Brother BAS-411, Service Manual

Page 1: ...SERVICE MANUAL FOR BAS 411 BAS 415 SINGLE HEAD ELECTRONIC EMBROIDERY MACHINE I From the library of Superior Sewing Machine Supply LLC ...

Page 2: ... 00 Adjusting cloth presser height 13 j Adjusting knife and fixed knife 14 Adjusting picker 15 Adjusting the thread wiper 16 1 Adjusting wire tension 17 1 X feed wire 17 2 Y feed wire 18 00 Adjusting thread breakage detect stud 19 00 Adjusting bobbin winder 20 lim BAS 411 415 test mode 21 In Adjusting synchronizer 23 1m Adjusting home position using home position plate 26 lj Positioning over limit...

Page 3: ...tors 67 1 troubleshooting flowchart 70 BAS 411 70 BAS 415 81 00 Harness connections and connectors number 92 EXPLANATIONOFOPTIONALPARTSINSTALLATION 106 ML 6511amp set 106 Light marker 107 00 Connecting optional parts with machine 112 1 1 Bobbin winder 116 TROUBLESHOOTING 118 Mechanical problem 118 Electrical problem 120 00 List of error messages 122 BAS 411 122 BAS 415 125 BAS 411 KEYBOARD UNIT CO...

Page 4: ...d take up 0 Embroidery hoop 9 Table plate 6 Operation panel Spool shaft B Keyboard assembly CD Guard bar Speed dial 4D Disk drive 1 0 Thread take up cover Power switch 48 Contrast dial of liquid crystal display From the library of Superior Sewing Machine Supply LLC ...

Page 5: ...e up Embroidery hoop Table plate 8 Operation panel Spool shaft B tD Keyboard assembly 4D Guard bar Q Speed dial 4D Disk drive 2 8 Thread take up cover Power switch C8 Contrast dial of liquid crystal display From the library of Superior Sewing Machine Supply LLC ...

Page 6: ...t 8 The upper shaft 8 then rotates the thread take up driving cam 2 The thread take up driving cam transmits the motion to the connecting rod 9 3 The up and down motion parts 9 attached to the main needle bar 0 move the needle bar 8 up and down 4 The needle bar 8 is guided by the needle bar case 3 From the library of Superior Sewing Machine Supply LLC ...

Page 7: ... gear A transmits the movement to the lower shaft gear 0 via the vertical shaft e 3 The lower shaft gear 0 transmits the rotation to the attached lower shaft Then the rotary hook 6 attached to the lower shaft rotates in the direction of the arrow NOTE In BAS 411 and 415 the rotary hook makes two revolutions for each revolution made by the pulley 4 From the library of Superior Sewing Machine Supply...

Page 8: ... After the final stitch roller shaft A 0 moves into the groove of the cam and connecting plate B moves Then the knife 0 engages with the fixed knife 0 trimming the thread 5 From the library of Superior Sewing Machine Supply LLC ...

Page 9: ...uide solenoid 0 moves the plate in the direction of the arrow and the upper thread guide hook attached to the plate brings the trimmed thread to the thread presser The thread presser secures the trimmed thread 6 From the library of Superior Sewing Machine Supply LLC ...

Page 10: ...sm After receiving the set needle bar flip up signal cam gears A 8 and B attached to the pulse motor 0 are activated The needle bar flip up is performed by the change cam 9 7 From the library of Superior Sewing Machine Supply LLC ...

Page 11: ...hread trimming The picker attached to connecting plate A moves in the direction of the bobbin case e then pulls the upper thread under the material During thread trimming the picker operates to keep the needle thread length constant 8 From the library of Superior Sewing Machine Supply LLC ...

Page 12: ...e motor 0 rotates then transmits the rotation to idle gear A 2 When idle gear A rotates the X wire CD reeled in the wire drum X e moves the carriage in the direction ofthe X axis left e right via the pulley 9 9 From the library of Superior Sewing Machine Supply LLC ...

Page 13: ...its the rotation to idle gear A 2 When idle gear A rotates the Y wires left and right reeled in the wire drums Y 8 on the right and the left move the carriage fi in the direction of theY axis backwards e forwards via the pulley8 10 From the library of Superior Sewing Machine Supply LLC ...

Page 14: ...the rotary hook shaft tighten the screw of the needle bar clamp so that the screw 0 leans to the right 25 30 2 Raise the needle bar to its highest position Lightly press the stopper to the cushion rubber 9 side Then tighten the screw 0 so that it is positioned in the front NOTE Make sure that the stopper does not strike the needle bar guide rail 11 From the library of Superior Sewing Machine Suppl...

Page 15: ...option into the lower shaft 3 Loosen the screw e of the needle bar clamp Turn the pulley until the needle tip lightly contacts the gauge at its lowest position NOTE Do not use the flat part of the gauge at this time 4 Tighten the screw 9 of the needle bar clamp firmly 12 From the library of Superior Sewing Machine Supply LLC ...

Page 16: ...porarily tighten the two stop screws At this time the needle bar height should be about 1mm Figure A 4 As for other needle bars if the gap between the needle and rotary hook point is 0 01 0 2 mm tighten the 3 screws of the rotary hook Adjusting cloth presser height Cut and insert Adjust the cloth presser 0 height with the cushion rubber The cloth presser 0 height should be raised 1 1 5 mm from the...

Page 17: ...the knife begins to move the blade in the rotary hook should be in the center of the rotary hook supporter 3 Knife position Loosen the screw and adjust the knife position so that its end projects 1 mm beyond the fixed knife s tip After thread trimming the knife should be in this position Ifthe knife does not stop at the stop position the upper shaft will be locked and it cannot make one full revol...

Page 18: ...cker so that there is no looseness and so that it functions lightly Then tighten the picker bracket with the screw 8 4 Adjust the gap between the point of the picker and the bobbin to 1 1 5 mm Leave the solenoid arm pushed to the pulley side the solenoid operation position then tighten the screw 5 Adjust the picker position so that it is bisected by the bobbin case spring see figure A 15 From the ...

Page 19: ...the direction of the arrow Loosen the two screws then adjust the upper thread guide hook so that it moves slightly 2 Adjust the upperthread guide hook so that its cut part is located at the center of the needle hole 16 From the library of Superior Sewing Machine Supply LLC ...

