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Thick Thread
Service Manual
Edition No.: English 2.0 Rights Reserved In All Countries Printed in China
SAFETY INDICATIONS
Indicates that incorrect handling may cause hazardous conditions, resulting in death or severe injury. Indicates that incorrect handling may cause hazardous conditions, resulting in medium or slight personal injury or physical damage. Note that CAUTION
DANGER
CAUTION
level may lead to a serious consequence according to the circumstances. Always follow the instructions of both levels because they are important to personal safety.
CAUTION INDICATIONS
No 1 Caution indication Description Precaution for sewing machine operation: Indicates that removing the safety and operating the sewing machine for some other purposes with power-on are prohibited. z Please do not operate the sewing machine without protective equipment such as an eye guard, a belt cover or the others. z Please turn off the power switch when threading, changing a needle and a bobbin, cleaning, and lubricating.
Caution for fingers injury: Indicates a possibility of fingers (hands) injury in a certain condition.
Caution for squeezing fingers: Indicates a possibility of squeezing fingers in a certain condition.
Indication of pulley rotation direction: Indicates a normal pulley rotation direction of sewing machine.
SAFETY PRECAUTIONS
DANGER
To prevent from receiving an electric shock, always turn off a power switch and unplug power supply when opening a control box, and then open after ten minutes passes.
CAUTION
USAGE ENVIRONMENT
Please do not operate the sewing machine under the following conditions. (1) In the ambient temperature of 35 degrees (95F) or more than 35 degrees, or the ambient temperature of 5 degrees or less than 5 degrees (41F). (2) In the ambient temperature of 55 degrees (131F) or more than 55 degrees, or the ambient temperature of -10 degrees or less than -10 degrees (18F) during transportation. (3) In the relative humidity exceeding 85% or less than 45%. (4) In the open-air place or the location that receives direct sunlight. (5) In the place near heat sources such as heating devices. (6) In the atmosphere filled with dust, explosive gas, or corrosive gas. (7) In the place where the fluctuation in the power voltage of 10% or more than 10%, or the power voltage of -10% or less than -10% of the fixed power voltage. (8) In the place where the power source cannot supply enough voltage to keep the motor running. (9) In the place filled with strong electric noises such as high-frequency welders.
INSTALLATION
(1) Please have some specialists, who have enough experience for the sewing machine installations, install the sewing machine. (2) Please have a qualified electrician perform necessary electric wiring. (3) Please do not operate until the sewing machine is repaired when any damage or fault is found on the sewing machine at the installation. (4) Please do not refurbish the sewing machine. (5) The sewing machine is heavy. For the safety, please make sure to install the sewing machine head by more than one person. (6) When tilting the sewing machine, please stand at the hinge side and hold the sewing machine with both hands. Also, please lock the caster on the steel stand (7) Please lock the caster on the steel stand to prevent the machine from moving before tilting the sewing machine.
(9) Please make sure to fit the safety protective equipment (the motor cover or the others) and the accessory protective equipment (the eye guard) that removed temporarily for installation. (10) If the table and steel stand are not HIGHTEX original, the table and the steel stand have to be strong enough to withstand the weight and vibration of the sewing machine. (11) When fitting the caster to the steel stand that is not HIGHTEX original, the caster with locking function has to be strong enough to withstand the weight and vibration of the sewing machine.
SEWING
(1) Please make sure to turn the power switch off before installing or replacing needles. (2) Please pay attention for the fingers not to be injured by the needle point. (3) Please make sure to turn power switch off before lubricating. (4) Please pay attention that oil does not get on your skin or in your eyes as it may cause an inflammation. (5) Please make sure to keep oil out of the reach of children who may drink oil by mistake. (6) Please make sure to turn the power switch off before threading a needle. (7) Before starting the sewing, please make sure the position and the function of the halt switch. (8) Please do not touch the operating parts during sewing operation. (9) It is very dangerous to operate the sewing machine without safety guards (eye guards, belt covers, link covers, finger guards or the others). (9) Please make sure to operate the sewing machine with safety guards. (10) Please make sure to turn the power switch off when stopping the sewing machine temporarily.
ADJUSTMENT
(1) Please make sure to turn the power switch off before adjusting the sewing machine. (2) If the adjustment is required while the power switch on, do not step on the foot switch by mistake. (3) Please be careful not to be injured by a sharp part (such as the needle and the shuttle hook point). (4) Please make sure to put the safety guards (eye guards, belt guards, link covers, or the others) back on the initial position after the sewing machine adjustment. (5) Please make sure to lock the caster on the table when tilting the sewing machine.
Contents
1. STRUCTURE OF THE SEWING MACHINE......................................................................... 1 2. TECHNICAL PARAMETERS................................................................................................... 2 3. INSTALLATION.......................................................................................................................... 3
PREPARATION OF THE TABLE....................................................................................................................... 3 PREPARATION OF THE STEEL STAND........................................................................................................... 3 INSTALLATION OF THE MOTOR...................................................................................................................... 3 INSTALLATION OF THE CONTROL BOX.......................................................................................................... 3 CONNECTION OF THE OPERATION PANEL................................................................................................... 3 INSTALLATION OF THE POWER SWITCH....................................................................................................... 4 CONNECTION OF THE FOOT SWITCH........................................................................................................... 4 INSTALLATION OF THE SEWING MACHINE HEAD AND INSTALLATION REQUIREMENT FOR SPINDLE SYNCHRONIZING BELT.............................................................................................................................................. 5 3-9. CONNECTION OF THE ELECTRIC CABLES (REFER TO THE FIGURE ON THE FOLLOWING PAGE)...............5 3-10. INSTALLATION OF THE THREAD STAND.................................................................................................... 6 3-11. CONNECTION OF THE AIR TUBE............................................................................................................... 7 3-1. 3-2. 3-3. 3-4. 3-5. 3-6. 3-7. 3-8.
