Toyota ESP9000 Скачать руководство пользователя страница 106

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4. REPLACEMENT OF MAIN COMPONENTS

［Installation］

(1)

Insert A of needle bar reciprocator into

the connecting rod and also the needle

bar drive shaft from the top of the arm.

Install the felt, needle bar reciprocator,

felt B and bearing case collar in that order.

(Fig.1)

(2)

The set hole of the needle bar drive shaft

is turned in the direction of set screw (a)

and it binds tight firmly in the place where

the set hole suited. (Fig.2)

(3)

Install the arm front cover L with five

setting screws (b). (Fig.3)

(4)

Bring the case linear to the left end, and

cam roller pin is put into the slot of the

change cam, imposing the needle case

on the positioning board from the top,

and putting the slot on the take-up lever

into the take-up lever guide rail.

Note: When installing the needle case,

check that the thread wiper hook is

inside the Velcro.

(5)

After checking that all the slits of the

take-up lever are in the take-up lever

guide rail, set the needle case to the right

most stopper of the case linear and fix by

pushing from the top. (Fig.4)

(6)

Check the needle position at the needle

No.15.

Note: No play with the needle case.

Note: If the needle position is wrong,

loosen the setting screw for the change

base and adjust the needle position by

moving the needle case right and left.

The change base must be located in the

position where the cam roller pin does

not touch also in the front and back.

(7)

Install the tension base set with two

setting screws (a). (Refer to Fig.3 of

removal)

(8)

Install the sensor arm with two setting

screws (b). (Refer to Fig.3 of removal)

Note: Check the position of the sensor.

[Please refer to 『 “ 3-11. Thread

sensor” 』 on page 34 ]

(9)

Install the change cover and the relay

card cover with two setting screws.

(Refer to Fig.2 of removal)

(10)

Install the tension base set, upper cover,

under cover. (Fig.4)

FIG.1

FIG.2

FIG.3

FIG.4

Needle bar

reciprocator

Felt

Needle bar

drive shaft

Connecting

rod

Set

Felt B

Bearing

case collar

hole

Arm upper

surface

(a)

Set hole

(b)

Arm front cover L

Case linear

Upper cover

Stopper

Under cover

-46-

Содержание ESP9000

Страница 1: ...SERVICE MANUAL Embroidery Machine ESP9000 15 needles...

Страница 2: ......

Страница 3: ...ery machine in reference to this Service Manual refer to TROUBLESHOOTING first Then refer to ADJUSTMENT or REPLACEMENT as suggested 3 Only the critical instructions are given When a component must be...

Страница 4: ...ed to be replaced use only parts certified by Aishin Seiki Co Ltd to ensure machine performance 2 To prevent any accident from occurring be sure to turn the power OFF before repair CONTENTS SPECIFICAT...

Страница 5: ...n error message is displayed Check X MOTOR 4 2 4 An error message is displayed Check Y MOTOR 5 2 5 An error message is displayed NEEDLE CASE ERROR 6 2 6 Holder does not return to stroke center after h...

Страница 6: ...s 1 3 2 12 Thread wiper hook does not operate 14 2 13 Thread trimming fails 15 2 14 Puckering 16 2 15 Improper tension 17 2 16 Jump function does not work 18 2 17 An error message is displayed THREAD...

Страница 7: ...ook 21 3 2 Position of the hook support 23 3 3 Standby position of thread catcher 24 3 4 Blade pressure 25 3 5 Picker position 2 7 3 6 Position of the thread wiper hook 28 3 7 Adjustment of the jump m...

Страница 8: ...C 30 3 9 Tension of deceleration belts B D E 31 3 10 Limit sensor 32 3 11 Thread sensor 3 4 3 12 Power box 35 36 4 1 Rotary hook 36 4 2 Thread...

Страница 9: ...cutter 3 7 4 3 Thread catcher 3 8 4 4 Needle bar 39 4 5 Needle bar reciprocator 41 4 6 Thread change motor 43 4 7 Power supply board 44 4 8 Power circuit board 45 4 9 Jump motor 46 4 10 Main circuit...

Страница 10: ...4 11 Operation box assembly 48 4 12 Upper shaft sensor 49 4 13 Sewing machine motor 50 4 14 X motor 51 4 15 Y motor 52 4 16 Thread wiper motor 53 4 17 Thread sensor 54 4 18 Operation control circuit...

Страница 11: ...p lever return spring on the jump lever holder and pull down the spring as low as possible so that the spring will not be located on the jump positioning collar Fig 4 3 Tighten the setting screw c and...

