Engineer'S Manual: Computer-Controlled Dry-Head, Lockstitch, Sleeve Setting Machine With Multi-Programming Device

R
Computer-controlled Dry-head, Lockstitch,

Sleeve Setting Machine
with Multi-programming Device
DP-2100
ENGINEER’S MANUAL
40018531
No.E363-00
PREFACE
This Engineer’s Manual is written for the technical personnel who are responsible for the service and maintenance
of the machine.
The Instruction Manual for these machines intended for the maintenance personnel and operators at an apparel
factory contains operating instructions in detail. And this manual describes “Standard Adjustment”, “Adjustment
Procedures”, “Results of Improper Adjustment”, and other important information which are not covered by the
Instruction Manual.
It is advisable to use the relevant Instruction Manual and Parts List together with this Engineer’s Manual when
carrying out the maintenance of these machines.
In addition, for the motor for the sewing machine with thread trimmer, refer to the separate Instruction Manual
or Engineer’s Manual for the motor. And for the control panel, refer to the Instruction Manual for the control
panel.
This manual gives the “Standard Adjustment” on the former page under which the most basic adjustment value
is described, and on the latter page “Results of Improper Adjustment” under which stitching errors and troubles
arising from mechanical failures are described together with the “Adjustment Procedures”.
CONTENTS
1. SPECIFICATIONS...................................................................................1
2. CONFIGURATION .................................................................................. 2
(1) Sewing machine main unit ................................................................................. 2
(2) Operation panel ................................................................................................... 3
3. STANDARD ADJUSTMENT ...................................................................4
(1) Adjusting the height of the needle bar .............................................................. 4
(2) Adjusting the needle and the hook .................................................................... 4
(3) Removing the main shaft motor and the coupling ........................................... 6
(4) Adjusting the main shaft belt tension ............................................................... 8
(5) Adjusting the hook shaft belt tension ............................................................... 8
(6) Adjusting the feed belt tension .......................................................................... 10
(7) Adjusting the height of the feed foot bar .......................................................... 12
(8) Adjusting the height of the presser foot bar ..................................................... 12
(9) Adjusting the amount of alternate vertical movement .................................... 14
(10) Height of the presser screw ............................................................................. 16
(11) Assembling the guide plate .............................................................................. 16
(12) Adjusting the initial position of the auto-lifter ................................................ 18
(13) Adjusting the speed of the auto-lifter .............................................................. 18
(14) Adjusting the stroke of the auto-lifter ............................................................. 20
(15) Adjusting the thread trimmer cam ................................................................... 20
(16) Adjusting the initial position of the moving knife .......................................... 22
(17) Adjusting the initial position of the thread trimmer solenoid ....................... 22
(18) Adjusting the position of the moving knife and the counter knife ............... 24
(19) The fixing position of the auxiliary feed motor pulley ................................... 24
(20) The fixing position of the main feed motor pulley .......................................... 26
(21) The fixing position of the thrust collar of AT solenoid ................................... 26
(22) The fixing position of the thread tension shaft collar .................................... 28
(23) Adjusting the height of the feed foot ............................................................... 28
(24) Adjusting the height of the auxiliary feed foot ............................................... 30
(25) Adjusting the height of the presser foot ......................................................... 30
(26) Adjusting the feed eccentric cam .................................................................... 32
(27) Adjusting the assembly of the counter knife guard plate ............................. 32
(28) Replacing procedure of the top feed belt........................................................ 34
(29) Replacing procedure of the bottom feed belt ................................................. 48
4. PARTS TO BE GREASED ......................................................................50
5. SET-UP MANUAL FOR IP-200 ............................................................... 52
(1) Connecting procedure of operation panel with external vehicle .................... 52
(2) Re-setup of operation panel ............................................................................... 56
(3) Re-setup of main program .................................................................................. 59
(4) Re-setup of servo program ................................................................................. 65
(5) When using smart media other than that which has been packed
together ................................................................................................................ 71
6. INITIALIZING THE BACKUP DATA ........................................................ 72
7. SEWING DATA LIST ............................................................................... 73
8. MEMORY SWITCH DATA LIST ..............................................................76
9. ERROR CODE LIST ............................................................................... 82
10. TROUBLES AND CORRECTIVE MEASURES .................................... 87
(1) Mechanical parts ................................................................................................. 87
(2) Electrical parts..................................................................................................... 93
11. CIRCUIT DIAGRAM .............................................................................. 104
(1) Block diagram (1/2) ............................................................................................. 104
(1) Block diagram (2/2) ............................................................................................. 105
(2) Head and table/stand circuit diagram................................................................ 106
(3) Main and panel circuit diagram .......................................................................... 107
(4) Power source A circuit diagram ......................................................................... 108
(5) Power source B circuit diagram ......................................................................... 109
(6) Power source C circuit diagram ......................................................................... 110
(7) Motor circuit diagram .......................................................................................... 111
(8) Servo motor circuit diagram ............................................................................... 112
12. VARIOUS PRINTED WIRING BOARDS ............................................... 113
(1) FLT-T p.c.b. ........................................................................................................... 113
(2) FLT-S p.c.b. ........................................................................................................... 113
(3) PWR p.c.b. ............................................................................................................ 114
(4) MAIN p.c.b. ........................................................................................................... 114
(5) PANEL p.c.b. ........................................................................................................ 115
(6) DATA p.c.b. ........................................................................................................... 115
13. DRAWING OF THE TABLE ...................................................................116
(1) Slant table ............................................................................................................ 116
(2) Work top table ...................................................................................................... 117
(3) Edge Stopper A ................................................................................................... 118
(4) Edge Stopper B ................................................................................................... 119
1. SPECIFICATIONS
No. Item Specifications
1 Model DP-2100
2 Model name Computer-controlled dry-head, lockstitch, sleeve
setting machine with a multi-program device
3 Max. sewing speed 3,500 rpm (*1)
4 Feed system Intermittent belt feed by direct drive of stepping motor
5 Stitch length Both top and bottom 1.5 to 6 mm
6 Stitch length adjustment system Panel input
7 Stitch length adjustment minimum resolution 0.1mm
8 Needle bar stroke 30.7mm
9 Needle DP X 17 #10 to #14
10 Hook Full-rotary non-lubrication horizontal-axis hook
11 Bobbin case Bobbin case for full-rotary non-lubrication
horizontal-axis hook
12 Bobbin Standard aluminum bobbin
13 Presser foot lift By hand lifter : 5.5 mm, by auto-lifter : 10 mm
14 Amount of alternate vertical movement of presser 3.5 mm (0.2 to 0.3 mm at the time of delivery)
foot/feed foot Max.
15 Adjustment of amount of alternate vertical movement Slot stop position adjustment
of presser foot/feed foot
16 Lubrication Non-lubrication
17 Number of programs that can be inputted 99 programs
18 Number of steps that can be inputted (per program) 30 steps
19 Data mirroring Provided
20 Right/left alternate sewing Possible
21 Data record Smart media
22 Grease Exclusive grease : 23640204 (500g can)
JUKI grease A : 40006323 (tube of 10g)
23 Weight of complete set 106 Kg (head 65 Kg)
24 Control box model MC-650
25 Power voltage 3-phase Single phase
200V/220V/240V 220V/230V/240V
26 Frequency 50Hz / 60Hz
27 Rated current 2.6A/2.4A/2.2A 2.8A/2.6A/2.5A
28 Power/power consumption 560VA
29 Operating temperature/humidity 0 to 40, Less than 90%
30 Noise Workplace-related noise at sewimg speed
n=3,000 min-1 : LPA ≦ 84dB(A)
Noise measurement according to DIN 45635-48-A-1
* 1. The maximum sewing speed is limited in accordance with the amount of alternate vertical movement of
presser foot and feed foot, and stitch length.
2. Limitation by the stitch length is automatically limited.
3. Set the limitation by the amount of alternate vertical movement with the memory switch K02.
Limitation by the amount of alternate vertical movement of presser foot and feed foot
Max. sewing speed (rpm) Amount of vertical movement of feed foot (mm) Amount of vertical movement of presser foot (mm)
3,500 Less than 0.3 (2.7)
2,600 Not less than 0.3 to 1.5 (1.5)
2,000 Not less than 1.5 to 2.5 (2.5)
1,600 Not less than 2.5 to 3.5 (3.5)
Limitation by stitch length

Max. sewing speed (rpm) Stitch length (mm)
3,500 1.5 to 4.0
2,500 4.1 to 6.0
−1−
2. CONFIGURATION
(1) Sewing machine main unit
1 8
9
4
!0
3
7
6
1 Sewing machine head

2 Operation panel
3 Control box
4 Auxiliary table (WORK TOP TABLE)
5 Power switch
6 Main pedal
7 Auxiliary pedal
8 Thread stand
9 Shirring release switch
!0 Knee switch for step changeover
−2−
(2) Operation panel
(Front face) (Right side face)
1
4
5
6
1 Touch panel, LCD display section

2 Smart media slot card (Use with the lid closed.)
3 Slide switch (Unused • OFF)
4 Connector for RS-232C communication
5 Variable resistor for adjusting color LCD screen contrast
6 Connector for external input
7 Cable
−3−
3. STANDARD ADJUSTMENT
(1) Adjusting the height of the needle bar
Standard Adjustment
1. Bring the needle bar to its lower dead point, and adjust so that the upper marker line engraved on the
needle bar aligns with the bottom end face of the needle bar lower bushing.
To align
(2) Adjusting the needle and the hook

Standard Adjustment
1. Adjust the blade point of hook to the center of needle so that the clearance between the blade point
and the needle is 0.04 to 0.1 mm when the lower marker line engraved on the needle bar aligns with
the bottom end face of the needle bar lower bushing. Then tighten three setscrews in the hook.
0.04 to 0.1 mm
To align
* RP hook (dry hook) rolls thread waste or cloth dust, and there is a possibility of breakdown or sewing
trouble. Periodically perform cleaning of the hook.
−4−
Adjustment Procedures Results of improper Adjustment
1. Turn the handwheel by hand to bring the needle bar to its ™ Stich skipping or thread breakage
lower dead point. may occur.
2. Remove the plug of the face plate cover.
3. Loosen needle bar connection setscrew 1 to adjust the
height.
4. Tighten needle bar conection setscrew 1, and attach the
plug.
1. Remove throat plate auxiliary plate 1, hook cover asm. 2 and hook ™ When the clearance is excessively
base 3. narrow, the blade point of hook is
2. Turn the handwheel and adjust the lower marker line engraved on the damaged, and when it is
needle bar to the bottom end face of the needle bar lower bushing. excessively wide, stitch skipping
3. Loosen three setscrews in the hook, adjust the needle to the blade will be caused.
point, and tighten three setscrews in the hook. ™ Place counter knife guard plate 5
4. Put bottom feed belt 4 on hook base 3, and assemble them to the located inside hook base 3 to the
hook shaft base. inside of counter knife 6 since
5. Assemble throat plate auxiliary plate 1 and hook cover asm. 2. pull-up trouble will be caused.
6
1
2
−5−
(3)Removing the main shaft motor and the coupling
Standard Adjustment
1. Clearance between main shaft motor 1 and coupling 2 has to be 0.5 mm.
1
2
Screw No. 1 3
0.5mm
Screw No. 1 7 Flat section
4
7
5
−6−
1. Loosen the respective setscrews in side plate 4, pulley 5 and ™ When setscrews 3 and 7 in
pulley cover 6, and remove the respective parts. the coupling are not adjusted to the
2. Loosen two setscrews 7 in the coupling. flat section of main shaft motor 1
3. Loosen four setscrews 8 in the main shaft motor and remove and that of the main shaft :
main shaft motor 1. 1. UP-stop position does not
4. Loosen two setscrews 3 in the coupling. come near to 50˚.
5. Insert a spacer of 0.5 mm between the end of main shaft motor 2. Thread is not cut.
1 and coupling 2, and tighten setscrews 3 in the coupling.
6. When assembling, assemble in the aforementioned order of 3, 2,
and 1 in the reverse order of removing.
(Caution) When tightening setscrews 3 and 7 in the

coupling, assemble so that screw No. 1 in terms of
the rotating direction A of the main shaft should
come to the flat sections of main shaft motor 1
and the main shaft.
−7−
(4) Adjusting the main shaft belt tension
Standard Adjustment
1. Press in the direction of A with a load of 19.6 N (2 Kgf), and tighten setscrew 2.
Main shaft belt
(5) Adjusting the hook shaft belt tension

Standard Adjustment
1. The hook shaft belt has to sag 3 mm when the center of hook shaft belt 3 is pressed with a load of
1.3N (130gf).
1
2
Press the center 1
−8−
1. Loosen setscrew 2 in idler installing plate 1. ™ When belt tension is excessively

2. Press idler installing plate 1 in the direction of arrow mark A low, the side where the belt is
with a load of 19.6 N (2 Kgf), and tighten setscrew 2. loosened vibrates and noise
occurs.
™ When belt tension is excessively
high, the side where the belt is
tense vibrates with a sharp noise.
1. Loosen lock nut 2 in belt idler 1. ™ When belt tension is excessively

2. Press belt idler 1 in the direction of arrow mark B, and tighten low, the side where the belt is
lock nut 2. loosened vibrates and noise
occurs. At the same time, the slip
of hook position occurs, resulting
in needle breakage or damage of
hook.
™ When belt tension is excessively
high, the side where the belt is
tense vibrates. At the same time,
the load to bearing is increased,
and the life of machine is
shortened.
−9−
(6) Adjusting the feed belt tension
Standard Adjustment
1. Main feed belt

Adjust so that main feed belt 9 sags 3 mm when it is pressed with a finger with a load of 1.3N (130 gf).
2. Auxiliary feed belt
Adjust so that auxiliary feed belt !0 sags 3 mm when it is pressed with a finger with a load of 0.4N (40 gf).
3. Bottom feed belt
Adjust so that bottom feed belt !1 sags 3 mm when it is pressed with a finger with a load of 1.5N (150 gf).
* The standard of the replacing time of the respective belts is one year although it depends on the
frequency of use.
Replace the belt when excessive decrease of feed force or the like is observed.
1 8
4
5
8 !3
!4
!0
9
3 !1
Press the center

2 6
Press the center
3 6
B
B
C
A
− 10 −
1. Main feed belt ™ If the tension is not proper, shirring

(1) Remove 10 setscrews 8 in top feed covers A 1 and B 7. trouble due to feed pitch error will
(2) Move tension adjustment plate L 2 to the right and left be caused.
to adjust the tension. Move to the right (direction A) to
increase the tension, and to the left to decrease it.
2. Auxiliary feed belt
(1) Move tension adjustment plate S 3 to the right and left
to adjust the tension. Open both sides (direction B) to
increase the tension, and close both sides to decrease it.
3. Bottom feed belt
(1) Remove throat plate auxiliary plate 4, hook cover asm.
5, frame cover !3 and bottom feed cover !4.
(2) Move bottom feed tension plate 6 to the right and left to
adjust the tension. The tension is increased in the
direction of C.
− 11 −
(7) Adjusting the height of the feed foot bar
Standard Adjustment
1. Adjust the clearance between top and bottom feed belts to 0.1 mm.
2
1 5
0.1 mm
4
7
Be careful of parallel
(8) Adjusting the height of the presser foot bar

Standard Adjustment
1. Adjust the clearance between the bottom face of

presser foot 4 and needle hole guide 7 to 0.1 mm.
(Refer to the previous item (7) Adjusting the
height of the feed foot bar.)
4
0.1mm
− 12 −
1. Height of the feed foot bar ™ When the clearance is larger than
(1) Bring the needle bar to its upper dead point. 0.1 mm, feed force is deteriorated.
(2) Remove plug 1. ™ Clearance between top and bottom
(3) Loosen feed foot bar connection clamp screw 2. feed belts is 0.1 mm. If the
(4) Move feed foot 3 up or down and adjust the clearance clearance is widened more than the
between top feed belt and bottom feed belt to 0.1 mm. specified value, components
Then tighten feed foot bar connection clamp screw 2. interfere with each other.
™ When tightening feed foot bar
clamp screw 2, take care of the
parallel between feed foot 3 and
presser foot 4.
Bend of cloth or feed trouble will
be caused.
1. Height of the presser foot bar ™ When the clearance is widened,

