Service manual

ManualsBrandsBrother ManualsBusiness equipmentBAS-761

Summary of content (179 pages)

PAGE 1
BAS-7610, 761 SERVICE MANUAL Please read this manual before making any adjustments.
PAGE 2
This service manual is intended for BAS-7610, BAS-761; be sure to read the BAS-7610, BAS-761 instruction manual before this manual. Carefully read the “SAFETY INSTRUCTIONS” below and the whole of this manual to understand this product before you start maintenance. As a result of research and improvements regarding this product, some details of this manual may not be the same as those for the product you purchased. If you have any questions regarding this product, please contact a Brother dealer.
PAGE 3
2. Notes on safety DANGER Wait at least 5 minutes after turning off the power switch and disconnecting the power cord from the wall outlet before opening the face plate of the control box. Touching areas where high voltages are present can result in severe injury. CAUTION Environmental requirements Use the sewing machine in an area which is free from sources of strong electrical noise such as high-frequency welders. Sources of strong electrical noise may cause problems with correct operation.
PAGE 4
CAUTION Sewing This sewing machine should only be used by operators who have received the necessary training in safe use beforehand. Attach all safety devices before using the sewing machine. If the machine is used without these devices attached, injury may result. The sewing machine should not be used for any applications other than sewing. Do not touch any of the moving parts or press any objects against the machine while sewing, as this may result in personal injury or damage to the machine.
PAGE 5
3. Warning labels The following warning labels appear on the sewing machine. Please follow the instructions on the labels at all times when using the machine. If the labels have been removed or are difficult to read, please contact your nearest Brother dealer. 1 Direction of operation 3 Safety devices: Thread take-up cover, Guard bar, Belt cover, etc.
PAGE 6
INDEX 1. MECHANICAL DESCRIPTIONS .........................................................................................1-01 1-1. Upper shaft and needle bar mechanism ..................................................................................................1-01 1-2. Lower shaft and rotary hook mechanism .................................................................................................1-01 1-3. Needle zigzag mechanism ................................................................
PAGE 7
5. ADJUSTMENT .................................................................................................................................5-01 5-1. Adjusting the zigzag movement ...............................................................................................................5-02 5-2. Adjusting the needle bar height and, the needle and the rotary hook timing .......................................................5-05 5-3. Adjusting the thread trimmer timing.................................
PAGE 8
6. ELECTRIC COMPONENTS.....................................................................................................6-01 6-1. Precautions at the time of adjustment......................................................................................................6-01 6-2. Components inside the control box and the operation panel...................................................................6-01 6-3. Power supply ...................................................................................
PAGE 9
1. MECHANICAL DESCRIPTIONS 1. MECHANICAL DESCRIPTIONS Operate in the order of the numbers in the illustration. The “A”, “B” and other alphabets with the numbers indicate different sequences of operation which can occur at the same time. 1-1. Upper shaft and needle bar mechanism 2.Upper shaft 3.Thread take-up crank 4.Thread take-up 1.Motor 5.Needle bar crank 6.Thread take-up crank rod 7.Needle bar clamp 8.Needle bar 1557S 1-2. Lower shaft and rotary hook mechanism 2.Upper shaft 3.Timing pulley 1.
PAGE 10
1. MECHANICAL DESCRIPTIONS 1-3. Needle zigzag mechanism 6.Zigzag cam 5.Sub shaft 1.Pulley 2.Upper shaft 4.Sub shaft gear 1559S 3.Speed reduction gear 8.Zigzag adjusting link 6.Zigzag cam 7.Zigzag adjusting fork 9.Zigzag adjusting lever R 10.Zigzag adjusting lever F assy 11.Needle bar bracket slide block 12.
PAGE 11
1. MECHANICAL DESCRIPTIONS 1-3-1. Zigzag generation mechanism 8.Zigzag adjusting link 8 7 7.Zigzag adjusting fork 9 9.Zigzag adjusting lever R 1562S 1561S 1-3-2. Standard sewing and bar tacking C Standard sewing Zigzag adjusting lever R (9) : Not swing 8.Zigzag adjusting link C’ 8 7.Zigzag adjusting fork 9.Zigzag adjusting lever R 7 9 14.Zigzag connecting shaft 13.
PAGE 12
1. MECHANICAL DESCRIPTIONS 1-4. Lubrication mechanism 1-4-1. Needle bar and thread take-up lubrication 1566S 1.Oil tank B2.Wick B3.Felt A2.Wick C3.Wick A3.Wick B6.Zigzag cam C4.Zigzag lever shaft bush F A4.Needle bar bracket B4.Wick A5.Wick B5.Speed reduction gear A6.Needle bar bracket slide block A9.Wick A7.Needle bar A8.Felt A11.Sewing machine holder A10.Spiral gear A12.Poly oiler D3.Flat wick D4.
PAGE 13
1. MECHANICAL DESCRIPTIONS 1-4-2. Rotary hook and gear lubrication A3.Rotary hook shaft bearing A5.Rotary hook A4.Felt C5.Tube C4.Valve (Speed controller) B3.Pinion B2.Wick 1.Oil tank A3.Rotary hook shaft bearing A4.Felt A5.Rotary hook C5.Tube A2.tube C4.
PAGE 14
1. MECHANICAL DESCRIPTIONS 1-5. Thread trimmer 5.Forked shaft 1.Thread trimmer solenoid 2.Thread trimmer cam lever assy 7.Movable knife Rotary hook shaft 3.Roller shaft 4.Thread trimmer cam 9.Lower thread finger 8.Fixed knife 1568S 6.
PAGE 15
1. MECHANICAL DESCRIPTIONS Lower thread Movable knife Upper thread Fixed knife Lower thread finger 1571S This point the needle thread take-up is raised slightly above its lowest position. 1572S When the movable knife is spreading the needle thread, the tension release relieves the needle thread tension to prevent excessive tension and to enable the needle thread to be extended smoothly.
PAGE 16
1. MECHANICAL DESCRIPTIONS 1-6. Presser bar lifter 2.Lever 1.Presser bar lifter cylinder 3.Rocking connector shaft 5.Presser bar lifter connector 4.Presser bar lifter arm 7.Presser bar guide bracket 8.Presser bar 6.Knee lifter lifting lever 9.Presser foot 1575S 1-7.
PAGE 17
1. MECHANICAL DESCRIPTIONS 1-8. Feed guide mechanism 6.Clamp arm 4.Timing belt 3.Pulley 5.Feed bracket 2.Gear 1.Motor 7.Work clamp 1577S 6.Machine head 3.Pulley 2.Gear 5.Machine head holder 1.Motor 4.
PAGE 18
1. MECHANICAL DESCRIPTIONS 1-9.
PAGE 19
1. MECHANICAL DESCRIPTIONS 1-10.
PAGE 20
1. MECHANICAL DESCRIPTIONS 1-11. Bobbin winder mechanism 1.Bobbin presser plate 5.Stopper 2.Bobbin winder claw 6.Switch 3.Spring plate 7.Motor 4.Bobbin winder lever 1652S 1-12. Suction (Vacuum) mechanism 2.Vacuum plate 3.Vacuum base 1.
PAGE 21
2. BEFORE DISASSEMBLY AND ADJUSTMENT 2. BEFORE DISASSEMBLY AND ADJUSTMENT DANGER Wait at least 5 minutes after turning off the power switch and disconnecting the power cord from the wall outlet before opening the face plate of the control box. Touching areas where high voltages are present can result in severe injury. CAUTION Ask your Brother dealer or a qualified electrician to carry out any maintenance and inspection of the electrical system.
PAGE 22
2. BEFORE DISASSEMBLY AND ADJUSTMENT (1) (2) (3) (4) (5) 1585S 1656S 1584S Operate in order of the air cock, the power switch, the FOLDER RESET switch (1). The sewing machine detects the home position and stop at the stand-by position. E-510 The needle bar is in positions other than an upper needle position at the time of a start. (After the FOLDER RESET switch (1) was pushed.
PAGE 23
2. BEFORE DISASSEMBLY AND ADJUSTMENT 2-2. Disassembling and assembling for transfer through narrow doors Machine dimensions Depth : 1,432 mm (except stacker guard) Width : 2,148 mm Height : 1,240 mm (except spool stand) By removing each unit, it is possible to make a depth size small. Remove stacker : 1,265 mm Remove stacker roller : 1,161 mm Remove folding base : 878 mm 1,432 mm 1,265 mm 1,161 mm (283 mm) 878 mm 1657S Mark air tubes to prevent misconnection.
PAGE 24
2. BEFORE DISASSEMBLY AND ADJUSTMENT 1659S * Carry this out only at the last and final operation. Carry out the operation carefully and correctly with two personnel or more. Work is done by removing a rear cover and a side cover. Note Never loosen two socket bolts of two positioning pins on the right and left sides during this operation, or reproducibility will be lost.
PAGE 25
3. DISASSEMBLY 3. DISASSEMBLY DANGER Wait at least 5 minutes after turning off the power switch and disconnecting the power cord from the wall outlet before opening the face plate of the control box. Touching areas where high voltages are present can result in severe injury. CAUTION Ask your Brother dealer or a qualified electrician to carry out any maintenance and inspection of the electrical system. Hold the machine head with both hands when tilting it back or returning it to its original position.
