Page 2 - SAFETY INSTRUCTIONS; Safety indications and their meanings; Indications; D A N G E R; Symbols
BAS-7610 i This service manual is intended for BAS-7610, BAS-761; be sure to read the BAS-7610, BAS-761 instruction manualbefore this manual.Carefully read the “SAFETY INSTRUCTIONS” below and the whole of this manual to understand this product before youstart maintenance.As a result of research and ...
Page 3 - Notes on safety; DANGER; Environmental requirements; Installation
BAS-7610 ii 2. Notes on safety DANGER Wait at least 5 minutes after turning off the power switch and disconnecting the power cord from the wall outletbefore opening the face plate of the control box. Touching areas where high voltages are present can result insevere injury. CAUTION Environmental req...
Page 4 - CAUTION; Sewing; Cleaning
BAS-7610 iii CAUTION Sewing This sewing machine should only be used byoperators who have received the necessarytraining in safe use beforehand. The sewing machine should not be used for anyapplications other than sewing. Be sure to wear protective goggles when using themachine.If goggles are not wor...
Page 6 - INDEX; MECHANICAL DESCRIPTIONS
INDEX 1. MECHANICAL DESCRIPTIONS .........................................................................................1-01 1-1. Upper shaft and needle bar mechanism ..................................................................................................1-01 1-2. Lower shaft and rotary ...
Page 8 - ELECTRIC COMPONENTS
6. ELECTRIC COMPONENTS .....................................................................................................6-01 6-1. Precautions at the time of adjustment ......................................................................................................6-01 6-2. Components insid...
Page 9 - -1. Upper shaft and needle bar mechanism
1. MECHANICAL DESCRIPTIONS BAS-7610 1-01 1. MECHANICAL DESCRIPTIONS Operate in the order of the numbers in the illustration.The “A”, “B” and other alphabets with the numbers indicate different sequences of operation which can occur at the sametime. 1-1. Upper shaft and needle bar mechanism 1-2. Lowe...
Page 15 -
1. MECHANICAL DESCRIPTIONS BAS-7610 1-07 <Explanation of the upper and lower thread trimming> Lower thread 1571S Upper thread Movable knife Fixed knife Lower thread finger 1572S This point the needle thread take-up is raisedslightly above its lowest position. 1573S When the movable knife is sp...
Page 21 - BEFORE DISASSEMBLY AND ADJUSTMENT
2. BEFORE DISASSEMBLY AND ADJUSTMENT BAS-7610 2-01 2. BEFORE DISASSEMBLY AND ADJUSTMENT DANGER Wait at least 5 minutes after turning off the power switch and disconnecting the power cord from the wall outlet before opening the face plate of the control box. Touching areas where high voltages are pre...
Page 24 - Note
2. BEFORE DISASSEMBLY AND ADJUSTMENT BAS-7610 2-04 <Removing stacker roller> <Removing folding base> * Carry this out only at the last and final operation. Carry out the operation carefully and correctly with two personnel or more.Work is done by removing a rear cover and a side cover. N...
Page 46 -
5. ADJUSTMENT BAS-7610 5-06 <Adjusting the needle and the rotary hook timing> Turn the pulley to raise the needle bar (1) from its lowest position. Adjust the rotary hook so that the side “2” of the gauge(5) and the lower end of the needle bar (1) align. At this time, the clearance between the...
Page 47 -
5. ADJUSTMENT BAS-7610 5-07 5-3. Adjusting the thread trimmer timing Remove the slide plate (the needle plate), the bottom plunger and the work clamp while making this adjustment. <Adjusting the thread trimmer cam position> 1. Remove the thread guide of the needle bar (1). 2. Turn the machine ...
Page 48 -
5. ADJUSTMENT BAS-7610 5-08 <Adjusting the movable knife, fixed knife position> 4. The fixed knife (8) and the movable knife (9) must overlap when the slide block of the thread trimmer cam (5) is lifted to the top of the roller (4) the thread trimmer cam lever. To increase the overlap, loosen ...
Page 52 -
5. ADJUSTMENT BAS-7610 5-12 5-6. Adjusting the machine sensor Both of the sensors -- adjustment width -- it becomes a central position mostly.Remove the pulley cover (1) while making this adjustment. <The sensor position to send the thread trimmer signal properly> The needle rises 3 mm from it...