6. SEWING.................................................................................................................................... 12
6-1. THE SEWING OPERATION........................................................................................................................... 13 6-2. OPERATION OF EMERGENCY STOP SWITCH............................................................................................. 13 6-3. INPUT METHOD OF PATTERNS................................................................................................................... 14 6-4. SETTING OF THE CLAMP PRIORITY ORDER............................................................................................... 14 6-5. THE THERMAL TRIMMING OPERATION....................................................................................................... 15 6-5-1. Manual / Test mode conversion switch (No.1)........................................................................... 15 6-5-2. Thermal thread trimming device switch (No.2)...........................................................................16 6-6. ADJUSTMENT OF THE THREAD TENSION................................................................................................... 16 6-6-1. Bobbin thread tension..................................................................................................................... 17 6-6-2. Upper thread tension...................................................................................................................... 17
7-8. ADJUSTMENT OF THE TENSION RELEASE................................................................................................. 22 7-9. UPPER THREAD THERMAL TRIMMING DEVICE........................................................................................... 23 7-9-1 Setting thread puller........................................................................................................................ 23 7-9-2 Setting of the thickness detector...................................................................................................24 7-9-3 Thread stripper.................................................................................................................................25 7-9-4 Adjustment of the upper thread heater........................................................................................ 25 7-10. ADJUSTMENT OF LOWER THREAD TRIMMER HEATER.......................................................................... 26 7-11. ADJUSTMENT OF THE BOBBIN WINDER................................................................................................. 27 7-12. ADJUSTMENT OF THE WORK HOLDER PRESSURE................................................................................ 28 7-13. ADJUSTMENT OF THE THREAD TAKE UP SPRING TENSION..................................................................29 7-14. POSITION OF THE STOP POINT.............................................................................................................. 29 7-15. RELATION OF SHUTTLE HOOK POSITION AND STOP POINT POSITION................................................. 30 7-16. ADJUSTMENT OF THE MECHANICAL HOME POSITION........................................................................... 30 7-16-1. Adjustment of X direction (left and right)..................................................................................... 31 7-16-2. Adjustment of Y direction (front and rear)................................................................................... 32 7-17. ADJUSTMENT OF X-Y SYNCHRONOUS BELT TENSION......................................................................... 33 7-17-1. Adjustment of X synchronous belt tension.................................................................................. 33 7-17-2. Adjustment of Y synchronous belt tension.................................................................................. 33
8. MAINTENANCE....................................................................................................................... 34
8-1. 8-2. CLEANING................................................................................................................................................... 34 DISPOSING OF OIL WASTE......................................................................................................................... 34
(1) Sewing machine head (4) Emergency stop switch (8) Start foot switch
(10) Right material-presser plate foot switch (11) Electric trimming control box (13) Manual trimming text button (14) Automatic and manual trimming change-over switch (12) System control box
2. TECHNICAL PARAMETERS
Model: Optional sewing area: 7273CNC series X-direction (left/right) 500mm (optional within the area), Y-direction (front/back) 160mm Maximum sewing speed: Speed setting: Stitch length: Stitch line: Maximum number of needles: Storable sewing data: Data memory: Needle bar stroke: Thread take-up-level stroke: Needle type: Presser foot lift*1 Material-presser plate lift: Shuttle hook: Bobbin: Thread trimmer system: 700rpm 200-700rpm 0.1-12mm Single-needle and double-line lock stitch 20,000 per pattern 520 patterns (internal memory) Internal memory, USB memory 56.3mm 94mm 794 or DYX3 20mm 25mm (max 30mm) HAD-204 Large-scale bobbin Thermal trimming system Input voltage: AC 210/230V Output voltage: AC 2V Thread: Lubrication system: Lubrication oil: X-Y drive system: #8 to #10 (Synthetic) Manual oiling Silicone oil Stepping motor feedback control Timing belt drive system, intermittent or continuous feeding*2 Controller model: Power: Typical Applications: This automatic industrial sewing machine is designed for Ropes, Belts and Slings manufacturers serving high-end industrial markets such as fire and rescue, cargo transportation, military, automotive, aviation and rigging operations. Ideal for stitching 3-5 ply Nylon or Polyester slings with each of 3.5mm, or join 2 ropes and cords with each of 18mm (Dia.), for example lifting slings and cargo lashing straps, safety harness, fall protection equipment, parachutes rigging, hoisting belts, military belts, rope lanyards, climbing ropes, arborist harnesses and other critical area that needs extra reinforcement stitch. HT44X 200V-240V single-phase
*1Presser foot lift is the height of the presser foot after the sewing has stopped. *2Recommend intermittent feeding.
