Single Head Serging Unit
Series 1225/4
Operating Instructions
Version 1.0, 04-21-1999 – GB
© 1999 Beisler GmbH
Frohnradstr. 10 • D-63768 Hösbach • Phone-No. Service: +49-6021-501940 • Fax: +49-6021-540061
These Operating Instructions contain the following parts:
Part 1: Operating instructions (pages 1-xx)
adresses to the operator of the machine, that means the person
who works at and with the machine.
Part 2: Mechanics manual (pages 2-xx)
is used for the putting into operation, adjustment, troubleshooting
and maintenance of the machine and adresses to qualified staff
only.
Please obtain all safety , warning and other hints and regulations in this
manual.
The machine described in the Operating Instructions on hand is subject to
continuous technical development. T echnical changes can be implemented
without further notice.
Part 1 Operating instructions
Hint
These operating instructions contain all information required for the operation
of the machine. It adresses to the operator of the machine, that is the person
that works at and with the machine. Please obtain all rules and regulations.
Contents Page
Part 1 Operating instructions ...................................................................................... 1-1
1 Security advice and warning hints ................................................................... 1-3
1.1 Classification........................................................................................................ 1-3
1.2 General security advice and warning hints........................................................... 1-3
1.3 Introduction .......................................................................................................... 1-4
1.4 Target groups of the manual ................................................................................ 1-4
1.5 Authorized person................................................................................................ 1-4
1.6 Contents of this manual ....................................................................................... 1-5
1.7 Range of validity .................................................................................................. 1-5
1.8 Copyright ............................................................................................................. 1-5
1.9 Additional regulations........................................................................................... 1-6
2 Preliminary remarks .......................................................................................... 1-7
2.1 Limitation of liability .............................................................................................. 1-7
2.2 Guarantee regulations ......................................................................................... 1-7
2.3 Use as agreed ..................................................................................................... 1-8
2.4 Description of the machine .................................................................................. 1-8
2.5 Main parts of the machine.................................................................................... 1-9
2.6 Technical data...................................................................................................... 1-9
3 Switch on/off, Emergency Stop, Restart ........................................................ 1-10
3.1 Switching on ...................................................................................................... 1-10
3.2 Switching off ...................................................................................................... 1-10
3.3 Quick switch-off with the Program-Stop-Button...................................................1-11
3.4 Restart after an Emergency-Stop........................................................................1-1 1
3.5 Adjust air pressure............................................................................................. 1-12
4 Operation of the sewing head......................................................................... 1-12
5 Components of the machine........................................................................... 1-13
5.1 Adhesion facility ................................................................................................. 1-13
5.1.1 Switch on/off the adhesion device...................................................................... 1-14
5.1.2 Fixing of kneelining and front trouser ................................................................. 1-14
5.1.3 Changing the stamp temperature....................................................................... 1-14
5.1.4 Remove the adhesion tape roll........................................................................... 1-14
5.2 Working table..................................................................................................... 1-15
5.3 Operation device................................................................................................ 1-15
5.3.1 Elements of the operation device ....................................................................... 1-16
5.3.2 Contents of the display ...................................................................................... 1-16
5.4 Working table..................................................................................................... 1-16
5.5 Sewing head ...................................................................................................... 1-17
5.6 Foot pedal machine sequence ........................................................................... 1-17
1-1
6 Operation of the machine................................................................................ 1-18
6.1 Production sequence ......................................................................................... 1-18
6.2 Program control ................................................................................................. 1-18
6.2.1 Existing sewing programs .................................................................................. 1-18
6.2.2 Select a different sewing program...................................................................... 1-19
6.3 Adjustment of the transports .............................................................................. 1-20
6.4 Additional settings at the operation device ......................................................... 1-20
6.4.1 Selection of the operation language ................................................................... 1-21
6.4.2 Setting the display contrast ................................................................................ 1-21
7 Cleaning and maintenance.............................................................................. 1-22
7.1 Cleaning of the machine .................................................................................... 1-22
7.2 Empty waste baskets ......................................................................................... 1-22
7.3 Check oil level in the sewing head ..................................................................... 1-23
7.4 Empty water separators ..................................................................................... 1-23
7.5 Error messages and troubleshooting hints......................................................... 1-23
1-2
1 Security advice and warning hints
1.1 Classification
Three different types of hints are used in this manual, which are indicated
with different symbols and signalling words:
DANGER
This indicates a possibly dangerous situation or action, which may cause
injuries to persons or severe damage to the machine.
ATTENTION
This indicates a situation or action, which may cause damage to the machine.
Hint
This indicates hints for a better use and other helpful information or hints.
Please obey all rules and regulations.
1.2 General security advice and warning hints
Danger
Danger might arise for persons, things and environment by inappropriate
operation of this machine. Installation and maintenance duties may only be
carried out by authorized staff.
Danger
Danger of injuries in the range of the sewing head! Don’t grasp into the
affected area of the needle during the sewing process!
Danger
Before any operations at or with the machine (putting into operation, operation, maintenance, repair, etc.) the person carrying out has to read and understand this manual with each appendix completely .
Danger
Before carrying out maintenance or repair duties, the mains supply must be
cut off. Additionally pressure must be released from the pneu-matical system.
Attention
The machine will be destroyed by a connection to a wrong mains voltage!
See the section ‘Technical data’ before connecting the power supply.
1-3
1.3 Introduction
The manual on hand is divided into two main sections:
• the Operating Instructions with all information required for the operation
and daily cleaning and maintenance routines of the machine;
• the Mechanics and Programming Instructions with all further maintenance
and repair duties and a instruction for the programming of sewing programs.
1.4 Target groups of the manual
The two sections of the manual are adressed to:
Operating Instructions to the operator of the machine which is the person
that works at and with the machine;
Mechanics Manual to qualified staff which is trained to estimate the
working duties and recognize possible danger at an
early time.
ATTENTION
All actions at and/or with the machine may only be executed by authorized
persons, who have read and understood the corresponding parts of this
manual.
Especially the following actions are subject to this regulation:
• operation including preparation, troubleshooting during production, cleaning, care
• Servicing (maintenance, inspection, repair)
• Transportation
ATTENTION
A specialist in accordance to IEC 364 and DIN EN 60204-1 is regarded as
qualified staff.
1.5 Authorized person
DANGER
There is danger to human beings, things and environment through inandequate operation of this machine. Installation and maintenance duties may
only be carried out by authorized staff.
Persons are regarded as authorized, who are able to recognize possible
danger and judge the assigned duties from their technical education and
experience.
1-4
Operator of the machine
Persons are regarded as authorized, who were trained in the operation of this
machine and have read and understood the first part of this manual completely .
Staff for installation, preparation, programming and maintenance
Persons are regarded as authorized, who were trained in all aspects of the
machine and have read and understood the complete manual on hand.
