ESP9000
Contents
1. 7 Presser foot Needle bar linked driving system with noise reduction mechanism Bobbin thread winding Semi auto winding auto return also stop Thread trimming method Horizontal reciprocation motor drive 10 Thread wiper Motor drive sliding type with thread retaining mechanism 11 Picker method Picking at start end of sewing and cutting thread 12 Stitch speed 1 200spm maximum 800spm standard 13 Embroidery area 360 mm long x 500 mm wide 14 Embroidery control and Touch switch control with LED LED displays indication Stitch memory 280 000 stitches 16 Memory back up Memory saved during operation and after power off kept for 4 weeks Weight 80 1kg without table 18 Machine oil High grease NX 2 molybdenum grease NO 2 SF oil multi grade AC servo motor machine revolution Control motor AC servo motor X axis Y axis Needle thread failure detection Rotary detection system photo sensor Power supply and consumption 100 120 200 240VAC 50 60Hz 220W SO TAS x 7400 2 TROUBLESHOOTING el AMO N 2 1 The power supply does not turn on Power cord may be unplugged AC power cord Cable from the power box to the embroidery machine may be disconnected DC power cord Main circuit board Fuse Take out fuse and inspect it 250y6 3 Replace outside visually A without fuse fusion En 9 0to5 2V Adjust or Y Di when replace S Fuse turned on the DZ Circuit2. Adjustment 1 If the amount of deflection of deceleration belt B differs from that specified loosen the nut and two set screws d and turn setting screw e in the direction of the arrow After adjustment tighten two set screws d and the nut Fig 3 2 If the amount of deflection of deceleration belt D differs from that specified loosen three set screws f and nut A then turn setting screw g in the direction of the arrow After adjustment tighten three setting screws f and nut A Fig 4 3 If the amount of deflection of deceleration belt E differs from that 252 3 ADJUSTMETN specified loosen two set screws h and nut B then turn set screw i in the direction of the arrow After adjustment tighten two setting screws h and nut B Fig 4 Note Check the tension after tighting screws d f and h F Force kg at span center G Deflection mm FIG 2 FIG 4 33 3 ADJUSTMENT 3 10 Limit sensor Inspection 1 Loosen two setting screws a remove the table set Fig 1 2 Remove four set screws e and then base cover rear L Fig 1 3 Remove two setting screws c and Base cover front L the then base cover rearL Fig 1 4 Remove three set screws b and then base cover front L Fig 1 5 Remover four set screws d and then X cover Fig 1 6 Turn power on and carry out home position return Note Press the SET key 7 Check the di
3. FIG 4 40 4 4 REPLACEMENT OF MAIN COMPONENTS REPLACEMENT OF 4 1 Rotary hook Removal 1 Remove the table set 2 Bring the needle bar to the top dead center and remove the needle 3 Remove two set screws a and remove the needle plate Fig 1 4 Take out the bobbin case Fig 1 5 Remove two set screws b and remove the hook support Fig 1 6 Loosen three set screws c and remove the rotary hook Fig 1 Installation 1 Turn DS1 1 on and turn the power on 2 Put the rotary hook along the lower shaft Fig 1 3 Align the protrusion of the hook support with the dent in the rotary hook and temporarily fit the hook support with setting screw b Fig 1 Rotate the hand wheel to move the needle bar to the bottom dead center Rotate the hand wheel further until LCD display shows the needle position at 201 3 Fig 2 Rotate the rotary hook manually to align the hook tip with the needle center Secure a clearance of 0 1 to 0 3mm between the needle and the hook tip and temporarily tighten setting screw c closest to the hook tip Figs 1 2 6 Rotate the hand wheel again and check the position of the needle and hook when LCD display shows the needle position at 201 3 Then tighten three setting screws firmly Figs 1 2 7 Adjust the hook support position and retighten set screw b Figs 1 3 Please refer to 3 2 Position of the hook support
4. mni the thread Check the position of the catcher thread cutter when the cutter retum to the waiting position after cutting 16 Smear the Thread R Q thread Must be Adjust cutter dU m contact See SS afeltpen 25 evenness Fe I and check i evenly P29 Felt pen 4 e s marking Oo Contact evenly Blade pressure 2 TROUBLESHOOTING The needle or bobbin thread tension may be too tight The needle and thread may be too thick for the cloth The cloth tension may be too loose The needle tip may be blunt The hole in the needle plate may be burred The needle thread may be stuck around the threading tube holder and the thread take up Dia lever Wem Method Standard Action Hold the thread before the needle Thread take roller Pull the thread downward and A 20 Move the up spring the RE Pe spring Sua 1mm retracting stroke A moving Check the length of threa levar pulled until the spring stops position up and down to adjust Lower cover A Thread Take up Spring Retracting Lever Equivalent to 8 teeth of ratchet 247 The screw of the retracting lever Initial thread take up ratchet Hold the thread before the needle mark roller and pull the thread downward Check the tension when the thread take up spring moves approximately 1mm Clearance Check protrusion on hook under the support visually rotary hook support Relative po
5. 1 If the thread wiper hook does not catch the thread loosen four set screws a to move the thread presser base in the direction of the arrow Position the base where the guide pin moves smoothly and tighten four set screws a Fig 3 2 If distance A from the needle center to the thread wiper hook tip differs from that specified loosen two set screws b adjust by moving the thread wiper motor base right left and tighten two set screws b Fig 3 3 If distance B from the needle center to the thread wiper hook tip differs from Needle plate Bobbin r Picker that specified loosen two set screws c and adjust by moving the thread wiper hook base right left and tighten two screws c Fig 3 Guide pin Needie center LEX 4 Needle A J Cs Thread wiper hook S FIG 1 Thread wiper hook FIG 2 Thread wiper motor base 39 FIG 3 3 ADJUSTMENT 3 Adjustment of the Jump motor position Inspection 1 Remove the needle case Refer to 4 5 Replacement of needle bar reciprocator 4 2 Remove three set screws a two set screws b and remove the arm front Za cover L Fig 1 3 In this state the clearance between a p the jump lever and needle bar D N reciprocator must be 0 5mm Fig 2 Arm front cover L Adjustment 1 Loose the two set screws c and adjust the jump motor position by FIG 1 moving the jump motor right left Fig
6. 48 FIG 2 49 4 REPLACEMENT OF MAIN COMPONENTS 4 8 Power circuit board Removal 1 Remove two setting screws a and the table set Fig 1 2 Loosen four setting screws b and the rear cover Fig 2 3 Remove each four set screws c and the base cover rear R Fig 1 4 Loosen two setting screws d remove other two setting screws e and move the case cover upper Fig 3 5 Remove the connector CN9 of the computer board and all the connectors of the power circuit board Fig 4 6 Remove six set screws f and remove the power circuit board Fig 4 Installation Attached in the reverse procedure of removal Base cover per YN E Q gt FIG 1 FIG 4 Rear cover A Q Q Q 5 Som o gt O O ol Y O FIG 3 y da O O 5 O O da D O D 50 Printed in Japan 2002 8
7. SEWING MOTOR nee 3 2 3 An error message is displayed Check X MOTOR era aE 4 2 4 An error message is displayed l Check Y MOTOR oir cent isis 5 2 5 An error message is displayed NEEDLE CASE ERROR spera 6 2 6 Holder does not return to stroke center after home position Ol Mises 7 2 7 Thread comes off Ae 8 2 8 Skips BUCHES EE 9 2 9 Needle thread O CRORE CR IM M EP DI MU O RR 10 2 10 Bobbin thread A TTE 12 2 11 Needle A A II MM a AE NE MEJ 1 3 2 12 Thread wiper hook does not so A eo o ature Me 14 2 13 Thread trimming em 15 2 14 PU KO gne T er NER 16 2 15 Improper C Eg Nese IR Temm 17 2 16 Jump function does not e 18 2 17 An error message is displayed THREAD BREAK nunmehr 19 2 18 Stitch registration slips Olli een 20 3 AD JUS TMEN T OF MAIN COMPONEN DIS 21 3 1 Timing of the needle and the rotary NO A se o aetna 21 3 2 Position of the hook 210 6 Eeer 23 3 3 Standby position of thread Oe gE 24 3 4 Blade BEE EE Os 25 3 5 Picker Sede n PER T Ts 2 7 3 6 Position of the thread wiper OO sinter O A NE ON OTA RO OV 28 3 7 Adjustment of the jump motor DOSO Nas 29 3 8 Tension of drive belts A amp SENSO see A ri 32 3 11 Thread A A A RO EO O RE ee A AS RO 3 4 REPLACEMENT OF MA I N COMPON 4 2 Thread U ag geen nee neon ee NN 3 7 4 3 Thread A A 3 8 4 4 Needle Bee 39 4 5 Needle bar o enn NEN 41 4 6 Thread change MO EE 43 4