Страница 12: ...case cover upper upwards disconnect the connector CN2 and remove the case cover upper Fig 2 4 Disconnect all the connectors Fig 3 5 Remove two setting screws e and remove the main circuit board by hol...

Страница 13: ...FIG 3 48...

Страница 14: ...n box cover Fig 1 3 Remove four retaining screws d Unplug the cord and remove the operation box Fig 2 Installation 1 Plug in the cord 2 Secure the operation box to the bracket with four retaining scre...

Страница 15: ...g screws d Fig 3 2 Insert the connector of the upper shaft sensor in CN3 on the main circuit board Fig 5 3 Fix the upper shaft sensor set with two setting screws c in the position where the center of...

Страница 16: ...et surfaces of the sewing machine motor shaft and two setting screws c of the lower shaft joint are aligned and insert the sewing machine motor 2 Fix the sewing machine motor with four setting screws...

Страница 17: ...d Lower shat joint 1 Mount the X motor to the motor base with four setting screws d Fig 2 Sewing machine motor c 2 Set the X motor gear to the belt and temporarily secure the motor base to the X base...

Страница 18: ...e four set screws a and the base cover rear R Fig 1 2 Remove two setting screws b and the fan set Fig 2 3 Remove the Y pulley box adjusting screw c and nut d and loosen setting screw e and nut f Fig 2...

Страница 19: ...rarily secure them with two setting screws g Fig 3 3 Adjust the belt tension with setting screw e and then firmly tighten with two setting screws g and nut f Fig 3 Note Check the tension after tightin...

Страница 20: ...hat is contained in each setting screws of 3 and 4 sections Y motor bracket h Installation Y motor 1 Attached in the reverse procedure of removal Note Set the vertical position of the upper thread hoo...

Страница 21: ...FIG 1 FIG 2 Motor base Upper thread hook lever f d e Thread wiper motor base c FIG 3 b Thread wiper hook base Connecting rod plate 56...

Страница 22: ...the setting screw c Fig 4 2 Put the code of thread sensor base upwards into the thread sensor rail Fig 3 3 Putting a sensor arm into the slot of the thread sensor base and secure it with two setting s...

Страница 23: ...ng screws c and disconnect connectors CN12 and CN7 then remove the case cover upper Fig 2 3 3 Remove the two setting screws d and the resin spacers then remove the console board Fig 4 Installation Att...

Страница 24: ...FIG 4 59...

Страница 25: ...motor drive 10 Thread wiper Motor drive sliding type with thread retaining mechanism 11 Picker method Picking at start end of sewing and cutting thread 12 Stitch speed 1 200spm maximum 800spm standard...

Страница 26: ...22 Power supply and consumption 100 120 200 240VAC 50 60Hz 220W 23 Dimensions 835 H x 745 W x 740 D 2...

Страница 27: ...power supply does not turn on Preliminary inspection Power cord may be unplugged AC power cord Cable from the power box to the embroidery machine may be disconnected DC power cord Power box Main circu...

Страница 28: ...e P 44 Connection of connector CN 12 Must be connecte d correctly Connect the cable correctly or replace the main circuit board See 47 P Connection of connector CN 7 Must be connecte d correctly Conne...

Страница 29: ...ust be connecte d correctly Connect correctly Resistance Check connector visually Disconnect the power connector and check the resistance between and and and with a circuit tester 0 2 to 0 6 Replace S...

Страница 30: ...Connection of connector CN 3 Must be connecte d correctly Connect the cable correctly or replace the main the circuit board See P 47 CN3 5...

Страница 31: ...f power and sensor connectors Must be connecte d correctly Connect correctly Resistance Disconnect the power connector and check the resistance between and and and with a circuit tester 0 4 to 0 8 Rep...

Страница 32: ...Take out the fuse and check it visually 125V 20 A Must be in good condition Replace the fuse Connection of connectors CN 1 CN7 Must be connecte d correctly Connect correctly or replace See P 47 CN1 C...

Страница 33: ...ion of power and sensor connectors Must be connecte d correctly Connect correctly Resistance Disconnect the power connector and check the resistance between and and and with a circuit tester 0 2 to 0...

Страница 34: ...Take out the fuse and check it visually 125V 20 A Must be in good condition Replace the fuse Connection of connectors CN 4 CN 6 Must be connecte d correctly Connect correctly or replace See P 47 CN4 C...

