Brother MD-803, MD-813 Mark II Instruction Manual

brothec

DC

SERVOMOTOR

MD-803

l\/ID-813

(Single-Phase Type)

(Three-Phase Type)

""I.

•g

^*«her

K93S1I

INTRODUCTION

This service manual is compiled forthe technical staff responsible for maintaining

automatic

Read

thread

trimming machine.

the

service manual carefullysothat you

DESCRIPTION
SPECIFICATIONS

NAME
PRINCIPLE

OF

EACH

OF

The

manual

TABLE

OF

THE

PART

CONTROL

describes

understand

OF

MOTOR

SYSTEM

the

motor

and

the

right handling

CONTENTS

CONFIGURATION

COMPATIBILITY

(except

MOTOR

OPERATION
OPERATION

ADJUSTMENT

B738

OF

MD-802,

or

B7380) 7

812

AND

MD-803,

PANEL
INSTRUCTION

TROUBLESHOOTING

CHECKING

CHECKING
PARTS

SPEED

NOTES
DC

MOTOR

CONTROL

CONTROL
TIMING
BLOCK
DETAILS
TIMING
HIC

CIRCUIT
FRAME
INSTALLATION
USING

USING

THE

THE

CODE

NOS.

ADJUSTMENT

REGARDING

TROUBLESHOOTING

BOX

TROUBLESHOOTING

BOX

TROUBLESHOOTING

CHART

DIAGRAM

OF

CONNECTOR

CHART

ASSEMBLY

THE

THE

OF

DIAGRAM

OF

MATERIAL

PRODUCTION

MOTOR

MACHINE

FOR

FOR

DC

OF

CONTROL

OP.

#2

REPLACEMENT

OPTIONS

SOLENOIDS

SPACE

EACH

MOTOR

PANEL

PANEL

EDGE

QUANTITY

PARTS

MACHINE

INSTALLATION

GUIDE

GUIDE

GUIDE

CIRCUIT

E-40

SENSOR

COUNTER

and

inspecting the drive motor

the

control box

and

adjustment.

813

OUTLINE

DETAILS

and

also

covers

1
2

3
5

6

8

8
9

10

17

18

19
20

22

24
25

34

35
57
58
60
73

77
80
84
91

92

designed

adjustments.

for

the

★

The

Brother DC servomotor is

advanced

functions

are

best

suited to labor-saving applications. To

provided with a full

systems

design.

FEATURES

1.

Energy

Power consumption is
the sewing machine is stopped, the DC servomotor is

2.

Quiet

Whilethe clutch motor produces a whirring idling sound

run

3.

Easy

Maintenance isaseasyasadjusting the solenoid brake spacing.

4.

Reliability

High integration microcomputers

when

maintenance

Saving

Operation

the

sewing

reduced

machineisstopped.

about

and

50%

hybrid ICs

with the DC servomotorascompared

also

stopped, resulting in highly effective

and

vibrations, the DC servomotor is free of

are

used

for higher reliability.

There

save

sewing labor

and

enhance

with coventional Brother clutch motors.

energy

these

becauseitdoes

is no

needtoreplace

the

moving brake plate.

automation,

When

savings.

not

★The

DC servomotor is also

wotref

•

used

with

automatic

[DB2-B791J

thread

trimming

machines

models

A;

DB2-B748,

•iflrL'^SlIiLSS

8795,

and

B798.

[DB2-B7910]

SPECIFICATIONS

J«The

operation panel is

optionally

available.

Use the operation panel

which

is best suited to your

Operation panel

work.

Machine

Head to be

Applied

.

[DB2-B737

[LT2-B842

[L22-B852 • B853 • B854]

• B748 •

• B845 • B847 • B848 • B872 • B875]

B791

Production quantity

• B793 • B795 •

counter

P.COUNTER

B798]

i

Power

switch

Synchronizer

Treadle

unit

NAME

OF

EACH

PART

Stator (magnet)

Rotor

Brake

coil (lining)

Brake

armature

Pulley

Reactor
Brush

holder

Thermistor

Sewing machine plug

Presser

foot lifter plug

Brake

plug

Synchronizer plug

Slow

start

switch

Correction

Needle

Backtack
High

Treadle

position

sewing

sewing

unit

switch

speed

Power lamp

switch

speed

control

control

Motor

Mounting

Template

160

80

20

RIO

RIO

01510.1

CO

in

O CO

60

(O

^ CN

RIO

in

-4-

C PRINCIPLE OF CONTROL

m

aa

p

aa

SYSTEM

)

gg

CB

1. When the powerswitchO is turned on and the treadle O Isdepressed, the start signal and a voltage corresponding to how far

the treadle Is depressed are suppliedto the control box O by the treadle

control circuit board Inthe control box Osothat

machine.

2. When the treadle 0 Isreturnedto the neutralposition

the

motor runs Inproportion to

(with

foot

off),

unit.

The voltageIs supplied to the motorO by the

the

depression of

the

treadle to drive the sewing

the neutral signal Issent to the controlboxO bythetreadle
unit 0 and the brake command Is given by the control circuit board to decelerate the motor O- Then the signal from the
synchronizer
the operation of the sewing machine Is stopped at the needle down stop position set by the synchronizer

3. When the treadle Is stepped on again, the thread

command Is given by the control circuit board to run the motor O at the thread trimming

O,

mounted on the pulleyof the sewing machine. Issent to the controlbox O and the brakes are applied so that

O.

trimming

signal Is sent to the control boxO by the treadle unit0 and the

speed

(Inching speed).

Then the signalfromthe synchronizer 0 Issent to the controlbox0 and the brakes O are applied so that the operation of the
sewing machine Is stopped at the needle up stop position set by the synchronizer

-5-

0.

CONFIGURATION )

anon

gP

DC.

motor

bdbd

BS

Servo

O

aaaa

Synchronizer

auaa

61/03 mm

Source

r

I

Mt-

I

I

Fuse

Treadle

Operation

panel

Full-wave

rectification

circuit

Trans

former

Speed

detection

Power

supply

Protective

circuit

POWER

CIRCUIT

Power

supply

circuit

Power

detection

ON-OFF

UNIT

Motor

circuit

(PWM)

^ — ——/5

Power

supply

circuit

CPU

Power

detection

ON-OFF

Power

transistor

drive

5^

Solenoid

brake

transistor

Look

protective

circuit

Brake

I

L_.

CONTROL

CIRCUIT

UNIT

Note: The sections enclosed by the broken line indicate where high voltage is applied. Handle these sections with great care.

CAUTION:

1. When setting down the machine head or touching the needle, be sure to turn offthe power switch and

confirm

that the

lamp is OFF.

2. Groundcords re providedforboth single-phase and three-phase types. Do not

provided

for

single-phase

110V

types.

Be sure to

ground

the

motor

3. Whenadjustingthe controlsinthe controlbox, be sure to tum offthe powerswitch,removethe

fail

to ground the motor. (Aground cord is not

frameifnecessary.)

front

cover and

confirm

pilot lamp is OFF.

*lt

is dangerous to handle the control boxwhen the power is on because high voltage is applied. Handle

4. Do not

use

the

DC

servomotor

rear

machines

which

generate

-6-

strong

highe

frequency

noise,

e.g.,

are

with

great care.

welders.

pilot

that the

f COMPATIBILITY OF MD-802, 812

V

(except

B738

or

B7380)

AND

MD-803,

813

Control

circuit

board

Threadle

unit

Operation

box or panel

Power
board

Transformer

Motor

Synchronizer

1-110V

1-230V
3-230V
3-400V
comp.

p.c.b.

1-110V
1-240V

3-240V

3-400V

110V

(6V)

220V

(6V)

220V

(12V)

230V (6V)

240V

(6V)

240V (12V)
380V

(6V)

380V

(12V)

415V (6V)

415V

(12V)

S-PCB300B1

MD-802,

-1OOV

812

(291270-110)

S-PCB300B1-230V (291270-123)
S-PCB300B3-230V (291270-323)
S-PCB300B3-400V (291270-340)

PS-UNIT#8
PS-PCB#8

(291442-001)

(291443-001)

E-2 (137209-90103)
E-4 (137209-90203)

There

is fundamentally two kinds of motor,

anotherishigher

than

380V. Butasmotor lavel

or

phase,

Synchronizer

S-PCB500B1 -1

S-PCB500B1-230V (291782-123)

S-PCB500B3-230V (291782-323)

S-PCB500B3-400V (291782-340)

PS-UNIT#11 (291790-001)
PS-PCB#11

Markll

E-20

137208-91111

E-40

137208-91211

E-100

137208-91311

SI,

SII

reference

D-PCB1-110V (291273-001)

D-PCB1-240V (291274-001)
D-PCB3-240V (291275-001)

D-PCB3-415V (291276-001)

229963-001
229643-001

230660-001

229645-001
229646-001
231335-001
229561-001

229623-001

230214-001
229644-001

one

there

are

many

motors.

#13

(291079-001)

#14

(291670-001):For

MD-803,

OOV

813

(291782-110)

(291792-001)

others

137208-91120
137208-91220

137208-91320

*1

is from 100V to 240V,

depends

twin

on

needle

each

voltage

Note: Power board 1-110V

Note: ( ) is lamp

*1

Sensor

tap

Sewing machine

B737

Markll

B748

B842

type

B791

B793,

B795

B798

(100-110V),

voltage.

SENS0R#1-1
SENS0R#1-1

SENS0R#1-3

SENS0R#1-4

SENS0R#1-5
SENS0R#1-6

1-240V (200~240V), 3-230V (220~240V), 3-400V (380~440V)

SI

(291655-002)
(291655-002)

(291673-002)

(291656-002)

(291658-002)
(291744-002)

SENSOR#2-2
SENS0R#2-1

SENSOR#2-3
SENSOR#2-4
SENSOR#2-5

SENSOR#2-6

-7-

SII

(291657-002)
(291659-002)

(291674-002)
(291640-002)
(291641-002)

(291642-002)

i MOTOR )

Motor

Assembly

Bracket

Brush

Rotor#145

MD-802

-812

phase

Single

Three

phase

L

Single

phase

Three

phase

Three

phase

Single

phase

Three

phase

Three

phase

Single

phase

Single

phase

Three

phase

110V

220V

230V

240V
220V
380V
415V

220V

380V,

415V

220V

380V, 415V

110V

220~240V

380V,

415V

291408-001

291409-001
291410-001
291411-001
291412-001
291413-001
291414-001

291823-001 (MD-803C)

291824-001 (MD-803A)

291825-001

291826-001

231001-001

231003-001

231556-001

231558-001

231004-001

231018-001

MD-803

-813

(MD-813A)

(MD-813B)

231646-001

( OPERATION PANEL )

00

00

00

00

00

Operation

137-208-911-11

137-208-912-11
137-208-913-11
137-208-911-15

137-208-912-15

137-208-913-15

137-208-911-17

137-208-912-17

137-208-913-17

137-208-911-19

137-208-912-19
137-208-913-19

137-208-911-20
137-208-912-20

137-208-913-20

B737

Markll

B791
B798

B748

LT2-B842

B793

B795

Operation

Model

Type

panel

E20

E40

El

E20

E40
El
E20
E40

El

E20

E40
El
E20
E40

El

panel

-8-

(

OPERATION

[U

Motor

control

INSTRUCTION

and

ONI

o

control

(OFF

box

)

use

tDDl

o o o o

oiocn

ycsssm

-At

The power lamp O

•k Sewing speed

turned

towards

The sewing

-k Start backtack sewing speed

the

controlisturned

The start backtack continuous sewing

cannotbeadjusted.

When

sewn

When the correction switch 0 is ON, the machine

depressed

reverse

The machine
to the needle down position. Conversely,the machine

the

needle

the

slow

at low

sewing

speed

speed.

while

will

up position.

will

light up when the power switch O is turned on.

will

increaseasthe speed control O is turned toward

LOW (to

start

the

mode.

stop

the

left).

range varies from a minimum 215spm to an adjustable maximum speed.

will

increaseasthe backtack sewing speed control O is turned clockwise, and

counterclockwise.

speed

rang is 215 to 3000spm. The end backtack sewing

switch 0 is switched to ON,

Sewing

machine is stopped. If

with

speed

after

these

the

the needle inthe down positionifthe machine is stopped after setting the needle positionswitch0

I

right),

0

and

and

o

HIGH

(to the

the

first two

first two stitches is regulated by depressing

will

actuator is

stitches

sew

depressed

will

stop inthe needle up positionifthe needle positionswitchO<sset to

(after

thread

trimming

in the correction stitch mode (215spm) when the actuator 0 is

during machine operation,

@ 0

will

decreaseasthe control is

will

speedisset

needle

the

the

at 1800spm and

up position stop)

treadle.

machine

decrease

will

enter

will

as

be

the

-9-

i

ADJUSTMENT

)

[U DC

About13mm

Needle

Model

★

Take

down signal

Servomotor

Rotatinq

of

machine

0

position

DB2-B791

off

the

synchronizer

and

the

direction

thread

detector

•

B793

cover

for adjustment.

trimming signal with

Lower

the

machine

machine

pulley.

head

and

then

mount

the

belt on

the

motor pulley

and

the

The belt fitsthe machine pulleyand the motor pulleyas shipped. Belttension may

loosenIntime.

The

machine rotates counterclockwiseasseeen

Adjust

the

about

13 mm

belt

Check

O by

when

the

loosening

pressed

belt

tension.

theset screw0 and

by hand.

from

the

pulley side.

turning

thenut0 sothatItgives

(synchronizer)

•

B795

The

Needle

stop

position

•

B798

synchronizer

one

sensor.

down

18-22

detects

mm

the

needle

I]"

with two

sensors

Needie up

stop

and

controls

position

For

medium

materials

'For thick materiais

10~12mm

9~11mm

the

needle

11—14mm

* In adjusting

Position

★

Tumthe machine

each

adjustment

upper end of the thread

Model

sensor, do not fall to turn off the power switch.

for

needle

pulley

thisside and set the needle5mm up

down

trimming

signal

needle down sensor

from

0.

B798

the

bottomtoalign

22-26

mm

the

7.5

mm

lower

end ofthe magnetO

(As for the model 8747 • 0748, adjust the needle 7 mm up from the bottom andasfor the model 8798, 7.5mm up.)

When

the

lower

loosen

the

end ofthe magnetO does not

screw 0

and

move

the

thread trimming needle down

coincide

with

the upperend of the thread

sensor

for adjustment.

trimming

needle

down

sensor

When the thread trimming needle down sensor0 Ismoved Inthe rotating direction, the needle bar comes up.And when Inthe

reverse

direction,

the

needle

bar

comes

down.

Turnon the power switchand stop the machine at the needle downstop position so that the distance between the top ofthe
needle plate and th lowerend of the needle clamp screw Is 18~22mm. (Asfor the model 8798, the distance Is22~26mm.)

Position

★

adjustment

for

needie

up

signal

Stopthe machineatthe needleupstop

and

medium materials,

and

10—12mm

position.

The needle pointstops

for thick materials.

9—11

mmaway

from

the topofthe needle plateforthin

(As for the model 8798, the needle point stops 11—14mm away.)

When

the needle

point

does notstop

properly,

loosenthe screwO and movethe needie up stop sensor 0 foradjustment.

When the needle up stop sensor 0 Is moved Inthe rotatingdirection, the needle bar comes down. Andwhen Inthe reverse

direction,

the

needle

bar

comes

up.

• Tighten the screw 0 and O by the force of 6—lOkg-cm.

with

the

0,

-10-

Synchronizer

Model DB2-B737 •

B748

18--22

mm

Reference

e

★

The

synchronizer

The

thread trimmer signal is timed to the

★

When the power is turned on and the needle stopped in the down position, the distance between needle plate top and needle

set

screw

When the needle Is
between

needle

(With Model B748
Adjustasfollows

★

Turn

the

power

Needle

up

position

1. Slightly loosen the two screws
Move the

to

Needle

1.

Set
The

2.

set

lower

the

down

the

treadletoreverse

needle

bottom

detects

should

plate top

when

the

be

stopped

in the up position

and

the

needleupstop

necessary.

needle

18to22mm.

needle

position with two

needle

down position signal

and

the pulley reference line is within

tip should be 10 to 12 mm withthin

position is

10~14mm.)

sensors.

and

the treadle

the

and

reguiar materials, 10 to 14 mm withthick materials.

belt

reverse

cover

signal.

reference

lines, the

distance

off.

O-

screws O inthe direction of normal pulley movement to raise the needle bar O stop position. Turn the other way

needle

position

plate top to

bar.

and

needle

then

screw

release

bottom

it to neutral. (This is

gap

should

be

18—22mm.

the

needle

down

stop

position.)

3. Loosen screw and move the synchronizer O to adjust.

★

Check

the

needleupstop

★

When the machine puliey is removed

installation.

(Improper

When

★

Turn

Use

clearance

the

synchronizerisoutoforder.

off

the

power

switch

the

machine

with

causes

standard

position.

improper

and

disconnect

function (without

once,

machine

. .

provide

operation)

the

synchronizer

0.5mm

thread

clearance

cord.

trimming) until

beween

the

pulley bottom

the

synchronizerisreplaced.

and

the

synchronizer for

-11-

[^Control

Control

The high

box

speed

box

(Model DB2-B737)

volume, backtack stitch volume, power lamp, needle position switch, one-stitch modification switch, slow start

switch and connector for synchronizer

control

The

The

The

three-phase
The
*Do not fail to

•Never

circuit

board.

control

power

right

control circuit board is provided with

circuit

boardisinstalled

circuit

board

side

wall is furnished with

type

and

secure

short-circuit

the

two

the

is at

3A

fuse

lamp

the

fuses

holder

terminal

are

arranged on the front of

on

the

insideofthe

back

and

the

treadle

one

15A fuse for

for 380—440V

the

8A

cap

after replacing or inspecting

(AC6Vor

the

control box.

control

unit is on

the

three-phase

fuse

for solenoid load.

