AW-2
Automatic Bobbin Winding and Feeding Device
ENGINEER’S MANUAL
29328408
PREFACE
This Engineer’s Manual is written for the technical personnel who are responsible for the service and maintenance of
the machine.
The Instruction Manual for these machines intended for the maintenance personnel and operators at an apparel
factory contains operating instructions in detail. And this manual describes “Standard Adjustment”, Adjustment
Procedures”, “Results of Improper Adjustment”, and other important information which are not covered in the Instruction
Manual.
It is advisable to use the relevant Instruction Manual and Parts List together with this Engineer’s Manual when carrying
out the maintenance of these machines.
This manual gives the “Standard Adjustment” on the former page under which the most basic adjustment value is
described and on the latter page the “Results of Improper Adjustment” under which stitching errors and troubles
arising from mechanical failures and “How To Adjust” are described.
CONTENTS
1. SUMMARY......................................................................................................... 1
(1) SpecifIcaions (AW-2) ....................................................................................................... 1
2. CONFIGURATION............................................................................................. 2
3. ASSEMBLY/DISASSEMBLY OF THE DEVICE................................................ 4
(1) Disassembly of the device.............................................................................................. 4
(2) Assembly of the device................................................................................................... 4
4. STANDARD ADJUSTMENT ............................................................................. 6
(1) Rotating belt tension ....................................................................................................... 6
(2) Horizontal feed belt tension ........................................................................................... 6
(3) Chuck cylinder................................................................................................................. 8
(4) Horizontal feed sensor .................................................................................................... 8
(5) Dummy shaft rubber ....................................................................................................... 8
(6) Thread drawing force .................................................................................................... 10
(7) ZA frame asm................................................................................................................. 10
(8) Unwinding belt tension ................................................................................................. 10
(9) ZA diffuser...................................................................................................................... 10
(10) ZA pipe direction ......................................................................................................... 12
(11) Unwinding guide air flow rate ................................................................................... 12
(12) Winding belt tension ................................................................................................... 14
(13) Threading belt tension ................................................................................................ 14
(14) Threading knife............................................................................................................ 16
(15) Counter knife................................................................................................................ 16
(16) Threading wiper ........................................................................................................... 18
(17) Threading wiper ........................................................................................................... 18
(18) Nozzle belt tension ...................................................................................................... 18
(19) Thread measuring roller sleeve ................................................................................. 20
(20) Thread tension No. 1 asm. and Thread tension asm. .............................................. 20
(21) Thread measuring motor ............................................................................................ 22
5. PARAMETER ADJUSTMENT......................................................................... 24
(1) Swing axis home position ............................................................................................ 25
(2) Horizontal axis home position ..................................................................................... 25
(3) Swing axis to stand by position ................................................................................... 26
(4) Swing axis to unwind position ..................................................................................... 26
(5) Bobbin winder rotating position adjustment .............................................................. 27
(6) Hook pick up distance .................................................................................................. 27
(7) Stand by pick up distance ............................................................................................ 28
(8) Unwind pick up distance .............................................................................................. 28
(9) Winding position distance ............................................................................................ 29
(10) Trim position distance ................................................................................................ 29
(11) Threading position distance 1.................................................................................... 30
(12) Threading position distance 2.................................................................................... 30
(13) Threading position distance 3.................................................................................... 31
(14) Start wind tube position.............................................................................................. 31
(15) Tube thread length ...................................................................................................... 32
6. SENSOR ADJUSTMENT ................................................................................ 33
(1) Unwinding sensor adjustment ..................................................................................... 33
7. MAINTENANCE............................................................................................... 34
(1) Removing ZA drive gear ............................................................................................... 34
(2) Removing ZA idler gear ................................................................................................ 34
(3) Removing winding clutch ............................................................................................. 35
(4) Replacing chuck tube.................................................................................................... 35
8. FUSE REPLACEMENT ................................................................................... 36
9. TROUBLES AND CORRECTIVE MEASURES............................................... 37
10. BLOCK DIAGRAM ........................................................................................ 47
(1) Electrical components .................................................................................................. 47
(2) Air (pneumatic) components ........................................................................................ 49
4. STANDARD ADJUSTMENT
Standard Adjustment
(1) Rotating belt tension
• Adjust so that belt sags 1.5 mm with a 9.8N (1 kgf) load and so that belt sags 2 mm with a 9.8N (1
kgf) load.
• Apply a load to the center between the centers of the respective pulleys to adjust the belt tension.
