futu race 100 and 200 service

7/30/2019 Futu Race 100 and 200 Service

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Service ManualOriginal issue

March 2004

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SEC. ModelCE-100/200

*Revised on April 2006


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SEC. ModelCE-100/200 Index

* Removing cover for circuit board --- page 3

* Removing face, bottom and base covers --- page 4- 5

* Removing top cover and thread sensor cover --- page 6

* Removing rear cover --- page 7

* Removing front cover --- page 8

* Removing control panel assembly --- page 9-10

* Test mode of sewing machine --- page11-15* Needle bar height --- page16

* Feed-dog height --- page17

* Feed-dog timing (vertical movement) --- page18

* Feed timing ( horizontal movement) --- page19

* Needle position at zigzag stitching --- page20

* Adjustment of needle position --- page21-22

* Needle timing to shuttle --- page23

* Needle clearance to shuttle --- page24-25

* Adjustment of "0" feed --- page26-27

* Retaining bracket for bobbin case --- page28-29

* Upper thread tension unit --- page30

* Tension of pulley belt --- page31

* Tension of timing belt --- page32

* Test mode of sewing machine with embroidery unit --- page33

* Test mode patterns --- page34

* Recognizing hoop size --- page35

* Mechanical origin point and maximum moveable area --- page36-37

* Wiring diagram between main and control circuit boards --- page38

* Main circuit board and functions of each connector --- page39-40

* Block diagram --- page41

* Connecting wire to switch board --- page42

* Electronic specifications --- page43-46

* Operating specifications --- page47-48

* Specifications with embroidery unit connected --- page49

* Thread breakage sensor --- page50


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Removing cover for circui t board

Circuit board is located inside of rear cover.

Remove cover for circuit board by loosening screws as illustrated.


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Removing face, bottom and base covers

Pull out cap in the center and remove screw.

Remove support leg by loosening two screws.

Remove bottom cover by loosening screw.


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Remove four screws on base cover.

Remove base cover.


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Removing top cover and thread sensor cover

Remove top cover by loosening two screws.

Remove thread sensor cover by loosening a screw.


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SEC. ModelCE-100/200 Removing rear cover

Remove top, face, bottom and base covers beforehand.

Remove rear cover by loosening four screws as illustrated below.

Use thin Phillips screw driver.


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SEC. ModelCE-100/200 Removing front cover

Remover rear, bottom, base, top and face covers beforehand.

Loosen a screw on the bottom of thread guide plate.

Lay the machine on its back and remove two screws on the bottom.

Pull out the front cover taking care of wiring harnesses.


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Removing control panel assembly

Remove support leg and base cover without removing rear and front covers.

Circuit board of control panel assy. is fixed under the control panel which is fixed onto

front cover with two screws

Lay the machine on its back and remove two screws by tuning them through the hole

of bracket.


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SEC. ModelCE-100/200 Removing control panel assy. (continued)

Push up the control panel from the bottom of machine.

Pull out the control panel from the front cover.

Disconnect each connector from the control panel for removal.


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SEC. ModelCE-100/200 Test mode of sewing machine

Remove connector cap from machine.

Micro switch is located on the lower right corner. It works to make start/stop switch

invalid. Turn on this switch to enter the test mode.

Put small folded paper between

connector and micro switch.

to turn it on.

Connect foot control (4C-333B) to operate the machine.

Micro switch


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SEC. ModelCE-100/200 Test mode of sewing machine (continued)

Mode 3 Push C-SW three times and push A-SW to decide.

Needle position: left - right - center left and repeat afterward

Mode 4 Push C-SW four times and push A-SW to decide.

Stitch width: 7 mm, stitch length: 5 mm

ModePush C-SW five times and push A-SW to decide.

Needle position: center position fixed.

Stitch length: 4mm(forward) at start 3mm2mm1mm and

machine stops automatically.

Mode Push C-SW six times . Push A-SW to decide.


Stitch length: 3.5mm(backward) at start 2.5mm1.5mm0.5mm and

machine stops automatically.

Mode 7 Push C-SW seven times . Push A-SW to decide.

Honey comb stitch

Mode 8 Push C-SW eight times and push A-SW to decide.

