Toyota ESP9000 User manual

SERVICE MANUAL
Embroidery Machine
ESP9000
(15 needles)

Ｈｏｗ to Ｕｓｅ ｔｈｉｓ Ｓｅｒｖｉｃｅ Ｍａｎｕ
ａｌ
1．This service manual applies to the ESP9000.
Model names are indicated only for sections equipped with each model.
2．Refer to the section on TROUBLESHOOTING first.
Trouble often results from two or more causes. The TROUBLESHOOTING
section indicates the correct order and method of troubleshooting. When
need arises to repair the embroidery machine in reference to this Service
Manual, refer to TROUBLESHOOTING first. Then, refer to ADJUSTMENT or
REPLACEMENT as suggested.
3．Only the critical instructions are given.
When a component must be removed for troubleshooting, adjustment or
replacement, the Service manual explains how to remove other components
before the component in question can be removed.
However, the manual does not explain how the other components are fitted,
unless such information is necessary for technical reasons, when adjustment
or replacement is completed.

Ｉｎｓｐｅｃｔｉｏｎ & Repairs
1．When parts need to be replaced, use only parts certified by Aishin Seiki Co.,
Ltd., to ensure machine performance.
2．To prevent any accident from occurring, be sure to turn the power OFF
before repair.
CONTENTS
１．
SPECIFICATIONS
...............................................................................................................
.....................1
２．
TROUBLESHOOTING ............................................................................................
.......................2

2-1 The power supply does not turn
on........................................................................................2
2-2 An error message is displayed ”Check ! SEWING
MOTOR”........................................3
2-3 An error message is displayed “Check ! X
MOTOR”......................................................4
2-4 An error message is displayed ” Check ! Y
MOTOR”.....................................................5
2-5 An error message is displayed ”NEEDLE CASE
ERROR” ............................................6
2-6 Holder does not return to stroke center after home position
return......................7
2-7 Thread comes off
needle.............................................................................................................8
2-8 Skips
stitches..................................................................................................................................
..9
2-9 Needle thread
breaks...................................................................................................................10

2-10 Bobbin thread
breaks...................................................................................................................12
2-11 Needle
breaks..................................................................................................................................1
3
2-12 Thread wiper hook does not
operate....................................................................................14
2-13 Thread trimming
fails....................................................................................................................15
2-14
Puckering...............................................................................................................................
............16
2-15 Improper
tension............................................................................................................................17
2-16 Jump function does not
work...................................................................................................18
2-17 An error message is displayed “THREAD
BREAK” .......................................................19
2-18 Stitch registration slips
out.......................................................................................................20

３．ＡＤＪＵＳＴＭＥＮＴ ＯＦ ＭＡＩＮ ＣＯＭＰＯＮＥＮ
ＴＳ ..................................21
3-1 Timing of the needle and the rotary
hook...........................................................................21
3-2 Position of the hook
support....................................................................................................23
3-3 Standby position of thread
catcher.......................................................................................24
3-4 Blade
pressure................................................................................................................................
25
3-5 Picker
position................................................................................................................................2
7
3-6 Position of the thread wiper
hook..........................................................................................28
3-7 Adjustment of the jump motor
position...............................................................................29
3-8 Tension of drive belts A &

C....................................................................................................30
3-9 Tension of deceleration belts B, D,
E...................................................................................31
3-10 Limit
sensor....................................................................................................................................
..32
3-11 Thread
sensor.................................................................................................................................3
4
3-12 Power
box.........................................................................................................................................
35
４．ＲＥＰＬＡＣＥＭＥＮＴ ＯＦ ＭＡＩＮ ＣＯＭＰＯＮ
ＥＮＴＳ ..........................36
4-1 Rotary
hook.......................................................................................................................................
36
4-2 Thread

cutter...................................................................................................................................3
7
4-3 Thread
catcher................................................................................................................................3
8
4-4 Needle
bar.........................................................................................................................................
.39
4-5 Needle bar
reciprocator...............................................................................................................41
4-6 Thread change
motor...................................................................................................................43
4-7 Power supply
board.......................................................................................................................44
4-8 Power circuit
board........................................................................................................................45
4-9 Jump
motor.....................................................................................................................................
..46
4-10 Main circuit

board...........................................................................................................................47
4-11 Operation box
assembly...............................................................................................................48
4-12 Upper shaft
sensor.........................................................................................................................49
4-13 Sewing machine
motor..................................................................................................................50
4-14 X
motor.....................................................................................................................................
...........51
4-15 Y
motor.....................................................................................................................................
...........52
4-16 Thread wiper
motor........................................................................................................................53
4-17 Thread
sensor...................................................................................................................................
54
4-18 Operation control circuit
board................................................................................................55

