Text preview for : Brother Compal Galaxie 870 ServiceManual.pdf part of Brother Compal Galaxie 870 Service Manual for Brother Compal Galaxie 870 sewing machine. (Same model as Empisal Compal Galaxie, not written Galaxy.)



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SERVICE MANUAL FOR COMPUTERIZED SEWING MACHINE

"COMPAL GALAXIE"
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GENERAL INFORM ATION
Th1s service manual is compiled for repa1ring service of COMPUTERIZED SEWING MACHINE "COMPAL GALAXIE" (Factory code #114-870). Use this manual with Parts Catalogue (H3030294) for fault f1ndmgs when you make a repair.

SYMBOLS USED ARE:

Th1s machine IS manufactured based on the up-to-dated product specifications at the time of this issue. but there may be changes of specifications for improvements. Contact manufacturer or local sales company for such changes. Brother industries. Ltd. Nagoya.Japan

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Move the part as this way (one way)

Move the part as this way (both way)

Move the part to its highest or lowest position

Set the clearance as indicated
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How to adjust mechanical elements ........................................................................ .............................. 2 9 .. . . 57 IV. How to adjust electric elements
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111.

11.

I. Principal mechanism

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D1sassembl1ng & Reassembling

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CAUTION
1 Always use rubber glove when handling printed circuit board and do not touch the metal portion of printed circuit board w1th bare hands. 2. Keep the human body earthed in order to avoid generating static electricity. 3. Pack printed circuit board w1th alumin1um f01l and avo1d impact on it when keeping or transporting. 4. Do not touch or damage on the metal portion of printed circuit board with screw driver or any other tools even
.

dunng repainng.

I. PRINCIPAL MECHANISMS
1. MECHANICAL CHART

Balance wheel
Eccentuc counter weoght

Thread take-up lever assembly

Needle bar supporter

Needle bar crank ---"1 Needle bar crank rod Needle bar Needle bar clamp --

---r-±::t=fi-Ji!f'ij't{'"f"L
+-t-;;r-+11---;----Linear actuator
Clutch mechanosm

-------fl/=

Lower timong pulley Verucal feed Lower shah Horozontal feed Horozontal feed regulaung mechanism roller shah

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2 . POWER TRANSMISSION CHART
ene r t a ing mechan ism o f needle bar, t hread (A) G tak e-up lever and z igzag movemen t s s le (B) Movemen t o f feed dog and shutt hook

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Balanoe whot l o t

Balance wheel

Feed regula1or shah

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3. ELECTRONIC PARTS ARRANGEMENT CHART

Sub-pronted corcuot

Bobbin wonder swotch

Ne.ctle POI+Iton (0ownt IAChCit+ng
lED

Buttonhole (BHI SWitCh

Transformer Junction for foot controller

Sode cutter swotch

Feed dog swotch Cord reel unot

Speaker

Common pronted circuot board

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4. CONTROL SYSTEM BY MICRO-COMPUTER
The micro-computer being used in Compal Galaxie is 8-bit computer fabricated on a single chip using N-MOS (N channel silicon gate MOS process) in 40 pins dual-in-line package with built in 4 K byte mask ROM. 96 byte RAM. oscillator. timer and 1/0 port. Moreover 1 28K bit mask ROM and 1 6 K bit RAM are expanded on external CPU. All function of this machine are fully controlled by this micro-computer.



tPotenhOi'l'letet)

Foo t com roller

Speed volume

Ceram· c O S C III ai O f

CPU

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ROM (4K byte)

II

RAM (96 byte)

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(Other switches) (Other sensors) Star!/stop sw·tch. S·de·cutter R everse SWitCh. detecr.ng swuch. Needle pos·tton Bobbin Winder switch SWitCh. Presser loot pos·t·on Panern select·on detecung sw·tch. button. Feed dog pOSit·on Manual st·tch length detecting SWitch. control sw·tch. Buttonhole lever Manual s titc h w1dth pos·flon detecttng control sw·tch, SWitCh. Ten eys. Buttonhole SWitch. Program star! key. Pattern d·splay Program end key. change sw·tch Joint ev Foot conrroller Tw·n needle key tack SWitCh

(Dtsplay de v·cel Pattern dtsplay LED. Manual d·splay LED. Need le pos·tlon ( UP/DOWNI LED. 7 segments LED

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6. THE FUNCTION OF MICRO-COMPUTER (MAL-WARNING VOICE)
CPU be1ng used in this machine i s supervising the k1nd of selected pattern. position of presser foot. feed dog and buttonhole lever. state of bobbin-winding. Start/stop switch. reverse switch. etc. If the customer operates the machine erroneously. the error 1s pointed out by mal-warning vo1ce. The output of voice made by voice synthetic system is PARCOR way which cons1sts of 2 pes. of P-MOS LSI. One i s mask ROM which stores information digitally analysed for the output voice. of which memory capacity is 1 28K bit. The other 1s acting synthesiS of the voice according to the information from former ROM and CPU output. The mal-warning voice contains 1 0 messages i n total which are as follows: 1 . Please lower presser foot lever. 2. Please change position of red knob to right to raise feed dog. 3. Please change position of red knob t o left to lower feed dog. 4. Please lower blue lever. 5 . Please raise blue lever. 6 . Reverse stitch cannot be obtained using this pattern. 7. Memory capacity full. Please check instructton book. 8. Please check instruction book. 9 . Th1s pattern combination is not acceptable. Refer to instruction book. 1 0 . Please use a foot controller.

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A mam motor for sewing machine IS requ1red to have stable revolution from low speed to h1gh speed against load fluctuatiOn and temperature change. To fully comply with th1s requ1rement. th1s Compal Galaxie IS adopt1ng low voltage D.C. motor and PWM ( Pulse W1dth Modulation) by transistors.

6. MAIN MOTOR CONTROL

7. UNEAR ACTUATOR CONTROL (PATTERN GENERATING DEVICE)
(LINEAR ACTUATOR CONTROL BLOCK CHART)

Pattern selectoon swoteh

onwnt

0/A t0ogllfi/An·logl

Drovong corcuot

Needle bar movong devoce

Ooflerentoator

CPU
Orovong corcuot

Feed regulatong devoc

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11. DISASSEMBLING
1. Outer parts

8r. REASSEMBLING
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2 . Cord reel unit .................................................................................. ......................... ................................... 24 .. . 3. Printed circuit boards 25 . . . . .. .
.................... .......... . . . . . . . . . ...................................... ............. ............ .. .. ..... .. .....