PAGE 26
3. DISASSEMBLY 3-2. Presser foot mechanism 6.Adjusting screw 5.Adjusting nut (Loosen) 7.Spring guide 8.Spring 11.Presser bar 9.Screw (Loosen) 10.Presser bar guide bracket 1.Screw 3.Two flat screws 2.Work clamp 4.Bottom plunger 1662S 3-3. Rotary hook and fixed knife 6.Fixed knife 3.Three set screws (Loosen) 5.Flat screw 4.Rotary hook 2.Bobbin case holder position bracket 1663S 1.
PAGE 27
3. DISASSEMBLY 3-4. Movable knife and thread trimmer 1664S 2.Two flat screws 3.Movable knife 1.Thread trimmer rod (It moves in the direction of an arrow.) 12.Retaining ring 21.Thread trimmer lever spring Collar 8.(Remove) 22.Forked shaft 18.Cushion 2.Thread finger 17.Washer 13.Thread trimmer cam lever shaft 1.Socket bolt 14.Collar 19.Screw (Loosen) 16.Thread trimmer cam lever 11.Set screw (Loosen) 15.Thread trimmer cam lever spring 7.Washer 6.Movable knife 20.Thread trimmer 3.
PAGE 28
3. DISASSEMBLY 3-5. Needle bar 1666S 8.Needle bar bracket 5.Two rubber caps 6.Two set screws (Loosen) 9.Washer 7.Support shaft 1.Screw (Loosen) 2.Needle bar 4.Needle bar bracket guide 3.Two Set screws (Loosen) 11.Rubber cap 12.Set screw (Loosen) 13.Rubber cap 14.Two set screws (Loosen) 16.Washer 15.Thread take-up lever set 10.Slide block 17.
PAGE 29
3. DISASSEMBLY 3-6. Motor 3.Rubber cap 7.Two set screws (Loosen) 15.Four socket bolts 9.Screw (Loosen) 4.Screw (Loosen) 11.Two set screws 1. * Two screws (Loosen) 2. ** Two sensors 5.Three socket bolts 10.Coupling 6.Motor bracket Not remove 12.Sensor dog 8.Pulley 1668S 14.Sensor holder collar 13.Two socket bolts * Mark installing position of the two sensors, before loosen these screws. ** Mark so that distinction of a sensor may stick, before remove these sensors. 3-7. Timing belt 3.
PAGE 30
3. DISASSEMBLY 3-8. Auxiliary shaft 1.Three screws 12.Zigzag cam 9. Auxiliary shaft 2.Ball bearing cover 10.Ball bearing collar 3.Ball bearing presser 4.Retaining ring 7.Two set screws (Loosen) 5.Ball bearing 8.Two set screws (Loosen) 6.Two set screws (Loosen) 11.
PAGE 31
3. DISASSEMBLY 3-9. Zigzag 13.Two set screws (Loosen) 12.Set screw 17.Adjusting arm shaft, B (Loosen) 16.Set collar 4.Spring 6.Set screw (Loosen) 15.Washer 11.Adjusting arm shaft, A 14.Retaining ring 7.Two set screws (Loosen) 10.Set collar 2.Screw (Loosen) 8.Retaining ring 9.Washer 5.Spring 1.Rubber cap 3.
PAGE 32
3.
PAGE 33
4. ASSEMBLY 4. ASSEMBLY 4-1. Zigzag 1.Adjusting arm shaft, B 15.Set screw 9.*Two set screws 2.Set collar 12.Spring 16.Set screw 5.Adjusting arm shaft, A 3.Washer 4.Retaining ring 10.*Two set screws 6.Set collar 14.Screw 8.Retaining ring 7.Washer 11.Spring 17.Rubber cap 13.**Zigzag lever assy, * Tighten the arm fastens in a washer and a set collar so that there is no longitudinal play in the arm. ** Adjust on “5-1. Adjusting the zigzag movement”.
PAGE 34
4. ASSEMBLY 4-2. Auxiliary shaft 1669S 9.Three screws 1. Auxiliary shaft 2.Zigzag cam 8.Ball bearing presser 7.Ball bearing cover 6.Retaining ring 5.Ball bearing 4.Ball bearing collar 11.Two set screws 10.Two set screws Center 3.Auxiliary shaft gear 12.Two set screws 1673S 4-3. Timing belt 6.Ball bearing 8.Two set screws 7.Collar Rubber cap 3.*Nut (left handed screw) 2. Idler pulley (It pushes against a timing belt.) 1.Timing belt 4.Head support stud 5.
PAGE 35
4. ASSEMBLY 4-4. Motor 1672S 1668S 13.Four socket bolts 15.Rubber cap 6.Two screws 10.Two set screws 8.Screw 4.Two set screws 14.Screw 5. * Two sensors 12.Three socket bolts 7.Coupling 9.**Pulley 11.Motor bracket Not remove 3.Sensor dog 1.Sensor holder collar 2.Two socket bolts 5 mm 1671S * Adjust on “5-6. Adjusting machine sensor”. ** When turn on the power, turn the pulley until the error mark U51 (needle lowered) disappears.
PAGE 36
4. ASSEMBLY 4-5. Needle bar 1667S 7.Rubber cap 6.Set screw 5.Rubber cap 2.Washer 4.Two set screws 3.Thread take-up lever set Thread take-up support shaft 1.Washer 8.Slide block * Thread take-up support shaft is noticed about oil supply and attachment. It may burn and adhere depending on the case. 13.Two rubber caps 12.Two set screws 10.Needle bar bracket 9.Washer 11.Support shaft 17.Screw 14.*Needle bar 15.Needle bar bracket guide 1666S 16.Two Set screws * Adjust on “5-2.
PAGE 37
4. ASSEMBLY 4-6. Movable knife and thread trimmer 6.Retaining ring 1.Forked shaft 9.Cushion 22.Thread finger 3.Thread trimmer lever spring 2. Collar 16.(Hang) 8.Washer 7.Thread trimmer cam lever shaft 10.*Thread trimmer cam lever 23.Socket bolt 13.Set screw 12.Collar 11.Thread trimmer cam lever spring 5.Screw 4.*Thread trimmer lever 17.Washer 18.Movable knife holder 19.Thrust washer 20.Retaining ring 21.Shoulder screw 14.Thread trimmer solenoid 15.Two screws * Adjust on “5-3.
PAGE 38
4. ASSEMBLY 4-7. Rotary hook and fixed knife 2.Three set screws 3.Fixed knife 4.Flat screw 1.*Rotary hook 5.Bobbin case holder position bracket 1663S 6.Socket bolt * Adjust on “5-2. Adjusting the needle bar height and, the needle and the rotary hook timing”. 4-8. Presser foot mechanism 6.Adjusting screw 37 mm 5.Adjusting nut 4.Spring guide 3.Spring 2.*Presser bar 7.Screw 1.Presser bar guide bracket 9.Screw 11.Two flat screws 8.Work clamp 10.Bottom plunger 1662S * Adjust on “5-7.
PAGE 39
4. ASSEMBLY 4-9.
PAGE 40
4.
PAGE 41
5. ADJUSTMENT 5. ADJUSTMENT DANGER Wait at least 5 minutes after turning off the power switch and disconnecting the power cord from the wall outlet before opening the face plate of the control box. Touching areas where high voltages are present can result in severe injury. CAUTION Ask your Brother dealer or a qualified electrician to carry out any maintenance and inspection of the electrical system. Hold the machine head with both hands when tilting it back or returning it to its original position.
PAGE 42
5. ADJUSTMENT If the power switch is turned on, take sufficient safety measures, such as to make E-800 (emergency stop) come on in the manual mode. 5-1. Adjusting the zigzag movement Remove the top cover, the rear cover, the slide plate (the needle plate), the bottom plunger and the work clamp while making this adjustment. (5) (6) B : 9.2 mm (1) (7) (2) (3) A : 34.4 mm (4) (S24987001) 1308S 1307S 1309S (Approximately 10 mm) (Approximately 10 mm) (7) (5) (4) (3) Reference 1674S 1.
PAGE 43
5. ADJUSTMENT 1311S 1310S (13) Needle (9) (8) (14) (12) A (10) (11) Index mark 1675S Lowest position (13) (12) 1312S A B Index mark To front A B To rear Index mark (7) (5) 1313S 4. Attach the zigzag gauge (8) (accessory) to the bed. Using the two flat screws. 5. Attach a needle. (thin needle equivalent to #9-11) 6. The needle is aligned with needle hole A of the zigzag gauge (8). Adjust → Loosen the screw (11), move the needle bar bracket (10) in the direction of the arrow 7.
PAGE 44
5. ADJUSTMENT (16) (8) (15) B (17) 1314S 1315S 9. The zigzag cylinder (1) pulls in the zigzag connecting shaft (2). (Zigzag ON) 10. Install the rear cover. 11. Turn the pulley to lower the needle bar. Needle hole B of the zigzag gauge (8) is aligned with the needle. Adjust → Turn the zigzag dial (15) 12. When needle hole B is aligned with the needle, align the positioning pin (16) with scale “3” of the zigzag dial (15). Adjust → Loosen the screw (17).
PAGE 45
5. ADJUSTMENT 5-2. Adjusting the needle bar height and, the needle and the rotary hook timing Remove the slide plate (the needle plate), the bottom plunger and the work clamp while making this adjustment. (1) (2) (4) (3) (1) 1316S 1317S Turn the pulley to set the needle bar (1) to its lowest position. Put the side “1” of the gauge (2) at the end edge of the needle bar (1).
