FuturaTM XL-400 Futura QuartetTM FQ-4

Transcription

Futura XL-400
Futura Quartet FQ-4
TM
TM
© 2011 SVP Worldwide - All Rights Reserved.
Service Manual
104 73 16-26
19 September 2011
Index
ESD ..............................................................................................................................................................3
Service tools .................................................................................................................................................4
1. Needle bar height ....................................................................................................................................5
2. Needle threader height ............................................................................................................................6
3. Presser foot height ..................................................................................................................................8
4. Presser foot parallelism to the needle hole in needle plate ......................................................................9
5. Presser foot parallelism to the needle plate feed dog slot’s ...................................................................10
6. Feed-dog height .................................................................................................................................... 11
7. Adjustment of synchronizer ....................................................................................................................12
8. Feed timing ............................................................................................................................................13
9. Positioning of Step motor for feeding - Feed balance basic point .........................................................14
10. Feed Balance .......................................................................................................................................15
11. Basic positioning of zigzag step motor ................................................................................................16
12. Adjustment of needle at center position................................................................................................17
13. Tension of timing belt ............................................................................................................................18
14.The timing of the hook in relation to the needle ....................................................................................19
15. Play of hook gears ................................................................................................................................20
16. Retaining bracket for bobbin case ........................................................................................................21
17. The Timing of take-up lever in relation to the hook...............................................................................22
18. Play of gears for take-up lever..............................................................................................................23
19. Parallelity of needle bar swing ..............................................................................................................24
20. Needle clearance to hook ....................................................................................................................25
21. Alignment of needle plate to hook ........................................................................................................26
22. Bobbin case thread tension .................................................................................................................27
23. Upper thread tension unit ....................................................................................................................28
Function mode of sewing machine - thread sensor deactivated. ...............................................................29
Test mode of sewing machine ....................................................................................................................30
Test mode for sewing machine ...................................................................................................................31
Error code list .............................................................................................................................................32
Test mode for sewing machine with embroidery unit ..................................................................................33
Removing face, thread cutter , bobbin winding and covers ......................................................................34
Removing base , front and back covers .....................................................................................................35
Removing base , front and back covers cont. ............................................................................................36
Main PC Board ..........................................................................................................................................37
Remove the top cover.................................................................................................................................39
Remove Hoop carrier cover........................................................................................................................41
Adjustment origin position of embroidery foot along X & Y axis .................................................................42
System error ...............................................................................................................................................43
2
Singer Futura XL-400 , FQ-4
ESD
ATTENTION!
It is of the utmost importance that precautions are being taken in order to avoid damage of the electronics
by electro static discharges ESD (=Electro Static Discharge). To avoid that these errors arise it is important
to handle loose circuit boards in a controlled way.
Electrostatic charges are caused by:
• When a person is walking (influence) over synthetic tilled or carpeted floor
• When its friction between and separation of two insulating materials.
If this static electricity discharges through electronic components, these may be partially or irreparably
damaged. Electrostatically charged persons represent the greatest danger for components. This can be dissipated by controlled electrostatic discharge.
Always use wrist band when servicing.
Please note that on disposal, this product must be
safely recycled in accordance with relevant
National legislation relating to
electrical/electronic products. If in doubt please
contact your retailer for guidance.
Bitte beachten Sie, dass hinsichtlich der Entsorgung dieses Produkts, vorschriftsmäßig entsprechend der gültigen nationalen Gesetzgebung für
elektrische/elektronische Produkte, recycelt
werden muss. Bei Zweifel setzen Sie sich bitte mit
Ihrem Fachhändler in Verbindung.
Veuillez noter qu’en cas de destruction, ce produit doit
bénéficier d’un recyclage sécurisé, conforme à la
législation nationale applicable aux produits
électriques/électroniques. En cas de doute, veuillez
contacter votre distributeur agréé.
• All casted parts within our products are marked with name of
material if allowed by size.
• All molded plastic parts within our products are marked with name
of material if allowed by size.
• Innerhalb unserer Produktion werden alle gegossenen Teile mit dem
Materialnamen bezeichnet, wenn es deren Größe erlaubt.
• Innerhalb unserer Produktion werden alle geformten Teile mit dem
Materialnamen bezeichnet, wenn es deren Größe erlaubt.
• Toutes les pièces moulées (en métal) de nos produits sont marquées
du nom du matériau utilisé, quand la taille de la pièce le permet.
• Toutes les pièces moulées (en plastique) de nos produits sont
marquées du nom du matériau utilisé, quand la taille de la pièce le
permet.
3
Service tools
A reasonable requirement in a domestic sewing machine is that it should able to sew all types of fabrics
used in the home. The settings made when assembling and sewing-in the machines are those most suited
to
give the best results in the majority of fabrics and fabric combinations. In doing so, consideration has been
given to the requirements of different markets. This does, however, mean that when sewing extreme fabrics,
better results may be obtained in certain cases by altering the settings. It must be pointed out that these
altered settings can cause poorer results on more normal fabrics. How the different standard ratings are
set can be seen from the description under each setting instruction. The following list of setting gauges and
service tools is intended as an instruction about the special service tools needed to servicing this machine.
