JUKI ACF-164-1903 Engineer's Manual

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Button Attaching Indexer

ACF-164-1903

ENGINEER’S MANUAL

29347606

No.00

PREFACE

This Engineer’s Manual is written for the technical personnel who are responsible for the service and maintenance of the sewing machine. This manual describes “Adjustment Procedure”, “Results of Improper Adjustment”, and other functions which are not covered by the Instruction Manual intended for the maintenance personnel and sewing operators at a sewing factory. All personnel engaged in repair of ACF-164-1903 are required to carefully read Section 2 “Standard Adjustment” which contains important information on the maintenance of ACF-164-1903. The “Standard Adjustment” consists of two parts ; the former part presents illustration and simplified explanation for the convenience of reconfirmation of the required adjustment values in carrying out actual adjustment after reading this manual once; and the latter part provides “Results of Improper Adjustment” in which sewing and/or mechanical failures, and the correcting procedures are explained for those persons who perform such adjustment for the first time. It is advisable to use “ACF-164-1903 Parts Book” together with this Engineer’s Manual.

CONTENTS

1. SPECIFICATIONS .......................................................................................................... 1

(1) Main unit................................................................................................................................................ 1

(2) Button sewing machine ......................................................................................................................... 1

(3) Button feeder......................................................................................................................................... 2

2. CONFIGURATION OF THE MAIN PARTS .................................................................... 3

3. NAME OF EACH PART AND PREPARATION FOR TRIAL RUN................................. 4

(1) Operating switches................................................................................................................................ 4

(2) Adjusting the seam allowance............................................................................................................... 6

(3) Adjusting the position of the work clamp............................................................................................... 8

(4) Adjusting the stacker............................................................................................................................. 9

(5) Adjusting the knee switch...................................................................................................................... 9

4. OPERATION OF LK ..................................................................................................... 10

(1) NAMES ON THE operation BOX OF LK............................................................................................. 10

(2) HOW TO OPERATE THE operation BOX OF LK ............................................................................... 10

1) Setting the item data.................................................................................................................... 10

2) Changing to the other sewing pattern........................................................................................... 13

3) Performing sewing using the function keys ( P1, P2 and P3 keys) ........................................ 13

4) Adjusting the position of the button clamps ..................................................................................14

5) Checking the contour of a sewing pattern .................................................................................... 15

(3) Winding the bobbin thread .................................................................................................................. 16

1) To wind a bobbin while the sewing machine is performing sewing .............................................. 16

2) To wind a bobbin independently................................................................................................... 16

5. ADJUSTMENT OF COMPONENTS OF LK ................................................................. 17

(1) Adjusting the feed plate....................................................................................................................... 17

(2) Adjusting the button clamp jaw lever................................................................................................... 17

(3) Adjusting the lifting amount of the button clamp ................................................................................. 18

(4) Adjustment of the pressure of the button clamp unit........................................................................... 18

(5) Adjustment of the wiper....................................................................................................................... 19

(6) Adjustment of the wiper spring............................................................................................................ 19

(7) Adjusting the rising amount of the thread tension disk........................................................................ 20

(8) The moving knife and counter knife .................................................................................................... 20

(9) Cleaning the filter ................................................................................................................................ 21

(10) Adjusting the height of the needle bar............................................................................................... 21

(11) Adjusting thre needle-to-hook relation .............................................................................................. 21

(12) How to use the memory switch ......................................................................................................... 22

1) Starting the memory switch .......................................................................................................... 22

2) Example of the memory switch setting .........................................................................................23

3) Setting the counter operation ....................................................................................................... 24

4) Table of functions of the memory switch ......................................................................................25

6. OPERATION OF ACF .................................................................................................. 26

(1) Explanation of the operation panel of ACF ......................................................................................... 26

(2) Preparation before operation .............................................................................................................. 27

(3) Inputting and confirming data.............................................................................................................. 27

1) Memory number selection ............................................................................................................ 27

2) Input of the sewing data ............................................................................................................... 28

3) Checking the sewing data ............................................................................................................ 31

4) Counter settings ........................................................................................................................... 33

(4) Operation ............................................................................................................................................ 34

1) Automatic operation...................................................................................................................... 34

2) Manual operation.......................................................................................................................... 35

3) Independent operation.................................................................................................................. 35

4) Emergency stop............................................................................................................................ 36

5) Error message and the reset procedure....................................................................................... 36

7. SWITCHES INSIDE THE PANEL BOX AND THE CONTROL BOX ........................... 42

(1) Inside the panel box ............................................................................................................................ 42

(2) Inside the control box .......................................................................................................................... 42

8. ADJUSTMENT OF UNIT .............................................................................................. 46

(1) Carriage unit........................................................................................................................................ 46

(2) Button feeder components .................................................................................................................. 56

(3) Detecting mechanism and its adjustment ........................................................................................... 63

(4) Replacing the components and positioning them ...............................................................................66

9. MAINTENANCE INSPECTION..................................................................................... 69

(1) Maintenance and inspection of the sewing machine components ...................................................... 69

(2) Maintenance and inspection of electrical components........................................................................ 69

(3) Diagnostic feature ............................................................................................................................... 69

10. PERFORMANCE FLOW CHART............................................................................... 75

11. SEQUEMCE CHART .................................................................................................. 83

12. AIR PIPING................................................................................................................. 85

13. WIRING COMPONENTS ............................................................................................ 87

14. CONFIGURATION (ELECTRICAL UNIT) .................................................................. 89

(1) Components of control box and its function ........................................................................................ 89

(2) Connector and its functions of the control box .................................................................................... 90

(3) Power voltage ..................................................................................................................................... 91

(4) Measuring the DC power voltage........................................................................................................ 92

(5) Changing the thermal values inside the switch box ............................................................................ 93

(6) Replacing fuses................................................................................................................................... 93

(7) Replacing the P-ROMs for data .......................................................................................................... 94

(8) CPU circuit board ................................................................................................................................ 95

(9) I/O circuit board................................................................................................................................... 96

(10) Power circuit board ........................................................................................................................... 97

(11) Panel circuit board ............................................................................................................................ 98

(12) Functions of the stepping motor driver.............................................................................................. 98

(13) I/F circuit board whole asm. .............................................................................................................. 99

15. BLOCK DIAGRAM ................................................................................................... 100

16. BLOCK DIAGRAM ................................................................................................... 101

17. WIRING DIAGRAM................................................................................................... 102

18. CIRCUIT DIAGRAM ................................................................................................. 105

(1) Transformer (ass’y) ........................................................................................................................... 105

(2) Power circuit board (ass’y) circuit diagram ....................................................................................... 106

(3) Circuit diagram of the stepping motor driver (ass’y).......................................................................... 107

(4) Circuit diagram of the stepping motor (ass’y).................................................................................... 107

(5) Circuit diagram of the indexer switch ................................................................................................ 108

(6) Output circuit board diaram............................................................................................................... 109

19. TROUBLES AND CORRECTIVE MEASURES........................................................ 111

20. TROUBLES AND CORRECTIVE MEASUTRES ..................................................... 112

1. SPECIFICATIONS

(1) Main unit

1 Feed interval : 25 to 650 mm (1 to 25.6”) 2 Overall feed amount : 650 mm (25.6”)

(When the machine is set to the long-sized material sewing mode : 1,200 mm)

3 Number of buttons

which can be sewn : 1 to 20 pcs. (the machine is

set to the independent sewing mode when sewing only one button on the material.)

4 Distance from the top end of the

garment body to the 1st button : 40 to 140 mm (1.6 to 5.5")

(20 mm or more : when the special order part is used.)

5 Distance from the side end of the

garment body to the button : 12 to 25 mm (0.5 to 1")

6 Applicable garment sizes

that can be sewn (standard) : Width 220 to 420 mm (8.7 to 16.5")

Length 400 to 880 mm (15.7 to 34.6")

7 Number of patterns

that can be stored in memory : 20

8 Power supply : 200V (3-phase) (Rated voltage ±10%) 9 Power source frequency : 50/60 Hz

!0 Power consumption : 600 VA (Rated voltage ±10%) !1 Operating air pressure : 0.5 MPa !2 Air consumption : 20 Nl/min. or less !3 Machine dimensions : Width 1,860 mm

Depth 970 mm Height 1,250 mm

!4 Weight : 220 kg

(2) Button sewing machine

1 Machine head : LK-1903 (exclusive machine head) 2 Sewing speed : Normal 2,300 rpm

Max. 2,700 rpm [only when using the Z165 (for small button) and cotton thread]

3 Needle : DP x 17 #14 4 Buttons : Kind : Flat buttons (2-holed, 4-holed) 5 Lifting amount of

button clamp jaw lever : 11 mm

6 Number of standard patterns : 33

Standard

For small buttons

Outer diameter of buttons to be sewn (mm)

Length

Sewing size (mm)

Button clamp jaw lever

Width

Thickness

(mm)

Right

Part No.

Left

MAZ165070B0 H

MAZ167140A0

ø10 to ø15

0 to 3.5 0 to 3.5

2.2

Engraved

mark

Optional

For medium-size buttons

ø12 to ø18

0 to 4.5 0 to 4.5

2.7

Engraved

mark

MAZ166070B0 J

MAZ168140A0

Needle hole guide Feed plate

MAZ15601000 MAZ15502000

− 1 −

MAZ15601000 MAZ15602000

(3) Button feeder

1 Discrimination of buttons to be fed : By vibration system using the piezoelectric feeder 2 Button setting method : Buttons are loaded from the rear section of device 3 Individual button feed : By index method 4 Detection of a failure : Provided with three detectors ™ The first detector detects a

button at the section where the button is correctly positioned.

™ The second detector checks

whether the button is correctly inserted in the carrier pin.

™ The third detector detects a

button at the button clamp jaw lever.

5 Driving source for the feeder : DC motor (24 Vdc) 6 Function of sewing buttons

without cross-over stitch : Provided

7 Automatic button

discharging function : Provided

8 Independent operation of the

sewing machine : Possible

9 Time required to feed a button : 0.5 sec./pc.

Noise: Workplace-related noise at sewing speed

n = 2,300 min–1 : LPA ≦ 84 dB(A) Noise measurement according to DIN 45635-48-B-1.

− 2 −

2. CONFIGURATION OF THE MAIN PARTS

!0!1

!1 Conveyor !2 Cloth plate !3 Operation panel of the feeder !4 Air gun !5 Operation box of LK

1 Sewing machine head 2 Button feeder 3 Work clamp (carriage unit) 4 Stacker 5 Operation panel of ACF

6 Power switch 7 Knee switch 8 Emergency stop switch 9 Hand switch

!0 Thread stand

!6 Hand pulley

CAUTION : To avoid malfunction and damage of the machine, confirm the following :

1. Before you put the machine into operation for the first time after the set-up, clean it thoroughly. Remove all dust gathering during transportation and oil it well.

2. Confirm that the voltage has been correctly set. Confirm that the power plug has been properly connected to the power supply.

3. Never use the machine in the state where the voltage type is different from the designated one.

4. The sewing machine has been completely adjusted at the time of delivery. For caution’s sake, however, turn ON the power switch after releasing the stop-motion and turning the handwheel by hand when operating the machine for the first time.

5. Operate the machine with the air pressure set to 0.5 MPa (5 kgf/cm2).

− 3 −

3. NAME OF EACH PART AND PREPARATION FOR TRIAL RUN (1) Operating switches

7 8

1 Power switch

Use this switch to turn ON/OFF the power to the unit. (If installing the optionally available MC-6,use independent power for the MC-16 that is located on section A on the right-hand side of the main unit.)

2 Emergency stop switch

Use this switch to stop the machine from running.

3 Knee switch

This switch is used as the start switch.

4 Hand switch

This switch is used as the work clamp release switch.

5 Feeder switch 6 Button feeder switch

Used to supply buttons to the button clamp jaw lever.

7 Set-up switch

This switch is used for operating the spinner oscillating arm under the step-operation mode. The spinner oscillating arm performs step operation as long as the switch is held pressed.

8 Button discharging switch

This switch is used to discharge buttons in the index unit.

− 4 −

9 Feeder breaker

This is the breaker for the spinner oscillating arm motor and index unit motor. This breaker can be reset by pressing.

!0 Men’s / Ladies mode selective switch

Used to change modes when sewing men’s or ladies’ wear.

!1 Body of the garment / finished garment mode selective switch

Used to change modes when sewing garments using the finished workpiece table (Optional : G55101640A0).

!2 Stacker release switch

This switch is used when sewing garments using the second presser (Optional : G55141640A0).

Stacker release switch

This switch is used for taking out the materials from the stacker after the predetermined number of pieces of finished material has been stacked. Lift lever in the direction of arrow A , and the second presser will move away from the stacking board to allow the operator to

take out the materials from the stacker.

(Caution) Do not take out the workpieces while the

stacker is in operation. Doing so is very dangerous.

− 5 −

(2) Adjusting the seam allowance

1 In the case of sewing garment bodies of men’s wear (set Men's/Ladies' mode selective switch !0

mounted on the right-hand side of the operation panel to its lower side.) (See p.4.)

1) Adjust the seam allowance from the side end of

™Adjusting distance A

the garment to the button (distance A in the figure), and from the top end of the garment to the 1st button (distance B in the figure.)

(Caution) Be sure to make adjustment of the seam

allowance after you have turned OFF the power switch.

2) The number of buttons and the intervals between the buttons can be adjusted using the panel switches. (Refer to “Inputting the sewing data” on page 28.)

As viewed from above the unit

Loosen screws 1 in setting plates,right 2 and left 3. Shift the respective setting plates to the desired values and tighten the screws.

™Adjusting distance B

As viewed from above the unit

Loosen thumbscrew 1, and shift gauge 2 to the right or left until desired scale value 3 is reached. Then tighten the thumbscrew.

− 6 −

2 In the case of sewing garment bodies of ladies’ wear (set Men's/Ladies' mode selective switch !0

mounted on the right-hand side of the operation panel to its upper side.) (See p.4.)

1) Adjust the seam allowance from the side end of

the garment to the button (distance A in the figure), and from the top end of the garment to the 1st button (distance B in the figure). The number of buttons and the intervals between

the buttons can be adjusted using the panel switches. (Refer to “Inputting the sewing data” on page 28.)

(Caution) Be sure to make adjustment of the seam

allowance after you have turned OFF the power switch.

2) Adjust dimension A for ladies’ wear should be adjusted following the same procedure as that for men’s wear.

™ Adjusting distance B

Insert gauge 1 for ladies’ wear supplied with the machine into setting plate,right 2. Then shift the setting

plate to the right or left according to scale value 3 desired.

™ Dimension B can also be adjusted in the following procedure.

(Caution) In this case, perform the adjustment after changing over the operation mode from the

ladies' wear sewing mode to the men's wear sewing mode.

Move gauge 1 for ladies’ wear supplied with the machine toward the right-hand side of setting plate, right

2. Then sewing is carried out in the order from the button that is closest to the bottom edge of the garment

body toward the first button at the top.

− 7 −

(3) Adjusting the position of the work clamp

The position of the work clamp of this unit can be adjusted as desired according to the size of garment to be sewn.

1For garment bodies of men’s wear

5 1

Loosen knob 4 and shift left-hand side work clamp 2 to its leftmost position. Then tighten the knob so that the left-hand side work clamp is fixed at that position. Then loosen knob 1 and adjust the position of righthand side work clamp 5 according to the length of the workpiece to be sewn.

(Caution) When making adjustment,be sure that work clamp (right) 6 is positioned in the right side

of the last button and the distance between them is 40 mm or more. If work clamp (right) 6 is not positioned as stated above, the Error (E52) may occur when the machine runs under the automatic operation mode.

2 For garment bodies of ladies’ wear

Loosen knob 1 and shift left-hand side work clamp 5 to its rightmost position. Then tighten the knob so that the work clamp is fixed at that position. Then adjust the position of left-hand side work clamp 2 according to the length of the workpiece to be sewn.

(Caution) When making adjustment, be sure that work clamp (left) 3 is positioned in the left side

of the last button and the distance between them is 40 mm or more. If work clamp (left) 3 is not positioned as stated above, the Error (E52) may occur when the machine runs in the automatic operation mode. This device is equipped with a conveyer on its left-hand side. This may prevent you from setting garment bodies of ladies' wear in place on the machinre with ease. In this case, you can attach buttons of the garment from its bottom by using the jump function (see p.31.) and the men's wear sewing mode in combination.

− 8 −

(4) Adjusting the stacker

(Caution) The stacker provided for this device automatically computes the timing to stack the

garment regardless of its size and atacks the garments on the stacking board as long as its dimensions are about 180 mm wide or more and 1,000 mm long or shorter. (The stacker does not actuate under the long-material mode or the finished garment mode). Approximately 140 garment bodies (material: T/C broad cloth) with a folded top center plait can be stacked.

1) If the garment bodies are stacked on stacking board 3 with its side A shortened,loosen fixing knob 6 and raise stacking board 3. The stacker can also be adjusted by tightening speed controller 9 (turning speed controller clockwise) of work clamp cylinder 7. At this time,loosen fixing knob 4, and adjust so that work clamp 1 contacts with the center of stacking board 3. Then confirm that swing bar 2 does not come in contact with stacking board 3. (If the bar comes in contact with the board,loosen fixing knob 5, and adjust the height of the stacking board properly.)

2) If the garment bodies are stacked on stacking board 3 with its side B shortened, lower stacking board

3) The machine is designed to detect the quantity of garments stacked on the stacker using sensor 8 mounted on work clamp cylinder 7. You can make the alarm occur when the quantity of the stacked garment reaches the desired volume predetermined only adjusting the position of sensor 8 appropriately.

(Even when the alarm occurs,the machine will not stop running.)

(5) Adjusting the knee switch

As viewed from above the unit

1) Loosen screw 2 in the switch fixing plate 1, and adjust the stroke of the knee switch.

2) Now,confirm that presser plate 4 stops when stopper 3 is reached without fail.

− 9 −

4. OPERATION OF LK

(1) NAMES ON THE operation BOX OF LK

• Sewing LED

• Ready key

• Function key

• ＋ /Forward key

• − /Back key

• Reset key

• Data display

• Item selection LED

• Selection key: Every time this key is pressed, the selection will be made as follows.

Pattern No. → X Scale → Y Scale → Speed → Counter → Bobbin winder

↑

(2) HOW TO OPERATE THE operation BOX OF LK

1) Setting the item data

Set each item following the procedure described below.

Setting of the

pattern No.

Setting of the X scale Setting of the Y scale

1 Turn ON the power switch.

Pattern No. of the item selection lights up, and the pattern No. is indicated on the data display. (Pattern No. 1 has been set at the time of delivery.)

2 Setting of the pattern No.

SELECT

key to indicate the item “PATTERN

FORWARD

the standard sewing patterns (p.12).

SELECT

PATTERN No. X SCALE Y SCALE SPEED COUNTER WINDER

FORWARD

BACK

1) Press the No.”.

2) Press the screen. (Pattern No. is set to 14.)

