INDUSTRIAL SEWING MACHINE

MODEL

PLK-G5050R

PLK-G10050R

TECHNICAL MANUAL

SEWING MACHINE HEAD

A180E702P02

FOR SAFE USE

Before the installation, operation, and inspection for this product, read the “FOR SAFE USE” and the technical manuals carefully. Also read the other technical manuals, “Control Unit” and “Operation Panel” describing some instructions, which are not in this manual, and use the sewing machine properly.

SAFETY INDICATIONS

DANGER

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

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.

 Please do not operate the sewing machine without protective equipment such as a needle guard, an eye guard, a belt cover or the others.

 Please turn off the power switch when threading, changing a needle and a bobbin, cleaning, and lubricating.

2

Caution for fingers injury:

Indicates a possibility of fingers (hands) injury in a certain condition.

3

Caution for squeezing fingers:

Indicates a possibility of squeezing fingers in a certain condition.

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 (95°F) or more than 35 degrees, or the ambient temperature of 5 degrees or less than 5 degrees (41°F).

(2) In the ambient temperature of 55 degrees (131°F) or more than 55 degrees, or the ambient temperature of -10 degrees or less than -10 degrees (18°F) 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) 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.

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).

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, and finger guards or the others) back on the initial position after the sewing machine adjustment.

CONTENTS

1. STRUCTURE OF THE SEWING MACHINE

····································

1

2. SPECIFICATION

·······································································

2

3. INSTALLATION

········································································

3

3-1. Installation of the electric cables

·······························································

3-2.

Connection of the air tube

·······································································

3-3. Installation of the thread stand

·································································

3-4. Installation of the eye guard

····································································

3-5. Installation of the spindle motor

································································

3

3

4

4

5

4. LUBRICATION

·········································································

6

4-1. Filling the oil tank

··················································································

4-2. Oiling

·································································································

6

6

5. PROPER OPERATION

······························································

7

5-1. Initial setting of the control box

·································································

5-2. Installation of the needle

·········································································

5-3. Threading the upper thread

·····································································

5-4. Winding the bobbin thread

······································································

5-5. Setting the bobbin

·················································································

5-6. Setting the bobbin case

··········································································

7

7

8

9

10

10

6. SEWING

·················································································

11

6-1. The sewing operation

············································································

6-2. Operation of the halt switch

·····································································

11

12

6-3. Adjustment of the thread tension

······························································

12

7. STANDARD ADJUSTMENT

·······················································

13

7-1. Adjustment of the needle bar position·······················································

7-2. Adjustment of the position between the needle and the rotating hook··············

7-3. Adjustment of the hook positioner’s position···············································

7-4. Adjustment of the lubrication for the rotating hook·······································

7-5. Adjustment of the presser foot timing························································

7-6. Adjustment of the presser foot lift·····························································

17

18

13

14

15

16

7-7. Adjustment of the presser foot height position············································

7-8. Adjustment of the presser foot position·····················································

7-9. Adjustment of the presser foot walk during the sewing·································

7-10. Adjustment of the presser foot spring pressure·········································

7-11. Adjustment of t the wiper······································································

7-12. Adjustment of the thread trimmer···························································

7-12-1 Structure of the thread trimmer mechanism··········································

7-12-2 Assembling and readjustment of the thread trimmer mechanism···············

7-12-2.1 Attaching the knife bracket and the knife mounting unit·······················

7-12-2.2 Mutual relation among the movable and stationary knife edge··············

7-12-2.3 Connection of the knife bracket and the driving crank·························

7-12-2.4 Adjustment of the component parts of the knife driving mechanism········

7-12-2.5 Adjustment of the mounting position of the air cylinder························

7-12-2.6 Adjustment of the mounting position of the thread trimmer cam·············

7-12-2.7 Adjustment of the knife engagement···············································

7-13. Adjustment of the work holder pressure··················································

7-14. Adjustment of the bobbin winder····························································

7-15. Changing the work holder····································································

7-16. Adjustment of the thread take up spring··················································

7-17. Adjustment of the thread tail after the trimming·········································

29

30

30

31

7-18. Adjustment of the upper thread tension release (the width between thread 31 tension discs)···················································································

7-19. Adjustment of the opening time of the upper thread tension release disks·······

7-20. Adjustment of the mechanical home position············································

7-20-1. Adjustment of the X direction····························································

31

32

33

7-20-2. Adjustment of the Y direction ···························································

7-21. Adjustment of the X-Y detector clearance················································

7-21-1. Adjustment of the X detector clearance···············································

7-21-2. Adjustment of the Y detector clearance···············································

7-22. Adjustment of the X-Y timing belt tension················································

7-22-1. Adjustment of the X motor timing belt tension·······································

7-22-2. Adjustment of the X timing belt tension···············································

34

35

35

35

36

36

37

25

25

27

28

22

23

24

24

21

22

22

22

19

19

20

20

7-22-3. Adjustment of the Y timing belt tension··············································· 38

8. MAINTENANCE

·······································································

39

8-1. Cleaning

·····························································································

8-2. Disposing of oil waste

············································································

39

39

9. TROUBLESHOOTING

·······························································

40

1. STRUCTURE OF THE SEWING MACHINE

PLK-G5050R/G10050R electronic pattern sewing machine consists of the following main parts.

<9>

<3>

<5>

<10>

<7>

<6>

<1>

<4>

<2>

<8>

<1>: Sewing machine head <2>: Main shaft motor <3>: Halt switch <4>: Control box

<5>: Operation panel <6>: Work holder foot switch <7>: Start foot switch <8>: Thread stand

<9>: Sewing machine table <10>:Power switch

- 1 -

2. SPECIFICATIONS

Model PLK-G5050R PLK-G10050R

Sewing area

Maximum sewing speed

*3

X-direction (left/right) 500 mm X-direction (left/right) 1000 mm

Y-direction (front / back) 500 mm

2,000rpm (Continuous feeding) 1,600rpm (Intermittent feeding)

Setting speed

Stitch length

10 speed levels in 200 rpm to 2,000 rpm

0.1 to 4.3 mm (Continuous) 0.1 to 20.0 mm (Intermittent)

Stitch type Single needle lock stitch

Maximum number of needles 20,000 per pattern

Storable sewing data item

Data memory

Needle bar stroke

Thread take up lever stroke

Class of needle

900 patterns (internal memory)

Internal memory, USB memory

40.0 mm

73.0 mm

DPX17#18 (at standard installation)

Wiper system

Presser foot lift

*1

Work holder lift

Hook

Bobbin case

Bobbin

Presser foot stroke

*2

Thread trimmer system

Lubrication system

Lubrication oil

X-Y drive system

Back to front wiping system

12 mm (maximum 15 mm )