PAGE 46
5. ADJUSTMENT (7) (1) (6) 0 - 0.05 mm X2.4 rotary hook : 2.4 mm (5) X1.7 rotary hook : 1.8 mm (8) 3 places X2.4 rotary hook : 1.2 mm X1.7 rotary hook : 1.8 mm 1319S 1318S 1320S Turn the pulley to raise the needle bar (1) from its lowest position. Adjust the rotary hook so that the side “2” of the gauge (5) and the lower end of the needle bar (1) align. At this time, the clearance between the needle and the rotary hook point should be 0 to 0.
PAGE 47
5. ADJUSTMENT 5-3. Adjusting the thread trimmer timing Remove the slide plate (the needle plate), the bottom plunger and the work clamp while making this adjustment. 1323S 1324S For X2.4 rotary hook Tr-gauge, 2.4 (S55275-000) (1) For X1.7 rotary hook Zigzag gauge (S24983-000) (2) (3) 22. 4 mm 25.7 mm (5) (5) 0.6 - 0.8 mm (4) (6) (5) (4) (4) (7) A 1325S 1326S 1327S 1. Remove the thread guide of the needle bar (1). 2.
PAGE 48
5. ADJUSTMENT (9) (8) (9) (8) (11) (10) (12) (9) (8) 1328S 1330S 1329S 4. The fixed knife (8) and the movable knife (9) must overlap when the slide block of the thread trimmer cam (5) is lifted to the top of the roller (4) the thread trimmer cam lever. To increase the overlap, loosen the screw (10) to move the thread trimmer lever (11) in the direction of the arrow. * Set the lower thread finger (12) under the movable knife (9).
PAGE 49
5. ADJUSTMENT 5-4. Tension release (4) X1.7 rotary hook (3) (1) (2) 1332S Make sure that the tension disks (2) are open and there is no resistance in the needle thread when the cylinder (1) operates (after the presser foot is raised by pressing the presser foot switch on the operation panel). 1. Adjust → Loosen the four screws (3), the position of the claw (4) 2. Make sure that the tension disks (2) are close and there is resistance in the needle thread when the cylinder (1) returns. 5-5.
PAGE 50
5. ADJUSTMENT (1) (1) 5 - 10 mm (2) 1338S 1339S 1. Stroke : Adjust → Loosen set-screw (2), Turn the whole unit of the tension regulator assembly (3) (3) 0.4 - 0.6 N 1340S 0.4 - 0.6 N X2.4 rotary hook X1.7 rotary hook 1341S 2. Force : Adjust → Insert a screwdriver tip into the groove of tension stud (3), Turn the tension stud (The tension in the thread take-up spring when it is pulling the upper thread straight to the side at the point where the spring starts to move.
PAGE 51
5. ADJUSTMENT The surface state of the fixed knife may influence tightening of thread. 1680S When polishing the fixed knife, only the portion shown in the figure is polished. Note Do not polish the edge of the fixed knife by any means. The edge of the fixed knife is ground with reference to of “5-3. Adjusting the thread trimmer timing”. Since special rotary hook is used, be sure to use the exclusive needle.
PAGE 52
5. ADJUSTMENT 5-6. Adjusting the machine sensor Both of the sensors -- adjustment width -- it becomes a central position mostly. Remove the pulley cover (1) while making this adjustment. 1342S 1343S (4) (For needle threading, synchronizing) (2) (1) (5) (For needle highest position) 3 mm Needle bar lowest position (3) (6) (2) 1344S The needle rises 3 mm from its lowest position.
PAGE 53
5. ADJUSTMENT 5-7. Adjusting the work clamp height Rubber cap A Work clamp down Work clamp up X2.4 rotary hook 3.5 mm 16.5 mm X1.7 rotary hook 2 mm 14.5 mm Screw A Needle plate 1681S 5-8. Adjusting the rotary hook lubrication amount 1348S 1349S Race (1) 1682S The amount of oil : In the illustration (Sewing speed 4250 rpm, 7 second) ---Factory setting Adjust → Turn the screw (1) 1. Use machine head operation check : Mode change → Turn the power OFF, DIP switch A - 8 ON, Turn the power ON 2.
PAGE 54
5. ADJUSTMENT 5-9. Adjusting the air pressure (1) (3) Open (2) Shut 1350S 1. Air pressure : 0.5 Mpa Adjust → Pull and turn the cap (1), After adjustment → Push the cap (1) down and lock it. 2. When water is collected in the bottle (2), turn the cock (3) to drain water (direction O). * The water in a bottle will be automatically drained, if it collects to some extent. 5-10. Adjusting the pressure switch Adjust the pressure switch accurately so as to operate with 0.34 Mpa pressure.
PAGE 55
5. ADJUSTMENT 5-11. Adjusting speed of the pneumatic mechanism Cover 1353S 1354S Remove the cover while making this adjustment. 1 2 3 4 5 Folding clamp Inner clamp Center blade Sewing clamp Folding base (10 mm-stroke) 6 7 8 9 Folding base (1.5 mm-stroke) Label attachment device (Option) Suction (Vacuum) Slide plate elevator Only X1.
PAGE 56
5. ADJUSTMENT 5-11-1. Folding clamp Activate air compression. Turn on the power. Attach the folding clamp and lock it. Attach the multi-connector. Detach the connectors on valve 1B and valve 1A while making this adjustment. Valve 1B side 1A side Action by manual button Raise Descend Two cylinders End side, Rod side Setting of the speed controller Turn the screw all the way but tighten lightly. Next, loosen the screw 3 turns. Fix the screw with the nut.
PAGE 57
5. ADJUSTMENT 5-11-4. Sewing clamp Activate air compression. Turn on the power. Attach the Folding clamp and lock them. Detach the connectors on valve 4B and valve 4A while making this adjustment. Action by Setting of the speed controller manual button 4B side Raise Turn the screw all the way but tighten lightly. Next, loosen the screw 3 turns. Fix the screw with the nut. If the ascending speed is too fast, the sewing clamp may be severely jolted and may interfere with the operation of the folding machine.
PAGE 58
5. ADJUSTMENT 5-11-7. Label attachment device (Option) Before the speed adjustment, set the speed controllers to the minimum to prevent the set screws from being loosened by the shock. Activate air compression. Turn on the power. Valve 7 Action by manual button Turn For inserting For return (Manual button side) Setting of the speed controller When inserting the label, reduce the speed of the label attachment device to the extent that the machine still functions smoothly.
PAGE 59
5. ADJUSTMENT 5-11-9. Stacker wiper Activate air compression. Turn off the power. Valve 19 Action by manual button Wiper---Move Cylinder Rod side End side 1365S Setting of the speed controller Move toward you Make the operating speed as fast as possible without (Manual button side) operating jostling of the stacker wiper. Move away from you Setting of the air cushion Turn the screw all the way but tighten lightly. Next, loosen the screw 1.5 turns. Fix the screw with the nut.
PAGE 60
5. ADJUSTMENT 5-11-12. Stacker roller Activate air compression. Turn off the power. Valve Action by manual button 22 Up and down For ascending (Manual button side), For descending Setting of the speed controller Make the operating speed as fast as possible without operating jostling of the stacker roller. 1375S 5-12. Adjusting the folding clamp This adjustment may possibly spoil the compatibility of different models. Be sure to adjust the tucking blades on the folding machine in advance.
PAGE 61
5. ADJUSTMENT 5-13. Adjusting the inner clamp Compatibility of different models may be lost through this adjustment. Activate air compression. Turn on the power. (3) (2) (5) (4) (3) (2) (1) 1377S 1378S 1. Set the step mode. (Press the [FOLDING MODE] switch.) Lower the inner clamp (1). (Press the [STEP] switch.) 2. Secure the inner clamp lever (2) as its longitudinal direction is accurately positioned by the two collars (3). 3.
PAGE 62
5. ADJUSTMENT 5-15. Replacing and adjusting the bearings for center blade supporter Activate air compression. Turn off the power. (11) Mark A (8) (5) (9) (6) (10) (7) (8) Mark (9) (3) (10) (4) (1) (2) (3) 1422S 1423S 1. Disconnect the four air tubes (1). * Mark the air tubes (1) and union-Y4 (2) to prevent misconnection. 2. Pull the center blade supporter (3) toward you, loosen the nut (4), and remove the center blade supporter (3) by turning the rod end (5).
PAGE 63
5. ADJUSTMENT 5-16. Adjusting the folding base height Activate air compression. Turn off the power. (1) (5) (4) (1) (2) (3) (7) (6) 1381S 1382S Height of the folding base (1) : Some resistance can be felt when the front cloth is clamped at the lowest point of the folding base.
PAGE 64
5. ADJUSTMENT 5-18. Adjusting the stacker table and the outside stacker bar Release air compression. Turn off the power. Stacker table Stacker bar For adjust the height (4 pcs) For adjust the position of presser For adjust the right and left (2 pcs) For adjust the height and the position of end 1383S 1374S Adjust the outside stacker bar at the same time.
PAGE 65
5. ADJUSTMENT 5-21. Adjusting the work clamp pressure 1384S 1367S Activate air compression. Turn off the power. Remove the either rear cover while making this adjustment. 0.15 - 0.20 MPa Stronger Weaker Lock 1387S 1388S Pressure will change greatly by turning the cap only a little. Be sure to press the manual buttons A, B of the valve No.4 alternatively to check for pressure. * This pressure greatly influences folding.