(Caution) For the pattern No. refer to the table of

Setting of the max.

sewing speed limitation

key to indicate “ ”on the

BACK

− 10 −

3 Setting of the X scale

BACK

SELECT

PATTERN No. X SCALE Y SCALE SPEED COUNTER WINDER

SELECT

4 Setting of the Y scale

PATTERN No. X SCALE Y SCALE SPEED COUNTER WINDER

SELECT

FORWARD

BACK

1) Press the

SELECT

SCALE”.

2) Press the

FORWARD

range of 20% to 200%.

1) Press the

SELECT

SCALE”.

2) Press the

FORWARD

range of 20% to 200%.

key to indicate the item “X

key to set the scale in the

key to indicate the item “Y

key to set the scale in the

5 Setting of the max. speed limitation

PATTERN No. X SCALE Y SCALE SPEED COUNTER WINDER

FORWARD

SELECT

6 Finish of setting

READY

SEWING

BACK

1) Press the

2) Press the

SELECT

key to indicate the item “SPEED”.

FORWARD

key to indicate “ ” on

BACK

the screen. (Setting of 400 rpm)

1) Press the

READY

key.

2) After the work clamp feet have moved and gone up, the sewing LED lights up, and the sewing is ready.

＊ If the

key is pressed, you can make sure of

the set values of the respective items again.

(Caution) Use the sewing machine after checking the pattern No. If the Ready switch is pressed

while the pattern No. "0" is being displayed (state at the time of delivery), Error "E-1" is displayed. At this time, perform re-setting of the pattern No.

− 11 −

Pattern

No.

Stitch

shape

TABLE OF THE STANDARD SEWING PATTERNS

Number

of threads (thread)

Standard

sewing

size X

(mm)

Standard

sewing

size Y

(mm)

Pattern

No.

Stitch

shape

Number

threads (thread)

Standard

sewing

size X

(mm)

Standard

sewing

size Y

(mm)

1 (34) 6-6

2 (35) 8-8

3 10-10

4 12-12

5 (36) 6-6

6 (37) 8-8

7 10-10

8 12-12

9 (38) 6-6

10 (39) 8-8

11 10-10

18 (44) 6

19 (45) 8

20 10 3.4 0

21 12

22 16

23 (46) 6

24 10 0 3.4

3.4 3.4

25 12

26 (47) 6-6

27 10-10

3.4 3.4

28 (48) 6-6

12 (40) 6-6

13 (41) 8-8

14 10-10

29 10-10

30 (49) 5-5-5

31 8-8-8

2.9 2.5

15 (42) 6-6

16 (43) 8-8

17 10-10

32 (50) 5-5-5

33 8-8-8

＊ The standard sewing sizes of X and Y are when the enlargement/reduction rate is 100%. ＊ Use (34) to (50) when the button hole is small (ø1.5 mm or less).

Table of X/Y scales in terms of the sewing width

X, Y

(mm)

2.4 2.6 2.8 3.0 3.2 3.4 3.6 4.0 4.3 4.5 4.7 5.2 5.6 6.0 6.2 6.4

% 71 76 82 88 94 100 106 118 126 132 138 153 165 176 182 188

− 12 −

2) Changing to the other sewing pattern

READY

key. (The sewing LED will go off.)

SELECT

key to indicate the item “PATTERN

READY

PATTERN No.

X SCALE

Y SCALE

SPEED

COUNTER

WINDER

SELECT

FORWARD

1 Press the 2 Press the

No.”.

3 Set the items 2 through 6 of 1) setting the item

data, and move to the step of “5) Checking the contour of a sewing pattern”.

BACK

3) Performing sewing using the function keys ( P1, P2 and P3 keys)

If the patterns (No. 1 to 99) which have been already registered are registered in P1 to P7, the pattern calling can be made by one-touch without performing the selection by the pattern No. scrolling.

＊ When selecting P4, P5, P6 or P7, the selection can be made by the combination of

keys.

P1 : Press the P2 : Press the P3 : Press the

key. P4 : Simultaneously press the

key. P5 : Simultaneously press the

key. P6 : Simultaneously press the

P7 : Simultaneously press the

and

P1, P2

and

keys. keys. keys.

keys.

1 Registration to the function key

Setting example : Register the following setting to the P1. Pattern No. 3, X Scale rate : 50%, Y Scale rate : 80%, Max. sewing speed limitation : 2,000 rpm

1) Pressing the

2) Press the

3) Press the Set the pattern No. to Pattern No. “ ” using the

4) Press the

SELECT

key, turn ON the power switch.

key.

SELECT

key to indicate the PATTERN No.

SELECT

key, ans set X scale rate to 50%, Y Scale

FORWARD

BACK

key.

rate to 80% and Max. sewing speed limitation to 2,000 rpm using the

FORWARD

BACK

key.

5) Press the

＊ If you desire to register in P2 to P7, select P2 to P7 in combination of

READY

key to finalize the registration.

keys at the step 2),

and perform the steps 3) to 5).

6) When the registration has been completed, turn OFF the power switch, and again turn ON the powr switch. Then the sewing machine can be used as usual.

− 13 −

2 Sewing operation

BACK

Operation example : After performing sewing with the contents of the registered P1, perform sewing with the contents of P3.

1) Turn ON the power switch.

key.

READY

key, and when the sewing LED lights

READY

SEWING

2) Press the

3) Press the up, the work clamp foot goes up after it has moved.

4) Check the contour of the sewing pattern. (Refer to the item “Checking the contour of a sewing pattern”.)

5) If the contour of the sewing pattern is acceptable, the sewing can be made.

6) After the completion of sewing, press the

Then the work clamp foot will move to the sewing start point after the origin retrieval. The P keys can

READY

SEWING

operate the pattern change by one-touch even when the sewing LED is lighting up.)

7) Perform the above items 4) and 5).

✽ The P1 to P7 keys can be indicated on the display

when selecting the pattern by pressing the

key. → 0 to 99 ←→ P1 to P7 ←

key.

FORWARD

P1 to P7 which have not been registered are not indicated.

4) Adjusting the position of the button clamps

1) Set the mode to “Independent operation” mode

(P.35) with the operation panel of ACF.

2) Press the button feeding switch (P.4) on the BR control box, and place a button in button clamps 1.

3) When the knee switch (P.4) is turned ON, button

clamps 1 come down.

4) Holding the knee switch ON, turn the hand pulley until the digital display on the LK control box becomes E3.

5) Release the knee from the knee switch.

6) Further turn the hand pulley to lower the needle and confirm that the center of the needle is in the

Button

Holes in the button

center of the button.

(Caution) If the needle is returned to the up-stop

position when turning the hand pulley, E3 of the digital display on the LK

Needle entry position

control box will disappear, and the button clamps 1will go up.

7) When the center of the needle is not in the center of the button, loosen setscrews 2 in the button clamp unit and adjust so that the center of the needle is in the center of the button.

8) After the adjustment, turn the hand pulley to return the needle to its up-stop position. Then E3 of the digital display goes out and the button clamps 1go up.

9) Press again the button feeding button on the BR control box, place a button again and perform the step of checking the contour of a sewing pattern (P.15). Then confirm that the needle surely enters the hole in the button.

− 14 −

5) Checking the contour of a sewing pattern

FORWARD

RESET

FORWARD

BACK

1) Set the mode to “Independent operation” mode with the operation panel of ACF. (P.35)

2) Press the button feeding switch (P.4) on the BR control box, and place a button in button clamps 1. (See P.14.)

3) When the knee switch (P.4) is turned ON, button clamps 1 come down. (See P.14.)

Details of the sewing pattern at the sewing start

™ 1st stitch is a jump stitch and the needle does

not enter.

™ 2nd, 3rd and 4th stitches are tie stitches.

Needle enters in the same button hole.

3rd stitch

2nd and 4th stitches

1st stitch (jump feed) Needle does not enter.

After 5th stitch

Needle entry origin

4) Holding the knee switch ON, press the

FORWARD

key on

the LK control box, and the button clamps move by one stitch

If the

key is pressed even one time, the button

FORWARD

clamps do not go up even when the knee is released from the knee switch.

In addition, After the the

key becomes effective as well.

BACK

key has been pressed,

5) Turn the hand pulley to lower the needle and confirm that the needle enters the hole of the button.

(Caution) When the hand pulley is turned, E3 of

the digital display on the LK control box is displayed. When the E3 is displayed,

and

FORWARD

make

keys are ineffective. To

BACK

FORWARD

and

keys effective, turn

BACK

the hand pulley, raise the needle up to its up-stop position and make E3 go out.

6) After confirmation of the needle entry position, prees

the

key on the LK control box. The button

RESET

clamps return to the origin and go up.

(Caution) At this time, if E3 is displayed, the

RESET

key becomes ineffective. To make the

key effective, turn the hand pulley,

raise the needle up to its up-stop position and make E3 go out.

＊ Buttons cannot be fed during confirmation of the

needle entry position. When feeding the buttons

again, press the

key to return the button clamps

RESET

to the origin.

− 15 −

(3) Winding the bobbin thread

1) To wind a bobbin while the sewing machine is performing sewing

Thread the bobbin winder and wind the bobbin thread onto the bobbin as illustrated in the figure.

2) To wind a bobbin independently

1) Pull out the thread from the needle.

2) Winding a bobbin is performed at the position of the origin of the sewing machine. Be sure to remove the button from the button clamps.

3) Set the operation panel of ACF to “Independent operation” mode. (P.35)

4) Press

READY

key on the control box of LK to make the

sewing LED go out.

5) Select “WINDER” with the box of LK.

6) Press again time, a display as shown below is indicated on the operation panel of ACF.

SELECT

PATTERN No. X SCALE Y SCALE SPEED COUNTER WINDER

Sewing machine start switch on operation panel of ACF

READY

SELECT

key on the control

READY

key to light the sewing LED. At this

＊＊＊＊＊ BOBBIN WINDING MODE ＊＊＊＊＊

LK BOBBIN SW OFF

7) Press the sewing machine start switch on the operation panel of ACF. Then the sewing machine rotates and bobbin thread winding is started.

8) To stop the operation, press again the sewing machine start switch on the operation panel of ACF or press any key on the control box of LK.

9) To return to the normal sewing, press again “WINDER” with

SELECT

key and press again

READY

key on the control box of LK, select the item other than

READY

key to light the sewing LED.

10) At this time, a display as shown below is indicated on the operation panel of ACF. Then press

switch on the operation panel of ACF.

14 ＊＊＊＊＊ LK NOT READY ＊＊＊＊＊＊＊

LK CHECK → RESET → START

＊ Sewing machine start switch does not work for two seconds after stop of bobbin winding operation. ＊ Buttons cannot be fed during bobbin winding operation. ＊ When the operating method of operation panel of ACF is “Automatic operation” (P.34) or “Manual

operation” (P.35), the sewing machine start switch does not work even when performing the aforementioned operations of steps 4), 5) and 6). Perform the operations of steps 9) and 10) once to set the operating method of the operation panel of ACF to "Independent operation" mode (P.35), and perform the operations of the aforementioned steps 4), 5) and 6).

− 16 −

5. ADJUSTMENT OF COMPONENTS OF LK

(1) Adjusting the feed plate

(2) Adjusting the button clamp jaw lever

0.2 to

0.4 mm

1) Select the pattern No. 99 using the operation panel.

2) Press the [READY] key on the operation panel. Then the button clamp unit will travel to the position of the origin and go up.

3) Press again the [READY] key to make the sewing LED go out.

4) Adjust feed plate 1 by loosening screw 3 so that needle hole guide 2 comes to the center of the recessed part of feed plate 1.

Bring the machine to its stop-motion state. Then lift button clamps 1. Loosen screw 2 in the button clamp jaw lever and adjust so that a clearance of 0.2 to 0.4 mm is provided between button clamp jaw 3 and hinge screw 4 when placing a button in between button clamps 1.

− 17 −

(3) Adjusting the lifting amount of the button clamp

1) Select the pattern No. 99 using the operation panel.

2) Press the [READY] key on the operation panel. Then the button clamp unit will go up and come to the position of the origin.

3) Press again the [READY] key to make the sewing LED go out.

4) Loosen two screws 1, and move work clamp foot lifting plate 2 back and forth in the direction of arrow to adjust so that the top end of button clam 4 is 11 mm above throat plate 3. Move work clamp foot lifting plate 2 in direction A to decrease the lifting amount, and move it in direction B to increase the lifting amount. After the adjustment, securely tighten screws 1.

5) Turn knob 9 of the spinner oscillating arm motor on the unit side, and when work clamp lifting arm 7 has stopped its lifting once, loosen screw 5 and turn work clamp hook 6 to adjust so that a clearance of 0 to 0.5 mm is provided between roller 8 and work clamp lifting arm 7.

6) After the adjustment, check that the buttons are securely supplied.

0 to

0.5 mm

11 mm

(4) Adjustment of the pressure of the button clamp unit

The pressure of the button clamp unit should be minimized as long as the material does not warp during sewing. Loosen adjusting screw 1 and turn adjusting screw

2 to obtain the aforementioned pressure.

− 18 −

(5) Adjustment of the wiper

2.5 mm 15 to 17 mm

(6) Adjustment of the wiper spring

1) Loosen screw 1 to adjust so that a clearance of

2.5 mm or more is provided between the wiper and the needle.

2) Loosen screw 2 to adjust so that a distance of 15 to 17 mm is provided between the end face of the wiper and the center of the needle. After the adjustment, securely tighten the screw.

(Caution) The position of the needle is where the

sewing machine has stopped at the end of sewing.

Wiper spring 1 retains the needle thread after thread trimming in between wiper 2 and the wiper spring. Correct properly the tension of wiper spring 1 so that the tension at that time becomes 0.2 to 0.3 N (a little higher tension than that of the bobbin thread coming out of the bobbin case).

(Caution) If the retaining of the needle thread is

excessive, the thread may protrude from the upper side of the button.

− 19 −

(7) Adjusting the rising amount of the thread tension disk

Widen

Narrow

(Thread tension disk)

(Tension release link)

1) Remove the top cover. Make sure that tension release pin 3 rides on tension release notch 4.

2) If the pin does not ride on the notch, push cam follower 5 by hand to the e direction, and rotate the main shaft in the correct direction to make a state as illustrated in the figure.

3) Under the state as illustrated in the figure, loosen setscrew 2 in the tension release adjusting arm. By moving tension release adjusting arm 1 to the left or right, the rising amount of the thread tension disk will change.

S type : 0.6 to 0.8 mm H type : 0.8 to 1.0 mm

(8) The moving knife and counter knife

0.5 mm

Throat plate

18.5 mm

(Caution) If the rising amount is insufficient, the

length of the remaining thread after thread trimming will be not stable. If the rising amount is excessive, after releasing the rising of the thread tension disk, the disk closing will be defective.

1) Loosen adjusting screw 3 so that a clearance of

18.5 mm is provided between the front end of the throat plate and the top end of thread trimmer lever, small 1. To adjust, move the moving knife in the direction of arrow.

2) Loosen setscrews 5 so that a clearance of 0.5 mm is provided between needle hole guide 2 and counter knife 4. To adjust, move the counter knife.

− 20 −

(9) Cleaning the filter

(10) Adjusting the height of the needle bar

Clean filter 2 of the control box fan once every week.

(Caution) The sewing machine may stop to protect

it from overheating when the sewing is continued in the state that the filter clogs with dust.

1) Pull screen kit 1 in the direction of arrow to remove it.

2) Wash filter 2 under running water.

3) Reinstall filter 2 and screen kit 1.

Engraved line for DP X 17

4 Upper engraved line

Bring needle bar 1 to the lowest position of its stroke. Loosen needle bar connection screw 2 and adjust so that upper marker line 4 engraved on the needle bar aligns with the bottom end of needle bar bushing, lower 3.

(Caution) After the adjustment, make sure that there is no uneven torque.

(11) Adjusting thre needle-to-hook relation

Relation between needle and engraved lines

1) Turn the handwheel by hand. When needle bar 1 has gone up, adjust so that lower marker line 2 engraved on the needle bar aligns with the bottom end of the needle bar bushing, lower.

− 21 −

2) Loosen setscrew 1 in the driver. Open inner hook

presser hooks 2 to the right and left, and remove inner hook presser.

(Caution) At this time, be careful not to make inner

hook Úò come off and fall.

0.05 to 0.1 mm

0 mm

7.5 mm

0 mm

3) Adjust so that the blade point of inner hook 4 aligns with the center of needle 5, and that a clearance of “0” mm is provided between the front end of the driver and the needle as the front end face of driver 6 receives the needle to prevent the needle from being bent. Then tighten setscrew 1 of the driver.

4) Loosen setscrew 7 of the shuttle, and adjust the longitudinal position of the shuttle. To do this adjustment, turn shuttle race adjusting shaft 8 clockwise or counterclockwise to provide a 0.05 to

0.1 mm clearance between needle 5 and the blade point of inner hook 4.

5) After adjusting the longitudinal position of the shuttle, further adjust to provide a 7.5 mm clearance between the needle and the shuttle by adjusting the rotating direction. Then tighten setscrew 7 of the shuttle.

(12) How to use the memory switch

1) Starting the memory switch

Pressing

READY

key and the indication of the memory switch and the sewing machine operation can be changed.

key, turn ON the power switch. The display gives

RESET

− 22 −

2) Example of the memory switch setting 1 Setting of max. sewing speed limitation

Example of setting : Setting the max. sewing speed limitation to 1,800 rpm.

1) After the memory switch has started, press the

FORWARD

BACK

key to

indicate “ ” on the display.

2) Press the

3) Indicate “1800” using the

4) After setting, register using the

READY

key to light up the sewing LED.

key.

BACK

READY

key.

2 Setting the soft start speed at the sewing start

The speed of the first stitch to the fifth stitch at the sewing start can be changed in a unit of 100 rpm.

Unit [rpm]

1st stitch 2nd stitch 3rd stitch 4th stitch

State when delivered

400

900 2,300 2,300

Setting range 400 to 900 400 to 2,700 400 to 2,700 400 to 2,700

5th stitch

2,300

400 to 2,700

(Caution) For the max. sewing speed, the memory switch No. 01 (setting the upper limit of sewing

speed) has priority.

Example of setting : The speed is changed as follows : 1st stitch 400 → 900 rpm, 2nd stitch 900 → 1,200 rpm

1) After the memory switch has started, press the

FORWARD

BACK

key to

indicate “ ” on the display.

2) Press the

READY

key to light up the sewing LED.

(The 1st stitch, 400 rpm. will be indicated.)

3) Press the

key to indicate “ ”.

FORWARD

(900 rpm is set.)

4) Press the

SELECT

key.

(The 2nd stitch, 900 rpm, will be indicated.)

5) Press the

key to indicate “ ”.

FORWARD

(1,200 rpm is set.)

6) After setting, register using the

READY

key.

− 23 −

3 Setting whether the calling of the pattern data is operative or not

By making inoperative the calling of the unnecessary pattern, this setting prevents the different pattern from calling by mistake. Also, it is possible to call and use the necessary pattern.

1) After the memory switch has started, press the indicate " " on the display.

2) Press the

READY

key to light up the sewing LED.

Indication on A section : 0 : Pattern No. Indication on B section : 0 : Calling is inoperative.

1 : Calling is operative.

3) Press the

4) Press the

5) Press the

6) After setting, register using the

key to make the indication on B " " → " ".