3. INSTALLATION
CAUTION
(1) Please have some specialists, who have enough experience for the sewing machine installations, install the sewing machine. (2) Please have a Qualified Electrician perform necessary electric wiring. (3) Please do not operate until the sewing machine is repaired when any damage or fault is found on the sewing machine at the installation. (4) Please do not refurbish the sewing machine. (5) If the table and the steel stand are not HIGHTEX original, the table and the steel stand have to be strong enough to withstand the weight and vibration of the sewing machine. (6) When fitting the caster to the steel stand that is not HIGHTEX original, the caster with locking function has to be strong enough to withstand the weight and vibration of the sewing machine.
3-1.
If the table is not HIGHTEX original, the thickness of the table is required to be over 40mm.
3-2.
If the steel stand is not HIGHTEX original, please refer to the assembly drawing for your own preparation. The assembly drawing is shown on the last page of this technical manual as Appendix 6. If the steel stand is not HIGHTEX original, please install the steel stand with the assembling instructions enclosed in the packing.
3-3.
box.
If the motor is purchased with installing on the machine head, please connect the motor with the control
Please conduct wire connection according to the instruction (motor installation) explained in another (control box) technical manual.
3-4.
If the control box is purchased without installing on the table, the control box shall be installed underneath the table. Please install the control box with the instruction in the paragraph [installation of the control box] on another [CONTROL UNIT] technical manual.
3-5.
Please install the operation panel referring following figure of control box backside view.
3-6.
(1) Mount the power switch (No.1) with the wood screw (No.2) underneath the table as shown on the
figure.
(2) Fix the electric cords with the staples (No.3) underneath the table. (3) Hook up the connector of power switch (No.1) to the connector of system control box (No.6). (4) Connect the terminal (No.10) of the black cable to wiring board on the transformer (No.8).Two
terminals have been prepared on this transformer (for 210V and 230V separately). Please refer to Appendix 1 of this technical manual for wiring details.
(5) Connect the other terminal (No.11) of white cable to the terminal adapter No.5 port of the relay
socket (No.9).
(6) These wiring boards are included in the electric cutting control box.
3-7.
Connect the foot switch (No.7) to X12 connector of the control box (No.6). Please refer to [3-8 cable connection] of this technical manual for more details.
3-8.
Installation of the sewing machine head and installation requirement for spindle synchronizing belt
CAUTION
(1) The sewing machine is heavy. For the safety, please make sure to install the sewing machine head by more than one person. (2) When tilting the sewing machine, please stand at the hinge side and hold the sewing machine with both hands. At the same time, please lock the caster on the steel stand. (1) (2) Make sure to hold the caster brake so as to control the table. Install rubber gasket on each corner of the table. The rubber gaskets are enclosed in the accessory box. (3) Put the sewing machine head on the table and set each leg to the corresponding rubber gasket. Left side of the table is equipped with two hinge covers temporarily. (4) (5) (6) These parts are all enclosed in the accessory box. Fix the hinge to the sewing machine with fixed screw. Push the middle part of synchronizing belt with finger and the force is about 0.1N (1kgf). If degree of tightness of the synchronizing belt is suitable, then there is no caving problem. If degree of tightness of the synchronizing belt is not suitable, please adjust regulator screw of the synchronizing belt so as to adjust tightness of it. Note: After a while of machine operation, the synchronizing belt will be loosening. If it is certain, please turn off the power and then conduct adjustment.
3-9.
Connection of the electric cables (Refer to the figure on the following page)
CAUTION
(1) Please make sure to ground the place where there is a electric shock and or malfunction. 1 Remove the stepping motor cover from sewing machine head. 2 Connect cable plug with its socket as shown in the socket diagram below. 3 Fix the cable with nylon clip and U-type nail. 4 Hold the dangling cables under the table with ties. At this time, please check whether the cables are not pulled when tilting the sewing machine. mark. Failure to do so may cause
Direction Y motor
Foot plate
Direction X motor
Spindle
Display
Grounding
<1>: Upper column pipe <2>: Lower column pipe <3>: Spool stand base (two stand bases) <4>: Spool mat (two mats) <5>: Spool holder (two holders) <6>: Spool shaft (two shafts) <7>: Spring washer (two washers) <8>: Nut (four nuts) <9>: Thread hunger <10>: Spool holder <11>: Column joint <12>: Washer <13>: Nut
4. LUBRICATION
CAUTION
(1) Please make sure to turn power switch off before lubricating. (2) Please pay attention that oil does not get on your skin or in your eyes as it may cause an inflammation. (3) Please make sure to keep oil out of the reach of children who may drink oil by mistake. [Notice] Please make sure to lubricate when operating for the first time after the installation. Also, please make sure to check the amount of oil when the machine has not been used for a long time. NOTE Please use high quality white machining oil. Put some oil to red marked oil holes and other part as described below arrow sign.
1. Thread slack mechanism 2. Shaft sleeve of differential shaft 3. Differential crank 4. Thread take-up cam 5. Thread take-up bar 6. Arm shaft bushing (front) 7. Differential eccentric gear 8. Arm shaft bushing (middle) 9. Big connecting rod 10. Arm shaft bushing (rear) 11. Bottom shaft bushing (front) 12. Bottom shaft bushing (rear) 13-16. Presser foot mechanism 17. Hook shuttle driving device
5. PROPER OPERATION
5-1. Initial setting of the control box
When using the sewing machine for the first time, the model and the language of the sewing machine in use have to be set. Refer to instructions in section 8.2 (U200 of 1-class parameter setup) setting of this Control system technical manual.