4. REPLACEMTNT OF MAIN COMPONENTS
4-9. Jump motor
［Removal］
(1) Remove the needle case.
[Please refer to 『“ 4-5. Needle bar
reciprocator” 』 on page 41]
(2) Remove five set screws (a) and the arm
front cover L. (Fig.1)
(3) Remove each setting screws and the
thread stand plate, bobbin winder base
and rear cover. (Fig.2)
(4) Cut the cable tie and remove the relay
harness.
(5) Remove two setting screws (b) and the
jump motor set. (Fig.3)
(6) Loosen the setting screws (c) and
remove the jump lever holder. (Fig.4)
(7) Remove four setting screws (d) and the
jump motor. (Fig.4)
［Installation］
(1) Install the jump motor with four setting
screws (d). (Fig.4)
(2) Hang the jump lever return spring on
the jump lever holder and pull down the
spring as low as possible so that the
spring will not be located on the jump
positioning collar. (Fig.4)
(3) Tighten the setting screw (c) and check
that the jump lever holder returns with
the spring and stops with the stopper.
(Fig.4)
(4) Install the jump motor set with two
setting screws (b). Adjust the clearance
between the jump lever and the needle
reciprocator at 0.5 mm by moving the
jump motor right and left.
(5) Connect the relay harness, bundle the
cord with cable tie and install the thread
stand plate, bobbin winder base and
rear cover.
(6) Install the needle case.
FIG.1
FIG.2
FIG.3
(a)
Arm front cover L
Thread stand plate
R
ear cover
Bobbin winder base
(b)
Jump motor set
Jump lever return spring
Jump positioning
collar Stopper
(d)
(d)
(c) Jump lever holder
-46-

FIG.4
4-10. Main circuit board
［Removal］
(1) Remove two setting screws (a) and the
table set. (Fig.1)
(2) Remove four set screws (b) and the
base cover rear R. (Fig. 1)
(3) Loosen two setting screws (c), remove
other two set screws (d), move the
case cover upper upwards, disconnect
the connector CN2 and remove the
case cover upper. (Fig.2)
(4) Disconnect all the connectors. (Fig.3)
(5) Remove two setting screws (e) and
remove the main circuit board by
holding the plastic spacer with pliers.
［Installation］
Attached in the reverse procedure of
removal
FIG.1
FIG.2
4.REPLACEMENT OF MAIN COMPONENTS
(b)
Base cover
rear R
Table set
(a)
(d)
(c)
Case cove
r
upper
Main circuit board
(e) CN2
-47-

FIG.3
-48-

4.REPLACEMENT OF MAIN COMPONENTS
4-11. Operation box assembly
［Removal］
(1) Loosen retaining screw (a) and rotate
the operation box in the direction of the
arrow to set the box in the upright
position (Fig.1).
(2) Remove retaining screw (b) and two
retaining screws (c) and the operation
box cover (Fig.1).
(3) Remove four retaining screws (d).
Unplug the cord and remove the
operation box (Fig.2).
［Installation］
(1) Plug in the cord.
(2) Secure the operation box to the
bracket with four retaining screws (d).
One of these screws is for grounding
(Fig.2).
(3) Mount the operation box cover with
retaining screw (b) and two retaining
screws (c) (Fig.1).
(4) Rotate the operation box to set it at
the desired angle for easy operation
and secure it with retaining screw (a)
(Fig.1).
FIG.1
FIG.2
-49-

4-12. Upper shaft sensor
［Removal］
(1) Remove two setting screws (a) and the
bobbin winder base set. (Fig.1)
(2) Loosen four setting screws (b) and
remove the rear cover. (Fig.1)
(3) Remove two setting screws (c) and the
upper shaft sensor set. Then remove
two setting screws (d) and the upper
shaft sensor. (Figs.1, 2)
(4) Remove four setting screws and the
base cover rear L. (Fig.1)
(5) Loosen two setting screws, remove
other two setting screws, move the
case cover upper upwards, disconnect
the connector CN3 and cut the cable
tie and then remove the upper shaft
sensor. (Refer to Fig.2 on page 47)
［Installation］
(1) Install the upper shaft sensor on the
sensor base with two setting screws (d).
(Fig.3)
(2) Insert the connector of the upper shaft
sensor in CN3 on the main circuit board.
(Fig.5)
(3) Fix the upper shaft sensor set with two
setting screws (c) in the position where
the center of the sensor comes to the
center of the rotation detecting plate.
(Figs.2, 4)
(4) Bundle the cords with cable tie.
(5) Set the DS1-1 on and turn the power
on. Rotate the hand wheel to move the
needle bar to the bottom dead center.
Check that the LCD display shows the
needle position at 180°.
Note: In case the LCD display does not
show 180 ° , loosen the set screw,
adjust the position of the detecting
plate and fix it. (Fig.1)
(6) Install the case cover upper, base
cover rear L, rear cover and bobbin
winder base set.
FIG.1
FIG.2
4.REPLACEMENT OF MAIN COMPONENTS
(c)
U
pp
er shaft sensor set
Upper shaft sensor
(a)
R
ear cover
(b) (b)
B
ase cover
Rear L
Bobbin winder base set
-50-

