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EverSewn CH04AX Repair Manual

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REPAIR MANUAL
CH04AX

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Summary of Contents for EverSewn CH04AX

  • Page 1 REPAIR MANUAL CH04AX...

  • Page 2: Table Of Contents

    6-3. Trouble shooting – Stepping motor(stitch length)................2 6-4. Trouble shooting – Stepping motor(upper tension) ................2 6-5. Trouble shooting – Stepping motor(thread trimmer) ................. 2 6-6. Trouble shooting – Stepping motor(zigzag) ..................2 6-7. Trouble shooting –Wi-Fi module (CH04AX) ..................2...
  • Page 3 6-8. Operation Panel Malfunction ....................... 2 6-9. Start/Stop button & Reverse button malfunction ................2 6-10. Bobbin winder cannot stop ....................... 2 6-11. Buttonhole Sewing Failure........................ 2 6-12. Foot Controller Failure ........................2 6-13. LED Light Failure ..........................2 6-14.

  • Page 4: Gauge & Tool List

    Gauge & Tool List Gauge Appearance ZH SAP# Item Description Spec. Purpose For needle bar Needle bar height height 031CAA0044 29.05mm gauge adjustment (see page 16) For adjusting 031CAA0013 Hook timing gauge 3.5mm the hook timing (see page 18) For adjusting Hook timing gauge 031CAA0014 the hook timing...
  • Page 5 Tool Type Head Type Item Description Specs Remark Hexagon 1.5mm screwdriver Hexagon 2.0mm screwdriver Hexagon 2.5mm screwdriver Hexagon 3.0mm screwdriver Hexagon 4.0mm screwdriver L-shape slotted screwdriver (twin heads)

  • Page 6: Remove Machine Covers

    Remove machine covers 2-1. Remove accessory box 2-1-1. Grasp the accessory box then pull toward by the arrow direction to remove it. 2-2. Remove face plate 2-2-1 Use Philips head screwdriver to remove the setscrews of the face plate, free arm cover, free arm base cover and bed cover.
  • Page 7 2-3. Remove Front cover 2-3-1 Use Philips screwdriver to remove the front cover 2-3-2 Remove the harness &WIFI module cable...

  • Page 8: Remove

    2-4. Remove Back cover 2-4-1 Use Philips screwdriver to remove the back cover (Please lower the presser foot lever first) 2-4-2 When removing the back cover, please pay attention to avoid hitting the receptacle holder and break it. 2-5. Remove bed cover 2-5-1 Use Philips screwdriver to remove the bed cover...

  • Page 9: Mechanical Components Adjustment

    Mechanical components adjustment ① ② ③ ④ ⑤ ⑥ ⑦ ⑧ 3-1. Play of the Arm shaft (※Please remove face plate, free arm cover, free arm base cover, base cover, front cover in advance) Use 2.5mm hexagon screwdriver to loosen 2 setscrews on arm shaft collar (as shown in area ⑤).
  • Page 10 3-1-2 Follow the arrow direction to pull the hand wheel outward. 3-1-3 Pull arm shaft collar to left (as shown in area ⑤) and fit tightly against the arm shaft bushing. Then tighten 2 setscrews on the arm shaft collar 3-1-4 Check if the arm shaft can rotate smoothly.

  • Page 11: Thread Take Up Lever Adjustment

    3-2. Thread take up lever adjustment (※Please remove face plate, free arm cover, free arm base cover, bed cover, front cover and back cover in advance) 3-2-1 Turn the hand wheel to check the noise location 3-2-2 Loosen the screw M4X8A (as shown in area ③) . Check and adjust the tightness of thread take up lever supporter.

  • Page 12: Adjusting The Needle Drop Position

    3-3. Adjusting the needle drop position (※Remove the face plate) 3-3-1 Select straight stitch pattern 3-3-2 Loosen the 2.0mm hex socket setscrew. (as shown in area ④) 3-3-3 Pull the needle bar supporter backward to move the needle forward and vice versa. (as shown in area ④) 3-3-4 Adjust the needle position to the hole center of the needle plate then tighten the setscrew.