FORWARD

SELECT

key to make the indication on A " " → " ".

key to make the indication on B " " → " ".

FORWARD

READY

key.

(Caution) After operating the step 2), if the

setting will return to the state when the machine was delivered.

FORWARD

key is pressed, the

RESET

BACK

key to

3) Setting the counter operation

Example of setting : The production counter (adding counter) can be changed to the bobbin thread counter (subtracting counter).

1) After the memory switch has started, press the indicate “ ” on the display.

2) Press the

3) Press the

READY

key to light up the sewing LED.

key to indicate “ ”.

FORWARD

Indication on A section : 0 : Production counter

FORWARD

key to

BACK

1 : Bobbin thread counter

4) After setting, register using the

READY

key.

− 24 −

4) Table of functions of the memory switch

No.

Setting of the max. sewing speed limitation (in a unit of

Function

100 rpm) Starting speed of 1st to 5th stitch at the sewing start is

set in a unit of 100 rpm.

This function sets whether or not the calling of the

standard 30 pattern data is acceptable (Interference of the needle with the aork clamp feet can be prevented prohibiting the calling of the sewing pattern which is large than the work clamp feet). This function sets whether or not the display and change

of X/Y scale rate and max. sewing speed are acceptable. (Prevention of maloperation) Setting of the counter operation

Production counter : Adding counter Bobbin thread counter : Subtracting counter

This function sets the needle bar stop position.

Under the upper dead point stop mode, the machine rotates in the reverse direction from the upper stop position and returns to the needle bar upper dead point. Then it stops. Do not change the setting of Nos. 07 to 99.

07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 99

Setting range

400 to 2,700 rpm

1st stitch : 400 to 900 2nd stitch : 400 to 2,700 3rd stitch : 400 to 2,700 4th stitch : 400 to 2,700 5th stitch : 400 to 2,700 Pattern Nos. 1 to 33 can be individually set. 0 : Calling not accepted 1 : Calling accepted

0 : Effective 1 : Ineffective

0 : Adding 1 : Subtracting

0 : Upper position stop (53°) 1 : Upper dead point stop (0°)

State when delivered

2,300 rpm

400 rpm

900 rpm 2,300 rpm 2,300 rpm 2,300 rpm

0 0 0 0 0 0 1 0 0 0 1 0 0 0 0 8

− 25 −

6. OPERATION OF ACF

(1) Explanation of the operation panel of ACF

Switch

No.

Panel

indication

1 3

!3 !4 !5 !6

Switch name

Memory No. selector switch

Sewing data input switch

Sewing data check switch

Counter setting switch

6789 !0

Function and operation

Used to select the memory number.

Used to input the data for the number of buttons or button intervals. Used to check the data for the number of buttons or button intervals. Used toinput numbers for the shirt counter.

〜

Shirt counter clear switch

Back switch

Forward switch

Bobbin counter reset switch

Minus (reduction) switch

Plus (addition) switch

Number switch (numeric keys)

Entry key

Automatic operation selecting switch Carriage travel switch

Sewing machine start switch

Reset switch

Used to clear the numbers counted on the shirt counter. Used to return the current screen display or to shift the carriage to the left under the manual operation mode. Used to forward the current screen display or to shift the carriage to the right under the manual operation mode. Used to reset the number shown on the bobbin counter to the initial value (set value). Used to reduce numbers when inputting data.

Used to add numbers when inputting data.

Used to specify numbers when inputting data.

Used to enter numeric data.

Used to select automatic operation.

Used to move the carriage in the manual operation mode or independent operation mode. Used to actuate the sewing machine independently. Used to clear an error message on the display, and reset the machine.

− 26 −

(2) Preparation before operation

Be sure to check the following before turning ON the power switch.

1) The machine is supplied with an adequate amount of machine oil.

2) The power connector is properly connected and the voltage is correct.

3) The connectors are connected.

4) The operating air blower is connected and the operating air pressure is correct.

5) The machine rotates in the correct direction.

6) The “Function setting” described on pages 42 to 45 habe been made properly.

7) The sewing machine is in the state of stop-motion.

Turn ON the power switch. (Refer to the figure on the right.) After the work clamp goes up, the carriage is raised to start retrieving the origin. When retrieving the origin, the following message will be indicated on the display screen, and pressing any other switch except the emergency stop switch will not be possible.

AUTOMATIC BUTTON INDEXER ACF-164

JUKI Corporation

＊ The origin of carriage is the sewing start position of the first button. When the origin is reached, the standard indication of the memory numbers indicated before the power was tirned off will appear on the display screen.

No. 1 BUTTON = ＊＊ ps INDEX <1→ 2> = ＊＊＊ .＊ mm

SHIRT COUNT = ＊＊＊＊ BOBBIN COUNT = ＊＊＊＊

Memory number

Number of buttons

Number of workpieces counted

Intervals shown by〈→〉 Remaining amount of

bobbin thread

The asterisks (*) on the display screen show the spaces where the specified numbers required for the sewing operation are to be inputted.

(Caution) When an error message is indicated on the display screen (the display screen is in red),

the machine will not retrieve the origin until the error is released (the error mode is released). Refer to the pages 36 to 41 as to how to clear the error.

Upon completion of the above procedures, "Imputting and confirming data" or "Operation" can be performed. However, these operations using the panel switches are possible only when the following conditions are satisfied.

• The machine is ready to run in the automatic operation mode or in the independent operation mode. (Refer to pages 34 to 35 for automatic operation and independent operation.)

• The standard indication appears on the display screen. (No error message is indicated on the screen.)

(3) Inputting and confirming data

1) Memory number selection

Used to call up the sewing pattern data stored in a memory number except that on the display screen. (Example) How to select memory No. “2”

No. 1 BUTTON = 6 ps INDEX <1 → 2> = 85. 0 mm

SHIRT COUNT = 0 BOBBIN COUNT = 400

Press so that the LED lights up. ( )

• • • • • • • • • • • • • No. SELECT • • • • • • • • • • • • • MEMORY No. = 2

Input the desired memory number (2).

− 27 −

No. 2 BUTTON = 5 ps INDEX <1 → 2> = 100. 0 mm

SHIRT COUNT = 0 BOBBIN COUNT = 400

The details of specified pattern No. “2” are indicated.

* The following switches are valid when inputting data.

Increase the number specified. Return to the previous number. Reduce the number specified Delete the input data.

(Caution) Numbers “1 to 20” can be specified.

If a number except one of the above is specified, the error message shown below will be indicated for three seconds, and then the screen display will return to give indication 2.

00 ＊＊＊＊＊＊＊ DATA INPUT ERROR ＊＊＊＊＊＊

FROM 1 TO 20

2) Input of the sewing data

Input the data required for sewing. (Example) ™ Number of buttons 5

™ Button intervals 100.0 mm ™ Cross-over stitch Provided ™ Distance for jump 66.0 mm ™ The designated number

under which is to be stored No. 2

66.0 100.0 mm (Equidistance)

The input procedure is as follows :

No. 1 BUTTON = 6ps INDEX <1 → 2> = 85.0 mm

SHIRT COUNT = 0 BOBBIN COUNT = 400

If any data are previously stored under memory number “1”, the description of the data will be shown on the display screen. When there is no data stored under the specified memory number, asterisks (**) will be shown on the display screen. Press so that the LED lights up. ( )

No. 1 • • • • • • DATA INPUT • • • • • • • • • • • • • •

BUTTON NUM. = 5ps

Input the number of buttons (5 pcs.).

• Input data in the area bounded by a dotted line will be shown only for the “jump function” (Refer to page 60 for how to set the function.)

No. 1 • • • • • • DATA INPUT • • • • • • • • • • • • • •

JUMP = 66.0 mm

Input the “distance for jump” from the material set position to the first button (66.0 mm).

The distance for jump can be specified in 0.1 mm increments.

No. 1 • • • • • • DATA INPUT • • • • • • • • • • • • • •

BUTTON = 5ps INDEX < 1 → 2> = 100.0 mm

Input the distance (100.0 mm) between the first button and the 2nd one.

The button intervals can be specified in 0.1 mm increments. If you know that seam shrinkage will occur because of the material used, be sure to input distance data properly adjusted to allow for the shrinkage.

− 28 −

[Shortened operation] When the buttons are sewn in the equal interval, you only input steps of procedure from 1, 2 and 4’. Steps 5 to 7 are omitted to enable the shortened input operation.

4’

No. 1 • • • • • • DATA INPUT • • • • • • • • • • • • • •

BUTTON = 5ps INDEX < 1 → 5> = 400.0 mm

Input the distance from the first buttonhole to the 5th one (400.0 mm).

The button intervals can be specified in 0.1 mm increments. If you know that seam shrinkage will occur because of the material used, be sure to input the distance data properly adjusted to allow for the shrinkage.

No. 1 • • • • • • DATA INPUT • • • • • • • • • • • • • •

BUTTON = 5ps INDEX < 2 → 3> = 100.0 mm

Input the distance (100.0 mm) between the 2nd and the 3rd button.

No. 1 • • • • • • DATA INPUT • • • • • • • • • • • • • •

BUTTON = 5ps INDEX < 3 → 4> = 100.0 mm

Input the distance (100.0 mm) between the 3rd and the 4th button.

No. 1 • • • • • • DATA INPUT • • • • • • • • • • • • • •

BUTTON = 5ps INDEX < 4 → 5> = 100.0 mm

Input the distance (100.0 mm) between the 4th and the 5th button.

• Input data in the area bounded by a dotted line will be shown only for the “long material mode”. (Refer to page 43 for how to set the mode.)

No. 1 • • • • • • DATA INPUT • • • • • • • • • • • • • •

RETURN BUTTON No. = 4

Input the button number “4” to specify the position to return the carriage to its origin.

No. 1 • • • • • • DATA INPUT • • • • • • • • • • • • • •

STACK MODE = AUTO

Select the mode which allows the stacker timing to be automatically determined.

AUTO = The mode under which the cloth sensor automatically determines the stacker timing. MANUAL = The mode under which requires the operator to input the stacker timing through the

operation panel. Most kinds of materials can be automatically stacked. However, if using the material (e.g., black materials, light-weight materials, etc.) which cannot be detected by the sensor, set the mode to the “MANUAL” and input the desired value for stacker timing through the operation panel.

− 29 −

If the cloth sensor is incapable of detecting the material used, input data described in 9’ instead of that in 9.This will allow you to specify the stacker timing.

9’

No. 1 • • • • • • DATA INPUT • • • • • • • • • • • • • •

STACK MODE = MANUAL

Select the mode to allow you to input the data on the stacker timing through the operation panel.

No. 1 • • • • • • DATA INPUT • • • • • • • • • • • • • •

STACKER TIMING = 10

Specify the value for the stacker timing “10”. [As observed from the operator’s side]

You can specify the value for the stacker timing from 1 through 20. Decrease the value for the stacker timing if the top center plait is stacked as A (solid line), or increase the value if it is stacked as B (broken line). ＊Confirm that the setting of the frequency (50/60Hz) are correct (Refer

to page 43.)

• Input data in the area bounded by a dotted line will be shown only for the “pair stacking mode”. (Refer to page 44 for how to set the mode.)

No. 1 • • • • • • DATA INPUT • • • • • • • • • • • • • •

PAIR STACKING = ON

Specify the pair stacking mode. Once the stacker is set to this mode, the machine repeats the steps of “normal button sewing” and of “stacking oly in the written order.

or (ON = With pair stacking, OFF = Without pair stacking)

How to operate the pair stacking feature

1 Carry out the steps of procedure for the normal button sewing. 2 Set the material in place on the sewing machine as in the case of the normal button sewing. 3 Press the Start switch, and release it. Then the material will be clamped and fed without being sewn,

and it will be stacked.

From step 4 and beyond, steps 1 through 3 will be repeated.

• • • • • • • • • • • N o . SELECT • • • • • • • • • • • • • • • MEMORY No. = 2

Input the memory number (2) under which the data is to be stored.

N o . 2 BUTTON = 5 p s INDEX <1 → 2> =100. 0 mm

The details of the previous data under the memory number designated in step !2 will flash on and off. Press again when the newly input data is to be stored instead of the previous data. (If other data is to be inputted, press to return the display screen to step !2.

− 30 −

N o . 2 BUTTON = 5 ps INDEX <1 → 2> =100. 0 mm CROSS SHIRT COUNT = 0 BOBBIN COUNT = 400

The newly input data is stored under memory switch number “2”. This completes the input procedure. (The previous data remains stored under memory number “1”.)

＊ The following switches are valid when inputting data.

The number specified is increased. The previous number is restored. The number specified is reduced. The inpu data is deleted. The previous indication display is restored. The indication display is scrolled forward.

(Caution) 1. The number of buttons that can be specified in step 2 is from “2” through “20”. If you

input any number except these, the corresponding error message will appear on the display screen for three seconds. If this occurs, specify the correct number of buttons.

※ A single button can be sewn only when the machine is in the manual operation

mode or independent operation mode. (See page 35.)

2. When the total sum of each button interval specified in step 3 through 7 is not within the range of 25.0 mm to 650.0 mm, the same error message as stated above will appear on the screen. However, for the long-material mode, when the total sum of each button interval is not within the range of 25.0 mm to 1,200.0 mm, the error message will apppear.

3. If the button number specified in step 8 indicating the position to return the carriage to its origin exceeds the number of buttons specified in step 2 or is set to “1”, the same error message will be shown on the display screen.

4. If the total sum of the feed amount up to the button number specified in step 8 indicating the position to return the carriage to its origin exceeds 650 mm, the same error message will appear on the display screen.

5. If a number except “1 through 20” is specified for the value for stacker timing in step !0’, the same error message as stated above will be shown on the display screen.

6. If a number except “1 through 20” is specified in step !2, the same error message as stated above will be shown on the display screen.

Error indication on the display screen

00 ＊＊＊＊＊＊ DATA INPUT ERROR ＊＊＊＊＊＊＊

Error message

3) Checking the sewing data

The details of the sewing data stored under the designated memory number are shown on the display screen. (At this time, the data input is not possible.) (Example) Machine operation to check the details of the data stored in memory in “2. Input of the sewing data”

N o . 2 BUTTON = 5 ps INDEX <1→ 2> = 100. 0 mm

CROSS SHIRT COUNT = 0 BOBBIN COUNT = 400

Press so that the sewing LED lights up. ( )

• Input data in the area bounded by a dotted line will be shown only for the “jump function” or “longmaterial mode”. (Refer to page 60 for how to set the mode.)

JUMP = 66. 0 mm

RETURN BUTTON No. = 4

The distance for jump and the button number indicating the position to make the carriage return to its origin are shown on the display screen.

BUTN (ps) 1 ––––– 2 ––––– 3 ––––– 4 ––––– 5 ––––– ＊ INDX (mm) 100. 0 100. 0 100. 0 100. 0 ＊＊＊. ＊

The intervals from the first button to the 6th button are shown on the display screen.

− 31 −

＊ ––––– ＊ ––––– ＊ ––––– ＊ ––––– ＊＊ ––––– ＊＊ ––––– ＊＊＊＊＊ . ＊＊＊＊ . ＊＊＊＊ . ＊＊＊＊. ＊＊＊＊ . ＊＊＊＊ . ＊

The intervals from the 6th button to the 12th button are shown on the display screen.

＊＊ ––––– ＊＊ ––––– ＊＊ ––––– ＊＊ ––––– ＊＊ ––––– ＊＊＊＊＊ . ＊＊＊＊ . ＊＊＊＊ . ＊＊＊＊. ＊＊＊＊ . ＊

The intervals from 12th button to the 17th button are shown on the display screen.

＊＊ ––––– ＊＊ ––––– ＊＊ ––––– ＊＊ ––––– ＊＊ ––––– ＊＊＊＊＊ . ＊＊＊＊ . ＊＊＊＊ . ＊＊＊＊ . ＊＊＊＊ . ＊

The intervals from the 17th button to the 20th button are shown on the didplay screen.

PAIR STACKING = ON

With/without pair stacking is shown on the display screen only when the machine is set to the “pair stacking mode”. (ON = With pair stacking, OFF = Without pair stacking)

STACKER STACK MODE = AUTO

This indication shows that the mode under which the cloth sensor automatically determines the stacker timing has been specified.

If the stacker timing is set to the manual mode, the indication given in step 8') will be shown on the display screen instesd of that given in step 8)

8’

STACKER STACK MODE = MANUAL

STACKER TIMING = 10

This indication tells you that the mode under which requires the operator to input the stacker timing through the operation panel has been specified. This indication also tells you that the stacker timing has been set to “10”.

N o . 2 BUTTON = 6 ps INDEX <1 → 2> = 90. 0 mm

SHIRT COUNT = 0 BOBBIN COUNT = 400

The display screen returns to the standard screen.

(Caution) The following switches are valid when checking the details of data.

The previous indication display is restored.

The entered data is canceled.

− 32 −

4) Counter settings

Specify the initial values for the shirt counter and bobbin thread counter. Shirt counter : The counter adds one (1) to the value after one shirt is finished. Bobbin thread counter : The counter subtracts one (1) from the value after one button is finished. (Example) The initial value for the shirt counter : 0 (The counter starts counting from the 1st shirt finished.)

The initial value for the bobbin thread counter : 400 (400 buttons can be sewn. Under the automatic operation, the machine finishes 80 pieces of shirt each of which has five buttons and then automatically stops. If sewing six buttons on each of shirt, the machine finishes 66 pieces of shirt (6 buttons x 66 = 396 buttons) and automatically stops with the button thread to sew four buttons remained.)

N o . 1 BUTTON = 5 ps INDEX <1→ 2> = 100. 0 mm

SHIRT COUNT = 0 BOBBIN COUNT = 450

Press so that the LED lights up. ( )

• • • • • • • • • • • • DATA INPUT • • • • • • • • • • • • SHIRT COUNTER = 0

Input the initial value for the shirt counter.

• • • • • • • • • • • • DATA INPUT • • • • • • • • • • • •

BOBBIN COUNTER = 400

Input the initial value for the bobbin counter.

N o . 1 BUTTON = 5 ps INDEX <1→ 2> = 100. 0 mm

SHIRT COUNT = 0 BOBBIN COUNT = 400

This completes the data input for the counter settings.

＊ The following switch operations are valid when inputting data.

Increase the number specified. Return to the previous number. Decrease the number specified. Delete the input data. The previous indication display is restored. ( ) Delete the input data. The indication display is scrolled forward.

Note that if any of these switches is pressed when the data for the bobbin thread counter in step 3 is being inputted, the initial value for the shirt counter in step 2 is entered. Consequently, if you wish to change only

the shirt counter, be sure to press the ( ) switch before step 3 as stated above. ＊ The initial value “0” for the shirt counter can be set by pressing the switch (only when the machine

is waiting for the next operation).

＊ The initial value (set value) for the bobbin thread counter can be restored by pressing the switch

(only when the machine is waiting for the next operation).

− 33 −

(4) Operation

1 Power switch 2 Operation panel 3 Knee switch 4 Hand switch 5 Emergency stop switch

1) Automatic operation

When the start switch is pressed, the following series of operation will be performed automatically. [Series of operations for men’s wear]

Start

Stacking

Carry the material to the carriage so that it is clamped.

Button sewing

(last button)

The carriage returns to its

home position.