8. on page 23 8 Insert the bobbin case and attach the needle plate with two setting screws 2 9 36 N Rotary hook A S Hook support b Bobbin case FIG 1 Needle T 20113 d FIG 2 Needle Hook tip 0 1 to 0 3mm FIG 3 Rotary hook FIG 4 Hook support 0 2mm or less Bi i center Center of protrusion on hook support A 0 5 to 0 8mm a7 4 2 Thread cutter Removal 1 Remove the table set 2 Remove two setting screws a detach the needle plate Fig 1 3 Remove two set screws b and detach the thread cutter Fig 1 Installation Slightly pressing the thread cutter set it in parallel with the needle plate bracket A B and fix it in that position with two setting screws b Fig 2 Inspection After setting the thread cutter check again that the thread catcher makes an initial contact with the thread cutter at a clearance of 2 to 3mm Also check the sharpness of the thread catcher by hanging thread on the thread catcher and pushing it to the knife by hand F Please refer to 3 4 Blade pressure on page 25 38 4 REPLACEMENT OF MAIN COMPONENTS Thread cutter Pn 969 Lese Needle plate bracket 2 to 3 mm FIG 2 Thread catcher FIG 3 4 REPLACEMENT OF MAIN COMPONENTS 4 3 Thread catcher Removal 1 Remove the table set 2 Remove two setting screws a and detach the needle plate
9. Fig 1 3 Remove set screw b and detach the thread catcher Fig 1 Installation FIG 1 1 Put hole B of the thread catcher through pin A of the thread catcher drive arm 2 Tighten setting screw b Fig 2 Inspection Drive arm 1 When the thread catcher is in the standby position the dimension between the shoulder and the thread cutter must be 0 0 5mm Fig 3 FIG 2 Please refer to 3 3 standby position of thread catcher on page Waiting position 24 2 Remove the bed cover A and remove the connecting plate from the pin of the thread trimming lever 3 Move the thread catcher by hand and check the blade pressure of the Thread catcher 0 0 5mm thread catcher and the thread cutter Thread cutter Fig 4 Please refer to 3 4 Blade pressure on page 25 FIG 3 39 Thread catcher FIG 4 40 4 4 Needle bar Remove 1 Remove two setting screws a and the upper cover Fig 1 2 Remove set screw b and the under cover Fig 1 3 Remove two each setting screws c then remove the change cover and the relay circuit board cover Fig 2 4 Disconnect the card from the connector of CN2 and remove the tension base cover Fig 2 5 Remove the tension base cover Fig 2 6 Disconnect the cord from the connector of CN1 and remove two setting screws d and the sensor arm Fig 3 7 Remove two setting screws e and the tension base set F
10. Needle at the bottom dead center 19 Installation position of jump motor Connection of power connector Resistance Needle bar reciprocator Wrong movement or damage of needle bar r Connection of connector CN 7 Method Standard Action Remove the rear cover and A 0 5 Adjust check P i L P 29 e l IT Jump lever RA ALTA H Zi Needle bar reciprocator Connector Must be O connecte Connect d correctly correctly Replace See Disconnect the power 2 connector and check the resistance between and O and Gand UY and 6 with a circuit tester Free of Replace CI burrs See ML P 41 Needle bar reciprocator M Repl Vid a a ir init SS C a ae d P 45 oo correctly gt c EETEMER CEST pus Ce Gd 300 Mm men CN7 Check the condition visually connection 20 2 TROUBLESHOOTING dd de displayed When not displayed even if the needle thread breaks IE E pl ENS THREAD BREAK 128310 PM The thread sensor may be OFF When displayed even if the needle thread is not Operation panel break The needle thread may not be set correctly The bobbin thread may be broken The bobbin thread may be run out Torque of Must turn rotary ege disk smoothly tension disk A gt Check position of sensor Joint circuit board Connection Must be Connect
11. c Top dead center stopper needle bar connecting stud FIG 3 A32 4 5 Needle bar reciprocator Remove 1 Remove two setting screws a and the upper cover Fig 1 2 Remove set screw b and the under cover Fig 1 3 Remove two setting screws and the face plate 4 Remove two each setting screws c and the change cover the relay circuit board cover and then disconnect the connector CN2 Fig 2 5 Remove the tension base cover Fig 2 6 Disconnect the cord from the connector CN1 and remove the two setting screws d and the sensor arm Fig 3 7 Remove the setting screws e and the tension base set Fig 3 8 Turn DS1 1 on and turn the power on 9 Press SET key in the test mode of LCD locate the cursor at No 2 and press SET key 10 Select the No 15 of a needle number by color change key 11 Turn the hand wheel until the angle of LCD displays 107 5 12 Remove two setting screws f and pull out the needle case by holding it upwards Fig 1 13 Remove five set screws g and the arm front cover L Fig 4 14 Loosen the setting screw h bring the connecting rod to the bottom dead center and pull out upward the needle bar drive shaft Fig 5 15 Move the connecting rod to the left and pull out the needle bar reciprocator Fig 5 44 4 REPLACEMENT OF MAIN COPONENTS Needle case Upper cover FIG 1 FIG 2 FIG 4 Needle bar reciprocat
12. lower shaft joint gradually locate them vertically to the setting points and tighten them Insert two connectors and bundle the cords with the cable tie Install case cover upper with four setting screws a and b Fig 1 Install the base cover rear R L and the rear cover Main circuit board FIG 2 Power circuit board FIG 3 ewing machine motor FIG 4 4 14 X motor Removal 1 Remove two setting screws a and motor cover Fig 1 2 Loosen the nut and remove the setting screw b Fig 2 3 Disconnect the connectors Remove two setting screws c and the X motor Fig 2 52 4 Remove four setting screws d and X motor from the bracket Fig 2 Installation 1 Mount the X motor to the motor base with four setting screws d Fig 2 2 Set the X motor gear to the belt and temporarily secure the motor base to the X base B with two setting screws c Fig 2 3 Adjust the belt tension by setting screw b and firmly tighten two setting screws c then tighten the nut Figs 2 3 Note Check the tension after tighting screws C 4 Insert the connector 4 REPLACEMENT OF MAIN COMPONENTS Motor cover FIG 1 X motor c Motor base 4 REPLACEMENT OF MAIN COMPONENTS 4 15 Y motor Removal 1 Remove four set screws a and the FIG 2 base cover rear R Fig 1 2 Remove two setting screws b and the fan set Fig 2 3 Remove the Y pulley
13. 2 10 Bobbin thread breaks Needle thread Cloth END Bobbin Item Burred edges on hold in the needle plate Burred edges on the rotary hook Burred edges on the bobbin case The bobbin thread tension may be too tight he bobbin thread may be threaded incorrectly The bobbin thread may be wound too loose Method Standard Needle plate C ts Check the hole for burrs Check the Free of burrs thread path for burrs Bobbin case 12 Action Repair or replace the needle plate Repair or replace the rotary hook See P 36 Repair or replace the bobbin case Needle and rotary hook Thread wiper mechanism Ir Item Needle to rotary hook clearance Needle bat height Needle lift D Needle lift Reference value C 2 TROUBLESHOOTING The needle may be clamped incorrectly The needle may be bent or blunt The needle may be too thin for the cloth The starting position may be incorrect Method Standard Action A Align the needle to the hook tip and check the clearance A visually Standar d 18to Hook tip must be at the needle center 3 1mm a Needle bar at bottom dead center Rotary hook center 43 Thread wiper hook return Push the guide pin down as far as it will go in the direction of the arrow and check the returning movement of the pin 14 Must return smoothly
14. 2073 Rotary hook center li 8 0 0 1mm ON FIG 1 FIG 2 Needle bar Stopper Needle bar Connecting stud FIG 3 24 3 2 Position of the hook support Inspection 1 Remove the table set 2 Remove the needle plate 3 There must be a clearance of 0 5 to 0 8mm between the hook support and the rotary hook Fig 1 4 Distance B clearance between the needle center and the center of the protrusion on the hook support must not exceed 0 2mm Fig 1 Adjustment 1 Loosen the two setting screws a 2 Move the hook support in direction C or D to adjust the clearance between the hook support to the rotary hook Fig 2 3 Move the hook support fully in direction A or B to adjust the offset between the centers of the needle and the protrusion on the hook support Fig 2 4 Retighten the two set screws a Fig 2 5 Attach the needle plate and the table set 3 ADJUSTMENT Rotary hook Within 0 2mm Bi j center Center of protrusion on hook support A 0 5 to 0 8mm FIG 1 A C Rotary hook FIG 2 25 3 ADJUSTMENT 3 3 Standby position of thread catcher Inspection 1 Remove the needle plate 2 Remove the table set 3 Turn the power on and press the thread trim key to perform the thread trimming 4 The relative positions of the thread catcher and the thread cutter must be a clearance of 0 0 5mm Fig 1 5 At that poi