Stitch width: 7 mm.

Stitch length: 5 mm (forward) / 3.5 mm (backward)


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SEC. ModelCE-100/200 Test mode of sewing machine (continued)

M O D E M O DE M O DE M O DE

M O D E

No feed

M Ndl. position

Push A button,

Needle descends to it's

lowest position

Under this condition, push

B button,

Feed regulator block

reset to Feed "0"

position.

Push A button continuosly,

Needle goes up to it's

highest position .

Under this condition, push

B button,

Needle bar is reset to

M -position.

Ndl position

N dl position

No feed

L Ndl. position

( 7m m )

R Ndl. position

(3.5m m )

M Ndl. position

(3.5m m )

L Ndl. position

W idth 7m m


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Test mode of sewing machine (continued)

M O D E 5 M O DE6 M O DE7 M O D E8

Honey com b

Stop autom atically

Stop

autom atically


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Needle bar height

Note: Make this checking before checking Needle timing to shuttleFeed-dogtiming (vertical motion)

Remove needle plate and bobbin case.Select straight stitch (center needle position).

Raise needle to its highest position by turning hand wheel.

Check to see if distance from needle point to the surface of needle plate is as illustratedbelow.

Remove face cover and adjust as illustrated above.Loosen screw of needle bar clamp using hex screw driver and adjust the heightof needle bar.

Check to see if needle threader operate correctly and there is not interference

in vertical movement of needle bar.Tighten the screw securely after adjustment.

fromthe surface of needle plate

Highest position

of Needle

Needle position

at center


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Feed-dog height

Note: set test mode 0

1. Move feed dog to its highest position by turning hand wheel.Check to see if feed dog height is as illustrated below.

from the surface of needle plate

Remove bottom cover.

Adjust the height by turning screw as illustrated.

Position of adjustment and

adjustment hole on front cover

are shown with the cover removed.

Adjustment hole is shown withFront cover in position.


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Feed-dog timing (vertical movement)

Note: Before checking, follow section Needle bar height, Feed-dog height.After adjustment , be sure to followNeedle timing to shuttle.

1. Turning hand-wheel , bring needle bar to its highest position and move downneedle bar and feed dog.

2. Check if clearance between tip of needle and surface of needle plate is about

4 - 5mm when top of feed dog has reached to needle plate surface level.

3. Adjust the angle of timing gear to main shaft by turning main shaft with hand wheel,

with 2 screws loosened on timing gear and hex driver inserted into one of the screws.

If feed-dog motion too early Turn hand-wheel towards you.

If feed-dog motion too late Turn hand-wheel away from you.

Tighten screw temporarily , check feed-dog motion.

4. Tighten 2 screws securely after adjustment.

Needle plate

4 to 5 m m

Too early Too late

Main shaft


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Feed timing ( horizontal movement)

Set test mode 1 or 2 ( maximum stitch length).Set feed-dog at the start of its movement

(when feed cam starts to activate forked connection rod)Turning hand wheel, bring up needle to its highest dead position.Check if total lateral movement(A) of feed-dog during the period from Step2 to

Step3 above is within the range of 0.1mm 0.1.5mm.

Main shaft

0.1 to 0.15

Needle at highest position


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Needle position at zigzag stitching

Set test mode at 3 or 4.

Turn hand wheel by hand and see if needle leaves the same clearance at bothright and left end of needle plate hole.

Remove face cover and loosen hex screw of 2 mm dia.Turn eccentric screw on needle bar support to correct the condition as

illustrated below.

ba

ab


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Adjustment of needle position

When turning off and on power, sector gear rotates

and turns on switch for machine origin point.

Switch for machine origin point

Sector gear

Zigzag guide bar

Fixing screw for switch support plate

Adjusting screw for switch position

Loosen fixing screw for switch support plate and adjusting

screw for switch position while pressing the support plate to

the screw.:

1. If needle is positioned to the right, tighten adjusting

screw.

2. If needle is positioned to the left, loosen adjusting

screw.

Needle position at M is where sector gear rotates 14 pulses

from position where switch for machine origin point is turned

on. Convex portion is guidance only.


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Adjustment of needle posit ion2

Limiting needle position on modif ied version

Version modified to limit needle position is

illustrated above.