PAGE 66
5. ADJUSTMENT 5-22. Adjusting the belt tension 1384S 1391S 16.8 ± 0.5 mm (1) 43.6 N (42.1 - 45.1 N) 1392S Weaker Stronger (2) (3) 6.2 ± 0.5 mm 39.7 N (38.2 - 41.2 N) (1) (2) (3) Stronger Weaker 1393S Remove the rear covers (X-direction) and the needle plates (Y-direction) while making this adjustment. The belt tension : Refer to the illustration.
PAGE 67
5. ADJUSTMENT 5-23. Replacing the nylon gears (4 pcs) (4 pcs) (8 pcs) Grease (8 pcs) (5 pcs) 1421S 1420S After removing the timing belt, exchange the nylon gear . Loosening and adjustment of the timing belt → Refer to “5-22. Adjusting the belt tension”.
PAGE 68
5. ADJUSTMENT 5-24. Adjusting the AC servo motor backlash Release air compression. Turn off the power. Less than 98N 11 mm Less than 49N 1395S 1394S Remove the needle plates, the rear covers and the right side cover while making this adjustment. The load (Power OFF) : Refer to the illustration. Adjust → Loosen the four bolts of the AC servo motor 5-25. Checking and adjusting the home position * Compared with the BAS-750/751, Y home position is located 5 mm closer toward you.
PAGE 69
5. ADJUSTMENT 1398S Dog X (+) over travel sensor X home position sensor 1 mm X (-) over travel sensor 1 mm Y home position sensor Dog Y (+) over travel sensor 1 mm 1 mm Y (-) over travel sensor 1399S 5.
PAGE 70
5. ADJUSTMENT 5-26. Adjusting the bobbin winder (6) (7) (1) (5) (4) (3) (2) 1400S 1401S 1. Move the bobbin holder arm (1) in direction of the bobbin winder shaft (2) to a position just before finishing bobbin thread winding. 2. Tighten the two screws (3) so that the spring plate (4) will be positioned on a stepped part of the bobbin winder claw (5).
PAGE 71
5. ADJUSTMENT (1) (2) LED (3) 1347S Approximately 24 mm 1683S Adjust the sensor (1) in the middle of the indicator on the sensor (1) lights within a certain range. When the power is ON and the presser foot is up, the indicator on the cylinder sensor lights within a certain range when slowly raising the sensor (1) along the cylinder (2) from bottom to top.
PAGE 72
5. ADJUSTMENT 5-28. Adjusting the rise-and-fall equipment When the tucking blade and the center blade evacuate and cloth shifts, spring pressure of rise-and-fall equipment is checked. 1690S Coil spring 1691S 1692S Adjust the spring pressure of rise-and-fall equipment by the number of coil springs. The coil spring can be increased to four pieces. (Two pieces are equipped at the time of shipment. Two pieces are appended as accessories.) 5-29. Upper thread breakage sensor.
PAGE 73
5. ADJUSTMENT 5-30. Adjusting the upper thread breakage detector 5-30-1. How to insert the fiber Fiber lock lever 1695S Fiber The fiber is inserted till the place at which it stops. (Detection distance will become short if it fixes on the way.) Light receive part Light projection part (Single line) Light projection part 1696S Light receive part (Plural line) If a fiber makes light projection and light receive side reverse, detection accuracy will fall. 5-30-2.
PAGE 74
5. ADJUSTMENT 5-30-3. Setting of sensitivity It adjusts, after performing thread through to usual. Operation Procedure Volume indicator 1 The mode selection switch is changed to the "SET" side. 1700S 1701S 1703S 1704S 1705S 2 If the jog switch is pushed when thread is on a sensor line, "3" of the volume indicator and "6" will blink. If the jog switch is detached within 3 seconds, "4" of the volume indicator and "5" will blink and the quantity containing light in case there is thread will be read.
PAGE 75
6. ELECTRIC COMPONENTS 6. ELECTRIC COMPONENTS DANGER Wait at least 5 minutes after turning off the power switch and disconnecting the power cord from the wall outlet before opening the face plate of the control box. Touching areas where high voltages are present can result in severe injury. 6-1. Precautions at the time of adjustment Pay attention to the following when opening the control box for maintenance.
PAGE 76
6. ELECTRIC COMPONENTS The panel PCB is fixed to the inside of the operation panel. It is a PCB which controls the switch of a panel, and the display to a LCD (liquid crystal display). Inverter LCD LCD contrast adjustment volume PROM Panel PCB 1764S The programmer PCB is fixed to the inside of the programmer. It is a PCB which controls the switch of a programmer, and the display to a LCD (liquid crystal display).
PAGE 77
6. ELECTRIC COMPONENTS 6-3. Power supply 6-3-1. Fuse Note When replacing a fuse, be sure to use the specified ones listed below. 1766S No. F1 F2 F3 F4 Part name Fuse C (2A-125V) Fuse B (5A-125V) ↑ ↑ Part code 152566000 152565000 ↑ ↑ Manufacturer SATO F7161 2A SATO F7161 5A ↑ ↑ BAS-7610 6-03 When a fuse has blown The bobbin winder does not turn. The air valve does not operate. The over travel sensor LED is not lit. The stacker roller does not turn. The light marker lamp is not lit.
PAGE 78
6. ELECTRIC COMPONENTS 6-3-2. Circuit protector of bobbin winder motor When winding thread on successive bobbins and with strong tension or the motor does not rotate for the thread has got tangled on the bobbin winder motor shaft, the protector will project to cut off the current to the circuit. After a while (about 30 seconds), depress the protector. Thread winding can be performed. Check the bobbin winder so that its tension is proper. Protector 1767S 6-3-3.
PAGE 79
6. ELECTRIC COMPONENTS 6-3-4. Conversion of power supply voltage White Red Breaker (A type changes with voltage.
PAGE 80
6. ELECTRIC COMPONENTS 6-4. PROM Kind Main Folding clamp Operation panel Programmer Function Control of a sewing machine Read and write of data Programming Control of a folding clamp Communication with a panel Control of a panel Control of a programmer The place attached Main PCB MN-* Name Main PCB FL-* PL-* PG-* * = version No. (A, B, ....) The version of PROM can be checked also on an operation panel. Press a [TEST] switch when the power supply switch is turned ON.
PAGE 81
6. ELECTRIC COMPONENTS 6-5. Connector 6-5-1. Main PCB The figure is a part code S51862 - PCB. 1771S No. Connection No.
PAGE 82
6. ELECTRIC COMPONENTS P2 [STACKER-MOTOR] (JAPAN SOLDERLESS TERMINAL B6P-SHF-1AA) Pin No. 1 2 3 4 5 6 Signal name Probable symptoms due to poor contact Stacker roller does not rotate. Pulse motor output +36V P3 [TRIM] (MOLEX 5273-02A) Pin No. 1 2 Signal name +24V Thread trimmer solenoid Probable symptoms due to poor contact Defective thread trimming P4 [POWER] (MOLEX 5566-10A) Pin No.
PAGE 83
6. ELECTRIC COMPONENTS P5 [VALVE (FL)] (JAE PS-30PE-D4T1-LP1) Pin No. A1 B1 A2 B2 A3 B3 A4 B4 A5 B5 A6 B6 A7 B7 A9 A8 B8 B9 A10 B10 A11 B11 A12 B12 A14 A13 B13 B14 A15 B15 Signal name Folding clamp valve A output Inner clamp valve A output Center blade valve A output Clamp valve A output +24V +24V Folding clamp valve B output Inner clamp valve B output Center blade valve B output Clamp valve B output Folding base 10 valve output Folding base 1.
PAGE 84
6. ELECTRIC COMPONENTS P6 [VALVE (MN) ] (JAE PS-16PE-D4T1-LP1) Pin No.
PAGE 85
6. ELECTRIC COMPONENTS P10 [PANEL] (JAPAN SOLDERLESS TERMINAL B12B-XH-A) Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 Signal name ±0V Receive data Receive control Send data Send control Error lamp Probable symptoms due to poor contact Power lamp of the operation panel does not light. Back light of the operation panel does not light. Operation panel does not operate. Switch does not operate. Indication of LCD is abnormal. +12V -12V +5V P11 [Z-SRV] (JAE PS-20PE-D4T1-LP1) Pin No.
PAGE 86
6. ELECTRIC COMPONENTS P15 [FL-SENS] (JAPAN SOLDERLESS TERMINAL B12P-SHF-1AA) Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 Signal name Probable symptoms due to poor contact +5V Folding clamp sensor input “E-900” appears. ±0V +5V Inner clamp sensor input “E-901” appears. ±0V +5V Center blade sensor input “E-902” appears. ±0V +5V Folding base sensor input “E-903” appears. ±0V P16 [EM/START] (MOLEX 5045-09A) Pin No.
PAGE 87
6. ELECTRIC COMPONENTS P19 [CLAMP-IN] (JAPAN SOLDERLESS TERMINAL B6B-PH-K-S) Pin No. 1 2 3 4 5 6 Signal name +24V CLAMP-IN sensor 1 ±0V +24V CLAMP-IN sensor 2 Probable symptoms due to poor contact Center blade does not operate. Folding clamp does not operate. “E-960” appears. ±0V P20 [ORG/OVR] (JAPAN SOLDERLESS TERMINAL B18P-SHF-1AA) Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Signal name Probable symptoms due to poor contact +24V +X over-travel input “E-830” appears.