1. On several different occasions the needle is used as a setting gauge.
The setting ratings are adapted to needle 90. Make sure to use an undamaged needle.
2. Screwdriver Philips 2PH
3. Screwdriver Philips 1PH
4.Gauge for the feed dog lift.
Ref. No 413 12 73-01
5. Gauge for the needle height - 28.95 mm
Ref. No 412 35 29-02
6. Distance gauge 0.05-1,00 mm
Ref: No. 412 38 85-01
7. Wrench 7 mm
8. Allen Key (hex driver) : 2 mm
9. Allen Key (hex driver) : 2.5 mm
10 Allen Key (hex driver) : 1.5 mm
11. Wrist band
Ref No 412 23 02-01
4
1. Needle bar height
A
Check
Note: ALWAYS check the Needle Height before checking the following settings
“Needle timing to hook” and ”Feed-dog timing (vertical motion) “
Check 1
The check 1 is done with a gauge which is 28.95 mm long.
1. Remove needle plate and bobbin case.
2. Select straight stitch (center needle position).
3. Replace needle with the special needle gauge.
Ref. No 412 35 29-02
C
4. Bring the needlebar into its lower turning position.
6. The distance between the upper end of the needle and the
surface (B) of the hook ring should be 28.95 (+/- 0.05 mm).
5. Check this by push on the tip (B) of the Special needle
gauge, and it should just touch the upper part of hook
ring(C).
B
28.95 mm
Check 2
Use a # 90.
1 .Set needle at straight stitch and at its highest position.
2. The distance between top of needle plate and a tip of needle should be
14.6-15 mm
Adjustment
The setting is done with a gauge which is 28.95 mm long.
14.6-15mm
1. Remove face cover
2. Bring the needle bar to its highest position, from the front , loosen set screw (A) and retighten it lightelly.
3. Bring the needle bar to its lower turning position.
4. Move the needle bar until the correct distance is obtained, the tip of needle must be flush with hook ring.
5. Tighten set screw (A).
6. Check by means of a twin needle that the needle bar is not twisted, it may cause jump
stitches when sewing with a twin needle.
7. Check also so the needle threader operates correctly
NOTE! This setting affects:
2. Needle threader height
5. Feed-dog timing (vertical movement)
12. Needle timing to hook
A
5
2. Needle threader height
Check.
1. Insert a new # 70 needle.
2. Set the machine to straight stitching (center needle position).
3. Bring the needlebar to its highest turning position.
4. Go down with the threader hook into the needle eye, the threader hook shall go smoothly into the
needle eye and the tip of hook should be approx. 1,5 mm out side the needle, to the front.
~1.5 mm
Adjustment of threader hook hightways
2. Remove the face cover.
3. Turning the hand wheel by hand to so the needle bar comes to its highest position.
4. Loosen screw (A) of the threader stopper.
5. Go down with the threader hook into the needle eye.
6. Move the threader holder so that the threader hook is on the upper side of the needle eye.
see Fig 1.
7. Tighten the screw (B) . Make sure to attaching the threader stopper onto stopper pin (D).
NOTE! The direction of threader stopper should be facing to the front so it does not hit the needle support
bracket.
Fig 1
A
#90
6
#80
#70
Adjustment of threader hook sideways
1. If the sideways position of the hook isn’t correct, adjust the hook position with a small screw driver.
2. Recheck that the needle threader works correctly.
Adjustment of threader hook lenghts
2. Remove the face cover.
3. Turning the hand wheel by hand to so the needle bar comes to its highest position.
4. Remove screw (K) that holds the Thread stop pipe.
5. Loosen the nut (F), located under threader support shaft.
6. Go down with the threader hook into the needle eye.
7. Turn the hook, until the tip of threader hook is approx 1,5 mm out side the needle on the front side.
8. Tighten the nut (F) .
9. Re position the Thread stop pipe and Enter the screw (K).
Tip of needle should be according to (L) , then the screw (K) position is approx. 0.4-0.6 mm from the bottom of the thread stop pie hole.
K
G
F
~1.5 mm
L
K
~0.4-0.6
7
3. Presser foot height
Check
1. Lower the feed dog, with the feed dog drop mechanism,so it is below the needle plate.
2. Raise the presser foot to its heighest position.
3. The clearance between the needle plate and the presser foot should be 5.6 mm.
4. Lower the presser foot (A) , it should be parallel to the needle plate slot (B).
C
5.6 mm
B
A
Adjustment
1. Remove the face cover,
2. Lower the feed dog, with the feed dog drop mechanism, so it is below the needle plate.
3. Raise the presser foot to its heighest position.
4. Loosen the set screw (D) and adjust the presser foot height by moving the presser bar up or down.
5. Tighten the set screw (D) securely
6. Lower the presser foot and check so the presser foot is parallel with the needle plate slot (B).
if not
a. Raise the presser foot
b. Loosen up set screw (D) and adjust the parallelity of the presser foot, by turn the Presser bar to the
left or to the right.
