the

knob 0 can

and

the

keyboard circuit board

the

above procedure.

be

removed easily. Then, remove

0.

For

assembling, note

the

following

the

knob

points.

0.

NOTE1:

NOTE2:

Attach Align

Insert

of

Pull If

and insert

the

connector

the

flat

cable

the

flat

contrast knob 0

white

point

of

flat

cable 0 connector

to

.lock

cable 0

is

into

lightly

loose,

the

the slots correctly.

as

follows:

the knob 0

it

in place.

to

check

cables may have been improperly inserted

with

while

if

the

position line. Tighten

the

black connector lock

it

is

locked properly.

is

the

screw@.

released. Insert

into

the

slots.

the

hatched

Release

the

part

lock

-56-

Keyboard

unit

When

1)

Manually

2)

Remove stand At

3)

When

LCD

module

1)

Remove

2)

Remove

replacing

the

loosen

the

four

whole

the

0.

this

time,

be careful

assembling, reverse

assembmly

the

connector@

three

screws@) and

keyboard

two

screws@

screws e

not

from

unit,

follow

in

the

on

the

back side

to

drop

the

keyboard unit@).

the

above procedure.

the

keyboard

the

LCD

module

the

procedures below.

board cable 0 and remove

of

the

keyboard

circuit

assembly e.

board

0.

unit

@).

it.

Then remove

it

from

the

keyboard

-57-

~.

Fuses

1.

Position

of

fuses

F6

FS

F2

F1

Bobbin

winder

1)

Remove cover

2)

There holder@.

NOTE:

2.

NOTE: NOTE:

NOTE:

Be

Fuse

No.

F1 F2 F3 F4

F5 F6

Be

While

cool During replacement,

(B)

0.

is

a fuse

sure

to

holder

turn

off

in

the

front

type and capacity

Fuse

type

& capacity

Fuse

15A S02887-000

Slow

blow

FuseB

Slow

blow

Fuse

B 152565-000

G

Fuse

5AFB

sure

to

use

only

fuses

the

circuit protector

for a while

before pushing

tightly

of

the

transformer in

power

fuse S11705-000

before replacement.

of

authorized types and capacities.

is

activated,

it

back. Otherwise,

attach each fuse

the

power supply unit.

Part code

152565-000

S08030-000

thread

into

winding

it

may

its socket.

trip

motor

again.

Six

fuses are fixed

Reference

for

Pulse

for

Regulator

for

Bobbin

for

Sewing machine

will

not

rotate. Let

motor

Solenoid

winder

Lamp

in

motor

the

fuse

protector

-58-

3.

Replacing fuse

The

following

When

replacing fuse, be sure

Fuse

problems occur

No.

if

the

to

use a new

fuse

is

blown.

one having

the

same

Problem

quality

and capacity

as

the

old

one.

F1

F2 F3 F4

FS

F6

Before replacing fuse 6, check

X and Y carriages

Home position detection Operation panel display Thread Bobbin

Light Sewing machine

Overload

trimmer winder

marker

the

TR

do

not

move

at

all.

error

occurs.

is

blank

and

does

not

function.

motor

does

alley assembly referring

not

motor

does

light.

does

not

operate.

not

run

Using a tester, measure

If

the

If

the alley assembly and replacing fuse

the

sewing machine does

at

all.

to

below.

resistance

6.

is

not

is

either

the

not

operate.

the

resistance between + and

600,

it

is

defective.

00

or

oon,

replace

motor

circuit board instead

the

TR

of

Power

source

-59-

[11

P-ROMs

( BAS-411 )

,~~,

Main

~

circuit board

0

D

oru

ID ID ID

0

oe

-

~6}

==:;;;;Ill§][]

Sewing machine (common

, e

._

__

,..._..J

c::::J

OCJ

Keyboard circuit board

OE::::3

0

E=:J

for

all models)

[

r::::~Q

~0

0

motor

circuit board

( BAS-415 )

0

0~§

o®

0 °

DO

®

I I

0~~~

Main

EJ

00

DO

circuit board

0

D

oru

ID

0~

.

~

ID

([J

m

~

0

c::::3

~o

Keyboard circuit board

0

D

-60-

Be

sure

NOTES:

1.

Use

2.

Do

3.

Confirm

4.

Use be used, be sides.

to

turn

off

the

power

care when handling

not

apply excessive force when mounting the

that

the

PROMs

of

the

See

special

the

PROM

careful

figure.

before replacement.

the

PROMs.

are in

the

not

removal

to

damage

tool

Make sure

correct position and direction.

is

the

pins are properly inserted in

PROM

recommended when removing

PROM

socket. Carefully

on

the

circuit board.

lift

the

PROM

the

PROM.

little

sockets.

If

a screwdriver must

by

little

from both

Screwdriver

~

Circuit board

Socket

-61-

1§1

DIP

(

BAS-411

switches

)

1.

SW1

At

shipping,

sewing area

Display

in

inches

DIP

can

~

~3

Fm:J

4

~

fmC~

m:::J

~8 ~8

~

5LV

6

1

ON

All dip

switches

before shipping.

Use

this

SW1

is

set

to

OFF.

be

specified in inches.

~1

~2

~3

Fm:J

~

fmC~

m:::J

are

setto

key

to

By

switching the

4

s

6

1

ON

OFF

choose

between

DIP

switch on, the total length

mm and inch

unit

system.

of

a pattern

or

the set

Example1

(ARA:

Example2 Totallength

(LG:

Example3

(HoP:

Area

V 10.10mm H 15.30mm )

V 10.00 mm H

To

set and confirm hoop feed

X 10.00 mm Y 15.00 mm J

15.00

mm J

point

-62-

This

indicates

inches ( = 257mm) and the horizontal length

15.30

inches ( = 389mm).