Page 20: ... 0 and the two covers LR LL 2 Loosen the two screws 0 of both hook LX and hook RX 0 3 There are two stoppers U S on the right and the left sides Turning them clockwise will increase the tension and turning them counterclockwise will decrease the tension 4 When the tension is proper tighten screw 0 5 After tightening screw 0 firmly retighten stoppers U S so there is no looseness 17 From the library...

Page 21: ...ove the seven screws 0 and the two covers LR LL 2 Loosen the two screws CD of both hook LY and hook RY 8 3 There are two stoppers U S on the right and the left sides Turning them clockwise will increase the tension and turning them counterclockwise will decrease the tension 4 When the tension is proper tighten screw 5 After tightening screw firmly retighten stopper U S so there is no looseness 18 ...

Page 22: ...wly returned the thread breakage detect stud 0 should return to its position smoothly Adjust the tension by moving shaft no 1 right or left _ Adjust so that the spring moves within 3 4 of the hole ofthe 2 stage thread guide NOTE When 120 thread is used the needle thread tension should be from 60 120 g 19 From the library of Superior Sewing Machine Supply LLC ...

Page 23: ...ser toward the bobbin winder shaft 9 Stop moving just before it reaches the position where thread winding ends 3 Tighten the two screws so that the plate spring fi is at the stepped section of the bobbin winder claw 2 Positioning button presser Loosen the screw 41 and adjust the bobbin presser tD so that the proper amount of thread can be wound on the bobbin 20 From the library of Superior Sewing ...

Page 24: ...it board 1 J oo P ROM version on the keyboard circuit board JIIoo test options IL J oo P ROM version on the main circuit board J oo P ROM version on the keyboard circuit board 2 Explanation of P ROM version CD P ROM J Ver M r j_S __r _ _ _ version No 1 Z Jstands for P ROM for domestic use Japanese Estands for P ROM for overseas English P ROM K Ver r __ ________ version No 1 Z Kstands for P ROM on ...

Page 25: ...e machine upper shaft 2 ____ ___r ___ r__ a__v ___ e__ l_____ The menu for adjusting the position of the overtravel sensor Pressing alphanumeric keys 1 or 2 will set the machine into one ofthe test modes After adjustment press the END key to return to the main menu BAS 411 415 22 From the library of Superior Sewing Machine Supply LLC ...

Page 26: ...position stop signal BAS 411 DSYNCH Ov TRVL ROM J Ver M S ROM K Ver BAS 415 SYNC TRVEL J Ver K Ver BAS 411 SYNCH check TDU BAS 415 _SY_N_C_H __T_ _ _D_ _ _U_ _O __ 1 Turn on the machine power 2 BAS 411 Press the alphanumeric key 0 key in the main menu BAS 415 Press the key in the main menu 3 BAS 411 Press the 1 key to select DSYNCH 4 The green LED located on the upper right of the panel will displ...

Page 27: ...elow its highest position When t he needle bar is lowered 29 mm below it shighest position 210 When the needle bar is raised 20 mm above its lowest position 5 Turn the machine pulley in its normal direction 24 To adjust the synchronizer assembly loosen the screw 0 so that the needle stop signal goes off when t he needle is 20 mm below its highest position NOTE At this t ime the curved mark on the ...

Page 28: ...n signal will move to the same angle Be sure to adjust the needle down signal when machine stop position has been adjusted When only the needle down signal is adjusted the machine stop position does not need to be adjusted NOTE 2 How to attach the sewing machine pulley Rotate the sewing machine in the normal rotation direction Align the first screw with the screw stop of the upper shaft and attach...

Page 29: ... tighten the screw so that the X limit dog is centered in its hole 5 Attach the X limit dog so that it is opposite 180 degrees from the sensor CD when the X axis home position dog interrupts sensor 4D light 6 While holding down the EMERGENCY key turn on the power 7 The machine detects the X home position and the XY axis home position plate stops 8 Turn XY home position plate assembly 26 manually a...

Page 30: ... pressing the 2 key and END key alternately adjust the sensor bracket e by moving it in the y direction forward and backward BAS 415 1 Turn on the power Press the key in the main menu 2 Press the key to select TRVEL 3 Loosen the bolt While pressing the key and END key alternatly adjust the sensor bracket e by moving it jn the y direction forward and backward NOTE Move the sensor bracket toward the...

Page 31: ... main menu 2 Press the 2 key t o select Ov TRVL 3 Press the 1 key The hoop and the holder base move 227 3 mm to the left The figure 227 3 is displayed on the panel and the cursor appears under the number CD 4 Loosen two screws of the X limit dog and adjust so that the thread sensor indicator lights with the figure on the display between 227 0 mm and 227 5 mm when E and keys are pressed 5 Pressthe ...

Page 32: ... on the panel and the cursor appears under the number 0 7 Loosen two screws of the X limit dog and adjust so that the centering indicator lights with figure on the display between 227 0 mm 227 5 mm when jog keys and are pressed Screws 8 Press the END key twice The message 11 CAUTION MOVING II is displayed and the hoop and the holder base move to the center 9 Press the END key again to return to th...

Page 33: ...s the 3 key The hoop and the holder base move 143 5 mm toward the operator The figure 143 5 is displayed on the panel and the cursor appears underthe number 4 Loosen two bolts Adjust sensor bracket A position so that the thread sensor indicator lights with the figure on the display between 143 0 mm 144 0 mm when f or J is pressed 143 5 mm desireble 5 Press the END key 30 From the library of Superi...

Page 34: ...143 5 mm away from the operator The figure 11 143 5 is displayed on the panel and the cursor appears underthe number 7 Adjust sensor bracket B position so that the centering indicator lights with the figure on the display between 143 0 mm 144 0 mm when f or L is pressed 143 5 mm most desireble 8 Press the END key three times to return to the main menu 31 From the library of Superior Sewing Machine...

Page 35: ...Press the V key again Loosen two bolts and adjust the sensor bracket A position so that the circle of the Y 0 turns black when length is between 143 0 mm and 143 7 mm 5 After adjustment press the END key 6 Press the 6 key The hoop and the holder base move 143 5 mm away from the operator and the figure 11 143 5 is displayed on the display 7 Press the 6 key again Loosen two bolts and adjust the sens...