PAGE 88
6. ELECTRIC COMPONENTS P22 [JIG-PATTERN] (JAPAN SOLDERLESS TERMINAL B8P-SHF-1AA) Pin No. 1 2 3 4 5 6 7 8 Signal name +12V Pattern sensor input 1 Pattern sensor input 2 Pattern sensor input 3 Pattern sensor input 4 Pattern sensor input 5 Pattern sensor input 6 Probable symptoms due to poor contact “E-530”, “E-535”, “E-536” appears. ±0V P23 [CLAMP] (MOLEX 5045-03A) Pin No. 1 2 3 Signal name +5V Clamp sensor input Probable symptoms due to poor contact “E-970” appears.
PAGE 89
6. ELECTRIC COMPONENTS P26 (P25) [MN-OP-IN] (JAPAN SOLDERLESS TERMINAL B16B-PHDSS) Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Signal name +5V +24V Expansion sensor input 1 Probable symptoms due to poor contact ±0V +5V +24V Expansion sensor input 2 ±0V +5V +24V Expansion sensor input 3 For automatic bobbin changer (option). ±0V +5V +24V Expansion sensor input 4 ±0V P27 (P26) [MN-OPT-OUT] (MOLEX 5045-06A) Pin No.
PAGE 90
6. ELECTRIC COMPONENTS P29 (P28) [FL-OPT-OUT] (MOLEX 5045-05A) Pin No. 1 2 3 4 5 Signal name Expansion valve output 5 Expansion valve output 6 Expansion valve output 7 Expansion valve output 8 +24V Probable symptoms due to poor contact Not use (It does not use by BAS - 761, 7610.) P30 [PRESS] (JAPAN SOLDERLESS TERMINAL B9B-XH-A) Pin No. 1 2 3 4 5 6 7 8 9 Signal name Probable symptoms due to poor contact +24V NC ±0V +24V NC Not use (It does not use by BAS-761, 7610.
PAGE 91
6. ELECTRIC COMPONENTS 6-5-2. Power supply PCB Main PCB Transformer 2 Motor for the bobbin winder Light marker 1772S P1 [MAIN] (MOLEX 5277- 04A) Pin No. 1 2 3 4 Signal name ±0V +24V ±0V +36V Probable symptoms due to poor contact The air valve does not operate. The over travel sensor lamp is not lit. The stacker roller does not turn. P2 [THREAD MOTOR] (MOLEX 5277-02A) Pin No. 1 2 Signal name +24V Probable symptoms due to poor contact The motor of the bobbin winder does not turn.
PAGE 92
6. ELECTRIC COMPONENTS 6-5-3. Operation panel PCB Inverter LCD Main PCB RS-232C 1773S P1 [LCD] (JAPAN SOLDERLESS TERMINAL 19FE-ST) Pin No. Signal name 1 - 19 LCD control Probable symptoms due to poor contact LCD does not indicate. P2 [MAIN] (JAPAN SOLDERLESS TERMINAL B12B-XH-A) Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 Signal name ±0V Sending data Sending control Reception data Reception control Error lamp Probable symptoms due to poor contact The power lamp of the operating panel is not lit.
PAGE 93
6. ELECTRIC COMPONENTS P4 [RS-232C] (FUJITSU FCN-675J009-L/C#QD) Pin No.
PAGE 94
6. ELECTRIC COMPONENTS 6-5-4. Programmer PCB Inverter LCD Main PCB FG 1774S P1 [LCD] (JAPAN SOLDERLESS TERMINAL 19FE-ST) Pin No. 1-19 Signal name LCD control Probable symptoms due to poor contact LCD does not indicate. P2 [MAIN] (MOLEX 5268-12A) Pin No. 1 2 3 4 5 6 7 8 9 10 11 12 Signal name ±0V Reception data Reception control Sending data Sending control +11V -11V +5V +5V CTS RTS Probable symptoms due to poor contact The programmer does not operate.
PAGE 95
6. ELECTRIC COMPONENTS 6-5-5. Pattern sensor PCB Main PCB 1775S P1 [MAIN] (JAPAN SOLDERLESS TERMINAL B8B-XH-A) Pin No. 1 2 3 4 5 6 7 8 Signal name +24V Pattern sensor input 1 Pattern sensor input 2 Pattern sensor input 3 Pattern sensor input 4 Pattern sensor input 5 Pattern sensor input 6 Probable symptoms due to poor contact “E-530”, “E-535”, “E-536” appears.
PAGE 96
6.ELECTRIC COMPONENTS 6-6. Sensor 6-6-1. Sensor location 1776S 1777S No. 1 2 3 4 Sensor name Over travel sensor (-X) X home position sensor Over travel sensor (+X) Over travel sensor (+Y) Type A A A A No.
PAGE 97
6. ELECTRIC COMPONENTS 6-6-2. Function of sensor < Home position sensor (X, Y) > Sensor Connecto r X (2) P20 Sensor Connecto r Y (5) P20 Pin No. 13 14 15 Pin No. 16 17 18 Signal name +24V X home position ±0V Signal name +24V Y home position ±0V State in case sensor LED is ON Sewing clamp is in home position. State in case sensor LED is ON Machine head is in home position. The error No. at fault E-840 The error No.
PAGE 98
6.ELECTRIC COMPONENTS < Over travel sensor (X+, X-, Y+, Y-) > Sensor Connector X+ (3) P20 Sensor Connector X(1) P20 Sensor Connector Y+ (4) P20 Sensor Connector Y(6) P20 Pin No. 1 2 3 Pin No. 4 5 6 Pin No. 7 8 9 Pin No. 10 11 12 Signal name +24V X over travel right ±0V Signal name +24V X over travel left ±0V Signal name +24V Y over travel up ±0V Signal name +24V Y over travel down ±0V State in case sensor LED is ON Sewing clamp is in normal position.
PAGE 99
6. ELECTRIC COMPONENTS < Jig pattern sensor > Sensor Connector Jig pattern (8) P22 Pin No. 1 2 3 4 5 6 7 8 Signal name + 12V Pattern 1 (Weight X4) Pattern 2 (Weight X2) Pattern 3 (Weight X1) Pattern 4 (Weight X32) Pattern 5 (Weight X16) Pattern 6 (Weight X8) ±0V 1. The jig pattern sensor checks if the number of the program read from the floppy disk and the number of the sewing clamp set to the machine are identical. 2. The jig pattern sensor consists of six photo sensors.
PAGE 100
6.ELECTRIC COMPONENTS < Cylinder sensor > Sensor Connector Folding clamp (11) P15 Sensor Connector Inner clamp (10) P15 Sensor Connector Center blade (13) P15 Sensor Connector Folding base (12) P15 Sensor Connector Work clamp (18) P23 Sensor Connector 2 row (21) (22) Pin No. 1 2 3 Pin No. 4 5 6 Pin No. 7 8 9 Pin No. 10 11 12 Pin No. 1 2 3 Pin No. 1 2 3 P21 4 5 6 7 Sensor Connector Pressure foot (9) P1 Sensor Connector Zigzag (19) P1 Pin No. 10 11 12 Pin No.
PAGE 101
6. ELECTRIC COMPONENTS < Sewing machine sensor > Needle up sensor Pin Signal name The error No. at fault No. 4 +5V Needle up P1 E-510 – 513, E-550 5 Needle up (14) 6 K The needle up sensor sends a signal when the needle bar approaches its highest position. This signal stops the needle at its up position. When sewing is completed or when the sensor does not operate, the error code “E-550” will be displayed, and the machine will stop. Sensor Connector Synchronizing sensor Pin Signal name The error No.
PAGE 102
6.ELECTRIC COMPONENTS < Air pressure sensor (switch) > Sensor Connector Air pressure (20) P14 Pin No. Signal name 2 Air pressure 3 ±0V The error No.
PAGE 103
6. ELECTRIC COMPONENTS 6-7. Harness Refer to “6-12. Control circuit block diagram” together. 6-7-1.
PAGE 104
6.
PAGE 105
6. ELECTRIC COMPONENTS 6-7-2. Harness connecting pin number table 1. Power supply harness A (S23868) Terminal side Black White Red Green/yellow Breaker side Black White Green/yellow Voltage (AC) 200V, 220V, 380V, 400V, 415V E (Ground) 2. Breaker-NF1 harness (S46608) Breaker side Black White Noise filter Black White Voltage (AC) 200V, 220V, 380V, 400V, 415V 3.
PAGE 106
6.ELECTRIC COMPONENTS 7. Main power supply harness (S46612) Switching power supply CN2 5 7 1 2 3 - Power supply PCB P1 Power supply PCB P4 Signal/Voltage (DC) 2 1 4 3 1 2 3 4 5 6 7 8 9 +5V ±0V +12V ±0V -12V +24V ±0V +36V ±0V 8. Servo power supply harness X (S46622) Noise filter OUT OUT X axis servo amplifier L1, L11 L2, L21 Voltage (AC) 220V 9. Servo power supply harness Y (S46623) Noise filter OUT OUT Y axis servo amplifier L1, L11 L2, L21 Voltage (AC) 220V 10.