(1) Bring the needle bar to its lower dead point. feed force is deteriorated.
(2) Remove face plate 5.
(3) Loosen presser foot bar connection clamp screw 6.
(4) Adjust the clearance between the bottom face of presser
foot 4 and needle hole guide 7 to 0.1 mm, and tighten
presser foot bar connection clamp screw 6.
(Refer to the previous item (7) Adjusting the height of
the feed foot bar.)
− 13 −
(9) Adjusting the amount of alternate vertical movement
Standard Adjustment
1. State of feed foot and presser foot at the time of delivery

Cam rod position Top feed arm lowest position
Amount of alternate vertical movement of feed foot 0.2 to 0.3 mm
Clearance at lower dead point of feed foot 0.1mm
Amount of alternate vertival movement of presser foot Approximately 2.7 mm
Clearance at lower dead point of presser foot 0.1mm
2. Relation between amount of alternate vertical movement and max. sewing speed
1 2 3 4
Amount of vertical
Less than 0.3 Up to 1.5 Up to 2.5 Up to 3.5
movement of feed foot (mm)
Amount of vertica
2.7 1.5 2.5 3.5
movement of presser foot (mm)
Max. sewing speed (rpm) 3,500 2,600 2,000 1,600
(Caution) When changing the amount of alternate vertical movement, change max. sewing speed.
When it is not changed, components breakage or damage occurs and the life of the
machine is excessively shortened.
2 Hole A 3
Be careful of parallel
4
B
− 14 −
1. Turn the handwheel and bring the needle bar to its lower dead ™ When the clearance is widened,
point. feed force is deteriorated at high
2. Adjust the position of cam rod 1 to the lowest position of top speed.
feed arm 2. ™ When the clearance is widened,
3. Remove stopper plug 6, insert a hexagonal wrench key from noise or vibration is increased at
hole A, and loosen top feed arm clamp screw 3. high speed.
/ Feed foot 4 moves downward. Adjust so that clearance B ™ When the clearance is excessively
between top and bottom belts becomes 0.1 mm. narrow, efficiency of rotation of
(Range : 0.1 to 1.0 mm) material is deteriorated.
(It is the premise that (7) Adjusting the height of the feed foot bar
has been performed.)
4. Turn presser foot lever 5, raise feed foot 4, and insert a
spacer so that the clearance between top feed belt and bottom
feed belt becomes 0.2 to 0.3 mm.
5. Tighten top feed arm clamp screw 3.
6. Turn presser foot lever 5 and remove the spacer.
− 15 −
(10) Height of the presser screw
Standard Adjustment
1. Adjust the height of top feed spring adjusting screw 1 to 30 ± 0.3 mm from the machined plane of
frame.
2. Adjust the height of presser spring regulator 2 to 19 ± 0.3 mm from the top surface of spring base 3.
2
30 ± 0.3 mm
19 ± 0.3 mm
5
4
3
(11) Assembling the guide plate

Standard Adjustment
1. Roller guide 1 has to always receive roller 2 when roller moves 2 up and down.
2. Assemble presser foot guide plate 3 so that presser foot shaft connection 4 smoothly moves up
and down.
5
2
− 16 −
1. For the adjustment of top feed spring adjusting screw 1, loosen ™ When the height is excessively
nuts 5, adjust the height to 30 ± 0.3 mm, and tighten nuts 5. high, shortage of feed force occurs
2. For the adjustment of presser spring regulator 2, loosen presser and jumping at high speed occurs.
spring regulator nut 4, adjust the height to 19 ± 0.3 mm, and As a result, damage of components
tighten presser spring regulator nut 4. is caused.
™ When the height is excessively low,
pressure applied to the belt is
increased and belt mark remains
on the cloth.
1. Remove the face plate cover, loosen setscrews 5 in roller guide ™ Excesiive side pressure is applied
1, move roller guide 1 to the right and left, move the auto-lifter to the presser bar. As a result, the
up and down, and adjust so that roller 2 always comes in contact presser bar will break down.
with the inside of roller guide 1. Then tighten setscrews 5. ™ A proper amount of alternate
2. Loosen setscrews 6 in presser foot guide plate 3, and adjust vertical movement cannot be
with the hand lifter or auto-lifter so that the guide section of presser obtained.
foot shaft connection 4 smoothly moves up and down the ™ Lifting amount of auto-lifter cannot
groove section of presser foot guide plate 3. be obtained.
™ Bend of feed is increased due to
the unevenness of right/left of feed
foot.
™ A proper amount of alternate
vertical movement cannot be
obtained.
™ Groove section of presser foot
guide plate 3 is cut and
unevenness of right/left of presser
foot is increased.
− 17 −
(12) Adjusting the initial position of the auto-lifter
Standard Adjustment
1. Adjust so that the clearance between the top surface of presser lifter link 1 and the bottom face of
feed foot bar connection 2 is 0.1 to 0.3 mm at the upper dead point of the needle bar.
3
0.1 to 0.3 mm
(13) Adjusting the speed of the auto-lifter

Standard Adjustment
1. Adjust throttle valve 4 of AK solenoid section 3 to the state that it is turned four times from being
fully closed.
2
1
B A
− 18 −
1. Remove the side plate, and loosen setscrews 3 in stopper ™ When the clearance is excessively
installing plate 4. wide, a big noise occurs when the
2. Move stopper installing plate 4 in the direction of the arrow auto-lifter goes up.
mark, and adjust the clearance between presser lifter link 1
and feed foot bar connection 2 to 0.1 to 0.3 mm. Then tighten
setscrews 3.
1. Loosen lock nut 1. ™ When the opening amount of the

2. Turn knob 2 until it will turn no further in the direction of A. throttle valve is larger than the
(Set throttle valve 4 to the state that it is fully closed.) specified value :
3. Turn knob 2 four times in the direction of B. 1.Feed foot, presser foot, needle
(Set throttle valve 4 to the state that it is opened four times hole guide, etc. will break.
from the state that it is fully closed.) 2.The life of the respective feed
4. Tighten lock nut 1. belts is shortened.
™ When the opening amount of the
throttle valve is smaller than the
specified value :
1.The force to feed material is
deteriorated immediately after
the motion of auto-lifter.
2.The lifting amount of auto-lifter is
decreased.
− 19 −
(14) Adjusting the stroke of the auto-lifter
Standard Adjustment
1. Adjust so that the clearance between the bottom face of the top feed belt and the top surface of the
bottom feed belt is 10 to 10.3 mm.
2
1
10 to 10.3 mm
(15) Adjusting the thread trimmer cam

Standard Adjustment
1. Turn the handwheel to the position where the thread take-up lever comes a little before it goes up to its
upper dead point.
2. Turn ON the thread trimmer solenoid, slide roller 8to thread trimmer cam 7, and make them engage
with each other using the output signal check I06-09 of the check program
(refer to the Instruction Manual).
3. In the state as it is, turn the handwheel in the normal operating direction and in the reverse direction.
Then set the handwheel to the position where it does not turn.
4. When marker dot 5engraved on the pulley cover aligns with marker dot 1engraved on the
handwheel, the timing is normal.
8 Slide
4: White
3: Green
2: Red
1: Colorless
5
9
!
1
7 !
0
− 20 −
1. Loosen nut 2of link ball shaft 1. ™ When the clearance is excessively
2. Turn link ball shaft 1and tighten nut 2when the specified wide, feed foot comes in contact
value (10 to 10.3 mm) is reached. with the feed foot bar bushing and
3. If the adjustment range is insufficient, loosen setscrews 4in a noise occurs when the presser
AK solenoid, and move AK solenoid 3downward to adjust the lifter goes up.
stroke.
1. Remove the bottom cover. ™ Length of needle thread remaining

2. Loosen setscrews !0 in the thread trimmer cam. on the needle is shortened.
3. When cam collar !1 moves, adjust so that thread trimmrer cam ™ Thread trimming motion is not
7does not engage with roller 8and thread trimmer cam 7 completed at the time of UP-stop
and roller 8come to the almost equal position in the range position.
where thread trimmer cam 7enters roller 8. Then tighten
setscrew !1 in the cam collar.
4. Adjust marker dot 1on the handwheel to marker dot 5on the
pulley cover.
5. Pressing driving block 6to the right, make thread trimmer cam
7engage with roller 8.
6. Turn thread trimmer cam 7only, without turning hook driving
shaft 9, in the reverse direction against the rotating direction of
the hook driving shaft.
7. Press roller 8to thread trimmer cam 7at the position where
thread trimmer cam 7does not turn, and press thread trimmer
cam 7to cam collar !1. Then tighten setscrews !0 in the thread
trimmer cam.
− 21 −
(16) Adjusting the initial position of the moving knife
Standard Adjustment
1. The initial position of the moving knife is the position where marker dot 1engraved on the hook shaft
base aligns with V groove 2on the moving knife base 3.
At this time, end 6of the cam roller is higher by 1.7 mm than hook driving shaft center 7.
1.7 mm
2
6 Bottom surface
of base plate
1
11.8 mm
7
4
8
(17) Adjusting the initial position of the thread trimmer solenoid

Standard Adjustment
1. Adjust the initial position so that the clearance between slide arm 1and driving shaft aem 2is 0.1
to 0.5 mm when the thread trimmer solenoid performs suction.
0.1 to 0.5 mm
65
2 1 7
3 A
− 22 −
1. Adjusting the engraved marker dot ™ Thread handling trouble

(1) Loosen clamp screw 4in knife driving arm 5, make The blade section of moving knife
engraved marker dot 1align with V groove 2, and tighten does not fully pass the blade
clamp screw 4. section of counter knife, and thread
2. Adjusting the position of the cam roller trimming failure will occur.
(1) Loosen stopper lock nut 8, turn the stopper, and tighten ™ When the position of cam roller 6
cam roller 6at the proper position (11.8 mm). is excessively higher as against
hook driving shaft 7, the moving
knife rocking stroke is decreased
and thread trimming failure will be
caused. On the contrary,the
position is excessively lower, the
rocking stroke is increased and the
length of remaining needle thread
is shortened or the blade point is
damaged.
1. Remove the bottom cover and press driving block 3by finger ™ When the clearance is excessively
in the direction of the arrow mark A. At this time, loosen setscrews large, thread trimming motion
4and adjust so that the clearance is 0.1 to 0.5 mm. trouble may occur.
2. Detach the finger and make sure that there is a clearance ™ When the clearance is excessively
between cam roller 5and the edge of thread trimmer cam 6. small, the load applied to the
3. Secure a clearance of approximately 0.5 mm between slide arm respective components is
1and E ring 7. increased, and abnormal worn-out
of components may occur.
− 23 −
(18) Adjusting the position of the moving knife and the counter knife
Standard Adjustment
1. Install moving knife 1with setscrews 2in the moving knife by making it come in contact with the
moving knife base.
2. Install counter knife 4together with knife pressure adjustment plate 5with setscrew 3in the counter
knife.
1 2 A
5
4
(19) The fixing position of the auxiliary feed motor pulley

Standard Adjustment
1. Adjust the dimension from the end of the shaft of auxiliary feed motor 3to the end of pulley 2to
3.6 ± 0.2 mm.
3.6 ± 0.2 mm
3
− 24 −
1. Adjust so that the blade section of the eye of moving knife 1 ™ When the parallel is not obtained,
and the blade section of counter knife 4come in contact with remaining of thread end will be
each other in parallel, slightly press knife pressure adjustment caused.
plate 5in thre direction of A, and tighten with setscrew 3in ™ When the knife pressure is
the counter knife. excessively low, thread trimming
failure will be caused. When it is
excessively high, it is related to the
damage of the blade section of
counter knife 4.
1. Loosen setscrews 1. ™ When the dimension is large, timing

2. Adjust the position of pulley 2(dimension : 3.6 ± 0.2 mm). belt comes off pulley 2.
3. Tighten setscrews 1. ™ When the dimension is small,
timing belt is abnormally worn out.
− 25 −
(20) The fixing position of the main feed motor pulley
Standard Adjustment
1. Adjust the dimension from the end of the shaft of main feed motor 3 to the end of pulley 2 to 9 ± 0.2 mm.
9 ± 0.2 mm
(21) The fixing position of the thrust collar of AT solenoid

Standard Adjustment
1. Adjust so that the dimension from the main body of AT solenoid 3to the end of the shaft of AT
solenoid 3to 19.5 ± 0.1 mm when thrust collar 2is pressed to the main body of AT solenoid 3
(direction of A).
19.5 ± 0.1 mm
− 26 −
1. Loosen setscrews 1. ™ When the dimension is small,

2. Adjust the position of pulley 2(dimension : 9 ± 0.2 mm). timing belt comes off pulley 2.
3. Tighten setscrews 1. ™ When the dimension is large,
timing belt is abnormally worn out.
1. Loosen setscrews 1. ™ When the dimension is large,

2. Adjust the position of thrust collar 2(dimension : 19.5 ± 0.1 mm). needle thread tension is not
3. Tighten setscrews 1. stabilized.
™ When the dimension is small,
needle thread tension is not
stabilized.
− 27 −
(22) The fixing position of the thread tension shaft collar
Standard Adjustment
1. Pull thread release pin adjustment collar 2in the direction of B, and adjust so that the dimension from
the end of thrust collar 3to the main body of AT solenoid 4to 1 ± 0.1 mm when thread tension disks
6are fully closed.
1 ± 0.1 mm
2
1
B
3
5 6
(23) Adjusting the height of the feed foot

Standard Adjustment
1. Adjust the clearance between the bottom face of main feed belt 4and the top surface of bottom feed
belt 5to 0.1 mm when needle bar 1is in the position of its upper dead point.
3
0.1 mm
− 28 −
1. Loosen nut 1. ™ When the dimension is large,

2. Loosen thread release pin adjustment collar 2. needle thread tension is not
3. Insert a spacer 5of 1 mm between thrust collar 3and the main stabilized.
body of AT solenoid 4. ™ When the dimension is small,
4. Tighten thread release pin adjustment collar 2until thread needle thread tension is not
tension disks 6are fully closed. stabilized.
5. Tighten nut 1.
6. Remove a spacer 5of 1 mm between thrust collar 3and the
main body of AT solenoid 4.
1. Bring needle bar 1to the position of its upper dead point. ™ When dimension is large
2. Loosen screw 2. / 1. Material cannot be fed well.
3. Adjust the height of feed foot 3to 0.1 mm. ™ When dimension is small
4. Tighten screw 2. / 1. Worn-out of main feed belt 4
is accelerated.
− 29 −
(24) Adjusting the height of the auxiliary feed foot
Standard Adjustment
1. Make the clearance A between the bottom face of auxiliary feed belt 5and the top surface of bottom
feed belt 6the same as that B between the bottom face of main feed belt 7and the top surface of
bottom feed belt 6when needle bar 1is in the position of its upper dead point.
(A = B)
1
7 5
2
B A
3
4
(25) Adjusting the height of the presser foot

Standard Adjustment
1. Adjust the clearance between the bottom face of presser foot 3and the top surface of needle hole
guide 4to 0.1 mm when needle bar 1is in the position of its lower dead point.
3
0.1 mm
− 30 −
1. Bring needle bar 1to the position of its upper dead point. ™ When dimension is large
2. Loosen nut 2. / 1. Material cannot be fed
3. Turn screw 3, and adjust the height of auxiliary feed foot 4. straight.
2. Shirring cannot be performed
* When screw 3is turned clockwise, auxiliary feed foot 4goes well.
up. ™ When dimension is small
* When screw 3is turned counterclockwise, auxiliary feed foot 4 / 1. Material cannot be fed
comes down. straight.
2. Shirring cannot be performed
4. Tighten nut 2.
well.
3. Worn-out of auxiliary feed
belt 5 is accelerated.
1. Bring needle bar 1to the position of its lower dead point. ™ When dimension is large
2. Loosen setscrew 2. / 1. Material cannot be pressed.
3. Adjust the height of presser foot 3. ™ When dimension is small
4. Tighten setscrew 2. / 1. Needle hole guide 4 is
broken.
2. Presser foot 3 is broken.
− 31 −
(26) Adjusting the feed eccentric cam
Standard Adjustment
1. Adjust feed eccentric cam 2so that screw No. 1 faces the center of hinge screw 4in cam rod at the
upper dead point of the needle bar.
2 5
(27) Adjusting the assembly of the counter knife guard plate

Standard Adjustment
1. Adjust so that counter knife guard plate 1does not come in contact with the periphery of hook at the
time of sewing, and the top end of counter knife guard plate 1is pressed down by moving knife 5and
enters the bottom side of moving knife 5at the time of thread trimming operation.
2 End of the guard
1
plate goes along
4 the internal plane
of the hook base
A
3 B
C
5
− 32 −
1. Turn top feed arm cover 1. ™ When timing is improper, troubles

