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SERVICE MANUAL

15-1, Naeshiro-cho, Mizuho-ku, Nagoya 467-8561, Japan. Phone: 81-52-824-2177

Printed in Japan

117-S11

I2010820H

2002.09. H (1)

Table of Contents

Default Chapter2
- Safety Instructions2
- Notes on Safety3
- Maintenance and Inspection4
- Warning Labels5
- Table of Contents6
1 Specifications8
2 Optional Parts10
3 Notes on Handling11
- Carrying the Machine11
- Tilting Back the Machine Head11
4 Mechanical Descriptions12
- Upper Shaft and Needle Bar Mechanism12
- Lower Shaft and Rotary Hook Mechanism12
- Feed Mechanism13
- Quick Reverse Mechanism14
- Lubrication Mechanism (Thread Take-Up Lever and Rotary Hook)15
- Thread Trimmer Mechanism17
- Thread Trimmer Operation17
- Upper and Lower Thread Trimming19
- Tension Release Mechanism20
- Thread Wiper Mechanism21
- Presser Foot Lifter Mechanism (-9[][], Option) (Built into Machine Head)21
- Lower Thread Detector Mechanism22
5 Disassembly23
- Bed Cover and Safety Switch23
- Connectors24
- Solenoid-Type Presser Lifter (-9[][], Option)24
- Lower Thread Detector (-31[], -41[], -91[], Option)24
- Covers and Operation Panel25
- Tension Release Wire, Ground Wire and Thread Trimmer Solenoid26
- Wick Holder and Oil Tube (Thread Take-Up Lever)27
- Oil Tank, Bed under Cover and Sub Tank27
- Quick Reverse Solenoid28
- Needle, Presser Hoot and Reverse Actuator Assy29
- Thread Tension Mechanism29
- Needle Plate and Feed Dog29
- Bobbin Case, Rotary Hook and Thread Trimming Mechanism30
- Feed Bar Mechanism30
- Feed Rocker Shaft30
- Presser Foot Mechanism31
- 5-17.Knee Lifter Lever Mechanism31
- Needle Bar and Thread Take-Up Mechanism2532
- Pulley and Motor32
- Timing Belt33
- Spring and Feed Regulator33
- Lower Shaft, Lower Shaft Gear and Feed Regulator Set34
- Plunger, Rotary Hook Shaft, Gear and Thread Trimmer Cam34
- Stitch Length Dial35
- Reverse Stitching Lever and Feed Regulator35
6 Assembly36
- Stitch Length Dial, Reverse Stitching Lever and Feed Regulator Mechanism36
- Rotary Hook Shaft, Thread Trimmer Cam and Gear38
- Plunger38
- Lower Shaft, Lower Shaft Gear and Feed Regulator Set39
- Timing Belt, Motor and Pulley41
- Knee Lifter Lever Mechanism43
- Needle Bar and Thread Take-Up Mechanism43
- Presser Foot Mechanism46
- Feed Rocker Shaft47
- 6-10.Spring47
- 6-11.Feed Bar Mechanism48
- 6-12.Sub Tank, Wick Holder and Wick49
- 6-13.Thread Tension Mechanism50
- 6-14.Oil (Feed Rocker Shaft)51
- 6-15.Thread Trimming Mechanism51
  - Installing the Thread Trimmer Cam Lever51
  - Adjusting the Needle and Feed Mechanism Timing52
  - Installing the Movable Knife and Fixed Knife53
  - Adjusting the Thread Trimming Timing54
- 6-16.Rotary Hook and Bobbin Case Holder Position Bracket55
- 6-17.Ruler Plate and Needle Plate56
- 6-18.Reverse Actuator Assembly and Presser Hoot56
- Adjusting the Presser Foot Height57
- Adjusting the Thread Guide Height57
- Adjusting the Tension Spring Vertical Position57
- Adjusting the Thread Tension Bracket57
  - Forward/Back Position57
- 6-19.Tension Release Wire58
- 6-20.Quick Reverse Solenoid59
- 6-21.Bed under Cover (Gear Box)60
- 6-22.Oil Tank61
- 6-23.Tension Release Wire62
- 6-24.Ground Wire62
- 6-25.Operation Panel62
- 6-26.Face Plate and Thread Take-Up Cover63
- 6-27.Safety Switch64
- 6-28.Arm Cover, Rear Cover and Bobbin Winder Tension Assembly64
- 6-29.Other Devices64
- 6-30.Connectors65
- 6-31.Lubrication66
- 6-32.Bed Cover and Knee Lifter Lever67
- 6-33.Test Operation68
- 6-34.Adjusting the Safety Switch Position69
7 Adjustments70
- Adjusting the Thread Tension Spring70
- Adjusting Arm Thread Guide R71
- Adjusting the Presser Foot Height71
- Adjusting of the Feed Dog Height72
- Adjusting the Feed Dog Angle73
- Adjusting the Needle Bar Height74
- Adjusting the Needle and Feed Mechanism Timing74
- Adjusting the Needle and Rotary Hook Timing75
- Quick Reverse Mechanism76
- 7-10.Matching Stitch Lengths for Normal Feed and Reverse Feed76
- 7-11.Synchronizer Adjustment77
- 7-12.Adjusting the Tension Release Wire78
- 7-13.Adjusting the Treadle79
- 7-14.Adjusting the Rotary Hook Lubrication Amount80
8 Control System82
9 Removing and Installing the Control Box83
10 Control Box and Motor Rating Plate84
11 Control Circuit Board86
12 Function Setting Methods88
- 12-1.DIP Switch Functions88
- 12-2.Parameter Setting Flowchart89
- 12-3.Parameters90
- 12-4.Memory Switch Setting Flowchart93
- 12-5.Memory Switches94
13 Treadle Unit Assembly97
- 13-1.Types97
- 13-2.Standard Setting Values98
- 13-3.Setting Method for Standard Depression Strokes99
14 Standing Operation Pedal103
- 14-1.Installing the Foot Plug103
- 14-2.Connectors104
15 Puller105
- (Commercially Available)105
- 15-1.Timing105
- 15-2.Connector105
- 15-3.Binding the Cord105
16 Auto Bobbin Changer106
- 16-1.Timing106
- 16-2.Connector106
- 16-3.Binding the Cord106
17 Speed Setting Methods107
- 17-1.Types of Speed Settings107
- 17-2.Setting Method107
- 17-3.Checking the Speed Settings108
18 Clearing the Memory Data109
19 Checking the Motor and Power Supply110
20 Checking the Solenoids111
21 Wiring Diagrams112
- 21-1.Control Circuit Board Assembly112
- 21-2.Power Supply Circuit Board Assembly (DD7100A, 710A)118
- 21-3.Power Supply Circuit Board Assembly (DD7100)127
- 21-4.Transformer136
- 21-5.Operation Panel B-40137
- 21-6.Operation Panel B-100140
22 Troubleshooting143
- 22-1.Sewing143
- 22-2.Error Code Displays150

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