7. Tighten the set screw (D) securely.
8. Re-check height and parallelity of the presser foot.
D
8
D
4. Presser foot parallelism to the needle hole in needle plate
Check
2. Lower the presser foot (A) so its on the needle plate, it should now be parallel to the needle plate slot
(B).
3. The hole for needle (C) in the Needle plate, should pe parallel, front to back, to the presser foot’s (A)
hole.
C
B
A
Adjustment - Front to back
1. Lower the presser foot and check so the presser foot is parallel with the needle plate slot (B).
if not
a. Raise the presser foot
b. Loosen up set screw (D) and adjust the parallelity of the presser foot, by move the Presser bar to the
front or to the back.
7. Tighten the set screw (D) securely.
D
D
C
C
9
5. Presser foot parallelism to the needle plate feed dog slot’s
Check
2. Lower the presser foot so its on the needle plate, it should now be parallel to the needle plate slot.
side to side. It must be same distance on the left side as on the right side of the presser foot to the feed
dog slot.
A
B
A
A
Adjustment - side ways
1. Remove the face cover,
2. Lower the feed dog, with the feed dog drop mechanism, so it is below the needle plate.
3. Loosen the three set screws (A) and adjust the presser foot side setting by moving
the presser bar unit (B)so it’s same distance on the left side as on the right side of the presser foot to the
feed dog slot.
4. Tighten the three set screw (A) securely
10
6. Feed-dog height
Check
1. Set machine into test mode and select mode 2.
2. Raise the presser foot.
3. Bring the feed dog to its highest position by turning hand wheel.
4. The top of the feed dog ishould now be 0.9 to 1.1 mm above the needle plate.
0.9-1.1 mm
Adjustment
1. Bring the feed dog to its highest position.
2 Remove the needle plate.
3. Loosen up the nut (A).
4. Adjust by turning the screw (B) until a correct feed dog height (0.9-1.1 mm) is obtained.
Turn clockwise : It will be higher
Turn counter clockwise : It will be lower
5. Tighten the nut (A)
3. Mount the needle plate and Re-check the feed dog height.
B
A
11
7. Adjustment of synchronizer
Check:
1. Insert a new needle.
2. Remove the presser foot.
9-10 mm
9-10 mm
3. Turn on the master switch.
4. Select stitch pattern 07
5. Turn the handwheel forward by one full turn.
6. Continue turning the handwheel slowly and check the timing of the needle bar sideways movement.
A change of sideways needle bar movement shall take place when the needle is 9 to 10 mm above the
needle plate surface
B
A
1&2
Adjustment:
1.
2.
3.
4.
5.
6.
7.
Remove the covers.
Loosen fastening screw (1 and 2) of sensor cam (A) just slightly.
Turn the handwheel until the needle is about 9 to 10 mm above the needle plate surface .
Turning sensor cam (b) very slowly until the zigzag stepping motor switches.
Tighten fastening screw (1 and 2 ) of sensor cam.
Make sure that the Flag of sensor cam 1, 2 and 3 rest in the center of the circuit board guides.
Cross-Check.
The following machine positions or functions are controlled by the synchronizer:
1. Change of feeding direction and change of stitch length
2. Sideways movement of needle bar
3. Take-up lever top position/needle „up“ position
4. Needle „down“ position
12
8. Feed timing
Check
Note: Always check “Needle bar height”, “Feed dog height” before any check is done on ”Feed Timing”.
1. Set machine at function mode and select straight stitching and maximum stitch length.
2. Set needle to its upper turning position.
3. Turn the hand wheel in the sewing direction,
4. When the feed dog starts its movement backwards it should move 0-0.3 mm, before the needle start to
travel down from its upper turning position.
Adjustment
NOTE! Remove the covers, but the front cover must be connected to the pc board.
1. Set machine at function mode and select straight stitching and maximum stitch length.
2. To adjust the Feed dog timing , loosen up the 2 set screws (A) on the Lower shaft (B).
3. Insert a hex driver into one of the screws.
If feed-dog motion too early - Hold the hex screw in position and turn hand wheel towards you.
If feed-dog motion too late - Hold the hex screw in position and turn hand wheel away from you.
4. Tighten the set screw (A) on the main shaft (B)
5. Turning hand wheel and set the needle to its upper turning position and in the position just before it start
to travel down.
7. Check so the feed dog movement is in the range of 0-0.3 mm, before the needle start to travel down from
its upper turning position.
8. If wrong:
Re-do from point 2.
9. If ok :
Tighten both set screws firmelly after the adjustment.
NOTE! After adjustment , be sure to check and/or adjust “Needle timing to hook”
Needle at upper turning position
0 - 0.3mm
B
A
A
13
9. Positioning of Step motor for feeding
- Feed balance basic point
This adjustment would normally only be carried out if the feed step motor has been replaced.