2. Turn the handwheel and adjust the main shaft to the upper dead below will be caused.
point of the needle bar. 1. Stitch skipping is apt to occur.
3. Draw top feed arm 3to this side. 2. Material is not fed.
4. Tighten the screw No. 1 of feed eccentric cam 2so that it faces 3. Pitch is not obtained.
the center of hinge screw 4in cam rod.
5. Turn the handwheel to rotate the main shat, and tighten the screw
No. 2.
(Caution) Tighten the screws so that there is no clearance

between top feed arm 3and drive shaft rear
bushing 5.
1. Adjust so that counter knife guard plate 1 is along the internal ™ When the clearance between the
plane of hook base 2, and tighten it with screws. top surface of counter knife guard
2. Set hook base 2 to hook shaft base 3, and adjust so that the plate 1 and the bottom face of
clearance between the top surface of counter knife guard plate 1 counter knife 4 is excessively
and the bottom face of counter knife 4 becomes 0.2 to 0.5 mm. large,
3. Actuate moving knife 5, press down section A of counter knife 1. The guard plate comes in contact
guard plate 1 at the bottom face of moving knife 5, and adjust with the hook and thread-stain
so that moving knife 5 enters between counter knife guard plate 1 will occur at the time of sewing.
and counter knife 4. 2. A noise will occur.
3. It is related to the early
deterioration of counter knife
guard plate 1.
4. Thread trimming trouble may
occur.
™ When the clearance is excessively
small, or pressing down at section
A is insufficient,
1. Section B of moving knife 5
collides with section C of
counter knife guard plate 1 at
the time of thread trimming. As
a result, main shaft will be locked.
− 33 −
(28) Replacing procedure of the top feed belt (1/7)
Procedures of disassembling / assembling
3 1
!2
!3
B B
!1 !1
!0 !0
8
8
9
A
− 34 −
Caution in disassembling Caution in assembling
1. Loosen setscrew 1, and remove needle 2.
2. Remove setscrew 3, and remove presser foot 4.
3. Remove 10 setscrews 5, and remove cover A 6 and cover B 7.
4. Loosen setscrew 8, move tension adjustment plate L 9in the

direction of A, and loosen the tension of main feed belt !2 and
auxiliary feed belt !3.
5. Loosen setscrew !0, and move tension adjustment plate S !1 in

the direction of B.
− 35 −
!2
!4
!3
!6
!5 !7
− 36 −
6. Remove main feed belt !2 from the pulley.
7. Remove auxiliary feed belt !3 from the pulley.
8. Raise manual presser lifting lever !4.
9. Remove setscrew !5, and remove auxiliary feed foot !7 from

feed foot bar !6.
− 37 −
!7
!3
!9 !2
!6
!5 !7
C !4
− 38 −
10.Remove the old auxiliary feed belt !3 of auxiliary feed foot !7,
and replace it with the new auxiliary feed belt !3.
11.Remove the old main feed belt !2 of feed foot !9, and replace it
with the new main feed belt !2.
12.Set auxiliary feed foot !7 to auxiliary feed foot bar !6 while taking
care so that the belt does not come off, and temporarily tighten it
with setscrew !5.
13.Lightly drawing the feed belt in the direction of C, lower manual * When lowering manual presser
presser lifting lever !4. lifting lever !4, make sure that the
respective belts enter the guide
grooves located in the bottom faces
of feed foot !9 and auxiliary feed
foot !7.
− 39 −
4
!3
3 3
2 2
1
1
!2
2 2
1
1
!2
8
8
9
D
− 40 −
14.Set auxiliary feed belt !3 to the respective pulleys in order of * When setting auxiliary feed belt !3
the numbers in the illustration on the left side. to the pulley, do not twist or draw
forcibly auxiliary feed belt !3.
15.Set main feed belt !2 to the respective pulleys in the order of the * When setting main feed belt !2 to
numbers in the illustration on the left side. the pulley, do not twist or draw
forcibly main feed belt !2.
16.Move tension adjustment plate L 9in the direction of D to such

an extent that the slackness of main feed belt !2 disappears, and
temporarily tighten setscrew 8.
− 41 −
!5
!9
0.1 mm
!2
@0
!2
8
8
9
E F
!3
!1
!1
!0 !0
G G
− 42 −
17.Bring the needle bar to the position of its upper dead point, and * For the details of adjusting the
tighten screw !5 after adjusting the height of feed foot !9 so that height of the feed foot, refer to
the clearance between main feed belt !2 and bottom feed belt @00 "(23) Adjusting the height of the
is 0.1 mm. feed foot".
18.Adjust main feed belt !2 to the proper tension by adjusting the * For the details of adjusting the belt
lateral position of tension adjustment plate L 9, and tighten tension, refer to "(6) Adjusting the
setscrew 8. feed belt tension".
* Tension of main feed belt !2 is increased when tension adjustment

plate L 9is moved in the direction of F, and decreased when the
plate is moved in the direction of E.
19.Move tension adjustment plate S !1 in the direction of G to such

an extent that the slackness of auxiliary feed belt !3 disappears,
and temporarily tighten setscrew !0.
− 43 −
@2
!2
@1
!3
!3
!1 !1
!0 H H
!0
G
G
@4
4
0.1mm
@3
− 44 −
20.Bring the needle bar to the position of its upper dead point, loosen * For the details of adjusting the
nut @1, turn screw @2, and adjust so that the bottom face of auxiliary height of the auxiliary feed foot,
feed belt !3 is as high as that of main feed belt !2. After the refer to "(24) Adjusting the
adjustment, tighten nut @1. height of the auxiliary feed foot".
* The height of the bottom face of auxiliary feed belt !3 becomes

high when turning screw @2 clockwise, and low when turning it
counterclockwise.
21.Adjust auxiliary feed belt !3 to the proper tension by adjusting the * For the details of adjusting the belt
position of tension adjustment plate S !1, and tighten setscrew !1. tension, refer to "(6) Adjusting the
feed belt tension".
* The tension of auxiliary feed belt !3 becomes high when moving
tension adjustment plate S !1 in the direction of G, and low when
moving it in the direction of H.
22.Bring the needle bar to the position of its lower dead point, and fix * For the details of adjusting the
presser foot 4 to presser foot bar @4 with setscrew 3 so that the height of the presser foot, refer to
clearance between the bottom face of presser foot 4 and needle "(25) Adjusting the height of the
hole guide @3 is 0.1 mm. presser foot".
− 45 −
− 46 −
23.Install needle 2, and tighten setscrew 1.
24.Tighten 10 setscrews 5, and fix cover A 6and cover B 7.
− 47 −
(29) Replacing procedure of the bottom feed belt
4
1
7 6
8 3
!5
!2
!3
!0
!4
!1
− 48 −
1. Loosen cover setscrews 1, 2and 3.

2. Remove throat plate auxiliary plate 4, hook cover 5, hook belt
cover 6, frame cover 7and bottom feed cover 8.
3. Loosen setscrews 9in the bottom feed tension plate.
4. Remove bottom feed tension plate !0.
5. Replace bottom feed belt !5 with a new one.
6. Put new bottom feed belt !5 to bottom feed pulley !1 and belt
roller !2.
7. Put bottom feed belt !5 to idler pulleys !3 and !4 as illustrated on
the left side, and tighten bottom feed tension plate !0 with
setscrews 9in the bottom feed tension plate.
8. Move bottom feed tension plate !0 in the direction of A to apply * For the details of adjusting the belt
proper tension to bottom feed belt !5. tension, refer to "(6) Adjusting
the feed belt tension".
9. Tighten throat plate auxiliary plate 4and the respective covers
5, 6, 7, and 8 with setscrews 1, 2, and 3.
− 49 −
4. PARTS TO BE GREASED
(1) Periodically perform grease-up to the indicated sections below approximately every six months as
a standard.
(2) Apply the exclusive grease (500g can, Part No. :23640204 or tube containing 10g, Part No. :
40006323) to the sections for which lubrication is necessary excluding the lubricating sections.
(3) Tighten the respective hinge screws excluding the auxiliary feed foot hinge screw with a tightening torque
of 5.88±0.49N • m (60±5 kgf • cm).
Driving shaft arm
L-shaped
Connecting link Hinge screw plate
Roller guide
Crank connecting
link
Hinge screw Roller bearing
Presser foot Presser bar bracket

guide plate
Presser bar holder
A Feed driving shaft

(shaft located on the inside
of stopper plug A)
Cam rod
Drive shaft arm
Slide arm
Clutch pin A
Thread trimmer cam

Drive block
Hinge screw
− 50 −
Presser
vertical link
Internal plane
of belt roller
(4) Tighten the auxiliary feed foot hinge screw with a tightening torque of 4.9±0.49N • m (50±5 kgf • cm).
Auxiliary feed
foot hinge screw
− 51 −
5. SET-UP MANUAL FOR IP-200
(1) Connecting procedure of operation panel with external vehicle

It is possible for this operation panel to perform communication or input of signal with the external vehicle
below other than the control box.
1. Smart media card
2. RS-232C
3. Input of signal by means of the connector for external input
1. Smart media card

It is possible to give and take data by using the smart media card.
For the smart media card, it is recommended to use SmartMedia of 3.3V voltage type which is prescribed by
SSFDC forum. The card is different in the position of notch as shown in the figure below. Judge it by the
position of notch.
< 3.3V type > < 5V type >
Notch
(Caution) When the contact part becomes dirty, contact failure will be caused. Control so that the
contact part is not touched by hand, or that dust, oil or other foreign material does not
adhere to the contact part. Besides, be very careful of handling the card since the internal
data is broken by the static electricity or the like.
(Setting procedure)
1) When the upper side cover located on the side of
operation panel is opened, there is the inserting
Contact part opening of the smart media card. Insert the card
there while facing the contact part to the front.
2) When continuing inserting the smart media card, the card stops once in the state that it protrudes by
approximately 10 mm. When some force is applied to it, it is further inserted and goes to the end. When
it goes no further, reduce the force and it returns by approximately 1 mm. This work completes the
setting of the card.
– 52 –
3) When the setting of the card is completed, close the smart media card cover. It is not possible to receeive
or send the data with smart media card with the cover opened. For the operating procedure, refer to
“USING COMMUNICATION FUNCTION” of the Instruction Manual.
If the smart media card comes in contact with the cover and the cover is not closed, check the following
matters.
• Check that inserting is stopped in the state that the card protrudes by approximately 10 mm.
• Check that the coantact part is faced downward and inserted.
• Check that the smart media card other than 3.3V voltage type is used.
(Removing procedure)
1) Open the smart media cover, press the card until it goes no further and reduce the force. The card
returns by approximately 10 mm by reversing order at the time of setting.
2) Then drawing up the card completes removing.
< Handling the smart media card >

• Smart media is a precision instrument. Do not bend or shock it.
• It is recommended to periodically save the data saved in the smart media into the other vehicle for the
accident.
• When initializing data, perform it after checking that there is no necessary data in the card. When the
data is initialized, the internal data is deleted.
• Avoid using or keeping the card in a high temperature or high humidity place.
• Avoid using the card near heating or combustible articles.
• When the contact part becomes dirty, contact failure will be caused. Control so that the card is not
touched by hand, or that dust, oil or other foreign material does not adhere to the card. Besides, be
careful of handling the card since the internal data is broken by the static electricity or the like.
• Smart media has the life, and writing and deletion cannot be performed after an extended period of use.
In this case, replace the smart media with a new one.
< Prevention of memory error >

• When write protect seal is pasted, the card < 3.3V type >
becomes exclusive for reading and writing cannot
be performed.
• Strip off the seal when you desire to record again.
• Do not use again the seal which was pasted once
and stripped off. The trouble of the main unit will
be caused.
– 53 –
2. Communication by means of RS-232C
Operation panel can give and take the data with the personal computer by using communication by means
of RS-232C.
For the cable to be connected, connect the reverse type 9-pin (female) to the operation panel side. Signal
names of the operation panel are as follows.
Pin No. Signal name Function Signal direction

1 N.C. Not connected
2 RXD Receive data To panel
3 TXD Transmit data From panel
4 DTR Data terminal ready From panel
5 GND Earth
6 DSR Data set ready To panel
7 RTS Transmission request From panel
8 CTS Transmission approved To panel
9 N.C. Not connected
adhere to the contact part. Besides, be careful of handling the contact part since the
internal element is broken by the static electricity or the like.
(Setting procedure)
1) When the lower side cover located on the side of operation panel is opened, there is a 9-pin connector
for RS-232C. Insert the cable there. When the screw for lock is attached to the connector, tighten the
screw to prevent the screw from falling.
– 54 –
3. Input of signal by means of the connector for external input
It is possible to input the signal from the outside.
When the switch is connected, it is possible to use as the input of the production control information.
For the details, refer to "Observing the production control information" of the Instruction Manual.
Cable (separately-sold) as shown in the figure below

can be connected.
1 Relay cable A (asm.) (40008168)
2m
1
321
+5V 1
SW 2
GND 3
Connector housing : KYOCERA ELCO CO. 60-8263-3038-15-000

Pin contact : KYOCERA ELCO CO. 60-8263-0513-00-808
(Note) The switch main unit is not installed to the

relay cable A (asm.).
adhere to the contact part. Besides, be careful of handling the contact part since the
internal element is broken by the static electricity or the like.
– 55 –
(2) Re-setup of operation panel
When the case is as below, it is necessary to perform re-setup of the program of the operation panel.
™ When the operation panel is used as that for other model.
™ When version-up of the program is performed.
The way of performing setup of the program from the smart media is shown below. Besides, it is regarded
that the program to perform setup has already entered the smart media card.
1) First, turn ON the power. Normally, the sewing ready screen is displayed.
2) Insert the smart media card into the operation panel.
3) Perform operation by the procedure below.
Data edit screen

1) Press key
d for three seconds.
Communication screen 1
2) Press key .
3) Press key .
d
Data selection screen

4) Press key .
5) Press key .
d
– 56 –
d
6) Press key .
File selection screen

7) Press key and select the download
program at display .
8) Press key .
d
9) Press key .
d
<-<- Start of communication ->->
d
– 57 –
d
Screen during data deletion Screen 1 during data writing Screen 2 during data writing
d
d
End screen
If the screen below is displayed, quickly

turn OFF the power and perform the set-
up again after checking [Checking items]
below.
Data writing abnormal screen
The procedure above completes

the replacing work of application
software.
Checking items
1 Smart media cover is opened during the data communication from the smart media.
2 Data of the smart media is not correct. Or, there is no data file.
3 Contact of the smart media is dirty. Contact is defective.
(Caution) Do not turn OFF the power and close/open the smart media cover during the work.
The main unit may be broken.
– 58 –
(3) Re-setup of main program
When you have purchased the single unit of IP-200 operation panel, the smart media card is packed together.
You can perform re-setup of the main program of MAIN circuit board on the control box side by using this
smart media card.
It is necessary that the main program and panel program have to match with each other.
If not, there is a possibility that trouble such as Error "E703 or E704" occurs. Be sure to perform setup by
using the smart media card which is packed together.
1. When panel program matches with main program

Perform the work by the procedure below when performing version-up of the main program by using the
smart media card.
1) First, turn ON the power.
3) Perform operation by the procedure displayed in the screen below.
Data edit screen

1) Press key for three seconds.
d
2) Press key .
3) Press key .
d

4) Press key .
5) Press key .
d
– 59 –
d
6) Press key .

7) Press key and select download
8) Press key .
d
9) Press key .
d
d
– 60 –
d
Screen during data writing Screen of end of data writing
d
software.

below.
Checking items
– 61 –
2. When panel program does not match with main program and an error occurs
Perform the work by the procedure below when replacing the main program in case trouble such as Error
"E703", "E704", etc. occurs.
1) First, turn ON the power. Error screen (E703 or E704) is displayed after turning ON the power.
Error screen
1) Press key .
d
2) Press key .
d

3) Press key .
4) Press key .
d
– 62 –
d
6) Press key .

7) Prees key and select the download
8) Press key .
d
9) Press key .
d
d
– 63 –
d
d
software.

below.
Checking items
– 64 –
(4) Re-setup of servo program
Perform the work by the procedure below when rewriting the servo program in the same way of “Re-setup of
main program”.
1. When main program matches with servo program

Perform the work by the procedure below when making the servo program version-up by using the smart
media card.
1) First, turn ON the power. Normally, the sewing ready screen is displayed.
Data edit screen

1) Press key for three seconds.
d
2) Press key .
3) Press key .
d

4) Press key .
5) Press key .
d
– 65 –
d
6) Press key .