5-2.
It is necessary to conduct initial setting of thermal trimming system on the sewing machine. Please refer to 7-6 to conduct the procedures. [Note] If this initial setting is not performed, thermal trimming system may not operate normally.
5-3.
CAUTION
(1) Please make sure to turn the power switch off before installing or replacing needles. (2) Please pay attention for the fingers not to be injured by the needle point. 1 Loosen fastening screw (No.1). Then, insert a new needle (No.2) until the needle head is reached the end of needle bar (No.3). 2 Tighten the fastening screw (No.1) with the needle groove (No.4) facing to the front.
5-4.
Threading
CAUTION
(1) Please turn the power switch off when threading a needle. Thread the upper thread as shown on the figure.
5-5.
CAUTION
Please do not touch the rotating part during winding thread. Doing so may cause injury and/or the machine failure. [Note] Please make sure to pull the upper thread out of the needle before winding the bobbin thread.
(1)
Route the thread as shown in the below figure. Then, wind the thread to the bobbin (No.1) in the direction of A arrow several times. Then, fix the bobbin on bobbin winder and push the full-thread spring-board (No.2) in the direction of B arrow.
(2)
(2) With the machine in the Bobbin Wind Mode, step on the work holder foot switch first and then the start switch second so that the thread continues winding to the bobbin while the start switch is stepped on.
(3)
When thread on the bobbin finishes winding a certain amount (80% to 90% of the outside diameter of bobbin), full-thread spring-board returns to the initial position.
(4)
(4) To wind the bobbin thread during the sewing operation, carry out the procedure (1) above then, the bobbin winding is performed automatically.
For bobbin winding mode, please refer to [2.7] winding instruction 5. Bobbin winding interface of Operation instruction technical manual is shown as below.
5-6.
5-6-1.
(1) As shown below, press the bobbin removal spanner (No.1) at the right side of shuttle hook to the right. Then, the bobbin shell (No.3) will open. At this time, remove the bobbin (No.2) from bobbin shell. Note: If the bobbin shell is still closed when the spanner is pressed to the right, adjust screw (No.9) so as to change route or rotate bobbins position. Rotate belt pulley by hand to set the thread take-up bar to the uppermost position. Then, press the bobbin removal spanner to the right.
5-6-2.
(1) After pulling out thread about 10 cm from bobbin (No.4), put the bobbin into bobbin shell (No.6). (2) Pass the thread through thread groove (No.5). At this time, check if the rotation of bobbin (No.4) is
the same as arrow of the below figure with pulling the thread. Pull thread out of the thread seam (No.8). Then, pull thread out of bobbin spring (No.7) and push the bobbin shell to its initial position.
Bobbin shell
6. SEWING
CAUTION
(1) Before starting the sewing, please make sure the position and the function of the halt switch. (2) Please do not touch the operating parts during sewing operation. (3) It is very dangerous to operate the sewing machine without safety guards (eye guards, belt covers, link covers, or the others). Please make sure to operate the sewing machine with safety guards.
(4) Please make sure to turn the power switch off when stopping the sewing machine temporarily.
6-1.
Operation sequence is shown as follows: (1) Turn on the power switch. After this step, data input interface displays. (2) Select a sewing pattern No. The current interface will display the selected pattern No., press pattern display button to select
pattern No.. For operation of pattern selection, please see section [2.8 pattern selection] of instruction for electronic pattern machine. (3) Set to sewable status. Press prepare button status. (4) Set the sewing speed Set a appropriate sewing speed by pressing (5) Set the sewing material under the presser plate (No.1). (6) When stepping on (middle and right) foot switch, material-presser plate will go down. (If there is need to reset sewing material, step on (middle and right) foot switch again, then the presser plated will go up.) (7) Step on left start foot switch so that the sewing machine starts sewing. (8) After the sewing finishes, the work holder (No.1) is lifted automatically then, the sewing material is released. . , background color of the LCD will turn blue which means it is now in sewable
6-2.
(1) If accidents such as a thread breakage, needle breakage and others happening during sewing, please press emergency stop switch (No.2) immediately. The sewing machine stops instantly and Machine turns into emergency stop status
. After pressing
, it is ready to conduct trimming and enter into step setup interface. And after , presser foot goes up and there can be no further
operations, which shall turn off the power and restart again. Note: After parameter U56 is set to pause, the interface will enter step setup directly during automatic trimming. (4) To conduct step setup, adjust presser foot to re-sewing position. Press the trimming button Middle presser action to enter into step setup interface.
: go back and remove materials : go forward and remove materials : original point reset
Press or so as to move presser foot to re-sewing position.
6-3.
For detailed operation method, please refer to 3.1 of technical manual [pattern operation].
6-4.
If specification of right and left alternating clamps is changed according to clients requirement, alter setups as the following procedures. Note: Left and right clamps are applicable for sewing two parts together. Change the application method by purpose so as to utilize the sewing material more validly.
CAUTION
Do not modify the sewing machine. Otherwise, there may be injury and/or machine fault. 1
Press
to switch to data input interface and mode interface, in which can conduct detailed
setups and editing operation. 2 3 Choose to enter into 1-class parameter setup interface.
Select parameter U212 to set the declining mode of foot board controlling right and left
:2 right decline
There are 2 operation switches for thermal trimming operation <1>: Automatic (normal mode) and Manual (test mode) conversion switch. <2> Manual trimming test button
6-5-1.
