DH4-B981 SERVICE MANUAL Please read this manual before making any adjustments. ELECTRONIC EYELET BUTTON HOLER (< =a 7G RPMNICBMLTE EU.This service manual is intended for B981; be sure to read the B981 instruction manual before this manual. Carefully read the "SAFETY INSTRUCTIONS” below and the whole of this manual to understand this product beforeyou start maintenance. Asa result of research and improvements regarding this product, some details of th’s manual may not be the same as those for the product you purchased. I you have any questions regarding this product, please contact a Brother dealer. SAFETY INSTRUCTIONS @ Safety indications and their meanings This service manual and the indications and symbols that are used on the machine itself are provided in order to ensure safe operation of this machine and to prevent accidents and injury to yourself or other people. The meanings of these indications and symbols are given below. Indications A DANGER [feitstusions which flow this term indicate tutions where failure to follow the instructions will almost certainly result in death or severe injury. The instructions which follow this term indicate situations where failure to A. CAUTION | totow tte instructions could cause injury when using the machine or physical damage to equipment and surroundings. _-- This symbol (A) indicates something that you should be careful of. The picture inside the triangle indicates the nature of the caution that must be taken. (For example, the symbol at left means “beware of injury”.) ~- This symbol() ates something that you must not do. his symbol (@) indicates something that you must do. The picture inside the circle indicates the nature of the thing that must be done. (For example, the symbol at left means "you must make the ground connection") ua.nantf@ Notes on safety A DANG ER 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. ACAUTI ON Installation Machine installation should only be carried ‘out by a qualified technician. © Contact your Brother dealer or a qualified electrician for any electrical work that may. need to be done. 8 e oe @ © © The sewing machine weighs more than 87 kg. The installation should be carried out by ‘two or more people. © The top of the table should be 50 mm in thickness and should be strong enough to hold the weight and withstand the vibration ofthe sewing machine. Qo OO © Do not connect the power cord until installation is complete, otherwise the machine may operate if the start switch is pressed by mistake, which could result in injury. ‘© Be sure to connect the ground. If the ground connection isnot secure, you run the risk of receiving a serious electric shock. © If using a work table which has casters, the casters should be secured in such a way 50 ‘that they cannot move. @ ©All cords should be secured at least 25 mm away from any moving parts. Furthermore, do not excessively bend the cords or secure them too firmly with staples, otherwise there is the danger that fire or electric shocks could occur. Install the belt covers to the machine head and motor. Be sure to wear protective goggles and gloves when handling the lubricating oil and grease, so that they do not get into your eyes or onto your skin, otherwise inflammation can result. Furthermore, do not drink the oil or eat the grease under any circumstances, as they can cause vomiting and diarrhoea. Keep the oil out of the reach of children. Avoid setting up the sewing machine near sources of strong electrical noise such as high-frequency welding equipment. If this precaution is not taken, incorrect machine operation may result. Sewing © This sewing machine shoutd only be used by operators who have received the necessary training in safe use beforehand. © The sewing machine should not be used for any applications other than sewing. © Attach all safety devices before using the sewing machine. If the machine is used without these devices attached, injury may result. © 8 A e Turn off the power switch at the following times, otherwise the machine may operate if tthe start switch is pressed by mistake, which could result in injury. + When threading the needle ‘* Whenreplacing the needle ‘* When not using the machine and when leaving the machine unattended ® e AS ‘© 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. © ifan error occurs in machine operation, or if abnormal noises or smells are noticed, immediately turn off the power switch. Then contact your nearest Brother dealer or a qualified technician. ‘* If the machine develops @ problem, contact your nearest Brother dealer or 2 qualified technician. © If using a work table which has casters, the casters should be secured in such a way so that they cannot move. DHe-89Bt0 A CAUTION Cleaning ‘@ Turn off the power switch before starting any cleaning work, otherwise the machine may operate if the start switch is pressed by mistake, which could result ininjury. ‘© Be sure to wear protective goggles and gloves when handling the lubricating oi! and grease, so that they do not get into your eyes or onto your skin, otherwise inflammation can result Furthermore, do not drink the oil or eat the ‘grease under any circumstances, as they can cause vomiting and diarrhoea. Keep the oil out of the reach of children, © Maintenance and inspection ‘® Maintenance and inspection of the sewing machine should only be carried out by 2 qualified technician. Ask your Brother dealer or a qualified electrician to carry out any maintenance and inspection of the electrical system. 8 @ ‘4 Tum off the power switch and disconnect At power cord from the wall outlet at the following times, otherwise the machine may operate if the start ewitch is pressed by mistake, which could result in injury. ‘© When carrying out inspection, adjustment and maintenance ¢ When replacing consumable parts such as the loopers, spreaders, knife and cutting block Disconnect the air hoses from the air supply and wait for the needle on the pressure geuge to drop to “0” before carrying out inspection, adjustment and repair of any parts which use the pneumatic equipment. AAT ite power snitch ond alr need to be let ‘on when carrying out some adjustment, be extremely careful to observe all safety precautions. e © Use only the proper replacement parts as specified by Brother. If any safety devices have been removed, be absolutely sure to re-install them to their original positions and check that they operate correctly before using the machine. ‘* Any problems in machine operation which result from unauthorized modifications to the machine will not be covered by the warranty. DHe.2981Warning labels + The following werning labels appear on the sewing machine. 1 Please follow the instructions on the labels at all times when using the machine. If the labels have been temoved or are difficult to read, please contact your nearest Brother dealer. |. DANGER] ADANGER |4PELIGRO| esau age ilaese iy Tus a ain suichardvats inwsowoe oping isco veya ron ace provoquer. Einerterue stsore Sinus are cures Uivotap necesaao puede pear, ene Apapare emptor praoaly spears its sae ence Donot touch the cutter and hammer ‘or press any objects against the machine while sewing, as this may {result in personal injury ordamage to > the machine. Be sureto connect the ground. If the around connection is not secure, you run the risk of receiving a serious electric shock. ‘@ 5 _ Direction of operation | Eye guard. Needle bar guard oH4-8981CONTENTS — 4. MECHANICAL DESCRIPTIONS ------- 1. 1-2, Upper and lowershaft mechanisms. Needle bar and thread take-up mechanisms ... 1-3. Zigzag mechanism... 4-4, Needle bar rocking mechanism. 1-5. Feedmechanism . 4-6. Work clampand cloth opener... 1-7. Cutter mechanism . 1-8. Looper mechanism 1-9, Spreodermechonism . 4-10. Double chain stitch looper mechanism 2. DISASSEMBLY - wee 2-4, Covers and work clamp plates 2-2. Feedmechanism 2-3, Lubrication « 2-4 Looper and spreader 2-5. Needle bar rotating mechanism 2-6. Looperbase .. 2.7, Needle bar, thread take-up, and zigzag mechanisms . 2-8 Knife pipe assembly - 2-9. Lower shaft mechanism . 2-40, Synchronizer... 2-11. Upper shaft mechanism 2-12. Cutter mechanism 2.13. Zigzag fork - }. ASSEMBLY 34, Tigzag fork... 3-2. Cutter mechanism . 3-3. Uppershaft mechanism .. 3-4 Lower shaft mechanism 3:5. Upper thread trimmer mechanism 3-6 Attaching the knife pipe and the knife base 3-7. Drivinggearshaft mechanism .. 3-8 Needle bar, thread take-up, and zigzag mechanisms .......... 3-9, Looperbase .. wees Hassr 1 3-10. Needle bar rocking mechanism . 34 3-11. Looper and spreader . _37 1 (3-12. Lubrication . . 40 2 3-13. Feedmechanism . 42 3 3-14. Synchronizer AG 3. | 345: Coversand workclamp mechanism ... 47 | 318 Saferyswitch assembly ee... eseeeses AT 5 7 7 | 4, ADJUSTMENT - 48 8 | 44. Adjusting the work dampliftheight .. 48 g | 42. Adjustingthework dampplate ...... 49 43. Adjusting the loth spreading amount .......05 vee 49 44, Adjusting the pesition of the work clamp... er) 45, Adjusting the X-axishome position ... 50 10 | 46. Adjustingthe Y-axishome position ... 50 4-7. Adjusting position (reference line) oftheneedle vee 51 12 | 2.8. Adjustingthe home position ofthe looper base =... 49, Fineadjustmentof knifeposition ..... 52 440. Adjusting the sideways movement ofthe cutter lever .. 53 4-11. Adjusting the height of the throat plate 1g | 412. Adjusting the heights of the spreader i andthe looper s+... 413. Adjustingtheloop stroke... 414, Adjusting the height of the neediebar .... . 4-15. Adjusting the clearance between the looper and the needle 416. Adjusting theneedleguard . 417. Adjusting the spreader mounting position 58 21 | 418. Adjusting the spreader timing 59 22 4-19, Adjusting the amount to pull the B upper thread and tension release .. 24 | 420. Adjusting upperthread trimming 60 4-21. Adjusting thelowerthread trimmer .. 61 4-22. Adjusting the position of the lower ‘thread presser 4-23, Adjusting the rotating centers of the rneedle bar and the looper base - 4-24, Adjusting the needle bar stop position . 69LS 5. POWER SUPPLY EQUIPMENT +70 5-1. Componentsinside the control box ... 70 5-2. Fuse explanation 72 5-3. Connectors .... 74 5-3-1. Connector positions eens TH 5-3-2. Signal names for: connectors and probable symptoms due to poor contact .. aeeeee . ci) 5-4. Specification harness: connections 88 5-5. Summaryof DiPswitches .. 89 5-6. Usingthememory switch ............ 93 5-7. Sensors ..-.....+ 94 @ 6. AIRPRESSUREMECHANISM ------»- 98 6-1. Solenoid valves and air tubes os 6-2. Airtubelayout ... . 99 7. SOFTWARE seseeecesees 102 7-4, Motion flowchart ......-- oe 102 7-2. Inputcheck list 103 7-3. Output checklist ceceeersess 105 7-4. Errorcodes ... 107 7-5. Troubleshooting 110 7-6. Control circuit block diagram (1)... 117 7-7. Control circuit block diagram (2) bHt-g9811. MECHANICAL DESCRIPTIONS 1. MECHANICAL DESCRIPTIONS 1-1. Upper and lower shaft mechanisms ‘© When the motor pulley @ rotates, its motion is transmitted to the V belt @, the idler pulley ©, andthe V belt@, and finally to the pulley®. ‘* When the pulley @ rotates in the direction of the arrow, its motion is transmitted to the upper shaft timing puliey ©, the timing belt @, and the lower shaft tension pulley ®, and the lower shett ©, causing ‘the lower shaft cam @ to turn in the direction of the arrow. DHa-89811, MECHANICAL DESCRIPTIONS 1-2. Needle bar and thread take-up mechanisms 1) Needle bar mechanism ‘When the pulley rotates in the direction of the arrow (towards you), its rotation is transmitted to the upper shaft @, the needle bar gear ©, and the driving gear @, that makes the eccentric rod @ rotate. ‘+ The driving rod ®, whichis engaged with the eccentric rod ®, rocks the needle bar driving lever @. ‘The rocking motion of the needle bar driving lever @ is transmitted to the needle bar york @, the needle bar level feed link ©, and the needle bar clamp @, and then the needle bar @ moves up and down. ‘The needle ber @ is guided by needle bar bush (U) ® and the needle bar block @. 2) Thread take-up mechanism * When the pulley © rotaterin the direction ofthe arrow, the reece bar gear © rotates wa the upper shatt@. «The thread take-up cam @, which is attached to the needle bar gear ©, moves the thread take-up @ via the thread take-up cam roller @. the thread take-up cam roller @ is always kept in contact with the cam @ by the thread take-up spring @ attached to the thread take-un ©. DHaB9811. JECHANICAL DESCRIPTIONS 1-3. Zigzag mechanism + When the pulley @ is tumed in the direction of the arrow, its motion is transmitted to the upper shaft @ ‘that rotates the zigzag cam ©, and the zigzag fork @ rocks. + The zigzag rock shaft @ is rocked by the zigzag fork @, via the zigzag connecting rod @, and the zigzag crank@. + The rocking motion of the zigzag rock shaft @ is transmitted to the zigzag lever ®, the needle bar lever feed link ©,, andthe needle bar block clamp @, those move the needle bar block up and down. «The needie bar @ is fitted on the needle bar block ®, and the needle bar guide @ is fitted inthe notch of the needle bar block @. When the needle ber block @ moves upand down, the needle bar @ oscillates. 