12V

terminal)Wlighting,orthe

box.

the

110~240V

type.

single-phase type, two 5A

left

the

side

fuses.

All

these

wall.

transformer

parts

are

fuses

maybebroken.

already provided on the

for

the

200~240V

Control

Explanationofeach

*Do not turn

Model

1.

2.

circuit

the

volume knobs when not necessary.

B737•B748•B791•B793•B795•B798

Take

off

the

When

the

LOW VR O (low

volume

front

board

knob

cover.

speed

thread trimming) is turned clockwise, the

low machine

creases.

3. When

the

speed

is adjusted to in

EBT VR O (end backtacking

speed) is turned clockwise, the backtack

ing

speedisadjustedtoincreases.

4.

The

SBT

VR O is

and

continuous backtacking

volume.

start

backtacking

speed

5. The HIGH VR O is high sewing

adjust volume.

6.

The

AUTO VR 0 is

speed

adjust volume.

automatic

7. The SLOW VR 0 is slow start

adjust

volume.

8. When the

is

turned

VR1

O is (brake-offtimming set)

clockwise,

the

brake

adjusted to increase. And when counter

clockwise, it is

adjustedtodecrease.

9. When the TVR0 (torque setting) is turned

clockwise, the torque is adjusted to in

creases.

and

speed

adjust

speed

sewing

speed

force is

AUTO 0

Automatic

speed

LOW O
Low

speed

EBT 0

Backtacking
speed

SLOW ©

TVR ©

Torque

setting

m

Brake-off

time setting

CAUTION:

Other volume knobs are factory set, so that they never require adjustment.

Note 1: Itis dangerous to touch the volumeknobs by finger because highvoltage is applied. Do not

fail

to turn offthe power

switch before adjustment. To check the setting, tum it on again.

Note 2: Take care that the driverdoes not touch other parts but the volume knobs for adjustment. Adjustthe volumeknobs

great care. They may be broken if turned past the stop point.

Note 3: When any volume knob is turned by mistake, turn it back so that the red indexes match

-12-

with

each other.

with

Explanation

each

dip

switches

Dip A

1

2 Position of

3 Position of

4

5

6

7

8

Position of
thread

presser

trimming

presser

thread

trimming with

at

neutral

presser

machineisstopped

treadle
Double

Double

AB-i-10

CD-I-10

Continuous
selection

at

neutral

start

end

backtack

backtack

backtack

backtack

backtack

after

after

treadle

when

with

ON

OFF

ON

OFF

ON

OFF

ON

OFF
ON

OFF

ON

OFF

ON

OFF
ON

OFF

Down

Raised
Raised

Down

Raised

Down

Double

Single

Double

Single

10

stitches
Seam
10

stitches

Seam

A-l-C, B-i-C,

A, B, C, D

Dip B

1

2

3

4

5 Normally ON

6

Start

Start
stitch

Actuator

Unused

backtack

and

End

number

switch

selection

backtack

ON

OFF
ON
OFF

ON
OFF

Normally

Stops

Sews

to

Fixed 4-stitches setting

Fixed

at4stitches

Thread

none

start

backtack

start

backtack

end

backtack

end

backtack

addedtothe

AB

sewnasdisplayed

addedtothe

CD

sewnasdisplayed

sewn

(W)

(V)

(W)

(V)

displayed

displayed

repeatedlyDtimes

OFF

when

treadle

endofB

is returned to neutral

when

treadle

becomes

trimming controllable with

AB

seam

CD

seam

isatneutral

variable with

actuator

length

length

switch

models

E-20, E-40

Model

B7380

1.

Take

off

the

front

cover.

mnn

n

2. When

VR1

O (low speed and thread trimming) is turned

clockwise, the low machine

speed

increases.

3. VR2 O (backtacking speed) is preset at ISOOspm. It

require adjustment. (Do not touch

i

varies.)

4. VR30 (automatic speed) is changed bythe maximum sewing

speed

volume knob,soVR3 requires no adjustment.

VR2,

5. When TVR O (torque setting) is turned clockwise, the torque

increases.

6. When the

the

decreases.

CAUTION:

other

volume knobs

O

SVR

CVR

are

BD

\ \ ©

\ OVR2

OVRI (Low speed)

factory

VR3

(Backtacking)

set,

OS

so that they never require adjustment.

Note 1: It is dangerous to touch the volume knobs by finger because high voltage is applied. Do not

switch before adjustment. To

Note 2: Take care that the driver

great care. They may be broken if turned

check

the

setting, turn it on again.

does

not touch other parts but the volume knobs for adjustment. Adjustthe volume knobs with

past

the stop point.

brake

VR1

O (brake-off time setting) is turned clockwise,

force

increases.

When

turned

fail

Note 3: When any volume knob is turned by mistake, turn it back so that the red indexes match with

does

not

or the stop position

counterclockwise,

to turn offthe power

each

other.

it

-13-

Use

1-pin

1-pin DlPA ON

open

short

of

2

DlPA

3

the

OFF

ON

presser

After

Allways up at neutral

Down

Allways upatneutral
DownatO

Allways

Up at O

irrelevance

foot

thread

at O

down

connector

trimming

at neutral

(1-pin)

1-pin

and

Stop
Allways up

Down at O

irreevance

Allways up at neutral

Down at O

Allways

DIPA2, 3

state

after

at

downatneutral

Up at O

connector

returned

neutral

to neutral

Presser

foot conditions

Presser

Low

are

indicated by UP (raised) and DOWN (lowered).

foot

speed-High

connector

speed

Thread

trim

Treadle

operation

Motor

brake

Asbestos

* Adjust

does

Adjustment

1. It is
setatapprox.

2. Remove the screw O

3.

Remove

brake

spacing

the

brake

not

stop

stably.

Procedures

recommended

0.2

theVbelt.

spacing

that

mm.

when

about

you

remove

and

the pulley cover

two

years

the

motor pulley

have

O.

passed.

and

4. Remove the nut O and the motor pulley assembly O-

5. Remove the

thickness, 0.1mm, 0.15mm and

washer

© from the shaft ©sothat

0^.3mm.

Adjust the brake spacing approx. 0.2mm by removing the waher

the

brake spacing

0.2

mm

Window fro adjusting

the brake spacing

And

also

measure

the

0.1

mm

O

adjust

when

brake

spacingInadvance.

becomes

0.2mm. The

the

brake

0.15mm

generates

The

washer

0.3

mm

abnormal

brake

spacing

noises

is factory

and

© is available with the

©.

Cork

brake

★

Check

for

brake

lining

wear

(excessive

worn (the gap is large), replace the brake

Replace

1. The brake

2. Remove screw

3.

4. Remove nut

5. Remove the three

Remove

the

brake

the

liningasfollows.

lining

gap is factory-adjusted to approximately 0.2mm.

O.

and remove the pulley cover

V-belt.

©.

and remove the motor pulley assembly

set

screws

©,

Use supplied spacers © to adjust the brake

There

are

three

spacer

thicknesses:

gap)ifthe

lining

and

replace the brake

lining

0.1mm,

-—0.2

mm

brakes

become

noisy or

©.

©.

©.

lining

©.

gap to approximately 0.2mm.

0.12mm,

0.15mm.

the

sewing

stop

position fluctuates. If

0.1

mm

O

0.12mm

0.15mm

0

the

lining is

Note 1: Pulley Ml25 O for

brake.

Note 2: For the cork brake, be

because

rubbing will

the

asbestos

sure

cause

brake cannot be installed to the cork

to adjust so that the brake

excessive

brake

wear.

-15-

lining

does

not rub,

N0.123456J"

J

cork

and

thereafter

brake.

indicate

[7|

Brush

replacement

1. Be

sure

to turn off tfie

2. Disconnect tfie motor plug.

3. Remove tfie clamp

4.

Remove

tfie

bruslies

power

screws

©.

switcfi.

O-

5. After cfiecking tfie reference line of tfie brusfi

usable

brusfi Osotfiat tfie

treadle unit. Replace tfie brusfi

a

new

one.

6. Tigfiten tfie clamp screws ©

7. Connect tfie motor plug.

reference

used

witfi

line O directs toward tfie

to tfie reference line©

10~15kg/cm

0,

torque.

mount tfie

witfi

Checking

o

the

lamp

terminal

f-o

Lamp

o

tap

code

* Tfie lamp terminal cord © is provided at tfie back of tfie control

box. Tfie AC 6V or 12 V lamp

terminal

Tfie lamp terminal cord

Black

Grey

For tfie lamp cord, tfie primary

CAUTION:

Be

suretowrap

tfie

lamp

cord

cord

cord.

cord.

tfie

6V

12V

end

20W

20W

of tfie

canbeconnected

side

is insulated by tfie transformer.

cord

witfi

tape

witfi tfiis lamp

after

disconnecting

o

Primary

side

Secondary

side

-16-

TROUBLESHOOTING

When

the

troubleshooting is required, inspect

operation panel box, synchronizer, power switch, machine solenoid
When

the

control box is found to be out of order, inspect

separately.
Whatever

troubles

you

encounter,

check

Pay great attention to the maintenance of

Refer to

1.

2. The machine

3. The machine

4.

5.

6. Abnormal motor running (variation in rpm)

7.

8. The operations related to the machine solenoid do

9. Abnormality related to automatic backtacking, etc.

the

circuit drawings provided

The

machine

does

treadle while
(1)

(2)

(1)

(2)

power
neutral position.

The

The
returnedtothe

The

operation.

not

work.

(thread trimming,
and

the

Power

indicator lamp (red LED)

ON.

Power

indicator lamp (red LED) is ON.

stops

Power

indicator

Power

indicator

flicker.

starts

switch

machine

does

machine

does

brake

produces

presser)

Trouble

not run

evenbysteppingonthe

power

switch is ON.

during operation.

lamp

(red LED) flickers.

lamp

(red LED)

running just by tuming on the

even

with

the

treadle

not run at high

not

stop

evenifthe

neutral position.

abnormal

reverse

rotation,

noises

thread

does

does

set

speed.

treadle

during

not go

in the

wiper,

separately

whether

the

separatelytocheck

Check

(Try to plug into

Fuse

blown:

(Replace

Check

(Check especially the 6P connector of the motor.)

The

machine

[The machine or the motor (brake lining) is locked.

Remove

machine

Power

not

(The motor is not out of order.)

Check whether the high

(The

rangeofthe

the

maximum.)

If

the

is

machine

such

main

the

control circuit board, power board, treadle unit,

the

connectors

power

and

control circuit boards

the

quality of

Check

the

power

source

voltage.

another

outlet.)

3-phase5Afuse

Single-phase 15 A fuse (1 pc.)

with

new

ones.)

whether

the

connection

the

should

source

pulley is to

cause

run normally.)

voltage

high

stops

heavy

and

tumonthe

drop.

speed

speed

after tuming off

removing the synchronizer switch, then turning it on
again, the synchronizer is out of order.

(Useasa clutch motor for a while,.)

Adjustment of

Check the 8-A fuse provided on the control circuit

traard.

brake

clearance

_________

partsasthe

and

are

secured.

the

Point

(2 pcs.)

are

secured.

to tum manually.

volume is

control is from

the

control box, motor, operation

pressure

detailed

power.

set

to "Low".

215spm

power switch,

foot lifter.

because

parts

The

to

the

(semiconductors) for maintenance.

Parts

to Be

Fuse

Control

t}ox

Control

box

Control

box

Power

switch

Control

box

Synchronizer

Control

box

Remove

washer.

8-A

fuse

Control

box

Control

box

Operation

panel

panel

box, motor,

and

transformer

high voltage is applied.

Replaced

assembly

Ref.

P.I

Page

5

P.19

-17-

CHECKING

Q]

Motor

THE

MOTOR

Motor

Approx.

1.2

Brake

ohm

Approx.

0.3

ohm

Brake

Black

coil

approx.8ohm

W

Torque

Yellow

Revolution

thermister

Black

Black

Yellow

thermister

Remove

of

Measure
If

(red)

should

motor pulley slowly. If it

the

the

the

motor cord

control

tester

and

read

box.

with

the

reads

6 (black) with the resistance range x 1, it is normal. It

approx.

(6P

connector)

tester

setinthe

approx. 2-3 ohm at

2-3ohmateach

reads

approx. 10

resistance

any

position while turning

positions, it is out of order. However, if

much

extent

while turning

after stopping

If

the

tester

the

reads

position between 3 (black)

range

x1,

it is normal.

If

the

tester

reads

position between 1 (yellow)

range

x1,

it is normal.

Remove

1.

of

2.

Measure

• If

the

the

the

control

with

tester

brake

box.

the

reads

tester

the

motor pulley,besuretomeasure

pulley.

approx. 5K-40Kohm

and

6 (black) with

approx. 5K-40Kohm when

and

2 (yellow) with

cord

(2P

connector)

setinthe

resistance

approx. 7-9 ohm when

position between 1 (black) and 2 (black) with

range

xl,

it is normal.

from

the

connector

rangeasfollows.

position

between

ohmormoreatsome

the

pointer swings to

when

measuredatany

the

resistance

from

measured

the

the

connector

at any

resistance

rangeasfollows.

measuredatany

the

resistance

part

4

the

part

-18-

CHECKING

Q]

Solenoid

load

THE

of

MACHINE

the

machine

SOLENOIDS

1.

Remove

2.

Measure

<

Machine

•

The

•

The

•

The

<

Presser

•

The

•

The

Connector

Reverse

Reverse

solenoid

l-W—I

Thread

solenoid

the

load

connector

with

the

tester

Head>

thread

trimming solenoid at pins 4

thread

wiper

solenoidatpins7and

actuator

presser

presser

at pins 9

Lift>

lift solenoid at pins 1

lift switch at pins 2-5 is normal if

from

switch

<5®©i

wiper

(12P

setinthe

and

12

the

machine

®®|®.

—w-l

Thread

solenoid

connector) of

resistance

and

is normal if

and

4 is normal if

head

-=•

GND

trimming

the

machine

range

xl

5 is normal if

8 is normal if

the

tester

the

tester

as

the

reads

the

follows.

the

tester

Oohm

tester

Oohm

from

tester

the

reads

reads

when

reads

when

Presser

foot

Solenoid

[—W—I

Knee

switch

connector

approx.

pressed,

approx. 5ohm.

pressed,

partofthe

approx.

5ohm.

and

lift

connecter

®©®

7ohm.

and

<»ohm

<»ohm

=

GND

control box.

when

when

released.

released.

-19-

/r\

>

9S

lU

Three

Voltage

Power

Source

B737

Mark

220V

380V

415V

B7380

220V

380V

415V

to

o

B7910

220V

380V

415V

1 Digit

D

La

12V

NIL

12V

12V

NIL

12V

12V

NIL

12V

mp

II

6V

6V

6V

6V

6V

6V

6V

6V

6V

phase

Destination

USA/Canada

Germany

France

U. Kingdom

USA/Canada

Germany

France

U. Kingdom

USA/Canada

Germany

France

U. Kingdom

2 Digit

Treadle

Ref.

A

B

1-6

291812-

291817-

291820­291821-

291824-

291827-

291844­291847­291848­291849-

291850­291851-

291813-

291818-

291854-

291822-

291825-

291856-

unit

#10

#11

control

Parts

Code

Digit

r.p.m.

DB212A

DB212B

DB212A
DB212C
DB212B

DB212A

3 Digit

Pulley

size

Ref.

1
2

3

4
5

box

No.

020 025 035

2000 2500

DB322A DB342A

outer

Meter

DB322B

DB322A

DB322C

DB322B
DB322A

dia.

75

80
90

105
125

DB342B
DB342A DB552A

DB342C

DB342B DB552B
DB342A

DB348A
DB348B

DB348A

DB348C

DB348B

DB348A

DB349A
DB349B

DB349A

DB349C

DB349B
DB349A

4 Digit

Ref.

1

2

3
4

5

6
7

8

3500

DB552A

DB552B

DB552C

DB552A

spm

2000

2500

3500
4000
4500

5000

040

4000 4500

045

DB562A
DB562B

DB562A

DB562C

DB562B
DB562A

DB569A
DB569B

DB569A
DB569C
DB569B
DB569A

Control box

Ref.

1

2

6 Overlock

8

9

7.8.9

5 Digit

B737MII

B7380
B7910

Digit

050

5000

DB572A

DB572B

DB572A
DB572C
DB572B

DB572A

DB578A
DB578B
DB578A

DB578C

DB578B
DB578A

Spec.

(Semiauto)

spec.

046

4500

B795
DB462A1
DB462B1
DB462A1

DB462C1

DB462B1
DB462b1

047

4500

B852

DB562A2

DB562B2
DB562A2

DB562C2

DB562B2

DB562A2

6 Digit

Ref.

A

B
C

033

3000

DB332A3
DB332B3
DB332A3

DB332C3
DB332B3

DB332A3

Voltage

•6V

12V

NIL

038

3500

2

Needle

DB342A3
DB342B3

DB342A3
DB342C3
DB342B3
DB342A3

TYPE

No.