When this switch in ON, operation mode is changed to test mode. In this mode, there is no need to operate upper and lower trimming cylinder separately by operation panel. Please refer to [7-6 Test mode
6-5-2.
Note: thermal thread trimming device switch needs to be operated according to the following procedures. (1) Set the changeover switch (No.1) to manual mode (select online/offline test mode): (2) Confirm presser foot has been already declined and needle has reached upper position. (3) Press manual trimming test button, and operate upper/lower trimming cylinder separately.
6-6.
Thread tightness degree between upper and lower thread must be balanced in the best condition. When upper thread tension is well balanced with lower thread, both threads are interlocked along the center line of fabric layers that is shown as follows. Note: Normally the weaker lower thread tension is, the better sewing quality will be. Therefore, it is better to set lower thread tension according to quality and thickness of the sewing material and then set upper thread tension.
Upper thread is too tight and Upper thread is too loose and lower thread is too tight. lower thread is too loose.
6-6-1.
(1) Loosen the screw (No.1). Adjust the bobbin thread tension with the thread tension adjusting screw (No.2). To increase the bobbin thread tension, Turn the screw to the clock-wise (A). To decrease the bobbin thread tension, turn the screw to the counterclockwise (B). (2) After adjustment, fasten the screw (No.1).
6-6-2.
According to lower thread tension, adjust upper thread tension. This adjustment is realized by adjusting clamp bolt (No.1). Adjust bolt (No.1) clockwise (A) to increase upper thread tension; rotate this bolt counterclockwise (B) to decrease upper thread tension.
CAUTION
(1) Please make sure to turn the power switch off before adjusting the sewing machine. (2) When adjusting the sewing machine with the power switch on, please be careful not to step on the foot switch by mistake. (3) Please be careful not to be injured by a sharp part such as the needle and the shuttle hook point. (4) Please make sure to put safety guards (eye guards, belt guards, connecting rod cover and fingerstall) back on the initial position after adjustment of the sewing machine.
7-1.
(2) Rotate shuttle hook (No.2) counterclockwise until it will not swing any longer. Place shuttle hook (No.1) and shuttle hook (No.2) as shown in the following figure, that is both of them are contacting on No.3 position. (3) Check a distance (No.4) between the pointed end of shuttle hook (No.1) and the shuttle race. Retain 1mm. If the distance is not correct, please adjust it in accordance with the following procedures. (4) Turn the shuttle (No.1) until at the point described in (3). (5) Tilting the sewing machine, and loosen the bolt (No.5). (6) Align the blade point of the shuttle (No.1) by turning the shuttle by hand. (7) After adjustment has been completed, tighten screw (No.5) firmly
7-2.
(1) Rotate the hand wheel to make needle bar ascend 4mm from its lowest position. At this time, the pointed end of shuttle hook (No.2) shall be aligned with the center of the needle (No.1). (2) At the same time, distance between upper surface of needle plate and lower end of the needle bar shall be 30.55mm.To adjust the position of needle and shuttle hook in accordance with the following procedures. (3) Remove the cover of the arm top. (4) Loosen screw (No.5). (5) Loosen screw (No.6) and conduct adjustment so that marker dot (No.3) engraved on the eccentric cam of the spindle is aligned with marker line (No.4) engraved on the spindle. (6) After the adjustment, securely tighten screws (No.5 and 6).
7-3.
The correct height is that the distance from the blade point of the shuttle (No.2) to the upper end of the needle eyelet (No.1) is 2.5 mm when the blade point of the shuttle is aligned with the center of the needle. To adjust the height of the needle bar, (4) Loosen screws (No.3). (5) Adjust the height by moving needle bar (No.4) up and down. (6) After adjustment has been completed, tighten screws (No.3) firmly.
7-4.
Correct clearance between the recess in the needle (No.1) and the blade point of the shuttle (No.2) is 0.25 ~ 0.35 mm. To adjust the needle-to-shuttle clearance 1 Loosen screw (No.3) 2 Adjust gap by moving shuttle race (No.4) left and right. 3 After adjustment has been completed, tighten screw (No.3) firmly
7-5.
Correct clearance between the needle (No.1) and the shuttle hook driver (No.2) shall be 0-0.05mm.To adjust needle-to-shuttle-hook-driver clearance in accordance with the following procedures: 1 Turn the hand wheel to make the needle bar lowest position. 2 Tilt the sewing machine. 3 Loosen two screws (No.3) and Bolt (No.4). 4 Adjust clearance between the convex section of needle (No.1) and shuttle hook driver (No.2) to range from 0 to 0.05mm by moving lower shaft (No.5) to the left and right. 5 After adjustment has been completed, fasten the fixed ring of lower shaft (No.6)and lower shaft crank (No.7). And make sure there is no axial gap of lower shaft.
7-6.
7-7-1.
2 Set the changeover switch (No.1) to manual (test mode). 3 For detailed operation method, refer to section 6-5-2.
7-7-2.
1. In the test mode, there is no need to operate thermal thread trimmer equipment (cylinders or relay) independently by keys on operation panel. Also, start switch is disabled in test mode. 2. When declining the presser plate, each cylinder will move. 3. During testing, it is necessary to turn on the key according to the following orders: presser foot > thread tensioner > fabric thickness detection > upper trimmer; and it is necessary to turn off the key according to the following orders: upper trimmer > fabric thickness detection > thread tensioner > presser foot. One cycle operation One cycle of operation contains the following series of operations.