Button sewing

Index (the carriage shifts)

Index

Button

sewing

[Series of operations for ladies’ wear]

Start

Stacking

Carry the material to the carriage so that it is clamped.

The carriage returns to its

home position.

Button

sewing

Button sewing

(last button)

Index (the carriage shifts)

Index

Button

sewing

[Series of operations for finished product]

Start

The clamp of the carriage is released.

Carry the material to the carriage so that it is clamped.

The carriage

returns to its

home position.

Button

sewing

Button sewing

(last button)

Index (the carriage shifts)

Index

Button

sewing

[How to operate] 1 Operate the and switches on the operation panel so that the LED on the left-hand side lights

up. ( LED : ON LED : OFF)

2 Properly set the material on the carriage. 3 Press knee switch 3, and the work clamp feet at both ends of material come down. Release the knee

switch, then the sewing machine starts sewing.

＊ If you press hand switch 4 before the knee switch has been released, the work clamp feet at the both

ends of material go up and the sewing machine is released from its starting state.

The proper material setting

1) Men’s shirts (See P.6.) Place the material so that there is no clearance between the side end of material and the pressing board 1, and align the top end of the material with marker 2.

2) For ladies’ shirt (See P.7.) Place the material so that there is no clearance between the side end of material and the pressing board 1, and align the top end of the material with marker 3.

− 34 −

2) Manual operation

Use the manual operation mode to perform each step of operation manually for jump sewing, etc. [How to operate]

1) Press the and switches on the operation panel so that both LED’s light up. (Both light up. )

2) Set the material, following the same procedure as that for the automatic operation mode.

3) Depress the knee switch, and the work clamp feet come down.

Use the following switches described below to go on the next step of operations to be carried out.

: The carriage travels to the left in a single step.

1 When sewing a men’s shirt body, the material is stacked after the carriage has reached its

leftmost position and the the carriage will return to its origin.

2 When sewing a finished product of men’s wear, the carriage will finally return to its origin and

the clamp on the carriage will be released.

: The carriage travels to the right in a single step.

1 When sewing a ladies’ shirt body, the carriage will finally return to its origin and then the

material will be stacked.

2 When sewing a finished product of ladies’ wear, the carriage will finally return to its origin and

the clamp on the carriage will be released.

: The sewing machine is actuated.

Knee switch : The operation mode changes from manual to automatic during sewing by depressing the

knee switch.

＊ If the operation mode is changed from manual to automatic during sewing, the machine performs a

series of operation in the oder of sewing machine actuation to the button sewing → index . Be careful not to sew two buttons at the same position.

3) Independent operation

Use the independent operation mode to perform each operation step independentlyfor trial sewing or checking the travel of the carriage. [Operation]

™ Operate switches and so that both LED’s go out. (LED OFF )

Now, each operation step can be performed independently using the switches described below.

: The carriage travels to the left when the carriage has been adjusted for men’s wear or it travels to

the right when it has been adjusted for the ladies’s wear in a single step. (Finally, the carriage returns to the origin.)

: The sewing machine is actuated.

Example) Trial sewing

1 Place the workpiece for trial sewing under the work clamp. 2 Press to actuate the sewing machine.

− 35 −

4) Emergency stop

When the emergency stop switch is pressed during operating, the following message will be shown on the display screen.

＊＊＊＊＊＊＊＊＊＊ EMERGENCY STOP ＊＊＊＊＊＊＊＊＊＊

CHECK → RESET → START

The operation process when the emergency stop switch is pressed determines when and how the operation is stopped or how the emergency stop is released.

1 When the emergency stop switch is pressed after the knee switch has been pressed and the work clamp

has lowered, the work clamp will go up and stop in its highest position. Press switch, and the indication on the screen will return to the standard display.

2 When the emergency stop switch is pressed when sewing a button, the sewing machine stops after the

button sewing is finished. Press the switch, and the machine operation mode will automatically change to the manual.

3 When the emergency stop switch is pressed when the carriage is moving (indexing), the sewing machine

stops as soon as the switch is pressed. Press the switch, and the carriage will automatically return to the sewing start position of the 1st button and the machine operation mode will be changed to the manual operation mode.

4 When the emergency stop switch is pressed when the last button(in men’s garment bod) is veing sewn

or when the carriage is returning to the origin upon completion of button sewing, the sewing machine stops as soon as the switch is pressed. Press the switch, and the carriage will automatically return to the sewing start position of the 1st button and the machine operation mode will be changed to the manual operation mode.

5) Error message and the reset procedure

01 ＊＊＊＊＊＊ NEEDLE THREAD STITCH ERROR ＊＊＊＊＊＊

STITCH CHECK → RESET → START

Cause : If the needle thread breaks or

needle thread stitch error occurs, the above error message will be shown on the display screen.

How to reset : Re-thread the needle, and

press switch 1.

(Caution)Do not press the reset switch

before threading the machine

head.

02 ＊＊＊＊＊＊＊ BOBBIN THREAD ERROR ＊＊＊＊＊＊＊

BOBBIN CHANGE → RESET → START

Cause : If the remaining amount of bobbin thread is not enough (when the bobbincounter indicates

“0” or the remaining amount of bobbin thread is too short to finish one piece of garment), the above error message will be shown on the display screen.

How to reset : Under the automatic operation mode, replace the bobbin, and press switch  .

− 36 −

04 ＊＊＊＊＊＊ WORK CLAMP POSITION ERROR ＊＊＊＊＊＊

WORK CLAMP CHECK → RESER → START

Cause : If the wrok clamp of the

sewing machine is not raised, the above message will be shown on the display screen.

How to reset : Lift work clamp 2 by hand

and press the switch on the operation panel of ACF.

09 ＊＊＊＊＊＊＊＊ RAM BACK UP ERROR ＊＊＊＊＊＊＊＊

RESET → DATA INPUT

Cause : If the data stored in RAM has been deleted, the above message will be shown on the

display screen.

How to reset : Press the switch on the operation panel of ACF, and re-input the data.

10 ＊＊＊＊＊＊＊＊ INDEX DATA ERROR ＊＊＊＊＊＊＊＊＊

RESET → DATA INPUT

Cause : If the input data is not correct, the above message will be shown on the display screen,

when the machine is started in the automatic mode or manual mode.

How to reset : Press the switch on the operation panel of ACF, and re-input the data.

11 ＊＊＊＊＊＊＊ START SWITCH ON ERROR ＊＊＊＊＊＊＊

START SWITCH OFF → RESET → START

Cause : If the start switch is pressed when the power is ON, the above message will be shown on

the display screen.

How to reset : Release the start switch (knee switch or hand switch), and press the switch on the

operation panel of ACF.

13 ＊＊＊＊＊＊＊＊ BUTTON FEED ERROR ＊＊＊＊＊＊＊＊＊＊

LOADER SWITCH ON → RESET → START

Cause : If the button is not fed to button

clamp jaw lever 1, the above message will be shown on the display screen.

How to reset : Press button feeding switch

3 after you have confirmed that the buttons are fed to index unit 2.

− 37 −

14 ＊＊＊＊＊＊＊＊＊＊＊ LK NOT READY ＊＊＊＊＊＊＊＊＊＊＊

LK CHECK → RESET → START

Cause : If an error occurs in the operation box of LK, the above message will be shown on the

display screen. Also, in addition to the above error, the message will be shown on the display screen when the sewing LED is gone out by pressing the ready key on the control box of LK.

How to reset : Release the error of LK, and press the switch on the operation panel of ACF.

15 ＊＊＊＊＊＊＊＊ BOBBIN WINDING MODE ＊＊＊＊＊＊＊＊＊

LK BOBBIN SW OFF → RESET

Cause : If “WINDER” is selected by the control box of LK in the “automatic operation” or “manual

operation” mode, the message will be shown on the display screen.

How to reset : Release the selection of “WINDER” of the control box of LK and presss the switch

on the operation panel of ACF.

50 ＊＊＊＊＊ STEPPING MOTOR DRIVER ERROR ＊＊＊＊＊

POWER OFF → CHECK

Cause : If the stepping motor driver inside the control box is out of order, the above message will

be shown on the display screen.

How to reset : Turn OFF the power switch, and check the connection of the respective connectors.

51 ＊＊＊＊＊＊＊ A IR PRESSURE ERROR ＊＊＊＊＊＊＊＊＊

POWER OFF → CHECK

Cause : If the operating air pressure is insufficient for the machine to operate, the above message

will be shown on the display screen.

How to reset : Turn OFF the power switch, and properly adjust the operating air pressure.

52 ＊＊＊＊＊＊＊＊ CLAMP POSITION ERROR ＊＊＊＊＊＊＊＊

POWER OFF → CHECK

Cause : If carriage clamp 1 is likely to hit against the sewing machine, the above message will be

shown on the display screen.

How to reset : Tuen OFF the power to the sewing machine. Then move carriage 2 by hand or by using

carriage clamp position adjusting screw 3 so that carriage clamp 1 is carried away from the sewing machine.



− 38 −

54 ＊＊＊＊＊＊＊＊ BUTTON INDEX ERROR ＊＊＊＊＊＊＊＊＊

POWER OFF → CHECK

Cause : If the button index motor is

energized for a period of time longer than the predetermined time, the above message will be shown on the display screen.

How to reset : Turn OFF the power switch,

and check button index unit 2 for any clogged button. Give two clockwise turns to manual screw 4 using a screwdriver after you have confirmed that 2 would not turn any further.

55 ＊＊＊＊＊＊＊ SEWING MACHINE ERROR ＊＊＊＊＊＊＊

POWER OFF → CHECK

Cause : If an error occurs in LK machine after sewing has started, the above message will be

shown on the display screen. Also, if the sewing continues for 20 seconds or more, the message will be shown. Consequently, this message may be shown after 20 seconds from the start of sewing.

How to reset : Turn OFF the power switch, and check the state of the LK machine.

56 ＊＊＊＊＊＊ BUTTON SENSING OVER ERROR ＊＊＊＊＊＊

CHECK → RESET → START

Cause : I f a button is not detected

after the index unit has continuously performed the button sensing (indexing the

button and detecting the existence of button) by ten times or more, the above message will be shown on the display screen.

How to reset : Check parts feeder 3 for its

correct performance, and adjust so that buttons are fed to the index unit properly.

− 39 −

57 ＊＊＊＊＊＊＊＊＊ BUTTON SET ERROR ＊＊＊＊＊＊＊＊＊

CHECK → RESET → START

Cause : If the button cannot be set on

the spinner oscillating arm even after the fine positioning of button has been performed twice, the above message will be shown on the display screen.

How to reset : Check button carrier pin 1 of

the spinner oscillating arm for any clogged button.

58 ＊＊＊＊＊＊＊ REVOLUTION ARM ERROR ＊＊＊＊＊＊＊

POWER OFF → CHECK

Cause : If the spinner oscillating arm motor is energized for a period of time longer than the

predeterminded time or it is not in its origin, the above message will be shown on the display screen.

How to reset : Turn OFF the power switch. Then turn manual rotating shaft 2 and check the clogged

button. (The normal rotational direction is the direction of arrow.) If breaker 3 is not in its set position, press the push-button to set breaker 3. If the arm is not in its origin, press button feeding switch 4.

− 40 −

100 ＊＊＊＊＊＊＊＊＊ INIT SW ERROR ＊＊＊＊＊＊＊＊＊

INIT SW CHECK

Cause : This error massage will be shown if the origin detect switch dose not work properly. How to reset : Check the origin detector switch.

(Refer to pages 46 to 48 for adjustment.)

101 ＊＊＊＊＊＊＊＊＊ SPEED SW ERROR ＊＊＊＊＊＊＊＊＊

SPEED SW CHECK

Cause : This error message will be shown if the speed reduction detector switch reduction detector

switch dose not work properly.

How to reset : Adjust the installation position of the decreasing speed detector switch or replace it.

(Refer to pages 46 to 48 for adjustment.)

102 ＊＊＊＊＊＊＊＊＊ SELECT SW ERROR ＊＊＊＊＊＊＊＊＊

SELECT SW CHECK

Cause : This message will be shown if the selector switch dose not work properly. How to reset : Adjust the installation position of the decreasing speed detector switch or replace it.

(Refer to pages 46 to 48 for adjustment.)

− 41 −

7. SWITCHES INSIDE THE PANEL BOX AND THE CONTROL BOX

(1) Inside the panel box

1) Mode selection for men’s wear and ladies’ wear

Loosen screws 2 and open switch cover 1 mounted on the right side face of operation panel. Set selector switch 3 to its lower side to sew men’s wear or to its upper side to sew ladies’ wear. (Before you change the setting of this switch, be sure to turn OFF the power to the sewing machine.)

2) Mode selection for shirt body and finished product

Loosen screws 2 and open switch cover 1 mounted on the right side face of operation panel. Set selector switch 4 to its lower side to sew shirt bodies or to its upper side to sew finished products. When the switch is set to the finished product sewing mode, be sure to operate the sewing machine using an auxiliary feed plate (optional). (Before you change the setting of this switch, be sure to turn OFF the power to the sewing machine.)

(2) Inside the control box

Remove six screws 1 of the control box under the table, and open cover 2. Then you may switch over the functions using the switches mounted on I/O circuit board 3 and CPU circuit board 4. Note that the switches and variable resistors mounted on POWER circuit board 5 of the ACF-164-1903 are inoperative.

(Caution) Be sure to change over the setting of

the switches after turning OFF the power to the machine.

− 42 −

1 Switches on I/O circuit board 3(Refer to “(2) Inside the control box” on p.42.)

(Caution) Set the SW1-1 and -8, SW4-5 through -8, and SW5-4 through -8 to their OFF positions, and set

the SW1-2 and -3, and SW4-1 and -2 to their ON positions.

Switch

No.

Switch

name

SW1-4

SW1-5

SW1-6

Description of function

This switch is used to set the jump function.

(OFF) : The jump function cannot be specified.

(ON) : The jump function can be specified.

(This switch has been set to its OFF position at the time of delivery.)

This switch is used to set the long-material mode.

(OFF) : The long-material mode cannot be specified.

(ON) : The long-material; mode can be specified.

(This switch has been set to its OFF position at the time of delivery.)

This switch is used to specify the frequency of power source (50 Hz or 60 Hz).

50 Hz (OFF) : For the 50 Hz zone

60 Hz (ON) : 60 Hz zone

(This switch has been set to 50Hz/60Hz according to the destination of the machine.)

− 43 −

SW1-7

This switch is used for setting the pair-stacking function.

(OFF): The pair stacking mode cannot be selected.

(ON) : The pair stacking mode can be selected.

(This switch has been set to its OFF position at the time of delivery.)

SW2

SW3

SW4-3

SW4-4

This switch is used to set the length of time from the actuation of the button positioner (triple pawl) to the detection of the button.

(The aforementioned length of time has been factory-set to “5” at the time of delivery.)

This switch is used to set the length of time from the completion of index of a button to the time when the actuation of the button positioner (triple pawl) becomes possible.

(The aforementioned length of time has been factory-set to “1” at the time of delivery.)

This switch is used to set the function of detecting a button fed on the button clamp jaw lever.

(ON) : The aforementioned button detecting function does not work.

(OFF): The aforementioned button detecting function works.

(This switch has been set to its OFF position at the time of delivery.)

This switch is used to set the function of detecting a button fed on the index unit.

(ON) : The aforementioned button detecting function does not work.

(OFF): The aforementioned button detecting function works.

(The switch has been factory-set to its OFF position at the time of delivery.)

SW4-□

567 OFF OFF OFF Waiting time of the spinner oscillating arm 290ms (Standard value) OFF OFF ON Ditto 190ms OFF ON OFF Ditto 390ms OFF ON ON Ditto 490ms

ON OFF OFF Ditto 590ms ON OFF ON Ditto 690ms ON ON OFF Fine positioning completion detection control

(Fine positioning completion switch is necessary.)

ON ON ON Both positioning and fine positioning detection control

Expected control by timer

Detection control by sensor

− 44 −

2 Switches on CPU circuit board 4(Refer to “(2) Inside the control box” on p.42.)

Switch

No.

Switch

name

SW1-1

(Caution) Be sure to set SW2-3 and -4 to their

OFF positions.

Description of function

This switch is used to switch over the characters indicated on the display screen from/to Japanese/English.

Japanese (OFF) : The characters are indicated in Japanese.

English (ON) : The characters are indicated in English.

SW1-2

SW2-1

SW2-2

(This switch is set to its ON position at the time of delivery.)

This switch is used to switch over the unit of length for the distance setting from/to mm/ inches.

mm (OFF) : The length is set in mm.

inch (ON) : The length is set in inches.

(Caution) After switching over between mm and inches, all previously stored data will be

cleared once the power switch is turned ON.

(This switch is set to its OFF position at the time of delivery.)

This switch is used to change over the automatic repeated operation of the sewing machine.

(OFF) : The sewing machine operates under the normal operation mode.

(ON) : The sewing machine operates under the automatic repeated operation

mode.

(This switch has been set to its OFF position at the time of ddelivery.)

This switch is used to change over the failure diagnostic feature.

(OFF) : The sewing machine operates under the normal operation mode.

(ON) : The sewing machine operates under the failure dianostic mode. (Set

the DIP SW4-8, mounted on the I/O circuit board, also to its ON position.)

(This switch has been set to its OFF position at the time of ddelivery.)

− 45 −

8. ADJUSTMENT OF UNIT

(1) CARRIAGE UNIT

1) Adjusting the driving section of the carriage

Carriage

Screw

Rack

Pinion

Screw

Backlash 0 to 0.05 mm (0.002”)

1) Loosen the attaching screw and adjust so that a backlash of 0 to 0.05 mm is provided between the rack and the pinion gear over the length.

2) After the completion of the aforementioned adjustment,measure the starting load of the carriage. Press the section marked with the arrow in the figure and measure the starting load at the start,intermediate position and the end of the entire stroke. As long as the starting load of 2 kgf or less is provided at all the aforementioned positions, no trouble will result.

(Caution) If the backlash between the rack and

the pinion is not properly adjusted,step-out of the stepping motor or failure of feeding may result.

Screws

3) Confirm that the two screw in the gear presser are securely tightened. (Tighten either screw in the flat part on the motor shaft.)

2) Adjusting position of origin and the presser switch of the carriage swtich

Adjust the sewing machine both in the men’s wear sewing mode and the ladies’ wear sewing mode. Be sure to mode slide bearings (right and left) 6 to both ends of the carriage and fix them with slide bearing knob 7 before starting the adjustment. Names of each adjusting area

Left-hand side of the unit

1 Photo sensor 1 2 Photo sensor 2 3 Discriminating sensor 4 Origin detecting plate

(for men’s wear)

5 Origin detecting plate

(for ladies’ wear)

6 Slide bracket 7 Slide bearing knob 8 Carriage

9 !0

9 Pinion gear

!0 Rack !1 Presser detecting plate

(for men’s wear) !2 Presser detecting plate (for ladies’ wear)

!3 Presser switch (for men’s wear) !4 Presser switch (for ladies’ wear)

!5 Stopper (for men’s wear) !6 Stopper (for ladies’ wear)

Right-hand side of the unit

(Caution) Functions of photoelectric sensors 1 and 2 change over as shown in the table below under

the men’s wear sewing mode and the ladies’ wear sewing mode.