15. Adjustme nt is performe d by loosenin g a guide pin Screw 2 TROUBLESHOOTING 2 12 Thread wiper hook does not operate Thread wiper motor pulse motor wiper hook return Connection of power connector Resistance Connection of connector CN 6 Thread wiper hook may need cleaning lint dust etc Upper thread hook lever may be deformed Method Push the guide pin down as far as it will go in the direction of the arrow and check the retuming movement of the pi Connector O Disconnect the ower connector and check the resistance between and and Gand and with a circuit tester a a td tay C C i Qi esi j Ke Check the connection condition visually 15 Standard Must retum smoothly Must be connecte d correctly Must be connecte d correctly Action Connect correctly Replace see P 53 Replace See P 45 2 13 Thread trimming fails j 2 TROUBLESHOOTING Lint may be built up between the movable knife and fixed knife Check thread trim timing push function key and check thread trim timing position Thread trimming of the thread drive lever trimming drive lever Check the clearance between the lever and stopper At this point LED must be turned on Flaw on the Thread catcher Repair or thread replace catcher Fitted position of
16. board Figs 3 4 Installation 1 Attach the sensor board with the setting screw c Fig 4 2 Put the code of thread sensor base upwards into the thread sensor rail Fig 3 3 Putting a sensor arm into the slot of the thread sensor base and secure it with two setting screws b Fig 2 Note At this time check the sensor position Please refer to T 3 11 Thread sensor on page 34 4 Secure the cord with a cable tie and insert the connector Note The blue field of a code is turned and inserted in a spool side At this time check the connector connection by pulling a code with hand 5 Mount the relay circuit board cover change cover and tension base cover 57 Tension base cover FIG 1 FIG 2 FIG 3 FIG 4 4 REPLACEMENT OF MAIN COMPONENTS 4 18 Operation control circuit board Removal 1 Remove four setting screws a and the base cover rear R Fig 1 2 Loosen the two setting screws b remove the two setting screws c and E Base cover disconnect connectors CN12 and CN7 K Se then remove the case cover upper Fig 2 3 3 Remove the two setting screws d and FIG 1 the resin spacers then remove the console board Fig 4 Installation Attached in the reverse procedure of removal 58 FIG 4 59 1 SPECIFICATIONS 1 SPECIFICATIONS ESP9000 1 Type of stitch Lock stitch type sewing machine for automatic embroidery only
17. center of the rotation detecting plate Figs 2 4 4 Bundle the cords with cable tie 5 Set the DS1 1 on and turn the power on Rotate the hand wheel to move the needle bar to the bottom dead center Check that the LCD display shows the needle position at 180 Note In case the LCD display does not show 180 loosen the set screw adjust the position of the detecting plate and fix it Fig 1 Install the case cover upper base O lt 4 REPLACEMENT OF MAIN COMPONENTS cover rear L rear cover and bobbin winder base set Bobbin winder base set ase cover Rear L FIG 2 50 FIG 3 FIG 5 4 REPLACEMENT OF MAIN COMPONENTS 4 13 Sewing machine motor Removal 1 Remove the rear cover and base cover rear R L 2 Loosen two set screws a remove other two set screws b move the case cover upper disconnect CN5 of the main circuit board and CN3 of the power circuit board and cut the cable tie Figs 1 2 Loosen two setting screws c which are located on the motor side of the lower shaft joint Fig 1 4 Remove four setting screws d and the sewing machine motor Fig 4 3 51 Installation 1 Two set surfaces of the sewing machine motor shaft and two setting screws c of the lower shaft joint are aligned and insert the sewing machine motor Fix the sewing machine motor with four setting screws d Fig 4 Insert two setting screws c of the
18. of connecte correctly connector d or CN 1 correctly replace Remove the cover of joint circuit board and check the connection 21 Connection of connector CN 7 aha a ai OR Mise en fe EE di Li CN7 Check the connector visually 2025 Must be Replace connecte See d P 45 correctly 2 TROUBLESHOOTING 2 18 Stitch registration slips out The cloth may be set incorrectly in the embroidery frame The embroidery frame holder may be interfering The cloth may be stuck in the table The embroidery frame may be interfering The embroidery frame screws may be loose Belt tension Se AE EA T pe A F Force kg at span center G Deflection mm 2073 Encoder X motor Press the emergency stop button and check the voltage of the sections below with a circuit tester X motor Across D5V red and GND red and black Y motor Across 5V red and GND red and black 24 5V when turned on Replace see Pgs 51 and 52 3 ADJUSTMENT 3 1 Timing of needle and rotary hook 1 Needle lift rotary hook position and clearance between needle and rotary hook Inspection 1 Remove the table set Remove the needle plate Turn DS1 1 on and turn the power on Press SET key from test mode of LCD display select No 2 and press SET key 5 Rotate the hand wheel anti clockwise to move the needle bar to the bottom d
19. one al correctly replace 6 REGE See P A7 2 TROUBLESHOOTING 2 5 An error message is displayed Upper thread may be stuck or thread trimming error NEEDLE LCD display at right bottom corner is lt gt PH EN ved HO E cr t2 c amp DATA Lal i th ki gt TEE CASE ERROR Instead of lt 8 gt 4 5 6 EK 12 310 Operation panel Tr ME ei eg od Connection n da Mustbe Connect of power Connector d connecte correctly connector D d correctly Resistance 4 8 to 6 0 Replace Disconnect the power pi connector and check the ax Connection Must be Connect connected correctly correctly or replace of connectors CN 3 CN 4 Joint circuit board Remove the cover of the joint circuit board and check vie rally gt Power circuit board Connection N RAR Must be Connect of connector E connected correctly CN 7 correctly or replace see UNI P 45 Main circuit board Check the connector visually 10 Connection AA Must be of connector I HN connected See CN 10 EME ae Ca correctly 11 2 TROUBLESHOOTING 2 6 Holder does not return t
20. remove the X operation box Fig 2 Nor RS e Operation box cover Installation FIG 1 1 Plug in the cord 2 Secure the operation box to the bracket with four retaining screws d One of these screws is for grounding Fig 2 3 Mount the operation box cover with retaining screw b and two retaining screws c Fig 1 4 Rotate the operation box to set it at the desired angle for easy operation and secure it with retaining screw a Fig 1 Operation box Operation box cover FIG 2 49 4 12 Upper shaft sensor Removal Remove two setting screws a and the bobbin winder base set Fig 1 Loosen four setting screws b and remove the rear cover Fig 1 Remove two setting screws c and the upper shaft sensor set Then remove two setting screws d and the upper shaft sensor Figs 1 2 Remove four setting screws and the base cover rear L Fig 1 Loosen two setting screws remove other two setting screws move the case cover upper upwards disconnect the connector CN3 and cut the cable tie and then remove the upper shaft sensor Refer to Fig 2 on page 47 Installation 1 Install the upper shaft sensor on the sensor base with two setting screws d Fig 3 2 Insert the connector of the upper shaft sensor in CN3 on the main circuit board Fig 5 3 Fix the upper shaft sensor set with two setting screws c in the position where the center of the sensor comes to the