  • Page 13: Adjust Height Of The Presser Foot

    3-4. Adjust height of the presser foot (※Remove the face plate) 3-4-1 Drop down the feed dog 3-4-2 Raise the presser foot lifter 3-4-3 Use a 2.0mm hexagon screwdriver to loosen the setscrew. (as shown in area ⑥) 3-4-4 Put the gauge with the smaller side down below the presser foot.
  • Page 14 3-4-5 Adjust the presser bar position to make it fit against the gauge. 3-4-6 Drop down the feed dog 3-4-7 Slightly tighten the hex socket setscrew. (as shown in area ⑥) 3-4-8 Use the gauge to check the height of the presser foot. By the smaller side, the gauge can be put beneath the presser foot 3-4-9...

  • Page 15: Adjust The Zigzag Movement Of The Needle

    Note: The presser foot should be aligned with the feed dog hole of the needle plate without slanting. 3-5. Adjust the zigzag movement of the needle (※Remove the face plate, free arm cover, free arm base cover, bed cover and front cover) 3-5-1 ”...

  • Page 16: Adjust Needle Drop Positions

    3-6. Adjust needle drop positions (※Remove the face plate) 3-6-1 ” ，and set the stitch width to 7mm Choose the stitch pattern “ 3-6-2 Use a 1.5mm Hex screwdriver to loosen the setscrew of the needle bar supporter. (as shown in area ⑦) 3-6-3 Turn setscrew (as the picture shown below) to adjust the needle bar position.

  • Page 17: Adjust The Automatic Needle Threader

    3-7. Adjust the automatic needle threader (※Remove the face plate) 3-7-2 Turn the hand wheel and move the needle to its highest position. 3-7-3 Use a 1.5mm hex screwdriver to loosen the setscrew of threader stopper. 3-7-4 Move the threader stopper upward to make the threader hook go up.

  • Page 18: Adjust The Needle Bar Height

    3-7-7 Tighten the threader stopper firmly and make sure the threader stopper is not skewed. 3-8. Adjust the needle bar height 3-8-1 Remove the face plate 3-8-2 Move the needle to its center position 3-8-3 Use a flathead screwdriver to remove the needle plate. 3-8-4 Press the shank complete lever to release the presser foot 3-8-5...
  • Page 19 3-8-5 Use a flathead screwdriver to loosen the needle clamp and remove the needle. 3-8-6 Install the needle bar height gauge (29.05+/-0.05mm) 3-8-7 Turn the hand wheel to let needle go to its lowest position 3-8-8 When the needle is at lowest position, the gauge will slightly touch the inner brink of the shuttle hook holder 3-8-8 If the needle bar height is set too high or low, use a 2.0mm hex...

  • Page 20: Adjust The Hook Timing

    3-9. Adjust the hook timing 3-9-1 Use a flathead screwdriver to remove the needle plate 3-9-2 ” ，and set the stitch width to 7mm Choose the stitch pattern “ 3-9-3 Turn the hand wheel to move the needle to the left side and down to its lowest location 3-9-4 Install the timing gauge (3.5mm) and its holder then tighten the...
  • Page 21 3-9-6 Take the gauge (3.5mm) out. 3-9-7 Turn the hand wheel to raise the needle bar and make the positioning plate touch the top side. 3-9-8 Turn the hand wheel to make the needle go down until the tip of shuttle hook holder meets the needle from the front view (but not physical touch).