Page 53 - -8. Adjusting the rotary hook lubrication amount
5. ADJUSTMENT BAS-7610 5-13 5-7. Adjusting the work clamp height 5-8. Adjusting the rotary hook lubrication amount The amount of oil : In the illustration (Sewing speed 4250 rpm, 7 second) ---Factory settingAdjust → Turn the screw (1) 1. Use machine head operation check : Mode change → Turn the powe...
Page 55 - -11. Adjusting speed of the pneumatic mechanism;
5. ADJUSTMENT BAS-7610 5-15 5-11. Adjusting speed of the pneumatic mechanism <The valves location of the folding machine> Remove the cover while making this adjustment. 1 Folding clamp 6 Folding base (1.5 mm-stroke) 2 Inner clamp 7 Label attachment device (Option) 3 Center blade 8 Suction (Vac...
Page 61 - -14. Adjusting the center blade support
5. ADJUSTMENT BAS-7610 5-21 5-13. Adjusting the inner clamp Compatibility of different models may be lost through this adjustment.Activate air compression. Turn on the power. 1. Set the step mode. (Press the [FOLDING MODE] switch.) Lower the inner clamp (1). (Press the [STEP] switch.)2. Secure the i...
Page 73 - -30. Adjusting the upper thread breakage detector
5. ADJUSTMENT BAS-7610 5-33 5-30. Adjusting the upper thread breakage detector 5-30-1. How to insert the fiber 5-30-2. Setting of MODE While making adjustment, the mode selection switch is changed to the "MODE" side. (The volume indicator under setupblinks.)It will be set up if the jog switc...
Page 75 - -1. Precautions at the time of adjustment
6. ELECTRIC COMPONENTS BAS-7610 6-01 Control circuit board Servo amplifier (Sewing machine) Servo amplifier (Y) Servo amplifier (X) Noise filter Power supply transformer 1 Power supply unit (Transformer 2) 6. ELECTRIC COMPONENTS DANGER Wait at least 5 minutes after turning off the power switch and d...
Page 77 - Fuse
6. ELECTRIC COMPONENTS BAS-7610 6-03 6-3. Power supply 6-3-1. Fuse Note When replacing a fuse, be sure to use the specified ones listed below. No. Part name Part code Manufacturer When a fuse has blown F1 Fuse C (2A-125V) 152566000 SATO F7161 2A The bobbin winder does not turn. F2 Fuse B (5A-125V) 1...
Page 79 - Conversion of power supply voltage
6. ELECTRIC COMPONENTS BAS-7610 6-05 6-3-4. Conversion of power supply voltage 1769S Breaker (A type changes with voltage.) Red White 1770S Breaker F10A(S21504000) Breaker F5A(S21181000)
Page 81 - PCB
6. ELECTRIC COMPONENTS BAS-7610 6-07 6-5. Connector 6-5-1. Main PCB The figure is a part code S51862 - PCB. No. Connection No. Connection P1 Machine sensor P17 Foot switch P2 Stacker motor P18 Start switch P3 Thread trimmer solenoid P19 Clamp-in sensor P4 Power supply PCB P20 Home position, over tra...
Page 91 - Power supply PCB
6. ELECTRIC COMPONENTS BAS-7610 6-17 6-5-2. Power supply PCB P1 [MAIN] (MOLEX 5277- 04A) Pin No. Signal name Probable symptoms due to poor contact 1 ± 0V 2 +24V The air valve does not operate.The over travel sensor lamp is not lit. 3 ± 0V 4 +36V The stacker roller does not turn. P2 [THREAD MOTOR] (M...
Page 94 - Programmer PCB
6. ELECTRIC COMPONENTS BAS-7610 6-20 6-5-4. Programmer PCB P1 [LCD] (JAPAN SOLDERLESS TERMINAL 19FE-ST) Pin No. Signal name Probable symptoms due to poor contact 1-19 LCD control LCD does not indicate. P2 [MAIN] (MOLEX 5268-12A) Pin No. Signal name Probable symptoms due to poor contact 1 2 ± 0V 3 Re...
Page 96 - ELECTRIC COMPONENTS; Sensor location
6.ELECTRIC COMPONENTS BAS-7610 6-22 6-6. Sensor 6-6-1. Sensor location No. Sensor name Type No. Sensor name Type 1 Over travel sensor (-X) A 12 Cylinder sensor (folding base) C 2 X home position sensor A 13 Cylinder sensor (center blade) C 3 Over travel sensor (+X) A 14 Machine sensor (needle up) B ...
