Brother MD-602 Service Manual Download Page 7

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MD-602, 612

1. Outline

1.1

Features

•

Thread trimming motor MD602/MD612 is a low-priced version of the MD601/611.

•

Start tacking (2 to 9 stitches) and end tacking (2 to 9 stitches) are possible even without the operation panel (option).

•

Voltage specifications for the single-phase 100V system, single-phase 200V system and 3-phase 200V system are avail-
able.

•

The rated output is 400W.

•

The motor torque has been greatly increased compared to the MD601/611.

1.2

Combination with Brother sewing machines

1. Single needle lockstitch machines (forward rotation)
B737, (B201) B791, B774, B722, B724, B748A, B798, B728, B772A, B778A, B781, B852, B853, B854, B883

2. Twin needle lockstitch machines (forward rotation)
B842, B872, B845, B875, B847, B848, B837, B877, B878

3. Overlock machine (reverse rotation)
(Note) The motor connections do not need to be changed to enable reverse rotation.

4. Post-type sewing machine (forward rotation)
P73, P81, C51

1.3

Options

•

Operation panel F-20, F-40, F-100

•

Material edge sensor II, material edge sensor IV, B sensor, bobbing thread detector

•

Standing work pedal (variable speed pedal, 2-speed pedal)

1.4

Input/output

•

Solenoid output: Four outputs (thread trimming, thread wiper, reverse run, presser foot lift) + one output for options

1.5

Miscellaneous

•

Lamp terminal block and fuse mounted on control PCB.

•

Only high-speeds are set with the head setting mode.

•

Incompatible with magnetic synchronizer.

Summary of Contents for MD-602

Page 1: ...MD 600 Series AC Servomotor for Industrial Sewing Machines SERVICE MANUAL MD 602 Single Phase Power Specifications MD 612 Three Phase Power Specifications ...

Page 2: ...adle unit 10 6 1 Operating the treadle 10 6 2 Adjusting the treadle 12 6 3 When using the automatic pressor foot lifter device 12 7 Using the control box 13 7 1 Before turning on the power switch 13 7 2 Power switch and the power indicator 13 7 3 Setting the sewing speed 13 7 4 Control box DIP switch setting procedure 14 7 5 Description of functions 15 7 6 Periodic checks 17 8 Connecting options 1...

Page 3: ...tching speed setting mode 40 16 Operational instructions 41 16 1 When the power SW is ON 41 16 2 When the power SW is OFF 41 16 3 Operation of the pedal 41 16 4 While running 41 17 Memory switch list 42 18 Parameter list 47 19 Panel display table 51 20 How to remove the control box 52 Control box block diagram 53 Control PCB assembly diagram 54 Control PCB circuit diagram 1 3 2 3 3 3 55 Power PCB ...

Page 4: ...ration of this machine and to prevent accidents and injury to yourself or other people The meanings of these indications and symbols are given below Indications Symbols The symbols which are used in this manual and their meanings are shown below WARNING Failure to observe the instruction which appears after this indication while using the motor will result in death or severe injury to the user CAU...

Page 5: ...ox when closing the control box cover Turn off the power switch before connecting the cords otherwise damage to the control box synchronizer operation panel or material edge sensor may result Any fluctuations in the power supply voltage should be within 10 of the rated voltage for the motor Voltage fluctuations which are greater than this may cause problems with correct operation of the sewing mac...

Page 6: ...schalten sie den hauptschalter aus und warten sie 5 minuten bevor sie diese abdeckung ffnen Un voltaje inadecuado puede provocar las heridas Apagar el interruptor principal y esperar 5 minutos antes de abrir esta cubierta The warning label shown below is affixed to the cover of the control box Please follow the instructions on the label at all times when using the motor If the label has been remov...

Page 7: ... B728 B772A B778A B781 B852 B853 B854 B883 2 Twin needle lockstitch machines forward rotation B842 B872 B845 B875 B847 B848 B837 B877 B878 3 Overlock machine reverse rotation Note The motor connections do not need to be changed to enable reverse rotation 4 Post type sewing machine forward rotation P73 P81 C51 1 3 Options Operation panel F 20 F 40 F 100 Material edge sensor II material edge sensor ...