When setting the total the data

0.01inches.

is

that

the vertical length

length:

in 4 digits, the minimum

is

unit

10.10 is

being

Example

entry

When setting

Vertical

Horizontal

NOTE: In

the

vertical

0

1

using inches, errors

In

using millimeters, errors

2. SW2

o

SW2=0N

Pattern mode is displayed first.

length

1

3

for

3.5 inches and

5

1

I o I o I

within

Mode mode using

0.254 mm should be tolerated,

within

switching

the

horizontal length

Press

numeric

ol

Press

ol

1 mm should be tolerated,

DIP

switch 2.

order

can

numeric

Enter degits in order

be changed by PATIERN key in

for

keys

the

minimum

the

10

inches:

from

minimum

left

unit

to

right

is 0.01

is

1 mm.

.

inches.

entry

oSW2=0FF

Alphabet

3. SW3

o When

When stitch).

In this In

entry

same

o

SW3= The sewing start

Pattern mode

mode

is

displayed

Alphabet

mode

first

key

The sewing

switching

the

DIP

switch 3

the

entered data is one pattern,

case,

the

area check and

mode

or

as

when

the

OFF

when

SW3

point

is

ON

the

is

OFF

is

selected by

.

start

DIP

switch

the

test feed

entered data

.

the

centering function.

Alphabet

mode

Code mode

point

3.

the

needle location

function

is

two

patterns

key

of

are

the

embroidery

will

not

available.

or

more,

Code

Pattern mode

be

the

sewing start

the

sewing start

mode

can be

changed

point

will

(the

be

by

first

the

-63

-

4.

SW4

oSW4=0N

Thread

oSW4=0FF

Thread

5.

SWS

oSWS=ON

Even

will

o

SWS=OFF

If

another

stop operation

· · · · · · · · ·

trimming

Use

this key

format)

will

not

will

be automatically done between characters. (Cross-over stitch

to

be done between characters. (Cross-over stitch

. . . . . . . . . Data reading

is

inserted

if

another

floppy

at

disk

that

disk

is

inserted during data reading

or

sewing

is

inserted during data reading

point.

to

set

ON/OFF.

or

sewing

halfway.

until

it

is

the

done.

thread

can

be completed even

or

trimming

or

sewing

of

between characters (Brother

is

possible.)

is

not

possible.)

if

another

of

a character (pattern), machine

a pattern (character), machine

floppy

disk

will

NOTE:

6.

SW6-SW8

Do

not

errors

take

out

the

floppy

or

hinder correct sewing.

. . . . .

Not

available (Should be set

disk from

the

disk drive during data reading

to

OFF.)

or

sewing.

It

may

cause

-64-

(

BAS-415

1.

Dip switch functions on main printed circuit board

)

WJD

~ ~

l?%LJ

~ ~ ~

I?ZL)

~

1 2

3

.,.ON

4

I

5

6

sw

7

8

-

switch

SW1

SW2

SW3

SW4

sws

SW6

SW7

SW8

All dip switches are

number

state

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

set

to

OFF

before shipping.

To set paper To set paper To store data To read and sew data

(Data cannot be stored

If

another

pattern

Even

if

of

a character (pattern), machine

until

it

To displav

To display sewing speed (rpm.)

Spare

Spare (Use

Spare

To display Japanese To display English

tape

reading speed

tape

reading speed

of

floppy

(character), machine

another

is

done.

pattern

(Use

with

disk

floppy

name

OFF.)

disk

of

floppy

in

the

is

inserted

disk

of

function

to

9600 baud

to

4800 baud

in

the

memory

disk

memory.)

during

will

stop

operation

is

inserted

sewing data

will

durina

during

sewina

data

reading

data reading

during

or

at

that

sewing

point.

or

sewing

or

sewing

of

a

NOTE:

The

If

the

power

of

the

machine should be

is

not

turned

off,

functions

turned

do

off

before changing switch.

not

change;

-65-

2.

Dip switch functions on operation panel

switch

SW1

SW2

SW3

SW4

sws

SW6

SW7

number

state

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

To

jump

stitch

after

thread

trimming

To set

boring To set boring mode To set

boring To set boring To return Not

to

return To adjust To adjust To set sewing start To

set sewing start

Spare

(Use

more more more

without thread

mode

shift shift

to

sewing start

to timing timing

with

function

SW1

than

--------

to to

sewing start

of of

point point

·OFF.)

8 stitches

than

5 stitches

than

3 stitches

trimming

to

OFF

to

ON

OFF

(when

ON

(when

point

hoop

movement and needle rise

hoop

movement and needle rise of of

dip

dipsw 3 is

after

point

editing editing

sw 3

sewing

after

system data system data

OFF

ON

OFF

ON

is

ON)

sewing

to

center

for for

first

thick thin

stitch

of

SW2

OFF OFF

ON ON

material

mask

NOTE:

The

If

the

power

of

the

machine should be

is

not

turned

off,

functions

turned

do

off

before changing switch.

not

change.

-66-

[II

Connectors

1.

Main circuit board connectors

Refer

to

the

control block diagram

to

check

the

connector locations.

Connector

No.

P1

P2

P3

P4

PS

P6

P7

Connecting

Not

available

Main circuit Main circuit board +

-Power

board-

supply

point

Drive signals

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

Solenoid Solenoid drive signal

SV

(whole

control

equipment

+ 12V

(RS232C)

- 12V

(RS232C)

+ 60V (Solenoid)

Main circuit board Pulse

- PMD circuit board

Main

circuit board Sewing machine

-Sewing circuit board

Not

available

Main

-Synchronizer circuit board needle location signal

machine

circuit board

(P1)

motor

(P3)

motor

control signal

signal

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

movement

needle

PCB)

motor

control

possible •

Symptoms resulting

from

bad

connection

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

Solenoid does

· Control function does does

• Communication

• Solenoid

• X-axis pulse

• Y-axis pulse

•

Pulse not

run. (Needle

· Sewing machine

• Thread

·Overload

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

Improper case

· Needle bar

· Improper needle

• Improper needle

needle

not

motor

trim

does

bar

not

operate

does

not

motor motor

for

mer

needle not

move.)

case

is

selected.)

operate.

not

at

all.

function

operate.

does

not

does

not

needle

bar

does

motor

does

not

bar

position (Needle

locking

bar

case

bar

position (Wrong

operate

does

function

position

well,

not

work.

run. run.

replacing does

not

move.)

not

run.