PAGE 107
6. ELECTRIC COMPONENTS 15.Motor power supply harness X (S46630) 16.Motor power supply harness Y (S46631) 17.Motor power supply harness Z (S46632) Servo amplifier U V W E Servo motor 1 2 3 4 Signal U V W E Servo motor 7 8 1 2 4 5 3 8 9 Signal P5 LG MR MR R MD MD R BT LG Shield 18.Encoder harness X (S46633) 19.Encoder harness Y (S46634) 20.Encoder harness Z (S46635) Servo amplifier CN2 19, 20 11, 12 7 17 6 16 9 1 Plate 21.Servo harness X (S46625) 22.
PAGE 108
6.ELECTRIC COMPONENTS 23.Servo harness Z (S46627) Main PCB P11 A2 A10 B4 B5 A6 B6 A7 B7 A9 B9 A8 B8 B1 B2 B3 A4 A5 B10 A3 - Servo amplifier CN1A CN1B 8 1 19 18 13 3 12 2 6 16 7 17 Plate 1 15 14 10 18 20 5 19 CN1B 3 and 13 3 13 Connect → Plate Signal CR LG RD INP PG PP NG NP LA LAR LB LBR Shield LG EMG RES SG ALM SG SON ZSP Shield 24.FDD power supply harness (S46641) Main PCB P8 1 2 3 4 FDD 1 2 - Voltage (DC) +5V ±0V - Air switch 1 2 Voltage (DC) AIR ±0V 25.
PAGE 109
6. ELECTRIC COMPONENTS 27.Foot switch harness (S46653), Foot switch plate L1 assy (S46265) Foot switch harness Main PCB P17 Relay 1 1 2 2 3 4 5 6 7 7 8 8 9 - Foot switch plate L1 assy Relay Foot switch 7 N.O Switch 8 COM - Signal FOOT SW ±0V - 28.
PAGE 110
6.ELECTRIC COMPONENTS 31.Switch box harness (S46699) Main PCB P16 1 2 3 4 5 6 7 8 9 - Switch EMERGENCY STOP RESET START FOLDER RESET - Signal N.C COM (X2) N.O N.O COM N.O COM N.O COM Shield 32.Hand switch harness (S46654) Main PCB P18 6 7 8 9 Switch Signal N.O (X2) COM (X2) N.O (X2) COM (X2) Left switch (x2) Right switch (x2) 33.
PAGE 111
6. ELECTRIC COMPONENTS 36.Jig pattern harness (S46588) Main PCB P22 1 2 3 4 5 6 7 8 Pattern PCB 1 2 3 4 5 6 7 8 Signal +12V JP1 JP2 JP3 JP4 JP5 JP5 ±0V 37.
PAGE 112
6.ELECTRIC COMPONENTS 39.
PAGE 113
6. ELECTRIC COMPONENTS 40.Folding clamp valve harness (S46657) Main PCB P5 A1 A3 B1 B3 A2 A3 B2 B3 A4 A3 B4 B3 A5 A3 B5 B3 A6 A8 B6 A8 A7 A8 B7 A8 A9 A8 B9 B8 A10 B8 B10 B8 A11 B8 B11 A13 A12 A13 B12 A13 A14 A13 6-39 SMC 1A 1B 2A 2B 3A 3B 4A 4B 5 6 7 8 9 10 11 12 13 19 20 21 22 Signal/ Voltage (DC) Folding clamp A +24V Folding clamp B +24V Inner clamp A +24V Inner clamp B +24V Center blade A +24V Center blade B +24V Sewing clamp A +24V Sewing clamp B +24V Folding base 10 +24V Folding base 1.
PAGE 114
6.ELECTRIC COMPONENTS 41.
PAGE 115
6. ELECTRIC COMPONENTS 6-8. Servo amplifier 6-8-1. Names of major parts < Servo amplifier > 1782S 1 2 3 4 1783S No. 1 2 3 4 6-41 Name, Use Battery holder The battery for position data preservation is contained absolutely. It does not use by BAS-761, 7610. Connector for battery (CON1) The battery for position data preservation is connected absolutely. It does not use by BAS-761, 7610. Display The state of servo and alarm No. are displayed by the 4-figure 7 segment LED.
PAGE 116
6.ELECTRIC COMPONENTS 5 6 10 7 8 9 11 12 13 No. 5 6 7 8 9 10 11 12 13 1784S Name, Use Input and output signal connector (CN1A) A signal of main PCB is connected. Input and output signal connector (CN1B) A signal of main PCB is connected. Usually, it is not used. The connector for communication It connects with PC or an analog monitor is outputted. Rated plate Charge lamp The light is switched on when the electric charge exists in the main circuit.
PAGE 117
6. ELECTRIC COMPONENTS 6-8-2. Abnormalities and a measure If abnormalities occur on servo amplifier or a motor (E-870, 880, 890), “AL. **” will be displayed on the display part of servo amplifier. The meaning of an error code and the list of check items are as follows. < Servo amplifier error code > Error code The contents of an error AL. 10 Voltage is insufficient. AL. 12 AL. 13 AL. 15 Memory problem 1 Clock problem Memory problem 2 AL. 16 Encoder problem 1 AL. 17 PCB problem 2 AL.
PAGE 118
6.ELECTRIC COMPONENTS 6-8-3. Exchange the servo amplifier Note Servo amplifier does not operate, if the parameter is not set up. When you exchange servo amplifier, check that the parameter is set as servo amplifier. As for the servo amplifier with which the parameter is set up, the seal is stuck on the lower part of the side. Although the servo amplifier X and Y are the same form, each parameter setup differs. It cannot be used being able to change.
PAGE 119
6. ELECTRIC COMPONENTS 6-9. DIP switches Note Always turn off the power supply before changing any of the DIP switch settings. The function of the DIP switches are subject to changes without notification. If DIP switches B-1 to B-6 are ON, be sure to check the cylinder movement and data version thoroughly. In some cases a peculiar error may be displayed.
PAGE 120
6.ELECTRIC COMPONENTS DIP switch C No. 1 2 3 4 5 6 7 8 Motion when set to ON 7 stitches counted before upper thread breakage is detected OFF : 3 stitches counted before upper thread breakage is detected After sewing, the work clamp and machine head return to the previous standby position, even if folding has been completed. Movement to the feed destination occurs immediately when the program data requires it. After sewing, the timer starts 0.2 seconds after the work clamp is raised.
PAGE 121
6. ELECTRIC COMPONENTS 6-10. Error code When there is the possibility that harness is faulty, check connections and pin omissions, etc. with reference to "6-7-2. Harness connecting pin number table”. It is possible for it to be made not to indicate by setup of a DIP switch by error provisionally depending on the contents of an error. However, set up after checking the safety of operation of a sewing machine in that case.
PAGE 122
6.ELECTRIC COMPONENTS E-536 E-540 E-550 E-560 E-570 E-580 E-600 E-700 E-701 E-710 E-711 E-720 E-730 E-740 E-750 Model numbers are for single • The check of data (Delete the double switching command.) (32 - 63) but data does not * Turn ON DIP switch B-6 and carry out error disregard. contain a single switching (A data check and sewing clamp are surely carried out.) command. (Model No. 32 - 63) Machine head synchronization • Malfunction of machine sensor (synchronizing).
PAGE 123
6. ELECTRIC COMPONENTS E-780 E-781 E-800 E-801 E-802 E-803 E-810 E-820 E-821 E-830 E-840 E-850 E-860 E-870 E-880 E-890 E-891 E-900 E-901 E-902 6-49 Sewing data exceeds sewing area No end code in sewing data EMERGENCY STOP button pressed. EMERGENCY STOP button pressed during sewing. (Omission) (Omission) (Omission) (Omission) EMERGENCY STOP button • Reset is impossible. Turn the power OFF. pressed during programming. EMERGENCY STOP button (Omission) pressed during programming.
PAGE 124
6.ELECTRIC COMPONENTS E-903 E-910 E-920 E-960 E-970 • Disconnection or poor connection of the folding clamp sensor. Malfunction of folding base • Poor adjustment of the folding clamp sensor. cylinder or sensor • Malfunction of solenoid valve No.5 or 6. • Poor connection of folding clamp valve harness No.5 or 6. X axis positioning error • Slack of a feed timing belt • The backlash of a feeding gear is large.
PAGE 125
6. ELECTRIC COMPONENTS 6-11. Exchange of PCB 6-11-1. Main PCB After main PCB exchange should initialize a memory. 1. All the connectors that open a control box and are connected to the main PCB are removed. Note When remove connectors, do not pull a harness portion. The harness may disconnect. 2. Remove the main PCB from six supports. 3. Remove the two PROMs from the removed main PCB and attach in the new main PCB. 4. Install the main PCB to the six supports.
PAGE 126
6.
PAGE 127
6. ELECTRIC COMPONENTS 6-12.
PAGE 128
6.
PAGE 129
6.
PAGE 130
6.
PAGE 131
7. FOLDING MACHINE 7. FOLDING MACHINE 7-1. Basic adjustments for delivery There is not perfect compatibility between the folding machine and the sewing machine. A folding machine which is ordered at the same time as the sewing machine does not have to be readjusted much because the folding machine has been adjusted to the sewing machine at shipping. But a folding machine which is ordered separately needs to be readjusted when delivered because it has been adjusted to a different sewing machine at shipping.
PAGE 132
7.