21. tester ower Check the voltage across is See 5V power supply and with a circuit tester P 44 Connection aje Must be Connect of excu ee via connecte the cable connector en d correctly or CN 12 Rote ae correctly replace the ee db main circuit board See PAT Connection d ale Must be Connect of e 2 connecte the cable connector Accor ME Wu E d correctly CN 7 EP ME E i correctly or I E replace the main circuit board see P 55 Connection Remove Must be Connect of the cover connecte correctly connector CN 3 and inspect connectio n visually correcily or replace defective connectors See P48 2 2 An error message is displayed Tee 121340 40 Check SEWING MOTOR Operation panel 24V power Connector connection Resistance Connection of connector CN 3 2 TROUBLESHOOTING Upper shaft torque may be too large Needle may be interfering with the embroidery hoop Thread may be stuck Check the voltage across and 4 with a circuit tester while shorting to Sensor connector Disconnect the power connector and check the resistance between Mand and and with a circuit tester CR TR E JI SA oes Oot Check visually the conn
22. the needle position by MA C moving the needle case right and left Za The change base must be located in the position where the cam roller pin does not touch also in the front and back 7 Install the tension base set with two setting screws a Refer to Fig 3 of removal 8 Install the sensor arm with two setting screws b Refer to Fig 3 of removal Note Check the position of the sensor Please refer to F 3 11 Thread sensor 4 on page 34 9 Install the change cover and the relay card cover with two setting screws Refer to Fig 2 of removal FIG 4 10 Install the tension base set upper cover s Jd Under cover 46 4 6 Thread change motor Removal 1 Remove two each setting screws a and remove the change cover and relay circuit board cover Fig 1 2 Remove each set screw b and remove the thread stand plate bobbin winder base and rear cover Fig 1 3 Remove the tension base cover and disconnect the cord by holding the connector CN1 upwards 4 Remove two setting screws c and the sensor arm Remove two setting screws d and the tension base set Fig 2 5 Cut the cable tie and disconnect the connector 6 Remove two each set screws e and the thread change motor base Fig 3 7 Loosen the set screw f and remove the hand wheel B Fig 3 8 Remove four setting screws g and the thread change motor Fig 4 Installation 1 Install the thread change motor a
23. 3 refer to 4 Replacement of needle bar reciprocator 4 2 After adjusting locate the jump motor at its highest position and tighten two set screws 3 Install the arm front cover L with five set screws Fig 1 FIG 2 CIS gt En ge aa ii pile PA WE l EA USERS ne TUT LS cranes FIG 3 34 3 ADJUSTMENT 3 1 Timing of needle and rotary hook 1 Needle lift rotary hook position and clearance between needle and rotary hook Inspection 1 Remove the table set Remove the needle plate Turn DS1 1 on and turn the power on Press SET key from test mode of LCD display select No 2 and press SET key 5 Rotate the hand wheel anti clockwise to move the needle bar to the bottom dead center 180 Rotate the hand wheel further and when LCD display shows the needle position at 201 3 Standard 18 to 3 1mm the hook tip must be aligned with the needle center Fig 1 6 The clearance between the needle and the hook tip must be 0 1 to 0 3mm Fig 3 Adjustment 1 Slightly loosen the rotary hook set screw a closest to the hook tip and loosen the other two set screws Fig 2 2 Rotate the hand wheel anti clockwise to move the needle bar to the bottom dead center 180 Rotate the hand wheel further until LCD display shows the needle position at 201 3 Fig 1 3 Loosen set screw a further and rotate the rotary hook in either direction A or B Alig
24. 7 Power supply erem e 44 4 8 Power circuit 010 ES 45 4 9 Jump BEE 46 4 10 Main circuit 4 11 Operation box asse le 48 4 12 Upper shaft SSIS een Senna ee 49 4 13 Sewing machine e e PO O O EEE OO MO NO 50 4 14 A MO EE EN 51 4 15 Y MOTOT PT n 7 T 52 4 16 Thread wiper e er Hm Per 93 4 17 Thread SONS One Cx A A ee ee 54 4 18 Operation control circuit 4 REPLACEMTNT OF MAIN COMPONENTS 4 9 Jump motor Removal 1 Remove the needle case Please refer to F 4 5 Needle bar reciprocator on page 41 2 Remove five set screws a and the arm front cover L Fig 1 3 Remove each setting screws and the thread stand plate bobbin winder base and rear cover Fig 2 4 Cut the cable tie and remove the relay harness 5 Remove two setting screws b and the jump motor set Fig 3 6 Loosen the setting screws c and remove the jump lever holder Fig 4 7 Remove four setting screws d and the jump motor Fig 4 Installation 1 Install the jump motor with four setting screws d Fig 4 2 Hang the jump lever return spring on the jump lever holder and pull down the spring as low as possible so that the spring will not be located on the jump positioning collar Fig 4 3 Tighten the setting screw c and check that the jump lever holder returns with the spring and stops with the stopper Fig 4 4 Install the jum
25. OS ab connecte correctly connectors mee d or CN 1 CN7 CNIHE Sra correctly replace Ss See P 47 2 TROUBLESHOOTING 2 4 An error message is displayed The embroidery frame holder may be jammed The cloth may be stuck at a table corner Check 13908 Y MOTOR The embroidery frame may be interfering dj 5 8 E 11213410 Operation panel Replace 24V power Seg SUDpiy P 44 Oj Shorted i Tester 4 A Queda S OOM Check the voltage across and AD with a circuit tester while shorting to Connection T Power connector Must be Connect of power connecte correctly and sensor NW s d connectors x correctly Sensor connector Resistance Disconnect the power 0 2 to 0 5 Replace RENTES kap eg ies eie E A Co S ee resistance between and P 59 Hand and with a circuit tester Connection Check the connector Must be Connect of connecte correctly connector or CN 2 correct replace idk y S E visually pode dens ae mm Te len An Si pedi S COT iP B Me eme J d EU 125V 20 A Must Replace Take out the fuse and be in the fuse check it visually good eS SE condition Connection Ee Must be Connect of ae E connecte correctly connectors CN4 l LONG ES d or CN 4 CN
26. TOYOTA SERVICE MANUAL Embroidery Machine A ESP9000 15 needles EXPERT COMPUTERIZED EMBROIDERY SYSTEMS 7 How toUse this Service Manu 1 This service manual applies to the ESP9000 Model names are indicated only for sections equipped with each model 2 Refer to the section on TROUBLESHOOTING first Trouble often results from two or more causes The TROUBLESHOOTING section indicates the correct order and method of troubleshooting When need arises to repair the embroidery machine in reference to this Service Manual refer to TROUBLESHOOTING first Then refer to ADJUSTMENT or REPLACEMENT as suggested 3 Only the critical instructions are given When a component must be removed for troubleshooting adjustment or replacement the Service manual explains how to remove other components before the component in question can be removed However the manual does not explain how the other components are fitted unless such information is necessary for technical reasons when adjustment or replacement is completed I ns pec t ion amp Repairs 1 When parts need to be replaced use only parts certified by Aishin Seiki Co Ltd to ensure machine performance 2 To prevent any accident from occurring be sure to turn the power OFF before repair CONTENTS 1 SEC II GATIONS as 1 2 TROUBLESHOOTING tette 2 1 The power supply does not turn Ol m EE 2 2 2 An error message IS displayed Check
27. box adjusting screw c and nut d and loosen setting screw e and nut f Fig 2 53 4 Disconnect the connector remove two set screws g and Y motor bracket set Fig 3 5 Remove four setting screws h and the Y motor Fig 4 Installation 1 Mount the Y motor to its bracket with four setting screws h Fig 4 2 Set the Y motor gear to the belt and temporarily secure them with two setting screws g Fig 3 3 Adjust the belt tension with setting screw e and then firmly tighten with two setting screws g and nut f Fig 3 Note Check the tension after tighting screws Q 4 Insert the Y pulley box adjusting screw c into the backmost position and tighten the nut d Fig 3 5 Mount the fan set with two setting screws b Fig 2 6 Insert the connector Base cover rear R 54 Y motor bracket set Fan set FIG 1 FIG 2 FIG 3 Y motor bracket Y motor FIG 4 4 16 Thread wiper motor Removal 1 Remove the each setting screws a and the change cover the relay circuit board cover the thread stand plate the bobbin base and the rear cover Fig 1 2 Cut a cable tie and remove the relay connector 3 Remove the setting screw b and two setting screws c and the thread 55 wiper motor Fig 1 4 Remove the setting screw d and e and the upper thread hook lever Fig 3 5 Remove the three setting screws f and the moto
