r computer-controlled dry-head, lockstitch, sleeve setting ...semsi.com.mx/manuales/juki/dp-2100...

40018531No.E363-00

R

DP-2100

Computer-controlled Dry-head, Lockstitch,Sleeve Setting Machinewith Multi-programming Device

ENGINEER’S MANUAL

PREFACE

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

of the machine.

The Instruction Manual for these machines intended for the maintenance personnel and operators at an apparel

factory contains operating instructions in detail. And this manual describes “Standard Adjustment”, “Adjustment

Procedures”, “Results of Improper Adjustment”, and other important information which are not covered by the

Instruction Manual.

It is advisable to use the relevant Instruction Manual and Parts List together with this Engineer’s Manual when

carrying out the maintenance of these machines.

In addition, for the motor for the sewing machine with thread trimmer, refer to the separate Instruction Manual

or Engineer’s Manual for the motor. And for the control panel, refer to the Instruction Manual for the control

panel.

This manual gives the “Standard Adjustment” on the former page under which the most basic adjustment value

is described, and on the latter page “Results of Improper Adjustment” under which stitching errors and troubles

arising from mechanical failures are described together with the “Adjustment Procedures”.

CONTENTS

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

2. CONFIGURATION ..................................................................................2(1) Sewing machine main unit ................................................................................. 2(2) Operation panel ................................................................................................... 3

3. STANDARD ADJUSTMENT ...................................................................4(1) Adjusting the height of the needle bar .............................................................. 4(2) Adjusting the needle and the hook.................................................................... 4(3) Removing the main shaft motor and the coupling ........................................... 6(4) Adjusting the main shaft belt tension ............................................................... 8(5) Adjusting the hook shaft belt tension ............................................................... 8(6) Adjusting the feed belt tension .......................................................................... 10(7) Adjusting the height of the feed foot bar .......................................................... 12(8) Adjusting the height of the presser foot bar ..................................................... 12(9) Adjusting the amount of alternate vertical movement .................................... 14(10) Height of the presser screw ............................................................................. 16(11) Assembling the guide plate .............................................................................. 16(12) Adjusting the initial position of the auto-lifter ................................................ 18(13) Adjusting the speed of the auto-lifter .............................................................. 18(14) Adjusting the stroke of the auto-lifter ............................................................. 20(15) Adjusting the thread trimmer cam ................................................................... 20(16) Adjusting the initial position of the moving knife .......................................... 22(17) Adjusting the initial position of the thread trimmer solenoid ....................... 22(18) Adjusting the position of the moving knife and the counter knife ............... 24(19) The fixing position of the auxiliary feed motor pulley ................................... 24(20) The fixing position of the main feed motor pulley .......................................... 26(21) The fixing position of the thrust collar of AT solenoid ................................... 26(22) The fixing position of the thread tension shaft collar .................................... 28(23) Adjusting the height of the feed foot ............................................................... 28(24) Adjusting the height of the auxiliary feed foot ............................................... 30(25) Adjusting the height of the presser foot ......................................................... 30(26) Adjusting the feed eccentric cam .................................................................... 32(27) Adjusting the assembly of the counter knife guard plate ............................. 32(28) Replacing procedure of the top feed belt........................................................ 34(29) Replacing procedure of the bottom feed belt ................................................. 48

4. PARTS TO BE GREASED ......................................................................50

5. SET-UP MANUAL FOR IP-200 ...............................................................52(1) Connecting procedure of operation panel with external vehicle .................... 52(2) Re-setup of operation panel ............................................................................... 56(3) Re-setup of main program.................................................................................. 59(4) Re-setup of servo program................................................................................. 65(5) When using smart media other than that which has been packed

together ................................................................................................................ 71

6. INITIALIZING THE BACKUP DATA ........................................................72

7. SEWING DATA LIST ...............................................................................73

8. MEMORY SWITCH DATA LIST ..............................................................76

9. ERROR CODE LIST ...............................................................................82

10. TROUBLES AND CORRECTIVE MEASURES ....................................87(1) Mechanical parts ................................................................................................. 87(2) Electrical parts..................................................................................................... 93

11. CIRCUIT DIAGRAM ..............................................................................104(1) Block diagram (1/2) ............................................................................................. 104(1) Block diagram (2/2) ............................................................................................. 105(2) Head and table/stand circuit diagram................................................................ 106(3) Main and panel circuit diagram.......................................................................... 107(4) Power source A circuit diagram ......................................................................... 108(5) Power source B circuit diagram ......................................................................... 109(6) Power source C circuit diagram ......................................................................... 110(7) Motor circuit diagram.......................................................................................... 111(8) Servo motor circuit diagram............................................................................... 112

12. VARIOUS PRINTED WIRING BOARDS ...............................................113(1) FLT-T p.c.b. ........................................................................................................... 113(2) FLT-S p.c.b. ........................................................................................................... 113(3) PWR p.c.b. ............................................................................................................ 114(4) MAIN p.c.b. ........................................................................................................... 114(5) PANEL p.c.b. ........................................................................................................ 115(6) DATA p.c.b. ........................................................................................................... 115

13. DRAWING OF THE TABLE ...................................................................116(1) Slant table ............................................................................................................ 116(2) Work top table ...................................................................................................... 117(3) Edge Stopper A ................................................................................................... 118(4) Edge Stopper B ................................................................................................... 119

－ 1 －

1. SPECIFICATIONS

Limitation by the amount of alternate vertical movement of presser foot and feed foot

Limitation by stitch lengthMax. sewing speed (rpm) Stitch length (mm)

3,500 1.5 to 4.0

2,500 4.1 to 6.0

* 1. The maximum sewing speed is limited in accordance with the amount of alternate vertical movement ofpresser foot and feed foot, and stitch length.

2. Limitation by the stitch length is automatically limited.3. Set the limitation by the amount of alternate vertical movement with the memory switch K02.

Max. sewing speed (rpm)

3,500

2,600

2,000

1,600

No. SpecificationsDP-2100

Computer-controlled dry-head, lockstitch, sleeve

setting machine with a multi-program device3,500 rpm (*1)

Intermittent belt feed by direct drive of stepping motor

Both top and bottom 1.5 to 6 mm

Panel input0.1mm

30.7mm

DP X 17 #10 to #14Full-rotary non-lubrication horizontal-axis hook

Bobbin case for full-rotary non-lubrication

horizontal-axis hookStandard aluminum bobbin

By hand lifter : 5.5 mm, by auto-lifter : 10 mm

3.5 mm (0.2 to 0.3 mm at the time of delivery)

Slot stop position adjustment

Non-lubrication99 programs

30 steps

Provided

PossibleSmart media

Exclusive grease : 23640204 (500g can)

JUKI grease A : 40006323 (tube of 10g)106 Kg (head 65 Kg)

MC-650

50Hz / 60Hz

560VA0 to 40, Less than 90%

Workplace-related noise at sewimg speedn=3,000 min-1 : LPA ≦ 84dB(A)

Noise measurement according to DIN 45635-48-A-1

Item

ModelModel name

Max. sewing speed

Feed system

Stitch lengthStitch length adjustment system

Stitch length adjustment minimum resolution

Needle bar stroke

Needle

HookBobbin case

Bobbin

Presser foot lift

Amount of alternate vertical movement of presserfoot/feed foot Max.

Adjustment of amount of alternate vertical movement

of presser foot/feed foot

Lubrication

Number of programs that can be inputtedNumber of steps that can be inputted (per program)

Data mirroring

Right/left alternate sewing

Data record

Grease

Weight of complete set

Control box model

Power voltage

FrequencyRated current

Power/power consumption

Operating temperature/humidity

Noise

12

3

4

56

7

8

9

1011

12

13

14

15

16

1718

19

20

21

22

23

24

25

2627

28

29

30

Amount of vertical movement of feed foot (mm)

Less than 0.3

Not less than 0.3 to 1.5



Amount of vertical movement of presser foot (mm)

(2.7)

(1.5)

(2.5)

(3.5)

3-phase

200V/220V/240V

Single phase

220V/230V/240V

2.6A/2.4A/2.2A 2.8A/2.6A/2.5A

－ 2 －

2. CONFIGURATION

1 Sewing machine head

2 Operation panel

3 Control box

4 Auxiliary table (WORK TOP TABLE)

5 Power switch

6 Main pedal

7 Auxiliary pedal

8 Thread stand

9 Shirring release switch

!0 Knee switch for step changeover

(1) Sewing machine main unit

1

2

3

4

5

6

7

8

9

!0

－ 3 －

(2) Operation panel

1 Touch panel, LCD display section

2 Smart media slot card (Use with the lid closed.)

3 Slide switch (Unused • OFF)

4 Connector for RS-232C communication

5 Variable resistor for adjusting color LCD screen contrast

6 Connector for external input

7 Cable

1

2

3

4

5

6

7

(Front face) (Right side face)

－ 4 －

3. STANDARD ADJUSTMENT

(1) Adjusting the height of the needle bar

To align

1

1. Bring the needle bar to its lower dead point, and adjust so that the upper marker line engraved on the

needle bar aligns with the bottom end face of the needle bar lower bushing.

Standard Adjustment

0.04 to 0.1 mm

3

4

(2) Adjusting the needle and the hook

1. Adjust the blade point of hook to the center of needle so that the clearance between the blade point

and the needle is 0.04 to 0.1 mm when the lower marker line engraved on the needle bar aligns with

the bottom end face of the needle bar lower bushing. Then tighten three setscrews in the hook.

* RP hook (dry hook) rolls thread waste or cloth dust, and there is a possibility of breakdown or sewing

trouble. Periodically perform cleaning of the hook.

Standard Adjustment

To align

－ 5 －

12

5

6

Adjustment Procedures Results of improper Adjustment

1. Remove throat plate auxiliary plate 1, hook cover asm. 2 and hookbase 3.

2. Turn the handwheel and adjust the lower marker line engraved on theneedle bar to the bottom end face of the needle bar lower bushing.

3. Loosen three setscrews in the hook, adjust the needle to the bladepoint, and tighten three setscrews in the hook.

4. Put bottom feed belt 4 on hook base 3, and assemble them to thehook shaft base.

5. Assemble throat plate auxiliary plate 1 and hook cover asm. 2.

™ When the clearance is excessivelynarrow, the blade point of hook isdamaged, and when it isexcessively wide, stitch skippingwill be caused.

™ Place counter knife guard plate 5located inside hook base 3 to theinside of counter knife 6 sincepull-up trouble will be caused.

1. Turn the handwheel by hand to bring the needle bar to its

lower dead point.

2. Remove the plug of the face plate cover.

3. Loosen needle bar connection setscrew 1 to adjust the

height.

4. Tighten needle bar conection setscrew 1, and attach the

plug.

™ Stich skipping or thread breakage

may occur.


－ 6 －

(3)Removing the main shaft motor and the coupling

1. Clearance between main shaft motor 1 and coupling 2 has to be 0.5 mm.

Standard Adjustment

Flat section

3

2

Screw No. 1 3

0.5mm

Screw No. 1 7

5

6

4

8

1

A

7

－ 7 －

1. Loosen the respective setscrews in side plate 4, pulley 5 and

pulley cover 6, and remove the respective parts.

2. Loosen two setscrews 7 in the coupling.

3. Loosen four setscrews 8 in the main shaft motor and remove

main shaft motor 1.

4. Loosen two setscrews 3 in the coupling.

5. Insert a spacer of 0.5 mm between the end of main shaft motor

1 and coupling 2, and tighten setscrews 3 in the coupling.

6. When assembling, assemble in the aforementioned order of 3, 2,

and 1 in the reverse order of removing.

™ When setscrews 3 and 7 in

the coupling are not adjusted to the

flat section of main shaft motor 1

and that of the main shaft :

1. UP-stop position does not

come near to 50˚.

2. Thread is not cut.


(Caution) When tightening setscrews 3 and 7 in the

coupling, assemble so that screw No. 1 in terms of

the rotating direction A of the main shaft should

come to the flat sections of main shaft motor 1

and the main shaft.

－ 8 －

(4) Adjusting the main shaft belt tension

1. Press in the direction of A with a load of 19.6 N (2 Kgf), and tighten setscrew 2.

Standard Adjustment

Main shaft belt

(5) Adjusting the hook shaft belt tension

1. The hook shaft belt has to sag 3 mm when the center of hook shaft belt 3 is pressed with a load of

1.3N (130gf).

Standard Adjustment

Press the center

1

2

A

3

12

1

B

－ 9 －


1. Loosen lock nut 2 in belt idler 1.

2. Press belt idler 1 in the direction of arrow mark B, and tighten

lock nut 2.

™ When belt tension is excessively

low, the side where the belt is

loosened vibrates and noise

occurs. At the same time, the slip

of hook position occurs, resulting

in needle breakage or damage of

hook.


high, the side where the belt is

tense vibrates. At the same time,

the load to bearing is increased,

and the life of machine is

shortened.

1. Loosen setscrew 2 in idler installing plate 1.

2. Press idler installing plate 1 in the direction of arrow mark A

with a load of 19.6 N (2 Kgf), and tighten setscrew 2.


low, the side where the belt is

loosened vibrates and noise

occurs.


high, the side where the belt is

tense vibrates with a sharp noise.


－ 10 －

8

81

7

4

5

!3

!4

(6) Adjusting the feed belt tension

1. Main feed beltAdjust so that main feed belt 9 sags 3 mm when it is pressed with a finger with a load of 1.3N (130 gf).

2. Auxiliary feed beltAdjust so that auxiliary feed belt !0 sags 3 mm when it is pressed with a finger with a load of 0.4N (40 gf).

3. Bottom feed beltAdjust so that bottom feed belt !1 sags 3 mm when it is pressed with a finger with a load of 1.5N (150 gf).

* The standard of the replacing time of the respective belts is one year although it depends on thefrequency of use.Replace the belt when excessive decrease of feed force or the like is observed.

Standard Adjustment

A

B

B

3

2

6

C

Press the center

6

!1

Press the center

39

2

!0

－ 11 －

1. Main feed belt

(1) Remove 10 setscrews 8 in top feed covers A 1 and B 7.

(2) Move tension adjustment plate L 2 to the right and left

to adjust the tension. Move to the right (direction A) to

increase the tension, and to the left to decrease it.

2. Auxiliary feed belt

(1) Move tension adjustment plate S 3 to the right and left

to adjust the tension. Open both sides (direction B) to

increase the tension, and close both sides to decrease it.

3. Bottom feed belt

(1) Remove throat plate auxiliary plate 4, hook cover asm.

5, frame cover !3 and bottom feed cover !4.

(2) Move bottom feed tension plate 6 to the right and left to

adjust the tension. The tension is increased in the

direction of C.

™ If the tension is not proper, shirring

trouble due to feed pitch error will

be caused.


－ 12 －

(8) Adjusting the height of the presser foot bar

1. Adjust the clearance between the bottom face of

presser foot 4 and needle hole guide 7 to 0.1 mm.

(Refer to the previous item (7) Adjusting the

height of the feed foot bar.)

Standard Adjustment

1 52

6

3

Be careful of parallel

4

3

(7) Adjusting the height of the feed foot bar

1. Adjust the clearance between top and bottom feed belts to 0.1 mm.

Standard Adjustment

0.1

mm

4

7

7

0.1m

m

4

－ 13 －

1. Height of the feed foot bar

(1) Bring the needle bar to its upper dead point.

(2) Remove plug 1.

(3) Loosen feed foot bar connection clamp screw 2.

(4) Move feed foot 3 up or down and adjust the clearance

between top feed belt and bottom feed belt to 0.1 mm.

Then tighten feed foot bar connection clamp screw 2.

™ When the clearance is larger than

0.1 mm, feed force is deteriorated.

™ Clearance between top and bottom

feed belts is 0.1 mm. If the

clearance is widened more than the

specified value, components

interfere with each other.

™ When tightening feed foot bar

clamp screw 2, take care of the

parallel between feed foot 3 and

presser foot 4.

Bend of cloth or feed trouble will

be caused.



1. Height of the presser foot bar

(1) Bring the needle bar to its lower dead point.

(2) Remove face plate 5.

(3) Loosen presser foot bar connection clamp screw 6.

(4) Adjust the clearance between the bottom face of presser

foot 4 and needle hole guide 7 to 0.1 mm, and tighten

presser foot bar connection clamp screw 6.

(Refer to the previous item (7) Adjusting the height of

the feed foot bar.)

™ When the clearance is widened,

feed force is deteriorated.

－ 14 －

(9) Adjusting the amount of alternate vertical movement

1. State of feed foot and presser foot at the time of delivery

Standard Adjustment

6

5

4

4

B

1

(Caution) When changing the amount of alternate vertical movement, change max. sewing speed.

When it is not changed, components breakage or damage occurs and the life of the

machine is excessively shortened.

2. Relation between amount of alternate vertical movement and max. sewing speed

Cam rod position Top feed arm lowest position

Amount of alternate vertical movement of feed foot 0.2 to 0.3 mm

Clearance at lower dead point of feed foot 0.1mm

Amount of alternate vertival movement of presser foot Approximately 2.7 mm

Clearance at lower dead point of presser foot 0.1mm

Amount of verticalmovement of feed foot (mm)

Amount of verticamovement of presser foot (mm)

Max. sewing speed (rpm)

1

Less than 0.3

2.7

3,500

2

Up to 1.5

1.5

2,600

3

Up to 2.5

2.5

2,000

4

Up to 3.5

3.5

1,600

Hole A 32

Be careful of parallel

－ 15 －

1. Turn the handwheel and bring the needle bar to its lower dead

point.

2. Adjust the position of cam rod 1 to the lowest position of top

feed arm 2.

3. Remove stopper plug 6, insert a hexagonal wrench key from

hole A, and loosen top feed arm clamp screw 3.

/ Feed foot 4 moves downward. Adjust so that clearance B

between top and bottom belts becomes 0.1 mm.

(Range : 0.1 to 1.0 mm)

(It is the premise that (7) Adjusting the height of the feed foot bar

has been performed.)

4. Turn presser foot lever 5, raise feed foot 4, and insert a

spacer so that the clearance between top feed belt and bottom

feed belt becomes 0.2 to 0.3 mm.

5. Tighten top feed arm clamp screw 3.

6. Turn presser foot lever 5 and remove the spacer.


feed force is deteriorated at high

speed.


noise or vibration is increased at

high speed.

™ When the clearance is excessively

narrow, efficiency of rotation of

material is deteriorated.


－ 16 －

(10) Height of the presser screw

1. Adjust the height of top feed spring adjusting screw 1 to 30 ± 0.3 mm from the machined plane of

frame.

2. Adjust the height of presser spring regulator 2 to 19 ± 0.3 mm from the top surface of spring base 3.

Standard Adjustment

(11) Assembling the guide plate

1. Roller guide 1 has to always receive roller 2 when roller moves 2 up and down.

2. Assemble presser foot guide plate 3 so that presser foot shaft connection 4 smoothly moves up

and down.

Standard Adjustment

1

2

5

34

30 ±

0.3

mm

19 ±

0.3

mm

5

1

4

6

3

2

－ 17 －


1. Remove the face plate cover, loosen setscrews 5 in roller guide1, move roller guide 1 to the right and left, move the auto-lifterup and down, and adjust so that roller 2 always comes in contactwith the inside of roller guide 1. Then tighten setscrews 5.

2. Loosen setscrews 6 in presser foot guide plate 3, and adjustwith the hand lifter or auto-lifter so that the guide section of presserfoot shaft connection 4 smoothly moves up and down thegroove section of presser foot guide plate 3.

™ Excesiive side pressure is appliedto the presser bar. As a result, thepresser bar will break down.

™ A proper amount of alternatevertical movement cannot beobtained.

™ Lifting amount of auto-lifter cannotbe obtained.

™ Bend of feed is increased due tothe unevenness of right/left of feedfoot.

™ A proper amount of alternatevertical movement cannot beobtained.

™ Groove section of presser footguide plate 3 is cut andunevenness of right/left of presserfoot is increased.

1. For the adjustment of top feed spring adjusting screw 1, loosen

nuts 5, adjust the height to 30 ± 0.3 mm, and tighten nuts 5.

2. For the adjustment of presser spring regulator 2, loosen presser

spring regulator nut 4, adjust the height to 19 ± 0.3 mm, and

tighten presser spring regulator nut 4.

™ When the height is excessively

high, shortage of feed force occurs

and jumping at high speed occurs.

As a result, damage of components

is caused.

™ When the height is excessively low,

pressure applied to the belt is

increased and belt mark remains

on the cloth.