.

or

bar

P8

pg

P10

P11

Main

circuit board Mechanical area

- Overtravel sensor displayed

Main

circuit board

- Y

home

position sensor

Main circuit board

-X

home

position sensor

Main

circuit board

-Thread breakage detector)

sensor (Thread

Y-axis center detection

X-axis center detection

thread

Needle

over

signal

breakage signal

When

•

sewing area.

• During sewing,

although

· When displayed.

· Thread breakage

• Thread breakage

-67-

power

although

the

power

is

turned

"area

needle

is

turned

is

turned

detector

on,

"area

the

needle

over"

is

in

the

on,

"area

on,

"area

does always activates.

over"

is

in

the

is

displayed

sewing area.

over"

not

activate.

is

Connector

No. connection

Connecting

point

Drive signals

Symptoms resulting

from

bad

P12

P13

P14

P15

P16

P17

P18

Main circuit

Main circuit board

-3.5

Main circuit board

- 3.5 in.

Main circuit board

-Editing reader

Main

-Operation

Main circuit board

-Synchronizer

Main circuit board

-Rotary

board-

in.

floppy

system

circuit board

keyboard signal

encoder

cap sensor

disk drive

or

paper

tape

cap

frame

overtravel signal

frame

cap

Input/Output

FDD

Serial comminucation control signal be done. (Data cannot be received.)

Operation keyboard control

Needle

X-Y feed synchronize signal · Thread

home position signal

signal

power

supply

up

signal

of

FDD

Cap

frame

· When

· displayed.

· Machine cannot

·

FDD

· Data in floppy disk cannot

• Comminucation

· Data in paper

· Nothing happens

· Display

· Synchronizing signal

· Timing pulse signal

· Hoop and holder base

or

X

home position

power

is

turned

does

not

function.

the

tape cannot be read

tape

reader.

is

blank.

trimming

Y direction.

on,

enter

cap frame mode.

with

editing system cannot

after

power

is

not

performed.

do

is

not

detected.

"overtravel"

be

read.

through

is

turned

not

move

is

on.

either

in

-68-

2.

Sewing machine

Refer

to

the

motor

circuit board connectors

control block diagram

to

check

the

connector locations.

Connector

No.

P1

P2

P3

3.

X- andY-carriage pulse

Refer

to

Connector

No. connection

P1

Connecting

Sewing machine board

-Power

Sewing machine board

-Power

Sewing machine board

-Main

the

supply

circuit board

control block diagram

Connecting

Pulse

motor

circuit board

-Main

circuit board

point

motor

unit

motor

unit

motor

point

circuit 6V

drive signal)

circuit Sewing machine

signal

circuit Sewing machine

signal · Thread

(PS)

motor

(P4)

(PMD}

to

check

Pulse

Drive signals

AC

(Sewing machine

PCB

the

connector locations.

Drive signals

motor

drive signal · X-axis pulse

motor

drive

motor

drive

connectors

Symptoms resulting connection

• Sewing machine

· Thread

·Overload

· Sewing machine

· Thread

·Overload

· Sewing machine

·Overload

trimming

motor

is

not

motor

is

not

motor

is

not

Symptoms resulting

motor

does

· Y- axis pulse

·

Pulse

move.

motor

does

for

needle bar change does

from

bad

does

not

run.

performed.

does

not

run.

performed.

does

not

run.

performed.

from

bad

not

move.

not

move.

not

P2

P3

P4

Pulse

motor

- Power supply

Pulse

motor

-XV

pulse

Pulse

motor

-Index

circuit board

unit

circuit board

motor

circuit board

motor

Pulse

motor

driving

Approx. + 37V

Y pulse

X and

control

power

Drive control change pulse

power

motor

drive · X

supply

power

for

motor

· X

andY

home position

power

is

turned on.

· Unbalanced pattern

· Needle bar cannot be replaced.

· Needle bar

· Improper needle bar

andY

power

· Unbalanced pattern

needle · Needle bar cannot be replaced.

· Needle bar

· Improper needle bar

case

home position

is

turned on.

case

locking

case

locking

case

is

not

position

is

not

position

detected

when

-69-

[1]

Trouble

(

BAS-411

1. Symbols

shooting

)

flow

chart

1.

2.

3.

4.

indicates manual operation.

indicates switch operation.

selects a yes-or-no decision-making process.

indicates appears determination and solution

the

in

course

that

the

first column

of

action

procedure

to

follow,

to

follow

of

"problem

table."

using

5.

6.

v

indicates setting-up operation.

indicates

appears on

0

7.

-70-

indicates

that

the

procedure

the

next page.

turning-off

the

to

power

follow

switch.

2.

Troubleshooting

(1) When power

flow

is

turned ON:

chart

YES

·EJ

NO

YES

NO

\

0

\

}

·EJ

}

·EJ

}

·EJ

-71-

(2) In data

entry

mode

[ENTER] [EDIT] [COMMUNICATE] [START(sewing)]

Machine

goes

into

ENTRY

mode.