PAGE 133
7. FOLDING MACHINE 7-2. Valve 1354S 1 2 3 4 5 Folding clamp Inner clamp Center blade Sewing clamp Folding base (10 mm-stroke) 6 7 8 9 Folding base (1.5 mm-stroke) Label attachment device (Option) Suction (Vacuum) Slide plate elevator 1788S 1387S 10 11 12 Folder 1 Folder 2 Folder 3 13 14 15 Folder 4 Retractable type sewing clamp Retractable type sewing clamp Only X1.
PAGE 134
7. FOLDING MACHINE 7-3. Operation order and connection of folding machine The multi connectors and valves (page 7-03) connections are as follows. The valve operation order : Valves 10 → 13 turn ON in turn, and they turn OFF in order 10 → 11 → 13 → 12. Speed controller 1363S Multi connector No. 1 2 3 4 5 6 8 9 10 11 12 Valve No. and Port 10-B 10-A 11-B 11-A Speed controller Speed controller Speed controller 12-B 12-A 13-B 13-A Multi connector No. 1 2 3 4 5 6 8 9 10 11 12 Cylinder No.
PAGE 135
7. FOLDING MACHINE Four corner model (1) (7) (2) (6) (5) (3) (4) 1796S Multi connector No. 1 2 3 4 5 6 8 9 10 11 12 Cylinder No. and Port (1)B, (7)B (1)A, (7)A (2)B, (4)B, (6)B (2)A, (4)A, (6)A Speed controller Speed controller Speed controller (3)B, (5)B (3)A, (5)A Cap Cap Multi connector No. 1 2 3 4 5 6 8 9 10 11 12 Cylinder No. and Port (1)B, (7)B (1)A, (7)A (2)B, (4)B, (6)B (2)A, (4)A, (6)A Speed controller Speed controller Speed controller (3)B, (5)B (3)A, (5)A Cap Cap Multi connector No.
PAGE 136
7. FOLDING MACHINE 7-4. Adjustment Problems are described on page 7-07. During actual use, some of the problems may happen simultaneously. Solve the biggest one first. Reprogramming must be done only when folder adjustment is not enough to solve the problems. 7-4-1. Fine adjustments The function which allows fine adjustment of the folding clamp height The purpose of this function is to reduce the clearance between the body and the tucking blades when the folding clamp falls to its lowest position.
PAGE 137
7. FOLDING MACHINE 7-4-2. Characteristic troubles of three corner pocket model 1.Seam deviates down 2.Seam deviates up in 3.The seam margin at 4.Seam deviates to 5.Seam deviates to in parallel. parallel (reverse case the pocket top is the left in parallel. the right in parallel. to 1). different. 1801S 6.Partial seam deviates in parallel. 1806S 1803S 1802S 1808S 1807S 11.The folded line at 12.The seam margin 13.The pocket outline is curved. at the bottom is too the bottom corner small. is round.
PAGE 138
7. FOLDING MACHINE 1. Seam deviates down in parallel. A. The pocket material is improperly folded because the center blade is positioned above the correct position. After loosening the eight bolts (1), shift the center blade forward in the loose holes of the connecting blocks (center blade) then fasten the bolts (1). At this time, the inner clamp assembly and the folding clamp assembly may both need to be shifted forward at the same time.
PAGE 139
7. FOLDING MACHINE B. The pocket material or body strays when the center blade retracts from the pocket. B-1. The center blade has burrs. B-2. When the power is turned OFF, the clearance between the center blade bottom surface and the needle plate top surface is not correct. A small clearance moves the pocket material and the body simultaneously; a large one causes only the pocket material to stray backward.
PAGE 140
7. FOLDING MACHINE 2. Seam deviates up in parallel (reverse case to 1). A. The pocket material is improperly folded because the center blade is positioned above the correct position. After loosening the eight bolts (1), shift the center blade backward in the loose holes of the connecting blocks (center blade), then fasten the bolts (1). At this time, the inner clamp assembly and the folding clamp assembly may need to be shifted backward simultaneously.
PAGE 141
7. FOLDING MACHINE 3. The seam margin at the pocket top is different. A. The pocket material is improperly set. Set the pocket material correctly up to plate spring R and L. Center blade 3-corner J Plate spring R0.8 Pocket material Plate spring L0.8 1829S B. Plate spring R and L are improperly adjusted. Adjust the plate spring positions by loosening their two screws (1). At this time, the plate spring must be centered in the grooves of the center blade. (1) 1829S C.
PAGE 142
7. FOLDING MACHINE 4. Seam deviates to the left in parallel. A. The pocket material is improperly folded because the center blade is attached to the right of the correct position. After loosening the eight bolts (1), shift the center blade to the left in the loose holes of the connecting blocks (center blade), then fasten the bolts (1). At this time, the inner clamp assembly and the folding clamp assembly might need to be shifted to the left simultaneously.
PAGE 143
7. FOLDING MACHINE 5. Seam deviates to the right in parallel. A. The pocket material is improperly folded because the center blade is attached to the right of the correct position. After loosening the eight bolts (1), shift the center blade to the right in the loose holes of the connecting blocks (center blade), then fasten the bolts (1). At this time, the inner clamp assembly and the folding clamp assembly might need to be shifted to the right simultaneously.
PAGE 144
7. FOLDING MACHINE 6. Partial seam deviates in parallel. A. The inner clamp blades are improperly positioned. The seam margin is large. This happens when the clearance between the center blade edge and the inner clamp blades is too small or too large, or when the inner clamp blades strike the center blade. Adjust the clearance width to the pocket material thickness + α, as shown in the figure on the left. • The seam margin is small.
PAGE 145
7. FOLDING MACHINE C. Tucking blades R, L, RD and LD have burrs. Remove the burrs and buff the tucking blades. D. Because tucking blades R, L, RD and LD are attached below the correct position, the pocket material strays with the body when the tucking blades retract. Raise and reattach the tucking blades. Be sure not to move the tucking blades back and forth or side to side.
PAGE 146
7. FOLDING MACHINE 7. The stitch at the bottom corner is not aligned with the center line of the folded pocket. A. The left edge of tucking blade RD is off to the left. Set the clearance between the center blade top and tucking blade RD left edge to 0.5 - 1 mm, as shown in the figure on the left. Connecting block SR assembly Bolt 5X25 Adjusting screw Bolt 4X8 Setting plate Folding clamp 3-corner J Chamfering blade RJ Tucking blade RD Chamfering blade LJ 0.
PAGE 147
7. FOLDING MACHINE 8. The seam margin at the bottom is large. Connecting pin Connecting block Plate spring R 0.8 Center blade 3-corner J (1) Bolt 4X20 Plate spring L 0.
PAGE 148
7. FOLDING MACHINE D. There is no clearance between tucking blades LD and RD. Adjust the clearance so that it is about the same thickness as a piece of pocket material. E.
PAGE 149
7. FOLDING MACHINE 9. The seam margin at one side of the bottom is large. A. The inner clamp blades are improperly adjusted. Refer to “Trouble 6. Cause A”. B. Tucking blades LD or RD has burrs at the place corresponding to the pocket trouble. Remove the burrs and buff the tucking blades. At this time, be sure not slide the tucking blade side to side. C. The clearance between tucking blade LD and the center blade is improperly adjusted.
PAGE 150
7. FOLDING MACHINE 10.The seam margin is too small at the corners on both sides. A. The inner clamp blades are improperly adjusted. Refer to “Trouble 6. Cause A”. B. Tucking blades LD and RD are improperly adjusted. Shift tucking blade LD slightly to the left to increase the seam margin on the left side. Shift tucking blade RD slightly to the right. Tucking blade LD Tucking blade LD 0.5 - 1 0.5 - 1 0.5 - 1 1832S C.
PAGE 151
7. FOLDING MACHINE 11. The folded lone at the bottom corner is round. A. Tucking blades LD and RD are improperly adjusted. If this is caused by tucking blade RD being off to the left, refer to “Trouble 7. Cause A”. Connecting block SR assembly Bolt 5X25 Bolt 4X8 Adjusting screw Setting plate Folding clamp 3-corner J Tucking blade LD Tucking blade LD Chamfering blade RJ 0.5 - 1 0.5 - 1 Chamfering blade LJ Tucking blade R-3J Tucking blade RD-3J Tucking blade LD-3J Tucking blade L-3J 0.
PAGE 152
7. FOLDING MACHINE 12. The seam margin at the bottom is too small. A. The inner clamp blades are improperly adjusted. Slightly enlarge the clearance between the center blade edge and the inner clamp blades at the place corresponding to the pocket trouble. The clearance should be the material thickness + α. Material thickness + α Connecting pin Connecting pin Connecting block 1830S Inner clamp 3-corner J Bolt 5X25 Plate spring R 0.
PAGE 153
7. FOLDING MACHINE 13. The pocket outline is curved. A. The flap margin is small. Make the flap margin at least 8 mm. B. The tucking blades have burrs. Remove the burrs and buff the tucking blades. C. The clearance between the tucking blades of the folding clamp assembly and the center blade is improperly adjusted. Reduce the clearance. At this time, be sure not to move the tucking blades back and forth or side to side.
PAGE 154
7. FOLDING MACHINE E. When the inner clamp assembly descends quickly, or excessively high pressure is applied to the pocket, or the material is fine, the outline is curved because the air is pressed out to the side of the pocket. To adjust the inner clamp descending speed, remove the valve cover, then rotate clockwise the speed controller of the valve 4A. The too slow speed results in “Trouble 1”. To decrease the pressure, refer to “Trouble 1. Cause B-3”.