－ 18 －

(12) Adjusting the initial position of the auto-lifter

1. Adjust so that the clearance between the top surface of presser lifter link 1 and the bottom face of

feed foot bar connection 2 is 0.1 to 0.3 mm at the upper dead point of the needle bar.

Standard Adjustment

(13) Adjusting the speed of the auto-lifter

1. Adjust throttle valve 4 of AK solenoid section 3 to the state that it is turned four times from being

fully closed.

Standard Adjustment

0.1

to 0

.3 m

m

2

1

4

3

21

4

3

2

1

B A

－ 19 －

1. Remove the side plate, and loosen setscrews 3 in stopper

installing plate 4.

2. Move stopper installing plate 4 in the direction of the arrow

mark, and adjust the clearance between presser lifter link 1

and feed foot bar connection 2 to 0.1 to 0.3 mm. Then tighten

setscrews 3.


wide, a big noise occurs when the

auto-lifter goes up.



1. Loosen lock nut 1.

2. Turn knob 2 until it will turn no further in the direction of A.

(Set throttle valve 4 to the state that it is fully closed.)

3. Turn knob 2 four times in the direction of B.

(Set throttle valve 4 to the state that it is opened four times

from the state that it is fully closed.)

4. Tighten lock nut 1.

™ When the opening amount of the

throttle valve is larger than the

specified value :

1.Feed foot, presser foot, needle

hole guide, etc. will break.

2.The life of the respective feed

belts is shortened.

™ When the opening amount of the

throttle valve is smaller than the

specified value :

1.The force to feed material is

deteriorated immediately after

the motion of auto-lifter.

2.The lifting amount of auto-lifter is

decreased.

－ 20 －

8

9

!17 !0

6

Slide

(15) Adjusting the thread trimmer cam

1. Turn the handwheel to the position where the thread take-up lever comes a little before it goes up to itsupper dead point.

2. Turn ON the thread trimmer solenoid, slide roller 8 to thread trimmer cam 7, and make them engagewith each other using the output signal check I06-09 of the check program(refer to the Instruction Manual).

3. In the state as it is, turn the handwheel in the normal operating direction and in the reverse direction.Then set the handwheel to the position where it does not turn.

4. When marker dot 5 engraved on the pulley cover aligns with marker dot 1 engraved on thehandwheel, the timing is normal.

Standard Adjustment

4 : White

3 : Green

2 : Red

1 : Colorless5

(14) Adjusting the stroke of the auto-lifter

1. Adjust so that the clearance between the bottom face of the top feed belt and the top surface of the

bottom feed belt is 10 to 10.3 mm.

Standard Adjustment

10 t

o 1

0.3

mm

2

1

4

3

－ 21 －

1. Remove the bottom cover.2. Loosen setscrews !0 in the thread trimmer cam.3. When cam collar !1 moves, adjust so that thread trimmrer cam

7 does not engage with roller 8 and thread trimmer cam 7and roller 8 come to the almost equal position in the rangewhere thread trimmer cam 7 enters roller 8. Then tightensetscrew !1 in the cam collar.

4. Adjust marker dot 1 on the handwheel to marker dot 5 on thepulley cover.

5. Pressing driving block 6 to the right, make thread trimmer cam7 engage with roller 8.

6. Turn thread trimmer cam 7 only, without turning hook drivingshaft 9, in the reverse direction against the rotating direction ofthe hook driving shaft.

7. Press roller 8 to thread trimmer cam 7 at the position wherethread trimmer cam 7 does not turn, and press thread trimmercam 7 to cam collar !1. Then tighten setscrews !0 in the threadtrimmer cam.

™ Length of needle thread remainingon the needle is shortened.

™ Thread trimming motion is notcompleted at the time of UP-stopposition.



1. Loosen nut 2 of link ball shaft 1.

2. Turn link ball shaft 1 and tighten nut 2 when the specified

value (10 to 10.3 mm) is reached.

3. If the adjustment range is insufficient, loosen setscrews 4 in

AK solenoid, and move AK solenoid 3 downward to adjust the

stroke.


wide, feed foot comes in contact

with the feed foot bar bushing and

a noise occurs when the presser

lifter goes up.

－ 22 －

6 57

4

2

0.1 to 0.5 mm

(17) Adjusting the initial position of the thread trimmer solenoid

1. Adjust the initial position so that the clearance between slide arm 1 and driving shaft aem 2 is 0.1

to 0.5 mm when the thread trimmer solenoid performs suction.

Standard Adjustment

3 A

1

3

2

1

4

5

11.8

mm

6

7

8

Bottom surfaceof base plate

(16) Adjusting the initial position of the moving knife

1. The initial position of the moving knife is the position where marker dot 1 engraved on the hook shaftbase aligns with V groove 2 on the moving knife base 3.At this time, end 6 of the cam roller is higher by 1.7 mm than hook driving shaft center 7.

Standard Adjustment

1.7

mm

－ 23 －

1. Remove the bottom cover and press driving block 3 by finger

in the direction of the arrow mark A. At this time, loosen setscrews

4 and adjust so that the clearance is 0.1 to 0.5 mm.

2. Detach the finger and make sure that there is a clearance

between cam roller 5 and the edge of thread trimmer cam 6.

3. Secure a clearance of approximately 0.5 mm between slide arm

1 and E ring 7.


large, thread trimming motion

trouble may occur.


small, the load applied to the

respective components is

increased, and abnormal worn-out

of components may occur.



1. Adjusting the engraved marker dot

(1) Loosen clamp screw 4 in knife driving arm 5, make

engraved marker dot 1 align with V groove 2, and tighten

clamp screw 4.

2. Adjusting the position of the cam roller

(1) Loosen stopper lock nut 8, turn the stopper, and tighten

cam roller 6 at the proper position (11.8 mm).

™ Thread handling trouble

The blade section of moving knife

does not fully pass the blade

section of counter knife, and thread

trimming failure will occur.

™ When the position of cam roller 6

is excessively higher as against

hook driving shaft 7, the moving

knife rocking stroke is decreased

and thread trimming failure will be

caused. On the contrary,the

position is excessively lower, the

rocking stroke is increased and the

length of remaining needle thread

is shortened or the blade point is

damaged.

－ 24 －

(19) The fixing position of the auxiliary feed motor pulley

1. Adjust the dimension from the end of the shaft of auxiliary feed motor 3 to the end of pulley 2 to

3.6 ± 0.2 mm.

Standard Adjustment

3

1

2

3.6 ± 0.2 mm

1 2

3

54

A

(18) Adjusting the position of the moving knife and the counter knife

1. Install moving knife 1 with setscrews 2 in the moving knife by making it come in contact with the

moving knife base.

2. Install counter knife 4 together with knife pressure adjustment plate 5 with setscrew 3 in the counter

knife.

Standard Adjustment

－ 25 －

1. Loosen setscrews 1.

2. Adjust the position of pulley 2 (dimension : 3.6 ± 0.2 mm).

3. Tighten setscrews 1.

™ When the dimension is large, timing

belt comes off pulley 2.

™ When the dimension is small,

timing belt is abnormally worn out.



1. Adjust so that the blade section of the eye of moving knife 1

and the blade section of counter knife 4 come in contact with

each other in parallel, slightly press knife pressure adjustment

plate 5 in thre direction of A, and tighten with setscrew 3 in

the counter knife.

™ When the parallel is not obtained,

remaining of thread end will be

caused.

™ When the knife pressure is

excessively low, thread trimming

failure will be caused. When it is

excessively high, it is related to the

damage of the blade section of

counter knife 4.

－ 26 －

(21) The fixing position of the thrust collar of AT solenoid

1. Adjust so that the dimension from the main body of AT solenoid 3 to the end of the shaft of AT

solenoid 3 to 19.5 ± 0.1 mm when thrust collar 2 is pressed to the main body of AT solenoid 3

(direction of A).

Standard Adjustment

19.5 ± 0.1 mm

3

1

2

1

A

(20) The fixing position of the main feed motor pulley

1. Adjust the dimension from the end of the shaft of main feed motor 3 to the end of pulley 2 to 9 ± 0.2 mm.

Standard Adjustment

9 ± 0.2 mm

3

1

2

－ 27 －


2. Adjust the position of thrust collar 2 (dimension : 19.5 ± 0.1 mm).


™ When the dimension is large,

needle thread tension is not

stabilized.



stabilized.




2. Adjust the position of pulley 2 (dimension : 9 ± 0.2 mm).



timing belt comes off pulley 2.


timing belt is abnormally worn out.

－ 28 －

(23) Adjusting the height of the feed foot

1. Adjust the clearance between the bottom face of main feed belt 4 and the top surface of bottom feed

belt 5 to 0.1 mm when needle bar 1 is in the position of its upper dead point.

Standard Adjustment

(22) The fixing position of the thread tension shaft collar

1. Pull thread release pin adjustment collar 2 in the direction of B, and adjust so that the dimension from

the end of thrust collar 3 to the main body of AT solenoid 4 to 1 ± 0.1 mm when thread tension disks

6 are fully closed.

Standard Adjustment

1 ± 0.1 mm

4

3

5

2

1

6

B

2

3

5

0.1

mm

1

4

－ 29 －

1. Bring needle bar 1 to the position of its upper dead point.

2. Loosen screw 2.

3. Adjust the height of feed foot 3 to 0.1 mm.

4. Tighten screw 2.

™ When dimension is large

/ 1. Material cannot be fed well.

™ When dimension is small/ 1. Worn-out of main feed belt 4

is accelerated.



1. Loosen nut 1.

2. Loosen thread release pin adjustment collar 2.

3. Insert a spacer 5 of 1 mm between thrust collar 3 and the main

body of AT solenoid 4.

4. Tighten thread release pin adjustment collar 2 until thread

tension disks 6 are fully closed.

5. Tighten nut 1.

6. Remove a spacer 5 of 1 mm between thrust collar 3 and the

main body of AT solenoid 4.



stabilized.



stabilized.

－ 30 －

(25) Adjusting the height of the presser foot

1. Adjust the clearance between the bottom face of presser foot 3 and the top surface of needle hole

guide 4 to 0.1 mm when needle bar 1 is in the position of its lower dead point.

Standard Adjustment

2

1

4

3

0.1

mm

(24) Adjusting the height of the auxiliary feed foot

1. Make the clearance A between the bottom face of auxiliary feed belt 5 and the top surface of bottom

feed belt 6 the same as that B between the bottom face of main feed belt 7 and the top surface of

bottom feed belt 6 when needle bar 1 is in the position of its upper dead point.

Standard Adjustment

(A = B)

2

1

43

5

A

6

7

B

1

－ 31 －

1. Bring needle bar 1 to the position of its lower dead point.

2. Loosen setscrew 2.

3. Adjust the height of presser foot 3.

4. Tighten setscrew 2.

™ When dimension is large

/ 1. Material cannot be pressed.

™ When dimension is small/ 1. Needle hole guide 4 is

broken.2. Presser foot 3 is broken.



1. Bring needle bar 1 to the position of its upper dead point.

2. Loosen nut 2.

3. Turn screw 3, and adjust the height of auxiliary feed foot 4.

* When screw 3 is turned clockwise, auxiliary feed foot 4 goes

up.

* When screw 3 is turned counterclockwise, auxiliary feed foot 4

comes down.

4. Tighten nut 2.

™ When dimension is large/ 1. Material cannot be fed

straight.2. Shirring cannot be performed

well.

™ When dimension is small/ 1. Material cannot be fed

straight.2. Shirring cannot be performed

well.3. Worn-out of auxiliary feed

belt 5 is accelerated.

－ 32 －

(27) Adjusting the assembly of the counter knife guard plate

1. Adjust so that counter knife guard plate 1 does not come in contact with the periphery of hook at thetime of sewing, and the top end of counter knife guard plate 1 is pressed down by moving knife 5 andenters the bottom side of moving knife 5 at the time of thread trimming operation.

Standard Adjustment

4

1

3

(26) Adjusting the feed eccentric cam

1. Adjust feed eccentric cam 2 so that screw No. 1 faces the center of hinge screw 4 in cam rod at the

upper dead point of the needle bar.

Standard Adjustment

1

4

3

5

2

5C

BA

End of the guardplate goes alongthe internal planeof the hook base

2

－ 33 －

1. Adjust so that counter knife guard plate 1 is along the internalplane of hook base 2, and tighten it with screws.

2. Set hook base 2 to hook shaft base 3, and adjust so that theclearance between the top surface of counter knife guard plate 1and the bottom face of counter knife 4 becomes 0.2 to 0.5 mm.

3. Actuate moving knife 5, press down section A of counter knifeguard plate 1 at the bottom face of moving knife 5, and adjustso that moving knife 5 enters between counter knife guard plate 1and counter knife 4.

™When the clearance between thetop surface of counter knife guardplate 1 and the bottom face ofcounter knife 4 is excessivelylarge,1. The guard plate comes in contact

with the hook and thread-stainwill occur at the time of sewing.

2. A noise will occur.3. It is related to the early

deterioration of counter knifeguard plate 1.

4. Thread trimming trouble mayoccur.

™When the clearance is excessivelysmall, or pressing down at sectionA is insufficient,1. Section B of moving knife 5

collides with section C ofcounter knife guard plate 1 atthe time of thread trimming. Asa result, main shaft will be locked.



1. Turn top feed arm cover 1.

2. Turn the handwheel and adjust the main shaft to the upper dead

point of the needle bar.

3. Draw top feed arm 3 to this side.

4. Tighten the screw No. 1 of feed eccentric cam 2 so that it faces

the center of hinge screw 4 in cam rod.

5. Turn the handwheel to rotate the main shat, and tighten the screw

No. 2.

™ When timing is improper, troubles

below will be caused.

1. Stitch skipping is apt to occur.

2. Material is not fed.

3. Pitch is not obtained.

(Caution) Tighten the screws so that there is no clearance

between top feed arm 3 and drive shaft rear

bushing 5.

－ 34 －

(28) Replacing procedure of the top feed belt (1/7)

Procedures of disassembling / assembling

2

1

4

3

5

6

5

5

7

5

B

8

8

9

!2

!1

!0

!1

!0

!3

B

A

－ 35 －

1. Loosen setscrew 1, and remove needle 2.

2. Remove setscrew 3, and remove presser foot 4.

3. Remove 10 setscrews 5, and remove cover A 6 and cover B 7.

4. Loosen setscrew 8, move tension adjustment plate L 9 in the

direction of A, and loosen the tension of main feed belt !2 and

auxiliary feed belt !3.

5. Loosen setscrew !0, and move tension adjustment plate S !1 in

the direction of B.

Caution in disassembling Caution in assembling

－ 36 －



!2

!4

!5

!6

!7

!3

－ 37 －

6. Remove main feed belt !2 from the pulley.

7. Remove auxiliary feed belt !3 from the pulley.

8. Raise manual presser lifting lever !4.

9. Remove setscrew !5, and remove auxiliary feed foot !7 from

feed foot bar !6.


－ 38 －



!3

!7

!9 !2

!5 !7

!4

!6

C

－ 39 －

10.Remove the old auxiliary feed belt !3 of auxiliary feed foot !7,

and replace it with the new auxiliary feed belt !3.

11.Remove the old main feed belt !2 of feed foot !9, and replace it

with the new main feed belt !2.

12.Set auxiliary feed foot !7 to auxiliary feed foot bar !6 while taking

care so that the belt does not come off, and temporarily tighten it

with setscrew !5.

13.Lightly drawing the feed belt in the direction of C, lower manual

presser lifting lever !4.

* When lowering manual presser

lifting lever !4, make sure that the

respective belts enter the guide

grooves located in the bottom faces

of feed foot !9 and auxiliary feed

foot !7.


－ 40 －



8

9

!2

8

!3

!2

D

11

2 2

3 3

4

3

2 2

11

－ 41 －

14.Set auxiliary feed belt !3 to the respective pulleys in order of

the numbers in the illustration on the left side.

15.Set main feed belt !2 to the respective pulleys in the order of the

numbers in the illustration on the left side.

16.Move tension adjustment plate L 9 in the direction of D to such

an extent that the slackness of main feed belt !2 disappears, and

temporarily tighten setscrew 8.

* When setting auxiliary feed belt !3

to the pulley, do not twist or draw

forcibly auxiliary feed belt !3.

* When setting main feed belt !2 to

the pulley, do not twist or draw

forcibly main feed belt !2.


－ 42 －



!2

!0 !0

8

!1

!3

!1

8

9

E F

G G

!5

!9

@0

!2

0.1

mm

－ 43 －

17.Bring the needle bar to the position of its upper dead point, and

tighten screw !5 after adjusting the height of feed foot !9 so that

the clearance between main feed belt !2 and bottom feed belt @00

is 0.1 mm.

18.Adjust main feed belt !2 to the proper tension by adjusting the

lateral position of tension adjustment plate L 9, and tighten

setscrew 8.

* Tension of main feed belt !2 is increased when tension adjustment

plate L 9 is moved in the direction of F, and decreased when the

plate is moved in the direction of E.

19.Move tension adjustment plate S !1 in the direction of G to such

an extent that the slackness of auxiliary feed belt !3 disappears,

and temporarily tighten setscrew !0.

* For the details of adjusting the

height of the feed foot, refer to

"(23) Adjusting the height of the

feed foot".

* For the details of adjusting the belt

tension, refer to "(6) Adjusting the

feed belt tension".


－ 44 －



0.1m

m!3

!3

@3

@4

!1

@1

!2

@2

4

3

!1

!0 !0

G

H

G

H

－ 45 －

20.Bring the needle bar to the position of its upper dead point, loosen

nut @1, turn screw @2, and adjust so that the bottom face of auxiliary

feed belt !3 is as high as that of main feed belt !2. After the

adjustment, tighten nut @1.

* The height of the bottom face of auxiliary feed belt !3 becomes

high when turning screw @2 clockwise, and low when turning it

counterclockwise.

21.Adjust auxiliary feed belt !3 to the proper tension by adjusting the

position of tension adjustment plate S !1, and tighten setscrew !1.

* The tension of auxiliary feed belt !3 becomes high when moving

tension adjustment plate S !1 in the direction of G, and low when

moving it in the direction of H.

22.Bring the needle bar to the position of its lower dead point, and fix

presser foot 4 to presser foot bar @4 with setscrew 3 so that the

clearance between the bottom face of presser foot 4 and needle

hole guide @3 is 0.1 mm.


height of the auxiliary feed foot,

refer to "(24) Adjusting the

height of the auxiliary feed foot".


tension, refer to "(6) Adjusting the

feed belt tension".


height of the presser foot, refer to

"(25) Adjusting the height of the

presser foot".


－ 46 －



5

6

5

5

7

5

2

1

－ 47 －

23.Install needle 2, and tighten setscrew 1.

24.Tighten 10 setscrews 5, and fix cover A 6 and cover B 7.


－ 48 －

(29) Replacing procedure of the bottom feed belt


5

4

8

!2

6

1

2

7

3

!0

!1

!5

9

!3

!4

A

－ 49 －

1. Loosen cover setscrews 1, 2 and 3.

2. Remove throat plate auxiliary plate 4, hook cover 5, hook belt

cover 6, frame cover 7 and bottom feed cover 8.

3. Loosen setscrews 9 in the bottom feed tension plate.

4. Remove bottom feed tension plate !0.

5. Replace bottom feed belt !5 with a new one.

6. Put new bottom feed belt !5 to bottom feed pulley !1 and belt

roller !2.

7. Put bottom feed belt !5 to idler pulleys !3 and !4 as illustrated on

the left side, and tighten bottom feed tension plate !0 with

setscrews 9 in the bottom feed tension plate.

8. Move bottom feed tension plate !0 in the direction of A to apply

proper tension to bottom feed belt !5.

9. Tighten throat plate auxiliary plate 4 and the respective covers

5, 6, 7, and 8 with setscrews 1, 2, and 3.



tension, refer to "(6) Adjusting

the feed belt tension".

－ 50 －

4. PARTS TO BE GREASED(1) Periodically perform grease-up to the indicated sections below approximately every six months as

a standard.

(2) Apply the exclusive grease (500g can, Part No. :23640204 or tube containing 10g, Part No. :

40006323) to the sections for which lubrication is necessary excluding the lubricating sections.

(3) Tighten the respective hinge screws excluding the auxiliary feed foot hinge screw with a tightening torque

of 5.88±0.49N • m (60±5 kgf • cm).

Roller guide

Hinge screw

Presser footguide plate

Presser bar bracket

Driving shaft arm

Hinge screw

Roller bearing

Cam rod

Hinge screw

Connecting linkL-shapedplate

Presser bar holder

Crank connectinglink

A Feed driving shaft(shaft located on the insideof stopper plug A)

Drive shaft arm Slide arm

Thread trimmer cam

Drive block

Clutch pin A

－ 51 －

Auxiliary feedfoot hinge screw

(4) Tighten the auxiliary feed foot hinge screw with a tightening torque of 4.9±0.49N • m (50±5 kgf • cm).