1.6 Contents of this manual
The Operating Manual of this Single-head Serging Unit, Series 1225/4
contains the following parts:
1. Operating Instructions
2. Mechanics Manual
3. Electrical wiring plans
4. Parts list
5. Operating Manual of the sewing head
Please check the documents delivered with the machine for completeness.
1.7 Range of validity
This operating manual is valid for Serging Units manufactured by Beisler
named ‘Single-head Serging Unit, Series 1225/4’.
This operating manual is not valid for the sewing head applied in the machine. Please refer to the operating manual of the sewing head delivered with
the machine, for which we don’t take any liability .
Further security advice (verbal and written) for this machine or the components will not be repealed by this manual.
1.8 Copyright
© 1999 Beisler GmbH, Hösbach
Single-head Serging Unit
The ‘Single-head Serging Unit, Series 1225/4’ and this operating manual with
all parts are protected on copyright. Manufacture without license will be
prosecuted by law. All rights reserved on this operating manual, including
reproduction in any thinkable way , either by copying, printing, on any data
recording media or in translated form. Reproduction of this operating manual
- even in extracts - only with written approval by Beisler GmbH.
This operating manual contains a description of the product, but no promise
of certain qualities or results of use. The operating manual has been proved
before delivery . The Beisler GmbH takes the liability, that this operating
manual if free of errors reducing its value for the estimated use. The editors
don’t take liability for consecuting damage arising through application of the
operating manual. We are always thankful for hints and ideas.
The technical standard of the common delivery of product and operating
manual by the Beisler GmbH is decisive, if not other information is given.
Technical changes without prior notice are reserved, previous operating
manuals loose validity .
The general conditions of sales and delivery of the Beisler GmbH are valid.
Do you have questions or problems with installation or putting into operation?
Don’t hesitate to call us.
Beisler GmbH
Frohnradstr. 10 - D-63768 Hösbach
Tel: (+49) 6021 / 50 19 0
Fax: (+49) 6021 / 50 19 10
1-5
1.9 Additional regulations
This manual must be available at the machines location at any time.
The operator has to assure that only authorized persons work at and with the
machine.
The operator is obliged to check the machine for visible damage and faults at
least once per shift. Visible changes must be reported to the corresponding
official immediately after discovery .
The company using this machine has to assure that the machine is always
operated in faultless condition. Security installation may not be dismounted or
put out of function.
If security installation must be dismounted for preparation, repair or maintenance of the machine, they must be mounted immediately after the duties
have been terminated.
Unauthorized changes to the machine exclude liability of the manufacturer for
damages.
1-6
2 Preliminary remarks
2.1 Limitation of liability
We guarantee the faultless functioning of our product in accordance with our
advertising, the product informations edited by the Beisler GmbH and this
manual. Further product-features are not guaranteed. We take no liability for
the economy and faultless function if the product is used for a different
purpose then that described in the chapter „Use as agreed“.
Compensation claims are generally impossible, except if intention or culpable
negligence by the Beisler GmbH is proved, or if assured product-features are
not provided. If this machine is used in environments, for which it is not suited
or which do not represent the technical standard, we are not responsible for
the consequences.
We don’t accept responsibility for damages at installations and systems in
the surroundings of this machine, which are caused by a fault of the product
or an error in this manual.
We are not responsible for the violation of patents and/or other rights of third
persons outside the Federal Republic of Germany .
We are not liable for damages, which result from improper operations according to this manual. We are not liable for missed profit and for consecuting
damages due to non-regardance of security advices and warning hints. We
don’t accept liability for damages which resulted from the use of tools and
accessoires which are not delivered and/or approved by the Beisler GmbH.
The prdocuts of the Beisler GmbH are designed for a long life. They represent the standard of technique and science and were checked on all
functions individually before delivery . The electrical construction corresponds
to the current norms and regulations, particularly DIN 5713 / VDE 01 13.
Beisler GmbH is doing product and market research for the further development and permanent improvement of their products. In the case of faults
and/or technical trouble please contact the Beisler GmbH service staff. We
assure that suitable measures will be done immediately .
The Beisler GmbH guarantee regualtions are valid, which we will send to you
on demand.
2.2 Guarantee regulations
We guarantee the fault-free functioning of the Automatic Single-head Serging
Unit, Series 1225/4 according to this operating manual except the tools for a
time range of six months after delivery . If the machine is used in double- or
triple-shift operation, the term of guarantee is reduced to three or two months.
The term of guarantee starts with the date of delivery to the customer, independant from the time of putting into operation. Guarantee will be spoiled, if
the machine isn’t installed and operated according to this operating manual
and the regulations given by the Beisler GmbH staff. A cost-free repair is only
possible, if all regulations considering storage, transportation and putting into
operations have been obeyed.
Customers and third persons may only mesh with the machine after getting a
written approval by the Beisler GmbH. The Beisler GmbH takes no responsibility for injuries and damages arising from non-obeyance of this stipulation.
All warranty will be spoiled in this case.
The Beisler GmbH takes no responsibility for faults of the machine as consequence of defective or functional faulty equipment in the surrounding of the
machine or by the use of accessoires, which were not delivered by the
Beisler GmbH.
The general conditions of sale and delivery of the Beisler GmbH are valid.
1-7
2.3 Use as agreed
The Single-head Serging Unit 1225/4 has been developed for the automatic
serging of inside and outside seams at trouser parts with or without kneelining.
DANGER
This machine has been developed and build for a certain purpose. Adaptions
may influence security equipments negatively . We recommend to contact our
service staff in such a case.
2.4 Description of the machine
The Single-head Serging Unit 1225/4 allows the rational and automatic
serging of trouser parts. The machine is equipped with a sewing head and a
transportation facility , with which the fabrics are transported in the range of
the sewing head and to the stacker.
The machine is equipped with a hot adhesion facility for the production of
front trousers with kneelining, where one point can be fixed.
All components of the machine are mounted on a base frame made of
square steel pipes and controlled by an innovative micro-processor system.
Machine operation is achieved with an operation device. Here you can open
several control programs, define new programs and check all machine
components individually for maintenance and repair duties.
1-8
2.5 Main parts of the machine
1
2
3
4
5
6
7
1 Spool rack
2 Operation device
3 Sewing head
4 Stacker
5 Mains / Emergency-Stop switch
6 Foot pedal machine sequence
7 Foot pedal open stacker
8 Pre-laying tables
9 Collecting basket
10 Temperature pre-selection and display of the adhesion facility
11 Adhesion button
12 Adhesion facility
8
9
10
11
12
Further information on the major parts of the machine are contained in the
following chapters.
