button attaching indexer acf-164-1903 - semsi...

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ENGINEER’S MANUAL

29347606No.00

Button Attaching Indexer

ACF-164-1903

PREFACE

This Engineer’s Manual is written for the technical personnel who are responsible for the service and maintenance

of the sewing machine. This manual describes “Adjustment Procedure”, “Results of Improper Adjustment”, and

other functions which are not covered by the Instruction Manual intended for the maintenance personnel and

sewing operators at a sewing factory.

All personnel engaged in repair of ACF-164-1903 are required to carefully read Section 2 “Standard Adjustment”

which contains important information on the maintenance of ACF-164-1903.

The “Standard Adjustment” consists of two parts ; the former part presents illustration and simplified explanation

for the convenience of reconfirmation of the required adjustment values in carrying out actual adjustment after

reading this manual once; and the latter part provides “Results of Improper Adjustment” in which sewing and/or

mechanical failures, and the correcting procedures are explained for those persons who perform such adjustment

for the first time.

It is advisable to use “ACF-164-1903 Parts Book” together with this Engineer’s Manual.

CONTENTS1. SPECIFICATIONS .......................................................................................................... 1

(1) Main unit ................................................................................................................................................ 1(2) Button sewing machine ......................................................................................................................... 1(3) Button feeder......................................................................................................................................... 2

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

3. NAME OF EACH PART AND PREPARATION FOR TRIAL RUN................................. 4(1) Operating switches................................................................................................................................ 4(2) Adjusting the seam allowance............................................................................................................... 6(3) Adjusting the position of the work clamp ............................................................................................... 8(4) Adjusting the stacker ............................................................................................................................. 9(5) Adjusting the knee switch ...................................................................................................................... 9

4. OPERATION OF LK ..................................................................................................... 10(1) NAMES ON THE operation BOX OF LK ............................................................................................. 10(2) HOW TO OPERATE THE operation BOX OF LK ............................................................................... 10

1) Setting the item data .................................................................................................................... 102) Changing to the other sewing pattern ........................................................................................... 133) Performing sewing using the function keys ( P 1 , P 2 and P 3 keys) ........................................ 134) Adjusting the position of the button clamps .................................................................................. 145) Checking the contour of a sewing pattern .................................................................................... 15

(3) Winding the bobbin thread .................................................................................................................. 161) To wind a bobbin while the sewing machine is performing sewing .............................................. 162) To wind a bobbin independently ................................................................................................... 16

5. ADJUSTMENT OF COMPONENTS OF LK ................................................................. 17(1) Adjusting the feed plate....................................................................................................................... 17(2) Adjusting the button clamp jaw lever................................................................................................... 17(3) Adjusting the lifting amount of the button clamp ................................................................................. 18(4) Adjustment of the pressure of the button clamp unit ........................................................................... 18(5) Adjustment of the wiper....................................................................................................................... 19(6) Adjustment of the wiper spring ............................................................................................................ 19(7) Adjusting the rising amount of the thread tension disk ........................................................................ 20(8) The moving knife and counter knife .................................................................................................... 20(9) Cleaning the filter ................................................................................................................................ 21(10) Adjusting the height of the needle bar ............................................................................................... 21(11) Adjusting thre needle-to-hook relation .............................................................................................. 21(12) How to use the memory switch ......................................................................................................... 22

1) Starting the memory switch .......................................................................................................... 222) Example of the memory switch setting ......................................................................................... 233) Setting the counter operation ....................................................................................................... 244) Table of functions of the memory switch ...................................................................................... 25

6. OPERATION OF ACF .................................................................................................. 26(1) Explanation of the operation panel of ACF ......................................................................................... 26(2) Preparation before operation .............................................................................................................. 27(3) Inputting and confirming data .............................................................................................................. 27

1) Memory number selection ............................................................................................................ 272) Input of the sewing data ............................................................................................................... 283) Checking the sewing data ............................................................................................................ 314) Counter settings ........................................................................................................................... 33

(4) Operation ............................................................................................................................................ 341) Automatic operation ...................................................................................................................... 342) Manual operation .......................................................................................................................... 353) Independent operation .................................................................................................................. 354) Emergency stop ............................................................................................................................ 365) Error message and the reset procedure ....................................................................................... 36

7. SWITCHES INSIDE THE PANEL BOX AND THE CONTROL BOX ........................... 42(1) Inside the panel box ............................................................................................................................ 42(2) Inside the control box .......................................................................................................................... 42

8. ADJUSTMENT OF UNIT .............................................................................................. 46(1) Carriage unit ........................................................................................................................................ 46(2) Button feeder components .................................................................................................................. 56(3) Detecting mechanism and its adjustment ........................................................................................... 63(4) Replacing the components and positioning them ............................................................................... 66

9. MAINTENANCE INSPECTION..................................................................................... 69(1) Maintenance and inspection of the sewing machine components ...................................................... 69(2) Maintenance and inspection of electrical components ........................................................................ 69(3) Diagnostic feature ............................................................................................................................... 69

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

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

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

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

14. CONFIGURATION (ELECTRICAL UNIT) .................................................................. 89(1) Components of control box and its function ........................................................................................ 89(2) Connector and its functions of the control box .................................................................................... 90(3) Power voltage ..................................................................................................................................... 91(4) Measuring the DC power voltage ........................................................................................................ 92(5) Changing the thermal values inside the switch box ............................................................................ 93(6) Replacing fuses ................................................................................................................................... 93(7) Replacing the P-ROMs for data .......................................................................................................... 94(8) CPU circuit board ................................................................................................................................ 95(9) I/O circuit board ................................................................................................................................... 96(10) Power circuit board ........................................................................................................................... 97(11) Panel circuit board ............................................................................................................................ 98(12) Functions of the stepping motor driver .............................................................................................. 98(13) I/F circuit board whole asm. .............................................................................................................. 99

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

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

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

18. CIRCUIT DIAGRAM ................................................................................................. 105(1) Transformer (ass’y) ........................................................................................................................... 105(2) Power circuit board (ass’y) circuit diagram ....................................................................................... 106(3) Circuit diagram of the stepping motor driver (ass’y) .......................................................................... 107(4) Circuit diagram of the stepping motor (ass’y) .................................................................................... 107(5) Circuit diagram of the indexer switch ................................................................................................ 108(6) Output circuit board diaram ............................................................................................................... 109

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

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

－ 1 －

1

2

6

4

5

6

Outer diameter of buttons to be sewn (mm)

Sewing size (mm)

Button clamp jaw lever

Needle hole guide

Feed plate

Length

Width

Thickness

(mm)

Standard

For small buttons

ø10 to ø15

0 to 3.5

0 to 3.5

2.2 Engraved

mark

MAZ165070B0 H

MAZ167140A0

MAZ15601000

MAZ15502000

Optional

For medium-size buttons

ø12 to ø18

0 to 4.5

0 to 4.5

2.7

MAZ166070B0 J

MAZ168140A0

MAZ15601000

MAZ15602000

Part

No.

Right

Left

Engraved

mark

1. SPECIFICATIONS(1) Main unit

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

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

3 Number of buttonswhich can be sewn : 1 to 20 pcs. (the machine is

set to the independent sewingmode when sewing only onebutton on the material.)

4 Distance from the top end of thegarment body to the 1st button : 40 to 140 mm (1.6 to 5.5")

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

5 Distance from the side end of thegarment body to the button : 12 to 25 mm (0.5 to 1")

6 Applicable garment sizesthat can be sewn (standard) : Width 220 to 420 mm (8.7 to 16.5")

Length 400 to 880 mm (15.7 to 34.6")7 Number of patterns

that can be stored in memory : 208 Power supply : 200V (3-phase) (Rated voltage ±10%)9 Power source frequency : 50/60 Hz!0 Power consumption : 600 VA (Rated voltage ±10%)!1 Operating air pressure : 0.5 MPa!2 Air consumption : 20 Nl/min. or less!3 Machine dimensions : Width 1,860 mm

Depth 970 mmHeight 1,250 mm

!4 Weight : 220 kg

(2) Button sewing machine1 Machine head : LK-1903 (exclusive machine head)2 Sewing speed : Normal 2,300 rpm

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

3 Needle : DP x 17 #144 Buttons : Kind : Flat buttons (2-holed, 4-holed)5 Lifting amount of

button clamp jaw lever : 11 mm6 Number of standard patterns : 33

－ 2 －

(3) Button feeder

1 Discrimination of buttons to be fed : By vibration system using the piezoelectric feeder

2 Button setting method : Buttons are loaded from the rear section of device

3 Individual button feed : By index method

4 Detection of a failure : Provided with three detectors ™ The first detector detects a

button at the section where

the but ton is cor rec t ly

positioned.

™ The second detector checks

whether the button is correctly

inserted in the carrier pin.

™ The third detector detects a

button at the button clamp jaw

lever.

5 Driving source for the feeder : DC motor (24 Vdc)

6 Function of sewing buttons

without cross-over stitch : Provided

7 Automatic button

discharging function : Provided

8 Independent operation of the

sewing machine : Possible

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

Noise: Workplace-related noise at sewing speed

n = 2,300 min–1 : LPA ≦ 84 dB(A)

Noise measurement according to DIN 45635-48-B-1.

－ 3 －

2. CONFIGURATION OF THE MAIN PARTS

1 Sewing machine head

2 Button feeder

3 Work clamp (carriage unit)

4 Stacker

5 Operation panel of ACF

6 Power switch

7 Knee switch

8 Emergency stop switch

9 Hand switch

!0 Thread stand

!1 Conveyor

!2 Cloth plate

!3 Operation panel of the feeder

!4 Air gun

!5 Operation box of LK

!6 Hand pulley

1. Before you put the machine into operation for the first time after the set-up, clean it

thoroughly. Remove all dust gathering during transportation and oil it well.

2. Confirm that the voltage has been correctly set.

Confirm that the power plug has been properly connected to the power supply.

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

4. The sewing machine has been completely adjusted at the time of delivery. For caution’s sake,

however, turn ON the power switch after releasing the stop-motion and turning the handwheel

by hand when operating the machine for the first time.

5. Operate the machine with the air pressure set to 0.5 MPa (5 kgf/cm 2).

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

1 234

5

67

8

9

!0!1

!2

!3

!4

!5

!6

－ 4 －

A

3. NAME OF EACH PART AND PREPARATION FOR TRIAL RUN

(1) Operating switches

1 Power switch

Use this switch to turn ON/OFF the power to the unit.

(If installing the optionally available MC-6,use independent power for the MC-16 that is located on

section A on the right-hand side of the main unit.)

2 Emergency stop switch

Use this switch to stop the machine from running.

3 Knee switch

This switch is used as the start switch.

4 Hand switch

This switch is used as the work clamp release switch.

5 Feeder switch

6 Button feeder switch

Used to supply buttons to the button clamp jaw lever.

7 Set-up switch

This switch is used for operating the spinner oscillating arm under the step-operation mode. The spinner

oscillating arm performs step operation as long as the switch is held pressed.

8 Button discharging switch

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

d

1

2

3

4

5

6

7

8

9

!0

!1

!2

－ 5 －

9 Feeder breaker

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

by pressing.

!0 Men’s / Ladies mode selective switch

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

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

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

G55101640A0).

!2 Stacker release switch

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

This switch is used for taking out the materials from

the stacker after the predetermined number of pieces

of finished material has been stacked. Lift lever in the

direction of arrow A , and the second presser will move

away from the stacking board to allow the operator to

take out the materials from the stacker.

(Caution) Do not take out the workpieces while the

stacker is in operation. Doing so is very

dangerous.

Stacker release switch

A

－ 6 －

(2) Adjusting the seam allowance

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

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

1) Adjust the seam allowance from the side end of

the garment to the button (distance A in the figure),

and from the top end of the garment to the 1st button

(distance B in the figure.)

(Caution) Be sure to make adjustment of the seam

allowance after you have turned OFF the

power switch.

2) The number of buttons and the intervals between

the buttons can be adjusted using the panel

switches. (Refer to “Inputting the sewing data” on

page 28.)

™Adjusting distance A

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

values and tighten the screws.

™Adjusting distance B

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

Then tighten the thumbscrew.

As viewed from above the unit

A

B


1

23

1

2

3

1 1 1

－ 7 －

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

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

1) Adjust the seam allowance from the side end of

the garment to the button (distance A in the figure),

and from the top end of the garment to the 1st button

(distance B in the figure).

The number of buttons and the intervals between

the buttons can be adjusted using the panel

switches. (Refer to “Inputting the sewing data” on

page 28.)

(Caution) Be sure to make adjustment of the seam

allowance after you have turned OFF the

power switch.

2) Adjust dimension A for ladies’ wear should be

adjusted following the same procedure as that for

men’s wear.

™ Adjusting distance B

Insert gauge 1 for ladies’ wear supplied with the

machine into setting plate,right 2. Then shift the setting

plate to the right or left according to scale value 3

desired.

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

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

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

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

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

body toward the first button at the top.

A

B

B

12

3

1 2

－ 8 －

(3) Adjusting the position of the work clampThe position of the work clamp of this unit can be adjusted as desired according to the size of garment to

be sewn.

1 For garment bodies of men’s wear

Loosen knob 4 and shift left-hand side work clamp 2 to its leftmost position. Then tighten the knob so that

the left-hand side work clamp is fixed at that position. Then loosen knob 1 and adjust the position of right-

hand side work clamp 5 according to the length of the workpiece to be sewn.

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

of the last button and the distance between them is 40 mm or more. If work clamp (right)

6 is not positioned as stated above, the Error (E52) may occur when the machine runs

under the automatic operation mode.

2 For garment bodies of ladies’ wear

Loosen knob 1 and shift left-hand side work clamp 5 to its rightmost position. Then tighten the knob so

that the work clamp is fixed at that position. Then adjust the position of left-hand side work clamp 2

according to the length of the workpiece to be sewn.

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

of the last button and the distance between them is 40 mm or more. If work clamp (left) 3

is not positioned as stated above, the Error (E52) may occur when the machine runs in

the automatic operation mode.

This device is equipped with a conveyer on its left-hand side. This may prevent you from

setting garment bodies of ladies' wear in place on the machinre with ease. In this case,

you can attach buttons of the garment from its bottom by using the jump function (see

p.31.) and the men's wear sewing mode in combination.

1

2

1

4 5

6

5

－ 9 －

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

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

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

2) If the garment bodies are stacked on stacking board 3 with its side B shortened, lower stacking board3.

3) The machine is designed to detect the quantity of garments stacked on the stacker using sensor 8mounted on work clamp cylinder 7. You can make the alarm occur when the quantity of the stackedgarment reaches the desired volume predetermined only adjusting the position of sensor 8 appropriately.(Even when the alarm occurs,the machine will not stop running.)

(5) Adjusting the knee switch1) Loosen screw 2 in the switch fixing plate 1, and

adjust the stroke of the knee switch.2) Now,confirm that presser plate 4 stops when

stopper 3 is reached without fail.


12

3

4

5

6

7

8

9

A

B

1

2

34

3

－ 10 －

4. OPERATION OF LK

(1) NAMES ON THE operation BOX OF LK

• Sewing LED• Item selection LED

• Selection key: Every time this key is pressed, the selection

will be made as follows.

• Function key

• ＋ /Forward key

• － /Back key

• Ready key

• Reset key

• Data display

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

　　↑

(2) HOW TO OPERATE THE operation BOX OF LK

1) Setting the item data

Set each item following the procedure described below.

1 Turn ON the power switch.

Pattern No. of the item selection lights up, and the pattern No. is indicated on the data display.

(Pattern No. 1 has been set at the time of delivery.)

2 Setting of the pattern No.

1) Press the SELECT key to indicate the item “PATTERN

No.”.

2) Press the FORWARD or BACK key to indicate “ ”on the

screen.

(Pattern No. is set to 14.)

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

the standard sewing patterns (p.12).

Setting of thepattern No.

Setting of the X scale Setting of the Y scaleSetting of the max.

sewing speed limitation

SELECT

FORWARD BACK

PATTERN No.

X SCALE

Y SCALE

SPEED

COUNTER

WINDER

－ 11 －

3 Setting of the X scale

1) Press the SELECT key to indicate the item “X

SCALE”.

2) Press the FORWARD or BACK key to set the scale in the

range of 20% to 200%.

4 Setting of the Y scale

1) Press the SELECT key to indicate the item “Y

SCALE”.

2) Press the FORWARD or BACK key to set the scale in the

range of 20% to 200%.

5 Setting of the max. speed limitation

1) Press the SELECT key to indicate the item “SPEED”.

2) Press the FORWARD or BACK key to indicate “ ” on

the screen. (Setting of 400 rpm)

6 Finish of setting

1) Press the READY key.

2) After the work clamp feet have moved and gone

up, the sewing LED lights up, and the sewing is

ready.

＊ If the SELECT key is pressed, you can make sure of

the set values of the respective items again.

SELECT

FORWARD BACK

PATTERN No.

X SCALE

Y SCALE

SPEED

COUNTER

WINDER

SELECT

FORWARD BACK

PATTERN No.

X SCALE

Y SCALE

SPEED

COUNTER

WINDER

SELECT

FORWARD BACK

PATTERN No.

X SCALE

Y SCALE

SPEED

COUNTER

WINDER

READY

SEWING

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

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

displayed. At this time, perform re-setting of the pattern No.

－ 12 －

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

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

X, Y(mm)

1 (34) 6-6

2 (35) 8-8

3 10-10

4 12-12

5 (36) 6-6

6 (37) 8-8

7 10-10

8 12-12

9 (38) 6-6

10 (39) 8-8

11 10-10

12 (40) 6-6

13 (41) 8-8

14 10-10

15 (42) 6-6

16 (43) 8-8

17 10-10

18 (44) 6

19 (45) 8

20 10 3.4 0

21 12

22 16

23 (46) 6

24 10 0 3.4

25 12

26 (47) 6-6

27 10-10

28 (48) 6-6

29 10-10

30 (49) 5-5-5

31 8-8-8

32 (50) 5-5-5

33 8-8-8

3.4 3.4

3.4 3.4

2.9 2.5

Standardsewingsize Y(mm)

Pattern

No.

Stitch

shape

Numberof

threads(thread)

Standardsewingsize X(mm)

TABLE OF THE STANDARD SEWING PATTERNSStandardsewingsize Y(mm)

Pattern

No.

Stitch

shape

Numberof

threads(thread)

Standardsewingsize X(mm)

＊ The standard sewing sizes of X and Y are when the enlargement/reduction rate is 100%.

＊ Use (34) to (50) when the button hole is small (ø1.5 mm or less).

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

－ 13 －

1 Registration to the function key

Setting example : Register the following setting to the P1.

Pattern No. 3, X Scale rate : 50%, Y Scale rate : 80%, Max. sewing speed limitation : 2,000 rpm

1) Pressing the SELECT key, turn ON the power switch.

2) Press the P 1 key.

3) Press the SELECT key to indicate the PATTERN No.

Set the pattern No. to Pattern No. “ ” using the FORWARD or BACK key.

4) Press the SELECT key, ans set X scale rate to 50%, Y Scale

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

using the FORWARD or BACK key.

5) Press the READY key to finalize the registration.

＊ If you desire to register in P2 to P7, select P2 to P7 in combination of P 1 to P 3 keys at the step 2),

and perform the steps 3) to 5).

6) When the registration has been completed, turn OFF the power switch, and again turn ON the powr

switch. Then the sewing machine can be used as usual.

e

e

e

2) Changing to the other sewing pattern

1 Press the READY key. (The sewing LED will go off.)

2 Press the SELECT key to indicate the item “PATTERN

No.”.

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

data, and move to the step of “5) Checking the

contour of a sewing pattern”.

SELECT

FORWARD BACK

PATTERN No.

X SCALE

Y SCALE

SPEED

COUNTER

WINDER

READY

3) Performing sewing using the function keys ( P 1 , P 2 and P 3 keys)

If the patterns (No. 1 to 99) which have been already registered are registered in P1 to P7, the pattern calling

can be made by one-touch without performing the selection by the pattern No. scrolling.

＊ When selecting P4, P5, P6 or P7, the selection can be made by the combination of P 1 to P 3 keys.

P1 : Press the P 1 key. P4 : Simultaneously press the P 1 and P 2 keys.



P7 : Simultaneously press the P 1 , P 2 and P 3 keys.

e

－ 14 －

P 1

P 3

Needle entry position

Holes in the button

Button

4) Adjusting the position of the button clamps1) Set the mode to “Independent operation” mode

(P.35) with the operation panel of ACF.2) Press the button feeding switch (P.4) on the BR

control box, and place a button in button clamps 1.3) When the knee switch (P.4) is turned ON, button

clamps 1 come down.4) Holding the knee switch ON, turn the hand pulley until

the digital display on the LK control box becomes E3.5) Release the knee from the knee switch.6) Further turn the hand pulley to lower the needle

and confirm that the center of the needle is in thecenter of the button.

(Caution) If the needle is returned to the up-stopposition when turning the hand pulley,E3 of the digital display on the LKcontrol box will disappear, and thebutton clamps 1 will go up.

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

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

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

2 Sewing operationOperation example : After performing sewing with the contents of the registered P1, perform sewing with thecontents of P3.

1) Turn ON the power switch.2) Press the P 1 key.3) Press the READY key, and when the sewing LED lights

up, the work clamp foot goes up after it has moved.4) Check the contour of the sewing pattern.

(Refer to the item “Checking the contour of a sewingpattern”.)

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

6) After the completion of sewing, press the P 3 key.Then the work clamp foot will move to the sewingstart point after the origin retrieval. The P keys canoperate the pattern change by one-touch evenwhen the sewing LED is lighting up.)

7) Perform the above items 4) and 5).✽ The P1 to P7 keys can be indicated on the display

when selecting the pattern by pressing the FORWARD or

BACK key.

→ 0 to 99 ←→ P1 to P7 ←

P1 to P7 which have not been registered are notindicated.

READY

SEWING

READY

SEWING

1

2

－ 15 －

After 5th stitch

3rd stitch

2nd and 4th stitches

1st stitch (jump feed)

Needle does not enter.

Needle entry origin

5) Checking the contour of a sewing pattern

1) Set the mode to “Independent operation” mode with

the operation panel of ACF. (P.35)

2) Press the button feeding switch (P.4) on the BR

control box, and place a button in button clamps 1.

(See P.14.)

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

clamps 1 come down. (See P.14.)

4) Holding the knee switch ON, press the FORWARD key on

the LK control box, and the button clamps move by

one stitch

If the FORWARD key is pressed even one time, the button

clamps do not go up even when the knee is released

from the knee switch.

In addition, After the FORWARD key has been pressed,

the BACK key becomes effective as well.

5) Turn the hand pulley to lower the needle and

confirm that the needle enters the hole of the button.

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

the digital display on the LK control box

is displayed. When the E3 is displayed,

FORWARD and BACK keys are ineffective. To

make FORWARD and BACK keys effective, turn

the hand pulley, raise the needle up to

its up-stop position and make E3 go out.

6) After confirmation of the needle entry position, prees

the RESET R key on the LK control box. The button

clamps return to the origin and go up.

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

key becomes ineffective. To make the

RESET R key effective, turn the hand pulley,

raise the needle up to its up-stop

position and make E3 go out.

＊ Buttons cannot be fed during confirmation of the

needle entry position. When feeding the buttons

again, press the RESET R key to return the button clamps

to the origin.

FORWARD BACK

Details of the sewing pattern at the sewing start

™ 1st stitch is a jump stitch and the needle doesnot enter.

™ 2nd, 3rd and 4th stitches are tie stitches.Needle enters in the same button hole.

－ 16 －

(3) Winding the bobbin thread

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

Thread the bobbin winder and wind the bobbin thread

onto the bobbin as illustrated in the figure.

2) To wind a bobbin independently

1) Pull out the thread from the needle.

2) Winding a bobbin is performed at the position of

the origin of the sewing machine. Be sure to remove

the button from the button clamps.

3) Set the operation panel of ACF to “Independent

operation” mode. (P.35)

4) Press READY key on the control box of LK to make the

sewing LED go out.

5) Select “WINDER” with the SELECT key on the control

box of LK.

6) Press again READY key to light the sewing LED. At this

time, a display as shown below is indicated on the

operation panel of ACF.

7) Press the sewing machine start switch on the operation panel of ACF. Then the sewing machine

rotates and bobbin thread winding is started.

8) To stop the operation, press again the sewing machine start switch on the operation panel of ACF or

press any key on the control box of LK.

9) To return to the normal sewing, press again READY key on the control box of LK, select the item other than

“WINDER” with SELECT key and press again READY key to light the sewing LED.

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

switch on the operation panel of ACF.

Sewing machinestart switch onoperation panel ofACF

SELECT

PATTERN No.

X SCALE

Y SCALE

SPEED

COUNTER

WINDER

READY

＊＊＊＊＊ BOBBIN WINDING MODE ＊＊＊＊＊LK BOBBIN SW OFF

14 ＊＊＊＊＊ LK NOT READY ＊＊＊＊＊＊＊LK CHECK → RESET → START

＊ Sewing machine start switch does not work for two seconds after stop of bobbin winding operation.

＊ Buttons cannot be fed during bobbin winding operation.

＊ When the operating method of operation panel of ACF is “Automatic operation” (P.34) or “Manual

operation” (P.35), the sewing machine start switch does not work even when performing the

aforementioned operations of steps 4), 5) and 6). Perform the operations of steps 9) and 10) once to set

the operating method of the operation panel of ACF to "Independent operation" mode (P.35), and

perform the operations of the aforementioned steps 4), 5) and 6).

－ 17 －

5. ADJUSTMENT OF COMPONENTS OF LK

(1) Adjusting the feed plate1) Select the pattern No. 99 using the operation panel.

2) Press the [READY] key on the operation panel.

Then the button clamp unit will travel to the position

of the origin and go up.

3) Press again the [READY] key to make the sewing

LED go out.

4) Adjust feed plate 1 by loosening screw 3 so that

needle hole guide 2 comes to the center of the

recessed part of feed plate 1.

(2) Adjusting the button clamp jaw leverBring the machine to its stop-motion state. Then lift

button clamps 1. Loosen screw 2 in the button clamp

jaw lever and adjust so that a clearance of 0.2 to 0.4

mm is provided between button clamp jaw 3 and hinge

screw 4 when placing a button in between button

clamps 1.0.2 to0.4 mm

1

2 3

1

2

34

1

－ 18 －

(3) Adjusting the lifting amount of the button clamp1) Select the pattern No. 99 using the operation panel.

2) Press the [READY] key on the operation panel.

Then the button clamp unit will go up and come to

the position of the origin.

3) Press again the [READY] key to make the sewing

LED go out.

4) Loosen two screws 1, and move work clamp foot

lifting plate 2 back and forth in the direction of arrow

to adjust so that the top end of button clam 4 is 11

mm above throat plate 3.

Move work clamp foot lifting plate 2 in direction A

to decrease the lifting amount, and move it in

direction B to increase the lifting amount.

After the adjustment, securely tighten screws 1.

5) Turn knob 9 of the spinner oscillating arm motor

on the unit side, and when work clamp lifting arm

7 has stopped its lifting once, loosen screw 5 and

turn work clamp hook 6 to adjust so that a

clearance of 0 to 0.5 mm is provided between roller

8 and work clamp lifting arm 7.

6) After the adjustment, check that the buttons are

securely supplied.

0 to0.5 mm

11 mm

(4) Adjustment of the pressure of the button clamp unitThe pressure of the button clamp unit should be

minimized as long as the material does not warp

during sewing.

Loosen adjusting screw 1 and turn adjusting screw

2 to obtain the aforementioned pressure.

1

2

3

4

5

67 8

9

B

A

7

8

1

2

－ 19 －

(5) Adjustment of the wiper1) Loosen screw 1 to adjust so that a clearance of

2.5 mm or more is provided between the wiper and

the needle.

2) Loosen screw 2 to adjust so that a distance of 15

to 17 mm is provided between the end face of the

wiper and the center of the needle. After the

adjustment, securely tighten the screw.

(Caution) The position of the needle is where the

sewing machine has stopped at the end

of sewing.2.5 mm

15 to 17 mm

(6) Adjustment of the wiper springWiper spring 1 retains the needle thread after thread

trimming in between wiper 2 and the wiper spring.

Correct properly the tension of wiper spring 1 so that

the tension at that time becomes 0.2 to 0.3 N (a little

higher tension than that of the bobbin thread coming

out of the bobbin case).

(Caution) If the retaining of the needle thread is

excessive, the thread may protrude from

the upper side of the button.

12

1

2

－ 20 －

(7) Adjusting the rising amount of the thread tension disk1) Remove the top cover. Make sure that tension

release pin 3 rides on tension release notch 4.

2) If the pin does not ride on the notch, push cam

follower 5 by hand to the e direction, and rotate

the main shaft in the correct direction to make a

state as illustrated in the figure.

3) Under the state as illustrated in the figure, loosen

setscrew 2 in the tension release adjusting arm.

By moving tension release adjusting arm 1 to the

left or right, the rising amount of the thread tension

disk will change.

S type : 0.6 to 0.8 mm

H type : 0.8 to 1.0 mm

(Caution) If the rising amount is insufficient, the

length of the remaining thread after

thread trimming will be not stable. If the

rising amount is excessive, after

releasing the rising of the thread tension

disk, the disk closing will be defective.

Widen

(Tension release link)

Narrow

(Thread tension disk)

(8) The moving knife and counter knife1) Loosen adjusting screw 3 so that a clearance of

18.5 mm is provided between the front end of the

throat plate and the top end of thread trimmer

lever, small 1. To adjust, move the moving knife

in the direction of arrow.

2) Loosen setscrews 5 so that a clearance of 0.5

mm is provided between needle hole guide 2 and

counter knife 4. To adjust, move the counter knife.

0.5 mm

18.5 mm

Throat plate

1

2

34

5

1

2

3

45

－ 21 －

(9) Cleaning the filterClean filter 2 of the control box fan once every week.

(Caution) The sewing machine may stop to protect

it from overheating when the sewing is

continued in the state that the filter clogs

with dust.

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

it.

2) Wash filter 2 under running water.

3) Reinstall filter 2 and screen kit 1.

(10) Adjusting the height of the needle bar

Engraved line for DP X 17

4 Upper engraved line

Bring needle bar 1 to the lowest position of its stroke. Loosen needle bar connection screw 2 and adjust

so that upper marker line 4 engraved on the needle bar aligns with the bottom end of needle bar bushing,

lower 3.