Presservertical link

Internal planeof belt roller

– 52 –

5. SET-UP MANUAL FOR IP-200

(1) Connecting procedure of operation panel with external vehicle

It is possible for this operation panel to perform communication or input of signal with the external vehicle

below other than the control box.

1. Smart media card

2. RS-232C

3. Input of signal by means of the connector for external input

1. Smart media card

It is possible to give and take data by using the smart media card.

For the smart media card, it is recommended to use SmartMedia of 3.3V voltage type which is prescribed by

SSFDC forum. The card is different in the position of notch as shown in the figure below. Judge it by the

position of notch.

(Caution) When the contact part becomes dirty, contact failure will be caused. Control so that the

contact part is not touched by hand, or that dust, oil or other foreign material does not

adhere to the contact part. Besides, be very careful of handling the card since the internal

data is broken by the static electricity or the like.

(Setting procedure)

1) When the upper side cover located on the side of

operation panel is opened, there is the inserting

opening of the smart media card. Insert the card

there while facing the contact part to the front.

2) When continuing inserting the smart media card, the card stops once in the state that it protrudes by

approximately 10 mm. When some force is applied to it, it is further inserted and goes to the end. When

it goes no further, reduce the force and it returns by approximately 1 mm. This work completes the

setting of the card.

Contact part

Notch< 3.3V type > < 5V type >

– 53 –

3) When the setting of the card is completed, close the smart media card cover. It is not possible to receeive

or send the data with smart media card with the cover opened. For the operating procedure, refer to

“USING COMMUNICATION FUNCTION” of the Instruction Manual.

If the smart media card comes in contact with the cover and the cover is not closed, check the following

matters.

• Check that inserting is stopped in the state that the card protrudes by approximately 10 mm.

• Check that the coantact part is faced downward and inserted.

• Check that the smart media card other than 3.3V voltage type is used.

(Removing procedure)

1) Open the smart media cover, press the card until it goes no further and reduce the force. The card

returns by approximately 10 mm by reversing order at the time of setting.

2) Then drawing up the card completes removing.

< Handling the smart media card >

• Smart media is a precision instrument. Do not bend or shock it.

• It is recommended to periodically save the data saved in the smart media into the other vehicle for the

accident.

• When initializing data, perform it after checking that there is no necessary data in the card. When the

data is initialized, the internal data is deleted.

• Avoid using or keeping the card in a high temperature or high humidity place.

• Avoid using the card near heating or combustible articles.

• When the contact part becomes dirty, contact failure will be caused. Control so that the card is not

touched by hand, or that dust, oil or other foreign material does not adhere to the card. Besides, be

careful of handling the card since the internal data is broken by the static electricity or the like.

• Smart media has the life, and writing and deletion cannot be performed after an extended period of use.

In this case, replace the smart media with a new one.

< Prevention of memory error >

• When write protect seal is pasted, the card

becomes exclusive for reading and writing cannot

be performed.

• Strip off the seal when you desire to record again.

• Do not use again the seal which was pasted once

and stripped off. The trouble of the main unit will

be caused.

< 3.3V type >

– 54 –

2. Communication by means of RS-232C

Operation panel can give and take the data with the personal computer by using communication by means

of RS-232C.

For the cable to be connected, connect the reverse type 9-pin (female) to the operation panel side. Signal

names of the operation panel are as follows.



adhere to the contact part. Besides, be careful of handling the contact part since the

internal element is broken by the static electricity or the like.

(Setting procedure)

1) When the lower side cover located on the side of operation panel is opened, there is a 9-pin connector

for RS-232C. Insert the cable there. When the screw for lock is attached to the connector, tighten the

screw to prevent the screw from falling.

Pin No.

1

2

3

4

5

6

7

8

9

Signal name

N.C.

RXD

TXD

DTR

GND

DSR

RTS

CTS

N.C.

Function

Not connected

Receive data

Transmit data

Data terminal ready

Earth

Data set ready

Transmission request

Transmission approved

Not connected

Signal direction

To panel

From panel

From panel

To panel

From panel

To panel

– 55 –

3. Input of signal by means of the connector for external input

It is possible to input the signal from the outside.

When the switch is connected, it is possible to use as the input of the production control information.

For the details, refer to "Observing the production control information" of the Instruction Manual.

Cable (separately-sold) as shown in the figure below

can be connected.



adhere to the contact part. Besides, be careful of handling the contact part since the

internal element is broken by the static electricity or the like.

Connector housing : KYOCERA ELCO CO. 60-8263-3038-15-000

Pin contact : KYOCERA ELCO CO. 60-8263-0513-00-808

2m

3 2 1

+5VSW

GND

123

(Note) The switch main unit is not installed to therelay cable A (asm.).

1 Relay cable A (asm.) (40008168)

1

– 56 –

Data edit screen

1) Press key for three seconds.

Communication screen 1

2) Press key .

3) Press key .

Data selection screen

4) Press key .

5) Press key .

d

d

d

(2) Re-setup of operation panel

When the case is as below, it is necessary to perform re-setup of the program of the operation panel.

™ When the operation panel is used as that for other model.

™ When version-up of the program is performed.

The way of performing setup of the program from the smart media is shown below. Besides, it is regarded

that the program to perform setup has already entered the smart media card.

1) First, turn ON the power. Normally, the sewing ready screen is displayed.

2) Insert the smart media card into the operation panel.

3) Perform operation by the procedure below.

– 57 –


6) Press key .

File selection screen

7) Press key and select the download

program at display .

8) Press key .


9) Press key .

<-<- Start of communication ->->

d

d

d

d

d

– 58 –

Screen during data deletion Screen 1 during data writing Screen 2 during data writing

Data writing abnormal screen

End screen

If the screen below is displayed, quickly

turn OFF the power and perform the set-

up again after checking [Checking items]

below.

d

d d

d

(Caution) Do not turn OFF the power and close/open the smart media cover during the work.

The main unit may be broken.

The procedure above completes

the replacing work of application

software.

Checking items

1 Smart media cover is opened during the data communication from the smart media.

2 Data of the smart media is not correct. Or, there is no data file.

3 Contact of the smart media is dirty. Contact is defective.

– 59 –

Data edit screen



2) Press key .

3) Press key .


4) Press key .

5) Press key .

d

d

d

(3) Re-setup of main program

When you have purchased the single unit of IP-200 operation panel, the smart media card is packed together.You can perform re-setup of the main program of MAIN circuit board on the control box side by using thissmart media card.It is necessary that the main program and panel program have to match with each other.If not, there is a possibility that trouble such as Error "E703 or E704" occurs. Be sure to perform setup byusing the smart media card which is packed together.

1. When panel program matches with main programPerform the work by the procedure below when performing version-up of the main program by using thesmart media card.1) First, turn ON the power.2) Insert the smart media card into the operation panel.3) Perform operation by the procedure displayed in the screen below.

– 60 –


6) Press key .


7) Press key and select download


8) Press key .


9) Press key .


d

d

d

d

d

– 61 –

Screen during data writing


Screen of end of data writing




below.

d

d





software.

Checking items




– 62 –

Error screen

1) Press key .


2) Press key .


3) Press key .

4) Press key .

d

d

d

2. When panel program does not match with main program and an error occurs

Perform the work by the procedure below when replacing the main program in case trouble such as Error

"E703", "E704", etc. occurs.

1) First, turn ON the power. Error screen (E703 or E704) is displayed after turning ON the power.


3) Perform operation by the procedure displayed in the screen below.

– 63 –


6) Press key .


7) Prees key and select the download


8) Press key .


9) Press key .


d

d

d

d

d

– 64 –







below.

d

d





software.

Checking items




– 65 –

Data edit screen



2) Press key .

3) Press key .


4) Press key .

5) Press key .

d

d

d

(4) Re-setup of servo program

Perform the work by the procedure below when rewriting the servo program in the same way of “Re-setup of

main program”.

1. When main program matches with servo program

Perform the work by the procedure below when making the servo program version-up by using the smart

media card.

1) First, turn ON the power. Normally, the sewing ready screen is displayed.



– 66 –


6) Press key .




8) Press key .


9) Press key .


d

d

d

d

d

– 67 –







below.

d

d





software.

Checking items




– 68 –

Error screen

1) Press key .


2) Press key .


3) Press key .

4) Press key .

d

d

d

2. When panel program does not match with main program and an error occurs

Perform the work by the procedure below when replacing the main program in case trouble such as Error

"E703", "E704", etc. occurs.

1) First, turn ON the power. Error screen (E703 or E704) is displayed after turning ON the power.



– 69 –


5) Press key .




7) Press key .


8) Press key .


d

d

d

d

d

– 70 –







below.

d

d





software.

Checking items




– 71 –

(5) When using smart media other than that which has been packedtogether

When copying the contents of the smart media card which is packed together to the other smart media,

create the directory structure mentioned below with the personal computer after formatting the smart media

to be the copy destination with IP-200.

For the formatting procedure of the smart media, read "USING COMMUNICATION FUNCTION" of Instruction

Manual.

Save program file (.prg) and image file

(.bin) corresponding to the machine

model of the aforementioned folder name.

ROUTE DIRECTORY

¥¥

PROG

DP2100

Make the folder name the machine model name.

The example above is in case of DP-2100.

However, do not put "-" (hyphen) of the machine

model name.

－ 72 －

6. INITIALIZING THE BACKUP DATA

Perform the work in the order of the procedures below in order to return the backup data which are memorized

in the sewing machine to the status at the time of delivery.

1) Press down shirring release switch 1, press down knee switch for step changeover 2, and turn ON power

switch 3 with auxiliary pedal 4 depressed.

2) In a short time, the buzzer sounds, and release the respective switches 3, 1 and 2, and auxiliary pedal 4.

3) After a few minutes has passed, E001 "MAIN EEP-ROM initialization contact of MAIN p.c.b." is displayed on

the panel.

4) Turn OFF power switch 3.

5) When power switch 3 is turned ON again, the data which have been set up to now are initialized and

returned to the status (sample pattern only) at the time of delivery .

Backup data to be initialized are sewing data, and all data which have been set in the mode screen (memory

switch, counter, check program, etc.)

However, thread tension data (tension during operation. tension during waiting and base tension) cannot be

initialized.

3

4

1

2

－ 73 －

7. SEWING DATA LIST

No. Item Setting range Edit unit Initial display

Selection of gents and ladies (Fully-automatic only)

Select from two kinds of gents and ladies.

: Gents : Ladies

Shirring amount increase/decrease setting

Increase/decrease value of the shirring amount

of the whole of the pattern is set.

Sewing size setting (Fully-automatic only)

Sewing size is set. Here, the description is

in case of Japanese gents. Size value changes

in accordance with the country classes.

Sewing pitch setting

Pitch at the time of sewing is set.

Length between steps setting

(Fully-automatic only)

Length of each step is set.

Grading value setting

(Full-automatic only)

Offset value at the time of grading is set.

Compensation thread tension setting

Increase/decrease of thread tension value

in terms of the set value of needle thread

tension is set.

Compensation pitch setting

Increase/decrease value in terms of the

sewing pitch set with is set.

Start position change

Start position of the program is changed.

Mirroring

Mirroring of the program of one sleeve is

performed and the program of the other

sleeve is created.

– – –

(Numerical

value input)

-50 to 50

(Ratio input)

-95 to 95

2 to 16

1.5 to 6.0

1.0 to 255.0

0 to 255

-200 to 200

-4.5 to 4.5

1 to 15

– – –

– – –

1

5%

1 size

0.1mm

0.1mm

0.1mm

1

0.1mm

1

– – –

Gents

0

0%

No. 5

In case of

Japanese

gents

2.0mm

Without

0mm

0

0mm

1

– – –

This list is the list of sewing data to set for every pattern.

"Semi-automatic selection and fully-automatic selection"

－ 74 －


Compensation shirring amount setting

Number of stitches to increase/decrease the

shirring amount immediately after changing

over the step and the shirring amount are set.

Addition of step

A new step is added to the rear of the

selected step.

Deletion of step

The selected step is deleted.

Number of

stitches of

compensation

0 to 15

Compensation

shirring

amount

-30 to 30

– – –

– – –

1 stitch

1

– – –

– – –

0 stitch

0

– – –

– – –

－ 75 －


Auxiliary pedal motion selection

The motion is selected from two kinds of step mode and

interlocking mode.

: Step mode

: Interlocking mode

Auxiliary feed mode selection

Motion mode of the auxiliary feed is selected.

: Manual numerical value input

: Manual ratio input

: Interlocking numerical value input

: Interlocking ratio input

Sewing pitch setting

Pitch at the time of sewing is set.

Auxiliary feed interlocking mode setting

Setting of the interlocking mode is performed

when the interlocking numerical value input or

the interlocking ratio input is selected under

Auxiliary feed mode selection.

Shirring amount range setting

The upper limit value and lower limit value of

shirring amount is set when the interlocking

mode is selected under Aux i l ia ry

pedal motion selection.

Compensation thread tension setting

Increase/decrease of tension value in terms

of the set value of needle thread tension is

set.

– – –

– – –

1.5 to 6.0

– – –

-4 to 35

-200 to 200

– – –

– – –

0.1mm

– – –

1

1

"Manual selection"

Interlocking

mode

Manual

numerical

value input

2.0mm

– – –

Lower limit

value -4

Upper limit

value 35

0

－ 76 －

8. MEMORY SWITCH DATA LIST1) Level 1

Memory switch data (level 1) are the motion data that the sewing machine has in common and the data that

operate on all sewing patterns in common.


Reverse stitching at the sewing start selection

Select from among three kinds of without, single and double.

: Without : Single : Double

Reverse stitching at the sewing end selection

Select from among three kinds of without, single and double.

: Without : Single : Double

Number of stitches of reverse stitching

Number of stitches at the sewing start and

that at the sewing end are set.

Reverse stitching speed

Speed of the reverse stitching at the

sewing start and the sewing end is set.

Needle position at the time of stop

Needle position at the time of temporary stop during sewing

is selected.

: DOWN : UP

Number of stitches of soft start setting

Number of stitches of soft start at the

sewing start is set.

Soft start speed setting

Speed of soft start at the sewing start is

set.

Condensation sewing selection

Select from among four kinds of without, start only, end only

and both start and end.

: Without : Start

: End : Both

Number of stitches of condensation

Number of stitches of condensation sewing

is set.

Condensation speed setting

Speed of condensation sewing is set.

Base tension in waiting state

Base tension in waiting state (except during

sewing) is set.

– – –

– – –

0 to 19

200 to 3000

– – –

0 to 9

200 to 2000

– – –

0 to 9

200 to 2000

0 to 200

– – –

– – –

1 stitch

10rpm

– – –

1 stitch

10rpm

– – –

1 stitch

10rpm

1

Without

Without

5 stitches

800rpm

DOWN

0 stitch

800rpm

Without

0 stitch

800rpm

20

－ 77 －


Compensation tension mode selectionSelect from among manual (numerical value), manual (level)and automatic.

: Numerical value : Level

: Automatic

For setting procedure of the manual (numerical value), referto "Explanation of compensation tension (numerical value)"of the Instruction Manual.

Compensation tension manual (level) setting

This item is displayed when "manual (level)" is selected in

Compensat ion tension mode select ion.Compensation tension value for each level is set./ Refer to "Explanation of compensation tension manual(level)" of the Instruction Manual.

Compensation tension automatic setting

This item is displayed when "automatic" is selected in

Compensation tension mode selection. Compensation tension

value for each shirring amount range is set.

/ Refer to "Explanation of compensation thread tension

automatic" of the Instruction Manual.

Shirring smoothing function setting

Use of shirring smoothing function is selected.

/ Refer to "Explanation of the shirring smoothing function"

of the Instruction Manual.

: Unused : Us

Number of stitches of shirring smoothing

function setting

Number of stitches of shirring smoothing function

is set.

Shirring smoothing function shirring amount

setting

Shirring amount of shirring smoothing function is set.

Data storing function at the time of sewingWhether storing data or not when data is changed in thesewing screen is selected.

: No storing : Storing

Sound output at the time of changeover of step selectionWhether buzzer sounds or not when step is changed overis selected.

: No sound : Sound

Auxiliary pedal use selectionWhether auxiliary pedal is used or not is selected.

: Unused : Use

Shirring release switch use selection

Whether shirring release switch is used or not is selected.

: Unused : Use

– – –

– 200 to 200

Shirring

amount

– 4 to 35

Compensation

tension value

– 200 to 200

– – –

0 to 99

1 to 35

– – –

– – –

– – –

– – –

– – –

1

– – –

– – –

1 stitch

1

– – –

– – –

– – –

– – –

Manual

(numerical

value)

Level 1) 10

Level 2) 20

Level 3) 30

– – –

Unused

1 stitch

1

Storing

No sound

Use

Use

－ 78 －


Knee switch use selection

Whether knee switch for step changeover is used or not is

selected.

: Unused : Use

Shirring amount interlock function at the time of change

of pitch selection

Whether shirring amount set to each step at the time of

change of pitch is corrected or not according to the change

amount of pitch is selected.

: Not correct : Correct

Screen changeover function at the time of thread

trimming on the way selection

Whether screen is changed over or not when thread trimming

is performed at the step other than the last step is selected.

: No changeover : Changeover

Auxiliary feed input mode selection

Whether auxiliary feed input is performed with offset

numerical value or % ratio is selected.

: Numerical value : Ratio

Shirring amount increase/decrease input mode

Whether Shirring amount increase/decrease valueinput is performed with offset numerical value or with % ratio

is selected.

: Numerical value : Ratio

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

– – –

Use

Not

corrected

No

changeover

Numerical

value

Numerical

value

2) Level 2

Memory switch data (level 2) can be edited when pressing MODE switch for as long as 6 seconds.


Presser position after thread trimming selection

Position of the presser after thread trimming is set.

: DOWN : UP

Max. sewing speed setting

Max. sewing speed of the sewing machine

is set.

Sewing speed at low speed setting

Min. sewing speed of the sewing machine is

set.

Sewing speed of thread trimming setting

Sewing speed at the time of thread trimming

is set.

– – –

200 to 3500

200 to 400

100 to 250

– – –

10rpm

5rpm

5rpm

UP

3500rpm

200rpm

160rpm

－ 79 －

Pedal curve selection function

Curve of the number of rotation of the sewing machine in

terms of pedal depressing amount is selected.

0 : Straight line 1 : Square

2 : Square root

Reverse rotation to lift needle after thread trimming

function selection

Sewing machine is rotated in the reverse direction after

thread trimming, and needle bar is lifted near to its upper

dead point.

: Ineffective : Effective

– – –

– – –

– – –

– – –

Straight line

Ineffective

Pedal stroke

0

2

1

Number of

rotation

Flicker reduction function setting

This function is set when hand lamp flickers.

0 : Without flicker reduction function

1 : Less effective / 8 : more effective

Rotation start pedal stroke setting

Stroke from the neutral position of pedal to

sewing machine rotation start position is set.

Pedal low speed section

Section from pedal neutral position to sewing

machine acceleration start position is set.

Pedal presser lifting start position

Section from pedal neutral position to cloth

presser lifting start position is set.

Thread trimming start pedal stroke

Section from pedal neutral position to thread

trimming start position is set.

Pedal max. number of rotation reach

stroke

Section from pedal neutral position to max.

number of rotation reach position is set.

Pedal neutral position compensation

Compensation value of neutral point of pedal

is set.

Auto-lifter lifting holding time

Waiting time of lifting the presser lifter is set.


0 to 8

1.0 to 5.0

1.0 to 10.0

– 1.0 to –6.0

– 1.0 to –6.0

1.0 to 15.0

– 15 to 15

10 to 600

1

0.1mm

0.1mm

0.1mm

0.1mm

0.1mm

1

10sec

0

3.0mm

6.0mm

– 2.1mm

– 5.1mm

15.0mm

– 1

60sec

－ 80 －


Reverse stitching at the sewing start A/M changeover

function selection

Designation of sewing speed of reverse stitching at the

sewing start is selected.

: In accordance with the speed by manual

operation of pedal or the like

: In accordance with the speed set by

Reverse stitching speed

Stop function immediately after reverse stitching at the

sewing start selection

Function to make the sewing machine stop once when

reverse stitching at the sewing start is completed.

: Without function : With function

Condensation/EBT changeover speed

Initial speed at the time of start of EBT

(reverse stitching at the sewing end) is set.