DB572A

A 8 E

043

4000

DB352A3

DB352B3
DB352A3
DB352C3

DB352B3

DB352A3

12345-

Code

291825001

291826001

291825001

291826001

291825001

291826001

-Production

Modification
Year

Month

No.

Motor

Type

MD-813A

MD-813B

MD-813A

MD-813B

MD-813A

MD-813B

serial

No.

No.

H

Vi

O

o

o

(S)

2

o

(/I

o

fd

Cfl

Id

>

H

C/5

W

Single

Voltage

Power

Lamp

Source

B737

Mark

110V

12V

220V

NIL

230V

NIL

12V

240V

B7380

lO

I

110V

220V

230V

240V

B7910

110V

220V

230V

415V

12V

NIL

NIL

12V

12V

NIL

NIL

12V

II

6V

6V

6V

6V

6V

6V

6V

6V

6V

6V

6V

6V

phase

Destination

USA/Canada

Germany

France

New

Zealand

U. Kingdom

Australia

USA/Canada

Germany

France

New

Zealand

U. Kingdom

Australia

USA/Canada

Germany

France

New

Zealand

U. Kingdom

Austraiia

control

Parts

Code

1-6

Digit

r.p.m.

291798-

291801­291802-

291805­291806-

291807-

291808-

291809-

291828­291830­291831­291833-

291834-

291835-

291838-

291837-

291799-

291835-

291836-

291838­291839­291840-

291841-

291842-

box

No.

020

2000 2500

DB212A

DB212B
DB212A

DB212C

DB212A
DB212C
DB212B
DB212A

025

DB322A

DB322B

DB322A
DB322C

DB322A

DB322C
DB322B DB342B
DB322A DB342A

035

3500

DB342A

DB342B

DB342A

0B342C
DB342A DB552A
DB342C

DB348A
DB348B

DB348A
DB348C

DB348A
DB348G
DB348A

DB348A

DB349A

DB349B

DB349A
DB349C
DB349A

DB349C

DB349B
DB349A

040

4000

DB552A DB562A
DB552B

DB552A

DB552C

DB552G DB562G

DB552B

DB552A DB562A

045 050 046 047

4500

DB562B

DB562A

DB562G
DB562A

DB562B

DB569A

DB569B

DB569A
DB569G

DB569A
DB569G

DB569B
DB569A

7.8.9 Digit

DB572A

DB572B

DB572A
DB572G
DB572A

DB572G

DB572B

DB572A

DB578A
DB578B

DB578A

DB578G
DB578A
DB578G
DB578A
DB578A

5000

4500

B795 B852

DB462A1

DB462B1

DB462A1

DB462G1

DB462A1

DB462G1

DB462B1
DB462B1

033

4500

DB562A2

DB562B2

DB562A2

DB562G2

DB562A2
DB562G2
DB562B2 DB332B3
DB562A2

3000

DB332A3
DB332B3

DB332A3 DB342A3 DB352A3

DB332G3 DB342G3

DB332A3

DB332G3 DB342G3 DB352G3

DB332A3

038

3500

2

Needle

DB342A3 DB352A3

DB342B3

DB342A3

DB342B3

DB342A3

043

4000

DB352B3

DB352G3
DB352A3

DB352B3

DB352A3

Code

291823001

291824001

291823001

291824001

291823001

291824001

No.

Motor

Type

MD-803G

MD-803B

MD-803G

MD-803B

MD-803G

MD-803B

SPEED

HI

Selection of motor pulley

1) Selection of motor pulley

Select the correct motor pulley for relative machine according to the

ADJUSTMENT

(Remark): The figures described for motor pulley are outer diameters of V groove.

2)

Replacement
a)

Take

b)

Remove

c) Unfasten pulley

d) Assemble them back in reverse way.

(Remark): In

121

Adjustment of

1) Adjustment of high

a)

Setupthe

b) High sewing

right in full.

c)

Remove

turn

When

(Remark): Turn VR to

d) Put power switch on

the maximum

adjustment.

2) Adjustment of
a)

Open

b)

Put

Set

c)

E20, E40 or

Depress

d)

Remove

e)

Depress the pedal backward then the machine keeps running at backtacking

f)

EBT.

3) Adjustment of
a)

Open

Depress

b)

Remove synchronizer plug from control box

c)

machine

After adjustment, put power switch off,

d)

of pulley

off pulley

V belt

cover

set

screw,

case

the pulley is exchanged,

each

speed

machine

speed

the

rubber

the

inside volume

it is turned to

speed

the

mal

end

the

cover

power

switch

operation panel and put only end backtacking switch on. (even in

E100

the pedal forward to put it back to the neutral position then stop the machine at needle-down position.

synchronizer plug from control box.

thread

the

cover

the pedal forward lightlyto put it back to

keeps

& motor.

volume in front of control box to the

cockatrear

O-

the

right,

the

adjustmentfrom lower

troubles

speed.

and

backtacking

can

and

keep

under this condition, make

of control box.

on.

operation panel)

trimming

of control box.

running at low

M5xl2

FOR

screw (3 pcs.)

and

EACH

method of replacement

each

speed

sideofcontrol

the

machine

left first

be

speed

speed

and

avoided

the pedal lever down to

speed

box

speed

then,

speed

thereby

duetoabnor

and

depress

therefore

close

MACHINE

speed

and

up.

make

speed

separate

and

then

exchange

of high speed, backtacking speed, low

Inside volume O

list.

the pulley.

speed

0^

caseofEO,

the

neutral position then stop the machine at needle-down position.

the

pedal forward to put it back to

make

adjustment by VR LOW.

the

cover

and

then, insert synchronizer plug.

make

necessary

speed

therefore make adjustment by VR

the

adjustment using

neutral position then the

will

change.

In

case

the

torque

but in

that

case,

maximum sewing

becomes

make
speed

insufficient

suretoselect

of machine. Machine pulley

duetosome

such

pulleys

specific sewings,

that

speed

of DC servomotor will notbemore

mustbecalculated

-22-

use

one-class

basedonthe

smallerpulley to

effective

diameter

increase

than

of approx. 70 mm.

the

3,000

torque

RPM at

Explanation

of

each

VR

(printed-circuit

board

BPD500-1)

VR

name

LOW

(VR1)

EBT

(VR2)

SBT

(VR3)

HIGH

(VR4)

AUTO

SLOW

VR1

(VR5)

TVR

(TVR)

SVR

(SVR)

CVR

(CVR)

Remark :

Low

speed

End

backtacking

speed

Start&continuous

BT.

speed

High

speed

Auto

speed

Slow

start

Brake

power

Torque

Voltage

Current

limit

Speedisbased

CONTENTS

Inching

and

trimming

setting

End backtacking

ting

Start

&

tacking

Speed

depressed

Auto
Slow

Brake off

Torque

trimming

Standard

continuous

speed

setting when pedal Is

at maximum

process

start

speed

speed

speed

setting for Inching &

speed

setting of all

Setting of maximum electric

on

current

125

Into

motor

pulley. ( ) Is prlnted-clrcult board E or C.

speed

setting

setting

setting

speed

set

back

setting

speed

ANTI-CLOCKWISE

Decrease

about

Decrease

Decrease

Decrease

Decrease
Decrease
Brake

effective

power

Penetration

Ineffective

Speed

Speed

reduction of all

down at

about

low

low

low
low

power

150spm

I.OOOspm

speed

speed

speed
speed

becomes

becomes

the

start

In

CLOCKWISE

Increase

Increase

Increase

Increase

Increase

Increase

at>out

about

about

5,000spm

4,800spm

1,500spm

Brake power

tive

It

makes

ping

accuracy

worse

Speed

transistor

Break

Increase

downofthe

becomes

hunting

300spm

2,500spm

3,000spm

effec

and

stop

becomes

of all

power

Sewing

Model

No.

Spec

B737-1

-3

-5

B747-5

B748-7

B798

B852
B853

B854

B791-3

-5

B793-403

B795

B842-3

-5

speed

&

of

High

each

Speed

4,000

5,000

3,500

3,500
2,500

2,000

4,500

4,500
4,500

4,500

3,500

4,500
4,500

4,500

4,000

3,500

machine

Each

Sewing

Speed

Backtacking

Speed

1,800
1,800
1,800

1,800

1,800

900

1,800

1,800
1,800

1,800
1,800

1,800

1,800

1,800

1,000
1,000

Thread

trimming

speed

215

215
215

215
215

215

185 125
185

185

215
215

215
215

215

185

185

Motor pulley

(outer

diameter)

125

125

90

90

90

80

125

125

125

90

125

105

105

90
90

B845
B847
B848

3,000
4,000
3,000

1,000

1,000

1,000

-23-

185
185
185

90

90

90

NOTES

(1)

Be sure,

Be careful to not use a single-phase powersupply. Even ifsingle-phase is used, there may be no abnormal condition.

however, that quick repeated starting and stopping
(The fuse interior

(2) The power supply voltage should be

(3)

Securely connect each connector. The

(4)Ifsingle-phase 110V is used,

For that reason, indoor

(5) For cold regions,

Inparticular, needle

(6)

Needle

wiped

(7)

Avoid

use near anyequipment, such as a

will

cause operational errors and/or damage to the D printed-circuit board (fuse

(8) For a three-phase powersupply, if130% or higher of the rated voltage is applied,the fuse

black), thus protecting the control circuitry.

REGARDING

for

use of a three-phase

will

care

(lower)

(lower)

stop

willbeabnormal

clean.

DC

power

not become black.)

±10%

all

functions

wiring

capacity should be 20A or higher, and the use of extension cords should be avoided.

shouldbetaken

stop

will

be abnormal ifmoisture condensationoccurs on the reflector plate of the synchronizer.

ifthere is

MOTOR

supply,

6-pin

will

to avoid moisture condensation.

high-frequency

to check the

will

cause

of the rating.

connector

stopifthere is even a

oil

orgrease onthe

from

welder,

INSTALLAtTo^

connection

the fuse to

the

motor

reflector

etc.,thatemits

of the

power

plug.

fail.

is, in

particular,

momentary

plateofthe synchronizer, so itshouldbe

drop of the voltage to 75% or

high-pitched

failure).

very

important.

noise,because such equipment

will

melt (fuse interior becomes

Note,

below.

carefully

-24-

(DC

MOTOR TROUBLESHOOTING GUIDE

CjEZD

Set

the

control

• Needle

er)

•

Correction-none

•

Slow

start-none

•

Set

the

all the way to the left.

Set

all

switchesinthe

boxtoOFF.

Set

the

swtichtoOFF.

Set

the

box

position-needle

maximum

machine's

thread

treadletoneutral.

switches:

speed

operation

(low

VR

wiper

Press

Does

Return

Does

Set

the

all

the

speed)

the

treadle

the

machine

at low

the

treadletoneutral

the

speed

way to

the

slightly forward

operate

speed?

machine

stop?

adjustment

right (maximum

control

Set

the

Canaclear

power

switchtoON.

brake

sound

("click")beheard?

Is

the

control box

illuminated?

lamp

Is the operation box lamp

illuminated?

Gradually

depress

the

treadle

forward until it's completely

pressed

Does

the

machine

speed become high speed

in

accordance

the

treadleisde

with

the

amount

pressed?

Return

the

treadletoneutral

Does

the

the

forward

there

brake

decelaration?

needle

stop?

depression

steps

vanance

(lower)

stopping

function during

Does

(lower)

Repeat

the

and

return to neutral

Is

of

the

needle

position?

de

Is

the

Is

the

machine

stopped?

needle

(lower) stopping position

-25-

good?

Depress

operate

the

Does

treadletothe

the

machine

at low

speed?

rear

Depress

Does

the

the

actuator

treadle

fonivard

function?

Does

the

thread

tnmmer

(upper)

Yes

fonvard

depression

there

needle

Does

the

Repeat
ward

treadle

varianceofthe

function?

needle

the

Is

(upper) stopping position?

and

stop?

back

steps.

Depress

Set

the

pedal backward

the backtacking

speed

(con

trol box) to minimum.

Set

the

front

and

end

backtack

switches (operation box) to ON.

Set

the

stitch

countasdesired

Depress

the

treadle

fully forward.

Is

there

forward backtacking

at low

speed?

Is the

needle

position

Set

the

switchtoON

Depress

backward

Does

machine's

the

the

Is

the

thread-wipe time OK?

(upper)

good?

treadle

thread-wipe

stopping^No

thread-wipe

fonivard

and

function?

Is

the

stitch

count

Does

high

speed

begin after completion of

forward backtacking?

Return

the

treadle

Once

again

depress

forward.

Is

there

forward backtacking?

OK?

to

neutral

the treadle

-26-

Is there high-speed sewing?

Set

the

treac

Jletoneutral.

Set

Is

there

fixed-stitch

the

treadleto

low-speed

sewing?

neutral.

Depress

Is

Is

there

the

the

stitch

tr(

end

After

completion of end

backtacking,

do the thread

thread wiper and needle

(upper) stop?

^adle

backward.

backtacking?

count

OK?

trimmer

Depress

Set

the treadle backward.

the

thread-trim switch

tion box) to ON.

Depress

SwitchONthe

Is

there

and

the

fixed-stitch

thread

co

ing (operation bo

desired

stitch

cou

Depress

the

(opera

t

readle

forward.

sewing

cutting?

ntinuous

backtack-

x) and set to the

nt.

t

readle

forward.

No

Set

the

treac

tietoneutral.

Set

the

start

and

end

backtack

ing switches (operation box) to

OFF.

Set

the fixed-stitchsewing switch

(operation box) to ON

desired

stitch

Set

the high speed-adjustment

count.

and

set

the

control all the way to the left

(minimum).

Depress

the

tr

eadle

forward.

-27-

Is

there

backtacking?

there

Is

Set

SwitchONthe

thread trimming?

the

treac

con

trol box).

Set alloperationbe

continuous

lietoneutral.

ection switch (con-

)x

switchestoOFF.

After

depressing

turn to neutral

machine.

Switch

ON

the

Is

there

correction

the

treadle, re

and

actuator

one-stitch

sewing?

stop

switch

the

Does the needle (upper) stop?

Set

the

needle

(control box) to

#

31

position switch

needle

(lower).

Switch

OFF

the

correction

switch

(control box).

Depress

Switch

ON

the

the

treadle

slow

backward.

start

switch

(control box).

Set

the speed-adjustmentcontrol

all the way to

the

right (maximum

speed).

Depress

Are

the

the

ti

eadle

forward.

first

two stitches at lowspeed, and"

^hose thereafter at higl^

speed?

No

Completely

forward.

Move

trol

from

the

depress

the

speed-

the

min

maximum p

the treadle

adjustment

mum

position to

osition.

Does the speed

change in accordance with the

setting of the speed-

adjustment control?

Yes

Return

the

treadletoneutral.

End

C

)

con-

Set

the

treat

Switch

OFF

the

(control box).

Set

the

needle

(control box) to

Completely depre

ward,

and

then

Yes

lietoneutral.

slow

start

position switch

needle

(upper).

5S

the

treadle

tumitto

re

switch

for-

neutral.

-28-

ITEM

#1

and

#2

#3

#4

#5

#6

#7

PROBLEM

No

"click"

from

power

ON.

Control box

doesn't

No

illumination

sound

brake

when

is switched

lamp

illuminate.

of

operation box lamp.

Machine

starts

when

power is switched

ON.

Machine

operate.

Machine

reverse.

Unsuitable

speed

Machine

high

speed.

Machine

when

treadleisset

neutral.

Operation

correspond

amount

doesn't

operates

low-

operation.

operates

doesn't

doesn't

to

of

treadle

stop

depression.

CHECKING

• Is

the

PROCEDURES

connection

4-pin or 3-pin power plug

OK?

•

The

fuse

(outer

control box)

•

Fuse

fails

again

placement.

•

The

fuse

(8A

the

control box)

•

Other

than

the

•

Does

the

operation

function correctly? (YES)

•

Other

than

the

•

Does

the

control box

flash?

•Isthereamotor

•

Other

than

the

in

at

to

•

Uneven

dle

• Initial

operation at

maximum.

operation

fast (no low-speed range).

has

failed.

fuse

has

above.

above.

above.

speed

of

side

(YES)

after

failed.

noise?

the

of

re

inside

box

(NO)

lamp

(YES)

(YES)

trea

PROBABLE

Power

connected.

Fuse

Malfunctionof8A

plug is incorrectly

has

CAUSE

failed.

control printed-circuit board.

Malfunction

of

the

printed-circuit board.

Bulb

failure-no

problem.
Malfunction of

box.

Malfunction

printed-circuit

Malfunction

the

of

board.

of

the

the

printed-circuit board.
Malfunction of

circuit

board.

(single

phase

the

110

er)

Large

torque

Malfunction

printed-circuit

Malfunction

Large

torque

Malfunction

Malfunction
Malfunction

Malfunction

Synchronizer
position is not
Synchronizer

(head).

of

control

board

of

treadle

(head).

of

treadle

of

treadle

of

treadle

of

treadle

installation

good.

malfunction.

Control printed-circuit board

malfunction.

is

Malfunction

Malfunction

Malfunction

of

of

of

treadle

control

treadle

fuse,

the

control

functional

operation

control

control

D printed-

V or high

unit.

unit.

unit.
unit.

unit.

unit.

box.

unit.

REMEDY

Connect

the

power

rectly.

Replace

Replace

trol

Replace

box.

Replace

Replace

Replace

Replace

Replace

motor.