8) Press key .
d
9) Press key .
d
d
– 66 –
d
d
software.

below.
Checking items
– 67 –
2. When panel program does not match with main program and an error occurs
Perform the work by the procedure below when replacing the main program in case trouble such as Error
"E703", "E704", etc. occurs.
1) First, turn ON the power. Error screen (E703 or E704) is displayed after turning ON the power.
Error screen
1) Press key .
d
2) Press key .
d

3) Press key .
4) Press key .
d
– 68 –
d
5) Press key .

7) Press key .
d
8) Press key .
d
d
– 69 –
d
d
software.

below.
Checking items
– 70 –
(5) When using smart media other than that which has been packed
together
When copying the contents of the smart media card which is packed together to the other smart media,
create the directory structure mentioned below with the personal computer after formatting the smart media
to be the copy destination with IP-200.
For the formatting procedure of the smart media, read "USING COMMUNICATION FUNCTION" of Instruction
Manual.
Save program file (.prg) and image file

ROUTE DIRECTORY
(.bin) corresponding to the machine
¥¥
model of the aforementioned folder name.
PROG
DP2100
Make the folder name the machine model name.

The example above is in case of DP-2100.
However, do not put "-" (hyphen) of the machine
model name.
– 71 –
6. INITIALIZING THE BACKUP DATA
Perform the work in the order of the procedures below in order to return the backup data which are memorized
in the sewing machine to the status at the time of delivery.
1) Press down shirring release switch 1, press down knee switch for step changeover 2, and turn ON power
switch 3 with auxiliary pedal 4 depressed.
2) In a short time, the buzzer sounds, and release the respective switches 3, 1 and 2, and auxiliary pedal 4.
3) After a few minutes has passed, E001 "MAIN EEP-ROM initialization contact of MAIN p.c.b." is displayed on
the panel.
4) Turn OFF power switch 3.
5) When power switch 3 is turned ON again, the data which have been set up to now are initialized and
returned to the status (sample pattern only) at the time of delivery .
Backup data to be initialized are sewing data, and all data which have been set in the mode screen (memory
switch, counter, check program, etc.)
However, thread tension data (tension during operation. tension during waiting and base tension) cannot be
initialized.
−72 −
7. SEWING DATA LIST
This list is the list of sewing data to set for every pattern.
"Semi-automatic selection and fully-automatic selection"

No. Item Setting range Edit unit Initial display
Selection of gents and ladies (Fully-automatic only) ––– ––– Gents
Select from two kinds of gents and ladies.
: Gents : Ladies
Shirring amount increase/decrease setting (Numerical

Increase/decrease value of the shirring amount value input) 1 0
of the whole of the pattern is set. -50 to 50
(Ratio input)
-95 to 95 5% 0%
Sewing size setting (Fully-automatic only) 2 to 16 1 size No. 5

Sewing size is set. Here, the description is In case of
in case of Japanese gents. Size value changes Japanese
in accordance with the country classes. gents
Sewing pitch setting 1.5 to 6.0 0.1mm 2.0mm

Pitch at the time of sewing is set.
Length between steps setting 1.0 to 255.0 0.1mm Without

(Fully-automatic only)
Length of each step is set.
Grading value setting 0 to 255 0.1mm 0mm

(Full-automatic only)
Offset value at the time of grading is set.
Compensation thread tension setting -200 to 200 1 0

Increase/decrease of thread tension value
in terms of the set value of needle thread
tension is set.
Compensation pitch setting -4.5 to 4.5 0.1mm 0mm

Increase/decrease value in terms of the
sewing pitch set with is set.
Start position change 1 to 15 1 1

Start position of the program is changed.
Mirroring ––– ––– –––

Mirroring of the program of one sleeve is
performed and the program of the other
sleeve is created.
− 73 −
Compensation shirring amount setting Number of
Number of stitches to increase/decrease the stitches of
shirring amount immediately after changing compensation 1 stitch 0 stitch
over the step and the shirring amount are set. 0 to 15
Compensation
shirring
amount 1 0
-30 to 30
Addition of step ––– ––– –––

A new step is added to the rear of the
selected step.
Deletion of step ––– ––– –––

The selected step is deleted.
− 74 −
"Manual selection"
Auxiliary pedal motion selection ––– ––– Interlocking
The motion is selected from two kinds of step mode and mode
interlocking mode.
: Step mode
: Interlocking mode
Auxiliary feed mode selection ––– ––– Manual

Motion mode of the auxiliary feed is selected. numerical
value input
: Manual numerical value input
: Manual ratio input
: Interlocking numerical value input
: Interlocking ratio input
Sewing pitch setting 1.5 to 6.0 0.1mm 2.0mm

Pitch at the time of sewing is set.
Auxiliary feed interlocking mode setting ––– ––– –––

Setting of the interlocking mode is performed
when the interlocking numerical value input or
the interlocking ratio input is selected under
Auxiliary feed mode selection.
Shirring amount range setting -4 to 35 1 Lower limit

The upper limit value and lower limit value of value -4
shirring amount is set when the interlocking Upper limit
mode is selected under Auxiliary value 35
pedal motion selection.
Compensation thread tension setting -200 to 200 1 0

Increase/decrease of tension value in terms
of the set value of needle thread tension is
set.
− 75 −
8. MEMORY SWITCH DATA LIST
1) Level 1
Memory switch data (level 1) are the motion data that the sewing machine has in common and the data that
operate on all sewing patterns in common.

Reverse stitching at the sewing start selection ––– ––– Without
Select from among three kinds of without, single and double.
: Without : Single : Double
Reverse stitching at the sewing end selection ––– –––

Without
Select from among three kinds of without, single and double.
: Without : Single : Double
Number of stitches of reverse stitching 0 to 19 1 stitch 5 stitches

Number of stitches at the sewing start and
that at the sewing end are set.
Reverse stitching speed 200 to 3000 10rpm 800rpm

Speed of the reverse stitching at the
sewing start and the sewing end is set.
Needle position at the time of stop ––– ––– DOWN

Needle position at the time of temporary stop during sewing
is selected.
: DOWN : UP
Number of stitches of soft start setting 0 to 9 1 stitch 0 stitch

Number of stitches of soft start at the
sewing start is set.
Soft start speed setting

200 to 2000 10rpm 800rpm
Speed of soft start at the sewing start is
set.
Condensation sewing selection ––– ––– Without

Select from among four kinds of without, start only, end only
and both start and end.
: Without : Start
: End : Both
Number of stitches of condensation 0 to 9 1 stitch 0 stitch

Number of stitches of condensation sewing
is set.
Condensation speed setting 200 to 2000 10rpm 800rpm

Speed of condensation sewing is set.
Base tension in waiting state 0 to 200 1 20

Base tension in waiting state (except during
sewing) is set.
− 76 −
Compensation tension mode selection ––– ––– Manual
Select from among manual (numerical value), manual (level) (numerical
and automatic. value)
: Numerical value : Level
: Automatic
For setting procedure of the manual (numerical value), refer
to "Explanation of compensation tension (numerical value)"
of the Instruction Manual.
Compensation tension manual (level) setting – 200 to 200 1 Level 1) 10
This item is displayed when "manual (level)" is selected in Level 2) 20
Compensation tension mode selection. Level 3) 30
Compensation tension value for each level is set.
/ Refer to "Explanation of compensation tension manual
(level)" of the Instruction Manual.
Compensation tension automatic setting Shirring ––– –––

This item is displayed when "automatic" is selected in amount
Compensation tension mode selection. Compensation tension – 4 to 35
value for each shirring amount range is set. Compensation
/ Refer to "Explanation of compensation thread tension tension value
automatic" of the Instruction Manual. – 200 to 200
Shirring smoothing function setting ––– ––– Unused

Use of shirring smoothing function is selected.
/ Refer to "Explanation of the shirring smoothing function"
: Unused : Us
Number of stitches of shirring smoothing

0 to 99 1 stitch 1 stitch
function setting
Number of stitches of shirring smoothing function
is set.
Shirring smoothing function shirring amount 1 to 35 1 1

setting
Shirring amount of shirring smoothing function is set.
Data storing function at the time of sewing ––– ––– Storing

Whether storing data or not when data is changed in the
sewing screen is selected.
: No storing : Storing
Sound output at the time of changeover of step selection ––– ––– No sound
Whether buzzer sounds or not when step is changed over
is selected.
: No sound : Sound
Auxiliary pedal use selection ––– ––– Use

Whether auxiliary pedal is used or not is selected.
: Unused : Use
Shirring release switch use selection ––– ––– Use

Whether shirring release switch is used or not is selected.
: Unused : Use
− 77 −
Knee switch use selection ––– ––– Use
Whether knee switch for step changeover is used or not is
selected.
: Unused : Use
Shirring amount interlock function at the time of change ––– ––– Not
of pitch selection corrected
Whether shirring amount set to each step at the time of
change of pitch is corrected or not according to the change
amount of pitch is selected.
: Not correct : Correct
Screen changeover function at the time of thread ––– ––– No

trimming on the way selection changeover
Whether screen is changed over or not when thread trimming
is performed at the step other than the last step is selected.
: No changeover : Changeover
Auxiliary feed input mode selection ––– ––– Numerical

Whether auxiliary feed input is performed with offset value
numerical value or % ratio is selected.
: Numerical value : Ratio
Shirring amount increase/decrease input mode ––– ––– Numerical

Whether Shirring amount increase/decrease value value
input is performed with offset numerical value or with % ratio
is selected.
: Numerical value : Ratio
2) Level 2
Memory switch data (level 2) can be edited when pressing MODE switch for as long as 6 seconds.

Presser position after thread trimming selection ––– ––– UP
Position of the presser after thread trimming is set.
: DOWN : UP
Max. sewing speed setting 200 to 3500 10rpm 3500rpm

Max. sewing speed of the sewing machine
is set.
Sewing speed at low speed setting 200 to 400 5rpm 200rpm

Min. sewing speed of the sewing machine is
set.
Sewing speed of thread trimming setting 100 to 250 5rpm 160rpm

Sewing speed at the time of thread trimming
is set.
− 78 −
Flicker reduction function setting 0 to 8 1 0
This function is set when hand lamp flickers.
0 : Without flicker reduction function
1 : Less effective / 8 : more effective
Rotation start pedal stroke setting 1.0 to 5.0 0.1mm 3.0mm

Stroke from the neutral position of pedal to
sewing machine rotation start position is set.
Pedal low speed section 1.0 to 10.0 0.1mm 6.0mm

Section from pedal neutral position to sewing
machine acceleration start position is set.
Pedal presser lifting start position – 1.0 to –6.0 0.1mm – 2.1mm

Section from pedal neutral position to cloth
presser lifting start position is set.
Thread trimming start pedal stroke – 1.0 to –6.0 0.1mm – 5.1mm

Section from pedal neutral position to thread
trimming start position is set.
Pedal max. number of rotation reach 1.0 to 15.0 0.1mm 15.0mm

stroke
Section from pedal neutral position to max.
number of rotation reach position is set.
Pedal neutral position compensation 1

– 15 to 15 –1
Compensation value of neutral point of pedal
is set.
Auto-lifter lifting holding time 10sec

10 to 600 60sec
Waiting time of lifting the presser lifter is set.
Pedal curve selection function ––– ––– Straight line

Curve of the number of rotation of the sewing machine in
terms of pedal depressing amount is selected.
0 : Straight line 1 : Square
2 : Square root
2
Number of
rotation 0
1
Pedal stroke
Reverse rotation to lift needle after thread trimming ––– ––– Ineffective
function selection
Sewing machine is rotated in the reverse direction after
thread trimming, and needle bar is lifted near to its upper
dead point.
: Ineffective : Effective
− 79 −
Reverse stitching at the sewing start A/M changeover ––– ––– Speed by
function selection manual
Designation of sewing speed of reverse stitching at the operation
sewing start is selected.
: In accordance with the speed by manual
operation of pedal or the like
: In accordance with the speed set by

Reverse stitching speed
Stop function immediately after reverse stitching at the ––– ––– Without
sewing start selection function
Function to make the sewing machine stop once when
reverse stitching at the sewing start is completed.
: Without function : With function
Condensation/EBT changeover speed 0 to 250 10rpm 170rpm

Initial speed at the time of start of EBT
(reverse stitching at the sewing end) is set.
Retry function selection ––– ––– Without retry

Function to make the sewing machine rotate again in the function
normal direction with max. torque after rotating the machine
in the reverse direction once when the sewing machine is
locked is selected.
: Without retry function
: With retry function
Sewing machine start-up curve selection ––– ––– Normal curve

Start-up curve of the sewing machine is selected.
: Normal curve : More sharp curve
Presser position at the time of stop of the sewing ––– ––– DOWN
machine selection
Position of the presser foot when the sewing machine
temporarily stopped is selected.
: DOWN : UP
Size class setting ––– ––– Japan

Initial value (size country class, gents'/ Gentlemen
ladies' selection, and basic size) when No. 6
creating a new pattern is set.
/ Refer to "Explanation of the size class".
Initial pitch setting 1.5 to 6.0 0.1mm 2.0mm

Initial value of pitch when creating a new
pattern is set.
Bottom feed amount compensation –1.0 to 1.0 0.1mm 0mm

value setting
Compensation value of set value and
actual value of bottom feed amount is set.
− 80 −
Top feed amount compensation value –1.0 to 1.0 0.1mm 0mm

setting
Compensation value of set value and
actual value of top feed amount is set.
Thread tension curve selection ––– ––– Standard

Inclination of thread tension curve is selected.
: Standard : Gentle (thin materials)
Reverse stitching button display selection ––– ––– Non-display

Display of reverse stitching button in the sewing screen is
selected.
: Non-display : Display
Dish-rise timing setting

0 to 40 1 18
Disk-rise timing from the start of thread
trimming is set.
Length of remaining thread setting

0 to 40 1 5
Length of remaining needle thread at the
time of thread trimming is set. When the
set value is changed, the disk-close timing
from the disk-rise timing changes.
(Caution) When the contents of level 2 have been changed, the screen becomes POWER OFF screen
after pressing CLOSE button . Accordingly turn ON the power again after turning
OFF the power once.
"POWER OFF screen"
− 81 −
9. ERROR CODE LIST
Error code Pictograph Description of error How to recover Place of recovery
E000 Contact of initialization of main shaft Turn OFF the
EEP-ROM of MAIN p.c.b. power.
When data is not written in EEP-ROM or data
is broken, data is automatically initialized and
the initialization is informed.
E001 Contact of initialization of main EEP-ROM Turn OFF the

of MAIN p.c.b. power.
E003 Main shaft motor encoder defectiveness Turn OFF the

Angle counter of needle UP detection has power.
exceeded the value equivalent to 1.1 turns.
Angle counter of needle DOWN detection has
E004 Main shaft motor needle DOWN detection Turn OFF the
defectiveness power.
Angle counter of needle UP detection has not
E005 Main shaft motor needle UP detection Turn OFF the

defectiveness power.
Angle counter of needle UP detection has
E006 Contact of initialization of machine head Turn OFF the

EEP-ROM of the circuit board mounted power.
on the machine head
E007 Main shaft motor-lock Turn OFF the

When large needle resistance sewing power.
product is sewn
E011 External media not inserted Possible to Previous screen

External media is not inserted. recover by reset.
− 82 −
E012 Read error Possible to Previous screen
Data read from external media cannot be recover by reset.
performed.
E013 Write error Possible to Previous screen

Data write from external media cannot be recover by reset.
performed.
E014 Write protect Possible to Previous screen

External media is in the write prohibition state recover by reset.
E015 Format error Possible to Previous screen

Format cannot be performed. recover by reset.
E016 External media capacity over Possible to Previous screen

Capacity of external media is short. recover by reset.
E022 File No. error

Possible to Previous screen
Designated file is not in smart media.
recover by reset.
E029 Smart media error Possible to Previous screen

Lid of smart media slot is open. recover by reset.
E062 Sewing data error Turn OFF the

When sewing data is broken or revision is power.
old.
Confirmation of tilt of machine head Turn OFF the

E302
When tilt of machine head sensor is OFF. power.
E303 Main shaft semilunar plate sensor error Turn OFF the
Semilunar plate of sewing machine motor is power.
abnormal.
− 83 −
E702 Abnormality of control Turn OFF the
CPU performed processing other than power.
supposed.
E703 Panel is connected to the machine other Possible to

than supposed. (Machine type error) rewrite program
When machine type code of system is after pressing
improper in case of initial communication. down
communication
switch.
E704 Nonagreement of system version Possible to Communication