Retry function selection

Function to make the sewing machine rotate again in the

normal direction with max. torque after rotating the machine

in the reverse direction once when the sewing machine is

locked is selected.

: Without retry function

: With retry function

– – –

– – –

0 to 250

– – –

– – –

– – –

10rpm

– – –

Speed by

manual

operation

Without

function

170rpm

Without retry

function

Sewing machine start-up curve selection

Start-up curve of the sewing machine is selected.

: Normal curve : More sharp curve

Presser position at the time of stop of the sewingmachine selectionPosition of the presser foot when the sewing machinetemporarily stopped is selected.

: DOWN : UP

Size class settingInitial value (size country class, gents'/ladies' selection, and basic size) whencreating a new pattern is set./ Refer to "Explanation of the size class".of the Instruction Manual.

Initial pitch setting

Initial value of pitch when creating a new

pattern is set.

Bottom feed amount compensation

value setting

Compensation value of set value and

actual value of bottom feed amount is set.

– – –

– – –

– – –

1.5 to 6.0

–1.0 to 1.0

– – –

– – –

– – –

0.1mm

0.1mm

Normal curve

DOWN

Japan

Gentlemen

No. 6

2.0mm

0mm

－ 81 －


Top feed amount compensation value

setting

Compensation value of set value and

actual value of top feed amount is set.

Thread tension curve selection

Inclination of thread tension curve is selected.

: Standard : Gentle (thin materials)

Reverse stitching button display selection

Display of reverse stitching button in the sewing screen is

selected.

: Non-display : Display

Dish-rise timing setting

Disk-rise timing from the start of thread

trimming is set.

Length of remaining thread setting

Length of remaining needle thread at the

time of thread trimming is set. When the

set value is changed, the disk-close timing

from the disk-rise timing changes.

–1.0 to 1.0

– – –

– – –

0 to 40

0 to 40

0.1mm

– – –

– – –

1

1

0mm

Standard

Non-display

18

5

(Caution) When the contents of level 2 have been changed, the screen becomes POWER OFF screen

after pressing CLOSE button . Accordingly turn ON the power again after turning

OFF the power once.

"POWER OFF screen"

－ 82 －

9. ERROR CODE LIST

Contact of initialization of main shaft

EEP-ROM of MAIN p.c.b.

When data is not written in EEP-ROM or data

is broken, data is automatically initialized and

the initialization is informed.

Contact of initialization of main EEP-ROM

of MAIN p.c.b.




Main shaft motor encoder defectiveness

Angle counter of needle UP detection has

exceeded the value equivalent to 1.1 turns.

Angle counter of needle DOWN detection has


Main shaft motor needle DOWN detection

defectiveness

Angle counter of needle UP detection has not




Main shaft motor needle UP detection

defectiveness

Angle counter of needle UP detection has




Contact of initialization of machine head

EEP-ROM of the circuit board mounted

on the machine head




Main shaft motor-lock

When large needle resistance sewing

product is sewn

External media not inserted

External media is not inserted.

Turn OFF the

power.

Turn OFF the

power.

Turn OFF the

power.

Turn OFF the

power.

Turn OFF the

power.

Turn OFF the

power.

Turn OFF the

power.

P o s s i b l e t o

recover by reset.Previous screen

E000

E001

E003

E004

E005

E006

E007

E011

Error code Description of error How to recover Place of recoveryPictograph

－ 83 －

Read error

Data read from external media cannot be

performed.

Write error

Data write from external media cannot be

performed.

Write protect

External media is in the write prohibition state

Format error

Format cannot be performed.

External media capacity over

Capacity of external media is short.

File No. error

Designated file is not in smart media.

Smart media error

Lid of smart media slot is open.

Sewing data error

When sewing data is broken or revision is

old.

Confirmation of tilt of machine head

When tilt of machine head sensor is OFF.

P o s s i b l e t o

recover by reset.

P o s s i b l e t o

recover by reset.

P o s s i b l e t o

recover by reset.

P o s s i b l e t o

recover by reset.

P o s s i b l e t o

recover by reset.

P o s s i b l e t o

recover by reset.

P o s s i b l e t o

recover by reset.

Turn OFF the

power.

Turn OFF the

power.

Previous screen

Previous screen

Previous screen

Previous screen

Previous screen

Previous screen

Previous screen

E012

E013

E014

E015

E016

E022

E029

E062

E302

E303 Main shaft semilunar plate sensor error

Semilunar plate of sewing machine motor is

abnormal.

Turn OFF the

power.


－ 84 －

Abnormality of control

CPU performed processing other than

supposed.

Panel is connected to the machine other

than supposed. (Machine type error)

When machine type code of system is

improper in case of initial communication.

Nonagreement of system version

When version of system software is improper

in case of initial communication.

Main motor hole sensor defectiveness or

position sensor defectiveness

When motor hole sensor error signal

(UVWE) is detected with the motor locked

(2 seconds or more have passed at 20 rpm

or less).

Reverse rotation of main shaft motor

When motor has continued to rotate 40 times

or more in the reverse direction as against

the control direction at 500 rpm or more

during motor running (excluding at the time

of holding).

Phase-lack of power

When 400 ms or more of power phase-lack

signal (PHE) is detected after 2 seconds of

phase-lack observation invalid time passed

from turning ON the power.

Power instantaneous cut detection

When power instantaneous cut detection

signal (PWF) is detected.

Solenoid power short-circuit

When solenoid power short-circuit signal

(PWSH) (CPLD internal signal) is detected

while power phase-lack signal (PHE) is not

detected after 2 seconds of phase-lack

observation invalid time passed from turning

ON the power.

Turn OFF the

power.

Possible to

rewrite program

after pressing

down

communication

switch.

P o s s i b l e t o

rewrite program

after pressing

down

communication

switch.

Turn OFF the

power.

Turn OFF the

power.

Turn OFF the

power.

Turn OFF the

power.

Turn OFF the

power.

C o m m u n i c a t i o n

screen

E702

E703

E704

E731

E733

E801

E802

E810


－ 85 －

Overvoltage

When power overvoltage signal (OVL) which

is output when input power is 280V or more

is detected.

Low voltage

When low voltage signal (LVL) which is

output when input power is 150V or less is

detected.

Abnormality of stepping motor power

When stepping motor power abnormality

signal (LVPMP) which is output when the

stepping motor power, 48V, fluctuates -15%

or more when turning ON the power is

detected.

Abnormality of communication between

operation panel and main CPU

When abnormal i t y occurs in da ta

communication.

Abnormality of communication between

main CPU and main shaft CPU


communication.

Failure of communication between

operation panel and personal computer


communication.

Turn OFF the

power.

Turn OFF the

power.

Turn OFF the

power.

Turn OFF the

power.

E811

E813

E903

E915

E916

E917

E918

E920

E922

E924

Abnormality of heat sink temperature for

MAIN p.c.b.

When temperature of heat sink for MAIN

p.c.b. is 85˚C or more.

CPLD writing abnormality

When 1 bit each is written in the test port

and it does not agree with Verfy when turning

ON the power.

Main shaft motor control impossible

When the number of rotation of measuring

exceeds 50 ms or more than the upper limit

value (3,500 rpm).

Main shaft drive trouble

When motor driver error signal (GTRE) is

detected while motor overcurrent signal

(OCL1) is not detected with the motor locked

(2 seconds or more have passed at 20 rpm

or less).

Turn OFF the

power.

P o s s i b l e t o

recover by reset.

Turn OFF the

power.

Turn OFF the

power.

Turn OFF the

power.

Turn OFF the

power.


－ 86 －

Error code Description of error How to recover Place of recovery

CPLD reading abnormality

When input signal from CPLD is read twice

and they do not agree with each other even

when trying 10 ms or more when turning ON

the power.

Main shaft EEP-ROM trouble

When data writing to EEP-ROM cannot be

performed.

Main EEP-ROM trouble


performed.

Head EEP-ROM trouble


performed.

Turn OFF the

power.

Turn OFF the

power.

Turn OFF the

power.

Turn OFF the

power.

E941

E942

E943

E946

Pictograph

－ 87 －

1. T

hrea

d br

eaka

ge

2. S

titch

ski

ppin

g

Tro

ub

leC

ause

(1)

Cau

se (

2)In

spec

tin

g o

rder

an

d a

dju

stin

g p

roce

du

re

10. T

RO

UB

LE

S A

ND

CO

RR

EC

TIV

E M

EA

SU

RE

S(1

) M

ech

anic

al p

arts 1-

1) T

hrea

d pa

th is

bad

.

1-2)

Nee

dle

thre

ad te

nsio

n is

impr

oper

.

1-3)

Adj

ustm

ent o

f thr

ead

take

-up

sprin

g is

impr

oper

.

1-4)

Nee

dle

is b

ad.

1-5)

Par

ts r

elat

ed to

the

hook

are

bad

.

2-1)

Nee

dle

is b

ad.

1-A

) T

hrea

d pa

th is

not

sm

ooth

.

1-B

) T

hrea

d pa

th h

as fl

aws.

1-C

) T

hrea

d pa

th h

as b

urrs

.

2-A

) N

eedl

e th

read

tens

ion

is to

o hi

gh o

r to

o lo

w.

3-A

) S

trok

e is

too

larg

e or

too

smal

l.

3-B

) S

prin

g te

nsio

n is

too

high

or

too

low

.

4-A

) N

eedl

e is

ben

t.

4-B

) N

eedl

e ha

s fla

ws.

4-C

) N

eedl

e tip

is b

lunt

.

4-D

) In

stal

ling

dire

ctio

n of

nee

dle

is im

prop

er.

4-E

) N

eedl

e in

term

s of

thre

ad u

sed

is to

o th

in o

r to

o th

ick.

4-F

) N

eedl

e tip

is to

o sh

arp.

5-A

) T

hrea

d pa

th o

f the

hoo

k ha

s fla

ws.

5-B

) B

lade

poi

nt o

f the

hoo

k is

blu

nt o

r w

orn

out.

1-A

) N

eedl

e is

ben

t.

1-B

) In

stal

ling

dire

ctio

n of

nee

dle

is im

prop

er.

1-C

) N

eedl

e tip

is b

lunt

.

1-D

) N

eedl

e in

term

s of

thre

ad u

sed

is to

o th

in o

r to

o th

ick.

To

the

next

pag

e

Fin

ish

the

thre

ad p

ath.

Fin

ish

the

thre

ad p

ath.

Cor

rect

the

thre

ad p

ath.

Adj

ust t

he te

nsio

n to

the

prop

er te

nsio

n.

Adj

ust t

he s

trok

e (s

tand

ard

: 10

to 1

2 m

m).

Adj

ust t

he te

nsio

n.

Rep

lace

the

need

le.

Rep

lace

the

need

le.

Rep

lace

the

need

le.

Inst

all t

he n

eedl

e ag

ain.

Rep

lace

the

need

le.

Cha

nge

the

need

le to

the

ball-

poin

t nee

dle.

Fin

ish

the

thre

ad p

ath.

Cor

rect

the

blad

e po

int o

r re

plac

e th

e ho

ok.

Rep

lace

the

need

le.

Inst

all t

he n

eedl

e ag

ain.

Rep

lace

the

need

le.

Rep

lace

the

need

le.

－ 88 －

Tro

ub

leC

ause

(1)

Cau

se (

2)In

spec

tin

g o

rder

an

d a

dju

stin

g p

roce

du

re

3. L

oose

stit

ches

2-2)

Par

ts r

elat

ed to

the

hook

are

bad

.

2-3)

Nee

dle

thre

ad te

nsio

n is

too

high

.

2-4)

Adj

ustm

ent o

f thr

ead

take

-up

sprin

g is

impr

oper

.

3-1)

Thr

ead

tens

ion

is to

o lo

w.

3-2)

Adj

ustm

ent o

f thr

ead

take

-up

sprin

g is

impr

oper

.

3-3)

Thr

ead

take

-up

leve

r st

roke

is to

o la

rge.

3-4)

Par

ts r

elat

ed to

the

hook

are

bad

.

3-5)

Thr

ead

path

is b

ad.

3-6)

Bob

bin

or b

obbi

n ca

se is

bad

.

Fro

m th

e pr

evio

us p

age

2-A

) B

lade

poi

nt o

f the

hoo

k is

blu

nt o

r w

orn

out.

2-B

) H

ook

timin

g is

impr

oper

.

2-C

) H

eigh

t of t

he n

eedl

e ba

r is

impr

oper

.

2-D

)Cle

aran

ce b

etw

een

the

need

le a

nd th

e bl

ade

poin

t of

hook

is im

prop

er.

3-A

) T

ensi

on is

too

high

.

4-A

) S

trok

e is

too

larg

e.

4-B

) T

ensi

on is

too

high

.

2-A

) S

trok

e is

too

smal

l.

2-B

) T

ensi

on is

too

low

.

4-A

) H

ook

timin

g is

too

fast

.

4-B

) H

ook

timin

g is

too

slow

.

4-C

) H

ook

is b

ad (

scra

tch)

.

5-A

) T

hrea

d pa

th is

not

sm

ooth

.

5-B

) T

hrea

d pa

th h

as fl

aws.

5-C

) T

hrea

d pa

th h

as b

urrs

.

6-A

)Bob

bin

thre

ad is

cau

ght i

n bo

bbin

or

bobb

in c

ase

due

to im

prop

er fi

tting

of b

obbi

n an

d bo

bbin

cas

e.

Cor

rect

the

blad

e po

int o

f hoo

k or

rep

lace

the

hook

.

Per

form

adj

ustm

ent.

Adj

ust t

he n

eedl

e ba

r up

or d

own

in te

rms

of th

e bl

ade

poin

t of t

heho

ok.

Mak

e th

e cl

eara

nce

as s

mal

l as

poss

ible

.

Dec

reas

e th

e te

nsio

n.

Dec

reas

e th

e st

roke

.

Dec

reas

e th

e te

nsio

n.

ncre

ase

the

tens

ion.

Incr

ease

the

stro

ke.

Incr

ease

the

tens

ion.

Mov

e th

e ar

m th

read

gui

de A

to th

e rig

ht a

nd d

ecre

ase

the

supp

lyam

ount

of t

hrea

d by

mea

ns o

f the

thre

ad ta

ke-u

p le

ver.

In c

ase

of c

otto

n th

read

and

spu

n th

read

, adj

ust t

he ti

min

g to

the

stan

dard

or

dela

y th

e tim

ing

a lit

tle.

In c

ase

of s

ynth

etic

thr

ead,

adj

ust

the

timin

g to

the

sta

ndar

d or

adva

nce

the

timin

g a

little

.

Rep

lace

the

hook

.

Fin

ish

the

thre

ad p

ath.

Fin

ish

the

thre

ad p

ath.

Cor

rect

the

thre

ad p

ath.

Rep

lace

the

bobb

in o

r th

e bo

bbin

cas

e.

To

the

next

pag

eT

o th

e ne

xt p

age

－ 89 －

Tro

ub

leC

ause

(1)

Cau

se (

2)In

spec

tin

g o

rder

an

d a

dju

stin

g p

roce

du

re

4.S

ever

al s

titch

es s

kip

at th

est

art o

f sew

ing.

3-7)

Thr

ead

tens

ion

is im

prop

er.

4-1)

Nee

dle

thre

ad r

emai

ning

at n

eedl

e tip

afte

r th

read

trim

min

g is

too

shor

t.

4-2)

Nee

dle

thre

ad is

not

sco

oped

with

the

blad

e po

int

of h

ook.

4-3)

Bob

bin

thre

ad a

t the

sta

rt o

f sew

ing

is to

o sh

ort.

4-4)

Nee

dle

thre

ad a

nd b

obbi

n th

read

are

diff

icul

t to

bekn

otte

d at

the

star

t of s

ewin

g.

Fro

m th

e pr

evio

us p

age

6-B

) W

indi

ng o

f bob

bin

thre

ad is

impr

oper

.

6-C

) T

hrea

d te

nsio

n sp

ring

of th

e bo

bbin

cas

e is

impr

oper

.

6-D

) B

obbi

n th

read

in th

e bo

bbin

cas

e ru

ns id

le.

7-A

) T

hrea

d te

nsio

n di

sk is

ris

en.

1-A

)Nee

dle

thre

ad te

nsio

n is

too

high

at t

he ti

me

of th

read

trim

min

g si

nce

ther

e is

abn

orm

ality

in th

e ne

edle

thre

adro

ute.

1-B

)Thr

ead

tens

ion

give

n by

the

thre

ad te

nsio

n co

ntro

ller

No.

1 is

too

high

.

1-C

)Ris

e of

the

thre

ad te

nsio

n di

sk N

o. 2

at t

he ti

me

of th

read

trim

min

g is

inco

mpl

ete.

1-D

)Thr

ead

trim

min

g tim

ing

is to

o fa

st a

nd th

e m

ovin

g kn

ifem

oves

whi

le th

read

s ar

e no

t sep

arat

ed.

2-A

) T

imin

g be

twee

n ne

edle

and

hoo

k is

impr

oper

.

2-B

)Ten

sion

or

mom

entu

m o

f the

thre

ad ta

ke-u

p sp

ring

isto

o hi

gh o

r to

o la

rge.

2-C

) B

lade

poi

nt o

f the

hoo

k is

wor

n ou

t.

2-D

) In

stal

latio

n of

the

need

le is

impr

oper

.

3-A

)End

of b

obbi

n th

read

is d

raw

n in

the

bobb

in c

ase

due

toth

e id

ling

of th

e bo

bbin

.

3-B

)Bob

bin

thre

ad is

cut

sho

rt s

ince

ther

e ar

e fla

ws

in th

eho

ok.

4-A

)Spe

ed a

t the

sta

rt o

f sew

ing

is to

o fa

st a

nd n

eedl

e th

read

and

bobb

in th

read

are

diff

icul

t to

be in

terla

ced.

Ten

sion

of t

he b

obbi

n w

inde

r is

too

high

or

too

low

.

Rep

lace

the

bobb

in c

ase.

Incr

ease

the

sprin

g pr

essu

re o

f the

idle

-pre

vent

ion

sprin

g.

Adj

ust t

he th

read

tens

ion

disk

to th

e pr

oper

pos

ition

.

Che

ck th

e ne

edle

thre

ad r

oute

and

cor

rect

the

posi

tion

of th

read

gui

de o

fth

e th

read

sta

nd.

Dec

reas

e th

e te

nsio

n of

thre

ad te

nsio

n co

ntro

ller

No.

1.

Per

form

che

ckin

g an

d ad

just

men

t of t

he p

arts

rel

ated

to th

e th

read

ris

e.

Che

ck a

nd a

djus

t the

thre

ad tr

imm

er c

am ti

min

g.

Che

ck t

he h

eigh

t of

the

nee

dle

bar

and

adju

st t

he h

eigh

t to

the

sta

ndar

dad

just

men

t.

Dec

reas

e th

e te

nsio

n an

d de

crea

se t

he m

omen

tum

(st

anda

rd :

10

to 1

2m

m).

Cor

rect

the

blad

e po

int o

r re

plac

e th

e ho

ok.

Adj

ust t

he in

clin

atio

n of

nee

dle

or r

epla

ce th

e ne

edle

in c

ase

it is

ben

t.

Incr

ease

the

sprin

g pr

essu

re o

f the

idle

-pre

vent

ion

sprin

g.

Incr

ease

the

bobb

in th

read

tens

ion.

Cor

rect

the

flaw

of t

he h

ook

or r

epla

ce th

e ho

ok.

Dec

reas

e th

e sp

eed

at th

e st

art o

f sew

ing.

Fro

m th

e pr

evio

us p

age

－ 90 －

Tro

ub

leC

ause

(1)

Cau

se (

2)In

spec

tin

g o

rder

an

d a

dju

stin

g p

roce

du

re

5.T

hrea

d sl

ips

off t

he n

eedl

e at

the

star

t of s

ewin

g.

6.Lo

ose

stitc

hes

at th

e st

art o

fse

win

g

7.N

eedl

e th

read

is n

ot tr

imm

ed.

(Bob

bin

thre

ad is

trim

med

.)

8.B

obbi

n th

read

is n

ot tr

imm

ed.

(Nee

dle

thre

ad is

trim

med

.)

1-A

)Thr

ead

is c

ut w

ith c

ount

er k

nife

onl

y in

cas

e sh

arpe

ning

of c

ount

er k

nife

is n

ot g

ood

(too

sha

rp).

1-B

) T

here

are

flaw

s on

the

mov

ing

knife

or

the

hook

.

2-A

)Thr

ead

trim

min

g tim

ing

is to

o fa

st a

nd e

ven

the

thre

adon

the

need

le s

ide

is c

ut.