28. d L Fig 1 4 Remove four set screws d and remove X cover Fig 1 5 When applying a force of 0 48 kg to drive belt A amount of deflection G must be 10 8 2 16mm Fig 2 6 When applying a force of 0 95kg to drive belt C amount of deflection G must be 7 4 1 48mm Fig 2 FIG 1 F Force kg at span center G Deflection mm Adjustment 1 If amount of deflection G of drive belt A differs from that specified loosen nut e and adjust the deflection using nut f Fig 3 2 If amount of defection G of drive belt C differs from that specified loosen two set screws g and nut then adjust the deflection using hex socket screw h Fig 4 Note Check the tension after tighting nuts e f and a screw g FIG 3 30 FIG 4 31 3 9 Tension of deceleration belts B D amp E Inspection 1 Loosen two set screws a and remove the table set Fig 1 2 Loosen two setting screws b and remove the motor cover Fig 1 3 Loosen four set screws c and remove the base cover rear R Fig 1 4 When applying a force of 0 46 kg to the center of deceleration belt B amount of deflection G must be 0 9 0 18mm Fig 2 5 When applying a force of 0 64 kg to the center of deceleration belt D amount of deflection G must be 1 1 0 22mm Fig 2 6 When applying a force of 0 51 kg to the center of deceleration belt E amount of deflection G must be 1 2 0 24mm Fig 2
29. d trimming drive lever must be 0 0 1mm from the motor spacer 5 If the LED is not turned on and the clearance between the lever and stopper is 0 5mm loosen the set screw FIG 2 of the drive arm set the thread catcher at O 0 5mm from the thread cutter and tighten the set screw of the drive arm FIG 3 Then perform the thread trimming to 296 Drive arm FIG 5 eA 3 4 Blade pressure Inspection 1 Remove the needle plate 2 Remove the table set 3 Remove four set screws a and remove the bed cover A Fig 1 4 Remove knife connecting plate from the pin of the thread trimming lever and smear the thread catcher with a felt pen Fig 2 5 Perform trimming manually and check that the felt pen marking on the thread catcher is scraped evenly even contact 6 Perform trimming again and check that the thread catcher makes an initial contact with the thread cutter at a clearance of 2 to 3mm blade pressure 0 6 to 1 5kg cm Fig 3 28 3 ADJUSTMENT Thread catcher Felt pen marking FIG 1 Thread catcher Thread cutter 2 to 3 mm FIG 2 FIG 3 cutter in position with the left side set screw a Fig 5 and 6 3 ADJUSTMENT Adjustment If the felt pen marking on the thread catcher looks like A or B adjust the angle of the thread cutter as necessary then adjust the blade pressure Fig 4 1 If the felt pen marking looks like A Fig 4 1 Turn adjusting screw b
30. e hand wheel anti clockwise When the needle bar comes to the bottom dead center the distance from the rotary hook center to the needle tip must be 8 0 0 1mm Fig 1 Adjustment 1 Remove the lower cover Fig 2 2 Loosen the set screw of the needle bar connecting stud set the needle bar height gauge adjust the height and tighten the screw Figs 3 4 Note Change the needle to check the needle can be easily changed Note If the needle can not be easily changed check the distance from the surface of needle bar connecting stud to the bottom of the upper dead point stopper must be 4 5 0 2mm Fig 3 3 Mount the needle plate and the table set 2073 Rotary hook center li 8 0 0 1mm ON FIG 1 FIG 2 Needle bar Stopper Needle bar Connecting stud FIG 3 Needle bar Needle bar height gauge Needle plate bracket 24 FIG 4 3 2 Position of the hook support Inspection 1 Remove the table set 2 Remove the needle plate 3 There must be a clearance of 0 5 to 0 8mm between the hook support and the rotary hook Fig 1 4 Distance B clearance between the needle center and the center of the protrusion on the hook support must not exceed 0 2mm Fig 1 Adjustment 1 Loosen the two set screws a 2 Move the hook support in direction C or D to adjust the clearance between the hook support to the rotary hook Fig 2 3 Move the hook support ful
31. ead center 180 Rotate the hand wheel further and when LCD display shows the needle position at 201 3 Standard 18 to 3 1mm the hook tip must be aligned with the needle center Fig 1 6 The clearance between the needle and the hook tip must be 0 1 to 0 3mm Fig 3 Adjustment 1 Slightly loosen the rotary hook set screw a closest to the hook tip and loosen the other two set screws Fig 2 2 Rotate the hand wheel anti clockwise to move the needle bar to the bottom dead center 180 Rotate the hand wheel further until LCD display shows the needle position at 201 3 Fig 1 3 Loosen set screw a further and rotate the rotary hook in either direction A or B Align the hook tip with the needle center Fig 1 and secure a clearance of 0 1 to 0 3mm between the needle and hook tip Fig 3 4 Slightly tighten the set screw a closest to the hook tip Fig 2 5 Rotate the hand wheel anti clockwise again until LCD display shows the needle position at 201 3 and check 2 3 4 son 3 ADJUSTMENT the position of the needle and hook tip 6 Firmly tighten the three retaining screws a Fig 2 7 Mount the needle plate the hook cover and the table set Needle bar Needle Hook tip 201 3 Standard 18 31mm FIG 1 FIG 2 FIG 3 sa 3 ADJUSTMENT 2 Needle bar height Inspection 1 Remove the table set 2 Remove the needle plate 3 Rotate th
32. ector Must be EEN Must be connecte d correctly Replace see P 44 Connect correcily Replace See P 50 Connect correctly or replace see P 45 Connection of connector CN 3 Must be connecte d correctly Connect the cable correctly or replace the main the circuit board See P 47 2 TROUBLESHOOTING 2 3 An error message is displayed The embroidery frame holder may be jammed Check The cloth may be stuck at a table corner EAE 7800 X MOTOR The embroidery frame may be interfering 112 3140 Replace 24V power See supply E P 44 Check the voltage across and d with a circuit tester while shorting to Connection KEE Must be Connect of power BEN connecte correctly and sensor Lekt e d connectors correctly Sensor connector Resistance Disconnect the power 0 4to 0 8 Replace connector and check the Q See resistance between and P 51 and and wih a circutt tester Connection Check the connector Must be Connect of connecte correctly vis connectors ert nis d or CN 1 CN4 en E Ge correctly replace jm e bb See ui EM P 45 om Un 125V 20 Replace A Must he f l Take out the fuse and be in MEUSE check it visually good condition Connection eC Must be Connect of lon a
33. er end of the needle bar to the same height as the next ones and tighten the setting screw c temporarily and also the needle bar connecting stud with the setting screw d Fig 1 5 Remove the needle plate 6 Rotate the hand wheel to bring the needle bar to the bottom dead center Loosen the set screw d and adjust 42 the needle bar height from the surface of the needle bar bracket to the lower end of the needle bar at 15 4 0 03 mm then tighten the setting screw d in the right direction Figs 1 2 7 Adjust the distance from the lower end of the top dead center stopper to the upper end of the needle bar connecting stud to 4 5 mm and tighten the setting screw c Fig 3 Rotate the hand wheel and check the needle bar reciprocator is properly set with the needle bar connecting stud Note Check that the needle bar returns smoothly with the spring when pushing down the needle bar If the needle bar does not return smoothly adjust the direction of the top dead center stopper 8 Check the needle and hook timing Please refer to 3 1 Timing of the needle and the rotary hook on page 21 b m Needle bar 2 holder spring Washer Needle bar case Needle bar E Under cover op dead center stopper c needle bar A connecting stud a OX Presser spring ee foot bushing Presser foot Cushion rina A Needle clamp FIG 1 Needle bar 15 4 0 03mm FIG 2 Needle bar
34. etting value of 9 of a function key is enlarged Thread wiper mechanism Method Standard Action Thread E Must wiper hook Push the guide pir return return down as far as it je smoothly will go in the Bo o direction of the arrow and checkthe Guide pin retuming movement of Hook tip No damage E damage is identified on the Upper thread hook hook tip picker g Clearance stops Check the clearance between between the picker tip and the the picker Pobbin and the bobbin A Ser Bobbin 4 Rotary hook center Picker B 1mm right left epe or less position di Picker tip center Clearance between the picker tip center and rotary hook center 14 C 7 9 mm when piker solenoid is ON 15 2 TROUBLESHOOTING mmm A needle may be bent A needle may be fitted incorrectly Thread path may be incorrect Needle size may be incorrect for the thread Cloth tension may be too weak Needles and rotary hook Needle and A 201 Adjust rotary hook 3 timing o ea eee Standar A ne See d 18 to needle center 31 mm Needle at the bottom dead center Needle to Meet B 0 1to Adjust hook clearance Hook tip Align the needle to the hook tip and check the clearance B visually 16 2 TROUBLESHOOTING 2 9 Needle thread breaks Rouge edges or burrs on thread path Rouge edges in needle plate hole Rouge edge
