SERVICE MANUAL

Model 2005A
HOUSEHOLD SEWING MACHINES

by SINGER*

A Publication of SPG Parts and Services Part No. 119573

T h i s manual i s d e s i g n e d f o r u s e by t r a i n e d and q u a l i f i e d s e r -
v i c e persons.

The S i n g e r Company w i l l n o t be r e s p o n s i b l e f o r any p a r t s r e -

q u i r i n g r e p l a c e m e n t owing t o n a t u r a l wear o r t o a b u s e o r
n e g l i g e n c e o f t h e u s e r o r i n t h e e v e n t t h e m a c h i n e i s ser-
v i c e d by o t h e r t h a n a t r a i n e d and q u a l i f i e d s e r v i c e p e r s o n ,
o r i f p a r t s a r e s u b s t i t u t e d which do n o t meet a p p l i c a b l e
specifications.

Copyright @ 1981 THE SINGER COMPANY

All Rights Reserved Throughout the World

* A Trademark of THE SINGER COMPANY

Printed i n U.S.A.
 TABLE OF CONTENTS

PAGE

.
. SECTION 1 GENERAL INPORMATION ........................................... 1
Scope of Manual * M e t e r s * Machine S e r i a l Number * C o n t r o l s Diagram

SECTION 2 . ELECTRONIC TEST POINTS. SEQUENCE OF ELECTRONIC

AND ELECTRO/MECHANICAL ADJUSTMENTS AND ELECTRONIC TROUBLESHOOTING
PROCEDURE ................................................................

E l e c t r o n i c T e s t P o i n t s ................................................ 11
Sequence of E l e c t r o n i c and E l e c t r o / M e c h a n i c a l Checks and Adjustments .. 25
E l e c t r o n i c T r o u b l e s h o o t i n g P r o c e d u r e .................................. 35

SECTION 3 . ADJUSTMENT PROCEDURES ............................................ 63

S e q u e n t i a l C h e c k l i s t and I n t e r l o c k i n g Adjustments C r o s s R e f e r e n c e ..... 64

A r m S h a f t and A r m S h a f t Sprocket ...................................... 66
Thread Take-up Lever and Needle Bar Connecting Link L o s t Motion ........ 69
Needle Bar V i b r a t i n g Bracket B a l l J o i n t ............................... 69
Needle Bar D r i v i n g A r m P o s i t i o n i n g S o l e n o i d ........................... 70
S e t t i n g Needle L o c a t i o n ............................................... 73
Needle Bar Height ..................................................... 74
I n s p e c t i o n and L u b r i c a t i o n of Needle Bar R e l e a s e Mechanism ............ 77
Needle Bar R e c o i l S p r i n g .............................................. 78
Needle Bar L a t c h C a r r i e r E c c e n t r i c .................................... 81
Needle Bar R e l e a s i n g Bracket .......................................... 82
Needle Bar R e l e a s e S o l e n o i d ........................................... 85
P r e s s e r Bar Height. and Alignment
Timing B e l t Tension ...................................................
.......................... 86
89
blotor B e l t Tension and Motor Switch .................................... 89
Needle Crossover -- Timing t h e S y n c h r o n i z e r ............................ 90
Hook Gear Mesh 92
Hook and Feed Timing .................................................. 97
Hook-to-Needle R e l a t i o n s h i p ........................................... 1 0 1
Alpha Feed ............................................................ 102
Needle P l a t e Magnet Height * Feed Dog Alignment * Feed Dog
Centralization * Feed Dog Throw * *
Feed Dog H e i g h t Feed Zeroing
Bobbin Case Thread C l e a r a n c e s ......................................... 110
Bobbin Case I n s p e c t i o n and P r e l i m i n a r y Adjustments * Bobbin Case
R a d i a l Alignment w i t h Needle * P o s t i o n F i n g e r and Bobbin Case
P o s i t i o n P l a t e Adjustments
..................................
A r m Top Thread Guide and P r e - t e n s i o n 118
Bobbin Winding Adjustments
Tension Module
............................................
........................................................ 121
122
Dial Tension * Thread Take-up S p r i n g
Tension R e l e a s e ....................................................... 125
.....................................................
E l e c t r i c a l System 126
Lubrication .......................................................... 129
Sew-In T e s t ........................................................... 130
SECTION 4 . PARTS REMOVAL AND REPLACEMENT ................................ 135
Face P l a t e ..........................................................
L-
136
Top Cover ............................................................. 136
Front Cover ........................................................... 139
Bottom Cover .......................................................... 139
Buttonhole Switch ..................................................... 140
Head-End Assembly ..................................................... 143
Needle Bar ............................................................ 143
P r e s s e r Bar and P r e s s e r Bar Bushing ................................... 144
Tension Assembly ...................................................... 147
Take-up Lever Assembly ................................................ 147
L i n e a r Servo Board P.C. Assembly ...................................... 148
P a t t e r n S e l e c t i o n Button C a r r i e r Assembly ............................. 148
Master C o n t r o l Logic Board Assembly ................................... 151
Hand Wheel ............................................................ 152
Motor .................................................................. 152
Motor B e l t ....................................... 155
A r m S h a f t Sprocket . .Timing B e l t ..................................... 155
Arm S h a f t ............................................................. 156
Needle Bar R e l e a s e Solenoid ........................................... 160
Needle Bar D r i v i n g Arm ................................................ 160
Needle Bar D r i v i n g Arm P o s i t i o n i n g Solenoid .......................... 163
Override C o n t r o l P.C. Board and Panel Assembly ........................ 164
Transformer ........................................................... 167
F i l t e r C a p a c i t o r s .................................................. 168
L i n e a r Feed Motor ................................................... 171
L i n e a r Bight Motor .................................................... 171
S l i d e P l a t e ........................................................... 172
Bobbin Winder A c t u a t i n g Lever and D r i v e r Assemblies ................... 172
Hook ......................................
Hook Drfve Shaft
............................ 175
* Hook Drive Gear * Feed Drive Gear .................. 176
Feed Drive S h a f t ...................................................... 179
Feed R e g u l a t o r S h a f t and Feed R e g u l a t o r and Block ..................... 180
Feed Bar Connecting Link .............................................. 183
Feed Bar .............................................................. 187
 SECTION 1
GENERAL INFORMATION
SCOPE

This s e r v i c e manual d e s c r i b e s all of t h e s e r v i c i n g p r o c e d u r e s , i n c l u d i n g

a l l mechanical and e l e c t r o n i c a d j u s t m e n t s , e l e c t r o n i c t r o u b l e s h o o t i n g and
p a r t s removals and replacements f o r t h e 2000623 machine.

With t h e i n t r o d u c t i o n of new c o n c e p t s i n sewing machines by t h e i n c l u s i o n

of e l e c t r o n i c systems, s e r v i c e personnel must a l s o become aware of new
concepts i n procedures. C a r e l e s s probing o r trial and e r r o r methods may
e a s i l y c a u s e damage t o t h e e l e c t r o n i c systems. There must b e a thorough
u n d e r s t a n d i n g of t e s t equipment b e f o r e a t t e m p t i n g any e l e c t r o n i c t e s t i n g
o r adjustments. S e q u e n t i a l t e s t i n g must b e followed a s o u t l i n e d i n t h e
S e q u e n t i a l C h e c k l i s t and I n t e r l o c k i n g Adjustments.

METERS

The Volt-Ohm Milliammeter (VOM) i s designed t o measure t h e c h a r a c t e r i s -

t i c s of e l e c t r i c a l and e l e c t r o n i c c i r c u i t s i n a f a s h i o n s i m i l a r t o t h e
way gauges a r e used t o measure c h a r a c t e r i s t i c s of mechanical mechanisms.
The VOM i s a r e q u i r e d t o o l f o r t h e s e r v i c i n g o f t h e 2000623 machine.
P r o p e r t e s t i n g and a d j u s t m e n t s CANNOT BE MADE w i t h o u t t h i s meter.

Although t h e r e a r e many good meters a v a i l a b l e , only t h o s e w i t h t h e r e q u i r e d

degree of accuracy a r e a c c e p t a b l e . Most d i g i t a l m e t e r s a r e a c c e p t a b l e .
However, any meter f u l f i l l i n g t h e f o l l o w i n g s p e c i f i c a t i o n s c a n be used.

RANGES

DC M i l l i v o l t s AC V o l t s
0-250 MV minimum 0-2 -5-..O-50-250
S e n s i t i v i t y : 20,000 ohms p e r v o l t minimum Sensitivity:
5000 ohms p e r v o l t
DC V o l t s DC Milliamperes
0-1-2.5-10-50 0-1 -10
Sensitivity: 20,000 ohms p e r v o l t minimum 0 -100
OHMS 0-500
m 0-2,000 DC Amperes
moo 0-200,000 0-1 0
RXl0,OOO 0-20 megohms
Accuracy

DC V o l t a g e AC Voltages
A l l ranges 2% o r l e s s o f f u l l s c a l e A l l ranges 3% o r l e s s
DC Amperes of f u l l scale
A l l ranges 2% o r l e s s
of f u l l s c a l e

R e s i s t a n c e Ranges Analog Digital

RX1 0-2,000 ohms 2.5' o f a r c 1 .O%
RX100 0-200,000 ohms 2' of a r c 1 .O%
RX1000 0-20 megohms 2' o f arc 1 .O%

C o n s r u c t i o n o f Machine

C o n s t r u c t i o n c o n s i s t s o f a number o f modules and a s s e m b l i e s mounted

on t h e a r m and bed c a s t i n g . Each o f t h e s e is b r i e f l y d e s c r i b e d i n
t h e f o l l o w i n g p a r a g r a p h s and t h e i r l o c a t i o n s i l l u s t r a t e d .

The machine c o n t a i n s t h e f o l l o w i n g m e c h a n i c a l s y s t e m s .
HEAD-END ASSEMBLY AND HOOK - I l l u s t r a t i o n A. The head-end a s s e m b l y
i n c l u d e s t h e n e e d l e b a r and n e e d l e b a r v i b r a t i n g b r a c k e t , b a s t i n g
s t i t c h l a t c h , p r e s s e r f o o t and p r e s s u r e r e g u l a t i n g d i a l and mechanism
and b u t t o n h o l e t r i p p i n g l e v e r . The c e n t a u r hook i n c l u d e s t h e f r o n t
d r o p - i n bobbin and bobbin winding mechanism.

TENSION MODULE - I l l u s t r a t i o n B. The t e n s i o n module h a s a n a d j u s t a b l e

d i a l l o c a t e d u n d e r n e a t h t h e arm. A t e n s i o n r e l e a s e l e v e r u n d e r n e a t h
t h e module is o p e r a t e d by t h e p r e s s e r f o o t l e v e r when t h e p r e s s e r
f o o t is r a i s e d .

ALPHA FEED SYSTEM AND HOOK D R I V E - I l l u s t r a t i o n C. The Alpha f e e d

s h a f t i s d r i v e n by t h e hook d r i v e s h a f t t h r o u g h ears. Feed dog
motion is c o n t r o l l e d by e c c e n t r i c s o n t h e Alpha f e e d s h a f t . The f e e d
r e g u l a t o r c o n t r o l s t h e amount and d i r e c t i o n o f t h e f e e d . The hook
s h a f t is d r i v e n by t h e arm s h a f t t h r o u g h t h e t i m i n g b e l t .

ELECTRICAL SYSTEM - I l l u s t r a t i o n D. The motor d r i v e s t h e arm s h a f t

t h r o u g h a b e l t . Two r a n g e s o f speed are s e l e c t e d by a s w i t c h on
t h e a r m . Motor speed i n e a c h r a n g e is v a r i e d by a s o l i d s t a t e
(SCR) c i r c u i t c o n t r o l l e d by t h e f o o t c o n t r o l l e r .
The e l e c t r o n i c and e l e c t r o / m e c h a n i c a l s y s t e m s and t h e i r sequence o f
o p e r a t i o n c o n s i s t o f t h e following:

O p e r a t o r s e l e c t s p a t t e r n by f i r s t moving mode s w i t c h . T h i s s e l e c t s a
p a r t i c u l a r s t i t c h o u t o f a g r o u p o f f o u r and p l a c e s t h e d e s i r e d s t i t c h
i n p o s i t i o n t o be c a l l e d o u t o f memory. C a l l up i s performed by p u s h i n g
b u t t o n under d e s i r e d p a t t e r n which is h i g h l i g h t e d i n y e l l o w o n t h e
S e l e c t i o n P a n e l . I l l u s t r a t i o n A.