Page 36: ...3mm I I 8 After adjustment pressing the END key twice returns the machine to its home position and pressing it three times returns the machine to the main menu Screws 1 Press the key in the main menu 2 Press the I keytoselectTRAVEL 3 Press the l key The hoop and the holder base move 227 3 mm to the left and the figure 11 227 3 11 is displayed on the display 33 From the library of Superior Sewing M...

Page 37: ... After adjustment press the END key 6 Press the I key The hoop and the holder base move 227 3 mm to the right and the figure 11 227 311 is displayed on the display 7 Press the key again Loosen two screws of the X limit dog and adjust so that the circle of the II X 011 turns black when length is between 227 0 mm and 227 5 mm 8 After adjustment pressing the END key twice returns the machine to its h...

Page 38: ...hat the swit ch indicator lights at each needle bar position 3 If the indicator of the switch does not light at most needle bar positions adjust the switch position 4 If the indicator of the switch does not light at a specific needle bar adjust its thread breakage detect stud 0 by gently bending it with a plier NOTE Do not overbend The stud 0 may break 35 From the library of Superior Sewing Machin...

Page 39: ...E DBe sure to use Brother specified sewing machine oil for lubrication Overlubrication may cause oil to drip on to the material 1 Lubricate these six places 2 Add a drop of oil at the reel ofthe rotary hook NOTE Do not lubricate aside from the rotary hook 3 Lubricate two places on each needle on the needle bar 18 places should be lubricated in all 36 From the library of Superior Sewing Machine Sup...

Page 40: ... the left side From the side of the machine head apply one or two drop s of grease to the base needle bar and the base needle bar felt When the machine is used every day lubricate daily before using 37 From the library of Superior Sewing Machine Supply LLC ...

Page 41: ...e Brother specified grease tank 30 NOTE 2 Be sure to lubricate every 6 months NOTE 3 After applying grease to the X Y guide rail move the X carriage right and left 2 3 times NOTE 4 Before applying grease remove covers to make the work easier 38 From the library of Superior Sewing Machine Supply LLC ...

Page 42: ...vers A e and B in that order 2 Remove the belt from the pulley i 3 Remove the wires from the curcuit board the synchronizer and the ground 4 Loosen the four nuts securing the sewing machine base With the sewing machine base attached to the machine head remove the machine head 39 From the library of Superior Sewing Machine Supply LLC ...

Page 43: ...have an approximately 2 mm space between nut 9 and nut 0 when adjusting 2 The distance from table C to the end ofthe cyrindrical bed and distance should be the same Use the two rear nuts to adjust 3 After adjustment tighten the four nuts and 40 From the library of Superior Sewing Machine Supply LLC ...

Page 44: ...remove the needle bar case 1 Loosen the four screws ofthe thread presser base 0 2 Remove the four screws e of the needle bar case and the case 3 Adjust the needle bar case so that it moves right and left slightly when attached with four screws 41 From the library of Superior Sewing Machine Supply LLC ...

Page 45: ... main needle bar from above 4 Remove the up and down motion parts i from the connecting rod 4D 5 When assembling reverse the above procedure NOTE1 When attaching the main needle bar secure the bearing by pressing it with theE ring which wiII be attached to the main needle bar NOTE2 When attaching the thread take up lever s 0 and the thread take up stopper 9 fix them so there is a 0 5 mm space betw...

Page 46: ...TE1 The end of the solenoid should not contact the up and down motion parts fi Adjust the distance between them to approximately 0 2 mm by moving nut Adjustment references When the solenoid rod is pushed the distance between the end of the rod and the nut is 7 2 mm When the solenoid rod is returned the distance between the end of the rod and the nut is 4 0 mm NOTE2 To avoid mispositioning of the s...

Page 47: ... the wire around pulley feed some slack into the wire Then put the ball on the wire into the hole ofwire drum X Fit the wire completely into the groove then wind the wire eight times around the wire drum 5 Feed the wire around the back of pulley tiDI then around pulley mfrom the left 6 Wind the wire onto pulley from below then around pulley from the left 7 Wind the wire over pulley I from above th...

Page 48: ...d the wire four times put it around pulley then attach it to stand RL with the bolt Ywire R 1 Pull the carriage 0 forward and secure it 2 Use the bolt to attach Y wireR ID end the end closest to the ball to stand RR 0 3 Put the wire on to pulley 4 Then put the wire ball into the hole of wire drum Y Wind the wire four times put it around pulleys and CD then attach itto hook RY with the bolt 45 From...

Page 49: ... Circuit board locations BAS 411 BAS 415 46 0 Main circuit board PMD circuit board Sewing machine motor circuit board 0 Synchronizer circuit board 0 Keyboard circuit board From the library of Superior Sewing Machine Supply LLC ...

Page 50: ...ectors treat them c refully Do not pull on the wires when detaching the connectors NOTE2 Note that the flat cable P13 is directional refer to the arrow It can not be inserted in the opposite direction NOTE3 Treat the circuit boards carefully MOS IC in the circuit boards is easily damaged by static electricity Also do not touch IC pins NOTE4 Do not bend circuit boards The circuit pattern or IC may ...

Page 51: ...own near each of the supports The support tips will snap into position securing the circuit board 1 Disconnect the three connectors 2 Push the four circuit board supports towards the inside and remove the machine motor circuit board Replace the machine motor circuit board 3 Place new machine motor circuit board on the supports Secure the circuit board by pushing down near each of the supports The ...

Page 52: ...expansion circuit board option 1 Remove four screws 0 and then remove the memory expansion circuit board from the main circuit board NOTE When turning on power of BAS 411 415 for the first time after replacing the memory expansion circuit board be sure to do it while holding down the EMERGENCY switch The inside memory will be cleared 49 From the library of Superior Sewing Machine Supply LLC ...

Page 53: ... it 2 Loosen the two screws Pull the upper part of the panel 0 toward yourself and detach it At this time do not pull strongly on the EMERGENCY stop switch cable 3 Disconnect the EMERGENCY switch 0 connector C9 from the keyboard circuit board fi 50 From the library of Superior Sewing Machine Supply LLC ...

Page 54: ...ck and pull the flat cable toward yourself 4 Disconnect the connector 0 from the keyboard circuit board 5 Disconnect the flat cables and 0 from the keyboard circuit board 6 Loosen the four screws on the right and left sides of the supporter 0 Remove the key sheet fi from the panel base 51 From the library of Superior Sewing Machine Supply LLC ...