When version of system software is improper rewrite program screen
in case of initial communication. after pressing
down
communication
switch.
E731 Main motor hole sensor defectiveness or Turn OFF the

position sensor defectiveness power.
When motor hole sensor error signal
(UVWE) is detected with the motor locked
(2 seconds or more have passed at 20 rpm
or less).
E733 Reverse rotation of main shaft motor Turn OFF the

When motor has continued to rotate 40 times power.
or more in the reverse direction as against
the control direction at 500 rpm or more
during motor running (excluding at the time
of holding).
E801 Phase-lack of power Turn OFF the

When 400 ms or more of power phase-lack power.
signal (PHE) is detected after 2 seconds of
phase-lack observation invalid time passed
from turning ON the power.
E802 Power instantaneous cut detection Turn OFF the

When power instantaneous cut detection power.
signal (PWF) is detected.
E810 Solenoid power short-circuit Turn OFF the

When solenoid power short-circuit signal power.
(PWSH) (CPLD internal signal) is detected
while power phase-lack signal (PHE) is not
detected after 2 seconds of phase-lack
observation invalid time passed from turning
ON the power.
− 84 −
E811 Overvoltage Turn OFF the
When power overvoltage signal (OVL) which power.
is output when input power is 280V or more
is detected.
E813 Low voltage Turn OFF the

When low voltage signal (LVL) which is power.
output when input power is 150V or less is
detected.
E903 Abnormality of stepping motor power Turn OFF the

When stepping motor power abnormality power.
signal (LVPMP) which is output when the
stepping motor power, 48V, fluctuates -15%
or more when turning ON the power is
detected.
E915 Abnormality of communication between Turn OFF the

operation panel and main CPU power.
When abnormality occurs in data
communication.
E916 Abnormality of communication between Turn OFF the

main CPU and main shaft CPU power.
communication.
E917 Failure of communication between Possible to

operation panel and personal computer recover by reset.
communication.
E918 Abnormality of heat sink temperature for Turn OFF the

MAIN p.c.b. power.
When temperature of heat sink for MAIN
p.c.b. is 85˚C or more.
E920 CPLD writing abnormality Turn OFF the

When 1 bit each is written in the test port power.
and it does not agree with Verfy when turning
ON the power.
E922 Main shaft motor control impossible Turn OFF the

When the number of rotation of measuring power.
exceeds 50 ms or more than the upper limit
value (3,500 rpm).
Main shaft drive trouble Turn OFF the

E924
When motor driver error signal (GTRE) is power.
detected while motor overcurrent signal
(OCL1) is not detected with the motor locked
(2 seconds or more have passed at 20 rpm
or less).
− 85 −
E941 CPLD reading abnormality Turn OFF the
When input signal from CPLD is read twice power.
and they do not agree with each other even
when trying 10 ms or more when turning ON
the power.
E942 Main shaft EEP-ROM trouble Turn OFF the

When data writing to EEP-ROM cannot be power.
performed.
E943 Main EEP-ROM trouble Turn OFF the

performed.
E946 Head EEP-ROM trouble Turn OFF the

performed.
− 86 −
10. TROUBLES AND CORRECTIVE MEASURES
(1) Mechanical parts
Trouble Cause (1) Cause (2) Inspecting order and adjusting procedure
1. Thread breakage 1-1) Thread path is bad. 1-A) Thread path is not smooth. Finish the thread path.
1-B) Thread path has flaws. Finish the thread path.
1-C) Thread path has burrs. Correct the thread path.
1-2) Needle thread tension is improper. 2-A) Needle thread tension is too high or too low. Adjust the tension to the proper tension.
1-3) Adjustment of thread take-up spring is improper. 3-A) Stroke is too large or too small. Adjust the stroke (standard : 10 to 12 mm).
3-B) Spring tension is too high or too low. Adjust the tension.
1-4) Needle is bad. 4-A) Needle is bent. Replace the needle.
4-B) Needle has flaws. Replace the needle.
4-C) Needle tip is blunt. Replace the needle.
− 87 −
4-D) Installing direction of needle is improper. Install the needle again.
4-E) Needle in terms of thread used is too thin or too thick. Replace the needle.
4-F) Needle tip is too sharp. Change the needle to the ball-point needle.
1-5) Parts related to the hook are bad. 5-A) Thread path of the hook has flaws. Finish the thread path.
5-B) Blade point of the hook is blunt or worn out. Correct the blade point or replace the hook.
2. Stitch skipping 2-1) Needle is bad. 1-A) Needle is bent. Replace the needle.
1-B) Installing direction of needle is improper. Install the needle again.
1-C) Needle tip is blunt. Replace the needle.
1-D) Needle in terms of thread used is too thin or too thick. Replace the needle.
To the next page

From the previous page
2-2) Parts related to the hook are bad. 2-A) Blade point of the hook is blunt or worn out. Correct the blade point of hook or replace the hook.
2-B) Hook timing is improper. Perform adjustment.
2-C) Height of the needle bar is improper. Adjust the needle bar up or down in terms of the blade point of the
hook.
2-D) Clearance between the needle and the blade point of Make the clearance as small as possible.
hook is improper.
2-3) Needle thread tension is too high. 3-A) Tension is too high. Decrease the tension.
2-4) Adjustment of thread take-up spring is improper. 4-A) Stroke is too large. Decrease the stroke.
4-B) Tension is too high. Decrease the tension.
3. Loose stitches 3-1) Thread tension is too low. ncrease the tension.
3-2) Adjustment of thread take-up spring is improper. 2-A) Stroke is too small. Increase the stroke.
2-B) Tension is too low. Increase the tension.
− 88 −
3-3) Thread take-up lever stroke is too large. Move the arm thread guide A to the right and decrease the supply
amount of thread by means of the thread take-up lever.
3-4) Parts related to the hook are bad. 4-A) Hook timing is too fast. In case of cotton thread and spun thread, adjust the timing to the
standard or delay the timing a little.
4-B) Hook timing is too slow. In case of synthetic thread, adjust the timing to the standard or
advance the timing a little.
4-C) Hook is bad (scratch). Replace the hook.
3-5) Thread path is bad. 5-A) Thread path is not smooth. Finish the thread path.
5-B) Thread path has flaws. Finish the thread path.
5-C) Thread path has burrs. Correct the thread path.
3-6) Bobbin or bobbin case is bad. 6-A) Bobbin thread is caught in bobbin or bobbin case due Replace the bobbin or the bobbin case.
to improper fitting of bobbin and bobbin case.
To the next page To the next page

From the previous page From the previous page
6-B) Winding of bobbin thread is improper. Tension of the bobbin winder is too high or too low.
6-C) Thread tension spring of the bobbin case is improper. Replace the bobbin case.
6-D) Bobbin thread in the bobbin case runs idle. Increase the spring pressure of the idle-prevention spring.
3-7) Thread tension is improper. 7-A) Thread tension disk is risen. Adjust the thread tension disk to the proper position.
4. Several stitches skip at the 4-1) Needle thread remaining at needle tip after thread 1-A) Needle thread tension is too high at the time of thread Check the needle thread route and correct the position of thread guide of
start of sewing. trimming is too short. trimming since there is abnormality in the needle thread the thread stand.
route.
1-B) Thread tension given by the thread tension controller Decrease the tension of thread tension controller No. 1.
No. 1 is too high.
1-C)Rise of the thread tension disk No. 2 at the time of thread Perform checking and adjustment of the parts related to the thread rise.
trimming is incomplete.
1-D)Thread trimming timing is too fast and the moving knife Check and adjust the thread trimmer cam timing.
moves while threads are not separated.
− 89 −
4-2) Needle thread is not scooped with the blade point 2-A) Timing between needle and hook is improper. Check the height of the needle bar and adjust the height to the standard
of hook. adjustment.
2-B) Tension or momentum of the thread take-up spring is Decrease the tension and decrease the momentum (standard : 10 to 12
too high or too large. mm).
2-C) Blade point of the hook is worn out. Correct the blade point or replace the hook.
2-D) Installation of the needle is improper. Adjust the inclination of needle or replace the needle in case it is bent.
4-3) Bobbin thread at the start of sewing is too short. 3-A) End of bobbin thread is drawn in the bobbin case due to Increase the spring pressure of the idle-prevention spring.
the idling of the bobbin.
Increase the bobbin thread tension.
3-B) Bobbin thread is cut short since there are flaws in the Correct the flaw of the hook or replace the hook.
hook.
4-4) Needle thread and bobbin thread are difficult to be 4-A) Speed at the start of sewing is too fast and needle thread Decrease the speed at the start of sewing.
knotted at the start of sewing. and bobbin thread are difficult to be interlaced.
5. Thread slips off the needle at 5-1) Needle thread length remaining at the needle tip 1-A) Thread is cut with counter knife only in case sharpening Sharpen again or replace the counter knife.
the start of sewing. after thread trimming is uneven. of counter knife is not good (too sharp).
1-B) There are flaws on the moving knife or the hook. Correct the flaw or replace the corresponding part.
5-2) Thread slips off the needle simultaneously with 2-A) Thread trimming timing is too fast and even the thread Adjust the thread trimming timing.
thread trimming. on the needle side is cut.
2-B) Thread rise is not performed. Check and adjust the parts related to the thread rise.
5-3) Needle thread and bobbin thread are difficult to be 3-A) Speed at the start of sewing is too fast, and needle thread Decrease the speed at the start of sewing.
knotted at the start of sewing. and bobbin thread are difficult to be interlaced.
6. Loose stitches at the start of 6-1) Needle thread tension at the start of sewing is too 1-A) Bobbin thread tension at the start of sewing is too low Increase the spring pressure of the idle-prevention spring.
sewing low. due to idling of the bobbin.
1-B) Tension of both needle and bobbin threads is too low. Increase the tension of needle and bobbin threads.
7. Needle thread is not trimmed. 7-1) Stitch skipping at the last stitch 1-A) Installation of the needle is improper. Check the installation of the needle and make sure of the bend of needle.
(Bobbin thread is trimmed.)
1-B) Momentum of thread take-up spring is too large. Decrease the momentum (standard : 10 to 12 mm).
− 90 −
1-C) Hook adjustment is improper. Check stitch skipping at low speed sewing and perform hook adjustment.
7-2) A part of the cutting blade section of the knife is not 2-A) Cutting blade sections of moving knife and counter knife Remove the hook base, and move the moving knife to cut three pieces of
sharp. are not closely fit at the time of thread trimming. spun #50. It is OK when three pieces are cut evenly. If not, sharpen the
(Installing angle and position of the counter knife are counter knife or correct the inclination of the top end of counter knife.
not fit to the cutting blade section of the moving knife.)
Adjust the installing position of counter knife.
7-3) Thread waste collects on moving knife, counter Perform cleaning.

knife and counter knife guard plate, and thread
handling is improper.
8. Bobbin thread is not trimmed. 8-1) Thread trimming timing is delayed and the moving Re-adjust the timing.
(Needle thread is trimmed.) knife cannot be handled.
To the next page

8-2) Thread waste collects on moving knife, counter Perform cleaning.
knife and counter knife guard plate, and thread
handling is improper.
9. Moving knife is locked. 9-1) Timing of respective sections is improper. 1-A) Thread trimmer cam timing is improper. Check and adjust the thread trimmer cam timing.
9-2) Moving knife comes in contact with the counter 2-A) Improper adjustment Correct the bend of the counter knife guard plate.
knife guard plate.
10. Noise from the face plate 10-1) Roller guide does not come in contact with the 1-A) Improper adjustment Adjust so that the roller guide comes in contact with the roller.
section roller.
10-2) Amount of the alternate vertical movement is too 2-A) Improper adjustment Adjust to the proper value (standard feed foot : 0.2 to 0.3 mm).
large.
10-3) Needle and hook interfere with each other due to Check the hook adjustment.
improper hook adjustment.
11. Vibration is large. 11-1) Main shaft motor belt tension is improper. Adjust the main shaft motor belt tension.
11-2) Gear back-lash is improper. 2-A) Hook driving shaft gear Check the back-lash.
11-3) Looseness of main shaft and hook driving shaft 3-A) Looseness of main shaft thrust Check the looseness of main shaft thrust.
is large.
− 91 −
3-B) Looseness of hook driving shaft Check the looseness of hook driving shaft.
12. Needle breakage. 12-1) Presser foot interferes with needle. Adjust the installing position of presser foot.
12-2) Contact with the moving knife Adjust the installing position of moving knife.
12-3) Interference with the needle hole guide Adjust the installing position of needle hole guide.
13. Irregular stitches. 13-1) Parts related to the hook are improper. 1-A) Hook is improper (scratch or improper thread path). Replace the hook or correct the thread path.
13-2) Bobbin or bobbin case is improper. 2-A) Bobbin thread is caught due to improper fitting of bobbin Replace the bobbin or the bobbin case.
and bobbin case.
2-B) Winding of bobbin thread is improper. Tension of the bobbin winder is too high or too low.
2-C) Thread tension spring of bobbin case is improper. Replace the bobbin case.
2-D) Bobbin thread in the bobbin case runs idle. Increase the spring pressure of the idle-prevention spring.
To the next page 2-E) Putting way of bobbin into the bobbin case Check the putting way.
13-3) Thread path is improper. 3-A) Thread path is not smooth. Finish the thread path.
3-B) There are flaws in the thread path. Finish the thread path.
3-C) There are burrs in the thread path. Correct the thread path.
13-4) Needle thread tension is improper. 4-A) Needle thread tension is too high or too low. Adjust the tension to the proper tension.
13-5) Adjustment of the thread take-up spring is 5-A) Stroke is too large or too small. Adjust the stroke (standard : 10 to 12 mm).
improper.
5-B) Spring tension is too high or too low. Adjust the tension.
13-6) Stroke of the thread take-up lever is too large. Move the arm thread guide A to the right and decrease the supply
amount of thread by means of the thread take-up lever.
14. Material bends. 14-1) Position of the top feed belt is improper. 1-A) Top feed belt is bent. Adjust the feed foot.
14-2) Height of the main feed foot and the auxiliary feed 2-A) Height of the main feed foot and the auxiliary feed foot Adjust the height of the main feed foot and the auxiliary feed foot.
foot is improper. is wrong.
14-3) Auxiliary feed shirring amount set value is 3-A) Auxiliary feed shirring amount set value is wrong. Set to the optimum set value.
− 92 −
improper.
15. Feed pitch is not obtained. 15-1) Feed belt has been worn out. Replace the belt.
15-2) Feed foot is excessively raised. Adjust the height of the feed foot.
15-3) Belt tension is too low. Set to the proper tension value.
16. Shirring is not performed. 16-1) Feed belt has been worn out. Replace the belt.
16-2) Feed foot is excessively raised. Adjust the height of the feed foot.
16-3) Belt tension is too low. Set to the proper tension value.
16-4) Set value is too small. Set to the optimum set value.
17. Shirring is excessively 17-1) Set value is too large. Set to the optimum set value.
performed.
(2) Electrical parts
1) Turning ON the power
1. Power fails to work. 1-1) Power is not supplied up to the power switch. 1-A) Power plug is disconnected. Connect the power plug.
1-2) Power is not supplied up to the control box. 2-A) Connection of power cord is different. Check the connection of wiring.
2. Panel is not displayed. 2-1) +5V is not supplied to MAIN p.c.b. 1-A) Connector (CN44) of MAIN p.c.b. is disconnected. Connect CN44.
2-2) +5V is not supplied to PANEL p.c.b. 2-A) Connector (CN34) of MAIN p.c.b. is disconnected. Connect CN34.
2-3) +24V is not supplied to MAIN p.c.b. 2-B) POWER p.c.b. is broken down. Replace POWER p.c.b.
3-A) Connector (CN59) of MAIN p.c.b. is disconnected. Connect CN59.
2-4) +24V is not supplied to PANEL p.c.b. 3-B) Connector (CN13) of POWER p.c.b. is disconnected. Connect CN13.
4-A) Connector (CN34) of MAIN p.c.b. is disconnected. Connect CN34.
2-5) Data is not sent to LCD (liquid crystal display device) 4-B) POWER p.c.b. is broken down. Replace POWER p.c.b.
of the panel.
− 93 −
5-A) Connector (CN105) of PANEL p.c.b. is disconnected. Connect CN105.
2-6) +24V is not supplied to the back-light of LCD (liquid 6-A) Connector (CN108) of PANEL p.c.b. is disconnected. Connect CN108.
crystal display device) of the panel.
2-7) Panel cannot be displayed. 7-A) PANEL p.c.b. id broken down. Replace the panel.
3. E062 (sewing data error) is 3-1) Sewing data is broken. Turn ON the power again (the broken sewing data is automatically
displayed. deleted with this action).
4. E302 (head tilt check) is 4-1) Head tilt check switch is inputted. 1-A) Installation of the head tilt check switch is improper. Adjust the installation of head tilt check switch.
displayed.
1-B) Head tilt check switch is broken. Replace the switch. (Caution) Switch is the normal open type and
error does not occur with disconnection of connector or breaking
of wire.
5. E703 (panel is connected to 5-1) Panel which is different in model setting is Connect the panel of the same model.
the machine other than connected.
supposed one) is displayed.
Press down the communication switch and rewrite the panel to
the same program as that of the model code of the sewing
machine.
To the next page

5-2) Communication cannot be performed between 2-A) Contact of connector (CN34) of MAIN p.c.b. is improper. Check the connection of CN34.
operation panel and MAIN CPU.
2-B) Program of MAIN is broken. Perform rewriting of the program of MAIN.
2-C) Data on the side of MAIN of MAIN p.c.b. is broken. Initialize the data on the side of MAIN of MAIN p.c.b.
2-D) MAIN p.c.b. is broken down. Replace MAIN p.c.b.
2-E) PANEL is broken down. Replace PANEL.
6. E704 (disagreement of system 6-1) R or V of R-V-L of main shaft, MAIN and PANEL is 1-A) R or V of main shaft is different. Press down the communication switch and rewrite the program of main
version) is displayed. different. shaft.
1-B) R or V of MAIN is different. Press down the communication switch and rewrite the program of MAIN.
1-C) R or V of PANEL is different. Press down the communication switch and rewrite the program of PANEL.
6-2) Communication cannot be performed between 2-A) Contact of connector (CN34) of MAIN p.c.b. is improper. Check the connection of CN34.
operation panel and MAIN CPU.
2-B) Program of MAIN is broken. Rewrite the program of MAIN.
− 94 −
2-E) PANEL is broken down. Replace PANEL.
7. E811 (overvoltage) is 7-1) Input voltage is 280V or higher and power 1-A) Input power is high. Check the input power.
displayed. overvoltage signal (OVL) is detected.
1-B) POWER p.c.b. is broken down. Replace POWER p.c.b.
8. E813 (low voltage) is 8-1) Input voltage is 150V or lower and low voltage signal 1-A) Input power is low. Check the input power.
displayed. (LVL) is detected.

9. E915 (abnormal 9-1) Communication cannot be performed between 1-A) Contact of connector (CN34) of MAIN p.c.b. is improper. Check the connection of CN34.
communication between operation panel and MAIN CPU.
operation panel and MAIN
CPU) is displayed. 1-B) Program of MAIN is broken. Perform rewriting of the program of MAIN.
10. E916 (abnormal 10-1) Communication cannot be performed between 1-A) Program of main shaft is broken. Perform rewriting of the program of main shaft.
communication between MAIN CPU and main shaft CPU.
MAIN CPU and main shaft
CPU) is displayed. 1-B) Data on the side of main shaft of MAIN p.c.b. is broken. Initialize the data of the side of main shaft of MAIN p.c.b.
1-C) MAIN p.c.b. is broken down. Replace MAIN p.c.b.
11. E920 (abnormality of CPLD 11-1) Writing cannot be performed to CPLD. 1-A) MAIN p.c.b. is broken down. Replace MAIN p.c.b.
writing) is displayed.
12. E941 (abnormality of CPLD 12-1) Reading cannot be performed from CPLD. 1-A) MAIN p.c.b. is broken down. Replace MAIN p.c.b.
reading) is displayed.
− 95 −
2) Panel operation
1. E000 (contact of initialization 1-1) Data of main shaft EEP-ROM is broken. 1-A) MAIN p.c.b. is broken. Replace MAIN p.c.b.
of main shaft EEP-ROM of
MAIN p.c.b.) is displayed.
1-B) Main shaft EEP-ROM is broken. Replace MAIN p.c.b.
2. E001 (contact of initialization 2-1) Data of MAIN EEP-ROM is broken. 1-A) MAIN p.c.b. is broken. Replace MAIN p.c.b.
of MAIN EEP-ROM of MAIN
p.c.b.) is displayed.
1-B) MAIN EEP-ROM is broken. Replace MAIN p.c.b.
3. E006 (contact of initialization 3-1) Data of head EEP-ROM is broken. 1-A) P.c.b. mounted on machine head is broken. Replace p.c.b. mounted on the machine head.
of head EEP-ROM of p.c.b.
mounted on machine head) is
displayed. 1-B) Head EEP-ROM is broken. Replace p.c.b. mounted on the machine head.
3-2) P.c.b. mounted on machine head is not connected. 2-A) Connector (CN55) of MAIN p.c.b. is disconnected. Connect CN55.
4. E011 (external media is not 4-1) Recognition of smart media cannot be performed. 1-A) Smart media is not inserted. Insert the smart media.
inserted) is displayed.
1-B) Reading section of the smart media is dirty. Clean the reading section.
− 96 −
1-C) Inside of the throttle of the smart media is dirty. Clean the inside of the throttle.
1-D) Smart media is broken. Replace the smart media.
5. E012 (read error) is displayed. 5-1) Data cannot be read from the smart media. 1-A) Reading section of the smart media is dirty. Clean the reading section.
1-B) Inside of the throttle of the smart media is dirty. Clean the inside of the throttle.
1-C) Smart media is broken. Replace the smart media.
6. E013 (write error) is displayed. 6-1) Data cannot be written to the smart media. 1-A) Reading section of the smart media is dirty. Clean the reading section.

7. E014 (write protect) is displayed. 7-1) Smart media is in the writing prohibited state. 1-A) Write prohibition seal is pasted on the smart media. Strip off the seal.
8. E015 (format error) is displayed. 8-1) Smart media is in the writing prohibited state. 1-A) Write prohibition seal is pasted on the smart media. Strip off the seal.
9. E016 (external media capacity 9-1) Capacity of the smart media is full. 1-A) Space region is not in the smart media. Delete the inside data of the smart media and secure the space region.
over) is displayed.
9-2) Recognition of the smart media cannot be 2-A) Reading section of the smart media is dirty. Clean the reading section.
performed.
− 97 −
10. E022 (file No. error) is 10-1) The designated file is not in the smart media. Designate the existing file.
displayed.
10-2) Recognition of the smart media cannot be 2-A) Reading section of the smart media is dirty. Clean the reading section.
performed.
11. E029 (smart media slot error) 11-1) Cover of the smart media is open. Close the cover.
is displayed.
11-2) Close/open detection switch of the cover is broken. Replace the close/open switch (SW2).
12. E702 (abnormal control) is 12-1) Program of the panel has run away. 1-A) PANEL p.c.b. is broken. Replace PANEL p.c.b.
displayed.
1-B) Program of the panel is broken. Rewrite the program of the panel.
1-C) Writing of the program of the panel is not properly Rewrite the program of the panel.
performed.
13. E917 (failure of communication 13-1) Communication cannot be performed between 1-A) Contact of RS232C connector (CN102) of the panel is Check the connection of CN102.
between operation panel and operation panel and personal computer. improper.
personal computer) is displayed.
1-B) Contact of RS232C connector of personal computer is Check the connection of RS232C connector of the personal computer.
improper.
1-C) PANEL p.c.b. is broken down. Replace the panel.
14. Key is not accepted even 14-1) Signal does not come to PANEL p.c.b. 1-A) Connector (CN109) of PANEL p.c.b. is disconnected. Connect CN109.
when pressing the touch panel.
14-2) PANEL p.c.b. dos not accept the signal. 2-A) PANEL p.c.b. is broken down. Replace the panel.
− 98 −
3) Sewing
1. E003 (failure of main shaft 1-1) Angle counter of main shaft motor is abnormal. 1-A) Encoder of main shaft motor is broken. Replace the main shaft motor.
motor encoder) is displayed.
1-2) Encoder signal is not inputted. 2-A) Connector (CN21) of POWER p.c.b. is disconnected. Connect CN21.
2-B) Connector (CN10) of POWER p.c.b. is disconnected. Connect CN10.
2-C) Connector (CN44) of MAIN p.c.b. is disconnected. Connect CN44.
2. E004 (failure of needle DOWN 2-1) Needle DOWN detection signal of main shaft motor 1-A) Encoder of main shaft motor is broken. Replace the main shaft motor.
detection of main shaft motor) is abnormal.
is displayed.
2-3) Normal/reverse rotation signals are frequently inputted. 3-A) Encoder of main shaft motor is broken. Replace the main shaft motor.
− 99 −
3-B) Repeated operations of normal/reverse rotation by hand Perform the repeated operations slowly.
are quickly performed.
3. E005 (failure of needle UP 3-1) Needle UP detection signal of main shaft motor is abnormal. 1-A) Encoder of main shaft motor is broken. Replace the main shaft motor.
detection of main shaft motor)
is displayed.
3-3) Normal/reverse of rotation signals are frequently 3-A) Encoder of main shaft motor is broken. Replace the main shaft motor.
inputted.
3-B) Repeated operations of normal/reverse rotation by hand Perform the repeated operations slowly.
are quickly performed.
4. E007 (main shaft motor lock) 4-1) Main shaft motor is locked. Release the locking.
is displayed.
4-2) Power is not supplied to motor. 2-A) Connector (CN2) of FLT p.c.b. is disconnected. Connect CN2.
4-4) Drive signal is not output to motor. 4-A) Connector (CN38) of POWER p.c.b. is disconnected. Connect CN38.
5. E303 (main shaft woodruff 5-1) Woodruff plate sensor of main shaft motor is abnormal. 1-A) Encoder of main shaft motor is broken. Replace the main shaft motor.
plate sensor error) is displayed.
5-2) Encoder signal (woodruff plate) is not inputted. 2-A) Connector (CN21) of POWER p.c.b. is disconnected. Connect CN21.
− 100 −
6. E810 (solenoid power short- 6-1) Solenoid power short-circuit signal (PWSH) is detected. 1-A) Thread trimmer solenoid is broken down. Replace the thread trimmer solenoid.
circuit) is displayed.
1-B) Presser lifter solenoid is broken down. Replace the presser lifter solenoid.
1-C) POWER p.c.b. is broken down. Replace POWER p.c.b.
7. E918 (abnormal temperature 7-1) Temperature of heat sink of MAIN p.c.b. is more 1-A) Fan located inside of box is not rotating. Connect CN23 and CN24 of POWER p.c.b.
of heat sink for MAIN p.c.b.) is than 85˚C.
displayed.
1-B) Air hole of control box is blocked. Clean the air hole.
1-D) Stepping motor is broken down. Replace the stepping motor.

8. E922 (impossible to control 8-1) Number of revolution of measurement exceeds the 1-A) Encoder of main shaft motor is broken. Replace the main shaft motor.
main shaft motor) is displayed. upper limit (3,500 rpm).
9. E924 (failure of main shaft 9-1) Motor driver error signal (GTRE) is detected. 1-A) Main shaft motor is broken down. Replace the main shaft motor.
drive) is displayed.
10. Shirring amount changes 10-1) Setting of auxiliary pedal is improper. Refer to 21-2 "Performing setting of the auxiliary pedal" in Instruction Manual
when changing over to and set again.
sewing screen.
11. Shirring display is not "0" in 11-1) Setting of auxiliary pedal is improper. Refer to 21-2 "Performing setting of the auxiliary pedal" in Instruction Manual
the manual screen. and set again.
12. Thread tension during waiting 12-1) Base tension during waiting is improper. Set again the base tension during waiting of level 1 [U12] of memory switch data.
is high.
13. Compensation thread tension 13-1) Compensation tension mode is selected to the Stop the automatic selection of compensation tension mode selection of
setting button is not displayed automatic. level 1 [U12] of memory switch data.
even when pressing the step
details button.
− 101 −
14. Data changed in the sewing 14-1) Sewing is completed at the step other than the Complete the sewing at the last step.
screen is not stored in memory. last step.
14-2) Not to store is selected in the data storage function Set to storing the data storage function selection at the time of sewing of
selection at the time of sewing. level 1 [U16] of memory switch data.
15. Buzzer does not sound when 15-1) Output of sound when changing over the step is Set to sound the output of sound when changing over the step selection of
changing over the step. selected to not to sound. level 1 [U17] of memory switch data.
16. Auxiliary pedal cannot be used. 16-1) Selection of auxiliary pedal use is set to not to use. Set to use the auxiliary pedal use selection of level 1 [U18] of memory
switch data.
17. Change does not occur even 17-1) Selection of shirring release switch use is set to Set to use the shirring release switch use selection of level 1 [U19] of memory
when pressing the shirring not to use. switch data.
release switch.
18. Knee switch fails to work at 18-1) Selection of knee switch use is set to not to use. Set to use the knee switch use selection of level 1 [U20] of memory switch data.
the time of full auto sewing.
19. Shirring amount changes at 19-1) Shirring amount interlocking function is set to use Set to not to use the shirring amount interlocking function selection at the
the time of change of pitch. at the time of change of pitch.] time of change of pitch of level 1 [U21] of memory switch data.
20. Screen changes over even 20-1) Selection of screen changeover function at the Set to not to use the screen changeover function selection at the time of
when performing thread time of thread trimming on the way is set to use. thread trimming on the way of level 1 [U22] of memory switch data.
trimming on the way of step.
4) Starting of the sewing machine
1. E731 (failure of main shaft 1-1) Motor hole sensor error (UVW) is detected. 1-A) Main shaft motor is broken down. Replace the main shaft motor.
motor hole sensor and the
position sensor) is displayed.
2. E733 (main shaft motor 2-1) Main shaft motor rotates in the reverse direction. 1-A) Main shaft motor is broken down. Replace the main shaft motor.
reverse rotation) is displayed.
3. E801 (power phase-lack) is 3-1) Power phase-lack signal (PHE) is detected. 1-A) POWER p.c.b. is broken down. Replace POWER p.c.b.
displayed.
1-B) MAIN p.c.b. is broken down. Replace MAIN p.c.b.
4. E802 (power instantaneous 4-1) Power instantaneous cut signal (PWF) is detected. 1-A) POWER p.c.b. is broken down. Replace POWER p.c.b.
cut detection) is displayed.
1-B) MAIN p.c.b. is broken down. Replace MAIN p.c.b.
− 102 −
1-C) PANEL is broken down. Replace PANEL.
5) Others
1. E942 (failure of main shaft 1-1) Data of main shaft EEP-ROM is broken. 1-A) MAIN p.c.b. is broken. Replace MAIN p.c.b.
EEP-ROM) is displayed.
1-B) Main shaft EEP-ROM is broken. Replace MAIN p.c.b.
2. E943 (failure of main EEP- 2-1) Data of main EEP-ROM is broken. 1-A) MAIN p.c.b. is broken. Replace MAIN p.c.b.
ROM) is displayed.
1-B) MAIN EEP-ROM is broken. Replace MAIN p.c.b.
3. E946 (failure of head EEP- 3-1) Data of head EEP-ROM is broken. 1-A) P.c.b. mounted on the machine head is broken. Replace p.c.b. mounted on the machine head.
ROM) is displayed.
1-B) Head EEP-ROM is broken. Replace p.c.b. mounted on the machine head.
4. Buzzer sounds two times at a 4-1) CPU mode check error 1-A) MAIN p.c.b. is broken down. Replace MAIN p.c.b.
regular cycle.
5. Buzzer sounds three times at 5-1) Internal RAM check error 1-A) MAIN p.c.b. is broken down. Replace MAIN p.c.b.
a regular cycle.
6. Buzzer sounds four times at a 6-1) External RAM check error 1-A) MAIN p.c.b. is broken down. Replace MAIN p.c.b.
regular cycle.
− 103 −
7. Buzzer sounds five times at a 7-1) NORTi setting error 1-A) MAIN p.c.b. is broken down. Replace MAIN p.c.b.
regular cycle.
8. Buzzer sounds 7 times at a 8-1) EEP-ROM writing error 1-A) MAIN EEP-ROM is broken. Replace MAIN p.c.b.
regular cycle.
9. Buzzer sounds 8 times at a 9-1) Communication error with PANEL 1-A) Contact of connector (CN34) of MAIN p.c.b. is improper. Check the connection of CN34.
regular cycle.
1-B) Program of MAIN is broken. Perform rewriting of the program of MAIN.
1-C) Data on the side of MAIN of MAIN p.c.b. is broken. Perform initialization of the data on the side of MAIN of MAIN p.c.b.
1-D) MAIN p.c.b. is broken. Replace MAIN p.c.b.
10. Buzzer sounds 9 times at a 10-1) Communication error with the main shaft 1-A) MAIN p.c.b. is broken. Replace MAIN p.c.b.
regular cycle.
1-B) Writing of the program of main shaft is not performed. Perform writing of the program of main shaft.
1-C) Initialization of EEP-ROM of main shaft is not performed. Perform initialization of EEP-ROM of main shaft.
11. CIRCUIT DIAGRAM
(1) Block diagram (1/2)
No. PART No. DESCRIPTION ASSEMBLED PLACE REMARKS
1 40008173 CONTROL BOX A ASM. CONTROL BOX A (3-PHASE : JAPAN, JUS)
40017733 CONTROL BOX B ASM. B (SINGLE PHASE : GENERAL EXPORT)
40017734 CONTROL BOX C ASM. C (SINGLE PHASE : CE TYPE)
2 40008187 MAIN P.C.B. A ASM. CONTROL BOX EXCLUSIVE
3 40017736 PWR P.C.B. B ASM. CONTROL BOX EXCLUSIVE
4 40000056 FLT-T P.C.B. A ASM. CONTROL BOX A (FOR 3-PHASE),MC-601/OTHERS
40000046 FLT-S P.C.B. A ASM. CONTROL BOX B • C (FOR SINGLE PHASE),MC-601/OTHERS
5 40017743 DC POWER CORD ASM. CONTROL BOX EXCLUSIVE
6 40005987 PDD RELAY CORD A ASM. CONTROL BOX SC-915
7 40005974 FLT-FG CORD A ASM. CONTROL BOX SC-915
8 40005975 AC INPUT 3 ø CORD A ASM. CONTROL BOX SC-915
40005976 AC INPUT 1 ø CORD A ASM.
40005977 AC INPUT 1 ø CORD CE ASM.
9 40005979 REGENERATIVE RESISTANCE A ASM. CONTROL BOX SC-915
!0 40016435 BOX FAN MOTOR ASM. CONTROL BOX SC-916
!1 40016435 FAN MOTOR IN BOX ASM. CONTROL BOX SC-916
!2 40005980 PEDAL SENSOR ASM. CONTROL BOX SC-915
!3 40016436 CE REACTANCE ASM. CONTROL BOX C (CE TYPE ONLY),SC-916
!4 HA004250000 POWER SWITCH TABLE/STAND A • B (EXCLUDING CE TYPE)
!5 M90175800A0 POWER CORD ASM. TABLE/STAND A (FOR 3-PHASE),MC-580
M90245800A0 B • C (FOR SINGLE PHASE),MC-580
!6 40016702 AUXILIARY PEDAL SENSOR ASM. TABLE/STAND EXCLUSIVE
!7 40017738 KNEE SWITCH CORD ASM. TABLE/STAND EXCLUSIVE
!8 40010034 IP-200C TOTAL ASM. HEAD IP-200
!9 40017737 FEED MOTOR CORD ASM. HEAD EXCLUSIVE
@0 40015794 AUXILIARY FEED MOTOR CORD ASM. HEAD EXCLUSIVE
@1 40015795 TOP FEED FAN CORD ASM. HEAD EXCLUSIVE
@2 40015796 BOTTOM FEED FAN CORD ASM. HEAD EXCLUSIVE
@3 40017740 HEAD RELAY CORD 1 ASM. HEAD EXCLUSIVE
@4 40017741 HEAD RELAY CORD 2 ASM. HEAD EXCLUSIVE
@5 40017739 PRESSER LIFTER CORD ASM. HEAD ONE BODY WITH AK SOLENOID
@6 40017742 HEAD EARTH CORD ASM. HEAD EXCLUSIVE
@7 KM000000350 TOP FEED MOTOR HEAD LZ-2290
@8 KM000000350 BOTTOM FEED MOTOR HEAD LZ-2290
@9 HM001940000 AUXILIARY FEED MOTOR HEAD EXCLUSIVE
#0 KM000000470 MAIN MOTOR HEAD EXCLUSIVE
#1 40005402 TOP FEED FAN ASM. HEAD EXCLUSIVE
#2 40005402 BOTTOM FEED FAN ASM. HEAD MC-601(LBH-1790)
#3 40016908 AT SOLENOID HEAD EXCLUSIVE
#4 40014098 OPTIONAL SWITCH ASM. HEAD EXCLUSIVE
#5 40017612 THREAD TRIMMER SOLENOID ASM. HEAD 11043106(DDL-5550)
#6 23638554 SAFETY SWITCH CORD ASM. HEAD DDL-9000
#7 40017823 AK SOLENOID HEAD EXCLUSIVE
#8 40017744 DATA P.C.B. ASM. HEAD EXCLUSIVE
− 104 −
(1) Block diagram (2/2)
1 CONTROL BOX ASM. (A TYPE)
CONTROL BOX ASM. (B TYPE)
CONTROL BOX ASM. (C TYPE)
@3 HEAD RELAY
!8 IP-200 C ASM. CN104
CORD 1 ASM. #3 AT SOLENOID
THREAD
2P
OPERATION PANEL
26P
26 TENSION
CN34
CN105
#4 OPTIONAL
CN53 SWITCH ASM.
6P
MONITOR
6P
CN101
@7 TOP FEED MOTOR !9 FEED MOTOR CORD ASM.
TOP SHIRRING
8P
5 5 RELEASE
FEED PM
10P
@8 BOTTOM FEED MOTOR CN102 CN56 !7 KNEE SWITCH CORD ASM.
BOTTOM KNEE
4P
5 CN54
8P
5 SWITCH
FEED PM
@4 HEAD RELAY #5 THREAD TRIMMER
CN107
CORD 2 ASM. SOLENOID ASM. THREAD
CN103
AUXILIARY @9 AUXILIARY FEED MOTOR @0 AUXILIARY FEED MOTOR CORD ASM. TRIMMER
SOLENOID
6P
6P
FEED PM CN57
4P
6P
CN52 #6 SAFETY SWITCH
CORD ASM. SAFETY
SWITCH
#0 MAIN MOTOR
AC SERVO 2 MAIN P.C.B. A ASM. @5 PRESSER LIFTER
9 CN38
9P
MOTOR CN108
CORD ASM. #7 AK SOLENOID PRESSER
LIFTER
2P
CN51
2P
SOLENOID
30P
30P
4 CN21 CN10 30
4P
CN44
!6 UXILIARY PEDAL SENSOR ASM. CN109
3 PWR P.C.B. B ASM. AUXILIARY
4P
CN62
5 DC POWER PEDAL
9 REGENERATIVE RESISTANCE A ASM. CORD ASM.
12P
!2 PEDAL SENSOR ASM.
8P
REGENERATIVE CN13 8 12 CN59
2
2P
CN11 PEDAL
RESISTANCE CN36
4P
SENSOR
4P
!0 BOX FAN MOTOR ASM. CN22 4
#8 DATA P.C.B. ASM.
FAN MOTOR 2 CN23
2P
10P
HEAD CN55 EEP-ROM
CN50
4P
IDENTIFICATION
!1 FAN MOTOR IN BOX ASM.
FAN MOTOR 2 CN24 LEVEL
2P
PLD METER
14P
@1 TOP FEED FAN CN70
8P
#1 TOP FEED FAN ASM. CN111 WRITING CN61
CORD ASM.
FAN MOTOR
2P
2
2P
CN25
H8 MAIN FOR
10P
#2 BOTTOM FEED FAN ASM.
9P
CN71 CN63
CN110 WRITING EXTENSION
@2 BOTTOM FEED
FAN MOTOR FAN CORD ASM.
2P
CN26
2P
2
CN12
T14 T15 5P T16 H8 MACHINE
9P
CN72
3 WRITING
4 @6 HEAD EARTH
!3 CE REACTANCE ASM.
6 PDD RELAY CORD ASM.
3P (C TYPE)
CORD A ASM.
!5 POWER CORD ASM.
(A TYPE)
POWER CORD ASM. 8 AC INPUT 3ø CORD
(B • C TYPES) A ASM. 5P 3P
CN3 CN2
6P
CN1
4 FLT-T P.C.B. A
!4 POWER SWITCH 7 FLT-FG CORD ASM (A TYPE)
(A • B TYPES) A ASM. FLT-S P.C.B. A
FG1
ASM. (B • C TYPES)
− 105 − − 105 −
(2) Head and table/stand circuit diagram
MAIN P.C.B.
PEDAL SENSOR CN36
CN53 CN104
WHITE 1 1 AT SOLENOID
3 +5V
WHITE SHIRRING RELEASE 1 1 1
2 2 2 PDL 1
MON 2 2 13.8Ω
1 WHITE 2 2
3 3 SGND
SOL_ACT– 3 3
4 4 SHIELD
GND 4 4
GND 5 5
CN105 MONITOR
SOL_ACT+ 6 6
AUXILIARY PEDAL SENSOR CN62 1 1
RED 2 2
3 1 1 +5V
WHITE 3 3
2 2 2 PDL
BLACK 4
1 3 3 SGND CN54 4
SHIRRING RELEASE
4 4 SHIELD +5V 1 1
KNEE SWITCH
STEP CHANGEOVER 2 2
GND 3 3
GND 4 4
CN52 CN107 THREAD TRIMMER SOLENOID

TRMD 1 1 1 1
SFSW_N 2 2 2 7.5Ω
2
TRMCOM 3 3 3 3
GND 4 4 4 4
SAFETY SWITCH
CN51
CN108 PRESSER LIFTER SOLENOID
FL 1 1 1 1
DATA P.C.B. CN55 FLCOM 2 2 4Ω
2 2
1 1 1 +5V
2 2 2 +5V
3 3 3 DI
4 4 4 CS
5 5 5 SCK
6 6 6 DO
7 7 7 GND
8 8 8 GND
9 9 9 GND
10 10 10 GND
− 106 − − 106 −
(3) Main and panel circuit diagram
MAIN P.C.B. PANEL P.C.B.

CN34 CN100
TXD 1 1 1 1 TXD
TXD (N) 2 2 2 2 TXD [N]
RXD 3 3 3 3 RXD
RXD (N) 4 4 4 4 RXD [N]
RTS 5 5 5 5 RTS
RTS (N) 6 6 6 6 RTS[N]
CTS 7 7 7 7 CTS
CTS (N) 8 8 8 8 CTS [N]
CLK 9 9 9 9 CLK
CLK (N) 10 10 10 10 CLK [N]
S_RES (N) 11 11 11 11 SYS_RESET [N]
PWR_F 12 12 12 12 PWRF [N]
SL_VR 13 13 13 13 NC
NC 14 14 14 14 NC
NC 15 15 15 15 NC
NC 16 16 16 16 NC
+24V 17 17 17 17 NC
+24V 18 18 18 18 NC
+5V 19 19 19 19 +5V
+5V 20 20 20 20 +5V
+5V 21 21 21 21 +5V
+5V 22 22 22 22 +5V
GND 23 23 23 23 GND
GND 24 24 24 24 GND
GND 25 25 25 25 GND
GND 26 26 26 26 GND
− 107 − − 107 −
(4) Power source A circuit diagram
POWER SWITCH
FLT - T P.C.B. PWR P.C.B. MAIN P.C.B.
CONNECTION TO 200V CN13 CN59
CN1 1 1 BLUE OCRS_N
+33V 1 1
GREEN GREEN PURPLE
1 1 FG +33VRTN 2 2 2 2 +24V
BLACK BLACK
power 2 2 NC +24V 3 3 ORANGE
3 3 +33V
WHITE WHITE ORANGE
3 3 NC HEATP 4 4 4 4 +33V
source RED RED
4 4 5 RED +48V
AC200-240V +33V 5 5 5
5 5 6 RED +48V
AC200-240V +33VRTN 6 6 6
6 6 7 YELLOW HEATP
AC200-240V +24VRTN 7 7 7
8 8 BLACK +24VRTN
OCRS_N 8 8
CN2 BLACK +33VRTN
T16 9 9
WHITE BLACK
280V 1 1 1 280V CN22 10 10 +33VRTN
RED BLACK
CENTER 2 2 2 CENTER +48V 1 1 11 11 +48VRTN
BLACK BLACK
AGND 3 3 3 AGND +48V 2 2 12 12 +48VRTN
+48VRTN 3 3
+48VRTN 4 4
CN3 CN12
BLUE
FCANCEL 1 1 1 1 +12VRTN
BROWN CN10 CN44
+12V 2 2 2 2 +12V
N.C 3 3 3 3 N.C +5V 1 1 1 1 +5V
+5V 2 2 2 2 +5V
WHITE
RL1 4 4 4 4 RL1 (N) +5V 3 3 3 3 +5V
OCL1 (N) 4 4 4 4 OCL1 (N)
YELLOW
PDD 5 5 5 5 PD0 (N) OVL (N) 5 5 5 5 OVL (N)
LVL (N) 6 6 6 6 LVL (N)
GTRE (N) 7 7 7 7 GTRE (N)
PWF (N) 8 8 8 8 PWF (N)
PHE (N) 9 9 9 9 PHE (N)
MCLA (N) 10 10 10 10 MCLA (N)
MCLB (N) 11 11 11 11 MCLB (N)
RESPW (N) 12 12 12 12 RESPW (N)
UP (N) 13 13 13 13 UP (N)
VP (N) 14 14 14 14 VP (N)
WP (N) 15 15 15 15 WP (N)
UN (N) 16 16 16 16 UN (N)
VN (N) 17 17 17 17 VN (N)
WN (N) 18 18 18 18 WN (N)
SGND 19 19 19 19 SGND
SGND 20 20 20 20 SGND
S.STATE (N) 21 21 21 21 S.STATE (N)
HU 22 22 22 22 HU
HV 23 23 23 23 HV
HW 24 24 24 24 HW
MA 25 25 25 25 MA
MB 26 26 26 26 MB
SDET (N) 27 27 27 27 SDET (N)
+12V 28 28 28 28 +12V
SGND 29 29 29 29 SGND
SFSW (N) 30 30 30 30 SFSW (N)
− 108 − − 108 −
(5) Power source B circuit diagram
PWR P.C.B. MAIN P.C.B.

POWER SWITCH
FLT - S P.C.B. CN13 CN59
CN1 1 1 BLUE
GREEN/ GREEN/ +33V 1 1 OCRS_N
YELLOW YELLOW 1 1 PURPLE
power FG +33VRTN 2 2 2 2 +24V
BROWN BROWN
2 2 3 3 ORANGE
LIGHT BLUE LIGHT BLUE NC +24V 3 3 +33V
source 3 3 4 4 ORANGE
NC HEATP 4 4 +33V
4 4 5 5 RED
AC200-240V +33V 5 5 +48V
5 5 6 6 RED
AC200-240V +33VRTN 6 6 +48V
6 6 7 7 YELLOW
NC +24VRTN 7 7 HEATP
8 8 BLACK
OCRS_N 8 8 +24VRTN
CN2 T16 BLACK
9 9 +33VRTN
WHITE BLACK
280V 1 1 1 280V CN22 10 10 +33VRTN
RED BLACK
CENTER 2 2 2 CENTER +48V 1 1 11 11 +48VRTN
BLACK BLACK
AGND 3 3 3 AGND +48V 2 2 12 12 +48VRTN
+48VRTN 3 3
+48VRTN 4 4
CN3 CN12
1 BLUE
FCANCEL 1 1 1 +12VRTN
2 BROWN CN10 CN44
+12V 2 2 2 +12V
N.C 3 3 3 3 N.C +5V 1 1 1 1 +5V
WHITE +5V 2 2 2 2 +5V
RL1 4 4 4 4 RL1 (N) +5V 3 3 3 3 +5V
YELLOW OCL1 (N) 4 4 4 4 OCL1 (N)
PDD 5 5 5 5 PD0 (N) OVL (N) 5 5 5 5 OVL (N)
LVL (N) 6 6 6 6 LVL (N)
PWF (N) 8 8 8 8 PWF (N)
PHE (N) 9 9 9 9 PHE (N)
MCLA (N) 10 10 10 10 MCLA (N)
MCLB (N) 11 11 11 11 MCLB (N)
RESPW (N) 12 12 12 12 RESPW (N)
UP (N) 13 13 13 13 UP (N)
VP (N) 14 14 14 14 VP (N)
WP (N) 15 15 15 15 WP (N)
UN (N) 16 16 16 16 UN (N)
VN (N) 17 17 17 17 VN (N)
WN (N) 18 18 18 18 WN (N)
SGND 19 19 19 19 SGND
SGND 20 20 20 20 SGND
HU 22 22 22 22 HU
HV 23 23 23 23 HV
HW 24 24 24 24 HW
MA 25 25 25 25 MA
MB 26 26 26 26 MB
SDET (N) 27 27 27 27 SDET (N)
+12V 28 28 28 28 +12V
SGND 29 29 29 29 SGND
SFSW (N) 30 30 30 30 SFSW (N)
− 109 − − 109 −
(6) Power source C circuit diagram

POWER SWITCH
FLT - S P.C.B.
CN13 CN59
GREEN/ GREEN/ CN1 1 BLUE
+33V 1 1 1 OCRS_N
YELLOW YELLOW PURPLE
1 1 FG +33VRTN 2 2 2 2 +24V
power BROWN BROWN
2 2 ORANGE
LIGHT BLUE LIGHT BLUE NC +24V 3 3 3 3 +33V
source 3 3 NC HEATP 4 4 ORANGE
4 4 +33V
4 4 5 RED
AC200-240V L50 +33V 5 5 5 +48V
5 5 6 RED
AC200-240V +33VRTN 6 6 6 +48V
6 6 7 YELLOW
NC +24VRTN 7 7 7 HEATP
8 BLACK
OCRS_N 8 8 8 +24VRTN
RED RED CN102 BLACK
CN2 T16 9 9 +33VRTN
WHITE BLACK
280V 1 1 1 1 1 280V CN22 10 10 +33VRTN
RED RED BLACK
CENTER 2 2 2 2 2 CENTER +48V 1 1 11 11 +48VRTN
BLACK BLACK BLACK
AGND 3 3 3 3 3 AGND +48V 2 2 12 12 +48VRTN
+48VRTN 3 3
+48VRTN 4 4
CN3 CN12
BLUE
FCANCEL 1 1 1 1 +12VRTN
BROWN CN10 CN44
+12V 2 2 2 2 +12V
N.C 3 3 3 3 N.C +5V 1 1 1 1 +5V
WHITE +5V 2 2 2 2 +5V
RL1 4 4 4 4 RL1 (N) +5V 3 3 3 3 +5V
YELLOW OCL1 (N) 4 4 4 4 OCL1 (N)
PDD 5 5 5 5 PD0 (N) OVL (N) 5 5 5 5 OVL (N)
LVL (N) 6 6 6 6 LVL (N)
PWF (N) 8 8 8 8 PWF (N)
PHE (N) 9 9 9 9 PHE (N)
MCLA (N) 10 10 10 10 MCLA (N)
MCLB (N) 11 11 11 11 MCLB (N)
RESPW (N) 12 12 12 12 RESPW (N)
UP (N) 13 13 13 13 UP (N)
VP (N) 14 14 14 14 VP (N)
WP (N) 15 15 15 15 WP (N)
UN (N) 16 16 16 16 UN (N)
VN (N) 17 17 17 17 VN (N)
WN (N) 18 18 18 18 WN (N)
SGND 19 19 19 19 SGND
SGND 20 20 20 20 SGND
HU 22 22 22 22 HU
HV 23 23 23 23 HV
HW 24 24 24 24 HW
MA 25 25 25 25 MA
MB 26 26 26 26 MB
SDET (N) 27 27 27 27 SDET (N)
+12V 28 28 28 28 +12V
SGND 29 29 29 29 SGND
SFSW (N) 30 30 30 30 SFSW (N)
− 110 − − 110 −
(7) Motor circuit diagram

BOX FAN MOTOR CN56
CN23
RED
M1M_A 1 1
1 1 +24V ORANGE TOP FEED
M1M_B 2 2
2 2 +24VRTN YELLOW E MOTOR
M1M_C 3 3
3 3 +24VRTN BLUE R = 0.93 Ω / 1 ø
M1M_D 4 4 D
BLACK
M1M_E 5 5 A
FAN MOTOR IN BOX

CN24 C
B
1 1 +24V
2 2 +24VRTN RED
M2M_A 6 6
ORANGE BOTTOM FEED
3 3 +24VRTN M2M_B 7 7
YELLOW E MOTOR
M2M_C 8 8
BLUE R = 0.93 Ω / 1 ø
M2M_D 9 9 D
TOP FEED FAN BLACK
M2M_E 10 10 A
CN111 CN25
C
1 1 1 1 +24V B
2 2 2 2 +24VRTN
CN57
BOTTOM FEED FAN RED
CN110 M3M_A 1 1
CN26 ORANGE AUXILIARY FEED
M3M_B 2 2
+24V YELLOW E MOTOR
1 1 1 1 M3M_C 3 3
+24VRTN BLUE R = 0.75 Ω / 1 ø
2 2 2 2 M3M_D 4 4 D
M3M_E BLACK A
5 5
NC 6 6
C
B
− 111 − − 111 −
(8) Servo motor circuit diagram
SDC P.C.B.
AC SERVO MOTOR
CN21
SHIELD WHITE (DRAIN WIRE)
SGND BLACK
HU ORANGE
HV BLUE
HW PURPLE
NA LIGHT BLUE
ENCODER
MB PINK
+5V RED
SDET YELLOW
R = 1.29 Ω
CN38
U BLACK
U
V RED
W WHITE
FG GREEN/YELLOW V W FG
− 112 − − 112 −
12. VARIOUS PRINTED WIRING BOARDS
(1) FLT-T p.c.b. (2) FLT-S p.c.b.
3-phase 200V~240V Single-phase 200V~240V
Single-phase 200V~240V
Pulse generation is carried out for the purposes of power supply rectification, Pulse generation is carried out for the purposes of power supply rectification,
noise reduction, and the detection of a momentary interruption noise reduction, and the detection of a momentary interruption
CN1 : Power input , Power switch CN1 : Power input , Power switch
In the signal-phase mode, the Since single-phase specifications are adopted, the
power supply is connected to power supply is connected to Pins 4-5.
Pins 4-5. In the 3-phase mode,
the power supply is connected
to Pins 4-5-6.
Voltage changeover
For 200V to 240V

Do not connect to 100V side.
CN2 : Power output / PWR board

CN3 : Momentary interruption
CN2 : Power output / PWR board
detection signal / PWR board
CN3 : Momentary interruption
detection signal / PWR board
− 113 − − 113 −
(3) PWR p.c.b. (4) MAIN p.c.b.
This p.c.b. performs generation of power, check of power and drive of main motor. This p.c.b. performs the whole control such as control of feed stepping motor, control of main motor, control
of active tension, memory switches, etc.
CN44
CN34 Power +5V,
Signal for main shaft LD2
Panel cable For U18 motion/error check
control
To IP-200C From PWR p.c.b. BZ2
CN65For testing For U18 motion/error check
CN26 CN25 CN55 DATA p.c.b. CN36
Bottom feed fan motor Top feed fan motor Pedal sensor
CN24 CN54 Knee switch
Fan motor located inside of box
CN53 CN62
CN23 Auxiliary pedal sensor
Box fan motor Head relay cord
AT solenoid Shirring
release switch Monitor SW4 For CPU writing
F2 10A F5 4A
Time-lag fuse for +33V Fuse directly attached to p.c.b. CN52 Head relay cord CN72
For primary side of +33V power Thread trimmer For U18 writing
CN13 solenoid Safety switch
DC power cord +33V, +24V
CN51
To MAIN p.c.b. F4 4A Presser lifter solenoid CN63 For extension
CN22 Fuse directly attached to p.c.b.
DC power cord +48V For primary side of +48V power CN50
To MAIN p.c.b. Head discrimination W2, W3
F1 10A For CPU initialization
Time-lag fuse For +48V
CN12
CN38 instantaneous cut detection
Main motor encoder cable signal relay power +12V CN61 Level meter
To FLT p.c.b. LD1
For U11 motion/error check
CN21 CN70 For U20 writing
CN71
Main motor power cable For U11 writing
LD1 LED for power check BZ1
For U11 motion/error check CN32
For standing work machine
CN2 CN59
+280V power supply DC power cord
To FLT p.c.b. +48V, +33V, +24V
From PWR p.c.b.
CN44 CN56
F3 2A Top/bottom
Power +5V, Signal for Time-lag fuse
main shaft control feed motor
For +280V regenerative resistance
To MAIN p.c.b. CN57
Auxiliary feed motor
CN11
Regenerative resistance
− 114 − − 114 −
(5) PANEL p.c.b. (6) DATA p.c.b.
This p.c.b. performs input of operation, creation of sewing data, change of various setting of memory switches, This p.c.b. records the data which are specific to the machine head such as compensation value of active
storing of various data, writing, communication with external equipment, etc. tension and the like.
CN104
For U13 writing
CN111 CN105
For software debug For LCD display/control
Not mounted
CN106
CN103 Reserve for LCD display/control
For smart media
SW3
For flash memory
SW2
Smart media cover detection
SW1 Unused CN107

For EXTENSION p.c.b.
CN102
RS-232C for serial
communication
VR1
For LCD contrast
adjustment
CN101 CN55
BZ1 DATA p.c.b. cord
For external input For motion/error check
To MAIN p.c.b.
CN108
Power for back light
CN34
PANEL cable
To MAIN p.c.b.
CN109
Touch panel input
− 115 − − 115 −
13. DRAWING OF THE TABLE Part No. : 40013092
(1) Slant table
1200
Y-Y Z-Z
321
17 1 8
18
R2 R2
Z Y
R
8.5
30 D 0
R3
ø8.5
50
50
105 W W 375 ± 0.5 W W
ø26
E 50
290 223 7˚
ø20
ø9
W W
ø30
A 27.5 ± 0.5
151 ± 0.5
75.5 ± 0.5
346.5
F
8.5
12 12
ø8.5
12.5
( 7˚) 56.5
R8 C
R8
(27) V
ø26
V
10
X
G
R
R1 R8
12.5
8
0
R
28 ± 0.5 22.5 22.5
18 28 ± 0.5
40
360
18 375 ± 0.5 75
535
C2
C2
R8
R8
258.5
30
15 ± 0.5 A
175
15 ± 0.5
(219.3)
406
21.5
238
R242.5
43
(183.6)
(181)
225
183.6
181
23.5
13.5 R1
141
30
10
3.5 22.4 ± 0.5 13.5 0 14 9
84
R
23.5
86.5
R242.5
B
21.5
52 3.5
ø10
0 R1 22.4 ± 0.5
(44.3)
ø7
R1 22.5 22.5 0
12
R8
R2
W W
R8
23.5
13.5
13.5
ø10
23.5
21
ø7
R8
R
810 V V 141
R8
21 50
88
12.5
90
7.5
R8
12 12
96
R2
R8
27.5
72
18 55
R2
7.5
24
18
R R2
30
W W W
R2
W Z Y X 30
R
160 710 ± 0.5 90 52.5

H 195 18
X-X A
(55.9)
49.5 W - W (6 places)
R1
10
(55.9) 0
R
V - V (2 places) A 4 x ø3.4 on the bottom surface, depth 20
.5
49.5
R 22
10
R1
R
0 (Drill a hole at the time of set-up.)

30
ø7 ø11
B JUKI logotype
1
R2
10
30
39
17
R2
2.5 C Jointless at the joining of slant section
39 30
D ø24 drilled hole
22
R2
1
20 ø19
ø3.5 ø3.5 68.5 ± 0.5 E ø18 drilled hole
279 ± 1 F 2 x ø3.5 depth 10
30
(172.5) G 3 x ø13 drilled hole
H 2 x ø3.5 depth 10
21
− 116 − − 116 −
(2) Work top table Part No. : 40013086
700
810
A
880
293 305
34 ± 0.5 34 ± 0.5
11
24
8
R5
0
R5
0
Z Z Z Z Z Z
100 250 ± 0.5 250 ± 0.5
Z Z
34 ± 0.5
14.5
275 ± 0.5
153
20
305
460
R1
5
Z Z
755
34 ± 0.5
315
15
R
B 5
R1
275 ± 0.5
363 610 240
5
R1
34 ± 0.5 34 ± 0.5
180
0
R3
R5
0
285
Z Z
R3
R3
178
0
71 50 70
100
R5
0
R5
0
24
545
1140
595
895
960
Z - Z (1:1) (6 places)
ø4
1
A 4 x 6.6 drill
B 8 x 6.6 drill, depth 17, spot facing depth 2
ø8
C JUKI logotype
90˚
− 117 − − 117 −
(3) Edge Stopper A Part No. : 40013087
630
40 275 ± 0.5 275 ± 0.5

15
3 x ø 2.5 depth 14
7.5
A
26
− 118 − − 118 −
(4) Edge Stopper B Part No. : 40013088
580
40 250 ± 0.5 250 ± 0.5

15
3 x ø 2.5 depth 14
7.5
A
26
− 119 − − 119 −
R
INTERNATIONAL SALES H.Q.

8-2-1, KOKURYO-CHO,
CHOFU-SHI, TOKYO 182-8655, JAPAN
PHONE : (81)3-3430-4001 to 4005
FAX : (81)3-3430-4909 • 4914 • 4984 Please do not hesitate to contact our distributors or agents in your area for further information when necessary.
TELEX : J22967 ＊ The description covered in this engineer's manual is subject to change for improvement of the
commodity without notice.
Copyright C 2004 JUKI CORPORATION.
All rights reserved throughout the world. 04 · 02 Printed in Japan (E)

Engineer'S Manual: Computer-Controlled Dry-Head, Lockstitch, Sleeve Setting Machine With Multi-Programming Device

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Computer-controlled Dry-head, Lockstitch,

Limitation by stitch length

(1) Sewing machine main unit

1 Sewing machine head

(Front face) (Right side face)

1 Touch panel, LCD display section

(2) Adjusting the needle and the hook

Adjustment Procedures Results of improper Adjustment

Screw No. 1 7 Flat section

(Caution) When tightening setscrews 3 and 7 in the

Main shaft belt

(5) Adjusting the hook shaft belt tension

1. Loosen setscrew 2 in idler installing plate 1. ™ When belt tension is excessively

Adjustment Procedures Results of improper Adjustment

1. Loosen lock nut 2 in belt idler 1. ™ When belt tension is excessively

1. Main feed belt

Press the center

Press the center

1. Main feed belt ™ If the tension is not proper, shirring

(8) Adjusting the height of the presser foot bar

1. Adjust the clearance between the bottom face of

Adjustment Procedures Results of improper Adjustment

1. Height of the presser foot bar ™ When the clearance is widened,

1. State of feed foot and presser foot at the time of delivery

(11) Assembling the guide plate

Adjustment Procedures Results of improper Adjustment

(13) Adjusting the speed of the auto-lifter

Adjustment Procedures Results of improper Adjustment

1. Loosen lock nut 1. ™ When the opening amount of the

(15) Adjusting the thread trimmer cam

Adjustment Procedures Results of improper Adjustment

1. Remove the bottom cover. ™ Length of needle thread remaining

(17) Adjusting the initial position of the thread trimmer solenoid

1. Adjusting the engraved marker dot ™ Thread handling trouble

Adjustment Procedures Results of improper Adjustment

(19) The fixing position of the auxiliary feed motor pulley

Adjustment Procedures Results of improper Adjustment

1. Loosen setscrews 1. ™ When the dimension is large, timing

(21) The fixing position of the thrust collar of AT solenoid

1. Loosen setscrews 1. ™ When the dimension is small,

Adjustment Procedures Results of improper Adjustment

1. Loosen setscrews 1. ™ When the dimension is large,

(23) Adjusting the height of the feed foot

1. Loosen nut 1. ™ When the dimension is large,

Adjustment Procedures Results of improper Adjustment

(25) Adjusting the height of the presser foot

Adjustment Procedures Results of improper Adjustment

(27) Adjusting the assembly of the counter knife guard plate

1. Turn top feed arm cover 1. ™ When timing is improper, troubles

(Caution) Tighten the screws so that there is no clearance

Adjustment Procedures Results of improper Adjustment

1. Loosen setscrew 1, and remove needle 2.

2. Remove setscrew 3, and remove presser foot 4.

3. Remove 10 setscrews 5, and remove cover A 6 and cover B 7.

4. Loosen setscrew 8, move tension adjustment plate L 9in the

5. Loosen setscrew !0, and move tension adjustment plate S !1 in

6. Remove main feed belt !2 from the pulley.

7. Remove auxiliary feed belt !3 from the pulley.