-72-

(3)

In

sewing

mode

[ENTER] [ST

[EDIT]

ART(sewi ng)]

[COMMUNICATE]

YES

\

}

·U

}

·U

NO

-73-

·U

YES

\

)

·EJ

YES

NO

YES

\

)

·U

)

·U

·EJ

r-"

-74-

·EJ

(4)

In communication mode

I

Communicate

I

Can't

communi

I Edit-sy busy

[ENTER] [EDIT] [START{sewing)]

ERR

[COMMUNICATE]

-75-

(5)

Electric

solenoid

[ENTER] [EDIT] [COMMUNICATE] [START(sewing)]

YES

\

YES

\

YES

~YE~S

-~\'------'

YES

I

f

·U

-76-

3.

Problem determination and solution

Precautions

1.

Be

sure

to

turn

off

the

2.

Be

sure

to

turn

3. Letters marked

items

should be checked

4.

When

5. Check

replacing a fuse, be sure

that

all harnesses and connectors are correctly connected.

power

off

the

power

with

an asterisk (ex. (a)*)

before plugging/unplugging

switch before opening

while

the

power

to

use a new

in

the

CHECK/ADJUSTMENT/REPAIR

is

applied.

one having

the

machine cover

the

same

power cord.

or

quality

and capacity

disconnecting cables.

column indicate

as

the

old one.

that

those

Before

1.

Check

2.

Confirm

making

that

the

adjustment

no

fuse

is

blown

problem area referring

and each plug

is

correctly inserted.

to

the

troubleshooting

flow

chart.

-77-

NO.IN FLOW

AND

ERROR

CHART

STATUS

CAUSE

CHECK/ADJUSTMENT/REPAIR

PARTS

TO

REPLACED

BE

REF.

PAGE

#1

Keyboard ROM displayed.

NG

is

#2

"CAUTION MOVING!"

is

not

displayed.

1. Keyboard

P-ROM

improper.

1. Power

is

not

2. Power switch defective

version

supplied.

or

its cord

is

Replace main

circuit

(a)*

Measure If

the voltage

depending Remove power plug Input terminals of the power supply

unit.

Is

defective.

3. Regulator defective (a)* With

output terminal

normal. Similarly,

terminals.

4. Power harness defective (a)* While

and

they

normal.

5. Keyboard cable defective

6.

Operation

7.

Main

8.

Fuse

panel defective

circuit board defective

F2

blown

Check In

double

Is

no

continuity, Replace Replace Replace

that there

the

keyboard

board

voltage

on

face

cover

unconnected,

If

there

connector

If

connector

-12V

terminals

are

+

sv.

end

connector

operation

main

circuit board.

fuse.

P·ROM

with the

P·ROM.

of

single

phase

Is

not

100V

AC

where

It

Is

used.).lt

on

the left, turn

then

supply

Is

no

continuity, the power

P3

unplugged,

of

regulator.

check

the +

ltls + 12V

or·12V,It

P3

Is

plugged,

on

the

+

12V

and

·12Veach, they

Is

continuity between

of

keyboard

It

Is

defective.

panel.

one

matching

power

supply.

(120V,

220V,

240V

Is

defective.

on

the power with Power supply cord

measure

transformer Breaker

plug

and

power

measure + 5V

If It

Is

+

sv,

12Vand

·12V

Is

normal.

check + 5V, + 12V

main

circuit board.

are

same

numbers

assembly.

switch

It

Is

If

P-ROM

Regulator P92

Power supply P92

If

harness A Main

Keyboard cable

there

Operation panel Main Fuse

of

keyboard

circuit board

PSO

P96

PSO P47 PSS

#3

"Missed "MissedY-ORG.PT"

displayed.

X-ORG. PT"

:#4

"Overtravel"

displayed.

is

1. Pulse

motor

harness defective or is

2. Pulse

motor

power

defective

3. Pulse

motor

defective

4. PMD circuit board defective

5. Main circuit board

6.

Fuse

F1

blown

1. Home position sensor defective

Over

travel

2.

3.

Main

sensor defective

circuit board defective

supply

Check

that

connector

P41s proper continuity tested for. (a)* With

connector

P2

on

unplugged,

No.5(·). Replace Replace Replace Replace

Check connected Check proper continuity tested for. Replace

check

the voltage

If

It

Is

not

37V,

pulse

motor.

PMD

circuit

board.

main

circuit

board.

fuse.

that

main

connectors

and

connector

P9

proper continuity tested for.

PB

circuit board.

and

Is

correctly

PMD

circuit board

It

Is

defective.

P10

correctly

connected

of

pins

are

correctly

connected

No.1

and

Pulse harness Power supply

(

+)

and

Pulse PMD circuit board Main circuit board

Fuse

Home position

sensor

and

Over

Main

motor

unit

motor

travel

sensor

circuit board

P92

P48 P47 P58

P93,94

P93

P47

-78-

NO.IN FLOW

AND

ERROR

CHART

STATUS

CAUSE

CHECK/ADJUSTMENT/REPAIR

PARTS

TO

REPLACED

BE

REF.

PAGE

#5

"Disk

ERR."

displayed.

#6

."Short

of

displayed.

#7

"*th

data

displayed.

#8

"*th

Memory

displayed.

is

Area"

ERR."

OVR"

1. Floppy harness defective

FDD

power

2.

supply harness

defective

3. Floppy disk drive defective

4.

Improper media

5. Main circuit board defective

Mis-operation

Check

that

connector

P131s proper continuity tested for. (a)

Check

that

connector

P141s

proper continuity tested for.

(b)* With

connector

P14

removed, between pin 1 defective.

Replace (a)

Check

(b)

Check replaced

Replace

Check

area

floppy

main

disk

that

It

Is

that

media

by

2HO,

circuit board.

and

ratio

(+)and

drive. correct for

type

and

vice

In

editing

correctly

pin 2

machine.

Is

correct.

versa.

mode.

connected

measure

(-).