By means o f w i r i n g between t h e s e l e c t i o n p a n e l and Master C o n t r o l ( D i g i -

t a l P.C. B o a r d ) . I l l u s t r a t i o n B, t h e i n f o r m a t i o n is passed t o t h e d i g i -
t a l c o n t r o l c i r c u i t r y c o n t a i n e d i n t h e L.S.I. ( L a r g e S c a l e ~ n t e g r a t e d )
c h i p . The s e l e c t i o n s i g n a l is passed t h r o u g h a series o f l o g i c g a t e s
w i t h i n t h e L . S . I . and i s encoded i n t o a b i n a r y number. T h i s number i n
combination w i t h t h e b i n a r y i n f o r m a t i o n a l r e a d y s u p p l i e d by t h e mode
switch locks the s e l e c t i o n i n t o a l a t c h o r holding c i r c u i t .

The i n f o r m a t i o n t h e n g o e s i n t o t h e a d d r e s s memory where t h e a c t u a l l o c a -

t i o n a d d r e s s e s o f t h e p a t t e r n d a t a i n t h e main READ-ONLY MEMORY i s s t o r e d .
The R.O.M. i s t h e n a d d r e s s e d a n d , much l i k e s e l e c t i n g a r e c o r d i n a j u k e
box, t h e s t o r e d p a t t e r n d a t a is made r e a d y t o be f e d s t e p - b y - s t e p t o t h e
l i n e a r c i r c u i t r y Servo C o n t r o l and Power C i r c u i t y ( S e r v o P.C. Board), 11-
l u s t r a t i o n C , a f t e r c o n v e r s i c n t o an analog-type d a t a o u t p u t .

When t h e a d d r e s s memory mentioned above i n i t i a l l y g e t s t h e i n f o r m a t i o n , i t

p r o v i d e s a n i n f o r m a t i o n o u t p u t t o t h e LIGHT EMITTING DIODE v e r i f i c a t i o n
system on t h e L.E.D. P.C. board ( l o c a t e d above t h e s e l e c t i o n p a n e l ) , I l l u s -
t r a t i o n D. The a p p r o p r i a t e L.E.D. d r i v e r is a c t i v a t e d t h u s l i g h t i n g t h e
L.E.D. o v e r t h e p a t t e r n s e l e c t e d .

The s e r v o c o n t r o l and power c i r c u i t r y a c c e p t s d a t a i n a n a l o g ( c o n t i n u o u s

v o l t a g e ) form from t h e Master C o n t r o l ( D i g i t a l P.C. Board). The s i g n a l
p a s s e s t h r o u g h v a r i o u s c o n d i t i o n i n g and s h a p i n g s t a g e s and a r r i v e s a t
t h e i n p u t s t o t h e b i g h t , I l l u s t r a t i o n E, and f e e d , I l l u s t r a t i o n F,
l i n e a r m o t o r s , which, when p r o p e r d a t a is p r e s e n t e d , p o s i t i o n t h e
n e e d l e and f e e d p r o p e r l y .

From a p r e c i s i o n p o t e n t i o m e t e r ( v a r i a b l e r e s i s t a n c e ) coupled t o t h e
l i n e a r motor o u t p u t , a f e e d b a c k , o r error s i g n a l , i s g e n e r a t e d . T h i s
s i g n a l is r o u t e d back i n t o t h e l i n e a r c i r c u i t r y and a p p r o p r i a t e correc-
t i o n s a r e made s o t h a t t h e a c t u a l p o s i t i o n o f t h e s e r v o s c o r r e s p o n d s t o
t h e r e q u i r e d p o s i t i o n as programmed and s t o r e d i n t h e memory.
When sewing i s s t a r t e d by d e p r e s s i n g t h e f o o t c o n t r o l l e r , t h e p o s i t i o n
of t h e arm s h a f t i s fed t o t h e d i g i t a l c i r c u i t r y by means of a magnetic-
a l l y o p e r a t e d s e n s o r , I l l u s t r a t i o n G. A t t h e a p p r o p r i a t e time, when
t h e n e e d l e is o u t of t h e f a b r i c o r whep t h e f e e d dog i s down, b i g h t and
f e e d d a t a r e s p e c t i v e l y a r e e x t r a c t e d from t h e system.

Programmed i n t o t h e memory i s optimum i n f o r m a t i o n w i t h r e g a r d t o t h e

w i d t h and l e n g t h of t h e p a t t e r n . I f an a l t e r a t i o n i s d e s i r e d on t h e
programmed s t i t c h i n g , t h e o p e r a t o r touches t h e knobs on t h e O v e r r i d e
C o n t r o l s , (Override P.C. Board), I l l u s t r a t i o n H, s i g n a l i n g t h e l o g i c
i n t h e L.S.I. t o change c o n t r o l of width and l e n g t h from preprogrammed
( a u t o m a t i c ) t o completely manual. Reset t o a u t o m a t i c mode is accom-
p l i s h e d by r e - p r e s s i n g t h e p a t t e r n s e l e c t i o n b u t t o n . When t h e b i g h t
and f e e d o v e r r i d e s a r e a c t i v a t e d , a n L.E.D. l i g h t s up on t h e L.E.D.
board f o r each o v e r r i d e .

A s p a r t of t h e e l e c t r o n i c s package, t h e r e a r e m i s c e l l a n e o u s systems
which e i t h e r p r o v i d e i n p u t s , such a s t h e b u t t o n h o l e r s w i t c h , I l l u s t r a -
t i o n I, and t h e n e e d l e p l a t e s w i t c h , I l l u s t r a t i o n J, (which is p a r t of
t h e s t r a i g h t s t i t c h s a f e t y system) and t h o s e which a c c e p t o u t p u t s such
a s t h e n e e d l e b a r l o c k s o l e n o i d , I l l u s t r a t i o n K, and t h e s t r a i g h t
s t i t c h s o l e n o i d , I l l u s t r a t i o n L, ( a l s o p a r t of t h e s t r a i g h t s t i t c h
s a f e t y system).

The b u t t o n h o l e r s w i t c h works w i t h t h e one-step b u t t o n h o l e f o o t . The

b u t t o n h o l e p a t t e r n i s chosen by p r e s s i n g t h e a p p r o p r i a t e b u t t o n . The
machine is s t a r t e d , b a l a n c e is a d j u s t e d t o g i v e e q u a l f e e d ( d e n s i t y ) i n
b o t h d i r e c t i o n s , and t h e o p e r a t o r can t h e n proceed. Automatic r e v e r s e
o c c u r s a t t h e bottom of t h e b u t t o n h o l e and a u t o m a t i c s t o p ( n e e d l e up,
zero feed) occurs a t buttonhole closure. Second t i m e around o r addi-
t i o n a l b u t t o n h o l e s can be accomplished by r e p r e s s i n g t h e s i n g l e p a t t e r n
button. Both t h e b u t t o n h o l e p a t t e r n L.E.D. and s i n g l e p a t t e r n L.E.D.
w i l l l i g h t a s reminders of t h e r e p e a t procedure.

Needle b a r l o c k i n t h e UP p o s i t i o n i s used f o r i n i t i a l p a t t e r n starts,

c e r t a i n p a t t e r n s ( B a s t i n g , M a x i - s t r e t c h ) and machine s t o p s (end s i n g l e

memory .
p a t t e r n , end b u t t o n h o l e ) . A c t i v a t i o n is provided d i r e c t l y o u t of

The s t r a i g h t - s t i t c h s a f e t y system i n v o l v e s a s o l e n o i d which l o c k s o r

unlocks t h e n e e d l e b a r g a t e upon command. When t h e s t r a i g h t - s t i t c h
n e e d l e p l a t e o r c h a i n s t i t c h n e e d l e p l a t e is i n s e r t e d , t h e n e e d l e p l a t e
s w i t c h i s d e p r e s s e d , removing power from t h e s a f e t y s o l e n o i d , l o c k i n g
t h e g a t e and c l o s i n g a c o n n e c t i o n i n t h e s e m o c i r c u i t t o c e n t e r t h e
n e e d l e . Any n e e d l e p l a t e w i t h a z i g z a g opening meant f o r u s e i n t h e
2000623 h a s a r e c e s s c u t i n t o i t t o avoid l o c k i n g t h e n e e d l e b a r by n o t
depressing t h e switch.
 SECTION 2
ELECTRONIC TEST POINTS,
SEQUENCE OF ELECTRONIC AND
ELECTRO/MECHANICAL
ADJUSTENTS AND ELECTRONIC
TROUBLESHOOTING PROCEDURE
 ELECTRONIC TEST POINTS
The e l e c t r o n i c t e s t ~ o i n tc h a r t p r o v i d e s a d e s c r i p t i o n o f t h e t e s t
p o i n t s i n n u m e r i c a l s e q u e n c e o n l y and t h e r e a d i n g s t o be e x p e c t e d i f
a l l e l e c t r o n i c s y s t e m s a r e f u n c t i o n i n g , u n d e r optimum c o n d i t i o n s . Do
not attempt t o use t h e t e s t point c h a r t as a s u b s t i t u t e f o r trouble-
s h o o t i n g a n e l e c t r o n i c f a i l u r e . It i s p r o v i d e d o n l y a s a r e f e r e n c e
and t o f a m i l i a r i z e t h e t e c h n i c i a n w i t h t e s t p o i n t r e a d i n g c o n d i t i o n s
and p r o c e d u r e s . The t r o u b l e s h o o t i n g p r o c e d u r e d o e s n o t f o l l o w t h e
n u m e r i c a l s e q u e n c e of t e s t p o i n t s .

CAUTION :

Although t h e r e a r e many o t h e r t e s t p o i n t l o c a t i o n s o n t h e p r i n t e d
c i r c u i t b o a r d , o n l y t h o s e l i s t e d i n t h e f o l l o w i n g c h a r t s a r e t o be
u s e d f o r s e r v i c e . Do n o t a t t e m p t , u n d e r any c a n d i t i o n s , t o t a k e
v o l t a g e r e a d i n g s from a n y o t h e r t e s t p o i n t s . These t e s t p o i n t s a r e
used o n l y w i t h h i g h l y s p e c i a l i z e d t e s t equipment i n t i g h t l y c o n t r o l l e d
l a b o r a t o r y e n v i r o n m e n t s . Any a t t e m p t t o p r o b e t h e s e p o i n t s w i t h f i e l d
m e t e r s may c a u s e damage t o t h e a s s o c i a t e d c i r c u i t r y . It is important
t o n o t e t h a t when a t t a c h i n g p r o b e s t o t h e s e r v i c e t e s t p o i n t s , t h e
power m u s t b e o f f and t h e c o n n e c t i o n v e r i f i e d . I f an accidental
touching of a t e s t p o i n t n o t d e s i g n a t e d f o r s e r v i c e o c c u r s w i t h t h e
power on, s e v e r e and costly damage may result.

P r i n t e d c i r c u i t b o a r d l a y o u t s have b e e n p r o v i d e d t o a s s i s t i n l o c a t i n g
t h e t e s t p o i n t s and h a r n e s s p l u g s .