Page 97 - Function of sensor
6. ELECTRIC COMPONENTS BAS-7610 6-23 6-6-2. Function of sensor < Home position sensor (X, Y) > Sensor Connecto r Pin No. Signal name State in case sensor LED is ON The error No. at fault 13 +24V 14 X home position X (2) P20 15 ± 0V Sewing clamp is in home position. E-840 Sensor Connecto r Pin ...
Page 115 - Names of major parts
6. ELECTRIC COMPONENTS BAS-7610 6-41 6-8. Servo amplifier 6-8-1. Names of major parts < Servo amplifier > No. Name, Use 1 Battery holder The battery for position data preservation is contained absolutely.It does not use by BAS-761, 7610. 2 Connector for battery (CON1) The battery for position ...
Page 117 - Abnormalities and a measure
6. ELECTRIC COMPONENTS BAS-7610 6-43 6-8-2. Abnormalities and a measure If abnormalities occur on servo amplifier or a motor (E-870, 880, 890), “AL. **” will be displayed on the display part ofservo amplifier. The meaning of an error code and the list of check items are as follows. < Servo amplif...
Page 119 - < Functions of operation panel DIP switches >
6. ELECTRIC COMPONENTS BAS-7610 6-45 6-9. DIP switches Note Always turn off the power supply before changing any of the DIP switch settings.The function of the DIP switches are subject to changes without notification.If DIP switches B-1 to B-6 are ON, be sure to check the cylinder movement and data ...
Page 134 - -3. Operation order and connection of folding machine
7. FOLDING MACHINE BAS-7610 7-04 7-3. Operation order and connection of folding machine The multi connectors and valves (page 7-03) connections are as follows. The valve operation order : Valves 10 → 13 turn ON in turn, and they turn OFF in order 10 → 11 → 13 → 12. Multi connector No. Valve No. and ...
Page 139 - assembly are improperly attached.
7. FOLDING MACHINE BAS-7610 7-09 B. The pocket material or body strays when the center blade retracts from the pocket. B-1. The center blade has burrs. B-2. When the power is turned OFF, the clearance between the center blade bottom surface and the needle plate top surface is not correct. A small cl...
Page 140 - are improperly attached.
7. FOLDING MACHINE BAS-7610 7-10 2. Seam deviates up in parallel (reverse case to 1). <Cause> A. The pocket material is improperly folded because the center blade is positioned above the correct position. After loosening the eight bolts (1), shift the center blade backward in the loose holes o...
Page 141 - The seam margin at the pocket top is different.; A. The pocket material is improperly set.; B. Plate spring R and L are improperly adjusted.
7. FOLDING MACHINE BAS-7610 7-11 3. The seam margin at the pocket top is different. <Cause> A. The pocket material is improperly set. Set the pocket material correctly up to plate spring R and L. B. Plate spring R and L are improperly adjusted. Adjust the plate spring positions by loosening th...
Page 142 - Seam deviates to the left in parallel.
7. FOLDING MACHINE BAS-7610 7-12 4. Seam deviates to the left in parallel. <Cause> A. The pocket material is improperly folded because the center blade is attached to the right of the correct position. After loosening the eight bolts (1), shift the center blade to the left in the loose holes o...
Page 143 - Seam deviates to the right in parallel.
7. FOLDING MACHINE BAS-7610 7-13 5. Seam deviates to the right in parallel. <Cause> A. The pocket material is improperly folded because the center blade is attached to the right of the correct position. After loosening the eight bolts (1), shift the center blade to the right in the loose holes...
Page 144 - A. The inner clamp blades are improperly positioned.
7. FOLDING MACHINE BAS-7610 7-14 6. Partial seam deviates in parallel. <Cause> A. The inner clamp blades are improperly positioned. • The seam margin is large.This happens when the clearance between the center blade edge and the inner clamp blades is too small ortoo large, or when the inner cl...
Page 145 - material strays with the body when the tucking blades retract.
7. FOLDING MACHINE BAS-7610 7-15 C. Tucking blades R, L, RD and LD have burrs. Remove the burrs and buff the tucking blades. D. Because tucking blades R, L, RD and LD are attached below the correct position, the pocket material strays with the body when the tucking blades retract. Raise and reattach...
Page 146 - C. The inner clamp blades are improperly adjusted.