If

200

connected

voltage

It

Is

not +

cannot

and

Floppy harness

or

FDD harness

SV,

It

Is

Floppy disk drive Media

be

Media

Main circuit board

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

power

type

supply

P94

P47

is

Improper

media

Check

media.

Replace media.

is

1. Mis-operation

is

2.

Memory

expansion board

Entered cannot Replace

data

be

managed.

memory

exceeds

expansion

the

Inside

board.

memory

capacity

and

·-----------

Memory

expansion P49

defective board

Replace

main

circuit

3. Main circuit board defective

board.

Main circuit board P47

#9

Hoop does

#10

not

move. Refer

Mis-operation

to

item

#3.

1. Encoder harness defective Sewing machine runs but

hoop

does

not

2. Rotary encoder defective move. 3. Synchronizer defective

#11 1. Sewing machine

motor Overload occurs board harness defective immediately sewing began.

after

2. Sewing machine board

motor

3. Transistor alley defective

4.

Fuse

F6

blown

#12 Machinery defective

Overload occurs automatic

trimming.

#13

Errors relative

bar

needle appear.

thread

to

case

during

Refer

to

item

#11.

1. Index circuit board harness defective

2.

Pulse

motor

harness defective

·Needle change

3.

p~lse

motor

defective

4. PMD circuit board defective

5.

Fuse

F1

blown

circuit

Area

Is

set too

small.

Re-edit

In

editing

mode.

Refer

to

Item #3.

Check

that

connector

P181s

correctly

connected proper continuity tested for. Replace

rotary

encoder.

Replace

synchronizer.

Check

that

connector

P17

Is

correctly

connected proper continuity tested for.

Replace

sewing

machine

motor circuit

Replace

transistor alley. PS9

Replace

fuse.

Repair

and

adjust

machinery.

Refer

to

Item

#11.

Check

that

connector

P7

Is

correctly proper continuity tested for. Check

that

connector

P4

Is

correctly

proper continuity tested for.

Replace

pulse

motor.

Replace

PMO

circuit

board.

Replace

fuse.

board.

connected

and

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

Refer

to

item

and

Encoder harness P98

Rotary encoder

Synchronizer

Sewing

and

machine

circuit board

Sewing circuit board

transistor

Fuse

Refer

harness

machine

and

alley

to

item

Index circuit board harness

Pulse

motor harness Pulse

motor

PMD circuit board P48 Fuse

#3.

motor

motor P48

Refer

ltem#3.

P98

PSB

#11.

P93

P92

P58

to

-79-

NO.IN FLOW

AND

ERROR

#14

Thread

CHART

STATUS

trimming

is

not

Refer

CAUSE

to

"(5) electric solenoid" in troubleshooting.

normal.

#15

Embroidery

is

1. Improperly adjusted machinery

2. PMD circuit board defective

distorted. 3. Mis-operation

CHECK/ADJUSTMENT/REPAIR

Re-adjust

machinery.

Replace

PMD

circuit

board. PMD circuit board

(a)

Check

If

machine

Is

operated

cap

sensor.

(b)

Check

If

machine

Is

operated

without

cap

sensor.

In

hoop mode with

In

cap frame

mode

PARTSTOBE

REPLACED

·-----------

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

·-----------

REF.

PAGE

P48

#16 1. Improper

Errors relative

communication

appear.

#17

"Tape read Error"

displayed.

#18

Solenoid does operate.

to

not

2. Paper

tape

3. Editing system defective

4. Main circuit board defective

1. Mis-operation

is

2.

lmpropertape

3. Tape reader defective

1. Solenoid harness defective

Solenoid

2.

3. Solenoid defective

4. Main circuit board defective Improper machinery

5.

6.

Fuse

F3

blown

7. Refer

to

RS

cable

reader defective

power

defective

item

#10.

Check

that

RS

cable

Is

correctly continuity tested for. (a)

Check

that power

(b)

Check

that paper tape

(c)

Replace

(a)

Check

that power

(b)

Check

that

(c)

Replace

main

Select correct tape type. (a)

Poor

punch

(b) Paper tape runs short.

(a)

Dirty

head

(b)

Replace

Check

connector continuity tested for. (a)*

With

connector

between pins 6

normal.

With connector

values of

pins

~

thread

ND.2

~

thread

No

A

jump

I

:~.!

I

No.7

picker solenoid

No.8

Each

voltage should have above spedfled

Replace

main

Readjust

machinery.

Replace

fuse.

Refer

to

Item

Is

paper tape reader.

Is

machine

editing

system.

circuit

board.

of

paper tape

of

paper tape reader

tape reader.

P2

Is

correctly

P3

unplugged.

(+)and 8 (·).

P2

unplugged. measure

below.

trimming

wiper

solenoid

drcult board.

#10.

connected and proper

turned on.

Is

set.

turned

on.

enters

communication

connected and proper

check

lflt

solenoid

voltage

Is

+ 60V,Itls

resl$18nce

mode.

470

230 1850 6500

values.

RScable

Paper

tape

reader

Editing system Main

circuit board

·-----------

Re-punch tape.

Clean head.

Tape reader

Power supply

Thread solenoid Thread solenoid

unit

trimming

wiper

Jump solenoid Picker solenoid

Main

circuit board

·-----------

Fuse Refer

to

item

#10.

P47

P92

P47

P58

-80-

(

BAS-415

1.

Symbols

)

1.

2.

3.

4.

indicates manual operation.

indicates switch operation.

selects

a yes-or-no decision-making

indicates appears in determination and solution

the

course

that

the

first column

of

action

procedure

to

follow,

process.

to

follow

of

"problem

table."

using

5.

6.

v

indicates setting-up operation.

indicates

appears on

0

7.

-81-

indicates

that

the

procedure

the

next page.

turning-off

to

the

power switch.

follow

2.