Page 55: ...he knob 0 with the position line Tighten the screw White point Jjt SPEED Position line NOTE2 Insert the connectors of the flat cables 0 and while the black connector lock is released Insert the hatched part ofthe connector to lock it in place Pull the flat cables 0 and lightly to check if they are locked properly If flat cable is loose the cables may have been improperly inserted into the slots Re...

Page 56: ...keyboard unit 3 When assembling reverse the above procedure LCD module assembmly 1 Loosen two screws of the keyboard cable 0 and remove the cable from the keyboard unit 2 Remove two screws and the 411 panel 0 3 Remove the flat cables and S from the keyboard circuit board fj 4 Remove four screws and the support 5 Remove the LCD module assembly connector 4D from the keyboard circuit board fj 6 Remov...

Page 57: ...ove it 2 Loosen the four screws Pull the upper part ofthe panel 0 toward yourself and detach it At this time do not pull strongly on the EMERGENCY stop switch cable 3 Disconnect the EMERGENCY switch connector 9 from the keyboard circuit board 54 From the library of Superior Sewing Machine Supply LLC ...

Page 58: ...e on the left Release the lock and pull the flat cable toward yourself 4 Disconnect the connector from the keyboard circuit board 6 5 Disconnect the flat cable from the keyboard circuit board 6 6 Lift the key sheet support and remove it from the panel base m 55 From the library of Superior Sewing Machine Supply LLC ...

Page 59: ...s follows Align the white point of the knob 0 with the position line Tighten the screw NOTE2 Insert the flat cable 0 connector while the black connector lock is released Insert the hatched part of the connector to lock it in place Pull the flat cable 0 lightly to check if it is locked properly If flat cable is loose the cables may have been improperly inserted into the slots Release the lock and i...

Page 60: ...ews e on the back side of the keyboard unit Then remove it from the keyboard stand 0 At this time be careful not to drop the keyboard unit 3 When assembling reverse the above procedure LCD module assembmly 1 Remove the connector from the keyboard circuit board 0 2 Remove three screws and the LCD module assembly e 57 From the library of Superior Sewing Machine Supply LLC ...

Page 61: ... blow fuse S11705 000 for Regulator F3 FuseB 152565 000 for Solenoid F4 Slow blow fuse S11705 000 for Bobbin winder F5 Fuse B 152565 000 for Lamp F6 G Fuse 5AFB S08030 000 for Sewing machine motor NOTE Be sure to use only fuses of authorized types and capacities NOTE While the circuit protector is activated the thread winding motor will not rotate Let the protector cool for a while before pushing ...

Page 62: ...perate F3 Thread trimmer does not function F4 Bobbin winder motor does not operate FS Light marker does not light F6 Sewing machine motor does not run at all Overload Before replacing fuse 6 check the TR alley assembly referring to below Power source Using a tester measure the resistance between and Ifthe resistance is not 600 it is defective If the resistance is either 00 or oon replace the TR al...

Page 63: ...uID o 0 00 0 ID J DO m DO m I I 0 0 Main circuit board 60 oe e __ _ _ J c J 6 Ill OCJ r Q Keyboard circuit board OE 3 0 0 E J 0 Sewing machine motor circuit board common for all models 0 o c 3 c 3 D 0 0 Keyboard circuit board From the library of Superior Sewing Machine Supply LLC ...

Page 64: ...M on the circuit board 3 Confirm that the PROMs are in the correct position and direction 4 Use of the special PROM removal tool is recommended when removing the PROM If a screwdriver must be used be careful not to damage the PROM socket Carefully lift the PROM little by little from both sides See the figure Screwdriver Socket Circuit board 61 From the library of Superior Sewing Machine Supply LLC...

Page 65: ...tern or the set sewing area can be specified in inches Display in inches Example1 Area ARA V 10 10mm H 15 30mm Example2 Totallength LG V 10 00 mm H 15 00 mm J Example3 To set and confirm hoop feed point HoP X 10 00 mm Y 15 00 mm J 62 This indicates that the vertical length is 10 10 inches 257mm and the horizontal length is 15 30 inches 389mm When setting the total length the data is in 4 digits th...

Page 66: ... 0N Pattern mode is displayed first Pattern mode Alphabet key Code mode mode oSW2 0FF Alphabet mode is displayed first Alphabet key Code mode Pattern mode mode 3 SW3 The sewing start point of the embroidery can be changed by switching DIP switch 3 o When the DIP switch 3 is ON When the entered data is one pattern the needle location will be the sewing start point the first stitch In this case the ...

Page 67: ...disk is inserted halfway oSWS ON Even if another floppy disk is inserted during data reading or sewing of a character pattern machine will continue reading or sewing until it is done oSWS OFF If another floppy disk is inserted during data reading or sewing of a pattern character machine will stop operation at that point NOTE Do not take out the floppy disk from the disk drive during data reading o...

Page 68: ...or sewing of a pattern character machine will stop operation at that point SW3 Even if another floppy disk is inserted during data reading or sewing ON of a character pattern machine will continue reading or sewing until it is done SW4 OFF To displav pattern name of sewing data during sewing ON To display sewing speed rpm durina sewina sws OFF Spare Use with OFF ON SW6 OFF Spare Use with OFF ON SW...

Page 69: ... OFF To return to sewing start point after sewing ON Not to return to sewing start point after sewing SW6 OFF To adjust timing of hoop movement and needle rise for thick material ON To adjust timing of hoop movement and needle rise for thin material SW7 OFF To set sewing start point of editing system data to first stitch ON To set sewing start point of editing system data to center of mask SW7 OFF...

Page 70: ...read trimmer does not function circuit board P3 Overload P6 Not available P7 Main circuit board needle movement possible Improper needle bar position Needle bar Synchronizer circuit board needle location signal case does not move Needle bar case locking Improper needle bar case position Improper needle bar position Wrong needle bar is selected P8 Main circuit board Mechanical area over signal When...

Page 71: ...py disk drive P15 Main circuit board Serial comminucation control Comminucation with editing system cannot Editing system or paper tape signal be done Data cannot be received reader Data in the tape cannot be read through paper tape reader P16 Main circuit board Operation keyboard control Nothing happens after power is turned on Operation keyboard signal Display is blank P17 Main circuit board Nee...