Reduce
Replace

Replace

Reduce

Replace
Replace
Replace

box.

the

fuse.

the

motor

the

fuse

the

control box.

the

operation box.

the

control box.

the

control box.

the

the

torque.

the

control box.

the

control box.

the

torque.

the

control box.

the

control box.

the

control box.

Adjust VR LOW

Replace

Position

Replace

Replace

Replace
Replace
Replace

the

control box.

adjustment:

the

synchronizer.

the

control box.

the

control box.

the

control box.

the

control box.

plug

cor

and

con

and

control

control box

and

TVR.

0.5mm

-29-

ITEM

#8

#9

#10

#11

#12

#13

PROBLEM

Needle

doesn't

(lower)

stop.

Needle (lower)

at

various

Poor

dle

After

places.

position of

stop.

treadle

machine won't

ate

at low

speed.

Thread
doesn't

Needle
doesn't

trimmer
function.

(upper)
stop.

stops

nee

return,

oper

CHECKING

• Is

the

PROCEDURES

synchronizer

OK?

(NO)

(YES)

• Is

the

V-belt

loose?

(YES)

• Is

there

oil,

grease,

scratches,

etc.onthe

chronizer's reflecting

face?

the

• Is

motor's

braking

loud?

dirt

syn

sur

(YES)

noise

(YES)

(NO)

Is adjustment at synchroniz

er

possible?

(YES)

(NO)

• Is

thread

OK?

trimming

speed

(YES)

(NO)

• Is

the

pins) in
connected?

•

Does

1-pin plug (of

the

the

thread

the

control box

(NO)

trimmer

solenoid switch ON?(YES)

(NO)

• Switch

OFF

measure
the

thread

noid.

Is

there7ohms

and

© of

the

the

the

power

resistance

trimmer

between

12-pin?

and

sole

(NO)

•

Does

the

8A

fuse

(at
topofthe
circuit board)
mal?

• Is

the

OK?

control printed-

appear

speed

at low

nor

(NO)

speed

(NO)

• Is the synchronizer OK?

(NO)

(YES)

PROBABLE

Synchronizer

installation

position is not good.

Synchronizer

malfunction.

Control printed-circuit board

malfunction.

Insufficient

V-belt

Malfunction of

nizer.

Reduced motor braking

force.

Malfunction of

nizer.

Malfunction

of

printed-circuit board.

Poor position of needle (low

er) stop.

Reduced motor braking

force.

Low

speedistoo

Malfunction

printed-circuit

12

Improper

connectionofthe

1-pin plug.

Malfunction

thread

Malfunction

related

trimming.

printed-circuit board.

of

Malfunction

trimmer

of

solenoid.

O

8A

fuse

the

Speed

fast.

failure.

at low

Improper installation of

synchronizer.

Malfunction

of

printed-circuit board.

CAUSE

the

the

the

of

board.

of

the

speed

the

tension.

synchro

synchro

control

fast.

control

to

head

control

thread

is too

control

Position

Replace

Replace

Adjust
Replace

Adjust

ance.

Replace

Replace

Adjust

18—22

Replace

Adjust VR LOW

Replace

Connect

rectly.

Adjust.

Replace

Replace

solenoid.

Replace

Adjust VR LOW

the

Replace

Replace

REMEDY

adjustment;

the

synchronizer.

the

control box.

the

V-belt tension.

the

synchronizer.

the

motor

the

synchronizer.

the

control box.

needle

(lower)

mm.

the

motor.

the

control box.

the

1-pin plug cor

the

control

the

thread

the

8A fuse.

the

synchronizer.

the

control box.

brake

and

and

0.5

mm

clear

stop

by

TVR.

box.

trimmer

TVR.

-30-

ITEM

#14

#15

#16

#17

#18

#19

PROBLEM

Needle

(upper)

stops

at various places.

The

stop

needle

position of

(upper) is

the
not good.

Thread

function.

Thread

tion

function.

backtack.

timeistoo

Reverser

(when

pressed

is

switched

Does

wiper

doesn't

wiper

opera

short.

doesn't

treadieisde

and

actuator

ON)

not

forward

CHECKING

• Is

the

• Is

there

scratches,

chronizer's
face?

PROCEDURES

V-belt

oil,

etc.onthe

reflecting

loose?

grease,

(YES)

dirt

syn

sur

(YES)

(NO)

• Are

the

speed

and

torque

at low

speed

OK? (NO)

(YES)

•

Can
at

the

adjustment

synchronizer?

be

made

(YES)

(NO)

• Switch OFF the power

switch

and

then

measure

the

resistanceofthe

wiper

• Is

there5ohms

and

O of

solenoid.

the

thread

between

12-pin?

(NO)

(YES)

•

Other

than

above.

•

Can

the

reverser be

atedbythe

reverse

oper

lever?

(NO)

• Switch OFF the power

switch

and

then

measure

of

the

between

• Is

the
verse

resistance

there

solenoid.

7ohms

and 0 of the 12-pin?

•

Measure

the

Is

actuator.

there

the

Oohms

(YES)

resistance

between

and 0 of the 12-pin with

the

actuator

and

00

actuator

• Is itOKwhen

stitch count is

you try

ohms

switch

again?

switch

with

OFF?

the

backtack

changed

ON,

the

(NO)

(YES)

and

(YES)

(NO)

PROBABLE

Insufficient

V-belt

Malfunction of

nizer.

Malfunction

of

printed-circuit board.

Speed

slow.

at low

Operational malfunction re

lated

to

head

ming.

Improper needle (upper)

stop

position.

Reduction
force.

of

O

Malfunction

of

wiper solenoid.

Improper

thread

Malfunction

printed-circuit

installation of

wiper solenoid.

of

board.

Improper installation of the

thread

wiper solenoid.

Operational malfunction re

latedtohead

Malfunction

solenoid.

re

of

0

of

Malfunctionofthe

O

Malfunction

printed-circuit

of

board.

Malfunction of the operation

box.

Malfunction

printed-circuit

of

board.

CAUSE

tension.

the

synchro

the

speed

thread

motor

the

the

reverse.

the

actuator.

the

the

control

is too

trim

brake

thread

control

reverse

control

control

REMEDY

Adjust the V-belt tension.

the

Replace

Replace

Adjust

TVR.

Adjust.

Adjust
stop

Replace

Replace

solenoid.

Adjust

Replace

Adjust

the

the

the

VR LOW

the

position by

the

the

the

installation.

the

the

installation.

Adjust.

Replace

noid.

Replace

Replace

Replace

Replace

the

the

the

the

the

synchronizer.

control box.

and

needle

(upper)

10~12mm.

motor.

thread

wiper

control box.

reverse

sole

actuator.

control box.

operation box.

control box.

-31

-

ITEM

#20

#21

#22

#23

#24

PROBLEM

Does

backtack

number

not

of

(Note

stitch pitch

Won't

operate

speed

after

backtacking.

Forward
after

treadleisset

neutral.

Won't

sew

speed

after

backtacking.

Won't

reverse

tack.

fonward

the

stitches.

that

at high

forward

backtacks

at high

forward

back

CHECKING

• Is itOKwhen

set

c

are

is forward or

to

Same

stitch count is

you try

again?

mustbetaken

as

#19.

PROCEDURES

the

backtack

changed

(YES)

(NO)

because

reverse.)

PROBABLE

CAUSE

Malfunction of the operation

and

box.

Malfunction

of

the

printed-circuit board,

the

re is a dirference in stitch lengt

Malfunction

printed-circuit

Malfunction

of

board.

of

the

the

printed-circuit board.

Malfunction

of

the

printed-circuit board.

Same

as

#19.

control

control

control

control

REMEDY

Replace

Replace

h

dependingonwhether

Replace

Replace

Replace

Same

the

the

the

the

the

as

operation

control

control box.

control box.

control box.

#19.

box.

box.

the

#25

#26

#27

#28

#29

#30

#31

#31

Won't

forward

tack

set

stitch

Needle

thread

thread

stop

(upper),

trimmer

wiper won't

after

backtacking.

Won't

fixed-stitch

sew

at low

Won't

thread

after

fixed-stitch

ing.

Won't

thread

after

continuous

backtacking.

Won't

thread

after

continuous

backtacking.

Won't

1-stitch

tion

sew.

Won't

slow

Needle

stop
Speed

accordance

setting of

(upper) won't

(control box).

is not in

the

adjustment

back

count.

and

reverse

speed.

trim

sew

trim

trim

correc

start.

with

speed-

control.

the

Same

as

#20.

•Isit

OK

when

stitch count is

you try

•IsitOKwhen

stitch

you try

again?

countischanged

again?

the

changed

the

backtack

fixed-

and

(YES)

(NO)

and

(YES)

(NO)

Same

as

#20.

Malfunction

printed-circuit

Malfunction of

box.

Malfunction

of

board.

the

of

the

control

operation

the

control

printed-circuit board.

Malfunction of the operation

box.

Malfunction of

box.

Malfunction

printed-circuit

Mulfunction of

box.

Malfunction

printed-circuit

Malfunction

printed-circuit

the

of

board.

the

of

board.

of

board.

operation

the

control

operation

the

control

the

control

Same

Replace

Replace

Replace

circuit

Replace

Replace

circuit

Replace

Replace

circuit

Replace

Replace

Replace

as

#20.

the

operation

the

operation

the

control printed-

board.

the

operation

the

control printed-

board.

the

operation box.

the

control printed-

board.

the

operation box.

the

control box.

the

control box.

box.

box.

box.

-32-

ITEM

#32

PROBLEM

Machine

ing sewing.

stops

CHECKING

dur

• Is the power lamp

flashing? (YES)

PROCEDURES

(NO)

PROBABLE

Head

torque

Safety

circuit

because

rication of

Malfunction

unit.

Malfunction

is large.

of

insufficient

the

of

of

CAUSE

has

rotary hook.

the

the

printed-circuit board.

Malfunction

printed-circuit

of

board.

the

operated

lub

treadle

control

control

Lubricate

Replace

Replace

Replace

REMEDY

the

rotary hook.

the

control box.

the

contorl box.

the

contorl box.

-33-

(control

box

troubleshooting

guide

outline

PROBLEM

1. Motor won't

operate.

Lamp won't illuminate with power

ON.

(Fuse

the

failed.)

2. Motor won't operate. B
Lamp illuminates with power ON.

3. Machine
rotation wih

4. With

Thread

Reverse
Brake

All

5. With

high

6. With
imum,

power

tirmmer

remains

continue.

treadle

speed;

treadle

abnormal

power

ON:

continues.

ON.

forward,

won't

depressed

high-speed

high-speed

ON.

continues.

abnormal

stop.

changes.
(High-speed rotational irregularity)

7. During

speed,
great

stop

speed

reduction from high

brake

doesn't

deviation of

position.

function, or

needle

A

to

max

rotation

(lower)

(1)

Fuse

CHECK

is replaced

METHOD

and

fails again.

(2) Operation OK after fuse replace

ment.

(1) LED

(2) Motor
(3)

flashes

tack.

Others

during fon/vard

roarsorhums.

back-

REPLACEMENT

PART

D printed-circuit board PTR, D (If PTR
broken

motor frame

assembly)

then

Due to operation of overvoltage protec

tion

circuit;noabnormal

Treadle

C1,
CPU.

HIC1,

HIC4, HIC5,

printed-circuit

HIC5

brake

HIC2,

PTR

HIC6

HIC6

D printed-circuit

phase

110V)

Thread
Reverse

Brake

CPU

HIC2

HIC6

Poor

board.

HIC6

HIC3

trimmer

PTR5

PTR1

solderingoftreadle

1

PTR2

board

condition.

board

tantalum

PTR (single-

printed-circuit

-34-

C

CONTROL

BOX

TROUBLESHOOTING

GUIDE

DETAILSl

(1) For other than

(2) Do not

(3) About

use

the

the

control box, it is particularly Important to

an extension cord for

power supply of

the

the

motor's 6-pin cord. Extension cords

p.c.b. BPD500-1.

use

products of confirmed good quality.

can

be used, however, for other cords.

• The p.c.b. BPD500-1 is divided into three power-supply groups (part A, part B and part C).

• Although part A (0Vgroup) is insulated at

circuits (primary

side

voltage)

duetothe

• For that reason, it is extremely important, before checking part B

suretofirst

Also disconnect

disconnect

the

CN5

motor

and

connector

/

j oil

•Jest

M

CSIu

DM M

V*

•ST YA

DM W

vv

DS7

M

n|

CN4.

the

transformer, part B

CN5

and

(which is

i -

II

among

%

(O50V

CN4 connections,

(O50V

the external connectors).

CU

I 4 CM

5

a-r

group)

and

part C

andsoare

group) and part C

•

«

BP0500-I

<•

* - s >

§ BCMX$

is

(^^$_

(O100V

dangerous.

(O100V

<2,

H

on sn wsS|

group)

are

high-voltage

group), to be absolutely

\

A

cw*

o*Ol

•rt>o«

•

8*(S)

OV

sr

ViA

CSS

KlOl

uiu

xi

PartCO100V

Tir

tf

00

•MS

XX

group

HICO

m

5 1

,

§*8

.c.

»•«'

001 ^

Dios

Part B

O50V

group

t W

VA

Part

O '

A OV

Mri I I

am*

group

DMi

11

I

11

n

-35-

Ul Main

Fuse

Motor

starts

switch

ON.

flow-chart

failure.

when power

START

Disconnect (among the external connectors) the power-supply connector, the

motor connector,

trimmer connector,

the

brake

and

connector,

the

three

the

presser

stand-operation

foot connector, the thread

connectors.

Among the internal connectors, disconnect the CN5 from he D printed-circuit

board.

Connector

related (p.39)

Machine

ate.

doesn't

oper

PTR,D:OK

#1 (p.39)

Fuse

Fuse

#2

failure

(p.39)

replacement

(operation of overvoltage
protection circuit)

1. Connect only the power-supply connector (which is one of the extemal

connectors).

2. Among the internal connectors, disconnect the CN5 from he D printed-

circuit

boardanthe

Note:

All

other

3. Turn the VR for high

CN8

internal

from

connectors

speed

Power

ON

LED1illumination

#3

(p.39)

CN8 voltage: OK

#4

(p.42)

the

transformer.
mustbeconnected.

all the way to the right. (Note)

Transformer replacement

Refer to the section concerning disconnection

and

removalofprinted-circuit

then disconnect and remove the printed-circuit

boards and

replace

the

transformer.

Printed-circuit

board/removal

(p.40)

Connector

related (p.39)

Connector

related (p.29)

#3-1

(p.41)

boards (p.40):

Switch OFF the power, connect CN8,

and then the power switch ON.

Set

the

treadle

lever

for forward

LED1 flashing.

#5

(p.39)

Set

the

treadle

levertoneutral

Power

OFF

Connector

related (p.39)

depression.

#5-1

Treadle

related

#7-1

p.43)

2 (p.51)

(p.44)

Note:

Be absolutely

disconnection

board

sure

to disconnect CN5. If

is forgotten,

willbedamaged.

the

printed-circuit

A

Wiper operation with

power ON.

w

Caution (p.47)

1.

Connect

2. Three printed-circuit board switches: needle

correction switch:

3.

Turn

ail

connectors

the

high-speedVRall the way to the

except

the

OFF;

slow-start switch: OFF.

Power

ON

Motor

starts

operation

box.

position

left.

YES

switch:

lower;

Connector

related (p.39)

Retum

to

"START"

(p.36)

Thread

tion with

Reverser

power

Brake

ON.

Motor

trimmer

power

operation with

ON.

ON with

roarsorhums

opera

ON.

power

dur

ing forward backtack.

LED flashing during for

ward

backtack.

Wiper

Thread

operates.

Reverse

Brake

Machine

operates

#100

trimmer

#101

operates

#102

sound

#103

pulley is light

#103

YES

YES

YES

#100-1

#101-1

#102-1

#103-1

Abnormal high

forward

Pedal

one-stitch

difficult.

Sometimes

speed

depression.

sewing

not

thread

trimming.

Deviation of

er)

and

needle

needle

(low

(upper)

stopping.

speed

High

low

OK, but no

speed.

Pedal low-speed range

is

narrow.

Treadle

at

lever to forward

flashes

Operation

depression

Retum

"START"

(p.36)

#104-1

to

(p.50)

Retum

Operation

to

"START"

(p.36)

Have

#3-#7

adjustments

been

made?

D printed-circuit
board

check

e

(p.42)

Tum high-speed VR all the way to the right.

#106-1

(p.50)

A

-37-

Starting rotation slow

#107-1

YES

speed.

—•

NO

Treadle

(p.51)

related

(P37)

2

High-speed rotational
irregularity.

Speed

reduction brake

doesn't

function.

Continuous

low

speed.

rotation

Good

Rotation

to

slow-speed

#107-1

corresponds^

treadle

stroke.

^

YES

depression.

NO

NO

-iTYES

High-speed

rotationisstable.

^

#107-4^-.--

YES

Pedal

neutral

Speed-reduction

functions.

at

Machine

brake

#108

YES

stops.

#109

YES

NO

NO

NO

#108-1

(p.53)

#109-1

(p.54)

Needle

stop.

(upper)

doesn't

Stop

position: OK

#110

♦4

YES

Backward treadle depression.

Machine

Thread

#111

trimmer

operates.

YES

functions.

#112

YES

Stops.

YES

Wiper functions.