4 . Lead wires

....................................... ..................... ............................................................. . . . . . . . ...................

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5 . Transparency display plate ........................................................................................................................ 27

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1. OUTER PARTS
1 . Raise pressure regulating lever and remove face plate by loosening a screw. 2. Remove bobbm wmder cover by loosening a screw. 3 . Remove front cover by loosening three screws. 4. Remove bed cover by loosening two screws. 5. Remove extension plate by l ooseni ng two screws. 6. Remove manual regulator cover by using screw driver. 7. Remove plug case by loosening a screw.

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Arm base plate

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8. 9. 10. 1 1.

Remove stop nng then remove zigzag connecting link. Loosen a screw on eccentric counter we1ght. Lower pressure regulating lever. & 1 2 . Remove pressure regulating mechanism by loosening two screws.

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Remove power supply base plate cover. Dtsconnect power supply swttch connector A and transformer connector B.

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1 5. Remove plug case by loosenmg screw. 1 6. Remove cord reel unet by looseneng three screws.

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1 7. Loosen a screw. 1 8. Loosen a screw. 19 . Remove a eccentric shaft from lower shaft holder (Right ). 20. Remove feed mechantsm untt by loosening five screws.

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Stud plate



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Remove ztgzag connecting lever by loosentng a stud screw. Remove stop nng then remove ztgzag connecting ltnk. as done at step 8. Remove transformer by loosentng two screws. Remove ftxtng plate by loosentng a screw. Remove supporttng plate by loosentng a screw Remove ltnear actuator by loosentng two screws. Ztgzag connecttng lever

Ztgzag connecttng hnk

Transformer

Ltnear actuator
0 0

Fuung plate

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Reassembling 24. Determine the pos1tion to f1t feed mechan1sm unit by a pm, of which diameter IS 6 mm. 25. Fit feed mechanism unit by using five screws. 2 6. Change the pos1tion of red knob to left to lower feed dog and make sure the clearance between stud plate and vertical arm IS more than 0. 5 mm. 2 7. Tighten the stud plate by a screw. 28. Insert the eccentric shaft into lower shaft holder (A1ght). 29. T1ghten tentatively.

Stud plate

Lower shalt holder (Left)

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Meet the convex portions of linear actuator gear and feed regulator gear to face each other then trghten i n two screws making sure the clearance between both gears is 0.0 3 "' 0.04 mm. Fit the zigzag connecting l i n k to vertical arm by a stud screw. Attach supporting plate to the linear actuator. Attach fixing plate onto supporting plate i n a screw making the lower part of the fixing plate hold the right bushtng of lower shaft holder. Tighten the supporting plate by a screw. Zogzag connecting lever Fix transformer.

nsf orme r lonear acruator 0

Feed regulatng gear

Foxong plate

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32. Fit the pressure mechanism unit to vertical arm incerting eccentric counter weight into upper shaft. 3 3. Tighten pressure mechanism unit in two screws. At that time tighten upper screw slightly and after adjusting the top of needle drop to the center of needle hole. tighten two screws securely. 34. Assemble zigzag connecting link to zigzag connecting lever and attach stop ring together with thermoplaStiC washer. 3 5. Tighten a screw tentatively.

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36. Lower the needle until 1ts lowest pos1t1on by turmng balance wheel. 37. Turn the balance wheel so that the base line of lower t1mmg pulley IS nght under then make sure the clearance between eccentric counter we1ght and upper shaft bushmg IS 0 - 0.02 mm. 38. T1ghten the screw of eccentriC counter we1ght securel y. ,.-, .., ,-Eccenuoc coun1er weoghl

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39. 40.

loosen a screw. lower the needle from ·ts highest pos1t1on by 2 1 .4 mm turnmg balance wheel forward . Arm port1on
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Needle bar stand

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11i---Need

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4 mm

le bar

a : The h1ghest pos1t1on of needle bar b . The ume thal brake 1S released (The brake os released at th1s po.nll b =a+ 21.4 mm 4 1 . Make sure the clearance between feed regulator and brake gum is 0 - 0.05 mm by turning eccentric shaft. 4 2 . Tighten the screw. 43 . 4 4. Ra1se the needle from its lowest position by 1 5.2 mm turnmg balance wheel forwa rd. (Brake operation startmg pomt) Make sure the brake IS properly operated to feed regulator.

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Needle bar h1gh est pomt

On the way needle bar lowenng

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Brake gum
Screw

a Measurement on the needle bar h1ghest po1nt c =a+ 15.2 mm
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45.

PositiOn rotation shutter so that it can cross rotat1on sensor when needle IS pos1t1oned at 22.9 mm lower than its h1ghest position. Then pos1t1on N. P. shutter so that 1t can cross N. P. sensor when the clearance between thread take-up lever and the nb of thread guard IS about 0 mm. (Th1s 1s temporary adJUStment and make f1nal adJUStment later. Refer to page 34.)

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Posotron of rotatron shutter

The measure· ment should be Omm

Posrtton of N P shutter

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46 . Connect mam power sw1tch connector A and transformer connector B . 47. Fit the power supply c1rcu1t board . 48. Fit cord reel unit by t1ghtemng three screws. 49. Fit plug case by t1ghten1ng a screw.

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5 1 . Fit extension plate with two screws. 52. Fit bed cover with two screws. 5 3. Fit front cover with two screws. 54. Fit bobbin winder then tighten a screw. 55. Fit a face plate with a screw.
56. Fit a manual stitch control switch cover.

50.

Fit plug case by tightening a screw.

A rm base p late

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2. CORD REEL UNIT
remove) 1. Loosen 3 screws and remove those screws holdmg cord reel base so that it does not turn. Turn cord reel base counterclockwise about 4 - 5 times until it is free from the tension of spiral spring. 2. Remove cord reel wheel from cord reel cover.

(How 10

(How to fit)

4. Put cord reel wheel in cord reel case. 5. Make sure that cord goes as far as possible by moving the notching lever toward outside using screw driver. 5 times 6. Turn cord reel base counterclockwise about 4 and hold it not to turn clockwise in the tension of spiral spring. 7. Fit cord reel base with 3 screws.
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3. Put cord reel washer on cord reel wheel.

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3. REMOVING PRINTED CIRCUIT BOARDS

St art / atop SWit ch un1 1

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Stan ltl O & reverse sew. ng t c. e U ed "'ST /Sfr1 connectOf P SuttonhoN fctUtd · H " ) S t C h connector i W

Um.pc oon&c:tor
8unonhote lever te l l '"' BHL "') sw.tch connect Ot Pres.ser fool tcaUecl · pf: J S'Mtcl't conn ecto r Aottt 1on /Needle pos·hon senso r c c alted NPSEN! connec to1 Li mp SWi tch fct lltd -LPSW ) Leogth lt ntl I C 1Uil0f conn ector r S.de c u Ut t Ccalt td - s ew ) connec tor connector

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connoc 1or

T.cno..g ene rtt or ( Cf lltd I G ) connec'tor ·

Soeake r con ntct Of

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4. LEAD WIRES ARRANGEMENT

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5. REMOVING TRANSPARENCY DISPlAY PlATE
(The order of di..uembling) 1 . Loosen a screw then remove a stop rsng and a spring. 2 . Remove pattern change lever. 3. Loosen 2 screws. 4. Remove transparency display plate. (The order of reaaaembling) Proceed sn reverse order of disassembling. Make sure to f1t sprsng as Illustrated.

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Fitt ing position of micro-switch
1 . Make sure the micro-switch actuator i s in l1ne with micro
switch body. Make sure LED is lighted when mi cro-switch lead wire IS connected t o printed circuit board and pattern change lever is moved to right. 2. Make sure micro-switch actuator is not contacted with pattern change lever when pattern change lever is moved to left. Make sure LED continues to light to left direction when mi cro-switch 1s connected to printed circuit board and pattern change lever 1s moved to left then the pattern selection switch (left) is keeping depressed .

Pattern dtsplay change lev

--1--- actua Mtcro-swttch
T o be

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Mtcro-swttch

Pattern dtsplay change lever

Some clearance

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Ill. HOW TO ADJUST THE MECHANICAL ELEMENTS
1 . Position of shuttle hook 2 . Height of needle bar ........ ........................................................................................................................ 3. Bobbi n case holder bracket ............................... ............. ....... ................................................................. 4 . Height of presser bar .............. ................................................. ..... ........................................................... 5 . He1gh t of feed dog ....................... ....... ....................... ............................................................... ............... 6. Position of rotation shutter & N.P. (needle position) shutter ..................................... ......................... 7. Brake timing for feed regu lator ..................................................................................... ............ ............. 8. Tensio n of motor belt ......................................................................................... ............. ............. ...........
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30 31 32 32

33 34 36 37 ................ .................................................................... .......................................... 38 9 . Tension of tim1ng belt 1 0. R.P. M. of main motor ............................................................................................................................... 39 11. Needle stopping speed ...... .......... ..... .............................................. ............ .................................... . . . . ..... 41

12. Centering of the needle ....... ......................................................................... ........................................... 42 ........................................... 43 1 3. Settrng of the maximum needle swing ..................................... .................. ........................ .................................. . . . . 44 1 4 . Forward feeding at straight stitches ... ..................................... 1 5 . Length of forward and reverse stitches for super automatiC patterns ............................................... 45 1 6 . Position of buttonhol e sw1tch lever .................. ............... ................... ... ................................................ 46 .. .. . . . 48 .. 1 7. Upper tension dial . . 1 8. Thread tension release ......... .................... ... .............. ............................................................ .................. 49
.. ........ ......................... .............................. ..................... . ........ .......... ................

1 9 . Side-cutter adjustme nt (lock lever posi ti on) ................................................................ ........................ . ... ..... 20. Side-cutter adjustment (lower & upper kn 1ves) ................. ................................. .......................... ............... .......... ........... ....... 21. Side-cutter adJUStment (upper knife does not work) ................................ .. 22. Side-cutter adjustment (attachrng guide plate A & B) ............................... ................ ........................ 23. N eedle threader 24. Needle threader (exchange) ............................................................................................. ....................... 2 5 . Needle threader (checki ng the hook position) ................. ......... ............................................................ 2 6 . Needle threader (adjustment of hook position) .................................... ................................................

50 51

52 53 54 55 56 57

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1. POSITION OF SHUTTLE HOOK
STANDARD When z1gzag stitch is selected and the width IS set at its maximum position. 1. When needle raises from its lowest pos1tion by 4.0-4.3 mm. the hook point should meet with the side of the needle at left needle movement. 2. The clearance between the hook and needle IS less than 0.1 mm and never touch each other. ADJUSTMENT 1. Set the machine at z1gzag pattern. 2 . Set zigzag width at its maximum position. 3. Loosen three screws. 4. Adjust the hook to achieve above two standard. 5. T1ghten the screws. .

NOTE Make sure two standard are ach1eved if you loosen the screws.

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Less than 0. 1 mm

3 mm

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The lowest pos1t1on of needle bar The measurement when hook po1nt meet w1th lhe s1de of needle la-4 o-a-4. 3)

4 0-4.3 mm

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2 . HEIGHT OF NEEDLE BAR
STANDARD When the zigzag st1tch IS selected and the w1dth 1s set at 1ts max1mum position. 1. The clearance between the upper top of needle eye and bottom top of hook IS 0.4- 1.0 mm when needle and hook meet at left needle POSitiOn. ADJUSTMENT 1. Set the machme at z1gzag pattern. 2 . Set the zigzag w1dth at its max1mum pos1tion and seek the POSitton that needle meets with hook point by turn1ng the balance wheel. 3. Loosen the screw. 4 . Move the needle bar up or down to obtam correct postt1on. 5. T1ghten the screw. NOTE Care should be taken when you adJuSt the needle bar. the needle bar eastly turns and 1f tightened mcorrectly, 1t m1ght be caused the trouble of twm needle sewmg.