Adjustment:
1. Turn off main power.
2. Remove front cover and back cover.
3. Move the feed step motor gear and loosen ONLY screw (2) at feed step motor gear (A) which is fixed
with stepping motor axis for feeding.
2
A
4. Turn on machine and select button sewing (Zero feed).
NOT! If both screws are loose at this point - error #6 will apper in display.
5. Loosen screw (1) at pinion gear (A). The feed step motor gear is now disengaged from the motor.
A
1
5. Rotate feed step motor gear (A) and then tighten screw (2) at a position where pinion gear hits with
stopper (B)
6. Turn off the main power and then tighten screw (1)
2
Fig. 2 ---
A
B
14
10. Feed Balance
*Pay much attention to this adjustment which is very important and critical.
Check of ”Zero” feeding
1. Enter Test mode and select stitch 2 to check “Zero” feed.
2. Place a piece of paper or fabrics under presser foot and run the machine, at this point there should not
be any feeding.
Adjustment of “Zero” feeding
1. Enter Test mode and select stitch 2 .
2. Place a piece of paper or fabrics under presser foot and
run the machine and check to see the feeding direction
3. To adjust eventuall feeding, loosen up the screw (A).
4. Adjust by turning screw (B) in either way until correct
- If the 3 mm Hex screw (B) is turned clockwise, it will feed
in forward direction.
- If the 3 mm Hex screw (B) is turned counter clockwise, it
will feed in reverse direction.
5. Hold the 3 mm Hex screw (B) while tighten the screw (A).
6. Re-check.
Adjustment can be done without removing the front and the
rear covers . Only the base plate should be removed before adjustment.
B
Check of stitch balance
After checking or setting the ”Zero” feeding , the fine tunning of the
stich balance has to be done.
A
1. Turn on the machine, select a large key button hole in normal
sewing mode.
2. Thread up the machine.
3. Sew larger size of keyhole buttonhole and the balance of the head portion should be equal between
right and left sides.
Adjustment of stitch balance
1. If feed is not correct,
Adjustment can be done without removing the front and the rear covers .
Only the base plate and feeding cap should be removed before adjustment.
2. Turn on the machine in function mode, select a large key button hole in
normal sewing mode.
3. Loosen up the screw (A) .
4. Adjust by moving the motor gear in either direction with 3 mm hex driver.
- Turn the screw (B) clockwise to adjust reverse stitch.
- Turn the screw (B) counter clockwise to adjust forward stitch.
Repeat the process until desired feed balance is obtained.
4. Tighten the screw (A).
5. Re-check from point 1 in ”check of stitch balance”
15
11. Basic positioning of zigzag step motor
Adjustment
1. Turn off the main power and remove face cover and needle bar unit
2. Loosen two screws (1&2) fixing pinion gear by rotating pinion gear (A).
Position of screw (1) and screw (2) will be located as shown in fig. 1&2 below.
3. Rotate pinion gear (A) to shift needle position. After needle position is shifted to center, temporally fix
the screw (1).
4. Turn on the main power and pinion gear will move so that screw (1) may be located upward and then
loosen screw (1). After above steps, the motor shaft will be excited so the shaft will not move and pinion
gear can be rotatable. Rotate pinion gear (A) again until it hits with stopper (B) then tighten screw (2) by
inserting tool from lower as shown on picture below. At this time, shift needle bar to right end so the pinion gear will hit with stopper.
)LJ
)LJ
B
A
1
2
2
16
12. Adjustment of needle at center position
Check
1. Set the machine on straight stitching, center position.
3. The needle position should now be in the centre of the middle slots of needle plate, see illustation 1.
Adjustment
1. Remove face cover.
2. Break loose the 2mm hex set screw (A).
3. Turn eccentric screw (B) on needle bar until the needle is in the centre of the middle slots of needle
plate, see illustation 1
4. Tighten the 2 mm hex set screw (A).
Needle position
A
B
17
13. Tension of timing belt
Check
This checking is needed before adjusting “Needle timing to hook”.
1. Remove the covers
2. Push on the belt, it should not be to hard or to loose.
- Too weak tension may result in slippage between hook gear and lower shaft
gear due to thread jamming, bunching and fabric snagging.
- Too strong tension may result in incorrect operation due to increased machine torque.
Adjustment
1. Loosen two screws (A) on support plate for idler pulley.
2. Move the position of idler pulley ontil the correct belt tension is obtained.
3. Tighten the two screws (B).
A
18
14. The timing of the hook in relation to the needle
Check 1
- Set a new needle size 90 universal into the machine.
- Remove the needle plate, bobbin case holder and the bobbin case.
- Set machine on straight stitching.
- As the needle is moving upwards, the tip of the hook should pass behind the centre of the needle, when
the needle is 2.8 mm above its lower turning position.
NOTE! Before any adjustment is done check that the setting "7. Feed timing" is correct.
Check with setting gauge,
Spacer, Ref. No: 63-102600-18/000, feeler gauge 2.8 , Needle clamp Ref. No: 413 10 22-01
1. Turn the hand wheel until the needle is at its lower turning position.
2. Put the spacer onto the needle bar and push it
C
A
upwards against the needle bar frame (C).