2-B

) T

hrea

d ris

e is

not

per

form

ed.

3-A

)Spe

ed a

t the

sta

rt of

sew

ing

is to

o fa

st, a

nd n

eedl

e th

read

and

bobb

in th

read

are

diff

icul

t to

be in

terla

ced.

1-A

)Bob

bin

thre

ad te

nsio

n at

the

star

t of s

ewin

g is

too

low

due

to id

ling

of th

e bo

bbin

.

1-B

) T

ensi

on o

f bot

h ne

edle

and

bob

bin

thre

ads

is to

o lo

w.

1-A

) In

stal

latio

n of

the

need

le is

impr

oper

.

1-B

) M

omen

tum

of t

hrea

d ta

ke-u

p sp

ring

is to

o la

rge.

1-C

) H

ook

adju

stm

ent i

s im

prop

er.

2-A

) Cut

ting

blad

e se

ctio

ns o

f mov

ing

knife

and

cou

nter

kni

fear

e no

t clo

sely

fit a

t the

tim

e of

thre

ad tr

imm

ing.

(Ins

talli

ng a

ngle

and

pos

ition

of t

he c

ount

er k

nife

are

not f

it to

the

cutti

ng b

lade

sec

tion

of th

e m

ovin

g kn

ife.)

5-1)

Nee

dle

thre

ad le

ngth

rem

aini

ng a

t the

nee

dle

tipaf

ter

thre

ad tr

imm

ing

is u

neve

n.

5-2)

Thr

ead

slip

s of

f the

nee

dle

sim

ulta

neou

sly

with

thre

ad tr

imm

ing.

5-3)

Nee

dle

thre

ad a

nd b

obbi

n th

read

are

diff

icul

t to

bekn

otte

d at

the

star

t of s

ewin

g.

6-1)

Nee

dle

thre

ad te

nsio

n at

the

star

t of s

ewin

g is

too

low

.

7-1)

Stit

ch s

kipp

ing

at th

e la

st s

titch

7-2)

A p

art o

f the

cut

ting

blad

e se

ctio

n of

the

knife

is n

otsh

arp.

7-3)

Thr

ead

was

te c

olle

cts

on m

ovin

g kn

ife, c

ount

erkn

ife a

nd c

ount

er k

nife

gua

rd p

late

, and

thre

adha

ndlin

g is

impr

oper

.

8-1)

Thr

ead

trim

min

g tim

ing

is d

elay

ed a

nd th

e m

ovin

gkn

ife c

anno

t be

hand

led.

To

the

next

pag

e

Sha

rpen

aga

in o

r re

plac

e th

e co

unte

r kn

ife.

Cor

rect

the

flaw

or

repl

ace

the

corr

espo

ndin

g pa

rt.

Adj

ust t

he th

read

trim

min

g tim

ing.

Che

ck a

nd a

djus

t the

par

ts r

elat

ed to

the

thre

ad r

ise.

Dec

reas

e th

e sp

eed

at th

e st

art o

f sew

ing.

Incr

ease

the

sprin

g pr

essu

re o

f the

idle

-pre

vent

ion

sprin

g.

Incr

ease

the

tens

ion

of n

eedl

e an

d bo

bbin

thre

ads.

Che

ck th

e in

stal

latio

n of

the

need

le a

nd m

ake

sure

of t

he b

end

of n

eedl

e.

Dec

reas

e th

e m

omen

tum

(st

anda

rd :

10 to

12

mm

).

Che

ck s

titch

ski

ppin

g at

low

spe

ed s

ewin

g an

d pe

rfor

m h

ook

adju

stm

ent.

Rem

ove

the

hook

bas

e, a

nd m

ove

the

mov

ing

knife

to c

ut th

ree

piec

es o

fsp

un #

50.

It is

OK

whe

n th

ree

piec

es a

re c

ut e

venl

y. I

f no

t, s

harp

en t

heco

unte

r kn

ife o

r co

rrec

t the

incl

inat

ion

of th

e to

p en

d of

cou

nter

kni

fe.

Adj

ust t

he in

stal

ling

posi

tion

of c

ount

er k

nife

.

Per

form

cle

anin

g.

Re-

adju

st th

e tim

ing.

－ 91 －

Tro

ub

leC

ause

(1)

Cau

se (

2)In

spec

tin

g o

rder

an

d a

dju

stin

g p

roce

du

re

9. M

ovin

g kn

ife is

lock

ed.

10

. N

ois

e f

rom

th

e f

ace

pla

tese

ctio

n

11. V

ibra

tion

is la

rge.

12. N

eedl

e br

eaka

ge.

13. I

rreg

ular

stit

ches

.

1-A

) T

hrea

d tr

imm

er c

am ti

min

g is

impr

oper

.

2-A

) Im

prop

er a

djus

tmen

t

1-A

) Im

prop

er a

djus

tmen

t

2-A

) Im

prop

er a

djus

tmen

t

2-A

) H

ook

driv

ing

shaf

t gea

r

3-A

) Lo

osen

ess

of m

ain

shaf

t thr

ust

3-B

) Lo

osen

ess

of h

ook

driv

ing

shaf

t

1-A

) H

ook

is im

prop

er (

scra

tch

or im

prop

er th

read

pat

h).

2-A

)B

obbi

n th

read

is c

augh

t due

to im

prop

er fi

tting

of b

obbi

nan

d bo

bbin

cas

e.

2-B

) W

indi

ng o

f bob

bin

thre

ad is

impr

oper

.

2-C

) T

hrea

d te

nsio

n sp

ring

of b

obbi

n ca

se is

impr

oper

.

2-D

) B

obbi

n th

read

in th

e bo

bbin

cas

e ru

ns id

le.

2-E

) P

uttin

g w

ay o

f bob

bin

into

the

bobb

in c

ase

8-2)

Thr

ead

was

te c

olle

cts

on m

ovin

g kn

ife, c

ount

erkn

ife a

nd c

ount

er k

nife

gua

rd p

late

, and

thre

adha

ndlin

g is

impr

oper

.

9-1)

Tim

ing

of r

espe

ctiv

e se

ctio

ns is

impr

oper

.

9-2)

Mov

ing

knife

com

es in

con

tact

with

the

coun

ter

knife

gua

rd p

late

.

10-1

)R

olle

r gu

ide

does

not

com

e in

con

tact

with

the

rolle

r.

10-2

)A

mou

nt o

f the

alte

rnat

e ve

rtic

al m

ovem

ent i

s to

ola

rge.

10-3

)N

eedl

e an

d ho

ok in

terf

ere

with

eac

h ot

her

due

toim

prop

er h

ook

adju

stm

ent.

11-1

) M

ain

shaf

t mot

or b

elt t

ensi

on is

impr

oper

.

11-2

) G

ear

back

-lash

is im

prop

er.

11-3

)Lo

osen

ess

of m

ain

shaf

t and

hoo

k dr

ivin

g sh

aft

is la

rge.

12-1

) P

ress

er fo

ot in

terf

eres

with

nee

dle.

12-2

) C

onta

ct w

ith th

e m

ovin

g kn

ife

12-3

) In

terf

eren

ce w

ith th

e ne

edle

hol

e gu

ide

13-1

) P

arts

rel

ated

to th

e ho

ok a

re im

prop

er.

13-2

) B

obbi

n or

bob

bin

case

is im

prop

er.

Per

form

cle

anin

g.

Che

ck a

nd a

djus

t the

thre

ad tr

imm

er c

am ti

min

g.

Cor

rect

the

bend

of t

he c

ount

er k

nife

gua

rd p

late

.

Adj

ust s

o th

at th

e ro

ller

guid

e co

mes

in c

onta

ct w

ith th

e ro

ller.

Adj

ust t

o th

e pr

oper

val

ue (

stan

dard

feed

foot

: 0.

2 to

0.3

mm

).

Che

ck th

e ho

ok a

djus

tmen

t.

Adj

ust t

he m

ain

shaf

t mot

or b

elt t

ensi

on.

Che

ck th

e ba

ck-la

sh.

Che

ck th

e lo

osen

ess

of m

ain

shaf

t thr

ust.

Che

ck th

e lo

osen

ess

of h

ook

driv

ing

shaf

t.

Adj

ust t

he in

stal

ling

posi

tion

of p

ress

er fo

ot.

Adj

ust t

he in

stal

ling

posi

tion

of m

ovin

g kn

ife.

Adj

ust t

he in

stal

ling

posi

tion

of n

eedl

e ho

le g

uide

.

Rep

lace

the

hook

or

corr

ect t

he th

read

pat

h.

Rep

lace

the

bobb

in o

r th

e bo

bbin

cas

e.

Ten

sion

of t

he b

obbi

n w

inde

r is

too

high

or

too

low

.

Rep

lace

the

bobb

in c

ase.

Incr

ease

the

sprin

g pr

essu

re o

f the

idle

-pre

vent

ion

sprin

g.

Che

ck th

e pu

tting

way

.

Fro

m th

e pr

evio

us p

age

To

the

next

pag

e

－ 92 －

Tro

ub

leC

ause

(1)

Cau

se (

2)In

spec

tin

g o

rder

an

d a

dju

stin

g p

roce

du

re

14. M

ater

ial b

ends

.

15.F

eed

pitc

h is

not

obt

aine

d.

16.S

hirr

ing

is n

ot p

erfo

rmed

.

17.S

hirr

ing

is e

xces

sive

lype

rfor

med

.

3-A

) T

hrea

d pa

th is

not

sm

ooth

.

3-B

) T

here

are

flaw

s in

the

thre

ad p

ath.

3-C

) T

here

are

bur

rs in

the

thre

ad p

ath.

4-A

) N

eedl

e th

read

tens

ion

is to

o hi

gh o

r to

o lo

w.

5-A

) S

trok

e is

too

larg

e or

too

smal

l.

5-B

) S

prin

g te

nsio

n is

too

high

or

too

low

.

1-A

) T

op fe

ed b

elt i

s be

nt.

2-A

)H

eigh

t of t

he m

ain

feed

foot

and

the

auxi

liary

feed

foot

is w

rong

.

3-A

) A

uxili

ary

feed

shi

rrin

g am

ount

set

val

ue is

wro

ng.

Fro

m th

e pr

evio

us p

age

13-3

) T

hrea

d pa

th is

impr

oper

.

13-4

) N

eedl

e th

read

tens

ion

is im

prop

er.

13-5

) A

djus

tmen

t of t

he th

read

take

-up

sprin

g is

impr

oper

.

13-6

) S

trok

e of

the

thre

ad ta

ke-u

p le

ver

is to

o la

rge.

14-1

) P

ositi

on o

f the

top

feed

bel

t is

impr

oper

.

14-2

) Hei

ght o

f the

mai

n fe

ed fo

ot a

nd th

e au

xilia

ry fe

edfo

ot is

impr

oper

.

14-3

) A

uxili

ary

feed

shi

rrin

g am

ount

set

val

ue is

impr

oper

.

15-1

) F

eed

belt

has

been

wor

n ou

t.

15-2

) F

eed

foot

is e

xces

sive

ly r

aise

d.

15-3

) B

elt t

ensi

on is

too

low

.

16-1

) F

eed

belt

has

been

wor

n ou

t.

16-2

) F

eed

foot

is e

xces

sive

ly r

aise

d.

16-3

) B

elt t

ensi

on is

too

low

.

16-4

) S

et v

alue

is to

o sm

all.

17-1

) S

et v

alue

is to

o la

rge.

Fin

ish

the

thre

ad p

ath.

Fin

ish

the

thre

ad p

ath.

Cor

rect

the

thre

ad p

ath.

Adj

ust t

he te

nsio

n to

the

prop

er te

nsio

n.

Adj

ust t

he s

trok

e (s

tand

ard

: 10

to 1

2 m

m).

Adj

ust t

he te

nsio

n.

Mov

e th

e ar

m th

read

gui

de A

to th

e rig

ht a

nd d

ecre

ase

the

supp

lyam

ount

of t

hrea

d by

mea

ns o

f the

thre

ad ta

ke-u

p le

ver.

Adj

ust t

he fe

ed fo

ot.

Adj

ust t

he h

eigh

t of t

he m

ain

feed

foot

and

the

auxi

liary

feed

foot

.

Set

to th

e op

timum

set

val

ue.

Rep

lace

the

belt.

Adj

ust t

he h

eigh

t of t

he fe

ed fo

ot.

Set

to th

e pr

oper

tens

ion

valu

e.

Rep

lace

the

belt.

Adj

ust t

he h

eigh

t of t

he fe

ed fo

ot.

Set

to th

e pr

oper

tens

ion

valu

e.

Set

to th

e op

timum

set

val

ue.

Set

to th

e op

timum

set

val

ue.

－ 93 －

Tro

ub

leC

ause

(1)

Cau

se (

2)In

spec

tin

g o

rder

an

d a

dju

stin

g p

roce

du

re

(2)

Ele

ctri

cal p

arts

1-1)

Pow

er is

not

sup

plie

d up

to th

e po

wer

sw

itch.

1-2)

Pow

er is

not

sup

plie

d up

to th

e co

ntro

l box

.

2-1)

+5V

is n

ot s

uppl

ied

to M

AIN

p.c

.b.

2-2)

+5V

is n

ot s

uppl

ied

to P

AN

EL

p.c.

b.

2-3)

+24

V is

not

sup

plie

d to

MA

IN p

.c.b

.

2-4)

+24

V is

not

sup

plie

d to

PA

NE

L p.

c.b.

2-5)

Dat

a is

not

sen

t to

LCD

(liq

uid

crys

tal d

ispl

ay d

evic

e)of

the

pane

l.

2-6)

+24

V is

not

sup

plie

d to

the

back

-ligh

t of L

CD

(liq

uid

crys

tal d

ispl

ay d

evic

e) o

f the

pan

el.

2-7)

Pan

el c

anno

t be

disp

laye

d.

3-1)

Sew

ing

data

is b

roke

n.

4-1)

Hea

d til

t che

ck s

witc

h is

inpu

tted.

5-1)

Pan

el w

hich

is d

iffer

ent i

n m

odel

set

ting

isco

nnec

ted.

To

the

next

pag

e

1-A

) P

ower

plu

g is

dis

conn

ecte

d.

2-A

) C

onne

ctio

n of

pow

er c

ord

is d

iffer

ent.

1-A

) C

onne

ctor

(C

N44

) of

MA

IN p

.c.b

. is

disc

onne

cted

.

2-A

) C

onne

ctor

(C

N34

) of

MA

IN p

.c.b

. is

disc

onne

cted

.

2-B

) P

OW

ER

p.c

.b. i

s br

oken

dow

n.

3-A

) C

onne

ctor

(C

N59

) of

MA

IN p

.c.b

. is

disc

onne

cted

.

3-B

) C

onne

ctor

(C

N13

) of

PO

WE

R p

.c.b

. is

disc

onne

cted

.

4-A

) C

onne

ctor

(C

N34

) of

MA

IN p

.c.b

. is

disc

onne

cted

.

4-B

) P

OW

ER

p.c

.b. i

s br

oken

dow

n.

5-A

) C

onne

ctor

(C

N10

5) o

f PA

NE

L p.

c.b.

is d

isco

nnec

ted.

6-A

) C

onne

ctor

(C

N10

8) o

f PA

NE

L p.

c.b.

is d

isco

nnec

ted.

7-A

) P

AN

EL

p.c.

b. id

bro

ken

dow

n.

1-A

) In

stal

latio

n of

the

head

tilt

chec

k sw

itch

is im

prop

er.

1-B

) H

ead

tilt c

heck

sw

itch

is b

roke

n.

Con

nect

the

pow

er p

lug.

Che

ck th

e co

nnec

tion

of w

iring

.

Con

nect

CN

44.

Con

nect

CN

34.

Rep

lace

PO

WE

R p

.c.b

.

Con

nect

CN

59.

Con

nect

CN

13.

Con

nect

CN

34.

Rep

lace

PO

WE

R p

.c.b

.

Con

nect

CN

105.

Con

nect

CN

108.

Rep

lace

the

pane

l.

Tur

n O

N th

e po

wer

aga

in (t

he b

roke

n se

win

g da

ta is

aut

omat

ical

lyde

lete

d w

ith th

is a

ctio

n).

Adj

ust t

he in

stal

latio

n of

hea

d til

t che

ck s

witc

h.

Rep

lace

the

switc

h. (

Cau

tion)

Sw

itch

is th

e no

rmal

ope

n ty

pe a

nder

ror

does

not

occ

ur w

ith d

isco

nnec

tion

of c

onne

ctor

or

brea

king

of w

ire.

Con

nect

the

pane

l of t

he s

ame

mod

el.

Pre

ss d

own

the

com

mun

icat

ion

switc

h an

d re

writ

e th

e pa

nel t

ot h

e s

am

e p

rog

ram

as

t ha

t o

f t h

e m

od

el

cod

e o

f t h

e s

ew

ing

mac

hine

.

1)T

urni

ng O

N th

e po

wer

1.P

ower

fails

to w

ork.

2.P

anel

is n

ot d

ispl

ayed

.

3.E

062

(sew

ing

data

err

or)

isdi

spla

yed.

4.E

302

(hea

d til

t che

ck)

isdi

spla

yed.

5.E

703

(pan

el is

con

nect

ed to

the

mac

hine

oth

er th

ansu

ppos

ed o

ne)

is d

ispl

ayed

.

－ 94 －

Tro

ub

leC

ause

(1)

Cau

se (

2)In

spec

tin

g o

rder

an

d a

dju

stin

g p

roce

du

re

6. E

704

(dis

agre

emen

t of s

yste

mve

rsio

n) is

dis

play

ed.

7.E

811

(ove

rvol

tage

) is

disp

laye

d.

8. E

813

(low

vol

tage

) is

disp

laye

d.

2-A

) Con

tact

of c

onne

ctor

(CN

34) o

f MA

IN p

.c.b

. is

impr

oper

.

2-B

) P

rogr

am o

f MA

IN is

bro

ken.

2-C

) D

ata

on th

e si

de o

f MA

IN o

f MA

IN p

.c.b

. is

brok

en.

2-D

) M

AIN

p.c

.b. i

s br

oken

dow

n.

2-E

) P

AN

EL

is b

roke

n do

wn.

1-A

) R

or

V o

f mai

n sh

aft i

s di

ffere

nt.

1-B

) R

or

V o

f MA

IN is

diff

eren

t.

1-C

) R

or

V o

f PA

NE

L is

diff

eren

t.

2-A

) Con

tact

of c

onne

ctor

(CN

34) o

f MA

IN p

.c.b

. is

impr

oper

.

2-B

) P

rogr

am o

f MA

IN is

bro

ken.

2-C

) D

ata

on th

e si

de o

f MA

IN o

f MA

IN p

.c.b

. is

brok

en.

2-D

) M

AIN

p.c

.b. i

s br

oken

dow

n.

2-E

) P

AN

EL

is b

roke

n do

wn.

1-A

) In

put p

ower

is h

igh.

1-B

) P

OW

ER

p.c

.b. i

s br

oken

dow

n.

1-A

) In

put p

ower

is lo

w.

1-B

) P

OW

ER

p.c

.b. i

s br

oken

dow

n.

5-2)

Com

mun

icat

ion

cann

ot b

e pe

rfor

med

bet

wee

nop

erat

ion

pane

l and

MA

IN C

PU

.

6-1)

R o

r V

of R

-V-L

of m

ain

shaf

t, M

AIN

and

PA

NE

L is

diffe

rent

.

6-2)

Com

mun

icat

ion

cann

ot b

e pe

rfor

med

bet

wee

nop

erat

ion

pane

l and

MA

IN C

PU

.

7-1)

Inpu

t vol

tage

is 2

80V

or

high

er a

nd p

ower

over

volta

ge s

igna

l (O

VL)

is d

etec

ted.

8-1)

Inpu

t vol

tage

is 1

50V

or l

ower

and

low

vol

tage

sig

nal

(LV

L) is

det

ecte

d.

Che

ck th

e co

nnec

tion

of C

N34

.

Per

form

rew

ritin

g of

the

prog

ram

of M

AIN

.

Initi

aliz

e th

e da

ta o

n th

e si

de o

f MA

IN o

f MA

IN p

.c.b

.

Rep

lace

MA

IN p

.c.b

.

Rep

lace

PA

NE

L.

Pre

ss d

own

the

com

mun

icat

ion

switc

h an

d re

wri

te t

he p

rogr

am o

f m

ain

shaf

t.

Pre

ss d

own

the

com

mun

icat

ion

switc

h an

d re

writ

e th

e pr

ogra

m o

f MA

IN.