Troubleshooting

{1) When

power

flow

is

turned ON:

chart

YES

NO

\

}

~EJ

YES

NO

\

}

~EJ

-82-

(2)

In

data entry mode

FileNo.**

Machine goes

into

ENTRY

mode.

YES

\

}

~Q

-83-

(3) In sewing mode

FileNo.**

YES

NO

\

}

~u

-84-

\

}

~u

\

}

·U

·[:/]

~u

}

·[:/]

-85-

(4)

In communication mode

File

No.**

I

Line

ERR.

I Off line I

Line

busy

---..-u

-86-

(5)

Electric solenoid

FileNo.**

YES

~YES

~\"--------'7-

YES

-87-

3.

Problem determination and solution

Precautions

1.

Be

sure

to

turn

off

the

2.

Be

sure

to

turn

off

the

3.

Letters marked items should be checked

4.

When replacing a fuse, be sure

5.

Check

that

with

an asterisk (ex. (a)*)

all harnesses and connectors are correctly connected.

power power

before plugging/unplugging

switch before opening

while

the

power

to

use a new

in

the

CHECK/ADJUSTMENT/REPAIR

is

applied.

one having

the

machine cover

the

same

power

quality

cord.

or

disconnecting cables.

column indicate

and capacity

as

the

that

old one.

those

Before making

1.

Check

that

2.

Confirm

the

adjustment

no

fuse

is

blown

problem area referring

and each plug

is

to

the

troubleshooting

correctly inserted.

flow

chart.

-88-

NO.IN

FLOW

AND

ERROR

#1

Keyboard

displayed.

#2

"CAUTION is

not displayed.

CHART

STATUS

ROM

NG

MOVINGI"

PARTS

TO

CAUSE

CHECK/ADJUSTMENT/REPAIR

BE

REPLACED

Change

CPU

version

of

keyboard

to

proper

1.

CPU

version

of

keyboard

is

incorrect.

1.

Power

is

not supplied.

2.

Power switch or its defective

3.

Regulator defective

4.

Power

harness

defective

5.

Keyboard

6.

Operation panel defective

7.

Main circuit board defective

8.

Fuse

F2

cable

blown

defective

cord

is

matching

PROM

of

PCB.

(a)*

Measure

voltage of

single

phase

If

the voltage

depending

Remove

power plug

Input terminals supply

unit.

Is

defective.

(a)* With

Output normal.

terminals.

(a)* While

and

they

normal.

Check

that there

In

double

Is

no

continuity Replace Replace Replace

on

face

cover

unconnected,

of

If

there

connector

terminal

Similarly.

If It

connector

·12V

terminals

are

+

sv.

end

connector

,It operation main

circuit

fuse.

Is

not

100V

where

It

Is

on

the left. turn

then

the power

Is

no

continuity. the power

P3

unplugged.

of

regulator.

check

Is

+ 12Vor-12V,It P3

Is

plugged.

on

the

+

12V

and

Is

continuity

of

keyboard

Is

defective.

panel.

board.

AC

used.), It

measure

supply

the+

main

·12V

between

version

power

supply.

(120V,

220V,

240V

Is

defective.

on

the power with

transformer Breaker

plug

and

power

switch

measure

+

sv

If

It

Is

+ SV,It

Is

12Vand

-12V

Is

normal.

check

+

sv.

+

12V

circuit

board.

If

each.

they

are

same

numbers

assembly.

If

there

CPU

of

keyboard P54

Power supply

cord

Regulator P92

Power supply P92 harness

A

Main circuit board

Keyboard

cable

Operation panel Main circuit board Fuse

REF.

PAGE

P97

P57 P47 P58

1.

Pulse

#3

"X_ORG.Error" "Y _ORG.Error"

or is

2.

motor

Pulse

motor power supply

displayed. defective

3.

Pulse

motor defective

4.

PMD

circuit board defective

5.

Main circuit board

6.

Fuse

F1

1.

Home

#4

"Overtravel"

displayed.

is

2.

3.

position

Over travel

Main circuit board defective

harness

blown

sensor

defective

Check

that

connector

proper continuity

(a)*

With

connector unplugged. No.5(·).

If It

Replace

pulse

motor.

Replace

PMD

circuit

Replace

main

circuit

Replace

fuse.

Check

that

connectors connected Check

proper continuity Replace

that

main

and

connector

circuit

P41s

correctly

tested

for.

P2

on

PMD

check

the voltage of

Is

not 37V,It

proper continuity

tested

board.

P9

PSis

board.

Is

and

P10

correctly

for.

connected

circuit

board

pins

defective.

are

correctly

tested

connected

No.1 ( +)

for.

and

Pulse

motor harness Power

supply

unit

and

Pulse

motor

PMD

circuit board P48 Main circuit board P47 fuse

Home

position sensor Over travel

sensor

Main circuit board

P92

P58

P93,94

P93

P47

-89-

NO.IN FLOW

AND

ERROR

CHART

STATUS

CAUSE

CH

ECK/ADJUSTMENTIREPAIR

PARTSTOBE

REPLACED

REF.

PAGE

#5

"Disk

ERR."

displayed.

#6

"Short

of

displayed.

#7

"Data

ERR."

displayed.

#8

"Memory

displayed.

is

Area"

is

over"

Check

that

connector

P131s

correctly

P14

Is

vice

sewing

Is

correctly

measure

(·).

machine.

correct.

versa.

connected

voltage

If It

Is

not + SV,It

200

cannot

area.

1. Floppy harness defective

2.

FDD

power

supply harness

defective

3. Floppy disk drive defective

4.

Improper

5.

Main

Improper

media

circuit board

sewing

data

defective

proper continuity tested for. (a)

Check

that connector

proper continuity tested for. harness

(b)* With

connector

P14

removed, between pin 1 (+)and pin 2 defective.