Page 72: ...block diagram to check the connector locations Connector Connecting point Drive signals Symptoms resulting from bad No connection P1 Pulse motor circuit board Pulse motor drive signal X axis pulse motor does not move Main circuit board P4 Y axis pulse motor does not move Pulse motor for needle bar change does not move P2 Pulse motor circuit board Pulse motor driving power X andY home position is n...

Page 73: ...n to follow using a yes or no decision making process indicates that the procedure to follow appears in the first column of problem determination and solution table indicates setting up operation indicates that the procedure to follow appears on the next page indicates turning off the power switch From the library of Superior Sewing Machine Supply LLC ...

Page 74: ...2 Troubleshooting flow chart 1 When power is turned ON YES NO YES YES NO EJ EJ 0 EJ EJ EJ 71 From the library of Superior Sewing Machine Supply LLC ...

Page 75: ... 2 In data entry mode ENTER EDIT COMMUNICATE START sewing Machine goes into ENTRY mode 72 From the library of Superior Sewing Machine Supply LLC ...

Page 76: ... 3 In sewing mode ENTER EDIT COMMUNICATE START sewing YES YES YES NO U U U U 73 From the library of Superior Sewing Machine Supply LLC ...

Page 77: ...YES EJ YES U YES U YES U NO EJ YES EJ r 74 From the library of Superior Sewing Machine Supply LLC ...

Page 78: ... 4 In communication mode ICommunicate ERR ICan t communi IEdit sy busy ENTER EDIT COMMUNICATE START sewing 75 From the library of Superior Sewing Machine Supply LLC ...

Page 79: ... 5 Electric solenoid ENTER EDIT COMMUNICATE START sewing YES YES YES I f YE S YES 76 U From the library of Superior Sewing Machine Supply LLC ...

Page 80: ...TMENT REPAIR column indicate that those items should be checked while the power is applied 4 When replacing a fuse be sure to use a new one having the same quality and capacity as the old one 5 Check that all harnesses and connectors are correctly connected Before making adjustment 1 Check that no fuse is blown and each plug is correctly inserted 2 Confirm the problem area referring to the trouble...

Page 81: ...Is continuity between same numbers Keyboard cable P96 In double end connector of keyboard assembly If there Is no continuity It Isdefective 6 Operation panel defective Replace operation panel Operation panel PSO 7 Main circuit board defective Replace main circuit board Main circuit board P47 8 Fuse F2 blown Replace fuse Fuse PSS 3 1 Pulse motor harness defective Check that connector P41s correctly...

Page 82: ...efer to Item 3 Referto item 3 Referto ltem 3 10 1 Encoder harness defective Check that connector P181s correctly connected and Encoder harness P98 Sewing machine runs proper continuity tested for but hoop does not 2 Rotary encoder defective Replace rotary encoder Rotary encoder move 3 Synchronizer defective Replace synchronizer Synchronizer 11 1 Sewing machine motor circuit Check that connector P1...

Page 83: ...board Main circuit board P47 17 1 Mis operation Selectcorrect tape type Tape read Error is 2 lmpropertape a Poor punch of paper tape Re punch tape displayed b Papertape runsshort 3 Tape reader defective a Dirty head of paper tape reader Clean head b Replacetape reader Tape reader 18 1 Solenoid harness defective Check connector P2 Is correctly connected and proper P92 Solenoid does not continuityte...

Page 84: ...ng a yes or no decision making process indicates that the procedure to follow appears in the first column of problem determination and solution table indicates setting up operation indicates that the procedure to follow appears on the next page indicates turning offthe power switch From the library of Superior Sewing Machine Supply LLC ...

Page 85: ...2 Troubleshooting flow chart 1 When power is turned ON YES NO YES YES NO EJ EJ EJ EJ EJ 82 From the library of Superior Sewing Machine Supply LLC ...

Page 86: ... 2 In data entry mode FileNo Machine goes into ENTRY mode YES Q YES Q 83 From the library of Superior Sewing Machine Supply LLC ...

Page 87: ... 3 In sewing mode FileNo YES u YES u NO u 84 From the library of Superior Sewing Machine Supply LLC ...

Page 88: ... u u U u 85 From the library of Superior Sewing Machine Supply LLC ...

Page 89: ... 4 In communication mode File No ILine ERR IOff line ILine busy u 86 From the library of Superior Sewing Machine Supply LLC ...

Page 90: ... 5 Electric solenoid FileNo YES YES 7 YES YES YES 87 From the library of Superior Sewing Machine Supply LLC ...

Page 91: ...MENT REPAIR column indicate that those items should be checked while the power is applied 4 When replacing a fuse be sure to use a new one having the same quality and capacity as the old one 5 Check that all harnesses and connectors are correctly connected Before making adjustment 1 Check that no fuse is blown and each plug is correctly inserted 2 Confirm the problem area referring to the troubles...

Page 92: ...Is continuity between same numbers Keyboard cable P97 In double end connector of keyboard assembly Ifthere Is no continuity ItIsdefective 6 Operation panel defective Replace operation panel Operation panel P57 7 Main circuit board defective Replace main circuit board Main circuit board P47 8 Fuse F2 blown Replace fuse Fuse P58 3 1 Pulse motor harness defective Check that connector P41s correctly c...

Page 93: ...3 Refer to Hoop does not move ltem 3 10 1 Encoder harness defective Check that connector P181s correctly connected and Encoder harness P98 Sewing machine runs proper continuity tested for but hoop does not 2 Rotary encoder defective Replace rotary encoder Rotary encoder move 3 Synchronizer defective Replace synchronizer Synchronizer 11 1 Sewing machine motor circuit Check that connector P17 Is cor...

Page 94: ...n circuit board P47 17 1 Mis operation Select correcttape type Tape read Error is 2 lmpropertape a Poor punch of paper tape Re punch tape displayed b Paper tape runs short 3 Tape reader defective a Dirty head of papertape reader Clean head b Replace tape reader Tape reader 18 1 Solenoid harness defective Check connector P2 Is correctly connected and proper P92 Solenoid does not continuity tested f...