Page 8: ... speed switch Note 3 The E panel for the MD800 series cannot be used with the MD600 Series Assembly cord for standing work Standing treadle 40 variable speed 6 J80081 040 Standing treadle two speed 8 J80380 040 J80630 001 Foot plug J02824 001 Operation panel Sewing machine Installation Type Code no of model type operation panel F 20 137 207 711 11 B737MK II built in F 40 137 207 712 11 F 100 137 2...

Page 9: ...Greece 7 230V Standard part General 8 230V SAA compatible part New Zealand 9 100V Domestic specifications Japan A 240V Standard part General B 110V SJT OCR Canada C 220V With OCR General D 220V SJT OCR Canada E 220V FOR B883 General For single phase Voltage Switch Destination 0 200V Domestic specifications Japan 1 220V Standard part 2 220V With OCR USA 3 220V With SJT Canada B 220V With SJT OCR Ca...

Page 10: ...D 60A AC SERVO MOTOR NO yuio 0 1 2 3 4 OUT PUT 400W R P M 3500 SUPPLIED FROM CONTROL BOX MD 602 612 MADE IN JAPAN BROTHER INDUSTRIES LTD Control box name plate Motor name plate display phase voltage phase voltage single 110V SINGLE 110 single 220V SINGLE 220 230 240 single 230V SINGLE 220 230 240 single 230V CE SINGLE 230 single 240V SINGLE 220 230 240 three 220V THREE 220 r Machine Head Model No ...

Page 11: ...ling the motor to the work table 1 Insert the bolts w into the holes in the work table q and then secure the motor u to the work table q by tightening the motor mounting brackets e to the work table q with the flat washers r spring washers t and nuts y as shown in the illustration 2 The positions of the work table q holes are shown in the illustration 5 2 Attaching the belt 1 Tilt back the machine...

Page 12: ... e Note The finger guard is a safety mechanism that prevents fingers from being caught in the belt Change the position of the finger guard r to match the direction of rotation of the motor pulley e r w q Forward rotation Mark for 105 mm diameter pulley Mark for 90 mm diameter pulley Mark for 80 mm diameter pulley Mark for 105 mm diameter pulley Mark for 90 mm diameter pulley Mark for 80 mm diamete...

Page 13: ...ed electric shocks may result CAUTION 5 6 2 Connecting the sewing machine and control box 6 pin plug Synchronizer cord 12 pin plug 5 6 1 Connecting the power cord power switch and ground cord Power switch Power cord Ground Green yellow Sewing machine oil pan Ground cord Mounting bracket grounding screw Ground symbol Loosen the two screws q and then gently pull the cover w toward you to open it Con...

Page 14: ...ircuit board to ON Refer to 7 5 2 Other DIP switch functions For machine solenoid For standing pedal option For synchronizer For presser foot lifter 12 pin plug 6 pin plug 12 pin plug No Thread trimming solenoid r t Thread wiping solenoid u i Quick reverse solenoid 0 1 Quick reverse switch o 2 Option output q w Ground e Spare y 12 pin plug terminal 6 pin plug No Presser lifter solenoid q r 40 V po...

Page 15: ...nels can be used 2 Disconnect the synchronizer cord q 3 Loosen the screw w and then gently pull the cover e toward you to open it 4 After opening the pawl of the circuit board connector r align the mark on the operation panel connector t with the mark on the circuit board connector r and securely insert operation panel connector t until the pawl locks 5 Fit the rubber plug y onto the operation pan...

Page 16: ...le plate 5 If using with the synchronizer cord disconnected When the treadle is pressed forward and then back to the neutral position q the machine will stop regardless of the needle position Thread trimming will not be carried out even if the treadle is pressed backed to position r The sewing machine does not operate 6 If an automatic presser foot lifter is being used The presser foot will rise w...

Page 17: ... to neutral position q the thread trimmer operates and then the needle will be raised and stop above the needle plate 5 If using with the synchronizer cord disconnected When the needle is pressed forward and then back to the neutral position q the machine will stop regardless of the needle position Thread trimming will not be carried out even if the treadle is pressed backed to position r The sewi...