Sensor No. Mode Men’s Speed reduction sensor Origin sensor Ladies’ Origin sensor Speed reduction sensor

− 46 −

1 Adjusting the men’s mode

S=0 mm

A=122±1.5 mm

C=6 mm

Speed reduction

Center of

needle

Origin Discriminating

123

B=3±1 mm

1) When turning ON the power switch under the men’s sewing mode, carriage 8 should retrieve the origin and stop at the position as shown in the figure. To adjust dimension A to 122 ±1.5 mm (4.803” ± 0.059”),loosen the screw in origin detecting plate 4 and move the plate in the direction of the arrow until the specified dimension is provided. (If origin detecting plate 4 is moved to the right, dimension A will be larger than 122 mm (4.803”). If the plate is moved to the left ,dimension A will be smaller than 122 mm (4.803”). When dimension A is properly adjusted, dimension B will be 3 ± 1 mm (0.118” ± 0.039”) and dimension C will be 6 mm (0.236”).)

2) To check the result of the aforementioned adjustment, turn OFF the power to the machine once, move carriage 8 by hand to the left by 20 to 30 mm (0.787” to 1.181”), loosen the knob of slide bearing 6 and set dimension S to 4 mm (0.157”). Now, turn ON the power to the machine, and the error message “CLAMP POSITION ERROR” will be shown on the display after the machine stars retrieving the origin. If the sewing machine fails to stop while indicating the above-stated error message, move presser switch !3 to the left and re-turn ON the power to the machine. If the sewing machine, this time, stops while indicating the error message, adjust the position of stopper !5.

3) Turn OFF the power to the machine and set dimension S to 2 mm (0.079”).As long as no error is indicated in this state, the sewing machine is correctly adjusted under the men’s wear sewing mode.

After the completion of checking procedure steps 2) and 3), be sure to move slide bearing 6 to the left and set dimension S to 0 mm. Now, fix the slide bearing.

This completes the adjustment of the origin, presser switch and stopper under the men’s wear sewing mode.

− 47 −

2 Adjusting the ladies’ mode

Center of

needle

A=122±1.5 mm

C=6 mm

S=0 mm

Origin

Speed

reduction

Discriminating

B=3 ± 1 mm

1) Change over the sewing mode from the men’s wear sewing mode to the ladies’ wear sewing mode and turn ON the power to the machine, carriage 8 should retrieve the origin and stop at the position shown in the figure. As same as in the case if the men’s wear sewing mode, adjust first dimension A. If origin detecting plate 5 is moved to the left, dimension A will be larger than 122 mm. If the plate is moved to the right, dimension A will be smaller than 122 mm.

2) Adjust the machine under the ladies’ wear sewing mode following the procedure taken under the men’s wear sewing mode.

− 48 −

3 Adjusting the work clamp unit

1. Adjusting slide bearing

25 mm

(77)

(52)

35 mm

2. Adjusting the clamps

Center of needle

7±1 mm

Clamp

(left)

13±1.5 mm

20±1 mm

Clamp (right)

Collars

Clamp holder

1±0.5 mm

1) Loosen knob 1, and move slide bearings (left, right) 2 to check for their smooth movement.

2) Adjust so that the respective distances of 25 mm (0.984”) and 35 mm (1.378”) are provided between slide shafts 3. The distances may change after installing slide shaft connecting plate 4. However, confirm the corect distances are provided between the slide shafts after tightening slide shaft connecting plate 4 at both ends and centers of slide shalts 3. ( 6 in the figure indicates the carriage rail.)

3) Eliminate a play at slide bearing 2 by adjusting slide shaft holder 5.

1) To adjust the position of the clamps (right and left), loosen the screws in the collars and adjust the position of the clamp holders so that a clearance of 20±1 mm is provided between the clamp (right) and the center of needle and a clearance of 7±1 mm is provided between the clamp (left) and the center of needle.

2) Adjust the height of clamps (right, left) after confirming that a clearance of 1±0.5 mm is provided between clamp receiving plates 1(Carry out the adjustment after loosening screw 5.) Adjust the height of clamps by moving clamp holder receiving plate 4 up or down so that a clearance if 13±1.5 mm is provided between clamps 6 (right, left) and clamp receiving plates 1 (right, left).

− 49 −

4 Adjisting the set plate

1. Adjusting the height of the set plate

4 mm

– 2

1±0.5 mm

4 mm

0 – 2

1 Set plate (right) 2 Set plate (left) 3 Set plate support (right) 4 Set plate support (left) 5 Rail installing plate support 6 Set plate installing base 7 Set plate support fixing plate

(Caution) Be sure to turn OFF the power to the machine before adjustment.

Loosen screws in set plate support fixing plate 7 and set plates support (right and left) 3 and 4, and adjust the height of the set plates to 1±0.5 mm above the top surface of the throat plate by moving set plate support (right and left) 3 and 4 and rail installing plate support 5 up or down. Then check that the specified height of 1±0.5 mm is provided at both ends and center of the respective set plates.

− 50 −

2. Adjusting the position of the scale on the set plates

Center of needle

A’

1) Adjusting the gauge (left) Confirm that dimension A provided from the center of the needle to gauge (left) 2 is equal to the value shown on the scales on both sides. If the value shown on the respective scales is different from dimension A, loosen first screw 5 and the screws in collars 6, and move set plate (left) 9 in the direction of the arrow until the scales are correctly positioned. At this time, use the rightmost end of set plate (left) 9as reference and adjust the leftmost end to it. (It is recommended to adjust distance B provided between gauge (left) 2 and clamp support plate (left) 7 equally at both ends when the clamp support plate (left) 7 moves laterally.)

2) Adjusting the gauge (right) After the completion of the adjustment of the gauge (left),adjust the position of gauge (right) 1 so that “A’ equals to A”. Then fix the gauge (It is recommended to fit a straight ruler or the like against the gauge surface.) Then, loosen screws 4 in scale plates 3, and adjust so that the value read at section D equals to A. Move clamp support plate (right) 8 to the right and left and measure dimension C at the rightmost end and the leftmost end of the travel so as to confirm that equal adjustment value is provided both at the rightmost end and the leftmost end of gauge (right) 1.

3. Adjusting the gauge

20 to 23 mm

1) Normally,the height of gauge 1 should be adjusted to 20 to 23 mm (0.78” to 0.906”) when the gauge is raised. To adjust the height of the gauge, change the engagement between driving gear 2 and driven gear 3.

2) Only the speed at which the gauge comes down is controlled. The speed controller for controlling the controlled. The speed controller for controlling the speed is mounted on the solenoid value (the fourth solenoid value as counted from the leftmost one.) To adjust the speed,open/close the speed controller.

− 51 −

5 Adjusting the conveyor unit

1. Adjusting the belt tension

Loosen M10 nut 2, and adjust the belt tension by moving idler pulley 1 in the direction of the arrow. Adjust the belt tension to allow the belt to slack by 10 mm when a load of 80 to 120 g is applied to the belt.

80 to 120 g

10 mm

2. Adjusting the longitudinal inclination of the conveyor

Loosen screws 2 in motor bracket installing plate 1 and adjust so that the difference between dimensions

A’

A and A’ between table (left) 3 and conveyor frame 4 does not exceed 2 mm.

3. Adjusting the lateral inclination of the conveyor

Loosen screw 1, and adjust so that belt 2 inclines by

an angle of 0˚ at the position where the belt comes in contact with table (left) 3 when the conveyor comes down with its dead weight. (Lowert conveyor, loosen

θ=0˚

the screw and re-tighten it. This can sufficiently adjust the inclination of the belt.)

4. Adjusting the vertical inclination of the conveyor

Loosen screws 1, and adjust so that belt 2 inclines by an angle of 0˚ at the position where the belt comes in contact with table (left) 3 when the conveyor comes

down with its dead weight.

40 ± 2 mm

θ =0˚

5. Adjusting the height of the conveyor when it is raised

When the conveyor is raised,belt 2 should be 40± 2 mm above table (left) 3. To adjust the height of the conveyor, loosen screw 4 and move cylinder 5 up or down.

− 52 −

6 Adjusting the stacker

(Caution) The stacker provided for this device automatically computes the timing to stack the

[Configuration]

Side A

1. Performance

Side B

1 Cloth presser bar 2 Swing bar 3 Stacking board 4 Fixing knob of cloth presser bar

5 Fixing knob of swing bar 6 Fixing knob of stacking board 7Cloth presser cylinder 8 Sensor of cloth presser 9 Swing bar cylinder

!0 Swing bar sensor !1 Cloth presser speed controller

1) Length of cloth 5 fed by conveyor 1 is

automatically measured by material edge sensor

2) At the same time when conveyor 1 stops, one

dangling end of cloth 5 is pressed against stacking board 4 by cloth presser bar 3.

1 Conveyor 2 Swing bar 3 Cloth presser bar 4 Stacking board 5 Cloth 6 Material edge sensor

− 53 −

3) At the same time when conveyor 1 goes up, swing bar 2 spreads the other end of cloth 5. This will stack the cloth on stacking board 4.

4) After stacking cloth 5, swing bar 2 returns to the home position. Then, cloth presser bar 3 returns to the home position.

2. Adjusting the stacking length of cloth (See the configuration on page 53.)

If the cloth on A side is shorter (longer) than the cloth on side B, perform the following adjustment.

1) Loosen fixing knob 6 of the stacking board,and raise (lower) stacking board 3.

2) Turn speed controller !1 of cloth presser cylinder 7 clockwise (counterclockwise) to decrease (increase) the speed.

Side BSide A

12 mm

(Caution) If the speed is unnecessarily increased,

the stacker will generate an impact noise and durability of the stacker will be shortened. So, it is recommended not to increase the speed excessively. If the garment body to be stacked is short, raise stacking board 3 and cloth presser bar 1.

(The height of the speed controller has been factoyadjusted to 12 mm at the time of delivery.)

3. Adjusting the position of the sensor (See the configuration on page 53)

1) If cloth presser sensor 8 is set at the position where the indicator lamp of the sensor lights up when cloth presser bar 1 moves toward stacking board 3, the sensor produces an alarm sound. In this case, the sensor detects the stacking amount of garment bodies on the stacking board and products an alarm sound only, and the device does not stop.

(Caution) The sensor does not produce an alarm sound immediately after the sensor detects the

stacking amount of garment bodies. The alarm occurs when the sewing machine sews the next garment body.

2) Swing bar sensor !0 detects swing bar 2 that has moved in the direction of the arrow. The sensor determines the returning timing of the swing bar by detecting the aforementioned state of the swing bar. Consequently, it is necessary to adjust the stroke of swing bar 2 by changing the position of the sensor. (Adjust the sensor of long materials are to be used. Moving the sensor in the direction of the arrow will lengthen the stroke of the swing bar. In this case,however, be sure to confirm that the indicator lamp of swing bar sensor !0 lights up.)

− 54 −

4. Operating timing of the stacker under the automatic stacking mode

1) Material of which length is larger than 600 mm

1) For materials of which length is larger than 600 mm. While the material is being fed in the direction of the arrow, the length of time required from the time when the front end of the material passes sensor 2 (solid line) to the time when the rear end of the material passes sensor 1 (two-dot chain line) is measured. The material length is calculated based

600 mm

Sensor1

Sensor2

on the aforementioned length of time measured.

2) For materials of which length is smaller than 600 mm. While the material is being fed in the direction of the arrow, the length of time required from the time when the rear end of the material passes sensor 1

2) Material of which length is smaller than 600 mm

(solid line) to the time when the front end of the material passes sensor 2 (two-dot chain line) is measured. The material length is calculated based on the aforementioned length of time measured.

3) The length of time during which the conveyor rotates should be specified in accordance with the material length calculated in the aforementioned steps 1) and 2).

Sensor2

600 mm

Sensor1

When the conveyor stops rotating, the cloth presser bar actuates.

5. Operating timing of the stacker under the manual stacking mode

Length if time during which the conveyor rotates (a value on the timer) is specified regardless of the material length. After the conveyor stops rotatong,the cloth presser bar actuates. A value on the timer can be set to any of twenty steps ranging from level 1 (0.6 sec.) to level 20 (2.1 sec.). It

600 mm

Sensor1

Sensor2

is specified on the operation panel. (Operate the stacker under the manual stacking mode if long materials are to be used or light-weight materials or black-coloured materials that cannot be detected by the sensor are to be used.)

− 55 −

(2) Button feeder components

1) Removing the covers

Before adjusting the button feeder components,remove top cover 1, set plate 2 and front cover 3. Remove screws 4, 5 and 6.

2) Adjusting carrier pin

1. Adjusting the clearance between the carrier pin and the shutter plate

Loosen screws 2 and 3. Adjust clearance R provided between the carrier pin and shutter plate 1, by turning adjusting stopper 4, to 0.1 to 0.3 mm. At this time, fit

the button carrier against adjusting stopper 4 with no clearance between them. Then,tighten screw 3 to fix adjusting stopper 4 in

Button carrier

Carrier pin

position.

2. Centering the carrier pin

Remove the work attachment from rotary rod 2. Insert the carrier pin into centering ring 1. (At this time,the shutter plate should be kept open.)

(Caution) Whenever the centering ring is used, set

it with its smaller diameter side up.

1) Adjusting the center of the carrier pin in the lateral direction. Loosen screw 3 to allow the button carrier to swing in the right or left as desired. Then move the button carrier until the position where rotary rod 2 smoothly enters centering ring 1is found. Tighten screw 3 so that the button carrier is secured at that position. Now,press eccentric cam (1. -5) against the button carrier, and tighten screw shown in (1.-6) while carefully preventing the button carrier from moving from the secured position.

− 56 −

2) Centering the carrier pin in longitudinal direction If the carrier pin cannot be properly centered by following the procedure 1), keep screw 3 loosened and perform the following adjustment. Loosen two locknuts 4 (the left-handed screw is located in front of the locknut) in the end of the rod. Loosen screw 5, and move urethane rubber 7 from the end face away from the LM guide 8. Move connecting rod 6 until rotary rod 2 is brought to the position where it smoothly enters centering ring 1. Then press the urethane rubber 7 against the LM guide 8 so as to eliminate a longitudinal play. Confirm that the carrier pin is correctly centered then tighten nut 4 so that connecting rod 6 does not rotate any longer. Then tighten screw 5. After the carrier pin has been fixed with respect to its longitudinal position,the carrier pin should be laterally positioned and fixed in its cause. It is, therefore, necessary to re-center the carrier pin both in the lateral and longitudial direction. ＊ The urethane rubber 7is excessively pressed against the LM guide 8. → The excessive contact

between the urethane rubber and the LM guide can be corrected by providing a small clearance between them.

(Caution) Perform the aforementioned adjustment only when it is necessary. If necessary, be sure

to confirm the following points.

1 The spinner oscillating arm does not have any longitudinal play when it is in its origin. 2 The spinner oscillating arm is correctly centered when it is in its origin. 3 The spinner oscillating arm actuates and the button is set on the button clamp jaw

lever.

4 The center of the button clamp jaw lever should be aligned with the center of the

button carrier. If not, refer to “6) Centering the button clamp jaw lever and the button carrier” on p. 60.

3. Adjusting the clearance provided between the work attachment and the carrier pin

Fine positioning magnet

Rotary rod

Draw the iron core of the fine positioning magnet until the work attachment 3is carried to its lowest position. Now, loosen screws 2, and adjust the screw so that

Fine positioning elevating lever

clearance R of 0.1 mm or less is provided between the work attachment 3and the carrier pin as long as the work attachment 3does not come in contact with

the carrier pin. In this state, tighten screws 2 while maintaining the relation between vertical hook 1 and

Carrier pin

the rotary rod.

(Caution) Open the shutter plate, and adjust the

clearance between the work attachment 3and the carrier pin.

− 57 −

4. Adjusting the fine positioner when using a button which has a large recess at the center

1. Start of the fine positioning

Work attachment

Shutter plate

1. Start of the fine positioning

Fine positioner

Button

Triple-pawl

Carrier pin

Lower

2. End of the fine positioning The button fails to fully come off the triple pawl. (The shutter does not open.)

Fig.1

2. End of the fine positioning The button completely comes off the triple pawl. (The shutter opens.)

Lower

Fig.2

Normally, the fine positioning completion switch opens the shutter plate after the button has been set on the carrier pin. When using a button which has a large recess at the center, however, the edge of the button cannot come off the triple-pawl. As a result, the shutter cannot open due to the mechanism of the fine positioning completion switch, and the button cannot be fed to the carrier pin. (Fig.1) In this case, lower the carrier pin and the work attachment to allow the button to completely come off the triple-pawl. (Fig.2) At this time, be sure to adjust the clearance between the work attachment and the carrier pin to the value same as that provided between the work attachment and the carrier pin when they are normally positioned (See p. 57.). Adjust the button clamp jaw lever in accordance with the button height. [Refer to " 8) Adjusting the height of the button clamp" on page 61.]

Adjust clearance C provided between the button guide

Adjusting plate

Feeder bowl

Button guide

and the adjusting plate, by bending the button guide, to 2 ± 0.5 mm.

− 58 −

3) Centering the positioning until

Shutter magnet

4) Replacing and positioning the feed disk

ø16

Pan

ø22

1) Loosen bolts 1 and check bolt 6 of the shutter magnet support plate.

2) Fit centering ring 3 in the center of triple-pawl 2. Draw out triple-pawl dog 5 to allow centering ring

3 to be fitted in place. Move the index base plate 7 until a position where the rotary rod 4(with the

work attachment removed) smoothly enters centering ring 3 is reached.

3) After the positioning unit is correctly centered, tighten bolts 1 and 6.

(Caution) Be sure to check again that the

positioning unit has been properly after tightening bolts 1.

1) Pan Use the feed disk (standard) of ø16 for buttons of which size is ø10 to ø15. When buttons of which size is ø16 to ø18 are used, use the feed disk (optional) of ø22. In this case, adjust the pan located under the feed disk according to the diameter of the hole in the feed disk. Ten pan has two holes, one is ø16 and the other is ø22. Bring the hole of ø16 for the feed disk of ø16 or the hole of ø22 for the feed disk of ø22 this size of the pan in terms of the direction of rotation of the feed disk by turning over the pan.

* Turn over the pan, and buttons of which size is

ø22 can also be used.

Align the matchmarks.

Pinion

Feed disk

a mm

2) To position the feed disk, check first that the pinion is in its origin. Then adjust the position of the feed disk so that the matchmark on the feed disk aligns with the matchmark on the pinion (countersinking). At this time, align the hole in the pan with the hole in the feed disk on the triple pawl.

3) Take the value obtained by adding 1 mm to the buttonhole diameter in the feed disk used as criterion of the initial diameter of the triple pawl. Adjust the initial diameter of the triple pawl using the positioning stopper bolt.

a+1mm

Triple pawl

Feed disk

− 59 −

5) Adjusting the feed disk of the index unit

Buttton

guide

Button

Adjuster

Locknut

Pin hole

1) Confirm that the index unit is in its origin. Then loosen the locknut, and remove the adjusting plate.

2) Loosen screws 3 and screw 4, and remove frame 1 and the adjusting plate 2.