Page 95: ...rimming solenoid 3 WIPER 1 Thread wiper solenoid P2 4 RET 2 SOL2 5 JUMP 1 Jump solenoid 6 RET 2 7 PICKER 1 Picker solenoid 8 RET 2 1 SV 1 2 12V 2 3 12V 3 P3 4 OV 4 CN11 Power supply unit POWER 5 OV 5 6 OVRET OV 6 7 N C 7 8 Vmm 8 9 N C 9 1 SV 1 2 SV 2 3 IUP 3 P4 4 IDOWN 4 P1 PMD circuit board PMD 5 YUP 5 CNT 6 YOOWN 6 7 XDOWN 7 8 XUP 8 9 SAVE 9 10 ISAVE 10 N C not connected 92 From the library of S...

Page 96: ... 5V 2 OVTR X 3 RET PS 4 5V OVER 5 OVTR Y 6 RET 7 5V 8 OVTR Y 9 RET pg 1 5V 2 YINDEX Y ORG 3 RET N C not connected Pin No 11 12 13 14 15 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 2 3 4 5 6 7 8 1 2 3 1 2 3 1 2 3 1 2 3 93 Connect to P1 PMD circuit board CNT P3 Sewing machine motor circuit CNT board Synchronizer circuit board X Y Over travel sensor Y Y home position sensor A K P8 P9 P 10 Sensor circuit bo...

Page 97: ...DRIVE SELO 25 12 DRIVESEL1 23 14 DRIVESEL2 21 16 MOTOR ON 19 18 DIRECTION 17 P13 20 STEP 15 3 5 floppy disk drive FDD FDD 22 WRITE DATA 13 24 WRITE GATE 11 26 TRACKOO 9 28 WRITE PROTECT 7 30 READ DATA 5 32 HEAD SELECT 3 34 DISK CHANGE 1 1 3 5 7 9 2 4 6 8 10 11 13 15 12 14 16 17 19 21 SIGNAL RETURN 0 18 20 22 23 25 27 24 26 28 29 31 33 30 32 34 P14 1 5V 1 FDDPOWER 2 OV 2 3 5 FDD power supply 1 FG O...

Page 98: ... 8 9 N C 9 10 N C 10 11 N C 11 12 N C 12 13 N C 13 P15 14 N C 14 Papertape reader or editing RS232C 15 N C 15 system 16 N C 16 17 N C 17 18 N C 18 19 N C 19 20 DTR 6 21 N C 21 22 N C 22 23 N C 23 24 N C 24 25 N C 25 N C not connected 95 From the library of Superior Sewing Machine Supply LLC ...

Page 99: ...RD 3 4 5V 4 5 CTS 5 6 DSR 6 7 OV 7 8 EMRET OV 8 9 EMSTOP 9 10 5V 10 11 01 11 P16 12 FLM 12 pg Operation KEY 13 MB 13 HOST 14 CL1 14 panel 15 CL2 15 16 02 16 17 OV 17 18 OV 18 19 OV 19 20 N C 20 21 N C 21 22 N C 22 23 5V 23 24 5V 24 25 SV 25 N C not connected 96 From the library of Superior Sewing Machine Supply LLC ...

Page 100: ... 3 4 5V 4 5 CTS 5 6 DSR 6 7 OV 7 8 EMRET OV 8 9 EMSTOP 9 10 5V 10 11 N C 11 P16 12 N C 12 CN3 Operation KEY 13 N C 13 Hosn 14 N C 14 panel 15 N C 15 16 N C 16 17 OV 17 18 OV 18 19 OV 19 20 N C 20 21 N C 21 22 N C 22 23 5V 23 24 5V 24 25 5V 25 N C not connected 97 From the library of Superior Sewing Machine Supply LLC ...

Page 101: ... Signal Pin No 1 N C 1 2 5V 2 3 NLUP 1PIR 3 4 N C 4 P17 Synchronizer 5 OV 5 TIMING1 6 N C 6 7 NLDW 1P R 7 8 ENC 24PIR 8 1 A PHASE 1 2 N C 2 P18 3 N C 3 Rotary encoder 1 OOOP R TIMING2 4 5V 4 5 OV 5 N C 6 N C not connected 98 From the library of Superior Sewing Machine Supply LLC ...

Page 102: ...AVE 10 11 IHALF N C 11 12 PESET 12 13 N C 13 14 OV 14 15 OV 15 1 Vmm 1 P2 2 Vmm 2 Power supply CN12 POWER 3 01V 3 unit 4 01V 4 1 X A 5 2 X A 6 7 X 8 2 X X pulse motor 8 X B 3 N C 1 P3 N C 2 X y 3 Y A 5 MOTOR 4 Y A 6 5 Y B 2 y Y pulse motor 6 Y B 3 N C 1 N C 2 1 1 A 1 P4 2 1 A 2 INDEX 3 1 B 3 Needle change pulse motor MOTOR 4 1 B 4 5 N C 5 6 N C 6 N C not connected 99 From the library of Superior S...

Page 103: ...IHALF N C 11 12 PESET 12 13 N C 13 14 OV 14 15 OV 15 1 Vmm 1 P2 2 Vmm 2 Power supply CN12 POWER 3 01V 3 unit 4 01V 4 1 X A 5 2 X A 6 7 X B 2 8 X X pulse motor X B 3 N C 1 P3 N C 2 X Y 3 Y A 5 MOTOR 4 Y A 6 5 Y B 2 6 Y B y Y pulse motor 3 N C 1 N C 2 1 1 A 1 P4 2 1 A 2 INDEX 3 1 B 3 MOTOR 4 1 B 4 Needle change pulse motor 5 N C 5 6 N C 6 N C not connected 100 From the library of Superior Sewing Mac...

Page 104: ...9 SL5 9 1 DATA LOAD 1 2 R7 2 3 RO 3 4 4 5 SHIFT2 5 Sheet key 6 R6 6 7 R5 7 P2 8 R4 8 Tail B KEY2 9 R3 9 10 R2 10 11 R1 11 12 SHIFT1 12 13 JOGY 13 14 JOGX 14 15 JOGX 15 16 JOGY 16 1 N C 1 P3 2 LED3 2 Shift key 3 LED2 3 J1 LAMP1 4 LED1 4 lamp board 5 LEDCOM 5 1 LEDCOM 1 P4 2 LED3 2 7SEG 3 LED2 3 J2 LAMP2 lamp board 4 LED1 4 N C not connected 101 From the library of Superior Sewing Machine Supply LLC...