1
4
5
6
1kg
2
3
7
1kg
1. Rotating pulley
2. Rotating idler pulley asm.
3. Rotating idler shaft
4. Rotating motor pulley
5. Rotating motor
6. Timing belt (P=192)
7. Timing belt (P=180)
(2) Horizontal feed belt tension
• Adjust so that belt sags 2 mm with a 2.94N (300gf) load and so that belt sags 1.5 mm with a 4.9N
(500gf) load.
• Apply a load in the center between the centers of the respective pulleys to adjust the belt tension.
300g
9
1. Horizontal feed motor pulley
2. Horizontal feed motor
3. Horizontal feed idler pulley
4. Hozrizontal feed pulley asm.
5. Horizontal feed pulley plate
3
8
6. Bolt M4
7. Nut M4
8. Timing belt P=264
9. Timing belt P=303
5
7
6
4
1 2
500g
Adjustment Procedures Results of Improper Adjustment
(1)Adjusting belt F on the convey shaft side
aLoosen M8 nut fixing eccentric shaft C and adjust the tension
by rotation of the eccentric shaft.
(2)Adjusting belt G on the motor side
aLoosen setscrews (4 pcs.) fixing the rotating motor to adjust
the tension.
(Caution) When the above step (1) is performed and
eccentric shaft C is rotated, tension of belt G on
the motor side varies as well. In some case, readjustment of the above step (2) may be required.
a Belt tension adjustment
Low Belt tooth skipping
Looseness (play) in the rotating
direction occurs resulting in defective
convey.
High Step-out of motor
(1)Adjusting belt H on the motor side
aLoosen three setscrews fixing the horizontal feed motor and
adjust in the horizontal direction.
(2)Adjusting belt I on the convey arm side
aLoosen two G M4 nuts and adjust with M4 bolt F.
a Belt tension adjustment
Low Belt tooth skipping
Looseness (play) in the horizontal
feed direction occurs resulting in
defective convey.
High Step-out of motor
(3) Chuck cylinder
0
2
1
(4) Horizontal feed sensor
+0.5
0
Standard Adjustment
(A) Adjust the installing position
of D so that end face of B is
aligned with top end of C.
3
4
1. Convey arm asm.
2. Chuck base plate
3. Chuck nail
4. Cylinder
3
4
Align end faces of A and
B with each other.
(A)
2
(5) Dummy shaft rubber
• Adjust with bolt E and nut F so that
upper end face of D rubber protrudes
0.3 mm from A support base face.
1. Horizontal feed sensor plate
2. Horizontal sensor asm.
3. Bolt M3
4. Nut M3
1
3
4
2
1
1. Support base
5
6
A
2. Dummy base
3. Bobbin case waiting shaft
4. Hook release lever rubber
5. TN Bolt M2.5
6. Nut M2.5
Adjustment Procedures Results of Improper Adjustment
aLoosen the nut fixing air cylinder D and rotate the air cylinder
to adjust the blowing amount.
aLoosen bolts and nuts (2 pcs. each) fixing the horizontal feed
sensor cirduit board, align end face (A) of the horizontal feed
sensor circuit board and the horizontal feed sensor plate with
each other and fix them.
aClearance dimension
Small (in case of clearance < 0)
Chuck cylinder comes in contact
with the bobbin case lever resulting
in defective chucking.
Large (in case of clearance > 0.5)
Chuck cylinder comes in contact
with sewing machine hook and feed
dog or bobbin case chucking
becomes improper resulting in
defective chucking or defective
convey.
(Reference) Re-adjustment of the horizontal feed origin
position is not required since the sensor
positioning can be performed by aligning end
face (A) even when the replacement of sensor
or the like is performed.
aLoosen M2.5 F nut and adjust the rubber in the vertical
direction with M2.5 bolt E.
(Caution) Note that the top end of the bolt should not
protrude from the top surface of the rubber.
aPush D rubber into E bolt by approximately 5 mm (top end
of the bolt should not protrude from the rubber).
aAs shown in Fig A, it is accepted to assemble the height of
5.3 mm between upper end of D rubber and B dummy base
face beforehand. Check, however, the aforementioned
dimension of 0.3 mm.
aProtruding amount of the rubber
Small (protruding amount < 0.2 mm)
Bobbin idles resulting in thread
scatter.
Large (protruding amount > 0.4 mm)
Bobbin is pushed resulting in
defective setting to the bobbin case
waiting shaft.
Standard Adjustment
(6) Thread drawing force
aAdjust so that a pair of ZA drive gear and ZA idler
ZA drive gear
Tension gauge
gear should be parallel.
After assembling the unit, make the thread
drawing force F = 0.78N (80gf) or more.
(Thread : Tetron #80 The force should be equally
ZA idler gear
Thread
applied to the whole area of the gears if possible.)
ZA shaft S
ZA arm
Setscrew
(7) ZA frame asm.
Clearance provided between ZA drive gear (tooth top) and bobbin case (outer perimeter) “g” = 0.5 mm
Bobbin case
Jig
0.5±0.1
g
ZA drive gear
(8) Unwinding belt tension
The belt sags 1 mm when the center of the belt is applied with a 1.57N±0.39N (0.16 kgf±0.04 kgf) load “F”.
F
Setscrew
ZA pulley M
Unwinding motor
(9) ZA diffuser
Clearance provided between the inclined plane of ZA diffuser and ZA drive gear (tooth top) “g” = 0.5 mm
The hole (ø3) of the support base should be half hidden by ZA diffuser.
Hole (ø3)
ZA drive gear
g
Setscrew
ZA diffuser
Adjustment Procedures Results of Improper Adjustment
aLoosen two setscrews in the ZA arm, and adjust so that the
ZA drive gear and the ZA idler gear should be parallel with
each other when the claw spring force is applied.
aLoosen three setsscrews in the ZA frame asm., and adjust
the clearance in the vertical direction.
aWhen the thread drawing force is
weakened, in case of thick thread
or the like, thread slips and thread
may be not drawn from bobbin case.
aClearance dimension
Small (clearance < 0)
Bobbin case interferes with gear.
Large (clearance > 1)
Thread is likely to enter the
clearance between gear and bobbin
case when thread end is guided.
aLoosen three setscrews in the unwinding motor, and adjust
the tension laterally so that a load of 1.57N±0.39N is applied
when the belt is sagged 1 mm at the position of F mark in the
figure.
aLoosen two setscrews in the ZA diffuser, and adjust the
clearance in the vertical direction.
aBelt tension adjustment
Low Belt tooth skipping
High Step-out of motor
aIf the position of ZA diffuser is
improper, suction of thread tends to
be malfunctioned.
Standard Adjustment
(10) ZA pipe direction
1) Oscillating direction
Air exhaust direction should be in the direction of
thread outlet hole in the bobbin case.
2) Sense of length
Air exhaust direction should be in the direction of
adjusting screw in the bobbin case.
ZA pipe
Bobbin case
Thread outlet hole
Support base
Sense of length
ZA pipe
Oscillating direction
ZA pipe holder
Setscrew
(11) Unwinding guide air flow rate
1) Initial setting
Set the speed controller to close by three rotation
from full open.
Counterclockwise
Adjusting screw
Unwinding guide solenoid
valve
2) Fine adjustment
Perform adjustment of increase/decrease in accordance with thread type or thread count used if necessary.
Adjustment Procedures Results of Improper Adjustment
aInstall the ZA pipe holder after adjusting the looseness in the
counterclockwise direction beforehand.
aLoosen two setscrews in the ZA pipe holder and adjust the
oscillating direction and the sense of length of the ZA pipe.
a Oscillating direction
When the direction is turned to the
frame side
Thread end to be guided flows to
anti frame side.
When the direction is turned to the anti
frame side
Thread end to be guided flows to
frame side.
a Sense of length
When the direction is turned to the
lower side of adjusting screw
Thread end to be guided flows
between ZA drive gear and bobbin
case.
When the direction is turned to the
upper side of adjusting screw
Thread end to be guided is likely to
be floppy.
aAdjust the flow rate by turning the knob of speed controller
located just below the outlet of solenoid valve on the piping
plate.
a Flow rate
Small Air flow is beaten by thread
strain and thread end cannot
be guided into the gear.
Large Thread runs around and the
thread end enters the
opening of bobbin case. As
a result, the thread end
cannot be guided into the
gear.
Standard Adjustment
(12) Winding belt tension
aAdjust so that the belt sags 1 mm when the center between the centers of pulleys of the belt is applied
with a 2.94N (300gf) load.
Winding pulley
300gf
Setscrew
Winding belt
Bobboin motor pulley
Bobbin motor
(13) Threading belt tension
aAdjust so that the belt sags 1.1 mm when the center between the centers of pulleys of the belt is applied
with a 1.96N (200gf) load.
Threading pulley
200gf
Setscrew
Threading
motor pulley
Threading belt
INTERNATIONAL SALES DIVISION
Copyright ﾂ 1998 JUKI CORP.
8-2-1. KOKURYO-CHO.
CHOFU-SHI. TOKYO 182-8655. JAPAN
PHONE : 03 (3430) 4001 to 4005
FAX : 03 (3430) 4909 • 4914 • 4984
TELEX : J22967
To order or for further information, please contact :
Please do not hesitate to contact our distributors or agents in your area for further information when necessary.
＊ The description covered in this engineer's manual is subject to change for improvement of the
commodity without notice.
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