#113

YES

NO

NO

NO

NO

NO

#110-1

(p.54)

#111-1

(p.55)

#112-1

(p.56)

#113-1

(p.56)

END

-38-

HI

Connector

Fuse

failure (#2,

LED 1 illumination

LED 1 flashing

(#5)

related

#3-7)

(#3)

Thread

Presser

trimmer

foot

Brake

connector

connector

connector

PTR,

D: OK

#1

PTR

High-speed

installation

Brown

screw

VR

wire

8A

fuse

Operation

Fuses

connector

(#2)

(#3-7)

Motor

connector

Power-supply

connector

Purple

wire

PTR

andDcheck

1.

2.

Remove

Set

the

the tester to the X 1Q range (Oohm adjustment).

3. PTR continuity

Between PTR installation screw

Should

not

4. D continuity

Between

Should

Note:

If

the PTR is damaged, replace the frame assembly of the motor used as a set

weak

and

not

all rotation

methods

three

treadle

unit installation

screws

O-

test

and

purple wire

be

Oohms

in

both

directions.

test

D

case

and

brown

wire

be

Oohms

in

becomes

both

directions

higher.)

Treadle

with

the controlbox. (The motortorque becomes

unit

Installation

screw

O

-39-

Printed-circuit

board

removal

Nylon

band

Remove

the

three

treadle

Transformer

installation

screvt^s.

Disconnect the transformer connector from the nylon band. Disconnect the transformer connector.

connector

®

r~in

n

Printed-circuit

installation

Printed-circuit

installation nylon

(1)

Disconnect

(2)

Remove

(3) Remove the three printed-circuit board installation nylon pins.

CN2, CN3, CN5, CN6, CN7,

the

two printed-circuit

Nylon pin

board

and

installation

screws

CN8.

screws.

r

Press

from

both

sides.

board

board

(two)

pins

(three)

Remove

Transformer

the four printed-circuit board installation screws.

connector

Printed-circuit

installation

ml

board

screws

(four)

E]

o ^

®

Remove

UtibtitiUUtd

©

o ®

-D printed-circuit board

installation

C

© ®

the

four D printed-circuit

^

11^1)

i a 0

Pull

the

printed-circuit

©

screws

board

—en

a

r

board

(four)

JJ

installation

o (

panel.

screws.

@

CO

1

®

Printed-circuit

D printed-circuit board—

(1)

Remove

(2) Remove the nylon pin (same as @-(3)).

board

panel

V

the

two D printed-circuit

-Remove the hexagonal screws.

D printed-circuit

installation

screws

board

(two)

©

'

(j

•Nylon

pin

board

installation

screws.

-40-

LED

illumination

More

than

1

#3

#3-3

CPU pin 28 (Reset)

+4.5

Less

ttian

5V

V

Dispose

of

printed-circuit

board.

Replace

the

CPU.

#3-4

(REG1 IN)

Check

Replace

LED

Replace

the

CPU

HIC2.

YES

1

Power

OFF

0.6

CN6 voltage: OK

#3-6

Power

s

ON

yes

failure

Transformer

vollage: OK

#3-8

(p.32

D

C20isshort

or

circuited;

replace.

Replace

REG1.

#3-1,

Replace

BD

#3-5

1

D

presented

circuit

check

(p.32)

board

O

Replace

transformer

(p.30)

the

(REG1 OUT)

presented-

circuit

check

(p.32)

board

Q

#3-6

Between

red

wires

#3

OV:

5V

related

Check

OUT:

#3-1

REG1

+5±0.5V

OUT

pin OV

OK

Check

CLK:

Refer

above.

#3-2

to figure

OK

pin

CPU

pin 28: OK

#3-3

Must

be

or higher.

+4.5V

5V

REG1

Refer

above.

#3-3

#3-2

Check

IN:

#3-4

IN

to figure

CPU-28

pin CLK

#3

OK

(LED1)

REG1

OohmsatXI

range

5V

+0.5V

OUT:

#3-5

OUT

+4.5

V or higher

or

ower

CN6 voltage: OK

OO

AC 8V or higher

between

wires

10msor

H

#3-6

red

+8V

less

-I

or higher

Transformer

Rating

(Refer to p.32.)

primary

voltage: OK

#3-8

10%

-41

-

SI D printed-circuit

D printed-circuit board

1-110Vassembly

1-240V

assembly

board

D

printed-circuit

5"

D printed-circuit board

3-240V

3-415Vassembly

assembly

board check 0 D printed-circuit board check 0

(evil)

(Jd

'—*•

!m]cH2

o

(vclIiJi**)

CM2

^S)

printed-circuit

check

O

D printed-circuit

check

0

D

printed-circuit

board

board

board

check

O

BD 0 - 0 both directions: must not be OQ

D

printed-circuit

board

check

0

Is solder of connector lead wiring OK?

D

printed-circuit

Between

Transformer

Nylon

band

Transformer

connector

primary

orange

board

check

wires: must be

voltage:

OK

0

#3-8

0-5

D1-D6

D printed-circuit

board

check

O

D printed-circuit board
check

0

I'

D

printed-circuit

BD

D1-D6

D

printed-circuit

both

board

directions:

board

check

check

O

must

0

not

be

OQ

Is solder of connector lead wiring OK?

D

printed-circuit

Q

Between

CN8

voltage:

orange

Orange

board

check

wires: must be

OK

#4

BPD500-1 printed-circuit board

wire

Gray wire

0

0-5

Q

/ Orange

wire

(1)

Remove

the

three

treadle

unit installation

(2) Disconnect the transformer connector from

(3)

Check

the

AC

voltageofthe

transformer

Treadle

screws

screws.

the

connector.

unit

(three)

nylon band.

-42-

installation

Orange

Gray

wire

Orange

wire

AC15±3V

AC15±3V

wire-

AC30±6V

More

flashing

than

15V

Dispose

printed-circuit

board

LED

1

#5

Less

than15V

of

Disconnect

CN3.

#5-2

Power

OFF

Replace

i " SI

MHi

*It*

ts

HIC5

2 I ^

Treadle

1 (p.41)

CN3

connection

related

+15V NG Replace

C71 or

C80

-15V

NG Replace

C72

or C81

b,

BPDSOO-

+15V

NG

Replace

-15V

REG51

NG

Replace REG52

#5-4

D51.»K"

D54"A"

CN7

voltage: OK

#5-5

Replace

the

transformer

(p.40)

10msor

+25

-25V

Replace

BD51

less

V or higher

or

lower

(P36)

#5-1,

(D51"A")

#5-4

#5-3

P51»K

#5-1,

(D54»K")

#5-5

-4

#5-3

(CN7)

#5-5

Yellow

CN7

wire

(D54"A")

Black

wire

#5

related

O50V:

Check pin

±15VOUT:

D51mA"

D54/.K"

#5-1

+15±0.5V

-15±0.5V

O50V

OK

±15V

D51-A"

D54»K"

#5-3

OUT:

OQ

-43-

Refer to

±15V

the

IN:

#5-4

figure

OK

above.

P

CN7 voltage: OK

Refer to

#5-5

the

figure above.

AC

AC

Yellow

20±4V

40±8V

wire

CN5 pin 2: OK

^

#7

More

than15V

Dispose

printed-circuit

board.

NO

^

NO

of

±15V

OUT:

#7-1

OK

^

YES

NO

Less

than15V

Power

OFF

CP9:

OK

#7-4

NO

PH52 pin 1: OK

#7-5

|N0

(P35)

+15V:

-15V:

YES

YES

NG

Replace C110.

NG

Replace C111.

Replace

HIC4.

YES

±15V

IN:

#7-3

±15V

IN:

#7-2

+15V:

NG

Replace REG101.

-15V:

NG

Replace

Replace

HIC4

R111

PTR101.

OQ

NO

OK

YES

REG102.

NO

Replace

BD101.

#7-1,

#7-3

#7-2

#7-2

#7-1,

#7-1-#7-5

OiooV:

HIGH VR

#7

(HIGH)

#7-5

PH52-4

(D101"K")

(0101

(D104»A")/

#7-3

related

Check pin

must

•^^st

»K")

(D104mK")

OiooV

be fully to right.

CN5 pin 2: OK

#7

—£to.EC_i5

' ' "•

ttf-iu

#7

(CN5-2)

#7-4

(CP9)

±15VOUT:

#7-1

OK

SB"

-M-rtiTs

±15V

#7-2

8 til * Ml *

IN:

OK

±15V

#7-2

D101.-K"

D104//A"

OUT:

#7-3

OQ

CP9:

#7-4

OK

+17V

10msor

-17Vor

PH52

(P36)

or higher

less

lower

pin 4: OK

#7-5

Pedal

Pedal

neutral

forward

-0.7±0.2V

+

12Vorhigher

DIOImA"

+

15±0.5V

D104.rK"

-15±0.5V

Refer

upper

gure.

to

-44-

right fi

•101»A"

D104r,K"

OQ at XI

range

+

14V

-14

V or higher

or higher

-0.3V

or

lower

+0.3Vorhigher

CP3:

#7-6

CPS:

#7-7

CP4:

#7-8

OK

YES

OK

NO

OK

NO

NO

YES

YES

Replace

Replace

Replace

HIC6.

HIC6.

HIC6.

A(P36)

#6

CPS:

OK

OsoV:

Check

pin O50V

With VR4 fully right:

Pedal

Pedal

neutral:

fully

#6

#6

OV

forward: 8.5V or higher

(CPS)

HIGH)

'I"r

00

CM

CM

PH1B

NO

(P46)

#7-8

#7-7

#7-8

YES

(LOW)

(HIGH

(CP4)

Replace HIC5.

n-i

^ f—

t "

5=8

tiss.g

I.OQ.'tZj

.aotrt'i

(CPS)

#7-9

(PH1B-6)

CM

IF

#7-6

(CP3

#7-6—#7-9

O50V:

Check

Pedal

Pedal

neutral

forward

related

pin

O50V

CP3:0K

#7-6

^ ^

V

-3+1V11500+50

v^v

J-3±1V

\

mS

HIGH VR

right.

H-6.S±0.SV

CP6:

OK

#7-7

mustbefully

-8±2V

-45-

CP4:

OK

#7-8

LOW VR: at 12:00 posi

tion

0~+0.1V

+1.0Vorhigher

PH1B-6 pin

#7-9

0~+0.1V

-H.OV

or higher

HIC2 pin 15: OK

#7-10

CPU pin 9: OK

#7-11

CPU pin 28: OK

#7-12

Check

pin

CLK:

OK

#7-13

ICS

PS:

OK

#7-14

ICS

P4:

OK

#7-15

Replace

the

CPU

Replace

HIC2

I

Replace

the

CPU

Replace

HIC1.

Replace

CPUorHIC2

Treadle

the

related

{p.51)

Replace

HIC1

i

Replace

Replace

#7-18

#7-17

#7-16

#7-10

#7-15

#7-14

Pedai

Pedal

Pedal

Pedal

(HIC1-18)

(HiCI-11

(ZD1»K")

(HIC2-15

(ICS-4)

ICS-S

neutral

forward

neutral

forward

.

HIC2 pin 15: OK

#7-10

4.5V or higher

0.5Vor

0.5Vor

0.5Vor

lower

HIC1 pin 11:

OK

#7-17

lower

lower

CPU pin 9: OK

#7-11

4.5

V or higher

0.5Vor

lower

HIC1 pin 16:

OK

#7-18

4.5

V or higher

0.5Vor

lower

"»'.«[

j LJ:

s=t=

5

CPU pin 28: OK

#7-12

4.5

V or higher

#7-10—#7-18

OV:

'I—I.

Check

Refer

upper

gure.

Check

pin

CLK:

#7-13

to

right fi

related

pin OV

Check pin OV

#7-12

#7-11

OK

ICS

0.5Vor

0.5Vor

CPU-28)

(CPU-9)

P3:

#7-14

lower

lower

0.5Vorlower

OK

ICS

4.5

0.5Vor

#7-15

V or

mu

P4:

higher

lower

#7-13

OK

4.5

V or

ZD1

#7-16

4.0

V or higher

"K":

(PS6)

250nsec

higher

OV

OK

-46-

Caution

/

l^jmCD^^^FCRSA:^^

DM M

•M

KT

BM M

DST M 4.

y

m

¥h

»tagf

D».

8

•>..'W*

U*

<4-

Oi ~

"8

FERSr

^^''^'i-Wrsn'

s*wir^r-s

tt

«

KIC.

OO

94

91

♦

sSS

s

CM CM

.Q;0

»«

t"

•"

--0

'I

J

11

Ml

4t

^«a

3„i

\

i

•"

M

BP0500-1

+ *

a

"

<»

Ota

•ro«o

•

"O

1

Part

B +

Part

C

Note:

Because part Band part C are connected to the high-voltage

touch

them.

circuitry

for this and subsequent tests, care must be taken not to

-47-

Wiper

operates

#100

trimmer

Thread

operates.

#101

Check

#100-2

#100-4

Replace

the

CPU

Replace PTR5

Replace HIC2.

Replace

CPU

Replace

the

and

the

HIG2.

CPU

Check

Replace

the

CPU

Replace PTR2

Replace HIC2.

Replace

CPU

Replace

the

and

the

HIC2

CPU.

#100

OV:

#101

OV:

related

Check

Base

related

Check

pin OV

PTR

3B:

#100-1

1Vorlower

pin OV

Si

#100-2

#101-2

OK

a •

-1

(PTR2-B)

(CPU-46)

(CPU-47)

CPU pin 46: OK

#100-2

4.5

V or

higher

CPU pin 28: OK

4.5

#100-3

V or

0.5Vorlower

higher

#100-4,

#100-3,

#101-4

#101-3

(CLK)

(CPU28)

#100-4,

/f

Check

#100-4

Refertoupper

#101-4

250nsec

4.5

V or higher

pin CLK: OK

right figure.

PTR

2B:

Base

OK

#101-1

IVorlower

CPU

pin 47: OK CPU pin 28: OK

#101-2

4.5

V or

higher

-48-

4.5

#101-3

V or higher

Refer to upper right figure.

Check

pin CLK: OK

#101-4

Reverser

operates

#102

Brake

soundisheard

#103

#103-2

(PTRI-Base)

#102-1

(PTR5-Base)

#102-2

(CPU-45)

#103-3

(CPU-48)

"^11®"*

® '

\ "•

Check

'r)"'

IN?

Replace

the

—II—I

i

h 1

CPU

"oV:

I ^ zhii' w '

1!!.

RsnMM—I

•"

Replace

Replace

Replace

CPU

Replace

I

and

I

the

the

PTR5

HIC2.

HIC2

CPU.

***

•'O*

#102-4,

(CLK)

#102-3,

(CPU-28)

Check

#103-5

#103-4

Replace

the

CPU.

IVorlower

0.5Vor

Replace

the 8Afuse

Replace

Replace

Replace

CPU

and

^

YES

Replace

#103-2

When power ON.

I ^I

#103-3

#102-4,

When

lower

If

synchronizernoconnect

#103-5

PTR1

HIC2.

the

HIC2.

the

CPU.

Approx.40ms

power

—

Approx. 40ms

1.5±0.5V

ON.

4.5V

250nsec

or higher

300

ms

P37)

#102

OV:

#103

OV:

Refer to

related

Check

Base

related

Check

pin OV

PTR

#102-1

IVorlower

pin OV

PTR

#103-2

upper

5B:

OK

IB:

OK

right figure.

CPU pin 45: OK

4.5V

CPU pin 48: OK

Refer to

CPU

#102-2

or higher

#103-3 #103-4

upper

right figure.

-49-

4.5

CPU

4.5Vorhigher

0.5Vorlower-

pin 28: OK

#102-3

V or higher

pin

28:

OK

4.5

jMnn:

Check

pin CLK: OK

#102-4

upper

Refer to

Check pin CLK; OK

Refer to upper right figure.

right figure.

#103-5

V or higher

Operate

at high

#104

speed.

Motor 6-pin

OK

Replace

HIC6

adjustment

Replace

connector

#104-1

HIC5 &

RIGS &

Motor 6-pin

connector

repair

#104-1

Cheak

this

related

I

ID

mm

connection

©

is

correct.

#106,

#106-1

Operate

the

machine

without "hunting",

maximized.

related

make

at low

the

speed.

Hold

the

machine

TVR adjustmentsothat

#106,

(P37)

pulley

and,

torque is

#106-1

(TVR)

DM

M

KL ft « ^ 204

Wl

If

iLSiiiJ

OO

CM

zx

ajpc

N1C4

CM

-50-

CM CM

Treadle

Phot

Int&VC

unit

chart

CP5

(VC) V

8.5-

2.0-

0.5-

4000

•1000

-215

t

SPM

I

Adjustments

FRONT

REAR

PRES

DOWN

-8

Trim

Pres.

up

itral

Nei

Shutter

231079001

0.5Vor

L

level

Pres.

down

...

Low

sp

Shutter

lower

Variable

sp.

14.5

16

Top

sp.

Adjust

the

shutter positionsothat it uniformlycontacts both Q2

Q3atneutral.

Note:

When

the

treadle is fully

be

within

the

Connector

left

related

depressed,

1/3ofQ1.

the

edge

Aof

the

shutter must

and

©

1) Connect only the power-supply connector of the external

connectors.

2) For

the

internal connectors, remove only CN5 from

the

D

printed-circuit board.

3) Making

approximately
the

the

above

adjustments

adjustments

4000spm

are

completed,

will

(125 pulley),

use

set

the

so,inthe

VR3 to

machine

condition after

set

to maximum

speed

to

speed.

-51

-

©

4000

SPM

3000

VR1

ADJUSTMENT

4000

SPM

3000

VR2

ADJUSTMENT

<

3

>

&

"c

B

o
a

VR1

left

^

2000

1000

215

U1
to

4000
SPM

3000

2000

VR3

ADJUSTMENT

VR3

right

w ; VR1

• right

; I ;

; ^ I ^ /

16

VR3

left

mm

2000

1000

215

4000
SPM

3000

2000

VR4

ADJUSTMENT

;

VR2

' left

16

mm

VR4

right

VR4
left

1000

215

16

mm

1000

215

16

mm

Deceleration

brake

^

#108

functions.

NO

^

VR1:

OK

#108-1

YES

CPU 26 pin: OK

^

#108-2

YES

Replace

HIC6.

Si—II—I =oS^

" stT. I

B 1

£ -

i

£

•

•

ii

•

E

»

•*

NO

Adjust VR1.

NO

^

Replace HIC3.

(P37)

iSTi

'Hgteasgl

BP0500-1

B CM

^ _It^ Bi

*=5?<2.

>_

an

"

au

•

o«

sn

#108-2

(CUP-26)

#108

related

OV:

Check

CPU pin 26: OK

pin OV

VR1:

#108-1

The

VR1 position

#108-2

OK

During high

During low

mustbewithin

speed

0.5Vorlower-

speed

0.5Vor

lower

J

M

*"

1

the

range

to

© ~

(3:00)

fUMiuum

(S)

(extreme

4.5Vor

right)

higher

4.5 V or higher

#108-1

(VR1)

-53-

Machine

#109

stops.

NO

Stop

position: OK

#110

NO

Low-speedIsgood.

#109-1

YES

CPU pin 39: OK

^

#109-2

Replace

^

NO

HIC1.

#109-2

(CPU-33) Needle down signal

NO

Adjust VR LOW.

YES

Replace the CPU.

(P37)

Low-speed is good.

#110-1

YES

Replace

HIC3.

NO

Adjust VR LOW.

(P37)

#109-1,

(VR LOW)

#109,

#110

#110-1

related

OV: Check pin OV

II 1

.^Ir

Xi

[

b

. rV-^'.ig^»'\

8<2»

y5r

ov

^

^:[][][]1

XX

^Gy

fp'

Low-speed is good.

#109-1

VR LOW:

215±10spm

pin 39: OK

#109-2

Needle

(lower) position:

Other

than

position: 4.5V or higher

0.5Vor

needle

lower

(lower)

Low-speed is

VR LOW:

-54-

#110-1

good.

215±10spm

CPU

Machine

operates.

#111

Replace

the

#111-4

#111-5

CPU.

HIC1-11)

(HIC1-16)

,11,

Replace

61^

DifJ

HIC1

, ,

,11.

Replace

'

HIC1

Treadle

(p.51)

related

Replace

HIC1

(P37)

II

"c:

0

rt_

1

#111-3

(CPU-34)

1

#111

related

OV:

Check

103 pin 3: OK

4.5

V or higher for

ward

depression

#111-1

pin OV

back

103 pin 4: OK

0.5Vor

ward

depression

#111-2

lower

for

back

CPU pin 34: OK

#111-3

Needle

(upper) position:

Other

per) position:

0.5Vor

than

4.5

-55-

needle

V or

lower

(up

higher

#111-2

#111-1

4.5 V or higher for

ward

(IC3-4)

(IC3-3)

HI01 pin 11: OK

#111-4

depression

back

HI01 pin 16: OK

#111-5

0.5Vor

ward

lower

depression

for

back

Wiper

operates.

#113

NO

trimmer

.

Thread

operates.

#112

NO

.

Replace

#113-1

PTR

SB:

OK

#113-1

NO

CPU pin 46: OK

#113-2

NO

the

CPU.

(PTR3-Base)

YES

YES

Replace

Replace

HIC2.

the

CPU.

Replace the CPU.

(P37)

#112-1

PTR4

PTR

28:

OK

#112-1

NO

CPU pin 47: OK

#112-2

NO

Needle (lower) Needle (upper)

I

PRT2

B

IVorlower

base

YES

YES

Replace

1.5±0.5V

Replace

HIC2.

PTR2.

(P37)

#112-1

(PTR2-Base)

#112-2

CPU pin 47

0.5Vor

/

#113-1

PTR3 B '

.w

IVorlower

#113-2

CPU

pin

0.5Vor

#113-2

#112-2

u.jrfTiuj

2 « M

7^

y ) "

|],.r

Q

a

.—.—Bn-

1

s

iX»

..

BPOSOO-I

* '

%!][

lower

I

PTR3

base

—

i

T1

h

. 1.5±0.5V —

46

4.5 V or higher —

lower

(CPU-46)

(CPU-47)

4.5V

1-

r—1

or higher

T2

1

1

1

#112,

#113

related

OV;

Check

pin OV

PTR

2B:

#112-1

Refer to figure

OK

above.

CPU pin 47: OK

#112-2

Refer to figure

above.

-56-

Refer

PTR

#113-1

to figure

3B:

above.

OK

CPU pin 46: OK

Refer

to figure

#113-2

above.

m Needle (lower)

stop

Needle

(upper)

stop

H

Machine (spm)

Machine

(spm)

VR

-- Adjust

LOW

speed

2:

c

o

VR1 Adjust

-VR LOW Adjust

speed

A (FRONT) H

IC3-4

(OV) L

B

(REAR)

IC3-3

CJ1

PEDAL

CPS

BRAKE

103-1

BRAKE

103-15

(O50V)

(OV) L

SENSOR

ON

(OV)

OFFL

(OV) L

H

H

L

H

speed

A

(FRONT)

103-4

B (REAR) H

103-3

NEEDLE

OPU-33

DOWN

(OV)

NEEDLE

OPU-34

TRIMMER

OPU-47

WIPER

OPU-46

BRAKE (M) H

OPU-48

(OV) L

(OV)

UP

(OV) L

(OV)

(OV)

(OV)

H

L

H

L

H

H

L

; I

W >1

;50ms

40

ms

20ms

——

H

L

L

s

>

so

H

NEEDLE

OPU-33

DOWN

(OV)

BRAKE (M) H

OPU-48

LOW

OPU-9

(OV)

SP

(OV) L

H

L

L

H

iini

Li

60

ms

r

LOW

OPU-9

PRESSER

OPU-44

SP

(OV)

(OV)

For

the

H

L

H

L

presser

40

ms

FULL

ON

300ms

foot, OPU-16 at S printed-circuit board G.

200

Hz

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Model

OF

DB2-B737

CONNECTOR

• B747 • B748 •

PANEL

B791

• B793 • B795 • B798 (Type 500B)

)

No.

1 Leading power
2
3
4 Thread trimming power

5
6

7

8

9

10

11

12

Machine

12P

Leading output

Thread trimming output

Thread

Thread wiper output

Reverse
Reverse
Reverse

connector

GND

Not

wiper

OV

head

used

power

input

power

output

Machine

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®<D®

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5q)^i)62)

Presser

6P

Presser

Presser

Presser

head

foot

connector

power

input

Option

output

OV

GND

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lifter

P)®

p)®

Brake

foot

lifter

Brake

2P

connector

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Brake

______— "

_____ "

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®

1

power

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[Three-phase]

No.

6P

1

2 Vf.

3 if.

4

5

6

Motor

connector

Vf.

TH

Motor

Vf

Motor

TH

TH

Side

faceofcontrol

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Fuse

(Note)

380V-440V

Power

4P

connector

GND

AC dlOlQ] (yj

AC |2][0l|0] [y]

+

-

AC

lll(0][0]

______

0

— •

3A

box

Power

Front

faceofcontrol

Synchronizer

No.

box

Synchronizer

1
2

3

4
5
6

7
8
9

10

DC

Needle

NO.

Needle

Encoder

GND

-1-

OV

GND

5V

down

SYC

up

-60-

Model DB2-B7380 (Type

#470B)

Cycle output

Q
®

No.

Cycle

2P

connector

1
2

3
4
5
6

Collector

Emitter

______— ______—

— •

(8) (8) (0)

Correction

switch

output

—^

Needle position

switch

>

O

Hem

detection

6P

connector

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Collector

Cathode

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thin

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thick

0

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detection

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3P

connector

+5V

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OV

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(D

(D

—

No.

10

11

12

1

2

3

4
5

6

7

8

9

Machine

Leading

Leading

Thread

Thread

Thread

Thread

Reverse

Reverse

®(D(D

®(D(D
(2)<D(D

@0©

Machine

12P

connector

GND

trimming

trimming

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wiper

wiper

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OV

head

power

output

used

power
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head

power

output

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p®

p)®

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power

output

foot

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2

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foot

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lifter

power

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output

power

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©

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faceofcontroi

1

jOAj

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box

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faceofcontrol

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o a

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panel

8738

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J

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6P

connector

1

2
3
4

5

6

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Motor

TH
TH

TH

4-

Vf

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3P

connector

GND

AC 0

—

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1
2

3

4
5
6

'

7

8

DC

Needle

NO.

Needle

Encoder

GND

-1-

OV

GND

5V

down

SYC

No.

1
2

DC

3

4
5

6

up

7

8

9

10

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BUZZER

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SCAN
SCAN

SCAN

SCAN

SCAN

OV

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Operation

5V

7

5
6

3

4

1

2

panel

11

12

13

14

15
16
17

18

19

20

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PCI
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0

3

1

2

-61

-

SEWING

MACHINE

CONTROL

SYSTEM

BLOCK

DIAGRAM

MD-803,

813-500

(B737)

Power

Detection

ON-OFF

S

printed-circuit

board

BPD500-1

Pedal

Front

SW

Rear

SW

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SW

SW

Synchronizer

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UP

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ro

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sync

L

CN9

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INP

Circuit

1

A

CPU

M50747

(pcP7

Hie

3

ENC

Trans

former

Power

Supply

+35V

+

+

+

12V

5V

0V

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Machine

CONT

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Timing

Photo

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Y2

Yi

V

TE

A

y

HICI

INP

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i2Pr-h

Hic2

Drive
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j—tfo-

Correct

j—W—d'S-

[Needle Position

6Pf

Pho

toX

CN10

Machine

*

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Wiper

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•

Start.

Back
Pedal

Electric

»

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>

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Feed

Solenoid

Solenoid

Solenoid

Solenoid

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Tack

Speed

Speed

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SW

SW

SW

MOTOR

CONTROL

4P

Fuse

SYSTEM

|--~Wr

BD

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CN4

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former

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supply

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supply

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<!)-(^-q)h1>—(aKg>-

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+15V

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OiooV

-15V

A

CVR

+15V

if

if

w

CP3

0+15V

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Z

Pedal

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Low

Electric

TVR:Torque

*SVR:Speed

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if

V

Speed)

Speed

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Brake

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limit adj.

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Motor

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OOsoV

ijf

Lock

O

-H5V

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Z

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Yz

Base

driver

^

QjooV

6050V

Photo

+15V

CPS

o

-15V

O-

JUUUU

Yi

CN5

O Base

I

O Emitter

380VM15V

220V^240V

220V^.240V

100V•^•110V

NOTE

3Phase

3Phase

iPhase

iPhase

291782340

291782323

291782123

291782110

CODE

500B3-400V
500B3-230V

500B1-230V

500B1-100V

NAME

L8J_|J

S-PCB
S-PCB

S-PCB

S-PCB

nM

ii

!~Ml

E3TH

UI03

3H1

3tfJU4

J

po

885

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OVA^-V^V>-^^

s srll-,

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MD-803.813(8737)

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131

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SftbtJ

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101
102

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Sl<»53

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11

106

3 4. 9

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9

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PIN

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233961001
233130001
001100191

001)00042

00)000006

001)00004
002004920

'•>raWA

226300001
226310001
226311001

226312001
230810001
233201001
usisoeooo
230039001
233139001
233276001
233277001
233199001
233160001
233161001

101

216399000
226320001

132990001

226321001
230936001
23090001
230966001

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23093400

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23097900
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233260001

12900

23326100

230979001

216229000

23326200

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j

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1

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233142001

230619001
230666001

230618001

AUTO

230671001
233266001

233209001

Y61036041

95

000)02620
090391620
000682620

11.

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V41012001

106

Y44712001
V43395001
Y44719001

Y41029001

Y42210001

Y42202001

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Y44714001£CEAtVU47t
Y42289001

233290001

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Y210524SO

67

Y21O42420

2

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Y3t042l00
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14

Y21032420
Y91024200

CoO*

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0SS706

mB22203H
Ma22l02H
PNe22502H

A<i2Ki14-lOK
AGH06Y62)J
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Cn)-^TUi02

E7D-S27J39)

EACKSZTJESS
EfO-S2TJl03

E7O-S2TJ109
0D-S2TJ223
ERD-S2TJ100

ePD-S2TJ242
ePD-S2Tje2l
ER0-S2TJ471

En>-S1TJ331

CPD-SlTJOSl
ERD-SlTOSai

EPF-9AJ101

eCEAlVUl02
ECEAOJUlOl

ECEA101471

ECEAlCUlOl

ECEA1CU471

ECEAlHUSnS

ECEA9HM71
ECEA1HU102

ECEAOOB21

eCCAlCU220
ECEAlHUOlO

ECEA91i)2R2

ECEAICNIOOS

E£CP9n9U474

RPei21F109290V

RPE121F104Z9OV

00306-282F104ZS9
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FV«t2iP103290y

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2.4K

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470
330
620

660

47 2H

100

9H

lOOOv

lOOu

470u

lOu

2SV

lOOu

470u

3.3u

470u

looou

220U

22u

16V
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470u

0.22U

90U

16V

0.47F

9U

90V

O.IU

O.IU

300

90V

O.Olu

1000O400V

1/2H

1/2H
t/2H
1/4H
1/4H

1/4M

1/4H
j/4y
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1/4H
1/4M
1/2M
1/2H

1/2M

1/41

1/4(1

1/4(1

6.3V
63V

16V

ISV

90V

90V

6.3V

99V

90V

29y

39V

ao>

OOV

80V

Note

Label

indication

•-•••V

Phase

Voltage

S-PCB

S-PCB

S-PCB

S-PCB

NAME

500B1-100V

500B1-230V

500B3-230V

500B3-400V

CODE

291782110

291782123

2917B2323
291782340

iPhase
iPhase
sphase
3Phase

NOTE

loov^iiov
220V^240V
220V^240V
30OVM15V

Com

\

Syi69l

C106

»1

cte
CN6
CK7
M
cr«
»to
CN12
VR2

230629001

A30A2700ll

234977001

rU^WnitCCMCTTGH

234950001

233263001

234560001

23386400:

234561001
234562001

2332660011
23328600:
23|}|700:

230680001

22830900

233134001

23393900l|>CATED

C12
C26

mm

^C71VE6d4

ECSF 9

VE109

ECQB1H122UZ

«

•

,

•

«

4

4

•

«

M221041

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504S-04A

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SO4S-04A
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6273*03A

8277.03A

S-i3d64

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i;

0.66U

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1

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1

1

2

1

1

1

1
1

1

1
1

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1

602

1

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MD-803,

813

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509

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vc

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VR4

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R14

R12
R3

R4
R1
R2
R5.

R7.
RIO

R13

RB

Rll

A

B
C

Jl-xJB

symboI

TR2.

R6

RB

Code

22B24600D

03

TR3

228264000
22B247000

233132001
Y51020010
YS4730040
Y4229S301
231BB7001

233154001

233154001

233155001

233156001

224291000

Y03910S11

090561320

090B21620
090102620
090153620
090472620
090222620

090684620

090103620

090333620

090562620

090752620

233153001

22437B001

233157001

PHOT

INT

SITR

UN1213

BIPIC

UPC451C

ZO

RD4.7JSB1

ECQB1H102JZ
ECQV1H473JZ

ECEA1HXS2R2

THS102A

PK502H103H0

•

103HO

*

502H0

*

103V2

SID

1S15BB

ERQ-1S0391
ERO-S1T0561

•

S2TJB21

•
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•

•

ERD-S2TJ103

*

•

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PS

board#4

NRP-365

PS

connector

Nsme

102
153

472
222

684

333

562

752

QP-1S02

ASSM.#3

a;

1

2

1

1
1
1

1

1

1

1
1
1
1

1

2
2

1

6

1

3
3

1

5OO111V

1

50V

1

50V
50V

lOK

lOK

5K

lOK

IN

0.5M

0.25W

0.25M

0.25M

0.25W

0.25N

0.25M

0.2SW

1

0.25M

1

0.25W

1

0.25W

1

Note

4.7V

O.OOluP

0.047UF

2.2uF

390

560

820

IK
19<

4.7K

2.2K
680K

lOK
33K

5.e<

7.5K

l

9 /

16

acN2

nCN3

NAME

PS-PCB#11

ASSM.

CODE

291792001

NOTE

D

printed-circuit

O

board

1-110V

assembly

I-Siov-T

FA n

O——o-

5

(white)

o o

(whiia)

R

G

(red)

(red)

(green)

MOV

DSA

{erango)

{orangal

r--«*

(orenge)

Ptr

(wvhite)

•(VioJei

(brown)"'

(brown)

vrolet)

M

(blue)

Iveilow)

I 8

9

N

Holderi

10

40W

low.

5W.

Holder

Coil

15A

YJ

T30K

Wire
Wire

ame

400A105

400A222

SN5D51

A

0-2n

473

20OB222

5.6(2

630B104

4GD

74-06

0.1 a

393

224

0.8^55

0.6X35

SN2054

ENC621D

NV621D

DSA382MA

Symbol

C1

C2.3

_ (i-o)

O

___\y

lc>5l

(»»)

o>

Fuse

15A

W

TTT

(!.*»»

ulijy

F

Fueo

BD

R1

R2.3

C4

R9

C5

PTR

D

R6.7.8

R4

R5

JP1

JP2

FA

Fuse

L

ZR

MOV

DSA

Code

228372001

228373001

228359001

225432001

224119000

228374001

090473420

228377001

228366001

228358001

224127001

228367001

228368001

225433001

218469001

228358001

232380001

232382001

232384001

P—Capacitor
p—Capacitor

Fuae

Fuse

SIDS15VB40

MR

0R-A1

A~Capacltor

MR

P—Capacitor

SITR

SIDERD

MR

DR-A12YJ

DR-A12YJ

Jumper
Jumper

Fuae

F

uae

SF

SABSORBER

SABSORBER

SABSORBER

tfty

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Note

400V1«F

400V0.0022»F

1.0A

400V.15A

40W.

0.2ii

1W.

47KU

200V

2200^F

10W

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u

630V

.O-lfF

400V

.20A

60DV.12A

5W.0.1(2

1/2W.39kI2

1/2W.220l<(2

250V

AC

20A

ISA

620V

620V

3A

•MD-803- (B737, 738)

NAME

D-PCB1-110V

CODE

2B1273001

IPhaee

NOTE

110V

rTD

D

printed-circuit

E

board

1-240V

assembly

l-MOV-T

R

S

(white)

O

: ^

(white)!

R

(red)

6 (green)

O W

(red)

MOV DSA

(orange)

(orange)

r—.-;-

"Bm

(orange)

Pir

(white)

2 1

(Violet)

(brown)"®

(brown)

2 3 4

R4

(violet)JL4

blue

(yellow)

I e

Symbol

C1

C2.3

F

o

(«)KT •*

a>

00

use

i5A

'—^

o

Fuse

BD

R1

R2.3

C4

R9

C5

PTR

D

R6.7.8

R4

R5

JP1

JP2

FA

Fuse

L

ZR

MOV

DSA

Code

229143001

228357001

228359001

225432001

229142001

229141001

090224420

229139001

228368001
228356001
229138001

228367001

228368001

225433001

218469001

228358001

232380001

232382001

232384001

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P—Cspeci

P—Cspaeitor

Fuse

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1.0

SIDS15VB60

MR

40W

DR-A1

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10W.5.6n

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SITRT

SIDERD

MR

5w.

DR-A12YJ

DR-A12YJ

Jumper

Wire

Jumper

Wire

Fuse

Holder

Fuse

15A

SF

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SABSORBER

SABSORBER

SABSORBER

Name

tor

A

a4n

224

30K

74-06

am

ENC621D

NV621D

DSA362MA

630A105

6308223

SN5051

450B821

630B104

40DA

393

224

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1

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630V

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630V.a

022pF

250V

AC

600V.15A

40W.

a4a

1W.220kU

450V.820r<F

10W

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630V

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450V

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600V.12A

5W

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1/2W.39kU

1/2W.220kil

250V

AC 2OA

15A

620V

620V

1.0A

3A

MD-803- (B737, 738)

NAME

D-PCB1-2A0V

CODE

281274001

IPbsse

NOTE

220V-<.240V

D

printed-circuit

board

3-240V

II

™

assembly

0*

3-2iOV-T

FA ft

O—OV6—O

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blue)

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012

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R14

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Code

226356001
228357001

228358001

228359001

225432001

228360001

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228362001

228365001
228366001
229138001
228367001
228368001

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224087001
215822000

Y54740040
Y54730040

090224420
229144001
228615001
229027000
229146001
Y51040040

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232380001

232382001

232384001

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SABS0R8ER

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DR-A1YJ
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CVR-1RL8

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ERD-25TJ

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224

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103

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NV621D

DSA362MA

630B104
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SN5051

45OB271

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6A.600V

8V

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1/4W.1 k n

1/4W.

10K

620V

620V

3A

1.0

A

0

5A

MD-813- (B737,

738)

NAME

D-PCB3-240V

CODE

2912T6001

3Phaee

NOTE

220V-^40V

D

printed-circuit

3-40]

0{9'<9^

board

3-415V

assembly

22

SO

FA R

s

F8 T

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VR

012

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JP2
JP3

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DSA

Code

229149001

229178001

228358001

228359001
225432001
229150001

229151001

090224420
090105420

229153001

229154001

229155001
229156001

228368001

229157001
229158001
229027001
229148001

Y51040040

—

Y54740040

Y54730040

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224576001
215769001

232380001

232382001

232384001

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Name

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SF

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Holder

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1.0A

SIDERC

MR

DR-A1YJ

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01-10

40W.4a

224

105

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MR

15W.10a

SITR

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77-10

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0R-A12YJ

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100

SC10C-100

8A

CVR-1RLB501RJ6P

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DR-A14YJ

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ERD-25TJ

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Wire

Wire
Wire

Holdor

3.0 a

103

ENC621D

NV1120

DSA382MA

1000B104

1000B103

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450B101

393

274

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50B474
50B473

0.8x30

0.8x15

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1

2
2
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1

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1

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1000V.aiFiF

1000V.

0.01/<F

1000V

1.5A

40W.

4n

1W.

220K

1W.

1M

450V.100/iF
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800V.30A

1000V.10A

5w.o.in

1/2W.39K

1/2W.270K

1000V.10A

1000V.10A

8V

5K

50V.aUF

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IK

50V.a47F'F
50V.a047aF

3.0

A

1/4W

10K

11(XIV

1100V

3A

1.0A

MD-813- (B737, 738)

NAME

D-PCB3-41BV

CODE

201276001

3Phaso

NOTE

380V-416V

8 " " * *

tVrtflrx'

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SHLEOl

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SENSOR

ICl

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532315000

53S235000

132993001

U52015001

23306lOOl

233083001

Y63338041
Y8220<4441
090391620

090101620
091100042
233O59001
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Y41002301
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233065001
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a

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DAnREY0A-N4
DAfW£Y0A-P4
S101SS177
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LEDTLR32S

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FlARREY333Xej
RAIVIEY220Y4J
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BlPiC74LS42
BlPiCte4581
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Q'ty

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532315000
538235000

132999001

Mame
0ARREY0A-N4
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810133177

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233061001

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233083001

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Y63338041

Y62204441
090391620
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091100042
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091000047

Y41002301

233835001
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DARREYDA-P4

810133177

LED6L-SHDS3

LEDTLR32S

LEDTLR353
RARREY333X8J

RARREY220Y4J

Dfl-A14AJ3913

DR-A14AJ101S

DR-A14AJ1843
C»-A14AJ471S
DR-A14AU1033

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B1P1CI4S4S81
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53S31S000
538235000

132999001

U52015001

23308lOOl

233062001

Y63338041

Y62204441

090391620

090lO1820
090184620
090471620

090103620

091000154

233059001
233060001

233856001

Y41002301

233835001

221791000

22779500O

233064001

233065001

233098001
234336001
234337001

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U74631000
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091100074

091100042
230938001

132999001
234338001
233082001

u52015001
233083001
U1S090000
233835001

13S476001
233262001
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Y21032420

Y21042420

090391B20
090101620

090124620
090153620

090391620
090103620

090392620
090472620

090200320

Y61033041

090221620
090822620
090222620

Name

B1P10HS184SL
B1P10MS223L
BiP10MS1201TL

B1P1074LS74

BiP1074LS42

SiDlSB3S-100
810188177

SiDBD5.6J8B3

LED6L-SHD4
LE06L-9O22

8W83F-1020
81TB2SA1115
8iTBuN1124

0N84a-XH-A

088ENOOAO

VBV08L-B104

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A-OAPAOITOBIBBIOO
0-OAPA0iT0fB0B103
0-OAPA01T0BS0B104

0B-A14AJ3918
DB-A14AJ1018
DB-A14AJ124S

DB-A14AJ1S38
DB-A14AJ391S
DB-A14AJ103S

C»-A14AJ3928

0B-A14AJ4728
DB-A12AJ2008

BABREY103XBJ

0B-A14AJ221S
0B-A14AJ822S
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HBSENS0RC0AD#2

SENSOR

SENSOR

ON

iCl

1C2

R6.
HIS.

Ra

H12.

H7

fll
m
Hie

R22

OFF

SyiBbol

RIO.

R18

R13

Rll

Code

234340001
U74631000
234341001
091100074

230938001
234338001
U52015001

233083001
U15090000

136476001

2^271^0^

233274001
233261001
Y41012301
Y41002301
Y21032420
Y81042420
090124620
090153620
090391620
090103620

09039262O
090472620
090200320

O90391620
090221620
090622620
090222620

Name

81P1CM51B48L

BlPlCHSaaX

BlPlCMSiaOlTL

B1P1C74LS74

S101SR35-100
S10flD5.6vlSB3

LEOGL-SHOaa
SHB3F-1080
S1TR2SA111S
CNS4B-XH-A

_HBSENSOflCOAO#l

HBSENSORCO^Fa"

VRV08L-B104

A-CAPAC1TOR16B101
A-CAPAC1TOR16B100
C-CAPAC1T0R50B103
C-CAPAC1T0RS0B104
DR-A14AJ124S
DR-A14AJ153S
DR-A14AJ391S

OR-A14AJ103S

0H-A14AJ39aS

QH-A14AJ47aS

Ofl-A12AJaOOS
0R-A14AJ391S

DR-A14AJ821S
[)fl-A14AU888S
0R-Ai4Ajaaas

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BiTlU-ln

lOOkQ

3.

alia
4,7ta
1/2W.

200

3eofi

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JR22

V2

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R3$

-1

.R8

•C4

TC3

RIO

B

o

Lif-

fiS

iP

nii_

SENSOR

OFF:OV

2^

SENSOR

OFF:

3-4V

"

"inoc-^:;

5

LEDl

1

(MONl.)®

10

8

LED2

(SENSOfl)(

HlC

CIRCUIT

DIAGRXMI)

m INP

CIRCUIT

(228307001)

IN

[21

OUT DRIVE (228308001)

O

8 O

O w

OUT

Pin No (IN-OUT)

IN

OUT

2 3
4 5

7

6

9

10

IN

OUT

11

13
16
18

12

14
15

17

OUT

IN

20

19

22

21

24

23
26

25

3, 6, 9,

11,

13 Q

O 4, 7,

10,

12,

14

19, 21, 23 O

>

27. 29 O

-77-

28,

30

ENC

CONT

(228309001)

8v

power supply

+5V

11

TTT

1

D

PR

Q

o

+5V

C

CL

One-shot

timer70ms

Q

70

ms

-6

13

VR5

CP7

H

MOTOR

DRV

(228310001)

7 6

-I-15V

O

-15V

-78-

MOTOR INST (228311001)

+

15V

-15V

M

MOTOR

CONT (228312001)

2 3

+

15V

-15V

Power

Detection

ON-OFF

m

2

KHz

COMP> Q 7

COMP

-79-

((FRAME ASSEMBLY

#2

REPLACEMENT)")

Refer to

the

motor

disassembly

diagram (Fig. 1).

(U Disassembly

(I) Remove the two MD carbon

Note:

The

position of

Take off the lead clamps 0 at two places from

(2)

Remove

(3)

Remove the nut O

(4)

Remove the brake armature

(5)

Remove the screw 0 and the brake stator assembly

(6)

Note: If

Remove the screw

(7)

Take out the rotor 0 from the frame assembly

(8)

the

screwOand

the

stator

each

and

is difficult to remove, strike it gently to loosen it for removal.

0.

brushes

carbon

the

the

screw0.and

assembly

O-

brush should be noted

the

belt cover.

then remove the pulley

0 from the rotor shaft, and then remove

and

installation plate.

remembered.

0.
the

woodruff key 0

and

the

0.

and then separate bracket R 0 and bracket assembly L0.A slight impact may help.

0.

(Note)

Becausethe rotor is held to the frame assembly 0 by magnetic force, the rotorshould be grasped tightlyand care should

be taken so that

Be careful not to lose the motor shaft's spring washer 0 and collar

Using

(9)

the

(10) Pull out the plug cover 0

(II)

Cut at

the

(12)The frame assembly 0 can then be removed from bracket assembly L

A slight impact may be

(Note)

the

commutator part

(see

Fig. 3) of

the

rotor

does

not touch the magnet inside

0.

molex pin remover (J5800-03), take out all pins from the 6-pin plug

and

crimped part of

the tube 0 from the cord assembly

the

two black cords,asclose

the

0.

endofthe

cordaspossible,

0.

necessary

to facilitate removal.

the

0.

and

then

separate.

Performsteps 1-3 below before removingthe rotor on motors witha serial number ending withany letter G-Z(see the motor

name

plate).

(1) Remove the screw 0 and Reactor cover
(2) Remove the screw 0 and Reactor

(3) Remove the screw

©.

0.

0.

washer

frame.

Q.

No.123456G^

(Fig.

G

and

thereafter

1)

indicate

-80-

Assembly

(1)

Pass

the

cable

of the new frame assembly through bracket assembly L.

When doing so, note the following.

1) Be careful that

2) Be

sure

Frame

Assembly

to align

the

cable

the

bracket's rib with the

Bracket Assembly L

is not

caughtinthe

spaceofthe

frame.

upper

magnetinthe

frame.

Space

of upper magnet in frame

(2)

Align

the projection of bracket R with the groove of bracket L, and then try the insertion.

Note that insertion

magnet

within

the

cannot

frame.

Bracket

be completely in unless

rib

For alignment , move the position of hte frame assembly.

(3)

When

the

installation position of

the

frame

assembly

way into bracket L.
Atthis time the rotor must be

the

frame.

Be

sure

not to forget to

grasped

check

tightly so that

whether

or not

the

rib within bracket R is aligned with

is adjusted, remove bracket R

the

commutator part of the rotor

the

spring

washer

is included.

once

does

the

again

and

not contact

(Fig. 2)

clearance of the upper

Align

push

the

rotor all

the

magnet inside

the

Commutator

(4) Install bracket Rsothat it is positioned to bracket Lasdescribed in 2. above.

When the position is correct, gently tap it in by using a wooden hammer.

(5) Insert

and

tighten

the

four

secresinthe

screw

holes

-81

in bracket L.

-

(Fig. 3)

(6) Temporarily

(7) Insert the

secure

washer

the

brake

stater

assemblytobracket

and

woodruff key to the rotor shaft,

(8) Make the positional alignment of the brake stator.

R by

using

the

screw.

and

then insert the brake armature

Brake

Stator

assembly.

Brake

Armature

Clearance

Adjust the position of the brake stator so that,asshown in the figure at the right, the clearance

armature's
heardifthere

After
armature interferes, remove the brake

armature

the

correct position

stopper

ant

is contact,sothe

has

been

the

inner

sideofthe

position is OK if no

determined, tighten the

armature

after tightening to a certain extent,

brake

stator

noiseisheard.

screw

that

when

the

brake

armature

was

previously temporarily tightened. If

and

Armature

opens

between the brake

is rotated. A

then

tighten further.

noise

the

Stopper

will

be

brake

(9) After installing the pulley and securing with the three screws, tighten the 14 lock nut to the rotor shaft.

(10) Install the belt

cover

and

tighten the screw.

(11)Simultaneously crimp together,asdescribed below, the black cord divided at the time of disassembly and the new

frame's

black

cord.

Plug pin

Thick

Thin

black

black

cord

cord

-82-

Plug pin =

Pin

Crimper = JHTR

remover

Part

=

No. 217133-001

molex

J5800-03

1031C

(12)

(13)

Pass

all

through

If,

rather

thananew

Pass

all plug pins through the plug cover and insert at the 6-pln plug's designated position.

the

new

tube,

tube.

the

plate

tube

used

beforeIsusedasis,

Suitable

cord

the

following

Wrap

Red

Blue

Black

Black

methodIseasy.

with

tape

(two)

(14)

Secure

secure

(15) Insert

the installation plate by the screw,

the

cable.

the

carbon

brushesattheir

Base

line

designated

and

then affix two lead

positions

'

clamps

andinthe

Base

line

Base

line

to the holes at the upper part of the plate

correct

direction.

Base

line

and

Megger
After

test

assemblyiscompleted,

check

(by

usingamegger)tobe

-83-

sure

that

there

is 100

mega-ohms

or more.

i

INSTALLATION

OF

OPTIONS

)

m Operation

★

Remove the

★

Remove

★

The removed control panel can be turned over and attached to the

right
accessories

the

endofthe

front

control

tray.

panels

panel

(E-0)

box

cover

work

table

Models DB2-B737

from

the machine, and then

and

with

connect

wood

the

screws

connector.

for

use

install

as

the new optional operation panel (E-20/40/100).

Set

screw

Panel

guide

an

Cord

Cord clamp

Wood

screw

E-0

panel

Screw

Connecting

the

cord

1. Remove screwO.and remove face plate

e

2. Connect operation panel connector O to

the

circuit

board.

3. Fit

the

rubber

cushionOover

the

cord,

and fit the cord in the control box, being

carefui not to

damage

the

cord.

* When removing face plate0,unplug the

synchronizer.

-84-

ffi Installation of

1.

Remove

2. Of the six

3.

Mount

the

long

operation panel bracket O on the back of the arm bed

operation

three

screws

screws, use the

panel

O in

bracket

the

backofthe

long

screws O that are the same diameter as screws O-

arm

bed.

with

screws

O.

Models

Models

DB2-B791>

DB2-B748

B793

Models

u

DB2-B793-015
DB2-B795

Models

DB2-B798

panel

O-

eio

bracket

the

backofthe

arm

OHrtfwD

\e e

HB

Installation of

1.

Remove

bed.

the

operation

three

screws

2. Use the three long screws

O in

3. Mount operation panel bracket O on the back of the

arm

bed

with

screws

O-

Models

LT2-B842,
LT2-B847,

LT2-B872,

LT2-B845
LT2-B848

LT2-B875

LL

"nj

-85-

Material

o Be

sure

to turn the power switch off before Installing

-k When Installing

-k

When

Installing

edge

sensor

sensorI,remove

sensor

II, connect

Models

the

sensortothe

the

control

DB2-B737

connector on

box

cover

the

material

adn

edge
the

connect

sensor.

right side of

the

connector.

the

operation panel

Rubber

O-

cushion

Washer-

Screw

^Install

€f>

Collar

•

Reflector

the

reflector

below

the

sensor.

•Secure

so

that

Connector

the

cord

they

do not droop.

with

the

Cable

cable

stay

stay

sAlso

secure

clampsothat

the

cords

they

do not droop.

Screw

'Cord clamp

with

the

cord

Models

★

When

DB2-B748

Installing

sensorIIon the

operation

panel,

refertomodels

-86-

DB2-B791,

Models

o Be

sure

DB2-B791

to turn

the

power switch off before installing

the

material

edge

sensor.

§iToinstall

1. Shift

the

position of

Sensor

2. Remove the rubber

3.

Secure

BH

Material

sensorIIwith two

Operation

Screw

edge

sensor

II

the

operation

caponthe

screws,

panel

panelasshowninthe

side of

the

operation panel,

being careful not to pinch

figure below.

Sensor

Screw

and

the

II

connect

flat cable.

the

sensorIIconnector.

O

o

Washer

Screw

M Connecting

the

Collar

power

900

type

cord

Reflector

^Install

the

3

reflector

300

below

type:

the

sensor.

-87-

Models

DB2-B793,

DB2-B795

o Be sure turn the power switch off before installing the material edge sensor.

S

To

install

1. Shift

the

2. Remove
Secure

3.

Sensor

position of

the

sensorIIwith two screws, being careful not to pinch

Screw

11

the

operation panelasshown in

rubber

caponthe

Operation panel

sideofthe

the

operation panel,

Sensor

Screw

figure below.

and

connect

the

flat cable.

II

the

sensorIIconnector.

o

M Material

edge

washer

Screw

S Connecting

the

sensor

power

Collar

400,

cord

900

<a

type

Reflector

^Install

the

reflector

:300

below

type))

the

sensor.

-88-

Models

o Be sure turn the power switch off before installing the material

S

To

1.

Shift

2.

Remove

3. Secure sensorIIwith

ffi

Material

DB2-B798

install

the

Sensor

position

II

of the operation panel as shown in the

figure

the rubber cap on the side of the operation panel, and connect the sensorIIconnector.

two screws, being careful not to pinch the flat cable.

edge

sensor

edge

below.

n

sensor.

M

Connecting

the

power

cord

i

Models

o Be

M

To

1. Shift

2. Remove the rubber

3.

Secure

LT2-B842,

sure

turn

the

install

Sensor

the

position of

sensorIIwith two screws, being careful not to pinch

Operation

Screw

LT2-B845, LT2-B847,

power switch off before installing

II

the

operation panelasshown in

caponthe

panel

side of the operation panel,

the

the

Sensor

Screw

LT2-B848, LT2-B872,

material

figure below.

and

the

11

edge

sensor.

connect

flat cable.

the

sensorIIconnector.

LT2-B875

O

o

M Material

•^Install

edge

sensor

^1^

Reflector u

the

reflector

below

the

sensor.

Sensor

ffi Connecting

/S-^|o

the

power

cord

f

y.

-90-

(

USING

-k

The material edge sensor can be used to automatically stop the sewing machine when the material edge Is reached.

★

The material

•k To adjust the material

★

To adjust the materialedge stop positionwithsensor

stitches

HI

setting

Part

THE

edge

shownonthe

names

<

MATERIAL

sensor operates In conjunction with operation panels E-20/40/100, and cannot be used alone.

edge

stop position with

operation panel.

and

Sensor

functions

l>

EDGE

sensor

II,

change the mountingpositionof the sensor, or change the number of

SENSOR

I, change the mounting position of the sensor.

)

<

Sensor

II>

brother

8EN80RI

O

Sensor

O

Sensor

O Sensitivity control

O AUTO key

key

W.

7 •Press to

sensitivity Indicator

AUTO

/

•The

•Usedtoadjust

•Press

AUTO

•

/S

o

TVJ—1

light

the

Indicator.

Indicator Is out while material Is under

sensor

to lightthe Indicator. Whilethe IndicatorIson, simplypress the treadle once to sew automatically to the

material

edge.

Material

sensitivity.

edge

detectionIsactive

the

sensor,

and

8EN80Rn

^ .

1

while

the

Indicator

lights when there Is no material under the

Is on.

sensor.

O Thread trimmer key

•Presstolight

•>§

Adjusting

•Press

•The

*1) To cancel

*2)

the

Indicatorwilllight.

If the sensitivity control Is turned too far In step 3 above, the material edge sensor

IndicatorIson.

sensor

key.

the

material

the

the

Indicator.

material

•Turn

control

•The

Indicatorwillgoout.

edge

sensor,

edge

the

sensitivity

up.

press

Thread

the

trimming

sensor

sensor

-91

will

be performed automatically at the

•Slowly

turn

the

backdown. A underthe sensor.

•Stop

where

the

Indicator

lights.

key O again so

-

the

control

I

Indicator

material

i

•Insertapieceofmaterial

Make

sure

out.

goes

out.

will

not

function

the

properly.

edge

Indicator

while

Matenal

goes

the

C

USING

THE

PRODUCTION

QUANTITY

COUNTER

)

•k The number of completed work pieces can be displayed on the stitch number display on the operation panel.

★

The production quantity counter operates in conjunction with operation panels E-20/40/100, and cannot be used alone.

11

Part

names

and

functions

Production quantity display indicator

•The

counter

this

indicatorison.

Production quantity

•The

production quantity display
indicator lights when this switch is on,
and

the

the

in

operates

production quantity is displayed

LED on the operation panel.

only

counter

when

switch

PUSH

COUNTE

Counter plus switch

•Press

to increment the production quantity in the LED.

Model E-20 only/Nur E-20

•Display

Press to

and

The

displayed.

Counter

•Press

V

Counter

•The

*With operation panel E-20, [00] will be displayed.

selector

display

hundreds

first two digits (ones, tens)

minus

to decrement the production quantity

in

the

LED.

deiar

production quantity counter will be

when

the

are

pressed

show

[0000].

switch

the 3rd and 4th

places) in the

switch

switch

counter

plus

simultaneously,

and

digits

counter.

are

minus

and

the

normally

switches

(thousands

cleared

display will

<E-20>

I A B I

<E-40>

i A B I I C

<E-100>

[oJ

t / I / I / I

/ E /

*1)The

*2) The production quantity is displayedsolongasthe production quantity indicator is on.

same

display is used to separately display the firsttwoand second twodigits(1s, 10s and 100s, 1000s) on the E-20 panel.

The

100s

and

1000s

places

are

displayed when

The production quantity is displayed in four digits, e.g. [9999], on

Note

that

start

and

end

backtack will not be displayed at this time.

the

selector

I F I I E I

switch is

pressed.

the

E-40/100 displays.

PI

[Oi

-92-

12

Production

-k The production quantity counter operates in conjunction with operation panels E-20/40/100, and cannto be used alone.

ir Mount the production quantity counter to the table with wood screws O­k Secure the production quantity counter cord to the underside of the table with a staple O-

quantity

counter

-93-

D

printed-circuit

wMte

arean

board

1-110V

F

(1A>

assembly

orjnjtt.

_oiM08

G>A\Ar©

R9

CS

VWi

orsngtf

IZI

lllll

TrmX

flo

CHI

blu«_

orav

O—-®

B

Symbol

C1
C2.
C5

C4-1.
C4-3.

R1

R6,7.8

R9

TRM

60

R2.

R4

RS

L

F

ZR
HOV

OSA

FIN

flC

+C

CC

cec

BC

EC

s

Q

R

FA

Code

228372001

C3

228373001

228356001

-2

233641001

-4
228375001

228368001

228366001
233643001

224119000

R3

234373001

090393320
090224320

228358001
228359001
233645001
232382001
232384001

233637001

22B384001
233649001
233650001

233661001

233662001
233653001
218859001
233655001
227189001
225433001

216469001

Name

MTa-2G-105K
MTB-2G-222K
M00-2J-104K

HFR20681M

MF540AR2K
MSS05NR1K
MSSlONSReK

SITRMIOI30F-050

SIOS15Va40
EBC-1GJ473

ERD-50TJ393

ERO-60TJ224
SF-T10-50M

Fuse

HolOer

ENC2710-10A

HV620D10

05A362MA
27Cy078

RC

cooe

f •

c •

CE

•
6 •
E •
Band

HiSO

Band

U270

Fastener

Fuse

Holder

Fuse

16A

5.2L

S-N50S1

93

Note

400V.

luF

1

400V.

2200pF

2

630V.0.lUF

1

200V.680UF

4

40W.0.2 G

1

5W.0.1
10«.5.6 C

1

450V.30A

1

400V.ISA
IW.

47K

0.

5V.

39X

0.

5V.

220X

3A

270V
620V

Syrnhnl

A
8
0

E

F

N

M

CNA
CNB
CNC

CN1*CN2

ypi

yp2

p

Code

233636001
224090001

062501680

025060370
028050280
021500260

224120001

233688001
216872001
230862001
228376001
228296001
228383001

228371001

228379001

233639001

Name

Connector

Label

16A

screw

5X16

Hasher

5 2

soring

Hasher

Nut

2-6

Sat

screw

wire

Label

set

screw

Power

connector

Motor

Connector

Trans

Connector

Fie

Connector

Juiwer

Hireo.8X30

yunoer

wire0.8X55

FIN

70X110

Base

4X160S

axsos

-4

2-5

Assem.

Assem.
Assem.

Assem.

Qty

1

1
2

2

2

1
1

1

1
1

1

Note

-94-

MD^02,

803

D-PCB1-110V-B

291273101

1

Phase

110V

NOTE: This D-PCB

•

assembly

6*

is interchangeable for MD-802.

voilow

oray

05

vnlte

X

T

D-PCB

1-liOV-B

Emmna

n

5:

7ciiiTcN2

-95-

RH

detalis

E

BROWN

CE

VIOLET

B1

WHITE

c

obanbe

{5)—0—©—®

D printed-circuit

MOV

-N ®

grean

Symbol

C1
C2.

C3

cs

C4-1.

C4-3.
R1

RB.7.B

R9
TRM
BO
R2.

R3

R4

RS

L

F
ZR

KOV

DSA

FIN
RC

tc

CC

CEC

3C
EC

S

0
R
FA

Code

229143001

228357001
228356001

233640001

-2

-4
229140001

228368001

228366001

233643001

229142001

234372001

090393320

090224320

228358001
228359001

232380001

232382001
232384001
233637001

228384001

233649001

233650001

233651001
233652001
233653001
218859001
233655001
227188001
225433001
219225000

Name

MT8-2<)-105K

MDD-2J-223K
M0D-2J-104K
KPR2W221M

MFS40AR4X
MSS05NR1K

MSS10NSR6K

SITRM1DI30F-0S0
SIDS15VB60

ERC-1GJ224
ERO-SOTJ393
ERO-50TJ224
SF-T10-60M

FUS9

ENC6210-10A

NV620D10

DSA3S2MA
27CU078

RC

code

+ • 1

c *

CE *

8 *

E *

Bend

send

Feeteners.2L

Fuee

Fuee

board

Holder

Miso

M270

Holder

8A

DSA

s-n50si

03

1-240V

F

<1A)

Q tw

1

2

1

4

1

1

1

1

1

1

1

1

1

1

1

1

1

1
1
1

4

1

1

1
1

assembly

oratyjp

Note

630V,

luF

630V.

2200PF

eSOV.0.lUF

450V.220UF

40V.

0.4

5V.0.1 N
lOV.5.6

450V.

30A

600V.

ISA

IW.

220X

0.

SH.

38K

0.

5V.

220K

3A

620V
620V

R1

oxcinae

A

8

0
E

F

G

C
M
CNA
CNB
CNC
CN1+CN2

OPl

JP2

P

Symbol

ZlZlZ

orengo

ZZ Z

C4

D4

Code

233836001

233838001
062501660

026050370

028050280

021500260

224120001

233688001

216872001

229146001
228376001
229146001
228383001

228371001

228379001

23363S001

W\H

Name

connector
Uabel

Screw

weeher

Spring

Nut

Set

wire
Set
Power
Motor

Trans

FI8

Jumper

Jumper

FIN

RB

C5

TRH-L

vhitfO ,

5X16

5

weeher

2-5

screw

Label

screw

Connector
connector

Connector

Connector

Wire

wire

70X110

Base

8A

4X1608

4X808

(Vlot

0.8X30

0.8X55

ro^n

-4

2-6

Assent

Aseem.
Aasem.

Assent

CMl

Q 'tv

1
1

2
2

2

2

1

1

1

1

violat

-O—®

bluo^s

O—@

1
1

1

1

_4

iuo^i

Note

-96-

MD-802,

803 D-PCB1-240V-B 291274101 1

Phase

240V

NOTE: This D-PCB assembly Is interchangeable for MD-802.

•

F(1A)

A

T

D-PCB

1-iaov-B

[znminii

T

Drovn

6i

R7|

RbI

n

yellow

vnlte

CNltCN2

-97-

en

detalis

E

BROWN

CE

VIOLET

B1

WHITE

c

ouawse

<s)—(i>—0—®

o

,^

D

printed-circuit

lo

s

board

0

3-240V

gg

iii

assembly

orenae

orenoe

R9

TRM-1-Ivio

CS

violet

4

-O—®

6' 5

Svmtjol

Cl.
Cll.

eg

C12
ClO

C7-1.

R1

Rg

R6. R7.
TRM

SO

Vfl
SCR

SBS

DB
R2

R4

R5

Ri3
RlO-1.-2

R12-1.

R14
Rll

L
F
ZRl.

HOV

DSA
FIN
TC

♦C

cc

CEC
ec
EC

RC

AC
QC
S

a

R
FA.

C2. C3.

C13

-2

ZR2.

FB

i^R3~ci"::

wMte

0

adk

b

Ick

F

lA

Code

ca

228358001

226357001

754740040

YS1040040

Y54730040

233840001

226383001

22B388001

RB

226388001
23384300!
234386001

229146001

226816001

226027000

226144001
234372001

090383320

090224320
234374001
090244320

-2

090822120

090102120
228358001

228366001

ZR3

2323B0001
232362001
232364001
233837001
226366001

233849001
233850001
233861001

233852001

233853001

226384001

233854001

234368001
218669001
233655001
227189001
224087001
215622000

Name

U0D-20-104K

HDD-2J-223K

EC0-V1H474JZ
ECO-V1H104JZ
ECQ-V1K473JZ

HPR2V221U

MFS40A020K
MSS10N5R8K
MSSOSHRIK

SITRUIOI30F-050
SiDDF20DQ

CVR-lRLB502RiJ-6P

SCRCR8AM-12

8S08A

SIDS12KC40
ERC-1GJ224
ERO-50TiJ393
ERD-50TJ224

ERC-1Q0330

ERO-50T4244

ERD-26TJB22
ERO-25TJ102

SF-T10-50M

Fuse

Holder
EHC6210-10A
HV820010

DSA362MA

27CU078

T

code

+ •

c •
CE

•
8 •
E •

R '
A •

0 •
Band

H150

Band

H270

Faatener

Fuse

Holder

Fuse

SA

5.2L

S-N5051

82

Note

QVy

830V.0.lUF

8

6307.0.022UF

3

50V.0.47UF

1

SOV.0.luF

1

60V.0.047UF

1

4S0V.220UF
40W.

1

low.5.8 J

1

5W.0.1
4S0V.30A

1

800V

1

6K

1

800V.

1

BV

1

400V.

1

IW.

1

0.

5W,

1

0.

5V.

1

IW,

1

0.

5W.

4

0.

25W.8.ZK

1

0.

25W,

1

3A.

1

820V
820V

2

2 1

20A

8A

12A

220K

39K
220K

33

240K

IK

IIOUH

A

6
0
E
F
G

H

K

L

M

CNA
CN8
CNC

CN1»CN2

dPl

JP2

C
N
P

Svmbnl

I

til

233636001

224089001

062501660

025060370

028060280
021500260
062301260
025030270
028030280
021300260

062300860

216872001
228386001

228376001
228367001
228363001
226371001

228620001
233666001
217093001
233839001

Code

Name

Connector

Label

5A

Screw

5X18

washer

5 2

Ssrino

washer

Nut

2-5

Screw

3X12

washer

3

SorIno

washer

Nut

2-3

screw

3X8

Set

Screw

Power

connector

Motor

connector

Trans

Connector

FI9

connector

Jumoar

wireo.8X30

juntoer

wire0.8X15

wire

Label

Set

Screw

FIN

70X110

ease

4X606

4Xi20

m"

-3

2-5

2-3

Assam.

Assem.

Assein.
Asssm.

CNl

3 2

l—(>—©

Q ty

1

2
2

2
2

1

2
2
2

1

3
1

1

1
1
2
1

1

2

Note

-98-