Page 18: ...imply resting on the treadle or if the treadle pressure is too weak adjust the position a to c at which the treadle spring q is hooked onto the treadle lever w Note The treadle pressure will increase from position a to po sition c 6 2 2 Adjusting the treadle return pressure Loosen the nut e and turn the bolt r The treadle re turn pressure becomes heavier as the bolt r is tight ened and becomes lig...

Page 19: ...reen e turns off and the power switches off 7 3 Setting the sewing speed Turn the speed adjustment knob r on the front of the control box clockwise to increase the sewing machine speed the speed corresponding to the treadle depres sion amount and turn it counterclockwise to reduce the speed The maximum sewing speed that can be set is the sew ing speed which is determined by DIP switch settings Ref...

Page 20: ...x DIP switch setting procedure Do not clamp the cords inside the control box when closing the control box cover CAUTION Make sure that the DIP switches are set correctly otherwise incorrect operation may result Disconnect the synchronizer cord q Loosen the two screws w and then gently pull the cover e toward you to open it Set the DIP switches Refer to the tables for details of DIP switch function...

Page 21: ... provided with the following functions Can be used Cannot be used Function No panel F 20 F 40 F 100 Maximum sewing speed setting Start backtacking speed setting Needle stop position Automatic thread trimming thread trimming after Fixed stitch sewing Slow start Correction sewing Highest needle position stop Start backtacking using control box N 2 9 stitches End backtacking using control box N 2 9 s...

Page 22: ...backtacking stitches D Note At the time of shipment from the factory DIP switches A B C and D are all set to OFF As a result the number of stitches is set to 2 for each of A B C and D When using an operation panel backtacking functions using the control box are all disabled Display A B C D DIPSW No SW3 SW2 No of stitches 1 2 3 4 5 6 1 2 3 4 5 6 2 OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF 3 O...

Page 23: ...the dust cover at periodic intervals If the dust cover becomes blocked there is the danger that the motor may overheat If not using the motor for long periods turn off the power and disconnect the motor from the power supply Single needle machine and overlock machines setting Twin needle machine setting High High 1 2 3 4 1 2 3 4 SW1 1 ON Presser foot is lowered when treadle is returned to neutral ...

Page 24: ...incipal y esperar 5 minutos antes de abrir esta cubierta q e w o 5 t 7 r y 6 1 3 3 Loosen the screw r do not remove it and then turn the connector presser plate t approximately 90 around the axis of the screw r in the direction of the arrow A in the illustration 4 Pull the foot plug cap i toward you to remove it 5 Insert the 9 pin connector o of the foot plug assembly NDD J02824 001 u into the con...

Page 25: ...602 612 Connector wiring diagram VARIABLE SPEED PEDAL TWO SPEED PEDAL When the switch for the target function has been turned ON turn the other OFF HIGH S 8V 0V TRIMMER LIFT INPUT HIGH S 8V LIFT TRIMMER LOW S ...

Page 26: ...terial edge sensor may result CAUTION The sensor II is used for this product Sensor II is used in conjunction with the F 20 F 40 or F 100 operation panel and cannot be used by itself The sensor II connection method differs according to the operation panel type Built in type External type 1 Remove the operation panel q from the mounting bracket w 2 Bend the protrusion e on the right side of the ope...

Page 27: ...backtack stitches A B C and D the number of fixed length stitches E the number of label sewing stitches E and F the number of pleat presser stitches E the sewing speed A B C and D and the backtack sewing speed A B C and D These keys are used to set the number of start and end backtack stitches A B C and D the number of fixed length stitches E the number of label sewing stitches E and F the number ...

Page 28: ...e automatically carried out up until the set position when the treadle is depressed This key is only valid when the continuous backtack key t fixed stitch key y or name label key u has been pressed When this key is pressed the thread is trimmed after sewing is completed This key is only valid when the fixed stitch key y or name label key u has been pressed When this key is pressed the sewing speed...