Replace

floppy

disk

drive.

(a)

Check

that

It

Is

correct for

(b)

Check

that

media

type

replaced

by

2HO,

and

Replace

main

circuit board.

Pattern

size

of data

exceeds

is

Improper

1. Mis:..operation

is

2.

Memory

media

expansion board

Check

Entered cannot Replace

media.

data

be

managed.

memory

exceeds

expansion

the

Inside

board.

memory

capacity

defective

3.

Main

circuit board defective

Replace

main

circuit

board.

Floppy harness

and

or

FDD

Is

Floppy disk drive Media

be Media

Main

This

cannot be sewn.

Replace media.

and

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

Memory board Main circuit board

power

supply

type

circuit board

pattern

data

expansion

P94

P47

P49

P47

#9

Hoop does

not

move.

#10

Sewing machine runs

but

hoop

does

not

move.

#11

Motor

is

locked

immediately

after

sewing began.

#12

Motor

is

locked

during

automatic

thread

trimming.

#13

bar

to

case

Errors relative needle

appear.

Refer

to

item

#3.

1. Encoder harness defective

2. Rotary encoder defective

3. Synchronizer defective

1.

Sewing machine

motor

circuit

board harness defective

2. Sewing machine

motor

circuit

board

3. Transistor

4.

Fuse

F6

blown

~lley

defective

Machinery defective Refer

to

item

#11.

1.

Index circuit board harness defective

2. Pulse

3. Needle change pulse

motor

harness defective

motor

defective

4. PMD circuit board defective

5.

Fuse

F1

blown

Refer

to

Item

#3.

Check

that

connector

P181s

proper continuity tested for.

Replace

rotary

encoder.

Replace

synchronizer.

Check

that

connector proper continuity tested for. Replace

sewing

Replace

transistor

Replace

fuse.

Repair

and

Refer

to

Item

Check

that

connector proper continuity tested for. Check

that

connector

proper continuity tested for.

Replace

pulse

Replace

PMD

Replace

fuse.

adjust

#11.

motor.

circuit

P17

machine

alley.

machinery.

P7

P4

board.

Is

motor drcult board.

Is

correctly

connected

Refer

and

Encoder harness

Rotary encoder Synchronizer

and

Sewing circuit board Sewing circuit transistor

Fuse

Refer

and

Index circuit board harness

and

Pulse harness Pulse

PMD circuit board Fuse

to

item

machine

board

alley

to

item

motor

#3.

motor

harness

mo~or

and

#11.

Refer

to

ltem#3.

P98

P48

P59 P58

P93

P92

P48 P58

-90-

NO.IN FLOW

AND

ERROR

CHART

STATUS

CAUSE

CHECK/ADJUSTMENT/REPAIR

PARTS

TO

REPLACED

BE

REF.

PAGE

#14

Thread

trimming

is

not

Refer

to

"(5) electric solenoid" in troubleshooting.

normal.

#15

Embroidery

distorted.

is

#16

Errors relative

communication

to

1. Improperly adjusted machinery

2. PMD circuit board defective

3. Mis-operation

1. Improper

2. Paper

RS

cable

tape

reader defective

Re-adjust Replace

(a)

(b)

Check continuity tested for. (a)

appear. (b)

(c)

3. Editing system defective

4. Main circuit board defective

#17 1. Mis-operation

"Tape read Error" displayed.

is

2.

lmpropertape

3. Tape reader defective

(a)

(b)

(c) Replace

Select (a)

(b)

(a)

(b)

machinery.

PMD

drcult board. Check H machine cap

sensor. Check H machine without

that

Check

that power

Check

that paper tape Replace Check

that power Check

that Replace

main

correct tape type.

Poor

punch

Paper

tape

Dirty

head

Replace

Is

operated

In

hoop

mode

with

Is

operated

In

cap frame

mode

cap

sensor.

RS

cable

Is

correctly

connected and proper

Is

turned

on.

Is

set.

paper tape reader.

Is

turned

on.

machine

enters

communication

editing

system.

circuit

board.

of

paper tape Re-punch tape.

runs

short.

of paper tape reader Clean head.

tape reader. Tape reader

mode.

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

PMD circuit board

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

RScable

Paper

tape

reader

Editing system Main

circuit board

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

P48

P47

#18

Solenoid does

not

1. Solenoid harness defective

operate. 2. Solenoid

3. Solenoid defective

4.

Main

circuit board defective

5.

Improper

6.

Fuse

F3

7. Refer

to

power

machinery

blown

item

#10.

defective

Check

connector

P2 continuity tested for. (a)*

With

connector

between

pins

6 (

normal.

With

connector

P2

values of

pins

below.

~

thread

No.2

~

thread

No.4

...,Hg,L

jump

No.6

~

No.8

Replace Readjust Replace Refer

to

Each

solenoid

picker solenoid

voltage

main

circuit

machinery.

fuse.

Item

#10.

Is

correctly

connected and proper

It

Is

470

230 1850 6500

values.

Power supply

Thread solenoid Thread solenoid

Jump solenoid

Picker solenoid

P3

unplugged,

+)

and 8

unplugged,

trimming

wiper

should

board. Main circuit board

(-).

If

measure

solenoid

have

above

check

It

Is + 60V,

voltage

resistance

specified

unit

trimming wiper

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

Fuse Refer

to

item

#10.

P92

P47

P58

-91-

[I]

Harness

connections

( BAS-411·415 )

and

connectors

number

Connector

P1 (SOL 1)

P2 (SOL2)

Main

Pin No.

1 2

3

4

5 6

7

8

1 2

3

4

5 6

7

8

circuit

board

N.C. N.C. N.C. N.C. N.C. N.C.

N.C. N.C.