3) Select one hole from among three holes with different diameters (ø18,ø16 and ø12) in the feed disk, and finely adjust the hole selected to the buttons to be used using the adjuster. Adjust the feed disk so that the periphery of the button is flush with the periphery of the feed disk.

4) Adjust the clearance into which the button is placed allow only one button to go through it. Once the adjusting plate is correctly positioned, fix it by tightening the screw 4.

5) Shut the button feeding hole in the feed disk which is not used for the sewing with frame 1, and fix the frame with screws 3.

6) Install the feed disk which has been properly adjusted on the feeder. At this time, be careful to set the feed disk so that the button hole in it to be used meets the outlet of the feeder bowl. Then, tighten the locknut.

Fixing screw

Adjusting plate

(Caution) Adjusting plate 2 is fragile. So, take care

6) Centering the button clamp jaw lever and the button carrier

1) Tilt the machine head.

2) Loosen three locking bolts 3 in the main body frame and bolts 6 → (“(2)-2)-1 setscrew 6 (p.56)”.

3) Raise the machine head. Turn the manual rotating shaft until carrier 2 on which the button is placed is brought to its front end position.

4) Move the main body from until the button in carrier 2 meets the button clamp jaw lever.

5) Once the button clamp jaw lever has been properly positioned, return carrier 2 to its origin and tilt the machine again. Then, tighten bolts 3 and 6.

6) Raise the machine head, and confirm again that

the button clamp jaw lever is correctly positioned by turning the manual rotating shaft by hand.

(Caution) This adjustment should be carried out

not to excessively tighten the screw in the adjusting plate.

after the adjustment (2)-2)-2 (P.56) has been completed.

Left plate

Right plate

− 60 −

7) Adjusting the opening amount of the button clamp jaw levers

This sewing machine has been designed to make the button clamp jaw levers automatically open to release the finished button at the very moment when the button has been sewing on the material. The opening amount

Roller

of the button clamp jaw levers to release the button can be adjusted. Manually turn the manual rotating shaft, and the clamp release arm will move and button

Clamp release

arm

clamp jaw lever will open. Adjust the position of the clamp release arm by loosening the hexagon socket head bolt so that a clearance of 1 to 2 mm is provided

Hexagon socket

head bolt

between the button and the button clamp jaw lever when pressing the roller away from you until it will go no further. After the adjustment, tighten the hexagon socket head bolt. If the clamp jaw lever from the sewing start, the button clamping force will be insufficient resulting in button setting failure or needle breakage. On the other hand, if the clamp release arm is positioned too far from the button clamp jaw lever, the finished button may not be automatically released from the button clamp jaw lever. So be careful.

8) Adjusting the height of the button clamp

Hexagon socket

head bolt

Work clamp hook

Button clamp jaw lever

10 to 11 mm

Feed plate

When the sewing machine is in its stop-motion state and the button feeder runs idle, the standard distance of 11 mm should be provided between the button face of the button clamp jaw lever and the top surface of the feed plate of the sewing machine. Loosen the hexagon socket head bolt, and turn the work clamp vertical hook which is an eccentric shaft until the button clamp is correctly positioned. Then tighten the bolt. The standard height of the button clamp is 11 mm as stated above. And, in principle, the button supporting plane should be flush with the top surface of the set pin. It would be better to slightly adjust the height of the button to be used. The button should ne placed in the button clamp jaw lever without fail.

Button supporting

plane

Top surface of set pin

− 61 −

9) Adjusting the output level of the positioning solenoid

Double nut

Slightly draw this screw.

1 mm 12 mm

If the output level of the positioning solenoid is excessive, the clamped button may be raised or broken. On the other hand, if the output level of the solenoid is inadequate, the button may fail to be clamped. It is, therefore, necessary to adjust the output level of the solenoid properly. Loosen the M4 double nut located at the rear of the solenoid, and adjust the protruding amount of the male screw properly so that an adequate output level of the positioning solenoid is provided. The standard protruding amount of the male screw is 12 mm (0.472”). At this time, position the magnet so that an approximately 1 mm (0.039”) play is provided for the spring attached at the top of the iron core of the solenoid. If the spring does not have a play, loosen screw 1, and make the adjustment properly.

(Caution) When performing the aforementioned

adjustment, the triple-pawl of the ø16 feed disk should be opened.

10) How to use an electrostatic shielding cloth

Electrostatic shielding

Feeder bowl

Guide plate

Electrostatic shielding cloth

Washer

In-line arrangement plate

Static electricity may impair smooth feeding of buttons. In this case, stick electrostatic shielding cloths and electrostatic string supplied with the machine on the button feeding components with double-sided adhesive tape as shown in the figure. (When adhering the cloth, and string is on the in-line arrangement plate, cut them into an appropriate size with a pair of scissors or the like. If the in-line arrangement plate is adhered with the electrostatic shielding cloths and string, the plate should be cleaned up periodically since smooth feeding of buttons may be impaired by thread waste that is likely to gather on the plate.)

(Caution) 1. A clearance of 1 to 2 mm should be

provided between buttons and electrostatic shielding cloth to prevent the cloth from coming in direct contact with buttons.

2. If the adjusting range of the vertical position of the in-line arrangement plate is limited by the thickness of buttons to be sewn, remove the washer.

11) How to use the separation plate (supplied with the machine)

The separation plate supplied with the machine is not adhered with a scale marker sheet. So, adhere the scale marker sheets on the plate. At this time, adjust the position of the sheets so that they do not come in contact with buttons when the feeder bowl is used. If buttons come in contact with the scale marker sheets, they may fail to be sorted

normally. Determine dimensions R1 and R2 in the figure as desired as long as they satisfy the requirement described above.

− 62 −

(3) Detecting mechanism and its adjustment

1) Adjusting the thread breakage detector (THR)

The detector detects thread breakage by checking whether the thread tension is applied to the take-up spring when the detector receives the up-position signal from the main shaft.

1. Adjusting the thread take-up spring The standard stroke of thread take-up spring 1is 6 pull the thread at the starting point is 20 through 40 g. To adjust the stroke of the thread take-up spring,loosen set screw 2, and turn tension controller assembly 3 clockwise to increase the stroke or counterclockwise to decrease it. To adjust the tension of the thread take-up spring, insert the blade of a flat-bit screwdriver into the groove in tension post 4, and turn it clockwise to increase the tension or counterclockwise to decrease it.

(Caution) Decrease the tension of the thread take-

up spring for a synthetic fiber thread.

Now, loosen setscrew 8, and adjust so that detector plate 5 comes in contact with thread take-up spring 1 without fail. Finally, confirm that detector plate cable 7 is insulated by grounding wire 6 when the thread take-up spring starts pulling the thread to apply appropriate tension to the thread.

Decrease

Increase

2) Adjusting the fine positioner mechanism

Fig.1

Fig.2

1) Attach fine positioning motor !2 to rod driving arm !3 so that fine positioning link !4 smoothly moves without interfering with rod gear B 6. When fitting fine positioning motor !2 in rod driving arm !3, attach hinge screws 4 which join fine positioning link !4 and fine position bracket

7. If the hinge screw is attached to the opposite side, fine positioning link !4 will interfere with fine positioning motor bracket 1 and fail to actuate. (See Fig.2)

2) When attaching fine positioning rod gear B 6 to fine positioning motor bracket 1, position fine positioning rod gear B 6 so that it can be rotated smoothly by hand and deflects by 0.5 mm (0.020”) or less at the top end of the gear teeth. (Adjust the position of the fine positioning rod gear B 6 with hinge screw . Then fix the hinge screw with out !1.)

3) Attach fine positioning motor bracket 1 to main body frame 2 so that a clearance of 1 mm (0.039”) is provided between LM guide 3 and hinge screws 4 and a backlash of 1.5 mm (0.059”) or less is provided between fine positioning rod gear B 6.

4) After the fine positioning motor bracket has been attached to the main body frame, manually move the manual rotating shaft to check the clearance provided between LM guide 2 and hinge screws 4. Fix spring suspension to spinner oscillating arm returning spring 8 and LM guide 3.

− 63 −

3) Button detecting mechanism at the positioner

A button is detected at the button positioner. If a button is detected by the sensor, the machine starts fine-positioning of the button. If no button is detected, the machine repeats index until the sensor detects a button by means if the gear. However, no button is detected after having continuously tried indexing a button ten times, the machine terminates indexing and the alarm indicator on the operation panel repeats flashing on and off. Now, press the manual operation switch, and the machine will re-start indexing until the

Triplepawl

Hole in the feed disk

Gear

Sensor

sensor detects a button.

4) Spinner oscillating arm origin switch (A.ORG) and spinner oscillating arm forward switch (AFRT) (The switches are different from those mounted on the BR10. So be careful.)

Spinner oscillating arm origin switch 1 (hereinafter called “A.ORG”) and spinner oscillating arm forward switch 2 (hereinafter called AFRT) each of which is equipped with a photo-micro sensor (PM-T53B) are

sensors to detect the origin of the cam shaft.

Fig.a

Adjust cam follower 3 for the button clamp jaw lever so that it is located above attaching screw 5 in twostepped cam 4 by turning the manual rotating shaft, as illustrated in Fig.a. Fix AFRT 2at the lowest position of the slot in metal fitting A 7 of the spinner oscillating arm.

7.5

At this time, note that sensor dog 6 should come to

1 2

(30˚)

3.7

the center of the sensor as shown in Fig.c.

Fig.c

Fig.b

(Caution) Notch of the shape of sensor dog 6 is

different from that of sensor dog for BR20.

5) Adjusting the index origin switch (IORG)

0.8 to 1.2 mm

Index origin switch 1 (hereinafter called IORG) which incorporates a proximity sensor (GXL-8F) is a sensor to detect the stop of feeding of the feed disk. Adjust the clearance between the periphery of Zeneva wheel 2 and the detecting plane of the IORG to 0.8 to

1.2 mm (0.013” to 0.047”)

− 64 −

6) Adjusting the button positioning detection switch (BUT)

Button positioning detection switch 1 (hereinafter called BUT) which incorporates a proximity sensor (GXL8F) is a sensor to detect whether a button exists in the positioner 2 when actuating the positioner (triple pawl). (It turns OFF when a button exists in the positioner or turns ON when it does not detect any button there.) Draw the iron core of positioning solenoid 3 when there is no button in positioner 2, and the triple pawl will be closed. In this state, loosen the fixing screw of triple-pawl dog 4, and move triple-pawl dog until BUT which has been in the OFF state turns ON. Then further move the triple pawl dog forward from the aforementioned position (Fig. A- 1) by 1.5 mm (0.059”) (Fig. B- 2), and tighten the fixing screw of the triple-pawl dog. Then, confirm that BUT turns OFF when the triple-pawl clamps a ø10 mm (0.394”) button. Also confirm that BUT turns ON when the triple pawl is closed after taking out the button from it.

7) Adjusting the button detecting switch and cylinder

1mm

Fig.A-1 Fig.B-2

BUT ON

Triple-pawl dog

BUT1

1.5 mm

1) Adjust first the operating air pressure to 0.5 MPa (5 kgf/cm2.) Loosen cylinder nut 6 and adjust the position of the cylinder so that clearance (a) provided between button clamp jaw lever (left) 7 and detecting lever 8 is minimized with the power to the machine turned OFF (the cylinder is fully extended).

2) Set the operating air pressure to 0 MPa (0 kgf/cm2) and retract cylinder 3. (The cylinder automatically returns to its retracted position by means of the spring.) Now, loosen screw 5 and adjust so that a clearance of 1 mm is provided between sensor 1 and the end face of detecting plate 2.

− 65 −

8) Adjusting the work clamp lift detecting switch

When the work clamp

of the sewing machine is raised

1.5 mm

1) Adjust metal fitting 2 so that a clearance of 1.5 mm (0.059”) is provided between work clamp lift detecting switch 1 and vertical lever 3.

2) Then, fix switch 1 at the position where the LED lights up when the work clamp is raised by turning the manual rotating shaft.

3) Confirm that the LED lights up when the work clamp is lowered.

(Caution) Be sure to pass switch cord 4 through

the section of metal fittings 2.

(4) Replacing the components and positioning them

1) Replacing the button carrier and positioning it

Dolly nut

Button carrier

2) Replacing the work attachment

Rotary rod

(fine positioning shaft)

Work attachment

Large type

To replace the button carriers, remove first the fixing knob of the set plate (right). Loosen screw 1 and remove the button carrier, Replace the button carrier with another button carrier with a proper center-to-center distance. Fit the selected button carrier to the eccentric cam stopper, and simultaneously make the top face of the carrier come in contact with the dolly nut. Now, dix the button carrier at that position.

(Caution) The above-stated positioning procedure

Remove the work attachment currently attached to the sewing machine from the rotary rod. Then attach the work attachment of another type to the machine. At this time, be sure to confirm that the work attachment securely fits in the position. This should be confirmed in the case of replacing any other components in the normal operation of the sewing machine.

should be carried out with the sewing machine set to the origin.

− 66 −

3) Adjusting the parts feeder

1. Operation of the operation panel

1) Turn ON the power to the parts feeder.

2) Set variable resistor 1 to the middle of the graduation.

3) If the feeder does not vibrate adequately, turn sensitivity sensitivity adjustment variable resistor 2 until it reaches the position to allow the feeder to vibrate most. Then turn sensitivity adjustment variable resistor 3 and make a fine adjustment so that vibration of the feeder is maximized.

4) Adjust the flow of buttons using the parts feeder adjusting variable resistor 1.

(Caution) Sensitivity adjusting variable resistor 2 is

very delicate. It is recommended to place buttons with flat bottom in the feeder bowl, and adjust the flow of buttons while checking the actual flow of the buttons. This will allow you to adjust the flow of buttons with ease.

4) Adjusting the attachments in the feeder bowl

1. Guide plate

Track surface

Button

2. Separation plate

The appropriate clearance between the button top face and the guide plate 1 is approximately 0.7 mm. Loosen screws 2, and move guide plate 1 up and down to adjust the clearance appropriately.

The separation plate sorts the right-sided buttons from the wrong-sided buttons and feeds only the right-side buttons to the index unit. Loosen bolt 1, and move separation plate 2 back and forth until it is correctly positioned. Now, fix the plate with bolt 1. The separation plate comes in three different sizes, i.e., large, medium and small. Select one from among them in accordance with the size of buttons to be used.

3. In-line arrangement plate

This plate prevents buttons which have passed the separation plate from piling up. The appropriate clearance between in-line arrangement plate 2 and the top face of a button is approxiamtely 0.7 mm. Loosen bolt 1, and move the in-line arrangement plate 2 up and down to adjust the clearance to the correct value.

− 67 −

4. Button guide

Appropriate clearance R1 between the button guide 1 and the button is approximately 3 to 4 mm (0.118” to 0.157”). Loosen screw 2, and adjust the clearance to the correct value. A clearance which is larger than the value twice as thick as a button by approximately

0.7 mm should be provided between overflow

prevention plate 3 and the button. Loosen screw 2, and adjust the clearance to the correct value. Appropriate clearance R 2 between lower surface of the button guide and the track surface of the feeder bowl is 0.3 to 0.5 mm (0.012” to 0.020”).

5. Adjusting the height of the feeder bowl

6. Adjusting the position of the feeder bowl

Feeder bowl attaching screw

Loosen six locknuts 1 of feeder base 2, and adjust height difference R between the outlet for buttons and the disk to 0.5 mm (0.020”) or less while the disc is positioned higher than the outlet for buttons. (At this time, never adjust 3.) If an excessive difference in height is provided, two buttons may enter the notch of the feed plate with overlapped. So be careful.

Adjust clearance R between the feeder bowl and the disk 4 to approximately 1 to 1.5 mm (0.039” to 0.059”). Loosen nut 1 (above figure) and move the entire unit of the parts feeder until it is properly positioned. The position of the feeder bowl can be finely adjusted by loosening the feeder bowl attaching screw and changing the position of the feeder bowl.

− 68 −

9. MAINTENANCE INSPECTION

For maximum performance of this machine, be sure to perform periodic maintenance and inspection as shown below.

(1) Maintenance and inspection of the sewing machine components

Dirts and dust accumulated on the components described below may adversely affect the sewing capabilities and performance of the sewing machine. So, be sure to clean them after operation is finished.

1) Blow dust off the photo sensor slit area with the air gun.

2) Remove the fibrous wastes or dust from the contact plane of the lelctrode of thread breakage detector with a dry rag.

3) Apply lithium system soap group grease No.2 onto the nipples (located on the both side of the carriage unit) of the LM guide that is used for feeding the

Nipple

carriage unit once every two or three months.

(2) Maintenance and inspection of electrical components

Inspect periodically each joints for loose connector,etc., caused by vibration of the machine,etc. (Also check each power plug for lifting and screws for looseness.)

(3) Diagnostic feature

Input signals of the sensor or output signals of valves can be checked on the operation panel. Use this feature troubleshooting at the time of maintenance.

1. Details of inspection

1) Checking the liquid crystal display (LCD) of the operation panel

2) Checking the input signals.

3) Checking the output signals.

2. Preparations for operation

1 Turn OFF the power to the machine, and set the DIP switches in the control box as described below.

•DSW4-8 in the I/O circuit board → ON

•DSW2-2 in the CPU circuit board → ON

* When carrying out “2) Checking the input signals” remove the operating air supply from the machine and

the connector (P61) of the stepping motor from the rear face of the control box.

− 69 −

3. Operating procedure

1) Checking the liquid crystal display (LCD) on the operation panel

If an abnormal indication is shown on the operation panel, failure of the LCD components can be inspected. 1 Turn ON the power to the machine, and the following screen will appear on the LCD of the operation

panel.

DLAGNOSTIC PROGRAM

1. LCD CHECK

2 Press the ENTRY key , and the sewing machine will enter the LCD check mode. Now,the indicarions

will change at intervals of five seconds in the following order.

ENTIRE SCREEN (FRAME) LIGHT OFF → ENTIRE SCREEN(FRAME) ULTRA-GREEN

↑↓

ENTIRE SCREEN (FRAME) ORANGE LIGHT ON ← ENTIRE SCREEN (FRAME) LIGHT OFF

* Check the LCD components for failure. If the indicated frame on the screen breaks in part, replace the

panel circuit board with a new one.

3 Press the RESET key , and screen 1 will be restored on the LCD.

2) Checking the input signals

Input signals of the switches and sensors can be inspected through the LCD on the operation panel. * Turn OFF the power to the machine and remove the operating air supply to the machine and the

connector (P61) of the stepping motor connector from the rear face of the control box.

1 Turn ON the power to the machine, and the “LCD CHECK” will be shown on the liquid crystal display

(LCD) on the operation panel.

2 Press the RIGHTWARD key once, and the indication shown on the LCD will change to the following

one.

DLAGNOSTIC PROGRAM

2. INPUT SIGNAL CHECK

3 Press the ENTRY key , and the sewing machine will enter the input signal check mode. Now, the

frame corresponding to each switch is shown with “0” or “1”.

00000000000・・・・・

* Refer to the next page for the corresponding table.

01101111111・・・・・

4 Manually actuate the switches and sensors corresponding to the LCDs to check that the LCD indication

changes from “0” to “1” or “1” to “0”.