1-4. Needle bar rocking mechanism ‘© When pulse motor (R) @ operates, the motion is transmitted to the driving needle pulley assembly @, x ing belt (D) ©, and the looper pulley assembly @, which then moves the driving looper shaft assembly The looper base © isrotated by the looper pulley assembly @ ‘¢ When the vertical shaft (T) pulley (U) assembly @, which is attached to the driving looper shaft assembly ©, rotates, the motion is transmitted to timing belt (U) ©, and the needle bar block assembly © that rotates the needie bar @. pue.nant1. MECHANICAL DESCRIPTIONS 1-5. Feed mechanism 1) X-direction feeding « When pulse motor (X) @ operates, its motion is transmitted to the actuating gear @, the idle gears © and @, and the X racks @ and @, that finally moves X-feed shaft holder (L) @. + The X-feed guide shafts (A) © and (8) @, which are connected to X-feed shaft holder) @, move X-leed shaftholdor (R) ®. « The Y-feed guide shafts @ and @, which are attached to X-feed shaft holders (L) @ and (R) @, move the feed bar ® inthe x direction. @ =) Ydirection feeding + When pulse motor (¥) © rotates, its motion is transmitted to the actuating gear G, the idle gear ©, timing pulley (A) ®, that finally moves the Y-timing belt ®. + The Y-timing belt @ is secured by the Y-driving shaft holder © and the belt holder @, and that moves the Y shaft @ « The linear bush @ , whichis fitted in the ball bearing @, is fitted in the Y-guide shaft @ to move the feed bar ® inthe direction. 4.8981 41, MECHANICAL DESCRIPTIONS 1-6. Work clamp and cloth opener 1) Work clamp mechanism © Cylinder 16x10 @ moves clamp lever (8) @ in the direction of the arrow according to the cylinder's motion, via the presser cylinder rod @, the cylinder rod pin @, the presser driving lever @, and the clamp lever shaft 6. ‘© The end of clamp lever (B) © is fitted on clamp lever (L) @, and the work clamp @ attached to damp arm (0@ lowers. «When the cylinder @ isreturned by the presser spring @, the work clamp © rises. The speed controller @ attached to the cylinder @ controls the | 1g speed of the work clamp © * The work clamp mechanism is activated by independently-operated left and right cylinders, that can ‘equalize the pressure of the work clamp. The pressure of the work clamp is always applied to the material equally even when the material thickness changes. 5 bwa-89811. MECHANICAL DESCRIPTIONS 2) Cloth opener 05mm ormore 1.» The feed bracket © carries the cylinder 16%15 assembly @, whose end is connected to the opening oylinder rod ®, cylinder rod pin (8) @, and the opening driving lever ©. + The opening connecting rod @ attached to the opening driving lever @ is connected to the fulerum lever plate ® and the lever © viatheslide block @. + The projection @ of the fulcrum lever plate @ and the pin @ of the lever © are fitted on the hole of ‘the work clamp plate ® and the slide block or + When the cylinder 163¢ 15 assembly @ operates, and the stopper ® of the opening driving lever © and the bolt @ make contact, the work clamp plate @ moves in the direction of A, consequently ‘opening a button eyelet on the material. 2. © At this time, there should be at least 0.5 mm clearance between the throat plate @ and the needle plate ®. Adjust the clearance using the bolt ©. + When the cylinder 16% 15 assembly @ is not pressurized, the work clamp plate @ is moved in the direction of B by the opening spring @. At this time, the stopper ® of the work clamp plate @ makes contact with the stopper plate @. Indicates the movement of the work clamp plate @. bHas9Bt 64, MECHANICAL DESCRIPTIONS LL 1-7. Cutter mechanism © When cylinder 63 x 100 © operates, the motion is transmitted to the cylinder rod @, link (C) @, and link (A) @, which then activates the cutter lever assembly ©. © The cutter sensor partition plate © attached to link (C) @, and the cutter sensor assembly @ monitor the motion of the cuttersensor assembly @. «Engagement of the hammer @ attached to the end of the cutter sensor assembly © and the cutter © attached tothe bed, cuts the material requiring button eyelets. 1-8. Looper mechanism ‘¢ At the end of the looper link assembly @ which has the looper link support shaft @ as the pivot of the rocking motion, the looper cam roller © is fitted in the groove in the lower shaft cam:@. The two looper linksprings@ are attached to the other end. ‘* The looper link springs © are secured by the looper driving plate @ through which the looper driving shatt © passes. ¢ When the lower shaft cam @ rotates in the direction of the arrow, the looper link assembly @ is rocked via the looper cam roller ©. The looper driving shaft @ moves up and down due to the motion of the looper ink assembly bHansat = 71, MECHANICAL DESCRIPTIONS 1-9. Spreader mechanism ~@ Atthe end of the spreader cam lever @ which has the looper link support shaft @ as the pivot of the rocking motion, the spreader cam roller © makes contact with the circumference of the lower shaft cam @, and the spreader driving lever © is attached to the other end using the screw @. The forked part of the spreader driving lever @ is fitted in the groove @ of the spreader link shaft @. ‘» Whensthe lower shaft cam © rotates in the direction of the arrow, the spreader cam lever @ isrocked via the spreader cam roller @. ‘The spreader link shaft @ moves up and down due to the motion of the spreader cam lever @. oHt-s981 81. MECHANICAL DESCRIPTIONS 1-10. Double chain stitch looper mechanism ‘« When the looper driving shaft @ moves up and down, the motion is transmitted to the looper link clamp @, and the looper link ©, which rocks LS- holder bracket © with the holder support shaft © secured to the loop base @ regarded 2s the pivot. ‘+ When the spreader link shaft. @ moves up and down, the motion is transmitted to the spreader link base © and the spreader cam tink ©, which ‘then rocks the spreader differential cam @® with ‘the holder support shaft © secured to the loop base @ rogarded as the pivot. + The rocking mations of the S holder bracket @ and the spreader differential cam @ cause spreader (L) to rock. In the sameway, spreader (R) @ is rocked. 9 Diase12. DISASSEMBLY 2. DISASSEMBLY A CAUTION © Disassembly should only be carried out by Be sure to wear protective goggles and qualified technician. gloves when handling the lubricating oil and grease, so that they do not get into your eyes or onto your skin, otherwise inflammation may result. Furthermore, do not drink the oil or eat the grease under any circumstances, as they may cause vomiting and diarrhea. Keep the oil outof the reach of children. {any safety devices have, been removed, be absolutely sure to re-install them to their original positions and check that they operate correctly before using the machine. S © Any problems in machine operation. which result from unauthorized modifications to the machine will not be covered by the warranty. AX? Went heybomer zaiteh before disassembly, otherwise the machine may ‘Operate If the foot switch is depressed by mistake, which could result in injury. A’ Disconnect the air hoses from the air supply and wait tor the needie on the pressure gauge to drop to "0" before Earrying out inspection, adjustment and repair of any parts ‘which use the pneumaticequipment. ‘© Use only the r replacement parts as Oe seer ee if disassembly is not performed in the correct order, it may be hard to remove parts. Disassemble as follows. The following is the main points of disassembly. 2-1. Covers and work clamp plates 1. RemovatheneedieO 2. Remove the faceplate @, belt covers (F) © and (R) @, the top cover © , the zigzag window cover @, and the driving needle guard cover @ 3. Remove work clamp plates (R)@ and (\) © Dwaaset 102. DISASSEMBLY 2-2. Feed mechanism 7. Feed bracket Remove the two Y-feed guide shafts @ toward you. The feed bracket @ unit will come off. Remove the motor support ©, which includes the X motor unit. Loosen the screw @ of the Y driving shatt holder, pull out the Y-shaft © toward you, and remove the Y-feed base @, including the ¥ motor unit. 2-3. Lubrication 1. Remove the wick supports @ and @. 2. Remove the wicks @ and@ from the hole@. 3. Remove the two screws © and wick support (L) @.2. DISASSEMBLY 2-4. Looper and spreader 1. Loosen the set screws @ of theset collar @, and set screws ©, and remove the looper link support shaft e. 2. Position the needle at its lower position. Pull the spreader link shaft @ downward, and remove the spreader cam lever @. 3. Remove the looper link springs ©. - 4. Loosen the set screws © of the set collar © and the set screws @, and remove the looper link support shaft ®. 5. Slide the lower shaft cam @ in the direction of the arrow, and remove the looper link ®. Ha.8981 n2 DISASSEMBLY 2-5. Needle bar rotating mechanism. Remove the tension pulley ® and timing belt (U) @. Remove the tension pulley © and timing belt(D) @. Remove the R sensor set plate ©. . Remove the motor base @. Loosen the bolt @ of the vertical shaft (1) pulley @ and the set screws @ of the set collar ©. Remove the driving looper shatt @ downward. oma wN Ha.B9812. DISASSEMBLY 2-6. Looper base “gs 1. Loosen the screw @, and remove the spreader link shaft @ in the direction of the arrow. 2. Loosen the screw @, and remove the looper ‘driving shaft @ in the direction of the arrow. 3. Remove the tension nut @, pre-tension spring (8) @, the thread guide discs @, and the L-tension stud @. Loosen the screw © of the looper pulley assembly ©, and remove the looper base @ inthe direction of the arrow. *Be careful not to drop the ball bearings @ when removing the looper pulley assembly ©. DH4-8981 42. DISASSEMBLY 2-7. Needle bar, thread take-up, and zigzag mechanisms DHA-B9BT2. DISASSEMBLY eS =e A wE Needle bar mechanism Remove the screw @, the needle bar guide support plate @, the needle bar guide spring @, the needle bar quide@, andthe washer ®. Loosen the set screws@, and remove the needle bar guide collars @. Remove the set screw @, the stud screw ©, the tension spring @, and the thread guide discs ®. Loosen the bolts of the needle bar clamps @, and remove the needle bar @ in the direction of the arrow. Remove the caps © and ®. Loosen the set screw @, and remove the driving rod pin @. Loosen theset screws @ and the setscrews @ of the set collar @, pull out the driving lever shaft @ in the direction of ‘the arrow, and remove the needle bar driving lever @. Zigzag mechanism Loosen the screw @ of the needle bar block clamp @, and remove the needle bar block @ in the direction of the arrow. Remove the needle bar block clamp @, the needle bar level feed links @ and ©, and the needle bar block collar ®. Remove the cap @. Loosen the screw @ of the needle bar clamp @, and remove the zigzag lever @ in ‘the direction of the arrow. Loosen the screw @ of the needle bar block clamp @, and the screw @ of the zigzag crank @, and remove the zigzag rock shaft @ in the direction of the arrow. Thread take-up mechanism Remove the thread take-up spring @ and the cap®. Loosen the set screws @ and the set screws @ of the set collar @, and remove the thread take-up support shaft @ and the thread take-up assembly @. DH4-8981 182. DISASSEMBLY —————— 2-8. Knife pipe assembly 1. Remove the screw @. 2. Remove the knife pipe @ 2-9. Lower shaft mechanism *Before removing the lower shaft, loosen the timing belt, referring to 3-4. 1. Loosen the sctews @ of the lower shaft tension pulley assembly ©. 2, Loosen the screws @ of the lower shaft cam @ 3. Loosen the set screws @ of the set collar @, and remove the lower shaft @ in the direction of the arrow. 7 DHe-89812. DISASSEMBLY 2-10. Synchronizer 1. Loosen the two set screws @ and @, and remove the pulley @. 2. Loosen the two screws @, and remove the synchronizer assembly (8) @. 3, Remove the twoscrews @, and the NP support bracket (B) @. 2-11. Upper shaft mechanism 1. Remove ball bearing cap (5) @ and the retaining ring @. 2. Loosen the set serews of the needle bar gear ©, the zigzag cam @, and the upper shaft tension pulley assembly © 3. Pullthe upper shaft @ in the direction of the pulley to remove it. The upper shaft unit will come off. DHA-B9Bt 182. DISASSEMBLY 2-12. Cutter mechanism PY Remove the extension spring @, loosen the set screw @, and remove link shaft (B) © inthe direction of thearrow. Remove the two nuts @ and the cutter arm support screw @. Loosen the set screw ©, and remove the cutter lever shaft @ in the direction of the arrow, and the cutter lever @ along with the cutter lever cover ©. Remove the wick @, and loosen the set screw. Remove the cylinder rod shaft @. Loosen the setscrew @, and remove link shaft (A) ®, and the combination of link (A) ®, link (C) @, and linkshaft () ®. Remove the airtubes ® and @, loosen the two set screws ®, and remove the cylinder support shaft @ and the cutter cylinder @. 2-13. Zigzag fork ‘8 4, 1. 2 Remove the two nuts @, and the zigzag connecting rod assembly @. Remove the nut ©, the zigzag fork support pin @, and the zigzag fork @. Di4-8981 &3. ASSEMBLY 3. ASSEMBLY . 8 AY A’ AS Assembly should only be carried out by qualified technician. Turn off the power switch before assembly, otherwise the machine may ‘operate if the foot switch is depressed by mistake, which could result in injury. connect the air hoses from the air supply and wait for the needle on the pressure gauge to drop to “0” before carrying out inspection, adjustment and repair of any parts which use the pneumatic equipment. If the power switch and air need to be left ‘on when carrying out some adjustment, be extremely careful to observe all safety precautions. A CAUTION © Be sure to wear protective goggles and gloves when handling the lubricating oil and grease, so that they do not get into your eyes or onto your skin, otherwise inflammation may result. Furthermore, do not drink the oil or eat the grease under any circumstances, as they may cause vomiting and diarrhea. Keep the oil out of the reach of children. Use only the proper replacement parts as specified by Brother. if any safety devices have been removed, be absolutely sure to re-install them to their original positions and check that they operate correctly before using the machine. Any problems in machine operetion which result from unauthorized modifications to the machine will not be covered by the warranty. ifthe assembly is not performed in the correctorder, it may be hard to attach parts. Assemble as follows. The following is the main points of assembly. 3-1. Zigzag fork by 1 Combine the zigzag fork @ and the zigzag connecting rod assembly @ using the nuts @. Insert the zigzag fork support pin @ into the hole in the zigzag fork @,, and put them into the arm from above. 2. Insert the zigzag fork support pin @ into the hole in the side of the arm, and secure it using the nut @ DHé-981 203. ASSEMBLY 3-2. Cutter mechanism oR w ex a Put the air cylinder for cutter @ into the arm with the joints facing the front. Insert the cylinder support shaft @ into the hole in the air cylinder @, and secure it using the set screws ©. Attach No, 18 airtube @ to the upper tube of the cylinder. Attach No. 19 air tube ® to the lower tube of the cylinder. Combine link (C) @, link (A) @, and link shaft (C) @. Position them in the bed from below, and attach link shaft (A) © tothem using the set screw ®. Attach the cylinder rod shaft @ with the lubrication hole facing the left. Insert the cutter lever shait @ with its slit facing the right, into the hole in the bed, the cutter lever ®, and the hole in the bed, end tighten the screw @ on the screw fiat of the cutter lever shaft @. Tighten the cuter arm support screw @ on each end ofthe cutter lever shaft @, ancl secure itusing the nut ®. Hook the extension spring @ over the cutter lever ® ond the tab of the bed. Pass link shaft (B) © with its slit facing the right, through the slot of link (A) @, and the hole in the cutterlever ®, and tighten the set screw ®. Wind the wick @ around the right of link (€) G, and insert the end of the wi inthe cylinder rod shaft ®. into the lubrication hole DH4.898t3. ASSEMBLY 3-3. Upper shaft mechanism * The emergency stop switch cord should be routed above the upper shaft. 1. insert the upper shaft unit @ into the arm from the right, and place the upper shaft collar @, the needle bar gear ©, the zigzag cam @, the thrust washer ©, the upper shaftttension pulley @, and the ‘timing belt on it. Position the zigzag fork so that the zigzag carn @ is between the arms. Attach the ball bearing cap @ using the set screws. Place the ball bearing @ on the upper shaft, and secure it using the retaining ring ®. Lightly press the needle bar gear © and the zigzag cam @ toward the pulley so that the ball bearing @ is pressed between the retaining ring @ of the upper shaft unit @ and the upper shaft collar @. Tighten the set screw which comes first when the shatt is rotated in the rotation direction, against the screw flat. 6 Position the zigzag fork between the zigzag cam @ and the thrust washer @ so that there is no play between them, face the screw flat to the front, and secure the upper shaft tension pulley @ by tightening the set scraw which comes first when rotated in the rotation direction, against the screw flat. Then tighten the other set screw. 7. Temporarily tighten the pulley with its screw flat facing the front. oH4-8981 23. ASSEMBLY 3-4. Lower shaft mechanism 4 a ‘

1. Fitthe two ball bearings into the holes in the bed, insert the lower shaft @ from the left. Put the timing belt, the lower shaft tension pulley assembly @, the lower shaft cam ©, and the set collar @, in this ‘order, onthe lower shaft ©, and tighten the set screws @ of the set collar @ so that there is no play between the parts on thelower shaft @. 2. Lightly prose the lower shaft tension pulley assembly @ and the lower shaft cam @ against the left ball bearing, and tighten the set screws © of the lower shaft cam @. *The screw flat should align with the set screw which comes first when the lower shaft is rotated in the rotation direction. 3. When the screw flat of the upper shaft is at the top, and the set screws @ of the lower shaft tension pulley assembly @ are as shown in figure 2, loop the timing belt over the lower shaft tension pulley assembly @. Adjusting the timing belt Use a screwdriver or similar tool to press the notch of ‘the tension pulley arm assembly @ with a force of 39.2N(4 kgf), and attach the tension pulley assembly. 23 DHa-B9@t3. ASSEMBLY 3-5. Upper thread trimmer mechanism 27mm 1, Assemble the thread trimmer lever @. the thread trimmer adjust screw ©, and the nut @, and attach them to the cylinder 10x 15 assembly ©. Insert them into the tubular part of the bed, and temporarily tighten the bolts ©. 2. Insert the thread trimmer lever shaft @ into the hole in the bed, and passit through the thread trimmer lever @ and the set collar @. 3. Secure the thread trimmer lever @ using the retai screw. 4, Insert the thread trimmer lever hammer @ into the hole in the bed, and tighten the thread trimmer adjusting screw © and the nut @, until there is 2.7 mm between the nut and the head of the screw ®. 5. Manually move the thread trimmer lever hammer @ up and down, and tighten the set screws @ where the thread trimmer hammer @ motion is the smocthest. 6. Tighten the bolts @ in the same way. ring © and the set collar @, and tighten the set H4-8981 243. ASSEMBLY Adjusting the thread trimming hammer stroke 25 Raise the thread trimming hammer @, and adjust the screw @ so that the clearance with the bed is 11mm. 2. Lower the thread trimming hammer ©, and adjust the screw © so that the clearance with the bedis6mm. 3-6. Attaching the knife pipe and the knife base 1) Knife pipe Insert the knife pipe © into the bed from below, and secure itusing the screw @. 2) Knife base Insert 2 ber with a diameter of 4 mm into the hole @ in the knife base to fix the knife base position, and tighten the screws @ to @. DHan98t3. ASSEMBLY 3-7. Driving gear shaft mechanism 1) Assembling the needle bar gear and the needle bar driving gear Engage the needle bar gear @ with the needle bar driving gear © by matching their identification holes @. and @. Note: Do not mistake the hole @ for the hole in which the dowel pinis inserted. 2) Adjusting the set collar of the needle bar gear Tighten the set screws © of the set collar @ with either set screw at the center of the screw flat on the driving gear shaft ©. 3) Adjusting the backlash between the needle bar gear and the needle bar driving gear - 1. The driving gear shaft @ is eccentric. Turn it to adjust the backlash. *The driving gear shaft @ should be turned in the direction where its lubrication hole is moving upward. 2. While pressing the set collar @ toward the pulley so that the driving gear shaft @ has no end play, tighten the set screws @. DHs-8981 263, ASSEMBLY po UEEEEEEEEEEEemeemenal 3-8. Needle bar, thread take-up, and zigzag mechanisms 1) Eliminating end play of the thread take-up on the arm Eliminate end play of the thread take-up @ on the arm by placing it between the end of the arm and the set collar @. 2) Applying grease to the ends of the thread take-up spring Apply grease to the ends @ of the thread take-up spring @. * Apply grease to the ends of the thread take-up © and the spring hook @ 3) Eliminating end play of the needle bar driving lever Adjust the position of the set collar @ to eliminate ‘end play of the needle bar driving lever @. a Dva.398t3. ASSEMBLY Leone ee El 4) Eliminating end play of the driving rod \\ The driving rod @ is attached to the needle bar ing lever iving rod pin ©. The eccentric wheel of the driving rod @ is free in the thrustdirection. Place the driving rod @ between the edge of the needie bar driving lever @ and the head of the rod pin © to eliminate end play of the driving rod 5) The strength to tighten the set screw of ball bearing 25/20 The set screw © of ball bearing 25/20. @ for the needle bar gear @ should be tightened as little as possible. If it is tightened excessively, unnecessary load may be applied to the needle bar gear 0, causing pulse motor R to go out of control. “Be sure to apply the screw lock to the circumference of ball bearing 25/20 @ before press fittingit. Insert the zigzag eccentric pin @ into the zigzag crank @, attach the washer_@ and the needle position control plate @ as shown in the above figure, and pass the zigzag rock shaft @ through the arm from the right. At this time, insert a wadge or similar tool into the split of the zigzag crank @ far easier adjustment. Note: Do not fail to attach the washer ©. ona.n98t 283. ASSEMBLY 7) Eliminating end play of the zigzeg lever Adjust the needle bar clamp (set collar) © so that there is no end play of the zigzag lever @ whichis connected to the zigzag rock shat @. The zigzag lever @ should rotate easily in the rotation direction. Pass the wick @ through the zigzag lever @, and fitthe cap ©. Attach the needle bar level feed link @ to the zigzag lever @ vertically, and turit 90°. 8) Attaching the needle bar yoke and the needle bar level feed link 1 Combine the needie bar @ and the needle bar yoke @, pass the wick © through the needle bar © , and fit the cap @. Attach the needle bar level feed link © to the needle bar yoke @ vertically, and turnit 90°. 2 DH4-B9813. ASSEMBLY 9) Attaching needle bar bush (U) and the needle bar 1 Puttthe thrust bearing @ and the thrust washer © on the needle bar gear @. Attach them to bearing 25/20 @, and secure them using needle bar gear supports (A) @ and (B) @ and the screws © so that the needle bar gear @ can turn easily butwithout any end play. Do not forget to attach timing belt (U). Insert the needle bar bush (U) rings @ and the needle bar bush (U) spring © into the hole in the arm, and bind them using needle bar bush(U) @ and the needle bar bush (U) nut ©. Temporarily attach needle bar presser bracket (2) @ using the bolts ®. Pass the needle bar @ through the arm from above, through the needle bar bush (U) @, the needle bar felt @, the needle bar clamp @, the needle har level feed link @, the needle bar block damp @, the needle bar level feed link ®, and the needle bar block collar @, in this order. bH4-8981 303. ASSEMBLY 10) Eliminating end play of the needle bar block 8 ‘Adjust the positions of the needle bar level feed link @ and the needle bar block collar @ using the flange @ of the needle bar block © and the needle bar bloc damp ©, so that there is no end play. Notes: Be sure to insort the needie bar block felt @. ‘When assembling the needle bar block and ‘the needle bar gear, align their white paint marks with each other. 11) Adjusting the needle bar in the radial direction Insert the needle bar guide collars @ into the needle bar block @, and adjust the position of the needle bar @ using the set screws @ so that the needle bar cen move smoothly. Note: Position the needle bar © so that the thread guide disc will face the front when the set screws © are facing the front. n DH4-8981 White paint markeASSEMBLY 12) Attaching the needle bar block assembly ‘The needle bar block assembly s a set of the needle bar gear, the needle ber block, and the washers. When disassembling and then reassembling the needle bar block assembly, align the white marks of the needle bar gear, the neadle bar block, and the washers, with each other. Ort White paint marks 1. Insertthe needle bar guides @ into the hole in the needle bar block ® on each side, taking care of the white paint mark of the washer O. 2. Attach the spring @ using the needle bar guide support plate ®, and tighten the screw @. 413) Adjusting the height of the needle bar ‘Turn the pulley to set the needle bar level fead link @ at its highest position, Set the height of the needle bar @ to approx. 62 mm, eliminate end play between ‘the needle bar clamp @ and the neadle bar level feed link @ and tighten the screws @. Approx.62.mm DHe-s98t 323. ASSEMBLY 3-9. Looper base 1 3 Insert the shaft of the looper base @ through the hole in the bed, attach the ball bearings @ and the looper pulley ® to theshatt of the looper base © so that there is no end play, and tighten the screw @. Insert the looper driving shaft @ into the shaft of the looper base @, then the looper link camp @ into the looper driving shaft @, and tighten the screw @. Insert the spreader link shaft © into the hole in the looper driving shaft ©, then the spreader link base © intothe spreader link shaft @. Align the reference line @ with the top surface of the spreader link base ©, and tighten the screw O Attachthe L-tension stud @, the thread guide discs ®, pre-tension spring (8) ®@, and the tension nut © tothe looper base O. oH4-981 &ASSEMBLY 3-10. Needle bar rocking mechanism 1) Driving looper shaft owag981 . Insert the driving looper shaft @ through the hole in the bed from below, place the ball bearing @, the set collar @, the vertical shaft (7) pulley (U) assembly @, the washer ©, and finally the ball bearing @ on the driving looper shaft ©. . Set the clearance between the set collar. © and the bed @ to 0.02 - 0.03 mm in the thrust direction, and tighten the set screws @. . Press the vertical shaft (T) pulley (U) assembly @ and the washer © against the ball bearing @, and tighten the screw ®. *Be sure to pass the driving looper shaft @ through timing belt (U). Attach the tension pulley arm (U) assembly @ while itis being pulled by a force of 19.6N (2 kai). 3. ASSEMBLY SS 2) Needle bar rocking mechanism 35 a. Adjusting the positional relationship between the driving needle pulley assembly and the looper base 1. Align the match mark in the looper base @ with thatin the bed, asshown in the figure on the left. 2. Turn the driving needle pulley assembly @ until the pin © makes contact with the motor base. 3. Attach the timing belt. 4. Make sure that the looper base © can rotate through 360” easily. *Tighten the screw of the looper pulley at the front. bb, Adjusting the timing belt tension Timing belt (0) see Attach the tension pulley arm (U) assembly while it is being pulled by a force of 68.6 N (7 kgf). ‘ Ha-89813. ASSEMBLY . Adjusting the positional relationship between the looper base and the needle bar gear eo Ife ere Loosen the scraw of the vertical shaft (1) pulley (U) assembly ©. Align the match markin the looper base @ with that in the bed, as shown in the figure. Orient the needle bar gear @ in the direction shown in the figure, and align it with needle bar gear support (8) @. Tighten the screw of the vertical shaft (7) pulley (U) assembly @. bi4.8981 363. ASSEMBLY 3-11. Looper and spreader |. Attach the looper link support © using the screw @. 2. Wind the wick @ around the boss of the looper ink . é Be sure to pass the two wicks @ under the wick @. ‘Wind the wick © around the spreader driving lever @, as shown in the figure. 7 Die-#9813. ASSEMBLY ey Place the looper link @ and the set collar © on the looper link shaft @, and secure the latter using the set screws @. Tighten the set screws © of the set collar © to eliminate end play. Position the lower shaft cam @ and the timing pulley @ so that they lightly make contact, then tighten ‘the screw on the screw flat at the front and another screw. (The screw flat should face the front and align with the screw which comes first when the lower shaft is rotated in the rotation direction.) Ingertan allen wrench (2.5 mm across flats) into the hole in the bed and the hole @ in the lower shaft. cam @. Position the screw flat of the upper shaft at the top (where the needle isat its lowest position) , and tighten the set screws © of the timing pulley @. (Thero is no screw flat for these set screws.) Attach the looper link springs @ to the looper link @ using the four screws. ‘Turn the pulley, adjust so that the looper link clamp wili be at the center of the looper driving shatt's stroke, and temporarily tighten the screw. Ha-a981 383. ASSEMBLY Turn the pulley until it comes to its stop position, and attach the spreader link shaft © to the forked portion of the spreader driving lever @ while pulling the former downward, € . Pass the shaft @ through the spreader driving lever @ and the set collar @, and secure them using the set screws ©. (The splitin the shaftshould be facing the right.) . Tighten the set screws © of the set collar @ to eliminate the end play. bs4.89813. ASSEMBLY 3-12. Lubrication 1) Machine head wow se Hold the wick using the wick support @. Hold the wick @ using the wick support @. Insert the wicks © and @ into the hole ©. Attach wick support (L) © using the two screws. At this time, the emergency stop switch cord should be routed above wick support (L) @. Using a pair of tweezers, insert the wick @ into the hole in the oi! tank. At this time, insert the oil tube into the hole, as shown in the figure. Pass the wick @ under the felt © of the wick support (L) @. Push the felt © of the wick support (1) © into the lubrication hole in the thread take-up ®. Dye-961 403. ASSEMBLY LL 2) Driving gear shaft “Oil issupplied to the gear shaft, the eccentric wheel, and driving rod © through the wick @ of the driving gearshatt @. *The wick @, which is wound around the boss of the driving rod @, makes contact with the felt @, and oil tothedrivingrod pin ©. ” DHa-89813. ASSEMBLY 3-13. Feed mechanism 1) Xdirection a. Adjusting the backlash between the driving gear and the idle gear Note: Be sure to remove the motor support. Adjustment should be carried out with the driving gear and theidle gear treated as @ unit. ‘Adjust the backlash between the driving gear and the idle gear when they are engaged, using the weight of pulse motor (X) © (asshown inthe figure above). Tighten the bolt @. b. Adjusting the idle gear ‘Adjust tha positions of the X racks and the idle gear 1. Loosen the set screws @ of the idle gear to adjust the engagement between the X rack @ and the idle gear @ based on the engagement between the X rack @ and the idle gear ©. Engage the idle gears @ and © with the X racks @ and ©, respectively, and attach the motor support © while pressingit. 3, Tighten the set screws @ of theidie gear O. *Theidle gear @ should have no end play. 2 DH4-B961 423. ASSEMBLY 2) Y direction ‘a, Adjusting the tension of the Y-timing belt Secure Y-pulley support (L) @ while pulling it with a force of 117.6N (12kgf). When the belt deflection is used instead to determine Y-pulley support (L) © position, the deflection will be 1£0.5mmwhen the belt is pressed at the center with a force of 4.9 N (0.5 kgf). ‘The belt tension can be adjusted when the Y-feed base is still ettached to the bed. Loosen the bolts @ of Y-support (I) , and use the bolt © to adjust the belt tension. The tension in this case should be the same value as thatabove. 3B DH4.89813. ASSEMBLY b. Adjusting the position of the Y-driving shaft holder inthe left end of the Y-driving shaft holder © with the reference line @ of the Y shaft ©. *When tightening the bolt @, the sensor partition plate assembly © should face the top. ¢ Adjusting the backlash between the driving gear and the idle gear Remove the ¥ feed base ©. Adjustment should be carried out with the driving gear and the icle gear treated as a unit. Adjust the backlash between the driving gear @ and the idle gear © when they are engaged under the weight of pulse motor (Y) @ (as shown in the figure above). Tighten the bolt @. bias9813. ASSEMBLY 3) Attaching the X-feed guide shaft 1. Loosen the screw @ and the set screw @ of the X-feed guide shaft @ so that the shaft is stil temporarily held in place. 2. Insert the Y-feed guide shafts @ into the X-feed shaft holders © and © and the feed bracket @, and tighten the set screws @ and © (two each). 3. Movathe feed bracket © in the X direction a few times. 4. Tighten the screw @ and theset screw @ of the X-feed guide shaft @. 45 DH4-89812. ASSEIVBLY 3-14. Synchronizer a ‘Attach the NP support bracket (8) @ with its notched portion facing the rear, using the screws @. Secure the synchronizer assembly (8) © using the two screws @. Tighten the set screw @ inthe V-groove in the upper shatt, and attach the pulley @. Then tighten another setscrew @. ‘The set screw © should be tightened in the front hole which comes first when the pulley is rotated in the rotation direction. After attaching the synchronizer, check the machine torque. bia-398 453. ASSEMBLY eee eee 3-15. Covers and work clamp mechanism Assembly should be performed in the reverse order of disassembly, referring to 2-1. 3-16. Safety switch assembly 4. Switch to the input check mode. 2. Adjust the height of the safety switch © using the screw @ so that that the LED does not go off even if the machine head is lowered and the bed is shaken up and down. ete ig Bt AT Nw Ist, 7 Dia-e9814. ADJUSTMENT 4, ADJUSTMENT A CAUTION S © Maintenance and inspection of the sewing machine should only be carried outby a qualified technician. eo © Ask your Brother dealer or a qualified electrician to carry out any maintenance and inspection of the electrical system AX® Temetttne power switch and disconnect the power cord from the wall outlet at the following times, otherwise the machine may operate if the start switch is depressed by mistake, which could result © Disconnect the air hoses from the air supply and wait for the needle on the pressure gauge to drop to "0" before carrying Out inspection, adjustment and repair of any parts which use the pneumatic equipment. A © Ifthe power switch and air need to be left ‘on when carrying out some adjustment, be extremely careful to observe all safety precautions. Use only the proper replacement parts 2s ininjury. specified by Brother. sWhen carrying out inspection, If any safety devices have been removed, adjustment and maintenance be absolutely sure to re-install them to When replacing consumable parts such ‘their original positions and check that as the loopers, spreaders, knife and cutting block they operate correctly before using the mechine. © any problems In machine operation which result from unauthorized modifications to the machine will not be covered by the warranty. @ © @ Work clamp and cloth opener 4-1, Adjusting the work clamp lift height ‘The work clamp lift height is adjusted to 16 mm. (The lift height includes the clearance between clamp lever (B) @ and clamp lever L (R) @) Clamp arm 1. Insert the block or the thickness gage © between the work clamp © and the needle plate @ DHA898t 484. ADJUSTMENT. ——— 2. Loosen the screw @ of the presser driving lever ©, and put the end © of clamp lever (8) @ on the end ofclamp lever L(R) @ Note 1: Make sure that work clamp L (R) © securely holds the block or the thickness gage ©. Note 2: Make sure that work clamp cylinder is fully extended. 4-2. Adjusting the work clamp plate Before this adjustment, make sure that adjustment in 4-5 has been completed. Adjusting the position of the work clamp plate after the cloth is stretched out] “itis necessary to adjust the throat plate @ and needle plate (R) @ so thet they do not make comact during sewing. *The standard clearance between the throat plate @ and needle plate (R) @ is 0.5 mm (when the cutting ___ space isset 10 0). ST 1. Set CUTTING SPACE to O by the panel DIP switch B. 2. Selectthe FEED mode, and press the start switch, 3. Keep pressing the stert switch, and make sure that the clearance between the throat plate @ and needle plate (R) @ is 0.5mm. 4. Ifthe clearance is not0.5 mm, loosen the nut ©, and turn the bolt @ toadjust the clearance. Note: Adjust the clearance between the throst plate @ and needle plate (l) inthe same manner. 4-3. Adjusting the cloth spreading amount Refer to page 59 of the instruction manual. 4-4. Adjusting the position of the work clamp The back and forth and sideways movement of the work clamp can be respectively adjusted. ‘The work clamp. should be centrally positioned as to the needle movement. 1. For back and forth movement, loosen the screw @, and adjust the position of the clamp arm @; ‘for sideways movement, loosen the screws @, and adjust the position of the clamp lever @ 49 Dia9874. ADJUSTMENT @ Home position 4-5. Adjusting the X-axis home position Dimension a (when the looper base is at 0°) and dimension b (when the looper base is at 180°) from the stepped portion of the throat plate to both edges of the feed bracket must be equal. eens - ‘Set TACKING LENGTH D to 0 by the panel DIP switch A, and switch to the FEED mode. Remove the work clamp plate, and press the start switch. Novethe feed bracket, and measure dimensions a and b. Ifdimensionsa and bare net equal, turn off the power. Raise the machine head, secure it using the head support lever @, loosen the screw @, and adjust the position of the X-sensor set plate © in the diractionof the arrow. Return the machine head to its original position. Repeat the above steps from 1. Note: The X-axis home position can be adjusted in increments of 0.05 mm. 4-6. Adjusting the Y-axis home position ‘The clearance from the rear end surface of the feed bracket to the bed should be2 mm +0.2 mm. ‘After detecting the home position, measure the clearance from the rear end surface of the feed bracket to the bed. IFitisnot 2mm ¢ 0.2mm, tum off the power. Loosen the screws @, and move the Y-sensor set plate @ in the direction of the arrow. Repeat the above steps from 1. Note 1: The Y-axis home position can be adjusted in increments of 0.05 mm. Note2: If the clearance is too great, the movable knife and the throat plate may hit each other. He-9981 504, ADJUSTMENT 4-7. Adjusting 0 position (reference line) of the needle “The 0 position (reference line) of the needie isat the inside needle penetration points. “If the needle gage is changed, the 0 position (reference line) of the needle is not changed, only the outer needle cloth penetration positions are changed. S 2 Po S LPS, oe 0200000 00020000 om 1. Insert ashort needle (for adjustment). 2. Onthe operation panel, set KNIFE to OFF position. 3. Place a sheet of paper under the work clamp, and turn the pulley to trace where the needle will penetrate for an eyelet button hole on the paper. At this time, adjust the height of the short needle so that it can penetrate the paper with as small holes as possible. 4, When the inside needle forward doth penetration points are not identical with that of the returning ‘ones for the straight portion, remove the faceplate, and loosen the bolt ®. 5. Insert ascrewdriver into the arm from the left, and turn the zigzag eccentric pin @ to adjust. 4-8. Adjusting the home position of the looper base ‘The match mark in the looper base must be aligned with that on the bed. 1. After detecting the home position, make sure that the match mark @ in the looper base is aligned with ‘the match mark @ in the bed 2. Ifitis not, turn off the power. 3. Raise the machine head, secure itusing the heed support lever @, loosen the screws @, and move the sensor set plate @ in the direction of the arrow. 4. Returnthe machine head to its original position. Repeat above steps from 1. Note: The home position of the looper base can be adjusted in increments of 0.45°. 31 DHa-89814. ADJUSTMENT LNT el @ Cutter 4-9. Fine adjustment of knife position *Before this adjustment, make sure that adjustment in 4-7 has been completed, * The knife position should be adjusted so that it can correctly cut the eyelet button hole which is formed by ‘the portion where the needle will penetrate at the inside position and round the eyelet. “The back and forth and sideways movement, and inclination of the knife position can be independently adjusted. 1. Use ashort needle (for adjustment). 2. Set theair pressure of the regulator under the table to 0.2-0.3MPa. (This isto protect the hammer irom being damaged by the knife after the knife positionis adjusted.) 3. Select AFTER in the KNIFE erea on the operation panel. 4. Place a sheet of paper under the work clamp, and turn the pulley to trace where the penetrate for an eyelet button hole on the paper. 5. Meke sure that the portion where the needle penetrates for the eyelet button hole uniformly overlaps ‘the knife cutting positions. (For easier checking, change the value for CUTTING SPACE by the DIP switch B on the operation panel.) 6. Ifitisnot, turn offthe power, and adjust the position of the knife. edle will [Back and forth movement adjustment] ') Loosen the screw @, and adjust the position of ‘the knife. After adjustment, loosen the screw @, and press the block stopper plate @ against the knife. [Sideways movement agjustment] ') Loosen the screws @, @,and ©, of the knife bracket. li) Loosen the screws © and © of the knife bracket guide. i) Turn the knife adjusting screw @. Fine adjustment for sideways movement of the knife can be performed without removing the knife bracket and the knife bracket guide. UInclination adjustment] - i) Loosen the screws @, @,and @, of the knife T bracket. | Loosen the screw @, which secures the knife i bracket and the knife bracket guide. ) Turn the knife adjusting screw ©. Indination of the knife can be adjusted by rotating the knife bracket and the knife bracket guide, regarding ‘the pivot @ as the center. Diaagat 524, ADJUSTMENT Ne ee nn el 4-10. Adjusting the sideways movement of the cutter lever ‘The cutter lever should be positioned so that the knife can make contact with the center of the hammer. cutterlever Hammer Knife Loosen the nuts @ and @ ‘Tum the cutter arm support screws ® and @ to adjust the sideways position of the cutter lever. Tighten the nuts @ and @. Note: Adjust the cutter arm support screws © and @ so that the cutter lever has no end play, and it can Too much end play may damage the knife. vo 4-11. Adjusting the height of the throat plate Toprevent material from being pressed down by the needle which penetrates the material, the top surface of the throat plate @ should be flush with the top surface of the needle plate @. 1. Loosen thescrew ©, turn the set screw @ which fits the guide, and adjustthe height of the throat plate oe. Note: The set screw @ is adjusted to maintain the height of the throat plate when it is removed and re- installed. 53 DHe-89814. ADJUSTMENT. 4-12. Adjusting the heights of the spreader and the looper [Spreader height] *The clearance between spreader (L) and looper (L} must conform to the thickness of the looper thread. *The clearance between spreader (R) and looper (R) must be just enough that they can move. 1. Spreaders (R) @ and(L) @ move by means of the springs ©. Make sure that spreaders (R) @ and (L) @ move smoothly between the spreader stoppers (R) @ and (L) ©, and the Ls-holder bracket ©, withno looseness. 2. Hadjustmentis necessary, loosen the screws @ and move spreaders (R) @ and (L) © up and down. [Looper height] 1. Set the clearance between looper (L) @ and spreader (L) @ to the same distance as the thickness of thé looper (lower) thread. 2. Set the clearance between looper (R} © and spreader (R) @ to as small as possible, but make sure that they do not make contact. 3. IFadjustment is necessary, loosen theset screw @, and move loopers (L) © and (R) © up and down. DH4-2981 344, ADJUSTMENT tS 4-13. Adjusting the loop stroke Theloop stroke is the distance the needle bar rises from its lowest position to the position where the tips of loopers(t) and (R) are aligned with the center of the needle. The standard loop stroke is 2.7mm. (The loop stroxe may need changing depending on the material and thread being used.) a. Adjusting the timing between the needle and loopers (L) and (R) “Before this adjustment, it is necessary to make the amount until the tip of looper (l)is aligned with the center of the needle when the needle rises from its lowest position, and the amount until the tip of looper (R) is aligned with the center of the needle, equal. *Before this adjustment, set the needle zigzag width to 2.5 mm (standard), Needle ber lowest position Whenthe center ofthe needleisalicned ‘with thepointof the fcoper Ht. 1. Setthe needle bar to its lowest position. 2. Use calipers to measure the distance between the end of the needle bar @ and the top surface of neodle bar presser bracket (2) @. 3. When the needle © is at the inside sewing position, turn the pulley until the tip of looper (L) @ is aligned with the center of the needle, and measure the distance between the end of the needle bar © and the top surface of needle bar pressor bracket (2) @. Find distance a which is the difference between this distance and the distance obtained in step 2. 4. When the needie © is at the outside sewing position, find distance a’ in the same manner as in the above steps. *When the needle @ is at the inside sewing position, the center of the needles aligned with the tip of, looper (L) @, and at the outside sewing positi is aligned with the tip of looper (R) ©. 5. Distance a obtained in step 3 should be equal to distance a' obtained in step 4. 6. Turn the looper base © inthe direction of the arrow, loosen the screw @, and move the looper link @ up and down to adjust the LS-holder bracket © in the direction of the arrow (sideways). 55 Dya.n9814. ADJUSTMENT, b, Adjusting the loop stroke Before this adjustment, the timing between the needle and loopers (L) and (R) must be adjusted (as explained in 4-13.2). 27mm, Lo A a 1. Set the neadie bar to its lowest position with the needle at the inside sewing position, and use calipers - ‘tomeasure the distance from the end of the needle bar @ and the top of needle bar presser bracket (8) e. 2. Add'2.7 mm tothe value obtained in step 1. 3. Touch the end of the calipers against the top of needle bar presser bracket (8) @, and then turn the pulley until the end of the needle bar @ touches the edge of the calipers. Make sure that the tip of looper {L) is aligned with the center of the needle. 4. Inthe same way, make sure that the tip of the right looper is aligned with the center of the needle when the needle is at the outside sewing position. Endof clipes = 5. Ifthe tips of loopers (U) and (R) are not aligned with the center of the needle, adjust as follows: i) Reise the machine head. fi) Loosen the two set scraws © of the lower shaft tension pulley, hold the pulley so that it does not move, and then turn the lower shaft cam @ in the direction of the arrow until the tip of looper (L) is aligned with the center of the needle ©. Tighten the screws @. After adjustment, make sure ‘that the screws have been adequately tightened. *Basically, the machine is assembled so that the hole @ of the lower shaft cam @ is aligned with the hole © of the lower shaft base @ when the needle bar is at its lowest position and at the inside sewing position DHa8961 564 ADJUSTMENT 4-14, Adjusting the height of the needle bar The standard height for the needle bar is 2.5 mm, (The needle bar height may need changing depending ‘onthe material and thread being used.) j L las mm 1. Wen the need i at he ine sewing position, align the tip of looper (L) @ with the center of the needie®. 2. Remove the faceplate. 3. Loosen the screws @ of the needle barclamps @, and adjust the height of the neecle bar @. * First, align the tip of looper (L) @ with the top edge of the hole in the needle, and then lower the needle ber 25mm. 4. Torotate the needle bar smoothly, adjust so that there is as little play as possible and only enough to maintain the oil membranes of the needle ber clamps © and the needle bar level feed link ©. 4-15, Adjusting the clearance between the looper and the needle This adjustment is necessary when the needle size is changed. Set the clearance between the looper and the needle to 0.05-0.2 mm. —— 005-0.2mm “oN 1. Loosen the setscrew © to adjust the clearance. *The dearance must be uniform while the looper base is rotating (through 360°). If the clearances not uniform, adjust the turning center for the needle bar. (This adjustment is performed before shipment fromthe factory) 37 DwA.89814. ADJUSTMENT 4-16. Adjusting the needle guard ‘This adjustmentiis necessary when the needle sizeis changed. ‘The needle must remain stationary with respect to the needle guard, until the tip of the looper reaches the needle. 1. Loosen the screw @, and move the needle guard © in the direction of the arrows, by an appropriate amount in accordance with the ‘thickness of the needle @. Note: The looper must securely hook the needle thread. 4-17. Adjusting the spreader mounting position 1. Loosen the screw ©, and adjust the position of spr hole in looper (L) @ is between the forks spreader | 2. Loosen the screw @, and adjust the position of spreader stopper (R) @ so that the tip of spreader (R) © isaligned with the tip oflooper (7) @ Note: Both spreaders (L) @ and (R) © should be installed so that they do not project past the tips of Joopers (L) @ and (R)@, respectively. sder stopper (L) © so that the looper thread guide DHE-8981 584, ADJUSTMENT 4-18. Adjusting the spreader timing ‘When the needle is at the inside sewing position, spreader (L) should touch spreader stopper (L) and stop immediately before the needle bar reaches its lowest position. When the needle is at the outside sewing position, spreader (R) shauld touch spreader stopper (R) and stop immediately before the needle bar reachesits lowest position. 1. Raise the machine head, 2. Loosenthe screws ® and the nut , then turn the adjust screw © to adjust. 3. After adjustment, tighten the screws © and thenut@. Note: Make sure that the LS-holder bracket @ does not touch the spreader cam link @. IF it does, return to "4-13. a, Adjusting the timing between the needle and loopers (L) and (R).” 4-19. Adjusting the amount to pull the upper thread and tension release *The amount to pull the upper thread should be sufficent'y maintained to form the correct stitches at the start of sewing. + Tho upper thread take-up lever operates as soon as sewing is completed, and is released when the start switchis pressed to move the feed bracket with the needle stopped. 1. Loosen the screw @, and move the upper thread take-up lever guide @ up and down to adjust the amount to pull the upper thread, © The upper thread tension mechanism has double tension mechanisms. The main tension disc © is open after sewing iscompleted, and closed when the start switch is pressed to move the feed bracket, with the needle stopped. «The upper thread tension plate @ and the upper thread take-up lever are interlocked. The sub tension disc @ is always kept closed to give the upper thread tension. The tension will change the thread end length at the start of sewing. 59 DHe-89814. ADJUSTMENT 4-20. Adjusting upper thread trimming Upper thread trimming will be performed on the correct time after sewing is completed. ‘a. Adjusting the upper movable knife mounting position The mounting position of upper movable knife (8) @ is determined by the position of the lower thread preser®. oswg, iL 1. Loosen the screw ©, and position upper movable knife (8) @ between the projection of the throat plate @ and spreader (R) ©. 2. Adjust the clearance between the needle and the point of upper movable knife (B) @ 10 0.5- 1.0mm. Ifadjustment can not be performed, reconfirm 4-11 and 4-22, b. Adjusting the position of the thread trimmer lever bracket ‘When the needle is swinging to the right with the maximum stitch width, the needle should be able to ppass the upper movable knife sufficiently. 1. Loosen the nut @, and turn the screw @ to adjust ‘the position of the thread trimmer lever bracket. At this time, dimension a to the shoulder of the ‘thread trimmer lever bracket should be 10 mm. Note: Turn the looper base, and make sure that the thread trimmer lever bracket can smoothly go in under the thread timmer lever hammer. The height of the thread trimmer lever hammer is adjusted to 11 mm. H4-8981 604, ADJUSTMENT pn EEEEEEEEIEDSEEEEEEEeeeeemmmnl 4-21. Adjusting the lower thread trimmer [Adjusting the thread trimmer which can cut the lower thread and gimp, leaving them shorter] ‘The thread trimmer operates by means of an air cylinder when the feed bracketis at the home position. a. Adjusting the knife engagement Movable knives (L) and (R) should overlap each other by approx. 1 mm. 1. Loosen the screw. 2. With springs (1) @ and (R)_@ attached to movable knives (1) @ and (R) ©, align the end of thread trheg ink lever) © with the match mark on the rear of the link fulcrum plate @, and tighten the screw Note: Make sure that the movable knife driving cam @ and thread trimmer lever arm(B) © rotate smoothly without any gap. 3. Move thread trimmer link lever ()) @ to check engagement between movable knives (L) @ and(R) ©. If the-engagement is insufficient, return to step 2 to perform fine adjustment so that the end of thread ‘trimmer link lever (J) © overlaps with the match mark on the rear ofthe link fulcrum plate @. 51 bHa.3981‘4, ADJUSTMENT b, Adjusting the knife pressure Adjust the knife pressure to the lowest where the knife can still cut the material. 1. Loosenthenut @. 2. Turn the stud screw @ to adjust the knife pressure. Note: When the stud screw @ is fully tightened, the movable knife will not operate. Tighten the stud screw @ slowly while checking that the movable knife can operate smoothly. ¢. Adjusting the gimp pull force and tension “The gimp should be completely sewn in a few stitches at the stort of sewing, and the gimp end length ‘rom the stitches should be as small as possible. *The gimp is pulled by utilizing the difference in distance between gimp thread guide () @ and gimp thread guide (¢-J) @ when the looper base returns 1000" from 180° after the gimp is rimmed. *The gimp is trimmed when the feed bracket is at the home position. When the stitch length is changed, dimensions 8 and A will change. Its necessary to adjust the force to pull the gimp. ‘Also, dimension A differs according to the gimp type and the gimp tension, so it is necessary to adjust ‘the force to pull the gimp. Thesinpistinnet The amped athe areotseing ‘hou ape pone ftomnentan ‘ J) Larger eT y] <= Looper base at 180° Looper base at 0° Pe sine end lenathat te ord 1. Loosen the screw ©, and adjust so that the gimp appears about 2 mm from the first covering stitch at the start of sewing. Note: The tip of the gimp is pressed down on the material by a few stitches at the start of sewing, and pulled by the movement of the feed bracket. if the gimp is excessively taut when the feed bracket is at the sewing start position, or dimension Ais too small, the gimp may come out from under thestitches. bHA-8981 64, ADJUSTMENT ‘When the looper base rotates andthe gimp @ is pulled, the gimp tension at the side of the spool stand should be stronger than that close to throat plate, regarding gimp thread guide()) @ asthe center. During sewing, on the contrary, the tension should be weak so that the gimp can be sewn under the stitches, <210v> encov> ov 100V tiov oy a2ov Gv Zany 240 co0V 4 41G7 oy 220) 2any amy anv AV © ©0609 0696 Input side Powersupply Input side Powersupply Input side Power supply re eee ret board Great bong ue de ro <:20v> oy 1a0y Trov Ov a0 OY 2257 Zev aan OV AN OY 2am day aay nV aa © @9 06 090 Input side. Powersupply Inputside. Power supply Input side. Power supp “reat boo veut bond Peer Pm ae aoe “oe bHa8961 2D5. POWERSUPPLY EQUIPMENT crear ofthe control bor>5, POWER SUPPLY EQUIPMENT EEE EEE EE NNE nee eat 5-2. Fuse explanation Before replacing a fuse, besure to read "Before replacing a fuse" on the following page. If a. component on a PCB isdamaged, a fuse may blow again immediately even when ithasbeen replaced. ‘When replacing a fuse, be sure to use the specified ones listed below. No. Part name Part code | Manufacturer ‘When a fuse has blown 1 | fuse AFB) s08030-o0o [7¥° Fuse Company | The feed mechanism does not (quick melting type, 5A-250V) TOYOSA —_| operate. G fuse (SAFB) |Toyo Fuse Company | The machine motor does not $0803 2 | quick melting type, 5A-250V) 0-000) Tovosa | turn, 3 | Fuses 153242-000 fl! Tanshi Company] The power amps not It, and (lass tube fuse, 64-250V) FBO nothing operates. 4 | Fase +53242.000 Fi Tansti Company| The power lampis not lit, and {glass tube fuse, 64-250V) FGBO nothing operates. ear i498! n5. POWER SUPPLY EQUIPMENT Before replacing a fuse Separate connectors P5 (DC300) on the power supply circuit board, and measure the resistance with the — _ | polarities asshown in the figure. If the fuse has blown due toa short-circuit, replace the power supply circuit board, Al | eo. esKooa3- rate connectors P1 (POWER) on the power supply ircuit board, and measure the resistance between 4 and 7 on the board with the polarities as shown, inthe figure. LAK If the fuse has blown due toa short-circuit, replace the y power supply circuit board. fe) | tI. u iY Separate connectors P15 (DC300) on the contro! circuit board, and measure the resistance between pins 1 and 2 on the board with the polarities as shown inthe figure. If the fuse has blown due toa short-circuit, replace the power supply circuit board. € k Separate connectors P1 (ACIN) on the power supply 2 circuit board, and measure the resistance of the three places between A and B, A and C, and B and C on the board with the polarities as shown in the figure. : If the fuse has blown due to a short-circuit, or the resistance between A and C or B and Cis not infinity, replace the power supply circuit board. B DHe-89815. POWER SUPPLY EQUIPMENT LT 5-3. Connectors ‘Most of the machine trouble is due to connector problems including improper connection or insufficient contact. Therefore, be sure to check if each connector is correctly inserted and that there is no contact failure between pins and wires before starting troubleshooting procedures. 5-3-1. Connector positions Head harness relay For ¥-axs pulsemotor (red) For Xanls pulse motor (white) ‘— ForY-anis puise motor (blue) For @-axishome potition sonsor For Bais pulse motor (red) DH4-B981 . a5. POWER SUPPLY EQUIPMENT See eee Outside of the control box For specificationhomess For hang switch {For foot switch) Control circuit board Pig #20. OPTION pat Pa t_ Bay — te ns cS 8 PANEL fz Ss a HEAD - = "1 voll She Po le Pa exn U a ie gO 8a] P25 FANG. J Fo FAN »y ——tal] om eT — — Piz |—Foer PIB. By PIB. oe Bes ns . ockdé 5 DHe-s981POWER SUPPLY EQUIPMENT. Powersupply circuit board Ps 1c300 pet Power Pa CIN ° Fa °2 pcre PER Panel circuit board °3 ‘OPTION o oO Pa rH a WE 2 a EXTRS c ©, {0 ] a to | PMD PCB for 8-axis shaft —P ° a-s] conto Dras961 765, POWER SUPPLY EQUIPMENT Indexer mechanism (optional) “The harness which relays the valve of the incexerisinsertedintoconnector P21 EXOUT) ofthe control circu boar, Indexer sensor harness is inserted intothe relay connector for -axis ‘home pesitionsensor.. Relays the vahe hesness ofthe indexer, Select switch mechanism (optional) ‘Select switch harnessisnsertedinte connector 3 (OPTION) of the panel cicuit boars. 7 bH4-B981 6.5. POWER SUPPLY EQUIPMENT LOE ee 5-3-2. Signal names for connectors and probable symptoms due to poor contact © Relay connectors ‘*For X-axis pulse motor (MOLEX 5557-06R, 5559-O6P) Pinno. Signal name Probable symptoms due to poor contact 7 BeanisP dng eurent OA) 7 Teftandightmorement of feedbracket inoteorreet 2 - Home postion can note found. 3 + EnrorE8 appears 2 ands PM driving eurene OO) 5 eaxis PM driving current XE) é = ‘*For ¥-onis pulse motor (MOLEX 5557-068 [blue], 5559-06? [bluel) Pin no. Signal name Probable symptoms due to poor contact, 7 SHEP diving current VAD jack ard forth movement al feod bracts notcormeck 2 | Weaxispe diving currant 2) «Home postion can notbe found. 3 "Y-axisPM ariving current YO) + Eror€B1 appears. rn "YeaxisPM diving current YD) S| Y-axis Pa driving current (VE) = = For 8-axis pulse motor (MOLEX 5557-06R [red], 5559-O6P [red) Pin no. Signal name Probable symptoms due to poor contact 7 ‘axis Pv driving currentiRA) ~ Needlebar motionis not correct z ‘axis PM driving current (RB) + Home position can notbe found. 3 (Gays PM erving current (RC) + Error 82 appears. « ‘axis PM driving current (RD) 5 ‘@axis PM driving current (RE) = = ‘*For 8-axis home position sensor (AMP 172163-1, 172171-1) Pin no. Signal name Probable symptoms due to poor contact “+50 (or @-axishome position sensor ~ Home position can not be found Vv = Error E52 or £82 appe: 2a + ndexer does not work property +24 (For rightoylindar driving sensor) (when inderer is attached) + One of errors £06, £07, £36, 37,£38,£66,E67, and £68 appeas. ‘Caxishome position sensor signal Feed plate home position sensor signal (when indesar is attacned) Reserved we fo] ~ fafa} > fujrl Right cylinder driving sensor signal ‘(whenindever ivattached) Left cinder driving sensorsignal (when indexer sattacred) a {0V (for8-axis home pestion senson) 2 (OV (forfeed plate home pesiton sensor) (when indexer igattached) @ w 4 (0 (forright eyinder driving senso) (whenindererisattached) 1s OV {forleft eyinder drivingsensor) (whenindexerisattached) Dw4.8981 785, POWER SUPPLY EQUIPMENT SN + For specification harness (MOLEX 5557-16R, 5559-16P) Fin no. Signal name Probable symptom due to poor contact, 7 TYPE (COM) 7 Error code E09 appears. 2 TvPE2 (com) 3 TWPE3 (COM) a TPE a (COM) 3 “TYPES (COM), 6 "TYPES (CoM) 7 “TyPE7 (COM) 8 TYPES (COM 3 TYPEL 10 TyPEZ 1 TPES 2 Types cE TYPES: 14 TWPE6 15 TVPE7 16 TYPES = For hand switch (foot switch) (AMP 172 161-1, 172169-1) Fin no. Signal name Probable symptom due to poor contact 7 Work clamp switch signal commonsidel | + work clamp doesnot work when work clampawitih a pressed 2 Work lamp switch signal + Machine does not start. 3 Reserved (commonside) a Reserved 5 ‘Ground z = 7 ‘Start awich egal (common tide) & Stertowiteh signal 3 = +» For indexer valve (MOLEX 5025-15P1, 5025-15R1) (when indexer is attached) Fin no. Signal neme Probable symptom due to poor contact, 7 Reserved "indexer doesnot work propery 2 Reserved + One of error codes E07, E37, E38, 66, E67, and ESB appears. 3 eserves a Feed plate fixing valve motionsignal 3 Chuck valve motion signal 6 2a 7 2a 8 2a 3 1 24V (for feed plate ring valve, 10, + 24V (forchuck valve) 1 Feed plate driving valvesigral 32 = 24) (for feedplate driving valve) 3 = ree n DH4-B98T5. POWER SUPPLY EQUIPMENT TS © Connectors to be attached to control circuit board ‘= Pt [ORG] (JAPAN SOLDERLESS TERMINAL MFG. CO., LTD. XHR-12) Pinno. Signal name Probable symptom due to poor contact = T Home position ean not be found. Xcavis home postion sensor signal + One of error codesE50, £51, £80, nd EBt appears. ‘OV (for Xan home postion serser) “+5 (for X-ans home position sensor) "Yoanis home postion sensor signal ‘OV for V-axishome position sensor) -+5V (for Y-avis home position sensor) n = 1 = 72 = ‘#2 [SYNCHRO] (JAPAN SOLDERLESS TERMINAL MFG. CO., LTD. XHR-5) 9 Pinno. Signal name Probable symptom due to poor contact i esd Machine motor doesnot run, z Encodertiming signal ‘One of error codas £10,€40,£70,£71,£76,£77, and E81 appears. 3, ‘Neeaile down signal 4 Needle up signal 5 ov ‘+3 [HEAD] VAPAN SOLDERLESS TERMINAL MFG. CO.,LTD. XHR-9) Pinno. nal name Probable symptom due to poor contact 7 ‘Emergency dap switchnormal lose signal | - frrorcodeE6) appearsand machine sops. z OV for emergency stopswitch) ‘Onecof error codes 00,£12,£30, £42, and E72 appears. 3 Emergency stop switer normal opensignal 2 = 5 = € = 7 “BV (for krife ON sensor) 8 Knife Of sensorsignal 2 ‘Knife OW sensor cathode '# P4 [AIR] UAPAN SOLDERLESS TERMINAL MFG. CO.,LTD. H12P-SHF-AA) Pino. Signal name Probable symptom due to poor contact. i Upper thread adjuster valvesignal ~ Upper thread adjuster does not work. 2 Upper thread trimmer valve signal + Upper thread can not betrimmed. 3 Lower threed triemer valve signal Lower throad can not be trimmed. + a Knife driving valve signal + Knifedoes notwork. 5 ‘Cloth opener valve signal + Cth opener does not work. 6 = = Work clamp dost not work. 7 = = One of error codes £12, £15, £42, £45,£72, and £75 appeavs. e ‘Work damp valve 2 = 7 24V (for work damp, cloth opener, and lower thease trimmer) “174 (Tor upper thread adjuster, upper ‘thread trimmer, and knife criving) @ = Dw4-8981 805, POWERSUPPLY EQUIPMENT Meee ne en eee cn el ‘*P5 [SOL] (not connected) P6 [YPN] (JAPAN SOLDERLESS TERMINAL MFG. CO., LTD. VHR-SN [blue] ) Pino. Signal name Probable symptom due to poor contact 7 "Yan Paving corent VA) ~ Backard ont motion of feed brackets nat correct. 2 Y san PM driving current 9B) Home petition an not be found. 3 "Yani PM driving current YC) + Errorcede £51 appeas. 4 "Yan PM diving current YD) = YPM ving curren E) ‘©P7 XPM} JAPAN SOLDERLESS TERMINAL MFG. CO., LTD. VHR-5N) Pinno. Signal name Probable symptom due to poor contact 7 “canis PM driving current AY ~ Left and right motion of feed bracketis notcorrect. 2 “Xeanis PM driving current XB) + Home position can not be foune. 2 axis PM driving current OO) + ror code £80 appears a X-axis PM driving current OD) 3 eanls PM diving curent XE) ¢P8 [EXINA] UAPAN SOLDERLESS TERMINAL MFG. CO., LTD. PHDR-16VS) Pin no. Signal name Probable symptom due to poor contact 7 O (forhesd safety switch) ~ One of error codes £02, £15, £32, 48, £62, and E75 appears. 2 Headsafety switch signal 3 = @ ‘OV orlower thread wiring OFFsensom) 5 Lower threed trimming OFF sersor signal . -24V forlower thread trimming OFFsensor) Z = $ = : 2 = 10 = 1 = 72 = 3 = 14 = 15, = 16 = 81 Dia.a9815. POWER SUPPLY EQUIPMENT eel ‘#P9 [EXINB] (JAPAN SOLDERLESS TERMINAL MFG. CO., LTD. PHDR-18VS) Pin no. Signalname Probable symptom due to poor contact 1 OV (forleft cylinder driving sensor) (whenindexerisattached) * Home postion can notbe found. + Error code £52 and E82 appears. 2 Left ejinder driving sansorsignal (whenindexoris attached) + Indexer does notwork properly. = Oneof error codes£05, £07, £36, £37, £38, 666,67, and E68 +24V forleft glinder diving sensor) (whenindexerisattached) appears. ‘OV (Forright cylinder driving sensor) (when indexer isattacned) Right cylinder driving sensor signal (whenindexerisattached) “¢24V forright cylinder driving sensor) (when indexer isattached) DV (for feed plate home positon sensor) (whenindevar ieattached) Feed plate home portion sorsorsigral (whenindoxarisattached) 2 '+24V for feed plate home postion sensor] (when indexer isattached) cE ‘OY (for @-axls home postion sen501) 14 ‘@.axishome position sensor signal 15 +24v. 76 +5v 7 +5 18 “+5 (lor @anishome position aso) PIO [FAN-R] (APAN SOLDERLESS TERMINAL MFG. CO.,LTD. PHR-3) Pin no. Signal name Probable symptom due to poor contact 7 saa 7 Error code £99 appeers, Fan lock enor signal 2 3 ov P11 [HATOME] (JAPAN SOLDERLESS TERMINAL MFG. CO., LTD. PHDR-12VS) Pin no. Signal name Probable symptom due to poor contact ~ Rotation mation of feed mechanism snotcorrect. + Homepesition can notbe found. + Brror code £52 or E82 appears. ‘Banish dock signal ‘GaxisPM irectonsignal ‘BaxiePih rave sgnal D-axsPM excitation signal =5v =5v ov sls felo]sofa|>fuo|m]— ‘ov oka.a9815. POWER SUPPLY EQUIPMENT Hee nn a cc ce RAED E RARE «P12 [POWER] (JAPAN SOLDERLESS TERMINAL MFG. CO., LTD. VHR-7N) Pin no. Signal name Probable symptom due to poor contact 1 ra ~ Power doesnot come on. 2 a 2av Feed bracket doesnot move, 3 av + Machine operation becomes unstable. 4 1384 + Home position can netbe found. * + Error code £80 apear 6 ov (POV) pears, z 9v (FOV) «P13 [DC55] JAPAN SOLDERLESS TERMINAL MFG. CO., LTD, VHR-2N) | Pin no. Signal name Probable symptom dueto poor contact Hv 7 Feed bracket doesnot more. + Home positon ean notbe found 2 ov OM) + Error code FB0 appear. «P14 [UVW] (MOLEX 3191-0381) Pin no. Signal name Probable symptom due to poor contact. 7 Twachine motor phase 7 Machine mator 608s aot Fun, ‘Machine motor phase + Rotationof machine motor notcorrect. 3 Machine motorW phase + Error code £70 oF 91 appears. ‘+ P15 [C300] (MOLEX 3191-02R1) Pinno. Signal name Probable symptom due to poor contact 7 (V (lor machine motor) ‘Machine motor dossnot run. + Rotation of mactine moter isnot correct. 2 +3007 + Error code £70 or £91 appears. «P16 [DC18] JAPAN SOLDERLESS TERMINAL MFG. CO., LTD. PHR-11) Pin no. Signal name Probable symptom due to poor contact + ev AE ~ Machine motor does not run. Rotation of machine motoris not correct. ‘OW (AV) 3 Tevierey + Error code £70 or £91 appears. ‘ov Gov) Fiavicrauy ov (COV) “+ 16V(D16V) Lavon, +P 17 [EXPN] (not attached) «P18 [PANEL] (JAPAN SOLDERLESS TERMINAL MFG. CO., LTD. XHR-10) Fin no. Signal name Probable symptom dueto poor contact ow ~ Wo keys onpanel areactivated. ov Send (CHO) [DIR (CHO) Receive (CHO) DSRICHO) nv =v 5v Jz |o| c/s fonfun]a fos po] =v 83 DHag9815, POWER SUPPLY EQUIPMENT LT © P19 [FOOT] WAPAN SOLDERLESS TERMINAL MFG.CO.,LTD. PHR-6) Pinno. Signal name Probablesymptom due to poor contact 1 Start switch signal common side) ~ work damp does not move when work damp switch presed. z Start sich + Machinedoesnot start, 3 "Work clamp switehsignal Gammon side) a ‘Work clamp switchsignal 3 Reserved (common side) é Reserved © P20 [PER] UAPAN SOLDERLESS TERMINAL MFG.CO., «LTD PHR-5}) Pinno. Signal name Probable symptom due to poor contact ol Relay condition Input ~ One of error codesE26,£92, £98, and £99 appears z Primaryvoltage detect 3 Reley OFF output « +55V OFF output 5 ov © °21 [EXOUTI (JAPAN SOLDERLESS TERMINAL MFG. .CO.,LTD. H10P-SHF-AA) (when indexer is attached) Pinno. Signal name Probable symptom due to poor contact Feed plate drving valve notionsigral "indexer does not work propery. 2 Chuck valve notion signal + One of ror codes E07, £37, £38, £66, £67, and 268 appears, 3 Feed plate fing valve motion signal ¥ Reserved 5 Ressrved < Ressrved 7 = = = + = 10 28 1# P24 [OPTION] (not attached) (#25 [FAN-L] (JAPAN SOLDERLESS TERMINAL MFG.CO.,LTD. PHR-3) Pinno. Signal name Probable symptom due to poor contact o 2 3 28 Fanlockerto” signal ov ~ Error code€Sd appears 4-98POWER SUPPLY EQUIPMENT © Connectors to be attached to power supply circuit board © 1 [POWER] (JAPAN SOLDERLESS TERMINAL MFG.CO.,LTD. VHR-7N) Pin no. Signal name Probable symptom due to poor contact 7 av T Power does not come on. 2 +28 + Feedbracket does not move, 3 7 + Machine operation becomes unstable. a +55 + Home postion can not be found. 5 +55 + Errorcode £80 appears. 6 BV POV) 7 ov POV) ‘© P2 [PER] (/APAN SOLDERLESS TERMINAL MFG.CO.,LTD. PHR-5) Signal name Probable symptom dueto poor contact 7 Relay condition input ~ One of errr codes E26, £92, E98, and E99 appears. 2 Primary voitage detect 3 Relay OFF outout a +55 OFF output 5 bv ‘© P3 [DC18] JAPAN SOLDERLESS TERMINAL MFG.CO.,LTD. PHR-11) Pin no. Signal name Probable symptom due to poor contact i +180 (IBV) ~ Machine motor does notrun. z Dv (RoW) + Rotation of machine motor isnot correct, 3 = Enot cede €700r E91 appears. a + 18 (6T8V) 5 OV GOV) ~ = 7 “+ iev (Ciev) 3 avicow) 3 = 70 +18 (DIBV) u ov wow) © PA [ACIN] (JAPAN SOLDERLESS TERMINAL MFG.CO.,LTD. LP-04-2V) Pinno. Signal name Probable symptom due to poor contact 7 ACinput T Pawerdosendt comer. 2 + Machine operation becomes unstable. a = + Error code E92 appears. a Ground ‘© P5 [DC300} (MOLEX 3191-02R1) Pin no. Signal name Probable symptom due to poor contact 1. | ov (for machine motor) ~ Machine mater does not run. + Rotation of machine motor isnot correc. 2 +300 + Error code £700r £91 appears. 85 DHe-3981NNN Enea neeme ean at © Connectors to be attached to panel circuit board 5. POWER SUPPLY EQUIPMENT ‘©P1 [MAIN] UAPAN SOLDERLESS TERMINAL MFG.CO.,LTD. XHR-10) Pin no. Signal name Probable symptom due to poor contact ov, ~ No kayson panelare activated ov, Send GHO), DIRIGIO) Receive (CHO) DSR (CHO) anv av v 3v ‘©P2 [EXTRS] (not attached) ‘©P3 [OPTION] (APAN SOLDERLESS TERMINAL MFG.CO.,LTD. XHR-8) (when select switch is attached) Pin no. Signal name. Probable symptom due to poor contact 7 TED ouput Select awitch ib notactiveted. 2 LED outputs + Select switch LED does not ight. 3 LED output @ Switching ut, 5 ‘Switehinput 6 Suitchinpute 7 Resetawiteh inpit 3 ‘Common input ‘@P4 [TYPE] (JAPAN SOLDERLESS TERMINAL MFG.CO.,LTD. PHDR-16V5) Pin no. Signal name Probable symptom due to poor contact 1 TYPE 1 (COM) « Error code £09 appears. 2 Tweet 3 “Tyee 2(CON) a TYPE? 5 TPE 3(COMD 6 TPES Z TYPE #(COMD 3 TYPE a 9 TYPE 5(COM) io | hees rT TPE sion) 12 | Tes 73 Tyre 7(COM 14 TyPET 15 Tyre a(Con 16 az ont-a9e1 865. POWERSUPPLY EQUIPMENT Hee ee eee el © Connectors to be attached to PMD PCB for 8 axis Pt IRPM] VAPAN SOLDERLESS TERMINAL MFG.CO.,LTD. VHR-6N) Pinno. Signal name Probable symptom due to poor contact 1 apis FM diving current A) * Needle ber motionisnot corect. 2 ‘Canis PM driving current (RB) + Home position can not be foune, 3 ‘axis PM driving current (RC) + Error code €52 £82 appens. a ‘axis PM driving current (RO) 3 ‘axis PM driving current (RE) + = ‘¢P2 [DC55] VAPAN SOLDERLESS TERMINAL MFG.CO.,LTD. VHR-2N) Pine. Signal name Probable symptom due to poor contact 7 =] ~ Feed bracket doesnot move. + Home positon cannot be found. 2 ov (POV) - E1ror code EBO appears. ‘#P3 [CONTROL] (JAPAN SOLDERLESS TERMINAL MFG.CO..LTD. H8P-SHF-AA) e Pinno. Signal name Probable symptom due to poor contact 7 Canis PW clock sgnal ~ Needle bor motionisnot eorex 2 ‘-axis PM direction signal + Home position cannot be foune. 3 Cons PM seve signal + Error code £52 oF £82 appears 4 C-anis PM excitation signal 5 35V, ‘ 7 7 ov 3 ov a7 DHe-89815. POWER SUPPLY EQUIPMENT 5-4. Specification harness connections * The broken lines are only for -52 specification. ajojo . A s|2[3]+[>|sfo[]-[-]-]-] v 16 }------~ bi4.8961 8B5, POWER SUPPLY EQUIPMENT SS 5-5. Summary of DIP switches ‘Always turn off the power supply before changing any of the DIP switch settings. 1) Front panel DIP switches ‘The ON/OFF positions of the DIP switches inside the front panel are checked only once when the power is tumedon. Any changes to the DIP switch positions will not be effective until the power is swiched off and back on again. Factory default settings Caliswiches areset 9 OFF Sith pitch Tamm No. of eyelet stitches Standard no. of stitches Taper bar tacking length mm Knife operation method Cutting after sewing Eyelet shape Eyelethove (No. 2) Offset 4.5mm Cutting space 0.2 mm. Sewing speed 7,800spm Mode Tatomatie made e 5 Changing cutting on/off, stich Panel protaction Tength setuings alowed Fam settng por Horizontal seting No. of eyelet holes 7 (52specifcations) Panel DIPswitch A No. conor | Description ON, ON, ON Stiteh pitch = 1.8mm ON, ON, OFF Stitch pitch = 1.6mm. ON, OFF,ON Stitch pitch = 1.4mm ON, OFF, OFF Stitch pitch = 1.3mm ‘203 V OFF OFF, OFF Stitch pitch = 12mm ‘OFF, ON, ON Stitch pitch = 1.1mm € ‘OFF, ON, OFF Stitch pitch = 1Omm OFF, OFF,ON. ‘Stitch pitch = 0.9mm. ON,OW No. of eyelet stitches = Standard no. of stitches + 1 4s OFF, OFF No. of eyelet stitches = Standard no. of stitches " ‘ON, OFF No, of eyelet stitches = Standard no. ofstitches- 1 ‘OFF, ON No. of eyeletstitches = Standard no. ofstitches- 2 ‘ON, ON, ON Taper bar tacking length = 10mm ‘ON, ON, OFF Taper bartackinglength = 9mm ON, OFF,ON ‘Taper bar tacking length = 8mm ‘ON, OFF, OFF 7mm 67.8 V OFF, OFF, OFF iength = 6mm ‘OFF, ON, ON ‘Taper bar tacking length = 5mm ‘OFF, ON, OFF “Taper bar tacking length = 4mm OFF, OFF, ON “Taper bar tacking length = omm 89 DHa-39615. POWER SUPPLY EQUIPMENT LOE ne el Panel DIPswitch B No. ON/OFF Description 1 ON Cutting after sewing OFF Cutting before sewing ‘ON, ON Straight buttonhole (No. 5) ON, OFF Eyelet buttonhole (No. 3) 23 OFF, OFF Eyelet buttonhole(No. 2) OFF, ON Eyelet buttonhole (No. 1) ON Offset = 1.2mm ‘ OFF Offset = 1.5mm ‘ON, ON Cutting space = -0.1 mm ‘ON, OFF Cutting space = Omm 56 OFF, ON Cutting space = 0.1mm (OFF, OFF Cutting space = 0.2mm ‘ON, ON ‘Sewing speed = 2,000spm ‘OFF, OFF Sewing speed = 1,800spm ne ON, OF Sewing speed = 1,600spm ‘OFF, ON ‘Sewing speed = 1,400spm Panel DIPswitch ¢ No. ON/OFF Description ON, ON spare ON, OFF Feed mode 12 OFF, ON Manual mode OFF, OFF Automatic mode ; ON Changing cutting orvoff, stitch length settings prohibited OFF, ‘Changing cutting onvoff, stitch length settings allowed ON Spare ‘ OFF Spare ON Spare 5 ‘OFF Spare ox ‘ON Left setting . OFF Horizontal setting ON, ON No. of holesper cycl ON, OFF No. of holesper cycle 7.88 | OFF, OFF No, of holes percych OFF, ON No. ofholespercycle = 3 & Valid only for -52 specifications Dw4-2961 905, POWER SUPPLY EQUIPMENT 2) Circuit board DIP switches A DANGER A © 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. The ON/OFF positions of the DIP switches inside the front panel are checked only once when the power is turned on. Any changes to the DIP switch positions will not be effective until the power is switched off and back on again. Circuit board DIP switch No. ON/OFF Description ‘ON 1 pedal (for start switch) ' OFF 72 pedals (for cloth presser switch and start switch) ON Front position setting (reduces cycle time when cutting after sewing and no 2 __ lower thread trimming are set) OFF Back position setting (reduces cycle time when cutting before sewing and no tower thread trimming are set) ‘ON Cloth presser ONafter sewing 3 OFF ‘Cloth presser OFF after sewing ‘ON Upper and lower thread trimming ‘ OFF Upper thread trimming Ow Spare 5 OFF Spare ON Spare 6 OFF Spare , ON y ‘Spare OFF Spare ON ‘Spare € 5 OFF ‘Spare Themachine is shipped from the factory with the DIP switches set as follows. oF ‘DHa-B9815. POWER SUPPLY EQUIPMENT. Gircuit board DIP switch D No. ON/OFF Description ON Spare ' OFF Spare ON Spare 2 OFF Spare , ON ‘Spare 3 OFF ‘Spare ON ‘Spare 4 OFF Spare ON Spare 5 OFF Spare ON Spare 9 § OFF Spare © ON Spare 7 OFF Spare ON Spare 8 OFF Spare ‘The machine is shipped from the factory with the DIP switches set as follows. DHe.898t 925, POWER SUPPLY EQUIPMENT 5-6. Using the memory switch The condition of the memory switch is memorized even if the power is OFF, however, if data of the memory switch is initialized, the memory switch will become OFF. Thememory switch is OFF at shipment. Turn on the power, while pressing the KNIFE switch O. Set the desired memory switch number at the left of the Number display window @ by pressing the “Up" switch @ or “Down' switch ©. 1. Set the Knife to ON (” =") or OFF (" £ 3. When the home position is detected, the X-axis home position sensors turned on a \ 4. ifthe X-axis home position sensor is out of order, its connectors are not attached correctly, or the cord does not flow electricity, error code E-50 or E- 80will appear. The Y-axis home position sensor determines the home position of the feed bracket in the Y direction. .. The Y-axis home position sensor is set to on only ‘when the feed bracket is at the home position. . If the Y-axis home position sensor is out of orde:, its connectors are not attached correctly, or the cord does not supply electricity, error code E-51 or E81 will appear. 3) Looper base home position sensor (-axis home position sensor) 1. The looper bate home position sensor determines therone position of the looper base (when itis at 2. The looper base home position sensor is set to on only when the looper base is at the home position. 3. If the looper base home position sensor is out of ‘order, its connectors are not attached correctly, or ‘the cord does not supply electricity, error code & # 52 or E-82 will appear. - 5 Dia-89615. POWER SUPPLY EQUIPMENT 4) Knife ON sensor 1. The knife ON sensor is intended to sense that the oper and to know thecutter lever @ liftstroke. ration of the cutter lever @ has been completed, 2. The cutter sensor partition plate (slit) © is attached to link (C) @ which moves the cutter lever @. The signal is sent from the cutter sensor @ mounted on th 5) Lower thread trimmer OFF sensor oHas9a1 e bed. |. The lower thread trimmer OFF sensor is attached to the cylinder which drives the lower thread trimmer. The lower thread trimmer OFF sensor is intended to mak the lower tread trimmer securely st to off. If the lower thread trimmer OFF sensor is out of control or attached incorrectly, its connectors are not attached correctly, or the cord does not supply electricity, error code E-15, £-€5, or £75 will appeer.5, POWER SUPPLY EQUIPMENT 6) Safety sensor 1. The limit switch Is attached to the front of the bed. 2. The safety sensor is intended to check that the i machine head is positioned correctly for safe operation. 3, The safety sensor will be activated to stop all 0 motions when the machine head is raised during sewing. @ | 4 I the machine. head is kept raised, the safety fo sensor is out of control, its connectors are not attached securely, or the cord dees not flow electricity, error code £-02, E-32, or £-62 will appear. 9 Ha-p9eté 6. AIR PRESSURE MECHANISM 6. AIR PRESSURE MECHANISM A CAUTION 8 ‘© Machine installation should only be carried outby a qualified technician. © Disconnect the air hoses from the air supply end wait for the needle on the pressure gauge to drop to “0” before ‘arrying out inspection, adjustment and repair of any parts which use the pneumatic equipment. A ‘@ If the power switch and air need to be left ‘on when carrying out some adjustment, be extremely careful to observe all safety Precautions. @ Turn off the power switch at the following times, otherwise the machine may operate if the start switch is depressed by mistake, which could result ininjury. 