B
3. Take then the timing clamp and put it on the
needle bar and tighten its screw lightly.
4. Take a 2.8 mm feeler gauge (A) and put its cutout
on the needle bar, above the clamp.
5. Loosen the clamp a little and push both feeler
gauge and clamp upwards against the spacer.
6. Tighten the screw on the timing clamp.
7. Remove the 2.8 mm feeler gauge (A).
8. Turn the hand wheel, in the sewing direction, until the timing clamp (B) stops against the spacer.
9. The tip of the hook should now be behind the centre line of the needle.
Check 2
1. Turn on machine and Select stitch number 33 to 36. Set Zigzag width to the maximum of 7mm
2. Remove needle plate
3. Insert a new needle.
4. Needle to its lowest turning position.
4. As the needle is moving upwards, the tip of the hook is on the right side of the needle,
I t should be 0.7 to 1.2 mm from top of needle eye to tip of hook.
Adjustment
1. Loosen the 2 setting screws in the wheel of the lower shaft.
2. Make sure that the feed dog is in its down stroke position.
3. Repeat checking points 1 to 8 with the setting gauges.
4. Turn the hook until its tip arrives behind the centre line of the needle.
5. Tighten one of the setting screws.
6. Check.
7. Tighten both screws.
)LJ
19
15. Play of hook gears
Check
1. Move the cog wheel with the hand wheel and check play of the gears at 4 positions – at each 90 degree
angle
2. At each position - rotate the hook back and forth with the finger tip to check the play
- a play should be found in two or three diffrant positions.
- no play should be found on one position(max two positions).
Adjustment
1. Remove backcover and frontcover.
2. Loosen, screw (B) holding the bearing clamp.
3. By using the slot (C) and turn the eccentric bearing (A) the play can be adjusted.
NOTE! The hole (C) in the bearing shall always be to the front.
A
C
B
20
16. Retaining bracket for bobbin case
Check
2. Check if bobbin case stop (C) is aligned with the lower side of plate spring’s alignment line (D) as
illustrated below.
Adjustment
1. Loosen screws (A and B),
2. Move the retaining bracket in either direction as illustrated, tighten screw (B) temporarily.
3. Check if bobbin case stop (C) is aligned with the lower side of plate spring’s alignment line (D) as
illustrated below.
4. Tighten screw (A).
C
21
17. The Timing of take-up lever in relation to the hook
Checking
1. Thread through thread guide of take-up lever and then move the take-up lever to the position where tip of
the lever may catch thread.
2. Remove needle plate and bobbin case
3. At the position of take-up lever above, check to see if portion (A) of hook is located approx 1-1.5 mm
from the spring plate of bobbin case stopper (B).
Note! The needle bar should be in its upper turning position.
Adjustment
1. Remove front cover.
2. Loosen two hex screws on main shaft gear () which is engaged with take-up operating gear (B).
3. Set the hook to its setting position (A) then should the needle bar be its in its upper turning position.
4. While inserting screw driver into accessible hex screw, turn main shaft in either way to get correct timing
of take-up lever to shuttle
4. Tighten 2 screws securely after adjustment.
Note: Gear D is fixed by collar F and E. If collar B is adjusted, make sure gear D must be tightened securely.
Take up lever
Top thread
Take up lever thread guide
B
A
1-1.5 mm
᧾
A
F
D
E
B
E
22
18. Play of gears for take-up lever
Checking
1. If excessive noise is generated from take-up lever, there should be a problem in meshing of take-up
operating gear (A) with main shaft gear.
2. Remove front cover and check play of gear (A) by turning pulley by hand.
There should not be play at 4 positions of the gear and it should not be tightened too much.
3. Also check to see if there is no play of gear (A) vertically.
Adjustment
1. Loosen screws (C&D) fixing eccentric gear shaft.
Rotate gear clockwise to hit slightly to another gear, this will be eccentric situation.
2. Adjust by turning gear shaft (B) slightly while pushing it with screw driver as shown, since the gear
shaft tends to pop up.
3. Tighten the screw (D) and then screw (C) securely after adjustment.
A
D
C
B
23
19. Parallelity of needle bar swing
Check
1. Set machine at test mode and select mode 2 - needle at L/C/R positions.
3. Turn the hand wheel and check that the needle clearance to hook at both left and right sides of needle
positions is even. See Illustration.
NOTE! If distance left and right sides of needle positions are evan, but the distance between needle and hook
is to close or to wide, re-set ”16. Needle clearance to hook”.
Needle
Adjustment
1. Remove needle plate, bobbin case and face cover.
2. Set machine at test mode and select mode 2 for needle at L/C/R positions.
3. Loosen the set screw (A) on the needle bar unit, see illustrated below.
4. Adjust by moving shifting bracket (B).
- If needle touches the hook at left side, move the shifting bracket (B) to the right.
- If needle touches the hooks at right side, move the shifting bracket (B) to the left.