Pre

ss d

own

the

com

mun

icat

ion

switc

h an

d re

writ

e th

e pr

ogra

m o

f PA

NE

L.

Che

ck th

e co

nnec

tion

of C

N34

.

Rew

rite

the

prog

ram

of M

AIN

.

Initi

aliz

e th

e da

ta o

n th

e si

de o

f MA

IN o

f MA

IN p

.c.b

.

Rep

lace

MA

IN p

.c.b

.

Rep

lace

PA

NE

L.

Che

ck th

e in

put p

ower

.

Rep

lace

PO

WE

R p

.c.b

.

Che

ck th

e in

put p

ower

.

Rep

lace

PO

WE

R p

.c.b

.

Fro

m th

e pr

evio

us p

age

－ 95 －

Tro

ub

leC

ause

(1)

Cau

se (

2)In

spec

tin

g o

rder

an

d a

dju

stin

g p

roce

du

re

9. E

915

(abn

orm

alco

mm

unic

atio

n be

twee

nop

erat

ion

pane

l and

MA

INC

PU

) is

dis

play

ed.

10. E

916

(abn

orm

alco

mm

unic

atio

n be

twee

nM

AIN

CP

U a

nd m

ain

shaf

tC

PU

) is

dis

play

ed.

11. E

920

(abn

orm

ality

of C

PLD

writ

ing)

is d

ispl

ayed

.

12. E

941

(abn

orm

ality

of C

PLD

read

ing)

is d

ispl

ayed

.

9-1

) C

om

mu

nic

atio

n c

an

no

t b

e p

erf

orm

ed

be

twe

en

oper

atio

n pa

nel a

nd M

AIN

CP

U.

10-1

) C

omm

unic

atio

n ca

nnot

be

perf

orm

ed b

etw

een

MA

IN C

PU

and

mai

n sh

aft C

PU

.

11-1

) W

ritin

g ca

nnot

be

perf

orm

ed to

CP

LD.

12-1

) R

eadi

ng c

anno

t be

perf

orm

ed fr

om C

PLD

.

1-A

) Con

tact

of c

onne

ctor

(CN

34) o

f MA

IN p

.c.b

. is

impr

oper

.

1-B

) P

rogr

am o

f MA

IN is

bro

ken.

1-C

) D

ata

on th

e si

de o

f MA

IN o

f MA

IN p

.c.b

. is

brok

en.

1-D

) M

AIN

p.c

.b. i

s br

oken

dow

n.

1-A

) P

rogr

am o

f mai

n sh

aft i

s br

oken

.

1-B

) D

ata

on th

e si

de o

f mai

n sh

aft o

f MA

IN p

.c.b

. is

brok

en.

1-C

) M

AIN

p.c

.b. i

s br

oken

dow

n.

1-A

) M

AIN

p.c

.b. i

s br

oken

dow

n.

1-A

) M

AIN

p.c

.b. i

s br

oken

dow

n.

Che

ck th

e co

nnec

tion

of C

N34

.

Per

form

rew

ritin

g of

the

prog

ram

of M

AIN

.

Initi

aliz

e th

e da

ta o

n th

e si

de o

f MA

IN o

f MA

IN p

.c.b

.

Rep

lace

MA

IN p

.c.b

.

Per

form

rew

ritin

g of

the

prog

ram

of m

ain

shaf

t.

Initi

aliz

e th

e da

ta o

f the

sid

e of

mai

n sh

aft o

f MA

IN p

.c.b

.

Rep

lace

MA

IN p

.c.b

.

Rep

lace

MA

IN p

.c.b

.

Rep

lace

MA

IN p

.c.b

.

－ 96 －

Tro

ub

leC

ause

(1)

Cau

se (

2)In

spec

tin

g o

rder

an

d a

dju

stin

g p

roce

du

re

1.E

000

(con

tact

of i

nitia

lizat

ion

of m

ain

shaf

t EE

P-R

OM

of

MA

IN p

.c.b

.) is

dis

play

ed.

2.E

001

(con

tact

of i

nitia

lizat

ion

of M

AIN

EE

P-R

OM

of M

AIN

p.c.

b.)

is d

ispl

ayed

.

3.E

006

(con

tact

of i

nitia

lizat

ion

of h

ead

EE

P-R

OM

of p

.c.b

.m

ount

ed o

n m

achi

ne h

ead)

isdi

spla

yed.

4.E

011

(ext

erna

l med

ia is

not

inse

rted

) is

dis

play

ed.

5.E

012

(rea

d er

ror)

is d

ispl

ayed

.

6.E

013

(writ

e er

ror)

is d

ispl

ayed

.

1-1)

Dat

a of

mai

n sh

aft E

EP

-RO

M is

bro

ken.

2-1)

Dat

a of

MA

IN E

EP

-RO

M is

bro

ken.

3-1)

Dat

a of

hea

d E

EP

-RO

M is

bro

ken.

3-2)

P.c

.b. m

ount

ed o

n m

achi

ne h

ead

is n

ot c

onne

cted

.

4-1)

Rec

ogni

tion

of s

mar

t med

ia c

anno

t be

perf

orm

ed.

5-1)

Dat

a ca

nnot

be

read

from

the

smar

t med

ia.

6-1)

Dat

a ca

nnot

be

writ

ten

to th

e sm

art m

edia

.

1-A

) M

AIN

p.c

.b. i

s br

oken

.

1-B

) M

ain

shaf

t EE

P-R

OM

is b

roke

n.

1-A

) M

AIN

p.c

.b. i

s br

oken

.

1-B

) M

AIN

EE

P-R

OM

is b

roke

n.

1-A

) P

.c.b

. mou

nted

on

mac

hine

hea

d is

bro

ken.

1-B

) H

ead

EE

P-R

OM

is b

roke

n.

2-A

) C

onne

ctor

(C

N55

) of

MA

IN p

.c.b

. is

disc

onne

cted

.

1-A

) S

mar

t med

ia is

not

inse

rted

.

1-B

) R

eadi

ng s

ectio

n of

the

smar

t med

ia is

dirt

y.

1-C

) In

side

of t

he th

rottl

e of

the

smar

t med

ia is

dirt

y.

1-D

) S

mar

t med

ia is

bro

ken.

1-A

) R

eadi

ng s

ectio

n of

the

smar

t med

ia is

dirt

y.

1-B

) In

side

of t

he th

rottl

e of

the

smar

t med

ia is

dirt

y.

1-C

) S

mar

t med

ia is

bro

ken.

1-A

) R

eadi

ng s

ectio

n of

the

smar

t med

ia is

dirt

y.

1-B

) In

side

of t

he th

rottl

e of

the

smar

t med

ia is

dirt

y.

1-C

) S

mar

t med

ia is

bro

ken.

Rep

lace

MA

IN p

.c.b

.

Rep

lace

MA

IN p

.c.b

.

Rep

lace

MA

IN p

.c.b

.

Rep

lace

MA

IN p

.c.b

.

Rep

lace

p.c

.b. m

ount

ed o

n th

e m

achi

ne h

ead.

Rep

lace

p.c

.b. m

ount

ed o

n th

e m

achi

ne h

ead.

Con

nect

CN

55.

Inse

rt th

e sm

art m

edia

.

Cle

an th

e re

adin

g se

ctio

n.

Cle

an th

e in

side

of t

he th

rottl

e.

Rep

lace

the

smar

t med

ia.

Cle

an th

e re

adin

g se

ctio

n.

Cle

an th

e in

side

of t

he th

rottl

e.

Rep

lace

the

smar

t med

ia.

Cle

an th

e re

adin

g se

ctio

n.

Cle

an th

e in

side

of t

he th

rottl

e.

Rep

lace

the

smar

t med

ia.

2)P

anel

ope

ratio

n

－ 97 －

Tro

ub

leC

ause

(1)

Cau

se (

2)In

spec

tin

g o

rder

an

d a

dju

stin

g p

roce

du

re

7.E

014

(writ

e pr

otec

t) is

dis

play

ed.

8. E

015

(form

at e

rror

) is

disp

laye

d.

9.E

016

(ext

erna

l med

ia c

apac

ityov

er)

is d

ispl

ayed

.

10.E

022

(file

No.

err

or)

isdi

spla

yed.

11.E

029

(sm

art m

edia

slo

t err

or)

is d

ispl

ayed

.

1-A

) W

rite

proh

ibiti

on s

eal i

s pa

sted

on

the

smar

t med

ia.

1-B

) R

eadi

ng s

ectio

n of

the

smar

t med

ia is

dirt

y.

1-C

) In

side

of t

he th

rottl

e of

the

smar

t med

ia is

dirt

y.

1-D

) S

mar

t med

ia is

bro

ken.

1-A

) W

rite

proh

ibiti

on s

eal i

s pa

sted

on

the

smar

t med

ia.

1-B

) R

eadi

ng s

ectio

n of

the

smar

t med

ia is

dirt

y.

1-C

) In

side

of t

he th

rottl

e of

the

smar

t med

ia is

dirt

y.

1-D

) S

mar

t med

ia is

bro

ken.

1-A

) S

pace

reg

ion

is n

ot in

the

smar

t med

ia.

2-A

) R

eadi

ng s

ectio

n of

the

smar

t med

ia is

dirt

y.

2-B

) In

side

of t

he th

rottl

e of

the

smar

t med

ia is

dirt

y.

2-C

) S

mar

t med

ia is

bro

ken.

2-A

) R

eadi

ng s

ectio

n of

the

smar

t med

ia is

dirt

y.

2-B

) In

side

of t

he th

rottl

e of

the

smar

t med

ia is

dirt

y.

2-C

) S

mar

t med

ia is

bro

ken.

7-1)

Sm

art m

edia

is in

the

writ

ing

proh

ibite

d st

ate.

8-1)

Sm

art m

edia

is in

the

writ

ing

proh

ibite

d st

ate.

9-1)

Cap

acity

of t

he s

mar

t med

ia is

full.

9-2)

Rec

ogni

tion

of th

e sm

art m

edia

can

not b

epe

rfor

med

.

10-1

)T

he d

esig

nate

d fil

e is

not

in th

e sm

art m

edia

.

10-2

)R

ecog

nitio

n of

the

smar

t med

ia c

anno

t be

perf

orm

ed.

11-1

)C

over

of t

he s

mar

t med

ia is

ope

n.

11-2

)C

lose

/ope

n de

tect

ion

switc

h of

the

cove

r is

brok

en.

Str

ip o

ff th

e se

al.

Cle

an th

e re

adin

g se

ctio

n.

Cle

an th

e in

side

of t

he th

rottl

e.

Rep

lace

the

smar

t med

ia.

Str

ip o

ff th

e se

al.

Cle

an th

e re

adin

g se

ctio

n.

Cle

an th

e in

side

of t

he th

rottl

e.

Rep

lace

the

smar

t med

ia.

Del

ete

the

insi

de d

ata

of th

e sm

art m

edia

and

sec

ure

the

spac

e re

gion

.

Cle

an th

e re

adin

g se

ctio

n.

Cle

an th

e in

side

of t

he th

rottl

e.

Rep

lace

the

smar

t med

ia.

Des

igna

te th

e ex

istin

g fil

e.

Cle

an th

e re

adin

g se

ctio

n.

Cle

an th

e in

side

of t

he th

rottl

e.

Rep

lace

the

smar

t med

ia.

Clo

se th

e co

ver.

Rep

lace

the

clos

e/op

en s

witc

h (S

W2)

.

－ 98 －

Tro

ub

leC

ause

(1)

Cau

se (

2)In

spec

tin

g o

rder

an

d a

dju

stin

g p

roce

du

re

12. E

702

(abn

orm

al c

ontr

ol)

isdi

spla

yed.

13.

E91

7 (fa

ilure

of c

omm

unic

atio

nbe

twee

n op

erat

ion

pane

l and

pers

onal

com

pute

r) is

dis

play

ed.

14.

Key

is n

ot a

ccep

ted

even

whe

n pr

essi

ng th

e to

uch

pane

l.

12-1

) Pro

gram

of t

he p

anel

has

run

aw

ay.

13-1

) Com

mun

icat

ion

cann

ot b

e pe

rfor

med

bet

wee

nop

erat

ion

pane

l and

per

sona

l com

pute

r.

14-1

) Sig

nal d

oes

not c

ome

to P

AN

EL

p.c.

b.

14-2

)PA

NE

L p.

c.b.

dos

not

acc

ept t

he s

igna

l.

1-A

) P

AN

EL

p.c.

b. is

bro

ken.

1-B

) P

rogr

am o

f the

pan

el is

bro

ken.

1-C

) W

ritin

g o

f th

e p

rog

ram

of

the

pa

ne

l is

no

t p

rop

erl

ype

rfor

med

.

1-A

) C

onta

ct o

f RS

232C

con

nect

or (

CN

102)

of t

he p

anel

isim

prop

er.

1-B

) C

onta

ct o

f RS

232C

con

nect

or o

f per

sona

l com

pute

r is

impr

oper

.

1-C

) P

AN

EL

p.c.

b. is

bro

ken

dow

n.

1-A

) C

onne

ctor

(C

N10

9) o

f PA

NE

L p.

c.b.

is d

isco

nnec

ted.

2-A

) P

AN

EL

p.c.

b. is

bro

ken

dow

n.

Rep

lace

PA

NE

L p.

c.b.

Rew

rite

the

prog

ram

of t

he p

anel

.

Rew

rite

the

prog

ram

of t

he p

anel

.

Che

ck th

e co

nnec

tion

of C

N10

2.

Che

ck th

e co

nnec

tion

of R

S23

2C c

onne

ctor

of t

he p

erso

nal c

ompu

ter.

Rep

lace

the

pane

l.

Con

nect

CN

109.

Rep

lace

the

pane

l.

－ 99 －

Tro

ub

leC

ause

(1)

Cau

se (

2)In

spec

tin

g o

rder

an

d a

dju

stin

g p

roce

du

re

1.E

003

(fai

lure

of m

ain

shaf

tm

otor

enc

oder

) is

dis

play

ed.

2.E

004

(fai

lure

of n

eedl

e D

OW

Nde

tect

ion

of m

ain

shaf

t mot

or)

is d

ispl

ayed

.

3.E

005

(fai

lure

of n

eedl

e U

Pde

tect

ion

of m

ain

shaf

t mot

or)

is d

ispl

ayed

.

1-A

)Enc

oder

of m

ain

shaf

t mot

or is

bro

ken.

2-A

) C

onne

ctor

(C

N21

) of

PO

WE

R p

.c.b

. is

disc

onne

cted

.

2-B

) C

onne

ctor

(C

N10

) of

PO

WE

R p

.c.b

. is

disc

onne

cted

.

2-C

) C

onne

ctor

(C

N44

) of

MA

IN p

.c.b

. is

disc

onne

cted

.

1-A

) E

ncod

er o

f mai

n sh

aft m

otor

is b

roke

n.

2-A

) C

onne

ctor

(C

N21

) of

PO

WE

R p

.c.b

. is

disc

onne

cted

.

2-B

) C

onne

ctor

(C

N10

) of

PO

WE

R p

.c.b

. is

disc

onne

cted

.

2-C

) C

onne

ctor

(C

N44

) of

MA

IN p

.c.b

. is

disc

onne

cted

.

3-A

) E

ncod

er o

f mai

n sh

aft m

otor

is b

roke

n.

3-B

)Rep

eate

d op

erat

ions

of n

orm

al/r

ever

se ro

tatio

n by

han

dar

e qu

ickl

y pe

rfor

med

.

1-A

) E

ncod

er o

f mai

n sh

aft m

otor

is b

roke

n.

2-A

) C

onne

ctor

(C

N21

) of

PO

WE

R p

.c.b

. is

disc

onne

cted

.

2-B

) C

onne

ctor

(C

N10

) of

PO

WE

R p

.c.b

. is

disc

onne

cted

.

2-C

) C

onne

ctor

(C

N44

) of

MA

IN p

.c.b

. is

disc

onne

cted

.

3-A

) E

ncod

er o

f mai

n sh

aft m

otor

is b

roke

n.

3-B

)Rep

eate

d op

erat

ions

of n

orm

al/r

ever

se ro

tatio

n by

han

dar

e qu

ickl

y pe

rfor

med

.

1-1)

Ang

le c

ount

er o

f mai

n sh

aft m

otor

is a

bnor

mal

.

1-2)

Enc

oder

sig

nal i

s no

t inp

utte

d.

2-1)

Nee

dle

DO

WN

det

ectio

n si

gnal

of m

ain

shaf

t mot

oris

abn

orm

al.

2-2)

Enc

oder

sig

nal i

s no

t inp

utte

d.

2-3)

Nor

mal

/reve

rse

rota

tion

sign

als

are

frequ

ently

inpu

tted.

3-1)

Nee

dle

UP

dete

ctio

n si

gnal

of m

ain

shaf

t mot

or is

abn

orm

al.

3-2)

Enc

oder

sig

nal i

s no

t inp

utte

d.

3-3)

Nor

mal

/rev

erse

of r

otat

ion

sign

als

are

freq

uent

lyin

putte

d.

Rep

lace

the

mai

n sh

aft m

otor

.

Con

nect

CN

21.

Con

nect

CN

10.

Con

nect

CN

44.

Rep

lace

the

mai

n sh

aft m

otor

.

Con

nect

CN

21.

Con

nect

CN

10.

Con

nect

CN

44.

Rep

lace

the

mai

n sh

aft m

otor

.

Per

form

the

repe

ated

ope

ratio

ns s

low

ly.

Rep

lace

the

mai

n sh

aft m

otor

.

Con

nect

CN

21.

Con

nect

CN

10.

Con

nect

CN

44.

Rep

lace

the

mai

n sh

aft m

otor

.

Per

form

the

repe

ated

ope

ratio

ns s

low

ly.

3) S

ewin

g

－ 100 －

Tro

ub

leC

ause

(1)

Cau

se (

2)In

spec

tin

g o

rder

an

d a

dju

stin

g p

roce

du

re

4.E

007

(mai

n sh

aft m

otor

lock

)is

dis

play

ed.

5.E

303

(mai

n sh

aft w

oodr

uff

plat

e se

nsor

err

or) i

s di

spla

yed.

6.E

810

(sol

enoi

d po

wer

sho

rt-

circ

uit)

is d

ispl

ayed

.

7.E

918

(abn

orm

al te

mpe

ratu

reof

hea

t sin

k fo

r M

AIN

p.c

.b.)

isdi

spla

yed.

4-1)

Mai

n sh

aft m

otor

is lo

cked

.

4-2)

Pow

er is

not

sup

plie

d to

mot

or.

4-3)

Enc

oder

sig

nal i

s no

t inp

utte

d.

4-4)

Driv

e si

gnal

is n

ot o

utpu

t to

mot

or.

5-1)

Woo

druf

f pla

te s

enso

r of m

ain

shaf

t mot

or is

abn

orm

al.

5-2)

Enc

oder

sig

nal (

woo

druf

f pla

te)

is n

ot in

putte

d.

6-1)

Sol

enoi

d po

wer

sho

rt-ci

rcui

t sig

nal (

PW

SH

) is

det

ecte

d.

7-1)

Tem

pera

ture

of h

eat s

ink

of M

AIN

p.c

.b. i

s m

ore

than

85˚

C.

2-A

) C

onne

ctor

(C

N2)

of F

LT p

.c.b

. is

disc

onne

cted

.

3-A

) C

onne

ctor

(C

N21

) of

PO

WE

R p

.c.b

. is

disc

onne

cted

.

3-B

) C

onne

ctor

(C

N10

) of

PO

WE

R p

.c.b

. is

disc

onne

cted

.

3-C

) C

onne

ctor

(C

N44

) of

MA

IN p

.c.b

. is

disc

onne

cted

.

4-A

) C

onne

ctor

(C

N38

) of

PO

WE

R p

.c.b

. is

disc

onne

cted

.

1-A

) E

ncod

er o

f mai

n sh

aft m

otor

is b

roke

n.

2-A

) C

onne

ctor

(C

N21

) of

PO

WE

R p

.c.b

. is

disc

onne

cted

.

2-B

) C

onne

ctor

(C

N10

) of

PO

WE

R p

.c.b

. is

disc

onne

cted

.

2-C

) C

onne

ctor

(C

N44

) of

MA

IN p

.c.b

. is

disc

onne

cted

.

1-A

) T

hrea

d tr

imm

er s

olen

oid

is b

roke

n do

wn.

1-B

) P

ress

er li

fter

sole

noid

is b

roke

n do

wn.

1-C

) P

OW

ER

p.c

.b. i

s br

oken

dow

n.

1-A

) F

an lo

cate

d in

side

of b

ox is

not

rot

atin

g.