Page 29: ...73 P81 C51 Note If the SW1 2 5 or SW6 1 2 3 4 settings are changed the control box head setting will change to 7373 SW1 5 OFF or 8423 SW1 5 ON 10 2 Setting the DIP switch maximum speed setting for the head Low Thread Tack Stop Low Thread Tack Stop Single needle sewing machine SW1 5 OFF Head High speed DIP switch SW1 6 7 8 setting B737 3 4700 Set 850 rpm to 1000 rpm B737 5 3500 Values given in pare...

Page 30: ... q Before turning on the power check that the motor pulley diameter matches the machine head w Check the settings for DIP switch 1 2 pulley size and whether DIP switch 1 5 is set to single needle machines overlock machines or twin needle machines e Change to machine head setting mode While pressing the sewing speed key turn on the power switch will appear in the ABCD display represents the previou...

Page 31: ...000 1500 B848 250 185 250 1000 1000 1500 B837 250 185 250 1000 1000 1500 B877 250 185 250 800 800 1500 B878 250 185 250 800 800 1500 P73 P81 250 185 250 1000 1000 1500 C51 250 185 250 1000 1000 1500 10 4 1 Setting procedure q Turn on the power switch and clear the ABCD display w Press the key and the key at the same time d 5 appears in the display e Press the key and the key at the same time S P a...

Page 32: ... While pressing the key press the key d S will appear at the AB display 3 Press the key The first display will be 1 1 o OFF or 1 1 ON 4 Set the memory switch No to 6 8 using the A B keys The default setting is 6 8 o OFF 5 Press the D key and turn memory switch 6 8 ON 6 8 ON 6 Using the A key set the AB display to E n and then press the key d S will reappear 7 Using the B key set the AB display to ...

Page 33: ...ls With Model B748 the needle up stop position is 10 14mm Adjust as follows when necessary Turn the power off Needle up position 1 Slightly loosen the two screws q Move the set screws q in the direction of normal pulley movement to raise the needle bar w stop position Turn the other way to lower the needle bar Needle down position 1 Set the treadle to reverse and then release it to neutral This is...

Page 34: ...ressed 1 The power indicator green LED is not illuminated Check the main power voltage Try connecting the power cord to a dif ferent outlet Check for a blown 8A fuse FU will flicker when using the operation panel The control box is defective so replace it Power indicator 2 The power indicator green LED is illuminated Is the treadle pressed down The treadle must be returned to the neutral position ...

Page 35: ...chine stops while sewing Voltage drop Occurrence of various errors Check the power voltage Even if the measured voltage is normal if the wiring is too long or if branched wiring is used the voltage may drop during sewing causing the reset function to activate and the machine to stop Refer to 13 1 Error display and de tails 4 The machine does not stop in the needle down or needle up position after ...

Page 36: ...ower voltage The momentary power voltage may increase when the factory s breaker trips etc This error may occur during deceleration if the load inertia is too large Lightly rotate the machine pulley by hand and confirm that it turns Check the details for the synchronizer in section 4 of the troubleshooting section Open the cover and check the 8A fuse on the circuit board Check the power voltage If...

Page 37: ...asure wirewould resistance 2 6ohm between each phases Check IPM operation Replace motor Replace power PCB Motor start up is not good and motor does not rise in its rotation Or the power relay becomes OFF Is power relay ON Heating of the R101 resistor Is the contact point of power relay open When the power switch is ON the contact point is closed Is R101 resistor broken Replace relay RY The lead wi...

Page 38: ...ck power transformer Replace fuse Replace control PCB Something is wrong with the operation of sewing head and motor Power transformer When power SW is ON LED Red does not illuminate Fuse F101 F102 blown Check resistance value at the primary side of transformer Is there about 15ohm Check BD101 Replace transformer Replace BD101 ...

Page 39: ...m the connector part of the power board 2 Measure with the tester set in the resistance range 1 as follows Presser foot lift connecter GND Solenoid 9 5 Ω Presser foot lift switch 0 Ω pressed Ω released Connector from the machine head B737 B883 Reverse switch 0 Ω pressed Ω released GND 7 4 Ω 5 0 Ω 6 7 Ω Thread wiper solenoid Thread trimming solenoid Reverse solenoid GND 8 0 Ω 6 7 Ω Nipper solenoid ...

Page 40: ...ion There are two adjusting ways as follows 1 Please indicate the voltage after indicating A3 in 7 segment display in CP check mode 1 d S 2 S P 3 of B C P Input output check mode 4 A 3 HEXA 5 A 3 DECMAL Then please adjust to display 14 16 in the neutral position if you turn VR1 in clock wise the value goes down Please adjust VR2 to display 45 47 in the full step position of pedal if you turn VR2 i...

Page 41: ...35 MD 602 612 Stroke VC analog voltage Chart Stroke rpm chart ...

Page 42: ...e operation 15 1 Initialization mode Various data can be registered in the memory on the control PCB and can be changed as required If the data is changed by mistake the data can be initialized with the initialization mode Note Only this function can be used with the F 20 panel Initialization mode i n Initialization mode menu When is pressed the display will change to the initialization mode menu ...

Page 43: ...F single needle Power switch ON 7 3 7 3 7 3 7 5 7 3 7 1 7 9 1 3 7 9 1 5 7 7 4 3 7 7 4 5 of B of B of B of B of D of D of D of D of D of D of D of D of D Stitching mode Note 1 Only the maximum speed is set to match the head specifications but the maximum stitching speed is limited by the SW1 6 7 8 setting Note 2 The settings will be registered when the key is pressed If the settings are not to be c...

Page 44: ...of the parameters the parameter setting mode cannot be entered unless the memory switch 01 is set to ON Setting mode menu 1 Memory switch setting mode d S of B Parameter setting mode P A of B End code E n of B Thread trim ming validity Memory switch setting mode 1 1 o o off on of B of B of B 1 2 o Start backtack double 2 1 o of A of A of A o E n End code Presser UP after thread trimming of A Param...

Page 45: ... and keys Change with and keys Stitching speed setting mode Input output check mode ROM version mode End the setting mode menu 2 when the key is pressed and return to the setting mode menu 1 ROM version display key Reverse solenoid key Thread trimming solenoid key Thread wiper solenoid key Presser foot lifter solenoid LED Needle UP signal LED Needle DOWN signal LED ENC signal LED Actuator switch L...

Page 46: ...er of each speed type are as follows Note 1 The upper limit of the maximum stitching speed limit value is limited by the SW1 6 7 and 8 If 5000rpm is set with SW1 6 7 and 8 when φ 105 pulley single needle are designated the speed can be set to a maximum of 5000rpm Note 2 If the SW1 2 5 SW6 setting is changed all these speed settings will be initialized The head settings will also be initialized a W...

Page 47: ...e minutes for the motor power s smoothing capacitor to discharge after the power is turned OFF Make sure that the LED red on the PCB is OFF before starting maintenance of the power PCB 16 3 Operation of the pedal The treadle unit outputs an analog voltage according to the pedal position The control unit reads this voltage and converts it into a motor command If it is not detected that the pedal is...

Page 48: ...sabled Treadle repression always includes thread trimming Presser lifter rise after thread trimming when the treadle is neutral ON In the case of SW1 1 ON Presser lifter descent after thread trimming when the treadle is neutral In the case of SW1 1 OFF Presser lifter descent after thread trimming when the treadle is neutral OFF In the case of SW1 1 ON Presser lifter rise after thread trimming when...

Page 49: ...king A B C D ON No of continuous tacking stitches 10 stitches OFF Normally ON Enable to stop during start tacking speed is variable with treadle start tacking speed at maximum treadle repression OFF Not enable to stop during start tacking speed is keep speed by treadle start tacking speed ON F 20 40 No of tacking stitches change enabled Tacking stitches are ABCD set No F 20 40 No of tacking stitch...

Page 50: ...correction by actuator switch after trimming OFF Inactive correction by actuator switch after trimming ON Not used OFF Normally OFF ON Not used OFF Normally OFF ON Not used OFF Normally OFF After presser foot lowers with treadle repressed forward to 1st step presser foot does not lift when treadle is pressed to neutral position ON After repressing treadle backward presser foot lowers when treadle ...

Page 51: ...FF Normally OFF ON When reverse needle UP operation is enabled presser turns ON before needle UP When memory switch 62 is set to OFF presser turns ON after thread wiping OFF When reverse needle UP operation is enabled presser turns ON after needle UP ON Not used OFF Normally OFF Sewing machine stops temporarily when automatic tacking reverse solenoid is changed over Machine can stop when switching...

Page 52: ...king OFF Speed of end tacking Speed of end tacking ON Servo lock timer OFF operation disabled OFF Servo lock timer OFF operation enabled ON Brake force increases with presser UP DOWN signal When memory switch 88 is set to ON OFF Brake force does not increase with presser UP DOWN signal When memory switch 88 is set to ON ON Servo lock enabled OFF Servo lock disabled ON Not used OFF Normally OFF ON ...

Page 53: ...not used 07 01 to 99 not used 07 01 to 99 not used 10 01 to 99 not used 24 00 to 47 Start tacking A B reverse solenoid ON timing pulse pulse The larger the value is the larger the timing delays The smaller the value is the faster the timing becomes 24 00 to 47 Start tacking B end reverse solenoid OFF timing pulse pulse The larger the value is the larger the timing delays The smaller the value is t...

Page 54: ...memory switch 76 is set to ON 00 00 to 99 10 Thread release OFF delay time 0ms 0 to 990ms When B781 is set Time to OFF after needle trimming stop 02 00 to 09 Slow start number of stitches stitch stitch 00 00 to 99 not used 00 00 to 99 not used 00 01 to 99 not used 00 00 to 99 not used 00 00 to 99 not used 00 00 to 99 not used 00 00 to 99 not used 10 00 to 99 not used 18 00 to 99 5 Thread trimmer O...

Page 55: ...stroke variable speed range start point 02 When the numerical value is small the variable speed area will DOM 2 6V 00 to 04 increase EXP 3 0V When the numerical value is large the inching speed area will increase Treadle stroke high speed reach point 02 When the numerical value is small the stroke to the high speed 4 2V 00 to 04 area is short When the numerical value is large the variable speed ar...

Page 56: ...01 to 20 don t change 07 01 to 20 don t change 28 04 to 70 don t change 14 04 to 70 don t change 20 04 to 70 don t change 10 01 to 20 don t change 24 04 to 70 don t change 50 10 to 99 don t change 40 05 to 70 don t change 15 00 to 50 don t change 05 00 to 70 don t change 05 01 to 30 don t change 15 01 to 30 don t change 20 01 to 99 don t change 30 01 to 99 don t change M6 M7 M8 M9 MA Mb MC Md ME M...

Page 57: ...ters and symbols are displayed on the operation panel 7 segment display 7 segment display 7 segment display 7 segment display 0 0 A A N n ON 1 1 B B O o OFF o 2 2 C C P P 3 3 D d Q Q 4 4 E E R r 5 5 F F S S 6 6 G G T t 7 7 H H U U 8 8 I i V u 9 9 J J W W K X L L Y M M Z ...

Page 58: ...or principal y esperar 5 minutos antes de abrir esta cubierta 20 How to remove the control box q Disconnect the synchronizer cord w Loosen the two screws and open the box s cover q w r t e Disconnect the cords from the machine and panel r Disconnect the motor connector t Disconnect the power supply connector and bushing y Loosen the screws fixing the control box to the motor by about half Two plac...

Page 59: ...53 MD 602 612 ...

Page 60: ...54 MD 602 612 NAME CONTROL PCB ASSY MD602 CODE J80900001 J03766001 ...

Page 61: ...55 MD 602 612 NAME CONTROL PCB circuit 1 3 NOTE MD602 612 ...

Page 62: ...56 MD 602 612 NAME CONTROL PCB circuit 2 3 NOTE MD602 612 ...

Page 63: ...57 MD 602 612 NAME CONTROL PCB circuit 3 3 NOTE MD602 612 ...

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Page 75: ...69 MD 602 612 NAME TREADLE PCB assy B47A127 CODE J80875001 ...

Page 76: ...BROTHER INDUSTRIES LTD NAGOYA JAPAN Printed in Japan J90113 001 2001 06 ...

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Brother MD-602, Service Manual

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