35. g tighten the set screw a then move the picker base to the backmost position set the picker stopper and tighten two set screws c Fig 3 2 If clearance B between the picker tip center and the rotary hook center differs from that specified loosen two set screws b to shift the picker bracket Tighten screws b after adjustment Fig 4 3 If the picker height differs from that 3 ADJUSTMENT specified loosen two set screws b to adjust the height Tighten screws l BR b after adjustment Fig 3 3 5 Picker position Inspection 1 Remove the table set A _0 5to 1 5mm 2 When the picker solenoid is on clearance A between the picker tip and the bobbin must be 0 5 to 1 5mm Picker Fig 1 Bobbin 3 Clearance B between the picker tip center and the rotary hook center must not exceed 1mm Fig 2 FIG 1 4 The picker height C must be 7 to 9mm from the center of the rotary hook 30 Rotary hook center C Bobbin Picker FIG 2 Picker solenoid lt gt FIG 3 FIG 4 3 ADJUSTMENT 3 6 Position of the thread wiper hook Inspection 1 When the guide pin is pushed down 31 the thread wiper hook must catch the thread Fig 1 2 Distance A from the needle center to the thread wiper hook tip must be 11 to 12mm during operation Fig 2 3 Distance B from the right end of the thread wiper hook to the needle center must be 1 to 3mm Fig 2 Adjustment
36. he rotary tension disk and rotary disk slit plate should turn smoothly Fig 1 3 The rotary disk slit plate should be located at the position where the distance A between the center of the disk and the center of the sensor is less than 0 8mm Fig 2 Adjustment 1 If the distance differs from that specified loosen two set screws a and adjust the position by moving sensor arm right and left Fig 3 Refer to 4 17 Thread sensor on page 54 Rotary disk Slit plate F G 1 Center of the disk Center of the sensor a7 FIG mY j MN ji ENT S N A A Spe A VH T a ON Sensor arm FIG 38 3 ADJUSTMENT 3 12 Power box Inspection 1 Turn power on and connect the circuit tester as shown in Fig 1 Check that the voltage across and O is 5 0 5 2V Fig 1 2 Short to Y and turn power on Connect the circuit tester as shown in Fig 2 and check that the voltage tester across and is 24 0 24 5V Fig 2 Power box tester Adjustment 1 Remove eight setting screws a and then the case cover Fig 3 FIG 2 2 Turn power on 3 If the 24V power supply differs from that specified replace the power circuit board Refer to 4 7 Power supply board 4 on page 44 4 If the 5V power supply CD C2 differs from that specified adjust power using VR6 Fig 4 5 Turn power off and mount the case cover 39 FIG 3
37. he thread wiper hook must catch the thread Fig 1 2 Distance A from the needle center to 31 Guide pin FIG 1 FIG 3 Needle i J L CS Thread wiper hook E l 3 ADJUSTMENT Needie center Thread wiper hook 3 7 Adjustment of the Jump motor position FIG 2 Inspection Thread wiper motor base a 1 Remove the needle case Refer to 4 5 Needle bar reciprocator on page 41 2 Remove three setting screws a two set screws b and remove the arm front cover L Fig 1 3 In this state the clearance between the jump lever and needle bar reciprocator must be 0 5mm Fig 2 Adjustment 1 Loose the two setting screws c and adjust the jump motor position by moving the jump motor right left Fig 3 refer to 4 5 Needle bar reciprocator on page 41 2 After adjusting locate the jump motor at its highest position and tighten two setting screws 3 Install the arm front cover L with five setting screws Fig 1 TE USAGE al iji s il E SE ET APN M gl a 4 N Arm front cover L 332 Jump lever 0 5mm Needle bar reciprocator FIG 2 FIG 3 34 3 ADJUSTMENT 3 8 Tension of drive belts A 4 C Inspection 1 Remove two setting screws a and then remove the table set Fig 1 2 Remove four each set screws b and then remove base cover rear R and L Fig 1 3 Remove three each set screws c and remove base cover front R an
38. ig 3 8 Loosen the set screw f and remove the needle needle clamp and cushion ring A Fig 4 9 Remove the setting screw g and the needle bar holder spring 10 Loosen the setting screw h for the top dead center stopper and the setting screw i for the needle bar connecting stud Remove the needle bar upwards and take out the washer cushion ring E top dead center stopper and needle bar holder Fig 4 41 4 REPLACEMENT OF MAIN COMPONENTS FIG 2 Upper cover DNU li ie FIG 1 Tension base cover Relay circuit board cover e Tension base set FIG 3 9 e Needle bar 8 holder spring Washer Needle bar Under cover Cushion ring Ten dead rod stopper IR es dle ees E stud AN E spring ne foot bushing Presser foot e N Cushion ring A Needle clamp FIG 4 4 REPLACEMENT OF MAIN COMPONENTS Installation 1 Insert the needle bar from the top of the needle bar case install the cushion ring E top dead center stopper needle bar connecting stud spring presser foot and presser foot bushing in that order Then insert the needle bar all the way down to the needle bar case Fig 1 2 Install the cushion ring A and needle clamp to the needle bar in that order and fix the needle with the setting screw a Fig 1 3 Install the washer needle bar holder spring to the needle bar and tighten the setting screw b Fig 1 4 Set the upp
39. in direction B and while steadying the thread cutter by hand turn adjusting screw b in direction C just so the screw tip barely touches the thread cutter Fig 5 2 While steadying the thread cutter Thread cutter by hand tighten set screws a alternately and evenly until the cutter is fixed firmly Fig 5 2 If the felt pen marking looks like B Fig 4 1 Slightly loosen two set screws a Fig 5 2 While steadying the thread cutter by hand turn adjusting screw b in direction C just so the screw tip FIG 4 barely touches the thread cutter Fig 5 3 While steadying the thread cutter by hand tighten set screws a alternately and evenly until the cutter is fixed firmly Fig 5 3 If the felt pen marking looks like C adjust the blade pressure Fig 4 1 If the clearance is less than 2mm slightly loosen the right side set screw a tighten the left side set screw a then tighten the thread cutter in position with the right side set screw a Fig 5 and 6 2 If the clearance is larger than 3mm slightly loosen the left side FIG 5 set screw a tighten the right side set screw a then tighten the thread 2 to 3 mm 29 Fig 2 FIG 6 Adjustment 1 If clearance A between the picker tip and the bobbin differs from that specified loosen two set screws C and the set screws a adjust the position of the picker by sliding the picker solenoid base back and forth After adjustin
40. ing looks like C adjust the blade pressure Fig 4 1 If the clearance is less than 2mm slightly loosen the right side set screw a tighten the left side set screw a then tighten the thread cutter in position with the right side set screw a Fig 5 6 2 If the clearance is larger than 3mm slightly loosen the left side FIG 5 set screw a tighten the right side set screw a then tighten the thread 2 to 3 mm 29 Fig 2 FIG 6 Adjustment 1 If clearance A between the picker tip and the bobbin differs from that specified loosen two setting screws b to adjust the clearance A Fig 4 Note Incase the picker solenoid is exchanged Loosen two set screws c and the set screws a adjust the position of the picker by sliding the picker solenoid base back and forth After adjusting tighten the setting screw a then move the picker base to the backmost position set the picker stopper and tighten two setting screws c Figs 3 4 2 If clearance B between the picker tip center and the rotary hook center differs from that specified loosen two setting screws d to shift the picker 3 ADJUSTMENT bracket Tighten screws d after adjustment Fig 3 l BF 3 If the picker height differs from that 3 5 Picker position specified loosen two setting screws b to adjust the height Inspection Tighten screws b after adjustment Fig 4 1 Remove the table set 2 When the picker