1. Thread release is opened. 2. Pull out the required amount of thread. 3. Thread release is closed. 4. Put thread tensioner back to its initial position. 5. Presser foot rises. 6. Thread tensioner pulls up the rest stitches to the position where the thread can be trimmed. 7. Fabric thickness detector lowers to the position above presser plate. 8. Move upper and lower thermal trimmer to thread path (thread is heated and cut). 9. Return back upper and lower thermal trimmer to initial position. 10. Fabric thickness detector rises. 11. Thread tensioner returns to its initial position. 12. Presser foot declines.
7-7.
7-7-1.
(1) Turn the power switch OFF. (2) Remove the side cover and the face cover. (3) Rotate the belt pulley by hand and turn the middle presser foot to lowest point. Stop differential adjusting crank (No.1) at its largest swing position in arrow direction via adjusting the screw (No.11) on differential eccentric gear. (4) Remove the connecting screw (No.4) to disconnect lifting arm (No.2) from presser lifting arm (No.3). (5) Loosen screw (No.9) on the presser foot (No.10). Then, adjust the position of presser foot to make 0-0.5mm clearance between bottom surface of presser foot and surface of the sewing machine. (6) Tighten the screw (No.9) on presser foot to adjust it to the center of needle hole of the presser foot. (7) Insert a 12.7mm high block between lifting presser arm (No.5) and manual lifting bar (No.6). (8) Tighten the screw (No.8) of differential adjusting crank without clearance of the shaft sleeve. (9) After the adjustment, tighten hinge screw (No.4) to connect presser lifting arm (No.2) and presser
foot lifting plate (No.3). And put face plate and side plate back on the original position.
7-8.
When closing the tension, sensor IF (No.4) on the cylinder is ON and sensor IE (No.3) is OFF. When opening the tension (tension release plate is close to clamping plate), signals of these sensors will be reversed.
7-9.
For a correct sewing at the seam beginning, a certain length of stitches shall be reserved. Thread stripping hook shall be reserved at the bottom position after finishing sewing, then the thread can be reserved. Function of upper thermal trimming according to the following procedures: 1. Sewing pattern is finished. 2. Needle stops at the high position of needle bar. 3. Upper clamper opens. 4. Thread puller pulls the required thread quantity forward. 5. Upper clamper closes again. 6. Thread puller returns back to its original position. 7. Presser foot lifts in its highest place. 8. Thread stripping hook pulls the reserved needle thread into heating position. 9. Thickness detector lowers on the clamps. 10. Upper thermal trimmer declines. 11. Thread is heated off. 12. Clamp rises. 13. A new sewing process can be started.
moving in the direction of A, thread slack amount will increase; and when moving in the direction of B, thread slack amount will decrease.) (3) Securely tighten screw (No.1). (4) Check the sensor during thread puller operation. Sensor IB (No.3) is ON.
downward until it touches the bottom clamp (No.1). 5 Tighten the setting screw (No.2). 6 At this time, make sure functions of the thickness detector cylinder (No.5). At upper (normal) position the sensor I 8 should be ON.
Thread stripping hook shall be moving freely under the needle. Please adjust the height of thread blocker as follows: (1) Place material of the maximum allowance thickness (10mm) or spacer between upper and lower clamp. (2) Swing the thread stripper hook under needle by hand to make sure that it will not strike against the needle. If the hook interferes with needle, adjust it according to the following procedure. (3) Loosen clamping screw (No.7). (4) Adjust the height of thread stripper hook (No.3). (5) Tighten clamping screw (No.7).
The fully extended thermal trimmer must have a contact with upper thread tightened by stripper hook with some pressure. To adjust the position of the upper thread heater 1 Extend the heater (No.1) manually. 2 Loosen the screws (No.2) and the screws (No.3). 3 Adjust the heater vertically and horizontally. 4 Tighten the screws (No.2 and 3) and the screws. 5 After this adjustment, check the sensor I A (No.4) of the heater cylinder (No.6) should be ON and the sensor I 9 (No.5) should be OFF at the normal position.
7-10.
(NO.4).
The lower heater is in its initial position, when the thread puller (No.2) is outside the area of needle hole
1 Distance between thread outlet plate (No.2) and lower thermal trimmer (No.1) shall be about 6mm. Loosen screw (No.5) and adjust the position of thread outlet plate (No.2) so as to correct the position of lower thermal trimmer.
Thread outlet plate
2 After withdrawing the cylinder, distance between cylinder and connector (No.6) is 9mm and distance between them after pushing out the cylinder is 34mm. At this time, lower trimmer device is just at the proper position. Loosen nut (No.9) to adjust the above distance. Proper height of thermal trimmer (No.1) is where the trimmer is very adjacent to needle plate (No.3) and also it does not have any contact with other parts. Adjust the shape of lower trimmer for correction. 3 In normal position, thread outlet plate (No.2) shall be 2.2mm lower than needle plate (No.3). Adjust the shape of thread outlet plate (No.2) for correction. 4 After this adjustment, check the sensor I6 (No.7) of the heater cylinder should be ON and the sensor I7 (No.8) should be OFF at the normal position.
7-11.