< Switches on the operation panel-LCD frame Corresponding No. >

1 2 ......................................4 0

41 ......................................... 8 0

5 Press the RESET key , and the LCD restores screen 2.

− 70 −

LCD NO. Name of input signal

1 Numeric key SW ON→ 1 2 Numeric key SW ON→ 1 3 Numeric key SW ON→ 1 4 Numeric key SW ON→ 1 5 Numeric key SW ON→ 1 6 Numeric key SW ON→ 1 7 Numeric key SW ON→ 1 8 Numeric key SW ON→ 1

9 Numeric key SW ON→ 1 10 Numeric key SW ON→1 11 Plus SW SW ON→1 12 Minus SW SW ON→1 13 Back SW SW ON→ 1 14 Forward SW SW ON→ 1 15 – 16 Entry switch 17 Memory No. selector SW SW ON→ 1 18 Hiding key (under the ) SW ON→1 19 Sewing data input SW SW ON→ 1 20 Sewing data check SW SW ON→ 1 21 Counter setting SW SW ON→ 1 22 Shirt counter clear SW SW ON→ 1 23 Hiding key (under the and ) SW ON → 1 24 Bobbin counter reset SW SW ON→ 1 25 Automatic operation selecting switch SW ON → 1 26 Sewing machine start SW SW ON → 1 27 Hiding key (right,right and right of the ) SW ON→ 1 28 Hiding key (right and right of the ) SW ON → 1 29 Carriage travel SW SW ON→ 1 30 Hiding key (right of the ) SW ON → 1 31 – 32

Men’s mode/ladies’ mode change-over SW ladies’ mode→1

Garment body/finished product change-over SW Finished product 34 Sewing machine start SW SW ON → 0 35 Emergency stop SW SW ON→0 36 Carriage clamp release SW SW ON→0 37 Compressed air detector Compressed air is supplied →0 38 Alarm output SW ON→0 39 – 40 Japanese/English DSW SW ON→ 1

LCD NO. Name of input signal

41 mm/inch DSW SW ON→ 1 42 43 44 Used for diagnosis 45 Normal/aging DSW SW ON→0 46 A/B type DSW SW ON→0 47 M/BLK DSW SW ON→ 0 48 Cross-over SW DSW SW ON→0 49 Front end input DSW SW ON→0 50 Long-material DSW SW ON→ 0 51 50/60 Hz DSW SW ON→0 52 Pair-stacker DSW SW ON → 0 53 Used for diagnosis 54 – 55 Carriage origin detector shielded→1 56 Carriage speed decreasing detector shielded →1 57 Carriage discrimination detector shielded →1 58 Stacked No. of pcs. detector Lights up → 0 59 Swing bar detector Lights up→ 0 60 Carriage clamp position detector shielded→0 61 Material edge detector (left) shielded→0 62 Material edge detector (right) shielded→0 63 – 64 – 65 – 66 – 67 Spinner oscillating arm forward detector Forward→ 1 68 Manual button feeding SW SW ON→1 69 Step-operation SW SW ON→1 70 Button discharging SW SW ON→ 1 71 Stop-motion detector Stop-motion→ 1 72 Button detector shielded→0

→

73 Button positioning detector Lights up → 1 74 Detection of button detector Lights up → 1 75 Spinner oscillating arm origin detector Origin → 1 76 Indexer origin detector Origin→ 0 77 – 78 Sewing failure detector Contact → 1 79 Needle-up position detector Upper position→ 1 80 Work clamp lift detector Liftıî1

− 71 −

3) Checking the output signals

Performance of the values and motors can be checked by making them operate independently for a predetermined period of time using the switches on the operation panel. * Turn OFF the power to the machine, connect the operating air supply to the machine and connect the

connector of the stepping motor on the rear face of the control box.

1 Turn ON the power to the machine, and the indication “LCD CHECK” will appear on the liquid crystal

display (LCD) of the operation panel.

2 Press the Forward key twice, and the indication on the LCD of the operation panel will change to the

following screen.

DLAGNOSTIC PROGRAM

1. OUTPUT SIGNAL CHECK

3 Press the ENTRY key , and the machine will enter the output signal check mode. The following

screen will appear on the LCD of the operation panel.

CHECKING OUTPUT SIGNAL

4 Actuate the cylinders and stepping motor by pressing the respective switches on the corresponding

table on the next page to check the cylinders and stepping motor for correct performance.

(Caution) When checking outputs related to the machine head, the machine will run at a high speed

or the peripheral components will operate. So, keep your hands away from the components near the machine head.

5 Press the RESET key , and screen 2 will be restored on the LCD.

− 72 −

Switch on the

operation panel

Output signal ON state of switches

Memory No. selector LED Sewing data input LED Sewing data check LED Counter set LED Conveyor shift cylinder Stacker cloth presser cylinder Swing bar stacker cylinder Conveyor motor Material edge gauge cylinder Carriage clamp cylinder

Used as the entry key for diagnosis Automatic operation selector LED

The LED of the memory No. selector switch on the operation panel lights up. The LED of the sewing data input switch on the operation panel lights up. The LED if the sewing data check switch on the operation panel lights up. The LED of the counter setting switch on the operation panel lights up. The conveyor comes down. The cloth presser of stacker actuates. Swing bar of stacker actuate. The conveyor motor rotaes. Material edge gauge comes down. The carriage clamp comes down.

The LED of the automatic operation selector switch on the operation panel

lights up. Carriage travel LED Work clamp check lowering cylinder Used to restore the previous screen

for the diagnostic feature BR positioning solenoid BR shutter solenoid BR fine positioner lowering solenoid

Sewing machine starting cylinder BR fine positioning motor BR index motor BR spinner oscillating arm motor BR parts feeder BR button detecting cylinder

The LED of the carriage travel switch on the operation panel lights up.

The work clamp check of the sewing machine comes down.

The positioning solenoid actuates.

The shutter solenoid actuates.

The fine positioner lowering solenoid actuates.

The starting cylinder actuates and the sewing machine rotates. * Caution

The motor of the fine positioner rotates.

The motor of the indexer rotates until the next feeding hole is reached.

The spinner oscillating arm feeds a button.

The parts feeder vibrates.

The button detecting cylinder actuates.

* Caution When checking outputs related to the machine head,the machine will run at a high speed or

the peripheral components will operate. So, keep your hands away from the components near the machine head.

− 73 −

− 74 −

10. PERFORMANCE FLOW CHART

Motor for men’s wear

Power ON

OFF

Ladies’ wear

To body of a garment

N.G.

Independent

Manual

The carriage stops

Faulty work clamp position

error indication

Manual operation

Bobbin thread error is

shown.

1-1

Ladies’ wear

travelling

Stop

1-3

Bobbin thread error

is shown.

R switch

Reset error indication

Work clamp goes up error

indication

Work clamp goes up

The carriage returns to

Thread breakage ?

the origin.

OFF

The carriage switch

LED comes ON

The last indexing

finished

Not finished

The carriage indexing

Work clamp position

N.G.

The carriage stops

traveling

Faulty work clamp position

error indication.

Stop

Work clamp goes up

OFF

Reset error indication

The carriage returns to

OFF

Finished

Good

Button error indication

R switch

the origin.

The carriage returns to

the origin.

Auto/Manual

Set the start release

SW to ON.

R switch

Reset error indication

Set to Manual

Stitch error indication

OFF

Reset error indication

Button error

Independent ?

R switch

The machine

start switch

None

YThread trimming error

Bobbin thread counter

OFF

Supply buttons ?

Yes

Machine starts

Thread broken ?

= 0

BR motion

Independent ?

Manual/independent

OFF

Bobbin thread error

is shown.

Men’s/ladies’ wear

Long sized material

1-5

Long sized

men’s wear

Finished workpiece/ for

Work clamp goes up

Set the start SW to OFF

BR motion

Conveyer motion

Stacking

1 cycle finished

Work clamp goes up error

indication

Finished

workpiece

1-2

men’s wear

Finished workpiece/the

OFF

In the amount of bobbin

Work clamp comes down

Work clamp of the sewing

machine comes down

The last button sewing

Bobbin thread counter

The carriage indexing

Men’s wear

Long sized material/

standard

Standard

body of a garment

The carriage origin

searching

Work clamp position

Good

Read the memory

No.1-20

Auto/independent

Automatic

Auto/Manual

Automatic

Start switch

thread sufficient ?

The start release SW

Supply buttons

Work clamp

comes down

Machine starts

Thread breakage ?

Work clamp goes up

= 0

BR motion

Continuous motion

− 75 −

Men’s wear

manual operation

1-3

Work clamp goes up

Set the start SW to OFF

The start SW

Work clamp comes down

The start release switch

OFF

The start SW

Set to the AUTO

OFF

switch

Home position

The carriage indexing

OFF

The last indexing finished

The carriage indexing

Good

Work clamp position

The carriage stops travelling

switch

Not finished

N.G.

OFF

Finished

Work clamp goes up

Feed the carriage to the origin

Conveyer motion

Stacking

Machine start SW

OFF

Faulty work clamp position error

indication

Stop

− 76 −

Finished men’s wear/manual operation

1-4

Work clamp goes up

Set the start SW to OFF

The start SW

Work clamp comes down

The start release switch

OFF

The start SW

Set to the AUTO

OFF

switch

Home position

The final indexing

OFF

Good

switch

The last indexing finished

Not finished

The carriage indexing

Work clamp position

N.G.

OFF

Finished

Work clamp goes up

Feed the carriage to the origin

Conveyer motion

Machine start SW

OFF

− 77 −

The carriage stops traveling

Faulty work clamp position error

indication

Stop

Note 1) The motion for ladies’ finished wear and that for men’s are identical except for the motion

of the carriage, where motions on the left side and right side are reversed.

Motion for ladies’ wear

1-1

Finished wear

2-1

Note 1) Ladies’ finished wear

Work clamp goes up

Set the start switch to OFF

Work clamp goes up

Return the carriage to

the origin

BR motion

Conveyer motion

Stacking

1 cycle finished

Finished wear/The body

of a garment

The carriage searches

the origin

Work clamp position

Read the memory No.1-20

Auto/independent

Auto/Manual

OFF

The start switch

Is the amount of bobbin

thread sufficient ?

Work clamp comes down

The start reset switch

Supply buttons ?

Work clamp of sewing machine

comes down

Work clamp of sewing machine comes down

The machine starts.

Thread broken ?

The last button finished

Work clamp goes up

Bobbin thread counte

The carriage indexing

BR motion

The body of a garment

Good

Auto

OFF

= 0

The carriage stops traveling

N.G.

Independent

Manual

Bobbin thread error is shown.

Faulty work clamp position

error indication

Stop

2-3

Manual operation

Bobbin thread error is shown.

R switch

Reset error indication

Work clamp goes up error

indication

Work clamp goes up error

indication

OFF

The carriage switch

LED comes ON

The fianl

indexing finished

Not finished

The carriage indexing

Work clamp position

N.G.

The carriage stops traveling

Faulty work clamp position

error indication

Stop

OFF

Finished

Good

Button error indication

Work clamp goes up

R switch

Reset error display

Return the carriage

to the origin

Return the carriage

to the origin

Auto/Manual

Start release SW “ON”

R switch

Reset error indication

Set to Manual

Stitch error indication

OFF

Thread trimming error

Independent ?

R switch

Reset error indication

Machine start switch

NoneButton error

OFF

Supply button ?

Yes

Machine starts

Thread broken ?

Bobbin thread counter

= 0

BR motion

Independent ?

Manual / Independent

OFF

Bobbin thread error is shown.

Continuous motion

− 78 −

Men’s finished wear motion

1-2

Carriage switch

LED comes ON

OFF

The carriage searches

the origin

Work clamp position

Good

Read the memory No.1-20

Auto/Independent

Auto

Auto/Manual

Auto

Work clamp goes up

Set the start SW to OFF

Work clamp goes up

The carriage returns to

BR motion

Conveyer motion

1 cycle finished

OFF

the origin

Start switch

Is the amount of bobbin

thread sufficient ?

Work clamp comes down

The start release SW

OFF

Supply buttons ?

Work clamp comes down

Machine starts

Thread broken ?

The last button

finished

Work clamp goes up

Bobbin thread counter

= 0

The carriage indexing

BR motion

N.G.

Independent

Manual

The carriage stops traveling

Work clamp position error

Manual operation

Bobbin thread error

indication

Stop

1-4

Bobbin thread error indication.

R switch

Reset error indication

Work clamp goes up error

indication

Work clamp goes up error

indication

OFF

Last indexing finished

Finished

Not finished

Carriage indexing

Work clamp position

N.G.

Carriage stop traveling

Faulty work clamp position

error indication

Stop

OFF

Finished

Carriage returns to the origin

Good

Button error indication

Work clamp goes up

R switch

Reset error indication

Carriage returns to the origin

Auto/Manual

The start release

SW “ON”

R switch

Reset error indication

Set to Manual

Stitch error indication

OFF

Thread trimming error

Independent ?

R switch

Reset error indication

OFF

The machine

starts switch

NoneButton error

Supply buttons ?

Yes

Machine starts

Thread broken ?

Bobbin thread counte

= 0

BR motion

Independent ?

Manual/Independent

OFF

Bobbin thread error is shown.

Continuous motion

− 79 −

Ladies’ wear manual operation

2-3

Work clamp goes up

Set the start SW to “OFF”

Start switch

Work clamp goes down

Start release switch

OFF

Start switch

Set to auto

OFF

switch

Home position

Carriage indexing

OFF

Good

switch

Last indexing finished

Not finished

Carriage indexing

Work clamp position

N.G.

Carriage stops traveling

OFF

Finished

Work clamp goes up

Return carriage to the origin

Conveyer motion

Stacking

Machine start switch

OFF

Faulty work clamp position

error indication

Stop

− 80 −

Long sized men’s wear motion

1-5

The carriage origin

searching

Work clamp position

Reset the memory

No.1-20

Auto/Independent

Auto/Manual

Work clamp goes up

Set the start SW to OFF

BR motion

Conveyer motion

Stacking

1 cycle finished

Work clamp goes up error

indication

OFF

Start switch

Is the amount of bobbin

thread sufficient ?

Work clamp comes down

The start release SW

Supply buttons ?

Carriage turning point

Work clamp comes down

Comes down

Start the machine

The last button sewing

Thread broken ?

Work clamp goes up

Bobbin thread counte

= 0

The carriage indexing

BR motion

N.G.

Good

Independent

Auto

Manual

Auto

OFF

Bobbin thread error

The carriage stops

traveling

Faulty work clamp position

error indication

Stop

Manual operation

Work clamp comes down

The carriage returns to the

Work clamp comes down

Work clamp goes up error

indication

1-6

Bobbin thread error

indication

R switch

Reset error indication

Conveyer comes down

Work clamp goes up

origin

Conveyer goes up

indication

Work clamp goes up

Carriage returns to the

Thread broken ?

origin

Not finished

N.G.

OFF

Finished

Good

OFF

Carriage returns to

the origin

Carriage returns to

the origin

Button error indication

Work clamp goes up

R switch

Reset error indication

Carriage returns to

the origin.

The start release

Reset error indication

Auto/Manual

SW “ON”

R switch

Set to Manual

Stitch error indication

OFF

Button error None

Thread trimming error

Independent ?

R switch

Reset error indication

OFF

The machine

start switch

Supply buttons ?

YES

Machine starts

Thread broken ?

Bobbin thread counte

= 0

BR motion

Independent ?

Auto/Independent

OFF

Bobbin thread error

indication

Carriage switch

LED comes ON

Carriage turning point

Last indexing finished

Carriage indexing

Work clamp position

Carriage stops traveling

Faulty work clamp position

error indication

OFF

Stop

Continuous motion

− 81 −

Long sized men’s wear

manual operation

1-6

Work clamp goes up

Set start SW to “OFF”

OFF

Conveyer comes down

Work clamp goes up

OFF

switch

Home position

Carriage indexing

OFF

switch

Carriage turning point

OFF

Conveyer comes down

Work clamp goes up

Return carriage to

the origin.

Work clamp comes down

Machine start switch

OFF

The start SW

Work clamp comes down

The start release

switch

OFF

The start SW

Set to Auto

Carriage turning point

(indexing)

Work clamp comes down

Conveyer goes up

Good

Work clamp position

Faulty work clamp position

The last indexing

finished

Not finished

Carriage indexing

N.G.

The carriage

stops traveling

error indication

Stop

Conveyer goes up

Finished

Work clamp goes up

Carriage return to the origin

Conveyer motion

Stacking

− 82 −

11. SEQUENCE CHART

Origin SW

Speed reduction SW

Knee SW

Work clamp goes up detector SW

Cloth edge detector (1) SW

Cloth edge detector (2) SW

ACF-164 INPUT

Swing bar detector SW

Reset error SW

Indexing (right) SW

Gauge cylinder

Carriage work clamp cyl.

Work clamp comes down cyl. Conveyer cyl.

Conveyer motor Work clamp stacker cyl.

ACF-164 OUTPUTLK, BR INPUTLK, BR OUTPUT

Stacker swing bar cyl.

Stepping motor

INIT

SPEED

START

FL.POS

WRK. FWD

WRK. BCK

STCK2

RESET

MOV. R

GAU. CL

CLP. CL1

FUT. CL COV. CL

COV. MTR STK. CL1

STL. CL2

CCW CW

Motion of the ACF-164-1903

Origin

searching Start Sewing

OFF

CCW

OFF

Auto operation Error

Indexing

Sewing (stitch skipping, thead bra\eakage error)

Manual operation

Reset

Auto operation

Re-start a (button supply error)

Error

Reset

Stacking motion

Manual operation Manual operation Auto operation

Button supply Indexing (manual)

Re-start (Last button sewing,return to the origin)

Stop-motion SW Upper position detector SW Thread breakage detector SW Oscillating spinner arm origin SW Oscillating spinner arm forward SW Button detector SW Button positioning detector SW Index origin SW Button discharging SW Step operation SW Button supply SW

Button detector cyl. Machine starter

Oscillating spinner arm motor Positioning SOL

Fine positioning motor

Fine positioning SOL Shutter SOL

Index motor Parts feeder

L. SW UP. SW THR A. ORG AFRT BUT POS I. ORG EXHST ARNGE MANU. FD

BUT. CL STR. CL

ARM. MTR

SET. SOL RUB. MTR

RUB. SOL SHT. SOL

IND. MTR

PT. FDR

OFF

− 83 −

T : Indicates the value on the timer

Motion of the LK-1903/BR21

Origin SW

Speed reduction SW

Knee SW

Work clamp goes up detector SW

Cloth edge detector (1) SW

Cloth edge detector (2) SW

ACF-164 INPUT

Stacker swing bar detector SW

Reset error SW

Indexing (right) SW

Gauge cylinder

Carriage work clamp cyl.

Work clamp comes down cyl.

Conveyer cyl.

Conveyer motor

Work clamp stacker cyl.

ACF-164 OUTPUTLK, BR INPUTLK, BR OUTPUT

Stacker swing bar cyl.