1-B

) A

ir ho

le o

f con

trol

box

is b

lock

ed.

1-C

) M

AIN

p.c

.b. i

s br

oken

dow

n.

1-D

) S

tepp

ing

mot

or is

bro

ken

dow

n.

Rel

ease

the

lock

ing.

Con

nect

CN

2.

Con

nect

CN

21.

Con

nect

CN

10.

Con

nect

CN

44.

Con

nect

CN

38.

Rep

lace

the

mai

n sh

aft m

otor

.

Con

nect

CN

21.

Con

nect

CN

10.

Con

nect

CN

44.

Rep

lace

the

thre

ad tr

imm

er s

olen

oid.

Rep

lace

the

pres

ser

lifte

r so

leno

id.

Rep

lace

PO

WE

R p

.c.b

.

Con

nect

CN

23 a

nd C

N24

of P

OW

ER

p.c

.b.

Cle

an th

e ai

r ho

le.

Rep

lace

MA

IN p

.c.b

.

Rep

lace

the

step

ping

mot

or.

－ 101 －

Tro

ub

leC

ause

(1)

Cau

se (

2)In

spec

tin

g o

rder

an

d a

dju

stin

g p

roce

du

re

8.E

922

(impo

ssib

le to

con

trol

mai

n sh

aft m

otor

) is

disp

laye

d.

9.E

924

(fai

lure

of m

ain

shaf

tdr

ive)

is d

ispl

ayed

.

10.S

hirr

ing

amou

nt c

hang

esw

hen

chan

ging

ove

r to

sew

ing

scre

en.

11.S

hirr

ing

disp

lay

is n

ot "

0" in

the

man

ual s

cree

n.

12.T

hrea

d te

nsio

n du

ring

wai

ting

is h

igh.

13.C

ompe

nsat

ion

thre

ad te

nsio

nse

tting

but

ton

is n

ot d

ispl

ayed

even

whe

n pr

essi

ng th

e st

epde

tails

but

ton.

14.D

ata

chan

ged

in th

e se

win

gsc

reen

is n

ot s

tore

d in

mem

ory.

15.B

uzze

r doe

s no

t sou

nd w

hen

chan

ging

ove

r th

e st

ep.

16.A

uxili

ary

peda

l can

not b

e us

ed.

17.C

hang

e do

es n

ot o

ccur

eve

nw

hen

pres

sing

the

shirr

ing

rele

ase

switc

h.

18. K

nee

switc

h fa

ils to

wor

k at

the

time

of fu

ll au

to s

ewin

g.

19. S

hirr

ing

amou

nt c

hang

es a

tth

e tim

e of

cha

nge

of p

itch.

20. S

cree

n ch

ange

s ov

er e

ven

whe

n pe

rfor

min

g th

read

trim

min

g on

the

way

of s

tep.

1-A

) E

ncod

er o

f mai

n sh

aft m

otor

is b

roke

n.

2-A

) C

onne

ctor

(C

N21

) of

PO

WE

R p

.c.b

. is

disc

onne

cted

.

2-B

) C

onne

ctor

(C

N10

) of

PO

WE

R p

.c.b

. is

disc

onne

cted

.

2-C

) C

onne

ctor

(C

N44

) of

MA

IN p

.c.b

. is

disc

onne

cted

.

1-A

) M

ain

shaf

t mot

or is

bro

ken

dow

n.

1-B

) P

OW

ER

p.c

.b. i

s br

oken

dow

n.

8-1)

Num

ber o

f rev

olut

ion

of m

easu

rem

ent e

xcee

ds th

eup

per

limit

(3,5

00 r

pm).

8-2)

Enc

oder

sig

nal i

s no

t inp

utte

d.

9-1)

Mot

or d

river

err

or s

igna

l (G

TR

E)

is d

etec

ted.

10-1

) S

ettin

g of

aux

iliar

y pe

dal i

s im

prop

er.

11-1

) S

ettin

g of

aux

iliar

y pe

dal i

s im

prop

er.

12-1

) B

ase

tens

ion

durin

g w

aitin

g is

impr

oper

.

13-1

)C

ompe

nsat

ion

tens

ion

mod

e is

sel

ecte

d to

the

auto

mat

ic.

14-1

) S

ewin

g is

com

plet

ed a

t the

ste

p ot

her

than

the

last

ste

p.

14-2

) Not

to s

tore

is s

elec

ted

in th

e da

ta s

tora

ge fu

nctio

nse

lect

ion

at th

e tim

e of

sew

ing.

15-1

) O

utpu

t of s

ound

whe

n ch

angi

ng o

ver

the

step

isse

lect

ed to

not

to s

ound

.

16-1

) Sel

ectio

n of

aux

iliar

y pe

dal u

se is

set

to n

ot to

use

.

17-1

) S

elec

tion

of s

hirr

ing

rele

ase

switc

h us

e is

set

tono

t to

use.

18-1

) S

elec

tion

of k

nee

switc

h us

e is

set

to n

ot to

use

.

19-1

) S

hirr

ing

amou

nt in

terlo

ckin

g fu

nctio

n is

set

to u

seat

the

time

of c

hang

e of

pitc

h.]

20-1

) S

elec

tion

of s

cree

n ch

ange

over

func

tion

at th

etim

e of

thre

ad tr

imm

ing

on th

e w

ay is

set

to u

se.

Rep

lace

the

mai

n sh

aft m

otor

.

Con

nect

CN

21.

Con

nect

CN

10.

Con

nect

CN

44.

Rep

lace

the

mai

n sh

aft m

otor

.

Rep

lace

PO

WE

R p

.c.b

.

Ref

er to

21-

2 "P

erfo

rmin

g se

tting

of t

he a

uxili

ary

peda

l" in

Inst

ruct

ion

Man

ual

and

set a

gain

.

Ref

er to

21-

2 "P

erfo

rmin

g se

tting

of t

he a

uxili

ary

peda

l" in

Inst

ruct

ion

Man

ual

and

set a

gain

.

Set

aga

in th

e ba

se te

nsio

n du

ring

wai

ting

of le

vel 1

[U12

] of m

emor

y sw

itch

data

.

Sto

p th

e au

tom

atic

sel

ectio

n of

com

pens

atio

n te

nsio

n m

ode

sele

ctio

n of

leve

l 1 [U

12] o

f mem

ory

switc

h da

ta.

Com

plet

e th

e se

win

g at

the

last

ste

p.

Set

to s

torin

g th

e da

ta s

tora

ge fu

nctio

n se

lect

ion

at th

e tim

e of

sew

ing

ofle

vel 1

[U16

] of m

emor

y sw

itch

data

.

Set

to s

ound

the

outp

ut o

f sou

nd w

hen

chan

ging

ove

r th

e st

ep s

elec

tion

ofle

vel 1

[U17

] of m

emor

y sw

itch

data

.

Set

to

use

the

auxi

liary

ped

al u

se s

elec

tion

of le

vel 1

[U

18]

of m

emor

ysw

itch

data

.

Set

to u

se th

e sh

irrin

g re

leas

e sw

itch

use

sele

ctio

n of

leve

l 1 [U

19] o

f mem

ory

switc

h da

ta.

Set

to u

se th

e kn

ee s

witc

h us

e se

lect

ion

of le

vel 1

[U20

] of m

emor

y sw

itch

data

.

Set

to n

ot to

use

the

shirr

ing

amou

nt in

terlo

ckin

g fu

nctio

n se

lect

ion

at th

etim

e of

cha

nge

of p

itch

of le

vel 1

[U21

] of m

emor

y sw

itch

data

.

Set

to n

ot to

use

the

scre

en c

hang

eove

r fu

nctio

n se

lect

ion

at th

e tim

e of

thre

ad tr

imm

ing

on th

e w

ay o

f lev

el 1

[U22

] of m

emor

y sw

itch

data

.

－ 102 －

Tro

ub

leC

ause

(1)

Cau

se (

2)In

spec

tin

g o

rder

an

d a

dju

stin

g p

roce

du

re

1. E

731

(fai

lure

of m

ain

shaf

tm

otor

hol

e se

nsor

and

the

posi

tion

sens

or)

is d

ispl

ayed

.

2.E

733

(mai

n sh

aft m

otor

reve

rse

rota

tion)

is d

ispl

ayed

.

3.E

801

(pow

er p

hase

-lack

) is

disp

laye

d.

4.E

802

(pow

er in

stan

tane

ous

cut d

etec

tion)

is d

ispl

ayed

.

1-1)

Mot

or h

ole

sens

or e

rror

(U

VW

) is

det

ecte

d.

2-1)

Mai

n sh

aft m

otor

rot

ates

in th

e re

vers

e di

rect

ion.

3-1)

Pow

er p

hase

-lack

sig

nal (

PH

E)

is d

etec

ted.

4-1)

Pow

er in

stan

tane

ous

cut s

igna

l (P

WF

) is

dete

cted

.

1-A

) M

ain

shaf

t mot

or is

bro

ken

dow

n.

1-B

) P

OW

ER

p.c

.b. i

s br

oken

dow

n.

1-C

) M

AIN

p.c

.b. i

s br

oken

dow

n.

1-A

) M

ain

shaf

t mot

or is

bro

ken

dow

n.

1-B

) P

OW

ER

p.c

.b. i

s br

oken

dow

n.

1-C

) M

AIN

p.c

.b. i

s br

oken

dow

n.

1-A

) P

OW

ER

p.c

.b. i

s br

oken

dow

n.

1-B

) M

AIN

p.c

.b. i

s br

oken

dow

n.

1-A

) P

OW

ER

p.c

.b. i

s br

oken

dow

n.

1-B

) M

AIN

p.c

.b. i

s br

oken

dow

n.

1-C

) P

AN

EL

is b

roke

n do

wn.

Rep

lace

the

mai

n sh

aft m

otor

.

Rep

lace

PO

WE

R p

.c.b

.

Rep

lace

MA

IN p

.c.b

.

Rep

lace

the

mai

n sh

aft m

otor

.

Rep

lace

PO

WE

R p

.c.b

.

Rep

lace

MA

IN p

.c.b

.

Rep

lace

PO

WE

R p

.c.b

.

Rep

lace

MA

IN p

.c.b

.

Rep

lace

PO

WE

R p

.c.b

.

Rep

lace

MA

IN p

.c.b

.

Rep

lace

PA

NE

L.

4) S

tart

ing

of th

e se

win

g m

achi

ne

－ 103 －

Tro

ub

leC

ause

(1)

Cau

se (

2)In

spec

tin

g o

rder

an

d a

dju

stin

g p

roce

du

re

1. E

942

(fai

lure

of m

ain

shaf

tE

EP

-RO

M)

is d

ispl

ayed

.

2. E

943

(fai

lure

of m

ain

EE

P-

RO

M)

is d

ispl

ayed

.

3. E

946

(fai

lure

of h

ead

EE

P-

RO

M)

is d

ispl

ayed

.

4. B

uzze

r so

unds

two

times

at a

regu

lar

cycl

e.

5. B

uzze

r so

unds

thre

e tim

es a

ta

regu

lar

cycl

e.

6. B

uzze

r so

unds

four

tim

es a

t are

gula

r cy

cle.

7. B

uzze

r so

unds

five

tim

es a

t are

gula

r cy

cle.

8. B

uzze

r so

unds

7 ti

mes

at a

regu

lar

cycl

e.

9. B

uzze

r so

unds

8 ti

mes

at a

regu

lar

cycl

e.

10. B

uzze

r so

unds

9 ti

mes

at a

regu

lar

cycl

e.

1-A

) M

AIN

p.c

.b. i

s br

oken

.

1-B

) M

ain

shaf

t EE

P-R

OM

is b

roke

n.

1-A

) M

AIN

p.c

.b. i

s br

oken

.

1-B

) M

AIN

EE

P-R

OM

is b

roke

n.

1-A

) P

.c.b

. mou

nted

on

the

mac

hine

hea

d is

bro

ken.

1-B

) H

ead

EE

P-R

OM

is b

roke

n.

1-A

) M

AIN

p.c

.b. i

s br

oken

dow

n.

1-A

) M

AIN

p.c

.b. i

s br

oken

dow

n.

1-A

) M

AIN

p.c

.b. i

s br

oken

dow

n.

1-A

) M

AIN

p.c

.b. i

s br

oken

dow

n.

1-A

) M

AIN

EE

P-R

OM

is b

roke

n.

1-A

) Con

tact

of c

onne

ctor

(CN

34) o

f MA

IN p

.c.b

. is

impr

oper

.

1-B

) P

rogr

am o

f MA

IN is

bro

ken.

1-C

) D

ata

on th

e si

de o

f MA

IN o

f MA

IN p

.c.b

. is

brok

en.

1-D

) M

AIN

p.c

.b. i

s br

oken

.

1-A

) M

AIN

p.c

.b. i

s br

oken

.

1-B

) W

ritin

g of

the

prog

ram

of m

ain

shaf

t is

not p

erfo

rmed

.

1-C

) Ini

tializ

atio

n of

EE

P-R

OM

of m

ain

shaf

t is

not p

erfo

rmed

.

1-1)

Dat

a of

mai

n sh

aft E

EP

-RO

M is

bro

ken.

2-1)

Dat

a of

mai

n E

EP

-RO

M is

bro

ken.

3-1)

Dat

a of

hea

d E

EP

-RO

M is

bro

ken.

4-1)

CP

U m

ode

chec

k er

ror

5-1)

Inte

rnal

RA

M c

heck

err

or

6-1)

Ext

erna

l RA

M c

heck

err

or

7-1)

NO

RT

i set

ting

erro

r

8-1)

EE

P-R

OM

writ

ing

erro

r

9-1)

Com

mun

icat

ion

erro

r w

ith P

AN

EL

10-1

) C

omm

unic

atio

n er

ror

with

the

mai

n sh

aft

Rep

lace

MA

IN p

.c.b

.

Rep

lace

MA

IN p

.c.b

.

Rep

lace

MA

IN p

.c.b

.

Rep

lace

MA

IN p

.c.b

.

Rep

lace

p.c

.b. m

ount

ed o

n th

e m

achi

ne h

ead.

Rep

lace

p.c

.b. m

ount

ed o

n th

e m

achi

ne h

ead.

Rep

lace

MA

IN p

.c.b

.

Rep

lace

MA

IN p

.c.b

.

Rep

lace

MA

IN p

.c.b

.

Rep

lace

MA

IN p

.c.b

.

Rep

lace

MA

IN p

.c.b

.

Che

ck th

e co

nnec

tion

of C

N34

.

Per

form

rew

ritin

g of

the

prog

ram

of M

AIN

.

Per

form

initi

aliz

atio

n of

the

data

on

the

side

of M

AIN

of M

AIN

p.c

.b.

Rep

lace

MA

IN p

.c.b

.

Rep

lace

MA

IN p

.c.b

.

Per

form

writ

ing

of th

e pr

ogra

m o

f mai

n sh

aft.

Per

form

initi

aliz

atio

n of

EE

P-R

OM

of m

ain

shaf

t.

5) O

ther

s

－ 104 －

No. PART No. DESCRIPTION ASSEMBLED PLACE REMARKS

1 40008173 CONTROL BOX A ASM. CONTROL BOX A (3-PHASE : JAPAN, JUS)

40017733 CONTROL BOX B ASM. B (SINGLE PHASE : GENERAL EXPORT)

40017734 CONTROL BOX C ASM. C (SINGLE PHASE : CE TYPE)

2 40008187 MAIN P.C.B. A ASM. CONTROL BOX EXCLUSIVE

3 40017736 PWR P.C.B. B ASM. CONTROL BOX EXCLUSIVE

4 40000056 FLT-T P.C.B. A ASM. CONTROL BOX A (FOR 3-PHASE),MC-601/OTHERS

40000046 FLT-S P.C.B. A ASM. CONTROL BOX B • C (FOR SINGLE PHASE),MC-601/OTHERS

5 40017743 DC POWER CORD ASM. CONTROL BOX EXCLUSIVE

6 40005987 PDD RELAY CORD A ASM. CONTROL BOX SC-915

7 40005974 FLT-FG CORD A ASM. CONTROL BOX SC-915

8 40005975 AC INPUT 3 ø CORD A ASM. CONTROL BOX SC-915

40005976 AC INPUT 1 ø CORD A ASM.

40005977 AC INPUT 1 ø CORD CE ASM.

9 40005979 REGENERATIVE RESISTANCE A ASM. CONTROL BOX SC-915

!0 40016435 BOX FAN MOTOR ASM. CONTROL BOX SC-916

!1 40016435 FAN MOTOR IN BOX ASM. CONTROL BOX SC-916

!2 40005980 PEDAL SENSOR ASM. CONTROL BOX SC-915

!3 40016436 CE REACTANCE ASM. CONTROL BOX C (CE TYPE ONLY),SC-916

!4 HA004250000 POWER SWITCH TABLE/STAND A • B (EXCLUDING CE TYPE)

!5 M90175800A0 POWER CORD ASM. TABLE/STAND A (FOR 3-PHASE),MC-580

M90245800A0 B • C (FOR SINGLE PHASE),MC-580

!6 40016702 AUXILIARY PEDAL SENSOR ASM. TABLE/STAND EXCLUSIVE

!7 40017738 KNEE SWITCH CORD ASM. TABLE/STAND EXCLUSIVE

!8 40010034 IP-200C TOTAL ASM. HEAD IP-200

!9 40017737 FEED MOTOR CORD ASM. HEAD EXCLUSIVE

@0 40015794 AUXILIARY FEED MOTOR CORD ASM. HEAD EXCLUSIVE

@1 40015795 TOP FEED FAN CORD ASM. HEAD EXCLUSIVE

@2 40015796 BOTTOM FEED FAN CORD ASM. HEAD EXCLUSIVE

@3 40017740 HEAD RELAY CORD 1 ASM. HEAD EXCLUSIVE

@4 40017741 HEAD RELAY CORD 2 ASM. HEAD EXCLUSIVE

@5 40017739 PRESSER LIFTER CORD ASM. HEAD ONE BODY WITH AK SOLENOID

@6 40017742 HEAD EARTH CORD ASM. HEAD EXCLUSIVE

@7 KM000000350 TOP FEED MOTOR HEAD LZ-2290

@8 KM000000350 BOTTOM FEED MOTOR HEAD LZ-2290

@9 HM001940000 AUXILIARY FEED MOTOR HEAD EXCLUSIVE

#0 KM000000470 MAIN MOTOR HEAD EXCLUSIVE

#1 40005402 TOP FEED FAN ASM. HEAD EXCLUSIVE

#2 40005402 BOTTOM FEED FAN ASM. HEAD MC-601(LBH-1790)

#3 40016908 AT SOLENOID HEAD EXCLUSIVE

#4 40014098 OPTIONAL SWITCH ASM. HEAD EXCLUSIVE

#5 40017612 THREAD TRIMMER SOLENOID ASM. HEAD 11043106(DDL-5550)

#6 23638554 SAFETY SWITCH CORD ASM. HEAD DDL-9000

#7 40017823 AK SOLENOID HEAD EXCLUSIVE

#8 40017744 DATA P.C.B. ASM. HEAD EXCLUSIVE

11. CIRCUIT DIAGRAM

(1) Block diagram (1/2)

－ 105 －－ 105 －

OPERATION PANEL

TOPFEED PM

BOTTOMFEED PM

AUXILIARYFEED PM

AC SERVOMOTOR

!8 IP-200 C ASM.

@7 TOP FEED MOTOR !9 FEED MOTOR CORD ASM.

@8 BOTTOM FEED MOTOR

@9 AUXILIARY FEED MOTOR

#0 MAIN MOTOR

@0 AUXILIARY FEED MOTOR CORD ASM.

REGENERATIVERESISTANCE

9 REGENERATIVE RESISTANCE A ASM.

3 PWR P.C.B. B ASM.5 DC POWER

CORD ASM.

FAN MOTOR!0 BOX FAN MOTOR ASM.

FAN MOTOR!1 FAN MOTOR IN BOX ASM.

HEADIDENTIFICATION

#1 TOP FEED FAN ASM.

FAN MOTOR

FAN MOTOR

@1 TOP FEED FANCORD ASM.

PLDWRITING

#2 BOTTOM FEED FAN ASM.@2 BOTTOM FEED

FAN CORD ASM.