The amount of thread has already been adjusted so that thread can be wound round approximately nine-tenths of the bobbin. If the amount is excessive or insufficient, adjust by following method. (1) Loosen the adjusting screw (No.1) and nut (No.2). (2) Turn the adjusting screw (No.1). To decrease the amount, turn clockwise. To increase the amount, turn counterclockwise. (3) After adjusting the amount of thread has been completed, tighten the nut to secure firmly. If bobbin thread is wound unevenly, (4) Loosen the screw (No.4). (5) Move the bobbin winder thread guide (No.5) forward and backward so that thread can be wound evenly.
7-12.
CAUTION
If cylinder pressure is set too high, troubles such as operation faults may occur. Set the pressure within 0.4Mpa at any time.
(1) Upper tabouret pressure is provided from the cylinder. Lift and turn filter regulating valve button (No.1) under the table to realize air pressure adjustment. (2) If rotate the regulating button (No.1) clockwise, both air pressure and upper tabouret pressure will increase. (3) If rotate the regulating button (No.1) counterclockwise, both air pressure and upper tabouret pressure will decrease. (4) 0.4Mpa (4kgf/cm2) is the standard air pressure as a normal sewing operation.
7-13.
The standard stroke of thread take-up spring (No.1) is 8 to 15 mm. To adjust operating range, (1) Loosen screw (No.2). (2) Adjust the operating range by moving thread the take-up spring adjusting plate (No.3) up and down. (3) After adjustment, tighten screw (No.2) firmly.
7-14.
Position of stop point refers to the highest position that take-up bar can be detected by inductor (No.2) and it needs no adjustment in normal condition. It is necessary to check whether it is located in the below positions. 1 Turn off the power. 2 Remove upper chassis cover (No.1). 3 Adjust the position of stop point corresponding to the following procedures, loosen fixed screw (No4) of the spindle inducting iron (No.3) and rotate inducting iron (No.3). After adjustment, fasten screw (No.4).
CAUTION
If position of stop point is changed, proper trimming cannot be executed.
4 Turn on the power. 5 If stop point is not in an ideal position, fine adjustment can be conducted by electric control system. Zero deviation is installed on spindle allowed by electric control system. Correction for angle error during automatic installation can be carried out by zero correction operation. However, the value of zero deviation must be within -30 ~ +30, otherwise, dangers such as other executing mechanisms malfunction resulting from angel disorder of spindle may be caused. Specific method is shown as follows: Press for 3s in data input interface and then enter into setting mode class 2; press to enter into
icon to enter into angle correction interface of spindle. Move machine hand wheel in this interface so as to turn the needle bar into its highest position (mechanical zero position). Electric angle of spindle motor will display on icon . And deviation correction value will show under entry FIXED, the
corresponding corrected mechanical angle value will show under entry MACH. Press will be stored automatically by system and corrected into spindle motor angle.
, the value
Note: This corrected value is stored in operation panel. If spindle motor is re-installed or operation panel is changed, angle correction shall be conducted again. 6 After adjustment, put upper chassis cover back to its original position.
7-15.
The relation between shuttle hook (bobbin case) position and stop point (highest position of thread take-up bar) is shown as follows: the position of stop point (highest position of thread take-up bar) is the position where shuttle race (No.1) and bolt released by stop spring are aligned as shown in the figure. (If bobbin removal spanner (No.3) is pressed to the right, the bobbin case will open.)
7-16.
The mechanical home position is fixed at the center of the sewing area when the sewing machine is shipped from the factory. However, it can be moved within the area covered with diagonal lines.
77
parameter setup interface. Please refer to 1-class parameter setup for operation method.
Set valid range of X left direction by Set valid range of Y left direction by
. Set valid range of X right direction by . Set valid range of Y right direction by .
5 Turn the power switch on. Press the home position return icon mechanical home position.
6 If the mechanical home position is not the desired position, carry out the same procedure (4) and (5) again. In that case, turn the power switch off each time. [Notice] The machine has a function that the motor memorizes the home position at the first home position returning operation after the switch is turned on. Therefore, from the second home position returning, it does not use the home position return sensor. Make sure to turn the power switch off to change the mechanical home position.
(a)
In the case described above, available amount of adjustment of the original position is 0-25mm. For further adjustment, loose screw (No.4) and move the position of the sensor.
(b) (c)
If move the detector to the right, then mechanical original position will move to the left. After adjustment, fasten the set screw (No.4).
7-16-2.
1 Turn the power switch off. 2 The mechanical original position of Y direction is the position where inductor (No.2) can detect the edge of Y drive (No.1). 3 Adjust mechanical original position of Y direction in accordance with the following procedures: loosen set screw (No.3) of inductor plate; then move the detector plate in the arrow direction which is shown in the figure below. 4 Turn the power switch on. Press the home position return icon home position. 5 If the mechanical home position is not the desired position, carry out the same procedure (3) and (4) again. In that case, turn the power switch off each time.
[Notice] The machine has a function that the motor memorizes the home position at the first home position returning operation after the switch is turned on. Therefore, from the second home position returning, it does not use the home position return sensor. Make sure to turn the power switch off to change the mechanical home position.
a In the case described above, available amount of adjustment of the original position is 0-25mm. For further adjustment, move the position of inductor (No.2) within (A). b After adjustment, fasten the set screw (No.3).
7-17.