Stepping motor

INIT

SPEED

START

FL.POS

WRK. FWD

WRK. BCK

STCK2

RESET

MOV. R

GAU. CL

CLP. CL1

FUT. CL

COV. CL

COV. MTR

STK. CL1

STL. CL2

CCW CW

OFF

CCW

OFF

Oscillating spinner

Sewing (with cross-over stitch) Sewing (without cross-over stitch) Discharge of the button

arm inching

Oscillating spinner arm

returns to the origin.

Button supply

Stop-motion SW

Upper position detector SW

Thread breakage detector SW

Oscillating spinner arm origin SW

Oscillating spinner arm forward SW

Button detector SW

Button positioning detector SW

Index origin SW

Button discharging SW

Step operation SW

Button supply SW

Button detector cyl.

Machine starter

Oscillating spinner arm motor

Positioning SOL

Fine positioning motor

Fine positioning SOL

Shutter SOL

Index motor

Parts feeder

STP. SW

UP. SW

THR

A. ORG

AFRT

BUT

POS

I. ORG

EXHST

ARNGE

MANU. FD

BUT CL

STR CL

ARM MTR

SET SOL

RUB MTR

RUB SOL

SHT SOL

IND MTR

PT. FDR

OFF

1 2 9 10

− 84 −

T : Indicate the value on the timer.

12. AIR PIPING

1. Piping components for ACF-164

1A Green 1400 1B Yelowish green 1300 2A Red 1400 2B Yeloow 1300 3A Blue 2000 3B – 4A Yellow 2700 4B Yellowish green 2700 5A – 5B Green 1400 6A Black 1600 6B –

Valve

Cylinder

PV020501000

Cylinder 1A

PC015108000

PA2002513A0

PX500017000

PC015108000 (4 pcs.) (1/8 X ø4)

PJ046052503

PS304040504 (M5 X ø4)

PA0601004A0

(M3Xø4)

PJ210304010

G5046164000

ø4

PA160100500

PJ308040002

PA800012000

PJ032526001

PJ304040504

(M5 X ø4)

G5046164000

G64011640A0

(PV1551080A0)

PJ309005201

PJ309005203

ø4

PJ050525201

PA160100500

ø4

PJ301065201

PJ308040002

PJ303060001

ø6

1/4

ø6

G5458116000

PJ030520001

1/4

PF0552090A0

16111502

1/8

1/4

16111403

PX065101000

PJ015251001

PJ050525201

PJ301065201

ø6

PJ301040504 (X7)

PJ308040002 (X3)

PV010507000

Second work clamp (optional)

Valve 1A

PC015108000

G61081640A0 (PA2015004A0)

G61091640A0 (PA2007504A0)

Options (when VAC.MC-16 is used)

PJ301040504 (M5 X ø4)

⑤

1800

PA160100600

PJ301040505

PJ301040504

(M5 X ø4)

①

Cloth presser

of stacker

③ Conveyer

② Swing bar

shift

of stacker

④ Gauge

PJ020500001

⑤ Work

clamp

⑧ Spare

⑦ Spare

⑥ Button

detector

PJ301040504 (M5 X ø4 meter-in)

− 85 −

2. Air piping drawing

(PA160100500)

(PA2007503A0)

(PV020501000)

PA2007504A0

(PC015108000)

PC015108000

(PJ308040002)

PA2015004A0

PC015108000

PA2002513A0

PC015108000

PJ210304010

(PJ305040503)

PA800012000

PA160100500

PJ304040504

PJ308040002

PJ046052503

PA0601004A0

(PA160100600)

PX065101000

(PJ301040505)

PJ015251001

16111403

PJ303060001

(PJ301040504)

(PV010507000)

PV1551080A0

① PJ020500001

② PJ301040504

(PJ301040504)

②

Stacker

(presser)

②

Stacker

(swing bar)

① ②

Conveyer

(upper/lower)

Gauge

②

Work clamp of the carriage unit

PC010514000

16111502

G5458116000

PJ301065201

PJ030520001

PF0552090A0

②

①

②

Button

detector

② ①

Spare Spare

(suction)

① ①

PJ301065103

PJ301065201

PJ050525201

PJ030520001

PJ50525201

PJ309005203

PJ309005201

Caution) 1. The part No. with parentheses ( ) is optional.

− 86 −

13. WIRING COMPONENTS

1. Wiring the frame (large) components

Decreased speed detecting switch

Carriage clamp position switch ②

Screw SL4041081SF

Clamp HX00150000A

Screw SL4041081SF Clamp HX00150000A

6 places

Air tube for work

clamp release switch

Conveyor motor junction cord

Screw SL4041081SF

Clamp HX00150000D

※ With three air tubes

Swing bar cylinder

G61081640A0 Stacker cloth presser cylinder

G61091640A0

G61021640A0

G61051640A0

(Front)

(Rear)

Material edge sensor 1

G62021640A0

Origin detecting switch G61011640A0

Discrimination switch G61031640A0

Carriage clamp position switch ① G61051640A0

Screw SL4041081SF

Clamp HX001500000

(Rear)

Screw SL4041081SF Clamp HX00150000A ※ 4 places

Wooden screw SK3381311SC

Clamp HX001500000

G61101640A0

※ 2pcs.

Screw SL4041081SF

Clamp HX00150000G

(Front)

Material edge sensor 2 G61111640A0

With three air tubes

See figure A.

Screw SL4041081SF Clamp HX001500000

to the control box

Work clamp release switch G61121640A0

Operating air pressure detecting switch

※ To be tightened with plate Screw SM0040601SA Clamp HX001500000

G61071640A0

Start switch G61041640A0

Duct (A) G6801164000

Screw SM0040601SA Clamps HX001500000A

Screw SL4041081SF Clamp HX001500000

Work clamp

release switch

Screw

SL4041081SF

Clamp

HX00150000D

Protecting tube

Air tube

Detailed figure of section A

※ Clamp HX00150000D

Power

Emergency stop switch G61061640A

switch

See figure B.

※ Attach the clamp to the attaching switch for the

※ 2 places

Screw SL4041081SF

Plain washer WP0450801SD

(large)

power switch with a nut.

Power

switch

※ Attach the clamp,with a nut,to the clamp screw

on the front side.

※ Y is the power cord of the MC-16.

If the MC-16 cannot be attached in place,use the clamp of HX00123000A as the cable clamp for the front side.

(See the next page.)

※ Clamp HX00150000D

Detailed figure of section B

G6802164000

※ 4places Screw SL4041081SF Plain washer (large) WP0450801SD

Duct (B)

− 87 −

Solenoid box (1) G64011640A0

Front side

Caution) The mark in the figure indicates the direction of the clamp.

2. Wiring the frame (small) components

White

Black

Fine positioner

lowering magnet

Shutter magnet

Positioning magnet

RMG

SHMG

SEMG

DC motor for fine

positioner

DC motor for spinner

oscillating arm

DC motor for indexer

Press this recess with a thin screwdriver to allow each cord to be connected in place.

Terminal board wiring diagram

Screw

MAQ1230400

Nut

NS6110420SP

Clamp

HX001500000

Button detecting switch asm.

MAZ167820A0

Air tube for button detector

RMT

AMT

IMT

Thread breakage detector SW asm. MAZ16780A0

(To be tightened from inside the machine head) Screw HAZ16728000 Nut NS6110420SP Clamp HX00150000B

Brown Red Orange Yellow Green Blue Gray White Black Purple Pink Light blue

Adhesive clamp HX00305000A Spiral tube G545161000

Hexagon screw

SM6061202TN Spring washer WS0610002KN

Plain washer

WP0641601SC

Inner clip washer

WT0640001KN

※2 places ea.

Panel box asm.

M85305440A0

100

Washer WP0451026SD Spring washer WA0510002KN

※MC-16 (optional)

Screw SL4041081SF

Clamp HX00150000H

Screw SL4041081SF

Clamp HX00150000H

Power switch for

Inner clip

washer

Panel asm. GB117810A0

Ground wires for operation panel

Panel junction cord

MC-16

Screw SM1040801SC

Clamp HX001350000

Screw SL4041081SF

Clamp HX00123000A

Plain washer

Spring washer

G6704160A0

Ground wire asm. G67021640A0

See the terminal

board wiring

diagram.

※ 2 places

On the motors side

Button detecting switch asm. MAZ167820A0 Thread breakage detecting switch asm. MAZ167840A0 Air tube for button detector

※ Wind a spiral tube round these three

Output junction cable asm. G65011640A0

Screw SL4041081SF Clamp HX00150000K

※3 places ea.

Ground wire for panel

Screw SL4041081SF

Clamp HX001230000A

Output junction cord asm.

G65011640A0

Parts feeder cord

cords up to the underside of the table.

※ 2 places ea.

Motor

To bundle slackened cord here.

Screw SL4041081SF Clamp HZ00150000E

Magnet, motor cord

Screw SK3381301SC Clamp HX00150000M

P/F power cord

※ To be connected to P/F

junction cord in the way.

Screw SK3381301SC Clamp HX00123000A

To MC-544

Screw SL4041081SF Clamp HX00150000K

To MC-544

Motor Power cord for MC-544

Screw SL4041081SF Clamp HX00150000F

※3 places ea.

Duct G6801164000

Ground wire asm. J G67011640A0 GND cord for thread breakage detector MAZ167850A0 Sewing machine stop-motion switch asm.

To MC-544

MAZ167810A0 Upper position detecting switch asm. MAZ089830A0

P/F power junction cord asm. GB118220A0 Sensor junction cable asm. GBR218460A0 Output junction cable asm. G65011640A0 Breaker asm. GBR117860A0 Button detecting switch asm. MAZ167820A0 Thread breakage detecting switch asm. MAZ167840A0 Ground wire asm. G67021640A0 Work clamp lift detecting switch asm. GBR118470A0 Manual button feeding switch asm. GBR118470A0 Work clamp lift detecting switch asm. GBR118470A0 Manual button feeding switch asm. GBR117850A0 Step operation switch asm. GBR117830A0 Discharging switch asm. GBR117840A0

V : Power cord for MC-544 W : Power cord for general-purpose motor X : AC input power cord Y : Power cord for MC-16 Z : MC-16 motor cord

ACF power cord

To power plug

Rear face

Screw SL4041081SF Clamp HX00123000F

※2 places ea. ※ To use an optionally-available

MC-16,replace the clamp with the clamp HX00150000H

Screw SL4041081SF Inner clip washer WT0430001KN

Screw SL4041081SF Clamp HX00150000K

− 88 −

14. CONFIGURATION (ELECTRICAL UNIT)

(1) Components of control box and its function

1 CPU circuit board : Use to control all the equipment of the panel. 2 I/O circuit board : Used to input/output the signals of the machine head or button feeder control,

each sensor or each valve.

3 Power circuit board : Used to rectify 7.5,20,24 and 26 Vac output from the transformer and convert

them to 5 VDC, +12 VDC, –12 VDC, 24 VDC and 34 VDC.

4 Transformer : Used to convert input voltage to each voltage. 5 DC fan : Used to blow off the internal air to prevent each unit from generating heat. 6 Stepping motor driver : Used to drive the stepping motor by the exciting signal from the CPU. 7 Terminal block : Used to relay AC input codes and the transformer.

Table of ACF circuit board asm.

POWER circuit board asm. CPU circuit board whole asm. I/O circuit board whole asm.

ACF172

M86035440A0

M8601543CA0

ROM:058,059

M8602544BA0

ROM:060

ACF164-1851

M8601543BA0

ROM:043

M8602544AA0A

ROM:044

ACF164-373

M8603544AA0

M8601543BA0

ROM:043

M8602544AA0A

ROM:044

ACF164-1903

M8601543EA0

ROM:135

M8602544DA0

ROM:134

ACF286

M8601543DA0

ROM:110,111

M8602544CA0

ROM:109

1. POWER citcuit board of ACF172 can be used for 164 and 286. (The reverse is not possible.)

2. Part No. (CPU circuit board asm.) of CPU circuit board whole asm. without ROM is common to M86015430A0.

3. Part No. (I/O circuit board asm.) of I/O circuit board whole asm. without ROM is common to M86025440A0.

− 89 −

(2) Connector and its functions of the control box

J41

(4pin)

J42

(20pin)

J43

(14pin)

J44

(16pin)

J45

(12pin)

J61

(6pin)

J62

(8pin)

J31 (34pin) J32 (50pin)

J66 (4pin) J33 (2pin)

J35 (40pin) J34 (30pin)

J37 (7pin)

J63 (4pin)

J64 (2pin)

J65 (2pin)

< Input >

J31 (34 pin) : Each sensor signal of the machine and the BR body is entered. J32 (50 pin) : Each sensor signal of the machine and the BR body is entered. J34 (30 pin) : Not used. J35 (40 pin) : The sensor signal of the indexer is entered. J37 (7 pin) : Not used.

< Output >

J41 (4 pin) : A control signal is output to the feeder for oscillating. J42 (20 pin) : A signal is output to the magnet, motor and valve for driving the machine head and the BR

body. J43 (14 pin) : A signal is output to the valve for driving the machine head. J44 (16 pin) : A signal is output to the valve for driving the indexer. J45 (12 pin) : Not used. J33 (2 pin) : A signal is output external counter (optional). J61 (6 pin) : A signal is output to the stepping motor. J62 (8 pin) : The power (100 VAC) is supplied to the feeder. A signal is output to the motor for driving

the conveyer. J63 (4 pin) : Not used. J64 (2 pin) : 4.5 VAC is supplied to the marking light (optional). J65 (2 pin) : 4.5 VAC is supplied to the marking light (optional). J66 (4 pin) : Not used.

− 90 −

(3) Power voltage

When a failure occurs, first check the power voltage.

1) Connecting the power voltage to the input voltage of the transformer (on the left of the terminal block.)

FGFG

Ground mark

440 V

Orange

415 V

blue

380 V

Purple

240 V

Gray

220 V White

200 V

Brown

0 V

Black

440 V

415 V

380 V

240 V 220 V

200 V

0 V

Orange

Blue

Purple

Gray

White

Brown

Black

Brown

Sky blue

Switch voltage (brown) in this range. See the left input voltage seal.

AC input (In case of 200 Vac)

Input voltage seal

(Transformer side) Terminal block

(Power supply side)

2) Secondary output voltage of the transformer (AC) Caution) Take care not to allow short circuit of the terminal.

100 VAC (white-white) Approx. 20 VAC Remove 100 VAC of the stepping motor driver and measure it. 20 VAC (blue-blue) Approx. 20 VAC Remove connector P5 with the power circuit board and measure it.

7.5 VAC (red-red) Approx. 7.5 VAC Remove connector P5 with the power circuit board and measure it. 26 VAC (gray-gray) Approx. 26 VAC Remove connector P4 whit the power circuit board and measure it. 24 VAC (brown-brown) Approx. 24 VAC Remove connector P5 with the power circuit board and measure it.

4.5 VAC (yellow-yellow) Approx. 4.5 VAC Use connector J64 or J64 and measure it.

GRAY

S9 SCT

S10 S7 S8

S4 S3

S5 S6 S1

S2 S11

S12

BLACK GRAY

RED

BLUE

WHITE

BROWN

YELLOW

ORANGE

BLUE

PURPLE

GRAY

WHITE

BROWN

BLACK

GREEN/

YELLOW

P7 P6 P5 P4 P3 P2 P1

AC440 V

AC26V 0.3A

AC415 V AC380 V

AC7.5V 3A

AC240 V AC220 V

AC20V 4A

AC200 V

0 V

AC100V 2A

AC24V 5A

AC4.5V 2A

− 91 −

(4) Measuring the DC power voltage

1) CPU circuit board

2) I/O circuit board

(Tester black)

+4.9 to +5.1 V

(Tester red)

(Tester black)

+11.8 to +12.2 V

(Tester red)

+11.6 to +12.4 V

(Tester red)

(Tester black)

(Tester red) (Tester black)

3) Power circuit board

+33 V to +38 V +27 to +30 V

(Tester black)

(Tester red)

4 Pin 1 Pin

3 Pin 6 Pin

(Tester red) (Tester black)

+4.9 to +5.1 V

− 92 −

(5) Changing the thermal values inside the switch box

Remove the switch box cover, turn the dial and adjust figures (thermal values) to ▲.

NO. Voltage Destination Phase Thermal set value

Thermal value setting dial

Set value

1 380 V Export 3ø 2.4 A

415 V

440 V 2 220 V U.S.A. 3ø 4 A 3 380 V Germany 3ø 2.4 A 4 415 V U.K. 3ø 2.4 A

(6) Replacing fuses

Use a fuse having the specified capacity < MC-544 > Remove the control box cover for MC-544

1 F1, Fuse (6 A) 2 F2, Fuse (10 A) 3 F3, Fuse (4 A) 4 F4, Fuse (1 A) 5 F5, Fuse (1 A) 6 F6, Fuse (4 A)

< BR >

F7 (1 A)

− 93 −

(7) Replacing the P-ROMs for data

134※

MC-544

135※

Turn OFF the power and replace the P-ROMs. When mounting the P-ROMs, take care of the correct position and direction of them. In addition, the English characters with an asterisk (※ ) in each P-ROMs indicate REV.No. (Revision Number).

− 94 −

(8) CPU circuit board

The CPU circuit board is mainly used for controlling the stepping motor. It serves as a timer for transferring the stepping time of the stepping motor to the CPU (8085)

The power is supplied form the power

circuit board. (5 VDC and 12 VDC)

The signal of each sensor is input from the I/O circuit board. In addition,the signal of each cylinder is output to the I/O circuit board.

ROM (27C256) Mainly indexer control programs are stored.

RAM (5565)

135

This inputs the SW signal (mainly operation,etc.) from the panel and outputs the lighting signal to the LED. In addition,this outputs the display data to the LCD.

The memory backup battery.

Main CPU (8085)

CPU (8085) controls the indexer and its components.

Used for maintenance

This inputs the SW signal (mainly operation, etc.) from the panel and outputs the lighting signal to the LED.

Switch for function setting This switch is used to change from English to Japanese or mm to inches and vice versa.

This is the input port to transmit the signal of the panel SW to the CPU (8085).

This is the output port to transmit the signal of the CPU (8085) to LCD and LED.

− 95 −

(9) I/O circuit board

Signal of each sensor is entered from the

machine head and the BR.

This is the output port to control the

machine head and the BR.

A 24 VDC and 33VDC are supplied from the power circuit board.

This is the output used to turn ON / OFF the oscillating of the feeder.

This is the output used to drive the magnet, valves and motor of the machine head and BR.

This is the output used to drive the valves of the machine head.

Signals of the sensors output from the

indexer are input here.

This is not used.

This is the CPU used to control the

machine head and the BR.

ROM (27C256)

The control program of the machine

head and BR is written in it.

This is the output used to drive the indexer valve.

This is the output port used to transmit the CPU (8085)

signal to the valves.

This is not used.

This is the input port used to transmit the signal of each sensor to the CPU (8085).

This outputs the signal of each sensor to the CPU circuit board. In addition, the signal of each cylinder is input from the CPU circuit board.

The power is supplied from the power circuit board.

(5 VDC,12 VDC and –12 VDC)

This is the solid state relay used to drive the conveyer motor.

This is the output used to drive the conveyer motor.

This output the signal commanding normal rotation or reverse rotation to the stepping motor driver unit.

− 96 −

JUKI ACF-164-1903 Engineer's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual