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Brother BAS-342G PS, Service Manual

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Brother BAS-342G PS Service Manual Download Page 149

10. TROUBLESHOOTING 

 

 

140

BAS-342G 

 

Problem Cause 

Remedy 

Reference 

Upper thread tension is too strong. 

Adjust the upper thread tension. 

Instruction 

manual 

Needle is incorrectly installed. 

Install the needle correctly. 

Instruction 

manual 

Thread is too thick for the needle. 

Select a thread that matches the 
needle. 

Instruction 

manual 

Thread take-up spring tension and 
height are incorrect. 

Adjust the tension and height of the 
thread take-up spring. 

P. 87 

Damage or burring of the rotary hook, 
needle hole plate or needle. 

Repair or replace the problem part. 

 

Thread breaking from heat (Synthetic 
thread) 

Use a cooling tank. 

Instruction 

manual 

Upper thread breaks. 

Thread is threaded incorrectly. 

Thread the thread correctly. 

Instruction 

manual 

Lower thread tension is too strong. 

Adjust the lower thread tension. 

Instruction 

manual 

Lower thread breaks. 

Damage to corners of needle hole 
plate or bobbin case. 

Repair or replace the problem part. 

 

Clearance between needle and rotary 
hook tip is too great. 

Adjust the needle clearance. 

P. 89 

Needle and rotary hook timing is 
incorrect. 

Adjust the needle bar lift amount. 

P. 88 

The driver is covering the needle more 
than necessary. 

Adjust the driver. 

P. 88 

Needle is bent. 

Replace the needle. 

 

Skipped stitches occur. 

Needle is incorrectly installed. 

Install the needle correctly. 

Instruction 

manual 

Adjust the needle clearance. 

P. 89 

Clearance between needle and rotary 
hook tip is too great. 

Adjust the needle bar lift amount. 

P. 88 

Needle is bent. 

Replace the needle. 

 

Needle deflection 

Select a needle that is suitable for the 
sewing conditions. 
Reduce the sewing speed. 

Instruction 

manual 

Needle is broken. 

Needle is too thin. 

Select a needle that is suitable for the 
sewing conditions. 

Instruction 

manual 

Thread take-up spring tension and 
height are incorrect. 

Adjust the tension and height of the 
thread take-up spring. 

P. 87 

Needle and rotary hook timing is 
incorrect. 

Adjust the needle bar lift amount. 

P. 88 

Thread jamming. 

Shuttle race thread guide is not 
separating the threads. 

Adjust the position of the shuttle race 
thread guide. 

P. 89 

Summary of Contents for BAS-342G PS

Page 1: ...BAS 342G Please read this manual before making any adjustments DIRECTDRIVE PROGRAMMABLE ELECTRONIC PATTERN SEWER SERVICE MANUAL ...

Page 2: ...he SAFETY INSTRUCTIONS and the whole of this manual to understand this product before you start maintenance As a result of research and improvements regarding this product some details of this manual may not be the same as those for the product you purchased If you have any questions regarding this product please contact a Brother dealer ...

Page 3: ...th or serious injury CAUTION The instructions which follow this term indicate situations where failure to follow the instructions could cause injury when using the machine or physical damage to equipment and surroundings Symbols This symbol indicates something that you should be careful of The picture inside the triangle indicates the nature of the caution that must be taken For example the symbol...

Page 4: ...our Brother dealer or a qualified electrician for any electrical work that may need to be done The sewing machine weighs approximately 160 kg Use equipment such as a crane or hoist when installing the machine head and adjusting the height of the table If you try to lift the machine head yourself it may cause injuries such as back injury Do not connect the power cord until installation is complete ...

Page 5: ...o that they do not get into your eyes or onto your skin If the oil and grease get into your eyes or onto your skin inflammation can result Furthermore do not drink or eat the lubricating oil or grease They may cause diarrhea or vomiting Keep the oil out of the reach of children Maintenance and inspection Maintenance and inspection of the sewing machine should only be carried out by a qualified tec...

Page 6: ...s 4 Be sure to connect the ground If the ground connection is not secure you run a high risk of receiving a serious electric shock and problems with correct operation may also occur 5 Direction of operation Safety devices Devices such as eye guard finger guard thread take up cover motor cover X motor cover tension release solenoid cover inside cover outside cover middle cover fixed cover and rear ...

Page 7: ...BAS 342G v Tension release solenoid cover Motor cover Rear cover Inside cover L Outside cover Fixed cover Middle cover 3957M X motor cover ...

Page 8: ...Reading extended option output data from floppy disks 34 4 MECHANICAL DESCRIPTIONS 35 4 1 Needle bar and thread take up mechanisms 35 4 2 Lower shaft and shuttle race mechanisms 35 4 3 Work clamp lifter mechanism 36 4 4 Intermittent presser foot lifter mechanism 36 4 5 Intermittent presser foot stroke mechanism 37 4 6 Feed mechanism 38 4 7 Thread trimmer mechanism 39 4 8 Tension release mechanism ...

Page 9: ...installation position 95 7 13 Changing the intermittent stroke 95 7 14 Adjusting the work clamp lift amount 97 7 15 Adjusting the air pressure 97 7 16 Adjusting the thread trimmer cam position 98 7 17 Belt tension adjustment 98 7 18 Adjusting the tension release amount 100 7 19 Adjusting the lower shaft gear backlash 101 7 20 Adjusting the home position 103 7 20 1 Presser foot lift home position 1...

Page 10: ...d type work clamp Intermittent presser foot lift amount 22 mm Intermittent stroke 2 4 5 mm 4 5 10 mm or 0 Default setting 3 mm Rotary hook Double capacity shuttle hook standard shuttle hook sold separately Wiper device Standard equipment Thread trimmer Standard equipment Data storage method Internal memory Flash memory CF card 32 MB 2GB Option 3 5 floppy disk 2HD 1 44MB 2DD User programs 50 Cycle ...

Page 11: ...Advanced 7 Software version display function Refer to 2 9 Software version checking method 3 Data initialization function Refer to the Instruction Manual 8 Home position adjustment mode Refer to 7 20 Adjusting the home position 4 Error log display function Refer to 2 6 Error history checking method 9 Needle up stop position adjustment mode Refer to 7 22 Adjusting the needle up stop position 5 Inpu...

Page 12: ...counter setting mode Refer to the Instruction Manual 6 Parallel movement mode Refer to the Instruction Manual 3 Production counter setting mode Refer to the Instruction Manual 7 Stitch counter checking mode Refer to 2 5 Stitch counter checking method 4 Production counter temporary display function When SPEED indicator is illuminated Refer to the Instruction Manual 8 CF data read write mode Refer t...

Page 13: ...nged from default settings While pressing the SELECT key press the or key The numbers of memory switches that have been changed from default settings will appear in order If no memory switches have been changed from their default settings the display will not change and the buzzer will beep twice 3 Ending setting mode TEST indicator switches off Press the TEST key The changes will be memorized and...

Page 14: ...stitch at 900 rpm 5th stitch at 2 000 rpm OFF Single stitch test feed OFF Test feed starts when the start switch is depressed and it continues automatically until the final stitch 200 ON Test feeding Is carried out one stitch at a time each time the work clamp switch is depressed Is carried out continuously while the start switch is depressed Is carried out one stitch at a time when the pulley is ...

Page 15: ... fully and then lifts in that order Dropping in one step or two steps can be set by means of memory switch No 002 9 Standard triple pedal The left pedal lowers the work clamp to the intermediate position and the right pedal center lowers it all the way The start pedal right starts the sewing machine If the right pedal center is depressed first the work clamp will drop to the intermediate position ...

Page 16: ...ly for 2 position valve specifications Right work clamp reverse Option output No 4 Left work clamp reverse Option output No 5 When using a separate type work clamp 0 Thread winding operation before home position is detected OFF Thread winding cannot be carried out before home position is detected 056 ON Thread winding can be carried out before home position is detected 5 OFF Work clamp operation w...

Page 17: ...tch sewing speed at the sewing end 157 4 27 Units x100 rpm 27 3rd last stitch sewing speed at the sewing end 158 4 27 Units x100 rpm 27 2nd last stitch sewing speed at the sewing end 159 4 20 Units x100 rpm 12 Piercing force boosting operation OFF Disabled 161 ON Piercing force boosting operations are carried out when the sewing machine motor is locked OFF Regulation of sewing speed changes due to...

Page 18: ...Standard 10 Late 0 Changes the feed timing for the 1st stitch at the sewing start 261 10 10 10 Early 0 Standard 10 Late 0 Changes the feed timing for the 2nd stitch at the sewing start 262 10 10 10 Early 0 Standard 10 Late 0 Changes the feed timing for the 3rd stitch at the sewing start 263 10 10 10 Early 0 Standard 10 Late 0 Changes the feed timing for the 3rd stitch before the sewing end 264 10 ...

Page 19: ...d for each thread trimming operation 352 2 Counted when sewing data ends or when split stops 0 Counter timing for lower thread counter OFF Counted at the end of sewing 353 ON Counted at the start of sewing OFF Switching program numbers using an external switch 0 Disabled 354 1 9 Program number is switched by means of the 5 bits of option input EXIN6 EXIN10 The applicable numbers are Setting number...

Page 20: ...writing mode Sewing data is overwritten into the temporary buffer area If sewing data with the same program number already exists in internal memory it is deleted 466 2 Interrupt mode Sewing data is overwritten into the temporary buffer area If sewing data with the same program number already exists in internal memory it is not deleted but only the data in the temporary buffer is used If sewing da...

Page 21: ...o 11 ON when error is generated OFF Automatic ejector Option output No 3 output option input No 1 right sensor input No 2 left sensor 0 Disabled 1 Operates as standard 9 2 Sewing starts when cassette sensor is ON 9 560 3 Start switch is enabled even if cassette sensor is OFF 9 0 Timer from sensor detection to sewing start when automatic ejector automatic starting is set memory switch No 560 2 561 ...

Page 22: ...position when sewing is interrupted by the STOP switch 0 Needle stops in the down position 1 Needle stops in the up position 651 2 Needle stops in the up position after thread trimming 0 Thread trimming operation when sewing is paused OFF Thread trimming is carried out when the pause is canceled 652 ON Thread trimming is not carried out when the pause is canceled OFF Resuming sewing after sewing i...

Page 23: ... down movement when memory switch No 050 2 or 4 0 Run in operation cycle time adjustment timer 751 0 255 Units x10 ms 20 Sewing machine ID code 752 00 99 Sewing data specified on CF card 00 Reading writing sewing data for old models OFF Only compatible with floppy disks 755 ON Reading and writing using CF cards is possible in data read write mode OFF Main shaft angle display mode OFF Disabled 756 ...

Page 24: ...nits of 100 stitches in all 7 digits of the PROGRAM No display and the menu display 4 2 When the TEST key 1 is pressed the display will return to the normal display Clearing the cumulative number of stitches 1 When Cnt is displayed press the key 6 The cumulative number of stitches will change to 0000 and the display will flash 2 Press the RESET key 7 for two seconds or more The cumulative number o...

Page 25: ...e will be displayed in the menu display 3 2 Press the or key 4 to switch the error history sequentially 3 When the TEST key 5 is pressed the display will return to the normal display and the sewing machine will change to home position standby Display example Details PROGRAM No display 2 Menu display 3 If there is no error history 000 E Error E130 is displayed first 001 E130 While the key 6 is bein...

Page 26: ...ernately in the PROGRAM No display 2 3 Refer to the input check list for key and sensor responses 4 To return to normal operation turn off the power switch and then turn it back on again Input check list PROGRAM No display Menu display Check code Name Input status Check item and checking method 1 orX H L X axis motor home position sensor signal Move the feed mechanism by hand in the X direction 2 ...

Page 27: ...2 FtA 0 255 Foot switch analog value when one pedal is installed Depress the foot switch 13 CL1 on oFF Work clamp switch 1st step Depress the work clamp switch to the 1st step 14 CL2 on oFF Work clamp switch 2nd step Depress the work clamp switch to the 2nd step 15 Stt on oFF Start switch 16 EMC on on STOP switch Press the STOP switch 17 HEd on oFF Safety switch Tilt back the machine head 18 Air o...

Page 28: ...and checking method 28 Por on oFF Work clamp home position sensor 29 Xor on oFF X feed home position sensor 30 Yor on oFF Y feed home position sensor 31 in6 on oFF Option input IN6 32 in7 on oFF Option input IN7 33 in8 on oFF Option input IN8 34 in9 on oFF Option input IN9 35 in10 on oFF Option input IN10 ...

Page 29: ... display Check code Name Operating details 51 PM X When the key is pressed the work clamp moves to the left When the key is pressed the work clamp moves to the right 52 PM y When the key is pressed the work clamp moves forward When the key is pressed the work clamp moves back 53 PM F When the key is pressed the work clamp is raised When the key is pressed the work clamp is lowered 54 CAtH No devic...

Page 30: ...mpatible with the BAS 342G 65 oP1 Turns on option output 1 66 oP2 Turns on option output 2 67 oP3 Turns on option output 3 68 oP4 Turns on option output 4 69 oP5 Turns on option output 5 70 oP6 Turns on option output 6 71 oP7 Turns on option output 7 72 oP8 Turns on option output 8 73 oP9 Turns on option output 9 74 oP10 Turns on option output 10 75 oP11 Turns on option output 11 76 oP17 Turns on ...

Page 31: ...Keep pressing the key 1 until the model name is displayed and the buzzer beeps once 2 The display in the PROGRAM No display 4 switches as follows each time the or key 3 is pressed PROGRAM No display 4 Software 1 Mn Main CPU 2 Mt Motor CPU 3 PL Panel CPU 4 iP Main CPU IPL 5 PG Programmer 3 When the TEST key 5 is pressed the display will return to the normal display and the sewing machine will chang...

Page 32: ...N data for older series models program numbers 0 99 can be transferred from a floppy disk to a CF card using a computer and then be read from the CF card In such cases the effective reading mode will be r 1 Option 0 99 100 999 or r9 mode or r1 mode 0 99 100 999 Old model series data range BAS SEW BAS 311G BAS 326G BAS 342G data range ISM SEW Sewing machine internal memory Old model series data cop...

Page 33: ...and so you should not reformat them The recommended CF cards are commercially available ones from SanDisk or HAGIWARA SYS COM CF cards from other manufacturers can be used but different formatting methods may mean that loading from or writing to such cards may not be possible For more information refer to the documentation provided with the CF card This product is compatible with CF cards that hav...

Page 34: ... read from the CF card 1 w 2 SEd Sewing data is written to the CF card r 3 MEM Memory switch settings are read from the CF card w 4 MEM Memory switch settings are written to the CF card r 5 UPG User programs are read from the CF card w 6 UPG User programs are written to the CF card r 7 SyS Control programs are read from the CF card and used to update the firmware version w 8 LoG Error log data is ...

Page 35: ...read at once 3 Loading Press the R W key The buzzer will sound and the selected sewing data will be loaded from the CF card and copied into the sewing machine s internal memory The program numbers that have been read will be displayed in the menu display If there is a large volume of data in the CF card it will take some time for all of it to be read To halt the reading of data press the STOP swit...

Page 36: ...99 will be written at once 3 Writing Press the R W key The buzzer will sound and the selected sewing data will be copied from the internal memory onto the CF card The program numbers that have been written will appear in the PROGRAM No display If there is a large volume of data in the internal memory it will take some time for all of it to be written To halt the writing of data press the STOP swit...

Page 37: ... process is complete Turn off the power switch remove the CF card and then close the cover of the CF slot 3 8 Writing memory switch data to CF cards 1 Select the w 4 data read write mode 2 Writing Press the R W key The buzzer will sound and the memory switch data will be copied from the internal memory onto the CF card 3 End data read write mode TEST indicator switches off Press the TEST key Turn ...

Page 38: ...process is complete Turn off the power switch remove the CF card and then close the cover of the CF slot 3 10 Writing user program data to CF cards 1 Select the w 6 data read write mode 2 Writing Press the R W key The buzzer will sound and the user program data will be copied from the internal memory onto the CF card 3 End data read write mode TEST indicator switches off Press the TEST key Turn of...

Page 39: ...Version updating may take about 3 10 minutes The time taken will vary depending on the manufacturers and storage capacity of the CF card being used Never remove the CF card or turn off the power switch while reading of the CF card is in progress Restoring the control program if an error occurs during updating If the version updating did not complete normally such as because of a power outage the s...

Page 40: ... off Press the TEST key Turn off the power switch remove the CF card and then close the cover of the CF slot 3 13 Reading sewing data from floppy disks 1 Insert the floppy disk into the floppy disk drive 2 Select the r 9 data read write mode 3 Press the R W key Fdd will change to ALL Press the or key to select the program number to be read Program numbers that contain no data will also be displaye...

Page 41: ...then press the RESET key the display will change back to ALL NOTE If there is no data in the selected program number error E421 will be displayed Press the RESET key and then select another program number 5 End data read write mode TEST indicator switches off Press the TEST key Turn off the power and remove the floppy disk 3 14 Writing sewing data to floppy disks 1 Insert the floppy disk into the ...

Page 42: ...If you then press the RESET key the display will change back to ALL 5 End data read write mode TEST indicator switches off Press the TEST key Turn off the power and remove the floppy disk 3 15 Reading extended option output data from a CF card 1 Select the r 11 data read write mode 2 Loading Press the R W key The buzzer will sound and the extended option output data will be loaded from the CF card...

Page 43: ...T key Turn off the power switch remove the CF card and then close the cover of the CF slot 3 17 Reading extended option output data from floppy disks 1 Insert the floppy disk into the floppy disk drive 2 Select the r 13 data read write mode 3 Loading Press the R W key The buzzer will sound and the extended option output data will be loaded from the floppy disk and copied into the sewing machine s ...

Page 44: ...up crank 4 Needle bar crank 5 Needle bar connecting rod 6 Needle bar clamp 7 Needle bar 1233B 1232B The mechanisms operate in the order of the numbers given in the illustrations 1 Motor assembly 2 Upper shaft 3 Crank rod assembly 4 Rock gear 5 Lower gear 6 Lower shaft 7 Lower shaft adjusting bush 8 Lower shaft M bush 9 Driver 10 Shuttle hook 5 Thread take up lever assembly 6 Thread take up support...

Page 45: ... lever 3 Work clamp lifter lever 4 Work clamp 1 Work clamp pulse motor 2 Work clamp driving gear 3 Work clamp cam gear 4 Stepping foot driving lever 5 Stepping clamp lifter rod 6 Stepping clamp lifter 7 Stepping clamp lifter link 8 Stepping clamp link 9 Stepping clamp link B 10 Presser bar clamp 11 Presser bar 12 Intermittent presser foot 1234B 1235B ...

Page 46: ...hanism 1 Motor assembly 2 Upper shaft 3 Stepping clamp cam 4 Stepping clamp connecting rod 5 Stepping clamp arm R 6 Stepping clamp arm F 7 Stepping clamp link A 8 Stepping clamp link A 9 Stepping clamp link B 10 Presser bar clamp 11 Presser bar 12 Intermittent presser foot 1236B ...

Page 47: ...reated through combinations of X and Y movements Y direction X direction 1 X feed motor assembly 2 Y motor gear 3 X gear 4 X GT belt 5 X base plate 6 Y base plate 1 Y feed motor assembly 2 Y motor gear 3 Y gear 4 Y GT belt 5 Y arm 6 X LM guide bracket 7 Work clamp arm 1237B 1238B ...

Page 48: ...id lever 3 Pushing lever 4 Driving lever 5 Thread trimmer collar 6 Thread trimmer cam 7 Thread trimmer rod V 8 Thread trimmer lever V 9 Thread trimmer lever H 10 Thread trimmer rod H 11 Movable knife lever D 12 Movable knife lever 13 Movable knife connecting plate 14 Movable knife 15 Fixed knife 1239B ...

Page 49: ...echanism 1 Tension release solenoid 2 Bolt 3 Tension release bar 4 Tension release pin 5049Q 1 Thread wiper solenoid assembly 2 Thread wiper rod 3 Thread wiper crank assembly 4 Wiper 5050Q When the thread wiper solenoid assembly is turned off the wiper operates in the opposite direction ...

Page 50: ...lt Furthermore do not drink or eat the lubricating oil or grease They may cause diarrhea or vomiting Keep the oil out of the reach of children Use only the proper replacement parts as specified by Brother If any safety devices have been removed be absolutely sure to re install them to their original positions and check that they operate correctly before using the machine Any problems in machine op...

Page 51: ... 2 Thread wiper mechanism 1 Thread wiper solenoid harness Pull out 2 STOP switch harness Pull out 3 Bolt 4 Plain washer 5 Removed plain washer Assemble 6 Removed bolt Assemble 7 Bolts with washers 2 pcs 8 Thread wiper unit 5090Q ...

Page 52: ...BAS 342G 43 5 3 Work clamp arm mechanism 1 Set screw 2 Needle 3 Needle bar thread guide 4 Bolts 8 pcs 5 Bolts with washers 4 pcs 6 Screws 2 pcs 7 Work clamp arm assembly 8 Bolts with washers 2 pcs 9 Feed plate 1241B ...

Page 53: ...ng 5 Presser bar spring collar 6 Screw 7 Shoulder screw 8 Screw 9 Plain washers 2 pcs 10 Finger guard 1242B 11 Intermittent presser foot 12 Bolt Loosen 13 Presser bar Pull downward from presser bar clamp 14 Set screw Loosen 15 Stepping clamp lifter link shaft Pull out 16 Washer 17 Stepping clamp lifter link Remove as unit 18 Presser bar 19 Bolt Loosen 20 Stepping clamp arm F ...

Page 54: ...aft assembly 9 Thread take up support 10 Screw Loosen Do not remove the slide block guide if possible to prevent the machine from overheating due to needle bar rubbing Left hand thread 11 Needle bar connecting rod 12 Needle bearing 13 Rubber cap 14 Set screws 3 pcs Loosen 15 Needle bar crank 16 Needle bearing 17 Thread take up lever assembly 18 Washer 19 Bolts 2 pcs 20 Slide block guide 5092Q 5093...

Page 55: ...osen 15 Set screws 2 pcs Loosen 16 Set screws 2 pcs Loosen 17 Set screws 2 pcs Loosen 18 Set screws 2 pcs Loosen 19 Screws 3 pcs Loosen 20 Fries wheels 2 pcs 21 Bolts 4 pcs Loosen 22 Motor assembly 23 Thread trimmer cam 24 Joint assembly 25 Upper shaft 26 Pulley gear R 27 Bobbin winder driving wheel 28 Stepping clamp cam assembly 29 Set screw Loosen 30 Pulley assembly If the motor assembly cannot ...

Page 56: ...Set screw Loosen 15 Adjusting stud Pull out 16 Set screw Loosen 17 Shuttle race base assembly 18 Set screws 2 pcs Loosen 19 Bolt Loosen 20 Pinch sleeve A 21 Pinch sleeve B 22 Set screw Loosen 23 Set screw collar R 24 Set screws 2 pcs Loosen 25 Rock gear shaft Pull out from the rear of the machine 26 Set screw collar B 27 Rock gear 28 Crank rod Lower part 1246B If the adjusting stud will not pull o...

Page 57: ...plate 3 Screws 4 pcs 4 Bellow assembly 5 Screws 6 pcs 6 Inside cover R 7 Inside cover L 8 Bolts 20 pcs 9 Cover rail FL assemblies 2 pcs 10 Cover rail FR assemblies 2 pcs 11 Outside cover assemblies 2 pcs 12 Middle cover assemblies 2 pcs 13 Screws 14 pcs 14 Fixations 2 pcs 1249B 1248B ...

Page 58: ...et 10 Screws 4 pcs 11 Fan 12 Bolts with washers 4 pcs 13 X motor bracket 14 Bolts 4 pcs 1250B 1251B 1252B 15 X motor 16 Set screws 2 pcs Loosen 17 X motor gear 18 Set screws 8 pcs Loosen 19 Retaining rings C 2 pcs 20 X drive shaft 21 X gear 22 Pulley B assembly 23 Set screws 2 pcs Loosen 24 Pulley fulcrum shaft 25 Pulley A assembly 26 Pulley fulcrum shaft collar 27 X pulley bracket 28 X GT belt ...

Page 59: ...osen 36 Y motor gear 37 Y motor 38 Screws 3 pcs 39 Y gear cover 40 Bolts 2 pcs 41 Fan bracket 42 Screws 4 pcs 43 Fan 44 Set screws 12 pcs Loosen 45 Y drive shaft 46 Pulley B assemblies 2 pcs 47 Y gear 48 Set screws 4 pcs Loosen 49 Pulley fulcrum shafts 2 pcs 50 Pulley fulcrum shaft collars 2 pcs 51 Pulley A assemblies 2 pcs 52 Y pulley brackets 2 pcs 53 Y GT belts 2 pcs 1253B 1254B 1255B ...

Page 60: ...osen 15 Screw 16 Plain washer 17 Retaining ring C 18 Work clamp fulcrum shaft 19 Work clamp cam gear 20 Ball bearings 2 pcs 1 Bolt 2 Bolts 4 pcs 3 Pulse motor assembly P Disconnect the harness 4 Set screws 2 pcs Loosen 5 Work clamp driving gear 6 Bolts 2 pcs 7 Work clamp motor plate 8 Set screws 2 pcs Loosen 9 Set screw 10 Work clamp lever shaft 1256B ...

Page 61: ...Solenoid cover 7 Tension release solenoid 8 Bolts 2 pcs 9 Spring washers 2 pcs 10 Plain washers 2 pcs 11 Solenoid setting plate 12 Bolt 13 Nut 14 Plain washer 15 Solenoid cushion 16 Tension release bar 17 Plain washer 18 Compression spring 19 Retaining ring E 5111Q 1 Bolts 2 pcs 2 Stepping clamp lifter rod holder 3 Flat screw 4 Set screw Loosen 5 Stepping clamp lifter shaft Pull out 6 Stepping cla...

Page 62: ...enoid cushion 11 Bolts 2 pcs 12 Spring washers 2 pcs 23 Nut 24 Shoulder screw B 25 Thread driving lever 26 Set screw 27 Retaining ring E 28 Collar shaft 29 Thread trimmer collar 30 Screws 2 pcs 31 Flat screws 2 pcs 32 Needle plate 13 Plain washers 2 pcs 14 Thread trimmer solenoid 15 Shoulder screw 16 Driving lever pushing lever 17 Nut 18 Set screw 19 Set screw 20 Guide shaft 21 Compression spring ...

Page 63: ...n washer 48 Nut 49 Shoulder screw B 50 Thread trimmer rod V 51 Nut 52 Shoulder screw B 53 Set screws 2 pcs Loosen 54 Thread trimmer lever shaft 55 Spacers 2 pcs 56 Retaining ring C 57 Thread trimmer lever V 58 Thread trimmer lever H 59 Set screws 2 pcs Loosen 60 Movable knife lever shaft 1259B 1318B 61 Movable knife lever 62 Bolt 63 Spring washer 64 Plain washer 65 Movable knife lever D 66 Nut 67 ...

Page 64: ...1 Thread trimmer lever shaft 12 Retaining ring C 13 Spacers 2 pcs 14 Thread trimmer lever H 15 Thread trimmer lever V 16 Set screws 2 pcs 17 Shoulder screw B 18 Nut 19 Extension spring 20 Spring hook When the ball joint assembly of the thread trimmer rod H 6 has been disassembled assemble it so that the distance between the centers of the holes is 527 0 5 mm Tighten the two set screws 16 on the sc...

Page 65: ...crew 42 Bolts with washers 2 pcs 43 Driving lever pushing lever 44 Shoulder screw 45 Set screw 46 Nut 47 Movable knife connecting plate 48 Shoulder screw 49 Shoulder screw B 50 Nut 51 Plain washer 52 Spring washer 53 Bolt When the ball joint assembly of the thread trimmer rod V 26 has been disassembled assemble it so that the distance between the centers of the holes is 287 5 0 5 mm 4615Q 1270B 12...

Page 66: ...ws 2 pcs 17 Tension release pin 18 Tension bracket 19 Set screw 5139Q Adjust the thread take up spring height while referring to 7 2 Standard thread tension Adjust while referring to 7 18 Adjusting the tension release amount 1 Stepping clamp lifter Insert from the front 2 Stepping clamp lifter shaft 3 Set screw 4 Flat screw Stepping clamp lifter rod adjustment Screw the stepping clamp lifter rod i...

Page 67: ...ing C 5 Plain washer 6 Screw 7 Set screw 8 Set screw 9 Stepping work clamp driving lever 10 Set screw collar 11 Work clamp lever shaft 12 Set screw 13 Set screws 2 pcs 14 Shoulder screw 15 Stepping clamp lifter rod holders 2 pcs 16 Bolts 2 pcs Align the screw stop and then tighten the screw 12 so that there is no play in the stepping work clamp driving lever 9 and the set screw collar 10 Check tha...

Page 68: ...set screws 19 17 Pulse motor assembly P 18 Work clamp driving gear 19 Set screws 2 pcs 20 Work clamp motor plate 21 Bolts 4 pcs 22 Bolts 2 pcs 2 Install the pulse motor assembly P 17 to the work clamp motor plate 20 with the four bolts 21 so that the motor connector is facing downward 3 Align the index marks on the work clamp cam gear and the work clamp driving gear and then install the work clamp...

Page 69: ...her in the places indicated by Continued on the next page 1 Y pulley brackets 2 pcs 2 Y GT belts 2 pcs 3 Pulley fulcrum shafts 2 pcs 4 Pulley fulcrum shaft collars 2 pcs 5 Pulley A assemblies 2 pcs 6 Set screws 4 pcs 7 Y pulley bracket assemblies 2 pcs 8 Bolts with washers 4 pcs Temporarily tighten 1278B 1279B ...

Page 70: ... Y gear 13 and then tighten the set screw Push the pulley B assembly 11 and pulley B assembly 16 against the ball bearings a tighten the set screw and then move the Y drive shaft 9 in the direction of the arrow and check that there is no play Reference line 19 Y gear cover 20 Screws 3 pcs 21 Y motor 22 Y motor gear 23 Set screws 3 pcs 24 Y motor bracket 25 Bolts 4 pcs 26 Bolts with washers 4 pcs T...

Page 71: ...sunk hole 31 Belt holders 2 pcs 32 Bolts 8 pcs Temporarily tighten 33 Bolts M6X35 2 pcs Tighten and then pull 34 Bolts with washers 4 pcs Fully tighten 35 Bolts 2 pcs Fully tighten 36 Bolts M6X35 2 pcs Remove 1283B Tighten the two bolts M6X35 33 into the holes in the side of the bed and then pull the Y pulley bracket assembly c to adjust the belt tension After adjusting the belt tension measure th...

Page 72: ...s For a new belt 650 to 750 N For a reused belt 520 to 600 N Be sure to use a belt tension gauge to measure the belt tension and measure from the middle of the lower belt The belt tension gauge should be set to measure a unit weight of 0 04 kg m a belt width of 50 mm and a span length of 333 mm It is recommended that you use the Yunitta U 505 tension gauge 1284B 1285B Finger pressing position Lowe...

Page 73: ...e center of the feed plate is aligned with the center of the needle hole and then install the Y motor so that the index mark on the end of the Y motor shaft is facing directly upward 1286B Index mark Y direction Center Center of needle hole Adjust and install so that the backlash is within 0 01 to 0 05 1287B ...

Page 74: ...ear 13 Set screws 4 pcs 14 Retaining ring 15 X pulley bracket assembly 16 Bolts with washers 2 pcs Temporarily tighten Reference line 1289B 1290B Before inserting the X drive shaft 7 apply grease in the place indicated by Align the reference line and the edge of the X gear 12 and then tighten the set screws 13 Reference line Push the retaining ring 14 and the pulley B assembly 10 against the ball ...

Page 75: ...n in the illustration and then tighten the bolts 20 Install the belt holder 17 so that the side with the countersunk hole is at the top 1291B 1292B 21 Y base plate tool 22 Bolts 2 pcs 23 Bolts 16 pcs Install the Y base plate tool 21 so that its edges are positioned as shown in the illustration Once installation is complete remove the Y base plate tool 21 Edge Edge Edge Countersunk hole 1355B ...

Page 76: ...B 1295B Touch the X motor gear 25 against the edge of the ball bearing c and then tighten the two set screws 26 Apply grease to the places indicated by the arrows Apply grease to the holes and grooves of the X motor shaft Move the feed plate in the X direction so that the center of the feed plate is aligned with the center of the needle hole and then install the X motor so that the index mark on t...

Page 77: ...ten and then pull 36 Bolts 4 pcs Fully tighten 37 Bolts with washers 2 pcs Fully tighten 38 Bolts M6X30 Remove Tighten the bolts M6X30 35 into the holes in the side of the bed and then pull the Y pulley bracket assembly d to adjust the belt tension After adjusting the belt tension measure the tension Refer to the next page 1297B ...

Page 78: ...ithin the following value ranges For a new belt 650 to 750 N For a reused belt 520 to 600 N Be sure to use a belt tension gauge to measure the belt tension and measure from the middle of the lower belt The belt tension gauge should be set to measure a unit weight of 0 04 kg m a belt width of 50 mm and a span length of 485 mm It is recommended that you use the Yunitta U 505 tension gauge 1298B 1299...

Page 79: ...ace into cover rail 4 Outside cover assemblies 2 pcs Place into cover rail 5 Cover rail FR assemblies 2 pcs 6 Bolts 4X10 10 pcs 7 Cover rail FL assemblies 2 pcs 8 Bolts 4X10 10 pcs 9 Inside cover R assembly 10 Screws 4X8 3 pcs 11 Inside cover L assembly 12 Screws 4X8 3 pcs 13 Bellow assembly 14 Screws 4 pcs Tighten the inside cover R assembly and inside cover L assembly together 1300B 1301B 1353B ...

Page 80: ...h washers 14 pcs 1302B Install the support plate bracket so that the notches are aligned with the edge of the bed Support plate bracket Bed Needle plate 1304B 1303B After installing check that the height of the needle plate is as shown in the illustration ...

Page 81: ...nce of the joint assembly bearing 1 Tighten the screw of the thread take up crank 5 so that it is aligned with the upper shaft hole 2 While pressing the thread take up crank 5 so that there is no play in it tighten the two set screws 8 Apply adhesive Threebond 1401 to the thread section of the screw 5204Q Reference line Before inserting the upper shaft 1 apply the grease SA8837 001 specified by Br...

Page 82: ...rews 2 pcs Temporarily tighten 23 Pulley assembly 24 Set screw Tighten the set screw so that the screw stop A on the motor shaft is in the same phase as the screw stop B on the thread trimmer cam Tighten the set screw so that the screw stop C on the upper shaft is at a phase of approximately 180 degrees from the screw stop A on the motor shaft 1419B 1306B Install the motor assembly so that the har...

Page 83: ...take up support shaft assembly 14 Set screws 2 pcs 15 Rubber caps 2 pcs 16 Rubber cap 17 Slide block Left hand thread 5142Q Set so that this hole faces vertically and then push in gently while tightening the set screws 14 to install Inside hole While gently pushing the needle bar crank in the shaft direction align the set screw with the screw stop and then tighten the set screw After securing the ...

Page 84: ...edle bar or reference line a top reference line is aligned with the lower edge of the needle bar bush when the machine pulley is turned to lower the needle bar to its lowest position and then set the cut section so that it is facing forward and tighten the screw 4647Q Needle bar bush 1392B Cut section Inside hole After inserting the needle bar 19 apply grease in the places indicated by ...

Page 85: ...g the link shaft 10 Link shaft with retaining ring 11 Set screw 12 Shoulder screw 13 Screw 14 Shoulder screw 15 Screw 16 Presser bar spring collar 17 Presser bar spring 18 Presser bar spring guide 19 Adjusting screw nut 20 Presser adjusting screw 21 Intermittent presser foot 22 Plain washers 2 pcs 23 Finger guard 24 Screw Temporarily tighten 1 Stepping clamp arm F 2 Stepping clamp arm R 3 Set scre...

Page 86: ...ntermittent presser foot 7 and the needle hole and then tighten the bolt 8 4 Set the height of the intermittent presser foot 7 to 22 mm above the needle plate and then tighten the screw 9 5 Turn the work clamp cam gear 1 to move the stepping work clamp driving lever 2 to the dotted line position shown in the illustration 6 Set the needle bar to the timing position 1 7 Loosen the nut 10 and turn th...

Page 87: ...Temporarily tighten 12 Set screw collar R 13 Set screw Temporarily tighten 14 Set screws 2 pcs Temporarily tighten 1309B 1 Shuttle race base assembly 2 Set screw 3 Set screw 4 Adjusting stud Tighten the set screw 2 until the head of the screw is flush with the edge of the bed Refer to 7 8 Adjusting the rotary hook lubrication amount 1308B Viewed from the front Adjust while referring to 7 19 Adjust...

Page 88: ...Insert into upper shaft crank 29 Needle bearing 30 Crank rod Upper part Align the mating mark 31 Bolts 2 pcs 32 Crank cover 33 Screws 3 pcs Insert the crank rod lower part 28 into the crank of the upper shaft align the marks on the crank rod 30 upper part and then gently tighten the two bolts 31 Check that the pulley turns smoothly 1310B 1312B Mating Mark 1311B Push a screwdriver gently against th...

Page 89: ...ttle hook 5 Shuttle race base 6 Shuttle race base setting claw Close 7 Bobbin 8 Bobbin case 1 Fixed knife 2 Plain washers 2 pcs 3 Screws 2 pcs 4 Movable knife spacer 5 Movable knife assembly 6 Movable knife collar 7 Thrust washer 8 Movable knife 9 Shoulder screw 10 Needle plate 11 Screws 2 pcs 12 Flat screws 2 pcs 1313B 1314B 5151Q Insert the pin of the movable knife assembly into the hole in the ...

Page 90: ...cs 5 Bolts 8 pcs After assembling adjust the home position Refer to 7 20 Adjusting the home position After that carry out a test feed to check that the needle hole does not go outside the frames of the work clamp and feed plate If the needle hole goes outside the frames adjust the position of the feed plate or readjust the home position 1349B ...

Page 91: ...n tighten the two bolts 4 3 Loosen the two nuts 7 at left and right 4 Turn the shafts of the air cylinders 8 at left and right until the work clamp 6 is 30 mm above the top of the needle plate and then tighten the two nuts 7 Work clamp adjustment 1 Loosen the four bolts 9 2 Lower the work clamp 6 and then install the work clamp 10 with the four bolts 9 Work clamp pressure adjustment 1 Remove the f...

Page 92: ...ve 4 Plain washer Remove 5 Removed plain washer 6 Removed bolt 7 STOP switch harness 8 Thread wiper solenoid harness 5153Q Adjust the thread wiper after installing Refer to 7 11 Adjusting the thread wiper Align the thread wiper shaft bracket and the bottom of the arm and then tighten the two bolts with washer ...

Page 93: ...6 ASSEMBLY BAS 342G 84 6 15 Covers 1 Shuttle race cover assembly 2 Face plate 3 Eye guard 4 Rear cover FL 5 Rear cover FR 6 Rear cover 7 X motor cover 8 Motor cover 9 Top cover 1316B ...

Page 94: ...his is not observed the machine head may become unbalanced and fall down and serious injury or damage to the sewing machine may result Be sure to wear protective goggles and gloves when handling the lubricating oil and grease so that they do not get into your eyes or onto your skin If the oil and grease get into your eyes or onto your skin inflammation can result Furthermore do not drink or eat th...

Page 95: ...20 or similar Lower thread 20 or similar Upper thread tension N 1 4 1 8 Lower thread tension N 0 3 0 4 Thread take up spring height mm 7 10 Thread take up spring tension N 0 6 1 2 Pre tension N 0 2 0 4 Needle DP x 17 19 7 2 1 Upper and lower thread tension 1378B 1377B ...

Page 96: ...ud 5 in order to adjust the tension of the thread take up spring 3 NOTE If the thread tension spring 3 is not adjusted correctly the upper thread trailing length will be uneven after thread trimming 7 2 3 Arm thread guide R The standard position of arm thread guide R 1 is when the screw 2 is aligned with the index mark Loosen the screw 2 and move arm thread guide R 1 to adjust When sewing heavy ma...

Page 97: ...ge of the needle bar bush 1 and then loosen the bolt 2 and move the driver 3 so that the tip of the rotary hook is aligned with the center of the needle If using a DP X 5 needle use the second reference line from the top of the needle bar reference line b 7 5 Adjusting the driver Turn the machine pulley to align the tip of the rotary hook with the center of the needle and then loosen the set screw...

Page 98: ...7 Adjusting the shuttle race thread guide Install the shuttle race thread guide 1 by pushing it in the direction of the arrow so that the needle groove is aligned with the center of the needle plate hole NOTE If the shuttle race thread guide 1 is in the wrong position thread breakages soiled thread or tangling of the thread may occur The position of the shuttle race thread guide 1 is adjusted at t...

Page 99: ...e edge of the bed use the following method to make the adjustment Adjusting by changing the amount of oil supplied from the sub tank 1 Remove the four screws 1 and then remove the X motor cover 2 2 Tilt back the machine head 3 Insert a screwdriver into the holes in the left side of the sewing machine bed and loosen the two bolts 3 4 Move the sub tank 4 up or down to adjust its position and then ti...

Page 100: ...rn the pulley 1 by hand to set the driving lever 5 to the reverse position when the thread take up 6 is close to its lowest position 4 Remove the rubber cap 7 5 Loosen the bolt 8 6 Move the movable knife connecting plate 10 back and forth to adjust so that the distance from the ridge on the right side of the needle plate to the ridge on the movable knife 9 is 9 5 to 9 9 mm 7 After tightening the b...

Page 101: ...eck that the collar 3 is not touching the inside of the groove in the thread trimmer cam 4 In addition push the driving lever 5 by hand toward the thread trimmer cam until the collar 3 touches the groove of the thread trimmer cam 4 and then check that the driving lever 5 returns smoothly to its original position when it is released 11 Check that there is a gap of about 0 1 mm between the outside o...

Page 102: ...st washer 10 and the movable knife spacer 11 6 Check that the movable knife 6 and fixed knife 7 cut the thread cleanly Replace the movable knife spacer with accessory spacers t 0 2 0 3 0 4 so that the knives trim the thread accurately If the knife pressure is too weak and the thread is not completely cut use a thinner movable knife spacer If the knife pressure is too strong and the movable knife 1...

Page 103: ... 3 and shift the entire solenoid setting plate 4 up or down to adjust so that the thread wiper 2 is 15 mm in front of the needle center when the plunger 1 of the thread wiper solenoid is driven to the full stroke 2 Loosen the screw 5 and adjust the position of the thread wiper 2 so that the distance from the thread wiper to the tip of the needle is approximately 2 mm and the tip of the thread wipe...

Page 104: ...n of stepping clamp link A Changing the installation position of stepping clamp link A 1 Remove the face plate 2 Remove the two screws 1 and the two shoulder screws 2 and then remove stepping clamp link A 3 3 Change the installation position for stepping clamp link A 3 to either A B or C above If the position of the stepping clamp connecting rod is adjusted as described in the following at any one...

Page 105: ...a DP x 5 needle align with the second reference line from the top reference line b 4 Open the top cover and loosen the two set screws 6 5 Align the index marks on the stepping clamp cam 7 and the stepping clamp connecting rod 4 and then tighten the set screws 6 Check the following after changing the intermittent stroke 1 With the intermittent presser foot 1 lowered turn the pulley to move the inte...

Page 106: ...ress the work clamp switch 1 to raise the work clamp 2 3 Loosen the two bolts 4 of the work clamp lifter lever 3 and then move the work clamp lifter lever 3 up or down to adjust the lift amount 7 15 Adjusting the air pressure Lift up the handle 2 of the regulator 1 and then turn it to adjust the air pressure to 0 5 MPa After adjustment is complete push the handle 2 downward to lock it 4052M 5018Q ...

Page 107: ...and the two bolts 2 of the X pulley bracket 3 4 Remove the M6X30 bolt 5 Move the X base plate 4 to the left edge 6 Use a tension gauge to measure the tension at the middle of the lower belt while referring to Measurement position in the illustration Refer to 6 5 2 X feed mechanism for details on measuring the tension Check that the value for the belt tension is within the following value ranges If...

Page 108: ...t while referring to Measurement position in the illustration Refer to 6 5 1 Y feed mechanism for details on measuring the tension Check that the value for the belt tension is within the following value ranges If it is not within this range repeat steps 2 to 7 For a new belt 650 750 N For a reused belt 520 600 N The belt tension gauge should be set to measure a unit weight of 0 04 kg m a belt widt...

Page 109: ...the tension release solenoid 1 is pushed in as far as it will go 2 Check that the tension disc opening amount is 1 0 1 5 mm when the tension release solenoid 1 is installed to the arm and the plunger is pushed with a screwdriver or similar tool through the hole in the solenoid cover If memory switch No 552 has been set so that the tension release timing is early you can increase the trailing lengt...

Page 110: ...aft gear backlash 1 Remove the two screws 1 and then remove the motor cover 2 2 Remove the sixteen screws 3 and then remove the rear cover 4 3 Remove the two screws 5 and then remove the Y motor fan 6 4 Gently tilt back the machine head 1379B 1380B 1381B ...

Page 111: ...nnot turn smoothly loosen the set screw 10 and turn the pulley while moving the rock gear 11 back and forth At the position where the pulley moves smoothly place set screw collar R 9 against the edge of the bed and tighten the set screw 10 7 Turn the rock gear shaft 12 to adjust the tip of the driver 13 so that there is 0 05 to 0 15 mm of play and then tighten the two set screws 7 and the bolt 8 1...

Page 112: ... 0 4 Remove the rear cover align the index marks of the work clamp cam gear 2 and the work clamp driving gear 3 to the center line and then press the or key to change the offset value 999 999 The work clamp driving gear 3 will move in conjunction with the setting value 5 Press the RESET key Intermittent presser foot home position detection will be carried out Check if the index marks are aligned w...

Page 113: ...zer beeps once orG will flash in the PROGRAM No display and the offset value default 0 will be displayed in the menu display 3 Press the SELECT key so that either the X SCALE indicator or the Y SCALE indicator illuminates 4 Press the RESET key Home position detection will be carried out and the work clamp will stop at the currently registered home position If you press the RESET key for 2 seconds ...

Page 114: ... 1 The home position reference plate 1 will move in accordance with the setting value 6 Press the RESET key Home position detection will be carried out Check the home position If the home position is correct remove the home position reference plate 1 and then install the feed plate Refer to 7 10 1 Installing the feed plate 7 End adjustment mode TEST indicator switches off Press the TEST key The di...

Page 115: ...ance h 5 Tighten the screw 6 and then install the rubber cap 5 6 While pressing the key 7 turn on the power switch Keep pressing the key 7 until the model name is displayed and the buzzer beeps once 7 Press the key 7 or the key 8 to select check code 8 Refer to 2 7 Input checking method for details 8 Remove the flywheels and then loosen the bolt 3 of the magnet 2 1 4 of a turn 9 Turn the pulley to...

Page 116: ...will appear in the menu display 2 Lower the work clamp and then depress the start switch X Y feed home position detection will be carried out and then orG will stop flashing and illuminate steadily 3 Depress the start switch once more The upper shaft will operate and the needle bar will stop at the needle up stop position 4703Q 4448Q 4421Q 1385B 5211Q Use the operation panel to adjust the needle u...

Page 117: ... move up NOTE After changing the offset value check that the thread trimming operation is normal and that error E110 is not generated 5 Lower the work clamp and then depress the start switch The upper shaft will operate and stop at the offset value which has been set 6 End adjustment mode TEST indicator switches off Press the TEST key The changes to the offset value will be memorized and the sewin...

Page 118: ...l box Replacing fuses Inserting and disconnecting connectors Measuring resistance values Any other tasks that may involve touching components inside the control box Some inspection items require the control box to be open when the power is turned on and voltages are measured At such times be extremely careful never to touch anywhere other than the specified locations In addition note that high vol...

Page 119: ...This fan cools the inside of the control box The filters at the air intake slots in the cover and base plate should be cleaned about once a month Conversion transformer This breaks down the power supply voltage into the voltages that are required for control operations NF P C board This eliminates the electrical interference that is generated by the power supply fan Panel P C board Secured to the ...

Page 120: ...ermittent presser foot does not operate and E300 is displayed F3 Fuse 6AFB Glass tube fuse 6A 250V SA3759 001 Thread trimming solenoid or digital tension tension release solenoid does not operate and thread trimming or thread tightening problems occur F4 Fuse 3AFB Glass tube fuse 3A 250V 616167 001 Communication problem with PMD P C board and E403 is displayed F5 Fuse 3AFB Glass tube fuse 3A 250V ...

Page 121: ...ms are often caused by connectors that are not inserted correctly or which are contacting poorly As a result check that all connectors are inserted correctly and that the pins and wires are crimped properly before carrying out problem diagnosis 8 4 1 Connector positions Main P C board 5072Q ...

Page 122: ...8 ELECTRICAL MECHANISM 113 BAS 342G PMD P C board Power supply motor P C board 1260B 4593Q ...

Page 123: ...8 ELECTRICAL MECHANISM 114 BAS 342G Panel P C board 4594Q ...

Page 124: ... but does not detect the home position correctly E200 P20 X_ENC or E210 P4 Y_ENC is displayed Feed mechanism moves to the left and right briefly and then error E210 appears Feed mechanism moves forward and back briefly and then error E200 appears Feed mechanism does not move and E300 appears Work clamp mechanism Trouble symptom Connector No and position The work clamp pulse motor operates but the ...

Page 125: ...rror displayed Digital tension specifications Analog tension does not operate No error displayed Analog tension specifications Sewing operations Trouble symptom Connector No and position Power indicator does not illuminate and sewing machine does not operate Operation is unstable E403 is displayed when the power is turned on and the sewing machine does not start 4713Q 4714Q 5243Q 5244Q 4717Q ...

Page 126: ...played DC fan motor for Y feed motor does not operate E742 is displayed Operation panel display is incorrect Power indicator does not illuminate Operation panel keys do not work Sewing machine does not start when foot switch is depressed Work clamp is lowered when work clamp switch left is depressed Home position is detected and sewing machine starts when start switch right is depressed 5245Q 5246...

Page 127: ...8 ELECTRICAL MECHANISM 118 BAS 342G After the power is turned on E055 is displayed After the power is turned on E452 is displayed 5248Q 5249Q ...

Page 128: ...ing to 8 4 Description of connectors 2 Diagnosis flowchart Carry out diagnosis while following the steps in 8 5 2 Diagnosis flowchart on the next page and if a problem is reached continue to the next procedure 3 Remedy Refer to 8 5 3 Remedy for the item that corresponds to the problem Carry out the inspections for the problems in the order of the numbers in the Cause column NOTE When replacing the...

Page 129: ...ECHANISM 120 BAS 342G 8 5 2 Diagnosis flowchart Description of symbols Setting and status Switch operation Continued on previous next page Judgment OFF Power switch OFF Problem symbol in the 8 5 3 Remedy lists 1429B ...

Page 130: ...8 ELECTRICAL MECHANISM 121 BAS 342G 1424B ...

Page 131: ...8 ELECTRICAL MECHANISM 122 BAS 342G 1425B ...

Page 132: ...8 ELECTRICAL MECHANISM 123 BAS 342G 1426B ...

Page 133: ...ng position may vary depending on the voltage specifications OK if same as wall outlet voltage Voltage select harness indicates voltage specifications 2 Malfunction of transformer 1 OK if there is continuity between pins 1 3 2 3 3 4 3 5 and 3 6 of the 6 pin connector coming out from the transformer Fig A 2 OK if there is continuity between pins 1 2 3 4 and 5 6 of the 6 pin connector coming out fro...

Page 134: ...ect connector P17 M MOTOR of the main P C board turn on the power and then measure the voltages between the pins at the cord side connector OK if the voltages are as shown in the table below After measuring turn off the power wait 5 minutes or more and then insert P14 Power supply motor P C board 6 Malfunction of main P C board With connector P17 M MOTOR inserted into the main P C board turn on th...

Page 135: ...P C board 2 Check if there is a harness short circuit Harness Power supply motor P C board Main P C board 5 If E401 is displayed there is a poor connection between the main P C board and the power supply motor P C board 1 Check that connector P6 MAIN is inserted into the power supply motor P C board and that connector P17 M MOTOR is inserted into the main P C board 2 Check if there is a harness sh...

Page 136: ...es at all Cause Inspection Remedy Adjustment Replacement if a malfunction Malfunction of two pedal foot switch Disconnect connector P6 FOOT from the main P C board and check the continuity between pins 5 6 and 7 8 at the cord side connector OK if normally Ω and 0 Ω when the foot switch is depressed Two pedal foot switch Problem 6 Home position is incorrect Cause Inspection Remedy Adjustment Replac...

Page 137: ...alfunction of the pulse motor or cord 1 Disconnect connector P10 XPM from the PMD P C board and measure the resistance between pins 1 2 and 3 4 at the cord side connector OK if 2 3 Ω After measuring insert P10 2 If 1 is OK there is a malfunction of the PMD P C board Pulse motor X assembly PMD P C board Problem 8 An error code is displayed Cause Inspection Remedy Adjustment Replacement if a malfunc...

Page 138: ...V 2 If the intermittent presser foot does not operate and E300 is displayed there is a malfunction of the PMD P C board or of the power supply motor P C board 1 Disconnect connector P9 POWER1 from the PMD P C board and measure the resistance between pins 1 2 at connector P9 OK if Ω if 0 Ω there is a malfunction of the PMD P C board 2 Measure the resistance between the fuse F2 terminal that is clos...

Page 139: ...5 If the intermittent presser foot does not move and E300 is displayed there is a malfunction of the pulse motor or cord 1 Disconnect connector P3 PPM from the PMD P C board and measure the resistance between pins 1 2 and 3 4 at the cord side connector OK if 2 3 Ω After measuring insert P3 2 If 1 is OK there is a malfunction of the PMD P C board Pulse motor P assembly PMD P C board Problem 10 CF m...

Page 140: ...witch No 200 to OFF 2 Set memory switch No 252 to OFF Problem 15 Feed mechanism does not move fast during test feed Cause Inspection Remedy Adjustment Replacement if a malfunction Malfunction of work clamp switch or cord Refer to inspection 5 Problem 16 Sewing machine does not operate during sewing and an error code is displayed Cause Inspection Remedy Adjustment Replacement if a malfunction 1 Mal...

Page 141: ...nected to a secure ground and that there is no equipment nearby that is generating strong electrical interference 7 If E121 is displayed when the sewing machine stops Check if the thread trimming solenoid is operating Adjust the thread trimming mechanism Motor assembly CCD 430D 2 If E150 is displayed after the sewing machine operates the motor is abnormally overheating 1 Turn off the power and let...

Page 142: ... 6 of the cord side connector OK if 6 8 Ω Thread trimming solenoid 4 Malfunction of tension release solenoid digital tension Disconnect connector P7 SOL2 from the PMD P C board and measure the resistance between pins 1 2 of the cord side connector OK if 6 8 Ω Tension release solenoid digital tension solenoid 5 Malfunction of PMD P C board 1 With connector P6 SOL1 connected to the PMD P C board tur...

Page 143: ... P6 SOL1 connected to the PMD P C board turn on the power and carry out sewing and measure the voltage between pins 2 5 of connector P6 SOL1 OK if voltage is output momentarily at the sewing end PMD P C board Problem 21 Needle does not stop in the up position E110 or E111 is displayed Cause Inspection Remedy Adjustment Replacement if a malfunction 1 Incorrect adjustment Adjust while referring to 7...

Page 144: ...r the work clamp E035 The work clamp switch is depressed Turn off the power and then check the work clamp switch E036 A foot switch that does not match specifications is connected or work clamp mode has not been set correctly Use a foot switch that matches specifications or initialize the memory switch settings E050 Machine head tilting was detected after the power was turned on Turn off the power...

Page 145: ...5 X feed motor stopped abnormally while moving to the sewing start position Turn off the power and then check if there are any problems in the X feed direction E206 X feed motor stopped abnormally during test feeding Turn off the power and then check if there are any problems in the X feed direction E207 X feed motor stopped abnormally during programming Turn off the power and then check if there ...

Page 146: ...ith this program number E422 Error occurred while reading the CF card or floppy disk Check the data on the CF card or floppy disk E424 Insufficient free space on the CF card or data cannot be written to the floppy disk Use a different CF card Check if the floppy disk is write protected and if it has enough free space E425 Error occurred while writing to the CF card or floppy disk Use the specified...

Page 147: ... power supply voltage Turn off the power and check the input voltage E710 Abnormal current detected in sewing machine motor Turn off the power and then check if there are any problems with the sewing machine E711 Abnormal current detected in X feed motor Turn off the power and then check if there are any problems in the X feed direction E712 Abnormal current detected in Y feed motor Turn off the p...

Page 148: ...correct Adjust the position of the work clamp lifter lever P 97 Work clamp does not lift to the maximum height Cylinder joint position is incorrect Adjust the position of the cylinder joint Adjust the height of the thread wiper P 94 The thread wiper is obstructing the needle Adjust the stroke of the thread wiper P 94 Thread wiper does not operate correctly Thread wiper position is incorrect Adjust...

Page 149: ...t Clearance between needle and rotary hook tip is too great Adjust the needle clearance P 89 Needle and rotary hook timing is incorrect Adjust the needle bar lift amount P 88 The driver is covering the needle more than necessary Adjust the driver P 88 Needle is bent Replace the needle Skipped stitches occur Needle is incorrectly installed Install the needle correctly Instruction manual Adjust the ...

Page 150: ...al Upper thread trailing length is uneven Adjust the sub tension Instruction manual Upper thread tension is too weak Adjust the upper thread tension Instruction manual Lower thread tension is too weak Adjust the lower thread tension Instruction manual Thread take up spring tension and height are incorrect Adjust the tension and height of the thread take up spring P 87 Incorrect tightening of the t...

Page 151: ...11 7 SEGMENT DISPLAY 142 BAS 342G 11 7 SEGMENT DISPLAY ０ １ ２ ３ ４ ５ ６ ７ ８ ９ Ａ Ｂ Ｃ Ｄ Ｅ Ｆ Ｇ Ｈ Ｉ Ｊ Ｋ Ｌ Ｍ Ｎ Ｏ Ｐ Ｑ Ｒ Ｓ Ｔ Ｕ Ｖ Ｗ Ｘ Ｙ Ｚ ...

Page 152: ...SERVICE MANUAL 15 1 Naeshiro cho Mizuho ku Nagoya 467 8561 Japan Phone 81 52 824 2177 Printed in Japan BAS 342G I7070928B 2007 09 B 1 http www brother com ...

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