Страница 35: ...to 6 0 Replace See P 43 Connection ofconnectors CN3 CN4 Remove the cover of the joint circuit board and check visually Must be connected correctly Connect correctly or replace Connection ofconnector...

Страница 36: ...Connection of connector CN 10 Must be connected correctly Replace See P 47 CN10 11...

Страница 37: ...istances Y set the X holder to its forefrontpositionbypressingtheemergency stop button and check the distances from thesurfaceofthedetectingplatetothecenter ofthephoto sensor X 65 7 1mm Y 213 5 1mm Po...

Страница 38: ...th a circuit ester t X motor Across GND red and black and U yellow U yellow and black V V white white and black W brown W brownand black A orange A orange and black k B pink and black B pin y motor o...

Страница 39: ...p damage Pushtheguidepin downasfarasit willgointhe directionofthe arrowand checkthe returning movementof thepin No damage is identified on the hook tip Repair Clearance between the picker and the bobb...

Страница 40: ...Picker height C 7 9 mm when piker solenoid is ON Adjust See P 27 15...

Страница 41: ...ncorrect Cloth tension may be too weak Needle size may be incorrect for the thread Needles and rotary hook Item Method Standard Action Needle and rotary hook timing A 201 3 Standar d 1 8 to 3 1mm Adju...

Страница 42: ...ndard Action Rouge edges or burrs on thread path Free of rough edges or burrs Smooth edges with emery paper 800 or replace tough parts Rouge edges in needle plate hole Free of rouge edges Repair or re...

Страница 43: ...P 21 Rouge edges on hook support Free of rouge edges Repair or replace See 23 P Clearance under the rotary hook support A 0 5 to 0 8mm Adjust See P 23 Relative positions of the center of the protrusi...

Страница 44: ...andard Action Burred edges on hold in the needle plate Free of burrs Repair or replace the needle plate Burred edges on the rotary hook Free of burrs Repair or replace the rotary hook See P 36 Burred...

Страница 45: ...n may be incorrect Item Method Standard Action Needle to rotary hook clearance A 0 1 to 0 3mm Adjust See P 21 Needle bat height B 201 3 Standar d 1 8to 1mm 3 Adjust See P 21 Needle lift D C 8 0 0 1mm...

Страница 46: ...hook return Push the guide pin down as far as it will go in the direction of the arrow and check the returning movement of the pin Must return smoothly Adjustme nt is performe d by loosenin g a guide...

Страница 47: ...st See P 28 Connection of power connector Must be connecte d correctly Connect correctly Resistance Disconnect the power connector and check the resistance between and and and and with a circuit teste...

Страница 48: ...lever and stopper At this point LED must be turned on A 0 5m m Adjust See P 24 Flaw on the thread catcher Free of flaws Repair or replace Fitted position of the thread catcher Check the position of t...

Страница 49: ...he needle plate may be burred The needle thread may be stuck around the threading tube holder and the thread take up lever Item Method Standard Action Thread take up spring stroke A Hold the thread be...

Страница 50: ...ions of the center of the protrusion on the hook support and the center of the needle Check protrusion on hook support visually B 0 0 2mm Adjust See P 23 2 TROUBLESHOOTING The thread tension may be to...

Страница 51: ...imately 1mm B 5 1g The screw of the retracting lever aligned with the ratchet mark Clearance under the rotary hook support A 0 5 to 0 8mm Relative positions of the center of the protrusion on the hook...

Страница 52: ...5 0 1mm Must be connecte d correctly 4 8 6 0 Adjust See P 29 Connect correctly Replace See P 47 Wrong movement or damage of needle bar reciprocato r Free of burrs Replace See P 41 Connection of connec...

Страница 53: ...Standard Action Torque of rotary tension disk Must turn smoothly Check position of sensor A less than 0 8mm Adjust See P 34 Connection of connector CN 1 Remove the cover of joint circuit board and che...

Страница 54: ...Connection of connector CN 7 Check the connector visually Must be connecte d correctly Replace See P 45 CN7 22...

Страница 55: ...able The embroidery frame may be interfering The embroidery frame screws may be loose Item Method Standard Action Belt A F 0 46 G 10 8 2 16mm Belt B F 0 46 G 0 9 0 18mm Belt C F 0 95 G 7 4 1 48mm Belt...

Страница 56: ...gency stop button and check the voltage of the sections below with a circuit tester X motor Across 5V red and GND red and black Y motor Across 5V red and GND red and black 5V when turned on Replace Se...

Страница 57: ...loosen the rotary hook set screw a closest to the hook tip and loosen the other two set screws Fig 2 2 Rotate the hand wheel anti clockwise to move the needle bar to the bottom dead center 180 Rotate...

Страница 58: ...FIG 2 FIG 3 201 3 0 1 0 3 mm 22...

Страница 59: ...ove the lower cover Fig 2 2 Loosen the set screw of the needle bar connecting stud set the needle bar height gauge adjust the height and tighten the screw Figs 3 4 Note Change the needle to check the...

Страница 60: ...FIG 2 FIG 3 FIG 4 Needle bar Stopper Needle bar Connecting stud Needle bar Needle bar height gauge Needle plate bracket 24...

Страница 61: ...must not exceed 0 2mm Fig 1 Adjustment 1 Loosen the two set screws a 2 Move the hook support in direction C or D to adjust the clearance between the hook support to the rotary hook Fig 2 3 Move the h...

Страница 62: ...4 4 If the LED is not turned on loosen the set screw d of the thread trimming drive lever and adjust the clearance between the lever and stopper to 0 5mm Fig 2 Then perform the thread trimming to che...

Страница 63: ...FIG 4 e Drive arm FIG 5 27...

Страница 64: ...thread trimming lever and smear the thread catcher with a felt pen Fig 2 5 Perform trimming manually and check that the felt pen marking on the thread catcher is scraped evenly even contact 6 Perform...

Страница 65: ...set screws a Fig 5 2 While steadying the thread cutter by hand turn adjusting screw b in direction C just so the screw tip barely touches the thread cutter Fig 5 3 While steadying the thread cutter by...

Страница 66: ...oosen two set screws c and the set screws a adjust the position of the picker by sliding the picker solenoid base back and forth After adjusting tighten the set screw a then move the picker base to th...

Страница 67: ...screws a to move the thread presser base in the direction of the arrow Position the base where the guide pin moves smoothly and tighten four set screws a Fig 3 2 If distance A from the needle center t...

Страница 68: ...IG 1 FIG 2 FIG 3 3 7 Adjustment of the Jump motor position Inspection 1 Remove the needle case Refer to 4 5 Replacement of needle bar reciprocator 3 ADJUSTMENT Guide pin B b Thread wiper motor base 32...

Страница 69: ...5mm Fig 2 Adjustment 1 Loose the two set screws c and adjust the jump motor position by moving the jump motor right left Fig 3 refer to 4 Replacement of needle bar reciprocator 2 After adjusting locat...

Страница 70: ...FIG 3 34...

Страница 71: ...loosen the rotary hook set screw a closest to the hook tip and loosen the other two set screws Fig 2 2 Rotate the hand wheel anti clockwise to move the needle bar to the bottom dead center 180 Rotate...

Страница 72: ...FIG 2 FIG 3 201 3 0 1 0 3 mm 22...

Страница 73: ...cover Fig 2 2 Bring the needle bar to the bottom dead center loosen the set screw of the needle bar connecting stud and set the needle bar height then tighten the screw Figs 1 3 Note Change the needle...

Страница 74: ...FIG 2 FIG 3 Needle bar Stopper Needle bar Connecting stud 24...

Страница 75: ...not exceed 0 2mm Fig 1 Adjustment 1 Loosen the two setting screws a 2 Move the hook support in direction C or D to adjust the clearance between the hook support to the rotary hook Fig 2 3 Move the hoo...

Страница 76: ...If the LED is not turned on loosen the set screw d of the thread trimming drive lever and adjust the clearance between the lever and stopper to 0 5mm Fig 2 Then perform the thread trimming to check th...

Страница 77: ...FIG 4 e Drive arm FIG 5 27...

Страница 78: ...thread trimming lever and smear the thread catcher with a felt pen Fig 2 5 Perform trimming manually and check that the felt pen marking on the thread catcher is scraped evenly even contact 6 Perform...

Страница 79: ...o setting screws a Fig 5 2 While steadying the thread cutter by hand turn adjusting screw b in direction C just so the screw tip barely touches the thread cutter Fig 5 3 While steadying the thread cut...

Страница 80: ...Note Incase the picker solenoid is exchanged Loosen two set screws c and the set screws a adjust the position of the picker by sliding the picker solenoid base back and forth After adjusting tighten t...

Страница 81: ...ing screws a to move the thread presser base in the direction of the arrow Position the base where the guide pin moves smoothly and tighten four setting screws a Fig 3 2 If distance A from the needle...

Страница 82: ...e case Refer to 4 5 Needle bar reciprocator on page 41 2 Remove three setting screws a two set screws b and remove the arm front cover L Fig 1 3 In this state the clearance between the jump lever and...

Страница 83: ...jump motor right left Fig 3 refer to 4 5 Needle bar reciprocator on page 41 2 After adjusting locate the jump motor at its highest position and tighten two setting screws 3 Install the arm front cove...

Страница 84: ...FIG 3 34...

Страница 85: ...8 2 16mm Fig 2 6 When applying a force of 0 95kg to drive belt C amount of deflection G must be 7 4 1 48mm Fig 2 Adjustment 1 If amount of deflection G of drive belt A differs from that specified loo...

Страница 86: ...FIG 4 31...

Страница 87: ...lection of deceleration belt B differs from that specified loosen the nut and two set screws d and turn setting screw e in the direction of the arrow After adjustment tighten two set screws d and the...

Страница 88: ...FIG 4 33...

Страница 89: ...t home position return Note Press the SET key 7 Check the distance X from the right most surface of the detecting plate to the center of left side X limit sensor shown in Fig 2 8 Move the X axis drive...

Страница 90: ...FIG 2 35...

Страница 91: ...t Fig 2 Note The slit is placed in the center of the sensor slot Fig 2 3 If the Y distance differs from that specified loosen two setting screws c and move the limit sensor to the specified position t...

Страница 92: ...ate should be located at the position where the distance A between the center of the disk and the center of the sensor is less than 0 8mm Fig 2 Adjustment 1 If the distance differs from that specified...

Страница 93: ...2 a Sensor arm 3 38...

Страница 94: ...and check that the voltage across and is 24 0 24 5V Fig 2 Adjustment 1 Remove eight setting screws a and then the case cover Fig 3 2 Turn power on 3 If the 24V power supply differs from that specifie...

Страница 95: ...FIG 3 FIG 4 VR6 Power supply board 40...

Страница 96: ...ottom dead center Rotate the hand wheel further until LCD display shows the needle position at 201 3 Fig 2 5 Rotate the rotary hook manually to align the hook tip with the needle center Secure a clear...

Страница 97: ...FIG 3 FIG 4 0 5 to 0 8mm 0 2mm or less Hook support hook support 37...

Страница 98: ...n parallel with the needle plate bracket A B and fix it in that position with two setting screws b Fig 2 Inspection After setting the thread cutter check again that the thread catcher makes an initial...

Страница 99: ...ng screw b Fig 2 Inspection 1 When the thread catcher is in the standby position the dimension between the shoulder and the thread cutter must be 0 0 5mm Fig 3 Please refer to 3 3 standby position of...

Страница 100: ...FIG 4 40...

Страница 101: ...d remove two setting screws d and the sensor arm Fig 3 7 Remove two setting screws e and the tension base set Fig 3 8 Loosen the set screw f and remove the needle needle clamp and cushion ring A Fig 4...

Страница 102: ...3 mm then tighten the setting screw d in the right direction Figs 1 2 g Needle bar holder spring Washer 7 Adjust the distance from the lower end of the top dead center stopper to the upper end of the...

Страница 103: ...FIG 2 Needle bar c Top dead center stopper needle bar connecting stud FIG 3 43...

Страница 104: ...ey in the test mode of LCD locate the cursor at No 2 and press SET key 10 Select the No 15 of a needle number by color change key 11 Turn the hand wheel until the angle of LCD displays 107 5 12 Remove...

Страница 105: ...FIG 5 45...

Страница 106: ...ide rail set the needle case to the right most stopper of the case linear and fix by pushing from the top Fig 4 6 Check the needle position at the needle No 15 Note No play with the needle case Note I...

Страница 107: ...tting screws g and the thread change motor Fig 4 Installation 1 Install the thread change motor and the hand wheel B with setting screws 2 Install the thread change motor base with two each set screws...

Страница 108: ...it board Fig 2 3 Remove four setting screws b and remove the power supply board Fig 2 Installation 1 Install the power supply board with four setting screws b Fig 2 2 Connects the connector and connec...

Страница 109: ...each four set screws c and the base cover rear R Fig 1 4 Loosen two setting screws d remove other two setting screws e and move the case cover upper Fig 3 5 Remove the connector CN9 of the computer b...

Страница 110: ...FIG 1 FIG 2 FIG 3 c Base cover rear R Table set a FIG 4 Rear cover b b e d Case cover upper Power circuit board f 50...

Страница 111: ...Printed in Japan 2002 8...

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