Never a t t e m p t t o t a k e v o l t a g e r e a d i n g s w i t h a n y t h i n g o t h e r t h a n approved
m e t e r s , a s o u t l i n e d i n S e c t i o n 1, G e n e r a l I n f o r m a t i o n .
 2005A -ELECTRONIC TEST POINTS -OVERRIDE BOARD

TEST EXPECTED ACCEPTABLE

POINT DESCRIPTION READING CONDITIONS OUTPUT RANGE

TP-1 GROUND OR COMMON USE FOR ALL TEST POINT 0 VOLTS

MEASUREMENTS FOR ALL
PRINTED CIRCUIT BOARDS.
CONNECT NEGATIVE METER
LEAD HERE.
TP-2 POSITIVE D.C.POWER NONE -
OUTPUT WILL VARY +15 VDC +15 VDC TO
VOLTAGE UNREGULATED WITH LINE VOLTAGE. +17 VDC
SUPPLY
-

TP-3 ..
POSITIVE D C NONE -
FACTORY PRESET +7.5 VDC +7.45 VDC TO
CONTROL VOLTAGE AND SEALED. REQUIRES +7.55 VDC
REGULATED SUPPLY DIGITAL METER TO SET (DIGITAL METER)
TO REQUIRED ACCURACY. +7.3 VDC TO
WHEN USING ANALOG +7.7 VDC
METER, READING TO BE (ANALOG METER)
TAKEN FOR VERIFICATION FOR VERIFICATION
ONLY PURPOSES ONLY

TP-4 NEGATIVE D.C. SAME COMMENTS AS FOR -7.50 VDC WITHIN0.150

CONTROL VOLTAGE TP-3. DEPENDS UPON VDC OF POSITIVE
REGULATED SUPPLY SETTING OF POSITIVE OUTPUT AT TP-2
CONTROL VOLTAGE (DIGITAL METER)
-7.3 VDC TO
-7 - 7 VDC
(ANALOG METER)
FOR VERIFICATION
PURPOSES ONLY

TP-5 NEGATIVE D.C. NONE -

OUTPUT WILL VARY -15 VDC -15 VDC TO
POWER VOLTAGE WITH LINE VOLTAGE. -17 VDC
UNREGULATED SUPPLY
 W i t h i n .150 VPC of
P o s i t i v e Output a t TP-2
-15 VDC TO -17 VDC
Negative D.C. Voltage Negative D.C. Voltage
Unregulated

+15 VDC TO +17 VDC +7.50 VDC %.05 VDC

P o s i t i v e D.C. Voltage b s i t i v e D.C. Voltage
Unregulated

C o m n o r Ground

J-24 J-l R*

I
/

O V E R R I D E BOARD AS V I E W E D FROM COMPONENT S I D E

~ e $ t h Override O f f
+4.0 VDC TO +5.0 VDC \
Length Override On

-7.3 VDC TO -7.7 VDC

\ -7.3 VDC TO -7.7 VDC
Bight Override Off
Forward Feed
6 . 4 VDC TO +6.8 VDC +4.0 VDC TO +5.0 VDC
Reverse Feed Bight Override On

\ o m am
S t i t c hVDC
+1.80
- Width i a l VDC
+1.90
TO B CW

Note: Use Ric-Rac P a t t e r n f o r Test p i n t s 7 t h r u 13

. CW = CLOCKWISE

I CCW = COUNTERCLOCKWISE
 2 0 0 5 A -ELECTRON\C TEST PO\NTS -OVERRIDE BOARD

TEST EXPECTED ACCEPTABLE

DESCRIPTION READING CONDITIONS OUTPUT RANGE
POINT

TP-7 STITCH LENGTH PLACE MACHINE I N R I C 0 VOLTS

WTENTI OMETER RAC PATTERN. FEOTATE DIAL FULL
MOVABLE ARM ARM SHAFT THROUGH CNE COUNTER-
REVOLUTION. ?URN CLOCKWISE
STITCH LENGTH DIAL TO +1.6 VDC
-
GET OUTPUTS POLARITY. DIAL FULL
DEPENIX; UPON MOTOR
FOSITION. CLOCKWISE

TP-8 BALANCE COhTROL PLACE MACHINE I N R I C -7.5 VDC -7.3 VDC TO

ACTIVATION RAC PATTERN. ROTATE FORWARD -7.7 VDC
ARM SHAFT TO CBTAIN FEED
MRWARD AND REVERSE +6.6 VDC 6 . 4 VDC TO
FEED W S I T I O N S . REVERSE 6 . 8 VDC
FEED
-

TP-9 MANUAL BIGHT PLACE MACHINE I N R I C -7.5 VDC -7.3 VDC TO

C r n O L ACTIVATION RAC PATTERN. ROTATE OVERRIDE -7.7 VDC
ARM SHAFT THROUGH CNE OFF
REVOLUTION. +4.5 VDC +4.0 VDC TO
OVERRIDE +5.0 VDC
C
N

TP-10 STITCH WIDTH PLACE MACHINE I N R I C 0 VOLTS

(BIGHT) RAC PATTERN. ROTATE DIAL FULL
FOTENTIWETER ARM SHAFT THROUGH ONE COUNTER-
MOVARLE ARM REVOLUTION. ?UPa CLOCKWISE
STITCH WIDTH CIAL TO +1.85 VDC
- +1.80 VDC TO
-
GET OUTPUI'S. POLARITY DIAL FULL +1.90 VDC
-
DEPENDS UPON MOTOR
POSITION. CLOCKWISE I
I

TP-11 MANUAL STITCH PLACE MACHINE I N R I C -7.5 VDC -7.3. - VDC TO

LENGTH CONTROL
ACTIVATION
RAC PATTERN.

REVOLUTION.
ROTATE
ARM SHAFT THROUGH ONE OVERRIDE
OFF
+4.5 VDC
1 -7*7
+4.0 VDC TO
OVERRIDE +5.0VDC
ON
 2005A -ELECTRONIC TEST POINTS -OVERRIDE BOARD

TEST EXPECTED
POINT DESCRIPTION I READING CONDITIONS

BALANCE PLACE MACHINE I N R I C 0 VOLTS

POTENTIOMETER RAC PATTERN. ROTATE DIAL FULL
OUTPUT ARM SHAFT TO CBTAIN COUNTER-
FOR9JARD AND REVERSE CLOCKWISE
FEED POSITIONS. ?URN rnrnRRD
BALANCE DIAL TO GET FEED.
OUTPUT I N BOTH 0 VOLTS
FORWARD AND REVERSE DIAL FULL
FEEDING DIRKTIONS. CLOCKWISE
FORWARD
FEED
+7.5 VDC +7.3 VDC TO
DIAL FULL +7.7 VDC
COUNTER-
CLOCKWISE
REVERSE
FEED
-7.5 VM3 -7.3 VDC TO
DIAL FULL -7.7 VDC
CLOCKWISE
REVERSE
FEED
BALANCE PATTERN SELECTION +7.5 VDC +7.3 VDC To
POTENTIOMETER UNIMFORTANT. ANY ONE DIAL FULL +7.7 VDC
MOVABLE ARM WILL SUFFICE. 'IURN COUNTER-
BALANCE DIAL TO GET CLOCKWISE
OUTPVT. -7.5 VDC -7.3 VDC TO
DIAL FULL -7.7 VDC
CLOCKWISE
 0 VDC CCW TO CW
+7.3 VDC TO +7:7 VDC CCW Fofward Feed
-7.3 VDC TO -7.7 VDC CW +7.3 VDC TO +7.7 VDC CCW
Balance Dial -7.3 VDC TO -7.7 VDC CW
Reverse Feed
Balance Dial

- -
I
41
I
/ \

I
0 . I
\

I
\ /
-
\
- 0

- Q10
- \
.*

/
I

OVERRIDE BOARD A S V I E W E D FROM COMPONENT S I D E

Note: Use Ric-Rac Pattern f o r Test p i n t s 7 t h r u 13

CW = CLOCKWISE
CCW = COUNTERCLOCKWISE
~ t r a i g E tS t itch-Single P a t t e r n ~ t r a i g f i tStitch-Single P a t t e r n
+.920 VDC +.005 VDC 1 / +.920 VDC +.010 VDC
Ric-Rac ~ e v e r s eFeed
I /
/
Ric-Rac ~ i $ t Needle

ZERO A
T T

SCALE 49108
0000

1 Sensor off
-5.8 VDC TO -6.2 VDC
Sensor On

LOGIC BOARD AS V I E W E D FROM COMPONENT SIDE

 2005A -ELECTRONIC TEST POINTS --LOGIC BOARD

TEST EXPECTED ACCEPTABLE

POINT DESCRIPTION READING CONDITIONS OUTPUT RANGE

TP-2 ARM SHAFT ROTATE ARM SHAFT TO +6 VDC +5.8 VDC TO

POSITION GET OUTPUT. SENSOR SENSOR ON +6 - 2 VDC
INDICATOR MUST CHANGE FROM -6 VDC -5.8 VDC TO
POSITIVE OUTPUT TO SENSOR -6.2 VDC
NEGATIVE OUTPUT OFF
ONCE PER REVOLUTION.

TP-8 BIGHT OUTPUT PLACE MACHINE I N 0 VDC -

+.005 VDC
STRAIGHT STITCH SINGLE
PATTERN. ROTATE ARM
SHAFT THROUGH SEVERAL
REVOLUTIONS

PLACE MACHINE I N RIC +.920 VDC +.910 VDC TO

RAC PATTERN. ROTATE +.930 VDC
ARM SHAFT TO BRING (DIGITAL METER)
NEEDLE TO RIGHT NEEDLE +.900 VDC TO
POSITION. +.940 VDC
(ANALOG METER)

TP-9 FEED OUTPUT PLACE MACHINE I N 0 VDC +.005 VDC

-
STRAIGHT STITCH
SINGLE PATTERN
ROTATE ARM SHAFT
THROUGH SEVERAL
REVOLUTIONS

PLACE MACHINE I N RIC +.920 VDC +.915 VDC TO

RAC PATTERN. ROTATE +.920 VDC
ARM SHAFT TO BRING (DIGITAL METER)
FEED TO REVERSE FEED. +.900 VDC TO
+.940 VDC
(ANALOG METER)
 2 0 0 5 A -ELECTRONIC TEST POINTS -LOGIC BOARD

1
TEST EXPECTED ACCEPTABLE
POINT DESCRIPTION READING CONDITIONS OUTPUT RANGE

TP-12 SAFETY SOLENOID DEPRESS NEEDLE PLATE -15 VDC -15 VDC TO
CATHODE SWITCH WITH MACHINE I N SOLENOID -17 VDC
LEAD OF R I C RAC. ROTATE ARM OFF
DIODE SHAFT THROUGH SINGLE
CR-2 REVOLUTION.

RELEASE NEEDLE PLATE 0 VDC

SWITCH. SOLENOID
ON

TP-13 NEEDLE BAR RELEASE PLACE MACHINE I N +15 VDC +15 VDC TO
ANODE SOLENOID STRAIGHT STITCH. SOLENOID +17 VDC
LEAD OF OFF
DIODE
CR- 1 PUSH SINGLE PATTERN. 0 VDC
ROTATE ARM SHAFT SOLENOID
THROUGH SINGLE
REVOLUTION
 -15 VDC TO -17 vDc OFF
Safety Solenoid

/ +15 VDC TO +17 VDC OFF

0 VDC CN
Needle Release Solenoid

LOGIC BOARD AS V I E W E D F R O M C O M P O N E N T SIDE

 k2.2 VDC Maximum

\ -t2.2 VDC Maximum

Honeycomb

S E R V O BOARD A S V I E W E D F R O M C O M P O N E N T SIDE
2005A -ELECTRONIC TEST POINTS -SERVO BOARD
SEQUENCE OF ELECTRONIC
AND ELECTRO/MECHANICAL
ADJUSTMENTS
S i n c e n e e d l e , f e e d and v a r i o u s o t h e r f u n c t i o n s a r e c o n t r o l l e d by t h e
e l e c t r o n i c s , i t is i m p o s s i b l e t o d e t e r m i n e whether many o f t h e mechanical
a d j u s t m e n t s a r e c o r r e c t w i t h o u t first v e r i f y i n g t h e e l e c t r o n i c c o n t r o l
systems. T h e r e f o r e , any machine r e c e i v e d f o r s e r v i c e , must have t h e e l e c -
t r o n i c systems v e r i f i e d a s o u t l i n e d i n t h e "Sequence of E l e c t r o n i c and
Electro/Mechanical Checks and Adjustmentsw, b e f o r e a t t e m p t i n g any f u r t h e r
adjustments.
 S E Q U E N C E OF E L E C T R O N I C A N D ELECTRO/MECHANICAL CHECKS A N D ADJUSTMENTS
1. GROUND OR COMMON

1 1 CONNECT NEGATIVE LEAD FRCM METER TO TP-1 CN 'THE OVERRIDE BOARD.