  • Page 22: Adjust The Distance Between Needle And Hook

    3-9-11 Use a 2.0mm hex screwdriver to loosen 2 setscrews on the lower shaft gear and adjust the hook position. Repeat step 3-9-3 to 3-9-8 for adjustment. 3-9-12 After adjusting to the right position, tighten the setscrews on the lower shaft gear. 3-10.
  • Page 23 3-10-5 Firstly turn the hand wheel to move the needle to the left side and its lowest position. Then turn the hand wheel again to make the hook tip meet the needle. At this point, the play should be between 0.05~0.1mm. 3-10-6 If the play does not fit the standard, use a 2.0mm hex screwdriver to loosen the hex socket screw for the needle bar...
  • Page 24 3-11-3 Take out the shuttle hook 3-11-4 Loosen 2 setscrews (M4*8) on the bias bushing presser plate. 3-11-5 Move the lower shaft bias bushing up will increase the play and move it down will reduce the play. 3-11-6 While adjusting the correct play, please notice that the movable distance for the shuttle hook holder should be within 0.5mm.

  • Page 25: Adjust The Play For The Rotary Hook Plates

    3-12. Adjust the play for the rotary hook plates. 3-12-1 Use a flathead screwdriver to remove the needle plate. 3-12-2 Turn the hand wheel in counterclockwise direction to let the bobbin case touch the rotary hook holder plate(2) and form a gap between the rotary hook holder plate(1).

  • Page 26: Adjust The Height Of The Feed Dog

    3-12-6 Turn the hand wheel in clockwise direction to make the bobbin case touch the rotary hook holder plate(1) and form a gap between the rotary hook holder plate(2). 3-12-7 Use the gauge to measure the play of the hook holder plate(2).
  • Page 27 3-13-3 Attach the power cable and start the machine. Select the straight stitch pattern and set the stitch length to 5.0mm. 3-13-4 Lay down the sewing machine. 3-13-5 Turn the hand wheel to make sure the Phillips screw driver can reach the screw (M4*8A, as shown below) and loosen it.
  • Page 28 3-13-8 Adjust M4 hex socket screw in counterclockwise direction. 3-13-9 It will lower the height of the feed dog. 3-13-11 Place the gauge on the needle plate with the side marked 0.9mm down then turn the hand wheel to make the feed dog move.

  • Page 29: Adjust The Feed Dog Position

    3-14. Adjust the feed dog position 3-14-1 Remove the free arm base cover and the free arm cover. 3-14-2 Loosen 2 setscrews with washers (M4*12). 3-14-3 Adjust the feed rock support shaft position to make sure that the feed dog is set to the center of the needle plate hole. 3-14-4 Tighten 2 setscrews back.

  • Page 30: Adjust The Bobbin Case Tension

    3-15-4 If it is out of the standard, adjust dial tension regulator. Push forward to get a weaker tension and do it in reverse way to get a heavier tension. 3-15-5 Use the gauge to re-check the tension strength to see if it fits the standard (60~70gf).

  • Page 31: Adjust Motor Belt

    3-16-4 If it is out of the standard, turn the bobbin case screw for adjustment. Turn it in clockwise direction to get a stronger tension and do it in reverse if the tension is too strong. 3-16-5 Use the tension meter to check the tension strength fits to the standard (13~17gf).

  • Page 32: Super Adjust Stitch Balance

    3-17-4 When the belt tension fits to the standard, tighten the setscrews. 3-18. Super Adjust stitch balance 3-18-1 Choose the stitch pattern “ “and sew one complete pattern. 3-18-2 If the sewing stitch forms poorly as below picture, adjust 4.0mm hex socket screw in counterclockwise direction 3-18-3 If the sewing stitch forms poorly as below picture, adjust 4.0mm...

  • Page 33: Bobbin Winder Adjustment

    3-20. Bobbin winder adjustment 3-20-1 Put one empty bobbin in bobbin winder shaft and push to right position. 3-20-2 Place a spool of sewing thread in the spool holder 3-20-3 Follow the instruction to guide the thread through the thread guide.
  • Page 34 3-20-6 Turn the switch on and push the start button to start winding the bobbin thread. 3-20-7 Check the winding result. If the lower part of bobbin thread is winding much thicker (as the picture shows), turn the screw of the bobbin winder thread guide in counter-clockwise direction.
  • Page 35 3-20-11 After adjusting, winding the bobbin thread again and check if it fits to the standard (80% full and equally wound) 3-20-12 Note: After winding the bobbin thread, please push the bobbin winder shaft to the left for normal sewing.

  • Page 36: Electronic Components

    Electronic Components 1.Stepping motor 2. Stepping motor 3. BH photo sensor complete (upper thread tension) (zigzag) 4. Stepping motor 5. Micro switch 6. Photo sensor plate complete (trimming) (bobbin thread winding)
  • Page 37 7. LED Light (panel) 8. Stepping motor 9. LED Light (center) 10. Main board (stitch length) HF transformer board DC motor Receptacle assembly DC jack socket (foot controller)
  • Page 38 Wi-Fi module 15. Speed slider (CH04AX) Operation keys PCB Harness...

  • Page 39: Printed Circuit Board

    Printed Circuit Board 5-1. Main board...

  • Page 40: Hf Transformer Board

    5-2. HF transformer board J1：AC power input J2：Main Board...

  • Page 41: Trouble Shooting - Main Power

    Trouble shooting – Electronic parts 6-1. Trouble shooting – Main power Check if the cable is connected with both main board and HF transformer board correctly. 6-2. DC Trouble shooting - Motor 6-2-1 Check if the cable is connected with both main board and HF transformer board correctly. 6-2-2 If the problem still exists, please replace another DC motor or a new DC motor cable.

  • Page 42: Trouble Shooting - Stepping Motor(Stitch Length)

    6-3. Trouble shooting – Stepping motor(stitch length) 6-3-1 Check if the cable of the stepping motor is connected to the correct connector on the main board. 6-3-2 If the problem still exists, please replace a new stepping motor. 6-4. Trouble shooting – Stepping motor(upper tension) 6-4-1 Check if the cable of the stepping motor is connected to the correct connector on the main board.

  • Page 43: Trouble Shooting - Stepping Motor(Thread Trimmer)

    6-5. Trouble shooting – Stepping motor(thread trimmer) 6-5-1 Check if the cable of the stepping motor is connected to the correct connector on the main board. 6-5-2 If the problem still exists, please replace a new stepping motor. 6-6. Trouble shooting – Stepping motor(zigzag) 6-6-1 Check if the cable of the stepping motor is connected to the correct connector on the main board.

  • Page 44: Trouble Shooting -Wi-Fi Module (Ch04Ax)

    6-7. Trouble shooting –Wi-Fi module (CH03AX) 6-7-1 Check if the harness is connected with the Wi-Fi module and the main board properly. 6-7-2 If the problem still exists, please replace another Wi-Fi module or a new harness for connection.

  • Page 45: Operation Panel Malfunction

    6-8. Operation Panel Malfunction 6-8-1 Check if all buttons / speed slider work properly. 6-8-2 Please check if the operation panel board connects with the main board correctly. 6-8-3 If above items are working properly, please change the main board or operation panel board to fix the problem.

  • Page 46: Start/Stop Button & Reverse Button Malfunction

    6-9. Start/Stop button & Reverse button malfunction 6-9-1 Please check if all buttons function well with problem 6-9-2 Please check if the button PCB connects to the operational panel board correctly 6-9-3 If the above are checked and found no problems, please replace main board or operation panel board or button PCB and check if the problem is solved.

  • Page 47: Bobbin Winder Cannot Stop

    6-10. Bobbin winder cannot stop 6-10-1 Please check if the micro switch of the bobbin winder connects with the main board correctly 6-10-2 Please make sure if there is proper space between the micro switch and bobbin winder crank. 6-10-3 If no issues can be found in the first step, please change the micro switch or the main board to see if the problem can be solved.