2.6 Technical data
Dimensions (LxWxH) 2.000 x 860 x 1.760 mm
Tiable height 930 ... 1.200 mm (adjustable)
Weight 125 kg
Power supply 220 V AC
Air supply min. 5 bar
Power consumption 0,7 kW
Air consumption est. 20 NL/working day
1-9
3 Switch on/off, Emergency Stop, Restart
1
2
3.1 Switching on
Hint
The machine must be connected to the power and air supply before it can be
switched on.
The mains switch (1) is located at the front side of the machine beneath the
working table.
Turn the mains switch (1) clockwise until it is engaged. The grip of the switch
points to the marking „1 - ON“ now.
Press the green Reset key (2) beneath the operation device after switching
on. The main display will be imaged in the display of the operation device.
3.2 Switching off
Turn the mains switch (1) counter-clockwise until it engages feelable. The
grip of the switch now stands horizontally and points to the marking „0 –
OFF“.
1-10
3.3 Quick switch-off with the Program-Stop-Button
The mains / Emergency-Stop switch (1) is located at the frontside of the
machine beneath the working table.
Turn the mains / Emergency-Stop switch counter-clockwise until it is released. An immediate stop of all movements of the machine is triggered, the
complete machine will be free of electrical power.
1
3.4 Restart after an Emergency-Stop
ATTENTION
Before you restart the machine you should remove the reason for the
Emergency-Stop. Contact the responsible technician in any doubtful case.
The machine may only be restarted after the reason for the Emergency-Stop
has been removed.
Switch on the machine using the mains / Emergency-Stop switch. Press the
green Reset key located beneath the operation device.
The current program number will be imaged in the display of the operation
device. The machine is ready to use.
1-11
3.5 Adjust air pressure
The machine needs an air pressure between 5 and 6 bar. This is adjusted at
the air supply unit:
1 Air connecting hose
2 Control to adjust the air pressure
3 Pressure gauge
4 Collector for condensing water
5 Release valve for condensed water
Check the air pressure at the pressure gauge (3). If the indicated value
differs from 6 bar, adjust the pressure by turning the black control (2).
4 Operation of the sewing head
The operation of the sewing head is explained in the separate manual of the
sewing head, which is part of the machine’s documentation.
Please obtain all rules and regulations.
1-12
5 Components of the machine
The machine contains several components, which are arranged according to
their function:
1. Adhesion facility at the right-handed side of the working table for the fixing
of kneelining and front trouser.
2. Working table for the alignment and insertion of the fabrics.
3. Operation device above the working table.
4. Spool rack for the sewing threads.
5. Sewing head with contour guiding and top feed adjust for the serging of
inside and outside seam; additionally equipped with a swing-out device for
the transportation of the fabrics to the stacker.
6. Mains /Emergency-Stop switch to switch on/off the machine.
7. Stacker for the stacking of the sewed trouser parts.
8. Collecting basket for the warp threads and sewing rests.
5.1 Adhesion facility
1 Control stamp temperature
2 Display stamp temperature
3 Clamp button
4 Separation slot
5 Top stamp
6 Adhesion clamp
7 Adhesion button
8 Adhesive tape
9 Carrying paper
10 Roll of adhesive tape
11 Knob to open the holder of the adhesive tape roll
1-13
5.1.1 Switch on/off the adhesion device
The adhesion device is switched on, when the control for the adjustment of
the stamp temperature (1) is moved away from the zero position. The display
(2) shows the current stamp temperature.
As long as the display of the stamp temperature (2) flashes, the bottom
stamp is heated and hasn’t reached the set temperature. Wait until the
display stops flashing before you fix the first trouser with the kneelining.
5.1.2 Fixing of kneelining and front trouser
DANGER
Burning danger at the bottom stamp! Do not touch the area (4) beneath the
upper stamp (5). The bottom stamp is very hot (180° C).
To avoid the kneelining being moved during the sewing, an adhesion point
must be set at the adhesion facility , which fixes the kneelining in the correct
position.
To fix the kneelining and front trouser correctly, the following procedure is
required:
1. Insert the kneelining under the adhesion clamp (6).
2. Press the clamp button (3), the adhesion clamp (6) will be lowered and
clamps the kneelining. At the same time, the adhesion tape (8) will be
pushed forward and at the separation slit (4) the net-shaped adhesion
tape will be separated from the carrying paper (9).
3. Insert the front trouser and align it correctly . To open the adhesion clamp,
press the clamp button (3) again.
4. Press the adhesion button (7), the upper stamp (5) will be lowered and
presses the front trouser together with the kneelining and the adhesion
tape onto the hot lower stamp.
5. After the adhesion time expired, the upper stamp (5) and the adhesion
clamp (6) will be lifted. Kneeling and front trouser are fixed and can be
inserted into the machine.
5.1.3 Changing the stamp temperature
The display (2) shows the current stamp temperature. By turning the control
(1) you can raise (turn to the right) and reduce (turn to the left) the stamp
temperature.
We recommend a stamp temperature of 180° C, which should only be raised
when working with very heavy fabrics (up to max. 200° C).
After changing the stamp temperature you should wait, until the displayed
value stops flashing (2) and the desired temperature is present.
5.1.4 Remove the adhesion tape roll
Hint
We recommend to use the original adhesion tape rolls delivered by Beisler
(please ask for part number). When using different adhesion tapes, the
recommandations regarding adhesion temperatures and times are not valid.
1-14
This is how to change a tape roll:
1. Pull off the right-handed holding disc (11).
2. Press on the fixing screw of the adhesion tape holder and swing it to the
front and to the right.
3. Remove the core of the empty adhesion tape roll (10) and remove the
carrying paper (9) completely from the separation slit (4).
4. Insert a new adhesion tape roll (10) and press the right-handed holding
disc (1 1) on the pole until it is engaged.
5. Lift a piece of the adhesion tape (8) from the carrying paper (9) and insert
the carrying paper into the separation slit (4).
6. Swing the adhesion tape holder to the left until the fixing screw is engaged.
7. Cut the adhesion tape behind the adhesion tape holder.
5.2 Working table
The working table is used for the alignment of the trouser parts to be sewed.
Above it you can see two prelaying tables, where you can stock the fabrics.
The Mains- / Emergency-Stop-Switch is located below the working table.
5.3 Operation device
The machine can be operated during production using the operation device.
You can load existing programs and program new ones.
1
2
3
1 Display
2 Cursor keys
3 Key for stacking manually
4 Special key
5 Minus / Plus keys
6 Reset key
4
5
6
1-15
5.3.1 Elements of the operation device
The elements of the operation device have the following functions:
Display (1): all information required for the operation of
the machine is displayed here.
Cursor keys (2): move the cursor to mark all required com-
mands and options.
Key for manual stacking (3): press this key to trigger the stacking manual-
ly .
Special key (4): press this key to open the setup page of a
specific function or option.
Minus/Plus keys (5): are used to enable/disable functions, to
reduce/increase numeric values and to
select sewing programs.