USE FOR ALL TEST POINT MEASUREMENTS AND AI;UUSlP'lENTS.

2. POSITIVE J
X REGULATED VOLTAGE
2.1 METER ON D.C.V. 10 VOLT RANGE.

2.2 C O W C T POSITIVE LEAD T O T P 3 0 N 'THE OVERRIDE BOARD.

2.3 READING:+7.50 V.D.C. -

+.05 V.D.C.

3. NEGATIVE D=: RM;ULATED VOLTAGE

3.1 METER (3N D.C.V. 1 0 VOLT RANGE

3.2 CONNECT POSITIVE LEAD TOTP-4CP\J THE LOGIC BOARD.

3.3 READING WITHIN 0 . 1 5 0 V.D.C. OF OUTPUT ATTP3BUI' OPFOSITE I N

POLARITY. POSSIBLE RANGE -7.30 V.D.C. TO -7.70 V.D.C. IF
READING A T T P - 3 1 s WITHIN SPECIFICATION.

3.4 NO ADJUSTMENT FOR VERIFICATION PURPOSES CNLY.

OVERRIDE BOARD AS VIEWED FROM COMPONENT S I D E
LOGIC BOARD AS VIEWED FROM COMPONENT SIDE
 SEQUENCE OF ELECTRONICAND ELECTRO/MECHANICAL CHECKS AND ADJUSTMENTS

4. B I G H T OUTPUT

4.1 METER D.C.V. M I L L I V O L T RANGE.

4.2 CONNECT P O S I T I V E LEAD T O TP-8 ON THE L O G I C BOARD

4.3 S E L E C T S T R A I G H T S T I T C H AND S I N G L E P A T T E R N *

4.4 ROTATE ARM S H A F T SEVERAL T I M E S .

4.5 READING: 0 V.D.C. -

+.005 V.D.C.

4.6 A D J U S T P O T E N T I O M E T E R U - 5 O N THE L O G I C BOARD.

4.7 METER D.C.V. M I L L I V O L T RANGE.

4.8 SELECT RIC- RAC PATTERN.

4.9 ROTATE ARM S H A F T SEVERAL T I M E S TO B R I N G NEEDLE TO R I G H T NEEDLE

POSITION.

4.10 READING +.920 V.D.C. -

+.010 V.D.C.

4.11 A D J U S T P O T E N T I O M E T E R U - 6 ON THE L O G I C BOARD.

5. F E E D OUTPUT

5 -1 METER D .C .V. M I L L I V O L T RANGE.

5.2 CONNECT P O S I T I V E LEAD T O T P . 9 O N THE L O G I C BOARD.

5.3 S E L E C T RIC-RAC PATTERN AND S I N G L E PATTERN.

5-4 ROTATE ARM S H A F T SEVERAL T I M E S .

5.5 READING: 0 V.D.C. +.005

- V.D.C.

5.6 A D J U S T P O T E N T I O M E T E R U - 3 ON THE LOGIC BOARD.

5.7 S E L E C T R I C RAC PATTERN.

5.8 ROTATE ARM S H A F T SEVERAL T I M E S TO B R I N G F E E D T O REVERSE F E E D .

5.9 READING: +.920 V.D.C. +.005 V.D.C.

-
5-10. A D J U S T P O T E N T I O M E T E R U - 4 0 N THE L O G I C BOARD.
 d

SEQUENCE OF ELECTRONIC AND ELECTRO/MECHANICAL CHECKS AND ADJUSTMENTS

6. BIGHT MECHANISM BIND TEST

6.1 METER D.C.V. 10 VOLT RANGE.

6.2 CONNECT POSITIVE LEAD TO TP-15 ON THE SERVO BOARD.

6.3 SELECT HCNEYCOMB.

6.4 ROTATE AFM'SHAFT AT LEAST S I X COMPLETE REVOLVTIWS WHILE

CBSERVING METER.

6.5 READINGS: +2.2 V.D.C. MAXIMUM. READING I N EXCESS OF 2.2.

V.D.C. I N D I ~ T E S A BIND IN THE BIGHT SYSTEM AND MOVING PARTS.
CHECK ALL FRICTIONAL SURFACES AND MOVING PARTS OF THE BIGHT
MECHANISM FOR BINDING OR 1NTERFERENCES;SUCH AS BALL JOINT
CONNECTION, NEEDLE BAR BEARINGS, NEEDLE BAR DRIVING A m , EX.

6.6 I F UNABLE TO REDUCE VOLTAGE BELOW +2.2 V.D.C., DISCONNECT

NEEDLE BAR DRIVE AFM mm LINEAR BTGHT MOTOR AND REHECK
VOLTAGE READING. +1.0 V.D.C. MAXIMUM. m R S READIIG OVER
MAXIMUM ARE m BE REPLACED.

7. FEED MECHANISM BIND TEST

7.1 METER D.C.V. 10 VOLT RANGE.
7.2 CONNECT POSITIVE LEAD TO TP-8 ON THE SERVO BOARD.

7.3 SELECT HCNEYCCEIB.

7.4 ROTATE AWvI SHAFT AT LEAST S I X CCmPLETE REVOLUI'IONS WHILE

CBSERVING METER.

7.5 READING: +2.2 V.D.C. MAXIMUM. READINGS I N EXCESS QF 2 . 2 -

V. D.C. I ~ I C A T E A BIND IN THE FEED SYSTEM. C H E K ALL FRICTIONAL
SURFACES AND MOVING PARTS OF THE FEED MECHANISM EDR BINDINS OR
INTERFERENCES; SUCH AS FEED REGULATOR AND SLIDE BLCCK, FEED BAR
CONNECTING LINK, FEED BAR PIVOTS, E X .

7.6 I F UNABLE TO REDUCE VOLTAGE BELOW +2.2 V.D.C, DISCONNECT

FEED DRIVE LINK FROM LINEAR FEED M-~I'OR AND RECHECK VOLTAGE
READING. +l.OV.D.C. MAXIMUM. MOTORS READING OVER MAXIMUM
ARE TO BE %PLACED.
TP- 15 TP- 8

SERVO BOARD AS VIEWED FROM CIRCUIT SIDE

 SEQUENCE OF ELECTRONIC AND ELECTRO/MECHANICAL CHECKS AND ADJUSTMENTS ,

8. BUTTONHOLE SWITCH ADJUSTMENT

8.1 USING ONE-STEP BUTTONHOLE FOOT WITH UNDERPLATE, BUTTONHOLE

FOOT SET FOR ONE INCH BUTTON DIAMETER, SEW LEFT FORWARD LEG OF
BUTTONHOLE. VERIFY BUTTONHOLE I S OF CORRECT LENGTH BETWEEN
+ 1,588MM).
+ 1 / 1 6 " (28,575MM -
BAR TACKS, 1-118" -

8.2 I F BUTTONHOLE LENGTH REQUIRES ADJUSTMENT LOOSEN SCREW D AND NUT

CMAINTAINING A SLIGHT PINCH ON NUT c FOR CONTROL PURPOSES.
I F BUTTONHOLE I S TOO LONG PIVOT BUTTONHOLE SWITCH FROM THE TOP
TOWARD THE REAR OF THE MACHINE. I F I T I S TOO SHORT, PIVOT
TOWARD THE FRONT OF THE MACHINE. TIGHTEN NUT C AND SCREW D .
RECHECK FOR PROPER LENGTH AND READJUST I F NECESSARY.

8.3 MAKING SURE THAT THE FEED DOG I S BELOW THE THROAT PLATE AND
THE BUTTONHOLE FOOT I S COMPLETELY FORWARD AGAINST THE STOP,
TURN SCREW B IN (CLOCKWISE) UNTIL THE SCREW TOUCHES THE OUTER
CONTACT A .

8.4 TURN ADJUSTING SCREW 6 OUT 1 1 2 A TURN.

8.5 SEW TEST SEVERAL BUTTONHOLES FOR PROPER CLOSURE. I F NECESSARY

TURN SCREW 6 SLIGHTLY I N TO DELAY CLOSURE AND SLIGHTLY OUT TO
ADVANCE CLOSURE.

8.5 SEW SEVERAL BUTTONHOLES WITH BALANCE CONTROL DIAL I N NEUTRAL

(POINT OF DIAL ON CENTER GRAPHIC MAPXI. CHECK THAT BOTH LEGS OF
BUTTONHOLE CONTAIN AN EQUAL NUMBER OF STITCHES (BALANCED).
ADJUST MECHANICAL ZERO FEED I F BUTTONHOLE LEGS ARE NOT BALANCED
WITHIN 1 0 STITCHES OF ONE ANOTHER.
 ELECTRONIC
TROUBLESHOOTING
PROCEDURE
The f o l l o w i n g pages p r o v i d e t h e e l e c t r o n i c t r o u b l e s h o o t i n g procedure.
Because i t has been found from e x p e r i e n c e t h a t i t i s seldom more t h a n
one e l e c t r o n i c system t h a t f a i l s a t a time, each system has been broken
a p a r t s e p a r a t e from t h e o t h e r s . For t h o s e systems which r e q u i r e v e r i f i -
c a t i o n of o t h e r systems covered e a r l i e r i n t h e p r o c e d u r e , r e f e r e n c e i s
made back t o t h o s e systems r a t h e r t h a n r e p e a t t h e e n t i r e procedure.

T h e r e f o r e , i t would s e r v e t h e s e r v i c e p e r s o n w e l l t o memorize c e r t a i n
b a s i c t e s t procedures, such a s t h e "Power Supply V e r i f i c a t i o n " procedure
which must b e checked r e g a r d l e s s of which systems may have f a i l e d .

When t r o u b l e s h o o t i n g a n e l e c t r o n i c f a i l u r e , i t i s e s s e n t i a l t h a t t h e
s e q u e n t i a l o r d e r of t r o u b l e s h o o t i n g be followed. F a i l u r e t o do s o may
r e s u l t i n t h e replacement of a n i n c o r r e c t e l e c t r o n i c assembly and
produce f u r t h e r c o s t 1y f a i l u r e s .

The F u n c t i o n a l T e s t must always precede any t r o u b l e s h o o t i n g procedure.

I f t h e machine p a s s e s t h e F u n c t i o n a l T e s t , procede d i r e c t l y t o t h a t
system which h a s f a i l e d , i . e . S a f e t y S o l e n o i d , DC Regulated C o n t r o l
Voltage, e t c .

Once an e l e c t r o n i c f a i l u r e has been diagnosed and t h e r e q u i r e d assembly

r e p l a c e d , i t cannot b e assumed t h a t a l l o t h e r a d j u s t m e n t s , whether
e l e c t r o n i c , e l e c t r o / m e c h a n i c a l o r mechanical a r e c o r r e c t . It i s mandatory
t h a t any 2005A machine r e c e i v e d f o r s e r v i c e o r which h a s had p a r t s
r e p l a c e d , mechanical o r e l e c t r o n i c , be checked a c c o r d i n g t o t h e "Sequence
of E l e c t r o n i c and Electro/Mechanical Adjustments" and t h e " S e q u e n t i a l
C h e c k l i s t and I n t e r l o c k i n g Adjustments" S e c t i o n 3.
 FUNCTIONAL TEST
n

1. Turn machine on. I f machine e x h i b i t s a l o u d b u z z i n g n o i s e , immedi-

a t e l y t u r n machine o f f . Check f o r d e f e c t i v e f i l t e r c a p a c i t o r s by
r e p l a c i n g w i t h a known good assembly. Turn machine on. I f buzzing
c o n t i n u e s , t u r n machine o f f and check f o r a l o o s e t r a n s f o r m e r
harness connection.

2. With t h e power s w i t c h on, i f t h e motor runs and t h e sewing l i g h t

comes on b u t i t i s n o t p o s s i b l e t o s e l e c t p a t t e r n s , check f o r a
tripped or defective c i r c u i t breaker. I f the c i r c u i t breaker i s
O.K., check f o r opens i n t h e t r a n s f o r m e r primary h a r n e s s o r
windings.