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3. BOBBIN CASE HOLDER BRACKET
STANDARD 1 . The clearance between the bracket and hook 1s 0.5- 0 7
mm.

4. HEIGHT OF PRESSER BAR
STANDARD 1 . The clearance between presser foot and needle plate 1s 6 .0
-6.5 mm.

2 . Loosen two screws. 3 Adjust the pos111on of bracket (reght to left or back and forth). 4 T1ghten screws.

ADJUSTMENT 1. Select zigzag pattern and set Z1gzag width at ··o··.

ADJUSTMENT 1 . Ra1se presser foot lever.
2 . Loosen screw. 3. AdjuSt the height of presser bar. 4. T1ghten the screw NOTE Make sure the presser foot and feed dog are en l1ne.


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0 .5-0 7 mm

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5. HEIGHT OF FEED DOG
STANDARD 1. The feed dog is higher than needle plate by 0.9 - 1 . 1 mm

when drop feed IS set at up posit1on and 1t reaches its h1ghest position. 2. The clearance between the feed dog and needle plate 1s more than 0. 3 mm (below) when drop feed IS set at down position and feed dog reaches its h1ghest pos1tion.

ADJUSTMENT 1 . Set the drop feed at up position.

2. Turn the balance wheel and seek the posit1on that feed dog reaches 1ts highest poSitiOn. Loosen the set screw and turn the stud. Tighten the set screw.

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0 9-U mm

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6. POSITION OF ROTATION SHUTTER & N.P. (NEEDLE POSITION) SHUTTER
STANDARD 1. D1sappear the LED md1cat1ng ··w (horizontal) when needle 1 s reached at the position of 22.9 mm lower than 1ts h1ghest pos111on by turnmg balance wheel at test mode. 2. In case that needle is set at 1ts up position. the top of needle IS stopped at the pos1t1on of 8 mm upper than needle plate also thread take-up lever is stopped at the position of 1 4 ± 1 mm upper than thread tension bar. ADJUSTMENT w1tches depressed to be 1. Turn the power supply sw1tch on w1th keep1ng both manual StitCh length/w1dth control s set a test mode. 2. Set the needle at the positiOn of 22.9 mm lower than 11s highest position by turnmg balance wheel. 3. Loosen a hexagon socket screw of rotat1on shutter 4. Turn the rotat1on shutter forth slowly and seek the pos1t1on that the LED ''H'' disappears. 5. Tighten the screw. 6. Start sewing and stop 11 by usmg start/stop switch. 7. Loosen a hexagon socket screw of N. P shutt er. 8. Seek the correct stop pos1tion (h1ghest pos1t1on) of thread take-up lever to meet with above standard by turnmg N.P. shulter forth or back. ·1n case that the shulter turns too soon. thread take-up lever stops before 11 reaches to 1ts h1ghest pos1 110n. In case that the shuller turns too late. thread take-up lever stops after 11 IS over at 1ts h1ghest pos1t10n . 9. Tighten the screw. 1 0. Check 1f the adJUStment meets w1th above standard when the needle stops at its up position.

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22.9 mm

N. P . sensor R otatoon sen sor

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Needle lowest poont

Rotatoon shutter

Upper face of needle plate

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7. BRAKE TIMING FOR FEED REGULATOR
STANDARD
When balance wheel i s turned forward. feed regulator is released from the brake at the position that needle i s lowered by 21.4 mm from its highest pos1tion and brake operates again from the position that the need le 1s raised at 15.2 m m until its h1ghest posit1on through its lowest position.

ADJUSTMENT
1. Lower the needle by 21.4 m m from its highest position by turnmg balance wheel. 2. Loosen a screw. 3. Adjust the clearance between feed regulator and brake-gum to be 0 "' 0.05 mm by turning eccentric shaft. 4. T1ghten the screw. 5. Raise the needle by 15.2 mm from its lowest position through 1ts lowest position . 6. Make sure that the brake IS properly operated on feed regulator.

Needle bar h1ghest pomt

On the way needle bar IS lowerm

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On the way needle bar is ra1s1ng

c

a . Needle bar h1ghest po1nt

c =a+ 15.2 mm

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8. TENSION OF MOTOR BELT
STANDARD
There should be some slacks (4
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6 mm) when the motor belt is JUSt pushed (about 200 g pressure.)

ADJUSTMENT 2. Adjust belt tension by moving motor holder to meet with 3. Tighten the screws.
above standard. I I I 1. Loosen two screws.

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mm

Change che car· bon brushwhen 11 wears off aboul 3

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9. TENSION OF TIMING BELT
STANDARD
There should be some slacks ( 3 5 mm) when the timing belt is just pushed (abotu 200 g pressure.)
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ADJUSTMENT 1 . Loosen a screw.

2. Adjust the posit1on o f idle pulley to meet with above standard. 3. T1ghten the screw.

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10. R.P.M. OF MAIN MOTOR
STANDARD
Speed Control Lever R.P.M . CAUTION As each volumes are locked by paint. turn them slightly to the direction of rotation and not give any pressure to the direction of thrust. After adjustment. make sure t o be again locked by paint.

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100-1 20R. P.M.

800-85 0R .P. M. (STRAIGHT) 700-75 0 R.P. M . (ZIGZAG) 380-420R.P. M . (MEMORY & PROGRAM PATIERNS)

ADJUSTMENT
1 . Set a machine at test mode. 2. Set the speed control lever at its leftest position (lowest speed position ) . 3. Start the machine and turn the volume of VR 1 clockwise or counterclockwise so that number of rotat1on should be 1 00- 1 20R.P.M. 4. Set the speed control lever at its rightest position (h1ghest speed position) and select the straight stitch. 5 . Start the machine and turn the volume VR2 clockwise or counterclockwise so that numbers of rotat1on should be 800-850R. P.M. 6. Select zigzag st itch. 7. Start the machine and turn the volume VR3 clockwise or counterclockwise so that numbers of rotation should be 700- 75 0R.P. M. 8. Change to the memory mode and select one of memory patterns. (No. 4 7-67). 9 . Start the machine and turn the volume VR4 clockwise or counterclockw1se so that numbers of rotat1on should be 380-4 20R. P.M.

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VR9 VR10 t() D 00, i<=iVR2 VR6 VR7 !c=l@vRJ 0 000§· VR5 eVR4 VRB D (t}vRt

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NOTE 1 . Each speed s never exceed to the standard. 2. The sewi ng speed is indicated by 2 digits in digita l display window. Ex. "1 2" means "1 20R .P.M:·.

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11. NEEDLE STOPPING SPEED
STANDARD
When needle stops at 1ts up pOSitiOn. needle threader can be usable and pass the thread to thread take-up lever aslly.

ADJUSTMENT
1 . Set the machine at test mode. 2. Set the sew1ng speed at 1 40R.P.M. by movmg speed control lever. 3. Turn the volume VR5 clockw1se until LED 1nd1cating (vertical) w1ll be lighted. 4. Turn the volume VR5 counterclockwise unt1l the LED w1ll disappear.

))

I)

_)

-
-41-

®

J J :tD , .:, ,

.

.·

.

.

12. CENTERING OF THE NEEDLE
STANDARD
1. Needle should drop at the canter of needle hole when z1gzag pattern is selected w1th its mmimum stitch width.

ADJUSTMENT
1. Set a machine at test mode. 2 . Select the zigzag st1tch. 3. Turn the volume VR10 clockwise or counterclockw1se so that needle should drop at the center of needle hole.

J

& ,..----'i---

ij

·


-42-

13. SETTING OF THE MAXIMUM NEEDLE SWING
STANDARD 1. Needle enters the needle hole balanced when zigzag stitch IS selected w1th ItS max1mum st1tch w1dth. ADJUSTMENT
1. Set a machme at test mode. 2. Select z1gzag stitch 3. Set the z1gzag w1dth at 1ts max1mum pos1110n . 4. Turn the volume VR9 clockw1se o r counterclockw1se so that max1mum z1gzag w1dth should be 6.8"" 7.0 mm

VR9

@'

®


· 6 B-7.0 mm

J

-43 -

14. FORWARD FEEDING AT STRAIGHT STITCHES
STANDARD 1 . There should be no feeding when stitch length is set at its minimum position. 2 . When setting at stra1ght st1tch. 1 1 stitches are sewn 1n 24 mm. ADJUSTMENT
1. Set a machine at test mode. 2. Set the speed control lever at 1ts maximum position. 3. Turn the volume VR-8 clockwise or counterclockwise so that no feeding is obtainable in sewing on paper when stitch length IS set at its minimum position. (The paper is not fed at least 5 seconds.) 4. Set the machme at pattern (} .

5. Start th1s pattern on paper until it is finished and adjust to meet with above standard 2 by turnmg volume VR6 . Maximum stitch length should be more than 4.5 mm.

(j) --

VR6

G ·

))

@(}

_)cv l [ Jji;l
-44-

@'

TT

JJ
o 1 1 slltches

15. LENGTH OF FORWARD AND REVERSE STITCHES FOR SUPER AUTOMATIC PATTERNS
STANDARD
Make sure to obtain proper length of both forward and reverse stitches to make fine pattern.

ADJUSTMENT 1 . Change to memory mode by moving pattern change lever to right. . .. 2. Input following pattern numbers to sew as EPS . No. 04 + N o. 1 5 + No. 18.

3. Set the length fine adjustmg volume on the right side of machine to be honzontal direction. 4. Depress the start/stop button to sew sample. 5. Turn the volume VR7 clockwise or counterclockwise so that reverse stitch meets with forward stitch. In case that longer reverse stitch is required Turn the volume clockwise. In case that shorter reverse stitch is required Turn the volume counterclockwise.
· · · · · · · · · · · ·

==

§;0
·

-r - +-

I

j

-

45

-

16. POSITION OF BUTTONHOLE SWITCH LEVER
STANDARD
1 . When buttonhole lever {Blue lever) and presser foot lever are lowered. BHO touches with BH 1. The legs of buttonhole should be d1ameter of button plus 2. 2. 5 mm.

Bunonhole sw·tch body

ADJUSTMENT
2. Fit the buttonhole foot and push the top port1on of rt backward as far as 1t will go. 3. Loosen a screw. 4. In case that the legs are shorter than the standard. bend the BH 1 to be far from BHO. In case that the legs are longer than the standard. bend the BH2 to be near BHO . 5 . Tighten the screw. 1. Select buttonhole pattern.
0 mm-·-""-- 0 m m

BH2

/1\ BH 1 ....... v L..W" "" f.-f-.
B

HO

®

A


u
·

O.Smm

-

46

-

17. UPPER TENSION DIAL
STANDARD 1. The clearance between two discs should be 0 - 0.3
mm

when presser foot i s lowered and tension dial is set at 0.

2. Spnng i s touched with spring holder and the top of thread release plate begins to depress on the tension disc B. when presser foot is lowered and tension dial rs set at 8. ADJUSTMENT 1. Set upper tension dial at 0. 2. Lower the presser foot lever. 3. Loosen two screws. 4. Adjust the position of thread tension bracket to meet wrth above standard 1. 5. Tighten the screws. 6. Set upper tension dial at 8. 7. Loosen a hexagon socket screw. 8. Adjust the position of spring holder to meet with above standard 2. 9. Tighten the screw.

Screw

-47-

18. THREAD TENSION RELEASE
STANDARD
The clearance between two discs should be more than 0.5 mm when presser foot IS ra1sed and tens1on d1al IS set at 9.

ADJUSTMENT 1 . Set upper tens1on d1al at 9 and raise the presser foot lever.
2. AdJuSt the position of thread tens1on release B to meet w1th above standard. 3. T1ghten the screw and check 1f the clearance between two d·scs IS more than 0.5 mm by moving presser foot lever u p and down.

-48-

19. SIDE-CUTTER ADJUSTMENT (LOCK LEVER POSITION)
STANDARD
When the lock lever IS fully pushed down (2.5- 3.0 kgs). the lower part of lock lever should be pos1t10ned w1thm the red mark.

2. Take out bracket case and attach the s1de-cutter on the tubular arm. 3. Loosen a screw. 4. Turn the eccentnc stud with screw dnver and adJuSt the clearance between the lower s1de of lock lever and Side cutter to be 3 5 mm. 5. T1ghten the screw. 6. Attach the bracket cover and check agam.
-

ADJUSTMENT 1 . Loosen two screws and take out the upper plate.

Lock lever

- 49 -

20. SIDE-CUTTER ADJSUTMENT (LOWER 8t UPPER KNIVES)
STANDARD 1. When Side-cutter IS out of machine and upper kn1fe holder
IS at h1ghest pos1t1on. both knives meet each other by 0. 71.2 mm. 2. Lower and upper kmves b1te each other by 1.5- 2.5 mm when needle bar moves to its lowest pos1110n. 5. Move the holder downward and loosen a set screw. Adjust the clearance between guide axis and holder be 0 mm and then tighten the set screw.

ADJUSTMENT
1. Remove bracket case by loosening two screws. 2. Keeping holder at highest position. adJUSt lower and upper kn1ves to meet each other by about 1 .0 mm and set upper kn1fe temporanly. 3. Attach the side-cutter to tubular arm and set needle bar at 1ts lowest posit1on makmg sure they meet each other by 1.5 - 2.5 mm. 4. Remove side-cutter from machine and f1rmly tighten the upper knife with securing holder.

""' Upper knofe holder
-

f

50

-

21. SIDE-CUTTER ADJUSTMENT (UPPER KNIFE DOES NOT WORK)
STANDARD
Upper kn1fe should work when 1t IS set to machane.

ADJUSTMENT
1. Attach the s1de-cutter to tubular arm and set the needle bar at 1ts h1ghest pos1t1on. 2 Loosen a screw. 3. By mov1ng the holder up and down. seek the pos1tion that the pan 1s fitted 1nto gu1de plate. 4 . T1ghten the screw.

Pon Upper knofe holder

-

51

-

22. SIDE-CUTTER AD JUSTMETN (ATTACHING GUIDE PLATE A & B)
STANDARD
The clearance between gUide plate A and upper knife should be 0 mm.

2. Loosen the screws on gu1de plate A & B and adJUSt the clearance between the gu1de plate A and upper kn1fe to beO. 3. T1ghten the screw A & B

ADJUSTMENT 1 . S e t the holder at 1ts h1ghest pos111on.

Guode plate B

®'
Omm

-

52

-

23. NEEDLE THREADER
1. Needle threader accept o nly circle marked needle and thread combmations. 2. marked combination is not recommended since it might lead to the breakage of needle threader imperfect performance. 3. Lower the presser foot when you use needle threader. 4. Do not use needle threader when you use twin needle. 5 . Nylon transparent thread is applicable in needle # 1 4 1 6. 6. Do not turn the balance wheel when you use needle threader. 7. Do not touch needle threader when machine i s running. 8 . Needle should be located above needle plate for more than 8 mm for threading. 9. Needle threader does not work when you use the side-cutter.
· -


N

#30 X X

#50 X X 0
.

#60 X 0 0
.

#80 0
.

#100 0
.

#120 0
. .

#9

#1 1

0

0

#14

X

#16 #18

.

0

0

0
.

.
.

.

.

.

-

53 -

24. NEEDLE THREADER (EXCHANGE)
How to exchange needle threader 1 . Remove needle and lower the presser foot. 2 . Push down needle threader to take out 3 Place new one so that gu1de IS 1mmed1ately under the gu1de p1n. 4. Push needle threader all the way up so that gUide 1s placed 10 the pm.

- 54 -

26. NEEDLE THREADER (CHECKING THE HOOK POSITION)
STANDARD 1 . The clearance between the top of hook and the top of 2. Threadmg is capable when needle IS located h1gher than 8
mm from the needle plate. needle eye 1s 0.

CHECK
Case A Hook pos1t10n 1s too h1gh. Case B

Hook pos1t1on IS too low. (Hook enters needle eye but tt catches bottom part of needle eye.)

Top of hook

A
Needle

B
Hook

X

X

-

55

-

26. NEEDLE THREADER (ADJUSTMENT OF HOOK POSITION)
ADJUSTMENT
Case A (Hook pomt 1S too h1gh) 1 Remove face plate and loosen the screw. 2. Adjust needle threader slightly down and check the clearance between the top of hook and top of needle eye 1 s zero. and part 1s m line Case B (Hook pomt 1s too low) Adjust needle threader slightly up and check the clearance between the top of hook and top of needle eye 1s zero.

3. Check 1f part

®

@

Note
In case part

® and part @

IS not m I me. hook does not work. AdjuSt needle threader by loosenmg the screw.

'-:: .J -t- Needle rhreader ::::::t: :1r
pos1110n sener

+- - Needle bar

X

X

Frg. 1

Frg 2

- 56 -

IV. HOW TO ADJUST ELECTRONIC ELEMENTS
1.

Power supp ly

······································ · · · ················ · · · · ··············· · ··············· ································ ··················

59 63 63 64 65 66 67

2. When power supply is on . z1gzag st1tch is not indicated by LED 3. P attern selection

············································ ·············

································· ······························ · · · · · ·····················

· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ················

3-1 . P anern d1splay is not moved when pattern selection switch is depressed

···································

3-2. Memory mode is not selected when pattern display change lever is moved to right 4. Main motor

·················

3-3. Other patterns than the ones for Side-cutter are selected when side-cutter is attached
····································································

············

·································· ·· ··········· · · · · · · ························

4- 1 . Main moto r does not rotate when start/stop switch is depressed 4- 2 . Machine stops with warning buzzer in a second after it runs 4-3 . Out of speed control 5 . Main motor stop 5 - 1 . Main motor does not stop 6 . Pattern generation
.......

....

.

..........

....

........

... .
.

.............

. ....
.

.........................

... .
.

... 68 .. 69 69 70 71 72 73 74 77 71

....... . .. .

····························· · · · · · ············· · · · · · · · ················ ···································· ·················

··········································· · · · · · ············ · · · · · · · · · · · · · · · · · · ···························································

················ ········· · · · · · · · · ······················ ······································

·····················

5-2. Needle stop position (UP/DOWN) i s incorrect 6-1 . Zigzag width is not correct 6-2. Stitch length is not correct 6 - 3. Buttonhole is not obtained 7. Mal-warning voice is not made

··········· ······································· · · · · · · · · · · · · · · · · · · · ···········

················· ························································ ·············································· ···············

· · · · · · · · · · · · ············· · · · · · · ························· ································

·························

······························· ······················································ ····························

....... . .

..

............

.

...........................

...

...........

.....

........

.

................

.....

............

. 76

·······························································

················· · · · · · · · · · · · · · · · · · · · · ············

- 57 -

CONNECTORS TABLE

Start/stop swotch u not

Start/stop & reve rse stotch connector Maon pronted corcu o t board Buu onhole swotch connec tor Lamp connector Buttonhole lever swotch connector otatoon/ needle posotoon connector Lamp swotch connector Wodth lo near actuator connector Length lonear actuator connector Sode-cuner swotch connector Feed dog switch connector ache-generator connector Maon motor connector Speaker connector Sub-pr.nted corcuot board Speaker connector

-

58

-

-trHow to

adjust electric elements
Secondary voltage of transformer (P13) Terminals AC Voltage about 1 5 . 5V 1 5 . 5V about 1 3 .0V Notes for circu1t & main motor for lamp

1. POWER SUPPLV

source

Power

AC

1-7 4-7 9- 1 1

·

Cord reel unit 8t Power supply switch
1 . Take out cord reel unit from machine. 2. Take out power supply SWitCh connector A and transformer connector B. 3. Turn the power supply sw1tch on. 4. Measure the resistance between terminal 1 & 3 on connector A.
....:::

Transfurmer

1

R (Resistance) s: 1 fi?

No

Exchange power supply switch

1 . Insert power supplv plug to outlet. 2. Measure the voltage between terminal 1 & 3 on connector B .

Yes 1

I

_l
-=

AC

Power supply voltage Ves

No

T
59

iExchange cord reel unitl

-

-

·

Transformer (Secondary Voltage) 1 . Connect transformer connector Band take out circuit board cover. Fit cord reel unit to the machine. 2. Take out face plate and front cover. 3. D1sconnect transformer connector P1 3 from common crcu1t board. 4. Insert power supply plug to outlet and turn the power supply switch on. 5. Measure the AC voltage between terminal 1 & 7. 4 & 7 and 9 & 1 1 on the connector 1 3 .

No

Exchange transformer

Yes Che ck other portions

1

1 . Turn the power supply switch off and connect connector P1 3. 2. Turn the power supply sw1tch on. 3. Measure DC+ 1 7. 5V and DC-1 7. 5V. (Refer to printed circuit board diagram on page BO.)

-

60

-

No 1 . Turn the power supply switch off. 2 . Disconnect main motor connector P 1 S and actuator connector PS & P9 from c1rcu1t board . Yes
·

linear

"=> _ Refer @ - --:
on page 62. Disconnect connector P6 (for rotat1on & N.P. sensor). PS (for linear actuator) and P9 (for linear actuator) from mam circuit board.

Internal resiStance Main motor connector P 1 8 1 - 2 about 2.00 Linear actuator connector PS & P9 1 -2 about 8. 50

Yes

Exchange main motor and/or linear actuator Connect connector P6 to mam circu1t board.

Exchange mam CirCUit board units.

__,_"'" .__ Y es ""

_ _

___. Exchange

linear actuator

-

61

-

No

1 . R between P3 connector (for lamp) & GND = oo? R between P7 connector (for lamp switch) & GND = oo? 2. R of P3 connector = 34-380? 3. R of P7 connector at lamp switch on = 10? R of P7 connector at lamp switch off = oo?

Yes

Normal

No

Exchange main c1rcuit board units.

Exchange lamp. lamp switch or lead wire.

Note:

.. R stands for resistance. . . GND.. stands for frame ground (lt IS connected to .O.V) . . oo·· stands for infinite resistance.
. . .

.

-

82

-

2. WHEN POWER SUPPLY IS ON, ZIGZAG STITCH IS NOT INDICATED BY LED

Check 1f the power supply IS normal. No
Exchange mam 1.

Refer to item 1 "POWER SUPPLY" on page 59.

ClfCUit board un1ts.

3. PATTERN SELECTION
0

Flow chart

1

(Movement of machme when pattern selecting sw1tch is depressed)
sWitCh

Pattern depressed? os selectong
Shifting

A

to utility mode

Revolution stop Yes No------ Pattern selectmg wothon 4 patterns for sode-cuner R a pla Pchange o sv == == tt =: :: ig h t - == == er n dlever=: :: ::



_ - _ __ - ___ _ -__ -___ __ ,-Pat l e rn select o n g o ul o f m em o patterns

- 63 -

3-1. Pattern display ia not moved when pattern selection switch ia depressed

Turn the power supply switch off. D1sconnect connector P1 from c1rcu1t board. 3. Measure A between terminal 4 and 5 on P-1 R between termmal 4 and 7 on P-1
1. 2. No

Exchange start/stop switch unit

Disconnect connector P 1 4 Measure A between terminal 1 and 2 on P 1 4 No Exchange main c1rcuit board umts Exchange foot controller jack

- 64 -

3-2. Memory mode is not selected when pattern display change lever is moved to right

1 . D1sconnect connector P1 0 for s1de-cuner SWitCh. 2. Turn power supply sw1tch on and shift pattern display change lever to nght.

Check the f1tt1ng position of m1cro-sw1tch. (Refer to page
28)

- =: :: Memor selected?== == ---- --.\ Exchange side-cutter sw1tch. c: :: mode IS == =- ---- Yes J y No 1 . D1sconnect connector P1 7 for m1cro switch and shift pattern display change lever to right. 2. Measure R between terminal 1 & 2 on Pl 7 . No R :ai 1 n Yes ( Exchange main circuit board units.
J Exchange m1cro sw1tch ' -- -- -- ------

)

-65-

3-3. Other patterns than the ones for side-cutter are selected when side-cutter is attached

1. 2. 3.

Attach side-cutter to the tubular arm. Remove connector P 1 0. Measure R between terminal 1 & 2 on P 1 0
R :ii lfl

l

No

Exchange main circuit board units.