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

(11) Adjusting thre needle-to-hook relation1) Turn the handwheel by hand. When needle bar 1

has gone up, adjust so that lower marker line 2

engraved on the needle bar aligns with the bottom

end of the needle bar bushing, lower.

Relation between needle and engraved lines

1

2

1

2 3

1

12

3

12

3

1

－ 22 －

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

presser hooks 2 to the right and left, and remove

inner hook presser.

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

hook Úò come off and fall.

3) Adjust so that the blade point of inner hook 4 aligns

with the center of needle 5, and that a clearance

of “0” mm is provided between the front end of the

driver and the needle as the front end face of driver

6 receives the needle to prevent the needle from

being bent. Then tighten setscrew 1 of the driver.

4) Loosen setscrew 7 of the shuttle, and adjust the

longitudinal position of the shuttle. To do this

adjustment, turn shuttle race adjusting shaft 8

clockwise or counterclockwise to provide a 0.05 to

0.1 mm clearance between needle 5 and the blade

point of inner hook 4.

5) After adjusting the longitudinal position of the

shuttle, further adjust to provide a 7.5 mm clearance

between the needle and the shuttle by adjusting

the rotating direction. Then tighten setscrew 7 of

the shuttle.

0 mm

0 mm

0.05 to 0.1 mm

7.5 mm

1) Starting the memory switch

Pressing READY key and RESET R key, turn ON the power switch. The display gives

the indication of the memory switch and the sewing machine operation

can be changed.

(12) How to use the memory switch

e

12 3

4

1

4 5

4

5

7 8

6

2

3

－ 23 －

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

speed) has priority.

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

1) After the memory switch has started, press the FORWARD or BACK key to

indicate “ ” on the display.

2) Press the READY key to light up the sewing LED.

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

3) Press the FORWARD key to indicate “ ”.

(900 rpm is set.)

4) Press the SELECT key.

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


(1,200 rpm is set.)

6) After setting, register using the READY key.

2) Example of the memory switch setting

1 Setting of max. sewing speed limitation

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




3) Indicate “1800” using the BACK key.


2 Setting the soft start speed at the sewing start

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

e

e

e

e

e

e

e

e

e

e

Unit [rpm]

State when delivered

400

900

2,300

2,300

2,300

Setting range

400 to 900

400 to 2,700

400 to 2,700

400 to 2,700

400 to 2,700

1st stitch

2nd stitch

3rd stitch

4th stitch

5th stitch

－ 24 －

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

By making inoperative the calling of the unnecessary pattern, this setting prevents the different pattern

from calling by mistake. Also, it is possible to call and use the necessary pattern.

1) After the memory switch has started, press the FORWARD

or BACK

key to

indicate " " on the display.


Indication on A section : 0 : Pattern No.

Indication on B section : 0 : Calling is inoperative.

1 : Calling is operative.

3) Press the FORWARD

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

4) Press the SELECT key to make the indication on A " " → " ".

5) Press the FORWARD

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


(Caution) After operating the step 2), if the RESET R key is pressed, the

setting will return to the state when the machine was

delivered.

e

e

e

e

e

A

e

B

3) Setting the counter operation

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

(subtracting counter).





Indication on A section : 0 : Production counter

1 : Bobbin thread counter


e

A

e

－ 25 －

State when delivered

2,300 rpm

400 rpm

900 rpm

2,300 rpm

2,300 rpm

2,300 rpm

0

0

0

0

0

0

0

0

0

1

0

0

0

1

0

0

0

0

8

Setting range

400 to 2,700 rpm

1st stitch : 400 to 900

2nd stitch : 400 to 2,700

3rd stitch : 400 to 2,700

4th stitch : 400 to 2,700

5th stitch : 400 to 2,700

Pattern Nos. 1 to 33 can

be individually set.

0 : Calling not accepted

1 : Calling accepted

0 : Effective

1 : Ineffective

0 : Adding

1 : Subtracting

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

Function

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

100 rpm)

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

set in a unit of 100 rpm.

This function sets whether or not the calling of the

standard 30 pattern data is acceptable (Interference of

the needle with the aork clamp feet can be prevented

prohibiting the calling of the sewing pattern which is large

than the work clamp feet).

This function sets whether or not the display and change

of X/Y scale rate and max. sewing speed are acceptable.

(Prevention of maloperation)

Setting of the counter operation

Production counter : Adding counter

Bobbin thread counter : Subtracting counter

This function sets the needle bar stop position.

Under the upper dead point stop mode, the machine

rotates in the reverse direction from the upper stop

position and returns to the needle bar upper dead point.

Then it stops.

Do not change the setting of Nos. 07 to 99.

No.

01

02

03

04

05

06

07

08

09

10

11

12

13

14

15

16

17

18

19

20

21

99

4) Table of functions of the memory switch

－ 26 －

6. OPERATION OF ACF

(1) Explanation of the operation panel of ACF

SwitchNo.

Panelindication

1

2

3

4

5

6

7

8

9

!0

!1

!2

!3

!4

!5

!6

～

Switch name

Memory No. selector switch

Sewing data input switch

Sewing data check switch

Counter setting switch

Shirt counter clear switch

Back switch

Forward switch

Bobbin counter reset switch

Minus (reduction) switch

Plus (addition) switch

Number switch (numeric keys)

Entry key

Automatic operation selectingswitchCarriage travel switch

Sewing machine start switch

Reset switch

Function and operation

Used to select the memory number.

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

Used to clear the numbers counted on the shirtcounter.Used to return the current screen display or toshift the carriage to the left under the manualoperation mode.Used to forward the current screen display or toshift the carriage to the right under the manualoperation mode.Used to reset the number shown on the bobbincounter to the initial value (set value).Used to reduce numbers when inputting data.

Used to add numbers when inputting data.

Used to specify numbers when inputting data.

Used to enter numeric data.

Used to select automatic operation.

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

1

2

3

45 6 78 9 !0

!1

!2

!3 !4 !5 !6

－ 27 －

(2) Preparation before operationBe sure to check the following before turning ON the power switch.1) The machine is supplied with an adequate amount of machine oil.2) The power connector is properly connected and the voltage is correct.3) The connectors are connected.4) The operating air blower is connected and the operating air pressure is

correct.5) The machine rotates in the correct direction.6) The “Function setting” described on pages 42 to 45 habe been made

properly.7) The sewing machine is in the state of stop-motion.<Turning ON the power>Turn ON the power switch. (Refer to the figure on the right.)After the work clamp goes up, the carriage is raised to start retrieving theorigin.When retrieving the origin, the following message will be indicated on thedisplay screen, and pressing any other switch except the emergency stopswitch will not be possible.

A U T O M A T I C B U T T O N I N D E X E R A C F - 1 6 4

J U K I C o r p o r a t i o n

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

N o . 1 BUTTON = ＊＊ p s INDEX <1→ 2 > = ＊＊＊ . ＊ m m

S H I R T COUNT = ＊＊＊＊ BOBBIN COUNT = ＊＊＊＊

Memory number

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

(Caution) When an error message is indicated on the display screen (the display screen is in red),the machine will not retrieve the origin until the error is released (the error mode isreleased). Refer to the pages 36 to 41 as to how to clear the error.

Upon completion of the above procedures, "Imputting and confirming data" or "Operation" can be performed.However, these operations using the panel switches are possible only when the following conditions aresatisfied.• The machine is ready to run in the automatic operation mode or in the independent operation mode.

(Refer to pages 34 to 35 for automatic operation and independent operation.)• The standard indication appears on the display screen. (No error message is indicated on the screen.)

Number of

buttons

Number of

workpieces

counted

Intervals shown by 〈→〉 Remaining amount of

bobbin thread

(3) Inputting and confirming data1) Memory number selection

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

1

Press so that the LED lights up. ( )

2

Input the desired memory number (2).

N o . 1 B U T T O N = 6 p s INDEX <1→ 2 > = 8 5 . 0 m m

S H I R T C O U N T = 0 BOBBIN COUNT = 400

• • • • • • • • • • • • • No. SELECT • • • • • • • • • • • • •

M E M O R Y No. = 2

－ 28 －

3

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

* The following switches are valid when inputting data.

Increase the number specified. Return to the previous number.

Reduce the number specified Delete the input data.

(Caution) Numbers “1 to 20” can be specified.If a number except one of the above is specified, the error message shown below will beindicated for three seconds, and then the screen display will return to give indication 2.

N o . 2 B U T T O N = 5 p s INDEX <1 → 2 > = 1 0 0 . 0 m m


0 0 ＊＊＊＊＊＊＊ D A T A I N P U T E R R O R ＊＊＊＊＊＊F R O M 1 T O 2 0

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

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

under which is to be stored No. 2

66.0 100.0 mm (Equidistance)

The input procedure is as follows :

1

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

2

Input the number of buttons (5 pcs.).

N o . 1 B U T T O N = 6 p s INDEX <1→ 2 > = 8 5 . 0 m m


N o . 1 • • • • • • D A T A INPUT • • • • • • • • • • • • • •

B U T T O N NUM. = 5ps

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

3

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

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

N o . 1 • • • • • • D A T A INPUT • • • • • • • • • • • • • •

J U M P = 6 6 . 0 m m

4

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

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

N o . 1 • • • • • • D A T A INPUT • • • • • • • • • • • • • •

B U T T O N = 5ps INDEX < 1→ 2 > = 1 0 0 . 0 m m

－ 29 －

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

4’

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

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

N o . 1 • • • • • • D A T A INPUT • • • • • • • • • • • • • •

B U T T O N = 5 p s INDEX < 1→ 5 > = 4 0 0 . 0 m m

5

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

6

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

7

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

N o . 1 • • • • • • D A T A INPUT • • • • • • • • • • • • • •


N o . 1 • • • • • • D A T A INPUT • • • • • • • • • • • • • •


N o . 1 • • • • • • D A T A INPUT • • • • • • • • • • • • • •


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

8

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

N o . 1 • • • • • • D A T A INPUT • • • • • • • • • • • • • •

R E T U R N B U T T O N N o . = 4

9

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

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

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

N o . 1 • • • • • • D A T A INPUT • • • • • • • • • • • • • •

S T A C K M O D E = A U T O

－ 30 －

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

9’

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

!0

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

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

to page 43.)

N o . 1 • • • • • • D A T A INPUT • • • • • • • • • • • • • •

S T A C K M O D E = M A N U A L

N o . 1 • • • • • • D A T A INPUT • • • • • • • • • • • • • •

S T A C K E R TIMING = 10

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

!1

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

or (ON = With pair stacking, OFF = Without pair stacking)How to operate the pair stacking feature1 Carry out the steps of procedure for the normal button sewing.2 Set the material in place on the sewing machine as in the case of the normal button sewing.3 Press the Start switch, and release it. Then the material will be clamped and fed without being sewn,

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

N o . 1 • • • • • • D A T A INPUT • • • • • • • • • • • • • •

P A I R S T A C K I N G = O N

B A

!2

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

!3

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

• • • • • • • • • • • N o . SELECT • • • • • • • • • • • • • • •

M E M O R Y No. = 2

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

－ 31 －

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

2

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

!4

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

＊ The following switches are valid when inputting data. The number specified is increased. The previous number is restored. The number specified is reduced. The inpu data is deleted. The previous indication display is restored. The indication display is scrolled forward.

(Caution) 1. The number of buttons that can be specified in step 2 is from “2” through “20”. If youinput any number except these, the corresponding error message will appear on thedisplay screen for three seconds. If this occurs, specify the correct number of buttons.※ A single button can be sewn only when the machine is in the manual operation

mode or independent operation mode. (See page 35.)2. When the total sum of each button interval specified in step 3 through 7 is not within

the range of 25.0 mm to 650.0 mm, the same error message as stated above will appearon the screen. However, for the long-material mode, when the total sum of each buttoninterval is not within the range of 25.0 mm to 1,200.0 mm, the error message willapppear.

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

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

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

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

Error indication on the display screen

N o . 2 B U T T O N = 5 p s I N D E X < 1 → 2 > = 1 0 0 . 0 m m

C R O S S S H I R T C O U N T = 0 B O B B I N C O U N T = 4 0 0

0 0 ＊＊＊＊＊＊ D A T A I N P U T E R R O R ＊＊＊＊＊＊＊

Error message

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

1

Press so that the sewing LED lights up. ( )

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

C R O S S S H I R T C O U N T = 0 B O B B I N C O U N T = 4 0 0

3

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

B U T N ( p s ) 1 – – – – – 2 – – – – – 3 – – – – – 4 – – – – – 5 – – – – – ＊I N D X ( m m ) 1 0 0 . 0 1 0 0 . 0 1 0 0 . 0 1 0 0 . 0 ＊＊＊ . ＊

J U M P = 6 6 . 0 mm

R E T U R N B U T T O N N o . = 4

－ 32 －

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

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

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

P A I R S T A C K I N G = O N

8

This indication shows that the mode under which the cloth sensor automatically determines the stacker

timing has been specified.

S T A C K E R S T A C K M O D E = A U T O

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

screen instesd of that given in step 8)

8’

This indication tells you that the mode under which requires the operator to input the stacker timing

through the operation panel has been specified.

This indication also tells you that the stacker timing has been set to “10”.

S T A C K E R S T A C K M O D E = M A N U A L

S T A C K E R T I M I N G = 1 0

9

The display screen returns to the standard screen.

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

The previous indication display is restored.

The entered data is canceled.

N o . 2 BUTTON = 6 ps INDEX <1 → 2 > = 9 0 . 0 mm

S H I R T C O U N T = 0 B O B B I N C O U N T = 4 0 0

4

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

5

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

6

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

7

With/without pair stacking is shown on the display screen only when the machine is set to the “pair

stacking mode”. (ON = With pair stacking, OFF = Without pair stacking)

－ 33 －

4) Counter settings

Specify the initial values for the shirt counter and bobbin thread counter.

Shirt counter : The counter adds one (1) to the value after one shirt is finished.

Bobbin thread counter : The counter subtracts one (1) from the value after one button is finished.

(Example) The initial value for the shirt counter : 0 (The counter starts counting from the 1st shirt finished.)

The initial value for the bobbin thread counter : 400 (400 buttons can be sewn. Under the automatic

operation, the machine finishes 80 pieces of shirt each of which has five buttons and then

automatically stops. If sewing six buttons on each of shirt, the machine finishes 66 pieces of shirt

(6 buttons x 66 = 396 buttons) and automatically stops with the button thread to sew four buttons

remained.)

1

Press so that the LED lights up. ( )

2

Input the initial value for the shirt counter.

3

Input the initial value for the bobbin counter.

4

This completes the data input for the counter settings.



• • • • • • • • • • • • D A T A INPUT • • • • • • • • • • • •

S H I R T C O U N T E R = 0

• • • • • • • • • • • • D A T A INPUT • • • • • • • • • • • •

B O B B I N C O U N T E R = 4 0 0



＊ The following switch operations are valid when inputting data.

Increase the number specified. Return to the previous number.

Decrease the number specified. Delete the input data.

The previous indication display is restored. ( ) Delete the input data.

The indication display is scrolled forward.

Note that if any of these switches is pressed when the data for the bobbin thread counter in step 3 is being

inputted, the initial value for the shirt counter in step 2 is entered. Consequently, if you wish to change only

the shirt counter, be sure to press the ( ) switch before step 3 as stated above.

＊ The initial value “0” for the shirt counter can be set by pressing the switch (only when the machine

is waiting for the next operation).

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

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

－ 34 －

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

[Series of operations for ladies’ wear]

[Series of operations for finished product]

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

up. ( LED : ON LED : OFF)2 Properly set the material on the carriage.3 Press knee switch 3, and the work clamp feet at both ends of material come down. Release the knee

switch, then the sewing machine starts sewing.＊ If you press hand switch 4 before the knee switch has been released, the work clamp feet at the both

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

1 Power switch2 Operation panel3 Knee switch4 Hand switch5 Emergency stop switch

(4) Operation

Start Button sewing

Button sewing

Index

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

Stacking

Index (the carriage shifts)

Button sewing (last button)

The carriage returns to its

home position.

Start Button sewing

Button sewing

Index


Stacking




home position.

Start Button sewing

Button sewing

Index


The clamp of the carriage is released.




home position.

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

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

The proper material setting

1

2

3

4

5

1231

－ 35 －

2) Manual operation

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

[How to operate]

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

)

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

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

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

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

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

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

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

the clamp on the carriage will be released.

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

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

material will be stacked.

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

the clamp on the carriage will be released.

: The sewing machine is actuated.

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

knee switch.

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

series of operation in the oder of sewing machine actuation to the button sewing → index . Be careful

not to sew two buttons at the same position.

3) Independent operation

Use the independent operation mode to perform each operation step independentlyfor trial sewing or checking

the travel of the carriage.

[Operation]

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

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

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

the right when it has been adjusted for the ladies’s wear in a single step.

(Finally, the carriage returns to the origin.)

: The sewing machine is actuated.

Example) Trial sewing

1 Place the workpiece for trial sewing under the work clamp.

2 Press to actuate the sewing machine.

－ 36 －

4) Emergency stop

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

display screen.

The operation process when the emergency stop switch is pressed determines when and how the operation

is stopped or how the emergency stop is released.

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

has lowered, the work clamp will go up and stop in its highest position.

Press switch, and the indication on the screen will return to the standard display.

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

button sewing is finished.

Press the switch, and the machine operation mode will automatically change to the manual.

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

stops as soon as the switch is pressed.

Press the switch, and the carriage will automatically return to the sewing start position of the 1st

button and the machine operation mode will be changed to the manual operation mode.

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

or when the carriage is returning to the origin upon completion of button sewing, the sewing machine

stops as soon as the switch is pressed.

Press the switch, and the carriage will automatically return to the sewing start position of the 1st

button and the machine operation mode will be changed to the manual operation mode.

＊＊＊＊＊＊＊＊＊＊ E M E R G E N C Y S T O P ＊＊＊＊＊＊＊＊＊＊C H E C K → R E S E T → S T A R T

5) Error message and the reset procedure

1

Cause : If the needle thread breaks or

needle thread stitch error

occurs, the above error

message will be shown on the

display screen.

How to reset : Re-thread the needle, and

press switch 1.

(Caution) Do not press the reset switch

before threading the machine

head.

2

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

“0” or the remaining amount of bobbin thread is too short to finish one piece of garment),

the above error message will be shown on the display screen.

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

0 1 ＊＊＊＊＊＊ NEEDLE THREAD STITCH ERROR ＊＊＊＊＊＊S T I T C H CHECK → RESET → START

0 2 ＊＊＊＊＊＊＊ B O B B I N T H R E A D E R R O R ＊＊＊＊＊＊＊B O B B I N CHANGE → RESET → START

1

－ 37 －

3

Cause : If the wrok clamp of the

sewing machine is not raised,

the above message will be

shown on the display screen.

How to reset : Lift work clamp 2 by hand

and press the switch

on the operation panel of

ACF.

0 4 ＊＊＊＊＊＊ W O R K CLAMP POSITION ERROR ＊＊＊＊＊＊W O R K CLAMP CHECK → RESER → START

4

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

display screen.

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

5

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

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

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

6

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

the display screen.

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

operation panel of ACF.

7

Cause : If the button is not fed to button

clamp jaw lever 1, the above


display screen.

How to reset : Press button feeding switch

3 after you have confirmed

that the buttons are fed to

index unit 2.

0 9 ＊＊＊＊＊＊＊＊ RAM BACK UP ERROR ＊＊＊＊＊＊＊＊R E S E T → DATA INPUT

1 0 ＊＊＊＊＊＊＊＊ INDEX DATA ERROR ＊＊＊＊＊＊＊＊＊R E S E T → DATA INPUT

1 1 ＊＊＊＊＊＊＊ START SWITCH ON ERROR ＊＊＊＊＊＊＊S T A R T S W I T C H OFF → RESET → START

1 3 ＊＊＊＊＊＊＊＊ BUTTON FEED ERROR ＊＊＊＊＊＊＊＊＊＊L O A D E R S W I T C H O N → RESET → START

2

1 2

3

－ 38 －

�

8

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

display screen.

Also, in addition to the above error, the message will be shown on the display screen

when the sewing LED is gone out by pressing the ready key on the control box of LK.

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

9

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

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

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

on the operation panel of ACF.

!0

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

be shown on the display screen.

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

!1

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

will be shown on the display screen.

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

!2

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


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

carriage clamp position adjusting screw 3 so that carriage clamp 1 is carried away from

the sewing machine.

1 5 ＊＊＊＊＊＊＊＊ B O B B I N WINDING MODE ＊＊＊＊＊＊＊＊＊L K B O B B I N S W O F F → RESET

1 4 ＊＊＊＊＊＊＊＊＊＊＊ L K NOT READY ＊＊＊＊＊＊＊＊＊＊＊L K C H E C K → RESET → START

5 0 ＊＊＊＊＊ S T E P P I N G MOTOR DRIVER ERROR ＊＊＊＊＊P O W E R O F F → CHECK

5 1 ＊＊＊＊＊＊＊ A I R PRESSURE ERROR ＊＊＊＊＊＊＊＊＊P O W E R O F F → CHECK

5 2 ＊＊＊＊＊＊＊＊ C L A M P P O S I T I O N E R R O R ＊＊＊＊＊＊＊＊P O W E R O F F → CHECK

1

2

－ 39 －

!3

Cause : If the button index motor is

energized for a period of time

l o n g e r t h a n t h e

predetermined time, the

above message wi l l be


How to reset : Turn OFF the power switch,

and check button index unit

2 for any clogged button.

Give two clockwise turns to

manual screw 4 using a

screwdriver after you have

confirmed that 2 would not

turn any further.

5 4 ＊＊＊＊＊＊＊＊ B U T T O N INDEX ERROR ＊＊＊＊＊＊＊＊＊P O W E R O F F → CHECK

!4

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


Also, if the sewing continues for 20 seconds or more, the message will be shown.

Consequently, this message may be shown after 20 seconds from the start of sewing.

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

!5

Cause : If a button is not detected

after the index unit has

continuously performed the

button sensing (indexing the

button and detecting the

existence of button) by ten

times or more, the above


display screen.

How to reset : Check parts feeder 3 for its

correct performance, and

adjust so that buttons are fed

to the index unit properly.

5 5 ＊＊＊＊＊＊＊ S E W I N G MACHINE ERROR ＊＊＊＊＊＊＊P O W E R O F F → CHECK

5 6 ＊＊＊＊＊＊ B U T T O N S E N S I N G O V E R E R R O R ＊＊＊＊＊＊C H E C K → RESET → START

2 4

3

－ 40 －

!6

Cause : If the button cannot be set on

the spinner oscillating arm

even after the fine positioning

of button has been performed

twice, the above message will

be shown on the display

screen.

How to reset : Check button carrier pin 1 of

the spinner oscillating arm for

any clogged button.

!7

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

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

display screen.

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

button. (The normal rotational direction is the direction of arrow.) If breaker 3 is not in its

set position, press the push-button to set breaker 3. If the arm is not in its origin, press

button feeding switch 4.

5 7 ＊＊＊＊＊＊＊＊＊ B U T T O N SET ERROR ＊＊＊＊＊＊＊＊＊C H E C K → RESET → START

5 8 ＊＊＊＊＊＊＊ R E V O L U T I O N ARM ERROR ＊＊＊＊＊＊＊P O W E R O F F → CHECK

1

2

3

4

－ 41 －

!8

Cause : This error massage will be shown if the origin detect switch dose not work properly.

How to reset : Check the origin detector switch.

(Refer to pages 46 to 48 for adjustment.)

!9

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

switch dose not work properly.

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


@0

Cause : This message will be shown if the selector switch dose not work properly.

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


1 0 0 ＊＊＊＊＊＊＊＊＊ I N I T SW ERROR ＊＊＊＊＊＊＊＊＊ I N I T SW CHECK

1 0 1 ＊＊＊＊＊＊＊＊＊ S P E E D SW ERROR ＊＊＊＊＊＊＊＊＊ S P E E D SW CHECK

102 ＊＊＊＊＊＊＊＊＊ S E L E C T SW ERROR ＊＊＊＊＊＊＊＊＊ S E L E C T SW CHECK

－ 42 －

7. SWITCHES INSIDE THE PANEL BOX AND THE CONTROL BOX

(1) Inside the panel box

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

Loosen screws 2 and open switch cover 1 mounted on the right side face of operation panel. Set selector

switch 3 to its lower side to sew men’s wear or to its upper side to sew ladies’ wear. (Before you change the

setting of this switch, be sure to turn OFF the power to the sewing machine.)

2) Mode selection for shirt body and finished product

Loosen screws 2 and open switch cover 1 mounted on the right side face of operation panel. Set selector

switch 4 to its lower side to sew shirt bodies or to its upper side to sew finished products. When the switch

is set to the finished product sewing mode, be sure to operate the sewing machine using an auxiliary feed

plate (optional). (Before you change the setting of this switch, be sure to turn OFF the power to the sewing

machine.)

(2) Inside the control box

Remove six screws 1 of the control box under the

table, and open cover 2. Then you may switch over

the functions using the switches mounted on I/O circuit

board 3 and CPU circuit board 4.

Note that the switches and variable resistors mounted

on POWER circuit board 5 of the ACF-164-1903 are

inoperative.

(Caution) Be sure to change over the setting of

the switches after turning OFF the power

to the machine.

1

2

3

4

1

2

3

4

5

－ 43 －

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

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

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

SwitchNo.

Switchname

Description of function

SW1-4

SW1-5

SW1-6

This switch is used to set the jump function.

(OFF) : The jump function cannot be specified.

(ON) : The jump function can be specified.

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

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

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

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


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

50 Hz (OFF) : For the 50 Hz zone

60 Hz (ON) : 60 Hz zone

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

1

1

2

3

4

5

6

－ 44 －

Expectedcontrol bytimer

Detectioncontrol bysensor

SW1-7

SW2

SW3

SW4-3

SW4-4

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

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

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


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

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

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

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

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

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

(OFF) : The aforementioned button detecting function works.


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

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

(OFF) : The aforementioned button detecting function works.

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

1

2

3

4

SW4-□

5 6 7

OFF OFF OFF Waiting time of the spinner oscillating arm 290ms (Standard value)

OFF OFF ON Ditto 190ms

OFF ON OFF Ditto 390ms

OFF ON ON Ditto 490ms

ON OFF OFF Ditto 590ms

ON OFF ON Ditto 690ms

ON ON OFF Fine positioning completion detection control

(Fine positioning completion switch is necessary.)

ON ON ON Both positioning and fine positioning detection control

－ 45 －

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

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

OFF positions.

SW1-1

SW1-2

SW2-1

SW2-2

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

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

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

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

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

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

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

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

cleared once the power switch is turned ON.

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

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

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

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

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

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

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

(ON) : The sewing machine operates under the failure dianostic mode. (Setthe DIP SW4-8, mounted on the I/O circuit board, also to its ONposition.)

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

1

SwitchNo.

Switchname

Description of function

2

12

－ 46 －

8. ADJUSTMENT OF UNIT(1) CARRIAGE UNIT1) Adjusting the driving section of the carriage

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

2) After the completion of the aforementionedadjustment,measure the starting load of thecarriage. Press the section marked with the arrowin the figure and measure the starting load at thestart,intermediate position and the end of the entirestroke. As long as the starting load of 2 kgf or lessis provided at all the aforementioned positions, notrouble will result.

(Caution) If the backlash between the rack andt h e p i n i o n i s n o t p r o p e r l yadjusted,step-out of the steppingmotor or failure of feeding may result.

3) Confirm that the two screw in the gear presser aresecurely tightened. (Tighten either screw in the flatpart on the motor shaft.)

2) Adjusting position of origin and the presser switch of the carriage swtichAdjust the sewing machine both in the men’s wear sewing mode and the ladies’ wear sewing mode. Be sureto mode slide bearings (right and left) 6 to both ends of the carriage and fix them with slide bearing knob 7before starting the adjustment.Names of each adjusting area

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

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

Right-hand sideof the unit

1 Photo sensor 12 Photo sensor 23 Discriminating sensor4 Origin detecting plate (for men’s wear)

Carriage

Pinion

Screw

Screw

Backlash0 to 0.05 mm (0.002”)

Rack

Screws

Left-hand sideof the unit

5 Origin detecting plate (for ladies’ wear)6 Slide bracket7 Slide bearing knob8 Carriage

9 Pinion gear!0 Rack!1 Presser detecting plate (for men’s wear)!2 Presser detecting plate (for ladies’ wear)

!3 Presser switch (for men’s wear)!4 Presser switch (for ladies’ wear)!5 Stopper (for men’s wear)!6 Stopper (for ladies’ wear)

Sensor No.

Mode

Men’s Speed reduction sensor Origin sensor

Ladies’ Origin sensor Speed reduction sensor

1 2

1 2 3

4 5

6

7

8

9 !0

!1 !2!3

!4

!5!6

－ 47 －

1 Adjusting the men’s mode

1) When turning ON the power switch under the men’s sewing mode, carriage 8 should retrieve the origin

and stop at the position as shown in the figure.

To adjust dimension A to 122 ±1.5 mm (4.803” ± 0.059”),loosen the screw in origin detecting plate 4

and move the plate in the direction of the arrow until the specified dimension is provided. (If origin

detecting plate 4 is moved to the right, dimension A will be larger than 122 mm (4.803”). If the plate is

moved to the left ,dimension A will be smaller than 122 mm (4.803”). When dimension A is properly

adjusted, dimension B will be 3 ± 1 mm (0.118” ± 0.039”) and dimension C will be 6 mm (0.236”).)

2) To check the result of the aforementioned adjustment, turn OFF the power to the machine once, move

carriage 8 by hand to the left by 20 to 30 mm (0.787” to 1.181”), loosen the knob of slide bearing 6 and

set dimension S to 4 mm (0.157”).

Now, turn ON the power to the machine, and the error message “CLAMP POSITION ERROR” will be

shown on the display after the machine stars retrieving the origin.

If the sewing machine fails to stop while indicating the above-stated error message, move presser

switch !3 to the left and re-turn ON the power to the machine. If the sewing machine, this time, stops

while indicating the error message, adjust the position of stopper !5.

3) Turn OFF the power to the machine and set dimension S to 2 mm (0.079”).As long as no error is

indicated in this state, the sewing machine is correctly adjusted under the men’s wear sewing mode.

After the completion of checking procedure steps 2) and 3), be sure to move slide bearing 6 to the left

and set dimension S to 0 mm. Now, fix the slide bearing.

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

mode.

S=0 mm

C=6 mm

A=122±1.5 mm

B=3±1 mm

Center ofneedle

Speedreduction Origin Discriminating

1 2 3

4

6

8

9!0

!1

!3

!5

－ 48 －

2 Adjusting the ladies’ mode

1) Change over the sewing mode from the men’s wear sewing mode to the ladies’ wear sewing mode and

turn ON the power to the machine, carriage 8 should retrieve the origin and stop at the position shown

in the figure.

As same as in the case if the men’s wear sewing mode, adjust first dimension A. If origin detecting plate

5 is moved to the left, dimension A will be larger than 122 mm. If the plate is moved to the right,

dimension A will be smaller than 122 mm.

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

wear sewing mode.

A=122±1.5 mm

C=6 mm

S=0 mm

B=3 ± 1mm

DiscriminatingSpeed

reductionOrigin

Center ofneedle

1 2 3

5

6

8

9!0

!2

!4

!6

－ 49 －

3 Adjusting the work clamp unit

1. Adjusting slide bearing

1) Loosen knob 1, and move slide bearings (left, right)

2 to check for their smooth movement.

2) Adjust so that the respective distances of 25 mm

(0.984”) and 35 mm (1.378”) are provided between

slide shafts 3. The distances may change after

installing slide shaft connecting plate 4. However,

confirm the corect distances are provided between

the slide shafts after tightening slide shaft

connecting plate 4 at both ends and centers of

slide shalts 3. (6 in the figure indicates the

carriage rail.)

3) Eliminate a play at slide bearing 2 by adjusting

slide shaft holder 5.

2. Adjusting the clamps

1) To adjust the position of the clamps (right and left),

loosen the screws in the collars and adjust the

position of the clamp holders so that a clearance of

20±1 mm is provided between the clamp (right) and

the center of needle and a clearance of 7±1 mm is

provided between the clamp (left) and the center

of needle.

2) Adjust the height of clamps (right, left) after

confirming that a clearance of 1±0.5 mm is provided

between clamp receiving plates 1 (Carry out the

adjustment after loosening screw 5.) Adjust the

height of clamps by moving clamp holder receiving

plate 4 up or down so that a clearance if 13±1.5

mm is provided between clamps 6 (right, left) and

clamp receiving plates 1 (right, left).

(77)

(52)

25 m

m7±

1 m

m

20±1

mm

13±1

.5 m

m

1±0.

5 m

m

Clamp(left)

Clamp(right)

Collars

Clamp holder

35 mm

Center ofneedle

1

2

3

45

6

1

2

3

4

5

6

－ 50 －

4 Adjisting the set plate

1. Adjusting the height of the set plate

Loosen screws in set plate support fixing plate 7 and

set plates support (right and left) 3 and 4, and adjust

the height of the set plates to 1±0.5 mm above the top

surface of the throat plate by moving set plate support

(right and left) 3 and 4 and rail installing plate support

5 up or down.

Then check that the specified height of 1±0.5 mm is

provided at both ends and center of the respective set

plates.

1±0.

5 m

m

1±0.

5 m

m

1 Set plate (right)2 Set plate (left)3 Set plate support (right)4 Set plate support (left)5 Rail installing plate support6 Set plate installing base7 Set plate support fixing plate

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

0 – 24 mm 0

– 24 mm

1

2

3

4

5

6

7

7

7

－ 51 －

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

1) Adjusting the gauge (left)

Confirm that dimension A provided from the center of the needle to gauge (left) 2 is equal to the value

shown on the scales on both sides. If the value shown on the respective scales is different from dimension

A, loosen first screw 5 and the screws in collars 6, and move set plate (left) 9 in the direction of the

arrow until the scales are correctly positioned. At this time, use the rightmost end of set plate (left) 9 as

reference and adjust the leftmost end to it.

(It is recommended to adjust distance B provided between gauge (left) 2 and clamp support plate (left)

7 equally at both ends when the clamp support plate (left) 7 moves laterally.)

2) Adjusting the gauge (right)

After the completion of the adjustment of the gauge (left),adjust the position of gauge (right) 1 so that

“A’ equals to A”. Then fix the gauge (It is recommended to fit a straight ruler or the like against the gauge

surface.) Then, loosen screws 4 in scale plates 3, and adjust so that the value read at section D

equals to A. Move clamp support plate (right) 8 to the right and left and measure dimension C at the

rightmost end and the leftmost end of the travel so as to confirm that equal adjustment value is provided

both at the rightmost end and the leftmost end of gauge (right) 1.

3. Adjusting the gauge

1) Normally,the height of gauge 1 should be adjusted

to 20 to 23 mm (0.78” to 0.906”) when the gauge is

raised. To adjust the height of the gauge, change

the engagement between driving gear 2 and driven

gear 3.

2) Only the speed at which the gauge comes down is

controlled. The speed controller for controlling the

controlled. The speed controller for controlling the

speed is mounted on the solenoid value (the fourth

solenoid value as counted from the leftmost one.)

To adjust the speed,open/close the speed

controller.

20 to

23

mm

BA

D

A’C

D

Center of needle

12

3

45

6

7

8

9

3

4

1

2

3

－ 52 －

5 Adjusting the conveyor unit

1. Adjusting the belt tension

Loosen M10 nut 2, and adjust the belt tension by

moving idler pulley 1 in the direction of the arrow.

Adjust the belt tension to allow the belt to slack by 10

mm when a load of 80 to 120 g is applied to the belt.

2. Adjusting the longitudinal inclination of the conveyor

Loosen screws 2 in motor bracket installing plate 1

and adjust so that the difference between dimensions

A and A’ between table (left) 3 and conveyor frame

4 does not exceed 2 mm.

3. Adjusting the lateral inclination of the conveyor

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

an angle of 0˚ at the position where the belt comes in

contact with table (left) 3 when the conveyor comes

down with its dead weight. (Lowert conveyor, loosen

the screw and re-tighten it. This can sufficiently adjust

the inclination of the belt.)

4. Adjusting the vertical inclination of the conveyor

Loosen screws 1, and adjust so that belt 2 inclines

by an angle of 0˚ at the position where the belt comes

in contact with table (left) 3 when the conveyor comes

down with its dead weight.

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

When the conveyor is raised,belt 2 should be 40± 2 mm above table (left) 3. To adjust the height of the

conveyor, loosen screw 4 and move cylinder 5 up or down.

A’

10 m

m

80 to 120 g

40 ±

2 m

m

θ =0˚

θ=0˚

A

1

2

1

2

34

12

3

1

2

3

4

5

1

－ 53 －

6 Adjusting the stacker

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

garment regardless of its size and atacks the garments on the stacking board as long as

its dimensions are about 180 mm wide or more and 1,000 mm long or shorter. (The stacker

does not actuate under the long-material mode or the finished garment mode).

Approximately 140 garment bodies (material: T/C broad cloth) with a folded top center

plait can be stacked.

1. Performance

1) Length of cloth 5 fed by conveyor 1 is

automatically measured by material edge sensor

6.

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

dangling end of cloth 5 is pressed against stacking

board 4 by cloth presser bar 3.

1 Conveyor

2 Swing bar

3 Cloth presser bar

4 Stacking board

5 Cloth

6 Material edge sensor

1 Cloth presser bar2 Swing bar3 Stacking board4 Fixing knob of cloth presser bar5 Fixing knob of swing bar6 Fixing knob of stacking board7 Cloth presser cylinder8 Sensor of cloth presser9 Swing bar cylinder!0 Swing bar sensor!1 Cloth presser speed controller

[Configuration]

Side A

Side B

12

3

4

5

6

7

8

9

!0

!1

1

2

3

4

5

6

1

23

4

5

6

－ 54 －

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

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

2. Adjusting the stacking length of cloth (See the configuration on page 53.)If the cloth on A side is shorter (longer) than the clothon side B, perform the following adjustment.1) Loosen fixing knob 6 of the stacking board,and

raise (lower) stacking board 3.2) Turn speed controller !1 of cloth presser cylinder

7 clockwise (counterclockwise) to decrease(increase) the speed.

(Caution) If the speed is unnecessarily increased,the stacker will generate an impact noiseand durability of the stacker will beshortened. So, it is recommended notto increase the speed excessively.If the garment body to be stacked isshort, raise stacking board 3 and clothpresser bar 1.

3. Adjusting the position of the sensor (See the configuration on page 53)1) If cloth presser sensor 8 is set at the position where the indicator lamp of the sensor lights up when

cloth presser bar 1 moves toward stacking board 3, the sensor produces an alarm sound. In thiscase, the sensor detects the stacking amount of garment bodies on the stacking board and products analarm sound only, and the device does not stop.

(Caution) The sensor does not produce an alarm sound immediately after the sensor detects thestacking amount of garment bodies. The alarm occurs when the sewing machine sewsthe next garment body.

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

(The height of the speedcontroller has been factoy-adjusted to 12 mm at the timeof delivery.)

12 m

m

Side BSide A

1

2

3

4

5

6

1

2

3

4

5

6

－ 55 －

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

1) For materials of which length is larger than 600 mm.

While the material is being fed in the direction of

the arrow, the length of time required from the time

when the front end of the material passes sensor 2

(solid line) to the time when the rear end of the

material passes sensor 1 (two-dot chain line) is

measured. The material length is calculated based

on the aforementioned length of time measured.

2) For materials of which length is smaller than 600 mm.

While the material is being fed in the direction of

the arrow, the length of time required from the time

when the rear end of the material passes sensor 1

(solid line) to the time when the front end of the

material passes sensor 2 (two-dot chain line) is

measured. The material length is calculated based

on the aforementioned length of time measured.

3) The length of time during which the conveyor rotates

should be specified in accordance with the material

length calculated in the aforementioned steps 1)

and 2).

When the conveyor stops rotating, the cloth presser

bar actuates.

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

Length if time during which the conveyor rotates (a

value on the timer) is specified regardless of the

material length.

After the conveyor stops rotatong,the cloth presser bar

actuates.

A value on the timer can be set to any of twenty steps

ranging from level 1 (0.6 sec.) to level 20 (2.1 sec.). It

is specified on the operation panel.

(Operate the stacker under the manual stacking mode

if long materials are to be used or light-weight materials

or black-coloured materials that cannot be detected

by the sensor are to be used.)

600 mm

600 mm

Sensor1Sensor2

Sensor1Sensor2

Sensor1

Sensor2

1) Material of which length is larger than 600 mm

2) Material of which length is smaller than 600 mm

600 mm

－ 56 －

(2) Button feeder components

1) Removing the covers

Before adjusting the button feeder components,remove

top cover 1, set plate 2 and front cover 3.

Remove screws 4, 5 and 6.

2) Adjusting carrier pin

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

Loosen screws 2 and 3. Adjust clearance R provided

between the carrier pin and shutter plate 1, by turning

adjusting stopper 4, to 0.1 to 0.3 mm. At this time, fit

the button carrier against adjusting stopper 4 with no

clearance between them.

Then,tighten screw 3 to fix adjusting stopper 4 in

position.

2. Centering the carrier pin

Remove the work attachment from rotary rod 2.

Insert the carrier pin into centering ring 1. (At this

time,the shutter plate should be kept open.)

(Caution) Whenever the centering ring is used, set

it with its smaller diameter side up.

1) Adjusting the center of the carrier pin in the lateral

direction. Loosen screw 3 to allow the button

carrier to swing in the right or left as desired. Then

move the button carrier until the position where

rotary rod 2 smoothly enters centering ring 1 is

found.

Tighten screw 3 so that the button carrier is

secured at that position. Now,press eccentric cam

(1. -5) against the button carrier, and tighten screw

shown in (1.-6) while carefully preventing the

button carrier from moving from the secured

position.

R

Carrier pin

Buttoncarrier

1

23

4

56

1

2

34

56

1

2

3

4

5

6

7

8

5

－ 57 －

2) Centering the carrier pin in longitudinal direction

If the carrier pin cannot be properly centered by following the procedure 1), keep screw 3 loosened

and perform the following adjustment. Loosen two locknuts 4 (the left-handed screw is located in front

of the locknut) in the end of the rod. Loosen screw 5, and move urethane rubber 7 from the end face

away from the LM guide 8. Move connecting rod 6 until rotary rod 2 is brought to the position where

it smoothly enters centering ring 1. Then press the urethane rubber 7 against the LM guide 8 so as

to eliminate a longitudinal play. Confirm that the carrier pin is correctly centered then tighten nut 4 so

that connecting rod 6 does not rotate any longer. Then tighten screw 5. After the carrier pin has been

fixed with respect to its longitudinal position,the carrier pin should be laterally positioned and fixed in its

cause. It is, therefore, necessary to re-center the carrier pin both in the lateral and longitudial direction.

＊ The urethane rubber 7 is excessively pressed against the LM guide 8.→ The excessive contact

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

between them.

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

to confirm the following points.

1 The spinner oscillating arm does not have any longitudinal play when it is in its origin.

2 The spinner oscillating arm is correctly centered when it is in its origin.

3 The spinner oscillating arm actuates and the button is set on the button clamp jaw

lever.

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

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

carrier” on p. 60.

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

Draw the iron core of the fine positioning magnet until

the work attachment 3 is carried to its lowest position.

Now, loosen screws 2, and adjust the screw so that

clearance R of 0.1 mm or less is provided between

the work attachment 3 and the carrier pin as long as

the work attachment 3 does not come in contact with

the carrier pin. In this state, tighten screws 2 while

maintaining the relation between vertical hook 1 and

the rotary rod.

(Caution) Open the shutter plate, and adjust the

clearance between the work attachment

3 and the carrier pin.

Fine positioning magnet

Rotary rod

Fine positioningelevating lever

Carrier pin

1

2

3

R

－ 58 －

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

Normally, the fine positioning completion switch opens the shutter plate after the button has been set on

the carrier pin. When using a button which has a large recess at the center, however, the edge of the button

cannot come off the triple-pawl. As a result, the shutter cannot open due to the mechanism of the fine

positioning completion switch, and the button cannot be fed to the carrier pin. (Fig.1)

In this case, lower the carrier pin and the work attachment to allow the button to completely come off the

triple-pawl. (Fig.2) At this time, be sure to adjust the clearance between the work attachment and the

carrier pin to the value same as that provided between the work attachment and the carrier pin when they

are normally positioned (See p. 57.). Adjust the button clamp jaw lever in accordance with the button

height. [Refer to " 8) Adjusting the height of the button clamp" on page 61.]

Adjust clearance C provided between the button guide

and the adjusting plate, by bending the button guide,

to 2 ± 0.5 mm.

Button guide

1. Start of the fine positioning

Work attachment

Fine positioner

Button

Triple-pawl

Carrier pinShutter plate

Fig.1

2. End of the fine positioningThe button fails to fully comeoff the triple pawl.(The shutter does not open.)

1. Start of the fine positioning

Lower

Lower

Fig.2

2. End of the fine positioningThe button completely comesoff the triple pawl.(The shutter opens.)

Adjusting plate

C

Feeder bowl

e

e

－ 59 －

3) Centering the positioning until

1) Loosen bolts 1 and check bolt 6 of the shutter

magnet support plate.

2) Fit centering ring 3 in the center of triple-pawl 2.

Draw out triple-pawl dog 5 to allow centering ring

3 to be fitted in place. Move the index base plate

7 until a position where the rotary rod 4 (with the

work attachment removed) smoothly enters

centering ring 3 is reached.

3) After the positioning unit is correctly centered,

tighten bolts 1 and 6.

(Caution) Be sure to check again that the

positioning unit has been properly after

tightening bolts 1.

4) Replacing and positioning the feed disk

1) Pan

Use the feed disk (standard) of ø16 for buttons of

which size is ø10 to ø15. When buttons of which

size is ø16 to ø18 are used, use the feed disk

(optional) of ø22. In this case, adjust the pan located

under the feed disk according to the diameter of

the hole in the feed disk. Ten pan has two holes,

one is ø16 and the other is ø22. Bring the hole of

ø16 for the feed disk of ø16 or the hole of ø22 for

the feed disk of ø22 this size of the pan in terms of

the direction of rotation of the feed disk by turning

over the pan.

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

ø22 can also be used.

2) To position the feed disk, check first that the pinion

is in its origin. Then adjust the position of the feed

disk so that the matchmark on the feed disk aligns

with the matchmark on the pinion (countersinking).

At this time, align the hole in the pan with the hole

in the feed disk on the triple pawl.

3) Take the value obtained by adding 1 mm to the

buttonhole diameter in the feed disk used as

criterion of the initial diameter of the triple pawl.

Adjust the initial diameter of the triple pawl using

the positioning stopper bolt.

a mm

a+1mm

Shutter magnet

Feed disk

Pan

ø16 ø22

Align the matchmarks.Pinion

Triple pawl Feed disk

12

3

4

5

6

7

－ 60 －

5) Adjusting the feed disk of the index unit1) Confirm that the index unit is in its origin. Then

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

1 and the adjusting plate 2.3) Select one hole from among three holes with

different diameters (ø18,ø16 and ø12) in the feeddisk, and finely adjust the hole selected to thebuttons to be used using the adjuster. Adjust thefeed disk so that the periphery of the button is flushwith the periphery of the feed disk.

4) Adjust the clearance into which the button is placedallow only one button to go through it. Once theadjusting plate is correctly positioned, fix it bytightening the screw 4.

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

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

(Caution) Adjusting plate 2 is fragile. So, take carenot to excessively tighten the screw inthe adjusting plate.

6) Centering the button clamp jaw lever and the button carrier1) Tilt the machine head.2) Loosen three locking bolts 3 in the main body

frame and bolts 6 → (“(2)-2)-1 setscrew 6 (p.56)”.3) Raise the machine head. Turn the manual rotating

shaft until carrier 2 on which the button is placedis brought to its front end position.

4) Move the main body from until the button in carrier2 meets the button clamp jaw lever.

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

6) Raise the machine head, and confirm again thatthe button clamp jaw lever is correctly positionedby turning the manual rotating shaft by hand.

(Caution) This adjustment should be carried outafter the adjustment (2)-2)-2 (P.56) hasbeen completed.

Right plate

Locknut

Butttonguide

Pin hole

Button

Adjuster

Fixing screw

Adjusting plate

Left plate

1

2

34

1

2

3

－ 61 －

10 to 11 mm

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

This sewing machine has been designed to make the

button clamp jaw levers automatically open to release

the finished button at the very moment when the button

has been sewing on the material. The opening amount

of the button clamp jaw levers to release the button

can be adjusted. Manually turn the manual rotating

shaft, and the clamp release arm will move and button

clamp jaw lever will open. Adjust the position of the

clamp release arm by loosening the hexagon socket

head bolt so that a clearance of 1 to 2 mm is provided

between the button and the button clamp jaw lever

when pressing the roller away from you until it will go

no further. After the adjustment, tighten the hexagon

socket head bolt. If the clamp jaw lever from the sewing

start, the button clamping force will be insufficient

resulting in button setting failure or needle breakage.

On the other hand, if the clamp release arm is

positioned too far from the button clamp jaw lever, the

finished button may not be automatically released from

the button clamp jaw lever. So be careful.

8) Adjusting the height of the button clamp

When the sewing machine is in its stop-motion state

and the button feeder runs idle, the standard distance

of 11 mm should be provided between the button face

of the button clamp jaw lever and the top surface of

the feed plate of the sewing machine.

Loosen the hexagon socket head bolt, and turn the

work clamp vertical hook which is an eccentric shaft

until the button clamp is correctly positioned. Then

tighten the bolt. The standard height of the button clamp

is 11 mm as stated above. And, in principle, the button

supporting plane should be flush with the top surface

of the set pin. It would be better to slightly adjust the

height of the button to be used. The button should ne

placed in the button clamp jaw lever without fail.

Hexagon sockethead bolt

Top surface ofset pin

Roller

Clamp releasearm

Hexagon sockethead bolt Work clamp hook

Button clampjaw lever

Feed plate

Button supportingplane

－ 62 －

9) Adjusting the output level of the positioning solenoid

If the output level of the positioning solenoid is excessive,

the clamped button may be raised or broken. On the other

hand, if the output level of the solenoid is inadequate, the

button may fail to be clamped. It is, therefore, necessary to

adjust the output level of the solenoid properly. Loosen the

M4 double nut located at the rear of the solenoid, and adjust

the protruding amount of the male screw properly so that

an adequate output level of the positioning solenoid is

provided. The standard protruding amount of the male screw

is 12 mm (0.472”). At this time, position the magnet so that

an approximately 1 mm (0.039”) play is provided for the

spring attached at the top of the iron core of the solenoid. If

the spring does not have a play, loosen screw 1, and make

the adjustment properly.

(Caution) When performing the aforementioned

adjustment, the triple-pawl of the ø16 feed

disk should be opened.

10) How to use an electrostatic shielding cloth

Static electricity may impair smooth feeding of buttons.

In this case, stick electrostatic shielding cloths and

electrostatic string supplied with the machine on the button

feeding components with double-sided adhesive tape as

shown in the figure. (When adhering the cloth, and string is

on the in-line arrangement plate, cut them into an appropriate

size with a pair of scissors or the like. If the in-line

arrangement plate is adhered with the electrostatic shielding

cloths and string, the plate should be cleaned up periodically

since smooth feeding of buttons may be impaired by thread

waste that is likely to gather on the plate.)

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

provided between buttons and

electrostatic shielding cloth to prevent

the cloth from coming in direct contact

with buttons.

2. If the adjusting range of the vertical

position of the in-line arrangement plate

is limited by the thickness of buttons to

be sewn, remove the washer.

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

The separation plate supplied with the machine is not

adhered with a scale marker sheet. So, adhere the scale

marker sheets on the plate. At this time, adjust the position

of the sheets so that they do not come in contact with buttons

when the feeder bowl is used. If buttons come in contact

with the scale marker sheets, they may fail to be sorted

normally.

Determine dimensions R1 and R2 in the figure as desired

as long as they satisfy the requirement described above.

R2

a

1 mm 12 mm

R1

Slightly drawthis screw.

Guideplate

Doublenut

Electrostaticshielding

Feederbowl

Electrostaticshielding cloth

In-linearrangementplate

Washer

1

－ 63 －

1 1

(3) Detecting mechanism and its adjustment

1) Adjusting the thread breakage detector (THR)

The detector detects thread breakage by checking whether the thread tension is applied to the take-up spring when

the detector receives the up-position signal from the main shaft.

1. Adjusting the thread take-up spring

The standard stroke of thread take-up spring 1 is 6 pull

the thread at the starting point is 20 through 40 g. To

adjust the stroke of the thread take-up spring,loosen set

screw 2, and turn tension controller assembly 3

clockwise to increase the stroke or counterclockwise to

decrease it. To adjust the tension of the thread take-up

spring, insert the blade of a flat-bit screwdriver into the

groove in tension post 4, and turn it clockwise to increase

the tension or counterclockwise to decrease it.

(Caution) Decrease the tension of the thread take-

up spring for a synthetic fiber thread.

Now, loosen setscrew 8, and adjust so that detector

plate 5 comes in contact with thread take-up spring 1

without fail.

Finally, confirm that detector plate cable 7 is insulated

by grounding wire 6 when the thread take-up spring

starts pulling the thread to apply appropriate tension to

the thread.

2) Adjusting the fine positioner mechanism

1) Attach fine positioning motor !2 to rod driving arm !3 so

that fine positioning link !4 smoothly moves without

interfering with rod gear B 6. When fitting fine positioning

motor !2 in rod driving arm !3, attach hinge screws 4

which join fine positioning link !4 and fine position bracket

7. If the hinge screw is attached to the opposite side,

fine positioning link !4 will interfere with fine positioning

motor bracket 1 and fail to actuate. (See Fig.2)

2) When attaching fine positioning rod gear B 6 to fine

positioning motor bracket 1, position fine positioning

rod gear B 6 so that it can be rotated smoothly by hand

and deflects by 0.5 mm (0.020”) or less at the top end of

the gear teeth. (Adjust the position of the fine positioning

rod gear B 6 with hinge screw � . Then fix the hinge

screw with out !1.)

3) Attach fine positioning motor bracket 1 to main body

frame 2 so that a clearance of 1 mm (0.039”) is provided

between LM guide 3 and hinge screws 4 and a

backlash of 1.5 mm (0.059”) or less is provided between

fine positioning rod gear B 6.

4) After the fine positioning motor bracket has been

attached to the main body frame, manually move the

manual rotating shaft to check the clearance provided

between LM guide 2 and hinge screws 4. Fix spring

suspension to spinner oscillating arm returning spring

8 and LM guide 3.

Decrease

Fig.1

Increase

Fig.2

1

234

5

6

7

8

1

234

5

6 7

89

!0

!1 !2

!3

!4

1

6 7

!3

!4

－ 64 －

3) Button detecting mechanism at the positioner

A button is detected at the button positioner.

If a button is detected by the sensor, the machine starts

fine-positioning of the button. If no button is detected,

the machine repeats index until the sensor detects a

button by means if the gear. However, no button is

detected after having continuously tried indexing a

button ten times, the machine terminates indexing and

the alarm indicator on the operation panel repeats

flashing on and off. Now, press the manual operation

switch, and the machine will re-start indexing until the

sensor detects a button.

4) Spinner oscillating arm origin switch (A.ORG) and spinner oscillating arm forward switch (AFRT)

(The switches are different from those mounted on the BR10. So be careful.)

Spinner oscillating arm origin switch 1 (hereinafter

called “A.ORG”) and spinner oscillating arm forward

switch 2 (hereinafter called AFRT) each of which is

equipped with a photo-micro sensor (PM-T53B) are

sensors to detect the origin of the cam shaft.

Adjust cam follower 3 for the button clamp jaw lever

so that it is located above attaching screw 5 in two-

stepped cam 4 by turning the manual rotating shaft,

as illustrated in Fig.a. Fix AFRT 2 at the lowest position

of the slot in metal fitting A 7 of the spinner oscillating

arm.

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

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

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

different from that of sensor dog for

BR20.

5) Adjusting the index origin switch (IORG)

Index origin switch 1 (hereinafter called IORG) which

incorporates a proximity sensor (GXL-8F) is a sensor

to detect the stop of feeding of the feed disk.

Adjust the clearance between the periphery of Zeneva

wheel 2 and the detecting plane of the IORG to 0.8 to

1.2 mm (0.013” to 0.047”)0.8 to 1.2 mm

(30˚)

3.7

7.5

SensorTriple-pawl

Hole in thefeed disk

Gear

Fig.a

Fig.c

Fig.b

12

3

4

5

6

7

8

1

2

12

6

－ 65 －

6) Adjusting the button positioning detection switch (BUT)

Button positioning detection switch 1 (hereinafter called BUT) which incorporates a proximity sensor (GXL-

8F) is a sensor to detect whether a button exists in the positioner 2 when actuating the positioner (triple

pawl). (It turns OFF when a button exists in the positioner or turns ON when it does not detect any button

there.)

Draw the iron core of positioning solenoid 3 when there is no button in positioner 2, and the triple pawl will

be closed. In this state, loosen the fixing screw of triple-pawl dog 4, and move triple-pawl dog until BUT

which has been in the OFF state turns ON. Then further move the triple pawl dog forward from the

aforementioned position (Fig. A- 1) by 1.5 mm (0.059”) (Fig. B- 2), and tighten the fixing screw of the

triple-pawl dog. Then, confirm that BUT turns OFF when the triple-pawl clamps a ø10 mm (0.394”) button.

Also confirm that BUT turns ON when the triple pawl is closed after taking out the button from it.

7) Adjusting the button detecting switch and cylinder

1) Adjust first the operating air pressure to 0.5 MPa

(5 kgf/cm2.)

Loosen cylinder nut 6 and adjust the position of

the cylinder so that clearance (a) provided between

button clamp jaw lever (left) 7 and detecting lever

8 is minimized with the power to the machine

turned OFF (the cylinder is fully extended).

2) Set the operating air pressure to 0 MPa (0 kgf/cm2)

and retract cylinder 3. (The cylinder automatically

returns to its retracted position by means of the

spring.) Now, loosen screw 5 and adjust so that a

clearance of 1 mm is provided between sensor 1

and the end face of detecting plate 2.

a

Fig.A-1 Fig.B-2

BUT1BUT1

BUT ON1.5 mm

1 mm

Triple-pawl dog

1

2

3

46

7

1

2 3

4

5

7

8

4

－ 66 －

8) Adjusting the work clamp lift detecting switch

1) Adjust metal fitting 2 so that a clearance of 1.5

mm (0.059”) is provided between work clamp lift

detecting switch 1 and vertical lever 3.

2) Then, fix switch 1 at the position where the LED

lights up when the work clamp is raised by turning

the manual rotating shaft.

3) Confirm that the LED lights up when the work clamp

is lowered.

(Caution) Be sure to pass switch cord 4 through

the section of metal fittings 2.

(4) Replacing the components and positioning them

1) Replacing the button carrier and positioning it

To replace the button carriers, remove first the fixing

knob of the set plate (right).

Loosen screw 1 and remove the button carrier,

Replace the button carrier with another button carrier

with a proper center-to-center distance. Fit the selected

button carrier to the eccentric cam stopper, and

simultaneously make the top face of the carrier come

in contact with the dolly nut. Now, dix the button carrier

at that position.

(Caution) The above-stated positioning procedure

should be carried out with the sewing

machine set to the origin.

2) Replacing the work attachment

Remove the work attachment currently attached to the

sewing machine from the rotary rod. Then attach the

work attachment of another type to the machine. At

this time, be sure to confirm that the work attachment

securely fits in the position.

This should be confirmed in the case of replacing any

other components in the normal operation of the sewing

machine.

1.5 mm

When the work clampof the sewing machineis raised

Button carrier

Large type

Dolly nut

Rotary rod(fine positioning shaft)

Work attachment

1

2

3

4

1

1

2

3

－ 67 －

3) Adjusting the parts feeder

1. Operation of the operation panel

1) Turn ON the power to the parts feeder.

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

3) If the feeder does not vibrate adequately, turn sensitivity

sensitivity adjustment variable resistor 2 until it reaches

the position to allow the feeder to vibrate most. Then

turn sensitivity adjustment variable resistor 3 and make

a fine adjustment so that vibration of the feeder is

maximized.

4) Adjust the flow of buttons using the parts feeder adjusting

variable resistor 1.

(Caution) Sensitivity adjusting variable resistor 2 is

very delicate. It is recommended to place

buttons with flat bottom in the feeder bowl,

and adjust the flow of buttons while

checking the actual flow of the buttons. This

will allow you to adjust the flow of buttons

with ease.

4) Adjusting the attachments in the feeder bowl

1. Guide plate

The appropriate clearance between the button top face and

the guide plate 1 is approximately 0.7 mm.

Loosen screws 2, and move guide plate 1 up and down

to adjust the clearance appropriately.

2. Separation plate

The separation plate sorts the right-sided buttons from the

wrong-sided buttons and feeds only the right-side buttons

to the index unit. Loosen bolt 1, and move separation plate

2 back and forth until it is correctly positioned. Now, fix the

plate with bolt 1. The separation plate comes in three

different sizes, i.e., large, medium and small. Select one

from among them in accordance with the size of buttons to

be used.

3. In-line arrangement plate

This plate prevents buttons which have passed the

separation plate from piling up. The appropriate clearance

between in-line arrangement plate 2 and the top face of a

button is approxiamtely 0.7 mm.

Loosen bolt 1, and move the in-line arrangement plate 2

up and down to adjust the clearance to the correct value.

Track surface

Button

12

3

12

1

2

1

2

－ 68 －

4. Button guide

Appropriate clearance R1 between the button guide

1 and the button is approximately 3 to 4 mm (0.118”

to 0.157”). Loosen screw 2, and adjust the clearance

to the correct value. A clearance which is larger than

the value twice as thick as a button by approximately

0.7 mm should be provided between overflow

prevention plate 3 and the button. Loosen screw 2,

and adjust the clearance to the correct value.

Appropriate clearance R 2 between lower surface of

the button guide and the track surface of the feeder

bowl is 0.3 to 0.5 mm (0.012” to 0.020”).

5. Adjusting the height of the feeder bowl

Loosen six locknuts 1 of feeder base 2, and adjust

height difference R between the outlet for buttons and

the disk to 0.5 mm (0.020”) or less while the disc is

positioned higher than the outlet for buttons. (At this

time, never adjust 3.)

If an excessive difference in height is provided, two

buttons may enter the notch of the feed plate with

overlapped. So be careful.

6. Adjusting the position of the feeder bowl

Adjust clearance R between the feeder bowl and the

disk 4 to approximately 1 to 1.5 mm (0.039” to 0.059”).

Loosen nut 1 (above figure) and move the entire unit

of the parts feeder until it is properly positioned. The

position of the feeder bowl can be finely adjusted by

loosening the feeder bowl attaching screw and

changing the position of the feeder bowl.

R2

R

R1

Feeder bowlattaching screw

12 3

12

3

4

－ 69 －

9. MAINTENANCE INSPECTIONFor maximum performance of this machine, be sure to perform periodic maintenance and inspection as

shown below.

(1) Maintenance and inspection of the sewing machine components

Dirts and dust accumulated on the components

described below may adversely affect the sewing

capabilities and performance of the sewing machine.

So, be sure to clean them after operation is finished.

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

gun.

2) Remove the fibrous wastes or dust from the contact

plane of the lelctrode of thread breakage detector

with a dry rag.

3) Apply lithium system soap group grease No.2 onto

the nipples (located on the both side of the carriage

unit) of the LM guide that is used for feeding the

carriage unit once every two or three months.

(2) Maintenance and inspection of electrical components

Inspect periodically each joints for loose connector,etc., caused by vibration of the machine,etc. (Also

check each power plug for lifting and screws for looseness.)

(3) Diagnostic feature

Input signals of the sensor or output signals of valves can be checked on the operation panel. Use this

feature troubleshooting at the time of maintenance.

1. Details of inspection

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

2) Checking the input signals.

3) Checking the output signals.

2. Preparations for operation

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

•DSW4-8 in the I/O circuit board → ON

•DSW2-2 in the CPU circuit board → ON

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

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

Nipple

－ 70 －

3. Operating procedure

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

If an abnormal indication is shown on the operation panel, failure of the LCD components can be inspected.

1 Turn ON the power to the machine, and the following screen will appear on the LCD of the operation

panel.

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

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

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

panel circuit board with a new one.

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

2) Checking the input signals

Input signals of the switches and sensors can be inspected through the LCD on the operation panel.

* Turn OFF the power to the machine and remove the operating air supply to the machine and the

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

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

(LCD) on the operation panel.

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

one.

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

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

* Refer to the next page for the corresponding table.

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

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

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

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

DLAGNOSTIC PROGRAM

1. LCD CHECK

DLAGNOSTIC PROGRAM

2. INPUT SIGNAL CHECK

0 0 0 0 0 0 0 0 0 0 0 ・・・・・0 1 1 0 1 1 1 1 1 1 1 ・・・・・

1 2 ...................................... 40

41 .........................................80

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

↑ ↓

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

－ 71 －

LCD NO. Name of input signal

1 Numeric key SW ON→ 1










11 Plus SW SW ON→ 1

12 Minus SW SW ON→ 1

13 Back SW SW ON→ 1

14 Forward SW SW ON→ 1

15 –

16 Entry switch

17 Memory No. selector SW SW ON→ 1

18 Hiding key (under the ) SW ON→ 1

19 Sewing data input SW SW ON→ 1

20 Sewing data check SW SW ON→ 1

21 Counter setting SW SW ON→ 1

22 Shirt counter clear SW SW ON→ 1

23 Hiding key (under the and ) SW ON→ 1

24 Bobbin counter reset SW SW ON→ 1

25 Automatic operation selecting switch SW ON→ 1

26 Sewing machine start SW SW ON→ 1

27 Hiding key (right,right and right of the ) SW ON→ 1

28 Hiding key (right and right of the ) SW ON→ 1

29 Carriage travel SW SW ON→ 1

30 Hiding key (right of the ) SW ON→ 1

31 –

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

33 Garment body/finished product change-over SW Finished product→ 1

34 Sewing machine start SW SW ON→ 0

35 Emergency stop SW SW ON→ 0

36 Carriage clamp release SW SW ON→ 0

37 Compressed air detector Compressed air is supplied→0

38 Alarm output SW ON→ 0

39 –

40 Japanese/English DSW SW ON→ 1

LCD NO. Name of input signal

41 mm/inch DSW SW ON→ 1

42

43

44 Used for diagnosis

45 Normal/aging DSW SW ON→ 0

46 A/B type DSW SW ON→ 0

47 M/BLK DSW SW ON→ 0

48 Cross-over SW DSW SW ON→ 0

49 Front end input DSW SW ON→ 0

50 Long-material DSW SW ON→ 0

51 50/60 Hz DSW SW ON→ 0

52 Pair-stacker DSW SW ON→ 0

53 Used for diagnosis

54 –

55 Carriage origin detector shielded→1

56 Carriage speed decreasing detector shielded → 1

57 Carriage discrimination detector shielded→1

58 Stacked No. of pcs. detector Lights up→ 0

59 Swing bar detector Lights up→ 0

60 Carriage clamp position detector shielded→0

61 Material edge detector (left) shielded→0

62 Material edge detector (right) shielded→0

63 –

64 –

65 –

66 –

67 Spinner oscillating arm forward detector Forward→ 1

68 Manual button feeding SW SW ON→ 1

69 Step-operation SW SW ON→ 1

70 Button discharging SW SW ON→ 1

71 Stop-motion detector Stop-motion→ 1

72 Button detector shielded→0

73 Button positioning detector Lights up→ 1

74 Detection of button detector Lights up→ 1

75 Spinner oscillating arm origin detector Origin→ 1

76 Indexer origin detector Origin→ 0

77 –

78 Sewing failure detector Contact→ 1

79 Needle-up position detector Upper position→ 1

80 Work clamp lift detector Liftıî1

－ 72 －

3) Checking the output signals

Performance of the values and motors can be checked by making them operate independently for a

predetermined period of time using the switches on the operation panel.

* Turn OFF the power to the machine, connect the operating air supply to the machine and connect the

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

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

display (LCD) of the operation panel.

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

following screen.

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

screen will appear on the LCD of the operation panel.

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

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

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

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

near the machine head.

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

DLAGNOSTIC PROGRAM

1. OUTPUT SIGNAL CHECK

CHECKING OUTPUT SIGNAL

－ 73 －

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

the peripheral components will operate. So, keep your hands away from the components

near the machine head.

Switch on theoperation panel

Memory No. selector LED

Sewing data input LED

Sewing data check LED

Counter set LED

Conveyor shift cylinder

Stacker cloth presser cylinder

Swing bar stacker cylinder

Conveyor motor

Material edge gauge cylinder

Carriage clamp cylinder

Used as the entry key for diagnosis

Automatic operation selector LED

Carriage travel LED

Work clamp check lowering cylinder

Used to restore the previous screenfor the diagnostic feature

BR positioning solenoid

BR shutter solenoid

BR fine positioner lowering solenoid

Sewing machine starting cylinder

BR fine positioning motor

BR index motor

BR spinner oscillating arm motor

BR parts feeder

BR button detecting cylinder

The LED of the memory No. selector switch on the operation panel lights up.

The LED of the sewing data input switch on the operation panel lights up.

The LED if the sewing data check switch on the operation panel lights up.

The LED of the counter setting switch on the operation panel lights up.

The conveyor comes down.

The cloth presser of stacker actuates.

Swing bar of stacker actuate.

The conveyor motor rotaes.

Material edge gauge comes down.

The carriage clamp comes down.

The LED of the automatic operation selector switch on the operation panellights up.

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

The work clamp check of the sewing machine comes down.

The positioning solenoid actuates.

The shutter solenoid actuates.

The fine positioner lowering solenoid actuates.

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

The motor of the fine positioner rotates.

The motor of the indexer rotates until the next feeding hole is reached.

The spinner oscillating arm feeds a button.

The parts feeder vibrates.

The button detecting cylinder actuates.

Output signal ON state of switches

－ 74 －

－ 75 －

10. PERFORMANCE FLOW CHART

Manual/independent

Motor for men’s wear

Power ON

Men’s/ladies’ wear

Men’s wear

Long sized material/standard

Long sized material

1-5

Long sizedmen’s wear

Standard

Finished workpiece/thebody of a garment

To body of agarment

The carriage originsearching

Work clamp positionN.G.

The carriage stopstravelling

Faulty work clamp positionerror indication

StopGood

Read the memoryNo.1-20

4

1-2

Finished workpiece/ formen’s wear

Ladies’ wear

Ladies’ wear

1-1

Auto/independentIndependent

Automatic

Auto/ManualManual

1-3

Manual operation

Automatic

Start switchOFF

ON

In the amount of bobbinthread sufficient ?

Y

Work clamp comes down

The start release SWON

Work clamp goes up

Set the start SW to OFF

OFF8

Supply buttons

Y

Work clamp of the sewingmachine comes down

N

Work clampcomes down

N

Work clamp goes up errorindication

5

Y

Machine starts

The last button sewing

N

Thread breakage ?

N

Work clamp goes upN


5

Y

Bobbin thread counter = 0

Y

Bobbin thread error isshown.

5

N

The carriage indexing

BR motion

Continuous motion

The carriage switchOFF

ON

LED comes ON

The last indexingfinished

Finished

The carriage returns tothe origin.

Not finished


Work clamp positionGood

6

N.G.

The carriage stopstraveling

Faulty work clamp positionerror indication.

Stop

Bobbin thread erroris shown.

R switchOFF

ON

Reset error indication

4

Work clamp goes up


Thread breakage ?

N

Y

3

1

Button error indication

5

Work clamp goes up

R switchOFF

ON



4

Auto/Manual

Set the start releaseSW to ON.

Y

N

R switchOFF

ON


Set to Manual

7

1

Stitch error indication

NIndependent ?

Y

R switchOFF

ON


4

The machinestart switch

OFF4

ON9

Supply buttons ?

Yes

Machine starts

Thread broken ?YThread trimming error

N

Bobbin thread counter = 0

Y

Bobbin thread erroris shown.

5

N

BR motion

6

Independent ?N

Y

NoneButton error

N

Y

Y

3

BR motion

Conveyer motion

Stacking

1 cycle finished

Finishedworkpiece

－ 76 －

Machine start SW

Work clamp goes up


Men’s wearmanual operation

1-3

The start SWOFF

ON


The start release switchON

OFF

7

The start SWOFF

ON

Set to the AUTO

8

switchOFF

ON

Home positionY

N


switch OFF

ON

The last indexing finishedFinished

Not finished



N.G.

The carriage stops travelling

Faulty work clamp position errorindication

Stop

Work clamp goes up

Feed the carriage to the origin

Conveyer motion

Stacking

4

9ON

OFF

－ 77 －

Work clamp goes up


Finished men’s wear/manual operation

1-4

The start SWOFF

ON


The start release switchON

OFF

The start SW

27

OFF

ON

Set to the AUTO

28

switchOFF

ON

Home positionY

N

The final indexing

switchOFF

ON

The last indexing finishedFinished

Not finished



N.G.

The carriage stops traveling

Faulty work clamp position errorindication

Stop

Work clamp goes up

Feed the carriage to the origin

Conveyer motion

24

Machine start SWON

OFF

29

－ 78 －

Bobbin thread error is shown.

Note 1) The motion for ladies’ finished wear and that for men’s are identical except for the motionof the carriage, where motions on the left side and right side are reversed.

44

Work clamp goes up

Set the start switch to OFF

43

Work clamp goes up

Return the carriage tothe origin

BR motion

Conveyer motion

Stacking

1 cycle finished

2-1

Note 1) Ladies’ finished wear

Motion for ladies’ wear

1-1

Finished wear/The bodyof a garment

Finished wear

The body of a garment

The carriage searchesthe origin


Good

Read the memory No.1-20

Auto/independentIndependent

Auto

Auto/ManualManual

Auto

The start switchOFF

ON

Is the amount of bobbinthread sufficient ?

N

Y


The start reset switchON

OFF48

Supply buttons ?N

Y

Work clamp of sewing machinecomes down

N

Y

The machine starts.

Work clamp of sewingmachine comes down

Thread broken ? Y 41

N

The last button finished

Work clamp goes up

43Y

N

N

Y

Bobbin thread counte= 0

Y

N


BR motion

Continuous motion



Stop

2-3

Manual operation


OFF

ON


4


45


45


5

R switch

The carriage switch

ON

OFF

LED comes ON

The fianlindexing finished

Finished

Not finished



N.G.



Stop

Return the carriageto the origin

46


45

Work clamp goes up

OFF R switch

ON

Reset error display

Return the carriageto the origin

44

Auto/Manual

Start release SW “ON”

N

Y

R switch OFF

ON


Set to Manual

47

41


Independent ?N

Y

R switchOFF

ON


44

Machine start switchOFF

44

ON49

Supply button ?NoneButton error

Yes

Machine starts


N

Bobbin thread counter= 0

Y

N

BR motion

46

Independent ? N

Y

5

Manual / Independent

－ 79 －


24

Work clamp goes up


23

Work clamp goes up

The carriage returns tothe origin

BR motion

Conveyer motion

1 cycle finished

Men’s finished wear motion

1-2

The carriage searchesthe origin


Good

Read the memory No.1-20

Auto/IndependentIndependent

Auto

Auto/ManualManual

Auto

Start switch

ON


N

Y



OFF

OFF28

Supply buttons ?N

Y


Work clampcomes down

N

Y

Machine starts

Thread broken ?Y

21

N

The last buttonfinished

Y23

N

Work clamp goes upN

Y

Bobbin thread counter= 0

Y

N


BR motion

Continuous motion


Work clamp position errorindication

Stop

1-4

Manual operation

Bobbin thread error indication.

OFF

ON


4


25


25

Bobbin thread errorindication

5

Carriage switchOFF

ON

LED comes ON

Last indexing finishedFinished

Not finished

Carriage indexing


N.G.

Carriage stop traveling


Stop

Carriage returns to the origin

26


25

Work clamp goes up

R switch

R switchOFF

ON


Carriage returns to the origin

24

Auto/Manual

The start releaseSW “ON”

N

Y

R switchOFF

ON


Set to Manual

27

21


Independent ?N

Y

R switchOFF

ON


24

The machinestarts switch

OFF24

ON29

Supply buttons ?NoneButton error

Yes

Machine starts


N


Y

N

BR motion

26

Independent ?N

Y

Manual/Independent

5

Finished

－ 80 －

OFF

Ladies’ wear manual operation

2-3

Start switch OFF46

ON

Work clamp goes down

Start release switchON

Work clamp goes up

Set the start SW to “OFF”

OFF

Start switchOFF

ON

Set to auto

48

47

switchOFF

ON

Home position Y

N

Carriage indexing

switchOFF

ON


Not finished

Carriage indexing


N.G.

Carriage stops traveling


Stop

Work clamp goes up

Return carriage to the origin

Conveyer motion

Stacking

44

Machine start switchON

49

－ 81 －

57

Work clamp goes up


56

BR motion

Conveyer motion

Stacking

1 cycle finished


5

Long sized men’s wear motion

1-5

The carriage originsearching


Good

Reset the memoryNo.1-20

Auto/IndependentIndependent

Auto

Auto/ManualManual

Auto

Start switchOFF

ON


N

Y



OFF

60

Supply buttons ?N

Y

Carriage turning pointY

N


Comes downN

Y

Start the machine

The last button sewing Y

N

Thread broken ?Y

N

Work clamp goes up

Y

N

Bobbin thread counte = 0

Y

N


BR motion

Continuous motion


5

The carriage stopstraveling


Stop

1-6

Manual operation


R switchOFF

ON


4


Conveyer comes down

Work clamp goes up

The carriage returns to theorigin


Conveyer goes up


65

Work clamp goes up

Carriage returns to theorigin

Thread broken ?Y

N

56

1

Carriage switchOFF

ON

LED comes ON

Carriage turning pointY

NCarriage returns to

the origin


Carriage returns tothe originNot finished

Carriage indexing


68

N.G.

Carriage stops traveling


Stop


65

Work clamp goes up

R switchOFF

ON


Carriage returns tothe origin.

57

Auto/Manual

The start releaseSW “ON”

Y

N

R switchOFF

ON


Set to Manual

59

54


Button error None

Thread trimming error

Independent ?N

Y

R switchOFF

ON


57

The machinestart switch

OFF57

ON61

Supply buttons ?

YES

Machine starts

Thread broken ?Y

N


Y


5

N

BR motion

Independent ?N

Y

Auto/Independent

58

－ 82 －

Work clamp goes up

Set start SW to “OFF”

Long sized men’s wearmanual operation

1-6

The start SWOFF

ON


The start releaseswitch

ON

OFF

59

The start SW

OFF

ON

Set to Auto

60

Y

N

Conveyer comes down

Work clamp goes up

Carriage turning point(indexing)


Conveyer goes up

switchOFF

ON

Home position

N

Y

Carriage indexing

switchOFF

ON

Y

N

The last indexingfinished

Finished

Not finished

Carriage indexing


N.G.

The carriagestops traveling


Stop

Conveyer comes down

Work clamp goes up

Return carriage tothe origin.


Conveyer goes up

Work clamp goes up

Carriage return to the origin

Conveyer motion

Stacking

57

Machine start switchON

OFF

61

Carriage turning point

Carriage turning point

－ 83 －

11. SEQUENCE CHART

Motion of the ACF-164-1903

AC

F-1

64 IN

PU

TA

CF

-164

OU

TP

UT

LK, B

R IN

PU

TLK

, BR

OU

TP

UT

Origin SW

Speed reduction SW

Knee SW

Work clamp goes up detector SW

Cloth edge detector (1) SW


Swing bar detector SW

Reset error SW

Indexing (right) SW

Gauge cylinder

Carriage work clamp cyl.

Work clamp comes down cyl.

Conveyer cyl.

Conveyer motor

Work clamp stacker cyl.

Stacker swing bar cyl.

Stepping motor

Stop-motion SW

Upper position detector SW

Thread breakage detector SW

Oscillating spinner arm origin SW

Oscillating spinner arm forward SW

Button detector SW

Button positioning detector SW

Index origin SW

Button discharging SW

Step operation SW

Button supply SW

Button detector cyl.

Machine starter

Oscillating spinner arm motor

Positioning SOL

Fine positioning motor

Fine positioning SOL

Shutter SOL

Index motor

Parts feeder

INIT

SPEED

START

FL.POS

WRK. FWD

WRK. BCK

STCK2

RESET

MOV. R

GAU. CL

CLP. CL1

FUT. CL

COV. CL

COV. MTR

STK. CL1

STL. CL2

CCWCW

L. SW

UP. SW

THR

A. ORG

AFRT

BUT

POS

I. ORG

EXHST

ARNGE

MANU. FD

BUT. CL

STR. CL

ARM. MTR

SET. SOL

RUB. MTR

RUB. SOL

SHT. SOL

IND. MTR

PT. FDR

ONOFFON

OFFON

OFFON

OFFON

OFFON

OFFON

OFFON

OFFON

OFF

ONOFFON

OFFON

OFFON

OFFON

OFFON

OFFON

OFFCCWOFFCW

ONOFFON

OFFON

OFFON

OFFON

OFFON

OFFON

OFFON

OFFON

OFFON

OFFON

OFF

ONOFFON

OFFON

OFFON

OFFON

OFFON

OFFON

OFFON

OFFON

OFF

Auto operation Error Manual operation Auto operation Error Manual operation Manual operation Auto operation

Stacking motion

Originsearching Start Sewing Sewing (stitch skipping, thead bra\eakage error) Reset Re-start a (button supply error) Reset Button supply Indexing (manual) Re-start (Last button sewing,return to the origin)

T T T T T

T : Indicates the value on the timer

Indexing

－ 84 －

Button supply

Motion of the LK-1903/BR21

AC

F-1

64 IN

PU

TA

CF

-164

OU

TP

UT

LK, B

R IN

PU

TLK

, BR

OU

TP

UT

Origin SW

Speed reduction SW

Knee SW

Work clamp goes up detector SW



Stacker swing bar detector SW

Reset error SW

Indexing (right) SW

Gauge cylinder

Carriage work clamp cyl.

Work clamp comes down cyl.

Conveyer cyl.

Conveyer motor

Work clamp stacker cyl.

Stacker swing bar cyl.

Stepping motor

Stop-motion SW

Upper position detector SW

Thread breakage detector SW

Oscillating spinner arm origin SW

Oscillating spinner arm forward SW

Button detector SW

Button positioning detector SW

Index origin SW

Button discharging SW

Step operation SW

Button supply SW

Button detector cyl.

Machine starter

Oscillating spinner arm motor

Positioning SOL

Fine positioning motor

Fine positioning SOL

Shutter SOL

Index motor

Parts feeder

INIT

SPEED

START

FL.POS

WRK. FWD

WRK. BCK

STCK2

RESET

MOV. R

GAU. CL

CLP. CL1

FUT. CL

COV. CL

COV. MTR

STK. CL1

STL. CL2

CCWCW

STP. SW

UP. SW

THR

A. ORG

AFRT

BUT

POS

I. ORG

EXHST

ARNGE

MANU. FD

BUT CL

STR CL

ARM MTR

SET SOL

RUB MTR

RUB SOL

SHT SOL

IND MTR

PT. FDR

ONOFFON

OFFON

OFFON

OFFON

OFFON

OFFON

OFFON

OFFON

OFF

ONOFFON

OFFON

OFFON

OFFON

OFFON

OFFON

OFFCCWOFFCW

ONOFFON

OFFON

OFFON

OFFON

OFFON

OFFON

OFFON

OFFON

OFFON

OFFON

OFF

ONOFFON

OFFON

OFFON

OFFON

OFFON

OFFON

OFFON

OFFON

OFF

Sewing (with cross-over stitch) Sewing (without cross-over stitch) Discharge of the buttonOscillating spinner

arm inching

Oscillating spinner armreturns to the origin.

TT T

T : Indicate the value on the timer.

1 2 9 10

－ 85 －

12. AIR PIPING

1. Piping components for ACF-164

Valve1B

Cylinder1B

Cylinder 1A

PV020501000

Valve 1A

PV010507000

PC015108000

PJ301040504 (X7)

PJ308040002 (X3)

Second work clamp (optional)

PA0601004A0

PJ046052503

6A

(M3Xø4)PJ210304010

4A

4B

PA800012000

PS304040504 (M5 X ø4)

PC015108000

3A

PA2002513A0

PX500017000

PC015108000 (4 pcs.)(1/8 X ø4)

1A

2A

G61081640A0(PA2015004A0)

G61091640A0(PA2007504A0)

G64011640A0(PV1551080A0)

ø61B

2B

G5046164000

PA160100500ø4

ø4

5B

PJ308040002

PJ032526001

PJ309005201

PJ309005203PJ304040504

(M5 X ø4)

PJ0505252011/4

PF0552090A0

1/4

ø6

PJ301065201

ø6

1/4

ø6

ø6

PJ303060001 ø6

G5458116000

16111502

16111403

PJ030520001

PX065101000

1/8PJ015251001

1/4

PJ050525201

1/4 PJ301065201

Options (when VAC.MC-16 is used)

PJ301040504 (M5 X ø4)

1800⑤

A

B

PA160100600

PJ301040505

①Cloth presser

of stacker

② Swing barof stacker

③Conveyershift

④Gauge

⑤Workclamp

⑥ Buttondetector

⑦ Spare

⑧ Spare

PJ301040504(M5 X ø4)

PJ020500001

PJ301040504 (M5 X ø4 meter-in)A

A

A

A

A

A

A

A

B

B

B

B

B

B

B

B

1A Green 1400

1B Yelowish green 1300

2A Red 1400

2B Yeloow 1300

3A Blue 2000

3B –

4A Yellow 2700

4B Yellowish green 2700

5A –

5B Green 1400

6A Black 1600

6B –

ø4

G5046164000PJ308040002

PA160100500

1 23

4 56

78

－ 86 －

2. Air piping drawing

Caution) 1. The part No. with parentheses ( ) is optional.

PA2007504A0

PC015108000

PA2015004A0

PC015108000

PA2002513A0

PC015108000

(PA160100500)

PA160100500

PJ304040504

PA0601004A0(PA160100600)

(PJ305040503)PA800012000 PJ046052503

PJ210304010

PJ308040002

(PJ301040505)

(PA2007503A0)(PV020501000)

(PJ308040002)

(PC015108000)

(PJ301040504)

(PV010507000)(PJ301040504)

PV1551080A0

① PJ020500001

② PJ301040504Stacker

(presser)Stacker

(swing bar)Conveyer

(upper/lower)Gauge

PC010514000

Work clamp ofthe carriage unit

Buttondetector

Spare Spare(suction)

PJ301065103

PJ301065201

PJ050525201

PX065101000

PJ01525100116111403

PJ303060001

16111502

G5458116000

PJ301065201

PJ030520001

PF0552090A0

PJ50525201

PJ030520001

PJ309005203

PJ309005201

①

②

②

②

②

①

②

②

①

②

①

②①

②①

－ 87 －

13. WIRING COMPONENTS

1. Wiring the frame (large) components

Caution) The mark in the figure indicates the direction of the clamp.

Air tube for workclamp release switch

Screw SL4041081SFClamp HX00150000A

6 places


(Front)

Carriage clamp position switch ②G61051640A0

Decreased speed detecting switchG61021640A0

Origin detecting switchG61011640A0

Discrimination switchG61031640A0

Carriage clamp position switch ①G61051640A0

Screw SL4041081SF

Clamp HX001500000

See figure A.

D E

Work clamp release switchG61121640A0

(Front)

(Rear)

Screw SL4041081SFClamp HX00150000A※ 4 places

C

B

(Rear)

Screw SL4041081SFClamp HX001500000

Operating air pressure detecting switchG61071640A0

※ To be tightened with plateScrew SM0040601SAClamp HX001500000

Screw SL4041081SFClamp HX001500000

Material edge sensor 2G61111640A0

Wooden screw SK3381311SCClamp HX001500000

※ 2pcs.

Material edge sensor 1G61101640A0

Conveyor motor junction cordG62021640A0

Screw SL4041081SFClamp HX00150000D※With three air tubes

Swing bar cylinderG61081640A0 Stacker cloth presser cylinder

G61091640A0

※ 4placesScrew SL4041081SFPlain washer (large) WP0450801SD

Duct (B)G6802164000

Screw SL4041081SF

Clamp HX00150000G

With three air tubes

to thecontrolbox

B

C

Solenoid box (1)G64011640A0

Duct (A)G6801164000

Start switchG61041640A0

A

Front side

※2 places

Screw SL4041081SF

Plain washer WP0450801SD

(large)

V W

X Y

See figure B.

Emergency stop switchG61061640A

Detailed figure of section A

Work clamprelease switch

Protecting tubeScrewSL4041081SF

ClampHX00150000D

ED Air tube

ScrewSM0040601SAClampsHX001500000A

Detailed figure of section B

<For the switch made by clocknermuller>

E

※ClampHX00150000D

Powerswitch A

V W X Y

(See the next page.)

※ Attach the clamp to the attaching switch for thepower switch with a nut.

<For the switch made by HITACHI>

E

X Y

※ClampHX00150000D

Powerswitch

Y

V W

A

※ Attach the clamp,with a nut,to the clamp screw

on the front side.

※ Y is the power cord of the MC-16.If the MC-16 cannot be attached in place,usethe clamp of HX00123000A as the cable clampfor the front side.

－ 88 －

2. Wiring the frame (small) components

Terminal board wiring diagram

Fine positionerlowering magnet RMG

SHMG

SEMG

RMT

AMT

IMT

Black White

BrownRedOrangeYellowGreenBlueGrayWhiteBlackPurplePinkLight blue

Press this recess with a thin screwdriver to alloweach cord to be connected in place.

Thread breakage detector SW asm.MAZ16780A0

70

100

Adhesive clamp HX00305000ASpiral tube G545161000

Washer WP0451026SDSpring washer WA0510002KN

(To be tightened from insidethe machine head)Screw HAZ16728000Nut NS6110420SPClamp HX00150000B

Button detecting switch asm.MAZ167820A0

Air tube for button detector

ScrewMAQ1230400

NutNS6110420SP

ClampHX001500000

Hexagon screwSM6061202TNSpring washerWS0610002KN

Plain washerWP0641601SC

Inner clip washerWT0640001KN※2 places ea.

Panel box asm.M85305440A0

I H

Panel asm.GB117810A0

K

Ground wire asm.G67021640A0

J

See the terminalboard wiring

diagram.

Output junction cable asm.G65011640A0

Button detecting switch asm.MAZ167820A0Thread breakage detecting switch asm.MAZ167840A0Air tube for button detector※ Wind a spiral tube round these three

cords up to the underside of the table.

Inner clipwasher Plain washer

Spring washer

Output junction cord asm.G65011640A0

Parts feeder cord

Screw SK3381301SCClamp HX00123000A

KP/F power cord※ To be connected to P/F

junction cord in the way.

Screw SK3381301SCClamp HX00150000M

P/F power junction cord asm.GB118220A0Sensor junction cable asm.GBR218460A0Output junction cable asm.G65011640A0Breaker asm.GBR117860A0Button detecting switch asm.MAZ167820A0Thread breakage detecting switch asm.MAZ167840A0Ground wire asm.G67021640A0Work clamp lift detecting switch asm.GBR118470A0Manual button feeding switch asm.GBR118470A0Work clamp lift detecting switch asm.GBR118470A0Manual button feeding switch asm.GBR117850A0Step operation switch asm.GBR117830A0Discharging switch asm.GBR117840A0

To MC-544

Ground wire asm. JG67011640A0GND cord for thread breakage detectorMAZ167850A0Sewing machine stop-motion switch asm.MAZ167810A0Upper position detecting switch asm.MAZ089830A0

DuctG6801164000

Screw SL4041081SFClamp HZ00150000E

Magnet, motor cord

Shutter magnet

Positioning magnet

DC motor for finepositioner

DC motor for spinneroscillating arm

DC motor for indexer

Screw SL4041081SFClamp HX00150000K※3 places ea.

Ground wirefor panel

HI

Ground wires for operation panelG6704160A0※ 2 places

Panel junction cord

※MC-16 (optional)Screw SL4041081SFClamp HX00150000H

Screw SL4041081SFClamp HX00150000H

Power switch forMC-16

Screw SM1040801SCClamp HX001350000


ACF power cord

To power plug Screw SL4041081SFClamp HX00123000F※2 places ea.※ To use an optionally-available

MC-16,replace the clamp withthe clamp HX00150000H

Rear face

Screw SL4041081SFClamp HX00150000K

Screw SL4041081SFInner clip washer WT0430001KN

Screw SL4041081SFClamp HX00150000F※3 places ea.

Motor Powercord for MC-544

To MC-544

Screw SL4041081SFClamp HX00150000K

To MC-544

Motor


※ 2 places ea.

V W X

Y Z

To bundle slackenedcord here.

V : Power cord for MC-544

W : Power cord for general-purpose motor

X : AC input power cord

Y : Power cord for MC-16

Z : MC-16 motor cord

On themotors side

－ 89 －

14. CONFIGURATION (ELECTRICAL UNIT)

(1) Components of control box and its function

1 CPU circuit board : Use to control all the equipment of the panel.

2 I/O circuit board : Used to input/output the signals of the machine head or button feeder control,

each sensor or each valve.

3 Power circuit board : Used to rectify 7.5,20,24 and 26 Vac output from the transformer and convert

them to 5 VDC, +12 VDC, –12 VDC, 24 VDC and 34 VDC.

4 Transformer : Used to convert input voltage to each voltage.

5 DC fan : Used to blow off the internal air to prevent each unit from generating heat.

6 Stepping motor driver : Used to drive the stepping motor by the exciting signal from the CPU.

7 Terminal block : Used to relay AC input codes and the transformer.

Table of ACF circuit board asm.

1. POWER citcuit board of ACF172 can be used for 164 and 286. (The reverse is not possible.)

2. Part No. (CPU circuit board asm.) of CPU circuit board whole asm. without ROM is common to

M86015430A0.

3. Part No. (I/O circuit board asm.) of I/O circuit board whole asm. without ROM is common to

M86025440A0.

POWER circuit

board asm.

CPU circuit board

whole asm.

I/O circuit board

whole asm.

ACF172

M86035440A0

M8601543CA0

ROM:058,059

M8602544BA0

ROM:060

ACF164-1851

M8601543BA0

ROM:043

M8602544AA0A

ROM:044

ACF164-373

M8601543BA0

ROM:043

M8602544AA0A

ROM:044

ACF164-1903

M8601543EA0

ROM:135

M8602544DA0

ROM:134

ACF286

M8601543DA0

ROM:110,111

M8602544CA0

ROM:109

M8603544AA0

1

2

3

4

5

6

7

－ 90 －

(2) Connector and its functions of the control box

< Input >

J31 (34 pin) : Each sensor signal of the machine and the BR body is entered.

J32 (50 pin) : Each sensor signal of the machine and the BR body is entered.

J34 (30 pin) : Not used.

J35 (40 pin) : The sensor signal of the indexer is entered.


< Output >

J41 (4 pin) : A control signal is output to the feeder for oscillating.

J42 (20 pin) : A signal is output to the magnet, motor and valve for driving the machine head and the BR

body.

J43 (14 pin) : A signal is output to the valve for driving the machine head.

J44 (16 pin) : A signal is output to the valve for driving the indexer.


J33 (2 pin) : A signal is output external counter (optional).

J61 (6 pin) : A signal is output to the stepping motor.

J62 (8 pin) : The power (100 VAC) is supplied to the feeder. A signal is output to the motor for driving

the conveyer.


J64 (2 pin) : 4.5 VAC is supplied to the marking light (optional).

J65 (2 pin) : 4.5 VAC is supplied to the marking light (optional).


J31(34pin)J32(50pin)

J66(4pin)J33(2pin)

J35(40pin)J34(30pin)

J37(7pin)

J63(4pin)

J64(2pin)

J65(2pin)

J41(4pin)

J42(20pin)

J43(14pin)

J44(16pin)

J45(12pin)

J61(6pin)

J62(8pin)

－ 91 －

(3) Power voltageWhen a failure occurs, first check the power voltage.

1) Connecting the power voltage to the input voltage of the transformer (on the left of the terminal block.)

2) Secondary output voltage of the transformer (AC)

Caution) Take care not to allow short circuit of the terminal.

100 VAC (white-white) Approx. 20 VAC Remove 100 VAC of the stepping motor driver and measure it.

20 VAC (blue-blue) Approx. 20 VAC Remove connector P5 with the power circuit board and measure it.

7.5 VAC (red-red) Approx. 7.5 VAC Remove connector P5 with the power circuit board and measure it.

26 VAC (gray-gray) Approx. 26 VAC Remove connector P4 whit the power circuit board and measure it.

24 VAC (brown-brown) Approx. 24 VAC Remove connector P5 with the power circuit board and measure it.

4.5 VAC (yellow-yellow) Approx. 4.5 VAC Use connector J64 or J64 and measure it.

440 VOrange

415 Vblue

380 VPurple

240 VGray

220 VWhite

200 VBrown

0 VBlack

1

2

5

4

3

6

7 440 V

415 V

380 V

240 V

220 V

200 V

0 V

FGFG

AC input

(In case of 200 Vac)

(Transformer side) Terminal block

GRAY

ORANGE

BLUE

PURPLE

GRAY

WHITE

BROWN

BLACK

GREEN/YELLOW

P7

P6

P5

P4

P3

P2

P1

E

P

AC440 V

AC415 V

AC380 V

AC240 V

AC220 V

AC200 V

0 V

AC26V 0.3A

AC7.5V 3A

AC20V 4A

AC100V 2A

AC24V 5A

AC4.5V 2A

BLACK

GRAY

RED

BLUE

WHITE

BROWN

YELLOW

S9

SCT

S10

S7

S8

Ground mark

Input voltage seal

Orange

Blue

Purple

Gray

White

Brown

Black

Switch voltage (brown) in

this range.

See the left input voltage

seal.

Brown

Brown

Sky blue

(Power supply side)

S4

S3

S5

S6

S1

S2S11

S12

－ 92 －

(4) Measuring the DC power voltage

1) CPU circuit board

2) I/O circuit board

3) Power circuit board

(Tester black)

(Tester red)

(Tester black)

(Tester red)

+4.9 to +5.1 V

+11.8 to +12.2 V

(Tester red) (Tester black)


+11.6 to +12.4 V +4.9 to +5.1 V

(Tester black) (Tester red)


4 Pin

1 Pin3 Pin

6 Pin+33 V to +38 V +27 to +30 V

－ 93 －

(5) Changing the thermal values inside the switch boxRemove the switch box cover, turn the dial and adjust figures (thermal values) to ▲ .

(6) Replacing fusesUse a fuse having the specified capacity

< MC-544 > Remove the control box cover for MC-544

< BR >

1 F1, Fuse (6 A)2 F2, Fuse (10 A)3 F3, Fuse (4 A)4 F4, Fuse (1 A)5 F5, Fuse (1 A)6 F6, Fuse (4 A)

F7 (1 A)

NO. Voltage Destination Phase Thermal set value

1 380 V Export 3ø 2.4 A

415 V

440 V

2 220 V U.S.A. 3ø 4 A

3 380 V Germany 3ø 2.4 A

4 415 V U.K. 3ø 2.4 ASet value

Thermal valuesetting dial

1

2

3

4 5 6

－ 94 －

(7) Replacing the P-ROMs for data

Turn OFF the power and replace the P-ROMs.

When mounting the P-ROMs, take care of the correct position and direction of them. In addition, the

English characters with an asterisk (※ ) in each P-ROMs indicate REV.No. (Revision Number).

MC

-544

134※

MC-544135※

－ 95 －

(8) CPU circuit board

The CPU circuit board is mainly used for controlling the stepping motor. It serves as atimer for transferring the stepping time of the stepping motor to the CPU (8085)

The signal of each sensor is input from the I/Ocircuit board. In addition,the signal of eachcylinder is output to the I/O circuit board.

The power is supplied form the powercircuit board. (5 VDC and 12 VDC)

The memory backup battery.

Main CPU (8085)CPU (8085) controls the indexer and its components. This is the output port to transmit the signal

of the CPU (8085) to LCD and LED.

This is the input port to transmit the signalof the panel SW to the CPU (8085).

Switch for function settingThis switch is used to change fromEnglish to Japanese or mm to inchesand vice versa.

This inputs the SW signal (mainlyoperation,etc.) from the panel andoutputs the lighting signal to the LED. Inaddition,this outputs the display data tothe LCD.

RAM (5565)

ROM (27C256)Mainly indexer control programs are stored.

This inputs the SW signal (mainlyoperation, etc.) from the panel andoutputs the lighting signal to the LED.

Used for maintenance

13

5

－ 96 －

(9) I/O circuit board

Signal of each sensor is entered from themachine head and the BR.

This is the output port to control themachine head and the BR.

Signals of the sensors output from theindexer are input here.

This is not used.

This is the CPU used to control themachine head and the BR.

ROM (27C256)The control program of the machine

head and BR is written in it.

The power is supplied from the power circuit board.(5 VDC,12 VDC and –12 VDC)

This is the output used to turn ON / OFF the oscillatingof the feeder.

This output the signal commanding normal rotation orreverse rotation to the stepping motor driver unit.

This is the output used to drive the conveyer motor.

This is the solid state relay used to drive theconveyer motor.

This outputs the signal of each sensor to the CPU circuitboard. In addition, the signal of each cylinder is input fromthe CPU circuit board.

This is the input port used to transmit the signal of eachsensor to the CPU (8085).

This is not used.

This is the output port used to transmit the CPU (8085)signal to the valves.

This is the output used to drive the indexer valve.

This is the output used to drive the valvesof the machine head.

This is the output used to drive the magnet, valves andmotor of the machine head and BR.

A 24 VDC and 33VDC are supplied fromthe power circuit board.

－ 97 －

(10) Power circuit board

This is the protection fuse for 33 VDC line (6 A).

Power supply for DC fan(24 VDC)

AC power is supplied from the transformer (26 VAC)

The power (24 VDC and 33 VDC) is supplied to the I/O circuit board.

The power (5 VDC and 12 VDC) issupplied to the CPU circuit board.

The power (5 VDC, 12 VDC and –12VDC) is supplied to the I/O circuitboard.

Regulator for 5 V

This is the protection fuse for 12 VDC and –12 VDC (1 A).



AC power is supplied from the transformer (7.5 VAC, 20 VAC, 24 VAC)

－ 98 －

(11) Panel circuit board (12) Functions of the stepping motor driver

1 CW pulse input signal

Inputs a signal to make the motor rotate clockwise (CW).

2 CCW pulse input signal

Inputs a signal to make the motor rotate counterclockwise (CCW).

3 Power-down input signal (PD)

If “H” level is input, the exciting current to the motor will be cut off.

4 Alarm output signal (AL)

If the protection network inside the driver actuates, an alarm signal will be transferred outside.

5 Motor drive output (MOTOR)

This output feeds the electric current to the motor.

6 Frame ground output (FG)

Connected to the frame ground of the control box.

7 100 Vac input (AC)

Supplies the power supply of 100 Vac ± 10 % (50 / 60 Hz) to the machine.

8 Power supply indicating LED (POWER, green)

Lights when the 100 Vac is supplied to the machine.

9 Phase origin monitor indicating LED (MON, green)

Lights up when the exciting phase is in the origin (the state at the time of turning ON the power to the machine). Under the HALF step

mode (0.36˚/pulse), the LED lights up once every 20 pulse.

!0 Supply voltage drop indicating LED (P.E, red)

If the 100 Vac power supply drops to 85 Vac or lower, the protection network will actuate

to cut off the electric current to the motor coil. In this case, the LED lights up.

!1 Abnormal input indicating LED (O.F, red)

If a pulse of 1000 KPPS or more is input under the HALF step mode (0.36˚/pulse), the

protection network will actuate to cut off the electric current to the motor coil. In this

case,the LED lights up.

!2 Overheat display LED (O.H, red)

If the temperature inside the driver, including the ambient temperature, rises to 80˚C or

more, the protection network will actuate to cut off the elctric current to the motor coil. In

this case, the LED lights up.

!3 DIP switches

These switches are used for changing over the exciting method and automatic-current

down. For the ACF model of sewing machine, all of these switches should be set to the

ON position. (See the figure.)

1

2

5

4

3

6

7

8

9

!0

!1

!2

!3

LCD (Liquid Crystal Display)40 digits x 2 lines (2-color selecting system)

SW signal is output to the CPU circuit board.In addition, the LED and LCD signals are input.

The illuminance of theLCD is adjusted.

The membrance switchsignal is input.

This area enters the signal of the slide switchlocated at the side of the panel.

Outputs signals of switches and high-speed rotation variableresistor to CPU. Also used for inputting LED signals.

Buzzer

The membrance switchsignal is input.

Switch Label

－ 99 －

(13) I / F circuit board whole asm.

POWER circuit board asm.

NO Part No. Name of part Q’ty Remarks

1 M86515910A0 I / F circuit board asm. 1

2 M1001591000 Circuit board installing plate 1

3 HX00269000B Locking card spacer 4

4 SL4031281SF Installing plate attaching screw 1

1

2

3

4

1

2

4

3

Heat sink

－ 100 －

15. BLOCK DIAGRAM

TH. BRK

HEAD EARTH CABLE AASM.

OPERATIONPCB

26P

J41

(4A) UDET

SERVOMOTOR

P29

15P

ENCODER RELAYCABLE ASM.

P28

4P

4P

3P

J2 J3 J4J1

J6J9

J8

SERVO PCBA ASM.

30P SERVO SIGNAL CORD ASM.

2P

2P

SERVOPOWER CORD

B ASM.

4P

4P

SERVO POWERCORD A ASM.

J30

J31

J33 J32 J36

J37

J34

J38

MAIN POWERCORD ASM.

4P

TERMINAL

8P

POWERTRANSFORMER

ASM.

THERMOSTAT ASM.

10P

3P

FAN ASM.DC 24V

6P

J2326P

J1130P

J272P

J168P

MAIN PCB AASM.

J20 RED

J21 YELLOW

J19 BLACK

J13

J12

J2410P

J189P

J14 6PWHITE

J15 6PBLUE

J1712P

J2214P

(1A) UDET

3P

P17

P2

P22

J2 CONNECTORCORD ASM.

P58 U DET

X ORG

Y ORG

OUT_P

OUT_PSOL

TH SOL

P70 4P J70 4P

WIPER SOL

X PM

Y PM

J28P

I / F PCBASM.

J19P

P1

P31

P43

J1 CONNECTORCORD ASM.

J3134P

MC-544-1CONTROL BOX

J4314P

SERVO MOTORCABLE ASM.

POWER CORD ASM.

POWER PCB

8P

3P

TRANSFORMERPOWER CORD

ASM.

P56

P57

P59

3P

3P

2P

2P

－ 101 －

16. BLOCK DIAGRAM

MC-591-2 M8501591BC0 LK. ERROR. CYCLE. FL. POS IN

ARNGE. EXHST. MANU. FD IN

BUT. RUB. POS. AORG. IORG. WIP. AFRT IN

INIT. SPEED. SELECT. STKCNT. STCK2. LIMIT. WRK. FWD. WRK. BCK. START.EMM. SW. RCL. SW. AIR. SW IN

P31

P32

P35

34P

50P

40P

MC-544 PANEL BOX M85305440A0

PANEL SWM8630544000 P52

P53

P57

J52

J53

J57

13P

9P13

P

J71 J72 J732P 2P 2P

J54

J55

50P

34P

J56

14P

LCD

PANEL PCBM8631543AA0

P71 P722P 2P

SW SW

30P

P54

34P

P27

4PP6

M85415440A0

P55

50P M8540

5440A0

P5

50P

MC-544-1 CONTROL BOX M8501544CA0

CPU PCBM8601543EA0

J27

J6

J5

30P

4P50

P

J28

34P

4P

J26

P6

4P

4P

4P

P28

AC POWER

POWER SW

AC IMPUT CODE

M85295440A0

AC MOTOR

7

6

5

4

3

2

1

TB1 TRANS.AC

440 V

415 V

380 V

240 V

220 V

200 V

0 V

F.G

M85105440A0

AC

26 V

23.8 V20 V7.2 V

100 V

4.2 V

P4

P5

3P6P

J4

J5

3P6P

F6 4A

AC4.2 V

123456

TB2

TB2-2TB2-3TB2-5TB2-6

J6

POWER PCBM880354AA0

J1 P1

2P 2P

M85115440A0

FAN

J66

4P

J31

J32

J34

J35

J37

J46

34P

50P

40P

30P

7P

34P

34P

P26

J38 J39 J409P 5P 4P

J42

J43

J44

J45

J41

J33

J47

J48

2P10

P2P

4P12

P16

P14

P20

P

I/O PCBM8602544DA0

P40

P3

5P

5P

4P

6P

P39

P7

P42

20P

TB3

ARM. MTR. IND. MTR. RUB. MTR. RUB.SOL. SHT. SOL. SET. SOL. OUT

P43

14P

BUT. CL OUT

MC-591-2 M8501591BC0 PRESS. START OUT

CLP. CL1. STK. CL1. STK. CL2. COV. CL. GAU. CL OUT

P41

4P16

P

P44

5A BREAKER

J1 P1

FEEDERAC100 V

6P 6P FEED COUNT. BOX

P33

2P MANU.COUNT

P47

10P

TB2-2TB2-5

CW+CW-CCW+CCW-PD+PD-

AL1AL2

AC100 V

P.M.D.CHM000570010

BLACKRED

ORANGEYELLOW

BLUEF.G

J61

6P

TB2-3

TB2-6

6P

8P

J62

P61

STEP. MOTORHM000570000

BLACKREDORANGEYELLOWBLUE

P62

8P

FEEDERAC100 V

J90 P90

4P 4P CONV. MOTOR

G62031640A0

AC4.2 V

J64

J65

J63

2P 2P

2P 2P

4P 4P

P64

MARK LIGHT

P65

MARK LIGHT

P63

BOBBIN WINDER

AC MOTOR

AC MOTOR

J7 J35P 6P

TB2-2

TB2-5TB2-3

－ 102 －

17. WIRING DIAGRAM (1/3)

I/O P

CB

M86

0254

4AA

0A

S G

ND

1+

24 V

2S

ET

.SO

L3

+24

V4

RU

B.S

OL

5+

24 V

6+

24 V

7R

UB

.MT

R.C

W8

+24

V9

+24

V10

S G

ND

11N

.C12

S G

ND

13S

HT

.SO

L14

RU

B.S

OL.

RT

N15

N.C

16N

.C17

RU

B.M

TR

.CC

W18

IND

.MT

R19

AR

M.M

TR

20

TB

3

BR

MA

GN

ET

&M

OT

OR

&V

ALV

E O

UT

J42

20P

LKS

ig &

BR

VA

LVE

OU

T

J43

14P

+24

V1

+24

V2

+24

V3

+24

V4

+24

V5

+24

V6

+24

V7

N.C

8N

.C9

N.C

10N

.C11

PR

ES

S12

ST

AR

T13

BU

T.C

L14

AC

FV

ALV

E O

UT

J44

15P

+24

V1

+24

V2

+24

V3

+24

V4

+24

V5

+24

V6

+24

V7

+24

V8

N.C

9N

.C10

CLP

.CL1

11N

.C12

ST

K.C

L113

ST

K.C

L214

CO

V.C

L15

GA

U.C

L16

AC

FV

ALV

E O

UT

J45

12P

+24

V1

+24

V2

+24

V3

+24

V4

+24

V5

+24

V6

N.C

7N

.C8

N.C

9N

.C10

N.C

11N

.C12

FE

ED

ER

CO

NT

RO

L

J41

4

P

+24

V T

RN

1+

24 V

2P

F.R

TN

3P

T.F

DR

4

J37

7

P

N.C

1N

.C2

N.C

3

S G

ND

4+

5 V

5N

.C6

S G

ND

7

MA

NU

. CO

UN

T

J33

2

P

MA

NU

.C1

MA

NU

.C.R

TN

2

1 +5 V2 INIT3 S GND4 +5 V5 SPEED6 S GND7 +5 V8 SELECT9 S GND10 +5 V11 STKCNT12 S GND13 +5 V14 STCK215 S GND16 +5 V17 LIMIT18 S GND19 +5 V20 WRK.FWD21 S GND22 +5 V23 WRK.BCK24 S GND25 +5 V26 START27 S GND28 +5 V29 EMM.SW30 S GND31 +5 V32 RCL.SW33 S GND34 +12 V35 AIR.SW36 S GND37 +12 V38 +12 V39 +12 V40 +12 V

AC

F S

EN

SO

R IN

J35 40P

1+

5 V

2N

.C3

S G

ND

4+

5 V

5N

.C6

S G

ND

7+

5 V

8N

.C9

S G

ND

10+

5 V

11N

.C12

S G

ND

13+

5 V

14N

.C15

S G

ND

16+

5 V

17N

.C18

S G

ND

19+

5 V

20N

.C21

S G

ND

22+

5 V

23N

.C24

S G

ND

25+

5 V

26N

.C27

S G

ND

28+

12 V

29+

12 V

30+

12 V

AC

FS

EN

SO

R IN

J34

3

0P

J32

50P

1+

5 V

2N

.C3

S G

ND

4+

5 V

5B

UT

6S

GN

D7

+12

V8

RU

B9

S G

ND

10+

12 V

11P

OS

12S

GN

D13

+5

V14

A O

RG

15S

GN

D16

+12

V17

I OR

G18

S G

ND

19+

5 V

20N

.C21

S G

ND

22+

12 V

23A

FR

T24

S G

ND

25+

5 V

26N

.C27

S G

ND

28+

5 V

29N

.C30

S G

ND

31+

5 V

32N

.C33

S G

ND

34+

5 V

35N

.C36

S G

ND

37+

5 V

38N

.C39

S G

ND

40+

5 V

41N

.C42

S G

ND

43+

5 V

44N

.C45

S G

ND

46+

5 V

47N

.C48

S G

ND

49+

12 V

50+

12 V

LK, B

RS

EN

SO

R IN

BR

, LK

Sig &

SE

NS

OR

IN

J31

34P

1+

5 V

2N

.C3

N.C

4N

.C5

S G

ND

6S

GN

D7

+5

V8

N.C

9S

GN

D10

+5

V11

AR

NG

E12

S G

ND

13+

5 V

14E

XH

ST

15S

GN

D16

+12

V17

FL.

PO

S18

S G

ND

19+

5 V

20M

AN

U.F

.D21

S G

ND

22+

5 V

23N

.C24

S G

ND

25+

5 V

26U

P.S

W27

S G

ND

28 +

5 V

29 L

K.E

RR

OR

30 S

GN

D31

+5

V32

CY

CLE

33S

GN

D34

+12

V

－ 103 －

WIRING DIAGRAM (2/3)

TB1

AC 415 V 6

0 V 1

AC 200 V 2AC 220 V 3AC 240 V 4AC 380 V 5

AC 440 V 7

AC POWER

POWER SW

AC MOTOR

TRANS

TRANS

TRANS

F6

J4 3P1 AC26 V

2 CENTER3 AC26 V

J5 6P1 AC7.2 V2 AC7.2 V3 AC20 V

4 AC20 V5 AC23.8 V

6 AC23.8 V

POWER PCB M86035440A0

J3

8

9P

1N

.C

2N

.C3

N.C

4N

.C5

N.C

6N

.C7

N.C

8N

.C9

N.C

J7

5P

+5

V1

S G

ND

2+

12 V

3

S G

ND

4

-12

V5

J3

6P

+33

V1

+24

V3

S G

ND

4S

GN

D5

S G

ND

6

J2 4PN.C 1

N.C 2N.C 3N.C 4

J1 2PFAN+ 1FAN– 2

TB2P.M.D.CP48-2.P62-8

P.M.D.C.CONDENSERJ62-1.J62-4

AC100 V 1 1 AC100 VAC100 V 2 2 AC100 VAC100 V 3 3 AC100 VAC100 V 4 4 AC100 VAC100 V 5 5 AC100 VAC100 V 6 6 AC100 V

I/O PCBM8602544AA0A

J47 10PCW+ 1

CCW+ 2PD+ 3+5 V 4AL1 5

CW- 6CCW- 7

PD- 8

N.C 9AL2 10

J48 2PCOV.AC 1

COV.AC RTN 2

J3

9

5P

1+

5 V

2S

GN

D3

+12

V4

S G

ND

5-1

2 V

J4

0

4P1

+33

V

2+

24 V

3S

GN

D4

S G

ND

TB2-3

TB2-2TB2-5

TB2-6TB2-5 CONDENSER

TB2-6

TB2-3

TRANSTRANS

P.M.D.CHM00570010

AC100 VAC100 V

J61 6P P61 6P

BLACK 1 1 BLACKRED 2 2 RED

ORANGE 3 3 ORANGEYELLOW 4 4 YELLOW

BLUE 5 5 BLUEN.C 6 6 N.C

STEP.MOTORHM000570000

J62 8P P62 8PCOV (Y) 1 1 COV (Y)

COV (W) 2 2 COV (W)N.C 3 3 N.C

AC100 V (FEEDER) 4 4 AC100 V (FEEDER)COV (B) 5 5 COV (B)

N.C 6 6 N.CN.C 7 7 N.C

AC100 V (FEEDER) 8 8 AC100 V (FEEDER)

CONV. MOTOR

FEEDER

J64 2P P64 2PAC4.2 V 1 1 AC4.2 VAC4.2 V 2 2 AC4.2 V MARK LIGHT

J65 2P P65 2PAC4.2 V 1 1 AC4.2 VAC4.2 V 2 2 AC4.2 V

MARK LIGHT

J63 4P P63 4PF.G 1 1 F.GN.C 2 2 N.C

+24 V 3 3 +24 VS GND 4 4 S GND

BOBBIN WINDER

FANM85115440A0

+24

V2

－ 104 －

WIRING DIAGRAM (3/3)

1+

5 V

2S

GN

D3

+12

V4

S G

ND

PA

NE

L S

W

J5

3

9

P1

AU

TO

SW

2R

EE

D S

W3

RE

ST

AT

SW

4(S

W5)

5(S

W2)

6(S

W1)

7S

TR

OB

28

ST

RO

B3

9S

TR

OB

4

J

52

13

P1

92

83

74

65

56

4

73

82

91

10E

NT

ER

110

12(S

W7)

13R

ES

ET

SW

1S

TR

OB

12

SE

L3

J7

3

2

P

SW

1S

TR

OB

12

P/C

SW

J7

2

2

P

1S

TR

OB

12

G/L

SW

J

71

2

P

SW

J54

34P

+5

V1

+5

V2

+5

V3

+5

V4

AU

TO

LE

D5

FE

ED

LE

D6

(LE

D7)

7(L

ED

6)8

BC

KL

CN

T9

S G

ND

10A

UT

O S

W11

S G

ND

12F

EE

D S

W13

S G

ND

14R

ES

TA

T S

W15

S G

ND

16(S

W5)

17S

GN

D18

(SW

3)19

S G

ND

20(S

W4)

21S

GN

D22

(SW

2)23

S G

ND

24(S

W1)

25S

GN

D26

ST

RO

B4

27S

TR

OB

328

ST

RO

B2

29S

GN

D30

(SP

EE

D 1

)31

S G

ND

32(S

PE

ED

2)

33S

GN

D34

J55

50P

+5

V1

+5

V2

+5

V3

+5

V4

BU

ZZ

ER

5N

O S

EL

LED

6(L

ED

8)7

MO

DE

IN L

ED

8M

OD

E O

UT

LE

D9

CO

UN

T IN

LE

D10

PS

W1

11S

GN

D12

PS

W2

13S

GN

D14

PS

W3

15S

GN

D16

PS

W7

17S

GN

D18

PS

W0

19S

GN

D20

PS

W5

21S

GN

D22

PS

W6

23S

GN

D24

PS

W4

25S

GN

D26

ST

RO

B1

27S

GN

D28

LCD

DB

129

S G

ND

30LC

D D

B3

31S

GN

D32

L C

DR

S33

S G

ND

34LC

D R

/W35

S G

ND

36LC

D E

37S

GN

D38

LCD

DB

639

S G

ND

40LC

D D

B0

41S

GN

D42

LCD

DB

743

S G

ND

44LC

D D

B5

45S

GN

D46

LCD

DB

247

S G

ND

48LC

D D

B4

49S

GN

D50

J6

3

0P1

+5

V2

+5

V3

+5

V4

+5

V5

AU

TO

LE

D6

FE

ED

LE

D7

(LE

D7)

8(L

ED

6)9

BC

KL

CN

T10

S G

ND

11A

UT

O S

W12

S G

ND

13F

EE

D S

W14

S G

ND

15R

ES

TA

T S

W16

S G

ND

17(S

W5)

18S

GN

D19

(SW

3)20

S G

ND

21(S

W4)

22S

GN

D23

(SW

2)24

S G

ND

25(S

W1)

26S

GN

D27

ST

RO

B4

28S

TR

OB

329

ST

RO

B2

30S

GN

D

J2

7

4P1

S G

ND

2(S

PE

ED

2)3

S G

ND

4(S

PE

ED

1)

J5

5

0P1

+5

V2

+5

V3

+5

V4

+5

V5

BU

ZZ

ER

6N

O S

EL

LED

7(L

ED

8)8

MO

DE

IN L

ED

9M

OD

E O

UT

LE

D10

CO

UN

T IN

LE

D11

PS

W1

12S

GN

D13

PS

W2

14S

GN

D15

PS

W3

16S

GN

D17

PS

W7

18S

GN

D19

PS

W0

20S

GN

D21

PS

W5

22S

GN

D23

PS

W6

24S

GN

D25

PS

W4

26S

GN

D27

ST

RO

B1

28S

GN

D29

LCD

DB

130

S G

ND

31LC

D D

B3

32S

GN

D33

L C

DR

S34

S G

ND

35LC

D R

/W36

S G

ND

37LC

D E

38S

GN

D39

LCD

DB

640

S G

ND

41LC

D D

B0

42S

GN

D43

LCD

DB

744

S G

ND

45LC

D D

B5

46S

GN

D47

LCD

DB

248

S G

ND

49LC

D D

B4

50S

GN

D

A0

1S

GN

D2

A1

3S

GN

D4

D0

5S

GN

D6

D1

7S

GN

D8

D2

9S

GN

D10

D3

11S

GN

D12

D4

13S

GN

D14

D5

15S

GN

D16

D6

17S

GN

D18

D7

19S

GN

D20

IOR

21IO

W22

RE

SE

T23

RE

SE

T24

CS

025

CS

126

CS

227

CS

328

CS

529

S G

ND

30C

LOC

K31

S G

ND

32(S

PE

ED

1)33

(SP

EE

D2)

34

J28

4

P+

5 V

1S

GN

D2

+12

V3

S G

ND

4

1A

02

S G

ND

3A

14

S G

ND

5D

06

S G

ND

7D

18

S G

ND

9D

210

S G

ND

11D

312

S G

ND

13D

414

S G

ND

15D

516

S G

ND

17D

618

S G

ND

19D

720

S G

ND

21IO

R22

IOW

23R

ES

ET

24R

ES

ET

25C

S0

26C

S1

27C

S2

28C

S3

29C

S5

30S

GN

D31

CLO

CK

32S

GN

D33

(SP

EE

D1)

34(S

PE

ED

2)

PO

WE

R P

CB

M86

0354

40A

0

J5

4P

J5

7

13

P1

CO

M2

CO

M3

-SW

4+

SW

5B

CO

UN

T R

ST

6B

CK

SW

7F

WD

SW

8S

.CO

UN

T R

ST

9C

OU

NT

IN S

W10

MO

DE

OU

T S

W11

MO

DE

IN S

W12

(SW

6)13

NO

SE

L S

W

LCD

PA

NE

L P

CB

M86

3154

30A

0

CP

U P

CB

M86

0154

3BA

0

J26

34P

I/O P

CB

M86

0254

4AA

0A

J4

6

3

4P

1 Vss2 Vdd3 Vo4 Rs5 R/W6 E7 DB08 DB19 DB210 DB311 DB412 DB513 DB614 DB7

J56 14P

－ 105 －

18. CIRCUIT DIAGRAM

(1) Transformer (ass’y)

AC26 V

AC7.5 V

AC20 V

AC24 V

AC100 V

AC4.5 V

AC4.5 V

AC440 V

AC415 V

AC380 V

AV240 V

AC220 V

AC200 V

0 V

7

6

5

4

3

2

1

ORANGE AC440 V

BLUE AC415 V

PURPLE AC380 V

GRAY AC240 V

WHITE AC220 V

BROWN AC200 V

BLACK 0 V

TB1 (TERMINAL)

P7

P6

P5

P4

P3

P2

P1

F.GGREEN/YELLOW

TRANSFORMER

S9 GRAY

AC26 V

0.3 A SCT BLACK

S10 GRAY

P4

1

2

3

AC7.5 V

3 A

S7

S8

RED

RED

AC20 V

4A

S4

S3

BLUE

BLUE

AC24 V

5 A

S1

S2

BROWN

BROWN

AC100 V

2 A

S5

S6

WHITE

WHITE

AC4.5 V

2 A

S11

S12 YELLOW

YELLOW

P5

1

2

3

4

5

6

1

2

J64

1

2

J65

－ 106 －

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

+18 V

S.GND

AC7.5 V

AC7.5 V

J5

1

2

F3

4 A

DB1

S10VB20

C 310000µ16 V

C 510000µ16 V

+8 V

R2

1 K

1 W

4

0.1µ50 V

AVR1

STR9005

C2 50.1µ50 V

1

C4

TP4

C6

100µ50 V

0.1µ50 V

0.1µ50 V

+5 V

C26 C28

J6

1234

+5 VS.GND+12 VS.GND

J7

1

2

3

4

5

+5 V

S.GND

+12 V

S.GND

-12 V

AC26 V

CENTER

AC26 V

J4

1

2

3

F5

1 A

F4

1 A

DB2

1B4B41

C91000µ35 V

C111000µ35 V

R8

1 K

1 W

R7

1 K

1 W

1AVR3

µ PC24M12 HF

3

C130.1µ

C150.1µ

C120.1µ

C140.1µ

2

µ PC79M12 HF

AVR2

2

3

1

C17100µ50 V

C16100µ50 V

J1

12

FAN+FAN-

J5

AC20 V

AC20 V

AC24 V

AC24 V

3

4

5

6

F2

10 A

FMM32R

F1

6 AD1

D3

FMM32R

FMM32S

D2

FMM32S

D4

C84700µ63 V

R92K2W

J3

3

6

2

5

1

4

+24 V

S.GND

+24 V

S.GND

+33 V

S.GND

C74700µ63 V

R12K2W

+33 V

V03C

D9C18100µ50 V

1AVR4

78LO18AP2

3C190.1µ

C200.1µ

C21 100µ50 V

C100.1µ50 V

+ + +

+

+

+

+

+

+

+ +

－ 107 －

(3) Circuit diagram of the stepping motor driver (ass’y) (4) Circuit diagram of the stepping motor (ass’y)

BLACK

RED

ORANGE

YELLOW

BLUE

N.C

CW+

CW–

CCW+

CCW–

P.D+

P.D–

AL1

AL2

NC

NC

P47

1

6

2

7

3

8

5

10

4

9

WHITE

BLUE

RED

PURPLE

ORANGE

YELLOW

BROWN

BLACK

P.M.D

+

–

+

–

+

–

1

2

CW

CCW

P.D.

AL

BLACK

RED

ORANGE

YELLOW

BLUE

F.GGREEN/YELLOW

TRANSAC100 V

WHITE

WHITE

F.G

AC100 V

PMM-BA-5601

BLACK

RED

ORANGE

YELLOW

BLUE

J61

1

2

3

4

5

6

BLACK

RED

ORANGE

YELLOW

BLUE

103-89571-7142

BLACK

RED

ORANGE

YELLOW

BLUE

T.B.

1

2

3

4

5

BLACK

RED

BROWN

YELLOW

WHITE

P61

1

2

3

4

5

6

－ 108 －

(5) Circuit diagram of the indexer switch

MC-591-2

FL. POSCYCLE

LK. ERRORS. GNDS. GND

ACF-164-1903

BUT

+VOUT0V

BR11, 21

ARNGEC

NO

EXHSTC

NO

MANU. FDC

NO

RFIN

+OUT

–

BUT

+OUT

–

A. ORG

+VOUT0V

I. ORG

+VOUT

–

AFRT

+OUT

–

P95 J95

P96 J96

P99 J99

P97 J97

P98 J98

134

134

134

134

134

134

134

134

134

134

J31 J31

A4B4A5

A13B13A14

B5A6B6

A7B7A8

A10B10A11

A9B16A15B15B9

789

252627

101112

131415

192021

1732293018

+5VTHRS. GND

+5VUP. SWS. GND

+5VARNGES. GND

+5VEXHSTS. GND

+5VMANU. FDS. GND

FL. POSCYCLELK. ERRORS. GNDS.GND

J32 J32

B2A3B3

A4B4A5

B5A6B6

A7B7A8

B8A9B9

B11A12B12

456

789

101112

131415

161718

222324

+5VBUTS. GND

+12VRUBS.GND

+12VPOSS. GND

+5VA. ORGS. GND

+12VI. ORGS. GND

+12VAFRTS. GND

ACF-164-1903

INIT

+

OUT

–

SPEED

+

OUT

–

SELECT

+

OUT

–

STK. CNT

+5V

OUT

0V

STCK2

+5V

OUT

0V

LIMIT1

+

OUT

–

LIMIT2

+

OUT

–

WRK. FWD

+

OUT

–

WRK. BCK

+

OUT

–

START

+5V

OUT

GND

EMM. SW3

4

RCL. SWCOM

NO

AIR, SW OUT

0V

J35 J35

A1

B1

A2

B2

A3

B3

A4

B4

A5

B5

A6

B6

A7

B7

A8

B8

A9

B9

A10

B10

A11

B11

A12

B12

A13

B13

A14

B14

A15

B15

A16

B16

A17

B17

A18

B18

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

+5V

INIT

S. GND

+5V

SPEED

S. GND

+5V

SELECT

S. GND

+5V

STK. CNT

S. GND

+5V

STCK2

S. GND

+5V

LIMIT

S. GND

+5V

WRK. FWD

S. GND

+5V

WRK. BCK

S. GND

+5V

START

S. GND

+5V

EMM. SW

S. GND

+5V

RCL. SW

S. GND

+12V

AIR. SW

S. GND

－ 109 －

(6) Output circuit board diaram

+24v

CLP. CL1

+24v

STK. CL1

+24V

STK. CL2

+24V

COV. CL

+24V

GAU. CL

3

11

5

13

6

14

7

15

8

16

+24V

–

+24V

–

+24V

–

+24V

–

+24V

–

ACF-164-1903

CLP. CL1VALVE

STK. CL1VALVE

STK. CL2VALVE

COV. CLVALVE

GAU. CLVALVE

+24VPRESSSTART

+24V

BUT. CL

P44

P43

51213

7

14

P1 J1

123

123

MC-591-2

I/F PCBM86515910A0

ACF-164-1903

+24V

–BUT. CLVALVE

P61

BLACKRED

ORENGEYELLOW

BLUE

12345

STEP. MOTOR

P62

AC100VAC100V

COV (Y)COV (W)COV (B)

AC100V. 1 (14C)AC100V. 1 (14C)F.G (14C)

48

125

J90 P90

123

123

CONV. MOTOR

P63

+24VS. GND

F. G

341

BOBBIN. WINDER

P64

AC4.2V

AC4.2V

1

2MARK LIGHT

P65

AC4.2V

AC4.2V

1

2MARK LIGHT

P33

1

2

MANU. C

MANU. C. RTN

MANU COUNT

P42

SET. SOL

S. GND

+24V

SHT. SOL

RUB. SOL

RUB. SOL. RTN

RUB. MTR. CW

RUB. MTR. CCW

+24V

IND. MTR

+24V

ARM. MTR

3

13

4

14

5

15

8

18

9

19

10

20

TB3

5

6

3

4

1

2

7

8

11

12

9

10

BR

SET. SOL(SEMG)

SHT. SOL(SHMG)

RUB. SOL(RMG)

RUB. MTR(RMT)

IND. MTR(IMT)

ARM. MTR(AMT)

P41

+24V

+24V. RTN

PT. FDRPF. RTN

2

1

43

J1 P1

(11C) AC100V. 1(11C) AC100V. 1(11C) F.G

45123

45123

5A BREAKER

FEEDER CONTROL

－ 110 －

－ 111 －

19. TROUBLES AND CORRECTIVE MEASURES

™Decrease the tension of the tension controller No. 1.

™Adjust the disk rising amount of the tension control-

ler No. 2.

™Use a needle hole guide with a higher boss.

™Use a button clamp of which lever plate is thinner

than the current one.

™Correct the wiper spring.

™Adjust the position of the button clamp jaw lever so

that the needle enters the exact center of the holes

in the button.

™Adjust the position of the feed plate so that it does

not come in contact with the boss of the needle hole

guide. If the sewing size is larger for the feed plate

used, replace it with the feed plate for medium-size

buttons or for large buttons.

™Change the needle count in accordance with the

sewing product or the holes in the button.

™ Increase the tension of the tension controller No. 1.

™Adjust the disk rising timing of the tension controller

No. 2.

™Decrease the pressure of the wiper spring.

™Replace the current button clamp with another one

of which lever plate is thicker than the current one.

™ Improve the actuation of the button clamp.

™Correct the button clamp jaw lever spring so that it

increases the retaining force for the button.

™Correct the leaf spring so that it does not exces-

sively work.

™Replace the current button clamp with another one

of which lever plate is thicker than the current one.

1. Thread slips

off the needle

at the sewing

start. Or, the

machine starts

sewing a but-

ton from an in-

t e r m e d i a t e

step of button

sewing proce-

dure.

2. Needle break-

age frequently

occurs.

3. The finished

state of the

wrong side of

the material is

e x t r e m e l y

poor.

4. The button is

not sewn at

the correct po-

sition.

1 Length of needle thread remain-

ing in the needle is too short.

2 The material flops.

3 The wiper does not press the

thread.

1 The needle hits the edge of holes

in the button.

2 The boss of the needle hole guide

comes in contact with the re-

cessed part of the feed plate.

3 The needle used is too thin.

1 Length of needle thread remain-

ing in the needle is too long.

2 The thread catching force of the

wiper is excessive.

3 If sewing a button of which wrong

side is round-shaped, the stitches

on the wrong side of the material

are entangled to make a lump of

thread.

1 The button is not secured in the

correct sewing position.

2 The leaf spring of the button clamp

excessively works.

3 When using a button of which

wrong side is round-shaped, the

thread enters the space between

the bottom face of the button and

the top face of the boss of the

needle hole guide. As a result, the

button is not fed smoothly.

Trouble(Phenomenon) Cause Corrective measure

－ 112 －

20. T

RO

UB

LES

AN

D C

OR

RE

CT

IVE

ME

AS

UT

RE

ST

RO

UB

LEC

AU

SE

(1)

CA

US

E (

2)C

OR

RE

CT

IVE

ME

AS

UR

ES

(1)

Mac

hine

has

bee

n po

wer

ed u

p.

Mac

hine

can

not b

e po

wer

ed u

p.

Cha

ract

er d

ispl

ay fa

ils to

be

indi

cate

d on

the

pane

l.

Pow

er c

ord

has

been

unp

lugg

ed.

Def

ectiv

e se

ttin

g of

the

rmal

val

ues

in s

witc

hbo

x.

Fau

lty +

5 V

pow

er s

uppl

y to

the

CP

U c

ircu

itbo

ard.

Fau

lty +

5 V

pow

er s

uppl

y to

the

pan

el c

ircui

tbo

ard.

Fau

lty +

5 V

pow

er s

uppl

y to

the

liqu

id c

ryst

aldi

spla

y (L

CD

) on

the

pane

l circ

uit b

oard

.

P-R

OM

(U

14

) o

f th

e C

PU

cir

cuit

bo

ard

ha

sim

prop

erly

bee

n lo

aded

on

empt

y so

cket

of t

he(U

16).

The

set

val

ue is

inad

equa

te.

Con

nect

or (

J28)

on

the

CP

U c

ircui

t boa

rd h

asbe

en d

isco

nnec

ted.

Con

nect

ors

(J5

and

J6)

on t

he p

ower

cir

cuit

boar

d ha

s be

en d

isco

nnec

ted.

Fau

lty 7

.5 V

ac p

ower

sup

ply

to th

e po

wer

circ

uit

boar

d.

Fau

lty (

F3:

4A)

on th

e po

wer

circ

uit b

oard

has

blow

n.

Def

ectiv

e po

wer

circ

uit b

oard

.

Co

nn

ect

ors

(J5

an

d J

6)

on

th

e C

PU

cir

cuit

boar

d ha

ve b

een

disc

onne

cted

.

Con

nect

ors

(J54

and

J55

) on

the

pane

l circ

uit

boar

d ha

ve b

een

disc

onne

cted

.

Pow

er c

ords

for

LCD

(re

d co

rd a

nd b

lack

cor

d)ha

ve b

een

disc

onne

cted

.

U14

has

bee

n lo

aded

with

its

pin

faci

ng to

war

dth

e op

posi

te d

irect

ion.

Plu

g th

e m

achi

ne in

.

Ope

n th

e sw

itch

box

and

the

valu

e su

itabl

e fo

r th

e sp

ecifi

catio

ns.

Con

nect

the

conn

ecto

r J2

8.

Con

nect

ors

the

conn

ecto

rs J

5 an

d J6

.

Che

ck th

e co

nnec

tion

of th

e te

rmin

al b

oard

and

the

AC

inpu

t pow

er v

olta

ge.

Che

ck fo

r the

out

put v

olta

ge (7

.5 V

ac) o

f the

tran

sfor

mer

. If t

he o

utpu

t vol

tage

is n

ot s

uppl

ied

to th

e po

wer

circ

uit b

oard

, rep

lace

the

tran

sfor

mer

.

Rep

lace

the

fuse

.

Rep

lace

the

pow

er c

ircui

t boa

rd.

Con

nect

the

conn

ecto

rs J

5 an

d J6

.

Con

nect

the

conn

ecto

rs J

54 a

nd J

55.

Con

nect

the

cord

s.

Load

135

(27

C25

6) o

n U

14

Rep

lace

P-R

OM

with

a n

ew o

ne a

nd lo

ad it

taki

ng c

are

of th

e di

rect

ion.

－ 113 －

The

cyl

inde

rs (

all)

do

not

mov

e ev

en t

he p

ower

has

been

turn

ed O

N. (

The

gau

ge d

oes

not m

ove.

)T

he o

pera

ting

air

is n

ot s

uppl

ied

to th

e un

it.

Fau

lty s

uppl

y of

+24

V o

r the

sig

nal t

o th

e va

lue.

Fau

lty +

24 V

pow

er s

uppl

y to

the

I/O

cir

cuit

boar

d.

Fa

ulty

+5

V p

ow

er

sup

ply

to

th

e I

/O c

ircu

itbo

ard.

Con

nect

ors

J42,

J43

and

J44

mou

nted

on

the

back

of t

he c

ontr

ol b

ox h

ave

been

rem

oved

.

Con

nect

or (

J40)

on

the

I/O

cir

cuit

boar

d ha

sbe

en d

isco

nnec

ted.

Con

nect

or (

J3)

on th

e po

wer

circ

uit b

oard

has

been

dis

conn

ecte

d.

Fus

e (F

2:10

A)

on th

e po

wer

circ

uit b

oard

has

blow

n.

Def

ectiv

e po

wer

circ

uit b

oard

.

Con

nect

or (

J39)

on

the

I/O

cir

cuit

boar

d ha

sbe

en d

isco

nnec

ted.

Con

nect

ors

(J5

and

J7)

on t

he p

ower

cir

cuit

boar

d ha

ve b

een

disc

onne

cted

.

Fau

lty 7

.5 V

ac p

ower

sup

ply

to th

e po

wer

circ

uit

boar

d.

Fus

e (F

3:4

A)

on t

he p

ower

circ

uit

boar

d ha

sbl

own.

Def

ectiv

e po

wer

circ

uit b

oard

.

Che

ck fo

r in

put/o

utpu

t of a

ir to

the

serie

s of

8 v

alve

s.

Con

nect

the

conn

ecto

rs J

42,J

43 a

nd J

44.

Con

nect

the

conn

ecto

r J4

0.

Con

nect

the

conn

ecto

r J3

.

Rep

lace

the

fuse

.

Rep

lace

the

pow

er c

ircui

t boa

rd.

Con

nect

the

conn

ecto

r J3

9.

Con

nect

the

conn

ecto

rs J

5 an

d J7

.

Che

ck th

e co

nnec

tion

of th

e te

rmin

al b

oard

and

AC

inpu

t pow

er v

olta

ge.

Che

ck fo

r th

e ou

tput

vol

tage

(7.

5 V

ac)

of th

e tr

ansf

orm

er. I

f the

vol

tage

isno

t sup

plie

d fr

om th

e tr

ansf

orm

er, r

epla

ce th

e tr

ansf

orm

er.

Rep

lace

the

fuse

.

Rep

lace

the

pow

er c

ircui

t boa

rd.

TR

OU

BLE

CA

US

E (

1)C

AU

SE

(2)

CO

RR

EC

TIV

E M

EA

SU

RE

S

－ 114 －

Err

or m

essa

ge “

04 W

ork

clam

p po

sitio

n er

ror”

isdi

spla

yed.

With

pow

ered

ON

, th

e fo

llow

ing

erro

r m

essa

ges

are

dis

pla

yed

. W

ith

R

sw

itch

pu

she

d,

err

or

disp

lays

can

not b

e re

set.

1)”5

1 A

ir pr

essu

re e

rror

” is

dis

play

ed.

2)”5

2 C

lam

p po

sitio

n er

ror.

” is

dis

play

ed.

Wor

k cl

amp

is in

its

dow

n co

nditi

on.

The

wor

k cl

amp

lift d

etec

ting

switc

h ha

s be

enim

prop

erly

adj

uste

d.

Th

e w

ork

cla

mp

lift

de

tect

ing

sw

itch

fa

ils t

ow

ork.

Wiri

ng o

f the

wor

k cl

amp

lift d

etec

ting

switc

h is

impr

oper

.

Con

nect

or J

39 a

t th

e I/O

circ

uit

boar

d co

mes

out o

f pos

ition

.

Ope

ratin

g ai

r is

not

sup

plie

d to

the

unit.

Set

val

ue o

f the

air

dete

ctor

sw

itch

is to

o hi

gh.

I/O c

ircui

t boa

rd is

equ

ippe

d w

ith th

e pi

n of

the

P-R

OM

(U

20)

with

rev

erse

dire

ctio

n.

J35

at th

e re

ar o

f the

con

trol b

ox is

dis

conn

ecte

d.

Wor

k cl

amp

posi

tion

is n

ot p

rope

r.

Wo

rk c

lam

p s

witc

h o

f th

e c

arr

iag

e i

s in

ON

posi

tion

whe

n po

wer

ed O

N.

Th

e w

ork

cla

mp

co

me

s in

co

nta

ct w

ith t

he

mac

hine

.

Rai

se th

e w

ork

clam

p w

ith h

and.

Pus

h th

e lo

ader

sta

rt P

.B. s

witc

h.

Adj

ust t

he s

witc

h pr

oper

ly.

Rep

lace

the

switc

h.

Che

ck th

e w

iring

of t

he s

witc

h.

Con

nect

the

J39.

Con

nect

the

join

t of a

ir su

pply

and

adj

ust p

ress

ure

to 0

.5 M

Pa

(5 k

gf/c

m2 )

.

Dec

reas

e th

e se

t val

ue. A

djus

t pre

ssur

e to

0.3

MP

a (3

kgf

/cm

2 ).

Rep

lace

the

P-R

OM

with

a n

ew o

ne a

nd m

ount

it c

heck

ing

for

its c

orre

ctdi

rect

ion.

Con

nect

the

J35.

Cha

nge

the

posi

tion

of th

e w

ork

clam

p.

Tur

n O

FF

the

pow

er a

nd m

ove

the

carr

iage

to

the

cent

er s

ide

from

the

orig

in.

TR

OU

BLE

CA

US

E (

1)C

AU

SE

(2)

CO

RR

EC

TIV

E M

EA

SU

RE

S

－ 115 －

3)”5

5 S

top

mot

ion

posi

tion

erro

r.”

is d

ispl

ayed

.

4)”0

9 R

AM

ba

ck u

p e

rro

r.”

(If

this

occ

urs

freq

uenc

y.)

5)”1

1 S

tart

sw

itch

on e

rror

.”

6)”5

0 S

tepp

ing

mot

or d

river

err

or.”

Sto

p-m

otio

n sw

itch

of t

he s

ewin

g m

achi

ne is

defe

ctiv

e.

J32

at th

e re

ar o

f the

con

trol

box

com

es o

ut o

fpo

sitio

n.

Mac

hine

is n

ot in

its

stop

-mot

ion

posi

tion.

Sto

p-m

otio

n sw

itch

is n

ot in

ON

pos

ition

with

the

mac

hine

is in

its

stop

-mot

ion

posi

tion.

The

sto

red

data

in R

AM

is e

rase

d.

The

sta

rt s

witc

h is

kep

t pre

ssed

.

The

sig

nal f

rom

the

step

ping

mot

or d

river

fails

to b

e se

nt to

CP

U c

ircui

t boa

rd.

Ste

ppin

g m

otor

driv

er e

rror

.

The

bat

tery

has

exh

aust

ed.

Def

ectiv

e da

ta b

ack-

up c

ircui

try.

Th

e m

ech

an

ica

l a

dju

stm

en

t h

as

no

t b

ee

nco

mpl

eted

.

Def

ectiv

e sw

itch.

Con

nect

or (J

26) o

n C

PU

circ

uit b

oard

has

bee

ndi

scon

nect

ed.

Th

e r

eq

uir

ed

po

we

r vo

lta

ge

10

0 V

ac

ha

sdr

oppe

d to

85

Vac

or

less

.

Eith

er

the

in

tern

al

tem

pe

ratu

re o

r a

mb

ien

tte

mpe

ratu

re o

f th

e st

eppi

ng m

otor

driv

er h

asris

en to

80˚

C o

r m

ore.

Ste

pp

ing

mo

tor

dri

ver

ha

s re

ceiv

ed

an

abno

rmal

inpu

t.

Fau

lty s

tepp

ing

mot

or d

river

.

Rep

lace

the

stop

-mot

ion

switc

h w

ith a

new

one

.

Con

nect

the

J32.

Tur

n th

e pu

lley

until

sto

p-m

otio

n po

sitio

n is

rea

ched

.

Re-

adju

st s

witc

h po

sitio

n.

Rep

lace

the

batte

ry (

BT

) in

the

CP

U c

ircui

t boa

rd.

Rep

lace

the

CP

U c

ircui

t boa

rd.

Rel

ease

you

r ha

nd o

r kn

ee fr

om th

e sw

itch,

and

turn

ON

the

pow

er to

the

mac

hine

.

Adj

ust t

he s

trok

e of

the

switc

h an

d th

e w

ork

clam

p.

Rep

lace

sw

itch.

Con

nect

the

conn

ecto

r J2

6.

Che

ck fo

r th

e 10

0 V

ac o

f the

pow

er v

olta

ge, o

r in

put p

ower

vol

tage

.

Che

ck th

e D

C fa

n. (R

efer

to “

(8) O

ther

s” tr

oubl

e in

faul

ty ri

se o

f tem

pera

ture

.)

Rep

lace

the

P-R

OM

(U

14)

on C

PU

circ

uit b

oard

.

Rep

lace

the

CP

U c

ircui

t boa

rd.

Rep

lace

the

I/O c

ircui

t boa

rd.

Rep

lace

the

step

ping

mot

or d

river

.

TR

OU

BLE

CA

US

E (

1)C

AU

SE

(2)

CO

RR

EC

TIV

E M

EA

SU

RE

S

－ 116 －

7)M

otor

of t

he in

dexe

r ke

eps

on r

otat

ing.

Afte

r th

e po

wer

has

bee

n tu

rned

ON

, the

car

riage

fails

to s

earc

h th

e or

igin

. (If

the

erro

r m

essa

ge “

50S

tepp

ing

mot

or d

river

err

or”

is s

how

n on

the

pane

ldi

spla

y,re

fer

to th

e ite

m (

1) 6

).

Dur

ing

the

sear

ch f

or t

he o

rigi

n, c

arri

age

fails

to

mov

e st

eadi

ly.

The

orig

in s

witc

h of

the

inde

xer

fails

to w

ork.

The

mot

or o

f the

inde

xer

is d

efec

tive.

The

I/O

circ

uit b

oard

is d

efec

tive.

Pin

ion

gear

is lo

osen

ed.

The

ste

ppin

g m

otor

fails

to r

un.

Mec

hani

cal a

ccur

acy

has

not a

ttain

ed.

Fa

ulty

dri

vin

g c

om

po

ne

nts

of

the

ste

pp

ing

mot

or.

Rac

k/pi

nion

gea

r sc

rew

is lo

osen

ed.

If th

e co

nnec

tors

are

sec

urel

y co

nnec

ted,

repl

ace

the

switc

h w

ith a

new

one

.

Rep

lace

the

mot

or w

ith a

new

one

.

Rep

lace

the

I/O c

ircui

t boa

rd w

ith a

new

one

.

Re-

tight

en p

inio

n ge

ar s

crew

.

Rep

lace

the

fuse

with

a n

ew o

ne.

Con

nect

the

conn

ecto

r J4

7.

Con

nect

the

conn

ecto

r J6

1.

Rep

lace

the

step

ping

mot

or d

river

.

Rep

lace

the

step

ping

mot

or.

Adj

ust t

he b

ackl

ash

appr

opria

tely

.

Rep

lace

the

step

ping

mot

or.

Rep

lace

the

step

ping

mot

or d

river

.

Che

ck e

ach

scre

ws

tight

enin

g ar

e fo

r se

curit

y.

TR

OU

BLE

CA

US

E (

1)C

AU

SE

(2)

CO

RR

EC

TIV

E M

EA

SU

RE

S

Con

nect

ors

P32

and

97

have

com

e of

f.

Fus

e (F

6:4

A)

has

been

blo

wn.

Con

nect

or (

J47)

on

I/O c

ircui

t boa

rd h

as b

een

disc

onne

cted

.

Con

nect

or (

J61)

mou

nted

on

the

back

of

the

cont

rol b

ox h

as b

een

disc

onne

cted

.

Def

ectiv

e st

eppi

ng m

otor

driv

er.

Def

ectiv

e st

eppi

ng m

otor

.

Def

ectiv

e st

eppi

ng m

otor

.Exc

essi

ve b

ackl

ash

amon

g th

e st

eppi

ng m

otor

, pin

ion

gear

and

the

carr

iage

rac

k.

Fau

lty s

tepp

ing

mot

or.

Fau

lty s

tepp

ing

mot

or d

river

.

(2)

Sea

rch

the

orig

in

－ 117 －

In th

e m

en’s

mod

eT

he m

achi

ne s

tops

aft

er it

s ca

rria

ge h

as m

oved

10

0 m

m (

3.9

37

”) a

nd

th

e e

rro

r m

ess

ag

e “

10

1S

PE

ED

SW

ER

RO

R”

is d

ispl

ayed

.

In th

e la

dies

’ mod

eT

he c

arria

ge fa

ils to

mov

e to

the

orig

in a

nd s

tops

.

In th

e la

dies

’ mod

eT

he

ca

rria

ge

sto

ps

aft

er

it h

as

mo

ved

10

0 m

m(3

.93

7”)

an

d t

he

err

or

me

ssa

ge

“1

00

IN

IT S

WE

RR

OR

”is d

ispl

ayed

.

In th

e m

en’s

mod

eT

he c

arria

ge fa

ils to

mov

e to

the

orig

in a

nd s

tops

.

Th

e c

arr

iag

e u

nit

mo

ves,

an

d “

52

CL

AM

PP

OS

ITIO

N E

RR

OR

” is

indi

cate

d on

the

disp

lay.

“10

2 S

EL

EC

T S

W E

RR

OR

” is

in

dic

ate

d o

n t

he

disp

lay.

The

spe

ed d

ecre

asin

g de

tect

or s

witc

h (S

PE

ED

SW

) is

not

act

ivat

ed.

Th

e o

rig

in d

ete

cto

r sw

itch

(IN

IT S

W)

is n

ot

activ

ated

.

Def

ectiv

e po

sitio

n of

the

wor

k cl

amp

The

orig

in s

enso

r (IN

IT S

W) a

nd d

iscr

imin

atio

nse

nsor

(S

ELE

CT

SW

) do

not

wor

k.

Th

e m

en

’s w

ea

r se

win

g m

od

e/la

die

s’ w

ea

rse

win

g m

ode

is n

ot p

rope

rly s

peci

fied.

The

dis

crim

inat

ion

switc

h (S

ELE

CT

SW

) do

seno

t wor

k.

The

sen

sor

win

dow

has

col

lect

ed m

oist

ure.

Def

ectiv

e se

nsor

.

Pos

ition

of

the

orig

in d

etec

ting

plat

e ha

s no

tbe

en a

djus

ted.

The

sen

sor

win

dow

has

col

lect

ed m

oist

ure.

Def

ectiv

e se

nsor

.

Pos

ition

of

the

orig

in d

etec

ting

plat

e ha

s no

tbe

em a

djus

ted.

Wor

k cl

amp

switc

h of

the

carr

iage

is tu

rned

ON

whe

n th

e ca

rria

ge is

in it

s or

igin

.

The

pos

ition

of t

he s

enso

r is

out o

f the

det

ectin

gra

nge.

The

sen

sor

is d

etec

tive.

The

pos

ition

of

the

orig

in d

etec

ting

plat

e ha

sno

t bee

n ad

just

ed.

Win

dow

of t

he s

enso

r ha

s co

llect

ed m

oist

ure.

The

sen

sor

is d

efec

tive.

The

pos

ition

of

the

orig

in d

etec

ting

plat

e ha

sno

t bee

n ad

just

ed.

Blo

w a

ir t

o th

e sl

it of

the

sen

sor,

or

clea

n th

e w

indo

w w

ith a

pie

ce o

f dr

ycl

oth.

Rep

lace

the

sens

or.

Adj

ust t

he p

ositi

on o

f the

orig

in d

etec

ting

plat

e so

that

it r

each

es o

n th

e sl

it.

Blo

w a

ir t

o th

e sl

it of

the

sen

sor,

or

clea

n th

e w

indo

w w

ith a

pie

ce o

f dr

ycl

oth.

Rep

lace

the

sens

or.

Adj

ust t

he p

ositi

on o

f the

orig

in d

etec

ting

plat

e so

that

it r

each

es o

n th

e sl

it.

Re-

adju

st th

e po

sitio

n of

the

switc

h.

Turn

“ON

” the

pow

er s

witc

h af

ter b

ringi

ng th

e ca

rria

ge u

nit t

o its

cen

ter p

ositi

on.

Adj

ust t

he p

ositi

on o

f the

sen

sor.

Rep

lace

the

sens

or.

Adj

ust t

he o

rigin

det

ectin

g pl

ate

so th

at it

rea

ches

the

slit.

Pro

perly

set

the

chan

ge-o

ver

switc

h on

the

side

face

of t

he p

anel

, and

re-

turn

ON

the

pow

er to

the

mac

hine

.

Blo

w a

ir to

the

slit

of th

e se

nsor

. Or,

wip

e th

e se

nsor

win

dow

with

a p

iece

of

dry

clot

h.

Rep

lace

the

sens

or.

Adj

ust i

t so

that

the

orig

in d

etec

ting

plat

e re

ache

s th

e sl

it.

TR

OU

BLE

CA

US

E (

1)C

AU

SE

(2)

CO

RR

EC

TIV

E M

EA

SU

RE

S

－ 118 －

(3)

Pan

el o

pera

tion

Pan

el in

put i

s im

poss

ible

. (S

witc

hes

are

not v

alid

.)

Th

e l

ad

ies’

or

fin

ish

ed

we

ar

mo

de

ca

nn

ot

be

activ

ated

.

The

but

ton

feed

sw

itch

fails

to w

ork.

Sig

nal f

rom

mem

bran

e sw

itch

fails

to b

e in

put

to p

anel

circ

uit b

oard

.

Sig

nal f

rom

pan

el c

ircu

it bo

ard

has

not

been

inpu

t to

CP

U c

ircui

t boa

rd.

Sea

rch

for

the

orig

in h

as n

ot b

een

com

plet

ed.

The

slid

e sw

itch

of t

he o

pera

tion

pane

l doe

sno

t wor

k.

The

slid

e sw

itch

failu

re.

The

sw

itch

for

ladi

es’ m

ode

and

the

finis

hed

prod

uct s

witc

h ha

ve b

een

conn

ecte

d re

vers

ely.

Fau

lty +

24 V

pow

er s

uppl

y to

the

I/O

cir

cuit

boar

d.

Mot

or o

f the

spi

nner

osc

illat

ing

arm

fails

to w

ork.

The

sw

itch

is d

efec

tive.

The

man

ual r

otat

ing

shaf

t can

not b

e op

erat

edsm

ooth

ly.

Co

nn

ect

ors

J5

2,J

53

an

d J

57

on

th

e p

an

el

circ

uit b

oard

hav

e be

en d

isco

nnec

ted.

Con

nect

ors

J5 a

nd J

6 on

the

CP

U c

ircui

t boa

rd,

or J

54 a

nd J

55 o

n th

e pa

nel c

ircui

t boa

rd h

ave

been

dis

conn

ecte

d.

The

J71

and

J72

of t

he p

anel

circ

uit b

oard

com

eou

t of p

ositi

on.

Bre

aker

has

dro

pped

.

Con

nect

or (

J40)

on

the

I/O

cir

cuit

boar

d ha

sco

me

off.

Con

nect

ors

(J5

and

J3)

on t

he p

ower

cir

cuit

boar

d as

m. h

ave

com

e of

f.

Fus

e (F

2:10

A)

of th

e po

wer

circ

uit b

oard

asm

.ha

s bl

own.

The

pow

er c

ircui

t boa

rd a

sm. i

s de

fect

ive.

Con

nect

or J

42 lo

cate

d on

the

com

e of

f.

Th

e m

oto

r o

f th

e s

pin

ne

r o

scill

atin

g a

rm i

sde

fect

ive.

The

bre

aker

on

the

oper

atio

n pa

nel h

as b

een

cut o

ff.

The

cam

sha

ft co

mpo

nent

s ar

e lo

cked

.

Con

nect

the

conn

ecto

rs J

52,J

53 a

nd J

57.

Con

nect

the

conn

ecto

rs J

5 an

d J6

or

J54

and

J55.

Ref

er to

the

trou

bles

in “

(2)

sea

rch

the

orig

in”

Con

nect

J71

and

J72

.

Rep

lace

the

slid

e sw

itch

with

a n

ew o

ne.

Con

nect

the

switc

h fo

r la

dies

’ to

J71

and

that

for

finis

hed

wea

r to

J72

.

Res

et th

e br

eake

r.

Sec

urel

y co

nnec

t the

con

nect

or J

40.

Con

nect

the

conn

ecto

r J5

and

J3.

Rep

lace

the

fuse

with

a n

ew o

ne.

Rep

lace

the

pow

er c

ircui

t boa

rd a

sm.w

ith a

new

one

.

Sec

urel

y co

nnec

t the

con

nect

or J

42.

Rep

lace

the

mot

or w

ith a

new

one

.

Pre

ss th

e pu

sh-b

utto

n of

the

brea

ker.

Rep

lace

the

switc

h.

Insp

ect t

he w

orm

com

pone

nts

and

cam

com

pone

nts.

TR

OU

BLE

CA

US

E (

1)C

AU

SE

(2)

CO

RR

EC

TIV

E M

EA

SU

RE

S

－ 119 －

(4)

Sta

rt

The

wor

k cl

amp

does

not

com

e do

wn.

The

mac

hine

fails

to s

tart

.

Th

e m

ach

ine

ca

nn

ot

be

re

lea

sed

fro

m t

he

“sta

rt”

stat

e.

The

but

ton

cent

er a

nd t

he s

ize

of m

ater

ial e

dge

fail

to m

eet t

he s

cale

.

The

dis

tanc

e fr

om t

he m

ater

ial e

dge

to t

he f

irst

butto

n an

d to

the

last

but

ton

fails

to

acco

rd.

(not

para

llel)

Kne

e sw

itch

(ST

AR

T S

W)

fails

to w

ork.

Han

d sw

itch

(PC

L S

W)

fails

to w

ork.

The

wor

k cl

amp

cylin

der

does

not

wor

k.

The

rel

ated

com

pone

nts

of th

e m

achi

ne h

ave

not b

een

adju

sted

.

The

equ

ipm

ent h

as n

ot b

een

adju

sted

yet

.

Th

e w

ork

cla

mp

fo

rce

of

the

ca

rria

ge

is

insu

ffici

ent.

The

wor

k cl

amp

com

pone

nts

fiuct

uate

.

The

sw

itch

stro

ke h

as n

ot b

een

adju

sted

.

Def

ectiv

e sw

itch.

Def

ectiv

e sw

itch.

The

J44

at t

he b

ack

of th

e co

ntro

l box

com

esou

t of p

ositi

on.

Val

ue fa

ilure

.

Ope

ratin

g ai

r pr

essu

re is

too

low

.

Th

e g

uid

ing

ma

rk f

ails

to

me

et

the

nu

me

ric

valu

e on

the

scal

e.

Th

e l

eft

an

d r

igh

t si

zes

of

the

se

t p

late

an

dcl

amp

tabl

e ar

e no

t equ

al.

The

wor

k pi

eces

are

not

set

on

the

mac

hine

with

pro

perly

arr

ange

d.

The

cla

mp

sprin

g pr

essu

re is

too

high

.

The

com

pres

sed

air

pres

sure

is to

o lo

w.

The

slid

e be

arin

g kn

ob h

as lo

osen

ed.

The

slid

e sh

aft

supp

ort

has

been

impr

oper

lyad

just

ed.

Adj

ust t

he s

witc

h st

roke

.

Rep

lace

the

switc

h.

Rep

lace

the

switc

h.

Con

nect

the

J44.

Ch

eck

th

e r

esi

sta

nce

va

lue

th

at

is d

eve

lop

ed

be

twe

en

3 a

nd

11

of

the

conn

ecto

r P

44.

Adj

ust t

he o

pera

ting

air

pres

sure

to 0

.5 M

Pa

(5 k

gf/c

m2 )

.

Adj

ust t

he p

ositi

on o

f the

gui

ding

mar

k.

Loos

en s

crew

and

adj

ust t

he s

et p

late

.

Set

the

mat

eria

l pro

perly

.

Adj

ust t

he s

prin

g pr

essu

re p

rope

rly.

Adj

ust t

he c

ompr

esse

d ai

r pr

essu

re to

0.5

MP

a (5

kgf

/cm

2 ).

Tig

hten

the

slid

e be

arin

g, le

ft or

the

slid

e be

arin

g kn

ob, r

ight

.

Adj

ust t

he s

lide

shaf

t sup

port

TR

OU

BLE

CA

US

E (

1)C

AU

SE

(2)

CO

RR

EC

TIV

E M

EA

SU

RE

S

－ 120 －

(5)

But

ton

sew

ing

In t

he

au

tom

ati

c o

pe

rati

on

mo

de

, th

e s

ew

ing

mac

hine

fails

to s

tart

.In

th

e i

nd

ep

en

de

nt

op

era

tion

mo

de

,th

e s

ew

ing

mac

hine

fails

to s

tart

.T

wo

seco

nds

late

r, “

51 A

IR P

RE

SS

UR

E E

RR

OR

”is

indi

cate

d on

the

disp

lay.

Alth

ough

a b

utto

n is

sup

plie

d, “

13 B

UT

TO

N F

EE

DE

RR

OR

” is

dis

play

ed a

nd th

e m

achi

ne s

tops

.T

he b

utto

n de

tect

or s

enso

r fa

ils to

wor

k.

The

but

ton

dete

ctor

cyl

inde

r fa

ils to

wor

k.

The

but

ton

dete

ctin

g tim

ing

is d

efec

tive.

Con

nect

or J

42 o

n th

e ba

ck fa

ce o

f the

con

trol

box

has

been

dis

conn

ecte

d.

The

com

pres

sed

air

pres

sure

is to

o lo

w.

Th

e p

osi

tio

n o

f th

e s

en

sor

is n

ot

in t

he

defe

ctab

le r

ange

.

The

sen

sor

is d

efec

tive.

The

det

ectin

g le

ver d

oes

not s

hiel

d th

e se

nsor

.

The

link

ret

urni

ng s

prin

g ha

s co

me

off.

The

ope

ratin

g ai

r pr

essu

re is

too

low

.

Def

ectiv

e cy

linde

r.

Def

ectiv

e va

lve.

The

spi

nner

osc

illat

ing

arm

forw

ard

posi

tioni

ngse

nsor

is d

efec

tive.

Out

of

the

limit

of t

ime

to b

e us

ed t

o de

tect

abu

tton.

Con

nect

the

conn

ecto

r J4

2.

Adj

ust t

he c

ompr

esse

d ai

r pr

essu

re to

0.5

MP

a (5

kgf

/cm

2 ).

Adj

ust t

he p

ositi

on o

f the

sen

sor.

Rep

lace

the

sens

or.

Adj

ust t

he p

ositi

on o

f the

leve

r.

Atta

ch th

e lin

k re

turn

ing

sprin

g in

pos

ition

.

Adj

ust t

he o

pera

ting

air

pres

sure

to 0

.5 M

Pa

(5 k

gf/c

m2 )

.

Rep

lace

the

cylin

der.

Ch

eck

th

e r

esi

sta

nce

va

lue

th

at

is d

eve

lop

ed

be

twe

en

7 a

nd

14

of

the

conn

ecto

r P

43.

Rep

lace

the

sens

or.

Adj

ust t

he p

ositi

on o

f the

spi

nner

osc

illat

ing

arm

forw

ard

posi

tioni

ng s

witc

h.

TR

OU

BLE

CA

US

E (

1)C

AU

SE

(2)

CO

RR

EC

TIV

E M

EA

SU

RE

S

－ 121 －

Alth

ough

a b

utto

n is

not

sup

plie

d,th

e m

achi

ne fa

ilsto

dis

play

“er

ror

mes

sage

”,an

d th

e m

achi

ne g

oes

to th

e ne

xt s

tep

with

out d

ispl

ayin

g er

ror

mes

sage

.

Dur

ing

auto

mat

ic o

pera

tion,

the

mac

hine

sto

ps w

ithits

wor

k cl

amp

dow

n af

ter

sew

ing

is fi

nish

ed a

nd it

fails

to s

tart

the

next

ste

p.

The

but

ton

fails

to c

ome

off a

t the

sew

ing

end.

SW

4-3

on th

e I/O

circ

uit b

oard

has

bee

n se

t to

its O

N p

ositi

on.

But

ton

dete

ctiv

e se

nsor

fails

to w

ork.

Vol

tage

of +

24 V

is n

ot s

uppl

ied

to th

e I/O

circ

uit

boar

d.

Mo

tor

of

the

sp

inn

er

osc

illa

ting

arm

fa

ils t

om

ove.

The

sto

p-m

otio

n sw

itch

fails

to w

ork

norm

ally

.

The

cla

mp

jaw

leve

r op

enin

g is

not

adj

uste

d.

The

sen

sor

is o

utsi

de o

f the

det

ecta

ble

rang

e.

The

sen

sor

is d

efec

tive.

The

shi

ledi

ng p

late

fails

to s

hiel

d th

e lig

ht.

The

link

ret

urni

ng s

prin

g ha

s co

me

off.

The

con

nect

or (

J40)

of

the

I/O

cir

cuit

boar

dco

mes

out

of p

ositi

on.

Co

nn

ect

or

(J3

an

d J

5)

on

th

e p

ow

er

circ

uit

boar

d ha

s be

en d

isco

nnec

ted.

Fus

e (F

2:10

A)

on th

e po

wer

circ

uit b

oard

has

blow

n.

The

pow

er c

ircui

t boa

rd is

def

ectiv

e.

Con

nect

or J

42 o

n th

e ba

ck fa

ce o

f the

con

trol

box

has

been

dis

conn

ecte

d.

Th

e m

oto

r o

f th

e s

pin

ne

r o

scill

atin

g a

rm i

sde

fect

ive.

Fus

e (F

2:10

A) o

n th

e po

wer

circ

uit b

oard

asm

.ha

s bl

own.

The

str

oke

of th

e sw

itch

has

not b

een

adju

sted

.

Fai

lure

of t

he s

witc

h.

Whe

n th

e bu

tton

clam

p ja

w le

ver

open

s to

the

max

imum

,no

clea

ranc

e ex

ist a

t but

ton-

to-b

utto

ncl

amp

jaw

leve

r.

Set

the

SW

4-3

on th

e I/O

circ

uit b

oard

to it

s O

FF

pos

ition

.

Adj

ust t

he p

ositi

on o

f the

sen

sor

prop

erly

.

Rep

lace

the

sens

or w

ith a

new

one

.

Adj

ust t

he p

ositi

on o

f the

leve

r.

Atta

ch th

e lin

k re

turn

ing

sprin

g n

plac

e.

Con

nect

the

J40.

Con

nect

the

conn

ecto

r J3

and

J5.

Rep

lace

the

fuse

.

Rep

lace

the

pow

er c

ircui

t boa

rd.

Con

nect

the

conn

ecto

r J4

2.

Che

ck th

e cn

nect

or P

42 1

0 to

20

for

cont

inui

ty.

Rep

lace

the

fuse

.

Adj

us th

e st

roke

.

Rep

lace

the

switc

h w

ith a

new

one

.

Adj

ust t

he c

lam

p re

leas

e ar

m. A

djus

t the

ope

ning

of t

he b

utto

n cl

amp

jaw

leve

r.

TR

OU

BLE

CA

US

E (

1)C

AU

SE

(2)

CO

RR

EC

TIV

E M

EA

SU

RE

S

－ 122 －

Aft

er

the

ma

chin

e h

as

sew

n t

he

1st

bu

tto

n,”

52

CLA

MP

PO

SIT

ION

ER

RO

R”,

is d

ispl

ayed

.

Aft

er

the

bu

tto

n h

as

be

en

se

wn

,”0

1 N

EE

DL

ET

HR

EA

D S

TIT

CH

ER

RO

R”

is d

ispl

ayed

alth

ough

the

need

le th

read

is n

ot tr

imm

ed.

Stit

ch fa

ilure

err

or is

not

sho

wn

on th

e pa

nel e

ven

whe

n th

e ne

edle

thre

ad h

as b

roke

n.

The

wor

k cl

amp

posi

tion

switc

h of

the

carr

iage

is in

ON

pos

ition

at i

ts o

rigin

.

Th

e t

hre

ad

bre

aka

ge

de

tect

or

kee

ps

on

outp

uttin

g a

sign

al.

Th

e t

hre

ad

ta

ke-u

p s

pri

ng

ha

s n

ot

be

en

adju

sted

.

Ele

ctro

de h

as n

ot b

een

perf

ectly

insu

late

d.

SW

4-1

on th

e I/O

circ

uit b

oard

has

bee

n se

t to

its O

N p

ositi

on.

Th

e t

hre

ad

ta

ke-u

p s

pri

ng

ha

s n

ot

be

en

adju

sted

.

Thr

ead

brea

kage

det

ectin

g si

gnal

is n

ot o

utpu

t.

The

thre

ad ta

ke-u

p sp

ring

is n

ot th

read

ed.

The

cle

aran

ce p

rovi

ded

betw

een

the

thre

adta

ke-u

p sp

ring

and

the

elec

trod

e is

insu

ffici

ent.

The

tens

ion

of th

e th

read

take

-up

sprin

g is

too

high

.

The

str

oke

of th

e th

read

take

-up

sprin

g is

too

larg

e.

Ten

sion

of

the

thre

ad t

ake-

up s

prin

g an

d th

eel

ectr

ode

is o

bser

ved.

Poo

r con

tact

bet

wee

n th

e th

read

take

-up

sprin

gan

d th

e el

ectr

ode

is o

bser

ved.

Adj

ust t

he s

witc

h

Thr

ead

the

thre

ad ta

ke-u

p sp

ring.

Mov

e th

e el

ectr

ode

away

from

the

thre

ad ta

ke-u

p sp

ring

to a

llow

the

thre

adta

ke-u

p sp

ring

to m

ove

by a

larg

e am

ount

. (6

to 8

mm

)

Dec

reas

e th

e te

nsio

n of

the

thre

ad ta

ke-u

p sp

ring.

Insu

late

the

elec

trod

e an

d as

sem

ble

it pr

oper

ly.

Set

the

SW

4-1

on th

e I/O

circ

uit b

oard

to it

s O

FF

pos

ition

.

Brin

g th

e el

ectr

ode

to th

e th

read

take

-up

sprin

g to

dec

reas

e th

e am

ount

of

stro

ke o

f the

thre

ad ta

ke-u

p sp

ring.

(6

to 8

mm

)

Adj

ust t

he lo

ad a

pplie

d by

the

sprin

g to

20

to 4

0 gf

.

Adj

ust t

he p

ositi

on o

f the

ele

ctro

de.

Cle

an u

p th

e co

ntac

t poi

nt o

f the

ele

ctro

de.

TR

OU

BLE

CA

US

E (

1)C

AU

SE

(2)

CO

RR

EC

TIV

E M

EA

SU

RE

S

－ 123 －

In th

e m

en’s

mod

eW

hen

the

carr

iage

ret

urns

to

the

orig

in,

the

erro

rm

essa

ge “

100

INIT

SW

ER

RO

R”.

is d

ispl

ayed

on

the

pane

l.

In th

e la

dies

’ mod

eW

hen

the

carr

iage

ret

urns

to

the

orig

in,

the

erro

rm

essa

ge “

101

INIT

SW

ER

RO

R.”

is d

ispl

ayed

on

the

pane

l.

Whe

n th

e ca

rria

ge r

etur

ns t

o th

e or

igin

, th

e er

ror

me

ssa

ge

“5

2 C

LA

MP

PO

SIT

ION

ER

RO

R”

isdi

spla

yed

on th

e pa

nel.

Exc

essi

ve e

rror

in b

utto

n in

terv

als.

The

mat

eria

l slip

s w

hen

the

carr

iage

trav

els.

(6)

Mov

ing

the

carr

iage

Spe

ed d

ecre

asin

g de

tect

ing

switc

h (S

PE

ED

SW

) fa

ils to

wor

k.

Ori

gin

dete

ctin

g sw

itch

(IN

IT S

W)

fails

to

wor

k.

Spe

ed d

ecre

asin

g de

tect

ing

switc

h (S

PE

ED

SW

) fa

ils to

wor

k.

Ori

gin

dete

ctin

g sw

itch

(IN

IT S

W)

fails

to

wor

k.

Ori

gin

dete

ctin

g sw

itch

(IN

IT S

W)

fails

to

wor

k.

Spe

ed d

ecre

asin

g de

tect

ing

switc

h (S

PE

ED

SW

) fa

ils to

wor

k.

Mec

hani

cal a

ccur

acy

has

not a

ttain

ed.

Fa

ulty

dri

vin

g c

om

po

ne

nts

of

the

ste

pp

ing

mot

or.

Nei

ther

the

need

le th

read

nor

the

bobb

in th

read

are

not c

ut s

harp

.

The

sen

sor

win

dow

has

col

lect

ed m

oist

ure.

Def

ectiv

e se

nsor

.

Pos

ition

of

the

orig

in d

etec

ting

plat

e ha

s no

tbe

en a

djus

ted.

The

sen

sor

win

dow

has

col

lect

ed m

oist

ure.

Def

ectiv

e se

nsor

.

Pos

ition

of

the

orig

in d

etec

ting

plat

e ha

s no

tbe

en a

djus

ted.

Def

ectiv

e se

nsor

.

Pos

ition

of

the

orig

in d

etec

ting

plat

e ha

s no

tbe

en a

djus

ted.

Exc

essi

ve b

ackl

ash

amon

g th

e st

eppi

ng m

otor

,pi

nion

and

the

carr

iage

rac

k.

Th

e s

cre

w o

f th

e s

tep

pin

g m

oto

r p

inio

n i

slo

osen

ed.

Fau

lty s

tepp

ing

mot

or.

Fau

lty s

tepp

ing

mot

or d

river

.

The

kni

fe h

as n

ot b

een

adju

sted

or

brok

en.

Blo

w a

ir t

o th

e sl

it of

the

sen

sor,

or

clea

n th

e w

indo

w w

ith a

pie

ce o

f dr

ycl

oth.

Rep

lace

the

sens

or.

Adj

ust t

he p

ositi

on o

f the

orig

in d

etec

ting

plat

e to

that

it r

each

es o

n to

the

slit.

Blo

w a

ir t

o th

e sl

it of

the

sen

sor,

or

clea

n th

e w

indo

w w

ith a

pie

ce o

f dr

ycl

oth.

Rep

lace

the

sens

or.

Adj

ust t

he p

ositi

on o

f the

orig

in d

etec

ting

plat

e so

that

it r

each

es o

n to

the

slit.

Rep

lace

the

sens

or.

Adj

ust t

he p

ositi

on o

f the

orig

in d

etec

ting

plat

e to

that

it r

each

ed o

n to

the

slit.

Adj

ust t

he b

ackl

ash

appr

opria

tely

.

Re-

tight

en th

e sc

rew

to th

e se

t tig

hten

ing

torq

ue.

Rep

lace

the

step

ping

mot

or.

Rep

lace

the

step

ping

mot

or d

river

.

Adj

ust t

he k

nife

or

repl

ace

the

knife

with

a n

ew o

ne.

TR

OU

BLE

CA

US

E (

1)C

AU

SE

(2)

CO

RR

EC

TIV

E M

EA

SU

RE

S

－ 124 －

(7)

Sta

ckin

g

Fin

ishe

d m

ater

ial f

ails

to b

e st

acke

d.

The

sw

ing

bar

fails

to w

ork.

The

fin

ishe

d m

ater

ials

are

not

sta

cked

nea

tly o

nth

e st

acke

r.

Sta

ckin

g ba

r fa

ils to

wor

k.

The

sen

sor

of t

he s

win

g ba

r cy

linde

r fa

ils t

ow

ork.

The

sw

ing

bar

cylin

der

does

not

wor

k.

The

sta

cked

mat

eria

ls a

re li

kely

to

be p

ulle

dba

ck.

The

clo

th p

ress

er b

ar d

oes

not w

ork.

The

ope

ratin

g ai

r pr

essu

re is

too

low

.

Set

val

ue o

f the

spe

ed c

ontr

olle

r is

exce

ssiv

ely

decr

ease

d.

Def

ectiv

e cy

linde

r.

Def

ectiv

e va

lve.

Th

e p

osi

tio

n o

f th

e s

en

sor

is o

ut

of

the

dete

ctab

le r

ange

.

The

ope

ratin

g ai

r pr

essu

re is

too

low

.

Def

ectiv

e cy

linde

r.

Def

ectiv

e va

lve.

The

spe

ed o

f the

sw

ing

bar

is to

o hi

gh.

The

str

oke

of th

e cy

linde

r is

too

shor

t.

The

clo

th p

ress

er b

ar a

nd t

he s

tack

ing

boar

dha

ve b

een

loos

ely

fitte

d w

ith e

ach

othe

r.

The

com

pres

sed

air

pres

sure

is to

o lo

w.

Adj

ust t

he o

pera

ting

air

pres

sure

to 0

.5 M

Pa

(5 k

gf/c

m2 )

.

Adj

ust t

he s

et v

alue

of t

he s

peed

con

trol

ler.

Rep

lace

the

cylin

der.

Ch

eck

th

e r

esi

sta

nce

va

lue

th

at

is d

eve

lop

ed

be

twe

en

5 a

nd

13

of

the

conn

ecto

r P

44.

Adj

ust t

he p

ositi

on o

f the

sen

sor.

Adj

ust t

he o

pera

ting

air

pres

sure

to 0

.5 M

Pa

(5 k

gf/c

m2 )

.

Rep

lace

the

cylin

der.

Ch

eck

th

e r

esi

sta

nce

va

lue

th

at

is d

eve

lop

ed

be

twe

en

6 a

nd

14

of

the

conn

ecto

r P

44.

Adj

ust t

he s

peed

con

trol

ler.

Adj

ust t

he p

ositi

on o

f the

cyl

inde

r se

nsor

of t

he s

win

g ba

r.

Adj

ust s

o th

at th

e cl

oth

pres

ser

bar

and

the

stac

king

boa

rd a

re c

lose

ly fi

tted

with

eac

h ot

her.

Adj

ust t

he c

ompr

esse

d ai

r pr

essu

re to

0.5

MP

a (5

kgf

/cm

2 ).

TR

OU

BLE

CA

US

E (

1)C

AU

SE

(2)

CO

RR

EC

TIV

E M

EA

SU

RE

S

－ 125 －

The

fini

shed

mat

eria

ls c

anno

t be

stac

ked

unifo

rmly

over

the

wid

th.

Th

e b

uzz

er

fail

s to

so

un

d e

ven

wh

en

th

epr

edet

erm

ined

num

ber o

f wor

kpie

ces

to b

e st

acke

dha

s be

en r

each

ed.

Inne

r te

mpe

ratu

re o

f the

con

trol

box

is to

o hi

gh.

The

spe

ed o

f the

clo

th p

ress

er b

ar is

too

low

.(t

oo h

igh)

Th

e m

ate

ria

l e

dg

e d

ete

ctin

g s

en

sor

fails

to

dete

ct th

e m

ater

ial.

The

freq

uenc

y (5

0/60

Hz)

for

the

mac

hine

has

not b

een

set t

o th

e co

rrec

t one

.

The

sta

cked

qua

ntity

det

ecto

r sw

itch

fails

to

wor

k.

DC

fan

fails

to r

un.

Air

blow

s by

the

DC

fan

is b

low

n in

the

oppo

site

dire

ctio

n.

Dus

t has

acc

umul

ated

in th

e co

ver

on th

e M

C-

544

box.

The

mat

eria

l edg

e de

tect

ing

sens

or is

def

ectiv

e.

Th

e m

ate

ria

l e

dg

e d

ete

ctin

g s

en

sor

fails

to

dete

ct th

e ty

pe o

f the

mat

eria

l.

Th

e p

osi

tio

n o

f th

e s

en

sor

is o

ut

of

the

dete

ctab

le r

ange

.

Def

ectiv

e se

nsor

.

Co

nn

ect

or

(J1

an

d J

4)

on

th

e p

ow

er

circ

uit

boar

d ha

s be

en d

isco

nnec

ted.

Fau

lty 2

6 V

ac p

ower

sup

ply

to th

e po

wer

circ

uit

boar

d.

Fus

e (F

4,F

5:1A

) of t

he p

ower

circ

uit b

oard

has

blow

n.

Def

ectiv

e po

wer

circ

uit b

oard

.

The

air

blow

s fr

om o

utsi

de o

f the

box

to in

side

of it

.

Adj

ust t

he s

peed

of t

he c

loth

pre

sser

bar

pro

perly

.

Rep

lace

the

sens

or w

ith a

new

one

.

Spe

cify

the

set v

alue

on

the

sens

or u

nder

the

man

ual s

tack

mod

e.

Set

the

fre

quen

cy t

o th

e co

rrec

t on

e us

ing

the

SW

1-6

on t

he I

/O c

ircu

itbo

ard.

Adj

ust t

he p

ositi

on o

f the

sen

sor.

Rep

lace

the

sens

or.

Con

nect

the

conn

ecto

r J1

and

J4.

Che

ck th

e ou

tput

vol

tage

(26

Vac

) of

the

tran

sfor

mer

. If t

he 2

6 V

ac fa

ils to

be o

utpu

t, re

plac

e th

e tr

ansf

orm

er.

Rep

lace

the

fuse

.

Rep

lace

the

pow

er c

ircui

t boa

rd.

Cha

nge

the

air

blow

ing

dire

ctio

n fr

om in

side

to o

utsi

de o

f the

con

trol

box

.

Cle

an th

e fil

ter.

TR

OU

BLE

CA

US

E (

1)C

AU

SE

(2)

CO

RR

EC

TIV

E M

EA

SU

RE

S

(8)

Oth

ers

－ 126 －

(9)

BR

But

ton

fail

to b

e se

t on

the

carr

ier

pin.

Cen

ters

of t

he ro

tary

rod

is n

ot a

ligne

d w

ith th

atof

the

carr

ier

pin.

Cen

ters

of t

he ro

tary

rod

is n

ot a

ligne

d w

ith th

atof

the

posi

tioni

ng u

nit.

(Def

ectiv

e po

sitio

n of

the

sens

or fo

r co

nfirm

ing

the

butto

n is

fitte

d on

the

carr

ier

pin.

)

The

but

ton

cann

ot b

e tu

rned

due

to in

adeq

uate

grip

ping

for

ce o

f th

e w

ork

atta

chm

ent

(soi

led

with

oil

or th

e lik

e.)

Cle

aran

ce b

etw

een

the

shut

ter

plat

e an

d th

eca

rrie

r pi

n is

too

larg

e.

Tip

s o

f th

e p

ins

on

th

e c

arr

ier

pin

are

no

tun

iform

.

Cen

ter-

to-c

ente

r dis

tanc

e of

the

hole

s in

but

ton

used

and

that

of t

he p

ins

on th

e ca

rrie

r pi

n ar

eno

t equ

al.

Hei

ght o

f the

wor

k at

tach

men

t is

defe

ctiv

e.

But

ton

reta

inin

g fo

rce

of tr

iple

paw

l is

too

stro

ng.

Sh

utt

er

pla

te i

s n

ot

op

en

ed

or

ina

de

qu

ate

lyop

ened

.

Fin

e po

sitio

ner

fails

to r

otat

e.T

he fi

ne p

ositi

oner

sha

ft is

lock

ed.

Fau

lty +

24 V

sup

ply

to t

he m

otor

of

the

fine

posi

tione

r.

Alig

n th

e ce

nter

of t

he r

otar

y ro

d w

ith th

e ce

nter

of t

he c

arrie

r pi

n.

Alig

n th

e ce

nter

of t

he r

otar

y ro

d w

ith th

e ce

nter

of t

he p

ositi

oner

.

(Adj

ust t

he p

ositi

on o

f the

sen

sor.

)

Rep

lace

the

wor

k at

tach

men

t with

a n

ew o

ne.

Wip

e ou

t the

grip

ping

face

of t

he w

ork

atta

chm

ent.

Adj

ust t

he h

eigh

t of t

he c

arrie

r pi

n.

App

ly a

car

rier

pin

who

se p

in ti

ps a

re u

nifo

rm.

Use

a c

arrie

r pi

n w

ith p

ins

of w

hich

cen

ter-

to-c

ente

r di

stan

ce is

equ

al w

ithth

at o

f the

hol

es in

but

ton

used

.

Re-

adju

st th

e he

ight

of t

he w

ork

atta

chm

ent.

Che

ck w

heth

er th

e ou

tput

leve

l of t

he p

ositi

onin

g so

leno

id is

ade

quat

e.

Che

ck th

e sh

utte

r pl

ate

for

smoo

th m

otio

n. C

heck

whe

ther

the

shut

ter

plat

eis

ope

ned

as w

ide

as 2

2 m

m (

0.86

6”)

at th

e m

axim

um.

Insp

ect t

he b

ushi

ngs

and

gear

s. If

any

of t

hem

has

bee

n lo

cked

, the

mot

orm

ay a

lso

be d

efec

tive.

So,

they

sho

uld

be in

spec

ted.

Adj

ust

the

posi

tion

of t

he n

orm

al-/

reve

rse-

rota

tion

mec

hani

sm o

f th

e fin

epo

sitio

ner.

Mea

sure

the

volta

ge o

f the

term

inal

boa

rd. I

f +24

V is

not

sup

plie

d, r

epla

ceth

e I/O

circ

uit b

oard

with

a n

ew o

ne. I

f it i

s su

pplie

d, r

epla

ce th

e m

otor

with

a ne

w o

ne.

TR

OU

BLE

CA

US

E (

1)C

AU

SE

(2)

CO

RR

EC

TIV

E M

EA

SU

RE

S

－ 127 －

The

but

ton

is n

ot fi

nely

pos

ition

ed e

ven

whe

n th

eb

utt

on

is

pla

ced

at

the

tri

ple

-pa

wl

sect

ion

. F

ine

posi

tioni

ng is

per

form

ed w

ith n

o bu

tton

at th

e tr

iple

-pa

wl s

ectio

n.

Tw

o pi

eces

of

butt

on m

ay e

nter

the

not

ch in

the

feed

dis

k.

The

but

ton

is re

ject

ed w

hen

it is

fed

from

the

carr

ier

to th

e bu

tton

clam

p ja

w le

ver.

The

but

ton

is a

ttach

ed to

the

wor

k at

tach

men

t.

The

fine

pos

ition

er s

haft

fails

to c

ome

dow

n.

The

tri

ple-

paw

l dog

is im

prop

erly

pos

ition

ed.

As

a re

sult,

the

sens

or fa

ils to

det

ect a

but

ton.

Hei

ght

diff

eren

ce b

etw

een

the

feed

dis

k an

dth

e ou

tlet o

f the

par

ts fe

eder

is e

xces

sive

.

The

cle

aran

ce in

the

adju

stin

g pl

ate

is to

o la

rge

for

the

thic

knes

s of

but

ton

used

.

Dia

me

ter

of

the

no

tch

is

too

la

rge

fo

t th

edi

amet

er o

f but

ton

used

.

The

car

rier

and

the

butto

n cl

amp

jaw

leve

r ar

eno

t flu

sh w

ith e

ach

othe

r.

The

ope

ning

am

ount

of

the

butto

n cl

amp

jaw

leve

r is

not

app

ropr

iate

to th

e bu

tton

used

.

Cen

ter

of th

e ca

rrie

r is

not

alig

ned

with

that

of

the

butto

n cl

amp

jaw

leve

r.

The

wor

k at

tach

men

t is

wor

n ou

t.

The

fine

pos

ition

er s

haft

fails

to m

ove

smoo

thly

.

The

mag

net o

f the

fine

pos

ition

er fa

ils to

pro

vide

suffi

cien

t mag

netic

attr

actio

n.

Fa

ult

y +

24

V s

up

ply

to

th

e f

ine

po

siti

on

er

low

erin

g m

agne

t.

Che

ck th

e fin

e po

sitio

ner

shaf

t.

Tur

n th

e va

riabl

e re

sist

or (

VR

2) o

n th

e I/O

circ

uit b

oard

slig

htly

clo

ckw

ise.

Adj

ust t

he p

ositi

on o

f the

mag

net s

o th

at th

e iro

n co

re o

f the

fine

pos

ition

erlo

wer

ing

mag

net i

s in

line

with

the

fine

posi

tione

r lif

ting

link.

Mea

sure

the

volta

ge o

f the

term

inal

boa

rd. I

f +24

V is

not

sup

plie

d, r

epla

ceth

e I/O

circ

uit b

oard

with

a n

ew o

ne. I

f it i

s su

pplie

d, r

epla

ce th

e m

otor

with

a ne

w o

ne.

Adj

ust t

he p

ositi

on o

f trip

le-p

awl d

og p

rope

rly.

Low

er th

e pa

rts

feed

er.

Adj

ust t

he c

lear

ance

in a

ccor

danc

e w

ith th

e bu

tton

thic

knes

s.

Sel

ect t

he n

otch

sui

ted

to th

e bu

tton

diam

eter

.

Flu

sh th

e ca

rrie

r w

ith th

e bu

tton

clam

p ja

w le

ver.

Adj

ust t

he o

peni

ng a

mou

nt a

ccor

ding

to th

e bu

tton

used

.

Cen

ter

the

carr

ier

and

the

butto

n cl

amp

jaw

leve

r.

Rep

lace

the

wor

k at

tach

men

t with

a n

ew o

ne.

TR

OU

BLE

CA

US

E (

1)C

AU

SE

(2)

CO

RR

EC

TIV

E M

EA

SU

RE

S

－ 128 －

The

but

ton

is ra

ised

whe

n it

is c

lam

ped

by th

e tr

iple

-pa

wl a

t the

but

ton

posi

tioni

ng u

nit.

Trip

le-p

awl f

ails

to c

lam

p th

e bu

tton

at th

e bu

tton

posi

tioni

ng u

nit.

But

ton

is c

augh

t in

betw

een

the

feed

pla

te a

nd th

epa

rts

feed

er.

Cor

rect

ive

mea

sure

s to

be

take

n w

hen

a bu

tton

isja

mm

ed.

The

wor

k at

tach

men

t is

wor

n ou

t.

The

spe

ed a

t w

hich

the

tri

ple-

paw

l mov

es is

too

high

and

the

sole

noid

out

put i

s to

o la

rge.

The

out

put

leve

l of

the

sole

noid

is t

oo lo

w t

oac

tuat

e th

e tr

iple

-paw

l.

The

dis

tanc

e fr

om t

he f

eed

disk

to

the

part

sfe

eder

is to

o la

rge.

The

but

ton

is n

ot s

moo

thly

car

ried

to th

e fe

eddi

sk.

The

but

ton

guid

e is

impr

oper

ly p

ositi

oned

.

The

cle

aran

ce b

etw

een

the

butto

n gu

ide

and

the

trac

k su

rfac

e of

the

part

s fe

eder

is to

o sm

all.

The

but

ton

feed

ing

spee

d is

inad

equa

te.

Rep

lace

the

wor

k at

tach

men

t with

a n

ew o

ne.

Adj

ust t

he p

ositi

on o

f the

sol

enoi

d.

Adj

ust t

he p

ositi

on o

f the

par

ts fe

eder

.

Slig

htly

lift

the

part

s fe

eder

.

Adj

ust t

he p

ositi

on o

f the

but

ton

guid

e.

Slig

htly

lift

the

butto

n gu

ide.

Tur

n th

e va

riabl

e re

sist

or o

n th

e op

erat

ion

pane

l of t

he p

arts

feed

er c

lock

wis

eto

incr

ease

the

butto

n fe

edin

g sp

eed.

Whe

n a

butto

n is

jam

med

, ins

ert a

scr

ewdr

iver

into

hol

e 1

in th

e to

p of

the

fron

t cov

er a

nd tu

rn it

cou

nter

cloc

kwis

e.

TR

OU

BLE

CA

US

E (

1)C

AU

SE

(2)

CO

RR

EC

TIV

E M

EA

SU

RE

S 1

Mai

n un

it

A fl

at b

itsc

rew

driv

er.

Fro

nt c

over

Ope

ratio

n pa

nel

－ 129 －

But

tons

in th

e pa

rts

feed

er a

re n

ot s

moo

thly

run

.

But

ton

from

the

feed

er b

owl d

oes

not e

nter

the

feed

disk

.

Scr

ew �

whi

ch fi

xed

the

feed

er b

owl l

oose

ns.

Def

ectiv

e po

sitio

n of

the

sens

itivi

ty a

djus

tmen

tva

riabl

e re

sist

or.

Fe

ed

er

bo

wl

com

es

in c

on

tact

wit

h s

om

eco

mpo

nent

, the

reby

pre

vent

ing

the

feed

er b

owl

from

pro

perly

vib

ratin

g.

Def

ectiv

e po

sitio

n of

the

feed

er b

owl.

Def

ectiv

e po

sitio

n of

the

butto

n gu

ide.

Slig

htly

tigh

ten

scre

w 1

.

Adj

ust t

he p

ositi

on o

f the

sen

sitiv

ity a

djus

tmen

t var

iabl

e re

sist

or.

Pos

ition

the

feed

er b

owl a

t the

pos

ition

whe

re it

doe

s no

t com

e in

con

tact

with

any

com

pone

nt.

Adj

ust t

he p

ositi

on o

f the

feed

er b

owl.

Adj

ust t

he p

ositi

on o

f the

but

ton

guid

e.

TR

OU

BLE

CA

US

E (

1)C

AU

SE

(2)

CO

RR

EC

TIV

E M

EA

SU

RE

S

1

－ 130 －

Err

or “

58 R

EV

OLU

TIO

N A

RM

ER

RO

R”

occu

rs.

Fau

lty +

24 V

pow

er s

uppl

y to

the

I/O

cir

cuit

boar

d.

The

ori

gin

of t

he s

pinn

er o

scill

atin

g ar

m h

asno

t bee

n in

put.

Th

e m

an

ua

l h

an

dle

ca

nn

ot

be

sm

oo

thly

oper

ated

.

Fau

lty +

24 V

pow

er s

uppl

y to

the

mot

or o

f the

spin

ner

osci

llatin

g ar

m.

Th

e m

oto

r o

f th

e s

pin

ne

r o

scill

atin

g a

rm i

sde

fect

ive.

Bre

aker

has

dro

pped

.

Fau

lty 2

0 V

ac p

ower

sup

ply

to th

e po

wer

circ

uit

boar

d.

The

pow

er c

ircui

t boa

rd is

def

ectiv

e.

Con

nect

or P

32 a

nd P

99 o

n th

e I/O

circ

uit b

oard

has

been

dis

conn

ecte

d.

The

ligh

t em

ittin

g an

d re

ceiv

ing

win

dow

of t

heA

.OR

G s

enso

r is

sta

ined

.

A. O

RG

sen

sor

is d

efec

tive.

Inpu

t sec

tion

of th

e I/O

circ

uit b

oard

is d

efec

tive.

The

cam

sha

ft co

mpo

nent

s ar

e lo

cked

.

Co

nn

ect

or

P4

2 o

n t

he

I/O

cir

cuit

bo

ard

is

defe

ctiv

e.

Wiri

ng o

f the

term

inal

has

dis

conn

ecte

d.

The

I/O

circ

uit b

oard

is d

efec

tive.

Res

et th

e br

eake

r

Che

ck th

e tr

ansf

orm

er fo

r ou

tput

vol

tage

(20

Vac

). If

no

volta

ge is

out

put,

repl

ace

the

tran

sfor

mer

.

Rep

lace

the

pow

er c

ircui

t boa

rd.

Con

nect

the

conn

ecto

r P

32 a

nd P

99.

Cle

an u

p th

e lig

ht e

mitt

ing

and

rece

ivin

g w

indo

w o

f the

A.O

RG

sen

sor.

Rep

lace

the

A.O

RG

sen

sor.

Rep

lace

the

I/O c

ircui

t boa

rd.

Insp

ect t

he w

orm

com

pone

nts

and

cam

com

pone

nts.

Con

nect

the

conn

ecto

r P

42.

Join

the

term

inal

cab

le.

Rep

lace

the

I/O c

ircui

t boa

rd.

Rep

lace

the

mot

or o

f the

spi

nner

osc

illat

ing

arm

.

TR

OU

BLE

CA

US

E (

1)C

AU

SE

(2)

CO

RR

EC

TIV

E M

EA

SU

RE

S

－ 131 －

Err

or “

54 B

UT

TO

N IN

DE

X E

RR

OR

” oc

curs

.

Sev

eral

but

tons

are

fed

in th

e po

sitio

ning

uni

t.

Err

or “

57 B

UT

TO

N S

ET

ER

RO

R”

occu

rs.

The

orig

in o

f the

inde

x ha

s no

t bee

n in

put.

Th

e i

nd

ex

can

no

t b

e r

ele

ase

d b

y h

an

dsm

ooth

ly.

Fau

lty +

24 V

pow

er s

uppl

y to

the

mot

or o

f the

inde

x.

The

mot

or o

f the

inde

x is

def

ectiv

e.

Def

ectiv

e ad

just

men

t of

the

but

ton

dete

ctin

gse

nsor

.

The

fine

pos

ition

er fa

ils to

rot

ate.

Con

nect

or P

32 a

nd P

97 o

n th

e IO

RG

sen

sor

has

been

dis

conn

ecte

d.

Iron

chi

ps a

re a

ttach

ed o

n th

e IO

RG

sen

sor.

The

IOR

G s

enso

r is

def

ectiv

e.

Inpu

t sec

tion

of th

e I/O

circ

uit b

oard

is d

efec

tive.

A b

utto

n is

clo

gged

on

the

inde

x.

The

per

iphe

ry o

f whe

el c

ompo

nent

s ar

e lo

cked

.

Wir

ing

of

the

te

rmin

al

bo

ard

ha

s b

ee

ndi

scon

nect

ed.

Fau

lty c

onne

ctio

n of

con

nect

or P

42 o

n th

e I/O

circ

uit b

oard

.

The

I/O

circ

uit b

oard

is d

efec

tive.

The

fine

pos

ition

er s

haft

is lo

cked

.

Fau

lty +

24 V

pow

er s

uppl

y to

the

mot

or o

f the

fine

posi

tione

r.

Con

nect

the

conn

ecto

r P

32 a

nd P

97.

Rem

ove

the

iron

chip

s an

d du

st fr

om th

e se

nsor

.

Rep

lace

the

IOR

G s

enso

r.

Rep

lace

the

I/O c

ircui

t boa

rd.

Rem

ove

the

butto

n on

the

inde

x.

Insp

ect t

he p

erip

hery

of w

heel

com

pone

nts

and

wor

m c

ompo

nent

s.

Con

nect

the

term

inal

boa

rd c

able

.

Con

nect

the

conn

ecto

r P

42 p

rope

rly.

Rep

lace

the

I/O c

ircui

t boa

rd.

Rep

lace

the

mot

or o

f the

inde

x.

Adj

ust t

he s

enso

r pr

oper

ly.

Insp

ect t

he b

ushi

ng a

nd g

ears

. If a

ny o

f the

m is

lock

ed,th

e m

otor

may

be

also

def

ectiv

e. S

o be

car

eful

.

Adj

ust

the

posi

tion

of t

he n

orm

al/r

ever

se r

otat

ion

mec

hani

sm o

f th

e fin

epo

sitio

ner.

Mea

sure

the

vol

tage

of

the

term

inal

boa

rd.

If +

24 V

is n

ot s

uppl

ied

to t

hete

rmin

al b

oard

, rep

lace

the

I/O c

ircui

t boa

rd. I

f the

vol

tage

is s

uppl

ied,

repl

ace

the

mot

or.

TR

OU

BLE

CA

US

E (

1)C

AU

SE

(2)

CO

RR

EC

TIV

E M

EA

SU

RE

S

－ 132 －

Whe

n th

ere

is n

o bu

tton

in th

e po

sitio

ning

uni

t.

Whe

n th

ere

is a

but

ton

in th

e po

sitio

ning

uni

t.

Err

or”

57

BU

TT

ON

SE

T E

RR

OR

” o

ccu

rs w

he

ntu

rnin

g O

N th

e po

wer

to th

e m

achi

ne o

r w

hen

the

fine

posi

tione

r is

not

def

ectiv

e.

The

fine

pos

ition

er fa

ils to

com

e do

wn.

The

pos

ition

ing

unit

fails

to w

ork.

The

but

ton

dete

ctin

g se

nsor

rem

ains

in it

s O

FF

stat

e.

The

pos

ition

ing

unit

fails

to w

ork.

A b

utto

n is

clo

gged

bet

wee

n th

e tr

iple

-paw

l and

the

shut

ter.

The

fine

pos

ition

er s

haft

fails

to m

ove

smoo

thly

.

Fin

e po

sitio

ning

mag

net f

orce

is in

suffi

cien

t.

Fau

lty +

24 V

pow

er s

uppl

y to

the

fine

posi

tione

rlo

wer

ing

mag

net.

The

str

oke

of th

e po

sitio

ning

mag

net h

as b

een

impr

oper

ly a

djus

ted.

Fau

lty +

24 V

pow

er s

uppl

y to

the

pos

ition

ing

mag

net.

The

pos

ition

ing

sens

or h

as b

een

impr

oper

lyad

just

ed.

Co

nn

ec

tor

P3

2

an

d

P9

6

ha

s

be

en

disc

onne

cted

.

The

pos

ition

ing

sens

or is

def

ectiv

e.

The

I/O

circ

uit b

oard

is d

efec

tive.

Che

ck th

e fin

e po

sitio

ner

shaf

t.

Tur

n th

e va

riabl

e re

sist

er (

VR

2) m

ount

ed o

n th

e I/O

circ

uit b

oard

clo

ckw

ise

by a

littl

e.

Adj

ust t

he p

ositi

on o

f the

mag

net s

o th

at th

e iro

n co

re o

f the

fine

pos

ition

erlo

wer

ing,

mag

net i

s in

line

with

the

fine

posi

tione

r lif

ting

link.

Mea

sure

the

vol

tage

of

the

term

inal

boa

rd.

If +

24 V

is n

ot s

uppl

ied

to t

hete

rmin

al b

oard

, rep

lace

the

I/O c

ircui

t boa

rd. I

f the

vol

tage

is s

uppl

ied,

repl

ace

the

mag

net.

Adj

ust t

he s

trok

e of

the

mag

net p

rope

rly.

Mea

sure

the

vol

tage

of

the

term

inal

boa

rd.

If +

24 V

is n

ot s

uppl

ied

to t

hete

rmin

al b

oard

,rep

lace

the

I/O c

ircui

t boa

rd. I

f the

vol

tage

is s

uppl

ied,

repl

ace

the

mag

net.

Adj

ust t

he p

ositi

onin

g se

nsor

. The

sen

sor

shou

ld tu

rn O

FF

whe

n a

butto

n is

plac

ed in

the

posi

tioni

ng u

nit,

or tu

rn O

N w

hen

a bu

tton

is n

ot p

lace

d in

it.

Con

nect

the

conn

ecto

r P

32 a

nd P

96.

Rep

lace

the

posi

tioni

ng s

enso

r.

Rep

lace

the

I/O c

ircui

t boa

rd.

Tak

e th

e co

rrec

tive

mea

sure

s sa

me

as th

ose

take

n w

hen

no b

utto

n is

pla

ced

in th

e po

sitio

ning

uni

t.

Rem

ove

the

butto

n cl

ogge

d.

TR

OU

BLE

CA

US

E (

1)C

AU

SE

(2)

CO

RR

EC

TIV

E M

EA

SU

RE

S

－ 133 －

The

par

ts fe

eder

fails

to w

ork.

But

ton

crac

ks b

efor

e it

is f

ed t

o th

e bu

tton

clam

pja

w le

ver.

Fus

e 1A

on

the

part

s fe

eder

pan

el h

as b

low

n.

Fau

lty 1

00 V

ac p

ower

sup

ply

to th

e pa

rts

feed

erco

ntro

ller.

No

cont

rol s

igna

l.

The

low

erin

g pr

essu

re o

f the

fine

pos

ition

er is

too

high

.

Cen

ter

of th

e ro

tary

rod

is n

ot c

orre

ctly

alig

ned

with

the

cent

er o

f the

car

rier

pin.

Cen

ter

of th

e ro

tary

rod

is n

ot a

ligne

d w

ith th

ece

nter

of t

he p

ositi

onin

g un

it.

Cen

ter-

to c

ente

r di

stan

ce o

f hol

e in

the

butto

nto

be

used

is d

iffer

ent f

rom

the

cent

er-t

o-ce

nter

dist

ance

of p

ins

of th

e ca

rrie

r pi

n.

Bu

tto

n r

eta

inin

g f

orc

e o

f th

e t

rip

le-p

aw

l is

exce

ssiv

e.

Shu

tter

plat

e is

not

ope

ned

at a

ll,or

ope

ned

toan

insu

ffici

ent e

xten

t.

The

ope

ning

am

ount

of t

he b

utto

n cl

amp

jaw

leve

r ha

s no

t bee

n pr

oper

ly a

djus

ted.

The

hei

ght

of t

he b

utto

n cl

amp

jaw

leve

r ha

sno

t bee

n pr

oper

ly a

djus

ted.

Con

nect

or P

1 ha

s be

en d

isco

nnec

ted.

The

I/O

circ

uit b

oard

is d

efec

tive.

The

mag

net o

f the

fine

pos

ition

er fa

ils to

pro

vide

exce

ssiv

e m

agne

tic a

ttrac

tion.

Rep

lace

the

fuse

.

Con

nect

the

conn

ecto

r P

1.

Che

ck t

he t

rans

form

er f

or t

he o

utpu

t vo

ltage

(10

0 V

ac).

If

no v

olta

ge is

outp

ut, r

epla

ce th

e tr

ansf

orm

er.

Ope

n th

e re

ar c

over

of t

he p

arts

feed

er c

ontr

olle

r,an

d sh

ort-

circ

uit t

erm

inal

s1

and

2. If

the

part

s fe

eder

con

trol

ler

oper

ates

,rep

lace

the

I/O c

ircui

t boa

rdan

d re

turn

the

wiri

ng to

the

norm

al s

tate

. If t

he p

arts

feed

er c

ontr

olle

r fai

ls to

oper

ate,

repl

ace

the

cont

rolle

r.

Tu

rn t

he

va

ria

ble

re

sist

or

(VR

2)

on

th

e I

/O c

ircu

it b

oa

rd s

ligh

tly

coun

terc

lock

wis

e.

Pro

perly

alig

n th

e ce

nter

of t

he r

otar

y ro

d an

d th

e ce

nter

of t

he c

arrie

r pi

n.

Pro

perly

alig

n th

e ce

nter

of t

he r

otar

y ro

d an

d th

e ce

nter

of t

he p

ositi

onin

gun

it.

Use

the

carr

ier p

in w

hose

pin

s pr

ovid

es th

e co

rrec

t cen

ter-

to-c

ente

r dis

tanc

e.

Che

ck th

e ou

tput

of t

he p

ositi

onin

g so

leno

ide.

Che

ck th

at th

e sh

utte

r pla

te m

oves

sm

ooth

ly a

nd it

ope

ns b

y 22

mm

(0.8

66”)

at th

e m

axim

um.

Adj

ust t

he o

peni

ng a

mou

nt o

f the

but

ton

clam

p ja

w le

ver

prop

erly

.

Adj

ust t

he h

eigh

t of t

he b

utto

n cl

amp

jaw

leve

r pr

oper

ly.

TR

OU

BLE

CA

US

E (

1)C

AU

SE

(2)

CO

RR

EC

TIV

E M

EA

SU

RE

S

(10)

A b

utto

n cr

acks

.

－ 134 －

Please do not hesitate to contact our distributors or agents in your area for further information when necessary.＊ The description covered in this engineer's manual is subject to change for improvement of the

commodity without notice.

00 · 08 Printed in Japan (E)

R

INTERNATIONAL SALES H.Q.8-2-1, KOKURYO-CHO,CHOFU-SHI, TOKYO 182-8655, JAPANPHONE : (81)3-3430-4001 to 4005FAX : (81)3-3430-4909 • 4914 • 4984TELEX : J22967

Copyright C 2000 JUKI CORPORATION.

All rights reserved throughout the world.

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