H8 MAINWRITING

H8 MACHINEWRITING

6 PDD RELAYCORD A ASM.

!3 CE REACTANCE ASM. (C TYPE)

!5 POWER CORD ASM.(A TYPE)POWER CORD ASM.(B • C TYPES)

!4 POWER SWITCH(A • B TYPES)

8 AC INPUT 3ø CORDA ASM.

7 FLT-FG CORDA ASM.

4 FLT-T P.C.B. AASM (A TYPE)FLT-S P.C.B. AASM. (B • C TYPES)

1 CONTROL BOX ASM. (A TYPE)CONTROL BOX ASM. (B TYPE)CONTROL BOX ASM. (C TYPE)

2 MAIN P.C.B. A ASM.

@3 HEAD RELAYCORD 1 ASM. #3 AT SOLENOID

THREADTENSION

#4 OPTIONALSWITCH ASM.

MONITOR

SHIRRINGRELEASE

!7 KNEE SWITCH CORD ASM.KNEE

SWITCH

@4 HEAD RELAYCORD 2 ASM.

#5 THREAD TRIMMERSOLENOID ASM. THREAD

TRIMMERSOLENOID

#6 SAFETY SWITCHCORD ASM.

(1) Block diagram (2/2)

SAFETYSWITCH

@5 PRESSER LIFTERCORD ASM. #7 AK SOLENOID PRESSER

LIFTERSOLENOID

!6 UXILIARY PEDAL SENSOR ASM.AUXILIARY

PEDAL

!2 PEDAL SENSOR ASM.PEDAL

SENSOR

#8 DATA P.C.B. ASM.

LEVELMETER

FOREXTENSION

@6 HEAD EARTHCORD ASM.

CN101

CN102

CN103

CN38

CN21

CN11

CN23

CN24

CN25

CN26CN12

CN22

CN13

CN10

T14 T15 T16

4

3

3P

3P5PCN3 CN2

CN1

FG1

CN111

CN110

CN34

CN56

CN57

CN44

CN59

CN50

CN70

CN71

CN72

CN53

CN54

CN52

CN51

CN62

CN36

CN55

CN61

CN63

CN104

CN105

CN107

CN108

CN109

EEP-ROM

8P8P

6P

5

5

9

4

9P4P

2

2

2

2

2

2P2P

2P2P

2P

2P2P

5P

6P

30P

8P4P

26P

10P

6P30

P12

P4P

8P9P

9P

6P4P

4P2P

4P4P

10P

14P

10P

2P6P

6P2P

26

5

5

30

128

4

－ 106 －－ 106 －

(2) Head and table/stand circuit diagram

PEDAL SENSOR

AUXILIARY PEDAL SENSOR

DATA P.C.B.

WHITE

WHITE

WHITE

RED

WHITE

BLACK

MAIN P.C.B.

CN36

+5V

PDL

SGND

SHIELD

+5V

PDL

SGND

SHIELD

CN55

+5V

+5V

DI

CS

SCK

DO

GND

GND

GND

GND

SHIRRING RELEASE

MON

SOL_ACT–

GND

GND

SOL_ACT+

CN53

+5V

STEP CHANGEOVER

GND

GND

CN54

CN62

TRMD

SFSW_N

TRMCOM

GND

CN52

FL

FLCOM

CN51

CN104

CN105

CN107

CN108

AT SOLENOID

MONITOR

SHIRRING RELEASE

KNEE SWITCH

THREAD TRIMMER SOLENOID

SAFETY SWITCH

PRESSER LIFTER SOLENOID

3

2

1

3

2

1

1

2

3

4

5

6

7

8

9

10

1

2

3

4

5

6

7

8

9

10

1

2

3

4

5

6

7

8

9

10

1

2

3

4

1

2

3

4

1

2

3

4

1

2

3

4

1

2

3

4

5

6

1

2

3

4

1

2

3

4

1

2

1

2

3

4

5

6

1

2

3

4

1

2

3

4

1

2

1

2

1

2

3

4

1

2

3

4

1

2

1

2

1

2

3

4

1

2

3

4

1

2

13.8Ω

7.5Ω

4 Ω

－ 107 －－ 107 －

(3) Main and panel circuit diagram

MAIN P.C.B. PANEL P.C.B.CN34 CN100

TXD

TXD (N)

RXD

RXD (N)

RTS

RTS (N)

CTS

CTS (N)

CLK

CLK (N)

S_RES (N)

PWR_F

SL_VR

NC

NC

NC

+24V

+24V

+5V

+5V

+5V

+5V

GND

GND

GND

GND

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

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

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

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

TXD

TXD [N]

RXD

RXD [N]

RTS

RTS[N]

CTS

CTS [N]

CLK

CLK [N]

SYS_RESET [N]

PWRF [N]

NC

NC

NC

NC

NC

NC

+5V

+5V

+5V

+5V

GND

GND

GND

GND

－ 108 －－ 108 －

(4) Power source A circuit diagram

MAIN P.C.B.

GREEN

BLACK

WHITE

RED

GREEN

BLACK

WHITE

RED

POWER SWITCH

CN1

FG

NC

NC

AC200-240V

AC200-240V

AC200-240V

1

2

3

4

5

6

1

2

3

4

5

6

280V

CENTER

AGND

1

2

3

1

2

3

4

5

FCANCEL

+12V

N.C

RL1

PDD

CN2

CN3

1

2

3

1

2

3

4

5

1

2

3

1

2

3

4

5

1

2

3

4

5

FLT - T P.C.B.CONNECTION TO 200V

WHITE

RED

BLACK

BLUE

BROWN

WHITE

YELLOW

PWR P.C.B.

280V

CENTER

AGND

+12VRTN

+12V

N.C

RL1 (N)

PD0 (N)

T16

CN12

+33V

+33VRTN

+24V

HEATP

+33V

+33VRTN

+24VRTN

OCRS_N

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

CN13

CN22

1

2

3

4

1

2

3

4

+48V

+48V

+48VRTN

+48VRTN

123456789

101112131415161718192021222324252627282930

123456789101112131415161718192021222324252627282930

123456789

101112131415161718192021222324252627282930

123456789101112131415161718192021222324252627282930

+5V+5V+5V

OCL1 (N)OVL (N)LVL (N)

GTRE (N)PWF (N)PHE (N)

MCLA (N)MCLB (N)

RESPW (N)UP (N)VP (N)

WP (N)UN (N)VN (N)

WN (N)SGNDSGND

S.STATE (N)HUHVHWMAMB

SDET (N)+12V

SGNDSFSW (N)

1

2

3

4

5

6

7

8

9

10

11

12

1

2

3

4

5

6

7

8

9

10

11

12

OCRS_N

+24V

+33V

+33V

+48V

+48V

HEATP

+24VRTN

+33VRTN

+33VRTN

+48VRTN

+48VRTN

+5V+5V+5VOCL1 (N)OVL (N)LVL (N)GTRE (N)PWF (N)PHE (N)MCLA (N)MCLB (N)RESPW (N)UP (N)VP (N)WP (N)UN (N)VN (N)WN (N)SGNDSGNDS.STATE (N)HUHVHWMAMBSDET (N)+12VSGNDSFSW (N)

BLUE

PURPLE

ORANGE

ORANGE

RED

RED

YELLOW

BLACK

BLACK

BLACK

BLACK

BLACK

power

source

CN59

CN10 CN44

－ 109 －－ 109 －

(5) Power source B circuit diagram

MAIN P.C.B.POWER SWITCH

CN1

FG

NC

NC

AC200-240V

AC200-240V

NC

1

2

3

4

5

6

1

2

3

4

5

6

280V

CENTER

AGND

1

2

3

1

2

3

4

5

FCANCEL

+12V

N.C

RL1

PDD

CN2

CN3

1

2

3

1

2

3

4

5

1

2

3

1

2

3

4

5

1

2

3

4

5

FLT - S P.C.B.

WHITE

RED

BLACK

BLUE

BROWN

WHITE

YELLOW

PWR P.C.B.

280V

CENTER

AGND

+12VRTN

+12V

N.C

RL1 (N)

PD0 (N)

T16

CN12

+33V

+33VRTN

+24V

HEATP

+33V

+33VRTN

+24VRTN

OCRS_N

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

CN13

CN22

1

2

3

4

1

2

3

4

+48V

+48V

+48VRTN

+48VRTN

123456789

101112131415161718192021222324252627282930

123456789101112131415161718192021222324252627282930

123456789

101112131415161718192021222324252627282930

123456789

101112131415161718192021222324252627282930

+5V+5V+5V



MCLA (N)MCLB (N)

RESPW (N)UP (N)VP (N)WP (N)UN (N)VN (N)WN (N)SGNDSGND

S.STATE (N)HUHV

HWMAMB

SDET (N)+12V

SGNDSFSW (N)

1

2

3

4

5

6

7

8

9

10

11

12

1

2

3

4

5

6

7

8

9

10

11

12

OCRS_N

+24V

+33V

+33V

+48V

+48V

HEATP

+24VRTN

+33VRTN

+33VRTN

+48VRTN

+48VRTN


BLUE

PURPLE

ORANGE

ORANGE

RED

RED

YELLOW

BLACK

BLACK

BLACK

BLACK

BLACK

power

source

GREEN/YELLOWBROWN

LIGHT BLUE

CN59

CN10 CN44

GREEN/YELLOWBROWN

LIGHT BLUE

－ 110 －－ 110 －

(6) Power source C circuit diagram

MAIN P.C.B.POWER SWITCH

CN1

FG

NC

NC

AC200-240V

AC200-240V

NC

1

2

3

4

5

6

1

2

3

4

5

6

280V

CENTER

AGND

1

2

3

1

2

3

4

5

FCANCEL

+12V

N.C

RL1

PDD

CN2

CN3

1

2

3

1

2

3

4

5

1

2

3

1

2

3

4

5

1

2

3

4

5

RED

BLACK

PWR P.C.B.

280V

CENTER

AGND

+12VRTN

+12V

N.C

RL1 (N)

PD0 (N)

T16

CN12

+33V

+33VRTN

+24V

HEATP

+33V

+33VRTN

+24VRTN

OCRS_N

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

8

CN13

CN22

1

2

3

4

1

2

3

4

+48V

+48V

+48VRTN

+48VRTN

123456789

101112131415161718192021222324252627282930

123456789101112131415161718192021222324252627282930

123456789

101112131415161718192021222324252627282930

123456789101112131415161718192021222324252627282930

+5V+5V+5V



MCLA (N)MCLB (N)

RESPW (N)UP (N)VP (N)

WP (N)UN (N)VN (N)

WN (N)SGNDSGND

S.STATE (N)HUHVHWMAMB

SDET (N)+12V

SGNDSFSW (N)

1

2

3

4

5

6

7

8

9

10

11

12

1

2

3

4

5

6

7

8

9

10

11

12

OCRS_N

+24V

+33V

+33V

+48V

+48V

HEATP

+24VRTN

+33VRTN

+33VRTN

+48VRTN

+48VRTN


BLUE

PURPLE

ORANGE

ORANGE

RED

RED

YELLOW

BLACK

BLACK

BLACK

BLACK

BLACK

power

source

GREEN/YELLOWBROWN

LIGHT BLUE

GREEN/YELLOWBROWN

LIGHT BLUE

FLT - S P.C.B.

L50

RED RED CN102WHITE

RED

BLACK

1

2

3

1

2

3

CN59

CN10 CN44

BLUE

BROWN

WHITE

YELLOW

－ 111 －－ 111 －

(7) Motor circuit diagram

BOX FAN MOTOR

FAN MOTOR IN BOX

TOP FEED FAN

BOTTOM FEED FAN

PWR P.C.B. MAIN P.C.B.

1

2

3

4

5

RED

ORANGE

YELLOW

BLUE

BLACK

RED

ORANGE

YELLOW

BLUE

BLACK

RED

ORANGE

YELLOW

BLUE

BLACK

6

7

8

9

10

1

2

3

4

5

6

1

2

3

4

5

6

7

8

9

10

1

2

3

4

5

6

M1M_A

M1M_B

M1M_C

M1M_D

M1M_E

M2M_A

M2M_B

M2M_C

M2M_D

M2M_E

M3M_A

M3M_B

M3M_C

M3M_D

M3M_E

NC

1

2

3

1

2

3

1

2

3

1

2

3

1

2

1

2

1

2

1

2

1

2

1

2

1

2

1

2

+24V

+24VRTN

+24VRTN

+24V

+24VRTN

+24VRTN

+24V

+24VRTN

+24V

+24VRTN

CN23

CN24

CN25

CN26

BOTTOM FEED

MOTOR

R = 0.93 Ω / 1 ø

AUXILIARY FEED

MOTOR

R = 0.75 Ω / 1 ø

TOP FEED

MOTOR

R = 0.93 Ω / 1 ø

CN56

CN57

CN111

CN110

A

BC

D

E

A

BC

D

E

A

BC

D

E

－ 112 －－ 112 －

ENCODER

SDC P.C.B.

WHITE (DRAIN WIRE)

BLACK

ORANGE

BLUE

PURPLE

LIGHT BLUE

PINK

RED

YELLOW

BLACK

RED

WHITE

GREEN/YELLOW

AC SERVO MOTOR

SHIELD

SGND

HU

HV

HW

NA

MB

+5V

SDET

U

V

W

FG

CN21

CN38

U

V W

R = 1.29 Ω

(8) Servo motor circuit diagram

FG

－ 113 －－ 113 －

(1) FLT-T p.c.b.

12. VARIOUS PRINTED WIRING BOARDS

(2) FLT-S p.c.b.

Pulse generation is carried out for the purposes of power supply rectification,noise reduction, and the detection of a momentary interruption

3-phase 200V~240V

Single-phase 200V~240V

CN1 : Power input , Power switch

For 200V to 240VDo not connect to 100V side.

Voltage changeover

CN3 : Momentary interruption

detection signal / PWR board

CN2 : Power output / PWR board

In the signal-phase mode, thepower supply is connected toPins 4-5. In the 3-phase mode,the power supply is connectedto Pins 4-5-6.

CN1 : Power input , Power switch

CN3 : Momentary interruption

detection signal / PWR board

CN2 : Power output / PWR board

Single-phase 200V~240V

Pulse generation is carried out for the purposes of power supply rectification,noise reduction, and the detection of a momentary interruption

Since single-phase specifications are adopted, thepower supply is connected to Pins 4-5.

－ 114 －－ 114 －

(3) PWR p.c.b. (4) MAIN p.c.b.

This p.c.b. performs generation of power, check of power and drive of main motor. This p.c.b. performs the whole control such as control of feed stepping motor, control of main motor, control

of active tension, memory switches, etc.

CN26Bottom feed fan motor

CN24Fan motor located inside of box

CN23Box fan motor

F2 10ATime-lag fuse for +33V

CN13DC power cord +33V, +24VTo MAIN p.c.b.

CN22DC power cord +48VTo MAIN p.c.b.

F1 10ATime-lag fuse For +48V

CN38Main motor encoder cable

CN21Main motor power cable

CN25Top feed fan motor

F5 4AFuse directly attached to p.c.b.For primary side of +33V power

F4 4AFuse directly attached to p.c.b.For primary side of +48V power

CN12instantaneous cut detectionsignal relay power +12V

To FLT p.c.b.

LD1 LED for power check

CN44Power +5V, Signal formain shaft control

F3 2ATime-lag fuseFor +280V regenerative resistance

To MAIN p.c.b.

CN2+280V power supplyTo FLT p.c.b.

CN11Regenerative resistance

LD2For U18 motion/error check

CN59DC power cord+48V, +33V, +24V

CN34Panel cable

CN65For testing

CN55 DATA p.c.b.

CN54 Knee switch

CN53Head relay cordAT solenoid Shirringrelease switch MonitorCN52 Head relay cordThread trimmersolenoid Safety switch

CN51Presser lifter solenoid

CN50Head discrimination

LD1For U11 motion/error check

CN71For U11 writing

BZ1For U11 motion/error check

CN44Power +5V,Signal for main shaftcontrolFrom PWR p.c.b.

CN56Top/bottomfeed motor

CN57Auxiliary feed motor

BZ2For U18 motion/error check

CN36Pedal sensor

CN62Auxiliary pedal sensor

SW4 For CPU writing

CN72For U18 writing

CN63 For extension

W2, W3For CPU initialization

CN61 Level meter

CN70 For U20 writing

CN32For standing work machine

From PWR p.c.b.

To IP-200C

－ 115 －－ 115 －

(5) PANEL p.c.b. (6) DATA p.c.b.

This p.c.b. performs input of operation, creation of sewing data, change of various setting of memory switches,

storing of various data, writing, communication with external equipment, etc.This p.c.b. records the data which are specific to the machine head such as compensation value of active

tension and the like.

CN55DATA p.c.b. cord

To MAIN p.c.b.

CN109Touch panel input

CN111For software debugNot mounted

CN103For smart media

SW2Smart media cover detection

SW1 UnusedCN102RS-232C for serialcommunication

VR1For LCD contrastadjustment

CN101For external input

CN34PANEL cableTo MAIN p.c.b.

CN104For U13 writing

CN105For LCD display/control

CN106Reserve for LCD display/control

SW3For flash memory

CN107For EXTENSION p.c.b.

BZ1For motion/error check

CN108Power for back light

－ 116 －－ 116 －

(1) Slant table

Part No. : 40013092

Y - Y

17

ø9 ø20

( 7˚)

(27)

28 ± 0.5

30

C2

15 ± 0.5

3.5 22.4 ± 0.5

(181

)

(183

.6)

ø10

ø7

(219

.3)

1200

321

375 ± 0.5105

223

50

346.5

12 12 56.5

22.5 22.5

258.5

225

13.5

23.5

22.5 22.5

13.523.5

12 12

75 18

14 9

52

141810

710 ± 0.5160

21 50

18

90

195

52.5

18

375 ±

0.5

24

72

535 36

0

406

96

175

90

1823

.5

13.5

(44.

3)

238

23.5

13.5

12.5

12

27.5

84

21.5

21.5

86.5

43

141

88

5518

50 50 R30

R8

R8

R8

R8

R8 R8

R27.5 R27.5

R30

R10

R21

R10

75.5

± 0

.5

151 ±

0.5

R8

R8

R8

R8R10

R10

R10

R21

R30W W

W W

W W

W W

W W W W

12.5

12.5

Z

Z

Y

Y

X

X

R10

A

B

C

D

E

F

G

H

V V

VV

1 8

R2R2

ø26

8.5

ø8.

5ø

8.5

ø26

8.5

27.5 ± 0.5 ø30

7˚

40181

22.4 ± 0.5

30

28 ± 0.5

15 ± 0.5

183.

6

3.5

ø7

ø10

R2 R2

C2

V - V (2 places)

X - X

2210

ø7

ø3.5 ø3.5 20

21

R 22.5

30

(55.9)

49.5

39

30

R10

R10

R10

R10

R 21

39

30

(55.9)

49.5

R 2

2.5

R 2

1

(172.5)

279 ± 1

68.5 ± 0.5

30

A

W - W (6 places)

ø11

ø19

17

Z - Z

R30

18

290

R24

2.5

R242.5

A

R8R8

A 4 x ø3.4 on the bottom surface, depth 20

(Drill a hole at the time of set-up.)

B JUKI logotype

C Jointless at the joining of slant section

D ø24 drilled hole

E ø18 drilled hole

F 2 x ø3.5 depth 10

G 3 x ø13 drilled hole

H 2 x ø3.5 depth 10

13. DRAWING OF THE TABLE

－ 117 －－ 117 －

(2) Work top table

293 305

100 250 ± 0.5 250 ± 0.5

14.5

153

363 610

34 ± 0.534 ± 0.5

71 50

755

100

275 ±

0.5

275 ±

0.5

34 ±

0.5

34 ±

0.5

305

285

24

178

545

595

895

960

1140

70

180

240

315

460

700

880

824

34 ± 0.534 ± 0.5

20

R50R50

R50

R15

R30

R30

R15

R30

R15

Z Z

Z Z

Z Z

Z Z Z Z Z Z

11

Z - Z (1:1) (6 places)ø4

ø8

90˚

1

B

A

C

R50

R50

R15

Part No. : 40013086

A 4 x 6.6 drill

B 8 x 6.6 drill, depth 17, spot facing depth 2

C JUKI logotype

810

－ 118 －－ 118 －

(3) Edge Stopper A Part No. : 40013087

15

7.5

26

630

275 ± 0.5 275 ± 0.540

3 x ø 2.5 depth 14

A

－ 119 －－ 119 －

(4) Edge Stopper B

15

7.5

26

580

250 ± 0.5 250 ± 0.540

Part No. : 40013088

3 x ø 2.5 depth 14

A

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.

04 · 02 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 2004 JUKI CORPORATION.

All rights reserved throughout the world.

r computer-controlled dry-head, lockstitch, sleeve setting ...semsi.com.mx/manuales/juki/dp-2100...

Documents