PAGE 155
7. FOLDING MACHINE 14. The pocket opening is wide. A. When the chamfering blades are attached below the correct position, the body and the pocket stray when the chamfering blades retract. Move upward and reattach the chamfering blades. At this time, set the clearance between these chamfering blades and tucking blade L to about the material thickness.
PAGE 156
7. FOLDING MACHINE 15. The pocket opening is not tucked in. A. The flap margin is small. Make the flap margin at least 15 mm. B. Tucking blade L and R are improperly attached. Slide the tucking blades forward. If this adjustment is not enough to solve the trouble, enlarge the chamfered parts of the tucking blades by machining. At this time, remove the burrs and buff the blades. C.
PAGE 157
7. FOLDING MACHINE 16. The flap margin at the pocket opening is out of the pocket. A. The flap margin is large. Set the pocket material onto the center blade so that the flap margin is even at every point. The proper length of the flap margin is 12-15 mm. When the flap margin is larger than usual, reduce it or refer to “Cause B” below. Center blade 3-corner J Plate spring R0.8 Pocket material Plate spring L0.8 1829S B.
PAGE 158
7. FOLDING MACHINE 17. Material protrudes from the pocket opening. A. Tucking blade L and R are improperly positioned. Slide the tucking blades forward. If this adjustment is not enough to solve the problem, enlarge the chamfered parts of the tucking blades by machining. At this time, remove the burrs and buff the blades. If you slide the blades forward too much, the same problems as described in “16. The flap margin at the pocket opening is out of the pocket.” will occur.
PAGE 159
7. FOLDING MACHINE 18. The pocket pattern is not aligned with the body pattern (when the pattern is vertical). A. The pocket and the body are improperly positioned. Position them correctly in mode pattern matching. B. The pattern pitch of the pocket is different from that of the body. Check both pitches on a level surface. C. The inner clamp assembly or the sewing clamp assembly descends quickly.
PAGE 160
7. FOLDING MACHINE 19. The pocket pattern is not aligned with the body pattern (when the pattern is horizontal). A. The pocket and the body are improperly positioned. Position them correctly in mode pattern matching. B. The pattern pitch of the pocket is different from that of the body. Check both pitches on a level surface. C. The inner clamp assembly or the sewing clamp assembly descends quickly.
PAGE 161
7. FOLDING MACHINE 20.The needle location at the corners is improper. The inertia of the X-Y movement mechanism results in improper needle location, which is different from the programmed points. (Note: The machine motor rotating speed may vary the needle location at each corner.) To prevent uneven stitching at the corners, the machine can make stitching at the corners at low speed. Refer to the instruction manual for programmer.
PAGE 162
7. FOLDING MACHINE 21. The pocket top is narrow. A. The inner clamp blades are improperly positioned. Increase the clearance between the center blade edge and the inner clamp blades at the pocket top. B. When the top edge of the pocket material is not clamped by the sewing clamp assembly, it strays and is sewn. Affix the sponge to the inside of all the pocket edge of the sewing clamp while holding the pocket material with the sponge.
PAGE 163
7. FOLDING MACHINE 22. The seam margin is large. A. Because the forward part of the center blade is curved up, the clearance between the needle plate and the center blade is large only at the forward part. Remove the center blade. Distort the center blade to level. B. The inner clamp blades are improperly attached. Refer to “Trouble 6. Cause A”. C. Because the center blade assembly is attached too far forward, the pocket material is improperly folded.
PAGE 164
7. FOLDING MACHINE 23. The pocket has skipped stitches at the sewing start. A. The needle thread coming out of the needle is short. • Lengthen the thread in pretension. • Check the opening amount between the tension discs. • Perform reverse stitching 2-3 stitches after reprogramming. • Adjust the thread blower so that it correctly blows the thread end. B. The sewing clamp improperly presses the body and pocket materials. Refer to “Trouble 21. Cause B”.
PAGE 165
7. FOLDING MACHINE 24. The stitch pitch is uneven at the corners. The inertia of the X-Y movement mechanism results in improper needle location, which is different from the programmed points. (Note: The machine motor rotating speed may vary the needle location at each corner.) To prevent uneven stitching at the corners, the machine can make stitching at the corners at low speed. Refer to the instruction manual for programmer.
PAGE 166
7. FOLDING MACHINE 25. The pocket has skipped stitches or thread breakage at the pocket top. Because the sewing clamp improperly clamps the pocket top during sewing, the pocket material moves about. • Move the sponge as close as possible to the top edge of the pocket, then refer to “Trouble 21. Cause B”. Increase the sewing clamp pressure referring to “Trouble 5. Cause B”. Be sure not to increase the pressure excessively, which may result in vertical uneven material feeding or vertical gathering.
PAGE 167
7. FOLDING MACHINE 26. The seam margin is large. (Heavy material) When the material is relatively thick, the shape of the sewn pocket is large Refer to “Trouble 6.”. If the adjustment in “Trouble 6.” is not enough to solve this trouble, the center blade needs to be replaced by a smaller one. The standard center blade is 1.4 mm smaller on both sides than an actual pocket shape. When several sizes of center blades (for example, the 1.8 mm smaller one on both sides or the 2.
PAGE 168
7. FOLDING MACHINE 27. The distance between the inner row stitches and the outer row stitches is irregular. The inertia of the X-Y movement mechanism results in needle location different to the programmed points. Refer to the instruction manual for programmer.
PAGE 169
7. FOLDING MACHINE 7-4-3. Characteristic troubles of two corner pocket model 1.The tucked margins at the bottom protrude on both sides. 2.The flap margins at the bottom on both sides are not tucked in. 1836S 1837S 7.The bottom seam is 6.The bottom corners zigzag chain stitch. rise and the seam margins near the bottom on both sides are small. 1841S 3.The tucked flap margins at the bottom protrude below. 1838S 8.The corners are round. 1842S 1843S BAS-7610 7-39 4.The base is curved. 5.
PAGE 170
7. FOLDING MACHINE 1. The tucked margins at the bottom protrude on both sides. A. The flap margin is too large. Set the pocket material onto the center blade so that the flap margin is even at each point. The proper length of the flap margin is 12-15 mm. If the flap margin is larger than it should be, reduce it. Plate spring R Plate Spring L Center blade Pocket material 1844S B. Tucking blade RD or LD is improperly positioned.
PAGE 171
7. FOLDING MACHINE 2. The flap margins at the bottom on both sides are not tucked in. A. The flap margin on both sides are too small. Adjust the flap margin to 12-15 mm. B. Tucking blade RD or LD is improperly positioned. Shift the tucking blade backward, then adjust it so that its edge is aligned with the center blade corner when the cylinder driving the tucking blade works. (The alignment does not have to be perfect.
PAGE 172
7. FOLDING MACHINE 3. The tucked flap margins at the bottom protrude below. A. Tucking blade RD or LD is improperly positioned. Refer to “Trouble 2. Cause B”. Connecting pin Connecting block Bolt 4X20 Plate spring R 0.8 Center blade Plate spring L 0.8 1848S Center blade assembly B. Because the clearance between tucking blade D and RDD or LDD is too small, the pocket material strays when they retract.
PAGE 173
7. FOLDING MACHINE 4. The base is curved. First, refer to “Trouble 13.” of pentagon pocket. The cause described below is characteristic of square pockets. Because tucking blade RDD or LDD is attached below the correct position, the pocket material strays with the body when the tucking blade retracts. Raise the tucking blade and reattach it. Adjust the clearance between tucking blade RDD or LDD and tucking blade D to approximately 1-2 mm.
PAGE 174
7. FOLDING MACHINE 5. The tucking blades do not operate smoothly. Because tucking blade RDD or LDD is attached below the correct position, tucking blades RDD or LDD and D do not retract smoothly. Adjust the clearance between these two tucking blades to approximately 1-2 mm. Then, holding the clearance width between tucking blades RD and LD, raise all of the tucking blades and reattach them. At this time, be sure not to shift them side to side.
PAGE 175
7. FOLDING MACHINE 6. The bottom corners rise and the seam margins near the bottom on both sides are small. A. When the crease of the flap margin is aligned with the needle location, the pocket is sewn improperly and the seam margin is small. Shift tucking blades RD and LD forward and reattach to reduce the amount of margin to be tucked in. B. The inner clamp blades are improperly attached. Slightly increase the clearance between the inner clamp blades and the center blade. C.
PAGE 176
7. FOLDING MACHINE 7. The bottom seam is zigzag chain stitch. The seam sewn from left to right almost aligns with the border line between the hitch stitch and perfect stitch. This problem happens when both of these stitches appear. Because this is a basic property in a sewing machine, there is no fundamental measure for it. When adjusting, rotate the needle approximately 5-10 degree clockwise, looking from the bottom.
PAGE 177
7. FOLDING MACHINE 8. The corners are round. Tucking blade RD and LD are positioned backward from their correct position. Shift the tucking blades forward, then adjust them so that their edges are aligned with the center blade corners when the cylinders driving the tucking blades work. (The alignment does not have to be perfect.) At this time, check that these tucking blades come into the clearance between tucking blades D and DD.
PAGE 178
7.
PAGE 179
SERVICE MANUAL 15-1, Naeshiro-cho, Mizuho-ku, Nagoya 467-8561, Japan. Phone: 81-52-824-2177 Printed in Japan 151-761 I2110825 2002.12.