3. I f t h e c i r c u i t b r e a k e r h a s t r i p p e d o r f a i l e d , check f o r s h o r t s i n
motor c o n n e c t o r h a r n e s s and t r a n s f o r m e r p r i m a r y and s e c o n d a r y
h a r n e s s o r winding. I n s p e c t o v e r r i d e b o a r d f o r any f o r e i g n m a t e r i a l
which may b e i n c o n t a c t w i t h component l e a d s o r c o n n e c t i o n s . Inspect
a l l h a r n e s s e s t o b e s u r e none a r e pinched and grounded t o t h e c a s t i n g .

4. Turn machine on. Check t h a t sewing l i g h t i s l i t . S e l e c t a l l

p a t t e r n s and v e r i f y t h a t each p a t t e r n L.E.D. l i g h t s . S e l e c t Ric-Rac
and a c t i v a t e o v e r r i d e s . V e r i f y t h a t o v e r r i d e L.E.D.'s are lit. If
any one o r more of t h e L.E.D.'s a r e not l i t , r e f e r t o Troubleshooting
P r o c e d u r e s e c t i o n , L.E.D. Display.

,-

L
 SEWING LIGHT

TEST
LOCATION TEST PO INTS CORRECTION

CHECK FILAMENT FOR 5t IF NOT 0.K. REPLACE BULB.

CONTINUITY IF QK.

CHECK FOR PROPER

CON N ECTl ON
- IF NOT O.K. RECONNECT
HARNESS., IF O.K.
1

CHECK FOR PROPER I F NOT O.K., RECONNECT.

CONNECTION OF I F O.K.
MATE-N-LOCK CONNECTOR

t
READ NOMINAL AC L I N E
VOLTAGE AT MOTOR SIDE OF
MATE-N-LOCKCONNECTOR
- IF QK. REPLACE
LIGHT HARNESS.
I F NOT O.K.,

CHECK FOR PROPER

OR CONNECTOR ?INS PUSHED

INSIDE MOTOR HOUSING.
-
CONNECTION OF L I N E PLUG
I F NOT O.K., RECONNECT
OR RELOCATE
CONNECTOR PIN.
I F O.K., REPLACE MOTOR.
 . .
. t)
.-k .
' .-*
;F,i

*
;
.. :
.,*.: -
.&
., .-:.'. : u;
II ..

1 1..{j;,
.:.
.
. .-.-, ,?'*
,.
,i..

.
?

. '3

. ..
.
.....&, 'Ck
 PINS FOR
PLUG J-6
1 2 3 4 5 6 7 8 10

SERVO BOARD AS VIEWED FROM CIRCUIT SlDE

OVERRIDE BOARD AS VIEWED FROM COMPONENT SlDE

 ? I S V DC UNREGULATED POWER SUPPLY VERIFICATION
S E R V O BOARD

TEST
LOCAT ION TEST POINTS CORRECTION

NOTE: FOR THE FOLLOWING TESTS USE RESISTOR L E A D @ ON T H E SERVO BOARD FOR GROUND OR
COMMON.

SERVO
BOARD
* CONNECTOR
READ AT P L U G J - 6
PINS
---------)c I F O.K., NO F U T H E R
CHECK REQUIRED
P I N 8 / 1 0 t 1 5 V DC TO t 1 7 V DC I F NOT O.K.,
P I N 4 / 5 -15V OC TO -17VOC

NOTE : FOR THE FOLLOWING TESTS, USE T P - I ON T H E OVERRIDE BOARD FOR GROUND OR
COMMON.

BOARD
TP-2 t l 5 V DC TO + l 7 V DC
TP-5 -15V DC TO -17V DC
- I F O.K., R E P L A C E
POWER' H A R N E S S
I F NOT O.K.,

R E A D AT TRANSFORMER
CONNECTORS
J - 2 12V AC N O M I N A L
J-3 I Z V A C N O M I N A L
- I F O.K., R E P L A C E
OVERRIDE BOARD.
I F NOT O.K.,
CHECK FOR A TRIPPED
OR FAILED CIRCUIT
BREAKER, OPENS I N
MOTOR CONNECTOR AND
TRANSFORMER HARNESS
OR FAILED TRANSFORMER.
 ~ UNREGULATED POWER SUPPLY VERIFICATION
2 1 5 DC
LOGIC B O A R D
1 7
TEST
LOCATION T E S T POINTS CORRECTION

N O T E : FOR THE FOLLOWING TESTS USE T P - I ON THE OVERRIDE BOARD FOR GROUND OR COMMON.

LOGIC
BOARD
@CAPACITOR C s - I 5 V DC T O -17V DC

@ CAPACITOR C 6 C15V DC TO + l 7 V DC
-
IF O.K., NO FUTWER CHECK
REQUIRED.
I F NOT O.K.,

T P - 2 +15V DC TO +17V DC
T P-5 -15V DC TO -17V DC
- I F O.K., R E P L A C E POWER
HARNESS.
I F NOT O.K.,

-
@ R
CONNECTORS
E A D AT TRANSFORMER
J-2 12VAC N O M I N A L
J-3 12VAC N O M I N A L
IF
O V O.K.,
E R R I DREE P
I F NOT O.K.,
3OARD.

CHECK FOR A TRIPPED

OR FAILED CIRCUIT
LACE

BREAKER, OPENS I N
MOTOR CONNECTOR AND
TRANSFORMER HARNESS
OR F A I L E D TRANSFORMER.
 ZERO
CI 6

SCALE

ICALE

LOGIC BOARD AS V I E W E D F R O M C O M P O N E N T SIDE

 PINS FOR
PLUG 5-6

SERVO BOARD AS VIEWED FROM C I R C U I T SIDE

TP-4
0TP-3 TP-I

OVERRIDE BOARD A S VIEWED F R O M COMPONENT SIDE

 DC REGULATED CONTROL VOLTAGE V E R I F I C A T I O N AND ADJUSTMENT

SERVO BOARD

TEST
LOCATION TEST POINTS CORRECTION

NOTE: FOR THE FOLLOWING TESTS USE RESISTOR L E A D @) ON THE SERVO BOARD FOR GROUND
OR COMMON.

SERVO VERIFY +15V DC UNREGULATED POWER IF NOT O.K., REFER TO

BOARD SUPPLY ON THE SERVO BOARD. i 1 5 DC~ UNREGULATED
READ AT PLUG J - 6 POWER SUPPLY
CONNECTOR PINS VERIFICATION
P I N 8 / 1 0 +15V DC TO +17V DC BOARD.
P I N 4 / 5 -15V DC TO -17V DC I F O.K.,

I
READ AT PLUG J-6
CONNECTOR PINS
P I N 2 + 7 . 5 0 ~ 0 C ? . 0 5DC
P I N 3 -7.50V 0 C ? . 0 5 ~OC
~
- IF O.K., NO FURTHER
CHECK IS REQUIRED
I F NOT O.K.,
ADJUST TRIM
POTENTIOMETER U-I ON
THE OVERRIDE BOARD TO
NOTE: THE NEGATIVE REGULATED DC BRING POSITIVE DC
VOLTAGE SHOULD BE WITHIN 0.150V DC CONTROL VOLTAGE WITHIN
OF THE POSITIVE REGULATED VOLTAGE, SPECIFIED RANGE. ADJUST
WHEN THE POSITIVE REGULATED ONLY I F DIGITAL METER IS
VOLTAGE IS WITHIN SPECIFIED RANGE. A V A I L A B L E . IF DIGITAL
METER I S NOT AVAILABLE,
OR I F U N A B L E TO ADJUST
WITHIN SPECIFIED
TOLERANCE, REPLACE
OVERRIDE BOARD.
I F VOLTAGE IS NOT PRESENT

I N O T E : FQR T H E FOLLOWING TESTS USE T P - I ON THE OVERRIDE BOARD FOR GROUND

-
OR COMMON.

T P - 3 + 7 . 5 0 V DC i . 0 5 ~DC I F O.K.,
T P - 4 -7.50V DC 2 . 0 5 V DC REPLACE POWER HARNESS
ADJUST AS DESCRIBED
ABOVE.
I F NOT O.K., REPLACE
OVERRIDE BOARD.
 DC REGULATED CONTROL VOLTAGE VERIFICATION AND ADJUSTMENT

LOGIC BOARD
TEST
LOCAT l ON TEST POINTS CORRECTION
NOTE: FOR THE FOLLOWING TESTS USE TP-I O N T H E O V E R R I D E B O A R D FOR GROUND OR COMMON.

LOG l C
BOARD
VERIFY ?15V DC UNREGULATED POWER
SUPPLY ON T H E LOGIC BOARD.
@CAPACITOR c5 - 1 5 v DC TO - 1 7 v DC
-I F NOT O.K., R E F E R TO
t 15V DC UNREGULATED
POWER SUPPLYLOGIC
VERIFICATION
BOARD.
@ C A P A C I T O R C 6 C15V DC TO C17Y DC I F O.K.,

@ LOG lC
BOARD
- @CAPACITOR

@CAPACITOR
c I +7.50v
c
I - 7 . 5 0 V DC ?.O5V DC
DC i . 0 5 ~DC -IF ox., NO FUTHER CHECK
NOTE: T H E NEGATIVE R E G U L A T E D DC
VOLTAGE SHOULD B E W I T H I N 0 . 1 5 0 V DC
OF T H E P O S I T I V E R E G U L A T E D VOLTAGE,
W H E N THE P O S I T I V E R E G U L A T E D
VOLTAGE IS W I T H I N S P E C I F I E D RANGE.
IS REQUIRED
IF NOT o.K., A D J U S T T R I M
P O T E N T I O M E T E R U-l ON
T H E O V E R R I D E B O A R D TO
BRING P O S I T I V E DC
CONTROL VOLTAGE WITHIN
SPECIFIED RANGE. ADJUST
ONLY I F D I G I T A L M E T E R
IS A V A I L A B L E . I F D I G I T A L
M E T E R I S NOT A V A I L A B L E ,
OR I F U N A B L E TO A D J U S T
WITHIN SPECIFIED
TOLERANCE. REPLACE
OVERRIDE BOARD.
I F VOLTAGE IS NOT PRESENT.

@ OVERRIDE
BOARD
- T P - 3 + 7 . 5 0 V DC 2 . 0 5 ~DC
T P - 4 - 7 . 5 0 V DC 2 . 0 5 ~DC
- I F O.K., R E P L A C E POWER
H A R N E S S A N D A D J U S T AS
DESCRIBED A B O V E . ,
I F NOT O.K., R E P L A C E
OVERRIDE BOARD.
 LOGIC BOARD A S V I E W E D F R O M COMPONENT SlDE

TP- 4 @ TP-3 TP-I

OVERRIDE BOARD AS VIEWED FROM COMPONENT SlDE

 I
ZERO 1
T T

CI

SCALE

1 2 3 4 5 6.7 8 9 10111213

P l N S FOR
PLUG J-ll

LOGIC BOARD AS VIEWED F R O M COMPONENT SIDE

 L.E.D. DISPLAY

TEST
LOCATlON TEST POINTS CORRECTION

NOTE: FOR THE FOLLOWING TESTS USE TP-l ON THE OVERRIDE BOARD FOR GROUND OR COMMON.

BUTTON
CARRIER
VERIFY FUNCTION OF ALL L.E.D.'S - IF ANY ONE OR MORE BUT
NOT A L L OF THE L.E.D.'~
DO NOT LIGHT AND MACHINE
FUNCTION I S CORRECT,
REPLACE L.E.D. BOARD.
IF NONE OF THE L.E.D.'S
LIGHT.