Yesl

J \

Exchange Side-cutter sw1tch

)

- 66 -

4. MAIN MOTOR
Flow chart
2

(Movement of mach1ne when start/stop button or foot controller is depressed)
OFF

Motor do s not stan. e

Motor does not st art

No

Mal-warnmg voice

Motor is revolutmg at setting speed?
Mal-warning voice

Motor 1s revolut1ng at set point? No The revolution is stopped and warnmg is made by buzzer for 5 seconds.

-

67

-

4-1. Main motor does not rotate when start/stop switch is depressed

Warnong

os

made by buzzer?

No

Yes Turn the balance wheel both clockwise and counterclockwise.
®
Too much torque AdtuSl mechanocal poruons.

Disconnect connector and measure the while start/stop button is depressed.
P1 resistance between terminal 4 & 7 on P 1

Yes

Exchange main circuit board units.

Disconnect connector P 1 8. Measure the resistance between two terminals on P 1 8. = about 20 No Exchange main circuit board units.
R

Yes

Exchange main motor

-

68

-

4-2. Machine stops with warning buzzer in a second after it runs

Make the check as same as ® on page 68.
Rotation & N.P. shutter are properly pos111oned' (Refer to page 34

No

Adjust the rotation/N.P. shutter.

Yes Exchange N.P. circuit board.
4-3. Out of speed control

onnector P 1 2 IS p r OI)t!rly connected?

No

Re-connect

Yes Disconnect connector P1 2 and measure the resistance between terminal 1 & 2 on P12.
R 365n?

No

Exchange main motor

Yes Exchange main circuit board units.

-

69

-

5. MAIN MOTOR STOP
0 Flow chart 3

(movement when stopping machine) Set the machine at its lowest speed.

Yes

No No No

0

The relat1on of posit1on between N.P. sensor & N.P. shutter. (Refer to page 34) When N.P. sensor 1s blocked by N.P. shutter Needle-up position Needle-down position When N.P. sensor ·s opened from N.P. shutter
· · · · · · · · · ·

-

70

-

6-1. Main motor does not stop

Adjust R.P.M. at the lowest speed by turmng VR1 . (Refer to page 39) Adjust needle stop speed. (Refter to page 41) Yes Exchange main circuit board unets
6-2. Needle stop position (UP/DOWN) is incorrect

Finish

Turn balance wheel by hand.
Too much to rque. AdJUSI mechamcal portoons.

Adjust the pos1tion of N.P. shutter. (Refer to page 34) Ad1ust the lowest speed. (Refer to page 39) Adjust needle stop speed. (Refer to page 41)

Exchange mam c1rcuit board unets.
- 71 -

6. PATTERN GENERATION
0

Flow chart 4

Honzontal feed link moved. Needle bar is moved.
0

IS

Timing chart (Needle highest position
40" Needle-up pos1110n pulse
- - -

=

0°)
..- Nee;..,;. wn.;.. s1t1 0 n _ N.P ---T;..;.;,...;..o. po __ T-d le·d __ _ shutter (for detecung needle SlOP POS1t1on) ...,..,.,.., k Non-bloc,... 180° 160° Needle-up pos1t1on pulse W1dth drve

7.io· r·-··:.::"'"
81ock = =
-

ij

--: 2 :6 · ) 1 :-: e drve ed

.'\. :-:1

I

Non-block

2

Rota110n shutter (for detect1ng pattern pulse oulput pos1t1o

Lockng

I

120"

Non-locking

260"

I

- - ,-- - - Lock1ng mechan1sm

''LOCK MECHANISM'' 1s operated to hold honzontal feed link mechanically during fabric is fed. 1 . Horizontal feed link is hold at locked position. 2. Horizontal feed link is free at non-locked position and position of honzontal feed link can be moved by linear actuator. which means feed volume can be changed.
- 72 -

6-1 Zigzag width is not correct
.

Turn the power supply swttch off and move needle bar right and left by hand.

===---...:N..:;o:<...__,
ance between termmal 1 & 2.

AdJUSt rotauon shutter. (Refer to page 34 & 35)

Disconnect

connector PS and measure the restst·

No

Exchange linear actuator unit.

Measure the resistance between terminal 3 & 4 on PS while needle bar is moving. Yes No Exchange linear actuator unit.

Yes

Exchange main circuit board units.

- 73 -

6-2. Stitch length is not correct
Check following points: timing for feed regulator (refer to page 36). forward stitch length for super automatic pattern (VR7. refer to page 45). Yes height of feed dog (refer to page 33) . pressure lever. brake

length (VR6 & VRB. refer to page 44). forward & back stitch

No

ance between terminal 1 & 2 .

Disconnect connector P9 and measure the resist

No

Exchange linear actuator unit

Measure the resistance between terminal

3 & 4 while feed regulating mechanism is
operated. No

Exchange linear actuator unit

Exchange main circuit board units.

- 74 -

0

Flow chart

5

(Buttonhole)

Movement Movement Movement Movement

Movement

®
I

f! f! f!

I I

I I I

I I

t

rr )f q

@

©
I I I
I

- - -
I I I
I

l l

@

®

-

I I I I

11 l

-

-

-

75

-

6-3. Buttonhole is not obtained
(Different length of nght and left leg)

Let BHSW lever work by hand to make buttonhole.

AdJUSt the posit1on of BH lever. (Refer to page

46)

1 . D1sconnect connector P2. 2 . Measure the resistance between termmal 1 & 2 and 2 & 3 while BH lever is pushed
back.

Exchange BH switch.

Measure the resistance between terminal 1 & 2 and 2 & 3 while BH lever is pushed forth.

Exchange BH switch

Exchange mam circuit board umts.

- 76 -

7. MAL-WARNING VOICE IS NOT MADE

No

Exchange sw1tches or sensors.

01sconnect connector

res1stance between termmal

P 1 6. Measure the 1 & 2 on P 1 6.

No

Exchange speaker

Exchange ma.n circu1t board um ts.

- 77 -



Common Pnnted Circuit Board

'tfCAUTION Take care following points when handling printed circu1t board:

1 . Do not touch the connecting portion of the connector. especially
the pin for the plug with bare hands. for example. could be generated. causing bad connection. 2. If the surface of the connecting portion is dirty. polish it with

aJco Sub-

Pnnted Circu1t Board