41. ly in direction A or B to adjust the offset between the centers of the needle and the protrusion on the hook support Fig 2 4 Retighten the two set screws a Fig 2 5 Attach the needle plate and the table set 3 ADJUSTMENT Rotary hook Within 0 2mm Bi j center Center of protrusion on hook retainer A 0 5 to 0 8mm FIG 1 A C Rotary hook FIG 2 25 3 ADJUSTMENT check the standby position of the thread 3 3 Standby position of thread catcher Thread catcher SP Connecting plate Inspection 1 Remove the needle plate 2 Remove the table set Thread cutter 3 Turn the power on and press the thread trim key to perform the thread trimming 4 The relative positions of the thread catcher catcher and the thread cutter must be a clearance of 0 0 5mm Fig 1 5 At that point LED must be tumed on FIG 1 Fig 2 drive lever Stopper Adjustment 1 Loosen four set screws a and remove bed cover A Fig 3 2 Remove four set screws b and remove the base cover rear L Fig 4 3 Remove three set screws c and remove the base cover front L Fig 4 4 If the LED is not turned on loosen the set screw d of the thread trimming drive lever and adjust the clearance between the lever and stopper to 0 5mm Fig 2 Then perform the thread trimming to check the standby position of the thread catcher Note At this time vertical position of the threa
42. n the hook tip with the needle center Fig 1 and secure a clearance of 0 1 to 0 3mm between the needle and hook tip Fig 3 4 Slightly tighten the set screw a closest to the hook tip Fig 2 5 Rotate the hand wheel anti clockwise again until LCD display shows the needle position at 201 3 and check 2 3 4 son 3 ADJUSTMENT the position of the needle and hook tip 6 Firmly tighten the three retaining screws a Fig 2 7 Mount the needle plate the hook cover and the table set Needle bar Needle Hook tip 201 3 Standard 18 31mm FIG 1 FIG 2 FIG 3 sa 3 ADJUSTMENT 2 Needle bar height Inspection 1 Remove the table set 2 Remove the needle plate 3 Rotate the hand wheel anti clockwise When the needle bar comes to the bottom dead center the distance from the rotary hook center to the needle tip must be 8 0 0 1mm Fig 1 Adjustment 1 Remove the lower cover Fig 2 2 Bring the needle bar to the bottom dead center loosen the set screw of the needle bar connecting stud and set the needle bar height then tighten the screw Figs 1 3 Note Change the needle to check the needle can be easily changed Note If the needle can not be easily changed check the distance from the surface of needle bar connecting stud to the bottom of the upper dead point stopper must be 4 5 0 2mm Fig 3 3 Mount the needle plate and the table set
43. n the thread catcher is scraped evenly even contact 6 Perform trimming again and check that the thread catcher makes an initial contact with the thread cutter at a clearance of 2 to 3mm blade pressure 0 6 to 1 5kg cm Fig 3 28 3 ADJUSTMENT Thread catcher Felt pen marking FIG 1 Thread catcher Thread cutter 2 to 3 mm FIG 2 FIG 3 cutter in position with the left side set screw a Fig 5 6 3 ADJUSTMENT Adjustment If the felt pen marking on the thread catcher looks like A or B adjust the angle of the thread cutter as necessary then adjust the blade pressure Fig 4 1 If the felt pen marking looks like A Fig 4 1 Turn adjusting screw b in direction B and while steadying the thread cutter by hand turn adjusting screw b in direction C just so the screw tip barely touches the thread cutter Fig 5 2 While steadying the thread cutter Thread cutter by hand tighten setting screws a alternately and evenly until the cutter is fixed firmly Fig 5 2 If the felt pen marking looks like B Fig 4 1 Slightly loosen two setting screws a Fig 5 2 While steadying the thread cutter by hand turn adjusting screw b in direction C just so the screw tip FIG 4 barely touches the thread cutter Fig 5 3 While steadying the thread cutter by hand tighten setting screws a alternately and evenly until the cutter is fixed firmly Fig 5 3 If the felt pen mark
44. nd the hand wheel B with setting screws 2 Install the thread change motor base with two each set screws e Fig 3 Note After checking that the thread change motor base touches the change base fix it with two setting screws 3 Connects the connector and bundle the cords with cable tie 4 Install the sensor arm and the tension base set with the setting screws and connects the cord to the connector Note After connecting the cord to the connector check that the cord does not come off 5 Install covers with setting screws A7 4 REPLACEMENT OF MAIN COMPONENTS Change cover Relay circuit board cover ff y A Ne kb NSS Wu A mS LE SE A IA Le VI d D b s y mo ir xim LU T ei ij I 5 Er i Thread stand Bobbin winder plate base Rear cover FIG 1 d Tension base set FIG 2 Thread change motor base FIG 3 FIG 4 4 REPLACEMENT OF MAIN COMPONENTS 4 7 Power supply board Removal 1 Remove eight setting screws a and then the case cover Fig 1 2 Remove the connector CN3 and the cords connected to the circuit board Fig 2 3 Remove four setting screws b and remove the power supply board Fig 2 Installation 1 Install the power supply board with four setting screws b Fig 2 2 Connects the connector and connect all the cords Fig 2 3 Mount the case cover with eight setting screws a Fig 1 FIG 1
45. nt LED must be turned on Fig 2 Adjustment 1 Loosen four set screws a and remove bed cover A Fig 3 2 Remove four set screws b and remove the base cover rear L Fig 4 3 Remove three set screws c and remove the base cover front L Fig 4 4 If the LED is not turned on loosen the set screw d of the thread trimming drive lever and adjust the clearance between the lever and stopper to 0 5mm Fig 2 Then perform the thread trimming to check the standby position of the thread catcher Note At this time vertical position of the thread trimming drive lever must be O to 0 1mm from the motor spacer 5 If the LED is not turned on and the clearance between the lever and stopper is 0 5mm loosen the set screw of the drive arm set the thread catcher at 0 0 5mm from the thread cutter and tighten the set screw of the drive arm Then perform the thread trimming to MES Thread catcher NUT RS SP Connecting plate V Fl cutter check the standby position of the thread catcher Fig 5 FIG 1 FIG 2 FIG 3 Drive arm FIG 5 eA 3 4 Blade pressure Inspection 1 Remove the needle plate 2 Remove the table set 3 Remove four set screws a and remove the bed cover A Fig 1 4 Remove knife connecting plate from the pin of the thread trimming lever and smear the thread catcher with a felt pen Fig 2 5 Perform trimming manually and check that the felt pen marking o
46. o stroke center after home position return Initialize of LCD display may be OFF when turn the power on 78 4 5 6 ee 123140 Operation panel X Y holder Photo sensor x_65 7 Adjust position X holder t1mm See check Y 213 5 P 32 5 p 1mm Jit Position Joint plate Y of cap frame sensor is Y 133 5 1mm C 1 0 5mm Connection sa Must be Connect of sensor connecte correctly connector sa d correctly Output AG EH E obstructed voltag Turn the power on and check 3 5 5V voltage across green and When not blue with a circuit tester obstructed 0 0 8V 12 X motor Y motor O Press the emergency stop button While turning the motor by hand check the voltage of the pons below with a circuit ester X motor cross 2 GND red and black and U yellow U yellow and ac V white V white and black W brown W brownan SO okej orange A orange and V 2 B pink B pink and black meter ross GND red and black and ol ellow V white rown A orange B pink 43 X motor in the range of 0 to 35 V Y motor in the range of 0 DV Replace see Pgs 51 and 52 2 TROUBLESHOOTING 2 7 Thread comes off needle The needle thread tension may be too high The bobbin thread tension may be too high The thread may be stuck on the thread take up lever The margin of the needle thread may be insufficient The s
47. or drive shaft FIG 5 45 4 REPLACEMENT OF MAIN COMPONENTS under cover Fig 4 Installation 1 Insert A of needle bar reciprocator into the connecting rod and also the needle bar drive shaft from the top of the arm Install the felt needle bar reciprocator felt B and bearing case collar in that order met ed Fig 1 2 The set hole of the needle bar drive shaft recibrocator D Connecting is turned in the direction of set screw a dil and it binds tight firmly in the place where Set hole a the set hole suited Fig 2 Felt B S 3 Install the arm front cover L with five Case collar setting screws b Fig 3 4 Bring the case linear to the left end and FIG 1 cam roller pin is put into the slot of the change cam imposing the needle case on the positioning board from the top Saa m and putting the slot on the take up lever MJ into the take up lever guide rail m upper Note When installing the needle case check that the thread wiper hook is inside the Velcro 5 After checking that all the slits of the take up lever are in the take up lever guide rail set the needle case to the right most stopper of the case linear and fix by pushing from the top Fig 4 6 Check the needle position at the needle d mali lt a No 15 ei dE Note No play with the needle case EE Note If the needle position is wrong loosen the setting screw for the change N WENN pu N base and adjust