In 4 mm to 10 mm (4 mm as factory default setting)

30 mm

Large size rotating hook

With non racing spring

Large size steel bobbin

Horizontal engagement with fixed knife and movable knife

Manual oiling and replenishment with the oil braids from the oil tanks

Pulley SF oil

Stepping motor feedback control

Timing belt drive system. Intermittent or continuous feeding

Machine dimensions

(W)x(L)x(H)

Weight

Type of motor

1,384mm x 1,855mm x

1,234mm

Total 470 Kg

XL-K756-20

2,105mm x 1,855mm x

1,234mm

Total 500Kg

Type of controller

Type of operation panel

PLK-G-CU-20

PLK-G-PAL-2

Power

In 200V to 240V single-phrase or three-phrase

The power in 110V to 120V or in 380V to 415V is compatible with power unit (option)

*1 ： Presser foot lift is the height of the presser foot after the sewing has stopped.

*2 ： Presser foot stroke is the up and down movement of the presser foot while sewing.

*3 ： Sewing speed may be limited by the operation or sewing condition.

- 2 -

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.

3-1. Installation of the electric cables

Connect the foot switch to the connector CON H.

The foot switch is enclosed in the accessory box.

CON A

CON E

CON F

CON G

CON H

CON J

3-2. Connection of the air tube

CON B

CON C

CON D

CON K

CON A : Operation panel

CON B : Power supply

CON C : Various solenoid DC power

CON D : Spindle motor

CON E: Various solenoid

CON F : Spindle encoder

CON G : X-Y spindle encoder

CON H : Foot switch

CON J : X-Y spindle stepping motor

CON K : P-F spindle stepping motor

Insert the one end of the air tube (8mm Diameter) into the intake air fitting of the filter regulator (No.1) then, join the other end of the air tube with the suitable air coupling to be adopted with the air supply source provided in your factory. One of the air couplings (No.2) is enclosed in the accessory box.

<1>

<2>

<1>: Intake air fitting

<2>: Air coupling

- 3 -

3-3. Installation of the thread stand

(1) Assemble the parts of the thread stand as shown on the figure.

(2) Fit the thread stand into the hole at the far right on the table stand with the nut (No.13) and the washers (No.12) and the collar (No.14).

<1>: Upper column pipe

<9>

<6> <15>

<2>: Lower column pipe

<3>: Spool stand base (two stand bases)

<17>

<4> <16>

<5>

<1>

<4>: Spool mat (two mats)

<5>: Spool holder (two holders)

<6>: Spool shaft (two shafts)

<7>: Spring washer (two washers)

<8>: Nut (two nuts)

<11>

<18>

<3>

<9>: Thread hunger

<10>: Spool holder

<7>

<8>

<11>: Column joint

<2>

<12>: Washer (two washers)

<10>

<12>

<13>: Nut

<14>: Collar

<14> <15>: Bracket (large)

<12>

<16>: Bracket (small)

3-4. Installation of the eye guard

<13>

<17>: Holder

<18>: Thread guide

(1) Loosen the screws (No.2) on the eye guard unit (No.1) then, mount the screws (No.3) to the flat place of the sewing machine with the open guard.

(2) Return the open guard to the initial position then, tighten the screws (No.2).

<1>: Eye guard unit

<2>: SW-MW screw

<3>: SW-PW screw (two screws)

<2>

<1>

<3>

- 4 -

3-5. Installation of the spindle motor

(1) If the spindle motor (No.1) has been removed from the machine for the adjustment or the like, fix the spindle motor as the procedure described below.

(2) Set the pin (No.3) position of the bushing to the motor mark (No.2).

(3) Adjust the clearance between the motor and the coupling (No.4). Use the part measuring 7mm on the gauge (No.5). Position Bolt “A” (No.6) in the below described position when reinstalling the coupling to the machine top shaft. Make sure the clearance of the coupling is from 2.0 to 3.2mm.

(4) When the thread take up lever at top position, turn the pulley (No.8) in the direction of the arrow then, slip the gauge (No.5) in between the needle bar and the needle plate. Use the part of R side (52.6mm) on the gauge.

(5) Be careful not to make the motor turn and fit the coupling to the upper shaft, and then tighten the bolt

A (No.6) first and the bolt B (No.7) second.

<1>

<5>

<4>

2.0

～ 3.2mm

<5>

<8>

<2>

<3>

<6>

<7>

<1>: Spindle motor <2>: Motor mark <3>: Pin <4>: Coupling <5>: Gauge <6>: Bolt A

<7>: Bolt B <8>: Pulley

- 5 -

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.

4-1. Filling the oil tank

Pour the oil through the oil hole (No.1) to the oil tank (No.2) on the machine arm. Pour the oil hole

(No.3) to the oil tank for hook (No.4) on the machine bed. Pour the oil hole (No.5) to the oil tank for gear box (No.6) on the machine bed. Please fill with the oil over level mark (No.7) of the oil tank.

4-2. Oiling

Put some oil to the red marked oil holes (No.8 ~ 11).

<11>

<8> <9>

Oil hole <3>

Oil tank for hook <4>

<10>

<5>

<1>

<2>

<7>

<7> Level mark

<6> Oil tank for gear box

- 6 -

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 the instructions in the paragraph “[6] Initial Setting of System (Model/language Setting)” in the

CONTROL UNIT technical manual.

5-2. Installation of the needle

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 the set screw (No.1) then, insert a new needle (No.2) until the needle head is reached the end of the hole of the needle bar (No.3).

(2) Tighten the set screw (No.1) with facing the needle groove (No.4) to the front.

<3>

<1>

<2>

<1>: Set screw

<2>: Needle

<3>: Needle bar

<4>: Needle groove

<4>

- 7 -

5-3. Threading the upper thread

CAUTION

(1) Please turn the power switch off when threading a needle.

Thread the upper thread as shown on the figure.

- 8 -

5-4. Winding the bobbin thread

CAUTION

(1) Please do not touch the rotating part during winding thread. Doing so may cause injury and/or the machine failure.

[Notice] 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 fit the bobbin to the bobbin winder (No.2) and push the bobbin presser arm (No.3) in the direction of “b” arrow.

(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 the bobbin finishes winding a certain amount (80 to 90 % of the outside diameter of bobbin) of thread, the bobbin presser arm is returned to the initial position.

(4) To wind the bobbin thread during the sewing operation, carry out the procedure (1) above then, the bobbin winding is performed automatically.

For the bobbin winding mode, refer to the instructions in the paragraph “[3] Explanations of basic screen, icons and operation “5. The Bobbin Winding screen” is explained below” in the

OPERATION PANEL technical manual.

1

6

5

<1>: Bobbin <2>: Bobbin winder <3>: Bobbin presser arm

- 9 -

5-5. Setting the bobbin

(1) Set the bobbin (No.2) into the bobbin case (No.1).

(2) Pull the bobbin thread (No.3) into the slit (No,4) and pass the through the thread hole (No.5).

At this time, pull the bobbin thread (No.3) then, check with the bobbin (No.2) if it is rotated to the arrow direction. If it is not, set the bobbin (No.2) into the bobbin case (No.1) over again to get the proper rotation.

<4>

<1>: Bobbin case

<2>

<2>: Bobbin

<3>: Thread

<4>: Bobbin case slit

<5>: Bobbin case thread hole

<5>

<3>

<1>

5-6. Setting the bobbin case

(1) Pull the bobbin thread about 50mm out of the thread hole of the bobbin case (No.4).

(2) Open the cylinder cover (No.1).

(3) Open the bobbin case latch (No.2) and hold it then, fit it securely in the shuttle hook (No.3).

<3>

<2>

<1>

50 ｍｍ

<4>

<1>: Cylinder cover <2>: Bobbin case latch <3>: Inner hook

<4>: Bobbin case

- 10 -

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, finger guards 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. The sewing operation

(1) Turn the power switch on.

(2) Press the home position return icon .

(3) Select a sewing data.

Press the on the standard screen then, press the .

(4) Select a target (internal memory/USB memory) to read the data from.

The screen as default setting is set to the reading from internal memory mode.

(The mode display at the left top on the screen is .)

Press the ,when switching the reading from the internal memory to the reading from USB

memory mode.

(Pressing the also can switch the target.)

Press the to switch the page with full of data.

(5) Select a data then, set the data.

Press the target data number then, press the .

(6) Set the sewing speed.

Set the appropriate sewing speed by selecting or . (10 selections of 0 to 9)

(7) Set the sewing material under the work holder.

(8) When the black foot switch is stepped on, the work holder goes down.

(When the sewing material has to be reset, step the black color foot switch again to make the work

holder go up.)

(9) Step on the gray color start switch so that the sewing machine starts sewing,

(10) After the sewing finishes, the work holder is lifted automatically then, the sewing material is released.

- 11 -

6-2. Operation of the halt switch

(1) If accidents such as a thread breakage, needle breakage and others

happened during the sewing, press the halt switch immediately.

The sewing machine stops instantly.

(2) To cancel the halt state, press the halt switch again.

(3) When continuing sewing, step on the grey foot switch to restart at the halted position. (Press the jogging in forward/reverse direction icon so that the sewing start position will move.)

(4) To cancel sewing, press the home position return icon .

6-3 Adjustment of the thread tension

(1) Bobbin thread tension

Adjust the bobbin thread tension with the thread tension

Adjusting screw (No.2) on the bobbin case (No.1).

The thread tension become loose if turn the thread tension adjusting screw (No.2) to the counterclockwise, and the thread tension becomes tight if turn it to the clockwise.

<1>: Bobbin case latch

<2>: Adjusting screw

<1>

<1>

<1>: Halt switch

<2>

(2) Adjustment of upper thread tension

Adjust the upper thread tension corresponding to the bobbin thread tension. The upper thread tension becomes tight when tightening the thread tension adjusting nut (No.1) clockwise, and the upper thread tension becomes loose when loosening the thread tension adjusting nut counterclockwise.

<1>: Thread tension adjusting nut

<1>

- 12 -

7. STANDARD ADJUSTMENT

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 the safety guards (eye guards, belt guards, link covers, and finger guards or the others) back on the initial position after the sewing machine adjustment.

7-1. Adjustment of the needle bar position

(1) Turn the power switch off then, stop the needle bar (No.1) at the lowest position.

(2) Move the needle bar to the position where the needle bar timing mark A is matched to the needle bar bushing (No.4) bottom line. (For the needle class DP × 17)

(3) If the position of the needle bar timing mark A is not matched to the needle bar bushing bottom line, remove the rubber plug (No.2) from the face cover then, loosen the needle bar holder set screw

(No.3).

(4) For the needle class DP×5, move the needle bar to the position where the needle bar timing mark B is

matched to the needle bar bushing bottom line.

<4>

A

<3>

<2>

B

<1>

<1>: Needle bar

<2>: Needle bar bushing

<3>: Rubber plug

<4>: Needle bar holder set screw

Timing mark A: For the needle class DP×17

Timing mark B: For the needle class DP×5

- 13 -

7-2 Adjustment of the position between the needle and the rotating hook

(1) Turn the power switch OFF.

(2) Open the cylinder cover (No.1).

(3) Remove the bobbin case (No.2).

(4) Remove the sliding plate (No.3).

(5) Loosen the hook three set screws (No.4).

(6) Turn the sewing machine pulley (No.5) by hand in the direction of the arrow then, move up the needle bar (No.6) from the lowest position and stop it at the position (No.7) where the needle bar timing mark C is matched to the needle bar bushing bottom line.

NOTE If the needle class is DPx5, match the needle bar timing mark D to the needle bar bushing bottom line.

(7) Turn the hook by hand and stop it at the position where the hook point (No.8) meets with the center line of the needle (No.9).

(8) Move the hook by hand and adjust the clearance between the hook point and the needle to be about

0.05 mm.

(9) Hold the hook and tighten the hook set three screws (No.4) securely.

(10) After the adjustment, put the sliding plate (No.3) and bobbin case (No.2) back to the original locations and close the cylinder cover (No.1).

NOTE When put the sliding plate (No.3) back on the sewing machine, in order for the needle (No.9) to come into the right center of the needle hole of the needle plate (No.10), make sure that the needle plate hole center matches with the needle point then, tighten the set screws securely.

<2>

<9>

0.05mm

<8>

<9>

<6>

<1>

<9>

<8>

<8>

<7>

<4>

C

<4>

D

<9>

<3>

<5>

<10>

- 14 -

<1>: Cylinder cover <2>: Bobbin case <3>: Sliding plate <4>: Hook set screw <5>: Pulley

<6>: Needle bar <7>: Lowest position of needle bar <8>: Hook point <9>:Needle

<10>: Needle hole

7-3 Adjustment of the hook positioner’s position

(1) Remove the sliding plate.

(2) Loosen the hook positioner set screw (No.4) and adjust the hook positioner (No.1) position to align the right side of the projection (No.3) with the right side of the needle (No.2) as shown on the figure.

(3) After the adjustment, securely tighten the hook positioner set screw (No.4) and put the sliding plate back on the sewing machine.

0.5

～ 0.8mm

<1>

<2>

<3>

<4>

<1>: Hook positioner <2>: Needle <3>: Right side of hook positioner

<4>: Hook positioner set screw

- 15 -

7-4 Adjustment of the lubrication for the rotating hook

(1) Open the cylinder cover (No.1).

(2) Tighten the oil flow adjusting screw (No.2) lightly by fingers or a screw driver until it is stopped the turn.

NOTE Do not tight the oil flow adjusting screw (No.2) too much.

(3) Adjust the oil flow in the range of one reverse turn from the deadlock position of the oil flow adjusting screw (No.2). The oil flow is decreased if loose the oil flow adjusting screw (No.2).

(4) It can be checked the oil flow with the situation that the oil splashes on the paper (No.3) covered over the running rotating hook.

(5) After the adjustment, close the cylinder cover (No.1).

[Notice] The oil flow is adjusted for the sewing speed at 2,000rpm as the factory default setting. When using other speeds, adjust the oil flow each time.

<3>

<1>

<2>

(No.2)......Maximum flow

<1>: Cylinder cover

<2>: Adjusting screw

<3>: Paper

A B

A: The deadlock position of the oil flow adjusting screw

C

B: The two reversing turn position of the oil flow adjusting screw

(No.2)......Standard flow

C: The four reversing turn position of the oil flow adjusting screw

(No.2)......Minimum flow

- 16 -

7-5. Adjustment of the presser foot timing

NOTE The presser foot up and down movement during the sewing synchronizes with the needle up and down movement. With changing this synchronized timing to the sewing materials, the skip stitches can be prevented or the seam tightness can be improved.

For example, the delay of the presser foot timing against the needle movement prevents the skip stitches especially to the thin materials, and the advance of the presser foot timing can improve the seam tightness especially to the thick materials.

(1) Remove the cover (No.1).

(2) Loosen the set screw "C" of the eccentric cam (No.2).

(3) Turn the sewing machine pulley by hand and stop the needle bar (No.3) at the lowest position. At this stage, the set screw "A" of the eccentric cam (No.2) is positioned right beside the center line of the upper shaft. This is the standard position for the eccentric cam (No.2).

(4) Loosen the set screw "A" of the eccentric cam (No.2).

(5) If turn the eccentric cam (No.2) to the arrow direction "D", the presser foot timing is advanced, and turn the eccentric cam (No.2) to the arrow direction "F", the presser foot timing is delayed.

(6) After the adjustment, tighten the set screw "A" and "C" in turn with slightly pushing the eccentric cam

(No.2) to the arrow direction "E".

(7)Put the cover (No.1) back on the original location.

<1>

<1>:Cover <2>:Eccentric cam

Ｆ

<2>

- 17 -

7-6. Adjustment of the presser foot lift

The presser foot lift can be returned factory default setting at 15mm as the procedure shown below. Also, if the presser foot does not move after changing the presser foot correction value and the stroke, carry out the procedure below.

(1) Remove the face cover, the rubber plug (No.1), and the PF motor cover (No.6).

(2) Keep the thread take-up lever at the highest position then, loosen the arm set screw (No.2).

(3) Slide the 24mm part on the gauge (No.3) in between the presser bar holder (No.4) and the arm.

(4) Push down the presser foot lifting lever (No.5) then, tighten the arm set screw (No.2).

<6>

<3>

<1>

<5>

<2> <4>

<3>

<1>: Rubber plug <2>: Arm set screw <3>: Gauge <4>: Presser bar holder

<5>: Presser foot lifting lever <6>: PF motor cover

(5) Turn the power switch on then, press the home position return icon .

(6) Check the clearance between the presser bar holder (No.4) and the arm with the 41mm part on the gauge (No.3). Refer to the next figure.

(7) If the clearance is less than 41mm, loosen the detector plate set screw (No.7) on the presser foot drive motor (No.9) and adjust the notch part of detector plate (No.8).

*If it is more than 41mm, turn the detector plate to the direction “a”.

*If it is less than 41mm, turn the detector plate to the direction “b”.

(8) Remove the gauge then, press the home position return icon and make sure the clearance is

41mm.

[Notice] If it is not 41mm, carry out the same procedure (7) and (8) again.

(9) Put the face cover, the rubber plug (No.1), and the PF motor cover (No.6) back on the original location.

- 18 -

<3>

41mm

<9> a

<7>

<8> b

<4>

<3>

<3>: Gauge <4>: Presser foot bar holder <7>: Detector plate set screw

<8>: Detector plate <9>: Presser foot drive motor

7-7. Adjustment of the presser foot height position

The height of presser foot can be returned factory default setting as the procedure shown below.

(1) Turn the power switch on, and set the correction value at 0. (*1)

For details, refer to the instructions in the paragraph “[8] Controlling the Presser Foot” in the OPERATION PANEL technical manual.

(2) Press the on the standard screen and lower the presser foot.

(3) Turn the hand pulley and place the needle bar at the lowest position.

(4) Loosen the presser foot bar set screw (No.1) and adjust the clearance between the presser foot and slide plate to be 0mm and

<1> then, tighten the screw (No.1).

(5) The correction value is set at 3 as the factory default.

<1>: Presser foot bar set screw

*1: When changing the correction value at 0, an error message;

“ M-096: OVER LIMIT OF PRESSER FOOT STROKE “ may show up. This happens when the presser foot stroke is already set to the sewing data and by changing the correction value, the stroke in sewing data becomes 0mm or less. In that case, make new sewing data without the presser foot stroke or read out a sewing data that the stroke does not become 0mm or less.

7-8. Adjustment of the presser foot position

The presser foot lift during the sewing can be adjusted from 0 to 8mm. For details, refer to the instructions in the paragraph “[8] Controlling the Presser Foot” in the OPERATION PANEL technical manual.

[Notice] When using the long cylinder type of the presser foot, the correction value and the stroke are restricted.

- 19 -

7-9. Adjustment of the presser foot walk during the sewing

(1) The presser foot walk during the sewing can be adjusted with the walk at zero or the walk of 2 to

10mm. The walk at zero requires the exclusive parts (Option). Please feel free to contact the sewing machine stores.

(2) When turning the set position of the shoulder bolt (No.1) to the direction “a”, the presser foot walk

becomes bigger, and when turning the set position to the direction “b", the presser foot walk becomes

smaller.

(3) To adjust the walk in 2 to 4mm, connect the link (No.2) with the screw hole A and adjust with the

method (2) described above.

(4) To adjust the walk in 4 to 10mm, connect the link (No.2) shown on the figure and adjust the method

.

(2) described above.

<2>

<1>: Shoulder bolt

<2>: Link a b

<1>

Screw hole A

7-10. Adjustment of the presser foot spring pressure

The presser foot spring pressure can be changed with the <4> following two methods.

(1) To increase the spring pressure, remove the face cover and loosen

the bolt (No.1) then, adjust the spring A (No.3) pressure with the adjust screw (No.2). After the adjustment, tighten the bolt (No.1).

(2) To fine-tune the spring pressure, loosen the nut (No.4) then,

turn the thumb screw (No.5) to adjust the spring B (No.6) pressure.

* If tighten the adjust screw (No.2) spring A (No.3) pressure can be increase.

* If tighten the thumb screw (No.5) spring B (No.6) pressure

<2>

<1>

can be increase.

<1>: Bolt <2>: Adjust screw <3>: Spring A

<4>: Nut <5>: Thumb screw <6>: Spring B

<5>

<6>

<3>

- 20 -

7-11. Adjustment of the wiper

(1) Loosen the wiper set screw (No.3) and adjust the wiper (No.1) to be positioned where the wiper (No.1) passes under the needle (No.2) point with a clearance of about 2mm right after the sewing machine stops at the needle upper position.

(2) When setting the presser foot (No.4) to upper position during the sewing of thick material, the setting may not leave the clearance of passing wiper. The wiper cannot be used in this case.

(3) The wiper does not work enough, loosen the wiper adjust screw (No.5) and adjust the wiper position.

<1>: Wiper

<3>

<5>

<2>: Needle

<1> <3>: Wiper set screw

<1>

<2>

<4>: Presser foot

<5>: Wiper adjust screw

<4>

2mm

(4) When the wiper function is not be used (not able to be used), set the following.

Set the wiper function to off.

Press the on the standard screen to open the MENU mode.

(5) Press the > > [Wiper ON/OFF] in order.

(6) Select the on the [Wiper ON/OFF] screen, and press the .

- 21 -

7-12 Adjustment of the thread trimmer

7-12-1 Structure of the thread trimmer mechanism

The thread trimmer mechanism of sewing machine is shown on the figure.

<9>

<10>

<8>

<2>

<11>

<12>

<1>

<7>

<4>

<3>

<5>

<6>

<1>: Knife mounting unit <2>: Knife bracket <3>: Trimming cam <4>: Air cylinder <5>: Stopper

<6>: Cam follower crank 2 <7>: Cam follower crank 1 <8>:Knife driving shaft <9>:Driving crank

<10>: Movable knife <11>: Stationary knife <12>: Thread guide

CAUTION

★ A lower shaft cam method is incorporated for the thread trimmer mechanism. When adjusting the sewing machine, if the thread trimmer air cylinder is in the operable state (state in which the cam follower crank 2 arm is engaged with the thread trimmer cam) and the upper shaft is rotated, the movable knife will collide with the needle and cause damage.

For avoiding this incident, always activate the air cylinder only in the regular trimming cycle which the needle moves from its lower to upper position.

7-12-2 Assembling and readjustment of the thread trimmer mechanism

If take the trimmer mechanism apart and assemble it again, please refer to the following instructions for the readjustment. For adjusting the trimmer mechanism, it is necessary to remove the sliding plate.

7-12-2.1 Attaching the knife bracket and the knife mounting unit

(1) Knife bracket

Under the condition that the rotating hook and the hook positioner are removed, put the knife bracket

(No.1) on the lower shaft left bushing (No.2) and fix it with the two set screws (No.3).

- 22 -

(2) Knife mounting unit

<3>

<1>

<2>

<1>: Knife bracket

<2>: Bushing

<3>: Set screw

Under the condition that the rotating hook and the hook positioner are removed, attach the knife mounting unit (No.1) with the set screw (No.2).

<2>

<1>

<1>: Knife mounting unit

<2>: Set screw

7-12-2.2 Mutual relation among the movable and stationary knife edge

(1) Rotate the movable knife (No.1) by hand when it is engaged with the stationary knife (No.2), there is

0.3mm space between the movable and stationary knife edges. This is standard condition.

(2) If this space is too wide, it causes a thread tail from the needle to be pulled out after the automatic thread trimming. If it is too narrow, it causes the failure of the trimming.

For avoiding these incidents, adjust this space precisely.

(3) For this adjustment, suitably move the knife bracket or the knife mounting unit mentioned at above

7-14-2.1.

<3>

<2>

0.3mm <1>

<4>

<1>: Movable knife

<2>: Stationary knife

<3>: Movable knife edge

<4>: Stationary knife edge

- 23 -

7-12-2.3 Connection of the knife bracket and the driving crank

(1) Connect the knife bracket (No.1) and the driving crank (No.2) with the link (No.3).

(2) Loosen the driving crank set screw (No.4) and adjust the attaching position of the driving crank (No.2) in the right and left direction so that the link (No.3) can contact with the same flat surface of the knife bracket (No.1) and the driving crank (No.2) without any distortion. After the adjustment, tighten the driving crank set screw (No.4) securely.

<4>

<2>

<1>

<3>

<1>: Knife bracket

<2>: driving crank

<3>: Link

<4>: Set screw

7-12-2.4 Adjustment of the component parts of the knife driving mechanism

(1) Attach the component parts of the knife driving mechanism and adjust the locations as shown on the figure.

(2) Fix the knife driving shaft (No.1) with the set collar (No.2). At the time, make sure there is no play on the knife driving shaft (No.1) in the axial direction and it can be rotated smoothly. On the other hand, make sure the set screw (No.3) not to interference with machine bed when rotated the knife driving shaft (No.1) about 90 degree in the direction of the arrow.

(3) Fix the cam follower crank 1 (No.4) on the knife driving shaft (No.1) at the right end position 77mm away from the front surface of the sewing machine bed as shown on the figure.

(4) Fix the stopper (No.5) on the knife driving shaft (No.1) by tightening the set screw (No.11) at the flat cut of the shaft.

<6>

77mm

<10>

<4>

<8>

<5>

<2> <3>

<7> <9> <1> <11>

<1>: Knife driving shaft <2>: Set collar <3>: Set screw <4>: Cam follower crank 1 <5>: Stopper

<6>: Driving crank <7>: Set screw <8>:Adjusting bolt <9>: Cam follower crank 2 <10>: Spring

<11>: Set screw

- 24 -

7-12-2.5 Adjustment of the mounting position of the air cylinder

(1) Attach the thread trimmer air cylinder (No.1) by fixing with the bolt (No.2). When the thread trimmer air cylinder (No.1) is released, there will be a clearance of apporox. 1mm at section A. To adjust this clearance, loosen the set screw (No.4) for the mounting plate (No.3), and move the entire mounting plate (No.3).

After adjusting, securely tighten the set screw (No.4) for the mounting plate (No.3).

(2) When the thread trimmer air cylinder (No.1) is activated, there will be a clearance of 0.5mm between the cam follower crank 1 (No.5) and cam follower crank 2 (No.6). This is the standard state. This clearance can be adjusted by loosening nut (No.7) for the air cylinder (No.1), and rotating the shaft section (No.8) of the air cylinder (No.1).

After adjusting, securely tighten the nut (No.7) for the air cylinder (No.1).

<7> <8> <1> <2>

<1>: Air cylinder

<2>: Bolt

<4>

<3>: mounting plate

<4>: Set screw

<3>

<5>: Cam follower crank 1

<6>: Cam follower crank 2

<7>: Nut

<8>: Shaft

<5>

<6>

0.5mm

A

7-12-2.6 Adjustment of the mounting position of the thread trimmer cam

Before the trimmer mechanism is activated, when set the gauge (No.7) on the rower shaft (No.3) and cam shaft (No.2) as following drawing, the clearance between gauge (No.7) and cam follower (No.4) is

0.3mm. This is the standard condition. Make the following adjustments based upon this standard condition. If this standard condition is changed by such removing the stopper (No.5), set the cam follower crank 2 (No.1) back to the standard condition with the adjusting bolt (No.6).

A

<2>

Section A-A

<6>

<7>

<4>

<5>

<3>

<3> <4>

A

<1> <2>

Top of machine bed

0.3 mm

- 25 -

(1) Loosen 2 set screws (No.9) of the thread trimmer cam (No.8).Remove the slide plate and place the

4mm thickness gauge (No.10) on the top of sewing machine bed. Slide the gauge (No.11) in between the needle bar and the 4mm thickness gauge (No.10). Use the 26.2mm part of T side.

(2) Make the air cylinder activated condition, then turn the thread trimmer cam (No.8) in the arrow B direction by hand. Fix the thread trimmer cam (No.8) with the two set screws (No.9) at the point where the thread trimmer cam (No.8) contacts with the cam follower (No.13).

<11>

26.2mm

<10>

4mm

<13>

<9>

<8>

<1>

<13>

<8>

B

(3) Make sure that the clearance between the thread trimmer cam (No.8) right end and the cam follower

(No.13) left end is 0.5mm to 1.0mm when the cam follower crank 2 (No.1) is returned to the C arrow direction after the air cylinder is set back to the original condition. This is the standard condition.

<13>

<9>

C

<8> <1>

0.5

～ 1.0mm

- 26 -

7-12-2.7 Adjustment of the knife engagement

(1) The standard position for the movable and stationary knife

The standard mutual position for the movable

(No.1) and stationary (No.2) knife is as shown on the figure.

(2) Adjustment of the amount for the knife engagement

Activate the thread trimmer air cylinder, and rotate

the upper shaft. The movable knife (No.1) will rotate with the thread trimmer cam. When the edge of movable knife (No.1) is reached at most left position, the amount if the engagement with the stationary knife (No.2) becomes 1.5mm to 2.0mm.

This is the standard condition. For this adjustment, loosen the set screw (No.4) of the driving crank

(No.5), then move the driving crank (No.5) to have the proper engagement.

After the adjustment, tighten the set screw (No.4) of the driving crank (No.5) securely.

(3) Adjustment of the engaging presser for the knives a) The engaging presser for the movable (No.1) and stationary knife (No.2) can be controlled with adjusting the height of the stationary knife (No.2).

When the movable knife (No.1) is rotated, the contact of the both knives starts from the position where the distance between the edge of

the stationary knife (No.2) and the cut out line of

the movable knife (No.1) is 3mm.

This is the standard condition. b) If the trimming condition is not sharp enough to a

bigger thread, it can be improved with increasing

the knife engaging presser a little. c) For the adjustment of this knife engaging presser,

after removing the slide plate and loosening the lock nut (No.4), use the adjusting screw (No.5).

If tighten the adjusting screw (No.5), the knife engaging presser becomes tight and if loosen the adjusting screw (No.5), it becomes loose.

After the adjustment, tighten the lock nut (No.4) securely.

<3>

<1>

5.5

～

6mm 2.5mm

<4> <5>

1.5

～ 2.0mm

<1>

<1>

<2>

3mm

<2>

<2>

<4>

<5>

- 27 -

(4) Adjustment of the attaching position of the protector.

Attach the protector (No.6) underneath the movable knife (No.1) and fix it with the same set screw (No.7) for the movable knife (No.1) at the position where the point of the protector (No.6) is off 0.5mm left from the needle center (No.4) and 4mm backward from the point of the movable knife (No.1).

7-13 Adjustment of the work holder pressure

CAUTION

<6>

<1>

<3>

Within 0.5mm

<8>

<7>

★ If the secondary side air pressure is set too high, trouble such as operation faults may occur. Always set the pressure to within 0.4Mpa.

(1) The work holder pressure is provided from an air source.

Lift and turn the air regulator’s adjustment knob (No.1) located under the table to adjust the air pressure.

(2) If turn the adjusting knob (No.1) to the clockwise, the air pressure is increased and the work holder pressure is also increased simultaneously.

(3) If turn the adjusting knob (No.1) to counter clockwise, the air pressure is decreased and the work holder pressure is also decreased simultaneously.

(4) 0.4Mpa (4kgf/cm2) is the standard air pressure as a normal sewing operation.

<1>

<1> ： Adjusting knob

<2> ： Air regulator

<2>

- 28 -

7-14. Adjustment of the bobbin winder

(1) Adjustment of the winding volume

Adjust the amount of the winding thread with the subsidiary arm (No.1).

The winding volume is adjusted 80% of the full volume when the sewing machine is shipped from the factory.

(2) Adjustment of the proper position of the bobbin winder

Firstly, loosen the set screws (No.2) of the bobbin winder and put the empty bobbin (No.3) on the rotating shaft (No.4) then, push the adjusting lever (No.5) to the arrow direction "a". Secondary, move the whole bobbin winder to the arrow direction "b" and stop it at the position where the empty bobbin is rotated then, tighten the set screws (No.2) of the bobbin winder. This is the proper position of the bobbin winder.

<2>

<3> a b

<5>

<4>

<2>

<1>

<1>: subsidiary arm <2>: Set screw <3>: Bobbin

<4>: Rotating shaft <5>: Adjusting lever

- 29 -

7-15. Changing the work holder

(1) To remove the work holder (No.1), bobbin the set screw (No.3) of supporting block (No.2) at both end of work holder (No.1).

(2) To mount work holder (No.1), proceed in reverse way of (No.1). When replaced the work holder

(No.1) by changing the sewing operation etc. make sure that there is no play in the ⇔ arrow direction. If there is play, some irregular seam forming may happen.

<3>

<2>

<1>

<1>: work holder <2>: Supporting block <3>: Set screw

7-16. Adjustment of the thread take up spring

(1) Loosen the set screw (No.2) and turn the whole thread tension regulator (No.3) then, adjust the thread take up spring (No.1) stroke to be in 9 to 10mm, which is standard stroke.

(2) Insert the screw driver into the slit of the thread tension regulator and adjust the thread take up spring tension. When tightening the screw driver clockwise, the thread take up spring tension becomes tight, and when loosening the screw driver counterclockwise, the thread take up spring tension becomes loose. For the adjustment of the thread take up spring tension, tighten the set screw (No.2) so that the whole thread tension regulator does not turn.

9~10mm <1>

<3>

<1>: Thread take up spring

<2>: Set screw

<3>: Thread tension regulator

<2>

- 30 -

7-17. Adjustment of the thread tail after the trimming

(1) Adjust the thread tail with the pre-tension (No.1).

(2) When turning the nut clockwise, the thread tail becomes shorter.

When turning the nut counterclockwise, the thread tail becomes longer.

<1>: Pre-tension

<1>

7-18. Adjustment of the upper thread tension release (the width between thread tension discs)

(1) When the upper thread tension is released, the thread tension discs (No.1) open in 0.8mm to 1.0mm, which is standard width.

(2) For the adjustment of the upper thread release, loosen the set screw (No.2) and move the whole upper thread tension release to the arrow direction as shown on the figure. When moving the upper thread tension release to the direction “A”, the width between the discs becomes bigger and moving to the “B”, the width between the discs becomes smaller.

<1>

B

A

<2>

0.8~1.0mm

<1>: Thread tension disc <2>: Set screw

7-19. Adjustment of the opening time of the upper thread tension release disks

When the presser foot rises, the thread tension disks are open for a given length of time and close. The default setting is set at one-minute intervals. To change the set value, carry out the procedure shown below.

(1) Turn the power switch on.

(2) Press the on the standard screen to open the MENU mode.

(3) Press the > > [Setting for tension release outputs time length at presser] in order.

(4) Current set value is “60 sec”.

(5) Change the value from 0 to 10000 then press the .

If change the value to “0” the thread tension disks closed when the presser foot rises.

(6) Press the > . Changing set value has been completed.

- 31 -

7-20. Adjustment of the mechanical home position

NOTE The mechanical home position is fixed at the (A) position of the sewing area when the sewing machine is shipped from the factory. However, it can be moved any position for X direction and 3 position of (A) to (C) for Y direction within the area covered with diagonal lines.

Original home position

A

B

C

X

250(500)

500(1000)

Operator

( ) For PLK-G10050R

(1) After canceling the sewing area limit, change the mechanical home position.

(2) Press the on the standard screen to open the MENU mode.

(3) Press the > > [Cancellation of sewing area limit] in order.

(4) Select the on the [Cancellation of sewing area limit] screen, and press the .

(5) Press

→ press

to return the standard screen.

- 32 -

7-20-1. Adjustment of the X direction

(1) Turn the power switch off.

(2) Remove the X-axis left side cover of axis column upper side.

(3) Loosen the two screws (No.1) of detector set plate (No.2)by 2~3mm. If hit loosed screw (No.1) head,

T-nut underneath of set screw (No.1) comes out from the groove.

(4) After finish the adjustment of mechanical home position to X direction, tighten the set screw (No.1) firmly. With the advance of tightness. T-nut underneath of set screw (No.1) start to go in to the groove, and becomes necessary to give heavier power to tighten.

NOTE Make sure if X detector(No3.) lead wire is connected properly and do not touch some moving part such as X race etc.

(5) Turn the power switch on. Press the home position return icon , and check the mechanical home position.

(6) If the mechanical home position is not the desired position, carry out the same procedure (3) 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.

To use the sensor from the send returning, press > > [Home returning method since the second time returning] on the standard screen and set it ON.

<2> <1>

<2>

<1>

<3>

<3>

<1>: Set screw <2>: Detector set plate <3>: X detector

- 33 -

7-20-2. Adjustment of the Y direction

(1) Turn the power switch off.

(2) Remove the table cover plate (most left) (No.1).

(3) Remove one set screw (No.2) of Y detector (No.3).

(4) Y detector (No.3) can be relocated to the 3 different position (A) → (B) → (C) from this side to the other side having a distance of 125mm pitch. If moved Y detector to the other side, work holder is also moved to the same direction. As the result, mechanical home position is moved to this side.

(5) When positioning adjustment of mechanical home position to the Y direction is finished make sure the positioning of Y detector (No.3) then, tighten the set screw (No.2).

(6) Turn the power switch on. Press the home position return icon , and check the mechanical home position.

[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.

To use the sensor from the send returning, press > > [Home returning method since the second time returning] on the standard screen and set it ON.

1.0 to 1.5 mm

1

2 3

<1>: Table cover plate <2>: Set screw <3>: Y detector

- 34 -

7-21. Adjustment of the X-Y detector clearance

NOTE The work holder stop position which is the mechanical home position is detected by the X-Y detectors. If the clearance between the detector and the detector plate is changed, the mechanical home position is also changed. If such aberration is happened, make the following adjustment. Please keep it in mind if the detector senses the home position, the red pilot light of the detector goes on each time.

7-21-1. Adjustment of the X detector clearance

(1) Make sure clearance between surface of X detector (No.1) and the X detector plate (No.2). If this clearance is about 1.0

～ 1.5mm, it is the normal.

(2) If this clearance is out of the normal condition, preciseness of X moving race (No.3) set position is lost. Adjust the position of X moving race (No.3) again and reset to the proper position to have the normal clearance.

7-21-2. Adjustment of the Y detector clearance

(1) Make sure the clearance between surface of Y detector (No.4) and Y detection plate (No.5). If this clearance is about 1.0

～ 1.5mm, it is the normal condition.

(2) If this clearance is not normal, loosen the set screw (No.6) of Y detector plate (No.5) then, adjust the clearance properly.

(3) After the adjustment, tighten the set screws (No.6) securely.

Caution

If the detector clearance becomes more than 1.5mm, the work holder stop position becomes unstable, furthermore, if the clearance becomes far bigger than 1.5mm the work holder does not stop and becomes out of control.

<2> <3>

<1>

Ｘ

<4>

<5>

Ｙ

<6>

<1>: X detector <2>: X detector plate <3>: X moving race <4>: Y detector <5>: Y detector plate

<6>: Set screw

- 35 -

7-22. Adjustment of the X-Y timing belt tension

NOTE The proper condition of the X-Y timing belt tension is standing that they will not be got any yield even it is slightly pushed by hand.

7-22-1. Adjustment of the X motor timing belt tension

(1) Remove the X-axis belt cover (No.1).

(2) Loosen 4 bolts (No.3) of X motor bracket

(No.2) until the bracket can be moved slight.

Do not loosen too much, otherwise bracket

(No.2) will be slanted by belt tension.

(3) Loosen the lock-nut (No.5) and tighten the tension adjust screw (No.4). Then, X-axis motor timing belt tension will be increased.

(4) After the adjustment is make, lock the tension adjusting screw (No.4) by lock-nut (No.5), and fix the X motor bracket (No.2) by tightening the bolts (No.3). Same time, put back the belt cover (No.1) to it’s original position.

<1>

<4> <5>

<2>

<3>

<1>: X belt cover <2>: X motor bracket <3>: Bolt

<4>: Adjusting screw <5>: Lock nut

- 36 -

7-22-2. Adjustment of the X timing belt tension

(1) Loosen the 4 bolts (No.1) of bracket (No.2), until the bracket (No.2) can be moved slightly. Do not loosen too much, otherwise bracket (No.2) will be slanted by belt tension.

(2) When tighten the tension adjusting screw (No.3), X timing belt (No.4) tension wil be increased.

NOTE If the bracket (No.2) is not shifted even though the tension adjusting screw (No.3) is tightened, loosen the 4 bolts (No.1) by about 2 ～ 3mm, and hit the came up screw head somewhat strongly.

T-nut underneath of bolt (No.1) comes out from the groove, and the bracket (No.2) can be shifted.

(3) After the adjustment, tighten the bolt (No.1) securely

<4>

<1>: Bolt

<2>: Bracket

<3>: Adjusting screw

<4>: X timing belt

<1>

<2> <3>

- 37 -

7-22-3. Adjustment of the Y timing belt tension

(1) Remove the table cover which is located at the other side of slide plate.

(2) Loosen the bolts (No.1, 2) of bracket (No.3) (2 pieces of right & left) and bracket (No.4).

(3) Tension of timing belt (No.7, 8) will be increased, if the right and left tension adjusting screw (No.5) or motor driving part tension adjusting screw (No.6) are tightened.

(4) After the adjustment, tighten the bolts (No.1, 2) of bracket (No.3, 4) securely.

NOTE Distinct difference of the tension between the right and left timing belt will be possible to cause undesirable moving of X-Y table. Please adjust the tension of both side timing belt to be same.

<8>

<4>

<6>

<2>

<7>

<5>

<3>

<1>

<1>: Bolt <2>: Bolt <3>: Bracket <4>: Bracket <5>: Adjusting screw

<6>: Adjusting screw <7>: Y timing belt <8>: Y timing belt

- 38 -

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.

Recommended grease: Multemp PS2 (Produced by Kyodo Yushi Co. Ltd )

(Lithium grease 2)

8-2. Disposing of oil waste

If the waste oil pan is full filled in the oil bottle (No.1), remove the oil bottle then dispose of the waste oil.

<1>

- 39 -

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 Corrective action Reference

Upper thread is broken.

Upper thread tension is too tight.

Strength of thread take up spring is inappropriate.

Parts on needle plate, hook, and presser foot touching thread are damaged.

The needle size is bigger than the thread size.

Adjust thread tension.

Adjust thread take up spring.

Grind parts or change parts.

Change the needle size to suitable size.

6-3

7-16

-

5-2

Thread melts with heat. Slow down the sewing speed 6-1

Use needle cooler.

Bobbin thread is broken.

Bobbin thread tension is too tight.

Parts on needle plate and presser foot touching thread are damaged.

Upper thread is pulled from needle hole when starting sewing.

Thread tail is short.

Thread take up spring tension is too much.

Frequent skip stitching happens.

Adjust thread tension.

Buff parts or change parts.

Adjust thread tail with pre-tension.

Clearance between needle and rotating hook is too big.

Adjust thread take up spring tension.

Adjust clearance between needle and rotating hook properly.

Timing of needle and rotating hook is not proper.

Adjust position of needle and rotating hook properly.

Needle is bent. Change needle.

-

6-3

-

7-17

7-16

7-2

7-2

5-2

Trimming is not functioned.

Needle is at wrong position. Fix position properly.

Fixed knife is dull.

Movable knife is at wrong position.

Sharpen fixed knife or change fixed knife.

Adjust position of movable knife properly.

- 40 -

5-2

7-12-2

7-12-2.7

Trimming is not functioned.

Skip stitching happens in trimming.

Trimming setting is off.

Refer to the condition

“Frequent skip stitching happens”.

Turn trimming setting on.

Stitch forming is loose.

Upper thread tension is too loose.

Bobbin thread tension is too loose.

Strength of thread take up spring is inadequate.

Presser foot position is not proper.

Presser foot up and down timing is not proper.

Stitch on back comes apart.

Needle thread is too long.

Adjust upper thread tension.

Adjust bobbin thread tension.

Adjust strength of thread take up spring.

Adjust presser foot position properly.

Adjust presser foot up and down properly.

Adjust needle thread with pre-tension.

Work holder does not fall.

Foot switch is broken.

Work holder presser is not strong enough

Work holder switch is out of order

Wiper system does not work.

Wiper hits needle or presser foot.

Change foot switch.

Increase work holder presser

Change it new work holder switch

Adjust wiper position.

Wiper setting is turned off. Turn wiper setting on.

-

Operation panel section

6-3

6-3

7-16

7-7,7-8,

7-9

7-5

7-17

-

7-13

-

7-11

7-11

Sewing pattern is changed.

7-13

Returned home position is changed.

Sewing material is not pressed properly.

Sewing material in work clamp slips.

Adjust work holder pressure.

Put slip stopper on presser plate.

Sewing material is too heavy. Slow down sewing speed.

X-Y timing belt tension is loose.

Adjust X-Y belt tension properly.

Ambient temperature is out of use range.

Use sewing machine in ambient temperature in 5 degrees to 35 degrees.

Clearance between detector and detecting subject is too wide.

Adjust clearance in 1 to

1.5mm.

-

6-1

7-22

-

7-21

- 41 -

Printed in Japan