7. FOLDING MACHINE BAS-7610 7-16 7. The stitch at the bottom corner is not aligned with the center line of the folded pocket. <Cause> A. The left edge of tucking blade RD is off to the left. Set the clearance between the center blade top and tucking blade RD left edge to 0.5 - 1 mm, as shown i...
Page 147 - The seam margin at the bottom is large.; A. The inner clamp blades are improperly adjusted.
7. FOLDING MACHINE BAS-7610 7-17 8. The seam margin at the bottom is large. <Cause> A. The inner clamp blades are improperly adjusted. After loosening the inner clamp blade attaching screws, adjust the clearance between the center blade edge andthe inner clamp blades. If the clearance is large...
Page 148 - D. There is no clearance between tucking blades LD and RD.
7. FOLDING MACHINE BAS-7610 7-18 D. There is no clearance between tucking blades LD and RD. Adjust the clearance so that it is about the same thickness as a piece of pocket material. E. Program defect Reprogram partially
Page 149 - The seam margin at one side of the bottom is large.
7. FOLDING MACHINE BAS-7610 7-19 9. The seam margin at one side of the bottom is large. <Cause> A. The inner clamp blades are improperly adjusted. Refer to “Trouble 6. Cause A”. B. Tucking blades LD or RD has burrs at the place corresponding to the pocket trouble. Remove the burrs and buff the...
Page 150 - The seam margin is too small at the corners on both sides.
7. FOLDING MACHINE BAS-7610 7-20 10. The seam margin is too small at the corners on both sides. <Cause> A. The inner clamp blades are improperly adjusted. Refer to “Trouble 6. Cause A”. B. Tucking blades LD and RD are improperly adjusted. Shift tucking blade LD slightly to the left to increase...
Page 151 - The folded lone at the bottom corner is round.; A. Tucking blades LD and RD are improperly adjusted.
7. FOLDING MACHINE BAS-7610 7-21 11. The folded lone at the bottom corner is round. <Cause> A. Tucking blades LD and RD are improperly adjusted. If this is caused by tucking blade RD being off to the left, refer to “Trouble 7. Cause A”. B. There is no clearance between tucking blade LD and RD....
Page 152 - The seam margin at the bottom is too small.
7. FOLDING MACHINE BAS-7610 7-22 12. The seam margin at the bottom is too small. <Cause> A. The inner clamp blades are improperly adjusted. Slightly enlarge the clearance between the center blade edge and the inner clamp blades at the placecorresponding to the pocket trouble. The clearance sho...
Page 153 - D. The inner clamp blades are improperly positioned.
7. FOLDING MACHINE BAS-7610 7-23 13. The pocket outline is curved. <Cause> A. The flap margin is small. Make the flap margin at least 8 mm. B. The tucking blades have burrs. Remove the burrs and buff the tucking blades. C. The clearance between the tucking blades of the folding clamp assembly ...
Page 155 - stray when the chamfering blades retract.; E. The inner blades are improperly adjusted.
7. FOLDING MACHINE BAS-7610 7-25 14. The pocket opening is wide. <Cause> A. When the chamfering blades are attached below the correct position, the body and the pocket stray when the chamfering blades retract. Move upward and reattach the chamfering blades.At this time, set the clearance betwe...
Page 156 - B. Tucking blade L and R are improperly attached.
7. FOLDING MACHINE BAS-7610 7-26 15. The pocket opening is not tucked in. <Cause> A. The flap margin is small. Make the flap margin at least 15 mm. B. Tucking blade L and R are improperly attached. Slide the tucking blades forward. If this adjustment is not enough to solve the trouble, enlarge...
Page 157 - The flap margin at the pocket opening is out of the pocket.
7. FOLDING MACHINE BAS-7610 7-27 16. The flap margin at the pocket opening is out of the pocket. <Cause> A. The flap margin is large. Set the pocket material onto the center blade so that the flap margin is even at every point. The proper length ofthe flap margin is 12-15 mm. When the flap mar...
Page 158 - Material protrudes from the pocket opening.; A. Tucking blade L and R are improperly positioned.
7. FOLDING MACHINE BAS-7610 7-28 17. Material protrudes from the pocket opening. <Cause> A. Tucking blade L and R are improperly positioned. Slide the tucking blades forward. If this adjustment is not enough to solve the problem, enlarge the chamferedparts of the tucking blades by machining.At...
Page 159 - A. The pocket and the body are improperly positioned.; B. The pattern pitch of the pocket is different from that of the body.
7. FOLDING MACHINE BAS-7610 7-29 18. The pocket pattern is not aligned with the body pattern (when the pattern is vertical). <Cause> A. The pocket and the body are improperly positioned. Position them correctly in mode pattern matching. B. The pattern pitch of the pocket is different from that...
Page 161 - The needle location at the corners is improper.
7. FOLDING MACHINE BAS-7610 7-31 20. The needle location at the corners is improper. <Cause> The inertia of the X-Y movement mechanism results in improper needle location, which is differentfrom the programmed points. (Note: The machine motor rotating speed may vary the needle locationat each ...
Page 162 - A. The inner clamp blades are improperly positioned.
7. FOLDING MACHINE BAS-7610 7-32 21. The pocket top is narrow. <Cause> A. The inner clamp blades are improperly positioned. Increase the clearance between the center blade edge and the inner clamp blades at the pocket top. B. When the top edge of the pocket material is not clamped by the sewin...
Page 163 - and the center blade is large only at the forward part.; B. The inner clamp blades are improperly attached.
7. FOLDING MACHINE BAS-7610 7-33 22. The seam margin is large. <Cause> A. Because the forward part of the center blade is curved up, the clearance between the needle plate and the center blade is large only at the forward part. Remove the center blade. Distort the center blade to level. B. The...
Page 164 - The pocket has skipped stitches at the sewing start.; A. The needle thread coming out of the needle is short.
7. FOLDING MACHINE BAS-7610 7-34 23. The pocket has skipped stitches at the sewing start. <Cause> A. The needle thread coming out of the needle is short. • Lengthen the thread in pretension. • Check the opening amount between the tension discs. • Perform reverse stitching 2-3 stitches after re...
Page 165 - The stitch pitch is uneven at the corners.
7. FOLDING MACHINE BAS-7610 7-35 24. The stitch pitch is uneven at the corners. <Cause> The inertia of the X-Y movement mechanism results in improper needle location, which is differentfrom the programmed points.(Note: The machine motor rotating speed may vary the needle location at each corne...
Page 170 - The tucked margins at the bottom protrude on both sides.; B. Tucking blade RD or LD is improperly positioned.
7. FOLDING MACHINE BAS-7610 7-40 1. The tucked margins at the bottom protrude on both sides. <Cause> A. The flap margin is too large. Set the pocket material onto the center blade so that the flap margin is even at each point. The proper length ofthe flap margin is 12-15 mm. If the flap margin...
Page 171 - The flap margins at the bottom on both sides are not tucked in.; A. The flap margin on both sides are too small.
7. FOLDING MACHINE BAS-7610 7-41 2. The flap margins at the bottom on both sides are not tucked in. <Cause> A. The flap margin on both sides are too small. Adjust the flap margin to 12-15 mm. B. Tucking blade RD or LD is improperly positioned. Shift the tucking blade backward, then adjust it s...
Page 172 - The tucked flap margins at the bottom protrude below.; A. Tucking blade RD or LD is improperly positioned.
7. FOLDING MACHINE BAS-7610 7-42 3. The tucked flap margins at the bottom protrude below. <Cause> A. Tucking blade RD or LD is improperly positioned. Refer to “Trouble 2. Cause B”. B. Because the clearance between tucking blade D and RDD or LDD is too small, the pocket material strays when the...
Page 174 - The tucking blades do not operate smoothly.
7. FOLDING MACHINE BAS-7610 7-44 5. The tucking blades do not operate smoothly. <Cause> Because tucking blade RDD or LDD is attached below the correct position, tucking blades RDD orLDD and D do not retract smoothly. Adjust the clearance between these two tucking blades to approximately 1-2 mm...
Page 176 - The bottom seam is zigzag chain stitch.
7. FOLDING MACHINE BAS-7610 7-46 7. The bottom seam is zigzag chain stitch. <Cause> The seam sewn from left to right almost aligns with the border line between the hitch stitch andperfect stitch. This problem happens when both of these stitches appear. Because this is a basic property in a sew...
Page 179 - SERVICE MANUAL
SERVICE MANUAL 15-1, Naeshiro-cho, Mizuho-ku, Nagoya 467-8561, Japan. Phone: 81-52-824-2177 Printed in Japan 151-761 I2110825 2002.12. H (1)