FIG.3
FIG.4
FIG.5
4-13. Sewing machine motor
［Removal］
(1) Remove the rear cover and base cover
rear R.L.
(2) Loosen two set screws (a), remove
other two set screws (b), move the
case cover upper, disconnect CN5 of
the main circuit board and CN3 of the
power circuit board and cut the cable
tie. (Figs.1, 2)
(3) Loosen two setting screws (c), which
are located on the motor side of the
lower shaft joint. (Fig.1)
(4) Remove four setting screws (d) and the
sewing machine motor. (Fig.4)
［Installation］
(1) Two set surfaces of the sewing
machine motor shaft and two setting
screws (c) of the lower shaft joint are
aligned and insert the sewing machine
motor.
(2) Fix the sewing machine motor with four
setting screws (d). (Fig.4)
Center
(3) Insert two setting screws (c) of the
lower shaft joint gradually, locate them
vertically to the setting points and
tighten them.
U
pp
er shaft sensor
Detecting plate (4) Insert two connectors and bundle the
cords with the cable tie.
(5) Install case cover upper with four
setting screws (a) and (b). (Fig.1)
CN3
Main circuit board
(6) Install the base cover rear R.L. and the
rear cover.
FIG.1
4.REPLACEMENT OF MAIN COMPONENTS
(b)
(a)
Case cove
r
upper
CN3
CN5
-51- Main circuit board

FIG.2
FIG.3
FIG.4
4-14. X motor
［Removal］
(1) Remove two setting screws (a) and
motor cover. (Fig.1).
(2) Loosen the nut and remove the
setting screw (b). (Fig.2)
(3) Disconnect the connectors. Remove
two setting screws (c) and the X
motor. (Fig.2)
(4) Remove four setting screws (d) and X
motor from the bracket. (Fig.2)
［Installation］
Power circuit board
Lower shat joint
(1) Mount the X motor to the motor base
with four setting screws (d) (Fig.2).
Sewing machine
motor (c)
(2) Set the X motor gear to the belt and
temporarily secure the motor base to
the X base B with two setting screws
(c) (Fig.2).
Arm bed (3) Adjust the belt tension by setting
screw (b) and firmly tighten two
setting screws (c), then tighten the
nut. (Figs.2, 3)
Power circuit board
Note: Check the tension, after tighting
screws (c).
(4) Insert the connector.
(d)
Sewing machine
motor
4.REPLACEMENT OF MAIN COMPONENTS
(a)
Motor cover
-52-

FIG.1
FIG.2
X base B
(d)
Nut
(b)
4-15. Y motor
［Removal］
(1) Remove four set screws (a) and the
base cover rear R. (Fig.1)
(2) Remove two setting screws (b) and the
fan set. (Fig.2)
(3) Remove the Y pulley box adjusting
screw (c) and nut (d) and loosen
setting screw (e) and nut (f). (Fig.2)
4.REPLACEMENT OF MAIN COMPONENTS
(c)
X motor Motor base
-53-

(4) Disconnect the connector, remove two
set screws (g) and Y motor bracket set.
(Fig.3)
(5) Remove four setting screws (h) and the
Y motor. (Fig.4)
［Installation］
(1) Mount the Y motor to its bracket with
four setting screws (h). (Fig.4)
(2) Set the Y motor gear to the belt and
temporarily secure them with two
setting screws (g). (Fig.3)
(3) Adjust the belt tension with setting
screw (e), and then firmly tighten with
two setting screws (g) and nut (f).
(Fig.3)
Note: Check the tension, after tighting
screws (g).
(4) Insert the Y pulley box adjusting
screw (c) into the backmost position
and tighten the nut (d). (Fig.3)
(5) Mount the fan set with two setting
screws (b). (Fig. 2)
(6) Insert the connector.
FIG.1
FIG.2
Base cover
rear R
(a)
Fan set
(b)
Y motor bracket set
(g)
(d) (f)
(c) (e)
-54-

FIG.3
FIG.4
4-16. Thread wiper motor
［Removal］
(1) Remove the each setting screws (a)
and the change cover, the relay circuit
board cover, the thread stand plate,
the bobbin base and the rear cover.
(Fig.1)
(2) Cut a cable tie and remove the relay
connector.
(3) Remove the setting screw (b) and two
setting screws (c), and the thread
wiper motor. (Fig.1)
(4) Remove the setting screw (d) and (e),
and the upper thread hook lever.
(Fig.3)
(5) Remove the three setting screws (f)
and the motor base.(Fig.3)
Note: Be sure to insert the small
washer that is contained in each
setting screws of (3) and (4) sections.
Y motor bracket
(h)
［Installation］
Y moto
r
(1) Attached in the reverse procedure of
removal
Note: Set the vertical position of the
upper thread hook lever slightly
upward, and make sure that the
connecting rod plate has a little play.
(2) After attaching, check the distance A
from the needle center to the thread
wiper hook tip. [Please refer to 『“3-6
Position of the thread wiper hook.” 』
on page 28 ]
(3) If the distance A differs from that
specified, loosen two setting screw (c)
and adjust by moving the thread wiper
motor base up/down.
4.REPLACEMENT OF MAIN COMPONENTS
Change cover Relay circuit
board cover
(a)
(a)
(a)
(a)
-55- Thread stand
plate Bobbin winder
base Rear cover