Page 105: ... 12 CMN2 12 P6 LIGHT Unused Unused P7 RS232C Unused Unused 1 EMRET OV N OPEN P8 2 EMSTOP COMMON EMSW EMERGENCY STOP switch 3 5 v N CLOSE 1 FG 1 2 RD 2 3 so 3 4 CTS 4 5 RTS 5 6 DTR 6 7 OV 7 8 EMRET OV 8 pg 9 EMSTOP 9 P16 Main circuit HOST 10 5V 10 KEY board 11 01 11 12 FLM 12 13 MB 13 14 Cl1 14 15 Cl2 15 16 02 16 17 OV 17 18 OV 18 19 OV 19 N C not connected 102 From the library of Superior Sewing M...

Page 106: ...nal Pin No Connector 20 N C 20 21 N C 21 pg 22 N C 22 P16 Main circuit HOST 23 5V 23 KEY board 24 5V 24 25 5V 25 1 01 1 2 FLM 2 3 MB 3 4 CL1 4 P10 5 CL2 5 LCOmodule LCD 6 02 6 7 5V 7 8 OV 8 9 5v 9 10 CONTRAST 10 N C not connected 103 From the library of Superior Sewing Machine Supply LLC ...

Page 107: ...V 14 3 CONTRAST 13 4 RS 12 5 RIW 11 6 E 10 7 080 9 CN2 LCD module LCD 8 081 8 9 082 7 10 083 6 11 084 5 12 085 4 13 086 3 14 087 2 15 N C 1 1 FG 1 2 RD 2 3 so 3 4 CTS 4 5 RTS 5 6 N C 6 7 OV 7 8 EMRET OV 8 CN3 9 EMSTOP 9 P16 Main circuit Hosn 10 SV 10 KEY board 11 N C 11 12 N C 12 13 N C 13 14 N C 14 15 N C 15 16 N C 16 17 OV 17 N C not connected 104 From the library of Superior Sewing Machine Supp...

Page 108: ... Connector 18 OV 18 19 OV 19 20 N C 20 CN3 21 N C 21 P16 Main circuit HOST 22 N C 22 KEY board 23 5V 23 24 5V 24 25 5V 25 1 SCANO 1 2 SCAN1 2 3 RO 3 4 R1 4 5 R2 5 CN4 Tail Sheet key KEY 6 R3 6 7 R4 7 8 R5 8 9 R6 9 10 R7 10 N C not connected 105 From the library of Superior Sewing Machine Supply LLC ...

Page 109: ... e on the table where it is not an obstacle for the carriage movement 4 Insert the power supply cord of lamp into the connector 0 5 Turn on the power of sewing machine and switch on the lamp NOTE The lamp connector 0 is exclusive for the ML 651 lamp set assembly 515378 001 Do not use other lamps Others may cause trouble Use 6 3V17W AC for the lamp 106 From the library of Superior Sewing Machine Su...

Page 110: ...se motor 0 and the cord holder 8 Cord holder M4tapped hole 3 Attach the light marker setting plate 8 and cord holder to the M4 tap and the M6 tap unused with bolt 6 x 12 1 spring washer 2 6 1 plain washer 6 8 I bolt 4 x 10 and the plain washer 8 107 From the library of Superior Sewing Machine Supply LLC ...

Page 111: ...e two bolts Sx 14 40 the two spring washers CD and the two plain washers Q 5 While pulling the cord 4D of light marker fix its position where the cord is not an obstacle for the carriage movement with the cord clamp 108 From the library of Superior Sewing Machine Supply LLC ...

Page 112: ...6 Removethesixscrews and the cover ofsewing machine 7 Bend the knob of connector inside and remove connector 109 From the library of Superior Sewing Machine Supply LLC ...

Page 113: ... Plug the connectors and tl Direction of connector 9 Fit the connector tj in the position where the connector was plugged until it clicks 10 Attach the cover 4D of sewing machine with the six screws Light marker 11 PIug the connector of Iight marker into the connector tj 110 From the library of Superior Sewing Machine Supply LLC ...

Page 114: ...t it is aligned with the needle position by loosening the bolt fD and screw When the two position align loosen the bolt tD slide it and adjustthe focus of light After that make fine adjustment of the positions and tighten the screws 111 From the library of Superior Sewing Machine Supply LLC ...

Page 115: ... the circuit board cover 2 Connect the connector either of the two may be r used of the RS cable assembly optional with the connector 0 on the circuit board 0 Secure the two screws 9 3 Fitthe cord of the RS cable assembly in the cord clamp fi Pass the cord through the cut section and secure the circuit board cover with four nylatches 0 112 From the library of Superior Sewing Machine Supply LLC ...

Page 116: ...411 and 415 D Character length 8 bit Stop bit length 1 bit RS cable type optional GNT 27 RS cable assembly Code S17064 001 and RS cable assembly Code S15406 001 RS cable assembly Code S15406 001 GNT4604 cable assembly Code S18957 001 and RS cable assembly Code S15406 001 GNT291 0 cable assembly Code S21660 000 and RS cable assembly Code S15406 001 Baud rate 9 600 baud for 4 800 baud paper tape rea...

Page 117: ...ned off the set point returns to 9 600 baud BAS 415 Refer to page 65 Dip switch functions Operating and preparing paper tape reader Prepare the machine Turn on the power and select paper tape in the communication mode Power switch 1 Turn on the power ofthe paper tape reader 2 Thread the papertapetothe papertape reader 1 For GNT27 Turn the READ button ON indicator lights 2 For GNT4604 Turn the READ...

Page 118: ...ther connecter of the multiplexer cable e with the master channel of multiplexer Connecting the multiplexer with the BAS 411 and 415 Embroidery Units 5 Connect the RS cable with channels 0 to 4 on the multiplexer 6 Remove the cover 6 of the machine Connect the RS cable with the connector on the main circuit board and tighten the 2 screws 4D Fitthe RS cable in the cord clamp CD Connecting the switc...

Page 119: ...Attach the bobbin winder guide bracket assembly to the spool stand with the screw the washer and the spring washer 4 Attach the bobbin winder equipment assembly to the machine body with the two bolts and the washer then plug the connector ID of bobbin winder equipment assembly into the nylon connector en 5 Attach the bobbin winder cover c to the bobbin winder equipment assembly with the two screws...

Page 120: ...bobbin loosen the screw and move the bobbin presser e 6 When winding is completed remove the bobbin from the bobbin winder shaft and trim the thread by the thread trimmer fi NOTE If the thread comes out from the thread guide loosen the knob If the thread is wound too loose tighten the knob The bobbin winder motor does not operate ifthe circuit protector activated In that case leave the protector u...