48. p motor set with two setting screws b Adjust the clearance between the jump lever and the needle reciprocator at 0 5 mm by moving the jump motor right and left 5 Connect the relay harness bundle the cord with cable tie and install the thread stand plate bobbin winder base and rear cover 6 Install the needle case 46 Er Od an ae Zu gt FIG 1 FIG 2 FIG 4 4 10 Main circuit board Removal 1 Remove two setting screws a and the table set Fig 1 2 Remove four set screws b and the base cover rear R Fig 1 3 Loosen two setting screws c remove other two set screws d move the case cover upper upwards disconnect the connector CN2 and remove the case cover upper Fig 2 Disconnect all the connectors Fig 3 Remove two setting screws e and remove the main circuit board by holding the plastic spacer with pliers as Installation Attached in the reverse procedure of removal A7 4 REPLACEMENT OF MAIN COMPONENTS Main circuit board FIG 1 FIG 2 FIG 3 48 4 REPLACEMENT OF MAIN COMPONENTS 4 11 Operation box assembly Removal 1 Loosen retaining screw a and rotate the operation box in the direction of the arrow to set the box in the upright position Fig 1 2 Remove retaining screw b and two retaining screws c and the operation box cover Fig 1 3 Remove four retaining screws d Unplug the cord and
49. r base Fig 3 Note Be sure to insert the small washer that is contained in each setting screws of 3 and 4 sections Installation 1 Attached in the reverse procedure of removal Note Set the vertical position of the upper thread hook lever slightly upward and make sure that the connecting rod plate has a little play 2 After attaching check the distance A from the needle center to the thread wiper hook tip Please refer to 3 6 Position of the thread wiper hook a on page 28 3 If the distance A differs from that specified loosen two setting screw c and adjust by moving the thread wiper motor base up down 4 REPLACEMENT OF MAIN COMPONENTS Change cover Relay circuit board cover Thread stand Bobbin winder plate Rear cover base Motor base Thread wiper motor base Connecting rod plate Thread wiper hook base 56 FIG 2 Upper thread hook lever FIG 3 4 REPLACEMENT OF MAIN COMPONENTS 4 17 Thread sensor Removal 1 Remove the two each setting screws a then remove the change cover and relay circuit board cover Fig 1 2 Remove the connector CN2 3 Remove the tension base cover Fig 1 4 Raised the connector upwards and disconnect it 5 Cut the cable tie remove the two setting screws b then remove the sensor arm Fig 4 6 Extract the thread sensor base from the thread sensor rail remove the setting screw c and the thread sensor
50. s on rotary hook Needle thread path may be incorrect Thread tension may be too tight A needle may be bent A needle may be fitted incorrectly Needle size may be incorrect for the thread Thread density set to embroidery data may be to high The thread may be stuck on the spool o Standard Action Smooth edges with emery paper 800 or replace tough parts Rotary Tension Free of rough edges or Lower Threads Guide Set Needle Repair or replace Free of rouge edges Check needle plate hole for rough edges Repair or replace Free of rouge Check hook tip for edg es rough edges 10 2 TROUBLESHOOTING Needles and oe rotary hook pe ele Hook tip placed EU Adjust at needle center Standar d 18 to 3 1mm Needle bar height P A Lowest needle osition Needle B s heig ht Rotary hook center reference value Needle to Needle nook Rotary hook clearance tio D Align the needle to the hook tip and check the clearance B visually Pe Rouge Check the protrusion on Free of Repair or edges on hook support visually rouge replace hook edges See support P23 Clearance under the rotary hook B support KZU Relative B ositions of he center nero Center Protrusion 0 2mm of the on Hook protrusion SUPPO on the hook support and the center of the needle 11 2 TROUBLESHOOTING
51. sitions of the center of the protrusion E7 on the hook Center of support oon and the a a center of the needle 2 TROUBLESHOOTING The thread tension may be too loose The bobbin thread tension may be too loose Needle size may be incorrect for the thread Upper threading may be incorrect Bobbin thread may be loose Pt Thread _ SS O 18 2 TROUBLESHOOTING 2 16 Jump function does not work take up roller Pull the thread downward and A 20 1 sprin g the thread take up spring starts Move the p moving Check the length of thread retracting stroke A pulled until the spring stops lever sition p and down to adjust Lower cover Initial Thr 4 ead Take up B 5 1 g thread Spring Ea take up Retracting Lever of the sprin g Equivalent to 8 teeth of ratchet retracting tension B lever aligned Hold the thread before the needle with the roller and pull the thread downward ratchet Check the tension when the thread mark take up spring moves approximately 1mm Clearance Check protrusion on hook Adjust under the support visually See P 23 rotary hook support Relative B E positions of B 0 the center 0 2mm of the E protrusion Center of on the hook Protrusion on Hook mim center of the needle Needle and rota ry hook The rotary hook tip must timing be aligned with the Standar needle center d 1 Sto 3 1mm
52. solenoid is on clearance A between the picker tip and the bobbin must be 0 5 to 1 5mm Fig 1 A 0 5 to 1 5mm Picker 3 Clearance B between the picker tip center and the rotary hook center must not exceed 1mm Fig 2 4 The picker height C must be 7 to 9mm Bobbin from the center of the rotary hook 30 the thread wiper hook tip must be 11 FIG 1 mm or more during operation Fig 2 3 Distance B from the right end of the Rotary hook center thread wiper hook to the needle Bobbin center must be 1 to 3mm Fig 2 Picker Adjustment 1 If the thread wiper hook does not catch the thread loosen four setting screws a to move the thread FIG 2 presser base in the direction of the arrow Position the base where the guide pin moves smoothly and Picker solenoid tighten four setting screws a Fig 3 A 2 If distance A from the needle center to the thread wiper hook tip differs from that specified loosen two set screws b adjust by moving the thread wiper motor base right left and tighten two set screws b Fig 3 3 If distance B from the needle center to the thread wiper hook tip differs from that specified loosen two set screws Cc and adjust by moving the thread wiper hook base right left and tighten two screws c Fig 3 FIG 3 FIG 4 Needle plate Bobbin 3 ADJUSTMENT Picker 3 6 Position of the thread wiper hook Inspection 1 When the guide pin is pushed down t
53. stance X from the right most surface of the detecting plate to the center of left side X limit sensor shown in Fig 2 8 Move the X axis drive system to its forefront position and check the distance Y from the back most surface of the detecting plate to the FIG 1 center of middle side Y limit sensor Fig 2 Reference X 65 7 1mm Y 213 5 1mm Flat frame Y 1335 1mm Cap frame mm imit sensor Detecting plate slit Y 34 FIG 2 35 3 ADJUSTMENT Adjustment 1 If the X distance differs from that specified loosen two set screws a provided under the belt Move the Sensor bracket sensor bracket to the specified S position and tighten set screw a Fig 1 2 lf the adjustment is not successful after step 1 loosen two setting screws b and move the slit Fig 2 Note The slit is placed in the center of the sensor slot Fig 2 3 If the Y distance differs from that specified loosen two setting screws c and move the limit sensor to the specified position then tighten setting screw c Fig 3 3 lf the adjustment is not successful after step 3 loosen two setting screws d and move the slit Fig 4 Note The slit is placed in the center of the sensor slot Fig 4 FIG 2 FIG 3 Slit EA Sensor FIG 4 36 3 ADJUSTMENT 3 11 Thread sensor Inspection 1 Remove the tension base cover 2 When pulling the upper thread by hand t
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