  • Page 48: Buttonhole Sewing Failure

    6-11. Buttonhole Sewing Failure. 6-11-1 that the BH sensor board is connected to the main board correctly. Then refer to “BH adjustment” chapter to adjust the BH sensor position. 6-11-2 If the above item has been checked and found no issues, please change the BH sensor board or the main board to fix the problem.

  • Page 49: Led Light Failure

    6-13. LED Light Failure 6-13-1 Please check if the LED light wire has been connected to the main board properly. 6-13-2 Please replace LED light module or main board if no problems can be found on the item above. 6-14. Organize the cables 6-14-1 Keep the wires in A part flat and close to the body frame.
  • Page 50 6-14-3 Organize the wires and place them into the wire fixing bracket. 6-14-4 Use the cable tie to organize the wires as shown in the red circle. Keep the cable tie head inside to prevent interfering with outlook covers. 6-14-5 Use the cable tie to fix the wires for switch receptacle assembly.

  • Page 51: Embroidery Unit

    Embroidery Unit 7-1. Main parts of the embroidery unit 6. Vertical shaft under cover (2) 1. Handle grip 2. Top cover 7. Frame fixed position button 3. Vertical shaft under cover (1) 8. Y-axis slide plate 4. Vertical shaft cover 9.

  • Page 52: Dissemble The Embroidery Unit

    7-2. Dissemble the embroidery unit 7-2-1 Remove the top cover Use a Philips screw driver to remove the setscrews of the top cover. Push the top cover to the right (arrow direction) to remove Be sure not to break the harness while removing the top cover.
  • Page 53 7-2-2 Remove the vertical shaft under cover (1). Use a Philips screw driver to remove the setscrews of the vertical shaft under cover (1). 7-2-3 Remove the vertical shaft under cover (2). Use a Philips screw driver to remove the setscrews of the vertical shaft under cover (2).
  • Page 54 7-2-5 Remove the body cover of the embroider unit Use the screw driver to remove the setscrews Unplug the D-type connector wire. NOTE: When attach the embroidery unit to the body cover, please calibrate the center position again (please refer to user manual for detailed instructions)

  • Page 55: Mechanical Adjustment For The Embroidery Unit

    7-3. Mechanical adjustment for the embroidery unit. 7-3-1 Y-axis belt tension adjustment Use the screw driver to loosen the setscrew, push the plate to the right to tighten the belt or push it to the left side to loosen it. Use the tension gauge to measure the tension strength.
  • Page 56 7-3-3 Adjusting the distance of the Y-axis belt gear Use the screw driver to loosen the two setscrews Push the stepping motor toward the 105-teeth gear to make the gap smaller. Push to another side to enlarge the gap. Make sure the two gears gently fit together then re-tighten the two setscrews.

  • Page 57: Pcb Layout For The Embroidery Unit

    7-4. PCB Layout for the embroidery unit Converter Board J1: D-type connector J2: Harness (10P) J3: X-axis stepping motor connector J4: X-axis photo sensor connector Photo sensor complete (Y-axis home position) J1: Y-axis photo sensor JP1: Converter board connector JP2: Y-axis stepping motor connector JP3: Harness (10P)

  • Page 58: Quick Repair Reference

    Quick Repair Reference Primary factors and Items for Inspection Methods Problem Repair Method causes Inspection and Standards Stitch skipping 1. Incorrect hook Refer to page 16, Needle quality Place the needle on Thread abrasion timing adjustment 18, 25, 26 for level block and check Thread breakage 2.
  • Page 59 Does not turn BH lever does not push upward the Check if the BH Check if the BH lever (Electronic sounds and restore to the original BH lever to the set lever is in the set is in the set position. operating display lamps position position...
  • Page 60 Threading not possible. Bad auto threader Refer to page 13 Please follow Please follow the for adjustment the instructions instructions for for adjustment. adjustment. When the threader lever Improper auto threader Refer to page 13 Please follow Please follow the returns, it stops part way installment.

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