NOTE The proper condition of the X-Y synchronous belt tension is standing that they will not be got any yield even it is slightly pushed by hand.
7-17-1.
(1) Remove the right cover in direction of X. (2) Loosen the set screws (No.2) (4 pieces) of the bracket (No.1) (3) If fasten the tension adjusting screw (No.3), X timing belt tension will increase. (4) After adjustment, securely fasten the set screw (No.2) of the stand (No.1) and put the right cover on its original position.
8. MAINTENANCE
CAUTION
(1) Please make sure to turn the power switch off before cleaning the sewing machine. (2) Please pay attention to that staining your skin or eyes with oil may cause an inflammation.
8-1.
Cleaning
(1) Remove the dust and the thread waste sticking the threading parts or the hooks area regularly.
(2) The dust or the like sticking the X-Y slide guide absorbs lubrication oil on the rails and significantly lowers the slide guide running life.
Clean the slide guide regularly and also pour some grease. (Lithium grease 2)
8-2.
If the waste oil pan is full filled in the oil bottle (No.1), remove the oil bottle then dispose of the waste oil.
9. TROUBLESHOOTING
CAUTION
(1) Please make sure to turn the power switch off before adjusting the sewing machine. (2) If the adjustment is required while the power switch on, do not step on the foot switch by mistake. Condition Cause Poor thread quality Tight upper thread tension Strong thread take-up spring Stitches is thicker than needle Change needle to suitable size Shuttle hook or shuttle race breakage often happens Damages of needle hole Needle touches with presser foot needle hole Needle and shuttle hook are not in proper timing Thread melts with needle heat Slow down sewing speed Use silicon oil Clamping plate is not open Adjust thread tension release during trimming Upper thread is pulled out from the needle Thread take up spring swing is Adjust thread take up springs too much Needle size is bigger than thread size Needle and shuttle hook are Adjust the timing properly not in complete 7-2 swing stroke Change needle to suitable size Adjust the timing Damages inside presser foot needle hole Change them new ones or grind them with buffing wheel or grind stone Change it new one or grind it with buffing wheel Move presser foot position ---------Corrective action Use better quality thread Adjust thread tension Adjust thread take up spring properly Reference ---6-6 7-13
7-7
7-8
7-13
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synchronization
Adjust the cylinder position of thread stripper Adjust thread puller stroke Adjust upper heater position Adjust adjusting plate position
7-9-3
Bobbin thread tension is too Loosen bobbin thread tension tight spring
Thread take up spring swing is Adjust thread take up springs too small Thread tail from needle is too long after trimming swing stroke
7-13
Trimmer equipment position is Adjust the cylinder position of not correct thread stripper Adjust thread puller stroke Adjust upper heater position Bobbin thread tension is too Loosen bobbin thread tension loose Trimmer function is canceled Trimmer switch is off spring Resume trimmer function Put on the trimmer switch Change the heater knife at Adjust position of stop point
7-9-3
trimming Initial setting of the setting Set up the initial setting of the table is not set up. The hook position is deviated The bobbin cannot be removed setting table. Set the needle stop position to the thread take up lever 7-14 5-2
uppermost position Bobbin removal lever stroke is Adjust the bobbin removal lever short Needle and shuttle stroke hook Adjust needle and shuttle hook clearance properly hook Adjust needle and shuttle hook timing properly Change it new needle ---7-4 7-2 5-5-1
Needle is bent by shuttle hook Adjust driver needle-to-shuttle-hook-driver clearance properly Presser foot position is not Adjust presser correct properly Stitch forming is loose Upper thread release is closed during sewing Presser foot position is not correct foot
the 7-5
position
7-7
Upper thread tension is not Adjust upper thread tension tight enough
6-6
Adjust properly
presser
foot
position
7-7
Small
clearance
between Adjust
the 7-5
shuttle hook driver and shuttle needle-to-shuttle-hook-driver hook Presser foot up and down timing is not proper clearance properly Adjust properly Connect all cables precisely Cancel the halt switch Change it new start switch Change to the operation mode presser foot timing
7-7
Cables wiring is disconnected Halt switch is kept ON Start switch breaks down The test mode is valid
Ambient temperature is out of Use sewing machine in ambient Returned home position is changed. Clearance between detector and detecting subject is too wide. Work holder activate cable is Work holder does not work disconnected Work holder pressure is not strong enough Work holder switch breaks down Change it new work holder Increase work holder pressure Connect the cable precisely Control unit use range. temperature in 5 degrees to 35 degrees Adjust clearance in 1 to 1.5mm 7-16 ----
7-12
----
switch Sewing pattern is distorted X-Y timing belts are loose Sewing heavy Select sewing material weight level at feeding Slow down feeding speed Adjust X-Y timing belt tension properly X-Y detector cabled are Connect X-Y cables correctly Control unit 6-1 7-17 material weight is Slow down sewing speed 6-1
disconnected
----
Factory Setting 35 300 choose middle voltage plate 3 185 Open the enabled 53 5 800 150 200 300 400 500
Upper needle position of needle set angle Open upper control point after trimming Delay after thread stripping (delayed 3
setting of trimming time output signal) Presser mode controlled by foot plate Choose 0 external presser control
Decline mode of left and right separating Choose 1 decline left first, then presser controlled by foot plate right
U213
Rise mode of left and right separating Choose 0 rise at the same time presser controlled by foot plate