Page 121: ...ing data in floppy disk normal Is movable knife for thread trimming stopped in middle of operation How to adjust Remove thread or other interruption for good thread trimming operation Remove needle plate and reset it in proper position manually as in the figure below Movable knife NOTE When movable knife is in middle of operation the safety system works so that the upper shaft cannot rotate 2 Is t...

Page 122: ...erly 2 Is timing of needle and rotary hook correct 1 Is needle direction and height properly adjusted 2 Is needle bent 3 Is needle tip blunted 4 Istiming of needle and rotary hook correct 5 Is there looseness or play in the needle bar case When there is play in the needle bar case Collar Collar Adjust collar when there is looseness of cam shaft in needle bar flip up mechanism 6 Is rotary hook hold...

Page 123: ...functioning properly 3 When the power isturned on the hoop moves till the hoop is over the Turn off the power then turn on the power again while sewing area pressing the emergency stop button 4 When sewing is resumed in restart When there is a problem even if this is done contact your mode the hoop moves till the hoop dealer is over the area 5 Thread breakage detector functions Isthread breakage d...

Page 124: ...before the floppy disk may be defective Repairing is impossible Carefully deal with floppy disk And for security back up data on other storage medium like personal computer punching machine and so on 2 The floppy disk was originally defective If it occurs at a first time use the floppy disk may be originally defective Consult with shop you bought it or its maker 3 Following floppy disk cannot be u...

Page 125: ...ter of area manually then turn power on again If same error message is displayed again turn power off then on again while pressing EMERGENCY key Clearing backup memory 2 Overtravel sensor is in incorrect Contact your dealer position or defective 3 XY home position sensor is in incorrect position or defective 4 Damaged circuit board Memory Clear Back up data in the memory Press key according to mes...

Page 126: ...d data has something wrong Too much data or number of inputted stitches is over inside memory capacity and cannot manage it When sewing starts from current needle position sewing pattern is over the area Set sewing times in bobbin thread counter is completed 1 Needle thread breakage 2 Needle thread is not passed through the thread sensor spring 3 Bobbin thread breakage 4 Bobbin thread runs out 1 P...

Page 127: ...3 Dirty head of paper tape reader 4 Power of papertape reader is notturned on 5 Paper tape type is wrongly selected 6 Improper communication baud rate Message in replacing Cause needle bar N Case POS ERR 1 Needle bar case is not set properly 2 Damaged circuit board N Case locked 1 Needle bar case is too tight mechanically or locked and cannot move 2 Electrical failure 124 Solution Link with exclus...

Page 128: ...4 Damaged circuit board Back up data in the memory disappears Cause Data not registered in the floppy disk is entered Input data has something wrong 1 Data is input without inserting floppy disk 2 While reading data floppy disk is removed when machine runs in sewing mode 3 Damaged circuit board defective cable defective FDD Too much data or too many stitches of a data is over inside memory capacit...

Page 129: ...eakage 2 Thread is not wound on thread breakage detector 3 Bobbin thread breakage 4 Bobbin thread has run out Motor Lock 1 Pulley is too tight 2 Electrical failure Message in communication Cause mode Offline 1 Paper tape reader or editing system does not connect with machine by cable 2 Power of paper tape reader or editing system is not turned on 3 Editing system does not enter communication mode ...

Page 130: ...ongly selected 6 Improper communication baud rate Message in replacing Cause needle bar N Case POS Error 1 Needle bar case is not set properly 2 Damaged circuit board N Case Lock 1 Needle bar case istoo tight mechanically or locked and cannot move 2 Electrical failure 127 Solution Re communicate Set editing system to communication mode then communicate again Turn on power of editing system again e...

Page 131: ...7 P6 1 5 1 tll 3lC I litO I l t6HI J tc fl lUPl m OStl MAIN CONTROL KEY BOARD CIRCUIT BOARD CONTROl CIRCUIT BOARD CP16CKEYII PI PZ PJ Cll l J t l Y2 lt AUP D 0 _r 1 r 1 TT T TAIL A TAll 8 Jl t SHIFT KFY LAMP BOAPD FLAT KfY SWITCH SHEET E E F F 1 2 I 3 I 4 Ol 5 _j_____ ________j ___ __ 7_______ _ __l a 129 From the library of Superior Sewing Machine Supply LLC ...

Page 132: ... t hCNl IH05T j_ 3 71 5 BAS415 KEYBOARD UNIT CONTROL BLOCK DIAGRAM LCD MODULE KEY BOARD CONTROL CIRCUIT BOARD 4 CN4 IllY I T tAT KEY SWITCH SHEET Dl 5 EM SWITCH ____ CNI I USIII I 6 t I 8 A B c 6 j_ 7 L 8 J30 From the library of Superior Sewing Machine Supply LLC ...

Page 133: ...t l NOI t I FO PG ICAPOYlOI uo n tl ntrot CHtvtt DOord 15 PI CFODI P14 UOOPOWEQ n ISDLll P4 Pt5 PI PB P9 PlO Cllll P2 I PNOI II SZJZC I SHCI IOVUI Y OI GI IX OI GI PI ICIITI PAP TAP 1 AO Q fOI lOP P IIIID XI IPO ERI Pl Pull8 IIOlOr X V II Or 1 8 C I I CUI t bOOtd X 1 1 16 1HR A0 Sfll AKACr 5CN 0Cf CAP 5EH501 CN13 17 OVU IPAV l 5 N50Q 18 A B c u From the library of Superior Sewing Machine Supply LL...

Page 134: ... til 01 1 eon 1 r un P16 tNJ t J L U OSfJ D N G B C t1 r PI h J fOOl u l POw O J 0 0 CfJ tiOI tlftutt AtO r P14 h fl l FLODDY lllliiPOWEI I un11 ID lt1D AO li I I G SOL tiOI PI USIO 1 0111 ID WII R50l P2 t 50 i ID HOI r JCAIPSOL V lO I CAPOVl 0 I ID IS Pt PO pg PIO c PI R IOl c IPM0 l32Cl ISHKI IOV OI f t OQC C I 0QG1 r 1 _ _ r 1 uo SE Y PUlS L J T r A AKIS ORIGIII UOTOP MOHJll SENSO 1 fl Y AJIS O...