6-1. Solenoid valves and air tubes 1) Adjusting the solenoid valve speed controllers ‘There are 3 speed controllers: No.3 (for lower thread trimming), No. 5 (for upper thread trimming), and ‘one for the kni a st Bt lel 8 ie] 2 [ tomm 1. As for the No. 3 and No. 5 speed controllers, adjust their heights to 10 mr. Note: If the speed controllers are excessively throttled, error codes including £-75 (lower thread and operations are incorrect) and E-76 (upper thread operation is incorrect), may appear. 2. The exhaust throttle valve is only attached to the OFF side of the knife valve. Adjust the protrusion of the speed controller to 7.2 mm. Note: If the speed controllers are excessively throttled, error codes including £-72 (cutting block operationis incorrect), may appear. If excessively opened, abnormal noise may be emitted when the knife cylinder returns. oHe.2981 86 AIR PRESSURE MECHANISM 2) Airtubes iF tubes coming out from the left of feed bracket and cylinders Work clamp. Gylinder, 16x 100 Cloth opener Gylinder assy, A 16x 15@, Cylinder assy, B 16x 15@ Lower thread trimming ————— Gylinder assy, B 16x30 iv) Sub presser — Cylinder assy, 10% 153 2. Airtubes coming out from the rear of belt cover R and cylinders Vv) Upper thread tightening ———— Cylinder assy, 10x 15@ vi) Upper thread trimming —-——— Cylinder assy, 10 x 15 vii) Knife Cylinder assy, 63 x 100 © 6-2. Airtube layout ‘Work clamp cylinder work clamp eytnder be aa ef S od a 9) in | i 5 3 | PK @ w. fe a g ii) i) 6, 5, 99 Ha.89816. AIR PRESSURE MECHANISM [Reference] Dimensions for cylinder rod assembly Upper thread release cylinder and sub presser cylinder 2,_Upper thread trimming cylinder 112 (ain) 3. Cutter cylinder 234 (Min) beaasa1 1006. AIR PRESSURE MECHANISM 4, Work clamp cylinder 5. Cloth opener cylinder 6. Lower thread trimming cylinder 101 DH4.39817.SOFTWARE 7. SOFTWARE 7-1, Motion flowchart 1. Cutting before sewing, back position 2. Cutting after sewing, back position ° Startswitch ON Start switch ON Hammer operates. Cloth opener operates, and : t the upper thread tightened, Gahoper ops 1 +e upper tweadis tightened. Feed bracket moves tovening t stertpostion. Food bracket movestozewing } stort pesition. : Sewing + [Upperthreadtensionis : released. : 1 1 ‘Upper thraadtansion le released Xand ¥ axesstartto return to T thelrhome postions. KandV excsstart toreturnto : ‘heir home positions. [voper thread istrimmed jpper threads wimmed. and ¥ axestinish returning T totheirhome postions. andy avai ring Y totheirhome positions. Hammer operates. Work clamp rises. Workdlamp ries and cloth opener isclosed. ‘ower thread istrimmed. ‘Gani returned ‘axis is eturned home position. hhome position. K¥, and @ares each revurnto X,Y, andOaxes each eturao home positon (by means of hhome position (by means of - ective sonsoi) espectve sensor. DHa-8981 1027.SOFTWARE 7-2. Input check list Use the following procedure when checking for switch and sensor breakdown, cord breakage, and adjusting the sensor positions. The CPU can be checked as to whether it has correctly interpreted signals from switches and sensors. Segment meanings 8): rei A 3 c D 1. Turn off the power. 2. Turn onthe power while pressing the "Up" switch @. *The check mode number will appear as the tens digit @ on the number display window. *The check result will appear as the units digit © on the number display window. 3. Pressthe "Up" switch @ or "Down" switch @ to select a desired check mode number. 4. When the switch or sensor is turned on, the corresponding segment will appear as the units digit © on thenumber display Turn the desired switch on and off. = When checking a sensor, move the part being monitored manvally. *Whenreturning to normal operation, turn power off and then on again. Check mode Segment Check items: A X-axis home position sensor B ‘Y-axis home position sensor c 8-axis home position sensor 1 D Lower thread trimming OFF sensor E Head sensor F Knife ON sensor 6 DP. A Start switch B Work clamp switch c 2 D EMERGENCY STOP switch E F Needle up signal 6 Needle down signal pe. Speed detecting sensor A NIFE switch B RESET switch c 3 D E Switch A (select switch) F ‘Switch B (select switch) . 6 Switch C (elect switch) 1 DP. RESET switch (select switch) 103 DHe.29817. SOFTWARE Hoenn eel Check mode Segment ‘Check items A Limit switch R (feed platehome position) 8 Limit switch L (left feed plate) 2 ¢ Cylinder sensor (right feed plate) D 4 — F 6 pp. A ‘Specification harness No.1 8 Specification harness No. 2 c Specification harness No. 3 D Specification harness No. 4 5 z Specification harness No. 5 F Specification harness No. 6 6 ‘Specification harness No. 7 DP. Specification harness No.8 A B c D Panel DIP witch A No. 5 6 g Panel DIP switch A No. 4 F Panel DIP switch A No.3 6 Panel DIP switch A Wo. 2 DP. Panel DIP switch A No. 1 A Panel DIP switch B No. 8 B Panel DIP switch B No.7 c Panel DIP switch B No. 6 7 Dd Panel DIP switch B No. 5 z Panel DIP switch B No. 4 FE Panel DIP switch B No. 3 G Panel DIP switch B No. 2 DP. Panel DIP switch B No. 1 A Panel DIP switch C No. 8 B Panel DIP switch C No. 7 c Panel DIP switch C No. 6 8 D Panel DIP switch C No. 5 E Panel DIP switch C No. 4 F Panel DIP switch C No. 3 G Panel DIP switch C No. 2 DP. Panel DIP switch CNo. 1 A Circuit board DIP switch C No. 8 B Grcuit board DIP switch C No. 7 c Gircuitboard DIP switch C No. 6 9 D ‘Circuit board DIP switch C No. 5 E Circuit board DIP switch C No. 4 F Circuit board DIP switch C No. 3 s Gircuit board DIP switch ¢ No. 2 oP. Gircuit board DIPswitch € No. 1 *1 Available only when select switch (optional) is attached. *2 Available only when indexer is attached. DH43981 104‘7.SOFTWARE 7-3. Output check list Use the following procedure when checking for PCB-related failures, mechanism breakdown, and cord breakage. Itcan be checked as to whether signals that the CPU correctly output have been received. KEL ea Turn off the power. 2. Turn onthe power with the "Down" switch @ simultaneously pressed. 3. Press the start switch @. *The machine will startto detect the home position *The check code number will appear on number display window ©. 4. Pressthe “Up"switch @ or the "Down" switch @ to find the desired check code. 5. Pressthe start switch @. ‘While the switch is kept pressed, the machine will work as tis specified by each check code. *when returning to normal operation, turn power off and then on again. Check code Function After activating the buzzer for a second, X-, Y-, and 6-home positions are detected a when the machine stops with the needle at its upper limit. Head sensor will not conduct any error check. a The machine will hold the material. 3 The machine will open the material. oa ‘After activating the buzzer for a second, the machine opens the material, turns 180° (0), and activates lower thread and lower gimp trimmers. 6 ‘After activating the buzzer for a second, turns 180° (0), and the upper thread trimmer will be activated. 6 ‘After activating the buzzer for a second, the machine will hold the material and activate the knives. ‘After activating the buzzer for a second, the machine will hold the material, and 7 operate the machine motor at 700 spr. Turn off the start switch to stop the machine. 10 Upper thread will be tightened. ‘After activating the buzzer for a second, the X feed mechanism will reciprocatein the "1 range of -6 mmto + 6mm. Be sure to remove the work clampand check the motion of the X feed mechanism. ‘After activating the buzzer for a secon, the Y feed mechanism will reciprocatein the 2 range of -1mmto + 65mm. *Be sure toremove the work clamp and check the motion of the ¥ feed mechanism. 105 DHA-B9817.SOFTWARE nl Check code Function ‘After activating the buzzer for a second, the 0 feed mechanism will reciprocate inthe 3 range of -2.7° +3627. **Be sure to remove the work clamp and check the motion of the 6-axis feed mechanism. 16*1 Feed plate is temporarily fixed. (Fixing cylinder on) 7 Feed plate is fixed. (Chuck cylinder on) 181 Feed plate is moved to the right. (Cloth feed driving cylinder on) a1 ‘The buzzer sounds, All two display tubes will be lit. a | seereenerttat BA KNIFE indicator will be lit. Indicator A will be li Indicator 8 will be lit. | «2 Indicator Cwill be lit. 1 Available only when indexer is attached. *2_ Available only when select switch (optional) is attached. DHe-H961 1067. SOFTWARE le aaa SEE! 7-4. Error codes 1. Errors when the power is turned on Inputeneck one Contents Resetting Ss irareneee et—— £00 | Emergency stop switch is still activated. | [win of emergency sop switch, and press RESET] G@) 2.-D £-02 | machine head falls down. ‘Turn off the power. Ort £03 | dothpresser switch is stillbeing pressed, Turn oft cloth presser switch, and pressRESET switch. |) 2-B £04 | Startswitchis still being pressed. ‘Tuin off start switch, ond press RESET switen, @ra £06 | reedplatehome positionsensor remainsott. | Setit to on. Ora £07 | Left feed plate sensor remains off. Turn offthe power. Qas ©) 18 £-09 | Specification thet machinedoesnot —_| Turn offthe power. Osa- supports set. DP. £10 | Needle up signal remains off. Setittoon. @2F £-12 | Cutter sensor remains on. ‘Turn off tthe power. Qi © €-15 | Lower thread trimmer OFF sensor [Turn offthe power. Qrww remains off. @Qu £-26 | PERterminal connection error Turn offthe power. — E-27 | External RAM error ‘Turn off the power. — £-28 | Panel communication start error Turn off the power. Smeal £-29 | Machine motor communicationstart | Turn offthe power. error 2. Errors before any operation is performed Error D tnout eck code Contents Resetting @owuterec E-30 | Emergency stop switch is still activated. | T17",oFF emergency stop switth. and press RESET] (>) 2. E-31 | Program whose specificetion is different from Press RESET switch. thatof machine (work dampand indexer — specifications) is selected. £-32 | Machine heads raised. Turn off the power. Ore £-36 | Feed plate home position sensor ‘Turn off the power. Daa remains off. £37 | Left feed plate sensor remains off. ‘Tum off the power. Das (©) 18 £-38 | Right feed plate sensor remains off. Tum off the power. @ac Ow 107 (DH4-B9817. SOFTWARE ed to onwithina specified time of searching home position. Error . ID inputchece code Contents Resetting lO ‘output check| 40 | Needle upsignat remains off. ‘Turnon needle up signal, and press RESET switch. Ow £42 | Cuttersensorremainson. Turn off the power. 1F 06 £-45 | Lower thread trimmer OFF sensor Turn off the power. Ow remains off. @ 4 £50 | X-axishome position sensor remains _| Turn off the power. Ora off. E51 | Y-axishome positionsensor remains _| Turn off the power. O18 off. E52 | @-axishome position sensor remains _| Turn off the power. @1¢ off. £59 | Sewing data is damaged. Turn off the power. — 3. Errors during operation Error. , © inputchack code. Contents esatting (© output check) £60 | Emergency stop switch is pressed. Press RESET switch or start switch. — £.62 | Machine head falls down. (Head ‘Tum off the power. Ore sensor is off.) E66 | Feed plate home position sensor isnot | Turn off the power. Ora activated within a specified time. £-67 | Left feed plate sensorisnotactivated | Turn off the power. Oza within a specified time. © 8 £.68 | Right feed plate sensor is not activated | Tun off the power. Oc within a specified time. @ 8 £70 | Needle up signalis not activated Tur off the power. Ou within a specified time. Ow E71 | Needle down signal is not activated ‘Turn off the power. O26 within a specified time. Ow E72 | Knife ONsensoris not activated within. | Turn off the power. Ow a specified time. © 06 £-75 | Lower thread trimming OFF sensoris | Turn off the power. Oro not activated within a specified time. Ou £76 | Needle up signal turned off ‘Turn off the power. Or £-77 | synch signal is not activated withina —_| Tum off the power. © roe. specified time. £-80 | X-axis home position sensor isnot set__| Turn off the power. Ora Ha.8981 1087.SOFTWARE errer | ID npurctock coe Contents Resetting Douputerea £-81 | Y-axis home position sensorisnotset _ | Turn off the power. O18 toon within a specified time of searching home position. E-82 | G-axis home position sensorisnotset | Turn off the power. Ore to.on within a specified time of searching home position. 4, Hardware errors Error |D input check: tose Contents Resetting IO ourputchoee E-99 | Communication error Turn off the power. E-91 | Machine motorrotation error ‘Turn off the power. @2e 2G 2DP. @©v £.92_| Abnormal voltage error Tum off the power. £.93 [Fan(L) lock error Tur off the power. — £94 | Fan(S)lockerror Tum off the power. — £-95 |X motor overcurrent error Tum off the power. — £-96 | ¥ motor overcurrent error Tum off the power. — £97 |Control PCB temperature rise error | Turn off the power. — £98 | Power supply relayerror ‘Tum off the nower. — £-99 | Power supply circuit board overcurrent. | Turn off the power. i error 109 DHe-89617. SOFTWARE AR. 7-5. Troubleshooting Error code Countermeasure 4. Tum off emergency stop switch. 2. Check if connector P3 (HEAD) on the control circuit board is securely inserted and if any harness is broken or short-circuited. 3. With the power tured off, separate connectors P3 (HEAD), and check if conti ‘the following pairs of pins 1 to 3 in the connector on the harness is as follows: * When emergency stop switch is activated, between pins t and 2 is opened, and between £00 pins 2 and 3 isshort-circuited. «When emergency stop switch is not activated, between pins 1 and 2 is short-circuited, and £30 between pins? and 3is opened * If the result of continuity test is not acceptable in either case, replace the emergency stop switch and its harness. * Even if the result of continuity test is acceptable, harness may be broken or short-circuited. It may appear when oxcillation occurs. 4. If there is still an error even after replacing the emergency stop switch, replace the control

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