THCUT RET WIPER RET JUMP RET PICKER RET

Signal

Pin No.

1 2

1

2

1 2 1 2

1

2

1 2 1 2 1 2

Connect

Unused solenoid

Thread

Jump solenoid

Picker solenoid

to;

trimming

wiper

solenoid

P3 (POWER)

P4 (PMD)

*N.C.=

not

connected

1 2

3

4

5 6

7

8

+SV +12V

-12V ±OV 4

±OV OVRET(±OV) N.C.

+Vmm

9 N.C.

1

2

3

4

5

6

7

+SV

IUP IDOWN· YUP YO X DOWN

8 XUP 9

10

SAVE

ISAVE

OWN

7

8 9

4

10

1 2

3

CN11

Power supply

unit

5 6

1 2

3

5

(CNT)

P1

PMD circuit board

6

7

8 9

-92-

Main

circuit

board

Connect

to;

Connector

P4

(PMD)

PS (MOTOR)

P7 (INDEX)

Pin No.

11 12 13 14 15 ±OV

1 2

3

4 5

6

7

8

9 10 11 12 13 ±OV 14 15 OVLD

1 2 3 4 5

6

7

8

Signal

N.C. PESET N.C.

±OV

+5V

+5V HLSPD1 HLSPD2

MOVE UP SPDO SPD1 N.C. N.C. TG

±OV

N.C.

+12V

NP-ROT

±OV NP-CNGO NP-CNG1 NP-CNG2 NP-CNG3

±OV

Pin No.

11 12 13 14 15

1 2 3 4 5

6

7

8

9 10 11 12 13 14 15

1

2

3

4

5

6

7

8

P1

PMD circuit board

(CNT)

P3

(CNT)

Synchronizer circuit board

Sewing machine

motor

circuit

board

P8,

P9,

P 10

Sensor circuit board

1 2 3 1 2 3 1 2 3

1 2 3

±X

+Y

-Y

Y

home

Over

position sensor

PS (OVER)

pg

(Y-ORG)

*N.C.=

not

connected

1 2

3

4 5

6

7

8

9

1 2 YINDEX 3

+5V OVTR±X RET

+5V OVTR+Y RET

+5V OVTR-Y

RET

+5V

RET

-93-

travel

sensor

A

K

00

TOP

VIEW

Connector

Main circuit board

No. Signal

No.

Connect

to;

P10 (X-ORG)

p

11

(TH. BRK)

P12 (SEEK)

10 12 14 16 18

P13

(FDD)

20 22 24 26 28 30 32 34

1.3.

5.

11. 13. 15.

17.19.21.

23.25. 27.

29.

31.33

P14

(FDDPOWER)

P15 (RS232C) 3

1 2 3

1

2

3

1

2

3 4

5

6

2

4

6

8

7.

1

2

1

2

4

+5V XINDEX RET

+12V STINT

±OV 3

+5V L-SEEK RET

+5V R-SEEK RET 2HD/2DD RESERVED DRIVE

SEL3 INDEX DRIVE

SELO DRIVESEL1

DRIVESEL2 MOTOR DIRECTION STEP WRITE WRITE TRACKOO WRITE READ HEAD DISK

9.

SIGNAL

+5V

FG

ON

DATA GATE

PROTECT DATA SELECT

CHANGE

RETURN

±OV

(±OV)

so

RD RTS

( ± 0)

1 2 3

1

2

4

----------

1

----------

2

3 33 31 29 27 25 23 21

19 17 15

13

11

9

7 5

3

1

2.

4.

6.

8.

12.

14. 16.

18.

20.

22.

24.26.28.

30.32.34 1 2

1 3 2 5

X home position sensor

Thread breakage detector

CAP-ON

+5V CAP-OVER RET

3.5" floppy disk drive

10.

3.5"

Paper tape reader

system

FDD

power supply

Cap

sensor

(FDD)

or

editing

-94-

Main circuit board

Connect

to;

Connector

P15

(RS232C)

*N.C.= not connected

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

No.

5 6

7

8 9

CTS

DSR

±OV

N.C. N.C. N.C. N.C. N.C. N.C. N.C. N.C. N.C. N.C. N.C.· N.C. DTR N.C. N.C. N.C. N.C. N.C.

Signal

20

10 11

12 13

14

15 16 17

18

19

21

22

23

24

25

No.

4

7

8 9

6

Paper

tape reader or editing

system

-95-

(

BAS-411

)

<Main

Connector

P16

(KEY)

*N.C.=

circuit

not

connected

board>

Main

circuit board

No. Signal 1

2 3

4

5

6 7 8 9

10 11

12 13 14 15 16 17 18

19 20 21 22 23 24 25

FG

so

RD

+5V

CTS

DSR

±OV EMRET(±OV) EMSTOP

+5V 01 FLM MB CL1 CL2 02

±OV 17

±OV

±OV N.C. N.C. N.C.

+5V

+SV

Connect

No. Connector

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16

18

19 20 21 22 23 24 25

pg

(HOST)

to;

Operation panel

-96-

(

BAS-415

)

<Main

Connector

P16

(KEY)

*N.C.=

circuit

not

connected

board>

Main

circuit board

Pin No.

1 2 3 4 5 6 7 8

9

10 11 12 13 14 15 16 17 18

19 ±OV

20 21 22 23 24 25

Signal

FG

so

RD

+5V CTS DSR

±OV EMRET(±OV) EM

STOP

+5V N.C. N.C. N.C. N.C. N.C. N.C.

.±OV

±OV

N.C. N.C.

N.C.

+5V

Pin No.

1

2 3 4

5

6

7 8

9

10 11 12 13 14 15 16 17

18

19

20 21 22 23 24 25

Connect

Connector

CN3

(Hosn

to;

Operation panel

-97-

Brother BAS-411, BAS-415 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual