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Brother KH-930 Electroknit With KG-88 II 89 II 93 Service Manual EN

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492 views56 pages

Brother KH-930 Electroknit With KG-88 II 89 II 93 Service Manual EN

Uploaded by

Terrence Jones
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SERVICE MANUAL FOR KH-930 ELECTROKNIT. WITH KG-881I/89 11/93 *KH-930 1, PRODUCT CHARACTERISTICS .......--+ 2. PRODUCT SPECIFICATIONS .....-...-+ 3. QUICK TROUBLESHOOTING CHART. 4. NOTES OF CAUTION FOR CHECKING AND REPAIR 5. CIRCUITRY CONFIGURATION ...22.02000006+ 5.1 Main PC Board : 5.2 Operation PC Board ...... 5.3 Left Position Sensor PC Board and ig Position § CONTENT: PC Board ....... - 6 $4 Encovler PC Board. 6 nu. Solenoid PC Board 1 5.6 Relationship between Needle Selector Plate, Solenoid, Needle Number, re and Belt Phase Signals 5.7 FBIO .... 5.8 Power Supply 6, TEST PROGRAMS 6.1 Test 885 6.2 Test 886 6.3 Test 888 6.4 Test 889 ‘ 7. CHECKING AND REPAIR OF THE POWER SYSTEM 7.1 Checking the Power Cords ‘ 7.2 Checking the AC Power Source 73 Replacing the Fuses (F601) 74 Checking the Power Switch .......- 78 Checking the Power Transformer... CHECKING AND REPAIR OF THE POWER SUPPLY PCBOARD ....... : 8.1 Checking the Fuses (F201,202) ...-. 8.2 Checking Output Voltage ......++.+- 9, CHECKING THE NEEDLE SELECTOR 1 Checking with the Power Switch Turned Off - 9.2 Checking with the Power Switch Turned On. 9.3 Checking with the Solenoid On 94 Checking the Solenoid ...-..+- : 955 Checking Needle Selection by Test Pattern . 10, REMOVING ELECTRICAL/ELECTRONIC PARTS AND PC BOARDS ..... e 10.1 Removing the Lithium Battery and the Main PC Board 13, 4, 1s. oi *Ki L oe) . Differences between KG-8811/8911/93 and KG-88/89 in the assembly and, Ss 10.2 Removing the Operation PC Board 10.3 Reassembling the Operation PC Board and the Main PC Board . 104 Removing the Encoder PC Board and the Slit Dise « 105 Removing the Power Supply Board ....... He 106 Removing the Left Position Sensor PC Board ..... 10.7 Removing the Right Position Sensor PC Board . 108 Removing the Filter PC Board ‘ 10.9 Removing the Transformer WHEN “888” BEGINS TO BLINK WITH THE POWER SWITCH ON DISASSEMBLY, ASSEMBLY, AND ADJUSTMENT OF | K CARRIAGE . 12.1 Disassembling the K Carriage. 12.2 Assembling the K Carriage Comereays 123 Functional Check of the K Carriage 0.2.0... 124 How to Adjust the K Carriage DISASSEMBLY, ASSEMBLY, AND ADJUSTMENT OF | L CARRIAGE . . 13.1 Disassembling the L Carriage... 13.2. Assembling the L Carriage . 13.3 How to Adjust the L Carriage _ DISASSEMBLY AND ASSEMBLY OF THE MAIN BODY 14.1. Disassembling the Main Body oan 14.2 Assembling the Main Body ..... ADJUSTMENT AND CHECK OF TH! MECHANISM . 18.1 Adjusting the Card Reader Guide Plate. 15.2 Adjusting the Rotary Cam Position 15.3 Checking the Needle Selector Mechanism. svvte SB G-8811/8911/93. KG-8801/8911/93 product characteristics and points different from KG-88/89 - 3 Product specifications . . 33 mounting of the G carriage 33 |. Differences between KG-8811/1 - 54 . Troubleshooting... 4 *KH930 1. PRODUCT CHARACTERISTICS 2. PRODUCT SPECIFICATIONS 4 5. ‘The application of electronics to a pattern knitting device, and automatic needle selection through the internalization of pattern data utilizing a microcomputer. Patterns stored in memory may be altered in a variety of ways: ® The orientation of the pattern may be changed. @ The pattern may be expanded to two times horizontally as well as Vertically, and up to four times by expanding the pattern two times in both directions simultaneously. © The pattern may be knitted face to face) back to back @ KHCand KRC patterns may be knitted by merely switching the pattern variation key. Large sized patterns may be knitted (e.g., 200 Stitches, 68 Rows) Original patterns may be knitted through key input. Patterns stored in memory are not erased when the power is turned off. Origial pattern data my be stored or called up with external memory devices. (FB100), Intarsia and thread lace may be knitted with K carriage. Pitch, number of needles 4.5 mm, 200 needles Weight 15.6 kg Sire L 1129 mm x W 216 mm x H 97 mm Color White Needle bed materia! Knit reader KR-KHC-KRC usage Auto carriages External memory devices ‘Tempered steel can be installed KLII6 may be uses KR850, 830, KHC820, KRC830/900 ‘T carriages may be used (KA-8300) KG93 may be used FBI00 Pattern knitting function Pattern needle device Additional thread lace, intarsia with KH-910 Automatic needle selection by internal microcomputer Voltage-power requirements Pattern book Design sheet 115, 220, 230, 240V. 25 W 3. QUICK TROUBLESHOOTING CHART Treble Og Remedy Titers TE aige operation igh | Carag mig ma ae ned 10a he ban SR ad Nc bed sings oo vied 2 Ol i mcr and crafter 4 Th ser ab ad pop ee 2. Ceres dake pte omar adie Par i Te snr is ing te ining mete, 1; Cec wraps of dooce, Pa gz 5. "The gage i extremely fine. 5. Loosen keiong aie: Thee ol on bel log cra eo 6 Wipe of he pee on te Ba 7. Rotary cam requires horizomal adjustment (Rotary cam is 7, Corret horizamal adjustment of rotary cam. P3t ane 00 eho thee : Fob oats door Ens) eaiaes ete 1 ip eit espe nd pu 1 conidia. ars nai cee i 2: Cort vera efenen of kar Pie er [Neeson oe 3 Change ete i, Te ss me fs “boon Anning a Occasional sieaking fle hepa nes) 1 Uncten seed nearing operon 1: Mi aniaeeptaton sped aa 2. Poor yarn feed. 2. Lighten spring tension. [iran teeing he [ Atctnet f spe wen oF 1: Mike be: tegonarhaa GSE lo bas rhe cae is obstructed while 1. The needle bed is damaged J. Repair needle bed sing Tose one ae mage 7 Repuce rede 2 Wien hc ange Arab pac on | Ed neste section aim pcb (encion laggy worn) | 1 Repseend axed wlion ch Section ee wheton nx pose When cange nob pt on PERCU Reena als, Spina ato osm na Snap eo ca nian eb tet arama way | Thee bees on Tie nee ead vito aoe 7 Te Lara pa eae ang mera r : 1 Tecan poet pig eg 2itegbsealin peter wine oe ee ee Tg ag a 2. Yarn feeds pooriy 2, Use wax on yarn tention war star Speedo pein Wt ah Obras ree se [euler —— ‘CA ees Trea = On = : no [stitches are dropped 1. Newdle plate funetioning improperly |. Replace knitting needle 2. Gate peg bent = 2. Adjust gate per : SSAA teal fon Lapeper Coma Hehe arr of elk ele por a f ca prope pons carat hamacaiearag Lat Pa 3 5. Leaf spring position improper |S. Correct right-left adjustment of leaf spring pay Step be cnet ee pce Fale mel Ea made csi ting oar Sotppsiyar [Sandee wee Gangs py i Eod weil chesoneani ind 2 Reps nd ei seston am eg eo aR i re 7 2 Om ap 2 Ck pen pa va en cr 3 check ss pntion ear i, Cont hel ea por Replica ci sRonal oer poitin tawny ee iene eels econ FO Chest wd sion meron and cit esr dena | P36 6. Carriage problem: 6. Check carriage Pad 5 7. Power problem 7. Check power supply system i ose aE een eee errr ee) sare E Ea ee ea Re ai i 2 Sey Takesaeateeercomr enter | Thr grea Berar elt bar pce 1 Wipe pre ofrecer ne tee Tie NSP opaion rade pean er poser are [2 Repl nso Pas Pa ase la paserpnarg oe agi wv pas Taper eh Fo eT ce 1 Care tS pO PT Eee Le Ne et oben Regen ae ee eo agers ener oman nas ing rll car Bet tng el 7 Reger ng all Rosia et bed nom ep 2 Reyne Trouble Origin Remedy Notes | [Kniting needle js not selected at |. The vertical travel of the rotary cam lever iv nota egularas specified |. Labricate the card veader guide pate Teves Replace the needle selector unit Pas, Pat [An excess of ecdles come oat at eyes =—Th 12 Card reader guide plate oat of adjustment 2, Correct horizontal adjustment of card wader guide plate Rotary cams out of adjustient horizontally Needle seeetor plats |3. Correct horizontal adjustment of rotary eam BA travel is coo short (Roary ex ig positioned too much (0 the right) g [4 Neale selector solenoid is aot unctioning I. Check needle selector solenoid i [Nexdlesclcetion position is aff by | 1. The position sensor is out of adjustment |. Correct adjustment of position sensor level and mounting position stitches 2 3 2 Connection between belt and carrage connecting plate at carnage | 2. Correct functioning of carriage comnecting plate 2 forward travel opening (especialy that of the L carriage) is bad Replace i. Replace the belt pulley brake 3. Bek connecting bok i damaged 3, Replace the belt | Paw PSI 4. Cariage and belt sensor eievitry system is bad | 4. Replace the encoder PC board or replace the main PC board 5. Sit dis i damaged 5. Replace the st dsc P20 (6, K carriage and {carriage conrol cites are bad 3. Replace the left position sensor PC board the encoder PC board the ‘main PC board, in that order Ps * Check and replace the K carriage and L. carriage sensor magnets 4. NOTES OF CAUTION FOR CHECKING AND REPAIR In order to avoid secondary damage, please pay attention to the following points: (1) When assembling or disassembling the machine, always ensure that the power cord is unplugged from the socket (2), Be sure not to pull the plug by the cord when disconnecting it from the socket. (3) Tighten nuts and screws down securely. (4). Be sure not to lose any nuts, screws, or washers, and ensure not 10 leave any of them in the machine during assembly. These ean be the eause of shorts in the electrical circuitry. (5) Do not damage the cords or PC boards with the soldering iron. (6) The electrical parts used in the machine can be damaged by static electricity Therefore, be sure to hanille PC boards by the edges and to refrain from allowing your hands to come into direct contact with parts (7) When transporting PC boards. itis best to wrap them in aluminum foil or in an anti static electricity bag. When transporting the main PC board assembly, always ensure that the lithium battery has been removed. Never wrap the assembly with the lithium battery still attached. Polyethylene and styrene ean cause static electricity and should not be used for wrapping. (8) After the completion of assembly or disassembly, check to ensure that all connectors are properly connected and that the equipment operates normally (9) The main power should be the same as the rating of the machine. (10) Ensure that the positive and negative terminals of the lithium battery are not shorted, §. CIRCUITRY CONFIGURATION Opeation PC beard Tame (ue) | Ko sSmude PC bad | fev Main PC board avery PEPE poner supply a a ——— [ata a a tea one op = CM | A af —CE hema [Encoder OC bor Figure 51 2) Fig, 5-1 shows the circuitry configuration of the KH-930. 5.1 Main PC Board ‘The main PC board is the main control portion of the equipment, Itis comprised of the computer, memory, and control parts etc. 5.2 Operation PC Board ‘The operation PC board is the key PC board, made up of the lamps (LED) and keys. It is connected to the main PC board by a flat cable (P7. PS), 5.3 Left Position Sensor PC Board and Right Position Sensor PC Board The eft and right position sensor PC boardsare what send out the carriage position signal. It is eonneeted to the main PC board by a connector (S2, $6) The position sensor signal (pin 3 of S2, $6) is normally DC 1,6- 1.8V, but when the K carriage sensor magnet approaches the position sensor, it becomes DC 3.5V or more. and less than DC 0.7V when the L carriage approaches. When G carriage sensor magnet approaches, it begins at DC 0.7V and thereafter immediately changes to DC 3.2V or more. Itis by these changes in voltage that the computer is able to determine whieh carriage has passed by (refer to Fig. 5-2) When caniage paves Finofsocxapmanch $f Pole ofc peeach Votage rane Point dmestappromch Karape nove Tera gemma Tarps movement Figure $2 5.4 Encoder PC Board ‘The encoder PC board emits signals required in the detection of the direction and ‘amount of earriage movement and in solenoid selection. Itisconnected to the main PC board by a connector ($3), The V1 (Pin 4 of $3), V2 (Pin 3 of S3). and BP (Pin 5 of S3) signals are configured as shown in figure 5-3 below: Carriage cl ihe Gace Cariage trae oe et Pipe 68 The amount and direction of movement of the carriage are detected via the VI and V2 signals, and the type of engagement between the belt and the carriage is detected via the BP signal (Belt phase signal). There are two types of engagement, diseriminated between by sensing whether the BP signal is high or low when the carriage passes the position sensor. 5.5 Solenoid PC Board ‘The solenoid PC board is a PC board which is acted upon by the needle selector device. It is connected to the main PC board assembly by a connector (S4. SS). ‘There are 16 needle selector solenoids, with numbers on them, counted sequentially from left to right. There are 8 needle selector plates, the relationship to the rotary cam of which is given in figure 5-4 below. Romry cam selene New stor pte Figure 54 5.6 Relationship between Needle Selector Plate, Solenoid, Needle Number, and Belt Phase Signals es ‘Yellow ncedle numbers (left) Green needle numbers (right) 0] [olu[e[=[e[a[s] [nl»[slaln|n wor] sifasfin of as [oa] 7 so] uf] 2 Ey eletat a] as opal [6 ala ee par bar [is x] 50] 66] a2 | 98 ‘alae pop as] si [er] | 99 alste pa %6 [100 EE 7 5 ops ® %| 3 » a sr] apa 9 o = € 36] 0] 26 | 8 ® D spe[at7 pola] 0 E [afm te | fularla|ss aston F s[vputs| elwte[o so L Karrie ture mark seat [PELE [carvings nig rm mark TE ‘carriage left turn mark | Pe [a [enrages rm nk] 5.7 FB100 (external memory device - sold separately) ‘The FBIO0 is 3.5 inch floppy disc drive unit which stores the patterns input by the KH930. Ithas.an80 kilo byte capacity. Itis connected to the KH930 main PC board connector (P9) by an FB cord. 58 Power Very generally, the components of the power system may be divided into the AC cord, the power switch, the filter PC board, the power transformer, and the power PC board. Input power passes through the AC cord and the power switch and goes tothe filter PC board where line noise is filtered out, Itis next reduced in voltage by the transformer, separated and delivered to two circuits. These are finally transformed by the power PC board into DC SV and DC 12V currents. ‘The DC 12V current is supplied only to the interface circuits FBIOO of the solenoids and buzers. all other electrical requirements being met with the DC SV current. 6. TEST PROGRAMS 6.1 Test 885 ..... Needle Position Detect Circuit Test ‘© Step 1 —Display right or left position signal voltage. The computer will report that it has detected either the K, L. or G sensor magnet. Test procedure (1) Turn the power switch on. (2) Turn the display off by pushing the “CE ) 43). Input the digits [8)[8)(5] and push vie STEP} key. ‘The voltage of the left position signal will be indicated in the display (for example. [[Blindicates 1.76V). A yellow lamp will ight. indicating that the left side is being checked, When there is no earriage sensor magnet in front of the sensor.a voltage of 1,76V or |.92V will be indicated. At this point, ifthe VR on the left position sensor PC board is turned, the voltage displayed in the display will also change. *Note: Intheevert that the voltage displayed in the display does not fall between 1.76V. and 1.92V, adjust via the VR on the left position sensor PC board. This adjustment should be done as follows: first. turn the VR slowly until 1.92V is displayed, then turn it slowly to the left unt 1.76V is displayed and stop When there is a problem ‘When adjustment cannot be effected, replace the position sensor PC board and. attempt the above adjustment again, (4), Place the K carriage sensor magnet in front of the sensor(with the change knob ‘on ). At this time, the voltage indicated in the display should be 3.36V ‘or over, When voltage is 3.04V or over and the computer detects the K carriage, (N). aI" will be displayed in the memo display. (5) With the K carriage sensor magnet in front of the sensor, turn the change knob 10 (plain stiteh), Ensure that the voltage is below 2,72V, The memo display will not turn off even if the indicated voltage drops below 3.04V. If the rection of carriage movement changes from right to left (when the yellow lamp is on), it will turn off. 6) a &) O) Place the L carriage sensor magnet in front of the sensor. 0.64V or less should be indicated, When voltage drops over 0.80V or lower and the computer detects the L carriage (S), the memo display will indicate a “2” Pass the G carriage sensor magnet across the outside of the sensor, ws Gsersor ape 176] 0] 352} [3] T Te Geach Shae Note ten dct ‘When detecting the N magnet, a 3is displayed, Push the [GREEN] key. ‘The voltage of the right position sensor signal will be displayed. The green lamp will light indicating that the right side is being checked, Using the sequence given in (4)47) above. check the conditions of the K carriage, the L carriage, and the G carriage on the lett Note: To recheck the left side, pushing the YELLOW] key will put the equipment in the condition given in (3) above. ‘When there is no problem by performing the checks given above. Push the key, and the voltage display on the display well as the YELLOW, GREEN. and START lamps will be turned off, Then, the step 2 test will begin. "When there is a problem By performing the checks given above, check the mounting position of the position sensor PC board horizontally and vertically to sce that each have the proper voltages. If they do not, replace the position sensor PC board. pole magnet within 3 needles after deteeting the $ pole indicating detection of the G carriage. If voltage goes down during the K carriage check or up during the L carriage check, replace the carriage sensor magnet. If there is some abnormality during the G carriage check, check the G carriage sensor magnet. In the event that the magnet is properly mounted, replace the G magnet holder. If there is no problem with the indicated voltage. but nothing is displayed in the memo display. perform the step 2 check (refer to figure 6-1). ‘+The magnet with the white mark ¢N) ision the inside. Gearing Figae 61 # Step 2 —This is to check to see whether, of the needle position detect circuit signals, the V;, Vz, BP,and iRQ (count ed ge) signals have been properly sent to the computer, (10) Move the carriage forward and backward one time (20 needles or more). If problem is noted during step 2. an “E* will be displayed in the memo display. and an error digit in the display. When there is an error digit in the display, the step will proceed no further. If the[STEP] Key is pressed, the step 2 test will be repeated Error digits 3: the IRQ signal is not sent when the earriage moves to the left E4: the iRQ signal is not sent when the carriage moves to the right ES: the (RQ signal is not sent when the carriage is moving in either direction 6: the iRQ signal is sent when V2 is LOW When other than E3 to E6: The condition of the V;, V2, or BP signals will be indicated in a 3 digit display T210) 0: proper condition it |: The signal remains High Bp Ye ¥p nk ot an ot 2: The signal remains Low | Cound: ¥ ae 1 Coum eae (Cariage vein ote ght Cariage tli tothe ty a a When arr speed sal 25 1s. and geo 1 and are both oer 150 see al Tal Ifno problems are noted in step 2.a buzzer will sound, and the READY lamp. will light, “When there is @ problem Alter the check is completed. if the READY lamp does not light. orifan error digits is not indicated, replace the encoder PC board. After replacement perform the check again starting with step one. (11) Press the[ STEP] key. Move the earriage from the outside of the left turn mark toward the center. The step 3 test will begin, © Step 3 —Mounting position tests for the left and right position sensor PC boards ‘When the K carriage passes the left turn mark, and when the L. carriage passes the right turn mark, during the time from the bel phase signal reversing to the first Vi count edge in the right or left position signal, the Vi count edge should be one or more. @ Western lie Se iste ward : y Solent oat 100K Sabri woc are 1090 @ (ribs vo mark i wu) 1 1 1 Counsipe y umm EE i Soknsd vos wtrght I=7- Sokol neat rh =F When the L. carriage passes the left turn mark. and when the K carriage passes the right turn mark V; count edge should be one or more during the time from the first Y, count edge in the right or eft position signal to the belt phase signal reversing. @ Lietroen-ach Let 100 rn et 190 ey i wy testensnark LET Solenoid ot ef 100-0 Solemid no. ate 1008 @® Kriprecummare igh 100 Ben phase way If there is no problem, the READY lamp will go on, and the carriage type and belt phase signal level wll be displayed in two digits. In the memo display. the digit for ‘the count edge will be indicated. First digit: Belt phase signal Display When H 1 When L 0 Second digit: Carriage type Display Kearriage 1 Learriage 2 Geartiage 3 Anis ft wr nthe yeu sLL Indatesthat ore was ore coun = Araceae phan ig i Indices hat K erring pc by [Memo display carriage | Turn mark | Count edge ® K Left 1=2 @® L| Rew | 1-2 @ L leit 2-3 @ K Rig | 2=3 When there isa problem within step3, an “E" will be displayed in the memo display, ‘and also the carriage type and belt phase signal level will be displayed in the display. "When there is a problem ‘When an error is registered, check the position sensor PC board via the items as given inchart 1. Thestandard position for the magnet sensorsareat the 100th needle tothe left and tothe right. After checking these items, repeat the cheeks fromstep |. —10- Chart 1 lem Left position sensor | Right position sensor Error When there isan error | Leans toward the Leans toward the with the K carriage side outside Leans toward the outside Leans toward the inside ‘When there is an error with the L carriage When the READY lamp lights, or when an “E” is displayed, press the step key so that you can repeat the step 3 test. The 885 testis finished by turning the power switch off. With the STEP key, when the belt phase signals D.®,@.and @of step 3are H of L. altogether. a total of 8 checks are performed. 6.2 Test 886 ..... Needle Number Indication Test procedure ® Put the carriage out beyond the turn mark and turn the power switch on. ® Turn the display off by pushing the [CE_Jkey. ® Input the digits [8][8)[6} and push the [STEP ]key. @® When the carriage sensor magnet passes the turn mark. the indication will start. ‘The position of the carriage sensor magnet (the magnet on the direction of travel for the G carriage) will be indicated by its needle number (the number of theneedle position indicator). Itis normal for the actual sensor magnet position to differ from that indicated by one needle to the left or right, The computer does not diseriminate. The solenoid being controlled by the computer will also be indicated by a digit or a letter. 0-F, according to the needle then being indicated onthe memo display. The solenoid will be indicated, from the left, by 0.1.2.3.4. 5.6. 7.8.9.4. B. C.D. E,and F. *When there isa problem Perform test program “885.” 6.3 Test 88 ..... Memory Test The computer will test the memory. The execution of this test will clear the memory of the entirety of its contents. Test procedure ® Tum the power switch on and turn the display off by pushing the[CE key. ® input the digits (8][6)[6] and push the [STEP] key. 55 (HEX) will be written intoall memory fieldsand a check will be performed to ensure that $5 has been written, Then, AA (HEX) will be written, and a check performed to see that AA has been written intoall fields. When these checks are Passed, a Ois written intoall fields of the memory andthe READY lamp lights. Ifthe checks are not passed. an “E” will indicate in the memo display. Pushing button repeats this test. Note: The check requires 2-3 seconds for completion. Be sure not to turn the power switch off before itis completed *If there is a problem If an error is registered on the display, replace the main PC board. 19 64 Test 889 ..... Display Key Test ‘© Step 1 —Indicator lamps all blink. @ Turn the power switch on. @® Push the| CE] key, turning the display off. ® Input thedigits 8 display window (§{)8] and 8]. and the remaining lamps (IED) will all begin to blink on and off simultaneous! Press the [STEP] key. The display and the lamps will all go off, and the step 2 test will begin, Check to ensure that the step is functioning properly. ®© Ifa key is pushed, the number for that key should be displayed in the display. ‘The numbers for each of the keys is given in chart 2. ‘If there isa problem In the event that there is a problem. first check to ensure that the cords connected to the conneetors P7 and PS on the soldered side of the main PC board are properly joined. If they have been connected properly. then there isa problem in either the main PC board or in the operation PC board. Replace the main PC board and repeat the "889" test program. If the same problem reoccurs.that will indicate that there isa problem in the operation PC board, so replace it. In this event, the former main PC board should be normal. e Mee | RY | ow Key [Mow | Key o | 0 1s Green 2 4 1 1 1s 4 x» | SELECTOR 2 2 2 6 v x | VARIATION |_| 3 3 17 | nothing | 31_| VARIATION2 afd | © n | VARIATIONS | 3 5 19 | SELECTOR! | 3 | VARIATION3 | oi 6 » | input | _& | VARIATIONS 7 7 2 | CHECK | 3 | VARIATIONS * 8 2 | (Ctcbe [3 | VARIATION? | s{[ 9 2 | memo | » R 0 STEP au | nothing | 8 " cr a a cE % | Yellow | 7 | == 7. CHECKING AND REPAIR OF THE POWER SYSTEM 7.1 Checking the Power Cords Ensure that thereare no broken wires. Set the tester for {range X1! and connect the cords to both terminals. If resistance is 0 ©, then there is no break. 7.2 Checking the AC Power Source @ Remove the operation panel and disconnect connector S10 from the power supply PC board. @ Connect the power cord and turn the power switch on ® The voltage between S10 pins 1 and 2 (the orange cord) should be about I25VAC, and the voltage between pins 3 and 4 (the red cord) should be about 1OSVAC. ® If checks initem @ above should reveal the voltage of cither the orange or red cords tobe zero, yet show noabnormalities anywhere else. it will indicate a problem in the power transformer, and the transformer should be replaced. When voltage in both the orange and red cords are OV. the fuse in the filter PC board might be blown. or there may be a break in one of the wires, the power switch may be defective, or the power transformer may be bad. 7.3 Replacing the Fuses (F601) Measure the resistance of both of the terminals of the filter PC board fuse (F601). IF resistanee is 0 2, it is normal. If resistance measured is %/, the fuse is blown and. should be replaced. The capacity of the fuse is different according to the rated voltage. Replace the fuse by referring to the indication on the fier PC board. HO—11SV 1A Fuse (65.20 x 20) 220—240V 0,5 Fuse (65.20 x 20) 7.4 Checking the Power Switch Measure the resistance between the pin of the AC inlet connected to power switch and the BRI on the filter PC board. Turn the switch on and then off. Check to {ensure that when the switch is on, resistance is 0 0, and when the switch is off. itis 12 (infinity). 7.8 Checking the Power Transformer Measure the resistance between BR3 and BL3 on the filter PC board. If it registers about 10 0. it is normal (refer to figure 7-1) Fite PC band ——— Cie ar ansomnerf (i aaa Power itch loo.isy Figure 74 Fixer PC bow Cin pS ey J te Power witch 20240 13 8. CHECKING AND REPAIR OF THE POWER SUPPLY PC BOARD 8.1 Checking the Fuses (F201, F202) Measure the resistance of both of the terminals on fuses F201 and F202. Ifresistance is0 they are normal. If resistance ise=M, the fuse is blown and should be replaced, Fuse F201 is a 2A, and F202 a 5A, glass tube fuse (5.2 x 20). 8.2 Checking Output Voltage ® Disconnect connector SI from the main PC board. ® Check the voltage between pins | and 2 (pin 2 is the ground), If voltage is DC12V ~ DCISV or more. itis normal, If is not normal, replace the power supply PC board. If itis OV, check F202. @ Check the voltage between pins 3 and 4 (pin 3 is the ground), If itis between DC4,75 and 5.25V. itis normal. [itis not normal, replace the power supply PC board. Ifit is OV, check F201 @ Check the voltage between pins 3 and 5(pin 3 is the ground), Ifit is more than DC 10V. it is normal. If itis not normal, replace the power supply PC board {refer to figure 8-1), Pos T 2 3 8S igure Bt -~14— 9, CHECKING THE NEEDLE SELECTOR 9.1 Checking with the Power Switch Turned Off Set the K carriage change knob to . and put all of the needles in ___ position B. ® Turn the power switch off. and move the K carriage to check all, the needles should be selected to position D. *Note: Theabove check should be performed with the carriage traveling right. left.and at high speed and at low speed. *If there is a problem Then it will be in the carriage needle se edle selector mechanism of the main body or in the 9.2 Checking with the Power Sr @ Set the K carriage change knob to . and put all of the needles in position B. ® Turn the power switch on, and push the [MEMO]key. The should light 7 Note: If the [MEMO] key lamp does not light when the [MEMO] key is pushed, turn the pattern number lamp on after turning the selector (1) key on by pushing the [STEP] key. input pattern number 100 (or any of the others from 1-585 or 881-884), push the [STEP] key twice. and push the (MEMO) key once again when the READY lamp comes on. ©® Select needles after the K carriage has passed the turn mark from the outside. At this point, the needles should all be selected to position B. *Note: Theabove check should be performed with the carriage traveling right left. and at high speed and at low speed. f there is a problem I there are needles selected to position D, perform the check given in 9.3, EMO key lamp @Q @® 6® 3 Checking with the Solenoid On Remove the two operation panel screws. While holding up the left side of the panel and sliding the panel toward the left. remove it from the main body with connectors on, (+Place the removed panel on the rear of the main body case.) Remove the three cord cover screws and the cord cover. Set the K carriage needle change knob to ,and put all the needles in position A. ‘Turn the power switch on, and push the( MEMO) key (as in 9.2@). Move the K carriage past the turn mark from the outside, and then move it from right to left. The armatures should all remain in the down position. Pree 1 The fourth rmatare rom the rh ot of poston “Ifa problem is found in the 9.2 cheek Ifa problem is found during the 9.2 check but the 9.3 check produced none. it will indicatea problem in cither the ncedie selector mechanism of the main body or in the carriage needle selector mechanism (refer to 15 on P.S1 and 12.3 on P36), *Ifa problem is found in the 9.3 cheek It will indicate a problem in the electrical circuitry. Check this with the test program given in chapter 6 (885. 888). If this does not produce the answer. perform the check in9.4 (theexample shown in the picture isa solenoid no. “C7 problem), 9.4 Checking the Solenoid @® Tum the power switch off, and disconnect connectors s the main PC board). ‘and $$ (P4and PS on se 35 tyeses?i) [osevssesen TTTTTTTT TTTTITTTitiy Sobeiumnr 8 SAR COEF 450122465867 Soknalmmit gig iizisiaise | 234867 8 Pea Figure 92 ® Check theresistance between pin 9 or of the SS connector and the pin of the connector which corresponds to the unenergised armature. (Refer to figure 9-2. In picture 9-1, there is a problem in pin 10 of SS or pin 9 and pin 4 of 4), Resistance should be within 140- 150.0. If tis not, there isa problem, which may be found with the check given below. If no problem is found in the resistance values, perform the check given in 9.5. ® Disconnect the needle selector solenoid unit (refer to on P.4S item 1). Check the resistance values of the places which correspond to the solenoids on the solenoid PC board which were found to be bad. The resistance value of the solenoid coil should be between 140 - 150.0. the resistance value of the solenoid signal cord should be 0 . and the resistance value of the metal portion of the ‘main body and the solenoid should be 22 (refer to figure 9-3). Selenad F.C. (Ceding he solenoid eit ‘Checking she solenoid sgrl core (iio~ 1502) (ay ‘Check heen he solenoid a the mca potion f the min bods (2) Figure 93 “If there is a problem If a problem is found in a cheek between the solenoid coil and the solenoid chassis, replace the solenoid. If a problem is found when checking the solenoid signal cord, replace the solenoid signal cord. =e. 9.5 Checking Needle Selection by Test Pattern Pattern numbers | through 555 are internalized, but other than that, there are also 881 through 884 which are test patterns. The pattern for each of these is given in figure 9-4, The testis performed according to the following procedure. Puta sufficient number of needles in position B. “Turn the power switch on and push the selector (1) Key. Push the STEP key. and then the CE key. Then. enter the digits 881-884, and push the STEP key twice. The READY lamp should light. ‘Turn the variation (4) (double length) switch on, and set the K carriage change knob on . Select needles after passing the K carriage from the outside of the turn mark ‘The needle selection should change after every other pass. @ © 888 © Tes puters ht a aternatie nec eteston SxS ahernatne pedleseketion Home shten M4 1/55)9 nee eeton Fae 4 17 10. REMOVING ELECTRICAL/ELECTRONIC PARTS AND PC BOARDS 10.1 Removing the Lithium Battery and the Main PC Board ® Remove the operation panel (refer to 14.1) ® Disconnect all 6 of the main PC board connectors and remove the 6 screws (refer to picture 10-1) Raise the main PC board and remove the cable protection sheet Release the connector lock connected to the lat cable and disconne The main PC board should now be removed (refer to picture IC 10-3), @® Silkscreen printed part BI on the main PC board is thelithium battery. Remove the solder with the soldering iron holding the two logs of the lithium battery The lithium battery should now be removed. the cable. and figure ae Main PC board (Cable piecson shat Pitre 102 ® Pavnecone Occasionally, the start lamp will fail to come on and the keys will @ not function when the power ~~ switch is turned on for the first time after the lithium battery has been replaced. 1° this should happen; leave te poweron tor 30 ex D Unlaihont to 60 seconds. If the start lamp ire 105 lights and the keys function after this waiting periods, there are no problems with the main PC board. This temporary failure to start is normally caused by anti instability in the RAM data, Once the start lamp has come on, the backup battery will be activated and the problem will not occur again, The main PC ‘board where this problem occurs should thus not be assumed to be flawed. Also, in the event that the display “888” should start to blink when the power switch is turned on after the lithium battery has been replaced, see chapter 11 “when 888 begins (o blink with the power switch on.” If 888 does not start blinking, run 888 test program. (see chapter 6.3) 2 View from it id f main PC boa ~18- 10.2 Removing the Operation PC Board ® Remove the six operation PC board screws (refer to picture 10-4), @ Push the operation PC board and remove the operation PC board from the ‘operation panel (refer to picture 10-5). Operation panel Pitre 105, Operation PC tars 10.3 Reassembly of the Operation PC Board and the Main PC Board 1. Mounting the operation PC board (refer to figure 10-6) ® With the operation PC board turned upside down, place the display window (filter) into the opening in the operation PC board. ® Next, place the operation panel aver the operation PC board and put the serews in and tighten them (put the cable through the opening in the operation panel) Opeation pune Display wintow (her) BE} ovenion ¥¢ hes Figure 4 Reassembly of the main PC board ®D Undo the lock on the main PC board flat cable connector (P7, PS). ® Next, plug the cable into the connector, and lock the connector. D After mounting the cord protection sheet, assemble the main PC board to the operation panel and lighten the 6 tapping screws. Note: Be cautious to ensure that the volume (VR1) and the external memory device (FB100) connector (P9) fit through their respective openings in the operation panel face ~19— 10.4 Removing the Encoder PC Board and the S ® Remove the encoder PC board holder plate screws (refer to picture 10-7) ® Raise the encoder PC board straight up. ® Remove both of the screws on each of the encoder PC boards. @ Remove the two encoder PC boards from the encoder PC board holder plate ® Pulltheneedles near the sit disc toward you, and pulling the slit disc out toward the left, remove it from the rotary eam shaft (refer to picture 10-8). Ener PC bead A ‘e holder pate sere Fp Petre 108 10.5 Removing the Power Supply PC Board cl and the accessory box (refer o 14,1 and 14.2), ® Cur the binder thet holds the signal wires by stay center B. Remove connector $10 from the power supply PC board. Remove the two serews from the heat sinker of the power supply PC board (refer to picture 10-9), @ Remove the powersupply PC board by slidingit tothe left ofthe accessory box setting plate @ Remove the operation pa 10.6 Remoying the Left Position Sensor PC Board @ Curthe binder that holds the signal wires by stay center B ® Remove the let position sensor PC board screws (refer to picture 10-10) Volare R) Picture 1040 Let postion sensor PC board sre 10.7 Removing the Right Position Sensor PC Board 10.8 Removing the Filter PC Board @ Remove the right position sensor PC board screws, @ Take theright position sensor PC board off toward you (refer to picture 10-11) Loerie li me Ba net re 1012 @ Remove the 3 needle bed screws, the 3 plastic rivets, and the 2 AC inlet screws, @ Slide the right lower side plate toward the right, and remove the power switch from it @® Remove the filter PC board from the right lower side plate ee ght position seer PC board rem Petre 1041 Picture 0 10.9 Removing the Transformer ® Remove the needle bed from the main body case (refer to chapter 14.1, @ Remove the right lower side plate. ® Cutthe two binders holding the transformer cord. @ Remove the four transformer serews, Ji. WHEN “888” BEGINS TO BLINK WITH THE POWER SWITCH ON When the power switch is turned on andthe READY lampdoes not light but “888" begins to blink. an internal memory back-up error has occurred. If the [STEP] key and the INPUT] key are pushed at the same time. and thelNPUT] key pushed once ‘again, the READY lamp will light. At this point. the contents of the memory will have been completely cleared. ‘When back-up errors have occurred numerous times. itis possible that the lithium battery is bad or worn down. or that there is @ problem with the main PC board. Remove the main PC board and check the voltage of the lithium battery. If the voltage is less than DC 2.5V. replace the lithium battery (referto 10.1), Ifthe battery shows normal voltage. then there isa problem with the main PC board and it should be replaced. 242 12. DISASSEMBLY, ASSEMBLY, AND ADJUSTMENT OF K CARRIAGE @-1 Stitch dial cap @ Carriage cover @-1 HCL. knob @2 Plain lever knob @-3 Change knob 12.1 Disassembling the K carriage Removing the carriage handle 1.1 Keepthe handle down and remove the two right and left handle serews. Then the handle can be taken off the carriage, Removing the stiteh dial 2.1 Pull off the stitch dial cap upward. 22. Remove the fastening screw and pull off the stiteh dial upward Removing the carriage cover 3. Loosen, from the back of the carriage, and remove thetwo right and left carriage cover clamp screws (tapping screws) Pull off the carriage cover upward. Then the H.C.L. knob, the plain lever knob and the change knob will come off. 32 yee @-2 @1 G16 = Part nomenclature @ Cam button unit @-| Raising cam switch spring @2 Shifi spring for K carriage ® Kit reader tripper =I Row counter tripper —, ®© Upper slide plate ) = c=) @-! Snap ring 6 ® Handle lock spring =~ 5 9 be @® Front slide plate spring eS —| ° @ Intarsia lever oO ee 4 @-1 Intarsia lever spring = = za @2 Imarsia spring TI? fp oO | . YY t{ © ® @2 0 O1 ® @. tance sesea bee 4. Removing the eam button unit 7. Removing the handle lock spring 4.1 Remove the raising cam switch spring from the cam button unit side. 7.1 Remove the left and right handle lock spring screws from the handle 4.2 Remove the shift spring for K carriage sensor from the K carriage sensor setting base crimped onto the carriage plate. magnet. 8. Removing the front slide plate spring 4.3 Remove the two screws from the cam button unit, raise the cam button 8.1 Remove the front slide plate spring screws and take off the front stide unitand separate the hammer in the erew section from the carriage plate, plate spring. and pull it out toward you. 9, Removing the intarsia lever 5. Removing the knit reader tripper and the row counter tripper 9.1 Remove the intarsia lever spring (remove the spring from the intarsia 5.1 Remove the two screws from the knit reader tripper and the row counter lever side) ripper from the rear of the carriage. 9.2 Remove the intarsia spring 6. Removing the upper slide plate 9.3 Remove the right and left intarsia lever serews and the lever collar at the 6.1 Remove the snap ring from the change knob shaft and the left side shaft. 6.2 Remove upper slide plate by lifting the left and right ends up at the same time. same time. 9.4 Remove the intarsia lever from the gap between the handle setting base and the carriage plate, =26— Part nomenclature Connecting plate spring K carriage sensor magnet Rear plate Tuck eam spring ® -2 Tuck cam spring collar ® Change plate A ® -1 MC cam spring ® -1A MC cam spring ® -2 Change plate A spring ® Change plate B @®-1 Change plate B spring O898e @® End needle selection cam @ Valve cam F spring 10, n. 2 B. 15. Removing the connecting plate spring 10.1 Lift and pull off left and right connecting plate springs. Removing the needle selection change spring H1.1 Remove right and left needle selection change springs Removing the K carriage sensor magnet 12.1 Take out the shaft for K carriage sensor magnet and remove the K carriage sensor magnet Removing the earriage rear plate 13.1 Raise the carriage rear plate as itis and remove it Removing the tuck cam spring and presser ring collar 14.1 Remove the hooks on the two ends ofthe tuck eam spring from thetuck cam spring hook catches. 14.2. Remove the tuck cam spring collar from the stiteh dial shat. Removing change plate A 15.1 Remove the four left and right MC cam springs and the four left and 16. 17, right MC cam springs A from the cam side. 15.2. Remove the change plate A spring (black) from the carriage front foot side: 15.3, Remove the change plate guide collar and lift change plate A up and out Removing change plate B 16.1 Remove change plate B spring from the carriage front foot side. 16.2, Remove change plate B spring and lift change plate B up and out (as ‘well as the stitch cam collar). Removing the end needle selection spring 17.1 Remove the end needle selection spring from the pin crimping to the carriage plate. Removing valve cam F spring 18.1 Remove valve eam F spring from valve cam Fand the front slide plate set serew. = Needle selection change spring Part nomenclature @ Front slide plate @ Carriage front foot @ Guide cam A @ Guide cam B @ -1 Valve cam B @ Tuck cam @ -1 Tuck cam plate ® Stitch cam @ 3 Sub stitch cam @ 3A Valve cam D ® Stitch cam collar ® -I Stitch cam guide plate Carriage front side *Carriage rear 19. Removing the front slide plate 19.1 Remove the two set screws on the left and right and the one in thecenter of the front slide plate, and lift the front slide plate up and off. 20, Removing the carriage front foot 20.1 Remove the two carriage front foot clamp screws and then the foot itself, 21, Removing guide cam A 21.1 Remove the two left and right guide eam A clamp screws and then the cam itself (stide cam as well) 22, Removing guide cam B and valve cam B 22.1 Remove the left guide cam B screw as wellas the let valve cam B screw and remove the left guide cam B(as well as the left valve cam B, the left valve cam B spring, and valve cam Bshaft). Remove the right guide cam B in a similar way (as well as the slide cam guide). 25. Removing the tuck eam 23.1 Remove the tuck cam plate serews and remove the tuck cam plate and the tuck cam (as well as the washer and the tuck eam shat). Removing the stitch cam 24.1 Remove the snap ring on the left and right stitch cam shaft from the from side of the carriage 24.2 Remove the mut from the sub stitch cam from the front side of the carriage. 24,3. Remove the lft stitch cam clamp serew, and the left sub stitch eam, the left stiteh cam, the left valve eam D, the eft valveeam D spring, the stb stitch cam shaft, and the left MC cam will all come off. 24.4 Remove the right stitch cam in a similar way Removing the stitch cam guide plate 25.1 When the snap ring E7 on the left and right of the stitch cam shaft and the left and right raising cam guides are removed. the stitch cam collar and the stitch cam guide plate will come off. 28 G1 @ eoweat Part nomenclature @ @ Guide cam F ® Intarsia cam B @-1 Intarsia cam B plate ® Sub selection cam ® Valve cam G @ Cam plate @ Needle selection eam @-I Guide cam G @-1A Valve cam F @-IB Needle selection change cam @ Separation cam @ Intarsia cam A ® Carriage rear foot ® Connecting plate @_—D-IA Cornge toa side 26. nL 28. 29. 30. Removing guide cam F 26.1 Remove the left and right guide cam F clamp screws, and the left and right guide cam F will come off. Removing the intarsia eam B and intarsia cam B plate 27.1 Remove the left and right intarsia cam B plate clamp screws. and the left ‘and right intarsia cam B plate, left and right intarsia cam B, leftand right intarsia cam B springs, and intarsia cam B shaft will come off. Removing the sub selection cam 28.1 Remove the left and right sub selection eam serews, and the left and right parts of the sub selection cam will come off. Removing valve eam G 29.1 Remove the left and right valve came G shaft, snap ring E2, and plain washer 3.5 from the front side of the carriage. 28.2 Remove the left and right valve cam G on the back side of the carriage from the valve cam G spring left and right spring catches. and lift valve cam G up and off. Removing the cam plate 30.1. Remove the cam plate screws and take the cam plate off (the valve cam G spring will also come off). al. 32. 38. Removing the needle selection cam 31.1 Remove the guide cam G screws, and guide cam G, valve cam F, the needle selection change cam. and the needle selection cam will come off Removing the separation cam 32.1 Remove the nuts ofthe screws on the separation cam from the front side of the carriage. 32.2. Remove the separation cam screws, and the separation cam will come off Removing the intarsia cam A 33.1 Loosen both the intarsia cam A nuts from the front side of the carriage and the needle selection cam shaft from the rear side of the carriageand remove them. 332 Remove the intarsia cam A forward from the carriage plate hole. Removing the carriage rear foot 34.1 Remove thesix carriage reat foot screws, and the exrriage rear foot wil come off. 342. Remove the end needle selection eam, guide cam C, and the guide cam C spring. Removing the connecting plate 35.1, Pull off the connecting plate by lifting it by its right and left parts near the front foot. 29 Part nomenclature ® Connecting plate @® Carriage rear foot @-1 Guide cam C @-1A End needle selection cam @ Intarsia cam A @ Separation cam ® Needle selection cam @-1 Valve cam F @-1A_ Needle selection change cam @-1B Guide cam G 12.2. Assembling the K carriage 1, Mounting the connecting plate 1.1. Fit the left and right connecting plate into the earriage plate 2, Mounting the carriage rear foot 2.1. Placethe guide eam C spring on guide cam C and place guide cam Cin the centerof thecarriage, After mounting the left and right end needle sclection ‘cam, mount the carriage rear foot and tighten the screws. 3. Mounting the intarsia eam A 3.1 Place the needle selection cam shaft in from the rear side of the carriage then place the left and right intarsia cam A in from the front side of the carriage. Secure the needle selection cam shaft and tighten the intassia cam A nuts, 4. Mounting the separation cam 4.1. Mount the left and right separation cam with the screws (stud screws) and tighten the nuts on from the front side of the carriage. 5. Mounting the needle selection cam 5.1. Mount the valve cam F and the needle selection change eam and check the positioning of the needle selection cam. When this has been mounted, tighten the serews onto both this and guide cam G. _30_ Part nomenclature © Cam plate @ Valve cam G @® Sub selection cam @-1 Intarsia cam B @-2 Intarsia cam B plate Mounting the cam plate 6.1. Fit left and right valve cam G springsto the valve cam G shaft crimped onto the rear of the carriage. 6.2 Check the directional orientation of the cam plate and assembie it to the shaft, then tighten the eam plate serews. Mounting valve eam G 7.1. Fit the valve cam G screw while holding the valve cam G spring over the cam plate. 7.2. Put the washer in from the front ofthe carriage and secure it with the snap ring E2, Mounting the sub selection eam 8.1 Push thesub selection cam onto the selection cam side, When this isdone, put only one serew in (looking from direetly above the rear of the carriage. sub sclection cam tip should always be hidden by the intarsia cam A). ‘Mounting the intarsia eam B and the intarsia cam B plate 9.1. Pass the intarsia cam B shaft through the intarsia cam B spring and the intarsia cam B. 9.2. Place the shaft on the sub selection cam and tighten it and the intarsia cam B plate with screws (in such a way that the longer of the intarsia, ‘cam B spring stems is against the intarsia cam B plate). Part nomenclature ® Guide cam F @-1_ Raising cam guide ® Stitch cam @4 MCcam GHA Valve cam D GHB Sub stitch eam B Tuck cam @® Guide cam B @-I Slide cam guide @-2 Valve cam B ® Guide cam A @-I Slide cam @ Front carriage foot ® From slide plate ML. 2. BB. Mounting guide eam F 10.1 Mount and tighten the two screws of guide cam F. Mounting the stiteh cam guide plate 11,1 Mount the stiteh cam guide plate from the front side of the carriage. Pass the stitch cam guide plate shaft through the right and left raising cam guide from the rear side of the carriage. Fasten it down with snap ring E7, *Ensure that the tip of the raising cam guide enters the carriage plate and is secured Mounting the stiteh eam 12.1 Fitthe MC cam, the sub stitch cam shaft, the valve cam D spring. valve cam D, the stiteh cam, and the sub stitch cam, in that order, to the carriage plate and tighten it all down with a serew, Ensure that valve cam D functions with its spring. Mounting the tuck cam 13.1. Fitthe tuck cam shaft, the left and right tuck cam, the tuck cam washer, fané the tuck cam plate, in that order, to the top of guide cam C and tighten it all down with a serew. 4 15, 16, 1", Mounting guide cam B and valve cam B 14.1, Insert the slide guide into the carriage plate. 14.2. Fitthe valve cam Bspring, the valve cam B shaft, valve cam B.and guide ‘cam B. in that order, onto the top of the slide cam guide and tighten the valve cam B screw. Tighten thescrews on the right and left guide cam B. Valvecam Bison the inside of the sub stiteh cam and should function with the spring, spring. Mounting guide cam A 15.1. Fit the slide cam to the slide cam guide 15.2. Tighten the two screws on the right and left of guide cam A (such that the cam slides easily). ‘Mounting the front carriage foot 16.1 Tighten the front carriage foot on with the two screws. Mounting the front slide plate 17.1. Putthe frontstide plate on top of the front carriage foot and tighten iton with 2 screws on the right and left and one screw in the middle. 143 Part Nomenclature ® Valve cam F spring ® Change plate B ®-2 Change plate spring @-3 Change plate B spring @ End needle selection cam spring @ Change plate A @-2 Change plate A spring @-3 MC cam spring @4 MC cam spring A @ Tuck cam collar Q-1 Tuck cam spring @ Carriage rear plate @ K carriage sensor magnet @ Connecting plate spring @-1 Necdle selection change spring 19. 21. Mounting the valve cam F spring 18.1 Hook the valve cam F spring to the serew protruding from the carriage front foot and valve cam F. Mounting change plate B 19.1 Put the stitch cam plate collar on the stitch cam plate groove. 19.2 While inserting the change plate spring, mount the dial shaft to change plate B. 19.3, Hook the change plate B spring to the carriage front foot. Mounting the end needle selection cam spring 20.1 Hook the end needie selection eam spring over the end needle selection Mounting change plate A 21.1 Fit change plate A to the dial shaft and tighten the change plate guide collarin such way that it passes through the stitch cam plate collar. Hook the change plate A spring to the carriage front foot. Hook the left and right MC cam spring and the left and right MC cam spring A onto their respective pins 212 23 2. Mounting the tuck eam spring 22.1 Mount the tuck cam spring collar from the top of the dial shatt. 22.2. Hook the tuck cam spring ontothe tuck cam, Hook it on insuch a way: thatat theside with the change plate B spring. the opening part of hook of the tuck cam spring should be downside, Mounting the carriage rear plate 23.1. Set the carriage rear plate. Mounting the K earriage sensor magnet 24.1 Mount the K carriage sensor magnet with the K carriage sensor magnet shaft Mounting the connecting plate spring and needle selection ehange spring 25.1 Hook the connecting plate spring to the connecting plate calking pin land the change knob shaft 25.2 Place the U shaped needle selection change spring over the needle selection change cam calking pin and over the K carriage sensor magnet shaft. ~33- Part nomenclature ® Upper slide plate @® Intarsia lever @3 Intarsia lever spring @-3A Intarsia cam A spring @ Front slide plate spring @ Handle screw @ Knit reader tipper @-1_ Row counter tripper @ Cam button unit @2 Raising cam switch spring @- K carriage sensor shift spring 26. 2 Mounting the upper stide plate 26.1 Mount the upper slide plate and then insert the carriage plate calking pin, the change knob shaft, the left and right connecting plate calking pins, the left and right separation cam calking pins and left and right needle selection change spring into the long hole on the upper slide plate. 26.2 Fix the upper slide plate onto the carriage plate calking pin and the change knob shaft with a snap ring. Mounting the intarsia lever 27.1. Insert the intarsialeverinto the gap between the handle setting base and the carriage plate (perform this operation opposite of the disassembly sequence). 27.2 Tighten the intarsia lever collar and intarsia lever A. screws, in that order. 27.3. Mount the intarsia lever spring and intarsia cam A spring. Mounting the front slide plate spring 28.1 Tighten the front slide plate spring screws in such a way that there is pressure on the front slide plate pin. Mounting the handle screws 29.1 Tighten the handle spring screws onto the handle setting base. Mounting the knit reader tripper and row counter tripper 30,1 Place the knit reader tripper on the left and the row counter tripper on the right and tightenach of them from the rear side of the carriage with two screws. Mounting the cam button unit 31.1 Mount the cam button unit to the stitch dial shaft and tighten the left and right sides with serews. Hook the raising cam change spring to the raising cam calking pin. Mount the K carriage sensor shift spring to the K carriage sensor magnet. Part nomenclature ®@ Carriage cover @-1 H.CL. knob @-2 Plain lever knob @-3 Change knob ® Stitch dial ®-2 Stitch dial cap ® Carriage handle Mounting the carriage cover 32.1 Place the H.C.L. knob over the H.C.L. knob shai 32.2. Place the plain lever knob over the cam button unit. 323. Placethe change knob over the change knob shaft (pay attention to the position). 324 Mount the carriage cover and tighten it down with serews (tapping. serews) from the rear of the carriage, ‘Mounting the stiteh dia! 33.1. Fit the stitch dial on the shaft and tighten the serews in such a way that the noteh in the stitch di presser cap comes in front. 33.2 Bring the mark of the stitch dial presser cap to the notch in the knob retainer and put the cap in position. Align the line mark such that itis directly over the digits on the dial 34. Mounting the carriage handle 34.1. Placing the handle in the down position, tightenit down on the left and right with screws, 35— 12.3 Functional Check of the K Carriage 4 Functioning of the change knob 1.1 Switeh the change knob from to to to ensuring that each operates smoothly and that the left and right connecting plates, sensor magnets, left and right separation cams, left and right needle selection change cams, and the carriage rear plate make the switeh properly. Functioning of the MC eam 2.1 Without pushing the cam button, push the tips of the left and right MC cam upas far as they will go, and then help them down slowly with your fingers, ensuring that the left and right MC cam are returned properly to their original positions by the pressure of the spring. 2.2 Without pushing thecam button, check to ensure thatthe left and right tips of the MC cam are in proper contact with the tuck cam plate. Functioning of the raising cam 3.1 Push the tips of the left and right raising cam as far as they will go setting the knitting dial scale (0-5 - 10) and. helping them down slowly with your fingers, ensure that the left and right raising cams are returned properly to their original positions by the pressure of the spring. Functioning of the needle selection change cam 4.1 With the change knob in the or position, push the tips Of the left and right needle selection change cam up as far as they will go, and, helping them down slowly with your fingers. they ensure that the left ‘and right needle selection change cams are returned properly to its original positions by the pressure of the spring. Functioning of the separation cam 5.1 With the change knob in the position, ensure that the left and right separation cam are separated from the selection cam by the pressure of the spring, 4.2 With the change knob in the CKC(I)> position, ensure that the left and right separation cam are moved toward the needle selection cam and are within 0.5 mm of it Functioning of the tuck eam 6.1 Withthe left and right tuck cam buttons pushed, push the left and right tips of the tuck cam up as far as they will go, and. helping them down slowly with your fingers, ensure that the left and right tuck eam are returned properly to their original positions by the pressure of the spring. 6.2 Putthe cam button in the position, and, with the tips of the left and right tuck cam pushed all the way down, ensure that the leftand right tuck cam are returned properly to their original positions by the pressure of the spring. 7. Functioning of the intarsia cam B 7.1 Push the tip of the intarsia cam B up and slowly let it down with your fingers. Ensure that the pressure of the spring properly makes the tip of the intarsia cam B contact the side face of the sub selection cam as it comes down. 8. Functioning of the intarsia lever 8.1 Ensure that the tip of the intarsia cam A properly contacts the cartiage rear foot when the H.C.L. knob is put on the position. 8.2 Push the tip ofthe intarsiacam A up with your fingers and let it down again slowly. Ensure that the tip of the intarsia eam A is returned properly to its ‘original position by the pressure of the spring as it comes down. 9. Functioning of each of the valve cams 9.1 Rotate the tip of each of the valve cams with your fingers. Ensure that when you return them slowly with your fingers, the tip of each of the ‘cams is properly returned by the pressure of the spring to its original position. Vehe cam 8 Valve arn Toft Sepurtoncam Neale sckstion charge cam Tock ca Vahecam € Ieuan cam A igwe 11 36 - 12, Functioning of the cam button unit 10.1. Switch the cam button from left and right, , , and left and right, ensuring that thecam button unit operates smoothly and that left and right tuck cams, left and right MC cams, left and right MC change cams, guide cam C, and left and right raising cams switch properly. With any one of the cam buttons pushed down, switch the change knob ‘over from or to , ensuring that the cam button returns automatically, With the sinker plate installed to the carriage, press the button, ensuring that the yarn presser brush on the sinker plate switches properly. Functioning of the H.C.L. knob 11.1. Switch the H.C.L. knob to and . ensuring that operation is smooth and that left and right change cams properly make the switch 2. Ensure that the H.C.L. knob, when switched from to. stops at the position properly 11.3. While pushing the H.C.L. button, from the position, ensure that the switch to is made smoothly. 11.4 Ensure chat the tip of the intarsia cam A makes proper contact with the carriage rear foot, and that valve cam G jumps up properly when switching over from and to . LS Ensure that when switching from to and , the tip of the intarsia cam A properly contacts the cam plate, and that the tip of valve cam G contacts the sub selection cam, Functioning of the plain lever knob 121 Push the left and right, . . and left and right cam buttons, ensuring that when the plain lever knob is switched, operation is smooth and that the eam button returns properly to its original position. 12.4 How to Adjust the K carriage 2 Front and rear adjustment of the sinker plate 1.1 Mounting dimensions of the sinker plate The proper distance of the sinker plate from the rear carriage rail is 118.5 mm. If this distance is out of specification, adjust it by loosening the six screws to the left or right of the sinker plate, ‘Mounting dimensions of the yarn feeder The yarn feeder should be [20.5 mm {rom the rear carriage rail Sinker plat serews ‘Sinker plate sevens ve MAUR Ta Mss, Ow GE ath = ve ET Vertical adjustment of the sinker plate 2.1. Place the carriage over the needle bed and put the H.C.L. knob on . 2.2 Extend about five knitting needles to position E from three different places con the left, center, and right of the needle bed, 2.3 Bend the sinker plate to adjust it to make the gap between it and the needle stem to within 0.5 mm. Aeap within03 rm 37 13. DISASSEMBLY, ASSEMBLY, AND ADJUSTMENT OF THE L CARRIAGE 13.1 Disassembling the L Carriage 1. Removing the L carriage handle LI Keep the handle down and remove the two right and left handle screws. ‘Then the handle can be taken off the carriage, Removing the L carriage cover 2.1 Remove thetwo L cover screws. leftand right, from the L carriage holes in the center of the L cam portion in the rear of the L. carriage. 2.2. Pull off the carriage cover upward. Then the lace selecting cam knob and the valve cam C spring will come off. eatige cover 3. Remosing the L stopper .1 Remove the L. stopper pins (stud nuts) right and lef. 3.2. Remove the change lever spring, lift the L stopper, and pull it out toward ou. Figure 4 a} a ot 6) —+ 30) | 5g } estat 7 NEES onc coming nF EMOTE Serr rr ia aia mcg a etree arian End noeieseparationcam Eng acdc set camel Figure 132 Removing the separation cam 4.1 Remove the L separation cam plate screws from the front ofthe L. carriage, and the L- connecting plate spring, L separation cam plate, screws, washer, and L separation cam will all come off. 4.2 Remove the right and left in the same manner. Removing the I. end needle separation cam 5.1. Remove the Lend needle separation cam serews from the front side of the L carriage, 5.2. Remove the left and right Lend needle separation cams. Removing the connecting plate 6.1 Take the stud for release button plate off and remove the left and right connecting plates. Remove valve eam C 7.1. Take off the lever shaft and then remove valve cam Cand the valve eam C spring. R. End ned seestion hangs yp Connecting pte Rea baton ‘Connesing peng Levert PP Scruation cam Oe oe Caane im Change ve ping Wand spring an reer brs Froat oot holer, ase eketing knob 1 plate sprig t Foot ab sree Figur 18 Removing the I. handle setting base and the I. handle spring. 8.1 Remove the right and left L handle setting base screws and then remove the L handle setting base. 8.2 Remove the right and left L handle spring screwsand then remove the L. handle spring. Remove the L plate spring and the needle transfer plate 9.1 Remove the plate spring screws and then remove the left and right |. plate springs. 9.2 Remove the needle transfer plate screws and then remove the left and right needle transfer plates, Removing the yarn presser brush and magnet 10.1 Remove the yarn presser brush screws and then remove the yarn presser brush, 10.2 Remove the magnet screws and then remove the magnet, Removing the cam plate TL Remove the rubber wheel screws and remove the left and right rubber ‘wheel (there is a spring washer under the screws). 11.2. Remove the cam plate serews and remove the eam plate, Removing the L carriage front foot 12.1 Remove the four 1. eartiage front foot screws from the rear of the L carriage and remove the change lever spring, the L carriage front foot, and the L. front foot holder. Removing the L cam 13.1 Remove the four screws from the rear foot and the two serews from the front twa sides of the L eam. 13.2. With the reinforcing cam A and L valve cam B attached to the L cam, remove the 1. cam. At the same time, the lace selecting cam, the end needle selecting cam for L.. the end needle selection change cam switch, the end needle selection plate for L.. and the left and right end needle selection spring for L will come off, 29 _ 13.2 Assembling the L Carriage Can pte Lace chet ce Raber whos ® is 1, plate spring Front foot vane C Lam "End need ekstion charge for | nd mnie Ed ede seston change ps or sectioncam fr Han i54 Sepamoeeam 1 Fe eal puttin cam Mounting the L cam 1.1 Mount the end needle selection cam for L, the end needle selection change cam, the L end needle selection change plate. the left and right parts of the tend reedie selection spring for Land the lace selecting cam to the L cam. ‘Then, taking the L cam, align the lace selecting camand the convex part of the central portion of the L cam with the hole in the L carriage plate and assemble them together. Tighten the two screws, on cach of the to topends of the L. cam and the four screws on the rear foot (tighten the Leam while holding it parallel to the rear edge of the L carriage) ‘Mounting the L carriage front foot 2.1 Insert the L. front foot holder into the L carriage plate, mount the L. carriage front foot and tighten them down with the four screws. Mounting the Lend needle separation eam 3.1 Mount the L end needle separation cam to the L eam and tighten it from the front side with phillips head serews (3.18 x 11.6). 3.2. Mount both the right and left sides in the same manner. Mounting the L. connecting plate 4.1, Push the right side L connecting plate onto the L carriage plate pin and tighten it with the stud for release button plate 4.2. Mount both the right and left sides in the same manner. 5. Mounting the 1. separation eam fort Connesting pte 12 2 5.1 Mount the separation cam to the carriage plate, lightly tightening the serews onto the separation cam plate, the connecting plate. and the washer, and after hooking the connecting plate spring on the connecting plate, tighten the screws. Ensure that the separation cam is moved easily by the pressure of the sj Mount both the right and left sides in the same manner. Fd nl ston henge pring Conmctig pate ring $2 Connecting pve Release baton P—teve sat T>—Scpration cam Spite fort Tah cam Csi han sing be ee sine ‘are power brash \o%. j pie spring —— Fa | TT sin or Yaa ees Figure 16 6. Mounting the handle setting base 6.1 Mount the right and left handle setting bases, respectively, with their serews. 7, Mounting valve cam C 7.1. Mount valve cam C with the lever shaft, and then mount the valve cam C spring, The short stem of the valve cam € spring goes in the valve cam C hole, and the long side hooks onto the handle setting base. 7.2. Mount both the right and left sides in the same manner. 8. Mounting the L handle spring 8.1 Mount the L handle spring left and right with screws. —40— 10, u n 13, 15, Mounting the release button 9.1 Tighten the release button with the stud for release button plate (level nut) at two points Mounting the change lever spring 10.Mount the change lever spring. Mounting the magnet 11.1 Mount the left and right parts of the magnet with serews. Mounting the rubber wheel and the cam plate 12.1 Push the cam plate lightly toward the front foot and tig! screws 12.2 Mount the right and left parts of the rubber wheel with screws. Mounting the yarn presser brush and the panel spring 13.1 Mount the yarn presser brush right and left with screws. 13.2. Afterlightly tightening the screws on the plate spring right and left and adjusting the right and left sides (refer to page 44). tighten the screws down. en it with 14.1 Lightly tighten the serews on the needle transfer plate, adjust the right and left sides (refer to page 44), and tighten them down ‘Mounting the end needle selection change spring 15.1 Place the end needle selection change spring as shown in the picture. 16. Mounting the L. carriage cover and the L. carriage handle 16.1 Place the lace selecting knob and mount the L carriage cover. 16.2 Place the L handle on the handle seiting base and mount the handle Pa 13.3 How to Adjust the L Carriage 1. Adjusting the horizontal position of the plate spring Com pie B 1.1 Remove the L carriage cover and loosen the left and right plate spring serews. 1.2. Secure the plate spring toa position within 1.0 - 1.2 mm from the face of cam plate B and tighten it with screws. serews, 2. Adjusting the vertical position of the plate spring Pate spring (cam pate a Cam pte Campane C Figure 1k 2.1. Prepare cam plate B by placing the tip of the plate springat the same height scam plate B. 2.2 Be sure not to bend any part of the spring when making the adjustment with pincers or pliers. 3, _ Adjusting the position of the needle transfer plate Pua spine Nese ase plate (sg bee) | ‘Amount of feed increases — Amount of feed decreaney Figure 19 The needle transfer plate is secured by the needle transfer plate serews on the sinker plate side, 3.1 Loosen the needie transfer plate screws. When the tab is moved inward the feed will decrease, and when it is moved outward the feed will increase. 3.2. Adjust so that the gap between the two intersecting needles is 0.5 - 10 mm at the point at which they separate from the feed tab. 4 How to agjust the sinker plate bend 4 sar tha thin ip mie sur that te sem and he Sinker plat mae gt contact Put the L carriage over the needle bed, extend the kni position D, and check the gap between the L carriage sinker plate and the Knitting needle stems. If the needles have been brought higher than the sinker plate. or if there isa gap. assume that the sinker plate is bent. Correct, the bend in sucha way that there is light contact made between the stems and thesinker plate. Replacing the L eam 3 $2 $3 Sa 35 36 Remove the L carriage eover. Remove the end needle separation cam for L, the L separation cam, and the valve cam C right and left screws from the - carriage plate. Removethe four L cam rear foot screws from the rear and the screwat cach of the two ends of the front face. Mount | cam reinforcing cam A and L valve eam B to the L eam. Mount the end needle selection cam for L. theend needle selection change cam for L, the Lend needle selection change cam plate, the right and left parts of the L end needle selection springs for Land the lace selecting cam tothe L. cam, then match the lace selecting cam and the convex part of the ‘central portion of the L.cam to the holein the L. carriage plateand mount it all to the L eam, Holding the L cam parallel to the rear end face of the L carriage plate, tighten the four screws on the rear foot of the L cam and the screws on the front. Cam pate Lace skin am Robber whe a plate sing Front fost Lome cam ¢ ‘Seton Ln rele Td ocd wien change cam for rt Connecting pats separation cams Pd nace seketonchangs pats fo End neediest on cae igure 13 ae 14. DISASSEMBLY AND ASSEMBLY OF THE MAI BODY 14.1 Disassembling the Main Body 1, Removing the panel * Removal sequence: first, the operation panel is removed, and then the accessory box assembly. LI Removing the operation panel Remove the two screws, and then, while lifting the left side of the panel, slide it to the left and remove it from the right of the lower side plate. turning it over and then upside down toward the rear of the main body. * There are six connectors joined to the main PC board on the rear of the ‘operation panel which make it difficult to raise the operation panel. Be stire to exercise sufficient caution when raising the operation panel so as not 1o damage these connectors. 1.2. Disconnect the six conneetors from the main PC board at the rear of the operation panel 2. Removing the accessory box assembly 2.1 Remove the two screws (one of them is inside the accessory box), then, ‘while raising the right side of the assembly. slide it toward the right and remove it from the left of the lower side plate, 3. Removing the left belt cover 3.1 Remove the two screws on the let side of the belt coverand remove the belt ‘cover by bringing it toward you, turning it upside down, 4. Removing the main body 4.1 Remove the power PC board connectors 4.2 Remove the two screws from the yarn tension stand. 4.3. Remove two screws each from both the left and right of the needle bed. 44 4s Remove one screw from both the left and right of the front needle bed. Remove two main body screws each from both the leftand right of the rear of the main body. and then remove the table clamp setting plate Raise the right side of the needle bed gently and slide it toward the rig! removing it from the bottom of the case. 5. Removing the power PC board, the left position sensor PC board and the right position sensor PC board 3.1 Cut the binder from the yarn tension stand 5.2 ‘Take the screws from each of the PC boards and remove them. 6. Removing the cord cover 6.1 Remove the three screws from the cord cover and remove the cord cover. 7. Removing the belt 7.1 Loosen the pulley adjusting plate screws on the pulley holder plate on the left side of the main body. 46 7.2. Turn the pulley to move the belt joint before you to the center of the main body. 7.3. Remove the belt screws from the hole and remove the belt. Removing the needle selector unit (with needle selector plate holder) (ck he dian betwen the nish pai holder and ihe from mi Bot Mer the Jinasce between the male stor plate holler athe ct ci bed wh eas ncain he lae:iUe cemer nd ow ew ems) Figure 144 ke the measurements given the figure above and write them down, following the same measurements again during reassembly. Note: 1, Do not remove the 10 screws on the needle selector plate holder or the 5 serews on the needle selector unit unless the needle selector unit is being disassembled. 2, When adjusting the mounting measurements ofthe gate peg. the stay need not be removed. In the repair of the main body rotary cam lever and N.S.P. operation levers, the source of the problem may be discovered by removing the needle selector solenoid, the rotary cam lever holder, and the eam lever spring presser plate. ‘When the yarn tension support, lower holder plate, yarn tension stand and. the 18 serews with washers on the two gate peg right and center stays are removed, the needle selector unit and needle selector plate holder will come off as a single assembled unit, 81 9. Removing the needle selector plate holder from the needle selector unit 9.1 When four needle selector plate holder screws are removed. two from the center stay and two from the right stay, the needle selector unit comes off the needle selector plate holder. The 16 N.S.P. operation leversin the needle selector plate holderand the needle selector unit also come out, 10, Removing the needle selector plate holder 10.1 Remove the right lower holder plate, the 1wo operation lever presser serews, and the operation lever presser. 10.2 Remove the eight needle selector plate springs. (Make sure of the mounting direction and position of the springs before removing them.) Lone bolder pe Opcatom ker pre rews | Operon fever reser Figure 142 Needle lector pte sng Holder Fi 10.3 Remove the needle selector plate shaft B (angled) snap ring 2.$ from the rear side of the needle selector plate holder and pull the needle selector plate shaft out toward you. 104 Slidingeach of the8 needle selector plates toward the right, one by one, take them off the 6 grooves on shaft A. Disassembly of the needle selector unit 11.1 Remove the screw from the encoder board holder plate and remove the encoder board holder plate. 11.2. Remove the 4 screws from the encoder PC board and remove the encoder PC board 11.3 Take out the slit dise 114 Removing the needle selection solenoid unit ‘When the two serews on the right of the belt cover are removed. the needle selection solenoid unit will eome off Pictu ed 115. Removing the rotary encader (1) Remove the encoder board holder after removing the two screws and washers (2) Take the snap ring and washer from the rotary encoder shaft and remove the rotary encoder. Note: The washer on the rear of the rotary encoder has grease on it so be cautious that itis not lost when it comes off, seared Encaer baud holder fe Figure 145 11.6 Removing the rotary eam lever (1) When the five cam lever spring presser plate screws are taken off, the cam lever spring presser plate and rotary cam lever spring come ‘off and the I6 rotary cam lever may be taken oul. Can ear guide root a coer phx) & rage ss) 11.7 Removing the rotary eam (1) Take out the bevel gear spring pin and the slit dise spring pin. (2) Loosen the right and left rotary cam adjuster collar screws. Q) Take out the rotary cam holder (left) screws and then the rotary cam holder. (4) When the rotary cam is pulled toward the left and out of the rotary cam holder (right), the bevel gear and spacer will come out. Aduner sonar Beye gear ovary sen holler it) ‘Card caer guide copper a ripe 149 14.2 Assembling the Main Body Mounting the needle selector unit Spins dutetcaar Say | Bele ‘ Rouarycam nour (et)—Rotarycam ym oD eB AW sit dic ring in Rta at ein dy Cad reader pide sper 1.1 Mounting the rotary cam (1) Place the adjuster collars onto both ends of the rotary cam. (2) Place the washers onto the side of the rotary cam with the bevel gear spring pin hole, pass it over the rotary cam holder (right), place the spacer on, knock the bevel gear spring pin into its hole, and put the bevel gear on. (3), Insert the rotary cam holder (left) onto the other side of the rotary cam an¢ install it to the main bod (4). Knock the slit dise spring pi Note: Do not put the slit dise spring pin in so that itis even on both sides (the short side should be about 2 mm.) (5). Lightly oil the resin part of the rotary cam, the metal part of the bearing of the rotary cam holder right and left, and the teeth of the bevel gear with a soap based grease (Epinoch #1). 1.2. Mounting the rotary cam lever (1). Apply grease (Epinoch #1) to the card reader guide stopper hole on the rotary cam main body (2) Insert the long side of the rotary cam lever imto the guide hole of the ‘main body, and insert the short side into the guide hole on the rotary cam lever. into place. enc | i came Se me © Sew 3) Apply grease to parts which come in contact with the rotary cam lever and cam lever springand install the cam leverspringand the cam lever spring pressure plate. Install the cam lever spring pressure plate such that the side with the bend is toward the rotary cam lever. 1.3 Mounting the rotary encoder Fieue 1410 (1). Placethe rotary cam on the right end of the rotary cam before you and turn the rotary cam until the flat part of the shank isstraight down, as shown in the figure (14-10) 2) Put the washer on the rotary encoder and place the rotary encoder stich that its relationship to the rotary cam isas shown in Figure 14-10. (3). Put the washer on and secure it with a snap ring. (4) Mount the encoder board holder. Note: Apply grease (Epinoch #1) to the teeth of both the bevel gearand the rotary encoder. 1.4 Mounting the needle selector unit (1) Place the needle selection solenoid armature on the tip of the rotary ‘cam lever and install the right belt cover and the two installation screws. =415 2. Mounting the needle selector plate holder Newile stor pte shalt A Nene wetor pate shal eel selon paw ler ) fs srt woes igre 14 2.1 The needle selector plate holder should be mounted in the following sequence: (1) Fit needle selector plate number 7 into the six grooves in needle selector plate shaft A of the needle selector plate holder.and, sliding it toward the left, push it in (refer to figures 9-24). *The grooves in needle selector plate shaft A go, from the needle selector plate holder side, in the following sequence: 7,5, 1,3.8,6.4, and 2, Exercise sufficient caution in this regard when pushing the needle selector plates into the needle selector plate holder. * Also be cautious to ensure that the plates are not bent so far that they break when being inserted, Needle cht plate sping 3 4 (2) Next hook the needle selector plate spring onto needle selector plate 7 and the needle selector plate holder spring hook. ** The needle selector plate spring should be hooked as follows: 5.3.6, and 2, from the needle selector plate holder side, should be hooked to the spring hook on the lower side of the needle selector plate. The remaining plates, 7, 1.8, and should be hooked on the spring hook ‘on the upper side of the needle selector plate. The springs should be hooked alternately to the top and bottom of the plates. (3). Next place needle selector plate 5 to the needle selector plate holder in the sequence given in 1) and 2) above. Similarly. place the remaining needle selector plates, 1, 3, 8, 6,4, and 2 to the needle selector plate holder. in that sequence (refer to figure 9-25), (4) After placing the needle selector plates, insert needle selector plate shaft B (angled) and secure it with a snap ring2.5 (refer to figure 9-25). Mounting the needle selector unit and the needle selector plate holder to the main body 3.1 Mount the needle selector plate holder and the needle selector unit to the ‘center and right stays. The mounting holes in the center and right needle selector plate holder stays and in the needle selector unit are oblong horizontal holes, so use the center of the hole and tighten only lightly. 3.2 Put the 16 N.S.P. operation levers through the holes in the needle selector plate and into the left side of the rotary cam lever and mount the N.S.P. operation lever stay. Mounting the needle selector unit and the needle selector plate holder to the main body 4.1 Place the needle selector plate shaft B of the needle selector plate holder into the angled hole in the main body. 4.2. Putone screw into each of the oblong, vertical holders in the main body for the installation of the center and right stays, tightening it only lightly 4.3 Adjust the center of the rotary encoder so that it has the same relationship as in the above figure and tighten the center and right stays. 44 Install the yarn tension support, table clamp setting plate, and yarn take-up stand in such a way that the main body and the needle selector plate holder will be set in parallel with each other. Lage inant nome YE ave oe { ® | prof Groen 18.8 ‘ Figure Het Mounting the belt 5.1 Take the belt connecting pin such that it is on the' belt cover (right) groove. fitting onto the rotary encoder as shown in the figure 14-14. 5.2 Turn the rotary encoder pulley by the rib and pull out the rear rail sie. When turning the rotary encoder, be certain not to turn it by the comb. 5.3 Onthelett side. similarly, place the belt so that the long hole in itis matched to the notch in the pulley and pull out to the rear ral side. ill both ends of the belt together so that the connector pins ink with the joint hole in the other. 5.5 Adjust the pulley adjusting plate. With the pulley pushed toward the right, adjust it so that it can move 0.3 to 0.6 mm and tighten the screws, side and place it on the Picture 1415 Left postion sensor board 54 49 Mounting the encoder PC board 6.1 Fittheencoder PC board to theencoder board holder plate and tighten it up with the four screws. 6.2. Place theslitdise onto the rotary cam shaft (ensure that itis placed on so that the slit dise goes on properly), 6.3. Place the encoder board holder plate and secure it with one screw. 6.44. Place the board cord cover and secure it with three screws. ‘Mounting the power supply PC board, the left position sensor board and the right postion sensor PC board. 7.1 Tighten cach of the PC boards down with screws. 7.2. Gather the cords of the left position sensor PC board and the power supply PC board together in the hole under the yarn tention holderand secure them with a binder (the left position sensor PC board cord should ass under each of the stays). ‘The main body housing 8.1 Place the needle selector plate holder on the left side of the main body over the left lower side plate and put the main body under the case. 8.2 Fitand tighten the one screw on each the leit and right front portions of needle bed. 8.3 Fitand tighten the two serews on each the left and right needle beds. 8.4 Fitand tighten the two installation serews an the yarn tension stand. 8.5. Insert the power supply PC board connectors. 8.6. Mount the left and right parts of the table clamp setting plate from the rear of the main body and tighten each down with two screws, ‘Mounting the left belt cover 9.1 Place the left belt cover on from in front of you such that the belt goes inside of it and tighten it down with two serews. Mounting the accessory box assembly 10.1 Insert the left part of accessory box into the left lower side plate. 10.2. Tighten the two (one goes inside the accessory box) screws (the cord for the left position sensor PC board should pass through the rear of the case) Mounting the operation panel 1.1 Insert each of the operation panel connectors (in six places). 1.2 Insert the right part of operation panel into the lower right case panel, 11.3. Fitand tighten the two installation screws. —50— 15. ADJUSTMENT AND CHECK OF THE NEEDLE SELECTOR MECHANISM 15.1 Adjusting the Card Reader Guide Plate (1) Remove the operation panel and the remove the PC board cord cover. The ‘operation panel should be placed. with connectors still joined, to the rear of the main body. Connect the power cord. Turn the switch on and the MEMO key on. Align all ofthe knitting needles o position A. set the K carriage change knob to KC(1) or KC(I1). When the K carriage is operated. needle selector solenoids are all energized to be attracted, Loosen the screws on the card reader guide stopper. Then, after sliding the card reader guide stopper over to the right. slide it very lightly back to the left, and tighten the screws such that the right window of the card reader guide plate lightly touches the contact. @ a) “@ co) Rory car Roary ca ~abatebeted Shea hh 7 T Card ender ide topper Soe Figure ts 15.2 Adjusting the Rotary Cam Position (1) After thecompletion of the card reader guide plate adjustment, loosen the four stop screws on the rotary cam adjuster collar and the rotary cam presser collar. presser collar. With a fecler gauge make a 0.2 - 0.6 mm (TYP 0.3 mm) gap between the rotary cam and the rotary cam adjuster collar. Then, holding the rotary cam to the right with a flat head screw driver, tighten the screw (if no feeler gauge is available, approximate the distance visually), @ (3) Make a 0.2 mm gap between the rotary cam presser collar and the left rotary cam holder and tighten the screws. Tighten the four serews each twice to make sure that they are tight. Place all the knitting necdles at position B. Tur the power switch off. turn the K carriage change knob to and chion D both when the crriage is moved slowly and when it is moved quickly. when the carriage is moved slowly and when it is moved quickly. *The movement of the K carriage is unusually sluggish when there is no gap in the rotary cam pressure collar or when the gap in the rotary cam adjuster collar is too great. * When there are needles which do not come out to position D, make the gap in the rotary cam adjuster collar greater. ) See hil Waser Let ta tf ee pies Rosary cam pressure aster calle : BF head Zw eel aver ese gave Ot mos NY ila Plgre 182 a5. 15.3 Checking the Needle Selector Mechanism 1. The objectives of check sequence 1 First of all, in order to determine whether the eause of the error in needle selection isin the needle selection mechanism (the mechanical portion). or in the electronic portion. move the carriage with the power turned off. When the powers turned off, the solenoids are also ll off all of the rotary cam levers are om the rotary cams, and the knitting needles should all be selected to position D, The reason for turning the change knob to the KC(1I) position at this time is that. as the K carriage separation cam is separated from the needle selection cam, because precision is required of the needle selector plate as it grasps and releases the knitting needles it is especially easy for errors in needle selection to occur when operating at low speed. ‘With this test, the carriage needle selection mechanism, the rubbing surfaces of the needle selection solenoid armature, the rotary cam, the rotary cam levers, the N.S.P. operation levers, and the needle selector plate may be checked. 2. When the test determines that not all of the needles come out to position D, but that some remain in position B. (1) When there is no regularity (e.g. 8 pitches, 16 pitches. ete.) in the needles remaining in position B a. The knitting needles are bent b. The belt has not been properly mounted to the rotary encoder. © The rotary cam has not been properly mounted to the rotary encoder. d. The card reader guide plate or the rotary cam position are out of adjustment. (2) When the needles remaining the position B show regularity (8 pitches or 8 x n pitches) ‘The needle selector plate is not moving because the rotary cam levers and N.S.P. operation levers ave not been mounted properly. b. The rotary cam lever is getting caught on the card reader guide and, slipping, do not move. * Apply grease. 6. The needle selector solenoid armature and the solenoid yoke are ‘getting caught, and, slipping, do not move. 4d. The armature spring of the needle selector solenoid is broken or has come loose ‘Sokneid yoke Rowry amit) Armature Actwatue opring | | | (Cand ager guide I CBE Roary cam oer igure 153 ©. The N.S.P. operation lever stay is interfering with needle selector plate number 2. f. The needle sclector plate springs are loose or are interfering with one another 3. When carriage operation is unusually sluggish a, The carriage will not move The carriage will not move when the rotary cam lever has come loose from the face of the rotary cam. When too much pressure is applied to the rotary cam lever, it wil bend, After checking to ensure that the rotary cam lever has not become bent. adjust the positions of the card reader guide plate and the rotary cam, b. Carriage operation is sluggish The rotary cam presser collar is making contact with the metal portion of the left rotary cam holder bearing. The gap between the rotary cam and the rotary cam adjuster collar is too wide. = 9. *KG-88I1/8911/93 1, KG-8811/8911/93 product characteristics and points different from KG-88/89 1) ‘The same basic functions are shared between KG-88I] and KG-88 and between KG-89I1 and KG-89. However, the following functions in items 2) and 3) are added to KG-8I1 and 8911 2) Thee’ wrap method (cast-on) is possible. 3) The carriage stops automatically when tangled yarn passes through the yarn tension unit 4) KG.93 has been developed for KH-910/930 and shares the above functions with KG-88Il and 8911. 2. Product specifications 1) The basic color ofthe cover upper and lowerassemblies has been changed from pearl white to white. 2) Gearriage and knitting machine combinations re «fs | | a oo | a Ye [Ya [No [No Ne [ Yes He seal [ND no [Ne [No | o ves [No Nowe 1, All of KG can not be used with KH models older than KH-860, 2. % Additonal parts (487341001) are requried 3. Parts for No. 487341001 include Row courter triper B (412417001), Knit-leader triper B (412416001) and Magnet holder assembly (412785001), 3. Differences between KG-8811/8911/93 and KG-88/89 in the disassembly and mounting of G carriage 1) In KG-8811/8911/93, the change lever for casting-on is mounted to the G carriage upper plate with the lever spring afd the snap ring 4 *In the event that the G carriage upper plate is removed, mount it again in the following manner. Place the holes of the G carriage upper plate to the respective pins on the carriage plate. Atthe same time, mount the change lever for casting-on in such a ‘way that it will be engaged with the G carriage feeding lever at the right side. (carnage feeding kev (Change lever for casing Selector knob ‘The mounting position of the selector knob is the same as that of KG-88/89. Put the tum knob to the autoamtic stop (=—) position of the G carriage upper plate. and place the knob on the plate. Also, put the selector knob to the ‘e' wrap method and casting-off position, and place it onto the plate as 4. Differences between K G-8811/8911/93 and K G-88/89 in the sensor ‘The detecting lever and its spring are added to KG-8811/8911/93. Spring For detecting ier ae Daecting ener 5. Troubleshooting 1) *E° wrapping cannot be done. (CAUSE ...., The latch stopper brush is damaged, remedy... Replace the latch stopper brush. 2) Yarn feed is abnormal during ‘e wrapping. (e8U8e oo. The change lever spring for casting-on is weak remedy... Replace the change lever spring for casting-on 3) After e* wrapping, stitches in the next row are dropped. *Refer to KG-8811/ 8911/93 operation manual and reset the cast-on comb. —S4—

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