5. Tighten the set screw (A) firmly
6. Turn the hand wheel and check needle clearance to hook at both left and right sides of needle positions is
even.
NOTE! This setting influences”16. Needle clearance to hook”
B
A
24
20. Needle clearance to hook
Check
1. Always check ”14. Parallelity of needle bar swing” before any check of ”Needle clearnce to hook” is done.
4. Turn the hand wheel and check so the needle clearance to hook at both left and right side of needle positions are within 0.05 to 0.15 mm.
Adjustment
1. Always check ”14. Parallelity of needle bar swing” before any adjustment is done.
2. Remove needle plate, bobbin case and face cover.
4. Turn screw (A) for support shaft and adjust needle position until the correct needle clearance is obtanied.
- To decrease clearance, turn screw (A) to clock wise..
- To increase clearance , turn screw (A) to counter clock wise. .
5. Re-check to see so the needle clearance to hook is within 0.05 to 0.15 mm.
0.05~0.15 mm
0.05~0.15 mm
Right Zigzag position
Left Zigzag position
Hook
Hook
0.05~0.15 mm
A
25
21. Alignment of needle plate to hook
Checking
1. After adjusting needle clearance to shuttle, attach needle plate. At this time, make sure to check the
needle is correctly positioned to the needle hole as shown below.
Adjustment:
2. Loosen the two hexagonal screws (A)
3. Adjust the needle plate position, with the two plate stopper plates (B) located at either side of feed dog
,so that to needle is in its centre position of the needle hole in the needle plate, when looking from the
side of the machine
4. Tighten the the two screws (A) on the stopper plate securely.
A
B
26
A
22. Bobbin case thread tension
Check
1. Insert a full bobbin into the bobbin case, use normal polyester thread.
2. The thread tension spring of the bobbin case shall give a resistance of 10-14 g when pulling the thread
slowly, using normal polyester thread.
Adjustment
1. Insert a full bobbin into the bobbin case, use normal polyester thread.
2. Pull the thread slowly and turn screw (A) until the correct thread tension is obtained.
NOTE! Remove any loose pieces of thread or fluff from the thread tension discs before any adjustment is
done.
A
27
23. Upper thread tension unit
Check
1. Always check so the bobbin thread tension is correct before the upper thread tension is checked.
2. When the thread tension dial is set at ”S”, a correct take-up should be obtained at straight stitching and
zig-zag using normal cotton fabrics and polyester thread.
Adjustment
NOTE! Before any adjustment is done remove any loose pieces of thread or fluff from the thread tension
discs
1. Always check so the bobbin thread tension is correct before the upper thread tension is adjusted.
2 Remove the face cover.
3. Remove first the screw for that holds the adjustment dial then remove the dial (A).
Make sure to note the position of the default ”S” position.
4. Rotate Thread tension wheel (B) to adjust tension to be set.
Standard is 55-65gr at “S” position.
- Rotate anticlockwise to increase tension.
- Rotate clockwise to decrease tension.
Adjust tension while measuring it by tension gauge.
5. Fit the adjustment dial (A) to Thread tension wheel after adjustment.
It is needed to fit the dial (A) at same position as it was before taking it off.
Tighten screw with washer at the Thread tension wheel.
A
B
28
Function mode of sewing machine
- thread sensor deactivated.
In order to check or set of the different functions on the machine without having it threaded there is a Function mode.
After entering the function mode all the diffrent sensors of the machine
- Thread break
- Presser foot lever
- Bobbin Thread
is de-activated and the machine will run without thread.
Handling
Go to the Function mode of the machine by pressing buttons (1) and (2) and
(5) while the main switch is switched on. See illustration below
Sewing function mode
In Function mode all stitches are the same as in Normal sewing mode.
Embriodery function mode
In Functions mode when operating the embroidery mode of machine, it must be connect to a PC through a
USB cable.
To run the machine use start/stop switch after the embroidery data is transfered to machine from PC.
ON
29
Test mode of sewing machine
1
In order to check or set the step motor or
sensor functions of the machine there is a Test
mode.
Handling
Go to the Test mode of the machine by...
2
1. Put on a bobbin
2. Move bobbin winder stop to the winding
position.
3
+
ON
3. Press the reverse stitch switch and turn on
power switch at the same time
4
4. All the 6 lights in row 1 will light up.
then all lights in row 2 will light up.
5. Move bobbin winder stop to NON winding
position , then release the reverse button
NOTE! Those two action must be completed
before the lights in row 5 has lighten up.
5
+
In case of embroidery sewing, enter the Embriodery unit before enter the test menu.
30
Test mode for sewing machine
M4
M2
M3
M1
M5
Operation
Enter Test program.
Use the stitch width selector wheel (A) to go through the
diffrent test mode functions.
Mode 1: Needle position at Left/Centre/Right without feed.
After entering the test mode 2 all the diffrent sensors of the machine is de-activated (Machine will run without thread).
Mode 2: Needle position at center without feed
Is used for checking the movement of the zig-zag step motor and centre position of the needle in straight
stitching. The zig-zag stepmotor calibrates and takes its Centre position.
Mode 3: Balance check
Machine will feed 2 mm, at center position, stitch 11 needles forward and backward.
Needle must always stop at the staring stitch
Mode 4: Bobbin thread brake sensor
Is for chrcking the bobbins sensor .Machine will feed 0.5 mm, at center position.
The top thread detection is deactivated.
Mode 5: align
Machine will feed 2.5 mm forward and 2.5 mm reverse, at z-z 7mm.
31
Error code list
Error
06
09
16
32
Feed stepmotor
ZigZag Step motor
Cutter step motor
Test mode for sewing machine with embroidery unit
Operation
Enter Test program.
Use the stitch width selector wheel (A) to go through the diffrent
test mode functions.
M4
M2
M1
M3
M6
M5
M7
M8
To run the machine use start/stop button
NOTE! For safety remove the needle from the machine
Mode 1
Move to original point
Mode 2
Move diagonal from upper right lower left, and stop.
Mode 3
Sew 4 corners lower left upper left upper right lower right lower left, and stop.
Mode 4
Sew 4 corners lower left lower right upper right upper left lower left, and stop.
Mode 5
Sew diagonal from upper right lower left, continuously.
Mode 6
Sew diagonal from upper left lower right, continuously.
Mode 7
Sew large diamond shape continuously with maximum 400rpm.
Mode 8
Sew small diamond shape continuously with maximum 600rpm.
102
101
105
106
103
107
104
108
33
Removing face, thread cutter , bobbin winding and covers
1. Remove screw cap (A) with and aid of needle
2. Remove screw (B) from the left side of the Face cover.
3. Turn the machine around and remove the screw (c)
that holds face and back cover together and remove
the face cover
C
AB
4. Remove screw cap (D) with and aid of needle
5. Remove the screw (E),
then remove the Thread cutter cover (F).
F
D
E
G
6. Remove the screw (G) that holds the bobbin winding latch.
7. Remove the bobbin winding latch (H).
H
8. Remove the screw (I) for the bobbin winding cover
9. Remove the bobbin winding cover (J) by push on the cover at
marked area (K) to realese the hooks.
H
J
I
J
K
K
10. Remove the two screws (L) then remove the Switch cover.
M
L
34
Removing base , front and back covers
1. Remove the face, thread cutter and bobbin winding covers first
B
A
1. Remove the two screws (A) and the screw (B).
2. Lay the machine down and remove the two screws (C).
D
E
D
E
C
C
3. Remove the two screws (D) located in the center of the base plate.
4. Remove the two screws (E) located on the side and remove the base plate.
G
F
5. Remove the two screws (F and G) located back cover of the machine.
35
Removing base , front and back covers cont.
6. Remove the Screw (H) and washer (I) from the front cover.
H
I
7. Lay the machine down and remove the stitch balance cover,located on the free arms lower side
Usa Small Screw driver and push the rid located on the left side.
K
J
L
J
K
L
8. Us a small flat screw driver and insert it from the back and at positions (J), (K) and (L)
and lift up the Front Cover to un-hook the taps on the front cover from the back cover.
Once its a gap between the front and back cover at position (J), (K) and (L) , the front cover can be removed.
9. Lift up the front cover a bit and disconnect the Multi cable from the Main PC Board.
To do this just pull the cable to the front to realese it from the PC board contact.
10. Presser foot lifter to its down position.
11. Remove the back cover.
36
Main PC Board
CN17
CN16
CN18
CN15
CN19
CN14
CN13
CN1
CN2
CN20
CN3
CN12
CN4
CN11
CN5
CN10
CN6
CN9
CN7
CN8
CN1 AC circuit board
CN2 Main motor
CN3 Step motor for needle zigzag with lever switch
CN4 Not use
CN5 Not use
CN6 Step motor for feed material with lever switch
CN7 Drawer connector for embroidery unit
CN8 Not use
CN9 Not use
CN10 Not use
CN11 Foot control jack
CN12 USB connector
CN13 Bobbin winder switch
CN14 CAM sensor switch
CN15 BH sensor
CN16 BH lever switch
CN17 Top thread sensor
CN18 LED lamp
CN19 Motor for bobbin winder
CN20 Switch control panel circuit board
37
Start / stop
Speed control
CPU Board
CPU Board
Power Switch
38
Remove the top cover.
Removing top cover
1.Lay embroidery unit upside down and then remove accessory drawer and three tapping screws at drawer
side (1, 2, 3, 4 and 5 ). And also remove another four screws (6, 7, 8 and 9 ) marked with”△” symbol and
one screw (10 at lock lever side.
1
3㧒4
2
5
7
8
6
9
10
39
Push top cover along with an arrow shown below.
*Top cover and embroidery unit are attached by hooks. Release two hooks on each side to remove top.
40
Remove Hoop carrier cover
1.
Remove a screw on side of carriage cover.
2.
Remove two screws on the back of carriage cover.
3.
Remove carriage cover by removing it from hooks.
Note: Make sure to attach two square holes into projections correctly on the board at motor side when you
attach carriage cover.
41
Adjustment origin position of embroidery foot along X & Y axis
Adjustment: X axis
1. Loosen screw (1) and adjust position of braking plate (B) which passes through sensor (A).
Then check the position again.
B
1
A
Adjustment: Y axis
1. Loosen screw (2) and adjust position of braking plate (D) which passes through censer (C).
Then check again the position.
C
2
D
42
System error
Trouble contents with LED on panel
No. Name of al code
1
2
3
4
Way of detect
Solution
If exceed amount of electric current has
followed to bobbin winder motor more than
Trouble of protection
50ms out of 250ms at condition of PWM output
relay
is off and releasing protection relay while main
power is on.
In case if main axis rotates within about 250ms
Trouble of protection
at condition of PWM output is on and released
relay
protection relay while main power is on.
In case if main axis rotates within about 250ms
at condition of PWM output is off and
Trouble of PWM output
connecting to protection relay while main
power is on.
Regardless of motor turned on or off, if exceed
Trouble of loading
amount of electric current has followed to main
current
axis motor for more than 3seconds.
Trouble of main shaft
stop (detected it is
moving even though it
should be stopped.)
Trouble of main shaft
rotation (detected
abnormal speed)
5
Trouble of needle
swing motor H.P.
6
Trouble of feed motor
H.P.
Replace CPU
board is needed.
Replace CPU
board is needed.
Replace CPU
board is needed.
Replace CPU
board is needed.
In case if main axis rotates faster than 300rmp
for more than 300ms while main axis motor is
not been turned on.
Replace CPU
board is needed.
In case if main axis motor rotates more than 3
rotation while main axis motor is turned off.
Replace CPU
board is needed.
In case if main axis motor rotates faster than
1000rmp for 10ms.
In case if PWM output of main axis motor is
lowest duty and rotates 150rpm faster than
aiming number of rotation while main axis
motor is turned on.
HP signal is not turn to "ON" at initial
movement of hoop when turning on main
power.
HP signal is not turn to "OFF" at initial
power.
HP signal is not turn to "ON" at initial
power.
HP signal is not turn to "OFF" at initial
power.
Replace CPU
board is needed.
Replace CPU
board is needed.
Replace switch
of stepping motor
is needed.
Replace switch
of stepping motor
is needed.
Replace switch
of stepping motor
is needed.
Replace switch
of stepping motor
is needed.
43
Nil
Name of al
No. code
7
8
Trouble of X
axis motor of
hoop H.P.
Trouble of Y
axis motor of
hoop H.P.
Wa y of detect
HP signal is not turn to "ON" at initial movement
of hoop when turning on main power.
HP signal is not turn to "OFF" at initial movement
HP signal is not turn to "ON" at initial movement
HP signal is not turn to "OFF" at initial movement
Replace switch of
stepping motor is
needed.
Replace switch of
stepping motor is
needed.
Replace switch of
stepping motor is
needed.
Replace switch of
stepping motor is
needed.
9
nil
10
Problem in
Cam1 signal
Signal of Cam1 is not inputted while main axis
motor is operating.
Replace cam sensor is
needed.
11
Problem in
Cam2 signal
motor is operating.
needed.
12
Problem in
Cam3 signal
motor is operating.
needed.
Replace sensor board
at BH is needed. If
trouble is not solved
after replacement of
sensor board, CPU
board is needed to be
replaced.
Replace sensor board
at BH is needed. If
trouble is not solved
after replacement of
sensor board, CPU
board is needed to be
replaced.
Both signal of forward sensor and signal of
backward sensor are "ON" at same time when
turned on the sewing machine.
13
Problem in
B.H. lever
signal
Both signal of forward sensor and signal of
backward sensor are "ON" at same time while
sewing is in practice.
44
Solution
Nil
Name of al
No. code
Wa y of detect
Solution
14
Problem in
Hoop
movement
(hoop moved
with needle at
bottom
position)
Needle position became lower position before
hoop motion has completely end at embroidery
mode.
The embroidery data is
broken.
15
Trouble of
operation
board.
Any button of START/STOP, FORWARD
STICTH, REVERSE STITCH or AUTOMATIC
THREAD TRIMING is pressed more than
5seconds when turning on the sewing machine.
Switch button has been
stiffened and pressed.
It is need to check
button.
16
nil
If exceed amount of electric current has followed
to bobbin winder motor more than 50ms out of
250ms at condition of PWM output is off and
connecting to protection relay while main power
is on.
Replace CPU board is
needed.
If exceed amount of electric current has followed
to bobbin winder motor within 200rms while main
bobbin winder motor is turned on.
needed.
Regardless of motor turned on or off, if exceed
amount of electric current has followed to bobbin
winder motor for more than 3seconds.
needed.
Trouble of
PWM output
17
Trouble of
main shaft
stop (detected
it is moving
even though it
should be
stopped.)
Trouble of
loading
current
45

FuturaTM XL-400 Futura QuartetTM FQ-4

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