--.
@/kgib: VERIFY DC REGULATED CONTROL
VOLTAGE
IF NOT O.K., REFER TO DC
REGULATED CONTROL
VOLTAGE VERIFICATION
1 ~ f. O O ~ VDC
CAPACITOR C I t 7 . 5 0 DC AND ADJUSTMENT LOGIC
BOARD.
@ CAPACITOR Cl-7.50V DC +.OOSV DC I F O.K.,

READ AT PLUG J - l l
CONNECTOR PINS
P I N 7 -7.50V DC k . 0 5 ~DC
P I N 10-7.50V DC C . 0 5 ~DC
- I F O.K., REPLACE L.E.D.
BOARD.
I F NOT O.K., REPLACE
LOGIC BOARD
 -
SAFETY SOLENOID

TEST
LOCATION TEST POINTS CORRECT ION
NOTE: FOR THE FOLLOWING TESTS USE T P I ON THE OVERRIDE BOARD FOR GROUND OR COMMON.

El-- LOGIC
BOARD
C-5 -15V DC TO

C - 6 +15V DC TO
- IF NOT O.K., REFER TO
2 1 5 V DC UNREGULATED
POWER SUPPLY
VERIFICATION LOGIC
BOARD.
I F O.K.,

6 LOGIC
BOARD
- TP-I2
NEEDLE P L A T E SAFETY SWITCH
DEPRESSED (SOLENOID OFF).
-15V DC TO -17V OC
- I F THERE IS NO CHANGE
I N VOLTAGE

NEEDLE P L A T E S A F E T Y SWITCH
R E L E A S E D (SOLENOID ON).
OV DC TO +1.2V DC

@
SAFETY
SOLENOID
HARNESS
-PLUG J-13, RESISTANCE READING
B E T W E E N HOLES ;
I AND 2
R=100 OHMS +20°/0
- I F R = O O H M S C O OHMS
R E P L A C E SOLENOID AND
RECHECK VOLTAGE
READING AT TP-12.
I F SOLENOID I S O.K., OR
VOLTAGE S T I L L DOES NOT
CHANGE A F T E R
REPLACEMENT.

@
NEEDLE
PLATE
SAFETY
SWITCH
HARNESS
-
2

PLUG J-14, RESISTANCE READING-

B E T W E E N HOLES;
I AND 4
NEEDLE P L A T E S A F E T Y SWITCH
. RELEASED.
R z O . 5 OHMS ?2O0/o
HOLES 2 AND 4 .
NEEDLE P L A T E SAFETY SWITCH
DEPRESSED.
R =0.5 OHMS 2 20°/0
IF R = O OHMS OR C O O H M S
REPLACE NEEDLE P L A T E
S A F E T Y SWITCH AND
RECHECK VOLTAGE AT
TP-12.
I F S A F E T Y SWITCH IS O.K.,
OR VOLTAGE S T I L L DOES
NOT CHANGE A F T E R
REPLACEMENT. REPLACE
LOGIC BOARD.

A
LOGIC BOARD AS VIEWED FROM CDMPONENT SIDE
 ZERO A A
C5 C6

SCALE

I
T n

T P-13

LOGIC BOARD AS VIEWED FROM COMPONENT SIDE

L
 1

NEEDLE BAR RELEASE SOLENOID

TEST
LOCAT ION TEST POINTS CORRECT ION
N O T E : FOR THE FOLLOWING TESTS USE T P - l ON T H E OVERRIDE BOARD FOR GROUND OR COMMON.

LOG lC @CAPACITOR CS -15V DC T O -17V DC- I F NOT O.K., R E F E R TO

BOARD f 15V DC UNREGULATED
@ CAPACITOR C 6 t 1 5 V DC TO t l 7 V DC POWER SUPPLY
VERIFICATION LOGIC
BOARD.
I F O.K.,

0 LOGIC
BOARD
- TP-I3
STRAIGHT S T I T C H (SOLENOID O F F )
+ .+
15V DC TO 17V DC
S I N G L E P A T T E R N (SOLENOID ON)
OV DC TO +l.2V DC
I F T H E R E I S NO CHANGE
I N VOLTAGE.

@ RELEASE
SOLENOID
HARNESS
-
NEEDLE BAR '
PLUG J-12
RESISTANCE R E A D I N G B E T W E E N
HOLES I AND 2
R = 5 0 OHMS 220°/0
- IF R = O OHMS O R O O OHMS,
R E P L A C E S O L E N O I D AND
RECHECK VOLTAGE AT
TP-13.
I F SOLENOID IS O.K.,OR
VOLTAGE S T I L L DOES NOT
CHANGE A F T E R
REPLACEMENT, REPLACE
LOGIC BOARD.

A
 M A G N E T ~ CSENSOR

TEST
LOCAT l ON TEST POINTS CORRECTION
NOTE: FOR THE FOLLOWING TESTS USE TP-I ON THE OVERRIDE B O A R 0 FOR GROUND OR COMMON.

@ F ~- o
BOARD
A1 CAPACITOR

@$ 3 3
CI + 7 . 5 0 V DC

C I - 7 . M V OC
DC
I F NOT
CONTROL
O.K., REFER
VOLTAGE

VERIFICATION AND
ADJUSTMENT LOGIC
TO

BOARD.
I F O.K.,

LOGIC ------------)cTP-2 ROTATE H A N D WHEEL; -IF VOLTAGE DOES NOT

@ BOARD + ~ . O V DC 2 . 2 V DC SENSOR ON
-6.OV DC +.2V DC SENSOR O F F
CHANGE, OR IF NO
VOLTAGE IS PRESENT,
REPLACE LOGIC BOARD.

1
 0@
I
ZERO A 1
T T

CI
SCALE

SCALE

CI

TP-2
0
L O G I C BOARD AS V I E W E D FROM C O M P O N E N T S I D E
 PINS FOR

1 2 3 4 5 6 7 8 10

SERVO BOARD AS VIEWED FROM CIRCUIT SlDE

LINEAR

0
ZERO I
T

C-l

#CALI

0 0
0
--

LOGIC BOARD AS VIEWED

FROM COMPONENT SlDE

b
 BIGHT AND F E E D LINEAR MOTORS

TEST
LOCATION TEST POINTS CORRECTION
NOTE: FOR THE FOLLONING TESTS USE TP-I ON THE OVERRIDE BOARD FOR GROUND OR COMMON.

SERVO READ AT PLUG J-6 3- I F NOT O.K., REFER TO DC

BOARD CONNECTOR PINS REGULATED CONTROL
P I N 2 +7.50V DC k . 0 5 DC ~ VOLTAGE VERIFICATION
P I N 3 - 7 . 5 0 V DC r . 0 5 DC
~ AND ADJUSTMENT SERVO
BOARD.
I F O.K.,

@ CAPACITOR C l i 7 . 5 0 V DC t . 0 5 ~DC I F NOT O.K., REFER TO DC

@ LOGIC
BOARD
@CAPACITOR CI - 7 . 5 0 ~ DC 2 . 0 5 ~DC
REGULATED CONTROL
VOLTAGE VERIFICATION
AND ADJUSTMENT LOGIC
BOARD.
I F O.K.,

NOTE: FOR THE FOLLOWING TESTS, I F ONLY ONE OF T H E LINEAR MOTORS

DOES NOT FUNCTION, ONLY THOSE TESTS R E L A T I V E TO THE PARTICULAR
L I N E A R MOTOR NEED B E MADE, I.E. F E E D MOTOR/FEED O U T P U T S OR
BIGHT MOTOR/BIGHT OUTPUTS, I F BOTH MOTORS DO NOT FUNCTION, A L L
TESTS MUST BE M A D E .

@ *
LINEAR
MOTOR
- RESISTANCE READINGS, L I N E A R
MOTOR HARNESS PLUGS J-I7 AND J-i6
HOLES I AND 2
R = I O OHMS klOO/o
HOLES 4 AND 5
--
IF NOT O.K., REPLACE
APPROPRIATE L I N E A R
MOTOR.
IF O.K.,

R = 10,000 OHMS 2 2 0 ~ / 0
SET CENTER BUMP ON PLASTIC
BOBBIN OF LINEAR MOTOR E V E N WITH
FRONT OF L I N E A R MOTOR HOUSING.
HOLES 3 AND 4
R = 5 P 0 0 OHMS +20°/0
HOLES 3 A N D 5
R = 5 , 0 0 0 OHMS i 2 0 ° / 0

.
CONTINUED
NEXT PAGE
 BlGHT AND FEED LINEAR MOTORS (CONT.)

TEST
LOCATION T E S T POINTS CORRECTION

SERVO P L A C E MACHINE I N STRAIGHT STITCH, ----)L I F O.K., R E P L A C E SERVO

BOARD S I N G L E P A T T E R N . ROTATE A R M S H A F T BOARD.
THROUGH S E V E R A L R E V O L U T I O N S . I F NOT O.K.,
R E A D I N G AT
T P - 2 0 . 0 0 0 V DC i . 0 0 5 V DC
T P - I 0 0.000V DC i . 0 0 5 ~DC
P L A C E M A C H I N E I N RIC-RAC. ROTATE
A R M S H A F T THROUGH S E V E R A L
REVOLUTIONS TO BRING N E E D L E TO
RIGHT NEEDLE POSITION AND F E E D
T O R E V E R S E F E E D P O S I T ION.
R E A D I N G AT
T P - 2 + . 9 2 0 V DC i . 0 0 5 ~DC
TP-I0 + . 9 2 0 V DC C.010 V DC
ROTATE S T I T C H L E N G T H OVERRIDE
CONTROL D I A L F U L L COUNTER-
CLOCKWISE T O "o'.'
READING A T
T P - 2 0 . 0 0 0 V DC k . 0 2 0 ~DC
ROTATE STITCH W I D T H OVERRIDE
CONTROL D l A L FLI,LL COUNTER-
CLOCKWISE TO "0.
R E A D I N G AT
T P - I 0 0 . 0 0 0 V DC k . 0 2 0 V DC
R E A D A T PLUG J-6 P I N CONNECTOR P I N I.
ROTATE B A L A N C E OVERRIDE CONTROL
D l A L F U L L COUNTERCLOCKWISE.
f 7 . 5 0 V DC 2 . 0 5 V DC
ROTATE B A L A N C E OVERRIDE CONTROL
D l A L F U L L CLOCKWISE.
-7.50V DC i . 0 5 V DC

I S T I T C H LENGTH O V E R R I D E

TP-II I F NOT O.K., R E P L A C E

OVERRIDE OFF -7.45V DC T O -7.55V DC OVERRIDE BOARD.
OVERRIDE ON +4.OV DC TO +5.OV DC I F O.K.,
I
N O T E : T H E P O L A R I T Y OF T H E FOLLOWING
R E A D I N G S D E P E N D S ON T H E F E E D P O S I T I O N

CAPACITOR C f
O V E R R I D E O F F i 1 . 2 V DC TO t 1 . 9 ~DC
OVERRIDE ON
D l A L F U L L CW 2 1 . 2 ~DC TO i 1 . 9 DC ~
D l A L F U L L CCW O.OV D C T O k 0 . 1DC ~

CONTINUED
NEXT PAGE
 PINS FOR
0000 O0 O I 0 PLUG J-6

TP-I
\

SERVO BOARD A S V I E W E D FROM CIRCUIT S I D E

I OVERRIDE BOARD AS VIEWED FROM COMPONENT SIDE

USPECTION AND LUBRICATION OF NEEDLE BAR RELEASE MECHANISN

Preparation: 1. Remove f a c e p l a t e and arm t o p c o v e r .

Inspection: 1. R a i s e n e e d l e b a r t o i t s h i g h e s t p o i n t and remove n e e d l e

bar r e t u r n spring A .

2. Lower n e e d l e b a r t o i t s l o w e s t p o i n t and remove r e l e a s i n g

l e v e r r e t a i n i n g r i n g 6.

3. C l o s e i n s p e c t i o n o f r e t a i n i n g r i n g B w i l l show t h e i n s i d e
edge on o n e s i d e o f t h e r i n g t o have a s l i g h t r a d i u s ( c u r v e ) .
Reassemble w i t h t h e r a d i u s s i d e a g a i n s t t h e r e l e a s i n g l e v e r C.

4. Replace s p r i n g A .
Lubrication: 1. L u b r i c a t e t h e a r e a s i n d i c a t e d "L", w i t h " L u b r i p l a t e 107" o n l y .
S u f f i c i e n t amounts must b e a p p l i e d t o p r o v i d e l u b r i c a t i o n t o
a l l i n t e r n a l p o i n t s , p i v o t s , etc.
 LE BAR RECOIL SPRING

Machine S e t t i n g s ; 1. S t i t c h Selection: Straight Stitch.

Preparation: L. Remove f a c e p l a t e .

Check : 1. Turn hand wheel toward f r o n t o f machine u n t i l

n e e d l e b a r is a t t h e extreme t o p o f i t s s t r o k e .

2. Needle b a r clamping screw E should s l i g h t l y

deflect ( l i f t ) recoil spring D .
3. Rock hand wheel back and f o r t h t o o b s e r v e d e f l e c -
t i o n of r e c o i l s p r i n g . G e n e r a l l y , t h e l e s s r e c o i l
spring D is deflected, the b e t t e r the s e t t i n g .
Under c e r t a i n c o n d i t i o n s , however, t h i s d e f l e c t i o n
may b e a s much a s , o r more, t h a n . O I O n (0,25mm) t o
provide s u c c e s s f u l m a x i - s t r e t c h s t i t c h o p e r a t i o n .
If r e c o i l s p r i n g D does n o t d e f l e c t , n e e d l e b a r
l a t c h F does n o t engage.

Adjustment : 1. Loosen screw C h o l d i n g r e c o i l s p r i n g b r a c k e t A .

2. Using b l a d e o f a s m a l l s c r e w d r i v e r engaged i n s l o t
move b r a c k e t A up t o d e c r e a s e d e f l e c t i o n , down t o
i n c r e a s e d e f l e c t i o n of r e c o i l s p r i n g D .
3. Tighten screw C .
4. Recheck f o r c o r r e c t d e f l e c t i o n o f r e c o i l s p r i n g
and/or e x c e s s i v e n o i s e .

5. Check machine in b a s t i n g .
NEEDLE BAR RELEASING BRACKET

Machine S e t t i n g s : 1. Stitch Selection: Straight Stitch

Preparation: 1. Remove f a c e p l a t e and arm t o p c o v e r .

Check: 1. R o t a t e hand wheel u n t i l n e e d l e b a r i s a t i t s

highest point.

2. Rock r e l e a s i n g b r a c k e t A f r o n t - t o - b a c k .

3. Observe h o r i z o n t a l f r o n t - t o - b a c k movement a t t h e
t o p of t h e r e l e a s i n g b r a c k e t . There s h o u l d b e a
h o r i z o n t a l movement of .001" (0,025mm), minimum.

NOTE : When moving r e l e a s i n g b r a c k e t f o r w a r d , i t must j u s t

come t o r e s t a g a i n s t t r i p p i n g l e v e r B . E x c e s s i v e
p r e s s u r e w i l l r e s u l t i n movement of l e v e r B and a
s l i g h t opening of t h e n e e d l e b a r l a t c h C. I f t h i s
o c c u r s , a f a l s e measurement c l e a r a n c e w i l l r e s u l t .

Adjustment : 1. R o t a t e hand wheel u n t i l n e e d l e b a r i s a t h i g h e s t

point.

2. Check t h a t n e e d l e b a r l a t c h i s f u l l y engaged.

3. Loosen a d j u s t i n g b r a c k e t clamping s c r e w D.

4. Move a d j u s t i n g b r a c k e t E backward o r forward

a s r e q u i r e d u n t i l a movement of .001" (0,025mm)
minimum a t t h e t o p o f t h e r e l e a s i n g b r a c k e t i s
observed.

5. T i g h t e n clamping s c r e w D and r e c h e c k .
Removal : Remove f a c e p l a t e and arm t o p c o v e r .

Remove p r e s s e r f o o t w i t h p r e s s e r f o o t shank.

S e t p r e s s e r b a r t o down p o s i t i o n .

Remove n e e d l e .

Remove s c r e w A w i t h w a s h e r , c o n n e c t i n g n e e d l e b a r
b a l l j o i n t and n e e d l e b a r d r i v i n g arm.

I f head end i s t o be r e p l a c e d w i t h a new a s s e m b l y ,

remove b u t t o n h o l e s w i t c h C and p l a c e i t t o t h e
r e a r of t h e machine.

Turn hand wheel toward f r o n t o f machine t o b r i n g

needle bar t o its highest point.

Remove l o w e r ( p o s i t i o n i n g ) s c r e w D and f l a t
washer and u p p e r p i v o t s c r e w 6 and f l a t w a s h e r .

Remove head-end a s s e m b l y by d r a w i n g s t r a i g h t o u t
from c a s t i n g .

Replacement: Replacement is t h e same as removal i n r e v e r s e

order.

Adjust needle l o c a t i o n .

Adjust needle bar r e l e a s e s o l e n o i d .

Adjust b u t t o n h o l e s w i t c h .

lwauAuE
Removal : 1. Remove f a c e p l a t e , arm t o p c o v e r and head-end
assembly.

2. Remove n e e d l e clamp t h r e a d g u i d e G and n e e d l e clamp H

3. Loosen n e e d l e b a r c l a m p i n g screw E.

4. P u l l n e e d l e b a r F up and o u t o f head-end a s s e m b l y .

Replacement 1. Replacement is t h e same as removal i n r e v e r s e

order.

2. R e p l a c e n e e d l e b a r i n head-end ,assembly and

t i g h t e n c l a m p i n g s c r e w E t o pirrch t i g h t n e s s .

3. A d j u s t n e e d l e b a r l o c a t i o n and h e i g h t .

4. Check t h a t n e e d l e b a r l a t c h e n g a g e s p r o p e r l y .

5. Ad j u s t b u t t o n h o l e s w i t c h .
PRESSER BAR AND PRESSER BAR BUSHING

Removal : 1. Remove f a c e p l a t e , arm t o p c o v e r and head end.

2. Loosen p r e s s e r b a r clamping s c r e w A, and remove

p r e s s e r b a r F.

3. Loosen p r e s s e r b a r bushing clamping screw 6.

4. Use t h e b l a d e of a s c r e w d r i v e r t o push a g a i n s t t h e end

of p r e s s e r b a r s p r i n g D w h i l e r o t a t i n g p r e s s e r b a r
b u s h i n g u n t i l t h e s p r i n g i s unthreaded o f f p r e s s e r b a r
guide b r a c k e t C.

5. Repeat t h i s procedure t o u n t h r e a d t h e p r e s s e r b a r
s p r i n g o f f p r e s s e r b a r bushing E.

6. Remove p r e s s e r b a r bushing E.

Replacement : 1. Replacement i s t h e same a s removal i n r e v e r s e o r d e r .

2. Adjust n e e d l e l o c a t i o n .

3. Adjust p r e s s e r b a r h e i g h t .

4. Check b a s t i n g s t i t c h and a d j u s t i f n e c e s s a r y .

5. Adjust b u t t o n h o l e s w i t c h .
Removal : 1. Remove face p l a t e , arm t o p c o v e r and f r o n t c o v e r .
2. Turn hand wheel toward f r o n t o f machine t o b r i n g
take-up l e v e r A t o its l o w e s t p o i n t .

3. Remove screw F under arm a t head end.

4. Remove s a f e t y s h i e l d G .
5. Remove arm t o p screw s t u d C and mounting screw D
6. Remove n e e d l e b a r release s o l e n o i d E and l a y i t t o
rear o f machine.
7. T i l t t o p o f t e n s i o n assembly B toward t h e l e f t and
down, and remove from machine.

Replacement : 1. Replacement is t h e same as removal i n r e v e r s e

order.

2. Check t e n s i o n module f o r c o r r e c t t e n s i o n release.

3. Adjust n e e d l e b a r release s o l e n o i d .

4. Replace f r o n t c o v e r , arm t o p c o v e r , and face

plate.
LEV-
Removal : 1. Remove face p l a t e arm t o p c o v e r , f r o n t c o v e r ,
head-end assembly and t e n s i o n assembly.

2. Loosen take-up l e v e r h i n g e s t u d set screw H .

3. Loosen t h r e a d take-up c r a n k s e t screw M .
4. Push take-up l e v e r h i n g e s t u d I toward t h e l e f t
and p u l l it o u t .
5. Hold n e e d l e bar c o n n e c t i n g l i n k L and ease o u t
t h r e a d take-up c r a n k K and t h r e a d take-up l e v e r J .
Replacement : 1. Replacement is t h e same a s removal i n r e v e r s e o r d e r .
2. Be s u r e set screw M i s p r o p e r l y l o c a t e d on t h e
f l a t o f c r a n k K and t h a t c r a n k K is f i r m l y s e a t e d
in c o n n e c t i n g l i n k L .
3. Hinge s t u d i should be f l u s h w i t h t h e l e f t s i d e
of t h e c a s t i n g .

4. Check n e e d l e l o c a t i o n and n e e d l e r e l e a s e g o l e n o i d
function.
J , I N E A R SERVO BOARD P . C . ASSEMRLY

Removal : 1. Remove t o p c o v e r .

2. Remove mounting screws B a n d E and arm t o p

screw s t u d D.

3. C a r e f u l l y l i f t and t i l t up f r o n t edge o f s e r v o
board assembly.

4. Remove p l u g s J-15, J-6, J-18, and J-17 from t h e

s e r v o board assembly.

Replacement: 1. Replacement is t h e same a s removal i n r e v e r s e

order.

NOTE : When r e p l a c i n g s e r v o board assembly, it is mandatory

t h a t a l i b e r a l amount o f t h e r m a l t r a n s f e r compound
be s p r e a d o v e r b o t h mating s u r f a c e s o f t h e c i r c u i t
b o a r d ' s aluminum mounting ( h e a t s i n k ) and t h e a r m
s t a n d a r d b e f o r e s e c u r i n g board t o t h e machine.

Removal : 1. Remove arm t o p c o v e r and f r o n t c o v e r .

2. Remove s e r v o board assembly.

3. Replace screw 6 i n s p a c e r F and t i g h t e n t o

pinch t i g h t n e s s t o m a i n t a i n s t a b i l i t y o f t h e l o g i c
board assembly.

4. Remove b u t t o n c a r r i e r assembly mounting screws A

and C w i t h l o c a t i n g c l i p s .

5. C a r e f u l l y withdraw t h e b u t t o n carrier assembly

away from t h e l o g i c board assembly a s shown i n
i l l u s t r a t i o n G.

6. Remove p l u g s J-10 and J -1 1 from t h e l o g i c board

assembly.

Replacement : 1. Replacement is t h e same a s removal i n r e v e r s e

order.
LINEAR FEED MOTOR

Removal : 1. Remove arm t o p c o v e r and f r o n t c o v e r .

2. Remove o v e r r i d e c o n t r o l board and p a n e l assembly.

3. Remove t r a n s f o r m e r and t r a n s f o r m e r h o u s i n g .

4. Remove c o n n e c t i n g l i n k r e t a i n i n g c l i p B and
s p r i n g A.

5. Remove f e e d l i n e a r motor mounting s c r e w s C, D,

and E.

6. L i f t c o n n e c t i n g l i n k o f f motor l i n k and remove

l i n e a r f e e d motor from machine.

Replacement: 1. Replacement is t h e same a s removal i n r e v e r s e

order.

2. Perform "Sequence of E l e c t r o n i c Adjustments".

LINEAR BIGHT MOTOR

Removal : 1. Remove arm t o p c o v e r and l i n e a r s e r v o board assembly.

2. Remove c o n n e c t i n g l i n k r e t a i n i n g c l i p H and s p r i n g I.

3. Loosen b u t t o n c a r r i e r assembly mounting s c r e w s F and

G s o assembly c a n b e s l i g h t l y s h i f t e d f o r w a r d .

4. Remove l i n e a r b i g h t motor mounting s c r e w s J and K.

5. T i l t u p p e r r i g h t c o r n e r of motor up and l i f t motor

assembly s t r a i g h t o u t of machine.

Replacement: 1. Replacement i s t h e same as removal i n r e v e r s e o r d e r .

2. Perform "Sequence of E l e c t r o n i c Adjustments".

slas2uE
Remov a1 : 1. Loosen bottom cover screw O.

2. P u l l bottom c o v e r C approximately 1/4" (6,35 mm)

away from t h e machine bed.

3. P r e s s a s c r e w d r i v e r between t h e bed s k i r t and

s p r i n g E and t u r n s c r e w d r i v e r B enough t o
depress the spring.
4. P u l l t h e s l i d e p l a t e A forward and o f f t h e
machine.

Replacement: 1. Replacement is t h e same as removal i n r e v e r s e

order.

Removal : 1. Remove bottom cover.

2. Remove s l i d e p l a t e .

3. Loosen a c t u a t i n g l e v e r cam set screws G.

4. Remove a c t u a t i n g l e v e r cam H.
5. Remove bobbin winder d r i v e r assembly I by
drawing o u t o f hook s h a f t .
6. Remove bobbin winder a c t u a t i n g l e v e r assembly F
from t o p o f bed.
Replacement: 1. Replacement is t h e same as removal i n r e v e r s e
order.
2. Adjust bobbin winder a c t u a t i n g l e v e r r a d i a l ,
h e i g h t s e t t i n g s and bobbin d r i v e r h e i g h t
s e t t i n g a s o u t l i n e d i n Bobbin Case Thread
Clearances.
3. Replace s l i d e p l a t e and bottom cover.
HOOK

Removal : 1. Remove n e e d l e , p r e s s e r f o o t , n e e d l e p l a t e ,
s l i d e p l a t e , p o s i t i o n p l a t e H, b o b b i n E , b o b b i n
c a s e F, and f e e d dog 0.

2. Turn p o s i t i o n f i n g e r s l o t t e d screw C ( 1 e f t hand

t h r e a d ) CLOCKWISE t o unscrew. Remove screw C
and p o s i t i o n f i n g e r B .
3. Remove a c t u a t i n g l e v e r A and d r i v e r assembly N.

4. Loosen s e t screw M i n hook s h a f t g e a r L and remove

hook G t a k i n g c a r e n o t t o l o s e wave washer K b e t w e e n
t h e g e a r and t h e c a s t i n g .

Replacement: 1. Replacement i s t h e same a s removal i n r e v e r s e o r d e r .

2. A d j u s t hook g e a r mesh.

3. Ad j u s t hook t i m e and f e e d time.

4. Ad j u s t b o b b i n c a s e t h r e a d c l e a r a n c e .

5. A d j u s t b o b b i n . d r i v e r h e i g h t and a c t u a t i n g l e v e r r a d i a l
location.

6. Adjust a c t u a t i n g l e v e r height.
HOOK DRIVE SHAFT - HOOK DRIVE GEAR - FEED DRIVE GEAR

Removal : 1. Remove n e e d l e .

2. Remove f r o n t c o v e r and bottom c o v e r .

3. Loosen i d l e r p u l l e y set screw A and t u r n i d l e r

e c c e n t r i c B f o r maximum l o o s e n e s s of t i m i n g b e l t .

4. Loosen two s e t screws M i n t i m i n g cog p u l l e y and remove

p u l l e y L.

5. Loosen s e t screw D i n hook d r i v e g e a r and s e t screw

G i n f e e d d r i v e g e a r b e i n g s u r e b o t h a r e c l e a r of
recess i n shaft.

6. Loosen c o l l a r s e t screw I .

7. Withdraw hook d r i v e s h a f t F from t h e machine.

Replacement: 1. Thread d r i v e s h a f t t h r o u g h r i g h t s h a f t b u s h i n g , s p r i n g K
and c o l l a r J. B e s u r e t a i l of s p r i n g K i s i n t h e p r o p e r
direction as illustrated.

2. Continue t o t h r e a d s h a f t through g e a r H, l e f t s h a f t
b u s h i n g and hook d r i v e g e a r C.

3. Replace t i m i n g b e l t on p u l l e y L and t h r e a d p u l l e y on
s h a f t F.

4. A d j u s t hook g e a r mesh.

5. Adjust timing b e l t tension.

6. A d j u s t hook t i m i n g and f e e d t i m i n g .
FEED DRIVE SHAFT

Removal : Remove bottom c o v e r .

Loosen two s e t screws D i n f e e d t i m i n g e c c e n t r i c .

Loosen s e t screw F i n f e e d g e a r E.

Loosen s e t screw H h o l d i n g r e a r f e e d d r i v e s h a f t
bushing G .

S l i d e b u s h i n g G t o r i g h t o u t of b o s s i n c a s t i n g .

T i l t r i g h t end of f e e d d r i v e s h a f t up and remove

w i t h r e t a i n i n g c l i p I by s l i d i n g o u t t o r i g h t .

Replacement: S l i d e b u s h i n g G on f e e d d r i v e s h a f t w i t h r e t a i n i n g
c l i p I.

S l i d e f e e d d r i v e s h a f t through b u s h i n g h o l e i n b o s s
of c a s t i n g.
S l i d e f e e d d r i v e s h a f t through feed g e a r E , f e e d
b a r c o n n e c t i n g assembly B and b u s h i n g A .

Align b u s h i n g G i n b o s s of c a s t i n g and t e m p o r a r i l y
s e c u r e s e t screw H.

With r e t a i n i n g c l i p I a g a i n s t b u s h i n g G, l o c a t e
feed gear E a g a i n s t bushing G with l i g h t f i n g e r
p r e s s u r e and t i g h t e n s e t screw F.

Re-time f e e d .

Loosen s e t screw H . Move b u s h i n g G w i t h s h a f t l e f t

o r r i g h t t o a t t a i n p r o p e r alignment between f e e d
d r i v e c o n n e c t i n g l i n k B and f e e d d r i v e e c c e n t r i c C t o
prevent binding.

T i g h t e n s e t screw H.

Perform b i n d t e s t f o r f e e d mechanism.
FEED REGULATOR SIIAFT & FEED REGULATOR AND BLOCK

Removal : 1. Remove r e t a i n i n g c l i p K and s p r i n g J. Rotate feed

regulator shaft E to bring eccentric stud H as f a r
toward t h e f r o n t of t h e machine a s p o s s i b l e and c a r e f u l l y
remove c o n n e c t i n g l i n k I from e c c e n t r i c b a l l s t u d H.

2. Loosen s e t screw G i n r e g u l a t o r crank and remove

w i t h e c c e n t r i c s t u d from r e g u l a t o r s h a f t .

3. Loosen s e t screws D and F u n t i l t h e y a r e c l e a r

of r e c e s s e s i n f e e d r e g u l a t o r s h a f t .

4. S l i d e feed r e g u l a t o r s h a f t E t o t h e r i g h t u n t i l
i t i s c l e a r of t h e machine.

5. P o s i t i o n body of f e e d cam and e c c e n t r i c A t o a

p o s i t i o n which a l l o w s maximum c l e a r a n c e f o r re-
moval of f e e d r e g u l a t o r .

6. Remove f e e d r e g u l a t o r C and s l i d e b l o c k B.

Replacement: 1. Replacement i s t h e same a s removal i n r e v e r s e

order.

2. Check Alpha f e e d z e r o .

3. Perform b i n d t e s t f o r f e e d mechanism.
FEED BAR CONNECTING LINK

Removal : 1. Remove hook and f e e d d r i v e s h a f t t o r i g h t u n t i l t h e y

a r e c l e a r of d r i v e c o n n e c t i o n assembly I .

2. Loosen s e t screw C and remove h i n g e s t u d D w i t h

i t s r e t a i n i n g c l i p i n place.

3. Remove r e t a i n i n g c l i p H.

4. S l i d e b a l l bushing G o f f e c c e n t r i c s t u d A.

5. L i f t d r i v e c o n n e c t i o n assembly I o u t of feed l i f t i n g
f o r k 6.

6. Rotate feed r e g u l a t o r s h a f t counterclockwise t o

i t s maximum p o s i t i o n and remove s l i d e b l o c k J from
f e e d r e g u l a t o r K.

7. T i l t l o w e r end of d r i v e c o n n e c t i o n assembly t o
r i g h t t o remove i t from e c c e n t r i c s t u d .

8. L i f t d r i v e c o n n e c t i o n assembly I up and t o t h e l e f t
t o remove i t and f e e d b a r c o n n e c t i n g l i n k F from
machine. Be c a r e f u l n o t t o l o s e wave washer E.

NOTE : I f n e c e s s a r y , f e e d r e g u l a t o r K may now b e removed by

l o o s e n i n g s e t screw L and s l i d i n g f e e d r e g u l a t o r o f f f e e d
regulator shaft.
FEED BAR CONNECTING L I N K (CONTINUED)

Replacement: 1. If f e e d r e g u l a t o r K h a s b e e n removed, r e p l a c e i t
on f e e d r e g u l a t o r s h a f t . Do n o t t i g h t e n s e t screw
L a t t h i s time.

2. Be s u r e wave washer E i s i n p l a c e . I n s e r t d r i v e
c o n n e c t i o n assembly I a t a 45 d e g r e e a n g l e t o b r i n g
lower end of f e e d b a r c o n n e c t i n g l i n k F o v e r e c c e n t r i c
stud A.

3. I n s e r t s l i d e b l o c k J o n t o u p p e r end of d r i v e c o n n e c t i o n
assembly, and t h e n i n t o s l i d e of f e e d r e g u l a t o r K.

4. Replace b a l l b u s h i n g G and r e t a i n i n g c l i p H.

5. L o c a t e r e g u l a t o r s e t screw L on f l a t of feed r e g u l a t o r
shaft .
6. L o c a t e f e e d r e g u l a t o r K s o t h e r e i s no b i n d i n g o r
e x c e s s i v e p l a y between i t and s l i d e b l o c k J . T i g h t e n
f e e d r e g u l a t o r s e t screw L .

7. Replace h i n g e s t u d D and t i g h t e n s e t screw C .

8. P o s i t i o n d r i v e c o n n e c t i o n assembly I i n t o f e e d l i f t i n g
f o r k B.

9. Replace hook d r i v e s h a f t .

10. R e p l a c e f e e d d r i v e s h a f t .

11. Re-time hook and f e e d a s d e s c r i b e d i n Adjustment

P r o c e d u r e s u n d e r Hook and Feed Timing.

12. Check Alpha f e e d z e r o .

13. Perform b i n d t e s t f o r f e e d mechanism.

EEiLEm
Removal : 1. Remove f e e d dog.

2. Remove motor.

3. Remove n e e d l e p l a t e s a f e t y s w i t c h .

4. Remove feed b a r c o n n e c t i n g l i n k assembly.

5. Disconnect s p r i n g 6 from f e e d b a r .

6. Loosen set screw F and remove cone p o i n t b e a r i n g E.

7. Remove f e e d b a r assembly A.

Replacement : 1. P o s i t i o n f e e d b a r assembly A with upper f e e d bar pivot

s t u d C s e a t e d on upper cone p o i n t e d b e a r i n g D. Be sure
s p r i n g 6 is p r o p e r l y l o c a t e d over p i v o t s t u d C and t h a t
i t s s h o r t l e g i s engaged w i t h t h e r i b o f t h e casting.

2. Replace t h e lower cone p o i n t e d b e a r i n g E . Make s u r e it

is p r o p e r l y s e a t e d i n t o t h e f e e d bar lower p i v o t s t u d .

3. Applying f i n g e r p r e s s u r e t o t h e lower cone p o i n t b e a r i n g

E t i g h t e n set screw F.

4. Engage s p r i n g B o v e r t o p o f feed b a r A .

5. Check f o r any b i n d i n g o r l o o s e n e s s o f t h e f e e d b a r between

t h e cone p o i n t b e a r i n g s . There must b e a u p e r f e c t fit."
If n e c e s s a r y , reset by a d j u s t i n g t h e l o w e r cone p o i n t e d
bearing E.

6. Replace feed b a r c o n n e c t i n g l i n k assembly.

7. Replace motor.

8. Replace feed dog.

9. Adjust feed mechanism as d e s c r i b e d i n Adjustment Procedures

under Alpha Feed.
10. Perform bind t e s t f o r f e e d mechanism.