Limiting needle position is done at left side

only. Movement at right side is limited with

switch.

Limiting plate is to be positioned so that

needle may not be prevented to shift with

movement of switch.


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SEC. ModelCE-100/200Needle timing to shuttle

Check Feed timig (vertical movement) and Needle height beforehand.

1Set test mode at 3 or 4.

Remove needle plate. Check to see if needle is not bent.

Move needle to left position by turning hand wheel. Raise needle from its lowest

position slowly and check if distance is as illustrated below when point of shuttle

hook aligns with right side of needle.

Remove bottom cover. Loosen two screws on gear and adjust position of gearas illustrated below.

With one screw tightened temporarily, check to see if the distance is as

illustrated above.

Adjust it by turning main shaft with hand wheel, with screws loosened and

hex driver inserted into one of the screws.

Tighten screws securely after adjustment.

Point of

shuttle

0.5 0.8


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SEC. ModelCE-100/200 Needle clearance to shuttle ( 1 )

Note: Set test mode at 4 and check needle clearance to shuttle at both left and right sides

of needle positions.

Remove needle plate, bobbin case and face cover.

Shift shuttle hook at the rear of needle by turning hand wheel.

Check to see if needle clearance to shuttle within 0.05 to 0.15 mm.

Loosen screw for support shaft and adjust needle position by moving supportshaft back and forth.

To decrease clearance, move the support toward you.

Tighten the screw after adjustment.

Shuttle

0.05 0.15 0.05 0.15

Extrem e left Extrem e right

0.05

0.15


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SEC. ModelCE-100/200Needle clearance to shuttle ( 2 )

1. Check and see if each needle clearance to shuttle at extreme left and right position

is even . If not, adjust needle clearance to shuttle at both side following steps.

2. Loosen 2 screws as illustrated below.

B

A

*If needle touches with shuttle at left side, adjust by shifting bracket (C) to the right.

If it touches at right side, adjust by shifting bracket to the left.

Check to see if needle position is correct and tighten bracket (C) securely.


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SEC. ModelCE-100/200 Adjustment of "0" feed (1)

*Pay much attention to this adjustment which is very important and critical.

1. Select test mode 0 and check 0 feed.

Select test mode 0.

Push the switch at top and needle will be lowered to its lowest position.

Push the switch at middle to reset feed regulator. Repeat this process a few times.

Place a piece of paper under presser foot and run machine several times by

depressing foot control.

Check needle hole on paper. It is acceptable if there are up to 2 needles in length.

2. Loosen fixing screw A which holds sensor support rotation shaft by inserting screw

driver through hole of arm.

3. If feed amount is not 0 when checking feed regulator at 0 feed position,

adjust by changing position of sensor to machine origin point.

4. Adjustment to be made minutely by turning screw every 45 angles. Check by

resetting feed regulator for each adjustment.:

*If feed 0 tends to feed, turn the adjusting screw clockwise to rotate sensor clockwise.

*If feed 0 tends to reverse, turn the adjusting screw counter clockwise to rotae

counter clockwise.


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Adjustment of "0" feed (2)

5. Details of machine origin point and feed 0 point

Feed 0 point of feed

regulator:

When feed regulator returns

from machine origin point at

certain angle.

Machine origin point of feed

regulator:

When sensor changes from OFF

to ON

Sensor support plate rotationAdjustment screw for sensor

Sensor

Feed

Reverse side

Forward side

Feed 0

MachineFixing screw A


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Retaining bracket for bobbin case

Remove needle plate, bobbin case and retaining bracket beforehand.

1. Place the new retaining bracket aligning corner of plate spring with inside of wall (A) of

shuttle race as illustrated below and tighten the fixing screw temporarily.

2. Insert the new bobbin case into position and adjust the position of retaining bracket

so that the projection of bobbin case may be positioned against the spring plate

as illustrated below.

Tighten the fixing screw securely.


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3. Adjust the position of reverse rotation stopper so that there may be

a clearance of 1 to 1.5 mm between the projection and plate spring while

turning the bobbin case back and forth.

Tighten the fixing screw securely.

4. Place the new bobbin cover plate into position.


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Upper thread tension unit

(A) When face cover only is removed,1. Turn dial knob until thread tension of 40 to 50 g is obtained.2. Loosen cap screw to remove the dial knob.

3. Re-fit the dial knob with S set at the arking and tighten the cap screw.

BWhen face cover and front cover are removed,Set dial knob at S and turn adjustable nut until thread tension of 40 to 50 g is obtained.

Ca screw

GearAdjustable nut

Dial knob

Ca screw

Dial knob

Gear


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Tension of pulley belt

Check tension of pulley belt by pushing it lightly (about 300 g) with your finger

Too tight tension may result in abnormal rotation due more burden on motor and

more machine torque. On the contrary, too weak tension may result in noise from

belt and slipping of belt. Adjust to get suitable tension.

In case of removing rear cover In case of removing front and

rear covers.


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SEC. ModelCE-100/200Tension of timing belt

1.Timing belt is engaged with gears on main and lower shafts.

Too weak tension may result in slippage between shuttle gear and lower shaft

gear due to thread jamming, bunching and fabric snagging.

Too strong tension may result in incorrect operation due to increased machine torque.

This checking is needed before adjusting Needle timing to shuttle.

2.Loosen two screws on support plate for idler pulley and shift the position of idler pulleyfor adjustment.


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Test mode of sewing machine with embroidery unit

1. While pushing all three switches, turn on power switch and release the switches

in 3 seconds.

2A variety of test modes can be selected by changing number of times to push

the switch on the bottom (C-SW)

Every time when it is pushed, LED is lit red and green alternatively except mode0.

Test mode is decided by pushing the switch on top (A-SW).

3. Mode 0 Push all three switches,turn on power switch and release the switches

as decribed above 2. LED will be lit red. Push A-SW to decide.


Embroidery hoop moves as shown mode 0 on next page.

Mode 1 Push C-SW once and LED will be lit green. Push A-SW to decide.


Embroidery hoop moves as shown mode 1 on next page.

Mode 2 Push C-SW two times and push A-SW to decide.

Needle position: center position fixed.Embroidery hoop moves as shown mode 2 on next page



Embroidery hoop moves as shown mode 3



Embroidery hoop moves as shown mode 4


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Mechanical origin point and maximum moveable area (1)

Before sensor light is blocked After sensor light is blocked, hoop stops

shifting.

When the machine is turned on, hoop shifts automatically to the mechanical origin

points. Check to see if needle is positioned as illustrated below, if the embroidery unit

malfunctions.

Maximum moveable area: 115 mm on X axis and 170 mm on Y axis

When there is an error in mechanical origin points or the hoop shi fts excessively

1. If there is a malfunction on Y axis, remove carriage cover (see the previous section)

to fix the problem.


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Mechanical origin point and maximum moveable area (2)

2. If there is a malfunction, it is necessary to remove cover for embroidery unit.

Adjustment to be made by loosening fixing screw for sensor plate and shifting sensor

plate either to the right or left until right position is obtained.

If it is shifted to the left, hoop stops early since sensor light is blocked early.If it is shifted to the right, hoop may shift excessively, since sensor light is blockedlate,

Under the situation above, motor may be forced to run resulting in abnormal noisegenerated by motor.

Before sensor light is blocked After sensor light is blocked, hoop

stops shifting.

Hoop stop position differs depending upon timing of sensor light blocked by Y sensor

plate.

Adjustment is to be made by changing position of sensor plate after loosening fixing

screw below flat cable.

Also check to see if sensor plate passes through groove of sensor with enough depth.

If there is problem, hoop may shift excessively and motor may not stop resulting in

abnormal noise.


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Wiring diagram between main and control circui t boards


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Main circuit board and functions of each connector

Bobbin winder

Speed & needle position

Start/stop function

Presser foot

Thread sensor

Buttonhole sensor

Jumper wire

Foot control

Transmission

cord

PM for feed-dog

PM for ZZ

Lamp

Main motor

Transformer (secondary)

Transformer (primary)

Power supply Drawer for Embroidery


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Control circuit board and functions of each connector

Thread sensor

Start/stop, thread sensor,

Speed, needle

Start /stop

BH reset

Not used

USB


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Block diagram


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Connecting wire to switch board

Sensor for needle thread

BH lever SW

USB

Main circuit board

Stop/revrse/ needle

osition SW


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Electronic specifications

General specificationItem Specification Remarks

Power supply Supply from AFPA1002DC15V 0.4A or less

DC15V from the fifth of AFPA1002 CN1GND input from the fourth

Allowable powerfailure time

Conforms to AFPA1002. Operation continues for 20ms or less whileprimary side of sewing machine is working.

Currentconsumption

0.4A or less Evaluation needed

Ambienttemperature of

use

0-50 Internal temperature of sewing machine

Ambienttemperature of

storage

-20 - 70

Ambient humidityof use

30 - 85%RH Non condensing

Ambient humidityof storage

30 - 85%RH Non condensing

I/O specification for sewing machine operation AFPA1002 (sewing machine controller)

Connector

No.

Usage Input equipment Point to be

connected

Rotational speed detection

(cam 1)

Photo interrupter

Needle position detection (cam

2)

Photo interrupterCN1

Needle position detection (cam

3)

Photo interrupter

85315

Needle starting point Point of contact 85311CN2

Step motor for needle swing Step motor

Starting point of fabric feed Photo interrupter 85317CN3

Step motor for fabric feed Step motor


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CN4 Upper needle detection Photo interrupter CLEM controller CN6

Detection of buttonhole lever Point of contact

Detection of front end of

buttonhole

Point of contactCN5

Detection of rear end of

buttonhole

Point of contact

85304(revised)

RESET signal #6

added to CLEM

controller

CN6Detection of bobbin winder

lever

Point of contact 85313

Start/stop SW Point of contact

Reverse stitch SW Point of contact

Needle up/down stop SW Point of contact

Green LED LED

CN7

Red LED LED

CLEM controller CN6

CN8 Detection of presser foot lever Point of contact 85309

CN10Speed volume Variable

resistance

85321

CN11Foot controller Variable

resistance

Made by Matsushita

CN20 Lamp Lamp (6 VAC)

CLEM controller

Connector No. Usage Input-output devicePoint to be

connected

Upper thread detection Photo interrupter

Power supply GND

CN1

B3B-PH-K-S

Power supply DC15V

85307(revised)Power is suppliedfrom sewingmachine controller

Needle up/down SW Point of contact

Reverse stitch SW Point of contact

Start/stop SW Point of contact

Green LED LED

Red LED LED

CN2

B3B-PH-K-S

GND

85323(revised)Input of needleup/down SW,reverse stitch SW,and start/stop SWand output of redLED and green LED

taken into CPU.


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CN3B10B-PH-K-S

Pattern setting SW, 25 kindinput

Point of contactmatrix method

Pattern selectioncircuit board

CN4B11B-PH-K-S Pattern display LED 25 point LED matrix method

Pattern selectioncircuit board

Stitch width setting volumeand LED

Variable resistanceand LED

CN5

B7B-PH-K-S Stitch length setting volumeand LED

Variable resistanceand LED

Detection of upper thread CN1 #1 through

Power supply GND CN1 #2 through

Power supply DC15V CN1 #3 through

Sewing machinecontroller CN4

Needle up/down SW CN4 #1 through

Reverse stitch SW CN4 #2 through

Start/stop SW CN4 #3 through

Green LED From CN4 #4 CPURed LED From CN4 #5 CPU

GND CN4 #6 through


Serial port SO To CN14 #1

Serial port CLK To CN14 #2

Serial port SI To CN14 #3

CN6

B15B-PH-K-S

GND To CN14 #4


CN7B2B-PH-K-S RESET signal From RESET IC

Sewing machinecontroller CN5 #6

CN9USB Connector USB 2.0 PC


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Photo interrupterItem Flashing side Receiving side Point of contact

Rated voltage 15V 5V 5V

Rated input current (20mA) About 0.5mA About 1mA

Input impedance (430) About 10k About 4.7k

Maximum ON voltage(negative logic)

- 0.8V 0.8V

Minimum OFF voltage(negative logic)

- 4V 4V

Input specification of variable resistance

Item Stitch w idth setting

volum e divided into 13

Stitch length setting volum e

divided into 13

Low est resistance

(about 0)

M inim um width 1 m m M inim um length 0m m

Highest resistance M axim um width 7 m m M axim um length 5.0m m

O utput specification

Item Specification Rem arks

Rated output voltage of LED 5V DC C urrent lim itation resistance 1.5K

Buzzer 5V D C Piezo-electric buzzer (C LEM

controller)

Communication specification for sewing machine (communication between CLEM

controller and AFPA1002)Item Specification Remarks

Communication method Three line clocksynchronous type

Object: AFPA1002

Clock when transmitting 256 k bits/s Output from transmitting side,Synchronized with PC

Clock when receiving 256 k bits/sBit length 8 bitsProtocol Special protocol Conforms to AFPA1002.

Pattern data capacity 32767 bytes


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Operating specifications

When power supply is turned on

It is read out whether it is under test mode and abnormality exists in status 1 while

pattern display LED is lighted one by one for three seconds (as if LED runs),.

If abnormality is found, error is displayed..

When there is no initial malfunction, basic data for needle position and stitch

length is transmitted and LED for straight stitch is lighted.

Pattern selection

Push pattern selection SW and select pattern when you change pattern.

The basic data of stitch width and length is transmitted, and pattern selection LED

is lighted.

Change in stitch width and length

When changing basic data displayed, each of the stitch width and length can be

changed while LED next to each volume is lighted.

(See 7. specification of SW, volume and LED)

When basic data is changed, data is transmitted if there is no input with slide volume

for a few ten milliseconds.

If there is change in amount with slide volume during data transmission, changed

amount is read and data is transmitted after time elapses for data transmission and

original position resetting.

Data is transmitted similarly when there is SW input again after data is transmitted.

At error

1. In case of the error concerning status 2 of the content of the communication

data (except bit 1).Buzzer rings for two seconds when sewing machine stops by the error.

Buzzer stops because sewing machine starts when start SW is turned on.

Buzzer stops when the error due to abnormality of presser foot and buttonhole

lever is released

2. In case of the error concerning status 3 of the content of the communication

data.

The sewing machine is not operated and buzzer keeps ringing, as long as

sewing machine is not reset because this abnormality is important.

If the power supply is not put again, it is not released.


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Buzzer

It rings without fail for two seconds when stopped with erro.

Selection of mirrored image

Mirrored image symbols are printed on patterns available.

Select mirrored image pattern and push mirrored image switch, its LED will be

lighted and data will be transmitted.


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Specifications with embroidery uni t connected

Embroidery operation mode

Only when the sewing machine that installs the embroidery unit is connected

with PC, embroidery operation becomes effective.

Connected condition of the embroidery unit can be confirmed by status 1 of

command. (function of sewing machine controller)

Download of embroidery data

Embroidery data is downloaded to the sewing machine with the application software

for the embroidery installed in PC through USB communication.

(PCCLEM controllersewing machine controller)

Function of each SW when embroidery is done

Start/stop SW is start/stop SW for embroidery as well.

Reverse stitch SW functions as reversing embroidery data.

(movement of embroidery hoop).

Needle up/down SW functions as advancing embroidery data.

(movement of the embroidery hoop).

(function of sewing machine controller)

Slide volume

It becomes invalid. (function of sewing machine controller)

Maintenance of embroidery data

Embroidery restarts from the continuation of embroidery when the sewing machine

is stopped on the way of the embroidery work.

The controller is reset and data is reset as well when the embroidery machine unit

Comes off while sewing machine power supply is ON and it is installed again.

Data is not maintained when power supply is turned off on the way of embroidery work.

6. When sewing machine is not connected with PC

While sewing machine is connected with embroidery unit, but not with PC,

message is displayed with LEDs of switch area.

Display method: alphabets P, C is displayed continuously until it is

connected with PC.


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Thread breakage sensor

If the machine stops very often with warning signal, check as follows.

Remove the cover of thread breakage sensor.

With the cover removed, rethread the machine and test sewing.NOTE: Refer to the correct threading as illustrated below.

Pass thread under

tension plate.

Pass thread under rotation

roller.

futu race 100 and 200 service

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