Reset key (6): is used to reset sewing programs, if the
fabrics were inserted badly for a pre-seam;
then you can insert the trouser part again
and sew the pre-seam; the reset key is only
active, if it is pressed before the sewing of
the main seam.
5.3.2 Contents of the display
P R O G .
0 0 1
T X T : H A U P T P R O G R A M M
1 Number of current sewing program
2 Current step within the sewing program
3 Sewing speed
4 Photo cell mode
5 Automatic program execution
6 Stitch counter
5.4 Working table
The working table can be used to insert and align the trouser parts.
P c s .
A
0
F n
S T E P
0 3
A
D : 3 0 0 0
1 4
S T O P
A : 4 5
1-16
5.5 Sewing head
1
2
3
4
1 Sewing head
2 Top feed adjustment
3 Kett suction device
4 Sewing foot
5 Height adjustment contour guiding
6 Photo cell for contour guiding
7 Contour guiding
8 Adjustment screw spring pressure contour roll
9 Contour roll
Seven different seams can be sewed with this machine. The fabrics are
inserted in insertion direction below the contour guiding (7), until photo cell (6)
detects the cloth.
After switching the photo cell dark, the sewing foot of the sewing head (4)
and the contour roll (9) are lowered. The cloth is sewed. During that, the
photo cell (6) supervises the correct cloth transportation (contour guiding)
and adjusts the speed of the contour roll (9) if required.
5
6
7
8
9
5.6 Foot pedal machine sequence
This is used in several sewing programs to trigger different functions (see
section 6.2).
The foot pedal is equipped with two contacts. One is located in the rear area
and is closed by putting weight on the tip of the foot. The other one is located
in the front area and can be contacted by pressing down the heel („Kick
back“).
1-17
6 Operation of the machine
6.1 Production sequence
The Single-head Serging Unit 1225/4 achieves a full-automatic production
sequence together with a high production speed. The operator of the machine only has to:
• select the desired sewing program;
• fix front trouser and kneelining at the adhesion facility;
• insert the fabrics correctly;
• supervise the functionality of the machine.
The production sequence contains the following steps:
1. Fix front trouser and kneelining at the adhesion facility.
2. Lay fabrics on the working table and insert straightly below the contour
guiding of the sewing head.
3. As soon as the photo cell switches dark (and detects the inserted
trouser part), the sewing head starts sewing the trouser part. The
correct transportation is supervised by the photo cell, the speed of the
contour roll is adjusted if required. In this way , contours can be detected and serged correctly .
4. To ease the transportation of the cloth in the range of the sewing head,
table blowing can be enabled.
5. Towards the end of the sewing process, the movable blade will be
driven out to turn the trouser part for the sewing of the hip bow.
6. After serging the complete trouser part, the swing-out device transports it out of the machine where it will be stacked.
6.2 Program control
Hint
This machine is controlled with programs, which are stored in the memory
and can be selected by the operation personell. The editing of existing and
the programming of new sewing programs should be reserved to
experienced qualified staff. The possibilities are explained in the second part
of this manual.
6.2.1 Existing sewing programs
In the daily production process, the operating personell must only select one
of the pre-programmed sewing programs. The factory setting is:
ProgramDescription
001 front trousers with kneelining, sewing starts at the waist;
002 front trousers with kneelining, sewing starts at the hem;
003 1 main seam without kneelining;
004 1 pre-seam and 1 main seam without kneelining;
005 manual sewing without stacker;
006 front trousers with kneelining and pocket sewed-in previously;
sewing starts with left outside seam at the waist; manual sewing
with foot pedal over the pocket; after kicking back the foot pedal,
automatic sewing til the end and stacking;
1-18
007 front trousers with kneelining and pocket sewed-in previously;
sewing starts with left outside seam at the waist; automatic
sewing til the end and stacking;
008 back trousers with 3 pre-seams and consecutive main seam;
seam follow: seat seam, inside seam, waist, then outside seam
with stacking; WITHOUT STOP AFTER PRE-SEAMS;
009 back trousers with 4 pre-seams and consecutive main seam;
seam follow: waist seam, seat seam, inside seam, hem, then
outside seam with stacking; WITHOUT STOP AFTER PRE-
SEAMS;
010 back trousers with 3 pre-seams and consecutive main seam;
seam follow: seat seam, inside seam, hem, then outside seam
with stacking;
011 back trousers with 2 pre-seams and consecutive main seam;
seam follow: inside seam, hem, then outside seam with
stacking;
012 sew right and left back trousers alternatingly; seam follow: right
trouser part, seat seam, inside seam, hem, outside seam,
stacking, left trouser part, inside seam, hem, outside seam,
stacking;
013 left and right front trousers with kneelining, sewing starts at the
waist; seam follow: left trouser part, outside seam, stacking,
right trouser part, fly seam, inside seam, stacking;
014 left and right front trousers with kneelining, sewing starts at the
hem; seam follow: left trouser part, hem, inside seam, stacking,
right trouser part, hem, outside seam, stacking;
015 left and right front trousers with kneelining, sewing starts at the
waist; seam follow: left trouser part, outside seam, stacking,
right trouser part, inside seam, stacking;
016 left and right front trousers with kneelining, sewing starts at the
waist; seam follow: left trouser part, outside seam, stacking,
right trouser part, fly seam, inside seam, stacking;
017 sew left and right front trousers with kneelining alternatingly ,
sewing starts at the hem; seam follow: left trouser part, hem,
inside seam, stacking, right trouser part, hem, outside seam,
stacking;
018 front trousers with kneelining and pocket sewed-in previously;
sewing starts with left outside seam at the waist; manual
sewing over the pocket, after kicking back the foot pedal
automatic sewing til the end, stacking; right trouser part, inside
seam, stacking.
The sewing program currently selected is indicated in the left upper corner of
the display .
6.2.2 Select a different sewing program
To select a different sewing program, you have to move the cursor onto the
program number and press the Plus/Minus keys repeatedly , until the desired
program number is displayed.
1-19
6.3 Adjustment of the transports
1
Y ou can adjust the transportation facilities within the sewing head:
Permanent transport
The right-handed lever (2) influences the permanent transport, which is
active during the complete seam. The adjustment range is from -10 to +6.
The higher the adjustment (in the plus range), the more the cloth will be
stopped; the lower the adjustment (in the minus range), the more the cloth
will be stretched.
2
Additional transport
The left-handed lever (1) influences the additional transport that is programmable in the machine’s control and shall bring more width at certain
positions of the seam.
The adjustment range is between 0 and +16. The higher you work in the plus
range, the more lining will be stopped additionally at the programmed positions.
6.4 Additional settings at the operation device
The operating personell may not access the setup pages of the machine
control. This is reserved to experienced technicians which were trained
especially . The access to the setup pages requires the entry of the machine
code.
Attention
Possible damage to the machine due to inadequate programming! The
machine code should be kept as a secret and only be accessible to persons,
which are allowed and qualified to program and setup the machine.
The only exception to these regulations are two settings:
• selection of the operation language;
• setting of the contrast of the display .
1-20
6.4.1 Selection of the operation language
Position the cursor on the program number and press the Minus key once.
This will be displayed:
P R O G .
0 0 0
D E U T S C H
X X X
Move the cursor using the arrow keys onto the displayed operation language
(here: deutsch = german) and press the Plus key , until the desired operation
language is displayed.
Move the cursor back on „000“ and press the Plus key to select the desired
sewing program.
Hint
The names of the sewing programs will always be displayed in that language,
which has been used for the entering.
6.4.2 Setting the display contrast
Open the page „Program 000“ (see above) and position the cursor on the
circle icon colored black and white. Press the Plus or the Minus key to set the
contrast of the display .
Move the cursor back on „000“ and press the Plus key to select the desired
sewing program.
D : 8 0 0 0
1-21
7 Cleaning and maintenance
DANGER
Possible injuries due to improper execution of cleaning and maintenance
duties! The operator of the machine may only carry out the cleaning and
maintenance duties described in this section. Further measures are reserved
to the responsible service technician.
7.1 Cleaning of the machine
Hint
To achieve the value and daily functionality of this machine, it should always
kept clean and free of production waste.
Clean the machine using an industrial vacuum cleaner. All surfaces can be
cleaned with a dampened, not saturated clean cloth.
The operation device must be cleaned with a dry, clean cloth.
7.2 Empty waste baskets
The machine is equipped with two vacuum cleaning devices to keep the
sewing heads clean of superfluous warp threads and cloth rests.
The threads will be collected in two baskets, which are mounted beneath the
working table:
Turn the lower part of the basket to the left to unscrew it. Empty the basket.
Mount the empty basket with a turn-movement to the right.
1-22
Hint
Please assure that collected waste is disposed in accordance to environmental requirements. Please obtain the local rules and regulations regarding the
waste disposal.
7.3 Check oil level in the sewing head
ATTENTION
Possible damage to the sewing head due to low oil level! Check the oil level
in the sewing heads daily and fill in possible missing oil immediately .
Hints for the checking of the oil level in the sewing head and information on
the type of oil to be used and how it is filled in is contained in the Operating
Instructions of the sewing head which is part of the documentation of this
machine.
7.4 Empty water separators
This machine is equipped with a air supply unit with automatic water separator. If there is water in the collector, it will be dropped off when the air pressure is released from the machine.
7.5 Error messages and troubleshooting hints
In this section we show all possible error messages and how they are imaged
in the display of the operation device. An error number is displayed together
with an error text.
Please contact the responsible service technician if an error message is
displayed.
1-23
1-24
Part 2 Mechanics manual
Hint
This part of the operating instructions contains all information required to put
the machine into operation and to do programming, troubleshooting and
maintenance. It adresses to trained technical personnel, which is able to
overview their tasks and recognize possible danger at an early moment. The
operating instructions given in part 1 of this manual are to be considered as
part of this mechanics manual.
Contents Page
Part 2 Mechanics manual............................................................................................. 2-1
1 Delivery , transportation, storage ...................................................................... 2-2
1.1 Delivery ................................................................................................................ 2-2
1.2 Transportation...................................................................................................... 2-2
1.3 Storage ................................................................................................................ 2-2
2 Installation.......................................................................................................... 2-3
2.1 Technical data ...................................................................................................... 2-3
2.2 Mechanical installation......................................................................................... 2-3
2.2.1 Unpack and put up............................................................................................... 2-3
2.2.2 Connection of air supply....................................................................................... 2-4
2.3 Elektrical installation ............................................................................................ 2-4
2.4 First putting into operation.................................................................................... 2-5
3 Programming and machine setup .................................................................... 2-6
3.1 General hints ....................................................................................................... 2-6
3.2 Selection of the setup pages................................................................................ 2-6
3.3 Setup page -01 .................................................................................................... 2-7
3.4 Setup page -02 .................................................................................................... 2-7
3.4.1 Position actor, turn direction, needle position ....................................................... 2-7
3.4.2 Revs (min. and max.)........................................................................................... 2-8
3.4.3 Store error messages .......................................................................................... 2-9
3.4.4 Activate access code ........................................................................................... 2-9
3.5 Setup page -03 .................................................................................................... 2-9
3.5.1 Presser foot ......................................................................................................... 2-9
3.5.2 Photo cell ........................................................................................................... 2-10
3.6 Setup page -10 .................................................................................................. 2-10
3.7 Program inputs and outputs................................................................................2-1 1
3.7.1 Setup page of inputs and outputs........................................................................2-1 1
3.7.2 Settings for this machine.................................................................................... 2-12
3.8 Meanings of the used symbols........................................................................... 2-13
4 Use of the storage module .............................................................................. 2-15
4.1 Load data from the storage module ................................................................... 2-15
4.2 Write data on the storage module ...................................................................... 2-16
4.3 Write single programs on the storage module.................................................... 2-16
4.4 Read a single sewing program into the machine control .................................... 2-17
5 Troubleshooting hints ..................................................................................... 2-18
2-1
1 Delivery, transportation, storage
1.1 Delivery
Hint
Check right after receiving the machine, whether all parts according to the
parts list are complete and without damage. Later claims can’t be accepted.
If you see damage to the transportation packing of the machine, which
indicates a possible damage to the delivered parts, don’t hesitate to claim this
to the transportation company .
1.2 Transportation
Generally it is possible to move the machine. Obey the following hints:
1. Cut off the power supply, release the pneumatical pressure.
2. Fix movable and loose parts.
3. Lift the base with a hoisting device and be sure to lift possible additional
devices (e.g. stacker). If the machine is equipped with transportation
casters (option), you will have to release the brakes at every caster.
4. Move the machine carefully to the new location.
Attention
Attention when moving the machine on sloping areas! Enormous pull power
arises from the machine weight.
1.3 Storage
If no other agreement is fixed, the following limitations have to be kept:
1. In closed rooms only .
2. Temperature range -10 ... +45 °C.
3. Humidity max. 80% non-condensing.
Attention
If stored or transported in improper environments, the machine can be
damaged severely . Damages may not be visible from the outside.
2-2
2 Installation
Attention
Installation and putting into operation may only be carried out by mechanically
and electrically qualified staff. These people must read and understand the
complete operating manual before starting.
2.1 Technical data
Dimensions 2.000 x 860 x 1.760 mm (LxWxH)
Table height 930 ... 1.200 mm (adjustable)
Weight 125 kg
Mains power 220 V AC
Power consumption 0,7 kW
Fuse 15 A
Air connector min. 5 bar
req. Air quality oil-free
Air consumption est. 20 NL/working day
2.2 Mechanical installation
Attention
Check before starting the installation, whether the desired location meets the
requirements (see chapter 2.1, technical data). This is very important
regarding the stability of the ground.
2.2.1 Unpack and put up
1. Remove the packing material and possible transportation protections.
2. Position the machine on a solid and horizontal ground.
3. Level the machine to a horizontal stand using the adjustable frame feet.
2-3
2.2.2 Connection of air supply
1. Connect the air pipe (1) to your air system.
2. Open the air supply of your air system.
3. Level the air pressure to 6 bar using the control (2); the air pressure can
be read at the scale (3).
Attention
We recommend to switch off the air supply when the machine is not in duty.
Use the black control (2).
2.3 Elektrical installation
Hint
All work at the electrical components of the machine may only be carried by
qualified staff (qualified electrical employee or instructed person according to
IEC 364 and DIN EN 60204-1).
Danger
Parts under electrical current! Without cutting off the power supply, you might
be injured severely . Please obey the security advice given in chapter 1.
2-4
Attention
The machine will be destroyed by connecting to a wrong mains voltage!
Check, whether the requirements from chapter ‘Technical data’ meet the
local conditions.
1. Use the power cord located at the backside of the machine.
2. Plug it into a socket.
3. Lay the cord in a way , that the danger of stumbling is avoided.
Danger
Danger to life from unsufficient grounding! Do a grounding according to DIN
EN 60204-1.
2.4 First putting into operation
This machine has been configured to the individual requirements of the
customer. The first putting into operation can be done easily:
1. Adjust the machine to a horizontal stand.
2. Connect power and air supply .
3. Switch on the machine using the mains / emergency stop switch at the
front side of the machine.
4. Check all security systems for function and efficiency .
Danger
The machine may only be used for production purposes, after the security
systems have been checked. If a security doesn’t work adequately , it must be
repaired first.
As a factory setting, several production programs are contained in the buffer
of the machine. You may use one of them or create your own programs.
2-5
3 Programming and machine setup
As a factory setting, 18 sewing programs are contained in the memory of the
machine, which can be selected and used by the operator. These programs
had been programmed based on long experience and should be sufficient for
the use of the machine. The available programs are described in the first part
of this manual.
Existing programs can be modified and adjusted to your personal requirements. Y ou can also program completely new sewing programs. All modified
or new programs can be copied on a storage module for data recovery
purposes.
3.1 General hints
If you want to set or modify certain functions, you have to place the cursor
using the arrow keys on the icon of the function and change the setting using
the Plus/Minus keys.
At several functions you can press the Special key to open a setup page for
the specific function.
The machine setup can be modified on the following pages:
Setup -01 Machine type
Setup -02 Position actor, turn direction, needle position, revs, storing of
error messages, activate access code
Setup -03 Presser foot, photo cell
Setup -10 Inputs and outputs
3.2 Selection of the setup pages
1. Position the cursor on the program number and press the Minus key. This
will be displayed:
P R O G .
D : 8 0 0 0
0 0 0
D E U T S C H
X X X
2. Position the cursor on the left-handed „x“ below the key symbol.
3. Press the Minus key to change the „x“ to a zero.
4. Position the cursor on the middle „x“ and press the Minus key .
5. Position the cursor on the right-handed „x“ and press the Minus key .
6. Position the cursor on the program number 000 and press the Minus key .
Setup page -01 will be displayed.
2-6
3.3 Setup page -01
S E T U P
- 0 1
Here you can set the machine type. The type „Überwendlich“ must be selected.
3.4 Setup page -02
S E T U P
- 0 2
Here you can see six icons which represent the machine functions. To select
a function, position the cursor on the respective icon and press the Special
key to open the setup page or press the Plus/Minus key to switch the function
on or off.
M A R K E
Û B E R W E N D L I C H
P 1
P 2
T Y P E
3.4.1 Position actor, turn direction, needle position
S E T U P - 0 2
- - -
2 9 0
0
1 1 5
T urn direction
After opening the setup page, the cursor is positioned on the icon of the turn
direction. Press the Plus key to change the turn direction (viewed on the belt
disc).
Define needle zero-position
1. Position the cursor on the icon of the needle zero position.
2. Turn the hand wheel with impetus in the set turn direction until the angle
value below the turn direction icon changes.
3. Turn the hand wheel, until the needle stands at the top edge of the stitch
plate.
I I I P O S .
I I P O S .
0
I P O S .
2-7
4. Press the Plus key to accept the value as zero position.
5. Press the Special key to leave the page or continue with the setting of the
needle top and bottom position.
Define needle top and bottom position
These positions are defined as a factory setting but can be modified:
1. Position the cursor on the stroke „II. Pos.“.
2. Turn the hand wheel into the set turn direction, until the needle stands in
the desired top position.
3. Read the angle value below the turn direction icon (est. 290).
4. Press the Plus or Minus key to enter the displayed value into the entry box
beside the stroke „II Pos.“.
5. Position the cursor on the stroke „I Pos.“.
6. Press the Plus or Minus key to enter the value „1 15“ into the entry box
beside the stroke „I Pos.“.
7. Press the Special key to leave the setup page.
3.4.2 Revs (min. and max.)
S E T U P - 0 2
M I N . : 4 0 0
M A X . :
[ 8 0 0 0 ]
R E S E T
O N
5 4 0 0
P u l l : 7 5
1 0 0 %
A C C .
8 0 %
D E C .
Position the cursor on all sections listed below and set the recommended
values using the Plus or Minus key:
MAX.: 8000
MIN.: 400
ACC. 100 %
DEC. 80 %
Pull: 75
Press the Special key to leave the setup page.
2-8
3.4.3 Store error messages
S E T U P
- 0 2
The last 16 error messages are documented on this page. They are listed
together with the time of their issue and the time period until the issue of the
next error message.
Press the Special key to leave this page.
3.4.4 Activate access code
E R R O R
- - : - - 1 2 : 1 5
- - : - -
- - : - -
P A R T I A L T O T A L
0 4 : 3 5
3 0 : 0 0 %
3 8 : 2 0
2 7 : 1 5
4 0 : 0 0 %
Use the Plus key to activate (left) or deactivate (right) the icon of the access
code. If the access code is activated, the code must be entered before a
setup page can be opened.
3.5 Setup page -03
S E T U P
- 0 3
Six icons are displayed here, but only two of them are enabled. To select the
setup page of a function, position the cursor on the respective icon and press
the Special key .
3.5.1 Presser foot
Hint
A
S
If the presser foot cannot be enabled, you will first have to switch off output
F1 on setup page -10. Further explanations are contained below.
2-9
S E T U P - 0 2
3 0 V
( m a x )
1 5 V
1. Position the cursor on the time of maximum power (left value in lower row)
and press the Plus/Minus key until 150 ms is set. This assures that the
presser foot is lifted safely after seam end.
2. Position the cursor on the value of the holding voltage (upper row, value in
the middle of the display) and press the Plus/Minus key until 15 V is set.
This assures that the magnetic valve for the foot release will not be
overloaded.
3. Position the cursor on the value of the start delay (right edge) and enter
120 ms here. This time is required to assure that the sewing foot rests
safely on the cloth before sewing starts.
4. Position the cursor on both presser foot icons and set them to „Presser
foot up“ like shown in the picture.
5. Press the Special key to leave this page.
6. Check, whether the presser foot is programmed on „up“ on page „PROG
000“, too.
3.5.2 Photo cell
[ m s ]
1 5 0
0 0
1 2 0
Position the cursor on the photo cell icon and press the Plus key to set the
photo cell to „switch lighted“. This is indicated by the shown icon.
3.6 Setup page -10
S E T U P
- 1 0
F 1
M 1
All outputs (F1 ... F12) and inputs (M1 ... M8) are displayed here. Inputs and
outputs crossed out are disabled.
At this machine, the output F1 and the inputs M5, M6 and M7 must be
disabled. Position the cursor on the desired input/output and press the Plus
key to enable/disable this input/output.
The inputs are defined by the connector occupation at the switching box and
occupied as follows:
A
F 2
M 2
F 3
M 3
F 4
M 4
F 5
M 5
F 6
M 6
F 7
M 7
F 8
M 8
F 9
F 1 1
F 1 0
F 1 2
2-10
Inp. Connector occupation Input connector
M1 Reset key B 2-4
M2 Stacking manually B 4-6
M3 Lining clamp B 8-10
M4 Adhesion stamp B 10-12
M8 Photocell at prelaying table Pin 19-, Pin 20+, Pin 3 Signal
All outputs are valves and occupied as follows:
Va lve Connector occupation Output connector
Y0 - Sewing foot up A - 1
F2 Y2 - Table blowing A - 3
F3 Y3 - Contour guiding A - 5
F3 Y13 - Dirt suction A - 5
F4 Y4 - Lift contour roll A - 7
F5 Y5 - Kett-up A - 9
F6 Y6 - Holding stamp A - 11
F7 Y7 - Stacker impulse A - 13
F8 Y8 - Swing-out device A - 15
F9 Y9 - Swing blade A - 17
F10 Y10 - Top transport A - 18
F1 1 Y11 - Adhesion stamp A - 16
F12 Y12 - Lining clamp and tape advance A - 14
Hint
The output „Sewing foot up“ (Y0) cannot be programmed on setup page -10
and can be enabled on setup page -03 (see there).
3.7 Program inputs and outputs
The inputs and outputs can be enabled/disabled on setup page -10. Enabled
inputs and outputs can be programmed.
To program an input or output, position the cursor on the respective icon and
press the Special key . The setup page will be opened.
Hint
The programming of inputs and outputs is not executed program-specific.
The setting is the same for all programs. Modifications effect all sewing
programs.
3.7.1 Setup page of inputs and outputs
O U T F 6
S T E P
S T O P
P R G
0
1 0 0
2-11
A programming is shown for the example of output F6 (displayed in the upper
M 1
P R G
left corner of the display).
A function must be selected for each input/output, a start delay and duration
must be programmed. The selected function is displayed on the left side in
front of the background „I/O“. The icons will be explained further below.
The start delay is displayed to the right of the left-handed „hour glass“, the
active duration to the right of the right-handed hour glass. The avilable
functions are displayed above the hour glasses in a horizontal row.
Do the following to program an input or output:
1. Position the cursor on the icon of a function in the upper right part of the
display .
2. Press the horizontal arrow keys until the desired function icon is marked.
3. Press the Plus key to select the marked function icon. It will be displayed
in the area „I/O“.
4. Position the cursor on the time value to the right of the left-handed hour
glass icon if you want to program a start delay (in ms) for the selected
function.
5. Press the Plus/Minus key repeatedly , until the desired value is displayed.
6. Position the cursor on the time value to the right of the right-handed hour
glass, where you can program the active time (in ms) for the selected
funtion.
7. Press the Plus/Minus key repeatedly , until the desired time value is
displayed.
8. Press the Special key to leave the setup page and store the changes.
9. Repeat this procedure for all inputs and outputs which you want to modify .
3.7.2 Settings for this machine
The inputs and outputs at this machine should be programmed as follows:
Inputs
Reset key
Stacking manually
Lining clamp
Adhesion stamp and lining clamp
Photo cell 2 (pre-laying table)
Outputs
M 2
M 3
M 4
F n
F n
F n
M 8
+
S T E P
F 7 O N
F 1 2 T O G G
F 1 1 O N F 1 2 O N
Table blowing
F 2
S T E P
0 5 0
2-12
Contour guiding and waste suction
0
0
F 9
1 5 0 2 0 0 0
0
0
Contour roll
Kett-up
Swing-out stamp
Stacker impulse
Swing-out device
Swing blade
F 3
F 4
F 5
F 6
F 7
F 8
S T E P
S T E P
S T E P
S T E P
0 2 0
1 5 5 5 0
0 1 0
1 0 1 0 0 0
3 5 0 1 0
5 0 5 0
Top transport
Adhesion stamp
Lining clamp
F 1 0
F 1 1
F 1 2
S T E P
M
3.8 Meanings of the used symbols
Step type symbols
Pause - passing of a time
if the time symbol is programmed in a step, the program
sequence will be continued after the programmed time
has passed; outputs can be enabled in this step.
A
Continue with next step
0 4 0
0 4 0
0 4 0
it will be switched to the next step automatically after the
displayed step has been executed.
Program-specific symbols
Automatic execution
the displayed step is executed automatically .
2-13
Start and Stop with photo cell
the photo cell at the sewing head is active during this
step.
Photo cell inactive
F n
S T O P
S T O P
Active outputs
one or several outputs are active during this step; position
the cursor on this symbol and press the Special key to
display the active outputs; outputs crossed out are inactive.
Stop
the program will be stopped after the execution of this
step; normally , this is done in the last step of a program.
No Stop
there is no program stop but a switching to the next step.
Sewing foot up - down
shows the position of the presser foot at program start
and end.
Needle position after sewing stop
position the cursor on this symbol and press the Plus key
to select, whether the needle shall be in top or bottom
position after the Stop.
2-14
4 Use of the storage module
All sewing programs and the setup data are stored on the storage module
delivered with the machine.
Hint
The delivered module is a backup copy of the machine data. It should be
kept at a safe place.
4.1 Load data from the storage module
1. Switch off the machine using the mains switch.
2. Plug the storage module KK 195 into the slot on the right side of the
operation device.
3. Switch on the machine using the mains switch.
4. The display shows you what you can load from the storage module:
S E T U P / P R O G
S E T U P
P R O G
K K 1 9 5
D A T A T R A N S F E R F R O M K K 1 9 5 C H I P T O M O T O R
P R E S S + T O C O N T I N U E P R E S S T O C A N C E L
5. Press the Plus key .
6. Confirm the inquiry , whether the data contained in the machine’ s memory
shall be overwritten.
7. Use the arrow keys to mark one of the three options (SETUP/PROG =
setup-data and sewing programs will be loaded; SETUP = only setup-data
will be loaded; PROG = only sewing programs will be loaded).
8. Press the Plus key .
9. Now you have to confirm the loading of data into the machine control:
S E T U P / P R O G
S E T U P
P R O G
K K 1 9 5
C A U T I O N ! O L D K K 1 9 5 D A T A W I L L B E E R A S E D
P R E S S + T O C O N T I N U E P R E S S T O C A N C E L
10.Press the Plus key to start the loading. The selected data will be loaded
into the machine control.
1 1 .Then, setup page -02 will be displayed. Enter all data like described in
section 3.4.
12.Press the Special key. Program 001 will be displayed and the machine is
ready to use.
2-15
4.2 Write data on the storage module
1. Switch off the machine using the mains switch.
2. Plug the storage module KK 195 (Part No. 24.831.08) into the slot on the
right side of the operation device.
3. Switch on the machine using the mains switch. This will be displayed:
S E T U P / P R O G
S E T U P
P R O G
P R O D D A T A
D A T A T R A N S F E R F R O M K K 1 9 5 C H I P T O M O T O R
P R E S S + T O C O N T I N U E P R E S S T O C A N C E L
4. Press the key „Arrow to the right“ to turn the displayed arrow in the direction like shown in the picture.
5. Select one of four options using the vertical arrow keys: SETUP/PROG =
write setup data and sewing programs; SETUP = write setup data only;
PROG = write sewing programs only; PROG DA TA = write program data
only .
6. Press the Plus key and this will be displayed:
K K 1 9 5
S E T U P / P R O G
S E T U P
P R O G
P R O D D A T A
C A U T I O N ! O L D K K 1 9 5 D A T A W I L L B E E R A S E D
P R E S S + T O C O N T I N U E P R E S S T O C A N C E L
7. Press the Plus key to overwrite data which are contained on the storage
module. Then, the selected data will be written.
8. Pull the storage module out of the operation device. The machine is ready
to use.
4.3 Write single programs on the storage module
Hint
For each single program, a separate storage module is required.
1. Select the program to be copied on the storage module.
2. Press the Special key and this will be displayed (example):
K K 1 9 5
2-16
P R O G .
0 0 1
P R G
X X X
C O U N T I N G
M A N U A L
A U T O
P R O G .
O P E N
S E L F - T E A C H
E D I T .
a / A / B
A L L
P R G
L Ö S C H E N
W
R
3. Position the cursor on the „W“ in the upper right corner of the display and
push the storage module into the slot at the operation device.
4. Press the Plus key to write the selected sewing program on the storage
module.
4.4 Read a single sewing program into the machine control
1. Select the program memory location, where the program shall be read to.
2. Press the Special key . The same will be displayed like shown in section
4.3.
3. Position the cursor on the letters „PRG“ and press the Plus key to delete
the data contained on the selected memory location.
4. An inquiry will be displayed, where you have to confirm the deletion by
pressing the Plus key . The deletion cannot be undone.
5. Plug the storage module into the slot at the operation device.
6. Position the cursor on the letter „R“.
7. Press the Plus key to read the program from the storage module into the
machine control.
8. Press the Special key to leave the page. The machine is ready to use.
Hint
You can use this procedure to copy a sewing program from one memory
location to another.
2-17
5 Troubleshooting hints
Error – possible solution
The machine does not start and the control lamp on the operation
device MT800 is off – replace 10 A melting fuse; if the new fuse melts, too
or the machine does not start: replace control board KK66.
The devices will not be enabled – the motor functions but the devices like
thread cutter, foot lifting or needle cooling will not be enabled – replace 3 A
melting fuses, then cut off all devices electrically from the motor control;
switch on the machine and connect all devices one after another; after every
connection, switch on the machine and check melting fuses; in this way , the
defective device can be detected (possibly magnetic valve); if the electrical
elements of the devices are ok and the replacement of the fuses brought no
success: replace I/O-module, replace control board KK66.
The operation device MT800 is switched on, but the display is not clear
or without function – switch machine off and on; pull out the connecting
cable of the operation device MT800, check and remount it; possibly do the
same with the connecting cable between control board KK66 and I/O-module;
replace operation device MT800, replace I/O-module, replace control board
KK66.
Error messages in the display – possible solution
Fault in the control board (KG) – replace control board KK66.
External fault (KE) – switch machine off and on; check power supply; check
environment for disturbing devices (spark-generating devices, high-frequency
machines, a.s.o.).
Program defective (KP) – delete defective program and program it again; if
several programs are defective, all programs should be loaded from the
storage module; if the loaded programs are defective: replace control board
KK66.
Position actor defective (SG) – check the connecting cable of the position
actor; check the connecting cable between I/O-module and control board
KK66; replace position actor, replace I/O-module, replace control board
KK66.
Driving belt loosened (CA) – make correct belt tension; check, whether the
motor is fixed properly on the base frame.
Motor overloaded (MS) – there can be many reasons: e.g. missing oil in the
sewing head, oil too cold, possibly sewing thread wrapped around the belt
disc, ...
Motor blocked (MB) – possible causes: machine blocked, needle blocked,
...
2-18
Hints for several repair duties
Replacement of the I/O-module – the replacement of the I/O-module does
not require any adaption duties.
Replacement of the position actor – after replacement, the setting of the
needle zero position is required.
Replacement of control board KK66 – procedure: demount rear cover, pull
off four cable connectors to the control board, loosen both fixing screws, pull
off control board from the motor. Be aware to avoid damage to the electronical components; put the control board into a bag protecting it from electrostatical load and avoid any contact to metal things. After replacing the control
board, all setup data and the sewing programs must be loaded into the
machine.
Replacement of the front box – this is the statical element of the connection control box and of the foot pedal; each transmission element of the pedal
is calibrated; since that, the front box should only be replaced as a whole.
Replacement of the motor – this is fixed with four screws in the motor
housing; the control board must be removed before it can be demounted.
Loading of new software – future developments can be loaded into the
control by replacing an EPROM; to replace the EPROM, remove rear cover,
replace EPROM (mounted on a frame in the upper left corner); when inserting the new EPROM be sure to insert all pins and bend none.
2-19
2-20
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